Online Guide and Manuals

TIRE INFLATION (COLD)
Before attempting to check or adjust wheel alignment, check that tire pressures are to specifications give on driver's door lock pillar

Before attempting to check or adjust riding height, vehicle must be in static loaded condition. To load vehicle, fuel tank must be full, and weights placed in vehicle to simulate full passenger load (620 lbs. on 4 Dr. and 310 lbs. on 2 Dr.). Disconnect front and rear shock absorber. Disconnect stabilizer rods of front and rear suspension. Bounce vehicle several times and allow suspension to take up a static position.


All Models (Front) - Measure distance from lower control arm bushing to floor and front bottom of steering knuckle to floor. The difference between these two measurements should coincide with specifications. If adjustment is necessary, remove spring on affected side. See Alfa Romeo in SUSPENSION Section. Using suitable spacer between spring and its seat, adjust height to specifications. After reinstalling spring, check front suspension height.

All Models (Rear) - Measure distance between rear axle housing and rubber bumper pad. If measurement is not within specifications, remove spring on affected side. See Alfa Romeo in Suspension Section. Using suitable spacer bewtween spring and its seat, adjust height to specifications. After reinstalling spring, recheck clearance.

Caster angle should be checked under static load with shock absorbers disconnected at one end. Difference in caste angle between left and right front wheels, should not exceed 0°20'. If caster angle is not within specifications, loosen lock nuts on upper control arm strut rods and lengthen or shorten strut rods to obtain specified angle. Retighten lock nuts.

Camber angle difference between left and right front wheels should not exceed 2/3°. Adjust camber angle to specifications by adding or removing shims between lower control arm and frame.

Place wheels in straight-ahead position and measure toe-in. If toe-in is not to specifications, adjust by loosening lock nuts and adjusting tie-rods. Tighten lock nuts and recheck toe-in.

TIRE INFLATION (COLD)
Before attempting to check or adjust wheel alignment, check that tire pressure are to specifications given on driver's door lock pillar

Before attempting to check or adjust riding height, vehicle must be in static loaded condition. To load vehicle, fuel tank must be full, and weights placed in vehicle to simulate full passenger load (620 lbs. on 4 Dr. and 310 lbs. on 2 Dr.) Disconnect front and rear shock absorber. Disconnect stabilizer rods of front and rear suspension. Bounce vehicle several times and allow suspension to take up to static position

All Models (Front) - Measure distance from lower control arm bushing to floor and from bottom of steering knuckle to floor. The difference between these two measurements should coincide with specifications. If adjustment is necessary, remove spring on affected side. See Alfa Romeo in SUSPENSION Section. Using suitable spacer between spring and its seat, adjust height to specifications. After reinstalling spring, check front suspension height.

All Models Rear - Measure distance between rear axle housing and rubber bumper pad. If measurement is not within specifications, remove spring on affected side. See Alfa Romeo in SUSPENSION Section. Using suitable spacer between spring and its seat, adjust height to specifications. After reinstalling spring, recheck clearance
Caster angle should be checked under static load with shock absorbers disconnected at one end. Difference in caster angle between left and right front wheels, should not exceed 0°20'. If caster angle is not within specifications, loosen lock nuts on upper control arm strut rods and lengthen or shorten strut rods to obtain specified angle. Retighten lock nuts.

Camber angle difference between left and right front wheels should not exceed 0°40'. Camber angle is not adjustable. If not within specifications, check suspension system for damage. Repair or replace necessary components.

Lock steering wheel in center position so front wheels are in straight-ahead position. Start with steering link on steering box side, and set corresponding wheel to initial toe-in of 06". mEasure length of this steering link. Set steering link on opposite side to .20" less than this measurement. Now adjust center steering link to obtain .06' toe-in on wheel nearest steering box. With toe-in set, measure length of each steering link. If not within specifications, cause may be due to body distortion. Repair as necessary.

TIRE INFLATION (COLD)
Before attempting to check or adjust wheel alignment, ensure that tires are properly inflated. Giuletta requires 20 psi front and 21 psi rear. All other models 24 psi front and 26 psi rear. Check tire pressures given against specifications on driver's door lock pillar to verify pressure.

Before attempting to check or adjust riding height, vehicle must be in static loaded condition. To load vehicle, fuel tank must be full, and weights placed in vehicle to simulate full passenger load. Disconnect front and rear shock absorbers. Disconnect stabilizer rods on front and rear suspension. Bounce vehicle several times and allow suspension to take a static position


All Models Front Exc. Giuletta - Measure distance from lower wishbone shaft to floor and from bottom swivel pin to floor. Calculate difference between measurements and if not within specifications, adjustment must be made before preceding with wheel alignment checks. Remove spring on side affected with suitable tool (A.2.0169) and add suitable spacer with chamfered edge down. Install spring and recheck front suspension height.

