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QUICK REFERENCE INDEX

DATSUN 210

GENERAL INFORMATION ENGINE TUNE UP ENGINE MECHANICAL ENGINE LUBRICATION SYSTEM COOLING SYSTEM ENGI NE FUEL EMISSION CONTROL SYSTEM

GI ET EM EL CO EF EC EE ER CL
lMr

SERVICE MANUAL
Model
8310 Series

ENGINE ELECTRICAL SYSTEM ENGINE REMOVAL CLUTCH MANUAL TRANSMISSION AUTOMATIC TRANSMISSION
H

INSTALLATION

MT AT
PO

PROPELLER SHAFT
T

OIFFERENTlAL CARRIER

lTY OfOUoW

FRONT AXLE REAR AXLE BRAKE SYSTEM

FRONT SUSPENSION
10

FA RA BR WT
0

INISSAN
N OIlCOIIO

REAR SUSPENSION

WHEEL A NO TI RE STEERING SYSTEM ENGINE CONTROL FUEL BOOY BOOY ELECTRICAL SYSTEM AIR CONOITIONING
NISSAN MOTOR CO
17 1 Ginza 6Chome Chuoku

ST EXHAUST SYSTEMS
FE

BF BE AC

LTD Tokyo 104 Japan

REWO FO

RD

TJili service manual has been

authorized NISSAN DATSUN 1979

prepared for the purpose of assisting service personnel of dealerS in providing effective service and maintenance of the

I 210 DATSU

owners

Since proper maintenance and service are absolutely essential in satisfying the DATSUN this manu31 should be kept in a handy place for ready reference and should be
t

carefully studied
This manual includes removal and instaUation

procedures for maintenance adjustments minor service operations and for rli mblyand assembly of components

Some of these service

effective The As

performance of service
tools are

opemtions require operations

the

of Special Tools

especially designed

for

special

presented

at the end of each section

w ll lIintenance procedures inthis service lu y through the l lual m3 occasionally come across paragraphs headed NOTE CAUTION or WARNING A NOTE is supplemental information that is important to a particular procedure CAUTION and

you read

WARNING and
or

warn

of

steps

that must be fonowed to

prevent damage

to some

part

of the car

personal injury
Quick page
Reference Index At the
on

The

the first page enables the

user a

to

quickly

locate the

desired section

beginning

of each individual section is

table of contents

which

gives

the

mimber

on

which each

major subject begins specifications

contained in this manual
are

An information illustrations and

the latest

based

on

product information

available at

the time of

publication approval

If your

DATSUN model differs from the

specificationS

contained in this manual

consult your

NISSAN DATSUN dealer for information

Rights

for alteration at any time of specifications and methods

are

reserved

liability

for any
td

personal injury

or

property damage
of Y
1 r

occasioned

by
no

the

use

of this

service manual in

effecting maintenance or repair

using
a

DATSUN is in

way assumed

by

Nissan Motor Co

Accordingly
the
car s

anyone

service

procedure

or

tool

which is not

recommended by NISSAN

must first

completely satisfy

himself that neither his

specifically safety nor

safety

will be

jeopaiiliiedby

the service method selected

NISSAN MOTOR Co lTD 17 1 chomo G11ZlI6 kil TokyO l04 chuD

1978 N1SSAN MOTOR

LTD Printed in Japan CO Not to be reproduced in whole or in part without the prior writtenpermisUon of Nissan Motor Company Ltd Tokyo

Japan

DATSUN 210

Model 8310 Series

SECTIONGI
GENERAL INFORMATION
CONTENTS
MODEL VARIATION GI
GI GI GI GI GI GI PLATE 2 3 3 3 4 4 4 4

IDENTIFICATION NUMBERS
CAR IDENTIFICATION NUMBER CAR SERIAL

RECOMMENDED FuEL RECOMMENDED LUBRICANTS lMENDED RECOf

RECOMMENDED NUMBER

GI GI GI

5 5 5

LUBRICANTS
SAE VISCOSITY

IDENTIFICATION NUMBER PLATE ENGINE SERIAL NUMBER

COLOR M V S S CODE NUMBER LABEL LABEL CERTIFICATION

GI GI

5 6

LUBRICATION CHART

MAINTENANCE

SCHEDULE

GI

LIFTING
GARAGE
TOWING

POINTS AND
JACK

TOWING
STAND

Gill j9
GI 9 GI eGI

EMISSION CONTROL INFORMATION

LABE L MANUAL

PANTOGRAPH

GI

4 4 4 5

JA CK AND SAFETY

TRf NSMISSION

NUMBER

GI
GI

9
I

AUTOMATIC TRANSMISSION NUMBER APPROXIMATE REFILL

TIE DOWN

CAPACITIES

GI

SPECIAL TOOLS
j

p
O

General Inform ation

MODEL VARIATION
Differential carrier Destination Class Model

Engine

Transmission Model Gear ratio 3 700

3 889

door 4
Sedan do or 2

I
I

HL8310V HLB310AV

F4W60L

Hl50A

3N7lB F4W60L

H150

IHLB3IOR S V I HLB310RFV

I
I
AI4

Hl50A FS5W60L 3N71B F4W60L

HI50A Hl50

3 700

Ii I
I
Hatchba k

HLB310RAV KHLB310V KHLB310FV KHLB310AV WHLB310V WHLB310FY

WPLB310AV AI5

I
I

3 889

3 700 3 889
3 700

J
Wagon
sA u

I I I

J I
I

FS5W60L 3N71B
F4W60L H150

Hl50A FS5W60L 3N71B

Hl50

3 889

I
Sedan

HLB310U door 4

HLB310AU HLB3IOR S lL

I
2 door

t
f
l

HatChback

IHLB310RFU I HLB310RAU I KHLB310U O KHLB310FU I

I I I I
AI4

F4W60L 3N71 B

HI50A
Hl50

3 700
3 889

6Q Y 4

UOA J FS5W60L
3N7IBr
Hl50

3 700

3 889

I
I

F4W60L
Hl50A

3 700
3 889

FS5W60L 3N71B F4W60L HI50A

3 700 HI50

I
I
Wagon

KHLB310AU

WHLB3 WU WHLB310FU WPLB310AU AI5

g
E

FS5W60L 3N7IB F4W60L 3N71B F4W60L H150A

3

HI50 HI50A HI50

3 889 3 700 3 889

HLB310N door 4
J

HLB310AN
c

Ifi

Sedan
door 2

HLB310R S N

700

HLB310RF I
HLB3IOR S AN

FS5W60L 3N71B
AI4

i
c

HI50

3 889
3 700

ll 1J
C I

Canada KHLB310N Hatchback KHLB310FN KHLB310AN WHL83 ION F4W60L HI50A FS5W60L

I
I
I

3N71B F4W60L

Hl50

3 889

Wagon

WHLB310FN

WHLB310AN

I I

Hl50A FS5W60L
3N7lB

3 700

Hl50

3 889

Note

In this manual FU model refers to KHLB310FU

GI 2

General Information
The

meaning of prefix and suffix lL

K I

OR
R S

DlA
F
v

B310

0 K
W

Sedan

California models California Non California Non

4 5 models for U A

Hatchback

G
N

Wagon
A 14 A 15

models for Canada

@
p

engine engine

@J
F A

speed Manual transmission speed Manual transmission

iD

Left hand drive

Automatic transmission Deluxe model

Standard model
door 4

Note

0means

no

indication

L@

door 2

IDENTIFICATION NUMBERS
The
unit and
car

numbers

are

stamped and registered at the factory The engine and vehicle identifica
tion numbers are used on ments

CAR IDENTIFICATION PLATE

The cated
car

CAR NUMBER

SERIAl

legal

dacu for
as

identification plate is lo
cowl

These

numbers

are

used such

on

the

top in the engine

factory

communications

compartment

Techn cal Reports

tiOD

Warranty Claims

Service Journals and other informa

v r
LCQ23

HL

rp
LC025

Fig Gl

Car Identification Plate Location

Fig GI 2 Car Serial Number Location

GI 3

r
General Information

IDENYiFICAYiON
NUMBER PLATE
The located identification number
on

COLOR CODt NUMBER LABEL

plate
is is

EMISSION CONTROL INFORMATION LABEL

The emission control information label is attached to the back of the

The

body
core

color code number label the top face of the

the upper surface of the instrument panel and can be seen from outside through the windshield glass The identification number consists of
the car model and the serial number

attached to

radiator

support

engine hood on the right side

LC024

Fig

GI 3 Identification Number Plate JAJcation

GI391

Fig GI 5 Color Code Number Label

Location

MANUAL TRANSMISSION NUMBER

The transmission rial number is

stamped

on

the front upper face of the

case

transmission

ENGINE SERIAL

NUMBER
The

engine
on

serial

number

is the

stamped

the

right hand side of

cylinder
down
as

block The number is broken shown in the

tothe

M V 5 S CERTIFICATION LABEL
The M V S S certification label is
s

following

chart attached to the driver

or

GI225

according

engine

Fig GI B Manual Transmission

Number

side lock

pillar
6 GI

zti on Loc

center

Engine model
AI4 AIS

Engine

pillar as

shown in Fig

number

AI4 XXXXXX AIS XXXXXX

AUTOMATIC

TRANSMISSION NUMBER
The
transmission serial number

lL
s
I

plate

is attached to the
case

right hand side

of the transmission

C
SP062

p
LC026 AT344

Fig C 1 4 Engine Serial Numbf Location

Fig

GI 6

M V S S Certification Label Location

Fig

Gl 9 Automatic Transmission Num ber Location

4 GI

General Information

APPROXIMATE REFILL CAPACITIES

Liter

US
3

measure

Imp meas4re
2 2

Erigine crankcase

AI4 Without oil filter Al5

3 2 2 8 3 7 33 5 2 5 0

qt

qt qt

3 qt

Withoil

w
Al5 M T

llLgt
3 5

3Y qt
2 4 4

qt qt

it
qt
q

EIgine cooling system

Without heater

AfT
With

5Y qt 6 Y at

MiL

5 9
57

5Y qt
5 qt

heatfr

A T
soeed

6qt
2 Y ot

Transmission case

3 1 2 1 53
0 9

2Y
2 4 I

pt pt

MaDllal
5 spee Automatic Final drive
case

2
5 1

pt qt
pt

qt pt pt

housing

Steering gear box

Fuel tank
Air

25 0
50

pt
13 Y
I II

gal

conditioning system Refrigerant Compressor

oil 1

0 8 tol Okg 0 237 Includes 2 7 liters 2 US qt 2

1 8 to 2 2 1b

18 to 2 2 lb

8 0 floz

83f1
Ji

oz

Imp qt

for torque converter

j
j

RECOMMENDED FUEL
Use
91
an
a

f
It
1
contamination
t

tl
J
n

4i

unleaded

or

low lead gaso

els

For cars

equipp

with the

Cataly
to

protect the catalytic copverter froitr

line with RON

minimum octane rating of Research Octane Number

tic converter
use

California and FU mod

only unleaded gasoline

NDED LUBRICAN
RECOMMENDED L COMMENDED
NGON 0

VISCOSITY NUMBER
L
I lc 30 ItM

J
I

I
Lubricant

IlL

Specifications
APISE

Remarks

7 l

I
t1

l
I
ItM

U
I

L L

tJ
I
fu inld do

GasOline
Gear oil

engine oil
Transmission and steering Differential

30

Further details refer to API GL4

JIl

recommended SAE viscosity chart

I
I

API GL 5

liOwl L
1 I 1 10 I

II
I

Au omatic

TIM fluid

Type

DEXRON Lithium soap base US FMVSS No 116

21
l 1

Multi purpose grease

Brake and clutch fluid

NLGI No 2 DOT

I I

I
I

I
I

1
c

71

Anti freeze

Ethylene glycol

base

DIUt

I2lItMOl

UGIIII FI

I NIl 01

R a

GI 5

Gl

Z3

a0

0 3

oI

0
t

i q

NIOg 000
I

on

5 d
v 0

co ve
0
C h

uTE
n

ECTRO
E

R l RE

UIO

fl

tlSNISOtl
TER
fII
ER

cond Idling
vere
l NU

l 1R

ve oe

do
W

l OVl

SIIER

NEO

TIC l OM

dU
de
u

fll

i ERU
uent
oot
e

VlltlOSl lIE

l B

WINO W @fUEl

Ol

@EtlG

l U TR l

tlsMIS Otl

ten eog

unde
od
i

l M

ooe

drivIng

chenge ooth

OT

cle

eintoen it

ve ho dU It

dilone condilon 000

W
3

Nlo

condit
tj

ooo
If
1I v

000

0130
s

000
1 v u

Io li

or

Iofl

all

000
5

co
e

oed
Ol

everY hlCh
eree
0

ul ng 08c
In
h

eAiE QG REtlS
IP I IBR I

Ot
l IO
I
f

UIO
f

8o@

R l GE

ie
e e

on
3

tl l

coo

RIN

R l GE

l BE

CIl
U

llE l BR

lItlGE

TCII

l l OlffERENTI

o er tod
I

ve

or
1

ENGINE WIE I
itlNGE C iEel C

CI

STE RING
Cb

OCll 1 0 0
@
Q t 0

000 vohicle her 3

II o

cor o

fRON

lif

zs r
Ci

Cl ll

Qoo l o 3

g
a

P
P
I I

P
l

l l l P l
l
I I

u
L

72 45 36
l

VP

lEI

60 37 30
P

P
I

I P f

48 CE
P

301
5

24
l

36 2 24 15
1

18
P
2 1 l

1E
P
2 1 5

P P P
2 2 2

6
1

1000
j

NCE
l es

11 IO ra

efS

M N1E Jl Month
e

rpm turu
1

IdlG

fl

conv
e

t8

con
rto
V e

r
J

IV

O ca th

CONl
ot
e

conv
e V

ralV
c

ca
h
i

de

ra
e

rh
1

It

odO

numbef
ce

EMIS ON
on Ql1

QP
1

od

pped
SO
iI C
P

call
1

at co

one
ser

ink NOf
f 0
t

tc
It

ode
n
t

M
C

Caliorn
v c

on

ID w

Itlon

formed chOVe
hId
be
l

on

M
t

eonn ner
cl

O on cal

h C

ect

pl

mile
I

con
lI0 P

000 engine rlI tir lUl

1

should oontnlhO
OU
0 ot

ear1lf
c

con e
filter
0

eof
8l

dec
on
t

chOke
p

nO
p
p

tnte
caP
n P

control
r

ion
i

liel
I

nkca
p e

on
c

cI
v

NEt
a

hO

hOleS

hO
f

lodels ff
a

d 0

OPEl rollTIlelsele CE
terno
A P

Ie

600 and
t

ol

lE

periodicomet rt

exhaust

Brot

te v

8t
e lota

belU

11 0

COO
n

ti 1ng
lrn

dIe

h8

olt 0 t

elo
ca

ChO

h
1

filter
vel
iF

net
f

tO
P

1 laC f

bU ca

lk i l

Coo On EnQlt engine

carbuetor

3da CB

tl 1U plIJQ Spal

Iflng

r10lCS tlOll

cr

ln pol

nk

nd
p

and

grtl Ofl

nltIOfl Vtoti
po

e F

f
I

US

ance

Ip 1

lUe

erfol1
l

l G

72 45 36
5

60

INTERVAL
I I

1137
I I

30

48 30 24 36
I

511

16
r

MAINTEC
I I

24 12
6
1

15 12
I

Replace replace corect

R

condit
if
L

or

mile
000
3

12

611

Adjust Inspe necsary Lubricate

t

ty

du
in

6
I

117
111

A
I

drivng
or

first 000 com

km

000 1
000
1

Kilometrs
of at

Mile

3nthl M

MAINTEC
UNDERHO

Abreviatons
surfaces
road

idling first come

evary

inspect w h i c a v e r extnsive years drivng whlc evar materi l

4

or

ive

frequen
more
or

distance month condit

3

mila

hort

or

number first

perfomd whicewr
be

comes

schedul

varying

OPERATIN mainte c

should month
or

mainte c atmospheric veuhsicalege

normal and and
the

condit s aditona

condit s
under

dusty ever km under

000
3

mile

drivng
if

cor o 60 other
000 000
96

km alt

or

road
u

000
5

ing ery oile

first

mila

MAiNTEC

Periodc kilometrs

show weather charts upon drivng

required habits
i

operatd
If
1

every
oil

mainte c
2

gear
i

ereas
in

comes

be

may

vehicle change More Replace vehicle months

If
3 4

angine frequent

o p e r a t d diferntal whicevr

above
The

Dependir tg

indv ual mainte c

NOTE

Gl

General Information

LIFTING POINTS AND TOWING

PANTOGRAPH
of the

JACK

FRONT
I
car

SIDE
up the front of the
rear

Place wheel chocks at both front

and

When jacking
to

back

wheel diagonally

place the chocks behind the

hold them

opposite the jack position

wheels
2

gently just high place the safety stands under the rear axle case or body Place the stands at the positions
car

Jack up the
to

enough

the garage jack under the front suspension member Be sure not

Apply

indicated below

to lift up the

engine oil pan

GIOB5

Fig GI II Wheel Chocks

GI379

Apply

the

nished with the

pantograph jack fur car to the position

a

Fig GI
GI372

16

Rear Supportable Point Rear axle c rue

Fig GI 13 Front Jack Up Point 3 Jack up the

to
car gently just high place the safety stands

indicated below in

safe

manner

See

Fig GI

12

enough
WARNING
a

under both the side members Never get under the car while it is supported only by the jack
14

Place

the stands at the position indicated in

Fig GI

Always

use

safety

stands

to

support frame when you have to get under the car

b Block the wheels wheel chocks

diagonally with

GI392

Fig 01 17 Rear Supportable Point Body

GI373

Fig GI 14

Front Supportable Point

TOWING
CAUTION
a

Release the jack slowly It is necemry to use proper towing equipment to avoid possible dam
to the car during a towing operation Towing is in accordance with Tow ing Procedure Manual at dealer side All applicable State or Provincial

REAR SIDE
Jack up TROSO car

When jacking up the rear of the place the chocks at the front side

age

Fig GI 12 Jack Up Points

ofthe front wheels to hold them

2

Apply the

garage

jack

under the b

differential carrier

in

Canada

laws

and local

laws

GARAGE JACK AND SAFETY STAND

1 Il

regarding the
must be

towiilg

operation

obeyed

WARNING When carrying

out

operations

with
GI378

FRONT SIDE
Front

the garage jack be sure to support the car with safety stands

towing hooks

are

provided

Fig GI 15 Rear Jack Up Point GI 9

on

both front side members

General Information REAR SIDE CAUTION

a

Before

towing
r

make

sure

that the

Use

rear

towing

hooks

for

tie

transmission and p If any

axles

train

unit is

steering system in good order damaged a dolly

are

down at the rear side

must be used

If the transmission is

inoperative
off

tow the car with the

the

rear wheels

ground

or

with the

propeller

shaft removed
GI417
c

When the

car is

towed with its front

Fig GI 15 Front Towing Hook

wheels

on

the

steering position
REAR SIDE
Rear

wheel in with OFF

turnedin d When

ground secure the a straight ahead the ignition key position

automatic trans its
rear on

towing

an

towing hooks

are

provided

on

mission model and

e

wheels

rear sides bot

do not exceed 30
a

h 20 MPH km

distance of30 km 20 miles Release the parking brake and set

the

gearshift lever in position before starting

car

Neutral
to tow the

TIE DOWN
FRONT 51 DE
GI418

Use down
at

front

towing hooks

for

tie

Fig GI 16 Rear Towing Hooks

the front side

SPECIAL TOOLS
Special
are

Tools

play

very

important
cars

role in the maintenance of essential

to

These

the safe accurate and

times

The identification code of linte ffi nance tools is made up of 2 alphabeti calletters and The
digital 8 two

EMOOOOOOOO

Engine Overhauling
Machine General

speedy servicing The working

figures
letters roughly
as

GGOOOOOOOO lMOOOOOOOO HTOOOOOOOO

Gauge

listed in the

column under FLAT RATE TIME in FLAT RATE SCHEDULE

are
com

heading classify tools c equipment

Garage

Tool

Hand Tool

Refer to Service Bulletin DATSUN STOOOOOOOO KVOOOOOOOO

puted based
Tools

on

the

use

of

Special

Special Special Tool

GI l0

Tool

210 fOJ Special Tool List and further information of Special Tools

DATSUN 210

Model 8310 Series

SECTIONET
ENGINE TUNE UP
CONTENTS
EMISSION CONTROL DEVICES BASIC MECHANICAL SYSTEM
INTAKE AND EXHAUST ET DRIVE ET ENGINE OIL ET ET ET HOSES ET COMPRESSION ET 4 4 3 3 3 4 3 CLEARANCE AND ADJUSTING ADJUSTING VALVE ET ET 2 3 REPLACING CHECKING Hoses FUEL FUEL FILTER LINES
etc

ET

ET 10

piping

connections AIR

ET 10

REPLACING
FILTER

CLEANER ETlO

CHECKING BELTS CHANGING

CHECKING AUTOMATIC TEMPERATURE CONTROL AIR CLEANER ET 10

REPLACING 01 L CHANGING CHECKING

FI L TER COOLANT SYSTEM

EMISSION CONTROL SYSTEM

CHECKING VACUUM AND CONNECTIONS REPLACING AIR PUMP AIR CLEANER FITTING HOSES ET 11 FILTER E FILTER ET 11

ENGINE COOLING

AND CONNECTIONS CHECKING ENGINE

IGNITION AND FUEL SYSTEM

CHECKING CHECKING IGNITION BATTERY AND ADJUSTING TIMING ET ET 5 6 ET ET 5 5

Except FU models and Canada models

REPLACING AIR FU INDUCTION VALVE

1122i
C

models

and Canada models PCV VALVE AND FILTER

tlil1r2 E

REPLACING CHECKING CHECKING CHECKING ET 6 VALVE REPLACING ET 7

ETf
I

VENTI LATION HOSES VAPOR LINES VACUUM RELIEF

E1P12
Eli J2
III f
ET 13

CHECKING IGNITION WIRING

CHECKING AND PLUGS CHECKING IDLE RPM AND ADJUSTING AND MIXTURE CARBURETOR REPLACING SPARK

FUEL TANK

CARBON CANISTER ET

RATIO

FILTER
SERVICE DATA AND

CHECKING CHOKE MECHANISM

Choke plate and linkage ET SYSTEM ET 9 9

SPECIFICATIONS
TROUBLE DIAGNOSES AND CORRECTIONS SPECIAL SERVICE TOOL

ET 14

CHECKING FUEL SHUT OFF

FU models

ET 16 ET 23

m l Q 3ll l c l ll

A1S
I

Non CaliCor nia modeb Except for Can da

T A

Wagon
T

Califor models
nia

Staion models
I

Can da
B310
T

sy tem
I

M
I

models nada
for

FU
T A

models
I I

X
I I

DEVICS

C
X X X

AI4

Californa cept
Non

xl
X

X X

Except FU models
T A
I

X
I I

transmio transmio matic temprau injection backfire

Manual Automaic Aute POlitve
X

control coefi nt iAinductor ateumrpeeJ sy tem valve

or

Air

Anti valve

CONTRL EMISON
I

models

X X

X
I I

Californa
model
ine
En

C C S T T T T I B M A A P A A
X

M
I

X
I I

model
Car

ansmiuo

valve
S

Ti

e T

check valve valve valve valve

R

models
1979
on

type Dual

sy tem
duct
air

cleaner
air
C T A
I

Idle

compensatr Fresh Exhaust

fuel

evaporti

type

sy tem c h o k e gas open r off

auto
C T
P

Early

t Thr le

shut
I

po

ignitor timing vacum delay

C
I H
I

Fuel Dash

presu Newly i n d u c t i o n Spark Thermal Vacu m Combined Relief Exhaust Back Cat lyJc Remarks
pump valve
valve
gas
Air A
B

sy tem Filter valve pump control valve contra valve Air

A

cleaner

T
P

G
E

C C

air

air

reciulaton transducer convert

valve

unit

Air

Thetmalvcu

equiped

Availbe
X

avilabe
Not

CLEAN
AIR ER

ENGI E BASE CARBV RETOR

IGNTO SYTEM
miN

R G E

I A

SYTEM

CATLYZER

Engine

Tune up

BASIC MECHANICAL SYSTEM

ADJUSTING INTAKE AND EXHAUST fE CLEARANCE VAL
Note After
been nut

adjusted correctly tighten lock firmly to secure ihe adjustment

Hot

Valve clearance

CHECKING AND ADJUSTING DRIVE BELTS

I

Check for cracks Normal

drive

or

damage Re
deflection is

bolts

tightening cYlinder head adjust intake and exhaust

Intake

0 35 mm

0 014 inl

place if necessary
2

Exhaust 0 35 mm 0 014 in

belt
is

valve clearances

figure below showndI

when moderate

tJl
Valve clearance
be made while the tion To I

ljustment ai

cannot is in

engine
as

opera

Tightening torque Valve rocker adjusting 1 6 to 2 2 kltm

12 to 16 ft lb

thumb
nut

pressure

applied midway kg 221bl

between pulleys Thumb pressure

Idler

10

adjust proceed

follows

engine and warm it up uritil water temperature indicator points to

Start

pulley

Alternator

the middle of gauge Then stop engine

2 Rotate crankshaft to in

bring

No I
on

cylinder top dead compression stroke

3

center

its

Remove valve rocker cover

Adjust valve clearance at following four points while engine is still hot CD Exhaust valve of No I cylinder @ Intake valve of No I cylinder @ Intake valve of No 2 cylinder

@ Exhaust valve of No
Note

cylinder
Compressor
111ey p1

Numbers in circle agree with those in accompanying sketch

Unit
mm

Crankshaft

pulley
Idler

AC710

in

pulley

Fig ET 2

Checking

Drive Belts for Deflection oil filter

CHANGING ENGINE
OIL
1
or

Without
3 A15

3 2 liters

USqt

2 U

ImP ltl

Check if oil is diluted with water

Drain

gasoline necessary

and

refill oil

if

With oil filter 3 3 liters 3 US qt 2 U Imp qd Without oil filter 2 8 liters

tiri
Fig ET 1 Adjusting Value Clearanu

Note
a

milky oil iiulicates the presence of cooling water Isolate the cause
and take corrective
measure

3 us qt

Imp qd

b An oil with extremely low viscosity indicates dilution with gasoline

4
so

Again
that No

rotate crankshaft 4

one

turn

Check

oil

level
raise it

If

below

the

center on its

piston is in top dead ompression stroke Ad

specified level
level 3

up to the H

just following valve s

Change engine

oil in accordance

REPLACING OIL FILTER

The oil filter is
can
a

CID Exhaust valve of No 2 cylinder @ Intake valve of No 3 cylinder j Intake valve of No 4 cylinder @ Exhaust valve of No 4 cylinder
Adjustment should engine
is be made while

with the maintenance schedule

be

removed

cartridge type and using Oil Filter

Engine
A14

oil

capacity

Wrench STl9320000 Check for oil leaks past gasketed Oange If leakage is found retighten
I

With oil filter 3 7 liters

hot After all

valves have

3 U US qt 3 Yo Imp
ET3

qtl

just enough tightening is

to
no

stop leakage If longer effective

reo re

jngine
ice pl
2

Tune up
determine whether there is
exces

mter When
hand

as

an

assembly
oil mter

installing

tighten

sive

by

leakage past piston rings head gasket etc To test engine should
be heated to the operating t
ture and throttle valve
M

Note

overtighten oil filter lest leakage shoUld occur

Do not

opened
in

Cylinder

compre

on

Cylinders

should not be less than llO of the

highest reading
sion in
ET012

two

ore more an

Different compres cYlinder usual

ly indicates
valve
c or

improperly

seated

CHANGING ENGINE

Fig ET 3 Testing Radiator Cap

broken piston ring

in cylinders am piston rings This usuaDy be accom

COOLANT
PERMANENT ANTI FREEZE

Low

compression
worn

result from

COOLANT
Note anti freeze permanent coolant is an ethylene glya base l product containing chemical in

COOLING SYSTEM PRESSURE TEST Witli radiator cap removed reference

pressure

trouble

may
ex

panied by tion apply

23 I 2
means

ssive fuel consump

The

16

kgfcm2

psi
0

to

the
no

cooling system by

hibitors

protect the cooling system from rusting and corrosion The anti freeze does not cOntain
to any

Warm up engine sufficiently Disconnect aU spark plugs Disconnect dieseling anti solenoid

3
4

valve connector

glycerine
not

or

ethyl alcohol It
or

will
can

evaporate

boil

ay and low or

Properly attach a compression to spark plug hole in cylinder being tested

tester

be ilsed with either

high

temperature thermostats It flows freely transfers heat efficiently and will not clog the passages in the The anti freeze cooling system
must not be mixed

with other Fig ET 4

product This coolant can be used throughout the seasons of the year
Whenever coolant is changed the must be flushed and
a

cooling system
refilled with coolant level
See

Water

new

coolant Check the

capacity
5 2 liten

Tmodelsl M
ET529

Without heater

instructions

attached

to

the

anti freeze container for mixing ratio of anti freeze to water

1f US qt 4 5
With heeter 5 9 Iiten

Imp qt

FiI

ET S Testing Compre sion Pr s8ure

4 US qt 5 Y Imp qt 6

Depress accelenit6r pedal

to open

throttle and choke valves

CHECKING COOLING SYSTEM HOSES AND CONNECTIONS

Check hoses and fittings for loose
connections
or

Water capacity AfT modelsl

Without heater 5 0 liters 5 y US qt 4 With heater 5 7 liten

Note

Do not

pump
as

pedal
quickly
as

Imp qt

6 sible

Start

engine

pos

deterioration

Re

tighten

or

replace if necessary

6 US qt 5 Imp

ill

Compression pressllre kgcm2 ii at rpm

Standard 13 5 192 350 Minimum 12 5

INSPECTION OF RADIATOR
CAP

CHECKING ENGINE COMPRESSION

Note
a

1781

350
o a e

If cylinder compression in

or

Apply

reference
13

pressure

0 9

kgj cm2
means

psi

to

radiator cap by

cylinders is low quantity of engine oil

more

pour into

small

cylinders

of

cap tester to see if it is cap

To check cylinder
essential to

satisfactory Replace
necessary

assembly if

compression it is remove all spark plugs

of
4 ET

The

purpose

this test is

to

through the spark plug holes and retest compression I If addingoil helps the compres

Engine
sion

Tune up
sion there is

pressure
are

chances

are

that piston

rings
2

worn or

damaged

If pressure stays low the likeli hood is that valve is sticking or seating

improperly 3 If cylinder compression in any two adjacent cylinders is low and if adding oil does not help the compres

leakage past

the

gasketed

surface Oil and water in combustion cham bers

can

result from this problem

IGNITION AND FUEL SYSTEM

CHECKING BATTERY
I 2 Measure the

specific gravity of
WARNING When 0 and selector lever is shifted to

Remove six

vent

plugs

and check

battery electrolyte

electrolyte level

in each

battery cell If

necessary pour distilled water

position
block

apply parking
both front and

brake
rear

wheels with chocks

Overflow Correct

Shortage

t t j

tt
EE358
E T372

Note
a

On

FU models

set

idling speed
hose dis

with distributor vacuum

connected b Disconnect distributor vacuum hose

at

Fig ET 6 Checking Electrolyte

Level

Fig ET

Checking Specific Gravity of Battery Electrolyte

distributor
8 ET

diaphragm
plug

side

and

plug hose

with blind

See Fig

Permissible value

Full charge value at 200C 680F

28 1

Frigid climates
Other climates
Note
a

Over 1 22 Over I 20

26 1

CHECKING AND
ADJUSTING
IGNITION TIMING
2

Clean top of battery and terminals with a solution of baking soda and
water Rinse off and

dry with com pressed air Top of battery must be c1 n to prevent current leakage
between terminals and from tive terminal to b In
down hold

Check spark plugs for condition Thoroughly remove dirt and dust crank and

ET501

Fig ET B Disconnecting Distributor

Vacuum Hose

posi clamp

from

pulley
front

at

timing
at

mark

location indicator 3 4

cover

timing

addition to current leakage prolonged accumulation of acid and dirt on top of hattery may cause blistering of the material covering ronnector straps and rorrosion of straps Afte r tightening terminals coat them with

Warm up engine

sufficiently
and

Connect engine tachometer

in their proper
to

timing light 5 Adjust idling speed

ed value

positions

Check

ignition

timing

with

the

specifi

timing light
ed
to

to ensure that it is

adjust

specifications

indicated below

Idling speed
Manual transmission 700 pm Automatic transmission

Ignition timing
Manual transmission

petrolatum

vaseline

to

protect them from corrosion

CAUTION If the battery cables are disconnected they should be tightly clamped to the

SO B T 0 California 100 B T 0 California Non

models

f700 C

rpm FU models

6S0 rpm

f700 C

pm Canada

in

position

battery
contact

terminals

to

secure

good

Automatic transmission SO B T 0 f6S0 C

rpm California models

ET S

Engine
SO B T D California Non
except Canada

Tune up

l650 C

rpm
models

Connect the ohmmeter between

on

cable terminal and the cap 3

the

spark plug

side

corresponding electrode inside

resistance
remove

100 B T D C 650 rpm Canada models On FU models ignition timing under a condition where

CHECKING AND REPLACING SPARK PLUGS

I Remove and clean

If the

is

more

than

Note is

cable from cap and check the cable resistance only If

resistance is

30 000 ohms

plugs

in

sand

blast cleaner Inspect each spark Make

2
sure

plug

set

still

more

than

30 000

that they

are

of the

specifi
or

distributor vacuum hose is discon nected If necessary

as

ohms replace c3ble assembly

ed heat range

Inspect insulator

for

cracks

chips
adjust ignition timing
until dis follows Loosen
set screw

Check both center and

ground

electrodes
3

I
2

tributor cuJ be moved by hand

If they are excessively worn re place with new spark plugs 4 Replace spark plugs in accordance with the maintenance schedule

Adjust ignition timing

to

speci
and

fications 3
Lock distributor set screw

make sure that

timing

is correct

YJ

Fig ET IO Checking High Tension

Cable

Stan Fig
7 T 9 Adjusting Ignition Timing

rd

BP ES ll L46PW

sA u models

Hot type

BP4E ll L47PW ll BP7ES ll BP6ES ll

L44PW II L4 PW 11

On FU models proceed

as

fol

lows

Cold type Remove blind

plug

from

dis
S aridard BP5 EQ 13 L46PM 13

tributor

vacuum

hose

and

connect

hose to distributor diaphragm 2 If engine speed varies in this

state
set

Type

FU models

Hot type

BP4EQ 13 L47PM BP6EQ BP7EQ

13

idling speed

at

specified value

with throttle

adjusting

screw

Cold type Standard Canada Hot type Cold type

U

13 L45PM 13 13 L44PM 13

BPR5ES BPR4ES BPR6ES

1 0 to 1

CHECKING IGNITION WIRING

Use
ance on an

models

ohmmeter

to

check resist
mm in

A models S

high

tension cables

LQ39

to

0 043

1 Disconnect cables from spark plugs and remove distributor together with high tension cables

1g r

FU models

l to 1 3 0 043 to 0 051

Canada models

08 ft lb

to

0 9 0 031

to

0 035

Tightening
Note
Do not remove cables from cap

torque

kg

15 to

i6 P

to 14

6 ET

Engine
CHECKING AND ADJUSTING CARBURETOR IDLE RPM AND MIXTURE RATIO
WARNING
a

Tune up specifically
car or recom

engine

is

not

mended Either driving

operat

ing engine
3 Make

at

no

load will be

good

that water temperature indicator points to the middle Further

sure

keep engine running

rpm

at

about

2 000

for

about

minutes

without order to

a utomatic

transmission

applying load to engine in stabilize engine condition

Engine
ET501

models

checks should be per formed with the lever shifted to the 0

hood should be open 4 Run engine for about 10 minutes

Fig ET 13 Disconnecting Distributor

Vacuum Hose

engage both front and wheel chocks b

position Be sure to parking brake and to lock

rear

idling speed During this 10 minutes proceed as described in steps

at 5 to 9 below 5 6
two or

wheels with

Race engine I 500 to 2 OOO rpm three times under no load then

Oepress brake pedal celerating the engine

while
to

ac

I
check
check

Disconnect valve valve

and

air

hose

from
on

air air

prevent

install

cap

forward surge of car After idle adjustment has been made shift the
or

Except

Canada and FU

models

engine for one minute at idling speed 7 Adjust throttle adjusting screw until engine is at specified speed
run

lever

to the

positfon

and

Engine speed
Manual transmission 700
rDm

remove

wheel chocks

Automatic transmission

in CAUTION 00 not

position

650 rpm to
screw

attempt

the

idle
EF244

adjusting screw ing so could

which in
turn

down
cause

completely 00 damage to tip

to
cause

will tend

Fig ET 11 Disconnecting Air Hose from Air Check Valve Except Canada and FU models
Canada and FU models

malfunctions

Note
a

When measuring CO percentage in sert probe into tail pipe more than
40
cm

Disconnect

air

hose

from

air

15 7 in
case

induction pipe induction pipe

els

and install cap on air Canada and FU mod

2

In

thee

of air conditioner the idle

quipped
ment

models

adjust
Fig ET 14 Throttle Adjusting Screw and Idle Adjusting Screw

should be carried out while OFF do

the air conditioner is

c

When making idle

adjustment

not removt air cleaner 8 sary

Check ignition timing

If

neces

adjust

it to

specifications

CO

Idle adJustment
mixture

with CO meter Idle the

use

out at 1 600 km

This operation need nt be carried 1 000 miles service

adjustment

requires

EF849

Ignition timing
Manual transmission

of a CO meter

California models

especially for When preparing to

it is essential to up

Fig ET 12 Installing Cap on Air Induction Pipe

FU models

50 B T 0
California

f700 C

rpm FU models

adjust
have

idle mixture
meter

the

thoroughly warmed

100 B T O C noo rpm

Non California models 3 Canada

and calibrated
1

Check carburetor pipes for proper On FU models

vacuum

connection 2 Warm up engine until water tern perature indicator points to the middle
The

disconnect dis

Automatic transmission

tributor

hose at distributor and plug hose with

in

position

of gauge

procedure

to warm up

diaphragm blind plug

side

50 B T 0 CJ650 rpm
California model

ET 7 J

Engine
SO B T D
California Non except Canada C650 rpm models

Tune up 500 1
to

11

Race

engine

2 000

check nlve models 2

Except Canada
air

and FU
air air

rpm two or three times under no load and make sure that specified CO per

Disconnect

hose

from
on

100 B T 0

C650 rpm

centage is obtained
13 Remove
to

induction pipe induction

and install cap Canada

an

Canada models Note On FU models ignition timing

t

pipe

FU

I
hose
2

cap
check

and connect valve

and

air

models 3 On FU models
vacuum

air

Except
air

disconnect dis

under

con4ition

where

Canada and FU models

tributor
connect

hose at distributor and

distnoutor nected

vacuum

hose is discon

Remove

hose to air induction pipe and FU models If engine speed increases FU models

Canada
it

diaphragm ide plug Race 6 engine

blind
two run
or

plug

hose with

500 1

to 2 000 rpm
no

On

proceed

as

fol

readjust

three times under

load then

lows

specified speed with throttle adjusting screw

to

the

Remove

blind

plug from dis

and connect

14

On

FU

models

proceed

as

tributor

vacuum

hose

follows

engine for one minute at idling speed 7 Adjust throttle adjusting screw to that engine speeds are as indicated
below

hose to distributor diaphragm

Open
sure

throttle

valve

by tuming

throttle shaft

then close it And make click

turns to

throttle valve switch of fuel shut

Engine speed
Manual tra
mi ion

off system heard

or

operates continuity

sound is OFF

except FU models
740 rpm Automatic

when throttle valve is closed

If not adjust throttle valve switch In air conditioner equipped models

transmission

in

position

inspection
carried out with EC370A Fig ET 15 Connecting Distributor
Vacuum Hose air

in

step 13 should be when engine is running

in

665 rpm

FU models
765 rpm

conditioner

ON 8

F l CD is actuated

Check ignition timing

if

neces

Refer

to

Checking

Fuel

off Shut

sary

adjust

it to the value This at

System

in this section

specifications
miles service

required by operation need not

1 600

be carried out

km

000

2 state

If engine
set

speed
at

varies

in this

CO

Idle adjuatment

idling speed

specified value

9 lows

On FU models

without COmater If CO meter is

not

proceed plug

as

fol

with throttle

adjusting

screw

available

the

Remove

blind

from

dis

10

At about is run at

10 minutes after

following procedures
en

may be used

tributor hose
2 state
to

vacuum

hose

and connect
varies in this

gine
is
at

idling speed adjust

idle

Check carburetor pipes for proper

comiection

distributor diaphragm

adjusting

screw so

that CO percentage

specified level

CO percentage Manual transmission t1 2

at

Warm up engine until water t m perature indicator points to the middle of gauge The procedure to warm up

If engine
set

speed
at

idling speed

given
screw

in step 7 with

specified value throttle adjusting

en

engine
mended

is

not

700 rpm

Either
at
no

specifically driving car or

load will be

recom

operat

10

At about is run at

10 minutes after

Automatic transmission in 0

ing engine
3 Make

good

gine

idling speed adjust idle

until maximum rpm is described

position
2 1 t
at

650 rpm

that water temperature indicator points to the middle Further

sure

adjusting
obtained II

screw

keep engine running

rpm

at about

2 000

Repeat procedures
idle
7

as

for

about

minutes

without

in steps 6 7 and 10 above until

engine
is in
as

applying load to engine in order to stabilize engine condition Engine

hood should be open
4 at II Run

speed at best specified in step

10 7 12
Turn
can

mixture

Adjustment

be carried out

step right after step

engine for about 10 minutes

idling

speed
as

During

this

10

the

idle

Repeat procedures

as

described that CO

minutes proceed 5 to 9 below 5

described in steps

clockwise until engine value given below

adjustIng screw speed drops by

in steps 6 7 and 10 above percentage is at

so

specified level Check

can

Engine speed drops

Disconnect
air

ing idle CO in step 10 out right after step 7

be carried

hose

from
on

air air

Manual transmission except FU models

check valve

and install 8 ET

cap

Engine
35 to 45 pm Automatic transmission in 60

Tune up

CO

rich

CHECKING FUEL
SHUT OFF SYSTEM FU models
Precautions
a

position
10 to 20 pm

l 8 rotation

FU model 60 to 70 rpm CO
lean

Before checking make

sure

engine

is warmed up and choke

valve is mod

13
I Remove
to

fully
cap

open

and

connect

air

ISo

Idle limiter cap

b On air conditioner
els

equipped

hose Canada and FU models

2 Remove to air cap

air

check

valve

Except
ET031

turn off air conditioner switch

in steps I through S Idle engine Disconnect anti dieseling solenoid

connector and make sure that

and

connect

air

hose

induction

pipe

Canada

Fig ET

16

and FU models If engine speed rises readjust it to the specified speed with throttle ad

Setting of Idle Limiter Cap

2 valve

justing

screw

engine stops dieseling solenoid

If not
valve

replace assembly

anti

Note

Check throttle return spring for

squareness
or

CI3cks

deformation
with
a new

if necessary
one

replace

CHECKING CHOKE MECHANISM Choke plate and linkage

I

Check choke
free

valve and

mecha

14

On

FU

models

proceed

as

follows

Open
sure

throttle

throttle shaft

valve by turning then close it And make

throttle valve switch of fuel shut

off system operates click sound is heard or continuity turns to OFF

when throttle valv is closed If not

operation and clean or replace if necessary A binding can result from petroleum gum formation on choke shaft or from damage 2 Sefore starting engine fully de press accelerator pedal to ensure that choke valve closes properly 3 Push choke valve with a finger
and check for binding
4 Check to be
sure

nism for

adjust
in

throttle valve switch

Fig ET 18 Checking Anti dieseling Solenoid for Function

FU models

that bi metal

In air conditioner

equipped engine
is in

models

cover index mark is set at the center of

inspection
carried with
out

step

13 should

be

when

running
ON

choke housing index mark below

as

shown
3

air

conditioner

Connect

dieseling anti

solenoid

FI C D is actuated

Note
off Shut

Do not set bi metal cover index

valve connector 4 S

Refer

to

Checking Fuel

System

in this section

mark at any position except the center of choke housing index mark

Restart engine Increase

no

engine

speed
sure

slowly engine

under

load and make

speed
Idle limiter cap
Do not remove this idle limiter cap

is

within the specified range

when throttle valve switch is operated

unless moved
time

necessary it of
as

If this unit is
be

re

must

readjusted
To

at the

reinstallation
follows

adjust

proceed
I

adjusting throttle or idle screw check to be sure adjusting speed

After that the amount of CO contained in exhaust gases meets the established standard
2
1

tfljlL
05
Hi metal Choke
cover

i
ET034

Operation of throttle valve switch is Click sound judged by hearing caused by microswitch inside throttle valve switch Then decrease engine speed slowly and make sure engine speed is within the specified range when throttle valve switch is operated If not adjust throttle valve switch
6 In air conditioner

equipped

mod

els proceed as follows Check F 1 C D rpm and correct 1 if necessary

2 l F With D C air

Install idle limiter cap in position

sure

2 3

housing
cover

ind

marks

making
can

that the adjusting

1 8
turn

screw

Hi metal

index mark

conditioner in
increase

ON

rotate another direction

in the

is actuated

engine

CO RICH

Fig ET 17 Bi metal Setting

ET 9

speed slowly

then decrease it And

Engine Tune
make
sure

up

throttle

valve

click
turns to

sound is heard OFF

to

when

operates or continuity engine speed

Note

If it is difrlCUlt to judge open tion of throttle valve switch by

hearing
1

Click

decrease

If not

idling adjust throttle valve switch

microswitch check

sound caused by as follows va1ve switch

circuit

DiscollIecl throttle
ronnector

and

connect

CHECKING AUTOMATIC TEMPERATURE CONTROl AiR CLEANER

I

tester to throttle va1ve switch 2

Check that
to

vacuum

hoses Intake
3 way
sensor

Run engine under

it is within the

no

load Increase
sure

manifold to 3 way connector

connector

engine speed slowly and make

temperature
sensor to

range when throttle valve switch is turned on

specified

3 way connector to idle compensator

temperature
are

vacuum motor

Then decrease and make

engine speed slowly

it
is within

securely connected

in C9rrect

posi
or

sure

the

tion 2

specified
If not Fig ET 19 AdjlUting Throttle V
ve

range when throttle va1ve

Check each hose for cracks

switch is turned off

distortion
3

adjust
sure

throttle valve switch

Check A T C system for function

as

Make

continuity of throttle
OFF in the

by proceeding starting
With
test

follows

Switch

FU models

vaIve switch turns to

ConfIrm that engine is cold before

operation desaihed in step 6

If throttle valve switch g1f1not be

engine

stopp d

distonnect

adjusted

to

specification replace

fresh air duct Place a mirror at the end of air c1eaner inlet pipe as shown and check to see if air control valve is in correct

Engine speed
Engine operation throttle operates
When engine speed
increases

when

valve switch

Throttle valve switch

continuity

pOsition

2J
OFF ON
v

1 150 i200

rpm
1 000 1 200 rpm

When engine speed decreases

ON

OFF

EF210

REPLACING FUEL FILTER

I

Check for

contaminated filter

and water

deposit

CHECKING FUEL LINES Hoses piping connections etc

Check fuel lines for loose
connec

Fig ET 21 Inspecting Valve Position

Air control va ve is in correct

posi

tion if its cold air inlet is open and hot air inlet is closed 4

tions

cracks

and deterioration

Re

tighten loose connections and replace any damaged or deformed parts

Start engine and keep idling Immediately after engine starting

control

check air

valve for correCt

In this

position
case

as

described above

position of air control valve is the reverse of step 3 under

hood air inlet is closed
inlet is open 5

correct

and hot air

REPLACING AIR CLEANER FILTER

Viscous paper type air cleaner filter does not require any cleaning opera
ET011

Check

that

air

control

valve
as

gradually
engine
sensor

opens to cold air inlet side

warms

up When environmental

temperature
is low

around

spend

more

temperature time for

tion until it

is

Fig ET 20 Fuel Filter

Sushing
cause

or

replaced periodically blasting operation will

and result in enrich

engine warning up operation of facili tate smooth operation of air control

valve If the above test reveals any prob
lem valve in the

clogging
of
never

replaceable car fuel filter as an assembly tridge type 2 fuel filter in accordance Replace
use
a

All engines

ment

carburetor

mixture

and

should

be conducted

operation

of air control

Replace
ance

air cleaner filter in accord

carry out the further

inspection

with maintenance schedule

with maintenance schedule

ET 10

described in Section EF

Engine

Tune up

EMISSION CONTROL SYSTEM

CHECKING VACUUM FITTING HOSES AND CONNECTIONS Check fittings and hoses for ioose

loose
not

parts

or

replace parts

that

are

cqnriections

or

damage

Retighten

suitable for further use FU model

California model

w
o

Intake

manifold

fl11r

q California Non

model

Canada model

@
I T
M T

o
p
1

r T
J

M T A

1 2 3 4 5 6

Distributor Throttle opener From

vaaJum

Vacuum motor
From
vacuum

control valve

8 9 10
11

motor to

temperature

sensor

3 way connector to air cleaner

servo diaphragm switching valve

Carburetor From idle compensator to intake manifold

To A B valve

Throttle opener
Vacuum Thermal

@ @ @ @ @

B P T valve

l Q2
valve
ET502

C A C valve
E G R control A B

valve

Carbon canister

v3roum

valve

12

Vacuum d lay valve

Fig ET 22 Vacuum Hoses and Connections

ET 11

Engine
R EPIACING AIR PUMP AIR CLEANER FILTER Except FU models and
2

Tune up

Replace

P C V Valve and filter in with maintenance

CHECKING VAPOR
LINES
I Check all hoses and fuel tank flller cap 2
3

accord schedul

Canada models
replacing
ir air

necting

Disconnect vapor vent line con carbon canister to fuel tank Connect 3 way connector
or mana

When

cleaner filter
hood

remove cleane frO and detach lower body and filter

legge
as
an

meter and cock

equivalent

3w y

charge cock

to

end of vent line

assembly

ET531

ET530

Fig ET 23 Replacing Air Cleaner

Filter
ET532

REPI ACINGAIR INDUCTION VALVE FILTER FU models and Canada models

Remove screw

Fig ET 27 Vent Line

securirtg

valve to air
can

cleaner Air induction valve fIlter be

taken out

Fig

easily

Replace fIlter

ET 25 Replacing P C V Value and Filter

Supply

fresh air into vapor vent 400

line through cock little by little until

pressure become

periodically

in accordance with main

mmH20 is 75

tenance schedule

inH20
5

Shut cock completely and leave it After 2 5 minutes

2 C

CHECKING VENTILATION HOSES

I

unatiended
6
measure

height

of liquid in manometer 7 Varilllion in height should remain with 25

Check

hoses

and

hose

connec

tions for leaks

mmHp

0 98

inH20

l
I

11 l
EC9 Value Filter

Disconnect

all

hoses and be

clean of

with compressed air If any obstructions hose

cannot

When filler cap does not close completely height should drop to zero 8
ih a short time

free

replace

9
a

If height does not drop of a

to zero

in
re

Confirm that flame arrester is locat ed correctly in hose between rocker

cover

short time when filler cap

cause

is

moved it is

stuffy hose
tine B

and air cleaner Note In

case

vent

stuffy
is
not

Fig ET 24 R pklcing Air Induction

breathing

in

fuel

tank

thoroughly
or

made thlis caming in

REPLACING P C V

sufficient delivery of fuel to

engine

VALVEANb FILTER
Check P C V valve
as

vapor lock It must tberefore be

or

repaired

replaced

follows
remove

With engine running at idle if the valve is working will be heard valve and felt
a
as

the ventilator hose from P C V valve

a

hissing

noise

air passes through the strong vacuum should be when

a

inunediately
over

finger

is

ET277

placed

valve inlet

Fig ET 26 Cleaning Ventilation Hose

ET 12

Engine

Tune up

3 way connector

400 mmH20 15 75 inH20

ck
Air

Check valve Manometer

Carbon canister

filler cap with vacuum relief valve

F uel

o o o

0 0 0

1
EC091A

ET500

Fig ET 29 Fuel Filler Cap with Vacuum Relief Value

REPLACING CARBON CANISTER FILTER

Check for
Filter
tom can
a

contaminated fJlter

Fig ET 28 Checking Evaporatiue Emiuion Control System

be removed at the bot

on car

of canister installed

body

Replace fJlter

in accordance with

maintenance

chedule

CHECKING FUEL
TANK VACUUM RELIEF VALVE
Remove fuel filler cap and see it

companied
valve is in

by valve indicates that good mechanical condition by further inhaling air disappeared
or

Note also that the

resistance should be ks

functions properly
I

with valve c

Wipe

clean valve

housing

and have

3
ance

If valve is clogged
is felt

if

no

resist

EF201

it in your mouth 2 Inhale air A

replace

cap as an assem

Fig ET 30 Repfucing Carbon Canister

Filter

slight

resistance

ac

bled unit

ET

j3

Engine

T une up

SERVICE DATA AND SPECIFICATIONS

INSpECTION
AND ADJUSTMENT stem

Basic mechanical Valve clearance Hot

Intake Exhaust

mm mm

in in 0

35 0
5

0 014 O

i QI

Drive belt deflection Fan

Air
mm

in in in

8 to 12 8 to 12

31 0
31 0 31 0

to

0 47

pump
COo9itioner
compressor pressure

mm mm

to 0 47 to

Air

8 to 12 10
22

47 0

Applied thumb Engine oil capacity

AI4 engine

kg lb
liters US qt lmp qt

wmi oil
A 15

filter

37 3Ji

3 Y

Without oil filter

IT 3
33 3 2 8 3

2Ji

engine Ji
2 Ji

With oil fIlter Without oil filter Radiator

2 f

cap relief

pressure

kgfcm2 psi kg cm2 psi

0 9
16

13
23

Cooling system leakage testing pressure

Water capacity Without heater

liters US qt lmp qt

5 2

f 5 4
4 5

5 0 5Y

MfT AfT MfT AfT

With heater

liters US qt lmp qt

5 9 6Y 57

6 5

Compression

pressure at 350 rpm

Standard Minimum

kgfcm2 psi kgfcm2 psi

at

5 192 13
12 5

178

Battery specific gravity Frigid climates

Other climates

200C

680F
1 28

26 1

ET11

Engine
IBnition and fuel system Ignition timing
Manual transmission models

Tune up

degree

rpm

SO B T D California
T D
r

j700 C

rpm FU models

CJ700

i m

California Non models

Canada

Automatic transmission models in D

degree

rpm

SO B T D 80 B

j6S0 C j6S0 C

rpm

position

California models D T California Non

rpm models Canada

ex cept
1

100 B T D

j6S0 C

rpm

Canada models

Spark plug Gap

s A U

models

mm mm mm

in in in

1 0 to l 0 039 to 0 043 0 8 to 0 9

Canada models FU models

0 031

to 0

035

LI

to

3 0 043 to O OSI 1
an

High
CO

tension cable resistance No air

ohm

OOO 3O

percentage at idling speed

Manual transmission models Automatic transmission models

f

rpm

2 r

700 1

in

position

rpm

2 r1 6S0

Evaporatlv Supplied

emission control
pressure
l

system

mmH29 inH20 mmH20 inHP

400

IS

7S 0 98

Pressure variation

less than 2S

TIGHTENING

TORQUE
I

f
r

Valve rocker adjusting

nut

kg kg

m m

ftlb
ft lb

16 to 2 2 5 to 2 0 1

12 11

to 16 to 14

Spark plug

jf
0

ET1S

Engine Tune

up

TROUBLE
Condition CANNOT CRANK ENGINE OR CRANKING SLOW

DIAGNOSES
Probable
cause

AND

CORRECTIONS
Corrective action

Improper grade
Faulty battery
Loose fan belt

oil

Replace with proper grade oil

Discharged battery

Charge battery Replace Adjust Inspect

circuit

Malfunction in charge system

Wiring
F

connection

loose in starting

Correct

ul1Y

ignition switch
starter motor

Repair Repair

or
or

replace replace

Faulty

Trouble shooting procedure

Switch
on

on

starting circuit

the starting motor with gOO off or

light

ON

WheJlIJght

J1S considerably Ii
a

Check

battery

b Check connection and cable

c

Check starter motor

When

light stays bright

a

Check wlflng connection

motor

between

battery

and starter

b Check ignition switch Check starter motor c ENGINE WILL CRANK NOR
LLY BUT

WILL NOT START

In this

case

the

following
syst

trouble

causes

may exist but in many

cases

ignition system

or

fuel system is in trouble

19
FII

ition

in trouble

1 system in trowb Valmechanism do

not work

properly

Low

compression
shooting Trouble

procedure spark plug firstly by following procedure Disconnect high tension cable from one spark plug
Check about 10 the
mm

and hold it

0 39 in

from the engine metal part and crank

engine spark
occurs a

Good

Check spark

b
c

plug Checkignition timing

Check fuel system

d Check No spark
occurs

cylinder compression
Check the current now in primary circuit

Very high

current

Inspect primary

circuit for short

Check breaker point operation except tran sistor ignition system

ET l6

Engine

Tune up

Condition

Probable

cause

Corrective action

Low or

no

current

Check for loose terminal

or

disconnection in

primary

circuit

Check for burned points

Ignition system
order

out of

Burned distributor point

Repair

or

replace

Improper point

gap

Adjust Replace
Clean Clean
or

Faulty condenser
Leak at
rotor

cap and rotor

Faulty spark plug Improper ignition timing Faulty ignition coil

Disconnecrion of high tension cable Loose
connection circuit
or

replace adjust plug gap or replace

Adjust Replace Replace

in

disconnection

Repair

or

replace

primary
Fuel system out of order

Lack offuel

Supply

Dirty Dirty

fuel filter
or

Replace
Clean

clogged fuel pipe

Fuel pump will not w0rk

properly properly

Repair

or

replace adjust

Carburetor choke will not work

Check and Correct

Improper adjustment of float level

Improper idling
Dirty
or

Adjust
carburetor Disassemble and clean

clogged

Clogged breather pipe of fuel tank

Malfunctioning anti

Repair and clean

Check for loose terminal
Check
or

dieseling solenoid valve

off shut

wire harness

Malfunctioning fuel
models Low compression Incorrect

system

FU

fuel

off shut

system

Adjust

or

re

place if necessary

spark plug tightening

oil
or

or

faulty

Tighten

to

normal torque

or

replace gasket

gasket Improper grade engine

Incorrect valve clearance low viscosity

Replace Adjust

with proper

grade

oil

Compression Sticky
Weak

leak from valve seat

Remove cylinder head and Correct or

lap

valves

valve stem
or

replace

valve and valve

guide

damaged

valve springs

Replace gasket

valve springs

Compression

leak at cylinder head

Replace gasket Replace piston rings

Overhaul engine

Sticking or damaged piston ring

Worn piston ring
or

cylinder

Trouble looting procedure

Pour the

engine oil from plug hole

increases

and then

measurt

cylinder compression Compression Compression

Malfunctiong cylinder
or

piston ring

does not change

Compression
or

leaks from valve

cylinder

head

head gasket

ET 17

Engine

Tune up

Condition

Probable

cause

Corrective action

IMPROPER ENGINE IDLING

Fuelsystam
order

out of

Clogged

or

damaged

carburetor jets

Clean

or

replace

Incorrect idle adjustment

Adjust Replace
or

Clogged

air cleaner filter manifold

element
or

Damaged
insulator

gaskets

carburetor

Replace gasket Adjust

insulator

bnproper

float level

adjustment

LoOse air hoses carburetor

or air fuel mixture hoses of

Check for loose connections

Malfunctioning Malfunctioning Malfunctioning

trol air cleaner

carburetor choke
anti backfire valve automatic temperature con

Check lUId

adjust

Check for loose connection of vacuum hose Check A IC air cleaner

Inoperative idle compensator

Carbon canister purge line hose disconnected Stick E F E
Low
1

Check for connection hose

or

of idle compensator

replace idle compensator

or

damaged

or

Connect

replace

ve

shaft

Repair
Previously mentioned

ion

Othen

Incorrect valve clearance

Adjust Adjust Replace Adjust linkage

sensor or

Extremely low revolution

Malfunction of the ignition system spark plug high tension cable ignition coil etc

incorrect

basic ignition timing valve chol

e

Malfunction of Malfunction of

or

Adjust
Check for loose hoses

vacuum

motor

Replace system

com

hoses of air cleaner Incorrect idle adjustment

ponentsif necessary
lSt idle speed Adj

Cloged
cleaner

air cleaner fIIter

Replace
of air

air cleaner filter

Malfunction of

idle compensator

Replace
Clean
or

Malfunction

of E G R control valve

replace

Loose manifold and

cylinder

head bolts

Retighten bolts
Check ahd correct accelerator

Higli engine opem

idle

Dragged accelerator linkage

Incorrect idle adjustment Malfunction of T O
opener

linkage

Adjust
system
or

idle

speed
vacuum

s C

tluottle

Check for loose

connections

hose and harness

Except FU models

Adjust replace if necessary

Malfunction of speed switch and harness Check for loose
connections

Repair

or

Except FU

models

replace if necessary

ET 18

Engine liune

up

Condition Malfunction

Probable

cause

Corrective action Check throttle valve switch and linkage

of throttle valve switch and

linkage
ENGINE POWER NOT
UP TO NORMAL

FU models

Adjusi i replace if necessary

r

Low compmsion

Previously m entioned
Incorrect

Ignition system
order

out of

ignition timing

Adjust
Clean Dress

Damaged spark plugs Wom distributor points

adjust
or

or

replace plugs
points

replace

Also

check

condenser Malfunction of T C S cMalfunction of S D V

Fuel system order
out of

Check and correct Check and replace

Milfunction of choke system

Adjust
Clean

Clogged
Dirty
or

fuel pipe

or

floating

valve

clogged

fuel filter

Replace Repair or replace

t J

Fuel pump will not work

properly

Clogged
Air intake system out of order

carb retor jets air cleaner

Disassemble and clean

Clogged
Air

Replace
manifold g sket
r

element

aling

from

Replace gasket

carburetor gasket
Emission control

Malfunction of E G R valve
Stick E F E valve shaft

Check and

replace

Repair Replenish Adjust

fan belt

Overheating

Insufficient coolant Loose

J

fan bel
or

Wom

oiled fan belt

Replace

Inoperative therinostat
Wom
ater
or

Replace
Repl
ce or

pu p

Clogged

leaky radiator

Flush repair

replace

Wom radiator filler ca

f

ReplaCe

H r

Air in

cooling ystein
oil

Retightin
Replace Adjust

ch part of cooling system

Improper engine

grade

with proper

grade

oil

Incorrect ignition timing

Clogged
Overcooling

carburetor lean

miiture

Overhaui carburetor
Replace

Inoperative thermostat

ET 19

Engine

Tune up

Condition

Probable

cause

Corrective action

Othen

Improper Improper Dragging

Dutch

octane fuel

Replace

with

specified octane
pressure

fuel

tire pressure brake

Inflate to

sptcifled

Adjust Adjwt

slipping

NOISY ENGINE Cor knockillll Overloaded engine Carbon knocking Use

right

gear in

driving
head and
remove

Disassemble carbon

cylinder

Timing knocking
Fuel

Adjust ignition timing

Use

knocking
miswing of spark

specified

octane fuel

Preignition
M8chanicol knocking Crankshaft bearing

plug

Use

specified spark plug

knocking

This strong dull noise increases when engine is occelerated To locate the place cause a misfire
on

This is caused
or

each

by

the misfire

cylinder If the noise stops this cylinder generates the

by worn or damaged bearings Renew unevenly worn crankshaft bearings and adjust or change crankshaft
Check

lubrication system

noise This is little

Connecting rod

bearing knocking

crankshaft

higher pitched knocking and

noise than the also increases

Same

as

the case of crankshaft

bearings

when engine is accelerated Cause a misfire on each cylinder and if the noise diminishes almost

completely

this crankshaft

bearing

generates the noise

Piston and noise

cylinder

When you hear an overlapping metalic noise which increases its magnitude with the revolution of engine and which decreases as engil e is warmed up this noise is caused by

This

cylinder iexvces

may cause an abnormal wearing of and lower compression which in

turn will cause a lower out

put power and

consumption

of oil

piston
cause a

and

cylinder
on

To locate the

place
Overhaul

misfire

each

cylinder
at each

engine
cause a wear on

Piston pin noise

This

noise is heared

highest

and

This may

piston pin

or

lowest dead end of piston To locate the place cause a misfire on each cylinder Water pump noise This
noise may

piston pin hole Renew piston and piston

pin assembly

be
or

caused

by

worn

or

Replace

water pump with a new one

damaged b arings of sliding parts

Air pump noise

by the

uneven

surface

Damaged
models

air pump

Except Canada and

FU

Repair

or

replace

Others

An

improper adjustment

of valve clearance

Adjust Adjust
the tension of chain
new

Noise of timing chain An excessive end

play

on

crankshaft

Disassemble engine and

main beaung

Noisy E F

valve shaft

Repair

H20

Engine

Tune up

Condition

Probable

cause

Corrective action

Surging A T C
Note iI

air cleaner vacuum motor

Repair or replace

This noise will be hmnl when clutch

disengaged
on

We

clutch

pilot bushing
will be heared when

Renew bush and

adjust

drive shaft

Not e

This

noise

utch iI

disengaged

ABNORMAL COMBUSTION

backfire
run on

afterfire

etc

Improper ignition timing

Improper ignition timing Improper

heal range of spark carburetor
or

Adjust ignition liming plugs

gasket
Use

specified spark plugs

them with new parts

Fuel system out of order

Damaged

manifold

Replace

backfire aftedire

Clogged carburetor jet

Disassemble carburetor and check it

Improper
Uneven

function of the float Run

on

Adjust Adjust
set

the level and check needle valve

idling

Improperly adjusted Except

FU models

T O CS

pressure

Adjust
Check or

Malfunction of anti dieseling solenoid valve Malfunction of fuel models Malfunction shut off system FU

replace
Adjust
or
re

Check fuel shut off system

place

necessary

or auto
adjusted

hoke valve clearance

Adjust Adjust
Remove head and get rid of carbon

Feulty cylinder

heed etc

Improper

Excess carbon in combustion chamber laged Da Others alve spring

backfire

after he

Replace

it wit

new one

Malfunction of A T C air cleaner

Check for loose necessary

vacuum

hoses

Replace

if

Inoperative
EXCESSIVE OIL CONSUMPTION

anti4lackfire valve

Replace

Oilleek8111

Loose oil
ose or

tain plUI
damaged damaled
oil pan gasket chain
cover rear

Tighten
Renew Renew

it
iI

lasket or tighten gasket

or

Loose

or

gasket
of crankshaft

lighten

it

Wom oil seal in front and Loo

or

Renew oil seal Renew much

damaged

locker

cover

gasket

gasket

lighten tighten

it

but not too

Improper lilhtening of oU
Loose
or

filter

Renew gasket and

it with the proper

torque

damaled oil

pressure switch

Renew oil pressure switch

or

tighten

it

ET 21

Engine

Tune up

Condition

Probable

cause

Corrective action

Ex iv

oil

Cylinder

and piston

wear

Overhaul cylinder and gap

or

renew

piston

consumption

Improper lOcation of pi5ton ring reversely assembled piston ring Damage pi5ton r gs
Wom pilton ring groove and ring

Remount piston rings

Renew rings

Repair

or renew

piston and cylinder

Renew piston and

piston ring
a new one

Fatigue
Odlen

of valve oil seal

stem

lip

Replace

seal

lip
or

with

Worn valv

Renew valve of engine oil Us the

guide
ou

Inadequate qUality Engine overheat

designated

Previously mentioned

POOR FUEL ECONOMY See the explanation oI thtI power cIec 01hen

Exceeding idling

revolution
covel

Adjust Adjust Repair pipes

Except FU mod Adjust

it to the it
or

designated

rpm

Inoperative acceleration Fuelleakage

lighten the

connection

of fuel

Malfunction of T O C S els

Malfunction of A T C air cleaner

Check and

replace

PROBLEM IN OTHER FUNCTIONS t

1 oil pre

Inadequate
Overheat

oil

quality

Use the designated oil

Previously regulator valve

mentioned
or renew

Worn oil pump

Disassemble oil pump and repair

it

Functional deterioration of oil pump Blocked oil filter Increased clearanCe in various

Ref4ir

or

replace

it with

I new one

Renew i t

sliding parts

Disassemble and
n w

replace

the

worn

parts with

ofes

Blocked oil strainer

Clean it

Inoperative
eronthe

oil gauge pressure switch

Replace

it with

a new one

Oil pressure decreases

Previously mentioned Exchange the change element

oil with proper
one

lIiding par1J

Improper quality Damaged

Overheat

or

contamination ofoil

and

air cleaner
or

Otange element Previously mentioned

Oteck the fuel system

overcool

Improper

fuel nUxture

Scuffing
par1J

oIlliding

Decrease of oil presSure Insufficient clearances

Previously mentione d Readjust

to the

designated

clearances

ET 22

Engine

Tune up

Condition

Probable cause

Corrective action

Overheat

Previously
fuel mixture

mentioned

Improper
Floor temp
ture too

Check the fuel system

high California and

FU model

Problem in fuel system tion of Fuel System

Refer to

Inspec
In

Check and repair

Problem in ignition system

Refer

to

Check and repair

spection oflgnition System

SPECIAL SERVICE TOOL

Kent Moore No
Reference Kent Moore

No

Tool number

tool name
page
or

Tool number

tool

Reference
name

page

or

Fig

No

Fig No

STl9320000

Oil filter wrench

125664

Page ET

ET 23

DATSUN 210

Model 8310 Series

ENGINE MECHANICAL

GIll

CONTENTS
ENGINE COMPONENTS ENGINE DISASSEMBLY
PRELIMINARY CLEANING AND INSPECTION DISASSEMBL Y PISTON AND CONNECTING CYLINDER HEAD ROD EM EM EM EM EM EM EM EM EM AND EM ROD EM EM 9 9 9 3 3 4 5 5 5 5 7 7 EM EM 2 3

BEARING MISCELLANEOUS COMPONENTS ENGINE ASSEMBLY PRECAUTIONS CYLINDER

PISTON ENGINE HEAD ROD AND CONNECTING

EM fO EM ll EM 12 EM 12 EM 12 EM 12 EM 13

ASSEMBLY

INSPECTION AND REPAIR

PREPARATION FOR
CYLINDER

SERVICE DATA AND

INSPECTION

SPECIFICATIONS
GENERAL SPECIFICATIONS

EM lB EM lB EM 19 EM 30

HEAD AND VALVE

CAMSHAFT AND CAMSHAFT BEARING

CYLINDER PISTON PISTON

INSPECTION AND ADJUSTMENT TIGHTENING TORQUE TROUBLE

BLOCK

PISTON PIN RING

DIAGNOSES AND
EM 31 EM 34

CONNECTING CRANKSHAFT

CORRECTIONS SPECIAL SERVICE TOOLS

Engine

lnical Mech

ENGiNE COMPONENtS

ld
n

Rockel

covel

Cylindel head 3 Cylinder block

4

Cnnksbaft Piston Oil pan

5 6 7 8 9 10 11 12

Flywheel
Valve mechanism Cam haft

Timing

chain

t
I
EM765

Front cover Watel pump

Fig EM l Engine ComponentJ

EM 2

Engine Mechanical

ENGINE DISASSEMBLY
PRELIMINARY
CLEANING AND
air air pump pulley If so air bracket and pump pump 5

Remove

18
et

Remove

engine mounting brack

air
vacuum

LH
Disconnect

INSPECTION
disassembling engine ob serve the following items I check Prior to disassembling
Before

equipped
6 Remove fan fan spacer and

19

and
air

pul

ley
7 8
Remove oil level gauge Remove distributor cap and
an

blow by hoses from air cleaner 20 Remove air cleaner and cleaner brackets
21

parts for sign gasketed surfaces

outer 2

of leak

past their

high

Remove Remove

vacuum as

control
a

valve

tension cables as

assembly
vacuum

assembly and bracket

22

unit

Check carburetor and fuel pump fuel hoses for deteriora

or

Disconnect

distributor

carburetor and baffle

for condition
tion

line from distributor and remove dis

plate
23 24

cracks

otherwise leakage of

tributor 10
retor

Remove E G R control valve Remove intake and exhaust

fuel past their surfaces

3

jointed

or

connected

Disconnect fuel line from carbu

manifold assemblies
Remove fuel pump and fuel line

Wipe dust and mud off engine 4 Inspect outer parts for visual faults and broken or missing parts such
as

II 12 13
et

Remove
Remove

water

outlet

and

thermostat

bolts and nuts

Check

engine mounting brack

5 cuits

for

piping and electrical cir deterioration breakage

or

H R
Remove oil

14

pump

and filter

as

fittings discontinuity

insulation

sembly
EM528

DISASSEMBLY
To remove

Fig EM 5 Removing Manifold

car

engine from starting

refer

to

Section ER for Removal 1 Remove motor

then

re

move

transmission from engine

25

Remove P C V

hose

pipe

con

2 3

Remove clutch assembly Remove alternator fan belt alter

nector to control valve

26
EL043

Remove rocker cover

nator bracket and alternator bar 4

adjusting
air pump

27
nut

Loosen valve and turn

rocker

adjusting
out to

Fig EM 3 Removing Oil Pump

Remove idler pulley

adjusting disengage push rods

loosen rocker shaft bolts 28

screws

Then

evenly

belt and

idier pulley

bracket

If

so

15
16

Remove spark Install

plugs

equipped
Note belt Loosen idler

Remove rocker shaft

pulley

nut

and

adjusting

bolt in that order

Attachment Engine KVlOI02500 to cylinder block using engine f1ounling bracket R H attach studs fuel pump attaching studs and alternator bracket attaching bolt

assembly

ing

holes 17 Mount engine

on

Engine Stand

ST050I SOOO

@
EM453

Fig EM 6 Removing Rocker Shaft Assembly

Idler pulley nut

Belt

2 3
4

adjusting pulley

bolt

29
EM527

Withdraw

push

rods

and

keep 1

Air pump belt

Idler bracket

them in correct order 30

in

Fig EM 2 Removing Idle Pulley Air Pump Belt and Idle

little at Fig EM 4

Loosen cylinder head bolts a a time in the sequence shown EM and

remove

Fig

cylinder

Pulley Bracket
EM 3

head

Engine Mechanical
45

RemoVe camshaft
remove

ly

camshaft by

plate Careful pulling it to

ward the front of engine

EMA54
r

hi

EM456

Fig EM 7 Cylinder Head Bolt Looaening S quence

Fig EM l 0 Remooing Piston and Connecling Rod Assembly

EM461

Note
to

Numbers

are

stamped

on con

necting
each

rod and cap rllnding should be Care cylinder

Fig EM j3 Camshaft Plate

taken to avoid wrong comhination

46

Remove valve lifter and keep

including bearing
39

them in order

Remove

flywheel

and

rear

plate

WARNING When remnving flywheel be careful

Fig EM 8 Removing Cylinder Ht ad
not to

PISTON AND

drop

it loosen main bearing

CONNECTING ROD
I Remove piston rings with
a

40 Note Do not pry between head and block as gasket surfaces may be
come

Gradually
caps See

ring

cap bolt
remove

in two or three

stages and

remover

Fig EM
I

II

damaged

31 32 33 34 35 chain

Invert engine Remove oil pan and oil strainer Invert engine
kemove water pump

P l

D @

Remove crank
cover

pulley and timing

M458

Fig EM ll Main Bearing Cap Bolt Loo ning Sequ nce

41 Remove rear oil seal

EM292

Fig EM 14 Remooing PUton Ring

42
43

Lift out crankshaft Remove

main

2 from

Press out piston pin with Piston

bearings plate and

Pin Press Stand KVIOIOS300

block and bearing caps 44

EMA 55

Remove baffie

tee

net

Fig EM 9 Removing Timing Chain

Cover

36
37

Remove

i1 thrower and chain camshaft

tensioner

LQ9sen
remove

sprocket

bolt

EM103

and
3

both

procket and timing

EM460

rod caps and push piston and connecting rod assemblies out of the bores

an assembly chain Remove connecting

Fig EM 15 R moving Piston Pin

Fig EM l2 Remooing Baffle Plate and Steel Net 4 EM

Note

Keep

disassembled

parts

in

order

Engine Mechanical
CYLINDER HEAD
Using Valve lifter STl2070000 compress valve spring and remove
I

lll@8 vO@ CQ8@ a

EM463

valve collet 2 Release Valve Lifter and

remove

C
EM462

spring retainer spring oil seal spring

seat and valve

Fig EM 17 Valve

Components

Fig EM 16 Removing Value

Note

Take

care

not

to

lose valve

spring
3

seat

oil

seal

valve collet

Place valve components in order

and valve rocker

guide

INSPECTION AND REPAIR

PREPARATION FOR INSPECTION
I Note

Surface grinding limit The grinding limit of cylinder head

is determined

VALVE SPRING
I Check valve spring for squareness using a steel square and surface plate If spring is out of square S more than specified limit replace with new
ones

8efore

cleaning
s

check for signs

of water and oille 2

Clean

oil

from 3

all parts Clean all

carbon deposits They should be clean oil holes with solvent

and

by the cylinder block grinding in an engine Depth of cylinder head grinding

is A

from gaskets and sealant

and dry with compressed air Make sure that they are not restricted

Depth of cylinder block grinding

is 6B
as

Out of square

The limit is A B

follows

Less than 1 6
mm

0 2 mm 0 008 in

0 063 inl

VALVE

CYLINDER HEAD AND VALVE

CHECKING CYLINDER
HEAD MATING FACE
I

Check

each

of

the intake and

exhaust

valve for

worn or

damaged faulty

or

deformed valve caps

or

stems

Correct

replace
For

the valve that is

Make

visual check for cracks

standard size of valve refer to

L
1

and flaws 2
on

Service Data and 2

Specifications
or

Measure surface of cylinder head for warpage cylinder block sid

Valve

face

valve

stem

end
a

EM296 Sguareness

surface should be refaced by using

valve

If beyond
s

designated
a

limit

correct Note

grinder
When valve head has been
to
worn

Fig EM 20 Measuring Spring

rface with

surface grinder
urfece

Warpage
0 1

of

down

05

mm

0 020 in

in

Measure the free length and the

Less than
mm

tension of each

thickness

replace

the valve

spring If the measured

re

0 004 in

Grinding
less

allowance for valve stem 5 mm 0 020 in 0

or

value exceeds the specified limit

end surface is

place spring
Refer to Service Data and tions

pecifica

c
EM108 EM111 EMl13

Fig EM IS Checking

Cylinder

Head

Surface

Fig EM 19 Regrinding Valve Face

EM 5

Fig EM 21

Measuring Spring

Teruion

Engine Mechanical
VALVE

GUIDE
the

Max deflection limit

Measure valve guide

clearance

between If the limit

and valve

stern

clearance exceeds the

specified

replace the worn parts or both valve and valve guide In this case it is
essential to determine if such
ance a

clear
EM470

has been caused

or

by
a

worn or

bent valve stem

by

worn

valve

guide
Unit
mm

Fig EM 25 Reaming Valve Guide

in
EM467

5
new

Correct va1ve seat surface with valve guide

as

Fig EM 23 Mea6uring Clearance

the axis

Determining clearance
Precise needs
measurement stem
a

between Valve Stem and Valve Guide

of clearance

between valve

and valve

guide

VALVE SEAT Check valve

seat

the aid of

micrometer and a

for evidence of and

telescope
gauges stem

hole gauge

By using these
center and

check the diameter of valve

pitting
reface

at valve contact surface

or

in three

places top

replace if

worn

excessively
mm

bottom

Replacement of valve julde

I and To
a remove

Valve seat insert of 0 5

0 020

in oversize is available for service

old

guides

use a

drift

pie
cover

and drive them out of side toward combustion

Refaclng valve seat

When width of valve seat is wide
narrow or

rocker

chamber Heating cylinder head to I SO to 200 C 302 to 392 F will facili

tate

beyond grinding

specifications
stone

it

should be refaced with valve seat with

cutter or

operation

T11033000 iIT11670000
EM030

Fig EM 22 Checking Valve Stem

Diameter

Insert

telescope
the

hole gauge in valve

at center

guide bore measuring

Subtract

highest
the

reading of
1 II EM468

valve stem diameter from valve guide bore

to

obtain

stem

to

guide

clearance

Fig

As

EM 24 Driving Valve Guide out of Cylinder Head

EM411

an

expedient

valve is

in valve

guide

and moved to

pushed the right

2

Fig EM 26 Refacing Valve Seat with

Valve Seat Cutter

and left If its tip deflects beyond the specified limit there it will be known that the clearance between stem and

Ream cylinder head

0 480 in dia

valve

guide

Replaclna valve seat Insert

I

hole using Reamer STlI081000

mrn

12

guide exceeds the

maximum limit

Old insert

can

at room

tempera

be removed by

ture

Max allowabl 02
mm

deflection

0 008 in

Max tolerance Stem to

guide

clearance

Carefully press service Valve guide cylinder head guide hole It will fit smoothly after heating cylinder head to ISO to 200 302 to 392 F
3 into
4

boring collapses Machine depth stopper should be set So that

boring
cannot

out until it

continue beyond the

recess

bottom face of the insert

in

cylinderhead
2 Machine

0 1 mm 10 004 in

Ream bore with valve guide press

cylinder

head

recess

in

concentric circles to valve

so

ed in ote

using Reamer STll0320000 8

31 in dia 0

guide

center

that insert will have correct fit Ream

Valve

sbould

be

moved

in

mm

cylinder

head

recess

at

paraIlel with rocker ann General ly a large amount of wear occurs in

this direction

Reaming bore
8 000 to 8 015
mm

room

temperature Heat cylinder head

to

tempera

0 3150 to 0 3156 in

ture of 150 to 200C

302 to 3920F

6 EM

Engine
5 Fit insert

Mechanical
are
worn

ensuring that it
recess

seats on

determine whether bearings If

worn

bottom face of its

6 cut
or

Newly
or

fitted
stone

valve seat should be

ground

with suitable seat cutter

grinding

Apply smalliunount of fine grind ing compound to valve contacting face and put valve into guide Lap valve
7

15 mm 0 0059 in beyond 0 replace using Camshaft Bearing Drift STl6Il0000 In press fitting a new bearing make certain that oil holes in block and bearing are properly aligned

against its seat ing is obtained

valve seat

ntil proper valve seat

EM476

Remove valve and clean valve and

3

Fig EM 29 Checking Cam haft Bend Camshaft end play can be check by installing camshaft camshaft locating plate and camshaft sprocket in thier respective p sitions End play
ed
EM474 can
or

VALVE ROCKER ARM AND SHAFT

1

then be checked with

Check rocker
scores or

arm

bore and shaft each

dial guage

for 2

scuffs clearance and shaft between

Check
arm

Fig EM 27 Measuring Camshaft Bearing Inner

Diameter

feeler gauge If end play exceeds the specified limit replace locating plate
Max tolerance of camshaft end

rocker

by measuring
arm

inner diameter of rocker

outer diameter of shaft

bore and

pley
0 10
mm

0 0039 in

If either specification and or shaft 3

clearance is not within

replace

rocker

arm

CAUTION
a

After replacing all bearings finish

Check valve end contact surface

arm

of rocker scuffs

for abnormal

wear or

bearing ing
b I nstall block

inner diameters

by line

bor

welch

plug

into

cylinder

applying

sealant

VALVE LIFTER AND

PUSH ROD I Check valve lifter for
wear or
EM477

Fig EM 3D

Checking Cam haft End Play

scuffs lifter

Check bottom
to

end of valve has

a

make

sure

it

slight
are

convex

Replace
worn or

valve lifters that

scored
tom

have unsmooth bot

EM475

VALVE TIMING This Fig EM 28 Replacing Cam haft Bearings

inders

2 hole

Check
on

clearance

between lifter

diagram applies

to

all

cyl

cylinder

block and valve lifter

ex

Replace
ceeds
3

valve lifter if clearance

If any valve is found beyond specifications one possibility is that lobe is 1 or damaged exces worJ sively calling for replacement of cam
earn

wear limit

Check

push

rod for

bending

and CAMSHAFT ALIGNMENT

I

damage
Check end of push rod for
ness or

shaft

rough

excessive

wear

Check camshaft camshaft

earn

journal
wear
or

and

surface for If fault

is

bending
beyond
one

CYLINDER BLOCK
I

damage

limits

CAMSHAFT AND CAMSHAFT BEARING

CAMSHAFT BEARING CLEARANCE
Journal diameters should be check ed with with
an a

replace affected parts

2
A bend

Visually check cylinder

or

block for

cracks half of the

is 2

flaws
head

value is

reading obtained when camshaft

turned gauge
one

Measure

full revolution with

to the cen ter

dial

cylinder
age it

top of cylinder block mating face for warp

If warpage exceeds limits correct

applied

journal

Camshaft bend Total indicator Less than 0 10 mm 0 0039 in

Warpage of cylinder block reading

surface Less than 0 10
mm

micrometer

and

bearings

inside dial gauge Measure ments should then be compared to

0 0039 in

EM 7

Engine Mecha hical

4

When

wear

taper

or

of out
re

round is minor and within limits

move

CAUTION
a

ridge at topmost portion of cylinder using a ridge reamer or similar

tool

To prevent strain due to cutting heat bore the cylinders in the order of 41 3 2

b Before main

CYLlNDER
EM303

BORING

boring any cylinder install bearing caps in place and tighten to the specification so that the crankshaft bearing bores will
not become distorted

When any cylin der needs boring

from the bor

Fig EM 31

Checking Cylinder Block Surface

all other cY linders must also be bored

at same time 2

ing operation
4

Determine piston oversize accord

to amount of cylinder wear

Do not

cut

too

much out of

Note

Surface

grinding

6mit

ing
3

Grinding limit of cylinder block is dependent upon cylinder bead grinding of engjne Depth of cylinder head grinding is
A

The size to which honed

cylinder to

linders must

cylinder bore at a time Cut 0 05 mm 0 0020 in or so in diameter at a time

5 Measurement
of

be

is

determined

by adding
to

piston

clearance
at

the

cylinder

bore
care

just machined requires the utmost

since it is

largest piston diameter

in thrust direction

piston skirt

6
7

Depth
U

of cylinder block

is

expanded by cutting heal As a final step cylinders should

finished

be honed to final size Measure

of out

The limit is
A B

cylinder bore

O imm 0 008 in A and B should

for
8
ance

The total of
not exceed

round or tapered part Measure piston to cylinder clear

2 mm 0 0079 in 0

With

bore

inder bore for

out

measure cyl gauge of round or taper If out

f
EM126

This clearance
a

can

be checked easi

feeler gauge and a spring ly with balance hooked on feeler gauge meas

fround

or

taPer
walls

is excessive

re

uring

amount of force

required

to

pull

bore

cylinder

with

boring
be

out gauge

from between piston and

machine
taken

Measurement

should

Fig EM 34 Measuring Piston Diameter

E E 5

cylinder
Feeler gauge used 0 04
mm

along
for

bores

bores for taper and around out fround

0 0016 inl

Out of round

X Y
A B

g
or

Extracting

force

0 5 to 1

51rg

Taper
60 20 0 79
2

ge I

1 1 to 3 3 b

36 3 94

I Ii

100

PI

Note
H a

i I lEM480
B

Whenmeasuringcleanmce slowly pull feeler gauge straight upward

Fig EM 35 Piston Diameter Measuring

Position

b It is recommended that piston and cylinder be warmed to 20C

680F

E9 I

Unit

mm

in

Calculation of
ter to

cylinder

bore diame

EM479

be machined A B 0 003 to C A 00001 to 0 0009 in

Fig EM 32 Cylinder Bore Mea uring

Positions

0 023 mm

Where D
A B

Cylinder
machined

bore

diaIpeter
as

to be

r
EM379

Piston diameter Piston to

ance

measured bore clear

0 043
mm

cylinder
to

0 023

EM478

0 0009 to 0 0017 in C For honing

mm

Fig EM 33 Mecuuring Cylinder Bore

Diameter

allowance

0 02

Fig

EM 36 Measuring Pi ton Fit in

0 0008 in 8 EM

Cylinder

Engine
Note If cylinder bore beyond the wear limit liner Undersize has
use worn

Mechanical

cylinder
avail

cylinder

liners

are

able for service Interference fit of cylinder liner in

cylinder block ahould be 008

0 09 mm 0003 Ito 00035 in

to
u

EM482

EM133

Fig EM 38 Measuring Ring Gap

Fig EM 40 Checking Rod Alignment

PISTON PISTON PIN AND PISTON RING

I Remove carbon grooves with
a

Note
a

from piston and

ring
a

carbon scraper and curved steel wire The wire will be

b

piston ring only is to be replaced without cylinder bore be ing corrected measure the gap at the bottom of cylinder where the
wear

When

connecting rod for bend or torsion using a connecting rod aligner

Check

If bend
rect
or

or

torsion exceeds

limit

cor

is minor
are

replace When replacing connecting

rod
new

rod be

useful in cleaning bottom land of ring

groove

Clean out oil slots in bottom

Oversize piston rings 0 5 mm 0 020 in for service

mm

available
10

select
tween

so

weight

difference

and old ones is within 5 gr

land of oil ring groove

2

0 039 in oversize

0 180z
4

Check for damage

scratches and Measure piston pin hole in rela tion to the outer diameter of pin If
5 in
wear

Install connecting rods with bear

on

wear

Replace

if fault is detected

iogs
and
ured

to

corresponding crank pins

thrust clearance If
meas
con

measure

Measure side clearance of grooves as each

rings

ring

ring

is installed

value exceeds limit

rod

replace

exceeds limit
with

replace piston pin

on

together
If side clearance exceeds the speci fied limit replace piston together with installed

piston piston

which it is

necting

Max tolerance of Piston pin to clearance 0 4

mm mm

big

end play

piston ring
Max tolerance of side clearance 0 1 mm 0 0039 in Note

0 016 in

O OOS to 0 012

0 0003 to 0 0005 in

Determine the fitting of piston

hole to such be
an

Big

end

play

pin into piston pin

extent

that

it

can

pressed

smoothly by fmger at room tem perature This piston pin must be a tight press fit into connecting rod

t
t
EM483

Fig EM 41 Checking Big End Pwy

EM481

Fig EM 37 Me suring Piston Ring

Side Clearance
EM131

CRANKSHAFT
I

Fig EM 39 Piston Pin Fitting

4

Measure ring gap with

feeler
in

Repair
are

or

replace

as

required

If

CONNECTING ROD
1

faults
crocus

minor

correct

with fine

gauge inder

placing ring squarely

cyl
If
a

cloth
a

connecting
or

rod has any flaw

2
and

Check with crank

micrometer

Ring should be placed

If ring gap exceeds
limit

to diameter

on

either side of thrust face and large

journals

at upper or lower limit of

ring travel

end correct

replace

it

pins for taper and out of Measurement should be taken round along journals for taper
and around

the

specified

Bend and torsion per 100

mm

replace ring
1 0
mm

3 94 in

length

journals

for

of out

round
or

Max tolerance of ring gap 0 039 in

Less than 0 05
mm

If out of round
0 0020 in

taper exceeds
or

the specified limit replace

repair

EM 9

Engil e Mechllpjcal
of Out ound X Y Crsnk5haf end play

pilot

C
1

snd not
1

to

imat

Less than 0 03 mm 10 0012 in

Taper

A B

Less than 0 03 mm 0 0012 in

Out of round

X Y A B

Taper

BEARING

o
3
it cations

EM486

MEASURING MAIN BEARING CLEARANCE

I

Fig EM 44 Checking Crankshaft End Play

EM716

Thoroughly

clean

all

bearings
score or

Fig EM 42 Mea6Urement Point

replace crankshaft bushing proceed as follows

To

rear

pilot

Check
wear

for scratches

melt

1
After regrinding crankshaft fmish indicated in the

Pull

out

bushing using

Replace
Pilot detected 2

bearings journals

if

fault

is

Bushing Puller KvloI02800

Crankshaft

and

bearings

1 t t 1e necessary s ize chart under Service Data and

should be clean and free from dust and dirt before oil Clearance is meaSured

Specifi
dersize

by using Ill adequate bearing according to the extent of required repair

u

Crankshaft

can

be
on

checked for
V blocks and

bend by placing it

Plastigage

using

dial gauge with its indicating

on center

finger resting replace

or

If bend exceeds the

journal specified

limit

repair

Fig

EM 45

Pulling

Out Pilot

Bushing Bned Total indicator reading Less than 0 10 mm 0 0039 in

EM 141

installing a new bushing bushing hole 3 Insert pilot bushing until dis tance between flange end and pilot bushing is the specified A nce diJ1l thoroughly
clean 3 Distance
A 4 0 110 in

Before

Fig EM 47 Plastigage

Set main Cut

a

e1lfing b

on

cap block

Approximetely
2 8 mm

Do not oil

bushing
A

plastigage to width of bear ing and place it in parallel with crank pin clear of oil hole Install cap on assembly and tighten them together to

specified torque

fj
EM137 Pilot bushing

Tightening torque Main bearing cop bolt 5 0 to 6 0 kg m

36 to 43 fHb

Fig EM 43 Checking Crankshaft Bend

Note
EM719

Do not turn crankshaft while is

plastigage

being

inserted

Measure crankshaft end play as shown in Fig 44 If beyond the EM

Fig EM 46 Installing Pilot Bushing

specified

limit

replace

main

bearing
Note When be careful

Max tolerance of end

play

0 3 mm 10 012 in

installing pilot bushing not to damage edge of

EM l0

of

Remove cap and compare width plastigage at widest part with scale

printed in plastigage envelope

Engine Mechanical
found Install camshaft sprocket in posi tion and check for runout
2 Runout Total indicator Less then 0 15 mm 0 0059 in

reading

If runout limit

exceeds

the

specified

replace camshaft sprocket

reading
mm

Runout Total indicator Less than 0 1

0 004 in

EM142

Fig EM 48 Measuring Bearing

Clearance

6
size

If clearance exceeds the

specified
EM309

value

replase
bearing

bearing with an under and grind crankshaft

Fig EM 50 Checking Flywheel Runout

journal adequately
Max tolerance of main

Fig EM

49

Checking Cam haft Sprocket Runout

Note

Removal

and

installation
use

of

bearing

clearance 0 0039 in

ring gear requires

press
It is also

of

hydraulic

0 10 mm

necessary to heat

ring gear to 180 to 2000C 356 to 3920F thus facilitating removal MEASURING CONNECTING ROD BEARING CLEARANCE
I

and installation

Do not heat

ring

gear to more than To do

so

3000C 5nOF

Measure connecting rod

manner as

could result in

bearing
CHAIN AND CHAIN TENSIONER
I

impaired

clearance in same

above

hardness of ring gear

tfl Tightening torque

Connecting
rod cap nuts 3 2 to 3 8 kg m

23 to 27 fHb

Check chain
or

scratches links 2
size

other

stepped problems on

for

wear

roller

Replace if necessary
Check chain tensioner for
or

If clearance exceeds the

specified

CRANKSHAFT
wear

FRONT
rear

AND

value

replace bearing with an under bearing and grind the crankshaft

REAR OIL SEAL First check front and for

worn or

breakage
would

any

other fault
with

which chain
oil seals
or

interfere

proper

journal adequately
Max tolerance of rod

function

Replace

if necessary

folded

over

sealing lip

connecting

bearing

clearance 0 0039 in

oil leakage If necessary replace with a new seal When installing a new seal
pay attention to

0 10 mm

mounting direction
to renew oil

Note Note Since

It is

bearings

are

precision

good practice

FLYWHEEL
I

insert type it is not necessary to file bearing caps or to grindbeari surfaces with an emery cloth to
correct

seal whenever engine is overhauled If

worn or

Check ring gear Clutch

dam

aged excessively replace

2

bearing

clearance

contacting
be

face

of

fly

wheel

should

smooth

If

worn

damaged

MISCELLANEOUS
COMPONENTS
CRANKSHAFT SPROCKET AND CAMSHAFT SPROCKET
I

or roughened beyond limits replace 3 Before disassembling and after re assembling check flywheel run out

repair

or

Front

with

dial gauge

This check is made

Front

Check tooth surface for flaws

or

wear

Replace

sprocket

if

fault

is

by rotating flywheel with dial gauge finger resting on the farthest point from center of flywheel If it exceeds the specified limit replace it
EM II

u
Rear
EM487

Fig EM 51

Cranhhaft Oil Seal

Engine

Mechanical

ENGINE ASSEMBLY
PRECAUTION
p

lOted

Before assembling engine

observe

following precautions
I Clean all disass mbled parts with

clean solvent All 611 holes in crank

shaft

camshaft

valve rocker shaft etc

to re
or

should
move

be thoroughly cleaned
all traces

of grinding chips

lint Always use clean solvent In general used gaskets packings 2 and oil seals should be replaced
3

if
1 2 Valve

rJF il
@ @
4
Nallow

t
Wide

J
j

pilCh

pitch

l I
EM489

Fig EM 54 Valve Spring

Under

no

circumstances
reuse d

should
woshers

lockwashers be
4

Lip

seal

PISTON AND
seat EM688

Place

bolts

3 and 4
or

Valve guide
Valve

nuts

spring

CONNECTING ROD
I

back in their original parts

which 5

from Fig EM 52 tailing Valve Lip Seal

they MOst packing Serve liquid packing is applied

were

removed

best to
use

when

connecting cylinder

Assemble pistons piston pins and rods on the designated

sealing
suitable

2 Note
as

Insert valve into valve

guide
so

surfaces

When

desigiiated

Use

care

when inserting valve

liquid packing

to eliminate

possibility
all

not to scratch

of water oil and gas leak Prior to assemQling 6

7

lip

of oil seal

sliding

surfaces should be lioerally oiled successful

Install

valve

spring

and valve

valve

Proper tightening performanCe

It is

is essential to

spring

retainer

Compress place

pring

of all

car

re

with Valve Lifter STl2070000 and fit

pairs

also important to follow

valve collets in Lifter slowly

Release Valve
EM103

tightenig sequence in pulling up cylinder head Be on alert at all times to amount of clearance per
correct

Fig EM 55 Installing Piston Pin

mitted 8
as

Cleanliness of tools
work bench used jn

or

parts such

making a repai is essential When setting up a job every precaution should be taken that
tools oil
or

parts

are

free of dirt mud and

Do not work in dust and

grit for
EM462 EM157

they are primary engine

cause of wear in any

Fig EM 53 Inatalling Valve Note

8

Fig EM 56 Arranging Piaton and Connecting Rod

Note
3

CYLINDER HEAD
valve spring seat Install valve oil seal by lightly tapping its head with
a

Install

interchange valves between cylinders for their sliding or seating surfaces have undergone wearing in or have been lapped at assembly forming specific contact with mat
ing parts
sure

Do not

Piston is pressed into connecting rod Fitting force is from 1 to 3

tons and aid of Piston Pin Press Stand KVI 01 05300 is necessary When pressing piston pin in connec

plastic hammer through

b Check to be

that valves

are

ting rod apply engine oil

small end of b Arrange
so

to

pin and

Valve Lip Seal Drift KVI0104800

properly seated on valve seats with out foreign particles stuck in be

tween
c

8 connect i rod oil jet hole of connect end is directed toward

ing spring
Install side is
an uneven

rod

big

Valve

pitch
c

right side of cylinder block

Be Sure to installpiston in cylinders with notch mark of piston head toward front of

type
face

painted

Wte spring facing to cylinder head sur

engine

EM 12

Engine
2

Mechanical
d All bearings except No 2 and No 4 not interchangeable between are upper and lower bearings
7

Install piston rings Install

so

sliding surfaces of valve lifters

on

insert

that stamped mark

lifters in holes in cylinder block

3 coat

ring faces upward

Note
a

To install camshaft

be

sure

to

sliding
with a

surfaces of camshaft bush

There One

are

two

types of top rings

ings

light

coat

of engine oil block from

Apply engine oil

on

to

main

bearing

Insert camshaft in

is

conventional

special

cast

iron ring the other is steel ring which is called a high power ring b Second ring has

larger taper

surface

than top ring In combined oil ring upper rail is same as lower one

cylinder front side of engine exercising care not to damage camshaft bushings 4 Install camshaft locating plate and tighten bolts to specified torque

surfaces

both

sides

of cylinder

block and cap Install crankshaft 8

en

Install main bearing cap and tight bolts

to

specified torque
torque cap

l i

Tightening torque Camshaft locating plate

0 4 to 0 5

lil Tightening
Main

kg

bearing

2 9 to 3 6 ft Ibl

5 0 to 6 0

kg

36 to 43 ft lb
so as

Note

Set

locating plate
mark
comes

the

Lower

Note
a

to

engine

I
EM158

lnT

bottom side

Apply
ing
as

seal to each

rear

main bear

contact comer of cylinder block EM 61

10

shown in F

Fig EM 57 Installing Piston Ring

Fix bearings

on

connecting rod

and connecting rod cap

VALVE ROCKER SHAFT ASSEMBLY Install

EM 58 in

Fig EM 59 Installing Camshaft Locating Plate Fig EM 6

5 6

EM493

Applying Sealant

parts as shown in Fig place on rocker shaft

Install baffle plate and steel

Set main

net

bearings

at

proper por

tion of cylinder block and caps

3

b Arrange parts so arrow mark on bearing cap faces toward front of

engine
No 1
0

J
@
EM491

0 0 0 0

tightening bearing cap place bearing cap in proper position by shifting crankshaft in
Prior
to

bolts

axial direction d

Tighten bearing cap

bolts

gradually

upperW
Lower

in two to three stages outwardly from center bearing in the sequence shown in
e

J
EM492

Fig

62 EM

After securing bearing cap bolts ascertain that crankshaft turns

Fig EM 58 Valve Rocker Shaft As embly

Fig EM 60 Main Bearings and Caps

smoothly

ENGINE ASSEMBLY
I
is

@I
Note
a

The first step in engine assembly

to

bolt

Engine

Attachment
side

Center bearing

No

3 is

flanged
2 and
EM494 same

KV 10 102500 to right hand cylinder block In succession block

in

of

install

type for thrust force b Two internal bearings

No 4
c are

No

Engine

Stand ST0501S000

with engine bottom up 2 Apply a light coat of engine oil to

of the same type Front bearing No I is the

as rear

type

bearing
EM 13

No 5

Fig EM 62 Torque Sequence of Cap Bolts

Engine Mechanical
9 Make
at

SUre there

is

proper

end

ton Ring

Compressor EM03470000

play

crankshaft

Crankshaft end play 0 05toO 15mm 0 OO20 to 0 0059 in h

end

S Make sure there exists proper end play at connecting rod big end See Fig EM41

Big end play

01 play 16
EM497 to

2 mm 0

0 004 to 0 008 in

laJlk
Fig EM 66 Note
a

Insert

crank

sprocket keys

in

keyways

of crankshaft Install

cam

tolling Platon Rod Assem bly

shaft and crankshaft sprockets tempo rarily for adjustment of tooth height

by using adjusting pistons

in
L
r

washers

Insert inders

nding cyl

Height

dif

J
10

l11 h Less1
0 5 mm 0 020 in

EM486

b Apply engine oil to sliding parts

c

Fig EM 63 Checking Crank luJft

End

Play

Arrange pistons so number stamped on piston head faces to front of engine

should be

Adjusting
0 5

washer thickness
mm

10 020 in

Install

rear

oil seal using suitable

d Before

drift

installing piston piston rings positioned as shown in

67 EM

Fig

EM500

Fig EM 69 Adju ting

Sprocket

Tooth Height

Fig EM 64

talling Rear Oil Seal

Second

ring
EM49B

Oil ring lower rail

17 shaft

II 12

Install Install bolts

rear

plate secwely
and

Fig EM 67

Positioning

Piston Ring

Install tinting chain and cam sprocket with their markings See Fig EM 70
I at T D C

flywh el
to

Gap
14

properly aligned
Then set No

tighten

specified torque
Apply engine
oil
to

dl

Tightening torque Flywheel and drive plate A 14 engine fixing bolts

8 0 to 9 0 m kg

bearing

surfaces

on piston compression stroke See Fig EM 71 Oil sprocket teeth and chain with

dl Tighte ning torque

Connecting
rod cap nuts 3 2 to 3 8

engine oil

58

to

65 ft Ib
A 15

m kg

Drive plate

engine

23 to 27 ft b

fixing bolts
8 5 to 9 5

kgm
b

61

to

69 ft

Match mark

Key

groove

EM501

Fig EM 70 Aligning Markinga

EM499

Fig EM 68 Tightening Connecting Rod Cap Fig EM 65

13
n

talling Flywheel Note

turn

Note

Make

sure

camshaft

Rotate engine quarter

and Pis

connecting rods and Am11 rod caps so cylinder connecting

numben face in
same

dowel hole and crankshaft

sprocket sprocket

key

are

in line and both dowel hole

are

install piston rod

assembly using

direction

and key

located downward

EM 14

Engine
Correct

Mechanical
L

projection
mm

ifl

Less than
m

Tightening torque Crank pulley nut

15to 20 m kg b 108 to 145 ft

15

0 59 inl

camSM9tJ
down hole

26

Invert engine

Install oil stniiner

new

and oil pan using Key

groove

gasket

and oil

seal Note Give

coating

of sealant to

seam

EM767

between oil pan oil seal

lEM504

gasket

and oil pan

Fig EM 11 Setting No I Piston

atT D C

Fig EM 74 Checking Projection of Tfnsioner Spindle

21

ifl

Tightening torque
Oil pan bolts 0 4 to 0 6

18

Tighten camshaft sprocket bolt Tightening torque Camshaft sprocket 4 to 4 8 kgm

29 to 35 fHbl

Correctly install oil thrower

in

kgm

front of camshaft

sprocket

12

9 to 4 3 ft lb

ifl

22 bolt
cover

Press

new

oil seal in timing chain

cover

Frant cover oil seal should be is disassem 27 Note Install

replaced when front

bled 23

gasket and cylinder head

Do not

apply

sealant

to

any

Install timing chain

cover

with

gasket in place
Note When

other part of cylinder block and head surface

inatalling

oil seal

apply
28

coating of engine oil to mating shaft to prevent scratches and fold ed lip Also apply coating of oil to

Tighten cylinder
torque

head bolts

ifl Tightening
Cylinder

periphery of oil
EM502

seal

head bolts

7 0 to 7 5

kg m

ifl Tightening
Timing

torque
chain cover bolts

51 to 54 ft IM

Fig EM 72 Tightening Camshaft Sprocket Bolt

0 5 to 0 7

kg

3 6 to 5 1 ft Ib Note

19
en

Install chain tensioner and tight

tensioner

attaching

bolts

Z5
o

One of

cylinder head bolts is smal

ler in diameter than others and has

a

ifl

Tightening torque Tensioner enaching 0 6 to 0 8 kg m

14 3 to 5 8 ft b

hollow head It should be install

on

bolt

j
I

ed
b

right side

center of

cylinder

head

Tightening
or

should be made in two

f t
4

three steps

finally torquing

to

EM455 c

specification Retighten cylinder

engine

head bolt after Idle R P M

Fig EM 75 Installing Timing

Chain
Covtr

has been warmed up

Refer to Carburetor

and Mixture Ratio EF Section for 24

in

Install

water

pump

with gasket

Adjustment

and

Inspection

place

EM503

ifl Tightening torque

Water pump attaching bolts 0 9 to 1 4

Fig EM 73 Installing Chain

Tensioner

kg m

16 5 20 sioner Check

to

10 1 ft bl

projection

of ten 25 Install crank pulley then

con EM505

spindle
L exceeds the speci

If projection

firm and set No I piston

at T D C on

fied limit replace chain

compression stroke
EM 15

Fig EM 76 Cylinder Head Bolt Tightening Sequence

Engine Mechanical
29

Apply engine oiho both

rods and

ends of
se

Valve clearance

push

insert in proper

Intake and exhaust hot

0 35 cold 0 25
mm mm

CAUTION
a

quence 30 Apply

8e

sure

to

set

No

piston

to

engine oil to valve stem end and rocker arm contact surfaces
Position rocker shaft assembly inder head
31
on

0 014 in

LD C of b Before

compression

stroke

instaliation

return distribu

cyI

0 010 in

Tighten

rocker

shaft

bracket

fJ

Tightening torque
Velve rocker 1 6 to 2 g nut adjusti

bolts to

specified torque

kltm

approximately 30 degrees from its correct position Insert distributor meshing distributor drive gear and driven gear
tor rotor
c

fJ Tightening torque
Rocker shaft bracket bolts
2 0 to 2 5 m kg 33 34 14 to 18 ft b

After installation distributor rotor should cap

12

to

16 ft b

align

with mark

on

rotor

Install rocker

cover

Install intake and exhaust mani

folds Note

Tightening

should be done in

two or three

stages outwardly from

fJ Tightening torque
Manifold
nuts

center bracket

1 5 to 2 0

kg m

11 to 14 fHb

Note

When installing intake and haust manifolds locate bolt

center of fitting hole

J
ex

No 1 mark

in

EM508

EM506

Fig EM 80 Cornct P05ition of Rotor

Fig EM

77 Rocker Shaft Bolt

Tightening Sequence
32

Adjust

valve clearance to

speci
42
EM528

fied value
Note
a

Dismount

engine from Engine

on

Stand ST0501S000 and place it suitable engine stand

Re move

First

set

clearance

to

0 25

mm

Fig EM 79 Installing Manifolds 35

36 tor

0 0098 in when engine iscold After engine has been assembled

warm

Engine

Attachment

Install E G R control valve Install baffle plate and carbure

KVlOI 2500
43

it

up for at

least

several

minutes finally

adjust

clearance to refer to

Install spark plugs mounting bracket R H

44

and engine

specification

For details

Install oil pump and ftIter Install thermostat and

assem

Adjusting

Intake and Exhaust Valve

bly

Clearance in ET Section

fJ Tightening torque
Carburetor
nuts

45

water

outlet 46 Install fuel pump and fuel lines Do not

0 4 to 0 6

kg m

2 9 to 4 3 ft Ibl

forget

to

install spacer and

gasket
37 Install
47
vacuum

control valve

Install distributor

vacuum

line

as

sembly
38

and bracket

48

Install distributor cap and

an

high

tension cables as

assembly Connect

Install air cleaner bracket and air

high
49
50

tension cables Insert oil level gauge

or
Wrench 2
EM507

cleaner
39

Connect
to

air

vacuum

and

Install fan

fan

pulley

and fan

blow by hoses 40

air cleaner

Screwdriver Feeler gauge

Install pipe connector to control valve hose and engine mounting brack etLR
41

spacer Lock washers 51

bolt

by

bending

lock

Fig EM 78 Adjusting Value

Clearance

Install alternator bracket adjust

Install distributor
EM 16

ing bar water pump

pulley

alternator

Engine
and fan belt
Be sure that belt deflection is held 53 pump

Mechanical
air
so

Install idler pulley bracket belt and idler

54

Install clutch and

cover

assem

pulley

If

bly

using
For details

Clutch

Aligning

Bar

within

force is

specified range when moderate applied midway between pul

equipped

See Fig EM 2

STI0610000 refer to Installation in

CL Section

Be sure deflection of air pump belt is same as that of fan belt Belt deflection 8 to 12 mm 0 31 to 0 47 in Force

leys
Belt deflection 8t012mm 0 31 to 0 47 in Force 10

kg

22Ib
Fan

10 kg

22Ib

Deflection

pulley

Deflection 10 kg 22Ib

Alternator

pulley
Crank

Fig EM 83 Installing Clutch Assembly

pulley
EM768

Fig EM 81

Fan Belt Temion

52
pump

Install

air

pump pump

bracket

air
so

and air

pulley

If

equipped

Fig EM 82 Air Pump Belt Tension

EM 17

Engin

Mechanical

SERVICE

DATA AND 8PECIRCATION8

GENERAL SPECIFICATIONS

Engine

model

AI5

Cylinder arrangement Displacement

cc cu

4 in line

in

397 1
76 0

85 24

I 488 90 80 76 0 2 992 OR V
82 0

Bore and Stroke

x x

77 0 3 031

x x

mm

in

2 992

3 228

Valve arrangement

Firing

order

2 3 4
2

Compression
Number of piston rings Oil
Number of main

bearings

Compression

ratio

California and FU model of California Non

California Non

89 8 5

except FU model and Canada

EM 18

Engine
INSPECTION AND ADJUSTMENT
CYLINDER HEAD AND VALVE Cylinder head

Mechanical

Unit
Limit

mm

in

Standard
Less than

Head surface flatness

1 0 004 0

0 05

0 0020

Valve Intake valve

Unit

mm

in

Exhaust valve 0 014

0 010

Valve clearance

I
I

Hot

35 0

j
Valve lift

Cold
7 91 3114 0

0 25

8 22 30 0
181 1

3236 0

D
a

Valve head diameter H

37 0 to 37 2 1 457 to 1 465

to to

30 2
189 1

Valve length
L

103 6 to 104 0 4 079 to 4 094

Valve
EM769

stem diameter

7 970 to 7 985 3138 0

to

3144 0

0 3128 to

945 to 7 960 3134 0

Valve seat
a

angle

45030

Valve

spring
Free

height

in mm
30 2
mm

5 46

1831

Compressed height
valve open Assembled height valve closed Out of square S

2 to 25 6 22

kg in lb

189 1

49 0 to 56 4

mm

kg

in

lh

38 7 544 to 62 6 1 524 120 0 to 138 0

Less than 1 6

mm

in

0 063

EM 19

Engine Mechanical
Valve guide
INTAKE

senice

Dl

I
18 5 0 728
L

I
d

D21
EXHAUST

3 0 118 II

t 81

8 5

327 to 0 335 Unit

mm

1 in
EM171

Combustion chamber ide

EM770

Unit Intake Exhaust Valve guide length

L

mm

in

for

California Non

Intake

except FU
49
1 93

for California Canada FU model for Non

California
53 2 09

12 0331012 044
0 4737 to

Valve guide Outer diameter

4742 0
244 12

D2

12 233 to

0 4816 to 0 4820

Valve guide
Inner diameter

8 000 to 8 015

Finished size

3150 0

to

0 3156

Cylinder head valve guide

hole diameter

12 200 to 12 211

4803 0

to 0 4807

Interference fit of valve

guide

0 022 to 0 044

0 0009 to 00017

Unit Standard

mm

in

Max tolerance

In Stem
to

Q15 0

to 0 045

0 0006 to 0 0018 1 0 0 004

guide clearance
Ex 0 040
to

0 070

0 0016 to 0 0028

EM 20

Engine
Valve seat Intake valve insert
service

Mechanical

Unit

mm

in

California Non

California

9anada

FU model

D D

02

11

1
I

J
Ol
EM772

580 38

to

596 38

5189 1

to

5195 1

580 38

to

38 596

5189 to

5195 1

D2 D3
H

31 9 to

1 32

256 1

to 1264

5 36

to

36 7 I 437

to

I 445

5 9 to 6 0 0 232 to 0 236

3 to 1

3 2

0 051 to 0 091

600

O2 Do
38 500 to 516 38

200
1 5157 to 1 5164

Do
Exhaust valve insert service

Cylinder

head valve insert hole diameter

D2

31 9 to

1 32

256 1

to

264 1

35 5 to 35 7

398 1

to I 406

5 8 to 5 9 0 228 to 0 232

3 to 1

3 2

0 051 to 0 091

600

200 38 500
516 38 5157 1 5164 1

to

to

Unit D
33 580 to

mm

in

596 33
15 27

3220 1

to

3227 1

D2

26 85 to

1 0571 to 1 0689

I
C

D2

5 9 to 6 0 0 232 to 0 236

08

to

1 0

0 031 to 0 039
13189 to 1 3195

I I

l I
EM773

Do

500 33

to 33 516

EM 21

Engine
Finished size of service valve insert cutter
Intake

Mechanical

Unit

mm

in

For

Clilifornia Non

except FU model

For California Canada

FU model for

California Non

@
I
I

Lr

fil
I

JII

I
I
EM774

I
Dl
D

I
I

EM775

36 5 to 36 7

1437

to

I 445

5 to 36 7 36 34 4 to 34 6

1 437 to 1 445 354 1

to

D2

362 1

Exhaust All models

Unit

mm

in

III

900

L WII

I
EM776

D
C

5 to 29 7 29

161 1

to 1 169

1 8 0 071

EM 22

Engine
Valve rocker arm and shaft

Mechanical
Unit
mm

in

Rocke shaft outer diameter

19 979 to 20 000 0 7866 to 0 7874

Rocker

arm

to rocker shaft clearance

0 020 to 0 054

0 0008

to

0 002

Rocker ann bore diameter

20 020 to 20 033
0 7882 to 0 7887

Valve lifter and

push rod
Standard
0 02 to 0 05

Unit

mm

in

Wear limit

15 0 0 0059

Valve lifter lifter hole clearance

0 0008 to 0 0020

CAMSHAn
Camshaft journal and bearing specifications Standard

Unit

mm

in

Camshaft bearing

Camshaft journal
diameter

Camshaft journal
to

Camshaft journal
to

Bearing

Size

inner diameter

bearing clearance

bearing clear
limit

ance wear

No I

43 833 to 43 843 I 7257 to I 7261 323 43 to 43 333

43 783

to

43 796

0 037 to 0 060

1 7237 to I 7242 43 283 to 43 296 I 7041 to I 7046

0 0015 to 0 0024
0 027 to 0 050

No 2

1 7056 to 1 7060

0 0011

to

0 0020

42 836 to 42 846 Standard No 3

1 6865 to 1 6868

42 783

to

42 796

0 040 to 0 063 0 0016 to 0 0025 0027 to 0 05 0 00 II to 0 0020 0 037 to 0 060 0 0015 to 0 0024

0 15 0 0059

1 6844 to 16849 42 283 to 42 296 1 6647 to 1 6652

323 42 No 4

to

333 42

1 6663 to 1 6667 41258 to 41 268 16243 to 16247

No 5

208 41

to 41221

16224 to 1 6229

EM 23

Engine Mechanical
Camshaft journal and

bearing specifications Undemze

size

uillt
Finish of camshaft Camshaft journal
to

mm

in

Bearing position

Bearing

Camshaft bearing thickness

1 565 to 1 585 0 0616 to 00624

Finish of camshaft

journal diameter
43 783 to 43 796 I 7237 to I 7242

bearing clearance
0 037 to 0 060

bearing inner
diame tee
43 833 to 43 843

Standard

0 0015

to

0 0024

7257 to 1 7261

0 25 0 0098
No I

710 90 to 1

43 233

to

43 2

0 037 to 0 060 0 0015 to 0 0024 0 037 to 0060 0 0015 to 0 0024 0037 to 0 060 0 0015 to 0 0024 0 027 to 0 050 0 00 II to 0 0020 0 027
to

43 283 to 43 293

0 0665 to 0 0673 1 815 to 1835

17021 to I 7025

7041 1

to 1 7044 343 43

Under
size

0 50 0 0197 0 75 0 0295

43 283 to 43 296 7041 i

to I 7046

43 333 to

0 0715 to 0 0722
1940 to 1960

I 7060 to I 7064
43 083 to 43 093 1 6962 to 16966

43 033 to 43 046
1 6942 to 1 69 7 43 283 1043 296

0764 to 0 0772
1 565 to 1 585 0 0616 to 0 0624

Standard

43 323 to 43 333
I 7056 to 1 7060

I 7041

to I 7046

0 25

1690 to I 710

43 033 to 43 046 1 6942 to 1 6947 42 783 to 42 796 1 6844 to 1 6849

0 050

43 073 to 43 083
1 6958 to 1 6962 42 823 to 42 833 1 6859 to 1 6863

0 0098 No 2 Under
size 0 50

0 0665

to

0 0673

0 00 II to 0 0020

1 815 to 1 835 0 0715 to 0 0722

0 Oi7

10

0 050

0 0197 0 75 0 0295

000 II to 0 OQ20 0 027

to

11

940

to

1 960

42 533

546 1042

0 050

42 573 to

583 42

00764 to 00772

1 6745 to 16750

00011 to 0 0020
0 040 to 0 063

16761 to 1 6765
42 836 to 42 846 1 6865 to 1 6868

Standard

1 565 to 1 585 0 0616 to 00624

42 783 to 42 796
1 6844 to 1 6849

00016 to 0 0025 0 040 to 0 063

0 0016 to 0 0025

0 25 0 0098 No 3 Under
size

1 690 to 1710

42 533 to 42 546
1 6745 to 16750 42 283 to 42 296 1 6647 to 1 6652 42 033 to 42 046 1 6548 to 1 6554 42 283 to 42 296 1 6647 to 1 6652 42 033 to 42 046

42 586

to

42 596

0665 to 0 0673
1 815 to 1 835

16766 to 1 677
336 42
to

50 0 0 0197 0 75 0 0295

0 040 to 0 063 0 0016 to 0 0025 0040 to 0 063 0 0016 to 0 0025 0027 to 0 050 0 00 II to 0 0020 0027
to

