Download Service Manual Model G18 Engine

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QUICK REFERENCE
DATSUN
1800
ENGINE TUNE
SERVICE
MANUAL
MODEL
ENGINE
INDEX
GENERAL
EG
ET
UP
EM
MECHANICAL
ENGINE
G1I
ENGINE
ENGINE LUBRICATION
SYSTEM
EL
COOLING
CO
FUEL
SySTEM
SySTEM
EMISSION CONTROL
SYSTEM
EF
EC
I NISSAN I
ENGI NE ELECTRICAL SYSTEM H
NISSAN MOTOR CO
LTD
SERVICE
TOKYO JAPAN
SE
EQUiPMENT
r
I
I
t
r
W@ffim1 i IR
W
l
manual has been
This seroic
of
ollr
disfribllton and dealer
prepared for
for effeetive
the
purpose of assisting icnJice personnel
eroice and mainfenance of model G 8
engine
Since proper maintenance
by keeping their
The
1
only
to
refer
of the
2
and mroicp
the
both thi
effective
thi
and the DATSUN
thfl
uur
udomen
manual should be camfuJly studied
utilization
informations concaning
ati
fy
essential La
most
are
in the be d eondition
hould be noted for
following
Since
curs
of this
engine
manual
are
described
30 SEIiVIU MANUAL
huetn
please
detaiL
for complete
car
411 the part names in this manllal conform fa both VA TSIJN C30 PARTS CA T4
the genuint seroice parts listed in this parts catalog should be used
and only
03
replacement
3 All
on
4
informations
the
latest
specification
available at
information
product
It is
to
empha ised that
thi
tho who Il
the SER VICE JOUIiNAI is ued by the
approved scroidng
5
illustrations and
R ights
for
contained in this manual
the
time
factory
based
of publication approval
w lhe
rtmi
manual
are
t
which CIlrrie
ontents
ording
factory
aCf
the late t
mdhod
alteration in
tpecification
and othen at
any
time
are
reseroed
J
1
i
f
1
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1
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DATSUN
1800
r
l
SECTION
I
SERVICE
MANUAL
MODEL
EG
ENGINE
GENERAL
G11
ENGINE
NISSAN MOTOR CO
TOKYO
JAPAN
LTD
EXTERNAL VIEW Of ENGINE
EG t
MAIN SPECifICATIONS
EG 2
RE COMMENDED LUBRICANTS
PETROL AND COOLANT
EG 2
UNIT SERIAL NUMBER LOCATION
EG 4
PERIODICAL INSPECTION AND
MAINTENANCE
EG S
SPECIAL MAINTENANCE FOR
EMISSION CONTROL SYSTEM
EG 6
GI
ENGINE GENERAL
EXTERNAL VIEW OF ENGINE
External
view
of model GIS
engine
Fig
EG l
Right
Fig
EG 2
Left
EG l
hand side
hand ide
ENGINE
MAl N SPECIFICATIONS
Engine
model
Number of cylinders
GI8
in line
4
Valve arrangement
ORC
Bore
mm
in
85
3 346
Stroke
mm
in
80
3
Displacement
c
Compression
c
cu
in
1
ratio
Maximum power
Maximum torque
815
8 3
SAE
RP at rpm
SAE
kg
m
Oil pan
U
S
ft lb
qts
U
S qts
U K
115
3
600
3
8
qts
4
0 3
8
6
qts
9
1
L
Coolant
8
1
15 9
L
U K
110
105 at 5 600
at rpm
Capacities
150
7
0
3
6
The table specifies the quantity of oil which is required for periodic oil
replacement
when oil filter is not replaced
Should also the filter be replaced the total
quantit
is about 4 4 L 4 7 U S qts 3 9 U K
qts
RECOMMENDED LUBRICANTS
PETROL AND COOLANT
Use the
following grades
of oil
gasoline and coolant
Temperature
Above 320 C
320
00
to 00 C
to
Below
900 F
900
120 C
120 C
average
to 320 F
320 to 100 F
100 F
oil
Engine
minimum
minimum
minimum
EG 2
MSI
SAE 3D
10W 30
SAE 20
20W
10W 30
SAE lOW
10W 30
SAE lOW
10W 30
ENGINE GENERAL
Recommended lubricants
Engine oil
Multi
Maker
Multi purpose
single grade
Regular
grade
or
grease
double grade
Marfak All Purpose
TAXACO INC
Havoline Motor Oil
Havoline Motor Oil
IOW 30
lOW
20W 40
20W
30
40
Grease
40
Marfak Multi Purpose
Grease
CHEVRON
OIL CO
RPM Supreme Motor Oil
RPM
IOW 30
lOW
20W 40
Special
20W
Motor Oil
20
30
40
RPM Multi Motive
Grease
Marfak All Purpose
Five Star Motor Oil
Five Star Motor Oil
CALTEX
IOW
30
lOW
20W 40
20W
20
30
Grease
40
Marfak Multi Purpose
Grease
MobiloillOW
MOBIL
Mobiloil Super IOW 40
Arctic
20
Mobiloil Special lOW 3D
