Вы находитесь на странице: 1из 537

AV

C
MANUAL
r
Jl
01
D
L
o
c
i
1
L
J
L
1
J
o
4
4
p
6
1
I
o
j
r
rf
rJ
f
r
f
L
J
J
J
1
DATSUN
p
CK
UP
SEftV
CE
tf
AMUAl
MODE
620
SER
ES
I
I
I
1
1
t
QUICK
f
EFEf
ENCE
INDEX
1
ISSAtlIA0101l
CO
to
0KYO
J Atl
FOREWORD
This ser vice manual
has been
pr epar ed
for the
pur pose
of
assisting
ser vice
per sonnel
of
author ized NISSAN
DATSUN
dealer sfu
pr oviding
effective ser vice
and maintenance
of
the
1977
DatsunPick
up
Since
pr oper
maintenance
and ser vice
ar e
absolutely
essential
fu
satisfying
the Datsun
owner s
this inan la1
should be
kept
fu a
handy
place
for
r eady
r efer ence
and
should be
car efuny
studied
This
man la1fucludes
pr ocedur es for
ma
futenance
ac 1justr nents
minor
ser vice
oper ations
r emowl
and installation
and for
disassembly
and
assembly
of
components
Some ofthese
ser vice
oper ations r equir e
the
use of
Special
Tools
especially designed
for
effectiveper fonnance
ofser vice
oper ations
The
special
toolsar e
pr esented
inthe
SE
section
As
you
r ead
thr ough
the
maintenance
pr ocedur es
in this ser vice manual
you
will
occasionally
cor ne
acr oss
par agr aphs
headed
NOTE or CAUTION
ANOTE
is
supplemental
infor tl1ation that is
impor tant
to
B
par ticular
pr ocedur e
CAUTION
war ns
of
steps
that must
be
fonowed to
pr event
per sonal injur y
and Qr
damage
tosome
par t
of
your
DATSUN
The
Quick
Refer ence Index
on the fir st
page
enables the user to
quickly
locate the
desir ed
section At
the
beginning
of
each individual section
is atable ofcontents
which
gives
the
page
number on which each
major subject begins
An index
is
placed
at
the
beginning
ofeach
major
subject
withinthe
section
Allinfor mation
illustr ations and
specifications
contained
inthismanual
ar ebased on
the
latest
pr oduct
infor mation available at
the time
of
publication
appr oval
If
YOUT
DATSUN
model differ s fr om the
specifications
contained
in this manual consult
your
NlSSAN
DATSUN dealer for
infor mation
Rights
for
alter atiohat
any
time
of
specifications
and methods
ar e
r eser ved
liability
for
any per sonal injur y
or
pr oper ty damage
occasioned
by
the
use
ofthis
ser vice
man la1in
effecting
maintenance
or
r epair
of
your
Datsun
is in no
way
assumed
by
Nissan
M9tor
Co
Ltd
Accor dingly anyone
using
a
ser vice
pr ocedur e
or
tool which
is
not
specifically
w
mended
by
Nissan
must fust
completely satisfy
himself
that
neither his
safety
nor the
vehicles
safety
wi11be
jeopar dized by
the
ser vice
method
selected
NISSAN
MOTOR CO LTD
TOKYO
JAPAN
@
1976 N1SSAN MOTOR CO
LTD Pr inted
in
Japan
DATSUN PICK UP
MODEL 620 SERIES
I
NISSAN
I
NISSAN MOTOR
CO
LTD
TOKYO JAPAN
I
SECTION
GI
GENERAL
INFORMATION
GENERAL
INFORMATION GI 3
Gener al Infor ma
ion
Fig
GI I Standor d
wheelbase
model
Fig
GI
2
Delux Cob
GI 2
Gener al Infor mation
L
GENERAL
INFORMATION
CONTENTS
MOOEL VARIATION
GI
3
APPROXIMATE
REFILL
CAPACITIES
GI B
IDENTIFICATION NUMBERS
GI
5
RECOMMENDED
FUEL
GI
B
LIFTING
POINTS
AND
TOWING
GI
B
RECOMMENDED LUBRICANTS
GI
8
LIFTING
POINTS
GI
B RECOMMENDED
SAE VISCOSITY
SUPPORTABLE
POINTS
GI 7 NUMBER
GI 8
TOWING GI
7 LUBRICANT SPECIFICATIONS
GI
g
TIE DOWN
GI
7
MODEL
VARIATION
Differ ential
Pay
load
Destination
Class
Model
Engine
Tr ansmission
car r ier
model
kg Ob
and
gear
r atio
I
HL620TUV
F4W7lB
Standar d
I
HL620FTUV FS5W71
B
wheelbase
S
I
HL620KTUV
3 N7lB
E
I
HLG620TUV
Ol
F4W7lB
u
0
0
E
Long
E
I
HLG620FTUV
0
FS5W71B
wheelbase
0
I
HLG620KTUV
8 a 3 N7lB
0
Ol
0
u
I
KHL620TUV
Ol
F4W7lB
u
Deluxe
I
KHL620FTUV
FS5W7lB
Cab
KHL620KTUV 3 N7lB
Hl90
500
11
00
L20B
43 75
ui
0
HL620TU
F4W71 B
Standar d
HL620FTU
FS5W7l B
wheelbase
U
HL620KTU
3 N7lB
S
0
I
HLG620TU
0
E F4W7lB
0
8
Long
I
HLG620FTU
0
FS5W7lB
wheelbase
IHLG620KTU
Q
u
3 N7lB
0 0
Z
KHL620TU
F4W71B
Deluxe
Q
KHL620FTU
FS5W7l
B
Cab
I
KHL620KTU
3 N7lB
GI 3
r
Gener al
Infor mation
Differ ential
Pay
load
Destination Class Model
Engine
Tr ansmission
car r ier
model
kg lb
and
gear
r atio
Standar d
HL620TUN F4W71B
wheelbase
HL620KTUN
3 N71B
0
HLG620TUN
F4W7IB
Long
E
wheelbase
2
I
HLG620KTUN
Hl90
Canada
L20B
3 N71B 500 1100
43 75
I
KHL620TUN
F4W71B
0
Deluxe
Z
I
KHL620FTUN
Cab
FS5W7IB
I
KHL620KTUN
3 N7JB
Model identification
KHLG620KTUV
I I
L
U
V
N
T
K
F
0
G
o
H
K
I
Note
0
means noidentification
Destined for UsA and Canada
Califor niamodel
Canadamodel
Floor shift vehicle
Automatic
tr ansmission
5
speed
manual tr ansmission
4
speed
manual
tr ansmission
Long
wheelbase
Standar d wheelbase and Deluxe Cab
Equipped
withL20B
engine
Deluxe Cab
GI 4
IDENTIFICATION
NUMBERS
The unit and vehicle number s ar e
stamped
and
r egister ed
at the
factor y
The
engine
and vehicle
identifica
tion
number s
ar e
used on
legal
docu
ments These number s ar e used for
factor y communications
such
as
Technical
Repor ts
War r anty
Claims
Ser vice Jour nals and other infor ma
tion
Vehicle IdentHication
plate
The vehicle identification
plate
is
located at the hood
ledge
in
the
engine
compar tment
SP029
Fig
GI 3 Vehicle
identificationplat
location
Vehicle ser ial number
The vehicle ser ial number
is
stamp
ed
on the
upper
face ofthe
r ight
side
member The number
is identified
by
the
follQwing flgUr es
as a
ser ial
number
HL620XXXXXX
I
Ser ial number
Vehicle model
j
e
G1268
Vehicle
ser ial
number
location
Fig
GI 4
Gener al
Infor ma
tion
Engine
ser lliinumber
The
engine
ser ial number
is
stamped
onthe r ight
hand side ofthe
cylinder
block
L20B
XXXXXX
I
Ser ial
number
Engine
model
k
Color code number
The color code
number label
is
stuckon
ther adiator
suppor t
GI3 26
Fig
016
Color code number
label
location
MVS S cr tlflcatlon
label
The M
V
S
S cer tification label
is
located at thedr iver side lock
pillar
Gl 5
tW
I
1
I
il
j
SP03 1
Fig
GI 7 M
VS S
cer tification
label location
Vehicle emission
contr ol
Infor mation label
The vehicle emission contr ol
infor
mation label is stuck
onthe
insicr e
of
the
hood
panel
SP076
Fig
GI B Vehicleemiaioncontr ol
infor mation
label location
Manual tr ansmission number
The tr ansmission
ser ial number
is
stamped
on the fr ont
upper
face
of
tr ansmission
case
Number system
xX
XXXXX
I
Ser ial
number
monthly
Monthof
manufactur e
2 9 XY Z
Line
code of
manufactur e
Fig
GI 9 Manual tr ammiuionnumber
location
Automatic
tr ansmission
number
The tr ansmission
ser ial number is
attached tothe
r ight
hand side of
tr ansmission
case
Number ing system
X
XXXXX
I
Ser ial number
monthly
Month of
manufactur e
I 2
9 X Y Z
last
figur e
of
year
of
manufactur e
AT3 44
Fig
01 10Automatictr ammi
sion
number location
LIFTINGPOINTS
AND TOWING
LIFTING
POINTS
Scr ew
jack
Befor e
using
the
jack pr oceed
a
follows
Gener allnfor ml ition
Apply
par king
br ake
fir mly
and
block r ear wheels ifthe
fr ont
of
the
vehicle
is to
be r aised
Notes
a Never
get
under the
vehicle
while
it
is
suppor ted
only by
the
jack
Always use
safety
standsto
suppor t
fr ame
or r ear
axle
case
when
you
have
to
get
beneath thevehicle
b In noevent should the
jack
be
applied
to
any points
except
the
following specified por tions
When
jacking
up
the fr ont side
place
a scr ew
jack
under side fr ame
about 520
nun
20 5
in at r ear
of
fr ont axle center
WT012
Fig
GI ll Fr ont
lifting point
When
jacking up
the
r ear side
place
a scr ew
jack
under r ear axle case close
to
the side
ofr ear
spr ing
WH077
Fig
GI 12 Reor
lifting
point
Notes
a
When
the
yellow mar k
appean
on
the scr ew
jack
it indicates the
maximum
per missible height
Do
not
jack up
fur ther
b
When the
jack
is at lower llinit do
not
add
lar ge
for cedownwar d
GI 6
YeDowmar k
WHOSO
Fig
GI
13
War ning
ogai
t
over str oke
Gar age
Jack
Note When
car r ying
out
oper ntions
with
a
gar age
jack
be sur e to
suppor t
the vehicle withstands in
asafe manner
When
jacking up
the fr ont end
apply gar age jack
tofr ont cr oss
member or center
por tion
ofsus
pension
member
When
jacking up
the r ear end
apply
the
jack
tor ear axle case
rJ
uc
I
GI075 n9
Fig
GI
14Fr ont
lifting
point
GI076
Fig
GI 15 Rear
lifting
point
SUPPORTABLE POINTS
The fr ont
suppor table
points
ar e
under
fr ame
side
member
The r ear
suppor table
points
ar e
under r ear
axle case
Fig
GI
16
Fr ont
suppor table
points
v
GI078
Fig
GI 17 Rear
suppor tablepoints
TOWING
When
the vehicle is to
be
towed
for war d connect
a
r ope
secur ely
to
the hook under the
1st
Cr osSInember
Befor e
towing
make sur e
the
par king
br ake
is
r eleased
Gener al
Infor mation
Totow another car connect
t1ie
r ope
tor ear leaf
spr ing
shackle
Notes
a A
towing r ope
should not be con
nected to
any position
other than
as
descr ibed above
b Avoid
applying
load
suddenly
toa
towing r ope
as
it
may
cause dam
age
WH13 1
Fig
Gl 18
Fr onttowingpoint
Fig
0119 Rear towing point
GI 7
Manual tr ansmission
Befor e
towing
make
sur e
the tr ans
missionisinneutr al
gear
Ifthe r ear axle or
tr ansmission is
inoper ative
the
vehicle should be
towed
with
its
r ear
wheels offthe
gr ound
or the
pr opeller
shaft must be
r e l1oved
Automatictr ansmission
When the vehicle
is towed on its
r ear wheels make
sur e the tr ans
mission
is in N
Neutr al
position
Dont exceed 3 0km
h 20
MPH
and a
distance of
Hikin
6
miles Ifther ear
axle or tr ansmission
is
inoper ative
or
ifthe
speed
exceed the above condi
tions
the
vehicle must be towed with
its
r ear
wheels offthe
gr ound
or
the
pr opeller
shaft must be
r emoved
Note When the
vehicle is towedwith
its fr ont wheels
onthe
gr ound
the
steer ing
wheel
shouId be
secur ed
to
maintain a
str aight
ahead
position
TIE DOWN
The fr ont two
tie
down
hooks
ar e
located
under
the
1st cr osSInember
The hook
is
available as
a
towing
hook For r ear
tie down the r ear leaf
spr ing
shackle be used lIDs
point
is
alsoused
as a
towing point
Gener al Infor mation
APPROXIMATE REFILL CAPACITIES
I
Uter us
measur e
Imper
measur e
Fuel tank
I
45 J IUi
gal
9
Ji
gal
Cooling system
ManUal tr ansmission
I
8
0J
I
8Jiqt
7
qt
withheater
Automatictr smission
I
7
8J
I
8Y
qt
6Jiqt
Engine
lubr ication with
oil
f1lter
I
4
3 J
I
4Ji
qt
3
qt
system
without
oil f1lter
I
3
8J
I
3 Xqt
4
ql
I
4
speed tr ansmission
I
1
7J
I
3 X
pl
3
pI
Manual tr ansmission
I
5
speed
tr ansmission
I
2 0
I
4Y
pt 3 Mpt
Automatictr ansmission
I
5sJ
I
5Uqt 4Uqt
Steer ing
gear
box
I
03 3 J
I
pt pt
Differ ential
car r ier
I
10J
I
2M
pI
I
pt
RECOMMENDED FUEL
Use
an unleaded or lowlead
gasoline witha minimumoctane
r ating
of91
RON Resear ch
Octane
Nuniber
For Califor nia
models use
only
unleaded
gasoline
to
pr otect
the
catalytic
conver ter fr om contamina
tion
RECOMMENDED
LUBRICANTS
RECOMMENDED SAE
VISCOSITY
NUMBER
C
ENGINE
on
12O IIO 10Vt4ll 10Wf 2
I
ICWII
ao 40
J
SAE 5W20
oils
atenot lecom
mended for sustained
high speed
dr ivin
GEAR On
I
J
w
c
3 0 20 0
20 40 60 80 100
Temper atur e
Range
Anticipated
Befor e
Next Oil
Change
OF
GI 8
Gener al
Infor mation
LUBRICANT SPECIFICATIONS
Item
Specifications
Remar ks
SAE Classification
Fur ther mor e r efer to
Gasoline
engine
oil
SD
or
SE
SAE
r ecommended
viscosity
table See
Poge
GI
B
Tr ansmission
and API GL 4
0
steer ing
Differ ential
API GL S
Automatic
TIM
fluid
Type
DEXRON
Multipur pose
gr ea
NLGI2
lithium
soap
base
Br ake and
clutch fluid DOT
3
Per manent anti
fr eeze
Antifr eeze
Ethylene glycol
ba e
GI 9
DATSUN PICK
UP
MODEL
620
SERIES
I
NISSAN
I
NISSAN MOTOR CO
LTD
TOKYO JAPAN
SECTION ET
ENGINE
TUNE UP
ENGINE TUNE UP
ET 2
BASIC
MECHANICAL SySTEM
ET 7
IGNITION
AND
FUEL
SYSTEM
EMISSION CONTROL SYSTEM
ET
13
SERVICE
DATA AND
ET
25
SPECIFICATIONS
TROUBLE DIAGNOSES AND
CORRECTIONS
ET 9
H
27
Engine
Tune
up
ENGINE
TUNE UP
CONTENTS
LOCATION OF
EMISSION
CONTROL
SYSTEM COMPONENTS
INon
Califor nia models
LOCATION OF EMISSION CONTROL
SYSTEM
COMPONENTS Califor nia
models
ET 2
EMISSION
CONTROL
SYSTEM PIPING
lNonCalifor nia
models
EMISSION
CONTROL
SYSTEM
PIPING
Califor nia
models
EMISSION CONTROL DEVICES
ET 3
LOCATION OF EMISSION CONTROL SYSTEM COMPONENTS
Non Califor nia
models
I
Ther mal
vacuum valve
2
Check valve
3
Air
galler y
pipe
4Auto
choke
5
Automatic
temper atur e contr ol air
cleaner
6 Anti
Backfir e valve AB
valve
7
Bo05t Contr olled
Deceler ation Device 8
C
D
D
8 PCV
valve
9 Air
r eliefvalve
10 E
GR contr ol
valve
11
Air
pump
air
cleaner
12
Car bon
canister
13
Air
pump
14
Spar k delay
valve
AfT models
j
ET 4
ET
5
ET 6
6
7
@
9
ET3 65
Fig
ET
l Location
of
emaioncontr ol
sy
ter n
component
Non
Califor nia mod I
ET 2
Engine
Tune
up
LOCATION
OF EMISSION
CONTROL SYSTEM COMPONENTS
Califor nia
models
8
7
8
cv
@
1 Thennal vacuum
valve
2 Check
valve
3 Altitude
compensator in
air
cleaner
4Air
galler y pipe
5
Auto choke qj
6 Automatic
temper atur e
contr ol
air
cleaner
7
AntiBackfir evalve
A
B valve
8 Boost Contr olled Deceler ation
Device BCD
O
9 P C
V
valve
10
Air r eliefvalve
11
E G
R
contr ol valve
12 6C
D D contr ol valveand
solenoid
valve
13
Emer gency
air
r elief
valve
14Air
pump
air cleaner
IS Car boncanister
16 Air
contr ol
valve
17 Air
pump
ET3 66
Fig
ET 2 Location
01
emiuion contr ol
sydem
component
Califor nia
mod a
ET3
r
Engine
Tune
up
EMISSION CONTROL
SYSTEM PIPING
Non
Califor nia
models
1 Vacuum tube to
distr ibutor
yellow
2
Vacuum tube to
car bon canister
yeUow
3 Vacuum tube to
ther maJvaCuumvalve
white
4Vacuum tube
5
Vacuum tube tocar bur etor
yellow
6 Ther mal vacuum
valve toE G
R
contr ol
valve white
7 Vacuum tube to
car bur etor white
8 AB
valve
to
vacuumconnector
gr een
9 Vacuum tube
to
car bon
canister
yellow
10 S
D V
todistr ibutor yellow
11 Vacuum tubeto
S D
V
yellow
ET3 67
Fig
ET
3
Emi8ion
contr ol8
stempiping
Non Califor nia
models
ET 4
Engine
Tune
up
EMISSION
CONTROL
SYSTEM PIPING
Califor nia
models
1
Vacuum
tube todistr ibutor
yellow
2
Vacuum
tube
to
car bon canister
yellow
3 Ther mal
Vacuumvalve toE G
R
contr ol
valve white
4Vacuum
tube to
ther mal vacuumvalve
white
5
Vacuumtube
6 Vacuumtube
to
car bur etor
yellow
7
Vacuum
hose
connector tointake manifold
gr een
8
Vacuumtube
to
car bur etor white
9
Air con
tr ovalve tovacuum hose
connector
gr een
10
AB
valve
to
vacuum
connector
gr een
11 D CD D
tocontr ol valve white
12
B
C
D D contr ol
valve
tointake manifold
gr een
13 Vacuumhose connector
toE
AR
contr ol
valve
gr een
14
D
CD
D
contr ol valve
toair
pump
air
cleaner
ET3 68
Fig
ET 4
Emission contr ol
systempiping Califor niamodels
ET5
EMISSION
CONTROL
DEVICES
Enj
Jn
illUde
I
I
AI4
I
L20H
I
11210
FlU
620
NOll
Califor
Non
aUfon
C
hfor
C
lifomla
lIIodch
EJ
LlPI
Canada
models
Cilnada
Califor nIa
Non
CaliflJl
model
for C
anada
models
Except
modcb
r llodet
Canada
I
M
T
I
AlT
I
M
T
I
AlT
I
M
T
I
A
T
MT
MT
I
AfT
M
T
I
AfT
I
A
T
C
Jtr c1cancr
wllh l1r
numn
r clir fvalvc
I
I
I
X
I
X
I
X
I
X
I
X
I
X
I
I
1
X
I
I
A
T
e
lliT
dl
1er
wilh
l4t
air
llUlilpr Cn
r v
I
wflh
tlitlji Jc
m1JC
ill
i
l
I
I
I
X
I
I
I
I
I
I
AIR
CLEANER
I
A
T
e
air
deaner
with
air
PUlnt
r elicI
valve
wilh
iltitudc
compcn
alor
valvel
1
I
I
I
X
I
X
I
I
I
hlle
comDenlator
duallvQe
X
X
X
I
X
I
X
X
X
X
X
I
X
X
I
X
I
X
F
lh
air
due
fo
intr oducinil
ullidc
air
I
X
I
X
I
X
I
X
I
X
I
X
X
I
X
I
X
I
X
1
X
I
X
I
X
ENGINE
I
Ear ly
fuclcvupor atlYe
sYltem
exhaust
hcalm
I
X
I
X
I
X
I
X
I
X
I
X
X
I
I
X
I
X
I
X
I
X
X
PROPER
X
P
T
C
auluchnkc
I
I
X
1
X
I
X
I
X
X
X
I
X
X
X
I
X
X
X
I
a
c
OO
with
l
onlr ol
lIve
I
I
I
I
I
I
I
X
X
CARBURETOR
I
8
C
D
0
without
contr ol
valve
contr ol
valve
attached
to
body
I
I
I
I
X
I
X
m
Thr oltle
o
ncr
with
contr ol
val
l
X
X
X
X
X
X
X
l
Onlhoot
I
X
I
X
I
X
I
X
I
X
X
X
I
X
I
X
X
I
X
I
X
X
c
I
Altitude
c
Jmpcmalor
with
pipe
fo
UIC
in
air
bleed
I
X
I
X
I
I
I
I
X
I
X
I
X
0n
tr anmlor
unIt
Oiltr ibulor
II
olck
UD
I
X
I
X
I
I
I
I
X
I
I
X
I
X
I
IGNITION
T
C
S
ISwilchin
valve
I
m
d
llI11OfCuioll
Cl
1J1
TO
l
X
X
X
X
I
X
X
X
I
j
x
SYSTEM
I
S
D
V
Sn ar kdelayvalvc
I
I
I
X
I
I
I
I
I
T
V
V
Ther mal
vlcuum a
vc
r
c
s
I
X
I
X
I
X
I
X
I
X
I
X
X
X
I
X
I
I
I
I
Air
pump
AlP
all
cleaner
Ched
valve
A
B
vlllvc
I
X
X
I
X
I
X
I
X
I
X
X
X
I
X
X
I
X
X
I
X
1
C
A
t
valve
fAir
eonlr ol
valve
E
A
R
valve
Rcliefvalvel
X
X
I
X
I
AI
S
I
Air conlr ot
valve
I
I
I
I
X
I
X
I
E
A
R
valve
I
I
I
I
X
I
X
I
Rclier valvc
I
I
X
I
X
I
X
I
X
X
I
X
I
X
I
X
X
I
X
r
E
G
R
VUIVllID
P
T
svstem
I
X
X
I
X
I
X
I
I
X
X
E
G
R
LG
R
v
lvr
Ive
sv
tem
I
I
X
I
X
I
I
X
X
I
X
X
I
X
SYSTEM
fTher mal
acuum
valve
E
C
R
X
X
I
X
I
X
I
X
X
X
X
I
X
I
X
I
X
X
I
X
T
CJ
ITon
cut
E
G
R
I
I
I
X
I
I
I
X
I
I
Wamin
device
el
r y
12
500
mile
maintenance
I
I
I
I
I
I
I
I
I
X
I
X
CATALYZER
e
lalvIIC
ln
r ler
X
X
I
I
I
I
X
I
I
I
X
I
X
Fluor
h
mocr atur e
waminl
5Vllcm
with
noor
ICnlor
I
X
X
I
I
I
I
X
I
I
I
X
I
X
Newly
equipped
unit
1917
models
Remar k
X
Available
Not
available
M
T
AlT A
T
C
PT
Ch
T
V
V
C
A
C
Maouallr ammln
Automallctunsmls
Automatic
temper atur e
contr ol
Positive
temper atur e
cod icll
nt
Ther mal
vacuum
valve
Combined
oLir
contr ol
8
C
0
D
T
C
S
S
D
V
T
C
E
B
P
T
V
c
Boolt
contr olled
deceler ation
dov
Tr an
mlu
contr olled
vacuum
advam
system
Spar k
delay
valve
Tr ansmlSl
ulI
contr olled
exhausl
gu
r ecnculltlOn
1
lIem
Back
pr euur e
nansduce
Vacuum
AJ
S
A
B
vlllve
E
A
R
V
Jlvc
E
C
R
V
O
V
T
C
E
AHmjcL
Anu
b
H
ktiu
alvc
Emer
cncy
r elief
alvc
E
dlllu
ll
r
r
ula
Vacuum
dclay
11Ie
Tup
E
G
R
El
l
epl
t
or Canuda
lIIIII
m
J
C
r
l
l
cJlc
0
Engine
Tune
up
BASICMECHANICAL
SYSTEM
ADJUSTING INTAKE
AND EXHAUST
VALVE CLEARANCE
CHECKING AND
ADJUSTING
DRIVE
BELT
RETIGHTENING
CYLINDER HEAD BOLTS
MANIFOLD NUTS AND CARBURETOR
SECURING NUTS
CHECKING ENGINE OIL
REPLACING OIL FILTER
CHANGING ENGINE
COOLANT
ADJUSTINGINTAKE
AND
EXHAUST
VALVE CLEARANCE
Note After
tightening cylinder
head
bolts
adjust
intake
and exhaust
valve clear ances
Valve
clear ance
adjustment
is
impossible
whenthe
engine
is in
oper
ation
1 Loosen
pivot locking
nut and
tur n
pivot
scr ew
until the
specified
clear anceis obtained whilecold
Using
ser vice
tool
tighten
pivot
locking
nut
secur ely
after
adjustment
and r echeckthe clear ance
2 War m
upengine
for at least
sever al
minutes
and
stop
it Measur e
valve clear ance while hot Ifout of
specifications adjust
Unit mm in
Intake 0
20
0
008
Cold
Exhaust
0
25 0
010
Intake 0
25
OmO
Wann
I
Exhaust
03 0
0
012
STl 064000
I
ET009
Fig
ET
5
Adjusting
valve
clear ance
CONTENTS
ET 7
PERMANENT ANTI FREEZE
COOLANT
CHECKING COOLING
SYSTEM HOSES
AND CONNECTIONS
INSPECTION OF
RADIATOR
CAP
COOLING SYSTEM PRESSURE TEST
CHECKING VACUUM
FITTINGS
HOSES
AND CONNECTIONS
CHECKING ENGINE COMPRESSION
COMPRESSION PRESSURE TEST
TEST RESULT
ET 7
ET7
ET B
ET
B
ET B
CHECKINGAND
ADJUSTING
DRIVE
BELT
ET
B
ET
B
ET B
ET
B
ET
B
ET 9
ET 9
ET 9
2
Nor mal dr ive belt deflection
is
8
to
12 mm
03 15 to
0472
in when
moder ate thumb
pr essur e
is
applied
midway
between
pulleys
1 Check for
cr acks
or
damage
Re
place
if
necessar y
Compr essor pulley
8 to12
mm 0
3 15to0472
in
Idler
pulley
Water
pumppulley
8 to12
mm
0 3 15 to
0472in
Air
pump
pulley
Alter nator
AC456
Fig
ET 6
Dr iue
belt tension
RETIGHTENING
CYLINDER HEAD
BOLTS MANIFOLD
NUTS AND
CARBURETOR
SECURING
NUTS
Tightening tor que
Cylinder
head bolts
1st
tur n
4
0
kg
m 29 ft Ib
2nd tur n
6 0
kg
m
43 ft Ib
3 r d tur n
65to
85
kg
m
47
to
61 ft lb
Refer tothe
following
tightening
tor quespecifications
ET 7
r
ManifolJ nuts
I
2
to16
kg
m
8
7 to
I
6 ft lb
Car bur elor nuls
05
to10
kg
m
3
6 to72fltb
Fig
ET 7 Tightening
s
quence
CHECKING
ENGINE
OIL
Check if
oil is diluled with
water
or
gasoline
Dr ain
and r efill
oil if
necessar y
Notes
a
A
milky
oil indicates
the
pr esence
of
cooling
water
Isolate the cause
and take cor r ectivemeasur e
b An oil with
extr emely
low
viscosity
indicates dilution
with
gasoline
2 Check oil
level Ifbelow the
specified
level
r aise
it
up
10 the H
level
Engine
oil
capacity
including
oil
filter
MaximumH
leven
43 liter s
4
MUS qt
3 Y
Impqt
Minimum
L
level
33 liter s
3
fUS
qt
2U
Imp
ql
REPLACING
OIL
FILTER
The oil
mter is
a
car tr idge
type
and
can
be r emoved
using
Oil Filter
Wr enchSTI93 20000
I Check for oil leaks
past
gasketed
flange
If
leakage
is
found
r etighten
just
enough
to
stop
leakage
If
r etight
ening
is
no
longer
effective
r eplace
mter as
an
assembly
Engine
Tune
up
2 When
installing
oil
filter
tighlen
by
hand
Note Do
not
over tighten
oil
flIt
lest
leakage
should occur
CHANGING
ENGINE
COOLANT
PERMANENT ANTI FREEZE
COOLANT
Per manent
anti
fr eeze
coolant is an
ethylene glycol
base
pr oducl
conlain
ing
chemical
inhibilor s 10
pr otect
the
cooling systemagainst
cor r osion
The anti
fr eeze does not contain
any
glycer ine
ethyl or methyl
alcohol
It will not
evapor ate
or boil
away
and
can be used
with either
high
or low
temper atur ethennoslat
It
flows
fr eely
tr ansfer s heat
effi
ciently
and
will
not
clog passages
in
the
cooling
system
The antifr eeze must not be
mixed
with
other
pr oducts
This coolant can be used
thr ough
out
the
seasonsofthe
year
Whenever
coolant is
changed
the
cooling
syslem
should be flushed and
r efilled with
a
newcoolant
Check the level See the instr uc
lions fur nished
by
the
manufactur er
for the mixtur e
r atio
of
antifr eeze 10
water
CHECKING
COOLING
SYSTEM HOSES
AND CONNECTIONS
Check hoses and
fittings
for loose
connections
or deter ior ation Re
tighten
or
r eplace
if
necessar y
INSPECTION
OF
RADIATOR
CAP
Apply
r efer ence
pr essur e
09
kg
cm2 13
psi1
tor adiator
cap
by
means
of
a
cap
tester to
see ifit
is
satisfactor y Replace capassembly
if
necessar y
ET 8
Fig ET fJ
Teltill l
r odioto
cop
COOLNG
SYSTEM
PRESSURE
TEST
With r adiator
cap
r emoved
apply
r efer ence
pr essur e
1
6
kg
cm2 23
psi
tothe
cooling system
by
means
of
a lesler todetect
any leakage
Water
capacity
Without heater
7 4liter s
7U US
qt
6f
Impqt
With
heater
80liter s
8fUS
qt
7
Imp
qt
CHECKING
VACUUM
FITTINGS HOSES
AND CONNECTIONS
Check thecondition
of
filtings
and
hoses
Retighten
or
r eplace
ifneces
sar y
All vacuumhoses
can be identified
by
color s
Whiteline
Vacuwn
tube tocar bur etor
E
G
R
Tube
Vacuum tube
tother mal vacuum
valve
Thennal vacuum
valve toE
GR
contr ol valve
Yellow
line
Spar k
delay
valve
to
distr ibutor
Spar k delay
valve to
vacuumtube
Distr ibutor
tovacuumtube
Vacuumtube tocar bur etor
Vacuumtube to
canister
Gr eenline
Anti
backfir e valve to
intake mani
fold
Air
contr ol valve to
emer gency
air
r eliefvalve
Intake manifold to
vacuum hose
connector
Intake
manifold to
canister
CHECKING ENGINE
COMPRESSION
COMPRESSION
PRESSURE
TEST
I War m
upengine
sufficiently
2
Disconnect
all
spar k
plugs
3 Disconnect
anti
dieseling
solenoid
valve connector
4
Pr oper ly
attach
a
compr ession
tester
to
spar k
plug
hole in
cylinder
being
tested
Engine
Tune
up
I
ET010
Differ ent
compr ession
in
twoor
mor e
cylinder s usually
indicates
an
impr oper ly
seated
valve or br oken
piston r ing
9 Low
compr ession
in
cylinder s
can
r esult fr om wor n
piston r ings
This
condition
may usually
be
accompanied
by
excessive
fuel
consumption
TEST RESULT
If
compr ession
in
one or
mor e
cylinder s
is low
pour
a small
quantity
of
engine
oil into
cylinder s
thr ough
the
spar k plug
holes and r etest com
pr ession
I
If
adding
oil
incr eases the com
pr ession pr essur e
the chances ar e that
r ings
ar e
faulty
2
If
pr essur e
stays
low
pr obable
cause is
that valve
is
sticking
or
seating
impr oper ly
3
If
cylinder compr ession
in
any
two
adjacent cylinder s
is
low and if
adding
oil does not
help
the
compr es
sian ther e is
leakage past
the
gasket
sur face
Oil and water
in
combustion
cham
ber s
can r esult fr om
leakage
IGNITION AND
FUEL
SYSTEM
Fig
ET 10
Teding
compr ession
pr essur e
5
Depr ess
acceler ator
pedal
to
open
thr ottleand choke valves
Note
Do
not
pump
pedal
6
Star t
engine
as
quickly
as
pos
sible
7
Compr ession pr essur e
kg
cm2
psi
at
r pm
Standar d
120
171
3 50
Minimum
9
0
128
3 50
8
Cylinder compr ession
in
cylinder s
Should not
be less
than
80
of
highest
r eading
CONTENTS
CHECKING
BATTERY
ET 9
CHECKINGDISTRIBUTOR
CAP ROTOR
CHECKINGAND
ADJUSTING IGNITION
AND CONDENSER
ET 11
TIMING ET 10
CONDENSER
ET 11
ADJUSTING IGNITION
TIMING ET10
ADJUSTING
CARBURETOR IDLE RPM
CHECKING
AND REPLACING SPARK PLUG ETlO AND
MIXTURE RATIO
ET
11
CHECKING DISTRIBUTOR OPERATING
IDLE
LIMITER
CAP
ET 12
PARTS AND
IGNITION
WIRING ETlO CHECKING CARBURETOR
RETURN SPRING
ET
12
BREAKER
POINTS
lNon Califor nia
models
ET
10 CHECKING
CHOKE MECHANISM
AI R
GAP lCalifor nia
models ET11 Choke
plate
and
linkage
ET13
DISTRIBUTOR
ET 11 CHECKING
FUEL
LINES
IGNITION WIRING
ET
11 Hoses
pipings
connections
etc
ET 13
REPLACING
FUEL FILTER ET 13
CHECKING BATTERY
Check
electr olyte
level
in
each bat
ter y
cell
I Unscr ew
each
filler
cap
and
inspect
fluid level Ifthe fluid is low
add distilled water to
br ing
the level
upappr oximately
10to20mm
03 9
H9
to
079
in
above the
plates
Donot
over fill
2 Measur e the
specificgr avity
of
batter y electr olyte
p
r
ET002
Fig
E1
11
Checking specificgr avity
ofbotter y
electr olyr e
Clean
top
of
batter y
and
ter minals
with a solution
of
bakin
soda and
Pennissible
value
Fr igid
climates Over
1
22
Tr opical
climates
lOver
1 18
Other climates
lOver
120
CHECKINGAND
ADJUSTING
IGN
ITIONTIM
iNG
AD IUSTING
IGNITION
TIMING
I Check
spar k plugs
and distr ibutor
br eaker
points
for condition
2
Thor oughly
r emove dir t and
dust
fr om
timing
mar k oncr ank
pulley
and
timing
indicator onfr ont cover
3
War in
upengine
sufficiently
4Imtalla timing light
on
No
I
cylinder spar k
plug wir e
and
install a
tachometer
5 Set
idling sper otoappr oxintate
y
750
r pm
6 Check
ignition
timing
with a
timing
light
ifit is
specified
value
If
necessar y
adjust
it
as follows
1
Loosen setscr ew until distr ibu
tor
can be moved
by
hand
2
Adjust
ignition
timing
to
speci
fied value
30
Lock distr ibutor setscr ew
ai1d
make
sur e
that
timing
is cor r ec
Engine
Tune
up
water
Rinse offand
dr y
with com
pr essed
air
Top
of
batter y
must be
clean
to
pr event
cur r ent
leakage
be
tween ter minals and fr om
positive
ter minal
to hold down
clamp
In addition tocur r ent
leakage pr o
longed
accumulation of
acid
and dir t
o
n
topIf
l
l
r y may
ca uiCbli
t
r j Ig
ofthe mater ial
cover ing
connector
str aps
and cor r osion of
str aps
After
tightening
ter minals coat them with
petr olatum
vaseline to
pr otect
them
fr om
cor r osion
Full
char ge
value
at
200C680F
128
123
126
oo
I
ET169
Fig
ET
13
Checking ignition
timing
Ignition
timing
Manual tr ansmission
120
750
r pm
Non
Califor nia models
100 750
r pIll
Califor niamodels
Automatictr ansmission
120
650
r pin
in
0
position
ET 10
CHECKING
ANb
REPLACING
SPARK
PLUG
I
Remove
and clean
plugs
in
asand
blast cleaner
2
Inspect insulator for cr acks or
chips
3
Check both center and
gr ound
electr odes
If
they
ar e
excessively
wor n r e
place with
new
spar k
plugs
4
Spar kplug gap
Br eaker
points
type
0
8to
0 9
mm
003 1to003 5
in
Tr ansistor
ignition
type
10
to
11
mm
003 9to0043
in
Tightening
tor q
15to20
kg
m
11
toA4ft lb
Fig
ET 14
Checking
spar k
plug
point
gap
CHECK
I G
DISTRIBUTOR
OPERATING
PARTS
AND
1
lr I9N
WIRING
BREAKER
POINTS
Non
Califor nia models
Check the distr ibutor br eaker
points
for abnonnal
pitting
and wear
Replace
if
necessar y
Make sur e
they
ar e
pr oper ly
aligned
and that
point
dwell
and
gap
ar e cor r ect Clean and
apply
distr ibutor
gr ease
tothe car n
lobes
Note 00
not
apply gr ease
excessively
Point
gap
0
45 to055 mm
Om8to0022
in
Owell
angle
49 to55
degr ees
EE3 22
Fig
ET 15 Checking
diltr ibutor
point
gap
AIR GAP
Califor nia models
For
inspection pr ocedur es
and
r efer ence data r efer
tothe
topic
Air
Gap
in
Section
EE
page
EE 29
DISTRIBUTOR
Check
centr ifugal
advance
unit
for
loose
connection or
impr oper
oper a
tion Ifit is not
oper ating pr oper ly
the
pr oblem
may
be
due
toa
sticky
spr ing
or excessively
wor n
par ts
This
oper ation
needs adistr ibutor
tester
For
inspection pr ocedur es
and
r ef
er ence
data r efer
to
r elative
topic
under Distr ibutor in
Section
EE
Ifvacuumadvance mechanism
does
not
pr oper ly
oper ate
check
for the
following
items and
cor r ect
the
pr ob
lem
as
r equir ed
1 Check
vacuum inlet for
signs
of
leakage
at
connection If
necessar y
r etighten
or
r eplace
2
Check vacuum diaphr agm
for air
leak
If
necessar y r eplace
diaphr agm
3
Inspect
br eaker
plate
for
smooth
movement
If
plate
does not move smoothly
this
condition could be
due
to
sticky
steel
balls If
necessar y r eplace
br eak
er plateassembly
IGNITION
WIRING
Use
an
ohmmeter tocheck r esist
ance
of
secondar y
cables
Disconnect
cables
fr om
spar k
plugs
and install
a
pr oper
adapter
between cable and
spar k
plug
Remove
distr ibutor cap
and secondar y
cables
as an
assembly
Donot r emove cables
fr om
cap
Check
r esistance ofone
cable
at a
time
Connect
ohmmeter
between
spar k
plug
adapter
and
cor r esponding
elec
tr ade
inside cap
Ifr esistance
is mor e
than
3 0000
ohms r emove
cable fr om
Engine
Tune
up
cap
and
check cable r esistance
only
If
r esistance is still mor e
than
3 0000
ohms
r eplace
cable
assembly
EF125
Checking high
tension
cable
CHECKING
DISTRIBUTOR CAP
ROTOR AND
CONDENSER
Note This
oper ation
is
tobe
per
for med while
checking
distr ibutor
points
Inspect
distr ibutor
cap
for
cr acks
and
flashover
Exter nal sur faces ofall
par ts
of
secondar y system
must be cleaned
to
r educe
possibility
of
voltage
loss All
wir es should be r emoved fr om distr ib
utor
cap
and coil sothat
ter minals
can
be
inspected
and
cleaned Bur ned or
cor r oded ter minals indicate that
wir es
ar e not
fully
seated
which
causes
ar cing
between
end ofwir e and ter
minal When
r eplacing
wir es
in
ter
minaibe
sur e they
ar e
fully
seated
befor e
pushing
r ubber
nipple
down
over tower
Checkdistr ibutor r otor for
damage
and distr ibutor cap
for
cr acks
CONDENSER
I Clean
outlet of
condenser lead
wir e
and check
for
loose setscr ew
Retighten
if
necessar y
2 Check
condenser with a con
denser tester
Condenser
capacity
020 to0
24
IF
Micr o
Far ad
Condenser insulation r esistance
5Mn
Mega
ohms
ADJUSTING
CARBURETOR IDLE
RPM AND MIXTURE
RATIO
Cautions
a On
automatictr ansmission
equip
T 11
ped
models
check should be
per
fonned
in
the
D
position
Be sur e
to
engage
par king
br akeand
tolock both
fr ont and
r ear
wheels
withwheel
chocks
b
Keepyour
foot downon
the
br ake
pedal
while
depr essing
theacceler a
tor
pedal
Other wise
vehicle
sur ges
for war d
danger ously
Notes
a Donot
attempt
toscr ew the idle
adjusting
scew
down
completely
Doing
socould cause
damage
to
tip
which
in
tur n will
tend tocause
malfunctions
b
Ifidle limiter
cap
obstr ucts
pr oper
adjustment
r emove
it
Toinstall idle
limiter
cap
r efer to
Idle Limiter
Cap
c
After
idle
adjustment
has
been
made shift
the lever tothe
N or
P
position
for automatic
tr ans
mission
d When
measur ing
CO
per centage
in
ser t
pr obe
into
tail
pipe
mor e
than
40em
157 in
CO idle
adjustment
with
CD meter
Idle mixtur e
adjustment
r equir es
the use of
a
CO meter
especially
for
Califor nia models
When
pr epar ing
to
adjust
idle
mixtur e it
is
essential
to
have the
meter
thor oughly
war med
up
and
calibr ated
I Checkcar bur etor
pipes
for
pr oper
connection
2
War m
upengine
until
water
tem
per atur e
indicator
points
tothe middle
of
gauge
The
pr ocedur e
towar m
up
engine
is not
specifically
r ecom
mended Either
dr iving
vehicle or
oper
ating engine
at
noload
willbe
good
3
Make
sur e
that water temper a
tur e indicator
points
to
the
middle
Fur ther
keepengine r unning
at
about
2
000
r pm
for about
5 minutes with
out
applying
load to
engine
in
or der to
stabilize
engine
condition Engine
hood should
be
open
4Run
engine
for
about
10minutes
at idling speed Dur ing
this 10
minutes
pr oceeq
as descr ibed i
steps
5
to9
below
5 Remove air hose between 3
way
connector 5
way
connector for Cali
for nia models and
air
check valve
as
shown in
Figur e
ET 17
Plug
the
dis
r
connected
hose
to
pr event
dust
fr om
enter ing
To
air
check
valve
Fig
ET 17 Disconnect air hose
fr om
ojr check valve
6
Race
engine
1 500to2000
r pm
twoor
thr ee timesunder no
load then
r un
engine
for one
minute
at
idling
speed
7
Adjust
thr ottle
adjusting
scr ew
until
engine
is at
specified speed
Engine
speed
Manual tr ansmission
750
r pm
Automatictr ansmission
in D
position
650
r pm
8 Check
ignition
timing
If
neces
sar y
adjust
it to
specifications
This
oper ation
need not be car r ied
out
at
1 600
Ian
1
000
miles
ser vice
Ignitiontiming
Manual
tr ansmission
120 750
r pm
Non
Califor nia
100 750
r pm
Califor nia
Automatictr ansmission
in D
position
120
650
r pm
9
At about 10
minutes after
engine
is
r un at
idling
speed
adjust
idle
adjusting
scr ew
so
that CO
per centage
is at
specified
level
CO
per centage
Manual
tr ansmission
2tI
at
750
r pm
Automatictr ansmission
in
D
position
2t
I at 650
r pm
10
Repeat
pr ocedur es
as descr ibed
in
steps
6
7
and 9 above sothat CO
per centage
is at
specified
level Check
ing
idle
CO in
step
9can be car r ied out
r ight
after
step
7
11
Race
engine
I 500 to2 000
r pm
two
or thr ee
times
under noload
and make sur e that
specified
CO
per
centage
is obtained
Engine
Tune
up
12 Connect air
hose to
air check
valve
If
engine speed
incr eases
r eadjust
it
to
the
specified speed
with
thr ottle
adjusting
scr ew
CO
Idle
adjustment
without
COmeter
IfCO meter is not
available the
following
pr ocedur es
may
be
used
I
Check car bur etor
pipes
for
pr oper
connection
2 Wann
upengine
until water
ter n
per atur e
indicator
points
tothemiddle
of
gauge
The
pr ocedur e
to
war m
up
engine
is
not
specifically
r ecom
mended Either
dr iving
vehicle
or
oper
ating engine
at noload will be
good
3
Make sur e that water
temper atur e
indicator
points
tothemiddle Fur ther
keep
engine
r unning
at about
2000
r pm
for
about
5 minutes
without
applying
load to
engine
in or der to
stabilize
engine
condition
Engine
hood should
be
open
4
Run
engine
for
about
10minutes
at
idling peed
Dur ing
this
10
minutes
pr oceed
as descr ibed in
steps
5
to9below
5
Remove air hose between 3
way
connector
5
way
connector for Cali
for nia
modeis
and air
check valve
shown in
Figur e
ET 17
Plug
the
dis
connected hose
to
pr event
dust fr om
enter ing
6 Race
engine
1
500to
2
000
r pm
twoor
thr ee
times under
noload then
r un
engine
for
one
minute
at
idling
speed
7
Adjust
thr ottle
adjusting
scr ew so
that
engine speeds
ar e as indicated
below
Engine speed
Manual tr ansmission
815
r pm
Automatictr ansmission
in
D
position
670
r pm
8 Check
ignition timing
ifneces
sar y adjust
it
to
the
value
r equir ed by
specifications
This
oper ation
need
not
be car r ied out at
1
600 Ian
1
000
miles
ser vice
9
At about
10 minutes after
engine
is r un at
idling speed adjust
idle
adjusting
scr ew until maximum
r pm
is
obtained
ET 12
10
Repeat pr ocedur es
as descr ibed
in
steps
6
7 and
9
above
until
engine
speed
at best idle mixtur e is
815
r pm
for manual tr ansmission
models and
670
r pm
for automatic
tr ansmission
models
in D
position
Adjustment
in
step
9
can
be
car r ied out
r ight
after
step
7
II
Tur n the idle
adjusting
scr ew
clockwise until
engine speed dr ops
off
below
specified r pm
Engine
speed dr ops
off
Manual
tr ansmission
60to70
r pm
Automatic
tr ansmission
in D
position
15 to25
r pm
12 Connect air
hose
toair check
valve
If
engine speed
incr eases
r eadjust
it
tothe
specified
speed
with
thr ottle
adjusting
scr ew
IDLE LIMITER CAP
Donot r emove thisidle
limiter
cap
unless
necessar y
Ifthis
unit
is
r emoved
it is
necessar y
to
r eadjust
it
at the time of
installation To
adjust
pr oceed as
follows
1
After
adjusting
thr ottle
or
idle
speed adjusting scr ews check to
be
Sur e
that the amount of
CO con
tained in
exhaust
gases
meets
the
established standar d
2
Install idlelimiter
cap
in
position
making
sur e that the
adjusting scr ew
fur ther tur n
1
8 r otation in the
CORICH dir ection
Car bur etor
stopper
3 lSo
ldle
limiter
cap
T
ET03 1
Fig
ET 18
Setting
idlelimiter
cap
CHECKING
CARBURETOR
RETURN
SPRING
Check thr ottle
r etur n
spr ing
for
cr acks
squar ene
s
or
defonnation
if
necessar y
r eplace
witha newone
CHECKING
CHOKE
MECHANISM Choke
plate
and
linkage
1 Check choke
valve and
mech
anism
for fr ee
oper ation
and clean
or
r eplace
if
necessar y
A binding
can
r esult fr om
petr oleum
gum
for mation
onchoke shaft
or
fr om
damage
2
Check bimetal
cover
setting
Index mar k
on
bimetal
cover
is
usually
set
at center
ofscale
Note
Always align
the
index
mar k on
bimetal cover with
the center index
mar konchoke
housing
3
Ever y day
befor e
star ting engine
depr ess
the acceler ator
P
dal
tosee if
chokevalve
is closed
automatically
Ifit fails tobe closed
the
chances
ar e that link movement
is unsmooth
Engine
Tune
up
or
that bimetal
is
out
ofor der Refer
toCar bur etor
in Section EF
CHECKINGFUEL
LINES Hoses
pipings
connections
etc
Check fuel lines for
loose con
nections
cr acks and
deter ior ation
Retighten
loose
connections
and r e
place any
damaged
or
defor med
par ts
REPLACINGFUEL
FILTER
Check
for a
contaminated
filter and
water
deposit
All
engines
use
a
r eplaceable
car tr idge type
fuel filter as an as
sembly
@
Fig
ET
19 Fuel
filler
ET011
EMISSION CONTROL
SYSTEM
CHECKINGCRANKCASE EMISSION
CONTROL
SYSTEM
REPLACING P CV VALVE AND
FILTER
CHECKING
VENTILATION HOSE
CHECKING
EXHAUST MANIFOLD HEAT
CONTROL
VALVE
CHECKINGSPARK
TIMING
CONTROL
SYSTEM
SPARK DELAY
VALVE
Automatic
tr ansmission models
only
INSPECTION
CHECKING
AUTOMATIC
TEMPERATURE
CONTROL
AIR
CLEANER
OPERATING
PRESSURE
OF
BOOST
CONTROLLED
DECELERATION DEVICE
BCD D I
ADJUSTMENT
CHECKING B CDD
CIRCUIT
WITH
FUNCTION
TEST
CONNECTOR
CHECKING
CRANKCASE
EMISSION
CONTROL
SYSTEM
REPLACINGPCV VALVE
AND FILTER
Check
P
C
V
valve
in
accor dance
CONTENTS
ET 13
ET 13
ET 14
ET 14
ET 14
ET 14
ET 15
ET 15
ET
17
ET
17
ADJUSTMENT
OF SET PRESSURE OF
BOOST
CONTROLLED
DECELERATION
DEVICE B
CD
D
CHECKING B CD D SOLENOID VALVE
CHECKING AMPLIFIER Manual
tr ansmission models
REPLACING
AIR PUMP AIR CLEANER
ELEMENT
CHECKING
EXHAUST GAS RECIRCULA
TION E GR CONTROL SYSTEM
CHECKING EVAPORATIVE EMISSION
CONTROL
SYSTEM
CHECKING CATALYTIC CONVERTER
INSPECTION
CHECKING
FLOOR TEMPERATURE
WARNING
SYSTEM
INSPECTION
withthe
following
method
With
engine r unning
at
idle r emove
ventilator ose fr om PC
V
valve If
the valve
is
pr oper ly wor king
a
hissing
ET 13
ET 18
ET 20
ET 20
ET 20
ET 20
ET 22
ET
23
ET 23
ET
23
ET
23
noise will
be
hear d as air
passes
thr ough
the
valve and
a
str ong
vacuum
should be felt
immediately
when
a
finger
is
placed
over valve inlet
Fr esh air
Blow
by
gas
CHECKING
VENTILATION
HOSE
1
Check
hoses and hose connec
tionsfor leaks
2 Disconnect all hoses
and blow
themout with
compr essed
air
If
any
hose
cannot be
fr ee of
obstr uctions
r eplace
Ensur e
that flame
ar r ester is
sur ely
inser ted in
the
hose between air
cleaner and r ocker cover
CHECKINGEXHAUST
MANIFOLD HEAT
CONTROL
VALVE
Run
engine
and
visually
check
counter weight
to
see
ifit
oper ates
pr oper ly
I
For
some
time
after
star ting
engine
in cold
weather
counter weight
tur ns
counter clockwise until
it comes
into
contact
with
stopper
pin
installed
to
exhaust manifold
Counter weight
gr adually
moves
down
clockwise
as
engine war ms
up
and ambient
temper atur e goes higher
ar ound exhaust manifold
2
When
engine speed
is
incr eased
dischar ge pr essur e ofexhaust
gases
causes
counter weight
tomove down
war d
clockwise
Engine
Tune
up
CoOl
1
Oil
level
gauge
2
8affle
pia
te
3
Flamear r ester
4
Filter
5 P C
V valve
6
Steel net
7
Baffle
plate
1fiI
o
EC716
Fig
ET 20
Cr ankcaae emiion
contr ol8
tem
3 When heat
contr ol valve is inthe
full
open
position counter weight
moves fur ther
clockwise
exceeding
the
position
descr ibed
in 1
1
above
and
stops
again coming
into
contact with
stopper
pin
ct
t
C
EC245
1
Counter we ht
2
Stopper pin
3
Heat
contr ol
valve
Fig
ET 21 Cold
oper ation of counte
weigh
t
EC246
1
Counter weight
2
Stopper pin
3 Heat contr ol valve
Fig
ET
22 Hot
oper ation ofcounter
weight
ET
14
2 With
engine
stopped visually
check
E FE
system
for
the
following
items
I
Ther mostat
spr ing
for dismount
ing
2
Stopper
pin
for
bend
and count
er
weight stopposition
for
dislocation
3
Check
heat contr ol
valve for
malfunction
due tobr eak of
key
that
locates
counter weight
tovalve
shaft
4
Check axial clear ance
between
heat contr ol
valve and exhaust mani
fold Cor r ect clear ance is 0 7 to15
mm
0028 to
0059 in
5
Check welded
por tion
of
heat
contr ol
valve and
valve
shaft for
any
indication of
cr ack
or
flaking
6 Rotate heat
contr ol
valve
shaft
with a
fmger
and
check for
binding
between
shaft
and
bushing
in
closing
and
opening oper ation
ofheat contr ol
valve If
any
binding
is felt in
r otating
oper ation
move valve shaft in
the
r otation dir ection sever al times If
this
oper ation
does not
cor r ect
binding
condition it is due
toseizur e between
shaft and
bushing
and
exhaust mani
fold
should be
r eplaced
as an assem
bly
CHECKING
SPARK
TIMINGCONTROL
SYSTEM
This
system
is
installed on non
Califor nia automatic tr ansmission
models
SPARK DELAY
VALVE
Automatictr ansmission
models
only
This valve
delays
vacuum
spar k
advance
dur ing r apid
acceler ation
it
also
cuts
off
the
vacuwn
spar k
advance
imme
iately upon
deceler ation
The
valve
is
designed
for
one
way oper a
tion
and
consists
ofa
one
way
umbr el
la valve and sinter ed steel
fluidic
r estr ictor
Engine
Tune
up
EC284
When
installing
this
valve
ensur e
that it
pr oper ly
or iented
This valve
should be
r eplaced per iodically
Refer
toMaintenance
Schedule
I
To
distr ibut0
Fr om
car bur etor
Yl r
EC278 l
Fig
ET 24Oper ationofspar k delay
value
I
I
Car bur etor side
Distr ibutor side
r JmlL
lr
EC3 46
Fig
ET 25 Checking
spar k delay
value
Distr ibutor
side
Br own
lOneway
umbr ella
valve
2 Sinter ed metal
disc
Fig
ET 23 Spar k delay
valve
INSPECTION
I Remove
spar k delay
valve
2 Blowair
thr ough por t
on
car bur e
tor side
then
thr ough
the
other por t
on distr ibutor side
Spar k delay
valve
is in
good
condition
ifwhen
finger
is
placed
over
por t
on distr ib side
ajr
flow r esistance is
gr eater
than
that
on
the other
side See
Figur e
ET
25
3 Ifa consider able air
flowr esist
ance
is felt at
por t
on distr ibutor side
in
step
2
above
and
ifthe
conditionof
spar k delay
valve
is
questionable
dip
por t
on
car bur etor
side
intoa
cup
fIlled with water Blow
air
thr ough
the
other
por t
Small air bubbles should
appear
EC279
Fig
ET 26
Checking spar k delay
ualue
Note Be
car eful
to
avoid
entr y
ofoil
or dir t into
valve
ET 15
CHECKING
AUTOMATIC
TEMPERATURE
CONTROL
AIR
CLEANER
1
Air cleener element
Viscous
paper type
air cleaner ele
ment does not
r equir e any cleaning
oper a
tion
until
it is
r eplaced per iodi
cally Br ushing
or
blasting oper ation
will
cause
clogging
and
r esult inenr ich
ment
ofcar bur etor mixtur e and
should never
be conducted For r eo
placement
inter val
ofair cleaner ele
ment
r efer
to
Maintenance Schedule
2
Hot
elr contr ol system
In war mwealher
it is difficult to
find
ou
t malfunction
ofhot air contr ol
system
In
cold weather
however
malfunction
ofair contr ol
valve d
e to
disconnection
or deter ior ationofvacu
um
hose between intake manifold and
vacuum motor
and insufficient
dur a
bili
ty
of
air
con
tr ol valve will cause
insufficient
automaticcontr ol
oper a
tion for intake
air and r esult
in
engine
disor der
including
I
Stall or hesitation
of
engine
oper a
tion
2
Incr ease
infuel
consumption
3 Lackof
power
These
phenomena
r eveal malfunc
tionofhot
air contr ol
system
Ifthese
phenomena
should occur check
hot
air contr ol
system
as descr ibed
in
the
following
befor e
car r ying
ou
t
inspec
tionofcar bur etor
21 Vacuum
hoses
Intake
manifold to3
way
connec
tor
3
way
connector
to
temper atur e
sensor
3
way
connector
toidle com
pensator temper atur e
sensor
to
vacu
ummotor
1
Check
that vacuumhoses ar e se
cur ely
connected in
cor r ect
position
2 Check each hose for cr acks or
distor tion
hose
clip
for condition
Note Vacuum hose
position
R R
side
ofNissan mar k
on
the
top
of
sensor
for
intake
manifold
L R
side
of
the
mar k
is for vacuum
r ootor
22
Vacuummotor
I
With
engine stopped
disconnect
fr esh air duct
Place
a mir r or at the
end of
air
cleaner inlet
pipe
as shown and check
tosee if
air
contr ol valve
is in
cor r ect
position
EF213
Fig
ET 27
Impecting
lJalv
position
Air
contr ol valve
is incor r ect
posi
tionifits under hood
air
inlet is
open
and
hot air inlet
is
closed
Check
air
contr ol
valve
linkage
for condition
2
Disconnect
vacuum
motor inlet
vacuum
hose and connect
another
hose
to
the
inlet
to
apply
vacuum
to
vacuum
motor Vacuum
can
be
ap
plied
by
br eathing
in
the hose
end as
shown
Place
a mir r or at
the end of
air
cleaner inlet
pipe
and check
tosee if
air contr ol
valve is
incor r ect
position
Engine
Tune
up
EF217
Fig
ET 28
lmpecting
value
position
Cor r ect
pC6ition
of
air
contr ol valve
is
the
r ever seof
par agr aph
I above Air
contr ol valve
is in cor r ect
position
if
under hood
air inlet is closed and hot
air
inlet
is
open
3 With hot air inlet is
open posi
tion as
descnbed
in
par agr aph
2
above
pinch
vacuumhose with
finger s
and cut ofair fr omvacuum
hose
In
this condition check that
air
contr ol
valve maintains the condition
de
scr ibed in
step
2
for
mor e
than 3 0
seconds and
that
hot air inlet is
open
If
diaphr agm spr ing
actuates
the
air
contr ol valve
by
its
spr ing
for ce
to
open
under hood
air
inlet within 3 0
seconds
r eplace
vacuummotor as an
assembly since
this
may
be r esulted
fr om air
leak
at
vacuum
motor dia
phr agm
2
3
Temper atur e
sensor
Check
temper atur e
sensor for func
tion
by pr oceeding
as follows
Be
sur e
to
keepengine
cold
befor e
star ting
test
1 With
engine
offcheck
air
contr ol
valve for condition Inthiscase under
hood
air
inlet is
open
Use amir r or for
inspection
as 2
21
above
2 Star t
engine
and
keep
idling
Immediately
after
engine
star ting
check
air
contr ol
valve for cor r ect
position
as
descr ibed above
In this
case
cor r ect
position
ofair contr ol
valve is the r ever se of22
1 under
hood
air
inlet
is
closed
and
hot air
inlet is
open
ET
16
3
Check
that air contr ol valve
gr ad
ually
opens
tounder hood
air inlet
side as
engine
war ms
up
When
en
vir onmental
temper atur e
ar ound ter n
per atur e
sensor
is low
spend
mor e
time
for
engine war ming
upoper ation
to
facilitate
smooth
oper a
tion of
air
con
tr ol valve
Ifthe
above
test r eveals
any pr ob
lem
in the
oper ation
ofair contr ol
valve
car r y
out the
following
test
4
Remove
air cleaner cover Set
temper atur e
sensing
element
of
ther
mistor or
ther mometer to
a position
wher e
temper a
tur e
ar ound sensor can
be measur ed Inthiscase
fix
wir ing
of
ther mistor or ther mometer onthe
bot
tom sur face of
air
cleaner
with adhe
sive
tape
in
such amanner
that
the
set
position
of
temper atur e
sensing
ele
ment will
not
be affected
by
air flow
Then
install air cleaner cover
EF221
Fig
ET 29 Checking temper otur e
ensor
5
Car r y
out test
as descr ibed in
steps
I 2
and 3 above When
air
contr ol valve
begins
to
open
tounder
hood air inlet side sever a
minutes
after
engine
star ting
r ead the indica
tion
ofther mistor
or
ther mometer If
r eading
falls within the
wor king
ter n
per atur e
r ange
of
temper atur e
sensor
the sensor
is
nor maL
If
r eading
ex
ceeds the
r ange
r eplace
the
sensor
withnewone
Note
Befor e
r eplacing
temper atur e
sensor
check idle
compensator
as
descr ibed
inSectionEF
page
EF 8
OPERATI NG
PRESSURE OF
BOOST CONTROLLED
DECELERATION
DEVICE BCD
D
ADJUSTMENT
CHECKING
aCD D CIRCUIT
WITHFUNCTION TEST
CONNECTOR
Manual tr ansmission
models
I
Check for
continuity
between
@
and@
at a
speed
ofzer o
km Refer
to
Figur e
ET 3 0
BC
D
D
cir cuit is
functioning
pr oper ly
if
continuity
exists and volt
meter
r eading
is
0 volt d cin
step
2
below
If
continuity
does not
exist check
for disconnected connector
and or
faulty
amplifier speed
detecting
switchor B C
D D solenoid valve
2 Check for
pr esence
of
voltage
acr oss
@
and
@
at a
speed
ofmor e
than 16 km
h
10
MPH Refer to
Figur e
ET 3 1
Conduct
this
test
by
one
of
the
following
two
methods
iRaising
up
r ear
axle
housing
with
stand
2 Chassis
dynamometer
test
Ifvoltmeter
r eading
is
0 volt
at
a
speed
of
mor e than
16
km
h 10
MPH
cir cuit is
functioning pr op
er ly
Ifvoltmeter
r eading
is
not 0
volt
check for disconnected connector
bur ned
fuse
faulty
amplifier
B
CD D
solenoid valve or
speed
detecting
switch
3
If
by
above checks
faulty par t
or
unit is located
it
should be r emoved
and tested
again
If
necessar y
r eplace
Automatictr ansmission
models
I
With inhibitor
switch ON
UN
or P
position
check for
pr esence
of
voltage
acr oss
@
and
@
Refer to
Figur e
ET 3 0
If
voltmeter
r eading
is
12 volts
dc
BCD
D
cir cuit
is
func
tioning pr oper ly
Engine
Tune
up
If
voltmeter
r eading
is
zer ocheck
for
disconnected
connector
faulty
solenoid valve or inhibitor switch
er ly
Ifohmmeter
r eading
is
3 2ohms or
above check for
poor
connection
of
connector
faulty
B
C
D D
sole
noid valve
or inhibitor
r elay
3
If
by
above checks
faulty par t or
unit is
located it should be r emoved
and tested
again
If
necessar y r eplace
2
With
inhibitor
switch OFF
41 2 D or R
position
check for r esistance
between
@
and
@
Refer
to
Figur e
ET 3 1
If
ohmmeter
r eading
is 25 ohms or
below cir cuit is
functioning pr op
l
E
r
1
Ignition
key
2
Fuse
3
Amplifier
4
Speed detecting
switch
Above 10
mph
OFF
Below
10
mph
ON
5
Function test connector
6
B CD D
solenoid
valve
EF711
Fig
ET
3 0
BCD D cir cuit with
function
tedconnectoT
Manual tr ansmission modela
@
1
Ignition
key
2
Inhibitor switch
N P
positions
ON
I 2
D
R
positions
OFF
3 D CD D solenoid valve
4
Function test
connector
5 Inhibitor
r elay
EF712
Fig
ET 3 1
Checking
BCD D cir cuit withfunction
tfst connfctor
Automatictr ansmiMionmodtla
ET 17
r
ADJUSTMENT OFSET
PRESSURE OFBOOST
CONTROLLED
DECELERATION
DEVICE B
CD D
Gener ally
it is
unnecessar y
to
ad
just
the BCD
D however ifit
should
become
necessar y
to
adjust
it
the
pr ocedur e
is
as follows
Pr epar e
the
foUowlnB
tools
I
Tachometer tomeasur e the en
gine
speed
while
idling
and a scr ew
dr iver
2 A
vacuum
gauge connecting pipe
Note A
qui
k
r esponse type
boost
gauge
such as Bour don s
type
is
r ecommended
a
mer cur y
type
manometer should not beused
To
pr oper ly
set the
B
CD
D
set
pr essur e
pr oceed
as
follows
I
Remove
the
har ness
ofsolenoid
valve
TO D D
solenr od
VT
FJ
1
BCD D
solenni
valve har ness
J
r i
y
EF262
Fg
ET
3 2 Removing
har neS5
of
solenoid
valve
2 Connect r ubber hose
between
vacuum
gauge
and intake manifold as
shown
Fig
ET
3 3
Connecting vacuum
gauge
3
War m
up
the
engine
until it is
heated to
oper ating
temper atur e
Then
adjust
the
engine
at nor mal
Engine
Tune
up
idling setting
Refer
tothe
item
Idling Adjustment
in
page
ET II
Idling
engine
speed
Manual tr ansmission
750
r pm
Automatictr ansmission
in
D
position
650
r pm
4
Run the
engine
under no
load
Incr ease
engine speed
to3 000 to
3 500
r pm
then
quickly
closethr ottle
valve
5 At
the
time the
manifold vacuum
pr essur e
incr eases
abr uptly
to 600
mmHg
23
62
inHg
or
above
and
then
gr adually
decr eases tothe level
set at
idling
6 Check that the
BC D D
set
pr es
sur e is withinthe
specified pr essur e
Specified
pr essur e
0m sea level
and
760
mmHg
3 0
inHg
atmos
pher icpr essur e
Manual tr ansmission
510to
550
mmHg
20 1 to 21 7
inHg
Automatictr ansmission
490to53 0
mmHg
19 3 to 20
9
inHg
Note
When
checking
the set
pr essur e
ofBCD D
find the
specified
set
pr essur e
in
Figur e
IT
3 6 fr omthe
atmospher icpr essur e and altitutde
ofthe
given
location
For
example
ifa
manual tr ansmis
sion
model vehicle is
located at
an
altitude
of1 000m
3 280ft the
specified
set
pr eSsur e
for
B
CD D
445
mmHg
17 5
inHg
7
Ifit is
higher
than the set
level
tur n the
adjusting
scr ew
counter
clockwise
or
nut
clockwise until
cor r ect
adjustment
is
made
NonCalifor nia
models
Adjusting
scr ew
type
Califor nia
models
Adjusting
nut
type
Note When
adjusting
BCD D
for
Califor nia
models tur n
adjusting
nut in
or out
with lock
spr ing
in
place
Always
set
lock
spr ing
pr op
er ly to
pr event
changes
inset
pr es
sur e
ET
18
Non califor nia
models
1
Adjusting
scr ew
2
Cover
e
ET03 7
Califor niamodels
r
1
Adjusting
nut
2
Lock
spr ing
EC692
Fig ET 3 4
Adjusting
Bet
pr essur e
8
Race the
engine
and check for
adjustment
9 Ifit is
lower than the set level
tur n the
adjusting
scr ew or
nut until
cor r ect
adjustment
is made
10 Race the
engine
and check for
adjustment
If
engine speed
cannot
be decr eased
to
idling when
checking
BCD D set
pr essur e pr oceed as
follows
When the
engine speed
does
not fall
to
idling speed
it
is
necessar y
to
r educe the
negative
idling
pr essur e
of
the manifold tolower
than the
set
pr essur e
ofthe
B
C
D
D The
engine
speed
will not
dr op
to
idling speed
when the
negative idling pr essur e
is
higher
than the
set
pr essur e
of
the
B
C D D
In
this case the
engine
must be
labor ed
by I
r oad test or 2 chassis
dynamometer
or 3
by r aising up
r ear
suspension
member
on a
stand accel
er ating
the vehicle to64to
80
kr n
h
40
to50 MPH
in
top
gear
manual
tr ansmission or in D
position
auto
matictr ansmission
and then
r eleasing
the acceler ator
pedal
and
letting
the
vehicle
deceler ate After
doing
this
check
whether
the B
CD D set
pr es
sur e is at the
pr edeter mined
value
or
not
Engine
Tune
up
Vacuumgauge
Intake
m
dJi
IRoad te t
Vacuum
gauge
Vacuumgauge
1
2
Otassis
dynamometer
3
Raise
up
r ear
axle
housing by
stand
ET13 3
Fig
ET 3 5
Testing
set
pr essur e
of
the B CD D
mmHg
inHg
inHg mmHg
3 0
24
600
750
23
29
22
28
550
700
21
27
20
26
500
650
25
19
a
a
11
Co
Co
1
24
v
g
18
Co
450
600
8
0
E
0
17
23
16
22
400
550
15
2
0
20
14
3 50
500
13
19
3 00 1
o
1
000 2 000
3 000
4
000
5
000
6
000 ft
o
0
5
10
15
Altitude
2
0
km
EF55B
Fig
ET 3 6
Changes
inset
pr essur e
uer sus
changes
in
atmospher ic
pr e6Sur e
and
altitude
ET 19
r
CHECKING
BC
D D
SOLENOID VALVE
I Tur n on
engine key
Donot star t
engine
2 Ensur e that solenoid valve
clicks
when
inter mittently
electr ified as
shown
in
Figur e
ET 3 7
Fig
ET
3 7
Checking
solenoid uolV l
I
l
EF264
2
Tur n
ignition key
toON
posi
tion
3
Ensur e that tester
pointer
deflects
when
ignitionkey
is
tur ned on
4
If
tester
panter does not deflect
when
solenoid valve
and
speed
detect
ing
switch
cir cuits
ar e
functioning
pr oper ly amplifier
is
faulty
Engine
Tune
up
3 Ifa
click
is
hear d solenoid
valve
is nor mal
4
If
a clickis not hear d
at all check
for
continuity
with a cir cuit
tester If
discontinuity is
detected
r eplace
sole
naid
valve
CHECKING
AMPLIFIER
Manual tr ansmission
models
The
amplifier
is
installed at the
r ear
ofthe
speedometer
To
check
pr oceed
as follows
1 Set cir cuit
tester
in
dc
amper e
r ange
IA
min full scale
connect test
pr obes
oftester as
shown in
Figur e
ET 3 8
Do
not confuse
positive
line
with
negative
line
M
p
1
II
Lo
A
Iof
j
t J
f
T
1
Ignition key
2
Amplifier
3
Speed
detecting
switch
4B
C
D
D
solenoid valve
Fig ET 3 8
Checking
amplifiu
REPLACINGAIR
PUMP AIR CLEANER
ELEMENT
Remove
air
hose then detach
air
cleaner fr om
hoodledge
Air cleaner
element
and
air
cleaner lower
body
ar e
built into
a
unit constr uction
Replace
air
cleaner element and lower
body
as
an
assembly
ET
20
EC3 23
Fig
ET 3 9
Repl4cing
air cleaner
element
CHECKING
EXHAUST
GAS
RECIRCULATION
E G
R
CONTROL
SYSTEM
Checkln
E GR contr ol
system
In Ita
mounted
condition
I
M
ake a
thor ough
visual check of
E
GR contr ol
system
If
necessar y
wipe away
oil to
facilitate
inspection
If
hoses ar e
cr acked or
br oken fe
place
2 With
engine r unning
check
E GR
war ning
system
for
pr oper
function Make sur e
that E
GR war n
ing lamplight
when
ignition
switchis
tur ned toSTART
position
star ter mo
tor r uns IfE G
R
war ning lamp
does
not
light inspect
har nesses and con
nector s or
r eplace war ning lamp
Then
tur n
ignition
switch
to
ON
position
and checkthe
following
items
I
Ifodometer ofdetector dr ive
counter has not r eached
50
000
counts make sur e
that E
GR
war ning
lamp
does
not
light
2
Ifodometer ofdetector dr ive
counter has attained
50
000 counts
make
sur e that
E
G
R
war ning
lamp
lights
If
war ning
lamp
does not
light
check har nesses
connector
and de
tector dr ive counter
r eplace
war ning
lampor detector dr ive
counter if
necessar y
Note
Oper ation
ofE
GR
war ning
lamp
is
as
follows
Ignition
Switch
Position START
Detector Dr ive Counter
E
GR
War ning
Lamp
ON
a After
completing inspection
of
E GR contr ol
system
be sur e to
r eset odometer ofdetector dr ive
counter tozer o
b This
item
applies
to
620 models
except
those
bound for Califor nia
and Canada
3 With
engine
stopped
inspect
E GR
contr ol valve for
any
indication
of
binding
or
sticking by movir ig
dia
phr agm
ofcontr ol
valve
upwar ds
with
fmger s
Engine
Tune
up
ON
Below
50
000counts
Above
50000counts
OFF
ON
4
With
engine
r unning inspect
E GR contr ol valve
and ther mal
vacu
umvalve
for
nor mal
oper ation
I
When
engine
coolant
temper a
tur e is
low
Make sur e that E GR
contr ol valve
does
not
oper ate
when
engine speed
is
incr eased fr om
idling
to3 000
to
3 500
r pm
Place
finger s
on the
diaphr agm
of
E G
R
contr ol valve to
checkfor valve
oper ation
2
When
engine
coolant
temper a
tur e
is
high
I Make sur e that E GR
contr ol valve
oper ates
when
engine
speed
is in
cr eased fr om
idling
to3
000
to
3
500
r pm
Place
finger s
on the
diaphr agm
ofE
G
R
contr ol valve
tocheck for valve
oper ation
2 If
E
G
R
contr ol valve does not
oper ate
check as follows
Disconnect oneend E GR contr ol
valve side ofvacuumhose connect
ing
ther mal vacuumvalve
to
E GR
EC253
Fig
ET 40
Checking
E GR
contr ol valve
contr ol valve
Incr ease
engine speed
fr om
idling to
3
000to3 500
r pm
Make sur e
that ther mal vacuum
valve is
open
and that car bur etor
vacuum is
pr esent
at the end
E GR contr ol valve
side
ofvacu
ur n hose
Ifvacuumis weak or not
pr esent
at
all
r eplace
ther mal vacuumvalve If
vacuum is
pr esent r eplace
E
GR
contr ol
valve
ET 21
EC254
Fig
ET 41
Checking ther mal
vacuum
valw
If
any
difficulty
is encounter ed in
judging
the condition of
any
compo
nent
dur ing
above
inspection
check
the
questionable
component independ
ently
as
follows
E GR contr ol valve
Dismount E GR contr ol valve
fr om
engine
I
Apply
vacuum to
E GR contr ol
valve
r efer r ing
tothe
following figur e
Ifthe valve moves
to
full
position
it is
nor mal
E G
R contr ol
valve will
r emain
open
for
mor e
than 3 0
seconds
after
vacuumhas cut
off
0
r 11
hC
J
ET152
Fig
ET 42
Checking
E GR contr ol
VGlve
2
Visually
check E GR contr ol
valve for
damage
wr inkle or defor ma
tion
3 Clean the
seating
sur face of
E GR contr ol valve
with
a br ush and
compr essed
air
and r emove
for eign
matter fr om ar ound
the
valve
and
por t
rEC3 50
Fig
ET 43
Cleanill l
E GR contr ol
lJ Jlue
Ther mal VBCuumvalve
Dismount
ther mal vacuum valve
fr om
engine
Note Befor e
dismounting
dr ain e
gine
coolant
fr om
engine
Apply
vacuumto
ther mal vacuum
valve and check
tobe sur e that
ther
mal
vacuum valve
opens
or closes
in
r esponse
to
engine
coolant
temper a
lur t
i1 i
iYCl
lt lt U
Ther mal
vacuumvalve should
open
at a
temper atur e
of57 to
63 0C 13 4
to 1450F
completing
the
vacuum
passage
Note
Donot aUow water to
get
inside
thether mal vacuumvalve
EC 242
Fig
ET 44
Checkill lther mallXlCuum
valve
Engine
Tune
up
CHECKING
EVAPORATIVE
EMISSION CONTROL
SYSTEM
Vapor
Rnes
and fuel
vepor
contr ol
valve
Checking
fuel tank
vapor
liquid
separ ator
and
vapor
vent line
I Check
all hoses and
fuel
tank
r oler
cap
2 Disconnect
the
vapor
vent
line
connecting
car bon
canister to
vapor
liquid separ ator
3
Connect a 3way
connector
a
manometer
and a cock or
an
equiva
lent 3way
char ge
cock
to
the
end of
thevent
line
4
Supply
fr esh air
intothe
vapor
vent
line
thr ough
the
cock little
by
little until
pr essur e
becomes
3 68
mmH20 145 inH20
5
Shut
the cock
completely
and
leave
it unattended
6
After
25 minutes
measur e
the
height
of
the
liquid
in
the
manometer
7
Var iation
of
height
should
r emain
with25
mm l20
098inH20
8 When filler cap
does
not close
completely
the
height
should dr op
to
zer o
in
a
shor t
time
9 Ifthe
height
does
not
dr op
to
zer o
in
a
shor t
time when
filler
cap
is
r emoved
it is the
cause
ofa
stuffy
hose
Note In
case
the
vent
line
is stuffy
the br eathing
in
fuel tank
is not
thor oughly
made
thl
causing
in
suffICient
deliver y
offuel to
engine
or
vapor
lock It must ther efor e be
r epair ed
or
r eplaced
3way connectoT
3 6 mmH20
14
5
inH20
c
s
I
W
@
Car bon canister
r
EC786
Fig
ET 45
Checking
evapor ative
emission contr ol
By
tem
Checking
car bon
canister
pur ge
contr ol
valve
Check for fuel
vapor
leakage
inthe
distr ibutor VCline
at
diaphr agm
of
car hon
canister
pur ge
contr ol valve
Tocheck for
leakage
pr oceed
as
follows
1
Disconnect
r ubber
hose in
the
line between T connector and car bon
canister
at
T
connector
2 Inhale air
into
the
opening
of
r ubber hose
r unning
toVChole
in
car bon
canister and ensur e that ther e
is
no
leak
ET
22
I
I
L
I
ET3 49
Fig
ET 46
Checking
car boncaniter
pur ge
contr ol valve
3 Ifther e
is
a leak
r emove
top
cover
fr om
pur ge
contiol valve and
check
for dislocated
or
cmcked dia
phr agm
If
necessar y r eplace
dia
phmgm
kit
which
is made
up
ofa
r etainer
diaphr agm
and
spr ing
I
@
1 Cover
2
Diaphr agm
3 Retainer
4
Diaphr agm spr ing
Fig
ET 47
ET3 50
Car boncaniater
pur ge
contr ol valve
Car bon unlster
filter
Check for a contaminated
element
Element can be r emoved at
the
bottomofcanister
installed onvehicle
body
Fig
ET 48
Replacing
car bon
canister
filter
Fuel tank
vacuum r elief
valve
oper ation
Remove fuel filler
cap
and see
it
functions
pr oper ly
I
Wipe
clean valve
housing
and
have
it in
your
mouth
2
Inhale
air A
slight
r esistance
ac
companied by
valve indicates that
valve is in
good
mechanical condition
Note alsothat
by
fur ther
inhaling
air
the r esistance should
be
disappear ed
withvalve clicks
Engine
Tune
up
3 If
valve
is
clogged
or ifno
r esist
ance
is
felt
r eplace cap
as an assem
bled
unit
r
u
ET3 69
Fig
ET 49 Fuel