42 346

0 0715 to 00722

16668 to 16672
42 086 to 42 096 1 6569 to 1 6573

11

940 to 1960

0 0764 to 0 0772

Standard

1 565 to 1 585 0 0616 to 00624

42 323 to

333 42

1 6663 to 1 6667

0 25

1 690 to I 710 0 0665 to 0 0673 1 815 to 1 835

0050

42 073

to

42 083

0 0098 No 4 Under
size

16548 10 1 6554
41 783 to 41 796

0 0011 100 0020 0 027 to 0 050 0 00II

to

1 6564 to 16568

0 50 0 0197

41823 to 41833
1 6466 to 1 6470

0 0715 to 0 0722

16450 to 16455
41 533 to 546 41

00020

1
No 5 Unoer
size

0 75 0 0295

11

940 to 1 960

0 027 to 0 050 0 00II

to

41 573

to

41 583

0 0764 to 0 0772

1 6352 to 16357

00020

1 6367 to 1 6371 258 41

to

Standard

1 565 to 1 585

208 41

to

221 41

0 037 to 0 060 0 0015 to 0 0024 0 037 to 0 060 0 0015

to

41 268

0 0616 to 0 0624
1 690 to 1 710

1 6224 to 1 6229 40 958 to 40 971

1 6243 to 1 6247

0 25 0 0098 0 50
0 0197

41008 to 41018 16145 to 16149 40 758

to

0 0665 to 0 0673
1 815 to 1 835 0 0715 to 0 0722

16125 to 1 6130 40 708

to

0 0024

40 721

0 037 to 0 060 0 0015 0 037

to to

40 768

1 6027 to 1 6032 458 40 5928 1 to 471 40

0 0024

1 6046 to 1 6050

0 75

0 0295

11

940 to 1 960

0 060

40

508

to

518 40

0 0764 to 0 0772

to 1 5933

0 0015 to 0 0024

1 5948 to 15952

EM 24

Engine
Camshaft specifications

Mechanical

Unit

mm

in

Standard
Less than

Wear

repair

limit

Camshaft bend

oms

0 0006

0 05 0 0020

Intake
Carn

200 36

to

250 36

35 700 I 4055

I 4252 to I 4272

height
Exhaust
36 930 to 36 980 I 4539 to I 4559 430 36

4342

Intake
Cam lobe lift

5 65

0 2224 0 2331

I
worn

Exhaust

5 92

Difference in diameter

max

03 to 0 07 0

and min worn parts

0 0012

to

0 0028

10 0

0 0039

of camshaft

journal
om to 0 05 10 0

Camshaft end play

0 0039

0 0004 to 0 0020

Valve timing

ff

ff
s

fif
EM120
D C

Unit
a

degree
c

b 248

d
54

f 56

256

14

20

EM 25

Engine MechanicliIl
CYLINDER

BLocK
Standard Less than 0 05
0 0020

Unit

mm

in

Wear limit 01
0 0039

Surface flatness
60 2 36 20 0 79 t

100

CI

94

rJ
L
II

Inner diameter

76 000 to 76 050 2 9921 to 2 Less than

0 20

994i

0 0079

Cylinder bore

of Out

round

XV
Taper
A B

oI5 O

0 0006

E9
I
Unit
mm

Less than

oI5 O

0 0006 0 20 0 0079

in

EM479

Differential in inner diameter between cylinders

Less than 005

0 OO20

Piston to

cylinder

block clearance

025 to 0 045 0 00010

to

0 0018

Cylinder liner for service

Outside diameter 80 00 to 80 05
1496 3 to

Unit

riun

in

Inside diameter

4 0

157 0

Undersize

1515 3 55 80

50 75

to 75 60

45

0 177

Undersize

80 50 to 1692 3
to

2 9724 to 2 9763

1712 3

PISTON PISTON RING AND PISTON PIN

Piston

Unit

mm

in

Piston diameter
e e 5

Standard

75 967 to 76 017 2 9908 to 2 9927 0 0197 76 467 to 517 76 3 0105 to 3 0124

co

51

ED I

50 0
Over size H
EM4S0

1 00 0 0394

76 967 to 77 017 3 0301 to 3 0321

EM 26

Engine
Piston

Mechanical

ring
Standard
0 04 to

Unit

mm

in

Wear limit

Top
Side clearance

07 0 10 0 0 0039

0 0016 to 0 0028 0 03 to 0 06 0 0012 to 0 0024

2nd

Oil

Combined 0 20
to

35 0

Top

0 0079 to 0 0138 15 0
to

30 0

Ring

gap

2nd

1 00

0 0394

0 0059 to

0118 0

Oil
rail ring

30 0

to 0 90

0 0118 to 0 0354

Piston

pin
Piston pin diameter

Unit

mm

in

18 995 to 19 000 0 747 to 0 748 63 00 to 63 25

Piston pin length

480 2

to

490 2

Piston

pin hole diameter pin to piston

19 003 to 19 012

0 748 to 0 749
0 008 to 0 012 0 0003 to 0 0005

Piston

clearance Interference fit of piston

0 017 to 0 035
0 0006 to 0 0013

pin

to

connecting

rod

CONNECTING ROD
Unit
mm

in

Standard

Repair replace
limit
03 133

Center distance

132 97 to

5 2350 to 5 2374

Bend per 100

3 94 in Torsion 3 94 in

mm or

Less than 0 05 0 0020 10 0 0 0039

length
per 100
mm

or

Less than 07 0 0028 0 1 to 0 2 0 0 004 to 0 008

length

Big end play

04 0 016

EM 27

Engine Mechanical
CRANKSHAFT

Unit

mm

in

AI4

AI5
49 951 to 49 964

Journal diameter
I c
r

h9666 to 1967 1
44 961 to 44 974

j
A

l
B

Pin diameter

I 7701
38 45 to 38 55
1 5138 to 1 5177

to

1 7706

EM777

40 95 to 41 05

6122 to 1 6161

Unit Standard
Out of round
X Y A B
of out round of Taper and and crank pin journal

mm

in

Wear limit

Taper
A

Less than

A B

X Y

0 005 0 0002

0 03 0 0012

0
EM715

Less than

Crankshaft bend

025 0

0 0010

0 05

0 0020

Crankshaft free end play

0 05 to 0 15 0 0020
to

0 0059

30 0

0 0118

BEARING

Bearing

oil clearance
Unit
mm

in

Standard

Wear limit

Main bearing clearance

0026 to 0090 0 0010

to

0 035 0 10 0 0039

llecting CO clearance

rod bearing

0 030 to 0 079

0 0012 to 00031

EM 28

Engine Mechanical
Main bearing undersize
Unit
mm

in

Main bearing

ze undersi

Crank

journal
to

diameter

Standard size

49 943

49 964

19663 to 1 9671

0 25 0 0098

49701 to 49 714
1 9567 to 1 9572

Undersize

50 0

0 0197

49451 to 49 464
19469 to 1 9474

0 75

0 0295

49 201 to 49 214
19370 to 1 9376

Connecting rod bearing undersize

Unit
mm

in

Connecting

rod

bearing

undersize

Crank pin diameter

44 954 to 44 974 1 7698 to I 7706

Standard size

44 881 to 44 894

0 08 0 0031

1 7670 to 1 7675

0 25

0 0098

44 711 to 44 724 1 7603 to 1 7608

Undersize
44 461 to 44 474

50 0

0 0197

17504 to 1 7509

44 211 to 44 224

0 75 0 0295

1 7406 to I 7411

MISCELLANEOUS COMPONENTS
Unit
mm

in

Max tolerance

Runout of camshaft Runout of flywheel

1 0 004 0

0 15 0 0059

EM 29

Engine Mechanical
t IGHTENING
Cylinder head
bolt

TORQUE

Unit 7 0 to

kg

iii ft lb 51 to 54

5 7

Rocker shaft bracket bolt

ain

2 0t02 5 5 0
to

14to 18
36 to 43 58 to 65

bearing cap bolt

60

Flywheel fixing bolt

Drive

8 0 to 9 0

plate fixing

bolt

Al4 AlS

8 0 to 9 0 8 5 to 9 5 3 2 to 3 8
4 0 to 4 8 0 5 to 0 8

58 to 65 61 to 69
23 to 27

Connecting rod

cap nut

Camshaft sprocket bolt

29 to 35 3 6 to 5 8
12to 16

Locating plate
Valve rocker

bolt
nut

adjusting

16 to 2 2 09
to

Oil strainer bolt Oil pan bolt Oil pan drain

I 4

5 6

to

10 1 3 4

0 4 to 0 6

2 9 to

plug
cover

2 0 to 3 0

14 to 22 3 6 to 5 1

Timing chain
Crank

bolt

0 5 to 0 7 15to 20 0 9 to I 4 0 9 to I 4 5 to 2 0 1
19 to 2 5

pulley bolt

l08
6 5

to to

145 l 1O

Water pump bolt Fuel pump bolt

6 5 to 10 1 11 to 14 14to 18

Spark plug Engine mounting securing bolt

30 EM

Engine Mechanical

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable
cause

Corrective action

fonglno Noill

Loose main bearing Seized

Replace Replac
Repair
or

Knocking of crank
shaft and

bearing

bearing
Ben crankshaft Excessive crankshaft end

replace
l

play

Peplace

center thrust

bearing

Piston and

Loose

bearing bearing

Replace
Replace Replace pin
or

connecting rod

Seized

knocking

Loose piston pin Loose piston in cylinder Broken piston ring

bushing

Recondition cylinder

Replace

Improper
Camshaft knocking

connecting rod alignment

Realign
Replace

Loose bearing

Excessive
Rough
8roken
ge

axial

play

Replace bearing thrust plate

teeth
gear

Repair Replace

cam

Timilli chain noise

Improper chain
Worn and
I or

tension

Adjust Replace Replace

damaged chain

Wom

sprocket
or

Worn and
nism

broken tension adjusting mecha

Replace

Excessive camshaft and

bearing

clearance

Replace AdjUst
Replace

Camshaft and valve mechanism knock

Improper

valve clearance
screw

ing

Worn adjusting

Worn rocker face

Replace
Replace guide

Loose valve stem in guide Weakened valve Seized valve

pring

Replace Repair or replace

EM 31

Engine

Mechanical

Condition

Probab Ie cause

Corrective action

Waterpurnp knocking

Improper
Broken

shaft end play

Replace Replace

impeller

II

Othw

mllChani Improper valve clearance Insufficient clearance between valve stem and

Adjust
Clean stem
or ream

troubl

the

guide

Stuck valve

guide
Weakened
or

broken valve pring ofvalve stem

Replace

Biting

or

damage quality

Repilce
Use

or

clean

Poor fuel

good

fuel

Seized valve
seat

Il1 prop r valve

clearance

Adjust Replace Replace

Reface valve

Weakened valve pring Thin valve head

edge

Narrow valve seat

Overheating
Over

Repair

or

replace speed

speeding guide

Drive at proper

Sticked valve

Repair

Excessively

wom

Shortage ofengine oil

Add

or

replace oil
on

cylinder and piston

Check oil level

daily basis

Dirty engine

oil

Clean crankcase

replace

oil and

re

place oil
Poor oil

ftIter element

quality

Use proper oil

Overheat

Repair Repair

or

replace
replace

Wrong assembly of piston with connecting rod

or

Improper piston ring clearance

Dirty
air cleaner

Adjust

Clean

periodically
t

Too rich mixture

Adju

Engine

over run

Drive correctly Clean and

Stuck choke valve Over choking

adjust

Start in correct way

EM 32

Engine Mechanical

Condition

Probable

cause

Corrective action

Faulty connecting
rod

Shortage of engine oil

Add

or

replace oil
on

Check oil level Correct Use proper oil Grind and Clean

daily basis

Low oil pressure Poor engine oil

quality

Rough crankshaft surface Clogged oil passage Bearing

worn or

replace bearing

eccentric

Replace
Repair

Bearing improperly assembled

Loose bearing
Incorrect

Replace Repair
or

connecting rod alignment

replace

Faulty crankshaft

Shortage of engine oil

Add

or

replace
on

bearing
Low oil pressure Poor

Check oil level

daily basis

Adjust
oil Use proper oil

quality engine
of out

Worn or

round crankshaft journal

Repair
Clean

Clogged

oil passage in crankshaft

Bearing worn or eccentric Bearing inproperly assembled

Non co centric crankshaft
or

Replace Repair bearing

Replace

EM 33

Engine

hanical

SPECIAL SERVICE TOOLS

Kent Moore No Tool number

I Kent
Tool numb
r

Moore No

tool

name

Reference page
or

tool

name

Reference
page
or

Fig ST0501S000

No

Fig

No

Engine stand aJSe1Ilbly

126023

STII670000 2
1

valve

seat cutter set

CD @

ST05011000 ST05012000

Engine
Sase

stand

CD J26 m @126023
Fig
4 EM

Fig

EM 26

Page

EM 13

Page EM 16

KVIOI02500

Engine attachment

126097 4 EM Fig Page EM 13

STl207oo00

Valve lifter

125631

Fig EM 16 Fig EM 53

Page

EM 16

KV 10 1039S0

Valve guide
Reamer

reamer

set

125618

KYIOl05300
3 2 1

Piston

pin press stand Fig EM 15 Fig EM 55

CD

STl1081000

2 12
315 0

mm

0 480 in dia
2 STlI032000

8 0 mm dia Valve

in

CD 125618 @J25618 @ 125618

Fig Fig

3 STlI033000

guide

drift

EM 24 EM 25

I
STl611 0000

Ju

Camshaft bearing drift

125644

CD

Fig

EM 28

@
@
KV 10 104800 Valve lip seal drift 125624 KV 10 I02800

@
Pilot bushing

puller

125657

Fig EM

52

Fig

45 EM

34 EM

Engine

Mechanical

Kent Moore No

Kent

Moore No

Tool number

tool

name

Reference
page
or

Reference Tool number tool name page

or

Fig

No

Fig No

EM03470000

Piston

ring

compressor

ST20610000

Clutch aligning bar

125673 83 EM

Fig

66 EM

Fig

35 EM

DATSUN 210

Model 8310 Series

SECTIONEL
ENGINE LUBRICATION SYSTEM
CONTENTS
ENGINE LUBRICATION SYSTEM
LUBRICATION
01 L PUMP CIRCUIT EL 2 EL 2 EL 3 VALVE EL 4 4 EL 4 EL 4 EL

SERVICE DATA AND SPECIFICATIONS TROUBLE DIAGNOSES AND CORRECTIONS

SPECIAL SERVICE TOOL

EL 5

OIL PRESSURE REGULATOR

OIL PRESSURE RELIEF

5 EL EL 6

VALVE

OIL FILTER OIL PRESSURE WARNING SWITCH

Engine Lubrication System

ENGINE
LUBRICATION CIRCUIT

LUBRICATION SYSTEM

ll2 EL

Fig EL l Lubrication Circuit

Oil pump

Oilf1lter
I

I
I
Camshaft bearing

Main bearing
I

I
Chain
tensioner

Rocker shaft

Crankshaft

I
l

Camshaft

Rocker

arm

Connecting

rod

bearing

I
Piston

Valve lifter

Oil trainer

Cylinder wall

OiIpan

EL 2

Engine Lubrication System

OIL PUMP
The oil pump and filter assembly is bolted to the right side of the cylinder block and
can

DISASSEMBLY AND ASSEMBLY

I

INSPECTION
Wash all parts in cleaning solvent and dry wiih compressed air
I

Remove bolt securing pump

cover cover

be

removed

with

the

to pump

engine
the

in

c pl a

The oil pump which is

from
2

body Separate pump body

pump

hispect
or

pump

body

and

cover

for cracks 2
wear

excessive wear

driven by

gear on the camshaft has full flow element type filter in

Slide out outer rotor from pump Remove Assemble

oil pressure

Inspect
Check

pump rotors for excessive inner

body
3

rotor

shaft

for

stalled to the oil pump cover

regulator

plug
4

washer shim spring and valve oil pump in reverse

looseness in pump 4
or

body
wear

order of

disassembly

Inspect regulator valve for scoring

Check regulator spring
to see
or

that

it is not worn on its side

collapsed
check

REMOVAL
I

Note

Using

feeler gauge
in

tip

Place

suitable container under

When
use

placing

oil pump in
care

vice

clearance clearance

oil pump
2 Remove three bolts and filter

extreme

not

to

distort

00 CD shown

and outer rotor tobody

Fig

4 EL

pump
3 4

attaching oil assembly and with

pump body and b Do

not

cover

in the jaws
shaft

pull

out drive

pin

draw assembly

securing drive shaft and inner

the pin caulked

rotor

Separate

oil filter from oil pump

Shaft is press fitted to rotor with

Ciean off old gasket from mating

surfaces

EL059

1 2 i EL044
E

Outer rotor

3
4

to body clearance Tip clearance Gap between rotor and stnight edge Gap between body and straight edge

L043

Fig EL 3 Oil Pump

7

ig EL Place

4
a

Checking

Rotor Clea

nce

EL 2 R moving Oil Pump Asso mbly

Tightening torque
Oil pump cove 0 39 to 0 bolt

5 2 kltm

straight edge across the face of pUmp and depress it slightly as shown in Fig 4 Check gap @ EL between body and straight edge or gap @ between rotor and straight edge Gap
0 03 to 0 06 mm 0 0012 to 0 0024 in

INSTALLATION
I 2

2 8 to 3 8 ti Ib

Install oil filter to oil pump Locate oil pump and filter
or

as

sembly
spacer

cylinder block using a and new gasket Secure with

Regulator

valve

4 0 to 5

plug 0 kltm

Rotor side clearance

tom
cover

rotor to bot

clearance

with

gasket

three bolts

29 to 36 ft bl

should satisfy the Standard

specifications
Wear limit

Tightening torque Oil pump securing bolts 0 9 to 1 4 kg m

6 5 to 10 1 ft lbl

Rotor side clearance rotor to bottom cover

mm

in

0 04 to 0 08

0 0016 to 0 031 Less than 0 12 0 0047

0 15 to 0 21

0 20 0 0079

Check oil

level and

add oil

if

Rotor tip clearance

mm

in

0 20 0 0079

necessary Start engine leaks

and check for oil

Outer rotor to body clearance

Remove the container

CD

mm

in

00059 to 0083

0 50 00197

EL3

Engine Lubrication System

Not

8Peciflcatlons
rotors and

Pump
iced

body
or

are

not serv rotors

or

Oil pressure At

separatdy
are

If pump

idling
more

body

replace ment of the entire oil pump assembly isnecessary

worn

damaged

than 11

Blrgan2
2lrg 5

psi

At 3 000 rpm

3 B to

54 to 74

Regulator ai Free length

InstoJlod l

an2 psi spring

43 49 rom 1 7122 in

ngth

load

3 mm 3 67 30 193 1

kg inJB 09lbl
o

Fig

6 EL

Removing Oil Filter

Regulator

3 8 to

ning lrgan2 54 1060 psi

2 4

val

pressur

INSTALLAnON
I Coat the

packing

on

the

new on

f1lter with oil

Position the f1lter

OIL PRESSURE REGULATOR VALVE

The oil pressure regulator valve is At the released posi not adjustable the valve permits the oil by pass through the passage in tion pump
cover

the oil pump cover Hand tight en the f11ter until the packing contacts
the cover tum

flange

flange then advance

it

2 3

OIL PRESSURE RELIEF VALVE

The relief valve located in the oil
pump cover main

Note

Do not

overtighten the fiIter

occur

or

oil leak may

to the

to the inlet side of the

pump Check regulator valve spring to ensure that spring tension is correct

oil

elem nt for

by passes the oil into the gallery when the oil filter is exCessively clogged With
See

Operate

the engine at fast idle

and check for oil leaks Check the oil level and add oil if necessary

regula tor valve removed check valve

operation

Fig

EL5

OIL PRESSURE WARNING SWITCIt

The oil pressure warning switch is on the oil pump cover and wired to an instrument cluster See located

OIL FILTER

no
1

Fig

6 EL

tEMOVAL
Place f1lter
E

suitable container under the

Regulator valve
Relief

warning light glows whenever drops below 0 2 to 0 4 kg cm1 2 8 to 5 7 psi

the oil pressure

The

2 3

valve
L045

Valve

spring
5 Regulator and Reli EL

flange
Vatv

Unscrew f1lter from oil pump cover using Oil Filter Wrench

Prior to be
sure to

installing a switch to cover apply a conductive sealer to

I

Fig

STl9320000

threads of switch

4 EL

Engine

Lubrication

System

SERVICE DATA AND SPECIFICATIONS

Oil pump Rotor side clearance Rotor to bottom cover
Rotor
nun

Standard
in

Wear limit

0 04 to 0 08
0 0016 to 0 0031

0 20 00079

tip clearance

mm

in

less than
0 12

0 20 0 0079

0047
0 50 0 0197

Outer rotor to body clearance

nun

in

0 15 to 0 21 0 0059 to 0 0083

Oil pressure

regulator valve
at

Oil pressure

idling

kg cm2 psi kg cm2 psi

in

more

than 0 8 II

Oil pressure at 3 000 rpm

3 8 to 5 2 54 to 74

Regulator

valve spring
nun nun

Free length Installed length load

49 43 in lb

I 7122 193 1

kg

3 3 67 30

8 09

Tightening torque
Oil pump securing bolts Oil pump
cover

kg kg kg

ft lb ft lb ft lb

0 9 to I 4 39 0
to

5 to 6

1 10

bolt
cap nut

0 52

2 8 to 3 8

Regulator valve

4 0 to 5 0 29 to 36

TROUBLE DIAGNOSES AND CORRECTIONS

Condition

Probable

cause

Corrective action

Oil leakage

Damaged

or

cracked body

cover

Replace

Oil leakage from gasket Oil leakage from regulator valve Oil leakage from blind plug

Replace
Tighten or replace

Replace
Correct Clean
or

Decreased oil pressure

Leak of oil in engine oil pan

Dirty

oil strainer
or worn

replace

Damaged

pump rotors

Replace Adjust
or

Faulty regulator
Used of poor quality engine oil

replace

Replace Replace

Noise

Excessive backlash in pump rotors

EL 5

Engine Lubrication System

SPECIAL SERVICE TOOLS

Kent Moore No
I

Kent Moore No Reference page

or

Tool number

tool

name

Reference Pile
or

Tool number

tool name

Fig No STl9320000 Oilfilter wrench

Fig No

J2S664

Fig

6 EL

6 EL

DATSUN 210

Model 8310 Series

SECTIONCD
COOLING SYSTEM

em
CONTENTS
COOLING SYSTEM
DESCRIPTION
WATER PUMP TORQUE COUPLING COUPLlNG TEM RADIATOR RADIATOR RESERVOIR

CO 5

CO 2 CO 2
CO 2

TANk

CO 5

CO 3 4 CO 4 CO

SERVICE DATA AND SPECIFICATIONS TROUBLE DIAGNOSES AND

CORRECTIONS

CO 6

THERMOSTAT

CO 7

C09ling System

COOLING SYSTEM

DESCRIPTION
The

pump
cover

installed
serves

on

the

timing chain

installed

on

cooling system

is of the con A

to circulate the coolant

cooling system pheric pressure

the radiator operates the at higher than atmos

ventional pressure type

centrifugal

The pressure t pe radiator filler cap

1P

To heater

a
From heater

C0126

Fig COol Cooling System

COOLANT LEVEL Pour coolant into the radiator up to the cap and also into the reservoir up to the MAX level

at

the bottom of radiator and drain

on

plug

the left side of cylinder block set

If the heater system is instaDed

heater control

valve to open position Mter the coolant is drained complete

ly close drain cock and plug CAUTION

To avoid serious
remove

and refdl

the system with clean soft water

personal injury

never

radiator cap quickly when engine is hot Sudden release of cool ing system pressure is very dangerous
If it is necessary to remove radiator cap when radiator is hot turn cap

C0042

Fig CO 2 Water Pump and Timing Chain Couer

slowly
step

counterclockwise to the first

pressure in the cool is released turn cap passing the stop and remove it

After all

WATER PUMP
The water pump is of
a

ing system

centrifugal
engine

type which
front
cover a

is mounted on the

REMOVAL
1 Drain coolant into a clean
con

te TJ

pump
row

ported by
DRAINING AND FLUSHING THE COOLING To drain the
move

double

shaft is sup of baD bear

tainer 2
to

SYSTEM
re

ings

press fit in an aluminum die cast

Loosen bolts

retaining fan shroud

shroud
remove

cooling system

pump body The bearings are per manently lubricated and sealed to pre
vent loss of lubricant and entry of dirt

radiator and

remove

Loosen belt then

fan

radiator cap

release drain cock

blade fan spacer and

pulley

from hub

CO 2

Cooling System
2 Loosen

belt

then

remove

fan

INSPECTION Inspect
pump

blade

torque coupling and torque coupling and pulley from hub from
Air

assembly

for

the

following
necessary I

conditions and

replace if

conditioning models only

4 Remove pump ket from front cover

system

equipped
and gas

assembly

Badly rusted assembly and vane

2

or

corroded body
or

Excessive end play

in

roughness

of bearings
Note

operation
mechanical seal
mn

If

excessive
occurs

squeak
ning

when engine is

use

suitable water pump seal

lubricant to prevent

squeak

C0051

ADJUSTMENT
Check
10

Fig CO 3 Removing Water Pump

Wheel Disc

belt
Ib

deflection
a

between

alternator and fan pulley by

force of

3
C0052

Bearing

kg 22

INSTALLATION
1 Be sure to clean the flP pU

Fan belt deflection 8 to 12 mm

Fig CO 4 Torque Coupling

gasket

sur

0 31 to 0 47 in

faces in contact with

cover

and front If
bolt
to
or

Always use new gaskets when installing pump assembly Be sure to tighten bolts

adjustment
retaining

is necessary

loosen
bar

alternator

adjusting

alternator Move alternator toward away from

l i

engine

until the correct

Tightening torque
Water pump 0 9 to 1 4

REMOVAL
Lousen fan belt 2 Remove

tension is obtained

securing bolts kg m

fan

6 5 to 10 1 ft Ib

blade from torque

coupling
3

Fill

cooling system pulley

and check for

leaks at pump 3 InstaD fan

TORQUE COUPLING
spacer and fan blade
or

torque coupling from pulley and water pump hub by re moving securing nuts
to

Remove

The torque

coupling keeps
rated
or

the fan

torque coupling

and

speed

at 2 900 rpm

below

tighten attaching bolts securely Install belt and adjust for specified tension 4 Operate the engine at fast idle
and S Note
re

horsepower at high engine speed It also helps reduce fan noise to minimum during high speed opera a
conserve

INSTALLATION
I InstaD the torque

coupling

in the

reverse

order of removal belt

Check for leaks

tion This unit is filled with

a

Install

and adjust belt ten

Install fan shroud Ensure that clearance between fan even at any

special
Silicone

sian

silicone

oil

used

as

fluid coupling

shroud and

place

which controls the fan

oil can not be The

speed
is

DISASSEMBLY
The torque

replenished
installed

coupling

is

so

designed

torque coupling

that it

can

not be disassembled

DISASSEMBLY Water pump should not be disas sembled

only on the model equipped with the air conditioning system In this case 7 x 350 mm 13 78 in diam use eter cooling fan

INSPECTION
Inspect torque coupling for age If necessary replace
oil leak

3 CO

Cooling System COUPLlNG TEM

Califomia Non

THERMOSTAT
with air

model

equipped

conditioning

REMOVAL AND INSTALLATION

I 2 Drain cool nt

partiaUy
at

Disconnect upper radiator hose

outlet

water

3 tion

Disconnect air hose for air injec

systein
Loosen

at

check

valve

Fxcept injechon
se

FU models 4 belt

for

air

system by loosening
1 2 3
4 5

idler pulley

curing
metal Bi

nut

and adjusting bolt

Except

thermostat

FU models

Slide valve Reserve chamber fOl OFF

CD

ID

Bearing Coupling part labyrinth

Driven

part
C0130

Fig CO

Tem coupling

coupling Tem

is

type

of fan with
a

gal force
chamber the groove under OFF

and led into the Now oil and the system is condition

reserve

coupling

which is

provided

is eliminated from

temperature control system The conventional coupling always slips the fan at a high speed under a

placed
I 2 Nut

C0053

Idler pulley Water outlet

regardless cooling requirement

constant ratio

of the engine of the Tem

With this system when fan cooling is not required the output loss IS miniinized reduced
Q

and

noise

can

be

far

The

slipping

ratio

Fig CO 7 Disconnecting Air Hose and Loosening Belt

coupling
ON

however is

properly changed
that

Except
5 Loosen bolts and

FU models

with the cooling requirement denotes

cooling

is

remove

idler

required and the fan operates up to about 2 900rpm When high cooling is
not

required during

cold

season

with

i
Q

tionalCOUPling
WATER PUMP SPEED

pulley bracket
6
7

Except FU models pipe

Disconnect air induction

FU models
Remove bolts and remove water outlet
ON

the engine warmed up etc ation is placed under OFF

the oper condition

gasket

and thermostat

from

and the fan slips at about 2 050 rpm The coiled bimetal thermostat installed
on

thermostat housing

the front center portion of

coupling Tem

OFF

the Tem coupling detects temperature of air

The
ture

passing through the radiator temperature is directly relative to the engine coolant tempera
air

WATER PUMP SPEED

C0029

and
or

the

inside
as

slide valve is

opened
the

closed

ON OFF

required and thus control is performed

Fig CO 6 Characteristic of Tern coupling

When the air temperature rises the bimetal is expanded and the valve is

I 2

Thermostat
Air check

valve Except

FU models

opened

silicone oil is forwarded to the I

Water outlet

groove that transmits torque and the ON system is placed under con dition When the valve closes silicone oil is
not

SPECTION
Check Tem

Fig
for oil

CO

Removing Thennostat

coupling

leakage
8

or

bend ofbimetaL
are one

After checking thermostat

a

rein in

supplied

to the groove

oil in the

groove is accumulated on the Tem coupling periphery due to the centrifu

If the above symptoms replace it with a new

found
as an

stall with

new

housing gasket
outlet

place
9

assembly
4 CO

Reinstall

water

Cooling System
10 leaks

Replenish coolant

and check for

combined with

the

radiator

to

cool

transmission fluid

INSPECTION Submerge thermostat in hot 90F above the specified water SOC
I

REMOVAL AND

INSTALLATION
1 Drain coolant into
a

inspect radiator for leakage tester and applying a pres sure of 1 6 kgfcm2 23 psi If a leakage is detected repair or replace radiator using
cap

Also

clean

con

Refer temperature and Specifications

2

to

Service

Data

tainer 2 Disconnect radiator upper

and

After preparing for the marked

0 31 in

lower hoses On models with automat

ic transmission disconnect cooler inlet lines from radiator

screwdriver at about 8 mm

from
H

tip inspect the lift height of valve by inserting it

the

and
3

outlet

Ne Rem

fan

shroud

retaining

bolts and
4

remove

fan shroud

Remove

radiator

retaining bolts

and then remove radiator

upward
the fol

f
C0097

I nstaD radiator in the reverse se

quence

of removal

Note

lowing

I
until 2

Insert

hoses in their that

positions
marks
on

ET116

they
are

bottom
arrow

Ensure

Fig CO II Testing Cooling System

Prtuurt

hoses

clearly visible from

upper

direction when hoses are assembled

Fig CO g

In

pecting Thermostat

Ensure that clearance between

radiator hose and any

adjacent
a

parts is

30
3 Now

mm

18 1

in

min

On air condi minimum

place

thermostat in water

tioner

equipped

models
mm

SoC
ature

90F below the specified temper

clearance of 18

0 71 in

should

If thermostat does the above

not

operate

at

exist between compressor and hose 4 Ensure that clearance be tween

RADIATOR

specified

temperature

it

shroud and fan is

even

at any

place
radi

RESERVOIR TANK
OPERATION
The radiator reservoir tank
is

must be

replaced

because it cannot be Note Be careful not to

repaired
Note

damage

ator fins and core tube when install

If necessary check a new ther mostat before installing it in the

ing
INSPECTION Radiator cap should be checked for

mounted to the right hand side core support through the bracket When the coolant
rises

engine

temperature

in

the radiator

working pressure
intelVals
cap

at

regular
or

tune

up
on

extent

and pressure builds up to an relief valve the pressure

in the radiator cap opens to excess coolant into the re

First

check rubber seal

provided
release

for tears cracks

deteriontion

RADIATOR
The radiator filler cap is designed
maintain
a

after cleaning it Then ins taD radiator cap on a tester If cap does not hold or
to

servoir tank When the coolant

temper

ature lowers and pressure decreases in

will not release at the

sure

specified

pres

the radiator the

vacuum

valve provid

pre set pressure 0 9

kgfcm2
a

replace

cap

13 psi above atmospheric pressure

The relief valve and

ed in the radiator cap opens to allow the radiator the coolant to enter re

consisting of
a

blow off valve

vacuum

valve

helps to prevent the coolant from boiling by giving pressure to it How

ever

when

the

pressure is

reduced
vacu

below
wn

atmospheric pressure the valve allows air to enter re

in the

the

radiator preventing the formation ofa

vacuum

cooling system

On models

equipped

wi th the au to

malic transmission

the oil cooler is

Fig CO lO Testing Radiator Cap CO 5

Cooling System
INSPECTION

u
O
Pressure

MAX

iT
11

V Ii 1i i
I

Check the
reservoir

amount

of coolant in the

tank

If the coolant level is

below the MIN

level

remove

the

re

1
1

servoirtank ruler cap and add oolant to reach MAX level

enough
empty

If the
i

reservoir

tank

is

check the coolantlevel in the radiator

MINij
o

If the coolant in the radiator is insuf

CQ074

relief valve opens

ficient pour it into radiator up to the radiator cap and also pour it into the
reservoir tank until MAX

level

If the coolant in the reservoir tank decreases abnormally rapid check for a leak in the cooling system

G rl

MAX ii i
It

p
p ot
II

REMOVAL AND

INSTALLATION
Reservoir tank is reservoir tank

only

inserted to
can

bracket

and

be
the

MINi
L Vacuum valve opens C007S

easily removed

To install reservoir tank order of remova

reverse

Fig

CO 12

Opefation of ReserVoir Tank

SERVICE DATA AND SPECIFICATIONS

Thermostat

Temperate type
Valve opening temperature

Frigid type
88

Tropical type
5 76

Oc OF

82

180

190

I 70

Maximum valve lift

mmjOC in

oF

8 95 3 I 203 0

8 loo 31j2 0

8 90

i2

0 31 194

Radiator

Type
Manual transmission Automatic tralUJ1lission

Corrugated fm type

Corrugated kg cm2 psi kg cm2 psi

fm type 0 9

equipped

with oil cooler

Cap

relief pressure
pressure

I3

Testing
Fan

1 6 23

Fan belt deflection

mm

in

8 to 12

31 0

to 047

cO 6

Cooling System

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Loss of water Probable
cause

Corrective action

Damaged radiator

seams or

Repair plugs Repair Tighten Tighten

Leaks at heater connections Leak

at

water

temperature gauge

Loose joints

Damaged cylinder head gasket

Replace
Check engine oil for contamination and reml
as

necessary

Cracked cylinder block

Replace
Check engine oil
in crankcase

for mixing

with water by pulling oil level gauge Cracked cylinder head Loose cylinder head bolts Poor circulation Restriction in system

Replace Tighten
Check hoses for crimps and clear the system of rust and sludge by flushing radiator

Insufficient coolant

Replenish Replace
Adjust

Inoperative

water pump

Loose fan belt

Inoperative thermostat
Corrosion Excessive impurity in water

Replace
Use soft clean water
rain water is satis

factory Infrequent flushing

and draining of system

Cooling system should be drained and flush ed thoroughly at least twice a year Permanent antifreeze Ethylene glycol base can be used throughout the seasons of the year and change periodically at intervals
recommended

Overheating

Inoperative thermostat
Radiator fin choked with mud chaff etc

Replace
Clean out air passage thoroughly by using air pressure from engine side of radiator

Incorrect ignition and valve timing

Adjust
Refill

Dirty oil and sludge in engine Inoperative

water pump
or

Replace
tem

Inoperative torque coupling

Loose fan belt

coupling

Replace

Adjust
Flush radiator

Restricted radiator
Inaccurate temperature gauge

Replace
Use soft dean water

Impurity in water
Over cooling

Inoperative thermostat
Inaccurate temperature gauge

Replace Replace

CO 7

DATSUN 210

Model 8310 Series

SECTIONEF
ENGINE FUEL
CONTENTS
AUTOMATIC TEMPERATURE CONTROL A T C AIR CLEANER
EF EF EF EF EF EF EF EF EF EF EF 2 2 2 3 4 5 5 5 6 6 6 6 7 7 INSPECTION ASSEMBLY EF EF EF EF EF 7 7 B B B

DESCRIPTION
OPERATION REMOVAL AND INSTAllATION

CARBURETOR
DESCRIPTION STRUCTURE AND OPERATION

INSPECTION

INSPECTION AND ADJUSTMENT

MAJOR

EF 14 EF 23

IDLE COMPENSATOR
DESCRIPTION INSPECTION

SERVICE OPERATION
AND

TROUBLE DIAGNOSES

CORRECTIONS

EF 30

FUEL FILTER
DESCRIPTION

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT TORQUE

EF 32 EF 32 EF 32 EF 34

FUEL PUMP
OPERATING

TEST

EF EF EF

REMOVAL AND INSTAllATION

TIGHTENING

DISASSEMBLY

Engine

Fuel

AUTOMATIC TEMPERATURE COtirROL AIR CLEANER

A T C

DESCRIPTION
U

18 ExC mode
I

FU

model

ia Cana

and FU models

C1J
3

8
5 I 2 Air

relief valve Air hole forT C S

P Air

Non alifornia

models

6 7 8

Idle compensator Outlet for C A C valve California model

1 2

Air

hole for A B valve

3
4

C V mter hole forA B valve US A

Temperature

seIl50r

Heat control valVe

EF415A

for T C S Air induction valve and ftIter P C V mtet

Air hole

Idle compen ator

Temperature

sensor

Heat control valve EF041A

Fig EF l A T C Air Cleaner

model

except

FU model

Fig EF 2 A T C Air Cleaner

Canado ond FUmodel

OPERATION
The automatic

system of the air cleaner is control ed by the inlet air temperature and the
control

air

temperature

is

detected

by

th

sensor

and the vacuum motor is actu

vacuum

temperature

load condition of the engine The inlet

ated by the engine intake

Under hood air

Sensor

vacuum

at

Air con trol valve

Engine

temperature

vacuum motor

side

operation

Sensor operation

Below 380e IOO F

Below 40 mmHg 57 inHg 1 Above 160 mmHg

30 6

Open cold

air

Closed

inHg

Closed hot air

AI4

A15 38
to

S40C

Partially
cold air

open

100 to

l290F

hot air

Partially

open

Above 550e 1310F

Open cold

air

Open

HOT AIR OPERATION When the engine intake air tempera is low the sensor air bleed valve and betw n the intake manifold
and
vacuum to

the

vacuum

motor

diaphragm
on

to

ture

motor
um

With this condition the intake

the

vacu

introduce hot air into the air cleaner

remains in the closed position establishes vacuum passage

at

manifold

side

through

the hot air duct

the

ex

actuates the air control valve attached

haust manifold

EF 2

Engine

Fuel VACUUM MOTOR AND

AIR CONTROL VALVE

I 2 3 To manifold 4 5 6 7

Air inlet Air

con

pipe
valve The vacuum

trol

signal from

the tem

Hot air

pipe Diaphragm
V Bellum hose

perature
motor

sensor

acts upon the vacuum

tached to the up
on or

diaphragm The valve shaft at diaphragm is then moved

vacuum

Diaphragm spring
Air

bleed valve
sensor

down in response to the

closed 8

the

diaphragm

This

movement

of

Temperature
assembly

the valve shaft actuates the air control valve to control the

temperature of the
into the air

Hot

air

EC007

air

to

be

introduced

Fig EF 3 Hot Air Delivery Mode During cold engine operation

cleaner

COLD AIR OPERATION perature is high

1 When the

the

vacuum

is

small

or

The

ns r

air

bleed

valve

opens

when

engine

is

operating

under

fully

heavy load the air control valve opens widely irrespective of the temperature
around the cold air for
sensor

passage between the intake manifold and the vacuum motor Due to the force of the

to

break

the

vacuum

@
@ @

I 2 3 4

Valve

spring Diaphragm
Retainer
Valve shaft

to

introduce the power of the

vacuum

motor

diaphragm spring

tne

increased

air control valve closes the hot air

pipe

EF207

engine
2 When the

of the air cleaner and introduces the

engine

intake air tem

cold air See Fig

4 EF

Fig EF 6 Vacuum Motor

CD

Cold air I

LlF
JII

L
1

mf
I

Air

nlet

pipe

manifold

2 3 4 5 6 7

Air control valve Hot air

pfpc

REMOVAL AND INSTALLATION

AIR CLEANER
I
to

Diaphragm
Vacuum hoses

Diaphragm spring
Air bleed alve

Loosen bolts securing air cleaner air cleaner bracket Loosen air cleaner lock bolt and air cleaner the

fully open Temperature

assembly
EF715

remove

from

carburetor hoses when

Disconnect

Fig EF 4 Cold Air Deliuery Mode During hot engine operation

following

dismounting
I

air cleaner

TEMPERATURE SENSOR
The temperature sensor is attached the inside of the air cleaner The

Fresh air duct Hot air duct

Vacuum hose

engine

intake

air

temperature
vacuum

and

Sensor and idle

com

to

bi metal built in the sensor detects the

opens or closes the the sensor

passage in 4

pensator
Hose valve

to

intake manifold pump

Air

relief
models

Non California

I 2 3 4

Protector

cover

except Canada
5 Air induction hose FU models 6 7 Hose Hose A B valve to air cleaner

Screw

Canada and

Adjusting
Air Rivet

frame

temperature bi metal

5
6 7 8

Valve seat frame

Air cleaner to throttle opener switch Air cleaner to rocker

Lower frame
Air bleed valve

or vacuum

Blow
cover

by hose
install

Gasket
EF206

To

reverse

the removal

Fig EF 5 Temperature Sensor

procedure

EF 3

Engine
TEMPERATURE

Fuel

SENSOR

Removal
I

Using

pliers

flatten

clip

con

necting
tube

vacuum

hose

to sensor vacuum

Pipe
Catch Fixed with adhesive
Hose

Fig EF 9 Inspecting Valve Po man Fig EF 8 Removing Vacuum Motor

Air control valve is in correct

2 3
4

posi

tion if its cold air inlet is open and hot air inlet is closed

5 6 7
EC019

Tab

Clip
Gasket

INSPECTION
AIR CLEANER FILTER Viscous paper type air cleaner filter does o ot rt quire any cleaning opera

Start

engine

and

keep idling

Immediately after engine starting check air control valve for correct
position
case as

Fig EF 7 Removing Seruor

described above

In

this

correct

position

of air control

2 3

Disconnect hose from sensor

tion until it

valve is the reverse of step 3

hood air inlet is closed

under

is

replaced periodically

and hot air

tube

Take off clip from sensor vacuum and dismount sensor body from

Brushing or blasting operation will cause clogging and result in enrich

ment

inlet is open S Check that air control valve grad

air cleaner

of

carburetor be

mixture

and
reo

should
Note air

never

conducted

For

The gasket between cleaner is bonded side

and

sensor to

and

placement
refer
to

interval of air cleaner filter

the air
not

Maintenance Schedule

cleaner

should

be AUTOMATIC TEMPERATURE

removed

ually opens to cold air inlet side as engine warms up When environmental temperature around temperature sen sor is low spend more time for engine warming up operation to facilitate smooth operation of air control valve If the above test reveals any prob
lem in the
opera ion

CONTROL SYSTEM
Installation
Mount
sensor on

of air control
test

the

specified
tube of
vacuum

position
2

Engine malfunctioning A T C system are manifest during cold weather opera

a

failures

resulting from

valve

carry out the

following

Insert clip into After

tion Such failures include

VACUUM MOTOR
I

vacuum

sensor

hose

secure

installing each hose with the clip

Engine stall

or

hesitation

With

engine

stopped

confirm

Increase in fuel Lack of power

consumption

that cold inlet is

occur

air inlet is open and hot air

Sed c1 check air control valve link

Note

Be sure to install

11n vacUl

hose
R H

If these phenomena should

check the A Te

If

not

correctly Correct position is

side
to

Ntisan
sensor

face of

mark at the top for intake manifold

system as described in following before carrying out

of carburetor
vacuum

age for proper 2

operation
ac um

DiscoJln
hose
to

ct

motor

inlet

inspection
I
l

vacuum

and

connect

another
to

L H side for Deuum motor

Check that

hoses

hose
are

the inlet to
motor

se vacuum

apply

vacuum can

urely connected
2

in correct hose

position
or

Vacuum

be

Check each

for cracks

appli

by breathing in tile
Then

hos e end as

distortion

shown

confirm that

the air

VACUUM MOTOR
1

3
vacuum

Check A T C
as

Remove

screws

securing

function

system for proper Confirm that ys follo

control valve moves 3 tion

With hot air inlet in open posi

as

motor to

air cleaner

engine
from air
vacuum

is cold before

starting

described

test

pinch
cut

vacuum

Disconnect valve shaft attached

in step 2 above hose with fingers and

vacuum

With

engine
a

topped

disconnect

off air from

hose

In this

to vacuum motor

diaphragm
remove

fresh air duct if so equipped Place

mirror at the end

condition of air step 2 for

check that air control valve condition described in

than 30 seconds

control
motor

valve

and

maintains the

assembly from
install

air cleaner the

To

reverse

removal

cleaner inlet pipe as shown and check to see if air control valve is in correct

more

and

that hot air inlet is open

procedures

If diaphragm

position

spring

actuates

the air control valve by

4 EF

Engine
its 30 spring force to close within seconds replace vacuum motor as an assembly since this may be resulted

Fuel
2
or

hose If vacuum is weak

at all is not

Reconnect

vacuum

hose

to

vacu

present

um

motor and warm up

engine

from air leak

at

vacuum

motor

dia

phragm

hoses for leakage Replace temperature sensor if vacuum hoses are in good order check
vacuum

Check that air control valve grad ually opens to cold air inlet side as

engine
sor

warms

up When environmental
sen

temperature around temperature

is low

spend

more

time for
to

engine

TEMPERATURE SENSOR If tests indicate that A T C

is

warming
smooth

system

up operation operation of air

facilitate

control valve

malfunctioning and motor is func tioning properly check temperature sensor for proper operation Confirm that engine is cold before starting
tests

check

If air control valve does not open air control valve linkage for

binding Replace temperature sensor if air control valve linkage is functioning properly

engine and keep idling Immediately after starting engine

Start

EF978

disconnect
um

vacuum

motor inlet
suce

vacu

hose

and make

that intake
vacuum

Fig EF l0 Checking for Pressure of

Intake Vacuum

vacuum is

present

at

end of

IDLE COMPENSATOR

DESCRIPTION
The idle compensator is

INSPECTION
basically
a

to idle compensator

and connect
as

other hose
is in closed is To 2 Warm up

then carry out check

Check

that

valve

described above

thermostatic valve which functions

introduce the air cleaner
to

to

position
check

when bi metal

temperature
or

directly from the

intake manifold

air to

lower than

operating temperature leakage

the

breathe air into tube

suck

compensate for abnormal enrichmerit of mixture in high idle temperature

The bi metal

air If excessive air the valve

an

is found at

engine completely Open engine hood and remove

cover
warm

air

attached

to

the idle

replace idle compensator as assembly Note that two idle com

are

cleaner
4

Direct
a

air to idle compensa

compensator detects the temperature

of intake air and opens valve
or

pensators
valve tors

mounted
ne

to

air cleaner
to

tor with

heat gun

closes the

and that it is of
so one as to

essary

plug the

And measure

operating temperature

Two idle compensators

having

of these idle compensa

of idle compensator

different
are

temperature
one

characteristics

prevent
one

air leak while

installed

opens at an intake air

checking

the other

temperature of 60 to 700C 140 to IS80F and the other at 70 to 800C

158

to

1760 F

I tI
EF043A

I 2

Orifice
Rubber valve EF225

Fig EF 13

Checking Idle Compemator for Op ration

1 2

Fig EF 12 Checking Idle Compensator

Orifice Bi metal Rubber valve Note tor

Note
as

close to

Locate stick temperature gauge sensor as possible so that

air from

3
EF222

When
on car

checking

Fig EF ll

Idle Compensator

idle compensa disconnect hose leading

warm

dryer

is directed to

these parts evenly

EF 5

Engine Fuel
compensator is illgood order if a hissing sound is heard when its temperature reaches operating tern
S Idle

ldlerompensator
60
No 1

lb

to to

700C
15

perature
If not replace idle compensator

140

Of

70 to 800C No 2

158

to 1760F

FUEL FILTER

DESCRIPTION
The fuel filter is
useS
a a

cartridge type

It

paper element

t It
J

1 2 3

Body

Paper element
Cover

EFOOS

Fig

EF 14 Sectional View ofCartridge Type FuelFilte

FUEL PUMP

OPERATING TEST
Note
me

When
a

disconnecting
to

fuel hoses fuel

container

receive

remaining in fuel hoses

STATIC PRESSURE TEST

jf

conducted
I

The static pressure test should be as follows Disconnect fuel hose between
car

buretor and fuel pump 2 Connect a rubber hose to each

con open end of aT connector and nect this connector hose assembly be

tween carburetor and fuel pump

Note

Locate

this

T eonnector

as

close to carburetor as

possible

3
to

Connect the

suitable pressure gauge opening of T connector and

a

fasten the

hose

between carburetor
a

and T connector secUrely with

EC132

clip
at

Start

and

run

the

engine

Fig EF 15 Schematic View of Fuel Pump

various

speeds

6 EF

Engine
5

Fuel

The

static gauge

indicates pressure gauge fuel pressure in the line The

DISASSEMBLY

reading should be

within the

specified value
Fuel pump pressure 0 21 to 0 27

I 2

Packing
Valve
a5scm

bly

kg em2

3
4 5

Retainer
Screw

3 0 to 3 8 pli I

6 Note If the

Diaphragm assembly Diaphragm spring

Retainer

fuel in has

the
run

carburetor out

7 8

float

chamber

and

9
10 11 12

engine has stopped

pour

remove

clip and
pres

Diaphragm assembly Complete body lower

Screw Washer

fuel into carburetor Fasten

test

spring

clip securely and repeat static

sure

Fuel pump cap

13
14 15

Cap gasket
Connector inlet

Connector outlet
Rocker Nut
arm

If pressure is not within the specifi ed limit remove pump as an assembly

16

spring

@@
@@ @@
@

17 18 19

Washer spring
Washer Gasket

pJain

20
21 22

CAPACITY
The when

TEST
test is conducted is within this

Spacer
Rocker

capacity
static

only
the test

pin
arm

23
24

Spacer
Rocker EC134

pressure

specification To conduct proceed as follows

1 Disconnect T connector and install sump 2 pm 3 Start
a

Fig EF 16 Fuel Pump

pressure gauge from

in its vacant

place

suitable

container as a fuel

Remove

screws

and detach upper

wear

or

any abnormalities and

replace

and lower bodies

2

with

new

parts if necessary

engine and

run

at

1 000

Pump

should deliver the specified

Remove screws and take off cap and cap gasket from upper body 3 Remove inlet and outlet connee
tors 4 Remove valve retainer
screws

ASSEMBLY
I To assemble
reverse

amouni of fuel
If little or no fuel flows from open end of pipe it is an indication that

the order of
the

and

take off valve retainer S

remove diaphragm press down its center against spring force

To

disassembly Closely following instructions

Use link
new

observe

fuel line is clogged

or

pump is mal

gaskets
arm
arm

functioning
Fuel pump capacity 450 cc 27 46
eu

Lubricate rocker and rocker

With

diaphragm pressed

down

ilt it

rocker

arm

until end of inl min

pull

rod touches inner

pin

before

installation 2
as
a

wall of body Then release

to unhook

diaphragm

After follows

push rod
not to

assembly

test the function

at 1 000 rpm

Note

Be careful
or

damage dia

Position fuel pump assembly about I meter 3 ft above fuel level of fuel
strainer and connect
to
a

REMOVAL AND

phragm

oil seal

pipe

INSTALLATION
Note
use

from strainer

fuel pump
arm

b Operate rocker fuel lines fuel

by hand

If fuel

When
a

disconnecting

INSPECTION
Check all

is drawn up soon after rocker arm is

container to

receive

released

fuel pump is

functioning

remaining in fuel hoses

I Disconnect inlet and outlet fuel

components for cracks

properly

hoses from fuel pump

2 3 Remove fuel pump To

install

reverse

the order of

removal

EF 7

E ngine

Fuel

CARBURETOR
DESCRIPTION
The carburetors
two barrel
are

of downdraft
to increase ell
a

type fu l

designed
eC
t

ppwe r

l IlY 3

to

reduce exhaust gas emissions

These distinct
car

carburetors features

present several
to

I
J

of importance
as

owner

A summary

of features is

fol

lows

Secondary throttle valve is oper ated by throttle lever High power and good acceleration are gained with com bination of the auxiliary valve 2 Accelerating pump provide ex
cellent acceleration
3
urn

Power valve mechanism is a vacuo actuated boost type and

improves
1

high speed driving

4
tem

The throttle opener control sys

2 3 4

Primary main jet Idle adjust screw

hUe nozzle

10
11

Primary Primuy

air vent pipe main

19 20
21

nozzle

Plug Secondary slow jet

Needte Fuel fLlter

Except FU model incorporates a diaphragm which helps open the throttle valve at a decreasing speed so as to reduce hydrocarbon emissions to
servo
a

12 13 14 15 16

Choke valve

minimum An d anti

By pass hole 5 Primary throttle valve 6 Primary slow jet 7 ptug 8 Primary 5l w air bleed
9

17
18

Primary small venturi Secondary small venturi Secondary air vent pipe Secondary main nozzle Secondary main air bleed Secondary
slow

22
23

24 25

Secondary tIuottle valve Auxiliary valve Secondary main jet

eseling solenoid valve is installed to prevent dieseling When ignition key is turned off the fuel
passage involved in the
ow

Primary main air bleed

air bleed Note Do not remo the parts inarbd

system is
is

with anuteriak
EF416A

closed and

the

fuel supply

shut

down completely The solenoid valve also

actuator of the fuel the FU model
off shut serves as an

Fig EF 17 Carburetor

system
an

on

PRIMARY SYSTEM elec

to auto

In the choke mechanism

trie automatic choke is used

PrlinarJ main sJstam

The fUel flowing out of the passages bottom of float chamber passes

maticaDy control chok

tion 7

valve opera

during engin

war

up equipped
smooth
ensures

at

The carburetor

comes

with dash pot

which

deceleration without engine stall under aU operating conditions

through the primary main jet and is mixed with air coming from main air bleed The gas mixture is pulled out into the venturi through the main
nozzle When

throttle valve is wide open

STRUCTURE AND

and engine require dense mixture gas power valve opens and fuel also flows
into main system

OPERATION
These carburetors consist of system for
normal
a

main

1
2

Oloke valve

running a slow system for idling and an accelerating

and power mechanisIll Some emission control devices
are

Primary air Primary

vent

pipe

3 4

Prima y main nozzle

slow

jet
EF044A

added

Fig

EF 18 PtJrlially

Loading

8 EF

Engine
rod is

Fuel SECONDARY SYSTEM

Second ry
m

piston pushed up with linkage which pushes up piston through piston return spring When piston comes down inlet
valve

When throttle valve is closed

ln system

When the primary throttle valve is

wide

closes the

fuel within from

outlet valve opens and the pump is blown out

open and engine produces high the secondary throttle valve power

begins
open

to

open

pump

piston return against side wall of small venturi becoming minute drops and compen sating transient spareness of fuel
1 2

je t by compressed spring The fuel hits

However
at
a

by the linkage auxiliary valve does

not

slow

speed

due to counter

Primary

main nozzle

Primary main air bleed Primary slow air bleed Primary slow jet Primary main jet
Idle nozzle

3
4 5

weight connected to valve shaft As the engine picks up speeds auxiliary valve opens against the load of counterweight and secondary sys em starts operation for high power operation The fuel flowing out of the
passage at bottom of float chamter
main air is mixed air with passes The

6
7

Primary

throttle valve

EF417A

r
@ CD
Inlet valve Outlet valve

through secondary
main

fuel

jet coming
is

from

bleed and mixture

Fig EF I9 Portially Loading

blown in to the venturi through main nozzle When primary throttle valve is
in full open

position

secondary

throt

V
EF239

tle valve is also fully opened

IdUns

nd slow system
1 Piston 5 lever nozzle 6 7 8

Passing through
fuel line
passage is

the

main

jet

the

2 3 4

separated

from main

Pump Pump spring

through jet primary slow air bleed is ejected from the by pass hole and idle nozzle
fuel flows

the slow

Piston return

Primary throttle valve Pump connecting rod

Fig EF 21 Accelerating Mechani lve meeh nlsm

cp

Ii
l
1 2

Power The

vacuum

power va v

actuated boost type mechanism makes use of

the downward pulling force of the air

stream below throttle valve When throttle valve is

slightly
a

open

ed

during light
p ston

load running

high
the

vacuum

upward

against

spring leaving
When load Primary Primary
fieseling Anti
main air slow air or

power valve closed

vacuum

is lowered during full the spring pushes downward

acceleration

bleed bleed

vacuum

piston
to

opening
I 2 3 4

3
4

solenoid valve
main

power valve

furnish fuel

Secl ndary

slow air bleed

Secondary main air bleed

Secondary main nozzle Primary main nozzle

Primary Primary

jet
valve
EF711

5 6

Idle nozzle
throttle

Fig EF 20 Idling and Slow System

Primary main air bleed Primary slow air bleed Primary slow jet Primary main jet
Idle nozzle

I
Aceeler tlns meeh
A

9
10 11

f t
i
1 2 Vacuum piston Power valve
EF240

nlsm

pump synchronized with the throttle valve is used

mechanical

accelerating

Primary throttle valve Auxiliary valve 12 Secondary throttle valve 13 Secondary main jet 14 Counterweight 15 Secondary slow jet
EF418A

Fig

EF 22 Power Valve

Fig EF 23 At Full Open Stow Speed

EF 9

Engine

Fuel
deceleration manifold

Secondary slow system Step system

The
construction
to

During deceleration

the

vacuum

corresponds
This

of this system the idling and slow

aims at the

tity of

mixture

rises and the quan in the engine is not to

suffICient for
continue
4

normal combustion
a

system ofthe primary system system power

consequently

great

amount

filling
to the

up of the gap when fuel

supply

ofunburned HC is emitted Carburetors equipped with the

is transferred from the primary system secondary system The stepport

near

throttle opener
an

supply

the

engine

with

is located

the auxiliary valve in its

adequate charge
to

of combustible combus
in
a

mixture tion

maintain proper

fully

closed state

during deceleration resulting

dramatic reduction in HC emission The

I

system for the manual trans

servo

2 3
4

5 6 7 8 9 10
II

Secondary slow air bleed Secondary main air bleed Secondary main nozzle Primary main nozzle Primary main air bleed Primary slow air bleed Primary slow jet Primary main jet
Idle nozzle Primary throttle valve Auxiliary valve Seco dary throttle valve

mission model consists of

dia

phragm

vlicuum control valve

throttle

opener solenoid valve switch and amplifier

l detecting spee
On

the

auto

ANTI DIESELING SYSTEM

The carburetor is equipped with liese1i anti lg solenoid valye
As the
an

matic transmission model an inhibitor

and inhibitor relay

on

are used in place of speed detecting switch and amplifier

the manual transmission model An

corrector

12 13 14 IS

ignition switch is turned off the valve is brought into operation

altitude

fitted
to

to

vacuum

control valve

serves

automatically

Secondary main jet Counterweight Secondary slow jet

shutting
EF419A

off the supply of fuel to the

regulate the operating

pressure

slow circuit The

pressure in the system with variation of atmospheric

following figure

shows

a see

Fig EF 24 At Full Open High Speed

tional view of this control T oC S

n

operatIon
as

An

dies ti ON

eling

solenoid valve

At the moment when the manifold

vacuum

increases the

occurs

Ignition switch

OFF

Ignition

switch

celeration

vacuum

upon de control valve

li
Fig EF
25

opens to transfer the manifold vacuum to the servo diaphragm chamber and the throttle valve of the carburetor
opens

T Battery

slightly
a condition proper of fresh air is sucked into the

Under
amount

this

combustion chamber
niT
3 EC

As

the

result is
as

complete
amount

combustion

of fuel

sisted by this additional air and the of H C contained in exhaust

gases is

dieseling Anti

Solenoid Valve

dramatically reduced

FLOAT SYSTEM There is only

and
one

The float chamber

its

needle valve

includes special
wear

Throttle Clpener sol nold valve

hard steel ball and wiD not

for all

operation

while two carburetor systems primary

considerably long
Besides

use a

Manual transmission models

secondary

are

provided

the insertion of

spring
is

Fuel fed from the fuel pump flows through the filter and needle valve into the float chamber A constant fuel level is maintained by the float and needle valve Because of the inner air vent type float chamber ventilation
is not

will prevent the flooding at rough road

running

The throttle opener solenoid valve controlled by a speed detecting

switch which is actuated by the ometer needle THROTTLE OPENER CONTROL SYSTEM T O C S As the km h vated
car

speed

sp ed

falls below 16

10 MPH

this switch is acti

Except

FU

model

producing a signal
so can

fuel

con
ac

sumption

affected by dirt

The function of the throttle opener is to open the throttle valve of the carburetor slightly while the
car

The signal is led to the amplifier that the signal be

amplified
to actuate

to a

cumulated in the air cleaner

is in

degree large enough

the

EF 10

Engine
throttle opener solenoid valve The throttle opener solenoid valve is actuated and the diaphragm servo chamber is opened to the atmosphere In this case the seIVo diaphragm does not opera te

Fuel
the

Automatic transmission models

As N

seIVo

diaphragm does
same

not operate
as men

long
or on

as

the shift lever is in the

because of the tioned model for

the

reason

p
the

position

the

inhibitor
is turned

manual transmission

switch
on

transmission

and the throttle opener solenoid

valve is actuated Under this condition

ON OFF

Car peed Car peed

t6 km h to mph above 16 km h to mph

betow

jlJ

11

ti

To intake

manifold

i
1 2 3 4 5

ljn
L

o
Servo diaphragm Vacuum control valve
Altitude corrector Throttle

e
7
p I
I I I

1
l

opener solenoid valve

N

Inhibitor switch ON

for automatic
transmission switch below for manual

Speed detecting
10 MPH ON

I
I

I
I

transmission
7

I
l L
I

Amplifier 8 Ignition switch 9 Primary throttle valve

EF105A

Note

Broken tine

applies only

to Automatic

Transmission

Fig EF 26 Throttle Opener System

FUEL SHUT OFF SYSTEM The fuel shut off system is to shut
off the fuel

dieseling Anti Electric current

solenoid valve

OFF

ON

during deceleration there

This

I
ill

by reducing fuel consumption

system also
ture rise in

helps
the

prevent

tempera
converter

catalytic

during long periods

an

of deceleration
are

h
L
Battery

The major parts of the system

anti

dieseling
switch
an

solenoid
a

neutral valve

detecting
switch
switch

throttle

and

engine

revolution

o
Ignition
switch

I 2

Neutral detecting switch Throttle valve switch

l
Ignition
coil

3
4

Engine revolution

switch EF846

Transistor ignition unit

Fig EF 27

dieseling Anti

Solenoid Valve

EF 11

Engine
Fuel
oH shut s

Fuel
3 Throttle valve switch
The throttle valve switch is installed
on

stein operation
en

During deceleration when the gine speed is above a certain level

dieseling anti solenoid
so

the the

the carburetor

It turns off when

valve

of

the throttle valve is closed and turns

on

carburetor closes shut off

When

that the fuel is

engine

speed

falls

The

when the throttle valve is open opening position of the throt

below a certain level the anti

dieseling

oP lS so that the fel flows However if the engine speed is solenoid vaJv below the

tle valve switch is calibrated in engine rpm when the engine is revved up
under no load

designated

level even

during Fig

I
EF 28 Location of Engine Revolution Switch

The

switch

turns

on

when

the

deceleration does
not

the fuel off shut system operate When the shift lever the fuel shut off system
2

engine revolution is above 1 150 rpm and turns off when the engine revolu
tion is below 1 000 rpm

is in neutral

does

not

operate
on

The functions of each part of this

Neutral detecting switch The neutral detecting switch turns

in neutral

system
I

are as

follows

and

turns

off in other

Engine revolution switch

shift lever

positions

The engine revolution switch turns off when the engine revolution is above 2 100 rpm the engine revolution falls below 1 650
is actuated hy rpm This switch of the ignition system
a

h
1 1

and turns on when

pulse
Micro switch Connector

This switch is located

hand dash side

on

the right
2 3 Neutral detecting switch Revenelamp switch

panel

in the passenger

compartment ing figure

as

shown in the follow

3
EC275

Adjusting

screw

Top

switch detectim

EF848

Fig EF 29 Locotion of Neutral Detecting Switch

Fig

30 EF

Location of Throttle Valve Switch

Fuel system

off shut

Anti

dieseling

solenoid valve Closed

Engine revolution

Throttle valve opening

Shift lever position

Activated

Except neutral OFF

Closed OFF
Neutral

ON neutral OFF

High OFF

Open
Inactivated

ON

Except

Neutral ON

Open
Closed OFF Low ON

Excep t neutral
Neutral ON

OF

Except neutral

OFF

Open
Continuity of switch

ON Neutral ON

EF 12

Engine
ELECTRIC AUTOMATIC CHOKE
An electric heater warms
a

Fuel

bi metal

interconnected to the choke valve and controls the position of

the time
c

oke

valve

and throttle valve in accordance with

tion of the

elapsed the warm up condi engine and the outside

ambient temperature Electric heater

semiconductor The electric heater is made up of a and installed in the
cover

automatic choke 2 Bi metal

in the

body

r
@ @

Alternator
Automatic

2
3

L terminal choke relay

cover

Automatic choke
P T C heater Bi

Electric

current

flows through the

starts

4 5

heater as the the bi metal

engine

and

warms

metaJ spring
EF045A

The deflection of the

to

Choke valve

bi metal is transmitted valve 3

the choke

through
Fast idle

the choke valve lever

cam

Fig EF 31 Electric Automatic Choke

leater

The

fast idle
of

cam

determines the
Hi metal PT

opening
the

the throttle valve SQ that

amount to

proper

of mixture

cor

1 2

responding
choke valve

the

opening

of

the The

e heater
cover

will

be

obtained

3
4

Thermostat
Vacuum Fast idle

opening of the choke valve is de pendent upon the warm up condition

of the 4

diaphragm
earn
cover

5 6 7 8 9 10 11

engine

index mark Choke shaft lever Bi metal Choke valve Unloader tang Throttle valve
Fast

Choke unloader When

accelerating the engine during the warm up period that is before the choke valve opens sufficiently this
unloader forces the choke valve open
little
so as to
a

idle adjusting

screw

l
EF243

obtain

an

adequate

air fuel mixture S

Vacuum break diaphragm

A

After the engine has been started by cranking this diaphragm forces the choke valve open
extent
so as to

Higher ambient temperature

Clearance B

to

predetermined provide the proper

vacuum

the

air fuel ratio A

two

stage acting type

is

Manifold
vacuum

diaphragm
6 The

employed
index mark is
B

t 2 3

Si metal case index mark

bi metal case

Diaphragm Spring I Spring 11

Rod Choke valve

used for selling the moment of the bi metal which controls the air fuel
mixture ratio

Lower ambient temperature

Clearance

5 6

required for starting

Plate
Bi metal

@
Manifold
vacuum

EF884

Fig EF 32 Electric Automatic Choke

EF 13

Engine
DASH
These with
a

Fuel
4

POT SYSTEM carburetors

are

Adjust

bottom float

position

so

that clearance

hl between float seat

3 to I 7 1
mm

equipped

and needle valve stem is 0 051 to 0 067 in

pot interlocked with the primary thrott Ie valve through a link mechanism
dash The dash valve

when float is
as

raised
5

Bend float stopper

fully required

Install choke chamber After adjustments in steps 3 and have been made make sure
the fuel level is maintained

pot prevents the throttle

from closing abruptly

thereby

4 above

reducing He emissions during deceleia tion or gear shifting In automatic transmissi9fi models it also prevents engine stall resulting
from quick application of the brake or from quick release of the accelerator

that when fuel is delivered to the float chamber

EF088A

within the

specified

value H

Fig EF 33

Checking

Fuel Level

pedal after slightly

it

been tread upon

To

adjust fuel level

proceed

as

follows
2 3

Remove choke chamber Turn

down

choke

chamber
H

to

allow float to come into contact with needle

valve and

measure

shown

INSPECTION AND ADJUSTMENT

CARBURETOR IDLE R P M AND MIXTURE RATIO CO idle adjustment with

below
H is approximately 15 mm top float position is correct The top float position can be ad justed by bending float seat Upon completion of the adjust

When
in

59 0

ment

check fuel level with attached

COmeter
Refer to Carburetor Idle rpm and

level gauge

Mixture Ratio Section ET for check

ing and a justment

CO

idle adjustment without

COmeter Non California models

Refer to Carburetor Idle rpm and Mixture Ratio Section ETl fot check

nhH
J

ing and adjustment

1 2

Float Float stopper

3 4

Float seat

Needle valve

Idle limiter cap Refer

to

Idle Limiter

Cap

SeCtio

Fig EF 34 Adjusting Floot Level

ET for checking and adjustment

FUEL LEVEL
I

fuel

With engine idling visually check level through sight window of

correct

float chamber Fuel level is

is at the indicator

if it

point
indicator point is 59 in below top 0
H as shown in

Note

Fuel

level
mm

located IS

of carburetor body

Figure below
EF 14

Engine
FAST IDLE
I Remove

Fuel

carburetor

assembly

Clearance

from engine Remove bi metal 2

3

in mm
cover

Engine

speed

rpm

Place fast idle

cam

of first idle

second step Then adjust fast idle

arm on

Manual transmission

0 73 to 0 87

0 0287

to

0 0343

1 900 to 2 700

adjusting
The

screw

as

shown at

in Automatic transmission 1 00 to 1 14 2 400 to 3 200

illustration clearance
value in the A

should

be

0 0394

to

0 0449

specified
4

To check fast idle

following table cam setting by

Fast

engine speed proceed as follows Warm up engine sufficiently

fast idle Fast
Hons
cam at

idle

earn

steps

Set read

2nd step
is

and

engine speed
idle
cam

engine speed

is within above

properly set if specifica

g g
to

2 5

t
J

ti

j Ogc
r

jdle

adjusting

screw

Throttle

chamber

II

EF098A

Fiil EF 35 Adjusting Fast Idle

VACUUM BREAK
I 2

completely Hold choke valve by stretching

Close choke valve

rubber band between choke shaft lever

and 3

stationary part of carburetor

Push and
vacuum

break

stem

with

plie
4

puD fully straight

this condition
8

Under
at

adjust body

gap

shown

in illustration

between

@ cv
Push

choke valve and carburetor

Clearance

Bu except FU model
mm

All model

1 80 to 1 98 0 0709 FU model 1 98 to 2 16
to

0 0780 in

mm

0 0780 to 0 0850 in

I
1 2 EF885 Rubber band Vacuum break stem 4 5

Choke valve Vacuum break stem

E F099A

Vacuum break rod

Fig EF 36 Adjwtirig Vacuum Break

EF 15

Engine Fuel
CHOKEUNLOADER
I 2 c
a

Close choke valve completely Hold choke valve by stretching

rubber band between choke shaft lever

and stationary part of carllUretor 3 Pull throttle lever until it

com

opens Under this condition adjust clear ance e See illustration between
4

pletely

choke valve and carburetor

body by
See

bending
EF 37

unloader

tongue

Fig

Clearance

C
expt

All modelS

FU model

2 36 mm FU model 2 17 mm

0 0929 in

CD
0 0854 in

Note

Make

sure

that throttle valve carburetor is

1

opensfuDy

when

Rubber band
Unloa er tongue Choke vaJve

mounted on car

2 3

If throttle valve fails to open fully unloader becomes inoperative re

suiting

in poor acceleration after

EC150

engine is started Fig

EF 37 Adjusting Choke Unloader

AUTOMATIC CHOKE HEATE IRCUIT Checking heater circuit with

function connector

rC

CAUTION
00 not attach test leads of tester to those other than
8

f
circuit

designated
check

With

engine

not

running

for continuity between A and B If continuity exists heater is fune

SJ

tioning properly If continuity does

P TC 2

not exist
or

check
open

for discon nected connector heater circuit

With engine running at idle check

across

for presence of voltage If voltmeter heater circuit is

A and B 12 volts
1

reading

is

functioning

proper

Ignition switch
Automatic choke

Automatic choke heater

Function test connector L

ly
If voltmeter reading is for disconnected
circuit
or zero

relay

4 5

check open

connector

Engine stop ON Engine start OFF

terminal of alternator

faulty

automatic choke

EF433A

relay
3

Fig

Replace faulty parts

EF 16

EF 38 Checking Automatic Choke Heater Circuit with Function Teat Connector

Engine
AUTOMATIC CHOKE
MECHANISM Before starting engine fully de press accelerator pedal to ensure that
I choke valve closes 2

Fuel

properly
with
a

Push choke valve

finger

and check for 3

binding
be
sure

Check

to

that bi metal
EF855

cover

index mark is set at the center of

as

choke housing index mark below

shown
I

Fig EF II

42

Checking Automatic
Choke Heater

Note

Do not set b metal cover index at any

If measured

value is

not

within

mark center

position except

the

the
cover

specification

replace

bi metal

of

choke

housing

index

mark

INTERLOCK OPENING OF
PRIMARY AND SECONDARY THROTTLE VALVES
EF422A

Fig EF 40 Location of Automatic Choke Relay

2

480 from
measure

Open primary side throttle fully closed position

clearance
valve
as

valve

and

G1

between

throttle

and

throttle

chamber
43 EF

CD
Thermosta t covel Bi metal chamber 2 3 Thermostat

as

Check the continuity of the relay follows

In normal condition

inside wall

shown in

Fig

Clearance 6G1
5 83
mm

continuity

be 0 230 in

tween

CV

and

should exist l2V

Then
across

apply
and

battery voltage

housing
E T034

CID

Under this condi

tion

contin

Groove

ity

between

CV

and

@
it

should disappear Fig EF 39 Bi metal Setting

W

If not

the

relay

is

faulty replace

hWO

Check

automatic

choke

heater

source

wiring for proper connection engine

see

then start S

@ CID CV Q I CID
o

480

After warming up the engine

that choke valve is fully open

6 If automatic choke heater source and choke valve does
warm

CD

wiring is normal
not

J
GI
1 2

operate

after

up

replace

bi metal cover

@ r@ o @
0

Connecting
lever

rod

Secondary connecting
Throttle lever

mit r
6
E F089A

AUTOMATIC CHOKE RELAY

The automatic choke

4 EF989

Secondary throttle
valve

relay

is local

Primary

throttle valve

ed in the relay box

I

Fig EF 41

Remove automatic
two

choke

Checking Automatic Choke Relay

Throttle chamber

relay
AUTOMATIC CHOKE HEATER
I

by removing

securing screws

Fig EF 43 Adjusting Interlock Opening Primary and lecondary throttle

values 2

Measure

resistance

of 3 7

choke
to 8 9

Without disturbing above setting

as

heater

bend connecting rod

resistance is

necessary

so

Specified
ohms

that secondary
to

throttle valve is about

open

EF 17

Engine Fuel
Upon completion
make
sure

of adjustment

It is necessary to
tor

remove

Carburetor

that

link system opera tes

from engine in adjusting this accelera

pump stroke limiter 1 2

smoothly

Remove Insert
in
a

carburetor from l to I S mm
a

engine

ACCELERATOR PUMP
STROKE LIMITER In rmal service

0 043 to

0 059 round this

feeler gauge

piece of

operation

best

stock of proper thickness is betwee l primary ca buretor

limiter should not be removed or bent

throat and throtile valve

In

J
@
l

Lock nut

Dash pot
E F730

ID
Fig
1IJl

EF 4

Ll dj

ting

hP ot

J
oj

00

Primary carburetor throat Throttle valve

Lever

5
6

Piston

4 5

Tighten lock
Make
sure

nuts

2 3
4

Pin
Feeler gauge

that

engine

speed

drops smoothly from

2 000 to 1 000

Limiter
E F048A

rpm in about three seconds

f I
3 IO 2 1
mm

0 051 IO 004 in 44 EF

Fig

AdjlUting Acce

rator Pump

Stroke Limiter

ACCELERATING PUMP
3

With

throttle

valve

held

open

properly by feeler gauge lever barely contacts pin

check that

If lever and pin are not in contact bend limiter until proper contact is made

I Visually inspect accelerating pump cover for any sign of fuel leaks 2

If fuel

leaks

are

found

check

OZ
1

gasket and replace if necessary

3

00

fID
@
Full

Turn
sure

throttle fuel
is

1
f
6
area

make

valve by hand injected through

injector nozzle
Note
To

4
1

travel of
lever

check

or

fuel
rom

injection
upper side

peep

into nozzle

while
Correct cont ct area
Lever

Lever Correct contact Limiter Pin

ward

directing flashlight primary barrel

beam to

2 3
4 EF049A A 5

7 8

Limiter Pin Piston

9 10

Pistgn

Fig EF 45 Stroke Limiter DASH POT I

ture read

ANTI DIESELING SOLENOID

VALVI
Start the engine and keep speed Disconnect the lead w
dieseling anti tor If the lead at
e

engine speed when dash pot just

idling

Idling speed
must

of engine and mix tuned

up and

be

well

engine sufficiently
2

warm

toucnes stopper lever 3 Adjust position of dash pot by tuming nut until engine speed is in the

for the

solenoid at the

connec

Turn throttle valve by hand

and

specified

range

engine does
wire is

not

stop

when

the California models Automatic transmission Manual transmission

1 900 to 2 100 Non Califomia models

disconnected

the

solenoid is stuck Reconnect the lead

wire and start the

engine Then

turn

1 900 to 2 100

offthe ignition switch If the engine does not stop when the ignition switch is turned off this indicates that
or

1 900

tp 2 100

2 300 to 2 500

the

striking

solenoid

valve is stuck FU model

1 900 to 2 100

short circuited

If the harness i in good condition replace the solenoid valve as a unit

EF t8

Engine
Note
a

Fuel
If continuity does not exist sole Replace throttle

THROTTLE OPENER
18 2 2

to Tightening torque is kg m 13 to 16 ft Ib After replacement start engine and

CONTROL SYSTEM

noid may be faulty

check to be

sure

that fuel is not dieseling anti sole

idling speed is too high and does not drop to idling speed the
When throttle opener control system should be checked

opener control valve assembly

leaking

and that

noid i in

good

condition

Ift If
r
I

Manual transmission models

I and

Check for continuity between A 8 terminals specified in function

check connector with

ignition switch
not

OFF
EFOSOA

If continuity does noid may be faulty

opener

exist

sole

Fig EF47 Checking

dieaeling Anti Solenoid

Replace throttle control valve assembly

1J

Inhibitor switch N 2 p

ON

Solenoid
Function check connector EF43SA

3 5

l
2

SJ
1 2 3

Fig EF 49 Circuit Diagram for Throttle Opener Control Ignition switch Amplifier Speed switch
4 5

Solenoid
F nction

System AfT
check
EF434A

connector

Fig EF 48 Circuit Diagram for Throttle Opener Control System

MIT

Turn
8

on

ignition

switch

and
More than 10 miles

check voltage
in this step

across

terminals

A and appear

OV

l2V battery

voltage should
or

2 Turn ignition switch ON check voltage across A and 8 terminals Voltage between two terminals should be changed as follows If not replace inhibitor switch

Less than 10 miles

12V N
or

If not check fuse

3

amplifier
ON
remove

Keep ignition switch

Then

If not

position

OV

amplifier

speedometer
meter

cable from combination

switch may

speed detecting be faulty replace parts

or

Other than
N

spin speedometer in com bination meter with fingers and con firm that the speedometer pointer
indicates
MPH A
more

with new ones

and

position

l2V

than

16

km h

10

Automatic transmission models

I and

Voltage between and 8 terminals should be chang temporarily

Check for continuity between A 8 terminals specified in function

THROTTLE OPENER

OPERATING PRESSURE
I Remove harness of solenoid valve

ed as follows

check connector with

ignition switch

OFF

EF 19

Engine Fuel
Automatic transmission in
0

Adjusting

nut

position

Counterclockwise

650rpm
Note Note

When

adjusting
nut

TO C S

turn

On

automatic
never race

transmission 0

adjusting

in

or

out with lock

models

gearshift
4

lever is in

engine when position

no

spring in place Always set lock spring properly to prevent changes

in set pressure

Run engine
then At

under

load

In

crease

rpm
EF053A

engine speed to 3 000 to 3 500 quickly close throttle valve

the time

manifold

vacuum

Fig EF 50 Removing JWrneu of

Solenoid valve

600 pressure increases abruptly to 23 6 inHg or above and rnmHg then gradually decreases to the level
set at

Connect

rubber

hose

between

idling
a

Maximum negative pressure

vacuum

gauge and intake manifold

b
c

Operating pressure Idling pressure

Vo

Note

quick
such

gauge

as

response type Bourdon s type

a

boost is

Nega ive
pressure

recommended

mercury manometer should not be used

type
1

Adjusting nut Lock spring

EC502

Time

Fig EF 52 Characteristic Curve of

TO C S

Check that the T O

is within the

s operating C

pressure
sure

specified

pres

EC802

Specified
end 760

pressure

sea

level

mmHg

30 inHgl

atmOs

pheric pressure
Califomia Non

models
20

520
20 47

mmHg 0 79 inHg

California models 560 22 05

7 20

mmHg 9 79 inHgl

EF055A

Fig

EF 53 Adjusting

llting Ope
3ure Pre

specified adjusting screw or nut in the following direction until correct adjustment is made
level turn the

If it is lower than the

Note

The operating pressure varies in proportion to altitude When atmospheric pressure is known

Warm up engine until it reaches operating temperature Then confirm

3

operating

pressure will be
arrow

Adjusting

nut

found A

by tracing the

line op

Clockwise

that engine
valve

idling speed

is

When altitude is known

pressure will be found

specified
2

erating

by

Engine idling speed

Manual transmission 700 rpm

levei
in the

If it is higher than the specified turn the adjusting screw or nut

tracing
b

the arrow line

When

checking
note
sea

following direction until

is made

correct

pressure

operating atmospheric pressure

level in which check

T O C S

adjustment

and above

EF 20

Engine
is to be made

Fuel
SERVO DIAPHRAGM STROKE
I 2 Connect Warm up

and determine set information fur

level is

25

pressure

by

the

nished
For

mmHg 0 98 inHg away from the specified value 2 Turn adjusting screw l O of a turn
clockwise so that throttle opener oper

example
m

if above
be
on

sea

engine tachometer engine until it reaches

1 000
sure

3 280 ft then

will

operating pres 475 mmHg

non

ating
0 98 10

pressure

drops by
opener be

25

mmHg

operating temperature
3

inHg
If throttle
cannot

Disconnect rubber hose between

18 7

inHg
or

California 19 5

operating

servo

diaphragm
connect

and vacuum

control
in

models

495

mmHg

pressure
even

observed clearly

valve
Then rubber hose to

inHg
at

on

California models
TO C S 18 7 3

In other words 475

490

mmHg 19 mmHg

operates inHg or

in step 9 proceed as follows Turn adjusting screw counter

take manifold
Servo

inHg

clockwise so that tluottle opener oper ating pressure is on high vacuum side 50 mid

diaphragm

Rubber hose
T T

Race

engine

and check for

adjust

mmHg 1 97 inHg away from point of the specified range Turn adjusting screw lof a turn

O C S solenoid valve O CS control valve

ment

clockwise

If engine speed will not drop to idling speed when checking throttle opener operating pressure proceed as
9

Note

The throttle opener operating

should be

pressure

correctly

set

follows
I Turn

within the

specified

adjusting
on

screw

counter

above

adju stments

range after the even if the en

EF250

clockwise so that throttle opener oper

ating

pressure is

high

vacuum

side

gine speed idling

cannot be decreased to

inHg
30

mmHg
750

29

24
600 23

28 A 700 27

560 22 550 21 25
0

26 650
to

EF057A

Fig EF 55 Connecting Rubber Hose

Intake Manifold

20
500 19

24

600 23

0
o c

Servo

diaphragm

is

functioning
comes

properly if engine speed the specified range

into

ii
0 c

18 450
17

22

550
2

Specified engine speed 1 650 to 1 850 rpm except Californial

1 900 to 2 100 rpm

16 400 15 B California Non model

20 500

for California
5 If necessary it is in the

14
350

California model

until

diaphragm servo
13

adjust engine speed range using adjusting screw

specified speed
range

When engine
the 300 0 0
1 000 2

is lower than

prescribed

000

001

000

000

000

1ft
2 km

Turn
When

adjusting

screw

15

clockwise

Altitude
EF056A

engine speed the prescribed range

Turn

is

higher than

Fig EF 54 Clumges in Operating Pressure Versus Changes in Atmospheric

Pressure

adjusting

screw

counterclockwise

EF 21

Engine
rator any

Fuel
ISm

pedllI

when shift leVer

will surge

Conilect

anti ieselingsolenoid

position
car

other than neutral forward

valve connector 4 5 Restart

Otherwise

engine

abruptly
Note Do not

Connect circuit tester as shown in

attach test leads of

to

circuit

tester

terminals other

than those

designated

1 2

Servo diaphragm 4
Bracket 5

Stopper
Link
Carburetor

Run engine 2 valve

Disconnect connector

at

idling speed
dieseling anti solenoid
anti

Lock nut

Fig EF S8 Depress clutch pedal and shift gears into 5th position 7 Depressing clutch pedal increase engine speed to about 3 000 rpm by depressing accelerator pedal Then quickly close throttle wIve by re leasing accelerator pedal
6

and make sure that not

At this time
across

check for presence

EF732

engine

Fig EF 56 Adjusting Seroo Diaphragm Adjwting Screw

replace stops dieseling solenoid valve assembly

If

of voltage

A and B
ero

If voltmeter reading i
and is
off shut

dur
is

ing acceleration
deceleration fuel

12V

during

system

functioning
FUEL SHUT OFF SYSTEM Precautions
a

If voltmeter

l2V in both
off shut

reading is zero or engine operations fuel

system is
any
case

malfunctioning
continue

In

with

the

Before
is

checking

make

sure

engine
9

ifotel mwinsg
Shift lever to neutral
and

warmed up and choke wive is

then in

fully open On air conditioner

in

crease

engine speed

quickly close

equipped

mod

throttle valve If voltmeter reading is zero in both engine operations and results of test i tern 8 are correct neutral detecting switch is functioning properly If not check neutral detecting switch harness and connections Replace if necessary
10 II Turn off ignition switch

els turn off air conditioner switch

steps

through 12

EF856

Keep

clutch

your foot

pedal held down with while depressing accele

Fig EF 57 Checking Function of die Anti eling Solenoid Valve

Disconnect throttle valve switch

and connect circuit tester

connector

to throttle valve switch connector 12

J
A

Run engine under

no

load

In

crease
sure

engine speed slowly engine speed is within the speci

and make

fied range when throttle valve switch is turned on Then decrease engine speed

1
1
2 3 4

31
II
To distributor

slowly

CID @ V

and make the

sure

engine speed

is within

specified

range when throttle valve

switch is turned off If not adjust throttle valve switch 13

In air

conditioner

equipped
and correct

l
o
n

models proceed as follows

I

l1on

coon

Check
With

l F

D rpm C

Ignition switch
Fuse

5 6
7

Throttle valve swltch Engine revolution switch Transistor ignition unit

Function test connector

if necessary
2 air conditioner in

ON

solenoid dieseling Anti Neu tral detecting switch

l C D is actuated F

increase

engine

speed slowly
make
EF436A sure

then

decrease it And valve

or

throttle

operates

Click sOund is heard

turns to

OFF

when

continuity engine speed

Fig EF 58 Checking Fuel

off Shut

System Operation with Function Test Connector

decreases to idling

EF 22

Eng
If
not

ine Fuel

adjust throttle valve switch

If throttle valve switch cannot be

adjusted

to

specification replace

MAJOR SERVICE OPERATION

The

perfectly adjusted

carburetor

deliver the proper fuel and air ratios at aD speeds for the particular engine for which it vals
was designed pletely disassembling at re

By

com

ular inter which will allow cleaning of all

parts and passages the carburetor can be maintained in its original condition and will continue to deliver the proper ratios Fig EF 59 Adjusting Throttle
Valve Switch

To maintain accurate

carburetion

of passages and discharge holes ex treme care must be taken in cleaning Use
Throttle valve switch

only carburetor solvent and

air to

Engine operation

Engine speed
rpm

compressed
other

clean all

passages

continuity

and discharge holes

Never use wire or

pointed

instrument to clean or

When

engine speed

OFF

ON

1 150 t200

carburetor calibration will be affected

increases

When engine speed

decreases ON

OFF

I 000 t 200

REMOVAL
Remove carburetor from
care

engine

taking sufficient
Precautions When
not

to the

following
do

Inspecting engine revolution

switch

2 3

Connect circuit tester Run

disconnecting

fuel lines

Note

Before

checking
switch

the

engine
the

revolution

make

sure

functions of other components are correct in accordance with the

items described above

engine at idling speed 4 Depress clutch pedal and shift gear into 5th position 5 Depressing clutch pedal increase engine speed slowly Make sure engine speed is within the specified range
when voltmeter goes from OV to l2V

spill fuel

from fuel

pipe
do not

b When removing carburetor

drop
c

any nut

or

bolt into intake

manifold
Be careful any not to bend or scrtch

part d Link system of carburetor differ

between Canada 60 models models for U S A and
EF For details is
see

Then decrease and make Disconnect throttle valve switch

connector
sure

engine speed slowly engine speed is within

range when

Figure

the

specified

voltmeter

which

based

on

Canadian

goes from 12V to OV

EF 23

En9ineFuel
DISASSEMBLY AND ASSEMBLY Except FU model

i
I

rJ

I
l

liO I c

JCJ
@

A
@fB
@ @ @
1

JS
10 11

1 11
23 24 25 26 27 28 29 30 31
Idle

Choke chamber Center body Throttle chamber Servo diaphragm of throttle opener Dash pot Automatic choke
cover

Power valve

limiter cap
screw

2 3
4

Secondary main air bleed 12 Primary main air bleed 13 Injector weight 14 Primary slow air bleed
15

Idle adjust

Spring
Throttle adjust
screw

Automatic choke Iody and diaphragm chamber

16
17

S 6
7

Accelerating pump lever Auxiliary valve

Venturi stopper
screw

Accelerating pump Plug Primary slow jet

Needle valve Float
c1ieseling Anti

Spring Primary and secondary

valves Fast idle adjust
screw

throttle

18
19

Accelerating pump rod Throttle retum spring

Stroke limiter

Primary
venturi

and

secondary maU

20 21

solenoid valve

32

Secondary slow jet

Primary main jet 22 Secondary main jet

Note

Do nOt

remove an

marked with

the puts uterisk

EF420A

Fig EF 60 c rburetor

EF 24

Engine
FU

Fuel

model

If

EF567A

@ @ @
1

Choke chamber Ceo ter Throttle chamber Dash pot An tomatic choke
Automatic

body

8 9 10
11
cover

Secondary small venturi Primary small venturi

Power valve

20 21 22 23 24 25 26 27 28 29

Primary slow jet Float dieseling Anti

solenoid

valve

2 3
4 5

12 13 14 15 16 17 18 19

choke body and diaphragm

chamber Throttle valve switch assembly

Throttle

valve switch adjust

screw

screw

Secondary main air bleed Plug Primary main air bleed Plug Injector weight Primary slow air bleed Accelerating
Needle valve
pump

Secondary main jet Primary main jet

Idle limiter cap
Idle Throttle

adjust screw adjust screw

screw

Vaeuum

6
7

Fast idle adjust

Primary and secondary throttle valves

Secondary

slow

jet

Plug

Note

Do not remove

the parts muked

with

an

utemk

Fig EF 61

Carburetor

EF 25

Engine
Dhassembly
1
screws

Fuel
3 Do
not

arid nuts

and

cafe

must

be

attempt
an

to remove any

Properly

fitting
must

wrenches

and
the the

exercised not to damage any parts

2

parts marked with

asterisk

screwdrivers nozzles

be
as

used
as

on

Clean the carburetor thoroughly

lSembly disa

and jets

well

on

before

Choke chamber

parts

Except

FU model

@
Servo diaphragm of throttle
opener 2 Automatic choke
cover

3
4

Dash pot S pring hanger

Automatic

S 6
7

chlke body
chamber

and

diaphragm

Choke valve

8 9 10 11 12 13 14 IS

Pump lever retufn sprina Accelerating pump lever Accelerating pump lever
shaft

Accelerating

pump dust

cover

Accelerating pump Primary slow air bleed

Needle valve Float Stroke limiter
Do Dot
remove

Notc

the parts

marked with

an asterisk

EF085A

FU model

CHOKE CHAMBER PARTS

1 2

Dash pot Automatic choke

cover

3
4 S

Automatic choke body and diaphragm chamber Throttle valve switch assembly

Primary
Float

slow

air bleed

6
7

Needle valve

EF086A

Fig EF 62 Chohe Chamber

EF 26

Engine
Choke chamber

Fuel

parts

Except

FU model

R
5 7

ft Y

li mJ
1

@ r

Secondary Plug

slow

jet

1 ft

3
4

Power valve Seeon d ary mam au bleed

P
r imary maID aIr bleed Injector we ight Plug Primary slow Jet

5 6

7 8 9
1O 11 12

dieseling Anti Pr

solenOl d

valve

imary malO Je t Secondary main Jet Auxiliary valve

Venturi stopper
Prima ventuns
a

13 14

screw

nd

seeonduv J

small

Note

Do not J eIIlove the p tl markedwt tIt an asterISk

EF421A

FU model

CENTER BODY PARTS

1

2 3 4 5 6 7 8 9

Secondary slow jet Secondary sm aU yenturi Primary small Yen turi

Power valve

Tl@@

10 11 12 13 14 IS 16 Note

Secondary m3Jn air bleed Plug on air bleed Primary mm Plug nJeetor weight Accelerating pump Plug Primary l w J et
An

dieseling ti

50lenoid

valve

Secondary mamJet Primary mamJc t

Auxill ar y valve

Do not remOVe the parts marked WIth an utens t

EF568A

FIg EF 63 Center Body

EF 27

Engine
Throttle chamber

Fuel

parts

Except

FU model

1 1
4
1 2 3 4 5

@
EF087A

Throttle return spring lluottlc opencr adjusuctew Accelerating pump rod

t idle adjust Fa
5CICW

6
1

Sprin8 Idle adjust

screw

8 9 10

Idle limiter cap

Primary and secondary throttle valve

Spring Throttle adjust

rew

FU model

Note

Do not remove the puts ked with an uterisk

on

oG

Il I

TIlROTfLE CHAMBER PARTS 1 2 3 4 S 6 7 Throttle valve switch adjust Fast idle adjust
limiter
screw screw

cap Idle adjust screw Throttle adjust screw Vacuum

screw

Primary and secondary throttle valves Do not remove the putl marked with
an

Note
EF864

uterist

Fig EF 64 Throttle Chamber

EF 28

Engine
CLEANING AND INSPECTION Dirt parts of
For this
gum
water or on or

Fuel
if they
are

Inspect gaskets
or

to
or

see

carbon

con

appear hard torn

or

brittle

if edges

tamination in
a

exterior
are

moving

distorted

If any such condi

must be

jets indicate larger diameters Ac cordingIy main and slow jets with larger numbers provide richer mixture
the smaller numbers the leaner mix

carburetor
reason

often respon

tion is noted 4

they

replaced
or

sible for unsatisfactory

performance
cleaning and

Check filter and if

screen

for dirt

lint
or

efficient carhuretion careful

Clean
remains 5

screen

is

distorted

depends
Blow

upon

inspection while servicing

passages and castings with compressed air and blow off all all

plugged replace Check linkage for

Conversely the main and slow air bleeds through which air to passes make the fuel leaner if they bear larger
ture

operating

numbers richer fuel

the

smaller

numbers

the

condition
6

Inspect operation of accelerating

parts until dry

Note Do not

through
as

pass drills or wires calibrated jets or passages

pump Pour fuel into float chamber and make throttle lever operate Check condition of fuel injection from the

this may

enlarge

orifice and

seriously affect carburetor calibra

tion

accelerating nome 7 Push connecting rod of dia chamber and block passage of phragm
with finger When connecting rod becomes free check for leakage of
vacuum

Assembly
To assemble
reverse

the disassem
care

bly

procedure following
I
2

taking

to

the

air or

damage to diaphragm

Thoroughly

wash
to

all

the

parts

Check all parts for wear If wear is noted damaged parts must be re 2

before

assembling
see

Inspect gaskets

if they
are

placed
I
wear

the following Check float needle and seat for

Note

especially
is noted

appear hard or brittle torn or distorted Jets Carburetor

on

or

if edges

If

wear

assembly

must

If any of such undesirable condi

tions is noted

be replaced
2 bores

they

must be

replaced
original

Check throttle and choke shaft

in throttle chamber and choke
wear
or

performance

chamber for 3

of out

roundness

these

jets and air components

care

depend bleeds That is why

must be fabricated To clean them
use

3
Same one

Install jet and air bleed having the

size number as that of

Inspect idle adjusting needle for hurrs or ridges Such a condition re quires replacement

with utmost

After

reassembling

carburetor

cleaning solvent and blow air on them Larger inner nwnbers stamped on the

check each rotating portion or portion for smooth operation

sliding

EF 29

Engine fuel TROUBLE

DIAGNOSES AND CORRECTIONS
In the following table
the symp toms and causes of carburetor troubles

and remedies for them facilitate quick repairs There

that
are

are

listed to

acfuaJIy

theelectric syslem iat fatilt

various causes of

engine
fault

Therefore whenever the engine is mal the electrical system functioning should be checked fust before adjust ing carburetor

malfunctions
a

It sometimes

happens
no

carburetor which has

to

appears

have some

problems when

Condition

Probable

cause

Corrective action

Overflow

Dirt accumulated

on

needle valve

Clean needle valve

Fuel pump pressure too Needle valve

high
seated

Repair pump Replace

See above item

improperly

Excessive fuel

Fuel overflow Slow jet too large Main air bleed

on

consumption

each main jet

Replace
Clean

clogged fully
pump of

Choke valve does not open Outlet valve

seat

Adjust Lap Adjust

accelerator

improper
Unked opening of secondary throttle valve opens ioo Power shortage

early
Clean
open

Mainjels clogged
Every throttle valve Joes not

fully

Adjust Repair Repair

Clean Clean

Idling adjustment
Fuel filter Vacuum jet Air cleaner

incorrect

clo ed ll

clogged clogged

Diaphragm damaged
Power valve operating improperly

Replace Adjust
Clean

Improper idling

Slow jet

clogged

Every

throttle valve does not close throttle valve

Adjust
im Overhaul and clean

Secondary properly

operating

Throttle valve shafts

wom

Replace Replace packing

Correct

Packing

between manifold carburetor faulty

Manifold carburetor tightening improper

Fuel overflow
T O C S

tightening

See the first item

incorrect

adjustment

Adjust Replace Replace

Vacuum control solenoid Stuck dash pot

damaged

30 EF

Engine

Fuel

Condition

Probable low jet

cause

Corrective action Clean Clean tube Clean Correct

Engine

hesitation

Main jet

or

clogged

By pass hole idle passage clogged

Emulsion tube Incorrect idling

clogged adjustment

adjustment

Secondary throttle valve operating improp erly

Overhaul and clean

Engine does
start

not

Fuel overflows No fuel

See the first item Check pump fuel pipe and needle valve
incorrect

Idling adjustment

Adjust Adju
t

Fast idle adjustment incorrect

Damaged

dieseling anti

solenoid

Replace

EF 31

Engine

Fuel

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS
CARBURETOR

California models Manual

tranlDlWion

ifornia caJ Non Manual transmission 60E DCH306 1 60 DCH306

2

model utomatic transmission 68 DCH306 3 DCH306 12 4

Automatic transmission 63 DCH306 69 DCH306

FU model 67 DCH306

Type Primary
Outer diameter
mm

6t DCH306

Secondary
30 27
18 1

Primary
26
102

Secondary
30 27 18 1 106

Primuy
26
102

Secondary
30 27 18 1 106 145

Primary
26 102

Secondary
30 27 18 1 106 145

Primary
26
1 02

Secondary
30 27
18 1

in in

26
23

102 0 9t 107 95

Venturi diameter
mm

106

23 0 91 107 95

23 0 91 106 104 2

22

0 87

23 0 91 105 t04 4

106

Main jet

145

1145 180 150

43

1107
65

1145
80

Main air bleed Slow jet

1145 143

180 150

145

Powerjet

1110 80 145 150 140 148 2

146 48

1M 150

195
45

150
4

138 140

1 2 4 3

With A15 engine For Canada models Common to models with A14and AlS engines except Canada

INSPECTION AND ADJUSTMENT

A T C AIR CLEANER
Air con trol valve

partially opens

Oc OF Oc
F

38 to 54 100 to 129 Above 55

131

Air control valve

fully

opens

IDLE COMPENSATOR Idle compensator partially opens Bi metal No I

Bi metal No 2

Oc OF
60 to 70 140
to

158

70 to 80 158 to 176

Idle compensator fully opens Bi metal No I Bi metal No 2

Oc OF
Above 70 158 Above 80 176

FUEL PUMP
Fuel pressure Fuel pump

kgfcm2
cc

psi
at rpm

27 0

3 8 1 000

capacity

cu in min

450 27 46

EF 32

m
aIIIC a11 140a

CO S Cl

Cl

12 75

59
0

7 1
to

to

of
0

AfT

Can da

DCH306
60

051 067
0

19

IS

3 1

Center index
of

mark

9 8

14 1
to

to

200
3

98
1

to

to
7 3

00
1

0394 04 9
to

to

to

0 0

400
2

80
1

0709 0780
0

0929
0

2 95
0

100
2

20

to

520 47 79 20

36
2

83
5

900
1

75
0

59
0

7 1
to

to

MfT

DCH306
68 DCH306

051 067
0 0

19

IS

3 1

Center index
of

mark

9 8

84
0

700
2

98
1

to

to
7 3

to

73

0287 03 1
00

to

to

900
1

80
1

0709 0780

0929
0

2 95
0

500
2

20

to

0 5

47 79 20

0 0

36
2

83
5

300
2

75
0

59
0

7 1
to

ro

AI5

r A

051 067
0

19

IS

3 1

Center index
of

mark

9 8

14 1

to

200
3

98 to
1

to
7 3

0394 04 9 00
to
1

to

0 0

400
2

0709 0780 80
to
0

0929
0

2 95
0

100
2

20

to

47 79
20
0

36
2

83
5

900
1

520

Can da Except modeli

A14
california Non

FU
T

67

75
0

59
0

to

DCH306
68 DCH306

051 067
3to17 1
0 0

19

IS

Cent r index
of

mark

9 8

84 to
0

700
2

16 to
2

2 95 0854
0

100
2

to
7 3

to

73

0287 03 1
0

to

900
1

0780 0850 98
to
1

to

00

17
2

83
5

900
1

T A

75
0

59
0

7 1
to

to

051 067
0

19

IS

3 1

Center index
of

mark

9 8

14 1
to

to

200
3

98 to
1

to
7 3

00
1

0394 04 9
0

to

to

400
2

80
1

0709 0780
0

0929
0

2 95
0

100
2

20

47 79
20
0

to

36
2

83
5

900
1

520

60E DCH306 T M

75
0

59
0

7 1
to

to

051 067
0

19

IS

3 1

Center index
of

mark

9 8

84
0

to

700
2

98
1

to

to
7 3

to

73

0287 03 1
to

to

to

0 0

900
1

80
1

0709 0780
0

0929
0

2 95
0

500
2

20 47

to

36
2

83
5

300
2

520

20

79
0

69 DCH306

75
0

59
0

7 1
to

to

A15 AfT

051 067

19

IS

3 1

0 0

Center index
of

mark

9 8

14 1
to

200
3

98 to
1

to
7 3

00
1

0394 04 9
to

to

to

0 0

400
2

80
1

0709 0780
0

0929
0

2 95
0

100
2

20 05

to

36
2

83
5

900
1

560

22

79
0

models

63 DCH306

75
0

59
0

7 1
to

to

Californa A4

AfT

051 067
0
0

19

IS

3 1

Center index
of

mark

9 8

14 1
to

200
3

98
to

to
7 3

00
1

0394 04 9
0

to

400
2

0780 0929 0 7 0 9 80
1
0 0

to

2 95
0

100
2

20 05

to

36
2

83
5

900
1

560

22

79
0

61 DCH306
T

75
0

59
0

7 1
to

to

051 067

19

t5

3 1

0 0

Center index

mark

9 8

84 to
0

700
2

98
1

to

ro
7 3

0287 03 1 73
to
0 0

to

900
1

0709 0780 80
to
0

0929
0

2 95
0

100
2

20 05

to

36
2

83
5

900
1

560

22 79 0

in mm

in

and mm
of

idle

and

in mm

in

top

stem

Fast

valve
step

step rpm earn

2nd
at

adjustmen from body

level level Fuel Fuel

vlave

carbueto

betwen scat
H

Gap float

set ing seting resitance 210C

70 F
H
h

metal mBietal meBital

Bi

adjustmen

throtle body

at

idle 2nd Fast earn Gap

m T1 W

betw n

carbueto

spe d
idle

Fast

primary valves 760 m Hg body a d j u s t m e n o p e r a t i n g adjustmen choke choke body openig throtle andlevel adpotjustmen loading openr inHg break betw n carbueto unloader betw en Vacum Gap and Choke Gap carbueto Interlock secondary Dash withou Throtle
valve valve
of

mm

and

m On

and

On

mm

rpm

presu m Hg presu inHg

atmospheric
29

sea
m

Engine Fuel

TIGHTENING
dieseling Anti

TORQUE
kg m
ft Ib
18 to 2

solenoid valve

13

to

16

EF 34

DATSUN 210

Model 8310 Series

SECTIONEC
EMISSION CONTROL SYSTEM
CONTENTS
GENERAL DESCRIPTION CRANKCASE EMISSION CONTROL
EC 2 SPARK T MING CONTROL SYSTEM EC 26 EC 33

CATALYTIC EC EC EC 6 6 6

CONVERTER

SYSTEM
DESCRIPTION
INSPECTION

EVAPORATIVE EMISSION CONTROL SYSTEM

DESCRIPTION OPERATION

35 C

EC 35 EC 36 EC 36 EC 36

EXHAUST SYSTEM

EMISSION CONTROL
EC EC EVAPORATIVE EC SYSTEM A IS A IS E G R 1 EC 21 EC 8 9 7 7

REMOVAL AND INSTALLATION

DESCRIPTION EARLY FUEL E F AIR AIR

INSPECTION SERVICE DATA AND SPECIFICATIONS INSPECTION AND ADJUSTMENT TIGHTENING TORQUE

E SYSTEM INJECTION

EC 38 EC 38 EC 38 EC 39

INDUCTION SYSTEM

EC 18

EXHAUST GAS

RECIRCULATION

SPECIAL SERVICE TOOLS

CONTROL SYSTEM

Emission Control

System

GENERAL DESCRIPTION

There

are

three
are

types of control
emission

2 3

Exhaust

emISSIon

control system
control

sefVIcmg of these systems should

be

system These
I Closed

Evaporative
Periodic

emission

carried

out

to reduce harmful emis

type crankcase

system

sions to a minimum

control system

inspection

and

required

CALIFORNIA

MODEL

1 2 3 4
5

Distributor Thrott1
opener vacuum

rol cont

valve

From 3 way connector to air cleaner Throttle opener servo diaphnigm Vacuum switching valve Thermal
vacuum

6
7

valve

8 9 10 H

Vacuwn motor From vacuum motor to temperature Carburetor

sensor

From idle compensator to intake manifold To A R valve

Check vane B C
o

E G R

8e pa

B P T vallie
P

c V nIter

Auto choke A B valve

heater

E f

E G R control valve

I
H I J

CA C

valve

Carbon canister Air pump

Throttle

opener control valve

EC377A

Fig EC

Emision Control System

California model

EC 2

Emission Control
NON CALIFORNIA MODEL

System

Except Canada

AfT

O@ l

j
M

CD
1 2 3 4

Distributor Vaellum delay valve Throttle opener vacuum control valve From 3 way connector to air cleaner Throttle opener servo diaphragm Thermal
vacuum

5 6 7 8 9 10 11 12

Intake manifold

valve

3 port type

Vacuum switching valve eMIT Vacuum motor From vacuum motor to temperature Carburetor
From
sensor rom

idle compensator to intake manifold To A B valve Check valve

It

C
I

B P T valve Air pump air reliefvalve D P C V mter

choke Auto

E GR

control valve

heater

A B

valve

E G R passage Carbon canister

Air pump

Throttle opener control valve

to
EC136A

Fig EC 2 Emission Control System Non Californin model except Canada EC 3

Emission Control
FU MODEL S

System

speed Hatchback

Carbon canister Vacuum motor Back pressure transducer valve B P T valve Thermal
vacuum

2 3 4 S 6
1

valve

I istributor
To air cleaner Vacuum switching valve Antibackfire valve A B valve To A B valve From idle compensator to intake
manifold

8 9 10 11 12 13

Carburetor E G R control valve

From
vacuum

ET502

motol to

temperature
EC308A

sensoI

Fig EC 3 Emission Control System

FU model

4 EC

Emission Control
CANADA MODEL

System

M T

CD
o@o
0

ft

LA

CID

Distributor Vacuum delay valve AfT Thermal vacuum valve E G R Throttle opener vacuum control valve To air cleaner Throttle opener Carbon canister Vacuum motor From vacuum motor to temperature
sensor servo

2 3 4
S

Intake
om

fuel

tank

6 7 8 9 10
11

diaphragm

manifold Intake manifold

E G R control valve Carburetor From idle compensator to intake manifold To A B valve

Anti backltre valve Vacuum A B valve It 9 Il

12 13 14 15

EC138A

switching valve

Fig EC

Emission Control System

Canada model

EC 5

Emission Control

System

CRANKCASE EMISSION CONTROL SYSTEM

DESCRIPTION
This system returns by gas to blow both the intake manifold and carbure tor

The

ventilating

air

is then drawn

from the dust side of the carburetor

air cleaner

INSPECTION
p C V VALVE AND FILTER With

through the tube connect ing carburetor air cle er to rocker

cover into the crankcase Under full throttle condition manifold draw valve
tion the
vacuum

aitdeaner
The

gine ei

runnirig

at idle remove

positive crankcase ventilation P C v valve is provided to conduct crankcase blow by gas to the intake
manifold

the
to

the ventilator hose from P C V valve if the valve is working wiD be heard valve and felt
a as a

is

insufficient

hissing

noise

blow by

flow through the

air passes

through the
should be
a

and its

During partial throttle operation of the engine the intake manifold sucks the blow by gas through the P C V
valve

tube connection

flow goes through the in the reverse direc

strong

vacuum

irnniediately

when

fmger

is

placed
cars

over valve inlet

On by blow

with

an

excessively high
flow will go
to car

some

of the

Normally
a

the

capacity of

the valve

through the tube

buretor air
tions

connection

is sufficient to handle any blow

by and

cleaner under all

condi

small amount of ventilating air

EC139A

Fig EC 6 Checking PC V Vo

ve

VENTILATION

HOSE
hose
connec

L
J

Check hoses and

tions for ieaks 2

oisconn

ct

all

hoses and
be

clean of

J
o
r
I

with compressed air If any hose cannot

free

obstructions replace Ensure that flame arrester is surly inserted in hose between air cleaner and rocker
rover

IiI e
LJ
1

Fresh air Blow

by

Seal type oil level gauge

DafOe

gas

2
3 4 5

plate

Flame arrester
Filter

6
1

P C V valve Steel net Baffle plate

EC871 ET277

Fig EC 5 Crankcase Emision Control Sy

tem

Fig EC 7 Checking Ventilation Hose

EC6

Emission Control

System

EXHAUST EMISSION CONTROL SYSTEM

DESCRIPTION
The exhaust emission control system is made up of the following components

California Non California models models FU model Canada models

except CanadaY Early fuel evaporative system

Manifold stove Heat valve
Air pump C A C valve A B valve Air pump Air relief valve A B valve

E F E

Air

injection system

Check valve

Check valve

Air induction

system

Air induction valve A B valve

E G R control E GR E G R system

control valve
vacuum

valve
3

E G R control

Thermal

valve

port type

Thermal
valve

valve
vacuum

B P T valve

2 port

Thermal
valve

vacuum

type

B P T valve
Vacuum switching valve Top switch

2 port

type

Spark tirningcontrol system

M T model

Thermal
California Non

vacuum

valve 3 port type

Vacuum switching valve

Vacuum delay valve models only

Top

switch

Vacuum switching

Spark timing control system

A T model

valve

Vacuum delay valve Thermal

vacuum

Top switch
Thermal valve
vacuum

Vacuum
valve

delay

3 port

type

valve 3 port type

Catalyst

Catalytic
converter

Catalytic
converter

EC 7

Emission Control

System
SYSTEM

EARLY FUEL
DESCRIPTION

EVAPORATIVE

E FE

jl @

W @

o0 0

UL @
7

If
I

@
1 2

Intake manifold Stove gasket Mar fold stove

Heat shield

9
10 11

Screw Thermostat spring Heat control valve Control valve shaft

Exhaust

3 4
5

Exhaust gas flows valve dosed

valve

plate

12 13
14 15

6 7 8

Snap ring Countczwcight Key Stopper pin

manifold

16

Cap Bushing Coil spring

opened

EC247

Fig EC 8 Early Fuel Eaaporatiae E F E

System

The early fuel evaporative system is provided with a chamber above a manifold
stove

rotate clockwise and

again

comes

into

the full open

mounted between the

up air fuel mixture in

contact with the stopper pin With this condition the heat control valve is in

position and exhaust gas passes through the exhaust manifold without heating the manifold stove

intake and exhaust manifolds During

engine warming
ber

the carburetor is heated in the cham

by exhaust

gas

This reuslts in of atomized fuel

in the

REMOVAL AND INSTALLATION

improved evaporation
droplets
content of

in the mixture and in smaller

hydrocarbons HC

exhaust gas

especially

in cold weather

operation

OPERATION The counterweight rotates counter clockwise and stops at the stopper pin mounted on the exhaust manifold while the engine temperature is low With this condition the heat control valve is in the fully closed position obstructing the flow of exhaust gas As
1

Snap ring
Lock bolt

2 3
4

5 6
7 EC913

engine temperature goes up and the ambient temperature becomes high enough to actuate the thermostat spring
the

Key Counterweight Thermostat spring Coil spring

Heat controlvalve Valve shaft

counterweight begins

to

Fig EC 9 KF E Sy tem Component

EC 8

Emission Control
Remove snap ring CD and lock bolt @ and the following parts can be detached from heat control valve shaft

System
Counterweight
down clockwise as

gradually
engine

moves

warms

up

and ambient temperature goes higher around exhaust manifold If it does not
move

Key ID Counterweight @ Thermostat spring Coil spring @

Note
As

at all

check and

replace thermostat spring

previously descnbed

heat

control valve

is welded to valve

Counterweight
Heat control valve

shaft

at exhaust manifold and

Stopper pin
EC249

cannot be disassembled

To

install

reverse

the

removal

AIR INJECTION SYSTEM A I S

DESCRIPTION
The Air

procedure

Injection System

A I S

is

adopted
models

on

U S A models except FU
air

and

INSPECTION engine stopped visually check the quick heat manifold system for the following items
1 With

secondary
pump

injects compressed coming from the

exhaust

air air

into the

port of the

Check

heat

control

valve for

Fig EC IO Checking Heat Control

Valve Movement

malfunction due to break of key that locates counterweight to valve shaft

2

cylinder head to reduce hydrocarbons He and carbon monoxide CO in exhaust gas through recombustion There are two types of Air Injection System
Fresh outside air is drawn by the air pump through the air pump air cleaner Compressed air is injected into
the

Rotate heat control valve shaft and check for binding

with fingers
and

between shaft and bushing in closing

opening operation of heat control valve If any binding is felt in rotating operation move valve shaft in the
rotation direction several times If this

engine visually check counterweight to see if it operates properly When engine speed is increased I discharge pressure of exhaust gases causes counterweight to move down
ward clockwise

Run

and

exhaust

manifold

through

the

check valve
The A B valve

supplies
to

air from the the intake after fire

carburetor air cleaner manifold

so
as

to

prevent injected
valve

operation does
condition

not

correct

binding

For
in

it is due to seizure between

engine

starting cold weather counterweight

some

time

after

during deceleration
The amount of air is
con

shaft and bushing

and exhaust mani

as an

turns counterclockwise until into contact with

to

it comes

trolled models

by
or

AC C air

California valve

fold should be replaced

assem

stopper pin installed

relief

Non

bly

exhaust manifold

California models

EC 9

mission Control
California modelS

System
AJrpunip
The paper type

air cleaner
is a viscous
re

air cleaner ftlter

and requires periodic

The air

hi

T1rID
j
I

placement

pump

air cleaner i

bolted to the carbon canister attaching bracket

rn lrr
I
00
Fig EC 13 AirPumpAirCl
an r

Air pump
Air Air

Check valve Exhaust manifold Carburetor

backfire Anti

Air pump The

air

2 3
4

pump air cleaner

relief valve

6 7 8

pump
vanes

has

displacement
valve
EC141A

two po itive which require no

Air deaner

lubricating
The

service rotate

vane

freely

around the

Fig EC ll A l S for CalifomitJ Mod 1s

enter pivot pin and follow the off circular shaped pump bore The vanes

form two chambers in the

housing
a

Non Califomiamodels
Air

Each

vane

complete
into

pumping

cycle

in every revolution of the rotor

is

drawn
a

tile

inlet cavity

through

tllbe

connected to the air

pump air cleaner Air is sealed between the vanes and moved into a maller

I
i

Ira
p

cavity the compression

area

After compression a yane passes the outlet cavity Subsequently it

passe

the stripper

and

section of

Pt

the housing that

parate the outlet

and inlet cavilies and again reaches the inlet cavity to repeat the pumping

cycle
Carbon shoes
rotor in the slots of the

upport
to

the

vanes

They

are

designed

permit sliding ofthe

Leaf

vanes

and to sealthe rotor interior from the

air cavities

I
I

springs which

are

behind the leading side of the shoes compensate for shoe abrasion The front and the
Air pump
Air pump

rear

SCheck vav1e air deaner 6 7 8 Carburetor Exhaust manirold

backfire Anti valve EC142A

2
4

3 C A C valve
Air

cleaner

ings The bearings have been greased There are two types of bearings which support the rotor The ball bearing is used for
the front
and the

bearing uses ball bearing bearings use needle bear vane uses needle bearing AU

needle

bearing

is

Fig EC 12 A I S for Non CalifomitJ Models

used for the rear

EC10

Emission Control System

CD

L
I

1 2 3
4

Air pump drive hub

5 6 7 8

ne

10 11

Housing Rotor rins

End
cover

Carbon shoe Shoe spri ng Stripper Rotor shaft

bearing bearing 12 Pulley 13 Pulley

Front

Ball

14
cOYer

Inlet

cavity

15

Outlet cavity

with needle

bearing

for air conditioner

EC066A

Fig EC 14 Air Pump

two

vane

lype

Anti backfire This valve manifold

in the

A B

valve

Check valve
intake A check valve is located in the air pump vents

is

then

distributed

to near

each exhaust
the

is actuated

by
the

port
valve

and

injected

exhaust

vacuum

to prevent backfire
at

discharge lines The valve

the

pre

exhaust system period of deceleration

At this

initial

backflow
air

of exhaust gas
cases

which occurs in the

I

following
pump

period
burn

the mixture in the

to

When

the

drive belt

intake manifold becomes too rich

fails
2 When relief valve

ignite

and

in the

combustion

spring fails

chamber and burns easily in the ex haust system with injected air in the exhaust manifold The A B
valve

provides

air to the

intake manifold

to

make the air fuel

mixture leaner and

prevents backfire

11
1 2 3

rom
pump

iJl
2 3 Ai gallery Exhaust port Exhaust manifold EC316

Spring
Rubber valve Seat

SecondarY air

To intake manifold
vacuum

J 4

Exhaust gas
EC322

Fig EC 17 Air Gallery

Fig EC 16 Check Valve Air pump relief valve Non California models The air pump relief valve controls the injection of secondary air into the exhaust system when the
at

Air gallery The secondary air fed from the air

EC069

Fig EC 15 A B Valve

pump goes through the check valve to the air gallery in the cylinder head It

running

high speed under

It

engine is a heavily

loaded condition

accomplishes the

EC lt

mission Control following

functions without

System
At this
a

affecting

and opening ihe No

ivalve

Wheo the engine is operating under

these
vacuum

the effectiveness of the exhaust emis sion control system

point
valve

the No

2 valve serves as

relief

cooditions is low

intake
and

manifold
valves
are

all

balanced Minimizes
ture

exhaust gas tempera

rise Minimizes

t
U
F air pump

To

intake

manUol

sulting

from

air

horsepower losses injection into

from

reo

the

exhaust system 3 Protects pump back pressure

111

No 3 valve

excessive

LL jjIi
EC787

ii ji

j Ii

JI

Jij l

ulJC

Fig EC

19

C A C

Valve

To atmosphere

1t
in

EC685

To carburetor air cleaner Secondary

ir

I Engine light load

these

in

low

and speed

Fig EC 21 Operation of C A C
Valve 2

When the engine is operating under conditions

I

intake

vacuum

is

Engine

high

speed

and

high
Not actuated intake

The No 2 valve

unitized with is lifted

middle load these

2

the No
the No

diaphragm

manifold

vacuum

by pushing
a

the up

When the engine is operating under intake conditions manifold lies midway between 1 and The No 3 valve moves to of high air pump

I valve These valves will then

a

vacuum

stop at

position where
exists between pressure and the No

balanced
air pump tension

above

condition

the

left because
pressure

J
To carburetor air cleaner

discharge acting on
Secondary
The

spring

discharge

I and No 2 valves

No 2 jiaphragm however

does

To intake

manifold

sir

Actuated

EC294

engine speed low air pump discharge pressure and spring tension acting on the No 3 valve For this reason these valves are brought to
a

not move due to low

t
L
J

Fig EC 18 Air Pump Relief Valve

balanced condition

bt
To intake manifold

f
I

E
5

c A C valve Californiamodels The C A C

valve

tfi 1 I
i
To

controls

the

t
tmg

LJr

quantity of secondary air fed from the

air pump tion and

according it discharges the secondary air into the atmosphere to prevent overheating of the catalytic converter This valve is operated by intake
manifold
vacuum

to the load condi

j J

1
EC 4

Fig EC 22 Operation of C A C
Volve 3

l
3
4

and air pump dis

in the

Spring
ValveNo 3
Di

charge pressure When intake manifold

vacuum

5 6
7

is

small

or

high load

phragm Spring
Valve No 1 Valve No 2

No

REMOVAL AND INSTALLATION

Air pump air cleaner

range

the No 2 valve opens when it is

great or in the low load range the No

I valve opens If air pump the or pressure is large

discharge

EC683

cleaner to Fig EC 20 Operation of C A C Valve 1

Loosen nuts securing air pump air bracket then detach air

running

at

valve opens

engine is high speed the No 3 admitting the air pump

2

cleaner from bracket Air cleaner filter and air cleaner lower body
into a unit construction
are

built
air
an

discharge pressure to the No 2 dia phragm chamber of the C A C valve

Engine
load

in

low

speed

and

cleaner filter and lower

Replace body as

heavy

assembly
EC12

Emission Control

System
2 Remove
to screws

securing

relief
can

valve
3

air

cleaner

Relief valve

then be taken out

easily
reverse se

Installation is in the

quence of removal

EC149A

EC151A

Fig EC 23 Removing Air Cleaner

Filter

Fig EC 25 Removing Check Valve

EC153A

Air pump
1 Remove air hoses from air pump

A B

valve

Fig EC

27

A B valve is located at the rear side

Removing Air Pump Relief Valve

2 3

Remove air pump pulley

Loosen air

of air cleaner
bar
vacuum

Remove air hoses and

A B valve
can

pump adjusting

tube

then be

mounting ing bolts then

belt
4 Air pump

bolts and air pump mount

remove

taken

out

C A C valve California models C A C valve is located beneath

trol device bracket Remove
con

air pump drive

assembly

can

be taken

out from bracket 5

clamps
screws

and disconnect

Installation is in the

reverse se

air hoses and vacuum tube 2 valve

quence of removal

Remove
Air

securing
can

C A C then be

control valve

taken out 3

easily
is in the reverse se

Installation

quence of removal

EC152A

Fig EC 26 Removing A B Valve

Fig EC 24 Removing Air Pump

Air pump relief valve Non California models

EC154A

Check valve
1

Loosen

clamp

of air

hose and Fig EC 28 Removing C A C Volvo

Disconnect air hose from

check

disconnect air hose from relief valve

valve
2

Remove check valve from engine Installation is in the of removal

reverse se

cylinder head
3
fluence

EC 13

Emission Control

System

DISASSEMBLY

AND ASSEMBLY OF AIR PUMP

Vane kit

Bearing
kit

EC562

Fig EC 29 Component of Air Pump

Disassembly
I

4 bolts and

Put match marks

on

rotor

Remove

vanes

from rotor

Remove

pulley drive
from hub

remove

pulley

ring and side of rotor to ensure correct reassembly and remove screws that
retain
rotor ring to rotor using Hexagon Wrench STl98l0000 a