A
30
AF
40
Mobil Grease MP
Shell Super Motor Oil
IOW
SHELL
Shell X
40
20W
Shell X IOO
lOW 3D
20W
IOW
BP
BP
British Petroleam
30
20W 30
Viscostatic
20
lOW
IOW
Lubricating points
20W
20
30
40
20W 20HD
10WHD
Castrol Super
40
E sso Multi
40
Purpose
Grease
BP
Energrease L2
Castrol 5WHD
Castrol XL 20W 40
IOW
40
30
Castrolite IOW 30
CASTROL
lOW
BP HD Motor Oil
Motor Oil
5W
30
E sso Motor Oil
20W 40
Super
Retinax A
20
40
Esso Extra Motor Oil
ESSO
IOO
lOW
30HD
50
40HD
Engine Carburetor Linkage
Distribulor Shaft
EG 3
Castrolease LM
Distributor
cam
heel
ENGINE
Nissan
long life
This L
L
C
ethylene glycol base
chemical
duct
conlaining
the cars cooling
corrosion
ethyl
ine
rate
or
high
or
L
or
L
inhibitors
against
sytem
C
LL C
coolant
is an
pro
to protect
and
rusting
does not contain any
glycer
Boiling point
o 9
Sea level
concen
tration
C
must
not be
total
through
miles
0 32
10
protection
tern pressure
14
20 4
30
106 C
124 C
221
255
F
two years or
km
24 000
Freeze
cooling sys
I
15 C
F
5
I
I
22
30
F
I
1
109
C
127
C
35 C
F
31 F
50
228 F
261
40
40
50
58
I
I
I
10
Fig
20
30
40
50
EF 3 Protection concentration
UNIT SERIAL NUMBER LOCATION
There
tification
two serial numbers for unit iden
the
number
engine
These numbers
number
car
are
identification plate
easy to
and the chassis
repealed
are
which
is
in the
located in
an
read position
Engine
serial number
The engine
number
is
side of cylinder block
surface
stamped
at
in the rear left
cylinder head
The number is preceded
contact
by engine
model
G18
T
000001
Serial No
Fig
Engine model
f
4
f ngine serial and model
number
EG 4
noi
out the seasons
exchange period is
running mileage of 40 000
Oc oF I
kg cm2
will
mixed with other product
of the year and
boil away and can be used with either
If flows
low temperature ibermostats
Percent
L L
This coolant can be used
It will not evapo
methyl alcohol
freely transfers heal efficiently and
clog the passages in ibe cooling system
mZ Q Z m Q m Z m
nU
n 88 00
0 00
E
MAINTEC
CALENDR
88 00
88 00
00
0
0
0 00 00 0 0
0
0 00
0
00
0
0
0
0 0
0
0 00 00
0
0 0
0 0
no
0
ui N
0
l
1J
N
E
E
0
uf
n U 000
E
0
r
N
0 00
0
0
00
0
0 0 0 0 00 0
0 0
0
0
E
E
MAINTEC
0
U
0
0 0
0
0 0 0 0 0
0
0 0
0
0 0
C
nU
0 00
O
0
0
00
0
E
E
U
0
0
n U MN
E
E
AND
88
0
0
0 0
0
0
INSPECTO ENGIE
LPERIODCAL UBRICATON CHEKING
AND
nU
EV RY
MAINTEC FREQUNCY
nU
E
E
@@
E
E
U
shaft
necsary
POINTS
0
elctroye
arm
COlANT level batery
beel
shaft earn
and
if
up
top
linkage rot r
level
distrbuo
0
LIFE
level
of
0
0
0
flange
gali pipe
exhaust
and
elctroye mhaenifoaldd
parts
ravity
water wate LONG color
of
terminals
point
and
fit ng
and
function
cylindel carbueto vco2n1tvroel Change
regulator
of
01
cords function el ment
pan
d
i
s
t
r
b
u
o
s
t
r
a
i
n
m
o
u
n
t
i
g
f
i
t
n
g
s
v
o
l
t
a
g
e
c
l
e
a
n
s
p
e
c
i
f
cap
c
l
e
a
u
f
u
n
c
t
i
o
n
c
h
a
m
b
e
r
v
e
n
t
i
l
a
o
cco ling o ling NIS AN batery staring timng tension stralU
cleau cap batery mot r
p
l
u
g
s
i
d
l
i
n
g
Sup ly
engm cylinder carbueto belt from engine leak ge filter plugs
f
l
o
a
t
p
u
m
p
Check Change Lubricate Lubricate Ap ly Check Change Change Check Measure valve igntiol1 leak fuel fuel fuel park spark distrbuo engint filer dirt altern o stare fuel jets conden crank se
Engm Gte
Check
tlghtel tighten tIghteu Repla
l
e
an
R
e
p
l
a
c
t
Replace
Check Check Check
engine enginl carbueto diltrbuo
oil oil
to
R
rotor
l
gre
pre
oil
of
oil
fan
Fluid
Oil
air
air oil
t
Re
Re
0
Re
n
0
compresin
Measure
Check Adjust Check Check Check Check Check Replact Check Check Check Check Clean Check
of
C
Check Check
0 0
U
ID
O
0 0 0
0
0
0 00
0
0 0 0
NN
0
0
0
0 0
0
1
0
0
0
M Cl
I
0 0 0 0
o
m Z G Zm
S
t
U
ES
CONTRL
EMISON
o
o
o
