SECTIONET

ENGINE
MODEL TUNE.UP
Jls, J15 & J15 SERTES
EilGnES

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 EngineTune-up

ENGINE
TUNE-UP

CONTENTS
DESCF IPTo N . . . . . . . . R E P L A CN G A R C L E A N E RF L T E R
BASC MEC H A N I C ASLY S T E.M . EI.2 ( v s c o ur sY P E ). . . . . . . . . . . ET5
ADJUSTN G I N T A K E A N D E X H A I J S T C L E A N I N GO R R E P L A CN G A B C L E A N E F
V A L V EC L E A F A N C E S Er-2 F I L T E F1 D R YT Y P E,). . . . . . . , . . . E T5
CHECK N G A N D A D J U S TN G F A N F E P L A C I N GF U E L F L T E R ET5
BELT.. ET.3 C L E A NN G F I ] E L F I L T E R C O U P L E DW T F
BETIGNTENIN CGY L N D E FH E A D N U T S , E L E C T F TPCI I M P ......... ET5
MAN FOLD BOLTSAND NUTSAND A D J U S T N G C A R B U R E T O R . I D L ERP [ 4
L A R B - RT O o I L U F I \ ' \ U - S . . . ET.3 M XTURERATO ET5
( n L L K I N Gr N C N t L O I V D R5 0 \ . . . ET-3 C H E C KN G F U E L L I N E S ( H O S E SP, I PN G S ,
L U B R I C A T I NAGC C E L E B A T OLBN K A G E . . E T 4 C O N N E COT N S ,e r c . )F O B L E A K S . . . . . . . . ET-6
I G NT l O N S Y S T E .N. 4. . ET.4 L U B RC A N TA N D C O O L ] N G S Y S T E \ .4. . . . , . ET-6
C H E C K ] NB GA T T E R Y EI.4 REPLAC NG OIL F LTEB ,, ,,.... ET.6
C H E C K ] NA GN D A D J U S T I N GG NT I O N CHANG N G E N GN E O I L . , . , . . . . . . . . . . ET.O
T M | N G. . . . . C F ] E CN K G E N G I N EO L F O R L E A K S. . . . . ET.7
C H E C K ] ND G S T R I B U T OBBF E A K E R C H A N GN G E N GN E C O O L A N T . . . . . . . . . ET.7
P ON T . . . . ET,4 C N A N GN G E N G N E C O O L A N T( L . L C , ) . . , E T7
CHECK N G O R R E P L A C I NSGP A F K C F ] E C K I N GC O O L N G S Y S T E M F ] O S E SA N D
P L U G .S. . . . . . ET.5 CONNECTION FSO F L E A K S. , . , , , , , E 11
C N E C K I NA GN D C L E A NN G H G H C F A N K C A S EE M S S O N C O N T R O L
TENSION W F E S ,D S T RB U T O RC A P S Y S T E f .i ,4. . ,,. .. ET-8
AND ROTOR D E S CPFT | O N . . . . . . . . . . . . . . . . . . . . . . .E. T 8
G R E A S I ND GI S T RB U T O FS H A F TA N D C H E C KN G V E N T L A T I O N H O S E S
CAN4HttL ET,5 ( A L L T 2 OA N D A 3 2 ] N 4 O D E L S E F I E SA N D
r-UtLSVSTIv ET.5 O T H E B SO N t Y F O R A U S T R A A L ) ....,, ET.8

bc Inadcwhilc cngincis strLlonnry.

DESCRIPTION
li may be needlcssto say, howevef,
to restorcpowcr and perfonnrncelhnt
has leen lost though wea!, cotrosion,
or deteriorrtion, periodicnl mainte-
nanc€tenglnetune'up) ts n€cessary.
Ii is cven nore inportant that the
engine tune-up be done accurately
accordingto the maintcnancescheduLe
shown in the applicrble Owneas
Manual.
This clupter descrlbesaciual opel
ating proceduresfor the maintenance
operationofitens to be inspectcd.
BASIC MECHANICAL
SYSTEM
ADJUSIING INTAKE AND
EXHAUST VALVE
CLEARANCES
Valve clearanceadiustment shol d
To ,diust, procecdxs tbllows:
1 . S i a r t c n g i n €a n d r u n i t u n t i l i l i s
h c a l c dt o o p e r a t i n gt e m t e r a t u i eo, r r t
least,more thrn 80oC (1760F) of
e glnc oil tenrperatLrreithen slop
2. Rotatc orritshrft io bring No. 1
cylinder in iop dead center on its
3. Renove valve rocker cover lo ET09A
gain rcccss to valve operating mech- Fie. ET 1 AdjustinE udlDecteomnce
Adjust valvc cicarance at the ,1. Again,rotatecrankshaftoncturn
following four pojnts while engine is so lhat No. 4 piston is in top dead
sllll hot: center on its compressionstroke.
Adjustfollowinsvalves:
O ExhaustvalveofNo. I cylindcr
@ ExhaustvalveofNo.2 cylinder
e) Intrke valvcof No. 1 cylinder
htake valveof No. 3 cylinder
Or Inrakevalveof No. 2 cylinder @
lntakevalveofNo.4 cylinder
O
O Exhaust valveofNo. 3 cylindel
@ ExhaustvalveofNo. l cylinder
Adjushlent shouldbe mddewhiLe
engineis hot. Atler aI valvcshave
been ,djrsted correctly.tightenlock
Note: Nmbers in par€nthesisagree
with those in accompanyingsketch. nut fifmly to secufethe adjusiment.
Er2
 E n g i n eT u n e - u p

