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Download Service Manual Datsun 510 1969-1973
Transcript
0 f 1 j 1R1 1M o o @ 7 o I r t Jot I 0 4 V J 7 F 2 V 4 y oomm llI IP J c ffi DRAKE PUBLlSHERS INC r O DATSU RANGE 1969 1973 MAINTENANCE REPAIR BY DRAKE AUTOMOTIVE EDITORS Quick Reference Indel MAINTENANCE TUNE UP STEERING 5 91 ENGINE 21 REAR DRIVE ELECTRICAL SYSTEM 39 CLUTCH FUEL SYSTEM 67 TRANSMISSION 107 COOLING SYSTEM 77 BODY WORK 115 BRAKES 81 SPECIFICATIONS 119 FRONT SUSPENSION 89 Tho purpose eference We of this manual source ndeavor specifications to at the Publisher rors or Upon make provide the he utomobila perform normal owner ervice not be held Ipon ible for nd mechanic with operations date manufacturing changes typographical omissions elying on this manual formation contained herein the combination of photograph we have tried illustration elul tool DRAKE PUBLlSHERS ING 381 PARK NEW AVENUE YORK NY SOUTH 1CXJ16 95 99 rporato the late t manufacturing design changes nd upto made to attain the time of publication While ryeffort ompiting the impls to with which SUSPENSION to be nd brief and l 1 to te cy ISBN 87749 302 2 Published in 1973 by Dlake Publishers Inc 381 Palk Avenue South NewYolk N Y 10016 @Dlake Publishels Inc 1973 Printed in the United States of America able of Contents MAINTENANCE TUNE UP CHARGING CIRCUIT DESCRIPTION ALTERNATOR 40 41 VALVE CLEARANCE 6 Description 41 FAN BELT 6 Removal 41 ENGINE OIL 6 Installation 44 OIL FILTER 6 COOLANT 7 Descri ption 44 7 Measure ofVoltage 45 7 Adjustment Charging Relay 47 Nissan Long Life Coolant COMPRESSION Test Result 8 BATTERY 8 IGNITION TIMING POINTS CONDENSER VOLTAGE REGULATOR 44 48 49 9 ALTERNATOR FUSES FUSIBLE LINKS 9 EMISSION CONTROL DIAGRAMS 50 9 DISTRIBUTOR 52 52 49 SPARK PLUGS 10 Construction CARBURETOR 10 Disassembly 52 11 Assembly 53 Idle Limiter CHECKING Cap ADJUSTING DASH IGNITION COIL POT Automatic Transmission Only 11 Installed on Engine DUAL POINT DISTRIBUTOR Cap and Rotor Head 11 12 56 Construction 56 Descri ption 57 SPARK PLUGS 5 12 Descri ption Point 12 Inspection 58 Phase Difference 12 58 TUNE UP GUIDE Cleaning and Regap 14 TROUBLE SHOOTING IGNITION 58 TROUBLE SHOOTING 15 HEATER UNIT REMOVAL 59 TROUBLESHOOTING HEADLIGHT 62 TROUBLESHOOTINQ 63 22 REMOVAL 23 24 24 Pistons and Connecting Rods 2 Cylinder 27 ASSEMBLY 63 Removal DESCRIPTION Head HORN RADIO ENGINE INSTALLATION DISASSEMBLY 5 63 TROUBLESHOOTING SPEEDOMETER 65 TROUBLESHOOTING RADIO 65 NOISE PREVENTION CHART 66 FUEL SYSTEM 27 Cylinder Head 28 AIR CLEANER ELEMENT Piston and Connecting Rods 29 AUTOMATIC TEMPERATURE Engine 30 OIL PUMP 36 Removal 36 Installation 3 CONTROL AIR CLEANER AIR CONTROL VALVE Idle Compensator TEMPERATURE SENSOR Removal ELECTRiCAL SYSTEM Removal 68 68 68 69 69 69 Installation 69 FUEL PUMP 69 Removal and Disassembly STARTER 64 TROUBLESHOOTING HEATER 40 Inspection 40 Assembly 69 O 70 1 Table of Gontents CARBURETOR Removal 3 FRONT SUSPENSION 3 Disassembly 3 Float Chamber ANTI DIESELING SOLENOID RECOMMENDATIONS 74 Removal 4 Installation 90 74 STEERING 74 BOOST CONTROLLED DECELERATION DEVICE Assembly and Installation Cleaning and Inspection JETS STEERING GEAR COMPONENTS 92 74 RECOMMENDATIONS 92 74 ASSEMBLY 93 74 STEERING LINKAGE 93 5 REAR DRIVE SUSPENSION COOLING SYSTEM SHOCK ABSORBERS DRAINING FLUSHING WATER PUMP 78 78 Removal 78 Disassemb y 79 Inspection 79 Installation 79 THERMOSTAT Removal and Installation RADIATOR 96 Inspection 96 Installation 96 DRIVE SHAFf 97 RECOMMENDATIONS 97 79 79 CLUTCH 79 Removal and Installation Inspection 9 80 REMOVAL 102 RELEASE BEARING 102 REPAIR 103 Refacing Pressure Plate BRAKES MASTER CYLINDER 82 Installation 82 FRONT DISC BRAKE 82 Description 82 Removal 82 Disassembly ADJUSTMENT INSTALLATION MASTER CYLINDER Removal 103 104 104 105 105 Disassembly Inspection 105 Assembly 106 Installation 106 BLEEDING CLUTCH SYSTEM 106 106 84 and Repair Piston Seal Replacement Assembly and Installation Pad Replacement 84 85 TRANSMISSION 85 86 REMOV AL 109 REAR BRAKE 86 INSTALLATION III Removal and 86 4SPEED TRANSMISSION 113 87 Removal and Installation 113 Inspection Assembly 2 82 Removal Inspection 96 Removal Disassembly 88 RECOMMENDATIONS 113 Table of Gontents BODY WORK FRONT FENDER Removal and Installation SPARK PLUGS 122 VALVES 122 116 OIL PUMP 122 116 GENERAL 123 123 116 ELECTRICAL Removal and Installation 116 MANUAL TRANSMISSION 12 Adjustment 11 CARBURETOR 131 TRUNK LID 11 CLUTCH 134 11 ENGINE HOOD Removal and Installation Torsion Bar Removal and Adjustment TORQUE 117 SPECIFICA liONS LUBRICANTS SAE DISTRIBUTOR 121 138 PRESSURES 139 AUTOMATIC TRANSMISSION 140 PROPELLER SHAFT 144 BRAKE CHASSIS 120 136 138 TUNE UP CAPACITIES Sf ARTER INFORMATION ALIGNMENT NOTES WHEEL 146 14 a llaiDteDlDce Tune up VALVE CLEARANCE 6 FAN BELT 6 ENGINE OIL 6 OIL FILTER 6 COOLANT Nissan 7 Long Life Coolant 7 COMPRESSION 7 Test Result 8 BATTERY 8 IGNITION TIMING 9 POINTS 9 CONDENSER 9 SPARK PLUGS 10 CARBURETOR 10 Idle Limiter CHECKING Cap POT Automatic Transmission Installed on Engine DUAL POINT DISTRIBUTOR Cap and 11 ADJUSTING DASH Rotor Head Point Only 11 11 12 12 12 Phase Difference 12 TUNE UP GUIDE 14 TROUBLE SHOOTING 15 I IlaiDteDlDce TUDe up VALVE CLEARANCE Valve clearance adjustment is FAN BELT performed with adjust the engine not running The initial ment is made while the engine is cold camshaft cover remove Each valve must be ad justed with the valve completely closed that the rocker arm should be at the base is Ilowest of the point cam nut and turn the locking specified the adjusting clearance is obtained screw as procedure on each valve engine over bv hand to position necessary Temporarily replace cover engi with two or Remove ne checked turning the each valve as the camshaft three bolts and warm up the cover and recheck the the according to the warranty cer Readjust as necessary Replace the cover using a new gasket if the old valve clearance tilicates camshaft gasket engine appears tlattened or broken Run and check for leaks from the gasket Valve clearance Unit mOl or damage lbl is nator 472 0 applied pulleys when thumb pressure 122 0 midway between fan and alter in ENGINE OIL Check if oil is diluted with water Drain and refill 0 20 0 008 Exhaust 0 25 0 010 Intake 0 25 0 010 30 0 0 012 Cold a A milky oil cooling water corrective indicates the presence of cause and take measure b An oil with extremely low viscosity gasoline Ag 8 1 Check oil level If below the specitied raise it up to the H level Engine oil capacity including oillilterl Maximum H leveli S qts Minimum IL leveli The oillilter is of a Adjusting valve clearance in dicates dilution with OIL FILTER Exhaust gasoline Isolate the 31 U S qts Warm or if necessary oil Notes 41 U Intake if It is correct if detlection is belt tension 0 315 to in I Replace until a this cracks Loosen the lobe fuel gauge between the rocker arm and camshaft Straighten the locking nut Repeat with for necessary Adjust Unbolt and Remove the air cleaner the Check cartridge type Fig 2 Drive belt tension level TUDe up llaiDteDlDce b Percent C0ncentralion Sea BoiHng point 0 level 2 I090C HeUUre Inlle 228OF Water 6 0 1 5 6 With heater leakage replace I Y leaks past gasketed is found retighten just stop leakage If retightening is tive X I Check for oil anv 1 tilter as an no lSOC SoF 3SoC 61UF 3IOP lcity cap 620 610 Without heater protection FreeL I coning 1240C 2SSor 2210F 50 kem i system I060C 3m Q U S gal Imper gal S s gal U Imper gal 60 flange enough longer I I t 1 5to U S gal 1 Imper gal U S 6 4t U S O 6 81 gal Imper gal gal Imper gal I 1 U U S gal I i Imper gal COMPRESSION If to effec When it becomes necessary to check it compression assembly is essential to cylinder remove an spark plugs purpose of this test is to determine whether there is excessive leakage The When Note installing Do leakage not should oiltilter tighten by hand occur past the piston rings head gasket etc To test the engine should be heated to the operating temperature and throttle and choke valves COOLANT opened overtighten oil filter lest Long Life Coolant L L C is an ethylene glycol base product con taining chemical inhibitors to protect the cooling system from rusting and corrosion The L LC does not contain any glycerine ethyl or alcohol It will not evaporate or boil away and can be used with either high or low temperature thermostats It flows freely tran sfers heat eniciently and will not clog the The L L C passages in the cooling system must not be mixed with other product This coolant can be used throughout the seasons of Nissan the year Whenever any coolant is changed the cooling system must be tlushed and relilled with a new coolant Check the level Cylinder compression in be less than 80cf of the c OF 0 32 10 14 20 4 cylinders should highest reading not Dif I I I 2 30 I l I 40 40 so 58 t t to 20 30 40 so EG001 Fig 3 Protection concentration 7 llaiDteDaDce Tune up fClcnt comprc sion in two llalh ll indiL an nte cylinder more Low piqoll ring he i1 ol1lpanit u mption nn Thi 1 R If l into c Frigid r climates usuallv Tropical fuel excessive Other c ll1pre low i bv result from may climates climates 20ne 6SoF I 28 Over I 23 1 Over I 10 126 ult lindf 1 ell rl can trouhle charge value value at ion in cYlinders ornpn oln Full Permissible hrokpll piston ring or n or improperlv seated valve sion in one or more cvlin Illall quantity of engine oil through the spark plug holes a pOll ylinder nd retest compression II oil adding Illl challn the compression Iwlp an II pn s ure tn alve is sticking II l low 01 is low the likelihood is that seating improperly and if the compres ion past the pressure arc defective linder compression in dinder help hat rings t any adding two adjacent oil does not this could be leakage Fig surface gasketed 4 Testing compression pressure Oil and water in comhustion in any two ad ent cylinder is low and if adding oil does ja help the compression this akage past the gasketed surface not I Oil and 1 11 from this trouhle nmpre water in ion prC could comhustion chambers be can Sl1re p i at rpm Standard 1 c 1350 Minimum 128 350 ET002 Fig 5 Checking specific gravity of battery electrolyte BATTERY Check electrolyte level in each batterv cell Unscrew each liller cap and inspect lluid level If the lluid is low add distilled water to bring the level up approximately 0 394 to be clean to prevent current leakage bet terminals and from positive terminal to hold down clamp must ween 0 787 in above the plates Do not overlill In addition to current Measure the cumulation of acid and dirt specitic gravity of battery elec may trolyte cause connector 8 Clean top of battery and terminals with a solution of baking soda and water Rinse 011 tightening petroleum and corrosion dry wi h compressed air Top of battery leakage prolonged ac on top of battery blistering of the material covering straps and corrosion of straps After terminals vaseline to coat them with protect them from TUDe up l1aiDteDIDce Clean and correct points and distributor breaker spark plugs Check for condition the earn and wick Note Do not apply grease excessively Thoroughly wipe oIl dirt and dust from timing mark on crank pulley and timing indicator on Point gap and front 0 0177 to 0 0217 in cover Dwell angle Warm up engine sufticiently Install plug Set a timing light wire and install idling speed to on a point dwell and gap are apply distributor grease to full contact and that IGNITION TIMING cylinder spark No 1 49 to 55 degrees tachometer approximately CONDENSER 800 rpm Clean outlet of condenser lead wire and check Check if it ignition timing iBefore Top of Dead is Center 50 B T D l by the use timing light If necessary adjust it as follows Loosen set screw to such Lock distributor set to 5 screw et screw Retighten if necessary capacity witb Check condenser meter Condenser insulation be also checked using an extent that distributor can be moved bv hand Adjust ignition timing for loose of BT D C and make sure thaI timing is correct a t 1Z large resistance value normal the tester pointer When condenscr is range to measure swings largely and rapidly and moves gradually back to the intinite side When thc pointer does not stay still or it points zero in resistance replacement is necessary Retard side Advance side POINTS Check the distributor breaker normal Make points for ab pitting and wear Replace if necessary they are in correct alignment for sure Fig Fig 6 Adjusting ignition timing capacit V resistance may testcr by adjusting its Ignition timing 5 a 7 Checking ignition timing Fig 8 Checking distributor point gap llainteDance Tune up Condeneer capacity Check ignition if neceesary adjust it to 800 rpm retard sidel timing the specillcations 15 Hctard side 0 05 I F idle Adjust Micro Farad adjusting that screw so CO per centage is 1 5 0 5 Advance oide 0 22 I F Repeat the procedures Micro Farad and 1 Condenser insulation resistance 5MlltMega ohms above 5 5 0 5 On a cleaner spect clean plugs in a sand blast Inspect each spark plug Make sure that thev of the heat range In insulator lor cracks and chips Check are both center and specitied ground electrodes replace with excessively plugs File center worn 0 028 to 0 031 in Tighten plugs If they are spark new electrode l1at Set the gap to using proper adjusting tooL to 110 to 15 0 ft lb meter mixture it thoroughly essential to have of a idle the meter warmed and calibrated Warm up engine Be lock engine operation idling speed Adjust throttle adjusting speed is 800 rpm 1 in N tor sure to both screw so minute at that D apply parking front and rear brake and to wheels witb b Hold brake on pedal while stepping down pedal Otherwise car will dangerously accelerator rush out And sure that the equipped model adjustment has been made then check the lever in engine range tor automatic D cent and idle CO one equipped wheel chocks Idling sulliciently Continue transmission check should be done in the with the selector lever in adjustment requires the use When preparing to adjust is is On automatic transmission torque CARBURETOR CO percentage range make Idle mixture CO at 800 rpm automatic model and described in items 3 Caution SPARK PLUGS Remove as that so position speed N position specitications Insure that are as with the CO per tollows rpm 650 percentage 1 50 5 Readjust by turning in or out throttle ad justing screw or idle adjusting screw if still out Notes transmission L a EEOBO Fig 9 Checking spark plug point 10 gap Do not attempt to screw down idle ad 2 Fig 10 Throttle and idle adjusting screws l1aiDteDlDce justing screw completely to avoid damage to tip which will tend to cause maIfunc CHECKING AND ADJUSTING DASH POT Automatic Transmission tions b After idle adjustment shift the lever to Not has been made plt or range for automatic transmission c Remove wheel chocks when Proper contact lonnance Do not this idle limiter cap unless If this unit is removed it is necessary to stallation To After re throttle check screws amount of adjust it at the time adjust proceed adjusting justing or Install idle limiter cap in adjusting rotation in the can be obtained between not CO RICH arm rotate dash pot to the proper position idle It is necessary that the idling speed of engine and mixture have been well turned up and speed sure ad that the position screw screw of in CO that the and Installed On be to lever follows as contained in exhaust gases meets the estahlished standard sure set dash pot stem and throttle Cap remove necessary throttle provides normal dash pot per Adju tmenl of the proper contact he made bv dash pot set If normal Idle Limiter hetween only dash pot stem can running TUDe up making further turn 18 direction engine Engine it sufticiently Turn throttle valve speed warm by hand and read engine when dash pot just touches the stopper lever Adjust the position of dash pot by turning nut speed is in the range of 1 600 to until engine 1800 rpm C Then fasten loosened lock nut rburctor h topper Make alation sure reduced that the engine speed is smoothly 2 000 to t 000 rpm in about from three seconds COlcan JIsoy1dle limiter Jp ET031 Fig 11 Setting idle limiter cap EE130 I Advanced break er point 2 Retarded breaker point Pha difference 3 Fig 12 Dash pot adjustment Fig 13 Dual point distributor u l1aiDteDlDce uDe up DUAL POINT DISTRIBUTOR Point gap C 018 to f i trihlltor has two breaker othl r with po itp each wn h in The ditl Figure rence in a e e can be adjusted bv point gap IS adjusted by install distributor angle as follows proceed If dillerence of 7 crank are placed parallel lht 1C lav i turned engine Using OFF and hend rotor ref iliaI inlervah be must I n addition inspected remove at cap and t and carhon dc sits from cap du lnd rotor Ii om time to time If cap is cracked e11 all 1Il 0 Ipaking replace with i a justment must Gap Roth tiOt At point or canHhaft cessively i made by loosening point required for adjustment must he checked from time to time gap this surface is rough take ot1 any with tine sand paper of No 500 with oil slone time dwell Adjust loosening point engine lead Disconnect of angle advance side by black of screw wire from B t distributor harness and then connect it to Y side and replace points together point screw After adjustment disconnect lead wire then engine harness and distributor har connect ness securely Phase Difference To check on phase dil1erence install engine and proceed as follows Disconnect grease must be supplied carn heel Do not applv 1 When wear on each breaker noticeable tact be gauge is irregularities or of of distributor harness Adjust dwell angle of retard side by loosening Standard gaps of both points are 0 0177 to Z17 0 0 in If the gap is ot1 the standard ad When black vellowl of distributor I Retard new one Point screwlS lead wire connect B black a advance side I al harnes harness and B ap lind Rotor lIead examining dwell on engine and Disconnect wiri ng harness of distributor from 01 and the advanced breaker point works ll angle the in thp pi imarv ignition circuit The retarded hreaker point when the relay is turned ork wht in 49 to 550 pha breaker points two Dwell z I adju ting screw A phase h ilnf i adopted Th points located op phase ditlcrence as con wiring harness of distributor from engine harness ex point with an11 to distributor Using a lead wire connect B Iblackl of harness and B black engine of distributor harness IAdvance sidel See Figure 15 EE135 Fig 12 14 Checking of distributor breaker point gap Fog 15 Connecllead wire lIaiDteDance Spark timing sontrol system for Automatic T TUDe up smission Spark timing Throttle SW Advance Engine start Idling Partial throttle opening ard Ret ON 0 ON 0 ON 0 Wide throttle and opening high speed rousing OFF 0 Adjuster plate EEl38 set screws EE136 Fig 16 Adjuster plate set Fig screws 18 Phase difference adjusting scale To correct further Referring set to proceed Figure as 6 turn out 12 to 2 turns The screw follows adjuster plate screw is located at contact set on retard side Using a notch in adjuster place as a hold turn adjuster plate as required until correct delay is ohtained Ignition is retarded when plate is turned counterclockwise Note Fig 17 engine idling adjust ignition timing by rotating distributor to specitications 112 800 advance side Disconnect lead wire from B tblack distributor harness and then connect yellow With of it to Y of distributor harness IRetard side engine still idling check to determine phase delay is 7 degrees in terms of crank shaft angular displacement that to make graduations on breaker One plate to crankshaft graduation corresponds angular displacement of 4 degrees to With rpm Refer adjustment Tighten adjuster plate adjustment Make set screws to secure the that the ignition timing specilications sure side is the easier ofadvance After adjustment remove lead wire and con wiring harness of distributor to engine harness securely nect 13 lJaiDteDance up