o
o
o
o
o
o
o
o
i
V
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
f
S
PERIODS
S
E
U
U
N
U
ON
t
E
S
MAINTEC
i
S
O
o
U
N
o
o
1
0
o
o
o
o
o
o
o
o
o
o
o
c
So
@ o
S
@ OD
E
S
N
S
E
88
S
o
o
valve
FOR
sy tem
points
control
breakr
POINTS emison
MAINTEC
CHEKING
control
wick
distrbuo
pomt5
of
with
Up
timing tdling tunc plugs plug
tension fit ng
s
p
a
r
k
19nItion engine major spark Replac hIgh for
Check Check Engintl Check Check Check
equiped
Engi es
breakr
cable andwear
distrbuo
Replace
shaft and
rot r carn
distrbuo distrbuo
to
to
e
gre
grea
elment
clea1t
air
vconetis entilao
fire
of
and
of
of
of
of
conetis
IOle
galery
and
of
of
proper proper proper proper proper
leak
leakl pump
for
for
for
of
function functlon Cunetou functlOI functiulI
for
for
hOlel
conec
valve
pump valve back nandoz le
relief check anti
cranklIe
hose
carbRueetopla leaks
tl
valve
t10n5
for
for
for
hOle
tenlon
t
bel
Check Check Check Check Check Check Check Check Check
Ap ly Ap ly
I
SYSiI
o
o
o
@
ES
EM
o
o
O
0
6
Ii
u
I
SPECIAL MAINTEC FREQUNCY
E
EV RY
l
E
z
U
t
E
U
E
l
m
o
ID
o
NN
o
o
o
S
U
o
o
o
Ln
ci
E
o
i
lh
o
o
o
0
1 Cl
t
I
o
o
o
o
o
o
o
ENGINE GENERAL
advisable
1 000 KM
AFTER FIRST
600 MILES
gularly
however
Changing Engine
Oil
the
at 3
Second replacement
2
Third
000 miles
at 6
replacement
4
000 miles
000 miles
6
3
is best done after
being thoroughly
a
000 miles
good
will flow
warm
bonnet up
1
2
readily
adjustment
is not
switched off and
the engine
push the belt gently downwards
to depress it about 10 mm
If the fan belt
in
through
bolts
ward
or
and
adjusting
the whole of tbe alt rnator to
lhe engine
This will take
and
Tighten the bolts again
make sure the belt has the required
If you tighten il too much itwill
from
away
slack
recheck
wear
has become slack
the fixing
loosen
wear
and move
lhe
free
when
run
With
tension re
You should be able
up
000 km
every 5
Thereafter
the oil
000 km
at 10 000 km
Fourth replacement
Draining
000 km
need for
that the
so
overlooked
check the
to
to
play
rapidly
and
also overload the water pump
and alternator bearings
and freely
Place a
under
er
drain
large bowl
the
plug
and
be hot
or
other shallow contain
engine
Then
Do this
carefully
it
will
spurt
the oil pan
remove
After completely draining the dirty oil
curely
will
the oil
as
out with some force
off
se
replace the oil drain plug and finally
engine in the usual way up to the F
on the dipstick
Make sure the car is on
refill the
mark
a
surface while
level
and
draining
filling
the
3 8L
7 U S
4
Scale
jacket
tion
out
sediment
or
radiator is
or
accumulated
in
water
obstructive to heat radia
The system should be thoroughly flushed
one at the
opening the two drain plugs
of the
4 0 U S qts
4L
including oil filter
water
Changing cooling
bottom of the radiator and oiber at the left side
engine
Oil pan capacity
EVERY 10 000 KM
6 000 MILES
block
cylinder
until clean water
comes
out
qtsl
clean soft water for filling the
Immediately ibe cold weaiber ar
rives
the coollng system should be protected
against frost by a good anti freeze solution such
Always
use
radiator
AFTER FIRST 3 000 KM
2 OOOMILES
as
Replacing
oil
filter
Second and thereafter
every 10
000 km
6 000 miles
Remove
element
can
the body of the oil fil ter
be taken off
a
LONG LIFE COOLANT
NISSAN
for expansion when hot
A t the
cold
should be just visible at ibe bottom of the filler
neck
alid the
same
To allow
when
the level
L
L
Do not overfill the
should be
C
This coolant
system
changed every 40 DUO km
24 000 miles
time
replace
the body gasket and center shaft gasket
The tightening torque of center shaft is 2 8 to
3 2
kg
m
20 to 23 ftlb
EVERY 40 000 KM
24000 MILES
air cleaner
Replacing