filler cap
CHECKING
CATALYTIC
CONVERTER
INSPECTION
Pr eliminar y inspection
Visually
check condition ofall
component
par ts including
hoses
tubes and
wir es
r eplace
if
necessar y
Refer to
Inspection
of
AI
S on
page
EC17
Catalyticconver ter
Whether
catalytic
conver ter
is nOf
mal or not can be checked
by
ob
ser ving
var iation in CO
per centage
The
checking pr ocedur e
is
as follows
Apply par king
br ake Shift
gear s
into
Neutr al for manual
tr ansmission
and Neutr al or Par k
for automatic
tr ansmission
1
Visually
check
catalytic
conver ter
for
damage
or cr acks
2 Remove
air
hose between 5
way
connector and
air
check valve
Plug
the
disconnected hose to
pr event
dust
fr om
enter ing
Refer to
page
ET 12
3 Checkcar bur etor
pipes
for
pr oper
connection
4
War m
up
engine sufficiently
5 Race
engine
1 500to2000
r pm
two
or thr ee
timesunder noload then
r un
engine
for
one
minute at
idling
speed
6
Adjust
thr ottle
adjusting
scr ew
until
engine
attains to
specified speed
Refer to
page
ET 12
7
Check
ignition timing
If
neces
sar y
adjust
it to
specifications
Refer
to
page
ET 10
ET 23
8
Adjust
idle
adjusting
scr ew until
specified
CO
per centage
is
obtained
Refer to
page
ET 12
9
Repeat
the
adjustment pr ocess
as
descr ibed
in
steps
5 to
8 above
until
specified
CO
per centage
is
obtained
Note
Adjustment
in
step
9should be
made ten minutes after
engine
has
war med
up
10 Race
engine 1
500 to2000
r pm
twoor thr eetimes
under
noload
and make
sur e
that
specified
CO
per
centage
is obtained
I 1 Remove
cap
and connect
air
hose toair checkvalve
If
idling
speed
incr eases
r eadjust
it
to
specified
speed
with
thr ottle ad
justing
scr ew
12
War m
upengine
for about four
minutes
at 2000
r pm
under nload
13 Measur e
CO
per centage
at
idling
speed
After
step
12 has been com
pleted
wait
for one
minute befor e
making
CO
per centage
measur ement
14
IfCO
per centage
measur ed in
step
13 is less than 03 the
catalylic
conver ter
is
nor mal
15 IfCO
per centage
measur ed
in
step
13
is
over 03
r echeck AIS
and
r eplace
air
check
valve Then
per for m
inspectionsteps
12
and
13
16 IfCO
per centage
is still
over
0
3 in
step
15
catalytic
conver ter is
malfunctioning Replace catalytic
con
ver ter
CHECKINGFLOOR
TEMPERATURE
WARNING
SYSTEM
INSPECTION
Floor
war ning temper atur e
system
Apply
par ldng
br ake
Shift
gear s
intoNeutr al for
manual
tr ansmission
and Neutr al or Par k
for automatic
tr ansmission
1
Ensur e that floor ter n
per atur e
war ning
lamplights
when
ignition
switch
is
tur ned tothe S
position
Ifnot check
lamp
for bur ned
bul bs
Replace
bulb if
bulb
is bur ned
out
If
bulbis not bur ned tr ace
wir eis
back
to
ignition
switch
Repair
or
r eplace
if
necessar y
2
Be sur e
that
floor
temper atur e
is
cool
below
800C
1760F
befor e
car r ying
out
the
following pr ocedur e
1
Remove r ear seat
2
Ignition
switch is tur ned to
the
Temper atur e
sensing
switch
Temper atur e
war ning lamp
Contact close Off
Contact
open On
Note
Avoid
heating
floor
temper a
tur e
sensing
switchdir ectly
If
lamp
does
not
glow
check floor
temper atur e
sensing
switch connector
for
continuity
witha cir cuit
tester
If
continuity
should
exist
after
heated
sur r ounding
ar eas offloor ter n
r v wnTP
sen cinq SVitch
r eolace tem
per atur e
sensing
switch
If
continuity
does not
exist
tr ace
the
wir ing
back to
r elay
or check the
following step
3
Repair
or
r eplace
wir e
s if
necessar y
Note The floor
temper atur e
sensing
switch
may
be heated
thr ough
the
floor
by
a
pr oper
heater
3 Tur n
ignition
switch tothe IG
position anf
disconnect floor
temper
atur e
sensing
connector The
lamp
should
r emain
on If
not
check floor
40
3
UJ
GJO
Engine
Tune
up
IGU
position
3 Ensur e
that
floor tem
per atur e
war ning
lampgoes
out
4
Heat
sur r ounding
ar eas offloor
temper atur e sensing
switch
with a
pr oper
heater
toensur e that floor
temper atur e war ning
lamp
glows
when
floor
is
heated to
lh
specifications
as
shown
inthe table below
Floor
temper atur e
Below
1050C
22IOF
Above
1050C
2210F
temper atur e r elay
for
continuity
with
a
cir cuit tester
Refer r ing
to
the
following
floor
temper atur e r elay
if
r elay
is nor mal
tr ace
wir e s back to
ignition
switch
Repair
faulty wir ing
Floor
temper atur e
r ela
To
check floor
temper atur e r elay
r emove
it
and
pr oceed
as
follows
1 Check for
continuity
between@
and
@ Continuity
should
exist
Check for
continuity
between
D
and@ Continuity
should exist
Check for
continuity
between
D
and@
Continuity should not
exist
2
Apply
a 12volt doC
acr oss@and
@
to
ensur e that
continuity
exists
between
D and@and
that
continuity
does not between
D
and
@
Iftest
r
I
141
ET
24
r esults donot
satisfy
the above r eo
place
the floor
temper atur e
r elay
When floor
temper atur e
war nln8 lamp
118hts
Check floor
temper atur e
war ning
lamp
I
Open
or
shor t cir cuit in
wir ing
har ness
2
Check fuel
system
with
r egar d
to
the
following
items Refer to
Inspec
tion
ofFuel
System
I Floa
t
level
2
Choke
3
Nor mal
fuel
supply system
Pr ima
r y
and
secondar y
4
Acceler ator
pump
5
Power valve
6
BC
D D
7
Fuel str ainer
8 Air
cleaner
3 Check
ignitionsystem
with
r egar d
to
the
following
items Refer
to
Inspection
of
IgnitionSystem
I
IgnItion
AMI
2
Distr ibutor
3
Ignition
coil
4
High
tension
code
5
Spar k
plug
4
Check
idle CO
adjustment
Refer
to
Inspection
ofIdle
CO
Adjust
r oeoC
Note Even
ifther e is
nothing wr ong
with
engine
war ning lampmay
come on ifvehicle is
being
dr iven
on a
steepslope continuously
in
lower
gear s
at
high engine
speeds
Tofloor
temper atur e
war ning lamp
2 Fr om S
position
3 Fr om
GOt
position
4
Fr om
ignition
switch
5
Tofloor
temper atur e
sensing
switch
EC3 43
Fig
ET 50
Checking floor
temper atur e
r elay
Engine
Tune
up
SERVICE
DATA
AND
SPECIFICATIONS
Ignitiontiming
and
idling
Manual tr ansmission
Automatic
tr ansmission
in D
position
Valve
clear ance
Cold
Intake
Exhaust
Intake
Exhaust
Hot
Belt
tension
Fan
Air
pump
Air
coo
compr essor
Pr essur e
Compr ession
pr essur e
at 3 50
r pm
Standar d
Minimum
Radiator
cap
r elief
pr essur e
Cooling system
Leakage testing pr essur e
Batter y
specific
gr avity
at
200C 680F
Distr ibutor
Point
gap
Air
gap
Dwell
angle
Condenser
capacity
Condenser
insulation
r esistance
Spar k
plug
Gap
degr ee r pm
120 BT D
Cj750 Non
Calif
models
100
BT
D
Cj750
Califor nia models
degr ee r pm
l20B
T
D
Cj650
mm in
mm in
mm
in
mm
in
020 0008
0
25
0010
025 0010
03 0 0
012
mm in
mm
in
mm in
kg
lb
8to12 03 15 to0472
8to12
03 15
to0472
8
to
12 03 15 to
0
472
10
22 is
applied
kg
cm2
psi
kg
em2
psi
kg
em
2
psi
120
171
90
128
0
9
13
kg
cm2
Psi
16
23
1
26
mm
in
mm
in
degr ee
IF
Mil
045to0
55 0
018
to0022
0
2to04
0
008to0
016
490 to
550
020to0
24
5
mm
in
08to09
003 1 to003 5
Br eaker
points
type
1
0to11
003 9
to
0043
Tr ansistor
ignition
type
Checking
CO
per cent
at
idling speed
No
air
Manual tr ansmissionmodel
r pm
Automatic
tr ansmission model
r pm
Adjustment
of
oper ating pr essur e
of
B
CD D
BCD
D
set
pr essur e
Manual
tr ansmission
Automatic
tr ansmission
21
1750
211 650
mmHg
in
Hg
mmHg inHg
510
to550 20
1
to
21 7
490to 53 0 19 3 to209
ET 25
r
Engine
Tune
up
AT
C
air
cleaner
Oper ating
temper atur e OC OF
3 0
to
54
86 to
129
Tightening tor que
Cylinder
head
bolts
1st
tur n
2nd tur n
3 r d tur n
Spar kplugs
kg
m ft b
kg
lll ft lb
kg
m ft lb
kg
m
ft
lb
kg
m
ft lb
kg
m ft
lb
40
29
6
0
43
65
to85 47to
61
12
to
1
6 8
7
to116
0
5
to
10
3 6 to
7
2
1
5 to20 II to14
Manifold nuts
Car bur etor nuts
ET
26
Engine
Tune
up
TROUBLE DIAGNOSES
AND
CORRECTIONS
Condition Pr obable cause
CANNOT CRANK
ENGINE
OR
SLOW
CRANKING
Impr oper gr ade
oil
Dischar ged batter y
Faulty batter y
Loose
fanbelt
Malfunction
in
char ge system
Wir ing
connection
loose in
star ting
cir cuit
Faulty ignition
switch
Faulty
star ler motor
Tr ouble
shooting pr ocedur e
on
star ting
cir cuit
Switchon the
star ting
motor with
light
ON
When
light goes
offor dims
consider ably
a Check
batter y
b Check
connection and
cable
cCheck star ter motor
When
light
stays br ight
Cor r ective action
Replace with
pr oper
gr ade
oiL
Char ge
batter y
Replace
Adjust
Inspect
Cor r ect
Repair
or
r eplace
Repair
or
r eplace
a
Check
wir ing
connection between
batter y
and star ter
motor
b Check
ignition
switch
c
Check star ter motor
ENGINE
WILL CRANK
NORMALLY
BUT
WILL NOT
START
Inthiscase the
following
tr oublecauses
may
exist
but
in
many
cases
ignition
system
or fuel
system
is in
tr ouble
Ignition
system
in tr ouble
Fuel
system
in
tr oubk
Valve mechanismdoes not wor k
pr oper ly
Low
compussion
Tr ouble
shooting
pr ocedur e
Check
spar k plug fir stly
by
following pr ocedur e
Disconnect
high
tension cable fr om one
spar k plug
and hold
it
about 10 mm 03 9
in
fr om the
engine
metal
par t
and cr ank
the
engine
Good
spar k
occur s
Check
spar k plug
b Check
ignition
timing
c
Check fuel
system
d Check
cylinder
compr ession
Check thecur r ent f10 in
pr imar y
cir cuit
Ver y high
cur r ent
Inspect pr imar y
cir cuit for shor t
Check br eaker
poiIit oper ation
except
tr an
sistor
ignitionsystem
No
spar k
occur s
ET
27
Engine
Tune
up
Condition
Pr obable
cause
Lowor no
cur r ent
Ign
tion
system
out of
or der
Bur ned distr ibutor
point
Impr oper
point
gap
Faulty
condenser
Leak at
r otor
cap
and
r otor
Faulty
spar k
plug
Impr oper ignition timing
Faulty ignition
coil
Disconnection
of
high
tension
cable
Loose connection or disconnection in
pr imar y
cir cuit
Fuel
system
out of
or der
Lack offuel
Dir ty
fuel str ainer
Dir ty
or
clogged
fuel
pipe
Fuel
pump
will
not wor k
pr oper ly
Car bur etor
choke willnot wor k
pr oper ly
Impr oper
adjustment
offloat level
Impr oper idling
Dir ty
or
clogged
car bur etor
Clogged
br eather
pip
offuel tank
Malfunctioning
anti
dieseling
solenoid valve
Incor r ect spar le
plug
tightening
or
faulty
gasket
Impr oper gr ade engine
oil or low
viscosity
Incor r ect valve clear ance
Compr ession
leak fr omvalve
seat
Sticky
valve
stem
Weak or
damaged
valve
spr ings
Compr ession
leakat
cylinder
head
gasket
Sticking
or
damaged piston r ing
Wor n
piston
r ing
or
cylinder
Tr ouble ooting
pr ocedur e
Pour
the
engine
oil fr om
plug
hole and then
measur e
cylinder
compr ession
Compr ession
incr eases
Compr ession
does
not
change
Low
comp ion
ET 28
Cor r ective action
Check for loose
ter minal or disconnection
in
pr imar y cir cuit
Check for
bur ned
points
Repair
or
r eplace
Adjust
Replace
Clean
or
r eplace
aean
adjust plug gap
or
r eplace
Adjust
Replace
Replace
Repair
or
r eplace
Supply
Replace
Clean
Repair
or
r eplace
Checkand
adjust
Cor r ect
Adjust
Disassemble
and clean
Repair
and clean
Checkfor
loose ter minal or wir e har ness
Tighten
tonor mal
tor que
or
r eplace gasket
Replace
with
pr oper gr ade
oil
Adjust
Remove
cyljnder
head
and
lap
valves
Cor r ect or
r eplace
valve
and valve
guide
Replace
valve
spr ings
Replace
gasket
Replace piston r ings
Over haul
engine
Malfunctiong
cylinder
or piston r ing
Compr ession
leaks fr om valve
cylinder
head
or head
gasket
Except
tr ansistor
ignition system
Condition
IMPROPER
ENGINE
IDLING
Fuel
system
out of
or der
Low
compr ession
Other s
High engine
idle
speed
Engine
Tune
up
Pr obable cause
Clogged
or
damaged
car bur etor
jets
Incor r ect
idle
adjustment
Clogged
air cleaner filter
Damaged
manifold
gaskets
or car bur etor
insulator
Impr oper
float level
adjustment
Loose
air
hoses or
air
fuel
mixtur e hoses of
car bur etor
Malfunctioning
car bur etor choke
Malfunctioning
anti
backfir evalve
Malfunctioning
automatic
temper atur e
con
tr ol
air
cleaner
Inoper ative
idle
compensator
Car bon
canister
pur ge
linehose
damaged
or
disconnected
Stick E
FE valve
shaft
Incor r ect
valve clear ance
Extr emely
lowr evolution
Faulty
malfunction
ofthe
ignition
system
spar k
plug
high
tension cable br eaker
point ignition
coil
etc
Incor r ect
basic
ignitiontiming
Malfunction
ofchokevalve or
linkage
Malfunction
ofvacuum
motor sensor or
hoses
ofair cleaner
Incor r ect
idle
adjustment
Clogged
air cleaner
fdter
Malfunction
ofidle
compensator
of
air
cleaner
Malfunction
ofE GR
contr ol valve
Loose manifold and
cylinder
head bolts
Dr agged
acceler ator
linkage
Incor r ect idle
adjustment
MalfunctionofB
CDD
system
Malfunction
of
speed
switchand har ness
ET 29
Cor r ective action
Clean or
r eplace
Adjust
Replace
element
Replace gasket
or insulator
Adjust
Check for loose
connections
Check
and
adjust
Check for loose
connection ofvacuumhose
Check
A
r C air
cleaner
Check
for connection ofidle
compensator
hose
or r eplace
idle
compen
tor
Connect
or
r eplace
Repair
Pr eviously
mentioned
Adjust
Adjust
Replace
Adjust
Adjust
Check for loose
hoses
Replace system
com
ponents
ifnecessar y
Adjust
idle
speed
Replace
air
cleaner fdter
Replace
Clean
or
r eplace
Retighten
bolts
Check
and
cor r ect
acceler ator
linkage
Adjust
idle
speed
Check
for loose
vacuum
hose and har ness
connections
Adjust
or
r eplace
if
necessar y
Check for loose connections
Repair
or
r eplace
if
necessar y
Condition
ENGINE POWER
NOT
UP
TO NORMAL
Lowcompr ession
Ignition
system
out
of
or der
Fuel
system
out
of
or der
Air
intake
system
out
of
or der
Emission
contr ol
Over heating
O
cooIing
Other s
Engine
Tune
up
Pr obable cause
Incor r ect
iSnition
timing
Damaged
spar k plugs
Wor ndistr ibutor
points
Malfunctionofchoke
system
Clogged
fuel
pipe
or
floating
valve
Dir ty
or
clogged
fuel str ainer
Fuel
pump
will not wor k
pr oper ly
C10ssed
car bur etor
jets
Malfunctionofaltitude
compensator
CIOJBed
air cleaner
Ail
inhaling
fr om manifold
gasket
or
car bur etor
gasket
Malfunction
of
E GR
valve
Stick E F
E
valve
shaft
Insufficient
coolant
Loose fanbelt
Wor nor oiled fanbelt
Inoper ative
ther mostat
Wor n
water
pump
Clogged
or
leaky
r adiator
Wor n r adiator filler
cap
Ail
in
cooling
system
Impr oper engine
oil
gr ade
Incor r ect
ignition timing
Clossed
car bur etor lean
mixtur e
Disconnected
altitude
compensator
hOlle
Inoper ative
ther mostat
Impr oper
octane fuel
L
j
tir e
pr essur e
Dr agging
br ake
Clutch
slipping
ET
3 0
Cor r ectiveaction
Pr eviously
mentioned
Adjust
Clean
adjust
or
r eplace plull
Dr ess
or
r eplace
points
Alsocheck
condenser
Adj lst
Clean
Replace
Repair
or
r eplace
Disassemble and clean
Check and
r eplace
Replace
element
Replace gasket
Checkand r eplace
Repair
Replenish
Adjust
fanbelt
Replace
Replace
Replace
Flush
r epair
or
r eplace
Replace
Retighten
each
par t
of
cooling system
Replace
with
pr oper
gr ade
oil
Adjust
Over haul car bur etor
Connect
Replace
Replace
with
specified
octane fuel
Inflate
to
specified
pr essur e
Adjust
Adjust
Except
tr ansistor
ignition
system
Condition
NOISY
ENGINE
Car
knocking
Mechanical
knocking
Cr ankshaft
bear ing
Imocking
Connecting
r od
bear ing knocking
Piston
and
cylinder
noise
Piston
pin
noise
Water
pump
noise
Air
pump
noise
Other s
Engine
Tune
up
Pr obable cause
Over loaded
engine
Car bon
knocking
Timing
knocking
Fuel
knocking
Pr eignition
misusing
of
spar k
plug
This
str ong
dull noise incr eases when
engine
is
acceler ated
Tolocate the
place
cause a
misfir e
on
each
cylinder
Ifthe noise
stops
by
the misfir e this
cylinder
gener ates
the
noise
This is a little
higher pitched
noise
than the
cr ankshaft
Imocking
and also
incr eases
when
engine
is acceler ated Cause a misfir e
on
each
cylinder
and ifthe
noisedeminishes
almost
completely
this
cr ankshaft
bear ing
gener ates
thenoise
When
you
hear an
over lapping
metalicnoise
which incr eases
its
magnitude
with the
r evolution
of
engine
and
whichdecr eases as
engine
is war med
up
thisnoise
is caused
by
piston
and cylinder
Tolocate the
place
cause a
misfir e oneach
cylinder
This noise
is
hear ed
at each
highest
and
lowest dead end
of
piston
To
locate
the
place
cause
a
misfir e on
each
cylinder
This
noise
may
be
caused
by
wor n or
damaged
ear ings
or by
the uneven
sur face
ofsliding
par ts
Damaged
air
pump
An impr oper adjustment
ofvalve clear ance
Noise
of
timing
chain
Anexcessive end
play
oncr ankshaft
Noisy
E F
E
valve
shaft
Wear onclutch
pilot
bushing
Note
This noise will be hear ed when
clutch is
disengaged
ET3 1
Cor r ective
action
Use
r ight
gear
indr iving
Disassemble
cylinder
head
and
r emove
car bon
Adjust ignition
timing
Use
specified
octane fuel
Use
specified spar k plug
This
is
caused
by
wor nor
damaged
bear ings
or unevenly
wor n
cr ankshaft Renew
bear ings
and
adjust
or
change
cr ankshaft
Check
lubr ication
system
Same
as the case
ofcr ankshaft
bear ings
This
may
cause an
abnor mal
wear ing
of
cylinder
and lower
compr ession
which in
tur n
will cause a lower out
put power
and
excessive
consumption
ofoil
Over haul
engine
This
may
cause a wear on
piston
pin
or
pistonpin
hole
Renew
piston
and
piston
pin
assembly
Replace
water
pump
witha newone
Repair
or
r eplace
Adjust
Adjust
the
tension ofchain
Disassemble
engine
and r enewmain bear ing
Repair
Renew
bush
and
adjust
dr ive shaft
Condition
ABNORMAL
COMBUSTION
backfue after flr e
r unon
etc
Impr oper
ignition
timing
Fuel
system
out of
or der
Faulty cylinder
head etc
Other s
EXCESSIVE OIL
CONSUMPTION
Oilloak
Excessi looil
consumption
Other s
Engine
Tune
up
pr obable
cause
Impr oper
ignition
timing
Impr oper
heat
r ange
of
spar k
plugs
Damaged
car bur etor
or
manifold
gasket
backfue after fir e
Clol l
ed
car bur etor
jet
Impr oper
function
of
the
float
Uneven
idling
Runon
Impr oper ly adjusted
B
CD
D
set
pr essur e
Malfunction ofanti
dieseling
solenoid
valve
Malfunctionof auio choke
Impr oper ly
adjusted
valve clear ance
Excess car bon
in
combustion
chamber
Damaged
valve
spr ing backfir e
after flr e
Malfunction
of
AT
C
air
cleaner
Inoper ative
ar iti backfue valve
Loose
oil dr ain
plug
Loose
or damaged
oil
pangasket
Loose or
damaged
chain
cover
gasket
Wor n oil
seal infr ont
and r ear ofcr ankshaft
Loose or
damaged
locker cover
gasket
Impr oper
tightening
ofoil
filter
Loose or
damaged
oil
pr essur e
switch
Cylinder
and
pioton
wear
Impr oper
location
of
piston
r ing
gap
or
r ever sely
assembled
pistonr ing
Damage piston
r ings
Wor n
piston
r ing gr oove
and
r ing
Fatigue
ofvalve oil seal
lip
Wor nvalve
stem
Inadequate quality
of
engine
oil
Engine
over heat
ET3 2
Cor r ective
action
Adjust ignition timing
Use
specified spar k
plugs
Replace
them
withnew
par ts
Disassemble car bur etor and check
it
Adjust
the
level and check needle
valve
Adjust
Adjust
Checkor
r eplace
Adjust
Adjust
Remove
head and
get
r id ofcar bon
Replace
it with
a newone
Check for loose vacuum
hoses
Replace
if
necessar y
Replape
Tighten
it
Renew
gasket
or
tighten
it
Renew
gasket
or
tighten
it
Renewoil seal
Renew
gasket
or
tighten
it but not
too
much
Renew
gasket
and
tighten
it withthe
pr oper
tor que
Renewoil
pr essur e
switchor
tighten
it
Over haul
cylinder
and r enew
piston
Remount
piston r ings
Renew
r ings
Repair
or r enew
piston
and
cylinder
Renew
piston
and
pistonr ing
Replace
seal
lip
with
a
newone
Renew
valve or
guide
Use
the
designated
oil
Pr eviously
mentioned
Condition
POOR
FUEL ECONOMY
Se
the
xplanation
ofthepow
r
dec
Oth n
PROBLEM IN
OTHER
FUNCTIONS
D cr
d
oil
p
ssur e
Excessive
wear onthe
sliding
par ts
Scuffing
of
sliding
par ts
Floor
temper atur e
too
high
Califor nia
only
Engine
Tune
up
Pr obable cause
Exceeding idling
r evolution
Inoper ative
acceler ationr ecover y
Fuel
leakage
Malfunction of
B
C
D D
Malfunction of
Ar C
air
cleaner
Inadequate
oil
quality
Over heat
Wor n
oil
pumpr egulator
valve
Functional deter ior ation ofoil
pump
Blocked oil f1lter
Incr eased clear ance
in var ious
sliding par ts
Blocked oil
str ainer
Inoper ative
oil
gauge pr essur e
switch
Oil
pr essur e
decr eases
Impr oper
quality
or contamination of
oil
Damaged
air cleaner
Over heat
or over coal
Impr oper
fuel
mixtur e
Decr ease
ofoil
pr essur e
Insufficient clear ances
Over heat
Impr oper
fuel
mixtur e
Pr oblem
in
fuel
system
Refer to
Inspec
tionofFuel
System
Pr oblem
in
ignition system
Refer to In
spection
of
IgnitionSystem
ET3 3
Cor r ective
action
Adjust
it
tothe
designated r pm
Adjust
it
Repair
or
tighten
the
connection
of
fuel
pipes
Adjust
Check
and
r eplace
Use the
designated
oil
Pr eviously
mentioned
Disassemble oil
pump
and
r epair
or r enew
it
Repair
or
r eplace
it
with
a
newone
Renew
it
Disassemble and
r eplace
the wor n
par ts
with
newones
Oeanit
Replace
it witha newone
Pr eviousiy
mentioned
Exchange
the
oil with
pr oper
one and
change
element
Change
elemen
t
Pr eviously
mentioned
Check thefuel
system
Pr eviously
mentioned
Readjust
tothe
designated
clear ances
Pr eviously
mentioned
Checkthe fuel
system
Checkand
r epair
Checkand
r epair
DATSUN PICK UP
MODEL
620 SERIES
lMlSSAN I
oJ
NISSAN MOTOR
CO
LTD
TOKYO
JAPAN
SECTION
EM
ENGINE
MECHANICAL
GENERAL
DESCRIPTION
ENGINE DISASSEMBLY
INSPECTION
AND REPAIR
ENGINE ASSEMBLY
SERVICE
DATA AND
SPECIFICATIONS
TROUBLE DIAGNOSES
AND
CORRECTIONS
SPECIAL SERVICE TOOLS
EM 2
EM 4
EM 8
EM 21
EM
2l
EM 3 1
EM
3 3
Engine
Mechanical
GENERAL DESCRIPTION
MODEL
L20B
ENGINE
CYLINDER BLOCK
CRANKSHAFT
PISTON
AND CONNECTING
ROD
CYLINDER
HEAD
CONTENTS
EM 2
EM 3
EM 3
EM 3
EM 3
CAMSHAFT
VALVE MECHANISM
CAMSHAFT DRIVE
MANIFOLDS
out smooth
dependable
power
The
cylinder
block is cast as a
single
unit
and
featllr es
deepskir ting
This
engine
is
equipped
with a
single
2
bar r el downdr aft car bur etor that
in
cor por ates
a
special
device to
contr ol
emissions
MODEL L20B
ENGINE
The L20B
engine
featur es O HC
valves
wedge
shaped
combustion
chamber aluminum head and
a
fully
balanced
5
bear ing
cr ankshaft to
tur n
Main
specifications
Oisplacemen
t cc
cu
in
Bor e x str oke
mm in
Compr ession
r atio
Ignition
timing
Degr ee
B
T O
C
r pm
MIT
AlT
MIT
Manual Tr ansmission
EM53 5
Fig
EM Cr osssectional view
L20B
1
952 1191
85
X
86
3
3 5 x 33 9
85
12 750
Non
Califor nia
model
10 750
Califor nia
model
12 650in 0
position
AIT
AutomaticTr ansmission
EM
2
EM 3
EM 3
EM 3
EM 3
CYLINDER BLOCK
The
cylinder
block a monoblock
special
casting
str uctur e
employs
a
five bear ing
suppor t
system
for
quiet
ness
and
higher
dur ability
The
cylinder
bor es ar e sur r ounded
by cooling
jackets
and machined di
r ectly
inthe block The
oil
ways
inthe
block
ar e ar r anged
sothat
the
full flow
oil filter is
dir ectly
attached to
the
r ight
hand side ofthe block
EM53 6
Fig
EM
2 Cylinder
block
CRANKSHAFT
The cr ankshaft
is
a
special
steel
for ging Fully
balanced it tur ns out
smooth
dependable power
at
high
speed
The L20B
engine
uses
eight
balance
weights
Main
bear ings
ar e lubr icated
by
oil
pumped
thr ough
the main
oil
galler y
and the oil
holes which
r unin
par allel
with
cylinder
bor es
Ther e
ar e
oilways
dr illed
in
the
cr ankshaft for the lubr i
cating
oil The
center main
bear ing
is
equipped
with thr ust
washer s
to
take
up
end
thr ust
ofthecr ankshaft
Fig
EM
3
Cr ankshafl
PISTON
AND
CONNECTING ROD
The
pistons
ar e
of
a
special
alumi
num
casting
and
have
str utstocontr ol
ther mal
expansion
two
compr ession
r ings
and
one combined
oil
r ing
The
piston
heads
ar e slightly
dished
The
piston pil1S
ar e a
special
hollow
steel
shaft
They
ar e full
floating
fit tothe
piston
and
pr ess
fit to
the
connecting
r ods
The
connecting
r odsar e ofa
special
for ged
steel Oil
is
spr ayed
to
the
connecting
r od small
ends
thr ough
dr illed
passages
in
the
lar ge
ends of
r od
Oil holes
in
the
connecting
r ods
ar e located soas to
insur e
optimum
lubr icationunder
heavy
load
050
1
o
E
Moao
Fig
EM
4
Pistonand
connecting
r od
CYLINDER HEAD
The
cylinder
head
is
made ofa
light
str ong
aluminum
alloy
with
good
cooling efficiency
it contains
wedge
type
combustion chamber s
A
special
aluminumbr onze valve seat
is
used on
the
intake valve while a heat r esistant
steel valve seat
is installed
on the
exhaust valve
These
par ts
ar e
all hot
pr ess
fitted
EM407
Fig
EM S
Cylinder
head
Engine
Mechanical
CAMSHAFT
The camshaft
is
made
ofa
special
cast
ir on and is located inside the
r ocker cover
Four aluminum
alloy
br ackets
suppor t
it Camshaft
bear ings
ar e
lubr icated fr om oil holes which
lead to
the
main oil
galler y
ofthe
cylinder
head
Concentr ic
passages
ar e dr illed
in
the
fr ont
and
r ear
par ts
ofthe
ear n
shaft
Oil toeach ear n
lobe is
supplied
thr ough
an oil
hole dr illed
inthe base
cir cle ofeach lobe Lubr icant
is
sup
plied
tothe fr ont oil
galler y
fr omthe
2nd
camshaft
bear ing
and to
the
r ear
oil
galler y
fr om
the
3 r d camshaft
bear ing
These
holes on
thebase
cir cle
of
the
lobe
supply
lubr icant tothe
ear n
pad
sur face ofthe r ocker
ar m
and
tothe valve
tip
end The camsfeatur e
a
long over lap pr ofile
tor educe NOx
emission
Fig
EM 6
Camshafl
VALVE MECHANISM
The
valve
system
has
the
pivot type
r ocker
ar ms
that
ar e
activated
dir ectly
by
the ear n
mechanism
thishas
made
its
moving
par ts
consider ably lighter
and
pr ovides
ideal
high speed per for m
ance
Dual
type
valve
spr ings
ar e in
stalled
h
@l
if
Exhaust
Intake EM084
Fig
EM
7 Valve mechanism
EM
3
CAMSHAFT DRIVE
The camshaft
is dr iven
by a
double
r ow r oller chain dr iven
by
the
cr ank
shaft The tension ofthe
chain
is
contr olled
by
a
chain
tcosioner
which
is
oper ated by spr ing
and oil
pr essur e
The r ubber shoe
type
tensioner
damps
vibr ation
of
the
chainand contr ols
its
tension
EM53 7
Fig
EM
8
Chain
dr iving
aystem
MANIFOLDS
The intake manifold is ofan
alumi
numcast
alloy
The exhaust manifold
is
ofa
dual
design
and
incor por ates
a heat contr ol
valve in it The
heal
contr ol valve is
used
to
war mthe
intake manifold
A
plate
is installed on the outer
face ofthe manifold to
dr aw hot
intake
air
out
thr ough
it The
exhaust
pipe
is connected tothe
flanged
sur
face oftheexhaust manifold
Fig
EM
9
Intak and exhaust
manifolds
r
I
I
PRELIMINARY CLEANING AND
INSPECTION
DISASSEMBL Y
PRELIMINARY
CLEANINGAND
INSt
ECTION
Befor e
disassembling
engine
note
the
following
I Fuel
oil or water
may
leak
past
cylinder
head and block Pr ior to
disassembling
check
cylinder
head
1 1lter mal vacuum valve
2 Check
valve
3
Altitude
compensator
in
air cleaner
4Air
galler y pipe
S
Auto choke
6
Automatic
temper atur e
contr ol air
cleaner
7 Anti8ackfir e
valve AB
valve
8 Boost Contr olled
Deceler ation
Device Bee D D
9 Pcv
valve
to Air r eliefvalve
11
E
G
R
contr ol valve
12 B
CD D
contr ol valve and
solenoid valve
13
Emer gency
air
r elief
valve
14
Air
pump
air cleaner
IS Car boncanister
16
Air contr ol
valve
11 Air
pump
Engine
Mechanical
ENGINE
DISASSEMBLY
CONTENTS
EM 4
EM 4
PISTONS AND CONNECTING RODS
CYLINDER
HE
AD
EM 7
EM 7
fr ont
chain
cover oil
pan
and oil
filter
gaskets
lInd cr ankshaft and water
pump
seals for
signs
of
leakage past
their
gasketed
sur faces
2 Check car bur etor
and
fuel
pump
for condition fuel hoses
for
deter ior a
tion cr acks
or
leakage
offuel
past
their
jointed
or
connected
sur faces
Fig
EM
0
Emiuioncontr ol devics
Califor nia
mod 18
E T3 66
3 Remove
car bur etor
air
cleaner
Remove fr esh
air duct
Disconnect hot air duct fr om
air
cleaner
Disconnect air
cleaner to
air
pump
hose at
air
cleaner
Disconnect air
cleanef
tor ocker
cover
hose at r ocker cover
Disconnect
air cIeaner
to
air
con
tr ol
valve hose at air
cleaner Cali
for nia
models
only
Disconnect air
cleaner
toA
B valve
hose at
air
cleaner
Disconnect air
cleaner
to
r elated
par t
vacuumhoses at
air
cleaner
Loosen
air
cleaner band bolt
and
r emove car bur etor air
cleaner as
sembly
fr om
car bur etor
4
Plug
up
car bur etor air
hor n
to
pr event entr y
of
for eign
matter
5
Remove
alter nator dr ive
belt
alter nator and
alter nator br acket
EM 4
6
Remove
air
pump
dr ive
belt
cool
er
compr essor
and
idler
pulley
if
so
equipped
7 Remove star ter motor fr omtr ans
mission
8
Visually
inspect
cylinder
head
cylinder
block
r ocker CNer
fr ont
chain
cover oil
pan
and all other outer
par ts
for oil water and fuel leaks
br eakage or
missing par ts
such
as
bolts
and nuts
9
Check
piping
and electr ical
cir
cuits for deter ior ation
br eakage
fit
tings
discontinuity
or insulation
DISASSEMBLY
To
r emove
engine
fr om vehicle
r efer to
the instr uctions under the
Engine
Removal
and Installation
ER section
I
Remove tr ansmission fr om
en
gine
2
Remove
clutch
assembly
fr om
flywheeL
3
Thor oughly
dr ain
engine
oil and
coolant
by
r emoving
dr ain
plugs
Stor e
engine
oil and
coolant
if
they
ar e
to
be
used
again
4Place
engine assembly
on
engine
stand
I
Remove
cooling
fan
2
Remove
r ight engine
mounting
br acket
3
Remove oil filter with Oil
Filter
Wr ench STI93 20000
4
Remove
oil
pr essur e
swi
tch
5
Install
engine
attachment to
cylinder
block
utilizing
bolt
holes in
alter nator
br acket and
water dr ain
hole
6
Set
engine
onstand
Engine
Attachment
ST05260001
Engine
Stand
ST050I
SOOO
EM410
Fig
EM II
Engine
on
engine
land
Remove
oil
level
gauge
6 Remove
car bur etor
fr om intake
manifold
1
Disconnect cylinder
block
to
PCV valve hose at P CV
valve
2
Disconnect
AB valve toE
G
R
passage
hose
at
E GR
passage
3 Disconnect vacuum tube to
car bur etor
hoses
white and
yellow
at
vacuum
tube
4Disconnect
fuel
hose
fr om
car bur etor
5
Remove dash
pot
br acket fr om
intake manifold
6 Remov
car bur etor
attaching
bolts and
r emove
car bur etor
assembly
and
gasket
7 Disconnect
distr ibutor
high
ten
sion cables
fr om
spar kplugs
8 Disconnect vacuum
hose
fr om
distr ibutor
and
r emove distr ibutor as
sembly
9
Disconnect
fuel
hose fr om
fuel
pump
and
r emove fuel
and
vacuum
hoses
combined
fr om
cylinder
head
10 Remove
fuel
pump
assembly
fr om
cylinder
head
EM412
Fig
EM 12
Removing fuel
pump
IJ Remove
intake and exhaust
manifold
assembly
fr om
cylinder
head
1
Disconnect vacuum hose
fr om
air contr ol valve and r emove
air con
tr ol
valve for Califor nia
and a r hoses
as an assembly
Engine
Mechanical
1 Air contr ol
valve
2 Distr ibutor
EM53 1
Fig
EM 13
Removing
air
contr ol
valve
Califor nio
model
2 Remove car bur etor air
cleaner
br acket
3 Disconnect
vacuum hose fr om
E GRvalve
4Remove check valve fr om air
galler y
pipe
5 Disconnect E GR
tube
fr om
E
G
R
passage
and exhaust manifold
6 Remove
E
G
R
passage
and
E GR
valve
fr om
intake
manifold
I E
G
R
passage
2 E GR tube
Fig
EM 14
EM53 2
Removing
E
G
R
tube
and
passage
7 Remove Fl
C
D
br acket fr om
cylinder
head
if
so
equipped
8
Disconnect vacuum
hoses fr om
ther mal
vacuum
valve
and
r emove
ther mostat
housing
and
gasket
fr om
cylinder
head
EM089
Fig
EM 15
Removing
ther mostat
housing
EM 5
9 Remove
cylinder
block to
P C
V
valve hose
blow
by gas
hose
fr om
cylinder
block
10 Remove
manifold
attaching
bolts and r emove intake
and
exhaust
manifold
assembly
and
gasket
fr om
cylinder
head
Fig
EM 16
Removing
intake and
exhaust
manifold
assembly
11
Remove
intake
and exhaust
manifold
attaching
bolts and
separ ate
intake
manifold
fr om
exhaust
mani
fold
12
Remove air
galler y pipes
fr om
exhaust
manifold
12 Remove
left
engi
e
mounting
br a et
fr om
cylinder
blopk
13 Remove air
pump
and cooler
compr essor
br acket
14 Remove
cr ankshaft
pulley
in
stalling
bolt
and
washer and then
r emove
pulley
with a two
jaw
puller
15 Remove water
pump
assembly
16 Remove r ocker
cover
17
R
emove
spar k plugs
18 Remove fuel
pump
dr ive ear n
19
Remove
camshaft
spr ocket
Refer tothe
following
note
dur ing
oper ation
when
r emoving
camshaft
spr ocket
fr om
engine
installed oncar
EM091
Fig
EM 17
Removing
cammaf
spr ocket
r
28 Remove
cylinder
head
assembly
Use
Cylinder
Head Bolt Wr ench
STl0120000
to
r emove
cylinder
head
bolts Loosen
bolts
fr om
CD
to
@
as
shown
in
Figur e
EM 18
Fig
EM IS
Cylinder head bolt
loosening
equence
Notes When
r emoving
cylinder
heao
fr om
engiJJe
installed
oncar follow
the
instr uctionsbelow
a Tur n cr ankshaft
until No
I
pilton
is at
T D C
on its
compr ession
str oke
b Remove
r ocker Cover and fuel
pump
cTofacilitate
assembling
o
tion
scr ibe 8 mar k
on
timing
c
8in
and
camshaft
spr ocket with
paint
be
for e r emoval
d Loosen camshaft bolt
and r emove
fuel
pump
dr iveear n
e
Suppor t timing
chain
by
utilizing
Chain
Stopper STl7420001 bet
ween
timiilg chains as shown
in
Figur e
EM 19
This 0
per ation
eliminates
the
pr ob
lem of
r ealigning
timing
mar ks
on
timing
chain and cr ankshaft
spr ocket
EM53 8
Fig
EM 19
Suppor ting timing
chain
f
Remove camshaft
spr ocket
g
Loosen
cylinder
head bolts
and
r emove
cylinder
head
Engine
Mechanical
29
Inver t
engine
3 0
Remove oil
pan
and
oil str ainer
EM094
Fig
EM20
Removing
oil tr aintir
and oil
pump
3 1
Remove oil
pump
and
its dr ive
spindle
See
Figur e
EM
20
3 2 Remove fr ont cover
3 3
Remove chain tensioner
and
chainslackside
guide
EM095
Fig
EM 21
Removing
chain ten ioner
and tim
ing
chain
3 4 Remove
timing
chain
See
Figur e
EM
2l
3 5 Remove
oil thr ower cr ankshaft
wonn
gear
and
chaindr ive
spr ocket
Fig
EM 22
Removing
chain dr ive
Pr oc
et
EM 6
3 6 Remove
piston
and
connecting
r od
a
mbly
Extr act
connecting
r od
bear ings keeping
theminor der
I
Fig
EM 23
Removing
pilton
and
connecting
r od aatmb
y
3 7
Remove
flywheel
and
r ear
plate
Be
car eful
not
to
dr op
them
EM415
Fig
EM
24
Removing
flywheel
3 8 Remove main
bear ing caps
Use Cr ankshaft
Main
Bear ing
Cap
Puller KVIOI04ISO
tor emove center
and r ear
main
bear ing
caps Keep
them
inor der
KVIOI04IS0
EM53 9
Fig
EM 25
Removing
r ear
main
bear ing
cap
3 9
Remove twoside seals fr om
r ear
main
bear ing
ca
p
40 Remove
r ear oil
seal
EM103
EM411
Fig
EM 29
Remouingpi
tonpin
Fig
EM 26 Remouing
r ear
oil eal
41 Remove cr ankshaft
42 Remove baffie
plate
and cyl
inder blocknet
Fig
EM 27 Removing baffle plate
and
nel
PISTONS
AND
CONNECTING
RODS
Remove
piston r ings
with a
r ing
r emover
O
EM102
Fig
EM 28
Removing piltonr ings
2 Pr ess
piston
pin
out with
Piston
Pin Pr ess
Stand STl3 03 0001
Engine
Mechanical
3
Keep
disassembled
par ts
inor der
CYLINDER
HEAD
I
Remove valve r ocker
spr ings
Loosen
valve
r ocker
pivot
locknut
and
r emove
r ocker ar m
by pr essing
valve
spr ing
down
Fig
EM 3 D
Removing
r ocker ar r m
2
Remove
locate
plate
and r emove
camshaft
EM105
Fig
EM
3 1 Remouing cammaft
EM
7
Note
Be
car eful
not to
damage
eam
shaft
bear ings
and
ear n lobes
3 Remove
valves
using
Valve Lifter
STl2070000
STl2070000
Fig
EM 3 2
Removing
ualves
Notes
a
Take
car e not to
lose
valve
spr ing
seat oil seal
valve
collet
and valve
r ocker
guide
b
Be sur e
tokeep
camshaft
bear ings
intact
or
the
bear ing
center
is
liable
tocomeout of
alignment
61
8
Exhaust Intake
EM101
Fig
EM 3 3 Value components
r
Engine
Mechanical
INSPECTION
AND REPAIR
PREPARATION FOR INSPECTION
CYLINDER HEAD AND VALVE
CHECKING CYLINDER HEAD MATING
FACE
VALVE ASSEMBLY
VALVE SPRING
ROCKER ARM AND VALVE
ROCKER
PIVOT
VALVE GUIDE
VALVE SEAT INSERTS
CAMSHAFT AND CAMSHAFT
BEARING
CAMSHAFT
BEARING CLEARANCE
VALVE TIMING
CAMSHAFT ALIGNMENT
CYLINDER BLOCK
HOW TO MEASURE
CYLINDER BORE
CYLINDER
BORING
PREPARATION FOR
INSPECTI
N
I
Befor e
cleaning
check
for
signs
ofwater
and oil leaks
in
cylinder
block
and
head
2 Clean oil car bon
deposits
and
sealant fr oman
par ts
Remove
gasket
3 Clean all
oil holes with solvent
and
dr y
with
compr essed
air
Make
sur e
that
they
ar e
not r estr icted
CYLINDER HEAD
AND VALVE
CHECKING CYLINDER
HEAD
MATING
FACE
EM407
Fig
EM
3 4Cylinder head
CONTENTS
EM 8
EM B
EM 8
EM 8
EM 9
EM
lO
EM l0
EM 11
EM
12
EM 12
EM 12
EM 13
EM
13
EM 13
EM 14
PISTONS PISTON PINS AND
PISTON RINGS
CONNECTING ROD
CRANKSHAFT
BUSHING AND BEARING
MEASUREMENT
OF MAIN
BEARING
CLEARANCE
MEASUREMENT
OF
CONNECTING ROD
BEARING CLEARANCE
FITTING
BEARINGS
MISCELLANEOUS COMPONENTS
CRANKSHAFT
AND
CAMSHAFT
SPROCKETS
CHAIN
TENSIONER
AND CHAIN
GUIDE
FLYWHEEL
FRONT COVER AND
REAR OIL SEAL
Note
Never
r emove
camshaft bear
ings
unless
you
have a
Suitable
machine
or
bor ing
Camshaft bear
ing
in line If
you
once r emove
camshaft
bear ings bear ing
center s
will come out
o
alignment
r eo
conditioning
is
ver y
difficult with
out center
bor ings
L Make
a
v
isual check for
cr acks
and flaws
2
Measur e the sur face
of
cylinder
head on
cylinder
block
side
for
war page
If
it is
found tobe
beyond
the
limit
designated
below
r egr ind
the
affected sur face
witha sur face
gr inder
Fig
EM 3 5
Checking cylinder
head
8JJr face
EM 8
Head sur face flatnes
Standar d
less than 005
mm 00020in
O
lmm
0003 9
in
EM 15
EM 16
EM 16
EM 17
EM 17
EM 1B
EM 18
EM
19
EM 19
EM
20
EM 20
EM 20
Maximum
VALVE ASSEMBLY
Check each intake
and exhaust
valve for wor n
damaged
or defor med
valve
caps
or stems
Cor r ect or
r eplace
any
valve that is
faulty
2 Valve
face or valve stem
end
sur face
should be r efaced witha valve
gr inder
10
L
I I
I
EM109
Fig
EM 3 6 Intak and
exhaust valve
dimensions
Engine
Mechanical
Valve
head
diameter
I
In
42
0to
42
2
1
654
to1661
VALVE SPRING
H
1
Check valve
spr ing
for
squar eness
mm
in
Ex 3 50
to3 5
2 13 78
to13 86 using
a steel
squar e
and sur face
plate
In 114
9to
115 2 4524
to
453 5
If
spr ing
is
out of
squar e
mor e than
Valve length
1
6 mm
0
063
in
r eplace
L
mm in
2
Measur e
lhe
fr ee
length
and ten
Ex 1157 to
116
0 4555 to4567
sion of
each
spr ing
If
the
measur ed
Valve stem
diameter
In 7 965
to
7
980
03 13 6 to
0
3 142 value exceeds
specified
limit
r eplace
D
mm in
spr ing
Ex
7 945
to
7
960
03 128 to
03 13 4
Valve
seat
angle
In
4503 0
a
Intake and
Exhaust
Ex 4503 0
EM110
Fig
EM 3 7
Checking
valve ter n
diameter
Spr ing
specifications
Valve
spr ing
fr ee
length
Intake
and exhaust
Outer
Inner
Valve
spr ing
pr essur ed
length
valve
open
Intake and exhaust
Outer
Inner
Valve
spr ing
assembled
height
valve
close
Intake and exhaust
Outer
Inner
EMll1
Fig
EM
3 8
Regr inding
valve
face
Note
When valve head has beenwor n
down to0
5 nun
00197 in in
thickness
r eplace
the valve
Gr inding
allowance for
valve
stem
end sur face
is 0
5 mm 00197
in
or less
mm in
mmlkg
in lb
mmlkg
in
lb
EM 9
I
i
JT
EM112
Fig
EM 3 9
Measur ing spr ing quar eneu
1
EM113
Fig
EM
40Measur ingapr ing
ten ion
49 98
1
968
44
85 1
766
29 5 490 1161
108
245 25 50965156 2
40
0
21 3
1575 47
0
3 5
012
3 1
3 78 27
I
r r
ROCKER ARM AND
VALVE ROCKER PIVOT
Check
pivot
head and
camcontact
and
pivot
contact sur faces ofr ocker
ar m
for
damage
or wear If
damage
is
found
r eplace
them A
faulty pivot
must
be
r eplaced
together
with
its
cor r esponding
r ocker ar m
VALVE GUIDE
Measur e clear ance
between
valve
guide
and valve stem Ifclear ance
exceeds
designated
limit
r eplace
wor n
par ts
or
both
valve and valve
guide
In
this
case
it is
essential todeter mine if
such a
clear ance has been caused
by
a
wor n or
bent valve
stem or by a wor n
valve
guide
Stemto
guide
clear ance
mm
in
Maximumlimit
ofabove
clear ance
mm
in
Engine
Mechanical
Exhaust
8 3 to8 5 dia
0
3 27 to03 3 5
41
3 0
I2JL
12
223
to1223 4
150
04812
to
04817
dia
1
P
Intake
I I
J
10 80
425
S9 0
2
3 23
7
6 to7
8
0299
to0 3 07 dia
1
Unit mm
in
EM572
Fig
EM41
Se11Jice value
guide
In
take
valve Exhaust
valve
0020
to
0053
00008to0
002
As an
emer gency expedient
a
valve
can be
pushed
intovalve
guide
and
moved
tothe
r ight
and
left
If
its
tip
deflects
about
02
mm 00079
in
or
mor e
it indicates that the clear ance
between stem and
guide
exceeds
the
maximum limit of01 mm 0003 9
in
Note Valve should bemoved in
par al
lel with r ocker ar m
Gener ally
a
lar ge
amount ofwear occur sin
this
dir ection
Max allowabledeflection
0 2 mm 0 0079
in
n
r
C1r
3 0mm l18Iin
r
EM115
Fig
EM
42Mea
ur ingclear ance
betweenvalve
ter n
and valve
gu
ide
0
040to
0073
000 6 to
00029
01 0003 9
Replacement of
valve
guide
I
Tor emove old
guides use
a
dr ift
and
a
pr ess
under
a 2ton
pr essur e or
a
hammer
Dr ive
them
out
fr om
combustion
chamber side
towar d r ocker
cover
Heated
cylinder head will facilitate
the
oper ation
2
Ream
cylinder head side
guide
hole at
r oom
temper atur e
10 6
E
e
417
5t
0
m3 l lj
106
Ofl
H
dl7
l
IV
II
Unit mm in
EM116
Fig
EM
43 Valve
guide
hole
Guide
hole
inner
diameter an mm in
For
factor y
standar d
valve
guide
11
985 to
11
996
04718 to0
4723
For ser vice
valve
guide
3
Car efully
pr ess
new valve
guide
into
valve sothat it will fit
smoothly
after
heating
cylinder
head
to150to
2000C
3 02
to
3 920
F
Valve
guide of0
2 mm
0
0079
in
over size
diameter is
available for
ser
vice
as indicated above
Inter fer ence fit ofvalve
guide
to
guide
hole
0027to
0049mm
00011 to0
0019
in
4
Reambor e
with
valve
guide
pr ess
ed in
using
Valve
Guide
Reamer Set
KVIOI03 9S0
EM 10
12
185to12 96
04797 to
04802
Reaming
bor e
8
000to
8
018r nm
03 150 to03 157 in
EM419
Fig
EM
44
Reaming
valve
guide
q
1
I
k
k
lO
i
I
3 7
9 to3 8
1
eel
1492to1500 dis
co
q
0
45 597 to45
613
1795 to1
796 dia
5
Cor r ect
valve
seat sur face with
newvalve
guide
as the axis
VALVE
SEAT INSERTS
Check valve seat
inser ts for
any
evidence
of
pitting
at
valve contact
sur face
and r eseat or r eplace
ifwor n
excessively
Valve seat inser t of05mm 0
0197
in over size is available for
ser vice as
shown below
Intake
Unit mm in
Engine
Mechanical
Fig
EM 45
Cor r ecting
valve
seat
EM573
0
3 2
6
1
283 5 dia
Exhaust
I
I
3 0
U81
dia
17 5
0 295
Unit mm
in
3 7580 to
3 7
596
14795 to14802 dia
Cylinder
head r ece diameter
For
factor y
standar d
inser t
Intake
For
ser vice inser t
For
factor y
standar d
inser t
Exhaust
I
For ser vice
inser t
Inter fer ence
fit
mm
in
Intake
Exhaust
Fig
EM 46 Ser oice valve
seat dimensions
Unit
mm
in
45000
to
45016
1
7717 to
1
7723
45 500 to 45 516
1
7913
to
I 7920
3 7
000to3 7 016
1
4567 to
I 4573
3 7 500to3 7
516 1
4764
toI 4770
0081to0113 0
003 2to00044
0064to0096
00025to0003 8
EM
11
Replacln
valve eat
In er t
1 Old inser t can be r emoved
by
bor ing
it out until
it
collapses
The
machine
depth stop
should
be
set
so
that
bor ing
cannot continue beyond
the bottomface ofthe
inser t
r ecess in
cylinder
head
2
Select
a suitable valve seat
inser t
and
check its outside diameter
3 Machine
cylinder
head r ecess
to
the concentr iccir cles
in
valve
guide
center so
that inser t
will have the
cor r ect fit
4Heat
cylinder
head toa
temper a
tur e of150to
2000C 3 02to3 920F
5 Fit inser t
ensur ing
that
it beds on
the
bottom face of
its
r ecess
and
caulk mor e
than4
points
6
Newly
fitted valve
seats should
be
cut or
gr ound
at
the
specified
dimen
sions
as shown
in
Figur e
EM 47
7
Apply
small amount offine
gr ind
ing
compound
tovalve
contacting
face
and
put
valve
into
guide Lap
valve
against
its seat until
pr oper
valve
seat
ing
is obtained
Remove valve and then
cleanvalve
and
valve sea
1
Intake
Engine
Mechanical
I
600
3 8 1
496I
dia
W
3 9 6 I559Ildia
18
1
6457 dia
45 171l1
Unit
mm in
Exhaust
3 0
3 0
1l811 di
I
3 2
6 283 5 dia
3 46 1
3 622
dia
13 7
1
4567
dia
Unit mm
m
CAMSHAFT
AND
CAMSHAFT BEARING
CAMSHAnBEARING
CLEARANCE
Measur e inside diameter
ofear n
haft
beating
withan
inside dial
gauge
and outside diameter of
camshaft
jour
nal with a micr ometer Ifwear
is
found inside
of
br acket
r eplace
cyl
inder head
assembly
EM121
Fig
EM 47
Standar d value aeat dimensions
EM119
Fig
EM
48
Checking
cam
haft bear ing
Camshaft
jour nal
to
bear ing
clear ance
Standar d
Wear limit
Oil
clear ance mm
in
003 8to0067
00015
to0
0026
0
1
0003 9
Inner diameter ofear n
shaft
bear ing
mm
in
48000to48016
18898to18904
EM
12
VALVE
TIMING
This
diagr am
applies
toall
cyl
inder s
If
any
valve
is found out of
specifications
one
possibility
that
car n lobe
is
wor n or
damaged
This
calls for
r eplacement
of
camshaft
B D
C
EM421
Fig
EM
49
Value timing diagr am
Standar d
Camshaft bend
mm
in
0
02 0
0008
CAMSHAFT
ALIGNMENT
I Check camshaft
camshaft
jour nal
and ear n sur face
for bend
wear
or
damage
If
damage
is
beyond
limits
r eplace
affected
par ts
2 A bend value
is one halfofthe
r eading
obtained
when
camshaft is
tur ned one
full r evolution
with a dial
gauge
applied
to
2nd
and
3 r d
jour nals
Standar d
height
of
tam mm in
I
Intake
1
Exhaust
Wear
limit ofear n
height
mm
in
Allo
able differ ence
in
diam
ter
betweimmax
wor n
and
min
mm
in
wor n
par ts
of
c
mshaft
jour nal
Engine
Mechanical
Bend limit
005 0
0020
I
Fig
EM
50 Checking
camMa
t bend
40 3 0
to 40 3 5
1
5866
to15886
025 0
0098
005 00020
Maximumtoler ance in
j01 ir r i
mm in
0 1
0003 9
diameter
CamShaft end
play
mm in 008to
03 8
0003 1 to
0 0150
Standar d
Sur face flatness
mm
in
less than
0
05 00020
Cy
LlNDER BLOCK
I
Visually
check
cylinder
block
for
cr acks or flaws
2
Measur e
top
of
cylinder
block
cylinder
head
mating
face for
war p
age
If
war page
exceeds limits
cor r ect
it
Maximum
toler ance
0
10 0
003 9
EM540
Fig
EM 51
Cheching cylinder
block
aur face
EM 13
j
Using
a
bor e
gauge
measur e cyl
inder
bor e for out of
r ound or
taper
If
out of
r ound or
taper
is excessive
r e
bor e
cylinder
walls with a
bor ing
machine Measur emen
t should be
taken
along
bor es
for
taper
and ar ound
bor es
for
out of
r ound
See
Figur e
EM
52
Qu
t ofr ound
Taper
X
Y
A
B
M12
Fig
EM
52
Measur ing cylinder
bor e
diameter
4When wear
taper
or
out
of
r ound
is minor
and within limits
r emove
step
at
topmost
por tion
of
cylinder using
a
r idge
r eamer
or
other similar
tool
HOW TO MEASURE
CYLINDER
BORE
A
bor e
gauge
is used
Measur e
cylind
r
bor e
at
top
middle
and bot
tom
positions
towar d
A and Bdir ec
tions
as shown
in
Figur e
EM
53
and
r ecor d
themeasur ed values
A
I
120
0 79
IlL
60 2 3 6
lll
B
100 3 94
el 1
Unit
mmm
EM 22
r
Fig
EM 53
Cylinder
bor t me08Ur ing
positions
Engine
Mechanical
Standar d
Wear limit
Inner diameter
85 000
to
85050
0
2 00079
33 465 to33 484
Cylinder bor e
mm
in Out ofr ound Oot5 00006
Taper
0015 00006
Differ encein
cylinder
bor e
005 00020
02 00079
mm
in
CYLINDER
BORING
I When
any cylinder
needs
bor ing
all other
cylinder s must alsobe bor ed
at the
same time
Over size
pistons
spec
Hicetlons
Pistondiameter mm in
Ser vioe standar d
050 00197
Over size
100
003 94
over size
3 The
size
towhich
cylinder s
must
be
honed is
deter mined
by
adding
piston
to cylinder
clear ance to the
lar gest piston
diameter
at
piston
skir t
in
thr ust dir ection
EM126
Fig
EM 54
Measur ing piston
diamet
r
2
Deter mine
piston
over size ac
cor ding
toamount ofwear of
cylinder
84985 to8503 5
33 459
to3 3 478
85465to85 515
33 648 to3
3 667
85
965to86 015
33 844 to3
3 864
Standar d clear ance
ffim in
Feeler
gauge
mm
in
Extr acting
for ce
kg
Ib
Notes
a
To
pr event
str ain due to
cutting
heat bor e the
cylinder s
intheor der
of
24
1
3
b
Befor e
bor ing any cylinder
install
main
bear ing caps
in
place
and
tighten
tothe
specification
sothat
the cr ankshaft
bear ing
bor es will
not become distor ted
fr omthe bor
ing
oper ation
4
Donot cut
toomuch out of
cylinder
bor e
at a time Cut
only 005
mm 00020 in
or soin diameter
at a
time
EM 14
L
7
A
aboull
6 m
o73 23 in
r
127
Fig
EM 55
MeCUJlJr ing
piston
skir t
diameter
Rebor ed
size
calculation
oA B C A 0005 to
0Q25
mm
0
0002to00010 in
wher e
D Honed
diameter
A
Skir t diameter as measur ed
B Pistontowall
clear ance
C
Machining
allowance 002mm
00008
in
0025
to
0
045 0
0010to00018
0040
0016
0
2
to
1
5 O
44
to
3 3 1
5
Measur ement
ofa
just machined
cylinder bor e
r equir es
utmost car e
since it
is
expanded by
cutting
heat
6
As a final
step
cylinder s should
be
honed to
size
7
Measur e the
finished
cylinder
bor e for
out ofr ound or
taper ed par t
8 Measur e
piston
to
cylinder clear
ance
This
clear ance can be checked
easily by using
a feeler
gauge
and a
spr ing
balance hooked
on
feeler
gauge
measur ing
the amount offor ce
r e
quir ed
to
pull
gauge
out fr om
between
piston
and
cylinder
Engine
Mechanical
Notes
a
When
measur ing
clear ance
slowly
pull
feeier
gaUge sir aight upwar d
b
It Is
r eConUnended that
piston
and
cylinder
be
hel
ted to200C 680F
PISTONS
PISTON PINS AND
PISTON RINGS
I
Remove car bon fr om
piston
and
r ing gr ooves
with
a
ca
bon
scr aper
and
a cur ved steel wir e
Clean out oil
slots
in
bottomland of
oil
r ing gr oove
2
Check for
damage
scr atches and
wear
Replace
if
necessar y
3
Meas1 1r e side
clear ance of
r ings
in
r ing gr ooves
as each
r ing
is
installed
Side clear ance
should be
as follows
00
I
EM542
Fig
EM
58
Measur ing r ing
gap
Notes
a
When
piston r ing only
is tobe
r eplaced
without
cylinder
bor e
being
cor r ected measur e
gap
at
bottom of
cylinder
wher e wear is
minor
b Over size
piston r ings
ar e
available
for
ser vce
Over size
05mm
0
0197 in and
1
0 mm 0
03 94in
5 Measur e
piston pin
hole in r ela
tion
toouter diameter of
pin
Ifwear
exceeds
limit
r eplace
each
piston
pin
together
with the
piston
onwhich
it is
installed
6 Deter mine the
fitting
of
piston
pin
into
piston pin
hole tosuch an
extent that
it
can
be
finger
pr essed
at
r oom
temper atur e
This
piston pin
must be a
tight pr e
s fit into
connect
ing
r od
t
J
f
r r
11
1
I
EM541
Fig
EM 56
Measur ingpiaton
fit
incylinder
Fig
EM 57
Measur ingpistonr ing
side
clear ance
Side clear ance
Unit mm in
I
Second
r ing
I
I
Wear limit Standar d
0040
to
0073
0
0016
to00029
003 0
to
0
070
I
00012
to
0
0028
I
Top
r ing
01 0003 9
Oil
r ing
f
feeler
gauge
Ring
should be
placed
todiameter
at
upper
or lower limit of
r ing
tr avel
4
Push
r ing
into
cylinder
with
pis
ton so as to
place
it
squar ely
in
cylinder
measur e
r ing
gap
with a
EM13 1
Ring gap Fig
EM
59 Piston
pin
fitting
Unit r om
in
Standar d
Wear
limit
025to040
00098to00157
03 0 to050
00II8to00197
Top
r ing
Second
r ing
1
0003 94
EM13 2
03 0to090
00118 to003 54
Oil
r ing
Fig
EM
60
Measur ing
pitonpin
diamet
EM 15
r
Piston
pin
outside
diameter
Piston
pin
hole diameter
Piston
pin
to
piston
clear ance
I
Inter fer ence
fit of
piston
pin
to
connecting
r od
CONNECTING
ROD
I Ifa
connecting
r od has
any
flaw
oneither side ofthe thr ust face
or the
lar ge
end
cor r ect or
r eplace
it
EM13 3
Fig EM 61 Ch
cking
r od
alignment
Connecting
r od
bend
or tor sion
per
100
mm
or 3 94in
length
mm in
3
When
r eplacing
connecting
r od
select r od
so
that
weight
differ ence
between newand old
ones
is
within
7
gr
0
25oz
Do
not use
a combination ofnew
and
for mer
connecting
r od
big
end
nuts and
connecting
r od bolts which
affect
specified weight
var iations
4Install
connecting
r ods
with
bear
ings
on
to
cor r esponding
cr ank
pins
and
measur e thr ust clear ance
Ifmeas
ur ed
valueexceeds
limit
r eplace
Engine
Mechanical
Unit
mm
in
20993 to20998
0
8265
to
08267
21
001 to21008
0
8268to08271
0003 to0 015
00001
to
0006
0 015
to003 5 0
0006 to
0 0014
2 Check
connecting
r od for bend or
tor sion
using
a
connecting
r od
aligner
Ifbend or tor sion exceeds the
limit
q
r r ect or
r eplace
Standar d
Maximum
0
03 0
0012 005
00020
Fig
EM 62
Checking big
end
play
Standar d
Maximum
Big
end
play
mm
in
02
to03
0
0079 to0
0118
06 0023 6
EM
16
CRANKSHAFT
1
Whenever cr ankshaft is r emoved
fr om
engine
it
should
be
cleaned
thor oughly
in
a
suitable
solvent
After
cleaning
check
cr ankshaft
jour nal
and
cr ank
pin
Jor scor e
bias
wear
or
cr acks
Rep
air
or
r eplace
as
r equir ed
If
damage
is minor
dr ess with fine
cr ocuscloth
2
Check
jour nals
and
cr ank
pins
for
taper
and
out
of
r ound with a micr o
meter
Measur ement should be taken
along jour nals
for
taper
and ar ound
jour nals
for
out of
r ound
See
Figur e
EM 63 for
detailed infor mation
If
jour nals
or cr ank
pins
ar e
taper ed
or out ofr ound
beyond limits
r eplace
witha
newshaft
A B
Out of
r ound
XY
Taper
AB
Unit mm
in
195
0768
tt
3 0
27
3 2
181 106 1260
43
Ol69
I
E
1
All
main
jour na
59942 to59955
All cr ank
pm
2
3 599 l
2
3 604
49 961 to
49
974
o
19670
to1
9675
EM424
Fig
EM 63
Cr ankshaft
and
jour nal
dimensions
Standar d
Taper
and
out ofr ound
of
jour nal
and
cr ank
pin
mm in
less than
0
01 0
0004
3 Cr ankshaft bend can be
checked
by
placing
it
on
Vblocks and
using
a
dial
gauge
with its
indicating finger
r esting
oncenter
jour nal
Standar d
Cr ankshaft bend
mm
in
less than
0
05 0
0020
Note
When measur ing
bend
use a
dial
gauge
Bend
value
is
halfof
the
r eading
obtained whencr ankshaft
is
tur ned one
full r evolution with a
dial
gauge
attached toits center
jour nal
4
After
r egr inding
cr ankshaft finish
it to
the necessar y
size indicated
on
page
EM 18
by using
an
adequate
under size
bear ing accor ding
to
the
extent of
r equir ed r epair
5
Install
cr ankshaft in cylinder
block and measur e
cr ankshaft fr ee end
play
Engine
Mechanical
Maximum
0Q25 0
0010
EM13 7
Fig
EM 64
Checking
cr ankshaft
bend
Maximum
0 10 0003 9
Fig
EM
65 Checking cr ankshaft
end
play
Standar d
Wear
limit
Cr ankshaft fr ee end
play
mm
in
005
to0
18
00020
to0
0071
03
00118
6
At the r ear end
ofcr ankshaft
check cr ankshaft
pilot
bushing
for
wear or
damage Replace
it if
any
fault
is detected
To
r eplace
cr ankshaft r ear
pilot
bushing pr o
ceed as
follows
I
Pull
out
bushing using
Pilot
Bushing
Puller
STl66 1000
I
EM
17
STl6610001
EM425
Fig
EM
66 Pulling
out
pilot
bushing
2 Befor e
installing
a
new
bushing
thor oughly
clean
bushing
hole
Pr ess
fit
bushing
sothat
its
height
above
flange
end is 45
to5
0
mm
0177
to
0197 in Donot
oil
bushing
EM418
Fig
EM 67 Pr ess
fitting
new
pilot
bush
ng
BUSHING
AND
BEARING
MEASUREMENT
OF
MAIN BEARING
CLEARANCE
I
Thor oughly
clean
all
bear ings
and
check for scr atches melting
scor e
or
wear
Replace
bear ings
ifany
fault
is
detected
2
Cr ankshaft
jour nals
and
bear ings
should
be
clean
and fr ee fr om
dust and
dir t befor e oil
clear ance
is measur ed
3
Set
main
bear ing
oncap
block
4
Cut
a
plastigage
to
width
ofbear
ing
and
place
it in
par allel
with
cr ank
pin
getting
clear
of
theoil hole Install
cap
onthe assembly
and
tighten
them
together
tothe
specified
tor que
Tightening tor que
45
to55
kg
m
3 3
to
40
ft lb
Fig
EM 68 P14stigage
Note
Do
not tum
cr ankshaft while
plastigage
is
being
inser ted
5 Remove
cap
and
compar e
width
ofthe
plastigage
at its widest
par t
with
the
scale
pr inted
in
plastigage
enve
lope
Fig
EM
69
Measur ing bear ing
clear ance
MEASUREMENT
OF
CONNECTINGROD
BEARING
CLEARANCE
I
Measur e
connecting
r od
bear ing
clear ance
inthe
same manner as above
Tightening tor que
45
to
55
kg m
3 3
to
40ft lb
Engine
Mechanical
Bear ing
011 clear ance
Standar d
Wear limit
Main
bear ing
clear ance
mm
in
0020
to
0
062
00008
to00024
012 00047
Connecting
r od
bear ing
clear ance
mm in
0
025
to0055
00010
to00022
0
12 00047
2 If
clear ance exceeds
specified
value
r eplace bear ing
with an under
size
bear ing
and
gr ind
cr ankshaft
jour
nal
adequately
FiniNGBEARINGS
Bear ings
ar e manufactur ed with
cr ush
to
make
bear ing snug
downinto
its
bor e
To
measur e this
pr oceed
as
follows
I Set main
bear ing
inmain
bear ing
cap
r ecess or
cylinder
block
bear ing
r ecess
cor r ectly
2 Lock one side of
bear ing and
pr ess
other side until
bear ing
back
sur face touchesther ecess
Bear ing
cr ush
All main
bear ings
mm in
All
connecting
r od
bear ings
mm in
4
Handle
connecting
r od
bear ing
in
3 Then
measur e
bear ing
cr ush H
witha feeler
gauge
See
Figur e
EM 70
The standar d
bear ing
cr ush value
is
listed below
Weight
H
Fig
EM 70
Checking bear ing cr um
oto003 0
to
00012
0015 to0045 0
0006 to
00018
the same manner as above
Main
bear ing
under size
Unit mm in
Bear ing
top
thickness
Cr ank
jour nal
diameter
1
827
to
183 5
59942
to
59
955
SID
00719
to
00722
2
3 599 to
2
3 604
025 00098
1952to
1960
59
692to
59
705
Under size 00769 to00772
2
3 501 to23 506
050 00197
2077to
2
085 59442
to59455
Under size
0
0818to
0
0821 23 402
to
23 407
075 00295
2202to2210
59
192
to
59 205
Under size
00867 to00870
23 3 04
to23 3 09
EM
18
Engine
Mechanical
Connectlns
r od be
r lns
under size
SID
025 00098 Under size
050 00197 Under size
075 00295
Under size
MISCELLANEOUS
COMPONENTS
CRANKSHA AND
CAMSHA
SPROCKETS
I Check tooth sur face for flawsor
wear
Replace spr ocket
iffault
is
found
2 Install camshaft
spr ocket
in
posi
tion and check for r ounout If
it
exceeds 0
1
mm 0
003 9 in
total
indicator
r eading r epl
ce
camshaft
spr ocket
Also
check
for end
play
Camshaft
end
play
0
08
to03 8
mm
0003 2to
00150
in
EMl48
Fig
EM 71
Checking
eam
haft
spr ocket
Tunaut
Unit mm
in
Bear ing top
thickness Cr ank
pin
diameter
1493 to
1506
00588to00593
49 961to49974
1
9670to
1
9675
49711
to
49724
19571
to
19576
1
618to
1
63 1
0063 7 to00642
1
743 to
1
756
00686
to
00691
49461 to49474
19473
to
19478
1
868to
1
881
0073 5
to0
0741
49211
to
49224
193 74to193 79
Fig
EM 72
Checking
camshaft
end
play
3
Check
chain for
damage
exces
sive
wear
or str etch at r oller links
Replace
if
faulty
4To
pr oper ly adjust
chain
tension
or valve
timing
camshaft
spr ocket
has a
ear n
locating plate
and thr ee
locationholes
Nos I
2and 3
Camshaft
spr ocket
is
pr eset
at
No
I
hole at
the
factor y
Ifchain
becomes loose
adjust
it
by
setting
camshaft
spr ocket
at NO 2 hole If
chain
is
tooloose
adjust
it
by
setting
camshaft
spr ocket
at
No3
hole
2
3
Befor e
adjustment
Location
match
3
After
adju5tmen
t
EM3 11
Fig
EM 73
Adjuating camshaft apr ocket
location
EM
19
I
Tur n
engine
until
No
I
piston
is
at
T D C on
its
compr ession
str oke
Deter mine
whether camshaft
spr ocket
location notch
comes
off
the left end
of
the
oblong
gr oove
on camshaft
locating plate
Ifthe location notch
is
off
the
left end ofthe
oblong gr oove
chain
str etch is
beyond
limits
40150
EMl46
Fig
EM 74
Camshafllocating plate
2
Tur n
engine
until No
I
piston
is
at
T D
C
on
its
compr ession
str oke
setting
camshaft
on
No2 location
hole in
camshaft
spr ocket
This No
2
notch
should then be
on
the
r ight
end
of
the
oblong
gr oove
WhenNo2hole
is
used NO 2
timing
mar k must also
be
used
The amount
of
the
modifica
tionis a
40r otation
ofcr ankshaft
3
When modification becomes im
possible
even
by tr ansfer r ing camshaft
location
hole
r eplace
chain
assembly
Engine
Mechanical
CHAIN
TENSIONER
AND
CHAIN GUIDE
Check for
wear
and
br eakage
Re
place
if
necessar y
r
I
L
EM147
Fig
EM 75 Cam
haft dr imechanilm
FLYWHEEL
I
Check clutch
disc
contact sur face
with
flywheel
for
damage
or wear
Repair
or
r eplace
if
necessar y
2
Measur e r unout ofclutch disc
contact
sur face
witha
dial
gauge
fit
exceeds
015
mm 00059
in
total
indicator
r eading
r eplace
it
EM 20
EM426
Fig
EM
76 Checking flywheel
deviation
3
Check
tooth sur faces of
r ing gear
for flaws
or wear
Replace
if
necessar y
FRONT
COVER AND
REAR OIL SEAL
Fir st
check
fr ont cover
an r ear
oil
seal for
wor nor folded over
sealing lip
or oil
leakage
If
necessar y
install
a
new seal When
installing
a new
seal
pay
attenti
on to
mounting
dir ection
Note It is
good pr actice
to
r eplace
oil
seal whenever
engine
is
over hauled
Fr ant
t
r
r
J
I
Fr ont
Real
EM150
Fig
EM
77
Oil
eals
of
cr ank
haft
PRECAUTIONS
CYLINDER HEAD
PRECAUTIONS
I Use
thor oughly
cleaned
par ts
Especially
make
sur e that oil holesar e
clear of
for eign
matter
2
When
installing sliding par ts
such
as
bear ings
be suIe
to
apply engine
oil
to
them
3 Use
new
packing
and
oil seals
4Donot
r euse lockwasher s
5
Keep
tools
and
wor k benches
clean
6
Keepnecessar y par ts
and tools
near
at hand
7 Be
sur e tofollow
specified
tight
ening
tor que
and or der
8
Applying
sealant
Use sealant toeliminate
water and
oil leaks
Par ts
r equir ing
sealant ar e
I
Fr ont
cover
and cor ner s of
cyl
inder block See
Figur e
EM
78
EM153
Fig
EM 78
Applying
alant
Fr ont cover and
cylinder
block
2 Main
bear ing cap
and
cylinder
block
Each
side
ofr ear
main bear ing
cap
and each cor ner
of
cylinder
block
See
Figur e
EM 79
Engine
Mechanical
ENGINE ASSEMBLY
CONTENTS
EM
21
EM 21
PISTON AND
CONNECTING
ROD
ENGINE
ASSEMBLY
EM
22
EM 22
Cylinder
block
Rear
main
bear ing cap
20to2Smm
Ill
Points
to
be
applied
sealant
EM151
s
e
00
000
o
Fig
EM 79
Applying
sealanl
Main
bear ing cap
and
cylinder
block
3
Cylinder
block
Steppor tions
at
four
mating
sur faces
cylinder
block to
fr ont chain
cover
and
cylinder
block
to
r ear main
bear ing cap
See
Figur e
EM 80
Note Donot
apply
too
muchsealant
J
Apply
sealant at hese
points
EM152
Fig
EM80
Applying
sealant
Cylinder
block
CYLINDER
HEAD
Valve assembly
and valve
spr ing
Using
Valve
Lifter STl2070000 set
valve
pr ing
seat
in
position
and
fit
valve
guide
withoil seaL
Assemble valve
in the or der shown
below valve
inner and outer valve
spr ings spr ing
r etainer
valve collet
and
valve r ocker
guide
EM
21
Fig
EM 81
Installing
valves
Notes
a
Ensur e
that
valve
face
is
fr ee fr om
for eign
matter
b The L20B
engine
uses double
type
valve
spr ings
2 Valve r ocker
pivot assembly
Scr ew valve r ocker
pivots joined
withlock nuts into
pivot
hushing
3 Camshaft
assembly
Set
locating
plate
and
car efully
install camshaft
in
cylinder
head Do
not
damage
the
bear ing
inside
Oblong
gr oove
of
locating
plate
must be
dir ected towar d fr ont side of
engine
Camshaft br acket
tightening
tor que
1
8
to20
kg
in
13
to
15ft lb
4
Install
camshaft
spr ocket
onear n
shaft and
tighten
it
together
with
fuel
pump
dr ive cam
to
specified tor que
Tightening tor que
12
tol6
kg
m
87 to
116 ft
lb
this time check camshaft end
Fig
EM 82
Installing
camshaft
spr ocket
5 Install r ocker
ar ms
by
pr essing
valve
spr ings
down with a scr ewdr iver
6 Install
valve
r ocker
spr ings
7 After
assembling cylinder
head
tur n
camshaft
until No
I
piston
is
at
T
D C on
its
compr ession
str oke
EM1S5
Fig
EM83
A
embling cylinder
head
PISTON AND
CONNECTINGROD
1
Assemble
pistons piston
pins
and
connecting
r ods
on
the de ignated
cylinder
STl3 03 0001
EM156
Fig
EM 84Installingpistonpin
EM157
Fig
EM 85 Assembling piston
and
connecting
r od
Notes
a
Piston
is
pr essed
into
connecting
r od with
fitting
for ce
of05to
5
tons
aid ofPiston Pin Pr ess
Stand STl3 03 000
I is
necessar y
When
pr essing piston
pin
intocon
necting
r od
apply
engine
oil to
pin
and small end of
connecting
r od
Engine
Mechanical
b
Ar r ange
sothat oil
jet
ofconnect
ing
r od big
end is dir ected towar d
r ight
side
of
eylinder
block
c
Be sur e to
install
piston
in
cylinder s
with notch mar k of
piston
head
towar d
fr ont of
engine
2
Install
piston r ings
InstalI
top
and second
r ings
in
r ight
position
withmar ked side
up
Notes
a
Topr ing
is
chr omium
plated
on
liner
contacting
face
b Second
r ing
has
lar ger taper
sur face
than
top
r ing
cInthe combined oil
r ing upper
r ail
is the same
as
lower one
j
c6J
EM158
Fig
EM 86
lalling pidonr ings
3
Fix
bear ings
on
connecting