Tune TUNE UP GUIDE nd l litiun 1J 1 t1illutl fll1 1t 1T tirnmll e dcgr 5 IB T O C Dislrihlltol I linl in lJP Dwellanglc degree 0 5510 45100 49 to 0177 toO 02t7 55 retard side 0 05 C Id iCf n rlnd n er F lpadty advance side 0 22 ilSiOulIl lanc MH 5 Idling ldjustmtnt Manual Trnnsmission Automatic Transmission Dash pot 3djuslrnenl die Anli 1 degree rpm 50 650 call 1 5 t05 t05 5 1 600 pm em lin Ib 35 to retard side to 0 range 1 800 55 30 to 48 conlrol system lluottle switch L18 operating angle AfT L16 t5tO Lib 620 MfT AfT MfT Thermo switch operating Adjustment 50 800 retard side COil ling solenoid tightening torque kg Spark timing rpm e deg of operating degK e 350 degree 400 degree 450 temperature or pressure OF 5 to 13 4 to 55 f a cO D R C 0 0 set pressure AfT mmHg inHg t 20 480 t8 t 0 787 9 MfT mmHg inHg t 20 500 19 t 7 787 0 A T C Air cleaner AT H C Valve opening temperature Or OF 5 37 to 4S 100 to 1 8 llaiDteDlDce TUDe up TROUBLE SHOOTING Probable Condition CANNOT CRANK Improper grade ENGINE OR StOW C II Defective Replace T c battery wble in Detective lrter st light Correcl n oloL T ouble shooting procedure the Inspect Hting Sl igmllon switch tive Defc starting goes off motor dims il Adjust charge system onnectiun trouble in Wiring When with Repla proper grade Charge ballery Loose fan belt on tive elion DIscharged bat tery CRANKING Switch rel Repair replace Repair replace starting cin uil with light ON nsiderably k baltery Che b Check Check When light 51 s nnection and s aller able olur bright k wiring Che cllOn between lt ery h nd Slarter OllH h k starter switch Chel Check starter ulm 1 I I IUD8 UP llaiDtelllDce Condition Probable Corrective action cause Low or no Check for loose terminal current disconnection or primary circuit Check for burned Ignition system in Burned distributor trouble Improper point Defective leak ondenser Clean rotor Clean spark plug Adjust Defective ignition oil Replace Tcuit la k of fue Dirty high connection primary tension cable or clogged Fuel pump will in ot Clogged work 01 properly work Repair properly of float level compreuion Adjust Disassemble pipe of fud tank breather Incorrect replace Check tnd adjust Correct ed carburetor dieseling anti Damaged replace Clean pipe Improper idling do Repair Replace fuel Improper adjustment or replace Supp1r Carburetor choke will Dirty or Replace disconnection or fuel strainer Dirty Low eplace adjust plug gap Improper ignition timmg L005C trouble replace Replace ap and Disconnection of Fuel system Repair Adjust gap at rotor Defective point points Repair olenoid spark plug tightening nd clean nd clean Replace or normal defective Tighten to viscosity Replace with proper torque or replace gasket gasket it Improper grade engine low Incorrect valve clearance leak fromvaIve Compression Sticky valve Weak Compression Slicking Worn Trouble Pour or leak Remove cylinder head and lap Correct alve at defective piston ing oil Adjust seat stem defective grade springs Replace cylinder head gasket piston ing replace valve nd valves lIve guide springs Replace gasket Replace pIston Overhaul cylinder alve ngs engine shooting procedure the engine iI from plug hole nd then measure cylinder compression Compression increases Compression does not change Trouble ill or 18 cylinder Compression head leak gasket or piston ring from valve cylinder head Tune up llaiDteDlDce Condition Probable Corrective action cause IMPROPER ENGINE IDLING trouble Fuelsyltem carburetor jets Clogged or damaged Incorrect idle Clean adjustment air cleaner Clogged Defective replace A1just Rplace element manifold gaskets carbureto or insulator Replace gasket insulator Improper Low float level adjustment Adjust i compreSlion Previously mentioned I I Others Incorrect valve clearance low Extremely Poor Adjust revolution acceleration above Adjust 1 000 rpm Twin carb or malfunction of the spark plug ignition coil ignition system tension high Incorrect basic cable nuts about a half etc ignition timing 8C D D adjustment Damaged vacuum Sticked Adjust Adjust incorrect Adjust control solenoid Replace Replace dash pot stall anti Replace breaker alve clearance Incorrect ENGINE idling adjusting turn Defect point Loosen POWER NOT UP TO NORMAL Low Previously mentioned comprnsion Ignition syltem trouble Incorrect ignition timing Adjust Defective spark plugs Clean adjust Dress or Defective distributor points or replace plugs replace points Also check condenser Fuel system trouble Malfunction of choke system Clogged Dirty fuel pipe clogged or floating or Air ntake trouble syltem in Replace Repair properly Replace cleaner inhaling from or eplace Disassemble and clean carburetor jets Gagged air Air Clean fuel strainer Fuel pump will not work Clogged Adjust valve manifold gasket or element RepJace gasket carburetor gasket fl IlainteDance TUDe up Condition Owrheating Probable Corrective action cause Insufficient coolant ReplenWt Loose fan Adjust Worn belt Replace defective fanbelt or Defective thermostat Replace Defective Replace water or Oogged pump Flush repair radiator leaky Air in Othen Replace with proper Incorrect ignition timing Adjust Defective carburetor lean mixture Overhaul carburetor e grade each part of e Defective thermostat Replace Improper octane fuel Repbce Improper tire pressure Inflate to Clutch Car replace Improper brake Adjust dipping Adjust Dragging NOISY Retighten cooling system oil or Replace Defective radiator mlct cap ooling Owen fan belt with specified specifted cooling system oil grade octane fuel pressure ENGINE knodting Overloaded engine Use Carbon Disassemble knocking right gear in driving cylinder head and remove carbon Mechmicll Timing knocking Adjust ignition timing Fuel knocking Use specified Preignition misusing of spark plug Use specified spark plug strong dull noise increases when engine the place cause a misflTe on each cylinder If the noise stop3 octane fuel kncdtinll Crankshaft bearing ThU This is caused knocking is accelerated To locate or by the this misfut by worn or damaged bearings worn Renew uneyen y crankshaft bearinp and adjust or change crankshaft cylinder generates the Check lubrication system than the Same noise Connecting rod bearing knocking This is a little crankshaft hisher pitched n9ise knocking and also as the of crankshaft bearinas case increases when engine is accelerated Cause a misfue cylinder and if the noise deminiwi almost completely this crankshaft bearing on each generates the noise Piston and noise 18 cylinder When you overlapping metalic noise magnitude with the revolution of enaine and which decreases u engiI e is warmed up this noi3e is caused by piston and cylinder To locate the place cause amisfue on each cylinder which hear an increases its This may cylinder turn will excessive erhaul cause and an lower cause I abnormal wearing compression which lower out put power consumption engine of oil of in and TUDe ail IlaiDteDance Probable Condition Piston pin noise Water pump noise This noise is heared at each ryighest and lowest dead end of piston To locale the place cause a misfire on ach cylinder This noise may damaged bearings of iding parts An Others Corrective action cause be caused or the by by timing play Renew piston pin on or piston and piston pin usembly with a new one Adjust Adjust the tension of chain Disassemhle engine and ankshaft on wear surface chain An excessive end a cause piston pin hole Replace water pump worn uneven improper adjustment of alve clearance Noise of This may new main bearing This noise will be heared when clutch Note is disengaaed Wear on Note Uta noise will clutch is disenpged adjust drive shaft Renew bush and clutch pilot bushing be when hur ABNORMAL COMBUSTION back fue after fire run on etc Improper ignition timing Improper Fuel system in trouble Adjust ignition timing Improper ignition timing heat range of carburetor fire after fire or Damaged back specified spaTk plugs spark plugs e manifold gasket Uneven f8C1iYe o eylinder hem Run Improperly adjusted Excess e calburetor and check it level and check needle valve Adjust valve clearance Remove head and gel rid of carbon chamber back fire after fire valve spring the parh Adjust on carbon in combustion llaged DaJ Adjust function of the noaL idling them with new Disas efnb Defective carburetor jet Improper Replace Replace it with Tighten it a new one EXCESSIVE OIL CONSUMPTION Oil I Loose oil Loose or Loose or drain plug damaged oil pan damaged chain Defective oil crankshaft Loose or seal in damaged gasket over cover Renew gasket front locker Renew and rear gasket of gasket or tighten it gasket or tighten it Renew oil Renew seal gasket or tighten it but ot too much fmproper tightening of oil mter Renew gasket and tighten it with the proper torque Loose or damag ed oil pressure switch Renew oil pressure switch or tighten it 18 TUDe up l1aiDteDIDce Probable Condition Cylinder Excessive oil consumption and piston Corrective action cause Overhaul wear of piston ring gap location Improper reversely assembled piston or Remount Renew Repair piston ing Fatigue of valve groove and oil seal ing rings renew piston piston and seal Replace lip and with a new lip cylinder piston ring one Renew valve or guide Inadequate quality of engine oil Use the designated oil Previously mentioned Engine overheat POOR piston piston ings or Renew Worn valve stem Otben new ng Damage piston rings Worn and cylinder FUEL ECONOMY See the explanation of the power deerea Adjust it Defective acceleration ecovery Adjust it Fuel leakage Repair pipes Exceeding idling Others TROUBLE IN revolution to or the designated tighten rpm of fuel the connection OTHER FUNCTIONS Oecreased oil pressure Inadequate oil Use the designated oil quality Previously mentioned Overheat Defective function of il pump regulator Disassemble oil pump nd repair or enew it valve Functional deterioration of oil pump Repair Blocked oil filter Renew it Increased clearance in various sliding part or replace it with a new one Disassemble and replace the worn parts with new ones Oean it Blocked oil strainer Troubles ExcessiYe wear on sliding pam the in oil gauge pressure switch Oil pressure decreases Defective quality PO contamination of oil Previously a new Change element Previously mentioned or overcoal fuel mixture Decrease of oil pressure lnsufficient clearances Improper fuel with proper Check the fuel system Previously mentioned Readjust to the Previously mixture one mentioned Exchange the oil change element Overheat Overheat 20 it with Defective air cleaner Improper Scuffing of sliding or Replace designated mentioned Check the fuel system clearances and IDgine DESCRIPTION 22 REMOVAL 23 INSTALLATION DISASSEMBLY 24 Pistons and Connecting Rods Cylinder Head ASSEMBLY Cylinder Head Piston and Connecting Rods 24 27 27 27 28 29 Engine 30 OIL PUMP 36 Removal 36 Installation 37 21 r B DglDe crankshaft DESCRIPTION to turn out smooth cylinder block is power unit featuring deep skirting The feature a H C and L18 engines wedge shaped combustion alminum heads and fully balanced The L16 valves a single chamber 5 bearing These engines are equipped EM256 Fig 19 Cross section view 22 dependable cast in with a single BngiD8 downdraft 2 harreL porates special a carburetor that incor device to control emissiuns If has shown that it is much easier engine with transmission as a Experience to remove the single The unit than to engine can transmission the engine remove then be only from separated Disconnect thc fuel tube from the fuel pump the assembly equippcd with heater engine attachment remove Disconncct accelerator control choke wire at the carburetor side its hoses at linkage and Disconnect the wirings for the starter alter n tor ignition coil oil pressure switch and thcrmaI transmitter REMOVAL Hemove the clutcb Scribe alignmcnt marks on hood around hood hinges and remove hood from hinge Completelv drain the cooling system engme and transmission lubricant Hcmove blow hy hosc ti remove om rocker cover and air cleaner remove the car Take oil hoth upper and lower radiator hoses by removing thc hosc clamps Then loosen the lixing holts of the radiator and take it out in sequence Note smission remove cooling pipes Rcmove engine with the automatic torque tran convertor from the radiator fan and reverse Disconnect the shift rods and select rods t hen remove s shart cro the cross a sembly and bv shail bracket from the side Disconnect thc front exhaust tube from exhaust manifold pulley and remove center tube ting the front tube pre mumer and assembly propeller shaft it from the companion by disconncc tlange of the gear carrier Jack up thc transmission a little and thcn remove the rear engine mounting cross mem ber by removing the tixing bolts of the engine mounting insulator mounting and hand brake cable Flg 20 Removing clutch operating cylinder thc Disconnect the center tuhe from the rear tube Disconnect the equipped Disconnect the memher Disconnect the battery cable and If speedometer cable tlat attaching plug connector from lamp switch Disconnect the rcmoving the Hemove the radiator grille battcrv off the and its operating cylinder spring return cross member clamp Fig 21 Lilting engine 23 IDgine Remove tixing bolts securing engine mounting insulators to cross Hook t the with hooks which cylinder the cable head or are one the front Remove transmission from chain to the installed on stringers the engine at the front and the other at rear At this DlSASSEMBL Y member drain engine oil and coolant by removing drain plugs Thoroughly Place engine lower the jack lifting transmission placed Idraw oil the jack at hoist up adequate stage engine observing the tension of wire and adjusting the position of chain block so that the engine tilts in order to make it cleared on the body At this lifting take care body side gradually under the that accessories installed do not touch the the on engine and transmission assembly Remove fan and fan Remove on the engine R H Remove oil tilter Remove oil pressure switch Install engine attachment to cylinder block using bolt holes securing alternator bracket Set engine on plug the stand Remove oil level gauge Reverse the removal to the nect any parts engine mounting replaced and procedure but do not con engine steadily until the Remove clutch insulators Remove high Remove spark plugs power unit weight them have been is taken by assembly tension cable Remove thermostat Fig 22 Engine on ngine stand housing Fig 24 Removing manifolds EM091 Fig 23 Removing thermostat housing 24 stand pulley engine mounting and water drain INSTALLATION engine Fig 25 Removing camshaft sprocket BDgiDe Remove rocker cover Remove carburetor Remove intake and exhaust manifolds Remove engine mounting L Remove crank H sprocket Remove head from cylinder assembly Loosen Figure 26 bolts 1 to 10 as shown in the convenience Note For head replacement special of cylinder Chain tool is prepared to sup Stopper STt742000I port timing chain during the service timing operation By using this tool marks on crankshaft sprocket and timing pullev Remove water pump Remove fuel pump Remove fuel pump drive Remove camshaft earn EM095 Fig 26 Cylinder head bolt loosening sequence fig 29 Removing chain tensioner and timing chain j 1r Jp k r EM096 Fig 27 Supporting timing chain Fig 28 Removing oil strainer and oil pump I W Fig 30 Removing chain drive sprocket Fig 31 Removing piston and connecting rod assembly 21i I r IDgine EM1Q2 Fig 32 Removing flywheel Fig 36 Removing piston ring STl651S000 ST I 3030001 J EM099 Fig 33 Removing rear main bearing cap EM103 Fig 37 Removing piston pin I I Fig 34 Removing rear oil seal Fig 38 Removing rocker arm EM105 Fig 35 Removing buffle plate and 28 net Fig 39 Removing camshaft BDgine chain will be unchanged So aligning timing marks will Cylinder be saved Loosen valve remove rocker so much Note Take Remove oil pan and oil strainer Remove oil pump and its drive and chain drive Take otr crankshaft Take tool drop it Crankshaft Main oil seal plate lose valve spring seat to oil Be sure leave camshaft bearing to Because the center bearing is liable to be out of alignment ASSEMBLY Precautions Use thoroughIv sure When and cleaned that oil holes parts are Particularly toreign clear of matter Remove crankshaft cylinder block net Connecting Rods piston rings with a ring remover Pistons and Remove Note make Remove baffie not care Bearing del rear to cam caps Cap Puller ST1651S0000 to remove center and rear main bearing caps Keep them in or H emove and seal valve collet and valve rocker guide intact Hemove tlywheel Be careful not to special not care gear them in order Use take bearings Remove valves worm sprocket bearing time lohes and connecting rod assembly connecting rod bearings and keep Remove main this camshaft damage piston Hemove At Note thrower not to lose valve rocker care Hemove camshaft cover Remove timing chain oil pivot lock nut and by pressing down valve guide spindle Remove chain tensioner Remove rocker arm spnng Invert engine Remove front Head the work for Press all t piston pin Keep the disassembled parts in order installing bearings Use new Do not be sure to packings reuse sliding parts apply engine oil such as to them and oil seals lock washers that have been removed Keep tools and work benches clean G G STl2070000 i t EM106 Fig 40 Removing valve Exh aust Fig 41 Intake EM107 Valve components rz r I BDgme Keep the at H ure a nd and tools ready near follow to specitied tightening torque order tool Using special et Applying U part necessary hand valve spring Assemble valve alve order shown below spring springs guide ealant to eliminate water and oil leaks e Front Front Main Notes are gasket Front side cover gasket See Figure cover hlock and Top cover affront cover see of cylinder 42 Figure cylinder block ide of rear main bem ing cap and each of cvlindl r hlock See Figure 43 urlan and cap and bearing Cylinder o block n ylindt Set portions lilldl r hloek 1 hlock to rpar at four main a Check whether the valve face is free from b foreign The L16 and LIS type valve corner Valve rocker pivot Screw mating cover bearing capl 110 nut apply sealant too much Not use double assembly valve nuts into rocker pivots joined pivot bushing with Set locating plate bearing inside and caretullv The install camshaft Do not Applying 20 Points 1 25 mm 0 984 in be appl Fig 44 Applying Fig 45 Installing valve sealant Front cover and gasket 7 to to ed II U sealant all I I E i EM151 S Fig 43 Applying sealant Main bearing cap and cylinder block be applied sealant EM152 EM153 scalant to to in damage the oblong groove of locating l H ad Cylind assemhly and valve spring l lock Camshaft assemblv Points 42 engines springs cvlinder head Vain matter Each tront chain to 42 SrI j lgurl I 28 in the inner and outer valve retainer valve collet and valve rocker requiring sealant Part Fig in po ition and tit valve with oil seal guide sealant Valve Lifter STt2070000 seat ICylinder block Ingine plate must be directed toward the front side of springs with engl ne Install camshaft tighten it together specilied torque sprocket on camshaft and with fuel pump cam 6 ft lb At this time check camshaft end to the a arms lw pressing down valve screwdriver Install valve rocker springs After assembling cylinder head shaft until No turn is at T D C piston cam on its compreHsion stroke Tightening torque 86 to rocker Install Piston and play Connecting Rod n pins and connecting pistons pist the designated cylinder Assemnle rods to Notes a Piston is pressed into connecting rod fitting force is 0 5 to 1 5 tons and the and aid of special tool Stand ST13030001 Piston Pin Press is necessary When pressing piston pin in connec apply engine oil to pin and small of connecting rod ting rod end EM154 b Arrange big end is so thatoil jet of connecting lod directed toward the right side of cylinder block Fig 46 Installing camshaft sprocket