wet paper
The
ment
AFTER FIRST 6 000 KM
4000 MILES
element
type
air cleaner is of a wet paper
viscous
type
performed special
treatment
there is
to clean the element for normal
until
Fan belt tension
it
is
replaced by
24 000 miles
Second and thereafter
every 5 000 km
3
Incidentally
it
drives
we
000 miles
can it ibe fan belt
but also
the water pump and alternator
It is
EG 7
as
to be
since
required dust
action
element
Care
new
no
but
no
need
driving condition
one
at
40 000
This element will lock
there is
type ele
As this element has been
never
try
so
to
km
dirty
clean
fear to reduce the cleaning
must be taken not 10
injure filter
ENGINE
SERVICE JOURNAL OR BULLETIN REFERENCE
DATE
JOURNAL
BULLETIN
or
No
PAGE
SUBJECT
No
EG 8
l
f
L
DATSUN
1800
t
t
SERVICE
MANUAL
MODEL
SECTION
ET
ENGINE
TUNE UP
G18
ENGINE
NISSAN MOTOR CO
TOKYO
JAPAN
LTD
ENGINE TUNE UP
n 1
TROUBLE DIAGNOSES ANO CORRECTIONS
n 6
ENGINE TUNE UP
ENGINE TUNE UP
CONTENTS
GENERAL DESCRIPTION
PROCEDURE
BASIC
Connect
tune
up
ADDITIONAL
ET 1
equipment
ET 2
remove
ET 2
Clean and adjust distributor
points
Set ignition timing
Inspection of fan belt
of
oil
engine
attaching
ET 3
nspection
Inspection
Inspection
of oi I fi Iter
ET 5
of air cleaner
ET 5
of fuel strainer
ET 6
Inspection
of
ET 6
test consists of
testing
replacing if
cleaning regapping or
required
spark plugs and distributor points
adjusting distributor dwell angle ignition tim
cedure consists of these basic items
retor
elec rical
compression
ignition
and
checks
a
final road
hot
a
use
basic
Timing light
2
Negative lead
3
Trigger lead
to
ground
to number 1
spark plug
test pro
Tachometer
1
Positive lead to distributor side of coil
2
Negative lead
plus other
and
test to
carbu
to
ground
ensure
4
Dwell meter
Positive lead to distributor side of coil
2 Negative lead
to
ground
equipment
manufacturer recommendations
of testing equipment
schematic
cooling system
Positive lead to positive battery terminal
3
BASIC PROCEDURE
the
ET 5
1
1
Follow
nuts
idle
continued trouble free operation
Connect tune up
ET5
intake manifold and
I
2
and
carburetor idle mixture
ing
speed
The complete or major tune and
ET 5
o istribu tor I ubricate
carburetor
GENERAL DESCRIPTION
battery
distributor cap and rotor
Tighten
ETA
tune and
ET 5
ET2
ET 3
adjustment
minor
ETA
pressure test each
ET 2
Carburetor overhaul and
A
ETA
Clean and inspect high tension wires
and
recondition
Inspection
adjustment
PROCEDURE
Compression
cylinder
ET 1
Battery inspection
Spark plugs
Valve clearance
ET 1
for
Fig
for
ET 1 shows
instrumentation
which
r
will apply to many types of test equipment and
if equipment
a rough guide
may be used as
manufacturer
s
instructions
are
follows
1
Voltmeter
ij
not available
Connections shown in figure ET 1
as
are
1
Positive lead to resistor side of coil
2
Negative lead
Spark plugs Trigger lead
Dwell meter Tachometer
made
Fig
to
fl
Timing light
ET 1
Simple
chematic
instrumentation
ground
ET
1
of
tuneup
ENGINE
Clean and
Battery inspection
1
adjust distributor points
Check the level of the electrolyte in battery
Check the level line on the case with the
cells
battery
If necessary
electrolyte
replenish
with distilled water
2
the specific gravity to the battery
Measure
electrolyte
Remove
for
contaci
ET 2 ln
peeting battery
Filing
burning
and
cap
or
Use a
necessary
area
is
di5tributor
distributor
excessive
points if
Fig
Checking
ET 3
Fig
remove
point gap
and
inspect point
pitting
Replace
point file
scale
for cleaning purposes
to clean
from
points
Do not
only
attempt to
Clean top of battery and
terminals
and dry with compressed air
of
Top
must
be clean to prevent current
tween
terminals
with
a
Rinse off