CHECKING
ENGINE
COMPRESSION
0 . 3 5i n m
Noter If this test is to be p€rformed,
( 0 . 0 1 4i n )
it shouldbe done wh€n plrgs are
remoYedfor seric€ during basic
tune-upprocedue.

CHECKINGAND ADJUSTING Unlesscheckh madefor worn rings

FAN BELT
With the engine switched off dnd
the hood u!. push th€ b€Lt gentiy
downward. You shoL d be able to
d e p r e s si t a b o u t i 0 ] n m ( l / l i n )
midway between fan pulley and
a l i c r n a t o rf u l l e y b y r f o r c e o f l 0 k g
( 2 2 . 0 l b ) . I f t h e f a n b e l t h a sb e c o m e
s l i c k t h r o L r s hw e a r , l o o s e nt h e f i x j n g
and ad.justnrsbolts. ard rnovc thc
aliernitor away tuonl the engine.This
will eli in!Le tho shck. Tighlcn thc
b o l 1 sa E d i i . r n d n r u k cs u r c t h r t L h c
b c L l h a s b c c n t i g h t c n c dc o f l e c l l y . I f
t i g h t c n e d c x c e s s i v c l yi t w i l l w e r r
rrpidly .lnd rlso ovcrlord lhe wrtet
p u r r p a n d r l l c n r a t o rb c a r i n g s .
Fln bcli dcflcction:
8 L o 1 2n n n
( 0 . 3 1 5 0r o 0 . 1 1 7 2i40
10k-s(22 !b)
Fig. ET's TiehteninEserruene
Tighieningtorque
Cylindcrhcadstudnut:
5.0 to 6.0 kg-nr
(36 ro 13 fflb)
Vdlverockcrshaftbrackel
2.0to 3.0kg-m
(i4lo 2? ftJb)
Whcnthe €ngincis wrm, lighton
thc bolts nnd nuts to r iorqu€0.5
kg n (3.6 ft lb) higherthnnthe specifi-
Intake and cxhausr nwrifold bolts
and nuts slrculd be tightened to the
or lbr the cnuseof low speed,con-
pressioncheckshouldnot be neces-
sary.
Fig. ET-4 Tejting comprc*ion
pressur.
Test comprcssion rvith enginc
wrrn1, r11 spark plugs rcmoved and
t h r o t t l c a n d c h o k e o p o n e d .N o . c y l -
inder compressionshouid be lessthun
80% of highest cylindefs. Exccssivc
variatjon betwe€n cylind€rs, ac-
companied by low sp€ed missing ol'
lhc cylinder or cylindcrs which are
]ow, usually indicatcs a valve not
proFrly sealing or a broken pislon
ring. Low pressures, ev€n thougll
uniform, may indicaieworn Iings.This
may be xccornpaniedby excessiveoil

FiE.ET-2 Adiustins fan belt Tighteningl0que:

Intake and enlaust manifold:
L7 to 2.3 kgin
(12 to 17ftlb) Il one of more cylinders read]ow,
CYLINDER
RETIGHTENING inject about one tabl€spoonof engine
HEADNUTS,MANIFOLD oil on top ofthe pistonsin low reading
cylinders through spa.k plug porl.
BOLTSAND NUTS AND
C{rburetor iNtallaiion nuts should Repeat compressionchcck on these
CARBURETORSECURING
be tjghteDed securely. Lcaks a1 this cylinders.
NUTS l[ If compression improves con-
xrca may crnse .ough idlc. surging.
Cyljnderheadnursandvalverockel deceleration fopping or deceleralion siderably,piston.ings are defective.
shaftbracketboltsl whistle. 2. If compressiondoesnot impfove.
Whenthe engineis cold, tightening ,ralvesar€ sticking or not sealingprop-
shouldbe madein severalstelsandin Tighreningtorque: erly-
the scquenccshown in Figure ET-3, Carburctornuts 3. If lwo adjacenicylindersindicate
starlingwith lhe centerand moving 0 . 8 t o 1 . 2k g - n low compressionand injecting oil on
(6ro9ft1b) pisions does not increasecompresslon,
ET3