c Be with sure to install notch mark of piston piston in cylinders head toward the front of engine EM155 Fig 47 Assembling cylinder head EM1S7 Fig 49 Assembling piston and connecting rod gd l STl3030001 o EM158 Fig 48lnstalling piston pin Fig 50 Installing piston ring 28 r IDgiDe I nstall piston Front rings In tall top and second rings in mal ked side up right position Top ring is chromium pIated tacting face on with the Second ring has larger taper liner con surface than top ring bearing No 1 is also the same type bearing No 5 The difference is that an oil hole is provided in the front bearing as rear All bearings except interchangeability lower bearings Applv engine In the combined oil tower same as ring upper rail is the oil to No 1 bearing between have upper an and main bearing surfaces on hoth sides of cylinder block and cap one Install crankshaft I ix hearings ting Od I Note connecting rod and on con nee cap Clean the back side of bearing carefully Install main bearing cap and bolts to tighten pecitied torque Tightening tOl que 32 5 to 39 8 ft lb Engine The IIlst tep in engine assemblv is to bolt Engine Attachment ST05260001 pecial tool to right cession hand side of install block in another Stand ST050tSOOO Engine hlock cylinder In suc special tool with engine bot tom up Set main beal ings at the proper portion of cylinder block Install hatlle plate including cylinder block net Notes Apply sealant bearing block as to each side of Arrange the parts so that the bearing cap faces toward engine on Prior to tightening place bearing shifting rear cap and each corner of shown in Figure 43 cap in arrow mark the front of bearing proper main cylinder bolts cap position by crankshaft in the axial direction Notes Only center bearing No 3 is flanged a type All inter same bearings No 2 and No 4 are the Tighten bearing cap bolts gradually in separating two to three stages and out wardly from center bearing in the sequence as shown in Figure 52 After type cap bolts securing bearing tain that crankshaft turn Rear fi 0 liS ll D ga 14 Fig 51 Main bearings CD @ J m L D D D 113 112 III EM159 30 ID Front ascer smoothly @ @ Fig 52 Torque sequence of cap bolts @ 60 BogiDe Make sure that there exists proper end cranksahft play at Install side oil cap Prior to Crankshaft end seals into rear installing applv main bearing sealant to these seals play Install rear oil seal tool using special Crankshaft Rear Oil Seal Drift STt5310000 Applv a lithium grease to sealing lip of oil seal 0 0020 to 0 007t in Install rear end plate Install tlywheel securely specitied torque and tighten bolts to Tightening torque 101 to 116 ft Ib Fig 53 Checking crankshaft end Ij play Pi r ction Fig 56 Installing piston rod assembly Fig 54 Driving side oil seal Fig 57 Piston ring direction STl5310000 r EM163 Ag 55 Installing rear oil seal Fig 58 Installing connecting rod cap 31 Bngine Insert pistons in tool pecial corresponding cylinder using Piston or Ring Compres EM03470000 Turn crankshaft T D C on Make sure until Apply engine Arrange so oil to their sliding parts that the notch mark that camshaft piston head faces to the front of engine Install piston rings avoiding their fit in pin directions at 180 plate oblong correct positions When on piston installing all sprocket location aligned at groove are head cylinder make valves are apart from rotate crankshatl and Do not separately because Temporarily tighten Tightening torque Figure 60 lor Ll6 Tightening torque 23 to 28 ft lb 14 5ft lb for LI8 Install cranksahll Note Make Note camshatl valves will hit heads two bolts 1 and distributor mating marks of sprocket sure that the crankshaft sprocket faces to the front bers face in the Install Big end same direction timing chain that there exists proper end play at rod big end play 0 0079 to 0 0118 in Install cylinder Thoroughly head assembly clean cvlinder block and head sur face Do not apply sealant to any other part cvlinder block and head surface of Fig 60 Tightening f sequence J L @61 Oj I Fuel o 1 2 Chain guide I eam tensioner Crank sprocket s earn 6 Chain uide j Fig 59 Checking big end play pump drive Chain ID 32 of 2 shown in Arrange connecting rods and con necting rod caps so that the cylinder num connecting of drive gear and fIt oil thrower 33 to 40 ft Ih sure sure heads pistons Install connecting rod caps Make at pistons to each other the thrust and that piston is its compression stroke notch and Notes 1 No Fig 61 Installing timing chain sprocket EM169 BDgine Instal1 front Notes Make sure keys point that crankshaft and camshaft upwards timing chain by making its mating marks align with those of crankshaft sprocket and camshaft sprocket at the right hand side There are forty twa chain links between twa mating marks of timing adjusted When chain elcessiveIy adjust camshaft No 2 hole is factary stretches sprocket Use a at No 3 hole set Of timing marks and location to sealant block and front Figure 42 Apply sealant cover as in place side of front gasket cover only shown in Install front chain gasket Notes Apply Set with cover ta as cylinder shown in the top of front Figure 42 cover with head gasket in place Check the height difference between cylinder block upper face and front cover Its difference must be less upper face than 0 0059 in hole numbers Install chain guide to cylinder Nate block Install chain tensioner Note Adjust sioner Press the spindle new Apply protrusion of chain ten to 0 in replaced cover front when front types of bolts are a cover cover is grease lithium to sealing lip of oil seal Tightening oil seal in front oil seal should be different that used torque Size M8 10 3151 disassembled I 7 2 to 11 6 ft lb Size M6 10 236 in 2 9 to 5 8 ft lb Install pression pulley and water pump piston at T D C on its com crankshaft then set No 1 stroke Crankshaft pulley nut Fig 62 Installing chain tensioner tightening torque 86 8 to 115 7 ft lb EM 172 Fig 63 Installing runt cover Fig 64 Front cover bolts 33 r BDgine Finallv tighten in torque tightening Note that head three sequence as two bolts to the specitied according to the shown in Figure 60 steps tvpes of bolts are 8 0 to 10 8 ft lb Notes used Assemble Tightening torque st Tightening torque oil pump and making driving spindle drive pump hole turn t2H 9ft lb Install oil pump so that the dle 2nd turn together with drive spin projection on its top is 4 ft lb 43 3rd turn 47 0 to 61 5 ft lb Notes 41 Be sure After to tighten two small bolts has engine been operated for several minutes if necessary retighten Install oil pump and distributor dle into front driving spin E 67 Setting distributor driving spindle EM175 Fig 65 Installing crankshaft pulley and water 8 LOO9 cover Ftg 0 pump o A 0 A 0 B B 0 B 0 8 0 o A B O 0 A Fig 68 Installing oil pump EM176 FIg 66 Cylinder head bolts at spindle mark face to oil Fig 69 Adjusting valve clearance IDliD8 located in 11 25 tbe smaUer position At this time shape will be placed am bow toward the front Do not forget to install gasket and spacer forget to packings spacer and block Install spacer and fuel pump in criss cross performed pattern and finally thermostat to install and oil pan Apply sealant to the step portions at four mating surfaces as shown in Figure 44 Tightening and vacuum housing thermostat and positions Do not forget to 4 3 to gasket Install rocker cover Note Bond gasket sealant Then cylinder hea 1 Install 6 5 ft Ib torque to rocker Cover install valve clearance to the specitied dimen rocker using cover to spark plugs Connect distributor to Adjust hose water outlet in their Notes oil pan should be pipes pipes and hoses should be clamped securely being careful not to allow them to in terfere with adjacent or surrounding parts instaU fuel pump between gasket assembly and carburetor in upward Tightening All inserted Install oil strainer oil pan Install carburetor Install fuel tightening torque Note Do not assembly sulator with stamp facing torque 3 6 to 7 2 ft lb Install fuel pump water inlet elbow and front engine slinger in their positions Fuel pump Install distributor plug high tension lead wire Hons Install Tightening torque 36 2 to engine mount side 4 ft lb 43 Install clutch assembly Notes First clearance set to the cold specifications After engine has been assembled run it finally adjust warm specifications for at least several minutes the clearance to the Install rear engine slinger exhaust manifold and intake manifold Tightening torque 8 7 to 116 ft lb Fig 70 Installing manitolds L16 and LIB Intake 0 2 0 0079 Exhaust 0 25 0 0098 Intake 0 25 0 0098 Exha1 Jsr 0 30 0 0118 Cold Valve clearance mm in Warm bracket on left hand IDgiDe Tightening torque held within 0 315 to 8 7 to 15 9 ft lb pressure is applied midway between A pressed force is about 22 0 lb Using hoist an overhead engine hoist and up away from lifting cable engine stand and then down onto nator bracket pulley engine carrier Install alter adjusting bar alternator fan fan and fan belt in this order check to be sure Then that deflection of fan belt is Install engine in when 472 0 mount bracket right thumb pulleys hand oil filter oil pressure switch oil level gauge and water drain plug When installing an oil filter fasten it cylinder on block Note Do not overtighten Ieakage may occur Pour engine oil up to specified by hand filter or oil level OIL PUMP Removal Remove distributor Drain engine oil Remove front stabilizer Remove splash Remove oil shield board pump body with drive spindle assembly Fig 71 Installing clutch assembly I I I I Front ETOO7 Fig 72 Fig 74 Setting drive spindle Fan belt tension Pumch mark E LO 11 El009 Fig 73 Aligning punch mark and oil hole 38 Fog 75 Installing oil pump BDgine on Installation Before installing crankshaft so oil pump in engine turn that No 1 piston is at T D C top is located in its this time placed the 11 25 a m smaller toward the front bow as position shape will shown in at be Figure 74 Fill pump housing with engine oil then align punch mark of spindle with hole in oil pump as shown in Figure 73 Ascertain whether the engagement is order or not by checking the top of spindle through distributor Using drive gasket spindle assembly a new pump and that the projection fitting hole install oil so Tighten bolts securing oil pump to front cover 1 B1ectrlcal IJStem STARTER Removal 40 40 CHARGING CIRCUIT DESCRIPTION 40 ALTERNATOR 41 Description 41 Removal 41 Installation 44 VOLTAGE REGULATOR 44 Description 44 Measure of Voltage 45 Adjustment Charging Relay 47 48 ALTERNATOR FUSES FUSIBLE LINKS 49 EMISSION CONTROL DIAGRAMS 50 DISTRIBUTOR 52 Construction 52 Disassembly Assembly 52 IGNITION COIL 53 56 Construction 56 Description 57 SPARK PLUGS Description Inspection Cleaning and Regap 57 57 58 58 TROUBLE SHOOTING IGNITION 58 HEATER UNIT REMOVAL 59 TROUBLESHOOTING HEADLIGHT TROUBLESHOOTING HORN 62 RADIO 63 RerilQyal TROUBLESHOOTING SPEEDOMETER TROUBLESHOOTING HEATER TROUBLESHOOTING RADIO 63 NOISE PREVENTION CHART 66 63 64 65 65 39 Ileetrical IJStem STARTER fJ @ l I ShiflleYerpin 2 Gur 3 hilt 5 Shiftlcvcr Dusl switchAssy Armature 8 Thrustw 9 Metal Thrust shcr washer II shcr Slopper 12 Pinion opper 1 Pinion COftr 7 10 13 ue Masnetic 6 IS tel runDinSclutch 16 Field coil 17 Yo 18 Brulfl 19 20 Broth Brush sprinS 21 Brush holder Auy 22 Metal 23 Rear 2 Slopperelipe e EE007 over Throush bolt 76 Exploded view of starting motor to battery ground cable switch terminal from battery to cable Disconnect black wire with yellow tracer from and black battery of magnetic terminal switch Remove two bolts gear case remove securing starting motor to assembly forward and Pull starter starting @ @@@@ Removal Disconnect I I Fig magnetic L Y@O i e1l motor operate all electrically operated units and keep the battery fully charged When ignition the from switch is current flows through the ignition switch set the to ON battery ground voltage regulator IG terminal primary side contact point PI movable contact point P2 voltage regulator F terminal alternator coil and alternator Figure 77 by E full line to F terminal terminal arrow as ield shown in marks Then the rotor in the alternator is excited On the other Installation charging circuit consists of the battery regulator and necessary wiring to alternator connect these system is parts The purpose of this to con vert mechanical energy from the engine into electrical energy which is used to current from the switch CHARGING CIRCUIT DESCmPTION The flows battery to warning ground through the ignition lamp voltage regulator L terminal lamp movable contact point side contact point P4 P5 and voltage regulator E terminal as shown by dotted line arrow marks Then the warning lamp lights hand Installation is the reversal of removal When three the alternator to operate phase alternating alternating current is roc the by positive and negative silicon the stator coil This tified begins current is induced in IlectricalSptem diodes The rectified direct reaches the alternator On the other hand reaches N and of the output voltage minaI shown in terminals N terminal to E VCl movable contact point P5 voltage winding side This action is excited and the comes causes the full line arrow winding creased cessively or alternator the the speed voltage movable secondary and alternator output voltage is mediately This action causes movable contact P3 Thus the contact lIide contact Then the rotor current is shut off point P2 rapid P2 or from im to separate secondary contact vibration of the movable breaking and completing the rotor circuit maintains put voltage ased decre an alternator out constant ALTERNATOR circuit marks speed is increased or the starts to rise voltage excessively the movable contact P2 is separated from the point side contact PI by the magnetic primary force of coil VC2 Therefore register Rl is applied into the rotor circuit and output voltage is decreased As the output voltage is decreased the movable contact point P2 and primary side contact PI comes into contact once again and the alternator voltage in the rapid vibration of the creases Thus movable contact point voltage constant the P3 point into contact When the alternator When into contact with contact point P6 to turn off the warning lamp and complete the voltage by comes ter ground through the coil VCI as Figure 78 by the dotted line arrow with shown point voltage Inearly a half and current flows from voltage marks Then the coil as output E terminals the neutral E regulator or current A and is starts contact further to rise point in ex P2 Description Alternator Vehicle 510 and LTl5005B 610 models except for Canada LTl60 19 SlOand610models for Canada LTl35 13B 620 model Removal Disconnect negative battery terminal Disconnect two lead wires and connector from alternator r I I t T BlItt ry 1 I I t I r i J J Alternator Voltage regulator fig T7 Charging Circuit 1 tl Ilectrical Sptem r itch Ignition r ell a Btmery 8 Ii T c 0 5 0 i 2 E r o I S l E Ii t Cl J Ln Voltage regulator Alternator fig 78 Olarging Circuit 2 TROUBLE DIAGNOSES AND CORRECTIONS Condition Starting ot motor wiD operate Probable Discharged batter Starting motor cranks slowly or Repair Loose connections Clean and Defective motor Charge Defective solenoid switch of terminal Defective brushes Noisy starting Corrective action cause Loose startina motor securing bolt replace battery eplace tighten Replace brushes Remove starting and mab test bolt Tighten Replace pinion Poor lubrication Fill in oil Worn commutator Disassemble Worn brushes Replace Discharged battery Charge oose connection of terminal l Clean and Worn brushes Replace brushes gear motor brushes Or Inspect brushes terminal motor Worn pinion gear Locked Olenoid switch replace bartery tighten terminal brush spring tension or repair brush holder Starting motor uanks slowly Dirty or worn Armature rubs Defective Starting motor operates but doe not rank engine Starting motor will not disengage even ignition switch is turned off t2 Worn field coil solenoid switch pinion Locked Worn commutator nd epalf Replace assembly Repair or replace switch Replace pinion pinion guide Repair pinion guide Replace ring ringgur Defective solenoid Defective gear Clean switch teeth gear Repair or replace Replace solenoid switch defective gear I1ectricalSptem I Pulley 2 Front Slembly Front bearing 4 Rotor 5 Rear bearing 6 Brush 1 RearcoVtr 8 Diode Diode 9 10 IScmbly sel plate aittmb y over h bolts Throu 7 Rg 79 Exploded View of LT 150 58 LT 135 138 2 I P ssemb y ulley Front over J Front bearing 4 Rotor 5 Rear 6 t J bearin 7 Stator Diode 8 Rear 9 set pbtc 9 Brush 10 Diode 11 Through bolts embly embl o Rg 80 Exploded View of LT 160 19 a Blectrical Sptem 3 Rg B1 I Fron 2 Rotor 4 5 Rear J Stalor 6 Enca beuing Pulley Sectional View ot LT d diode 56 LT 135 136 150 @ 5 Rear Rotor 6 Brush 3 Startor 7 DiOde 4 Pulley I Front bearinl Flg 82 Loosen adjusting holder ssembly eE121 Sectional View of L T 160 19 bolt Installation Installation is the reversal of removal Remove alternator drive belt Remove parts associated with alternator from engine Remove alternator from vehicle VOLTAGE REGULATOR Description The regulator regulator and basically charge relay consists a of a The voltage voltage B1ectrical Iptem VOLTAGE REGULATOR of contact points a lower set and upper set to control alternator voltage An armature plate placed between has two sets regulator the two sets of contacts downward vibrates or complete when closed the ground and closed complete the through a resistance to moves upward Measurement of The lower contacts the field circuit direct field coil is necessary to rotate when upper contacts field circuit to ground produces and 15 30Al the When the upper contacts warning lamp goes battery with cables charge relay is similar voltage regulator in construction to closed as Check to be as are engine at high speed Connect DC voltmeter 05 30Vl alternator output The VoItage Regulator voltage is measured with regulator assembled with alternator When measuring voltage with regulator mounted on vehicle it or and DC ammeter resistor 0 25 ohms shown that all electrical loads such sure air conditioner radio etc lamps are discon nected ignition on Before starting engine circuit with a be sure and minal of resistor 0 250 causes violently damaged 8 and negative side Failure to follow this terminal of ammeter caution to make short cable between fuse side ter needle of ammeter to reversely resulting swing in a ammeter Refer to the regulator following chart to determine if and relative parts are in good con dition Notes a Do not after mediately voltage im measure Do driving this while regulator is cold Fig 83 View of Removing Cover b To measure gradually voltage raise engine speed from idling to rated speed EEOSA 1 Point 10 Adjust pring 2 lower II Coil 3 ArmillurC 12 3mm O 11l11 4 Core S CnTl 1 Yoke II J ap lju At Lock I I ifll pTin rlnlE 2 n dir 3 screw p Yoke 6 I 4 mm 0 1575 n di Crew cw 14 Conlact 15 Upper set nber a Corutruction of Armature 5 Core gap 6 Yoke gap 7 Yoke 8 Adju Ag e Lock Ul II Adjust spring 12 Coil J3 3mmlO lJ81 n di n di screw 14 4mm 0 1575 w IS w ting Vultage egulator ollag relU14tOT 84 CI Cting ConM 4 9 ul 10 Pointglp Cliugc day b Contact Uction COfUt set of chart rrlay Structural View tI IlectricallJStem GENERATOR A CONNECTOR E WI RE HARNESS Short ircuit h between fuse side terminel and H terminal of before ammeter starting the operation BATTERY RESISTOR FOR IDA Rg 85 After IJOV Measuring Regulator Voltage with Regulator I Start 2 Rotate engine ngine at racing for several minutes ammeter reading Afler to see for several minutes racing Fully charged battery I ammeter SA reading over FuUy charged battery available I Replace with fuUy charged battery Check Vehicle on 2 500 rpm for several minutes below SA 2 V VOLTMETER MEASUREMENT AMMETER Connect a not available 0 25 ohm resistor in series if current falls below SA 1 I Current