solution of baking soda and water
battery
leakage
addition to
current
leakage
accumulation of acid and dirt
may
cause
blistering
connector straps
coat them with
of the
After
petrolatum
O
45 to O
55
mm
0
0177 to
Set
top of battery
material covering
tightening
terminals
to
them from
See
Spark
that
plug
and
remove
correct
spark
insulators
With
and
set
distributor
vacuum
line
disconnected
operating at normal idle speed
ignition timing
car
or below
recondition
plugs
should
cleaned to prevent poSSible flash
be
used
are
thoroughly
over
Thoroughly clean lower insulator and cavity by
sand blasting
File both electrodes flat rounded
surfaces increase voltage required to fire plugs
and set gap to 0 7 to 0 8
in
When
gaskets and
plugs
tighten
22 0 to 30 0 ft lb
are
0
mm
028 b O 031
reinstalled
plugs
to
3
use
0 to 4
0
0217
ignition timing
corrosion
Spark plugs
O
in
prolonged
on
protect
point gap
be
and from positive terminal to
hold down clamp
In
remove all roughness
Apply a trace
bearing lubricant to the breaker cam
Adjusi
distributor dwell angle to 49 to 55 degrees and
of
new
kg
m
Fig
torque
ET
Z
ET 4
Checking ignition timing
check
r
j
T
SEE
0
8
TlK
Tl
S
FIt
ENGINE
The timing
be observed
can
by the
at the front cover and the
ary poinier
the crankshaft pulley with
on
a
station
called
Check if the engine oil has been deierioraIed
Drain
by invading cooling water or gasoline
1
markings
device
UP
TUNE
a
and refill the oil
if necessary
also referred to as a timing
stroboscopic light
light as shown in Figure ET 4
Ignition timing is 80 BTDC 600
Note
rpm
a
A
milky oil
indicates the presence of
cooling
water
Discover the
b Oil
with
cause
for necessary treatment
extremely
low viscosity suggests
dilution with gasoline
2
Check the oil
necessary level
up to the F
ET 5
Fig
Timing
level
and if it Is lower than
replenish oil of the
same
grade
1
lev
mark
Inspection of fan belt
Fig
ET 7
Checking oil
Carburetor overhaul and
ET 6
Fig
1
Check for
a
Checking
cracked
level
adjustment
fan belt fen ion
or
damaged
V belt
Replace if defective
Adjust the belt tension if necessary
Permissible slackness of fan belt
8 to 12
2
0 315
point
to 0
473 in
Between fan
Inspection
Oil
of
Belt
pulley
tension
measuring
and alternator
pulley
engine oil
capacity
of engine
Oil pan
capacity
3
8 L l
0
Engine dried
mm
5
0 U S
8 U K
0 L 13 U
S
1 1 U K
gal
gal
gal
gal
Fig
ET 3
k
ET B
Adjruting idle rpm
ENGINE
Overhaul
ADDITIONAL
The
detailed
overhauling
FUEL
for
informaiion
is outlined in section
carburetor
EF
ENGINE
SYSTEM
For
it
is sometimes
diagnoses purposes
to
further
than
proceed
the basic
necessary
tune up procedure
The following steps plus a
road test
are
tune and test
Adjuslment
Adjust carburetor
to
get best idling engine
speed 600 rpm
included in
Compression pressure
each cylinder
when plugs
This
engine
adjustment
adjustment
is
is
tuneup
when
impossible
in operation
complete
a
or
major
procedure
Note If this test is
Valve clearance
PROCEDURE
be performed it should be done
to
are
test
removed for service during basic
procedure
the
Unless
Follow the procedure
described below
checking for
of low speed
cause
rings or for the
compression check
worn
miss
should not be necessary
1
Standard adjustment is made while the engine
is cold
Adjust to the following clearances
Both intake and exhaust
0
0
When hot
Both intake and exhaust
0
the top dead center
each cylinder in turn
lock
nut
and turn
2 mm
0079 in
O
reference
Locate
compression
plugs
with
engine
warm
and
throttle
and
removed
all
choke
No cylinder should be less than 80
of
Excessive variaiion be
highest cylinder
tween
cylinders
accompanied by low speed
open
When cold
2
Test
spark
28 mm