the causcmay b€ a cylinderhead
gasketlcak between the cylinders.
Engine oi1 and coolanr in cylhder
couldresullfrom thisploblem.
Compression pressure
ks/cn2 (psi)at rpm
(r7r)/3s0
12.0
r0.0(142y3s0
LUBRICATING ACCELERATOR
LINKAGE
Apply a light coatof nn tipurposc
greascto ail slidinSor trictionsurfaccs
exceptball joints. The entife ljnkage
shouldbe rnspectcdwhclhcr or not
foot rcsl rctums to nornal hcight
smoothlywhenreleasing foot from ii.
This test shouldbc madcwith cngine
funning.Added careshouldbe takcn
in checkingitems that affect proper
linkagcfunclion.
IGNITIONSYSTEM
CHECKING BATTERY
Checkthe electrolyte
levelin each
battc!y cell.
l4 Unsct€w o&ch filler cr! and
inspect fluid icvel. lf the fluid is low.
add distiled walcr io bring the lcvcl
up approxinately 10 lo 20 mrn (0-394
to 0.787 in) abovethe plates.Do not
overfill.
2. Mexsure the specific gravity of
Fie. ET-' che.kine the specific
eruuitr of bdttery electrollte
EngineTune-up
vdue
Fully charged
Permissible
value
(at20oC,680F)
Frigid climatcs O\et 1.22 1.28
Tropicalclimates OverL 18 1.23
Otherclimates Over1.20
Clean the top of baltery and ter- Adjusi the tining to the specifi-
minals with a solution of bxkirg soda cations, tuming distributor body
and water. Rinse off and dry with loosenedsccuringbolt.
conpr€ssed air. Thc top of bxttery
must be clean to prevent currenl lerk.
age between temrindh rnd ho posi
tjve temrinal to hold.down chrrp.
In addition to currenl leakrge,
prolonged accumulation oi acid and
dirt on (he lop of battcry nray cduse
corrosjon of slmps. After tigfitening
teflninals, coa! thcm i!ilh petrolatunr
(vaseline)to protcct thcn fronr cor
Fig. ET-7 Atljusting ignition litning
CHECKINGAND ADJUSTING
IG ITION TIMING
Wiih disLriburor li']cdis-
vacuunr
connecled and vehicl€ opcrrlirg nt lanition timing (B.T.D.C/rpm)
normal idle sp€ed or below, set J l 3 ,J l 5 a n dJ l 6 8 0 / 6 0 r0y m
jgnjtion tiIning.
The iiming can be observedby Lhc
siatio|ary pointer ai frcnt covcr lnd
tle groovcson craikshaft pulley with
a d€vice called a slruboscopic light CHECKINGDISTRIBUTOR
(alsofefer.ed lo as a tining lighl). BREAKER POINT
Note that the pullcy groove is
gnduated 5o per scale division in
tern$ of the crank rngle. Thc to! dcad
center is locrted to lhc extrernelefl as
viewedfrom rhe inspeclor'sside.
Fie. ET 8 Che.hitc dkhibutor
potnr gdp
' - f
Fis. ET 6 Checkinqignitian timins
ET-4

Rernovedistdbulorcapandinspecr
burningor pitting.
pointsfor excessive
Replacepoints if necessary. Use a
point file to cleancontaclareaand
removescalefrom points.Adjustdis-
tributor point g!p. Filing is tbr
cleaningpurposesonly. Do not af
tempt to removeall roughness.Adjusi
distributordwel angleon rll engin€s.
Distributorpointgap:
0.45io 0.55nm
(0.o177 to o.o2l7in)
Dwe[ ansle:
49oto 55o
CHECKING OR REPLACING
SPARK PLUGS
Fig.ET-g Ch.chingsparhpluqgop
See tMt conect spark plugs are
us€d.Sparkplus rnsulatofs
shouldb€
ro preventpossible
thoroughlycleancd
Thoroushly clean lower insulator
and cavityby blast type clcaner.Filc
bolh eleclrodcsilat Goundedsurfirccs
incrcasevoltagerequiredro fire pluBt
and set gap.Tightenplugs!o ldque.
Sparkpluggap:
J13
0.7 to 0.8 mn
(0.0276 to 0.031sin)
J 1 SJ, 1 6
0.8 to 0.9 nu
(0.0315 to 0.0354in)
Tightening torqxe:
1.5ro 2-0kg-m
(11 to 14 tt.lb)
CHECKING AND CLEANTNG
H|GH TENSTON W|RES,
DISTRIBUTOR CAP
AND ROTOR
Note: This op€rationis to be per'
formed while checkirg distributor
E n g i n eT u n e - u p
External surfacesol a[ parts of CLEANING OR REPLACII{G
secondafy be
systemmust cleaned to AIR CLEANER FILTER
reducepossibiliiyof voltage1oss.AI (DRY TYPE)
wires shouid be removedfrom dis- It is necessaryto clean the elemeni
tribuior ca! and coil so lhdt terminals or replace ii at the recomnended
canbe inspecl€daDdcieancd- Burned interval, nore often under dusty
or corrodedterninals indicatelhat driving condilions.
wifes were not fully seated,whioh
causes arcingbetweenend ofwire and REPLACING FUEL FILTER
terminal.Whenreplacingwiresin ter-
Check for a conianinated elernent,
minal, be surethey are fLllly sealed
before pushingrubber nipple down
overiow€r.Checkdistriburorrotor for
drmagc,anddislributorcapfor cncks.
GREASING DISTRIBUTOR
SHAFT AND CAM HEEL
Clcan and apply multi-purlose
grease
to camandwick.
Note: Do not apply greaseexces-
sively.
lE. ET'I1 Fuel sttainel
FUEL SYSTEM All engines us€ a cartljdge tYPe
shriner, so if r malfunction is
REPLACINGAIR CLEANER delecled,replaceasan assembly.
FILTER (VISCOUS TYPE)
The nif clerneruscsu wet papet CLEANING FUEL FILTER
lypc clerncr olcment (viscous lype). COUPLEDWITH EIECTRIC
As this elenrenl has becn manu- PUMP
faclured under speciNilreatmcnt, lhere
is ro need of cle ning until ii is
replacedwith a new one.Allhough the
cleaner clcment looks dirly, do noi
atlenrpl to clern. Thc clcaning peF
formanoe in con(antly maintained
though it looks contaminated.Cme
must b€ taken noi to injurc clcancr
Repl ce elemenl wiih a new one ar
recommended interval, norc often
Fis. ET 12 Replacingfuet putup
under dusty driving cordiiions. filt.r
Check for a coniamindtedliltel and
warer deposil. If filier is def€clive,
replaceit wiih a new one.
Also check packngs and o-rings, if
they rre defective, replace with new
ADJUSTING
CARBURETOR-IDLERPM
MIXTURE RATIO
is madeby throtlle
Idleadjustment
adjustscrewand idle adjxst screwafter
Fig. ET 10 Reptacinqdir.Ieaner engine is warmed !p. See Figure
filter ET-13.
ET.5