falls below SA Current does nol Recharge battery fall below SA and see if current falls below SA T I Reduce engine speed to idling and then raise it to 2 500 rpm while observing needle of voltmeter 1 I Needle of voltmeter held within limits shown in the below of voltmeter out of limits shown in following chart Needle table lhe Regulator functioning properly Regulator ou or order authoriled shop Have it repaired at llectrical Iptem Regulator model TLlZ 57 and TLlZ S8 HITACHI Temperature oc oF to Volta ge V 75 to 14 14 60 to 15 60 0 32 10 50 20 6S 30 86 15 75 14 14 45 to 15 45 30 14 to 14 15 14 00 104 40 15 30 to 15 15 to 15 00 may be approx 0 3 V higber the rated for two to three minutes af than Voltage c engine is started or more specifically regulator becomes self heated ter when should Measurements within when or then minute after one regulator be made starting engine is cold regulator is of a temperature com pensating type Before measuring voltage d The be sure to tem surrounding measure perature and correct measurements cording to the table in the left hand side ac Ag 86 1 Contact set 2 Thickness gauge 3 4mm 4 CIOsshead screwdriver O 1575in dia screw Adjusting Core Gap Adjustment As the result of above measurement when regulating voltage is deviated from rated value adjust regulator in accordance with the following instructions Inspect contact surface and if rough lightly polish surface with fine emery paper 1 500 or 600 EE057 Measure each gap and adjust if necessary Adjust core gap and point gap in that order 2 No adjustment 3 Adjusting Loosen screw is core 4 which is used to and move properly 4 required for yoke secure contact contact set or on yoke 3 mm to secure upper contact Ag m and diameter used move dia 3 Crosshead screwdriver 4 Upper contact Adjusting Point Gap upward Figure 87 tact 0 1181 gauge 0 1181 in downward See Figure 86 screw mm screw Adjusting point gap Loosen 3 diameter 0 1575 in upward Thickness 2 gap gap mm I upper con 5 or downward adequately See Adjusting voltage Adjust regulating voltage as follows II lIeetricalSptem Loosen screw terclockwise See Figure securing adjusting nut lock Turn this clockwise to increase to decrease screw or coun regulating voltage 88 Charging relay Normal relay operating voltage is 8 to 10V A terminal measured at alternator EE058 as U I Wrench 2 Cro 3 Adjusting 4 Lock it Relay self however operates at 4 to 5V Use a DC voltmeter and set up shown in a circuit Fig 88 Connect positive screwdriver screw nut as Figure 89 l ead tenninal of voltmeter lead regulator to Adjusting Regulating Voltage N connector terminal with negative terminal grounded Starl 3 engine od Take voltmeter keep it idle reading aVail l Check tween fm N Over 5 2 Volts Below 5 2 Volts ntinuity terminals b Pilot of lamp gulator and alternator If Alternator circuit defective od lamp emainslit lamp relay Oil points Qui of rdef Replace 1tregulor remains lit Pilot Check fan belt tension l adjust reet as remove Pilot egulator necessary ontact if continuity exists Over 5 2 Valls Pilot Pilot does 001 lit lamp lamp clay assembly TROUBLE DIAGNOSES AND CORRECTIONS Condition No output Probable Correct Dirty brushes Qean Loose connections or broken leads Replace rotor Replace diodes Replace rotor rotor Open diodes Shorted rotor Grounded BAT Broken ran belt t8 Repair stator terminaL and brush Retighten orsolder connections Replace leads if ecessary winding Open Shorted replace brushes Repair stator alternator or winding Open odition CorrectiYe action cause slip rings good Including Sticking brushes and is in or or replace replace Replace insulator Replace belt stator stator springs IlectrieallJStem Excessive Broken Otltput Replace neutral wire color of wire is whitt Poor grounding regula tor regulator operation replace as required and voltage of alternator Retighten terminal Loose output or worn Sticking and repair or connection terminal E Replace Broken ground wire color of wire is black Low wire Check Defective voltage regulator wire Retighten fan belt Correct brushes or or replace belt replace brushes and springs if and repair or necessary Low Replace brush spring tension Partial egulator operation replace as required Clean ngs short springs Check Defective voltage regulator Dirty slip brush ground or open stator Replace stator winding Replace rotor Replace diode in winding Partially shorted Open Noisy alternator Loose or or grounded rotor defective diode Retighten mounting bolts mounting Loose drive Defective Retighten pulley correctly puUey Replace bearing ball bearing Improperly Seat brushes seated brushes Fuses and Fusible Links Alternator Iu tIi E M P r re N r N tor O lp correctly t@C wt La Qo Lou t ftlor br A p 1 Mitllubillhi 2 500 24 2 SOO 24 5 215@ 5 AS203Al L320 LS20 L521 PL521 PUlO Engine compartment ight WPLSIO R Mit lbishi AC1lli I2X2H LOO Engine compartment riht fender well high temp U20 Mitsubishi AS2030A2 LIB Hitachi 41 LTl30 24 1 AI2 2 500 23 SPL3II SHL3ll Inside 500 22 L8ll0 KLBllO Under instrumfttt panel ight of steering column HLSJO Under Hitachi LTl45 35 2 500 5 000 45 34 Hitachi LTl35 05 2 500 5 000 24 33 glove nt lmpa c sh tray console battery alternA tor Between and At alternator at starter Morethan 41 IlectricalSptem EMISSION CONTROL DIAGRAMS IGNITION KEY TO TJlIIUTO OI IGNmClC COIL no DUAL PenNY OlSTRI8UTOII I NEUTRAl QEAfl SWITQt ANCED UlCER RETARDED BREAKER I CLUTOt PEDAL CARSURfTDR LENOID lr MTCH DETECTING CLOSE THIIOTTLE IlO5lnON Datsun emission control system manual transmission IGNITION WITOI TO ICHITlON BATTERY l OISTRIJUTOfI COIL DUAL IIOINT OISTRI8UTOII AUTOMATIC TRANSMISSION TAROED R Pat KE swtTQt DETlCTING nfROTTU DI CftN POSlnON SWITCH DETECTING CL CIS THROTTLE POSITION Datsun emission control system with automatic transmission 50 IIectricalSptem 1 FROM CARBURETOR AIR CLEANER FROM FUEL TANK 2 TO CllAHKCAlI VAPOR VENT LINE FLOW GUIDE VALVE v lv opan when the pr Ie Ie over 0 4 in Hg The CV lIE FUEL TANK Datsun evaporative emission control system 51 IIectricalSpt Battery I ReslSlor To starter C Retarded breaker P point Rotor bead Coo L 1 n DiStri Fig 89 IO Ignition Systems Circuit Diagram DISTRIBUTOR CONSTRUCTION Distributor model Applied engine 0410 66A LIS 0410 67 LI 6 The distributor for L1G and LIS two breaker other with Figure points a phase engines has opposite to each located difference as External View of Distributor shown in 90 The distributor follows the conventional de The difference in turning fig 90 the phase can adjusting screw be adjusted by sign except for the dual points i e plate with contact points centrifugal mechanism A phase difference of 70 crank ted Two breaker points is adop which consists of ad and retard breakers vance angles are a1Iel with each other in the placed relay 12 unit drive shaft 92 and 93 show retard breaker switched is point OFF point primary ignition ON works and works when the See Fig 91 an and exploded view of the unit Disassembly To disassemble follow the below breaker ched vacuum Figures in par circuit The rotor breaker advance when the the advance relay is swit procedure Take off cap and disconnect rotor head Remove vacuum controller Remove contact set I1ectrical Iptem Unscrew two contact breaker set remove Pull contact breaker knock remove pin screws and When assembly and disconnect collar to out is to be removed screw since screw to across the entire rotating parts cam hold can head cam and cam bination shaft is down shaft so be restored at first Put apply set the by matih mark original assembly that When governor weight and spring nected be careful not to stretch governor spring After disassembling remove fastened com are discon or deform grease to governor weights Assembly Assemblv can be made in reverse sequence of for 101 Refer to Figure disassembly replacement and reassembly of spring and cam assembling distributor use caution head positioning tip at cam is hook side governor spring circular In 1 Advanced breaker 2 3 FIg 91 rded breaker Ret Phase difft governor rotor point pomt rence so that set on for governor spring A with circular hook comes in long rectangular hole Then External View of Dual Points weight pin l 1 Center carbon 4 Condenser 7 Governor weight 2 Rotor head S Shaft 8 Cap 3 Breaker plate Contact 6 Hou ing 9 Side plug Rg 92 Construction 13 I iE1 asembly asembly set asembly asembly Shaft Colar Cam J 23 set weight spring asembly a s e m b l y asembly asembly asembly control asembly apoisemblny t asembly point embly point asembly point asembly head Advanced plate Bolt Retard wiLearde Advance wire Retard wiEarrteh point cap as set Governo Governo Screw Rot r Breakr Contac Conectr Vacum Screw Condesr Screw Distrbuo Carbon Fixng Condesr for 4 5678 9 10 II 12 13 14 15 16 17 18 19 for Screw 20 21 for Lead for 22 23 Distrbuo of 1 Compnets i I I 7iJ 93 o Flg 4 IlectricalSJStem 4 EE07D Fig 94 EE074 Fig Disassembling Vacuum Controller Removing Rotation Parts 98 EE075 Fig 95 Removing Carn Fig 99 Unscrewing Breaker Sets Screws Q s b i EE141 Ag 96 Removing Contact Breaker Fog 100 Exploded View Also check spring A is to be in sure slit in that cam clearance between the two at end of governor EE073 Fig fJ11 Removing Knock Pin operation weight pin on opposite rectangular hole Meanwhile in short weight pin on plate with a beginning and side comes 5 B1ectricalSptem 5 1 Shaft enter 2 I Governor 2 Clearance fOl Ieighl slart end of advancin 6 Rectangular hook printt R am plate Weight pin 7 Circular hook 8 Gm 9 Rotor 3 Governor 4 5 EE071 Ag 101 and angle spring A positioning tip ernuT Setting Governor s Spring and earn IGNITION COIL 1 2 CD 4 @ l rillliJr J Sl ndary l lnitlal 1 Tmin It Jp C @ @ EE143 Fig l02 Construction 18 4 Sprln 5 Side h Primary 7 S 8 In uhllllr HI 9 l III dar n nlcr III Segment II Case il IIectricalSJStem It does not leave clearance either at the start and end of advancing check to be With unit assembled driven slit and rotor position tip 9 the same direction See Figure 101 After before assembly installing check it on operation engine Ignition timing should mounted on engine be sure are that set in ignition coil circuit helps produce strong sparks from starting to high speed full power operation The resistor in the The internal resistor limits to safe flow of the primary of governor tested with unit current a maximum through coil and distributor contact points the Thus it protects the contact points during slow speed operation when they are closed for long inter vals The ignition dled as a coil and resistor should be han matched set IGNITION COIL Description The ignition nition coil coil is of case good insulating an oil filled type The ig which has is filled with oil and heat radiating teristics Description greater ratio between the primary and secondary windings to step The ignition SPARK PLUGS charac coil has a The spark plugs are of the resistor type up the having 0 551 in threads and 0 0276 to 0 0315 in gap The inspection and cleaning should be cause made every suitable maintenance battery voltage to the high voltage to stronger sparks to jump the spark plug gap necessary The cap is made of alkyd resin which offers high resistance to electric arc and increased Note engine insulation number of heat range i All spark plugs must be of the If installed same on an brand and l Carbon Normal period replace fould Life Overheating Fig 103 Spark Plugs 17 IlectricalSptem fuel pump pressure Inspection Remove spark plug wire by pulling on hotter boot not on wire itself Remove It is advisable to Check electrodes and inner and outer por celains of plugs noting the type of and the degree of electrode erosion Brown to electrode slight plug heat grayish tan indicate wear After cleaning deposits and spark correct gap to specification Install spark plugs Connect the and insulator on electrode speed driving nition too rich fuel mixture were mostly city weak ig dirty air cleaner parallel Set and torque each It is advisable to replace with spark plug plug to 11 blast type deposits wires a sand plugs having A void excessive show excessive oil entrance into combustion chamber through pistons or excessive clearance between valve guides and stems If the same condition remains after repair use a hotter plug worn and rings White Overheating or light gray insulator bluish gray brown spots and burnt electrodes indicate engine overheating Moreover the appearance results from in with black correct or ignition timing loose spark plugs low Fig 104 Selling Spark Plug Gap TROUBLE SHOOTING IGNITION Spark length No sparks at all Trouble location Distributor Causes Remedies of lead wire low tension Defective insulation of cap and Point does 19nition coil High I to 2 mm irregular 18 0 0394 0 0787 in or tension cable Distributor Replace Defective insulation of condenser Breakage to small blasting Clean and but do not remove carbon or oxide deposits If deposits are too stub wear away porcelain born discard plugs cleaner hotter heat range Wet black spark pi ug Cleaning and Regap Clean spark plugs in in etc Oil fouled a to 15 ft lb Dry fluffy carbon deposits slow plugs having dress electrodes with and side electrodes in range by with replace fine file to flatten the surfaces of both center deposits Carbon fouled caused a colder heat range spark plugs Normal plug wrong selection of fuel etc at open Wire breakage short Wire coming off ide rotor close cuit of coil head Repair Replace Repair Replace with new Repair Defective insulation Replace Point gap Correcl Oil too sticking Point burnt wide on point too much Clean Replace ne IlectricalSpt T ublt Less than 6 mm Trouble location Cause Spark plugs Electrode gap 0 2362 in Distributor Correct Broken neck of insulator Replace of life plug leak of eplace replace Clean Correct gap electricity of cap and olor head Repair or replace Defective insulation of condenser Replace Defective arm Oil shaft Defective spring of Breakage High tension code or Replace Dirty point il or Clean Improper point Ignitjo wide Too much carbon Expiry Engine misses too Remedies rm Replace assembly of lead wire Replace Worn out or shaky breahr plate Worn out or shaky Layer short circuit Deterioration f Replace assembly distributor shaft of oferior or insulation and Replace assembly quality Replace leak Replace of with good one electricity Spark plugs Clean Dirty Leak of electricity at upper porcelain Repair or replace nsulater Engine causes knocking very Distributor Improper Coming often A pin and advance off or a or Correct the timing breakage of governor hole of governor spring portion worn Correct or fitting replace Replace out Engine does not give enough Spark plugs Burnt Distributor Improper too much and Replace etarded Correct the timing Replace assembly Dirty point Clean power Point gap After cleaning spark plugs renew too Correct narrow Clean Dirty Spark plugs firing sur Disconnect connector of heater to face of electrodes with file mentioned above Then gap spark plugs to 0 0276 to 0 0315 in hot water round wire feeler gauge All spark new or used should have the gap checked and reset by Remove defroster hose using plugs a bending electrode fitting Defective function of governor ground engine well pipe Disconnect connector motor Remove the two heater control wires at heater unit HEATER UNIT REMOVAL Remove the four bolts and take out ventilator Remove the four heater unit Drain out coolant fixing bolts and detach heater unit 18 syste1ll J uJ a E t03 2 t 1 A 3 8 h s ii5 o J t tD 3 0 ft I d I Ii C El Ira 11 1 111 I II II lU1 oo 7J 11 HP IS I JI III l t q J 1 1 1 1 I II i l II 0 l c I i ti 1 lr I l t L l f l Ii II E ilt 1 l II 1 I il 1J lc INi I II ii II o c E z I i c l t J2l 1 c f r dJ J 11 I I III W r 0 T J I Ii I I l il o 1 e rs E is C i I l III Xrf Ii rt Ii i IC I 0 A III lW I l 1t I IIiI 1 C 1 Itti1nT I Q 1 11 I I c o J r l ir II lI I 1 1 u I fiF III r lli nnmm m 1 Ii i s Ti f i I @ s3iiLI m I J SI I C I yl nIII 1 J lJ r fuoO i r II 4 lll C L il I l i O Wt 0 r Ji3r c J I ll l F J r r e o I it 111 t I 0 hill IF u 5 I aft IleCtricalSystem Q 0 8 iii P 1 aa o 8 CD a 1J t c 1l g c o E c E l E a c cS z a c 1 E is rraa 1 8 Il dl It ir t g lf1l or 81 B1ectrical SpteJD TROUBLE SHOOTING HEADLIGHT Condition lamps Head engine shut Probable dim idling off Corrective action cause Partly discharged battery Charge battery Defective cells in Replace battery or High battery resistance in light Check circuit head lamp Make necessary Faulty sealed beam units Head lamps dim istance High light ci rcuit lighting Check ground sealed beam units Faulty voltage Replace sealed beam units control unit Test voltage control and Make necessary Loose connections wires in lighting or damaged ircuit Light wiring nsulation damaged producing momentary short Lights burn cut frequently includ circuit connection Make necessary repairs Faulty flicker repairs Replace sealed beam units engine running above idle Lights including circuit connection ground oltage regulator setting High Loose cOIUlections in Tighten connections damag d wiring Check generator repairs and check for light wiring and replace or tape damaged wires Adjust voltage regulator lighting Check circuitCor loose connections circuit LIght will not Discharged battery Recharge light battery and correct cause Loose connections in lighting Tighten connections Replace bulbs circuit Burned out bulbs Open ing or not lamps light will or sealed beam unit Replace lighting switch switch Open Slop corroded contacts in light or corroded contacts signal and Switch faulty Wires broken in turn switches lighting Replace Replace disconnected turn signal and lighting switches or switch Make necessary repairs loose Bulb burned out Loose connection od Replace or poorly ground lamp body 82 Faulty n sher unit Burned out that side parking Tighten loose connectIon perly ground tamp body or pro Check for shorts and replace fuse Burned out fuse Turning signal lamps light with out btinklng bulb Replace flasher unIt or tail lamp on Replace bulb IIectricalSJStem Blinking on Loose contact of bulb one Make necessary repair side too fast of bulb Improper capacity Turn indicator lever does return automati mechanism Faulty not of Replace bulb turn signal Replace with new parts switch cally TROUBLE SHOOTING HORN Condition Probable Horn does not F operate burned Improper Dead Replace mtaet uf horn bulton mtaet of Repair ch terminal or replace harness Correct each terminal battery Improper fuse Check and repair horn button f harness Open circuit Improper Corrective action cause ut yharge battery contact of horn Correct relay point Open circuit or rong nection of horn interior Wear of horn Low volume Improper improper tone nector ground coo Replace point contact of fuse contact of horn Wear of horn Crack in repair horn Adjust adjusting or Correct 000 Open circuit of harness Improper or screw contact Repair Correct horn point point point Adjust adjusting diaphragm Rephlce screw horn RADIO Removal HORN RELAY Disconnect all connections 1 i z z g ii I8 i 2 lI 2 L BATTERY I i i J Remove COIL IOINT Remove knob and volume control ashtray Remove cluster lid lid Ag 107 Horn Relay Wiring tuning knob fixing by unscrewing four cluster screws Separate cluster lid finisher by unscrewing lock nuts board and radio 83 B1ectrical Spt m TROUBLE SHOOTING SPEEDOMETER Condition Probable Speedometer does Improper Dot cable union nut operate setting Corrective action cause of speedometer Broken speedometer cable Broken speedometer drive gears Defective speedometer Swing of pointer Excessive bend in Correct setting Replace cable Replace meter Replace meter Correct cable speedometer installation place cable Broken speedometer Defective f Unsteady pointer Improper Replace speedometer drive gear speedometer setting of Replace speedometer speedometer Correct setting cable cable union nut Defective speedometer cable Replace Defective speedometer Replace speedometer Excessive