Secure air pump drive hub in vise and remove end cover bolts

Note

CAUTION
Never

Generally
by

match

marks

are

indi
rotor

clamp

on

the aluminum hous

cated on both rotor the manufacturer

ring and

ing

Fig EC 32 Removing Vanea

Ee111 EC302

Remove carbon shoes and shoe

nose

Fig EC 30 Removing Cover

Fig EC 31 Removing Rotor Ring

springs from rotor using needle pliers or tweezers

Note Carbon shoe
wider than 8 A

Remove

end

cover

by carefuDy
a

Discard moved

screws

which
use
new

were

re

tapping around dowel pin wi th tic mallet and lift up straight

plas

Always installing

ones

when

is I

mm

0 04 in

Do not confuse them

EC 14

Emission Control
II order

System
parts
in

Keep

disassembled

b After
ensure

rotor

is

installed in place

that

the rotor end is

posi

tioned

helow the end face of air

Assembly
Front

pump housing
Position of rotor end below air

bearing
the
rear

pump

Support housing with

with
a

end face of air Rotor Adapter

pump

housing
0 050 to 0 150 mm 0

STI 9890000

Press front bearing into

press and

0020

to

0 0059 in

place

Bearing Pressing
4 Air

Tool STI 9940000

pump drive

hub
ro

I
Fig EC 33 R moving Shoe Springs If replacement
necessary 7

Support
tor with

the inward bottom of

Rotor Stand STI 9920000

hub into

proceed puller

of fron t bearing is as follows

Remove air pump drive hub with

standard 8

J
j
2

Press drive

place

with a

press and Bearing Driver STI99l0000 until the end face of drive hub touches front

bearing

inner race

Remove

screws

bearing cover bearing cover

9

in

securing front place and detach

Support the rear end face of air pump housing with Rotor Adapter STI 9890000 Drive rotor out by push ing
rotor shaft with

71
Bearing
cover

STl99 10000
EC306

Fig EC 36 Pre88ing Ball Bearing

Bearing Pressing

Tool STI 9940000

T ighten bolts
STl9940000

bearing

cover

securing

Tightening torque
Bearing
cover

securing bolts

EC30B

0 1 to 02

kg

Fig EC 38 Pre sing A ir Pump Drive

Hub

0 7 to 1 4 ft Ib

JJr
10

Rotor shaft

Carbon shoe Place air pump drive hub in

Clean
a

STl9890000

Support the in ard bottom of ro tor with Rotor Staild STI 9920000
press and Bearing Driver STI9910000 until the stepped portion of rotor shaft
a

I
vise 2

Press rotor into

EC303

place

with

carbon

dust

etc

from

shoe grooves
3

Fig EC 34 Removing Rotor Shaft

Align

rotor

with housing prop

Support

housing

with

the fron t end face of Stand Bearing

touches front bearing inner

race

erly

Then insert carbon shoes into

their directions

place noting

STI9930000

Attach

Bearing

Driver

STI9910000 to front bearing on the inside of air pump housing and press
out

7 t
STl9910000

STl9910000

1
i
I

STl9920000
EC307

Fig EC 37

Pressing

Rotor Shaft

EC5 0

R
II

Fig EC 39 Install Carbon Sho Note

9930000

Note
EC304 a

Be sure to drive front

race

bearing

inner

Carbon

Fig EC 35 R mouing Ball B aring

in

sh wider than

A B

is I

mm

0 04 in

Do not confuse

EC 15

Emission Control
them
b

System
l Tighteningtnrque
End cover bolts 0 7 to 0 9 kg 5 1 to
m

If carbon shoes

are

exposed beyond
remove

shoe groove 6e Sure to push spring in SO that spring end face is flush with rotor 8
Rotor

the rotor end face semble carbon shoes

carbon

shoes and clean shoe grooves Reas

5 ft bl 6

ring

Install rotor ring by correctly

6 1

align

Vane
Pack
vane

ing bearing
with

the

rear

end face of rotor with the

in rotor

high
A

on mark

melting poinf grease MIL G 3S45

Es o ANDOK260 or

screws

with

ring and tighten Wrench Hexagon

equivalent

and
vane

ST98 10000

insert

dummy

shaft into the

bearing
STl9900000

Tightening torque Rotor ring screw 0 5 to 0 7 kg

13 6 to 5 1 ft lb

EC302

Fig EC 43 lnstolling End Cover

12
EC563

Pulley Tighten pulley securing bolts

Fig

40 EC

Va Assembly

Tightening

torque

Install

vane

in

place

on

rotor
as a

Pulley securing bolts 0 75 to 0 90 kg m

5 4 to Fig EC 42 Installing Rotor Ring 5 ft Ib 6

uMng Dummy Shaft STl9900000 guide

Note The
woes

may

require
wear

6 to 16

INSPECTION
9

km 4 to 10 miles time In the event

a

in running Removal of dummy shaft The

slight squeaking
car

following

procedures
various

are
or

re as

still remains drive the

to

about 64 MPH In 4 to 10
wear in

CarefuDy
from 10
vane

withdraw dummy shaft

commended for checking

and

80

h km
cases

40 to SO 16 km

certaining that the

of the
rear t

most

6 to

Vane shaft Pack

components exhaust emission control system components operating tempera

are

miles will be sufficient for

bearing
or

with

high

are

melting pain
Esso
7

grease ANDOK 260

MIL G 3S45 A

opera ting properly The engine and all

t be at normal

equivalent
vane vanf

mu

Shoe spring Place shoe springs in

deeper

groave

thin coating of grease to shaft and rotor ring and insert

Apply

tures

when the tests

performed
diag
as

Prior to

performing

any extensive

ofshoe

shafi into its bearing

Note
a

nosis of the exhaust control must be determined that the

a

ystem h

engine

unit is functioning

properly

Do not
vane

apply

an

undue stress to dislocated when

shaft when inserting

vanes are

b If two

11
c I 11 1 EC123

Air injection

s stem

hoses

inserting vane shaft correctly align Yanes by inserting dummy shaft Then draw out dummy shaft and
insert vane shaft

Check air system hoses for loose

connections

cracks

or

deterioration

Retighten
on

01

replace if necessary

When when

wear occurs

vane

shaft

or

replacement of rear bearing is necessary replace rear rover assem

bly

Air pump
I

Fig EC 4I Ins tolling Shoe Spring Note When installing

sure a

Operate engine

until it

reaches

shoe

spring

J I

End

cover

normal operating temperature 2 Inspect all hose hose

connec

make

that the outward bend

Position end cover in

place

Snugly

tions correct air

and air

gaDery

for leaks and before checking

ing

side faces in shoe and that both

ends of

sJlri

face in the wall of

tighten the bolt close to the dowel Then tighten end cover bolts
EC t6

if necessary

injection pump

Emission Control
3

System
hand
on

Check air

injection
to

pump

belt

Non California models

the air outlet of air

to

pump

tension and adjust necessary 4

specifications

if

1
2

Plug

up air

discharging

hose from

Repeat With engine speed

2 and 3 above at 1 500 rpm

relief valve relief valve

check for discharged air

If no air is felt

replace

the air pump

C A C valve

California models

y
o

tube from adapter and close hole of test gauge with finger If a leaking sound is heard or leaking air is

disconnect

felt by finger at relief valve

relief

valve is malfunctioning
should be 3
meet sure

Relief valve

replaced

or

repaired
not

If air injection pump does

minimum it test

requirement should be repaired

of pres

California models
Disassemble the air pump and
EC144A re

EC575

Fig EC

47

pair

it

Checking Air Pump Relief Valve

Fig EC

44

Plugging C A C Value Air Discharging Hose California model

air

Check valve Warm up engine thoroughiy

Anti backfire valve A B check

I 2 any indi and 3

valve

Disconnect
Insert open

supply

hose

at

Disconnect hose

leading

to

Warm up

engine thoroughly
near

check valve

valve from air hose connector

3 Check hose

Disconnect hose from air cleaner

pipe end of Air Pump Test Gauge Adapter STl9870000 in air supply hose Clamp hose securely to adapter to prevent it from blowing out Position adapter and test gauge so that air blast emitted through drilled pipe plug will be harmlessly dissipated 7 Install a tachometer on engine With the specified engine speed ob
6 serye air pressure gauge Air pressure More than 100
at

opening for
check valve

place
Run
no

cation of exhaust gas leaks If leaks are

finger engine
load

the outlet 3

at about

QOO

rpm

detected
4 Race 2 000

replace
and

the engine lightly

then

at about it
to

rpm

return

idling Visually check the hose for any indication of exhaust gas leaks before
the engine returns to idling speed If leaks are detected replace check valve

quickly return it to idling If you feel a pull or suction force on your finger the anti backfire valve is functioning normally If no suction is felt replace the anti backfire
under
then valve

produced

at test

mmHg

3 94 inHg

2 600 rpm

EC768

Fig EC 48 Chocking Anti backfire

Valve
EC146A

Fig EC 46 Checking Check Valve

C A C valve California models

I
um

100 m Hg 3 94 mHg

jff f1
EC145A

Make

sure

that C A C valve vacu

are

hose and air hose

not cracked

Air pump After

pump

relief valve of air

2 3

Warm up engine throughly With engine

over

completing inspection

at

idle

place

your to

check air pump relief valve in

fmger
4

relief

hose opening

Fig EC 45 Testing Air Pump

the following steps I Disconnect hoses leading to check valve and

air control

check for presence of air With

engine
sure

idling

disconnect

valve from air

c

vacuum hose at C A C valve

hose connector 8 If
air

and install blind

Then make ed from

that air is discharg

pressure does not

meet
as

to the connector 2

C C valve A

above follows

specifications

proceed

With

engine

running

at

about
your

C A C valve is functioning if air is discharged from it

properly

3 000 rpm under no load

place

EG 7

Emission Control
Note When tho vaCUUm hose is dis
or

System
The exhaust pressure in the exhaust
tube the

connected plug it up stumble

engine will

If teshesults satisfy 3 4 5 and 6 the C A C valve is properly function

7

ing

usually pulsates in response to opening and closing of the exhaust

it

valve and

decreases below atmos

AIR INDUCTION SYSTEM

DESCRIPTION The air induction system 1 s is A on the FU model and Canada

A I S

pheric pressure periodically If a secondary air intake is opened to the atmosphere under vacuum con ditions secondary air can be drawn
into the exhaust tube in

proportion

to

the

vacuum

adopted
models

I A s

Therefore the air induction system reduces CO and HC emissions

EC 47A

FiJ Fig EC 49 Disconnecting Vacuum Hose from C A C Valve

and is designed to send see ondary air to the exhaust tube utiliz ing a vacuum caused by exhaust pulsa
tion in the exhaust tube

operatiug the same as injection system I A s The system cpnsistsof an air in tJctio
the air valve
a

in exhaust gases

filter

an

A B valve and hoses

Connect
in to

operated hand

vacuum

pump order 250

to

place

apply

and manipulate it in a pressure of 2oo to

7 87 to

mmHg

9 84 inHg

C A C valve Increase engine speed to 3 000 rpm and confIrm that no air leaks from C

fl
V
t

C valve

Air ind9ction valve

Air
c eancr

2 3
4 5

Carburetor Exhaust manifold obRcldlre Anti

valve
EC919

Fig EC 50 Checking C A C Valve 1

Fig EC 52

Induction SYltem Ai

With the above condition discon

nect air hose at check valve and up At this point

plug

it

confirm the air leaks Air inductIon valve

A reed

from C A C valve

valve type check valve

is

installed in the air cleaner When the exhaust pressure is below atmospheric
pressure

negative

pressure

secondary
1

air is sent to the exhaust manifold

When the exhaust pressure is above atmospheric pressure the reed valve prevents secondary air from being sent back to the air cleaner

Reed valvo

Stopper
EC920

Fig EC 53 Air Induction

Val

ECl48A

Fig EC 51

Checking

A C C

Volve

EC t8

Emission Control
Air Induction The
air
v lve

System
Air Induction pipe Loosen out
to
a

filter filter
is

Air Induction

Into exhaust

induction

valve

port
The secondary air fed from the air induction valve goes through the check valve to the air gallery in the cylinder head It is
then distributed to

nut

securing

the

pipe

installed at the dust side of the air cleaner It

sent
to

purifies secondary
tube

air to be

the engine cylinder head At the same time remove the screws securing the bracket and rubber hose clamp The air induction pipe taken out sequence of removal
can

the exhaust

The fIlter

element should be

replaced periodical

each
the

then be
reverse

ly

in accordance with the Maintenance

exhaust

port

and

injected

near

Installation is in the

Schedule

exhaust valve

Fig EC 58
EC921

Fig EC 54 Air Induction Valve

Filter I 2
Air

gallery
manifold
EC316

A B

valve

Exhaust port
Exhaust

Antl beckflre

v lve

A B

lve v

The A B valve is located at the rear side of the air cleaner Remove the air

Tltis valve is controlled by intake manifold prevent backfire in the exhaust system at the initial
vacuum to

hoses and Fig EC 56 Sectional View of

Exhaust Port

vacuum

tube
can

The
out

A B

valve

then be taken
reverse se

Installation is in the

period ofdeceleration At this period the ignite

and burn

mixture in the
to

quence of removal

intake manifold becomes too rich

in the

combustion
ex

chamber and burns easily in the haust system with exhaust manifold
The anti backfire valve to the intake manifold

injected

air in the

REMOVAL AND

INSTALLATION
air

provides

to

make the

Air Induction valve and filter Remove the

screws

air fuel mixture leaner backfire

and prevents

valve and filter to the air cleaner

securing the body

EC152A

If the valve does not work

properly
emitted

The air induction valve and valve filter then be taken out easily Installa tion is in the reverse sequence of
can

unburned from the

ntixture

will

be

combustion chambers and

Fig EC 59 Removing A B

Valve

burns with the aid of high temperature and injected air which causes backfrre

removal

INSPECTION Preliminary Inspection

To intake

Check hose for looseness

manifold
vacuum

flatting
and If

damage
necessary

or

faulty

connections

each part for proper installation

replace
and filter

To intake manifold From air cleaner

EC069 EC922

Air Induction valve

I

Disconnect air induction hose at

air induction

pipe side Suck

sure

or

blow

Fig EC 55 Anti backfire Value

Fig EC 57 Removing Air Induction Valve and Filter

hose to make
on

that air flows only

the air induction pipe side

EC 19

Emission Control

System
and
3

place aflriger near

tneoutlet

Run engine at about 3 000 rpm under no load then quickly return it
to

idling
on

If you feel a

pull

or

suction

force

your

finger

the

J ackfire anti

valve is functioning
suction is felt

normally If no replace the anti backfire

valve

EC924

Fig EC 60 Checking Air Induction

Valve

1
2

Air induction valve filter Air induction valve

EC925

Fig EC 6I
2

Checking Air Induction

Valve and Filter

Check air induction

valve reed
At the

valve for
same

binding

or

damage

time

plugging

check filter for damage or If necessary replace Filter

Anti backfire valve

I Warm up

AB

alve

eC76S

should be replaced

periodically

in

ac

engine thoroughly

Fig EC 62 Checking Anti bock ire

Valve

cordance with Maintenance Schedule

Disconnect hose from air cleaner

EC 20

Emission Control

System
from
E G R passage trolled valve is valve the

EXHAUST GAS RECIRCULATION E G R CONTROL SYSTEM

DESCRIPTION
In

to lower the

spark flame temperature during combustion This results in a reduction of the nitrogen oxide NOx
content in the exhaust gas When the E G R control open
some

exhaust

manifold

to

the

chamber through the E G R

The exhaust gas is then in
con

quantity

by the

E G R

and is introduced into the intake

of the exhaust gas is led

manifold

the
a

exhaust gas recirculation part of the exhaust gas is the combustion chamber

system returned

to

U S A models

Thermal vacuum valve port 3 type T V V

r
i
From carburetor

EC309A 1 E GR E

Thermal thermal
vacuum

valve

6
7

Exhaust manifold E G R tube Orifice B P T tube B P T valve

port 2

vacuum valve type T V V for FU model

E GR

tube

2 3 4 5

G R control valve

Carburetor

8
9 10

R passage Intake manifold

E G

Canada models

CD
o

EG R

control valve

Thermal
2

vacuum valve port type T V v

E G R tube

1 2

Thermal
E

vacuum

valve

5 6
7

Intake manifold Exhaust manifold E G R tube

EC155A

C R control valve

3
4

Carburetor
E C R passage

Fig EC 63 E G R System
EC 21

Emission Control ATloN

The

System

operation of the

E G R system is as follows

U S A models

Except FU

model

Water temperature Oc OF

Thermal
vacuum

P T valve B Exhaust pressure mmH20 inH20 Exhaust pressure Below 21 to 33 0 82 to 1 30 Above 21 to 33 0 82 E G R system

valve

Below SO to 63

I22 to

145

Open

Open
Closed

Not actuated

to

30 1

Aliove SO
to

63 I 22 to 145

Closed

Exhaust pressure Below 21 to 33 0 82 to 1 30 Above 21 to 33 0 82 to 130

Open
Closed

Not actuated

Actuated

FU model

Water temperature Oc

Thermal
vacuum

B P T valve

valve

Exhaust pressure

mmH20 inH2O
Open

E G R system

Below 40 to 63 104 to 145 Closed

Below 21 to 33 0 82 to 1 30 Above 2 to 33 82 0
to 1 30

Not actuated Closed

Above 40 to 63 104 to 145

Below 21 to 33 0 82 to 1 30

Open
Closed

Not actuated

Open
Above 21 to 33 0 82 to 1 30 Actuated

Canada models

Water temperature Oc Below 40 to 63

OF
145

Thermal

vacuum

valve

R system

I04 to I04 to

Closed

Not actuated

Above 40 to 63

145

Open

Actuated

E G R control valve The E G R control valve controls the quantity of exhaust gas to be led to the intake manifold through vertical
movement
vacuum

is

applied
the

in response to the

and

car

destination For identification

opening
valve EG R

of

carburetor throttle

purposes the part number is stamped on the recessed portion at the top of the valve

of the the

taper valve

con

control

valve construction

nected

to

diaphragm

to which

and type vary with transmission type EC22

Emission Control
Thermal
vacuum

System
To E

valve

G R Vacuum
nal
Curce

1l

I
I

3 port type U S A models except FU

control valve

model

Air bleed

1J

The 3 port type thermal vacuum valve is located on the rear end of the

cylinder
It ture

head

defects engine coolant tempera

by

means

of

wax

expansion

and Exhaust pressure

EC310A

closes the air passage from the air cleaner

opens or When the air passage is closed the vacuum signal is applied to

Fig EC 67 B P T Value

carburetor
1

2 3
4

Diaphragm spring Diapliragm

Valve shaft
Valve ValVe seat

the diaphragm of the E G R control valve to actuate the taper valve con nected also
co to

REMOVAL AND INSTALLATION

the

diaphragm
as a

This valve is

5 6

used

component for the

E G R
I

control valve
vacuum

Valve chamber
EC231

Spark Timing

Control

System

Disconnect
nuts E G R

hose and

re

move

securing

E G R

control

valve to

passage

The E G R

Fig EC 64 E G R Control Value

JiI2

To air cleaner From B P T

valve

control valve can then be taken out

Thermal

vacuum

valve

From distributor

2 port type FU and Canada models

The 2 port is

type thermal
on

vacuum

valve

mounted

the

thermostat

housing

It detects

engine engine
of
a

EC156A

built in bi metal the

vacuum vacuum valve

coolant temperature by means and opens or closes

Fig EC 66 Thermal Vacuum Valve 3 port type Fig EC 68 Remouing E G R

Control Valve

the thermal passage in is open is

When the vacuum the carburetor vacuum to the

passage

signal applied diaphragm of the E G R con trol valve to actuate the taper valve connected to the diaphragm

CAUTION

B P T valve
The B P T pressure to

Pay attention packing of E G

valve monitors exhaust

not to

give damage

to

R control valve

activate intake

the diaphragm
vacuum

Installation

is in the reverse se

controlling

manifold

quence of removal

applied

to the E G R control vaNe In

other words the amount of recirculat ed exhaust gas vari s with the

Note

position of the E G R valve regulated by the operating condition of the engine

installing new E G R control valve confirm that the model num

ber and identification marks at the

In

top of valve

are

as

follows

1 2

Spring
Bi metal O ring
EC232

Fig EC 65 Thermal Vacuum Valve

2 port type

EC 23

Emission
E GR
I passage arid taibe tube
can

Corltr ol System
one

Drain engine coolant about Remove US qt Imp qt manifold nut

2 port type

E G R

be removed

by

liter I
2

loosening securing
2

nuts

securing

Disconnect blow by gas hose and remove securing bolts and nuts E G R
passage 3
can

heat shield

plate

then be taken out

reverse se

Installation is in the

quence of removal

port 3

type

LIkat shield plate

EC170A

Fig

EC 70

Removing

Heat Shield Plate

EC158A

Fig

S9 EC

Removing E G R Passage Fig EC 71 Removing Thermal 3 Disconnect

unscrew two vacuum

hoses B P T valve
I

Vacuum Valve

Note

New

gasket

should be used in

and
4

the
can

thermal

vacuum

installing

E G R passage

valve The valve

then be taken out

reverse
se

Installation is in the

Remove P T valve B

vacuum

tube

on

the

quence ofremoval
2

Remove

screws

securing

PT B

Note
a

valve to bracket
sure

Be

to

apply
prior

sealer to threads of
to

3 from

Disconnect P T valve B

back

the valve wive b When

pressure tube then be taken

installing
thermal

new

The

P T valve B

can

installing
make

new

vacu

out

um wive

sure

it is black

Thermal

vacuum

valve valve is made

pay attention

The thermal of plastic

not to

vacuum

Consequently
it

give damage to
s A U

On

models except for the

J Tightening torque t
Thermal
vacuum

FU model
vacuum

the 3 port type thermal valve is located on the rear

valve

Less than

end of the

cylinder head
and
on

2 mode the Manifold

m 16 ft kg
nut

On

Canada

FU

valve is located

the front end of the

5 to 2 0 1

kg m Fig
EC 72

cylinder head

EC770

11 to 14 ft b

Removing

B P T S curing Screws

Installation is in the

reverse se

quence of removal

Note

In

replacing
new one on

the
h

PT B that

valve the

with

type number
same 85

new

part is the
one

that

on

former

EC 24

Emission Control
INSPECTION Entire system
I

System
E G R control valve
Dismount E G R

Make sure that E G R control valve

Make

thorough vjsual
system

check of

engine speed is in creased from idling to 3 000 to 3 500 rpm Place fingers on the diaphragm of operates
when
E G R control valve to check for valve

control

valve

from engine
I

Apply

vacuum

to E G R control

E G R

control

If necessary

valve

referring

to the

following figure
it is

wipe

away oil to facilitate

are

inspection
or

operation
If E G R control operate check
as

If the valve
valve does not

moves

to full position

If any hoses

cracked

broken

normal
E G R

replace
2

follows end E G R control

valve to E G R

control

valve will remain

With

engine
or

stopped

inspect

Disconnect

one

E G R control valve for any indication

valve side of vacuum hose connect

open for more than 30 seconds after

vacuum

of binding

sticking by moving dia of control valve upwards with phragm

a

ing ihermal
Increase

has cut off

vacuum

control valve

finger
With

engine speed
3 500 rpm that

from

idling to
vacuum

engine

running

inspect

3 000 Make valve

to

E G R control valve and thermal vacu

um valve

sure

thermal
2

for normal operation When engine coolant tempera

sure

tun is low

or port type closed 3 port type and that car buretor vacuum is present at the

is

open

Make

that E G R control valve

end

E G R hose

control valve side

of

does not operate when

engine speed
to

is to

vacuum

5t
Fig EC 75

rl 1
Checking

orr
1
EC129A

E GR

Control Valve

increased
3 500 rpm

from

idling
on

3 000

If vacuum is weak
all

or

not

present

at

Place
E G R

finger

the diaphragm of

replace thermal vacuum valve If vacuum is present check E G R

control valve
or

control valve to check for valve

B P T valve

Visually

check

EG R
or

control deforma of

operation

If any difficulty is encountered in judging the condition of any com

wive for damage wrinkle

tion 3

ponent during above inspection check in the questionable component dependently as follows
U S A models

Clean

the

seating
a

surface

E G R

control valve with air and

brush and

compressed
matter

remove

foreign
and

from

around the

valve

port

Ie
EC773

Fig EC 73 Checking E G R Control

When

engine coolant tempera

EC160A

tureishigh
Fig EC 76 Cleoning E G R Control Canada models
Valve

Thermal

vacuum

valve

3 port type Remove thermal

vacuum

valve from R G that

engine Inhale
system thermal and

air from

port ofE
be
sure or

check

to

vacuum

valve opens

closes

in response to its

temperature dosing 630 C

Thermal vacuum valve

ET429

temperature Fig EC 74 Checking Vacuum of

E G R Control Valve Above 50 to 122 to

1450 F

EC 25

Emission Control

System
BoP T valve
1

CAUTION thermal
Do not allow water to get inside the vacuum valve

mal vacuum valve opens or closes in response ture as

engine coolant tempera specified

to vacuum

DiSCOIUlect two

vacuum

hoses

on

Thermal
at a

BY T valve 2 valve

valve should open

com

temperature specified below pleting the vacuum passage

Thermal vacuum valve

Plug
Apply

one

of two port

of BY T

opening
to

197 valve
valve

inHP
as

pressure above SO to B P T valve

nimH20
and
T

temperature
40 to

orally suck back other port of B P 63c 104

1450 Fl shown below to If
a

check for

leakage
CAUTION 00 not allow water to get inside the thermal1acuum valve

leak is noted

replace

EC161A

Fig EC 77 Ch

jng Th rmal Vacuum

Valve 3 port type g

Apply

pressure above SO mmH10 2 inH10

Jl
J

EC311A

Thermal

Fig EC 79 Checking B P T Valve

vacuum

valve

2 port type
Dismount from engine
Note

thermal

vacuum

valve

Before
oolant c

gine

dismounting from engine

drain

en eC
42

Apply

vacuum

to thermal vacuum
sure

valve and check to be

Fig EC 78 Ch ckjng Thermal Vacuum

Valve

that ther

SPARK TIMING

M T model

CONTflOL
DESCRIPTION

VI SYSTE

When

the

transmission

is shifted the electric

opened This weakens the vacuum signaUransmitted from the carburetor

As
a

into the 4th or 5th gear

result the ignition timing of the

current flows into the vacuum switch

distributor is On
3

slightly advanced
models except for the thermal vacuum valve is added
on

The spark timing control system is designed to control the distributor

vacuum

ing valve The

vacuum

switching

valve

sA U
a

is then actuated and close the vacuum

FU model

advance under varying

so as

driving

conditions

to

reduce He and

passage As a res li the distributor fully advances its ignition liming When the
transmission is shifted into any gear other than 4th and 5th current flow is

port type

the

vacuum

line between the carburetor and dis tributor The

vacuum

NOx emissions

signal

is controlled

by

interrupted
leak

The

vacu

this thermal
ance

vacuum

valve in accord

umswitclting
and the

valve is then deactuated passage

is

with variation in engine cooling

vacuum

water

temperature

E026

Emission Control
M T models For U S A models except FU model

System

Distributor
r

Water temperature OC OF

Transmission
ear

Thermal

position

Spark

timing

vacuwn valve

To B P T valve

Below HIGH
vacuum valve

Top 4th and

5111

Fully advanced Closed

5 to 18 41 to 64

Other than

Partially
advanced

Top
OrifiCO
Between 5 to

i
Vacuum switching valve
I

18 and 50 t063 41 to 64 and 122 to 145

jarburetor
l
Ignition switch
Battery Fuse

Above 50 to 63 122 to 145

I I I

Top
4th and 5th Other than

Partially
advanced

I
I I

Open

Partially
ad

Top
Top 4th and 5th Other than

ced

Fully
advanced

Closed

I
California Non

Partially
advanced

Top

To air

cleaner

models only

Top

switch

4th 5th

ON OFF

Others

EC162A

Canada and FU models

OM

cuum

switching valve

To air

cleaner

F
To intake

1orifJCMbur ico etor

1
manifold FU models only Fuse

Ignition switch
Transmission gear

Vacuwn

EJ

Top switch
4th 5th Others
ON

OFF

G1j
7

position

Ignition timing

switching
valve

Battery

Top

4th and 5th

Fully advanced Partially advanced

Closed

Other than

Top

Open

EC371A

Fig EC BO Spork Timing Control Sy EC 27

tem

MIT

Emission Control AfT

models The
vacuum

System
iJve and v 3 port Canada
3

switching
valve

the

thermal

vaCUUDl

lve Vl

Spark timing control systems on Arc models are divided into 3 types On California models a top detect ing switch
i3 added on the line pressure circuit beside

thermal
control

vacuum

the spark advance engine cooling temperature and position On California non models

type by the
gear

port type and vacuum delay valve control the spark advance
On Canada models the
vacuum

the transmission

case

excpt

valve is installed midway on the vacuum passage from the carburetor

delay
to

the distributor

AfT models

Califomle models
Distributor

To B P valve

T Water temperature OC oF
Transmission gear

Thermal

position
and

Ignition timing FuBy

advanced

vacuum

va1ve

R Orifice
D

Bdow 51018 41 to 64 Other than Rnand

D

1
To air

i1J
1
ICh

Oosed

Partially
advanced

3 a g d 3

R Between
5 to 18 D

and 50 10 63 411064 and

Partially
Other than R
0 3 and

advanced

Open

12210145

cleaner

Fu

EJ

Top 5witch D3 R
Others
4

OJ
LJ
Battery

R
D

aud 3

Fully
advanced Oosed

Above 50

to

63 Other than R m3 and

ON
OFF

122

to

145

Partially
advanced

californla Non

models except Canada

Distributor

Canada models
Distributor Vacuum delay valve

Toair cleaner

Thermal
o0

l
o

Vacuum delay valve

Ig
00

vacuum

valve

00 00

r
Carburetor Carburetor

Water temperature OC OF Below 5 10 18 41 io 64 Between 5 to IB and 50 to 63 411064 and 122 10 145 Above 50 to 63 122 to 145

Thennal

Ignition timing Fully advanced

vacuum

J l

l
EC163A

valve Oosed

PartiaDy advanced

Open

Fully advanced

Oosed

Fig

81 EC

Spark Timing Control Sy

tem

Af1J

EC2a

Emission Control
Vacuumswltching valve The
vacuum

System
In line orifice Some orifices
are

changes
valve

the continuity between two

switching

lead wires

installed in the
line The size

changes
electrical

the

vacuum

passage by the

midway

at

the

vacuum

signa

The solenoid installed in the valve moves the needle valve and controls
vacuum vacuum

of the orifice is important to control vacuum advance Therefore pay attention not to lose
them and install
a

signal

in order to

change

the

proper part when

advance

replacing

Orifice

I c

III
J
J

EC165A

Fig EC 84 Top Detecting Switch

jll IL

Top detecting switch For Celifornla AfT model

The top detecting switch for Arr models is installed as a plug for t e

EC164A

Fig EC 82 Vacuum Switching Valve

governor feed line pressure take out port for service This switch detects the line pressure for the band
servo

EC167A

Fig EC 87 In line Orifice

Thermal

vacuum

valve

release side and REMOVAL AND INSTALLATION Vacuum switching valve

The
vacuum
on

3 port type U S A modele except FU model

The thermal vacuum valve detects

front clutch and changes the continui ty between lead wires to the switch

body switching
valve is

engine cooling
controls the

water

vacuum

temperature and signal for distrib

vacuum

located
f

the

rear

end of the intake

of

utor vacuum advance mechanism

manifold
I Disconnect
a

This 3 port type thermal valve is a 2 stage action type when the water temperature is
or

pair

lead wires

That
too

is

from valve and two rubber tubes 2

valve
EC166A

low

Loosen

two screws

securing valve

high the

acuum

signal

is transmit

to intake manifold
can

ted to the distributor

To air cleaner From B PT
valve

Vacuum switching then be taken out

is in the
reverse s

Installation

ffi2

Fig EC 85 Top Detecting Switch

AfT model

quence

of removal

Vacuum delay valve

The
vacuum

From distributor

rapid

vacuum

delay valve prevents a change in the distributor

line
way

vacuum

advance
one

This valve is

designed for
and
EC156A
a

operation and

consists of a one way umbrella valve

sintered steel fluidic restrictor

Fig EC 83 Thermal Vacuum Valve 3 port type

P T valve side

J
EC16BA

Top detecting switch

For M T models The top detecting switch for M T on the side face of

l
1

Fig EC 88 Removing Vacuum Switching Valve

models is located
A

Sintered metric disc

One way

the transmission gear box

unbreUa valve
EC860

Top detecting switch For M T models

The top detecting switch is located the side face of the transmission

plunger
of

of the switch detects the the

position

striking

rod

and

Fig EC 86

Vacuum Delay Value

on

EC 29

Emission Control
gear box I 2

System
J T1g11taning torqUe t
Thermal
cuum

dl r

ingtorq
switch 2 0 to 3 0

pair of lead wires Unscrew the switch body itself

Disconnect a

Top detecting

waive

kllm

Less than 2

The switch
3

can

then be taken out

reverse se

14 to 22 ft bl

kllm

16 ft bl

Installation is in the

Manifold nut

quence of removal

Thermal

vacuum

valve

1 5 to 2

m 0kg

dl Tightening torque Top cietectingswitch

2 0 to 3 0

3 port type The thermal

led
on vacuum

11 to 14 ft bl

valve is instal the engine

one

kllm

the

rear

end of

14 to 22 fHbl

cylinder head I Drain engine coolant about

liter

lUllS qt Ulmp qt
Remove manifold nut

securing
From

From distributor
PT B

heat shield

plate

valve

From air cleaner

r
EC892

Fig

89 EC

Remouing Top Detecting

Switch
EC170A

Top detecting switch For AfT models

The top detecting switch is installed the side face of the gear box Disconnect
a

Fig EC 91 Remouing Hoot Shield

Pwte
ECl71A

Disconnect 3

vacuum

hoses and

Fig EC 92

mtalling Thermal Vacuum

Value 3 port type

on

unscrew

valve itself Valve can then be

lead wire for top

taken out
4 the Install thermal
reverse vacuum

switch 2 Loosen switch itself Switch

can

valve in

Vacl ul11 delay

The
on vacuum

valVe
is installed

sequence of removal At

delay Valve
o

then be taken out

this time the valve should be tighten ed to a tilt angle of 300

ed remo

the

midway

the

vacuum

tube

between the carburetor and distributor

vacuum

Note

When the switch is

advance mechanism make

sure

automatic transmission fluid flows out

Note

Be

sure o

to

threads
some

the valve

apply prior

oealer

to

In installing the valve that the brown face

to the carburetor side

to instal

sid

is connected

Prepare

rugs to prevent the

ling

new

valve

fluid rom flowing out

Carburetor sid Distributor

side r

C J
EC169A

Fig EC 90 Remouing Top Detecting

Switch An models

way One

umbreDa valve

Sintered metal disc

Insta

tion

is in the

reverse se

EC277

quence of removal

Fig EC 93 In tolling Vacuum Deloy Value EG 30

Emission Control
2

System
hoses
are

INSPECTION Entire system U S A MIT models

Ensure

that

vacuum to

properly connected
3

their

positions
vacuum

The entire system except for the top switch is properly functioning if

Ensure

that

distributor
ctions

controller 4

except FU
1

mo

el
connectors are

properly fu Set timing light

spark timing does not change If it changes check the thermal vacuum
valve

pori type

Ensure that in

wiring

tight
2

pla ce
that vacuum hoses
are

Ensure

WARNING To

properly
3

1o cof

ed

to

their positions
vacuum

protect against

CAUTION accidental for

Ensure

that distributor

controller properly functions

4

ward surge engage parking brake firmly while above check is being made

Pay
the

attention

not

to

make

short

circuit between other terminals than

specified

terminals get

or

electrical

Set timing light and start engine While engine cooling water tem

system of

car will

damaged

pefature is below SOOC I220F check function of system as follows

WARNING To protect ward surge

engine and keep it at ap proximately 1 600 1 m 6 Disengage clutch Shift gears in 4th 5th ihen neutral positions Read spark timing in respective shift posi
tions The system is properly functioning if spark timing advances in top gear

Run

against

accidental for brake

firmly
made

engage parking while above check is

being

position If spark timing does I proximately 1 600 rpm 2 Disengage clutch Shift
Run

not

vary at all

engine and keep it at ap

gears in

in

tests

des

rilied

in

step 6 above
or vacuum

check

control

circuit

switching valve

top 3rd then neutral positions Read spark timing in respective shift posi
tions The system is

4
EC328A

properly functioning
vacuum

Fig EC Entire system California AIT models

I

94

Making Short Circuit

if spark
valve 3

timir does not change g

If t changes check thefmal

port type
that thermal
vacuum

Ensure th
in

wiring connectors are

vacuum to

After
up

ihe

tight
Note

place
that
that hoses
are

warmed

engine sufficiently

has check

been the

Ensure

Ensure Ensure
Set

function of the system again in the

same

wIve is closed when i below 5 to

above SO to
I

cooling water lSoC 41 to 640F or 630C 122 to 14S0F

has check
been

properly
3 controller 4

coIDwcted
function s

thejr

positions
vacuum

manner

distributor

The
switch is

system
is

except lctioning fU

for

the

properly

properly

top if spark

After
up

the

warmed

engine sufficiently
I

the

function of Same
manner

the

system again in the

timing light and staft engine S While engine cooling water tem 1220F is below SOOC perature check the function of the system as
follows

timing

approximately

greater than
vacuum

that without a short circuit If not

check the thermal

or

valve control circuit

vacuum

switch

The
if
tion

ing valve
7 As the

system is properly functioning spark iimin advances in top posi WARNING check thefmal vacuum valve circuit or
vaeuum

final step of checking

system top switch should be checked as follows

entire

If not control

To

protect

againSt

accidental for

1
speed
2
um

Start engine and keep at idling Disconnect lead wires from

switching

valve

ward surge engage parking brake firmly while above check is being made

vacu

switching valve at connetors

Entire system FU model and Canada

I

MIl

models

Run engine and keep it proximately 1 600 rpm at P

at

ap

range

CAUTION Never

Make

short circuit between the terminals at function

Ensure that
in

forget

this

lg wiri

connectors are

specified
te t

two

tight

place

the circuit tester will get

operation otherwise damaged

connector

EC31

Emission Control
Entire

System
timing amttol
sure

system

systetn

andcheck to

Non California AfT models

except Canada
1

that thermal vacuum valve opens or closes in response to its tempera

ture are

Ensure

that

vacuum

hoses

properly connected to their positions And confirm that gearshift lever is in P position
2
3

Thermal vacuum walye closing

temperature
Above 50 to

63 c

Disconnect

vacuum

hose atdis
is be

122 to 1450 F
Below 5 to 41 to 64

tributor vacuum controller

While engine cooling wat

1SoC Fl

low SOoC
EC173A

1220F

race

engine and
valve

check
um

vacuum

for distributor If vacu

vacuum

Fig EC 95 Disconnecting Vacuum Switching Valve Connector

is felt

check thermal
is

3 4

port type

After
up

engine

sufficiently

warmed tion 3

repeat the above opera

vacuum

Apply parking

brake and keep

In this case

should be felt valve

brake pedal fully depressed Check continuity between two specified terminals ai function test
connector with
or

Ifnot check thermal

vacuum

Vacuu m switching
If

valve

gearshift

lever in

position

spark timing does not vary at all in checking entire system check vacu
um

The top detecting switch is func tioning properly if the continuity is as

switching valve i follows

Warm up engine sufficiently Disconnect vacuum switching
EC161A

I 2

following

table

If not replace the switch

valve lead wires 3

Set timing

light

and

keep engine

Fig EC 98 Checking Thermal

Vacuum Valv

position position

No

at approximately 1 600 rpm On AfT models geaishiftlever should be

speed
in R

or

P
to

Yes

4
one

Apply l2V battery voltage

of two lead wires from valve Then
connect

CAUTION
Do not allow water to get inside the thenna vacuum valve

vacuum

switching
Note At

the

idling

other lead wire to ground

spark timing change appioximately by 50

CAUTION
Never
race

At this time

should

Top detecting switch

M T models

If it the engine
or car will

does

not

replace

vacuum

creep

switching valve

To

check top

detecting

switch for

proper ON OFF operation contact leads of an ohmmeter with swiich lead wires TOP
versa

and

shift

transmiosion

from

to other forward gear and vice

If switch does not operate prop of top

erly replace Continuity

detecting

switch

should be a follows

EC175A

Other than 4th and 5th

4th and 5th No

Fig EC 97 Checking Vacuum

Switching

Valv

q
EC329A

Yes

Thermal

vacuum

valve Note In

3 port type

U s A models

except FU engine

model
vacuum

switch valve from OFF will get

checking continuity oCthe keep the ignition switch

Otherwise the circuit tester

Fig EC 96 Checking Top Detecting Switch Arr model

Remove thermal

Inhale air from port of spark EC32

damaged

Emission
4

Control Syst m He
and

If the condition of spark delay

carbon

monoxide

in

valve is

questionable dip port

face side

into a

cup filled with water

Blow air from

the exhaust gas and changes them into non harmful carbon dioxide and water
tiOD

In

brown

Small air bubbles

H20

This chemical
the

C02

reac

should appear CAUTION Be

c

mount of air air pump to avoid

process requires proper a which is supplied by the Refer to the item AJ S

areful

entry of oil

or

dirt

This air is called The

0

secondary air
converter is mounted

into valve

Catalytic

the models

destinbd

for California

OPERATION
Exhaust gas emitted from the
en

gine
due

contains some harmful substances

to

incomplete combustion

in the

combustion chamber The air injection stem i designed to reduce the con
tent of such substances in the exhaust 1 2 3 4

Ignition switch
Vacuum switching v3 lve Top detecting switch Function check connector
EC330A i

gas

In this system the

secondary

air is

led from the ch ck valve and injected

in
o

the

exhaust manifold

With this

7
E
C279

Fig EC 99 Checking Top Detecting

l

injection of the secondary air hydro carbons He and carbon monoxide

CO
in the exhaust gas are

Switch

Fig EC 101

Checking Vacuum
D lDy Valve

gradually
in the

oxidized

with

oxygen

02

secondary
Vacuum valve dela

air and converted into nOD

harmful carbon

dioxide

C02

and

Remove vacUum
2

delay
th

valve

CATALYTIC CONVERTER California

DESCRIPTION
1 The the

water The

HP
catalytic
converter gas

further

Blow air from

distributor side valve is in

3

port of the The vacuum delay

if the air

cleans engine

exhaust

Through

dels

go

ij condition

catalytic action it changes residual hydrocarbons and carbon monoxide

contained in exhaust gas into carbon dioxide and water before exhaust gas
is

flows through

Try

the valve again from the

Th
a

opposit side

of the

valve

valve is in

goo

catalytic converter accelerates chemical reaction of hydrocarbons

discharged

to the

atmosphere
air

condition if th

flow resistance is

0 Secondary

greater than the step 2 abov

Carbon monoxide

hydrocarbon
Distributor side Carburetor side
Carbon dioxide gas Nater

EC

CD
Distribu tor side Carburetor side

I EC346 2 3 4

Front tube

Catalytic converter
Center tube Main

Fig EC 100 Checking Vocuum Dewy Valve

EC215

murner

Fig EC I02 Function of Catalytic Converter EC 33

Control

System
Catalytic converter
Whether

REMOVAL AND
INSTALLATION
I

catalytic
can
e

converter is nor

Jack up the

car

mal

or

not

checked by ob

Note

Apply parking
chocks 2 Remove

brake and place wheel

CO percentage serving The checking procedure is as follows Apply parking brake Shift gears

variation

in

screws

securing

lower

shelter of catalytic converter Loosen

flange

bolt

connecting
and rear

catalytic

converter to front

exhaust tube

Catalytic
then be taken
3

converter
out

assembly

can

Installation i

in the reverse se

quence of removal

CAUTION a Be careful not

co

to

damage catalytic
with water oil

when handliilg

b Never wet etc

catalyzer

J Tightening torque t
Catalyti
converter bolts 2 6 to 3 4

kg
lb ft

19 to 25

INSPECTION PrelimInary
Vi ually component
In pectlon

Emison

into sion

Neutral and N

for manual transmis

transmission

I CO

or P for automatic position Adjust engine idling speed and

percentage Refer
Idle RPM Race engine
or

to and

Adjusting
Mixture

Carburetor

Ratio for adjustment 2

EC075A

1 500 to 2 000 rpm

no

two

three times under

load and

make sure that age 3

specified

CO percent

obtained Remove cap and connect air hose

to air check valve

it

If idling speed increases to specified speed with

screw

readjust
throttle

adjusting
4

minutes at 2 000 S
EC076A

Warm up engine for about four pm under no load Measure After

Cipercentage

at

idling

Fig EC 103 Removing Catalytic

Converter

speed stepAhas been complet ed wait for one minute before making
CO percentage measurement 6 If CO percentage measured
in

step 5 is less than 0 3 converter is normaL

7

the catalytic measured

1

If CO

percentage
3 0

in

step 5 is

over

recheck AJ S and The perform

replace
of all

air check valVe

check

condition

parts including hose wires tubes and replace if necessary Refer to Air Injection System for inspection

inspection steps 4 and S 8 If CO percentage is still over 0 3 in step 7 catalyt iC converter i mal functioning Replace catalytic con
verter

EC34

Emission Control System

EvApORATIVE
DESCRIPTION
The

EMISSION CONTROL SYSTEM

2
3 4
I

evaporative

emission

control

carbons is accomplished by activated charcoals in the I canister C bon This system is made up of the
I

Fuel check valve

Vapor

vent line

Carbon canister Vacuum

system is used to reduce hydrocarbons emitted to the atmosphere from the fuel system This reduction of hydro

foUo
I

ing
Fuel
tank with

ignalline

positive sealing

Canister purge line

filler cap

tank Fuel

Fuel filler cap with vacuum

relief valve Fuel

3
4 5

check valve
vent line

Vapor

Canister purge line

6 7

Vacuum signal line

Carbon canister

EC327

Fig EC 104 Evaporative Emission Control System for

n Sed

EC 35

Emission Control

System
opens
and
car

OPERATION
tank The Fuel vapors from the sealed fuel are led into the carbon canister
canister is filled

As the throttle Valve

INSPECTION
FUEL TANK AND VAPOR
1

speed
the

increases

vacuum

pressure in the purge

an

vacuum

signajline forces

control valve to open

and admits

VENT LINE hoses and fuel tank

with activated

orifice
vapor is

to

intake manifold and fuel

charcoals to

absorb the fuel vapors

or

then drawn into the intake

purge

Check all

when the engine is at rest

at

idling

manifold through the canister line

filler cap
2

Disconnect the vapor vent line connecting carbon canister to check valve 3 Connect
a

3w y
a

connector
or an

manometer and

cock

equi

valent 3 way charge cock ofthe vent line

to the end

Fuel vapor

Fuel tank Fuel filler cap with vacuum re1ief va1ve Fuel check vslve

Throttle valve

IZ 13
14

Filter

8 9 10 II

Engine
Carbon

cani5t

3 4 5 6

Activated carbon Screen

IS 16

Purge control valve DiaphraP spring Diaphngm

Fixed orifice
EC183A EC785

Vapor

t line

Vacuum signal line Canister purge line

Fig EC IOB Vent Line

Fig EC JOS Evaporative Emiuion Control System Fuel vapor flow when ngine is at rest or running

REMOVAL AND

CHECK VALVE The check valve is located behind the

vent

Supply fresh air into the vapor line through the cock little by
until pressure becomes 368

INSTALLAtiON
CARBON CANISTER FILTER
Check for Elemenl
a

little S

luggage
fuel tank

compartment board

on

the

mmHZO
Shut 6
7

5 14
the

inHZO
cock

completely
measure

and the

contantinated element be removed at the installed

on car

Remove the luggage compartment board and disconnect the vapor tube The check valve can then be taken
out

leave it unattended After 5 minutes 2

in the manometer remain

can

bottom of canister

height of the liquid

Variation in with 25 8

body

height should
0 98

mmHZO

inH20

When filler cap does not close completely the height should drop to
zero

in a short time

9
zero

If the height does not drop to in a short time when ruler cap is d it
is the cause of a

stuffy

hose

Note

EF201

case the vent line is stuffy breathing in fuel tank is not thoroughly IIIIIde thus causing in sufficient delivery of feul to engine

In

the

Fig

EC I06 Replacing Carbon Canilttr Filter

EC315A

or

It must vapor lock

or

therefore be

Fig

EC I07 Removing Check Volve

repaired

replaced

36 EC

Emission Control

System
3 leak remove top control valve and purge check for dislocated or cracked dia
a cover

If there is from

3 way connector

400 mmH20

15 75 inH20

phragm

If kit

necessary

replace

dia
a

phragrrt
ck

which

is made

up of

retainer Check valve

diaphragm and spring

Air

Manometer

i
Fuel filler cap

Carbon canister

r
CONTROL VALVE
connector on

ii
1 Cover 2

EC091A

Fig EC I09 Checking Evaporative Emiuion Control Syatem

Diaphragm
Retainer

3
4

Diaphragm spring
ET350

FUEL CHECK VALVE

CARBON CANISTER PURGE Fig EC

112

Carbon Canister Purge Control Valve

Blow

air

through

fuel tank side

A considerable resistance should be

Check for fuel vapor leakage in the distributor vacuum line at diaphragm of carbon canister purge control valve To check for leakage proceed as follows
I

felt at the mouth and a portion of air flow be directed toward the engine 2
Blow air

FUEL TANK VACUUM

in the

through

connector on

Disconnect rubber hose

RELIEF VALVE
Remove fuel filler cap

engine side
Air flow should be

line between T connector and carbon

and

see

it

smoothly direct

canister at T connector
2

functions

properly

ed toward fuel tank 3

I not

Inhale air

into the

opening of
hole in that there

Wipe clean valve housing and have

Inhale air
A

If fuel check valve is suspected of being properly functioning in steps and 2 above replace

rubber hose running to carbon canister and

is no leak

vacuum

it in your mouth 2

ensure

slight

resistance ac

companied

by

valve

indicates

that

valve is in good mechanical condition Note also that by further inhaling air the resistance should be with valve clicks 3
ance

disappeared

If valve is
is felt

clogged or if no resist replace cap as an assem

bled unit Engine side

Fuel

tank

side

Evaporative fuel flow

Fresh air flow
EC090A ET349

O
ET500

Fig EC 110 Checking Fuel Check Valve

Fig

EC

lll

Checking Carbon Canister Purge Control Valve

Fig

EC 1l3

Fuel Filler Cap

EC37

Emission Control

System

SERVICE DATA AND SPECIRCATIONS

INSPECTION AND ADJUSTMENT
AIR PUMP
Air pressure

With engine speed at 2 600 pm E G R SYSTEM

vacuum valve

mrriHg inHg

More than 100 3 94

Thermal

opening temperature

US

A models except FU FU and Canada models

model

Oc OF oCF

SO to 63 40 to 63

122 to 145

104

to 145

T C S

SYSTEM
vacuum

Thermal

valve

Except

Canada and FU models

Closing temperature Opening temperature

oC

Above SO

to

63 122 to 145
41 to 64

Below 5 to 18 OC F

5 to 18 and SO to 63 41 to 64 and 122 to 145

TIGHTENING
Air pump

TORQUE
kg
m m m m

Bea ring
End

cover

securing bolt

ft4b ft lb ft Ib ft b ft lb ft Ib ft ft lb Ib

1 0 05

to to

0 2 0 7 to 1 4 0 7 3 6 to 5 1 to
1 5

Rotor ring
cover

screw

kg
kg kg kg
sere

bolt

0 7 to 09

5 6

Pulley
Thermal BP T valve

securing bolt
valVe

0 75 to 0 90 5 4 to 6 5

vacuum

Less than 2 2 16 0 38 to 0 51
2 0 to 3

mounting

kg
kg kg

2 7

to

3 7

Top detecting switch Catalytic

converter bolt

14 0
4 3

to 22
to

2 6

to

19

25

38 EC

Emission Control System

SPECIAL SERVICE TOOLS

Kent

Moore No

Kent Moore No Reference

name page
or

Tool number

tool name

Reference page
or

Tool number

tool

Fig No STl98l0000

Fig

No

Hexagon wrench Fig EC 31 42 EC Fig

STl9930000

Bearing adapter

Fig

EC 35

@j
STl9900000

Dummy shaft

126021

STl99 10000

Bearing driver

Fig

40 EC

Fig Fig

EC 35 EC 37
38

Fig EC

STl9890000

Rotor

adapter

STl9920000 EC 34
36

Rotor stand

Fig

r J
STl9940000

Fig EC

CJ

Fig EC 37 Fig EC 38

Bearing pressing

tool

STl9870000

Air pump test gauge

125667 01

adapter Fig Fig

EC 34 EC 36 0

Page

EC 17

39 EC

DATSUN 210

Model 8310 Series

SECTIONEE
ENGINE ELECTRICAL SYSTEM
CONTENTS
BATTERY CHECKING ELECTROLYTE
CHECKING CHARGING INSTALLATION LEVEL EE EE EE EE EE EE EE EE EE EE INSPECTION EE EE EE 2 2 2 3 3 4 4 5 6 6 DESCRIPTION EE 20 EE 22 EE 22 EE 23 EE 23 EE 24 EE 24 EE 25 EE 25 EE 28 EE 29 EE 29 REGAP EE 29

DISTRIBUTOR
CONSTRUCTION CHECKING AND ADJUSTMENT

SPECIFIC

GRAVITY

I
IC

ISASSEMBL Y

AND ASSEMBLY

STARTING MOTOR
STARTING CIRCUIT CONSTRUCTION REMOVAL AND INSTALLATION DISASSEMBL Y CLEANING AND ASSEMBLY TEST

IGNITION
DESCRIPTION REMOVAL CHECKING

UNIT

AND INSTALLATION IC

IGNITION SYSTEM

IGNITION COIL
SPARK PLUG
INSPECTION CLEANING AND

6
8 8

CHARGING CIRCUIT ALTERNATOR

DESCRIPTION REMOVAL DISASSEMBLY INSPECTION ASSEMBLY ALTERNATOR TEST AND REPAIR

EE 10 EE 13 EE 13 EE 14 EE 14 EE 14 EE 16 EE 17

SERVICE DATA AND

SPECIFICATIONS
GENERAL SPECIFICATIONS INSPECTION TIGHTENING AND ADJUSTMENT

EE 30 EE 30 EE 31 EE 33

TORQUE

TROUBLE

DIAGNOSES AND CORRECTIONS

I II III BATTERY STARTING

EE 34 EE 34

REGULATOR
DESCRIPTION INSPECTION

EE 1B EE 18 EE 18 EE 20

MOTOR

EE 35

ALTERNATOR

Including voltage regulator

IV IGNITION CIRCUIT

EE 36 EE 37

IGNITION CIRCUIT

Engine

Electrical

System

BATTERY
The gravity of electrolyte changes I 80F temper ature Converted specific gravity at
0 0007 for every loe
Converted

WARNING
Never touch terminals
are

specific gravity S20

positive
Th

and

negative

at the

same

time with

200e

301 l

680F

can

hands

l I l d result in

using the following

then be made by form la

t

L2
12

injury

S20

St

0 0007

20

Ii
8

124 122

CHECKING ELECTROLYTE LEVEL

Remove six
vent

Where St

Specific
at tOe

gravity of electrolyte 2
of electrolyte
u
118
c

t 2e

plugs and check

S20
t

Specific gravity
corrected
al

for electrolyte level in each cell

If necessary pour distilled water

200e 680 F

Electrolyte temperature
A

161 i1
141 1

For example

hydrometer read

CHECKING SPECIFIC GRAVITY

Specific gravity of battery electro lyte is tested by a hydrometer If the state of charge of battery is below 70 battery must be recharged or
elbat ecttroelyryte concentration

ing of 1 260 at 300e 860F would be indi 1 267 corrected to 200e 680F cating fully charged battery On the olher hand a hydrometer reading of
1 220 at

12 1 10 1

I
to

lOoe

I40F

would be

14
EEOO3

0 32

to 50

20

30

68

40 86104

50 122

I 199 corrected to 200e

680F

indi

Electrolyte temperature Oc OF Fig EE 3 Conversion of Specific Gravity

cating

partially charged battery

ad

The state of charge of battery can e determined by the following table if the known

justed

specific gravity

of electrolyte is be
sure

BATTERY FREEZING

cells are filled

Before checking to correct level

that

Battery electrolyte freezing point

varies

with acid concentration

or

its

specific gravity

A battery with an insufficient charge will freeze al lower

EE473

temperatures If specific gravity of a I this is an battery falls below 1 indication that battery is completely discharged and will freeze readily when temperat res fall below freezing
Note

Fig EE

Charging Condition

Use extreme caution to avoid will

freezing battery since freezing generally ruin the battery

u
r
1

eleYel

60

76 94

E
8
70 80

Thermal gauze

112 100

Ji
108 104

I
I
16 1

Ik I I
24 1

f 32 1

Hydrometer
EE001

1 2 0 28 1 Specific gravity of electrolyte

EE004

12 1

Fig EE 2 Checking Specific Gravity EE 2

Fig

4 EE

Freezing Point ofElectrolyte

Engine Electrical System

CHARGING
If electrolyte level is satisfactory

charged
I Be
sure

flame while it is being charged that electrolyte level is

in a safe 6

After

all

vent

plugs

have been

battery
lyte gravi ty 122

must be

charged when electro reading falls below 1 20 or

If

above top of each plate 2 Keep removed plugs

tightened clean all sprayed electrolyte off upper face of battery

place
3
ture

NS70

battery

on

car

is

quick charged to bring it up to full charge the operation should be carried

out

to go over 4SoC

Do not allow electrolyte tempera 1130F After charging

that maximum
at

4 tain

check

to

be cer not

INSTALLATION
1 InstaU and tighten

with negative cable removed

specific gravity
20 C 680F

does

clamps

secure

Prior to nals

charging

corroded termi
a

exceed

charging

specific

ly
2

should be cleaned with

common

brush
In

gravity
can

Correction

After clamps have been

tightened
and

and

baking soda solution

be made by adding distilled water

clean

battery
to

cable

terminals

addition be

the

following

items should
is

into cells as necessary 5

apply
from
open

observed

while battery

being

Keep battery

away

grease corrosion

retard formation of

3 EE

Engine Electrical System

STARTING MOTOR
STARTING CIRCUIT
FUSE

lOA IGNITION SWITCH FUSIBLE LINK MIT OnIY

LJJ
u STARTING MOTOR

INHIBITOR SWITCH

IAfT onlv I

BATTERY

f
7

INHIBITOR RELAY IAfT only

lJ

I
I
B

1J I
BY BY VA

INHIBITOR

RELAY
A T onlyl

M T

only

ti
FUSIBLE
LINK YR

IGNITION

SWITCH

On

tl
WR

L YR

FUSE BLOCK
BATTERY

J GO c
lOA

J c

S
BL

BY

p
STARTING MOTOR INHIBITOR SWITCH IAIT only

EE741

Fig
EE4

EE 5

Circuit Liagrom ofStarting System

Engine
CONSTRUCTION
NON REDUCTION GEAR TYPE
6

Electrical

Systeni

3 @ 00 U

Ul
1 2

Magnetic switch assembly

Dust
cover

13 14 IS 16
17

Brush Brush Yoke

spring

Adjusting
3
4

washer

Torsion spring Shift lever

Dust
cover

Field coil
Armature Center bracket Pinion Dus t

5 6
7

18 19 20 metal
21

Thrust washer E

assembly

ring
cover

cover

8 9 10
11

Rear

Pinion

stopper

Through bolt
Rear
cover

22 23
24

Stopper clip
Gear Gear
case
case

Brush holder
Brush

metal
E

12

E660

Fig EE 6 Non Reduction Gear Type Starting Motor

REDUCTION GEAR TYPE

4 6

4
1

Magnetic switch assembly 2 Dust cover AdjUsting was 3 Torsion spring

r

4 5

Shift lever Through bolt

Rear
cover

6
7

O ring
Yoke Field coil Brush Armature 15 Dust
cover

8 9 10 11
12

16 17
18

Center housing Reduction gear

Pinion gear

Ceo tel bearing Brush spring Brush holder

13 14

19 20

Packing
Gear
case

EE614

Fig
EE 5

EE 7 Reduction Gear Type Starting Motor

Engine Electrical

ystem

AND INSTALLATION
REMOVAL
Disconnect battery ground cable Disconnect harness connector and

4
rear

Remove two ihrough bolts and

cover

5
er

Remove brushes from their hold

by moving each brush spring

a

away

from brush with

Remove

hook

battery
2

cable at

Remove

magnetic switch bolts securing starting

Pull start
in reverse and remove it
motor

Remove brush holder

6
draw

motor to transmission case

yoke assembly and with and shift armature assembly

iog
3

motor forward

lever Remove pinion stopper located at the end of armature shaft To remove
7

Inst 1I

7
Fig EE
ll

o
EE615

starting

order of removal

Removing

Yo and Armature

first move stopper toward stopper and after removing stopper clip pinion
remove

stopper

with

overruniling

4
as

To remove brush holders

proceed

clutch assembly from armature shaft

follows
Remove brush
on

DISASSEMBLY
NON REDUCTION GEAR TYPE
I M
move

positive side

from its holder

Note Brush
on

positive

side differs in

that it is isolated from brush holder

Disconnect connecting plate from terminal of magnetic switch Re

two screws

and its

lead wire is connected to

field coil
2 tive

securing magnetic switch and remove magnetic switch assembly Remove dust cover 2 E ring and
thrust washer s
EE271

Carefully lifting brush

on

nega
sur

away from commutator face remove it from brush holder

side

Fig EE

lg

Rf moving Pinion Stopper

REDUCTION GEAR TYPE

1

Disconnect connecting plate from terminal of magnetic switch Re

two
screws

@@
EE311

move

switch

and

remove

securing magnetic magnetic switch

EE616

O
Fig EE 8 Removing DUll Cover E ring and ThrUJJt
Washer two
screws

assembly
Fig EE 12 Removing
Note Torsion

Brh

spring magnetic switch

Remove

can be

pulled

off 5 Remove bolts

securing

center

through baIts and

rea

housing housing
6

to gear case and detach center

cover

Remove

pinion gear

Remove

securing

Note
a

Rear blade f1at

cover can

be

pried

off with

brush holder assembly

screwdriver inserted be

tween it and to

yoke

Be careful not

damage packing while removing

CLEANING AND INSPECTION

parts but do solvents for dissolving grease cleaning overrunning clutch armature assembly magnetic switch assembly
Clean all disassembled
use

reaf cover

Remove

yoke
as

armature

and

not

brush
center

holder

an

assembly from

housing

and field coils

since

such

solvent

CAUTION
When
EE318

removing
any

be

careful

not
or

to

would dissolve grease packed in clutch mechanism and would damage coils or other insulators Check them for excessive damage
or
wear

knock brush

commutator

coil

Fig

EE 9 Removing Bru h Hold Setacrews

against

adjacent part

and

replace if necessary

EE 6

Engine
TERMINAL
Check
wear

Electrical

System
ARMATURE ASSEMBLY Check external appearance of arma

BRUSHES AND BRUSH for damage and magnetic switch LEAD WIRE Check
loose

terminal

and replace assembly if necessary FIELD COIL

the

surface
wear

condition of brush

of If
a

ture and oommutator I

brush contact and

contact is

Inspect

commutator

If the

sur

found it

should be

face of commutator is rough

be sanded

it must

replaced
If
or

lightly with

No

500 sand

Check field coil for insulation the insulation of

worn

Ifbrush is less than

worn so

that its length is

oil

is

damaged

specified

value replace

If the depth of insulating mica paper is less than 0 2 mm 0 008 in from commutator

it should be

replaced

Minimum

length of brush

surface

insulating
so

mica

Testing field coil for continuity

Connect tester two
or an

Non reduction gear type 12 mm 0 47 in Reduction gear type

should also

be undercut
to 0 8 mm

that its
to

depth

is

0 5

0 020

0 031 in The wear limit of commutator dia meter is I

mm

the

probe of

circuit

11 mm

0 43 in

ohmmeter to

field coil
brush

0 04 in

If the

positive terminal of positive

no

Check the connection of lead clip

and lead wire

diameter of

commutator

is less than
armature

holder If tester shows

continuity field

circuit or coil is open

Replace

it

to

Check brush holders and spring clip see if they are not deformed or and will properly hold brushes
the commutator
or

specified assembly

value

replace

bent
If

Diameter limit Non reduction gear type

against

brushes

brush

holders

are

32

mm

1 26 in

dirty they should be cleaned

Reduction gear type

29

mm

1 14 in

BRUSH SPRING TENSION Check brush Fig EE 13 Testing Field Coil for Continuity

spring

tension

by

spring

scale

as

shown in Fig EE l 5

If it is faulty replace it

Spring

tension

Non reduction geaf type

Testing field coli for ground

Place
onto
one

1 4 to 1 8

kg

3 1 to 4 0 Ib

EE018

probe

of circuit tester
other of to field

Reduction gear type 1 6 to 2 0 kg 3 5 to 4 4 Ib

Fig EE 15 Inspecting Bnah Spring

Tension

yoke and the

coil lead positive terminal If very little resistance is read coil is grounded

field

Replace

it

I
I

File

r
4 1

0 5 to 0 8
O

rom

Commutator
nt

EE017

iO
Correct

Mica

I 1

11
EE021

Incorrect

Fig EE 14 Testing Field Coil for Ground

Fig EE 16

Undercutting Imulating Mica

EE 7

Engine
2

Electrical

System
BAIL BEARING
Reduction gear type

Inspect silldered conneetibn of

lead
and commutator

armature

If

loose connection

is found

solder it

using
3

resin flux Armature test for

ground Using a circuit tester place one probe onto armature core or shaft
other onto each commutator bar

test

@ ll
EE278

and

Holding outer race with finger bearing to see if there is any play or bind If necessary replace bearing
rotate

If tester shows
is

grounded and

must

continuity armature be replaced

Fig EE 19 Overrunning Clutch Assembly

MAGNETic SWITCH
ASSEMBLY
I Using a circuit tester check con tinuity between S terminal of mag netic switch and switch

body

metal If

continuity does

not exist

shunt coil is

opened
Replace
L I

switch
same

assembly
manner as

2
1 2

In

the

above

EE022

EE 17 Teating Armature for Ground

Pinion gear Reduction gear

EE617

check

Fig EE 20 Pinion and Reduction Gear Overrunni11C Clutch

AS5em bly

continuity between terminals S and M If continuity does not exist series coil is opened Replace switch assembly

Check armature for short by plac

it
a on

ing
with
core

armature

tester

growler
arma t ure

piece of iron over rotating armature If

armature

the

plate
BRUSH HOLDER TEST FOR

ASSEMBLY
Reassemble
verse

vibrates

is shorted

starting

motor

in

re

GROUND Using a circuit tester place one test probe onto negative side of brush holder and another onto positive side If tester shows continuity brush hold er is shorted to ground Replace brush
holder

sequence of disassembly
sure

When assembling be
grease to gear
case

to

apply
cover

and

rear

bearing pinion

metal and

apply oil lightly

to

jeBel
EE023

TEST
PERFORMANCE TEST Starter motor should be
to
a no

Fig EE 18 Testing Armature

or

Short 5

Check armature for continuity by placing probes of tester on two seg ments side by side If tester shows no continuity the circuit is open
EE025

subjected
it has

load

test whenever
ensure

been

overhauled to will be

that

its

perfo rmance
installed
on

satisfactory
Starter

when

engine

motor

OVERRUNNING CLUTCH
ASSEMBLY

Fig EE 21

Testing Brush for Ground

should also be subjected to the test

when the cause of abnormal is to be determined

operation

Inspect pinion assembly and

sleeve
or

screw

A brief outline of

reduction gear Screw sleeve must slide freely along armature shaft

the test is given below No loadtest BEARING METAL Connect willi

an

splines or pinion gear shaft must slide freely through reduction gear If dam
age is found
or

resistance

except

nor

Non reduction gear type

spect bearing metal for side
wear or

starting

motor

in series

specified
ammeter

12 volts

mal resistance due to spring felt when sliding it must be repaired Inspect

capable

of

battery and indicating

play

If the clearance between

1 000 amperes

pinion teeth
found
on

teeth

gear also must

rubbing is replace Flywheel ring be inspected

If excessive

bearing
more

metal and armature shaft is

mm

Specified
Cications

current draw and rev6lu

than 0 2

0008 in

replace

tion in this test are shown in

Sp

ci

metal

EE 8

Engine
Switch

Electrical

System
Non
reduction gear type
the

Battery

With Starting
motor S

switch

on

push pinion
measure

back to the

remove

all slack and between

clearance

pinion

front edge and pinion stopper Clearance L

mm

0 3 to 2 5

0 012 to 0 098 in

Vultmeter

Ammeter

EE738

Fig EE 22 No load Testing

DIAGNOSES OF TEST
I Low

speed
draw

with
may

no

load and

high
the

brush spring rubber bush of mica in commuta tor

tor burn

thrust out
or a

loose
bar to

EE644

current

result

from

contact between brush and conunuta

Fig EE 24 Measuring Clearance

l

following
I
2
3

would
Low

cause

commutator

Tight dirty

or

worn

bearings
or

Bent armature shaft

loosened

current

draw and low

cause

no

field probe Shorted armature Check armature further

4
a

load speed would

resistance due
to

high

internal

Reduction gear type

loose connections

Compare difference

in

height

Remove

grounded armature or field input terminal Raise two negative side brushes
A

damaged leads dirty commutator causes listed on item 2 3

MAGNETIC SWITCH ASSEMBLY TEST
Switch

and

of pinion when it is pushed out with magnetic switch energized and when it
is

pulled

out

by hand until
L

it touches

stopper
Difference

from commutator

Using a circuit tester place one probe onto input terminal and the other onto yoke d If tester indicates continuity
c

0 3 to 1 5 mm 0 012 to 0 059 in

2
Pull out by

Push out

raise the other two brushes and check

field and armature

mine

separately to
or

deter
is

hand until

pinion stops

whether

field

armature

grounded
2
rent

Failure to

draw

may

operate with high be caused by

cur

11

IB

p
Starter motor
EE351

1
n
11 r
EE688

the

Battery

following A grounded or open field I Inspect the connection and

circuit with 2
a

coil trace

Fig EE 23 Circuit of Magnetic Switch Assembly Test If the OK

L
Difference

circuit tester

Armature coil does not operate

Inspect commutator burning In this case arc may damaged commutator when operated with no load
3

for excessive
occur on

motor is

Burned out commutator bar Weak brush spring tension broken

bly negative battery terminal and start ing motor M terminal positive battery terminal and starting motor 8 terminal connecting a switch in
series as shown above

starting motor check is check magnetic switch assem Connect cables between

Fig EE 25

g Difference Measuri

If necessary
or

adjust it by changing adding adjusting washer s Adjust

washers
are

ing

available

into

two and

different sizes
0 8 mm

5 mm 0

0 020 in

0 031 in

EE 9

ngine Elect

ical

System

CHARGING CIRCUIT
The

charging
an

circuit consists of

indicated in the stator coil This alter

battery IC voltage regulator

connects these parts

alternator incorporating
and

an

nating

current is rectified

by the posi
8 is

generating voltage to be applied to the battery at terminal S When current

exceeds the

wiring that

tive and

negative silicon diodes

at

specified

value

it

then ZD

When the voltage

terminal

flows through the

zener

diode

The
convert

purpose of this system is to mec hanka energy from the into electrical energy which is

higher than battery voltage current produced at the stator flows to re charge the battery While the battery is being
nal
8
re

closing
tor

the circ it

consisting

of transis

Tr

and resistor
Tr I

R1
nor

At this through
to the

engine
used

point
rotor

current neither flows to

to

operate all electrically operat

to

ed units and

keep

the

battery fully
in ON the

charged the voltage at termi is equal to that of terminal point

there is
no

transistor

ground

charged
With the

ignition switch

circuit between transistor uTr I

of the

lC

voltage regulator
route

and ground is shown by the

voltage differential on either side of the charge warning lamp which causes the charge warning lamp to turn off In other
words
current does not flow from the to terminal L

At this

thereby reducing generated at the stator

EE 28

the

See

voltage Fig

When voltage generated at terminal S

is reduced to the

specified
to

value

closed

Current from the battery then

in

transistor

allows
the

current

flow the

flows along the

arrOW

battery
current

Accordingly
rotor
as

turning on the charge warning lamp and flowing on through terminal L to excite the Fig
rotor

EE 26

flow

through the

through generating voltage

rotor

increasing

shown in
current circuit

Fig EE 27 produced at

is taken over

by

In this manner output

voltage from

the stator
F

The
and

the alternator does not rise above the

between

terminal

specified value by voltage regulator

the ON OFF opera

When the alternator

ate

begins to oper three phase alternating current is

is then closed Tr

See Fig

EE 27

tion of the rotor coil

through the IC

The IC voltage regulator monitors

16

L
01
0 J

l R
011

ls
CHARGE LAMP
L

0
u a

e
0
a 0

M
09

io
F

i
R ZD

IGNITION R2

eJ

STATOR COIL

04

SWITC1 El1
BATTERY

1
I

Aa

AJ
TI 3
E

1
ALTERNATOR
7

1
IC VOLTAGE

REGULATOR

EE760

Fig EE 26 Simplified Charging Circuit Initial excitation current EE 10

Engine Electrical System

00IB

l
0 0
J

RJ

1
1s

o
ll

f
4 0

3
07
0 F

0111 rt ei
tOlD

CHARGE LAMP

09

11
I
Tts

IGNITION

1
ALTERNATOR

1
R

i R2

oJor I
R

SWITC1 EB
8

BATTERY

r XiJ G
RJ

o s

1
nJn
IC VOLTAGE REGULATOR

J
EE761

Fig EE 27 Simplified Charging Circ14it When battery voltage is lower than regulating voltage

16

l
01
J

03

1s
OIlI

o
U ll

o
I

o
cr

hf
r
1
0

it

r
L

CHARGE LAMP

l
0 F

IGNITION

@
JZO

R2

w
l R

SWITCH1
T
T

Lp Q7

BATTERY

1
j

RS

ALTERNATOR

J
Ie VOLTAGE REGULATOR

EE762

Fig

EE 28

Simplified Cluzrging

Circuit When battery

voltage i higher

than regulating

voltage

EE 11

Eng

l Electrical n

lOl Syst

IGNITION
SWITCH FUSIBLE LINK

FUSE lOA v o

FUSE
FUSIBLE LINK

lOA C

L@@
BAT L S

BI
I

I
BATTERY

f
V
R

sl
I
I

fRO

a
lE

K
ALTERNATOR

F I

EI

i
Ie

VOLTAGE

REGULATOR

@@

IGNITION SWITCH
WR

WR

BW

I
@@
G G FUSleLE

U 0
1

I
00
00

I
LI NK

ImrnI

t t

AUTO CHOKE
RELAY

G WR
J

gg 1
00

VR

1
MTI
I FUSE

BLOCK

I
Note

lDID

O @
W

BAT mID

CHARGE WARNING LAMP

J
@ V @
California models Qilifomo Non FU models
18

WR W BL

5J

models

EE742

Fig EE 29 Circuit Dinrswr mofCIuJ Tg ng Sy EE 12

Engine Electrical System

ALTERNATOR
DESCRIPTION
The alternator

produced by
an

the rotor which consists

diodes

are

used

as

main diodes

incorporates

Ie

of

voltage regulator which maintains volt age within the specified range and prevents output voltage from rising higher than the specified value Except
for the Ie circuit alternator parts
are

pole pieces and slip rings The slip rings pressed in the shaft conduct only a small field current Output current is generated
in the in the armature coils located stator

alternator

shaft

field

coil

Nine

diodes and

three

negative three
are

positive
as
an

three

sub diodes

installed in

positive and negative plates assembly

are

These diodes their

direct soldered at

The stator

has three

essentially
Service
section
on

the same as those of the

conventional

type

alternator

procedures

outlined in this information

is

are

restricted to

windings and generates three phase alternating current Silicon diodes act like a one way valve for electricity so that charging current passes easily but
reverse

other than the voltage regulator

In the alternator
a

current is shut out

tips and constructed with posi tive and negative conjunction They are mounted on the two plates which combine the function of heat dissipating plate and positive negative terminals and are light in weight and
easy to service

magnetic field

In this alternator

pack type

silicon

CD

1 2

Pulley
Front Front Rotor Rear

assem bly
cover

3
4

bearing

Qj

bearing

6
7

Stator Diode Set plate assembly

Brush

8 9
10 11

assembly

Ie voltage regulator
Rear
cover

Through bolt

EE647

Fig EE 30 Alternator

EE13

Engine Electrical System

REMOVAL
1

Pull

rear
a

bearfug

off rotor
or

assem

Disconnect wire from diode tor

bly with battery negative

wires and

bearing puller

press

minal at brush terminal with soldering

iron Remove brush assembly with IC regulator by loosening screws Remove diode holder by loosen 8 ing screws

Disconnect

cable
2

Disconnect

two

lead

oonnector from alternator 3 4 5

Loosen adjusting bolt Remove alternator drive belt Remove parts associated with

alternator from

engine
car EE037

Remove alternator from

Fig EE 34 Pressing Out Rear

DISASSEMBLY
I Remove
cover

Bearing

acefii

li

through

bolts

Separate
E E649

front

with rotor from rear cover

with stator

by lightly tapping front

bracket with a wooden mallet

I
EO

Fig EE 37 Removing Diode Holder

Fig EE 35 Pulling Out Rear

INSPECTION AND REPAIR

ROTOR INSPECTION
I

rnJ

Bearing
5

When removing IC regulator only proceed as follows I

J
2

Continuity test of rotor coil Apply tester between slip rings

If there is
no

of

i
rear cover

wire
EE525
T

Using soldering iron disconnect connecting diode set plate to

rotor

continuity field

coil is open

Fig EE 31 Separating Front COI Place

brush at brush terminal Remove bolt securing diode set to rear cover side face plate
3 2

Replace

rotor

assembly

side of rotor in a

vise with soft nuts

jaw

and remove

pulley
fan

Remove

nut

securing battery

Then Remove

remove

pulley

and

terminal bolt
4 stator

from rotor shaft

3 setscrews from

To facilitate removal

s1ighly

lift

bearing

retainer

and separate rotor from front

coil together with diode set plate from re r cover Then remove
screw

connecting diode

set

plate with

brush
5

Separate

stator

coil and diode and

remove

together
6
iron

with rear cover

Fig EE 38 Continuity Test of

Rotor Coil 2

brush and IC regulator Disconnect stator coil lead wires from diode terminals with a soldering Remove
move EE526

Ground test of rotor coil

Check continuity between slip ring and rotor core If continuity exists

screws

securing brush

re

replace
coil or

stator from rear cover

rotor assembly because slip ring may be grounded

rotor

Fig EE 32 Removing Pulley and Fan

tr
s

EE532

27

EE648

Fig

Fig EE 33 Removing Rotor

Fig EE 36 Removing Stator Coil

EE 39 Te ting Rotor Coil for Ground

EE 14

Engine
INSPECTION OF STATOR

Electrical

System

rp
is Conductive direction

Continuity
Stator
is

test when there

normal

continuity between individual stator coil terminals When there is no conti

nuity

between

individual

terminals

cable is broken

Replace

stator

assembly

1 2 EE045

plate ptate
Diode

Fig EE 42 Conductive Direction of Diode

EE533

Fig EE 40 Testing Stator for Continuity

Main diode installed

is
a

on

8 plate

Correct direction of current flow

rent

positive diode which allows cur to flow from terminal to EEl plate
In other words current does not

for three sub diodes is shown in Fig

4S EE

only
2

Ground test If each

lead wire of stator

flow from coil

is is not conduc

8 plate

to

terminal

including
tive

neutral wire stator

core

with

condition

satisfactory
stator

If there is

continuity

coil is grounded

plate
Terminal

Direction of EE046

electric current
EE650

Fig EE 43 Impecting Positive

Diode

Fig EE 45 Sub Diode

EE534

Main diode installed

on

Gplate is
only
If current flows in both positive negative directions diode is short If current flows in one direc

Fig EE 41

Testing Stator for

Ground

negative

diode which allows current

to flow from

Gplate

to terminal

In other words from terminal

current does not flow

and

toGplate

circuited
tion

INSPECTION OF DIODE Perform

a

only diode is in good condition If there is a faulty main diode replace See table all diodes as an assembly
below
ble

in both directions

continuity using

test on diodes
an

These diodes

are

unservicea

ohmmeter

There diodes sub

main

are

six main diodes and tluee

attached to set diodes

are

plate
to

Three

attached

EEl plate and three others to 8 plate Three sub diodes are attached
to terminals 1
2

positive negative

plate
Tenninal

The continuity test should be per formed

on

EE047

each diode

between the

Fig EE 44 Impecting Negatiue

Diode

terminal and plate

EE 15

Engine Electrical System

grOove V Test deflection 0 3 mm 0 012 in

probe

of a circuit tester Conduction

e
terminal

8J EB plate
terminal o

@ plate
terminal

slik

e plate
tenninal o

e plate e plate EB plate

1I
o

I
48 EE

EE051

8J plate e plate

Fig

Tightening Pull

Nut

Before installing

front

and

rear

sides of alternator Sub diodes

can

push

rear

cover

be

replaced

individ

measure use

ually CAUTION
If it is necessary to remove sub diode pinch diode lead wire with a pair of

of a

brush spring pressure by the spring balance Normally the

brush up with fingers and retain J brus 49 by inserting EE as shown in Fig brush tift into brush lift hole from

rated pressure of a new brush spring is 255 to 345 gr 8 99 to 12 17 oz Moreover

when brush is
worn

outsi4e

pliers to prevent heat transfer from soldering iron to diode when unsolder ing connection

pressure decreases a pproxirnately 20 gr O 71 oz per I mm 0 04 in wear

t

Bru h lift

mm

0 08 in

INSPECTION OF BRUSH
Check movement of brush and if
uv

L
0

ent is not smooth check brush

holder and clean if necessary Check brush for

down to
wear

0
ee049

If it

is worn

less than the

specified limit
tail
and

lJrJ

EE540

replace brush assembly Check brush pig damaged replace

Fig EE 47 Mea uring Spring

Pressure

if

ASSEMBLY
Assemble alternator in the sequence of disassembly
reverse

noting

the

following
I

When soldering each stator coil

lead wire to diode assembly terminal carry out the operation as fast as

possible
2
EE651

When installing diode A terminal

Fig EE 49 I

rUng Bru h Lift

install insulating bushing conectly 3 Fig

46 EE Brush Wear Limit

Tighten pulley nul

S

dJ

Tightening torque
Pulley
nut

After installing toward center

front

and

rear

sides of alteniator

pull

brush lift

by

4 5 to 6 0

kg m
lbl ft

pushing
Note

SPRING PRESSURE TEST

With brush

33 to 43 When

projected approximate
from brush holder

pulley is tightened

make

sure

Iy

2 mm

0 08 in

that deflection of Vgroove

Do not puD brush lift by push ing toward outside of cover as it will damage slip ring sliding surface

EE 16

Engine Electrical System

6

Tighten through bolts

ALTERNATOR TEST
Before

test

probes

are

rfl Tightening torque

Through
bolts 60 to 70 cm kg 52 to 61 in lb

conducting

an

alternator is

The alternator

necessary for the test can be checked easi the

test make sure that the

battery

fully

ly by referring

to

Inspection Table

charged
A

30 Volt

voltmeter and suitable

INSPECTION TABLE

With alternator

grounded
when

aide L tenninal short occurs diode is short circuited

internal

out Bumed

@
Ignition
switch ON Check light for operation f Light OFF

Disconnect
connector S L and ground L lead

Light OFF
Connect con nector S L
and

bulb Replace and Proceed toUA

wire

Light

ON

Check light for operation

Dim light

Light

Light

ON

ON

ground

I
I
I

Faulty IC Replace FaultyA Faulty

RG

1
Engine idling Check light for operation

for operation
rs

a1light

Light

OFF

I
I

i tf
Light
ON

AC G

1 I Contact positive lead lennina and negative of

voltmeter

on

lead

to L tenninal More

Light

OFF

Engine idling
Measure the

thanO 5V

I I

Faulty

Ae G

I
Engine speed
1

voltage
B

across

and

Less

thanO 5V

OK

terminals

500 rpm ON

Ligh tin
switch

Dim

light

Note 1 Use fully charged battery

2

Check light for operation

Light

OFF

Engine speed
1 500 rpm Measure B

Light
A

Charge warning light

Alternator parts except IC regu IC n guJator
tor

Mon than 15 5V

C RG

C G

terminal volt
sge

I3 to 15V

altemator IC is in good condition When reaching Faulty A C G remove alter nator from car and disassemble inspect and correct or replace faulty parts

IC RG OK

Make

sure

S
con

terminal is nected

correctly

Engine idling Lighting

switch ON Check light for operation

Method of grounding F terminal Contact tip of wire with brush and attach wire to alternator body

Light ON
Suitable wire

I
Light
OFF

I Faulty

A CG

OK

Fig EE 50 Grounding F Terminal

5 Terminals marked S L BA Tn and alternator
E
are

on rear cover of

EEl7

Engipe Electrjcal Syst em

REGULATOR
brush assembly inside the alternator Should any problem with the relay
arise it should be replaced together with the brush assembly In the charge circuit
a

DESCRIPTION
in The regulator consists essentially of egrated circuits incorporating tran

INSPECTION
To check the IC
as

regulator proceed

follows Remove IC regulator and brushes

as

sistors These transistors int errupt and admit current flow to the
rotor

warning lamp

diode is at
to

alternator

tached to the stator coil

monitor

an

assembly

as

outlined in

Disas

coil thus maintaining its output

at a constant value Unlike in
an
a

generating voltage
when
the

at the stator so that

sembly

and Assembly Alternator

section under

voltage
ic

monitored

mechanical type regulator

electron

relay employing
very

transistors is uti
are

lized These transistors

a

enclosed in
case to

compact

sealed
is

The

charging voltage are charging the charge warning lamp is turned off Accordingly a charge warning relay is not employed in this
circuit

voltage and equal during re

the heading

CAUTION
When

performing

test

continuously
If it be

electronic

relay

soldered

the

resistor may generate heat

comes

high

temperature

stop testing

for
Brush

while

to avoid

burning

The following test equipment and

accessories
are

required
R 10

t r
F L

I
watts 2

Resistor

ohms

20
x

Variable resistor
I and 2

Rv

0 to 300
x

ohms 20 watts
3

Batteries

12 volts

x2
E

DC voltmeter 0 to 30 volts
x

Ie regulator

2
EE629

Connect wiring
and

as

shown in Fig
at 13

EE S3
I it is

perform
10

tests as follows

Fig EE 51 lC Voltage RegultJtor

Measure voltage
not within

VI
to

battery
volts

If
re

charge
2
s
I

or replace battery as necessary Disconnect lead wire at terminal measure

voltage
and E

V2

between

B S

terminals 2 0 volts

If it is below

regulator is functioning properly Connect lead wire to termi

3

nalS Measure voltage V 3

re

J
DIO
R

total volt If it is not

age of batteries I and 2 within 20 to 26 volts

charge

or

replace

either

or

both batteries

i
Tn

ZD
R

4 Gradually decrease resistance of variable resistor Rv from 300 ohms

and

measure

voltage
F

between

terminals
B

En and

As resistance

S LE F

Terminal

R
Rh

Resistor
Thermistor Transistor Zener diode

Tr
E ZD

EE766

Fig EE 52 Circuit of RegultJtor

EE 18

Engine

Electrical

System
varies

voltage

V 2 should at
as

certain

lc

regula tor

T
BATI

j
EE631

high voltage V I Step I If there is such a variation the regulator is functioning properly Hold variable resistor Rv at the same voltage as VI If there is no voltage variation regula
increase to as which is measured in
tor

point

is

out

of order

and

must

be

replaced
5

Measure
E

center

between voltage V tap of variable resistor R and

Rv resistance in step
s

Cf CO I
BAT2
15

terminal

With obtained

set

at

value
within

4
e

above if
it is

measure

Fig EE 53 Testing Regulator 1

voltage V 4 to specified range

EE 54 If it
is

Fig regulator is not functioning properly Replace 6 Reconnect wiring as shown in Fig EE 55 and repeat steps 4 and
not

indicated

in

15
v

5 If voltage V is 5 to 2 0 volts 0 higher than that in step 5 regulator is functioning properly If it is not replace

v o o

14 5

Q
z o 14

13 5

13 0 N
0 0

N C

0 e
0 0 0

N
0 0

0
c 0 0 0 c

S
I

0 o

Regulator

case

temperature DC OF
EE632

Fig EE 54 Testing Reguhltor 5

IC

regulator
L S

j
R
EE633

BATI

1
I

Cf Cf I

BAT2

l
EE 19

Fig EE 55 Testing Regulator 6

EngineElect

ical

System

IGNITfON CIRCUIT
DESCRIPTION
The ignition circuit consists of igni
tion The current flows secondary through the high tension cable to the distributor cap then

the

rotor

switch

Ie

ignition

unit

dis

distributes the current to one of the

tributor

winng

ipark plugs

and

spark plug
cap

terminals in the distrubutor

battery
The distributor is of the contactless type and is equipped with

only their operation air gap of tightness of electrical terminals and wiring condition NLGI consistency Apply grease No I containing MaS or equivalent to distributor rotor shaft as required
distributor

for

pick up coil which electrically detects the igni tion timing signal in place of the ircuit I rea r of the conventional The IC ignition unit is a distributor
a new

Then the spark

occurs

while the

secondary

current

jumps the gap be WARNING

When
current

tween the insulated electrode and the

ground side electrode of the spark plug This process is repeated for each engine spark plug should be inspected cleaned and regapped at tune up Spark plugs should also be replaced as periodically specified in the
e

is

flowing

never

addition

which

generates

the

power stroke of t The

touch with bare hand high tension

cables them
even wear or

signal required for the make and break of the primary current for the ignition
coil

vollage If parts are

any other parts with high moist touching

cause an

could
if

electric shock

primary current is supplied by battery or alternator and flows through the primary circuit It consists of the ignition switch primary winding of the ignition coil IC ignition unit and all connecting low tension wiring
the

The

Maintenance Schedule

ignition component parti should be inspected

The

remainder

of

the

wrap before

they are insulated Always dry well insulated gloves or affected parts with dry cloth

handling

by

The secondary current is produced the ignition coil and flows through Battery
letink

the secondary circuit resulting in high voltage spark between the electrodes of the spark

plugs

in

engine cylinders
Primary winding Ignition coil Secondary

This circuit contains the secondary winding of the ignition coil distribu

To starter

high tension cables to coil and spark plugs distributor rotor and cap When the ignition switch is turned
tor and the distributor reluctor rotates the primary current flows through the
on

winding J

primary

When the primary circuit is opened by circuit of IC ignition unit the

winding of the coil and through IC ignitionu nit to ground

Ro

or

head

magnetic field built up in the primary winding of the coil moves through the secondary winding of the coil in ducing high voltage This high voltage is produced every time the primary
circuit opens

Ul
J

r
Spark plugs
EE743

Fig

EE 56 Ignition System Circuit Diagram

EE 20

Engine Electrical System

VIR

II

B4J

QJ

IGNITiON
SWITCH

9
FUSIBLE LINK

1l
V B II

IGNITION COIL

rID

jl
J

SPARK PLUG

H
BATTERY

IIC

IGNITION

UNIT

O
DISTRIBUTOR

EE744

Fig EE 57 Circuit DiGgram ofIgnition Sy

tem

EE 21

Engine

E ectrical

System

DISTRIBUTOR
CONSTRUCTION
In the conventional distributor the in

place of the breaker The amount of magnetic flux passing through the pick up coil is changed when the reluc
tor rotates is and

and breaks the primary

current

run

ignition timing
and breaker

is detected

by

the earn

then the electrical

ning through the ignition coil and generates high voltage in the secondary winding
The
vance

arm

while in this distribu

on

tor it is detected by the reluctor

the shaft and the pick up coil provided

generated in the pick up coil This electric ignal is conducted into the Ie ignition unit which makes

signal

mechanisms

centrifugal and vacuum ad employ the conven

tional mechanical type

l I

ID

ID J
I

2
3 4

Cap assembly Rotor head assembly

RoD

pin

ReluctoI Stator

6 7 8 9
10 11 12

Magnet assembly Pick up coil assembly Breaker plate assembly Rotor shaft assembly
Governor spring Governor weight Shaft assembly

13 14 15 16 17 t8

Housing
Grommet Ie igniq n unit VacuwncontroUcr

@f
EE 22

rw

Fixing plate
Collar

EE745

Fig EE 58 Diatributor

Engine Electrical System

CHECKING AND ADJUSTMENT
CAP AND ROTOR HEAD

DISASSEMBLY AND ASSEMBLY

DISASSEMBLY
in the I

Cap and rotor head should be spected periodically as specified in

Main teoanee Schedule

Take off cap and

Remove Ie

remove

rotor

head
2 IC

Remove cap

ignition

unit Refer to

and clean all dust and carbon deposits from cap and rotor from time to time If cap is cracked or is leaking replace
wi th a new
one

Ignition

Unit for removal and in

stallation 3 Remove stator

and magnet by
screws

EE704

removing
4

stator

securing
screws

Remove

vacuum

controller

by

Fig EE 61 Removing Knock Pin

removing securing
ADVANCE MECHANISMS

10

Remove

rotor shaft

and drive

SpecHlcatlons
Refer to Service Data and
tions for distributor

shaft assembly

Specifica

Vacuum advance mechanism mechanical parts If

to
vacuum

advance mechanism fails check

correct

operate

properly

for the
the mal
EE746

fB ol owin items and function as required

I

Check vacuum inlet for signs of leakage at its connection If necessary retighten or replace with a new one 2 Check vacuum diaphragm for air leak If leak is found controUer assembly

Fig EE 59 Removing Vacuum Controller

EE705

Using puller pry

5

two

pry

bars

or

suitable

Fig EE 62 Removing Rotor Shaft and Drive Shaft Assembly

reluctor from shaft 11

replace

vacuum

Mark

rotor

shaft and drive shaft

the top of rotor

CAUTION When

Remove

packing from
unscrew

Inspect breaker plate for smooth moving If plate does not move smoothly this condition could be due to sticky
3

removing

reluctor

be careful

shaft and

rotor shaft setscrew

not 10 distort or

damage

the teeth

Remove rotor shaft

steel balls steel halls

breaker

or or

pivot Apply
if necessary

grease

to

6 7 8

Remove roll Remove Remove

remove

pin
up coil

replace

pick

assembly

plate

as an

assembly

breaker

and

breaker

plate setscrews plate assembly

Centrifugal advance mechanical parts

When
nical
cause

EE706

of engine malfunction advance mecha

tester to

is traced to

centrifugal
use

Fig EE 63 Removing Rotor Shaft

parts

distributor

check its characteristics

If nothing is wrong with its charac teristics conceivable causes are faulty abnormal wear of driving part others So do not disassemble it
or or EE703

12

Mark

one

of

the

governor
one

springs pins
Fig EE 60 Removing Breaker Plate
Setscrews

and its bracket Also mark

of the governor weights and its pivot 13

In the
istics

event

of improper character
rotor

Carerully springs
Remove

unhook

and

remove

check closely

shaft

assem

governor

bly

governor weight and shaft If any of the above parts are mal

Punch knock pin out and

remove

functioning replace

the parts

pinion
EE 23

governor weights r A ply grease to guvernor weights after disassembling

14

Engine
ASSEMBLY
To

Electrical

System
6

assemble

reverse

the order of

disassembly Carefully observe the fol lowing instructions

tor

before

Properly eenterstatOr tightening

0 3 to 0 5
mm

and reluc

Standard air gap

0 012 to 0 020 in

CAUTION
tfore B
sure

ignition unit make mating surfaces of IC ignition unit

instal i lg sand and moisture

IC

and distriblitor are clean and free from

dust

5
EE747

Align
are

match marks
to

so

that parts

Fig EE 64 Driuing in Roll Pin

assembled

their original posi

3

tions 2

When installing pinion

on

shaft

Ensure that reluctor is

0 to 0 5 mm 3 012 to 0 020 in

EE748

properly
shaft Al
its

be sure to install to 4

pinion

gear

correctly

oriented when ways toward

installing

Fig EE 65 Air Gap

on

drive

in roll

pin with
to use
a

slit

the outer

end of shaft See

new

Fig pin

64 Be sure EE

roll

position where it was installed Apply grease to the top of rotor shaft as required 5 Check the operation of governor before installing distributor on engine

butor is installed on

Adjust ignition timing after distri engine

Ie IGNITION UNIT
DESCRIPTION
This
The IC
can

result

in

an

abnormal

rent of the 5

ignition

unit utilizes a semi and is mounted

ignition coil

conductor IC device
on

temperature

rise in the

the side surface of the distributor

The

IC

ignition

unit has the fol

lOwing
circuit

circuits

discharged battery tions can be prevented by this lock preventing circuit 3 Duty control circuit

ignition coil or These malfunc

Current This

limiting circuit
controls the current

circuit

value flow
cuit

so

that excessive current will not the power

through

switching

cir

Spark timing signal monitoring

This
circuit

This circuit controls the ratio of the

To ensure efficient

operation of the
are as

detects

the ignition

ignition coil primary current ON OFF time periods in one cycle of ignition operation
111is is

IC ignition unit these five circuits manufactured in one assembly shown in

signal

sent from

the distributor pick

Fig

66 EE

amplifies the signal 2 Lock preventing circuit This circuit cuts off the ignition coil primary current when the ignition switch is ON and the engine is sta tionary If the ignition coil primary current
is allowed to flow under such condi tions excessive current will be drawn

up coil and

equivalent

to the dwell

angle
dis

of the conventional point type tributor In order

to

conductor semi IC is utilized for all these circuits except the power

The

provide high

switching circuit The power switching

circuit uses one power transistor and the circuit is arranged on the ceramic

performance spark ruing over a wide range of driving speeds this duty can be controlled by the source voltage
and the ambient temperature as by the engine rpm
4
as

substrate

together

with resislors capa

well

citors and diodes

Power switching circuit This

circuit is

Each component part of this unit is highly reliable however should any
or

because of low internal resistance of the ignition coil

used

to make

part be

found

faulty
replaced

the entire

as

break directly the primary circuit EE 24

cur

sembly

musl be

Engine

Electrical

System

CAUTION
Battery

Ignition switch

Before
sure

CG

instelling IC ignition unit mike mlting surfaces of IC ignition unit

Ire

end distributor

cleen and free from

1
e PL @
JO
coil

dust sand and moisture

Note
a

When

connecting lead

wires to unit

insert lead wire terminal with fin

b 2P
as shown in Fig ger Connect lead wires

69 EE

according
face

to

J L
Ignition
r

color

marked

on

upper

of

fJ
Spark timing

1I

connector

grommet

8C
Power

signal 1oring oni

Clfcwt

0
Pi c k

uty control
ClICUlt

switching
circuit

Lock up
n

Current

co il

preventing
circuit

limiting
circuit Ie ignition unit

Ln

Distributor

EE749

EE752

Fig EE 66 Ie Ignition Unit Circuit Diagram

Fig EE 69 Connecting Pick

up

Coil

Terminal

REMOVAL AND INSTALLATION

I 2 Disconnect

Disconnect

pick

up coil wire from

IC ignition unit Note

CHECKING IC IGNITION SYSTEM

DESCRIPTION

battery ground cable

re

Holding

connector with needle

Take off distributor cap and

rotor head

move

3 4

Disconnect harness connector Remove Ie ignition unit securing

68 EE pliers as shown in Fig disconnect pick up coil terminal Be careful not to pull lead wire
nose

screws

rf
I
I EE751

ignition system ignition per fannance of the ignition system at a high speed cannot be measured direct ly However it can be checked by operating a vehicle actually at a high speed The IC ignition system can be checked easily by referring to the Inspection Table For the method of inspection refer to respective items
use a

To check the IC
circuit tester

The

Fig EE 68

Connecting Di

Pick up Coil Term inal

eE750

Fig EE 67 Removing Ie Ignition

Unit

InstaU

IC

ignition

unit

in

the

reverse

order of removal

EE 25

ngine
INSPECTION TABLE

Electrical

System

START

I
No spark
occur

Check sparking performance

1u Sparks oci OK

Check high tension cable NG OK

J
Check power supply circuit
NG

IC

IGNITION SYSTEM

Repair and lor replace

OK
or

Proceed

to

Repair

and

replace
NG

Check

primary

circuit

OK
or replace

Proceed to A

epair

an

DISTRIBUTOR ASSEMBLY lC IGNITION UNIT AND OR

PICK UP

NG

Proceed to A

COIL

NG

Mealure

pick

up coil resistance

as

distributor assembly

I
Approx 400n
PICK

Except

approx

4000

Measure

igilition coii 8terminalvoltage

UP COIL

OK

Battery voltage
Measure

t OV
coil resistance Approx
PICK IC

1C

IGNITION UNIT NG

pick

up

I
400n OK NG

Ie IGNITION UNIT

NG

Except
PICK UP COIL

approx

400n

NG

1
I

UP COIL UNI

Replace

Repair and

or

replace

IGNITION

Replace

l
I

Meuure

up pick

coil resistance
I

Proceed to A

Except approx 4000

Check sparking performance
No spark
occun

Approx 400n
NG

I
occur

Replace

PICK UP COIL

1 l

PICK UP COIL

OK

Sparks

IC IGNITION UNIT NG

flc IGNITION i UNIT OK

Proceed to A

Replace

Proceed to A

Replace

Proceed

to

CHECKING PROCEDURE

JUDGMENT

not

alwaY indicate performance

speed high

sufrlcienl for

Sparks
Sparking performance
check
L Turn

occur

operation

IC ignition system
In this case

OK

ignition switch
dieseling anti

to

OFF

IC ignition system and component parts need not be checked

position
2 Disconnect solenoid valve connector to cut off fuel to engine
3

IOgh tension cable check

Refer to Engine Tune up for Check

beyond this

supply

of

No spark

occurs

ing Ignition Wiring

NG and Rotor

Distributor Cap

IC ignition system
In case of NG

Disconnect

high

tension

cable

check

High

Tension

from spark plug

4

Cables
tension cable end 4 Nole

Keeping high

JUDGMENT

to 5 mm

0 16 to 0 20 in away from rotate starter motor and

occur across

engine block
clearance

check whether sparks

the

designed to deter only ignition spark perform ance when cranking engine If test results are satisfactory Ibis does
mine EE 26

This check is

If high tension cable is OK check Power SupplY Circuit If high tension cable is NG replace cable assembly

Engine
Power Make
in 2
sure

Electrical

System
to

circuit check suppl

that

5
is

Turn

ignition switch

OFF

Measure

resistance between two

as
a

ignition switch

position
JUDGMENT

terminals of pick up coil

tor

distribu

OFF

position
con

assembly with

circuit tester

Disconnect Ie ignition unit nector from unit

3 Turn

Battery voltage
ON IC In this Check
case

is indicated

OK

ignition switch
at

to

proceed

position
4

Ignition

Unit

to the step for and Pick up Coil

Measure voltage

the terminal as

shown in

Fig EE 70

Battery voltage is

not indicated

NG If NG check condition
circuit and con 1
2 Tester

wirings and connectors If results of these inspec tions are satisfactory check Ignition tinuity of primary
Coil

probes
EE736 up

Grommet Ie

ignition urnt

Fig EE 73 Measuring Pick

Coil

Resistance

1
5 Turn

Ignition coil check

EE734

4 is

Measure

resistance

Fig EE 70 Checking Power Supply

Circuit

I in 2

Make OFF

sure

that

ignition switch

polarity

of circuit tester

by reversing probes

position
harness connector

Disconnect

ignition switch

to

OFF

position
JUDGMENT

from ignition coil8terminal 3 Measure resistance between

and

8terminals
JUDGMENT
is indicated

Battery voltage
In this
case

OK
Resistance

1 range

Approx 400n
Pick up coil IC ignition unit
In this
case

are

indicated OK NG

check Primary Circuit

is not indicated

Battery voltage

C2J
NG

replace faulty IC igni

In case of NG

check power

supply
con

tion unit with new one

wirings tinuity

fusible link
s

ignition switch

Approx

400n are not indicated

and connecto

for condition and

Condition cannot be

judged
Thus
EE567

proceed

to

item 5

circuit check Primer

I in 2

Fig EE 72

Make 0FF

sure

that ignition switch is

con

Checking Ignition Coil Assem bly

Note
no

If resistance is approx 4OOn further inspection is required IC ignition unit

sure

position
JUDGMENT If resistance value is 0 84
to

replace
5
1 02n

Disconnect IC ignition unit Turn ignition

switch to

Make

nector from unit 3

connector unit

is

2 pin IC ignition unit securely connected to

ON

OK If resistance value is other than NG

position
4

6
7

Turn

ignition switch voltage

at

to

ON

Measure voltage at the terminal

as

shown in Fig EE 7I

the specified value

position
Measure

ignition coil 8
OFF

terminal Ie Ignition unit end pick up coli check 8 Turn ignition switch to

position

1
EE735

supply circuit primary high tension cables are in order IC ignition unit and or good coil are pick up malfunctioning
circuit and I in

If power

CAUTION
Turn
test

Make OFF

sure

that ignition switch is

circuit tester from nega tive terminal of ignition coil Failure

to

ignition probe of

switch off after

releasing

position
distributor cap and
ro

do this could result in

damage

to

Fig EE 7I

Checking Primary
Circuit

2
tor

Remove

circuit tester

EE 27

Engine Electrical System

JUDGMENT OV is indicated IC ignition unit
But condition not be of

Pick up coil IC ignition unit NG

OK NG
not

If NG

replace faulty IC ignition

one

unit with new

Approx 40011
Pick up coil

are

indicated NG
can up P1ck

pick

up coil can

judged Proceed voltage

to the item for II

Condition of IC ignition unit

not be

coil check

Pick up Coil Check

Bat tery is indicated

judged

Proceed

to

item 11 up coil with

Replace faulty pick

one

new

Condition cannot be judged Proceed to item 9

9

12
13

Install

original

IC ignition unit

Check parking

performance

sure that ignition switch is position 2 Remove IC ignition unit Refer to IC Ignition Unit for removal

Make

in

OFF

Measure resistance between two

Remove IC ignition unit Refer to IC ignition Unit for

terminals of pick up coil

re

moval 10 Measure resistance between two

JUDGMENT

JUDGMENT

terminals of pick up coil

Sparks

occur

IC ignition system JUDGMENT No spark

are OCCUrs

IC ignition unit OK

Approx 40011 Approx 40011

If NG

are

indicated indicated

OK

are not

NG

replace faulty pick

one

up coil

Approx 40011

indicated

IC ignition unit

NG

with

new

IGNITION COIL
ignition coil is an oil filled type ignition coil case is filled with oil which has good insulating and heat radiating characteristics The ignition coil has a greater ratio between the primary and secondary windings to step up battery voltage to high voltage This causes stronger sparks to jump the spark plug gap
The
The cap is made The

@ rJ
1

of alkyd resin

which offers high resistance to electric

arc

and increased insulation

C
I

to

When high tension cable is installed ignition coil there should be no

clearance between their caps

Note

Do not disconnect

cables from

high tension spark plugs during en

it jllll

gine running
r
1

EE578

2 3
4

Rubber cap for ignition coil Secondary tenninal

7
8

Primary winding
Side
core

5
6

Cap Primary terminal Spring Secondary winding

9 10
11

Insulator Center Case

core

Segment

12

Fig

EE 75 Ignition Coit

EE354 1

High tension cable

Rubber cap

Fig EE 74 Correct Instalhltion of High Tension Cable

EE 28

Engine Electrical System

SPARK PLUG
INSPECTION
I

Conventional type
tension
on

Disconnect

high

cables boot

from spark plugs by pulling not on cable itself 2

3

Remove spark

plugs
Normal
Carbon

Check electrodes and inner and

porcelains of plugs noting the of type deposits and the degree of electrode erosion Refer to Fig EE 76
outer

fouled

Normal

Brown

to

grayish

Ian

de
wear

posits and
indicate
range

slighl

electrode

correct

spark plug

heat Overheating
Worn EE079

Carbon fouled

Dry fluffy carbon de

caused

posits
trode

on are

the insulator and elec

Multi gap

type

mostly
in

by

slow

speed driving
too

city weak ignition rich fuel mixture dirty air

cleaner etc H is advisable to replace with plugs having hotter heat range Oil fouled Wet black

Nonnal

Carbon fouled

deposits
worn

show

excessive oil entrance into comb us

tion chamber through and pistons the

or

rings
If

excessive clearance

between valve
same

guides

and stems

condition

remains after Overheating

gray insu Worn
EE601

repair

use a

hotter plug
or

Overheating
lator with

White

light

black

or

gray

brown

Fig EE 76 Spark

Plug

spots and bluish burnt electrodes indicate engine overheating More

over

type cleaner Avoid excessive blasting

Clean and
remove

the appearance results from

carbon

or

oxide

incorrect

ignition

timing

loose

low fuel pump pres a wrong selection of fuel hotter range plug etc

spark plugs
sure

H is advisable to

replace
range

with

plugs

deposits porce lain If deposits are too stubborn discard plugs After cleaning spark plugs renew firing surface of electrodes with file
wear away

but do not

having colder heat

4 with After
a

mentioned above

Then check spark

gauge

plug

gap with wire feeler

new or

All

cleaning

dress electrodes

spark plugs ground

used should have

smaU fme file to flatten the

the gap checked and reset

by bending

surfaces of both center and side elec trodes in parallel Set

electrode

spark plug

gap to

specification
5

Install

spark plugs and torque

each 6

plug
Connect

spark plug

wires

CLEANING AND
REGAP
Clean
EEOSO EE586

spark plugs

in

sand blast

Fig EE 77 Setting Spark Plug Gap Except FU model

EE 29

Fig EE 78 Setting Spark Plug Gap FU models

Engine Electrical System

SERVICE DATA AND

GENERAL SPECIFICATIONS
BATTERY

SPECII ICATIONS

Type

N50Z

NS70
Canada U SA

A pplied model

A S

Optional

Capacity

V AH

60 12

12 65

STARTING MOTOR

SI14 160B

S1I4 163E

S1I4 253

Type
Non reduction gear

type

Reduction gear type Canada U S A

U S A MT

USA A T
A M T US

Applied

model

Optional

Optional System voltage

No load Terminal
Current v

12

voltage

5 11 Less than 60
More than 7 000

11 Less than 100 More than

Revolution

rpm

900 3

ALTERNATOR

Type
Nominal rating Ground
V A

LR15049

1250

trity pol

Negative

Minimwn revolution under no load

When

14 volt is

Less than 1 000

rpm

applied

Hot output current

A rpm

More than 40 2 500 50 5 000

PuUeyratio Regulated output voltage

v

2 06

144to15 0

EE 30

Engine Electrical System

DISTRIBUTOR Type
D4K8 19

D4K8 13

D4K8 18

D4K8 02

D4K8 15

D4K8 16

Applied model

California Non

models

FU model

California models

Canada

Transmission

MfT

AfT

MfT
I

MfT AfT
4 2 3

MfT

AfT

Firing order Rotating direction

Counterclockwise

IGNITION

COIL

Type Applied model Primary voltage Spark gap

v

cn 30

STC 30

All
12

mm

in

More than 7

0 28

SPARK PLUG

BP5ES II

Standard

BP5EQ

13

L46PW 1I BP4ES 1I L47PW 1I BP6ES 1I

L45PM 13

BPR5ES

Hot

BP4EQ

13

Type

L47PM 13

BPR4ES

Cold

BP7ES 1I L44PW 1I L45PW 1I

BP6EQ BP7EQ

13 13

BPR6ES BPR7ES

L45PM 13
L44PM 13

Applied
Size

model

U S A

FU model

Canada

screw

dia

reach
in

14

19 0 55

0 75

mm

INSPECTION
BATTERY

AND ADJUSTMENT

Type
Full charging

N50Z
126

NS70

specific gravity

128

EE

31

Engine Electrical System

STARTING MOTOR

Type
Outer diameter of commutator
mm

S1I4 160B

I
47 0

Sl14 163E

S114 253

in

More than 32

26 1

than More 29 L14

Minimum length of brush

mm

in

12

II

43 0

Brush

spring tension

kg Ib

1 4 to 1 8

1 to 4 0 3

1 6to 2 0 5 to 4 4 3

Clearance between bearing metal and

armature shaft
mm

Less than 0 2 0 008

in

Clearance

between

edge and pinioIl stopper

pinion front in mm

0 to 3

5 0 012 2

to

0 098

Difference T in height of pinion

nun

3 to 1 0 5 in 0 012 to 0 059

ALTERNATOR

Type
Minimum length of brush
mm

LRI5049

in

More than

5 0 295 7

Brush spring pressure Slip ring

outer diameter

gr

oz

255 to 345 8 99 to

17 12

nun

in

More than 30

18 1

DISTRIBUTOR

Type
Air gap
mm

D4K8 19

D4K8 l3

D4K8 18
3 to 0

02 D4K8

D4K8 15

D4K8 16

in

5 0 012 to 0 020 0

Cap il1s

ation resistance

More than 50

1 M

Rotor head insulation resistance

More than 50

Mil

Cap carbon point length

mm

10
in

39 0

Vacuum advance Distributor degree distributor

0 105

13 4

0 170 6 69
3 225

0 80

15 3

0 105 9 300 1181

13 4

70 0

2 76

0 170 6 69 5 300 6

9 250

12 265 10 43

15 300 1181

mmHg inHg

9 84

8 86

11 81 750 0
10 2 400

Centrifugal advance
Distributor rpm

0 550 14 2 300

550

0 550 5 2 400 13

0 550
5 2 400 13

0 750 10 2 400

degree distributor

14 2 300

EE 32

Engine Electrical System

IGNITION COIL

Type Primary
resistance at 200C

CIT 30
U

STC 30

680F

0 84 to 1 02
2 to 12 4 8

Secondary

resistance at 200C

680F

KU

SPARK PLUG

BP5ES ll L46PW ll BP4E ll L47PW ll

BP5EQ BP4EQ BP6EQ BP7EQ

13

L46PM 13

BPR5ES BPR4ES BPR6ES BPR7ES

0 8 to 0 9

13 L47PM 13 13 13

Type
BP6ES I1 L44PW I1 BP7ES II L45PW II
10 to 1

L45PM 13
L44PM 13

1 to 13

Plug

gap

mm

in

0 039 to 0 043

0 043

to

0 051

0 031 to 0 035

TIGHTENING TORQUE
Magnetic switch terminal
SI14 160B S114 163E S1l4 253

kg

em

in Ib 75 to 100 115 to 160

65

to

87
to

100

139

Magnetic switch attaching bolts Starting

motor
case

cm kg

in Ib

38

to

51

to 44

Gear

attaching bolts

kg kg

em m

in lb

64 to 85
5 to 6 0 4 60 to 70 15 to 2 5

56 to 74 33 to 43 52
to

Pulley

nut

ft Ib
in Ib

Alternator through bolts

cm kg

61

Spark plug

kg

ft Ib

II to 18

EE 33

Engine Electrical System

TROUBLE DIAGNOSES AND CORRECTIONS

I BATTERY

Battery
I 2

is not

charged correctly
belt tension ofalternator

Correctly adjust

Complete charging system Securely connect battery terminals

connections in

Lighting Joadtest
I 2

Make

sure

that electrolyte level is correct with ignition system open

one

Crank engine for three seconds

on

3 Turn

headlight low beam for gravity of each cell of battery

minute

and then

measure

specific

Specific gravity of each than 1 200 N50Z NS70

1 When

cell is less
or

gravity
above
200 1

of

some or

cells

is

1 220

specific gravity

can

not be

specific gravity

raised above 1 200 by charging the battery is down run

Specifc
NS70

N50Z
others

1 220

Specific gravity ofeach cell is above

1 200

but

show

lower

N50Z

or

1 220

NS70

Unbalance is within 0 05

Unbalance of
it

specific gravity
down

be

Discharged battery Charge and repeat lighting lood test

tween cells exceeds 005 I

Battery is run

Unbalance is within 0 05 Batter is satisfactory

Unbalance of

specific gravity

be

tween cells exceeds 0 05 I

Battery

is run down

EE J4

Engine Electrical System

II STARTING MOTOR

Condition

Probable

cause

Corrective action

Starting motor will

not

Discharged battery Damaged

solenoid witch
Loose connections of terminal

Charge Repair

or

repiace

battery

operate

or

replace solenoid switch

Clean and tighten terminal

Damaged
Damaged

field coil
brushes

Replace yoke

Replace Replace Tighten

Replace
Add oil

brushes

Damaged bearing

Replace bearing
armature

Damaged
Noisy starting
motor

annature

Loose securing bolt Worn pinion gear Poor lubrication

Worn commutator Worn brushes

Replace

Replace
Charge
Clean and

Starting
cranks

motor

Discharged battery
Loose connection of terminal
Worn brushes

lowly

tighten
repair brush

Replace
Inspect brush pring
holder
tension or

Locked brushes

Loose connections of terminal

Clean and tighten terminal

Damaged Damaged

field coil brushes

Replace yoke
Replace brushe

Damaged bearing Damaged

armature

Replace
Replace

bearing
armature

Starting

motor

Dirty

or

worn

commutator

Clean and

repair

cranks slowly

Armature rubs field coil

Repalce assembly

Damaged

splenoid

switch

Repair

or

replace

Starting

motor

Worn

pinion

Replace guide
Repair

operate but does not crank engine

Locked pinion Worn ring gear

Replace
Repair
or

Starting
not

motor will

Damaged

sOlenoid switch

replace

disengage even if ignition switch is

turned off

Damaged gear teeth

Replace damaged gear

EE 35

Engine Electrical System

III

ALTERNATOR
Condition

Including voltage
Probable
cause

regulator
Corrective action

No output

Sticking brushes Dirty brushes and slip rings

Loose connections
or

Correct Clean

or

replace bru

hes and brush springs

broken leads

Retigliten

or

older connection

Replace leads if necessary Open

stator
rotor

winding
winding

Repair or replace
Replace
rotor

stator

Open

Open diodes
Shorted diodes Shorted rotor Shorted stator Ground
BAT

Replace
Replace
Replace
rotor

Replace
terminal

Replace Replace
Check

insulator

Broken fan belt Excessive output

Voltage regulator breakdown

Poor connection of alternator S terminal

regulator operation and repair replace a required

Correct

or

Open diode
Low

Replace
belt

output

Loose

or worn fan

Retighten
Correct

or

replace
brushes and springs if

Slicking

brushes

or

replace

necessary Low brush

spring tension

Replace
Check

brush spring
or

Voltage regulator breakdown

Dirty slip ring
Partial hort

regulator operation and repair replace required

as

Clean

ground
or

or

open in stator

Replace tator
Replace
rotor

winding Partially
Open Noisy alternator
or

shorted

grounded

rotor

winding

damaged

diode

Replace

diode

Loose mounting Loose drive pulley Broken ball bearing

Retighten Retighten Replace

bolts

Improperly

seated brushes

Seat correctly

EE 36

Engine Electrical System IV

If

IGNITION CIRCUIT
When

there

engine does not start is no problem in fuel

can

between

high

tension cable and

engine
as

tery

and

dieseli lg anti

wlenoid

block

After

checking

this repair

valve connector

to cuI off

supply

system checked

ignition
This
a

system be easily done by

and ob

should

be

necessary

of fuel 10 engine Then observe the condition

motor is in

of sparks while starter

detaching
distributor

high

tension cable from

operation

starting engine serving oondition of spark that

Note

occurs

Turn ignilion switch off and disconnect ground cable from bat

Condition
No

Location

Probable

cause

Corrective action
low tension side

spark

at all

Distributor

Breakage of lead

wire

on

Repair Replace Replace

Poor insulation of cap and rotor head

Open pick

up coil

Air gap wider than

specification

Adjust Replace with Repair Replace

new
one

Ignition coil High

tension cable

Wire Wire

breakage

or

short circuit of coil

coming off

Faulty insulation
IC ignition unit

Faulty IC ignition Breakage

unit

Replace Replace Repair

of circuit

Detached connection

Spark length
More than 6 0 24 in
mm

Spark plugs

Spark plug gap too wide

Too much carbon

Correct Clean

or

replace

or

replace

Broken neck ofinsulator

Replace Replace
Correct

Expiration of plug life

Distributor IC ignition unit
Air gap too wide

Faulty IC ignition Breakage

unit

Replace Replace Repair

of circuit

Detached connection

EE 37

Engine Electrical System

2

Engine

rotates

but does

not run

system

or

other engine conditions not

first

complete inspection of ignition

out

smoothly
This may be caused by the ignition

related to

ignition system Therefore

system should be carried

Condition

Location

Probable

cause

Corrective action
coil

Engine

misses

Distributor

Foreign

matter

onpicl up

Clean
Correct

Improper

air gap

Leak of electricity at cap and rotor head

Repair

or

replace

Breakage of pick up coil lead wire

Worn or shaky breaker Worn
or

Replace Replace assembly

plate

shaky distributor driVing shaft

circuit or

Replace aSsembly Replace

with

Ignition coil

Layer short
coil

inferior quality

good one

High

tension cable

Deterioration

of insulation with

cense

Replace

quenlleak of electricity

Spark plugs

Fouled Leak of electricity

at

Clean upper

porcelain

Repair

or

replace

insulator

Spark plug
IC ignition unit

gap too narrow unit

Correct or

replace

Faulty IC ignition

Replace Replace Repair

too advanced of governor

Breakage of circuit
Detached connection

Engine causes knocking very

often

Distributor

Improper ignition timing Coming spring

Worn

Correct Correct or replace

off

or

breakage

pin

or

hole of governor

Replace

Spark plugs

Burnt too much

Replace
too

Engine
deliver power

does not

Distributor

Improper ignition timing

retarded

Correct

enough

Improper functioning governor

Foreign particles stuck in air gap Spark plugs
Fouled

Replace assembly
Clean Clean

38 EE

DATSUN 210

Model 8310 Series

SECTIONER
ENGINE REMOVAL

INSTAllATION

CONTENTS
ENGINE REMOVAL AND
ENGINE ER 2 ER 3 ER 5 MOUNTING INSULATOR ER 5

INSTALLATION
REMOVAL INSTALLATION

SERVICE DATA AND SPECIFICATIONS TIGHTENING TORQUE

ER 6 ER 6

Engine

lloval Re

In tallation

ENGINE REMOVAL AND INSTAllATION

Jp
40

1 2 3
4

Front engine mounting msulato R H Front c118ine mounting bracket R H Front engine mounting bracket LK Front engine mounting insulator L H Rear engine mounting member fengine mounting insulator Re4