r od
and
connecting
r od
cap
Note Clean back sideof
bear ing
car e
fully
ENGINE ASSEMBLY
The fir st
step
in
engine assembly
is
to bolt
Engine
Attachment
ST0526000
I
to
r ight
hand
ide of
cylinder
block Next install block on
another
Engine
Stand ST0501S000
with
engine
bottom
up
2
Set main
bear ings
at
the
pr oper
por tion
of
cylinder
block
Rear Fr ont
III III
m
It IlL
D
D
D
D D
15 14
13 12 11
EM159
Fig
EM 87
Main
bear ings
EM 22
3 Install baffle
plate including
cyl
inder
block net
Notes
a
Only
center
bear ing
No
3
is a
flanged type
b All inter bear ings
No2
and No
4
ar e
thesame
type
c
Fr ont
bear ing
No
I is
alsothe
same
type
as r ear
bear ing No
5
The differ ence
is
that anoil
hole is
pr ovided
inthefr ont
bear ing
d All
upper
and lower
bear ings
ar e
inter changeable
4
Apply engine
oil
to
main
bear ing
sur faces on both
sides of
cylinder
block and
cap
and then install cr ank
shaft
5 Install main
bear ing
cap
and
tight
en
boltsto
specified
tor que
Tightening
tor que
45to55
kg
m
3 3
to
40ft lb
Notes
a
Apply
sealant
toeach side ofr ear
main
bear ing cap
and
each comer
of
eylinder
block as shown in
Figur e
EM 79
b
Ar r ange par ts
so
ar r ow mar k
on
bear ing cap
faces towar d fr ont of
engine
c
Pr ior to
tightening
bear ing cap
bolts
place
bear ing cap
in
pr oper
position
by shifting
cr ankshaft in
the axial dir ection
d
Tighten bear ing cap
bolts
gr adually
in twotothr ee
stages
outwar dly
fr om center
bear ing
in
the
sequence
as
shownin
Figur e
EM 88
e After
secur ing bear ing
cap
bolts
ascer tain that
aankshaft tur ns
smoothly
@
i
d
l
j 1
@EM543
Fig
EM 8S Tor que
sequence
0
cap
bolt
6 Make
sur e
that
cr ankshaft has
pr oper
end
play
Cr ankshaft end
play
005 to
018
mm
0
0020to00071
in
Fig
EM 89
Checking cr ankshaft
end
play
7
Install side oil seals
into
r ear
main
bear ing
cap
Pr ior to
installing apply
sealant toseals
Fig
EM 90
Dr iving side oil seal
8 Install r ear oil seal
using
Cr ank
shaft
Rear
Oil Seal Dr ift
STI53 10000
r
STl53 10000
r
EM163
Fig
EM 91
Installing
r ear oiseal
Engine
Mechanical
Note When
installing
oil seal
give
coating
of
engine
oil to
mating
shaft to
pr event
scr atches
and
fold
ed
lip
Also
give
coating
ofoil to
per ipher y
ofoil
seal
9
Install
r ear end
plate
10
Install
flywheel secur ely
and
tighten
bolts to
specified
tor que
Tightening
tor que
14
to16
kg
m
101to116 ft lb
I I
Inser t
pistons
in
cor r esponding
cylinder
using
Piston
Ring Compr essor
EM03 470000
EM03 410000
I
EM544
Fig
EM 92
Installingpi8ton
r od
aSembly
Notes
a
Apply
engine
oil
to
sliding par ts
b
Ar r ange
80
that
notch mar k on
piston
head faces tofr ont ofen
gine
cInstall
piston
r ings
at 1800to
each
other
avoiding
their fit in the
thr ust and
piston pin
dir ections
6
Topr ing
I iilr ing
Piston
pin
ir eClioJ
EM165
Fig
EM
93 PUtan
r ing
dir ection
12 Install
connecting
r od
caps
Tightening tor que
45 to55
kg
m 3 3 to40 ft lb
EM 23
Fig
EM
94
Installing connecting
r od
cap
Note Install
connecting
r ods
and con
necting
r od
caps
80 that their
as
signed
number s ar e
positioned on
the
same side and in the SlIme
dir ection with
r espect
to
cylinder s
13 Make sur e
that
connecting
r od
big
end has
pr oper
end
play
Fig
EM
95
Checking big
end
play
Big
end
play
02to03 mm
0008to0Ql2
in
14
Install
cylinder
head
assembly
Fig
EM 96
Tightening sequence
01
cylinder
head bolts
J
Thor oughly
clean
cylinder
block
and
head sur face
Do
not
apply
sealant to
any
other
par t
of
cylinder
block and
head
sur
face
2 Tur n cr ankshaft until
NoI
pis
ton is
at T D C
on
its
compr ession
str oke
3
Make
sur e
thaicamshaft spr ock
et location
notch and
plate
oblong
gr oove
ar e
aligned
at their
cor r ect
positions
4
When
installing cylinder
head
make
sur e
that
all valves ar e
apar t
fr omheads
of
pistons
5
Do
not r otate
cr ankshaft and
camshaft
separ ately
or valves will
hit
heads of
pistons
6
Tempor ar ily
tighten
twobolts
CD
V
sJiown
in
Fig
r e
EM 96
Tightening
tor que
2
kg
m
14
ft b
15
Install cr ankshaft
spr ocket
and
oil
pump
dr ive
gear
and fit oil
thr ower
Note Make sur e lhat
maling
mar ks of
cr ankshaft
spr ocket
face 10
Cr ont
16 Install
timing
chain
Noles
a
Make
sur e
that cr ankshaft
and cam
shaft
keys point
upwar ds
Fuel
pump
dr ive
ear n
2 Chain
guide
3
Chain tensioner
4
Cr ank
spr ocket
5 ear n
spr ocket
6 Chai
guide
EM43 9
b Set
timing
chain
by
OOgning
its
mating
mar ks with those oCcr ank
shaft
spr ocket
and camshaft
spr ock
et at the
r ight
hand side Ther e ar e
for ty
four chainlinks between two
mating
mar ks of
timing
chain
c
NO 2 hole is
Cactor y
adjusted
When chain str etches
excessively
adjust
camshaft
spr ocket
at
No
3
hole
d Use
a
set of
timing
mar ks and
locationhole
number s
Engine
Mechanical
17 Install chain slack side
guide
to
cylinder
block
18 Install chain
tensioner
Note
Adjust
pr otr usion
oCchain ten
sioner
spindle
to0mm
0 in
Fig
EM 98
lmtalling
chain
tensioner
19
Pr ess new oil seal
in
fr ont cover
Notes
a
Fr ont
cover oil
seal should be r eo
placed
when
Cr ont cover
is
disas
sembled
b BeCor e
pr essing
oil seal intoCr ont
cover
give coating
of
engine
oil
to
per ipher y
ofoil seal
cThis
oil seal is a thr eaded seal
type
which has
impr oved sealing
char ac
ter istics
Donot
apply gr ease
to
sealing
lip
20
Install fr ont cover with
gasket
in
place
1
Timing
mar k
2
Timing
mar k
EM545
Fig
EM
99
Installing
fr onl
COlHlr
Notes
a
Apply
sealant toCr ont cover and
cor ner s
oC
upper
section
of
cylinder
block
as
shown
in
Figur e
EM 78
EM
24
b Install Cr ont cover
with head
gasket
in
place
c
Check
height
diCCer ence between
cylinder
block
upper
Cace and Cr ont
cover
upper
Cace DifCer ence
must
be less
than 015
mm
00059 in
d
Note
that difCer ent
types
oCbolts
ar e used
e
Befor e
installing
fr ont cover
on
cylinder
block
apply
coating
oC
engine
oil 10
sealing lip
ofoil
seal
EMS11
Fig
EM lOD Fr ont
cover bolts
Tightening
tor que
SizeM8 03 15
in
10to1
3
kg
m
7
2to9
4
ft lb
SizeM6 023 6 in
04to06
kg
m 2
9 to
4
3 ft lb
21 Install cr ankshaft
pulley
and
water
pump
assembly
then set No
I
piston
at ToO C
on its
compr ession
stloke
Cr ankshaft
pulley
nu
I
tightening tor que
12 to16
kg
m B7 to116
ft
lb
EM546
Fig
EM Ol
lnstallingcr an haft
pulley
and
water
pump
22
Finally
tighten
head
bolts to
the
specified tor que
in
thr ee
steps
accor ding
tothe
lightening sequence
shown in
Figur e
EM 96
Note thaiIwo
types
of
bolts
ar e
used
Speci
ol
Cylinder
Head
Bolt
Wr en h
8110120000
Tightening
tor que
1st tur n
4
0
kg
m
29
ft lb
2nd tur n
6
0
kg
m 43 ft lb
3 r d tur n
6
5
to
8 5
kg
m
47 to61 ft lb
B
O
A
A
B
A
A
B
O
B
O
R
O
EM 176
Fig
EM I02
Cylinder
head boll
Notes
a
Be sur e to
tighten
two
small bolts
b After
engine
has been
oper ated
for
sever al minutes
r etighten
ifneces
sar y
23 Install oil
pump
and distr
butor
dr iving
spindle
in
fr ont
cover
Tightening tor que
11to1
5
kg
m
8 0
to108ft lb
Notes
a
Assemble oil
pump
and dr ive
spin
die aligning dr iving
spindle
face
withoil
pump
hole
b Install oil
pumptogether
with
dr ive
spindle
so
that the
pr ojection
onits
top
is located at the II 25 a m
position
At this
point
the
smaller
bow shape will
be
facing
towar d the
fr ont
c
Donot
for get
toinstall
gas
et
Engine
Mechanical
I
Fig
EM
I04
11l6lalling
oil
pump
24Install
fuel
pump
water inlet
elbowand
fr ont
engine
slinger
in
their
positions
Fuel
pump
tightening tor que
12
to
18
kg
m
8 7
to
13
0ft
lb
Note Donot
for get
toinstall fuel
pumpspacer
and
packing
between
spacer
and
block
spacer
and
fuel
pump
25 Install oil
str ainer oil
pan
gasket
and oil
pan
27
Install r ocker cover
to
cylinder
head
Note
Make
sur e
that one ofthe
r ocker cover boltsis
longer
than the
other s It secur es FICD assist
br acket
28 Install air
pump
br acket
and
cooler
compr essor
to
cylinder
block
EM
25
Tightening tor que
Oil
str ainer
bolts
0
8to
I l
kg
m
5
8to
80 ft
lb
Oil
pan
bolts
06 to
0 9
kg
m
43
to
65ft
lb
Notes
a
Apply
sealant tothe
steppor tions
at
four
mating
sur faces
as
shown
in
Figur e
EM 80
b
Oil
pan
should
be
tigh
tened
in
cr iss cr oss
patter n
toafinal
tor que
of0
6 to0
9
kg
m
43 to6 5ft lb
26
Adjust
valve clear ance tothe
specified
dimensions
Special
tool
Pivot
Adj
iier STl064000l
Tightening tor que
5
0to6
0
kg
m
3 6 to43
ft lb
Fig
EM I05
Adjusting
valve clear ance
b After
engine
has been assembled
r un it for at least sever al
minutes
and
finally adjust
clear ance
to
the
war m
specifications
29
Install intake
manifold
to
ex
haust manifold The
intake manifold
face which comes
intocontact
with
gasket
should be even
with that of
exhaust
manifold Note that twodif
fer ent
sizes
of
attaching
bolts ar e
used
Tightening tor que
25
kg
m
18
0
ft
lb
3 0 Install
heatshieid
plate
on
mani
fold assembly
3 1 Install air
galler y pipe
on ex
haust manifold
3 2 Install
manifold
gasket
and
manifold
assembly
on
cylinder
head
Tightening tor que
1 2to
1
6kg
m
8
7 to116 ft
lb
3 3
Install
blow
by
gas
pipe
on
cyl
inder
block and tighten
with
r ear
engine
slinger
3 4Install ther mostat housing
gas
ket ther mostat
housing
and
ther mo
stat
3 5 Install ther mal vacuumvalve
on
ther mostat
housing
Befor e
installing
apply
a
liquid packing slightly
to
the
thr eads
3 6
Install
FJ
C
D br acket on
cylin
der
head
3 7
Install E GR
passage
and
E GR valve on
intake manifold
3 8 Connect
E
G
R tube to
E
GR
tube
and
exhaust
manifold
3 9
Install check
valve
on air
galler y
pipe
40 Install air cleaner
br acket on
intake
manifold
41
Install air contr ol valve
on air
cleaner
br acket Califor nia
models
42 Install vacuum and fuel
tubes
combined on
cylinder
head
43 Install distr ibutor
assembly
44Install
heatshield plate
joint
seat
and
car bur etor
Car bur e10r tightening
tor que
05
to
1
0
kg
m
3
6 to7
2
ft lb
Note
When
instalUng joint
seat be
sur e to
put
the duct into
pr imar y
hole
in
intakemanifold
S
J
Heatshield
plate
4Joint
seat
2
Pr imar y
hole
5
Secondar y hole
3 Duct
EM53 4
Fig
EM I06
Installing
car bur etor
joint
seat
Engine
Mechanical
45 Install dash
pot
br acket
and
dash
pot
tointake
manifold
46 Connect all
air
vacuum
and fuel
hoses
and
then
secur e with
clamps
I Cylinder
block
to
P
CV valve
hose
2
A
B
valve to
E
G
R
passage
vac
uumhose
3 A
B
valve
toE G
R
passage
air
hose
4Vacuum tube tocar bur etor vac
uum
hoses
5
Fuel ube
to car bur etor
fuel
hose
6 Fuel tube tofuel
pump
fuelhose
7
Distr ibutor tovacuumswitch or
spar k
delay
valve vacuum
hose
8 Air contr ol valve vacuumhose
9 Check
valve
to
air
contr ol
valve
hose
10 Ther mal vacuum valve to
E GR valve vacuum
hose
I
I Ther mal vacuum valve
to
vacuumtube hose
47 Install car bur etor
air
cleaner on
car bur etor and then connect
air
and
vacuumhoses
as
follows
I
Air
cleaner
to
exhaust
manifold
hot
air duct
2
Air c1eaner
toair
pump
hose
3
Air cleaner to
r ocker
cover hose
4
Air cleaner
to
air contr ol valve
hose
5
6
48 Install
spar k plugs
in
place
49 Connect all distr ibutor
high
ten
sion
cables to
spar k plugs
50 Install air
pump
dr ive belt cool
er
compr essor
and idler
pulley
51
Install left
engine mounting
br acket
52 Install clutch
assembly
on
flywheel
with Clutch
Aligning
Bar
KV3 0100200
Air
cleaner toA
B
valve
hose
Other vacuumhoses
Tightening
tor que
12to
22
kg
m
8
7to15
9
ft
lb
EM 26
I
I
KV3 0100200
EM440
Fig
EM I07 In
talling
clutch embly
53
Using
an over head hoist
and
lifting
cable hoist
engine
away
fr om
engine
stand
and
then down onto
engine
car r ier
54Install
r ight engine mounting
br acket oil filter oil
pr essur e
switch
oil
level
gauge
and
water
dr ain
plug
When
installing
oil
filter fasten it to
cylinder
block
by
hand
Note Donot
over tighten
flit
or
oil
leakage
may occur
55 Install alter nator br acket
adjust
ing
bar alter nator
cooling
fan
and
belt
56
Adjust
the deflection ofdr ive
belts when
thumb
pr essur e
is
applied
midway
between
pulleys
A
pr essed
for ce is above 10
kg
220lb
Deflection
ofdr ive belts
8to12mm
03 15
to
0472 in
EM613
Fig
EM lOB Fan belt
tension
57 Fill
engine
oil
up
to
specified
level
Engine
Mechanical
SERVICE
DATA
AND SPECIFICATIONS
GENERAL
SPECIFICATIONS
Engine
model
L20B
Cylinder ar r angement
Displacemen
t
Bor e and str oke
4in
line
cccoin
mm
in
1
952
J
19
1
85
x
86
3
3 5
x 3 3 9
O
H
C
I
34
2
Valve
ar r angement
Fir ing
or der
Engine
idle r pm
Manual tr ansmission
Automatic
tr ansmission in
D
r ange
750
650
8
5
Compr ession
r atio
Oil
pr essur e
War m
at
2
000
r pm
kg
cm2
psi
3 5 to40 50
to
57
SPECIFICATIONS
a Valve mechanism
Valve
clear ance
War m
Intake
Exhaust
Valve
clear ance Cold
Intake
Exhaust
Valve head diameter
Intake
Exhaust
Valve
stemdiameter
Intake
Exhaust
Valve length
Intake
Exhaust
Valve lift
Intake and exhaust
mm
in
0
25 0010
03 0
0 012
mmOn
0
20 0008
025 0010
mm in
42
0to42
2 1654
to
1
661
3 5
0
to3 52
1
3 78to13 86
mm
in
7
965
to7 980
03 13 6 to
03 142
7945 to
7 960 03 128
to
03 13 4
mmOn
1149
to115
2 4524 to4
53 5
115
7 to116 0
4555
to4
567
mmOn
Valve
spr ing
out
of
squar e
mm
in
10 5 0413
less
than 1
6
0
063
Valve
spr ing
fr ee
length
mm
in
Intake and exhaust Outer
Inner
49 98
1968
44
85J
766
EM 27
Valve
spr ing pr essur ed
length
valve
open
Intakeand exhaust
Outer
Inner
Valve
spr ing
assembled height
valve
close
Intake
and exhaust
Outer
Inner
Valve
guidelength
Intake
and
exhaust
Valve
guide height
fr omhead
sur face
Valve
guide
inner diameter
Intake and
exhaust
Valve
guide
outer diameter
ser vice
par ts
Intake
and
exhaust
Valve
guide
tostemclear ance
Intake
Exhaust
Valve seat
width
Intake
Exhaust
Valveseat
angle
Intake and
exhaust
Valve
seat inter fer encefit
Intake
Exhaust
Valve
guide
inter fer encefit
b Camshaft and
timing
chain
Camshaft end
play
Camshaft lobeift
Intake and exhaust
Camshaft
joumal
diameter
1st
2nd 3 r d and
4th
Engine
Mechanical
mm
kg in
lb
mm
kg in lb
mmin
mIll
in
mm
in
mm
in
mm
in
mm in
mm in
mm
in
r nm in
r nm
in
mm in
Camshaft bend
mm in
Camshaft
jour nal
to
bear ing
clear ance mm
in
Camshaft
bear ing
inner diameter r nm in
1st
2nd 3 r d and
4th
29 5
49 0
1IM
108
24
5
25 5
0965
56 2
400 21 3
1575
47 0
3 5 0123 13 78
27
I
59 0
23 23
106
0417
8
000to8018
0 3 150to
03 157
12223 to12
23 4
04812
to
04817
0020
to
0
053
0
0008to
00021
0
040
to
0
073
00016
to00029
14
to
1
6
00551 to0063 0
1
8to
2
2
00709to00866
450
0081 to0
113
0003 2to
0 0044
0064to0096
0
0025 to
0003 8
0027 to0
049 0
0011to
0
0019
0
08
to03 8 0003 2to00150
7
0 0276
47 949 to47962
18877
to1
8883
002
00008
0Q3 8 to0
067 000
I5
to00026
48000to48016
1
8898to18904
EM
28
Engine
Mechanical
c
Connecting
r od
Center distance
mm
in
Bear ing
thickness Standar d
mm
in
Big
end
play mm
in
Connecting r od
bear ing
clear ance
mm in
Connecting
r od bend
or tor sion
per
100mmor 293 7in
mm in
d Cr ankshaft
and main
bear ing
Jour nal diameter
Jour nal
taper
out ofr ound
Cr ankshaft
fr ee end
play
Wear limit ofdittoed
play
Cr ank
pin
diameter
Cr ank
pin
taper
out
of
r ound
Main
bear ing
thickness StJlndar d
146
5
748
1493 to1
506 00588
to
00593
020to03 0
0008
to
0012
0D25 to
0
055 00010to00022
less
than003 0 0012
mm
in
mm in
mm in
mm
in
mm in
mm in
mm in
59
942to
59
955
23 599 io
23 604
less
than 0
0
I 0
0004
005 to018
00020
to0 0071
03
0
0118
49
961 to499741
9670to19675
less than 001
0
0004
1
827
to1
83 5 00719
to
0
0722
0
020to0062 0
0008to
0
0024
0 12
00047
005 0
0020
Main
bear ing
clear ance
mm
in
Wear limit
ofdittoed clear ance mm in
Cr ankshaft bend
mm in
Flywheel
r unout
at
clutch
disccontact face
mm
in
e Piston
Pistondiar neter
Ser vice standar d
0
50 00197 Over size
100 0
03 94 Over size
Ring
gr oove width
Top
Second
Oil
Piston tobor e clear ance
Piston
pin
hole off set
Piston
pin
hole
diameter
fPiston
pin
Pin diameter
Pin
length
less than 0 15 0
0059
mm in 84985
to
8503 5
3
3 459 to33 478
85
465to 85 515
33 648 to
33 667
85965to86 015
3 3 844to
3
3 864
203 0to
2
050 00799 to
0
0807
2
020to
2
040 00795
to
00803
4015 to4040 0 1581 to01591
0Q25 to0045 00010
to
0
0018
095to1
05
0
03 74
to00413
21001
to21
008 08268to
0
8271
mm in
mm in
mm in
mm in
mm in
mm in
mm
in
20993
to
20998
08265to
0
8267
7225to73 00
28445to28740
0008toom000003
to00004
mm in
Piston
pin
to
piston
clear ance
mm
in
Inter fer ence
fit of
piston
pin
to
connecting
r od
bushing
mm in
om5
to
003 5 00006 to0
00
I4
EM 29
Engine
Mechanical
g
Piston
r ing
Ring
height
Top
and
second
Side clear ance
Top
Second
Ring
gap
Top
Second
Oil
mm
in
mr n
in
mm in
h Cylinder
block
Cylinder
bor e
inner diameter mm in
Wear limit ofdittoed
inner
diameter
Cylinder
bor e
taper
and
out ofr ound
Differ ence
in
cylind
bor e
Sur face
flatness
mm in
mm in
mm in
mm
in
i
Cylinder
head
Sur face
flatness
mm in
TIGHTENINGTORQUE
Cylinder
head
bolts
kg
m fl lb
Connecting
r od
big
end
nuts kg m
ft Ib
Flywheel
fixing
bolts
kg
m ft Ib
Main
bear ing cap
bolts
kg
m ft lb
Camshaft br acket bolts
kg
m ft lb
Camshaft
spr ocket
bolt
kg
m ft lb
Oil
pan
bolts
kg
m
ft
1b
Oil
pump
bolts
kg
m ft lb
Oil
str ainer
bolts kg
m
ft lb
Oil
pan
dr ain
plug
kg
m ft lb
Rocker
pivot
locknuts
kg
m
ft
Ib
Camshaft
locating plate
bolts
kg
m ft lb
Car bur etor
nuts
kg
m
ft lb
Manifold bolts
kg
m ft lb
Fuel
pump
nuts
kg
m
ft lb
Cr ank
pulley
bolt
kg
m ft lb
Water
pump
bolts
kg
m ft Ib
Fr ont cover bolts
kg
m ft
lb
EM
3 0
1977 to1990
0
0778
to
0
0783
0040to0073 00016
to
00029
0
03 0
to0
070 00012to
0
0028
025
to
040
00098to0
0157
0
3 0to
0
50 0
0118to
00197
03 0
to
0
90
0
0118 to003 54
85
000to85050
3 3 465
to
33 484
0
2
00079
om5
0
0006
005 00020
less than
0
05
0
0020
less than0
05
00020
65to85
47 to
61
45to5
5
3 3
to40
14
to16
101
to116
45
to
55 3 3 to40
1
8to
2
0
13
to
15
12to
16 87 to116
0
6
to09
43 to6 5
IJto1
5
80
to
108
0
8 to11 5 8to80
2
0
to3 0
14
to22
5 0
to
6
0
3 6
to43
06
to0
9
43
to65
05to
1
0 3 6
to
7 2
12
to16 8
7
to
11
6
12to18 87
to13
0
12
to
16
87 to116
04
to
05 2
9
to
3 6
8mm
03 15 in
dia
6mm
0
23 6
in dia
1
0
to13 72
to
9
4
04to06 2
9to
43
Engine
Mechanical
TROUBLE
DIAGNOSES
AND
CORRECTIONS
Condition
I
Noisy engine
Knocking
of
cr ankshaft
and bear ing
Knocking
of
piston
and
connecting
r od
Camshaft
knocking
Timing
chain
noise
Camshaft and
valve
mechanism
knocking
Water
pump
knocking
Pr obable cause
Loose main
bear ing
Seized bear ing
Bent cr ankshaft
Uneven
wear
of
jour nal
Excessive
cr ankshaft end
play
Loose bear ing
Seized
bear ing
Loose
piston pin
Loose
piston
in
cylinder
Br oken
piston r ing
Impr oper
connecting
r od
alignment
Loose
bear ing
Excessiveaxial
play
Rough gear
teeth
Br oken eam
gear
Impr oper
chain tension
Wor nand
or
damaged
chain
Wor n
spr ocket
Wor n and
or
br oken
tension
adjusting
mechanism
Excessive camshaft and
bear ing
clear ance
Impr oper
valve clear ance
Wor n
adjusting
scr ew
Wor n
r ocker face
Loosevalve stem
i1 1
guide
Weakened valve
spr ing
Seized valve
Impr oper
shaft
end
play
Br oken
impeller
II
Other mechanical tr oubles
Stuck
valve
Impr oper
valve clear ance
Insufficient clear ance between
valve stem
and
guide
Weakened
or
br oken
valve
spr ing
Biting
or
damage
ofvalve stem
Poor
Quality
offuel
EM
3 1
Cor r ectiveaction
Replace
Replace
Repair
or
r eplace
Cor r ect
Replace
center
bear ing
Replace
Replace
Replace
pin
or
bushing
Recondition
cylinder
Replace
Realign
Replace
Replace
bear ing
thr ust
plate
Repair
Replace
Adjust
Replace
Replace
Replace
Replace
Adjust
Replace
Replace
Replace
guide
Replace
Repair
or
r eplace
Replace
Replace
Adjust
Clean stemor r eamguide
Replace
Replace
or clean
Use
ood fuel
Condition
Seized
valve
seat
Excessively
wor n
cylinder
and
piston
Faulty connecting
r od
Faulty
cr ankshaft
bear ing
Engine
Mechanical
Pr obable
cause
Impr oper
valve
clear ance
Weakened valve
spr ing
Thinvalve head
edge
Nar r owvalve seat
Over heating
Over
speeding
Stuck valve
guide
Shor tage
of
engine
oil
Dir ty
engine
oil
Poor
quality
ofoiL
Over heating
Wr ong
assembly
of
piston
with
connecting
r od
Impr oper
piston
r ing
clear ance
Br oken
piston
r ing
Dir ty
aii
cleaner
Mixtur etoor ich
Engine
over
r un
Stuckchoke valve
Over choking
Shor tage
of
engine
oil
Lowoil
pr essur e
Poor
quality
of
engine
oil
Rough
sur face of
cr aokshaft
Clogged
oil
passage
Bear ing
wor nor
eccentr ic
Bear ingimpr oper ly
assembled
Loose
bear ing
Connecting
r od
alignment
incor r ect
Shor tage
of
engine
oil
Low
oil
pr essur e
Poor
quality
of
engine
oil
Cr aokshaft
jour nal
wor nor
out of
r ound
Clogged
oil
passage
in
cr ankshaft
Bear ing
wor n
or
eccentr ic
Bear ing impr oper ly
assembled
Eccentr ic
cr aokshaft
or
bear ing
EM 3 2
Cor r ective action
Adjust
Replace
Replace
valve
Reface
Repair
or
r eplace
Dr iveat
pr oper
speeds
Repair
Add or
r eplace
oil
Clean
cr ankcase
r eplace
oil and oil niter
element
Use
r ight
oil
Repair
or
r eplace
Repair
or
r eplace
Adjust
Replace
Clean
Adjust
Dr ive at
pr oper
speeds
Clean
and
adjust
Star t
cor r ect
way
Add oiL
Cor r ect
Use
pr oper
oil
Gr ind and
r eplace
bear ing
Clean
Replace
Cor r ect
Replace
Repair
or
r eplace
Add or
r eplace
Cor r ect
Use
pr oper
oil
Repair
Clean
Replace
Cor r ect
Replace
NAME
DDRE55
I
OUAN
fr
1
CHARGE
PART NO
J
LIST
I
IFfIDr nJr nJ 1r D fA1r ijJJlk1 1PlfIDr nJ1r
3 u
eSa u Se
WHIPPL E
AT
VETERANS TELEPHONE
3 15563 90
480VETERANS
BLV
D
REDWOOD CITY
CALIFORNIA
94063
DATE
r ETe
r DS I
CU5T
ORDER NO
I
RETAIL WHOLESAl
E
DESCRIPTION
r
1
1
I
1
C Q
11
1 svnAAwf AI v
r
k
I
1
r
Ji
i
idP
w
I
tl
Ii
If
II
JI
HI
1
ll
JJ
Y
J
plt
h
is
NO
REFUND AFTER 3 0DAYS
NO REFUND
ON ELECTRICAL OR
CARBURETOR
PARTS
10
RESTOCKING
CHARGE ON REFUNDED MER HANDISE
NO REFUND
WITHOUT THIS INVOICE
REC O BY
I
r
NET
TAX
Engine
Mechanical
SPECIAL
SERVICE
TOOL
No
Tool
number
tool
name
Descr iption
Unit mm
in
Engine
stand
assembly
This
engine
stand assembly
is
used for
disassembling
or
assembling engine
block
or
differ ential car r ier
thr oughout
3 600in
all
dir ections
ST050lS000
ST05011000
Engine
stand
ST050
12000
Base
For
use
on
Refer ence
page
or
Figur e
No
All
Fig
EM
II
models
SE184
2
ST0526oo0l
This
engine
attachment is installed to
engine
stand Ll6
Fig
EM II
ST0501S000
in
disassembling
or assembling engine
Ll8
Engine
attachment
L20B
Q
li
SE185
3 STl0120000 Special
hollowset bolts ar e
used in
tightening cylinder
heads All
Fig
EM
18
in
Lser ies
engines
Thiswr ench
is used to
tor que cylinder
L ser ies
Cylinder
head bolt
head boltsand
itshead can be
inser ted intothe
tor que
1
r ench
wr ench
10
03 9 SE186
4STl 064000I
Thistool is used
togetller
witha
tor que
wr ench
in
tightening
pivot
locknut
for valve clear ance
adjustment
Pivot
adjuster
SE187
EM 3 3
All
Fig
EM 105
Lser ies
Engine
Mechanical
Tool number
For
Refer enl
t
No
Descr iption
use
page
or
tool
name
Unit
mm
in
on
Figur e
No
S KV10103 9S0
Valve
guide
r eamer
This
guide
is used for
All
Fig
EM 44
set
o
Pr essing
used
guide
out of
place
L
ser ies
0
Dr iving
a
new
guide
into
place
and
STIlO81000
0
Finishing
the bor e ofnew
guide
Aser ies
Reamer
12
2mmdia
STlI 03 2000
Reamer
80
mm
dia
STl13 20000
Dr ift
V
SE192
6 STll6S0001
Valve seat cutter
set Thisvalve
seat
cutter set
is
used
toor r efinish
a
valve seat All
Fig
EM 4S
L
ser ies
7 STl2070000
Valve lifter
SE193
This t ol is
used
to
compr ess
valve
spr ing
by
the combined
action ofits eam
and
lever
ther eby facilitating
the
r emoval
or
installation of
valve
collet for
gener al
use
All
models
Fig
EM
3 2
Fig
EM 8l
SE194
EM 3 4
Engine
Mechanical
Tool number
For Refer ence
No Descr iption
use
page
or
tool name
Unit
mm
in
on
Figur e No
8 ST13 03 0001 Thistool
is
used
with
a
pr ess
todr ive
pin
into
or out of All
Fig
EM 29
connecting
r od
Lser ies
Fig EM 84
Piston
pin
pr ess
stand
1
20
0
79
I
8
M
e
120
4
722 0
SE1BS
9 ST153 10000 This
tool is used to
push
a
liptype
r ear oil seal
for
L
ser ies
All Fig
EM 9l
Cr ankshaft
r ear
oil
engine
into
placeby
giving
hammer blows Lser ies
seal dr ift
SE189
10 KVI01041S0 Thistool
is
used tor emove the
cap
fr ommain
bear ing
All
Fig
EM 25
When
using
thds tool tur n
its
adapter
into
the thr eaded hole
Lser ies
Cr ankshaft main
in
main
bear ing
cap
bear ing cappuller
KVI0104110
Body
250
9 8
ST16512001
l
Adapter
se1g0
II ST16610001 This tool is used to
pull
pilot bushing
out of
place
All Fig
EM 66
Pilot
bushing puller
L ser ies
SE191
EM 3 5
r
Engine
Mechanical
Tool number
For Refer ence
No Descr iption
use
page
or
tool
name
Unit mm in
on
Figur e
No
12
STl742000l This tool
is
used to
pr event
chains
fr om
falling
out
of
place
All
Fig
EM
19
in
r emoving cylinder
heads
or ear n
gear s
and shafts Lser ies
Chain
stopper
40 1S1
r
SE196
13
STl93 20oo0
This toolis
used
totake
oil filter
out
of
place
n
tightening
All
Page
EM4
Oil filter
wr ench
the
filter donot use this tool
to
pr event
excess
tightening
models
120
47
SE197
14 KV3 0100200 This tool is used toinstall
clutch
assembly
to
engine
All
Fig
EM
107
L
ser ies
Clutch
aligning
bar
SEGOl
Piston
r ing
compr essor
Thistool
is
used to
compr ess
piston
r ings
while
piston
is
being
inser ted into
cylinder
All
Fig
EM 92
models
15 EM03 470000
2
SE199
EM 3 6
DATSUN
PICK UP
MODEL
620 SERIES
I
NISSAN
J
NISSAN MOTOR CO
LTD
TOKYO
JAPAN
SECTION EL
ENGINE
LUBRICATION
SYSTEM
ENGINE LUBRICATION
SYSTEM
EL 2
SERVICE
DATA AND
EL
5
SPECIFICATIONS
TROUBLE
DIAGNOSES
AND
EL 5
CORRECTIONS
SPECIAL
SERVICE TOOLS
EL 6
ENGINE LUBRICATION
SYSTEM
ENGINE
LUBRICATION
SYSTEM
CONTENTS
LUBRICATION
CIRCUIT
01
L PUMP
Removal
Installation
Disassembly
and
assembly
EL 2
EL 2
EL 2
EL 2
EL 3
Inspection
OIL
PRESSURE
REGULATOR
VALVE
OIL
FILTER
RELIEF
VALVE
EL 3
EL 4
EL 4
EL 4
E L049
Fig
Elr I
Lubr icating
cir cuit
LUBRICATION
CIRCUIT
The
pr essur e
lubr ication
ofthe
engine
is
accomplished by
a tr o
choid
type
oil
pump
This
pump
dr aws the
oil
thr ough
the oil str ainer
into
pump
housing
and then for ces it
thr ough
the full flow
type
oil filter
intothe
main oil
galler y
Par t ofthe
oil is
supplied
toall cr ankshaft
bear ings
chain
tensioner and
timing
chain
Oil
supplied
to cr ankshaft
bear ings
is fed to
connecting
r od
bear ings
thr ough
the dr illed
passages
in the cr ankshaft Oil
injected
fr om
jet
holes on
connecting
r ods Iubr i
cates the
cylinder
walls and
piston
pins
The
other
par t
ofthe oil is
br ought
to
the oil
galler y
in the
cylinder
head to
pr ovide
lubr ication
ofthe valve mechanism
and
timing
chain as shown in
Figur e
EL2
ELOSO
Fig
EL 2
Lubr icating
vallie mechanism
EL 2
Fr om this
galler y
oil holes
go
dir ectly
toall camshaft
bear ings
thr ough
cam
br ackets
Oil
supplied
thr ough
the No2
and
No3 camshaft
bear ings
is then fed
tothe r ocker
ar m valve and eam
lobe
thr ough
the
oil
galler y
in
the
camshaft and the
small channel at the
base cir cle
por tion
ofeach ear n
OIL
PUMP
The
oil
pump
is
secur ed on the
bottom ofthe fr ont cover with four
boltsand dr iven
by
the oil
pump
dr ive
spindle
assembly
which
is
dr iven
by
the helical
gear
onthe cr ankshaft
The oil
pump
assembly
consists of
an oil
pr essur e r egulator
valve and
outer and
inn r
r otor s
The
spr ing
loaded oil
pr essur er egu
lator valve limits the oil
pr essur e
toa
maximum
of56
kg
em 80
psi
Removal
I
Remove distr ibutor
2
Dr ain
engine
oil if
necessar y
3
Remove
oil
pumpbody
with
dr ive
spindle
assembly
Installation
I
Befor e
installing
oil
pump
on
engine
tur n cr ankshaft
sothat No
I
piston
is
at TD C
ENGINE LUBRICATION
SYSTEM
2 Fill
pump
housing
with
engine
oil
then
align punch
mar k
of
spindle
with hole in oil
pump
as
shown in
Figur e
EL
3
Punch mar k
EL009
Fig
EL3
Aligningpunch
mar k
and oil hole
3
Using
a new
gasket
install oil
pump
and dr ive
spindle
assembly
so
that the
pr ojection
on
its
top
is
located in II 25 a m
position
at
this time the smaller bow
shape
will
be
placed
towar d the fr ont as shown
in
Figur e
EL
4
JI
I
c
J
V
Fr ont
J
@
9@
tr
i
d
L
It I
I EL010
Fig
EL
4Setting
dr ive
pindle
o
EL011
Fig
EL
5 Imtalling
oil
pump
Ascer tain whether
or
not
the
en
gagement
is inor der
by checking
the
top
of
spindle thr ough
distr ibutor fit
ting
hole
4
Tighten
bolts
secur ing
oil
pump
tofr ont cover
Disassembly
and
assembly
I Remove
pump
cover
attaching
bolts
pump
cover and cover
gasket
and slide
out
pump
r otor s
2 Remove
r egulator
cap
r egulator
valve and
spr ing
3
Install
pr essur e r egulator
valve
and r elated
par ts
4Install
outer r otor
inner r otor
and shaft
in
pumpbody
and donot
tur n cover
gasket up
CD
El012
r
@
@
CD@
1
Oil
pump
body
2
Inner r otor and shaft
3 Outer
r otor
4Oil
pump
cover
5
Regulator
valve
6
Regulator
spr ing
7 Washer
8
Regulator
cap
9 Cover
gasket
Fig
EL
6
Oil
pump
Inspection
Wash all
par ts
in
cleaning
solvent
and
dr y
with
compr essed
ir
I
Inspect pumpbody
and cover
for cr acks or
excessive
wear
2
Inspect
pump
r otor s for excessive
Rotor side clear ance
r otor
tobottom
cover
Olm
in
Rotor
tip
clear ance
@
mOl
in
Outer r otor to
body
clear ance
D
mm
inl
EL
3
wear
3
Check inner
r otor shaft for
looseness in
pumpbody
4
Inspect r egulator
valve for
wear
or
scor ing
5
Check
r egulator spr ing
tosee
that
it is not
wor non
its
side or
collapsed
6
Using
a
feeler
gauge
check
tip
clear ance 2 and
outer r otor
to
body
clear ance I
shown
in
Figur e
EL 7
1 Outer
r otor to
body
clear ance
2
Tip
clear ance
3
Gap
between
r otor and
str aight edge
4
Gap
between
body
and
str aight edg
e
Fig
EL 7
Checking
r otor clear ance
7
Place a
str aight edge
acr oss
the
face of
pump
and
depr ess
it
slightly
as
shown in
Figur e
EL 7
Check
gap
4
between
body
and
str aight edge
or
gap
3
between
r otor and
str aight edge
The
gap
should be 003 to
0
06
mm
00012 to
00024in then
r otor
side
clear ance r otor tobottom
cover clear ance with
gasket
should
satisfy
the
specifications
Standar d
Wear
limit
0 04
to
0
08
00016
to
0003 2
020
0 0079
Less
than
0 12
0
0047
0
20
00079
0
15 to
021
0
0059
to00083
0 5
00197
ENGINE LUBRI
CATION SYSTEM
Note
Pump
r otor s and
body
ar e
not
ser viced
separ ately
If
pump
r otor s
or body
ar e
damaged
or wor n
r eplacement
ofthe entir e oil
pump
assembly
is
necessar y
Tightening
tor que
Oil
pump
mounting
bolts
Oil
pump
cover
bolts
Regulator
valve
cap
nut
Specifications
Oil
pr essur e
at
idling
Regulator
valve
spr ing
Fr ee
length
Pr essur ed
length
Regulator
valve
opening pr essur e
OIL FILTER
The
oil filter is a
car tr idge type
The oil filter element should be
r eo
placed per iodically
with
the use
ofOil
Filter Wr ench
ST193 20000
When
installing
an oil filter
fasten
it to
cylinder
block
by
hand
Note Do
not
over tighten
filter or oil
leakage may
occur
OIL
PRESSURE
REGULATOR
VALVE
The oil
pr essur e r egulator
valve is
not
adjustable
At
the r eleased
position the
valve
per mits
the
oil
to
by pass thr ough
the
passage
in
the
pump
cover
tothe inlet side ofthe
pump
Check
r egulator
valve
spr ing
to
ensur e that
spr ing
tension is
cor r ect
kg
m
ft Ib
kg
m ft lb
kg
m ft lb
kg
cm2
psi
mm
in
mm
in
kg
em
2
psi
RELIEF
VALVE
The r eliefvalve located at the
center
por tion secur ing
oil
fIlter to
the
cylinder
block
by
passes
the
oil
intothe
main
galler y
when the oil
fIlter element is
excessively
clogged
STl93 20000
EL015
Fig
EL9
Removing
oil
filter
EL 4
EL014
Fig
ELB
Regulator
value
ll
to
15 80to
11
0
7 to
10
5 Ito7
2
4
to
5 29 to3 6
08to28
II
to
40
525 2067
3 48
13 70
3 5to5 0 50to
71
With oil
fIlter r emoved check
valve unit for
oper ation
Inspect
for a
cr acked or br oken
valve If
r eplace
ment
is
necessar y
r emove
valve
by
pr ying
it
out with a
scr ewdr iver
Install a new valve
in
place
by
tapping
it
EL016
Fig
ELJO Relief
lJOlue
ENGINE
LUBRICATION
SYSTEM
SERVICE
DATA AND
SPECIFICATIONS
Oil
pump
Standar d
Wear limit
mm
in
0 04
to
008
00016 to0
003 2
lessthan
012 00047
0
15toO 21
00059 to
0
0083
0
20
0
0079
0
20
00079
0
5
0
0197
Rotor side clear ance
r otor tobottom
cover
Rotor
tip
clear ance
mm
in
Outer r otor to
body
clear ance mm
in
Oil
pr essur e r egulator
valve
Oil
pr essur e
at
idling
Regulator
valve
spr ing
Fr ee
length
Pr essur ed
length
Regulator
valve
opening
pr essur e
kg
cm2
psi
0
8to28
II
to
40
mm in
mmOn
kg
em2
psi
525 2
067
3 48 13 70
35to
5
0
50to
71
Tightening tor que
Oil
pump
bolt
Oil
pump
cover bolt
Regulator
valve
cap
nut
kg
m ft lb
kg
m ft lb
kg
m
ft
Ib
11to15
8 0
to108
0
7to
1
0
5 1
to
7 2
4to5 29
to3 6
TROUBLE
DIAGNOSES
AND CORRECTIONS
Condition
Pr obable causes
Cor r ective
actions
Oil
leakage Damaged
or
cr acked
body
cover
Oil
leakage
fr om gasket
Oil
leakage
fr om
r egulator
valve
Oil
leakage
fr omblind
plug
Replace
Replace
Tighten
or
r eplace
Replace
Decr eased oil
pr essur e
Leak
ofoil
in
engine
oil
pan
Dir ty
oil str ainer
Damaged
or wor n
pump
r otor s
Faulty
r egulator
Use of
poor quality
engine
oiL
Cor r ect
Clean or
r eplace
Replace
Replace
Replace
War ning
light
r emains on
engine
r unning
Decr eased oil
pr essur e
Oil
pr essur e
switch
unser viceable
Electr ical fault
Pr eviously
mentioned
Replace
Check
cir cuit
Noise Excessive
backlash
in
pump
r otor s
Replace
EL
5
No
Tool number
tool name
STl93 20000
Oil filter
wr ench
ENGINE LUBRICATION
SYSTEM
SPECIAL
SERVICE TOOL
Descr iption
Unit
nun
in
For
use
on
Refer ence
page
or
Figur e
No
This tool
is
used
to
take oil f1Iter
out
of
place
In
tightening
All
Fig
EL 9
thef1Iter donot use thistool to
pr event
excess
tightening
models
I
120
47
SE197
EL 6
DATSUN
PICK UP
MODEL
620
SERIES
L
NISSAN
I
NISSAN
MOTOR CO LTD
TOKYO JAPAN
SECTION
CO
COOLING
SYSTEM
COOLING SYSTEM
SERVICE DATA
AND
SPECIFICATIONS
TROUBLE DIAGNOSES
AND
CORRECTIONS
CO
2
CO
6
CO 7
DESCRIPTION
COOLANT LEVEL
DRAINING AND FLUSHINGTHE
COOLINGSYSTEM
WATER PUMP
REMOVAL AND
INSTALLATION
DISASSEMBLY
INSPECTION
AND ADJUSTMENT
TORQUE COUPLING
REMOVAL
AND
INSTALLATION
DESCRIPTION
The
cooling
system
is ofthe con
ventional
pr essur e type
A
centr ifugal
pump
installed
on
the
timing
chain
cover ser ves to
cir culate the
coolant
The
pr essur e type
r adiator filler
cap
installed on the r adiator
oper ates
the
cooling system
at
higher
than
atmos
pher icpr essur e
The
higher
pr essur e
r aises the
boiling point
of
the
coolant and
in
Cooling System
COOLING SYSTEM
CONTENTS
CO 2
CO
2
OISASSEMBL Y
INSPECTION
TEM COUPLlNG
INSPECTION
THERMOSTAT
REMOVAL AND
INSTALLATION
INSPECTION
RADIATOR
REMOVAL AND
INSTALLATION
INSPECTION
CO
2
CO
2
CO 3
CO
3
CO 3
CO
3
CO 4
cr eases
the
cooling efficiency
of
the
r adiator
When
the
ther mostat is closed
the
coolant r emains in the
cylinder
head
and
block for swift
war ming up
ofthe
engine
After it r eaches
nor mal
oper
ating
temper atur e
the
coolant cir cu
lates
thr ough
ther adiator
The
cooling
fan
dr ive is ofa
coupling type
COOLANT
LEVEL
The
coolant level should
be check
ed
and maintained at SO
mm
197in
below
the
upper
face offiller
neck
whenthe
engine
is cold
C0055
Fig
CO
I Cooling
r y
lem
Caution
Toavoid ser ious
per sonal
injur y
never r emove I3 diator
cap
quickly
when
engine
is hot Sudden
r elease of
cooling
systempr essur e
is
ver y
danger ous
CO2
CO 4
CO 4
CO 4
CO 5
CO 5
CO 5
CO 5
CO 5
CO 5
CO 6
Ifit is
necessar y
tor emover adiator
cap
wben r adiator is hot tur n
cap
slowly
counter clockwise
tother
step
After all
pr essur e
inthe cool
ing system
is r eleased tom
cap
passing
the
stop
and r emoveit
DRAINING
AND FLUSHING
THE
COOLING
SYSTEM
Todr ain
the
cooling system
r e
move r adiator
cap
r elease dr ain
cock
at the bottom
ofr adiator and dr ain
plug
on
the
r ight
side of
cylinder
block Ifthe
heater
system
is installed
set heater
temper atur e
contr ol valve to
open position
After the
coolant is
dr ained
completely
close dr ain
cock
and
plug
and r efill the
system with
cleansoft water
WATER PUMP
The
water
pumpcooling
fan
pulley
and
tor que
coupling
ar e
a unitized
constr uction
The water
pump
is of
a
centr ifugal
type
which
is mounted on the
engine
fr ont cover
The
pump
shaft
is
suppor ted
by
a
double r ow
ofball
bear ings
pr ess
fit
in
an aluminumdie cast
pumpbody
The
bear ings
ar e
per manently
lubr icated
and sealed
to
pr event
loss oflubr icant
and
entr y
of
dir t
The
pump
is
pr ovided
with an
impeller
which tur ns on
a steel
shaft
The
steel shaft r otates
together
with
the
tor que
coupling
wheeL The volute
chamber is built in the
engine
fr ont
cover
assembly
The inlet of
the
pump
is
connected
to
the r adiator s lower tank
by
a hose
i
o
CQ047
Fig
CO 2
Water
pump
and
engine
fr ont cover
REMOVAL AND
INSTALLATION
Removal
into
a clean
con
assembly
I
CQ048
Fig CO 3 Removing water
pump
Installation
1
Be
sur e
toclean the
gasket
sur
faces in contact with
pump
and fr ont
cover
Always
use new
gaskets
when
installing
pump
assembly
Be sur e to
tighten
bolts
Cooling
System
Tightening
tor que
04to
0 5
kg
m
3
0to3 6 ft lb
2
Fill
cooling system
and check for
leaks at
pump
3
Install fan blade
and
tighten
at
taching
bolts
secur ely
Install belt and
adjust
for
specified
tension
4
Oper ate
the
engine
at fast
idling
and r echeck for leaks
5 Install fanshr ouds
Note Ensur e that clear ance between
shr oud and Can
is
evenat
any
place
DISASSEMBLY
Water
pump
is
made
ofaluminum
and
its
bear ing
outer r ace
is ofa
pr ess
fit
type
For this
r eason
water
pump
should
not be disassembled
INSPECTION AND
ADJUSTMENT
Inspection
Inspect
pumpassembly
for
the
fol
lowing
conditions and
r eplace
ifnee
essar y
1
Badly
r usted or cor r oded
body
as
sembly
and
vane
2
Excessive
end
play
or
r oughness
of
bear ings
in
oper ation
3 Reduced
cooling efficiency
due
to
deter ior ated silicone oil
4Oil
leakage
in
tor que coupling
Adjustment
Fan
belt
should
be
pr oper ly
ad
justed
at all times A
tight
belt causes
wear
of
alter nator
and water
pump
bear ings
A loose belt
br ings
about
impr oper cooling
fan water
pump
and alter nator
oper ation
Check the belt slack between alter
nator and fan
pulley by
for ceof10
kg
22lb
Slacknessoffanbelt
8to
12
mm
03 1 to047
in
If
adjustment
is
necessar y
loosen
bolt
r etaining
alter nator
adjusting
bar
toalter nator
Move
alter nator
towar d
or
away
fr om
engine
until the cor r ect
tension is obtained
TORQUE
COUPLING
Except
air
conditioner
equipped
models
The
tor que
coupling keeps
the
fan
speed
at 2500
r pm
r ated or
below
to
conser ve hor sepower
at
high engine
speed
It also
helps
r educefan
noise to
a minimum
dur ing high speed oper a
tion
This
unit is filled with a
special
silicone
oil used as
a
fluid
coupling
whichcontr ols
the
fan
speed
Silicone
oil
can not
be
r eplenished
1
Tor que
coupling
wheel
2
Tor que
coupling
cover
3
Tor que
coupling
bear ing
4
Pulley
5
Water
pump
C0060
Fig
CO 4Sectional view of
tor que
coupling
and water
pump
00
3
REMOVAL
AND
INSTALLATION
To
r eplace
the
tor que
coupling
follow
the
same
pr ocedur e
as in the
water
pump
The
tor que coupling can
not be
separ ated
fr om the
water
pump
Cooling System
DISASSEMBLY
The
tor que
coupling
is
so
designed
that it
can
not be
disassembled
INSPECTION
Inspect
tor que coupling
for oil
leakage
If
necessar y
r eplace
TEM
COUPLl G
For air conditioner
equipped
models
Tem coupling
is
a
type
offan
coupling
which is
pr ovided
with a
temper atur e
contr ol
system
The conventional
coupling
always
slips
the fan
at
a high
speed
under
a
constant r atio
r egar dless
of
the
engine
cooling
r equir ement
The
slipping
r atio
ofthe Ter n
coupling
however
is
pr oper ly
changed
withthe
cooling r equir ement
ON denotes
that
cooling
is r e
quir ed
and the fan
oper ates up
to
about
2
150
r pm
When
high
cooling
is
not
r equir ed
dur ing
cold season with
the
engine
war med
up
etc the
oper
w
6
I
1
Bimetal
ther mostat
2
Slide valve
3 Reser ve
chamber
for OFF
4
Bear ing
5
Dr iving
chamber for
ON
6
ouplingpar t labyr inth
coon
Fig
CO 5 Cr QMsectional view
of
Tem coupling
ation is
placed
under
OFF condition
and the fan
slips
at
about
1 650
r pm
The coiled bimetal ther mostat
installed
on
thefr ont center
por tion
of
the Tem
coupling
detects
temper atur e
ofair
passing
thr ough
the
r adiator
The
air
temper atur e
is
dir ectly
r elative tothe
engine
coolant
temper a
tur e and the inside
slide valve is
opened
or closed
as
r equir ed
and thus
the ON OFF
contr ol is
per for med
When the air
temper atur e
r ises
the
bimetal is
expanded
and the
valve
is
opened
silicon oil is for war ded
tothe
gr oove
that
tr ansmits
tor que
and the
CO 4
system
is
placed under ON
con
dition
When
the
valve closes siliconeoil is
not
supplied
tothe
dr iving
chamber
oil
in
the
dr iving
chamber is
accumu
lated on
per ipher y
due tothe
centr if
ugal
for ce and led
intothe r eser ve
chamber Now
oil
is
eliminated fr om
the
dr iving
chamber
and the
system
is
placed
under OFF condition
With this
system when fan
cooling
is not
r equir ed
the
output
loss
is
minimized
and
noise
can be far
r educed
Conventional
COUplin9
WATER PUMP SPEED
F
Z
Ter n
coupling
WATER
PUMP
SPEED
C0029
Fig
CO 6
Char acter istic
of
Ter ncoupling
INSPECTION
Check Tem
coupling
for oil
leakage
or bend ofbimetal
Ifthe above
symptoms
ar e found
r eplace
it with
a new one as an
assembly
THERMOSTAT
A wax
pellet type
ther mostat
is
mounted in the
ther mostat
housing
at
the
cylinder
head
water outlet
The function
ofthe ther mostat
is
to
contr ol
the
flowofcoolant
facili
tating
fast
engine
war m
up
and
r egu
lating
coolant
temper atur e
The
ther
mostat
is
designed
to
open
and close
at
pr edeter mined
temper atur es
and
if
not
oper ating
pr oper ly
should
be
r e
moved and tested as
descr ibed below
REMOVAL
AND
INSTALLATION
I
Dr ain
coolant
par tially
2
Disconnect
upper
r adiator
hose at
water
outlet
3
Remove
bolts
and r emove
water
outlet
gasket
and
ther mostat fr om
ther mostat housing
Fig
CO 7
Removing
ther m06t
t
Cooling System
4
After checking
ther mostat
r e
install
with
a new
housing gasket
in
place
5 Reinstall
water
outlet
6
Replenish
coolant and check
for
leaks
INSPECTION
A
sticking
ther mostat
will
pr event
the
cooling
system
fr om
functioning
pr oper ly
Ifthe ther mostat sticks
in
the
open
position
the
engine
war ms
up
ver y slowly
If
the ther mostat
sticks
in
the closed
position
over
heating
will r esult Ther efor e the ther
mostat
should be
inspected
to
make
sur e
that it is in
good
condition
1 Measur e coolant temper atur e
when ther mostat valve
star ts to
open
2 Measur e the
maximum
lift
of
ther mostat valve
Fig
CO S
Impecting
ther m06t t
Temper ate Fr igid
Tr opical
type
type
iype
Valve
opening
80
5 to 83 5 86 5to
895 75
to
78
temper atur e
177 to183 187 to193
167
to172
oCOF
Maximum
valve lift 895 81
00 8
90
mmoC
in
F
03 1 203
03 1
212 03 1
194
Ifther mostat
does not
oper ate
at
the above
specified
temper atur e
it
must be
r eplaced
because it cannot be
r epair ed
RADIATOR
The
r adiator is
a conventional down
flow
type having
top
and
bottom
tanks
to
distr ibute the coolant flow
unifor mly thr ough
the ver tical tube of
r adiator
cor e
The
r adiator filler
cap
is
designed
to
maintain
a
pr e
set
pr essur e
0
9
kg
cm2 13
psi
above
atmospher ic
pr essur e
The r eliefvalve
consisting
of
a
blow
off
valve and a
vacuum
valve
helps
to
pr event
the coolant fr om
boiling by giving
pr essur e
toit How
ever
when
the
pr essur e
is r educed
below
atmospher ic
pr essur e
the
vacu
um valve allows
air
tor e
enter
the
r adiator
pr eventing
the for mation ofa
vacuum
inthe
cooling
system
CO
5
On models
equipped
with auto
matictr ansmission
the oil cooler
is
combined with
the
r adiator
tocool
tr ansmission fluid
REMOVAL
AND
INSTALLATION
Dr ain
coolant
intoa clean con
tainer
2
Disconnect
r adiator
upper
and
lower hoses
On models
with auto
matictr ansmissions disconnect
cooler
inlet and
outlet lines fr omr adiator
3
Remove
fan shr oud r etaining
bolts
and
r emove
fan
shr oud
4
Remove
fr ont
gr ille
5
Remove
r adiator r etaining
bolts
and
then
r emove
r adiator
upwar d
6
Install r adiator
in the r ever se
se
quence
of
r emoval Note
the fol
lowing
I Inser t hoses
in
their
positions
until
they
bottom
2 Ensur e that ar r ow mar ks
on
hoses
ar e
clear ly
visible
fr om
upper
r
dir ection when hoses ar e
assembled
3 Ensur e
that clear ance between
r adiator
hose and
any adjacent par ts
is
3 0mm I 181 in minimum
On mod
els
equipped
with
air
conditions a
minimumclear ance of18
mm 0
709
in
should
exist
between
compr essor
and hose
4Ensur e
that clear ance between
shr oud and fan is
even
at
any place
Note Be
car eful not to
damage
r adia
tor
fins and
cor e
tube when in
stalling
INSPECTION
Radiator
cap
should be
checked for
wor king pr essur e
at
r egular
tune
up
inter vals
Fir st
check r ubber seal on
cap
for
tear s cr acks or deter ior ation
Cooling System
after
cleaning
it Then
install r adiator
cap
on
a
tester If
cap
does
not
hold
or
will
not r elease at the
specified pr es
sur e
r eplace cap
Fig
CO 9
Telting
r adiator
cap
Also
inspect
r adiator
for
leakage
using cap
tester
and
applying
a
pr es
sur e
of
1
6
kg cm
228
psi
Ifa
leakage
is
detected
r epair
or
r eplace r adiator
Fig
CO
IO
Testing cooling 6ystem
pUS
ur e
SERVICE
DATA AND SPECIFICATIONS
Ther mostat
Valve
opening temper atur e
oC F
Maximum
valve
lift mmoC
inj
F
Radiator
Type
Manual tr ansmission
Automatic
tr ansmission
Cap
r elief
pr essur e
Cooling system
Leakage testing pr essur e
Capacity
Manual tr ansmission
Automatic
tr ansmission
Fan
Number ofblades
x outer diameter
Without air
conditioner mm
in
With air
conditioner mm
in
kg
em
psi
kg
em
psi
liter s US
qt Imp
qt
liter s US
qt Impqt
CO 6
Temper ate
Fr igid type Tr opical type
type
80 5
to
83 5 86 5to895 75 to
78
177
to
183
187
to193
167
to172
8 95
8 100 890
03 1 203
03 1 212 03 1
194
Cor r ugated
fin
type
Cor r ugated
fin
type equipped
with
oil cooler
0 9
13
1 6 228
with
heater
8
0
8 Ii7
7 8 8
Y
6
Ji
without heater
747J i6
1i
7 2
7 X
6
X
7 x
3 80
15
8
x
3 80
15
Condition
Loss
ofwater
Poor cir culation
Cor r osion
Over heating
Over cooling
Cooling System
TROUBLE DIAGNOSES
AND CORRECTIONS
Pr obable
cause
Damaged
r adiator seams
Leaks at heater connections or
plugs
Leak at
water
temper atur e
gauge
Loose
joints
Damaged cylinder
head
gasket
Cr acked
cylinder
block
Cr acked
cylinder
head
Loose
cylinder
head
bolts
Restr iction in
system
Insufficient coolant
Inoper ative
water
pump
Loose
fanbelt
Inoper ative
ther mostat
Excessive
impur ity
in
water
Infr equent
flushing
and
dr aining
of
system
Inoper ative
ther mostat
Radiator finchoked
withmud chaffetc
Incor r ect
ignition
and valve
timing
Dir ty
oil and
sludge
in
engine
Inoper ative
water
pump
Loose fan
belt
Restr icted r adiator
Inaccur ate
temper atur e gauge
Impur ity
in
water
Inoper ative
ther mostat
Inaccur ate
temper atur e gauge
CO
7
Cor r ective action
Repair
Repair
Tigh
ten
Tighten
Replace
Check
engine
oil for contamination and r efill
as
necessar y
Replace
Check
engine
oil in cr ankcase for
mixing
with
water
by pulling
oil level
gauge
Replace
Tighten
Check
hoses
for
cr imps
and
clear
the
system
ofr ust and
sludge by
flushing
r adiator
Replenish
Replace
Adjust
Replace
Use
soft clean water
Rain
water
is satis
factor y
Cooling
system
should
be
dr ained
and
flushed
per iodically
Per manent antifr eeze
Ethylene glycol
base
can be
used
thr ough
out
the
seasons of
the
year
and
change
per iodically
at inter vals r ecommended
Replace
Clean
out
air
passage
thor oughly by using
air
pr essur e
fr om
engine
sideofr adiator
Adjust
Refill
Replace
Adjust
Flush r adiator
Replace
Use soft cleanwater
Replace
Replace
DATSUN PICK UP
MODEL 620
SERIES
l
NISSAN
I
NISSAN
MOTOR CO
LTD
TOKYO
JAPAN
SECTION
EF
ENGINE
FUEL
AUTOMATICTEMPERATURE
CONTROL
AT Cl
AIR CLEANER
IDLE COMPENSATOR
FUEL FILTER
MECHANICAL FUEL PUMP
ELECTRIC FUEL
PUMP
CARBURETOR
H 2
H 7
H
8
H
9
H
ll
H14
Engine
Fuel
AUTOMATIC
TEMPERATURE CONTROL AT
C
AIR
CLEANER
DESCRIPTION
OPERATION
AT
C
AIR
CLEANER
HOT AIR
OPERATION
AT
CAIR CLEANER COLD AIR
OPERATION
AT C AIR CLEANER COLD AND
HOT
AIR OPERATION
TEMPERATURE SENSOR
DESCRIPTION
The air
cleaner r emoves dust and
dir t fr om
the
air befor e
it enter s the
car bur etor and
engine
It also
muffles
noise
r esulting
fr om the
intake
ofair
intothe
engine
The air
cleaner
especially
designed
for
impr oved
exhaust emission
contr ol
is r efer r ed to
as Automatic
Temper a
tur eContr ol
Air Cleaner In or der to
r educe
HCemission
when the
under
hood
temper atur e
is
below 3 00C
860F
the
automatic
temper atur e
contr ol
system
maintains the
temper a
tur e
ofair to
be sucked in the
car bur e
tor at 3 0
to540C 86 to1290F
ther eby enabling
lean
setting
for
car bur etor
calibr ation
n
addition to
this
the
automatic
temper atur e
con
twl
system
is
effective
to
impr ove
war m
up
char acter istics ofthe
engine
CONTENTS
EF2
EF3
VACUUM
MOTOR AND AIR
CONTROL
VALVE
REMOVAL AND
INSTALLATION
TEMPERATURE
SENSOR
VACUUM
MOTOR
FRESH
AIR
DUCT
AIR
CLEANER
INSPECTION
1 AIR
CLEANER
ELEMENT
2
HOT
AIR
CONTROL
SYSTEM
EF3
EF4
EF4
EF5
and
to
r emove
car bur etor
icing
The
AT C air
cleaner
system
con
sists
ofthe
following
devices
1 Air cleaner
element
The
air
cleaner
element
employed
is
a
viscous
paper type
It
r equir es
only
per iodical r eplacment and should not
be
cleaned
2
Automatic
temper atur e
contr ol
air
cleaner
In the A
T C
air
cleaner the air
contr ol valve is actuated
by
intake
manifold
vacuumto
contr ol
the intake
air flow
cir cuit The
temper atur e sen
sor detects the
temper atur e
inside the
air
cleaner and
opens
or closes the
vacuum
passage
3
Hot air duct
The hot air duct is
mounted on
the
exhaust manifold The air war med
up
EF2
EF5
EF
5
EF
5
EF
5
EF5
EF6
EF6
EF
6
EF
6
between the
exhaust manifold
and hot
air duct
is led tothe air cleaner
thr ough
the
hose
4
Blow
by
gas
filter
The blow
by
gas
nIter r emoves
dir t
and oil fr om
the
blow
by gas
sucked
in
the air cleaner fr om the
engine
r ocker
cover
5
Fr esh air
duct
Except
for
Canada
The fr esh
air
duct leads
the
outside
fr esh air
dir ectly
to
theair cleaner
6
Idle
compensator
See
par agr aph
Idle
Compensator
Page
EF7
7
Altitude
compensator
Califor nia
models
See
par agr aph
Altitude
Compensa
tor
Page
EF
20
Engine
Fuel
@
1
Fr esh
air duct
Except
for Canada
2
Air
inlet
pipe
3 Vacuum
motor
assembly
4Air contr ol valve
5
Hot air
pipe
6
Idle
compensator
7
Blow
by
gas
fiIteT
8
Temper atur e
sensor assembly
9
Altitude
compensator
Califor nia models
EF713
Fig
EF
1 Automatic
temper atur e
contr ol air cleaner
OPERATION
The automatic
temper atur e
contr ol
system
ofthe
air
cleaner
is
contr olled
by
the
inlet
air
temper atur e
and
the
load condition
ofthe
engine
The inlet
air
temper atur e
is detected
by
the
sensor and the vacuummotor is actu
ated
by
the
engine
intake vacuum
Under hood air
Sensor vacuumat
Air
contr ol valve
Sensor
oper ation
temper atur e
vacuummotor side
oper ation
Below 60
mmHg
Open
cold
air
Below3 00C
23 6
inHg
860
F
Close
Above 210mmHg
Close hot
air
8 27
inHg
3 0
to
540C
Half
open
Open
86
to1290
F
cold air
hot air
Above
55oC
Open
cold
air
Open
13 10F
AT C AIR CLEANER HOT
AIR
OPERATION
When
the under hood
air
temper a
tur e is low
the
sensor
air bleed
valve
r emains in the
closed
position
and
establishes
vacuum
passage
between
the
intake
manifold
and
vacuum
motor With this condition the vacu
ur n
at the intake
manifold side actu
ates
the air
contr ol
valve attached to
the
vacuum
motor
diaphr agm
tointr o
duce
hot air intothe air cleaner
thr ough
the hot air
duct on
the
ex
haust
manifold
EF3
Under hood air
I
@
Dr
Under hood air
I
Engine
Fuel
f
f
l
l
ID
s
6
Cif
Ittl
ID
Air inlet
pipe
Air contr olvalve
Hot air
pipe
Diaphr agm
Vacuum
hose
Diaphr agm spr ing
Air bleed valve
closed
Temper atur e
sensor
assembly
Holair
EF114
Fig
EF2 Hotar
deliver y
mode
Dur ing
cold
engine oper ation
7
Tomanifold Small
vacuum
1 Air inlet
pipe
2 Air contr ol
valw
3 Hot air
pipe
4
Diaphnp
S Vleuumhoses
6
Diaphr agm pr inl
7 Air
bleed
valve
closed
II
Temper atur e
senSOr
assembly
EF20S
Fig
EF3 Cold air
deliver y
mode
Dur ing
cold
engine oper ation
f
1
J
liP
omanifold
2
@
Air inlet
pipe
Air
contr ol valve
Hot
air
pipe
Diaphr agm
Vacuum hoses
Diaphr agmspr ing
Air bleed valve
fully open
8
Temper atur e
sensor
assembly
EF715
Fig
EF4Cold air
deliver y
mode
Dur ing
hot
engine oper ation
ID
@
f
fjr
R
lfl
ow
2
under h r
5
r v
Itti
ID
Hot air
Air inlet
pipe
Air
contr ol valve
Hot air
pipe
Diaphr agm
Vacuumhose
Diaphr agmspr ing
Air bleed valve
par tially opened
8
Temper atur e
sensor
assembly
EF716
Fig
EF5
Regulating
air
deliver y
mode
EF 4
AT C AIR CLEANER
COLD AIR OPERATION
I
When under hood air
temper atur e
is low
The sensor air bleed
valve
r emains
in
the closed
position
and vacuum
passage
is
established between the in
take manifold and
the vacuummotor
and the intake manifold
vacuum
is
applied
tothe
vacuum motor
dia
phr agm
When the
vacuum
is
small or
when the
engine
is
oper ating
under
eavy
1004
the
air
contr ol valve
opens
widely
ir r espective
of
the
temper atur e
ar ound the
sensor tointr oduce the
under hood air
cold
air
for incr eased
power
ofthe
engine
2
When under
hood
air
temper atur e
is
high
The
sensor
air
bleed valve
opens
fully
toshut off
the vacuum
passage
between
the intake manifold and the
vacuummotor Due tothe for ceofthe
vacuum motor
diaphr agm
spr ing
the
air
contr ol
valve
closes thehot
air
pipe
ofthe air
cleaner
and
intr oduces the
under
hood
air
cold
air
AT CAIR CLEANER
COLD
AND HOT
AIR OPERATION
When the sensor
air
bleed valve
is
par tially opened
opening
of
the
air
contr ol valve
var ies
with the vacuum
of
the
intake manifold With the
air
contr ol valve half open
the
cold
air
and hot air ar e sucked
together
and
mixed for
contr olling
ofthe
air
tem
per atur e
ofthe
air
tobe intr oduced to
the
air
cleaner
TEMPERATURE
SENSOR
The
temper atur e
sensor
is
attached
to
the
inside ofthe
air
cleaner
The
bimetal built
in
the sensor detects
the
under
hood
air
temper atur e
and
opens
or
closes
the vacuum
passage
in the
sensor
The constr uction ofthe
temper a
tur e sensor is shown
in
the
following
CD V 00 @
I
I
@j
I
I
1
Pr otector cover
Scr ew
Adjusting
fr ame
Air
temper atur e
bi
metal
Rivet
Valveseat fr ame
Lower fr ame
Air bleed valve
Gasket
Fig
EF
6
Temper atur e
senior
EF206
VACUUM MOTOR AND
AIR CONTROL VALVE
The
vacuum
pr essur e
which
var ies
with
opening
ofthe car bur etor thr ot
tle acts
upon
the vacuum
motor
dia
phr agm
The valve
shaft attached to
the
diaphr agm
is then moved
up
or
down
in
r esponse
tothe vacuumon
the
diaphr agm
This
movement of
the
valve shaft
actuates
the air contr ol
valve
to
contr ol
the
temper atur e
ofthe
air to
be intr oduced
into
the
air
cleaner
pr to
I
1 Valve
spr ing
00
2
Diaphr agm
@
3 Retainer
E
F
207
4Valveshaft
Fig
EF7 Vacuummotor
REMOVAL AND
INSTALLATION
TEMPERATURE SENSOR
Removal
Using
plier s
flatten
clip
con
Engine
Fuel
neeting
vacuumhose tosensor vacuum
tube
I
Pipe
2 Calch
3
Fixed with
adhesive
4Hose
5
Tab
6
Clip
7 Gasket
EC019
Fig
EFB Removal
of
semor
2
Disconnect hose
fr om
sensor
3
Take off
clip
fr omsensor vacuum
tube and dismount
sensor
body
fr om
air cleaner
Note The
gasket
between
sensor
and
air cleaner is bonded tothe air
cleaner side and should not be
r emoved
Inatallatlon
Mount sensor on the
specified
position
For
mounting
position
ofsensor
see the
following
EF717
Fig
EF9
lalling
seor
2 Inser t
clip
intovacuum
tube
of
sensor After
installing
each vacuum
hose secur e hose with
the
clip
Note Be sur e toinstall
vacuumhose
cor r ectly
Cor r ect
position
is
R
H
side to Nissan
mar k at the
top
face
of
sensor
for intake manifold
LH side for vacuum
motor
VACUUM MOTOR
1
Remove
scr ews
secur ing
vacuum
motor
toair cleaner
2 Disconnect valve shaft attached
to
vacuum
motor
diapluagm
fr om
air
contr ol
valve
and r emove cacuum
motor
assembly
fr om
air
cleaner
3 Toinstall r ever se the r emoval
pr ocedur e
FRESHAIR DUCT
I Disconnect fr esh air duct at air
cleaner
2
Fr esh
air
duct
is
pr ovided
with
pr ojections
on
its air inlet side end
Hold
fr esh air duct with a hand and
car efully
pull
out fr om r adiator cor e
suppor t
while
tur ning
it in either
dir ection
3
To
install r ever se the
r emoval
pr ocedur e
Be sur e to
inser t
pr ojec
lions offr esh air duct
secur ely
into
mounting
hole
in
r adiator cor e
sup
por t
EF518
EF5
Fr esh air
duct
Air cleaner
Duct
mounting
hole
Radiator
Radiator
cor e
suppor t
Fig
EF
I0
Removal
offr esh
air duct
r
AIR CLEANER
1 Loosen
bolts
secur ing
air cleaner
toair cleaner br acket
2
Loosen air
cleaner lock
bolt and
r emove air
cleaner fr om car bur etor
Disconnect the
following
hoses when
dismounting
air
cleaner
Under hood air inlet
hose
Hot air inlet
hose
Vacuum
hose Sensor tointake
manifold
Vacuum hose Sensor tovacuum
motor
Vacuumhose
Idle
compensator
to
intakemanifold
Hose Air
pump
toair cleaner
Hose AB
valve
to
air cleaner
Hose Car bur etor
toair
cleaner
Blow
by
hose Air
cleaner
to
r ocker
cover
Hose Air
contr ol vaive to
air
cleaner Califor nia
models
only
3 To
install
r ever se
the r emoval
pr ocedur e
INSPECTION
1 AIR CLEANER
ELEMENT
Viscous
paper type
air cleaner
ele
ment does not
r equir e any cleaning
oper ation
until
it
is
r eplaced per iodi
cally Br ushing
or
blasting
oper ation
will
cause
clogging
and
r esult
inenr ich
ment
ofcar bur etor mixtur e
and
should never
be
conducted For
r eo
placement
inter val ofair
cleaner ele
ment r efer to Maintenance Sched
ule
2HOT
AIR
CONTROL SYSTEM
In
war m weather it is
difficult
to
find
out malfunctionofhot air contr ol
system
In
cold wea
thee
however
malfunction ofair contr ol valve
due to
disconnection
or
deter ior ationof
vacu
um
hose between intake manifold and
vacuum motor
and
insufficient dur a
bility
ofair contr ol valve
will cause
insufficient automaticcontr ol
oper a
tion
for intakeair and
r esult
in
engine
disor der
including
I
Stall
or
hesitation of
engine
oper
ation
2
Incr ease
in
fuel
consumption
3
uckof
power
Engine
Fuel
These
phenomena
r eveal malfunc
tion ofhot air contr ol
system
If
these
phenomena
should occur
check
hot
air contr ol
system
as
descr ibed
in the
following
befor e
car r ying
out
inspec
tion
ofcar bur etor
21 Vacuum
hose
Intake manifold
to3
way
connec
tor
3
way
connector to
temper atur e
sensor
3
way
connector
to
idle com
pensator temper atur e
sensor tovacu
um
motor
I
Check that
vacuum hoses ar e
se
cur ely
connected in
cor r ect
postion
2
Check each hose for
cr acks or
distor tion
hose
clip
for
condition
Note
Vacuum hose
position RH
sideofNissan
mar k onthe
top
of
sensor
is for
intake manifold L U
side of
the
mar k
is for
vacuum
motor
22
Vacuum
motor
I
With
engine stopped
disconnect
fr eshair
duct
Place
a mir r or
at the end ofair
cleaner inlet
pipe
as shown and
check
to
see if
air
con
tr ol valve
is in
cor r ect
position
EF213
Fig
EF11
Inspecting valve
position
Air
contr ol valve
is in
cor r ect
posi
tion ifits under hood air
inlet
is
open
and hot air inlet is
closed Check
air
contr ol valve
linkage
for
condition
2
Disconnect
vacuum motor
inlet
vacuum
hose and connect
another
hose tothe inlet to
apply
vacuumto
vacuum motor Vacuum can be
ap
plied by br eathing
in
the
hose end
as
shown
Place
a mir r or
at
the
end ofair
cleaner inlet
pipe
and
check to
see
if
air
contr ol
valve
is in cor r ect
position
EF 6
EF217
Fig
EF12
Inspecting
valve
position
Cor r ect
position
of
air
contr ol
valve
is
the r ever se
of
par agr aph J
above Air
contr ol valve is in cor r ect
position
if
under hood air inlet is
closed
and hot
air
inlet
is
open
3 With
hot
air
inlet
in
open posi
tion
as descr ibed
in
par agr aph
2
above
pinch
vacuumhose with
finger s
and cut off
air
fr omvacuum
hose In
thiscondition check that
air
contr ol
valve
maintains
the
condition
de
scr ibed
in
step
2
for mor e than 3 0
seconds and that hot
air
inlet
is
open
If
diaphr agm spr ing
actuates the
air
contr ol valve
by
its
spr ing
for ce to
open
under hood
air inlet
within 3 0
seconds
r eplace
vacuummotor as an
assembly
since this
may
be
r esulted
fr om
air leak at vacuum motor dia
phr agm
23 Temper atur e ensor
Check
temper atur e
sensor for func
tion
by
pr oceeding
as
follows Be
sur e
to
keepengine
cold befor e
star ting
test
I
With
engine
off
checkair
contr ol
valve for condition In
thiscase under
hood air
inlet
is
open
Use
a mir r or
for
inspection
as
22 1
above
2
Star t
engine
and
keepidling
Immediately
after
engine star ting
check air contr ol valve for
cor r ect
position
as descr ibed above
In
this
case
cor r ect
position
of
air contr ol
valve
is the r ever se of22 I
under
hood
air
inlet
is
closed and
hot
air
inlet
is
open
3 Check that air contr ol valve
gr ad
ually opens
tounder hood
air
inlet
side as
engine
war ms
up
When en
vir onmental
temper atur e
ar ound ter n
per atur e
sensor
is
low
spend
mor e
time
for
engine war ming upoper ation
to
facilitate smooth
oper ation
ofair
contr ol valve
Ifthe above test r eveals
any pr ob
lem
in the
oper ation
of
air
contr ol
valve
car r y
out
the
following
test
4Remove air
cleaner cover Set
temper atur e
sensing
element ofther
mistor or
ther mometer to
a
position
wher e
temper atur e
ar ound
sensor can
be
measur ed
In
thiscase
fIx
wir ing
of
ther mistor or
ther mometer on
the
bottom
sur face
ofair
cleaner
with
adhesive
tape
in
such a manner
that
the
set
position
of
temper atur e
sensing
DESCRIPTION
OPERATION
DESCRIPTION
The idle
compensator
is
basically
a
ther mostatic
valve
whichfunctions to
intr oduce the air
dir ectly
fr omthe air
cleaner to
the
intake manifold to
compensate
for abnor mal
enr ichment
of
mixtur ein
high
idle
temper atur e
The bimetal
attached tothe idle
compensator
detects
the
temper atur e
ofintake air and
opens
or closes
the
valve
Two
idle
compensator s
having
differ ent
temper atur e
char acter istics
ar e
installed
one
opens
at an intakeair
temper atur e
of
60 to700C
140 to
l580F
and
the other at 70
to900C
158
to
1940F
OPERATION
The constr uction ofthe idle
com
pensator
is
shown
inthe
following
Engine
Fuel
element will not be affected
by
air
flow
Then
install air cleaner cover
Fig
EF13
Checking temper atur e
sensor
IDLE
COMPENSATOR
CONTENTS
5
Car r y
out test
as descr ibed in
steps
I 2 and 3 above When air
contr ol valve
begins
to
open
tounder
hood air inlet side sever al minutes
after
engine star ting
r ead the
indica
tion
ofther mistor
or
ther mometer If
r eading
falls within the
wor king
ter n
per atur e
r ange
of
temper atur e
sensor
the sensor
is
nor mal If
r eading
ex