Strange sound eyncbronized witbrunning speed bend lack of lubricant Replace or lubricate cable and twist of meter cable inner wire Defective speedometer Replace speedometer Inaccurate Replace speedometer indication of pointer Defective Improper odometer third gears in gearing of second speedometer and Improper feed caused by deforma tion of pinion carrier ry 1 Replace speedometer 1 Cil @ @f fig 108 Heater System 84 Replace speedometer or re IIectricalSpteJD TROUBLE SHOOTING HEATER Condition Probable Corrective action cause Hot air does not out come Motor does not operate short Open or harness circuit of feed Check and repair wiring harness Defective switch Replace switch Defective motor Replace motor Fin is Clean fin Fan cannot be rotated smoothly by hand Hot air does Dot come out clogged Slow rotation of fan Replace Looseness of fan Repai r motor lesfJ although fan is rotating Air stallation temperature is low Hot wate r Defective water pump Repair water pump does not circulate or Bending clogging Check or clean piping hose Defective Water tem of connectir g hot water cock Repair Air is left in the hose Purge Defective thermostat Replace thermostat Defective water hose Replace Loose Retighten air out of hose perature is low Water rom leakage water hose heater clipping Defective of water hose cylinder head gasket Improper soldering of Defective Defroster defroster Vibrating Bend noise or heater core hose is removed Looseness leaking position Correct BUpport of each fixing Solder Correct connection break of defroster hose Looseness of heater clip Replace gasket or replace Tighten completely Retighten each screw screw TROUBLE SHOOTING RADIO Condition Pilot not lamp does light when switch is on Probable Melt Corrective action cause away fuse Improper Replace connection of cable or Inspect and tighten connector Broken Pilot lamp lights does but sound not come out pilot lamp Replace Improper switch Improper connection of antenna Tighten Improper connection of speaker Tighten Improper circuit operation of radio itself Repair or replace Consult Service Shop of radio manufacturer 85 B1ectrical I em NOISE PREVENTION CHART Condition Apparent Repair cause Ignition system Noise with present synchronized engine revolution High tension cord Ignition coil Do not worry about high tension cord because anti noise cable is uBed Keep choke wire far P08 coil as Set 0 5 IJ a8 F If from ignition condenser at primary side B terminal of Note away l f ignition coil 6 COI the is set at ondary or primbraker p engine will not Connect with bond wire between engine and ignition coil locating Secure Distributor side area of body ground of ignition coil Secure contact of carbon electric pole and rotor Eliminate excessive tips at rotor pole or cap pole scrubbing by driver Check veen bet stagger rotor and starter Charging system Sound of alternating current Alternator Set 0 5 F Note 00 not add If more nator hen pressing down leasing accelerator noise 88 present condenser at charging terminal A present or re pedal Regulator Set 0 5 F mote condan conden coil r is added alter will be broken condenser at B terminal of voltage regulator or Bat Fuel Sptem AIR CLEANER ELEMENT 68 AUTOMATIC TEMPERATURE CONTROL AIR CLEANER AIR CONTROL VALVE Idle Compensator TEMPERATURE SENSOR 68 68 69 69 Removal 69 Installation 69 FUEL PUMP Removal and 69 Disassembly Inspection Assembly CARBURETOR 69 70 70 73 Removal 73 Disassembly 73 Float Chamber 74 ANTI DIESEUNG SOLENOID 74 Removal 74 Installation 74 BOOST CONTROLLED DECELERATION DEVICE Assembly and Installation Cleaning and Inspection JETS 74 74 74 75 81 raelSpt AIR CLEANER ELEMENT ThE air cleaner element is of type and does not require When the temperature of suction air around the sensor reaches 37SC IIOOF or above viscous paper any cleaning until a the sensor actuates to open the air control When the temperature of suction air around the sensor further rises and reaches valve replacement lote Do before not brush replacement blast or element above 480C 11S0Fl the control valve air completely opens prevent the entrance of hot air and allows under hood air alone to be to AUTOMATIC TEMPERATURE CONTROL AIR CLEANER The temperature cleaner is provided with a temperature and a vacuum introduced into the carburetor control automatic operated valve The air See Figure 111 sensor AIR CONTROL VALVE vacuum ac ted upon the air control valve is controlled the sensor See Figure 109 by The air control described If the temperature of suction air is low when the engine is running the air control valve s i c n valve acts previously ir a IL in the manner and the temperature of e h sensor is always kept at about 430C II 10oFl closes the underhood air inlet and introduces hot air through the cover the exhaust manifold When the which is installed on See Figure is engine operating fully load the air control valve 110l I Air nlet 2 Vacuum 3 Temperature Hot rpipe 4 @ Ml EC 5 Air 6 Idle under heavy opens the un pipe molor ntrol s y censor ass y alve compresalor Rg l09 Automatic Temperature Control Air Cleaner To manifold I 3 Diaphragmspring 4 Diaphragm 5 Vacuum hose 6 Air bleed valve Partwly Hot Hg l10 inlet I Air 2 Air control pipe Hot Air Delivery Mold Operation open 7 Hot air 8 Temperature ly pipe censor ECOO7 During Cold Engine I Airinlclpipe 2 Air 3 Diaphrapn prins Diaphrqrn 4 5 6 Air 7 fully open Hot PJPC 8 Temperature ntrolvalvc Vacuum hoses fig 111 Underhood Air b1cedvahrc llsor K b1 Delivery Engine Operation ECOOB Mold lOuring Hot FuelSptem derhood air inlet to obtain full power dless ofthe temperature around sensor regar This control of carburetor air temperatures allows leaner carburetor calibration with ac companying reduced emissions than Note Use care not to damage Connect hoses to their proper Figure 115 conven sensor positions See FUEL PUMP tional controls and also eliminates carburetor icing Removal and Remove Idle Compensator of the mixture enriching idle temperatures temperatures are as a result of Disassembly assembly by unscrewing pump mounting following order two The idle compensator is essentially ather mostatic valve to compensate for excessive fuel nuts and disassemble in the high When the under the hood high the bimetal located in the air cleaner is heated by intake hot air and Catch ad hesivc 4 Hose 5 Tab 6 CHp 0 055 in dia orifice compensates for the increased richness of into the intake manifold mm and the air fuel mixture in order to maintain engine operation Pipe 2 3 Fixed with lifts the valve to open This pennits additional fresh air that is properly calibrated by the 1 4 smooth idle 1 7 GaSket Ag 112 Removal 01 Sensor The idle compensator thermostatic valve par tially opens at 650C l490F and fully opens at 750C l670F Never attempt to disassemble this unit since it is sealed for tightness and properly adjusted for valve timing TEMPERATURE SENSOR Removal Flatten tabs of clip with pliers Ag 113 Installing Sensor Pull off hoses Note Note the respective positions they were removed and clip of hoses from which Take off sensor Installation Install and sensor proper positions See Insert correct See clip Be position Fig Press fit tabs gasket assembly Figure 113 sure in Fig to hold sensor 113 to avoid In the at its damage 114 clips into pipe while straightening Ag 114 Inserting Clip 81 aelSpteI l l Separate upper body and screwing body set screws Take off cap and cap lower body by gasket by removing un cap this during operation diaphragm or oil seal Drive out rocker arm not damage to pin by using a press or hammer screws Unscrew elbow and connector Inspection Take off valve retainer valve retainer easily removed To remove against spring down and screws diaphragm force by unscrewing two valves two press down its center With diaphragm pressed pull rod touches tilt it until the end of the inner wall diaphragm to of body Then release the push rod Use care unhook Check upper body and lower body for cracks are Check val ve for valve valve assembly spring Blow wear on valve and assembly with breath to examine its function Check diaphragm for small holes cracks or at the portion in wear Check rocker arm for wear contact with camshaft Check rocker may cause Check all malities oil pin leakage arm for wear other components replace with and A worn pm for any abnor new parts if necessary Assembly Reverse the order of serve Use Ag 115 Connecting Hoses 1 OutIetvalve 2 Diaphragm Diaphragm spring 3 4 Inlet valve 5 Rocker the new following gaskets arm fig 116 Schematic View ot Fuel Pump 70 disassembly Closely instructions ob uelSJStem Lubricate rocker rocker arm rocker arm arm link and pin before installation To test the function proceed as follows Position fuel pump assembly about 3 3 ft above fuel level of fuel strainer and connect a pipe from strainer to fuel pump Operate up soon pump is Ag 117 Removing Pole Rod rocker after arm hand by rocker arm If fuel is drawn is released fuel functioning properly i o 2 @ 1 Fuel pump cap 2 3 Cap gasket Valve packing 4 Fuel pump 5 Valve 6 7 Diaphragm Ass y Diaphragm spring 8 PUU rod 9 Lower body seal 10 Lower body seal 11 12 Inlet connector 13 Rocker arm 14 Rocker arm 15 Rocker arm 16 Fuel pump packing Spacer Cuel pump to 17 EF008 Ass y valve Ass y retainer washer Outlet connector spring side pin cylinder block FIg 118 Structure of Fuel Pump 71 I ble d ble d tube hole valve air jet air jet emulsion throtle main slow slow main bypas i S S 9 S S S 15 16 17 18 19 ble d ble d air air slow gOW jet st 2nd P P I S 20 21 hole valve noz le venturi throtle slow bypas main smal P P P S 89 10 II 12 t of 9 do 1 c 6 I i of View 14 tube valve smal main ble d valve Float Float Choke S Carbueto 3 venturi noz le 1 S aic emulsion Primary Primary Main Primary 2 34 56 7 Sectional 119 Fig Fuellptem CARBURETOR Remove pump lever and pump rod Remove Removal Remove air cleaner Disconnect fuel connecting rod cam Remove thermostat and vacuum lines from cover by unscrewing three set screws car buretor Remove throttle lever Remove four nuts and washers retaining car buretor to manifold 1 Needle valve 2 Stopper plate 3 Filter 4 Filter l screw S Life carburetor off manifold Remove and discard the carburetor and used between gasket manifold it Replace Nipple o11 if y necessary @ Disassembly Do not remove Carburetor Remove ET040 throttle plates Fig 122 Removing Filter assembly throttle return spring from primary side w o @ I ET038 1 Ventui 2 Main air 3 Emuleion take 4 bleed 5 Secondary Primary Rg 120 Removing Thermostat 2 Chock chamber Thermostat cover CID 3 Pump lever 4 Throttle return spring 5 Pump ET041 rod Rg I23 Removing Venturies 1 2 fig 121 Removing Diaphragm Chamber ET039 EF134 Flg 124 B C D D Securing Screws 73 aelSptem l Remove et choke chamber screw from and remove secondary Separate float by unscrewing by unscrewing four spring throttle return side After inotalling anti dieseling solenoid leave more than 12 hours without carburetor operation chamber and throttle chamber After replacement four set check to be screws that anti Float Chamber diaphragm chamber assembly diaphragm chamber gasket cam over start and engine solenoid dieseling is in good and con Remove filter set valve and stopper nipple screw Notes result in getting on improper valve performance or clogged fuel passage filter needle b In hold plate tool Remove cylinder plate pump cover piston return piston spring and inlet valve by un two set screws screwing c installing valve use caution not to body directly Instead use special tightening nuts as required After to installing be certain cracks spring and Do not allow adhesive a valve Failure to follow this caution would and counter spring cam and lever Remove injector is that fuel is not leaking dition Remove Remove fast idle sure or a new solenoid that there is check leakage no otherwide deformation outlet valve BOOST CONTROLLED Remove small venturies emulsion tubes from main air bleeds and and primary secondary sides DECELERATION DEVICE Remove B C D D securing Remove slow jet and slow air bleed B C D n assembly Remove When primary and secondary main jets level Remove gauge cover float chamber rubber seal float shaft colour and level gauge float three unscrewing by 1 screws Do scrcw not unscrew three 2 after three screwing installing securing screws 1 rescrew three BC D D assembly screws 2 in order to prevent the warp of B C D D body Tighten torque Remove power valve Remove return spring hanger 17 to 35 in lb plate sleeve fast idle lever and throttle lever ANTI DIESELING SOLENOID Replace gaskets Solenoid is cemented at of pair a pliers factory loosen to body out of installing all solenoid First a solenoid or three pitches without all disturbing exposed threads Stud Lock ofLOCTITE Then torque R it is essential to threaded parts of carburetor and Supply screws in holes and turn them in two coat interlock disassembling link and related components any of components Installation clean In if necessary be careful not to bend position Before screws the above with or setting adhesive equivalent to 30 to 48 in lb in reverse Removal Use Assembly and Installation Follow disassembly and removal procedures the Careful reassembly operation of all interlock parts will Cleaning and or rest9re deform smooth Inspection Dirt gum water or carbon contamination in or on exterior moving parts of a carburetor are often mance responsible For this upon careful depends while servicing for reason unsatisfactory perfor efficient carburetion cleaning and inspection ruel IJStem Blow all pressed passages and castings with com air and blow oft all parts until dry Check filter Clean and screen if it Note Do not pass drills or wires through calibrated jets or passages as this may enlarge orifice and seriously affect car plugged replace buretor calibration Inspect operation Check all defective especially parts for wear If wear is noted be replaced Note parts must the following Push connecting rod of Check fuel linkage into of air and assembly must be wear If wear replaced ridges idle adjusting a or remains float of accelerating pump Pour and make throttle chamber lever operate And check condition of fuel in jection from the accelerating nozzle JETS needle for The carburetor performance depends on jets why these components and air bleeds That is must be fabricated with utmost care To clean out of roundness Such distorted damage of diaphragm Check throttle and choke shaft bores in throt tIe chamber and choke chamber for wear or Inspect lint chamber diaphragm Check float needle and seat for is noted is or for operating condition and block passage of vacuum by finger And when connecting rod becomes free check for leakage for dirt burrs or condition requires replacement Inspect gaskets to see if they appear hard or brittle or if edges are torn or distorted If any such condition is noted they must be replaced them cleaning sol vent and blow air on Larger inner numbers stamped on the indicate jets larger diameters Accordingly main and slow jets with larger numbers use them provice richer mixture and the smaller bers the leaner mixture Inversely and slow air bleeds which make the fuel through larger numbers are num the main for air to pass they bear leaner if and the smaller numbers the richer fuel 71 GaoUDI Sptem DRAINING FLUSHING WATER PUMP 78 78 Removal 78 ssembly Dis Inspection 79 Installation 79 THERMOSTAT Removal and Installation RADIATOR 79 79 79 79 Removal and Installation 79 Inspection 80 1 Cooling Sptem r JJ @ CiJ C0013 FIg 125 Cooling System The pump contains an shaft which a steel DRAINING AND FLUSffiNG To drain the cooling system remove the radiator cap release the drain cock at the bot tom of the radiator and drain plug on the right side of the system is cylinder installed block the set If the heater heater bearings the front position After the coolant is drained completely cover assembly a The fan and of pulley are Loosen four bolts remove retaining shroud centrifugal type engine front cover bolted at the pulley a hub The pump shaft is supported by a double row ball bearing press fit in an aluminum die cast pump body The bearings lubricated and sealed to lubricant and entry of dirt 78 are permanently prevent The inlet of the clean container WATER PUMP the on ball pump is connected to the radiator lower tank by a hose radiator and is the close and refill the system on in temp with clean water Thwater 1ump which is mounted that turns and the volute chamber is built in Drain coolant into plug rotates Removal erature control valve at open the drain cock and impeller loss of fill 126 Removing Water Pump fan shroud to Cooling IJStem Loosen belt then remove fan blade and pulley and gasket from hub assembly Remove five bolts pump from front cover Disassembly The water pump body is made of aluminum and its bearing outer race is press fit For this shaft bearing should not be reason the body disassembled fig 127 Removing Thermostat Inspection Inspect pump assembly for the following con ditions and replace it if necessary Badly rusted or corroded body assembly and mostat housing vane Excessive end play in Loosen two securing nuts and remove water outlet gasket and thermostat from ther or roughness of bearings After stall operation checking thermostat satisfactorily replacing with a new housing gasket in Reinstall water outlet and tighten securing Installation Make sure nuts clean the to gasket surfaces on pump and front cover Always use new gasket when installing pump assembly Be sure to tighten Fill bolts Replenish coolant and check for leaks RADIATOR uniformly and check for leaks cooling system at pump pulley and fan blade and tighten bolts fixing securely Install belt and adjust Install fan for proper tension conventional down flow type having the top and bottom tanks to distribute The radiator is the coolant flow above in wax pellet type thermostat is mounted the thermostat housing at the cylinder head A adjacent to the inlet manifold The function of thermostat is to control the atmospheric valve It boiling coolant a vacuum valve coolant temperature The up and regulating thermostats are designed to open and close at radiator predetermined temperatures opemting properly should be tested as and if not removed and listed below in the to maintain 13 Ib sq in The relief valve pressure valve and a vacuum lf1 bIow kglem2 On the contrary warm engine designed helps to prevent coolant loss from by raising the pressure on the below facilitating ver for reduced fast the tical tube of the radiator core consists of flow of coolant uniformly through The mdiator filler cap is 09 a pre set pressure THERMOSTAT water outlet a the pressure is as atmospheric allows air pressure to preventing the formation cooling system enter re the the of vacuum The bottom tank on cars equipped with the automatic transmission inoorplrates an oil cooler for the transmission fluid Removal and Installation Drain coolant Disconnect outlet Removal and Installation partially upper radiator Drain coolant into hose at a clean container water Remove front grille 19 GooUDI SJStem I emove bolts retaining radiator from radiator radiator upwards side support3 and remov of in Install radiator reverse sequense removal Inspection Iadiator cap should be checked for pressure at regular tune up intervals First check rubber Ag 128 Radiator for Manual Transmission seal Oil cap for tears cracks or deterioration after cleaning it Then install radiator cap on If docs not hold pressure or will a te ter cap not release at thp proper pressure replace cap Disconnect On a radiator upper vehicle with disconnect cooler radiator 80 and lower hoses automatic transmission inlet and outlet lines from Also in pect radiator for water leakage using a cap tester unde applying a pressure of 17 lblsq in If uch the replace radiator or defect is detected repair Brakes MASTER CYLINDER 82 Removal 82 Installation 82 FRONT DISC BRAKE 