2 Throtucadjuslsrew
1. Checkto be surethal float levelis
correctwhilecngineis al idlespeed.
2. Usinga suitablescrewdriver, lLrn
out idle adjusl screwapproximately
two or threelurns,startingfrom fully
clos€dposition.Turn in throttleadjust
screwtwo or lhree lurns dnd stlrt
3. Turn out lhrottle adjust screw
genilyuntil specjfied
engineidl€speed
is approxinatelyobrained.
4. Turn in or out idie adjustscrew
until engine runs srnootNy at the
higheslspeed.
5. Turn oul throttle adjus! screw
until specified€rgine speedis ob-
tained.
6. Readjustjdle adjusl screwuntil
engineruns smootl y al the high€st
speed (ltith the highesl vacuum
reading).
7. Then, throttle ddjustscrewmusi
be bdjusledso ihdt enginespeedis 20
rpm fastefthanspecified.
8- Finaly, turn in idle adjustscrew
until specified
enginespeedis attained-
a. Items 7 and 8: B€st n€thod to
elininate carbor mononde in ex-
haustenission.
b. Do not att€mptto screwdown th€
idle adjust screw completely.ff
damageto the tip may resultwhich
will tend to csusenalfunctions.
E n g i n eT u n e - u p
For cabovcrtype tuck
assemblyusing oil Filtcl Wrench
ST1932000.Whcn installingan ojl
filter, fastenft on cylinderblock by
hand.
2. Thc oil filter elemenlshouldbe
re!lacedat reconn1cnded inteNah.
Notes:
a. Do not overtightenfilter, or oil
leikngemayoccur.
b. Whenassenblingoil the sealring
lightly.
Fig. ET t3 ldling adiBhnent
f i C E f l 4 R . , n u r L n +o i t / i | L . l
Jl3,JlsandJ16
CHANGINGENGINEOIL
l. Chcck if cngiic oil hrs bcen
Enginemanilbld d c l c r i o n r c db y l i v x d i n 8c o o l i n gw a l c l
o r g r s o l i D c .D n i n r n d r c i l l o i l , i f
speed
tumHg (inHg) 2. Drrinlig rs bcsl donc rlicr a good
run, whcn drc oil, being thoroughly
wrrn, will flow rerdily ir d freely xnd
CHECKINGFUEL LINES
xny forcign malter will bc hcld in
(HOSES,PTPTNGS,
CONNECTIONS,etc.)
FOR LEAKS Placeit hrgc bowl or olher shxilow
cont.riner undcr ll1c cngine. Then rc-
Checkfuel lines for loosecon-
move thc oil pan dr.rin !lug. Do this
nections,
cracks
anddeterior.rtion.
Re,
carefully. as ihe oil will bc hot and it
tighten
looseconnectionsi
if recessary,
will spufi out with somc force. AfLer
replace any damaged or defeciive
complerely drainins the dnLy oil off
sccurelyfephce the oit drain plug and
finally refill the engine jn thc usual
LUBRICANTAND "H" nark on thc
wry up to lhe
COOLINGSYSTEM dipslick. Mrkc surethrt the cm is on a
level surlioe wlnle drahing lnd fi1ling
REPLACING OIL FILTER
the €ngiic-
The oi1 filter is of .t full-flow
cadridge type. The on I'iller elementn
sealedin the containeras a unit. It can a. A nilky oii indicatesthe presence
b€ easily removed by lrrnd with a of coolingwater.
specialtool. Discover the cause for necessary
l Check for oil leaks at packing
flan8e. If any leakagejs discovered, b. An oil with extremelylow vismsity
lighten a iittle, or rellace o tilter suggestsdilution with grsoline.
 EngineTune-up

3. Checkoil levei,andif it is below samegradeup to the H level. CHECKINGENGII{EOIL FON

the specifi€d
level,replenish
oil of the LEAXS
Check cylinder head, front chain
cover,oil pan, rockercover,oil filter
gasket,etc. or other parts for si8n
of leakspast their gasketedsurfaces.
.If necessary,replace gaskets or
def€ctiveparts.After maintenance las
beendone,checkthereplaced partsto
seeif nayleaksoccur.