ceeds the
r ange
r eplace
the
sensor
withnewone
Note
Befor e
r eplacing
temper atur e
sensor check
idle
compensator
as
descr ibed in
Idle
compensator
EF7
EF7
REMOVAL
AND INSTALLATION
INSPECTION
EF
B
EF
8
q
EF222
1
Or ifice
2 Bimetal
3 Rubber valve
Fig
EF
14
Str uctur e
of
idle
compensator
Bi
metal
Intake
air
temper atur e
No
1
Below600C
1400F
60to70C
140
to
l580F
Above 700C
158
OF
Below
700C
1580F
70to
900C
158 to
1940F
Above 900C 1940F
No2
EF7
The idle
compensator
oper ates
in
r esponse
tothe
under hood
air
temper
atur e
as
shownbelow
Idle
compensator oper ation
Fully
closed
Close to
open
Fully
open
Fully
closed
Close to
open
Fully
open
Engine
Fuel
REMOVAL AND INSTALLATION
Remove air cleaner
cover
2 Remove hose
connecting
idle
compensator
and
3
way
connector
3 Loosen scr ews
secur ing
idle com
pensator
to
air
cleaner then r emove
idle
compensator
Notes
a
When
r emoving
idle
compensator
r emove
gasket
and
plate
b When
r emoving
scr ew
secur ing
idle
compensator
toair
cleaner be car e
ful
not to
miss thesaew
4Toinstall r ever se the r emoval
pr ocedur e
INSPECTION
I Check
that valve IS m closed
position
when
bi
metal
temper atur e
is
lower
than
oper ating
temper atur e
To
check br eathe
air into
tube or suck
DESCRIPTION
The fuel fJlter
is
a
car tr idge
type
It
uses a
paper
element which can be
checked for condition fr om the out
side
EF718
Fig
EF15 Location
of
idle
compenl
otor
air If
excessive air
leakage
is found
at
the valve
r eplace
idle
compensator
as
an
assembly
Note that twoidle com
pensator s
ar e mounted toair cleaner
and that it is
necessar y
to
plug
the
valve ofone ofthese idle
compensa
tor s soas to
pr event
air leak while
checking
the other one
@
CD
I
tl
1 Or ifice
2 Rubber valve
EF225
Fig
EF
16 Checking
idle
compelll
lor
FUEL
FILTER
1
Body
2
Paper element
3 Cover
1
EFOO5
Fig
EF
18 Sectional
view
ofcar tr idge
typefuel filter
EF
8
Note
When
checking
idle
compensa
tor on vehicle disconnect
hose
leading
toidle
compensator
and
connect other
hose then
car r y
out
checkas descn bed above
2
When bi
metal
temper atur e
is
above the
specified
oper ating
temper a
tur e
visually
check tosee ifthe
valve
is in
open
position
If
valve
is not
open r eplace
idle
compensator
as
an
assembly
Watcr
temper atur e
Obser ve
valve
11t
No
1 Bknctal
60to70De
140to1580F
NO 2 Bi metal
70
to
900C
158to
1940F
EF226
Fig
EF17
Checking
idle
compensator
3 Other s
I Check
hoses
for
cor r ect installa
tion
distor tion or cr acks
2
Check r ubber valve seat ofidle
compensator
for
sticking
or
any
other
faulty
conditions
REMOVAL
Disconnect inlet and outlet fuel
lines
fr omfuel
fJlter and r emove fuel
fJlter
Note
Befor e
disconnecting
fuel lines
use a container
to
r eceive the
fuel
r emaining
inlines
DESCRIPTION
FUEL
PUMP
TESTING
STATICPRESSURE
TEST
CAPACITY
TEST
DESCRIPTION
The fuel
pump
tr ansfer s fuel fr om
the tank tothe car bur etor insufficient
quantity
tomeet the
engine r equir e
ments
at
any speed
or
load
The fuel
pump
is a
pulsating type
designed
for
easy
maintenance It
con
sists ofa
body
a
r ocker ar m
assembly
a
fuel
diaphr agm
a fuel
diaphr agm
spr ing
seal inlet and
outlet
valves
Figur e
EF
19
shows a cr osssectional
view ofthe
pump
The fuel
diaphr agm
consists
of
specially
tr eated r ubber which
is
not
affected
by
gasoline
and held
in
place
by
two
metal discs
and
a
pull
r od
FUEL
PUMP
TESTING
A fuel
pump
is
oper ating
pr oper ly
when its
pr essur e
is
within
specifica
tions
and its
capacity
is
equal
tothe
engine
s
r equir ements
at all
speeds
Pr essur e and
capacity
must be deter
mined
by
twotests whilethe
pump
is
still
mounted on the
engine
Be sur e
ther e is fuel
in
the tankwhen
car r ying
out the tests
Engine
Fuel
MECHANICAL
FUEL PUMP
CONTENTS
EF 9
EF 9
EF 9
EF10
REMOVAL
AND DISASSEMBLY
INSPECTION
ASSEMBL
Y
EF
10
EF10
EF
11
1
1
Outlet valve
2
Diaphr agm
3
Diaphr agmspr ing
4Inlet valve
S Rocker
ann
EF006
Fig
EF19 Schematicview
offuelpump
STATICPRESSURE TEST
The static
pr essur e
test should be
madeas follows
I Disconnect fuel linebetween car
bur etor and fuel
pump
2 Connect a r ubber hose toeach
open
end ofa T connector and con
nect this connector hose
assembly
be
tween car bur etor and
fuel
pump
Note Locate
this Tconnector as
close
to
car bur etor as
possible
3 Connect
a
suitable
pr essur e gauge
to
the
opening
ofTconnector
and
fasten hose between car bur etor and
T
connector with
a
clipsecur ely
EF9
4
Run the
engine
at
var ying speeds
5
The
pr essur e
gauge
indicates
staticfuel
pr essur e
in the line
The
gauge r eading
should
be
within
the
following r ange
0
21 to0
27
kg
em2
3
0
to
3
8
psi
Note
If
the fuel in car bur etor float
chamber has
r unout
and
engine
has
stopped clip
and
pour
fuel
into
car bur etor Fasten
clip
secur e
ly
and
r epe
1 static
pr essur e
test
Pr essur e below the lower limit indi
cates extr eme wear on one
par t
or
a
small amount ofwear
oneach
wor king
par t
It
alsoindicates
r uptur ed
dia
phr agm
wor n
war ped
dir ty
or
gum
ming
valves and
seats or a weak
diaphr agm
r etur n
spr ing
Pr essur e
above the
upper
limit indicates an
excessively str ong
tension ofdia
phr agm
r etur n
spr ing
or a
diaphr agm
that is too
tight
Both ofthese condi
tions
r equir e
the r emoval of
pump
assembly
for
r eplacement
or
r epair
CAPACITY TEST
The
capacity
test
is
made
only
when
static
pr essur e
is within the
specifications
To
make thistest
pr o
ceed
as follows
1
Disconnect
pr essur e gauge
fr om
T connector and in its vacant
place
install
a
suitable
container
as
a fuel
sump
2
Run
engine
at
1
000
r pm
3 The
pump
should
deliver
1 000
cc
211
US
pt
offuel in
one
minute or
less
Iflittle
or no
fuel flows fr om the
open
end of
pipe
it is
an
indication
that fuel line is
clogged
or
pump
is
malfunctioning
REMOVAL AND
DISASSEMBLY
Remove fuel
pump
assembly by
unscr ewing
two
mounting
nuts and
disassemble in
the
following
or der
1
Separ ate
upper
body
and lower
body
by
unscr ewing
body set scr ews
Engine
Fuel
2
Take
off
cap
and
cap
gasket by
r emoving cap
scr ews
3 Unscr ewelbow
and
connector
4Take off
valve
r etainer
by
un
scr ewing
twor etainer
scr ews and r e
move twovalves
5 To r emove
diaphr agm
pr ess
down its
center
against
spr ing
for ce
With
diaphr agm pr essed
down
tilt it
until the end of
pull
r od touches
the
inne
wall of
body
Then r elease
diaphr agm
tounhook
push
r od Be
car eful
dur ing
this
oper ation
not to
damage diaphr agm
or oil se L
i
J
EFOO7
Fig
EF
20 Remouingpull
r od
6 Dr ive r ocker ar m
pin
out with a
pr ess
or hammer
8
o
6
7
8
@
INSPECTION
I
Check
upper
body
and lower
body
for cr acks
EF10
I fuel
pumpcap
2
Capgasket
3 Valve
packing
4
fuel
pump
val e
assembly
S Valve r etainer
6
Diaphr agmassembly
7
Diaphr agm spr ing
8 PuRr o
9
Lower body
seal
washer
10 Lower body
seal
11 Inkl connector
12 Outlet connector
13 Rocker ar m
spr ing
14Rocker ar m
IS Rocker
ar tyl
side
pin
16 Fuel pumppacking
17
Spacer
fuel
pump
focylinder
block
EF510
Fig
EF21 Slr uc ur e offuel
pump
2 Check
valve assembly
for wear on
valve and valve
spr ing
Blow
valve
assembly
with br eath toexamine
its
function
3 Check
diaphr agm
for
small holes
car cks or wear
4
Check
r ocker ar mfor wear at
the
mating por tion
with
camshaft
5
Check r ocker ar m
pin
for wear A
wor n
pin may
cause oil
leakage
6 Check all
other
components
for
any
abnor malities and
r eplace
ifneces
sar y
DESCRIPTION
INSPECTION
REMOVAL AND
INSTALLATION
DESCRIPTION
The electr icfuel
pumpis
adopted
on air
conditioner
equipped
models
Engine
Fuel
ASSEMBLY
Rever se
the or der of
disassembly
Closely obser ve the
following
instr uc
tions
L
Use
new
gaskets
2
Lubr icate r ocker ann r ocker ar m
linkand
r ocker
ar m
pin
befor einstalla
tion
3
Totest
the
function
pr oceed
as
follows
Positionfuel
pumpassembly
about
I
meter 33 ft
above
fuel level of
fuel
str ainer and connect a
pipe
fr om
str ainer tofuel
pump
Oper ate
r ocker
ar mby
hand If
fuel
is
dr awn
up
soon after r ocker ar mis
r eleased
fuel
pump
is
functioning
pr oper ly
ELECTRICFUEL PUMP
CONTENTS
EF11
EF11
EF12
DISASSEMBL
Y
ASSEMBL Y
TROUBLE
DIAGNOSES AND
CORRECTIONS
EF
12
EF12
The silicon tr ansistor
type
fuel
pump
consists of
a tr ansistor diodes a
sole
I Tr
lOsistor
6 Ou
tIet valve
2
Plunger
7 Retur n
spr ing
3
Diaphr agm
8 Filter
4
Diode
9
Magnet
5
Magnet
coil
10 Inlet valve
INSPECTION
I Disconnect fuel hose at
pump
outlet
2
Connect
a suitable hose
appr oxi
mately
6
mm
0
24in
inner
dia
meter to
pump
outlet
ev J
J
Note Ifdiameter is toosmall the
following
pr oper
deliver y
capacity
cannot be obtained even if
pump
functions
pr oper ly
EF11
EF13
noid
a
pump
mechanism and
filter
par ts
I T nsistor
2
Re
ist f I
3 Dinde
4
Signal
coil
5 Maincoil
6 Resistor
3
7 Zener dlOdl
8
Resistor 2
EF719
Fig
EF22 Constr uction
of
electr ic
fuel
pump
3
With hose outlet
ina
higher posi
tion
than
pump
oper ate pump
and
check
deliver y capacity
for mor e than
15
seconds
4
The
capacity
should be I 400
cc
854co
in inone minute or less
Ifno
gasoline
or
only
a
little flows
fr om
open
end
of
pipe
with
pump
oper ated
or if
pump
does
not
wor k
per for m
the
following diagnosis
Notes
3
Donot
connect batter y
in r ever se
polar ity
which ifleft for a
long
time would
damage
tr ansitor
cir cuit and disable
pump
Engine
Fuel
b Donot let fall
pump
as it
may
damage
electr onic
components
cDonot
apply
over voitage
max
l8Y
Over voltage
star ting
by
quick char ge
or
tager unning
would deter ior ate or
damage
elec
tr onic
components
Fuel
pr essur e
maximum
03 2
kg
cm 4
6
psi
REMOVAL AND
INSTALLATION
Flomfuel tank
Electr icfuel
pump
is installed on
br acket withtwobolts Thisbr acket
is
located on R Hside member
adjacent
tofuel
tank
I Remove inlet hose fr om
fuel
pump
Alsor emove outlet hose r un
ning
to
engine
Receive
fuel
r emaining
infuel hose ina suitable container
2 Disconnect har ness
at
connector
3 Remove bolts
secur ing
fuel
pump
tobr acket and detach fuel
pump
4
Installation
is
ther ever se or der
of
r emoval
9
@
1 Cover
2
Magnet
3
Cover
gasket
4Filter
5 Gasket
6
Spr ing
r etainer
7 Washer
8 O
r ing
9 Inlet valve
10 Retutn
PIing
11 Plunger
12
Plunger cylinder
13
Body
Tocar bur etor
1 Elecuicfuel
pump
2
Mounting
br acket
3 Fuel mter
EF72D
Fig
EF23 Electr icfuel
pump
DISASSEMBLY
Donot disassemble unless
pump
is
faulty
I
Remove
cover with
wr ench and
take out cover gasket magnet
and
filter fr om
pump
body
2 When
r emoving plunger
take out
spr ing
r etainer fr om
plunger
tube
3 Then take
out washer O
r ing
inlet valve r etur n
spr ing
and
plunger
fr omtube
Note Do
not disassemble electr onic
components
If
n
r eplace
withnewones
6
EF721
Fig
EF24
Exploded
view
of
electr icfuel
pump
EF12
ASSEMBLY
I
Befor e
assembly
clean all
par ts
with
gasoline
and
compr essed
air
com
pletely
Notes
a
If
gask
t
an d
fdter ar e
faulty
r
place
b Clean
magnet
and cover for fault
cTakecar e not todefonn thintube
d Assemble
plunger
r etur n
spr ing
inlet valve O
r ing
washer and set
spr ing
r etainer inthat or der
e
Assemble filter
gasket
and cover
with
f
Tighten
cover with wr ench tothe
stopper
If
component par ts
ar e
dir ty
after
disassembly
clean as follows
Wash fIlter and str ainer with clean
gasoline
and blowwith
compr essed
air When
cleaning par ts
check
fllter for fault If
faulty r eplace
Wash
plunger plunger
cylinder
and
inlet valve withclean
gasoline
and
blow dust
off
with
compr essed
air
2
Check
cv
mlI
par ts
for wear
or
damage
If
they
ar e
found
faulty
r eplace
them
3
Inser t
plunger
assembly
into
plunger
cylinder
of
body
and
apply
electr iccur r ent
toit
Move the
assembly
up
and down
Ifthe
assembly
does not move it
shows
that
the electr ic
uuit
is
faulty
and it must be
r eplaced
Engine
Fuel
TROUBLE
DIAGNOSES
AND CORRECTIONS
Condition
Fuel
pump
fails to
oper ate
Fuel
pump
fails
to
dischar ge
sufficient
flow
Insufficient fuel
dischar ge
dur ing
high speed
tr avelling
Low
float level
at
idling
Fuel
pump
is actuated
mor e
fr equently
than
under
nor mal condi
tion
Rattling
noise
Pr obable cause
Ter minals
or connections
loose
Rust onter minalsor
gr ounding
metal
Fr ozen
liquid
in
plunger
or
pump
Clogged
filter
Insufficient fuel
Air
in
fuelhose
thr ough
connections
Hose
necked
down or bent
Fuel
tank br eather
tube bent
or necked
down
Weakened
r etur n
spr ing
Air sucked
thr ough
connection
fuel
hose
and
fuel
pump
joint
Fuel
hose onsuction side bent
Clogged
fIlter
Mounting
bolts
loose
EF13
Cor r ective
action
Retighten
Clean
Clean
plunger
assembly
Replace
pump
if
plunger
is
stuckor
seized
Clean
pump
inter ior Clean
and
if
necessar y
r eplace
fIlter
Replenish
Apply
a
coating
ofend sealing
compound
to
connections and
r etighten
Check
and cor r ect
Check
and cor r ect
Replace
Apply
a
coating
ofend
sealing
compound
to
connection and
r etighten
Checkand cor r ect
Clean or
r eplace
fIlter
Retighten
Engine
Fuel
CARBURETOR
CONTENTS
DESCRIPTION
EF14 CHOKE UNLOADER
EF23
STRUCTURE AND
OPERATION EF14
ELECTRIC AUTOMATIC CHOKE EF
24
PRIMARY SYSTEM
EF15 INTERLOCK OPENINGOF PRIMARY AND
SECONDARY
SYSTEM EF16 SECONDARY THROTTLE VALVE
EF24
ANTI DIESELING
SYSTEM EF 17
DASH POT
EF25
FLOAT
SYSTEM EF18
ACCELERATING PUMP
EF
25
BOOST CONTROLLED
DECELERATION
ANTI DIESELING SOLENOID VALVE
EF
25
DEVICE
B
CD D EF1B
B
C
D D CIRCUIT WITH
FUNCTION
ELECTRIC
AUTOMATIC
CHOKE
EF20 TEST
CONNECTOR
EF25
DASH POT SYSTEM EF20
ALTITUDE COMPENSATOR
ALTITUDE
COMPENSATOR
Califor nia modelsl
EF
29
Califor nia
models
EF20
MAJOR SERVICE
OPERATION
EF
29
ADJUSTMENT AND
INSPECTION EF21
REMOVAL EF29
CARBURETOR IDLE RPM AND DISASSEMBLY AND ASSEMBLY EF
3 0
MIXTURE
RATIO
EF21
CLEANING
AND
INSPECTION EF3 4
FUEL LEVEL
EF22
SERVICE
DATA AND
SPECIFICATIONS
EF
3 5
FAST
IDLE
EF22
TROU8LE
DIAGNOSES
AND
VACUUM BREAK
EF23
CORRECTIONS EF
3 6
DESCRIPTION
The
car bur etor s ar e of
downdr aft
two
bar r el
types
which
pr oduce the
optimum
air fuel mixtur e under
all
oper ating
conditions
They pr esent
sever al
distinct
featur es of
impor tance
tothe
vehicle
owner s
A
summar y
ofthe
featur es
is
as
follows
1 A
slow economizer to
make
a
smooth
connection with
acceler ation
or deceler ation
dur ing light
load
r un
ning
It
also
assur es stable low
speed
per for mance
2
An idle
limiter
to
r educe har mful
exhaust emissions to
a minimum
3 A
BC
D
D
device for
r educing
hydr ocar bon
HC emissions
4
An
electr icautomatic
choke to
facilitate cold
star ting
and tor educe
exhaust emissions
5
An anti
dieseling
solenoid to
eliminate
dieseling
r un
on
6 A
power
valve
or vacuumactu
ated booster
to
ensur e
smooth
high
speed oper ation
7
The
car bur etor
comes
equipped
with dash
pot
which ensur es
smooth
deceler ation
without
engine
stall
under
all
oper ating
conditions
8
The hand
oper ated
altitude
com
pensator
is
installed in the Califor nia
models
EF14
STRUCTURE AND
OPERATION
These
car bur etor s consist of
a
pr imar y
system
for
nor mal
r unning
and a
secondar y
system
for full load
r unning
A
float
system common toboth
pr imar y
and
secondar y systems
a se
condar y
switch
over
mechanism
an
acceler ating
mechanism etc
ar e
also
attached
An
anti
dieseling
solenoid
valve
and
a
power
valve mechanism ar e also
installed
The hand
oper ated
altitude
com
pensator
cor r ects
air
fuel mixtur e
to
an
optimum
r atio
tZr J
I Fuel
nipple
2
Fuel filter
3
Needle
4Float
S
Pr imar y
main
jet
6
Idle
adjust
scr ew
7 I diehole
8
Pr imar y
bypass
hole
9
Pr imar y
thr ottle valve
10
Pr imar y
altitude
compensator
pipe
Califor niamodels
11
Secondar y
altitude
compensator
pipe
Califor nia
models
Engine
Fuel
jli@
I
12
Air bleed
13 Pr imar y
slow
jet
14
Plug
15
Pr imar y
slow air
bleed
6
Pr imar y
mainair bleed
17
Pr imar y
air
vent
pipe
8 Pr imar y
mainnOlzle
Note
Do
not
r emove the
par ts
mar ked withan aster isk
PRIMARY
SYSTEM
Pr lmar
main sstem
The
pr imar y
main
system
is
a
Str ombur g
type
Fuel flows as
shown
in
Figur e
EF25
thr ough
the main
jet
mixting
with
air
whichcomes
in
fr om
the main
air bleed and
passes thr ough
the
emulsion tube and
is
pulled
out
into
the
ventur i
thr ough
the main
nozzle
IdUns and slow s
stem
Dur ing
low
engine
speed
as
shown
in
Figur e
EF
25
fuel flows
thr ough
the
slow
jet
located on r ear
r ight
side
of
main
nozzle
mixing
withair
com
ing
fr om the 1st slowair bleed
again
mixing
with air
coming
fr omthe 2nd
slow air bleed and then is
pulled
out
I
III
@
19
Choke
valve
20
Pr imar y
small ventur i
21
Highspeed
enr icher
air
bleed
22 Richer nozzle
23 Richer
jet
24
Secondar y
air
vent
pipe
intothe
engine thr ough
the idle hole
and
bypass
hole
Adoption
of
the
submer ged
type
of
slow
jet
eliminates
such hesitation
as
occur s on sudden deceler ation of
the
vehicle
Slow economizer
system
obtains
smoothdeceler ation at
high
speeds
Small
opening
ofthe
thr ottle
valve
at
idling
or
par tial
load
cr eates
a
lar ge
vacuum
pr essur e
in
the intake mani
fld
By
this
vacuum
pr essur e
fuel
is
measur ed
thr ough
the
slow
jet
located
behind the main
jet
And
air
coming
fr om
the 1st
slow
air
bleed
is mixed
with
fuel in
the
emulsion hole
This mixtur e
is
fur ther
mixed and
atomized with
air
coming
fr om the
2nd slow
air
bleed The
atomized
mixtur e is
supplied
tothe
engine
fr om
EF15
25
Secondar y
mainnozzle
26 Secondar y
small entur i
27 D CD D
a
sembly
28
Secondar y
thr ottlevalve
EF722
Fig
EF25 Sectional view
of
car bur etor
the idle hole and
bypass
hole via the
sow
sysem
passage
Accele
atlns
mechanism
The car bur etor
is
equipped
withthe
piston type acceler ating
mechanism
linked
tothe
thr ottle
valve When
the
pr imar y
thr ottle valve
shown in
Figur e
EF26
is closed the
piston
goes up
and
fuel flows fr om
the
float
chamber thr ough
the
inlet
valve
into
the
space
under the
piston
When
the
thr ottle
valve is
opened
the
piston
goes
down
opening
the outlet valve
and
fuel is for ced
out thr ough
the
injector
Engine
Fuel
1
L
if
1
Pumpinjector
2 Piston
3
Spr ing
4
Weight
5
Damper spr ing
6 Pistonr etur n
spr ing
7
Inlet
valve
8 Outlet valve
EF023
Fig
EF26 Acceler ation
mechanism
Power
valve mechanism
SECONDARY SYSTEM
The
power
valve
mechanism so
called vacuum
piston
type
utilizes
the
vacuumbelowthethr ottlevalve
When the
thr ottle valve is
slightly
opened dur ing light
load
r unning
high
vacuumis
cr eated
in
the intake
mani
fold This
vacuum
pulls
the
vacuum
piston upwar d
against
the
spr ing
leaving
the
power
valve closed When
the vacuumbelow the thr ottle
valve
is
lower ed
dur ing
full load or
acceler at
ing
r unning
the
spr ing
pushes
the
vacuum
piston
downwar d
opening
the
power
valve tofur nish
fuel
Secondar y
main
lIYlltem
pulled
out
thr ough
the
main
nozzle
intothesmall ventur i
Due tothe
double
ventur i
ofthe
secondar y system
the
higher
velocity
air
cur r ent
passing thr ough
the main
nozzle
pr omotes
the fuel atomization
The str uctur e
is
almost the
same as
the
pr imar y
side
The
secondar y
main
system
is
a
Str ombur g type
Fuel
air mixtur e
pr oduced
by
the
functions ofthe main
jet
main air
bleed
and emulsion tube
in
the same
manner as
in
the
pr imar y system
is
11 1
I
1
1
Pr imar y
vacuum
por t
2
Secondar y vacuum
por t
3
Diaphr agm
chamber
cover
of
Diaphr agm
spr ing
S
Diaphr agm
6
Secondar y
thr ottle
valve
7
Pr imar y
theonle
valve
lWll
I
1
11
lv
1
Vacuum
piston
2
Power
valve
ET02 a
EF 512
Fig
EF27 Sectional
view
of
po
r
valve
Fig
EF28 Full thr ottleal
high peed
EF
16
Stepsystem
The
constr uction ofthis
system
may
cor r espond
tothe
idling
and slow
system
of
the
pr imar y system
Tlr is
system
aims
at the
pr oper
filling up
ofthe
gap
when
fuel
supply
is tr ansfer r ed fr omthe
pr imar y system
tothe
secondar y one The
steppor t
is
located
near the
secondar y
thr ottle
valve
edge
inits
fully
closed
state
Secondar y
switchover mechanism
The
secondar y
thr ottle valve is
linked tothe
diaphr agm
which is
actuated
by
the vacuum
cr eated
inthe
ventur iA
vacuum
jet
is
pr ovided
at
each ofthe
pr imar y
and
secondar y
ventur ies and
the
composite
vacuum
ofthese
jets
actuates
the
diaphr agm
As
the
linkage
causes the
secondar y
thr ottle valve toclose until the
pr ima
r y
thr ottle valve
opening
r eaches
ap
pr oximately
500 fuel
consumption
dur ing
nor mal
oper ation
is
not exces
sive
Dur ing high speed r unning
as
shown in
Figur e
EF28 as the
vacuum
at the ventur iis incr eased the dia
phr agm
is
pulled
against
the
diaphr agm
spr ing
for ce and then
secondar y
thr ot
tievalve is
opened
The other
side
dur ing
low
speed
r unning
as the
pr imar y
thr ottle valve
opening
does not r each 500 the
secondar y
thr ottle
valve is
locked to
close
completely
by
the
locking
ar m
which is inter locked with
pr imar y
thr ottlear m
by linkage
When the
pr imar y
thr ottle valve
opening
r eaches
wider
position
than
500
the
secondar y
thr ottle
valve is
r eady
to
open
because the
locking
ar m r evolves and leaves
fr om the
se
condar y
thr ottle ar m
Engine
Fuel
HI h
speed
cir cuit
The high
speed
cir cuit
impr oves
high engine output per for mance
dur ing high
speed dr iving
This
cir cuit
oper ates only
when
dr iving
at
high speed
It consists ofa
r icher
jet high speed
enr icher air
bleed and r icher nozzle When the
velocity
ofsuction
air
flowing
thr ough
the
car bur etor secondar y
bor e in
cr eases
additional fuel is
dr awn
out of
the
r icher
nozzle
@ 2
EF23 4
Secondar y
I
Richer
jet
2
High
speed
enr icher
air bleed
3 Richer
nozzle
Pr imar y
Fig
EF29
High speed
cir cuit
ANTI DIESELlNG
SYSTEM
is
br ought
into
oper ation shutting
off
the
supply
offuel tothe slow cir cuit
The
following figur e
shows
a
see
tior ial
view
ofthiscontr ol
The car bur etor is
equipped
withan
anti
dieseling
solenoid
valve
As
the
ignition
switch is tur ned offthe
valve
EF23 0
@
l
CD
1
1
g
@eI
1 Anti dieseling
solenoid
va1
2
Ignition
switch
3
Batter y
Fig
EF3 0 Schematicdr awing of
anti
dieseling sydtm
EF17
FLOAT SYSTEM
Ther e IS
only
one
float chamber
while
twol
ar bur etor
systems pr imar y
Jnd
st
l
ondar y
ar e
pr ovided
Fuel fed fr omthe fuel
pump
flows
thr ough
the filler and needle
valve
into
the flot chamber A
constant fuel
level
is maintained
by
the float and
needle valve
Because of
the
inner air
vent
type
of
the float chamber ventilation
the
fuel
consumption
will
not
be in
fluenced
by
some dir t accumulated in
the air
deaner
The needle valve
includes
special
har d steel
ball
and will not
wear for all
its
consider ably
long
use Besides
the
inser r ion
of
a
spr ing
wiU
pr event
the
flooding
at
r ough
r oad
r unning
BOOST
CONTROLLED
DECELERATION
DEVICE
BC D D
A
Boost Contr olled Deceler ation
Device B
C
D
D ser ves
to
r educe the
hydr ocar bons
He
emitted fr omen
gine dur ing coasting
The
high
manifold vacuum
dur ing
coasting
pr events
the mixtur e
fr om
complete
combustion
because of
the
r educed amount ofmixtur e
per
cyl
inder
per
r otation
of
engine
with the
r esult
that
a
lar ge
amount of
hydr ocar
bons is
emitted into
tile
atmospher e
The
B
CD D has been
designed
to
cor r ect
this
pr oblem
It
oper n
tes
as
follows
when
the
manifold
vacuum exceeds a
pr e
Engine
Fuel
deter mined
value
the
BC D D intr o
duces
an additional
mixtur e
of
opti
mum
mixtur e r atioand
quantity
into
the
manifold
by
opening
a
separ ate
mixtur e
passage
in the
car bur etor
Complete
combustion
offuel is assist
ed
by thisadditional mixtur e
and the
amount
of
HC
contained in
exhaust
gases
is
dr amatically
r educed
Dur ing
the
tr ansition
per iod
fr om
coasting
to
idling
the tr ansmission
pr oduces
a
signal
which tur ns on the
vacuumcontr ol
solenoid valve As this
takes
place
the valve is
lifted off
its
seat
opening
the
vacuumchamber to
the
atmospher e
The
mixtur e
contr ol
valve
is then
closed
r etur ning
the
engine
tothe
pr edeter mined idling
speed
On
manual
tr ansmission models
this
system
consists
ofBCD D
vacuo
ur n
contr ol
solenoid valve
speed de
tecting
switch
and
amplifier
On automatic
tr ansmission
models
it consists
ofBC D
D
vacuumcon
tr ol
solenoid
valve
and
inhibitor
switch
BCD D
oper ation
Diaphr agm
I
Qj
monitor s the
mani
fold
vacuum and
when
the
vacuum
exceeds
a
pr e feter mined value acts so
as
to
open
the
vacuum contr ol valve
@
This causes
the manifold
vacuur n
to be
intr oduced
intothe
second
vacuum chamber and
actuates dia
phr agmll@
When
diaphr ngm
II
oper ates
the
mixtur e
contr ol valve
@ opens
the
passage
and intr oduces the additional
mixtur e into
themanifold
EF
18
The amount of
the mixtur e
is
con
tr olled
by
the
ser voaction
ofthe
mixtur e contr ol
valve
CID
and
vacuum
contr ol
valve
@
so
that
the manifold
vacuum
may
be
kept
at the
pr e
deter mined
value
The amount
ofmixtur e
depends
mainly
upon
the
coasting
air bleed
II@
while the mixtur e r atio
is deter
mined
by
the
coasting jet
@
and
coasting
air bleed
@
See
Figur e
EF3 1
Vacuum
contr ol solenoid
valve
oper ation
Manual
tr ansmission
models
The
vacuumcontr ol
solenoid valve
is
con tr oDed
by
a
speed
detecting
switch that is
actuated
by
the
speed
ometer needle
As the vehicle
speed
falls
below 10
MPH this switch is activated
pr o
ducing
a
signal
This
signal
actuatesthe
amplifier
to
open
the vacuum
contr ol
solenoid valve
Automatic
tr ansmission models
When
the
shift lever is in N
or
P
position
the inhibitor switch
mounted on the tr ansmission
tur nson
to
open
the vacuum
contr ol solenoid
valve
I Air
jet
2
Diaphr agm
II
3 Mixtur e
contr ol valve
4
Coasting
air
bleed
II
5 Mixtur eair
passage
6
Secondar y
baHel
7 Intake manifold
8 Boost
passage
9
Vacuumcontr ol solenoid
valve
10
Vacuumcontr ol valve
II
Diaphr agm
I
Engine
Fuel
12
Secondar y
main
jet
13
Coasting jet
14
Coasting
air bleed I
15 Inhibitor switch
N
P
ON for automatic
tr ansmission
16
Amplifier
17
Speed
de
tecting
switchbelow
10 M PH ON
for manual
tr ansmission
1
W
j
I
t
i J
l
J
18
Ignition
switch
CID
11
fI3
6
@
I
r
101
@ i
r
@
JJ
Note
Br okenline
applies
only to
AutomaticTr ansmission
I
Ignition
switch
2
Amplifier
3
Speed detecting
switch
below
10
M P
H ON
for manual
tr ansmission
4Inhibitor switch
N p
ON for automatic
tr ansmission
5 Solenoid valve
6 Vacuumcontr ol valve
7 Altitude
cor r ector
LlJ
I
I
l
f
L8
J
l
EF23 1
Fig
EF3 1 Schematic
dr awing
ofB
CD D Non
Califor nia
models
1
J
r u
I
r
lJ
i7
I
To
intake
manifold
Toair
cleaner
E F23 5
Note
Br okenline
appliesonly
toAutomatic
Tr ansmission
Fig
EF3 2 Schematicdr awing of
RCD D
Califor nia
models
EF19
ELECTRICAUTOMATIC
CHOKE
An electr icheater wanns a bimetal
inter connected tothe choke valve and
contr ols
the
position
of
choke valve
and thr ottle valve in accor dance with
the
time
elapsed
the war m
upcondi
tion
ofthe
engine
and the
outside
ambient
temper atur e
When outside ambient
temper atur e
is
above
oper ating temper atur e
the
automatic
choke contr ol ser ves tofur
ther r educe exhaust
gasemission
dur ing
war m
upby automatically
selecting
one of
the two
choke
oper a
tion modes fast
acting
or slow
acting
Slow
acting
choke
oper ation
When ambient
temper atur e
is low
electr iccur r ent flows
thr ough
the
automatic
choke
r elay
tothe
P T C
heater
A
and
gr adually
war ms the
bi
metal This causes the choke valve
to
open
slowly
Fast
acting
choke
oper ation
When ambient
temper atur e
is
high
the bimetal switch is in
on This
causes electr ic
cur r ent
toflow
thr ough
the automatic
choke
r elay
to
the
P
T C heater
A and heater
B r esult
ing
in
quick
opening
ofthe
choke
valve
r
@@
r
@
Engine
Fuel
The
constr uction
and
function of
each
par t
of
this car bur etor ar e
as
follows
l Bimetal and heater in choke
cover
Electr ic
cur r ent
flows
thr ough
the
ttea
r as
tle engine tl
1
SI
nd war
the bi
metal
The
deflection ofthe
bimetal is tr ansmitted tothe choke
valve
thr ough
the
choke
yalve
lever
2 Fast idlecam
The
fast idle
cam
deter mines the
opening
ofthe thr ottle valve
so
that
the
pr oper
amount
of
mixtur e cor
r esponding to
the
opening
ofthe
choke valve will be obtained The
opening
ofthe
choke valve
is
depend
ent
upon the war m
up
condition of
the
engine
3
Fast idle
adjusting
scr ew
This
scr ew
adjusts
the
opening
of
the thr ottle
valve ofthe fast
idleear n
4U
nloader
When
acceler ating
the
engine dur ing
the
war m
upper iod that
is
befor e the
choke
valve
opens sufficiently
this
unloader for ces
thechoke valve
open
a
liUle so
as toobtain
an
adequate
air fuel
mixtur e
5
Vacuum
diaphr agm
After
the
enginThas
been
star ted
by cr anking
this
diaphr agm
for ces
the
chokevalve
open
tothe
pr edeter mined
extent so
as to
pr ovide
the
pr oper
air fuel r atio
6 Bi metal
case index mar k
The bi metal
case index mar k is
used
for
setting
the
moment
of
the
D
Il
EF23 2
1
Alter nator
2 Automatic choke
r elay
3 Automatic choke cover
4P
T Cheater A
5 Bimetal switch
6
P
T Cheater
B
7
Bimetal
8 Choke
valve
Fig EF3 3 Schematic
dr awing ofelectr icautomaticchoke heater
EF
20
bimetal which
contr ols
the air
fuel
mixtur e r atio
r equir ed
for
star ting
DASH POT
SYSTEM
These car bur etor s ar e
equipped
with
a
dash
pot
inter l
ked wih
the
pr imar y
thr ottle
valve
thr ough
a
link
mechanism The
dash
pot
is intended
to
pr event
engine
stall
r esulting
fr om
quick application
ofthe br ake or
fr om the
quick
r elease ofthe acceler a
tor
pedal
after
tr eading
it
slightly
In
such a
situation a thr ottle lever
str ikes
against
the dash
pot
stemand
makes the
pr imar y
thr ottle valve close
gr adually
thus
keeping
the
engine
r unning
ALTITUDE
COMPENSATOR
Califor niamodels
The
higher
the altitude the r icher
the
air
fuel mixtur e r atioand ther e
for e the
higher
exhaust
gas
emissions
even
though
the
engine
is
pr oper ly
ad
justed
for low
altitude
dr iving
The altitude
compensator
is
design
ed
tomeet Eiir iSSion S13 ndar ds for
dr iving
inboth lowand
high
altitudes
At
high
altitudes additional air is
sup
plied
tothe car bur etor
by
the altitude
compensator
When the altitude
com
pensator
lever
is set at H air is
conducted
thr ough
an air
passage
to
the
car bur etor The
air
passage is
closed whenthelever
is set at L
H
L Lever
When
oper ating
the H
L lever fol
lowthese
instr uctions
H
position
Should be used for
gener al dr iving
in
those ar eas
designated
by
law
as
High
Altitude Counties
L
position
For use outside
those ar eas
desig
nated as
High
Altitude Counties
Notes
a
The idle
r pm
and CO
var y
accor d
ing
to
the altitude
Ther efor e
they
should
be
pr oper ly
adjusted
when
the
position
ofthe
HL lever is
changed
EF729
ADJUSTMENT
AND INSPECTION
CARBURETOR
IDLE R P M
AND MIXTURE
RATIO
Cautions
3
On
automatic
tr ansmission
equi
ped
models check should
be
per
for med
in
the
0
position
Be sur eto
engage
par king
br akeand
tolock bothfr ont
and
r ear
wheels
withwheel chocks
b
Keep
your
foot down
on thebr ake
pedal
while
depr essing
theacceler a
tor
pedal
Other wise
vehicle
sur ges
for war d
danger ously
Notes
a
00 not
attempt
toscr ew
the idle
adjusting
scr ew down
completely
Ooing
so
could cause
damage
to
tip
which in tur n will tend to
cause
malfunctio11ll
b If
idle limiter
cap
obstr ucts
pr oper
adjustment
r emove it
Toinstall idle
limiter
cap
r efer
to
IdleLimiter
Cap
c
After idle
adjustment
has
been
made
shift the lever to
the
N
or
P
position
for
automatictr ans
mission
d
When
measur ing
CO
per centage
in
Engine
Fuel
b Counties
1
219
m 4000 ft
or
mor e
above sea
level have been
designated by
lawas
High
Altitude
Counties
For
fur ther
details r efer
to1977 OATSUN
PICKUPSer vice
BulletinPub No
257
0
I
Air cleaner
r ID
mOl
If
Low
altitude
Ll
n
n
Ln
Fig
EF3 4
ser t
pr obe
intotail
pipe
mor e than
40em
15
7 in
CO
Idle
adjustment with
CO
meter
Idle mixtur e
adjustment r equir es
the use of
a
CO meter
especially
for
Califor nia models
When
pr epar ing
to
adjust
idle mixtur e it
is
essential to
have
the
meter
thor oughly
war med
up
and
calibr ated
I
Checkcar bur etor
pipes
for
pr oper
connection
2 War m
up
engine
until water
tem
per atur e
indicator
points
tothe
middle
of
gauge
The
pr ocedur e
towar m
up
engine
is not
specifically
r ecom
mended Either
dr iving
vehicle or
oper
ating engine
at
noload
will
be
good
3 Make
sur e that water
temper a
tur e
indicator
points
tothe middle
Fur ther
keep
engine r unning
at
about
2000
r pm
for
about
5
minutes with
out
applying
load to
engine
in
or der to
stabilize
engine
condition
Engine
hood
should be
open
4
Run
engine
for
about
10
minutes
at
idling
speed Our ing
this 10
minutes
pr oceed
as descr ibed in
steps
5
to9below
5 Remove
air
hose between
3
way
connector 5
way
connector
for Cali
for nia models and
air
check
valve as
EF
21
shown in
Figur e
EF
3 5
Plug
the
dis
connected
hose
to
pr event
dust
fr om
enter ing
0
o
EF259
Fig
EF3 5 Disconnecting
air hose
fr om
air check valve
6 Race
engine
I 500
to2
000
r pm
twoor
thr ee times
under no
load then
r un
engine
for
one minute at
idling
speed
7
Adjust
thr ottle
adjusting
scr ew
until
engine
is
at
specified
speed
Enginespeed
Manual
tr ansmission
750
r pm
Automatictr ansmission
in
0
position
650
r pm
8 Check
ignition timing
Ifneces
sar y adjust
it to
specifications
This
oper ation
need
not be car r ied
out at
1
600 Ian
1
000miles
ser vice
Ignitiontiming
Manual tr ansmission
120 750 r pm
NonCalifor nia
100 750
r pm
Califor nia
Automatictr ansmission
in
0
position
120
650
r pm
9
At
about 10
minutes
after
engine
is r un
at
idling
speed
adjust
idle
adjusting
scr ew
so
that
CO
per centage
is at
specified
level
CO
per centage
Manual tr ansmission
2t
l
at
750
r pm
Automatic
tr ansmission
in 0
position
2t
I at 650
r pm
10
Repeat
pr ocedur es
as descr ibed
in
steps
6
7
and 9 above
so
that CO
per centage
is at
specified
level Check
ing
idleCO
in
step
9
can
be car r ied
out
r ight
after
step
7
II
Race
engine
1
500 to
2
000
r pm
twoor
thr ee
iimes
under no
load
and make
sur e that
specified
CO
per
centage
is obtained
12
Connect
air
hose toair
check
valve
If
engine speed
incr eases
r eadjust
it
to
the
specified speed
with thr ottle
adjustingsqew
CO
idle edJustment
without
CO meter
IfCO
meter is
not
available the
following pr ocedur es may
be used
L Check
car bur etor
pipes
for
pr oper
connection
2 War m
upengine
until water
tem
per atur e
indicator
points
tothe
middle
of
gauge
The
pr ocedur e
towar m
up
engine
is not
specifically
r ecom
mended Either
dr iving
vehicle or
oper
ating engine
at
noload
will
be
good
3 Make
sur e
that
water
temper atur e
indicator
points
tothe middle
Fur ther
keepengine r unning
at about 2
000
r pm
for about
5
minutes without
applying
load to
engine
in or der
to
stabilize
engine
condition
Engine
hood should
be
open
4 Run
engine
for
about 10minutes
at
idling
speed
Dur ing
this
10
minutes
pr oceed
as
descr ibed in
steps
5
to
9below
5
Remove air
hose between
3
way
connector
5
way
connector
for Cali
for nia models and air
check valve
shown in
Figur e
EF
3 5
Plug
the dis
connected hose
19 pr event
dust fr om
enter ing
6 Race
engine 1
500to2000
r pm
twoor
thr ee
timesunder
noload then
r un
engine
for
one
minute
at
idling
speed
7
Adjust
thr ottle
adjusting
scr ew so
that
engine speeds
ar e
as indicated
below
Engine
speed
Manual tr ansmission
815
r pm
Automatictr ansmission
in D
position
670
r pm
8 Check
ignition timing
ifneces
sar y
adjust
it
tothe value
r equir ed by
specifications
This
oper ation
need
not
be car r ied out at 1
600 km
1
000
miles ser vice
9 At about
10minutes after
engine
Engine
Fuel
is
r un
at
idling
speed adjust
idle
adjusting
scr ew until maximum
r pm
is
obtained
10
Repeat pr ocedur es
as descr ibed
in
steps
6 7 and
9 above
until
engine
speed
at best idle mixtur e is 815
r pm
for
manual tr ansmission
models and
670
r pm
for automatictr ansmission
models
in
D
position Adjustment
in
step
9 can be
car r ied out
r ight
after
step
7
11 Tur n the
idle
adjusting
scr ew
clockwise
until
engine speed dr ops
off
below
specified
r pm
Engine
speed
dr ops
off
Manual tr ansmission
60to70
r pm
Automatictr ansmission
in D
position
15 to25
r pm
12
Connect air hose
to
air
check
valve
If
engine speed
incr eases
r eadjust
it
tothe
specified
speed
with
thr ottle
adjusting
scr ew
Idle limiter
cep
Do
not
r emove thisidle
limiter
cap
unless
necessar y
Ifthis unit is r e
moved it must
be
r eadjusted
at lime
of
installation To
adjust pr oceed
as
follows
I
After
adjusting
thr ottle
or
idle
speed
adjusting
scr ew
check
tobe sur e
that the amount
ofCO contained in
exhaust
gases
meets
the established
standar d
2
Install idlelimiter
cap
in
position
making
sur e that the
adjusting
scr ew
can r otate another 1 8
tur n
in
the
CO
RICH dir ection
Car boto
per
CO
r ich
450
lIS
r otation
t
CO lean
J
SQ
dl
lim
ET03 1
1 e Iter
cap
Fig
EF
3 6
Setting
idlelimiter
cap
FUEL
LEVEL
1
Tur n
down float
chamber toal
low float to
come into
contact with
needle
valve and measur e
Hu shown
EF22
in
Figu
r e EF
3 7
When H
is
appr oximalely
7
mill 0283
in
lOp
float
position
is
cor r ect
The
top
float
position
can
be ad
justed by
bending
float
seat
Upon completion
of
the
adjust
ment
check fuel
level with
attached
level
gauge
p
j
i
I
it
I Float seat
2
Float
3
Float
chamber
4Needle
valve
tIIIf
ET03 2
Fig
EF3 7
Adjusting float
level
2
Adjust
bottom
float
position
so
that clear ance h between
float seat
and needle
valve
stemis I
3
toL7
mm
0051 to0067 in when
Iloat is
fully
r als
n
Jloa
t
goppe
q
r e
3
After
adjustments
in
steps
I and
2
above have been made
make sur e
that
when fuel is
deliver ed tothefloat
chamber
the fuel level is maintained
withinthe
r ange
of23 mm
091
in
as
shownin
Figur eEF
3 8
H 23
mm 0 91
in
EF260
Fig
EF3 8
Checking
r uellevel
FAST IDLE
I With
car bur etor
assembly
r eo
moved fr om
engine
measur e thr ottle
valve
clear ance
A
with
a
wir e
gauge
placing
the
upper
side
offast
idling
scr ew on the fir st
step
on fast
idling
cam
EC527
Fig
EF3 9 Mea
ur ing
thr ottle valve
clear ance
MfT
AfT
3 To
check fast
idling
cam
setting
by engine
speed
pr oceed
as
follows
War m
upengine
sufficiently
Set
Engine
Fuel
Fast
idling
ear n
steps
o
04th
l
2nd
1st
EC528
Fig
EF40 Fast
idling
cam
steps
2 The clear ance
should
be
specified
value
in
the
following
table Ifnot ad
just
the
clear ance
by tur ning
fast
idling
scr ew
Clear ance A
mm in
1 3 3 to
I
47
0
0524to
0
0579
1 58to
1
72
0
0622to
0
0677
fast
idling
cam at 2nd
step
and r ead
engine
speed
Fast
idling
cam
is
pr op
er ly
set if
engine speed
is within
Engine speed
r pm
Fast
idling
ear n
MfT
AfT
VACUUM BREAK
I
Close
choke valve
completely
2
Hold choke valve
by str etching
a
r ubber band between choke
piston
lever and
stationar y
par t
ofcar bur etor
3
Gr ip
vacuum br eak r od with
plier s
and
pull
str aight
out
4Under this
condition
adjust
the
clear ance between
choke
valve and
car bur etor body
B in
Figur e
EF 42
to
specified
value
by bending
vacuum
br ake r od
I 900
to2 800
2nd
step
2200
to3 200
S
B
j
CK iXo
LL
r
I
il
L J
1
Choke
piston
r od
2
Choke
spr ing
3 Choke
piston
EF516
4
Diaphr agm
cover
5 Choke
piston
lever
6 Chokevalve
Fig
EF42
Adjusting
vacuumbr eak
EF23
Z
ET03 3
Fast
idling
car n
Nut
Fast
idling
scr ew
Choke
valve
Choke
connecting
r od
Thr ottlevalve
Fig
EF41
Adjusting
the clear ance
of
thr ottle
valve
Fast
idling
ear n
1st
step
specifications
below Clear ance
A in
2nd
step
is
r efer ence value
Clear ance
A
mm
in
094to
118 003 70to00465
L16
toI 40 0
0457
to00551
CHOKE
UNLOADER
Close chokevalve
completely
2 Hold choke valve
by str etching
a
r ubber band between choke
piston
lever and
stationar y par t
ofcar bur etor
3 Pull thr ottle lever
until full
open
Under this condition
adjust
clear
ance between choke valve
and car bur e
tor
body
to
245
mm 0096
in
by
bending
unloader
tongue
Note Make sur e that
thr ottle valve
opens
when car bur etor
is mounted
onthe
vehicle
Ifthr ottle valve r ails
to
open
un
loader becomes
inoper ative
r esulr
ing
in
poor
acceler ationafter
engine
is star ted
ELECTRIC AUTOMATIC
CHOKE
Checklna
automaticchoke
heater cir cuit with function
test connector
Caution
Donot altach
test
leads
of
a
cir cuit
tester tothose other than
designated
Refer
to
figur e
Ef 43
I
With
engine not r unning
check
for
continuity
between
A
and
B
as
shown
in
figur e
Ef 43
If
continuity
exists heater is func
tioning
pr oper ly
If
continuity
d s
not
exist check
for disconnected
connector
or
open
P
T
eheater cir cuit
2
With
engine r unning
at idle check
for
pr esence
of
voltage
acr oss
Aand B
as
shown in
figur e
EF 43
If
voltmeter
r eading
is 12 volts
dc
heater cir cuit
is
functioning
pr oper ly
If
vohmeter r eading
is zer ocheck
for disconnected connector open
cir cuit
or
faulty
automaticchoke
r elay
3
Replace faulty
par ts
J
j
N
j
EF710
1
ignitionkey
2 Automaticchoke
r elay
Enginestop
OFF
Engine
star t ON
3
Automatic
choke
heateI
4
Function
test connector
5 Altemator
Fig
EF43 Checking oulomalic
choke heater
cir cuit with
fu
ncnon
led
connector
Engine
Fuel
Automatic
choke
I Befor e
star ting engine
fully
de
pr ess
al
celer ator
pedaJ
toensur e
that
choke
valve
doses
pr oper ly
Push
choke
valve with a
finger
and heckfor
binding
3 Check
0 be sur e that
bi
r netal
cover
index
mar k
is set
at the cenleT of
choke
housing
index
mar k a
s shownin
Figur e
EF 44
Note Donot set
b metal cover index
mar k at
any position except
the
center
ofchoke
housing
index
mar l
tE
jL
J
Ther mostat cover
Bimetal
chamber
2
Ther mostat
housing
3 Gr oove
ET03 4
Fig
EF
44
Bi
metol
tting
4
Check
automaticchoke
heater
sour ce
wir ing
for
pr oper
connection
thenstar t
engine
5
After
war ming up
the
engine
see
that
choke
valve is
fully
open
6 Ifautomaticchoke
heater
sour ce
wir ing
is
nor mal
and
choke
valve
does
not
oper ate
after war m
upr eplace
hi
metal
co t er
Automatic
choke
r elay
I Remove automaticchoke
r elay
Autochoke
heater
r elay
EF278
Fig EF45
Location
of
automatic
choke
r elay
EF24
2
Make an
oper ational
check of
automaticchoke
r elay
as shown
in
Figur e
EF 46
Apply
2
volts
dcacr oss ter mi
nals
I and 3 toensur e that
i
ontinuity
exists between ter minals
2and
4
Check
t lal
continuity
does not
exist between
ter minals
2 and
4
when no
voltage
is
applied
acr oss
them If
r esults satisfies the above
automaticchoke
r elay
is
functioning
pr oper ly
ifnot
r eplace
choke
r elay
1 2
3
y
4
EF723
Fig
EF46
Checking
automatic
choke
r elay
Automatic
choke heater
I Measur e r esistance
ofchoke
heater
as
shownin
figur e
EF 47
spe
ified r e
s
an
ce
is 3 7 to8
9
ohms
F
EF261
Fig
EF47Automaticchoke heater
check
2 If
measur ed
value is
not
within
the
specification r eplace
bimetal
cover
INTERLOCK
OPENINGOF
PRIMARY AND SECONDARY
THROTnE
VALVE
Figur e
EF 48
shows
pr imar y
thr ot
tie valve
opened
SO When
pr imar y
thr otlle
valve is
opened
50 the
adjust
plate integr ated
with thr ottle valve is
incontact with
r etur n
plate
at A
When thr ottle valve is
opened fur
ther
locking
ar m is detached fr om
secondar y
thr ottle ar m
per mitting
see
ondar y
system
to
star t
oper ation
Linkage
between
pr imar y
and
see
ondar y
thr ottleswill function
pr oper ly
ifdistance
between thr ottle valve and
inner wall
of
thr ottle
chamber
is 74
mm
0291 in
Adjustment
is made
by bending
connecting
link
I
L
l
1
4 CAl
Secondar y
pr m
ar y I
Jl
I
7t
@
1 Roller
4
Adjust plate
2
Connecting
lever
5 Thr ottlec
amber
3 Retur n
plate 6 Thr ottle
valve
Fig
EF
48
Adjusting
inter lock
opening
DASHPOT
1
Idling speed
of
engine
and mix
tur e must
be
well tuned
up
and
engine sufficiently
war m
2
Tur n thr ottle
valve
by
hand and
r ead
engine speed
when
dash
pot
just
touches
stopper
lever
3
Adjust position
of
dash
pot by
tur ning
nut
until
engine
speed
is in the
specified
r ange
Specified
engine
speed
Manual tr ansmission
1
900
to2
100
r pm
Automatictr ansmission
1 650to1
850
r pm
4
Tighten
lock
nuts
5
Make
sur e that
engine speed
dr ops smoothly
fr om
2
000 to1
000
r pm
in
about
thr ee
seconds
Engine
Fuel
Fig
EF 49
Adjusting dash
pot
ACCELERATING PUMP
I
Visually inspect acceler ating
pump
cover for
any sign
offuel leaks
2 If
fuel leaks ar e found
check
gasket
and
r eplace
if
necessar y
ANTI
DIESELING
SOLENOID VALVE
If
engine
does not
stop
when
igni
tion switch is tur ned off
this
indicates
that
a
str iking
closed solenoid
valve
is
shutting
off
supply
offuel to
engine
Ifhar ness is in
good
condition
r eplace
solencid valve as a unit
Notes
a
Tightening tor que
is 1
8
to3 5
kg
m 13 to
25
ft Ib
b
After
r eplacement
star
engine
and
check tobe sur e that fuel is not
leaking
and that anti dieseling
sol
noid
isin
good
condition
BCD D
CIRCUIT
WITH
FUNCTION TEST
CONNECTOR
Caution
Do
not attach test leads
ofa
cir cuit
tester tothose
other
than
designated
Refer
to
Figur e
EF
50
Menuel
tr ensmlsslon models
I
Check
for
continuity
between A
and
B when
vehicle is
br ought
toa
complete stop
Refer to
Figur e
EF
50
BC
D
D
cir cuit is
functioning
pr oper ly
if
continuity
exists
and volt
meter
r eading
is
0
volt
d
c
in
step
2
below
If
continuity
does
not exist
check
for
disconnected
connector and or
faulty amplifier speed detecting
switch
or B CD D solenoid valve
2
Check for
pr esence
of
voltage
acr oss
A
and B at
a
speed
ofmor e
than 16
km
h
10MPH Refer
to
Figur e
EF
50
Conduct
this
test
by
one ofthe
following
two
methods
I Raising up
r ear axle
housing
with
stand
2 Chassis
dynamometer
test
Ifvoltmeter
r eading
is
0
volt at
a
speed
ofmor e than 16 km
h 10
MPH
cir cuit is
functioning pr op
er ly
If
voltmeter
r eading
is not
0 volt
check for disconnected connector
bur ned fuse
faulty amplifier
BCD D solenoid valve or
speed
detecting
switch
3 If
by
above checks
faulty par t
or
unit is located it should
be
r emoved
and
tested
again
If
necessar y r eplace
1
P4
11
0
8
l
1
Ignition Icey
2
Fuse
3
Amplifier
4
Speed detecting
switch
Above 10
mph
OFF
Below 10
mph
ON
5
Function test connector
6
B
CD
D
solenoid valve
EF711
Fig
EF
50
Checking
BCD D cir cuit with
function test
connector
for
manual tr ansmission
EF25
AUtomatic
tr ailamlsalon modela
I
With inhibitor
switch ON UN
or
P
position
check for
pr esence
of
voltage
acr oss A and B Refer to
Figur e
EF51
Ifvoltmeter
ading
is
12 volts
d c BC
D O cir cuit is
func
tioning pr oper ly
Ifvoltmeter
ading
is
zer ocheck
for disconnected
connector
faulty
solenoid valve
m
inhibitor
switch
2 With inhibitor
switch OFF
HI 2 IY or oR
position
Engine
Fuel
check
for r esistance
between
Aand B
Refer
to
Figur e
EF51
If
ohmmeter
r eading
is 25
ohms
or
below cir cuit is
functioning pr op
er ly
If
ohmmeter
r eading
is 3 2
ohms
or
above
check for
poor
connection
ofconnecor
faulty
BC D D sole
noid valve or inhibitor
r elay
3
If
by
above checks
faulty
par t
or
unit is
located it
should be moved
and
tested
again
If
necessar y
r eplace
yu
@
@
1
Ignition key
2
Inhibit
T switch
N
P
positions
ON
I
2
D R
positions OFF
3 D
C
D
D solenoid valve
4
Function test connector
5
Inhibitor
r elay
EF712
Fig
EF51
Checking B
C
D D cir cuit with
unction
t st connector
for
automatictr ansmision
Set
pr essur e
of
Boost Contr olled
Deceler ation Device BCD O
Gener ally
it is
unnecessar y
toad
just
the
BCD
D
however
if
it should
become
necessar y
to
adjust
it the
pr ocedur e
is 3 S follows
Pr epar e
the
foUowing
tool
I
Tachometer to
measur e
the en
gine speed
while
idling
and a
scr ew
dr iver
2 A
vacuum
gauge
and
connecting
pipe
Note
A
quick r esponse
type
hoost
gauge
such as Bour don s
type
is
r ecommended a
mer cur y type
manometer
should not be used
To
pr oper ly
set the
BC
D
D set
pr essur e pr oceed as
follows
I Remove
the har ness ofsolenoid
valve
ToB D D
solenoid valve
1
BCD D
olenoid
valve
har ness
EF262
Fig
EF52
Removing
har ness
of
solenoid valve
2
Connect r ubber hose between
vacuum
gauge
and intake
manifold
as
shown
Fig
EF53
Connecting
vacuum
gauge
EF26
3
War m
up
the
engine
until it is
heated to
oper ating temper atur e
Then
adjust
the
engine
at nunnal
idling setting
Refer to
the
item
Idling
Adjustmenl
in
page
EF
21
Idling
engine speed
Manual tr ansmission
750
r pm
Automatictr ansmission
in D
position
650
r pm
4
Run the
engine
under
no
load
Incr ease
engine
speed
to3 000 to
3 500
r pm
then
quickly
close thr ottle
valve
5 At the time the manifold vacuum
p
ssur e
incr eases
abr uptly
to
600
mmHg
23
62
inHg
or above
and
then
gr aduaUy
decr eases tothe level
set at
idling
6 Check that the BC D D set
pr es
sur eis
within the
specified pr essur e
Specified
pr essur e
0m sea level
and
760
mmHg
3 0
inHg
atmos
pher ic
pr essu
Manual tr ansmission
510
to 550
mmHg
20
1
to
21 7
inHg
Automatictr ansmission
490to
53 0
mmHg
19Tto20
9
inHg
Notes
a
When
atmospher ic pr essur e
is
known
oper ating
pr essur e
will
be
found
by tr acing
the
ar r ow line
A
See
Figur e
EF
56
When alti
tude is known
oper ating pr essur e
will
be found
by tr acing
the ar r ow
line B
See
Figu
EF56
b
When
checking
the set
pr essu
of
B
CD
D find the
specified
set
pr essu
in
Figur e
EF
56
fr om the
atmospher ic
pr essur e
and altitude
of
the
given
location
For
example
if
anautomatictr ans
mission model vehicle
is located at
an altitude of
1
000
m
3
280ft
the
specified
set
p
ssu
for
BCD D is 445
mmHg
17
5
inHg
7 Ifit is
higher
than
the set level
tur n the
adjusting
scr ew or nut until
cor r ect
adjustment
is
made
NonCalifor nia models
Adjusting
scr ew
Counter clockwise
Califor nia models
Adjusting
nut
Clockwise
Non Califor nia
models
1 2
1
Adjusting scr ew
s
2
Cover e
Califor niamodels
t
1
Adjusting
nut
2
Lock
spr ing
EC692
Fig
EF54
Adjusting
et
pr essur e
vacuum
gauge
Intake
gjl
11
Road test
CD
ET03 7
Engine
Fuel
Note When
adjusting
B
CD D for
Califor nia models tur n
adjusting
nut
in
or out with lock
spr ing
in
place
Always
set lock
spr ing
pr op
er ly
to
pr event changes
inset
pr es
sur e
8 Race
the
engine
and
check
for
adjustment
9 Ifit
is lower than the set level
tur n the
adjusting
scr ew
or nut
until
cor r ect
adjustment
is
made
10
Race the
engine
and
check for
adjustment
If
engine speed
cannot be decr eased
to
idling
when
checking
BC
D
D
set
pr essur e pr oceed
as
follows
When
the
engine speed
does not
fall
to
idling
speed
it is
necessar y
to
r educe the
negative
idling
pr essur e
of
the
manifold tolower than the
set
pr essur e
ofthe B CD O The
engine
speed
will
not
dr op
to
idling speed
when the
negative
idling
pr essur e
is
higher Ihan
the
sel
pr essur e
ofthe
BCO
O
acuum
gauge
Intakema M
V
9iI
21 Chas amomeler
In this
case
the
engine
must
be
labor ed
by
I r oad
test
or
2 chassis
dynamometer
or 3
by r aising up
r ear
suspension
member on
a
stand
accel
er ating
the vehicle to64to
80
km
h
4010 50
MPH in
top
gear
manual
tr ansmission or
in
0
position
auto
matic
tr ansmission and then
r eleasing
the
acceler ator
pedal
and
letting
the
vehicle deceler ate
After
doing this
check whether
the BCO D set
pr es
sur e is at
the
pr edeter mined
value or
not
Vacuum
gauge
niY
3 Raise
up
r ear axle
housing by
stand
ET13 3
Fig
EF55
Testing sel
pr e
ur e
of
the B
CD
D
EF27
3 00 n
o
o
B
C
D
D solenoid
valve
I Tur n on
engine key
Donot star t
engine
Ensur e
that solenoid
valve
clicks
when
inter mittently
electr ified as
shown in
Figur e
EF57
1
000 2000
3
000
4000
5000
0
5 1
0
6 000 ft
Altitude
km
1 5 2
0
EF558
Fig
EF56
Changes
inset
pr es
ur ever sus
changes
in
atmospher ic
pr essur e
and altitude
EF262
Fig
EF57
Checking solenoid
valve
EF
28
3
If
a
dick
is hear d solenoid
valve
is
nor mal
4I f
a
dickis not hear d ar all check
for continuity
with
a cir cuit
tester
If
discontinuity
is detected
r eplace
sole
noid
valve
Amplifier Manual
tr ansmIssIon
models
The
amplifier
is installed at
ther ear
ofthe
speedometer
Tocheck
pr oceed
as follows
I
Set
cir cuit tester in d c
amper e
r ange
IAmin
fuU scale connect
test
pr obes
oftester
as
shown in
Figur e
EF
58
Donot confuse
positive
line with
negative
line
2 Tur n
ignition
key
to
ON
posi
tion
I
t
EF264
1
Ignition
key
2
Amplifier
3
Speed detecting
switch
4BCD D solenoid valve
Inhibitor
switch
Automatic
tr ansmission
models
Refer totheAT section
Inhibitor
r elay
Automatictr ansmission
models
Inhibitor
r elay
EF724
Fig
EF59 Locationof
inhibitor
r elay
2 Make
an
inhibitor
r elay
check
as
shown
in
Figur e
EF 60
Apply
12 volts
dcacr oss ter mi
nals
1
and
4
toensur e
that
continuity
existsbetween
ter minals2and 3
Check
that
continuity
does
not
exist between
ter minals 2and 3 when
novoltage
is
applied
acr oss
them
Engine
Fuel
3
Ensur e
that tester
pointer
deflects
when
ignitionkey
is tur ned
on
4Iftester
pointer
does
not
deflect
when solenoid valve and
speed
detect
ing
switch
cir cuits ar e
functioning
pr oper ly amplifier
is
faulty
Fig
EF58
Checking amplifier
Ifr esults satisfy
the
above
inhi
bitor
r elay
is
functioning
pr oper ly
if
not
r eplace
inhibitor
r elay
it
@
j
l
j
4
L
I
44
11
oJ
EF287
Fig
EF
60 Checking
inhibitor
r elay
ALTITUDE
COMPENSATOR
Califor nia
models
Make sur e
that altitude com
pensator
to
car bur etor
hoses ar e con
nected
pr oper ly
and that
they
ar e not
cr acked and obstr ucted
2 Check that altitude
compensator
is
pr oper ly
set
At lowaltitudes
At
high
altitudes
Notes
a The idle
Pm
and CO
var y
accor d
ing
tothe altitude Ther efor e
they
should be
pr oper ly adjusted
when
the
position
ofthe HL
lever is
changed
Close
Open
EF29
b Counties 1
219
m
4000
ft or
mor e
above sea
level have been
designated
by
law
as
High
Altitude
Counties
For fur ther details r efer
to
1977
DATSUN PICKUP
Ser vice
BuUetin
Pub
No257
Q0
1
v
EF73 3
Fig
EF61
Checking
altitude
compensator
MAJOR SERVICE
OPERATION
The
per fectly adjusted
car bur etor
deliver s the
pr oper
fuel
and
air r atios
at all
speeds
for
the
par ticular
engine
for which
it
was
designed By
com
pletely disassembling
which will allow
deaning
ofall
par ts
and
passages
the
car bur etor can
be
maintained
its
or igi
nal condition and will
continue
to
deliver the
pr oper
r atios
Tomaintain
accur ate car bur etion
of
passages
and
dischar ge
holes
ex
tr eme car e must be taken
in
cleaning
Use
only
car bur etor solvent
and
compr essed
air
toclean
all
passages
and
dischar ge
holes Never
use wir eor
other
pointed
instr ument
toclean
or
car bur etor calibr ationwill be
affected
REMOVAL
Remove car bur etor
fr om
engine
taking
sufficient car e
to
the
following
Pr ecautions
a When
disconnecting
fuel lines do
not
spill
fuel
fr omfuel
pipe
b When
r emoving
car bur etor donot
dr op
any
nut
or
bolt intointake
manifold
cBe car eful
not tobend or scr atch
any par t
Engine
Fuel
DISASSEMBLY AND ASSEMBLY
ff
CoI
Q
f
@
ID J
@tJ
@
1 Lock lever
2 Filter
set
scr ew
3
Fuelfilter
4Fuel
nipple
5 Needlevalve
body
6
Needlevalve
7
Fuel
chamber
par ts
8
Acceler ating
pumppar ts
9 Altitude
compensator pipe
Califor nia
models
tng
ail
bleed
adJ
@
@1
@
A
Choke
chamber
B
Center
body
C Thr ottle
chamber
I
J
@
EF725
EF3 0
11
High
speed enr icher
air bleed
12 Choke
valve
13
Acceler ating pump
lever
14
Thr ottler etur n
spr ing
15
Acceler ating
pump
r od
16
Automatic
choke cover
17 Automaticchoke
body and
diaphr agm chamber
18 Richer
jet
19
Coasting
air bleed I
20
Pr imar y
main
jet
21
Secondar y
main
jet
22
Secondar y
slow
air bleed
23
Secondar y
slow
jet
24
Plug
25
Air
bleed
26
Coasting jet
27
Secondar y main
air
bleed
28 Power valve
29
Pr imar y main
air
bleed
3 0
Plug
3 1
Pr imar y slow
jet
3 2 No2
pr imar y
slow
air bleed
3 3
Pr imar y
and
secondar y
small
ventur i
3 4Ventur i
stopper
scr ew
3 5 Choke
connecting
r od
3 6
Anti dieseling
solenoid
valve
3 7
Fast
idle cam
3 8
Diaphr agm chamber
par ts
3 9 Idle
limiter
cap
40 Idle
adjust
scr ew
41 Idle
adjust
scr ew
spr ing
42 Thr ottle
adjust
scr ew
3
Thr 9ttle
dj
t
5Cr ew
spr ing
44
Pr imar y
and
secondar y thr ottle
valve
45
B
CD D
Califor nia
models
46 Vacuum
contr ol solenoidvalve
47 BC
D D Non Califomia
models
Note
Donot r emove
the
par ts
mar ked
withan aster isk
Ill
@ff
Fig
EF
62Car bur etor
par t
Engine
Fuel
Disassembly
Pr oper ly filling
wr enches and
scr ewdr iver s
must
be used
on
the
nozzles and
jets
as well as on
the
scr ews and
nuts
and car e must
be
ex
er cised
not to
damage
any
par ts
2 Clean the
car bur etor
thor ougWy
beior e
disassembly
3
Donot
attempt
tor emove
any
par ts
mar ked with
an aster isk
CO
in
Figur es
EF62 EF63 EF
64
and
EF
66
Chokechamber
par ts
1
Coasting
air bleed
adjusting
scr ew
2
High speed
enr icher air bleed
3 Choke
valve
4AcceJer a
ing pump
lever
5
Thr ottle
r etur n
spr ing
6
Acceler ating
pump
r od
7 Automatic
choke
cover
8 Richer
jet
9 Automaticchoke
body
and
diaphr agm
chamber
10
Coasting
air
bleed
I
fi
1i
8
J
@
Note Do
not
r emove the
par ts
mar ked
with
anaster isk
l
EF225
Fig EF
63
Removing
choke chamber
par ts
EF
3 1
Engine
Fuel
1
l
@
Vacuum contr ol solenoid
valve
2
BCD
D
3
Coasting jet
4
Secondar y
slow
jet
5
ptug
6
Air bleed
1
Secondar y
slowair bleed
8 Secondar y
main
air bleed
9 Power
valve
10
Pr imar y
main
air bleed
11
Weight
and outlet
valve
12
ptug
13
Pr imar y
slowjet
14
Ptir nar
slow
air
bleed
15
Acceler ator
pump
assembly
16
AntkUeselingsolenoid
vain
17 Fast
idle
ear n
18 Choke
connecting
r od
19 Fast idle ear n shaft
20 Ventuci
stopper
scr ew
21
Pr imar y
and
secondar y
small
ventur i
Center
body par ts
Sets
Note Do
not r emove
the
par ts
mar ked with anaster isk
It
EF726
Fig
EF64
Removing jets
Float
I
i
@
i
j
1
L
42
V
4
S
@
c
46
e4
11
Qll
1D
Yr
J 1
t
t
1
lil
c
@5 1
p
u
I
r
i
r
1
CJi
U
7
to1
8r tj lv
Ji
JlJ
if
I
1
2
3
4
4
1
4
2
4
3
44
45
Hi
5
Secondar y
main
jet
Pr imar y
main
jet
Float chamber
par ts
Fuel inlet
assembly
Lock
lever
Filter set scr ew
Fuelf1Iter
Fuel
nipple
Needle valve
body
Needle
valve
Diaphr agm
chamber
aiSembly
EF227
Fig
EF
65 Removing float
EF
3 2
Engine
Fuel
Thr ottlechamber
par ts
I
Idle
limiter
cap
2
Idle
adjust
scr ew
3
Idle
adjust
scr ew
spr inl
4Thr ottle
adjust
scr ew
5 Thr ottle
adjust
scr ew
spr ini
6 Pr imar y and secondar y
thr ottle valves
7
Nut
Notc
Do
not r emove the
par lS
mar ked withan aster isk
@ff
EF827
Fig
EF66
Removing
thr ottle
chamlHr
par ta
Assembly
To
assemble r ever se the disassem
bly
pr ocedcr e
taking car e to
the
following
I
Thor oughly
wash
all the
par ts
befor e
assembling
2
Inspect gaskets
tosee if
they
appear
har d or
br ittle or if
edges
ar e
tor n
or
distor ted
If
any
ofsuch undesir able
condi
tions
is
noted
they
must be
r eplaced
3 Install
jet
and
air bleed
having
the
same
size number
as
that of
or iginal
one
4After r eassembling
car bur etor
check each
r otating por tion
or sliding
por tion
for smooth
oper ation
EF
3 3
CLEANING
AND
INSPECTION
Dir t
gum
wuler or l ar bon con
taminatiun in
or on
exter ior
moving
par ts
ofa
ar bur ctor
ar coften
r espon
sihk
for
unsatisfactor y
per for mance
For
this
r eason
efficient car butetioll
dcpends
upon
car eful
cleaning
and
inspection
while
ser vicing
I
Blow all
passages
and
castings
with
compr essed
air
and blow offall
par ts
until
dr y
Note Donot
pass
dr ills
or wir es
thr ough
calibr ated
jet
or
passaaa
as this
may enlar ge
or ir lce
and
ser iously
affect car bur etor calibr s
lion
2
Check all
par ts
for wear Ifwear
is
noted damaged
par ts
must be r e
placed
Note
especially
the
following
Engine
Fuel
I
Check float
needle
and seat
for
wear Ifwear
is
noted
assembly
must
be
r eplaced
2 Check thr oule
and choke shaft
bor es
in thr otlle chamber
and
choice
chamber
for wear
or
out of
r oundness
3 Inspect
idle
adjusting
needle for
bur r s or
r idges
Such a
condition
r e
quir es
r eplacemen
1
3
Inspect
gaskets
0 see
if
they
appear
har d
or br iUle
or
if
edges
ar e
tor n or distor ted
If
any
such
condi
tion inoted
they
must
be
r eplaced
4
Check filter
scr een for dir t or lint
Clean and
ifscr een
is distor ted or
r emain
plugged r eplace
5
Check
linkage
for
oper ating
condition
6
Inspect oper ation
of
acceler ating
pump
Pour f
el into
jloat
chamber
and make thr otlle lever
oper ate
Check
condition offuel
injection
fr om
the
EF3 4
acceler ating
nowe
7
Push connecting
r od
ofdia
phr agm
chamber
and block
passage
of
vacuum
with
finger
When
connecting
r od becomes fr ee check for
leakage
of
air
or
damage
to
diaphr agm
Jets
Car bur etor
per for mance depends
on
jet
and air bleed
That is
why
these
components
must be
fabr icated
with utmost car e
To
clean
them
use
cleaning
solvent and blow
air
onthem
Lar ger
inner number s
tamped
on
the
jet
indicate
lar ger
diameter s Ac
cor dingly
main
and
slow
jets
with
lalger
nUmber s
pr ovide
r icher mixtur e
the smaller the
number s theleaner
the
mixtur e Conver sely
the
main and
slow
air bleeds
thr ough
which
air to
passes
thr ough
make the
fueLleaner if
they
bear
lar ger
number s
the smaller
the
number s
the
r icher
the
fuel
Engine
Fuel
SERVICE DATAAND
SPECIFICATIONS
Air clelllcr
Ailcontr ol val
par tially
opem
Air
ntr ol valve
fuUy opens
Idle
ompensatoI
par tially opens
HimettiNo
l
Bi metal No2
Idle
ompen
tor
fully opens
Bi metal
No1
Himetd No2
Fuels Stem
Fuel
pr tuur e
Fuel
pumpapacHy
Cr bu tor
Cr bu tor
type
Car bur etor model
Oc
oF
oCeF
oCeF
Oc
OF
kpJcm2 poi
US
pt
min at
r pm
Outlet
diameter
Ventur idiameter
Main
jet
Mainair bleed
Slow
jet
Power val
Float level U
fuel
pr euur e
r omin
mm in
mm
in
kg
cm2
psi
Adjustment
Engine idling Ignition timing
Idle
speed
COat
mlor o
Fuel level
adjustment
Gap
between Ive stemand noat
at mm
in
H
H
h
Fast idle
adjwtmcnt
Fast idle
ear n
tint
step
Gap
betweenthr ottle IYe and car bur etor
body
mm in
Vacuumbr eak
adjustment
Gap
betweenchoke alve and car bur etor
body
mm
in
Chokeunloadel
adjusttncnt
Gap
betweenchoke alw
and car bur etor
body
r omin
Bi
metalsettinl
Bi metal r esistance at 2Ioe 700F
n
Bi metalsettina
lnter lock
opcnina
of
pr imar y
and
secondar y
thr otUcvalves
mmOn
Duh pot
adjustment
without loadin
I
m
Anti diclClinasolenoid
valV C
tiahtenina
tor que
ka
m
in lb
ac
D D set
p
JSur e
0
msea
level and 760
mmHg
3 0inlla atmospher icpr essur e
J mmHa inHg
RC
D D
tiahteninl tor que kg
m
n
b
Nl
nCalifor nia modell
Manual tr ansmiSsion
I
Automatictr ansmission
Califor nia modeb
Manual tr ansmission
I
Automatictr ansmission
3 0to5486 to129
above
5513 1
3 0to5486 to129
above 55
13 1
60 to70
140
to158
70to90
158
to194
60to70
140
to158
70to90
158
to194
above 70
158
above 90
194
above 70
158
above 90
194
021 to027 299to3 84
t OOO
2iI
OOO
021 to027 299
to
3 84
1 000 2iI OOO
Str ombcr a type