Tightening torque

m ft lb kg

J i
@

5 6

@ @ @

3 2 4 3 23 to 31 1 6 to 2 1 12 10 15 16 to 2 1 12 to 15
to

0 91a 12 0 91012 3 2 to 4 3

510 8 1 6 5 to 8 1 23 to 31

E R479

Fig ER 1 Engine Mounting

ER 2

Engine
REMOVAL
It is much easier to remove and transmission as a to remove alone
can

Removal

Installation
Vacuum hose of brake booster at intake manifold

tor to

engine

single

unit than

body and detach radiator after removing radiator shroud 7 Remove air cleaner assembly
from carburetor as follows

After removal engine be separated from the transmission

1
2

Remove fresh air duct

from air

Air conditioner equipped model

10 Remove compressor belt remove loosen idler pulley nut

assembly
WARNING
a

cleaner
Remove

hot

air

duct

from air

To

cleaner
3 4 Loosen air cleaner band bolt Disconnect air

and

Place wheel chocks in fronl of front wheels and in wheels

rear

adjusting
Remove

bolt

1
2

of

rear

cleaner to air

Remove air pump

compressor

b Be

sure

to hoist

engine

in

safe

pump hose at air cleaner 5 Disconnect air cleaner ta rocker

cover

retaining

bolts and

manner c

hose at rocker cover Disconnect air

compressor toward fender to facilitate removal of engine

move

You should not

remove

engine
com

6
7

cleaner to A B

Nole

until exhaust system pletely cooled off Otherwise self and fuel line Note
to 1
or

has

valve hose at air cleaner

Disconnect air cleaner to related

Never discharge gas from com pressor while work is being per formed

you may burn your fire may break out in

vacuum

hoses at air cleaner accelerator control carburetor

8 wire 9

Disconnect from

Fender

coven

should be used

Disconnect the

following cables

protect

car

body battery ground

cable

wires and hoses Wire to auto choke heater Wire to throttle opener cut solenoid
or

Disconnect

from battery terminal and fusible link

at wire connector 2 Remove hood as follows

throttle switch
to vacuum

Wire to fuel cut solenoid

Wire

switching valve
between igni Compressor

II
EA478

High
CAUTION Have
an

tension cable

tion coil and distributor

assistant
to

prevent damage
I

help body

you

so

as

to

Battery cable

to starter motor

Fig ER

Location ofAir Compressor

Wire to distributor

Mark hood hinge

locations

on

Wire to thermal transmitter Wire to alternator

hood to facilitate reinstallation

Disconnect

vacuum

hose of air

Support hood by ltand and re bolts securing it to hood hinge being careful not to let hood slip when bolts are removed See Fig ER 2
2
move

Engine ground cable oil pressure switch and engine harness No 2 See Fig ER 3

conditioner from connector of intake manifold

4 Remove

F iC D actuator from

bracket
II Remove

Remove hood from hood

hinge

der from clutch housing mission only

clutch operating cylin manual trans

Il
I

o
1

Ground cable

BF133A

Engine harness

No

2
EA368

Fig ER 2 Removing Hood

Oil pressure switch

Fig
3 Remove under cover Drain radiator coolant and

ER 3 Disconnecting Cable and Wire

4 oil
5

engine
Fuel hose at fuel pump and fuel
return hose at connection

dJ

Disconnect upper and lower hoses from radiator and disconnect oil cooler hoses
automatic transmission

Tightening torque Clutch operating cylinder to clutch housing

3 1 to 4 1

E A3

Air pump air cleaner hose Carbon canister hoses Heater inlet and outlet hoses if so

kg Operating Cylinder

22 to 30 ft lbl

only
6 Remove four bolts securing radia

Fig

ER 5 Removing Clutch

equipped
3 ER

Engine
12

Remov 1
front

Installation
a

Disconnect

speedometer
housing
transmission

cable

15

Hang

tube end with wire

to

Note

Use slinger only wheo engine is

or

from
13

rear extension

suitable thread
control tube from J6

or a

prevent

removed from
Be
sure

installed

on car
Ulle

Remove

falling Propeller
Shaft Section
20
to

to

remove

it efter

linkage
I

Remove propeller shaft Refer to for

removal

This
as
a

slinger is
service

listed in Parts Cet log

For

cars

equipped

with manual
PO

optiop
or

transmission

remove gear shift control

lever

end of rear vent oil

Plug the opening extension housing to pre

Connect suitable wire

chain

leakage

Engine Slingers and raise engine a little to take weight off front mount ing insulators

WARNING
For

sofety

in

subsequent steps
or

ten

sion of wire slackened

P0315

chain

should be

against engine

liJ Tightening
Fig
2 6 ER

torque
shaft to

Removing Gear

Shift

Propeller flange

companion
21
m kg Remove

Control Lever

bolts

2 4 to

securing

front

For

cars

equipped

with auto

17 to 24 ft bl

matic transmission disconnect selector range lever

Fig ER 9 Removing Propeller Shaft

froni mounting insulators engine mounting Reise engine and transmission 22 engine
brackets to and
See
remove

from

car as a

single

unit

Fig ER IO

Note e

Pul

me tch

mark

on

both shaft

and companion flange so that shoft can be reinstalled in original posi

tion

CAUTION
a

Before

raising engine 10gether

make
sure

with all

a 17 18

transmission
transmission with

that

Support
Remove

jack
rear

hoses and wires connected thereto

are

bolts

disconnected
not to

or

removed be

securing

b When careful

EA163

engine mounting member to the body 19 Attach Engine slinger 10006H7202 as shown in Fig ER IO

raising engine

especially
it

knock

against

adjacent parts

Fig ER 7 Di8connecting Selector Range Lever

14

Disconnect exhaust front exhaust manifold

rom

tube

from

and exhaust
transmission

mounting bracket

liJ

Tightening torque
manifold 1 9 to 2 m 5kg

ER370

Front tube to exheust

14 to 18 ft Ibl

EA225

Fig

ER S Disconnecting E chaust Front Tube

Fig ER IO Removing Engine

4 ER

Engine
INSTALLATION
Install in the
reverse

Removal

Installation position pin is projected upward 3 Tighten the bolts and nut correct and ly securely See Fig ER I

order

of

re

ENGINE MOUNTING INSULATOR

FRONT INSULATOR

moval observing the following

Note

When

inslal1ing ly

be

sure

to
are

check thaI electrical harnesses connected

1

Removal
Disconnect 2

When installing

first

secure

rear

Suspend
Remove

battery ground cable engine with wire or engine mounting

upper nuts
on

REAR INSULATOR
Removal
l Support ajack 2 transmission

engine mounting member to body 2 Refer to applicable section when installing and adjusting any parts Adjust clutch pedal free
fer to Clutch Section CL
travel Re

chain 3 front

insulator lower and both sides 4 to

weight with

Make sure that wire or chain used

Remove nuts

Pedal Free

Travel and

for installation

adjustment Adjust
Refer
accelerator control system to

Section For

Engine Control System FE for adjustment

and

positioned prqper ly so that no load is applied to insulators and remove nuts complete ly 5 Lift up engine and separate in sulators from engine mounting rack suspend engine
is
ets

mounting insulator
ber
3 Remove bolts

securing rear engine to mounting mem connecting

rear en

gine mounting insulator to sion reaf extension housing

4

transmis

installation of air conditioner Idler belt adjustment Pulley and Com Belt for adjustment

Jack up the transmission and remove insulator

little

compressor

Refer to

Inspection
If there is damage deterioration or separation of bounded surface re

Inspection
If there is damage deterioration or separation of mating surface replace Installation

pressor Drive

of belt tension 3 tube

4 When
on

installing

exhaust
be

front
sure

place
Installation Install insulators in
reverse
rear

exhaust manifold
hood

to

use new

gasket When installing

following
Install
sequence

engine mounting

mem

engine installation be sure that it is properly centered and that hood lock operates securely Refer to Hood See tion BF for adjustment

front

ber and insulator in reverse order of removal I

of removal

noting the fol right

and
or

noting the following

lowing
1 Do not

Install insulator in
that in

place

so

that

confuse

left L

direction of mounted insulator is same

as

R right side left side identification mark

insulators
ed

is stamp

2 and

on

each insulator front insulator

so

Fig ER Tighten nuts and bolts correctly securely As for tightening torque
l

Install

that

see

Fig ER

ER 5

Engine Removal

Installation

SERVICE DATA AND

TIGHTENING TORQUE
Front

SPECIFICATIONS
1 6 to 1 2

engine mounting bracket

to

engine

rn kg

ft lb

12

to IS

Front insulator to

engine mounting
rn ft Ib kg
1 6 to 3 2 to

bracket
Front insulator to

p 12
3 4

suspension member mounting

gem ft Ib

23 to 31

Rear insulator to rear engine

member Rear engine mounting member Rear insulator to trailsmission Clutch operating
to

g body g

m
m

ft lb ft Ib

09 32 09

to to to

2 1

5 to 8 7 6
to

3 23 4

31

g m ft Ib kg g kg g
ft Ib ft lb ft lb

5 to 8 7 6

cylinder

to clutch
m m m

housing
Front tube to exhaust manifold

3 1 to 4 1
19 to 2 4 to 5 2 3

22 to 30

14 to 17

18

Propeller shaft

to

companion flange
to tranSmission

to 24

Emaust mounting bracket

m ft Ib

08

to

2 5 8 to 8 7 1

6 ER

DATSUN 210

Model 8310 Series

SECTIONCL
CLUTCH
CONTENTS
ADJUSTMENT
CLUTCH PEDAL HEIGHT CLUTCH PEDAL FREE TRAVEL
BLEEDING CLUTCH SYSTEM CL CL CL CL CL 2 2 2 2 3 3 4 5 6 7 7

RELEASE BEARING
PILOT BUSHING

CL CL

SERVICE

DATA AND
CL 10 CL 10 CL10 CL 11

SPECIFICATIONS
GENERAL SPECIFICATIONS

CLUTCH CONTROL
CLUTCH PEDAL
CLUTCH MASTER CYLINDER OPERATING CLUTCH CYLINDER

CL CL
CL CL CL CL

INSPEctiON
TIGHTENING

AND ADJUSTMENT TORQUE

LINE

CLUTCH UNIT
CLUTCH DISC AND COVER

TROUBLE DIAGNOSES AND I ECTIONS SPECIAL SERVICE TOOLS

CL 12 CL 14

Clutch

ADJUSTMENT

CLUTCH PEDAL HEIGHT

Adjust clutch pedal height H to specified range with pedal stopper adjusting nut Then tighten lock nut
the
I

tfl Tightening
Lock

torque

Withdrawalle er play nBn clearance between withdrawal

nut

CD
kg
m

0 8 to 1 2

er

push nut and withdrawal

1 0 to 2 0 mm

5 8 to 8 7 ft Ib

le erl

Lock nut

@
Icll m

0 8 to 1

0 039 to 0 079 in

CD
2

5 8 to 8 7 ft lbl

Clutch pedal free

at center of

tr

el

en

Adjust clutch pedal free play specified

range at

to the

pedal pad

pedal pad 16to33 mm

0 63 to 30 1 in

with clutch master cylinder push rod Then tighten lock nut @

Note
a

Pedal

free play

appeared

due

CLUTCH PEDAL FREE TRAVEL

to

clearance among pedal hole push rod and piston should be measured
on

Adjust properly
parts I
are

clutch

pedal

free

travel

whenever clutch does not disengage

or

BLEEDING CLUTCH SYSTEM

The hydraulic clutch system must
be bled whenever clutch line has been

top face of pedal pad Depress and release clutch pedal

its entire stroke to
ensure

whenever

new

clutch

lslal ed i

over

that

disconnected Loosen lock nut and push nut djust length of push rod by turning When

or

air has entered it

action has a spongy

the clutch linkage operates smooth ly without squeak noise inter ference and binding

pedal

feeling

it

is an indication that air has

rod with open end wrench until lsh p release bearing lightly touches clutch dia phragm spring
2

entered the system

Bleeding clutch system is an tial part of regular clutch service

I

essen

mately
lever

Then turn push rod back approxi I 4 turns so that withdrawal

Remove cap of reservoir and top

play

clearance

between

up with recommended brake fluid

withdrawal lever push nut and with drawal lever is within the specified range I

Thoroughly
so

clean mud and dust of operating cyl

from bleeder inder

any

screw

that outlet hole is free from material Install bleeder

on

foreign

V
@

hose vinyl hose Place the

3

bleeder

screw

other end

of it

in a

container filled with brake fluid

Have
two

a coworker
or

depress

clutch

1
I

pedal pedal depressed fully

screw

three times With clutch loosen bleeder

to bleed air out of clutch sys

tem Lock nut Push nut

Close bleeder

screw

quickly
to

as

2 3

clutch 5
CL327

pedal

is on down stroke

Withdrawallcver Fig CL 2

Allow

clutch

pedal
screw

return

slowly with bleeder

6

closed

AdjlUting

Clutch Pedal Free Trauel

Repeat steps

3 through 5 until no

I 2

Lock nut Lock nut

Cl325

air bubble shows in the

vinyl hose

3
nut

Tighten

lock

nut

against push

Fig CL I AdjlUting Clutch

Pedal Height

being careful adjustment

4

not to disturb the

tfl

Tightening torque
Bleeder screw 0 7 to 0 9

Depress
times

kg

and release clutch then recheck B

pedal
with if 7

5 1 to 6 5 ft

lbl

several
Pedal

height

H 5 63 to 5 87 in

drawal

lever

play
measure

Readjust

143 to 149 mm

necessary 5 C

Depress

and release clutch

pedal

Pedal free play

1 to 5
mm

An 0 04 to 0 20 in

Finally

pedal free travel

several times

then check for external

at center of pedal

pad

hydraulic

leaks at connections

CL 2

Clutch
Note
a

Brake fluid

conlaining

air is white

d Pour brake fluid into reServoir up to the specified level

and has visible air bubbles b Brake fluid containing

out
no

CAUTION
a

00 not

re use

brake fluid drained

air runs
a

of bleeder

screw

in

1lO6d

stream without air bubbles

c

during bleeding operation Exercise care not to splash brake

fluid
on

Pay close operation

exterior finish

as

it will

attention

to clutch fluid

level in reservoir

during bleeding

damage the paint e When tightening flare nut use ll Flal Nut Torque Wrench GG94310000

CLUTCH CONTROL

CLUTCH PEDAL
REMOVAL

l
JF
j
1

2 3

Clevis pin Master cylinder

push rod Snap pin 4 E ring 5 Bushfug 6 autch pedal 7 Return spring

Clutch ma5ter cylinder

2

j
Fig
4 CL

CL351

3
4 5

Clutch disc assembly Clutch cover assembly Release bearing and sleeve assembly Return spring Clutch line Clutch pedal

Clutch Pedal

6
7

8 9 10

Operating cylinder
Withdrawal lever Withdrawal lever ball pin

Remove snap pin from

end of

clevis pin

Separate
E

master

cylinder

push rod
2
C L369 crum

from clutch

pedal
clutch

Remove

ring from tip of ful

pin

and take out

pedal

Fig

CL 3

Hydraulic Clutch Control System

and return spring

CL 3

Clutch

INSPEctiON
Check clutch

Note CAUTION

When be

disconnecting
sure

dutch

tube clutch tube

use

to

receive draioillll

pedal parts
correcting

for the
neces

When

disconnecting
use

clutch fluid into a container Use of

rags is also

following
sary I 2 Bent

items

suitable flare nut wrench

Never pedal pin and

Weakened return spring
Worn or deformed clevis

adjus1able

open wrench

an

end wrench

or

cent

suggested to keep adja parts and area clean

3
4

fulcrum bwhings Cracks at welded part DISASSEMBLY

ATION INSTAl1 To install clutch

pedal

reverse

the

order of removal Observe the follow

ing
I

Apply coating of recommended

grease to

multi purpose

sliding

por

tions and return

spring

of

I
1 2 3 4 5
CL352

Lt
2 3
Insert

ii

Reservoir cap Reservoir Rescrvou band

6 7 8 9 10

Return

Cylinder body Supply yalYe stopper

prina Sprina seat Valve sprina Supply valve rod Supply valve

11 12 3 14 15

Primary
Piston

cup

16 17 18

StOppel rins
Dust
cover

Secondary cup
Push rod

Lock nut

Stopper
CL345

Fig CL 5 Lubricating Point

Fig

6 Clutch Mcuter Cylind CL

r

Fit return spring in hole in pedal

Remove dwt

cover

and take off

bracket and securely fit E ring in slit of fulcrum pin

INSPECTION

pedal
4

clevis pin through clutch from left to right side

stopper ring from body 2 Then the push rod and stopper can be taken out
3

CAUTION
To clean
or

After

installing
to

clutch

pedal

Loosen supply valve stopper and

The

wash all parts of masler

take it out
4 turn

cylinder
used

clean brake fluid must

use

be

check the clutch if necessary Refer

pedal height AdjUst

Adjwtment

Never

piston spring seat spring can be taken out

Discard

and

reo

gasoline

mineral oils such as and kerosene It will ruin tha

rubber parts of tha and dust

I

hydraulic

syslBm

Note

piston

cup

cover

Check cylinder bore

score or

and

for

rust and if found

CLUTCH MASTER

CAUTION
Never detach reservoir If it is removed for any
new one reason

2 for

Check
wear

cylinder

bore

piston replace and piston

If the clearance between

CYLINDER
REMOVAL
I Remove snap pin from clevis pin Pull out clevis pin Disconnect clutch tube from
mas

discard it and instill

cylinder bore and piston exceeds the specified value replace piston assem bly or master cylinder assembly
3

Check the

condition

of piston

2 3

cup and dust cover Always them after disassembly 4 Check all
recesses to

replace

ter 4

cylinder
Remove master

openings and
that

cylinder
4 CL

internal passages

ensure

they

Clutch
clean and free from

are

foreign

matter

if

Cearance between bore and piston

cylinder

Tightening torque Master cylinder

securing
nut

to

dash

panel

Leu than 0 15 mm 0 0059 in

0 8 to 1 2 kg

5 8 to 8 7 ft Ib Clutch tube flare nut 1 5 to 1 8

kg

11 to 13 ft lb

v
tube
use

ASSEMBLY Assemble clutch master cylinder in the

reverse

CAUTION
When F lere

order of disassembly

Ob

connecting
Nut

clutch

serve

the following

Torque

Wrench

Dip piston cup in brake fluid before installing Make sure that it is correctly faced in position

GG94310000
I Note
Bleeder
screw

5 6 7 8

Dust

cover

When

tightening
hand to
r

flare nut hold

it

Cylinder body
Piston cup Piston

Push rod
Lock nut

pipe by
twilling

from

3
4

Push nut
CL203

Fig

CL B Operating Cylinder

INSPECTION

2 3
4

Return spring Supply valve rod Piston

5 6
7

Spring seat Valve spring

Primary cup
Push rod

OPERATING CYLINDER
REMOVAL
I Disconnect at

Visually inspect all disassembled parts and replace parts which are worn or damaged too badly beyond specifi
cations

Secondary cup

CL283

clutch
the

tube
on

from side

Fig CL 7 Piston Asaembly

clutch hose member

bracket

CAUTION
To clean
or

WISh all parts of

operating
must be

Apply a coating of brake fluid to cylinder and piston when assembling

2

cylinder Used
Never
use

dean brake fluid mineral oils such

as

CAUTION When

gasoline

if

Tightening

torque

disconnecting
use

clutch tube

and kerosene
use

It will ruin the rubber

Reservoir band 0 25 to 0 4 kg
m

suitable flare nut wrench Never

an open end wrench wrench or

parts of the hydraulic system

I

11 8

to

2 9 ft lb

adjustable

Check cylinder bore

score or

and

piston

Supply valve stopper

0 15 to 0 3

for 2

rust and if found

replace

kg

Check cylinder bore

wear

and piston

1 1 to 2 2 ft Ib

Remove

lock spring

then dis

for

If clearance between cylinder

value

engage hose from bracket 3 Remove clutch hose from oper

ating cylinder 4 Remove operating cylinder INSTALLATION

Install clutch master cylinder in the
reverse order of removal Observe the

piston i5 more than the replace piston or oper ating cylinder assembly 3 Check condition of piston cup and dust cover Always replace them after disassembly
bore and

specified

Check bleeder

hole

to

be

sure

that it is clean DISASSEMBLY Remove

2
an

following hydraulic system Refer to Bleeding Clutch System for bleeding

2 I

Clearance between

cyliniler

bore

Bleed air out of

push

rod and dust

cover as

and piston less than 0 15 mm 0 0059 in

Remove piston and piston cup

assembly ASSEMBLY
Discard

Adjust pedal height

travel Refer
to

and

pedal
Pedal

Note

free

Clutch

piston

cup and dust

reverse

cover

Height and Clutch Pedal Free Travel for adjustment

Assemble operating cylinder in the order of disassembly Observe

Remove bleeder

screw

the

following

Cl 5

Clutch
t

Prior
cup

to

lWembly

dip

new

cylinder
3 1 to 4 1 22 to 30

to clutch

INSTALLAnOlll Wipe
line to

piston

in clean brake

fluid To

housing securing bolts

install piston cup on piston pay par ticular auention to its direction 2

kg
lbl ft

the opening ends of hydraulic

remove

any

foreign

matter

Dip cylinder

brake fluid before

piston assembly

and

in clean

before malting connections

Clutch hose to operating

cyli nder
1 7 to 2 0 kg m I

Connect clutch tuhe

with flare nut Fix clutch

to

master

12 to 14 ft lbl
Flare nut 1 5 to 1 8 m kg

cylinder
2

tube

to

dash

panel

and side member with 3 Then

clamp
nut

11 to 13 ft Ibl

tighten flare

INSTALLATION
Install
reverse

@
cylinder
in the

Tightening torque
Flar
nut

operating

order of removal Observe the

1 5 to 1 8 11 to

following
1 Bleed air thoroughly from clutch hydraulic system Refer to Bleeding Clutch System for bleeding 2 Adjust clutch pedal free travel

kg m 13 ft Ibl
on

InstaU clutch hose

with
a

operating

CLUTCH LINE
INSPECTION
Check clutch lines
tube and hose
or

cylinder
Note

gasket

in

place

Refer to Clutch Pedal Free Travel for

Use

new

gaslcet

adjustment
Note

for evidence of cracks deterioration

new

@ Tightening torque
1 7 to 2 0 kg m 12 to 14ft lbl

gasket b When operating cylinder is removed

a

Use

other damage If leakage

Replace
occurs

if necessary
at
or

around
re

from

or

instaUed

on

clutch haus clutch

ing

without

disconnecting

joints retighten and if place damaged parts

necessary

Engage opposite end of hose

with

bracket InstaU lock spring

to bracket

fIxing hose

hose from operating cylinder loos en bleeder screw so that push rod
mo
c

lightly
care

REMOVAL
not to Be away
sure

Note
a

xer e

p to

or

wist

When

tightening
to

flare

nut

hold

clutch clutch tube d When

hose hose

install exhaust hold from

CAUTION
When Never

from

disconnecting
use an

clutch tube

use

pipe by hand twisting

b Exercise
care

prevent it from

suitable flare nut wrench

not to warp or twist

tightening
to

flare

nut it

pipe by hand twisting CAUTION

When Flare

prevent

adjustable

open end wrench wrench

or

clu1ch hose

4
1

Connect clutch tube

to

hose with

Qisconnect

clutch

tube
on

from
mem

flare nut and tighten it 5 Check distance between line and 6

clutch
be

connecting
Nut

dutch

tuhe

uSe

clutch hose at bracket ber 2

3
emove

side

adjacent

parts

especially

Torque

Wrench

tween hose and exhaust tube

G694310000

lock spring then disen

Bleed air out of hydraulic system Refer to Bleeding Clutch System

gage hose from bracket

Remove clutch hose from oper

for

ating cylinder

bleeding

Tightening

torque

4 ter

Disconnect clutch tube from

mas

Bleeder screw 0 7 to 0 9

cylinder
Remove

kg

clamp fIxing

clutch tube

5 1 to 6 5 ft Ihl

to dash

panel and

side member

CAUTION When tightening flare nut NutWrench G G9431 0000

use

Flare

CL 6

Clutch

CLUTCH UNIT

1 2

Clutch disc assembly Clutch cover assembly ReleaJe bearing

3
4 S 6

Bearing

sleeve

Withdrawal lever Withdrawa11ever ball pin

Return

spring

CL370

Fig CL 9 Clutch Unit

CLUTCH DISC AND COVER

REMOVAL
1 Remove transmission

Loosen
to

cover

time

bolts attaching clutch flywheel one turn each at a until spring pressure is released them out in a crisscross

Be from
en

sure to turn

fashion
4

I If facings are oily disc should be replaced In this case inspect transmis sion front cover oil seal pilot bushing engine rear oil seals and other points for oil leakage 2 The disc should also
worn

Remove

clutch

disc and

cover

be

gine
2

Refer Insert

to

Removal
4

Section MT

replaced
or worn

assembly

when facings are

locally

Clutch

ST20610000 KV30100IOO

Bar Aligning speed tranSmission or 5

down io ihe

specified limit
A 0 012 in
mm

speed

transmission
no

INSPECTION
Wash all disassembled parts except
disc

Wear limit of facing Les than 0 3

into clutch disc hub

until it will

longer
weight
follow

gd

It is

important

to support

assembly

in

suiiable
and

of clutch disc in the steps that ST20610000

4

vent to

remove

dirt and

cleaning sol grease before

making inspection
peed FI

adjustment

1 and pressure plate Check friction surface of flywheel

transmission KV30100100
S

peed

and

pressure

transmission

roughness

plate for scoring or Slight roughness may be

9111
I
A
m M

smoothed by using fine emery cloth If surface is deeply scored or grooved the part should be replaced Clutch disc sembi

cL194

Fig CL W Supporting Clutch Assembly

Inspect clutch disc for worn or oily facings loose rivets and broken or loose torsional springs
CL 7

C L336

Fig CL ll M asurng Clutch Facing

Wear

Clutch
3
ever

Check disc plate for

the old disc or
a

runout new

when
one

ST200S0051 snOO50100 snoo 500 10

Slide clutch disc

several times

on

main drive gear

is

Remove clutch disc and lubricant

installed 4 If runout exceeds the

specified
g

value at outer circumference of fac

replace

or

repair disc

re1
2

wipe off excess by disc hub

A

pushed off

Note

Take special care to prevent grease or oil rrom getting on clutch

Runout limit

racing
eLlSl

ltotal
R

indicator

reading
0 020 in

Less than 0 5 mm

from hub center 85 mm 3 35 in

Fig CL J3 Measuring H ight of Diaphragm Spring Measure height

with a vernier A

Reinstall clutch disc and clutch

cover

assembly
cover

Support clutch disc

with Clutch
speed 4

and
at

assemblies

several

Aligning

Bar

ST20610000
or

points
gauge

caliper depth

transmission

KV30100IOO

If height
the

CAUTION When

beyond
disc

of spring end is specified value adjust

speed transmission
Note
Be
sure

repairing
with

plate

never

hold it
exces

forcibly
sively aged

otherwise

pUers or bend facing will

it

spring height with Diaphragm Ad justing Wrench ST20050240 as sh 1wn

in

to

keep

disc

racings

be dam

Fig

CL I4
A

flywheel and and dry

pressure

plate clean

KV30100100

Diaphragm spring height

29 0 to 31 0 mm 1 142 to 1 220 in

peed 5
transmission ST20610000 4 speed trammisaion

If necessary assembly Also

replace
toe

clutch

cover

unevenness

of dia

phragm spring
within the

height should be
limit
CL32

specified

Unevenness of toe

diaphragm spring Fig

mm

height
Less than 0 5 0 020 in

CL I5 Installing Clutch Diac and Cover Aaembly

CL112

Fig CL 12 Repairing DiM Runout

tighten clutch flywheel squarely Each bolt should be tightened one

to cover

Install

bolts

assembly

to

turn at a time in a crisscross fashion 5

Check fit of disc hub

on

transmis

sion main drive gear

splines

for smooth clutch disc

ifJ

Tightening torque
Clutch
cover

sliding If splines
r

bolt

are worn

main drive gear should be

replaced

1 6 to 2 1 kg m 12 to 15 ft N te

that is backlash exceeds the value at outer Backlash Less than 0 4

mm

specified
CL152

Ibl
to

edge of clutch disc Fig

0 016 in

Dowels
cover

are
on

used

locate

CL I4 Adjusting Spring Height 4

clutch

flywheel properly

Clutch
I

cover a

embly

Inspect thrust rings for wear or damage As these parts are invisible
from outside
and noise

Remove clutch aligning bar Reinstall transmission Refer

to

Installation Section MI

shake
to

cover

assembly

up

Check

the

end surface of dia

down
or

listen

for
on

chattering
rivets for
a

phragm spring for wear If excessive wear is found replace cluich cover assembly 2 Measure height of diaphragm springs as outlined below
I

lightly hammer
cracked noise

RELEASE BEARING
REMOVAL
1

slightly
noi
a

Any of these
as

indicates need of replacement

complete assembly

Remove

transmission

from

en

gine INSTALlATION Apply a light coat of grease in cluding molybdenum disulphide to transmission main drive gear splines
I

Refer to Removal Section MI Disconnect

return

Place

Distance
on

Piece Plate

2
3
as an

spring

from

ST20050100

Base

bearing sleeve
Remove release bearing and sleeve assembly from transmission case
cover

ST20050010 and then tighten clutch

cover

assembly

on

base

plate by using

Set Bolts ST20050051

front

8 Cl

Clutch
4 Take clutch release bearing out a universal
and
a

Contact surfaces of withdrawal

Remove

from bearing sleeve using

lever 3

puller

suitable adapter

pin and bearing sleeve sleeve Bearing sliding surface of

lever ball

shaft

by

Pilot

pilot bushing in crank Puller Bushing

KVI0102800

transmission case front cover KV10t02800

Fig CL 16 Di8auembling Release Bearing

C1195

Fig INSPECTION
Check for abnormal
tact
wear on COD

CL 19 Lubricating Points of Withdrawal Lever

Fig CL 21

Removing Pilot Bushing

Bearing Sleeve and

Front Cover

INSPECTION Check pilot bushing for fit in bore

surface of withdrawal lever

ball 4 Transmission
main

pin and bearing sleeve Hold bearing inner

outer race while it

drive

gear

of crankshaft

race

and rotate

splines Use
num

grease including molybde

applying pressure to If the bearing rotation is rough or

disulphide
A small amounl to of grease

ing
coated will the above
the

Check inner surface of pilot bush for wear roughness or bell

or

Note

mouthed condition
worn

noisy replace bearing

INSTALLATION
1

should

be it

points

If too

much lubricant is
n

ing

is

If pilot bushing is damaged replace When bush damaged be sure to check

main

applied
bearing
on

out

on

transmission
same time

drive gear

at the

Assemble
a

release press

friction
in

plates

when hot

resulting

sleeve using
Note

damaged clutch disc facings lubricating position

install
with

Do not

depress

outer race

After

INSTALLATION
Before installing a new bushing thoroughly clean bushing hole 2 Install pilot bushing so its height A above flange end is the specified value Bushing need not be oiled
1 Pilot

drawallever release bearing and sleeve

assembly

in

Connect them

with return spring

bushing inserting
A 0 110 in 2 8 mm

distance

L
Cl117

Note

When

inserting pilot bushing

be careful not to damage

edge

of

Fig CL 17
2

nstalling Release Bearing

or

pilot bushing
1 2 3

Before

cate the

during assembly lubri following points with a light

spring Release bearing

Return

Withdrawal1cver

CL196

coat of multi

purpose

grease of release
Pack this

Fig CL 20 Installing Release

bearing
4

Mechanism

eve

1groove nner
4

reces5

Reinstall

transmission

Refer to

Installation Section MT

PILOT BUSHING
REMOVAL
1

EM719

Fig
transmission

CL 22 Installing Pilot Bushing

Remove

from

en

Install

clutch

disc

and

clutch

gine
CL093

Refer to Removal Remove

Section MT and
cover

cover

assembly Refer

to Clutch Disc

clutch disc

and Cover for installation 4

Fig CL IB Lubricating of Rece Bearing Sleeve

assembly

Refer to Clutch Disc and

Install transmission

Refer to In

Cover for removal

stallation Section MT

CL 9

Clutch

SERVICE DATA AND SPECIFICATIONS

ENERALSPECIFICATIONS
Clutch control system

Type

of clutch control

Hydraulic

Clutch master cylinder Diameter Clutch operating cylinder

mill in 15 88

Type
Diameter Clutch disc
mm

Adjustable
in

1746

Type
Facing
size
x

180CBL

Outer dia

Inner dia

Thickness

mrn in

180

125
x

x x

5 3
0 138

7 09 Thicmess of disc Free Installed Number of torsion springs Clutch cover

4 92

assembly
mm

in in

5 to 9 2 0 335 to 0 362 8
7 6 to 8 0 0 299 to 0 315

mm

Type
FuU load

CI80S

kg Ob

335 to 385

739 to 849

INSPECTION AND ADJUSTMENT

Clutch pedal Pedal height Pedal free H A
mm mm

in in in in

143 to 149 1 to 5

5 63 to 5 87

play

0 04 to 0 20

Withdiawallever Pedalfree travel Clutch master

play
C

mm mm

1 0 to 2 0 0 039 to 0 079 30 16 to 33 0 63 to 1

cylinder
mm

Maximum clearance between

cylinder bore and piston

Clutch operating cylinder Maximum clearance belween

in

Less than 0 15 0 0059

cylinder
Clutch disc

bore and piston

mm

in

Less than 0 15 0 0059

Wear liinit of facing

Depth

of rivet head below

facing

surface

mm mm

in in

0 3

0 012

Runoullimit Distance of runout

5 0020 0

checking point
mm

from the hub center Maximum backlash of spline

at outer

in

85

35 3

edge

of disc

mm

in

4 0 016 0

CLIO

Clutch

Clutch

cover mm toe

Diaphragm spring height

Unevenness of

in in

29 0 to 310 Less than

142 1

220 to 1

diaphragm spnng

height

mm

5 0 020 O

TIGHTENING TORQUE
Pedal stopper lock nut Master

kg
lock nut

ft b

0 8 to 12 5 8 to 8 7
2 5 8 to 8 7 0 8 to 1

cylinder push rod

kg m ft Ib kg m ft kg
m

Operating cylinder push

rod lock nut

screw

0 8 to 1 2 5 8 to 8 7
0 7 to 0 9 5 1 to 5 6

Operating cylinder bleeder

ft b

Master cylinder to dash panel securing

nut

kg m ft lb kg m ft Ib housing kg
m

0 8 to 1 2 5 to 18 1

5 8 to 8 7 11 to 13

Clutch tube flare nut

Operating cylinder securing bolt

to clutch

ft lb

3 1 to

1 4

22 to 30

Qutch hose to operating cylinder Qutch

cover

kg m ft Ib kg
m

17 to 2 0 12 to 14 1 6 to

bolt

ft Ib

1 12 to 15 2

CL 11

Clutch

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Clutch Probable
cause

and testing

Corrective action

slips

Slipping of clutch during operation

I

may be noticeable when any of the

following

symptoms is encountered

Car will

not

respond to erigine speed during acceleration

car

2 3

Insufficient

speed

Lack of power

during uphill driving

Some of the above conditions may also be attributable to engine problem First determine whether engine or clutch is causing the problem If
an

slipping clutch

is left unheeded

wear

and or

overheating
follows

will occur

on

clutch

facing

to such

extent that it is no

longer

serviceable
as

TO TEST FOR SLIPPING CLurCH proceed

During upgrade havelling

lever in is

slipping

h 25 to 31 MPH with gear shift km 3rd speed position shift into highest gear and t the same time rev up engine If clutch car willnot readily respond to depression of accelerator pedal
run

engine

at about 40 to 50

Clutch facing Oil

or

warn on

excessively

Replace Replace plate Repair or replace

grease

clutch

facing
pressure

Warped
Clutch drags

clutch

cover or

Dragging clutch is particularly

noticeable when shifting gears especially into low gear TO TEST FOR DRAGGING CLurCH proceed as follows I Start engine Disengage clutch Shift into reverse gear and then into Neutral Gradually increase engine speed and again shift into reverse gear If clutch is is heard when shifting gears from Neutral into Reverse Stop engine and shift gears Conduct this test at each gear position

dragging

gear

grating

In step 2 gears are shifted smoothly except 1st speed position at idling a If dragging is encountered at the end of shifting check condition mechanism in transmission b If dragging is encountered at the

of synchro below

beginning

of shifting

proceed

to

step

Push
a

change

lever toward Reverse

can

ide

depress pedal

to check for free travel of pedal

If pedal

be

depressed

further check clutch for condition below

b 5

If pedal cannot be depressed further proceed to step 5

Check clutch control

pedal height pedal free play free travel withdrawal lever play etc If any abnormal condition does not exist and if pedal cannot be depressed further check clutch for condition

Clutch disc runout Wear disc

or

or

warped

Replace
in clutch

rust on hub

splines

Clean and lubricate with grease

or

replace

Diaphragm spring toe height adjustment or toe tip worn

Worn or

out

of

Adjust

or

replace

improperly

installed parts

Repair

or

replace

CL12

Clutch

Condition Clutch chatters

Probable Clutch chattering

cause

and

testing
noticeable when
car

Corr ctive action

is rolled off with clutch

is

usually

just

parlially

engaged
Weak
or

broken clutch

disc

torsion

Replace Replace

spring
Oil
or grease

on

clutch facing of proper contact

or

Clutch

facing

out

Replace

clutch disc runout Loose rivets

Replace plate
or

Warped
surface

pressure

clutch

cover

Repair Adjust

or

replace replace

Unevenness

of diaphragm

spring

toe

or

height
Loose

engine mounting

or

deteriorated

Retighten

or

replace

rubber

Noisy clutch

A noise is heard after clutch is

disengaged

Damaged release bearing

A noise is heard when clutch is

I Replace
disengaged Apply
grease

Insufficient grease of bearing sleeve Clutch

stalled
cover

on

the

sliding surface

and

bearing

are

not

in

Adjust

correctly
car

A noise is heard when

is

suddenly rolled off with clutch partially engaged

Damaged pilot bushing

Clutch grabs When grabbing of clutch
will be
occurs car

I Replace
will not roll off smoothly from
a

standing

start or clutch

engaged before clutch pedal

or

is

fully depressed Replace Replace

shaft Clean
or

Oil

grease

on

clutch
or

facing
loose rivets
in drive

Clutch facing Wear

or

worn

rust on

splines

replace

and clutch disc

Warped flywheel
Loose train units

or

pressure

plate
or

Repair
power

or

replace

mountings

for

engine

Retighten

CL13

Clutch

SPECIAL SERVICE TOOLS

IKent Moore No Reference
page
or

Kent Moore No
Reference

Tool number

tool name

Fig No Unit

Tool number

tool

name

page or FiR No Unit

application ST206100ll0 Clutch aligning bar 125673 ST2005005 I Set bolts

application

Fig CL Fig CL

1O
15

Fig

CL I3

YVYYVYVV
F4W60L

KV30100100

Clutch aligning bar

ST20050240

Diaphragm spring adjusting

wrench

Fig qIO Fig CL 15

Fig

CL 14

FS5W60L

STI0050100

Distance piece

KVIOl02800

Pilot bushing

puller

J25657

Fig

CL 13

Fig

CL 21

ST20050010

Base

plate Fig
CL 13

GG94310000

Flare nut torque wrench

0
@

Page Page Page

CL 3 CL 5 CUi

Applicable

to all B310 series model

C114

DATSUN 210

Model 8310 Series

MANUAL TRANSMISSION

CONTENTS
4 SPEED TRANSMISSION Model F4W60L
MT MT MT MT DISASSEMBLY ASSEMBLY MT MT MT MT MT CASE AND REAR MT MT MT 9 9 9 2 3 4 5 5 5 9 9 9 REMOVAL INSTALLATION DISASSEMBL Y TRANSMISSION CASE DISASSEMBLY OF ADAPTER REAR PLATE DISASSEMBL Y TRANSMISSION DISASSEMBLY ADAPTER CASE OF MT19

DISASSEMBLY
ASSEMBLY

MT19 MT19 MT 22 MT 22 MT 23

GEAR

PLATE

DISASSEMBLY DISASSEMBLY

REAR EXTENSION

INSPECTION TRANSMISSION CASE AND

REAR EXTENSION BEARING

GEAR

DISASSEMBLY

MT 23 MT 23 MT 23 MT 23 MT 24 MT 24

EXTENSION DISASSEMBLY

INSPECTION TRANSMISSION EXTENSION BEARING

GEARS AND SHAFTS

BAULK RING INSERT SHIFTING 01 L SEAL REAR ENGINE

GEARS AND SHAFTS

BAULK RING INSERT

MOUNTING
MT 24 MT 24 MT 24 MT 24 MT 24 MT 24 MT 25 MT 29

MT10 MT10 MT10

INSULATOR
ASSEMBLY

SHIFTING
01 L SEAL REAR

FRONT COVER ASSEMBLY

TRANSMISSION CASE ASSEMBLY REAR EXTENSION ASSEMBLY

ENGINE MOUNTING
MT10 MT10

INSULATOR ASSEMBL Y FRONT COVER

ADAPTER

PLATE

ASSEMBLY

ASSEMBLY

MT10 MT10 MT10 MTll MT 1 1 MT14

ASSEMBLY OF

GEAR

ASSEMBLY

TRANSMISSION CASE ASSEMBLY

REAR

TRANSMISSION ASSEMBLY SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS

EXTENSION ASSEMBLY
PLATE

ADAPTER

ASSEMBLY
ASSEMBLY

MT31 MT31 MT32 MT 33

ASSEMBLY OF TRANSMISSION

GEAR

ASSEMBLY

INSPECTION
TIGHTENING

AND ADJUSTMENT TORQUE

S SPEED TRANSMISSION

Model

fSSW60L

MT 16 MT17

TROUBLE DIAGNOSES AND CORRECTIONS

SPECIAL SERVICE TOOLS
MT 34 MT 35

REMOVAL

INSTALLATION

MT18

Manual Transmission

SPEED

TRANSMISSION

Model

F4W60L

t
f
i

J
6 16 17 with oil seal

QW

@ @ 4

il

TM281A

Rear cxtension

dust

cover

Y
0
6
7 8

jj
smi Tran

Top detecting switch

torque
0

sion

case

mbly

Tighteni

kg

ft lb

Filler

plug Adapter plate

Breather

9
10

@ @ @

10

16

2 0 to
0 1
to

7 to 12 3 0 14 to 22
10

5 1 to 1 2

Bearing retainer
Rear extension dowel pin Reverse lamp sWitch Rear extension assembly
Drain Retum

f
@

1 2 3
4 5

Front Front

cover cover

11 oil

@
@ itJ @ I8i

2 12 to 16 2 5 to 4 0 18 to 29 2 0 to 3 5 141025 5 to 4 0 18 to 29 2 2 0 to
5 3

1 6102

seal
shim

12 13
14 15

Front
Front

cover O cover

ring

c @

adjusting

Welch plug

plug spring bushing

MT l

14 to 25

Fig

F4W60L TrarwniuionClOMJ Components

TM093A

2 3
4

Main drive bearing Main drive gear top synchronizer 3rd gear mainshaft Mainshaft 3rd 2nd gear mainmaft ht 2nd synchronizer 1 It gear mainshaft Mainshaft bearing Reverse gear mainshaft Counter gear assembly Idler gear assembly G

5 6
7

8
I
I

9 10 11

12

Fig
MT 2

MT 2 F4W60L Transmi8aion

CompoMnla

Manual Transmission

o
@

I 2 3 4 5 6 7 8 9 10 11 12

ht 3rd

2nd fork
r

top fork rod

Reverse fork rod

Retaining pin
I
t

2nd shift fork top shift fork

ball

3rd

Checking

plug

16
17 18

Check ban spring Check ball

Interlock

plunger S topper ring

Shift rod A bracket Reverse shift fork
Lock

19 20
21

Striking rod Return spring plug Reverse check spring Return pring Plunger
D

25 26 27
28

Control lever bushing

Tightening torque

kg

lb ft

ring

13
14 15

22
23 24

pin
lever

Striking

Stopper pin bolt Striking guide assembly Striking guide oil seal

Expansion plug Control pin bushing Control arm pin

Control lever

@ @

0 5

to

0 8

3 6 tn 5

3 to 1 1 7

9 to 12
TM094A

29

Fig MT 3 F4W60L Tra11lmiBSion Shift Control Components

REMOVAL
To dismount transmission from the
car

Jack up the
on

car

and support its

Remove clutch operating cylinder

case a

weight

safety stands
or

Use

hy

from transmission
10

draulic hoist Make

5 and
sure

proceed as follows
Disconnect battery ground cable Remove console box and detach

open pit if available that safety is insured front

exhaust tube

Support engine by placing

jack

under oil

pan with a wooden block

Disconnect
remove

used between oil pan and jack

rubber boots if so 3

equipped
remove

securing mounting bracket from exhaust

tube side

bolt

exhaust
front

Place transmission control lever in

it

neutral position and

Disconnect

wires

from

reverse

back up lamp switch 7 Disconnect speedometer from

rear extension

CAUTION cable 00 not

At the same time

so

pan drain

place plug

the

jack

under the oil

removey top detecting switch if equipped

8
Remove

propeller

shaft Section PO 11

Refer to Removal

m
TM781

transmission Note

Support transmission jack

Loosen
rear

with

Plug

up the

opening

in the rear

12

extension to

prevent oil from flow

engine

mount se

Fig

MT 4 Removing Control Lever

ing out
MT 3

curing bolts CD temporarily and re move crossmember mounting bolts V

Manual Transmission
13
14

Remove starling motor Remove bolts securing transmis

Then support the

Before

installing
rear

surfaces of engine
mission case 2

cJean mating plate and trans

engine and gusset engine and trans mission with jacks and slide trans is
sion to sion
remove

Before
to

grease

installing spline parts

drive

lightly apply
of clutch disc

rearward away from engine and from the car

and main grease to lever

gear

And also apply

moving surfaces of control and striking rod Remove filler plug and fill trans plug
hole

mission with recommended gear oil to

CAUTION
Take
care

the level of the

not to

dismounting trammission strike any adjacent parts and

in

Oil capacity 1 3 liter 2 US pt 2 Y

Fig MT 5 Removing Rear

1IIline

main drive gear

Imp ptl

Mounting Croamember

Apply sealant

to threads of filler

plug

and install fdler

plug

to transmis

sion case

INSTAUATION
Install the transmission in the
verse re

IiJ

Tightening torque
Filler plug 2 5 to 4 0 fll klt

order of removal paying atten

tion to the

following points

18 to 29 ft

Ib

4 MT

Manual Transmission

DISASSEMBLY
TRANSMISSION CASE DISASSEMBLY
I sian

Remove main

drive bearing snap

ring with snap ring

pliers

Set up KV32100300

12

on

Adapter Setting adapter plate

Plate

Place the above assembly in a vise

Prior to

disassembling traiIsmis
off dirt and

thoroughly wipe
thoroughly
dust

grease from it 2 Drain oil 3

Remove

cover

from trans

mission case

Remove release bearing and with drawallever

4

Remove

reverse

lamp

switch and

TM188 TM789

top detecting switch if equipped 5 Remove speedometer pinion as sembly 6 Remove nut and stopper pin bolt
from
rear end

Fig MT 9 Rt mouing Main Drive BNring Snap Ring 10

wise

Fig MT 12 A ttaching Gear A mbly to Special Tool

Remove

rear

extenSion

secUring

of

rear extension

baits and turn the

striliing

rod clock

13

Detach

counter

gear

thrust

washer

Drive out

rear

extension backward
a

by lightly
hammer

ta

pping around it with

soft

DISASSEMBLY OF GEAR ASSEMBLY Shift forks and fork rods

TM783

Fig MT 6 Removing Nut and Stopper Pin Bolt

7

Drive fork

out

retaining pins from

with
Fork

each

rod

Rod Pin

Punch ST23540000 Remove return spring

plug

return

spring reverse check spring plunger from rear extension

and
TM787

Fig MT 10 Removing Rear Extemion

Separate adapter plate

11

transmission case from

by

evenly

tapping

around it with a soft hammer

CAUTION
TM784

TM790

Fig MT 7 Rt moving Return Spring Plug

Do not pry transmission case or rear extension from screwdriver

Fig MT 13 Drive Out Retaining Pim 2 Drive out

edapter plate

with
reverse

gear shift fork

and reverse 8 Remove front

cover cover

idief gea

Detach 0 shim

ring and front

adjusting

TM785

TM788

TM791

Fig

MT B Removing Front Cover a Ring and Adju ting Shim

Fig

MT II Removing Tronsmiuion COSf

1dkr Fig MT 14 Driving Out Re Gear and Shift Fork

MT 5

Manual Transmission
3

Remove

three

chick ball

Remove counter
gear and

plugs

g ar main dfN mainshaft assembly in that

order

CAUTION Be careful not to

drop

gears

TM794

TM792

Fig MT 17 R molJing Reuerse Gear SfUJpRing

Fig MT 15 Removing Check Ball Plug

2

Remove four
screws

attaching
4

with an

bearing retainer impact driver

TM797

Drive out fork rods from

on

adapter

and remove bearing retainer

plate by lightly tapping

end Detach shift forks Note
a

the front

Fig MT 20 Removing Gear AlSembly

Be

careful

not

to

lose 2

three

3 Malnshaft Disassemble mainsltaft gear

assem

check balls and two

interlock

pluDgl

rs

b Each gear and sbaft can be de tached from adapter plate without

bly
1

as

follows

removing each fork rod

Remove snap

ring from l Iinshaft

4th synchronizer

D
TM79S

front end Remove

3rd

Fif

MT 18 RemouingBcrews

t @ @ @
1

6 3
rear

assembly baulk rings 3r gear and mainshaft needle bearing toward the
front side

Remove snap ring from mainshaft

bearing using

snap

ring pliers

qeck

ball ptug
2nd

2 3
4 5

Fork Tod 1st

InterJock plunger 4th Fork rod 3rd Fork rod

reverse

Check ball

TM793

Fig MT 16 Check Ball and Interlock Plunger Gear assembly

TM796

Fig
Note
It is necessary to measure end

MT 19 Removing Mainshaft Rear

Fig
2

MT 21 Removing Snap Ring

Bearing Snap Ring Press out mainsltaft bearing using Bearing Puller ST3003Iooo See Fig
4 Drive out

play

before

sbaft and after shaft Refer and Shafts

disassembling reassembling to Inspection for

main main Gears mainshaft

gear
as

MT 23

Remove
rear

reverse

gear

snap ring

sembly together with counter assembly by lightly tapping the

end with
a

gear
rea

CAUTION
When

from the

ring pliers

of mainshaft using snap and remove thrust washer

reverse

soft hammer while

holding

pressing

out
so as

the front of mainshaft gear assembly and counter gear assembly by hand

shaft by hand

not to

bearing hold main drop it

and mainshaft

gear

6 MT

Manual Transmission
3 Remove thrust

washer

1 st gear

needle

2nd bearing bushing 1st synchronizer assembly baulk rings 2nd gear and needle bearing from
mains haft
ST30031000

TM693

Fig MT 22 RemotJing Mainshaft Bearing

fJ

I
@ 00
1 2 3 4 5

Snap ring Baulk ring Shifting imcrt Coupling sleeve

3rd gear mainshaft Needle bearing Mainshaft

II

12 13 14 15 16 11 18 19

2nd gear mainshat t 2nd synchronizer ht assembly

Mainshaft

bearing

6
7

1st gear mainshaft Bushing ht speed gear

Thrust washer mainshaft

8 9
10

Spread spring
Synchronil er hub

Reverse gear mainshaCt

Thrust washer

3rd

4th synchroniz er assembly

Snap ring
TM799

Fig

MT 23 Mainshaft

A mbly

Mein drive geer CAUTION

Remove sna p snap

ring

and spacer with

When

ring pliers
Press
out

main drive

bearing

with
a

pressing oul bearing by hand so as not to drop it

hold gear

1
ST22730000
TM 695

Bearing

Puller

ST22730000

and

suitable press

Fig MT 24 Removing Main Drive Bearing

MT7

Manual Transmission

J
1 2 3
4

TM698

Fig MT 27 Removing Counter

Reverse Gear

Snap ring Spacer

MaiJl4rive

be

ng

Main drive gear Pilot bearing

Press

out

counter gear

rear

bear

ing using Bearing

TM696

Puller ST22730000

CAUTION Be careful
01 to

Fig MT 25 Main Drive Gear

drop

counter gear

Counter gear
1 Remove snap

Press

out

counter

reverse

gear

ring from the

rear

using Bearing Puller ST22730000 and

suitable bar

of counter gear using snap ring pliers

9
iL

CAUTION When

pressing
hold gear

out

coiinter
as

reverse

gear

by

hand so

not to

drop

it

TM699 TM697

Fig MT 28 Removing Counter Gear

Rear Bering

Fig MT 26 Removing Snap Ring

@
5

1
2 3 4 5

Needle bearing Thrust washer Counter gear

Bearing
Counter
reverse

gear

Snap ring
TM800

Fig
MT 8

MT 29 Counter Gear

Manual Transmission Synchronizers spread springs take out shifting inserts@ 2 Separate coupling sleeve synchro hub @
I Remove

Remove striking rod and stiking guide from rear end of rear extension

Note

Do not remove
rear

rear

extension

j @

and

bushing from

extension

from

0
1

O L J J1
ID
4
S

2 3

Spread spring Shifting insert Coupling sleeve

Synchro
Baulk

hub 1 2 3 4 5 Lock

ring
TMSOl

pin Striking lever

Return

Fig MT 30 Synchronjzer Assembly

spring plug
rod fod guide

Con trollevcr

Striking Striking
Control

ADAPTER

PLATE

7
8

DISASSEMBLY 1 Remove reverse idler shaft snap snap pliers and draw 1g ri

eI o Ie pin Stopper pin bolt

TM804

Fig MT 33 Shifting Mechanism

ring using ping

out reverse idler shaft the shaft end with

by lightly tap
a

INSPECTION
Wash all parts in
other
a

worn of out

or

soft hammer

round

rough or when balls are or rough replace bearing

suitable cleaning

solvent and check for wear

damage

or

faulty conditions

CAUTION
a

Be careful not to

damage
or

any parts

with scraper b Do not clean wash

soak oil seals

TM372

Fig MT 31 Removing Reverse Idler Shaft Snap Ring

k
pin striking

in solvent

Fig MT 34 In pecting Ball Bearing

3

TRANSMISSION CASE AND REAR EXTENSION

I Check oil

Replace

needle

bearing if worn or

damaged
GEARS AND SHAFTS
I

for

cracks
or

which might

REAR EXTENSION DISASSEMBLY

I

cause

leak

other

faulty condi
case

Check all gears for excessive

or

wear

tions 2

Check mating surface of

or or

to

Remove lock pin

1

nut

and lock

from lever

striking

lever

Remov

engine projection

adapter plate for small nicks

sealant
all
a

cracks replace as required chips 2 Check shaft for bending crack

wear
or

worn

spline

if necessary

Remove sealant with 3

or

nicks
stone

projection

or

replace
3

fine

If

rear

ext

nsion

cracked replace it
rear

bushing is worn as an assembly of

play
and

It is necessary to measure end before disassembling mainshaft after

reassembling

rnainshaft

bushing and
BEARING

extension

Tighten mainshaft lock nut to speci fied limit and measure end play to in
sure

that it is within

If end play is not within

and

specified limit specified

Thoroughly clean bearing

TM803

dry
are

limit

with 2

compressed
When
race

air

condition
worn or

disassemble and check parts for Replace any part which is

Fig

MT 32 Removing Lock Pin Nut

and ball surfaces

damaged

MT 9

Manual Transmission
standard gea end play
1st gear 0 15 to 0 25 mm 0 0059 to 0 0098 inl 2nd gear 0 30 to 0 40
mm

SHlFTING INSERT
Replace
if
worn

TRANsMISSION
worn

CASE

unevenly deformed OIL SEAL

I
once

or

excessively damaged

ASSEMBLY
1 Press countershaft needle

bearing

into transmission case from outside

Note
or

0 0118 to 0 0157 in 3rd gear 0 15 to 0 30

mm

Discard a ring
removed is

oil seal which is oil

Or

Replace

seal

if

Needle bearing should not be used after removal

fe

sealing lip
position

deformed

cracked
is out of

b When
sure

iDstalling needle bearing

to

be

0 0059 to 0 0118 in

Also discard oil seal if

spring

project

it 2
so

mm

0 08 in

fromtramission
c

front surface

Check the oil seal lip contacting with shaft if necessary replace oil seal
and shaft as a set

Make

sure

that needle bearing turm

needle

d After

smoothly installing

bearing

apply multi purpose grease to the bearing surface

REAR ENGINE MOUNTING

INSULATOR

Replace
lator
TMB05

rear

engine mounting

insu
or

if weakened

deteriorated

cracked Fig MT 35
Me uring End

Phly

Front

t
0 08 in
TM 707

Check for

stripped
gear

or

damaged
2
mm

speedometer pinion
replace

If necessary

ASSEMBLY
To assemble
reverse

the order of

disassembly Observe
BAULK RING
1 structions

the

following

in

Fig

MT 38 Counterlhaft Needk

Bearing
COVER ASSEMBLY
sure

Replace
or

any baulk

ring which
in

is

deformed
2 gear

cracked

FRONT

Position baulk
cone

ring

place

on

Make

that seal mating

sur

2
on

Install withdrawal
case

lever

ball pin

and

measure

the

baulk

face is clean

and tighten

screw

ring to gear clearance with baulk ring pushed toward gear If the clearance is smaller than the

Using

press and

Oil Seal Drift

seal into

iJ

Tightening torque
Ball pin 2 0 to 3 0 14
to

ST23800000
on front cover

drive

new

place

specified

value replace baulk ring

to cone

kg

Note

Standard baulk ring

clearance

pressing oil seal into place apply coat of gear oil to surface adjoining oil seal
Lubricate seal
with
cover

When

22 ft lb

0 80 to 1 65 mm 0 0315 to 0 0650 inl

2 shaft front

lip

and main drive

REAR EXTENSION ASSEMBLY

I Make
sure

gear

oil

when installing

If it is less than 0 5
a worn a

mm

0 020 in

that seal

mating

sur

baulk

and

new

ring ring should

may be the cause be fitted

face is clean

Using a press and Oil Seal Drift ST35300000 drive new seal into place
on rear

extension

Front

Note

When

pressing

oil

seal

into

place apply
smace

coat of gear oil to rear

adjoining

oil seal

4
TM806

2 gear

Coat oil seal lip and bushing with oil for initial
tion Pack lubri
recom

Main drive gear Gear oil

cavity between seal lips with

TM098A

mended multi purpose grease when in

Fig MT 36 Baulh Ring 10 Cone Gap

Fig MT 37 Fronl Cover Oil Seal

sta1ling

See Fig MT 39

MT10

Manual Transmission

Front

t
1
2

if

r@

1
TM131A

Gear oil Bushing

Grease TM099A

Fig MT 43 Installing Spread Spring 2 Fig MT 4J Installing Snap Ring Mainshaft Assemble
2nd gear needle bear

Fig MT 39 Rear Extension Oil Seal

Apply grease to D ring and plunger grooves in striking rod guide

Insert striking rod with striking rod guide through rear extension

ASSEMBLY OF GEAR
ASSEMBLY
Clean all with

Install

striking
it

2nd ing 2nd gear baulk ting 1 st speed synchronizer assembly I st gear baulk ring 1st gear bushing needle bearing 1st gear and thrust washer on and dry mainshaft
2

lever

on

front end

of striking rod
nut and

Install lock pin and

parts

in solvent

tighten

compressed

air

Press

mainshaft

mainshaft

using

Mainshaft

bearing onto Bearing

fl

Tightening torque Striking lever lock

0 9 to 1 2 kg
nut
m

Drift ST22350000

H Synchronizers
Assemble synchronizer assembly in
the

16 5 5

to

8 7 ft Ib

When installing welch plug apply

following procedures
Place synchro hub into coupling

ST22350000

sealant to it

sleeve

ADAPTER

PLATE

ASSEMBLY 1 Place

shifting inserts in three 3 synchro hub 3 Insert protrusion of spread spring into groove so that insert is securely attached to inner side of coupling
grooves in in a vise with sleeve

Fit

TM711

adapter

plate

Fig MT 44 Installing Mainshaft Bearing

Position 3rd gear needle

Adaptet Selling

Plate KV32100300

Install the other spread spring the opposite side of synchro hub Note
e

on

with fork rod hole side up

bearing
4th front

3rd gear

baulk ring

and 3rd
on

synchronizer assembly
careful not to hook front and side of mainshaft
4

the

Be

rear ends of the spread same

spring

to the

Fit
so

new

suitable snap ring in

a

insert

place correctly by ring

Note

that there exists

minimum

b Be
ates

sure

that hub and sleeve oper

clearance between end face of hub and

smoothly and

hand Make
sure

snap

ring fits

in

groove

Available snap rings

TMB09

No

Thickness

mm

in

Fig MT 40 Attaching Adapter Phlte to Special Tool

1 55 to 1 60 1

0 0610
2

to

0 0630

1 60 to 165

Install

reverse

idler

shaft

in

0 0630
TM017

to

0 0650

adapter plate by lightly tapping

shaft end with
secure
a

the
a

soft hammer

Fig

3
42 MT

1 65 to I 70

it with snap

rings
MT 11

Installing Spread Spring

0 0650

to

0 0669

Manual
Available

Transmission
rings
No

nap

Thickness

mm

in

No

Thickness 34 1

in mm
1 40 2

2 20 to 2 25 0 0866 to 0 0886 2 25 to 2 30

to

0 0528 to 0 0551 2

140rol46
0 0551 to 0 0575 3

0 0886
30 2

to to

0 0906 35 2

3
TM798

146 to

52 1
4

0 0906 to 0 0925

0 0575 to 0 0598 4 1 52 to 1 58

35 2

to

40 2

0 0925 to 00945 40 2
to

Fig MT 45 In talling Snap Ring 5 Main drive Bear

I

0 0598
58 1

to to

0 0622 1 64

45 2

0 0945 to 0 0965

0 0622 to 0 0646

45 2 6 0 0965

to to

50 2 0 0984

1 64 to 1 70

Press main drive gear bearing onto

0 0646 to 0 0669 7 1 70 to I 76

2 50 to

55 2

shaft of main drive gear using Trans mission Drift ST23800000 Make
sure

0 0984 to 0 1004 2 55 to 2 60

0 0669 to 0 0693 8

that snap ring groove

00

0 1004100 1024

shaft clears bearing i L

Note Be sure to
measure on

at two or

Counter Beer
1 ST23800000
onto

more

positions

the end

urface

Press

counter

counter gear

gear rear bearing usingCountershaft

of outer race

Bearing Press Stand KV32 100200

KV32100100
TM714

Fig MT 46 Imtalling Main Drive Bearing

r
J
T

1
I
TM117

II

Place

main

drive

bearing spacer
main

on main drive

bearing and secure

a new

drive bearing with

thicker soap

Fig MT 49 Mecuuring Counter Gear End Phly

TM716

ring that will eliminate end

Note

play
Fig

3 MT 48 Installing Counter Gear Rear Bearing

Remove

counter

gear
case

assembly
gear onto

from the transmission

4

Mlike sure soap ring fits in

Press counter

reverse

groove

counter gear

assembly

shaft
2
er

Bearing

using Counter Press Stand

Install and

counter gear thrust wash

KV32 100200

unter gear with counter rear into transmission

case

bearing
select

and
Gear

counter gear thrust washer of

proper thickness using Counter Height Gauge KV32 100100 the

1 2 3 4 Main

Select washer from those shown in

KV32100200

dive

gear

following

table

so

that end play of value

Snap ring Spacer

Main drive bearing
TM715

counter gear is

specified

Standard end play 0 10 to 0 20

mm

TM719

Fig MT 47 Irutalling Snap Ring

0 0039 to 0 0079 in

Fig MT 50 Installing Counter Revene Gear

MT12

Manual Transmission
5 Fit snap ring to groove in rear end of counter gear by using snap ring 4

Fit snap ring

rear

to

groove in main

shaft

bearing with snap ring

pliers

Froni Gear side

pliers
Note Maire
sure

snap ring

fits in

groove

TM697

TM100A

Fig MT 5I Imtalling Snap Ring

TM796

Fig Fig MT 53 Fitting Mainshaft Rear Bearing Snap Ring

MT

55 Imtalling R

Vf

Gear

Shift forks and fork rods

I Insert

Assembly to adapter plate

Install baulk ring on main drive gear and combine with mainshaft to complete the mainshaft assembly
t Note in Be
sure

1st

2nd fork rod into 2nd

adapter plate
Note Make
sure

and assemble 1st

snap ring fils

in

fork 2
With 1st

2nd fork rod set at

groove
to install

place

when

pilot bearing combining with

Neutral
3

insert interlock

plunger

into

mainshaft
2

Combine
into

with counter gear

them
3

assembly assembly and place adapter plate simulta assembly

into

mainshaft

Install bearing retainer on adapter plate Torque screws and stake each screw at two points with a punch
5

adapter plate
Insert

3rd

4th fork rod into 4th

adapter plate and assemble 3rd fork

4 With

fj

3rd

4th fork rod set at

Tightening torque
Mainshaft bearing retainer saew 0 7

Neutral
m

insert interlock

plunger

into

neously
Pull

to
to

1 0 kg

adapter plate
S
er

mainshaft

15 1

7 2 ft Ibl

Insert reverse fork rod into

adapt

adapter plate using Mainshaft Puller KV32 100400 When installing main shaft assembly carefully hold gears by hand Install counter gear assembly together with mainshaft assembly by applying light blows with a soft faced
hammer

plate

Nole
a

Be

to install interlock plunger installing any adjacent fork rods to adapter plate Properly align the groove in assem
sure

when

Make

sure

mainshaft

rear

that snap ring groove on bearing clears adapter

bled

fork

rod

with

interlock

plunger
b Be
sure

plate
CAUTION
a

to

align

3rd

4th shift fork

wilh the groove in their sleeve before installing

not to

coupling

Take floor

care

drop
I

gears

on

TM811

b Take

care

not to

damage bearings

Fig MT 54 Staking B aring Retain r Screw

2nd shift fork with Also align 1st their coupling sleeve prop dy be fore inslalling 4th an 1st
same

d Shift forks for 3rd 6 Install mainshaft washer To

on reverse rear

gear and
end of snap with

2nd are Make

one

and the

parts

thrust

the

sure

that the long end of shift 2nd is

mainshaft

secure

with

new

fork for 1st

ring

first

hold

it

temporarily

snap ring pliers and then tap it lightly with Bearing Drift ST22350000 Note
a

counter gear side and the 4th is on the for 3rd

placed on the long end opposite

side

Install lhrust washer

concave side is
on

so

that

its

Install check balls and check ball

TM810

mainshaet

reverse

springs

Fig MT 52 Installing Mainshaft Assembly

gear b Make

Apply locking
sure

sealer to check ball

snap ring fits in groove

MT 13

plugs and install in place

Manual Transmission Align notches in reverse 3rd

and 1st balls
Note
a

4th

TRANS SSION ASSEMBLY

Transmission
case

2nd fork rods with check

assembly

In

the standard position the

upper

Remove adapter plale with gear assembly from Adapter Setting Plate KV32100300
2 Clean mating surfaces of adapter plate and transmission case Apply sealant to mating surfaces of adapter plate 3 nd transmission case 3

surface of the ping is nush with

b

thaI of adapter plate CheCk balfpIug for i st

2nd fork

rod is longer than those for reverse forkrod and 3rd 4th fork rod

Wooden block
TM813

Install counter gear thrust washer

selected previously

Fig
Note
a

MT 60 Installing Transmiuion Cale

Apply

grease to

stiding sorface

of 5
to

thrust washer b When

installing

thrust washer note

the front and

rear directions

groove in main

Fit main drive bearing snap ring drive bearing with

snap

ring pliers
Make
sure

Note

snap

ring fits in

groove

Fig MT 56 Installing Check Ball

Plugs
6 with 1nstall
reverse

rev

rse

idler gear together

shift fork

Fig

MT 58 Installing Thrust Washer

Fig

MT 61 Fitting Main

Dri

Bearing Snap Ring

TM791

Front

Oil groove side

Rear

Thrust side
TM727

Rear extension assembly Clean mating surfaces of

Fig MT 57 Installting

Getg

Re ldler and Shift Fork

adapter
of

Fig MT 59 Counter Gear Thru t Washtr

p I at aIld rear e Apply sealant adapter plate and

2

ite9n1s
to

mating surfaces
extension

rear

7 with
mer

Install each fork rod

new

on

shift fork
a

With

fork rods in their neutral

turn

g pin U retainif

ham

toseCUfe

pin

in

place plunger

Place wooden plate of more than 15 mm 59 in thick under transmis 0 Slide transmission

positions

striking
rear

rod clockwise extension onto

sure

and gradually slide

Note

To insure that interlock

sion case to make it level

case onto

adapter
striking
3
and with
a

plate
lever

making
engages

that rod

is installed properly slide 3rd 4th fork rod and operate the other fork rod Make lrd 8
or

with fork

adapter plate by lightly tapping

soft hammer until
case

brackets correctly Install through bolts with washer

sure

that the gear

except

4th gear does not mesh

ar

adapter plate
dowel pin
sur

bears against and be sure to line up

tighten
Rear extension installation bolt 1 6 to 2 2 kg
m

b Tightening torque
install main drive bearing gear front needle bearing

Apply

oil

all sliding

Carefully
and counter

faces and check to

see

that shift rods

are en

operate correctly

and gears

Make certain that rnainshaft rotates

gaged smoothly

freely
MT14

12 to 16 ft lb

Manual Transmission
4

Install stopper pin bolt into

rear

measure

depth

from front end of

shim in place
2

extension and

tighten
torque

transmission case to main drive outer race with front cover

bearing adjusting

Select

shim of thickness

measured

J l

Tightening

Stopper pin bolt

0 5 to 0 8 kg
m

No

in mm

3 6 to 5 8 ft lb Be
sure to

Adjusting in mm
50 0 0 55 0 60 0 65 0 70 0 75 0 80

shim

apply sealant

before

I 2 3 4 5

6 05 6 10

to to

6 09 0 2382 to 0 2398 6 14

0 0197 0 0217

installation

0 2402

to

0 2417

6 15 to 6 19

0 2421 to 0 2437

0 0236 0 0256 0 0276 0 0295 0 0315

and

6 20 to 6 24 0 2441 to 0 2457 6 25 to 6 29 0 2461 to 0 2476 30 6 35 6

to to

Sealant

6
7

34 6 39 6

0 2480

to

0 2496

Stopper
pin bolt

0 2500 to 0 2516

bly and tighten

install

securing bolt

J l
TM814

Tightening torque Speedometer Ieeve locking plate

bolt 0 3 to 0 5

Fig MT 62 Installing Stopper Pin

Bolt 5

kg

Apply
Install

grease to

plunger

and in 2

2 2 to 3 6 ft Ib

stall it in rear extension

6
reverse

Install

reverse

lamp

switch and

check spring and

return
TM816

spring Apply locking sealer to spring plug and install it in place

return

tighten At the same time install top detecting switch if so equipped Be sure to apply locking sealer
before installation

Fig MT 64 Meaauring Front Cover Adjusting Shim

J l

Tightening torque
Revene lamp switch and

J l

Tightening

torque

Return spring 0 5 to 1

plug 0 kg

CD
m

top detecting switch

2 0 to 3 5

kg

3 6 to 7 2 ft lb 3
1 2

14 to 25 ft Ib

Apply

light
to

coat

of

multi

purpose Transmission
case

grease

withdrawal

lever

Main drive gear

3
4

Adjusting Bearing

shim

release bearing and bearing sleeve in stall them on transmission case After connecting them with holder spring install dust cover to transmis
sian case 4

TM817

Install control lever temporarily

move

Plunger
Reverse check spring
Return TM815 Return

Fig MT 65 Selecting Front Co r Adju ting Shim

2

and

shift control lever through

to

all

gears

make

sure

that

gears

Clean

mating

surfaces of front
case

spring spring plug

cover

and transmission
with the

operate smoothly 5 Install drain sealant in place

plug coated with

3
case

Install front
in

cover to

transmission shim and 0

Fig MT 63 Installing Return Spring

adjusting

ring

place

J Tightening torque l
Drain plug 2 5 to 4 0

J l
Front
1
as cover

Tightening torque
Front cover installation bolt

kg

18 to 29 ft Ibl

assembly
cover

1 0 to 1 6 kg 7 to 12 ft Ib

Make

sure

that main drive shaft

in Neutral

Select front follows

adjusting

shim Outer parts assembly

rotates

smoothly

Main drive gear

assem

rotating torque Ibl

Using

vernier

caliper depth gauge

Install

speedometer pinion
MT15

Les than 1 8 kg cm 1 6 in

Manual Fransmission

S SPEED

TRANSMISSION

Model

FSSW60L

Tightening torque

m kg to

ftlb

@
@ @

10

to

16

12

0 7 to 10 5 1 to 7 2
16 to 2 2 12 to 16 2 0 to 3 5 14 to 25

@
@ @

2 5 to 2 5 to

2 0 to 3 5 14 to 25 3 5 18 to 25 3 5 18 to 25 2 0103 5 14 to 25

i8J

FU

model only

7
5

Ll@
10 11 12 Breather Rear extension dowel pin Retwn spring bushing
Filler ptug

o p

13
14

Bearing retainer
Rear

15 16

extension assembly
cover

e
5
1 2 Front
cover cover cover cover

17 18 19

Drain plug Rear extension dust

withoil seal

Welch ptug

6
oil seal

Front Front
Front

7 8
shim

Top detecting W tch Reve rsc lamp switch

TranSmission
case

3
TM282A 4

o rfug

assembly

Retaining pin Spe ometer sleeve 20 Speedometer pinion

21 Neutral switch nhl Compo

adjusting

Adapter plate

Fig MT 66 FS5W60L Tralllmimon Case

Main drive bearing Main drive gear 4th

TM283A

5th synchronizer

MT 16

Manual Transmission

S R
o

l D

@
@

l
@

l
25 26 27 1 2 3 4 Control lever boot Control Control

pin bushing
arm

2nd

3rd fork rod

9 10

4th 2nd Ist

5th shift fork

3rd

17 18 19 20 21 22

Shift

arm

bracket

pin

Retaining pin

shift fork
shift

Arm bracket O Arm bracket O

Checking

ball

plug

11

reverse

fork

ring plain washer

28 29

Control lever Control lever knob

Check ball

spring
fork rod

12 13
14

5 6
7 8

Check ball
ht
reverse

Striking rod Striking lever

Lock

ring

S lriking guide

Tightening torque

kg

fHb

Interlock plunger
4th 5th fork rod

15
16

pin Striking pin

Shift
arm

23
24

Striking guide oil seal Expansion plug Control lever bushing

@ @

9 to 1 2 8 2 to to O

5 to 6 59 to

8 7 72

TM229A

Fig MT 68 FS5W60L Transmission Shift Control Components

REMOVAL
To dismount transmission from the
car

Jack up the
on

car

and supporl its Use

a

Remove clutch operating

case

cylinder
a

weight
draul
c

safety
or

slands

hy

from transmission 10

proceed

as

follows
S

hoist

open

Make sure that Disconnect

remove

pit if available safety is insured

exhaust tube exhaust

Support engine by placing

with a wooden

jack

under oil pan

block

Disconnect battery ground cable Remove console box and detach

front

used between oil pan and jack

and

rubber boots if so equipped 3 Place transmission control lever in

neutral

securing mounting bracket from exhaust front

tube side
6 Disconnect wires

bolt

position

and remove it

from

reverse

back up
7

lamp switch speedometer

cable
extension At the same time

CAUTION Do not

Disconnect
rear

from

pan drain

place plug

the

jack

under the oil

remove

top

detecting

switch if

so

equipped
8 Remove

propeller shaft
Section PD

Refer

to

Removal

J CJi

Note

Plug

up the

TM781

extension to

opening in the rear prevent oil from flow

Support transmission with transmission jack Loosen rear engine mount 12 curing bolts
move

II

se re

CD temporarily

and

Fig MT 69 Removing Control Lever

ing out
MT 17

crossmember mounting bolts CV

Manual Transmission
3 14 Remove starting
motor

Before

installing
rear

Remove bolts securing transmis

surfaces of engine
mission case

mating plate and trans

Clean

engine and gusset Then support the engine and trans mission with jacks and slide transmis sion rearward away from engine and
sJon to
remove

Before

grease to

installing lightly apply spline parts of clutch disc

and main
grease lever and
to

from the

car

drive gear And also apply moving surfaces of control

striking rod

Remove filler plug and fill trans mission with recommended gear oil to 3

CAUTION
Take
cate

the level of the

plug

hole

in

dismounting

transmission

not to

strike any adjacenl parts and

Oil capacity t 2 liters 2

main drive gear

US pt 2

Imp ptl

Fig

MT 70 R

lB movi7l

ar

Ensi
4

Mounting Croum mber

Apply sealant

to thread

of filler

plug

and install filler plug totransmis

sian case

INSTALLATION
Install the transmission
verse

l
in the
re

Tightening torque Filler plug

2 5 to 4 0

order of removal paying atten

kgm

tion to the

following points

t8 to 29 ft bl

MT18

Manual Transmission

DISASSEMBLY
TRANSMISSION DISASSEMBLY
1 sion Prior to

Remove main with snap

drive

bearing

snap

12

Set

up

ring
CASE

ring pliers

KV32100300
Place the

Setting Plate adapter plate above assembly in a vise Adapter

on

disassembling thoroughly wipe off thoroughly

dust
cover

transmis dirt and

grease from it 2 Drain oil 3 Remove

from

trans

mission case Remove release

bearing

and with

drawallever

lamp switch and top detecting switch if so equipped 5 Remove speedometer pinion as
4 Remove
reverse

TM230A

Fig MT 74 Removing Main Drive Bearing Snap Ring

10 Remove extension

Fig MT 77 A ttaching Gear Assembly to Special

Tool

sembly
6 Remove nut and stopper
rear

pin

bolt

rear

securing

13

Detach

counter

gear

thrust

from

end of rear extension

bolts and

turn

striking

rod counter

washer

clockwise
Drive out
rear

extension backward

using

standard puller

DISASSEMBLY OF
GEAR ASSEMBLY Shift forks and fork rods Fig MT 71 Removing Nut and Stopper Pin Bolt
1 each

Drive fork

out rod

retaining
with

pins from
Rod Pin

Fork

Punch ST23540000
7 Remove return

spring plug
rear

return
exten

spring
sion

and plunger from

TM548

Fig MT 75 Removing R

ar

Extension @ transmission case from

@ @

Separate adapter plate

around it with

11

by
a

evenly

tapping

soft hammer
TM231 A

CAUTION
TM784

Fig MT 72 Removing Return Spring Plug

Remove

00 not pry transmission extension from adapter screwdriver

case

or

rear

Fig MT 78 Driving Out Retaining

Pim

plate

with
2

Remove

three

check

ball

front

cover

Detach 0

plugs

ring

and front cover

adjusting shim

l 1l

TM785

TM262A

TM232A

Fig MT 73 Removing Front Cover D Ring and Adju ting Shim

Fig MT 76 Removing Tran miuion Ca e

Fig MT 79

Removing

Check Ball

Plug

MT19

Manual Transmission
3

Drive out fork rods from

on

adapter

Remove

folloWIng

parts from

plate by lightly tapping

end

the front

counter gear rear end

Detach shift forks

Note
a

Retaining ring

Be

careful

not

to

lose 2

three

check balls and

two

interlock

plungers
b Each gear and shaft can be de tached from ar1apter plate without
TM234A

removing each fork rod

Fig MT B2 Releaaing Staking on Mainshaft Nut

TM236A

CD
3 Remove following parts mainshaft in rear extension side

from

Fig

ltiT 85 Removing Retaining Ring

I
2

Mainshaft hut
Remove

shifting

insert retainer 1st gear

2
er

1st counter gear using Gear Pull ST22480000

synchro
r

hub with reverse gear

@
1 2

bearing and bush ing and idler gear together with needie bearing simultaneously
3 Check ball
Fork rod Interlock 8 p1 Reverse

with needle togeth

ST22480000

Thrust washer

Ist

3
4

plu
2nd

er

Fork rod
Fork rod

3rd
4Ih 5th TM793

5
6

Check ball

Fig MT BO Check Ball nd Interlock

TM237A

Plunger
Fig MT 86 Remouing l t Counter Gear Gear Note
a

embl
6

It is necessary to measure end

Remove snap ring from mainshaft

play

before

shaft and after

disassembling reassembling

main
main

Fig

83 MT

Removing Reverw Main

Revere Idler and 1st Gea

rear

bearing using

snap

ring pliers

shaft Refer to Inspection for Gears and Shafts 1 end Remove snap

ring of rnainshaft

4 and

Remove

four

bearing baring using Bearing Puller KV32 10 1330 Remove olher sna p ring of rnainshaft end bear ing

Draw out

attaching

screws

with an

bearing impact

er retai

driver

remove

bearing retainer

TM238A

Fig MT B7 Removing Main haft Rear Bearing Snap Ring

TM233A

Fig MT BI Removing Mainshaft End Bearing

Drive

out

rnainshaft
with

gear

as

sembly together assembly by lightly tapping the

counter

gear
rear

With

engaged

1st and 2nd gears doubly release staking on main shaft

end with

sofl hammer while

holding

nut and loosen it

Fig

MT B4 Removing Screw

the front of rnainshaft gear assembly and counter gear assembly by hand

MT 20

Manual Transmission
Remove gear and order counter main

gear

dnve

R emove sna p nng from mainshaft

ma

mshaft assembly

in that

front end
Remove 4th baulk 5th
n gs

CAUTION

synchronizer
5th gear and

W hen shaft

assembly
CAUTION Be careful not to d rop gears
side

mamshaft needle b eanng toward f rant

pressin 9 oul bearing hold m aID by hand so as not 10 drop It

1
30031000

j
TM797

693

Fig MT 90 R emoving M amshaft Bearing

79B

Fig MT 88 Removing Gear

5embly A

Remove th rust wash er 2nd gear b u sit 109

Mainshaft Disassemble mainshaft gear

assem

Fig MT 89 Rema vmg Snap Ring

needl e bearing

2nd
b aulk
C

3rd
rings
ifom

synchronizer
2

assembly
needle

bly

as

follows

Bearing

Press out mamshaft be nng PuUer ST3003100

using

3rd

gear

and

bearing

mainshaft

@ @
2
6

r a
C

@ j j

lJ

JJ

10
11 12

Needle bearmg 3rd gear nizeI 2nd and S

3

19 20 21
22

Shift mg insert S hifting msert spring Reverse m 8mshaft hub

Reverse Shifti

gear

13
14

2nd gear 1 st gear bushing Thrust washer Mainshaft be anng Washer

1st gear

23 24 2S 26

Mains

fmsert

retainer

t nut

15
16 17

Mainshaft end bea nng

snap

ring

Mainshaft end b earmg

18

TM239A

Fig MT 91 Mainshaft A ssembly

MT 21

Manual Transmis ion liillim drIYe

1

geer

ADAPTER PeATE
and spacer with

Remove snap

ring

snap ring pliers 2 Press out main drive bearing with

Bearing Puller
suitable press

iOoOO ST227

and

T
ooo

DISASSEMBLY
1

Remove

reverse

idler shaft with out

reverse

thrust washer and draw drift with

hammer

idler shaft by tapping shaft

a

ld e

of

CAUTION When

pressing
so as

out

by

hand

not

bearing to drop it

hold gear

IJ
j

TM695

Fig

MT 92 Removing Main Drive

Bearing

TM241A

Fig MT 95 Removing Reverse Idler Shaft

2 brass

Remove needle bearing apply a drift to race side surface and

it

withdraw with
a

by tapping top of drift

hammer

REAR EXTENSION
1

2 3 4 5

Snap ring Spacer

Main drive bearing Main drive gear
t bearing PiI

DISASSEMBLY
I Remove lock pin nut and lock pin from striking lever Remove striking lever

TM 696

Fig MT 93 Main Drive Gear

Synchronizers
I 2nd

3rd

4th

5th

speed

synchronizer
Remove
out

spread springs
inserts

and take

shifting coupling sleeve

ID

Separate

from synchronizer

hub@
2 Ist
reverse

800
r@

synchronizer

Separate reverse main gear 00 from synchronizer hub @ Take out shift ing inserts ID and spread springs @ Pry off shifting insert retainer j
1

7
2 3
4

c19
5 6 7
Reverse

TM242A

Fig

MT 96 Removing Lock Pin Nut

Coupling sleeve Spread spring Shifting insert Synchro hub

gear

Spread spring Shifting

retainer insert

2 from

Remove
rear

oil seal with dust

cover

end of rear extension

and

remove TM240A

striking rod and striking guide

remove rear

Note

Do not

extension

Fig

MT 94 Synchronizer Assembly

bushing from

rear extension

MT 22

Manual Transmission
Standard end play 1 t gear 0 15 to 0 25 mm 0 0059 to 0 0098 in 2nd gear 0 15 to 0 25 mm 0 0059 to 0 0098 in 3rd gear 0 30 to 0 40 mm

1
1 2 3
4 Lock

0 0118 to 0 0157 in 5th gear 0 15 to 0 30

mm

0 0059 to 0 0118 in Reverse idler gear 0 15 to 0 40 mm

pin Striking lever Return pring plug

Control lever

0 0059 to 0 0157 in

5
6

Striking Striking

rod rod

guide
TM255A

7 8

Control lever pin Stopper pin bolt

Fig MT 97 Shifting Mechanism

INSPECTION
Wash all parts in
a

worn
of out

or

rough

or

when

balls

are TM256A

round or rough replace bearing

suitable cleaning

solvent and check for wear

damage

Fig MT 99 Measuring End Phly

or

other

faulty

conditions
4

Check for stripped

gear

or

damaged

CAUTION
a

Be careful not to

damage
or

any parts

speedometer pinion replace

If necessary

with scraper b Do not clean in solvent

wash

soak oil seals

TM372

Fig MT 98 Inspecting Ball Bearing

3 Replace needle bearing if worn or damaged

TRANSMISSION CASE AND REAR EXTENSION

1

BAULK RING
I

Check for oil leak

cracks
or

which might

GEARS AND SHAFTS

I

Replace
or

any baulk

ring which

is

cause

other

faulty condi

deformed Check all gears for excessive

as wear

cracked
on

tions

2
gear

Check mating surface of case to engine or adapter plate for small nicks

chips or cracks replace

2
wear

required

Position baulk ring in place

cone to

and

measure

the

baulk

Check shaft for

or

worn

bendillg crack spline if necessary

ring

projection
Remove

or

sealant all nicks

replace

pushed

gear clearance with baulk ring toward gear clearance is smaller than the value

projection

or

If th

sealant with
3
or

fine stone
worn

If rear extension bushing is cracked replace it

rear

It is necessary to measure end play before disassembling mainshaft and after reassembling mainshaft 3

specified

replace

baulk ring

as

an

assembly of

Standard baulk dearance

rinltto cone

bushing and BEARING

I

extension

Tighten mainshaft lock

fied limit and
sure measure

nut to

speci

that it is within

Thoroughly clean bearing and dry

are

with compressed air 2 When race and ball surfaces

end play is not disassemble and check parts for con dition Replace any part which is
worn

play to in specified limit If within specified limit

end
a worn

0 80 to 1 65 mm
0 0315 to 0 0650 in

If it is less than

5 0

mm

0 020 in
cause

baulk ring may be the

or

damaged
MT 23

and

a new

ring should be fitted

Manual Transmission
of
nut

striking
and

rod

Install lock pin and

it

tighten
I

ifl Tightening torque

Front

Striking
I

er

lock nut

h
it
1

0 9 to 12

kg

6 5 to 8 7

lbl ft

4
2 Main drive gear GearoiJ
TM098A

3
4

When

installing expansion plug

apply

sealant to it

TMS06

Fig

MT 101 Front Cover Oil S al

Fig MT 100 Baulk Ring to Con

Gap TRANSMISSION CASE ASSEMBLY

I
worn

Make sure that seal mating sur face is clean Using a press and Oil Seal Drift ST35300000 drive new seal into place
on rear

extension

SHiniNG

IIUERT

Note

When

pressing
coat

oil

seal

into

Replace if WOrn excessively unevenly defonned or damaged

OIL SEAL
I
once

Press countershaft needle bearing

place
mace 5

into transmission case from outside

apply adjoining

of geat oil to

oil seal

Note
a

Coat oil seal lip and bushing with oil for initial lubrication Pack
recom

Needle

bearing inslalling project

should not be needle bearing

it

re

gear

Disr lO

ring

or

oil seal which is oil

or

used after removal

b

cavity between seal lips with

be 2
mm

removed
is

sealing lip position

2

Replace qefonned

seal

if

When
sure

mended multi purpose grease when in

cracked
c

to

008 in

slalling

Also discard oil seal if spring is out of Check tlie oil seal

from tramission Make

sure

case

front mace

that needle

bearing

torm FroDt

lip contacting

smoothly
d After

with shaft if necessary replace oil seal and shaft as a set

instal6ng

needle

bearing

apply multi purpose bearing smace

grease to the

if
I

tI i

Cc

REAR ENGINE

MOUNTING
insu
or

INSULATOR Replace
lator if cracked
2mm 0 08 in
TM707
rear

engine mounting

Front

1 2 3

Gear oil

weakened

deteriorated

Bushing
Grease
TM099A

Fig

MT I03 Rear Eztemion Oil Seal

ASSEMBLY
Fig MT I02 Count To assemble
reverse

ADAPTER haft N edle Bearing

PLATE

ASSEMBLY
I Place adapter plate in a vise with Adapter Setting Plate KV32100JOO

the order

of
in 2

disassembly Observe
structions

the

following

Install withdrawal lever ball pin and tighten

screw

with fork rod hole side up

FRONT COYER ASSEMBLY

I

on case

Make

sure

that seal

mating

sur

ifl

Tightening torque
Sail pin 2 0 to 3 0 kgm
14 to 22 ft Ibl

face is clean press and Oil Seal Drift ST23800000 drive new seal into place

Using
front

on

cover

Nole

pressing oil seal into place apply coat of gear oil to surface adjoining oil seat
Lubricate seal
gear

When

REAR EXTENSION

ASSEMBLY
Apply grease to O ring and plunger grooves in striking rod guide Insert striking rod with striking rod guide through rear extension 2 Install striking lever on front end
MT 24 I

lip

and main drive when

shaft with front

cover

oil

installing

Fig MT 104 Attaching AdopterPhlte to Special Tool

Manual Transmission
2 Install needle bearing by lightly it with a brass drift
3rd gear SIde

tapping around
and a hammer
3 Install

hl

h2

2nd gear ide

reverse

idler

shaft with

thrust

washer

in

adapter plate
end with
a

by
soft
Front

tapping the hammer

shaft

TM131A hi h2

Fig MT I07 Installing Spre d Spring 2

Fig

MT 109 Inslalling 2nd

3rd

Speed Synchronizer

2 I

Ist

reverse

synchronizer

TM243A

Fig MT I05 Installing Re

Idler

Position shifting insert springs shifting inserts in three 3 slots in synchronizer hub
and

5th gear

Position 5th gear needle bearing 5th bawk ring and 4th
on

synchronizer assembly
side of mainshaft
4

the front

Shaft

2
hub 3

Put reverse gear

on

synchronizer
to

Fit

a new

suitable snap ring in

a

place
ring
Note

so that there exists

minimum

Install shifting insert retainer

sert is

clearance between end face of hub and

ASSEMBLY OF GEAR ASSEMBLY Clean all parts in solvent and dry with

inserts so that

securely attach

ed to inner side of reverse gear

Make

sure

snap

ring fits

in

groove

pressed

air

Available snap rings

Synchronizer
1 2nd

Mainshatt
41h 5th

No

Thicknc ss

mm

tin

3rd

speed

synchronizers
I Place

Assemble 3rd gear needle bearing 3rd gear baulk ring 2nd 3rd speed

1 55 to 1 60 0 0610 to 0 0630 1 60 to 1 65 2

synchro shifIing

hub into

coupling

sleeve
2 Fit inserts in

synchronizer assembly 2nd gear baulk ring 2nd gea buihirig needle bearing 2nd gea and thrust washer on main
shaft
2
to

0 0630

to

0 0650

t1lree

1 65 to 1 70

grooves in 3

synchronozer

hub

Press

mainshiift
uSi g

spread spring to inserts so that insert is securely attached to inner side of coupling sleeve Install Ihe other spread spring on the opposite side of synchro hub
Note
a

Install

mainshaft

bearing onto Mainshaft Bearing

0 0650

to

0 0669

Drifl ST22350000

Be
rear

careful not to hook front and ends of the spread spring

insert that hub and sleeve oper
sure to

the ST22350000

same

Be ates

smoothly

and

correctly by
TM798

hand

TM711

Fig MT IlO InslallingSnap Ring

Fig

MT I08 Enstalling Mainshaft

Bearing

Main drive gear

1 Press main drive gear

shaft of main drive gear

TM077

bearing onto using Trans

on

Note

Assemble

2nd

3rd

speed
to

mission Drift ST23800000 Make

sure

Fig MT I06 Enstalling Spread Spring

synchronizer
its direction

paying attention

that snap

ring groove

shaft clears bearing MT 25

Manual Transmission

thrust

washer

of

proper

thiclmess

2 with

Combine
counter

using straight edge

Select washer from those shown in
the ST23800000

them

into

assembly assembly and place adapter plate simulta

gear

mainshaft

following

table

so

that end play of

neously
Note Be careful
not to

counter gear is specified value Standard end

play

forget

to

install thrust washer

And

when

0 10 to 0 20 mm

M
Fig
MT 111

0 0039 to 0 0079 inl

TM714

installing

throst washer note front

djrections tt 1IIllIR

InstaUing Main

Drive

Bearing
2
on

No

Thickness 2 20
to

mm

in

2 25

Place main

drive

bearing

spacer

0 0866 to 0 0886 2 25 to 230 0 0886 to 0 0906 30 2 3

to

main drive bearing and secure main dtivebearing with a new tlii er snap ring that will eliminate end play

Front Thrust side

Rear

Oil groove side

TM285A

35 2

Note

Make

sure

snap

ring fits

in 4

0 0906 to 0 2 35 to

0925
40 2 3

Fig

MT I14

Gear Thru t Count Washer

groove

Pull

mainshaft

0 0925 to 0 0945 5 40 2
to

assembly

into

adapter plate using

KV32100400 shaft assembly hand

Mainshaft Puller
hold gears

2 45

When installing main

0 0945 to 0 0965 45 2 6
to

50 2

Install counter

0 0965 to 0 0984 2 50 to

Main drive gear

55 2

together with applying light blows with

hammer
Make sure that snap

by assembly mainshaft assembly by

gear
a

carefully

soft faced
groove on

2 3
4

Snap ring Spacer

Main drive bearing
TM715

0 0984 to 0 1004

ring

2 55 to 2 60
0 1004 to 0 024

mainshaft

rear

bearing

clears adapter

plate CAUTION
a

Fig

MT 112 In talling Snap Ring

Note

Be

sure

to measure at two or
on

more

Available snap

positions

the end surface

Take

care

not

to

rings
Thickness 34 1
mm

drop

geaB

on

of counter gear

floor
b Take
care

not

No

in

tndamage bearings

to

I 40

0 0528 to 0 055 I l40tol46 2

0 0551
3

to

0 0575

I 4610 1 52 0 0575100 0598 52101 1 4

rr
II
2
Remove
counter TM244A

58

0 0598 10 0 0622 1 58 to 1 64 5 0 0622 to 0 0646 1 64 to I 70

Fig MT 113 Measuring Counter Gear End Phly from

the 4 Fit snap
to

TM245A

Fig MT II5 Installing Main haft

gear A 6embly

transmission case

ring groove in main shaft rear bearing with snap ring pliers

0 0646 to 0 0669 I 70 to I 76

Assembly
I

to

adapter plate

0 0669

10

0 0693

Install baulk ring on main dtive gear and combine with mainshaft to

Counter cear
I

complete the mainshaft assembly

thrust gear gear into transmis counter
gear

Install

counter

Note
in

le

sure

to iJislall

pilot bearing
with

TM23aA
Fig
MT 116 Fitting Main haft Rear

washer and
sian
case

counter

place

when

combining

and

select

mainshaft

Bearing Snap Ring

MT 26

Manua

Transmission
II

Note

Make

sure

smp

ring fits

in

With

I st and 2nd gears

doubly
to
con

groove 5

engaged tighten
verted

mainshaft nut en
See

torque

Fig
to

MT 123

Install bearing retainer

on

adapter

using

Wrench ST22520000

plate Torque screws and stake at two points with a punch

each screw

Stake mainshaft nut mainshaft with a punch

groove of

Tightening tOrque
Mainshaft bearing retainer
0 8 to 3 kllm
screw

TM247 A

Fig MT 119 Installing Retaining Ring

8

15 8 to 9 4 ft lbl

Install thrust

washer to
hub with

rear

of
ST22520000

mainshaft and idler shaft

9 gear

Install synchro
I st

reverse

bearing together neously

gear together with and bushing and idler with needle

needle gear
TM248A

bearing simulta
Fig MT
o OTT

I2I

Tightening Mainshaft
Nut

1st gear side

Ui

TM246A Front

Fig MT 117 Staking Bearing Retainer

Screws

Fl
J

Press

Ist

counter

gear

onto

counter sltaft

using Drift ST22360002

I
TM263A
TM249A

Fig MT I20 In talling Ist Reverse Synchronizer

10 it Install mainshaft nut and

tighten

Fig MT I22 Staking Mainshaft Nut

temporarily
E

S
80

f2
t1

I
Upper
10

I
limit line

TM583

o c v

70

Fig MT 118 Installing I t Counter Gear

0

S
v

Converted 60

torq

7 in

Fit

new

suitable retaining ring

a

5
c o

place

so

th t there exists

mininum

clearance between end face of counter

gear and ring

Note

Make

sure

retaining ring

It in f

50

j
0 3
10

Iim ttine

groove Available retaining rings

40

No

Thickness

mm

in 0 2 0 4 5 1 0 5
0

6
2

0 7 0

0 8
25

1 25 to 1 35

ft

0 0492 to 0 0531
35 1
to

I 45

Effective length of torque wrench

TM258A

0 0531 to 0 0571

Fig MT 123 Converted Torque

MT 27

Manual Transmission
J xplanation of convetted torque
to

Available

Sllap ring
Thickness
IDm

Secureshift forks and fork rOd s

new

Mainshaft nut should be tightened 10 to 11 kg m 72 to 80 ft Ib with of

the

with
No in Note
a

retaining pins

torque
amount

aid

of

Wrench
w read the
on

Be

sure

to install interlock any

ST22520000

When torque

doing
to

1 2

10 0 039 2 0 047 1

plunger
fork

when

installing

adjacent

be
be

rods to

wrench

needle to the

should

modified

adapter plate Properly align the groove

bleMork rod with
er

in assem

according

following formula
b
to

rlQck inle

plung

See

Fig
to

MT SO

kg

10

L
x

Be

su

align

4th

5th shift fork

O I

on

with the groove in their

coupling

sleeve
11 L
x

LST22350000
O I

instalting befo Also align 2nd 3rd shift fork with

their coupling sleeve fore instalting

L
or

properly

be

C ft Ib

L
L
x

O 33
0 33

to TM250A

Install check balls and check ball

springs Align

Applying

locking sealer

to

80

Fig MT 125 In talling Main haft End Bearing

check ball plug and install in place

center notch in each fork rod

with check ball Shift forks and fork rods

Where C Value read

on

Note
a

the torque wrench

1 wrench Insert 1st
reverse

kg
m

ft Ib

fork rod into

L Effective

length of torque

its shift fork and

adapter plate
reverse

Check ball plug for 1st reverse fork rod is longer than those for 2nd 3rd fork rod and 4th 5th
fork rod

ft

With 1st

fork rod set at

Neutral
3
wrench

insert interlock

plunger

into

adapter plate
ST22520000

b To insure that interlock installed fork rnd

Insert 2nd

3rd fork rod into 3rd and 4th

at

Torque

adapter plate 2nd 5th shift forks

plunger i 3rd properly slide 2nd andoperate the other fork

sure

rod Make
or

thaI gear except 20d

Lm ft 0 1
m

r
TM587

With

2nd

3rd fork rod set

3rd gear doe not mesh

gear oil to all
see

Neutral

insert interlock

plunger

into

Apply

sliding

sur

adapter plate
5
Insert

faces and check to

5th fork rod into

that shift rods engage

0 3 ft

4th
and its

operate

correctly

and gears

adapter plate
Fig MT 124 Setting Wrench

Uft s

fork

smoothly

Example
When
a

4 0

Iong torque
in

wrench is

used

the

Fig

MT 123 will

be 8 0 to 8 8

kg

58 to 64 ft Ib

12

Measure gear end play

Make sure that

they

are

held within
1u

the

specified

values refer to Page MT 23 for

Revene

For details

Inspection
Fit 10 IDm 0 039 in thick snap ring 10 the front side of main shaft end bearing 14 Install mainshaft end bearing
13

using Bearing Drift ST22350000 thick snap ring to the rear side bearing to eliminate end play

Fit of
TM251A

Fig MT 126 In talling Shift Forks and Fork Roth

MT 28

Manual rransmission TRANSMISSION ASSEMBLY

Transmission
I Remove
case
r

5
to

groove in main drive

Fit main drive bearing snap ring bearing with

Note
a

Use shift

care

when

installing
Do

rear ex

assembly

snap Note

ring pliers
Make
sure

tension
sno

assembly

not

allow

ann to come out of

the strik
5th

adapter plate with gear assembly from Adapter Setting Plate

KV32100300
2

ring fits

in

ing

leVer
ann

groove

b Install shift

onto 4th

fork rod and then fit striking lever

Clean mating surfaces of

adapter

pin into oth

fork rods

plate and transmission case Apply sealant to mating surfaces of adapter plate and transmission case
3

Install counter gear tluust washer

selected
Note
a

previously
sliding surface
of

3
ers

Install through bolts with wash

Apply
When

grease to

GJ

Tightening
bolt

torque

thrust washer
b

Rear extension installation thrust washer note

installing

the front and

r ar

directions Fig MT 129 Fitting Main Drive flearing Snap Ring

1 6 to 2 2

kg

12 to 16 ft lb

4 in 5

Apply grease
rear

to

plunger install it

extension

ReBr extension assembly

I Front
Oil groove

InstaU return spring Apply locking sealer to return spring plug and mstall it in place

Clean I lating

surfaces of adapter
to

side

Rear Thrust side TM727

plate
t

and rcar extension

GJ

Fig MT 127 Counter Gear Thru

Apply sealant itd adapter plate a

2
as

mating surfaces of

rear extension

Tightening torque Return spring plug 0 5 to 1 0 kg

Wa her

Assemble follows

rear

extension

assembly

3 6 to 7 2 ft lbl

Place wooden
mm case

plate of

more

than

20

0 79 in thick under transmis

to

sion

make it level
case

Slide

transmission

onto with
a

adapter plate by lightly tapping

soft hammer until
case

bears against
line up

striking rod at Neutral position turn striking guide clockwise and then set striking lever and shift arm as shown in Fig MT 130 In this state align shift arm pin 3
2 sition

Set fork rod P

at

5th position

Front
I
as

coyer

assembly
cover

adapter plate dowel pin Carefully install

and be

sure to

with groove in fork rod and assemble

rear

Select fron follows

adjusting shim

extension

assembly

on

adapter

main drive

and counter gear front Make certain that mainshaft rotates

bearing needle bearing

plate

Using verruer caliper depth depth

A

gauge

measure

from front end of

transmission case to main drive outer race with front

cover

freely

bearing adjusting
A

shim in
2

place
a

Select

shim of thickness

measured

Wooden

Shift
TM252A MT280A J

ann

block

Fork rod
At 5th

Fig MT 128 Installing Transmis ion

Ca
e

Fig MT 130 Installing Rear Extension Assembly

MT29

Manual Ttansniissio n

No

mm

in

Adjusting shim
mm

ltening Ti

torque

in

Rewene lamp switch and

top detecting switch

I

05
10to 6

to

6 09 0 2382 to 0 2398 6 14 0 2402 to 0 2417

0 50 0 0197 0 55 0 0217
0 60 0 0236 0 6 3

2 0 to 3 5

m kg

2
3 4

14 to 25 fHb

6 15

to

6 19

2421 0

to 0 2437

Apply

light
to

coat

of multi
lever

6 20 to 6 2 49
6 25 to 6 29

41 1

19 t
to

2457
0 2476

0 9756

purpose

grease

withdrawal

release

5
6 7

0 2461

0 70 0 0276 0 75 0 0295 0 80 0 0315

bearing
on

ahd bearing sleeve in

stall them

transmission case

30 6
35 6

to

6 34

0 2480 to 02496
0 2500 to 0 2516

to

39 6

After connecting them with holder spring install dust cover to transmis
sion case 4

Clean

maling

surfaces of front
case

and
all

Install control lever temporarily move shift lceorviterorl through

gears to make
sure

cover

and transmission

that

gears

3
case

Install front with the

in

cover to

transmission shim and 0

op rate

adjUsting

smoothly
draiiI

InstaU

plug

coated

with

ring

place
ning torque

sealant in

place

@ Tight

Front co erinstallation bolt 1 0 to 1 6

kg

Tightening torque Drain plug

2 5 to 4 0

7 to 12 ft Ib

kg

18 to 29 fHb
TM816

Fig

MT 131 MetuUring Front

Make sure that main drive shaft

r CoV Adju ting Shim

Outer parts assembly I Install speedometer pinion install

assem

rotates

smoothly

in Neutral

Jin v

drive gear routing torque

bly and tighten

securing

bolt

and

less than 1 8 leg em 1 6 inIb

@
1

Tightening torque
Speedometer
sl

locking plate
m

Transmission
Main

bolt
case

2 3
4

drive gear Adjusting shim

3 to 0 5 kg 0

2 2 to 3 6 ft lb 2

Bearing

Install

reverse

lamp

switch and

tighten At
TM817
r Fig MT 132 Selecting Front CoV Adju ti1l8 shim

detecting
Be

install top switch if so equipped

to

the same time

sure

apply

locking

sealer

before installation

MT30

Manual Transmission

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS
Transmission model

F4W60L
Item

FS5W60L

No of speeds

Synchromesh type
Shift type
t 3

Warner

II
2 4

r
R 1

II
3 5 513 3 170 2

1st

513 3

2nd

2 170

3rd

378 1

378 1

Gear ratio 4th

5th 1000 1 000

0 846

Rev

3 764

3 464

Final gear ratio

3 700

3 700

155 13

15 6

4PR 13

16 5
16 5

Speedometer gear ratio

Tire

155SRI3

70SR13 175
Oil capacity
liter US

16 5

pt Imp pt

3 2 U 1

2Y

12

2 i

MT31

Manual Transmission

INSPECTION AND ADJUSTMENT

Transmission model F4W60L
Item

FS5W60L

Ist gear

15 0

to

0 25
to

15 0

to 0 25

0 0059

0 0098

0 0059 to 0 0098 15 0
to

2nd gear

30 to 0 40 0 0 0118 to 00157
15 0
to

0 25

0 0059 to 00098
30 0 to 0 40

30 0

Gear end
mm

3rd gear

play
in

0 0059 to 00118

0 0118 to 00157

5th gear 10 0
to 0 20
to

lSto O

30 0

0 0059 to

Q118 0

Counter gear

1 0 to 0 20 0
0 0039 to 0 0079

0 0039

00079

Reverse idler gear Clearance between baulk ring and gear rom in Main drive

1 0 to 0 27 0
0 0039 to 00106

0 15

to

0 40

0 0059 to

Q157 0

0 80 to 1 65 0 0315 to 0 0650 0 05
to

0 80

to

1 65

0 0315 1 0 0650

15 0

0 05

to

15 0
to

coupter
1st gear

drive gear

0 0020 to 0 0059
0 05 to 0 15 0 0020 to 00059 0 05 to 15 0

00020

0 0059

O OSto 0 15

0 0020 0 05
to

to

0 0059

2nd gear

15 0

0 0020
0 05 to

10
15 0
to

0 0059

0 0020 to 0 0059

Gear backlash
mm

3rd gear

0 05 to 0 0059

15 0

0 0020

0 0020 to 0 0059
0 05 to 15 0
to

in

5th gear Reverse counter to

reverse

0 0020
0 05 to 18 0

0 0059

0 05 to 0 18

idler

0 0020 to 0 0071

0 0020 to 0 071 0 05 to 18 0

Reverse idler to reverse main Main drive gear rotating torque

cm in lb kg

005 to

18 0

0 0020 to 0 0071

0 0020 to 0 0071

Ie thaI 18 1 6

less than 1 8 I 6

MT32

Manual Transmission

TIGHTENING TORQUE
Unit

kg

ft lb

F4W60L

FS5W60L
2 0 to 3

Ball

pin
nut

2 0 to 3 0 14 to 22

14 to 22 5 to 8 7 6

Striking lever lock

0 9 to 1 2

5 to 8 7 6

0 9 to 1 2

llft S
screw

arm

bracket
0 7 to 10 5 1 to 7 2

8 2 to 10 0 59 to 72

Mainshaft bearing retainer

08

to

3 1

5 8 to 9 4 80

Mainshaft lock nut Rear extension 16 to 2 2 12 to

10 0 to 110 72

to

16

installation bolt

16 to 2 2

12 to 16

Stopper pin bolt

Front cover installation bolt

5 to 0 8 3 6 to 5 8 0

10 to 1 6 7 to 12

10 to 1 6 7 to 12

Speedometer sleeve ing plate bolt Top detecting

lock 3 to 0 5 0

22

to

3 6

3 0

to

5 0

2 2 to 3 6

switch

2 0 to 3 5 2 0 to

14 to 25
to

2 0 to 3 5 2 0 to 2 0 to 5 3 5 3

14 to 25

Reverse lamp switch Neutral switch

Return

5 14 3

25

14

to

25 25

14 to

spring plug

05

to

10 3 6 to 7 2
18 to 29

5 to 1 0 3 6 to 7 2 0 5 to 4 0 2 5 to 4 0 i

Gear oil filler plug Gear oil drain

5 to 4 0 2 2 5 to 4 0

18

to to

29 29

plug engine

18

to

29

18

Transmission to

installation bolt
Tr msmissiori to
rear

1 6 to 2 2

12Jo 16

1 6 to 2 2

12 to 16

engihe

plate installation bolt

to gusset

1 6 to 2 2

12

t 16

1 6 to 2 2 12 to 16

Transmission
Starting
inissi
Rear
n

4 6 to 6 1

33 to 44

4 6 to 6 1

33

to

44

installation bolt
motor to trans 3 0 to 4 0 to 22

29

3 0 to 4 0 22 to 29

installation bolt
to

mounting insulator

transmission installation bolt Crossmember mounting bolt Rear engine mount installation bolt Clutch operating installation bolt

0 9 to 1 2 6 5 to 8 7

0 9 to 1 2

5 to 8 7 6

3 2

to

3 4

23 to 31

3 2 to

3 4

23

to

31

0 9 to 1 2

5 to 8 7 6

0 9 to 1 2

5 to 8 7 6

cylinder

1 to 4 1 3

22 to 30

3 1 to

1 4

22 to 30

Propeller

shaft to

differential carrier Control lever pin

installation nut

2 4 to

17

to

24

2 4 to 3 3

17 to 24

3 to 17 1

9 to 12

3to 17 9 1

to

12

Exhaust mounting bracket to exhaust front tube FU model only

3 2 to

3 23 to 31 4

2 3

to

3 23 to 31 4

MT33

Manual Transmission

TROUBLE
Condition Difficult to intermesh gears Causes for difficult gear fie
o t

DIAGNOSES

AND CORRECTIONS
Probable
cause

Corrective action

shifting

are

classi

Worn gears shaft and

or

bearing
worn

Replace
Repair
ClI

ro lb QncerlJing c coJltr 1 syste and transmission When gear shift lever is heavy and it is difficult to shiftgears clutch

Insufficient operating stroke due to or loose sliding part Worn or damaged syncluonizer

replace

disengagement
make
and
sure

may also be unsmooth First

Replace

that clutch operates correctly

inspect

transmjssion
this troubk
or occurs

Gear slips out of mesh

In most
cases

when

Worn

check baD and

or

weakened

or

Replace

check baD and

ed

is waIn or weaken or when control system is faulty In this

spring

broken spring
Worn fork rod baU groove

case

the

troubk

cannot

be

correct

by

Replace Replace
Replace

replacing gears and therefore trouble shoot ing must be carried out carefuDy It should
also be noted that gear slips out of mesh due to vibration generated by weakened front and
rear

Worn Worn

or or

damaged bearing damaged

gear

enigne mounts

Noise When noise

ceases occurs

with engine idling and

or

Insufficient

or

improper lubricant

Add oil

or

replace with
oil

when clutch is disengaged

occurs

when Oil

designated

noise

while

shifting
noise

indication
mission

that the

is

gears it is an from trans

leaking

due to damaged oil seal

or

Clean

or

replace

sealant clogged breather etc Worn

Transmission may rallk during engine

idling
Check
air fuel mixture

bearing High humming occurs at high speed

Damaged bearing
occurs

Replace
Replace

and ignition

Cyclic knocking sound

timing
After above

also at

low

speed Replace Replace

tension
as a rear ex

procedure readjust engine

Worn

idling

spline

Worn bushing

assembly

MT34

Manual Transmission

SPECIAL SERVICE TOOLS

I Kent Moore
Reference No

I Kent
Tool number

Moore No

Tool number

tool name

page

or

Fig
Unit

No

tool

name

Reference page or Fig No

application KV32 I 00300

Unit application

Adapter setting plate

J 25693

ST23800000

Transmission drift

J 25691

Fig Fig Fig Fig

MT 12 40 MT MT 77 MT 104

Page MT Fig Page MT

IO

46 MT 24

Fig MT I II

ST23540000

Fork rod

pin punch

J 25689

ST22350000

Mainshaft bearing drift

J 25678 44 MT Fig MT 55 Fig MT I08 Fig I 25 MT Fig

Fig Fig

MT 13 MT 78

ST22730000

Bearing puller

J 2568 1

KV32 100200

Countershaft bearing
press stand

Fig Fig MT Fig MT Fig MT

MT 24
27 28 92

Fig Fig

48 MT MT 50

F4W60L

STJ0031000

Bearing puller

J 25733 1

KV32 100100

Counter gear height gauge

J 26070

Fig MT Fig MT

22 90

Fig

49 MT

F4W60L STJ5300000 Oil seal drift KV32 100400 Mainshaft puller

J 26071

Page MT IO Page MT 24

Fig MT 52 Fig MT 115

Fe

rnuffiUQ

cP

Applicable
MT35

to all B310 series models

F4W60L and FS5W60L

Manual

lission Transl

Kent

Moore No
or

I
Tool number tool
name

Kent

Moore No
or

Reference Tool number tool

name

page

Fig No
Unit

Reference
page

Fig

No

application KV32101330

Unit I appliCation 5T2236ooo2

Bearing puller Fig

81 MT

Bearing drift

J 25679

Fig MT 118

r
22480000 S1

FS5W60L
22520000 51

FS5W60L Wrench

Gear

puller

I
Fig
86 MT

Fig MT 121 Fig MT 124

FS5W60L

FS5W60L

MT36

DATSUN 210

Model 8310 Series

SECTION

AT

AUTOMATIC TRANSMISSION

CONTENTS
DESCRIPTION HYDRAULlC CONTROL UNIT AND
VALVES HYDRAULIC CONTROL CIRCUITS REMOVAL AND INSTALLATION
TRANSMISSION ASSEMBLY AT AT 3 6 AT 2

TROUBLE DIAGNOSIS ADJUSTMENT

INSPECTION AND

AN
AT 39

ADJUStMENT
DIAGNOSIS
AT 39 AT 41 AT

BEFORE

TROUBLE

AT 25 AT 25 AT 27

STALL TEST ROAD TEST LINE PRESSURE

4i
44 AT

MAJOR REPAIR
SERVICE DISASSEMBL Y

OPERATION

TEST
CHART

NOTICE FOR
AND ASSEMBLY AT 27 AT 27 AT 27 AT 31

TROUBLE SHOOTING

45 AT
AT 51 AT53

SERVICE DATA AND SPECIFICATIONS

SPECIAL SERVICE TOOLS

TORQUE CONVERTER TRANSMISSION

COMPONENT PARTS

Autpmatic

Trimsmissi6n

DEScRIPTION
The 3N71 B trammission is automatic unit
a
a fully consisting primarily of hydraulic torque converter

FLUID RECOMMENDAnON

Identification of number

3 element two

and
brake

planetary
c1utclies

gear
a

sets

Two

type transmission fluid only

Use

DEXRON

automatic

arranaemanta

multiple disc provide

two

disc multiple

JAPAJllUTOIlATlC TRAJISIIISSIO C8 Ull MODEL X 0 12 3 7 6 0 1 2 34

brake band and one way clutch the friction elements necessary

NO

to obtain the desired function of the

A
to

planetary gear ets hydraulic control system

is used

IDENTIFICATION NUMBER

operate the friction elements and automatic shift controls TORQUE CONVERTER
The torque converter is attached to the crankshaft through a flexible drive

Stamped position
The

Number designation

plate

is attached to the
case

right
76 0
I 2

han

side of transmission

34

L Serial productioo
number

plate

Heat

generat

in the

for the month

t rque Month of production 1 Jan 2 Feb X Oct Y Nov Z Lut IJgUre denotins the year A D

converter is

dissipated by circulating the transmission fluid through an oil

to

Dec

water

type cooler
welded

in the

radiator

lower tank
The comtruction

of the
M AT

torque
or

co

verter

service

unless

3 ssembly prevents di highly specialized

equipment

is available

Fig

AT l

Identification

Number

IJ
JW
lrr r

III

f
T of
m

Tightening torque bolts and nuts kg

lb ft

@ @ @

T
T

5 29 to 36 14 to 16 101 to 116 T 4 5 to 5 5 33 to 40
T

4 to

Qj
1

gJ
8 One way clutch Low 4 Reverse brake
Oil 14 Oil pan

@
@

Transmission
Oil pump Front clutch

case

2 3
4

9 10 11 12 13

distributor

IS 16 18

Control valve

@
@

0 6 to 0 8 4 3 to 5 8 T 0 5 to 0 7 3 6 to 5 1 T 2 0 to 2 5 14 to 18 T 13 to 18 9 to 13
T T

Band brake Rear dutch

Front Rear

Governor

Input shaft 17 Torque converter

Converter

0 55 ta 0 75 4 0 to 5 4 0 25 to 0 35 1 8 to 2 5
AT312

CD

5
6 7

utput shaft
Rear extension

housi

planetary geat planetary gear

19

Drive pia te

Fig AT 2 3N71B Automatic Trammiuion

AT 2

Automatic Transmission

HYDRAULIC CONTROL UNIT AND VALVES

The

hydraulic

or

tomatic control

FLOW CONTROL VALVES Manual valve The manual valve is moved manual

Pre

ure

modified valve

system is comprised of four 4 basic groups the pressure supply system the pressure regulating system the flow control elements PRESSURE SUPPLY SYSTEM
The pressure of a gear

The pressure modifier valve assists the mainline pressure regulator valve in

valves and the friction

Iy by the

car

operator to select the

different drive ranges 1 2 ShHt valve shift valve automaticaIly shifts the transmission from first to second
or

lowering mainline pressure during high speed light load conditions such as steady speed cruise Governor pres
sure

working against

spring opens

the valve which aUows modified throt

supply system

consists

The

1 2

tle pressure to work against the pres

sure

type oil pwnp driven by the the torque converter through engine The pump provides pressure for aU hydraulic and lubrication needs

regulator

valve

spring

lowering

from second to first

depend

mainline

ing upon governor and throttle pres with accelerator position sure along solenoid downshift valve See Hy
draulic Control Circuits
Drive 2

Lower operating pressure pressure under light load reduces oil temperature and increases transmis
sian life

Throttle 2 3 ShHt valve PRESSURE REGULATOR VALVES

The pressure The throttle

up back

valve

The

2 3 shift valve automaticaIly from top to second de

governor and

back up valve assists

to

the

vacuum

throttle valve
I

increase

shifts the transmission from second to

regulating valves

con

line pressure when the manual valve is

top gear

or

trol the
pump

output pressure of the oil

shifted either

to

or

pending upon
pressure noid
or

throttle Second lock valve

The

range

accelerator position sole See Hydraulic

Drive 3

downshift valve

Pre

ure

rellulator valve
con
on

Control Circuits 2 3 Tlmlnll

Range

second lock valve is used 2

to

The pressure regulator valve trois mainline

pressure

the 1 2 shift valve to maintain bypa

based

valve
a

the band tion

throttle opening for the operation of the band clutches and brake Governor valve The governor
pressure valve transmits
on car re

apply pressure in The valve is also used

for the
in

posi
oil band and

as an

For 2 3 shifts slows the

restrictive orifice

application

fluid

to

the front

passage

1 2 shift valve

clutch while the slower reacting band is allowed to release This prevents a hard 23
or

apply pressure 12 Range

D2

D3

3 2 shift Under heavy

gulated

based

peed

to the shift valves to control

upshifts

load however the engine will tend to run away during the 2 3 or 3 2 shift
pause

and downshifts

therefore

2 3 timing valve

Vacuum throttle valve The

vacuum

throttle valve transmits based

on

using throttle and governor pressure is used to bypass the restrictive orifice during such heavy load conditions
Solenoid down hHt valve The solenoid downshift valve when the
a

CLUTCHES AND BAND SERVOS

The servo

regulated
load

pressure

engine

pistons of the clutches

to engage the clutches

vacuum

This pressure controls

low reverse brake and band are moved is

ac

the pressure regulator valve Also this pressure is applied to one end of the

hydraulically
brake and and brake

activated

electrically
f1oor d

apply

the band The clutch

are

shift valves in opposition to governor pressure which acts on the other end of the shift valves controlling and downshift speeds

celerator is

causing

forced

istons

released

upshift

downshift from top to second top to first or second to first gear depending upon
car

spring

tension

and band
tension

speed

governor pressure

released by spring draulic pressure

by piston is and hy

AT 3

Automatic Transmission

Tl IT

TI fT

c
Ii

t
i

u6
01
J
r Io
I

1
jJ li lUJ

AT090t

2 3 S

Pressure regulating valve Manual vahe ht 2nd shift valve 2nd 3rd lhift valve Pressure modifier wive

6 7 8 9 10

Vacuum throttle valve Throttle up back valve Solenoid down shift valve Second lock valve 2 3 timing valve