011 in
compression
adjusting
screw
missing of the cylinder
low
of
Loosen the valve screw
the
the
to set
usually
indicaies
or
cylinders which
a
not
valve
are
properly
seaiing of a broken piston ring Low pressures
even though uniform
may indicate worn rings
This may be accompanied by excessive oil
con
sumption
valve clearance to the specified value
Tighten the lock nut and recheck clearance
Follow
the
same
manner
for
the
remaining
cylinders
To
rotaie
manually
the
tighten
crankshaft
of
tile fan belt and
the
engine
pull
Compression pressure
11 3 kg cm 156 8 in
12 3 kg cm 170 8 in
Clean and
oz
to
oz
at 350 rpm
inspect high tension
wires distributor cap and
Inspection of timing chain
Note This operation is to be performed while checking
Tension of the timing chain is
adjusted by
distributor
turning the adjusting screw aitached to the
right hand side of the chain cover by observing
following
1
2
items at
nut
adjusting
securely
Tile wiEith
mm
2 16
Use the
the tensioner
same
External surfaces of all
voltage
lock it with lock
flats of the lock uut 10
as
thai of spark
adjustment
loss
g
l
tU
6
000 miles
additional adjusl
ment is not necessary until 100 000 km
60 000
is reached
pushing
it lA
terminal
be
sure
so
thitl
WiU
for cracks
b
wt
are
can
or
corroded
lt
llul
arcing between end
When
they
that terminals
Burned
rubber nipple down
distributor rotor
can
ET 4
uJit
i
which caused
terminal
secondary
possibility of
All wires should be removed from
distributor cap and coil
seaied
pings
parts of
be cleaned to reduce
must
wire and
at 10 000 km
when the initial period ends
miles
and flash over
system
spark plug wrench
After
points during the basic tuneup
Inspect distributor cap for cracks
be inspected and cleaned
ael9SS
in
procedure
running engine
Chain noise is not high ai idling rpm
Chain noise is no high at 2 000 rpm
After
rotor
flilt
of
replacing wires in
fully seated before
over
for damage
tower
and
Check
distributor
ENGINE TUNE UP
or
Di s tributor Iubrica te
Wipe
and
a
very
of special
small amount
ball bearing lubricant
on
cam
for 40 000 km 24 000 miles
running
under
normal conditions
lobes when
cam
servicing
Tighten intake manifold and
carburetor attaching nuts
Intake manifold attaching bolts and nuts
be
on
to
proper iorque
engines should
tightened
Carburetor attaching nuts should be tightened
Leaks at these areas can cause
securely
deceleration popping or
rough idle
surging
deceleration whistle
of oil
Inspection
1
filter
Check for oil leaks at oil
center
gasket
filter body gasket
that
replace
the oil
each
leaks
gaskets
and
2
3 to 23 2 lb
Replace oil
6 000 miles
be
2
8
protected
to
3
2
bolts
kg
m
ft
filter
Inspection
This
air cleaner element
of fuel strainer
engine
uses a
cartridge type strainer
replace as an
so if the malfunction is detected
assembly
element
each
10 000 km
running
Fig
ET 11
Inspection
Fig
ET 9
Removing
oil
Inspection
1l in2
of air cleaner
type element makes
un
necessary until the engine used for two years
ET 5
cap
pressure
to the radiator
0
9
kg cm2
12 7
cap and the reservoir
cap tester to see if it is
Replace the cap assembly if
means
satisfactory
necessary
stroiner
cooling system
reference
tank cap by
cleaning
of
Removing fuel
Inspection of radiator
filter
Apply
Viscous
Removing
it a little
each
tighten
under the prescribed torque
20
tighten
can not
ET 10
Fig
surface of
installing
If oil leaks are found
cover
after
shaft
and
of
a
ENGINE
Cooling syslem
With
pressure test
radiator cap
removed
apply reference
12 7Ib in2
kg cm2
cooling system by means of a tester
pressure
0
9
to
the
to check
for leakes at system
component
Fig
ET 12 Radiator cap te t
TROUBLE DIAGNOSES AND CORRECTIONS