All MOdels Rear Exc. Giuleta - Measure distance between rear axle housing and rubber pad. If measurement not within specifications, adjustment is necessary before proceding with wheel alignment checks. Remove spring. See Coil Springs in SUSPENSION Section. Insert spacer of suitable thickness between spring and its seat. Install spring and recheck rear measurement.

Guiletta - Caster is nonadjustable. If not within specifications, check suspension for damage. Repair or replace components as necessary.

All Others - Caster angle should be checked under static load with shock absorbers disconnected at one end. Difference in caster angle between left nad right front wheels should not exceed 1/3". If caster angle is not within specifications, loosen lock nuts on upper control arm stud rods and lengthen or shorten strut rods to obtain specified angle. Retighten lock nuts.

Giuletta - If camber not within specifications, loosen bolts for brackets on upper wishbones. Add or remove shims between bracket and body until camber set to specifications. Tighten bolts.

All Other Models - Camber is nonadjustable. If not within specifications, check suspension for damage. Repair or replace components as necessary.

Giuletta - Position wheels in straight ahead position. Loosen track rod lock nuts. Adjust left hand lateral track rod to set left front wheel to zero toe-in. Measure length of left track rod and adjust right track rod to same length. Adjust right track rod by loosening central track rod until right wheel set to zero toe-in. Reduce both lateral track rods by equal amounts to set toe-in to specifications. Tighten all lock nuts.

All Other Models - Position wheels in straight ahead position. Loosen lock nuts on left hand tie rod and rotate tie rod until toe-in on left wheel is 1/16". Measure left tie rod and adjust right tie rod to same length. Adjust right track rod by loosening central track rod lock nuts and rotating central track rod until right wheel set to 1/16" toe-in. Tighten all lock nuts. Measure both tie rod lengths and central track rod. If not within specifications, check suspension for damaged components. Repair or replace as necessary.

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NOTE - These illustrations are not intended to represent exact structure of the manufacturer's frame, underbody or body outline. These are presented only to give the mechanic some point of reference.

The following illustrations indicate areas (parts) of the underbody and frame which may be used to raise and support the vehicle, using either floor jack or hoist. Thse points are indicated by shaded areas on the frame (see sample illustration).

Those points designated on the outline of the body were specifically designed to facilitate the use of the vehicle's own jack, but may also be used to raise and support the vehicle by means of floor jack or hoist. These jacking points are indicated by circular dots on the outline of the body (see sample illustration). If floor jack or hoist is employed, extreme care should be exercised to prevent damaging the outer body shell.

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All Models - Check working surfaces of ball pins and their seats, and ball joint studs for damage or wear. Axial play should not exceed specifications (.04"). Replace complete ball joint unit when indicated

All Models - With lower control arm removed, measure axial (up and down) movement of ball joint stud. If movement exceeds .0945", replace ball joint.

All Models - With components removed from control arm and ball joint still installed, check the following: Horizontal and vertical free play (0") and ball joint rotation starting torque 4-7 ft. lbs. (.6-1.0 mkg). Replace ball joints if correct specifications are not obtained

All Models - Check working surfaces of ball joints and studs for wear or damage. End play should not exceed .031" (.8mm). If end play is excessive, replace ball joint.

All Models (Exc. 620 Pickup) - Remove lower control arm. Measure axial movement by lifting and depressing ball joint stud. Difference between these two measurements is axial movement. Using suitable spring tension gauge attached to top of ball joint stud measure force (INCH lbs.) required to move ball joint stud laterally. If either measurement is not within specifications, replace ball joint.
All Models - With vehicle raised and supported under lower control arms, grasp wheel at top and bottom and try to shake wheel. If any movement is noted, control arm must be removed for further inspection

All Models - Raise and support front of vehicle. Attach dial indicator onto lower control arm with indicator tip on steering knuckle near ball joint. Place pry bar between lower control arm and steering knuckle.

All Models - Upper ball joint must be replaced. If signs of wear or play are evident. The lower ball joint is adjustable with shims if axial play exceeds .004-.006" (.10-.15 mm). Shims must not be removed to take up excessive wear in ball pin and socket. If parts are excessively worn, replacement is required.

With vehicle raised and supported under lower control arms, grasp wheel at top and bottom. Try to shake wheel and if any movement is noted, inspect front suspension for wear or damage.

All Models - Check ball joint dust seal for wear or damage and, if necessary, replace seal. Ball joint end play must not exceed .039" (1 mm). If end play exceeds specifications, replace ball joint.