Fill

3 Control T

Vol

4 AT

Automatic Transmission
OIL CHANNEL
L

IDENTIFICATION
The circuit numbers shown in each

Hydraulic Control Circuit are classified as follows according to the function

Pressure

source

of the line

Operating

line pressure for

friction elements
I 2 3 4 5 6 g 9 10 13 14

AT106

11

12

Auxiliary line pressure Torque

Fig AT 5 Oil Channela in Cou Front Face

converter pressure 15

Governor pressure

Throttle system pressure 16 17 18 19

Oil pump discharge hole

lo
Oil pump discharge hole
1 h

o
o 0

Governor pressure 15

Torque Torque
converter pressure

converter

I
Servo release press re 10

pressure 14 14

f
e

Rear clutch

pressure 1 Front clutch pressure 11 suction hote

clutch pressure 1
Rear Front

Servo
0

tlghtemng

h0i1 W
8

6 pu

pressure

fI clutch 11 U
0

pressure 9
111 P
u n

li

rL nb
r
e

Governor reed

pressure 1

Low 1

reverse

brake pressure

12

1
AT107

IIlIlJJIII

ATlOS

Fig A T 4 Oil Channell in Oil Pump

Fig A T 6 Oil Channell in Cou Fac

MECHANICAL OPERATION
Cm

Clutch Front Rear

Low A

Band

servo

One
w

Parkin l pa

In the 3N71B automatic transmis sion

RanKe

ratio

brake

Operation

Release

y dutch

each part operates

as

shown in
Park 2 182
on on

the following table at each gear select

position

Reftrst

on

on

on

Neutral Lo 2 458
on

Dl
Drift 02

on

Second

1458 1 000 1 4 8 1458

on

03

Top
Second Second

on

on

on

on

on

12

on

on

Low

2 4 8

on

on

Note

The low

brake is

when coasting and aIlows engine

applied in braking

11

raiW

to

prevent free whee6ng

AT 5

Automatic

Transmission

HYDRAULIC CONTROL CIRCUITS

RANGE flow

PARK

Po

In the shift linkage P range actuated parking pawl meshes in a gear splined to the output shaft preventing movement of the car When the is

engine
Free Lock

running the low and reverse brake is applied by pressure from the manual valve passing through the 1 2 shift
valve

II
Manual Valve 4

AT086

Fig AT 7 Parking M

haniml

1d flow FI Downshift Valve 13

2nd 3rd Shift Valve

L
Throttle Back up Valve 5 1st

1st 2nd Shift Valve

2nd Shift

Valve

12

I Y Low

Throttle Back up Valve Reverse Brake

6 AT

Automatic Transmission

r n

rk
Brah bond

Lawand br

kr

Torqu

con r1lr

or

clutch

12@
011
cool

I
I

Ivacu m
throttl
yo lv c
u u

00

11

Throttl

e f

UP

Jf
j

di
lenOI
o n

Drain volv

r
Ora

Front

lubricatic

Otific chick volv

Throttl drain 01

I 1
II

@
2

r
x

13

@2nd 3rdShlft lv
10

Jl In

Si

2
x

j
L

J
2

@l
Shift

I
dl
r

u
CD pr
u

11 1
II
I

ator

II
I
l Ol

I
II

j2
U Xu J2
n

11 f1

Not

Mark

dX

ore

drain Go
nor

lint

r pru

u ur rn01

I I
101 Primary nor 90

X 01

Secondary
90

Govtrnor prusu
r r

cl

Torqu
I ratt TI

convert

ur

AT455 prUlur

Fig A T B Oil

Pre

re

Circuit Diagram

rang

Par

AT7

Automatic Tninsmission RANGE

Po
r

REVERSE

Front gear set

Rear gear ell

Output flow Input throush front With

range transmit
clutch

the

selector

lever

in

R to Held by low A
reverse

the front clutch is

applied

brake

clockwise engine torque through the connecting shell to the sull gear The clockwise otation of the sun gear causes the planet gears to
rotate counterclockwise

With the low the

rear

AT329

and

reverse

brake the
the

holding
rear

planet

carrier to

internal gear
turm

Low A

reverse

brake

ON

splined

output shaft
a

counterclockwise in

reduction ratio
1

ofapproximately2 18 to

w lW
Y

AT085

Front clutch Rear clutch Low and reverse brake Brake band
servo

ON OFF ON OFF Preuwe release oernmnin

way clutch On

AT 9 M

hanical Operation during

Range

Fluid flow

Manual Valve

Downshift Valve

13

2nd 3rd Shift Valve

L
Throttle Back up Valve
5 1st 2nd Shift Valve 12

1st 2nd Shift Valve

Throttle Back up Valve

I y Low
6 Pressure Regulator Valve

Reve

Brake

2nd 3rd Shift Valve

10

Band Servo Release Side

11

Front

h Clut

AT 8

Automatic Transmission
R
ren e

Rever

Torque

con

r1

moo la
x

OlenOid

j
C

ril
0

Q
I

II

lr

10

Oil cooler I

1Rear

lubr

otion

f L
r

ohl Front

lJ

1 2 El

Vacuum Throttl k JP

If
L
u

111
I old
I

J
x

J
co O chell 01

J
I
1
J

TO drain fol

I
il
3rd
Ii

II
I

@2nd3

Shift vol

IS

Xl tJj
2nd l 21

minQ
12

U1
j
L

1
to
6

1 1C li@S
1

I u
lr

ll
OC 0

IIF
iii

9r3
u

II

rm g

t
PRND2
I

uLrt
3

23

@
w

I
Mork

r 4
I l
Primarf Qo
lol i1lr

d X

Qr

droin Go
nor

Note
J

Lin G
1 0

prUltfrt
101 1

tced r rr

uur

Secondory
Qo
rnar

pr
tar can

01

J 3

Torqu
Tn
rotU

P
ur

Urt

pr

AT456

Fig AT 10 Oil Pr
AT 9

lSure

Circuit Diagram

range Reverse

Automatic Transmission
N RANGE

NEUTRAL

Po
In
are

flow range no friction elements thus no power is tranS

in

milled to the output shaft

AT10

Automatic Transmission
N
ran e

Neutral
Torqu
conv

rt

r e m

eoo
m

TIC Oil

pillut

Band
rvo

ii 0 I

@
Vacuum throttl olu Thronl boclt up Yolv

011 cool
r

RlOr lubricofion

j
loin
vo

r
I
Fron lub icati

Drain volv

lJ
X

Throttl drain volv

r
16 IO

L
16

O lie chick volv

18

J 3lIf
1X

24

IDpreiM
m

lh

llv
3
X

g
x

tJ1
8

2nd 3rd oh

timing

jr
2

U
CD
pr
utl o or

II

I
I I

II
II
r

I
X

t
3

U4lJ
J

i
Not hlorll td X Lin
pru
or

drain
rnor lGo

I
d
pr
ur

lr

60rnol pr
m

S condory governor lal

a
Primor gov
tO rnor

U1J
AT457

Torqu
W

convert
r

Plu

ur

I TI

rottl

nur

Fig AT II Oil Pr

Circuit Diagram

rang

Neutral

ATll

Automatic Transmission
DI Po

RANGE
r

LOW

GEAR

Fiont gear set

Rear gear set

flow 0 low the

Input t1uOllsh
rear

clutch

With the shift selector in gear

Output shaft

Held by

on

way clutch

engine
the

torque

is traJWnitted

through kwise c1o

applied

rear

clutch

to

internal gear of the front gear set The

of the front inter naI gear causes the front planet gears to rotate clockwise driving the com pound sun gear counterclockwise The front planetary carrier is splined to the
output
gears

rotation

Input from Output

to
real

front

gear set

gear set AT330

shaft

This

cau

the

planet
This
sun

to drive the sun gear instead of

walking
gear

around the

sun

gear

counterclockwise rotation of the

causes

the

rear

planet

gears to
one

rotate

clockwise

With the
rear

way

1
J

clutch holding the the

rear

planet

carrier

planetary

gears turn the rear

internal gear and output shaft clock wise in a reduction ratio of approxi

mately 2 46

to L

ld
AT081

Front clutch Reu clutch Low and revcrx brake Brake band servo Onto way clutch

OFF ON OFF OFF HOLDING Ra rationduri

Fig AT 12 MochanicaIOp

DJ

Fluid flow Governor Valve

15

Manual Valve

Pressure Modifier Valve 2nd 3rd Shift Valve lst 2nd Shift Valve 2nd 3rd Timing Valve

1st 2nd Shift Valve

j
2

Rear Clutch

Second Lock Valve Second Lock Valve

LOrifice

Check

Valve 2nd 3rd Shift Valve

AT12

Automatic Transmission
Low
r

ran

Fr on1 clutch Oil pump

Rear cl ulch

Brake ba n d

Low 0 nd reven

brQke

t
Torque
convlrter

o
h I
I b
Band
rvo

t
pr yalvl
ur

t
l

rlgula Tor l

Thralll ur pre

1V
Governor pre sur

Line

pr

ur

Governor

preslur

Torque conyert

pressure

Throttle

pr

iur
AT448

Fig AT J3 Oil Pr

ure

Circuit Diagrom

rang

Low gear

AT13

Automatic Tra
D2
Power In

mission l
Rear gear set

NGE RA
flow

2ND

GEAR

Front Bear set

Input throuah
the brake band is

rear

clutch

02
to sun

range

applied
and

hold the connecting shell gear

stationary

Engine

torque through the applied rear clutch is delivered to t he int D 1l1 gear of the front gear set in a clockwise rotation Clockwise rotation of the internal gear
causes

the

planet

gears

to

walk
AT331

around the stationary sun gear in a clockwise direction This causes the

output shaft which is splined to the front planet carrier to turn ina clock
wise

direction with
to

reduction ratio

of about I 46

1f
cW oo
w

j
Clutch Front Rearc1utch Low and
reverse

I
ATD79

OFF ON brake OFF ON OFF

AT447

Broke band One way clutch

S AT 14 MechanicalOperation during F

DJ

Range

Fluid flow As
car

speed and

governor pressure

overcomes

the force of the 1 2 shift

pressure

the

upshift position which

through
the
on

directs line

increase
on

the

the governor pressure acting end of the 1 2 shift valve

valve

spring and line

This
to

pressure

2nd lock valve

allows the 1 2 shift valve to

move

and

to the brake band

Manual Valve

Governor Valve

15

Pressure Modifier Valve 2nd 3rd Timing Valve 2nd 3rd Shift Valve
1st 2nd Shift Valve 9

1st 2nd Shift Valve

econd Lock Valve

Band Servo

I Apply Side

lRear CIutclt I
2 3

Second Lock Valve

Second Lock Valve

Orifice Check Valve

AT 14

2nd 3rd Shift Valve

Automatic Transmission
2nd gear

ren

Front clutch Oil pump

Rear clutch

Brake band

LOllii ond rlverse

brake

Tor q UI convlrt

l
valvl

t
ra

d
l
t

Prlssure

rlQulotor

tt1t
P

RN021

Govern or preslure

Line pressure

Governor

pre

ur

iiiiB

Torque

canverter

prollure

Throttle

pre

ur AT448

Fir AT 15 Oil Pr

re

Circuit

rang

2nd g

ar

AT15

Automatic Transmission
D3 RANGE

3RD GEAR

Front gear set

r Rei gear set

Power flow
In

Input through flODt

and
rear

clutches

D3
front

range

engine troque
both

is

transmitted
The

through

clutches

Output
shaft

clutch turns the internal

gear of the forward gear set clockwise

The

rear clutch turns the sun gears in a clockwise direction also With both the

internal gear and the sun gear of the forward gear set turning in the same direction at the same speed the planet locked in position and turn gears as a unit The output shaft spIined to
are

AT332

Front clutch

ON

the forward ratio of

planet

carrier turns at a

1f
Ij
Front clutch Rear e1utd Low reverse brake Brake band On way clutch ON ON
OFF
AT083

OFF Pressure rdeaJe OFF

Fill AT I6 Mechanical Operation hiring

Ronge

Fluid flow Governor

ure increases to the pre

valve
opens

When the 2nd 3rd shift valve the

release the brake band The

in

car is now

poinl that

it can overcome the com

bined forces pressure and

of spring and throttle

move

pressure passes through valve lands to the 2 3 timing valve and

on

D3

or

direct drive

the

rear

clutch

was

already applied

the 2nd 3rd shift I

to

apply

the

front IS

clutch

and Pressure Modifier Valve 2nd 3rd

Manual Valve

Governor Valve

Timin8

Valve

2nd 3rd Shift Valve

ht 2nd Shift Valve 1st 2nd Shift Valve 8 Second Lock Valve Band Servo

Apply Side
i

IRear Clutch I
2
J

I I

Second Lock Valve Second Lock Valve

Band Servo is released

t
3

Orifice Check Valve

2nd 3rd Shift Valve

10

Band Servo

Rele Side

2nd 3rd Timing Valve

II

I Front Clutch I

AT 16

Automatic Transmission
D3
ran

3rd g

ar

Front clurch Oi I pump

Rlar clutch

Brake bond

Low

and brake

rever

t
Torque
C onYlrt
r

0
J
L

I
Pressure

B J

i
t

thBond
so

1 1

reQula
Ya

or

lye

lt
T

r
t

tr
I

Throttle pressure

@
Governor au r pr

L i

ns

pressure

Goyernor

pressure

Torque

canYlr

er

pr

ssure

rIA

Throttle

pressure

AT449

Fill AT 17 Oil

ure Pro

Circuit Diagram

D3

range

3rd gear

AT 17

tic Transmission Autom

D

RANGEKICKDOWN
a

To achieve

forced downshift from

3rd

to

2nd

the car

speed
1st

must

be

under

approximately
from
2nd to

100 km h
il must

60 be 30

mph
under

approximately

50

kmh

Fully depressing the accelerator pedal energizes jhe dow hift sole mph
noid which opem the solenoid down shift valve Oil pressure is then exerted

against the shift valves Between 50 and 100 km h 30 and 60 mph this
pressure will close the 2nd 3rd shift vd t go mor pressure and the car downshifts When the car speed
is below

50

kmh

30

mph

the

Ist 2nd shift valve will be closed and

the transmission will be in Isl gear A

car

speed

and governor pressure in

crease

the shift valves

automaticaJJy

reopen

AT 18

Automatic Transmission

nnse klckdown

Shift valvas In 2nd sear position

Low

ond

brok Brak bond Vacuum control

dlophroem

Oil cooler

Ii
R
ar

80nd

no

J r
C

J
N

Throttl back up vain

lubrication

P aJ

8
I

ll

Ill
w

f
0 1

Throttl drain voh

P
1

F
b
Orific ch ck val 18 X 16

1r
@2n
lShift 3n 01

Xl
2

r Ii
@
II i
OI

r
jI
s

2
o

dl

U
CD
r

JJ 1
m

l 1

I 1

lIU volv

afor

I
II
N

N1
r
r pru

JJ
I

J r
J
n
o

@
1

ju

lln
l

Gov
IU

nor

Iud pr ssurel
x

Go

rnor

pr

I1
Primor rnor 00

Torqu
TIl rotll p

t r conv

pr

lur

S condary nor val 90V

olv

lure

AT458

Fig AT 18 Oil Pr

mn

Circuit Diagram

rong

kickdown

hift

va v

in 2nd gear position

AT 19

Automatic Transmission
2RANGE The range lock the
car or

2ND

GEAR
is used to

Fluid flow Uoe valve pressure opens the from

second

opening the valVe and

the manual
sure

alloWing

pr

position

to

into the

line of the

in 2nd gear

preventing
con

lock valve

throttle valve
tion

thus assuring
even

adequate
is

upshifts
ditions Po

downshifts under any

against spring pressure

opens pressure the band servo

As this valve

throttle pressure used

as a

during decelera

the passes to

apply

he downshift solenoid valve J

flow 2 raogo is the

same

flows to the

pressure also throttle back up valve

Une

passage for line prere to lock the 1 2 and 2 3 shift valves

Power flow in
as in

D2

range

UlllV

Governor Valve

IS

Pressure Modifier Valve 2nd 3rd Timing Valve 2nd 3rd Shift Valve
1st 2nd Shift Valve

1st 2nd Shift Valve Rear Clutch j 2 Second Lock Valve 9

1 Band Servo Apply Side l

3rd Shift Valve

Solenoid Downshift Vilve

1312nd
17

1st 2nd Shift Valve

Throttle Back up Valve

Vacuwn Throttle Vilve

16

Jre ModifJerVilve

2nd 3rd Shift Valve

2nd 3rd Timing Valve Throttle Drain Valve Pressure

Regulator

Valve

AT 20

Automatic Transmission
2 2nd Beer

renge

or

j
r

Oil cool

I
Reor lubrication

Bond

r
0

j
Throttl lc uP

41 10 I

II

o
Drain oha

ll

fr t
Fron lubricaf

Drain

vol

rr
i

Throttle drain ahe

1
I
II

I
j
01 1816

Shift @Zn6 3rd 101

1

is

t1

IS
N

x X
x

g 2nd vol

U
3rd

1x
timing n
I
I

J
l

I
2

s
S

Z t

Ii
D
r

II 1
fo4anuol

In
1

I
1
S

ou alar 1 01

II

P R 4

j
X

000j
Not
lIo

Morked X line pr G
o

art
ur

drain
I

I1
ViII

Go

nor

lid

pr

ure

Ul
Primor nor go

Slcondory
govunor

vol

rnOI

pr
con
r

Torqul Th rotU p

JUri
AT459

Fig AT 19 Oil
AT 21

Circuit Diagram ProIlU

range

2nd

tar

Automatic Transmission
l

RANGE

second
vents the

afwvernor preSsure 12
I 2 shift valve from

pre

Fluid flow Manual

Lolft

ar
passing through

LOW AND 2ND GEAR

The range 1

closing

pressure

lock the car in 1st

position is used to gear preventing any

the 1 2 shift valve is used to close the Po

r

flow

upshifts
to the

If the selector lever is moved

I

moving at sion ill not shift into first gear until w car speed slows to approxiniately 55
km h
35

position while the car is high speeds the transmis

ly
set

The power flow in differs slight in that the low and reverse from

11

band is

applied to hold the rear gear planet carrier providing engine

Power flow in

01

1 2 shift valve preventing a 1 2 up shift Manual pressure pusing through the downshift valve lock the 2 3 siuit

valve closed along with applying addi tional closing pressure valve
to

the I 2 shift

mph

Instead it will shift to

hraking a io02

12

is the same

Manual Valve

Governor Valve

15

Pressure Modifier Valve

2nd 3rd Timing Valve 2nd 3rd Shift Valve

1st 2nd Shift Valve lst 2ndSti ft Valve

iRea
4

Clutcb

I
13

Solenoid Downshift Valve

I2nd
12

3rd Shift Valve

ht 2nd Shift Valve

Throttle Back up Valve 5

C

1st 2nd Shift Valve

Throttle Back up Valve

I y
Fluid flow 2nd
ar

Reverse Bra1ce Low

Manual Valve

Governor Valve

15

Preuurc Modjfier Valve

2nd 3rd Timing Valve 2nd 3rd Shift Valve

1st

2nd Shift Valve

1st 2nd Shift Valve

Second Lock Valve

Band Servo

Apply Side

t
4

Rear Clutch

I
13 2nd 3rd Shift Valve

Solenoid Downshift Valve

I
Throttle Back up Valve 17

ht 2nd Shift Valve

PreSlure Modifier Valve 2nd 3rd Shift Valve

2nd 3rd Timing Valve Throttle Drain Valve Pressure Regulator Valve s ht 2nd Shift Valve

AT 22

Automatic Transmission
I
renge

Low geer

Torqut conv

rt

ar

lCh

j rJl
TIC

Il

r uur Ip tlno 101

Iii

cool

RIot

lubri c oJion

I
11

Bond
r

ff1
o CI

i
10

11
H
H

i
4
Fron

1 2 I
I
II

Vacuum

tlltOfflt volY

1
Otific ch ck 101

1
24
ol

I
l
ift

lubricat 0

1
j

TO

6 3 3 r X

tA

I
In

r3 @2n

II

g 2nd

3rd Ii

mln

12

IL

I
j
n
5 15

Xl
21

1
6 6

II
1
S dI
c

III 1
lJX
3

Sh

olQ1 1

CD r
r

II

ir
l

Il
l

2
1

f11

if

Not
Irtr

Mork L in P

all

droin
X l rno Go
u r

USUf

ud

pr

uu

11
1
1 101

Secon or l rnor QO

PnmOfJ
0 10 r 1 1 01

G ov

rnat

pt
r

Torqu
TII

convut

pr

ur

AT460

totUt pr

ur

Fig AT 20 Oil Pn AT 23

sure

Circuit Diagram

11

rang

Low g

ar

Automatic Transmission
I
ren e

2nd

eer

Torqul

con

rter

Front lulch Oil pump

Riot

@
Vacuum
Huottl Vol

Oil

tool l RIAr Ivbri cor ion

N

r
N

D
Orain
fa

hi

if
Front lti lubrici

II I

J
Throttl drain l yol

1 I
tU

i l
J

I ahl

18

16

@2ft

3rd Shiff 101 1

II

iii
8

1J
S

2nd 3rd
11 101

timino

U
21

1 F

2
lllvI Sflift

I
nd lock

dll
6

j Pr

UQU

l010r

II

Ir

Yol

P UX
Mo ol

I
u

f
uu

L
u u

t
Slcondor governor vol

LI Goy
u 1

OI

I Go prlUUAI

fo d

I f5
1

rnor

Primo vlrnor 00

va

Torque Cony
Th toni pt

tar
ure

pr

AT461

Fig AT 21 Oil Pr

Circuit Dwgrom

12

ro

2nd

ear

AT 24

Automatic Transmission

REMOVAL AND INSTALLATION

dial gauge rested

TRANSMISSION ASSEMBLY
When
to the I

CAUTION
Do not
automatic

eating finger of against plate

the

dismounting the
a car

pin dnin 13
cover

plecs plug

jack

under the oil

Maximum ellowable runout 0 5 mm 0 020 in

transmission from

pay attention Detach converter housing

Remove bolts

following points

dust

dismounting the trans mission rigidly inspect it by aid of the Trouble shooting Chart and dis mount it only when coll5idered to be
Before
necessary 2

securing torque

converter to drive

plate

Dismount the transmission with

care

utmost

and

when

AT268

mounting
Fig A T
3

observe cated
on

the

tightening torque indi

not to exert

another table

uring DrivePIote Me Runout

converter

excessive force

Installation of torque

REMOVAL
In sion I

AT261

Fig A T 22

dismounting automatic transmis from car proceed as follows

Disconnect battery ground
cable

Removi Torqu Converter Attachirrg Bolt

Line up notch in torque converter with that in oil pump Be extremely careful not to
eause

undue stresses in
converter

Note ter v

Before
ICnlJe match mark
10

toniCOD
011

parts

In

inataIIing torque

two

from terminal

parts
ac

that they may be

replaced
at sa

Disengage torsion shaft from eelerator linkage

3

in

their

original position
rear

Jack up vehicle and support its

sembly
14 Remove

weight on safety stands Recommend a hydraulic hoist or open pit be utilized

if available Make
4
sure

engine

mount Se

curing
IS 16

bolts and crossmember mount

i bolts 8

that safety is insured

Remove starter motor

Remove

propeller shaft

Note

ll up the Pl

Remove bolts securing transmis to sion engine After removing these bolts support engine and transmission
with

AT116

Fig

A T 24

Torqu

Converter

A ligning Cut

openina

in the rear

extension to prevent oil from flow

jack

until transmission

and lower the jack gradually can be removed and

ear

When
to A

connecting
transmission
10 be certain

torque
measure

con

ing out
S

take out transmission under the selector lever Note

verter tance

dis
are

Disconnect front exhaust tube Disconnect Disconnect Disconnect

8e ra

that

they

6
7

from manual shaft

wire connections at

I P1 up the opening such u oil chergina pipe oil cooler tuba etc

correctly

assembled

Distance HA

inhibitor switch
8
vacuum

lube

from

vacuum

diaphragm and

wire connee

tions at downshift solenoid 9

CAUTION Take cin in dismounting tnnStnlllioA not to strike any adjacent paru

Melre irian 21 5 mm

0 846 in

Disconnect

speedometer charging pipe

cable

from 10
II

rear exlension

Disconnect oil

INSTALLATION
Ill5tallation However of automatic transmls the following
in sian on car is reverse order of removal
a

Disconnect oil

cooler inlet and

case

outlet tubes al transmission

12

Support engine
pan

by locating

observe

jack under oil

with a wooden

stallation notes Drive

block used between oil pan and jack Support transmission by means of a
transmission

plate

runout

AT117

Turn crankshaft one full turn and

measure

Fig

jack

drive plate runout with indi AT 25

AT 26 1116talling Torque Convert r

Automatic Transmission
4

Bolt converter

to

drive plate

NOte
a

II to page AT40 for

Move
to

selector leve

Refer
and

Checking

through

all

positions

be sure that transmission

Note

Align chalk mark painted a cro5S both parts during disas sembling p

Inspect
whe

Adjusting Inhibitor Switch end edjust switch as

ever

abo it has to be removed for

operates correctly With hand brake

applied

rotate

engine through
and reU
to

at

idling

Without
move

e servi
9

disturbing
2 to I be

the above inhibitor switch

seUlng
N to A

selector lever

to

Check

S
r

After converter is installed

for op
into op

rotat

nkshait

be sure that

veral turns and check to transmission rotates freely recommended

automatic

eration

slight shock should

Starter should be
eration P

brought

by handgripping selector each

time transmission is shifted

without binding
6

only when selector lever is in N and positions it should not

D
n

Pour oil

be started when lever is in and Ru positions

Note

transmission fluid up to correct level

See page AT40 for Engine Idling Revolution

Checking

through
7 rod

charge pipe
manual lever
to

Back up shift
out in

lamp

should

Iso

light
R 12
sure

Connect

when selector lever is placed in

Check to be sure that line pres is correct To do AT43 for Line

Operation should be carried

m

position
10
sion

with N
8

mual

and selector

levers

Check level of oil in For detailed procedure

see

transm page

this refer to Pressure Test

page

13

Perform stan test as described in

Connect inhibitor switch wires

AT39

page AT41

AT 26

Automatic Transmission

MAJOR REPAIR OPERATION

sene

SERVICE NOTICE FOR DISASSEMBLY AND ASSEMBLY

I It is advisable

into torque

converter I J V S pt

mately pt
3

5 liter 0

approxi U Imp

Remove bolts which hold valve

to

body

transmission

case

Blow air into torque converter Fill

converter

that repair opera

in a dust

and flush and drain out gasoline

4

tions be
room

carried the

out

proof

torque oil

with

torque
to

converter

approximately
Imp pt

Due

differences of the

5 liter 0
5 verter

I J V S pt U

engine capacities the specifications of component parts for each model s

transmission do however may be

Again

blow air into torque con

and drain torque converter oil

different
common

They

have

adjust

ment

and repair
and

cleaning
3

inspection

procedures as well as procedures

refer to
H1s see

TRANSMISSION
Fig AT 28 Removing Valve Body

outlined hereinafter

DISASSEM
I

LY
6 Loosen lock
nut

During repair operations Service Data and Specific3ti

for the
correct

Drain oil

from the end of

transmission

CV

on

piston

rear
on

stem

tion

parts for

each

extension

Mount

CD

model
4

Transmission Case Stand ST07g70000

or

removing any of subas semblies thoroughly clean the outside

Before of the
transmission
to

ST07860000

Remove oil pan

Then tighten piston stem in order to prevent front clutch drum from falling
when oil

pump is withdrawn

prevent dirt

from entering the mechanical parts 5 Do not use a waste rag Use

nylon
6

paper cloth After disassembling

or

wash all dis

to or

assembled parts and examine them see if there 3re any worn damaged defective parts
and
to

how

they

are
AT118

affected Refer the

7 extent

Service Data that

for

of damage rule
once

justifies
and
2

Fig A T 26 R
Remove bolts
to

g Oil Pan movin

AT121

replacement
As
a

packings
ones

seals

securing
case

converter

Fig AT 29 Loosening Band

Jo Se11

similar parts

disassembled should

housing
3

transmission

Remove
7

be replaced with new

torque converter housing Remove

speedometer

pinion

Pull out input shaft Withdraw oil pump using Sliding Do

not

TORQUE CONVERTER
The torque
construction
converter can

sleeve bolt Withdraw pinion 4 Remove downshift solenoid and

vacuum

Hammer ST25850000 front clutch and drop

to come

allow

out of

position

is

welded disas

diaphragm

Do

not

leave dia

onto

floor

and

not

be

sembled

phragm rod at this stage of dis assembly Rod is assembled in top of

vacuum

diaphragm

INSPECTION
I Check torque convert for any

sign of damage

bending oil leak or deformation If necessary replace 2 Remove rust from pilots and bosses completely
contaminated If torque converter oil is fouled or due to burnt clutch
as

flush the torque converter

follows
AT122

I
2

Drain oil in torque converter Pour non lead gasoline or kero

Fig A T 27 Dowmhift Solenoid and Vacuum Diaphragm

Fig AT 30 Removing Oil Pump

AT 27

Automatic Transmission

AT126

Fig A T 34 Removing Connecting

D
m

Fig AT 37 Removing Drive and

Driven PltJte

Fig A T 31 Removing Bond

Stt

14 10
unit

Remove

snap

rings and then

carrier
one

18

Reaching through back side of

case remove use

remove rear

Remove
rear

brake clutch

band
as an

front

gear

planetary connecting drum

nd
one

internal

transnlission

hex head
Hex head

way clutch

slotted bolts To do this

E xt ens ion

clutch and

assembled

outer race

way clutch in that

S T 2 55 7 000 I One way clutch inner

order Remove
IS Remove
rear

ST25570000
extension

connecting shell rear clutch hub and front planetary carrier

II
asa

by

race

thrust

washer

unit

loosening securing bolts

spring and be removed

thrust

piston return spring ring can now

snSS70001

AT12

Fig A T 35 Removing Rear Extemion

Fig AT 32 Removing Connecting

Shell

12

With

the aid of Snap Ring Re

Pull out output shaft remove oil distributor @ together with governor Ive

16

Fig A T 38

Hex head Removi Slolted Boll

HT69860000 pry snap ring off output shaft

mover

19

Blowout low and

a

reverse

brake
into

piston by directing hole in cylinder

jet of

air

Fig

36 AT

Remov ngGovernorand Oil Ditributor

fig
13

A T 33

Removing Snap Ring

17

Pry

Remove

connecting drum and

inner gear of rear

an

planetary

carrier

as

pliers plate

off snap ring using a pair of Remove retaining plate drive

Fig A T 39 Rem wing Piolon

driven

plate

and dish

plate

in

20

Remove bolts

band

servo

loosening

assembly

that order
AT 28

allaching

Automatic Transmission
Note If difficulty is encountered in removing retainer direct 8 jet of air toward release side Geskots end Gorin
J

Tightening torque
Oneway clutch inner transminion case 1 3 to 1 8 m kg
race

Always

use

new

gaskets when the

or

to

units are to be disassembled 2

Check O rings for burrs

necessary

crack
new

ing If rings

replace with

9 to 13 ft b

011 distributor
ST25570001

Ph
i

I Check for signs of wear on seal ring and ring groove replacing with
new ones

h GG9 3010000

ST25490000

if found

worn

beyond

use

Check that clearance between seal

and

ring
AT132

ring

groove is correct If out whichever is

of

specification replace
beyond limits
n

Fig AT 40

Remov I Band Servo

worn

Clearence 1
21

58el

ring

end

Fig AT 43

Pry

snap rings

CD

from

both

ring

groove 0 04 to 0 16 mm 0 0016 to 0 0063 in

1 ll One way lalli Clutch Inner Race

ends of parking brake lever @ and remove the lever Back off manual shan lock
nut

CID

and

remove

manual Clearance Seal ring

plate

and

parking rod

CID

After low and

reverse

brake has

been assembled

measure the clearance

between snap

ring

CD

and retaining

ii

plate @ Select proper thickness of retaining plate to give correct ring to plate clearance
Low and revene br ke de r
nce

J
0

FI
AT13

0 80 to 1 25 mm 0 031 to 0 049 in

Fig AT 41 Rtmoving Manual Pl4tt

22

Remove

inhibitor

switch

and
secur

manual shaft by loosening two

ing bolts

Fig AT 42 Mea uring Seal Ring to Ring Groove Clearance

ASSEMBLY

INSPECTION Torque converter houslns

trensmlsslon
reer use

end

Assembly is in reverse order of disassembly However observe the fol lowing assembly notes
After installing piston of low and Drake assemble thrust spring
return way

Fig A T 44 Measuring Ring

to

Plate Clearance

extension

Check for

damage

or

cracking
score

if

reverse

Available

necessary replace 2 Check for dents

on

ring
or

spring thrust washer and

inner
race

retaining plete
Service Oeta and

Refer

to

marks
nee

one

clutch slotted

mating

surfaces

Repair

as

hex head

bolt

Tighten using Hex

3

Specifications
Install
mark It
one

essary If rear extelUlion bushing is 3

or

head
worn

Extension

ST2SS7000J Wrench
Extension

way clutch

so

that the front of

rotate

ST2SS70000 GG930JOOOO ST2S490000

and

Torque
Socket

arrow

is toward be

cracked

replace

it

an

bushing and

rear extension

mbly of housing

vehicle

should

free

to

ST2SSI200J
AT 29

only

in clockwise direction

Automatic Transmission
9

Adjust total

end

play and front

Adjustment of totel end pley

Select oil pump cover bearing race by calculating thc following formula

ITU

end

playas

follows

Front end

play

TT
where

lmQO d fJ
Fig A
45 T 4

t
AT137

TT
A

cover

Required thickness of oD pump mm in bearing race

mm mm race
mm

Measured distance A Measured distance B Thickness of bearing

in in

One way Cluleh

L
Total
end

Zl

B
W

installing rear extension tighten attaching bolts Place manual

After lever in that
P

r
play

temporarily inserted
A vaDable oil pump cover
race

in

bearing

range and check

to

be

sure

rear

outpul

shaft

is

securely
Thickness
AT138 nun

blocked

in

fl

Tightening torque
Transmission case to extension 2 0 to 2 5 m kg
rear

2 1
Front

0 047 0 055 0 063

0 071 0 079 0 Og7

clutch

3
4

thrust washer OH pump cover Front clutch Rear

clu tch

6
7

Transmission ca5e Oil pump gasket Oil pump

cover

I 4 1 6 18

bearing

race

14 to 18 fHbl

Fig AT48 End Play

5

2 0 2 2

Tighten
Place

servo

retainer

temporari I
C Measure the distance
A and

Iy
6
7

at this stage of assembly

rear

clutch assembly with front assembly

lb 4

needle bearing Install

on

by

vernier

calipers

Specified totel end play

0 25 to 0 50 mm o oio to 0 020 inl

rear

clutch

and front

planetary

carrier

fl

Tran

mission

case

Adjustment of front end pley

Select front clutch thrust washer by

r1

I
A

0
W

calculating
T
F C

the following formula

D

AT142

tic
I

0 2

mm

where

II

clulch

N ed1e bearing
lace

I
AT139

Required

thickness

of

front
in in in

clutch thrust washer C D Measured distance C rMeeadsu distance D

mm
nun

Bearing

J
A

mm

Fig AT 46

talling Planetary
Carrier

Fig A T 49 MeaSuring the Di tance

and B C and

Available front clutch thrust washer

Assemble parts

connecting shell and

to

2
D

Measure

the

distance

other
reverse

up order of disassembiy

front

clutch

in

of oil pump

cover

Thickness 5 1
I 7
B

mm

in

0 059 0 067 0 075

0 083 0 091

1 9 1 2 3 2 5 2

0 098 0 106

2 7

AT143

AT140 tance Fig A T 50 Measuring the Di

Specified

front end pley

Fig AT 47

talling Canneetin
Shell

0 5 to 0 8 mm 0 020 to 0031

cB

and

inl

AT30

Automatic Transmission
Note llTect L C
12

After

inhibitor
to

switch

is

in

thid ness of bearing

race

stalled
erates

check

be sure that in each range

to

it op For

I Pry off snap suitable screwdriver

ring
or

j @

with

pair of pliers
drive and dished
as

end thrust washer is always the one which is nearest the calculated one b InsteJled thid noss 4 mm 0
to

properly

Remove

of oil

pump

detailed procedure refer 40 for Checking and Adjusting lnhibi

tor

page AT

plate
in

retaining plate driven plate @

plate @
Fig
2

in the order listed

shown

gasket
10
servo

is

0 016 in
sure

Switch Check the length end

to

AT 52

Check

that brake

13
case

between

procedure
Servo

piston moves freely For detailed refer to page AT 33 for

Piston Use
care out

to

prevent
not

piston from coming ing testing since servo retainer is tightened at this point of assembly
II is

ofplace dur

fully pushed adequate diaphragm rod of sponding measured length

valve

rod end of vacuum throttle Then select in

corre

Clutch

Compress clutch springs using Compressor Spring

or

ST25420001
move

ST25420000 from

Re
reo

snap

tainer

ring @ using Snap

spring

Ring

Remover

dllidf

ST25320001

Make

sure

that brake band strut

correctly installed Tighten piston stem Back off two full turns end
secure

11f11 11 1
n 1 1

with lock nul

torqUl
L

Tightening

Piston stem
AT145

1 2 to 1 5

kg

9 to 11 ft lbl Piston tem lock nut 1 5 to 4 0

Fig A T 51 M asuring the Dutance

L

kg

11 to 29 ft lbl

Available diaphragm rod

Note

Fig AT 53 Removing Snap Ring

Distance measured Under 25 55 25 65 to 26 05

mm

in

Diaphragm

rod

length
142 1
161 1

mm

in

When Clutch

Spring Compres
is to be used three cut
a

sor

1 0059

29 0 295

the

ST2S420000 toe tips of

wheel

legs by

10098 to 1 0256 10295 to 1 0453 1 0492 to 1 0650 15 27 1 0689

grinding

15 26 26 65

to
to

55 26 27 05 Over

30 0

181 I
J

201 5 1 30

310

220 1

L
AT 148

E 5 Eo
U

COMPONENT PARTS
The transmission consists of many all

FRONT CLUTCH
Dl

mbly

20mm 0 79 in

Cut off hatched portion

parts that

are

quite

alike in
to very

oonstruction

yet close tolerances When disassembling

machined

Fig A T 54 Modifying Coil Spring Compressor 3 Take out spring retainer

parts be sure to place them in order in part rack so they can be restored in the unit in their proper positions It is also very important to perform func lional test whenever it is designated
I 2 Piston

and

@ @ @

spring 2 See Fig AT 52 Blowout piston by directing

jet

of air into hole in clutch drum

3
4

Coil spring Front clutch drum

Dished

plate
I

5 6
7

Driven plate R etammg plate

I

8 9 10

Snap ring Drive plate Spring retainer Snip ring

AT146

AT149

Fig AT 52 Section 1 View of

Fronl Clulch

Fig A T 55 Blowing Out Piolon

AT31

Automatic Transmission Insp ctIon

I age

Awilable
wear

reteiningplate
Thickness
mm

REAR a UTCH

Check for signs of

to

or

dam If
in

clutch drive plate

worn

facing

D1

mbl

found discard

or

damaged excessively
10 6
0 417

Drive

plm th
1 5 to 1 66mm 0 059 to O

10 8
11 0 112 II 4 11 6

0 425 0 433 0441 449 0 0 457

Standen

Inl

Allowable limit 1A mm

0 065 inl

Check fOI weer on snap ring and for weakened or broken coil spring 2 If necessary replace with new ones Spring retainer should also be in spected fOI warpage
AT313 1

Rear clutch drum Piston Dished plate Coil sprina

6 7 8 9 10

sembi 1 of

2 3 is in reverse the order 4 5

AT151

Assembly

disassembly Dip

automatic

all parts in clean transmission fluid before

Rctainins plate

Snap rina SpriDa SDap riJlI Driplate Iltmm plate

0

installing
Fig
67 AT Me

Fig AT 59 Sectional VielD

Rear Clutch

ring Ring to PIlIte

Cleo

1
3

Take out snap ring

Testing
cover

front clutch
on

With front clutch assembled direct

a

oil

plate @ drivc plate @ @ and dished plate ID nique can be applied

sembling front clutch
2 Remove snap

driven

retaining plate
disas

Same tech
as

in

pump jet hole in clutch drum for definite clutch

of air into

ring

from

coil

operation

spring retainer

Fig AT 56 2
sure

ting Clutch PIlIte embled make

After clutch is

th t clearance between

snap ring
is

CD

and

retaining plate
limits

held

within

specified

If necessary

lIy with other retaining plate having

different thickness until correct clear
ance

is obteined 1 deerence 1 6 to 20 mm
AT152

ST2S3200l

X
Fi6
60 AT

0 063

to

079 inl 0

Fig

58 AT

Taring Front Clutch

Remouing SruJP Ring

AT 32

Automatic Transmission
3

Blowout piston by directing

jet

Without

disturbing

the

above

of air into hole in clutch drum

setting check
between snap is within
use

to be sure that clearance

ring and retaining plate

nece ry

specified limits If other plates of different

thickness

until correct clearance is obtained

Specified deereM8
80 0
to 1 25 mm

II
AT1 7

0 031 to 0 049

inl
air into oil hole
to

Blow

compressed
roverse

in low 63 Fill A T
AT155

brake

test

for

Te ting Rear Clutch

deftnite brake operation

Fig In pectlon

61 AT

Blowing

out PWton

LOW
D1

REVERSE BRAKE

Refer to page AT 32 for Inspection of Front Clutch

mbly

As

mbly
in
reverse

I Follow steps as described in page AT 27 for Transmission Disassembly

Assemble

the order of
in

Blowout piston

by directing

jet

disassembly
automatic

Dip

all

parts

clean

of air into oil hole in clutch piston

transmission

fluid before Fill AT 64 Tuting Low In pectlon 1

or

assembling Note that the number of

drive and driven of vehicle ice Data I After

Reverse Broke

plates

varies with

type

For details refer to Serv

Specifications
rear

Check drive

plate facing

for

wear

demege if necesaary replace

Drive plate thielm Standard
1 9 to 2 05 mm 0 075 to 0 081 in

clutch

is

assembled

SERVO PISTON D1
I

check to be

sure

that clearance be

tween snap ring is held within

Q and

retaining plate
clearance

mbly

specified

Blowout piston by dilecting a jet of air into hole in release side of

Speelfied

Allowable limit
8 mm 1 2 0 071

0 8 to 1 6 mm

inl

piston
2 Remove
servo

piston

return

0 031 to 0 083 inl

Test

weakness
use

spring for Discard if weakened beyond piston

return

spring

3
ones

Replace

defective parts with

new

In p ctlon Check piston for

wear

damage

or

other defects which might interfere

with
As
I

proper brake opcration

mbly
After low
reverse

piston

is

installed
AT156

return
one

assemble thrust spring ring thrust washer and spring

inner race

Fig AT62 Meaiuring Ring to

Plate canInce C

way clutch

Refer to

Assembly page AT 29 for tightening torque and special

service tools 2

in Transmission

Testing
Install

rear

c1u ch clutch
on

rear

oil

pump

cover

drive plate oil hole

Insert dished plate driven plate and reiaining plate into Install Fig
65 AT
secure

Blow compressed air i 1to

to test for definite clutch

transmission case in that order

operation

snap ring to

the installation

Removing Piaton

AT 33

Automatic Transmission
3 If primary governor is to be dis for any purpose remove
governor valve

assembled

CD

spring seat primary spring and spring seal Inspection

Anchor end

pin

I tion

Check valve

for defective condi

I
I
@ @

2
3 4

Band strut

Apply
Release Return spring Band servo piston stem
Band
servo

Replace spring if found weaken use Defective piston ed beyond should also be replaced with a new
one

TL
66 T

S
6

7 8 9
10

piston

2
nor

Servo retainer Brake band usembly Transmission

cue

3
nor

AT290

Examine to see if primary gover slides freely without binding To determine if secondary gover is in good condition blow ir

Fig A

Sectional Voew ofSenJo PUlOn

and

under light pressure into hole at A listen for noise like thaI of a model

plane

Assembl I Prior
to

assembly dip all parts

in

Assembl
Reverse

clean automatic transmission fluid

Reverse

disassembly procedure
care

to

disassembly

procedure

to

assemble brake 2 Use extreme

to avoid dam

assemble governor Note

aging rubber ring when installing seal

lace 3 side Blow

compressed
to

air from

apply
Fig
AT 68 Te ting Pi ton Rele ide

spriDp Sec spring is than 1 governor sprinS Af ter insteIIation check thet spring is
Do not confuse

ondary

of piston

test

for definite

not deflected

piston operation

OIL PUMP
D1sessembl
I

GOVERNOR
D1sessembl
I

Free

pump

cover

from

pump

Separate

governor

from

oil dis

housing by removing allaching bolts

2 Take
out

tributor by unscrewing attaching bolts To disassemble secondary gover 2

remove spring secondary governor body in that order nor

inner

and ouler gears

from pump housing Note Be cerefnl not to confuse

Ie

seat valve

spring and
from valve

specti
geon

sides of inner

end

outer

To control valve Governor preuure IS I

Inspection
I

a Fig
67 AT Te ling Pi ton Apply Side

Inspect

for

wear

or

gear teeth Replace rub bel found damaged beyond use

damage to ring if

Using

straight edge and feelers

as

measure

pump and gear clearances

follows Clearance between inner

gear and pump cover
or outer

apply side of piston plugged with thumb blow compressed r into cylinder from release side Ifretainer is
4
With

From control e val I Line preS UJe I

I

AT090 4
r

SUndin deer1lnee
0 02 to 0 iJ4 mm

raised

little

it is an indication that
are

2 3

Primary governor Secondary govern Fig

69 AT

Oil dj tributor Output shaft

0 001

to

0 002 in

Governor valve body Te lingSecondQry Governor

attaching bolts retightening

loose

calling for

Replace
in

if

over

0 08

mm

11 00

AT 34

Automatic Transmission
Total indicator

reading

uan

Lell than 0 07 mm 10 0028 inl

J
Fig AT 70 MeG6Uring Clearonce Clearance between seal ring and
ST2SSBOOOl
AT264

I
Fig AT 73 Me ring Runout

I
AT1S7

ring groove
Stendard

Fig AT 74 MeG6UringPinion
Waaher to CanUr Clearance

0 04 to 0 16

mm

10 002 to

0 006 in

31earance
Seal ring w

Tighten pump securing bolts specified torque

to

Replace
in

if

over

0 80 mm

0 031

r Tightening torque
Oil pump

housing

to

oil

IJ

pump cover 0 6 to 0 8

kg m

14 3

to

5 8 ft Ibl

r
As L

I
Oil

11
AT1

Note
5

Be

sure

to

align

ter con

housini securing
6

bolt holes

Fig AT 71 MeG6Uring Clearance

CONTROL VALVE Again

cover

check

the

runout

of oil
Tlte control valve

pump

assembly

consists

mblr

Note

When

former

Oil

Pump

As

Set up pump housing with inner and outer pump gears on it 2

of many precision parts and requires extreme care when it has to be re moved and serviced It is good practice to place parts in a part rack so that

sembling Gauge
a screw

is to be used make

hole in side of it

Using

Pump

Assembling
instan pump

Gauge
cover

ST2SS80001
to pump

they

can

be reassembled in valve

body
care

houaing

in their proper

positions Added

should also be exercised to prevent springs and other small parts from

being

scattered

and lost

PLANETARY CARRIER
The

dip all parts in clean automatic transmission fluid and

be check to be certain that they are free of lint and other minute particles If clutch
or

Before assembly

planetary

carrier

cannot

divided into its individual components If any part of component is defec

tive
AT166

band

is

burnt

or

if oil
as

becomes fouled

the control valve

replace

the carrier as a unit

sembly should be disassembled and

flushed

Fig AT 72 Centering Oil Pump

In p ctlon Check clearance between

DI

mblr
Remove oil bolts and
nuts

pinion
a

which

Temporarily tighten pump

secur

washer and feeler

planetary

carrier with

retain

strainer
a

ing bolts
Set the cunout of oil pump cover within specified total indicator read
4

moved

with

Bolts may be re screwdriver but it is Wrench Handle

Standard d
0 20 to 0 70 mm

recommended that Hexagon lIT61000S00 lIT623S0000 b and

Spinner

ing

0 008 to 0 028 in AT 35

used

Automatic Transmission

Sf
AT171

HT61000800

HT6100800

Fig AT 78 Remouing Bide Plote

Fig AT 75 Dilaaumbling ValwBady

3 4

Pull out manual valve Remove Ist side

CAUTION 00 not work it off With

Take
out

rivers in8 screws do

plate

2nd

shift

dve

2nd 3rd

To
not

syoid

damaging

shift and

work it off with screwdriver

valve
2

Remove

attaching
lower wl

bolts
valve

With

body and valve body separate plate upper

bolts removed
are

pressure modifier valve Wee valve springs

5
sure

Remove side plate

free

for

rem

regulator

pull out pres valve second lock valve

two valve

pressure

regulator plug and

side

springs CAUTION
00 not IIlow orifice c111C1l VIlv8 end weIn spring In 1 nIn body to be I and lost wilen
aratll 6

Remove

plate

With

side

plate
valve

removed

solenoid

downshift

removinglllp
Fig AT 77 Remouing Manual Vallie

throttle valve

throttle back up valve vacuum 2nd 3rd timing valve

plata

and three valve removal

springs

are

free for

1
m

Prasur

gul8t

qrJ
UIiltOi

rio

ew o

e afW

SeccQdJock

V81V

2ncr 3fiftiming

Jd 3rd shift WiIVeL 2

q
nod SOJe

00ibiIi
v

aMi

iOtt
P iWWi

jJ tii

d m fiii

va

Fig AT 79 ComponentaPartaofeontrol Value

AT 36

Automatic Transmission Inspection

Check valves for sign of burning and if necessary replace I
2

Check

to

be

certain

that

oil

strainer is in

good

condition

If found

damaged
3

in any manner discard

replace Examine for any sign of damage 4 or score marks on separate plate If left unheerlcd oil will bypass correct oil passages causing many types of
abnormalities in the system

tension if necessary

Check oil passages in valve body for sign of damage and other condi
5 tions which
er

might interfere valve operation

Check bolts for
as

with prop

stripped

threads

Test valve

springs for weakened

Replace

required

Valve

spring chart
Installed No of active coil
Free

Mean coil Valve sprma Wiredia

mm

in

dia
mm

length
in mm

in

Length
mm

Load

in

kg lbl 5 5 12 1

Manual detent

3 1 0051

6 0 0 236

15 0

32 4 276 1

5 26 1 043

Pressure regulator

12 0 047 04 0 01 6 06

10 5 0 413

13 0

43 0 1693

23 5 0 925 90 0 354 16 0 0 630

17 0 0 669

2 8 62 01
0 2

Pressure modifier

8 0
315 0

5 0

18 5 0 728 32 0
1 260

1st

2nd shift

6 0
f

16 0

0 625 378 1
140 3 09

024

0 236 6 2 0 244 18 0

2nd

3rd shift

07 0 028

410
1 614

2nd

3rd timing

07 0 028 08 0 031 0 5 0 0217 0 55 0 0217 09 0 035

5 5 0 217 65 0 256 5 0 0 197 5 0 0

15 0

32 5
1 280

27 0
1 063

0 55 121 192
4 23

Throttle back up

14 0

36 0

18 8 0 740 12 5 0 492 210 0 827

19 0

1417
12 0 22 0 0 866 16 0 33 5 319 1 14 0 26 8
1 055

Solenoid downshift

0 60 32 1 0 60 32 1
2 19

Second lock

197

Throttle relief

5 6 220 0

0 74g
115

4 83

Orifice check

0 23 00091

4 77 0 lg78 8 3 0327

12 0

15 5 0 610

om 002 0 215 0474

0 453
7 5

0 45

5 0

218 0 858 25 2 0 992

Primary

governor

0 0177

0 295 10 5 0 413

Secondary governor

07 0028

8 5 335 0

5 5

10 1 2 43

T 37

Automa ic Transm ssion

tV
0

Ti teriing tmqile 0 25 to 1 8t 35 0

InsWl

I 1

1W
AT172

kll m

upper and

lower

valve

bodies

2 5 ft lbl

tV Tightening

torque Reamer bait

0 5 to 0 7

kllm

13 6 to 5 1 ft bl Other bolb
0 25 to 0 35

Fig

81 AT

ValveSpring

kg m

11 8

to 2 5 ft bl

0 u r
Assembly
Assemble in
reverse

ATt73

Fig
order of disas

AT 81

hi
ST25160000

Side Plate Il1Otalli

semblyHowever observe the follow ing assembly notes Refer 10 Valve

Spring Chall and illustration in as sembling valve springs Dip all pailS in
clean
automatic
ansmission t

lnstaD orifice check valve

valve
HT61000800
AT174

fluid parts to spec

spring throttle relief valve spring and steel ball in valve body

before assembly ificalions when

I

Tighten gmited des

Fig

82 AT

Value llIOlalli

ody

Slide valve into Valve body and be palticularIy careful that they re not forced in any way 2 Install side plates using Torque Driver ST2S

CAUTION IIIItIII check valve 8nd relief

tho valve

spring

Install oil strainer

10

160000

and

xagon Hc

Wrench HT61000800

they 8re properly positionadin 83 AT body See Figure

tV Titlltening torque
3 to OA kg m 0 122 to 2 9 ft bl

J
AT430

Fig AT 83 Position of Check Value and Spring

AT 38

Automatic Transmission

TROUBLE

DIAGNOSIS AND ADJUSTMENT

Since troubles

mo can

automatic transmission

For instance Lack of oil

tion
causes

In these

cases

the transmission must

be

repaired by simple

adjustment
media tely

do not disassemble im

by

brakes
auto

making slip resulting

defective opera the clutches and

in severe wear

be

repaired

Firstly inspect and adjust the

transmission in place D1 3tic the Trouble Shooting Chart

utilizing
by
It

This is because the oil pump sucks air causing oil foaming thus rapidly

CAUTION
I

In

checking

oil

IlVal

use

special

deteriorating the oil quality and pro

piper

Cloth tohandla the 18V81

Ind be careful not to let the

If the trouble this

is

can

not be solved

ducing sludge and

oil

varnish

llIugi

procedure

remove

and

disas

Excessive oil is also bad because of

semble the automatic tlllnsmission advisable

to check

overhaul

and

repair each part

the Trouble

in the order listed in

foaming caused by the gears stirring up the oil During high speed driving excessive oil in the transmission often
hlows out from the brealher

scraps of paper end cloth stick to the IlIUp b

lutomatic

transmission fluid
ons

Shooting
items

having OEXRON ida only in the 3N71 B eutomatic

mission
c

trans

Chart Chart

Shooting diagnosis arranged ac to from cording difficulty easy to difficult therefore please follow these
the
are

In the Trouble

Me

Pay

IttBntion blcau

the oil to be

urlns 011 level

used differs from that used in the

items

The tlllnsmission should riot be

removed unless necessary 2 Tests and adjustments should be inade

on the basil of standard values and the data Should be recorded

To check the nuid leyel sian Ihe engine and run it until normal operat ing temperatures oil temperature SO to 800C 122 to 1160F Approxi mately ten minute of operation will
raise

Nissen Full Autometic TllInsmis

sion 3N71A N8V8r mill thl oils

Note

Insert

it out

quickly

the gauge fully and take before splesbing oil

the temperature to this range and engine idling conditions are stabi lized Then apply the brakes and
move

edheres to the gauge Then observe the level

the

transmission In

shift

lever

through
in park

aU drive positions and P

place it

INSPECTION AND REPAIR OF OIL LEAKAGE

When oil leakage takes

INSPECTION AND ADJUSTMENT BEFORE TROUBLE DIAGNOSIS

TESTING INSTRUMENT FOR
INSPECTION
I

position

tion the car must be

placc

his inspec d on a level

place
is

the

surface The amount of the oil varies with the temperature As a rule the oil level must be measured after its tempera
ture becomes sufficiently

portion
with

near

the

leakage

covered
in the

oil

detecting

the

presenting difficulty spot Therefore

oil seals and

high
H The

places where equipped are

gaskets

are

enumerated below

Fill the oil to the line

Converter

housing

Engine

chometer

difference of capacities between both and H L is approximately 0 4 liter J U S pt Y therefore

to do not fill

2 Vacuum gauge 3 Oil pressure gauge It is

Imp pt and beyond the line

2

Rubber ring of oil pump housing Oil seal of oil pump housing Oil seal of engine crankshaft Bolts of converter housing to Transmission and
extension
rear
case

convenieni
a

install these 2

extension
rear

way that allows meas urements to be made from the driver s instruments in
seat

When
care

topping up and changing

to

Junction of transmission and Oil cooler tube connectors Oil

pan

oil

should be taken

prevent

mixing the oil with dusl and water

CHECKING OIL LEVEL

In

In pectlns oU condition The condition of oil sticking to the level gauge indicates whether to OVOl haul and repair the transmission or luok for Ihe defective part If the oil has deteriorated varnish ike quality trol valve to stick
it
causes

Oil pressure inspection Fig AT 81

holes

See

checkIng

the automatic transmis

sion the oil level and the condition of

Mounting portion of phragm and downshift

vacuum

dia

solenoid

oil around the oil level gauge should be examined every ooo Ion 3 000 S miles trouble This is
an

Breather and oil charging pipe Speedometer pinion sleeve Oil seal of rear extension

easy and

effective
some

to

shooting procedure
in

since
are

the

con

changes

oil

condition

often

Blackened oil indi

linked with

developed

troubles

cates a burned clutch brake band etc

To exactly locate Ihe place leakage proceed as follows

of oil

AT 39

Auto lT1atic Transmissiqn

Place the vehicle in
a

pit and by
The torque

sampling

the lealeed oil deiermine if it

is the torque converter oil

converter oil has a color like red wine

so

it is
or

easily distinguished from engine

oil

gear oil

tI @
as

ij

Wipe

off the lealeing oil and dust

and detect the spot of ill lell8e nonflammable organic solvent such carbon tetrachloride for wiping Raise the oil
D sp Q

IlV
AT Nut

@
84 J A T Fi op Down ltift id Sole
I

tcmperature by
the oil 1I8

erating the engine and shift the lever

to

Note

Watch

for
case

oil

leekage

from

2 3
4 5

Inhibitor switch Manual shaft Washer Nut Manual plate

6 1

Washer Inhibitor wilch

lever

to increase

The

of o 1 found more easily

Note As oil

pressure u J1en be

tnnsmission

8
9

Ran

q Iect

leakage from the breath er does not talee place except when at running high peed it iSimpos
sible
to ate

INSPECTION AND

J Fi

85 AT

Comtruction of Inhibitor
Switch

ADJUSTMENT OF MANUAL LINKAGE

i

Check

ethcr

he

leverse

this lealcage with

1p lal

vehicle stationary

The adjustmcnt of manual linkage equany important as Inspection of for the automatic transmis great
care

and the starter motor

operate nonnal
If there is any If no

Iy

in

these

ranges

Oil Level
sion

trouble

Therefore

should be

first check the inkage defect is nd in the Ii leage fo tlie inhibitor

check

cxercised oecause incorrect

adjustment

Swi

ch

will result in the breakdown of the

Separate

the manual lever from the

CHECKING ENGINE IDLING REVOLunON

The engine
be

remote control selector rod and turn the range select lever to

transmission

N
N

idling

revolution should

Note

In the

position

the slot of

properly adjusted
If the engine revolution is too low
e

Inspection
pun the selector lever toward you as far as p to range ell

the manual shaft is vertical

the

gine

does

Using the

tester

check the two

not

operate smoothly

and turn it

and if too creep from ON

high a strong shocle or develops when changing over

to

where clicks will be This is the detent the valve

by

the hand

of

manual valve in indicates the

black yellow BY wire from the in hibitor switch in the ranges N and p and the two blacle red RB wires
in the lange range select

Dn or

body

and

corrett

position ofthe lever Inspect whether the pointer

R for continuity Turn lever in both directions

of

selector dial

corresponds

to this point
comes

from each lever set position and check each continuity range It is normal if the electricity is within
an on

and also whether the lever

in

while the lever is

on

CHECKING AND ADJUSTING KICK WN SWITCH FT

alignment iion plate when

with the stepping of posi

itis released

angle of about 30

both How

sides from each lever set line

ever

AND

if its continuity range is obvioUs

on

DOWNSH
When
not made

SOLENOID
operation is the speed chang
and CHECKING

ly required
screw

nequal u

both sides

adjustment

is

the

Ieickdown

If any malfunction is found un the fastening nut o the range

properly or
too

selector lever and two of the switch the machine

fastening

bolts

ingpoint is
down switch

high check the kick

body
screw

and then

remove

downshift solenoid

under the switch

wiring between them When the igni tion Ieey is po ned at the 1st stage iti
and the accelerator

AND

ADJUSTING

pedal

is

depressed
hould be defect

INHIBITOR SWITCH
The
verse

body Adjust Iy to the position N by means of the selector leVer When the slot of the
shaft becomes vertical the detent worles to position the shaft with
a

the manual shaft correct

deeply

the switch contact

inhibitor switch lights the in the range

R

re

closed and the solenoid should clicle If it does not click it indicates
a

lamp

of the

correctly
aside
so

Then check each part with the inatrumen15

testing

transmission operation and also rotates the starter motor in the ranges N and P

clicking

sound

Move that the

the switch

slightly

hole will be scie

aligned

40 AT

Automatic Transmission
with the pin hole of the internal rotor combined with the manual shaft and check their alignment by inserting a 15 mm 0 059 in diameter pin into the holes If the alignment is correct fasten the switch body with the bolts

opened Quickly read and record the engine revolution when the engine begins to rotate steadily and then release the accelerator pedal
5 and Shift the selector lever to
N

revolution increases up to the same level as in 1st range It is impossible

to check it in the stall test 2

Standard stall rnoluiion If the

operate

pull
lever

out the

pin tighten

up the screw

mately

200 1

the engine at approxi rpm for more than one

con

engine
is

revoluiion
he

in stall

ondition values 2n
I

within

standard
are nOf

in the
as

hole

and fasten the selector Check the

lesler

before

continuity

minute to cool down the torque verter oil and coolant 6 2

the control elements

in the

mally operating
and the R Also norinal in The

ranges

pin with the

switch

If Ihe malfunc the inhibitor

tion still remains

replace

Make similar staU tests in ranges I and R

clutch of the

CAUTION

engine and one way torque converter are performance and operation
way clutch of the

STALL TEST
The purpose of this test is to check the transmission and engine for trou ble by measuring the maximum num bers of revoiutions o the cngine while vehicle is held in
a

The dill test i18m 4

operstion

81

specified

in

one

torque

should be I118de within fiv lIeonds If it tBkes too long the oil
If and b nd and
elll

converter

however

sometimes sticks

This is determined in the road test

3 Lower stall

the clutihn

blllke I Suf

revolution than lIand

ly

ard revolution

stalled condition

The carburetor is in fullthrollle opera tion with the selector lever in ranges 1 2 the and
I

ficient cooling time should be given r eech test for the four IlInges
0 Z 1 end R

If the engine revolution in stall condition is lower than the standard values it indicates that the engine is in abnormal condition
or

respectively Com
results with the

the

torque con

pale standard values

measured

JUDGEMENT
High
stall revolution
more

verter s one way clutch is

slipping

than

4 O hers

Components to be tested
test itelJUl
I

and

staitdard revolution If the condi ion values

it

I
in stall

If the

accelerating performance

Clutches brake and band in trans mission for slipping

engine is higher
in the

levolulion

than

the standard
onc or more are

indicates that

2 3

Torque
tioning

converter for proper

func

clutches

transmission
no

speed of approxi mately SO kmfh 30 MPH is attained and then normal beyond that speed it can be judged that the torque con
verte c s one

is poor until vehicle

slipping
for overall

and therefore

further test

way clutch is

slipping

Engine

properly

is required For the

If the

torque

converter sane

following
causes are

abnormalities

way dutch sticks

not

the respective

presumed
low line

exceed the

vehicle speed can approximately 80 kmfh road

tesl

STAU TEST PROCEDURES

Before testing check the engine oil and torque converter oil warm up the

High High

rpm in all ranges

rpm in

SO MPH
case

in the

In such a

pr ssure

and

and

perature

torque rises abnormally

is

converter

oil

tem so

and

engine cooling ter suitable tem perature by running at 1 200 rpm with
w

to

normal rpm in 6R

Rear clutch

special
3
erate

care

required
not

the selector lever in the range P for sevcral minutes Warm up the torque
converter

slipping High rpm

normal clutch

If the transmission does

op it

in
in

and

and

rpm

One way

speeds indicates poor engine performance

properly

at all vehicle

oil to suitable temperature 60 to lOOoC 140 to 2120F

slipping
Ipm
or

High
clutch

in

only
reverse

Front brake

Mount the engine tachometer at a location that allows good visibility from the driver s seat and put a mark
on

low

and

ROAD TEST
An accurate

slipping
To determine
or

knowledge

of the

au to

which

is

slipping
brake

matic
exact

transmission is

required for

an

specified

revolutions

on

the meter wheels

front clutch
a

low and

reverse

diagnosis

Secure the front and

rear

road test is needed If while

with chocks and Be

SIIre

to

apply the hand brake depress the brake pedal

coasting
I
not

after range
is

starting
engine
the

with the

levcr in

diagnosis guide chart with the standard vehicle speeds for each stage of the up and
down

II is recommended that a

firmly
3
4

with the left foot before de

braking
low

does

work brake

pressing the accelerator pedal

Throw the selector lever into the 11 range

properly

and

reverse

Otherwise

the front clutch is

slipping slipping
occurs

shiftings be prepared Measured speeds are to be filled in the adjoining column after each testing
vehicle Also
it

Slipping depress
the accelerator the throttle valvc is

of the band brake is diffi However jf it 1 range 41 AT

is

advisable

to

mount

Slowly pedal until

cuJt to ascertain with the

fully

lever in

engine

stopper opening

for

positioning the throttle

Automatic Transmission
CAR SPEED AND LINE callfornia Non models

PRESSURE

WHEN

SHIFTING

GEARS

Sedan and tletchback

Car

Intake manifold vacyum

pearshift

speed

Propeller shaft
rpm

Line pressure

km h MPH

kg

cm2

psi

mmHg

inHg
o

0 0

Kickdown

O2
o o 3
2

O2 03 O2
0

49 to 62 89 to 102 92 to 79 48 to 34

30

to

39

1 840 to 2 340

55 to 63 57 to 49

3 340

to

3 840

54
3 460 to 2 960 I 790 to 1 290

to

66

77 to 94

30 to 21
6to 14

200 7 87

01 O2 03 O2
12 12
All models

O2 03 O2 01
I
1

9 to 22

330 to

830
4 to 5 4 63 to 77

46to 59 29 to 37 36 to 23 19

1 720 to 2 220 1 350 to

22io

14

850
4 to 7 8 63 to III

I2

700 Max

o 0

Full throttle

50 to 36 31 to 22

1 860 to 1 360

5 8 to 7 1 5 8
7 I

82 82

to

101
101

450

I7

72

50 to 36 31 to 22

I 860 to I 360

to

to

Celilornia models Intake manifold

vacuum

and

calilornil Non

models

Wagon

Car Gearshift

speed

Propeller
rpm

shaft

Line pressure

Ion h MPH

kg cm2 Psi

mmHg

inHg
o

Kickdown

O2
0
3

O2 01 O2 03 O2
0 0 Full throttle

O2 03 O2 Dl O2 03 O2 01
I
I

52 to 59

32 to 37

1 970 to 2 220 3 480 3 160

to to

93 to 99 58 to 62 84 to 91 39 to 46
20 to 27 54 to 61 52 to 57 24 to 29

3 730 4 to 7 0 77 to 100 5
3 410

1 470 to 1 720

12 to 17
34 to 38

750 to 1 000 2 040

to

2 290 5 10 6 1 4

100 3 94

64 to 87

28

to

35

I7 to

22

I 050 to I 300

9 to 16

6 to 10

350 tq

600 5 6 to 7 2 80 to 102
5 6 to 7 2 80 to 102

12 12

40 to 47 25 to 29 40 to 47 25 to 29

1500 to 1 750
1 500 to 1 750

300

I 1 81

Reduce the Car

speed by shifting

to

range from

0 range output shaft 2 000 rpm

speed

can

be calcuiated by the following formula

2

V
where

xrxNpx6O RF x 1 000
V Car

Np
RF
r

speed Ion Propeller shaft

h revolution rpm

Final gear ratio Tire effective adius The ratio of ciIcumfe

m ence

of a circle to its diameter

14 3

Note

RF
r

3 889 0 27S
m

lSS 13

lS 6

4PR 13 42 AT

lSSSR13

or

7OSR13 17S

Automatic Transmission
CHECKING SPEED CHANGING CONDITION
The

CHECKING ITEMS DURING SPEED CHANGE

gear range gear changes DJ D3 are effected In R range the speed does not increase 2 The kickdown operates properly 3 By moving the lever from D to I 1 1 2 gearchangesD3 D
are

driver

feeling

during

In

range 6 In P

changes should lively

J

also be checked atten

vehicle

can

be

parked

properly
If any malfunction occurs in second
gear

sharp shock or unsrnoothness felt duting a gear change

sure

is

during
up in

the road

test
or

thai is

if

Tlus indicates that the throttle pres

is too

vehicle shakes

effected

high

or

some

valve

con

In the ranges

and

drags
D

nected to the throttle is

faulty
a

the engine braking works prop

In I the

shifting

from

slings while directly to

D to

2
and

change is dragging feeling

is too low
or

A gear

made with

long

erly
4

D3
D

or

shifting

up from

the

braKe band should be ad

speed

does

not

in

justed
servo

If these troubles remain after

oil

crease

This indicates that the throttle pres

sure

some

valve

con

Should be quickly fixed

the brake band is adjusted check the

at

piston seal for

leakage

nected to the throttle is

faulty

SHI
Cellfornla Non

SCHEDULE
models Sedan end Hetchbeck
1 2 2
I

Kickdown range

2 l 1 I

32

3 L

E
c E

7 87f

T
1

1 1
1

00 3

11 81f

5
u

a
0 u

400 15 75

00 5 19

69 0

500

000

500 0 4

000
speed
60

2 500
rpm 70

000

0 50

000

If
z km h MPH

Output

shaft

9 6

1P
10

29

30

50

80
50

90

100

io and Callfornie Non

1 1

30

40 models

60
AT434

California models
I
c

All models

Wegon
2
3

I
100
3 94 E I 00 2 7 87

Kickdown range
1 2

2 3

3 321

1 1

1 1

E c
E

300 11 81

11
1

12
1

5
400 15 75 a
0

500
0

19

500

000

500

600

50 2
rpm

600

500

000

i
z km h MPH

Output shaft speed 9

10

20

30

40

50
30

0 6
40

70

80

90

100

10

io

50

60
AT435

Fig A T 86 Shift Schedule

AT 43

Automatic Transmission

LlNE PRESSURE
TEST
or

snSOSSOOI

When any slipping occurs in clutch brake or the feeling during a speed
is not correct the line pressure

For

ing gem refer

1 too A

line pressure data when shift to Road Test

change

sharp

shock in up shifting
are

or

must be checked

Measuring

line pressure is done by

pressure gatqle attached to pressure measuring holea after removing blind

high changing speeds mostly by too high throttle pressure

2
tion

caused

CD

Slipping
is

or

incaPability
to oil

of opera pressure

pluga

located at transmission

mostly due

case

leakage
valve

The line pressure measurement is begun at idling and taken step by step

within the gear trains or

spool
AT454

by enlarging the throttle opening

1 2 3

Line pressure

Governorpressure
Servo release prenure

Fig

87 AT

Mecuuring

Line Pre

LINE PRESSURE
Cellfornil Non

GOVERNOR FEED PRESSURE

Seden and Halchbeck At stall test

models

At

idling
Range
R Une pressure

kg em
43 to 7S

psi

Range
R

Line pressure
14 0 to 16 0

kg cm2 psi
199
to

3 0 to

22S

o
2

3 0 to 4 0 43 to 57

94

to

11 0

134

to 156

6 0 to 12 0

S5to

171

10 0 to 12 0 142 to 171 94 to 110 134 to 156

3 0 to 4 0 43 to 57

California models

All models

end

Callfornil Non

modela

Wa

on

At

idling
Range
R
o

At stall test

Line pressure
4 2 to 5 6

kg cm
60 to SO 46 to 54

psi

Range
R

Une pressure
143 to 16 2

kg cm2 psi
203 to 230

3 2 to 3 S

9 9 to

1 11

141 to 15S

6 0 to II 7
3 2 to 3 S

S5 to 166

10 2 to II 7 145
1 11

to

166

46 to 54

9 9 to

14110 15S

AT44

Automatic Transmission JUDGEMENT IN MEASURING

LINE PRESSURE Low idling line pressure in the D 2 R and P
can

pressure due to valve

Vacuum

sticking regulator

A Oil level

B C

Range select linkage

Inhibitor switch and wiring diaphragm and piping solenoid switch and wiring throttle kickdown

ranges

leakage is checked by directly measuring the negative pres sure after removing the vacuum pipe puncture of the vacuum dia phragm can be easily ascertained
A

D Vacuum

E Downshift
F

This

be attributed to trouble in
or

the pressure supply system output of power caused by

I A worn oil pump An

too low

Engine idling rpm

because absorbed
the oil

the

torque converter oil is and the into the engine

G Oil pressure

H Engine stall rpm

I J

oil pressure leak in valve body or case pump 3 A sticking regulator valve
2 2
Low tain ranges

exhaust pipe emits white smoke

4 Item
e

Rear lubrication Control valve manual

to

be checked when the

K Governor valve
L

Ii
cer

idling only

line pressure in caused by

or

pressure is increasing In this c the line 1eck

Il SI

Band

servo

pressure

M Transmission air check N Oil

should be measured with

300

vacuums

of

quality

This is

presumably

an

oil

leak in the devices

circuits

con

mmHg inHg and 0 mmHg 0 inHg in accordance with the staIl

o Ignition switch and starter motor P Engine adjustment and brake in

test

nected to the relevant ranges

I
rear

procedure
2

spection Inspection after inspecting

Rear clutch auto

i
the

When there is clutch and

an

oil

leaJi in

If the line pressure does not in crease despite the vacuum decrease check
i 2

pressure in on but the pressure i nonnal in 2 When

an

governor the line 2 and I are low R

whether

the

vacuum

rod

is

matic transmission on vehicle

m n

corporated
If the line pressure does not meet standard iUs caused mostly by a

oil leak occurs in the brake circuit the line

are

Front clutch Band brake

Low and reverse brake

tile

low and

reverse

pressure in oR and P the pressure is normal in

I 3

low
2

b t

sticking pressure regulating valve pres sure regulating valve plug or amplifier

q
r

s t

and

Oil pump Leakage of oil passage One way clutch of troque converter One way clutch of transmission
Front

High idling line pressure

Thi
is

TROUBLE SHOOTING
an

u v w

presumably
aC1ulT
t

caused by
rott e

CHART
INSPECTING ITEMS
I

clutch check ball

increased

pr ssure
or

owing

to

leak in the vacuum tube

or

Inspection with
on

automatic trans

Parking linkage Planetary gear

diaphragin

by

an

increased line

mission

vehicle

AT45

Automatic Transmission
r

TROUBLE

SHOOTING CHART FOR 3N71B AUTOMATIC

TRANSMISSION

he number shown below indicates the sequence in which the checks should be taken up

Trouble

ABeD

EFGH

I J

K L

MNOP

In n

q r

t u v

wxy

Engine does
ranges

not start in

P
2

Engine
and P

starts in other lange than

Sharp

shock in

shifling

from

10

0 range
Vehicle will not run in
runs

@ @

D R

range bul ranges

in

and in

Vehicle will

not run

2
1
n

ranges but runs in R ronge ch slips Vcrypoor acc ler t C1u

Vehicle will Dn runs in C1urch slips

nol

run

in I

range ranges

but
1 2 3

and
poor

@@

Very

cceleralion

I
I 2 3 5

Vehicle will not

run

in any range

16
7 6

Clutches
in

or

brakes

slip somewhat

starting
runs

I 2

@@

Vehicle

in

wnge

I@
8

Maximum

speed

not

attained

I 2

Acceleration poor Vehicle braked when shifting into OR

range

4 5

@@@lNl
@ @ @

312
I 2

Ex cessive creep No creep at all Failure

to
In

I I
2

I
5 4 5

I
@@ @ @ @ @ @ @
7 4

dlilnge

gear fHlIll

nd

3rd
10
l h mgc 2nd

Fililurc
III

lr gC

frolll

ISf

817
3

Too high 15 3rd Gear

3rd to

gear change point from 2nd from 2nd to

change directly from

occurs

Ist

to

AT46

Automatic Transmission

Trouble

ABCDIEFGH
1 2 1

I JKL

M NO P

mnqr

t u v

Iw

Too 1st

sharp
to

shock in change from

2nd
3 3

@ ID

Too sharp a shock in change from 2nd o 3rd A1most

no

shock

or

clutches 1st to
1

slipping in change
2nd Almost
no

from

shock or 2nd

slipping in
to

change Engine

from
races

3rd

extremely
2

Vehicle braked by gear change from ist to 2nd Vehicle braked by gear 2nd to 3rd Failure to 3rd

change

from

I
1 1

I 21
5

@ Q @ @ @

@I I @I
V V

change gear
2nd

from

to
to

3 4 6

Failure
to

change
from

gear from 3rd

to

2nd 1st

htlt

or

I
3 4

3 4 6

5 2

Gear

change

deceler tion accelerator Too 3rd list

during by releasing pedal change point

from
to

shock felt

5 6

high
to

2nd

from

2nd

5 6

depressing pedal

Kickdown does not operate when in 3rd within

kickdown vehicle

speed
engine
in
1 2

Kickdown operates
runs

or

over

when depressing

pedal

3rd

beyond
limit

kickdown vehicle

5 6

7 4

speed
Races from

extremely
3rd
to

or

slips

in

changing
1 2 4

2nd

when

5 3

V@
@

depressing pedal
Failure to when Gear
or

change from 3rd changing lever into 2

from
to

to

2nd

range 1st 2

51

change

2nd 3rd

to

from

2nd

in

range

47 AT

Automatic Transmission

Trouble

ABeD

E FG H

KL

MNOP

mnqr

t u

No shock at change from lange

or

to

2
1 2 3 4 1

engine

races

extlemely
3rd I
to

Failure
when

to

change from
into

2nd

shifting lever

@@ @

range
1

Engine brake
I
range

does not operate in

Gear change from

or

1st 3rd

to in

2nd
1 1

from

2nd

to

range Does not to lst

change from
in 1 range

200
1 2

4 5 6

@ @

Large
to

shock
in

changing
I

from

2nd

lst

range

Vehicle moves when

into

changing
1

range or pinking gear doe not disengage when shifted out of P

range
1

Transmission overheats

3 4

2 6

@@@ @@@

Oil shoots out during operation White smoke emitted from exhaust
1

5 6

2 7

8 4

@@@ @@@

pipe during operation

Offensive smeU at oil

charging pipe
p and ON

@@@@ @ @ @

@@

@i

Transmission noise in ranges Transmission noise in and R langes

48 AT

Automatic Transmission

TROUBLE SHOOTING GUIDE FOR 3N71B AUTOMATIC TRANSMISSION

Ordel

Test item

Procedure Check gauge for oil level and leakage before and after each
test

Checking

Oil level gauge

Downshift solenoid

Check for sound of operating solenoid when depressing accelerator pedal fully with ignition key ON Check by shifting into P with selector lever ranges R
N

3 Manual linkage

and

Inhibitor switch

Check whether starter operates in and whether

reverse

N in

and
R

ranges

only

lamp operates
meet

range

only

5
6

Engine idling
Vacuum

rpm
vacuum

Check whether idling rpm Check whether

vacuum

slandard
than 450

pressure of

pipe

inHg increasing rpm

in each

17 72

in

idling

pressure is more and whether it

mmHg

decreases with

Operation

range

Check whether transmission engages positively by shifting N N R range 0 2 N to I and N while idling with brake applied

Creep

of vehicle

Check whether there is any creep in

R ranges D 2 I

and

Stall

test

Oil pressure before

sting t

Measure line pressures in

and

range while

idling
2 Stall test Measure engine rpm and line pressure in R ranges during full throttle operation Note
0 2 t

and

Temperature of torque should be from 6 to lOO C ficiently

1 up but not
o

erter con

oil used in test

to

140

2120F

e i

suf

heeted

CAUTION
To cool oil between IIch mil test for OH RH nnges idle engine i e rpm It Ibout
more

ZH

Ind

200 1

thin 1 minutll in
more

P nnge

ment MeeRlr

rpm for time mUlt

not be

then 5 seconds

Oil pressure after teSling

Same

as

item 1

Road test

L Slow acceleration Ist 2nd

Check vehicle speeds and engine rpm in shifting up 1 st 2nd range and 2nd 3rd range while running with lever in
D range and

3rd 2nd

engine

vacuum

pressure of about 200 mmHg

7 87 inHg 2 Quick acceleration

Ist 2nd

Same

as

item 1 above ie

o mrnHg 0 inHg

except with engine vacuum pressure of in position just before kickdown

3rd 2nd 3 Kick down operation 3rd 2nd

or

2nd

1st

Check whether the kickdown operates and measure the time delays while running at 30 40 50 60 70 km h 19 25 31
37 43 MPH in

OJ

range

49 AT

Automatic Transmission

Oldel
4

Test item Shift down O Or O Check vehicle 3rd 2nd accelerater

Procedure

speeds

1st

and engine rpm in shifting down from sequentiaUy while coasting with range and engine
vacuum

pedal

released in 0

pressure of about 450 5 Shift down

mmHg

17 72 inHg I nd engine

Or

blaking and braking tel shifting the leyer into I range with the accelerator pedal released and the engine vacuum pressure of 0 mmHg 0 inHg
Check for shifti ng n I do further for shifting down I I and

engine
in

while

driving

at about 50 km h 30 MPH

range

6 Shift down 0 2

Check for

quick shifting
0

down

OJ

2 and engine

braking

after shifting the lever into 50 km h 30 MPH in Further

ratio

2 range while driving at about range 2nd gear

chec

for locking of the transmission i of vehicle

regardless

sPeed
range

7 Shift up 1 1 8 Shift up
or

Check for failure of the transmission to shift up during acceleration when starting in down when start Check the transmission for not acceleration
or

ing
9

in

ranae

shifting up or down during deceleration when starting in 2 range

on

Parking

Confirm that yehicle will notmoye

to

grade

when shifting

pn range

Others

Abnormal shock oil

leakage

Enter into record conditions observed such

as

durq

these lests

gear noise abnormal clutch noise and acceleration

performance

AT 50

Automatic Transmission

SERVICE DATA AND SPECIFICATIONS

General specificetions Automatic transmission model Stall torque ratio Transmission gear ratio
1st 3N71B

20

2 458 1458
1 000

2nd

Top
Reverse Oil

182

Automatic transmission fluid Dexron

type

Oil capacity

5 5liten SUUS qt 4Ulmp qt Approximately 2 7 liten 2UUS qt

2

lmp qt

in

torque

converter

Spec lcetlona end edJuatment

Automatic transmission assembly

Model code number

California Non Califomia Non

models Sedan and Hatchback

X0l61

models Wagon California models All models

X0165 X01l5

Torque

converter

assembly TIC
C l2

Stamped
Front clutch

mark on the

Number of drive plates Number of driven plates Clearance Thickness of retaining plate
mm
mm

3
in in

16 to 2 0 0063 to 0 079
10 6 417 0

10 8 11 0 2 11 II 4
11 6

425 0 433 0
441 0 449 0 457 0

Rear clutch Number of drive plates Number of driven plates Clearance Thickness of retaining plate
nun

3
3

in
in

0 8 to 1 6 0 031 to 0 063 8 35 0 3287

mm

AT 51

Automatic Transmission
Low
eve se

br ke

Number of drive
N wnbe

plates
plates
ml11

of driven

Clearance Thickness of retaining

in

plate

in mm

3
40

0 80 to 1 25 15 8 0 622 16 0 0 630
16 2 0 638

0031 to 0 049

16 4 0 646
16 6 0 654

16 8 0 661 Brake band Piston size

mm

in

Big

dia

60 236 57 1

Small dia Control valve

assembly
mark on strainer

Stamped

California Non

models Sedan and Hatchback California Non models Wagon

LEA
LRJ

California models All models and Governor assembly

Stamped
Stall revolution AI4
AI5

mark

on

governor body

35

rpm 1 900 t02 200 1 850 to 2 150

engine
engine

TI

htenln

torque

kg

ft lb

Drive plate to crankshaft

AI4 8 0 to 9 0 5 to 9 5 8 4 0 to 5 0

58

to

65

AI5 Drive plate to torque converter Converter

61 to 69 29 to 36

housing

to

engine
2 0 to 5 2 14 to 18

Hexagon bolts with washer

Hexagon flange
Transmission
case

head bolts

1 6 to 2 2

I2to

16

to converter
cue

housing

5 to 4

33 to 40

Oil pan to transmission Servo piston Piston stem

0 5 to 0 7 0 5 to 0 7 1 2 to 1 5

3 6 to 5 1 3 6 to 5 1 9 to 11 II to 29 9 to 13 4 0 to 5 4 18 to 5 2

retainer to transmission case

when

adjusting

band brake

Piston stem lock nut One way clutch inner race to transmission Control valve Lower valve
case

5 to 4 0 1 3 to 1 8 1 0 55 to 0 75 0 25 to 035 0 25 to 0 35 0 5 to 0 7

body to

transmission

case

body to

upper valve

body

Side plate to control valve body Nut for control valve

reamer

8 to 2 5 1 3 6 to 1 5

bolt

AT 52

Automatic Transmission
Oil strainer to lower valve

body

3 to 0 4 0
0 5 100 7

2 2 to 2 9 3 6 to 5 1 3 to 5 8 4

Governor valve body to oil distributor

Oil pump

housing

to

9il pump

cover

0 6 100 8 5 0
to

Inhibitor switch to transmission case

07

3 6 to 5 1 22 to 29 22 to 36

Manual shaft lock nut Oil cooler pipe to transmission

case

3 0 10 4 0 3 0105 0

Test plug oil pressure inspection hole

14102 1
to rear extension

10

to IS

Support

actuator

parking rod inserting position

0 810 I I

5 8 to g O

Turn back two turns after

tightening

SPECIAL SERVICE TOOLS

Kent Moore

No Tool number

Kent Moore No

Tool number

tool

name

Reference
page
or

tool

name

Reference
page
or

Fig

No

Fig

No

ST07870000 ST07860000

Transmission

case

stand

J 25607

GG930 I 0000

Torque wrench

J 25703

Fig

AT 26

Fig

AT43

ST25850000

Sliding hammer

J 25721

ST25420001 ST25420000

Clutch spring compressor

J 26063

Fig

AT 30

Fig Fig

AT 53 60 AT

HT69860000

Snap ring remover

Fig
AT 33

ST25320001

Snap ring

remover

125710

Fig AT 53 Fig AT 60

AT 53

Automatic Transmission

Moore Kent

No

Kent Moore No

Tool number

tool name

Reference

Tool number

tool

name

Reference
01

r
25570001 51 5T25570000 head Hex
extension

Fog

No

J 25718

25580000 51

Oil pump assembling

gauge

J 25719

Fig AT 38 Fig AT43

Fig

AT 72

5T2549oooo 25512001 51

50cket extension

J 25713

HT61000800

Hexagon wrench Fig Fig Fig Fig

AT 75 AT 78

Fig

AT43

v
HT62350000

8l AT
82 AT

5pinner handle Fig AT 75 Fig AT 78

25055001 51

Oil pressure gauge set

25695

Fig

AT 87

5T25160000

Torque

driver

Fig Fig
L

AT 81 82 AT

AT 54

DATSUN 2JO

Model 83 J 0 Series

SECTIONPD
PROPELLER SHAFT DIFFERENTIAL CARRIER
CONTENTS
PROPELLER SHAFT INSPECTION
GENERAL INSPECTION SHAFT VIBRATION PROPEllER PD PD PD PD PD PD PD PD PD 2 2 2 2 2 2 2 3 3 3 4 4 4 4 5 5 5

AQJUSTMENT
SHIMS INSTAllATION

OF SIDE

BEARING PD PD 7 9 9

REPLACEMENT OF

FRONT

Oil SEAL

PD

REMOVAL AND INSTAllATION REMOVAL INSTAllATION

SERVICE DATA AND SPECIFICATIONS

PROPEllER PD lO PD lO PD lO PD lO PD lO PD l0 PD lO PD ll PD ll

SHAFT
DATA

DIFFERENTIAL CARRIER
REMOVAL PRE DISASSEMBl Y DISASSEMBLY FINAL DRIVE ASSEMBLY

GENERAL SPECIFICATIONS SERVICE

INSPECTION

PD PD PD PD PD

TIGHTENING TORQUE
DIFFERENTIAL CARRIER GENERAL SPECIFICATIONS SERVICE

DIFFERENTIAL CASE INSPECTION

DATA
TORQUE

TIGHTENING

ASSEMBl Y AND ADJUSTMENT

PRECAUTIONS IN ASSEMBLY OF

PD
PD PD

TROUBLE

REASSEMBLY

DIAGNOSES AND CORRECTIONS

PROPEllER SHAFT
DIFFERENTIAL CARRIER

PD 12 PD 12 PD 13 PD 15

DIFFERENTIAL CASE

ADJUSTMENT OF DRIVE PINION

HEIGHT PD 6

SPECIAL SERVICE TOOLS

ADJUSTMENT OF DRIVE PINION PRELOAD

PD 6

Rropeller Shaft

Differential Carrier

PROPELLER SHAFT

ff

Tightening torque kg

ft b

2 410 3 3

1710

24
PD468

Fig PD l

Propel erSha t

INSPECTION
GENERAL INSPECTION
Check propeller shaft tube sur Cace for dents or cracks If damaged
I

Again check shaft vibration

If

Draw out

propeller passing

shall sleeve

vibration still persists ler shaft assembly

replace propel

yoke from
axle

transmission

by moving
rear

shaft realWard

it under

replace with
2 Check there is

an

assembly

Plug housing

up rear end of rear extension to

prevent oil leakage not

journal for axial play If play replace propeller shaft

cannot

mbly
Note

REMOVAL AND INSTALLATION

REMOVAL
I

Note

Remove
so as

Cully

propeller aheCt care to demege spline

rear oil

sleeve yoke and be disassem

seal

JournaI

bled

Raise

car

on

hoist

Put

match

INSTALLAnON
To

malks both PROPELLER SHAFT

on

propeller shaft and

VIBRATION
To anced lows L Remove check
and correct
an

unbal
as

companion flange so that shaft can be reinstalled in its original position 2 Remove bolts connecting pro peller shaft to companion flange

removal

inS aJI reverse prOCedure

the

foregoing

CAUTION

propeller

shaCt proceed

Col

undercoating

and other

Align propeller shift with com penion fllnge of differentiel Clrrier in ulling reference marks 1Cribed prl Remova and procedure tightsn
them with bolts Failure
to do
so

foreign
tion

material which could road test

upset

shaft balance

and check shaft vibra

could resuh in

driving

vibration

by

If shaft vibration is noted disconnect

during
shaft et
PD459

fJ

road test

propeller

differential carrier companion flange rotate companion flange 180 degrees and reinstall propeller shaft

Tightening tOlquo Propellol sheft to companion f1enge bolts

2 4 to

3 kg

Fig PD 2 Removing Propeller Shaft

PD 2

117 to 24 ft b

Propeller Shaft

Differential Carrier

DIFFERENTIAL CARRIER

fQ

Companion flange
Oil seal Pinion front bearing

11 12

Thrust washer

2 3 4 5 6 1
8

Ring gear
Differential
case

13 14 15 16
17

Sidebearing
Thrust

Side bearing adjusting shim walher Side gear Lock pin Pinion mate shaft Pinion mate

Lock strap Drive pinion Pinion height adjusting washer Pinion rear bearing

Tightening torque kg rn ft lb

18 19 20

9 10

Collapsible spacer Side bearing cap

Gear carrier

@ @ @ @

14 to 30 101 to 211 6 0101 0 43 to 51 5 0 to 5 0 36 to 43

1 6 to 2 4

12 to 11
PD446

Fig PD 3 Differential Carrier

REMOVAL
I

spected before
from it of
car

any

parts
are

are

removed
in in

Visuany inspect parts for damage

3 any

wear

of

Jack

up

rear

and

sup

These

inspections
cause

port it by placing a safety stand under rear axle case Drain gear oil 2
Remove

fmding the
Mount

of a

helpful problem and

on

Rotate gears to

see

that there is

roughness

which would indicate

or

detennining the corrections needed

carrier Differential Carrier Attachment ST06320000

damaged bearings

chipped

gears

propener shaft
can

and

rear

axle shafts

These works
to Rear

be done

Check the gear teeth for scoring or signs of abnonnal wear Measure pre load of drive pinion
4

by referring Suspensionu
3

Axle and Rear

Set up

dial indicator and check

Loosen off bolts securing differ and ell tial carrier to rear axle ca se take out differential gear carrier
as

the backlash at several points around

ring gear Backlash should be specified

value

sembly

Ring

gear

drive to

pinion backlash

0 10 to 0 15 mm

PRE INSPE CTION

Differential

Y DISASSEMBI
5

0 0039 to 0 0059 inl

Check
a

the

gear

tooth

contact

carrier should be in

Fig PD 4 Holding Differential Carrier

PD 3

with

mixture

of

recommended

Propeller
I

Shaft

Differential Carrier
a

powder
ring

and oil

applied

hingly sp

to all

of drive

pinion with

soft baminet

gear teeth

For the tooth contact pattern see paragraph dealing with tooth contact pattern adjustl1ll nt

Drive pinion can be taken out together with rear bearing inner race collapsi
4

ble spacer and washer Remove oil seal front bearing inner
race

and

take out

Note 5

Oil seal must not be reused

race

DISASSEMBLY
FINAL DRIVE ASSEMBLY
I

Hold rear bearing inner

with Race

Drive Pinion Rear

Bearing Inner

Puller ST30031000 and extract from drive pinion with a press Fig PD 9 Removing Side Bearing

Put match marks

and carrier

on

side bearing
side

caps
case

and

remove

bearing

caps and take out differential

Note
a

assembly

Puller should be bandlOd with

in

care

using Slide Hammer

HTI2400000

catching
race

the

edge of bearing

inner

b Be careful not to confuse left and

STJ0031000 2

right

band parts
love Rel

out lock

ring gear by sp straps and loosening ring

readJ lg
gear

bolts in

diagonally
ring
gear

r 1

9 i
PD205

Punch off pinion mate shaft lock side using Solid

pin from

PD266

Fig PD 7 Removing Pinion Rear Bearing InfUr Race

Punch KV3810Ig00

Fig PD 5 Removing
e Ca

ntial Diffe A embly 6

To

remove rear

outer races of both

a

front and Note Care should be taken not to left end drift to confWle the

bearings apply

brass

KV3810I800

race

side surface

and with

right

hand

bearing
so

caps and

bearing

outer races

draw them by tapping the top of drift with a hammer

reassembly will be easily carried out with the same parts in the original position
2 Drive
love Rel

that

drive pinion nut using Pinion Wrench Flange

and

PD319

Fig PD I0 Removing Lock Pin

ST31530000

pull off companion

Note mouth Lock pin is slaked et pin hole on differential case Do not it off

flange using

standard puller

punch
PD268

forcibly

without

checking
4

how it is staked

Fig PD B Removing Pinion Front and Rear Bearing Outer Race

Draw out pinion mate shaft and

remove

pinion

ID3 tes

side

gears and

thrust washers
Note

Put mams
so

on

waaher

that

they

gear end thrust can be re

installed in their from which Fig PD 6 Removing Drive Pinion

Nut

origiital positions
were removed

they

DIFFERENTIAL
I
Wle

CASE

When

replacing side Differenliai Side

ST3305 1001 and

bearing Bearing
Adapter

INSPECTION
Thoroughly
parts clean all disassembled
see

Extract drive pinion assembly to

Puller

the rearwards by

tapping the

front end

ST33052000

and examine them to

that

4 PD

Propeller Shaft
they are worn damaged or otherwise faulty and how they are affected Re pair or replace all faulty parts which
ever is necessary

Differential Carrier

PRECAUTIONS IN REASSEMBLY

tiJ
and the

Tightening torque Ring gear bolt

6 0 to 7 0 kg m 43 to 51 ft Ib

Arrange shims washers like to install them correctly

2

1
that

Check
or

gear

teeth

for

scoring
sure

cracking
correct

chipping

and make

Thoroughly

clean the surfaces

on

which shims

washers

tooth

contact pattern indicates

bearings and

CAUTION
e

meshing depth
replace parts
as

If any fault

is evident

required
are

Note

Drive pinion and ring gear

for

supplied
therefore

replacement
as a set

as

set

bearing caps are installed 3 Apply gear oil when installing bearings 4 Pack grease cavity between lips when fitting oil seal
ASSEMBLY OF DIFFERENTIAL CASE
1

Use end

only genuine ring

new

gear bolts fashion

Tighten lightly tapping

with
a

lock straps bolts in

crilss criss

around bolt heads

hammer

should

either part be

damaged replece
2
and

When

measure

replacing side bearing bearing width using Side Bear

mates

Check pinion shaft and pinion for scores and signs of wear
as

Assemble pinion mates side gears

case

and thrust washers in differential 2

Fit
so

ST3250S000 Adjust Weight mock ST3250 I 000 and Weight

ing

replace

required
same

pinion shaft

to

differential

Master Gauge

ST325020oo 5 17

or

suit

FoUow the
gear
case

procedure for
on

side

and their seats

differential

that it meets lock pin hole ide gear 3 Adjust pinion mate to backlash or the clearance between the
case

able standard gauge in thickness and a

nun

0 689 2 5

weight block

kg 5 5 Ib prior

to installation

Inspect all bearing races and roU ers for scoring chipping or evidence of excessive wear They should be in condition such as not worn and tiptop with mirror like surfaces Replace if
3
there is
a

rear

face
to

of side
the

gear

and

thrust

Standald bearing width 17 5

y mm

washer

specified value

by

10 689 in

selecting

side gear thrust washer

Pinion mate to side gear backlash 0 10 to 0 20 mm

shadow of doubt
as
an

on

their

efficiency
seizure 4

10 0039

to

0 0079 in

incorrect bearing op eration may result in noises and gear

ST32501000

Inspect thrust washer faces SmaU

can

faults

be

corrected

with

sand
gear
re

If pinion paper backlash exceeds

mate to

de value

specified

place

thrust washers

Pinion mate to side gear backlash 0 10 to 0 20

mm

Select
to

ferring
Shims
PD023

re side bearing shims Adjustment of Side Bearing

0 0039 to 0 0079 in 5

Inspect gear carrier and

case

differ

Press fit side

case

bearing

cone

into

ential
either

for cracks
is

or

distortion

If

Fig PD l1 Measuring Clearance Side gear thrust washer

differential

using Gear Carrier

condition

evident

replace

Side Bearing Drift ST33220oo0 and

Jaulty parts
6 As
a

Adapter ST33052000
in

general
at

rule

oil seal should

be replaced

each disassembly

Thickness

mm

0 785 0 0309
0 835 0 885 0 0329

w
I
ST33220000

0 0348

1000
4

Lock pinion shaft lock pin using a

it is secured into

ASSEMBLY AND ADJUSTMENT

Assembly
reverse can

punch after 5 Apply

in the turn 6

place

oil to gear tooth surfaces and thrust surfaces and check if they

be

done

properly
PD244

order

of disassembly for

The

foUowing

directions

adjustment

Place ring gear on differential case and install bolts and lock straps Tor
que bolts to specification lock straps

ST33052000

and usage of special tools enable to obtain a perfect differential operation

and bend up

Fig PD 13 lnatalling Side Bearing

Cone

PO 5

Propeller
ADJUSTMENT
OF DRIVE T Where PINION HEIGHT

Shaft
W N

Differential Carrier
HxO 01

OJ8

EX 3
W T 2 80 W
mm

0 48 mm H OJg
0 01

Adjust
er

the pinion
between

height
rear

with wash

HxO OI OA8 0 20 2
x

provided

race

bearing inner and the back of piliion gear

Press fit front and
races
rear

T
W

Required thickness of pinion heightedjusting w shers

Thickness of
ed washer

2 80 3 28 3 08

OJ8

bearing
using
Drift

temporarily

insert

outer Drive

into

Pinion

gear Outer

carrier

mm use

Race

STJ070 I 000 and Bar ST30611000 gear carrier and install Dwnmy Shaft on rear bear
2

Be sure 0 1079 2 80
ness

to

washer of 2 74
0 1091 in
or

The
3 07

correct

washer

thickness

is

or

2 77
mm

mm

Fit

rear

bearing

1102 0

on

thick
Pinion

ing

and

place Height Gauge

on

gear

Measured

clearance
and

between

height adjusting washer

Thickness
mm

carrier STJII21000

height
face
H

gauge

dummy shaft
on

in

mm

Height gauge KV38 103500 Height gauge spacer ST3 II 22000 Dummy shaft KV3gl03600 Dummy shaft spacer
ST3112tOOO

Figure marked pinion head

the

drive 2 74 OJ 079 2 77 OJ09I

2 80 OJ 102 3 01 0 1185 1197 0 1209 0

3 04 07 3 3 10 3J3 16 3
3 19

Note
e

Figure

H is e dimensional variation

2 83 0 1114

1220 0 1232 0
1244 0 1256 0

in units of 1 100 mm

egainst stand given

2 86 OJ 126 2 89
1138 0

ard measurement b If value

signifying
zero

H is not

2 92 OJ 150
2 95 1161 0 1173 0

regard it as

and compute

3 22 OJ 268
3 25 l2g0 O

2 98 5

Set number Head number Hl

Fit detennined pinion height ad

in drive

justing washer
press fit rear

pinion

and

bearing
Pinion

inner race in it

using
P0186

Drive

Bearing

Drift

Bar STJ0600000
PD461

Fig PD 14 AqjUlting Pinion Height

Note

After

assembly

check to

see

Fig PD 16 Variation Number

on

thet tooth contact is correct If Dot

Drive Pinion

readjust

Measure

the

clearance

be

tween the

tip end of height

gauge and

the end surface of dummy shaft

a

using

Examples
EX I
W

of calculation

thickness gauge

ADJUSTMENT OF DRIVE PINION PRELOAD

30mmH 0
x

2 74mmN

W
2 74

0 01
I
x

18 0 0 01 OJ8

with with

Adjust the preload collapsible spacer

of drive pinion

30 0
0 19

3 04

This procedure has nothing to do thickness of pinion height ad

2 85
is

justing washer
Note

Collapsible

spacer

oil seal and

The
2 86 mm

correct

washer

thickness

pinion
I

nut cannot be reused

After

EX 2
W
P0322

adjusting

pinion

height

lubricate front
2 77
mm

0 21

mm

W 2 77 2 98

HxO 01 0 21 18 0

OJ8 OJ8

with gear oil and place it in gear carrier 2 Install a new oil seal in gear

bearing

Fig PD 15 Meouring Clearance

OxO 0I

carrier

using Oil

Seal

Fitting Tool

ST33400001 Lubricate cavity between seal lips recommended multi purpose Place
a

2 80
4

The proper

height adjusting
ed from the

thickness of pinion washers can be obtain formula

with The 2 g0
correct

washer

thickness

is

grease when

following

mm

3 PD 6

installing new collapsible

spacer

on

Propeller
drive

Shaft

Differential Carrier
Figures for
dimensional
1 A B

pinion bearing with

4 Insert

arid lubricate gear oil

pinion

rear

C D and H
in units

are

variations

of

companion flange
cone

into oil

100

mm

against

each

standard

seal and hold it firmly against pinion front bearing the gear
into 5

measurement

From the

rear

of

carrier insert

drive pinion

companion flange
Ascertain that threaded
new or

portion
ion

of drive pinion and nut are free from oil

6

drive p

grease
P0447 F

Holding companion flange with Pinion Wrench Drive Flange and then STJ1530000 tighten nut into front bearing pull drive pinion cone and into flange As drive pinion is pulled into front bearing cone drive pinion end play is reduced While there is still end play in drive pinion companion flange and
cone

Fig PD 17 Measuring Pinion

Preload

MarkS

specification replace collapsible spacer

Note Preload

If this

is

exceeded
MarkC D

will be fell to bottom out This

same

of used bearing is the value as that of new bearing

L
P0214

indicates that bearing cone and com panion flange have bottomed on col

lap

ible spacer From this

ADJUSTMENT OF SIDE BEARING SHIMS

I

Fig PD 18 Thickness of Shim on Left and Right Sides

point

much greater
to

torque must be applied

nut since spacer must

turn

pinion

be
nut

collapsed
hould be

differential

If hypoid gear set gear carrier case or side bearing ha

Also

from this point

been replaced

tightened very slowly and drive pinion end play checked often 0 that pinion bearing preload does not exceed the
limits When the drive

adjust the ide bearing preload with adjusting him The required thickness of adjusting shim can be calculated by the follow ing formulas
T
A

PD190

been eliminated the

i

pinion end play has specified preload

Fig PD 19 Variation Number on Ring Gear

C
D

xO OI

being approached T2

020
B F

E
H xO Ol 0 20

Examples of calculation
EX 1
A I B

CAUTION 00 not decrease

preload by

loosen
Where T

ing pinion nut This will remove compression between pinion front end rear bearing cones and collapsibla spacer and may permit front bear ing cone to turn on drive pinion
Moreover
7 nut becomes loose

2 C

2 D 0 01

3
mm

0 02 mm F 2

Required thickness of left side bearing adjusting shim

mm

Left side T
A

T2

thickness of right side bearing adjusting shim

Required
mm

D E 3 0 02

xO OI

0 20

Turn drive

pinion
times

in both direc set

lions

several

to

bearing

Figure marked
side carrier

on

the

left

0 01
rnm

rollers Then adjust bearing preload to specification using Preload Gauge STJ127S000
B

bearing housing
on

of gear

0 20
correct

0 26

Figure marked
side
carrier

the

right

The

shims
mm

are

005

plus

bearing housing
on

of gear the dif

three pieces of 0 07

thick

iil Tightening tOlque

Pinion nut 14 to 30

D
F

Figures marked
ferential case These
are

Right T2

side B

W
F

QI xO

kg m

differences in width

0 20 2

101 to 217 ft lb D iY8

of left

pinion preload
6 0 to 8 0

or right side bearing against the tandard width mm

2 001

0 01
16 0
mm

0 20 The 0 07
correct

with oil seal

kg

cm

Figure marked
gear PD 7

on

the ring

shims

are

10 0

plus

5 2 to 6 9 in Ib

mm

thick

Propeller Shaft
EX 2
A E 0 B 3 Side I

Differential Carrier
Side bolts
m

@Tightenirig tOrque
C
I D 2

bealing preload
cm kg
to

bealingcap

8 to 10

O IF

0 08 H

5 0 to 6 0 kg

6 9

8 7 in bl

36 to 43 ft b 5

At ring geer bolt 1 5 to 1 9

Left side T
A

Measure
micrometer e

dimension between
with

kg

D
E

xO OI
1

left and right bearing cap edges

a

3 3 to 4 2 Ibl

0 20

8
t c

H2 11 0

0 01

cljmension
153 40 to 153 45 mm 6 0394 to 6 0413 inl

Check and adjust the tooth con pattern of ring gear and drive

0 20

pinion
I

0 20

01

Thoroughly
gear teeth

clean ring and drive

0 31 The correct shims

0 10

pinion

are

plus

lIree pi
Right T2

ce s of 9

Q7

Il1I thick I

side

2 Paint ring gear teeth lightly and evenly with a mixture of recommend ed powder and oil of a suitable consist ency to produce a contactpaUern 3 Rotate pinion through several revolutions in the forward and
reverse

H F
I

xO OI
xO 01

direction until
tern i 4

definite contact pat

020 3 02 0
30 0

0 20

0 08 0 20
0 08
PD271

developed on ring gear contact pattern is in correct readjust thickness oLadjust

When

ing shim
Be
sure to

Fig PD 20 Measuring shims

10 0

Dimension

pletely
The
correct
are

upon

wipe off powder com completion of adjust

contact

plus
D

0 20 mm thick Note

Measure ring gear

drive to

pinion
decrease increase
same

ment

backlash If w1ues
are

5 teeth

Incorrect
can

pattern

of

sigoifying

A B C

If backlash is too smaU thickness of left shim and

be

adjusted

in the

foUowing

and H
zero

not

giVen regard them as

see

manner

After essembly Ifnot

end compote clteek to

thickness of right shim by the that

amount

Contact pettern
reverse

preload and backlesb ere

correct

Ifbacklash is too great above procedure

the

Heel contact To
correct

readjust adjusting
shim
in

increase thickness of

Ring
Side bearing

gear

drive to

pinion backlash
mm

drive pinion adjusting washer in order

to

0 10 to 0 15

bring drive pinion close

to

ring gear

0 0039 to 0 0059 in

Thickness

mm

0 05 0 0020 0 07 0 0028 1 0 00039 0 0 20 0 0079 50 0

0 0197
P0193

Fig PD 22 Heel Contact

Fit determined
on

side bearing ad
case

b Toe contact
To
PD272

justing shim
press Drift

differential

and

correct

reduce

thickness

of

fit left and right side

bearing

drive pinion

adjusting
pinion

washer in order
go away from

inner races on it

using Side Bearing ST3322OO00 and Adapter

case

Fig PD 21 Mea uring Backlash

to make drive

ring

gear

ST33052000 3 Install differential

assembly
a

into gear carrier tapping with mallet

4

rubber

At

the

same

time

check

side

bearing
cap with

preload

Bearing

preload

Align mark
on on

on

bearing

should be

specified torque
it with side bear
PD194

that cap

gear carrier and install bearing carrier

Ifpreload does not accord with tJiis

And

tighten

bolts to

specification adjust
ing shims
PD B

specified torque

Fig PD 23 Toe Contact

Propeller
c

Shaft

Differential Carrier
3
rier
re

Flank contact

INSTALLATION
Installation
verse can

Install

new

oil seal in gear Seal

car

Adjust

in the same manner as in b be done in the

using

Oil

Fitting

Tool

ST3340000l
Lubricate with

order of removal

cavity

between seal

lips

ifl Tightening torque

Gear carrier to rear axle
case

recommended

multi purpose

grease when installing

4 Place a new collapsible spacer on drive pinion and lubricate pinion rear bearing with gear oil 5 seal

fixing bolt
1 7 to 2 4

t
P019S

kg m

12 to 17 ft lbl Drain and filler plug 6 to 10 kg m 43 to 72 ft lbl Gear oil quantity

Insert companion
Insert drive from
rear

flange

into oil
com

Fig PD 24 Flank Contact

pinion

into

panion flange
and

of gear carrier

Face contact

0 9 liter 1

Adjust

in the same manner as in 3

1 U US pt Imp pt

Note
a

Discard remom Do not

gear

carrier

gasket
to the

after

secure them in position by tightening nut to given torque con firming specified preload These works can be done by re ferring to Adjustment of Drive Pinion Preload procedure 6 Install differential case assembly

cf
P0196

apply sealant
rear

into gear carrier Measure sion

dimen
shims

Apply

sealant to

gasket bolts securing gear

axle

backlash Theworks

with
be

specification
done

carrier case to

housing

adjust them with side bearing

can

ferring
Fig PD 25 Face Contact Shims

to

Adjustment procedure

of Side

by re Bearing

Correct tooth contact

REPLACEMENT OF FRONT OIL SEAL

When replacing front oil seal do follows
1 Remove differential carrier assem mount it on Differential Car
as

Reinstall differential gear carrier

assembly rear axle shafts and pro peller shaft Fill up differential carrier
with correct gear oil

bly and

rier Attachment ST06320000

P0197

Fig PD 26 Correct Contact

be done by referring procedure 2 Remove side bearing caps and take out differential case assembly
can

This work Removal

CAUTION
a

to

Replacement
ed
on car

of front oil seal with

differential carrier
must

assembly
not

install

be ellowed

Note

Change in thickness of adjust ing WlI8her is accompanied by

Remove drive pinion nut and extract drive pinion assembly Remove oil seal These works
can

collapsible spacer on iu model b Whenever front oil seal is replaced collepsible

spacer must be

due to used

change in backlash insteIIing gear

Check it when

be done by

re

replaced

ferring to Disassembly procedure

PD 9

Propeller

Shaft

Diffe

ntial Carrier

SERVICE DATA
PROPEL1 ER SHAFT
GENERAL SPECIRCATIONS

AND

SPECIFICATIONS

Model

T A
2856A
rnrn

M T

Type Length Outer

lluJ er dil
in 1 045 4Ll4

1 177

46 34

rnrn

jn

68

713 1

SERVICE DATA Permissible dynamic unbalance Axial play of spider journal

cm gr
rnrn

in oz

35 0 49 5 800 rpm 0 0

in

TIGHTENING TORQUE Shaft

to

companion flange bollS

kg fil

lb ft

2 4 to

3l17 3

to 24

DIFFERENTIAL CARRiER
GENERAL SPECIFICATIONS

Type
Automatic transmission

equipped models

HI50 HI50A

Manual transmission equipped models Gear ratio number of teeth

Automatic transmission equipped models Manual transmission Drive pinion preload

3 889

35 9

equipped

models

3 700 37 10

adjusted by

Collapsible

spacer

PO tO

Propeller Shaft
SERVICE DATA Drive pinion Preload with oil seal
cm kg in lb

Differential Carrier

6 0 to 8 0

5 2 to 6 9

Thickness of pinion height washer

adjusting
mm

em

2 74 0 1079 2 77 0 1091

2 80

0 1102

2 g3 0 1114 2 86 0 1126
2 89 0 1138

2 92 0 1150
2 95

0 1161
0 1185

2 98 0 1173 3 01 3 04 3 07 10 3 13 3

0 1197
1209 0 1220 0 1232 0

16 3 19 3 3 22

0 1244 0 1256
1268 0

3 25 0 1280
Side gear and

pinion

mate
mm

Thickness of side gear thrust washer

in

0 785 0 0309
0 835 0 0329

0 885 0 0348 Pinion mate to side gear backlash clearance between side gear and thrust washer

mmOn

0 10 to 0 20 0 0039 to 0 0079

Ring

gear

Ring
shint

gear

drive to

pinion backlash

mm

in

0 10 to 0 15 0 0039 to 0 0059

Thickness of side bearing

adjusting
mm

in

0 05 0 0020 Q7 0 0028 0 0 10 0 0039

0 20 0 0079 0 50

00197

Side
L

bearing

standard width

mm mm

in in

5 0 689 17 153 40 to 153 45 6 0394 to 6 0413

dimension

Oil capacity

liter

US pt Imp pt

approximately
09

IU

TIGHTENING TORQUE Drive pinion nut

kg m
kg
m

ft Ib ftIb ftlb

14to30

IOI t0217

Ring gear bolt

Side bearing cap bolt

6 0 to 7 0 43 to 51
5 0 to 6 0 36 to 43

kg m
propener kg
m

Companion flange shaft fixing bolt

Gear carrier to

to

ftIb ft b ft lb

4 to 2

3 17 to 24

rear axle case

fixing

bolt

kg kg

m
m

7to 2 4 1 6 to 10

12

to 17

Oil drain and ftller plugs

43 to 72

PD ll

Propeller Shaft

Differential Carrier

TROUBLE DIAGNOSES AND CORRECTIONS

PROPELLER SHAFT

Condition Vibration during at Unbalance due shafL Loose

Probable
to

cause

Corrective action

bent

or

dented

propeller

Replace propener shaft assembly

medium

or

high speed

propeller

shaft installation mud

on

Retighten
Clean up shaft

Undercoating
unb
ance

or

the shaft causing

Worn transmission Tire unbalance

rear extension

bushing

Replace
Balance wheel and tire

assembly

Balance weights missing

Replace Replace propeller

shaft assembly

Knocking

sound during

Worn

or

damaged

universal joint

starting or noise during coasting on propeller

shaft

Worn sleeve yoke and meinshaft spline Loose

Replace propeller shaft assembly

propeller

shaft installation

Retighten
out dust cover to remove inter

Scraping

noise

Dust

cover

on rear

sleeve

yoke rubbing
Dust
on

on

Straighten
ference

transmission

extension

cover on

companion
carrier

flange rubbing

differential

PD 12

Propeller
DIFFERENTIAL CARRIER
When
a

Shaft

Differential Carrier

differential carrier is

sus

tires

road surface exhaust shaft

universal

pected of being noisy it is advisable to make a thorough test to determine

whether the noise originates in the

joint propeller engine transmission

carrier
Noise

wheel bearings or differential

other places cannot be corrected by adjustment or replacement of parts

in the
rear

axle assembly

which

originates

in

Condition Noise drive coast

Probable

cause

orrective action

on

Shortage of oil
Incorrect tooth contact between ring gear and drive pinion
Incorrect

Supply gear oil

if necessary

Rebuild differential carrier

and float

Adjust tooth contact

set

or

replace hypoid gear

set if

ring gear

drive to

pinion backlash
and

Adjust backlash
necessary

or

replace hypoid gear

Seized

or

damaged

ring

gear

drive

Replace hypoid

gear set

pinion
Seized

damaged

or

broken drive

pinion

Replace pinion bearing

Replace side bearing
and

and

damaged parts

bearing
Seized damaged
or

broken side bearing

or

damaged parts
and

Loose clamp bolts

nuts

holding ring

gear

side retainers bearing cap etc

Noise on turn

Clamp to specified damaged parts Replace damaged parts

torque

replace

Seized gear Seized

damaged

or

broken side and pinion

damaged

or

broken side gear and

Replace damaged parts Replace damaged parts

pinion thrust washer

Pinion gears too

tight

on

their shaft

Knocking sound during starting or gear shifting

Excessive backlash
Incorrect backlash ion or side ta

ring gear pinion gear

drive to

pin

Adjust backlash Replace

Worn gears
Worn side

or case or
rear

worn worn

parts parts

side gear

flange spline

axle shaft

and

Replace

Pinion bearing under

preload

Adjust preload
Repair
or or

Loose drive pinion nut Loose

replace replace
if necessary

clamp

bolts

or

nuts

holding ring gear

Clamp

side retainers bearing cap etc Seizure

or

breakage

Shortage ofoil

or use

ofunsuitable oil

Refill

or

use

correct oil

Excessively small backlash

Incorrect

Adjust
or gears

backlash and
worn or

replace

as

required

adjustment
use

of bearings
an

Replace

damaged parts

Severe service due to

excessive loading

Replace damaged parts

improper
bolts

ofclutch
as

Loose bolts and nuts such

ring

gear

clamp

Tighten

PD 13

Pro eller Shaft 8i Differential Carrier

Condition

Probable

cause

Corrective action

Oil leakage

Jut Worn

front oil seal

damaged or improperly driven or bruiSed dented or abnor

slide face of companion flange
or

Replace damaged oil seal Repair flange sandpapel or replace if necessary

Treat
as

with

mally
Worn

worn

damaged
oil seal

improperly

driven side
or

above

flange

or

bruised dented

abnor

mally worn slide face of side flange

Loose bolts such
or as

side flange side retainer

Tighten
Replace Tighten Repair

bolts to

specified torque

gear carrier
or

Damaged gasket

O ring

Loose fdler or drain

plug

Cl9gged

or

damaged breather

or

replace

PD 14

Propeller Shaft

Differential Carrier

SPECIAL SERVICE TOOLS

IKent Moore Tool number tool
No

Kent Moore No
Reference
or

name

Reference page Unit

or

Fig No

Tool number

tool name

Fig No
Unit

application ST31530000 Drive pinion flange wrench

J 25774

application ST33052000

Adapter

J 25797 1

Fig
Page

6 PD PD 7

Fig PD 9 g PD Page

ST0632001i0

Differential carrier attachment

J 25601

KV38101800

Solid

punch

Fig PD4 Page PD 9

FiJi

PD IO

ST3003S000

Drive
race

pinion rear inner puller set

J 25733

ST3250SOO0

Side bearing adjust weight

J 25407 3

CD
J 25733 1

CD 00

ST30031000 ST30032000

Puller
Base

CD 00

ST32501000 ST32502000

Weight

block

CD
J 25407 3

Master gauge

00
J 25733 2

00
J 25407 1

Fig PD

Fig PD

12

Er
ST33220000 Differential side bearing drift J D1 25804

Fig PD 13

Page

g PD

ST33051001

Differential sIde bearing

ST30611000

Drive

pinion

outer race

J 25742 1

puller

Fig PD 9

drift bar

Page

6 PD

oiij
9

UI I IM

l JM r

Md

Applicable
PD 15

to all B310 series models

Propeller Shaft
Mooro IKent Reference page or Fig No
Unit

o ifferential
No

Carrier

nt Moore No e K Reference page or

Tool number

tool

name

Tool number

tool

name

Fig

No

Unit

auon applic ST3070 I 000

Drive

application ST30600000 Drive pinion bearing drift

bar J 25741

pinion

outer race

J 25742 2

drift

Pag

6 PD

1ge P

6 PD

5
I
ST3112S000 Drive pinion setting gauge set J 01 25269 ST33400001 Oil seal

fitting tool

J 26082

CD
J 01 25269

CD ST31121 000 @ST31122000

Height gauge Dummy shaft

Page

6 PD

@
J 01 25269
PD 14

Fig

ST3127S000

Preload gauge

J 25765

CD GG91030000 Torque wrench @ HT62940000 Socket adapter ID HT6290oo00 Socket adapter @

CD
J 25765

@ ID
Page
PD 7

KV38103500

Height

gauge spacer

Fig

PD 14

o
Slide hammer

KV38103600

Dummy shaft spacer

H172400000

Fig

PD 14

Page

4 PD

@
Applicable to all 8310 series models
PD 16

DATSUN 210

Model 8310 Series

SECTIONFA
FRONT AXLE FRONT SUSPENSION
CONTENTS
INSPECTION AND ADJUSTMENT
INSPECTION ADJUSTMENT FA FA FA FA FA FA FA FA FA BAR FA 2 2 2 4 4 5 5 6 6 9 lOWER ARM AND FA lO FA 12 lOWER BAll JOINT SUSPENSION CRDSSMEMBER

FRONT

AXLE

SERVICE DATA AND

REMOVAL

SPECIFICATIONS
GENERAL SPECIFICATIONS INSPECTION TIGHTENING AND ADJUSTMENT

FA 13 FA 13 FA 13 FA 14

INSPECTION INSTAllATION FRONT

SPRING

SUSPENSION
AND STRUT ASSEMBLY ROD AND STABILIZER

TORQUE

TROUBLE

DIAGNOSES AND
FA 16 FA 19

TENSION

CORRECTIONS
SPECIAL SERVICE TOOLS

Front Axle

Front

Suspension

INSPECTION AND ADJUSTIVIENT

INSPECTION
Inspect
Block
2 in accordance with AJ measuled et wheel hub bolt

periodic
With

Less then 1 2
u

kg 12 G Ibl bealing

maintenance schedule
rear

ed

gr

seal

wheels with chocks

the front

AJ measured at wheel

Jack

up

of

car

and

nut

support it with safety stands Refer

to

1 0 to 4 5

cm kg
at

Section

GI

for

lifting
bolt

9 0

to

9 in b 3 wheel hub

points
3

and

towing

AJ measuled

Shaking each fiont wheel by grasping the upper and lower surfaces of the tires check suspension parts for looseness wear or damage Tighten aU loose bolts and nuts to the specified torque Replace all worn parts as
4