82 Description 82 Removal 82 Disassembly Inspection and Repair Piston Seal Replacement Assembly and Installation Pad Replacement 84 REAR BRAKE Removal and Inspection Assembly Disassembly 84 85 85 86 86 86 87 88 II Brakes MASTER CYLINDER hydraulic forces the pressure from the master cylinder out of the piston of wheel cylinder Removal caliper Remove the clevis pin connecting the push rod with the brake pedal and disengage the til it contacts disc master cylinder from the pedal Disconnect the brake tube from pad by These forces cause rotating moment which increases reac This is called self energizing tion In this SC brake it is around cylinder As Screw out master remove and reaction force F outer tion force F the master pad forward un simultaneously pushes bore and thrusts inner the cylinder fixing master cylinder from nuts and pad the dash its elastic deformation ward causing thus Installation procedure of assuring slip is piston creased and when seal is deflected board Installation movement wears ac 50 more in than wiil slide out piston between seal and piston constant clearance between pad and disc is reversal a but the of the removal following operation Removal should be added Adjust the pedal height by changing rod length of the master cylinder Bleed air out of the master cylinder the Jack up the vehicle and support it and remove the wheel on stands push Disconnect the front hose brake from the brake tube Plug up the brake tube with a wooden peg to avoid spilling fluid during work on caliper Note FRONT DISC BRAKE Screw out the bolts Description Figure 130 shows the relation of forces As brake working pedal is depressed knuckle I @7cf I 0 Fig I29 Tandem Master Cylinder 82 to the the caliper remove t Push rod 2 Dust 3 Stopper ring 4 Piston ass 5 PistOn ass1y 8 6 Secondary piston cap 7 Pbton 8 Primary piston cap Master cylinder body 9 6 lY 4 Y caliper assembly Ii j I flange the fixing and ass y cover y A 10 Reservoir band 11 Reservoir 12 Reservoir 13 Filter 14 Bleeder 15 Check valve 16 Check valve 17 Valve cap 18 Valve cap ass cap ass1y screw spring ass y gasket y Brakes 4 3 I 2 9 11 I 6 QD1 @ 1 Cylinder 2 Pi 3 Wiper eal 4 Eletainer 5 Piston 6 Clip 7 Shim 8 Pad 9 Caliper plate eal ton 10 Torsion 11 Cotter 12 Nut 13 Washer 14 Support bracket 15 Hold down 16 Pivot 17 Mounting 18 Spring ipring pin I 10 17 pin pin bracket Fig 130 Front Disc Brake FIg 131 Sectional View ot Front Disc Brake 83 I lk Remove the separate the nut and the disc hub spindle rotor from the hub and assembly Disassembly the anti rattle Remove and then plate pick clip from pad the caliper up the Remove the tension springs plate and pull the cylin der out ofthe caliper To take out piston apply air or hydraulic rubber pressure from inlet hole Remove the seal from the groove on the cylinder Remove the retainer and wiper seal and then it can be easily taken out Ag 132 and Repair cylinder assembly for oil leakage damage and replace the cylinder Inspection Removing Front Brake Hose Check the and any assembly ted on Note if any abnormal condition is detec it Unlike drum brakes the wheel the cup of seal of SC type cylinder piston important functions sealing retracting piston and automatic If pistonseal is damaged adjusting whole replace cylinder assembly as a unit However if it is necessary to replace piston seal replace wiper seal at the When pads are replaced two or same time or seal three times cylinder assembly should be replaced though they still seem to be in good condition disc brake has three Ag 133 Removing Caliper Assembly fig M 134 Removing Brake Disc Fag 135 Removing Piston Brakes Check the pad is damag ed in in or for thickness replace and crack wear become worn Inot if it to less than 0 04 the including metal hacking plate Check the caliper for and damages replace it if any damag e is detected Check the rotor ccssive out of roundness and ditioning by machining reconditioning Limit of score forth so ex recon required fin pivot pin Insert avoiding tilting t two inches Standard rotor thickness 0 0394 in and Installation lnsc the piston into the t pindle cylinder till the face platc springs Kunout of the rotor should be less than 0 0048 Install the cylindcr into the caliper in total indicator reading seCure an ahnormal distortion r or condition excessive run such as crack is detected out the rotor place in bv two place tor ion emble the hold down pin spring a cotter pin hould bc replaced on caliper plate the pivot pin washer spring and nul in that ordcr Tighten nut with the paying piston seal it attention to the her to the nut Sccurc the mounting bracket and leakage is found wa and and nut in this order to support bracket lnsert Piston Seal Replacement If oil gently or piston hl ad hecomes almost flush with the j ace of the I ptailwt of the wiper seal tn If exists Clean the mounting surface and disc surface Attacb the disc to thc hub Install tbc bub to tbe knucklc in thickness is 0 331 damage piston surface Insert the piston Take care that the relieved position of the piston faces on Assembly and if it shows is Clean the piston Check that no and set a cotter washer complete pin following points Aftcr with brake fluid groove seal rinse disassembly taking Insert great care the new cylinder seal into not to borc the damage the wiper seal Apply a thin specified grease to the cylindcr Pry up and hold down bracket by a screw up to the upper end of the to mOll Ilt i ng bracket Turn tbe caliper platc drh mak and hook sure that it can slide smoothly Attach the coati ng of hol Fig 136 Measuring Runout of Disc Install the calipcr assembly to the knuckle flange Ftg l37 Assembling Piston Seals and Retainer 85 Brakes Attach shim to inner a pad proof and for noise Be sure to set the inner center of chassis pad first Draw the inside toward Insert lower cuts both toward caliper plate enough on ends of the bracket and then contacts the pad into the mounting push the pad until the pad caliper plate toward outside Insert upper cuts and center indentation of outer into the Attach the anti rattle pad Pull the caliper by as 0 lIS to 0 157 in Outer pad is loosened and can be easily pulled out caliper plate inwards and remove pad Wipe exposed surface of the piston thoroughly Push the piston enough into the cylinder bore Insert new pad into the caliper plate Draw the REAR BRAKE clip Be sure by the sticker indicated on Removal and Disassembly Jack up the vehicle and support it and remove the wheels on Replacement The clearance between the pad and rotor is adjusted automatically Check the pad for wear after the first 6 000 miles and every 3 000 miles and thereafter Pad thickness is the anti rattle worn to less than 0 04 in cluding pads Note easily checked by removing clip When linings become the metal in thickness not in backing plate replace Always replace the pads using genuine parts all in full sets of four Remove the road wheel Remove the anti rat tie clip from the caliper plate Fig 139 Pushing Pin t Fig 138 Removing Anti Rattle Clip 88 plate Push the piston the direc the clip Pad in caliper plate tion coincides screw inner piston Draw the Loosen the bleed outwards outward of chassis heat insulation Fig 140 Removing Pad stands Brakes @i J c r jj i Fig Release the cross parking rod from 141 ectional brake and disconnect the the lever of the rear wheel cylinder springs and then take out tube from the wheel cylinder and so and is score forth excessive out of reconditioning by required Drum inside out of Nominal inner diameter of the drum is 8999 in Remove the wheel ponents show roundness roundness below 0 0020 in the brake shoe assemblies Disconnect the brake Inspection Drums If they machining Remove the brake drum Remove the return View of Rear Brake as adjust cylinder by removing com cover plates then it is ready to be in the order of dust shims removed from the brake disc The wheel is cylinder removing the snap ring in diameter is 9 040 in If shoe Linings easily disassembled by and dust Limit of reconditioning cover seated excess soiled or linings greasy or are incompletely deteriorated due to heating repair or replace them If the of the lining is found less than in replace it thickness Remove the adjuster assembly Remove the brake disc 0 0591 Notes a If oil or grease is found in 1 8 Brakes 1 V Fig clean linings tetrachloride b After grind or thoroughly gasoline l42 with Sectional View of Rear Brake carbon lining installation and bonding lining face to a diameter equal the to that of the brake drum Check and adjust cams for When the wheel cylinder is overhauled it is replace cups even if ap parently they are in satisfactory conditions and they must be replaced if deformed due to damage crack corrosion and ageing recommendable their to smooth Assembly operation Assemble in the reverse order of disassembly If Springs they replace them are considerably weak Be careful not to oil or smear the brake linings with grease Check the brake disc for distortion grease thinly to the sliding areas such shoes and discs cam adjuster stud and Apply Check the bore of the wheel cylinder for sign of rust and damage 88 exceeds 0 0059 in as spacer If the clearance between the piston wear cylinder and replace them the Adjust the shoe hydraulic system clearance and bleed the rroDt Suspension 6 5 1 Stnrt mounting insulator 2 Coil spring 3 Strut assembly 4 Suspension cross 5 bilizer St 6 Tension rod 7 Transverse link 8 Steering knuckle member ann 7 Ag 143 Front Suspension Assembly RECOMMENDATIONS U to the need for a and lonl 80 large number alignment equipment it of special is recom repairs to the front completely equipped shop mended that a end be left to Steering STEERING GEAR COMPONENTS RECOMMENDATIONS ASSEMBLY STEERING LINKAGE 92 92 93 93 81 Steering STEERING GEAR COMPONENTS o 1 0 1 Steering 2 Shaft 3 Cover sector shaft 4 Screw adjurting ar ge steering housing 5 Shim sector 6 0 roller shaft Fig worm bearing 7 ing housing cover Camp jacket column 8 Ass y bearing 144 9 Ass y bearing 10 Ass y nut II Assfy column steering worm ball steering column Steering Gear Components RECOMMENDATIONS Due to the nepd for tooJ and al 82 ignment a large number of equipment it is special mended recom pOllenb be left to that repairs to the steering com a completely equipped shop Steering ASSEMBLY orque I 8 Tightening Tightening 2 5 kg torque 1 8 2 5 kg m Select the lhiml 0 01 0 03 18 1 13 0 13 0 m 0 ft Ib 0004 1 18 thatthr c1 orque 1 8 ft lb 2 5 kg 13 m 0 18 1ft Ib arance 0 0012 1 t17mm 6 693 1 i J r IBIJ I d i J f M Apply here thod of the gear assembly greue when II auembling l I BEARING be PRE LOAD ADJUSTMENT the thickn Adjust 0 to 6 0 kg u of the worm 55 em ahim adjust 83 thou the before the 1 of tbe rque lhaft sector steering whrel ames fiaed GtarumE II Tigbtening 1 2 torque 12 90 5 th 14kg 101 ft Ib of the lurfac ball hit ch 3 Lock the 4 Move the gear for 5 adjult After this Ild the the housing uml p the al tor point 5haft by turning the adju t crew os that the ctor 5ha ft ad ther ew with the lock mporarily imel from Ie ra the ide of the Beu arm E nd mak turn smoothly between the bottom of tlw T groove ah 5h tor the location of the m The rtandard distance the Place the AdJun 6 itlOD lll the op of the s ar arm should be brtweeD 0 O 1 mm 0 0 0039 more es of 2 proce the Finally tban O 5 til adjust 1 mm 0 0039 ome within the by 1 1 8 6 I th ew ndard turn adjust 5Crew funher IIId peat the figure nd lock firmly with the lock OILING Apply IV OIl point If the backlash th 7 backl uh t uual it MP90 sear STANDARD about O 33 The backlash should be 0 the liter5 4U 3 S S pu 8lrnper pli flACK LASH al Ag point l45 0 the ad the ldius 22 75 turning angle mm 0 896 of the sectOr of the haft sector pitch when tbe backlash O Sectional View of Steering Gear STEERING LINKAGE Fig l46 Front Bottom View of Steering Linkage on Vehicle 83 Bear Drive SHOCK ABSORBERS Suspension 96 Remvval 96 Inspection 96 Installation 96 DRIVE SHAFT 97 RECOMMENDATIONS 97 85 SuspensiOD Bear Drive 8 7 I 1 6 I 5 1 Suspension member 7 Spring 2 Suspension B Shock absorber 3 Member 9 Drive 4 Differential mcunting insulator 10 shaft Differential mounting member 5 Coil 11 Differential carrier 6 arm mounting insulator spring Bumper seat rubber Fig 147 Rear Axle on Suspension Installation Installation uf the shock absorber is the al ofthc procedure given for rcmoval SHOCK ABSORBER Removal Open the assembly trunk and remove rever the trunk finisher Remove the double nuts which fasten the up absorber to the body per end of the rear shock Remove the shock absorber mounting bracket on from its lower the axle housing Inspection Test the shock absorber and replace if necessary Check for oil leakage and cracks the shaft for Inspect the rubber bushings for damage Replace the parts if cracks and deformation necessary 88 Also check straightness Ag 148 Installation of End Rear Shock Absorber Upper Bear Drive Suspension DRIVE SHAFT 8 Drive shaft 6 Boot band 11 Flange yoke 2 Drive shaft ball 7 Snap 12 Oil 3 Ball spacer 8 Sleeve yoke 13 Needle 4 Drive shaft 9 Sleeve yoke plug 14 Snap 5 Rubber boot stopper 10 Rg ng ea bearing ing Spider journal 149 Drive Shaft RECOMMENDATIONS Due to required the large and number of the special tools advanced knowledge it is recommended that the necessary overhaul of the differential be left to a properly equipped shop 87 Olutch REMOV AL 102 RELEASE BEARING REPAIR 102 Refacing Pressure Plate ADJUSTMENT INSTALLATION MASTER CYLINDER 103 103 104 104 105 Removal 105 Disassembly Ins pection Assembly 105 Installation BLEEDING CLUTCH SYSTEM 106 106 106 106 81 Clutch 2 5 JJ FL Y WHEEl RING 12 o II 1 1 11 Clutch disc 2 Clutch cover 3 4 Bolt assembly with plate 8 Bearing sleeve 9 Clutch elease 10 Bearing sleeve 11 Dust Return spIing bolder cover 5 Lock washer t2 6 Clutch 13 Withdrawal lever push 7 Retainer t4 Lock withdrawal lever spring nut Rg 150 Outch Diaphragm Spring Type M bearing spring GEAR Olutch 2 o N 1 N m m l 1 2 3 4 Clutch disc 9 Release lever Clutch assembly 10 Relea Clutch 11 Lock t2 Release lever cover SUre Pre plate e tevet at nut support 17 Retainer 18 Seasing 19 Clutch pring sleeve 20 eleue bearing Bearing deeve holder spring S Prelllure 13 Retaining spring 21 Dun 6 Eye bolt pin 14 Bolt 22 Return 7 Pre IS Lock washer 23 Lock 16 Clutch 24 Withdrawal lever push 8 sure rlU e PreJ plate bolt fpring spring retainer F1g 151 withdrawal lever Clutch cover pring nut nut Coil Spring Type 101 11 uteb the Remove transmission assemblyTrom the clutch the Note Be engine insert a ST20600000l special screws sure not to soil with grease or oil tool Clutch aligning Bar spring to RELEASE BEARING the clutch disc hub on support the clutch Replace Ib Coil release lever control surface spring type if there is wear causes Temporarily lock If it is If the release lever stopper is not placed under each levers the release Note force when rough spot too much the release lever with the release lever stopper lever will be over Ioaded with excessive clutch the assembly is judged enough iJe ausc bearing that the front cover between than 0 5 Loosen the six there is step wear at the with the withdrawal lever bolts which the assembly to by diagonal are flywheel E E E E E E 0 i o 0 E E Bmm r4H1 mm 52 m Rg 152 Clutch Cover Assembly Diaphragm Spring Typel grease is not place the diiuneter of the 0 0197 in or mm contacting surface replace or repair if there is excessive i01 I 7 Replace o N i the at a mation II N turn selection until the spring pressure is relieved E E holding a more the if the inside the transmission and the inside sleeve is time 102 remaining lCJlkage of the If the clearance or wear on or play removed cover the the surface of the disc spring type al Diaphragm Fully completely and lift assembly away from the flywheel Remove REMOVAL wear or defor Glatah mm A E E lD lD N 0 B Rg l53 Clutch Cover Assembly Coil Spring Type Fig 155 Installing Release Bearing Ag l54 Removing Release Bearing Refacing can plate be refaced if the uneven wear the tension of clutch pressure specified Pressure Plate The pressure plate face is rough or has sur In this case springs working will be weakened from The refacing limit is 1 0 mm 0 0394 in standard di mension REPAIR on the If it needs to be cut in more the unit must be than 1 0 mm replaced After 0 0394 refacing the out of flatness should be less than 0 1 mm 0 0039 in 103 Clutch Note In case of the type the pressure refaced at any times diaphragm spring plate should not be Note This will enable the parts to settle down on their knife edges Replacing Release Bearing Removing the bearing Remove the bearing by using universal puller the bearing in Pressing Replace the height finger and pillar by the clutch actuating mechanism and actuate the clutch several times by operating the handle There are two types of the release bearing Specification of both bearings is quite the but particular attention is required same Replace the height linger and recheck the height of the release levers checked for run out as near the edge as possible if the error is more than 0 020 in adjust until it is true within spec limit INSTALLATION because of different construction when in the stalling bearing into the bearing sleeve as follows It is important to from oil type Release Diaphragm spring Bearing Fitting press fit the bearing in place on the bearing sleeve with the force of 400 kg 880 Ibs applied at the outer race as shown in Fig 155 a or the pillar into the base plate high finger over the pillar the and height of the release levers by unscrewing the eye bolt nuts un til the height when rotated just contact the highest point on the tip of the release lev Adjust screwing grease assembly on the flywheel with longer chamfered splined end of the disc assembly towards the transmission the Set the dummy position of the disc assembly 104 156 or Adjusting Release Lever Height hub and Tighten six bolts which are holding a cover assembly to the flywheel time by diagonal selection Note There flywheel are two the clutch turn dowels to locate the clutch cover r Ag assembly by a splined bore the pilot bearing drive shaft which fit the of the flywheel Screw the center slip friction facings free Place the disc of the disc ADJUSTMENT keep Fig l57 Actuating Clutch on at a the Olutch O@ I Cylinder 2 Return 9 Spring seat 10 Valve rtem 3 Pi 4 Secondary 11 12 S Piston cup 13 6 Supply valve eat 7 Supply valve 8 Supply valve Q 1J 17 Piston 18 Stopper ring Stopper gasket 19 Boot Calket 20 Oil reservoIr Pwh rod 21 Reservoir band 14 Pwb Od bead 22 Reservoir cap Item IS Weld Dut 23 Cap seal spring 16 Lock nut 24 Pipe spring ton cup stop ing Hopper Ie at Ag l58 Clulch Master Cylinder dummy fully tightened Remove the shaft after these bolts should be 11 to 16 lb ft Tightening torque Remove the clutch aligning bar Irelease lever bearing and stopperl Refit the release transmission to assembling apply grease small a clutch disc be amount of MILG 2108 splines Neglecting in clutch slippage or Removal Remove Disconnect the clutch hose from push master the master and drain out the fluid Remove the sure Multipurpose 10924 the clevis pm installed at the rod cylinder case Note In MASTER CYLINDER are securing bolts and take cylinder assembly from the car off the to the disc this caution will result Disassembly Remove the filler cap and drain out the fluid 105 Clutch Pull back the rubber boot and snap and then the ring push remove the Assembly rod and ring can This be removed Unscrew the piston stopper screw and the piston assembly completely remove The piston assembly can be separated by lif ting the spring seat edge over the shouldered end of the piston accomplished by reversing the disassembling procedure but the following points should be observed is Prior to assembly piston cup should be soaked in brake fluid Install piston cup taking care it is faced correctly Coat well brake fluid to cylinder