OCH3 40 7A DCH3 40 48A
Str omt r g
type
DCH3 4Q 45B DCH3 40 46A
Pr imar y
Secondar y Pr imar y Secondar y Pr imar y Secondar y Pr imar y Secondar y
3 0 I8t
3 40
3 3 9 3 0 1181 3 413 3 9 3 0 1181
3 4
13 3 9 3 0 1
181
3 413 3 9
240945
3 10
220 240945 3 11220 240945 3 1 1220 240945 3 1 1220
199 1160 199 1160 1101 1160
101
1160
170 160 170 160 170
60
170 160
148
1100 148 1100 148 1100 148 180
143 143 140 140
23 0906 23 0906 23 0
906 23
0
906
017 2408 017 240B 017 2408 017 2408
1201750
r pm
CO
2
1
120
650
r pm
0
100 750r pm C02 t 1
120 650
r pm
0
position
CO
2t
1
position
CO 2t 1
7
2
0283
7 2 0283 7 2 0283 72 0283
23 0906
23
0906
23 0906 23 0906
13 to17
1
3
to
17 1
3 to
1
7 13 to17
0051 to0067 0051 to0
067
0051 to0067 0051 to0067
13 3 to147 158to172 13 3
to
147
158 to172
00524to00579 00622to
00677
00524to00579
00622
to
00677
142 0056
1 42 0056 142 0056 1 5 0059
245 0096 245 0096 240096 2 45
0096
3 7
to
89
3 7 to8 9 3 7toB 9 3
7to89
Center ofthe ndex
mar k Center oftheindexmar k
7 3 8 0291
73 8 0
291
7 3 8 0
290
73 8 0291
1900
to
2100 1650
to
1850
1 900to2 100 1
650to
1
850
180
to3 50
156
to3 04 180 to3 50
156
to3 04 180 to3 50
156
to
3 04
180 to3 50
156
to3 04
510
to
550
490to
53 0
510to550 490to53 0
20 1 to217 19 3
to
209
201 to217
19 3
to
209
20to40
17
4to3 4
1 20
to
40
11
4to3 47 20to40
17
4to3 47 20
to
40174
to3 41
EF
3 5
Engine
Fuel
toms
and
causes ofcar bur etor tr oubles
and
r emedies for
them
ar e listed
to
facilitate
quick r epair s
Ther e
ar e var ious causes of
engine
malfunctions It sometimes
happens
that a car bur etor which has nofault
TROUBLE
DIAGNOSES AND
CORRECTIONS
In
the
following
table the
syml
Condition
Pr obable cause
Over flow Dir t accumulated
on
needle valve
Fuel
pumppr essur e
too
high
Needle valve
impr oper ly
seated
Excessivefuel
consumption
Fuel over flow
Slow
jet
too
lar ge
on
each main
jet
Main air bleed
clogged
Choke valve does not
open
fully
Outlet valve seat ofacceler ator
pump
impr oper
Linked
opening
of
secondar y
thr ottle
valve
opens
too
ear ly
Power
shor tage Main
jetsclogged
Ever y
thr ottlevalve does not
open
fully
Idling
adjustment
incor r ect
FIICI
tr
clogged
Vacuum
jet
clogged
Air
c1eane
clogged
Diaphr agmdamaged
Power valve
oper ating impr oper ly
Altitude
compensator setting
incor r ect Cali
for nia
models
Impr oper idling
Slow
jet clogged
Ever y
thr ottle
valve does not close
Secondar y
thr ottle valve
oper ating
im
pr oper ly
Thr ottlevalve
shafts wor n
Packing
between
manifold car bur etor
fauJiy
Manifold car bur etor
tightening impr oper
Fuel over flow
B
CD D
adjustment
incor r ect
Vacuumcontr ol solenoid
damaged
Stuck antistall dash
pot
EF
3 6
appear s
tohave
some
pr oblems
when
actually
the
electr ic
system
is at fault
Ther efor e whenever
the
engine
is
mal
functioning
the electr ical
system
should be checked r ust befor e
adjust
ing
car bur etor
Cor r ective action
Clean needle
valve
Repair
pump
Re
place
See
condition over flow
Replace
Clean
Adjust
Lap
Adjust
Clean
Adjust
AdjusL
pa ir
Clean
Clean
Replace
Adjust
Cor r ect HL lever
position
Clean
Adjust
Over haul and
clean
Replace
Replace
packing
Cor r ect
tightening
See
l ondition ov
r l1ow
Adjust
Replace
Replace
Condition
Engine
hesitation
Engine
does not
star t
Engine
Fuel
Pr obable
cause
Main
jet
or slow
jet
clogged
By pass
hole idle
passage
dogged
Emulsiontube
dogged
Idling
adjustment
incor r ect
Secondar y
thr ottle valve
oper ating
im
pr oper ly
Altitude
compensator setting
incor r ect
Cali
for nia models
Fuel over flows
Nofuel
Idling
adjustment
incor r ect
Fast idle
adjustment
incor r ect
Damaged
anti dieseling solenoid
EF3 7
Cor r ective
action
Clean
Clean tube
Clean
Adjust
Over haul and clean
Cor r ect HL lever
position
See condition over flow
Check
pump
fuel
pipe
and needle valve
Adjust
Adjust
Replace
DATSUN PICK
UP
MODEL 620 SERIES
I NISSANI
NISSAN
MOTOR CO LTD
TOKYO JAPAN
SECTION
EC
EMISSION
CONTROL
SYSTEM
EC
2
GENERAl DESCRIPTION
CRANKCASE
EMISSION
CONTROL SYSTEM
EXHAUST
EMISSION
CONTROL SySTEM
EC
3
EVAPORATIVE EMISSION
CONTROL SYSTEM
SPECIAL SERVICE TOOLS
EC 2
EC 3 0
EC
3 2
Ther e ar e thr ee
types
ofcontr ol
system
These ar e
J
Closed
type
CIllnkcase emission
contr ol
system
Emission Contr ol
System
of
GENERAL
DESCRIPTION
2
Exhaust
emission
contr ol
system
3
Evapor ative
ell lhsion
contr ol
sys
tem
Per icxiic
inspection
and
r equir ed
seCV1Clng
ofthese
systems
should be
car r ied
out
to
r educe
har mful
emis
sions toa minimum
CRANKCASE EMISSION CONTROL
SYSTEM
c
01
Lkf
If
1
TIL
II tll
1
j
GUuuu
DESCRIPTION
This
system
r etur ns
blow
by
gas
to
boththe intake
manifold and car bur e
tor air
cleaner
The
positive
cr ankcase
ventilation
p
C
V
valve
is
pr ovided
to
conduct
cr ankcase blow by
gas
tothe intake
manifold
Dur ing
par tial
thr ottle
oper ation
of
the
engine
the intake
manifold sucks
the
blow
by gas thr ough
the PC
V
valve
Nor mally
the
capacity
of
the
valve
is
sufficient to
handle
any
blow
by
and
asmall amount
of
ventilating
air
4
c
Fr esh air
Blowby
gas
The
ventilating
air
is
then
dr awn
fr om
the dust side ofthe cadlUr etor
air cleaner
tluough
the tube
con
necting
car bur etor air cleaner tor ock
er cover
intothe
cr ankcase
Under full
tluottle
condition the
manifold vacuwn
is
insufficient to
dr aw
the
blow
by
flow
tluough
the
valve
and its
flow
goes
thr ough
the
tube connection in the
r ever se dir ee
tion
Onvehicles withan
excessively
high
blow
by
some ofthe flow will
go
thr ough
the
tube
connection
to
car bu
r etor air cleaner under all conditions
1
Sealtypc
oil level
gauge
2 Bame
plate
3 Flamear r ester
4Filler
5 P CY valve
6 Steel net
7 Bame
plate
EC716
Fig
EC
l
Cr ankcase miaioncontr ol
ay
tem
EC
2
INSPECTION
P
cV VALVE AND
FILTER
Checking
PC
V valve in
accor d
ance
withthe
following
method
With
engine r unning
at idle
r emove
the
ventilator hose fr om
P
CV valve
if
the
valve is
wor king
a
hissing
noise
will be hear d as
air
passes
thr ough
the
valve
and a
str ong
vacuwnshould
be
felt
immediately
when
a
fmger
is
placed
over valve inlet
Replace
PCV
valve and
filter
in
accor dance with the maintenance
schedule
VENTILATION
HOSE
1
Check hoses
and
hose connec
tionsfor leaks
2 Disconnect all hoses
and clean
with
compr essed
air
If
any hose cannot be fr ee of
obstr uctions
r eplace
Ensur e that flame ar r ester
is
sur ely
inser ted
in
hose between air cleaner
and r ocker cover
Emission Contr ol
System
EXHAUST EMISSION
CONTROL SYSTEM
DESCRIPTION
EARLY
FUEL EVAPORATIVE
SYSTEM
E FE
DESCRIPTION
OPERATION
REMOVAL
AND
INSTALLATION
INSPECTION
SPARK
TIMING
CONTROL SYSTEM
DESCRIPTION
SPARK
DELAY VALVE
Automatic
tr ansmissiom
models
only
INSPECTION
AIR
INJECTION SYSTEM
DESCRIPTION
OPERATION
REMOVAL AND INSTALLATION
DISASSEMBLY
AND
ASSEMBLY
INSPECTION
DESCRIPTION
The exhaust emission contr ol
sys
tem
is
made
up
of
the
following
I
Ear ly
fuel
evapor ative system
2
Spar k
timing
contr ol
system
3
Air
injection
system
A
I
S
EC 3
EC
6
EC 6
EC 6
EC
7
EC
7
EC 7
EC
7
EC 7
EC
8
EC
8
EC 8
EC12
EC
14
EC14
EC 17
CONTENTS
EXHAUST GAS RECIRCULATION
CONTROL SYSTEM E
GR
DESCRIPTION
OPERATION
REMOVAL
AND
INSTALLATION
INSPECTION
CATALYTIC
CONVERTER
DESCRIPTION
OPERATION
REMOVAL
AND
INSPECTION
INSTALLATION
FLOOR
TEMPERATURE WARNING
SYSTEM
DESCRIPTION
OPERATION
REMOVAL
INSTALLATION
INSPECTION
EC19
EC19
EC19
EC23
EC24
EC26
EC
26
EC
26
EC27
EC27
EC27
EC27
EC
28
EC28
EC
29
EC
29
7 Altitude
compensator
Califor nia
models
4Exhaust
gas
r ecir culation E G
R
contr ol
system
5
Catalytic
conver ter
Califor nia
models
6 Boost
contr olled deceler ation de
vice B
CD D
As
r egar ds
the last twounits r efer
to
the
Engine
Fuel section
EC 3
Emission
Contr ol
System
IV
7
ID
9
I Ther mal vacuumvalve
2 Check
valve
3 Air
galler y pipe
4Auto
choke
5
Automatic
temper atur e
contr ol
air
ccanet
6
Anti
Backfir evalve
A
B valve
7 Boost Contr olled
Deceler ation
Device 8C
D D
8
P
C
V
valve
9
Air
r eliefvalve
10
E
G
R contr ol valve
11 Air
pump
air cleaner
12 Car bon
canister
t3 Air
pump
14
Spar k delay
valve AfT models
ET3 65
Fig
EC2 Exhaust
emissioncontr ol
system
Non Califor nia
models
EC 4
Emission Contr ol
System
5
7
@
@
1
Ther mal acuur nvalve
2 Check valve
3 Altitude
compcnlator
inair cleaner
4
Air
galler y
pipe
5
AutQ
choke
6 Automatic
temper atur e
contr ol
air cleaner
1
Anti8ackfue valve
A
B
valve
8 Boost Contr olled
Deceler ation
DeVice
B
C
D
D
9 P CV valve
10 Air r eliefvalve
II E GR contr ol
valve
12
B
CD D contr ol
valve and
solenoid valve
13
Emer gency
air
r eliefvalve
14Air
pump
air cleaner
15 Car bon
canister
16 Air
contr ol
yai
e
17 Air
pump
If
ET3 68
Fig
EC
3
E
hau
t
emilsion
contr olay
tem
Califor nia
mod ls
EGS
Emission
Contr ol
System
EARLY
FUEL
EVAPORATIVE
SYSTEM E
FE
DESCRIPTION
spr ing
and
counter weight
which ar e
assembled on
the
valve
shaft
pr ojecting
to
the
r ear outside of
the exhaust
manifold The
counter weight
is se
cur ed tothe valve shaft with
key
bolt
and
snapr ing
EC 4A
contr ol valve welded
to
the
valve shaft
is
wtalled on
the
exhaust
manifold
thr ough
bushing
This con
tr ol
valve is
called
Heat
contr ol
valve The heat contr ol
valve
is
ac
luated
by
the
coil
spr ing
ther mostat
Constr uction
ofthe
ear ly
fuel
evap
or ative
system
is
shown
in
Figur e
r
I
1
@
r W
9
Sc
w
10
Thennostat
spr ing
11
Coil spr iiig
12 Contr ol valve shaft
13 Heat
contr ol
valve
14
Bushing
15
Cap
16 Exhaust manifold
1 Intakemanifold
2
Stove
gasket
ManifoktstOve
4Heat shield
plate
5
Snapr ing
6
Counter weight
7
Key
g
Stoppel pin
EC53 2
Fig EC 4Ear ly
Fuel
Evapor utive
tem E FE
The
ear ly
fuel
evapor ative system
is
pr ovided
with a chamber above
a
manifold stove moonted between the
intake and exhaust
manifolds
Dur ing
engine
war ming up
air fuel mixtur e in
the
car bur etor
is
heated in the cham
bet
by
exhaust
gases
This r esults
in
impr oved evapor ation
of
atomized
fuel
dr oplets
inthe mixtur e and in
smaller
content of
hydr ocar bons
He
in the
exhaust
gas especially
in
cold weather
oper ation
The exhaust
gas
flow fr om the
engine
is
obstr ucted
by
the heat con
tr ol
valve
inthe
exhaust manifold
and
is
changed
in
dir ection as shown
by
the solid
lines
in
Figur e
EC 4The
exhaust
gas heats the manifold stove
Open close
oper ation
ofthe
heat
contr ol valve is contr olled
by
the
counter weight
and ther mostat
spr ing
whichis sensitive tothe
ambient tem
per atur e
ar ound the
exhaust manifold
With thiscondition
the
heat contr ol
valve
is in
the
fully
closed
position
obstr ucting
the flow
of
exhaust
gas
As
engine temper a
lur e
goes up
and
the
ambient
temper atur e
becomes
high
enough
toactuate
the ther mostat
spr ing
the
counter weight
begins
to
r otate clockwise and
again
comes
into
con
tact
with
the
stopper pin
With this
condition
the
heat contr ol valve
is in
the
full
openposition
and exhaust
gas
passes thr ough
theexhaust manifold as
shown
by
the
dotted
lines
in
Figur e
EC 4without heati
ng
the manifold
stove
OPERATION
The
counter weight
r otates counter
clockwise and
stops
at
the
stopper
pin
mounted on the exhaust
manifold
while
the
engine temper atur e
is low
EC 6
REMOVAL AND INSTAUATION
Emission
Contr ol
System
EC53 3
Remove
snapr ing D
and lockbolt
@
and
the
following par ts
can be
detached fr om
heat contr ol
valve
shaft
Key 00
Counter weight @
Ther I lostat
spr ing CID
Coil
spr ing
@
Note As
pr eviously
descnoed
heat
contr ol
valv
1
is
welded tovalve
shaft
@
at exhaust
manifold and
cannot
be
disassembled
To
install
r ever se
the r emoval
pr o
cedur e
INSPECTION
I Run
engine
and
visually
check
counter weight
to
see if
it
oper ates
pr oper ly
1
For some time after
star ling
engine
in cold weather
counter weight
tur ns counter clockwise until
it
comes
intocontact with
stopper pin
installed
to
exhaust manifold
Counter weight gr adually
moves
down
clockwise as
engine
war ms
up
and
ambient
temper atur e
goes higher
ar ound exhaust manifold
2 When
engine
speed
is
incr eased
dischar ge
pr essur e
of
exhaust
gases
causes
counter weight
to
move down
war d clockwise
3
When
heat
contr ol
valve is inthe
full
open
position
coun
ter weight
moves fur ther clockwiseexceeding
the
1
Snapr ing
2
Lock
bolt
3
Key
4
Counter weight
5
Ther mostat
spr ing
6 Coil spr ing
7
Heat
contr ol valve
8
Valveshaft
9 Stove gasket
10 Manifold stove
11 Heat shield
plate
Fig
EC
5
Exploded
viewof
E FE
stem
position
descr ibed
in 1
1
above
and
stops again coming
intocon tact with
stopper pin
j
EC246
1
Counter weight
2 S
topper pin
3
Heat contr ol
valve
Fig
EC6
Oper ation
ofcounter weight
when
engine
is
cold
EC246
1
Counter weight
2
Stopper pin
3
Heat contr ol
valve
Fig
EC7
Oper ationof
counter w ight
when ngine
is hot
EC
7
2
With
engine
stopped visually
check E FE
system
for the
following
items
1
Ther mostat
spr ing
for dismount
ing
2
Stopper pin
for bend
and count
er
weight stop
position
for
dislocation
3
Check
heat contr ol valve for
malfunction
due
to
br eak of
key
that
locates counter weight
to
valve shaft
4Check axial clear ance between
heat contr ol valve and
exhaust mani
fold Cor r ect clear ance
is
0
7
to
1
5
mm 0028 to
0059 in
5 Check welded
por tion
of
heat
contr ol valve
and valve shaft
for
any
indication ofcr ackor
flaking
6 Rotate heat contr ol valve shaft
by
a finger
and check
for
binding
between shaft
and
bushing
in
closing
and
opening oper ation
of
heat
contr ol
valve
If
any binding
is felt in
r otating
oper ation
move valve
shaft
in the
r otation dir ection sever al
times
If
this
oper ation
does
not
cor r ect
binding
condition it is due toseizur ebetween
shaft and
bushing
and exhaust
mani
fold
should be
r eplaced
as
an assem
bly
CHECKINGSPARK
TIMINGCONTROL
SYSTEM
DESCRIPTION
The
spar k
tir nin contr ol
system
ser ves
tocontr ol the distr ibutor vacu
um advance
under
var ying tr avelling
conditions
soas tor educe HC
and
NOx emissions
This
system
is installed on
non
Califor nia automatic
tr ansmission
models
SPARK
DELAY VALVE
Automatic
tr ansmission
models only
This
valve delays
vacuum
spar k
advance
dur ing
r apid
acceler ation
it
also
cuts off
the
vacuwn
spar k
advance
immediately upon
deceler ation The
valve is
designed
for one
way
oper a
tionand consists ofa one
way
umbr el
la valve and sinler ed
steel fluidic
r estr ictor
Emission Contr ol
System
C
bur tor
I
EC284
When
installing
this valve
ensur e
that it
pr oper ly
or iented Tlus
valve
shuuld
be
r eplaced
per iodically
Refer
to
MaintenanceSchedule
Note Car bur etor
sideBlack
DisInDutor
side
Br own
hor n distr ibutor
To
car bur etor
TOdi
r ibUI0
car bur Clor
EC
lCiJr
Fig
EC
9 Oper ation01
par k
delay
value
INSPECTION
Remove
spar k delay
valve
2 Blow
air
thr oughpor t
on
car bur e
tor
side then
thr ough
the
other
por t
ondistr ibutor side
Spar k delay
valve
Distr ibutor
side
1 One way umbr ella
valve
2 Sinter ed
metal
disc
Fig
EC8
Spar k delay
valve
is
in
good
condition ifwhen
finger
is
placed
over
por t
on distr ibutor side
air
flow
r esistance is
gr eater
than that
onthe
other side See
Figur
ET lO
3 If
a
consider able air flow r esist
ance
is
fell
at
por t
on distr ibutor side
in
step
2
above and
if
the
condition of
spar k delay
valve is
questionable dip
por t
on car bur etor side intoa
cup
filled with
water Blow
air
thr ough
the
other
por t
Small air bubbles should
appear
Car bur etor side
Distr ibutor side
EC3 46
Fig
ECIO
Checking par k
delay
valve
EC 8
EC219
Fig
EC
11
Checking spar k
d
tay
valve
Note Be car eful toavoid
entr y
ofoil
or
dir t intovalve
AIR
INJECTION
SYSTEM
DESCRIPTION
The Air
Injection
System
A
LS is
aeSigiieino
iiiject
coin
pr essed
air
sec
ODllar y
air
cor ning
fr omthe
air
pump
intothe exhaust manifold tor educe
hydr ocar bons
and car bonmonoxide in
exhaust lr i
s
thr ough
r e combustion
Ther e
ar e two
types
ofA
I
S
One
type
is
mounted on Califor nia models
and the other
is on non Califor nia
models The non Califor nia
type
con
sists ofan
air
pump
air
cleaner anair
pump
a
r elief
valve a check valve an
anti
backfIr e valve an air
galler y
and
hoses The Califor nia
type
has in
addition to
the
components
ofthe
non
Califor nia
type
an air contr ol
valve
and
an
emer gency
air
r eliefvalve
These valves
pr event
ahnonnal tem
per atur e
r ise ofthe
catalytic
conver ter
Emission
Contr ol
System
EC9
1 Check valve
2
Air
galler y pipe
3
Automatic
temper atur e contr ol
air cleaner
4Air
hose
car bur etor
air
cleaner
toAB
val
5 Antibackfir e valve
AB
valve
6 Air hose
A
Bvalve tointake
manifoW
7 Air hose car bur etor air cleaner
to
aU hose connector
8 Air hose check valve
to
air hose
connector
9 3
way connector
10 Air hose air hose
connector to
air
pump
11
Air hose air
pump
toair
pump
air
cleaner
12 Air
pump
air
cleaner
13 Air
pump
EC776
Fig
EC12 Non
Califor niatype
AIS
1
Air contr ol
valve
2 Check
val
3 Air hose checkvalve toair
hose
connector
4
Air
galler y pipe
5 Automatic
temper atur e
contr ol
air cleaner
6 Air hose car bur etor air
cleaner
toA
B
val
7 Antibackfir e valve ABvalve
8 Air
hose AB
valve tointake
manifold
9 Air r eliefvalye
10 Air hose car huIetor
air
cleaner to
air
contr ol
valve
11
Air hose air r eliefvalve
toair
hoseconnector
12 Air hose air hose connector to
emer gency
air r eliefvalve
13
Emer gency
air r eliefvalve
14Air
pump
air
cleaner
15
Air
hose air hose connector to
air
pump
16
Air hose air
pump
toair
pump
air cleaner
17 Air pump
EC777
Fig
EC13 Califor nia
typo
AIS
Air
pump
aIr cleaner
The
air
cleaner element
is a viscous
paper lype
and
r equir es per iodic
r e
placement
The air
pump
air
cleaner is
bolted tothe left fr ont
of
the hood
ledge
EC778
Fig
EC14Air
pump
air cleantr
Air
pump
The
air
pump
is
a twovane
type
It
has
two
positive
displacement
vanes
which
r equir es
no
lubr icating
seJVice
i
lJ1
I
Jr
l
Emission Contr ol
System
The die cast aluminwn air
pump
assembly
attached tothe fr ont ofthe
engine
is dr iven
by
an
air
pump
dr ive
belt
Ar otor
shaft dr ive
hub
inlet and
outlet
tubes ar e visible on the
pump
exter ior A
r otor vanes
car bon shoes
and
shoe
spr ings
make
up
the
r otating
unit ofthe
pump
The
r otor
located
in
the
center
ofthe
pump
is belt dr iven
The
vanes
r otate
fr eely
ar ound the
ofT center
pivot pin
and
follow
the
cir cular
shaped
pump
bor e In
the
twovane
type
the
vanes
for m
two
chamber s in the
housing
Each
vane
completes
a
pumping cycle
in
ever y
r evolution ofthe r otor Air is dr awn
into
the
inlet
cavity thr ough
a tube
connected to
the
air
pump
air
cleaner
Air is sealed between
the
vanes and
moved
into
a
smaller
cavity
the
com
pr ession
ar ea
After
compr ession
a vane
passes
the
outlet
cavity
Subsequently
it
passes
the
str ipper
and a section
ofthe
housing
that
separ ates
the outlet and
inlet cavities and
again
r eaches the
inlet
cavity
to
r epeat
the
pumping
cycle
Car bon shoes
in
the
slots of
the
r otor
suppor t
the
vanes
They
ar e
designed
to
penni
t
sliding
of
the
vanes
and
to
seal the
r otor
inter ior
fr omthe
air
cavities Leaf
spr ings
which ar e
behind
the
leading
side ofthe shoes
compensate
for shoe abr asion
The
r otor
r ing
is
a steel bolted to
the r otor end It
positions
ihe
r otor
and holds
the
car bon
shoes
The
vane uses needle
bear ings
All
bear ings
have been
gr eased
Ther e
ar e two
typCg
of
bear ing
which
suppor t
the
r otor Ball
bear ing
is
used for the fr ont
one and the
needle
bear ing
is
used for the r ear
j
1 Air
pump
dr ive
hub
2 HOII
ing
3
Rotor
r ing
4End cover with
needle
bear ing
5 Vane
6
Car bon
shoe
j
7
Shoe
spr ing
8
Str ipper
9
Rotor shan
10
Ball
bear ing
II Fr ont
bear ing
cover
12
Pulley
13
PuDey
for
air
con
itioner
EC560
Fig
EC
15 Stctionol view
ofoir pumptwtr vone
type
ECIO
Air contr ol
valve
Califor nIa models
The air contr ol
valve
con
tr oIs
the
quantity
of
secondar y
air
fed
fr om
the
air
pumpaccor ding
to
engine
speed
and
load condition
and
pr events
ex
cessive
temper atur e
r ise of
the
cataly
ticconver ter
The
constr uction
is as shown
in
Figur e
EC16 The
intake
manifold
vacuum
and
air
pump
dischar ge pr es
sur e
applied
to
the
diaphr agm
chamber
actuate
the
valve
which
is
coupled
to
the
diaphr agm
and
contr ol
the
quanti
ty
of
secondar y
air tobe fed
intothe
exhaust manifold
in
r esponse
to
the
engine
condition
c
Fr om
air
pump
To
car bur etor
air
cleaner
lr
J
EC291
Fig
EC16
Air contr ol valve
Antibackfir e
valve
This
valve
is
con
tr olled
by
intake
manifold vacuum
to
pr event
backfir e
in the
exhaust system
at
the
ini
tial
per iod
ofdeceler ation
At this
per iod
the
mixtur e in the
intake manifold becomes
too
r ich
to
ignite
and bur n in the
combustion
chamber
and bur ns
easily
in the
ex
haust
system
with
injected
air in
the
exhaust manifold
The
antibackfir e
valve
pr ovides
air
tothe intake manifold
to
make the
air fuel
mixtur e leaner and
pr events
backfir e
A schematicdr awing
ofthe anti
backfir e valve
is
shown in
Figur e
EC
17
The antibackfir e
valve inlet is
con
nected
tothe air
cleaner and the
outlet
to
the intake manifold
Th cor r ect function
ofItjS valve
r educes hydr ocar bon
emission
dur ing
aeceler ation
Ifthe valve does not wor k
pr oper ly
unbur ned
mixtur e will
be
emitted
Emission Contr ol
System
fr om
the combustion
chamber s and
bur ns withthe aid ofhigh
temper atur e
and
injected
air
whichcauses
backfir e
I
Tointake
c
manifold
vacuum
I
L
Air disChaJ1le
I
to
mtake
manifold Fr omair
cleaner
ECQ69
Fig
EC11
Antiback ir
valve
Check valve
A check valve is located
inthe air
pump
dischar ge
lines
The valve
pr e
ven ts
the backflow ofexhaust gas
which occur s
in
one
ofthe
following
cases
1
When
the air
pump
dr ive belt
fails
2 When r eliefvalve
spr ing
fails
Constr uction
is
shown
in
Figur e
EC
18
Fr om
m
pump
1
Spr ing
2
Rubber
valve
3
Seat
Secondar y
air
Exhaust
gas
EC292
Fig
EC1B Check valve
AIr
InJaction
Into
axhaust
por t
The
secondar y
air
fed
fr om the air
pump
goes thr ough
the
check
valve
to
the air
galler y
wher e it is distr ibuted
to
each exhaust
por t
The
secondar y
air
is then
injected
fr omthe
air
injection
nozzle
into
the exhaust
por t
near the
exhaust valve
n
L
y
r
V
Air pumpr elief
valve
The air
pump
r elief
valve
contr ols
the
injection
ofthe
secondar y
air into
the exhaust
system
when
the
engine
is
EG
11
3
I Air
galler y
2
Exhaust por t
3 Air
jnjection
nozzle
4Exhaust
manifold
EC293
Fig
EC19 Air injection
into
exhaust
por t
r unning
at
high speed
under
a
heavily
loaded condition It
accomplishes
the
following
functions without
affecting
the
effectiveness of
the exhaust
emis
sion contr ol
system
Minimizes exhaust
gas temper a
lur e
r ise
2 Minimizes
hor sepower
losses r e
suiting
fr om air
injection
intothe
exhaust
system
3 Pr otects
pump
fr om excessive
back
pr essur e
The air
pump
r eliefvalve
is installed
as
shown
in
Figur e
EC
20
The
secondar y
air is
dischar ged
fr om the air
pump
r elief
valve
to
the
dust
side ofthe car bur etor air cleaner
Tocar bur etor
air cleaner
Secondar y
air
Tocar bur etor
air
cleaner
J
er COndar y
r
r
EC294
Fig
EC
20Air
pump
r elief
valve
Emission Contr ol
System
Emar gency
air r etial valve
E AR Valve
Califor nia models
The
emer gency
air r eliefvalve con
tr ols the
quantity
ofsecondar y
air
fed
fr om
the air
pump
accor ding
to
load
condition and
it
dischar ges
the see
ondar y
air
intothe
atmospher e
to
pr event
over heating
ofthe
catalytic
conver ter
The
emer gency
air r eliefvalve con
sists ofa
diaphr agm
a
spr ing
and
a
valve
whichis
coupled
to
diaphr agm
1
Diaphr agm
2
Val
3
Spr ing
4
Diaphr agm
chamber
EC53 6
Fig
EC
21
mer gency
air
r elief
valve
OPERATION
As mentioned
pr eviously
ther e
ar e
two
types
ofAir
Injection
Systems
AI
S
a
non Califor nia
type
and a
Califor nia
type
The
Califor nia stand
ar d
type
includes
a
system
which
contr ols
injection
of
secondar y
air
so
as toassur e
pr oper
function
ofthe
catalytic
conver ter and a
system
which
contr ols the
supply
ofsecond
ar y
air to
pr event
abnor mal
temper a
tUfe
r ise in
the
catalytic
conver ter
The
AIS
consists of
the
following
systems
L A
system
which allows
injection
of
secondar y
air intothe exhaust
por t
2 A
system
which
bypasses
sec
ondar y
air
fr om the
air
pump
r elief
valve
to
the
car bur etor
air
cleaner
dur ing
high speed
engine oper ation
3 A
system
which
supplies
air
fr om
the car bur etor air cleaner
to
the intake
manifold
by
means ofthe
anti
backfir e
valve soas to
pr event
after fir e
dur ing
deceler ation
4A
system
which
contr ols
injection
ofthe
secondar y
air
by
means ofthe
air
contr ol valve
soas tomaintain
the
catalytic
conver ter at
an
optimum
temper atur e
level under
lightly
loaded
conditions
Califomia
type only
5 A
system
whichcontr ols the
sup
ply
of
secondar y
air
thr ough
the emer
gency
air
r eliefvilve
io pfevent
ab
nor mal
temper atur e
r ise ofthe
cataly
tic
conver ter
Califor nia
type only
AI
S
oper ation
is
as
follows
I
I
t
1
r
9
I Air
pump
6
Check
valve
I 0
L
2 Air
pump
air deaner
7 Air
galler y pipe
3
Air
r eliefvalve 8 Injection
non
e
r
4Air cleaner 9
Exhaust
manifold
5
Car bur etor
10
Anti
backflIevalve
EC179
Fig
EC22
Non
Califor nia type
A
IS
EC12
The non Califor nia
type oper ates as
follows
secondar y
air is sucked
thr ough
the air
pump
air
cleaner
into
the air
pump
dr iven
by
the
cr ank
pulley
It is
then
dischar ged thr ough
the
check
valve
to
the air
gallety
wher e
it is
distr ibuted
toeach
exhaust
por L
The
secondar y
air is then
injected
fr om
the
injection
nozzle
into
the
exhaust
por t
near the exhaust valve
The air r eliefvalve
opens only
when
the
dischar ge
pr essur e
ofthe air
pump
sur passes
the
spr ing
for ce ofthe air
r eliefvalve
dur ing high speed oper a
tion
When the
air
r eliefvalve
opens
the
secondar y
air is
dischar ged
into
the
car bur etor air
c1eaner
The
anti
backfir e
valve
opens
when
the intake manifold vacuum
r eaches
a
pr edeter mined
value
dur ing
deceler a
tion
and
per mits
fr esh air tonowinto
the intake
manifold fr om
the air
cleaner
f
I
Jl
r n
l
I Air
pump
2 Air
pump
air
cleaner
3
Emer gency
air
r eliefvalve
4
Air
r eliefvalve
r iu
Qj
j
I
@
Emission Contr ol
System
Tointake
manifold
The Califor nia
type includes in
addition tothe
components
ofthe
non Califor nia
type
an
air
contr ol
valve
and an
emer gency
air r eliefvalve
The air
contr ol
valve
opens
when
the sum ofthe air
pump
dischar ge
pr essur e
and
theintake
manifold vacu
um
applied
to
the
diaphmgm r eachesa
pr edeter mined level and
dischar ges
the
secondar y
air intothe
air cleaner
When the
pr essur e
becomes low the
valve doses
with the
spr ing
for ce of
3
5 Air
cleaner
6
Check valve
7
Air
galler y
pipe
8
Car bur etor
EC
13
To
intake
manifold
Air
diSlchar ge
to
intake manifold
Secondar y
air
EC297
Fig
EC
23
Oper ation
of
A
B lve
the air contr ol valve
and
stops
dis
char ging
the
secondar y
air
Figur e
EC
25
When
the
intake manifold
vacuum
applied
to
the
diaphr agm
r eaches
a
pr edeter mined
level E
A
R valve
oper ates
to
dischar ge
the
secondar y
air
intothe
atmospher e
When the
pr es
sur e
becomes
high
the valve
closes
by
spr ing
tension ofEAR valve
and
stops
dischar ging
the
secondar y
air
fl
t
9 Air contr ol valve
10
Injection
nozzle
II Exha l t
manifold
12 Antibackfir e valve
EC780
Fig
EC
24
Califor nia
type
AI
S
9
Fr omair
pump
l
h 1
Not
actuated
REMOVAL AND
INSTALLATION
Air pmp
sir cleaner
Remove air hose
then
detach air
cleaner
fr om
hoodledge
Air cleaner
element and Iir deancr lower
body
ar e
built intoa unit constr uction
Replace
air cleaner clcl
nen
and
lower
body
as
an
assembly
J
J
tt
c
t
o
J
EC 3 23
Fig
EC26 Replacing
oir cleaner
element
Air
pum
Remove air hoses
fr om
air
pump
2 Loosen air
pumpadjusting
bar
mounting
bolts and
air
pump
mount
ing
bolts
then
r emove
air
pump
dr ive
bell
3 Remove air
pumppulley
4 Remove air
pump
fr om
br acket
Air contr ol valve
Califor nia models
l Disconnect
air hoses and a vacu
umhose
fr omair contr ol valve
2 Remove
air contr ol valve fr om
br acket
E
A
R valve
Califor nia modela
Remove vacuum
pipe
and
air
hose
and dismount E
A
R valve
Emission
Contr ol
System
o
jJ
To
Intake
mamfold
r F
vacuum
r
To
air
cleaner
Fr om
air
pump
EC781
Fig
EC27 Locotion
of
E AR wive
Antl backflr avalve
Disconnect air hose and vacuum
hose fr omantibackfir e valve
Check valve
Disconnect hose and r emove check
valve fr omair
galler y pipe
Air
ganer y pIpe andinJactlon
nozzles
It is
ver y
difficult tor emove the
air
galler y
fr om the exhaust manifold
without
bending
the
pipe
whichcould
r esult in fr actur es or
leakage
Ther e
for e
r emoval
of
the
air
galler y pipe
and
injection
nozzles should be under
taken
only
when
they
ar e
damaged
I Lubr icate
ar ound the
connecting
por tion
of
air
injection
nozzle
and air
galler y
with
engine
oil
2 Hold air
injection
nozzle
hexagon
head with
a
wr ench
and unfasten flar e
scr ew
connecting
ait
galler y
to
injec
tionnozzle Remove air
galler y
EC14
Tointake
manifold
vaCUl lm
r
Y
49 Gf
T
I
To
air
cleaner
I
Actuated
EC299
Fig
EC25
Oper ation
of
air contr ol value
Notes
a
Apply engine
011 to r ews
sever al
times dur ing
above
wor k
b Be
atr eful not to
damage
other
par ts
3 Unfasten air
injection
nozzle
fr om
cylinder
head
applying
engine
oil
to
scr ewed
por tion
sever al
times
4
Check
air
galler y
and
nozzle for
fr actur es or leakage
Clean
air
injection
nozzle
with a wir ebr ush
5
At
time ofinstallation
hold air
injection
nozzle
hexagon
head
with
a
wr ench and
tighten
air
galler y
flange
scr ew to
a
tor que
of5 0 to5
9
kg
m
3 6 to43 ft lb
6
Check
cylinder
head
air
injection
nozzle and air
galler y
for leaks with
engine
r unning
Air
pump
r eliefvslve
Loosen car bur etor
air cleaner
mounting
scews
and
r emove
air
pump
r elief
valve
InstallatIon
Install in
the
r ever se or der ofr eo
moval
DISASSEMBLY AND
ASSEMBLY
Disassembly
ofair pump
1 Remove
four
pulley
dr ive
bolts
and r emove
pulley
fr omhub
2
Secur e
air
pump
dr ive hub
in
a
vise
as
shewn
in
Figur e
EC
28
and
r emovefour end cover
bolts
Note Never
clamp
on
the
aluminum
housing
EC3 02
Fig
EC28
Removing
cover
3 Remove end cover
by
car efully
tapping
ar ound
dowel
pin
with
a
plas
ticmallet and lift
upstr aight
4Put match mar ks 0 on
r otor
r ing
and side ofr otor toensur e
cor r ect
r eassembly
and r emove four
scr ews
that r etain r otor
r ing
to
r otor
using
a
Hexagonal
Wr ench
STl9810000
Notes
a
Gener ally
match mar ks ar e
indi
cated
on
both
r otor
r ing
and
r otor
by
the
manufactur er
ECll1
Fig
EC29
Removing
r otor r ing
Emission Contr ol
System
b Discar d scr ews which wer e
r e
moved
Always
use new ones
when
installing
5
Remove vane fr omr otor
EC661
Fig
EC
3 0 Remooing
vanes
6 Remove
four car bon
shoes and
twoshoe
spr ings
fr om r otor
using
needle nose
plier s
or tweezer s
Note
Car bon shoe
A
0
03 9 in wider than
confuse
them
is I mm
B Donot
If
r eplacement
offr ont
bear ing
is
necessar y
pr oceed
as follows
7 Remove
air
pump
dr ive hub
with
standar d
puller
EC
15
8 Remove four scr ews
secur ing
fr ont
bear ing
cover
in
place
and de
tach
bear ing
cover
9
Suppor t
the
r ear end face ofair
pump
housing
with Rotor
Adapter
STl9890000 Dr ive r otor
out
by push
ing
r otor shaft with
Bear ing Pr essing
Tool STl9940000
STl9940000
1Ul
STl9890000
I
I
EC3 03
Fig
EC3 2
Removing
r otor
shaft
10
Suppor t
the
fr ont end face of
housing
with
Bear ing Adapter
STl993 0000 Attach
Bear ing
Dr iver
STl9910000 tofr ont
bear ing
on the
inside ofair
pump
housing
iuid
pr ess
out
ll
I
I
STl9910000
i
L
993 0000
J
1
EC3 04
Fig
EC3 3
Remouing
ball
bear ing
11
Keep
disassembled
par ts
in
r der
Emission
Contr ol
System
Assembl ofair
pump
I Fr ont
bear ing
Suppor t
the r ear end face
ofair
pump
housing
with RotOL
Adapter
STl9890000 Pr ess fr ont
bear ing
into
place
witha
pr ess
ar id
Bear ing Ptessing
Tool STl9940000
I
I
STl9940000
X8
03
Fig
EC3 5
Pr essing
ball
bear ing
L
2
Bear ing
cover
Tor que
four
bear ing
cover
secur ing
bolts to
0
1 to
0
2
kg
m 0
7
to 14
ft lb
3 Rotor shaft
Suppor t
the inwar d bottom of
r otor with Rotor Stand STl9920000
Pr ess r otor into
place
with a
pr ess
and
Bear ing
Dr ive
STl9910000 until
the
stepped por tion
ofr otor shaft
touches
fr ont
bear ing
inner r ace
C1
ST
19910000
ST19920000
I
EC3 Q7
Fig
EC3 6
Pr essing r otor shaft
Notes
a Be
sur e
todr ive fr ont
bear ing
inner
r acein
b After r otor is installed in
place
ensur e
that the r otor end
is
pos
tioned below the
end face ofair
pump
housing
Position
ofr otor
end below
air
pump
housing
0
050
to0150 mm
00020to00059 in
4
Air
pump
dr ivehub
Suppor t
the inwar d bottom of
r otor with Rotor Stand STl9920000
EC16
EC562
Fig
EC3 4
Componenbr of
two
vane
type
Pr ess dr ive hub into
place
with a
pr e
and
Bear ing
Dr iver STI 9910000
until the
end
face ofdr ive hubtouches
fr oE c
ing
in
n c
j
STt9910000
STl9920000
e
r
EC3 08
Fig
EC3 7
Pr essing
air
pump
dr ive
hub
5
Car bonshoe
1
Place air
pump
dr ive
hub in a
vise
2
Clean car bon dust
etcfr om
shoe
gr ooves
3
Align
r otor with
housing
pr oper
ly
Refer to
Figur e
EC3 8
Theninser t
car bon shoes
into
place
noting
their
dir ections
EC540
Fig
EC
3 8 Install
car bonshoe
Notes
a
Car bon shoe A
is 1 mm 003 9
in
wider than B
Donot confuse
them
b Ifcar bon
shoesar e
exposed
beyond
the r otor
end face r emove
car bon
shoesand cleanshoe
gr ooves
Reassemble
car bon shoes
6
Vane
1
Pack vane
bear ing
with
high
melting point gr ease MIL G
3 545 A
Esso
ANDOK260 or
equivalent and
inser t
dummy
shaft into
the
Vane
bear ing
STl9900000
EC563
Fig
EC3 9 Vane
assembly
2 Install vane in
place
on r otor
using
Dummy
Shaft
STl9900000 as a
guide
Note The vanes
may
r equir e
6 to16
km
4
to
10
miles wear in
r unning
time
In the
event a
slight squeaking
still
r emains dr ive thecar about 64
to80 kmh 40 to50
MPH
In
most
cases 6
to16
km
4to
10
miles will be
sufficient
for wear
in
7
Shoe
spr ing
Place shoe
spr ings
in
deeper gr oove
ofshoe
Emission Contr ol
System
i
111
11
EC123
Fig
EC 40
Installing shoe
spr ing
Note When
instaUing
a shoe
spr ing
make sur e that the outwar d bend
ing
side
faces
in
shoe and that both
ends
of
spr ing
face in the
wall of
shoe
gr oove
Be sur e
to
push
spr ing
in
sothat
spr ing
end face is flush with
r otor
8
Rotor
r ing
Install
r otor
r ing by cor r ectly align
ing
the r ear
end
face of
r otor
withthe
0
mar k
in r otor
r ing
and
tighten
four
scr ews
to
the
specified
tor que
with
Hexagonal
Wr ench ST19810000
Tightening tor que
05
to0
7
kg
m
3 6 to
5 1
ft lb
5T19810000
EC124
Fig
EC41
In8talling
r otor
r ing
9 Removal of
dummy
shaft
Car efuny
withdr aw
dummy
shaft
fr om
vane
10
Vaneshaft
Pack
r ear
bear ing
with
high
melting
point
gr ease
MIL G3 545
A
so
ANDOK 260 or
equivalent
Apply
thin
coating
of
gr ease
tovane
shaft and r otor
r ing
and inser t
vane
shaft
into
its
bear ing
EC17
Notes
a
Do
not
apply
an
utue str ess
to
vane
shaft
when
inser ting
b
Iftwovanes ar e dislocated when
inser ting
vaneshaft
cor r ectly
align
vanes
by inser ting dummy
shaft
Then dr aw out
dummy
shaft and
inser t
vane
shaft
c When
wear occur sonvane
shaft
or
when
r eplacement
of
r ear
bear ing
is
necessar y r eplace
r ear cover as
sembly
Jl End cover
Position end
cover
in
place
Snugly
tighten
the bolt close to
the dowel
Then
tighten
four bolts
to
the
speci
fied
tor que
Tightening tor que
0
7 to
0
9
kg
m
5
1
t06
5 ft4b
EC3 02
Fig
EC42 Insla ling end
cover
12
Pulley
Tighten
four
pulley secur ing
bolts
to
the
specified tor que
Tightening tor que
07to
0
9
kg
m
5
lt06
5 ft
lb
INSPECTION
Air
InJection system
hosas
Check air
system
hoses for loose
connections cr acks or
deter ior ation
Retighten
or
r eplace
if
necessar y
Air
ystem
manifold
Check air
gaUer y
pipe
and
injection
nozzles for loose connections and
cr acks
Retighten
or
r eplace
ifneces
sar y
Air
pump
I
Oper ate engine
until
it r eaches
nor mal
oper ating
temper atur e
2
Inspect
all hose hose
connec
tions and
air
galler y
for leaks
and
cor r ect
if
necessar y
befor e
checking
air
injection
pump
3 Check air
injection pump
belt
tension
and
adjust
to
specifications
if
necessar y
4
Disconnect air supply
hose at
check
valve
5
Disconnect
vacuumhose fr omthe
air
contr ol valve
Califor nia
type
only
6 Inser t
open
pipe
end ofAir
Pump
Test
Gauge
Adapter
STl9870000
in
air
supply
hose
Clamp
hose
secur ely
to
adapter
to
pr event
it fr om
blowing
out Position
adapter
andtest
lliuge
so
that
air blast emitted
thr ough
dr illed
pipe plug
will
be
har mlessly
dissipated
7 Install
a
tachometer
on
engine
With
engine speed
at 2
600
r pm
ob
ser ve
pr essur e pr oduced
at
test
gauge
Air
pr essur e
should be 100
mmHg
3
94
inHg
or mor e
8 Ifair
pr essur e
does
not meet
above
specifications pr oceed
as
fol
lows
I
Repeat
2and
3
above
2 Disconnect air
supply
hose at
anti backfir e valve
Plug
air
hose
open
ing
and
scr ew with a
clamp
Repeat
pr essur e
test
3 With
engine
speed
at
1
500
r pm
close
hole oftest
gauge
with
finger
If
a
leaking
sound
is
hear d or
leaking
air
is
felt
by ftnger
at r elief
valve r elief
valve is
malfunctioning
Reliefvalve
should
be
r eplaced
or
r epair ed
4
If
air
injection pump
does not
meet minimum
r equir ement
of
pr es
sur e test
it
should be
r eplaced
Contr ol valve
The
following
pr ocedur es
ar e r eo
commended for
checking
and or as
cer taining
that thevar ious
components
ofthe exhaust emission conIr ol
system
ar e
oper ating
pr oper ly
The
engine
and all
components
must
be
at nor mal
oper ating
temper a
tur es
when the
tests ar e
per for med
Pr ior
to
per for ming any
extensive
diag
nosis
ofthe exhaust contr ol
system
it
Emission Contr ol
System
must
be deter mined
that
the
engine
as
a unit is
functioning pr oper ly
Check valva
War m
upengine thor oughly
2
Disconnect hose
leading
tocheck
valve fr om
air
hose COJUlector
3
Check hose
opening
for
any
indi
cation of
exhaust
gas
leaks Ifleaksar e
detected
r eplace
check
valve
4
Race the
engine
lightly
at about
2000
cpm
and then
r etur n
it to
idling VisuaDy
check the hose for
any
indication
ofexhaust
gas
leaks befor e
the
engine
r etur ns to
idling
speed
If
leaks ar e detected
r eplace
checkvalve
EC3 10
Fig
EC43
Checking checkvalve
Air
pump
r aIle valve
After
completing inspection
of
air
pump
check
air
pump
r eliefvalve
in
the
following steps
J
Disconnect hoses
leading
tocheck
valve and air contr ol
valve fr om air
hose
connector
and
install blind
cap
tothe
connector
2 With
engine r unning
at
about
3 000
r pm
under noload
place your
hand on the
air
outlet ofair
pump
r eliefvalve tocheck for
dischar ged
air
Ifno
air
is felt
r eplace
the air
pump
r elief
valve
EC3 11
Fig
EC 44
Checking
air
pump
r elief
valve
EC
18
Air contr ol valve
C
U or nla models
I War m
upengine thor oughly
2 Befor e
checking
air
contr ol
valve
check all
hoses
for loose connection
leaks etc and
r epair
or
cor r ect
if
necessar y
3
With
engine
idling
disconnect the
outlet side
hose of
the
air contr ol
valve and
place
your
hand on the
air
hose outlet
tocheck for air Ifnoair is
felt
r eplace
the
air
contr ol valve
4
Pull vacuum hose offfr om
air
contr ol valve
If
dischar ge
ofair fr om
air hose
stops
the air con tr ol
valve
is
nor maL
If
dischar ge
isstill felt
r eplace
the valve
Plug
up
the
r emoved
vacuum
hose
to
stabilize
engine r unning
EC3 12
Fig
EC 45
Checking
air contr ol
valve
Emar sancy air r ella
valve
E AR Valve
lCalHor nla
models
L War m
upengine thor oughly
2
Befor e
checking
air
contr ol valve
check all hoses for loose connection
leaks etc and
r epair
or cor r ect if
necessar y
3 Race
engine appr oximately
2000
r pm
under noload Place
your
hand on
air
outlet
ofE
AR
valve to
check for
pr esence
of
dischar ged
air If
no
air
is
felt
E
A
R valve
is nor mal
4
Disconnect vacuum
hose fr om
B
A
R valve as shown
in
Figur e
EC
46
Race
engine appr oximately
2000
r pm
under noload Place
your
hand
onair outlet ofE AR valve tocheck
for
pr esence
of
dischar ged
air Ifair is
felt
E
ARvalve is nor maL
5
If
E AR
valve does not function
pr oper ly
at above
steps
r eplace
E AR
valve
To
air
pump
I
ET267
Fig
EC46
Cheeking
E AR volve
Anti
backfir e
valve
A
valve
War m
upengine
thor oughly
2 Disconnect hose
fr om
air
cleaner
and
place
a
finger
near
the outlet
3 Run
engine
at about
3
000
r pin
under
noload then
quickly
cetum
it
to
idling
If
you
feel
a
pull
or suction
for ce on
your
finger
the
anti
backfir e
valve
is
functioning
nor mally
Ifno
suctionis
felt
r eplace
the
antibackflr e
valve
Fig
EC47 Checking
anti
backfir e
valve
1
tD
I Y1
VI
I
ID
4
JO
0
2 E
C
R contr ol valve
3
E C
R
passage
4Intake manifold
5
Ther mal
vacuum valve
6
E CR tube
7
Exhaust
manifold
Emission
Contr ol
System
tXHAUST
GAS
RECIRCULATION
CONTROL
SYSTEM
E
GR
DESCRIPTION
In
the
exhaust
gas
r ecir culation
system
a
par t
ofthe exhaust
gas
is
r etur ned
tothe
combustion
chamber
tolower the
spar k
flame
temper atur e
dur ing
combustion
This r esults
in a
r eduction
ofthe
nitr ogen
oxide
con
tent
in the
exhaust
gas
The exhaust
gas
r ecir culation
sys
tem consists
ofan
E G
R
passage
E GR
con
tr ol valve ther mal
vacuum
volve E GR
tube and hose
A
war n
@
I
ing system
which indicates
when the
E GR
contr ol
system
must be
in
spected
is alsoinstalled
in
all 620
models
except
those bound for
Coli
for nia
and Canada
When the E
G
R con
tr ol
valve is
open
some of
the
exhaust
gas
is
led
fr om
the
exhaust manifold tothe
E G
R chamber
thr ough
the
E G
R
passage
The exhaust
gas
is
then
con
tr olled
in
quantity by
the E G
R
valve
and
is intr oduced intothe
intake
manifold
Open
c1ose
oper ation
oftheE G
R
contr ol
valve
is contr olled
by
the
ther mal
vacuum
valve which
oper a
tes
on
car bur etor vacuumand
engine
cool
ant
temper atur e
EC3 49
Fig
EC4Exhaust Gas Recir culation
system
E GR
E G
R
systemoper ating
Ther mal
Intake manifold
E G
R
Remar ks
E G
R
water
temper atur e
oCOF vacuumvalve
vacuum
contr ol
valve
Below
570C 13 5OF
Close
Close
Non califor nia
Above
MfT
models
only
Idling
Not
Above
57
to
63 0C
Open
70
mmHg Close
actuated
13 5to
145OF
76
inHg
Califor nia models
Below
and Non
Fullthr ollle
f
alifomia
AfT
Above
57 to6
oC
models
Actua
ted
Open
Above
50
mmHg
Open
13 5to
145OF
197
inHg
EC19
OPERATION
Oper ation
ofE GR
system
is
as
shown below
E GR OFF
oper ation
When
engine
coolant
temper atur e
is low
r ecir culated exhaust
gas
causes
ir r egular engine
oper ation
To
pr event
Emission Contr ol
System
this r ecir culation
ofexhaust
gas
must
be cut
off
for
a few
minutes after
engine
has star ted The ther mal vacu
um
valve
is
pr ovided
for
this
pur pose
r
r n
11
L
e
7
E G
R
contr olval le clo
2
When
engine
coolant
temper atur e
is above
the
wor king
temper atur e
of
the ther mal
vacuum
valve
I
The valve
por t
come
to
the
top
J
It r emains
closed
while
engine
coolant
temper atur e
is low and
keeps
the
E GR contr ol valve
closed
ther eby
culling
offthe
E
GR cir cuit
I
lW
jS
1
Thr ottlevalve
Ther mal vacuum
valve
close
j
Note
m
Vacuumcondition
of
the
thr ottle
valve du
r ing
engine
idling
for
impr oved idling
oper ation
At
this
point
vacuum does not
actuate
the E GR contr ol valve
r
TD
L
t
i
q
II
E GR
contr ol
valve
close
2 In the full
thr ottle
dr iving
posi
tion
the suction vacuum
onthe vacu
Jllr I
Ther mal vacuum valve
ope
um
passage
does
not
sur pass
the vacu
um
r equir ed
to
actuate the E GR
EC20
EC227
Fig
EC 49 E G
R not
actuated
though
intake
manifold
vacuum
is
high
and
E GR
contr ol valve r emain
closed
l
Thr ottlevalve
EC228
Fig
EC50
E GR
nol
actualed
contr ol
valve
6
Ther mal vacuum
valve
Open
E GR contr ol
valve Close
E GR ON
oper ation
The E GR cir cuit is
completed
only
when
engine
coolant
temper atur e
Emission
Contr ol
System
I
I
Note Vacuum condition
EC793
Fig
EC51 E GR not actuated
is
above the
wor king temper atur e
of
the
ther mal vacuum
valve and car bu
r etor suction vacuum
is
lar ge enough
to
open
the E GR
contr ol
valve
Y
m
l
fj
t1f
1t 3 0
l
P
@ 0fY f
1
i0
Wg
1
i3 iiA
d
m
E
N ti
nk
i
l
i
Thr ottlevalve
n
L
r
E
GR
contr ol valve
Open
E GR contr ol valva
The
E G
R
contr ol valve contr ols
the
quantity
ofexhaust
gas
tobe led
to
the
intake manifold
thr ough
ver tical
movement ofthe
taper
valve connect
ed
to
the
diaphr agm
towhich
vacuum
Ther mal vacuum
valve
Open
Note
iiiI
Vacuum condition
EC794
Fig
EC52 E GR actuated
is
applied
in
r esponse
tothe
opening
ofthe car bur etor
thr ottle valve The
E GR contr ol
valve is installed onthe
E G
R
passage thr ough
a
gasket
E GR contr ol valve constr uction
and
type
var y
with
tr ansmission
type
and
car
destination For
identification
pur poses
the
par t
number
is
stamped
on the r ecessed
por tion
at the
top
of
thevalve
The
constr uction
ofthe E G
R
contr ol
valve is
shown below
EC
21
j
EC23 1
Ther mal
vacuumvalva
o
o
m
Emission
Contr ol
System
0
o
o
o
l
l
@
The ther mal vacuum
valve
is
mounted
in
the
engine
ther mostat
housing
It
detects
engine
coolan
t
tem
per atur e by means of
a
built
in
bi
metal and
opensor
closes
the
vacuum
passage
in the
ther mal
vacuum
valve
mt
li
t
00
t
EC23 2
Fig
EC54
Thennal
vacuumvalve
ToE
G
R contr ol valve
Fr omcar bur etor
1
Spr ing
2 Bimetal
3
O
r ing
E GR
war ning
system
The
E GR
war ning system install
1
Diaphr agmspr ing
2
Diaphr agm
3 Valve shaft
4
Valve
5 Valve
Seat
6 Valve chamber
Fig
EC53 E
G
R contr ol
value
When the
vacuum
passage
is
open
the
car bur etor suction
vacuum
is
applied
to
the
diaphr agm
ofthe EGR
con
tr ol valve to
actuate the
taper
valve
connected to
the
diaphr agm
theconsiiiictlo
nliether mal
vacuum valve is
shown below
ed
independently
of
the
E G
R
con
tr ol
system
monitor s
the distance the
car has tr avelled and
indicates when
EC22
the
E
G
R
contr ol
system
must be
checked
The E GR
war ning system
consists
of
an odometer switch
detector
dr ive
counter
E
GR
war ning
lamp
and
har nesses
When the
ear n
inthe
odom
eter switch connected to
the
speed
ometer tur ns
once
for
each OAkm4
mile the
contact
point
ofthe elec
tr ica cir cuit closes
allowing
electr ic
cur r ent toflow
thr ough
the
magnet
coil of
the
detector
dr ive counter
Thus
ener gized
the
magnet
coil ac
Wates
the
latchet to
tur n the cunter
wheel
by
one
pitch
When
the
number
of
counts r eaches 50000 the latchet
dr ops
in
a
gr oove pr ovided
on
the
per ipher y
of
the counter wheel to
activate
the detector
dr ive counter
switch
Then
the
E GR
war ning
lamp
comes on
indicating
that the E GR
contr ol
system
Should be checked
The
detector
dr ive
counteT is
equip
ped
with an odometer which
can tell
when to
ser vice
the
E
GR contr 0I
system
After
completing
per iodic
check
r eset the odometer to
zer oby hand
pr oceeding
as follows
1 Remove
gr ommet
installed on
the
side
sur face of
detector
dr ive
counter unit
2
inser t
a
bar
or
a scr ewdr iver
tip
intothe
hole
fr om
which
gr ommet has
been
r emoved
and
pr ess
down knob
pr ovided
in
the detector dr ive counter
for
r esetting
The
E
GR
war ning
lamp
comes
on
under the
following
cir cumstances
1 When the number of
countshas
r eached 50000 In this
case the
lamp
indicates that E
G
R
contr ol
system
must be checked
2 When
oper ating
star ter motor
Notes
a It is
an indicationof
pr oblem
in
the
E
GR
war ning lamp
or
pr oblems
inthe
point
or in the har nesses if
the
lamp
does not
light
at
50000
counts
b
The
E
GR
war ning system
is
mounted
on all 620models
except
those
bound for Califor nia and
Canada
1
1
I
I
I
1
v
v
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
L
0
I
Magnet
coil
Detector dr ive
counter
REMOVAL AND
INSTALLATION
Remove air
cleaner
befor e
r emoving
E GR contr ol
system
For r emoval
and
installation of
air
cleaner
r efer to
Air Cleaner section
Page
EFS
Removal
IE GR contr ol
valve
After
r emoving
the
following par ts
the E
G
R
contr oi
valve can
be dis
mounted
Vacuum
hose ther mal
vacuum
valve toE GR
contr ol valve
E GR contr ol valve
mounting
nut
Note To
r emove
vacuum hose
flat
ten
clipconnecting
vacuum
hose to
EGR contr ol valve and
pull
the
hose offwithhand
Emission Contr ol
System
Ignition
switch
E G
R
war ning lamp
f
1 Ignition
switch
star t
position
Fuse
1A
Odometer switch
r
I
I
I
I
v
I
I
I
i
lQ
U
1
mi
L
J
EC23 3
Fig
EC55 E GR
war ning
cir cuit
EC23 4
Fig
EC56
Removing
KGR contr ol
valve
2 E GR
pass ge
After
r emoving
the
following
par ts
the E GR
passage
can be dismounted
Exhaust gas
r etur n
tube exhaust
manifold
toE GR
passage
B1ow
by
hose
cylinder
block
to
P Cv
valve
Vacuum hose AB valve toE GR
passage
E GR
passage
mounting
bolt
EC
23
EC541
Fig
EC57
Removing
E GR
passage
3
Ther mal
vacuum
valve
After
r emoving
the
following
par ts
the
ther mal vacuum valve can
be dis
mounted
Vacuum
hose
car bur etor to
ther
mal
vacuumvalve
Vacuum hose ther mal vacuum
valve
to
E
GR contr ol
valve
Note
Dr ain
engine
coolant
befor e
dis
mounting
ther mal vacu
mvalve
Fig
EC58
Removing
ther mal
vacuumvalve
4E G
R
war ning system
EC251
Detector dr ive
counter
Detecfor dr ive
counter is secur ed
on the
top
ofR H
hoodledge panel
in
engine
r oom
To
r emove
detector
dr ive
counter disconnect
w COJUlector
and
loosen twobolts
secur ing
detector
dr ive counter tohoodledge
panel
2
E G
R
war ning lamp
E G
R
war ning lamp
ismounted
at
the
top
cen
ter ofinstr ument
pad
To
r emove E
G
R
war ning
lamppr oceed
as follows
1
Remove
maskingpanel
On models
equipped
with r adio
r emove
war ning lamp
fr om under
in
str ument
panel
2
E GR
war ning lamp
is
a
twist
type
Remove
lamp
and socket
as
an
assembly
Pushand twist
lamp
off
can
EC554
Fig
EC60 Removing
E GR
war ning
lamp
Emission Contr ol
System
3 Odometer
switch
Odometer switch
ismounted onthe
back side of
speedometer
Camin the
odometer switch
is r otated
by
the
speedometer
To
dismount
odometer
switch
pr oceed
as follows
I
Dismount combination
meter as
sembly
2 Remove
meter fr ont cover and
take
off
clips
and scr ews
to
dismount
shadow
plate
3
Loosen
scr ews
secur ing speed
ometer to
pr inted
cir cuit
housing
then
r emove
speedometer
4
Remove two
scr ews
secur ing
odomete switch
to
the
back side
of
speedometer
and detach odometer
switch
EC23 9
Fig
EC61
Removing
odometer
switch
InstaUatlon
Toinstall r ever se the r emoval
pr o
cedur e
EC24
V
r
CID
1 Detector dr ive
counter
2 E GR war ning lamp
3 Speedometer
Fig
EC59 E G
R
war ning y
tem
INSPECTION
Checking
E
GR contr ol
system
in
its mounted conditionS
I
Make a
thor ough
visual check
of
E
G
R contr ol
system
If
necessar y
wipe away
oil
to
facilitate
inspection
If
any
hoses ar e cr acked
or
br oken
r eplace
2
With
engine
r unning
check
E
G
R
war ning
system
for
pr oper
function Make sur e
that
E
GR war n
ing
lamplights
when
ignition
switch
is
tur ned
to
START
position
star ter
mo
tor r uns
IfE GR
wanung
lamp
does
not
light inspect
har nesses
and
con
nector s or
r eplace war ning
lamp
Then
tur n
ignition
switch toON
position
and
check thefollowing
items
I
If
odometer
ofdetector dr ive
counter
has not
r eached 50
000
counts
make sur ethat E
GR
war ning
lamp
does not light
2 Ifodomete
ofdetector
dr ive
counter has
attained 50
000 counts
make
sur e that E
GR
war ning
lamp
lights
If
war ning lamp
does not
light
check har nesses
connector s
and de
tector dr ive
counter r eplace war ning
lamp
or detector
dr ive counter if
necessar y
Notes
Oper ation
oC
E GR
war ning lamp
isas
Collows
Ignition
SwitchPosition
START
Detector
Dr ive
Counter
E GR
War ning Lamp
ON
b After
completing
inspection
of
E
G
R
contr ol system
be
sur e to
r eset
odometer
ofdetector dr ive
counter
to
zer o
c
This item
applies
toall 620
models
except
those bound for
Califor nia
and Canada
3
With
engine stopped inspect
E GRcontr ol valve
for
any
indication
of
binding
or
sticking by moving
dia
phr agm
ofcontr ol valve
upwar ds
with
a
finger
2 When
engine
coolant
temper a
tur eis
high
I Make
sur e
that E
G
R
contr ol valve
oper ates
when
engine speed
is
in
cr eased fr om idling
to3 000 to
3500
r pm
Place
a
fmger
on the
diaphr agm
ofE G
R contr ol
valve
to
check for valve
oper ation
2 If
E
GR contr ol valve does not
oper ate
check
as
follows
Disconnect oneend
E
G
R contr ol
valve
side ofvacuumhose connect
ing
ther mal vacuumvalve
toE GR
Emission Contr ol
System
ON
Below
50000
counts
Above
50000counts
OFF
ON
4
With
engine
r unning inspect
E G
R
contr ol
valve and ther mal
vacuo
umvalve for nor mal
oper ation
1
When
engine
coolant
temper a
tur e
is low
Make
sur e
that
E GR
contr ol valve
does not
oper ate
when
engine
speed
is
incr eased
fr om
idling
to
3 000 to
3 500
r pm
Place
a
fmger on
the
diaphr agm
of
E GR contr ol
valve to
check for
valve
oper ation
EC253
Fig
EC62
Checking
E GR contr ol valve
contr ol valve
Incr ease
engine speed
fr om
idling
to
3 000
to3
500
r pm
Make sur e that ther mal vacuum
valve
is
open
and that
car bur etor
vacuum is
pr esent
at the end
E
GR
contr ol
valve side
of
vacu
umhose
Ifvacuum
is weak or
not
pr esent
at
all
r eplace
ther mal vacuum
valve If
vacuum
is
pr esent r eplace
E G
R
contr ol valve
EC25
EC254
Fig
EC
63
Checking
lher mal
vacuumvalve
If
any difficulty
is encounter ed in
judging
the condition of
any
compo
nent
dur ing
above
inspection
check
the
questionable component independ
ently
as
follows
E GR
contr ol valve
Dismount E
G
R
contr ol valve
fr om
engine
I
Apply
vacuum to
E G
R
contr ol
valve
r efer r ing
to
the
following figur e
If
the
valve
moves tofull
position
it is
nor mal
E GR
contr ol valve will r emain
open
for mor e
than
3 0
seconds after
vacuumhascut
off
la
ET152
Fig
EC64
Checking
E GR
contr ol
ualue
2
Visually
check
E GR
contr ol
valve for
damage
wr inkle or defonna
tion
3
Clean the
seating
sur face of
E GR contr ol valve with a br ush
and
compr essed
air
and r emove
for eign
matter fr om ar ound the valve and
por t
EC3 50
Fig
EC65
Cleaning
E
GR contr ol
valve
Ther mal
vacuum
valve
Dismount ther mal
vacuum valve
fr om
engine
Note Befor e
dismounting
dr ain en
gine
coolant
fr om
engine
Apply vacuumtother mal vacuum
valve and
check tobe sur e thaI ther
mal vacuum valve
opens
or closes in
r esponse
to
engine
coolant
temper a
tur e as
specified
Ther mal vacuum
valve
should
open
at
a
temper atur e
of57
to63 0C
13 5
to 1450F
completing
the
vacuum
passage
Note
Do
not allow water to
get
inside
thether mal vacuumvalve
EC242
Fig EC66
Checking
hennal
vacuum
valve
Emission Contr ol
System
CATALYTIC
CONVERTER
DESCRIPTION
The
catalytic
conver ter acceler ates
the chemical r eaction of
hydr ocar bons
HC and car bon monoxide CO in
the
exhaust
gas
and
changes
them
into
nonhar mful
car bon dioxide
C02
OPERATION
Exhaust
gas
emitted
fr om the en
gine
contains
some har mful substances
due
to
incomplete
combustion in the
combustionchamber
The
air
injection
system
is
designed
to
r educe the con
tent ofsuch substances
in
the exhaust
gas
In
this
system
the
secondar y
air
is
led fr om the check valve
and
injected
intothe
exhaust manifold
With
this
injection
of
the
secondar y
air
hydr o
EC444
EC26
and water
H20
This
chemical r eac
tion
pr ocess
r equir es
the
pr oper
a
mount
of
air
which
is
supplied by
the
air
pump
Refer
to
the item AJ
S
This air is caUed
secondar y
air
The
catalytic
conver ter is mounted
on
the
vehicles
destined
for Califor nia Refer
to
Figur e
EC 67
3 4
1 Fr ont
tube
2
Catalyti
conver ter
3 Center tube
4Main muffler
5 Rear
tube
EC782
Fig
EC67
Location
ofcatalyticconver ter
car
ons
He
and car bon
monoxide
CO in the exhaust
gas
ar e
gr adually
oxidized
with
oxygen 02
in the
secondar y
air and conver ted
intonon
har mful car bon
dioxide
C02
and
water
H20
The
catalytic
conver ter
fur ther
cleans
engine
exhaust
gas
Thr ough
catalytic
action it
changes r esidual
hydr ocar bons
and car bon monoxide
contained
in exhaust
gas
intocar bon
dioxide
and water befor e
exhaust
gas
is
dischar ged
tothe
atmospher e
cSecondar y air
Car bonmonoxide
hydr ocar bon
Car bondioxide gas
water
F EC68
Oper ution
ofcatalytic
cor wer ter
REMOVAL
AND
INSPECTION
Removal and
inspection
can
be
done
as follows
Removal
Catalytic
conver ter
1
Apply par king
br ake
2
Place
wheel lock under each
tir e
3
Jack
up
thevehicle
4Remove lower
shelter of
catalytic
conver ter
5 Dismount
catalytic
conver ter
EC453
Fig
EC69 Removing
catalytic
conuer ter
Inspection
Pr eliminar y inspection
Visually
check condition
ofall
component par ts
including
ho
s
tubes and
wir es
r eplace
if
necessar y
Refer to
Inspection
ofA
IS on
page
EC17
Catalytic
conver ter
Whether
catalytic
conver ter is nor
mal or not can be checked by
ob
ser ving
var iation
in
CO
per centage
The
checking
pr ocedur e
is
as
follows
Apply
par king
br ake Shift
gear s
intoNeutr al for manual tr ansmission
and Neutr al or Par k for automatic
tr ansmission
1
Visually
check
catalytic
conver ter
for
damage
or cr acks
Emission Contr ol
System
2 Remove air hose
between
5
way
connector and air checkvalve
Plug
the
disconnected hose to
pr event
dust
fr om
enter ing
Refer to
page
ET 12
3
Checkcar bur etor
pipes
for
pr oper
connection
4
War m
up
engine sufficiently
5
Race
engine
1
500to2000
r pm
twoor thr ee
times
under no
load then
r un
engine
for oe
minute at
idling
speed
6
Adjust
thr ottle
adjusting
scr ew
until
engine
attains
to
specified
speed
Refer to
page
ET 10
7 Check
ignition timing
Ifneces
sar y adjust
it to
specifkations
Refer
to
page
ET 10
B
Adjust
idle
adjusting
scr ew until
specified
CO
per centage
is
obtained
Refer to
page
ET 12
9
Repeat
the
adju
stment
pr ocess
as
descr ibed
in
steps
5 to8
above
until
specified
CO
per centage
is obtained
Note
Adjustment
in
step
9should
be
made
ten
minutes
after
engine
has
wanned
up
10 Race
engine
1
500 to2000
r pm
twoor thr ee
times
under no
load
and make sur e that
specified
CO
per
centage
is obtained
11
Remove
cap
and
connect air
hose
to
air check valve
If
idling
speed
incr eases
r eadjust
it
to
specified speed
with
thr ottle ad
justing
scr ew
12 WaRn
upengine
for
about
four
minutes at 2000
r pm
under no
load
13 Measur e CO
per centage
at
idling
speed
After
step
12 has been coin
pleted
wait
for one
minute befor e
making
CO
per centage
measur ement
14
IfCO
per centage
measur ed
in
step
13 is less than
03
the
catalytic
conver ter
is
nor mal
15 If
CO
per centage
measur ed
in
step
13 is over
03
r echeck A
IS
and
r eplace
air check valve Then
per for minspection
steps
12and 13
EC27
16 IfCO
per centage
is
still over
03
in
step
15
catalytic
conyer ter
is
malfunctioning
Replace
catalyticcon
ver ter
INSTALLATION
To
install
r ever se
the r emoval
pr o
cedur e
Bolt
lightening
tor que
specifications
Tightening
tor que
Catalytic
conver ter
26 to3 4
kg
m
19
to25
ft Ib
FLOOR
TEMPERATURE
WARNING
SYSTEM
DESCRIPTION
The
floor
temper atur e
war ning
system
consists ofa floor
temper atur e
sensing
switch
installed
on
the vehi
cles floor floor
temper atur e
r elay
and
a
war ning
lamp
on the instr ument
panel
and wir es that connect these
par ts
When
the floor
temper a
tur er ises to
an abnor mal
level
the
war ning
lamp
will
light
tocall
the attention
of
the
dr iver
The
wir ing
diagr am
ofthis
system
and location
of
the
floor
temper atur e sensing
switch ar e ilIus
tr ated
in
Figur es
EC70and EC71
I
Emission
Contr ol
System
Ignition
switch
Ignition
key
Off
T
I
I
I
Batter y
I
J
77
77
Relay
J
Floor
temper atur e
sensing
swi
tch
Floor
temper atur e
war ning
lamp
77 77
EC3 3 2
Fig
EC
70 Win
ng
diagr am offloor temper atur ewar ning system
rl
J
@
1
Floor
temper atur e
Ij
cr
EC556
Fig
EC71 Location
of
iJoor
temper atur esensing
switch
OPERATION
Floor
temper atur e
will
exceed
nor
mal
level
when
temper atur e
r ise in
the
exhaust
system succeeding
the cata
lytic
conver ter is caused
byeilher
an
engine
malfunction
or sever e
dr iving
conditions
Under this condition the
floor
temper atur e
sensing
switch tur ns
off
causing
the
star ting
switch lineof
the floor
temper atur e r elay
totur noff
and the
ignition
switchline totur n
on
as a
r esult the floor
temper atur e
war ning
lamp
comes on
When the floor
temper atur e
is
lower
t
an
the
specific
temper atur e
the
floor
temper atur e sensing
switch
tur ns
on The
ignition
line
ofthe floor
temper atur e r elay
tur ns offwhile the
star ting
switch
side is in
on The floor
temper atur e war ning
lampgoes
out
EC2B
The
lamp
is
functioning
satis
factor ily
if
it is r emains on
while the
star ting
motor is in
oper ation
The
lamp
goes
out when
the
ignition
switchis
in
IG
position
The
foUowing
char t
fur nishes
the
infor mation on
the
r elationship
be
tween
floor
temper atur es
war ning
lamp
and
sensing
switch
L
Contact close
ECJ40
I
Contaclopen
ECJ41
Fig EC72
Oper ation
of
floor
t
mper atur esen6ing
6witch
REMOVAL
Floor
temper atur e
sensing
switch
1 Remove seat
Seat
section of
ser vice manual
2 Remove
sensing
sWitch
as outlined in
the
Body
and Fr ame
floor
temper atur e
Floor
temper atur e r elay
Fr om
under
r elay cover r emove
this
par t
Refer to
Figur e
EC
73
Floor temper atur e
EC783
Fig
EC73 Location
offloor
ttmper atur e r elay
Floor tempar atur e
war ning
lamp
Refer
to
Figur e
EC
74
for
the
loca
tion
ofthis
par t
L
1t
1
RAt
Fig
EC74Locationoffloor
temper atur e
war ning lamp
INSTALLATION
Toinstall r ever se
the or der
of
r em
ovaL
INSPECTION
Floor war ning temper atur e
system
Apply par king
br ake Shift
gear s
intoNeutr al foI manual
tr ansmission
and Neutr al
or Par k
for automatic
tr ansmission
1 Ensur e that floor
temper atur e
war ning
lamp
lights
when
ignition
switch
is iumed
to
the
S
position
If
not check
lamp
for bur ned
bulbs
Replace
bulb
ifbulbis bur ned out
If
bulb
is
not
bur ned tr ace wir e
s
back
to
ignition
switch
Repair
or
r eplace
if
necessar y
2 Be
sur e
that floor
temper atur e
is
cool below
800C
1760Fj
befor e
car r ying
out
the
following pr ocedur e
I Remove r ear seat
2
Ignition
switch
is
tur ned
tothe
IG
position
3
Ensur e that floor
temper atur e
war ning
lampgoes
out
4Heat
sur r ounding
ar eas offloor
temper atur e
sensing
switch with a
pr oper
heater toensur e that floor
temper atur e war ning lamp
glows
when
floor is heated
to
the
specifications
as
shown
inthe table below
Emission Contr ol
System
Temper atur e
sensing
switch
Contact
close
Temper atur e
war ning
lamp
Off
Contact open On
Note
Avoid
heating
floor
temper a
tur e
sensing
switch
dir ectly
If
lamp
does