CHANGING ENGII{E COOLANT

FE. ET-15 Checkingenqineoil leuel
Scaleor sedimentaccumulated in
Oil c{pacity of ensine(includingoil filter) water jacket or radjatorharmsheat
radiation.Thoroughlyflushtho system
Maximum (H level) nfter opcningiwo drainplugs,(on€at
4 . 4L ( 4 % , 3 % ) the bottom of the radiatorand the
J13 (U.S.qt,,Irnp.qt.)
J15 other at the riglt sideof the cylinder
Jl6 Minimum (L level) block),until cleanwatercomesout.
(U.S.qt.,lmp. qt.)
3.41(3%,3) Alwaysusecleansoft waterin the
radiator,Whencold season arrives,
the

cooling systelhshould be protected

againstfreezingby a goodanti-ffeeze Botlingpoint
solution suchas NISSANLONO LIFE Percent Freez€
COOLANT, 0,9k8/cmz(13psi)
Sealevel cooling
system
To allow for expansionwhenhot,
the level,whencold,shouldbe visible
just below the liller neck, Do not 1050c 1240c -150c
30% (2230F) (25soF)
overfill the system. This coolant
(L.L.C) shouldbe changed everyrec-
1090c 127"C -3soc
ommended interval. 50% (228'F) (261'F) (-3loF)

GHANGING ENGINE
CIOLANT (L.L.C.)
o (32) In3pection of radlrtor cap
l{laarn long lif€ coolanl
" 1 0{ 1 4 1 Apply refercnce pressure [0.9
L.LC. is an ethylen€glycol base kg/crnz(13 psi)l to radiatorcap by
product containingchemicalinhibitors -20 (41
meansof a captesterto seeif it is in
to protect tne cooling system frorn -N t-221 goodcondition.Replacecapassembly
rustingand corrosion.The L.LC. does ifnecessary.
not contain any glycerine,ethyl or 40 {-40)
methyl alcohol. [t will not evaporat€
-50i-58)
or boil away and can be usedwith 10 20 30 4() 50
€iiher high or low temperature
thermosiat.It flows freely, tra$fe$ Fig. ET-16 Ptutection .orcehttution
heat effici€ntly, and wi not clog the
passagesin the cooling sj,stem.The CHECKING COOLING
L.LC. must not be mixedwith other SYSTEM HOSES AND
products.This coolant can be used CONNECTIONSFOR LEAKS
throughoutthe sealonsof the year-
lvheneverany coolant is changed, Checkcoolingsyst€mhosesand
the cooling systemshould be flushed fittings for loose connectionsand
andrefiIed\tith a newcoolant. deterioration.Retightenor replaceas
Checkthe level. Fie- ET-U TettinA rc.li4tor cap
 EngineTune-up

Cooling 3yatem prcssure test referencepressure[1.6 kg/cn2 (23 systemcomponents.

pstl to thp coolingsystembY means
With radiatorcaprenoved,aPPIY of a tester to checklor leaksat the

620 A32l T20

Withheater(u.S.qt.,Imp. qt.) 6 . 0 1( 6 % , 5 ) 6 . 5L ( 2 %, 1 % ) 8L(8X,1)

Withoutheatei(U.S.qt.,Irnp.qt.) s.4L(s%,4%) s . s 1 . ( D t , 1 % ) '7r, ('t%, 04)

rnodeiseriesand othersexported1o CHECKING VENTILATION

onlyAustralia. HOSES(ALL T2O AND
The controi systemconsistsof a 4321 MODEL SERIES
hosc connccledto the Yalverock€r AI{D OIHERS ONLY FOR
coverfrom ihe crrburetorair cleaner. AUSTRALtA)
This is feferred to as a "sealed
system"whichprovides an escapepath
gas
for the blow-by with no provision
for the intfoductionot ventihtionair l Cheokhoseand hoseconnections
ior leaks.
FiS.ET-18 ?atine cooling sytem Flow of blow-by gas is inducted 2. Disconnectall hose and blow
inlo th€ hoscby tlrc ncgativepressrr€ themout with compfessed ajr.
croatedwhen thc enginesucks th€ Il any hosecannot be madefteeol
freshair ihioughthe air cleaner. obstruclions,replacewith a new on€.
CRANKCASE The oil filler capandoil levelgauge
EMISSION CONTROL areof a sealedtype1l)preventblow-by
SYSTEM gasin cfankcss€ from escaping inlo the