All Models - Raise and support front of vehicle. Inspect ball joint rubber boots for damage and replace as necessary. Using suitable gauge (J-23745) measure axial play. If axial play is more than .080" (2 mm), ball joint must be replaced.

All Models - Inspect ball joints for roughness or excessive wear. Replace ball joints as necessary.

All Models - When moving ball pin some friction torque should be felt. If ball pin can be moved without resistance and end play is shown, replace ball joint.

All Models - Inspect ball joints for wear or excessive play. Replace ball joint as necessary.

All Models - If ball joint exhibits excessive play, it must be replaced as a complete unit.

All Models - Check ball joint for excessive play by pushing and pulling on ball joint stud. Allowance loosness is less than .012". If play exceeds this specification, ball joint must be replaced.

All Models - While rotating hub, tighten spindle nut to 18 ft. lbs. Loosen nut, then retighten to 7 ft. lbs. Back off on nut 1/4 turn and install cotter key. If slot in spindle nut does not align with hole in spindle, tighten nut until it is possible to insert cotter key. After cotter key is installed, ensure that bearing retainer plate can be easily rotated by insterting a screwdriver in plate holes

NOTE - The following procedure can only be performed using special tools indicated.

Model 100 (Front) - 1) Raise and support front of vehicle. Remove lower wheel bolt and replace with special wheel bolt adapter (V-104) and special dial indicator (G-43). By means of retaining screw on special tool (V1-104), adjust dial indicator to pretensioned position of 1 millimeter.

2) Grasp wheel at front and rear. First push inward on front while pulling outward on rear, record dial indicator reading. Reverse this procedure and record dial indicator reading. Difference between these two readings is wheel bearing play. If play exceeds .04-.07 mm, adjustment will be necessary.

3.) Remove cotter pin and castle nut. If there was too much play, tighten spindle nut until play is within specifications. If there was insufficient play, remove wheel, spindle nut and its shim. Replace and tighten spindle nut. Using 1 millimeter feeler gauge, loosen spindle nut until it is possible to insert feeler gauge between spindle nut and wheel hub. Attach special hub puller (V-26) and withdraw hub until it is firmly in contact with spindle nut. Remove puller and retighten spindle nut until it is within specifications

Model 100 (Rear) - Raise and support rear of vehicle. Remove grease cup and one wheel bolt. Attach special dial indicator (30-43), using wheel bolt adapter (40-104) and attachment (10-22). Dial indicator activator foot should be pretensioned to 1 millimeter against the stub axle. Grasp wheel at front and rear. Move wheel on horizontal axis. If reading on dial indicator is not .02-.04mm, adjustment will be necessary. Adjust by loosening or tightening spindle nut

NOTE - Fox front wheel bearing is not adjustable. Torque stub axle nut to 13 ft. lbs.

Fox (Rear) - Remove grease cup, cotter pin and castle nut. Tighten spindle nut and loosen for adjustment. Adjust by lightly tightening spindle nut until plain washer (beneath spindle nut) can just be moved from side to side, using screwdriver. Thin adjustment will correspond to .0012-.0027" (.03-06 mm) wheel bearing play.

Austin Marina - Raise and support vehicle so that front wheel is not touching ground. Remove grease cup and attach suitable magnetic base dial indicator with base on brake drum and actuating foot touching spindle. Bearing wobble should be from .001-.005". If adjustment is required remove cotter pin and slacken castle nut. Torque castle nut to 5ft lb. while spinning wheel. Stop wheel, slacken castle nut, and retighten castle nut, finger tight only. Reinstall cotter pin. NOTE - At minimum end-float figure given a considerable amount of movement will  be felt in the front wheel. Do not reduce end-float below .001".

2002 Models - While rotating wheel hub, tighten castle nut to 22-24 ft. lbs., then rotate hub at least two more times. Loosen castle nut until bearing end play is noticed. Tighten castle nut to maximum of 2.2 ft. lbs., then loosen nut to nearest hole an install cotter key. NOTE - After adjustment, slotted washer should move easily, without noticeable resistance.

3.0 Si and 530 i Models - While rotating wheel hub, tighten castle nut to 7 ft. lbs. Loosen castle nut approximately 1/4 turn. Insert screwdriver in recess of bearing retainer washer and ensure washer can be rotated easily. Install suitable gauge holder (BMW 00 2 500) on wheel hub and install dial indicator with tip touching front axle stub. Move wheel hub back and forth several times and check bearing end play. Adjust castle nut until bearing end play is .0008-.0024". NOTE - Set bearing end play as close to lowest limit as possible. Install cotter key.