not glow
check floor
temper atur e sensing
switch
connector
for
continuity
with
a
cir cuit tester
If
continuity
should exist after
heated
sur r ounding
ar eas offloor tem
per atur e sensing
switch
r eplace
tem
per atur e sensing
switch
If
con
tinuity
does
not
exist
tr ace
the
wir ing
back to
r elay
or check the
following step
3
Repair
or
r eplace
wir e s if
necessar y
Note
The
floor
temper atur e sensing
switch
may
be heated
thr ough
the
floor
by
a
pr oper
heater
3
Tur n
ignition
switch to
the
IG
position
and disconnect floor
temper
atur e
sensing
connector
The
lamp
should
r emain
on
If
not
check floor
temper atur e r elay
for
continuity
with
200
r
I
141
J
Tofloor
temper atwe
war ning lamp
2
Fr om
S
position
3 Fr om
IG
position
4
Fr om
ignition
switch
5 Tofloor
temper atur e
sensing
switch
O
When
floor
temper atur e
war ning lamp
lights
Check
floor
temper atur e war ning
lamp
1
Open
or
shor j
cir cuit
in
wir ing
har ness
2
Check fuel
system
with
r egar d
to
the
following
items
Refer to
Inspec
lionofFuel
System
EC
29
Floor
temper atur e
Below1050C 221OF
Above
1050C 221
OF
a
cir cuit
tester
Refer r ing
tothe
following
floor
temper atur e r elay
if
r elay
is nor mal
tr ace
wir es
back
to
ignition
switch
Repair faulty wir ing
Floor
temper atur e r elay
When
checking
floor
temper atur e
r elay
for unit
r emove
it and
pr oceed
as
follows
1
Check for
continuity
between
@
and
ID Continuity
should exist
Check
for
continuity
between
CD
and@ Continuity
should exist
Check
for
continuity
between
CD
and
@
Continuity
should not
exist
2
Apply
a 12
volt
docacr oss
@
and
ID
to
ensur e
that
continuity
exists
between
CD
and
@
and
that
con
ti
nuity
does
not
between
CD
and
@
If
test r esults dn
not
satisfy
the
above
r eplace
the
floor
temper atur e r elay
EC3 44
Fig
EC75
Checking floor temper atur e r elay
1 Float
level
2 Choke
3
Nor mal fuel
supply
system
Pr ima
r y
and
secondar y
4Acceler ator
pump
5 Power
valve
6 BC
D D
7 Fuel str ainer
8 Air cleaner
3
Check
ignition system
with
r egar d
to
the
following
items
Refer to
Inspection
of
Ignition System
1
Ignition
AMP
2 Distr ibutor
Emission Contr ol
System
3
Ignition
coil
4
High
tension code
5
Spar k
plug
4
Check idle
CO
adjustment Refer
to
Inspection
of
Idle
CO
Adjustment
Note Even ifther e is
nothing
wr ong
with
engine
the
war ning lampmay
come on ifvebicle is
being
dr iven
on a
steepslope
continuously
in
lower
gear s
at
high engine speeds
EVAPORATIVE
EMISSION
CONTROL SYSTEM
CONTENTS
DESCRIPTION
OPERATION
INSPECTION
FUEL TANK
VAPOR
LIQUID
SEPARATOR
AND
VAPOR VENT LINE
DESCRIPTION
The
evapor ative
emission contr ol
system
is
used
to
r educe
hydr ocar bons
emitted tothe
atmospher e
fr om the
fuel
system
This
r eductionof
hydr o
EC3 0
EC
3 0
EC
3 1
CARBON
CANISTER PURGE CONTROL
VALVE
CARBON CANISTER
FILTER
FUEL
TANK
VACUUM
RELIEF VALVE
IEC3 2
IEC3 2
EC
3 2
EC3 1
car bons is
accomplished
by
activated
char coals inthe car bon canister
This
system
is made
up
to
the
following
I
Fuel tankwith
positive
sealing
filler
cap
@
2
Vapor liquid separ ator
3
Vapor
vent
line
4Car bon
canister
5 Vacuum
signal
line
6 Canister
pur ge
line
5
OPERATION
Fuel
vapor s
fr om
the sealed fuel
tank ar e led
intothe car bon canister
1 Fuel tank
2 Fuel nIler
cap
withvacuum
r elief
valve
3
liquid
vapor separ ator
4
Vapor
vent line
5
Canister
pur ge
line
6 Vacuum
signal line
7 Car bon
canister
EF274
Fig
EC76
Schematic
dr awing
of
lIapor otive
emiaion
contr ol6ydem
The
canister is fined with activated
char coals
to
absor b
the fuel
vapor s
EC 3 0
whenthe
engir ie
is
at r est or at
idlin ll
See
Figur e
EC
77
J
1 Fuel tank
2
Fuel f1l1er
cap
with
vacuum
r eliefvalve
3
Liquid
vapor
separ ator
4
Vapor
vent line
5 Vacuum
signalUne
As the thr ottle
valve
opens
and
vehicle
speed
incr eases
vacuum
pr es
sur e
in
the vacuum
signal
line for ces
r HL
JL
I
EC785
INSPECTION
FUEL TANK
VAPOR
LIQUID SEPARATOR
AND
VAPOR VENT LINE
I
Check all hoses and
fuel
tank
mler
cap
2 Disconnect
the
vapor
vent
line
connecting
car bon canister to
vapor
liquid separ ator
3 Connect
a 3
way
connector
a
Emission
Contr ol
System
Close at
idling
Open
at r est
i
J
17
f
Fuel
vapor
6 Canister pur ge
line
7 Thr ottlevalv
8
Engine
9 Car boncanister
10 Activated car bon
11
Scr een
12
Filter
13
Pur ge
contr ol valve
14
Spr ing
15
Diaphr agm
16
Fixed
or ifice
i
j
EC784
Fig
EC77
Evapor ative
emu ion contr ol
sy
tem
Fuel
vapor flow
when
engine
i6
at
r ed or
idling
the
pur ge
contr ol valve to
open
and
admits
an
or ifice tointake manifold
and fuel
vapor
is
then dr awn intothe
I
J
o I
Fuel
vapor
Fr esh air
intake
manifold
thr ough
the canister
pur ge
line See
Figur e
EC7B
Fig
EC78
Evapor ative
emiuion contr ol
system
Fuel
vapor
flow
when
engine
i
r unning
manometer and a cock or an
equiva
lent 3
way
char ge
cock
to
the end of
the
vent line
4
Supply
fr esh air into
the
vapor
vent line
thr ough
the cock little
by
little until
pr essur e
becomes 3 68
mr nH20
14
5 inH20
5 Shut the cock
completely
and
leave
it
unattended
6 After 25 minutes
measur e
the
height
ofthe
liquid
inthe
manometer
7
Var iation of
height
should r emain
EC3 1
with25
mmH20 098inH20
8 When filler
cap
does
not close
completely
the
height
should
dr op
to
zer o
in
a shor t
time
9 If
the
height
does
not
dr op
to
zer o
in
a shor t
time when filler
cap
is
r emoved
it is
the cause
ofa
stuffy
hose
Note
In
case
the
vent line
is
stuffy
the
br eathing
in fuel tank is not
thor oughly
made thus
causing
in
sufficient
deliver y
offuel to
engine
or
vapor
lock It must ther efor e be
1
3 connectur
COCk
Air Manometer
Emission
Contr ol
System
r epair ed
or
r eplaced
3 68 mmH20
14
5inH20
LL
IPO
liqUid epo
o
3 6
r
@
Car bon canister
EC786
Fig
EC79
Checking
evapor ative
emmion
contr ol
syatem
CARBON
CANISTER
PURGE
CONTROL VALVE
Check for fuel
vapor
leakage
in
the
distr ibutor vacuumline at
diaphr agm
of
car bon
canister
pur ge
contr ol valve
To
check
for
leakage pr oceed
as
follows
I
Disconnect r ubber hose in
the
line
between T connector
and car bon
canister at T
connector
2
Inhale air intothe
opening
of
r ubber hose
r unning
to
vacuumhole in
car bon
canister and
ensur e that ther e
is no
leak
ET3 49
Fig
EC so
Checking car bon canuter
pur ge
contr ol valve
3 Ifther e is
a leak
r emove
top
cover fr om
pur ge
contr ol valve
and
check for dislocated
or cr acked
dia
phr agm
If
necessar y
r eplace
dia
phr agm
kit
which is
made
up
ofa
r etainer a
diaphr agm
and a
spr ing
@
@
1 Cover
2
Diaphr agm
3 Retainer
4
Spr ing
ET3 50
Fig
EC81 Car bon
catU ter
pur ge
contr ol valve
CARBON
CANISTER FILTER
Check for a contaminated
element
Element
can be r emoved
at the
bottom
of
canister
installed onvehicle
body
EC 3 2
ET3 7Q
Fig
EC s2
Replacing car bon
canuter
filter
FUEL TANK
VACUUM
RELIEF VALVE
Remove fuel
filler
cap
and
see it
functions
pr oper ly
I
Wipe
clean
valve
housing
and have
it in
your mouth
2
Inhale air A
slight
r esistance ac
companied by
valve indicates that
valve is in
good
mechanical condition
Note
alsothat
by
fur ther
inhaling
air
the r esistance
should be
disappear ed
with
valve clicks
3 If
valve is
clogged
or if
no
r esist
ance is
felt
r eplace capas an assem
bled
uni
t
l
u
ET3 69
Fig
EC
83
Fuel
filler cap
Emission
Contr ol
System
SPECIAL SERVICE
TOOLS
Tool number For Refer ence
No
Descr iption
use
page
or
tool name on
Figur e
No
STI
9810000 For
r emoving
and
installing
ther otor
r ing assembly
L20B
Fig
EC29
A14
Fig
EC 41
Hexagon
wr ench
SE279
2
ST
19900000
For
assembling
the vanes
L20B Fig
EC
3 9
A14
Dummy
shaft
SE284
3
STl9890000 Used
as a mount whenr otor is r emoved and when
bear ing
is
installed L20B
Fig
EC3 2
A14
fig
IlC
3 5
f
Rotor
adapter
SE3 47
4
STl9940000 Used when
r otor is r emoved and whenfr ont
bear ing
installed L20B
Fig
EC3 2
A14
Fig
EC3 5
Bear ing
Pr essing
tool
d
9E3 48
This
ser vice
tool
is
designed
for use
in
disassembly
and
assembly
ofthe
air
pump
EC 3 3
Emission Contr ol
System
Tool number
For Refer ence
No
Descr iption
use
page
or
tool
name
on
Figur e
No
5 STl993 0000 Used as a mount
when fr ont
bear ing
is r emoved L20B
Fig
EC3 3
Al4
Bear ing adapter
E9
SE3 49
6
STl9910000 Used as a
dr ift
when
fr ont
bear ing
isinstalled Alsoused as a
suppor t
L20B
Fig
EC3 3
whenr otor
is installed Al4
Fig
EC3 6
Fig
EC3 7
Bear ing
dr iver
SE3 50
o
L20B
AI4
Fig
EC3 6
Fig
C3 7
7 STl9920000 Used as a dr ift whenr otor
is
installed
Rotor
stand
SE3 51
8 ST19870000
Used
as
a
adapter
when air
injection
pumppr essur e
is tested L20B
Al4
Page
EC18
Air
pump
test
gauge adapter
SE3 89
EC3 4
DATSUN PICK
UP
MODEL 620
SERIES
I
NISSAN
I
NISSAN MOTOR
CO LTD
TOKYO JAPAN
SECTION
EE
ENGINE
ELECTRICAL
SYSTEM
BATTERY
EE 2
STARTING
MOTOR
EE
4
CHARGING
CIRCUIT EE
12
ALTERNATOR
EE 15
REGULATOR
EE 20
IGNITION
CIRCUIT EE
26
DISTRIBUTOR
EE
3 0
Non
Califor nia
models
DISTRIBUTOR Califor nia models EE
3 3
TRANSISTOR IGNITION UNIT
Califor nia models
IGNITION COIL
SPARK PLUG
EE 3 6
EE
46
EE 47
REMOVAL
CHECKING ELECTROLYTE
LEVEL
CHECKING SPECIFIC
GRAVITY
REMOVAL
I Disconnect
negative
and
positive
cables
2 Remove
nuts
fr om
batter y
clamps
take off
clamps
3 Remove
batter y
CHECKING
ELECTROLYTE LEVEL
Remove
six
vent
plugs
and check
for
electr olyte
level
ineach cell
If
nccessaJ
pour
distilled
water
CHECKING
SPECIFIC
GRAVITY
Specific
gr avity
of
batter y
electr o
lyte
is tested
by
a
hydr ometer
Ifthe
sr ate
of
char ge
of
batter y
is
60or
specificgr avity
r eading
is below 1 20
as cor r ected
at 200e 680F bat
ter y
must be
r echar ged
or
batter y
electr olyte
concentr ation
adjusted
Add or subtr act
gr avity points
accor ding
to
whether the
electr olyte
temper atur e
is above
or
below 200e
680F
standar d
The
gr avity
of
electr olyte
chlll
ges
0
0007 for
ever y
Ioe 180F tem
petatur e
A
cor r ection
can then be
made
by using
the
following
for mula
Engine
Electr ical
System
BATTERY
CONTENTS
EE 2
EE 2
EE 2
BATTERY FREEZING
CHARGING
INST ALLATION
S
20
St 0
0007
t
20
Wher e
St
Specificgr avity
of
electr olyte
at
tOe
520
Specificgr avity
of
electr olyte
cor r ected at 200e
680F
t
Electr olyte
temper atur e
For
example
A
hydr ometer
r eading
of
1260 at
3 00e
860F
would
be
1 267 cor r ected
to
200e
6goF
indicating fully char ged
batter y On the other hand a
hydr o
meter
r eading
of1220 at lOoe
140F would be 1199 cor r ected to
200e 680F
indicating
a
par tially
char ged batter y
The state of
char ge
of
batter y
can
be deter mined
by
the
following
table
if
the
specific
gr avity
of
electr olyte
is
known BefOIe
checking
be sur e that
cells ar e filled tocor r ect level
G
U
o
N
b
t
E
u
ol
1
lilt
Ii
I
m
J
I
I
I
I
J 1
I
J
Sfto 71 II
It
100
0wJIztI
COJJditioD
EE002
Fig
EE 2
ChaJ ffing
condition
EE
2
1 28
@
126
S
Sow
E
l
l
u
o
o
l
e
u
0
U21
1
101
EE
3
EE
3
EE 3
Read
top
level
withscale
1 Ther mal
gauge
2
Hydr ometer
feOOl
Fig
EE
l
Checking
pccmegr avity
Conver ted
specificgavity
20
1Je
I
dOldlOiJ OSQ
Electr olytetemper atur e
oC
EEOO3
Fig
EE 3
SpecificlNWity
at
eiectr oly
te temper atur e
BATTERY FREEZING
Batter y
electr olyte fr eezing point
var ies with acid
concentr ation
or
its
specific
gr avity
A
batter y
with an
insufficient
char ge
will
fr eeze at lower
temper atur es
If
specific
gr avity
of
a
batter y
falls below
11 this
is
an
0
10
20
3 0
g
40
I
u
il
SO
I
0
e
60
0
E
70
Engine
Electr ical
System
indication that
batter y
is
completely
dischar ged
and
will
fr eeze
r eadily
when
temper atur es
fallbelow
fr eezing
Note Use extr eme caution toavoid
fr eezing batter y
since
fr eezing
will
gener ally
r uin
the
batter y
1
80
100 104
108 tl2 1 16 t 20 124128
Specificgr avity
of
electr olyte
CHARGING
I
felectr olyte
level
is
satisfactor y
batter y
must
be
char ged
whenelectr o
lytegr avity
r eading
falls below
1 20 If
batter y
on
car
is
quick
char ged
to
13 2
EEOQ4
Fig
EE
4Fr oezing point
of
electr olyte
br ing
it
up
to
full
char ge
the
oper a
tion
should
be car r ied
out
with nega
tive cable r emoved
Pr ior
tochar ging
cor r oded
ter mi
EE 3
nals
should
be
cleaned
with a
br ush
and common
baking
soda solution In
addition the
following
items
should
be
obser ved while
batter y
is
being
char ged
I Be
sur e that electr olyte
level is
above
top
of
each plate
2
Keep
r emoved
plugs
in
a safe
place
3
Do
not
allow
electr olyte temper a
tur e
to
go
over 450C
I13 0F
4
After
char ging
check tobe cer
tain that
specific
gr avity
does not
exceed 1260
at 200C 680P Cor
r ection can be made
by adding
dis
tilled water
into
cells as
necessar y
5
Keepbatter y away
fr om
open
flame
while it is
being
char ged
6 After all
vent
plugs
have been
tightened
clean
all
spr ayed electr olyte
off
upper
face
of
batter y
INSTALLATION
1
Install and
tighten clamps
secur e
Iy
2 After
clamps
have been
tightened
clean
batter y
cable ter minals and
apply
gr ease
tor etar d for mation of
cor r osion
DESCRIPTION
OPERATION
CONSTR
UCTI
ON
REMOVAL
DISASSEMBL
Y
CLEANINGAND INSPECTION
TERMINAL
FIELD
COIL
BRUSHES
AND BRUSH LEAD
WIRE
BRUSH SPRINGTENSION
ARMATURE ASSEMBLY
DESCRIPTION
The functionof
the
star ting system
whichconsists of
the
batter y ignition
switch
star ting
motor and solenoid
is
tocr ank
the
engine
The electr ical
ener gy
is
supplied
fr om the
batter y
the solenoid
completes
the
cir cuit
to
oper ate
the
star ling
motor and
then
the motor car r ies
out theactual cr ank
ing
ofthe
engine
Engine
Electr ical
System
STARTING
MOTOR
CONTENTS
EE 4
EE
6
EE
7
EE 7
EE
7
EE
8
EE
8
EE B
EE
B
EE
B
EE
B
OVERRUNNING
CLUTCH ASSEMBLY
BRUSH
HOLDER
TEST FOR
GROUND
BEARING
METAL
MAGNETICSWITCH ASSEMBLY
ASSEMBLY
TEST
PERFORMANCE TEST
MAGNETIC
SWITCH ASSEMBLY TEST
SERVICE
DATA
AND SPECIFICATIONS
TROUBLE DIAGNOSES
AND
CORRECTIONS
5
@
EE 9
EE 9
EE 9
EE
9
EE 9
EE
9
EE
9
EE
O
EE
EE
11
I Br ush
2 Field coil
3
Magnetic
switch
4
Pludgcr
5 Tor sion
spr ing
6
Shifll r
7
Over r unning
clutch
8 Pinion
9 Ar matur e
9
EE3 15
Fig
EE 5 Sectioool view
of
slar ting
motor Sl14180B
EE 4
fB
WBBYBY B
@@@@
I
I
FUSIBLE lIN
r
T
H
BATTERY
r J
BATTERY
f
EARTHPOINT
f
I I I
@@@
Y
BY
BWWB
@@@
I
I I
AfT
E
quipped with
cooler
COLOR CODE
B Black
OW Blackwith
white
str ipe
BY Blackwith
yellow
str ipe
W White
WB White
withblack
str ipe
Engine
Electr ical
System
FUSIBLE LINK
1Y Ob
INHIBITOR
RELAY
INHIBITOR SWITCH
A
I
J
Y
@
I
A
l
r BW
j
CJ
BW
BWI
000
000
ggg For
Califor nia
I
Bd
f
00
00
00
00
Q
BW
B
Y
BY WB
BY
@ @ @
BW
@
I
M T
Equipped
withcooler
@
I
@
BY
BY
@
I
STARTING
MOTOR
l
BY
BW
9
IGNITION
SWITCH
L
INHIBITOR SWITCH
STARTER
MOTOR
Notes
a
@
MT only
@
AT
only
b Inhibitor switchis
on
inneutr al
EE
5
Fig
EE 6 Cir cuit
diagr am
0
star ting systom
eE491
OPERATION
When the
ignition
switch tur ned
fully
clockwise tothe START
posi
tion
batter y
cur r ent flows
thr ough
ser ies
and shunt
coils ofthe
solenoid
magnetizing
the
solenoid
The
plunger
is
pulled
intothe solenoid
so
that
it
oper ates
the shift lever
to
move the
dr ive
pinion
into
the
flywheel r ing gear
Then
the
solenoid
switch
contacts close after the
dr ive
pinion
is
par tially engaged
with the
r ing gear
Closing
ofthe
solenoid switch
contacts cuses the
motor tocr ank the
engine
and alsocut out the ser ies
coil of
the solenoid the
magnetic
pull
ofthe shunt
coil
being
sufficient
to
hold the
pinion
in
mesh after the
shifting
has been
per for med
After the
engine star ts
r unning
the
dr iver
r eleases the
ignition key
and
it
automatically r etur ns to
the
ON
posi
tion
The
tor sion
spr ing
then
actuatesthe
shift
lever
to
pull
the
pinion
which
allows
the
solenoid swi
tch contacts to
open
Consequently
the
star ting
mo
tor
stops
Engine
Electr ical
System
I
I
Ring gear
2
Shift lever
guide
3
Ar matur e
4
Batter y
5 Fieldcoil
6
Stationar y
contact
7
Monble
contactor
Mor e
positive
meshing
and
demeshing
of
the
pinion
and the
r ing
gear
teeth ar e
secur ed
by
means
ofthe
over r unning
clutch The
over r uIUling
clutch
employs
a shift
lever toslide
the
pinion
along
the
ar matur e shaft
EE 6
F
l
cp
o
r
1
I I
W
m
EE274
8 Shunt coil
9
Plunger
10
Ignition
switch
11
Ser ies
coil
12 Tor sion
spr ing
13
Shift lever
14
Pinion
Fig
EE
7 Star ting
motor
cir cuit
intoor
out
of
mesh with the
r ing
gear
teeth
The
over r unning
clutch
is
de
signed
totr ansmit
dr iving
tor que
fr om
the motor ar matur e
tothe
r ing gear
but
pr event
the
ar matur e fr om over
r unning
after the
engine
has star ted
CONSTRUCTION
O
o
8
w
il
Engine
Electr ical
System
V
1
Magnetic
switch assembly
13
Br ush
spr ing
jj
JI
2 Dust cover
t4Br ush
Adjusting
washer
15 Yoke
P
3 Tor sion
pr ing
t6 Field coil assembly
4Shift
lever
17 Ar matur e
assembly
5 Dust
cover
18
Center
plate
SI141808only
6
Thr ust washer
19 Pinion
assembly
7 E
r ing
20 Dust
cover
8
Rear cover metal
21 Pinion
stopper
9
Thr ough
bolt
22
Stopper
clip
10 Rear
cover 23
Gear
case
tl Br ush
holder
assembly
24Gear case
metal
12
Br ush
REMOVAL
Disconnect
batter y
gr ound
cable
Disconnect black wir e with
yellow
str ipe
fr om
magnetic
switch ter minal
and black
batter y
cable
fr om
batter y
ter minal of
magnetic
switch
2 Remove two
bolts
secur ing
star t
ing
motor to
tr ansmission
case Pull
star ter
assembly
for war d and r emove
star ting
motor
DISASSEMBLY
I
Disconnect
connecting plate
fr om
M
ter minal of
magnetic
switch
Re
move twoscr ews
secur ing magnetic
switch
and
r emove
magnetic
switch
assembly
2
Remove dust
cover E
r ing
and
thr ust washer
s
EE3 17
@
@
O
Fig
EE
9 Remouing
dUlt
cover E
r ing
and thr ust
washer s
3 Remove
twoscr ews
secur ing
br ush
holder
assembly
EE3 18
Fig
EE IO
Removing
br ush holder
d
cr t
w
EE 7
S
4
f
Ijl
I
EE3 16
Fig
EE B
Exploded
view
of
star ting
motor
4Remove two
thr ough
bolts
and
r ear cover
5 Remove br ushes
fr omtheir
hold
er
by moving
each br ush
spr ing away
fr om
br ush witha hook
Remove
br ush holder
6
Remov
yoke assembly
and
with
dr aw ar matur e assembly
and shift
lever
7 Remove
pinionstopper
located at
the
end of
ar matur e
shaft Tor emove
stopper
fir st move stopper
towar d
pinion
and
after
r emoving
stopper clip
r emove
stopper
with
over r unning
clutch assembly
fr om ar matur e
shaft
Pinion
stopper
Pinion stopper clip
EE277
Fig
EE l1
Removing pinionstopper
CLEANINGAND
INSPECTION
Clean all disassembled
par ts
but do
not use
gr ease
dissolving
solvents for
cleaning
over r unning
clutch
annatur e
assembly
magnetic
switch
assembly
and field coils since such a
solvent
would dissolve
gr ease packed
in
c1u
tch
mechanism
and would
damage
coils or
other insulator s
Check them for excessive
damage
or
wear and
r eplace
if
necessar y
TERMINAL
Check
ter minal for
damage
and
wear
and
r eplace magnetic
switch
assembly
if
necessar y
FIELD COIL
Check field coil for insulation If
the insulation ofcoil
is
damaged
or
wor nit should be
r eplaced
Testing
field
coil for
continuity
Connect the
pr obe
ofa
cir cuit
tester
or an ohmmeter tofield coil
positive
ter minal
and
positive
br ush
holder
Iftester shows no
continuity
field
cir cuit or
coil is
open
EE016
Fig
EE
I2 Testing field
coil
for continuity
TestIng
field coD for
gr ound
Place one
pr obe
ofcir cuit tester
onto
yoke
and the other
onto
field
coil lead
positive
tenninal
If
ver y
little r esistance is r ead field
coil is
gr ounded
Engine
Electr ical
System
EE017
Fig
EE
I3
Testing r U
ld coil
for
gr ound
BRUSHES
AND
BRUSH
LEAD
WIRE
Check the sur face condition of
br ush contact
and wear
of
br ush Ifa
loose contact is found it should be
r eplaced
Ifbr ush
is
wor nso
that
its
length
is
less than 12mm
0472in
r eplace
Check
the
connection
oflead
clip
and lead
wir e
o
@
EE 8
Check br ush holder s
and
spr ing cUp
tosee if
they
ar e
not
defor med or
bent and will
pr oper ly
hold br ushes
against
the
commutator
If
br ushes or br ush holder s
ar e
dir ty they
should be
cleaned
BRUSH
SPRING
TENSION
Check br ush
spr ing
tension
by
a
spr ing
scale as shown in
Figur e
EE
13
The
r eading
should
be
1
6
kg
3 5
Ib
Replace
spr ing
if
tension
is
lower than
I 4
kg
3 1 Ib
ARMATURE
ASSEMBLY
Check exter nal
appear ance
of
ar matur e and commutator
1
Inspect
commutator If
the sur
face
ofcommutator is
r ough
it
must
be sanded
lightly
with a No
500
emer y
cloth If
the
depth
of
insulating
mica is
less
than
02 mm
0
0079 in
fr om commutator sur face
insulating
mica should
alsobe under cut
so
that
its
depth
is 05to08
mm 0
0197 to
003 15in
The wear limit ofcommutator dia
meter is
2
mm 0
0787
in Ifthe
diameter ofcammu
tator
is
less
than
3 1 mm 1220 in
r eplace
annatur e
assembly
EE018
Fig
EE 14
Inspecting
br ush
spr ing
tension
L
0 5 to0 8
mm
71j
Cor r ect
2
Inspect
solder ed
connection of
ar matur e lead
and
commutator If
loose connection is found solder it
using
r esin
flux
3
Ar matur e test for
gr ound
Using
a cir cuit tester
place
one
test
pr obe
ontoar matur e shaft and other
ontoeach commutator bar
If
tester
shows
continuity
ar matur e
is
gr ounded
and
must be
r eplaced
EE022
Fig
EE
16
Testingannatur e for
gr ound
4
Check ar matur e for shor t
by
placing
it onar matur e tester
gr owler
with a
piece
of
ir on
over ar matur e
cor e
r otating
ar matur e Ifthe
plate
vibr ates ar matur e
is
shor ted
j
l
EE023
Fig
EE
17
Testing
annatur e
for
ahor t
Engine
Electr ical
System
L
File l
0
Commutator
Segmen
t
IWMica
Incor r ect
EE021
Fig EE 15
Under cutting
i118ulating
mica
5 Check
ar matur e for
continuity
by
placing pr obes
of
tester on
two
seg
ments side
by
side Iftester shows
no
continuity
the cir cuit is
open
OVERRUNNING
CLUTCH
ASSEMBLY
Inspect pinion assembly
and scr ew
sleeve Scr ew sleeve
must
slide
fr eely
along
ar matur e shaft
splines
If
damage
is found or r esistance is felt
when
sliding
it must be
r epair ed
Inspect
pinion
teeth Ifexcessive
r ub
bing
is found on teeth
r eplace
Flywheel
r ing gear
also
must be in
spected
l
EE278
Fig
EE 18
Over r unning
clutch
auem
bly
BRUSH
HOLDER
TEST
FOR
GROUND
Using
a cir cuit tester
place
onetest
pr obe
onto
negative
side
ofbr ush
holder
and another onto
positive
side
If
tester
shows
continuity
br ush
holder is
shor ted to
gr ound
Replace
br ush
holder
EE
9
Ee026
Fig
EE 19
Testing
br ush
for
r ound
BEARING
METAL
Inspect bear ing
metal for wear or
side
play
Ifthe clear ance between
bear ing
metal and ar matur e shaft is
mor ethan 02mm 0
0079 in
r eplace
metal
MAGNETIC
SWITCH
ASSEMBLY
1
Using a
cir cuit tester
l
check
con
tinuity
between S ter minal of
mag
netic
switch and
switch
body
metal If
continuity
does
not exist shunt
coit
is
opened
Replace
switch
assembly
2 In the
same manner as above
check
continuity
between ter minals
S and
M
If
continuity
does not
exist ser ies
coil
is
opened
Replace
switch
assembly
ASSEMBLY
Reassemble
star ting
motor
in
r e
ver se
sequence
of
disassembly
When
assembling
be
sur e to
apply
gr ease
to
gear
case
and
r ear cover
bear ing
metal
and
apply
oil
lightly
to
pinion
TEST
PERFORMANCE TEST
Star ter motor should be
subjected
toa noload
test
whenever it has
been over hauled toensur e that
its
per for mance
will be
satisfactor y
when
installed on
engine
Star ter motor
should alsobe
subjected
to
the test
when the cause ofabnor mal
oper ation
is
tobe deter mined
Abr iefoutline of
the test is
given
below
No load test
Connect
star ting
motor
in
ser ies
with
specified
12
volts
batter y
and
an ammeter
capable
of
indicating
1
000
amper es
Star ter
motor
Diagnoses
oftest
1
Low
speed
with
no
load and
high
cur r ent dr aw
may
r esult fr om the
following
1
Tight
dir ty
or wor n
bear ings
2
Bent ar matur e shaft or
loosened
field
pr obe
3 Shor ted
ar matur e
Check
ar matur e fur ther
4
A
gr ounded
ar matur e
or field
a
Remove
input
tenninal
b
Raise
two
negative
side br ushes
fr omcommutator
c
Using
a cir cuit
tester
place
one
pr obe
onto
input
tenninal and the
other onto
yoke
d
I
ftester indicates
continuity
r aise the
other twobr ushes and check
field and ar matur e
separ ately
to
deter mine whether field or ar matur e is
gr ounded
2
F
allur e to
oper ate
with
high
cur r ent dr aw
may
be
caused
by
the
Engine
Electr ical
System
Specified
cur r ent
dr aw
and
r evolu
tion in
these test
ar e
shown in
Specifications
Switch
6
Batter y
Et
Voltmeter
Ammeter
Ee026
Fig
EE 20 Noload
l
ting
following
I
A
gr ounded
or
open
field coil
Inspect
the connection
and tr ace
cir cuit with
a
cir cuit tester
2 Ar matur e
coil does not
oper ate
Inspect
commutator for excessive
bur ning
Inthiscase
ar c
may
occur
on
damaged
commutator
when motor is
oper ated
withnoload
3 Bur ned
out commutator bar
Weak br ush
spr ing
tension br oken
br ush
spr ing
r ubber bush
thr ust out
of
mica in
commutator or a loose
contact between biush and com
mutator would
cause
commutator bar
tobur n
3 Low
cur r ent
dr aw and low
no
load
speed
would
cause
high
inter nal
r esistance
due to
loose con
nections
damaged
leads
dir ty
cor n
mutator and causes listed
on item
2
3
EE10
MAGNETICSWITCH
ASSEMBLY TEST
Switch
o
Fv
IB I
I
D
Batter y
Star ter motor
EE3 51
FiN
EE
21 Cir cuit
ofmagndic
awitch
assembly
ted
Ifthe
star ting
motor check
is
OK check
magnetic
switch as
sembly
Connect cables
between
negative batter y
tenninal
and star t
ing
motor M ter minal
positive
batter y
ter minal and
star ting
motor
S ter minal
connecting
a switch
in
ser ies as
shown
in
Figur e
EE
21
With the switch on
push
pinion
back to
r emove all
slack and
measur e
the clear ance l between
pinion
fr ont
edge
and
pinion
stopper
The
clear ance should
be
held within 03 to
15 mm
0012to
0
059
in
Ifneces
sar y adjust
it
by changing
or
adding
adjusting
washer
s
Adjusting
washer s
ar e available in
to
two
differ ent
sizes
05 mm 0
020
in
and
O S
mm
003 1
in
03 toIS r om
0012 to0 059
in
l
EE029
Fig EE 22 MeO
ur ing
clear ance
t
Engine
Electr ical
System
SERVICE DATA
AND SPECIFICATIONS
Type
Systemvoltage
Noload
Ter minal
voltage
Cur r ent
Revolution
v
V
A
r pm
Br ush
length
Outer diameter ofcommutator mm
in
mm
in
Br ush
spr ing
tension
kg
Ib
Clear ance
between
bear ing
metal and
ar matur e shaft
mm in
Clear ance
L between
pinion
fr ont
edge
and
pinionstopper
mm
in
TROUBLE DIAGNOSES
AND
CORRECTIONS
Condition
Star ting
motor
will
not
oper ate
Noisy star ting
motor
Star ting
motor
cr anks
slowly
Pr obable cause
Dischar ged batter y
Damaged
solenoid switch
Loose connections
of
ter minal
Damaged
br ushes
Star ti
g
motor
inoper ative
Loose
secur ing
bolt
Wor n
pinion
gear
Poor
lubr ication
Wor n
commutator
Wor nbr ushes
Dischar ged batter y
Loose
connection of
ter minal
Wor nbr ushes
Locked
br ushes
EE
ll
Manual
tr ansmission
Automatic
tr ansmission
Optional
for
manual
tr ansmission
SII4ISOB
S114
170B
12
12
Less
than
60
Mor e
than
7
000
Mor e
than6 000
Mor e
than3 9
1
54
Mor ethan 12 047
14
to
IS 3 1 to40
Less
than
0
2 O OOS
03 to15 0 012to
0
059
Cor r ective
action
Char ge
or
r eplace batter y
Repair
or
r eplace
solenoid switch
Clean and
tighten
ter minal
Replace
br ushes
Remove
star ting
motor
and make test
Tighten
Replace
Add oil
Replace
Replace
Char ge
Clean and tighten
Replace
Inspect
br ush
spr ing
tension
or
r epair
br ush
holder
Condition
Engine
Electr ical
System
Pr obable
cause
Star ting
motor
cr anks
slowly
Dir ty
or wor ncommutator
Ar matur e
r ubs
field coil
Damaged
solenoid switch
Star ting
motor
oper ates
but does
not cr ank
engine
Wor n
pinion
Locked
pinion
guide
Wor n
r ing
gear
Star ting
motor will
not
disengage
evenif
ignition
switch
is
tur ned off
Damaged
solenoid switch
Damaged
gear
teeth
The
char ging
cir cuit consists
ofthe
batter y
alter nator
r egulator
and
necessar y
wir ing
toconnect these
par ts
The
pur pose
ofthis
system
is to
conver t mechanical
ener gy
fr om the
engine
into
electr ical
ener gy
which
is
used to
oper ate
all
electr ically
oper at
ed
units
and to
keep
the
batter y fully
char ged
When the
ignition
switch is
set to
ON
cur r ent flows fr omthe
batter y
to
gr ound thr ough
the
ignition
switch
voltage r egulator
IGter minal
pr imar y
side contact
point
PI
movable
contact
point
P2
voltage
r egulator
IF
ter minal alter nator IF ter minal
r otor
field coil and alter nator
E
ter minal
as shown in
Figur e
EE
23
by
full line
ar r owmar ks Then the
r otor
in
the
alter nator is excited
On the
other hand
cur r ent flows
fr om the
batter y
to
gr ound
thr ough
the
ignition
switch
war ning
lampvoltage r egula
tor L
ter minal
lamp
side contact
point
P4
movable
contact
point
P5 and
voltage r egulator
E ter mi
nal as shown
by
dotted
line ar r ow
CHARGING CIRCUIT
mar ks
Then
the
war ning lamplights
When the alter nator
begins
to
op
er ate thr ee
phase
alter nating
cur r ent is
induced
in
the
stator ar matur e
coil
This
alter nating
cur r ent is r ectified
by
the
positive
and
negative
silicon
diodes The r ectified
dir ect
cur r ent
output
r eaches the alter nator
A
and
E
ter minals
On the other hand the neutr al
point
voltage
r eaches N and E
ter minals
near ly
a
halfof
the
output
voltage
and cur r ent flows fr om
voltage r egulator
N ter minal toE
ter minal or
gr ound thr ough
the coil
VCI as shown in
Figur e
EE 24
by
the dotted linear r owmar ks Then the
coil VCI is excited and the
movable contact
point
IPS comes
intocontact with
voltage winding
side
contact
point
P6 Thisaction causes
totur n
off
the
war ning lamp
and
complete
the
voltage winding
cir cuit
as shown
by
the
full
linear r owmar ks
When the alter nator
speed
is in
cr eased or the
voltage
star ts to
r ise
excessively
the movable
contact
point
EE
12
Cor r ective action
Clean and
r epair
Replace assembly
Repair
or
r eplace
Replace
Repair
Replace
Repair
or
r eplace
Replace
damaged
gear
P2
is
separ ated
fr om
the
pr imar y
side contact PI
by
the
magnetic
for ce
ofcoil VC2 Ther efor e
r egistor
RI is
applied
intothe r otor
cir cuit
and
output voltage
isdecr eased
AJ
the
output voltage
is
decr eased
the
movable contact
point
P2 and
pr imar y
side contact Pin
comes
into
contact once
again
and
the alter nator
voltage
incr eases
Thus the
r apid
vibr ation ofthe movable
contact
point
IPl
maintains an alter nator
output
voltage
constant
Whenthe alter nator
speed
is
fur ther
incr eased or the
voltage
star ts tor ise
excessively
the
movablecontact
point
P2 comes
intocontact with
secondllJ
side contact
point
P3
Then the r otor cur r ent
is
shut offand
alter nator
output voltage
is
decr eased
immediately
This
action causes
movable contact n to
separ ate
fr om
secondar y
contact P3 Thus
the
r apid
vibr ation
of
the movable
contact
point
P2
or
br eaking
and
completing
the
r otor cir cuit maintains
an alter nator
output voltage
constant
Engine
Electr ical
System
r
l
I
I
I
i
r
Ye
Ff
p
Stator
ma
tur e
coiJ
FF
vw
I
IRI
L
Rot r
field C
oil
e
R
I
I
II
I
J
1 J
Alter nator
Voltage r egulator
11
t
c
I
Fusible
link
t
8
c
J
5
9
i
c
c
0
Batter y
t
u
J
EE029
Fig EE 23
Char ging
cir cuit
II
p
ns
1
Slator ar
atur e coil
teJ
U
2iI
I
rRl
I
I
A3
R2
0
Fusible link
Rotofield coil
e
I
I
t
I
I
PS
M
g
j
t
i
H
U
Batter y
Lh
A
l
ao
J
L
V
It
g
t
f
EE03 0
Fig
EE
24
Char ging
cir cuit II
EE
13
Engine
Electr ical
System
B
v
W
WR
WL
L2
VOLTAGE REGULATOR
co
LW
IP
B
r
FUSIBLE LINK
m
I WLI
LW
cJ
I
B
t
EARTHPOINT
m
WR
WR
CHARGE
g
00
WARNINGlAMP
00000
Equipped
with
cooler
I I I I
TjT
m
CLB
W
WB B YWR
I I I I
1
W
B
r n
ALTERNATOR
I
l LW BW
j J
M IG
I
W
BwtIl
IGNITION
SWITCH
COLOR CODE
B Black
OW Black
with
white
str ipe
W White
WB White withblack
str ipe
WR White withr ed
str ipe
WL
White withblue
str ipe
LO
Blue
with
black
str ipe
LW Blue
withwhite
str ipe
Y Yellow
lOA
C o0
0 0
o
0 0
FUSE
BLOCK
M
0 0 0
lOA
Ii
Califor nia
models
E E492
Fig
EE 25 Cir cuit
diagr amofchar ging lfY
t
m
EE 14
DESCRIPTION
REMOVAL
DISASSEMBLY
INSPECTION
AND
REPAIR
ROTOR INSPECTION
INSPECTION
OF
STATOR
DESCRIPTION
In thealter nator
a
magnetic
field is
pr oduced
by
the r otor whichconsists
ofalter nator
shaft field
coil
pole
pieces
and
slipr ings
The
slipr ings
pr essed
in
the shaft conduct
only
a
small field
cur r ent
Output
cur r ent is
gener ated
inthe
ar matur e coils
located
in
the
stator The stator has
thr ee
windings
and
gener ates
thr ee
phase
alter nating
cur r ent Silicon
diodes act
@God
A
tfff
Engine
Electr ical
System
ALTERNATOR
CONTENTS
EE 15
EE 16
EE 16
EE 16
EE 17
EE 17
INSPECTION
OF DIODE
INSPECTION
OF BRUSH
SPRING
PRESSURE TEST
ASSEMBL Y
ALTERNATOR
TEST
SERVICE
DATA AND SPECIFICATIONS
EE 17
EE
1B
EE1B
EE
1B
EE19
EE 19
like a one
way
valve for
electr icity
so
that
char ging
cur r ent
passes easily
but
r ever se cur r ent
is shut out
In this alter nator
pack type
silicon
diodes
ar e used
Six
diodes thr ee
negative
and thr ee
positive
ar e
installed in
positive
and
negative
plates
as an
assembly
These diodes ar e
dir ect solder ed at
their
tips
and
constr ucted with
posi
3
2
I
4
e
o
e
9
tiveand
negative conjunction
They
ar e mounted on the two
plates
which
combine the function of
heat
dissipating plate
and
positive
negative
ter minals and ar e
light
in
weight
and
easy
toser vice
The
pulley
mounted on
the air
conditioner models
is
differ ent fr om
that on
the
standar d models without
air conditioner
1
Pulley
usem
bly
2
Fr ont cover
3 Fr ont
bear ing
4
Rotor
5
Rear
bear ing
6 Stator
7 Br ush assembly
8
Rear cover
9
Diode
set
plate
assembly
10 Diode
cover
11
Thr ough
botr s
EE 15
EE3 45
Fig
EE 26
Exploded
view
REMOVAL
1 Disconnect
negative batter y
ter
minaL
2
Disconnect
twolead
wir es
and
connector fr omalter nator
3
loosen
adjusting
bolt
4
Remove
alter nator dr ive belt
5 Remove
par ts
associated with
alter nator fr om
engine
6
Remove
alter nator
fr om
vehicle
DISASSEMBLY
1
Remove
pulley
nut and
pulley
assembly
11
C
@@@ EE03 3
Fig
EE 27
Removing pulley
ond
fan
2 Remove br ush holder
fIxing
scr ews and r emove br ush holder
cover Pull br ush holder fOIWar d
and
r emove br ushes
together
with br ush
holder
Note Donot
disconnect N tenninaJ
fr omstator
coil lead wir e
EE3 46
1 N ter minal
2
Br ush
holder
3
Br ush holder
co
r
Fig
EE 28
Remouing
br ush
Engine
Electr ical
System
3 Remove
thr ough
bolts
Separ ate
fr ont cover
with
r otor
fr omr ear cover
with stator
by lightly
tapping
fr ont
br acket witha
wooden
mallet
J
J
4
C
EE03 5
Fig
EE 29
Separ ating fr ont cover
with
r otor
fr om
r ear
cover
4Remove thr ee set
scr ews
fr om
bear ing
r etainer
and
separ ate
r otor
fr omfr ont cover
DO Q
EE03 6
Fig EE 3 D
Removing
r otor
5
Pull
r ear
bear ing
out fr om r otor
assembly
with
a
pr ess
or
bear ing
puller
L
I EE03 7
Fig
EE 3 I
Pulling
out
of
r oar
bear ing
EE 16
6 Remove diode
cover
fIXing
scr ew
and
r emove diode
cover
Disconnect
thr ee stator
coil lead wir esfr om
diode
ter minal
witha
solder ing
ir on
7 Remove
AtenninaJnut and diode
installation
nut
and
r emove
diode
assembly
CD
AJ
fe
ecA
O
1 Diode
assembly
o
2 Diodecover
o
EE03 9
Fig
EE 3 2
Removing
diode
088embly
Note Use car e
in
assembly
to
onit
handling
diode
an
undue
st
INSPECTION AND
REPAIR
Remove
alter nator
fr om car
and
connect a cir cuit tester between F
tenninal and E ter minal
When the
r esistance
is
appr oxi
mately
5il thecondition
of
br ush
and
fIeld
coil is
satisfactor y
When
no
continuity
exists
in br ush or fIeld
coil
or
when
r esistance differ s
significantly
between those
par ts
dis
assemble and
inspect
A
o
E
O
1
ld
Q
EE040
Fig
EE 3 3
Inspecting
alter nator
ROTOR INSPECTION
1
Continuity
test of
r otor coil
Apply
tester
between
slipr ings
of
r otor
as
shown
in
Figur e
EE 3 4If
ther e
is no
continuity
field
coil is
open
Replace
r otor assembly
EE041
Fig
EE
3 4
Continuity
test
of
r otor
coil
2
Gr ound test
ofr otor coil
Check
continuity
between
slipr ing
and r otor cor e
If
continuity
exists
r eplace
r otor
assembly
because
r otor
coil or
slipr ing
may
be
gr ounded
Fig
EE
3 5
Testing
r otor coil
for
r ound
INSPECTION
OF STATOR
1
Continuity
test
Stator is
nor mal
when
ther e
is
continuity
between individual stator
coil tenninals
When ther e is no
conti
nuity
between
individual ter minals
cable is br oken
Replace
withstator assembly
EE043
Fig
EE 3 6
Testing
stator
for
continuity
Engine
Electr ical
System
2 Gr ound
test
If
each lead wir e ofstator coil
including
neutr al wir e is not conduc
tive with stator cor e condition
is
satisfactor y
If
ther e is
continuity
stator coil
is
gr ounded
EE045
Stator cor e
Fig
EE
3 7
Ee044
Teding
stator
for
POund
Conductive dir ection
I
Diode installed on EEl
plate
is
a
positive
diode
which allows
cur r ent
flowing
fr om ter minal to
EEl
plate
only
Inother
wor ds cur r ent does not
flowfr om
EEl plate
toter minal
v
1 ptate
2 Ter minal
EE046
INSPECTION OFDIODE
Per for ma
continuity
test on
diodes
in
bothdir ections
using
an
ohmmeter
A
total of
six
diodes ar e
used thr ee
ar e
mounted onthe
positive
EEl plate
and other thr ee
ar e onthe
negative e
plate
The
continuity
test
should be
per for med
on
each diode betweenthe
ter minal and
plate
I
plate
2 ptate
3 Diode
Fig
EE 3 8 Conductive
dir ection
of
diode
Diode
installed
on e
plate
is
a
negative
diode which allows
cur r ent
flowing
fr om
e plate
to
ter minal
only
Inother wor ds
cur r ent
does not
flowfr omter minal
to
eplate
I
plate
2 Ter minal
EE047
Fig
EE 3 9
Inspecting
positive
diode
Fig
EE 40 Insp
cting negative
diode
EE
17
Ifcur r ent flows
in
both
positive
and
negative
dir ections diode
is shor t
cir cuited Ifcur r ent flows
inone
dir ec
tion
only
diode
is in
good
condition
Test
pr obe
ofa cir cuit
t
ter
e
Gl
ter minal
EEl
plate
EJ plate
ter minal
ter minal
e plate
e
plate
ter minal
e
plate @ plate
Xl
plate e plate
INSPECTION
OF BRUSH
Check
movement ofbr ush and
if
movement
is
not smooth check
br ush
holder
and cleanif
necessar y
Check br ush
for wear Ifit is
wor n
down toless
than the
specified limit
r eplace
br ush
assembly
Check br ush
pig
tail and if
dam
aged r eplace
Br ush
wear
limiting
line
EE127
Fig
EE 41 Bnlsh
wear
limil
Engine
Electr ical
System
Ifther e
is a
faulty
diode
r eplace
all
diodes ix
diode as an
assembly
See table
below
These diodes
ar e
unser viceable
Conduction
o
o
o
SPRING
PRESSURE TEST
With br ush
pr ojected
appr oximate
ly
2mm 0079
in
fr ombr ush holder
measur e br ush
spr ing pr essur e by
the
use of
a
pr ing
balance
Nor mally
the
r ated
pr essur e
of
a new
br ush
spr ing
is
255
to3 45
gr
90to12202
Mor evover when br ush is wor n
pr essur e
decr ease
appr oximately
20
g
0
7 02
per
1 mm
0003 9
in
wear
t
m 0 079
in
or
f
EEO 9
Fig
EE
42 MCJ
ur ing
pr ingpr eaur e
EE
lB
ASSEMBLY
Reassemble
alter nator inthe
r ever se
sequence
of
disassembly noting
the
following
I
When
solder ing
each
stator
coil
lead wir e todiode
assembly
ter minal
car r y
out the
oper ation
as fast
as
pas
sible
2 When
installing
diode
A
ter minal
install
insulating
bush
cor r ectly
1
Imulating bush
2
A
ter minal bolt
3
Diode
cover
4Rear
cover
5 Diode
a
sembly
EE3 47
Fig
EE
43 Sectional view
of
diode
and Ater minal
3
Tighten pulley
nut with
tighten
ing tor que
of
3 5
to
4
0
kg
m
25 3
to
290 ft Ib
When
pulley
is
tightened
make
sur e that deflection ofV
gr oove
is
less than 03
mm
001IS in
q
ffl t
EE051
Fig
EE
44
Tightening pulley
nut
Engine
Electr ical
System
ALTERNATOR TEST
Befor e
conducting
an
alter nator
test make sur e
th
tthe
batter y
is
fully
char ged
A
3 0
Volt
voltmeter
and suitable
test
pr obes
3 r e
necessar y
for the test
Set
up
a test
cir cuit
as shown in
Figur e
EE45 and test
auer nator in
the
manner indicated
in
the flow
char t
below
1 Disconnect
connector sat alter nator
2 Connect A
ter minal to
F
ter minal
3 Connect
one
test pr obe
fr om
voltmeter
positive
ter minal to
A
ter minal
Connect the other test
pr obe
to
gr ound
Make sur e that voltmeter
r egister sbatter y voltage
4
Tur n on
headlights
and
switchto
High
Beam
5
Star t
engine
6 Incr ease
engine speed gr adually
until
it is
appr oximately
1 100
r pm
and
take
the
voltmeter
r eading
Measur ed value Below 12 5 Volts
Alter nator is
in
tr ouble r emove
and check
it
for condition
Measur ed value Over 12 5Volts
Alter nator
isin
good
condition
Notes
a
DoDot r un
engine
at the
speed
of
mor e than 1
100
r pm
whiletest
is
being
conducted onalter nator
b
Donot r ace
engine
i
9
l
IV
I
Batter y
EE052 Voltmeter
Fig
EE
45 Testing
alter nator
SERVICE DATA AND
SPECIFICATIONS
Nominal
r ating
V
A
LT13 8
IB
LTl3 53 6B
For air
conditioner
123 5
123 8
Negative Negative
1 000 1
000
28 2500
3 0 2500
3 5
5
000 3 8 5 000
225
225
Mor ethan
750295 Mor e than 750295
255
to3 45 255
to3 45
90to
12
2
90to
122
Mor ethan3 0 1181 Mor e than
3 0 1181
EE
19
Type
Gr ound
polar ity
Minimumr evolution
when
gener ating
14Vwithnoload
r pm
Hot
output
cur r ent
Nr pm
Pulley
r atio
Br ush
Length
Spr ing
pr essur e
mm in
gr
oz
Slip
r ing
outer diameter mm
in
DESCRIPTION
MEASUREMENT
OF REGULATOR
VOLTAGE
ADJUSTMENT
VOLTAGE
REGULATOR
DESCRIPTION
The
r egulator
consists
basically
of
a
voltage r egulator
and a
char ge
r elay
The voltage
r egulator
has twosets of
contact
points
a
lower set
and an
upper
set
tocontr ol alter nator volt
age
An ar matur e
plateplaced
between
the
twosets ofcontactsmoves
upwar d
or downwar d or vibr ates The lower
contacts when closed
complete
the
jCV ID@
@
GJ
I
@
@
@
Engine
Electr ical
System
REGULATOR
CONTENTS
EE 20 CHARGING
RELAY
SERVICE
DATA
AND
SPECIFICATIONS
TROUBLE DIAGNOSES
AND
CORRECTIONS
Including
alter nator l
EE 25
EE 23
EE 24
EE
20
EE
23
EE 23
field cir cuit dir ect to
gr ound
and the
upper
contacts whenclosed
complete
the field
cir cuit togr ound
thr ough
a
r esistance field coil and
pr oduce
alter nator
output
The
char ge r elay
isimilar in
constr uction
to
the
voltage r egulator
Whenthe
upper
contacts ar e closed
char ge
war ning lamp
goes
on
v
1
Char ger elay
2
Voltage
r egulator
EE285
Fig
EE 46 View
ofr emovingcover
As
r egar ds the constr uction the
voltage r egulator
is
ver y
similar tothe
char ge r elay
as shown
in
Figur e
EE47
@
r
J
CD
@
@
@
Q @ID@
ID@
J
t
L
T
@
r
b
r
CD
L @
j
1
g
f
@
@ EEJ97
J I1Jlccting spr ing
2
Y kt
gp
3 Ar matur c
4Cor e
go
5
Low
Sllccd
lnlacl
h
Point
ap
7
High speed
conlat t
8 Contact
c
9
3 111111 0
118
ill
di
10
41l1I11W
157in
c1ia
few
II
Cuil
12
lock
nut
J3
Adjllslin
scr ew
14
Adjll
sting spr in
15 Yoke
9
Adjusting
scr ew
10
Lock
nut
11 Coil
12
4mm
0
157 in
dia
scr ew
13
3 mm 0 118 in
dla
cr ew
14Contact
iet
15
Voltage
cgulatm
contact
a
Cnl1
Tllltion f
lltagl
l
j
llIOltllT
I Point
gilp
2
Char ge
r elay contllct
3 Cor e
gap
4
Ar lllatlJr e
5
Connecting
spr in
6 Yoke
gap
7 Yoh
B
Adjusting pr ing
b
Constr uction of
char ge
r elay
Fig
EE 47 Str uctur al viw
EE 20
MEASUREMENT
OF
REGULATOR
VOLTAGE
Regulator voltage
is measur ed with
r egulator
assembled with
alter nator
When
measur ing
voltage
with
r egulator
mounted
on
car
it is
necessar y
to
r otate
engine
at
highspeed
Connect DC voltmeter
l53 0Y
DC
ammeter
l53 0A
batter y
and
a
O
25fl
r esistor
r ated
at 25W
with
cables
as
shown
I
Check tobesur e that all electr ical
loads such as
lamps
air
conditioner
r adioetcar e tur ned off
2
Befor e
star ting engine
be sur e to
make shor t cir cuit with a
cable be
tween fuse side ter minal ofr esistor
O 25fl
and
negative
side ter minal of
ammeter Failur e tofollow
this
pr e
caution
will
cause
needle ofammeter
to
swing
violently
r esulting
ina dam
aged
ammeter
Engine
Electr ical
System
Gener a
tor
A
r
iJ
IG
Fuse box
i
B
Rqulator
Connector
Wir e har ness
Shor t cir cuit her e between
fuse side
tenninal
and
ter minal ofammeter
befor e
star ting the oper ation
Ammeter
lOA
V
Voltmeter 3 0V
EE055
Fig EE 48
Measur ing r egulator voltage
with
r egulator
onvehicle
3 Refer tothe
following
char t to
deter mine if
r egulator
and r elative
EE 21
par ts
ar e in
good
condition
Engine
Electr ical
System
I
Star t
engine
2 Rotate
engine
at 2500
r pm
for sever al
minutes
Mter
r acing
for
sever al minutes
ammeter
r eading
belowSA
After
r acing
for
sever al minutes
ammeter
r eading over
5
A
Fully
char ged batter y
available
I
Replace
with
fully char ged
batter y
2 Check
tosee ifcur r ent falls
belowSA
Fully char ged
batter y
not available
I Connect a
025 ohm
r esistor in
ser ies
Cur r ent falls below
SA
Cur r ent does
not fall below
SA
Rechar ge batter y
and
see
if
cur r ent falls
below
SA
Reduce
engine speed
to
idling
and then
r aise
it
to2500
r pm
while
obser ving
needle ofvoltmeter
Needle of
voltmeter held within limits
shown
in
the below
table
Regulator
functioning pr oper ly
Needle ofvoltmeter out oflimitsshown in
the
following
char t
Adjust
or
r eplace r egulator
Regulator type
TLI
Z85C
Temper atur e
Oc
OF
Voltage
V
speed
c
Voltage
may
be
appr oximately
03
V
higher
than r ated for twoto
thr ee minutes after
engine
is
star t
ed or mor e
specifically
when
r egu
lator becomes selfheated
Measur e
ments should
then be
made
within
one
minute
after
star ting engine
or
when
r egulator
is
cold
d The
r egulator
is
of
a
temper atur e
compensating type
Befor e meas
ur ing voltage
be
sur e tomeasur e
sur r ounding temper atur e
and cor
r ect
measur ements
accor ding
to
the
table at left
10
14
0
3 2
10
50
20 68
3 0 86
40 104
1475 to
15
75
1460to1560
14 45 to1545
14
3 0
to
15 3 0
14
15
to15 15
14
00
to
1500
Notes
3
Do
not measur e
voltage
immediate
ly
after
dr iving
Dothis while
r egulator
is cold
b
Tomeasur e
voltage
r aise
engine
speed gr adually
fr om
idling
to
r ated
EE 22
ADJUSTMENT
VOLTAGE REGULATOR
When r egulating voltage
as meas
ur ed above
deviates
fr om
r ated value
adjust
r egulator
in
accor dance
withthe
following
instr uctions
I
Inspect
contact
sur face and if
r ough lightly polish
with
fine
emer y
paper
1500
or 600
2 Measur e each
gap
and
adjust
if
necessar y Adjust
cor e
gap
and
point
gap
in that or der No
adjustment
is
r equir ed
for
yoke
gap
3
Adjusting
cor e
gap
Loosen scr ew
4mm
0 157 in
diameter which
is used to
secur e
contact set
on
yoke
and
move contact
upwar d
or
downwar d
pr oper ly
See
Figur e EE 49
Cor e
gap
0 6
to
10mm
0024to0
03 9
in
EE3 98
I
Contact
set
2 ThicknesJ gauge
3 4
mm 0 157
in dia scr ew
4
Cr osshead
Jcr ewdr iver
Fig
EE
49
AdjUJJting
cor egap
Engine
Electr ical
System
4
Adjusting
point gap
Loosen scr ew
3
mm OlIS in
diameter used tosecur e
upper
con
tact and move
upper
contact
upwar d
or downwar d as
necessar y
See
Figur e
EE 50
Point
gap
03 5
to045 mm
0014
to
OD1S in
EE3 99
I Thicknes
gauge
2 3 mm
0118 in dia
scr ew
3
Cr o Sshelld
scr ewdr iver
4
Upper
contact
Fig
EE 50 Adjusting
point
gap
5
Adjusting
voltage
Adjust r egulating
voltage as
follows
Loosen lock nut
secur ing
adjusting
scr ew Tur n this scr ew clockwise to
incr ease or counter clockwise to
decr ease
r egulating voltage
See
Figur e
EE
5
J
CD
EE400
I
Wr ench
2
Cr osshead
scr ewdr iver
3
Adjusting
scr ew
4lock
nut
Fig
EE 51
AdjUJJting
r el Ulating
voltage
CHARGE
RELAY
Nonna
r elay oper ating
voltage
is S
toIOVas
measur ed at alter nator
A
tenninal
Relay
itselfhowever
oper
atesat 4to5V
Use a DCvoltmeter
and set
up
a
cir cuit
as shown
in
Figur e
EE 52
Adjust
char ge
r elay
in
the same
manner as
that for
voltage r egulator
L
Connect
positive
tenninal ofvoltmeter
to
r egulator
lead
connector N
tenninal with
negative
ter minal
gr ounded
2 Star t
engine
and
keep
it
idle
3 Take voltmeter
r eading
oVolt
I Check for
continuity
be
tween
ter minals of
r e
gulator
and
alter nator
2 Alter nator
cir cuit
inoper a
tive if
continuity
exists
Below5 2
Volts
Char ge war ning
lamp
on
I Checkfanbelt tension
2
Ifcor r ect r emove
r egulator
and
adjust
as
necessar y
Over
5
2
Volts
Char ge war ning
lamp
on
Char ge r elay
coil or
contact
points
out
ofor der
Replace r egulator
Over 5 2
Volts
Char ge war ning
lamp
off
Char ge
r elay
assembly
is in
good
condition
EE 23
Engine
Electr ical
System
RegulatoI
r
Yellowter minal
AW
L
WR
IG
WL
N
Y
E B F WB
Voltmeter
Fig
EE
52 Tuting
char ging
r e Qy
EE3 48
SERVICE DATAAND SPECIFICATIONS
Voltagelegulator
Type
Regulating voltage
with
fully
char ged
batter y
Voltage
coil
r esistance
RotOI coil
inser ting
r esistance
Voltage
coil
ser ies r esistance
Smoothing
r esistance
COle
gap
Point
gap
Ch uge
lay
Release
voltage
Voltage
coil
r esistance
Cor e
gap
Point
gap
v
fl
nun in
nun
in
V
fl
nun in
mID in
TLl
Z
S5C
14 3
to153 at
200C 680F
10 5at 200C 680F
10
3 1
40
06 to1 00024to003 9
03 5 to
045
0014to
O
OIS
4
2to5
2at
N ter minal
3 7S at 200C 680F
0
8
to10003 1 to003 9
04to06 0016 to0024
Standar d
tempelatUIe
gIlIdient
O OISVoC
EE 24
Engine
Electr ical
System
TROUBLE DIAGNOSES AND
CORRECTIONS
Including
alter nator
Condition
Pr obable cause
No
output
Sticking
br ushes
Dir ty
br ushes and
slip
r ings
Looseconnections
or br okenleads
Open
stator
winding
Open
r otor
winding
Open
diodes
Shor ted r otor
Shor ted stator
Gr ounded
A
ter minal
Br oken
fanbelt
Excessive
output
Br oken
neutr al
wir e COIOfofwir eis
yellow
Voltage fegulator
br eakdown
Poor
gr ounding
ofalter nator
and
voltage
r egulator
En
ter minal
Br oken
gr ound
wir e
color of
wir e is black
Low
output
Loose
or wor nfanbelt
Sticking
br ushes
Low
br ush
spr ing
tension
Voltage
r egulator
br eakdown
Dir ty
slip
r ings
Par tial shor t
gr ound
or
open
in
stator
winding
Par tially
shor ted
or
gr ounded
r otor
winding
Open
or damaged
diode
Noisy
alter nator Loose
mounting
Loose dr ive
pulley
Br okenball
bear ing
Impr oper ly
seated br ushes
EE
25
Cor r ective
action
Cor r ect
or
r eplace
br ushesand br ush
spr ings
Clean
Retighten
or soldef
connections
Replace
leads if
necessar y
Repair
Of
r eplace
stator
Replace
r otor
Replace
Replace
r otor
Repair
or
r eplace
Replace
insulator
Replace
Replace
Check
r egulator
oper ation
and
r epair
or
r eplace
as
r equir ed
Retighten
ter minal connection
Replace
Retighten or
r eplace
Cor r ect
or
r eplace
br ushes and
spr ings
if
necessar y
Replace
br ush
spr ings
Check
r egulator
OpefatiOn
and
r epair
or
r eplace
as
r equir ed
Clean
Replace
stator
Replace
r otor
Replace
diode
Retighten
bolts
Retighten
Replace
Seat
cor r ectly
NON CALIFORNIA MODELS
Engine
Electr ical
System
IGNITION CIRCUIT
CONTENTS
EE
26
CALIFORNIA MODELS EE 2B
NON
CALIFORNIA MODELS
The
ignition
cir cuit consists
of
the
ignition
switch coil
distr ibutor
wir ing spar k plugs
and
batter y
The
cir cuit
is
equipped
with a
r esistor
Dur ing
cr anking
electr ical
cur r ent
bypasses
the r esistor
ther eby
connecting
the
ignition
coil
dir ectly
to
batter y
This
pr ovides
full
batter y
voltage
available at coil and
keeps
ignition
voltage
as
high
as
possible
The
low
voltage
cur r ent is
supplied
by
the
batter y
or
alter nator and
flows
thr ough
the
pr imar y
cir cuit
It consists
of
the
ignition
switch r esistor
pr imar y winding
ofthe
ignition
coil
distr ibutor contact
points
condenser
and
all
connecting
lowtension
wir ing
The
high
voltage
cur r ent is
pr o
duced
by
the
ignition
coil
and flows
thr ough
the
secondar y
cir cuit r esult
ing
in
high
voltage spar k
between the
electr odes of
the
spar k plugs
in
engine
cylinder s
This cir cuit contains
the
0
cl
Batter y
Ignition
coil
secondar y winding
of
the
ignition
coil
high
tension
wir ing
distr ibutor r otor
and
cap
When the
ignition
switch
is
tur ned
on and the
distr ibutor contact
points
ar e closed
the
pr imar y
cur r ent
flows
thr ough
the
pr imar y winding
ofthe
coil
and
thr ough
the
contact
points
to
gr ound
When the
contact
points
ar e
opened
by
the
r evolving
distr ibutor ear n
the
magnetic
field
built
up
in the
pr imar y
winding
of
the
coil moves
thr ough
the
secondar y winding
of
the
coil
inducing
high
voltage
The
high
voltage
is
pr oduced
ever y
time
the
contact
points
open
The
high voltage
cur r ent
flows
thr ough
the
high
tension wir e
tothe distr ibutor
cap
Then the r otor
distr ibutes the
cur r ent to
one
ofthe
spar k
plug
ter minals inthe distr ibutor
Re5istor
To
star ter
Secondar y
winding
Cap
Br eaker
point
f
Distr ibutor
EE 26
cap
Then
the
spar k
obtains while the
high voltage
cur r ent
jumps
the
gap
between
the
insulated electr ode and
the
gr ound
side electr ode ofthe
spar k
plug
This
pr ocess
is
r epeated
for each
power
str oke
of
the
engine
The distr ibutor contact
point
and
spar k plugs
should be
inspected
clean
ed
and
r egapped
at
tune
up
They
should alsobe
r eplaced per iodically as
specified
in
the
Maintenance
Sched
ule In
addition
apply gr ease
NLGl
consistency
NoI
containing
MoS2
or
equivalent
to
distr ibutor
shaft and
gr ease
MIL
G
l0924B
containing
MoS2
or
equivalent
tocam as r eo
quir ed
The
r emainder
ofthe
ignition
component
par ts
should be
inspected
for
only their
oper ation tightness
of
electr ical ter minals and
wir ing
con
dition
The
ignition
cir cuit is shown below
IR
IB
I
is
21
Jg
Rotor
head
EE060
Fig
EE
53
Ignition ydem
cir cuit
diagr am
FUSIBLE LtNK
m
Engine
Electr ical
System
E
CJI2t
Bf
o
00
00
fOl
R
BL
I
ti
L
oj
LCJ
RESISTOR
IGNITION
COIL
COLOR CODE
B Black
OW
Black
withwhite
str ipe
DR Black
with
r ed
str ipe
aL Black
withblue
str ipe
W White
W
R
Wj
BW
BR
IGNITION
SWtTCH
DISTRtBUTOR
jjj
SPARK
PLUGS
EE493
EE
27
Fig
EE 54Cir cuit
diagr am
ofignition ByJt
m Non
Califor nia
models
Pr imar y winding
1
Ignition
coo
I
Secondar y
winding
CALIFORNIA
MODELS
The
ignition
cir cuit
consists of
igni
tion
switch tr ansistor
ignition
unit
distr ibutor
wir ing spar k
plugs
and
batter y
The
distr ibutor is
ofthe contactless
type
and is
equipped
with a
pick up
coil which
electr ically
detects the
igni
tion
timing
signal
in
place
ofthe
cir cuit
br eaker ofthe conventional
distr ibutor The tr ansistor
ignition
unit
is
a new addition which
gener ates
the
signal r equir ed
for
themake
and br eak
ofthe
pr imar y
electr iccur r ent for the
ignition
coil
The cir cuit
is
equipped
with a
r esistor
Dur ing cr anking
electr ical
cur r ent
bypasses
the
secondar y
r esis
tor
ther eby connecting
the
ignition
coil
thr ough
the
pr imar y
r esistor This
makes
batter y voltage
available at ef
ficiently
and
keeps ignition voltage
as
high
as
possible
The
pr imar y
r esistor
selVeS to
pr o
tect tr ansistor
ignitioncir cuit
The low
voltage
cur r ent is
supplied
by
the
batter y
or alter nator and flows
thr ough
the
pr imar y
cir cuit
It consists ofthe
ignition
switch
Engine
Electr ical
System
r esistor
pr imar y winding
ofthe
igni
tion
coil
tr ansistor
ignition
unit and
all
connecting
lowtension
wir ing
The
high voltage
cur r ent is
pr o
duced
by
the
ignition
coil and
flows
thr ough
the
secondar y
cir cuit
r esult
ing
in
high
voltage
spar k
between the
electr odes ofthe
spar k plugs
in
engine
cylinder s
This
cir cuit contains the
secondar y
winding
of
the
ignition
coil distr ibu
tor
high
tension wir es tocoil and
spar k plugs
distr ibutor r otor and
cap
When the
ignition
switch is tur ned
on
and the
distr ibutor r eluctor r otates
the
pr imar y
cur r ent flows
thr ough
the
pr imar y winding
of
the
coil and
thr ough
tr ansistor
ignition
unit to
gr ound
When
the
pr im
ar y
cir cuit is
opened
by
cir cuit
of
tr ansistor
ignition
unit
the
magnetic
field
built
up
in the
pr imar y winding
ofthe coil moves
thr ough
the
secondar y
winding
of
the
coil
inducing high voltage This
high
Batter y
Pr imar y Secondar y
I
Resistor
To
star ter
r
Tr ansistor
ignition
unit
I
I
Pick up
r coil
r
Rotor head
nl
J
R5
U1f
1
Retuctor
roi
l f
S
par k
plugs
voltage
is
pr oduced
ever y
time
the
pr imar y
cir cuit
opens
The
high
voltage
cur r ent flows
thr ough
the
high
tension wir e to
the
distr ibutor
cap
then the r otor
distr i
butor
cap
then
the
r otor distr ibutes
the
cur r ent to
one
of
the
spar k plug
ter minals
in
the distr ibutor
cap
Then the
spar k occur s while
the
high
voltage
cur r ent
jumps
the
gap
between the insulated electr ode
and
the
gr ound
side electr ode ofthe
spar k
plug
This
pr ocess
is
r epeated
for
each
power str oke
of
the
engine
The
spar k
plug
should
be
inspected
cleaned and
r egapped
at tune
up
Spar k plugs
should also
be
r eplaced
per iodically
as
specified
inthe Main
tenance Schedule
The
r emainder of
the
ignition
com
ponent par ts
should
be
inspected
for
only
their
oper ation
air
gap
of
distr i
butor
tightness
ofelectr ical ter minals
and
wir ing
condition
Apply gr ease
NLGI
consistency
No
I
containing
MoS or
equivalent
todistr ibutor r otor shaft as
r equir ed
EE287
EE 28
Fig EE 55
Ignition
8Y3 tem
cir cuit
diagr am
EARTHPOINT
r
W
b
FUSIBLE
LINK
BATTERY
L d
l
ilR
j
i
BW @
c
RESISTOR
COLOR CODE
8
Black
OW Black
withwhite
str ipe
DR
Blackwithr ed
str ipe
W White
L Blue
R
Red
G Gr een
Engine
Electr ical
System
TRANSISTOR
IGNITION
UNIT
IHIIl II II
BW
BBV
RG
111
I
I
TERMINAL BLOCK
rc
IGNITION
COIL
BW
B
ml
BR
lliJ
LldJ0
IGNITION SWITCH
EE
29
Fig
EE 56 Cir cuit
diagr amofignition system
Califor nia
models
EE494
a
B
lof1
@
00
00
00
SR
00
00
Et liiI
in
D1STRliUTOR
10
0
i9
J
SPARK
PLUGS
Engine
Electr ical
System
DISTRIBUTOR Non Califor nia models
CONTENTS
CONSTRUCTION
CHECKING AND ADJUSTMENT
CAP AND ROTOR
HEAD
CONTACT POINT
CONOENSER
EE 3 0
EE 3 1
EE 3 1
EE 3 1
EE
3 1
ADVANCE MECHANISMS
DISASSEMBL
Y
ASSEMBLY
SERVICE
DATA AND SPECIFICATIONS
EE
3 1
EE 3 2
EE 3 2
EE 3 3
CONSTRUCTION
The distr ibutor consists ofbr eaker
plate
with contact
points
centr ifugal
advance mechanism vacuum contr ol
ler distr ibutor shaft
and
r otor
D
@
t
Capassembly
2 Rotor
head
assembly
3 Condenser
assembly
4
Gr ound
wir e
assembly
5 Lead wir eassem
bly
6
Contact
set
7
Br eaker
plate assembly
8
Packing
9 ear n
assembly
10 Gover nor
spr ing
11 GoVer nor
weight
12 Shaft
assembly
13 Vacuumcontr oller
14Ter minal
assembly
IS
Housing
16
Fixing
plate
17
O
r ing
IS Collar
v
i
@
D
@
EE3 2Q
Fig
EE 57
EE 3 0
CHECKINGAND
ADJUSTMENT
CAP
AND ROTOR HEAD
Cap
and r otor
head should
be in
spected per iodically
as
specified
in
the
Maintenance
Schedule Remove cap
and clean all dust
and car bon deposits
fr om
cap
and
r otor If
cap
is cr acked
or is
leaking r eplace
with a Deone
CONTACT
POINT
Contact
point
should be
r eplaced
in
accor dance
with the Maintenance
Schedule
Standar d
point gap
is 045 to
0 55
mm O OIS to
0
022
in In
case
size
is offthe standar d
adjustment
is made
by loosening point
scr ews
Gapgauge
is
r equir ed
for
adjustment
When
point
sur face
is
r ough
take
off
any
ir r egular ities
with
fine sand
paper
ofNo
500 or 600 or
with oil
stone
When
wear
on
contact
points
is
noticeable r eplace points together
with
contact
ar m
To
r eplace
pr oceed
as
follows
EE3 22
Fig
EE 58 Adjuting
point
gap
EE3 21
I
Pr imar y
lead ter mina
2
Gr ound lead wir e
3 Set scr ew
4
Adjuster
5 Scr ew
Fig
EE 59 Br eaker
Engine
Electr ical
System
Fir st tur n
out set
scr ews
1
to
1 5
tur ns at contact ar mand
pr imar y
lead
wir e
connection
just
for
enough
to
pull
out
pr imar y
lead ter minal
Refer r ing
to
Figur e
EE
59 unSCr ew
twocontact set
fixing
scr ews
and
r emovelead wir e
While
holding
contact
ar m
by
finger s
pull
out contact
set
towar d
you by
r aising
it
slightly
Contact
point
and
afm
can
then be
r emoved
together
Install new contact
point
and
ar m
assembly
in
r ever se sequence
of
r emoval
Coat camwith
a
light coating
of
gr ease
ADVANCE MECHANISMS
Specifications
Application
Vacuumadvance
Distr ibutor
degr ees
distr ibutor
mmHg inHg
Centr ifugal
advance
Distr ibutor
degr ees
distr ibutor
r pm
For Canada
Vacuum
advance mechanism
mechanical
par ts
Ifvacuumadvance
mechanismfails
to
oper ate
pr oper ly
check for the
following
items
and cor r ect the mal
functionas
r equir ed
1 Check vacuum
inlet for
signs
of
leakage
at
its
connection
Ifnecessacy
r etighten
or
r eplace
witha newone
2 Check vacuum
diaphr agm
for
air
leak
Ifleak
is
found
r eplace
vacuum
contr oller
assembly
3
Inspect
br eaker
plate
for smooth
moving
If
pia
te does
not
move
smoothly
this
condition could be due
to
sticky
steel balls
or
pivot Apply gr ease
to
steel
balls or
if
necessar y
r eplace
br eaker
plate
as an
assembly
EE 3 1
CONDENSER
Satisfactor y per for mance of
con
denser
depends
on
capacity
and
degr ee
ofinsulation
r equir ing
attention
to
be
sur e
that ter minals ar e clean and set
scr ewsar e
tight
Checking
of
condenser
is made
by
a
condenser
tester
D4A406
D4A6
07
D4A4
07
D4A6
0S
Automatic
tr ansmission
Manual tr ansmission
00
150 5
91
3 0
250 9
S4
00
170 6
69
6 50 3 00
1I
S1
00 550
11
0
2
3 00
00 600
110 1 950
Centr ifugal
advance
mechanical
par ts
When cause of
engine
malfunction
is
tr aced to
centr ifugal
advance me
chanical
par t use distr ibutor tester
to
check its char acter istic
See the
specifications
above
When
nothing
is
wr ong
with its
char acter isticconceivable causes ar e
br eakdown abnor mal
wear ing out
of
dr iving par t
or other s So
do
not
disassemble
it
In
case
of
impr oper
char acter istic
take offcontact br eaker
assembly
and
check
closely
cam
assembly
gover nor
weight
shaft and
gover nor spr ing
etc
In case
centr ifugal
advance me
chanical
par t
is r eassembled be
sur e to
check advance char acter istic
by
dis
tr ibutor tester
DISASSEMBLY
Todisassemble
follow
the below
pr occd
ur e
I
Take
off
cap
and disconnect
r otor
head
2 Remove vacuumcontr oller
EE291
Fig
EE 60 Removing
vacuum
contr oller
3 Remove contact set
Refer
to
Page
EE 3 1 when
contact
set
ir emoved
EE3 23
Fig
EE 61
Removing
contact tel
EE3 24
Fig
EE 62
Removing
br eaker
plate
Engine
Electr ical
System
4When br eaker
plate
is r emoved
be car eful not
tolose
steel
balls
between br eaker
spr ing
and br eaker
plate
5
Pul
r oll
pin
out and
siconnect
collar to
r emove the entir e
r otating
par ts
EE3 25
Fig
EE 63 Removing
r oll
pin
EE3 26
Fig
EE
64Removil1l
r otationpaTta
6 Remove
packing
fr omthe
top
of
cam
assembly
and
unscr ewear n aster n
bly
setscr ew Put
match mar k acr oss
ear n and shaft sothat or iginal
combi
nation can ber estor ed at assembly
EE 3 2
EE075
Fig
EE
65 Removing
cam
7
When
gover nor
weight
and
spr ing
ar e disconnected be
car eful not
to
str etch or
defor m
gover nor spr ing
After
disassembling apply gr ease
to
gover nor weights
ASSEMBLY
Toassemble r ever se
the
or der
of
disassembly
Car efully
obser ve
the
fol
lowing
instr uctions
Align
match mar l
s
sothat
par ts
ar e
assembled
to
their
or iginal posi
tions
2
Apply
gr ease
tothe
top
ofcam
assembly
as
r equir ed
3 Check the
oper ation
of
gover nor
befor e
installing
distr ibutor on
engine
4
Adjust ignition
timing
afteT dis
tr ibutor is installed on
engine
Engine
Electr ical
System
SERVICE
DATA
AND SPECIFICATIONS