and piston and assemble them Inspection Prior to inspection all parts should be cleaned washed or Note To clean wash all parts of master operating cylinder and pipings cylinder or clean brake fluid must be used Never mineral oils kerosene etc such as as gasoline use and Installation Installation procedure is reversal a but the of the removal following operation should be added Adjust the pedal height by changing length the push rod to do so will ruin the rub ber parts of the hydraulic system To do so will ruin the the hydraulic parts of the Bleed air out of the hydraulic system hydraulic system Check sided and piston for abnormal one and damage and replace if found wear If the clearance between more than 0 005 in Renew and piston is cylinder replace cylinder when principle disassembled It must also be replaced when swell wear deformation due to fatigue and damage etc are found Damaged etc piston dust should be cup cover in oil reservoir and cap replaced spring and inlet valve spring replaced when they are broken or Remove the must also be weak bleed screw dust cap of the operating cylinder open the bleed screw ap proximately three quarters of a turn and at tach clean immersing the open end into receptacle containing a small amount a tube a of brake fl u id Fill the master cylinder recommended fluid and strokes entering Piston Replace clutch hose and tube if any abnormal signs of damage or deformation are found 108 BLEEDING CLUTCH SYSTEM cylinder pump the clutch reservoir with the by using slow pedal until the full fluid the container is free from air bub bles Screw up the bleed screw on a down stroke of the pedal remove the bleed tube and replace the dust cap TraDsmissioD REMOV AL J09 INSTALLATION 4 SPEED TRANSMISSION III Removal and Installa tion 113 RECOMMENDATIONS 113 113 l lO TraDsmissioD 11 I I I i I Fig 159 3Forward Speed Transmission C I Ll Fig l60 108 4Forward Speed Transmission Transmission FIg 161 3Forward Speed Transmission REMOVAL When removing the transmission from the vehicle it is necessary to follow the undermen tioned procedure Jack up the vehicle and support it with four stands If available a hydraulic hoist or open pit can be utilized the Disconnect equalizer pivot as hand brake shown in wire Figure Loosen the two exhaust center and turn the to the premuffier complete left as will allow sufficient shaft to be removed pipe Remove the four the room the 163 pipe clamps with center Figure shown in at for the 164 This propeller propeller shaft by disconnecting securing bolts at the companio n flange of the gear carrier Seal the end of the rear extension housing to prevent oil leakage FIg I62 Underside of Vehicle 108 Transmission Disconnect the the adapter speedometer in See Fig housing drive cable from the transmission extension 165 Disconnect the lower shift rods from the shift levers and remove the cross shaft assembly from the transmission the clutch Remove the clutch Support the oil Fig 163 case See Fig 166 operating cylinder housing the engine with pan a Do not locate jack placed under the jack under the Disconnecting Hand Brake Wire Fig 166 Disconnecting Remote Control Linkage Rg 164 Removing Propeller Shaft Cable Ag l65 Disconnecting Speedometer no from Fig 167 Detaching Clutch Operating Cylinder Transmission oil pan drain plug To prevent damage to the oil pan insert a wooden block between the pan Lower the and jack will allow sufficient Remove to be removed the two smission to the attaching the tran engine mount Place a bolts rear jack under the transmission and four bolts cross member to the fixing the rear body remove the engine mounting cline the jack supporting the engine to in engine in a rearward direction This room for the transmission Remove the taching starting motor and the bolts at housing to the engine jack gradually and withdraw the the clutch Lower the transmission INSTALLATION Installation of the transmission is the reversal of the procedure given for removal However be given to the following attention should points Notes Fill the transmission with the a recommended gear oil MP 90 Oil b capacity Adjust push the 45 0 U S the clutch rod so gal operating cylinder at play at the with that the drawaI lever will be 0 087 in Fig 168 Cross Member Removal Fig 169 4 Forward Speed Transmission lD Transmission lISSION TRANS AUTOMATIC @ CID @ CID @ @ i @ @ j @ if rT L 1 J L L J II I I I @ @ @ @ @ @ @ F @ @ AT260 I 2 Transmission Oil pump case II Governor Tightening torque CT 12 Output lihafl bolts and nuts 3 Fronl clutch 13 Rear 4 Band brake 14 Oil pan 5 Rear clutch 15 Control valve 6 Front ion exlen 16 7 17 Input shaft Torque converter 8 One way clutch t8 Converter 9 Low 19 Drive plate 10 Reverse brakC 4 to 5 @T 14 to kg m 36 ft Ib 16 kg m 101 to 116 ft Ib housin1 0 0 8 kg m 4 3 to 5 8 ft Ib 6 View of 3N71 B 0 5 to 0 7 to 6 to kg m 5 1 ft Ib h 2 0 to 2 5 h 14 to 18 f Ib 3 to 1 8 kg m 1 4 to 13 ft 9 lb @T 55 0 4 0 @T Oil distributor Fig 170 Cross Sectional U2 @T @T @T 3 29 to planetary gear Rear planetary gear of Automatic Transmission kg to 0 75 to m kg m 5 4 ft Ib 0 25 to 0 35 kg 1 9 to 2 5 ft Ib m Transmission 4 SPEED TRANSMISSION port is securely placed between the upper sup port plate and rubber insulator on one hand and the lower support plate and rubber in Removal and Installation Removal and installation of the 4 forward sulator on speed transmission are similar to the procedure given for the 3 speed transmission However the 4 speed transmission is of the floor shift type therefore in addition to com pleting the operations described in the section covering the 3 forward speed transmission it RECOMMENDATIONS Due the to disassembled will be necessary to remove the shift lever from the control lever bracket On the 4 speed special transmission ped shop the rear engine mounting sup the other tools that internal complexity of transmission necessary repairs it as is be left to setting well up as a the recommended a fully equip U3 Bod Work FRONT FENDER Removal and Installation HOOD 116 116 116 Removal and Installation 116 Adjustment 117 TRUNK LID 117 Removal and Installation 117 Torsion Bar Removal and Adjustment 117 U5 Bod Work FRONT FENDER HOOD Removal and Installation Removal and Installation Remove head the radiator light grill head light and finisher Remove all bolts securing the fender and then remove the fender Open Scribe on Installation of the fender is the reversal of the procedure given for removal hood and place a protective cover over damage to pain the front fenders to prevent ted areas the location of the hinge straps Ipenci under surface of hood Replace hood the bolts With attaching the hinge to a helper remove the aid of hood Fig 171 Removing the Fender Fig 173 Removing the Hood Support Rod ENCH BOW 1 fill U8 172 Removing the Hood fig 174 Removing Trunk Lid the the Bod Uing driver screw remove as shown in Figure 173 Adjustment adjust the the hood support rod from the support bracket bolts and the move After the position tighten the hinge Installation of the hood is the reversal of the procedure given for removal However the hinges within the scribe marks hood release the To align hood ork hinge attaching the to desired has been made adjustment bolts TRUNK LID Removal and Installation trunk lid and place Open fenders and damage painted to With the aid of attaching panel rear a a cover over to the rear protect them from area helper bolts and remove remove the trunk lid trunk lid See Fig 174 Torsion Bar Removal and Adjustment fixing wire then using a shown in Fig 175 remove the Remove torsion bar driver screw as torsion bar The tension of the torsion bar by changing use Rg 175 Removing the Torsion Bar 3 r 5 s Alo 1 of a screw i II 4 cd EGf Ie 6 r 8 7 III IN 111 1 I 10 J 1 i 10 0 I dri ver Outside handle Out ide handle rod 3 Clip 4 Pull knob 5 uOJtcheon 6 Spring clip 1 7 Inside handle I 8 Remote 9 Lockass y I cs I adjusted 2 J I be 1 t j can the location of the bar with the J ontrol 10 Striker 11 Key cylinder 12 Bell crank Rg 176 Door Lock Mechanism 117 Bod Work 1 z 3 Froot door Bottom channel 3 Front 4 Regulater U8 177 Window Regulator egulator ass S RaUer Stopper 7 Connecting clip 8 Nyloo 9 Rear docx Rear y handle 6 10 Fig glass 1 2 guide washer glass egulater ass y Specifications STARTER 120 DISTRIBUTOR 121 SPARK PLUGS 122 VALVES I OIL PUMP 122 GENERAL 123 ELECTRICAL 123 MANUAL TRANSMISSION 127 CARBURETOR 131 CLUTCH ENGINE 134 TORQUE INFORMATION TUNE UP 136 138 LUBRICANTS SAE 138 CAPACITIES 139 PRESSURES AUTOMATIC TRANSMISSION 140 PROPELLER SHAFT 144 BRAKE CHASSIS ALIGNMENT NOTES WHEEL 146 147 D8 Specifications STARTER LI6 and LI8engines Model HITACHI Type S1l4 IOJP HITACHI For manual transmission Voltage 12 Volts Output 10KW Slarling current No load No load rent starter 1 Voltage Less than 430 amps Voltage Less than 60 amps revolution 6 Volts SII4 126M utomatic transmiuion KW Less than 540 amps 5 Volts 12 Volts More than 7 000 pm For More than 6 000 Magnetic shift Shift type of pinion gear Number of teeth on pinion Number of teeth on ring gear 9 gear Weight 120 g lb 5 1 10 42 5 8 12 8 SPECIFICATIONS AND SERVICE DATA Specifications Model Item o58 LTI50 510 and 610 models AppliLable to Mak er 120 except LTlJ5 1J8 510 and 610 models 620 model for Canada HITACHI N lminal Ground for Canada LTI6019 ating polarity 12V SOA Negative 12V 60A 12V 35A Specifications DISTRIBUTOR SPECIFICATIONS AND SERVICE DATA Distributor type 0410 67 D1O 66A Make HITACHI Applied engine Ll8 610 Ub Qand S 6Q vehicle Firing 1 42 order Rotating direction Counterclockwise Ignition timing degree SO B T D C Idling adjustment MIT 5u 800 rpm AfT 5Uj6S0rpm 0 490 to Advanced isde 02 to Retarded side O Phase difference 70 vel angle degree Condenser capacity p range 550 F 0 24 t 15 05 at k ngle ldegree All distributors 55 0 9177 45100 0 in mm Point gap Point Shaft Jlll di lower pari eT p hp hafl wren in 1 r in in inner diameter J1011 lram Ic 0 50 lb kg pTt ssure nd hOll in il1g 430 to 450 to In 001 h arilnre in 0 Shaft diameter upper pi in H Repair limit 0 65 to ti III I C1c nam e nc in lIl cro shllf lrod un mmfin Clcilr mce b lw n i ot and hole lcqllyl 41 94 0 to 48 0 4Ml 0 4402 to 4 09 0 O G3R 0 0004 8 0 00 5 h 10 1 0003 I 00002 O JI50 1 0 0006 H 000 It 0015 II x 1115 fi J 9 lUISO ltl D002 tu 1 0 in mm 4 972 104 990 0 1959100 1 in 5 000 tnm ill 10 5 018 0 1 9 0 01 tnO 046 0 0004 to tv 156J 0 0 11 n Weight pivot diamctlo Weighl hole diameter 7 02 440 t1l4 O lllcter 0 I 1010 I 43 0005 C to ld Retarded side AJvauccd 5 0 1976 O OOI 121 SpecificatioDS SP ARK PLUGS SERVICE DATA AND SPECIFICATIONS Make NGK Model B6ES and Ll8 Applied engine Size screw dia Ll6 14 reach x 19 x 0 55 in mm x 0 75 0 7 to 0 8 Plug mm gap in 0 028 to 0 031 1 5 to 2 5 Tightening torque kg m 11 0 ft lb 15 0 to VALVES 654fO 1 661 In 42 Qtn42 2 Ex 33 0 33 2 1 299 10 1 307 In 42 01041 2 1 654 10 1 661 Ex 35 01035 2 1378101386 In 114 9 to 115 2 Ex 115 7 to 116 0 4 555 In 7 965 to 7 980 0 3136 Ex 7 945 107 960 0 lib Valve head diameter H to in nun LIB Valve L Valve lI6 length in mm stem D LIB diameter Valve seat angle 567 104 to 0 3142 LIB in mm a lI6 535 524104 4 In Ex 3128 100 3134 45030 OIL PUMP i lth I ning turque Oil pump mounting bolts kg m ftIb 1 to 15 8 010 II Oil pump kg m fl Ib 0 7101 0 5 1 kg m fl Ib 4 Cap nut cover bolts regulator alve to 5 29 to to 72 26 Specifications Oil preuure at idling kg cm Ib in 0 8102 8 1110 40 Regulator valve spring Free length mm in Pressured length mm in Regulator valve opening pressure 122 kgcm 5 2 52 34 8 Ib n 5t05 3 067 I 370 0 501071 Specifications GENERAL SPECIFICATIONS Li8 Li6 Model 4 in line Cylinder arrangement Displacement Bore and stroke V31ve mm 83 in 737 3 2677 Firing I iule Engine 2 9016 85 1 4 rrlll 800 650 in Compression l idle fold lHg I inllgl I BO M T 390 AIT Oil pressure em M T Ih 4 in 15 c N 35104 0 49 8 psi kg 000 rpm at range 85 l 111 idle TPIll Varm 3 0709 OH C A T at 3 3465 4 2 i MIT Engine 78 OH C ngemenl rder 108 01 770 1 1 595 62 80 in cu cc MalHI 11 rransllil AIT n 1ge ill 9 to Transmission Automatk STARTING MOTOR SPECIFICATIONS Specifications Distributor h flcut f Sprint Hum llen T N CUrr D C1W L d N pi DWtrilu lorCr1Iln S lb 67 61 66 6 MII ubl ME rla hI HiluM 5 114 MIt 6667 1 912 72 2 1 1 5 1 5 1 AtI u v IltaTt @ oJ JI Hitachi J E ND fIjq O HD 11 15@ 3 4 97 400 50 6 9@ 2 411 53 00 LI6 Hitachi 01lh5ll L2 Hitachi D60652 4 At2 Hitachi 412 1 63 550 IA Hlt chl 1 S 1 1 t1 13 4 2 1 5 1 5 1 1 122 1t4 HII t 00 00 Hltochl 114 103 5 71 1 hl 114 72 19 PI 1 p t Cur ehl 42 15 1 1O@ 4 1 9 9@ J 9 5 500 4 12 6@ 1 5 000 5@ 96 12 5@ 2 100 98 65@ 13 8 1I7L 114 DISTRIBUTOR SPECIFICATIONS C Pol M y DI trlbut I rlNo Inllln Dw t 0 n VD U srlnll II T AIIIII D IlIe Dnu1 IAd lllrlr II n SIDrI e O F Inl full Inch @ @ @ pm pm pm V cuu AdII hll 01 Ad D euuftl @V SIDrt Itn D407 I 6 9 7 51 0 dll 1 1 41 55O 4DO 5054 l Mltfu hl 021 16@ 1 12@ 475 5 12 6 1100 5r6 1 D411 J 6 01 53 50 55 I 1 411 n 4Q7 1 l 72 7i Wi 04105 I L 24 D 1200 I2 52 6 0 1 4955 1 411 4 011 022 cuu dVDII d cII t 1 016 02Q d with S I 1 1 1 1 @ IJ 1 4955 1 1 100 55 1200 @ @ @14 @11 12 1 1400 12 1 4 10@n 1500 1 411 00 @10 00 IO@ 1 4 OGO 021 ID J 6 5 O@ 40000 011 D412 41 2400 020 1 15@ 11 OU 5@ @9 5@ 9 12 00 x 123 Specifications Electrical 1 1l U Battery and Starter Specifications StGTt T T ModTl l V to 111 oI A Tn I U od No rut V T 1 L Tut V Ao 1 V i Wi LUI1tJ b f P 60 12 e El 50 12 P X A G R 12 X A Po 50 12 Neg 40 SO 12 Xeg V20 50 Ll6 50 60 PLSlO WPL510 1 520 i L521 8 500 40 N A 500 0 NA 0 60 7 OIXl 60 7 000 9 5 fL5 7 12 Xeg 500 12 eg 480 6 0 7 000 11 12 NA 2 60 79 N NA A 31 A N o 6 000 30 28 60 12 7 000 60 12 5 000 9 60 12 7 000 31 10 50 40 50 60 LS21 L24 A 12 Xeg 460 6 0 A12 XA 12 Xeg 420 6 3 10 1 6 5 fore Ltssthan Electrical CACTI i 4IM s G G J fiuubishi RLA l litsum hi Rd V Ai G p i 32 0 AC Specifications trul c i G N 60 500 60 NA NA A NA N A 7 7 9 5 XA A 1 044 Regulator R tA6 CouG Go rfJ Gap i than A i P d G i i R J OI I Yoolt i NA J 48 032 044 028 036 032 040 012 016 032 043 028 035 032 039 012 01614 15 032 043 028 035 032 035 012 015 14 15 12 U 032 043 o32 147 032 043 032 047 035 047 030 043 RL2220B5 Mit R uhishi RL 2B U20 liIslIhishi RU220B5 LIB Hitachi 1m 030 043 32 0 047 035 039 020 024 016 020 032 043 032 047 012 01613 5 14 5 012 01614 15 012 01614 315 3 TL l li L24 Hihlt hi TI 1 Z 7 tn2 0 12 032 039 i V XOTF t1 wllwlITU 124 024 019 @50F Hitachi TLI Z 37 hl HiJ Left 016 024 039 t illl Rillhl t t ltlllatOT lClllatllr d left 016 a 24 TLIZ 111 TLlZ 17 letennilloo with the left right 012 024 039 016 it it t J ltor glll tenninals Illlm s pluJI 14 315 3 50F Specifications hlClemodel Int Appli b SIOllln tlIO L1RI O 1I6 Item Mau rldtype ApplIed HANSHIN resister mm ll hl I68 Ce HS 15 HITACHI 60R St 6R 1 SIO in nIOrt Ihl n7 n 17 1 1 4J Kn 11 lb 8 n LJ 0 1756 F conduy 10 HANSHIN I V voltage Ptimu Sparkpp PlimlloiY fC HS IS RC IS 8OF f Extern J7 OCthaoF Light Bulb Specifications Wdlag u UlO PLUO 15 8 5 8 up Baclc Headlights 31 31 5 Tail top Parldng B Rear turn backup License plate Interior HeadliRhts Front parking M p Side 10 8 520 1 15 5 SO 8 5 25 1 5 5 turtI Tail stop LictrlIeplate In rior warning nll Instrumr L521 PLS21 Radio B I parking 37 5 50 37 5 25 B parking 25 B 25 25 6 8 clcup Headlights Front parking T i1 tum 37 5 50 37 5 25 8 25 B 25 25 bun StOP ckup License Interior HLS3Q plate B 10 Headligh Side marker B 25 Stop tum Side marker license Tall te pI l Reartun ckup 15 turn 25 8 25 8 25 B B turn top 5 35 B 50 turn parking Irtun PL5lO WPLSlO J Headlight Stop tail TilU 15 8 8 8 25 25 Turn Instrument Warning mt Interior L seplate Side marken Tail License plate Fog Inspection Parling 37 5 50 50 Headlights B 31 5 50 37 5 Interior rker Front turn 50 25 5 2 l6 Headlighu Stop Backup plate Headlilthn Fr 8 6 Inspection lamp Front License 25 plate light Warning lights Instrument SPUll SRL3Il v 50 42 21 6 216 Backup PUll RUll l Headlights Front paning turn Stnp tlil turn L plate lnstrument panel flasher ming light Turn License Interior SPL310 Mlld Instrument 40 25 S 28 B warning glove compartment clock Four way Suhet P 50 2311 75 7 23 23 23 J 23 B 125 Specifications WIRING DIAGRAMS III CD COOlI y o 0 Lr utomatic transmwion PLSIO r JIr 11 II l I t G 11 iil I JlI 7 IF 11111I 1 1 11 r i I j r i l I II I i 1 t4 L cnm Jfrdll V n I II IJ r r jll COLOIlCODE n 1 i I I III i o l I I d i l J tl c A e 7lI II L L l a l f DPTlONAL EQU PMEm 1 126 f Jo u 3 l 11 I f a 71 1rtJ r r w 10 ltomatic trarumission Specifications CO COOl I v 0 PL510 standard traosmiuion MANUAL TRANSMISSION APPLICATION Of TRANSMISSION MODELS Type of Transmission N510 S V 3 Forward speed P510 NL510 S V JNL510S JN510SU Column shift Warner edome Applied Model SlV PL510 Sl type synchromesh WP510U WPL510 r Final gear 1 gear atio R3W65L lot 3 263 2nd IS45 3rd 1000 Rev 3 355 19 5 4 375 1715 3 900 17 5 3 S99 IS 5 3 700 F4W63L 4 ro Fmw peed FloofS uft Warner type synchromesh f lot 3382 PL510 S T 2nd 2 013 N510TU 3rd 1312 4th 1000 Rev 3 364 P510 S TV JNL510 S T P510TKU PL510TK RPL510SWTV PL510TV I F4W63L ht WP510TU WPL510T 3657 2nd 177 3 d 1 419 4th 1000 Rev 3 63R 16 5 3 700 I I i 127 I Specifications Manual Transmission Ratios V FiN I 900 1 60 L320 94 L520 3 657 PUlO PL411 Rn No N 3 015 301 173 1 00 No 6 177 1419 1 000 None 3 638 3 009 1726 1 000 No 6 462 1 419 1 000 None 3 NOM 4 125 177 2 6 636 518 3 1725 100 No 3 197 1725 100 No N 125 1 000 N 5 159 3 945 94 1 490 3 945 403 2 1490 1 000 No 5 159 1 725 1000 N None 4 3 94 2 40 1 49 100 None 5 159 3 657 2 177 1419 1 000 None 3 638 2 013 1312 1 000 None 3 365 3 197 RL411 SPL311 1i u 1 3 657 000 Tel 1562 2 941 521 PL Tli s 3 382 e 5 12 PL510 l7 5 SPJ 110 3 515 1 328 1000 None SRL311 2 957 1858 1311 1 000 65 3 657 2 177 419 1 1 000 None 3 3 382 2 013 1312 1000 None 3 634 3 382 2 013 1312 1 000 N 3 634 3 549 2 197 420 1 1 000 None 3 2 957 1 857 1 311 1 000 852 3 757 2 169 1404 1 000 None PL510 HLS30 LHllO KLBllO CD L60 transfer cue ratiOl 2 264 1 nd I Probable Condition 140 2 2 922 638 164 922 3 640 I CorrectivE cause ction 1 Loosened bolts retainer gear camero or Defective gasket Loose tiller Clogged 128 or such or drain or as side aring plug damaged breather nange id Tighten thebolts to specified torque Replace defective parts with Tighwn the plug Repair replace or ew nes Specifications SERVICE DATA AND SPECIFICATIONS Nominal diameter of ring gear mm in 160 6 30 Gear carrier material Malleable cast iron Gear ratio number of teeth 3 700 with 37 10 AfT mQdel for U S nd Canada 111 4 Drive pinion preload adjusted by 37 9 Shim e Pinion Dri Preload At kg em in lb without oil seal 7 with oil seal S to 11 ompanion flange bolt hole to 10 61 to 8 7 7 0 to 9 6 kg Ib without oil seal 20 to 2 9 withoil seal 2 3 to 3 2 5 1 to 7 1 Thickness of 4 to 4 6 pinion height adjusting washer mm in 3 09 0 1217 3 12 0 1228 3 15 0 1240 3 18 0 1252 3 21 0 1264 3 24 0 127S 3 27 0 12S7 3 30 0 1299 3 33 0 1311 3 3S 0 1323 3 39 0 1335 3 42 0 134S 3 45 0 135S 48 3 0 1370 3 51 0 1382 3 54 0 1394 3 57 0 1406 3 60 0 1417 3 63 0 1429 3 6S 0 1441 129 Specifications Thickness of pinion bearing adjusting spacer and washer mm in Spacer Washer Side gelr and pinion 5S 2 2 2t26 56 4 2 2205 56 S 2 2283 56 8 2 23S2 57 0 2 2441 57 2 2 2520 2 59 0 2 57 0 1012 2 55 0 1004 2 53 0 2 51 0 0988 49 2 0 0980 47 2 0 0972 45 2 0965 10 43 2 0 0957 41 2 0 0949 2 39 0 0941 10201 09961 2 37 0 0933 2 35 10 0925 2 33 0 0917 2 31 10 0909 mate Thickness of side gear thrust washer mm in to Q 0 80 0 0295 0 80 to to 0 0315 0 85 to to gear or to ide gear mm in 0 1 to 0 2 0 0039 to ring gear and drive pinion mm in 0 1 to 0 2 O 0039 Runnut of reat ide of to 0 0079 iog gear mm gear Thickness of side retainer in Less than 0 05 10 0020 in 0 20 0 0079 0 25 10 00981 0 30 0 0118 adjusting shim 130 0 0079 ar Backlash between Side 0 03541 pinion mate and side clearance between and thrust washer Ring 0 03351 0 90 0 0335 Backlash in 0 