All Models - Rotate wheel, hub and drum assembly while turning adjusting nut to 17-25 ft. lbs. Back off nut one-half turn. Retighten adjusting nut to 10-15 INCH lbs. Reinstall cotter pin and check front wheel rotation

All Models - Tighten adjusting nut to 14.5 ft. lbs. After seating bearing components, loosen nut to 0 ft. lbs. Now make final adjustment to 3.6 ft. lbs. After installing lock cap, insert cotter pin. NOTE - Do not loosen adjusting nut more than 15 degrees to align spindle holes.

All models - While rotating wheel, hub and drum assembly, tighten adjusting nut to 17-25 ft. lbs. Back adjusting nut off 1/2 turn and retighten nut to 6-8 ft. lbs. Install new cotter key and check wheel rotation.

All models - Tighten spindle nut to torque specifications in following table. Spin wheel and retorque spindle nut. Loosen nut according to specifications in following table and then tighten to align cotter key hole. Insert cotter pin.

Application                        Torque                  Loosen
B210..................................22-25....................90 Degrees
Pickup................................22-25....................40 to 70 Degrees
All Other.............................18-22...................60 Degrees

Model 124 and 131 - While rotating hub, torque spindle nut to 14.5 ft. lbs. Completely loosen nut and retighten to 5 ft. lbs. Loosen nut 30 Degrees and stake collar of spindle nut into machined slot on spindle. Attach dial indicator with magnetic base on brake drum and actuating foot on spindle. Hub end play should not exceed .004". NOTE - When ever spindle nut has been removed it must be replaced with a new nut.

Models 128 and X 1/9 - Tighten front and rear spindle nuts to 112 ft. lbs. When spindle nuts are properly tightened, stake collar of spindle nut into machined slot on spindle.

All Models (Front) - Front wheel bearings are not adjustable. Torque front spindle nut to 87-130 ft. lbs. (Civic CVCC)

All Models - While rotating hub, tighten nut until no end play is evident. Loosen nut 1 or 2 flats to line up cotter key and install cotter key. End play should be measured with a dial indicator and should be .002-.006". If not within specifications, adjust axle nut to correct end play.

All Models - While rotating wheel, tighten spindle nut to 22 ft. lbs. Turn hub through two or three turns and loosen nut until just finger tight. Check free play. Using a pull scale attached to wheel stud, measure turning torque; adjust nut until pull recorded on scale is 1.1 to 1-2.6 lbs. when wheel begins to rotate.

All Models - With vehicle raised and supported under lower control arms, measure amount of bearing preload using a pull scale hooked on hub bolt. Preload should be 1.3-2.4 lbs. (81600) or .9-2.2 lbs. (all other models). If not to specifications, adjust by tightening spindle nut until correct bearing preload is obtained. Align slot of spindle nut with hole in spindle and install new cotter key.

All Models - While rotating hub, tighten clamping nut until hub can just be turned. Loosen clamping nut and release bearing tension by striking steering knuckle spindle with plastic hammer. Using a suitable dial indicator, check wheel bearing end play. End play should be .0004-.0008". Adjust clamping nut until end play is within limits. Tighten socket bolt of clamping nut. Washer between outer bearing and clamping nut should rotate with light pressure applied to it.

Midget - Raise front of vehicle and remove each wheel. Remove caliper assembly, but do not disconnect hydraulic brake hose. Support caliper to prevent damage to hose. Attach suitable dial indicator and measure runout of hub at outer edge of brake rotor. If runout exceeds .006" remove rotor and reposition on hub. Torque spindle nut to 46 ft lbs. and recheck runout.

MGB and MGB/GT - Raise front of vehicle and remove fron wheels. Using suitable dial indicator, measure hub end play. Correct end play is .002-.004". If not within specifications, remove spindle nut, washer and outer bearing. Add or remove shims behind outer bearing, until correct end play is obtained with spindle nut torqued to 40-70 ft. lbs.

All Models - Raise and support front of vehicle. While rotating wheel, torque spindle nut to 18 ft. lbs. Back off spindle nut 1/4 turn. If slot in spindle nut and hole in spindle do not align, back off nut until they are aligned and insert cotter pin. Properly adjusted wheel bearing will exhibit small amount of end play

All Models - While turning wheel tighten spindle nut to 22 ft. lbs. Loosen and retorque nut to 7 ft. lbs. Lock nut in this position by staking nut collar into slot of spindle.

All Models - Turn wheel and tighten clamping nut just enough to seat roller bearings. Loosen until tab washer can be easily moved in a lateral direction (by means of screwdriver) and no perceptible bearing play is felt when hub is moved axially. Tighten screw on clamping nut to specified torque and recheck adjustment.