DE3CRIPTlOT{
This systemis adoptedin all T20
andA32l

FE. ET 19 Sealedtrpe crdnhc$. uentilationslstem

ET.8
 EngineTune-up

SERVICEDATAAND SPECIFICATIONS
mm ain\

Iniake 0.35 (0.0138)

Hot
Exha st 0.35 (0.0138)

Fanbelt deflection (lnllb).......,.........

mnvkg 8 to t2lro(0.31
to0.47122)
Compression prcssure
Standad Rg/crn-$sr) at rpm (17r\13s0
12.0
Mlnlnum Kg/cm-$sr) at rpm (142y3s0
10.0

Batterylpeciflcgravity

Permfusible
valu€ FuUychargedvalue
(at20oC,68oF)

Frlgidclimatos O\er1,22 1.28

Tropicalcllrnates Overl.18 t.23

Other cllrnateg Over1.20 t.26

Ignitiontiming 8o/600
Distributorpointgsp 0.45to 0.55
(0.0177to 0.02I7)
Dwellangle 49to 55
Sprrkpluggap
J13 0.7to 0.8(0,028to 0.031)
J15,J16 0.8to 0.9(0.032to 0.035)

O capacityofengino (including oil flter)

J 1 3 J, l s a n dJ 1 6

4.4L (4%U-5.qt , 3%Imp. qt.)

3.4/ (3%U.S.qr, 3 Imp.qt.)

ET.9
 EngineTJne-up

Coolingsystem
Testingpressureof radiatorcap tg,/cln2(ps)......... ...... .........0.9 (13)
Testingpressureof coolhg gYstem
(psi) .... ..........
ks,/cm2 ..'....r.6Q3)

Watercapacity

620 A32l T20

With heater
(U.S.qt.,Inpiqt.)
6 . 0 L( 6 % , s x ) 6.sL(2%,
r%\ 8 L ( 8 X , 7)

Withoutheater 5.4L(5%,4%\ s . 5 L ( r xr,N ) 1 L (7%,6h' )

(U.S.qt,,lnp. qt.)

torque
Tighterung
headrtudnut
Cylinder
shaftbrackot
Rocker bolt
Manifoldnuk
Intake& exhaust
socuring
Carbur€tor nutd
Sparkplug

ET.IO
 EngineTune-up

AND CORRECTIONS
TROUBLEDIAGNOSES
Condition

CANNOTCRAIK lmpropergradeoil. Replacewith propergradeoil.

ENGINEOR SLOW Dischargedbattery. Charge
batlery.
CRANKING
Defectivebattery. Replace.
lrose fanbelt. Adjust.
Troublein charSesystem. Indpect.
wlring connectiontrouble in 8t&ting circuit. Corr€ct.
Defectivestarterswitch. R€pairor rcplace.
Defectivestartermotor. Repairor rcphc€.

(frouble-shootlng
procodure on stsrtingcircuit)
Switchon theshrtingmoto.with ltght 'ON."
whonllght 90e3off or dlrnsco8idonbly.

Check
bottery.
endcable.
b . Chcckconn€ctlon
Checkstsrtcrmotor.
Whcnlight strysbright.
Checkwlring conncctionbetweenbatt€ry and rtarter
motor.
b . Ch.ct strrterswitch.
Checkstlrtarmotor.

ENGINEWILL CRANK NORMALLY BUT WILL NOT START

In thls crr6, th€ following trouble crusesmay exist,but ln many casesiSnition tysternor fuel systemis in trouble,

IgnltlonVste,nnouble

Vabetn chadsmaoeraot uoth ptopetly

(Trolble-slwotlry prbcetute)
Chocksparkplugfirst by followinSproc€dure
Disconnocthigh temioncablefrcm one sparkplug andhold it
.bout l0 mm (0.3937tn) from dre€ngin€metalpsrt andcrank
theengine.

lfgoodspa.koccuru-

a. Checksparkplug.
b. Ch€ckignition tining.
c. Ch€ckfuel system.
d. Checkcylinder compre$ion.

If no sparkoccurs. Checkthe current flow in primary cncuit.

Veryhighcurrent. IrBpect for sho ed pdrnary circuit.

Checkbre.ter poht operation.

ET.lI
 EngineTirne-up

Condition Correctrve
action

Lworno cunent. Checkfor loos€terminalor disconnectionin

Checkfor burnedpoints.

Isnition Bum€ddistrlbutorpoint. Repairor replace.

rrouble Improper pointgap. Adjust.
Defective condinser. Replace.
laak at rotor capandrotor. Cleanor replace.
Defective sparkplug. Clean,sdjustpluggapor replace.
Improperignitiontiming. Adjust.
Defectlve ignitioncoil, Replace.
Disconneciion of hight€nsion
cable. Replace.
loose connoctionor disconnection in Repairor replace.
primarycircult.

Fuolwrtamtroubla Lackof fuel. Supply.