0 17 to 0 79

kg

0 37 to 1 741bl Fig FA Tighlening Wheel Bearing

Nul

described under Front Suspension Check wheel bearings If there is

Turn

wheel hub several times in

any axial end

play adjust bearings

or

to

specifications Replace worn

as

damaged bearings
oil

to seat wheel bearing correctly again tighten wheel bearing nut to the above torque 8 Turn back wheel bearing nut A

both directions

described under Front Axle Check

strut

degrees
or

for

leakage

damage

Return engle Install

above

AU

900
cap and

adjusting

align

any

of its slots with hole in

spindle

If the
and
as

procedure fails
as

to

align hole
hole

slot together then much

IS

tighten degrees until

lock nut

in

FA413

spindle

is aligned with eny slot

Fig FA 2 Metr uring Bearing Starting

Torq ue

ADJUSTMENT
WHEEL BEARING Block
2
rear

CAUTION 00 not overtighten wheel bearing

as

nuts

Repeat
rect

above

procedures

until

cor

this can

cause

wheel

bearing

seizure

starting torque

is obtained

wheels with chocks front of

car

Jack

up the

and 9
or

support it with
3

safety stands
brake

Remove

pads

Refer to

Turn hub in both directions two

Section BR for pad replacement 4 Remove hub cap cotter pin ad

three times

justing
S

cap and wheel

Sparingly

bearing nut apply recommended

torque and within the specified range

not

measuring its turning axial play to ee if they are

If they
are

Note
a

Correctly

meas

force toward
b

e rotation ting slar tangential direction

adjust

against hub bolt

Above

multi purpose grease to threaded por tion of spindle and contact surface between

figures do dragging resistance

on

not

include

with

pads re

moved
c

disc brake models

bearing washer and outer wheel bearing 6 Tighten wheel bearing nut using
a

wheel

Any slightest wheel bearing axial

Axial play Omm Din

play

cannot be tolerated

suitable torque wrench

Wheel bealing starting torque

With new gleaS8 l8al A

Tightening torque Wheel bearing nut 3 0 to 3 5 kllm 22 to 25 ft Ibl

measured

et

wheel bearing

nut

less than 7

cm kg

G 1 in Ibl

10 Insert new cotter pin with the legs through hese two parts spread legs away from each other against sides ofwheel bearing nut

FA 2

Front Axle
Toe In

Front

Suspension
Lines parallel to
center line of

Measure toe in and sary For

adjust

as

neces

Toe in
Toe in

body

adjustment

carry out the

28

following procedure
1

With steering wheel

at

its

straight

ahead position check front wheels to see if they are set in straight ahead

positions
2 Toe in can be

adjusted by varying
F

length of steering side rods

A696

Fig FA 3 Installing Coller Pin

II

Note
a

Loosen lock nuts and turn left and

Install hub cap with

new

Q ring

right side rods equally

b Turning side rods in forward direc tion of car inaeases toe in
c

and wheel

If side rods have been disassembled

set at

specified
to
s w

distance

be

forehand when reassembling d WHEEL ALIGNMENT Correct front wheel alignment

sures as

Be

sure

side rods into ball than 20

mm

joint

sockets

more

0 79 in

tics

handling characteris and minimum steering effort with

proper car
wear

FA724

the least amount of tire

Before
be

315

mm

12 40 in

Fig FA 4

ting Toe in Adj

adjusting
sure to

front

wheel alignment

make

preliminary inspection of
r

front end parts

Tire pressure and balance Wheel bearings and wheel nuts

bearing

EfJK

Li II

Steering gear play Steering gear housing loose at frame Steering linkage and connections Shock absorber operation repair or replace the damaged portion or parts When using equipment for front wheel alignment inspection follow the instructions furnished with equipment
If
wrong Note

Fig FA 5 Side Rod T

Toe in

Unladen 1 to 3 mm 0 04 to 0 12 in Side lod edjusting 8 to 10 0

nl

kg

Inspection should be made with the car set Ievel and at curb weight
Unladen conditions Tankful of fuel radiator filled and
mats in 1 Drive
means

58 to 72 ft

the following r

caf

Cember end caster

preset at factory and cannot be adjusted The car requires only toe in and car
caster are

Camber and

engine oil full Spare tire jack hand tools design position
All tires inflated to
sure

whetls ride properly

2

Gauge

sh

01
Ji
JI

rf

specified

pres

steenng whe
tion
1

posture adjustment
Note If camber

All excessive mud

caster

dirt and road

Rota
an

not within

sociated

alignment is specifications check as parts Repair or replace as

or

deposit accumulations away from

chassis and underbody 3 After correct toe in is obtained
nuts

right
on

A U

lOner

Tu
corre

7181 JOck CL
C

necessary

tighten side rod adjusting

J FA

Front Axle Turning engie

of front wheel

Front

Suspension
4

After

adjustment

l ck

adju

Inner wheel
Outel wheel

380
31

to
0

42
35
0

ment nut

to

Note

Turning angle of

outer wheel

will automatically be Set by

adjust
to

wheel ing turning angle ofin U f values specified

FA125

Fig FA 6 AdjUting Steering Angle

FRONT AXLE

FA726

Fig FA 8 RemouingBroke Caliper

5
t n

Work

off hub

cap from hub

as

using
If soft

screwdrivers

shown below
a

necessary

tap around it with

hammer while removing cap

1 2 3

Grease seal Inner wbeel bearin Wheel hub Outer wheel bearins Wheel bearing washer Wheel bearing nut

Tightening torque of bolts

and nuts

4
5

kg

ft lb

@ @ @ @ @

9 to 5 3 28 to 38 3 0 to 3 5 22 to 25 5 5 to 10 0 40 to 72 7 3 to 9 9 53 to 72
5

6 7 8 9 10

Adjusting
O ring Hub cap

cap

1 to 6 1

371044

Disc brake rotor

FA803

Fig FA 7 Front Axle

F A386

it with

safety

stands

Fig FA 9 Remouing Hub Cap

3
ear

wheels with chocks

car

Remove wheel and tire assembly Remove brake tube brake caliper
to

Note

fron t of

and support

assembly referring

Section DR

avoid deinaging

During operation be careful ring O

to

4 FA

Front Axle
Pry off cotter pin take out ad justing cap and wheel bearing lock nut
6
7

Front

Suspension
3 Coat each bearing
DOne

with

rec

ommended multi purpose grease

Remove

wheel

hub

with

disc

brake rotor from installed

spindle

with bearing

Fig FA 12 Removing Bearing Outer

Race
FA781

Fig FA 14 Coating Bearing Cone

with Grease

INSPECTION
FA199

WHEEL BEARING Fig FA

10

Place inner bearing cone in hub and install a new grease seal coating
4

Removing Wheel Hub

Note

Be careful

not

to

drop

outer

bearing DOne out of hub when removing hub from knuckle spin
dle

Thoroughly clean grease and dirt from wheel bearing with cleaning sol vent and dry with compressed air free from moisture Check wheel bearing to see that it rolls freely and is free from
noise crack

sealing lips with recommended

purpose grease

multi

Concerning installation
to

of brake

parts refer

Section BR

pitting

or wear

l i

Tightening tOlque
Disc brake Rotor to hub 3 9 to 5 3

WHEEL HUB 8
9 Remove outer

bearing

cone

Check
brake
means

wheel
a

hub

for crack

by
or

28 to 38 ft

kg m lbl

Loosen four bolts

remove

securing

of

disc

disc brake

rotor from

dyeing

test and

magnetic exploration replace if cracked

wheel hub assembly

INSTALLATION
Install front order axle in the
reverse

Install hub with rotor and

outer

of removal

noting the

fol

bearing cone 7 Sparingly

apply

recommended

lowing
I

Install

bearing
Wheel

outer

race

with

multi purpose grease to threaded por tion of spindle and bearing washer to

Front Inner

Bearing
Front

Drift
wheel

bearing contacting face Adjust wheel bearing

Then install

ST35321000 Drift Outer

washer and wheel bearing nut

nut
as

Bearing Fig
FA 11

ST35322000

de

and Drift Bar ST35325000 until

they
re

scribed in Adjustment in this section Note

a

Removing Due Broke

Rotor

seat in hub 2

Pack hub and hub cap with

In order

to assure DOrrect

bearing
sure

commended multi purpose grease up to shaded portions Loosen take out

screws

starting torque
ice nfe ofwheel

and to extend serv

bearings

be

to

securing baffle plate

avoid dirt and

baffle

plate
b

ting iIi bearing earing

cone

foreign particles get bearings grease seal Washer

nut etc

Grease should be changed at each

10

Remove inner

after

disassembly end

in aaordance with

prying
seaL
11

out grease seaL Discard grease

Periodic Maintenance Schedule

8

If it

is

necessary

to

replace
fA261

Install O ring
on

on

hub cap

and

earing

outer race
a

drive it out from drift and mallet

install hub cap

9

hub

hub with

brass

Install brake
to

caliper assembly

re

Evenly tap bearing

outer race

through

Fig FA 13 LubriCating Points of

Wheel Hub

ferring
10

Section BR

two grooves inside hub FA 5

Install wheel and lire

front

Ie

Front

Suspension

FRONT

SUSPENSION
e

@ @

@
c

09

@
@ t

@
I

f
t
@ tEl i
1

Illi
G

Fff
A
e

cID

iVI

Tightening torque of bolts

and nuts m kg

lb ft 23 to 31 37 to 44 23 to 31

@
1 2

3 2 to 4 3 5 1 to 6 1 3 2 to 4 3

Suspension

crossmem ber

8 9 10
II

Lower Lower

arm arm

Stabilizer bar Tension rod bracket Stabilizer bar bracket Tension rod bushing Tension rod Stabilizer bar connecting rod

bushing

16 17 18 19 20 21 22 23

3
4 5

Gland packing
O ing

erballjoint Str tmounting insulator Strut mounting bearing

Dust
upper seal Bound bumper rubber Dust cover

@ @ @
@

6
7

12 13 14 15

Shock absorber
Strut
e ssembly sub

Spring

1 6 to 2 1 12 to t5 4 5 to 5 1 33 to 37 5 1 to 6 1 37 to 44 1 6 to 2 1 6 0 to 7

Stru

assembly
arm

@ I8i
CD

12 to 15 43 to 54 58 to 80 40 to 72

Knuc1cle

Coil spring

8 0 to 110 5 5 to 10 0 2 5 to

FA727

Ql i8J
Fig

5 18 to 25 3 Sp ion

FA 16 Front

SPRING AND STRUT SSEMilLY

REMOVAL
L Disconnect brake tube from

lower arm down with

suitable bac

brake assembly 2 3 Remove brake

caliper

Remove bolt connecting strut to

ann FA728

knuckle

Fig FA 16 Removing Knuckle Arm

Bol 4

Detach knuckle
can

ann

from bottom

FA205

of strut This

be done by

forcing

Fig

FA 17

Removing

Knuckle Arm

6 FA

Front Axle
S

Front

Suspension
Note

Support
or nuts

strut

assembly with
and
strut to

AJ

Piston rod
are

piston rod guide

jack
three

suitable

stand

remove

and cylinder

adjusted
a

to

provide
and

securing

hoodledge
can

precision

mating

sutfeces

Strut assembly and spring removed as a unit

then be
7
r

should be handled as
Drain fluid

matched set
inner

thoroughly from

cylinder and discard

ST3565S001
8

DISASSEMBLY
When disassembling a strut extra caution should be exercised to avoid dirt and dust getting inside strut This dirt and dust is loaded with abrasive which if enters strut leak and premature parts
I
causes
wear

k
j F

Wash aU parts in suitable solvent Drain fluid thoroughly from

outer

casing
This

A059

h
Fig FA 19 Removing Mounting
Insulator

Note

operation
since

is

very

im

portant

performance

of strut

varies with amount of fluid filled within strut

internal

of moving
4

Retract piston rod by

pushing

it

Secure

Strut

Steering Gear
in

down until it bottoms Remove gland

Housing Attachment KV48100300

a

packing with Gland Packing Wrench

ST3SS00001

INSPECTION
I

vise and install strut on attachment

Replace gland packing O ring and

Wash aU perts parts

Compressor ST3S6S 100 I on spring Compress spring just far enough to permit turn ing of strut mounting insulator by hand Remove self locking nut
up

Set

Spring

fluid whenever strut is disassembled A

ST35500001 2

except
air

for

non

metallic

with suitable

solvent

1J
KV48 100300

and 3

dry with compressed

Blow dirt and dust off of

non

metallic parts using compressed air

Note
a

Oil oozing out at and around gland pecking does not call for strut maintenance If oil leaks past pring sest check piston rod and gland

FA209

Fig

FA 20 Removing Gland Packing

pecking problem
welded

to

cxirrect the leakage

of
strut

cause
occurs

of
on

If oil

portion

outer outer

strut

Note

Clean gland

pecking

of

mud
b

and other foreign perticles accumu

lated

casing replace essembly

If

casing

hock absorber itself is malfunc

FA658

Fig FA 18

ingSpring Comprt

ring from top of pis guide bushing Lift out piston rod together with 6 cylinder
ton rod

Remove O

tioning replace as an assembly in cluding piston rod cylinder bot

tom valve and

guide bushing

Note

Do

not
as

remove

pistion
cause

rod
to

Outer

ce

in

quickly
Remove lock nut

this will

oil

spurt out
3

deformation
age

Check outer casing for evidences of cracking or other dam If necessary discard

top of piston rod remove mounting insulator strut mounting bearing dust seal spring
on

Strut mountln

In uletor rubber to
or

seat

spring and bumper rubber

Replace
metal joints

if
are

cemented melted

cracked

CAUTION
Be
sure

Rubber parts should also be if deteriorated

to

replaced

hook

special
on a

tool
FA275

Strut mountln

beerln

8135651001 evenly
of three coils

minimum

Paying
lod

attention not to

Replace
mal noise direction

damage piston

Fig

FA 21

Removing

Pi ton Rod

or

if inspection reveals abnor excessive rattle in axial

and Cyliilder

FA 7

Front Axle
Note CbedI dust seal forsaatcbes
on or

Front

Suspension
7

mock absorber b U GENUINE NISSAN STRUT OIL or equivalent every after over 11101 4
in

Tighten gland packing Tightening torque

8 0 to 11 0 m kg 58 to 80 ft lb

aacb
sary

lips

end

replace if

neces

fl

Securely
cylinder

install piston rod guide Note

a

When

tightening gland packing

it i

Note

Be c aref 1l

ASSEMBLY
When assembling strut be careful 5 6

with thread Install

new

damage gujde portion of pistoo rod

O ring
in
over

t to

POrl t
teoded 4 72 in

It J

epproximately

d he ttJI 120 IDID

rod guide

drop or scratch parts since they precisely machined to very close tolerances Before assembly clean away all dirt to prevent any possible
not to
are

Lubricate

sealing lips

packing uterisked

of gland Fig F A 23 with

from upper surfece of gland packing to faclli18te spring iosteIlatioo b Gland

to

entry of dirt
Note If

into strut

lithium base grease containing molyb denum disulphide and install gland

packing should be tighteoed specified torque with the aid of Packing doing
Wreoch
so

packing
of

with Gland

Gland

Packing Guide

any strut is found to be compooent parts make sure tlllt neoesaery parta ere the
same

replacement

KV40101900

ST35500001 When

the

amouot of torque to be read be neath wrench oeedle should be modified formula

eccording

to the

brand

as

thoee used in the

following

strot essemhly

Ckg
I Install strut outer casing on Strut Steering Gear Housing Attachment Install

8x

L L O IO L
or

Cft Ib

58x

0 33

KV48 100300 See 2

Fig FA 20 cylinder and piston

rod

where C
L

assembly shock absorber kit in outer casing 3 Remove pistoo rod guide from

Value to he reed wrench Effective wrench

m

on

the torque

kg

ft

Ib of

length
ft

torque

cylinder
new

and

Pour

correct amount of and strut outer

Grease

fluid into

ylinder

FA659

casing
Amount of oil

Gland packing WIcoch

Torque

1
cu

325 cc

19 83

in
0

1
Lm
0 1
m

V
FA065

ft

I
FA278

0 33 ft

I
Fig FA 25 Gland
FA464

lWrench lbeltill
as

8 Fig FA 23 Grea ing Point of Gland lbelting

Bleed air out ofshock absorber

follows

KV40101900

Holding strut by hand with its spindle side facing down pull out d completely Then turn piston f strut upside down so that spindle side
I is
now

retract

Fig

FA 22

FillingShoelt

Absorber Fluid

facing up Under this condition piston rod all the way in Repeat the above procedure
so

several times
out from strut

that air will be bled

Note
e

It i important that correct emount of fluid be

assure

poured into strut correct damping force

to

F A276

orth oughiy If during the above step en 3 equal pressure is felt through the hand grippitig piston rod on both strokes it
is
t an

indication that air is

expelled

of

Fig FA 24

lung Gland lbelting

from strut

thoroughly

8 FA

Front Axle

Front

Suspension
17
u per

Raise bound bumper rubber 10

spring seal

I
FA070

1i I
13
seat

I
FA671

STALLATION

Fig FA 28 Grea ing Point

Install strut and spring assembly in reverse order of removaL

fil Tightening torque

Install dust
cover

upper spring

Strut to

dust seal mounting bearing and

2 5 to 3 5

hoodledge kg
knuckle

insulator in this written order Note

FA071
a

18 to 25 ft Ib

Steering

arm m

to strut

Fig FA 26 Air Bleeding from Strul

b 9

Place

Strut

Steering

Gear

damaging piston rod during disassembly and assem bly Do not use pliers or the like in an effort to extract piston rod InstaU thrust bearing so that it points in correct direction Fig
FA 28

Be careful to avoid

7 3 to 9 9

kg

53 to 72 ft lb

Note
a

Make
not

sure

brake hose is

secure

and

Housing Attachment KV48100300 in jaws of a vise 10 Before proceeding with further steps pull piston rod all the way out
to the limit of its stroke install bound

tw ted

14

Tighten
nut

new

piston

rod

self

b When
ann

installing
the

steering

knuckle
as

locking

to

bottom

of strut

sembly Iocking
m kg
nut as

epply

the suitable

fil

Tightening torque
Pi ton rod elf 6 0 to 7 5

material to the indicated

to

bumper rubber in place to prevent piston rod from falling by its own weight 11 Compress spring with Spring Compressor ST35651001

sealing portion so
rust

prevent ball stud from

43 to 54 ft lbl Note
a

Temporarily
nut
on

self locking tighten tip of piston rod After installing piston rod on car tighten self locking nut to

specification

b Replace self locking nut whenever

strut is disassembled ST35651001

15
r

dust

To prevent entry of water and apply a thick coat of recom

I
Note
To

mended multi purpose grease to

points

FA665

indicated by arrows in Fig F A 28 16 After placing spring in position between upper and loer spring seats release compressor graduaUy

FA660

Fig FA 30 Applying Sealant

Fig FA 27 Compressing Spring

J
prevent
interference
seat and

be

I k
TENSION ROD AND STABILIZER BAR
r

tween upper

spring

special

tool

leave upper spring coils free

5 to 3 turns of 2 compress spring

and assemble to strut 12 Lubricate dust seal indicated by

arrow in

Fig FA 28 with recommend Fig

1
FA 29

ed multi purpose grease

jt
FA 9

end FA074

REMOVAL
I

Jack

up

the

front

of

car

and

talling Front Spring

support

it with

safety

stands

remove

Front Axle
wheels
2 3
to

Front

Suspension
So Tension rOd to
Lower
ann m

Set
that

slabillz rliar mount bushingS

outer side

splaahboard if necessary Back off nut securing tension rod

Remove

of stabilizer bar
into inner side

bracket and tension

remove

bolts which lower

arm

bushing is brought of marking

5 1 to 6 1 kg

137
to

to

44 ft Ibl

secure

rod to

Tension rod bracket

Tension rod can then be 4

taken out
stabilizer

body
2 to 4 3 kg 3
m

Remove

nuts

securing

bar to

connecting rod
Two wrenches are
B n
1

23 to 31 ft Ibl

Note this 5

in

Stabilizer bar bleck

e 1 6to2

112
0
1 in

11rg
lbl ft

to

15

Remove bolts and nuts securing bar bracket

stabilizer

position Stabilizer bar can then be iaken o t

Marking 2 Bushing 3 Marking

4 5
F

Stabilizel bel connecting rod

1 6 to 2 1

kg

While

painting

CV

I
19
e

12 to 15 ft lbl

Marking

A667

Fig FA 32 Centering 8lDbilize Bar

2

Chec

to be sure that tension rod

bushing is propelly
3 Be
sure

centered in its seat

LOWER ARM AND LOWER BALL JOINT

The lower
ann

that tension rod bracket

is connected to the

bolt is

correctly torqued

Note
a

suspension member through a rubber bwhing end to the strut through a

rod ball joint The lower ball joint is assembled at the bled REMOVAL 1 Block
rear wheels

Noting
bushing
in

direction

of tension

properly center bushing tension rod bushing washer

factory

and cannot be disassem

Lower

ann

5 6

Tension bracket

rod

2 3 4

Stabilizer bar connecting rod Stabilizer bar Stabilizer bar bracket

Tension rod

with chocks

FA129

Fig FA 31 Removing Tension Rod

and Stabilizer Bar

Jack up front of car and support it with safety stands remove wheel 2 3
4

Remove

splashboard
knuckle
arm

Separate

from strut

INSPECTION
I

Pry pin off and separate side rod fromknilckle arm using Ball
colter

Check tension rod and stabilizer of deformation

or

Joint Remover HT72520000 Fig FA 33 Direclion of Tension Rod BUlhing b After installation
mum

bar for evidence

cracks if necessary replace 2 Check rubber parts such as ten sion rod and stabilizer bar bushings to
be
sure

make

sure

mini

they

are

not deteriorated or

clearances

between tension
are

cracked if 1ecessary

replace
c

rods end stabilizer bar both sides

equal on

INSTAllATION
Install tension rod and stabilizer bar
in

Closely observe torque specification

when

tightening

tension

rod

1e tJ

reverse

order of removal noting

bracket retaining bolts d First side to

the following
I to

tighten tension rod on bracket specified torque setting

on

FA661

Be

sure

stabilizer bar is not closer but is located at the

then install the other end

arm

lower

Fig

FA 34

Remoliing8ideRod
Ball Joint

either side

middle If stabilizer bar is

new use

the the

fJ

following
Position

procedure
arm

to

center

Tightening tOlque Tension rod bushing

installation
nut

Remove tension rod and stabilizer

stabilizer bar with white

car

bar from lower ann

paipt mark

4 5 to 5

toward left side of

11rg
lbl ft

7
ann

Remove
to

bolt

connecting lower

33 to 37
FA 10

suspension

crossmember

Front Axle
2

Front bushing

Suspension
if excessively Lower
I rust
on erm

Replace
Make

buahln rub off

e

worn or

cracked
sure

mating surface of bush

Before
or

installing bushing
insi

ing is clean and free from oil or grease apply soapy water to bushing to facili
tate installation

paint drops from

arm

collar

lower

with emery paper Using Replacer Set ST36720000

insert

bushing
arm

with a press until end is

Lower bell
I and Ball

Joint
is assembled at

face of

bushing

aligned

with collar

joint

factory
Check
nut

on

lower

cannot

be

disassembled

FA731

ball stud turning torque with place on ball stud If it

is

in

Fig
8

FA 35 Removing Wwer Arm

far

from

specifications

replace
Remove

suspension
arm

ball joint

from lower arm 9 Place knuckle

in a vise Re

liJ
from

Turning

torque ST36720000 cm kg

New parts 40 to 100

suspension ball joint knuckle arm using a press

move

35 to 87 in Ibl Used parts

@
I

More than 20

cm kg

117 in Ibl
I I 39 FA

HA734
I hi1f l Instal liff Wwer Ami Bu

Fig

Lower

erm

end atebIllzer ber

Fig FA 36 Remouing Suspension Ball

Joint
F

r
arm

662

lUJ
A333

To install lower arm and stabilizer

bar

temporarily tighten securing bolts tighten bolts to specifications at curb weight with tires on ground
Then

10 from

Withdraw
transverse Arm

lower link

bushing
2
it

Fig FA 38 Lower Ball Joint

Lower

Bushing
a

using Front Replacer Set

Check condition of dust

is cracked

cover

If

liJ Tightening torque

Bell joint socket to lower
arm

ST36720000 and

press

excessively

replace ball
recorn

joint
Lubricate ball joint with mended multi purpose grease
3 To

5 1 to 6 1

kg
to

37
in Bell
arm

to

44 ft Ibl lowel

lubricate

remove

plug and

joint socket
5 1 to 6 1

stall grease nipple

with tension rod

Pump grease slowly until old grease completely forced out After greasing reinstall plug
is
o

kg m

37
Bell

to

44 ft Ibl knuckle arm

joint to

Note

When a

high

pressure grease gun

Mrl
INSPECTION
Lower I
arm

used operate it
F

A669

Fig FA 37 Removing Wwer Am BuNUng

grease is injected grease does not

carefully so slowly and

DOme

that
new

5 5 to 10 0 kg m 140 to 72 ft Ibl
Lower
IIrm

bolt nut

out

from

3 9 to 5 0

kg m

clamp portion

28 to 36 ft Ibl Side lod ball knuckle

arm

joint to kg m lbl kg
m

3 0 to 7 0

INSTALLATION

122 Steering
and suspension order of removal

to

51 ft

knuckle erm to stlut

Repair

or

deformed cracked

replace lower or damaged

arm

if

Install lower ball joint in

arm

7 3 to 99

reverse

53 to 72 ft Ibl

FA

Front Axle

Front

Suspension
INSTALLAnON
Install suspension crossmember in
reverse

SUSPENSION CROSSMEMBER
REMOVAL
Remove lower
arm

order of removal

noting

the

following referring
to of this section

previous part
2

fj
to

Tightening torque

With

an

overhead hoist and lifting

Suspension

member to

cable
remove

support

weighi

of engine

loads from mountings

Remove

Separate from engine

4

engine mounting nuts crossmember suspension

arrow

n
FA732

boiIy fIe me

3 2

to

4 3

kltm
to

23 to 31 ft lb

Engine mounting insulator

suspension member
3 2 to 4 3

Remove bolt indicated by

Fig FA 40 Removing SUlpemion Croumember

m ka

and separate suspension crossmember from car body

23 to 31 ft b

INSPECTION Check suspension crossmember for evidence of deformation or cracking if

necessary

replace

FA 12

Front Axle

Front

Suspension

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS
COIL SPRING Models

equipped
x

with air

Models not
air 5 10
x

equipped
375
x

with

conditioning
Dimension A
x

conditioning
x

10 8

100
x

375
x

100
x

0 425

3 94 4 92

1476

0 413 162

3 94

1476

Spring

constant

kg

mm

Ib

in

1 65

90 7

AxCxL Wire diameter

mm

in

Coil diameter

mm

in

Free

length

mm

in

STRUT ASSEMBLY Shock absorber type

Piston rod diameter
mm mm nun

Double acting hydraulic

in
in in

20 0 79
30 18 1

Piston diameter Stroke

164

46 6

Damping force

at

3 0

10 ft

sec

Expansion

kg Ib kg Ib

30 to 40 66 17 to 23

to

88

37 to 51

Compression

STABILIZER BAR
Bar diameter
mm

in

20 0 79 Red

Identification mark

INSPECTION AND ADJUSTMENT

WHEEL ALIGNMENT Camber Caster

Unladen

1 0 to 1030

degree degree

j040

to

3010 2

1055 t9 3025

Toe in

mm

in

I to 3 0 04 to 0 12

degree

6 30

to

13

Kingpin

inclination

degree

70 SO to 9020

Turning angle of front wheel

Inside Outside
I 2

degree degree Spare

tire

380

to

420 i0 35

31 io to

Tankful of fuel radiator coolant and engine oil For

jack hand tool and mats

in

designed position

Wagon only

FA 13

Frpn
WHEEL
Wheel Wheel

Axle

Front

Suspension

BEARING
axial play
nut
mm

bearing bearing

in

0 0

tightening
kg
m

torque
Return

ft lb

3 0 to 900

5 22 to 25 3

angle

degree

Rotation starting torque With new grease seal With used grease seal
At wheel hub bolt

kg

cm em

in

lbr

Less than 7 0
1 0 to 5 4

1 6

kg

in Ib

0 9 to 3 9

With

new

grease seal

kg lb lb kg

With used grease seal

Less

than 1 2

2 6

1 7 to 0 79 0

37 0

to 1 74

SUSPENSIONBA
Turning torque
New parts Used parts

JOINT

cm kg cm kg

in Ib in Ib

40 to 100 35 to 87 More than 20 17

TIGHTENIN

TORQUE
kg
arm m

L JOINT LOWERBAl
Ball

ft Ib

joint socket to

lower
arm

1 to 5

1 37 to 44 6

Ball joint to knuckle

Stud nut

5 to 10 0 40 to 72

STRUT

Steering knuckle
Strut to

arm

to strut

3 to 9 9 53 to 72 7 5 to 2 6 0 to
5 3

hoodledge

18

to 25

Piston rod self locking nut Gland packing

5 43 to 54 7

8 0 to 11 0 58 to 80

DISC BRAKE
Rotor
to

hub

3 9 to

3 5

28 to 38

SIDE ROD
Side rod ball jOIDt to knuckle
arm

3 0 to 7 0 22 to 51

LOWER ARM
Lower
arm

bolt

nut nut

3 9 to 5 0 2810 36 8 0 to 10 0 58 to 72

Side rod

adjusting

TENSION ROD
Tension rod

bushing

installation nut

5 to 4
1 to 5 3 2 to

1 33 to 37 5 1 37 to 44 6 3 23 to 31 4

Tension rod to lower arm Tension rod bracket to

body

FA 14

Front Axle
STABILIZER BAR

Front

Suspension

Stabilizer bar bracket Stabilizer bar connecting rod SUSPENSION CROSSMEMBER

16 to 16 to

1 2 1 2

12 12

to 15 to 15

Suspension member to body frame Engine mounting insulator to suspension member

2 to 3 3 2 to

3 23 4
3 4

to

31 31

23 to

FA 15

Front Axle

Front

Suspension

TROUBLE DIAGNOSES AND CORRECTIONS

Condition
shock and Proba bIe ca use

Corrective action

Vibration wheel

shimmy of steering

Improper

tire pressure

Adjust
Correct ap 9f
r

Imbalance and deformation of road wheel

the

imbal
e

B4I

Vibration Loose connection of the serration parts and wear of each part of linkage cause vibration of front wheels and steering wheel vibration This is very noticeable when trav
road

Unevenly

worn

tire

or

insufficient

tight

Replace
Adjust

or

tighten

ening of wheel

nuts
or worn

elling on rough
Shock
on

Improperly adjusted bearing

front

wheel

or

tighten

Faulty wheel alignment

When the front wheels

Adjust Replace
gear hous

bumpy roads

travelling the play of the steering

are

Worn transverse link

bushings

linkage
This is
on

is transmitted to the

steering wheel

Insufficiently tightened steering ing

Wear of steering linkage Worn suspension ball joint Excessive backlash due
ment of the
to

Retighten

especially
road

noticeable when travelling

rough

Replace faulty parts Replace improper adjust Adjust correctly

Shimmy

Abnormal vibration of the front

suspension system linkage which occu

nd the whole steering

at

specific speeds

steering
arm

gear box

Damaged idler
Worn

Replace
weakened column

column

bearing
or

Replace

or

retighten retighten

bearing spring

loose drmp

Malfucntion of shock absorber inside the

strut
or

Replace
Correct
ance

or

loose install3t
e

on

b9

t5

Imbalance of car l

the

imbal

Car

pulls

to

right

or

left

When

wheel on
to

driving with hands off the steering a flat road the car gently swerves
or

Improper tire pressure ening of wheel nuts

Difference in
tire treads
wear

or

insufficient tight

Adjust

or

tighten

and tear of right and left

Replace Adjust

tires

right
the
see

left
rear

Note

A faulty
cause

of this

suspension may also be problem and therefore

Incorrect

adjustment
or

or

abrasion of front

or

replace

wheel bearing

ebo Section RA

Collapsed

twisted front spring

Replace
Adjust

Incorrect wheel alignment Incorrect brake Worn rubber

adjustment binding
for transverse link

Adjust
Replace

bushings

and tension rod Deformed

steering linkage and

transverse

Replace

link and tension rod Imbalance of

car level

Correct
ance

the

imbal

FA 16

Front Axle

Front

Suspension

Condition
of

Probable cause

Corrective action

Instability

car

Improper

tire pressure

Adjust
transverse link and

Worn rubber tension rod

bushings for alignment

Replace Adjust

Incorrect wheel Worn

or

deformed

steering

linkage and

Replace Adjust
Correct
or

suspension link
Incorrect

adjustment of steering
or

gear

Deformed

unbala 1ced

wheel

replace

Stiff steering wheel

Improper

tire

pressure
or or

Adjust
mixing impurities excessively worn Replenish grease replace the part
or

Checking
Jack
gear

up

procedure
detach the steering

Insufficient lubricants
in

steering gear box

up front wheels
arm

steering linkage
Stiff
or

and operate the steering wheel

and If it
is light check steering linkage and suspension parts If it is heavy check steering gear and

damaged suspension ban joint

or

Replace Replace Repalce adjust

lack of grease
Worn
or

incorrectly adjusted wheel bearing

or

Worn or

damaged steering gear

and bearing

steering column parts

Incorrectly adjusted steering

Deformed steering linkage
Incorrect wheel

gear

Adjust
Replace Adjust Replace Replace

alignment

Damaged

strut

mounting bearing
or

Damaged or stiff piston piston rod in the strut signal switch

Excessive steering wheel

shock absorber

Interference of steering column with turn

Adjust

play

Incorrectly adjusted steering

Worn

gear

housing

Adjust
Replace Retighten

steering linkage
fitted gear housing

Improperly

Incorrectly adjusted wheel bearing

Worn
transverse link

Adjust
rod

and

tension

Replace

bushings
Noises

Improper

tire pressure

Adjust Replenish
or

Insufficient lubricating oil and grease for suspension ball joint and steering linkage or their breakage
Loose

lubri

cating oil and grease replace

steering pension parts

gear bolts

linkage and

sus

Retighten

Faulty shock absorber inside the Faulty wheel bearing

Worn

strut

Replace Replace

steering linkage
transverse

and steering gear and

tension rod

Replace

Worn

link

Replace Replace

bushings
Broken or

collapsed

coil spring

FA 17

Front Axle

Front

Suspension

Condition

Probable cause

Corrective action

Loose stabilizer bar

nuts

installation bolts and

Retighten

Loose strut

to

hoodledge installation

nuts

Retighten

Grating

tire noise

Improper

tire pressure

Adjust Adjust
and suspension

Incorrect wheel alignment Deformed knuckle

spindle

Replace

linkage

Jumping

of disc wheel

Improper

tire pressure

Adjust

Imbalanced wheels

Adjust Replace Replace Replace Adjust Adjust Replace Adjust

Rotate
tires at
re

Faulty shock absorber Faulty

tire

Deformed wheel rim

Ex

J1 or

partially

worn tire

Improper

tire pressure

Incorrect wheel

alignment

Faulty wheel bearing

Incorrect brake

adjustment

Tires not rotated

commended vaIs

inter

Rough and improper driving

manner

Drive

more

gently

FA 18

Front Axle

Front

Suspension

SPECIAL SERVICE TOOLS

Kent Moore No Reference
Kent Moore No

Tool number

tool name

Tool number

tool

name

page or
Fig No

Reference page or

Fig

No

CD @ ID

S13532 I 000 S135322000 ST35325000

Front wheel
Inner

bearing bearing

drift drift

S135500001

G land

packing

wrench

J 25825

Front wheel Outer Drift bar

Page FA 5

Fig FA 20 Fig FA 25

GJ

KV40 I0 1900

Gland

packing guide
Fig FA 24

CI
KV48 100300 Strut and steering gear housing attachment J 25729 HT72520000

ilalljoinl

remover

Fig

FA 18

Page

FA IO

Fig FA 20

8 PageFA
Page FA 9

ST3565S001

Coil spring compressor set Coil spring compressor

S136720000

Transverse link

bushing

J 25847

CD @

ST35651001 S135652000
I

replacer

set

Clamp

Fig Fig

FA IS FA 27

Fig

FA 37

Fig FA 19

Fig F A 39

t9

11

FA 19

DATSUN 210

Model 8310 Series

SECTIONRA
REAR AXLE
REAR SUSPENSION
CONTENTS
LINK TYPE
REAR AXLE REAR AXLE REAR AXLE WHEEL ASSEMBLY SHAFT AND RA RA RA RA RA RA 4 5 5 5 6 6 RA RA RA 2 3 3

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT RA RA RA RA RA RA 8 8 8 8 8 9

BEARING CASE

SHOCK ABSORBER REAR AXLE TIGHTENING TORQUE

REAR AXLE

REAR SUSPENSION

SHOCK ABSORBER
COIL SPRING LI N K ASSEMBLY

TROUBLE

DIAGNOSES AND CORRECTIONS SPECIAL SERVICE TOOLS

RA lO RA ll

Rear Axle

Rear

Suspension

LINK TYPE

789

I
Gl

@CJe o
@

y
fI

1
12 13 14 1S 16
17

I
@
Shock absorber lower end bolt Shock absorber assembly 23 24 2S 26 27

Rear axle case Drain plug

Filler

2 3
4

Upper IinIt
Lower IinIt bUWDS bolt Lower link bushing Lower link

plug

Special washer
Shock absorber mounting bushing A Shock absorber mounting bushing B Bound bumper Bound bum
cover

5 6
7

Breather cap Breather Rear axle

case

Torque

arrester
m

end shim

Bearing
Oil seal

collar

18 19

rubber

Tightening torque kg

ft tb

8 9 10 11

Rear a le beariJ g wh elb Bearing spacer Rear axle shaft

ing

20 21 22

Shock absorbe c mounting insulator Coil spring

@ @

6 0 tu 10 7 0 to S O

43 to 72

Upper link bushing boIt Upper Iinkbu hing

@ @

51 to 58 1 to 2 0 11 to 14 5 7 0 to 8 0 51 to 58

RA543

Fig RA l Reo Axle ond Su pe1l8ion

A mbly

RA 2

Rear Axle

Rear
bolts

Suspension
shock

REAR AXLE
REAR AXLE ASSEMBLY Remove L
2

Remove

securing
on

absorber lower ends

each side

Block front wheels with chocks

Raise
rear

of

car

high enough

to

pennit working underneath and place stands solidly under body member
on

both sides Fig RA 7 Disconnecting Upper Link

RA485

and Lower Link

Fig RA 4 Removing Bolt Securing

Shock Absorber Lower End II

Release garage

jack slowly

and

pull
Note When

it out toward rear of car

removing shock absorber

from bracket and lift squeeze
it out
em

lower end

shock

absorber

right

above to accommodate

bossment inside bracket

RA544 C

In tenetlon Install
rear

axle in the

reverse

order

of removal Fig RA 2 Supporting Point

CAUTION
3

Support

under
a

center

of dif

ferential carrier with

4

garage jack Remove rear wheels Disconnect

When Flare

installing
Nut

brake

tubes

use

Torque

Wrench

GG94310000
b Before

by re moving bolts CD securing propeller shaft flange to companion flange of

propeller

shaft

tightening link bushing nuts temporarily attach upper and lower links to axle case Alter jacking up
center of differential carrier until

differential carrier 6 Disconnect tube

at

AA486

brake

hose

from
rear

brake cable

body

and

Fig RA 5 Shock Absorber Lower End

upper Bnd lower links are almost horizontal securely tighten link

adjuster @
8
Lower

bushing
jack slowly and
remove c

nuts

When
Clnter

supporting
load in
car

car

weight

at

cojI springs on each side after they are fully extended

of differential carrier do not

put

Tightening torque
Brake tube flare nut 1 5 to 1 8

kg

11 to 13 ft lb

Fig RA 3 Removing Propeller Shaft

and Brohe Hose

Propeller shaft to companion flange connecting nut 2 4 to 3 3 kg m

17 to 24 ft Ibl

Shock absorber lower end

7 0 to 8 0

nut

kg

CAUTION
e

AA546

51 to 58 ft Ibl lower link

When
use use

disconnecting
or

brake

tube Never 9 10

Fig RA 6 Removing Coil Spring Raise

suitable tube

wrench

7 0 to 8 0

fixing nut kg m

b Cover

ings

open to prevent entrance of dirt

open end adjustable brake hose end pipe

wrench

jack

to its

original position

51 to 58 ft Ib

Remove bolts

CD

and

se

Upper link fixing nut

7 0 to 8 0

curing upper and lower links at axle case side

RA 3

kg m

51 to 58 ft lb

Rear Axle
REAR AXLE SHAFT AND WHEn

Rea

Suspension
L

Check axle shaft for

sttaightness
for

BEARING

cracks damage wear or distortion 2 Check the lip of oil seal

Removal end disassembly

1 2

damage
3 age

deformation or wear
wear or

mock front wheels with chocks Raise

rear

Check bearing for

dam

of

car

and support

under axle case on stands

3
4

Remove

rear wheel

Ass mbl

end Instelletl

Pull off spring CD and discon nect brake cable from lever by re

Assemble and install in the

RA549

reverse

moving clevis pin

5 Disconnect brake disc

@
brake tube
at
rear

order

Fig RA lO Removing Shaft 9

ReAxle Aembly

disassembly and removal noting the following points bearing spacer bearing and bearing collar onto axle shaft and press bearing collar by specified load 3 to 5 tons using Rear Axle Shaft Bear
new

of

Install

Remove oil seal if necessary and

one

install new 10

Cut collar with cold chisel

ing Collar Press Stand S138210000

Note
e

New collar must be used end clean collar and we shaft

b Insert wbeel

bearing

with seaI side

facing

bnke disc

@
Fig
8 RA

CD
RA547

Removing Broke Port

I
Fig
RA II

Cutting Bearing Collar

CAUTION
e

Whim
use use

disconnecting

brake

tube Never

8
RA157

suitBble tube wrench

CAUTION
Take
care

or open end adjustabla wrench b Cover brake hose and pipe open ings to prevent entrance of dirt

not to

with cold chisel during

damage axle operation

shaft

Fig
2

RA 13

ling l1l1ta

Wheel Bearing

II 6 7 disc brake drum Re TIove Remove four nuts securing brake

Remove wheel

bearing and col

lar using Rear Axle Shaft Bearing Puller Hf72480000 Then take out brake disc

Install oil seal using Rear Axle Oil Pack cavity between

Seal Drift KV40100300 3

sealing lips

back plate

from

rear

axle

case

of oil seal with recommended multi

purpose grease 4

When
case

inserting
use

axle shaft

into

axle

Rear Axle Shaft Guide

1
RA548

ST37840000 not to

damage

the seal

ing lips

ofoil seal
case

To insert axle shaft into axle

proceed as follows
I Install Rear
on

Axle Shaft Guide

case

ST37840000 2
A
RA492

we

Fig

RA 9

Removing

Null

guide when the distance between axle flange and bearing is

2 76 to

Remove

Fig
8 Draw
out

RA 12 Removing Wheel Bearing

70 to 90 mm

54 3

in

See

Fig

RA 14 grease to of the rear we

axle shaft

assembly

together with brake disc using Rear Axle Stand KV401 01000 and Sliding
Hammer ST36230000

Inspection

Note and

Apply

purpose multi

Inspect the following parts replace as required

4 RA

the outer shaft

periphery bearing collar

Rear Axle

Rear

Suspension
Shaft and Wheel

Bearing for removal

axle assemblies
for

and

remove

rear

CD

Refer

to

Rear

Axle

Assembly

removal

177t
ID @
5

t
I
A

4
1 Rear axle Rear axle Rear axle

Remove differential carrier assem

rear

2 3
4

shaft shaft guide

case

bly from
5 cable

axle case

Remove

brake

tube

and

rear

Oil seal
70 2
to 90 mm 76 to 3 54 in

ill

Inspection
Check axle
case

A A560

tion or cracks and

yield deforma replace if necessary

for

Fig RA 14 Installing Rear Axle Slwft Installetion Install axle

recess case

Adjust
rear

of

c gap axle tube and

between
rear axle

in the reverse order

bearing

of removal
Note

by selecting shinto Gap

e mm

Change oil seal and gasket

ove

at

each
0 to 0 004 in

haul

o to 0 1

Gap
c

c a a

can

be calculated d

by
rear

ifl Tightening tOlque

Differential carrier fixing

where

Distance

from

axle

bolt 1 6 to 2 4
R

tube end to b
c

recess

kg

Bearing width Gap c

Shint thickness

550

12 to 17 ft lbl Oil drain and filler 6 0 to 10 0

Fig RA 16 Measuring End Play

plug
m

kg

43 to 72 ft lbl

CAUTION
When Nul

Blake connector 0 8 to 1 1

installing brake 1ubes use Flare Torque Wrench GG94310000

fixing kg m

bolt

5 8 to 8 0 ft Ibl

ifl

Tightening torque
Brake disc fixing nut 1 5 to 2 0

REAR SUSPENSION
SHOCK ABSORBER Removal
1 Remove nuts
secu

kg

11 to 14 ft lb
RA559

Brake tube flare nut 1 5 to 1 8 kg

m

Fig RA 15 Gap

11 to 13 ft lb Wheel nut

ng

shock

absorber

upper end

to

wheel house

Rear axle case end shim Thickness

mm

8 0 to 10

kg m

paneL

58 to 72 ft lb

in

om5 0 0030
1 50 0 0059 0

REAR AXLE CASE

0 225 0 0089
300 0

0 0118

Remove
I Raise

Measure axial

end

play of

axle

support
sides

shaft with dial indicator

Axial end

of car and securely body member on both Refer to Rear Axle Assembly
rear

under

for removal
2

plav
mm

Drain differential gear oil Remove

rear

RA551

0 10 to 0 45

3
on

axle shaft assemblies Axle

Fig RA 17 Shock Absorber Upper

End Sedan

0 0039 to 0 0177 in

both sides

Refer to Rear
RA 5

Rear Axle

Rear

Suspension
Inspection
1

@ Tightening tonlU1l
Shock absorber upper end nut 1 5 to 2 0 kg m 11 to 14 ft b

mation

Check coil spring for yield defor or cracks

2
and

Test

Shock absorber lower end n1t

7 0 to 8 0 lm k 51 to 58 ft bl

spring and compare with

in Service Data

specifications given
Specifications
3

cracks I
AA552 I

Check all rubber parts for wear damage or deformation Re

CAUTION
Be careful not to
RA 18 Shock A bllOrber

place if necessary

Fig

Upper
End

piston

rod

damage or bend during operation

InsteDatlon Install coil spring in the

reverse

sorber lower end and absorber Note

Remove bolt securing shock ab remove shock

b Do not open or heat gas filled type shock absorbers

order ofremoval

COIL SPRING

CAUTION

When removing shock ebsorber

Iueeze

Correctly
Removal
Block front wheels with chocks
2 Raise rear of car

fit open end

on

spring

seat

lower end from bracket

to accommodate

shock absorber end lift it out right

CD
to

Tightening torque
Shock absorber lowel end nut 7 010 8 0

aJ

J o

ss emb

high enough
and

ment inside bracket

permit working
stands

underneath under

place

kg

solidly

body member
center

51 to 58 ft b

on

both sides

3
4 5

Support
Remove

under

of dif

LINK ASSEMBLY Removal

It is possible to remove one link assembly alone When removing more

ferential carrier with a garage

rear

jack
shock

wheels

Remove

bolts

securing
on each

absorber lower ends

side

than two link assemblies

remove

axle

assembly Assembly

first

Refer

to

Rear Axle

for removal

RA486

J C

Remove upper link or lower link alone by removing bolt on each

end

Fig

RA 19 Shock Absorber Lower End Brocket

Inspection
I

with Data
nece

Test shock absorber and compare specification given in Service and

ry

I
Shock

v 1 JJJ
jack slowly
on

RA485

Fig RA 20 RemoviTIII Bolt Securing

Specifications

Replace if
6

Abwrber Lower End

and
remove

Check for cracks Also check pis

Lower

ton rod for

straightness
wear
or

coil springs
are

each side after they Fig RA 22 Removing Upper Link

Check all rubber parts for

fully extended

cracks

damage

deformation

Re

place

if necessary

Installation
Install shock absorber in the order of removal
reverse

Note

Tighten

end nut to

shock absorber upper specification until it is

to thread end of pis

fully tightened
ton rod
nut

Then securely

tighten

lock

RA546

RA553

Fig RA 21 Removing Coil Spring

Fig

RA 23

Remouing

Lower Link

RA 6

Rear Axle Inspection

Check for signs of cracks distor tion or other damage Replace if
I to rubber

Rear

Suspension
surface Instellation Install upper
or

bushing inserting

oflink

lower link assembly

in reverse order of removal

beyond repair
2

of cracks

If rubber bushing shows evidence replace it using Link Rubber Drift KV4010l6S0 See Fig

Note

CAUTION
a

Bushing
RA 24

00 not tap end face of bushing directly with a hammer as deforma tion may result in loose bolt When installing rubber bushing link never
on

Securing bolts for use with lower link differ in length from those
for
upper

link

If used

wrong

Note
on

Before instelling rubber bushing link apply

an

ample

amount of

securing bolts securely

b

cannot be

tightened

apply

mineral oil

Before

soapsuds
Removal

to link

bushing guide and

tightening

and nuts

link bushing bolts temporarily attach both

ends of upper and lower links to axle case and body After jacking

1 1 j
KV401016S0

up

center upper

of

differential lower

carrier
are

until

and

links

KV40101610

almost horizontal link

c

securely tighten
a

bushing

bolts

nuts

When

supporting
a

car

weight
carrier

at do

center of Lower link KV40101440 KV40101430

differential
car

upper

not

put

load in

link

Tightening
nut

torque

14
Installation
KV401016S0 KV4010161O

l t4

Upper link fixing bolt and

7 0 to 8 0 5t
0

kg

58 ft lbl

Lower link

7 0 to 8 0

fixing nut kg m

51 to 58 ft lbl

KV40101620

KV40101630
KV40101440

r
upper
link

KV40101430

h
RA572

Fig RA 24 Replacing Link Rubber

B hing

RA 7

ear

Axl

r Re

Suspen sion

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS
Model Sedan Hatchback
Item

I
Link
54 3

Wagon

Type
Coil spring Wire diameter Coil diameter Free length Effective turns
mm

in in in

102 OA02 90 365 37 14 8 75 71 1 95 8

5 OA 13 10

nun

nun

I
I I I I I

379

14 92

Spring

constant

kg mm

Ib in

L91 I07 0 Yellow 540 2126 187 5 738

Identification color Shock absorber Maximum length Stroke

L
mm

in in

nun

nDU
L

AA504

Shock absorber maximum length

INSPECTION AND ADJUSTMENT

SHOCK ABSORBER Damping force
at 3 0
m

LO ft

Expansion Compression
REAR AXLE
End

lb kg
kg lb

48 to 68 19 to 33

I 06 to

150

42 to 73

play
mm

in mm
in

0 10 to 0 45 0 0039 to Om77 Q75 0

150 0 0 0030

Thickness of rear axle case end shim

0 0059

0 225 0 0089 0300 0 0118

B RA

Rear Axle

Rear

Suspension

TIGHTENING TORQUE
Brake tube connector flare nut
Brake disc

kg m ft Ib kg
m

5 to 1 8 II to 13 1 5 to 2 0 1

fixing nut

ft lb

II

to 14

PropelJer

shaft to companion
nut

flange
kg kg
m

connecting
Wheel nut

ft tb ft lb ft Ib ft lb ft lb ft lb ft lb ft lb ft Ib

2 4 to 3 3 17 to 24 8 0 to 10 0 58 to 72

Drain and filler

ptug
case

kg
bolt

6 0 to 10 0 43 to 72
1 6 to

Differential carrier to axle

kg kg kg kg kg kg

4 12 2

to to

17

Shock absorber upper end nut Shock absorber lower end nut

5 to 2 0 1 7 0 to 8 0 7 0t08 0

II

14

51 to 58 51 to 58

Upper link fixing bolt Upper link fixing

Lower link
nut nut

m
m

7 0 to 8 0 51 to 58
7 0 to 8 0

fixing

51

to

58

RA 9

Rear Axle

Rear

Suspension

TROUBLE DIAGNOSES AND CORRECTIONS

When
rear

axle and suspension is

it is advis

propeller shaft
universal

engine
wheel

transmission

ment or
rear axle

suspected
able
mine
to

of being noisy

joint
which

bearings

or

replacement of parts and rear suspension

or

in the

make

thorough
the

test to deter

suspension
Noise

In case

of oil leak first check if

restriction in

whether

noise

originates
exhaust

originates

in other

there is any damage breather

in the

tir

roads rfac

places

cannot be corrected

by adjust

Condition

Probable Loose wheel nuts One

or more

cause

Corrective action

Noise unusual sound

Tighten Tighten
to

securing bolts loose

or

specified

torque

Lack oflubricating oil

grease

Lubricate

as

required

Faulty shock absorber

Incorrect

Replace
of
rear

adjustment

axle shaft end

Adjust

play

Damaged

or worn wheel

bearing

Replace Replace Replace

if necessary

Worn spline portion of rear axle shaft

Breakage of leaf spring

ose

journal

connections

etc

Tighten to torque
Balance

Unbalance ofwheel and tire

Damage
bU hing ing

of the rubber parts such as link shock absorber moun ting bush

Replace damaged parts

Faulty universal joints

Adjust

or

replace

Breakage

of coil spring

Replace

Instability
This

in

driving
is also

Loose wheel nuts

Tighten
rubber bushings

to

specified torque

problem

Damaged

rear link

Replace

related to the front

suspension

For trouble to

Worn shock absorber Incorrect wheel alignment

Replace
Adjust

diagnosis also refer

the FA section

Spring

wear

Replace

Oil

leakage

Damaged oil seal

Oil

on rear

axle shaft

Replace

leakage

from the differential carrier

Replace parts as required

Replace

Damaged grease seal of rear axle shaft

RA l0

Rear Axle

Rear

Suspension

SPECIAL SERVICE TOOLS

Kent Moore No

Kent Moore No

Tool number

tool name

Reference page or

Tool number

tool

name

Reference
page
or

Fig

No

Fig No

KV40101000

Rear axle stand

J 2560401

ST37840000

Rear axle shaft

guide Page
4 RA

Fig

RA 1O

ST36230000

Sliding hammer

J 25840

KV40l016S0

Link rubber

bushing
guide guide

drift

Fig RA 1O

esPY
HT72480000 Rear axle shaft bearing

CD KV40 10 I 610 Adapter V KV40101620 Link bushing ID KV4010l630 Link bushing @ KV40101430 Base KV4010144 Ring CID

Fig

RA 24

puller

Fig

RA 12

ST38210000

Wheel bearing collar press stand

GG943 1 0000

Flare nut torque wrench

Fig RA

13

Page RA Page RA

3 5

KV 401 00300

Rear axle oil seal drift

J 25729

Page

4 RA

RA ll

DATSUN 2 0

Model 83 0 Series

SECTIONBR
BRAKE SYSTEM
CONTENTS
ADJUSTMENT
BRAKE PEDAL

BR BR BR BR
BR BR BR BR

2 2 2 2 2 2 3 3 4 5 5 6 6

ROTOR
REAR BRAKE BRAKE BOOSTER

BR

BR l0 BR 12 BR 14

FRONT DISC BRAKE

REAR

BRAKE

HAND BRAKE

HAND BRAKE

BLEEDING HYDRAULIC SYSTEM

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT TIGHTENING TORQUE

BR 16 BR 16 BR 17 BR 18

SERVICE BRAKE
BRAKE MASTER PEDAL

CYLINDER

BR BR
BR BR BR

BRAKE FLUID LEVEL GAUGE BRAKE LINE

NP VALVE

TROUBLE DIAGNOSES AND CORRECTIONS SPECIAL SERVICE TOOL

8R 19 8R 22

FRONT DISC BRAKE

Brake

System

ADJUSTMENT

BRAKE PEDAL

With brake booster

Adjustment
normal

is not necessary under

conditions

Check pedal free

play
tion

If it exceeds the above

specifica
refer
to re

adjust push

rod

length

brake booster for adjustment moving master cylinder rerer

ter

by
to

f
BAQ05A

Mas Fig BR 2 Adjusting Hand Brake Then tighten lock nut securely After returning hand brake lever
that
rear

Cylinder
After

for removal

3
a

adjustment
it

is

completed
to its entire 3

depress brake pedal several times

ensure

that

travels

over

stroke noise

smoothly

without

squeaking
d

con

twisting
more

or

interference

trol

to

its

original position toggle

levers return

Pedal

deprd Might
than 70 mm

ensure e

2 76 in

All

brake

to their

original positions
are

Rear cables

not slack

FRONT DISC BRAKE

Front disc brake does
a

not

require

Fr

play height Depressed height

Free m Icg

HAND BRAKE WARNING LAMP SWITCH

Bend switch hand brake

adjustment
since ft tb
rod lock nut

under normal conditions

to rotor clearance is auto

Tightening torque

pad malically adjusted by piston seal

warning lamp

elasticity

of

plate down so that brake warn ing light comes on when ratchet at
hand brake lever is moved back one notch and goes out when returned to

@ @

Push

rod

or

operating

1 6 to 2

2 12 to 16

Brake lainp switch lock nut 2 to I 1 5 9 to 11

BR121A

REAR BRAKE
Auto edJuster type
is not necessary under normal conditions since brake drum

its

original position

Fig BR 1 Adjusting Broke Pedal

Adjustment

t shoe

clearance for by

is

Adjust pedal height h to the specifications by moving brake lamp

I switch and

compensated
brake

automatically operating hand

BLEEDING HYDRAULIC SYSTEM

Hydraulic brake system must be bled whenever any line has been dis connected or air has in some way
entered system
action is an indica

operating
h

rod if

equipped

Wlien brake drum to shoe clearance

is correct is not

with brake booster

Pedal

operating
even

noise of

adjuster

heard

if hand brake is

height

operated
mm

Spongy

pedal

143 to 149

tion that air has entered brake

5 63 to 5 87

inl

system Bleeding hydraulic system deserves

as

HAND BRAKE
I

much attention element in hand brake

that is

it

is

an

essential

regular

brake

servicing
reservoir cap

Adjust
Turn

rear

brake shoe to drum

Clean all dirt around master cyl inder reservoir

remove

clearance before Then

secure

adjusting
so

brake lamp switch and

2 hand

turnbuckle control force

when

operating rod

brake

lever lever
as

pulled
or

l C

by specified

stroke

and top up reservoir with recommend edbrake fluid

Note Do not mix two different brand

Tightening tOlque
Blake lamp witch lock nut 1 2 to 1 5

number of notches is

follows
44 Ib

oils

kg

Pulling

fOil

20

kg

9 to 11 ft lb

lever stroke

2
mm

Thoroughly

clean mud
so

or

dust

Operating

lad lock nut

m

93 to 106

from bleeder valve

is free from

that outlet hole

a

1 6 to 2 2 kg

3 66 to 4 17 in Numbel of notches
7 to 8

foreign particles Install

on

12 to 16 ft b

bleeder hose

bleeder valve

BR 2

Brake
Dip
3
other end of hose into brake

System
brake fluid drained
7
no

b Do not

reuse

Repeat bleeding operations

air bubbles show in hose

until

fluid bled in a container

Pepress brake pedal two or three and then keep pedal fully de pressed 4 With brake pedal fully depressed
times open bleeder valve to exhaust air

during bleeding operation Bleed air in the following sequence

Master

cylinder

Rear

wheel

Note
a

front wheel
d

Brake fluid

containing

air is white
air rons
a

Be careful not to
on

splash
valve

brake fluid

and contalns air bubbles b Brake fluid containing

out
no

painted

areas

of bleeder valve in

solid

Note
a

Close

bleeder

quickly

as

stream free of air bubbles

Carefully monitor brake fluid level at master cylinder during bleeding operation

brake pedal is on down stroke 6 Allow brake pedal to return slow

Repeat steps above

on

remaining

ly

with bleeder screw closed

brake line to expel air

SERVI CE BRAKE
INSTALLATION
fJ
brake pedal following the procedure of removal paying attention to the following items I Apply coating of recommended
reverse

BRAKE PEDAL
REMOVAL

Install

L
fl @

multi purpose grease to

sliding portion

and return coil spring

l
II
I

JJ

ff

m f
1 2
Brake

I II

lamp

switch

Lock nut
Fulcrum Brake

pin push rod Snap pin

Bolt E ring

or

operating rod
BA113A

Fit
kg
m

BR 4 Lubricating Point

s1

Tightening torque

ft Ib

Be

sure to

@
@

16 to 2 2 2 to 1

12 10 16

install E ring and bolt

S 9 to II l
BROS8A

securely
3

Insert CleviS pin brake

through

brake

Fig

BR 3 Broke Pedal

pedal 4 Adjust
tion
ment

pedal

after installa

Refer to Blake Pedal for

adjust

Remove snap pin installed at the

end of clevis

pin Draw out clevis pin and separate push rod or operating rod from brake pedal
2 Remove bolt and E

INSPEctioN
Check brake pedal for the
items I

j
following

Tightening torque Push rod or op8leting rod

lock nut 1 6 to 2 2

servicing

as

necessary

kltm

ring securing

Check brake

pedal

for bend

12 to 16 ft Ibl

fulcrum pin and draw out fulcrum pin Then brake

2
3

Check return springs for

fatigue

pedal

can

be taken out

Check clevis for deformation and

Brake lamp switch lock nut 1 2 to 1 5 kltin 9 to 11 ft lb

along with

return coil

spring

crack at welded part

BR 3

Brake

System

MAstER CYLINDER

Reservoir cap
Filter

2
3 4 5

Stopper ring Stopper Crew Stopper

Primary piston

6
7

8
9

Tightening torque

kg

ft Ib

10 11

Primary piston return spring Secondary piston Secondary piston return spring Plug
Check

@ @

8 0 to

9 0
09

0 7

to

581065 5 1 to 6 5

valve

12

Reservoir

BR009A

Fig BR 5 Ma

ler

Cylinder

Made by Tokico

1
2

Re

rvoir cap

Filter

3
4 5 6 7

Stopper ring Stopper screw Stopper Primary piston Primary pinon return spring Secondary piston Secondary piston return spring Plug
Check valve

8 9

Tightening torque

kg
l

ft Ib

10
11

@ @

5 to 3 5 18 10 25
o

0 15 00 3

2 2

12

Reservoir

BA010A

Fill BR 6 Master Cylinder Made by Nabco

4 BR
I

Brake
REMOVAL
I

System

Disconnect wiring to brake fluid Disconnect front and brake

CAUTION
Use brake fluid to clean Never
use

CAUTION When Flare

level gauge 2
rear

installing
Nut

brake

tubes

use

mineral oil

Torque

Wrench

tubes from master cylinder Check cylinder and pistons for evidence of abnonnal wear or damage
I
use

6694310000

CAUTION
When Never wrench

removing
use

brake end

tubes

CiJ Tightening
nut

torque

suitable tube wrench open

or

edjustllble

Replace if found faulty 2 Check piston cylinder to

ance

Brake master cylinder

securing

clear value

If it exceeds the
either

specified
cylinder

0 8 to t 1

kg m
nut
m

replace
When be
receive

piston

or

5 8 to 8 0 ft lb

Piston to

cylinder

clearance 0 0059 in

Brake tube flare

1 5 to 1 8

Note
to

disconnecting
sure

brake
3

less than 0 15 mm

kg

tubes

to

use a

container

Check
or

draining brake fluid Use of raga is also suggested to keep adjacent perts and area
clean

fatigue
sary 4

springs damage Replace if

master

for

weakness
neces

11 to 13 ft b

When

cylinder

is

disas

sembled
valves 3 Remove master

be sure to discard caps and any other

Replace

cylinder securing
can

parts which

BRAKE FLUID LEVEL GAUGE

Inspection
I

show evidence of deformation wear or

nut Master out

cylinder

then be taken

other damage S

Replace damaged oil

reservoirs

Disengage
Raise cap

hand

brake

control

and caps

lever 2
hand and

make

sure

that
on

brake float

warning lamp goes

comes

DISASSEMBLY
1
2

ASSEMBLY Assemble master cylinder following the

reverse procedure of disassembly paying particular attention to the fol lowing note

when

into contact with

Remove
off

reservoir caps and filtern

stopper

and drain out brake fluid

Pry

stopper stopper

ring
screw

using

screwdriver

Remove

and take

BRAKE LINE
REMOVAL
I Remove flare nuts on both ends

out stopper

spring

and

primary piston assembly secondary piston assembly

Note
a

Replace gaskets
new ones

and packing with

in the order shown

b Note if they are reo moved from piston assemblies and

caps
use

Discard

rubber grease Apply to sliding contact surface of parts

or

brake fluid

and remove retainers and

clips

to

facilitate

assembly of

master

new ones c

CAUTION When hoses Never wrench

cylinder
to
to

Unscrew

pluga

check valve for

gain access disassembling

The brake master cylinder is avail able in both NABCO make and There is
no

removing
use use

brake end

tubes

and

suitable open

tube
or

wrench

adjustable

TOKICO make Note

a

inter

changeability
reservoir
tanks

of repair kits

or com

Never detach

If

ponent parts

between NABCO and

removed for any reason discard them and install new ones
are

they
Do

TOKlCO makes When replacing the repair kit or component parts ascertain the brand of the brake master cylinder

To

remove

brake hose

first

re

move flare nut

not

remove

or

disassemble

brake

securing brake tube to and hose withdraw lock spring

can

brake fluid level gauge

End of hose

then be removed from

body
same

Be

sure as

to

use

parts of
ones

the

bracket Next

remuve

brake hose Do

make

the fonner

not twist brake hose

INSPECTION Thoroughly
wear or

INSTALLATION
all

INSPECTION
Check brake lines tubes and hoses
or

clean

parts

in

Install the
reverse

suitable solvent and check them for

cylinder following procedure of removal

master

for evidence of cracks deterioration

other

damage Replace any part that

After system

installation

bleed

brake

damage

Replace

any

faulty

is

faulty

parts

BR 5

Brake
If

System NP VALVE
Front wheel cylinder

leakage
re

oCcurs
Of

at

end around
re

D Tightening torque t
Brake tube flare nut 1 5 to 1 8

joints tighten place faulty parts

if necessary

kg m
Front wheel

11 to 13 ft lb Brake hose connector Master cylinder front

jde

INSTALLATION Pay particular ing

lines
I Leave sulfident space between lines and adjacent parts so that
a are

1 7 to 2 0
to

kg

cylinder

attention

follow brake

112

to

14 ft lb

instructions when

installing

Jway connector bolt

0 8 to 1 1 kltm
5 8 to 8 0 ft Ib Rear wheel 6

brake

Upon completion

of installation
out

cylinder
Master cylinder
BR114A
rear

brake lines 2

completely free from vibration during driving

Be careful not to warp
or

of brake lines

bleed air

of brake

lines

side

twist

Fig

B BR

NP

Valve

brake lines

3
a

When installing brake tube keep

certain

distance between tube and

adjacent parts as follows

Tube to rotating parts 30 mm Tube to 10 1 18 in parts

FRONT DISC BRAKE

moving

mm

10 39 in

Tube to other palls 5

mm

10 20 in

Always
On
rear

fasten brake tubes with

axle

mounting clips where necessary

case
are

two to

double
secure

dips which should be used

brake

tubes in manner described be

low brake tube Bend short clip straight up With on long clip bend clip up

and around tube

Finally
to

wrap short the in

clip

around

tube

secure

slallation
9

ilJ

J
2

I 2

Bias s pring
Yoke

6
7

Boot

11 12 13
14

Piston A

3
4

Bleeder Piston seal Piston B

8 9 10

Retaining ring Clip

Yoke spring
Bias

Cylinder body Pad spring

Pad Pin
BR123A

ring

15

Fig
BA141

BR 9 Dic Broke

Fig

BR 7 Fastening Brake Tube Securely with Double Clip

PAD REPLACEMENT

Note

Check

to

ensure

that

pad

tighten brake line mount ing flare nut excessively

Do not

springs rebound easily

Removal 3
I

Jack up front of

CAUTION
When Fla
e

it on

safety

and support Remove wheel stands

car

Detach pads from caliper bly with pliers

assem

installing
Nut

brake

tubes

use

Remove

clips

and pull

out

pins

Torque

Wrench

extracting coil spring and by hand

pad springs

CAUTION
After brake

6694310000

removing pads do not depress pedal or piston will jump out

BR

INSTALLATION INSTRUCTIONS
Typical Glrllng
B ake Pad

SYIlem

Girling disc brakes are very similar to ATE disc brakes except that the piston seal does with the not pul the piston and brake pads away from the rotor In the Girling System the touches rotor i the the relaxeilposition pad just pistons
Ped Removal
1 2

Raise the car alid removiHire and wheel Girling disc brake pads ere held in piece either by a retainer plates or b retainer to be loosened pins Retainer plates are boiled to the caliper housing and need only must be anti raWe which of the models use springs and roteted out way Some ere installed The retainer pins are held in place by whenever new pads replaced the retainer hairpin type spring clips There are two types of breke pads used with end the other is drilled These padS ere definitely is for the One cut away pin pins
not interchengeable Remove the reteiner

3 4

Lift padS up and out of the celiper

Pad Installation

Attach a piece of hose to the bleeder screw and place the hose into a container down to the Open bleeder screw one turn and with even pressure push the pistons bores bottom of the This procedure makes 3 Tighten the bleeder screw and remove the piece o hose room for the added thickness of the new linings 4 the retainer and the anti rattle spring i used and tighten the bolts 1 2

caliper

Reposition pad or replace the retaining pins

Check to be sure you have a

and screw them with the high hard pedal then test the car

hairpin

Iips
of EMP

See

Instructions On

Back of Ball

For Correct

Usage

Gh11ng
aUon

dlac brall atalnln

pilla

III Ilmple to artlc Depending nd clip placed by larga may blt

ppU
QU

pin

Form No 91

FOREIGN DISC PAD INSTALLATION INSTRUCTIONS

Typical
Removel
1 the Drain about half of the brake fluid out of the master cylinder prior to replacing room the brake fluid in the will allow sufficient for expansion disc brake pads This lines when the pistons are pushed back into their bores to make room for the added

Ate

Teves

System

3
4 5 6 7

Ihickness of the new pad linings Reise the car and lemove tire and wheel The breke pads can be removed without lemovinll the caliper from the car The brake pad reteining pins are held in plaCe bY lock rinlls in Ihe inner caliper housing The pins must be knocked out with e hammel end punch from theoulllide Remove spreader spring which is positioned under the pins A special tool is available flom the car manufacturer forremoving pads from caliper the rotor or pliers can be used to pull them oul be careful not to damage If into encounter in pushingil brake back their boros difficulty Push Ihe pistons you he pistofls back lhere may very weIL Wr9Jl l ern lhe caliper that calls for more in attention than simplY replecing worn out pads IUhe pistons are eticking or If the seals are leaking you should disassembl the caliper and repair il Lift out old pads from Ihe caliper Remove O Ring from inside caliper
II

8 9

Inslallatlon

Apply silicone lubricanl to Ihe O Rings ana 2 Assemble an O Ring in each groove 3 Position innor pads in caliper 4 Position oulpad in caliper 5 Replacespreadet spring 8 ReplaceiPtnsaM lighter
1 7

to

grooveS

inside each caliper

Install wheel and lire

l

Final
f

Checl

check the master cylinder A Iter Ihe new padS have been installed on bolh front wheel fluid level Rlllhe reservoiril necessary Depress Ihe brake pedal firmly severaUlmes
to sellhe new

pads

on

he rotor
i

See

Inst
J

k of Box For ctionsOnBat

rr

l8ge of EMP

iL l

TypIcal

Ale

System

New Brake Division

Boston MA 02135 Commerce CA 90040 Fort Worth TX 76106

Brake

System
4

installing pads depress pedal several times and pads will settle into proper position
After
brake Note

When

worn

out

pads

are

re

placed
may

with

new ones

brake fluid While

re

overflow reservoir

placing pads keep loosening

to release brake fluid
BR563 BR564

bleeder

Install

wheels and lower

car to

Fig

BR 10 Removing Pad

Fig BR

11

Pushing Piston

ground

Inspection
Clean pads with cleaning solvent

CAUTION

Use brake fluid

mineral oil

to clean

Never

use

When

pads
or or

are

heavily
or

fouled

with oil 3

grease

when

pad

is

easily pushed in by hand but if pushed too far groove of piston will go inside of piston seal as shown in Fig BR 12 At this point if piston is pressured or moved piston seal will be damaged If piston has been pushed in too far remove brake assembly and disassemble it Then push piston out in the direction shown by arrow Assemble it again referring to follow ing section

CAUTION Piston can

be

REMOVAL
I

Remove

pads

Refer to Pad Re

placement
2

Remove brake tube from caliper

assembly
CAUTION When

removing

brake tube
use

use

suit

able tube wrench Never

or

open end

adjustable

wrench

deteriorated

deformed replace it
less than the

Note

Plug

up hole in

caliper

so

that

If pad is worn to specified value replace

brake fluid does not flow out from

cylinder body
00

Pad

wear

limit

Minimum thickness
t 6 mm 0 063 in

Loosen bolts securing cylinder body to knuckle spindle and remove caliper assembly from strut

Note

Always replace pads

four

and four
4

pads two pad springs

pad kit clips four pad pins

in

I
I

Normal

DISASSEMBLY
I Drain brake fluid from

position

top hole

Check rotor

referring

to Rotor

L
BR409

for inspection

of cylinder body 2 Push both pistons A and B into

cylinder Refer
3

Fig BR 12 Position for Pushing Piston Push piston A

inner in

Installetlon Clean and apply P RC grease on yoke guide groove of cylinder body
I

piston
as

cylinder by pulling yoke The outer pad can then be installed

shown

Pad Replacement body lightly with a Tap cylinder will then hammer Cylinder plastic from yoke separate
to

sliding

contact

portions of yoke

and

end surface of piston Note

a

Do not

use common

brake grease

Be careful not to get brake grease on rotor and pads Loosen air bleeder and push pis
B outer

2
ton

piston

in

cylinder

until
BRS6S BR115A

end surface of piston B coincides with end surface of retaining ring on boot Then inner pad
can

be installed

Fig

BR 13 Pulling in Piston A

Fig

BR 14

Tapping Cylinder Block

BR 7

Brake Remove bias ring from piston A Remove retaining rings and boots
the end of both

System

Yoke Check for

wear

S
at

cracks

or

other

pistons

A and B

damage
tected

Replace

if any

fault is de

PIston Check piston for

score

rust

wear

Piston A

Piston B BR41S

damage orpresenco of foreign sub stances Replace if any fault is de

tected
I 2

Fig
Note

BR 17

A and B Pisto

Biuring
Boot

Bias ring must be instaDed

on

Retaining ring

BA567

CAUTION Piston sliding surface is plated 00

the original position

not 3 Apply rubber grease lightly to the sliding portions of pistons and insert into cylinder

Fig
6

BR 15 Cylinder

Body

and Pi tan

with emery peper even if rust or foreign matter is sticked on sliding

polish

pistons from cylinder by feeding compressed air gradually

out

Force

surface
Note PIston seal end dust seel
a

Insert pistons A and B from each outside

WARNING

Replace piston seal and dust seal at

10

b When

inserting pistons

be careful

Gradually increase air pressurs that piston does not pop out
7 Remove piston seals

each

dis

mbly
c

not to insert too far

Refer to Pad

Replacemeni
Install piston A of bias
so that yoke groove of piston A coincides with yoke groove of cylinder

ring

CAUTION Be careful

4 not to

damBlle piston

and

cylinder boily
8 Remove yoke spring from yoke

ASSEMBLY
Apply rubber grease to cylinder bore and install piston seal 2 Insert bias ring into piston A so that the roundish portion of it faces the bottom of piston A bore
1

S
on

Install yoke springs

Instau boot and retaining ring anbias ring

yoke

INSPECTION
Clean lows 11
e

I
u

ID
C

au parts and check

fol

jt if

CAutiON
Use brake fluid
minersl oil
I to

1
claan
Never use
I

@
BA

Front face

j
2 Roundish portion Piston A 3
4

Chamfer
Yoke

Cylinder bod
1

Check inside
score

surface

of cylinder
or

Fig

BR 16

for

A embly af Bia Ring to Piston A

rust

wear

damage

pres

ence

of

foreign

substances

If any

surface fault is detected inder body 2 Minor

replace cyl
rust

damage

from

of

foreign substances may be eliminated by polishing surface with a fme emery cloth If damage is major cylinder assembly must be replaced

CAUTION a Be careful not to mistaka piston B for piston A b Pistons A and B are distinguished from each other by a dent at the
inner bottom of

10

1
BA416

Rear face 1 2 Bias Sprinl Yoke spring

piston A

Fig

BR 18

Yoke with Yoke Spring

8 BR

Brake
Apply P B C grease to yoke slid ing part of cylinder Then reposition bias ring so that groove of bias ring coincides with yoke 7 Leaving yoke springs inserted lightly into cylinder groove assemble cylinder body and yoke by pushing or tapping yoke lightly
6

System
Note As this

ROTOR
REMOVAL
Refer to Front Axle
for removal

value increases vibration

of

wear

progressively responding to revolution

occurs

cor

tire

may

often be

tmnsmitted to in

Section FA

terior of car

INSPECTION
Check the following items and
necessary replace Checks made by removing only wheel
can

if be

Sliding surface
If there
are

cracks

or

considerable

chips replace
2 Runout

Adjust

wheel

bearing

correctly
Fig BR 21 Measuring Parallelism

BA570

dial gauge measure runout at the center of rotor pad contact sur

Using
face

Fig

BR 19

A embling Yoke and

Cylinder

Runout limit less than 0 12 mm 0 0047 in

Thickness

Install air bleeder valve

on

caliper

Total indicator

reading

If rotor thickness is beyond wear limit replace rotor When correcting thickness limit
Standard thickness be sure that the thickness not exceed the after correction does

INSTAlLATION
1

Install

in

reverse

procedure

of 10 0 mm Wear limit
more

0 394 in

removal

than 8 4 mm 0 331 in

CAUTION When

installing

brake tube

use

Flare

Nut Torque Wrench 6694310000

INSTALLATION

fJ

Tightening tOlque Calipel securing

4 6 to 6 1 bolts

BR025A

Fig BR 20 Mecuuring Runout

Install
removal

rotor

in

reverse

order

of

kll m
3 Parallelism Measure thickness of entire periph cry of rotor using a micrometer Parallelism when
less than 0 03
new mm

33 to 44 ft lb
Brake tube flere nuts 1 5to 1 8

Adjust wheel bearing preload correctly Refer to Front Axle Sec tion FA for adjustment

kg

ifl

Tightening torque
Rotor to wheel hub 3 9 to 5 3

11 to 13 ft Ib

kg

0 0012 in

28 to 38 ft rb

After

installing

pad

bleed

air

from system

BR 9

Brake

System

REAR BRAKE

Tightening torque

kg

ft lb

0 6 to 0 8 4 3 ro 5 8 2 2 to 2 7 16 to 20

Brake disc
Wheel

2 3
4 5

cylinder assembly

Brake shoe assembly

Return spring Adjuster assembly

6
1 8

9 10
11

Stopper Stopper pin Anti rattle pin Spring se t Anti rattle spring
Retainer

Dueetio

of

ro

tiO

Front of

car

BR116A

Fig

BR 22 Rear Broke

REMOVAL
L with 2 I 2 from 3 Jack up
rear

Remove

dust

cover

and

toggle

be disassembled

of car and support it

lever with 8

adjuster assembly
cylinder
of

safety

stands

Remove wheel

ble

Remove wheel and brake drum

Thoroughly wash all parts Assem wheel cylinder in reverse order disassembly

Engage hand brake lever

Pull pin out and
remove

DISASSEMBLY stopper

AND

toggle lever Disengage hand brake

drum cannot

ASSEMBLY
Wheel cylinder

CAUTION
Use brake fluid to clean Never
use

lever be 8

mineral oil

If brake removed diameter

out 3

easily
mm

install
I 25

two

baIts
to

Note
a

mm

pitch

drive it

Disconnect brake tube flare nut

a

Install

brake line plug in open end of

coating of brake fluid to piston cliP at assembly Charge with genuine Nissan disc

Apply

brake

grease

KR60900010

or

brake tube

equivalent
cover c

before

installing

dust

CAUTION When suitable open end

4 and

The brake wheel cylinder is avail able

in both

removing
tube
or

brake wrench

tube Never

I use 2 use

Dust

cover

Piston Piston cup

NABCO make and There is

no

3
4 5

TOKlCO make

inter

adjustable

wrench

Wheel cylinder body

changeability of repair kits

TOKlCO makes When

or com

Spring
Bleeder
Bleeder cap

ponent parts between NABCO and replacing the repair parts

to

Remove hand brake return

spring
BR909

6
1

pull

out

clevis

pin

to

separate

kit

or

hand brake cable and lever 5 6

component
Fig BR 23
Wheel Cylinder

ascertain

the

Remove anti rattle spring and pin

Remove
return

brand of the brake wheel cylinder

spring and brake

Remove

body
dust
cover

Be

sure

use

parts

of the

shoes

and parts will

same

make

as

the fonner

ones

BR l0

Brake INSPECTION
Brake drum
I Check inner diameter
sure

System
parts if piston to

Replace
Piston
ta

worn

cylinder clearance
of brake
round
or

is

beyond

limit

cylinder clearance
mm

drum to make and

it is is

properly
not

less than 0 15

0 0059 in

0
J
o

tapered If it replace brake drum

Inner diameter

repair

3
4

Replace
or

any

piston

cup which is

worn

otherwise damaged
if

Replace

Standard diametel
203 2 mm 8 in Maximum diameter

inder and shoe is step 5

contacting face of cyl worn locally or in

BR 117

204
of Out

5 mm

8 05 in

Replace any damaged dust cover fatigued piston spring or faulty thread
ed parts 6

Fig BR 24 Lubricating Points of Adju ter

4

loundness less than 0 02

mm

ellipticity

locations of
worn

Referring to Fig BR 25 for lubricating points apply a

points

Replace

0 0008 in

which is

on

tube connector any its threaded portion

coat of brake grease to these

Radial runout less than 0 1

mm

Exercise care not to allow grease to come into contact with lining or ad

0 004 in

juster

screws

Total indicator

reading

Lubricating points
e

Taper
less than 0 02
mm

Contact

areas

between wheel cyl

INSTALLATION
0 0008 in
a

inder anchor block and brake shoe

e

Measured at

point

40 mm

Install

rear

brake in reverse order of

Mating surfaces between brake shoe

and brake disc

1 57 in flam inlet 2

removal closely observing the follow

Contact surface with which lin

come

ing Tighten following parts fied torque

1 to

Contact

areas

between hand brake between brake disc

ings

into with

contact

should
to

be 150

speci

adjuster
Contact

and brake shoe

areas

fine finished

No

120

brake shoe and

sandpaper
3

toggle

lever

Contact
a

areas

between anti rattle

Using

drum

racer

finish brake

drum by

machining
marks

if it shows any

CAUTION
When Nut

pin spring

retainer and brake shoe

sign of stepped
Note

score

partial

wear

or

wear on

its contact surface

installing brake tube use Flare Torque Wrench 6694310000

After

brake
conditioned re

drum has

been
or
re

completely

ifl

Tightening torque
Flared nut 1 5 to 1 8 kg
m

placed check drum and shoes for

proper contact pattern

11 to 13 fHb

Brake
1

embly
any
or

Ail bleedel 0 7 to 0 9 kg
are
m

Replace
worn

linings which
stained oil

cracked
2 If

15 1

to

6 5 ft Ib

lining is worn to specified value replace

Lining
wear

less than the

Wheel cylinder 0 6 to 0 8

mounting bolt kg m

Fig BR 25 Lubricating Points

5 To prevent water from entering brake drum apply dry sealant to brake

4 3 to 5 8 ft b There are two types of adjusters which have right thread or left thread

limit

Minimum thickness
1 5 mm 3 0 059 in

disc mounting surfaces of the follow

ing parts
Wheel cylinder
Anti rattle

R H brake

Replace
are

any shoe return

springs

Right

thread adjuster 6

spring

which
4

broken

Replace spring damaged pin and

fatigued fatigued
or
or

LH brake
anti rattle

Left thread 3

Make sure that entire brake shoe

adjuster
a

fits in place of brake

7

retainer

Sparingly apply

coat

Make

sure

that

adjuster operates
is

grease to the

following points

properly
8 After installation

Wheel cylinder
I

Lubricating points
cylinder
scored
or

completed
drum to clear

check and adjust shoe

ance

Replace

any

piston

which is scratched
its

or

worn on

sliding contact

surface

Adjuster Mating surfaces between adjuster and toggle lever and pin and roller
BR ll

nut and rod threads

by operating

hand brake several

times 9

Bleed brake system

Brake

System
end merease
when

BRAKE BOOSTE R
INSPECTION OF

Start engine
Stop
indicates

engine

speed
gauge

engine
500

vacuum

mmHg l9 69

OPERATION Checking
I
vecuum
a

inHg

pressure gauge in the

JQeL f l i
BR119A

Connect

vacuum

tine

between check velve and brake Air tiKht test No load

booster

Fis BR 27 Location of Check Valllt

2

Fifteen seconds after engine is stopped observe the rate of drop in air pressure registered by vacuum gauge If vacuum pressure drop below the

Using a brake booster testel apply a vacuum pressure of 500 mmHg 19 69 inHg to the port of check
valve
on

specified
chart 1
2 to

value refer
determine

to

the

following
cause

the brake booster side

pressure

If the

the

of

vacuum

drops
new one

below

Check valVe Vacuum gauge BR 26 Air Tighte Te

BA942

failure
Maximum 25
vacuum

specified
mmHg
0 98

value in 15 seconds
a

replace

Fig

Set Up

leakage inHgl

check valve with

Maximum vacuum 01 eheck valn 10

leakage inHgl
to the

mmHg

0 39

Probable
Air 2 3 Air Air

cause

Corrective action

When

pressure is

applied

b rake booster side of check valve and

leakage leakage

at

check valve

Replace check

valve

valve

does
a

not

open

replace check

at

push

rod seal

valve with

new one

leakage between valve body and

seal
4 Air

Replace brake booster assembly

as an

leakage

at valve
or

plunger seat joints Repair

or

Damaged piping

replace
Manifold side
1

0
tLLiJ

Brake booster side

BR963

Air tight test Fifteen

Under loed after

Spring
Valve

seconds
rate

engine

is

pressure drops below the specified value refer to the following chart
to determine the cause offailure Maximum vacuum

Fig

BR 28

Check Value

stopped
serve

and brake

the

fully applied ob of drop in air pressure

gauge Ifvacuum

leakage

When

registered by

vacuum

25 mmHg 0 98 inHgl

installing check valve be

careful to avoid incorrect connectiolU See Fig DR 28

Probable
Air 2 3 4

cause

Corrective action

Operetlns
1 Connect ine brake

test
an

leakage

at check valve

Replace check

valve

oil pressure gauge to

on

Damaged diaphragm
Reaction disc

at connection

master

cylinder Replace brake booster assembly

seat
as an

dropped off

Install

pedal

force gauge

on

brake 3

pedal
until
a vacuum

Air leakage at poppet and valve body

assembly

Start engine

speed

end increase engine pressure of 500

is

mmHg 19 69 inHg
vacuum

registered

on

Inspec tinK check valve

Remove

pressure gauge With a steady vacuum pressure of 500 mmHg 19 69

at

connections The be removed

check valve

can

inHg
pect

measure

clip

and disconnect hoses

now

to each

oil pressure with pedal operating force

res

BR 12

Brake Relationship
between oil

System

pressure

Also check brake line for evidence

and pedal operating force is illustrated in Fig BR 29 If test results are not as

offluid leakage
Note

specified
booster

in

Fig

BR 29

check brake
manner

Detennine whether
is in brake

source

of
or

for condition in

des
re

problem
check fmal

booster

cribed under

Inspection

before

valve

Before you reach

moval of this unit

conclusion

always

inspect

check valve first

M60 1 710 110 560 1 1 e 100 1 420 90 1 280 I 1 80 1 140 70 1 000 60 850 o 50 710 40 570 I 120

AA
Z 1 0

I I

1
v

BR288

Fig BR 32 Adjusting Push Rod Length

t i
2 Install

I
d

clevis
to

Adjust length
value

of

operating rod length

B

specified

g i gl
ll

10 140 0

j
o 10
22

135

mm

5 31 in

221

2 0 441

Rod operating force kg lb

20 44

f c

30 66

40 88

50 110

Pedal operating force kg lb

BA121A

lIJ
B

Fig BR 29 Performance Diagram ofBrake Booster

BR947

REMOVAL
Remo

parts in numerical order

justment of push of push rod

rod is made at the

tip

Fig BR 33 Length

enumerated

ti
J
BR593

Length

A
mm

INSTALLATION
Install removaJ in the reverse sequence of

9 75 to 10 00

0 3839 to 0 3937 in

Irl

IiJ

I
Brake Booster

Tightening torque Master cylinder

0 8 to 1 1

to brake booster

kg m

5 8 to 8 0 ft Ib Brake booster to 0 8 to 1 1 5 8 to 8 Note

BA290

Fig BR 30 Procedures for Removing

if l
J L
Fig
BR 31

body kg m 0 ft lbl

ADJUSTMENT
I

installed in

After brake boOster is properly car conduct an air tight

as

the value indicated below

Adjust the length of push rod to Length ad

Length

and op rational tests described

previously

BR 13

Brake System HAND BRAKE

1 2

Control lever Front cable

Rear

3
4 S 6

cable adjuster

Rear cable

Strap
Oevis Return spring

BA120A

Fig BR 34 Hand Broke

REMOVAL Removal of control lever and front ceble terminal from hand

Remove

lock

plate

Disconnect

cable brake warning switch

2 Remove

adjuster

bolts

securing

hand

Disconnect

brake lever to floor

BR005A

Fig BR 36

Removi1l Front Cable 1

Pull front cable

out

into driver s it

compartment and
5

remove

together

with control assembly If necessary from hand brake lever by

1 2 3
4

separate front cable breaking pin

Hand brake warning switch Terminal

Bolt Pin B R036A

and

replace

front cable

CAUTION
Be careful not to deform control lever
or

damage

Fig BR 35 Hand Brake Lever

BR 14

Brake
Note Front

System
cable

cable
are

clevis

pin and
as

Pull off

return

cotter

pin

available

service

disconnect

rear

spring CD and from lever by

INSPECTION
I
wear

parts
Removal of
I Disconnect
eer

removing clevis pin

ceble

Check
or

control stem and lever for

other

damage
or

Replace if

necessary

Replace

worn

fatigued sprin
or

cable

adjuster

CD
and

Check wires for discontinuity

from front cable 2

Remove

deterioration Replace ifheces ary

lock

plate

Replace malfunctioning warning

Check parts
if
at

strap

00

at axle case

light or switch
5

each connection
or

@
1

and

found defonned

damaged

replace

Rear cable Lock

adjuster
BR037A

2 3

I 2

Return

plate

spring
6R122A

Strap

Clevis pin

INSTALLATION
Install hand brake assembly in the
reverse

Fig BR 37 Removing Rear Cable

Fig BR 38 Removing Rear Cable

procedure

of removal

BR 15

Brake

System

SERVICE DATA AND

SPECIFICATIONS

GENERAL SPECIFICATIONS
SERVICE BRAKE

Type
Front

Disc AN20
Drum LT20 Auto

Rear Pad
or

Width

lining dimension thickness x length

rnm

Front

in

Pad 2 x 10 0 41
1622
x x

61 4
x

0394

2 417

Rear

mm

in

Lining
35 0
378 1
x

4 8
x

195 0
x

0 189

7 68

Rotor outer diameter

Front

or

drum inner diameter

rnm
rnm

in in

245 0 9 65
203 2

Rear Wheel cylinder inner diameter Front Rear Master cylinder inner diameter Brake booster

8 00

rnm

in in in

1 51 20 64

2 012
13 16

mm rnm

20 64 13 16

Type Diaphragm
diameter
x mm

M60
in

4 6 152

NP valve split point

reducing

ratio

kg

cm2

psi

20

4 284 0

4 0

Type of adjusting

shoes

BR 16

Brake

System

INSPECTION AND ADJ USTMENT

BRAKE PEDAL

Free

height

mm

in

143 to 149 5 63 to 5 87

Free play at pedal pad

mm

in

I to 5

0 04 to 0 20 Full stroke at pedal pad With brake booster

s
mm

in in

140
more

51 5

1 I I
d Free h d h

Depressed height

mm

than

70

2 76

play Free height Depressed height

Full stroke

V
20 44

aR002A

HAND BRAKE

Pulling force
Stroke

lb kg

in mm

93 to 106 3 66 to 17 4

Number of notches

7 to 8

MASTER CYLINDER Allowable clearance between cylinder and piston less than 0 15 0 0059

in mm

BRAKE BOOSTER Maximum

vacuum

leakage

15 seconds after

engine

is

stopped
25 0 98

mmHg inHg

Push

rod length

mm

in

975 to 10 00 135
31 5

3839 0

to

3937 0

Operating rod length

in mm
I
c

tY

1I1

fF

IF
B

BA290 BR947

CHECK VALVE
Maximum
vacuum

leakage

15 seconds after 500

19 69 inHg

pressure is

applied

mmHg mmHg inHg

10

0 39

BR 17

Brake
FRONT

System

DISC BRAKE
Pad wear limit

Minim urn
Rotor

nun

in

1 6

thickness

0 063

repair limit
nun

Runout Parallelism Thickness

in in in

less than 0 12 less than than

0 0047

nun

03 00012 0
4 8

mm

more

331 0

DRUM BRAKE Lining

Drum
wear

limit Minimum thickness

nun

in

5 1

0 059

repair limit
Initial stage 203 2
nun

Maximum inner diameter 8 in

nun mm
nun

in in in in

5 8 05 204 less than less than 02 0 0008 0

1 0 0 004

Out of roundness Radial cunout

Taper
Wheel cylinder repair limit Piston cylinder to clearance

mm

less than 0 02 00008

nun

in

less than 0 15 0 0059

TIGHTENING TORQUE
Master cylinder to brake booster Brake booster
to

kg kg kg kg kg

ft lb ft lb ft Ib ft lb ft Ib ft lb
ft Ib

0 8 to

5 8 to 8 0
5 8 to 8 0 II to 13
to to

body

m m
m

0 8 to 1 1
15 to 18

Brake tube flare nut

Brake hose connector Air bleeder valve 3 way connector

7 to 2 0 12 1 0 7 to 0 9 5 1

14

mounting bolt
switch lock
nut

kg kg kg kg

m
m

0 8 to 1 5 8 to 8 0

Brake warning

lamp

2to 1 l 5 9 to II
3 to 9 9 53 to 72 7

Caliper fixing
Rotor

bolt

m
m

ft lb ft Ib

fixing

bolt

3 9 to

3 5

28 to 38

Rear brake wheel cylinder mounting bolts Front brake baffle plate Rear brake disc

kg kg kg

ft lb ft Ib ft Ib

0 6 to 08 34 0

3 to 5 8 4 2 3

fixing

bolts

to 0 44 2 5 to

fixing

bolts

2 to 2 7 16 to 20

BRAKE BOOSTER Brake booster

to

body

kg kg

m m
m

ft lb ft lb ft lb ft lb

08

to

5 8 to 8 0
to

Operating

rod lock nut

cover

16 to 2 2 12

16

Flange io shell
Push rod

kg
kg

0 8 to 1 5 8 to 8 0 16 to 2 2 12 to 16

adjusting

nut

BR 1B

Brake

System

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Excessive pedal travel Low brake Probable fluid level

cause

Corrective action empty

master

or

Fill and bleed

cyUnder

reservoir

as necessary Test for source of leakage by examining all lines connec tions and wheel cylinder

Leakage in

master

cylinder

Overhaul master cylinder

Deteriorated check valve

Replace check valve and bleed system

Bleed system

Air in system

Faulty

brake

adjustment
on

Adjust
auto

shoe to drum

clearance

Inspect

adjuster operation
or

Excessive loose parts

or

worn

lateral play wheel

disc caused by
or

Replace

adjust faulty parts

bearings

steering

Spongy pedal

Low fluid level in master Air in

cylinder

Top with fluid

and

inspect for leakage

system

Correct as necessary

Faulty brake adjustment

Reservoir fIller cap vent hole clogged Swollen hose due to deterioration or use of
poor

Adjust shoe to drum auto adjuster operation

Clean and bleed system

clearance

Inspect

Replace hose

and bleed system

quality hose
or

Distored brake shoes

or cracked

excessively

worn

Replace faul ty parts

brake drum

Soft

or

swollen

caliper

seals

Drain hydraulic system flush with alcohol and replace all seals

Use of

brake fluid with too low boiling

Replace with specified brake fluid and bleed

system

point
Poor braking effect Fluid

leakage
brake

in brake lines

Check

master cylinder p pmg and wheel cylinder for leaks and repair

Low

fluid level

or

empty

master

Fill and bleed

as

necessary

cylinder

reservoir

Air in brake lines

Bleed system

Excessive shoe to drum clearance Grease oil mud

or

Adjust
Clean brake mechanism and check for ofproblem Replace
cause

water on

linings or pads

linings

or

pads

Deterioration of linings Local fit of linings

or

or

pads

Replace
Shave
or

pads
worn

replace

Linings

or

pads excessively
or

Replace Repair
or

Master cylinder condition Frozen brakes

or

wheel cylinders in poor

replace caliper
and free up
as

seized caliper pistons

on

disc

Disassemble

required

Finding

mechanical

linkage

at

brake pedal

Free up

as

required

and shoes

BR 19

Brake

System
Corrective action Inflate to correct pressure

Condition Unbalanced brakes

Probable

cause

Improper

tire inflation

Improp
ance

adjustment
mud
or

of shoe

drum to

clear

Readjust
Clean brake mechanism and check for of problem Replace

Grease oil

water on

linings

or

pads

cause

linings

or

pads

Mud in brake drum Deterioration oflinings

wear Excessi or

Clean

pads

Replace

of linings

or

pads

Replace
Repair
or

Wheel cylinder in poor condition Poor

replace

sliding condition

of brake shoe
or

Adjust
F ten
or

Looseness of cylinder body

back plate

replace
or

securing bolts
Scored
or

fround drums out

Recondition

replace brake drum

as

re

quired
with

Check for improper and

or

lining

contact

dflllll

grind lining

if necessary

Sticking

cylinder wheel

cups

Recondition

replace cylinder

Deformation ofback plate Incorrect Incorrect

Replace

adjustment adjustment

of wheel

bearings

Adjust Adjust

or

replace
or

ofwheel aligoment

Looseness of leaf spring securing U bolts Brakes fade Brake fluid has too low Use of improper contaminated Brake drums
are

Tighten

replace
d fluid

boiling point
or

Drain and fill system with appr

are

linings

brake

linings

Replace linings

fround out

Repair
Repair

or as

replace

as

necessary

Hydraulic connections master cylinder and wheel cylinders are corroded or damaged
Bleed screw is open Brakes

necessary

Close
or

screw

and bleed system

drag

Pedal

linkage

is

binding

push

rod

adjust

Lubricate linkage check for condition and

sary

ment is too

long

pedal adjust push

return

spring

rod as neces

Master

cylinder compensator part

is

ob

Blowout foreign matter with

air Disassemble master

compresSed
and

structed Seized master cylinder piston

cylinder

replace

piston Bleed system

Poor shoe condition Poor wheel cylinder condition Deformation of piston cups Poor condition of Clean and repair

Repair

or

replace

Replace
because of faulty

caliper

Replace piston seals

piston seals
Excessive runaut of rotor
Hand brake will not return

Turn rotor Check and Clean

on

lathe

or

replace

repair

Clogged

m ter

cylinder

return port

BR 20

Brake

System

Condition

Probable

cause

Corrective action Check and clean

Brakes drag

Clogged brake lines

Incorrect

adjustment
drum to

of wheel bearings clearance

Adjust Adjust

or

repair

Improper shoe

Weak shoe return springs

No free travel in brake shoe return

Replace Adjust pedal height

Grind
or

Brake chatters

Groove or out of round brake drum or rotor Loose or bent

replace

as

required
to

support plate

Tighten
torque

or

support plate bolts replace plate

necessary

specified

Distorted brake shoes Grease Brake

or

or

pads

Replace

as

brake fluid on linings

Replace linings
Blowout assembly with compressed air refinish drum
or

squeals

Dirty

or

scored brake drums

Distorted brake shoes

Weak
or or

or

bent

support plate

Replace faulty Replace

Cam

unit

broken brake shoe retaining spring

if faulty

return

spring
contaminated brake lining

Glazed

or

ground lining

to

elilninate glaze

If it

doesn t replace linings Pedal pulsates

of Out

round or

center off

drum

Turn drum or

replace

as

necessary

On disc brakes is excessive

lateral runout of brake rotor

Check with dial indicator

hand

turning disc by
re

If runout exceeds

specifications

place disc
Excessive variation in thickness

of brake

Measure around disc face with micrometer

rotor surfaces

Replace disc

as

required

Rear lock

Improper
Excessive

tire pressures
wear of tires

Check and adjust Check and replace

under light brake

pedal force Faulty

Rear lock NP valve

Replace
Check and adjust Check and replace

Improper
Excessive
Poor front

tire pressures
wear

under heavy brake

of tires

pedal force braking effect

oil mud
or

Grease
or

water

on

linings

Clean

or

replace

pads
wear

Excessive

of linings
or

or

pads

Replace
Shave
or

Local fit of linings Master cylinder condition

or

pads

replace replace

wheel cylinder in poor

Repair

or

BR 2t

Braise System
1

SPECIAL
Kent

SERVICE

TOOL
Kent Moore No

Moore No

Tool number

tool

name

ReferenCe page or Fis No

Tool number

tool

name

Reference
page
or

Fis No

GG94310000

Flare nut torque wrench BR 5 BR 6 BR 9 BR II

Page Page Page Page

BR 22

DATSUN 210

Model 8310 Series

WHEEL AND TIRE

CONTENTS
WHEEL

AND TIRE MAINTENANCE

INSPECTION

WT2

GENERAL SPECIFICATIONS INSPECTION ANO

WT5
WT5 WT 6

WT2
WT 3

ADJUSTMENT

TIGHTENING

TORQUE

SERVICE DATA AND SPECIFICATIONS

WT5

TROUBLE DIAGNOSES AND CORRECTIONS

WT 7

ell

Wheel and Tire

t

WHEEL AND TIRE

MAINTEN

NCE

TIRE WEAR Tread Tires

are ar

Uneven Indicator Uneven camber

or

wear wear

TIRE INFLATION Correct tire pressure is very impor tant for steering ease and riding com fort Correct pressure also makes for quieter ride and extends tire life
If all tires are
a

is caused

caster

provided with lad tr wear at indicator six places around tire circumference indicating 1 6 mm J in tread depth When tires wear and
then marks appear
new ones

by incorrect malfunctioning sus

wheel
of out
or

pension

unbalanced

round brake drum

other mechani

inspected frequently
at correct pressure

replace

them wtth

cal conditions To stop this abnormal wear correct the above faulty parts

and maintained
any

sharp objects in tread can be quickiy detected nd abnormal wear

which invites serious

problems
valves

can

be Tread
wear

TIRE REPLACEMENT
indicator Tire tread

avoided After inflating tires should be checked for leakage Without valve

CAUTION

leakage will occur due to dirt and water resulting in underinflation Ac cordingly whenever tire pressure is checked be sure to tighten vaive caps firmly by hand
caps

Different types of tires sucb

L

as

bias

1
c

bias belted and radial tireS be

WH024

must not

mixed

except affect

in

an

emergancy

Mixed
can

use of different
car

types of tires

Fig WT l

Tread WearJndicator

adversely
cause

ilndlilig

and

may

driver to lose control

JW
I 1 I

in
1

Sri
II I

n
I
i

Note
a

Be

sure

to

check the wheel nut

I 000 km

II

I I

i l
14
01 I

M1
out toe

1
f

torque
run

after the wheel has been 600 also in of

for the rust

cases

I
ii
J
I h

miles tires

nl II

me
1111

tire rotation

repairing fiat etc and every

Toe

in

or

wear

Center

wear

10 000 km

000 6

miles thereafter

Retighten
I
J

if necessary
on

mnr n
I

It is recommended that new tires be

installed in pairs When

the

same

axle it

I
Ilnl 11111

IIii
i

replacing only

one

tire

should be tread
c

I lll

rt
Shoulder

I
1II

Jil
111
lie

When those

IllIlI
wear

paired with the most to equalize braking tl1lction replacing original tires with tires of an optional recom
rent diff

Uneven

wear

WT004

mended site and of

eter the

diam

Fig WT 2 A bnormal Tire Wtor

speedometer

must be reo

calibrated

To

replace

tire

with

Toe in

or toe out wear are out toe

Shoulder

wear

safe

manner

refer to

jack in a Lifting Points

a

When the front wheels

in an excessive toe in
or

aligned
condi

This

wear

may be caused

by under
or

and Towing
up

Section GI

for jacking

inflation continued
curves
are

incorrect

wheel camber

tion the tires will tend to scrape the

excessive

speed

around

tread rubber off and the tread will de elop

a

feathered edge

In general the first two causes the most common Underinflation both sides of treads

WARNING Never get under

car

whila

it is

causes wear on

supported only by jack

Center Center

while camber causes wear on

wear wear

only one

Always

side of tread
is caused

by overinfla

use Il fety stands to suppon side member of body construction

when you must get berreatb

car

tion of the tire

WT 2

Wheel and Tire

2
To

install wheel

tighten wheel proceed

as

Slightly pull
align
nuts

nuts in criss cross fashion As for aluminum wheels

erly

with bolt

wheel back to prop holes in

as

Bias and Bias Belted Tires

wheel and tighten nuts

much

as

Right

front

Right

rear

follows

possible
nuts after WT 3

with your fingers

nuts

J c evenly
with a

l c

Snugly tighten four wheel is positioned See Fig

Tighten four

wheel wrench in criss

cross fashion

lc c J
Left

X@
Left
rear

front
4 WH

EELS

Right front

Right

rear

J c

l c

Align

nuti with

bolt holes in
nuts
a

9
Left front
5

J c
Left

wheel and each

evenly tighten
little at

rear

one a

time

WHEELS

Radial Tires

f
WT016

Right

front

Right

rear

J c

l c

lc c J
Left front
4 Left
rear

Fig WT 3 Installing Aluminum Wheel Right

WHEELS

front

Right

rear

J c

Iil

Tightening torque
Wheel nut

Note ed

Be careful not to smear thread

portion of bolt

and nut and seat

Steel and aluminum wheels

8 0 to 10 0 m kg 58 to 72 ft Ibl

of nut with oil

or grease

J c
Left front

l c
Left
rear

5 WHEELS
WT021

Fig WT 5 Tire Rotation

CAUTION Two types of wheel nuts Bre used one is designed for use with steel wheel Bnd the other for wheel wheel nuts
use

INSPECTION
WHEEL BALANCE TIRE ROTATION
Tires tend to
wear

with aluminum

Do not mix different types of

The wheel and tire assembly should be kept balanced

statically
is

and

dy

unevenly
a

and

namically Proper
tire balance
car

become

unbalanced distance

after

certain
wear

necessary

running
often

Uneven

tire

when driving the

at

high speeds
as

results in tire
to rear

noise which is

Consequently

the

wheel and tire

attributed

axle gears
also of

bearing
to
wear

p
WT020

c
For teel

sembly should be

properly

rebalanced

etc

Front

tires

tend

unevenly because
ed front wheels

improperly align
tire
wear

whenever puncture is repaired The wheel and tire assembly be

comes out

WH246

of balance

according

to

For aluminum
wheels

Accordingly cally
as

to

equalize

uneven

tire wear

Severe acceleration

only

wheels only

it is necessary to rotate tires

periodi
Periodic

recommended in the

and braking or fast cornering is the of wear on tire resulting in cause unbalance of tire and wheel

Fig WT 4 Wheel Nut

Maintenance

assembly

3 WT

Wheel and Tire

The symptom of unbalance appears tramps car shake and steering mal To correct unbalance wheel balancer
Maximum allowable unbalance
at use

Lateral and radial runout Steel wheel less than 1 2

mm

inpsllorvi t1dcted iol

with tit

If

as

function proper

0 047 in

puncture damage to

is too

large

or

there is some
be

tire fabric

repair should

Aluminumwlte 1 lass than 0 5 Difference

mm

carried out 10 020 in

left

by

authorized tire dealer

Discard when any of the

following

right and

problems
I 2
or

occurs
or

rim

flange

lateral

runout

Broken

damaged bead wire

on

10 gr 10 35 ozl Balance weight 10 to 60 gr 10 35 to 2 12 ozl at 10 gr 10 35 ozl interval

Steel wheel

leu than 0 5
Aluminum wheel less than 0 2

mm

10 020

in

tread separation Ply 3 Worn fabric damage

tire 4 Cracked or 5

tubeless

mm

0 008 in

damaged
tread

side wall
wear

Tires

with
etc

indicator

Note
a

showing
sure

Be

to
on

place

correct

balance See points

weights Fig
b

inner edge of rim

6 wr

Do not put mOle than two on each side

Two

weights

l
use

types of balance weights are used one is designed for use with
steel wheel and the other for different types of balance with aluminum wheel Do not mix

Fig WT 6 Whee Rim RUllout Check

Points

JeCk C
or

Note
a WT005

When
care

not to

discarding tire take extra damage tire bead rim

flange
Do

and bead seat

ot use tire irons to foree beads

weights
Wheel must be of the
I

WHEEL In
tire life

2 to
ensure as

replaced when following problems occurs Bent dented or heavily rusted Elongated bolt holes
Excessive lateral
Air leaks

any

that is away from wbeel rim flange always use tire replacement device whenever tire is removed b Install wive
core

and inflate to

order

satisfactory
as

3 4

radial runout
s

proper pressure Check the locating rings of the tire to be sure they show around the rim

steering condition
Check wheel

well

maximum

follows proceed
rim seat

through
won

wel

flanges

on

5
rim

Wheel nuts

t stay

tight

both sides

especially

flange and bead

tion

for rust distor which of TIRE

cracks
cause

or

other faults leaks

and rust

might
tubeless

air

Function

tire tire

depends
bead
remove or

on a

good seal
rim oxi

WARNING
To

between

wheel dust

check for leaks

or

apply soapy
or

When

while tire is

being inflated

Thoroughly
dized rubber Note

solution tub
in

submerge
after

tire and wheel

sand from wheel rim

water

inflating

it

to

speCified
valve Note
or

pressure Special inspection

wheel rim and and
rim

bead snaps over safety hump it might break Thus to avoid satious personal injury never stand over
tire when
to
a

Rim bead seats should be clean Steel wheel Wile brush

etc
coone

for leaks should be carried out around

inflating
40

it Never inflate

ed with the following steel wool

along

tread

pressure

bead

where

leakage

kg em
seat It

greater then 2 8 psQ If beads fail to

deflate the

11rs

area

any which leaks air bubbles and then

Wipe

water away

from

that pressure it

tire

lubricate it

Aluminum wheel Neutral detergent cloth etc

mark

place

with chalk

reinflate which caused

again and then If the tire is ov might break pos in serious persona

After removing

object
a

inflated the bead

Use dial gauge to examine wheel rim for lateral and radial runout

puncture ing a puncture

furnished

seal the pain

use

by

any tire

Wilen repair repair kit dealer following

tire

sibly resulting

injury

4 WT

Wheel and Tire

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS
WHEEL AND TIRE

Applied
Sedan

del Remarks

Hatchback

Wagon
Steel wheel
30 mm

OJ 4 Road wheel size

13

I I8 in

offset

5J 13

Aluminum wheel
25 mm 0 98 in offset

155 13 Tire size

15 6

4PR 13

155 13

15 6

4PR 13

Tubeless Bias

l55SRl3

70SR13 l75

70SR13 l75

155SRl3

70SR13 l75

Tubeless Radial

INSPECTION
Wheel balance

AND ADJUSTMENT
at

Maxilnum allowable unbalance riln flange

Tire

gr

oz

10

0 35

balancing weight

gr oz

10 to 60

35 0

to

2 12

Spacing 10
Wheel riln lateral and radial runout Steel wheel Aluminum wheel Difference between right and
left lateral runout
mm mm

35 0

in in

Less than 1 2 Less than 0 5

0 047 0 020

Steel wheel Aluminum wheel

mm mm

in in

Less than 0 5 Less than 0 2

0 020

0 008

WT5

Wheel and Tire

Recommended tire inflation pressure

kgem

psi

Sedan Hatchback and Wagon

Car speed

For normal

speed

For

high speed

rife l
Tire size

Under 100 km h 60 MPH tio

Over 100 km h 60 MPH Front

Front

Rear

Rear

155 13

15 6

13

4PR

I 7 24

17 01 8

24 26

7 24 1

7 24 1

018

26

155SRl3

70SRI 175

17 24

17 24

7 24 1

17 24

Wagon only
are

Note

Inflation pressure should be measured when tires

cold

TIGHTENING TORQUE
Wheel
nut

Steel and aluminum wheels

kg

ft lb

8 0 to 10 0 58

to

72

6 WT

Wheel and Tire

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable
tire pressure tire
or

cause

Corrective action

Wheel wobbles

Improper Damaged

Measure and

adjust

distorted wheel rim

Repair

or

replace

Unbalanced wheel
Loose wheel nuts

Balance

Tighten
or

Worn

or

play

in wheel

damaged wheel bearing bearing

wheel

excessive

Correct play

or

replace wheel bearing

Improper front
Worn or

alignment

Align Replace

damaged

ball joint

steering steering linkage

Loose

Excessive

linkage

play

or

worn

Adjust

or

replace replace

steering linkage

connection

Tighten
worn

nuts

to

rated torque

or

parts if any

Broken

suspension spring

Replace Replace
Rotate tires Measure and

Faulty shock absorber Unevenly sively

or
exces

Improper Improper

tire rotation tire pressure

periodically
adjust

worn

tire

Unbalanced wheel

Balance
brake

or

replace

Improperly adjusted Improper

wheel

Adjust Align
installed

alignment
or

Excessively distorted suspension link High speed

Sudden
on curves

improperly

Repair replace
Reduce

or

if necessary reinstall

speed

starts and

rapid acceleration plication

Tire squeals

improper speed due to brake ap or improper

Drive in a proper manner

Improper Improper

tire pressure front wheel

or

Measure and

adjust

alignment

Align Repair
or

Distorted knuckle

suspension link

replace

WT7

DATSUN 210

Model 8310 Series

SECTIONST
STEERING SYSTEM
CONTENTS
STEERING COLUMN AND GEAR
STEERING WHEEL STEERING LOCK STEERING COLUMN
STEERING GEAR ST ST ST 2 2

GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT TIGHTENING TORQUE TROUBLE DIAGNOSES AND

ST 12 ST 12 ST 13

3
3 5

Collapsible type

ST
ST ST

RB45L

CORRECTIONS SPECIAL SERVICE TOOLS

ST 14 ST 15

STEERING LINKAGE SERVICE DATA AND

SPECIFICATIONS

ST 12

Steering System

STEERING COLUMN AND GEAR

bolts into threaded holes provided in

steering wheel Turn center bolt of the special tool clockwise to remove steer ing wheel

CAUTION
a

00 not strike end of

umn

steering
or

col col

shaft with

hammer

Striking

shaft will damage bearing lapsible shaft

b Be careful
not to

damage cancel

pole

Tightening torque
bolts and nuts

of rn kg to

ft4b 1 2 3
4 S

Steering Steering

wheel

3 8 to 5 2

@ @
@

27 38 3 to 18 9 to 13 1

olumn clamp
column

0 35 to 0 45 25 to 3 3
4

Jacket tube flange

@ lEi

0 to 5 0 29 to 36 7 0 to 8 0 51 to 58 13 to 15 94 to 108

RUbbercoupling Steering gear

ST860

Fig ST l Steering Column and Gear

STEERING WHEEL
I

spoke steering wheel

Remove bolts from back side of Lift

Fig

4 Removing ST

ing WhHl Ste

REMOVAL
I

steering wheel

Disconnect battery Remove horn pad

3 spoke

ground

cable

horn

pad

from

steering

wheel and disconnect horn wire

sport steering wheel

INSTALLATION
Install steering wheel in the
reverse

Pull off pad

order of removal Observe the follow

ing instructions Apply

2 When column
grease to sliding portions installing steering wheel to shaft align punch mark on
on

steering wheel with punch mark

the top end of column shaft
ST766

til Tightening torqu

Steering whee
nut

Fig ST 3 Removing Horn Pod

3 8 to 5 2

kg

27 to 38 ft Ibl

Note 3
ST765

After

imtol1ing steering
for catch

wheel

Remove steering wheel nut

turn it clockwise end counterclock

Using

Steering
install

Wheel

Puller anchor

wise

cheddng

or

drag

Fig

ST 2

Removing

Horn Pod

ST2718000l

puller

Also check horn for

operation

51 2

Steering System
STEERING LOCK
To
2 Remove two screws and dismount

INSTALLATION Align steering lock hole in jacket tube with the mating portion of steer
I

steering lock from steering jacket tube

provide

tamper

proof

self shear

type screws are used and their heads are sheared off when installed so that
the

ing lock
2

steering lock system removed easily

cannot

be

Install self shear type

screws

and

cut off their heads

REMOVAL
ST393

Break
a

two

self shear type screws

with

drill or other proper tool

Fig ST 5 Removing Steering Lock Securing Screw

STEERING COLUMN

Collapsible type
V 4

1
II

H
CAUTION
a

F
1 2

iC

Lu

Jr

3
4 5

Upper bearing Upper jacket shaft Steering post clamp Upper jacket tube
Steel ball
Lower

7 8
9 10 11

Lower jacket tube Lower jacket

tube flange Lower bearing Rubber coupling

Column

dust

cover

jacket shaft Fig 8T

6

ST664

Collapsibte Type Steoring Column

Remove

combination switch
screws

as

in any case should undue strass be applied to steering column Never in axial direction Whan

sembly by loosening 5 Remove baIts securing jacket tube flange to dash panel

installing do ing force to steering

not

apply

bend

it
j
a
ST 422

column

Fig ST 7 Worm 8lwft Securing Bolt

Removel I Remove bolt securing

worm

2 shaft

Remove

steering wheel Refer

to ST768

Steering Wheel
3
Loosen screws and remove upper
covers

and rubber

coupling

and lower steering column shell 3 ST

Fig 8T 8 Jacket Tube Flange Securing Bolt

Steering System
6 Removeoolts securing oolumn InstaU tlon Iostall steering column in order ofremoval Observe following instructions See Fig ST IO
I
reverse

3
en

Tighten
bolt

bolts

rid then tight

clamp

@
4 0 to 5 0 29 to 36

liJ

Tightening torque

@ @

m kg
lb ft

3 to 1 8 1

Set

wheels

in

straight ahead

m kg
lbl ft

9 to 13

position
2

Fit

steeririg

column

assembly

on

to worm

shaft serration through dash

4 to

After sliding dash

panel and ly
ST661

bolts@ temporari tighti

panel

jacket tighten

tube bracket bolt

to

support upper side of steering column assembly

to

retain it

Fig ST 9 Column CIDmp Securing

BoU

CAUTION
a

liJ Tightening torqu 0 35 to @

that undue stress is not
5 to ruhber

45 kg m 0

5 to 3 3 2

Mata

lbl ft

sure

bly from
Note

Draw out steering column the room side When

a

assem

epplied

b To evoid
is

head

rollision

inspect encountere
tem as

steeriJ tg

sys

coupling damaging bolt or serra tions align groove in worm shaft with bolt hole in rubber coupling

After installation
turns

make

sure

that

steering wheel

smoothly

allow

The steering system is very impor lant unit or driving The oollapsi ble type steering column hould not be disassembled snd if necessary Note

Carefully

install
o

so

that

punch

mark at top end

column slmft

replace it

a an

assembly

acesupwardc

1 2

Rubber coupling

Steering column 8ncmbly

Worm Dash

3
4 5

shaft

panel

Column shaft Column clamp Jacltct tube flange

6 1

Tightening torque of

C
VH
Fig ST IO 4 ST

bolts and nuts

m kg

lb ft

@ @ @
1

13 to 18 9 to 13 0 35 to 0 45 2 5 to 3 3 4 0 to 5 0 29 to 36

ST668

alling Sleering Column Aaembly

Steering System
Inspection
I When steering wheel but
can

3
not be

Remove

r
1

housing clamp
verter

securing V bolt gusset catalytic con equipped models only

to

bolt

rotated

smoothly steering gear steering linkage and suspension system are normal check the steering system
for the
I

Steering

wheel

side

following

matters and

replace
1 2 Column Block ST679

faulty parts
Check column bearings for dam age or unevenness If so lubricate with recommended multi purpose grease or

clamp

Fig ST 12 Standard Dimension

3

replace
2

with

new

one

as

steering Steering wheel Check steering wheel for axial play When steering jacket shaft is crush axial play exists

column assembly Check jacket tube for deforma

tion or sary 3

breakage and replace if

column spring
or

STa6l

neces

ed

Fig ST

5 Clutch Operating Cylinder and Front Tube

Check

and

re

place if damaged
2 When the check

weakened
comes

car

collision
I

the

light following parts

into

and replace if necessary Jacket tube Measure

tube 4 dimension A between

j
Fig ST 13
Sector shaft When

to exhaust

Remove bolt securing front tube mounting bracket

Axial direction ST194

column clamp and top end of lower

jacket
sion

mpecting Steering Wheel for Axial Play

When jacket tube is crushed dimen A is reduced

1
II

collision
is

occurs

abnormal
As
a

strength
Column

applied

to gear arm

length
mm

A 7 52 in

result of this serration of sector shaft

is apt to be distorted

Q
I
ST862

191

111111

Fig ST 16

t Exhau Mounting Bracktt

5
1

2 1 2 Jacket tube Column clamp

ST669

Serration of sector shaft Gear arm

Remove front tube from exhaust

ST195

manifold Note
Do not remove front

exhaust

Fig

ST l1 Standard Dimension

Fig ST 14
on

Collapsible Column

mpeeting Serration of Sector S IuJft for Deformation

tube

assembly from catalytic con Refer verter or muffler assembly

to Section FE

STEERING GEAR RB4SL

Removal
2

Column clamp Measure dimension 0

as

shown in

Remove clutch operating

cylinder
models

Fig ST 12
When sion
0

manual transmission

equipped

only

jacket
1J

tube is crushed dimen

Note

is increased

Do not

remove

clutch hose

from

8 cylinder
ST863

Length

Column bracket o mm

Remove nuts securing front tube

0 in

to exhaust manifold

Fig ST 7 Removal of Front Tube

ST 5

Steering System
6
7

Reriiovebolt

Securing worm shaft

8
gear

Remove

bolts
to

to rubber

coupling
arm

housing

securing steering body side member housing

Remove nut and lock washer se to sector shaft Arm

and

withdraw steering gear

curing gear Steering

arm

Using
Puller

from engine compartment

Thoroughly drail steCring gear oil by removing filler plug Place steer ing gear in a vise with Steering Gear Attachment KV48100300 in place
2 tor