All Models (Front) - Front wheel bearings are not adjustable. Torque front spindle nut to 145 ft. lbs.

All Models (Rear) - Install washer and lock nut. Tighten lock nut to 36 ft. lbs. (5 mkg) to seat bearings. Loosen lock nut completely, then tighten nut to 1.4-2.9 ft. lbs. (.2-.4 mkg) and lock nut in place by bending flange into slot of lock nut.

All Models (Front) - Front wheel bearing is not adjustable. Tighten spindle nut to 174 ft. lbs.

4WD Station Wagon (Rear) - Rear wheel bearings are not adjustable. Tighten spindle lock nut to 145 - 181 ft. lbs.

All Models - Check working surfaces of ball pins and their seats, and ball joint studs for damage or wear. Axial play should not exceed specifications (.04"). Replace complete ball joint unit when indicated.

All Models - With lower control arm removed, measure axial (up and down) movement of ball joint stud. If movement exceeds .0945", replace ball joint. See BMW in SUSPENSION Section.

All Models - To check ball joint wear, raise vehicle and attach a dial indicator to a suitable fixed pivot, with stem on ball joint cap. Raise wheel independently of vehicle and note maximum dial gauge reading. If gauge reading is in excess of .098", ball joint should be replaced.

All Models - With components removed from control arm and ball joint still installed, check the following: Horizontal and vertical free play (0"), and ball joint rotation starting torque 4-7 ft. lbs. (.6-1.0 mkg). Replace ball joints if correct specifications are not obtained.

All Models (Exc. 620 Pickup) - Remove lower control arm. See Datsun in SUSPENSION Section. Measure axial movement by lifting and depressing ball joint stud. Difference between these two measurements is axial movement. Using suitable spring tension gauge attached to top of ball joint stud, measure force (ft. lbs.) required to move ball joint stud laterally. If either measurement is not within specifications, replace ball joint.

Application                                      Axial                                      Lateral
                                                                                         INCH Lbs. (cmkg)
B210............................    .004-.012" (.1-.3mm)................................52 (60)
610 & 710....................   .004" (.1 mm) ...................................35 (40)
260Z.............................   .001-.024" (.03mm-.6mm).....................................

All Models - With vehicle raised and supported under lower control arms, grasp wheel at top and bottom and try to shake wheel. If any movement is noted, control ar must be removed for further inspection. See Fiat in SUSPENSION Section.

Raise and support front of vehicle. Attach dial indicator onto lower control arm with indicator tip on steering knuckle near ball joint. Place pry bar between lower control arm and steering knuckle. NOTE - Take care not to damage ball joint rubber boot. Push on pry bar and observe movement on dial indicator. If any movement is noted on dial indicator, ball joint must be replaced. See Honda in SUSPENSION Section.

All Models (Exc. "E" Type Series 3) - Upper ball joint must be replaced if signs of wear or play are evident. The lower ball joint is adjustable with shims if axial play exceeds .004-.006". Shims must not be removed to take up excessive wear in ball pin and socket. If parts are badly worn, replacement is required.

"E" Type Series 3 - Upper and lower ball joints are adjustable by using shims to keep play within limits. Lower ball joint should have .004-.006" axial play and upper ball joint should have .004" axial play. Shims should not be removed to take up excessive wear in ball pin and socket. If parts are worn, replacement is required.

Raise front of vehicle and support under each lower control arm. Grasp wheel at top and bottom and try to shake wheel. NOTE - Do not confuse axial play of wheel bearing with worn ball joints. If any looseness is observed, ball joints should be replaced. See Jensen - Healey in SUSPENSION Section.

With vehicle raised and supported under lower control arms grasp wheel at top and bottom. Try to shake wheel and if any movement is noted, inspect front suspension of wear or damage.

All Models  (Exc. Pickup) - Check ball joint dust seal for wear or damage and, if necessary, replace seal. Check ball joint for wear or looseness by disconnecting each tie rod and attaching a pull scale to tie rod hole in spindle arm. If this measurement is not within 27-40 lbs. (12-18 KG) or 13-22 lbs. (6-10 kg) all other it will be necessary to replace ball joint.

Mazda (Pickup) - Check ball joint dust seal for wear or damage and, if necessary, replace seal. Ball joint end play is preadjusted at factory to be from 0-.08" (0-2 mm). If end play exceeds specifications, replace ball joint in its assembled form.

All Models - Raise and support front of vehicle. Inspect ball joint rubber boots for damage and replace as necessary. Using suitable gauge (J-23745) measure axial play. If axial play is more than .080" (2 mm), ball joint must be replaced.