D4A4
06 D4A4
07
Type
D4A6
07 D4A6 08
Fir ing
or der
1 34
2 13 42
Rotating
dir ection
Counter clockwise
Counter clockwise
Owen
angle
degr ee
490to
550 490
to
550
Point
gap
mm in
0
45to
0
55
045 to
055
0018
to
0022 0018
to
0
022
Point
pr essur e
kg lb
0
40
to0
55 0 40to0
55
0
88to
1
21
088to
121
Condenser
capacity
JlF
0 20
to
024 0 20
to
024
Condenser isolate
r esistance Mr l
5 5
Cap
isolate
r esistance
Mr l
50
50
Rotor head isolate r esistance Mr l
50
50
Cap
car bon
point length
mm in 10
03 9
10 03 9
For Canada
DISTRIBUTOR
Califor nia models
CONSTRUCTION
CHECKING
AND ADJUSTMENT
CAP AND
ROTOR
HEAD
AIR
GAP
CONSTRUCTION
In the conventional distr ibutor
the
ignition liming
is
detected
by
thecam
and
br eaker ar m while in this
tr ansis
tor
ignition
unit it is
detected
by
the
r eluctor on the shaft and the
pick up
coil
pr ovided
in
place
ofthe br eaker
The
pick up
coil consists ofa
magnet
coil etcThe amount of
magnetic
flux
passing thr ough
the
pole piece
inthe
coil
is
changed
at
the
moment the
pole
CONTENTS
EE 3 3
EE
3 3
EE 3 3
EE 3 3
ADVANCE MECHANISMS
DISASSEMBLY
ASSEMBLY
SERVICE
DATA AND SPECIFICATIONS
EE 3 3
EE 3 5
EE 3 5
EE 3 6
piece
faces the
pr otr usion
ofthe
r e
luctor
and then the
electr ical
signal
is
gener a
ted
inthe
pick up
coil
This electr icsignal
is
conducted
into
the tr ansistor
ignition
unit
which
in
tur n br eaks
tI e
pr imar y
coil cur r ent
r unning thr ough
the
ignition
coil and
gener ates
high
voltage
inthe
secondar y
winding
Also
this tr ansistor
ignition
EE 3 3
unit
utilizes
this electr ic
signal
to
r estor e the
pr imar y
coil to
the
or iginal
state
after
cutting
off
the
pr imar y
cur r ent
for a
fIXed time
The
centr ifugal
and vacuum ad
vance
mechanisms
employ
the con
ventional mechanical
type
The con
tactor
is used toeliminate
vacuum
and
centr ifugal
advance
hyster esis
I
t3
l
l
J
@
r
9
V
fW
@
@
CHECKINGAND
ADJUSTMENT
CAP AND
ROTOR HEAD
Cap
and
r otor
head must
be in
spected per iodically
as
specified
in
the
Maintenance Schedule Remove cap
and clean all dust and
car bon
deposits
fr om
cap
and r otor fr om
time totime
If
cap
is cr acked or
is
leaking r eplace
with
a new
one
AIR GAP
Standar d air
gap
is 02
to
04mm
0008to0016 in
Ifthe
gap
is
offthe standar d
adjustment
mould
be
made
by
loos
ening pickup
coil scr ews
Gap
gauge
is
r equir ed
for
adjust
ment Air
gaps
must be
checked fr om
time
totime
Air
gap0
2
to
04mm
0008
to0
016
in
Engine
Electr ical
System
tl
@
9
EE3 28
Fig
EE 67
Checking
oir
gap
To
r emove
pick up
cail disconnect
distr ibutor
har ness
at
ter minal block
and r emovescr ew
secur ing pick
up
coil
ADVANCE MECHANISMS
Specifications
Type
Item
Vacuumadvance
Distr ibutor
degr ees
Distr ibutor
mmHg inHg
Centr ifugal
advance
Distr ibutor
degr ees
Distr ibutor
cpm
EE3 4
1
Cap
assembly
2
Rotor
head
a55embly
3
Roll
pin
4
ReJuctor
S Pick
upcoil
6 Contactoi
7 Br eaker
plate
assembly
8
Packing
9 Rotor
shaft
10 Gover nor
spr ing
11 Gover nor
weigh
t
12 Shaft aJscmbly
13
Cap
setter
14
Vacuumcontr oller
15
Housing
16
Fixing plate
17 O
r ing
18 Collar
EE3 27
Fig
EE 66
Exploded
view
of
di3 tr ibutor
assembly
and distr ibutor har ness
to
their
positions
EE3 29
Fig
EE
68
Remouing
pick
up
coil
D4F404 D4F4 Q3
Manual Automatic
00
150 5 91
3 0
250 9
84
00
550
110
2
3 00
00
600
110 1
950
Vacuum
advance
mechanism
mechanical
par ts
Ifvacuumadvance
mechanismfails
to
oper ate
pr oper ly
check for
the
following
items
and
cor r ect the
pr ob
lemas
r equir ed
1
Check vacuum
inlet for
signs
of
leakage
at its connection If
necessar y
r etighten
or
r eplace
with
a newone
2
Check vacuum
diaphr agm
for
air
leak
Ifleak
is
found
r eplace
vacuum
contr oller
assembly
3
Inspect
br eaker
plate
for
smooth
moving
If
plate
does not move
smoothly
this
condition
could be
due
to
sticky
steel
balls
or
pivot Apply
gr ease
to
steel balls or
if
necessar y
r eplace
distr ibutor
assembly
Centr ifugal
advance
mechanical
par ts
When
cause of
engine
malfunction
is
tr aced
to
centr ifugal
advance
mecha
nical
par ts
use distr ibutor
tester to
check its char acter istics See
tothe
specifications
above
If
nothing
is
wr ong
with
its
char ac
ter istics conceivable causes ar e
faulty
or
abnor mal
wear of
dr iving par t
or
other s
Sodonot disassemble
it
In the event of
impr oper
char acter
istics check
closely
r otor
shaft
assem
bly
gover nor
weight
and shaft
If
any
of
above
par ts
ar e
malfunc
tioning
r eplace
distr ibutor
assembly
DISASSEMBLY
To
disassemble follow
the
pr o
cedur e
below
1 Take off
cap
and r emove
r otor
head
2 Remove twoscr ews shown in
Figur e
EE 69 and detach vacuum
con
tr oller
Engine
Electr ical
System
EE291
Fig
EE
69
Removing
vacuum
contr oller
3 Remove
pick up
coil
assembly
4
Using
two
pr y
bar s
pr y
r eluctor
fr omshaft Be car eful
not
todistor t
or
damage
the teeth ofr eluctor
Remove
r oll
pin
S Remove
br eaker
plate
setscr ews
and
r emove
br eaker
plate
assembly
E3 3 0
Fig
EE 70
Removing
br eaker plate
etscr ews
6 Pull r oll
pin
out and r emove
collar
7 Remove r otor shaft
and dr ive
shaft assembly
EE3 3 1
Fig
EE 71
Removing
r otor
shaft
and
dr ive
shaft assembly
8 Mar k r otor shaft
and
dr ive shaft
Remove
packing
fr om
the
top
of
r otor
shaft and unscr ew r otor
shaft
setscr ew
EE
3 5
EE075
Fig
EE 72
Removing
r otor
shaft
9
Mar k one ofthe
gover nor spr ings
and its br acket Alsomar k
one
ofthe
gover nor
weights
and its
pivot pins
10
Car efully unhook
and r emove
gover nor
spr ings
11 Remove
gover nor weights
Apply
gr ease
to
gover nor weights
after
disassembling
ASSEMBLY
To
assem
ble
r ever se
the or der of
disassembly
Car efully
obser ve the
fol
lowing
instr uctions
1
Align
match mar ks
sothat
par ts
ar e assembled totheir
or iginal
posi
tions
2
Iffor
any
r eason contactor
is
r emoved fr om br eaker
plate adjust
cam to contactor clear ance
to
03
mm
0012
in
as shown in
Figur e
EE 73
after installation
T
EE298
Fig EE 73 Cam to contactor
clear ance
3
Ensur e
that r eluctor is
pr oper ly
or ien
ted
when
installing
on shaft
Always
dr ive
in
r oll
pin
with
its
slit
towar d
the outer
end ofshaft See
Figur e
EE
74
Be
sur e touse
a
new
r oll
pin
EE299
Fig
EE 74
Dr iving
inr oll
pin
Engine
Electr ical
System
4
Apply gr ease
to
the
top
of
r otor
shaft as
r equir ed
5
Check the
oper ation
of
gover nor
befor e
installing
distr ibutor on
engine
6
Adjust ignition timing
after
distr i
butor is installed
on
engine
SERVICE
DATAAND SPECIFICATIONS
Type
Fir ing
or der
Rotating
dir ection
Duty
Air
gap
mm in
MU
Cap
insulation
r esistance
Rotor head
insulation r esistance
MU
Cap
car bon
point length mm
in
D4F403 D4F4 04
1 34
2
Counter clockwise
7020to40at
idling
02to0
4O
OOS to0
016
Mor ethan50
Mor ethan
50
10 03 9
TRANSISTOR
IGNITION UNIT
Califor nia models
DESCRIPTION
TRANSISTOR IGNITION UNIT
REMOVAL AND
INSTALLATION
INSPECTION
1 POWER
SUPPLY WI
RING
AND
BATTERY
CHECK
DESCRIPTION
TRANSISTOR
IGNITION
UNIT
The tr ansistor
ignition
unit
pr ovides
the
following
functions
L It
makes and br eaks the electr ic
cur r ent
in
the
pr imacy
cir cuit
ofthe
ignition
coil
2
CONTINUITY CHECK
OF
PRIMARY
CIRCUIT
3
PICK UP
COIL CONTINUITY CHECK
4PICK UP COIL POWER
SIGNAL
PULSE
CHECK
5 TRANSISTOR
IGNITION
UNIT CHECK
CONTENTS
EE
3 6
EE
3 6
EE 3 7
EE 3 7
EE 3 7
2
The
duty
contr ol
cir cuit sets the
r ate ofmake
and br eak within
one
cycle
i
e
this
maintains
good
ignition
char acter istics of
engine
fr om low
speed
to
high speed
and is
equal
to
the
dweU
angle
in
the
conventional
br eaker
type
distr ibutor
3
A
pr eventive
cir cuit
against
lock
EE 3 6
EE 3 6
EE 3 8
EE 3 8
EE 3 9
ing
is
pr ovided
This
cuts off
the
pr ilnaCY
electr ic
cur r ent in
the
ignition
coil when the
ignition
switch
is
tur ned
onwiththe
engine
not
r unning
Each
component par t
ofthis
unit
is
highly
r eliable
however
should
any
par t
be found
faulty
theentir e assem
bly
must be
r eplaced
Engine
Electr ical
System
Tr ansistor
ignition
unit
r
1
Power
switching
cir cuit
Duty
contr ol
cir cuit
To
star ter
To
distr ibutor
Ba
tter y
Ignition
coil
1
Spar k
timing
1
Signal
mom
tor ing
cir cuit
Lock
j
pr evenling
cir cuit
nm
Distr ibutor
EE43 7
Fig
EE 75 Tr ansistor
ignition
unit cir cuit
diagr am
REMOVAL AND
INSTALLATION
Tr ansistor
ignition
unit is
located
on the
r ight
hand dash
side
panel
in
passenger compar tment
Disconnect
batter y negative
cable
2 Disconnect
wir ing
har ness fr om
unit
3 Remove two
setscr ews and te
move
unit
4
Toinstall r ever se the or der of
r emoval
Note
Be
sur e toconnect
wir ing
har
nesses totheir
pr oper
positio
Failur e todosowill
damage
the
unit
Refer to
Figur e
EE 76
Fig
EE 76 Exter nal view
of
ignition
unit
INSPECTION
Ifthe
engine
does
not
r undue
to
faulty ignition system
check
the
igni
tion
system
as
follows
Check for a cr acked distr ibutor
r otor or
cap
and cor r oded tenninals
Visually
inspect high
tension wir es
for
condition and
if
necessar y
use an
ignition oscilloscope
or a cir cuit
tester
to
make
per for mance
checks Check
spar k
plugs
and
adjust gaps
as neces
sar y
Replace
a
spar k plug
which
is not
suitable for fur ther use
Ifthe
above
checks cannot cor r ect the
pr oblem
check the
entir e
ignition
system
with
an
oscilloscope
or
a
cir cuit
tester
L
CHECKINGWITHAN
OSCILLOSCOPE
An
oscilloscope
can be used for
checking
almost
all
the items in
a
tr ansistor
ignition system
CHECKINGWITH
A
CIRCUIT
TESTER
Acir cuit tester can not
be
used
for
the
duty
contr ol cir cuit
and
power
t18nsistor
per for mance
tests
Both
methods use of
an
oscilloscope
and a
cir cuit tester
ar e
descr ibed in this
section
EE
3 7
The items
ar e
classified
by numer als
in
accor dance with
the
objective
of
checks
to
be
per for med
Sever al
wir ing
diagr ams ar e
found
on
pages
EE 41
to
EE 45 The thick lines indicate
the
objective
of
each individual item
check
When
checking
a cir cuit
with an
oscilloscope
or a
cir cuit tester be
car eful not
to
confuse the
polar ity
of
the lead wir esif
potential
differ ence
exists between the check
points
at
which the lead wir es ar e tobe con
tacted
Alsodo
not
attempt
tocon
nect
the
lead wir esto
any points
in the
cir cuit other
than those
designated
Car eless
handling
ofthe lead
wir es
will
r esult in
damage
tothe
tr ansistor
ignition
unit
as well as tothe oscillo
scope
or cir cuit
tester
The connection of
a
tachometer
or
a
timing
light
in
par allel
with an
oscilloscope
or a cir cuit tester is al
lowable
pr ovided
that such
a
connec
tionis
made withdue consider ation to
wir ing
connections
1
POWER SUPPLY
WIRING
AND
BAnERY
CHECK
See
wIr Ing diagr am
In
FIgur e
EE 88
Pr ocedur e
I Tur non
ignition
switch
2
Connect
a
cir cuit tester
or
an
oscilloscope
as shown in the
figur e
below
DC 50volt
r ange
EE3 02
Fig EE 77
Checking power supply
wir ing
and
batt
r y
Cr iter ion
When
power
sour ce
batter y
voltage
is
indicated OK
Lower
or noindication N G
If
the r esult
is N C Take
the
following
measur es
I Check BW and B color
wir e
har ness
r espectively
for
pr oper
con
ductance
2
Check
batter y
ter minals
for
pr oper
connection
3
Check
char ge condition of
bat
ter y
if
an
excessively
low
voltage
is
indicated
2
CONTINUITY CHECK OF
PRIMARY CIRCUIT
21
CheckIng pr Imar y
cir cuit See
wir ing
diagr am
In
Fig
EE 89
Pr ocedur e
I
Disconnect
L
color wir e
fr om
ignition
unit
2
Tur n on
ignition
switch
3
C
ooneet a cir euit
tester or an
oscilloscope
as shown in
Figur e
EE 78
DC
50
volt
r ange
tf S
EE3 03
Fig
EE
78 Checking pr imar y
cir cuit
Cr iter ion
When
Donnal
power
Sour ce
batter y
voltage
is
indicated
OK
Lower
or noindication
N
G
Ifthe
r esult
is
N C
Take
the
following
measur es
1
Check BW
and L color
wir e
Engine
Electr ical
System
har ness
r espectively
for
pr oper
con
ductance
2
Check r esistor
and
ignition
coil
ter minals for loose
contact
3
Check
r esistor and
ignition
coil
for
discontinuity
4Check
WB
color wir e har ness
of
ignition
coil
assembly
for
pr oper
continuity
22
Chacklng IgnitIon
coil
auembly
See
wir ing
diagr am
In
Fig
EE 90
Pr ocedur e
I
Disconnect
ignition
coil and dis
tr ibutor
har ness fr om
ignition
coil
exter nal r esistor
2
Connect a
cir cuit tester as
shown
in
the
figur e
below
Resistance
1
r ange
Q
ofD
r o
EE3 3 6
Fig
EE 79
Checking ignition coil
assembly
Cr iter ion
When
appr oximately
1 6
to
2
0
ohm
is
indicated
OK
Mor e
than
2
0ohm
N C
If
the
r esult is
N
C
Replace
ignition
coil
assembly
3 PICK
UP
COIL
CONTINUITY
CHECK
See
wir Ing dIagr am In
Figur e EE 91
Pr ocedur e
Disconnect R
and G
color
wir esfr om
ignition
unit
2 Connect
a cir cuit
tester as shown
inthe
figur e
below
EE
3 B
Resistance
10
r ange
fp
EE3 05
Fig
EE
BO
Checking pick up
coil
Cr iter ion
When
appr oximately
720ohm
is
indicated
OK
Far less than or mor e
than
720ohm N C
If
the r esult is N C
Replace
pick
up
coil
assembly
4
PICK
UP COIL POWER
SIGNAL
PULSE
CHECK
Pr ocedur e
I
Disconnect anti
dieseling
solenoid
valve
connector
2
Connect a cir cuit
tester as
shown
in
the
figur e
below
3
Rotate star ter
motor
4
Read the tester indication
AC 2 Svolt
r ange
EE3 06
Fig
EE 81
Checking pick up
coil
power
aignalpulse
Cr iter ion
When
pointer
deflects
slightly
OK
When
pointer
does not deflect
at all
N C
Ifthe
r esult
is
N C
Replace
pick
up
coil
assembly
Pr ocedur e withan
oscilloscope
1 Disconnect
anti
dieseling
solenoid
valve
connector
2
Connect
a
positive
lead ofan
oscilloscope
to
R olor
wir e
and a
negative
lead
ofan
oscilloscope
to
G color
wir e
3
Set a SLOPE select
switch of
an oscilloscope
to
the
positive
side If
so
equipped
4
Rotate
star ter motor
5 Check
the
wave for m
as shown
in
the
figur e
below
EE268
Fig
EE 82 Wave
for m ofpick up
coil
Cr iter ion
When
the
wave for m
takes
the
shape
of
a
full line OK
When
the
wave for mtakes the
shape
of
a dashed
line
or
when
ther e
is
nowave
for m
N
G
If
the r esult is N G
Replace
pick
up
coil
assembly
5
TRANSISTOR
IGNITION
UNIT
CHECK
See
wir ing
diagr amIn
Figur e
EE 92
Check
items 5 1 and 5
2 with
an
oscilloscope
Wher e
an
oscilloscope
is not availa
ble check tomake sur e
that all
pr evi
ous tests
ar e
satisfactor y
and that no
spar k
is
issuing
fr om the
secondar y
high
tensionwir e
If
ever ything
else
is
satisfactor y
then the tr ansistor
ignition
unit is
faulty
or ther e
is
discontinuity
in the
secondar y
high
tension
wir e
Replace
the
faulty par t
After
r eplacement
check the
spar ks
fr om the
secondar y
cor d
51
Checking
oper atIon
oftr ansIstor
Ignition
unit
Pr ocedur e
I
Connect
ignition
coil and dis
tr ibutor
har ness to
ignition
coil exter
nal
r esistor
Engine
Electr ical
System
Oscilloscope
o
EB
80
To
body
metal
Ignition
coil ter minal
8W
r8
0
C
0
EB
Fig
EE 83
Checking
oper ation of
tr ansistor
ignition
unit
EE3 07
@
@
2
Connect
wir ing
har ness
tothe
ignition
unit
3 Disconnect
anti
dieseling
solenoid
valve connector
4
Connect oscilloscope
as
shown in
Figur e
EE 83
r otate the
star ter motor
and
obser ve
the wave
for m
on
the
oscilloscope
Cr iter ion
See
Figur e
EE 84
When
a
wave for msimilar
to
a is obser ved OK
When a wave for m similar to
b
is
obseIVed
or
when nowave for mis
obser ved
N
G
Ifthe r esult is N G thefault lies
either in the tr ansistor unit
or
in
the
secondar y high
tension wir e
Replace
these
par ts
EE 3 9
EE452
Fig EE 84
Wuve
for m ofpulse
Ifan
oscilloscope
is
not
avail
able
Pr ocedur e
1 Connect
ignition
coil and dis
tr ibutor
har ness to
ignition
coil exter
nal
r esistor
2
Connect
wir ing
har ness to
igni
tionunit
3
Disconnect
anti
dieseling
solenoid
valve
connector
4
Keep
the
secondar y high
tension
wir e end 4to5
mm 0
16 to0 20 in
away
fr om
engine
block r otate the
star ter motor and
check
whether
spar ks fly
acr oss the
clear ance
Cr iter ion
Wher e spar ks
issue OK
Wher e
nospar k
issues
N
G
Ifthe
r esult is N G the fault
lies either
in
the
tr ansistor
unit or in
the
secondar y high
tension wir e
Replace
these
par is
52
Checking oper ation
of
duty
Pr ocedur e
Connect anti
dieseling
solenoid
valve
connector
2
While
the
engine
is
idling
obser ve
the wave
r onn
on
the
oscilloscope
in
the
same
way
as stated in item
5
Figur e
EE 83 Deter mine
the r atio
tiT
as shownin
Figur e
EE
85
I
T
x
100
20
to
401 1
at
idling
h
Lt 1
T
EE257
Fig
EE
85 Wove
for mofduty pulse
Cr iter ion
When
astandar d
r atioof
about
20
to
40
is
obtaiiied
OK
When the
r atioobtained
is
less than20
or
mor e than 40
N
G
If
the
r esult is N
G
tr ansistor
ignition
unit
Replace
53
Checking
lock
pr eventive
cir cuit
Ifa cir cuit tester
is used
Pr ocedur e
1
Connect a cir cuit
tester as
shown
in
Figur e
EE 83
or
EE 86
positive
ter minal
of
tester is connected toL
color wir e and
negative
ter minal of
tester is
gr ounded
2 Tur n
on
ignition
switch
Check to
see whether the tester indicates
the
vol
age
of
power
sour ce ba
t1er y
as soonas
ignition
switch
is
tur ned
on
Engine
Electr ical
System
DC
50volt
r ange
r C
o
8
Cr iter ion
When
power
sour ce
voltage
is indicated
When
appr oximately
is
indicated
OK
zer o
voltage
N G
If
the r esult is N G
Take the
following
measur es
Replace
tr ansistor
ignition
unit
Ifan
oscilloScope
isuSetl
Pr ocedur e
I When
using
an
oscilloscope
in
stead of
a tester
ar r ange
the
connec
Oy
EE 40
B
fJ
BW
O
L
t
1
V
Tr ansi
tor
ignition
unit
EE3 57
Fig EE 86
Checking
lock
p
uentive cir cuit
tion in
the
same
way
as shown
in
Figur e
EE 83 or
Figur e
EE 86
Tur n
on
ignition
switch
Check
to
see whether
the
wave
for m on
the
oscilloscope
r ises
up
to
the
power
sour ce
voltage
within
about
10 seconds after
ignition
switch
is
tur ned on
Cr iter ion
The same
as
descr ibed befor e
for
use ofatester
Power
sour ce
voltage
t
Ignition
switch ON
EE43 0
Fig
EE 87 Wave
for mof
lock
pr eventive
cir cuit
It
nitionS
l
tC
11
11
BR
o
IgnitiOn
coil
auemblY
i
stn
Utot
r
Ter minal
b
oC
II
o
llW
Power
switching
dtCuit
L
R
G
spar lt
timing
sign
1llonltor iOi
cir cui
t
Duty
contr ol
cir cuit
r n
5
l1
l1
n
Har ne
s
cam
P
oClt
pr eventing
cllcuit
1
A
l1
3
19nition
unit
E
E43 8
1
r
and
batte
c
c
Fill
EE
88
Wir ing
di l8
r am
for
item
l
PO
er
uPP
y
I
W
b
IlR
o
ignition
coil
assemblY
Distr ibutO
r
Ter minal
b
OC k
Il
IlW
L
R
G
o
Har ness
calnP
Spade
tiR
lng
oIgn
1
monitor ing
cltCuit
Loc K
Iteventins
cir cuit
powet
switcnlOS
cucuil
DUtY
conno
cir cuit
r nl
lO
3
D
W
Cl
0c
o
f
3
19 nit
on
unit
eE
43 9
w
0
b
gn1t10 O
sWitch
llR
o
19t
iUO P
coll
auefC
uW
tr i Dutot
r
let11
ina
o
OC
B
ll ll
L
R
G
@
o
Ha
r nesS
clar np
S1
atK
tunin
sign a
tnoo
t
oth1
citcuit
lflc K
ptellenunt
cir Cuit
r owel
sVI
tdl
ing
citCuit
putY
contto
ciIcuit
r nl0
r W
o
O
l
IlS
3
Ignition
unit
EeA40
R
1
ncoi1
blY
Fig
EE
90
Wir inll
dioS
for
ite
2
2
CMC
nll
iIln1
0
W
t
gni
on
sWitch
ll l
I
o
f1
t
Of
CO
a
r ntM
OliU
bUlot
r
Ter r n
oa
blocK
o
B
powet
swilchln
CltCU1l
BW
I
lG
@
DUtY
cof
lTO
C
tCU
lI
I
u
5
l
l
l
l
0
1Il
St
l
titr llt t
signa
tl
onitotifl
cir cuit
Ratt
e
cump
LOCK
pr eyen
tn
cir cuit
f
lo1
unl l
EE44
f
o
o
l
it
l
0
j
5
i
0
g
J
j
t
CI
C
15
0
g
i
l
0
l
l
0
e
a
a
l
t
e
t
I
S
ll
ll
2
oJ
u
t
l
1
1
ll
i
foil
i
0
t
a
e
0
0
u
S
r
CD
0
0
e
a
El19ine
Electr iCal
svstel O
EE 4S
The
ignition
coil
is
an oil f1l1ed
type
The
ignition
coil
case
is filled
withoil whichhas
good
insulating
and
heat
r adiating
char acter istics
The
ignition
coil has a
gr eater
r atio
between the
pr imar y
and
secondar y
windings
to
stepupbatter y voltage
t
high voltage
This causes
str onger
spar ks
to
jump
the
spar k plug
gap
The
cap
is made
of
alkyd
r esin
which
offer s
high
r esistance
tolectr ic
ar c
and incr eased insulation
The
ignition
coil and r esistor should
behandled
as a
matched set
When
high
tension
wir e is
installed
to
ignition
coil ther e should be
no
clear ance between their
caps
I
EE3 54
1
High
tension wir e
2 Rubber
cap
Fig
EE
94Cor r ecl installation
of
high
t Mjon
win
SPECIFICATIONS
Type
Pr imar y voltage
Spar k
gap
Pr imar y
r esistance at 200C 680F
Secondar y
r esistance
at 200C 680F KSl
Exter nal
r esistor
at20C
680F
n
Engine
Electr ical
System
IGNITION COIL
Califor niamodels
fID
@
J
C
ID
I
1W
1
R
bber
cap
for
ignition
coil
2
Secondar y
ter minal
3
Cap
4
Pr imar y
ter minal
5
Spr ing
6
Secondar y winding
7
Pr imar y winding
Notes
a
Do
not disconnect
high
tension
wir es fr om
spar k plugs dur ing
en
gine
mnning
Califor nia
models
only
b
RoD
uphigh
tension
wir e mbber
cap
and instaD
high
tensionwir e to
ignition
coil
secur ely
Refer to
Figur e
EE9S
Non califomia
models
EE3 14
8 Side cor e
9 Insulator coil
10 Center cor e
11
Segment
12 Case
13 Rubber
cap
Cor ter minal
Fig
EE 93 Sectional view
of
ignition
coil
Fig
EE
95
Installing
high
tension wir e
Non
Califor nia
Califor niamodels
models
C6R 618
HS 15 18
CIT
16 STC9
12 12
mor e than
7
028 mor e than
7
028
108to13 2 045 to
055
824to
12 4
85to
12
7
15
13
040
9
V
mm
in
n
EE 46
DESCRIPTION
INSPECTION
CLEANING
AND REGAP
DESCRIPTION
The
spar k plugs
ar e
of
the
conven
tional
type having
14mm
0
551
in
thr eads
The
spar k
plug gaps
ar e 1 0 to
11mm 003 9 to
0043
in on Cali
fomia
models and 0
8
to
09 mm
0 03 1 to
003 5
in on non
Califor nia
models The
inspection
and
cleaning
should be made ever y
suitable
mainte
nance
per iod
Ifnecessar y r eplace
Note All
spar k
plugs
installed on
an
engine
must
be
of
the same br and
and
the
same
number ofheat
r ange
INSPECTION
L
Remove
spar k
plug
wir e
by
pulling
on
boot not on
wir eitself
2 Remove
spar k plugs
3
Check
electr odes and
inner
and
outer
por celains
of
plugs
noting
the
type
of
deposits
and the
degr ee
of
electr ode
er osion
Refer to
Figur e
EE96
Nor mal Br own
to
gr ayish
tan de
posits
and
slight
electr ode wear
indicate cor r ect
spar k plug
heat
r ange
Car bon fouled
Dr y fluffy
car bon
deposits
on the insulator and
electr ode ar e
usually
caused
by
slow speed dr iving
in
city
weak
ignition
toor ich fuel
mixtur e
dir ty
air cleaner etc
It
is
advisable
to
r eplace
with
plugs
having
hotter heat
r ange
Oil
fouled Wet black
deposits
indi
cate
excessive oil entr ance into
combustion
chamber
thr ough
wor n
r ings
and
pistons
or excessive clear
ance between
valve
guides
and
stems
Ifthe same condition
r e
mains after
r epair
use a hotter
plug
Engine
Electr ical
System
SPARK
PLUG
CONTENTS
EE 4B
EE 47
EE
47
EE 47
SERVICE
DATA
AND SPECIFICATIONS
TROUBLE
DIAGNOSES
AND
CORRECTIONS
EE 4B
Over heating
White
or
light
gr ay
in
sulator with black
or
gr ay
br own
spots
and
bluish bur nt electr odes
indicate
engine
over heating
Mor e
over the
appear ance
r esults
fr om
incor r ect
ignition
timing
loose
Nor mal
Over heating
EE079
4After cleaning
dr ess
electr odes
with a
smaU fine file toflatten
the
sur faces of
both center and
side
electwdes
in
par allel
Set
spar k plug
gap
to
specification
5 InstaU
spar k plugs
and
tor que
each
plug
to
L5
to
20
kg
m
11
to
14
ft
Ib
6
Connect
spar k
plug
wir es
CLEANING
AND
REGAP
Clean
spar k plugs
in
a
sand blast
type
cleaner Avoid excessive
blasting
Clean
and r emove car bon
or oxide
deposits
but do
not
wear away
por celain
If
deposits
ar e
toostubbor n
EE 47
spar k plugs
low fuel
pumppr es
sur e
wr ong
selection offuel
a
hotter
plug
etc
It
is advisable to
r eplace
with
plugs
having
colder heat
r ange
Ir
i
Car bon
fould
Wor n
Fig
EE 96
Spar k
plug
discar d
plugs
After
cleaning spar k
plugs
r enew
fir ing
sur face of
electr odes with me
mentioned aboVe Then
gapspar k
plugs
to
specified
values with
a r ound
wir e feeler
gauge
All
spar k
plugs
new
or used should have
the
gap
checked
and r eset
by bending gr ound
electr ode
EEOBO
Fig
EE 97
Setting par k
plug gap
Engine
Electr ical
System
SERVICE DATA AND
SPECIFICATIONS
Califor nia
models
Non
Califor nia
models
For Canada
except
for
Canada
BP6ES ll BP6ES
BPR6ES Standar d
L45PWll L45PW
BP4E
ll BP5ES ll BP4E
BP5ES BPR4ES
Type
Hot
type
L46PW
ll
L47PW
ll
L46PW L47PW BPR5ES
Cold
type
BP7ES
ll
BP7ES
BPR7ES
LMPWll LMPW
10toll 0 8 to0
9 08to0
9
Plug
gap
mm
in
0
03 9
to0 043 0
03 1 to0D3 5 003 1 to
0
03 5
Tightening tor que kg
m ft
Ib
I
15to2
011
to14
TROUBLE
DIAGNOSES
AND
CORRECTIONS
When
engine
does not star t
Ifther e
is
no
pr oblem
in
fuel
system ignition system
should be
checked
This can be
easily
done
by
detaching
a
high
tension wir e
fr om
spar k
plug star ting
engine
and
ob
ser ving
condition of
spar k
that
occur s
between
high
tension
wir e and
spar k
plug
ter minal
After
checking
this
r epair
as
necessar y
Note On Califor nia models
discon
nect anti
dieseling
solenoid
valve
connector to
cut off
supply
offuel
to
engine
and
then obser ve
the
condition
of
spaIks
while star ter
motor
is
in
oper ation
Condition Location
Pr obable
cause Cor r ective action
No
spar k at
all
Distr ibutor
Faulty
insulation ofcondenser
NonCali
Replace
fomia
models
Br eakage
oflead wir eonlowtensionside
Repair
Poor insulationof
cap
and r otor head
Replace
Seized
points
Non Califor nia
models
Repair
Open
pick up
coil Califor nia models
Replace
Air
gap
wider than
specification
Cali
Adjust
for nia
models
Ignition
coil
Wir e
br eakage
or shor t
cir cuit
ofcoil
Replace
withnewone
High
tension wir e
Wir e
coming
off
Repair
Faulty
insulation
Replace
Tr ansistor
ignition Faulty
tr ansistor
ignition
unit
Replace
unit
Califor nia
models
EE 4B
Condition
Spar k
length
I
to
2r nm 003 9
to0
079 in Of
ir r egular
Mor e
than 6 r nm
023 6
in
Engine
Electr ical
System
Location Pr obable
cause
Distr ibutor
Point
gap
toowide Non Califor nia
mo
dels
Oil
onpoint Non Califor nia
models
Bur ned
points
Non
Califor nia
models
Spar k
plugs
Spar k
plug
gap
toowide
Too
much car bon
Br okenneck ofinsulator
Expir ation
of
plug
life
Air
gap
toowide Califor nia
models
Distr ibutor
Tr ansistor
ignition
unit Califor nia
models
Faulty
tr ansistor ignition
unit
Cor r ective
action
Cor r ect
Clean
Replace
Cor r ect or
r eplace
Cleanor r eplace
Replace
Replace
Cor r ect
Replace
2
Engine
r otates
but does not r un
smoothly
This
may
be
caused
by
the
ignition
system
or other
engine
condiHons not
r elated
to
ignition
Ther efor e
fir st a
complete inspection
of
ignition
system
should
be
car r ied out
Condition
Engine
misses
Location
Pr obable
cause
Distr ibutor Dir ty point Non
Califor niamodels
For eign
mattefon
pick up
coil Califor nia
models
Impr oper
point
gap
NonCalifor nia mo
dels
Impr opef
air
gap
Califor niamodels
Leak of
electr icity
at
cap
and r otor head
Damaged
insulation of
condenser
Non
Califor nia
models
Malfunctioning
contact ar m
NonCali
for nia models
Faulty
contact ar m
spr ing
Non Cali
for nia models
Br eakage
oflead wir e Non
Califor nia
models
Br eakage
of
pickup
coil lead wir e Cali
for nia models
Wor n
or shaky
br eaker
plate
Wor n or shaky
distr ibutor
dr iving
shaft
Layer
shor t cir cuit or
infer ior
quality
coil
Ignition
coil
High
tensionwir e Deter ior ation
ofinsulation with con
sequent
leak
of
electr icity
EE 49
Cor r ectiveac
ion
Clean
Clean
Cor r ect
Cor r ect
Repair
or
r eplace
Replace
Oil
shaft
Replace
Replace
Replace
Replace
assembly
Replace
assembly
Replace
with
good
one
Replace
Condition
Engine
causes
knocking
ver y
often
Engine
does
not
deliver
enough
power
Location
Spar k
plugs
Tr ansistor
ignition
unit
Califor nia
models
Distr ibutor
Spar k
plugs
Distr ibutor
Spar k
plugs
Engine
Electr ical
System
Pr obable cause
Fouled
Leak of
electr icity
at
upper por celain
insulator
Faulty tr ansistor
ignition
unit
Impr oper ignition
timing
too
advanced
Coming
off
or
br eakage
of
gover nor
spr ing
Wor n
pin
or hole of
gover nor
Bur nt
toomuch
Impr oper ignition timing
too
r etar ded
Impr oper functioning gover nor
Point
gap
too
nar r ow
Non
Califor nia
models
For eign par ticles stuck
in
air
gap
Cali
for niamodels
Fouled
EE
50
Cor r ective
action
Clean
Repair
or
r eplace
Replace
Cor r ect
Cor r ect
or
r eplace
Replace
Replace
Cor r ect
Replace
assembly
Cor r ect
Oean
Oean
DATSUN PICK UP
MODEL 620 SERIES
I
NISSAN
J
NISSAN MOTOR
CO LTD
TOKYO JAPAN
SECTION
ER
ENGINE
REMOVAL
INSTALLATION
ENGINE REMOVAL
AND
INSTALLATION
ER 2
Engine
Removal
Installation
ENGINE
REMOVAL AND INSTAllATION
REMOVAL
INSTALLATION
ENGINE MOUNTING
INSULATORS
REMOVAL
It is much easier
to
r emove
engine
and tr ansmission
as
a
single
unit
than
to
r emove them
separ ately
After r e
moval
engine
can be
separ ated
fr om
tr ansntission
assembly
Notes
a
Be
sur e tohoist
engine
and
jack up
tr ansmission inasafe manner
b Use
fender cove to
pr otect
vehicle
body
1 Remove
batter y
2
Scr ibe
hood
hinge
location for
pr oper
r einstallation and r emove
hood
Note Have
an assistant
help
you
soas
to
pr event damage
to
body
3
Dr ain
r adiator coolant
4
Disconnect
upper
and lower
r adiator
hoses
fr om
engine
5
Remove
twooil cooler hoses
fr om lower
end ofr adiator Auto
matictr ansmission
models
only
6
Remove
r adiator
shr oud
7
Remove four
bolts
secur ing
r adia
tor and
detach r adiator
Note
Always tighten secur ing
bolt at
upper
r ight
hand side
together
with
body
har ness
ter minal
8
Remove car bur etor air
cleaner as
follows
Remove fr esh air
duct
Remove
hot air
duct
Loosen
air
cleaner band
bolt and air
cleaner
suppor ting
bolts
Disconnect air
cleaner ta
air
pump
hose
Disconnect air cleaner
tor ocker
cover hose
at
r ocker
cover
Disconnect
air
cleaner
to
air
contr ol
valve hose Califor nia
models
only
CONTENTS
ER 2
ER 3
ER 3
FRONT
INSULATOR
REAR
INSULATOR
TIGHTENING
TORQUE
ER 4
ER 4
ER 4
Disconnect
air
deaner
to
AB valve
hose
Disconnect
air
cleaner ta
vacuum
hoses
Note
Pr otect car bur etor fr om dust
and
for eign
matter
by
placing
cover
over air inlet
opening
9
Disconnect
fuel
pump
tofuel
fdter hose and r etur n
hose
10
Disconnect car bon canister
hose
on
engine
side
II
Disconnect air
pump
air
C1eaner
to
al
p
p
hose
12
Disconnect
following
cables
wir es
and hoses
Engine gr ound
cable
Acceler ator wir eat
car bur etor
High
tension
cablebetween
ignition
coil
and distr ibutor
Wir e
todistr ibutor at
body
ter
minal
Wir e to
oil
pr essur e
switch
Wir estother mal
tr ansmitter
Wir es
to
BC
p
D cut solenoid
NonCalifor nia
models
only
auto
chokeheater and
anti
dieseling
solenoid
Wir es
toalter nator
Wir es tostar ter
motor
Heater inlet and outlet
hoses ifso
equipped
Vacuumhose of
Master Vacat in
taJce manifold
Wir es for
back
up
lamp
switch
Cable to
speedometer
13
Remove tr ansmission
contr ol
linkage
fr om
tr ansmission
Manual
tr ansmission models
I
Detach r ubber boot
2 Remove E
r ing
and
contr ol
lever
pin
fr om
tr ansmission
str iking
r od
guide
and
r emovecontr ol lever
ER 2
Fig
ER l
Automatic
tr ansmission models
I
Disconnect
selector
r ange
lever
fr ommanual shaft
2 Disconnect wir es
at inhibitor
switch and
downshift solenoid
14Air
conditioner
equipped
models
need
following
pr ocedur es
1
After
r emoving
flexible
hose
suppor t
r emove four
comi
r essor
se
cur ing
bolts
Then move the
com
pr essor
to
batter y
suppor t
2
Remove
vacuum hoses of
FLCD solenoid valve
3 Remove FLC
D actuator
15 Remove two bolts
secur ing
clutch
oper ating cylinder
Then dis
connect
oper ating
cylinder
and
flexi
ble tube
as an
assembly
Manual
tr ansmission
models
only
16 Disconnect fr ont
exhaust tube
fr omexhaust manifold
17
Remove
pr opeller
shaft
I
Disconnect
pr opeller
shaft
center
bear ing
br acket fr om
thir d
cr ossmember
2
Disconnect
pr opeller
shaft fr om
companion flange
ofdiffer ential
car r ier
3 Remove
pr opeller
shaft fr om
tr ansmission
and
plug
up
r ear end of
extension
housing
of
tr ansmission to
pr event
oil
leakage
18 Attach a suitable
wir e
or chain
tolift
engine
19
Remove
fr ont
engine mounting
bolts
at
engine mounting
fr ont
sup
por t
Fig
ER2
ER207
Removing fr ont engine
mounting
bolts
20
Place a
jack
under tr ansmission
and
jack
it
up
21
Loosen
twor ear
engine
mount
ing
bolts
CD
22
Loosentwo
exhaust tube
hanger
bolts
V
Califor nia models
only
23 Remove four bolts
CID secur ing
engine mounting
r ear
suppor t
toside
member and detach
r ear
suppor t
j
r
O
1
ER271
Fig
ER 3 Removing
r ear
engine
mounting suppor t
24Remove
steer ing
idler ar msecur
ing
bolts
and
push
down
cr oss
r od
iC
EA278
Fig
ER
4Removing
idler ar m
25
Pull
engine
towar ds fr ont as far
as
possible
and
car efully
r aise ifand
tr ansmission witha hoist and
cable
Note
In
this
r
an
car e
should
always
be taken not toallowthe
unit
tohit
against
any
adjacent
par ts
Engine
Removal
Installation
INSTALLATION
E R3 67
Fig
ER 5 Lifting engine
Install
engine
with
tr ansmission in
r ever se
or der of
r emoval
obser ving
the
following
I When
installing
fir st secur e
r ear
2
Fr ont
1 Br acket RH
2
Insulator RH
3 Br acket LH
4
Heat
shield
plate
5 Insulator
LH
6
Rear
suppor t
7 Rear insulator
8 Exhaust tube
hanger
Califor niamodels
only
engine mounting
suppor t
to
body
2 Refer to
applicable
section when
installing
and
adjusting any par ts
@
E
A279
Fig
ER
6 Str uctual
view
of
engine
mounting
ENGINE MOUNTING
INSULATORS
Thr ee
insulator s ar e used
to
mount
the
engine
and
tr ansmission
twoar e
located
at
the
left and
r ight
ofthe
cylinder
block and one
at thetr ansmis
sion
r ear
extension
housing
Replace
any
insulator that shows
signs
of
separ ation
or deter ior ation
Be
sur e to
keep
insulator fr ee fr om
oil
or
gr ease
ER 3
Engine
Removal Installation
FRONT
INSULATOR
Removal and installation
7
To
install r ever se or der of
r e
moval
1
Disconnect
batter y gr ound
cable
2
Remove
hood
3
Suspend engine
with wir e or
chain
4Loosen fr ont
engine mounting
insulator
upper
nuts
both
sides
5
Car efully
r aise
engine
a little with
ahoist and cable
6 Remove fr ont
mounting
insula
tor s
at fr ont
suppor ts
after
r emoving
fr ont
mounting
bolts
REAR INSULATOR
Ramoval and
Installation
1
Place a
jack
under tr ansmission
TIGHTENING
TORQUE
Fixing
boltsand nuts
Fr ont
mounting
br acket to
cylinder
block
Fr ont
mounting
in
lator tobr act
Fr ont
mounting
insulator tofr ont
suppor t
Rear
mounting
insulator to
tr ansmission
Rear
mounting
insulator to
r ear
suppor t
Rear
suppor t
tofr ame
Clutch
oper ating cylinder
totr ansmission
Exhaust fr ont
tube toexhaust manifold
Center
bear ing
br acket to
cr ossr nember
Pr opeller
shaft to
companion
flange
kg
m ft lb
kg
m
ft Ib
kg
m ft lb
kg
m ft lb
kg
m
ft Ib
kg
m ft lb
kg
m
ft Io
kg
m ft lb
kg
m ft lb
kg
m ft lb
ER 4
and
jack
it
up
slightly
2
Loosentwo
r ear
engine mounting
bolts
3
Loosen two
exhaust
tube
hanger
bolts Califor nia
models
only
4
Remove r ear
mounting
insulator
at tr ansmission r ear extension
after
r emoving
insulator
secur ing
bolts
5
To
install
r ever se
or der
ofIe
moval
26 to3 6 19 to26
2
6 to
3
6
19
t o
76
14
to18 10to13
3
2to3 7 23 to
27
16 to22
12
to16
3
2to43 23 to3 1
2
5
to
3
5
18
to25
1
9to25 14to18
16
to
22
12to
16
2
4to
33
17
to
24
DATSUN
PICK UP
MODEL
620 SERIES
LNISSAN I
NISSAN
MOTOR CO LTD
TOKYO JAPAN
SECTION
CL
CLUTCH
CLUTCH
CL 2
CLUTCH CONTROL CL 5
SERVICE
DATA AND
CL 9
SPECIFICATIONS
TROUBLE
DIAGNOSES
AND
CLIO
CORRECTIONS
SPECIAL SERVICE
TOOL CL12
DESCRIPTION
REMOVAL
AND INSTAllATION
Removal
Installation
DESCRIPTION
The clutch
is
a single dr y
disc
type
CLUTCH
CLUTCH
CONTENTS
CL 2
Cl2
CL 2
CL 3
DISASSEMBLY
AND ASSEMBLY
D
isassemb
I
y
Assembly
INSPECTION
CL 3
Cl3
CL 3
CL
4
using
a
diaphr agmspr ing
It consists
of
the
clutch disc
pr essur e plate
dia
phr agm
spr ing
thr ust
r ings
clutch
cover
I
and
clutch r elease
bear ing
e
M
0
s
8
o
8
l150
591 dia
225 8 86 dia
REMOVAL
AND
I NSTALLATIO
Removal
1
Remove tr ansmission
fr om ve
hicle
For details oftr ansmission
r emoval
r efer toTr ansmissionSection
2
Inser t
Clutch Aligning
Bar
KV3 0100200
intoclutch dischub
until it will no
longer go
It is im
A
u
o
6
o
C
62
2
44
dia
I
260
10
2
dia
CL23 1
Fig
CL
l
Constr uction of
clutchdiscand COller assembly
Unit mm
in
por tant to
suppor t
weight
ofclutch
disc
dur ing
fur ther
steps
See
Figur e
CL 2
3
Loosen
six
scr ews
attaching
clutch cover to
flywheel
one tur n
at a
time
each un
til
spr ing
pr essur e
is
r e
leased Be
sur e totur n
themout in
a
cr isscr oss
fashion
Note Exer cise
special
car e
toavoid
gr ease
or
on
getting
on
clutch
linings
CL2
Fig
CL2
Suppor ting
clutch
assembly
Installation
I
Apply
a
light
coat oflithiumbase
gr ease containing
molybdenum
disul
phide
on
tr ansmission
main dr ive
gear
splines
Slide clutch
discon
main
dr ive
gear
sever al times
Remove
clutch
discand
wipe
offexcess
lubr icant
pushed
off
by
dischub
2 Install clutch discand
clutch
cover assembly on
flywheel
Suppor t
twoassemblies with Clutch
Aligning
Bar KV3 0100200 See
Figur e
CL
3
Note Be
sur e to
keep
disc
facings
flywheel
and
pr essur e
plate
clean
and
dr y
7
00
R
r r
CL109
Fig
CL 3
l
talling
clutch
cover
assem
bly
3 Install
six
bolts to
tighten
clutch
cover
assembly
to
flywheel squar ely
Each bolt should be
tightened
one
tur n at
a time
tothe
specified tor que
15to22
kg
m II
to16
ft Ib
Note Thr ee dowels
ar e
used tolocate
clutch cover
on
flywheel
pr oper ly
4Remove
Clutch
Aligning
Bar
KV3 0100200 after
tightening
the
bolts
secur ely
5 Install tr ansmission
Note Make cer tain that withdr awal
lever
engages
lever ball
pin
6
Connect
push
r od ofclutch
op
er ating
cylinder
towithdr awal lever
DISASSEMBLY
AND
ASSEMBLY
Disassembly
I
Clutchcover
assembly
can
not
be
CLUTCH
disassembled
since
diaphr agmspr ing
is
secur ely
r eveted toclutch cover and
clutch
cover assembly
is balanced
If
necessar y r eplace
clutch cover
assembly
as a
complete
unit
2
Remove clutch
r elease mechanism
as follows See
Figur e
CL4
1
Remove dust cover
fr omclutch
houisng
2 Remove
withdr awal lever fr om
clutch
housing
3 Remove
r etainer
spr ing
fr om
withdr awal lever
4
Remove r elease
bear ing bear ing
sleeve
and
holder
spr ing
fr om clu
tch
housing
as an
assembly
1
lo
1
Release
bear ing
2 Release
bear ing
sleeve
3 Holder
spr ing
4
Dust
cover
5
Withdr awal
lever
6
Retainer
spr ing CL119
Fig
CL4
Exploded
view
of
clutch
r eleaae mechaniam
3 Take
out clutch r elease
bear ing
fr om
bear ing
sleeve
using
a
univer sal
puller
See
Figur e
CL
5
CL014
Fig
CL 5 D
embling
r ele
e
b
ar ing
4
Remove
pilot
bushing
in
cr ank
shaft
by
Pilot
Bushing
Puller
ST16610001 if
necessar y
See
Figur e
CL 6
CL3
CLOSS
Fig
CL 6
Removing pilot
bu
hing
Asse
bly
Release
mechaniam
1 When
assembling r elease
bear ing
on sleeve
use a
pr ess
and seat
bear ing
squar ely
on
sleeve See
Figur eCL 7
l J
I
CL215
I
1
J
1
Fig
CL 7 1
tailing
r ele
e
bear ing
2 Befor e
or dur ing
assembling
lu
br icate the
following points
with
a
light
coat ofmulti
pur pose
gr ease
I
Inner
gr oove
ofr elease
bear ing
sleeve See
Figur e
CL 8
Lf
I
n
JQt
CL216
Fig
CL
B
Lu
br icating
ee
of
bear ing
slee
2 Contact sur faces of
withdr awal
lever lever ball
pin
and
bear ing
sleeve
3 Contact sur faces of
tr ansmission
fr ont cover See
Figur e
CL
9
l
t
tJ
I
P
o
CUll
Fig
CL 9
Lubr icating
poinu of
withdr awal lever and
fr ont
cover
4
Contact sur faces oftr ansmission
main
dr ive
gear
splines lithium
base
gr ease including
molybdenum disul
phide
Note
Ver y
IIIIJllII amount of
gr ease
should be ated tothe above
points
Iftoomuch iubr icant is
applied
it will r un out on the
fr iction
plates
when hot
r esulting
in
d
gi
dutch disc
facings
3 Install r etainer
spr ing
towith
dr awal lever Fit holder
spr ing
to
r elease
bear ing
and sleeve
assembly
then assemble withdr awal Iever and
bear ing
sleeve as a unit Install this
assembly
on
tr ansmission case Then
install dust
cover
Pilot
bushing
Befor e
installing
a new
bushing
thor oughly
clean
bushing
hole Install
bushing
in cr ankshaft
using
a soft
hammer
Bushing
need not be oiled
INSPECTION
Wash all the disassembled
par ts
except
r elease
bear ing
and discassem
bly
in suitable
cleaning
solvent to
r emove dir t and
gr ease
befor e
making
inspection
and
adjustment
Flywheel
and
pr essur e plate
Check fr iction sur face
of
flywheel
and
pr essur e plate
for
scor ing
or
r oughness Slight r oughness may
be
smoothed
by using
fme
emer y
cloth
Ifsur face
is
deeply
scor ed or
gr oov
ed the
par t
shouldbe
r eplaced
Clutchdiscat llembly
Inspect
clutch discfor
wor nor
oily
facings
loose
r ivets and
br oken
or
loose
tor sional
spr ings
CLUTCH
I If
facings
ar e
oily
the discshould
be
r eplaced
In thiscase
inspect
tr ans
mission fr ont cover oil seal
pilot
bushing engine
r ear oil seals and other
points
for oil
leakage
2 The disc
should
also
be
r eplaced
when
facings
ar e wor nlocally
or wor n
down
less than 03 mm 00118
in
at
r evels See
Figur e
CL IO
DePth
ll
I
gauge
II
1
i
h
1
j1
t
f
Above
03 r om
10
012in
CL089
Fig
CL I0 Me JIur ingclutch
lining
3
Checkdisc
plate
for r unout when
ever
the old discor
a
new one
is
installed
4If
r unoutexceeds the
specified
value
at
the outer cir cumfer ence Ie
place
or
r epair
discSee
Figur e
CL
II
Runou
t
05mm 0020
in
total indicator
r eading
R
fr om
the
hubcenter
107 5mm
4
23 in
CL112
Fig
CL
ll
MeOlUr ing
disc
r unout
5 Check the fit ofdisc
hub on
tr ansmission main dr ive
gear
for
smoothly sliding
If
splines
ar e wor n
clutch discor main dr ive
gear
should
be
r eplaced
that
is backlash exceeds
0
4
mm 0016
in
at the outer
edge
of
clutchdisc
Clutch
cover
assembly
I Check
the
end sur face of
dia
phr agmspr ing
for wear
CL 4
Ifexcessive wear
is
found
r eplace
clutchcover
as an
assembly
2 Measur e the
height
of
diaphr agm
spr ing
as outlined
below
See
Figur e
CL
12
a Place Distance Piece ST20050100
on Base Plate ST20050010 and
then
tighten
clutch cover
assembly
onthe base
plate
by using
Set Bolls
ST20050051
b Measur e
diaphr agm
spr ing
toe
height
A
at sever al
points
with a
ver nier
caliper
depth
gauge
STl0050100
r Jr f
I
Tl
05001O
f
7
CL23
STl005Q051
Fig
CL12
Me
ur ing
the
height of
diaphr agm pr ing
Ifthe
height
A
of
spr ing
end
is
beyond
the
specified
value of3 3 to3 5
mm
123
to13 8
in
adjust
the
spr ing
height
with
Diaphr agm
Adjusting
Wr ench ST20050240 See
Figur e
CL
13
If
necessar y r eplace
clutch
cover as
an
assembly
Alsounevennessofdia
phr agm spr ing
toe
height
should be
less than05mm 0020in
ST20050240
CL152
Fig
CL13
AdjlUting
the
spr ing height
3
Inspect
thr ust
r ings
for wear or
damage
As these
par ts
ar e invisible
fr omoutside shake cover
assembly up
and down tolisten for
chatter ing
noise or
lightly
hammer onr ivets for a
slightly
cr acked noise
Any
of
these
noises mean
r equir ement
for
r eplace
ment as a
completeassembly
Release
bear ing
and sleeve
Check
for abnor mal wear oncon
tact sur face
ofwithdr awal
lever ball
pin
and
bear ing
sleeve
DESCRIPTION
CLUTCH
PEDAL
Removal
and installation
I
nspection
and
adjustment
CLUTCH MASTER CYLINDER
Removal
and
installation
Disassembly
and
assembly
DESCRIPTION
The
hydr aulic
clutch contr ol con
sists
ofa
pendent
pedal
a
master
cylinder
an
oper ating cylinder
and a
withdr awal
lever
When
the clutch
pedal
is
depr essed
the
piston
ofthe master
cylinder
CLUTCH
Pilot
bushing
Check
pilot bushing
in cr ankshaft
for wear
or
r oughness
If
necessar y
r eplace
it
CLUTCH CONTROL
CONTENTS
When
bushing
is
faulty
be
sur e
to
check
tr ansmission main
dr ive
gear at
the same
time
CL 5
CL
6
CL
6
CL 6
CL 7
CL 7
CL 7
Inspection
OPERATING
CYLINDER
Removal
and
installation
Disassembly
and
assembly
Inspection
BLEEDING
CLUTCH SYSTEM
CL
B
CL
B
CL
B
CL
B
CL B
CL B
for war ds clutch fluid
tothe
oper ating
cylinder
via
a
pipe
line
The movement
ofthe
oper ating cylinder piston
is
tr ansmitted tothe
withdr awal lever
thr ough
the
push
r od
thus
disengaging
the clutch
The
oper ating cylinder
is a non
adjustable
type
that uses
no
r etur n
spr ing
Inthis
unit
the
withdr awal to
push
r od
play
adjustment
is not neces
sar y
since the 8 as shown
in
Figur e
CL
15ser ves
to
automatically
compen
sate
for
wear
onthe
clutch disc
2
I
l
1 Clu
tch
pedal
6 Pushr od
2 Retur n
spr ing
7
Withdr awal
lever
3
Clutch master
cylinder
8
Release
bear ing
4Clutch
piping
9 Clutch
cover
5
Oper ating
cylinder
10 Clutch
disc
CL
5
5
Cl3 05
Fig
CL
14
Clutch
oper ating
system
Str oke
3 0 mm
Jt iI
118
in
Sj
1
iJ
o
Fig
CL 15 Non
adj
table
oper ating
cylinder
CLUTCH
PEDAL
Removal
and
installation
Removal See
Figur e
CL 16
1
Pr y
offcotter
pin
and take out
clevis
pin
disconnect
push
r od fr om
pedal
assembly
2 Unhook
r etur n
spr ing
Loosenoff
fulcr um
pin
and
r emove
pedal
as
sembly
CfJ
W5
6
3
ch
fD
ij
ll
iA
1 aevis
pin
2 Cotter
pin
3 Retur n
spr ing
4Pedal boss
S Pedal
assembly
6 Bush
7
Nut
8 Push r od
9
Fulcr um
pin
Fig
CL
16
Exploded
view
of
clutch
pedal
Note Befor e
r emoving
clutch
pedal
note toe boar d
clear ance at
pedal
pad
Installation
To
install
r ever se the
or der of
r emoval
Apply
multi
pur pose gr ease
to
the fr iction sur faces of
the disas
sembled
par ts
as
shown in
Figur e
CL 17
Tightening
tor que
Pedal
installation bolt
Fulcr umpin
1
9to24
kg
m
14
to17 ft Ib
Lock
nuts A and B
08to12
kg
m
58to87 ft lb
CLtJTCH
Note Refer
to
Figur e
Clot8for the
cor r ect dir ection of
r etur n
spr ing
1
Pedal
assembly
2 Pushr od
3 Retur n
spr ing
eL116
Fig
CL
1B
Hooking r etur n
pr ing
Inspection
and
adjustment
Clean all the
following par ts
in
cleaning
solvent and check for wear
damage
or
any
other abnor mal condi
tion
Replace
the
par ts
which ar e
faulty
1
Retur n
spr ing
2 Bush
3 Pedal boss
etc
CL
6
1
Lock
nut
A
2 Lock
nut
8
Pedal
beiBht
a
53
mm
6
02in
Pedal
full
str oke
b 117 10 23 46
104
84in
@
Multi
pur posegr ease
CL102
Fig
CL
17 Adju ting pedal height
1
Adjust
the
pedal height
to153
mm 6 02in
by
adjusting pedal stop
per
and
tighten
lock nut
A
tothe
specified
tor que
08 to
12
kg m
5 8
to87ft lb
2
Tur n
in
or out
push
r od
adjusting
scr ew until a
play
ofI to3 mm 0
03 9
to
0
118 in at clevis
pin
is
obtained
Then
tighten
lock nut B
to
the
specified
tor que
08 to
12
kg
m
5
8
to87ft Ib
Note Exer cise
car e in
adjusting
the
play
not toblock
the
por t
or
master
cylinder
A blocked
por t
may
r esult iftoosmall
play
at
clevis
pin
exists
3 After
adjusting
check
the
pedal
full str oke
is
in 117
to123 mm
4
61
to484
in
Note
Depr ess
and r elease clutch
pedal
over its entir e str oke
to
en
sur e that the clutch
linkage op
er ates
smoothly
without
squeak
noise inter fer enceand
binding
CLUTCH
CYLINDER
MASTER
Removal and
installation
Removal
I
Remove clcvis
pin
at
push
r od
2
Disconnect
clutch
tube fr om
master
cylinder
and dr ainclutchfluid
3
Remove bolts
secur ing
master
Disassembly
and
assembly
CLUTCH
cylinder
tothe vehicle
and dismount
master
cylinder
Note Remove dust
cover fr ommaster
cylinder body
on the
sideofdr iv
er
s
seat
Installation
To
install
r ever se the or der of
r emoval
Closely
obser ve the
following
instr uctions
1
Adjust
pedal
height
by
changing
pedal
stopper
length
Disassembly
1
Remove
dust
cover
and
r emove
stopper r ing
fr om
body
2
Remove
push
r od
and
piston
as
sembly
3
Take off
piston
cups
4
Remove
spiing
seat
fr om
piston
and take off
supply
valve if
necessar y
See
Figur e
CL
19
Note Discar d
piston cupsupply
valve and
spr ing
seat
after r emoval
Assembly
To
assemble r ever se the or der of
disassembly
Closely
obser ve the fol
lowing
instr uctions
I
Dippiston cup
in br ake fluid
befor e
installing
Make
sur e
that it is
cor r ectly
faced in
position
2
Apply
a
coating
of
br ake fluidto
cylinder
and
piston
when
assembling
3 Pr ess
piston
into
spr ing
seat when
assembling
CL
7
2
Bleed
air
out
of
hydr aulic
system
Tightening tor que
Master
cylinder
to
dash
panel
0
8
to12
kg
m
5 8to87ft
lb
Clutchtube
connector Flar e nut
15
to18
kg
m
II
to13 ft
lb
3
Using
Flar e
Nut
Tor que
Wr ench
GG943 10000
tighten
each
connector
to
the
specified
tor que
1 Reser voir
cap
2 Reser voir
3 Reser voir band
4
Cylinder body
5
Supply
valve
stopper
6 Retur n
spr ing
7
Spr ing
seat
8 Valve spr ing
9
Supply
valve r od
10
Supply
valve
11
Pr imar y cup
12 Piston
13
Pushr od
14
Secondar y
cup
15
Stopper
16
Stopper
r ing
17 DU5t cover
18 Locknut
CL265
Fig
CL 19
Exploded
view
ofmaater cylinder
Note
The
clutch master
cylinder
is
available inbothNABCO make and
TOKICO make Ther e is no
inter
changeability
of
r epair
kitsor
com
ponent par ts
between
NABCO
and
TOKlCO
makes
When
r eplacing
the
r epair
kit
or
component par ts
ascer tain the
br and
of
the clutchIIIBSter
cylinder
body
Be sur e touse
par ts
ofthe
same make as the for mer
ones
Inspection
Note Toclean or wash all
par ts
of
master
cylinder
oper ating cylinder
and
piping
clean br ake fluid must
be
used Never use miner a10ilsllUch
as
gasoline
and ker osene
It
will
r uin
the r ubber
par ts
ofthe
hydr au
lic
system
I
Check cylinder
and
piston
for
uneven
wear or
damage
and ifneces
sar y r eplace
2
Ifthe clear ance between
cylinder
and
piston
is
mor e
than
015 mm
00059
in
r eplace
cylinder
3
Renew
piston cup
when
dis
assembled It must alsobe
r eplaced
when wear or defor mation due to
fatigue
or
damage
is
found
4
Damaged
dust
cover oil r eser voir
or
cap
should be
r eplaced
Retur n
spr ing
and valve
spr ing
must
alsobe
r eplaced
when
they
ar e br oken
or weak
5
Replace
clutch hose and tube if
any
abnor mal
sign
of
damage
or de
fr o
ti
nisfound
OPERATING
CYLINDER
Removal and
installation
Removal
1
Detach clutch hose
fr om
oper at
ing cylinder
2
Remove twobolts
secur ing op
er ating cylinder
toclutch
housing
Installation
Install
in the r ever se
or der ofr e
moval
Obser ve the
following
instr uctions
Bleed air
thor oughly
fr om clutch
hydr aulicsystem
2
Donot
install
r etur n
spr ing
or
clutch will
not be
disengaged
pr oper ly
Tightening tor que
Oper ating
cylinder secur ing
bolt
25to35
kg
m
18
to25ft lb
Bleeder scr ew
07to09
kg m
5
1
to65ft Ib
Clutchhose connector
17
to
20
kg
m 12to14
ft
b
CLUTCH
Disassembly
and
assembly
Disassembly
1 Remove
push
r od with dust
cover
2 Remove
piston assembly
and
pis
ton
spr ing
3 Remove
bleeder scr ew
1
6
Cl11B
5
Piston
cup
6
Oper ating cylinder
7 Bleeder scr ew
1
Push
r od
2 Dust cover
3 Piston
spr ing
4
Piston
Fig
CL 20
Exploded
view
of
oper ating cyUnder
Assembly
Assemble in the
r ever se or der
of
disassembly Closely
obser ve the fol
lowing
instr uctions
1
Pr ior to
assembly
dip
piston cup
in
clean br akefluid
When
installing
cuppay par ticular
attention toits dir ection
2
Dipcylinder
and
piston
in clean
br akefluid befor e
assembly
Notes
a
Be
sur e
toinstall
piston assembly
with
pistonspr ing
in
place
b The clutch
oper ating
cylinder
is
available inboth
NABCO make and
TOKICO make Ther e
is nointer
changeability
of
r epair
kitsor com
ponent par ts
between
NABCO and
TOKICO makes
When
r eplacing
the
r epair
kit
or
component par ts
ascer tain the
br and ofthe clutch
oper ating cyl
inder
bndy
Be
sur etouse
par ts
of
the
same
make
as
the for mer ones
Inspection
Visually
inspect
all
disassembled
par ts
r eplacing
those found
wor nor
r l
Q
damaged
too
badly
beyond
speci
fications
BLEEDING
CLUTCH
SYSTEM
The
hydr aulic
clutch
system
must
be bled whenever clutch
linehas been
disconnected or
air
has
enter ed it
When
pedal
action has a
spongy
feeling
it is an indication that
air has
enter ed the system
Bleeding
clutch
system
is
an
es
sential
par t
of
r egular
clutch ser vice
I
Remove
r eser voir
cap
and
topup
with
r ecommended br ake
fluid
2
Thor oughly
clean mud and dust
fr om bleeder
scr ew of
oper ating cyl
inder so
that outlet hole
is
fr ee fr om
any for eign
r nater ial Install bleeder
hose
vinyl
hose onbleeder
scr ew
Place the other
end ofit in
a
clean
container
3 Have a cowor ker
depr ess
clutch
pedal
two
or
thr ee
times With clutch
pedal depr essed
fully
loosen bleeder
scr ew tobleed air out
ofclutch
sys
ter n
4Close bleeder
scr ew
quickly
as
clutch
pedal
is
ondown
str oke
5
Allow clutch
pedal
tor etur n
slowly
withbleeder scr ew closed
6
Repeat steps
4and
5 until
no
air
bubble shows
in
the
vinyl
hose
7
Oper ate
clutch sever al times
then check
connections for exter nal
hydr aulic
leaks
Notes
a Br ake fluid
containing
air is white
and has visibleair
bubbles
b Br ake fluid
containing
noair r uns
out ofbleeder scr ew in a
solid
str eamwithout air
bubble
c
Pay
close attention toclutch
fluid
level in
r eser voir
dur ing
bleeding
oper ation
d Do
not
r euse
br ake fluid dr ained
dur ing bleeding oper ation
e
Exer cise car e not to
splash
br ake
fluid
on
exter ior fInish as it
will
damage
the
paint
fPour
br ake fluid intor eser voir
up
to
specifIed
level
CLUTCH
SERVICE
DATA AND
SPECIFICATIONS
Clutch
cover
Clu
tch
cover
type
Diaphr agm
spr ing
to
flywheel
distance
Unevenness
of
diaphr agmspr ing
toe
height
Full load
Out offlatness of
pr essur e plate
Allowable
r efacing
limit of
pr essur e plate
Clutchdisc
Facing
size
Outer dia xinsidedia xthickness
Thicknessofdisc
assembly
Fr ee
Compr essed
Number oftor sion
spr ings
Allowableminimum
depth
of
r ivet
head fr omsur face
Allowable
facing
r un out
Allowablefr ee
play
of
spline
at theouter
edge
ofdisc
Clutch
pedal
Pedal
height
Play
at
clevis
pin
Full
str oke
Clutchmaster
cylinder
Dia ofmaster
cylinder
Allowablemaximumclear ance
between
cylinder
and
piston
Clutch
oper ating cylinder
Dia of
oper ating cylinder
Tightening tor que
Clutch
assembly
to
flywheel
secur ing
bolt
Pedal
installation bolt Fulcr um
pin
Pedal
stopper
lock nut
Push
r od
lock
nut
Master
cylinder
todash
panel secur ing
bolt
Clutch
tube connector Flar e nut
Clutch
hose connector
Oper ating cylinder
to
clutch
housing secur ing
bolt
Bleeder scr ew
mm
in
mm in
kg
Qb
mm
in
mm
in
Diaphr agm
C225S
3 3
to3 5
123
to
13 8
less than0
5
0020
400
882
0 1
0004
1
0 0040
mm
in 225 x
150
x 3 5 8
86
x
5
91 x 0
13 8
mm
in
mm
in
8
3 to
89
03 27 to0
3 50
7
6 to8
0 0299
to03 15
6
03 0012
05
0020
040016
mm in
mm
in
mm
in
mmin
153 6 02
mm in I
to
3
0
03 9
to0 118
mm
in 117
to123
4
61 to484
mm
in
15
87 5 8
mm
in
0
15
00059
mm
in
19
05
Yo
kg
m
ft lb 1
5 to
2
2
lito
16
kg
m ft
Ib
19to
24
14
to17
kg
m ft b 0
8to
12 5
8to87
kg
m
ft lb
08
to
12 5 8
to87
kg
m ftIb 08to12 5 8to8
7
kg
m ft lb
1
5 to
1
8 11 to
13
kg
m
ftlb
17to20 12to14
kg
m ft
lb
25
to35 18to25
kg
m
ft Ib
07to
09 5 1
to6
5
CL
9
CLUTCH
TROUBLE DIAGNOSES
AND CORRECTIONS
Condition
Pr obable cause
and
testing
Clutch
slips
Cor r ective action
Slipping
of
the
clutch
may
be
noticeable when
any
ofthe
following symptoms
is
encounter ed
dur ing oper ation
I Vehiclewill
not
r espond
to
engine
speed dur ing
acceler ation
2 Insufficient vehicle
speed
3 Lackof
power dur ing
uphill dr iving
Some of
the
above conditions ar e
also
exper ienced
when
engine
pr oblem
is
oc
ur r ing
Fir st
detennine whether
engine
or clutch is
causing
the
pr oblem
If
slipping
clutch
is
left unheeded wear and or
over heating
willoccur onclutch
facing
until
it is
no
longer
ser viceable
TO TEST FORSLIPPINGCLlJfCH
pr oceed
as follows
Dur ing upgr ade tr avelling
r un
engine
at
about 40 to
50 km
h 25
to3 1
MPH with
gear
shift
lever
in
3 r d
speed
position
shift
into
highest gear
and at thesame
time
r ev
up
engine
Ifclutch
is
slipping
vehiclewillnot
r eadily
r espond
to
depr ession
ofacceler ator
pedal
Clutch
facing
wor n
excessively
Oil or
gr ease
onclutch
facing
W
r dclut h cov
r
pr essur e plat
Replace
Replace
tpa
oe lace
Dr agging
clutch
is
par ticular ly
noticeable when
shifting gear s especially
into
low
gear
TO TEST FORDRAGGINGCLlJfCH
pr oceed
as follows
I
Star t
engine Disengage
clutch Shift into
r ever se
gear
and then intoNeutr al
Gr adually
incr ease
engine speed
and
again
shift intor ever se
gear
Ifclutchis
dr agging gear gr ating
is
hear d when
shifting
fr omNeutr al
into
Rever se
Clutch
dr ags
2
Stopengine
and shift
gear
Conduct thistest at each
gear position
3
Gear s
ar e smoothly
shifted in
step
2 but
dr ag
when
shifting
to1st
speed
position
at
idling
a
If
dr agging
is encounter ed at the end of
shifting
check condition of
synchr o
mechanismintr ansmission
b
If
dr agging
is encounter ed at the
beginning
of
shifting pr oceed
to
step
4
below
4Push
change
lever towar d Rever se side
depr ess pedal
tocheckfor fr ee tr avel
a
If
pedal
can be
depr essed
fur ther check clutchcondition
b
If
pedal
cannot
be
depr essed
fur ther
pr oceed
to
step
5 below
5 Checkclutch contr ol
pedal height pedal
fr ee tr avel withdr awal lever
play
etc
Ifno
abnonnal
condition
exists and if
pedal
cannot
be
depr essed
fur ther check clutch
condition
Clutchdiscr unout or
war ped
Wear
or
r ust
on
hub
splines
inclutchdisc
Diaphr agm spr ing
toe
height
out ofad
justment
or toe
tip
wor n
Wor n
or
impr oper ly
installed
par ts
CL10
Repair
or
r eplace
Clean and lubr icatewith
gr ease
or
r eplace
Adjust
or
r eplace
Repair
or
r eplace
Condition
Clutchchatter s
Noisy
clutch
Clutch
gr abs
CLUTCH
Pr obable cause
and
testing
Cor r ective
action
Clutch
chatter ing
is
usually
noticeable when
vchicle
is
just
r olled offwith
clutch
par tially
engaged
Weak or br oken
clutch disctor sion
spr ing
Oil or
gr ease
onclutch facing
Clutch
facing
out of
pr oper
contact or
clutch
disc
r unout
Loose
r ivets
War ped
pr essur e
plate
or clutch cover
sur face
Unevenness
of
diaphr agm spr ing
toe
height
Loose
engine
mounting
or deter ior ated
r ubber
Anoise is hear d after
clutchis
disengaged
Damaged
r elease
bear ing
Anoise
is
hear d when
clutchis
disengaged
Insufficient
gr ease
on
the
sliding
sur face
of
bear ing
sleeve
Clutch
cover and
bear ing
ar e not
installed
cor r ectly
Replace
Replace
Replace
Replace
Repair
or
r eplace
Adjust
or r eplace
Retighten
or
r eplace
I
Replace
Apply
gr ease
Adjust
A
noiseishear d when
vehicle is
suddei11y
staited
offwithclutch
par tially engaged
Damaged
pilot bushing
I
Replace
When
gr abbing
ofclutch occur s vehicle
will not star t
off
smoothly
fr om
a
standing
star t or
clutch is
engaged
befor eclutch
pedal
is
fully
depr essed
Oil or
gr ease
onclutch
facing
Clutch
facing
wor nor loose
r ivets
Wear or
r ust on
splines
in
dr ive
shaft and
clutchdisc
War ped flywheel
or
pr essur e
plate
Loose mountings
for
engine
or
power
tr ainunits
CLll
Replace
Replace
Clean
or
r eplace
Repair
or
r eplace
Retighten
Cl Ul
CFf
SPECIAL SERVICE TOOLS
Tool number
For
Refer ence
No
Descr iption
use page
or
tool name
on
Figur e
No
Unit mm
in
ST20050010
620
Fig
CL
12
Base
plate
00
B210
710
610
y
S3 0
2 ST20050051
Set bolt
SE002
q
3 ST20050100
Distance
@
piece
78mm
03 1
in
@1
@J
SEOQ3
4ST20050240
620
Fig
CL 13
Diaphr agm
B210
adjusting
710
wr ench
610
S3 0
SE03 2
5 KV3 0100200
Clutch
aligning
bar
This
tool
is
used
to
conduct disc
center il
g
by
inser ting
thetool
into
pilot
bush
in
flywheel
when
installing
clutch
assembly
to
flywheel
620
710
610
S3 0
Fig
CL 2
Fig
CL 3
SEaOl
6 STl6610001
Pilot
bushing
puller
Fig
CL 6 620
710
610
S3 0
SE191
CL 12
No
Tool number
tool name
7 GG943 10000
Flar enut
tor que
wr ench
CLUTCH
Descr iption
Unit
mm
in
This
tool
is used to
tighten
and loosenbr ake and
clutchtube flar e
nut
A
built
in
tor que
limiting
wr ench is
pr ovided
to
assur e
tor que
accur acy
y
SE227
CL
13
For
use
on
All
models
Refer ence
page
or
Figur e
No
Page
CL 7
DATSUN
PICK
UP
MODEL
620
SERIES
I
NIS
J
NISSAN MOTOR CO
LTD
TOKYO JAPAN
SECTION MT
MANUAL
TRANSMISSION
4SPEEo
TRANSMISSION
MT 2
TYPE
F4W71
B
5 SPEED
TRANSMISSION
MT 14
TYPE
FS5W71
B
SERVICE
DATA AND
MT 21
SPECIFICATIONS
TROUBLE DIAGNOSES
AND
MT 23
toRRECTloNS
SPECIAL SERVICE
TOOLS
MT
24
Manual
Tr ansmission
4SPEED
TRANSMISSION TYPE
F4W71B
CONTENTS
DESCRIPTION
REMOVAL
DISASSEMBL
Y
TRANSMISSION CASE
DISASSEMBLY
D
ISASSEMBLY OF GEAR
ASSEMBLY
REAR
EXTENSION
DISASSEMBLY
ADAPTER
PLATE
DISASSEMBLY
INSPECTION
TRANSMISSION
CASE
AND
REAR
EXTENSION
HOUSING
BEARING
GEARS AND SHAFTS
BAULK RING
Oil
SEAL
ASSEMBL
Y
FRONT
COVER ASSEMBLY
REAR
EXTENSION ASSEMBLY
ADAPTER
PLATE
ASSEMBLY
GEAR
ASSEMBLY
TRANSMISSION
ASSEMBLY
INSTALLATION
MT 2
MT 4
MT 4
MT 4
MT 5
MT B
MT 8
MT
8
MT B
MT 8
MT 8
MT 9
MT
9
MT 9
MT 9
MT 9
MT 9
MT 9
MT13
MT14
DESCRIPTION
pUshed
the
inner
teethof
the
coupling
sleeve slide over the
synchr onizer
hub
and mesh
with
the outer teeth
which
ar e
pr ovided
onthe mainshaft
gear
The
synchr onizer
hub is fitted to
the mainshaft
by
splines
sothe
main
shaft
gear tur ns together
with the
mainshaft
The baulk
r ing
ser ves to
synchr o
nile
the
coupling
sleeve and mainshaft
gear
Placing
the contr ol lever inr ever se
position br ings
the r ever se idler
gear
into
mesh withmainshaft r ever se
gear
The tr ansmission is ofa 4
speed
for war d
fully
synchr onized
constant
mesh
type
that
useshelical
gear s
The
r ever se
gear
is ofa
sliding
mesh
type using
spur gear s
Inconstr uction the
maindr ive
gear
is meshed withthe
counter
dr ive
gear
which is
keyed
to
the counter shaft
The for war d
speed
gear s
on
the
coun
ter shaft
ar e
in
constant mesh withthe
mainshaft
gear s
which r ide on the
mainshaft
fr eely thr ough
the needle
bear ing
When
shifting
is
accom
The
tr ansmission
assembly
consists
ofthr ee main
par ts
a
tr ansmission
case withclutch
housing
adapter plate
towhich an
gear s
and shafts ar e
installed and r ear
extension
The cast
ir on
adapter plate
suppor ts
the
mainshaft counter shaft
r ever se
idler shaft and thr ee for k r ods and
bolted
at the
fr ont
to
the
tr ansmission
case and at the r ear tothe r ear
extension
by
means of
thr ough
bolts
By r emoving
these
thr ough bolts
all
gear s
and shaftsar e
str ipped
e
TM
858
1
Fr ont cover
2 Tr ansmission case
3
Adapter plate
4
Bear ing
r etainer
5
Rear extension
hOUsing
Fig
MT 1 F4W71Blr ammiasion case
compon
nt
MT 2
Manual Tr ansmission
o
cCl
4
@
@
fl
t
o
@
Fig
MT 3
MT 3
TM857
1 Main
dr ive gear
2 Baulk
r ing
3
d 4th
3
Synchr onizer
hub
r
4
Shifting
inser t
spnng
5 Shifting
inser t
6 Coupling
sleeve
7 3 r d main
gear
8
Mainshaft
9
2nd
main
gear
10 1st main
gear
11 ht
gear spacer
12
Rever se main
gear
13 Counter
dr ive
gear
14Counter shaft
15 Rever se counter
gear
16
Rever se idler shaft
17
Rever se idler
gear
Fig
MT 2
n ear
component
F4W71Btr ansmlsBIO
g
@
f1f@
n
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Str iking
lever
Lock
pin
O
r ing
Str iking guide
Oil
sea1
Str iking
r od
E r ing
Stopper guide pm
Retur n
spr ing
plunger
Retur n
spr ing
Rever se
check
spnng
Retur n
spr ing
plug
Check
ball
plug
Check
spr ing
Check
baD
Inter lockball
Retaining pin
k
1st 2nd shift or
ht
2nd
for k r od
3 r d 4th
for k r od
Rever se
for k
r od
3 r d
4thshift
for k
Rever se shift for k
Contr ollever
Contr ol
lever b
shmg
Contr ol
lever
p
n
Contr ol
lever
bushmg
TM045A
I
ponents shift