Gear
remove

Loosen lock nut and shaft

cover

remove see

512902000 I

steering gear

attaching bolts After

shaft with
cover re

from sector shaft

Gear Cearar

removing

sector

housinif

move cover

from sector shaft by turn

ing screw clockwise

n
ST289

Fig ST IB Removing

Stei1l Gear Arm

Filler plug
Lock nut

2 3

Sector shaft bolts

cover

attaching

Disassembly

Fig ST 20

Gear Mounti1l Steeri1l in

a

Vue

Remove

rear cover

securing bolts

and detach
4

rear cover

Remove
s

shim

and

bearing adjusting steering worm assembly

ST426

Fig ST 21

Worm Drawi1l Steeri1l

y A em b

Tightening torque of bolts

and nuts
m kg

Lock nut Filler plug

9 10 11 12 13 14

Worm shaft Wonn bearing Wann bearing adjUsting shim Rear

cover

ft Ib

2 3 4
5

@
@

@ @
ST864

2 0 to 3 0 14 to 22 2 0 to 3 0 14 to 22 7 0 to 8 0 51 to 58 2 0 to 3 0 14 to 22

Adjusting shim Adjusting screw

Sector shaft bushing

6 7 8

Steering gearhou ing

Oil seal
BaU nut

Oil seal Sector shaft

Fig

ST 19

Gear Steeri1l

SHi

Steering System
CAUTION
Be careful
not to assemble with any
or worm

CAUTION
a

Be careful not to allow ball nut to

run

down to either end of ball

other element like dust

dirt

The ends of

guides

will

be

damaged
stops
b shaft

if nut is rotated until it

at the end of worm

worm

00 not detach ball nut from

Adjustment preload
4
ST037

of worm

bearing
worm

assembly assembly
c

If necessary

replace

Properly position steering assembly in gear housing with

worm

Do not

remove

sector shaft bush

ings

steering gear housing If necessary replace gear housing assembly Be careful not to allow penetration
of any other element like dust dirt
or

from

Fig ST 22 In pecting Steering Worm and Ball Nut A8sembly

bearings Install rear cover housing with worm bearing shims

on

gear

fJ Tightening
Bearings and bushings Inspect worm bearing for wear pitting or any other damage Replace
I with
a

torqu

Rear coyer 2 0 to 3 0

kltm

14 to 22 ft Ibl to install the thicker

new

one

as

required
worm

Note

Be

sure

Note

When replacing
it
as
a

replace Inspection
Wash
clean

set of

bearing bearing and

shUn

on gear

housing side

Standard shim total thickness is 1 5

mm

outer race

0 059 in

all

the

disassembled

parts in cleaning solvent and check for condition

Sector shaft

2 If sector shaft bushings in gear housing are found worn or damaged replace as an assembly of gear housing and bushings

Available No
I

worm

bearing

shUn

Thickness
0 762 0 254 0 127 0 050

mm

in

Oil seals
I

Check

gear

tooth

surface

for Discard oil moved deformed seal which is

if
once
re

0 0300 0 0100 0 0050

0 0020

pitting burrs cracks or any damage and replace if damaged

2 Check

other

Replace oil seal

or

sealing lip

is

2
3 4

sector shaft for distortion

cracked Also discard oil

or

of its serration

place

and if necessary re In this case be 8ure to check

worm

seal if spring is fatigued

dislocated

gear housing and steering sembly for deformation

as

adjust
Steering
I
worm

assembly

Assembly snd adjustment

Assemble steering gear in reverse order of disassembly Observe follow

Selecting suitable bearing shims worm bearing preload with Preload Drive Pinion Gauge
5

ST3I 27S000

Inspect ball nut gear tooth sur face and replace if pitting burrs wear or any other damage is found 2 Ball nut must rotate smoothly on worm If found too tight as gear sembly should be replaced Check as
follows
I
worm

Initial

ing
2

instructions Clean all parts Lubricate

Worm

turning torque bearing

4 0 to 6 0 3 5 to 5 2 in

gear

surface

bearing turning surface gear tooth and other

kgm bl

sliding parts
3
new

Move ball nut to either end of

gear

with clean gear oil Fill space between sealing lips of

and

gradually
on

stand worm

oil seal with recommended multi

grease

shaft and ball nut assembly until ball

nut moves

purpose

and fit

it

to

gear

downward

worm

gear

housing and
Note
a

rear cover

under its 2
not

own

weight
if ball nut does
entire
over

Note
a

In the above test

move

Rotate

worm

shaft

few turns in
worm

freely
may

stroke

To facilitate installation

coat seal gear

both directions to settle

bear

assembly
with Note

be

damaged

Replace

contacting face of oil seal with

oil b Press oil

ing

in and measure

preload
bearing
pre
s

a new one

b When seal into place with its

adjusting
correct

worm

load add and then until achieved

remove

shim

In this

not to

inspection be careful damage ball nut guide tube

lettered side facing outside of gear

adjustment

is

housing

or

rear cover

5T 7

Steering System
Adjusting shilli 13

Adjust backIashat
screw

tion of

Upper
sector cover

1
l

neutral posic by steering gear turning adjust

in or out so that movement
arm

iog

of gear

top end

is

less

than

specified

value

side

Backlash at gear arm top end

Less than
0 1 mm 0 004 in

Fig ST 23 Mea uring Initial Turning Torque

ST258

After correct
and

worm

bearing
remove on

pre
rear

Fig ST 24
tween

load has been obtained

cover

End l UJy Measuri Sector Shaft and

apply sealant
rear cover

housing

AeVusting Screw

and

cover

sides of shims with shims at

8
ST 427

Reinstall

tached under cover

Rotate

wonn

shaft by hand until Fig ST 25

Bocklash Measuri

fJ Tightening torque
2 0 to 3 0

ball nut is in the center of travel then install sector shaft together with ad
m

kg

14 to 22 fHbl

justing

screw

in gear

housing ensuring

14

Then

that center gear of sector shaft engages with the center gear of the ball nut
Be careful not to

tighten

lock nut after

mov

ing

sector shaft several tUnes

Adjustment of sector shaft and adjusting screw

7

fJ

Tightening torqu
Lock nut
2 0 to 3 0 14 to 22 ft

Note

damage seal

adjusting screw with adjust ing shUn into T shaped groove at the aft head and sector adjust the end play between sector shaft and adjust
ing
screw

Insert

ing lips of operation

9

oil

seal

during

thi5

kg m Ibl

Install sector shaft Be

sure

cover

chousing
when

to

apply

to gear sealant to

each face of sector shaft

cover

packing
counter

play betwean sector shaft and IKljusting screw

0 01 to 0 03 mm 0 0004 to 0 0012 in

End

installing cover By turning adjusting housing

screw

clockwise attach sector shaft cover to

gear

and then

temporarily
cover ST 428

secure it with its

futing bolts
to

10 Available sector shaft

screw

Pull sector shaft toward

2

adjusting

approxUnately
12 0
in

mm

0 08

to

Fig ST 26

Loek Tighteni

Nut

shims

by turning adjusting

screw

counterclockwise and No Thickness

mm

tighten

sector

in

shaft cover fIXing bolts

15
wonn

fJ Tightening torque
1575 to 1 600
0 0620 to 0 0630 Sector shaft co er bolts 2 0 to 3 0 m kg

Measure initial turning torque of shaft assembly

At center

4 0 to 9 0

portion m kt c
lbl in

14 to 22 ft Ib

1 550 to 1 575

3 5 to 7 8

0 0610 to 0 0620 525 1

to 1 550

Maximum turning torque II gear

screw

Push sector shaft against ball nut

Less than
11 0 m c kg 5 in Ib 9

by gradually turning adjusting

0 0600 to 0 0610

1500 to 1525 0 0591 to 0 0600

clockwise until sector shaft gear lightly meshes with ball nut gear and then
screw

temporarily
with lock nut Install gear
move

secure

adjusting

If found

out

of above

turning

torque
to sector shaft correct

readjust adjusting
turning torque

screw

uniil

12

arm

is obtained

Note
pay

When installing attention to

adjUsting

shim is

and from

sector

shaft several times

16

Pour recommended gear oil into

which face

upper and which is lower

the side of gear ann and make sure that it turns smoothly SHl

assembly through fdler hole and install

filler

plug

Steering System
Specified
rofill capaeity

GearcaS8
0 28 liter US pt

tighten bolts securing steering housing to body side member

gear

with the bolt hole in rubberoou

GJ Tightening
Imp ptl

torque b

piing flange yoke and press cou pling bolt through the undercut
section of wonn sheft four grooves of gear ann serrations with four projections of

Steering gear hou ing to body id member 7 0 to 8 0 kum

51 to 58 ft Ibl Rubber

Align

sector haft

haft serrations

and install

Inatallatlon Install steering gear in the order of removal Observe the following instructions
e

coupling
to

to worm

and

tighten

lock washer end nut

reverse

4 0 to 5 0 kg m

29

36 ft Ibl

GJ

Tightening torque
Gelr arm nut 13 to 15 m kg

Position steering gear and rubber coupling in place then install and

Note
a

Align

the groove in

wonn

haft

94 to 108 ft Ibl

STEERING LINKAGE
@

@
@
lID

2 3 4 5 6

Side rod outer socket Side rod Side rod inner socket Id ler arm

Tightening torque afbalt and nuts kg m ft lb

I O @

Steering

gear

arm

Cross rod

@ @ @ @ @ Iti @

3 0 to 7 0 8 0 to 10 0

22 to 51 58 to 72

3 0

to 7 0 22 to 51 5 5 to 7 0 40 to 51 13 to 15 94 to 108

3 0 to 7 0 7 0 to 8 0

22 to 51 to

51 58

ST773

Fig ST 27 St

ring Linka

9 ST

Steering System
REMOVAL
I

Jack

support
2

up the front of car and it on the safety stands cotter

for removal of the side rod ball joints at knuckle arm sides
2

to

get

on

its onter surface

Remove

the idler

arm

nut

and

Remove

pins

and

nuts

disassemble idler assembly

fastening
arms

side rod ball studs to knuckle detach side rod

ball

ASSEMBLY AND
ADJUSTMENT

To

studs A
reverse

from knuckle arms iJuert Steering BaII Joint Remover HT72520000 between them and separate them

mble st

rwg linkage in the

order of disassembly instrucitons

observing

the

following

Ban Joint Before be

sure

installing

new

dus

cover

to

pack with the recommended

grease

J Tightening torque t
Ballltud 3 0 to 7 0
ST675

ST676

kg

122 to 51

lbl ft

Fig

ST 29 Idler Arm

Note
a

Fig ST 28 Remouing Ball Joint

When

tightening

ball stud be

care

Remove ball studs of

arm

cross arm

rod

ful not to aBow grease to get On its tapered section b

Cro
I

rod

nd

Id

rod

When side rod sockets and side

from gear
cross

and idler
same

from
as c

rod

in

the

manner

descnbed in step 3 above Cross rod and side rods

removed as an

Tighten nut to the specified torque and align the cotter pin holes in the tightening direction Be sure to insert new cotter pin and
bend it securely

rod

adjusting

tube

are

separated
done be

adjust side rod length correctly

Adjustment

should

be

can

be

tween ball stud centers

assembly 5 Remove idler assembly from side member by taking off two fixing bolts
Note

Idl

rm

mbl
arm

Standard distance

AU between
conte

inner and outer ballltud

Assembly of the idler

is
I

assembly
Note
a

315

mm

12 40 in

be removed from gear

arm

Steering linkage assembly can CIC by mng rem

from Gear
sector shaft

accomplished

as

follows

with Puller

Steering assembly

Arm

ST2902000 I and by removing idler from side member

Apply recommended grease to the sliding portion of idler arm and rubber bushing
2

Standard

distance
to

an

ap

proximale value
Maire
sure

adjust

toe in

Apply

soapy water on the outer

descnbed in Section FA
tbat

circumference of bushing Press the bushing into idler body carefully until the bushin protrudes

specified
OSs O

toe in is

obtained with installed

on car

and side rods

toe in is not

INSTAllATION
I
verse

iJJ Tightening torque

Install steering linkage in the order of removal
re

ReadjUst
obtained b Be
sure

if

Specified
screw

Idler nut 5 5 to 7 0

to

adjusting adjusting
mm

bar in

qm
c

clret evenly
Make
sure

4010 51 ft Ib

that

iJJ

Tightening torque
Il8l1ltud 30 to 70 qm 122 to 51 ft Ibl Idler body to frame bolts
7 0 to 8 0 q m

Note

When

installing

rubber

bushing
or

screwed in socket 20
or

bar is 0 79 in

use care

not to allow grease

oil

more

151

to 58 ft Ibl

Check wheel

alignment

and if

necessary

adjust

Refer to SectionF A

Hj1
A

lf
ST
77

DISASSEMBLY
I

Disconnect both side rods from

cross

the

rod

following

the procedure

Fig
ST 10

ST 30 Standard Side Rod Length

Steering System
2 with
car

Tighten adjusting
cross

bar

lock

nut
on

deformed
new
one

be sure to

replace with

for

and side rods installed

necessary

breakage wear replace

or

play

and if

Note
Initial turning torque

Apply

grease to idler

ann

as

Note

Lock ball

that

adjusting bar lock joint on outer

arm

nut so

sembly when disassembled

Ball

joint
5 to 25

socket with

kg em
Cross rod and side rod Check side rod and
cross

knuckle

side

is 86019 inner

4 3 to 21 7 ft Ibl

respect
cross

to

that

on

socket Note if grease at recommended intervals and renew

necessary
screw

rod side

Check idler side

To

joint

rod for

breakage
with a

bend
one

or

crack

and

replace

renew

grease

new

if necessary

change INSPECTION AND REPAIR

Ball Joint
1 When ball stud exists
a new

with grease

nipple

and

apply recommended grease to joint through grease nipple until grease is

forced out between dust seal and

Fixing location fIxing location nuts and pins for looseness play or breakage When looseness or play is found check for wear on tapered
cotter

Check

joint
is worn
or

socket

axial Idler
erm

play
with 2

replace side
one

rod socket

8ssembly
arm

portion of ball stud

arm

gear arm or idler

When

dust

cover

is broken or

Check rubber bushing of idler

ST 11

Steering System

SERVICE DATA AND SPECIRCATIONS

GENERAL SPECIFICATIONS
Steering column type Steering
gear type

CollapSIble column Recirculating ball type RB45L

3 2 15 0 I

Turn of steering wheel Lock to lock

Steering gear

ratio

INSPECTION AND ADJUSTMENT

Front wheel

turning angle degrees degrees

m

Inner wheel Outer wheel Minimum turning circle Wall to wall

to

420 i0 35

ft

Steering wheel axial play Steering wheel play

nunin

in mm

380
1 5

i0 31

to

10 0 32 8

0 0 Less than 35
38 1

STEERING GEAR Worm Worm shaft turning torque

at center
as steering portion maxUnum turning torque

gear

assembly kg em in lb in lb cm kg
in

4 0 to 9 0

3 5 to 7 8

Less than 11 0 9 5

Worm

bearing

shUn
mm

Standard total thickness

0 059

Adjusting

shim thickness

mm in

0 762 0 0300 0 254 0 0100

0 127 0 0050

0 050 0 0020

Sector ahaft End play between sector shaft and

adjusting Adjusting

screw

mm

in

shUn thickness

in mm

om
575 1

to

Q3 0 0004 0

to

0 0012

to 1 600

0 0620 to 0 0630 0 06 0 0 0600

to to

1 550 to 1 575 1 525 to 1 500 to 550 1

0 0620
0 0610

525 1

0 0591 to 0 0600

Gear backlash at gear

arm

top end

mm

in

Less than

1 0 004 0

on capacity

liters US pt Imp pt

0 28

STEERING LINKAGE Ball Joint

Turning torque

cm kg

in lb

5 to 25

3 to 21 7 4

ST 12

Steering System
Side rod Standard side rod length

in mm

315

12 40

TIGHTENING TORQUE
COLUMN SHAFT

Steering wheel

nut

kg m
kg
m

ft lb

3 8 to 5 2 27 to 38 3 to 18 I 9 to 13

Column clamp bolts Jacket tube bracket to dash

ft lb

panel
Rubber

kg coupling
to worm

ft lb ft lb

35 0

to

45 0

2 5 to 3 3

shaft

kg

4 0 to 5 0 29 to 36

STEERING GEAR Gear

arm nut

kg
to

ft lb

13 to 15

94 to 108

Steering gear housing

Rear
cover

body

kg kg

ft lb
ft lb

7 0 to 8 0 51 to 58 2 0 to 3 0 2 0 to 3 0 14 to 22 14 to 22

bolt
cover

Sector shaft

bolt
screw

kg
lock

ft lb

Sector shaft adjusting

nut

kg m

ft lb

2 0 to 3 0

14 to 22

STEERING LINKAGE
Idler body
to

frame

kg kg

ft lb

7 0 to 8 0 51 to 58
3 0 to 7 0 22 to 51

Ball stud nut Side rod lock nut

Idler nut

ft lb ft lb ft lb

kg m kg m

8 0 to 10 0 58 to 72
5 5 to 7 0

40 to 51

ST 13

Steering System

TROUBLE DIAGNOSES AND CORRECTIONS

In addition to the following proba ble
causes

to Trouble in Front

Diagnoses and Corrections

section

and corrective actions refer

Axle and Front Suspension

Condition

Probable

cause

Corrective action

Excessive wheel play

Insufficiently tightened
Damaged steering linkage

or

ilnproperly

in

Retighten

stalled steering gear housing

or

ball joint

Re lace

faulty parts

Incorrect adjustment of steering gear Vibration shock

or

Adjust
in

Insufficiently tightened
Wear of steering

or

ilnproperly

Retighten

shimmying
wheel

of steering

stalled steering gear housing

linkage

Replace faulty parts Replace

weakened column

Damaged idler
Worn

arm

column bearing
or loose

Replace

or

retighten

bearing spring
Car pulls to right left
or

clamp
or

Deformed steering linkage and link

suspension

Replace

Stiff

or

heavy steering

Insufficient lubricants
in

wheel

steering linkage ing linkage

Worn
or

or

or mixing impurities excessively worn steer

Replenish

grease or

replace the part

damaged steering

gear and

bearing

Replace Adjust Replace

Incorrectly adjusted steering gear

Deformed steering liilkage Interference of steering column with turn signal switch

Adjust

ST 14

Steering System

SPEOAL SERVICE TOOLS

IKent
Tool number tool
name

Moore No

Kent Moore No

Reference
page
or

Tool number

tool

name

Reference
page
or

Fis No ST27180001

Fis No ST29020001

Steering

wheel

puller

J 25726

Steering gear

arm

puller

J 25725

Fig
n

4 ST

Fig ST 15

Page

ST 12

KV48100300

Strut

steering gear box

J 25729

H172520000

Ball joint

remover

attachment

Fig ST 20

Fig ST 28

11 1l

1
J 25765

III

ST3127SOO0

Preload gauge

DGG91030000 @HT62940000 l HT62900000

D
J 25765

Torque wrench Socket adapter Socket adapter

@ @
Fig ST 23

Q l

ST 15

DATSUN 210

Model 8310 Series

SECTIONFE
ENGINE CONTROL FUEL EXHAUST SYSTEMS
CONTENTS
ENGINE CONTROL SYSTEM
ACCELERATOR CONTROL SYSTEM FE 2 FE 2 4 FE FE 5 FE 5 INSTALLATION FE

Ii
8 FE

EXHAUST
REMOVAL

SYSTEM

FE 7

FUEL SYSTEM REMOVAL INSPECTION

INSPECTION

FE 9 FE 9

INSTALLATION

Engine

Control

Fuel

Exhaust

SYlltems

ENGINE CONTROL SYSTEM

ACCELERATOR CONTROL SYSTEM @

I
1 Acce i ator pedal
arm I

IJ

2 3
4 S

pedal Stopper bolt Stopper lock nut

Accelerator

II
V

Kickdown switch striker

Automatic transmission

6
1

models only Accelerator wire outer case Accelerator wire socket

Accelerator

8 9 10 11 12

inner wire Accelerator pedal bracket

and return

spring

Kickdown switch
Accelerator

pedal stopper rubber Accelerator pedal stopper bracket

I
@

109

mm

4 29 in
F E558

Fig

FE I Accelerator Control System

REMOVAL AND INSTALLATION

Accelerator I wI e

INSPECTION
I Check accelerator pedal
rust return

Note

adjustment securely tighten stopper bolt lock nut

Pull outer
sure

After

spring for

fatigue

or

damage
3
case

Disconnect accelerator wire from

Remove
arm

Replace
2

carburetor 2 snap pin then disconnect wire from

arm

if necessary Check accelerator

to uP

direction
re

wire

cases

making

that throttle lever is

from

tip of

socket and

pedal
3

damage

or

fastening locations for rust looseness Repair or replace

turned to
outer case

idle
I

position

Move back from

a

mm

0 04 in

accelerator

pedal

if necessary

Remove accelerator

pedal stopper
and

position where throttle lever starts moving and fasten outer case securely
with

bracket from dash

panel

pull

into

clamp

driver compartment 4 To install reverse order of moval

Ie

ADJUSTMENT
Accelerator pedal I
a

embly
Accelerator IInka I
e car

Disconnect accelerator wire at tip ofaccelerator pedal arm 2 Remove

screws

Connect accelerator wire to

securing accel

buretor and accelerator 2

pedal arm
H with stop FE I
1

erator

pedal bracket to body

accelerator

Adjust

dilnension

Q4t
Clamp
Outer
case

3 dash
4

Remove

pedal

from

per bolt

as shown in

Fig

panel
To install
reverse

FE1

order of

re

Dimension

moval

Fig FE 2 Adju ting Accolerator

109mm 4 29 in

Linkage

FE 2

Engine
4 When accelerator make
sure

Control

Fuel
to

Exhaust
idle position pedal is released

Systems
as

pedal
that

is

fully

returns
soon as

securely

switch

adjustment

is correct if kick

depressed

throttle have

accelerator

valve opens fuUy 5 After above

been made

adjustments
sure

K1ckdown switch On models the

it

down switch is actuated by the stop per located on the tip end of pedal
arm

when

accelerator

pedal

is

de

make

that accelerator

automatic

transmission

linkage operates smoothly without dragging Make sure that throttle lever

is also necessary to

adjust

pressed fuUy Always tighten lock nut securely when proper adjustment is
obtained

kickdown

switch

The

kickdown

FE 3

m l CO S C1 C l ol

1C1 Q j O m r llc Ul

CIl

Ul C13 VI

C2 m r0 C
V0 n I
O

Ct ms

c en l 3 I GOe

lb ft
m

17
10

kg

torque

12
4 2

to
6

Tightenig

unit

hose tank plug hose Fuel Drain Fil er

1

hose

23

Ventilao Breathr Evaportive

4

tank return outlet Fuel Fuel Fuel Fuel Fuel

gauge tube tube tubo

protec r canister tank strainer

Carbon

567 8 9

10 11 12

e
D D

tt

line

IlQ
A

pUlse

Canilter
m

t3

it

tt S

Engine Control

Fuel

Exhaust protector

Systems
FUEL TUBE Fuel tubes
are

REMOVAL
WARNING When
sure a

Remove fuel tank

Remove fuel tank

serviced

as an assem

bly
fuel line parts be Hatchback and Wagon I
2

so

that the

replacing
a

tube can be not

replacement of fuel easily done However do

to observe the

following
INFLAM

Put

CAUTION

Disconnect
Drain

battery ground cable

fuel tank then

disconnect

any

fuel line unless

sign in workshop Be sure to furnish workshop with In asphyxiator Be sure to disconnect battery ground cable before conducting operations Put drained fuel in an explosion proof container and put on lid securely
MABLE

fuel from

absolutely
2

necessary

disconnect fuel hose

Drain fuel from fuel tank

luggage carpet luggage board inspection covef and side finish

3

Remove

Loosen fuel hose clamps and dis connect fuel tube at each end
Note

er

Disconnect

fuel filler hose

vent

hoses and fuel tank gauge unit wire connector See Fig FE 5
5 Remove fuel tank Remove fuel tank

Plug hose and tube openings to prevent entry of dust or dirt while removing
Unfasten clips that hold tube
on

protector

underbody
car

and remove tube from the

FUEL TANK
Sedan FUEL TANK GAUGE UNIT
I

FUEL FILTER
I

Disconnect battery ground cable

Drain fuel from

Disconnect fuel hoses from fuel

fuel tank

then

Sedan
1

disconnect fuel hose

filter by removing clamps 2 Take out fuel strainer and discard

in 3

Remove

filler
cover

hose
in

and inspection

protector luggage com

inspection cover gage compartment See Fig FE

2 wire connector 3

Remove

lug

it

Disconnect fuel tank gauge unit

Remove fuel tank gauge unit

INSPECTION
Hatchback and Wagon
I Remove

FUEL TANK

Filler hose protector

tl f i
cover

board and
2

luggage carpet inspection cover

luggage

Check fuel tank for cracks

mation If necessary

or

defor

Disconnect fuel tank gauge unit

Remove fuel tank gauge unit

replace

wire connector

FUEL HOSE

Inspection

FE561

Fig FE

Removing Filler Hose

Protector and Inspection Cover

Inspect all hoses for cracks fatigue sweating or deterioration Replace any hose that is damaged
FUEL TUBE

CHECK VALVE
4 Disconnect

fuel filler hose

vent

Replace
Sedan
I Remove

any fuel tube that is crack

hoses and fuel tank gauge unit wire

connector

ed rusted

collapsed

or

deformed

inspection

cover

and fuel
com

JI

filler hose protector in luggage

FUEL FILTER

partment
2 Remove check valve

Replace fuel filter

maintenance interval

at the
or

specified

if it becomes

clogged or
Hatchback
I Remove

restricted

Fuel filter is of a cartridge type and

luggage carpet

luggage

cannot

be

cleaned
one

Always replace

board and luggage side finisher 2

I

with

a new

Remove check valve

CHECK VALVE
2 3
FE562

Wagon
I Remove
rear

Blow

air

through

connector on

side

finisher

in

fuel tank side

A considerable resistance should be

Fig FE 5 Diconnecting Ho

and

luggage compartment
2 Remove check valve

Connector

felt at the mouth and

portion of

air

FE 5

Engine Control f1lel

flow be directed toward
side 2

Exhaust

Systems
@ Tightening torque
Drain plug 1 6 to 2 4

atmosphere
on

Note
a

Install hose clamps securely Do not

Blow air tluough connector

atmosphere side Air flow should be smoothly directed toward fuel tank 3 If cbeck valve is suspected of not being properly functioning in steps I
and 2 above replace

tighten excessively to avoid dam aging hoses b Fasten clips holding fuel tube on underbody securely Failure to fol
low

kg

112 tn 17 ft bl
Fuel tank 0 8 to 1 2

kllm

this caution

could result in

15 8

to

8 7 ft Ibl

damage
c

to the surface of fuel tube

Do not kink or twist hOse and tube

To

fuel tank

when they

are

routed

d Run the engine and check for leaks

at connections

FUEL TANK GAUGE UNIT

Note unit When

Pressure valve

Vacuum valve
Return spring
FE477

installing fuel tank gauge aJign the projection of tank

FUEL TANK Not InstaU fuel filler hose after fuel

Fig

6 FE

Checking

Check Valve

gauge unit with the notch in fuel tank and tighten it securely Be sure
to

instaU

tank has been mounted in

tank

place

gauge

unit

with

Failure to foUow this rule could

ring

in

place

INSTALLATION
Install any parts of the fuel system
in the reverse order of removal Ob
serve

result in leakage from around hose connections

vent Do not twist or smash
are

CHECK VALVE
Note When

hoses when they

routed

Be sure to retain them with

clips

careful of its See

installing check valve be designated direction

the

following

notes

securely

Fig

FE

6 FE

m co i CD

21 CD

l2 m

Ul

CD 3

mX
e a

c en 4 en
@

en 4 m s

8 O

c 6l

8l

@@ @

l@ @
lb
ft

19 31 15 83 kg to to to to to 82 14 23 52

7 6

torque
5

12

63t 2

25

I r

Tightenig
up er
6

to

t04

to to to
1
0 0

026 8 3 23

@@ @@@

shelt r bracket

Convert Exhaust
@
I

mountig clamp housing mountig clamp

calmp
tail

bracket rub er

ring

bolt U bolt
V

Gus et Exhaust Mufler

789

10 11 12 13

exhaust convert exhaust mounti g exhaust lower Front Cat lyic Rear Exhaust Rear Convert
1

tube tube

insulator shelt r shelt r

tube

234S

ClI@
iJ @

transmio models
Aut

7Jr

omatic

equiped
m 3

3a 3 c1

32

TI m

Engine Control
Non California models except FU model

fuel

Exhaust Systems

8@
Automatic transmission equipped models

4 wp
8

Front tube assembly

muff1er Pre

Tightening torque

m kg

lb ft

2 3
4

Exhaust tube clip

Momer

@
@ @

wembly

5 6 7 8 9

Muffler clamp ring rubber Rear tube Exhaust mounting insulator Exha st tail mounting bracket Exhaust mounting 1 ttacket

2 0 to 2 6 14 to t9 0 8 to 12 5 8 to 8 7 3 2 to 4 3 23 to 31

FE629

Fig

B FE

E haust System Non California mode

cept FU modet

REMOVAL
CALIFORNIA

MODELS

AND FU MODEL
I

Remove catalytic converter shel

ter and rear exhaust tube shelter

2
and

Temporarily
remove

loosen bolts securing

exhaust mounting insulator to bolts

body

securing muffler

lower clamp imd muffler to muffler

upper

clamp
FE639

II
F

E640

Note

Take

care

Dot to

drop

muffler

heat insulator
3

Fig

FE 9 Putting Rear E halUt Tube 4

Fig FE IO Removing Rear

xhault E

Tube Assembly

Remove

rear

exhaust tube from and

remove

Remove catalytic converter from loosen nuts securing

catalytic
from

converter

it

front exhaust tube 5

2

car as

follows

Temporarily

Remove bolts securing exhaust mounting insulator to body and put

rear

f root exhaust tube to exhaust mani Pull

rear

exhaust tube
as

exhaust tube

on rear axle case as

forward FE

to

place
pull

shown in

assembly Fig assembly

fold 6 Remove front exhaust tube from V bolt

shown in Fig FE 9

IO

Then
rear

it

further while tube

swaying

exhaust

exhaust mounting bracket 7 Remove bolt securing

clockwise and counterclockwise

FE B

housing clamp

to

gusset

Engine Control
8

Fuel
a

Exhaust
tap

Systems
on

Remove front exhaust tube from

2 the

Using
front
it

rubber hammer

CatalytiC

converter to

front

exhaust manifold NON CALIFORNIA MODELS

end of the muffler while toward

rear

tube bolts 3 2 to 4 3

pushing
assembly
EXCEPT FU MODEL
I

The muffler

kg

can then be taken out

23 to 31 ft Ibl

Catalytic converter
rear

to

Temporarily
exhaust

loosen nuts securing

tUbe

bolts

front

tube

3 2 to 4 3

assembly

to

ex

kg

haust manifold 2
et 3 Remove front

23 to 31 ft Ibl
as

exhaust tube

Exhaust tail mounting bracket

to

sembly from exhaust mounting brack Temporarily loosen bolts securing

remove

body bolts
0 8 to 1 2

kg

5 B to 8 7 ft Ibl Exhaust
to

exhaust mounting insulator to body and bolts securing muffler clamp and muffler to muffler upper clamp
lower

exhaust tail

mounting insulator mounting kg

m

bracket nut
FE632

0 8 to 1 2

Fig FE 13 Tapping Muffler with

a

4 5

Remove exhaust tube clip Break sealant off the front tube

Rubber Hammer
rear

5 8 to 8 7 ft Ib Exhaust

mounting insulator kg
m

to

to rear tube connection

tube nut O B to 1 2

INSPECTION
Note
A sealant is

applied

to the tube I

5 8 to 8 7 ft Ib

connections to eliminate the leak

age of exhaust gases

Check

pre muffler

muffler

as

Observe the

section 6

procedures outlined later in this as a guide

Remove front tube from exhaust
remove rear tube

sembly and tubes for cracks damage or corrosion Replace if necessary 2 Replace bracket and mounting rubber that are cracked fatigued or
sweated

Catalytic converter shelter O B to 1 2 kg m

5 8 to B 7 ft Ib

bolts

Rear exhaust tube shelter bolts 0 3 to 0 5

kg

2 2 to 3 6 ft bl

manifold then
car

from Installation precautions

Refer to California Models and FU

Model for removal When

disconnecting

the

exhaust

INSTALLATION
Install exhaust system which has been removed
verse as an

I to

When assembling be careful not

tube connections

observe the follow

ing parts

assembly

in re

let gas leak from around connec tions of exhaust system components

I
tube

Break old sealant off the

con

order of removal

Observe the

Evenly tighten
2

nut

securing exhaust

nection

by lightly tapping around the

a

following
CALIFORNIA MODELS AND FU MODEL

manifold to front exhaust tube

with

hammer

and

twisting

Always maintain sufficient clear

between heat shield insulators

muffler

ance

and adjacent parts See Fig FE I7 3 Be

sure

1Jl

to install new

Tightening torque
Exhaust manifold to front tube nuts 2 0 to 2 6

gaskets and

bolts after removing following parts Front tube

kg

Catalytic converter
m

Rear tube
to

14 to 19 fHb U bolt

housing clamp

Install

gusset bolt
3 2 to 4 3 kg m
F

assembly
I
31 ft bl nuts

mounting parts as sub body Always locate mounting rubbers

on car

E630

23
U bolt

to

in such way that

preload applied

to

Fig FE 11 Breaking Sealant

clamp securing
lm k 12 to 15 ft

them is kept to minimum

1 6 to 2 1

bl

Exhaust mounting bracket to transmission nuts 0 8 to 1 2

f
m

kg

Do not apply excessive load I

5 8 to 8 7 ft Exhaust

Ibl
bracket to

mounting
to

front tube bolt

3 2 Fig FEd 2

4 3

km l

F E289

23 to 31 ft Ib

Fig FE J4 Mounting Rubbe

FE 9

Engine Control
2
For sulator refer to

Fuel

Exhaust

Systems
Aft instaDation bers and check that

inStallation of inounting in Figs FE 15 and FE 16

mOlmting brackets mounting rub

mounting

insoIator

are

Front

free from undue If

r r

l
FE600

oYof
i

str liboft part is DOtinstalled

excessM noises

or

wbra
car

tions may be

transmitted to

body
2 mm 2 t 0 08 to 0 08 in
Fig FE IS lrutalling Mounting
lruulator 1
FE501

2 to 8 mm oS to 0 31 in

b Check all tube colll1ections for

ell

Fig FE I6

tolling Mounting
lmulator 2

hanst gas leaks and entire system for unusual noises witb engine run

ning

1
A

Section A

Oearance 1 2

mm

in 6

20 to 30 0 79 to 1 18 13 5 to 5 19 531 0
to

0 768 3 20 5 to 26 5 0 807 to 143 4 23 to 33 0 91 to 1 30 5 20 to 30 0 79 to 1 18

Exhaust fmisher equipped models except Wagon 20 to 30 0 79 to 1 18 Other models 22 to 32 0 87 to 1 26

Fig FE I 7

Proper

nce Clea

for

rMust E

System

Note

Section B

FE633

Californw models and FU model

FE tO

Engine Control
NON CALIFORNIA EXCEPT FU

Fuel

Exhaust

Systems
3

MODELS

Exhaust to

MODEL

mounting insulator exhaust tail mounting

O B to 1 2

When installing exhaust tube and

sure

muffler make
ance

that a proper clear

Install exhaust order of removal Observe

system

in reverse

bracket nut

is maintained between these

on car

kgm

and parts
4 For sulator

following precautions

5 8 to 8 7 ft Ib

parts body See Fig FE 18 installation of mounting in precautions

Exhaust mounting insulator to

rear

refer to California Models and

til

Tightening torqu
Exhaust manifold to front tube nuts 2 0 to 2 6

tube nut 0 8 to 1 2 kg m 5 B to 8 7 ft Ibl

FU model for installation

kg

14 to 19 ft Ibl Exhaust

mounting

bracket to

transmission nuts 0 8 to 1 2

kgm
Note

5 8 to 8 7 ft Ibl Exhaust mounting bracket to front tube bolt 3 2 to 4 3

Installation precautions
I

After

installation

check

that

Always assemble parts

leaks from
nut

so

that

no

kg

gas

around connections

bbenl and mounting mounting I insulator are free from undue stress Ifany ofabove parts is not installed properly excessive noises or vibra tions
may be

23 to 31 ft b Exhaust tube clip bolt 0 8 to 1 2

Evenly tighten

securing exhaust

kg

manifold to front tube fixing plate 2 Insert end of tube until it comes
into contact with bracket to

transmitted to

car

5 8 to 8 7 ft Exhaust tail

bl

mounting kg
m

body bolts
0 8 to 1 2 5 8 to 8 7 ft Ibl

stopper clip and inject a suitable sealing compound through slit

it with exhaust tube in tube

Then secure

body
b Check all tube connections for
ex

until it

overflows

Refer to

haust gas leaks and entire system for unusual noises with engine run

Sealing Compound

ning

j
A

@
B

f
IA

Section A Oearance 1
2
mm

in to

30 to 40

18 1

57 1

Exhaust fmisher equipped models except Wagon 23 to 33 0 91 to 1 30 Other models 21 to 31 0 83 to 122

13 5 to 19 5 0 531 to 0 768 20 5 to 26 5 0 807 to 1043 23 to 33 20 to 30 0 91 to 1 30 0 79 to 1 18

3 4 5

Fig

FE 18 Proper Clearance for Exhaust System

Non California models except FU model

Section B

FE634

FE 11

Enr in e
SEALING

Control

Fuel

l Ixhaust
c

System i

COMPOuND
are

If exhaust tubes connection to

etc
renew

separated

at

muffler assembly

use the Genuine Nissan Sealant Exhaust Sealant Kit 20720 N2225

to eliminate gas

leakage past the joint

Be

sure

to

observe following proce

dures
I

ee

Fig

r21 FJ
the oontact por

Wipe

clean all

tions of tube

to dry thoroughly 2 Temporarily mount in place muf fler assembly and or exhaust tube as
an

joints allow them

assembled unit Insert the

on the car

male

tube

into the

female tube

fully

until the front end

FE109

of the female tube touches the stopper on the male tube

A B 55mm 2 17in

Fig FE 21 Exhaust Sealant Kit

t Smm 0 59i 6

AI
Il L
l

Position the nozzle of injector to

traces of sealant 7 Start the

the guide and press it there

firmly

engine

and let it minilnum

idle
to
ex

Inject sealant slowly until sealant be gins to flow out of the slit of the tube
This indicates that the bead requires no further sealant Excessive sealant
F

slowly for
harden haust gas 8

ten minutes

sealant with the heat of

Check the

oondition of sealant
car

E574

can

cause

clogged tube
wash

See

Fig

before

driving sharply
to

the

It is also essen

Fig FE 19 Ex unut Tube Connection

FE 22

tial that the car should not be accel

After injecting

injector thor
remove

erated

for 20 to 30 minutes this operation

Torque exhaust tube clip securing

oughly

in clean water to

all

subsequent

bolt and exhaust tube mounting bolt

to

specifications
Exhaust tube

liJ Tightening torque

0 8 to 1 2

15 8 to
5

clip bolt kg m 8 7 h bl
31 0
to

Squeeze

5 to 6 cc

37 0

cu in of sealant into

injector from the

sealant tube
Be sure to place the cap back to the sealant tube since sealant will dry

Sealant tube

5 to 6 cc 0 31 toO 37cuin

FEltl

Fig FE

20

Squeezing Senlant to Injector

FE 12

FE568

Fig FE 22 Injecting Seatant

Engine Control
Note
a

Fuel

Exhaust

Systems
tube with lukewarm water until the

place where the ambient tempera

ture is 400C

The sealant should be used within

I040F

or

above A I040F The most

sealant is softened the tube at 400C time d

a

Do not

warm

guaranty
case

term indicated

on

the kit

sealant hardened at 400 C

or

above cannot be used

temperature of over I040F for a long period of

read the instruction

b Exposure of sealant to the skin may cause a rash Wash sealant off the skin with water
c

suitable storage temperature is from 15 to 350C 59 to 950F If sealant beoomes hardened because of low the sealant warm

Thoroughly

sheet furnished with the kit before

Do not

keep

the sealant tube in

temperatures

using the sealant

FE 13

DATSUN 210

Model 8310 Series

F
BODY
CONTENTS
BODY CONSTRUCTION
BF BF BF BF BF BF SF 2 4 5 5 6 8 8 9 9 9 TAILGATE

Wagon

BF 20

BODY ALIGNMENT
BUMPER
DESCRIPTION INSPECTION FRONT BUMPER

WINDSHIELD AND
WINDOW GLASS
WINDSHIELD GLASS REAR WINDOW GLASS Sedan and BF 22 GLASS 8F 21 SF 21

Hatchback
REAR WINDOW SIDE

REAR BUMPER

Wagon
2 Door Sedan

SF 23

BODY FRONT
RADIATOR FRONT COWL FRONT FENDER HOOD HOOD LOCK

END

BF BF BF

WINDOW GLASS

GRILLE

and Hatchback REAR QUARTER Hatchback REAR SIDE WINDOW WINDOW GLASS

BF 26

APRON TOP GRILLE FENDER PROTECTOR

BF 10 BF 10 BF 10 BF 11

BF 26

GLASS

Wagon

BF 27 SF 29 BF 29 SF 30 BF 30

INTERIOR
INSTRUMENT PANEL CONSOLE BOX SEAT SEAT BELT

CONTROL

BF 11 BF 12 BF 12

DOORS
FRONT DOOR REAR DOOR 4 door Sedan and Wagon

BF 31 SF 32 BF 32 BF 32 BF 34

BF 15 BF 16 BF 16 BF 18

TRIM AND MOLDING

ROOF BODY TRIMMING SIDE TRIM AND MOLDING

BODY REAR END

TRUNK LID SAC K 000 R Sedan Hatchabck

SPECIAL SERVICE

TOOLS

Body

BODY

CONSTRUCTION

Z3
Section C Section D Section F

I
Section E Section G

w
Section B Section A

fTIf
Section H
BF512B

dan Fig BF l Body Construction S

BF 2

Body

Section D

Section C

Section F

L
Section E Section G

Wi
Section B Section A

ionl
II
Section F

BF5138

Hatchback Fig BF 2 BodY C onstruction

Section E

iii

Section G

J Section A Section B

Section J
BF514B

Section I Section H

Wagon Fig BF 3 B o d y Construe tion

BF 3

CD o 0

aJ o o

f C5 z3 m z4

00
i

bracket
13 37 35 28

floor
Rear
r 9
f

Wagon
8
1

absore
2740
95
2

65
35 36
O

943

Shock
k

33

ow
I
I

720 696

78
1

847 931
LB
I

5o 0

link
1

r
13

D D D
1

of

34 34
1

bracket

eu 90

18

Up er bracket
C C
i

Section

line

Center

axle
rear

SprIng

360 t4
r

17

1 0 00

1
i
0

s VI
c

57 1
C C

91

axle

67

40

w
I

lol
J
f

tJ
w
b c

bumper bracke ember bracket mount seat eat

I

20
0 5

234092
r

cro

link
r

ont ens
r

ine

floor

35 3

F t

ont Rear Frr

From

l r
c

1 r r
I

Lower acket
I

217

81
1

55 46
H H L R

Section
f
i

front
0

725 1
46
33
7

r
JIo
I

t
00 r Zv
I

43 1 701

II
18 1
j
f

III
v

06
1

line

7t
1
6

I t

t
I

JI 39 55 1

96 44 16

Center
I

850

43

635
0 O0 c

142 639

25

135

31

30 27
H H

L R

U9
A
I

r 474
10 1 28

0 00

J l

A
h

LLtL
I

II

TlI UI
t
I

58 28

505 19
50 38 1 J

88

Section
I

0O

rL Section

It

eo
l

g
J

side

Front me b r

68 681

E
tD 1 tD

l ii b

l0 b

Xl

Body

BUMPER

DESCRIPTION
The front and

section

reduces

to

nummum car

the

CAUTION

LABEL

possibility
when collision

of damaging the
is

body
a

essentially
side

of

bumpers consist center bumper two

rear

Pasted on shock absorbers

the bumper

involved in

bumpers

and two shock absorbers

DANGER i
Contents under
t

The bumper is attached to the side strut member through a gas filled

e
CAUTION The shock ebsorber is filled with
a

type shock absorber

at each end to

pressure Don t take

e e
t

effectively
The

absorb

the

energy
is

of

apart

puncture heat
or

collision upon ilnpact side

bumper

constructed
and porous

with a steel insert

pressure gn and should not be disassembled drilled or exposed to In

high

apply

fira

panel

open flame
3S
mm

urethane rubber The urethane rubber

1 38 in

FRONT BUMPER

x
I

1 2

Front center

bumper

Over rider Side bumper

3 4
5

Bumper mounting bracket Center bumper brace Bumper rainforce Sight shield
Shock absorber

6
7

8 9

Bumper attaching bolt

BF738B

Fig BF 5 Front Bumper

BF 5

Body
REAR BUMPER

sP
9

m
1 2 3 4
5 Rear
ceo ter

bumper

Over rider Side bumper Center brace

6
7

8 9 10

bracket Bumper moun Bame plate Bumpe r reinforce Sight shl ld Wagon only Shock absor

mg bumpe

1Doo
BF739B

Bumper

atta

mg bolt

Fig BF6 Rear Bump

r

INSPECTION
To

and shock absor

mg
c hart

tilize the follow d proceed in the

Good

order indicated

the chart

inspect condition of bumper

asaguld

Measure shock Good

absorber

Good

dimensions

Visually

c he ck

bumper

No

appearance

good

Measure

bumper height

No good

Check shock

absOrber operation compressed

and

No goo d

Adjust bumper height

expanded
No go od

Replace
shock
absorber

Good

6 BF

Body
Bumper height

Place car

on a

flat surface under Tires must be

curb weight condition

inflated to rated pressure 2 Measure height above

ground

of
as

bumper
3 If

at two

mounting locations

shown in Figs BF 7 and BF 8

bumper height

is not within

the

specification

loosen

shock

ab

sorber attaching bolts and nuts Then

adjust bumper height

ment

After nuts

adjust

tighten bolts and

securely

Front bumper height

360 to 408 mm 14 17 to 16 06 in Rear bumper

height

Sedan and Hatchback 391 to 433 mm 15 39 to 17 05 in

Wagon
376 to 418
mm

BF740B

14 BO to 16 46 in

Fig BF 7 Front Bumper Height

Sedan and Hatchback

Wagon

I
S
H

J O

j
BF741B

Fig BF 8 Rear Bumper Height

BF 7

Body
2

Length of shock absorber

FRONT BUMPER
REMOVAL AND INSTALLATION
1 Loosen
to

Front shock absorber 164 6 46

bolts

attaching
BF 5

front
re

q
67
2

j
I
64

0
0

bumper move bumper

0 2

shock absorbers and

See

Fig

Loosen bolts attaching shock ab sorbers to radia tor core support and side members and
remove

shock

absorbers Rear shock absorber

94 3 70

Install shock absorbers and front

bumper in reverse order and adjust bumper height Fig BF 7

rL
I

of removal
as

shown in

fj

G
Unit 3

riAl yll L J

i
r T

mm

in

67 2 64

f W L 1
8F742B

Tightening torque Front bumper Bumper to shock absorber attaching bolt 6 0 to 8 0 kg m

43 to 58 ft Ib
Shock absorber body to

Fig BF 9 Length of Shock Absorber

Checking
Place

shock absorber in

3
a

Make

sure

bumper
when

returns to its

attaching
67

bolt and nut front m kg B 7 ft Ibl

car

front

of

wall

original
tracted Note
ers

position

jack

is

0 93 to 1 2
re

Apply
2

hand brake and place wheel

a

to

chocks securely Place

attaching
When make

bolt and nut sida 5 2

jack between wall and

20
mm

extend 0 79 in
ward tion

jack approximately
The

bumper
I

should move 97 in back

type and

replacing shock absorb Sure they are of the same rating and manufactured

1 9 to

kg

14 to 18 ft b

approxilnately

50 mm

by the same maker

REAR BUMPER
REMOVAL AND

through shock absorber opera See Fig BF IO

Use
a

4
same

For

rear

bumper
as

utilize

the

INSTALLATION
1

Note

more

than 600

jack with kg I 3231b

of

procedures

described for front

Loosen
to

bolts

bumper

attaching Fig
BF 6

rear re

bumper
2

shock absorbers and

See

move rear

bumper

Loosen bolts and nuts shock absorbers

attaching

shock absorbers to side members and

remove

Install shock absorbers

in reverse order
rear

an

rear

bumper
and

of removal
as

adjust

bumper height

shown in Fig BF B

fj

Tightening torque
Rear bumper
absorber shock Bumper to attaching bolt rear 6 0 to 8 0 kg m

43 to 58 ft b
f Shock absorber to body

attaching

bolt and nut 2 1

rear

0 93 to
1

kg m side

Front bumper
Jack

6 7 to 8 7 ft b

2
BF7438

attaching bolt

and nut

Wheel chock

6 0 to BoO

kg

Fig BF 10 Checking Shock Abaorber Function

8 BF

43 to 58 ft b

Body

BODY FRONT END

RADIATOR GRILLE
REMOVAL AND INSTALLATION
I 2

Open hood
Remove

radiator grille attaching

screws

Detach radiator grille from front Disconnect

connectors front

end of car 4

combination
remove

lamp
tor S

Then

radia

grille
Installation is in the
reverse

order

of removal

Note
a

Radiator grille is made of plastic do not

use

so

excessive force to

Take

care

keep

any

oil away

from radiator grille

8F7448

Fig BF 11 Removing RadiIJtor Grille

FRONT APRON
REMOVAL AND

INSTALLATION
1

Remove

screws

attaching attaching attaching

support

front
4

apron to front fender 2

Remove

screws

front

apron to hood lock stay 3 Remove

screws
core

1
I

oo

front

apron to radiator 4

Remove

screws

attaching front

apron to bracket S Installation is in the reverse order of removal

g
o

Q i

I
i

S ole
f

nl

Jf

rf
BF745B

Fig BF 12 Remouing Front Apron

BF 9

Body
COWL TOP GRILLE
1 Cowl

REMOVAL AND
INSTALLATION
Remove

2 3 4 5

lOp grille Hood sealing rubber

Screw

Open

windshield wiper arms engine hood and protect

covers

Cowl top grille cap

Sealing

rubber

front fenders with

to

prevent

scratchirig the paint

3
4

Remove cowl top grille attaching

Draw cowl

screws

top grille forward

Installation is in the reverse order

of removal

BF5238

Fig BF 13

Cowl Top Grille

FRONT FENDER
REMOVAL AND INSTALLATION
I Remove front for

bumper Refer top grille Refer

to

Bumper
2

removal and installation

to

Remove cowl

Cowl Top Grille for removal and in stallation 3

4 Remove
as

front

turn

signal lamp

assembly

described in Section BE

Remove bolts attaching fender to

and

hoodledge upper side front apron

front 5

pillar

Then

remove

front fender
reverse

Installation is in the

order

of removal
Note Be
sure

to

apply sealant be

tween

front fender and

hoodledge
BF5248

panel
Fig BF 14

Front Fender

FENDER PROTECTOR
REMOVAL AND INSTALLATION I Remove
to
screws

Note

installing front fender panel apply clip to mating edge of

fender and protector

After

retaining fender
p nel
can

protector
2 taken 3

hoodledge

Then fender
out

protector
is in

be

Fender protector
Mud

easily
the
reverse

2 3 4

guard
BF525B

Clip
Fender panel

Installation

order of removal
BF 10

Fig BF 15 Fender Protector

Body HOOD
ADJUSTMENT adjusted with bolts hood hinges hood lock mechanism and hood bumpers Adjust hood for an even fit between
Hood
can

be

attaching hood

to

front fenders

Adjust hood according following procedures

I

to

the

Adjust hood fore and aft by loosening bolts attaching hood to hinge and repositioning hood 2 Loosen hood bumper lock nuts and lower bumpers until they do
not contact front

ZiIfii
1 2

of hood
of

when Striker

hood is closed
3

Set

striker

at

center

hood

lock bolts
4

and tighten hood lock securing

Hinge
Hood bumper
Hood lock

3
4

temporarily
Raise
two

hood bumpers

until
BF526B

hood is flush with fenders 5

Tighten

hood lock

after the proper obtained

securing bolts adjustment has been

Fig BF

16

Adju ting Hood

REMOVAL AND INSTALLATION

I with

Open hood
covers to

and

protect

prevent

body scratching
on

1 2 3 4

Cable bracket Cable clip

Hood lock

painted surface
2 Mark hood

Safety catth lever Striker 3

hinge

locations

hood for proper reinstallation 3

II

Holding
remove

both

sides

of

hood

unscrew

and

bolts securing hinge to hood hood This operation re

1 is in the
reverse LeS5 than 35
mm

quires
4

two men 5

Installation

order of removal

O l

rJ
BF746B

HOOD LOCK

CONTROL
REMOVAL AND INSTALLATION
1

Disconnect

control

cable

from

hood lock 2 3

Remove hood lock

cable

Fig BF 17 Hood Lock Control

Remove control retaining clamp from engine compartment

4

Remove hood lock release handle

remove

ment

Note

attaching bolts and

dash side 5

hood lock

Open

and

close

hood

several

Lubricate

pivot safety catch lever

release handle and control cable from

panel
reverse

Installation is in the

order

of removal

referring

to

Hood

Adjust

operation Make sure safety catch lever re 7 tains hood properly when hood lock is disengaged
BF ll

times to check

and return spring b Inspect safety catch lever and re turn spring for defonnation fatigue
or

rusting

Body

DOORS

FRONT DOOR

Doorglas5
Inside

door handle

3
4

Front lower sash

@ @

5 6 7

Regulator handle Regulator assembly Glass lower guide

Guide channel B
Door lock assembly Door lock cylinder

8
9

10

Outside door handle Guide channel A

Door

11 12

lock knob

BF52BB

Fig BF 18 Front Door

100r 4

mode16

Doorglass
Guide channel A Inside door handle Front lower sash

ID 1J

3
4

5 6
1

Regulator handle Regulator assembly

Guide channel B Glass lower guide Doorlock assembly
Door lock

tp

8 9

J
8

10 11 12

cylinder

Outside door handle Inside door lock knob

@
Fig BF 19 Door
100r 2

BF529B

mode16

BF 12

Body
FRONT DOOR ASSEMBLY
Note

Adjustment Proper door alignment can be by adjusting door hinge

Front door hinge
without
can

Apply grease to of levers and springs

DOOR

sliding surfaces

Remove

arm

rest

door door

inside

handle
3

escutcheon

and

lock

Remove door finisher and

sealing

ob and

FRONT

GLASS AND

screen

tained

REGULATOR

Remove

door

outer

molding

door lock striker be

adjusted

Adjustment
Door window glass alignment
nel A I
can

Except

Hatchback

removing front fender

Door hinge can be moved up and down and fore and aft in enlarged
holes

be performed by adjusting guide chan

guide

channel B

by loosening attaching bolts enlarged holes

an

Striker can be moved up and down and from side to side in

by loosening attaching
Door
even

bolts

should
and

be

adjusted for

and

parallel fit with the door surrounding body panels

not

opening
Be

careful and

to

distort

or

mar

door
when

surrounding body adjusting

panels

Partially tighten guide channel A guide channel B attaching screws 2 With glass in down position move guide channel A from side to side and move guide channel B up and down to obtain proper alignment of window glass to door sash glass 3 Cycle window glass up and down to assure a good window fit 4 After proper glass alignment is
and

fT
BF530B

Fig BF 24 Removing Door Outer Molding

II I

J
BF163A

tighten guide channel guide channel B attaching bolts

obtained

A and

Lower door

glass

with

regulator

handle until regulator to glass attach ing bolts appear at access holes in door
inside

panel

6
I

b G
O J

Supporting door glass by hand remove regulator to glass attaching

bolts

Fig BF 20 Adjusting Door Lock

Striker

moC
BF541B

Removal and installation

Open door fully with a stand or jack

Note

and

support

it

Fig BF 22 Adjusting Guide Channel

Place
or

rag between door and to

stand

jack

protect

door

panel

Removal and installation

a8
BF531B

from being sCaRed 2 Remove

door to

bolts and

remove

hinge attaching door from hinges

reguiator handle by pry ing pin Fig BF 23 shows set assembled to regulator handle and pin to handle regulator regulator with door glass raised fully
I Remove out set

Fig BF 25 Removing Bolt Attaching

Glass

Raise

door

glass

and

draw it

upwards
Front

600

Set pin

Pring
BF529B

9
o

Fig BF 21 Removing Front Door

BF285B

Installation is in the reverse order

Fig BF 23 Regulator Handle and

Set Pin

BF532B

of removal

Fig BF 26 Removing Door

8 Gla

BF 13

Body
8 Remove

regulator

attaching

Remove door fiWsher and sealing

Refer to Front Door Glass and

3 door

Loosen
handle

nuts and

attachiIg outside
remove

bolts

screen

outside

Regulator
2

handle
or

Turn adjusting nut clockwise

to

counterclockwise of
5 to 1 0 mm 0

obtain

clearance

0 020 to 0 039 in

q
o
Fig
OF 5338 IIulator Fig BF 27 Removing R A ttaching Bolt

I
Remove
screws

SF

170A

BF 31 Removing Outside Door Handle

retaining inside
lock from and
re

Remove

regulator
access

assembly
in door Unit
mm

door handle
move

and door

tIuough large panel

hole

lock

in

assembly

hole in

inside of door

BF5358

Fig BF 29

oting Adju

Handle Free

Play

Removal and installation

I

screen

Remove door finisher and sealing Refer to Front Door Glass and
I 2

2
BF534B

Regulator Turning

resin

clip
lock

in the

arrow

Imide door handle

Door

direction
rod

remove

cylinder from

lock
BF291B

Fig

BF 28 Removing Regulator A embly

Fig BF 32 Removing Lock Assembly

10

Installation

is

in

the

reverse

Remove

lock

cylinder

by

reo

order of removal Note

Apply grease of reguIator

to

sliding surfaces
J

moving retaining clip

6

Installation is in he

reverse

order

of removal

FRONT DOOR LOCK AND LOCK CONTROL

I Door

lock cylinder

Adjustment
Outside
can

door

handle

adjustment

be accomplished by adjusting the clearance between outside door lock lever and
on

Retaining clip Resin clip Lock cylinder

rod

BF290B

adjusting

nut

nylon located
r

outside door handle

as

follows

Fig BF 30 Removing Lock Cylinder Rod

BF 14

Body
REAR DOOR 4 door Sedan and

Wagon

ID

1 2 3

Door glass Inside

door lock knob

Inside door handle 4 Guide channel A

5 6

Regulator handle Regulator assembly

Lower sash

@I
9

7 8

Center sash
Door lock assembly

9 10

Outside door handle

BF536B

Fig BF 33 Rear Door REAR DOOR ASSEMBLY

6 Tilt center sash forward and then
corner

Adjustment
Follow the
front door
same

procedures

as

for

glass partition weathertrip

remove

together

with

7 8

Remove center sash Raise door

Remoyal and installation Follow the front door

BF537B
same

glass

and

draw

it

upwards
as

procedures

for

9 then

Remove

regulator attaching bolts

regulator
access

remove

assembly
in door

Fig BF 34 Removing Bolt Attaching REAR DOOR GLASS AND REGULATOR

4 Remove outside door Glass

through pene

large

hole

molding
l

Adjustment
Follow the
front door
same

Remove center sash bolts

procedures

as

for

Tn
I

Ramoyaland installation
I Remove door finisher and

sealing

B F 539B

screen

Refer to Front Door Glass and

Regulator
2
Lower door

Fig BF 36 Removing Regulator Attaching Bolt

glass with regulator

attach

handle until

regulator to glass

ing bolts appear inner panel

3

at access holes in door

10

Installation

is

in

the

reverse

order of removal
Note

BF538B

Remove regulator to glass attach

Fig BF 35 Removing Center Sash

Bolts

ingbolts
BF 15

Apply grease to sliding surfaces of regulator

Body
REAR DOOR LOCK AND
3

cRemove

outside handle
nuts Door

LOCK

lil

re

CONTROL

moving attaching
Refer
to Lock Control

Front

Lock

and
order

Adjustment
Follow the same

procedures

as

for

Installation is in the

reverse

front door Removal and installation Remove door finisher and sealing
screen

of removal

Note
1 2
3

Apply

grease to

sliding swfaces

Refer

to

Front Door Glass and Door lock

Inside

of levers and springs

door handte
BF299B

Regulator
2

Remove retaining and

screws

from in

side door handle bell crank and door

lock
remove

Bell crank

door lock assembly Fig BF 37 Remoping Lock Assembly

from hole in inside of door

BODY REAR END

TRUNK LID

Sedan

CD

idtV
j V

Trunk lid Trunk lid hinge Striker Torsion bar Trunk lid lock Lock cylinder

2 3
4 5

BF542B

Fig
BF 16

BF 38 Trunk Lid

Body
TRUNK LID ASSEMBLY
5

tained

After desired adjustment is ob tighten trunk lid lock striker

bolts

TRUNK LID LOCK AND LOCK CYLINDER Removal and installation

Adjustment
Trunk lid
can

attaching
be

securely Open
2 trunk lid

adjusted with
Remove trunk lid lock
remove

bolts
lid I

attaching trunk lid to trunk hinge and trunk lid lock striker
Loosen bolts

attaching

attaching

trunk lid Removal and Inatallatlon

bolts and trunk lid

trunk lid lock from

to trunk lid 2

hinge
fore and aft and

Move trunk lid

up and down to obtain a flush fit between trunk lid and rear fender

Open
2

trunk lid

Mark trunk lid

hinge locations

on

trunk lid for proper reinstallation

3
remove

Support trunk lid by hand and bolts attaching trunk lid to

remove trunk lid is in

hinge Then
4

Installation

the

reverse

order of removal
8F3138

L
BF543B

Fig BF 42 Removing Trunk Lid TORSION BAR Removal and installation 3

2 To remove lock
on

Lock

Fig BF 39 Adjusting Trunk Lid

3

cylinder

After alignment is properly made tighten bolts securely

4 To

Open trunk lid Support trunk

Use
a

pry off

retaining clip
lid and
remove

lock cylinder from

and remove lock

inside of trunk lid

4

each torsion bar from trunk lid brackets suitable

hinge

cylinder from trunk lid outer panel

Installation
is in

obtain
and

snug

fit

between loosen

screwdriver

the

reverse

trunk

lid

weatherstrip
striker lock striker

wrapped
Note

with rag to avoid

slipping
as

order of removal
it

trunk lid lock

enough

to

move

attaching bolts working

to

Take care when

removing

is under tension

striker up or down and from side side as required

J
n

YZ
BF545B

Fig BF 41

Removing Torsion Bar

Installation

is

in

the

reverse

Fig BF 40 Trunk Lid Lock Striker

order of removal

BF 17

Body BACK

DOOR

Hatchback

CV

J
@

J
6

1 2 3 4 S 6
7

Back door hinge Side stopper striker

Back door

Striker Back door stay Side stopper

Lock

cylinder Back door lock

BF547B

Fig BF 43 Back Door

BACK DOOR ASSEMBLY

Adjustment
Back door
can

5 door

To obtain and

snug fit between back

be

adjusted
to

with back
Af
0

weatherstrip loosen back door striker attaching bolts enough to

move

bolts attaching door

I

back door

striker

working
as

it up or down

hinge

and back door lock

and from side to side

l

required

Loosen bolts attaching back door

to back door 2

hinge
toide

To make side

move

back door to left

to obtain an

required

adjustment or right as equal clearance

rear fender on SF 596B

between back door and both sides 3

lion

g@VJ
Fig BF 44 Adjusting Back Door
BF548B

To make fore back door in

as

aft and and fore

adjustment
aft direc
an

move

required

to

obtain

equal

After

alignment

is

properly

made

clearance between back door and roof

tighten

bolts securely

Fig BF 45 Adjusting Back Door Striker

BF 18

Body
6 After desired adjustment is ob
5

Installation is in the

reverse

order

4 lock

To

remove

lock cylinder pry off

tained

tighten back door lock attach

of removal
Note to

ing bolts securely

car

Before securing back door stay body with bolts make sure
are

plate between lock cylinder and back door panel and take out lock cylinder

component parts
sembled

properly

as

Removal and installation

I 2
on

Open back
Mark

door

back door

hinge location
harness

back door for proper reinstallation

Disconnect
rear

CAUTION Be careful

not to

scratch back door

defogger
and

connector 4

stay when installing A scratched stay may cause gas leakage

J6 O
J

Support back door

door to back back
door

remove

back
and

stay bolts
door

door to back Then

hinge
back
two

II
BACK DOOR LOCK AND LOCK CYLINDER Fig BF 4 Removal and Installation
BF550B

attaching bolts
door
men

remove

This

operation

requires

Removing Lock Cylinder

CAUTION Place rags between roof and upper end of back door to avoid damaging paint ed surfaces

the open 2 3

Open back door position

Loosen bolts
to

and

keep

it in 5 Installation is in the reverse order

Remove back door finisher

of removal Adjust back door lock

attaching
and

back door

referring

to Back Door

Adjustment

lock

back door

remove

lock

assembly

I
1 d

o
BF161A

BF549B

Fig BF

47

Removing Back Door

Lock

Fig BF 46 Removing

Bac Door

BF 19

Body TAILGATE

Wagon

J
L il

@
2

1 2 3 4 5

Lock

Bumper rubber Tailgate Tailgate stay

Lock cylinder

6
7

Retaining clip
Striker C tcher Shim
Striker

8
9

10
11

Wedge bumper Back door hinge

BF1478

Fig BF 49 Tai gote

TAILGATE ASSEMBLY Adjustment

Follow the back door
same

Loosen and

bolt

attaching tailgate
lock
and

procedures

as

for

JUUUbJUlIbJUULJUU
I

lock

remove

striker

Hatchback

catcher from

tailgate

Removal and Installation Follow the

same

procedures

as

for

t
BF749B

III
d
l

J
I

back door Hatchback

TAILGATE LOCK AND LOCK CYLINDER

Fig BF 51 Adjusting Striker Fore and Aft

Adjustment
1 To

1l p
1
1
2

2
contact between striker

Adjust

bumper

rubber

with

RetBinin8 clip Lock cylinder

Lock

adjust
as

and catcher loosen

move

attaching

bolts and

shilns Also adjust wedge bumper with shilns

3

3
4

Striker catcher

BF750B

them

required

After

the desired adjustment is

obtained tighten bolts securely

4

Fig BF 52 Removing Lock and Lock Cylindir

Io

iL
Removal and Installation
BF748B

To

remove

lock cylinder pry off lock cylinder from

retaining clip
inside of

on

tailgate and remove lock cylinder from tailgate outer panel

5 Installation is in the reverse order of removal

Open tailgate
2

Adjust tailgate

lock refer

Fig BF 50 Adjusting Striker Catcher rom Side to Side

Remove tailgate fmisher and seal

ring

to Back Door

Hatchback

Adjust

ing screen from tailgate

BF 20

ment

Body

WINDSHIELD AND WINDOW GLASS

WINDSHIELD GLASS
used
I
to

check the

opening weatherstrip

Check

windshield

for irregularities 2 Clean off old sealer around wind

shield

opening and check entire body opening flange for irregularities 3 With the aid of a helper carefully
shield

position replacement glass opening

on

wind

CAUTION Care should be exercised not to let

glass
tion

strike

body metal during installa Edge chips can lead to future

breaks

1 2

Front windshield Windshield

00

3
4 5

weatherstrip glass Windshield molding set Roof panel Roof headlining BF5608 Fig BF 53 Wincthield
Ol

With

windshield

glass supported

and centered in body opening check

REMOVAL
I Place
a

After
from

windshield weatherstrip is

protective

cover

over

hood

front fenders

instrument

panel

and front seats 2 Remove windshield

body flange with aid of helper carefully lift windshield from opening
free Attach
two

relationship of glass to body opening around entire perimeter of glass The inside surface of glass I should completely lap to body flange 2 The curvature of glass should be uniform to that of the body opening 5 Mark any sections of body to be reformed Remove glass and reform opening as required
6
Install windshield

wiper

Suckers ST08800000

arm as

semblies
3

glass surface beforehand to facili tate lifting out windshield glass

to

moldings loosen lip of weatherstrip from body flange along top and sides of windshield opening
On inside of body Use
a

Remove windshield

sealer in glass and weatherstrip cavity around base of weatherstrip 2 Install weatherstrip to glass

Clean

out

old

of windshield

Insert of

strong

cord

in

the

groove

weatherstrip where body

conventional screwdriver and

over

flange fits
Tie ends of cord and tape to inside

carefully put weatherstrip flange

body

surface of glass at bottom center of

glass
Li ST08800000
BF334

With the aid of a coworker

care

fully position assembly in body opening

Note
Do not
or

and center windshield

Fig BF 55 Removing Windshield

Glass

position

glass

by

tapping
5 When

hammering

at any time

INSTALLATION
It is shield

important that the body wind opening be checked thoroughly

glass and weatherstrip are properly positioned in opening slowly pull ends of cord starting at lower center of windshield to seat lip of
weatherstrip
should be windshield
over

body flange Cord

up

before installation of the

BF5618

windshield glass The outlines the method

replacement procedure below

which may be

pulled
then

first across bottom of

each

side top

and

Fig BF 54 Removing Wind hield

finally

across

windshield

BF 21

Body
weatherstrip adhesive around weatherstrip
Seal

completely

Remove

rear window

molding by

prying out molding

4 to Attach two Suckers ST088oo000

glass

beforehand

to

facilitate lifting

out rear window 5

glass
room

From inside
hand

apply

pressure to

compartment edges of rear

window glass and sides Use

remove weather trip lip from body flange starting from top to
a

conventional steel bar

or

covered with cloth

BF562B Bf195A

other suitable

tool
over

and carefully

put weatherstrip

Fig BF 56 Installing Winchhield

Gla

body flange

Fig

BF 57 Weatherstrip

6
seal

Using a pressure type applicator inner and outer lips of weather

to

Reinstall all previously removed

remove

strip

glass

with

an

approved

parts and

protective coverings

REAR WINDOW GLASS Sedan and Hatchback

BF229B

Fig

BF 59 Removing Rear Window

Weatheratrip

6 Sedan Hatchback

After windshield weatherstrip is with aid of

a

free from body flange

helper carefully remove rear window glass with Suckers ST08800000

INSTALLATION
It is

important
in

that

rear

window

opening
before

body be

checked
of

throughly
window

installation

rear

glass
Procedure below includes

checking

of rear window opening in body 1 Check rear window weatherstrip

1

Weatherstrip
Window glass

and any 2

rear

window opening in body for

Suckers

2 3 4 5

irregularities
Stick ST08800000
With aid
on a

Molding set Roof panel Outer panel

rear BF751
B

window

coworker

glass carefuUy

of

position glass

in

Fig BF 58 Rear Window Glau and Weatherstrip Sedan and Hatchback

opening in body

RE
l

OVAL Sedan

Remove parcel shelf and rear side garnishes after removing rear seat cushion
covers on

and back

from

body

Sedan

Place protective and

rear

trunk lid

only
Then
remove

fenders

lead wires for

at connectors
cover on rear

rear

Hatchback Place protective floor and

covers on

willdow defogger
luggage

CAUTION Care should be exercised to make certain glass does not strike body
metal

rear fenders

Place protective Sedan only

during

installation

Edge chips

panel

can

lead to future breaks

BF 22

Body
3

With

rear

window
in

glass supported
in

Insert

and

centered

opening
entire

body
and

weatherstrip
Note

where

strong cord in groove of opening flange fits

so

from lower center of rear window glass

to seal

lip of weatherstrip

on

opening
across

check relationship between

glass

Insert cord

that its ends

are

flange
Cord should be pulled first
bottom of

9pening around glass

perimeter of
of glass
con

at bottom center of glass

glass then

up each side and

I
2

Entire

inside

surface

should be in contact with

Curvature

opening
n

of glass should
of

form to that of opening 3 Mark any section

Remove

finally across top 5 Carefully tap around rear window glass to assist in seating weatherstrip on flange
Note
Never

opening

to

I
I

be refonned

glass

and reform

Ii i
1j

tap

or

hammer at glass to

opening
4

as

required
rear

Install

window
window

glass

as

CD

V
ID
1 2 Rear window Cord

position

follows

I
to

Install

rear

weatherstrip

I
CV
3

glass

glass
BF648

Weatherstrip

Fig BF 61 In5talling Cord in Weatherstrip

3

With aid of a coworker carefully

position and center rear window glass in opening in body supporting it with
SuckerST08800000
4

Fig BF 62 Installing Rear Window

are

When

glass

and weatherstrip

Glass

8F647

Fig BF 60 Installing Weatherstrip

properly positioned in opening slowly pull ends of cord with a coworker pushing glass from outside starting

Install

all

previously

removed

parts

REAR WINDOW GLASS

Wagon

ll3
@
1 2 3 4 5 6
7

fJ

l1 eOO

81

2
Tailgate
Rubber
Rear Rear

1wV

6pf
BF752B

Rear window molding window glass window welt

Butyl seal
Adhesive
Dam Rear

8 9 10

rubber window retainer

Corner

molding

Unit

mm

in

Fig BF 63 Rear Window

Gla Wagon

BF 23

Body
DESCRIPTION
window glass is butyl sealed aU around the periphery and is
rear

arDUna entire

periphery
a

9 ofwirid6 by

From inside

car

push glass

up

The

pull

wire with

sawing

motion

and out of window opening Then dis

connect rear window

defogger

harness

retained with
areas

screws

in

the

corner

In addition
at

it

is also bonded

with adhesive
to the
corner

the upper and lower

dampened with un leaded gasoline wipe any trace of butyl seal or adhesive off tailgate
a

10

Using

rag

middle portions The molding is

glued glass

II

Remove
areas

most

of adhesive from
window scraper
mm

straight line of the glass and the moldings

are

bonded with

of

rear

opening
it to

fitted to the

a razor

blade

or

leaving
0 039

REMOVAL

10 to approx 0 079 in thick

2 0

CAUTION 00 not attempt to pry to rear window glass

CAUTION
BF754B

moldings glued

Fig BF 65 Cutting Butyl S

If be

body painted surtine is scratched sure to repair that area with paint

CAUTION
1 2 3

Remove

rear window

welt

To

Remove luggage rear finisher Disconnect rear window defogger Remove

rear

connections 4

window wiper

arm

to defogger lead running along the periphery of rear window glass on left and right lower half portions pull out steel music willi as it comes near upper

avoid

damage

planess har te

INSTALLATION
I

Remove

tailgate from body

s s

Re

along with blade

5

if

equipped
window
comer

side of harness and then insert it into

area near

fer to Tailgate for removal 2 Place a suitable stand

under is set

Remove Loosen

rear

lower side

of harness to seal

tailgate
level

so

rear

window gla

moldings
6

continue window glass

cutting butyl

screws

and remove rear

retaining window glass CAUTION

retainers

Securely
from

support tailgate being deformed

to

prevent it

71 f
0 II

fr

Clean contacting surfaces of tail

rear

gate and

window

glass

with

rag

dampened with unleaded gasoline

1
BF753B

Lead

plate
BF755B

CAUTION
on

Fig BF 64 Removing RNr Window

G Retainer

Fig BF 66 Location of Rear Window Defogger Lead Plate and

Harness

00 not allow oil grease clean surfaces

or

water to

get

Attach butyl seal around entire

Support

rear

window glass with

SuckerST08800000 7 Cut off butyl seal around entire of glass

one as

of rear window glass so that edge is 6 mm 0 24 in beyond glass See Fig BF 68

periphery
outer

periphery I
wire to
a

follows Note
a

Secure 05

end of steel music

Do not seal with

as

touch surfaces
comes

mm

0 020 in in diameter
can
serve

of

butyl

which

into

piece of wood that

nose

contact

as a

handle

glass

and

this will reduce

a

Using long
end of wire

pliers

insert other seal at

tailgate with hands sealing effects

continuous bead of
to

b Always amx

through butyl
secure

edge
BF756B

butyl

seal

be

sure

overlap

one

of glass then 2 With

that end of wire

to another wood handle

end of butyl bead i0 mm 39 0 in end A bread

approximately
over

the other
water

the
cut

aid of

an

assistant

Fig BF 67 Supporting Rear Window

GLus

can

cause

carefully

through

bytyl

seal

leakage

BF 24

Body
Note

Make

sure

that clearances be

tween

rear

window
in

molding
tailgate

and
are

window
t

Glm

s7
6 0 24

equal
9 6 0 24
on

at

opening all points

a

Using
inner

heat gun of

side

rear

heat butyl seal window to

approxilnately 800C l760F Apply ing reasonable pressure to glass adjust clearance between glass and tailgate

flange
A

to

specified

value

dimension
over en

Repeat this adjustment periphery of glass

A 0 16 in

If

tire

IJ
5

Dimension 4 mm

0 16

Note

Sectional view of butyl seal Unit

mm

in

Use sand bags or suitable weights and tires or similar cushion ing materials for applying pressure

BF7578

Fig BF 68 Affixing Butyl Seal

CAUTION

Insert an adhesive cartridge into Caulking Hand Gun ST08810000 Apply a continuously smooth bead of

Support

rear

window

glass

with

SuckerST08800000
7 With the help of an assistant bring rear window glass close to open iog flange of rear window and connect rear window defogger harness

place weights directly on glass apply excessive pressure on one area as this may cause glass breakage
or

Never

adhesive to upper and lower periph eries of glass approx 300 mm 1181
in

along

the

straight middle portions

r
I
Unit
mm

300

1S

300 1181

I
aF7SaB

in

Fig BF 69 Glass Puipherie with Applied Adhesive

I A

1T
rear

BF761B to

Fig BF 72 Apply Pressure

ST08810000
BF760B

Glass

10 tainers II

Install

window

glass

re

Fig BF 71

Connecting Rear Window Defogger Harness

and tighten retaining

corner

screws

Carefully position rear window glass on opening flange of rear win

8 dow ButYlseal
Adhesive
P

moldings tailgate on car body Refer to Tailgate for installation 13 Install all previously removed
12

Install Install

parts in the

reverse

order of removal

Molding
GlaSS

BF759B

Fig BF 70 Applying Adhesiue

BF 25

Bdy

SIDE WINIJOW GLASS

2 door Sedan and Hatchback
REMOVAL AND INSTALLATION

REMOVAL
I Remove
rear

quarter

window

molding

@V
BF5678 2

Door Sedan

Fig

BF 76 Removing Window

Molding

Remove

rear

quarter

window

weatherstrip and glass

l
Hatchback
SF 5648

INSTAUATION ilnportant that the body wind shield opening be checked thoroughly
before installation of the windshield glass
The It is

replacement

procedure

below outlines the

method which may be used to check

the

opening

Fig BF 73 Side Window

I I

Refer to Windshield Glass Clean out old sealer in glass cavity

Open

side window
remove

Remove blind rivet and

cover

lock pillar

Hatchback only

REAR QUARTER WINDOW GLASS

of window weatherstrip and around

base of weatherstrip

2
3

Insert weatherstrip to Insert

a

glass

Hatchback

strong cord in groove of where body flange fits

to inside

weatherstrip

Tie ends of cord and

tape

surface of glass

at

bottom center of

ID
1

gliss
4

Install

rear

quarter window glass

assembly
Refer to Windshield Glass

Rivet Lock piUar cover

BF5658

r A
1 2

Fig

BF 74 Removing Lock Pillar Caller

Loosen

screws

attaching

side win
win

dow handle
4

Weatherstrip Molding
Glass

Loosen

screws

attaching side

dow hinge and

remove

side window order

3 4

BF568B

Body
BF666B

Fig BF 77 In talling Window GltlII

assembly
5

Installation is in the

reverse

Fig BF 75 Rear Quarter Window

GI

Note

When

installing

window

of removal

glass

start at rear end

portion

BF 26

Body REAR SIDE WINDOW GLASS

Wagon

Using

knife

cut

off

butyl

seal

around entire Note

periphery
at

of glass

It is advisable to start seal

rear

butyl

window glass outward

4

while

cutting portion of pulling glass

1 2

Body
Rear side window Rear side

molding
BF765B

3
4 5

window glass

Butyl seal
Rubber Bf7628

Fig BF 81

Cutting Butyl Seal

Fig BF 78 Rear Side Window Glo

Remove

rear

side window glass

Using

rag

dampened with
remove

un

DESCRIPTION
The rear side window sealed all around its

leaded gasoline

any trace of

butyl seai glass is butyl periphery and is

from car

body

retained with four bolts

REMOVAL
INSTALLATION

CAUTION Do not attempt to pry moldings glued to the rear side window glass
BF763B

contacting surfaces of body glass with a rag with unleaded gasoline dampened
I

Clean

and

rear

side window

Fig BF 79 Removing Nuts front portion

CAUTION
on

Do not allow oil grease clean surfaces

or

water to

get

1 2
er

Remove

rear

side window welt

4 S

Remove air outlet Remove bolts

grille
rear

Remove luggage side upper finish

Remove
nut

tion of rear side window

securing glass

por

tion of rear side window

securing front glass

por

2 Attach butyl seal around entire periphery of rear side window glass so that inner edge is at specified distance from printed black area on glass See

Figs lt
Note
a

82 BF

and BF 83

Do not touch surfaces of butyl seal

which

comes

into contact with glass

as

and tailgate with hands will reduce sealing effects

b

this

Always affix

continuous bead of

butyl seal be sure to overlap one end of butyl bead approximately

BF7648

10

mm

0 39 in

over

the other

Fig BF 80 Removing Bolts rear portion BF 27

end A break age

can cause

water leak

Body
and
More than 5 0 20

CaibOdy molding specified value

5 0 20

are

ilithe

I
More than 5 0 20
More than

1
O

0 20

Glass

j
Yl

I
Unit 0 31
rom

ri 04
BF767B

in

Fig

BF83 Clearance between Rear Side Window and Car Body

I I

I
4
on

Prin ed portion

yi
rear side

Oi6 I
Sectional view or butyl seal
BF766B

Using

heat gun heat butyl seal

inner side of rear side window to

Unit

mm

in

Fig

82 BF

Attaching Butyl Seal

approxilnately 800C 1760F and apply hand pressure to glass 5 Tighten bolts and nuts securing rear side window glass
6

Position

window

glass

in

Note

Make

sure

that clearances be

Install

all

previously

removed

opening flange of

rear

side window

tween

rear

side window

molding

parts

in the reverse order of removal

BF 28

Body

INTERIOR
INSTRUMENT PANEL

1 2 3

Lock and

striker

6 7 8 9 10

Instrument

panel assembly

11

Instrument Heater

lower center cover

Lid fInisher Lid stopper Cluster lid B compartment Side vent grille

Cluster lid A Radio mask Center vent grille

Instrument lower assist
cover

12 13
14 15

control fInisher

Illumination lamp
Ash Heater

4
5

tray control lever bracket

BF768B

Fig BF 84 Instrument Panel Assembly

INSTRUMENT PANEL
ASSEMBLY Removal and installation
I Disconnect

ness

connector Remove instrument

remove

panel

12

panel

at

13

Installation

is

in

the

reverse

taching
cable

bolt and

instrument

order of removal

battery ground

Remove illumination control rhe Pull out heater control knob and heater control finisher
screw to

ostat

3
4

remove

Remove

control assembly 5
Draw out

instrument

attaching heater panel

remove

ash

tray and

grommet to ash tray 6

Remove

bolt

attaching

instru

ment lower assist cover to instrument

panel
7

steering column cover Disconnect speedometer cable be

Remove Remove radio
antenna

hind speedometer 9 10 cable Disconnect body and instrument

at

7Jf1ll

harness
11

connectors

8F5778

Disconnect heater

ground

har

Fig BF 85 Removing Bolt Attaching Point

BF 29

Body
IDA CLUSTER I
Removal and installation
I

Disconnect
Ash

following

wire harness

SEAT
FRONT SEAT Removal and installation
I
seat

connectors

Disconnect batterv ground cable Remove steering column cover Remove illumination control rhe Pull
out

tray illumination Cigarette lighter

Rear

2
3

defogger

switch

Warning light
Clock Turn
10

Remove bolts attaching front of bracket to floor

Remove

ostat 4

heater control knob and

c

signal

switch

bolts

attaching
seat

rear

of

remove

heater

ntrol finisher

Remove cluster lid A drawing it Installation

is in the

seat bracket

to floor

Remove

screw

attaching

heater

out backward 11
reverse

Then
car

remove

front

assembly
order

control assembly

to

cluster lid A

from
4

order of removal

Installation is in the

reverse

of removal

nQ

lQ

Ii
BF783B

CLUSTER LID B Removal and Installation

I

tl
rffmfLu O r
Heater

Remove instrument lower assist REAR SEAT With

cover

2 lid 3

glove

box lid open

screw

remove

stopper securing
Remove

Removal and Installation

cluster

lid

Fig BF 86 Removing Screw A Uoching

securing

Control

screws

Sedan
I

Remove bolts attaching

rear

seat

6
7

Pull

out

radio

dial knobs and

cushion front end and cushion

remove rear seat

remove

nuts and washers

remove

Draw out ash tray and

screws

securing ash tray holder

cluster lid
A

to

cluster lid A B Remove

i ll
I
BF580B

Remove

screws

attaching

rear

seat

back and lift

it

up

Then remove it

from body

securing

screws

II

1 G808
iS
Ill
BF7848

Fig BF 88 Removing Cluster Lid B

CJy
Cluster Lid A

4 5

Remove cluster lid B Installation is in the

reverse

Fig BF 87 Remooing Screw Attaching

order
f

of removal

CONSOLE BOX

8F5828

Fig BF 90 Removing Rear Seat

01

Installation is in the

reverse

order

of removaL

Hatchback and
Automatic control indicator
2

Console box Console box bracket

Wagon
and

BF581 B

Unfasten

screw

clip retaining

Fig BF 89 Console Bo

luggage

floor carpets

SF 30

Body
deceleration
This retractor serves to restraint the 3

On driver Remove

seat

disconnect seat
inner

belt switch and

4

remove

lap

belt

belt securely in thus

case

of emergency as

in a collision or sudden stop of the car

protecting the seat occupant against serious injury Under normal condition the belt can be freely pulled
out

securing through anchor at shoulder portion and bolt securing anchor at lap portion from lap shoulder belt
5

bolt

Remove
or

center

kicking

plate
Hatch

Sedan back 6

rear

side finisher

jJ
Release lock
seat

The inner lap belt is combined with

Z
BF769B

buckle The buckle includes

as a

switch

Remove

securing bolts and

re

which is used device The

rear

seat belt

warning point

lap shoulder belt with Emergen Retractor attached Locking cy

move

Fig BF 91 Removing Screws Attaching Floor Carpet and Clip

seat belt
an

is a two

type and includes

automatic belt

locking retracting device CAUTION

1 In be

on

rear

seat back

and tilt
ward

back approx
seat

600 for

conformity
sure

with MVSS No 302 the thin

to

remove

poly

Slide

rear

back backwards

and draw out outside seat back

hinge

pin from bracket

on car

body

ethylene 1 Pre delivery service 2 Parti replacements

covers

from seat belts at

2 If the

car

is collided

or

ovarturned

replace regardless
of
a

the

entire belt

assembly
BF311B

of nature of accident

3 If the condition of any component

seat belt is

questionable

do but
7

Fig BF 94 Removing Lop Shoulder

Belt

not

have

seat

belt

repaired

4 If

raplaced as a belt assembly webbing is cut frayed or dam aged replace belt assembly Do not spill drinks oil etc on Naver oil inner lap belt buckla
tongue and buckle
Use belt

Removing

rear seat

belts

Remove seat cushion and seat back

Then loosen bolts attaching belts and

remove rear

rear

seat

seat belts

only a NISSAN genuina assembly

seat

BF770B

Fig BF 92 Removing Rear Seat

Back

REMOVAL AND
INSTALLATION

Slide

rear

seat

back outwards
I

and draw out inside seat back hinge from bracket on car body and remove
seat back S

2 belt

Disconnect battery ground cable Loosen bolt attaching inner lap

BF772B

Installation is in the reverse order

Fig BF 95 Removing Rear Seat Belt

of removal

SEAT BELT DESCRIPTION

The front
seat

belts

are

three

8 the

Install front and

reverse

rear

seat belts in

point type consisting of an inner lap and an outer lap shoulder belt
This with
an

order of removal
torque

iil
BF771B

Tightening

lap shoulder belt is provided Emergency Locking Retractor by detecting

car

Anchor bolt 2 4 to 3 2

which locks the belt

Fig BF 93 Removing Inner Lap Belt BF 31

17 to 23 ft

kg m Ibl

Body
INSPECTiON OF
BELT SWITCH
The contacts of seat belt switch
are

SEAT

I 2

Disconnectbatter y ground cable Disconnect

seat

belt switch wire

belt latches buckle and go on when it unlatches buckle Replace belt

lape

harness
3

assembly
Note

if necessary

normally closed When tongue latches buckle the tip end of tongue pushes

operation using
should go
out

Check seat belt switch for proper a test light The light
when

When

checking

seat belt switch that

operation make

push

rod to open the switch contacts

tongue of

outer

power held below 16 volts and 13 mA

sure

TRIM AND MOLDING

ROOF TRIMMING
Removel end Inetelletlon
l
coat

T
grip
S
Tail rail

Remove

room

lamp

assist

hangers
sun

inside

rearview mirror

and
2

visors
re

Remove body side welts and

move

roof side garnishes and tail rail Remove

rear

garnish
3
4 side finishers
1 J

clamp

Draw out

windshield
5

roof headlining weatherstrip

reverse

from

Installation is in the

order

2
3 4 5

Rear side finisher

Tailrail garnish

of removal

6 7 8 9

Headlining Roof side garnish Coat hanger Assist grip

Sun visor Inside rearview
mirror BF173B

Fig BF 96 Roof Trimming

BODY SIDE TRIM AND MOLDING

SEDAN

1 2 3 4 5 6 7 8 9 10
11

Dash side Front

finisher

pillar garnish

Body front side welt Center pillar garnish

Body side

rear

welt

Rear seat back

finisher

Front kicking plate Rear kicking plate

12

Drip center molding Rear comer garnish Air outlet grille Front pillar molding

BF783B

Fig BF 97 Body Side Trim ond Molding 4 Door

BF 32

Body

5 6
7

Rear side finisher Rear

sea

t back

fini her

Front

8
1 2 Dash side

finisher

9
10 11 12

3
4

Front pi llargarms h Body front 51de welt Center p ilIargamlsh

kickmg plate Rear kIe king plate d rear molding Drip cente Rear Sld o r garnish r Front p molding Rear fender mo Iding
BF784B

Fig BF 98

Body Sid

Trim

and

Molding 2 Door

HATCHBACK
5

50
10
11 4 Rear
er

Luggage

rear

finis

er

Fropt

p liar

5 6
1 Dash side

Luggage
are

covslde finisher
wheel
cover

garnish

12

13
14

Drip cent r Lyggage f1 Lode pi ollar

Air

moldmg molding
boar d

or

cover
o

finishe

2 3

Front p ilJargarms h

8 9

Rear klc kIn g

ontkICkill8 plate plate

15
16

Rear fender

Iding molding
8F7878

Body

I de

welt

Rear SI de Imlsher

17

Qua rtel WlD

out1etgrd
a

Fig BF 99 Body Side Trim

nd Molding

BF 33

Body
WAGON
6

7 8 9 10
I

Front IticIting plate Rear kicking plate Jher Luggage side lower rmi
Rear window

welt

2 3 4 5 6

Da side fInisher h Front pillar garnish

II

12 13 14 15 16

Body front side welt Center pillar garnish Body rear side welt misher Luggage side upper f

Luggage rear fini3her Drip center and rear moldins Air outlet grille Rear Cender moldins Luggage floor board Front pillar moldins
8F7748

Fig BF IOO Body Side Trim and Molding

SPECIAL SERVICE TOOLS

I Kent
Tool number tool
name

Moore No

I
Tool number

Kent Moore No Reference page or FiB No

Reference
page
or

tool

name

Fis No

ST08800000

Sucker

ST088 10000

Caulking hand gun Fig BF 70

cf0

FIg BF 55 Fig BF 67 Page BF 22 Page BF 23

BF 34

DATSUN 210

Model 8310 Series

SECTIONBE
BODY ELECTRICAL SYSTEM
CONTENTS
BODY ELECTRICAL WIRING
DESCRIPTION FUSE AND FUSIBLE LINK BE BE BE BE HARNESS OF ELECTRICAL UNIT BE BE 2 2 2 4 5 8 OIL PRESSURE SEAT BELT WARNING SYSTEM SYSTEM BE 15 BE 15 BE 17 BE 17 BE 18 BE 20 BE 20 BE 21 DEFOGGER For automatic BE 23 BE 23 BE 23 BE 24 BE 26 BE 27 BE 21 WARNING

ELECTRICAL ACCESSORIES
WINDSHIELD WIPER AND WASHER REAR WINDOW WIPER AND WASHER CIGARETTE RADIO LIGHTER

WIRING WIRING

LOCATION

ELECTRICAL UNIT OF LIGHTING SYSTEM

BE BE 9 9 BULB SPECIFICATIONS REMOVAL AND INSTALLATION For lamp IGNITION SWITCH COMBINATION ILLUMINATION SWITCH BE 10 BE 10 BE 10 BE 11 BE 11

CLOCK REAR WINDOW STARTING

SYSTEM

transmission models

HEATER
DESCRIPTION AIR FLOW

CONTROL UNIT

AIMING ADJUSTMENT

REMOVAL AND INSTALLATION

ELECTRICAL UNIT OF SIGNAL SYSTEM

TURN SIGNAL RELAY SWITCH

ADJUSTING HEATER CONTROL

BE 12 BE 12 BE 12 BE 12 BE 12 BE 12 BE 12 BE 13 BE 13 BE 14 DISASSEMBLY HEATER UNIT AND ASSEMBLY OF

BE 27 BE 28

HORN
STOP

INSPECTION

HAZARD SWITCH LAMP SWITCH LAMP

WIRING

DIAGRAMS

AND
BE 29

TROUBLE

DIAGNOSES
SYSTEM BLOCK

BACK UP DOOR

SWITCH

ELECTRICAL

SWITCH

DIAGRAM
FUSE BLOCK CIRCUIT SUPPLY

BE 29

METERS AND GAUGES

COMBINATION METER TACHOMETER
FUEL LEVEL AND WATER TEMPERATURE INDICATOR

ROUTING
LIGHTING SYSTEM

BE 30 BE 31 BE 36 BE 41 44 BE SYSTEM 4B BE BE 55

SIGNAL SYSTEM
BE 14 BE 15 BE 15 BE 15 METERS AND GAUGES WARNING SYSTEM ELECTRICAL HEATER

SYSTEM

WARNING SYSTEM CHARGE WARNING SYSTEM BRAKE WARNING SYSTEM

ACCESSORY

Body

ectrical

System

BODY ELECTRICAL WIRING

DESCRI PTI ON
are covered with Cabl
coded color

The fusible link functions almost the

same

as

fuse though its characteris

than normal

3 No cable covering shows any evi dence of cracks deterioration or other

tics

are

slightly different

vinyl for easy identification In the wiring diagram olors are indicated by one or two alphabetical letters It is recommended that the battery
be

damage
4 Vay 3 5

fuses

Each terminal is at

safe distance

from any adjacent metal parts Each cable is fastened to its

disconnected

before

performing
CABLE COLORS Cable colors shown in the

any electrical service

or

other than bulb

proper connector or terminal 6 Each grounding bolt is fumly

fuse replacement
In addition to fuses
a

fusible link

has been installed

to

protect wiring

generally following table

are

used

as

planted 7 Wiring is kept away from any adjacent parts with sharp edges or high temperature parts pipe
8 such
as

exhaust

Wiring is kept away from any rotating or working parts fan pulley
Circuit system Color
B

fan belt etc 9 Cables between fIXed

portions

Starting

and

ignition system

Black
W

and moving parts are long enough to withstand shocks and vibratory forces Note
a

Charging system

White
R

Before starting to inspect and repair any part of electrical system or othparts which may lead to a short circuit disconnect cables at

Lighting system

Red

Signal system

G Green y

battery terminals

as

follows

Disconnect cable at
at

negative

terminal and then disconnect cable

Instrument system

positive

terminal

Yellow
L Br Blue Brown B

Before connecting cables to battery

terminal be

Others

Lg Light

1 to clean tenninals s

with
green at

rag Fasten cable at positive t minal and then ground cable

a

Grounding system

negative

tenninal

Apply

Black

grease to top of these terminals to prevent rust from developing on them b Ne

use a

screwdriver
a

or

service test

tool to oonduct Use test leads

Co

oontinuity

Nev ground an open

circuit or
a

circuits under of each system is coded with a single color generally

These colors are The main cable

no
or

lood Use

test
as a

INSPECTION Inspect
all

lamp I2V 3W
circuits
Ie

circuit tester

represented by such
Br Minor items of
are

electrical
or

lood

letters

as

G W
s

or

Terring
ty
or

to

wiring

circuit

diagrams

each circuit
a

terminal

coded with

Circuits should be tested for continui short circuit with a conventional

or

FUSE AND

two tone color as follows

test

lamp

low reading voltmeter

ensure

FUSIBLE LINK
MAINTENANCE INSTRUCTIONS
Fuse The fuse block is installed under
on

BW

Black with white stripe

Before inspecting circuit

I

that

LgR

Light

green with red

stripe

Each electrical component part or cable is securely fastened to its con

nector or tenninal 2

Each connection is fIrmly in place

and free from rust and dirt

the instrument panel

driver

side

BE 2

Body
When for one
reason or

Electrical

System
CAUTION

another proce
a

fuse has melted dure

to

use

systematic
new

check and eliminate

cause

of

If fusible link should melt

it is power

problem before installing

Note
a

fuse

possible supply

that critical circuit

current

or large circuit is shorted

sure

carrying
a case cause

In such

If fuse is blown be
nate
cause

to elimi

stalling new
b Use fuse of
use

of problem before in fuse

carefully check and eliminate of problem

b Never W
BE1100

fuse

of

specified rating Never more than specified

wrap periphery of fusible link with vinyl tape Extreme care should be taken with this link to
ensure

rating
c

Fig BE dirt is found thereon

grained fine

FU

Block

that it does not

come

into har

Check condition of fuse holders If much rust

or

contact with any other

ness or

wiring

Fusible link Fusible link protects starting

and d he

vinyl

or

rubber parts

clean metal parts with sandpaper until proper metal contact is made

metal to

Poor contact in any fuse holder will

lamp ignition charge wiring between fuse and fusible link

circuits and

often lead to voltage drop or heat ing in the circuit and could result in

improper

circuit

operation
A melted fusible link can be detect

ed either by visual inspection or by feeling with finger tip If its condition

is test

questionable use circuit lamp as required to

tester

or

conduct

BE1110

continuity test This continuity test can be performed in the same manner
as

Fig BE

Fusible Link

for any conventional fuse

BE 3

Body Electrical System

WIRING
Sedan and Hatchback

Wagon

1 2

Main harness

Engine harness

No 2

3
4 5

Instrument harness

Body harness Room tamp harness

Back door
harne ls

6
7

Hatchback

Tailgate harness Wagon

BEl12D

Fig BE 3 Wiring

BE4

to o Co

m 16 n

nOJ

13

a ZG z
I 0i z

I a Z Il

tIltIl

models
FU @

indcator
model
AfT unit unit

switch

switch
rn

control
H

switch harnes switch switch switch switch flasher switch lock switch flasher switch wiper mot r level timer relay lamp signal switch signal switch switch brake models engine rear wiper brake belt horn stop kic down haz rd turn igniton ste ring wiper turn lighting haz rd belt door hand AfT check

hC

revolutin

and

transmio conetr
automaic instrumen

To To To To To To To To To To To To To To To To To To To To

To To

37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 5i 53 54 55 56

57 58

models
FU

models models
AfT

Except FU models models FU E x c e p t solenid FU

Calif
and
T

alternao staring throtle

H

mot r open r solen id switch solen id choke solen id

cut

fuel

To To To To To To To To To To To To To To To To To 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36

throtle fuel auto

cut

cut VC

distrbuo

transmiter harnes presu window solenid lamp

mot r thermal body low rear FICO ro m co ling heater

unit

models models mot r switcn washer harnes

Con Air Con Air

models

on
C Air

L
H

models
Con Air

H R H R

lamp
H
L

t11p la

model
AfT
H R

lamp

marker
side
1

side oil To To To To To To To To To To To To To To To To To To To
234 5 6 7 89

headlmp horn front

combinat coler presu condesr combinato marke headlmp

co
H R

pres or switch

lamp

horn front

earth link body fusible

relay relay
choke aut6

No

coil

inhbitor igniton condesr

mot r harnes washer engine

0

10 11 12 13 14 15 16 17 18 19

to lI g

iF

mc n

BodyElectrital System
ENGINE HARNESS NO 2

Automatic

transmission

Manual

transmission

j
1 To main

Except FU models

harness

2 3 4
5

To inhibitor switch To top tch California models To kicJcdown solenoid

To top

gear switch Except FU models

6
7

To neutral switch FU models To back up switch To top gear switch FU models

BE1140

Fig BE 5 Engine Hame

No 2

INSTRUMENT HARNESS

1
2

To main

harness control switch

To illumination To rear

3
4 5

defogger switch To Ipeed witch AMP

To tachometer To combination meter To clock
To To

6 7 8 9 10
11

speaker
radio

To buzzer To heat control To stereo

To heat

12 13 14 15

control illumination To ash tray illumination

To

cigarette lighter
BE115D

Fig BE 6 Instrument Harne BE 6

Body Electrical System

BODY HARNESS

Sedan and Hatchback

To rear

wiper

motor

Hatchback models 10
11

defogger marker lamp R H 12 To combination lamp R n 13 To license plate lamp 2 14 To earth point 15 To license plate lamp 1 16 To combination lamp L U 17 To side marker lamp L H 18 To luggage room lamp
To side Hatchback models

To rear

Wagon @
Yj

qr
@ D

D
S

3
4

To main

hamess

To door switch R n To
rear

5 6
7

To rear

defogger defogger
R

8 9 10 11 12 13 14 15 16

up tail and stop lamp To license plate lamp

To back

To
To To

wiper motor body harness

rear

p tail and stop lamp LH baek To side marker lamp R H To turn tail and stop lamps R n To back

door harness

17 18 19

To turn To

To earth point To fuel tank unit

side marker lamp

room

tail and stop lamps L H L U

To luggage

lamp Fig BE
BE 7
7

BE116D

Body Harness

iBocdyEal lecti

System

LOCATiON OF ELECTRICAL UNIT

J Q
r
J

Inhibitor relay

2 3
4 5

chok Auto

AfT relay

7 8 9 10 11

Buzzer Door switch RlI Turn signal flasher Hazard flasher

H Door switch L relaY Horn Seat belt timer unit

Stop lamp switch

Kickdown switch Am
BEl17D

Fig

8 Locotiono BE

Ekctricol Unit

BE S

Body

Electrical

System

ELECTRICAL UNIT OF LIGHTING

CAUTION Before starting to work electrical
on any part of disconnect battery

SYSTEM

system

ground

cable

BULB SPECIFICATIONS
SAE Item

Capacity
60 12V

trade number

Quantity

Headlamp

Main Dilnmer

50W
1157

2 2

Front combination Turn

lamp

l2V 27 8W

signal

Clearance

Rear combination Turn

lamp
l2V 27W 12V 27 8W 1156 1157 1156 67 158 158 158 158 158 158 158 2 4 2 4 2 2

signal
Tail

Stop

Back up Side marker lamp

License Turn

12V 27W 8W 12V

l2V 3 4W l2V 4W 3

plate lamp

signal pilot lamp

beam

High

pilot lamp

l2V 3 4W 12V 3 4W 12V 3 4W 12V 3 4W

Charge warning lamp

Oil pressure Brake

warning lamp

warning lamp warning lamp lamp

lp laf

Seat belt

12V 3 4W l2V2W l2V 3 4W l2V lOW

Ash tray illumination Heater Room

panel lamp

illumination

158

Luggage

room

lamp

Hatchback and

Wagon

l2V 5W 12V 14W

Rear window

defogger lamp
lever illumination

AfT selector

lamp

12V 3 4W

158

BE 9

Body Electrical System REMOVAL AND IGNITION SWITCH

OFF ICC 01 ST 0 0

INSTALLATION
For
Note

lamp

battery ground cable before starting to work b To repJaoe bull push ill n bulb
a

Disconnect

turn
move

it it

counterclockwise from socket

reverse

and

re

61 ot
Steering
lock

Install

new re

bulb
moval

in tbe

order of

I OUT

9
Removing bulb Installing
bulb BE259C

Iso 16 6

I
I

T
BEll8D

Fig BE II Ignition Switch

Fig BE 9 Replacing Bulb

COMBINATION SWITCH
REMOVAL AND

wires at connector 6

move

Loosen retaining screw and combination switch assembly order of removal

Ie

INSTALLATION
c

lnstaD combination switch in the

To

repbce wedge
out

base type bulb

socket

I 2 3 4 5

Disconnect battery ground cable Remove horn ring Remove steering wheel Remove steering column Disconnect
cover

reverse

puD

bulb

from

To

inslaD new

bulb

pusb

bulb into

INSPECTION
Test with
a

socket

combination

switch

test

continuity through lamp or ohmmeter

switch

Removing

bulb

Installing bulb

BE260C

Fig BE 10 R eplac ing Wedge BlUe Type Bulb

TURN SIGNAL

HORN AND LIGHTING SWITCH

119 12 I
136 II

HORMI 0 I 6 I I
0 I

III
15 16 11

F c 0 I c I c

QQOQ 56 I 5
0

II

10 000Q
000000
BE119D

Fig BE 12 Combination Switch

BE l0

Body

Electrical

System
same c

ILLUMINATION CONTROL UNIT

flat surface
no

See

that there is

load in fIlled

car

coolant correct

engine
level and

oil

up to

full fuel tank

or s

other than the driver

equivalent
position

weight placed
8

in driver

For details

refer to SAE J599d

GY

GW

When performing headlamp aiming adjustment use an aiming machine aiming wall screen or headlamp tester For operating instructions of any almer it should be in good repair
calibrated

and

used

accordi g

to

respective operation
with the unit

manuals

supplied

If any aimer is not available aiming

BE1200

adjustment
Turn

can

be done

as
on

follqws

Fig BE I3 Illumination Control Unit

headlamp

low beam

AIMING ADJUSTMENT
To

adjust

vertical aim

use

adjusting
and

screw on to

upper side of

headlamp
use

adjust horizontal ailn

on

adjusting

screw

side of

headlamp

H 1 2

Horizontal center line of

Vertical adjustment Horizontal adjustment

BE1210

Unit

mm

in
I5

headlamps
BE297D

Fig BE

Aiming Adjustment

Fig BE 14 Aiming

Adiusting Screws
Note
a

Note

makiiIg headlamp aim ing adjustment observe the follow

Before

ing instructions
a

Adjust headlamps so that upper edge of hot spot is equal in height to headlamp height and left edge of hot spot is equal in height to each
center line of headlamps

Keep
Place

all

tires inflated

to correct b

pressures b
car

Dotted

lines

in illustration show

and tester

on

one

and

center of headlamp

BE 11

Body

Electrical

System

ELECTRICAL UNIT
CAUTION Before

OF

SIGNAL SYSTEM

HAZARD
to work

SWITCH

startill1l

electrical system ground cable

any part of disconnect battery

on

REMOVAL AND INSTAUATION

I

Disconnect battery ground cable

Remove upper

steering

column

cover

TURN SIGNAL SWITCH

Refer
to

3 4 5

Disconnect harness connector

Remove ret Install

combination switch

hazard

ining screw warning

lamp

switch in the

reverse

order of removal

HORN RELAY
REMOVAL AND INSTALLATION

BE68QC

Fig BE 19 Stop Lamp Switch

INSPECTION
Test oontinuity through stop lamp a test lamp or ohmmeter When

switch with

plunger

is

pressed into switch

are

I
BE123D

assembly
are

stop lamp switch contacts Contacts closed when

open is

plunger

projected

Fig

BE 16

ReplOving

om

ReIDy

INSPECTION

i
BE306C

lfI

1 2 V

4 5

OMI
1

t
5

BACK UP LAMP SWITCH

Back up lamp switch is installed transmission
on

01

Fig BE IS Hazard Switch

INSPECTION
When transmission lever is in R

there should be continuity between two terminals

position

l L

i
L CV

CD

j r t
@

1 I

STOP LAMP SWITCH

REMOVAL AND

DOOR SWITCH
Door switch is installed
on

lower

center pillar INSTALLATION

I

REMOVAL AND

Disoonnect battery

ground

cable

INSTAUATION
I 2 Disconnect battery ground cable To

pi

Disconnect harness connectors Loosen lock nut Switch then be taken out

101
D C 12V

3
can

assembly by rotating
order of

lower

pull pillar

switch assembly out of withdraw switch and

switch
BE124D

wiring assembly
the
reverse

Install in

Disconnect

lead

wire

at

con

Fig BE 17 Horn ReIDy

removal
BE 12

nector

Body
4

Electrical

System

Installation is in the

reverse

order

INSPECTION
Test

of removal

switch with
When

continuity through door a test lamp or ohmmeter

is

assembly
er

door

switch

contacts

are

open Contacts is

are

closed when plung

plunger

pressed

into switch

projected

METERS AND GAUGES

CAUTION
Before 3 work
on any part of disconnect battery

Remove steering column Remove cluster lid A

Panel Section

cover

7 to

Disconnect

lead wire terminals

starting to

referring
BF

for multi pole connector and tachome

ter

electrical

sYstem

Instrument

for

if

so

equipped
meter

ground

cable

COMBINATION METER
I 2

reqlOval and installation 5 Remove retaining screws 6 Disconnect speedometer cable by pushing and turning connector cap
counterclockwise

Install combination
order of removal Be careful not to

in the

reverse

Note

damage print

ed circuit

Disconnect battery ground cable Remove steering wheel

CD

Cl

lJ
Q

w
I a
Q Q Q

d
Q

Cl

Q J

3
Z I

j
0
J a w

C
J z

0
I

9
Q

CI

C
w

1 2

Water

temperature gauge

0
J

Cl
a l
1 w

CI
a

0 3 EO
l
to

J1 S2
c

J2
4

Z a
w

l I

3
4 5

gO

Speedometer Turn signal pilot lamp

Fuel level gauge

zO zO

Cl

12 11

3 C J

Q
U

Q
en

00

CjU
ffi
a

ffi
i

6 7 8 9 10 11 12

o 100

6
80
0
7

04

gO
o

Os

g10
U 8 lJ 7

U 4 BE125D

u 6

l
12

0 v 11 v 10

13
14

pilot lamp warning lamp Charge warning lamp Illumination lamp Turn signal pilot lamp To speedometer cable Illumination lamp Illumination lamp Charge warning lamp Oil pressure warning lamp
Oil pressure

High

beam

zO
Q
o I

15

16

Illumination lamp High beam pilot lamp

Fig BE 20 Combination Meter

BE13

Body Electrical System

DISASsEMlUY
AND

t18LV ASSEI

FUE LEVELAND WATER TEMPERATURE INDICATOR SYSTEM

REPLACEMENT

G11l1ge
I Remove combination meter Disconnect

2 from

harness
on

connector circuit

terminal
Remove Install

printed

board
3 4

retaining screws
gauge in the reverse

new

order of removal Fuel tank gauge unit

Fuel tank gauge unit is located on fuel tank Refer to Fuel Tank Gauge Unit
BE126D

Section FE

for removal and

installation Thermal transmitter

I Disconnect lead wire from termi

Fig BE

21

Combination Meter

TACHOMETER
REMOVAL AND INSTALLATION
I

Install tachometer in the

reverse

naL 2
3 Remove

order of removal

thermal transmitter by thermal transmitter in

loosening

it oountercIockwise
new

Install

the reverse order of removal Disconnect battery RemO

e

ground

cable

2
3 4

Remove combination meter

speedometer

reset knob

Disconnect tachometer connector

Remove

from printed circuit board terminal 5

screws

securing printed
Note
Be
aure

circui t board

to

apply

conductive

Remove tachometer

by loosening
Fig BE
22

BE744C

sealer to threads prior to installing hennal new

transmitter

retaining screws

Tachometer

BE 14

Body

Electrical

System

WARNING
CHARGE WARNING SYSTEM
Refer to Section EE connect

SYSTEM
SEAT BELT WARNING SYSTEM
DESCRIPTION
This system consists of switch
a
s

lead wire from switch termi

nal and unscrew switch

BRAKE WARNING SYSTEM

REPLACEMENT
Hand brake switch

an

ignition
a

timer unit

Oil

pressureswltch

warning light
to

driver buzzer

seat belt switch and a

warning

and is designed

remind the

driver to buckle his seat belt When the

to

ignition

switch is turned

the
comes

ON position
on

Disconnect battery Disconnect

Remove

ground
brake

cable

light
8

and remains the

same

the warning on for 4 to

time 4

2
3

Remove console box ifequipped

seconds

At

the
to

hand

switch

warning

buzzer

sounds

for

lead wire at connector 4 switch from switch bracket by pulling it 5

seconds intermittently if the driver s seal b lt is not fastened properly The

buzzer is also used as
a

theft warning
buzzer

Install

new

switch in the

reverse

buzzer
BE247

and back up 5

warning

order of removal Fig BE

24

Oil Pres5ure Switch

only for model

speed

manual transmission

@
SEAT BELT WARNING TIMER 3 2 SEAT BELT

SWITCH

BE 177C

Fig BE 23 Hand Brake Switch

SEAT

BELT

BUZZER

WARNING

LIGHT

Brake fluid level switch Brake fluid level switch

is

BE1270

Fig BE 25 Seat Belt Warning System

buiit
REMOVAL AND

into brake master

The cap

twisting

it

cylinder cap can be easily removed by after disconnecting lead

INSTALLATION Warning buzzer

Disconnect battery ground cable
2 Remove instrument lower
cover

wire terminals Then

replace

it

OIL PRESSURE WARNING SYSTEM

REPLACEMENT
011 pressure switch To replace oil pressure switch dis

and cluster lid B compartment 3 Disconnect buzzer wire

nector 4 Remove
screws

con

retaining buzzer
take
out

11

assembly and then assembly

5

buzzer
BE128D

Installation is in the

reverse

order Fig BE 26 Warning Buzzer

of removal
BE15

Body Electrical System

Seat belt wammg timer unit
1

INSPECTION

Connect terminal

j to

negative

Warning

buzzer

Disconnect battery ground cable Remove L A dash side finisher Disconnect b arness Remove
timer
conn ctor

terminaI of DC 12 volt power supply 2 Connect terminal to positive terminal of DC 12 volt power supply Buzzer should sound intermit
tenty 3 As to terminal nect to

2
3 4

unit

attaching the
everse

screw

and

con

Install timer unit in

order of removal

positive terminal of DC 12 volt power supply respectively

Buzzer

should

sound

intermit

tently

Note
BE308C

Make

sure

that negative termi

Fig BE 29 Warning Buzzer

nal of DC 12 volt power supply is a1ways connected to tenninal CD

Seat belt warning timer unit

Seat belt warning timer unit

Y BE1290

Fig BE 27 Seat Belt Warning Timer Unit

j
r
tIT
Lamp
4W 3

Q e

Battery

t2V

Seat belt switch

I 2 3 4

Disconnect battery ground cable Slide

seat

all the way forward

Disconnect harness connector Remove

inner seat

belt

by

re

moving securing bolt

5
verse

Install inner seat belt in the order of removal

re

BE312C

Fig

BE 30 Checking Seat Belt Warning Timer Unit

Seat belt switch Test

BE31QC

seat belt switch with

continuity through driver s a test lamp or

should be

tween

two

terminals when the seat

belt is unfastened

Conversely there

Fig BE 28 Driver s Inner Seat Belt

ohmmeter There

should not be continuity whenfasten

continuity

be

ed

BE 16

Body Electrical System

ELECTRICAL
CAUTION Before

ACCESSORIES

Wiper linkage
to work on any

starting

part of

electrical system ground cable

disconnect

battery

WINDSHIELD WIPER
AND

WASHER

REMOVAL AND INSTALLATION

Wiper motor
I

2
3

Disconnect battery ground cable Disconnect harness connector Remove

wiper

motor

attaching
Windshield washer

Fig BE 32 Wiper Linkage

bolts
4

Remove motor
motor

arm

attaching nut

securing

arm to

motor shaft

J
1
2 Washer

nozzle R n Washer nozzle LU

Wuher tube

I
BE683C

d4

Washer tank
Washer
motor

ID

BE762C

Fig

31 BE

Removing Wiper Motor

Fig BE 33 Wind hield Washer

Bend
a

pipe with
tool

suitable

CAUTION
Be careful not to bend removal

linkage during

4
Unit
mm

in
BE130D

Wiper

motor can then be detached

Fig BE 34 Nozzle Adju

tment

BE 17

Body Electrical Sys

I

em

There should be
Between

continuity

at the

ground
4 to

terminal
run

CID

this time

Wiper
or

CAUTION
a

following terminals
to
use

motor should

Be

sure

only

windshield

ill

and

and

CID

Ground either terminal

CID

washing

solution
or

@ and@
deter
2 terminal of a
to

Never mix soap powder gent with solution b To avoid

improper windshield washer operation do not operate windshield washer continuously for
more

CID
3

securely connect positive 2 volt DC power supply terminal @ and ground terminal Wiper motor should run Next ground terminal@ Do not

Then

keep wiper motor running Chec k continuity between

termi

nals

ill and@
should repeat

Continuity
OFF

ON

and

periodically

than 30 seconds

or

without

washer fluid seconds

washer should be
or

Normally windshield operated for 10

one

Wiper and washer switch

less at

time

Wiper and washer switch

When removing wiper and washer remove combination switch
to

t3

11

17

W PE I DFF lOW HI

WASH PUSH

switch Refer

Lighting

and

Turn

Signal

Switch

14

7b

11
0

16

116
117
o

gb
BE1330

Fig BE 37 Wiper and WcuherSwitch

REAR WINDOW WIPER AND WASHER

REMOVAL AND

window glass
3

Remove tailgate finisher and seal

Disconnect harness connector

ed screen 4

BE131D Fig BE 35 Wiper and Wll5her

Switch

INSTALLATION Wiper
2 motor unit

Remove wiper motor unit from tailgate by removiDg attaching bolts 6 Install wiper motor unit in the
reverse

Disconnect battery ground cable

order of removal
arm

INSPEctiON
Wiper
motor

wiper arm from pivot shaft by loosening wiper arm attaching bolt after raising wiper blade from rear

Remove

Install wiper
tion

in correct installa

angle

to

obtain correct

sweeping

wQes

P
6 LJ
3

i Jill

B
BE132D BE134D

gu

Fig BE 36 Wiper Motor Unit

Fig BE 38 Removing Rear Wiper Motor

BE1B

Body Electrical System

G
20 Unit
mm

91

100

0 78 Hatchback in

Wagon
BE135D

Fig BE 39 Nozzle Adju

tment

Rear window washer

To nozzle
c

Hatchback

Rear washer pump Rear Rear

2 3

washer tube washer nozzle

r
To
rear

washer

pump

I
Wagon
BE136D

Fig BE40 Rear Window Washer

BE 19

Body Electrical System

Rear wiper and her awltch 2
3 4 5 A

Remove comole box if equipped

Remove lead wire terminals

D m n ID

Remove retaining nut Remove lighter from cluster lid

re

Install cigarette lighter in the verse order of removal 6

ill

I
BE752C

Fig BE 41 Rear Wiper and Washer Switch

BE757C

Fig

43 BE

a CiI

tto

Lighter

INSPECTION
2

Between

and

@ @ and@
positive

Then securely connect

Wiper motor Wiper

motor

unit is made up of
stop auto

terminal of a 12 volt DC power supply to tenninal @ and ground terminal

motor and an

mechanism unit as

@
fol 3

Inspect wiper motor 42 BE lows See Fig

I
Th
re

Wiper motor should run Keep wiper motor running Check continuity between @ and Continuity should repeat periodically
ON and