03151 0 85 mm bearing standard with mm in 40 0 0 0158 0 50 10 0197 20 0 0 7874 Specifications Specifications Carburetor r f I l 1 il U I t f C Ir l t i h l SO P Leo 880 Pwlth nission LBO 079 EI PUIO 145 El 75eD 750 320 1 85@ J 520 1 850 J PUll N with A emission control L52ll L501 1 R 950 R with emisrion control 23 Jrl M 39 with 5 M 70 38W 6 38W with i 95 U20 SU 87 UOO M nll s 950 t Sole U20 with 32 uion emi N i1with 46W 5 N 25 with 46W 7 87 8 950 LIB PL510 071 87 LIe with emwion lrol 071 87 L24 wth D 95 95 23 N 21 079 ISO 13 rrT 950 emialon control HLS30 At2 with 71 78CD emission control UllO nJlllO From @ SOIt chamber top to fuelleYel 131 CDft Nt ft 8 l i l t tIn E 14 e i I 14 14 14 45 024 1 40 0 55 55 I il r 3 2nd i l l 210 100 220 2nd 120 5 2 B 100 220 2nd 120 ec I Specifatons 0 f 48 100 B tS 40 2 4Hlt sec B tWsce 48 48 7 el Carbueto 60 l ii 70 80 BO ec h 135 60 60 BO 15C1 sec ICf 14 92 140 827 024 788 06 1 788 06 102 022 1 180 022 LlSO 9B 115 96 827 024 1 81 90 I i c f 42 0l 1 102 1 1 1 1 81 1 1 1 1 M r D2630A M 4A Hitachi VC42 Rochest 7015 3 Imgle throat downraft Nihonki kakl 2D3OCE dual thrOlt downl1ft Nlhonkl kat 2D3OC dUll throat downraft Niho ki hln D2630A dUIlI thm downraft Nihonlia blu t i l f P tI L60 Pwlth eml contrl LOO El PUlO 320 El 1 J 520 1 J PlAl dual thro downNt CD P 400 8 n 131 1 1 4 I1 16 16 5 13 6 020 011 60 020 JIM 100 092 11 ec 200 100 220 100 180 100 C ISO 100 46 18 see 48 16 ec 41 100 071 100 14 sec 16 96 130 315 512 pnm 315 433 C 240 ll5 155 C f 1I1 1969 1 5 945 U02 394 456 1 01 62 1 495 i 240 120 35 551 710 nJ 7 495 1 1 1 C 2 200 l1 C 1 605 74 81 1 C I BO 1970 A 5 6 HJB38W Ildedr aft Hitacln DCA306 throat downraft l dUIil emJslon contml 5 1 L5U Hitachi HJB38W SUtypeIlde raft Hitachi HJB38W SUtype Ide rah HitachI HJ46W SUtype Mikunil SoJex R Rwith emluon control choke PHH twm f 7 8 S 96 135 155 315 pnm 216 SL2 2nd 900 1 I01 787 101 1 260 L81 c 1 180 1 f with 083 110 255 118 106 118 l 5O 6 138 157 02 3 8 DAF328 6 4 2 0 1 024 1 181 1 10 Ilderaft Hitachi HJG46W HJC46W type Ilderaft Hitachi DAF328 dual throat downraft Hitachi auto DAF328 DAF328 PL521 Hitachi HJG46W ASU tyPsiderlh HitlChl DC 306 throat downrah cont 16 with enul on control HLS30 AI2 with emis on COTltrol LBlIO KLBlO with emiSIOn with emlD n control puna du itd StI 24 U U U 1 16 1 1 i CDat 8 ft for P 05 1 1 frpl I j Vo J 5 1 0 580 111 2 98 1 18 A l JIO 1 80 98 I2 11 Z M Irnl 39 15 34 B 5 020 5 18 1 N without 1 00 57 8 5 020 020 020 012 012 012 e e 46 5 stop 020 020 020 020 020 020 012 012 012 012 012 012 012 e e e e B 9 7 we 338 358 333 A 4 339 31 4 339 31 339 354 127 350 aX 9X MX 00 X XX X XX 87 76 81 86X 90 g pl 1 d t lftM 98 lts 8 68 bl 0 98 A 10 60 A N 88 0 PlA r RIAl 1I d Ii A A N N N Specifatons Clutch c lI tI I N 299 315 laid N D I fiJlI J Xd D X IO B 14 f 14 87 12X 75 1S 226 32 I 176 41 7 1 7S 13 X 12X 87 1 UX X 1 75 15 A N 91 01 87 12X 1 75 X 87 5 12 14 XX A a5 N 7 00 92 A 740 XU O r 5 i R tlww r 1 2 00 2 04 011 2 22 1 77 2 I 1 98 OI 77 1 i 1 I 211 14 1 1 4 6pr1 l qUo 1 I 190 US6 180 A N 132 @1 99 I 1 15 87 78 @1 1 101 178 56 1 17 169 @J 6@1 1S 92 2 179 00 161 2 diaphr I587 99 @1 l 1 gm c roll pring ag Prh roll i1 spring sprinl dlaph1 J pbralJ SPL310 SPL31 SRL31 PUIO WPL510 510 WPL510 15IO PL021 lHlOA LBlO uBlO i1 spring spring il pring diaphrgm sprina roll LS21 y i LOO Eady L320 Lo L320 PLUO PUl RUll N Specifications SERVICE DATA AND SPECIFICATIONS Pressure I spring mm 2 mm 44 3 length Fitted length Free 29 2 load right angle Allowable min spring force 100 Qut of l j I 0 0 in l kg l I Ib 9 7 ill 0 196tl 1m AJ7 14Din I f h release lever Clut Release bearing ta diaphragm spring release lever 1 2 clearance J l Diaphragm spring ta flywheel height Release lever ta flywheel height 1 O O j 0 04i mm t 10m i 0 0 O o 1 1 9ti8 in ll j 1I O l Hl 019 in J t O Clutch disc ze Facing Outer dia inside dia x 1 O 200 thickness 7 Total friction area mtu 120 H7 12 362 O x tO I in i02 6 11 Thickness of disc assembly Free 8 6 Compressed 7 9 0 6 Material HITACHI Number of torsion spring Allowable min depth of rivet head G from facing surface Allowable facing ron out Allowable free play of spline nm 9 7 0 38G J 17 HT50S 0 3 mm 0 Ollb in O mm 0 0197 in 0 4 rom 0 0157 in 1 O 0 3012 IllIl1 O in lU 31 in I AKEBOXO A50 Pressure platlll Allowable refacing limit Clutch 10 mm 0 0394 in pedal Pedal height when not depressed 182 stroke of pedal head Pressing strength at full stroke Free Master cylinder Dia 1m 0 mm L kg 15 87 0 3 1 in R H 8 1 0 in L H 1 in 98 33 Ib clutch master Allowable 2 17 7 207 cylinder max mm il 8 in clearance between cylinder and piston Tightening torque Clutch assembly securing bolt 2 mm 2 0 0051 in Gkg m 17 IS S lb ft 135 Specifications ENGINE TORQUE n lBS Op I elle I 200 Ii CI1 heo ns c cti b h Ma n l 1 i3 7 O i i J 5 54 2 1 S 4 I 32 5 It cap h ft 2 9 J4 7 30 2 19 2 216 U n J 239 5 119 32 5 0I lu JIe 75 9 5 43 4 2 I 1t 011 9ii i2 U u I 2 6 5 10 91 2 5 oli3 b I e lu nettu ri 1o ls l 1 C I 112 5 1 05 I S 5 7 1 IS 2 U 1 15 7 uUay nk UO 130 7 lil15 boll PISTONS h lI I M r i I CI I I CRANKSHAFT I d B BEARINGS I lnlll Inch 01 C I Motna I ck Shott Jilek tn 8 CI Shoff in o cI i Inch 0131 0016 h n t u B Inch I N ooa I 001 Il Cl 01 I i 966 rlng I 1 h ck 101111 RINGS End 0 h hto I Y PINS T 010 1 67 1 1 1 9n 0 Shft h 1 Inch 1 0005 002 013 2 360 2 04 1 012 001 0027 01 a 012 U 20 0012 T 010 1 2045 0013 2 47 0024 012 1 0021 012 I 016 a 012 1 L I 121 1 001 I 009 12 1 7 012 a 2 161 1 012 002 0026 015 i 1 012 L U 001 T 1 009 12 1 67 012 0001 1 0021 0026 4 012 01S 1 012 1 1970 721 138 0017 014 012 035 617 1 770 1 1 967 1 0024 011 Specifications VALVE ADJUSTMENT I V L V h I Inch cI M V AIIIII Clearenc 1 Vol D SteDl to h lI S o lnl h lll lt bh ll feu 014 19 IOut 0 @ 64@ r @ I U 20 OO QUIl @ 1l 00 1 00 @ l Q17G Intah @l ur21 t 1 001 1 0004 @ L 72 197072 4 oliID OtOIl L 24 l 2 10 r Out 0 120 90100 1200 004 002 00 014 0 114 14 034 0 001 0312 00 il2 o 00 00 IS 0 3112 0 12 004 4o I 001 014 4 @ 5@ 1 1fw 56@ J tb o ut 11l OiG 0 00 I 19 bh Inteke IIII 00 00 160 172 l bh 00 0 14 5@1 In@II001 00 00 0 112 00 j Enlllneh t ENGINE GENERAL SPECIFICATIONS I Y d fn I ll r Inch C 1e Inch I 2 174 I J OSS n 4U 196661 17 71 nm 1I1 Dltpl ce I 196 6 I l 1 0 2 nS 2 6 3 433 17 2 3 261 n M Ma CeI I R 8 l 97 k @ 21 19 1299 30 9 I 7 plll @ 5200 0 22 @ 6000 92 U0 125 @ 1 1 2 113 2 2 2 1 3 2 74 1200 j 2 756 11 12 1 1972 16 2 26 l U2 2 4 1 12 2 1200 2 9 0 72 76 2 02 n 7 74 2 7 IT1 6t U92 71 5 I @ 0 000 I 96 1 1 14 n 2 0 151 @ 00 pm I 1 I 6000 70 100 70 2100 @ 4000 @ 00 100 2600 2040 I 5 4000 0 3040 I I @4400 1 @ I @ I @ I @ un nd @ 100@ I @S6OO1 @ OIlP 131@ 151@56OO1 1595 71 5 7 00 117H 7 2 @ 000 1595 902 n 76 2 I 97 6000 b 150@ 2 902 @ b SU U t 103 I Ne Cl fl n I 2 5 73 76 P U9S 09 2 T H 0 lo4 60 42 50 noo 5 60 4400 5 60 4000 4 50 11171 137 Specifications TUNEUP SPECIFICATIONS I I I SI 11I1I tllI Dbtrlbvt II PlrI e Y M d 1 T I Elllln 1 I 66 61 J G 191072 20 B I U I 2Q 1 16 DO l with S 24 1 G Rch 027 03 022 0 I ell D A Ihll 0 SO 55 1 I 027 027 01 016 020 031 035 017 022 1 55 o on 017 0211 1 55 0311 035 Olt D20 35 41 61 st hI MI ltlt t the ngine at normal It IS 11 11 I 4 1 1 I Idlin ldeg rpm M Tvehicle e 800 A Tvehicle io 650 D 3 n pvn 62 3 mge U4 r liming 0 relard side 15 5 0 511 BTlX 15 5 0 SAE o tI Or F 1IA inc API il dl il nall n IOW 30 IOW 10 lOW IOW O W 20 lOW IS ilSE carOil API 1 Ili iJ f1 EI jIJ 0 tion l fPS 40W Ily he used for hi h speeds Icmpcrutures 00 1 1 BlOC 5 T 1lI 30 IOW 10 lOW 40 IOW 40 20 20W 4 0 10 90 140 vll n 7 4 2 Recommended Lubricants T N vlley 42 1 11 I idling setting Engine idling S vlley 2 4 I Adjust e D 40 3 I k M L fTDC ADJUSTMENT OF IDLING 138 h l 04 e 012 0U 031 I 72 1 Inch 671 0 1 TI I 75 Specifications Capacities and Pressures l1iru Wttd l RA t U r ON ke lli tln fl T t Yo T Pc R pt Cool f m 11 s u ql d f ur d rul l azi e t a f u 0 r Hi qtf i Wi PiJi T WiLl Filt A M e UI S LBO 36 S PlAID 33 30 SIL1W 4 A PIAlI A HUll S1 11 1 A 1 Slt1 111 1 SI 11 111 ithtwlJ twin I hoke rhuretors L 1 8 12O i20 L L521 3 8 1 L51O 52 WlL51D 5 2 PL521 4 A 20 3 8 2 u J 5 4 4 3 4 R s 6 4 7 2 6 front nd rear 19 0 5 2 NA NA 20 10 6 8 5 4 NA 1 8 113 6 9 NA 4 2 2 110 5 7 N 6 4 3 19 110 7 4 6 2 0 11 4 8 3 4 4 3 1 3 54 20 11 1 90 7 5 2 11 4 90 5 32 4 0 43 18 42 17 10 93 5 7 9 NA N 8 4 6 4 IL4@ 11 1l9 6 4 6 4 IIA@ 21 11 9 68 2 7 2 with heater 17 10 68 36 42 8 4 6 4 6 6 43 4 3 5 32 4 A 3 A 13 13 N 1 25 2 A 6 16 8 7 2 with heater 3 4 13 6 4 3 1 2 6 4 3 11 7 4 with heater HLS30 4 7 43 32 LBllO NA 29 43 32 witllollt power takeoff 7 8 rll Q8 pb 4 @ 1 5 pts uil Oler 12 8 2 1 16 15 9 8 5 L1 57 44 1 NA 3 1 1 13 trnnder 138 SpecilicatioDS AUTOMATIC TRANSMISSION V t al h rl pring In 1 i 10 Jla No ul free II length mm in linl lallllal SSllrt Prl gULHllT Prssute Jdificr 1st d 6 13 Uh lIl Id shill O OSI 3rd timing Throttle Sulenoid k Ip downshift k lo 10 31501 06 6 0 36 0 24411 65 10 2559 0 55 50 0 0217 0 0354 0 0177 07 Secondary 140 governor 0 0276 0 12 0 16 0 5 6 14 0 5 0 26 8 Load lb q 55 23 5 0 925 90 2 8 62 0 1 0 3543 16 0 0 5 12 02 0 625 630 17 0 0 669 27 0 1063 18 8 4 1 140 3 1 0 55 12 192 0 740 4 2 5 12 0 60 492 0 3 1 210 0 60 0 827 19 0 3 1 2 19 1 055 0 748 48 5 21 0 846 5 11 om 218 0 858 3268 8 5 3346 0 15 0 1890 3 8 0 5 33 319 1 0 2205 1043 22 0 0866 0 1969 0 36 0 1417 0 1969 5 0 32 5 1280 14 4 8 10 078 45 0 Primary governor 15 0 10 0315 410 1 614 0 2165 08 02 Orifice check 5 32 0 260 1 18 0 6 2 10 0217 0 728 162 2 0 02761 0 01761 18 5 16 0 10 43 0 1693 5 0 0 7 09 Throttle elief 13 0 5 26 3 4 1276 004134 X O 55 0 und Se 15 0 10 01571 length mmOn Jb2 004 0 7 ud 0 1O 10 5 I to 04nl OO 3rd shifl 1 lalled d tliJ pfll11 I 25 1 0 988 453 0 75 0 0 02 0 2953 10 5 0 413 215 0 5 10 1 24 SpecifiCations SERVICE DATA AND SPECIFICATIONS General specifications Torque converter Type Stall SYllImelrit l1 J e1emc onverter ollpling torque alia 1t I lge Sl llfl phJx Ut 0 Transmission Type J pl Control elements Multiple disc speed lorward lIletal ld sp d lI r r iT l Jin lr clutch Band brake diMulstipcle brah One way clutch Gear ratio 1st 458 2 d 1458 3rd 1000 Reverse Selector positions P ParkJ 18 The transmission shaft is fixed R Reverse Backward N Neutral The transmission o Drive llo lIlr illl ltom IL Till llpl bl qarku utral t slarlc4 Up or downshillS nd and I plal cd Thl19inc TI1 I IU hI tlly lIil ill tr b llll bl lOp 2 d lock Fixed Lock up Fixed allow ld at downshifls tWill J Oil pump Type 11Ilernally I termeshing l1 11 p l ar pUlllp Number of pump Oil Capacity AUlOlllath transmissiOll fluid 5 5 liters 57 8 U S qls Hydraulic control system in rull IYlk 4718 Imp qls 1 7 Iill rs I Approxil JTdy Imp qts Dl torque 7S U S qh lS r T1c Controlled by detecting Ih nep ati e prc sllle of intake manifold and the YOhllioll speed It output shafl Lubrication system Fon ed lubrkation by Cooling system Water cooler coo edbya located at an Iii pump culaliOlHypc the Ixili JfY dialOr HI Specifications Specifications and adjustment Automatic transmission nsembly X0400 Model code number Torque converter assembly the tamped mark on Front 16 8 TIC lutch Number of drive Number r1ates in mm Clearance Thickness of 3 3 of driven plates in mm retaining plat 1 6 to 1 8 0 0630 to 0 0709 10 6 0 417 10 8 425 0 110 0 433 112 0441 114 0 449 116 457 0 Rear clutch Number of drive plates Number of driven Clearance IttW reverse in mm Thickness of retaining plate in mm 5 0 039 1 1 0 to 4 8 0 189 4 Clearance in mm of s retaining plate mm in 0 80 105 to 118 0 465 12 0 472 0 12 2 0 4S0 12 4 0 488 t2 6 0 496 12 8 504 0 Brake band Piston size Big mm dia Small dia Governor mark 64 520 2 40 575 1 E strainer assembly Stamped mark 142 in assembly Stamped 0 059 4 plattos Number of driven plates Control valve to hrake Number of drive Thickn 4 4 plates on governor body 35 0 031 to 0 041 Specifications and stall revolution Engine idling control device with emission Engine olution Idling rC 650 rpm D at 800 al Stall revolution Tightening torque Drive plate to Drive plale to Converter Piston stem lock Control valve Side plate Nut for to Governor comelIer 30 5 i I Inhibitor to ace to to plug ver body inspection hole parking inserting position extension to housing manual shaft Control lever boll Control lever bracket to to floor evel two turns after IU i1 11 to 9 4 5 to 19102 5 0 25 to 0 35 19 to 36 to 19 to to 07 to to 0 35 5 2 5 1 5 2 3 6105 1 44 08 5 8 to 3 6105 1 30 to 40 22 to 29 30 to 5 0 22 to 36 07 to J 5 0 14 to 1 08 to 11 s5 0 nut COfltlOj lever knob to to 40 ase to Selector rod lock rod 87 941013 5 to 0 7 0 case 1 1 0 35 case connector to 18 5 to 0 7 0 transmission II 3 to 06 ut IX 3 61 75 0 25 COVeT 1hl 1 In 0 05 body oil pump to t 0 55100 75 iI distributor to converter Turn back 13 case ase bolt transmission Selector range lever 0 7 1 210 I 5 body reamer oil pressure charging pipe to 5 tnO 0 onnecting nut actuator to case transmission upper valve to to 0 0 5 band brake transmiiSion for oil cooler pipe Oil cooler pipt Suppor case 5 1 5104 0 to Manual shaft lock lock nut housing extension body housing Dust 30101c 0 lower alvc to alve switch Oil 5 0 to control valve Oil pump Test to oOlrol valve Oil strainer 6 40 nner body to 101 40 verter adjuting body 16 0 ngine ut One way clutch to 00 u16 to ase Piston stem when Lower vain 14 0 retainer to transmission piSlon ft lb 5 0 to 0 position 2 000 to transmission to m to 40 torque housing Transmission Servo kg nhhaft Transmission case Oil pan I 800 pm position N to 0 75 055 100 75 to 0 08 tu 0 1 6 to 0 1 ItJ 0 0 h 40 to 79 4 5 In 4 0to 5 4 II tll 5 tI 4 0 O 79 1010 15 5 8 30 to S 10 to tt 610 I t I I I 1 lightening 143 Specilications PROPELLER SHAFT SERVICE DATA AND SPECIFICATIONS ut diD Length Propeller shaft 1 080 For Sedan 42 5 For 48 9 Axial Sleeve play of the spider journaJ yoke spline Spline Maximum lash out run 60 3 25 4 2 1 242 Wagon to mainshaft wear of limit propeller shaft Spider journal diameter wear limit 75 0 x dia x 63 5 30 0 08 mm o 0 08 71 8 0 0315 in mm 0 mm 0 0197 06 mm 0 0236 mm in 28 05 0 15 mm 0 0031 0 0059 j Pennissible unbalance 35 Dynamic Thickness of available snap 0 486 in cm gr rings Standard white 2 00 mm 0 0787 in Oversize yellow 2 02 mm 0 0795 I 2 04 mm 0 0803 in green 2 06 mm O OSll in blue 2 08 mm 0 0819 in brown 2 10 mm 0 0827 in colorless 2 12 mm 0 0835 in pink 2 14 mm 0 0843 in Tightening torque Fixing nuts of flange yoke to companion flange 144 oz 20 14 2 7 kg m 20 nIb at 5 800 p m Specifications kg Tightening torque Drive pinion m ft Ibl 17 ut 50 S to 57 8 2 6 5 to S 7 0 9 to 1 Side etainer rolt Side flange fix bolt 1910 2 6 13 7 10 18 8 fix bolt 19 to 2 6 13 710 lS S Rear Rear cover cover to mounting member lock nut Differential Differential to drive shaft fix bolt mounting Companion flange Oil dram Oil uspension member fix bolt to Differential carrier to nd filler member Variation elf lock nul propeller shaft fix bolt 6 8 43 410 57 S 5 to 7 3S 2 10 50 6 5 to 6 36 2 to liter DS qt Imper qt 6 28 9 to 43 4 to 08 7 8 3 4 ethods umbers pressed by o pinion adjusting formula GO mm u T W N S I Side bearing adjusting formula Tl A H O OlJ C 0 01 L 4 43 50 6 to 72 3 2 0 to 2 7 14 5 to 19 5 Oummv shaft Dri to 7 to 10 4 plug i y ahOllO Ipal djll tiltg I 122 9 to 144 6 20 7 to S Ring gear bolt I to T2 B 0 01 Gl 0 76 D D 02 D E G2 0 76 F 145 Specifications Brake Specifications C i S nJ Bore D LM r w Mu R Ii C Drum Drum J R n F 1 60 rti r ur u c R t 1000 1 000 USO 11 5 115 93ll KA i A NA S A Drum Drum 875 1000 Drum Drum 875 1000 93ll PL411 Drum Drum 875 1 000 93 HUll Dbl Dmm 875 2 000 9 1 Dbc DrUllI 750 125 l i1 Dnllll 750 5 12 Drum DrUIll 77 77 rnm I Drom 750 750 i50 Di1c Drum 750 000 tln 9 1 WPL5lO Disc Dn 750 000 l U3 9 PL521 Drum Drum KA KA 10 0 10 0 HLS30 Disc Dnnn 875 2 125 875 10 7 9 0 Drum 688 1894 688 8 4 8 0 PIAW SPL310 SPL311 SRLl11 320 1 520 1 L521 PL510 LBllO KLBllO l Disc m tf r CukT IIq J C u r k T 10 0 0 10 0 1 g 1 Ru r B q 9 0 9 0 R 1 Wltul Pi U 0 w JIII f f S t B W bd lio 54 ll l 10 0 KilO i o M 9 tJ 10 ill UlO 11 2 11 2 W rlAIa C w 9 0 Alignment Specifications Chassis and Wheel Mod 1 81 9 0 55 3 d ll Ii 30 1 30 12 166 45 2S 25 2S 25 32 32 7 15 WL60 98 4 54 B 1 30 55 3 1 30 12 16 6 45 7 15 PUlO 5PL310 PUll RU11 311 5P1 5RL3ll L320 93 8 89 8 93 7 93 7 89 8 89 8 97 2 47 0 1030 1030 00 13 6030 3B 28036 47 1 1030 1026 06 13 6034 38 28036 75 47 2 0 1045 06 136015 38 28036 47 5 47 2 0 1045 13 6015 3B 28036 2 1 30 1025 08 12 6035 36016 29020 47 2 30 1025 08 12 6035 36016 29020 30 1 30 08 126 34 29030 1 08 12 6 34 29 30 35 478 3839 22030 47 5 47 8 50 47 50 46 1 3 46 7 SO L520 99 B 49 2 49 9 510 P1 95 3 50 4 50 510 WP1 95 3 50 49 6 WI PWI 99 B 49 2 49 9 j HLS3O 90 7 83 3 83 0 LBllo JLBllO 90 0 48 8 49 0 40 SO 105O 20 3030 i Uo ooded 148 1 5 202 3025 I oSO 3 SO 50 2055 20 1020 040 1 10 35 5 103 10 12 24 7050 1020 08 126 50 os 20 OOS 1 11040 12040 24 7oSS 3B 39 2203 3030 34 29 30 13 32 31024 32024 42 3537 s b o r r 1 If fIT7L7 7JrwF wM C Ju i J 7 cif 1 tI lifftrf u UJ 1 4 I IRING AND AUTO BODYR REFINISIUNG by B B Weston Every possible phase is highly ompetitive auto body ir tf rep ide light of the correct repair techniques and tools to be used to return a damaged n materials welding hand tools and auto body auto to likenew condition Topics such at constrocti in this text Designed to serve as a shop mahual few of the areas are a clearly explained design just major for auto body men and as a reference tool for the owners of auto repair shop s it is a must for any well equipped school shop or library delves deeply This b discus into the and eXplained in SBN 030 87749 9 58 95 X GltEA1 bY 13arrie Gill MTOR RACING THE GRA Banie Gill the internationally famous r ej ert has created a book that offers portraits of ten f being the gre of t1iem all Graham c ntenders for the honor iver dr Jill tirIing M s J en Jack Brabham Bruce McLaren dt I Hawthorn k ikl FangJQ n Huh lt ryIanuel Ju@ enny JunClm and nd Jackie Stewait Eaclimim is disCjlssed ii1 this book by the writerS o knew 1llm th e best s sport shiueCi his triumphs agedies SIde look at some ofthe world s most h Tl book cOIof W and will give courageous t evet racing enthusiast 1 c liiI il di lC dj ii at eve1 l p a s 1 s s t w r 9tl sl n 11 c1nditi CP This book Contains and garage ldeil fncl dshieId rtqntrol wipe wi lwmdiftsow speedqm power voted to controls for the JD1 b ELECTRO it RE5l by Edward J 5 95 eters and c eIe adjustment i c cloc Ysl1ers a nd eId wmdshi s and sign There tum Wipers l 1 l87749 SB 128 3 paper N 87749 129 1 1 i 9 3 95 lcore are fsimple and very useful electric devices that can be made at home for the car circuits for the car that warn of danger from ice arid overheating an autoinatic and an automatic sidelight switch Two projects that will be Of great help in the SBN 87749 32 1 5 95 YOuRBIUTISH SPORTSCAR by Charles Williams This bOOK will liel t ers of British made cars tune them for maximum power and speed TUNING ORTSCAR gives a non technical but practical guide to how f8InllY cars can be made YOUR BRITIS TUNING to behave mpre liKe sport cars An added feature is a list of major Americ8n suppliers of the British IlUide in this book TUNING YOUR BRITISH SPORTSCAR is profusely illustrated with auto parts discuss and iJii grams SBN 87749 f ij T f FOR CAR AND GARAGE by R M Marston L li photos 4 handicapped S JECTS l8iring rej garage are a e atiilgbattery charger and a speed control for electric drills f described by ll d and easily understandable instructions and ilustrateq by clear Each project is diagrams All necessary components ate listed fot each device This book wilI l e ofgreat value to all car owners meMtanics and electricians many II Mezo on the latest autom ccessory developments and for the imtomobile Qwner anll theprofessionaI mechanic li Hters o b e reIease signals cigare teitieatis e t r mdl SBN 87749 229 8 AeBESSORIESIDE oslJm1Jtho liv ly and y rJbTI U fresh sPfirtsmen t lof a df 165 8 7 95 ti E