contr ocom
F4W71
B
tr ansmuswn
REMOVAL
In
dismounting
tr ansmission
fr om
the vehicle
pr oceed
as follows
I Disconnect batter y gr ound
cable
fr omter minal
2
Place
tr ansmission contr ol lever
in
neutIal
position
3
Remove
E
r ing
and
contr ol lever
pin
fr om tr ansmission
str iking
r od
guide
and r emove contr ol
lever See
Figur e
MT 4
TM3 3 5
Fig
MT
4Remouing
contr ollelJ
r
4Jack
up
the vehicle and
suppor t
its
weight
on
safety
stands Use a
hydr aulic
hoist or
open
pit
ifavail
able
Confir m
that
safety
is insur ed
5 Disconnect
exhaust fr ont tube
6 Disconnect
wir es fr om r ever se
lamp
switch See Figur e
MT 5
7 Disconnect
speedometer
cable
fr om r ear extension
housing
See
Figur e
MT 5
8 Remove clutch
oper ating cylinder
fr om tr ansmission case See
Figur e
MT5
O
m
J
@
1
Speedometer
cable
2 Rever se
lamp
switch
3 Outch
oper ating cylinder
TM774
Fig
MT 5 Bottomviewofcar
Manual
Tr ansmission
9 Remove br acket
holding
center
bear ing
on 3 r d
cr ossmember
by
loosening
off
attaching
bolts See
Figur e
MT 6
PD219
Fig
MT
6 Removing
center balr ing
holding
br ucket
10 Uetach
pr opeller
shaft fr om
companion flange
of
gear
car r ier
by
r emoving
four
bolts
See
Figur e
MT
7
Not
aRemove
pr opeller
shaft
car efully
so
as
not to
damage
spline
sleeve
yoke
and r ear oil seal
b
Plug
up
the
opening
in
the
r ear
of
r ear exteDSion
housing
to
pr event
oil fr om
flowing
out
P0220
Fig
MT 7
Remouing four
bolt
6ecur ing
pr op
ller
shtJft to
companion
ltJnge
11
Suppor t
engine
by locating
a
jacft
under
oil
pan
with a
wooden
block
used between oil
pan
and
jack
12
Suppor t
tr ansmission with
a
tr ansmissionjack
13 Remove exhaust
pipe
btacket
by
unscr ewing attaching
bolts 2
Califor nia models
only
See
Figur e
MT 8
14Remove r ear
engine mounting
insulator
secur ing
bolts I and r ear
mounting
member
secur ing
bolts 3
See
Figur e
MT 8
MT 4
E A277
Fig
MT 8
Removing
engine mounting
r ear
suppor t
15
Remove
star ter motor
16 Remove
bolt
secur ing
tr ansmis
sion
to
engine
After
r emoving
these
bolts
suppor t
the
engine
and tr ansmission with
jacks
and then slide tr a
ion r ear war d
away
fr om
engine
and r emove fr om
the vehicle
Note Take car e in
dismounting
tr ona
mission not tostr ike
any adjacent
par ts
and main dr ive
shaft
DISASSEMBLY
TRANSMISSION CASE
DISASSEMBLY
I Pr ior to
disassembling
tr ansmis
sion
thor oughly wipe
offdir t and
gr ease
fr om
it
2
Dr ain
oil
thor oughly
3 Remove
dust cover fr om tr ans
mission case
Remove
r elease
bear ing
and with
dr awallever
4
Remove
r ever se
lamp
switch
5 Move
gear
toNeutr al
6 Remove speedometer pinion
and
pinion
sleeve
by
taking
off
lock
plate
7 Remove
E
r ing
and
stopper
guide
pin
fr om r ear end of
r e ll
extension
See
Figur e
MT
9
TM3 3 7
Fig
MT 9
Removing tr iking
r od
E
r ing
and
topper pin
8
Remove r etur n
spr ing
plug
r etur n
spr ing
r ever secheck
spr ing
and
plung
er fr om r ear
extension
See
Figur e
MT 10
TM3 3 8
Fig
MT
10 Removing
r etur nspr ing
plull
9
Remove r ear
extension
secur ing
boltsand tur n
the
str iking
r od towar d
left
Dr ive out r ear extension
backwar d
by
lightly
tapping
ar ound it witha soft
hammer See
Figur e
MT
11
TM3 3 9
Fig
MT
11
Removing
r ear extension
10
Remove
fr ont cover
secur ing
bolts and r emove fr ont cover
Detach counter shaft
fr ont
bear ing
shim
II
Remove main
dr ive
bear ing snap
r ing
with
Expander
See
Figur e
MT 12
j
12
Separ ate
tr ansmission case
fr om
adapter plate
witha soft
hammer See
Figur e
MT 13
Manual Tr ansmission
qJiiiiiI
TM3 41
Fig
MT 13
Removing
tr ammission
case
13 Set
upSetting
Plate
Adapter
ST23 81000
I
on
adapter plate
Withcounter shaft side
upplace
the
above
assembly
in a vise
See
Figur e
MT
14
TM3 42
Fig
MT 14
Attaching l
or
mbly
to
special
tool
DISASSEMBLY OF GEAR
ASSEMBLY
For k r od
Dr ive out
r etaining pins
fr om
each for k r od with
For k
Rod Pin
Punch ST23 540000 See
Figur e
MT 15
S
ST23 540000
TM3 43
Fig
MT 15 Dr ive
out
r etaining
pim
2 Removethr ee 3 checkball
piugs
and dr ive out for k r ods fr om
adapter
pia
te
by lightly tapping
on the
fr ont
end
Be
car eful
not
tolose thr ee
3
check
balls and
four
4
inter lock balls
See
Figur e
MT 16
Note
Each
gear
and shaft can be
detached
fr om
adapter plate
with
out
r emoving
each for kr od
MT 5
For k r od
ht 2nd
Inter lock
ball
TM3 44
Fig
MT 16
Layout
och ck boll
and inter lock ball
Gear
assembly
I
With
gear s doubly engaged
dr aw
out
counter shaft fr ont
bear ing using
a
suitable
gear puller
See
Figur e
MT 17
2 Remove counter dr ive
gear
snap
r ing
3 Dr aw
out
counter dr ive
gear
com
plete
withmain
dr ive
gear
assembly by
means
ofa
gear puller
When
dr awing
out main dr ive
gear
assembly
be
car eful not
to
dr op
pilot
needle
bear ing
ontofloor fr om the
fr ont
end
ofmainshaft See
Figur e
MT 18
TM3 98
Fig
MT 17
Removing
counter shaft
fr ont
b
ar ing
TM3 45
Fig
MT 18
Removing
count
r dr ive
gear
and main dr ive
gear
4Remove
snap
r ing
and then thr ust
washer fr ommainshaft
fr ont end
Dr aw
out
3 r d
4th
synchr onizer
assembly
and r emove
3 r d
gear
as
sembly
5 Release
caulking
on mainshaft
nut and
loosen
it
See
Figur e
MT
19
TM3 46
Fig
MT 19
Removing
maimhaft
nut
6
Remove
mainshaft nut thr ust
washer and mainshaft r ever se
gear
7
Remove
snapr ing
fr om counter
shaft
r ear end
and r emove
r ever se
idler
gear
8 Dr aw out mainshaft
gear
as
Manual Tr ansmission
sembly together
with counter shaft
by
lightly tapping
the
r ear
end with
a
soft
hammer while
holding
the fr ont of
mainshaft
gear
assembly by
hand
Be
car eful not to
dr op
off
gear
shaft See
Figur e
MT 20
IJ
t
I
TM3 47
Fig
MT
20
Dr iving
out
gear
Cl
embly
Mainshaft
assembly
1 Remove thr ust washer steel ball
I
st
gear
and needle
bear ing
Be
car eful
not tolose steel ball
r etaining
thr ust
washer
12
2 Pr ess out Ist
gear
mainshaft bush
ing
together
with 2nd
gear
and
1 st
2nd
speed synchr onizer using Bear ing
Puller STJ003 1000 See
Figur e
MT 2l
Note When
r
out
bushing
hold
h
ft
by
hand
so
as not to
dr op
it
H
S1 3 003 1000
TM049A
Fig
MT 21 R
moving
lIt
gear
mtUlIIhaft
bu
hing
1
Pilot
bear ing
2 3 r d
4th
synchr onizer
assembly
3 Baulk
r ing
43 r d main
gear
5 Needle
bear ing
6 Mainshaft
7
Needle
bear ing
8
2nd main
gear
9 1st
2nd
synchr oni
r
assembly
to
Coupling
sleeve
II
Shifting
inser t
12
Shifting
inser t spr ing
13
Synchr onizer
hub
141st main
gear
15 Needle
bear ing
16
1st
gear
bushing
17 Thr ust
weher
18
Maimhaft
bear ing
19 ReftllSe main
gear
20 Thr ust washer
21 Nut
22 Steel ball
23 Thr ust washer
24
Snapr ing
TM3 48
Fig
MT
22
Explod
d view
of
main haft
mbly
MT 6
Manual Tr ansmission
M in dr lv g
r
1 Remove
main dr ive
gear snapr ing
and
spacer
2
Remove
main dr ive
bear ing
with
Bear ing
Puller
ST3 003 1000 and
a
suit
able
piess
See
Figur e
MT
23
TM3 49
Fig
MT 23
1
Main
dr ivebear ing
2 Main
dr ive
gear
Removing
maindr ive
bear ing
cl iiiiiE
l
1
Snapr ing
2
Spacer
3 Main
dr ive bear ing
with
snapr ing
4Maindr ive
gear
TM3 50
Fig
MT 24
Exploded
view
of
maindr ive
gear
eq 1
f
1 Counter shaft
fr ont
bear ing
shim
2 Countenhaft fr ont
bear ing
3
Snapr ing
4Countenhaft dr ive
gear
5
Woodr uffkey
6 Countenhaft
1
Counter shaft
r ear
bear ing
8 Rever se counter
gear
9
Snap
r ing
Count
r
h ft
mbl
Install
Bear ing
Puller STJOO3 1000
on counter shaft r ear bear ing pr essout
counter shaft r ear
bear ing thr ough
a
r od
See
Figur e
MT 25
Note When
pr essing
out
bear ing
hold
shaft
by
hand soas not to
dr op
shaft ontofloor
III
TM3 51
Fig
MT
25
Removing
counter shaft
bear ing
@
@
j
i
TM3 52
Fig
MT 26
Exploded
view
of counte
haft auembly
MT 7
REAR
EXTENSION
DISASSEMBLY
Remove
lock
pin
fr om
str iking
lever and r emove
str iking
r od
Manual
Tr ansmission
Note 00
not
diSlssemble
r ear exten
sionbush fr om
r ear
extension
ADAPTER PLATE
DISASSEMBLY
I
Remove
six
6
bear ing
r etainer
attaching
scr ews with an
impact
wr ench and r emove
bear ing
r etainer
fr om
adapter plate
2
Remove r ever se idler shaft
3 Remove mainshaft
bear ing
fr om
the r ear extensionside
INSPECTION
Wash all
par ts
ina suitable
cleaning
solvent and check for wear
damage
or
other
faulty
conditions
Notes
a Be car eful
not to
damage any
par ts
with
scr aper
b
00
not
clean washor soak oil seals
insolvent
TRANSMISSION CASE
AND
REAR
EXTENSION HOUSING
I Clean with
solvent
thor oughly
and check for
cr acks
which
might
cause oil leak
or other
faulty
con
ditions
2
Check
mating
sur face ofthe
case
to
engine
or
adapter plate
for small
nicks
pr ojection
or sealant
e
1 Contr ol lever
2
Str iking r od
guide
3
Str iking
r od
4
Str iking
lever
5
Retur n
spr ing plug
6
Stopper
pin
TM3 53
Fig
MT
27
Exploded
view ofshifting
mechani6m
Remove all
nicks
pr ojection
or
sealant with
a
fr ne
stone
3
Ifr ear
extension
bush is
wor nor
cr acked
r eplace
it as an
assembly
of
bushand r ear extension
housing
BEARING
I
Thor oughly
clean
bear ing
and
dr y
witha
compr essed
air
2 When r ace and ball sur faces ar e
wor nor
r ough
or whenballs ar e out
of
r ound or
r ough
r eplacebear ihg
witha newone See
Figur e
MT 28
I
TM3 72
Fig
MT 28
l
pecting
ball
bear ing
3
Replace
needle
bear ing
if
wor nor
damaged
GEARS AND
SHAFTS
I
Check all
gear s
for excessive
wear
chips
or cr acks
r eplace
as
r equir ed
MT 8
2
Check shaft for
bending
cr ack
wear and wor n
spline
if
necessar y
r eplace
3 Measur e backiasii
in
gear s
Standar d
005
to0 10mm
00020to0003 9
in
Ifthe above limits ar e exceeded
r eplace
dr ive and dr iven
gear s
as
a
set
4Measur e
gear
end
play
1st
gear
03 2to03 9 mm
00126 to00154in
2nd
gear
012to
019
mm
00047
to00075
in
3 r d
gear
0 13 to03 7 mm
00051to
0
0146
in
TM3 74
Fig
MT
29
Measur ing
end
play
5
Check for
str ipped
or damaged
speedometer pinion gear
If
necessar y
r eplace
BAULK RI NG
I
Replace
baulk
r ing
iffound tobe
defor med
cr acked or other wise
dam
aged excessively
2 Place baulk
r ing
in
position
on
gear
cone
While
holding
baulk
r ing against
gear
as far as
it
will
go
measur e
gap
between baulk
r ing
and outer
gear
If
gap
is small discar d baulk
r ing
See
Figur e
MT 3 0
5lr 1
25
to
1
60
r om
0 0492 to
0
063 0
in
Baulk
r ing
TM3 75
Fig
MT 3 0Baulk
r ing
to
cone
gap
OIL
SEAL
Discar d
O
r ing
or oil seal
which is
once
r emoved
Replace
oil
seal if
sealing lip
is
defor med
or
cr acked
Alsodiscar d
oil
seal
if
spr ing
is
out
of
position
ASSEMBLY
Toassemble
r ever se
the
or der
of
disassembly
Obser ve
ihe
following
instr uctions
FRON1
COVER ASSEMBLY
I
Wipe
clean seal seat in fr ont
cover then
pr ess
fit oil seal in
place
Coat oil seal
with
gear
oil
to
pr ovide
initial
lubr ication
Fr ont
J
f
CJ
TM3 54
Fig
MT 3 1 Fr ont
cov
oil
eol
Manual Tr ansmission
2
Apply
sealant to
withdr awal
lever
ball
pin
scr ew Install withdr awal lever
ball
pin
tofr ont cover and
tighten
scr ew to16 to
21
kg
m
12
to
15
ft lb
tor que
REAR
EXTENSION
ASSEMBLY
1
Wipe
clean
seal seat
in
r ear exten
sion
housing
pr ess
fit oil seal in
place
Coat oil seal and
bushing
with
gear
oil for initial lubr ication
Fr ont
h
TM3 55
Fig
MT 3 2 Rear extemionoil seal
2
Apply gr ease
toO
r ing
and
plung
er
gr ooves
in
str iking
r od
Inser t
str iking
r od with
str iking
r od
guide thr ough
r ear
extension
3 Install
str iking
lever onfr ont end
of
str iking
r od Install lock
pin
and
tor que
scr ew to0
9 to
12
kg
m
7
to
9ft Ib
ADAPTER
PLATE ASSEMBLY
1 Place
dowel
pin
mainshaft bear
ing
and oil
gutter
on
adapter plate
and
tap
with a
soft hammer until
they
ar e
pr oper ly
positioned
in
place
Use a new
dowel
pin
Bend oil
gutter
on
fr ont side and
expand
on r ear
side See
Figur e
MT3 3
J
7
r
M3 56
Upper
Fr ont
Fig
MT 3 3
Oil
gutter
MT 9
2 Inser t r ever se idler shaft in
adapt
er
plate
Make sur e that
the
cut out
por tion
of
r ever se
idler
shaft is lined
up
with
inner face
of
adapter plate
3 Install
bear ing
r etainer in
adapter
plate
Align bear ing
r etainer
with r ever se
idler
shaft at the cut out
por tion
of
this
shaft
tor que
scr ews to
1
9
to
25
kg
m
14to
18 ft
lb
and stake each
scr ew
at two
poin
Is
with
a punch
See
Figur e
MT 3 4
TM400
Fig
MT 3 4Staking
SCNW
4 Install counter shaft r ear
bear ing
in
adapter plate
by lightly tapping
ar ound it
with
a soft hammer
GEAR ASSEMBLY
Clean all
par ts
in
solvent and
dr y
with
compr essed
air
Synchr onizer
888embly
Assemble
synchr onizer assembly
Position
shifting
inser t
spr ings
and
shifting
inser ts in thr ee 3 slots in
synchr onizer
hub
put coupling
sleeve
on
synchr onizer
hub
r
Fr ont
3 r d
4th 15t
2nd
TM3 51
Fig
MT
3 5
Installing synchr onizer
hub
Malnshaft
assembly
I
Assemble
2nd
gear needle
bear
ing
2nd
gear
baulk
r ing
1st 2nd
speed
synchr onizer assembly
st
gear
baulk
r ing
I st
gear
bush needle bear
ing
I
st
gear
steel ball and thr ust
washer onmainshaft Befor e
installing
a
steel ball
apply
gr ease
to
it See
Figur e
MT 3 6
TM3 58
Fig
MT
3 6
l
talling
thr ust washer
2
Set Tr ansmission Pr ess Stand
KV3 1100400 and
place adapter plate
assembly
on
it
See
Figur e
MT
3 7
For
counter manand r ever se idler shaft
For
main5haft and r ever se
tdler haft
V3 1100400
J
UJ
V
TM43 8
Holesfor r ever se Idler
shaft
Fig
MT
3 7 Tr omminion
Pr eS3 S tond
3 Install mainshaft
assembly
to
adapter plate
assembly
Be sur e to
place bear ing squar ely against
shaft
and
pr ess
it into
place
on
shaft
gr adu
ally
See
Figur e
MT
3 8
KV3 1100400
TM43 9
Fig
MT 3 8
Installing
mai
haft
em
bly
Manual
Tr ansmission
Counter shaft
assembly
I Place new woodr uff
keys
in
gr ooves
in
counter shaft and
tap
them
lightly
until
they
ar e seated
secur ely
Use a
soft
hammer to
avoid dam
aging keys
2
Place
adapter plate assembly
and
mainshaft
assembly so
that
counter
shaft r ear
bear ing
r ests on
Tr ansmis
sion
Pr ess Stand KV3 1100400
pr op
er ly
3 Install counter shaft
into
adapter
plate
by
pr essing
it See
Figur e
MT 3 9
TM440
Fig
MT 3 9
l talling counter sha t
4Position
3 r d
gear
needle
bear ing
fnaiiiSh ifOfd
gear
baulk
r ing
and 3 r d
4th
synchr onizer
assembly
on the
fr ont ofmainshaft
S Insiall thr ust washer
on
mainshaft
and e ur e it
with
snapr ing
of
pr oper
thickness that
will fit the
gr oove
in
mainshaft See
Figur e
MT 40
Available
snapr ing
No Thickness mm
in
I
2
3
14
0055
150059
16 0063
TM441
Fig
MT 40
l talling snapr ing
MT l0
Main dr ive
gear assembly
1
Using
Tr ansmission Adapter
ST23 800000
pr ess
main dr ive
bear ing
onto
the shaft of
main
dr ive
gear
Make sur e that
snapr ing gr oove
on
shaft clear s
bear ing
2
Place
main dr ive
bear ing spacer
on
main dr ive
bear ing
and
secur e
main
dr ive
bear ing
with thicker snap
r ing
that
will eliminate end
play
See
Figur e
MT 4l
Available
snapr ing
No Thickness
mm
in
2
3
4
5
6
180 00709
187 0073 6
1
94
00764
201
00791
208
00819
2 15
0
0846
CD
I
TM3 64
Fig MT 41 Installing snapr ing
3
Position baulk
r ing
on cone sur
face of
main
dr ive
gear
Apply
gear
oil
to
mainshaft
pilot
bear ing
and install it
onmainshaft
Assemble main dr ive
gear assembly
onthe
fr ont
end ofmainshafl
4
Pr ess counter dr ive
gear
onto
counter shaft
with Counter Gear Dr ift
ST23 860000
by
meshing
gear s
and
secur e counter dr ive
gear
with thicker
snapr ing
See
Figur es MT
42 and
MT 43
Note
Be
sur e todr ive in counter
dr ive
gear
and main dr ive
gear
simultaneously
ST23 860000
TM442
Fig
MT 42
l
talling
counte
haft
dr ive
gear
Available counter dr ive
gear
mapr ing
No Thickness mm
in
I
2
3
1
40
055
1
5 0
059
16 0063
II
TM3 66
Fig
MT 43
Installing napr ing
5 Pr ess
counter shaft fr ont
bear ing
onto counter shaft
with Dr ift C
ST223 60002
See
Figur e
MT
44
ST223 60002
KV3
II
00400
TM443
Fig
MT 44Installing
counte
haft
fr ont bear ing
Manual
Tr ansmission
6
Suppor t
adapter plate
in
a
vise
with
Setting
Plate
Adapter
ST23 810001 with
mainshaft
facing
down
7
Install
mainshaft r ever se
gear
plain
washer
on the r ear ofmainshaft
and installmainshaft nut
Tighten
mainshaft nut
tempor ar ily
8 Install
counter r ever se
gear
onthe
r ear
of
counter shaft and secur e with
map
r ing
Use
snapr ing
to
give
a minimum
gear
end
play
See
Figur e
MT 45
No Thickness mm in
I
2
3
1
40055
15 0059
1
6 0063
o
TM3 61
Fig
MT 45
Imtalling
counter r ever se
gear
nap
r ing
9 Install r ever se idler
gear
on r e
ver se idler shaft
10 With 1st
and 2nd
gear s
doubly
engaged
tighten
mainshaft nut tothe
conver ted
tor que
Cn See
Figur e
MT 48
using
Wr ench ST22520000
See
Figur e
MT
47
ST22520000
TM768
Fig
MT 46
Tightening
mainshaft nut
MTll
Explanation
of
conver ted
tor que
Mainshaft nut
should be
tightened
to14
to17
kg
m
101 to
123 ft lb
tor que
with
the aid
of
Wr ench
ST22520000 When doing so
the
amount of
tor que
tobe
r ead on
wr ench needle should be modified
accor ding
tothe
following
for mula
L
C
kg
m 14x to
L
O lO
L
17 x
L
010
or
L
C ft
lb
101
x
L 03 3
to
L
123 x
L 03 3
Wher e
C Value r ead onthe
tor que
wr ench
kg
m
ft lb
L Effective
length
of
tor que
wr ench
m ft
ST22520000
Tor que
wr ench
Lm ft
c
h
I
O IOm
03 3
ft
TM587
Fig
MT 47
Setting
wr ench
Example
When a 0
40
m 13 1
ft
long
tor
que
wr ench is used the Cn
in
Figur e
MT 48
will be 112to13 6
kg
m
81 to98 ft lb
I
Upper
limit line
I
r
6 1
f fdl
13
Conver ted
tor que
90
I
Lower
limit line
80
11
70
10
V
S
s
15
110
15
c
u
c
c
9
S
c
o
C
U
100
14
9
02 03
10
04
Manual
Tr ansmission
05
06
2
0
07 0 8
m
25 It 15
L
Effective
length
of
tor que
wr ench
Fig
MT 48
CO 1Ver t
d
tor que
11
Tighten
mainshaft
nut
to
140
to 17 0
kg
m
101
to
123
ft lb
tor que
and
stake
mainshaft nut to
gr oove
ofmainshaft
witha
punch
See
Figur e
MT49
TM3 62
Fig
MT 49
Staking
mai
haft
nut
12
Measur e
gear
end
play
and back
lash
Make sur e that
they
ar e held within
the
specified
values
For details r efer
tothe instr uctions
under
topicInspection
Note The main dr ive
gear
and coun
ter
dr iVe
gear
should be handled as
a
matched
set
When
you
r eplace
amaindr ive
gear
or
counter
dr ive
gear
be sur e to
r eplace
as a set
of
main dr ive
gear
and counter
dr ive
gear
ShUt for k nd
for k r od
mbly
I
Place 1st 2nd shift for k in
gr oove
in 1st
2nd
coupling
sleeve
and slide 1st 2nd for kr od
thr ough
adapter plate
and
1st 2nd
shift
for k
Pr ior
to
installing
1st
2nd for k
r od
install
3 r d 4th
shift
for kin
gr oove
in
3 r d 4th
coupling
sleeve
Note
Shift
for ks for 1st 2nd and
3 r d 4th
ar e one
and the
same
par ts
Make sur e that the
long
end ofshift
for kfor
lot 2nd is
placed
onthe
counter
gear
side and the
long
end
for 3 r d 4th is on the
e
side
MT12
Secur e 1st
2nd for kr od to
shift
for kwith
a new
r etaining pin
2 Install check
ball check ball
spr ing
and check
ball
plug
Pr ior
to
tightening
check ball
plug
apply
sealant tocheckball
plug
Align
notch
in
1st 2nd for kr od
with
checkball
See
Figur e
MT 50
TM3 67
Fig
MT
50
l
talling 1st
2nd
for k
r od
3
Slide
3 r d 4thfor k r od
thr ough
adapter plate
and 3 r d
4thshift
for k
and secur e withanew
r etaining pin
Note Pr ior
to
a
mbling
3 r d 4th
for k r od install
two
2
inter lock
balls
into
dap
er
plat
own
in
Figur e
MT 16
4Install check ball and check ball
spr ing
Apply
sealant tocheck
ball
plug
and install it in
place
Align
notch
in
3 r d 4th for k
r od
with check ball
by
sliding
3 r d 4th
for k r od as
necessar y See Figur e
MT51
TM3 68
Fig
MT 51 Installing
3 r d 4th
for k
r od
5
Place r ever se shift for k
in
r ever se
idler
gear
Slide r ever se for k
r od
thr ough
r e
ver se shift for k
and
adapter plate
and
secur e witha new
r etaining pin
Note Pr ior to
assembling
r ever se
for k
r od instaU two2 inter lock balls
into
adapter
piate
as shown in
Figur e
MT I6
6 Install check ball and check
ball
spr ing
Apply
sealant tocheck
ball
plug
and install
it in
place
Align
notch
in
r ever se for kr od with
checkball
See
Figur e
MT
52
TM3 69
Fig
MT 52
Installing
r ever se
for k
r od
7
Tor que each
check
ball
plug
to
1
9
to
25
kg
m
14
to18ft Ib
Note
BaD
plug
for ht 2nd for kr od
is
longer
thanthose
for r ev shift
for k
r od
and
3 r d 4thfor kr od
8
Apply
gear
oil toall
sliding
sur
faces
and check tosee that shift
r ods
oper ate
cor r ectly
and
gear s
ar e
engaged
smoothly
TRANSMISSION
ASSEMBLY
Tr anmis
lon
ea
mbly
1 Clean
mating
sur faces of
adapter
plate
and tr ansmission
case
Apply
sealant
to
mating
sur faces
of
adapter plate
and
tr ansmission case
2
Slide
tr ansmission
case onto
adapter
plate by
lightly tapping
with
a
soft hammer until case
bear s
against
adapter plate
Car efully
install main dr ive
bear ing
and counter shaft fr ont
bear ing
Make
cer tain
that mainshaft
r otates
fr eely
3 Fit
main dr ive
bear ing
snap
r ing
to
gr oove
in main
dr ive
bear ing
by
using
Expander See Figur e MT 53
Manual
Tr ansmission
Fig
MT 53
Fitting
maindr ive
bear ing snapr ing
R ar xt
nslon ass
mbly
I Clean
mating
sur faces of
adapter
plate
and
fear extension
Apply
sealant to
mating
sur faces
of
adapter plate
and
r ear extension
2 With for k
r ods
in
their neutr al
positions
gr aduaUy
slide r ear exten
sion
onto
adapter
plate
making
sur e
that
speed change
cr oss
lever
engages
with
for k
r od br ackets
cor r ectly
3
Install washer s and
thr ough
bolts
and
tor que
to
1
6
to
21
kg
m
12
to
15 ft
lb
Available
shim
Fr ont eov r s
mbly
I
Select counter shaft fr ont
bear ing
shimas follows See
Figur e
MT 54
1
Measur e
depth
A fr om
fr ont
end oftr ansmission
case to
counter
shaft fr ont
bear ing
2 Select a shim of
thickness A
measur ed
D
A
JJ
ID
@
2J1
I
Tr ansmission
case
2
Counter shaft
fr ont
bear ing
3
Counter shaft
4
Shim
TM3 71
Fig
MT 54
Selecting counter shafl
fr ont bear ing
shim
No
A
Counter shaft
fr ont
r nm in
bear ing
shim mm in
I 292to3
01 0
1150
to
0
1185 0
6 0024
2
3
02to
3
11
01189 to01224
05 0020
3 3 12
to3
21 0
1228 to0
1264 0
4
0016
4 3 22to
33
I
01268to0
13 03 03 0012
5
3
3 2to3
41
0
13 07
to
013 43
02 0008
6
342
to3 5
I
0
13 46
to0
13 82 0 1 0004
7 3
52
to
3 61
0
13 86
to
01421
8
3 62
to3 71 0 1425to0
1461
2 Clean
mating
sur faces offr ont
cover
and
tr ansmissioncase
Apply gr ease
toshim selected to
r etain it on fr ont cover install fr ont
cover totr ansmission case with
gasket
inplace
Install
thr ough
bolts
with
washer s
under them and
tighten
to
1
6 to2
1
kg m
12
to15
ft lb
tor que
Apply
sealant to thr eads of
thr ough
boltsbefor e installation
MT13
3
Install
speedometer pinion
assem
bly
on r ear
extension
After
making
Sur e
that
lock
plate
is
lined
up
with
gr oove
in
speedometer
pinion
sleeve
install
thr ough
boltsand
tor que
to04
to05
kg m
3
to
4ft
lb
4
Install back
uplampswitch and
tor que
to
2
0to3
0
kg
m
14
to22
ft
lb
Be sur e to
apply
sealant befor e
installation
5
Apply
a
light
coat
ofmulti
pur pose gr ease
to
withdr awal lever
r elease
bear ing
and
bear ing
sleeve in
stall themonclutch
housing
After
connecting
them
with holder
spr ing
instaU
dust
cover on clutch
housing
6 Install contr ol lever
tempor ar ily
and
shift contr ol
lever
thr ough all
gear s
to
make
sur e
that
gear s
oper a
Ie
smoothly
Note
Install
dr ain
plug
and
filler
plug
ithsealant in
place
Manual
Tr ansmission
INSTALLATION
Install the tr ansmission in the r eo
ver se
or der ufr emoval
paying
atten
tion
to
the
following
points
1 Befor e
installing
dean
mating
sur faces of
engine
r ear
plate
and
tr ans
missioncase
2
Befor e
installing lightly apply
gr ease
to
spline
par ts
ofclutch
disc
and
main dr ive
gear
3
Tighten
bolts
secur ing
tr ans
mission
to
engine
to
specifications
See
Figur e
MT 55
5 SPEED TRANSMISSION
TYPE
DESCRIPTION
REMOVAL
DISASSEMBL
Y
TRANSMISSION CASE DISASSEMBLY
DISASSEMBL
Y OF GEAR
ASSEMBLY
REAR
EXTENSION DISASSEMBLY
ADAPTER PLATE
DISASSEMBLY
INSPECTION
TRANSMISSION CASE AND REAR
EXTENSION HOUSING
DESCRIPTION
The
tr ansmission
is ofa 5
speed
for war d with over dr ive
4
OD
speed
fully
synchr onized
constant
mesh
type
that
useshelical
gear s
The5
speed tr ansmission cover ed
in
this section is
similar
in
all
r espects
to
the 4
speed
tr ansmission
type
F4W71B stated
pr eviously except
the
CONTENTS
MT14
MT17
MT17
MT17
MT17
MT18
MT19
MT19
44
to5 9
kg
m
3 2to43 ft Ib
1
09 to12
kg
m
7to9 r t
lb TM773
Fig
MT 55
Tightening tor que
4Remove filler
plug
and
fIll tr ans
mission with r ecommended
gear
oil
to
the level ofthe
plug
hole
Appr oxi
mately
I 7
liter s 3
pt
3
pt
FS5W71B
BEARING
GEARS
AND
SHAFTS
BAULK
RING
OIL
SEAL
ASSEMBLY
FRONT COVER ASSEMBLY
REAR
EXTENSION
ASSEMBLY
GEAR
ASSEMBLY
TRANSMISSION ASSEMBLY
INSTALLATION
MT19
over dr ive
position
ofit
The
over dr ive
gear
r ides on
the
mainshaft
fr eely thr ough
the
needle
r oller
bear ing
and
counter
over dr ive
gear
is fitted tothe
counter shaft
by
splines
The over dr ive
synchr onizer system
is
onthe mainshaft r ear side
MT14
MT19
MT19
MT19
MT19
MT19
MT19
MT19
MT19
MT
20
MT20
Placing
the contr ol lever
in
over
dr ive
position br ings
the r ever se OD
coupling
sleeve r ever se
gear
on
main
shaft intomesh with over dr ive clutch
gear
The r ever se OD
synchr onizer
hub
is
fItted
to
the mainshaft
by
splines
sothe over dr ive
gear
on main
shaft
tur ns
together
with the
main
shaft
Manual Tr ansmission
@
Ij
b
00
7
@
f
1 Fr ont
cover
2
Fr ont cover oil seal
3
Fr ont
cover
gasket
4
Tr ansmissioncase
5
Adapte plate
6
Maimhaft bear ing
7
Bear ing
r etainer
8
Rear
extension
9
Br eather
10 Rear
extension
oil seal
11 Sleeve
yoke
dust cover
f
@3
TM046A
Fig
MT
56
FS5W71Btr ansmission case
components
MT15
Manual
Tr ansmission
j
W
h
I
l
1
Main
dr ive
gear
2
Baulk
r ing
3
Shifting
inser t
4
Shifting
inser t
spr ing
5 Synchr onir cr
hub
6
Coupling
slee
7 3 r d main gear
g
Needle
bear ing
9
Mainshaft
10
2nd main
gear
11
Bushing
12 1st main
gear
13 O
r evcr se
synchr onizer
hub
14
Rever
gear
15
Cir clip
16
Thr wt
block
t 7 Br ake band
18
Synchr onizer
r ing
19 Over dr ive main gear
20 Over dr ive gear bushing
21 Washer
22 Mainshaft
nut
13 Over dr ive
mainshaft
bear ing
24
Speedometer
dr ive
gear
25
COlplteBhaft fr
mt
bear ing
shim
26 Counter shaft fr ont bear ing
27 Counter shaft dr ive
gear
28 Coontcr shaft
29 Counter shaft bear ing
3 0 Rever se counter gear
spacer
3 1 Rever Ccounter gear
3 2
r dr ive
counter
gear
3 3 Counter shaft zear bear ing
3 4Cunter shaft nut
3 S Rever se idler lIhaCt
3 6 Rever se idlcr thr ust washer
3 7 Rever se idler
gear
3 8 Reye ncidler
gear bear ing
3 9 Rever se idler
thr ust w8her
TM041A
MT 16
Fig
MT 51 FS5W11B
tr u
miasion
gear componenta
Manual Tr ansmission
CD
t
e
I
2
3
4
5
6
7
8
9
10
11
12
13
14
17
18
19
O
20
o
21
24
25
j
@
Str iking
lever
Lock
pin
Q
r ing
Str iking
guide
Oil seal
Str iking
r od
Expansionplug
Stopper
guide pin
Retur n
spr ing
Retur n
spr ing
plug
Retur n
spr ing
plunger
Check ball plUS
Check
spr ing
Check ball
Retaining pin
Inter lockball
ist 2nd shift
for k
1st
2nd for k
r od
3 r d
4th
for k r od
Rever se OD
for k r od
3 r d 4th
shift for k
Revene OD shift
for k
Contr ol1ever
Contr ol1cver pin
Contr ollever bushing
TM048A
Fig
MT 58 FS5W71B
tr ammi
ion
shift
contr ol
component
3
Dr awout counter dr ive
gear
com
plete
withmain dr ive
gear assembly by
means
of
a
gear
puller
When
dr awing
out
main dr ive
gear
assembly
be car eful not to
dr op
pilot
needle
bear ing
ontofloor fr om
the
fr ont end
ofmainshaft See
Figur e
MT 60
REMOVAL
Same
as
for the F4W71B
DISASSEMBLY
TRANSMISSION
CASE
DISASSEMBLY
Same as
for the F4W71B
DISASSEMBLY
OF
GEAR
ASSEMBLY
For k r od
Same as for the F4W71B
Geer
sembi
I
With
gear s doubly engaged
dr aw
out
counte
haft fr ont
bear ing using
a
suitable
gear puller
See
Figur e
MT 59
2 Remove counter dr ive
gear
snap
r ing
TM3 98
Fig
MT 59
Removing counter shaft
fr ont bear ing
MT
17
TM756
Fig
MT 60 Removing counter
dr ive
gear
and main
dr ive
gear
4
Rem6vesnapr ing
and then thr ust
washer fr ommainshaft fr ont end
Dr aw out 3 r d 4th
synchr onizer
assembly
and r emove 3 r d
gear
assem
bly
5 Remove
snap
r ing
and then dr aw
out
speedometer
gear
and
bear ing
fr ommainshaft r ear side
6 With
gea
doubly engaged
r e
lease
caulking
on
counter shaft and
mainshaft
nutsthen loosen
them
Remove counter shaft nut
TM757
Fig MT 61
Removing
counter ahaft
nut
Note
When
r emoving
mainshaft as
sembly
loosenmainshaft nut
7 Dr aw
out counter over dr ive
gear
and
bear ing
fr om counter shaft r ear
end
by using
a suitable
gear puller
See
Figur e
MT 62
TM758
Fig
MT 62
Removing
count r
over dr iv
gear
and
bear ing
8 Remove counter
r ever se
idler
gear
and
spacer
9 Remove counter shaft
by lightly
tapping
the r ear end with
a
soft
hammer
Be car eful not to
dr op
off
gear
shaft
10 Remove r ever se idler
gear snap
r ing
TM759
Fig
MT 63
Removing
r ever se idler
gear
nap
r ing
Manual
Tr ansmission
II Remove
r ever se idler
gear
12 Remove
snap
r ing
of
mainshaft
end
bear ing
Dr aw
out
bear ing
using
Mainshaft
Rear
Bear ing
Puller
KV3 21013 3 0
Remove other
snap
r ing
of
mainshafl
end
bear ing
See
Figur e
MT
64
tw
KV3 21013 3 0
TM160
Fig
MT 64
Removing
mai
haft
nd
bear ing
13
Remove
mainshaft nut
thr ust
washer
mainshaft r ever se
gear
OD
synchr onizer
and
over dr ive
gear
14Dr aw out
mainshaft
gear
assem
bly together
with
counter shaft
by
lightly tapping
the
r ear
end
with
a
soft
hainmer Me
holding
the fr ont
of
mainshaft
gear assembly by
hand
Be car eful
not
to
dr op
off
gear
shaft See
Figur e
MT 65
k
r
IT
TM761
Fig MT 65
Dr iving
out
gear sembly
Malnahaft
Same as for the F4W7IB
Main
dr ive ear
Same as for the F4W71
B
Counter ahaft
aaaembly
Same as for the
F4W7l B
REAR EXTENSION
DISASSEMBLY
Remove lock
pin
fr om
str iking
lever and r emove
sir iking
r od
Note Donot disassemble
r ear exten
sion
bushing
fr om r ear extension
J
l
J
@
1
Str iking
lever
2
Str iking
r od
3
Stopper
pin
4
Contr ol
lever
5
Str iking
r od
guide
6 Rever se select
plunger
7 Rever se select
plug
TM767
Fig
MT 66
Exploded
view
of
shifting
mechanilm
MT1B
ADAPTER PLATE
DISASSEMBLY
Same as
for
theF4W71
B
Fig
MT 67
Removing
scr ews
INSPECTION
Wash
all
par ts
in
a
suitable
cleaning
solvent and check for wear
damage
or
other
faulty
conditions
Notes
a Be
car eful
not to
damage
any
par ts
with
scr aper
b
Do
not clean washor
soakoil seals
in
solvent
TRANSMISSION
CASE
AND
REAR
EXTENSION
HOUSING
Same as
for the F4W71B
BEARING
Same
as for the F4W7l B
GEARS
AND SHA S
I Check all
gear s
for
excessive
wear
chips
or cr acks
r eplace
as
r equir ed
2
Check shaft for
bending
cr ack
wear and wor n
spline
if
necessar y
r eplace
3
Measur e
backlash
in
gear s
Maindr ive and
counter dr ive
gear
005 to0
10
mm
00020to0003 9
in
1st
2nd 3 r d 5thand
r ever se
gear s
005 to020mm
00020to00040
in
Manual
Tr ansmission
Ifthe above limits ar e exceeded
r eplace
dr ive and dr iven
gear s
as
a
set
4
Measur e
gear
end
play
1st
gear
03 2 to
03 9 mm
0
0126 to0
0154in
2nd
gear
012
to
0 19 mm
00047 to
0 0075in
3 r d
gear
0
13 to 03 7 mm
0
0051
to
00146
in
OD
gear
onmainshaft
03 2
to
0
3 9 mm
00126 to
0
0154
in
BAULK
RING
Same
as for the F4W7IB
OIL
SEAL
Same as
for the F4W71B
ASSEMBLY
Toassemble r ever se the or der of
disassembly
Obser ve the
following
in
str uctions
FRONT COVER ASSEMBLY
Same
as for the F4W7l
B
REAR EXTENSION
ASSEMBLY
I
Wipe
clean
seal
seat
in
r ear
exten
sion
housing pr ess
fit oil seal in
place
Coat oil seal and
bushing
with
gear
oil
for initial lubr ication See
Figur e
MT 68
Fr ont
r
I
TM3 55
Fig
MT 68 R ar extemion
oil sea
2
Apply
multi
pur pose gr ease
to
O
r ing
and
plunger
gr ooves
in
str iking
r od
Inser t
str iking
r od with
str iking
r od
guide
thr ough
r ear
extension
MT19
3 Install
str iking
lever
onfr ont end
of
str iking
r od Install lock
pin
and
tor que
scr ew to09 to
1 2
kg
m
7
to
9 ft lb
4
Install
filainshaft bear ing
by
lightly tapping
ar ound
it with a
soft
hammer
5 Inser t
r ever se
idler shaft in
adapt
er
plate
Make sur e that the
cut out
por tion
ofr ever se
idler shaft
is
lined
up
with
inner face of
adapter
plate
6
Install
bear ing
r etainer in
adapter
plate
Align bear ing
r etainer
with r ever se
idler shaft at the cut out
por tion
of
thisshaft
tor que
scr ews
to1
9 to25
kg
m 14to18 ft lb and stake each
scr ew at two
points
with a
punch
See
Figur e
MT 69
TM764
Fig
MT 69
Stahing
scr ew
7 Install
counter shaft
r ear bear ing
in
adapter
plate
by lightly tapping
ar ound
it
witha soft
hammer
GEAR
ASSEMBLY
Clean all
par ts
in solvent and
dr y
with
compr essed
air
Synchr onlz
r embly
Same
as
for the
F4W71
B
Ov
r dr lve
r
ynchr onlz
r
mbly
I
Assemble
r ever se OD
synchr o
nizer
assembly
2
Assemble over dr ive
gear
assem
bly
Position synchr onizer r ing
band
br ake
thr ust block and anchor
block
on
over dr ive clutch
gear
install
cir clip
Malnshaft
assembly
Same as for the F4W7IB
Counter shaft
assembly
Same as
for
the F4W71B
Main dr ive
gear assembly
Pr ocedur es
ar e
the
same as for the
F4W7IB tr ans
i
n
except
as
follows
I
Inser t counter shaft and mainshaft
into
adapter
plate
and
place adapter
plate
in
a
vise with
setting plate
Manual Tr ansmission
Synchr o
r ing
8andbr ake
Cir clip
Anchor
block
TM449
Fig
MT 70
Imtalling
over dr ive
gear assembly
Install
snapr ing spacer
needle
r oller
bear ing
r ever se
idler
gear spacer
and
snapr ing
h
I
L
TM4S1
Fig
MT 71 R lJer se
idler
gear
MT
20
2
Assemble OD r ever se
synchr o
nizer
assembly
OD
gear bushing
needle
bear ing
OD
gear assembly
sr eel ball
and
thr ust washer
on
main
shaft r ear side Befor e
installing steel
ball
apply gr ease
to
it
3
Install new mainshaft
nut
and
tighten
it
tempor ar ily
4
Install counter r ever se
gear
counter 5th
gear
bear ing
and new
counter shaft nut
Tighten
nut tem
por ar ily
5
Tighten
mainshafl and
counter
shaft
nuts and stake nuts at
gr oove
in
shafts
with
a
punch
Tightening
pr oce
dur es
for mainshaft
nut ar e the same
as
those for the F4W7IB
Shift for ks and for k
r ods
assembly
Same
as
for
theF4W71B
u
TRANSMISSION
ASSEMBLY
Same as for
the F4W71B
INSTALLATION
Same
as
for
the F4W71B
Manual Tr ansmission
SERVICE
DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS
Tr ansmission
type
F4W71B FS5W71B
Synchr omesh
type
War ner 1st to4thWar ner 5thSer vo
Shift
type
1 3
T
ii
2 4R
1 3 5
II
1
2
4R
Gear r atio
1st
2nd
3 r d
4th
5th
Rever se
3592
2246
1
415
1
000
3 657
33 21
2077
13 08
1000
0864
33 82
Final
gear
r atio
43 75 43 75
Speedometer gear
r atio 20 6
I
7
3 3
206
20 4X 3f
Oil
capacity
US
pt
Imppt
MT 21
Manual
iTr ansmission
TIGHTENINGTORQUE
Installation
Engine
totr ansmission
installation bolt
Tr ansmission to
engine
r ear
plate
bolt
Clutch
oper ating cylinder
installation
bolt
Rear
mounting
insulator to
tr ansmission installation bolt
Cr ossmember
mounting
bolt
Pr opeller
shaft todiffinstallationbolt
Gear
assembly
Rear
extensioninstallationbolt
Fr ont cover
installationbolt
Bear ing
r etainer to
adapter
plate
scr ew
Mainhaft nut
Checkball
plug
Str i
lever
lock
pin
Rever se select
r etur n
plug
Speedometer
sleeve
locking
plate
nut
Rever se
lamp
switch
year
oil Ier
pl
g
Ge r oil dr ain
plug
Unit
kg
m ft
lb
44
to
5
9
3 2
to
43
0
9
to
127 to9
2 5
to3 0
18
to22
08to116
to
8
3
2to
43
23 to3 1
24
to
3 3
17
to
24
1
6
to
21
12
to
IS
16 to21
12to
IS
19 to2S 14to18
14
0to17 0
101 to
123
19to2S
14to18
09to
1 2
7to9
09 1 2 7
to
9
0
4
to
O S
3
to
4
20to3 0
14
to
22
2S
to
3 5
18
t02S
2S
toTS
l8
to
2S
or
SPECIFICATIONS
Gear backlash
Maindr ive
gear
tocounter dr ive
gear
1st
gear
2nd
gear
3 r d
gear
OD
gear
Gear
end
play
1st
gear
2nd
gear
3 r d
gear
OD
gear
Counter
gear
Rever se idler
gear
Clear ance
betweenbaulk
r ing
and
gear
All
gear s
Counter
bear ing
adjusting
shim
Unit
mm
in
005 to0
10 00020
to
0003 9
005 to0
20 00020to00079
O OS to020 0
0020to00079
005to020 00020to00079
005to
0
20 00020to00079
03 2 to
03 9
00126 to00154
0 12 to019
00047 to
0
0075
013 to03 7 00051to00146
03 2 to03 9
00126 to
0
0154
001to
0 21
00004to00083
005
to020 0
0020
to00079
125to
1
60 00492to0063 0
06 0024
05
0020
0
40
016
03 0
012
02 0008
01
0004
MT 22
Manual Tr ansmission
I
TROUBLE DIAGNOSES
AND CORREGTIONS
Condition
Difficult
to
intel11lesh gear s
Causes Jor difficut
gear
shifting
ar e classi
fied to
tr oubles
concer ning
contr ol
system
and tr ansniissioo
When
gear
shift lever
is
heavy
and it is difficult toshift
gear s
clutch
disengagement may
alsobe
unsmooth
Fir st
make sur e
that
clutch
oper ates
cor r ectly
and
inspect
tr ansmissi
o
Gear slips
out of
mesh
In most cases this tr ouble
occur s when
inter lock ball check ball
and
or spr ing
is
wor n
or weakened
or
when
contr ol
system
is
faulty
In this
case the
tr ouble cannot be
cor r ected
by r eplacing
gear s
and
ther efor e
tr ouble
shooting
must
be
car r ied
out
car e
fully
It should also
be
noted that
gear slips
out
ofmesh
due tovibr ation
gener ated
by
weakened fr ont and r ear
engine
mounts
Noise
When noise occur s with
engine
idling
and
ceases
when
clutch
is
disengaged
or
when
noise occur s while
shifting
gear s
it
is
an
indicati90
that the noise
is
fr om
tr ansmis
sion
t
Tr ansmission
may
faule
dur ing engine
idling
Check
air
fuel
mixtur e and
ignition
timing
After above
pr ocedur e
r eadjust engine
idling
Pr obable
cause
Wor n
gear
shaft and or
bear ing
Insufficient
oper ating
str oke
due towor nor
loose sliding
par t
Faulty
or
damaged
synchr onizer
Wor n inter lockball
Wor n check
ball
and
or
weakened
or br oken
spr ing
Womfor kr od ball
gr oove
Womor damaged bear ing
Wor n or
damaged gear
Insufficient
or
impr oper
lubr icant
Oil
leaking
due
to
faulty
oil
seal
or
sealant
clogged
br eather
etc
Wor n
bear ing
High
humming
occur s at a
high speed
Damaged
bear ing
Cyclicknocking
sound
occur s also at
a
19Wspeed
Wor n
spline
Wor n
bushing
j
MT 23
Cor r ective
action
Replace
pair
or r eplace
Replace
Replace
Replace
Replace
Replace
Replace
Add
oil or
r eplace
with
designated
oil
Clean
Of
r eplace
Replace
Replace
Replace
Replace
No
Tool number
tool name
ST23 540000
For k r od
pin
punch
2 ST223 60002
Dr ift
C
3 ST23 800000
Tr ansmission
adapter
4 ST23 810001
Setting plate
adapter
Manual Tr ansmission
SPECIAL
SERVICE
TOOLS
Descr iption
Unit
mm
in
For r emoval
offor kr od
r etaining pin
L
i
150 5 91
10 0
3 9 dia
For
assembly
ofcounter dr ive
bear ing
oOler dia 3 2 126
inner
dia 23 091
SE03 4
For
assembly
ofmain
bear ing
480
18
90
outer dia 44
1
73
inner dia 3 1
122
SE03 7
For
setting adapter plate
in
a vise
SE13 2
742
91
MT 24
For
use
on
Refer ence
page
or
Figur e
No
All
Fig
MT 15
models
llBT M
Fig
MT 44
FS5W
63 A
All
Page
MT
1O
models
71BT M
Fig
MT
14
Fig
MT 15
Fig
MT 45
Manual Tr ansmission
No
Tool number
tool
name
Descr iption
Unit
mm
in
For
use
on
Refer ence
page
or
Figur e
No
5
ST22520000
Wr ench
3 8mm
150
in
For
r emoval
and
assembly
ofmainshaft nut
71BT M Fig
MT46
63 A
TIM
Fig
MT47
SE3 13
6 ST23 860000
For assembly
of
counter
dr ive
gear
7IBT M
Fig
MT42
Counter
gear
dr ift
outer dia
3 8 50
inner
dia
3 3
13 0
SE03 9
7
KV3 1100400
For assembly
of
r nainshaft counter shaft
counte dr ive
gear
and
7IBT M
Fig
MT
3 7
Tr ansmission
counter dr ive
bear ing
Fig
MT 3 9
pr ess
stand
48 189 75 295
Fig
MT44
0
Q
0
J
I
0
TM43 8
8 STJ003 1000
For
r eplacing
bear ing
All
Fig
MT
21
Bear ing puller
models
Fig
MT
23
Fig
MT 25
80
3
15
50 197
SE041
MT 25
Manual
Tr ansmission
No
Tool
number
tool
name
Unit mm in
Descr iption
9 KV3 21013 3 0
For r emoval ofmainshaft
end
b
ar i lg counter
over dr ive
gear
and
Bear ing puller
bear ing
3 00 11
81
SE3 08
MT
26
For
use
on
Refer ence
page
or
Figur e
No
63 A
lfM Fig
MT 64
FS5W
7IBT M
DATSUN
PICK UP
MODEL 620 SERIES
I
NISSAN
I
NISSAN
MOTOR CO
LTD
TOKYO
JAPAN
SECTION AT
j
AUTOMATIC
L
TRANSMlsSIO
N
I
I
DESCRIPTION
HYDRAULIC
CONTROL
SYSTEM
REMOVAL AND INSTALLATION
MAJOR REPAIR
OPERATION
TROUBLLDIAGNOSES AND
ADJUSTMENT
SERVICE DATA AND
SPECIFICATIONS
I
SPECIAL SERVICE
TOOLS
At 2
AT 4
AT
3 3
AT 3 6
AHD
AT
59
AT
62
The model
3 N7lB automatic
tr ans
mission is
a
fully
automatic
unit con
sisting
pr imar ily
of3element
hydr au
lic
tor que
conver ter
and
two
planetar y
gear
sets Two
multiple disc
clutches a
multiple disc
br ake a band br ake and
a one
way
spr ag
clutch
pr ovide
the
fr iction elements
r equir ed
toobtain
the desir d function oflhe two
plane
tar y gear
sets
The
two
planetar y
gear
sets
give
thr ee for war d
r atios
and one r ever se
Changing
ofthe
gear
r atios is
fully
automaticin r elationtovehicle
speed
and
engine tor que input
V
chide
speed
and
engine
manifold vacuum
signals
ar e
constantly
fed
tothe
tr ansmission
to
pr ovide
the
pr oper gear
r aliofor
maximum
efficiency
and
per for mance
at all thr ottle
openings
The model 3 N71Bhas six
selector
1
9sition LP
R
N D 2
1
I
Par k
position positively
locks
the
output
shaft
to
the
tr ansmission
case
by
means of
a
locking
pawl
to
pr event
the vehicle fr om
r olling
in
either dir ection
This
position
should
be
selected
whenever the dr iver leaves Ihe vehicle
Thc
engine
may
be slar ted in Par k
position
R Rever se
r ange
enables the
vehicle tobe
oper ated
in
a r ever se
dir ection
N Neutr al
position
enables the
engine
to
be star ted and r un
without
dr iving
the vehicle
0 Dr ive
r ange
is
used
for all
nor mal
dr iving
conditions
Dr ive
r ange
has thr ee
gear r atios
fr omthe
star ting
r atio
todir ect dr ive
Automatic
Tr ansmission
DESCRIPTION
2
2
r ange
pr ovides
per for mance
for
dr iving
on
slipper y
sur faces
2
r ange
can alsobe used for
engine
br aking
2
r ange
can be selected at
any
vehicle
speed
and
pr events
the tr ans
mission fr om
shifting
out of
second
gear
I I
r ange
can be
selected
at
any
vehicle
speed
and the tr ansmission
will shift to
second
gear
and r emain in
second until
v
hicle
speed
is r educed
10
appr oximately
40 to50
kmfh
25
to3 0MPH
I
r ange position pr events
the
tr ansmission fr om
shifting
out oflow
gear
This is
par ticular ly
beneficial for
maintaining
maximum
engin br aking
when
continuous low
gear oper ation
is
desir able
The
tor que
conver ter
assembly
is of
welded
constr uction and can
nOlbe
disassembled
for
ser vice
FLUID RECOMMENDATION
Use automatictr ansmission
fluid
having
DEXRON identifications
only
in the3 N71B
automatic
tr ansmis
sion
IDENTIFICATioN NUMBER
Stamped
position
The
plate
is
attached tothe
r ight
hand
side oftr ansmission case
as
shown
io
Figur e
AT
I
AT 2
AT3 44
Fig
AT
I
Identification number
Identification
ofnumber
Ar r angements
See below
Modelcode
JAPAN
AUTOMATIC
0J
TRANSMISSION CO LTD
I
MODEL X2402
I
J
I
NO
49123 45
I
Unit number
Number
designation
49
I
23 4
5
L
Ser ial
pr oduction
number for
the month
Month of
pr oduction
X
Oct
Y
Nov ZDec
last
figur edenoting
the
year
AD
AutomaticTr ansmission
oJ
II
IIlI
rI
r
A
T288
I Tr ansmission
ca e
2
Oil
pump
3 Fr ont clutch
4Band br ake
5
Rear clutch
6
Fr ont
planetar y
gear
7 Rear
planetar ygear
8 One
way
clutch
9
Low
Rever 5e br ake
10 Oil distr ibutor
II
Gover nor
12
Output
shaft
13 Rear
extension
14
Oil
pan
IS Contr ol
valve
16
Input
Jlihafl
17
Tor que
conver ter
t 8
Conver ter
housing
19 Dr ive
plate
Tightening
tor que
T of
bolts and nuts
kg
m
ft lb
@
T
4105
29
10 3 6
@
T
141016 10110116
@
T 45
to5 5 3 3 1040
@
T
0
6100
8 4106
@
T 05to0 7 4105
T
2 0102 51410 18
@ T 13 10
1
8 9 10 13
T
0
5510075
4105
CD
T 025 10 0
3 5
2to3
Fig
AT 2 Cr oss sectional view of
3 N71Bautomatic
tr ansmission
AT3
AutomaticTr ansmission
HYDRAULIC
CONTROL SYSTEM
FUNCTIONS
OF HYDRAULICCONTROL
UNIT AND VALVES
OIL
PUMP
MANUAL LINKAGE
VACUUM DIAPHRAGM
DOWNSHIFT SOLENOID
GOVERNOR
VALVE
CONTROL VALVE
ASSEMBLY
HYDRAULIC
SYSTEM AND
MECHANICAL OPERATION
FUNCTIONS
OF
HYDRAULICCONTROL
UNIT AND VALVES
The
hydr aulic
contr ol
system
con
CONTENTS
P RANGE PAR
K
R
RANGE REVERSE
N
RANGE
NEUTRAL
D1
RANGE
LOW GEAR
D2
RANGE
2ND
GEAR
D3 RANGE TOP
GEAR
D RANGE KICK
DOWN
2
RANGE 2ND GEAR
t RANGE LOWGEAR
12
RANGE
2ND
GEAR
AT 4
AT 4
AT 4
AT 5
AT 5
AT 5
AT
6
AT13
tains
an oil
pump
for
packing p
oil
fr om the oil
pan thr ough
the oil
str ainer
A
shift contr ol is
pr ovided
by
two
centr ifugally
oper ated hydr aulic
gover nor s
onthe
output
shaft
vacuum
contr ol
diaphr agm
and downshift
AT14
AT16
AT18
AT
20
AT
22
AT
24
AT
26
AT
28
AT
3 0
AT
3 2
solenoid
These
par ts
wor kin
conjunc
tion
with valves
in the valve
body
assembly located
in
the base ofthe
tr ansmission The valves
r egulate
oil
pr essur e
and dir ect it
to
appr opr iate
tr ansmission
components
Oil
pump
I
I
Contr ol valve
I
Tor que
conver ter
1
I
I
I
Manual
linkage Fr ont clutch
Vacuum
diaphr agm
I
Rear clutch
I
Lowand
r ever sebr ake
Downshift solenoid
I
Band br ake
Gover nor valve
r
I Lubr ication
OIL
PUMP
The oil
pump
is
the sour ce of
contr ol medium
i
e
oil for the
contr ol
system
The
oil
pump
is
ofan inter nal
involute
gear type
The dr ive sleeve is a
par t
ofthe
tor que
conver ter
pump
impeller
and
ser ves todr ive the
pump
inner
gear
with the dr ive sleeve dir ect
ly
coupled
with the
engine oper ation
The oil flows
thr ough
the
following
r oute
Oil
pan
Oil
str ainer bottomofthe
contr ol valve
Contr ol valve lower
body
suction
por t
Tr ansmission
case
suction
por t
Pumphousing
suction
por t Pumpgear
space Pump
housing
deliver y por t
Tr ansmission
case
deliver y
por t
Lower
body
deliver y
por t
Contr ol valve line
pr essur e
cir cuit
AT071
I Housin 4
Inner
gear
2
Cover
5 Cr escent
3 Ouler
gear
Fig
AT
3 Oil
pump
AT 4
MANUAL
LINKAGE
The hand
lever motion the hand
lever is localed in
the dr iver s
compar t
ment
mechanically
tr ansmitted
fr om
lhe r emote
contr ol
linkage
is
fur ther
tr ansmitted to
the
inner
manual lever
in the tr ansmission
case
fr om the
r ange
selector lever in
the
r ight
center
par
tion ofthe tr ansmission
case
thr ough
the
manual shaft The inner
manual
lever is
ther eby
tur ned
A
pin
installed on
the bottom of
the
inner
manual lever
slidesr he manu
al valve
spool
ofthe
conlr ol valve thus
positioning
the
spool opposite
r he
appr opr iate
select
posilion
The
par king
r od
pin
is
held
in r he
gr oove
on the
top
of
Ihe inner
manual
plate
The
par king
r od
pinoper ates
the
r od
at p
r ange
and
oper ates
the
mechanical
lock
system
The
above descr ibed manual shaft is
fur ther
equipped
with
an inhibitor
switch A
r otor
inside
the
inhibitor
switch
r otates in
r esponse
toeach
r ange
When tne
r ange
is
selected
at
por
N the
r otor
closes
the
star ter
magnet
cir cuit
so that the
engine
can be star ted When the
r ange
is
selected at R the r olor closesthe
back
up
lamp
cir cuit and the back
up
lamp
lights
CD
1 Manual
pia
te
2 Inhibitor
switch
ATOB7
Par king
r od
Manual shaft
Fig
AT 4
Manual
linkage
VACUUM
DIAPHRAGM
The
vacuum
diaphr agm
is
installed
on the left
center
por tio
n ofthe
tr ansmission
case The
inter nal con
str uction ofthe
vacuum
diaphr agm
is
as follows
Ar ubber
diaphr agm
for ms a
par ti
tion in
the
center The
engine
intake
manifold
negative pr essur e
l
led
thr ough
a
vacuum
tube and
spr ing
for ce is
applied
tothe fr ont sur faceof
the
r ubber
diaphr agm
while
atmos
pher ic
pr essur e
is
applied
to
the back
sur face The
differ ence
between
pr es
sur e
applied
tothe fr ont and
baK
I
sur faces causes
a
vacuum r eactIOn
which activates the thr ottle valve of
the contr ol valve inside the tr ansr his
sion
case
Wher i
acceler ator
pedal
is
fully
de
pr essed
and the bur etor
is
fU
IIy
opened
but th
engir ie
sp
eed
is
not
suificientl
incr eased
the
manifold
negative plr e
sur e
lower s
Le
tends
towar ds
atmospher ic
pr essur e
and the
Automatic
Tr ansmission
vacuum
r eaction incr eases since
the
flow
velocity
ofmixtur e inside the
intake mmifold is slow
Contr ar ily
when
the
engine speed
incr eases and
the flow
velocity
of
the
mixtur e in
cr eases
or
when
the car bur etor
is
closed
the
manifold
negative
pr essur e
incr eases Le tends
towar ds vacuum
and
the
vacuum
r eaction is
r educed
Thus
a
signal
to
gener a
Ie
hydr aulic
pr essur e
P
r fe
tly
suited
tothe
engine
loading
at
tr ye
contr ol valve
is
tr ans
mitted fr om the vacuum
diaphr agm
and the most suitable
timing
for
speed
change
and line
pr essur e
is obtaine
so
that the
most
pr oper tor que capacity
is
obtained
against
the
tr ansmitting
tor que
To
inl lkc
manifold
AT088
Fig
AT 5 Vacuum
diaphr agm
DOWNSHIFT
SOLENOID
T e
downshift solenoid is
ofa
magnetictype
installed on
the left
r e r
por tion
ofthe tr ansmission
case When
a dr iver
r equir es
acceler ating power
and
dePr esses
the
acceler ator
pedal
down
tothe
stopper
a kickdown
switch
19ca
ted in the
middle of
the
acceler ator
link
is
depr essed
by
a
push
r od he
kickdown switch
doses
cur
r ent flows to
the solenoid
the
sole
noid
push
r od is
depr essed
the down
shift valve ofthe
contr ol valvcinsidc
the
tr ansmission
case is
depr essed
nd
the
speed
is
changed
for cedly
fmm
3 r d to 2nd within a cer laill
vehi
cle
speed
limit
Note Since theki
kdown switch
closes when the acceler ator
pedal
is
d
epr
ssed fr om
7
i
t I S I6
oftiie
whole
str oke the a
ccel r ator
ped
1
should
be cor r ectly
adjusted
soas
ar f
r d
a
omplete
str o
e
I
The
ar r angement
ofthe
swit
h
wr ies
ccor ding
m
eI
AT
S
c
C
r
11
I
Kickdown
h
switch
Dowr i
shift
solenoid
AT089
Fig
AT 6
Downshifl80lenoid
GOVERNER
VALVE
The
pr imar y
and
secondar y
gover
nor valves ar e installed
separ ately
on
the
back ofthe oil distr ibutor
on
the
tr ansmission
outp
t
sha ft
tn
y op
er ate
al the same
speed
as th
ar
iJf
tile
output
shaft thaiis
they oper ate
at
a
speed
in
pr opor tion
10
the vehicle
speed
The line
pr ess
r etis
applied
to
those valves
s
the
input
fr om the
contr ol
valve
thr ough
the
tr ansmission
case
r ear
flange
and oil distr ibutor
The
gover nor
pr essur e
in
pr opor tion
tothe
ouiput
shaft
speed
vehicle
speed
is
led tothe shift valve ofthe
contr ol valve
thr ough
the
opposite
r oute ofthe
output
In
this manner
speed change
and line
pr essur e
ar e
contr olled
Oper ation
of
secondar y
gover nor valve
T
e
secon
ar y
valve
is
a
contr o
valve
Y
hich r eceives
line
pr essur e
an
cqQ
r ols the
gover nor
pr essu
e
When the manual
valve is selected
at D 2
or l
r ange
line
pr essur e
is
applied
t the r i
g
sh
aped
ar ea of
this valve fr om cir cuit I
l
and this
I
v
Jy
is
depr essed
lOW jr tI c
fer
Movemcnt
of
this valvl III a cr
in
positillll doses
the dr uit
fr om
Olto
15
while
simultaneously
making
a
sr
r r onl IS toIii center
dniin
por t
and
pr ess
r e
in tllc
ci r J
it
l5j
is
lower ed
When
thcvehicle
is
stopped
1
d
the
cenlr ifugal
for ce ofthis valve iszer o
the
v lve
is balanced At this
poini
a
govcr
lOr
pr essur cy
hich
bal i1
nced
with
th
spr ng
for ce
occur s on IS
Wh n
thcvehicle is
st r ted
nd
the
centr ifugal
fqr
incr e
ses this valve
movcs
slightly
10
IhcoUlSide and
as
the
space
fr om
I
toIS
incr eases
space
fr om 15
to
the
dr ain
por t
simultaneously
decr eases
As
a
r esull
gover nor pr essur e
of
15
incr eases
and the
gover nor pr essur e
is
balanced
with the sum
of
centr ifugal
for ce
and
spr ing
for ce The gover nor
pr essur e
thus changes
in
r esponse
tothe vehicle
speed change
centr ifugal
for ce
Oper ation
of
pr lmar
gover nor
valve
The valve
is
an
ON OFF
valve
which closes the
gover nor
pr essur e
IS
r egulated
by
the
secondar y
gover
nor valve when the vehicle r eachesthe
minimum
speed
and when the vehicle
speed
exceeds a
cer tain
level the
gover nor opens
and
for war ds
the
gov
er nor
pr essur e
15 tothe contr ol
valve
When the vehicle is
stopped
the
gover nor
pr essur e
is zer oHowever
when
the
vehicle
is
r unning slowly
this
valve
is
depr essed
to
Ihe
center
and the
gr oove
to15 is closed since
the
gover nor pr essur e applied
tothe
r ing
shaped
ar ea
is
higher
than the
centr ifugal
for ce ofthis valve When
the
gover nor speed
exceeds a cer tain
r evolution the
gover nor pr essur e
in
the cir cuit 15 alsoincr eases How
ever as the
centr ifugal
for ce
incr eases
and exceeds the
gover nor pr essur e
this
valve moves towar d the outside and
the
gover nor pr essur e
is
tr ansmitted to
the cir cuil 5
Twodiffer ent valves ar e
employed
in
the
gover nor
sothat it will inde
pendently
contr ol the
speed
at
high
and low
speeds
That
is withinthe low
speed
r ange
the
gover nor
pr essur e
is
not
gener ated
because
ofthe
pr imar y
valve wher eas at the
high speed r ange
above the
br eaking point
gover nor
pr essur e
is
r egulated
by
the
secondar y
valve
The
br eaking
point
is
the
point
at
which
the
function
of
one
ofthe
gover nor
is tr ansfer r ed
to
the other
as
the
speed
changes
fr om the
low
speed
to
the
high
speed
r ange
AutomaticTr ansmission
Toonlml
valve
l
Gover nor
pr e S1I
1I5 j
I
QJ
J
f 1
1
CID
l
l
m
Line
pr essur e
t
D@
I
Pr imar y gover nor
2 Secondar y
gover nor
3 Gover nor valve
body
AT090
4
Oil di
lr ibutor
5
Output
sh lft
Fig AT 7 Cr 05s
sectionallliew
of
gover nor
CONTROL
VALVE
ASSEMBLY
Ai09
Fig
AT
S
Output shaft
with
oil
distr ibutor and
over nor
r
@
@
0
aBUlllI8
iUQlli
V
JlAU
I Oil distr ibutor
2 Gover nor
nlve
body
A
T092
3
Pr imar y gover nor
valve
4
Secondar y gover nol
valve
Fig
A
T
9
Exploded
view
ofgover nor
Flow
cbar
of
contr ol
valve
system
Oil
fr om
pump
Regulator
valve
1
I
i
j
Thr ottle
valve
I I
l
Manual
valve
I
I
I
I
I
I
I
L
n
L
j
Speed change
valve
I
I
t
t
I
I
I
I
I
I
Gover nor
I
I valve
I
I
I
L L
1
II
Auxiliar y
valve
Line
pr essur e
j
Clutchand br ake
The contr ol valve
assembly
r eceives
oil fr om the
pump
and individual
signals
fr om
the vacuum
diaphr agm
and tr ansmits the
individual
line
pr es
sur es to
the
tr ansmission
fr iction
ele
ment
tor que
conver ter cir cuit
and
lubr icating system
cir cuit as
outputs
Mor e
specifically
the oil fr omthe oil
pump
is
r egulated
by
the
r egulator
valve as line
pr essur e
build
up
the line
pr essur e
is
fed
out fr om
the
contr ol
valve
assembly thr ough
var ious
dir ec
AT 6
tion
changeover
valves
including
ON
OFF valve and
r egulator
valves ar e
newly
r efor med toa
thr ollle
system
oil
pr essur e
and
oper ate
other valves
Finally
the line
pr essur e
is
tr ansmilled
to
the
r equir ed
dutch
or
br ake ser vo
pisJon
unit in
r esponse
to
the individu
af
r unning
conditions
after
r e
ejving
signals
fr om
the
va uum
diaphr agm
downshift solenoid
gover nor
Vdlvc
and or manual
linkage
The contr ol
valve
assembly
consists
of
the
following
valves See
Figur e
AT
20
I Pr essur e
r egulator
valve
PRV
2
Manual valve
MNV
3 I
st
2nd
shift valve
FSV
4
2nd
3 r d
shift
valve
SSV
5
Pr essur e modifier valve
PMV
6 Vacuumthr ottle valve
VTV
7
Thr ottleback
up
valve
TBV
8 Solenoid downshift valve SDV
9
Second lockvalve SL
V
10 2nd 3 r d
timing
valve
TMV
Pr essur e
r egulator
valve
PRV
The
pr essur e r egulator
valve r e
ceives valve
spr ing
for ce for ce fr om
the
plug
cr eated
by
the
thr ottle
pr es
sur e 16
and line
pr essur e
7
and
for ce ofthe thr ottle
pr essur e
18
With the
inter action
ofthose for ces
the PRY
r egulates
the
line
pr essur e 7
to
that
most
suitable for individual
dr iving
conditions
The oil fr om the oil
pump
is
ap
plied
to
the
r ing
shaped
ar ea
thr ough
or ifice 20
As
a r esult the
PRVis
depr essed
downwar d and
moves fr om
por t
7
up
tosuch extent
that the
space
to
the next dr ain
por t
mar ked
with
X in
Figur e
AT 10
opens
slightly
Thus
the
line
pr essur e
7 is
balanced with the
spr ing
for ce
ther e
by balancing
the PRV In this
oper a
tion Ihe
space
fr om
por t
7
tothe
subsequent
conver ter oil
pr essur e 14
cir cuit has alsobeen
opened
As a
r esult the conver ter is
filled
with
pr essur ized
oil incir cuit 14and this
oil
is fur ther used for lubr ication of
the r ear unit Mor eover
par t
ofthe oil
is br anched and used for
lubr ication
of
the fr ont unit for the fr ont and r ear
clutches
When Ihe acceler ator
pedal
is de
pr esscd
the thr ottle
pr essur e
16
in
cr eases as descr ibed in the
pr eceding
par agr aph
oil
pr essur e
is
applied
to
the
plug
thr ough
or ifice
21
and this
pr essur e
is
added tothe
spr ing
for ce
As
a r esult
the PRV is
contr ar ily
for ced
upwar d space
to
the
dr ain
por t
is r educed
and Ihe
line
pr essur e
7
incr eases
Automatic
Tr ansmission
11
AT095
Fig
AT 10
Pr essur e
r egulator
ualue
When
the
r ange
is selected at
R
Rever se
the
line
pr essur e
6 is
applied
10
the
plug
ina manner identi
caito
the
thr ottle
pr essur e
16
and
is
added
10 the
spr ing
for ce
Consequent
ly
the line
pr essur e
7
fur ther
in
cr eases
When vehicle
speed
incr eases
and
the
gover nor pr essur e
r ises the
theot
tle
pr essur e
18
is
applied
tothe
por t
onthe
top
ofthe
PRV
and
pr essur e
is
applied
contr ar ily against
the
spr ing
for ce As
a
r esult the line
pr essur e
7
decr eases Mor eover at
individual
con
ditions
the line
pr essur e
7
is
equal
to
the line
pr essur e
6
and
the thr ottle
pr essur e
16 is
equal
to18
Manual valve
MNV
The manual lever
tur ning
motionis
conver ted to
r ecipr ocating
motion
of
the manual
valve
thr ough
a
pin
and
the MNV
is
positioned
sothat theline
pr essur e
7 is distr ibuted to
the
indi
vidual line
pr essur e
cir cuits
at each
P
R
N
D 2
or I
r ange
as
shown below
P
r ange
7 4SDVand
TBV
5
FSV 12 TBVand
Low
r ever se br ake
R
r ange
7
4
same as above
5
same as above
6
PRY
and
SSV
F C
and band
r elease
N
r ange
D
r ange
7
7
None
I
Gover nor
valve
FSV
and
r ear clutch
2
SLY
3
SL
V
and SSV
2
r ange
7 I Same as above
2
SL
V 9 Band
applied
4 SDVand TBV
I
r ange
7 I Same as above
4Same
as
above
5
FSV
Mor eover
1
2
3 45
and
6
ar e
always
dr ained at
a
position
wher e the line
pr essur e
is
not dis
tr ibuted fr om
7
u
JJX
g4Vhl
dIillillt 1
dlMIi
W ld
IiIb
It iB
J
jd l
tJj
fitMi
td
j
L@
x
x
j
j
P R
N
17
l
AT7
AT096
Fig
AT
11
Manual ualvp
1st
2nd shift
valve FSV
The
FSV is
a
tr ansfer valve which
shifts
gear s
fr om
low
to
second When
Ihe vehicle is
stopped
the
FSV is
depr essed
to
the
r ight
side
by
for ce of
a
spr ing
located on the
left side
putting
the
FSV is in the
low
position
When vehicle
speed
incr eases
the
gover nor
pr essur e
15 is
applied
to
Ihe
r ight
side of
the FSV and the FSV
is for ced
towar d the left
Contr ar ily
the line
pr essur e
I
togelher
with the
spr ing
for ce for ce
the FSV
towar d the
r ight
opposing
the
gover nor
pr essur e
15
When
the
vehide
speed exceeds
a
cer tain level
the
gover nor pr essur e
15 exceeds the sumofthe
thr ottle
pr essur e
and
Ihe
spr ing
for ce and the
FSVis
for ced towar d theleft
When the FSV is
depr essed
10 a
cer tain
position
the
lir epr essur e
I
is
closed and
only
the
spr ing
depr esses
the
FSV towar d the
r ight
and it is
depr essed
to
theend for
a moment As
a
r esull
the
line
p
r essur e
lJ
is for
war ded
to 8 the band
ser vo
is
engaged
thr ough
the SLY
and the
speed
is shifted to 2nd
With the
acceler ator
pedal
depr essed
the FSV
r emains iIi
the Low
position
unless
the
gover nor pr essur eIS
incr eases
to
a
high
leVel
cor r esponding
tothe line
pr essur e
I since
the
line pr essur e
I
incr ease when the acceler ator
pedal
is
depr esse9
Contr ar ily
when
vehicle
speed
de
cr eases
the
gover nor
pr essur e
15
decr ease Howeve
f
the
gear is
not
shifted
to
Low
nless the
gover nor
pr essur e
15
becomes
zer o
since
the
for ce
depr essing
the FSV towar d the
r ight
is
being
deliver ed
only
by
the
spr ing
Low in
r ange
I is led to
the
lowand r ever se
clutch fr om line
pr es
sur e
5
thr ough
line
pr bssur e
12
2nd is simultaneousi
y
led
to
the
ieft
end
spr ing
unit
Consequently
al
thougp
the
gover flor
pr essur e
in
cr eases
the valve is still for ced towar d
the
r ight
and the SFV
is
fixedjn the
Low
position
Whenkicked downto
the 2nd
speed
the SDV
oper ates
and
the line
pr essur e 13
for ces the
FSV
towar d the
r ight Although
the
AutomaticTr ansmission
gover nor pr essur e
15
is
consider ably
high the
valve is
for ced
completely
towar d
the
r ight
and the
FSV is
r etur ned
tothe
Low
position
This
oper ation
is
alled
Kickdown shift
15
j
13
1
c5
I
0
t
r
I
I
q
1
AT091
Fig
AT 12
lsl
2nd
shift
valve
2nd 3 r d
shift valve SSV
The
SSV
is
a tr ansfer valve
which
shifts
gear s
fr om
2nd
to
3 r d
When the vehicle is
stopped
the SSV
is
for ced towar d
the
r ight by
the
spr ing
and
is inthe
2nd
position
It
is
so
design
d however
that the FSV
can
decide toshift
either
to
Low or
2nd
When
the vehicle
is
r unning
the
gover nor pr essur e 15
is
applied
to
the r ight
end sur face
and th SSV is
for ced
towar d the left
Contr ar ily
the
Spr i l
for ce
line
pr essur e
3
and
thr ottle
pr ess
r e 19 for ce the
SSV
towar d the
r ight
When vehicle
speed
exceeds a
cee
tain
level
the
gover nor
pr essur e
sur
passes
the sumofthe
spr ing
for ce line
pr essur e
and thr ottle
pr essur e
and the
valve is for ced towar d
the left The
line
pr essur e
3 is
then closed Con
sequently
the for ces
being r apjdly
unbalanced the for ce
depr essing
the
SSV towar d the
r ight
decr eases and
thus the SSV is
depr essed
to
the
l
ft
end for a moment
With
Ihe
SSV
depr essed
towar d the
left end
lhe
line
pr essur e
3
is connected with
the line
pr essur e
10
the band ser vo
is r e
leased the fr ont
clutch is
engaged
and
AT 8
speed
is shifted to
3 r d
When the
acceler ator
pedJI
is
de
pr cssed
both the
line
pr essur e
3 and
the
thr ottle
pr essur e
19
ar e
high
allll
the
SSV is thus
r etained in nd
unless
the
gover nor
pr essur e
15
ex
ceeds the
line
pr essur e
3 and
the
thr ottle
pr essur e
19
In the
3 r d
position
for ce
de
pr essing
ihe SSV
towar d the
r ight
is
r etained
only
by
the
thr ottle
pr essur e
16
and
the thr ottle
pr essur e
16
is
slightly
Idwer
than that towar d the
r ight
which
is
applied
while
shifting
fr om 2nd
to
3 r d
Consequently
the
SSV is r etur ned
tothe
2nd
position
at a
slightly
lower
speed
Shifting
fr om 3 r d
to
2nd
occur sat
a
speed slightly
lower
than
that
for 2nd to
3 r d
shifting
When kicked down at 3 r d
line
pr essur e
13 is
led fr omtheSDV and
the
SSV is for ced
towar d the
r ight
Although
the
gover nor pr es
ur e
is
con
sider ably high
the valve is for ced
completely
lowar d the
r ight
and tht
SSV
is
thus r etur ned to 2nd
posi
tion
fhis
oper ation
is called Kcli
downshift
When
the shift iever
is
shifted
to
2
or
I
r ange
at
the 3 r d
speed
the line
pr essur e
3 ifdiained
at the
MNV
Consequently
the
fr ont clutch
and band ser vo
r eleasing
oils
ar e
dr ained As a r esult
the tr ansmission
is
shifted to 2nd or low
speed
ai
though
the
SSV
is in
the 3 r d
posi
tion
When the
specd
IS
shifted
io
the
3 r 1 a one
way
or ifice 24
on the
topof
theSSVr elieves
oil
tr ansmitting
velocity
fr om the line
pr essur e
3 to
th