Troubles
Possible
CANNOT CRANK ENGINE
Rem ed ies
causes
Improper grade oil
Replace with
OR SLOW CRANKING
proper
grade
oil
Discharged battery
Charge battery
Defective battery
Replace
Loosen fan bel t
Adjust
Trouble in charge system
Inspect charge system
Wiring
connection
trouble
in
starting
Correct
circuit
Defective starter switch
Repair
or
replace
Defective starter moior
Repair
or
replace
Trouble shooting procedure
Switch
on
When
the
light
starting
on
starting
moior with
goes off
or
circuit
light put
on
dims considerably
a
Check battery
b
Check connection and cable
c
Check starter moior
a
Cbeck wiring connection
starter moior
ET
b
Check starter switch
c
Check starter motor
6
between battery and
ENGINE TUNE UP
ENGINE WILL CRANK NORMALLY BUT WILL NOT START
In this case
system
following
trouble
cause
may
exist
but in many causes
ignition system
or
fuel
is in trouble
Ignition system in trouble
Fuel system in trouble
Valve mechanism does not worl properly
Low compression
firstly by following procedure
high tension cable from one spark plug
from the engine
about 10 mm 0 3937 in
Check spark plug
Disconnect
and hold it
metal part and crank the engine
Good spark
No spark
occurs
a
Check spark plug
b
Check
c
Check fuel system
d
Check
ignition timing
cylinder compression
Check the current flow
occurs
in
Very high
primary
circuit
Inspect primary circuit
current
for short
Check
breaker
point
operation
Low
or no
Check for loose termi
current
nal
or
disconnection in
prirn3 ry circuit
Check for burned
Ignition
system in trouble
Distributor point burned
Repair
Improper point
Adjust
gap
Defective condenser
Replace
Rotor cap and rotor leak
Replace
Defective spark plug
Clean
or
Adjust
Defective ignition coil
Replace
Disconnection of high tens ion cable
Replace
Loose connection or disconnection in
Repair
Supply
Dirty fuel strainer
Clean
or
or
replace
circuit
Lack of fuel
Dirty
replace
adjust plug gap
replace
Improper ignition timing
primary
Fuel system in trouble
or
points
clogged fuel pipe
Fuel pump will not work
ET 7
properly
or
replace
Clean
Repair
or
replace
ENGINE
Adjustment of f10allevel
Correct
good
no
Improper idling
Dirty
C
Low
or
clogged carburetor
breather
logged
Incorrect
compression
Adjusl
Disassemble and clean
Clean
pipe
Tighten to normal torque
replace gasket
spark plug
defective gasket
tighlening
Improper grade engine oil
droppi ng
or
viscosity
grade
Incorrect valve clearance
with proper
Replace
oil
Adjust
Compression leak from valve
seat
cylinder head
Remove
and lap the valves
Stick valve stem
Correct
Weak or defective valve
Compress ion leak
Piston
Worn
pis
ton
ring
cylinder
at
ring sticking
or
springs
or
head
Replace
gasket
defective
or
replace valve
valve
springs
Replace gasket
Replace piston rings
Overhaul engine
cylinder
Trouble shooting procedure
Pour the
and then
engine oil from plug hole
cylinder compres
measure
sion
Trouble in cylinder
Compression increased
or
piston ring
Compression leak from
valve cylinder head or
Compression unchanged
head gasket
IMPROPER
ENGINE
IDLING
Fuel system in trouble
Clogged
or
damaged
Incorrecl idle
Clogged
carburetor jets
adjustment
Clean
or
Adjust
air cleaner
Replace element
Defective gaskets of manifolds
or
Replace gasket
carburetor insulator
Adjustment of float level
no
good
Adjus t
LUW
Others
Incorrect valve clearance
Extremely
low revolution
ET
replace
8
Adjust
Adjust
ENGINE TUNE UP
ENGINE
POWER NOT UP
TO NORMAL
Low
Previously mentioned
compression
Ignition system
in trouble
Incorrect
Adjust
ignition timing
Defective spark plugs
Clean
adjust
or
replace
plugs
Dress
Defective distribuior points
or
replace points
also check condenser