Dirtyfuelstniner. Replace.
fuel piFe.
Dirty or clogged Clean.
Fuelpumpwill notworkprcperly. Repairor rcplace,
Carburetor chokenrlllnotworkproperly. Checkandadjust.
Improper adjulimentof floatlev€I. Correct.
Irnpropcridllng. Adjust.
Dlrtyor cloSg€dcarburetor. Disassemble
rnd clean.
CloggedbreEtherpipeof fireltrnk. Repairandclean,

Incorrectsparkplug tlghtenlngor defective Tlghtento normaltorqueor replac€gssket.

gasket.
Improper gradeengin€oil or low vhcosity. Rephcewith propergradeoil,
lncorrectwlv€ clearance. Adjust,
Compression leakfromvalveseat. Removecylind€r headand lap !"ives.
Stlckyvalvestem. Corrector replacevah€ andvalveguide.
Weakor defectivevalYesprings. Replacevalv€springs.
Compression lo.k at cylind€rheadgasket. R€placegalk€t.
Stickingor defectivepistonrin8. Replacepiston rings.
Wo|npistonringor cylinder. Overhaulengjne.

(TroubleNhootingprocedur€)
Pour engin€oil into plug hole, and then meaiur€cylind€r
compressron.
Comprescjon
increases. Troublein cylinderor pistonring.
Compressiondoesnpt change. Compressionleaksfrom valve,cylinder h€ad
or headgasket.

EI-12
 EngineTune-up

Condition conectiveaction

ENGINE
IMPROPER
IDLING

Fu6l syrtemt.oublo Cleanor replace.

Adjust.
Replac€element.
Replacegasketor rnsulator.

Adjust.
Previouslymentioned.

Othsr! Adjust.
Adjust.

ENGINEPOWERNOT
UP TO NORMAL

Pr€viously
mentioned.

l0nlllonry3Fmtroubla Incorrectignltloniiming. Adjwt.

Defectivesplrk plugs, plu8t.
Cleln,adjustor reploce
distributorpoints.
Defective Dresr, or replace potnts. Also check

Fu6l rylt m roublr Malfunctionof cho*e syst€m. Adjust.

ClogSedfuelpipeor floatlngvalve.
fuel strainer.
Dirty or clogged Replace.
Fuelpumpwill not work properly. ReFir or replac€,
Clogged jets.
carburetor andcl.{n.
Dlsassemble
Throttlevrlvedo€snot openfully. Readjust.
.
Fu€lpumpout of adjustment, Runajqtt.

Cloggedair clean€r, Replac€element.

troub16 Air inhaling from rnanifold gasket Replac€gasket.

overheatins Insufficientcoolant. Replenish.

Loosefanbelt. Adjustfanbelt.
fanbelt.
Womor def€ctive Replace.
Defectiv€thermostat. Replac€.
Defectiv€water pump. Replace.
Cloggedor lealy radiator. Flush,rcpairor replace.

ET-13
 EngineTune-up

Condition action
Corrective

Defective
radiatorfiller cap. R€plac€.
Air in coolingsystem. R€tighteneachpartof coolingsystem.
Improperengineoil grade. with propergradeoil.
Replace
Incorrectignitiontiming. Ad.iust.
carbur€tor(leanmixtur€).
Defectiv€ Overhaul
carburetor.

Ovo.cooling Defective
thermostat. R€place.

Orh€rs Inproperoctanefuel. Replace

with specified
octanefu€l.
Imprcpertire pressure, pressure.
Inflateto specified
Draggine
brake.
Clutchslipping.

NOISYENGINE

Carknod(ing Overloaded
engine. Userightgearin driving.
Carbonkno€king. Disassernble
cylinder head and remove

Timingknocking. Ad.iustignitiontimtng.
Fu€lt(nocking. Usespecifi€d
octansfuel.
(misusinS
Preignition of sparkplug). sparkplug.
Usespe€ified

Moch6nic!l
knockins

Crankshaft
bearing Thh stronSdull nohe increas€s wh€nengine
knockinB. is accel€rat€d.'Iolocateth€ place,causea
misfireon eachcylind€r.lf the nois€stops
by the rnisfire,this cylinderg€nerat€s
the
This is causedby wornor drmagedb€anngs,
or un€v€nly worn crankshaft. Renew
bearings andadjustor chrngecranksllAft.
Ch€cklubricationsystem.

ConneciinSrod noisethanthe
This is a little highel-pitched Sameasth€ cac€ofcrankshaftbearings.
bearingknocking. crantshaft knocking, and aho incr€ases
whenengineis acc€lerated. Causea misfire
on eachcylinderand if the noisediminishes
alrnostcompletely,this crankshaftb€arin8
Senerates the noise.

Pistonandcylinder Whenyou hearan overlapping m€ralicnoise
which increasesits magnitudewith the
revolutionof engineandwhich decreas€sas
by
engineis warmedup, this noiseis caus€d
phton and cylinder.To locatethe place,
caus€a misfireon e3chcylinder.
This may cause an abnormal wearing of
cylinder and low€r compression which in
turn will causea lower out-put powerand
excessiveconsumptionof oil,
Overh.ulengine.

This noise is heard at each highestand This rnay causea weai on piston pin, or
lowest dead end of piston.To locatethe pistonpin hole.
place,causea misfueon eachcylinder. Renewpistonandpistonpin ass€mbly.