RADIO
REMOVAL AND INSTALLATION
Radio receiver
I 2 3

should be continuity be

@
OFf

tween

the following terminals

Disconnect battery
Remove

ground

cable

Remove cluster lid A radio with bracket by

screws

loosening attaching
4
antenna

DiscOnnect harness connector and feeder cable

receiver in the
re

Install radio

verse order of removal

cv @

JL

CD

Fig
BE753C

tf
44 BE in

BE759C

Removing Radio

Fig BE 42 Rear Wiper Motor

Speaker
I

Rear wiper and waaher switch Test continuity

CIGARETTE

2 3 4

Disconnect battery ground cable Remove radio receiver Disconnect harness connector Remove
nuts

through

wiper and
a

LIGHTER
REMOVAL AND INSTALLATION
I

washer switch at each step with

test

speaker by loosening
speaker
the

at

lamp

or

ohmmeter See Fig

41 BE

taching
5

Install

reverse

Disconnect battery
BE 20

ground

cable

order of removal

Body
2
Tune

Electrical

System REAR WINDOW DEFOGGER

REMOVAL AND
but dis

Extend antenna

completely
of the 16
12 and

in

to

frequency
between
on

weakest

station

I 200

to 1 600 kHz

dial

Noise may be

generated
to
a

INSTALLATION Defogg
I 2

regard
3

it

Turn anteiln3 trimmer

and set it at

left and position highest

switch cable

right slowly where receiving sensitivity

Fig BE 45 Speaker

is

Disconfi ect battery ground

Remove

defogger
with
a

switch

by

prying it off pull it out

3 4

screwdriver and

Disconnect harness Install

connector
reo

defogger

switch in the

Antenna Remove
screws

verse

order of removal

fastening
to

upper

Rear

window filaments

and lower antenna supports

front

The fIlaments are

rear

printed inside

the

pillar
2

window glass

Therefore

the ele

Install

antenna

in

the

reverse

ment cannot be removed

order of removal Feeder cable

I 2 3 4 5

BE29SD Fig
47 BE

Trimmer Adjusting Screw

INSPECTION Defogger switch

Test
test

Disconnect battery ground cable

Remove antenna Remove front

pillar molding
cable
from

Remove cluster lid A

continuity of switch lamp or ohmmeter

with a

Disconnect

feeder

radio receiver
6

Pull out feeder cable through hole

in front 7

pillar
reverse

Install feeder cable in the

order of removal

CLOCK 2
REMOVAL AND INSTALLATION
I

d 1
1 3

Disconnect battery ground cable

Remove combination meter Disconnect harness connector Remove
screws reverse

r
BE251C

3
4

clock by loosening

re

L
BE254C

taining
5

Install clock in the

order Fig BE 49 Rear Window Defogger

Switch

of removal

Rear window filaments Rear window

Fig

46 BE

Antenna and Feeder Cable

Jf rr i1
r
b

defogger

tfilaments

can
one

be

inspected

for circuit breaks by

of three methods

ADJUSTING ANTENNA TRIMMER When

or a new

8
Start engine and turn
on

Ii

Method

1 window
a

radio receiver antenna antenna

eE758C

defroster

system

If

area

around

feeder cable is installed shoul be adjusted

specified

filament is not defogged that

trimmer

Fig
BE 21

48 BE

Clock

line is broken

B6 Y

Electrica

System
88 N N
cci
Heat wire

I I I 11111111

111

f EIIII
1

4
I

reak

777 j
r7 1

Rea

window

I Lr

glass

GJ
area

W777 n

t T u I

cD
BE537

j t

ID
3

Defogged Fogged

BE540

Ora

I
wing
pen

Ruler

Unit

mm

in

Broken heat wire

area

Fig

BE 53

Pmitioning

Ruler

Fig BE 50 Broken Filament

4

Wipe

clean

silver

composition

Method 2 Start engine and turn defroster system With a voltmeter

BE 51
on

from tip of drawing pen

window
current direct

n
I

After repair has been

completed

check
minutes

repaired
after

wire

for continuity
is

setup

as

shown

in

Fig

This check should be conducted 10 silver composition

check each

heat wire for dis ates indic wire 12

I
SE539

continuity lfmeter or 0 on a specific

broken
Break in

Y9lts

deposited
Note Fig BE 52 Checking for Broken
Filament with

that line is 6 volts then be

Do

not

touch

repaired

area

Normal indication that line

can

while test is

being

conducted

detected by moving positive lead of

meter tion

phmmder
Drawing
pen Rear window

along

line until an

abrupt

varia

in meter

indication is

encoun

teredo FILAMENT MAINTENANCE

Repair equipment
I

Conductive silver composition

1 2

Heat wire Silver composition Ruler

iI
aE541

Dupont No 4817
2 3

Ruler 30 em 12 in

long

Drawing
Alcohol

pen

4 Heat gun

Fig BE 54 Depositing Silver Compo ition in Place

6 Cloth 6 Fig BE 51
air

Apply directly

consla11t

stream of hot
area

to the

repaired

for

approxUnately 20 Repair procedure

I

minutes with a heat

Wipe broken heat

wire and its

gun A minilnum distance of 3 em 1 2 in should be kept between repaired

area

Method 3 With
in
an

surrounding area clean dampened in alcohol

2
as

with

cloth

not available

and hot air outlet Ifa heat gun is let the repaired area dry

Apply

for 24 hours

small amount of conduc

ohmmeter setup

shown
one

tive silver composition to

tip of draw

Fig

BE 52
a

place

one

lead at

ing pen
Note Shake silver composition
con

end of

heat wire and the other in the

meter

middle section of that wire If

tainer before use 3 Place ruler

on

registers

on a

specific grid line

value

twice as much 8S on any other line that line is broken A break in that line can then be in

line to be repaired silver composition

glass along broken Deposit conductive

break with draw heat
mm

After repair

on

Wipe repaired
soft clean cloth Note Do not
use

area

clean with

located
meter

by

an

abrupt
as

variation

ing

pen

indication

test

lead

moves

wire on both sides

Slightly overlap existing preferably 5

of the break

cleaning

nt solvt

along

broken heat wire

0 20 in

containing much

soapy water

BE 22

Body

Electrical

System
STARTING SYSTEM For automatic transmission models
REPLACEMENT AND
Hea t wire

Break

points

INSPECTION
Inhibitor switch Refer to Section AT

Incorrect

Overlapped

area

BE542

Inhibitor relay
See

Fig BE 55 Incorrect and Correct Deposition of Silver Composition

Fig

BE B

HEATER
CAUTION Before

starting to

work

electrical system ground cable

on any part of disconnect battery Air lever

1
DESCRIPTION
CnID Off lEU B I HUT HDI

DEI
III

R C HUT

OFF 1
I
lev

Outside air drawn in through the cowl top grille is directed through the
air intake
case

to the heater unit

by

Fan p lever

switch

the blower The heater unit includes an air mix door which controls the air

temperature

and

ventilation door

To defroster

and floor door which change the distri bution of air flow The air intake door inside the air intake
case

shuts out the

Outside air

fr

outside air when the heater is off The heater controls three levers
are

consisting of panel They

Inside air

located in the middle

r
C
i
5

rf
1

To side

t defroster

portion of the
are

instrument

the AIR lever which selects the air

inlet and outlet the TEMP lever which controls the temperature and the FAN switch lever which regulates air flow with the blower Side defrosters
are

U
6

D
@

LJ

1 2

Air mix door

Ventilation door
Heater
core

provided

on

3 4 5 6
7

To

Ooor

models bound for Europe Heated air

is

Floor door
Water cock

discharged from the side

in

outlets to

remove
ness

side window frost and cloudi

Blower Air intake door

BE137D

frigid

weather for better side

view

Fig BE 56 Heater Control

BE 23

Body Electrical System

liP
1 2 3
4

to
1
ill
BEl38D

Center t duct fV ltilation Side defroster duct

Defroster

6 7 8 9 10

Heater control
Water cock Water

nozzle

inlet hose hose

duct

Defroster duct
Heater

Water outlet Air

con

unit

AIR FLOW
VENTILATING

Fig BE 57 Heater Construction

VENT

position

Duwde air

To center

ventilator

J
2
3
J

UV

Off COlD

IUl

HUT HOl

OIF fll

HEC HEll

OFl l

Move

the

lever to the

Move

the lever to the air flow

desired temperature

desired

ir
BEl39D

Fig BE 58
BE 24

VentiIDting

Air Flow

Body
VENTILATING AND HEATING BI LEVEL

Electrical

System

To defroster nozzle

ft
BI

To side defroster

LEVEL position

Outside

air

L
L

Ul
OFF COl VENT Bl HElT HOT Olf fIN RECHEIl

OfF 1

Move the

lever to the

Move the lever to

the

desired temperature

desired air flow

To floor BEl40D

Fig BE 59 Ventilating and Heating Air Flow HEATING

To defroster

nozzle

fr
HEAT

position

Outside air

t c

Ul
OFF COlO IINl L HElT HOT Olf RECHll FIN OfF 1

B
Toflaor

yO
BE141D

Move

the lever to the temperature

desired

Move the lever to the desired air flow

Fig DEFROSTING

BE

60 Heating Air Flow

To defroster nozzle

fr
OEF position
Outside air

Ul
OFF COlf VENT L HElT HOT J
Move

Olf fIN

RECHll

OFH

@Jtc l
Fig BE

Y
1
61 To defroster

the lever to the

Move the lever to the

desired temperature

desired air flow

BE142D

Defrosting Air Flow

nozzle

RECIRCULATING

RECIRC position

J
OFF COlOr VENT L HEll HOT OEf RECHEIl fIN PfF

1
3

LJ
Iniideair

@
To floor BE143D

Move

the lever to the

Move

the lever to the

desired temperature

desired air flow

Fig BE 62 Recirculating Air Flow

BE 25

Body
REMOVAL AND INSTALLATION
HEATER CONTROL SEMBLY
I 2 3 4 Disconnect 6

Electrical

System
3

Disconnectharness tonnec1or Remove heater control assembly with bracket from instrument panel by
7

Remove blower moto

motor

after
screws
re

rti

moving blower
4
verse

retaining

Install blower motor in the order of removal

loosening attaching
8 the
reverse

screw

Install heater control assembly in

battery ground cable

r

order of removal After

Pull off control lever knobs

Remove

cllJs

lid A

Remove defroster ducts Disconnect

installing heater oontrol assembly oon trol cables and rod must be adjusted by referring to Adjusting Heater Con
trol RESISTOR
I 2 3

door

control cables

and rod at each door

Disconnect

battery ground
by pulling

cable

Disconnect harness connector

Remove resistor it

Note

Resistor can be removed iIy by prying from above and below with
unit
a

blade fbt

screwdriver with raised from heater

resmor

slightly

Install

resistor

in

the

reverse

order of removal
To

air

intake door

BE19

Fig BE 63 Heater Control Assembly

1

Remtor Blower BlOWer motor

BE244D

2 3

HEATER
I
2

UNIT

13

Install heater unit in the

or

reverse

Disconnect
Remove

battery ground

cable

order

removal Fig BE 65 Removing Blower Motor

and Resistor

Drain engine coolant

package tray

with brack

et if equipped 4 Remove console box if Remove cluster lid A Remove heater control Remove radio receiver

equipped assembly equipped

ducts
at

rf o t

5 6
7

On

air

conditioner

models

disconnect

cooler

heater unit side

WATER COCK

9
10

Remove center ventilator duct

BE190C

Disconnect

blower

motor

har

Fig BE 64 Removing Heater Unit

Remove heater unit Remove

water

ness connector

2 of wat
core
r

cock

attaching

II

Disconnect inlet

cock

screw

and outlet of heater

hoses by after

BLOWER MOTOR
I

3 hose 4

Disconnect

hoses

by loosening
reverse

loosening hose clamps

12

Disconnect battery ground cable Disconnect blower motor harness

clamps
Install water cock in the

Remove

heater

unit

re

moving heater unit retaining bolts

connector

order of removal
BE 26

Body

Electrical

System
Note
is

VENTILATION DOOR IJi

I tion 2 Push ventilation door
arrow

Make

sure

that air intake door outside air

can

Set

AIR lever at

RECIRC posi

fully

open

flow

into air intake case

when AIR lever

Ir

c
r

relay lever

is in VENT

position

in direction of

to shut out air

flow to center outlet and press venti

lation door control rod into

relay lever

clamp
FLOOR DOOR

Set AIR lever at OFF 2

position

Push floor door lever in direction

to

of arrow and

shut out air flow to floor

and press floor door control cable outer case in direction of While doing
so secure

defroster

AIR lever
case

outer

with clip

BE192C

Fig BE 66 Removing Water Cock

BE253C

Fig BE 68 Adjusting Ventilation

Door

ADJUSTING HEATER CONTROL

AIR MIX DOOR
I Note is

Make

sure

that ventilation door AIR lever is in

BE256C

Set

TEMP

lever

at

maximum

fully open when VENT position

HOT position
2

Fig BE 70 Adjusting Floor Door

Push air mix door lever in direc

tion of arrow and press

temperature
so secure

control cable outer case in direction of TEMP lever While doing

outer
case

Note

Make

sure

that floor door is

flows to floor and

fully open air

defroster
HEAT

with

clip
AIR INTAKE DOOR Set AIR lever
2 Push air
at

when

AIR lever

is

in

position

OFF position
door

intake
to

lever

in

direction of arrow
air flow

shut out outside

and press air intake door

case

control cable outer AIR lever While

case

in direction of
secure outer

doing

so

with

clip

DISASSEMBLY AND ASSEMBLY OF HEATER UNIT

Remove heater uni t
BE252C

Disconnect heater core inlet and

Fig BE 67 Adjusting Air Mix Door

outlet hoses by loosening hose clamps 3 Remove clips securing front and
rear

Note

Make

sure

that water cock is

BE255C

4 5

heater cases and separate them Take out heater core Assemble heater unit in the
re

fully

closed when TEMP lever is in

Fig BE 69 Adjusting Air Intake

Door

maxilnum COLD

position
BE 27

verse

order of removal

Body Electdcal System

OFF 1

2 0

I I

01 I
01
BE766C

2 3
I 2 Heater Heater
case

as

mbly

cote

Fig BE 72 Fan Switch

BE193C

Fig BE 71

Heater Unit

RESISTOR TItere should exist continuity be

tween

terminals of resistors
are

althouBh

INSPECTION
Check the

to

main harness for blower motor and

to

values of resistors

different

the other

following

items if blower

ground
HEATER RELAY For

motor fails to rotate

Turn ignition switch to ACC position test lamp should go on BLOWER MOTOR

heavy duty type

should be continuity be
and terminals

FUSE
To check for the same
out burned as

There

fuse

use

Disconnect blower motor harness

tween

procedure

that for ordina

or

to connect fan switch and connect the

between 2

D @ and @

but not

ry fuses with a circuit tester

test

harness to ground
2 Turn

There

lamp

ignition switch

to

ACC

tween

terminals

should be continuity be @ and @ when

across

position

Blower motor should rotate

supplying

OC 12 volt

terminals

D and@

BLOWER MOTOR POWER SUPPLY Disconnect blower motor harness

to connect main harness 2

FAN SWITCH
Test

continuity through fan switch

Connect

one

test

lamp

lead wire

with

test

lamp

or

ohmmeter

I
i
@ j

j
i

fc 4@
V I
AC197A

Fig BE 73 Heater Relay

BE 2B

OJ 0

m CD

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l3

e xI n
II IInIa

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xl l3 CJ lC m
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RELAY
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B

S W I T C H BLOCK
FUSE
W

AIR

IGNTO
1 WR

A
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for

models

models

model
FU
CaliforOlB Non

1 R
W w

Californt Non
Note

alifornt8 models

Canda

@i

MOT R
I

STARING

J @@ @@ L

0
L r

ffi 8

12V

BATERY
i iO
ll ii I
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In Ql CIl
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SWITCH

CHEATR ONDITER
l t1

lAIR

LAMP TEMPRAU S O L E N I D H E A T R BELT BUZ ER LAMP SOLEN ID O P E N R S O L E N I D L A M P P R E S U REVOLUTIN CHOKE SIGNAL FUEL WATER BRAKE CHARGE SEAT DEFOGR ENGIE FUEL VACUM AUTO THRO LE TURN GAUGE WARNIG WARNIG BACK KICDOWN TACHOMER REAR
CUT CUT
OIL
UP
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SOLENID

10A

20A fA
l t1
16

CO

lm lm 0z
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CO

1m 0 z

CJ
1 m 0z CJ

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CO

15A

14
I

LIGHTER FLASHER RO M LAMP PLATE MOT R WIPER WINDOW LAMP LAMP LAMP WIPER WINDSHEL REAR REAR HORN CIGARET CLOCK HAZ RD STOP RO M LUG A E TAIL CLEARN LICENS
m wo

MOT R MOT R WASHER MOT R WASHER

LAMP

LAMP LAMP LAMP MET R

COMBINAT
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0 m ll6 I lii C en g
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l oill

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MAIN
8

LINK

1
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A FUSIBLE

BATERY

Jj

2ND AlBic 1ST Off

Q I Q5
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LAMP
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SIDE LAMP

MARKE

TAIL

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LAMP
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TAIL IL
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B

IR

JJ
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JJ
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MARKE

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Q
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3m

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WAGON
l i

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00 00 00
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IR

SlOE LAMP

An
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L
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LINK

RG
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BLOCK

E
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FUSIBLE m

Gl CANOA Q
cALlFORNIA NON

FUSE r J

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SWITCH

3 P

SlOE LAMP

MARKE

BATERY
B

LIGHTN
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@
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GV

MARKE

H
L

SlOE LAMP

On

tJ

nm S

nm F i too 1 l

ii

oil tl

Cl 3

r a J enII

mW

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0Ql

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RAOI LAMP
j
H

ILUMNATO

HEATR PANEL LAMP

l 3
r L
I

CONTRL ILUMNATO
I

TRAY
I

ILUMNATO
CJ

INATO
CLOCK
L

ASH LAMP

C3
3

ILUMNATO CONTRL
B

UNIT

COMBINAT
W
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LAMP

t1 L

GI

lOr c

Jl
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to

INSTRUME HARNES
GW
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B
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B
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CALIFORN MOELS
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MO ELS

FU
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cALlFORNIA NON

CANOA
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BLOCK
FUSE
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0 0 0
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r
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I

BATERY

er 15A

RG

2ND liB
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OI6
116
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12

2 2

SWITCH

10
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AND
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IR

SWITCH 1
O OR

HARNES
BO Y
g00 00
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RO M

OFF

O OR

CE

LUGAE RO M HATCBK WAGON

r

LAMP

O L 0
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SWITCH
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rr

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of

@J GY
BA

HARNES
MAIN

BLOCK
FUSE

0 0

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uQ G
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BATERY

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toom

Body Electrical System

Head lamp

Condition
Head

Probable
Burnt fusible link

cause

Corrective action

lamp do

not

Corree

cause

and rep1ace
or

light for either high

or

low beam

Loose connection or open circuit

Check wiring and

repair

connection

Faulty combination switch ground

Conduct continuity test and replace if nee

essary

No

Clean and tighten ground terminal Conduct continuity test and replace if
essary
nee

High beam
or

cannot be

Faulty combination switch

switched to low beam

vice versa

Head

lamps

dim

Partly discharged

or

faulty battery

Measure

recharge Faulty charging system

or

specific gravity of electrolyte replace battery if necessary

less than

and

Measure voltage at headlamp terminals If it

is

12 8V

check

charging

system for proper operation

Poor

ground or loose connection

Clean and or

tighten

Burnt fusible link

Replace Repair Replace

Head lamp lights

on

Loose head lamp connection

only one side

Faulty headlamp beam

Tail

clearance

aide marker and license plate lampa

Condition
Burnt fuse

Probable

cause

Corrective action

Neither left

nor

Correct
or

cause

and replace
or

right lamp lights

Loose connection

open circuit

Check wiring and

repair

connection

Faulty lighting
Lamps light
connected fuse

switch

Replace if necessary
and

when

terminals of

harness connector
with

to

combination switch are lead

test

iIlc1uding

15A

Lamp

on

only one

Burnt bulb

Replace
Correct

side does not light

LOose

bulb

Loose connection to

lamp

Correct

35 BE

ml

CIl

a
a

F to l

to
e

fURN

fION COMBINA

COMBINATiO
ANO

COMBINAT
im 11
H

IR

REAR AMP

IR
P

J
L

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fER ME

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IFORNIAMODELS
CAI FU

REAR

A
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BLOCK
fUSE

fION COMBINA

TURN
Q
1

g
1

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FLASHER SIGNAl
T

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ARO a TURN a
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INSTRUME HARNES
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6

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2
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BAT ERY

MOO

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WARNIG
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LAMP
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TURN

Ii

41

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COMBINAT
WAGON
STOP
I

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STOP LAMP

IR

REAR LAMP
v
v

COMBINAT
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3
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REAR LAMP
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COMBINAT

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COMBINAT lLAMi
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REAR

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CALIFORN
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Body Electrical System

Turn signsl snd hszsrd wsrnlng Ismp

Condition
Burnt fuse

Probable

cause

Corrective action

Turn

signals do

not

Correct cause and replace

or

operate
Hazard

Loose connection

open circuit

Check wiring and

or

repair

connection

warning
te

lamps

oper

Faulty flasher Faulty

turn

unit

Replace
Conduct
sary

signal switch

continuity

test and

replace if neces

Faulty
Turn

hazard switch

Replace if necessary
when

signals operate
are

CD
to

and

terminals of harness connector switch

l5A fuse

hazard

connected with test lead including

Haza d

warning lamps do not operate

Turn

Burnt fuse

Correct cause and replace

unit

Faulty hazard warning flasher

Replace
Replace if necessary

signals

operate

Faulty hazard switch Left Right side lamps operate when

and

@
to

and

terminals of harness switch are connected

connector

hazard with test lead including l5A fuse

No flasher click is heard

Burnt bulb

Replace
Reconnect

Loose connection
Bulb

firmly
one

slow

Flashing cycle is Pilot lamp

or

too

other than

specified

wattage

being

Replace
Replace Repair

with

specified

does too

used
Burnt bulbs Loose connection

not go out

fast

Faulty flasher Flashing cycle irregular

is Burnt bulb

unit

Replace
Replace Repair

Loose coimection Bulbs

other than

specified

wattage being

Replace

with

one

specified

used

Stop Ismp

Condition
Burnt fuse

Probable

cause

Corrective action

Neither left

nor

right

Correct

cause

and replace

lamp lights

Faulty stop switch

Loose connection

Conduct continuity test and replace if neces

sary

or

open circuit

Check wiring and

or

repair connection

Lamp lights

on

only one side

Burnt bulb

Replace Repair lamp socket

Check wiring nd
or

Loose bulb
Loose connection or open circuit

repair connection

BE 39

Body Eleptrical
up Back

S stem I

lamp
Probable
cause

Condition

Corrective action

Neither left

nor

right

lamp lights

Faulty back up lamp switch hibitor switch A T

Burnt fuse Loose connection
or

MT

or

in

Conduct continuity test and

sary

replace

if

eces

Correct cause and replace open circuit Check wiring andlor repair connection

Lamp on only
side

one

Burnt bulb Loose bulb Loose connection

or

Replace Repair lamp

open circuit

lights

socket
or

Check wiring and

repair

connection

40 BE

Body Electrical System METERS AND GAUGES

GAUGE FUEL LEVEL AND WATER TEMPERATURE

II

Q lb
en
en w

J W

Z 0 J 0 o o
w w

wg
l JC Ow
0 z

L
wC1 cct 3 CJ o

L
1CJ w
0 LLO

riiOOOOIIO
OO OI

0 J

1
z
w

0co

6 Pp t6 0 0

Q 2

E
w

0 Z

C1

0 c
J

LI
gg

CD L

I 0 1

fggglr

f
i
J I
I
CD

I
O
J

I
0

MAIN

HARNESS

I
0 o
J W
en

riJn
0
w

Z 1
Q

r c
u

t
en

0
J

ffi

QM

f
Q

f
u

i1 Tf
00

J
J

l
01
a

010 lC
a 0

Z 0

to
Z

IE

fD

01

I
Fig

t
83 BE

BE150D

Leuel and Water Temperature Gauge Wiring Diagram for Fu l

41 BE

Body Electrical System

Fuel level gauge

Condition Fuel level gauge does

not operate

Probable

cause

Corrective action

Faulty fuel gauge tank

terminal connection

unit or loose unit

Replace fuel

gauge

tank

unit or

correct

terminal connection

pointer
yellow

deflects when fuel gauge tank unit

wire

isgrounded
gauge

Faulty fuel level

Replace
Check wiring and
or

Loose connection or open circuit Pointer indicates only F 10 position

repair

connection

Faulty fuel gauge tank unit Pointer drops below E 0 ignition switch is turned off Faulty fuellevel gauge

Replace
mark when

Replace
F 10

pointer
when

still indicates

position

ignition switch

is turned off

Fuel level gauge does

not

Faulty fuel

gauge tank unit

Replace Replace fuel

level gauge

operate accurately

Faulty fuel level gauge

Poor
or

loose connection

Correct connector terminal contact

Faulty gauge voltage regulator Gauge pointer fluctuates excessively

Replace fuel level gauge Main temperature gauge Sub

or

water

Water temperature gauge Condition

Water

Probable

cause
or

Corrective action loose terminal

temperature

Faulty
connection

ttherrrui ransmit eJr

Replace thermal
minal connection

transmitter or correct ter

gauge does not

operate

When yellow white wire to thermal trans mitter is grounded gauge pointer fluctuates
Faulty
water temperature gauge

Replace

water temperature gauge

Open
Gauge indicates only
maximum temperature

circuit

Faulty thermal transmitter Gauge pointer returns to original position when ignition switch is turned off Faulty water temperature gauge Gauge pointer indicates maximum tempera ture even after ignition switch is turned off

Replace thermal transmitter

Replace

water

temperature

gauge

Water temperature
gauge does not

Faulty
Loose

water temperature gauge

or

Replace

water temperature gauge

operate

poor connection

Correct connector terminal contact

accurately

42 BE

Body
Speedometer

Electrical

System

Condition
Loose

Probable

cause

Corrective action

Neither

speedometer
nor

speedomeTer cable union speedometer cable speedometer

drive

nut

Retighten Replace

pointer

odometer

Broken

operates

Damaged

pinion

gear

Replace

Transmission side

Faulty speedometer
Unstable speedometer

Replace
or

Improperly tightened
cable union nut

loose speedometer

Retighten

pointer

Damaged speedometer cable Faulty speedometer

Unusual sound
occurs

Replace Replace

in

Excessively

bent
or

or

twisted

speedometer

Replace

or

lubricate

response to increase in

cable inner wire

lack of lubrication

driving speed
Inaccurate indication Inaccurate odometer

Faulty speedometer Faulty speedometer

Replace Replace

speedometer

Improperly
worn

meshed second and third gear

or

Replace speedometer Replace speedometer

operation

gears
to

Faulty feeding due and pinion carrier

deformed odometer

43 BE

OJ oCl

m CD

CIl

l3

J az Z G Ut 0
lIIll 11 1III Ill 11 1

iUt ali
Ill

I
11 1 a li i IllZ i a X

BRAKE i
HANO SWITCH
J G

ETER
qN
AT
N

z 1

LAMP

OMB

BRAKE WARNI G

PRESU WARNIG LAMP

OIL
YB

INSTRUME HARN
ESS
I

YG

10 100 00
0
I

Fo e 1
o
J

fG

RELAY
cHOKE AUTO
I

f YB WR
G
L

BL

V
r

MAIN

HARNES
W W
B
I

ANO

WR

wr

WR
IA

J @ @ Q

LB

PRESU SWITCH
OIL
BY

BLOCK

0 lOA lOA

cr cr r L
1

FUSE 0
wr

BJ

l Y

CALIFORN
0

MO ELS ffM Q
FU
N G G

MO

C j
i

iji
i

o0
Ot JO

cALIFOR NON

CANO
ANO
i B i

II

IC

ANO

BATERY

ALTERNO VOLTAGE
I

REGULATO

SI

jJ Ys
IS
s

J
1

fh
cIo

9 l
tl
3

OH

mQ
l
I I

SWITCH

IW LEV L
FLUIO

SWITCH

OflAC 01
lOCI
I

10

D
l

IGNTO
I

BRAKE
toom
a

Cl

4Ii

i ii lI C llg I

ll

CD mt

OJ o Cl
III e IIll aI IIIZi C

m CD n

oQ

CIl

en l3

LAMP

BUZER
II
I

WARNIG
S

WARNIG
B

81

ORIVER BELT
tl

SWITCH

ij
aB

feB
B

WB

OI

00 00

00

iP

VB

BL

J l

BLOCK
FUSE

0 lOA

ew

D
i

if
i

GtG ug
e

LINK

16

Sf

FUSIBLE

aNI

SWITCH

TIMER
BELT
I I

OfIAC I
lOCI

0 0

IGNTO
I

BATERY 8

ll cio ii I

t sa i

Cl

m lU1

Body
Oil pr

Electrical

tem Sy

re charg

and brake warillng Probable Corrective action

Condition

cause

Lamp does not glow when ignition switch

is turned
out

Burnt bulb Loose

or

or

loo ebulb

Replace bulb

or

correct

ON

with

poor connection

Correct connector terminal contacts

running engine Faully bulb

is check

Door and charge

relay

or

alternator

Correct adjust

or

replace

warning lamps go out when engine

started

do not

Charge waming amp Lamp does not go out when engine is started
Oil pressure warning

Faully charging

system

Inspect charging

system

Faully oil pressure switch

terminal connection

or

loose switch
to

Replace

or

correct connection

lamp

Lamp
when

does not light ignition switch ON

When

lead

wire

connected

switch is

is set to

grounded warning lamp lights

Lamp does not go out while engine is being

Lack of engine oil Oil pressure too low

Check oil level and add oil

as

required

operated
Faully oil pressure
Brake

Inspect
Replace When hand brake

engine oil pressure system

switch

warning lamp Lamp does not go out

Faulty hand

brake switch

Replace Replace

lever is released

Faully

brake fluid level switch

When

brake

fluid level is normal

Door door switch

warning lamp Lamp does not glow with door opened and engine running

Faully

Replace

46 BE

Body
Seat belt warning

Electrical

System

Condition
Seat belt Neither buzzer sounds

Probable

cause

Corrective action

Loose connection

or

open circuit

Correct connector terminal contacts

warning lamp glows when ignition switch is turned to ON posi

nor

Faulty

timer unit

Replace

tion

Lamp should glow

for 4
to

8 seconds

Buzzer should sound

for 4 to 8 seconds
without belt

fastening

seat

Either buzzer

or

Burnt bulb

Replace
or

warning lamp does

not

Loose connection

open circuit

Correct connector terminal contacts

operate when
is

ignition switch
turned to
tion

Faulty

seat belt switch

Repair

or

replace

ON

posi

Faulty buzzer

Replace

47 BE

OJ 8

l l

CIl

l3

Em I In zo t

Im

a
1 11 I a

lI11 1a

JonZIIaen

a
i III

io

It 0It
a

In

MOT R ANO

HATCBK
i

WAGON

T1

WASHER
REAR

IHATCBK WAGON
LR

OO OEFGR
REAR
TO

Jj
I

WIPER

lJ

REAR MOT R
1

CRWl RlifBilW
BW
R

LR

ti LR

r R
B

BOYHARNES

LRh ftn
0
I

l c

mC g

1 i

c
L

iOl

0 0

o BLOCK r
FUSE

1
I

BY
z

LR

rLB

III
I I

n
LR
Y

MOT R
ER

R B

iI
MOT R
WIPER
1 1
I I

wr

BY
1

LW

WR LB

WAS
l

LINK
G
E

J m
J 11

iL
II

iW
l I

4d

SWITCH

J 14 16
I

J FUSIB All

13

u
0

WASH
HI

WASHER
ANO

2 Sf
OM

m OnOOB
IG
S

0
I

SWITCH

WASHV
ON

11
I

2 3

II
o

Q
I

00 0
I

Off

Q n

BATERY

UN Off

9o

WIPER
I

ACe

00
0

OfF

IGNTO
5

WIPER
REAR SWITCH
oil tl

lGCK

HATCBK
0

Co

Cl

mJ

Body Electrical System

HORN
CIGARETTE LIGHTER AND CLOCK SYSTEM

CIGARETTE LIGHTER

CLOCK

Itt
ti
I Z
w en

0 01

l
o

9
J

z
0
en

1
fJ1 8ho

I
g

Zrl tEl
i I
al

1
J

J tf

II
J

MAIN HARNESS

J
u

Jti
J w

o
J

9W

W en u

tutJ
I
j

0
I

I
e
o

I
0
en

srb
I

U
E

h
z U

t
LL

TURN

SIGNAL SWITCH

J
w

I
I

I 0 W

l I

on

QlJ

6
I
Fig
87 BE I
r

fD CCI

BE154D

Wiring Diagram for Horn Cigarette Lighter and Clock System

BE49

OJ oCl

mCD

Ce

CIl

en

Jo0 0

RAOI
nIn

LJUJJ
U i ffi

SPEAKR
O WB
W

t LW

ClO
LW

WB

GY GW

INSTRUME HARNES
oGW
I

LW
I

GY

LW
00 og
0

0 0
LB
I

O BLOCK r

00 lO

FUSE

j LW
GW GY

I@o
B

J8
GW

1 w

RG

Z 1

D Z m en

WR
W

WR

J
GY GW

WR LB

1lRG
B

ANO

M O E L S CALIFORN
fB
Ef1

f t MO ELS ao t
I

FU
G

LINK

dG FUSIBLE
g

uQ G

cALIFORNIA NON

CANOA
AND

00
I

i1
I B

II

1 l 5
LAMP

J1
WITCH
5 67 8 9 C

BATERY

8 TORQUE INOCATR
m

CONVERT

C OHST7 OO
A

ti
u v

Q0 Q
I

0 0

Off

lOCK

IGNTION

2ND
lS1

B
I

QIQ
I

0 0

QIQIQ
I

SWITCH

Q 0 0O

AI8
A

LIGHTN
m g 0

Oil

cIo 00 ii lil

3 Cl tl i

OJ o Cl
1IIo8 11 1II 11 a

m CD

c Ql

CIl

en l 3

JoII E z II11 1

ISEOAN

HARNES
BO Y
LG l LG

nUl
OEFGR

60

WINO W
REAR

SWITCH

0rF
2

OEFGR

INSTRUME HARNES
00 03 8 M1R2 106 n
II
I
B

LB
0

0 to i

gg

f
BL

Z J

Z menen

WR

BW

WR

l rT
LINK
G
B

Q
I

BLOCK
FUSE
0

A FUSIBLE
t
i

S17
ON

16

IA

60 J O O o

SWITCH
ITON
IGN

ACC
OfF

BATERY
I

lOCK
I

nm ii Co 0 itl
c

Cl 0

oE 0

Cl l

iO

Body Electrical System

THEFT

CTlON SYSTEM

t
o
BATTERY CALIFORNIA ANO FU MOOELS

at
STEERING
LOCK

tWT FUSIBGLE I QQ L
G LINK

WARNING BUZZER

2 00

WRJ

i
B

RG

ANO

cNON ALlFORNIA CANAOA MOOELS U 7 DRC JQ RL

Le

SWITCH

n u

RljG
RLel

FUSE BLOCK
0
R

OOOR

ITCH

CJ

E
W BEl580 tem Fig BE 90 Wiring Diagram for Theft Protection Sy

KICKDOWN SYSTEM

Automatic Transmission models

tf
@
BATTERY

l rT
I 1 t

FUSIBLE LINK

I I
ENGINE HARNESS
No 2

KICKOOWN SWITCH

rfi

I IOCI
10
I OOWNSHIFT SOLENOIO

OIl ICtOI Sl

009 5

Irs
0 0

li

IT

@ 1
I
8W

FUSE BLOCK

WR

IGNITION SWITCH

3
Fig BE 91
BE 52

C8L

BE1590 tem

Wiring Diagram for Kickdown Sy

Body
Windshield wiper and washer Condition Windshield Motor
not

Electrical

System

Probable
Broken seized
m

cause

Corrective action

armature tor shaft

worn

motor

brush

or

Replace

motor

wiper does operate

Power

Blown fuse
and

Checkshort circuit

burnt

supply
cable

side and
Loose open
or

motor corr ct

or

other part for

component in operation

problem

broken

wiring
I t

Correct Correct
Correct

Improper grounding
Switch

Improper switch

contact

Link

Foreign material interrupts

link mechanism Disconnect link rod Seized
or

movement of

Correct

Correct

rusted

arm

shaft

Lubricate

or

replace

arm

shaft

Windshield

Motor

Short circuit
motor

of motor

armature

worn

Replace

motor or

lubricate bearing with

wiper operat ing speed is

too slow

brush or seized motor snaft

engine oil
Measure

Power

Low source

voltage

voltage

check

other

electrical

supply and cable

Link

parts for operation and take corrective action for power supply if necessary

Humming

occurs

on

motor in

arm

operat

Lubricate

or

replace

infcycle
Switch

due to seized arm shaft

Improper switch

contact

Conduct necessary

continuity

test

and replace if

Windshield

Motor

Motor brush for either low is worn

or

high speed

Replace

motor

wiper speed can not be adjusted

correctly
o

Stops
any

Motor

Contaminated auto stop relay contacts

or

Remove auto contacts

improper

contact due to

foreign

matter

stop device carefully so as

cover

and clean deform

not to

fi 5
2
0

where
Does

relay plate
Motor

E
0 0

not

Incomplete auto stop operation Contact is not interrupted

Remove auto stop device cover rect

and

cor

relay plate bending

stop
Washer motor does not operate
when Burnt fuse

Correct

cause

and replace fuse

Faulty switch Faulty

washer motor
or

Replace Replace
at

pushing
on

washer switch

Loosen

poor

connection contact

Repair

motor or

switch Clean nozzle

I

Washer motor

logged

washer nozzle

or

replace

operate
not

bu t

washer fluid is

ejected
BE 53

Body Electrical System

Horn
Condition Neither high nor low horn operates
Burnt fuse

Probable

cause

Corrective action

Correct

cause

and

repbce

fuse

Faulty

horn button contact

Repair

horn button

Horn sounds

when
to

terminal of inst

harness connector

combination switch is

grounded Faulty horn relay

Horn sounds when

Replace

CD

and

ID

terminals of

engine harness
with
a

to horn

test lead

relay are connected including 15A fuse

Check wiring and
or

se conn ection or open circuit Lo

repair

connection

High Low horn

does not operate

Faulty horn
tion

or

loose horn terminal

connee

Correct horn terminal connection horn

or

replace

Break in wire to horn

Repair
button and
or

Horn does not stop

to

circuited Short

horn

horn

Repair

horn button

or

its

wiring

sound

button lead wire When inst harness is disconnected from

combination switch horn stops sounding

Faulty horn relay

Reduced volume and
or

Replace Repair

Loose or poor connector contact

tone

quality

Fuse relay horn and

or

horn button

Faulty

horn

Replace

Radio Noise

prevention chart
car

Position

in

an

open area away

set

from steel

buildings
no

run

engine extend

antenna to its maximum

length

set volume

control to maximum and

dial at

median point where

broadcasting wave
cause

is received

Condition

Probable

Corrective action

Ignition system
Noise
o curs

when engine is operated

High

tension cable

Install

new

high
lF 5

tension cable

Ignition coil

Replace O

capacitor installed

to

primary side

terminal of ignition coil with ne Note

in

ones

ondary

not to install capacitor to see primary breaker side This will result improper engine operation
or

Be

careful

Charging

system

Sound of

alterilating

current

present

Alternator

Replace
minalA Note

5 O lF capacitor installed to charging ter

Do not use a

larger capacitor
to

When accelerator released noise

pedal

is

depressed

or

Voltage regulator

Install

occurs

a 5lF capacitor O voltage regulator

IGN

terminal

of

BE 54

OJ o Cl

m CD n

nQl

CIl

CJ l3

Z II

II a

MOt R

3
2
I

HEATR
LW
i

IOf l

Kro lli
1

SWITCH
FAN

TYPE
ST

ANOR

11L1

ri
w

RESITOR

Il

and

U6
BW

TYPE

OUTY

Can da
for

A
S

for

M
L
I

i 1 R
L

BLj

lljlj BWY
L

HEAVY Standr option

8

W
B

ii
w

oa
LW
R

LN

ANO
S

gWR MOELS
LINK

15A
B
I

CALIFORN
B

BLOCK

d FUSIBLE
o

is

BATERY

wGLQ
JSt

GALIFORNIA NON

CANOA
ANO
Sf

0 0 0
ON

v FUSE o

SWITCH
0 o

Ace Off LOC

IGNTO
Ul 0

ll ic ii I

tl i

Cl

Body Electrical System

Condition

Probable

cause

Corrective action

Insufficient

heating performance
No heated air

Cooling

water temperature too low

Check thermostat

discharged
Heater
core

Rep1ace
plugged
Clean

as nece

ry

Insufficient cooling water level

Rem

Malfunctioning Malfunctioning
Insufficient air flow
to

air mix door

water

Adjust

control cable

cock

Adjust control cable

Check motor terminal voltage

Blower

motor

speed

too

low

floor

Repair poor connection and discontinuity Replace motor if necessary Replace

sary blower

control

amplifier

if

neces

Malfunctioning floor
Insufficient defrosting

door

Adjust control cable

performance
Cold air

discharged

Refer

to

No heated air

discharged
or

Insufficient air flow

to

Malfunctioning hoor door

Defroster nozzle plugged

faulty

seal

Adjust
Clean Correcl

control cable

defroster

Leak at defroster duct lo nozzle connection

Heated air discharged

with lever in

Water cock not operating properly Mode door not operating properly
or

Adjust
seal

control cable

VENT

Adjust control cable

damaged
Blower motor does
not run

Fuse melted MOlor wire connector disconnected

Correct

cause

and

replace

qrrect

Faulty
Faulty

switch
motor

Replace
Check and correct

Faultyblower control amplifier

Replace

Control lever drags

Inner wire

rubbing against

outer

case

end

Adjust control cable

Correct
Ch ck and COrrect

Control cable bent

excessively

Malfunctioniilg
Outside air
comes

doors door levers etc

in

Air intake door not

operating properly

Repair

or

replace
cable

with fan in OFF

Control cable out of

adjustment

Adjust control

Noise frol11 blower

motor

Loose bolt in blower motor

Check and tighten loose bolts

BE 56

DATSUN 210

Model 8310 Series

SECTIONAC
AIR CONDITIONING
CONTENTS
DESCRIPTION OUTLINE
AIR OF AIR AC 2 2 3 5 6 7 9 9 9 9 9 9 BLOWER RESISTOR AIR FAN CONDITIONER SWITCH MOTOR AC 23 AC 23

CONDITIONER

AC AC AC AC

REFRIGERATION SYSTEM
FLOW

CONTROL

AC 23 AC 23

VACUUM SYSTEM ELECTRICAL CIRCUIT

MICROSWITCH LOW PRESSURE SWITCH

AC23
AC 24 AC 24 AC24 AC 24 AC 25 AC 26 AC 27 AC 27 AC28 VALVE PLATE AC30

AC AC
AC AC

GENERAL SERVICE
REFRIGERANT COMPRESSOR R 12 OIL

MAGNET VALVE FUSE

REPLACEMENT HOSE DIAGRAM

DIAGRAM

VACUUM WIRING

MAINTENANCE GENERAL SERVICE

AC INSTRUCTIONS
SYSTEM AC AC

COMPRESSOR MODEL SC206

PRELIMINARY CLEANING COMPRESSOR CLUTCH SHAFT SEAL
CYLINDER HEAD AND

SAFETY

PRECAUTIONS AND CHARGING

EVACUATING CHECKI NG

AC

FOR

LEAKS
LEVEL CHECK

AC14

REFRIGERANT PERFORMANCE
REFRIGERANT

AC15
AC

COMPRESSOR OIL LEVEL OHECK

TEST

17

DISCHARGE AND sU CTiON CONNECTORS

AC30

AC17
AC17

LEAKS

SERVICE PROCEDURES
FAST IDLE IDLE ACTUATOR

AC18
AC1B

DIAGNOSES AND CORRECTIONS

TROUBLE
AIR

AC32 AC 32 AC 33 AC34 AC35 AC36 AC37 41 AC

CONDITIONER
MOTOR

DIAGNOSES

PULLEY

AND

COMPRESSOR
AC19 AC19
AC 20 AC 20
I

BLOWER

DIAGNOSES

DRIVE BELT COMPR ESSOR

COMPRESSOR COMPRESSOR

DIAGNOSES
CLUTCH

DIAGNOSES

CONDENSER
RECEIV ER DRIER

VACUUM SYSTEM

DIAGNOSES

PERFORMANCE TEST DIAGNOSES PERFORMANCE CHART

REFRIGERANT
COOLING UNIT EXPANSION

LINES

AC 21 ACc21 AC 22 AC 22

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS 42 AC 42 AC 42 AC 43 AC 44 AC

VALVE

THERMOSTAT
MAIN

RELAY UNIT
COCK

AC 23
AC 23

INSPECTION TIGHTENING

AND ADJUSTMENT TORQUE

HEATER WATER

AC 23

SPECIAL SERVICE TOOLS

Air

Conditioning

DESCRIPTION

OUTLINE OF AIR CONDITIONER

Th unit

level

and

ventilation

functions
and

Its

control system consists of a mechani

mer

compressor and condenser in the for and the unit comprising the heater and blower and i Is

cal system
vacuum

using cables

engine
air

evaporator

ipr
of

conditio

er

isa

combine4

and electric system component

are

control in the latter The units in the

passenger

an

evaporator

heater and

The
and

units of the

compartment

aTe

summa

blower and provides heating and cool lng functions In addition it has hi

conditioner

installed in the

engine
the

rized

as

foUows

passenger

compartments

1 2 3
4

Heater unit Ventilation door Air mix dom Air intake door

5 6 7 8

Cooling
E
r

unit
or

Blower motor Floor door

AC377A

Fig
AC 2

AC 1 Air

Conditioning

Unit and Air Flow

Air

Conditioning
pie The liquid
R 12
used is the

REFRIGERATION
SYSTEM
If you
were

perature inside the box will drop This

is

refrigerant

to

with alcohol

your

paint your rmger finger would feel

because the alcohol is evaporated absorbing the heat from the air inside the If the gaseous alcohol is collected and cooled with cold water
it will be box

The heat inside the passenger compartment is absorbed by changing the refrigerant from
and then
a

liquid

to a gas

cold This is because the takes heat

away

liquid

alcohol

from

your

rmger

while it evaporates Ifa quickly evapo rating liquid such as alcohol is placed in
a

changed back into a liquid by absorption of its heat by the cold

water The cooler

container inside a box

the tern

operates

on

this princi

dissipated changing the refrigerant from back to a liquid The refrigeration system is in Fig AC 2

to the outside
a

by gas

shown

High l I
Outside air gas

pressure

Low pressure

liquid

High pressure liquid

J C

Low pressure gas

t
Condenser

Compressor

lf P

9
n

Inside

air

v
Jj

U
Receiver drier

Blower
motor

1f

AC378A

Cooled air

Fig
The operation ofthe five devices of the refrigeration system below EVAPORATOR The heat of the inside air which is
is
are

AC 2 Refrigeration Cycle

COMPRESSOR
The compressor is installed to the side of the engine and is driven by crank pulley through a belt The refrig
gas leaving the evaporator is forced out to the condenser by com erant pressor and the low pressure ant gas is
sure

CONDENSER The condenser is installed to the front of the radiator The heated and

described

irculated by the blower motor force absorbed by vaporizing the liquid the evapora This cools the air

compressed refrigerant gas from the compressor condenses to a liquid by being cooled by air passing between
the fins of the condenser

refriger
pres

refrigerant passed through

tor

compressed

to

high

and

high temperature
AC3

Air Conditioning
RECEIVER DRIER The
pose of receiver drier
rves

the pur

To expansion valve

storing tl e liquid refrigerant The amount of the liquid refrigerant

flowing through
the conditioner

the system varies with of the

air be accurate

operating condition
To

the

receiver drier stores excess amount of

refrigerant
ered when

when the heat load is low

rl J L
C
d

From condenser

It also releases stored

refrigerant
f

additional cooling is needed thus maintaining the optimum flow of

refrigerant within the system The receiver drier includes

er

strain

and desiccant They have the

moisture and

removing
cles
as

job of foreign parti

1
u

the refrigerant circulates within

f
1 2

4 4

the system The pressure relief valve is installed beside the sight glass of the receiver drier The purpose of the valve is to release preSsurized refrigerant vapor
into the

lc
AC167A

J
Pressure relief valve

atmosphere

in the event of

excessive pressure build up in the pressure line The pressure at

a

high

3
4

Sight glass Suainer

Desiccant

relief

valve

opens

automatically
38 kg cm2

pressure

of about Fig AC 3 Receiver Drier

540 psi

EXPANSION VALVE The flow of

expansion valve restricts the liquid refrigerant as it passes

it and delivers

through

sprayed refrig

erant to the evaporator for

faCilitating

refrigerant evaporation
The bulb

refrigerani

within the sensing

changes

in pressure

through

the

super heat condit ion of vaporized re frigerant gas which comes out of the

JD

evaporator causing the deflection of

the

diaphragm
attached

The
to

lift

of the ball

diaphragm is changed by the deflection of the dia phragm thus controlling the amount of refrigerant passing the orifice

valve

the

To evaporator

v
I 2

From receiver drier

Sensing bulb Diaphragm Eq ualizer line

Orifice Valve ball

AC423

Fig
4 AC

4 C

Expansion

Valve

Air

Conditioning

AIR FLOW

Air control lever

Sidedefrostcr duct

1M
l tCliO

r
I

1 ar

all

IC

1T

I
7

afH

Defroster

nozzle

1 I

7
r

l
i

Jf L

SOd

Fan

switch

Ftont seat flOO

t
I

Air intake door

If

J
Heater

ft

I
nside air

outlet

l
Front seat

floor

Evaporator

Side outlet

i
D

IIll
Center

I 91
udet

Side outlet

i
D

r2

Air control lever

Air mix door Air intake door

Ventilation

and Water cock

Floor door

Blower
motor

Compressor
and
F 1 actuator

door

OFF

OFF ON OFF OFF

AIC
VENT B L HEAT DEF REC HEAT

Inside air

100

Open Open
Controlled by 0 Open Closed Closed Closed

Closed
Closed

Outside air 100 Outside air 100 Outside air 100 Outside air 100 Inside air 100

Open
ON

temperature
lever

Open
0 Open

OFF OFF OFF

Open

AC379A

Fig AC S Air Flow AC 5

Air

Conditioning
side

VACUUM SYSTEM
MAGfilET
The tween the the

Actuator

VALVE valve idle

is located actuator
vacuum

magnet fast

be and
con

intake

manifold

nector

Valve cloaed When current to the coil is inter

rupted

passage fold side closes

on

the intake mani

the actuator
1

leaving

side line open to the

atmosphere
Intake manifold
AC176A

Adjusting
Lock nut

screw

2 3

side

Diaphragm
AC266A

Actuator side

Fig AG 7 Magnet Valve

Open

Fig AG B FlUI Idle Actuator

FAST IDLE CONTROL

I
i
AC175A

DEVICE

F I CD

FAST

INTAKE ACTUATOR The intake actuator is actuated by

IDLE ACTUATOR
1
2

Filter
Return

r
the

spring

The
creases

fast

idle control
so

device

in

the intake vacuum or the air introduced

atmospheric

3
4

Coil Valve

engine idle speed

that the air

Intake manifold side

conditioner continues to cool the pas senger compartment even when the car
Glosed is at
a

Fig AG 6 Magnet Valve

standstill
device is
a

by turning on or offthe vacuum switch thereby opening or closing the intake door The intake port for atmospheric air is located on
the vacuum

The
and is

vacuum a

actuator

switch

equipped applied

with

diaphragm
as a

The
the

Velve open While

holds the

diaphragm deflects when vacuum pres

sure

The check valve is a one way valve and it prevents negative pressure from

is

and

result

passing through

it

except when

the

magnet
an

valve
in the

coil

is it

energized by position and

vacuum

electric current

operating The operating

vacuum

wire attached to it is moved wire is connected with

pressure at the actuator side is

higher

than at the intake manifold side

valve needle
vacuum

raised
on

the carburetor throttle lever When the pressure acting on the dia lost the diaphragm is reo

eliminating
closing
urn

thus the variation in opening or

intake door

is

imposed
the

the

the

due to

the

actuator

from

intake

phragm

is

variation in the

engine manifold

vacu

manifold

turned to its original position

6 AC

Air

Conditioning
ELECTRICAL CIRCUIT
DESCRIPTION The vides
a

following wiring diagram pro complete description of the

whole circuit When both the ignition switch and fan switch are tu ned on
4

the main relay is actuated and electric power is supplied to the blower motor and electric clutch of the compressor
The blower motor
1 2 3 4 5

speed

is controlled the

Control wire
Control rod

by

the

fan

switch with

aid of

resistors

Intake actuator
Vacuum

compressor actuated by the thermostat A fuse is part of the air conditioner harness

The

clutch is

switch

Check valve
Intake
return

6
7

spring

Intake door

AC268A

Fig AC 9 Intake Actuator

AC 7

Air

Conditioning

Ale

position

Main

relay

Blower motor

Fan switch

c Fuse
Fusible This fuse is built into air
con s harnes

RW L

B
I I

link

r
o
Battery

2nd olst

Ignition
switch

Fuse Micro switch

Resistor

1
Low pressure switch

0
Thermost

I
CompreSsor
clutch

Magnet valve

h roo
AC269A

VENT

HEAT

DEF

and REC HEAT position

Main

relay

Blower

motor

Fan switch

C O
Fuse Fusible link This fuse is built into air coil harness

RW

o
I

5d
2nd olsl
0

1
0
Battery

o r
Resistor

Ignition
switch

Fuse Micro switch

j
Low pressure switch

0 J

The

most

rI tr
Compressor
clutch

Magnet valve

AC270A

Fig AC IO Electrical Circuit Ac a

Air

Conditioning

GENERAL SERVICE
REFRIGERANT R 12
The conditioner
dust

Wipe
with

water off from

a

the line

requires
Therefore

sufficient

refrigerant used is generally

R 12

in

the

air

fittings
2

clean cloth before dis

it is of first

connecting
Have all necessary tools in prepar ation beforehand and have tools clean
and 3

called

Re

tance that any other

training impor personnel

than the

well trained serviceman

frigerant 12
be used

No other

refrig

erant than the above

refrigerant should

should not be allowed to handle

dry Handling plug when the system Handling compressor

oil

refrigerant

line is disconnected Note

Exercise care when
as

handling

re

frigerant
pressure

it is stored under

high

For details

refer

to each

descrip

tion in this manual

COMPRESSOR OIL
The

SAFETY

EVACUATING AND CHARGING SYSTEM

During servicing use caution to keep air from getting into refrigerant When air enters the system all refriger

PRECAUTIONS
the

SUNISO

5GS

refrig

ration

lubricant should be used to

assure

successful compressor operation Use of oils other than recommended or

WARNING
1 Since direct contact ofthe

liquid

ant

must

be

evacuated

from system

mixing
cause

of the oil with other oils would

refrigerant
cause

with your skin will

chemical

reaction
or

or

lead to

frostbite always be carelul

prior to charging new refrigerant Air in refrigerant has the following delete
rious effects 1 Since the condensation tempera

lowered viscosity
tion

deficient lubrica
it

when

The oil absorbs moisture

tacts the air This

as

con

handling the refrigerant Always wear goggles to protect your eyes when working around

ture of the air is

extremely low the

air

points

out the need to atmos

for

care

not to
an

expose it

the system 2 The refrigerant service container has

will not be condensed when refrigerant gas is condensed in the condenser and the air will thus remain in gaseous

phere for

extended

period

of time

strength However if handled incorrectly it will ex plode Therelore always follow

a

safe

fonn

Consequently

the

effective

thermal transmission

area

of condenser

the instructions

On

the label In

for refrigerant gas will be reduced and

MAINTENANCE
The
tenance

particular
location
or

never

store it in a hot

refrigerant
reduced
in system

gas to be condensed will be

following checks and are especially important

main to the

air conditioner
I

1260F a high height drop The refrigerant gas is odorless and colorless and breathing may
it from become difficult due to the lack of oxygen Since the relrigerant gas is heavier than air and will

above 520e

The pressure rise will become

to the volume of the air

proportional
2
tixed r

When

air

and
a

refrigerant

are

in system

chemical reaction affect the

and other

Check refrigerant level Check

will be

produced and hydrochloric

copper iron

2 3

refrigerant

leaks

acid which will adversely aluminum

Check compressor drive belt for proper deflection

4

Even in the off season for

10 minutes

turn the

lay close to cially careful

4 The

the floor

be espe when handling it in

materials in system may be generated

at least compressor once a month by running the engine at 1 500 rpm

small confined spaces refrigerant itself is nonflam mable toxic gas a gas is produced when it contacu fire and special care is However

HANDLING MANIFOLD
GAUGE
The pressure at the

phosgene

GENERAL SERVICE

INSTRUCTIONS
If dirt
water or air enters the air

therefore required when check ing for leaks in the system with a halide torch
5 Do not steam clean
tem
On

high and low

sides

of system should be measured

when evacuating and charging

erant and when

refrig

the sys

diagnosing

trouble in

conditioner system it will be seriously affected Be sure to observe the

following
I

Always keep

the

working place

especially condenser since excessively high pressure will build up in the system resulting in explosion of the system The above precautions are essen tial in handling of Refrigerant
12 and their strict observation

the system The manifold gauge is used for these purposes A manifold gauge has two pressure gauges gauge and gauges low side
are a

low pressure These and

high

pressure gauge

connected to the high valves of

service

system The
is

through

flexible of

charging
manifold

hoses

clean and dry and free from dirt and

construction

gauge

AC 9

Air
shoWn in

Conditioning
are

Fig

AC II
stem

and the tenter path

is

blocked When

When valve the valve is

fully screwed front seated and valve path

valve stem is backed off the

paths

are

formed without valve cap a negative pressure will gradually build up at the
low pressure

opened

side of system and air

dirt and enter the valv matter

may be sucked in In addition dust will

Low pressure gauge

easily

result

ing
High pressure gauge

in

foreign

entering the

Compound pressure gauge

system

CAUTION
00 not
Back seated Full counter clockwise
over

tighten

valve cap

Check valve wiJI be half opened

FronHeated Fun clockwise

I

VA l
C

f
To low side service valve To
vacuum

f lr
pump
01

r
AC243

during connection and disconnection of charging hoses and refrigerant will be forcefully discharged Therefore connect and disconnect charging hoses quickly while pressing flare nut of charging hose against service valve WARNING
Work with cloth

To

high side

refrigerant

can

service valve

Fig AC II Manifold Gauge ConnectIon to service valve

I

fingers protected with against frostbite by reo frigerant

Since close contact between the

HANDLING
An into

SERVICE VALVE check valve is built When this valve

Fully

close both valves of mani Connect high

to and low

automatic service

thread of valve cap and the thread of

service

fold gauge
pressure

valve

charging hoses

manifold

gauge 2
Remove caps from service valves

presses against the connection fiUing that is when charging hose is con nected to service valve the valve is
open

Connect high and low pressure charg ing hoses to service valves in system The
since

nected

When charging hose is discon the valve is closed auto

refrigerant
check

gas will be

valve

is

discharged open when

matically Always observe the follow ing usage precautions

valve will prevent gas leakage keep these areas clean and free of scratches and damage 4 Since packing of charging hose will be lost during long use always check packing prior to installing charg ing hose

pressing charging
valve 3

hose

onto service

HANDLING CAN TAP

A

wide

variety of
The

can

taps

are

Next

loosen the connection fit

hose at

available

following procedures

ting of charging

manifold

apply

gauge side for 2 to 3 seconds to purge any air inside charging hose by the

to conventional can taps For the correct usage refet to the manufacturer s instructions

pressurized

gas in system

DIsconnection from servIce val ve

I

Fully

close both valves of mani

fold gauge 2
Disconnect two

charging

hoses the

from service valves

gas will be is

At this time

1ts
Close
I

ir
Open
4

Connect

charging hose

to

the

of manifold gauge At this time confirm that both stems are

center

fitting

fully
2

turned in frontoSeated
Turn can tap handle
so

fully

coun

terlockwise

that

the

needle

is

pulled
3

up
can

Attach

tap to refrigerant

can

discharged until check valve

Therefore disconnect hose

Cap
Service valve

Packing
Check valve
AC244

firmly
4 wise
can

closed

2 3

Turn
to

can

tap handle fully clock

a

quickly
WARNING Work with cloth

Charging hose

make

hole in

refrigerant
counter

See

Fig

AC 12 Service Valve

Fig

AC 13 the handle

Turn

fully

fingers protecte with against frostbite by reo

clockwise to raise the needle

I

Refriger

Always

install

valve

cap

after

ant gas

frigerant

using

service valve

fitting of manifold
is per

will flow up to the center gauge See Fig AC

When high

speed operation
AC I0

14

Air
6 Loosen the
connection

Conditioning
DISCHARGING SYSTEM
The

at

the

center

fitting

of manifold gauge for a

few seconds to purge air inside charg ing hose See Fig AC 14
Counterclockwise

pressurized refrigerant gas

in
a

Clockwise

side system must be

pressure pressure

discharged

to

approaching atmospheric prior to evacuating refrigerant inside system This operation should be also made to pennit safe removal when replacing system components
A Close

high

and

low pressure

valves of manifold gauge fully 2 Connect two charging hoses

of

manifold
I

gauge

to

their

respective

2 3
4

Can tap handle ChlcginS hose Needle

service valves

WARNING
can

Refrigerant

Securely
charge
manifold

connect

service

pressure dis valve to that of

high

AC246

Fig AC 13 Can Top

gauge with

hose

also
serv

connect low pressure

suction

ice valve to that of manifold gauge For locations of high and low pres
sure

valves

discharge see Fig

and suction AC 29

service

Open both manifold gauge valves slightly and slowly discharge refriger ant from system See Fig AC 15 WARNING
Purging
air

Protect

fingers with cloth against by refrigerant when con the necting charging hose to the
frostbite service valve
or

disconnecting

it

therefrom

12
AC247

Nole out

Do not allow Otherwise

refrigerant
with

to rush

compressor oil will

Fig AC 14 Purging Air

be
ant

discharged along

refriger

To

service valve

L9w

pressure

Ta

High

pressure
EVACUATING SYSTEM
I

service valve

Connect

high

and low pressure of sys refrigerant from

valves

charging hoses of manifold gauge to

their respective service
tem

discharge system Refer to Discharging System WARNING

and

Securely charge
manifold

connect

service

high pressure dis valve to that of

a

gauge with

hose

also
servo

connect low pressure

suction

ice valve to that of manifold gauge For locations of high and low pres
sure r AC181A

valves

discharge see Fig

and wction service AC 29

Fig

AC 15

Discharging System

AC ll

Air
2

COl ditioning
ftom
system See 6

When
to

refrigerant
a

has

been

dis
at

old
5 has

refrigerant

When pressure insill

system h as 28 inHg
of manifold pump Let

charged mospheric
3
4

pressure

approaching
connect pump

Fig AC 16
When low pressure gauge

pressure to
a

center

reading

dropped to 710 mmHg fully close both of valves

gauge stand state and it

charging hose
Close gauge

vacuum

reached

both valves of manifold Then start

vacuum

nunHg

approximately 500 20 inHg slowly open high

to

stop
to

vacuum

for 5

10 minutes in this that

fully

pump

pressure valve

and
not

confirm

the reading

Open low pressure

valve and suck

does Note
a

rise

The low pressure gauge reads lower by 25 mmHg I inHg per a 300 m
1 000 ft

elevation Perfonn
to

evacu

First step

alion

according

the

following

To Low pressure service valve

To

pressure service valve

High

table

Elevation
m

Vacuum of system

ft

nunHg inHg
710 28 685 27

0 0
300

1 000

600 2 000 900 3 000

Note

660 26 635 25

Values show reading of the

pressure low gauge

rtl
Second step

b The
25 utes

rate of ascension of the low

pressure gauge should be less than

mmHg

inHg

in five min

If the pressure rises

or

the

specified
In this

To Low pressure service valve

To

High

pressure

negative pressure
lhere is
case
a

can

not be obtained

service valve

leak in the system

refrigerant

immediately charge system with and repair the leak de

scribed in the

following J Charge system with a can of Re refrigerant about 0 4 kg 0 9Ib fer to Charging Refrigerant 2 Check for refrigerant leakige with a leak detector Repair any leak ages found Refer to Checking for
Leaks 3

Discharge refrigerant again

and

then evacuate system

CHARGING REFRIGERANT
AC182A

Fig

AC 16 Evacuating System

First and Second Steps

Refer to

Install manifold gauge to system Handling Manifold Gauge

AC 12

Air

Conditioning
To

WARNING

Securely charge

connect

high
valve

service

pressure dis to that of also

serv

To Low pressure service valve

High

pressure

service valve

manifold gauge with a hose connect low pressure suction

ice valve to that of manifold gauge For locations of high and low pres
sure

discharge
see

and suction AC 29

service

valves

Fig

CAUTION
a sure to purge air from the high and low pressure charging hoses

Be

b If air is mixed with in

refrigerant
of Refer

gas
to

system
be

evacuation

system

should

performed Evacuating System

t
@ I J
AC183A

charging hose of manifold gauge to refrigerant can through can tap Break seal of refriger
center ant can
to

Attach

Fig AC 17 Charging Refrigerant

CAUTION When

allow

refrigerant

to

enter

manifold gauge
at the center and

Loo en

charging hose
p
lmmene in water heated to about

charging liquefied refrigerant

fitting

of manifold gauge inside

R 12

charging Handling Can Tap 3 and low pressure Open high valves of manifold gauge and charge See Fig refrigerant into system
hose Refer
to

purge air

from

into the system with the can turned upside down to reduce charging time

1040F 400C for

a

hort time
AC184A

AC 17

Fig AC 18 Charging Refrigerant

charge it only through high pressure service valve but not discharge through low pressure suction service valve See Fig AC 19 After comple of charging the compressor tion should always be turned several times manually

Note

When

refrigerant charging speed

refrigerant
can

is slow

immerse

in

To Low pressure service valve

To

High

pressure

service valve

water heated to a

about 400C
time See

temperature of 1 040 F for a short

t
Low

Fig AC 18

WARNING
a

Under any circumstances the re frigerant can must not be warm ed in water heated to
ature of over
a temper 520C 1260F or

rJ
AC185A

b A blow
never can

toreh

stove

must

be used to

warm

up the

Fig AC 19 Chorging Liquefied Refrigerant

AC 13

Air
4

Conditioning efiigerani
40 psi
or

Wfefrlgerant charging
charge
it while

speed slows
the

Charge

while con

Note

The

Ce

of btibble

hi
an

down

running

compressor for ease of charging After having taken the steps up to 3 above

trolling 2 8 kg cm2

low pressure gauge

reading

at

sight glass
amount

of receiver drier is

proceed with charging in the following

order

less by turning in or out low pressure valve of mani fold gauge See Fig A 20

unsuitable method of of

checking refrigerant charged

the

in

system The state of the bubbles iJt sight glass should only be used ior

1
2

Shut

off

high

pressure valve of

manifold gauge

WARNING
Never

the engine at idling speeds below 1 500 rpm 3 Fan

Set the

Run

charge refrigerant through

high

pressure side

discharge

side

Temperature lever and

at maximum

switch

cool and

of system since this will force re frigerant back into refrigerant can
and
can

checking whether the amount of charged refrigerant is small or not The amount of charged refrigerani can be correcdy judged by means
of

maximum speed

respectively

may

explode
7

discharge pressure frigerant Level Check

After the

Refer to Re

specified

amount

of

To

service valve

Lpw

pressure

To

High

pressure

service valve

refrigerant has been charged intosys tern close manifold gauge valves Then
detach

charging

hoses Be

from
sure

service

valves of system
valve cap to service

to install

valve
are no a

Confirm that there

leaks in

system by checking with

tor Refer to Note

leak detec

Checking
8

for Leaks

Conducting
to

performance

test

prior
8

removing manifold gauge is

service

good

operation

Refer to

Performance Test

A
CHECKING FOR
AC380A

LEAKS
Conduct age when of
a

Fig AC 20 Charging Refrigeront

leak t st whenever leak

is

When

refrigerant

can

is

empty
can

refrigerant conducting

fully
a

close both

valves

of manifold with
Measure the amount
of

which are
or

suspected and operations accompanied by disassembly

service

gauge and
new e ot

replace refrigerant

loosening of connection fittings Refrigerant is a colorless odorless

Before valve to
can

opening manifold gauge charge refrigerant from new

to purge air from inside

charged refrigerant
scale

with a

Make a note of the

amount
can

gas and leakage from system is diffi cult to detect Accordingly the use of
a

be

sure

charged

from

leak detector facilitates check for

Two methods
one

charging
6

hose the specified

into system
amount

leaks

of

checking
a

are

Charge

of

available
AC252

employs

halide leak

refrigerant

by weighing
Over
pressure

charged refrigerant

with scale

charging
to rise

wiU

cause

discharge

Fig

detector which bums propane gas or butane gas and the other is an electric

AC 21 Chorging Refrigeront

type

leak detector

Refrigerant capacity

If any trace of oil is noted at and around connection fittings it is indication that
Unit
a sure

refrigerant
can

is

kg lb

This condition

be corrected

leaking easily

Refrigerarit
R 12

Minimum 0 8 18

Maximum 10 2 2

by retightening the joints If any joint

on

line is

suspected
use a

ofsmall amount of

leakage

leak detector to locate

leaking points
AC14

Air
LEAK DETECTOR

Conditioning
4

HALIDE

The flame will be almost colorless

no

Since the propane leak detector and

burning of propane Refrigerant gas decomposes to color the flame when it

contacts the heated screen

when there is

refrigerant
a

gas

being
or

burned When there is

small refriger

butane leak detector respect to their describes the

leak detector

are

the

same

in

The gas to

ant gas leak the flame will be green

operation operation ofthe

this section
propane

be checked is drawn into the

sampling

tube and sent out to the burner A

yellowgreen When refrigerant gas leak age is large the flame will be brilliant
blue flame
or

The copper screen is heated

by the

refrigerant leak can clearly be detected by variations in the color of the flame

purple
or

Since the color of the

will be

yellow

when

dust

is
on

being burned

there is aging scale

copper reaction

plate always keep the

strainer of sampling tube and reaction

plate clean
5

Major check points Compressor Compressor shaft seal compressor by hand

Front and
rear

rotate the

Flexible hose connections

head gaskets

Service valve 2 Condenser Condenser pipe fitting

1 2 3 4

Copper reaction plate Flame adjusting lines

Burner

Condenser
connections

inlet

and

outlet

pipe

3
tube

Refrigerant

lines

Sampling
Strainer

Flared section of

high pressure and

5 6
7

Gas bomb Flame adjuster

AC010

low pressure flexible hoses Une connections 4

Evaporator housing
Inlet and outlet line connections

Fig AC 22 Checking for Leaks

Expansion

valve

Propane type
NO LEAK SMALL LEAK LARGE LEAK Greenish blue Yellow

Butane

type

ELECTRIC LEAK DETECTOR

For the

Pale blue

operational

procedures

Bright

blue

refer to the instructions furnished with

Purple

Vivid green

each electric leak detector

Discharge

refrigerant

in

one

or

Suitable ventilation is

required

If

two seconds to ascertain that system has a sufficient pressure needed for

refrigerant

gas is

mixed with the and

surrounding

air

leak detector will

a

REFRIGERANT LEVEL CHECK

SIGHT GLASS

leak detection Ib
2

4 kg Charge with 0 of refrigeranl if necessary

0 9

always indicate
difficult
c

response

detection of the actual leak will be the

Light leak

detector

Adjust

Sight glass
leak detector at
an receiver drier

is

provided

at the

top of
m

height of the flame between flame adjusting lines at the top and bottom of combustion tube A reaction plate will immediately become red hot 3 Place the end of sampling tube near the point of the suspected leak in system
Note
a

Never

hold

One guide for whether

is flow

angle

there is enough refrigerant in syst

WARNING
a

Never inhale the fumes

by refrigerant
gas is heavier than

combustion of

produced refrigerant gas place explosive

a

since b be easily detect tube direct

they
use

are

toxic

given by observing refrigerant through sight glass However this method is unsuitable for judging the aJTlount of refrigerant The correct refrigeranl level can be judged by measuring the system pressures in ac cordance with the procedures as de
scribed in Performance Test
1

Since ed by

Never

halide torch in
or

air small leaks

can

where combustible gas is present

Start the engine and hold engine

al 1 500 rpm
to

placing sampling

speed
2

ly below the check point

AC 15

Set AIR lever

AlC position

I
I

Air
3 Set temperature lever
4 S

Conditioning
of abOut five rilintJtes Jullgeaccording
to the

to

max

Sefblower to maximum speed Check sight glass after the lapse

imum cold

position

following

table

Almost Check item

no

refrigerant

Insufficient

Suitable

Too much refrigerant

Temperature of high

prenure

Almost

no difference

High

pressure side is and

High
side

pressure side is

and low pressure lines

between high presswc and lowpressufC side temperature

low pressure side is fairly cokt

warm

hot and low pressure is cold

High pressure side abnormally hot

is

State in sight

ltS3 gl

Bubbles flow continu

The bubbles
at

are seen

ously Bubbles will disappear and some thing like mist wiD
flow when rerrigell llt is nearly gone

intervals of 1

Almost transparent Bubbles may appear when engine speed is raised and lowered No clear difference exists conditions

No bubbles

can

be

seen

seconds

these two

nl
AC256 AC257 AC258 Pressure

of system

High pressure side abnormally low

is

Both pressures

on

high

Both pre55ures

on

high

and low pressure

are

sides

and low pressure sides

are

Both pressures on high and low pressure sides

are

slightly low

normal

abnonnally high

Repair

Stop

compressor
an

and

Check for gas leakage

Discharge refrigerant
from service valve of
low

conduct check

overall

repair as required re plenish and chaxge

system

pressure side

Note
a

b Wben
are

the

screen

in tbe

receiver

The bubbles

glass

tbrough the sight influenced by the ambient

seen

drier is appear
erant

clogged

tbe bubbles wiD

PERFORMANCE TEST Check for the amount of

in the system can be made

even

if the amount of refrig this

case

refrigerant
by
meas

tempemture Since the bubbles are

bard to show up in
F it is

is nonnaL In

tbe

comparatively

outlet side pipe of tbe receiver drier becomes

uring
in

pressure on

discharge

side

low tempemtures below 200C 680

considembly

cold

The correct amount of refrigerant is the

possible that a slightly larger amouot of refrigemot would be filled if supplied according to tbe sight glass Be sure to recheck
the amount when it exceedS 20 C

discharge
range

if pressure on the system side i within the specified refer

to

For details

Trouble

Diagnoses and Corrections for per

fannance test

680F
bubbles

In
are

higher tempemture
easy to show up

tbe

Overcharging
presstJre
AC 16
on

will show up in higher

discharge side

Air

Conditioning
charge
11 air at the center outlet

COMPRESSOR OIL LEVEL CHECK

The oil used to lubricate compres
sor

Check the cleanliness of the oil If

grille

the oil contains material clean

chips or oil sump

new

other with

foreign
oil

Measure

the

temperature and

new

6
the

Discard
same

the used

oil and fill with oil Add oil if

humidity of the evaporator in take air at the recirculating air inlet of the
evaporator
12 Measure the

circulates into system from the oil

while compressor
to

amount of

sump

is

operating flowing
If
a

found less than above

If compressor is

amount

temperature
a

and

Therefore
pressor oil
to

correctly
be

measure com

the amount of oil must

system

considered
of the

considerable

amount

refrigerant
compressor

gas

happens
is
no

leakage of leakage of

faulty compressor refrigerant remove compressor and repair as necessary Then pour oil up to correct level and install on engine
After
above

inoperative or heavy loss of

due to

humidity
I
m

of the ambient air at

3
a

point

ft

front
bulb

of

condenser
wet bulb

However
must not

dry

and

be

placed in

direct sunlight

oil

also

considered

steps oil

have

been

com

Check for any abnormalities by comparing the test results with stand
13 ard pressure Refer
to

There will be

compressor oil leak

pleted
correct

recheck

level

drain oil

to

Performance

age from a completely sealed system When system operates under satisfying condition the compressor

level if level is

excessively high

Chart
Note

oil
of

level

CAUTION
a

The pressure

will

change

in the

check is unnecessary When pressor

The oil from the

a

should not be transfused container into another will

as

following
conditions
When

manner

with changes in

checking
oil
or

the level

com

replacing any component part of the system use the following service procedure This facio
litates to return oil to compressor

when

failure

possibly

cause

moisture to mix with the oil b The used oil should not be returned into
c a

container of

Operate compressor idling speed I OOO rpm

and

at or

engine
below

The oil should not be used if its

state

preservation

is not clear

with controls set for maximum cooling

enough

speed is low dis will drop charge pressure When the relative humidity of in take air is low discharge pressure will drop The temperature will change in the following manner with changes in
blower conditions
When the ambient air

high

blower speed for 10 to 15

compressor

minutes in order to return

temperature

oil to compressor
2

PERFORMANCE TEST
and

Stop refrigerant
3

the

engine

discharge

of system and then remove

compressor from the car

Remove

Drain
sor

compressor filler plug compressor oil from compres

measure

cooling per ormance of the air changes considerably with changes in surrounding conditions Testing must be performed using the
conditioner correct method This test is used to

The

the outlet air temperature will become low

is low

If the

test

reveals that there is any

abnormality

in system pressure

isolate

the cause and

repair Refer

to Trouble

oil sump and

the amount

Diagnoses and Corrections

judge whether system is operating cor rectly and can also be used as a guiqe
in 1

checking
Park

for

problems
car

the

indoors

or

in the

shade

REFRIGERANT LEAKS
If leaks should be
are

Open all Open

the windows of the

car

noticeable leaky parts

fully
3
4 and

However close the doors the hood

should be fIlled with

Then system repaired refrigerant

Connect manifold gauge to high low side service valves of the

system

Refer

to

Handling

Manifold

CAUTION
00
not

Gauge
5

operate
level

6
AC742

Set air lever to AIC position Set temperature lever to maxi

cold

refrigerant

compressor excessively low

with

If this caution is

neglected

burnt

mum

position engine
and hold

Fig AC 23 Filler Plug

4 the

Set blower to its highest speed

Start the

loss compressor will result since heavy of refrigerant usually indicates heavy loss of compressor liil

Compressor
following

oil is satisfactory if

engine

amount of oil remains in

speed at
9

1 500 rpm If system has been exposed to atmosphere for an extended period of time receiver drier must be replaced
I

After the air conditioner has been

about 10 minutes
meas

the compressor Residual oil 140 to 220

4 9 to 7 7
cc
oz oz

operated for
ure

4 7 to 7 4 US fl

system pressures at high pressure side and low pressure suc tion side

discharge

If leaks

are

slight and

no

air is
as

present

in system

add

refrigerant

necessary

Imp fl

10

Measure the temperature of dis AC 17

To detect leaks

refer to Checking

Air
for
I

Conditioning
continues been
ven

Leaks

Here

is

how leaks

are

2 the

stopped
Check torque
on

the connection

fitting and
proper

tighten to the lorque Check for gas leakage

if too loose

with

leak detector

retightened charge refrigerant from system disc on net the fittings and check its seating face for damage Always replace even if damage is slight

leakage fitting has

If

after
dis

Check compressor 6il and add oil

if required
4 for

Charge
gas leaks and

refrigerant and recheck

If
no

leaks

are

found

evacuate

charge system

SERVICE PROCEDURES
FAST IDLE ACTUATOR
ADJUSTMENT OF IDLE SPEED

Engine

model

Transmission

When A C

is

OFF

When A C is ON
F LCD is actuated

Manual A14 A15

700 rpm 650 rpm at D

800 rpm 800 rpm

at N

Automatic

position

position

The fast idle control device is used

on

cars

equipped
raise

with an air condi

ed

tioner to

the

idle speed auto

when

If engine speed cannot be adjust properly with adjusting screw check and adjust clearance e again
2 3

REMOVAL AND

INSTALLATION
Remove vacuum hose from actua tor 2 3

matically
Use the

Depress

and release accelerator

following procedures

adjusting
engine until ating temperature
2 1 Run it reaches oper

pedal several times and make sure that engine speed reduces to 800 rpm as pedal is released If correct adjustment is not made
repeat steps

Remove air cleaner assembly Remove

cotter

pin

and

pin and
F LC D

disconnect
4

actuator

from

With

air

conditioner
is not

in

OFF

to

above

until

lever connected to throttle shaft Remove

remove

when

compressor

operated
e between
mm

engine speed

is 800 rpm at

idling

actuator actuator actuator

attaching
in

nuts

make sure that clearance

then
5

levers
J

and

8 is

more

than J

Install

the

reverse

0 12 in
mm

If clearance 0 12 in

is less than

order of removal 6 After

to

loosen cable
on

lock
A
so
mm

screw

and

push down
C

lever

Refer

installing adjust actuator Adjustment of Idle Speed

that clearance 0 12 in 3 Make

sure

is more than J

that engine is at

cor

rect idle 4

speed
is actuated set engine speed using following procedures

With air conditioner in ON when

F LC D

to 800 rpm
as
a

guide
1

Turn adjusting screw until en is 800 rpm speed gine On cars equipped with automatic transmission make this adjustment

FlCD adjusting Lever Lever

A B

screw

Clearance

2 3
4

with shift control lever in

tion

Cable lo k

screw

posi Fig

AC381

AC 24 Fast Idle Actuotor

AC 18

Air

Conditioning
REMOVAL
I at

IDLER PULLEY AND COMPRESSOR DRIVE BELT

ADJ USTMENT OF BELT TENSION
Idler pulley
Alternator

Operate compressor if possible engine idling speed with air condi

blower all

tioner controls set for maximum cool

ing and high

minutes
return

speed for20 to 30
windows
open to

with

oil into compressor

2 and

Disconnect compressor

battery ground cables

lead
wire at con

nector

Discharge refrigerant from cool ing system Refer to Discharging Sys

3
tem

Jack up front of
cover

car

and remove

under
5

Loosen idler tension

loosen
Remove

pulley lock nut and adjusting bolt fully

belt

compressor drive
26

See

Fig AC
Crankshaft pulley
Unit
mm

Remove

high and low flexible

in Idler pulley

hoses from compressor Fig AC

25

Belt Tension

Specified
8 to

compressor belt tension is 31 0

to

bolt 3 4 Remove idler

WARNING
Install

12 mm

0 47 in

when is

thumb pressure of 10 kg

22 Ib

pulley pulley in

the

reverse

applied midway between

and compressor
1 then

idler

pulley

order of removal 5

Gradually loosen discharge side hose fitting and remove it after remaining pressure has been re
leased

pulley
lock nut and

Adjust

compressor belt tension

Loosen idler

pulley adjust pulley by turning adjusting

adjustment tighten

bolt
2

CAUTION
After
idler

Be

sure

to

immediately put plug

in

pulley

lock nut

flexible hose

and compressor open

ings
REMOVAL AND INSTALLATION Jack up front of car and under cover
2 Remove idler 1
remove

7
AC382A

Remove bolts securing lower part Remove bolts securing upper part Hold compressor with hand when

of compressor
nut

pulley
tension

lock

and

loosen

belt

adjusting

Fig AC26

Idler Pulley

of compressor
one

removing bolts and

up

then remove compressor With compressor clutch

lift

compressor out with both hands

CAUTION 00 not pressor for more

attempt
on

to

leave the
or

com

its than oil

side 10 will

upside

down
as

minutes
enter

the low that

compressor pressure chambers condition

the

If

under

compressor should be oper ated suddenly internal damage would result TIghtening torque To

expel

oil from chambers

3 7 to 5 1 kg

27 to 37 ft lb
AC383A

compressor several times in its installed condition

crank hand

Fig AC 27

Compressor and Bracket AC 19

Air

COl1ditioning
mounting
bolts

L1ATION INSTA
InstaU
I in the
reverse

Remove

ihen

order

of

remove

condenser from car

Keep piugsin place until im mediately before connecting work is

2
started

removal observing the When

following
add

installing

required

3
tions 4 1a

Refer

to

Refrigerant
on

Line

for

amount

Compressor
2

Of compressor oil Refer to Oil Level Check

tightening
Refer

torque
to and

line

connec

Apply a coat of fresh compressor oil to sealing surfaces of pipe joints

3 Check tightening torque of
com

General

Service

for

evacuating

charging system
sure

mounting bolts compressor mounting bracket mounting bolts and refrigerant line See Figs AC 27 and
pressor AC 29
4

11
AC384A

Conduct leak test and make

no

that there is

leak from connections

DO not
and

remove

plugs

from

RECEIVER DRIER
com

pressor

flexible

hose

before

REMOVAL AND INS ALLATION See Fig AC 29

connecting hoses
S Turn compressor several
drive times

Fig AC 28 Removing Condenser

before installing 6
7

compressor tension See Fig AC 2S

Evacuate
to

Adjust

belt

INSPECTION Inspect joints of inlet and outlet pipes for cracks and scratches Upon finding any problem which may cause gas to leak repair or replace con
denser Condenser fins
air passages clog insects or leaves will
or

Disconnect battery ground 2

3

Discharge system
Disconnect

Refer to Gen

and

recharge system
Service

eral Service for

discharging
refrigerant

system
lines from

Refer

General system and

for
re

evacuating frigerant
8 that there is

charging

receiver drier

Conduct leak test and make

no

sure

CAUTION

leak from connections

CONDE NSER
REMOVAL
Disconnect

ged with dirt reduce cooling

denser
air passages with

Plug

all

openings

to

prevent entrance

of dirt and moisture

effiCiency
compressed

of
air

con
or

In such a case

clean fms

Remove

receiver drier mounting

screws

Remove receiver drier

battery ground cable Discharge system Refer to Gen

Remove

CAUTION
Do not clean condenser with ste8m Be
sure

Install receiver drier in the reverse order of removal With plugs taken off

eral Service for 3

4

discharging system radiator grille

to

use

cold water

or

com

immediately before connecting

Refer to Refrigerant ing torque 6
Refer to and Une for

work is

Remove center stay

pressed

air

started connect line and receiver drier

tighten
for

Disconnect refrigerant lines from

condenser

General

Service

INSTALLATION CAUTION
8

evacuating
7 in the

charging

system
sure

Conduct leak test and make

Use wrench to fix

union

on con

Install

condenser

reverse

that there is no leak from connections

denser and then loosen flare nut of

order of removal

observing

Ihe follow
add

refrigerant
wrench b

line

with

another

ing
I

When

replacing
of oil

condenser
as was

Plug

up all

openings

in condenser

same

amount

drained
com

INSPECTION
Check receiver drier for leaks
or

and system

from
pressor

previous

condenser

to

damage

If necessary replace

AC 20

Air

Conditioning

REFRIGERANT LINES

1
2

High

pressure

discharge
suction

service

valve

Low pressure

service valve

3
4

Compressor
Condenser
Receiver

@
J

I
L
S

drier switch
lb

6
7

Cooling unit
Low pressure

lightening torque kgm ft

ZS t
CD

@ @

5 5 0 3 0 to 3 5 22 to 25

to

33 to 36

AC385A

Fig AC 29 Refrigerant Lines

See

Fig

AC 29
and

When

replacing
the

flexible hose

tube

observe

following
1

refrigerant line is clamped securely Start engine and raise engine speed to inspect if there is
sure

Make

CAUTION

Immediatelv plug
to

up

all of

openings
dirt and

Before starting work

be sure to

vibration
7

or

unusual noise
t st

prevent

entrance

discharge system 2 When disconnecting

sure

Conduct leak
no

and make

su

moisture

tubes
on

be both

that there is

leak from connections

to

use

two

wrenches

Refer

to

General

Service

for 4 Remove instrument under cover

tubes

evacuating
discon

and

charging system

ecting tubes plug all openings immediately to prevent

3

After

5 6

Remove glove box

Disconnect

wiring

harness

con

entrance of dirt and moisture 4

nectors
never

from

compressor

relay and

Compressed air used to clean dirty refrigerant gas

5

must line

be

thermostat
7 Remove upper and lower attach
remove

Clean with

ing bolts and

cooling

unit

In connecting tubes be sure to apply compressor oil to seating surface and then tighten tubes to specified tightening torque See Fig AC 30 Be sure to
use

two

wrenches when

tightening

flare nut of tube

COOLING UNIT
REMOVAL
I 2

Coat seat surfaces with com pressor oil and then tighten

Disconnect battery ground cable

Discharge
Loosen

refrigerant
nuts at

from

sys

tern Refer to General Service

3
AC263

flare

each

con

nection of inlet and outlet pipes of evaporator AC 21

AC386A

Fig AC 30 Line Connection

Fig

AC 31 Removing Cooling Unit

Air
to

Conditioning
are circulated in the system frost cwill form near the ball of expansion alve
and block the flow of this case

DISASSEMBLY AND

ASSEMBLY

y
7
1
II

r
1 2

valve

can

refrigerant In operation of the be returned to normal by

however

heating the valve

an

Expansion valve is equipped with adjusting screw However since the

is set

l
Mainrelay
Thermostat 3
4

screw

properly
is

at

the factory If expan

with

adjustment
sion
new one

unnecessary

valve is

damaged

replace

5 6

Upper case Expansion valve Evaporator assembly

Lower
case

RIEMOV
See

L AND

INSTALlATION Fig AC 32 baltery ground cable 2 Remove ev porator Refer to for Unit removal Cooling 3 Remove heat insulator covering expansion valve assembly 4 Remove clamp attaching sensing
Disconnect

ID
AC387A

Fig AC 32 Cooling Unit

1

Using

knife

cut

packings

at

This them

means

that you have

time to time
car

to to

remove assure

bulb
5

upper and lower case fit in portion 2 Remove clips fixing upper case to lower case

from

Loosen

flare nuts

and

remove

healthful fresh air inside

expansion valve from evaporator and

inlet

Separate upper case case by pulling it upward

3 4 Withdraw out oflower case

from lower

pipe

INSTAllATION assembly
evaporator in the reverse order of removal observing the follow Install CAUTION

evaporator
thermostat

Plug

all

openings

to

prevent

entrance

5
case

Remove

from upper

ing
I
new

of dirt and moisture

by removing attaching screWs

When
one

replacing evaporator charge compressor

with with 6

Installation is ill the

reverse

order

CAUTION
too

same

amount of new oil as was drained

of removal

Capillary tube sharply

should

not

be

bent

before
2

Evaporator
as

case s

should
to

be

in

stalled
unit

close

possible

heater

To assemble Be
of

reverse sure

the order of

Refer to Fig AC 29 for Refer

to

THERMOSTAT
tighten
REMOVAL AND for

disassembly
surfaces lower
case

to
at

join mating
upper
an

ing torque of flare nuts

4

packings
in fit

and

General

Service

portion with

adhe

evacuating and charging system

5 Conduct leak test and
ensu
e

INSTALlATION
See

sive substance

that
2

Fig AC 32

Note
sert it

When

installing thermostat in capillary tube in same place as

before removal Be
sure

there is no gas leak from conne tion

Remove

cooling unit
attaching thenno

Remove screws

stat and then remove thermostat

was

to

insert
em

capillary

tube end about 50

core

19 7 in

from evaporator

EXPANSION VALVE
Expansion valve malfunctions such
valve stuck open

INSPECT ON In
sion
case

as

valve stuck close

CAUTION
too

evaporator

core or

expan
or

refrigerant leakage and improper in stall tion of sensing bulb are de

scribed The first
two

Capillary tube sharply

should

not be

bent

valve have gas

leaking repair

replace

it with a new one as necessary Dirt and nicotine accumulation on case will go b d and smell

conditions require 3 Installation is in the reverse order

replacement of expansion valve

When both water and

evaporator

refrigerant

of removal

AC 22

Air
Note
sert it

Conditioning
AIR CONDITIONER

When

installing

thermostat

in
as

HEATER UNIT
Refer to Heater Unit Section BE

capillary

tube in same

place
sure

CONTROL
Refer to Heater Control Assembly for Air Conditioner Section BE Note When

was

before removal Be
7 in from

to

insert capillary tube end about SO

em

WATER COCK
Refer to Water Cock Section BE

19

evaporator

core

cable and rod

BLOWER MOTOR
INSPECTION
1 Test

adjusting AIC control keep in mind that

front
air

OFF Section
A C tem

on

panel is used

as

Refer to between
test two
or

Blower

Motor

for

conditioning

sys

continuity
with

BE

switch

terminals

lamp

ohmmerter
2 With

Continuity should exist capillary tube end dipped

I oc

RESISTOR
Refer to Resistor

FAN
Section BE Refer

SWITCH
to

Fan Switch

Section BE

into ice salt water maintained to

300 F
switch

test

terminals

continuity between two Continuity should

found damaged
re

MICROSWITCH

not exist 3 If switch is

place

MAIN

RELAY
AND

REMOVAL

INSTALLATION
I 2 3 Disconnect Remove

battery ground cable glove box

Disconnect connector from main

relay
4

Remove
to

screw

retaining
remove

main

relay relay
5

cooling

unit then

main

Installation is in the

reverse

order

of removal

INSPECTION
Test
meter

CV
of
1 Microswitch

relay
tween

relay with ohm or test lamp In testing main there must be continuity be continuity
and

Fan switch

CD

CV
applied normally close
REMOVAL AND

AC19SA

When l2Y direct current is

to

Fig AC 34 Microswitch

CD CV CID @

rnicroswitch when its is

protruding part

ti
I

INSTALLATION
1 Remove air

pushed

conditioner control
to Heater

assembly
2

Refer

Control

Assembly Section BE
Remove
screws

attaching

micro

I
i

switch and then 3

remove

rnicroswitch
reverse

w
AC199A

f i

Install rnicroswitch in the

order of removal

i
I NSPECTI ON

f
Fig
AC 33

Make sure that

continuity

exists in

Fig AC 35 Microswitch

AC 23

Air

Conditioning
this state
vacuum

LOW

PRESSURE

031

under
one

orally
to

blow
ensure

J
2 3 4

Disconnect batiery Remove

ground

cable
cover

SWITCH
REMOVAL AND

through

port

Remove instrument under

that there is air flow at the other

glove box
air and

Take out fuse holder from

conditioner harness with

a new one

replace fuse

INSTALLATION
I

Disconnect battery ground cable

FUSE REPLACEMENT
REPLACEMENT CAUTION If fuse is blown part of
nate the cause

Discharge
Disconnect

refrigerant
connector

from

sys

tem Refer to General Service 3 to

low
A 20 ampere in line fuse is air conditioner harness located behind

be

sure

to climi
new

pressure switch 4 Remove low pressure switch

befure

installing

by

fuse in position

turning the
5

switch

glove box

Installation is in the reverse order

of removal

INSPECTION

Using

circuit tester

make

sure

that low pressure switch exhibits con tinuity when gas pressure of refriger
ant in system is normal pressure and that low switch does not exhibit con gas pressure

tinuity when
2 2

drops

below

kg cm2

31 p i

MAGNET VALVE r
REMOVAL AND INSTALLATION
I Disconnect

battery ground cable

magnet
valve lead
AC276A

2
3

Disconnect

wires and vacuum hoses

Remove and

magnet then

valve

securing
magnet

Fig AC 37 Fu

Replacement

screws

remove

valve

VACUUM HOSE DIAGRAM

i
4

i
AC389A reverse

CJ
Magnet
valve

WrE
Installation is in the ofremoval

Intake Check valve

actuator
I
0 0

Fig AC 36 Removjng Magnet Valve

Al
1

Vacuum
switch

order From intake manifold Fast idle

actuator

1l
AC27BA

INSPECTION
I rest

continuity with ohmmeter Apply D C 12 volts across termi

AC 24

Fig

AC 38 Vacuum Hose Diagram

Air

Conditioning

WIRING DIAGRAM
CIRCUIT DIAGRAM Air conditioner system

DD G
FUSIBLE LINK BATTERY

I
W B 8

LG

Lr

J c LG J LW

THERMOSTAT

W W

FUSE 20A MAIN RELAY

ALTERNATOR

rn

IGNITION

SWITCH

il
W LB

fJ
J Dt
Wc J

RESISTOR

LLG J
LOW PRESSURE

J c L

SWITCH

C J c

BLOWER MOTOR

J c L

J
L

l
MAGNET
VALVE

BvM r
LW LY

J c

C CJ
COMPRE SOR CLUTCH
LIT

I
MICRO SWITCH

IACC

15A L1 8

3E

FUSE BLOCK

1
AC 25

AC404A

Fig AC 39 Circuit Diagram of Air Conditioner

I

0l9

l0

0os

xlm uU0xJ s oo me r U0I 0 0

I

Ib
ft m
2

23 IS

kg

to to
1

torque

2 0 3

to to
1

11

1 5
7 0

Tightenig
i

5 1

@ @@ @

asembly gasket asheadembly gasket plug asembly asembly plate plate fil er ting Valve Cylinder Cylinder Bale Clutch Compreslo
te

pla

au

10 11 12 13 14 IS 16 17 18

1
K

alsembly asembly head ghaesakdet whe l ring whe l Clutch Snap Clutch Magnetic Shaft Conectr ring Cylindet CyUhder
bearing
I

coil

seal

2 34

5 67 89

l0 C
i

en

Air

Conditioning
DISASSEMBLY
1

PRELIMINARY

CLEANING
Before starting work
remove

dirt

bearing

Remove two snap rings retaining They are located inside of

from outside the detached compressor Clean the workbench tool hands and your

clutch wheel
I

AC392A

COMPRESSOR

CLUTCH
The most likely source of problem is clutch slippage Factors are listed here
1

Fig AC 42 Removing Clutch Assembly 3 Loosen four

screws

electromagnetic
Coil assembly

coil
can

AC500

mounting

Fig AC 44 Removing Snap Ring

Exercise Clearance

ample

then be taken out easily 2

care

between

clutch

hub
mm

and pulley should be 0 4 to 0 6 0 016 to 0 024 in

at aU

Using

Clutch

Wheel

Remover

peripheral
no

points
2

KV99100700 and conventional puller remove V pulley with bearings from clutch wheel

Make
on

sure

that there is

oil or

dirt

friction surfaces of clutch disc

or

clutch hub and pulley Remove oil dirt with clean lint free cloth
3 Make sure that terminal coil is above 10 5V

voltage

at

magnetic

REMOVAL I

AC869

Using Clutch
remove

Spanner Wrench

hold clutch hub wrench hub to crankshaft

With suitable socket bolt retaining clutch

Fig AC 43 R mouing Magnetic Clutch

KV99100100

AC501

INSTALLATION
Locate the electromagnetic coil at the
correct

Fig AC 45 Removing V Pulley from Clutch Assembly

position

on

housing

Then

secure

compressor four electro

3

magnetic coil mounting screws

@ Tightening torque
Electromagnetic
screws

Us i

Bearing

Remover

coil

mounting

ST33061000 press clutch wheel bear ings out from clutch wheel

0 7
AC391A

kltm

5 1 ft Ibl

Fig

41 AC

Removing

Bolt

InstaU the clutch assembly

on

the

crankshaft

Note

Key should be

set

on

crank
assem

shaft before installing clutch 2 Bolt Then

ST33061000 I

using

Clutch

remove

clutch

Removing assembly from

bly
3

crankshaft

Using

Clutch

Spanner Wrench I

hold clutch hub

secure

With socket wrench

CAUTION
Be careful
not to

clutch hub securing bolt

demage key

on

iJJ

compressor crankshaft

Tightening torque Clutch hub securing bolt 1 5 kg m 11 ft Ib

AC 27

Jiffi
ACSD2

Fig AC 46 Removing Clutch

Wheel

Bearing

rt

Air

Conditioning

ASSEMBLY
1

The

clearance between V pulley

and clutch wheel should be 0 4 to 0 6 Press bearings into V Instal er 5T0237

pulley

with

mm

0016 to 0 024 in

Bearing

1000

If not

replace
dirt

clutch wheel

assem

bly
3 Oil
or on

friction surfaces of
clot or

clutch wheel and V pulley should be

02371000 51

cleaned with

clean Iint

free
or

suitable solvent 4 Check coil for shorted

opened
to
AC393

lead wire Pay

particular

attention

grounding part of coil If there is no continuity replace electromagnetic

coil

Fig AC 50 Removing Filler Plug

AC503

Remove clutch

Refer to Com

Fig
2

AC 47 In

talling Bearing

pressor Clutch for removal 3 Remove shaft key from shaft

crank

Install outer snap ring in groove

of V pulley 3

Using Installer KV99l 0061 0 and

ST33061000 press clutch
L
C

Stopper
4

wheel into V

pulley

Install inner snap ring in groove of clutch wheel

IJ
I
0

Fig AC 49 Grounding Point 01Coil

ACS07

Fig

AC 51

Removing Shott Key

If clutch

assembly

must

be

re

Remove seal

plate

placed remember that break

tion is

in opera

The break in opera neceSS3I tion consists of engaging and disen

gagingthe clutch

some

tirty tlines

J
e I

SHAFT SEAL
Installer KV99100610 2

IR j

@
n

AC866

Stopper
ST33061000
AC504

assembly of this compressor is of a simplified design yet tight sealing and long lasting

The

shaft

seal

Fig AC 52 Removing Seal Plote

With

Fig

48 AC

Installing Clutch Wheel

out seal

Compressor Seal gland and discard

Puller

pull

INSPECTION
I

REMOVAL It is recommended that the pressor be removed from the shaft seal replacement
I
com

CAUTION
a

iscard

all

parts of
ring O a

he seal in
to

Check friction surface of clutch

or

cluding tha
b 00 not
use

for damage due to excessive heat excessive grooving due to

neceSS3I replace

car

for

screwdrivel
as

pry to

slippage

If

shaft seal from shaft shaft may result

damage

clutch wheel and

V pulley

as a

set

with O ring and drain the compressor oil

Remove oil filler

plug

AC 28

Air

Conditioning
with

7
ance

Space seal plate

around shaft

equal

clear
cap

10

Install

oil

filler

plug together

and

insert

with O

ring

screws

Tighten

these

screws

evenly

CAUTION Use
new

IiJ

Tightening torque Seal plate securing 0 7 to 1 0 kg m

ring

when

installing

oil

cap screws

filler plug

5 1 to 7 2 ft Ibl

INSPECTION
Check for gas leakage as follows Plug high and low pressure joints compressor with blind caps Connect charging hoses in lines

I
AC867 on

Fig AC 53 Removing Shaft Seal

between manifold gauge and low pressure service valves

high

and

INSTALLATION
1 2 oil 3 Push seal
over

Connect

refrigerant

can

to middle

Clean shaft

and seal cavity with

in clean

clean lint free cloth

hose of manifold gauge 3 Open valve of can tap and charge refrigerant Loosen oil filler plug at side of compressor to purge air out of
AC869

Dip seal gland

refrigerant
carbon

compressor
4 Turn shaft that 5
or

assembly except

ring ring
4
on

end of shaft

with carbon

Fig AC 55 Spacing Seal Plate and Tightening Cap Screws

6 turns does

Then

confIrm

retainer Move

facing out seal assembly

decrease
into

position
8

shaft

Install clutch Refer to Compres for installation

gauge there is

not pressure low pressure gauge If indicates a pressure decrease

on a

leak Conduct
a

leak test and

sor Clutch

Under such

condition

remove

Charge lubricant

then install parts again

To Low pressure service valve

To

High

pressure

service valve

Low
ACB68

High

Fig AC 54 1merting Shaft Seal Assembly

5
so

Place carbon ring in ring reta iner lapped surface is facing outward The indentions in outside

Note

of carbon

lugs

and

ring must be rmnly

engage seated

edge driving
in
re

r
fi IZl
AC183A

tainer Q ring in groove of

6 seal

Install

new

plate
Use

Note

refrigeration

oil to make it

adhere to surface

Fig AC 56 Checking for Gas Leakage AC 29

Air

Conditioning
2

CYLINDER HEAD AND VALVE PLATE

Insufficient

Place

CAUTION
a

cylinder gasket
so

in

position

on

cylinder

dowel pins in crankcase

In

removing
not

head
to

gasket

refrigerant

sion

careful

damage

be very machined

go

through Apply

dowel pin holes in cylinder

thin flim of clean refri

gasket
3
a

is likely to be caused by damaged head gasket or damaged valves Prior to servicing the head and valve

b 00 not reuse

sealing surface gaskets

plate
opened

both
to

service

valves should be

free any gas pressure which

geralion oil to top and bottom valve plate areas to be covered by gaskets 4 Place valve plate in position on cylinder gasket so discharge valve as
semblies

may be in the compressor

smaller diameter
over

assem

blies with restrainer REMOVAL

I
are

valve reed

Remove

cylinder head securing

bolts

facing up and locating dowel pins through dowel pin holes in valve plate
go

AC815

Fig AC 59 Removing Gasket

INSTALLATION
Valves and valve
ed

Fig AC 57 Removing Cylinder Head

plates

are

furnish
AC817

only

as a

complete assembly

Fig AC 62 Placing Valve Plate 2 Remove valve

plate

and

head

from cylinder by prying under the valve

ears

or tapping which extend from

plate plate
adhere hold

If head and valve

head and tap valve plate ears away from head with a soft hammer

8
AC872

5
valve

Place head gasket in position

on

plate Apply

so

dowel pins go

through

dowel pin holes in gasket

6
a

thin mm of clean refri

Fig AC 60 Valve Plate Assembly

geration oil on the machined surface of cylinder head which matches head

gasket
CAUTION
00 not hit
or

llIp head

to

separate

head and valve

plate

because

Apply a thin mm of clean refri geration oil on area of crankcase to be covered by cylinder gasket

Place head
so

on

cylinder

head gas

dowel pins go into dowel holes in head ket 8

pin

damage

to head may result

Tighten

screws

to

specified

limit

iil

Tightening torque Cvlinder head screws 2 1 to 3 2 kg m

15 to 23 ft Ibl

AC871

Fig AC 58 Removing Volve Plate

and Head

DISCHARGE AND SUCTION CONNECTORS

Fig AC 61 Applying Clean

When removing the gaskets edged sharp knife

use a

Discharge
are

and suction

connectors

Refrigeration
30 AC

Oil

located

on rear side

of compressor

Air
REMOVAL
1

Conditioning
2 Insert each

INSTALLATION
screw

discharge

and suction

Remove each
suction

securing dis using

suc

Attach

new

O ring to each cy
suc

valves into correct valve port in crank case by matching it with mark on

charge and
2

connectors

TOD Driver Bit Pull out each discharge and

lindrical portion of discharge and tion valves

cylinder
3 tion
as

head
same

Set each valve in the

it
was

posi
and

before with

removal

tion connector

tighten

screws

specified

torque

Note

Memorize mounted direction of

cD
Note

discharge
ensure

and suction connectors to

correct

reassembling

ring so that it can be fitted tightly to cylindrical portion and crankcase

Apply clean lubricant

to O

Tightening torque Discharge and suction

connectors

2 1 to 3 2

kg

hole

15 to 23 ft b

a@
AC873

Fig AC 63 Removing Discharge and

Suction Connectors

AC 31

Compreso
not

run not

Com

does

Ref r pres or Diagnose

to

gromets dash
s

air

of

for

Check panel eaks other car

on

car

check seal

does

Blower
to

Blower rotae
in

Refei Mot r

Diagnose
discharge Perfom sy tem Measure
tem
of

discharge
of
to

sy tem
but

flow
air

Air
to

gauge

pres

bu les glsiagssht
No

manifold
line

Tempratue pres5ure
is

abnormal

normal
is

Check sy tem Ref r

iJ

Conditer Operation Chart

gasket replace
or or
is

is

air

co ling

With check sures

peratue
case
In

Test

air

Refer ance
l re

presu while presu Suction high charge low

dis
is

Valve

of

compres damged Repair compreuo

is

Insuficent

glaS sight
in

repair
and

re

Bub les
J
I

refigaton
Check

leaks
gas for

Charge corect
any
if

com and of stop

too

the

to

leaks level many pres or sy tem

reso com engine changed are sounds brsacokret
is

frigerant

leaks

discharge evaCUte

sy tem replace
the
As

may in

sight

air

recharge necsary rec iver

is

drier

sy tem bu les
in

of

discharge Diagnose

Test

presure

Air

cause glass

and

temprau Perfomanc
to

Discharge high
pres high
for

refigrant some Discharge replace recharge dented dust surface corect mixed ext rio water c l o g e d Overchage Discharge erani sytem Evacute sytem Condesr Clean
of of
in

refrig level drier

and
to
is

fin
s

and

with

Air

or

with

ON

When rpm there nant

Compreso
Noisy
I

Retighen

reso Add

pre

bolts Pip ng nating clamp lo se belt

pres ure Ref r

System abnormal detail

Suction sure
low
is

is

Expansio valve excsively Replace pansion

is

open

ex

valve

of
I

Compreso itself noise Repair replace presor

OFF

makes

or

com

is

tube
and
Fin

Belt

Adjust
or

presure
Suction

leak ge expansio e x c s i v e l y evaport laminted rator dents Replace evaport Expansio close thermo Replace valve
or

evapo some repair

have
or

is

valve

from

bulb

gas
or

presor
I

makes

re

or

Com

Blower noise Repair place

blower

com
of

Bearings presor idler make Replace

l C W

clutch puley noise

drier Replace drier s t r a i n e r r e c i v e r resticed outlet Strainer Line Replace Pipe drierlow Rec iver resticed rec iver
is

pipe

has

in

Is

at

temprau

Air

Conditioning

BLOWER MOTOR DIAGNOSES

I I
Fuse blown

Blower motor inoperative

Check 20 ampere fuse in air conditioner harness

Fuse OK

Locate short circuited

or

spot

and

repair

replace faulty parts

Ground one of lead wires Black blue 3 speed Black white 2 speed l speed 1eading to fan switch Black

yellow

Blower

runs

Blower does not

run

Check ground circuit and lead wire con oeetion When no problem is found

Ground black wire of blower motor

i

replace

blower switch

Blower runs

Blower does

not run

Check resistor for connection When

no

problem

is found

replace

resistor

Connect 12 volt test light to white wire leading to blower motor

Light ON

Light OFF

When no

Check lead wire for connection problem is found replace blower motor

Check for presence of voltage

at

main

relay

No

Yes

Check for presence of voltage at air conditioner harness

Check lead wire for connection When no problem is found replace

relay

AC 33

o lCl

ol

tC

01

Utoa a oB 0 a Ut

oUt A i

of

by

for
is

oil
n

is

J videnc leakS
e

us

teftig
I
ing NO lea

ing

leak
oil

oil e
r

Compte

whcre for
on

refigrant
blOW
Air

clean Jag Wipe wi

clutch

when enga ed

Noisy not

cQm1JresOt Turn
oo
c

is

Remove belL compresot hand noise MaId preM

or

pul eyclutch check noisC clutCh and repair

If

com

spot check

Then

round leak

det cof

leaking

replace

01

Refrig ant
problem tem replace Internal cornpre inder Check Repau nece
tY
y

Repau

comptUOr

when enga ed
onlY

mount bolts
Dolts
ing

drive Adjust

is

sor

is

for

Noisy clutch

Check compreno Retigh n Compreso

islOosc tM1on
belt belt

cotTlprerepair compres yet replace noisY

If

or

sor

l
T

rod

teS OI

cyl sor

or

sor

son

mp

compre
but

in

enga ed

teMion
belt

out
l bwor

j
ie
iI

it

is

clutch IUn

Check and

adjust

dam ged lfbelt

ce

or pl

Compreso

not

doe

rCPlaO con J clutch and gap contact face slip ng compreso clutch Cbeck adjust clutch
re of

System

service
J

repair
grel t
stm
is

the

dust

ftom side arge

sur

OJ

oil

Clea Il

of

on

ues

refigration
compreso

sy tem discharge

rech
nd
a

in

if

n ti

Air

Discharge valve Evacute Lystem

j
cnt
t

on

ctorqueompreso
When

rtV1ace
or j

J
not
is

coil
00 of

en

decr ased thall

5V
lO

voltage

terminal conection con ection

t

not
is

Clutch yet
e c

replace dutch
gaged

lr1
ge1ant
Ief
of
I

pres
l

has

not
is

o n

es

clutch
reS OI

ha to

Ground

poor Repair
is

In
r

10

drier

gas

COnlp enga ed

com
or

is

J wire clutch

CompreSio Diagnose
to

vetChagO refigotan sight

of
ss

rec iver bub leO rpm

l

Discharge
dis

sure

reduced
is

gla

few

that onlY
I

Engie5p d

i
r

for

Check charge OK

pres ure dbcnarge pres

if

ure

reduced

Lead pres ordead

Refer Clutch

Air

Conditioning

COMPRESSOR CLUTCH DIAGNOSES

Compressor

clutch is not

engaged

Check 20 arnpere fuse in air conditioner harness

Fuse blown

Fuse OK

Locate short circuited spot and

repair

or

replace damaged parts

Connect 12 volt test light to compressor clutch lead wire Ground the otherend of test light Set air control lever to A C posi
tion

Light ON

Light OFF
I

Check lead wire and ground wire of compres When there is sor clutch for connection

Check low pressure switch for L H drive only

continuity

nothing
clutch

wrong with them

replace compressor
No
I Measure pressure in system Ifthere is a leak service system Ifpressure is normal Yes

check low pressure switch place if necessary

as a

part

reo

light to terminal of blue green wire leading to thermostat Ground the other end of test light
Connect 12 volt test

Light

ON

Light OFF

Check ground circuit and make

sure

of

proper connection Further check lead wire connection

no

and when

Connect 12 volt test light to blue white wire of microswitch Ground the other end of
test

problem
or

is found

replace

air conditioner

light

harness

main harness
I

Light
I

ON

Light OFF
I

Check lead wire connection When no problem is found replace thermostat

Check for current flow in lead wire

to

main

relay

Yes

I I

No

Check lead wire for connection When no problem is found replace microswitch or main relay

Check power

supply

AC 35

v
Air

Conditioning

VACUUM SYSTEM DIAGNOSES

FAST IDLE CONTROL DEVICE

F I C O does

not

operate

Disconnect vacuum hose from fast idle actuator and connect vacuum tester

light ON

Light

OFF

Replace

actuator

Disconnect magnet valve hose at intake mani fold side and connect vacuum tester to the open end of the hose and magnet valve

light ON

I
connectors are

light OFF

Connect 12 volt valve lead wires

test

light between magnet

Check vacuum connector and hose Ifhose

or

damaged replace

it

light ON

light OFF

Replace magnet valve

Inspect circuit of magnet valve Refer to Compressor Clutch Diagnoses

Note Vacuum lester Tester Iighl

keeps

OFF unless normal

wcuum level

exists in each check

point

AC 36

Air

Conditioning
perfonnance
gauge scale indicates a range based
on

PERFORMANCE TEST DIAGNOSES

Of various conditions caused to the
air

As to the method of a test

refer to the item of Perfonnance

the

assumption
system

that
is

the
in

air

Test

conditioning
order

good

conditioning system
on

the character Note In the

istics revealed

manifold gauge read

following

table
on

the each

ing

are shown in the

following

portion smeared with ink

Condition

Probable

cause

Corrective action

INSUFFICIENT REFRIGERANT CHARGE

I
Refrigerant
sight leaking
a

Insufficient cooling
I

is

small

or

I 2 3

Leak test

Bubbles

appear

in

little

glass

Repair leak Charge system

Evacuate
8S
neces

Note
sary tem

and recharge sys

@
I

@
08A

ALMOST NO REFRIGERANT

Stop
ately
No In

rompressor immedi

cooling action sight glass

bubbles
appear
a

Serious refrigerant leak lot

Leak test

2
3 4

Discharge system Repair leak s Replace receiver

necessary drier if

i
@
I

of

or

something

like mist

Check

oilleve and

6 Evacuate

recharge

@
AC209A

system

FAULTY EXPANSION VALVE

Slight cooling Sweating or frosted

expan

Expansion valve refrigerant flow

restricts

If valve inlet reveals

or

sweat

frost

sion valve inlet

Expansion

valve is clog
is in

Discharge system
Remove valve and clean it

I
@ @
AC210A

ged Expansion valve operative

Valve
stuck

Replace

it

if

neces

sary

closed has

3 4

Evacuate system

Thermal lost charge

bulb

Charge system

If valve does not operate

I 2

Discharge system
Replace valve
and

3 Evacuate system

charge

AC37

l r

Air

Coitioning

Condition

Probable Insufficient

cause

Corrective action Check valve for operation If suction side does not show
a

cooling

Expansion valve allows

much refrigerant evaporator

too

6
@

Sweated suction line

through

replace

pressure decrease valve

@
AC211 A

No cooling

Faul ty

expansion

valve

Discharge system
Evacuate system and

Sweating
tion line

or

frosted

sue

2 Replace valve 3

replace

o
@
g I
fj
AIR IN SYSTEM

@
212A

Insufficient cooling

Air mixed with in system

refrigerant

Discharge system

Sight glass shows occasion

al bubbles

2
3

Replace
system

receiver drier

Evacuate

and

charge

lI

IJI
I I

l
J

ole

@
AC213A

MOISTIJRE IN SYSTEM

After
while side

operation
may

for

Drier

is

saturated

with

Discharge system Replace

receiver drier twice if necessary

pressure on sllction

moisture
zen

Moisture has fro

show

vacuum

at

expansion

valve

pressure this

reading

During

Refrigerant flow
ed

is restrict

3 Evacuate

system

com

condition

discharge
warn

pletely
times 4

Repeat

30

air will be wann As

minute evacuating three

ing of this reading

shows

@
AC214A

0 4 tion

kg cm2

psi

vibra

Recharge

system

38 AC

Air

Conditioning

Condition

Probable

cause

Corrective action

I FAULTY CONDENSER I
o

cooling

action

engine
in

Condenser is often found

not

Check fluid Check

fan

belt

and

may overheat Bubbles appear

functioning well

coupling
condenser

sight

for

glass of drier
Suction line is very hot

dirt accumulation Check

engine
for

coqling

system for overheat

Check

refrigerant

overcharge

@
AC215A

Note

high

If pressure remains in spite of aU

re

above actions taken

move

and inspect the

condenser for oil

possible

clogging

I HIGH PRESSURE liNE BLOCKED I

r
Insufficient

cooling
pressure

Drier

Frosted high

tion in

clogged or restric high pressure line

I 2

Discharge system
Remove
or

receiver

drier

liquid

line 3

strainer

and
and

replace
charge

it

Evacuate system

@
AC216A

I FAULTY COMPRESSOR

I
Insufficient cooling
Internal

problem in com damaged gasket pressor

or

Discharge

system and check

2 Remove
compressor

and valve

3 Repair
4 5

or

replace

com

pressor Check oil level

Replace
system

receiver drier and

@
rg
j r
AC217A

6 Evacuate

charge

39 AC

Air

Conditioning

Condition

Probable

cause

Corrective action

TOO MUCH OIL IN SYSTEM

Excessive

lostlfficient cooling

Too with

much

oil

circulates

Refer to Oil Level Check for correcting oil level

refrigerant causing the cooling capacity of the

aystem to be reduced

@
g
Ti

@
AC218A

AC40

Air

Conditioning

PERFORMANCE CHART
TEST CONDITIONS
Test car location

Indoor or in the shade

Door windows Door Hood

Air lever

Open
Closed

Open
COOL Ale Max cold 3rd
1 500 rpm

Temperature lever Fan switch Engine speed

TEST

READING

Inside air Recirculating air at cooling unit inlet Relative humidity

Air temperature

Discharged

air temperature at

center outlet

oe OF

oC OF 40 to 60 20 68 25 77 30 86
35 95 5 to 5 0 1 6 0 to 9 5

35

to

41

42 to 49

10 5 to 14 0 51 to 57

i5

O to 19

6 59

to

66

60

to

80

20 68

5 0 to 8 0 41 to 46

25 77
30 86

5 9

to

13 0 49 to 55

14 0 to 18 0 19 0 to 23 0

57 66

to to

64

35

95

73

Relative

humidity

Ambient air temperature oe OF 20 68 25 77 30 86

35 95

Pressure

high Discharge kg cm2 psi 139 171 9

235
to 152

side

Pressure low

Suction side

kg

cm2

psi

40 to 80

9 8 to 10 7

1 1 to 1 8 1 2 to 1 9 14 to 3 2

16

to

26
i

5 10

to

118

149 to 168 to 198

17 to 27 20 to 33

12 0 to 13

13 9

to

16 7

198 to 237
to

1 9 to 2 8 27 to 40

40 104

16 5 to 20 5

292

2 7 to 3 8 38

to

54

41 AC

r
Air

Conditioning

SERVICE DATA AND

SPECIFICATIONS

GENERAL SPECIFICATIONS
Compressor
Model SC206 Yoke
cc ell

Type Displacement
in
rev

100

10 6

Cylinder
Bore
x

stroke

mm

in

47 6 x

1 28
x

1874 Direction of rotation

106 1

Clock wise

View from
Lubrication oil

drive end

Type

SUNISO 5GS
in

Capacity

refrigeration system

cc

US 11

OZ

Imp 11

oz

237 8 0 8 3

Refrigerant Type
R 12

Capacity

kg lb

8 to 1 0 0 1 8 to 2 2

INSPECTION AND ADJUSTMENT

Belt tension
Fan belt
mm

in

kg lb
8 to 12 031 to 0 47 10 22

applied

pressure

A C compressor belt

applied

pressure

8 to 12 31 0
to

47 0

10 22

F I C D adJustment

Engine model

Transmission

When AlC

When

OFF

AlC

is ON

F LC D

is actuated

Manual AI4 AI5

700 rpm 650 rpm

at

800 rpm 800 rpm Nu position

Automatic

Du position

at

Clutch hub to pulley clearance

mm

in

0 4 to 0 6 0 016 to 0024

42 AC

Air

Conditioning

TIGHTENING TORQUE
kg
Compressor bracket Compressor Refrigerant
to m

ft lb 1 5 1 5

cylinder block

3 7 to 37 to

27

to

37

to compressor bracket line connection

27 to 37

3 8 in diameter tube 1 2 in diameter tube

3 0 to 3 5 4 5 to 5 0

22 to 25 33 to 36

Compre Cylinder

or

kg

ft lb

head and connector

2 1 to 3 2 0 7 to 10 5 11 1

15
5 1

to to

23
7 2

Seal plate securing cap

Clutch hub

Electromagnetic

coil

0 7

5 1

43 AC

olIIl

v
Air

Conditioning

SPECIAL SERVICE TOOLS

Kent Moore No Kent

Moore No

Tool number

tool

name

Reference

Tool number

tool

name

Reference

ftrN
KV99100700 Clutch wheel
remover

KV99412302

Clutch

spanner wrench

J 24878 1

Fig

45 AC

Fig

41 AC

KV99I006SO

Clutch wheel installer set Installer

@J25797
2

Clutch removing bolt

J 26344

CD KV9910061 0 @ST33061llOO

Stopper

Fig Fig
48 AC

42 AC

CD

Compressor

seal

puller

J 10549

Fig

AC 53

ST3306IOOO

Bearing

remover

J 25797 2

Torx driver bit

J 24392

Fig

46 AC

Page AC 31

ST02371000

Bearing installer

Oil

dip

stick

J 10545

Fig

47 AC

AC44

l1l 1IE WASHEII

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SW

1979
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FUSE

ITHERMO H IMICRO
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sw Th ng

diagram

ha

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car

BLACK WHITE

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The

fullyeqU1pped erv l ght IS e

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Omefll eQU l d g
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ffi
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1
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any tme Note r

ro

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as

on

1011010 n8R
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n I 5

BLUE l@ at pe
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GW

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1m

1W231
rAN SW A NMOTOR

pa

wh te Sl l

o11Id blaCk

cao th

AUTOMATIC
I 1 j MANUAL CALIFORNIA

fRAN MISSION MODUS M TRAN MOD tS FOR USA AllFORN A t ION MODELS I

A MODELS

1
AIR

HATCHBACK WAGON AIR CONDITIONER

NONCAUroRNIA FU MODEtS FOR

CONDnION R UNIT
Iof l

it

SWITCH AND RE J IGNITION SWI KEY

POSITIONS n IN lOCII

co o

011 lhe hown

me w n

It
NO

w w
g

I I

UNITCSlAMDUOTYPEl

lii

I
I
i
HEATER UNIT

rr
c

REMOVEO SWITCH W P ER SWITCH IN OFF I EUTRAl SSIDN IN

con 10

CONNECTION

CONNECTION

@ 11
ffi III

LIGHTING DOORS

be w of

CtoSlO

th nthec

1m231 11
FA

TRANSMISSION
AUtOMATIC T lEVER IN PAIU

oKlualhne

SlLECfORi

HANOBRAIIEPUllEO

t
C JiOR lOPEN NORMAL CLOSE

II

fi @

ORIVEWS

SEAT BELT UNOCCUPIED

Mun DUT

J N

NISSAN MOTOR CO

LTD

v
i

l MOTOR CO NOSSAi

lTD

11 1 Ginza e Cflome Chuo ku Tokyo 104 Japan

Printed

in

Japan

sued July 1978 010775 Publication No Sl19E B310UO