This noise may be causedby worn or waterPumPwith a newone.

Replace
darnagedb€arings,or by the unevensurface
of slidingparts.

ET.14
 EngineTune-up

Cotdition Probablecause Cofiectiveactlon

Othe$. An improper adjustmentof valv€cl€srrnce. Adjust.

Nois€of timing chain.
An exc$;ive €nd-playon crankshaft,
Note: Thir troire w l b€ h€ord when clutch
b direqaged,
Wearon clutch pilot busbing,
Adjust the tensionofchein.
Dsassembleengineand r€newmaln bearing.
Rene],bushand adjustdrive shaft.

Noter Thir noisewill be heardvhetr clutch

is dir.ngsged.

ABNORMAL
coMausTtott
(backflre, afterflre
ru["onetc,)

lmprop.lignitioniining Ift properlgnltlontlrnlng. Adjuit tgnltlontlning.

lnlproparheatftngeof sporkplugs. Usespeclned iparkplugs.

Fualryiofi troubla Danagedca6uretoror manifoldgasket, themwlth nowpart3.

Replace
Oackflre, afrcrnrc).
crrburltorjet.
Daf€ctlv€ Dlsr$€mblecarburetorandchecklt.
Inproperfunctionof th€float. valve,
Adjwt thelevel,andcheckne€dle
Un€venidling.(Runon) Adjust.

Drtrctlvacyllndarh.ad, lnprop€rlyadjultedr€lveclearance. Adj$t.

elc. Excorsorrbonin combustlon chlmber, Remowh6rdrnd g€trid of crrbon.
D&maged valvespring(backftle, after flr€). Replsceit wlth r n€iwon€.
EXCESSTVE
OtL
CONSUMPTION

Oll loakago Looseoil dralnplug. Tightenit,

loose or damagedoil pangasket.
loose or damagedchaincov€rgasket,
Defective oil seal in front and r€ar
crankslEft.
lrose or drmagedlocker covergasket.
otoil filter.
ImpropertighteninS
l-ooseor damagedoil pressur€switch.
Ren€wgrskct or tighten it.
Renewgasketor tightenit.
Ren€woil seal,
Renew gasket or tlghten il (but not too
rnuch).
Renewgasketand tight€n it with the p.op€r
torque.
Renewoil pr€ssur€switch or tiShtenit.

Exc4.ive bil Cylinderand pirton wear. Overhaulcylinder andrenewpiston.

tmproper location of piston riflg gap Remountpiston rings.
reverselyassembled piston ring.
Damagepiston rings. Renewrings,
Repairor ren€wpiston and cylinder.

ETIS
 EngineTune-up

Cofldition Probabl€cause Corrective

action

lvorn piston ring grooveanalring. Renewpiston andpiston ring.

Fatigueofvalveoil seallip. Replaceseallip with a new one.
Renewvalv€or guide,

Olhaas Inad€quetequality of engineoil. Usethe designatedoil.

Engineoverh€at. Predouslymentioned,

POORFUEL
ECONOMY

S.. thooel.oation
of lha porr€rdaqaaro

Olh.ri Bxceeding idllngrevolutlon. Adjult lt to the designatedrpm.

recovery.
Dcfectivescc€leration Adj$t it.
Fuelle.lag€. Repair or tighten the cormection of fuel
pipes.

TROUSLEIN OTHEN
FUNCTIONS

Dacr€rrd 9ll prot.un oil quallty.

Inadequate oll.
Usethedesignated
Overhest. mentioned.
Previously
Defectivefuncdon of oil pump regulator oil pumpandrepairor rcnewit.
Dis!$emble

Functionaldeterlor.tionof oil pump. R€pairor replaceit with a newo'Ie,

Blockedoil fllter. R6nowit.
Increasedcleannce in various sliding Par$, and roplate th€ worn partawith
Disass€mble

Blockedoil strainer. Cleanit.

Troubl6 in oil gaug€pressureswitch. Replaceit with a new one,

Ercr-lvo w6aron tho Oil pressuledecreases. Previously

mentioned.
.ldin0p.rtr Defectiv6qualily or contamlnatlonof oil. Exhangethe oil with porp€r olte andchsnge

Defective
air cl€n€r. Chaeelement.
Overheator overcoot. Previously
m€ntioned.
lmprope. fu€l nixture. Checkthe fuel syst€m.

Sdtffing of Ciding in oil pr€ssure.

Decr€ase Previouslym€ntioned.
partt Ineufficient cloarances. Readjurtto the designatedclearances.
Overheat. Previouslym€ntioned.
lnproper fuel ftixture. Checkthe fuel system.
 EngineTune-up

SPEC]ALSERVICETOOL
Tool rumb€r For Reference
Description
No. & use pageor
toolname Unit: rnm(in)
figure No.

l. sT19320000 This tool is usedto take oil filter out ofphce. In tightening All
the filter, do not uselhis tool, to proventoxcesrtightening. FisBT"l4
Oil filt€r models

120(4.1'

;
ET-I7