Incorrect octane
Fuel system in trouble
Air intake system in
trouble
seLector
Adjust
setting
Adjust
Malfunction of choke system
Clogged
fuel pipe
Dirly
clogged
or
octane selector
Clean
fuel strainer
Replace
repLace
Fuel pump will nol work properly
Repair
C logged carburetor
Disassemble and clean
Clogged
jets
or
Replace element
air cleaner
Air inhaling from manifold gasket
or
Replace gasket
carburetor gasket
Overheating
Insufficient coolant
Replenish
Loosen fan belt
Adjust
Worn or defective fan belt
Replace
Defective thermostat
Replace
Defective water pump
Replace
Clogged
or
leaky radiator
Flush
fan belt
repair
or
replace
Defective radiator filler cap
Replace
Air
Retighten each part of
cooling system
mixing
into
cooling system
Improper grade engine oil
Incorrect
ignition timing
Replace with
grade oil
proper
Adjust
Defective carburetor lean mixture
Overhaul carbureior
Overcooling
Defective thermostat
Replace
Others
Low octane fuel
Replace
with
specified
octane fuel
Improper
tire pressure
ET
9
Make
specified pressure
ENGINE
Dragging brake
Adjust
Clutch slipping
Adjust
NOISY ENGINE
Car knocking
Overloading
to
Use
engine
in driv
right gear
ing
Carbon knocking
Disassemble
head
cylinder
and
remove
carbon
Timing knocking
Adjust ignition timing
knocking
Fuel
Use
specified
octane
specified
spark
fuel
Preignition misusing of spark ping
Use
plug
Mechanical knocking
Crankshaft bearing
knocking
This strong dull noise increases when the
accelerated
is
engine
place
cause
misfire
a
If the noise stops
by
locate
To
on
the
each cylinder
the misfire
this
cyl
inder generates the noise
This
caused
is
worn or
ings
or
by the
damaged bear
unevenly worn
Renew the
crankshaft
and adjust
bearings
or
change the crankshaft
Check
the
lubrication
system
Connecting rod bear
This
ing knocking
the
is
little
Cause
a
knocking
misfire
noise
and
also
in
Same
as
the
case
of
crankshaft bearings
each cylinder and if
on
deminishes
crankshaft
this
noise than
higher pitched
when the engine is accelerated
creases
the
a
crankshaft
almost
bearing
completely
generates
the
noise
Piston and cylinder
When
noise
noise
the
you
hear
revolution
decreases
this
an
which Increases
noise
on
and
the engine
which
the
is
To
cylinder
misfire
as
of
overlapping metalic
its magnitude with
each
engine is warmed up
caused by the piston and
locate
the
place
cause
a
cylinder
This
may cause
normal
wearing
and
cylinder
compression
an
ab
of the
lower
which
in
turn will cause a lower
out
put
cessive
power
and
ex
consumption of
oil
Overhaul the engine
Piston pin noise
This
noise
is
heard at each
highest
and
lowest dead end of the piston
To locate
the place
each cyl
cause
a
misfire
on
This may
cause a wear
the piston pin
piston pin hole
on
inder
Renew
the
piston
piston pin assembly
ET IO
or
and
ENGINE TUNE UP
Water pump noise
This
may be caused
noise
damaged bearings
face of sliding parts
Others
An
by
by the
or
Replace the
uneven sur
with a new one
of
adjustment
improper
the worn or
the
valve
water pump
Adjust
clearance
Noise of the
tension
the
Adjust
timing chain
of
the chain
An
excessive end
Remarks
and this
on
Disengage the
noise will stop
Wear on the clutch
Remarks
play
This
the clutch is
the crankshaft
clutch
slightly
and
noise will be heard when
engine
the
renew
main
bearing bush
Renew
pilot bush
the
Dismantle
adjust
bush
the
and
the drive shaft
disengaged
ABNORMAL COMBUSTION
back fire
run
on
after fire
etc
Improper ignition timing
Adjust the ignition
ing
Improper ignition timing
Improper
heat
range of the spark plugs
Use
specified
tim
spark
plugs
Fuel system in trouble
Damaged
back fire
carburetor
manifold
or
gasket
after fire
Replace Ibem with
new
parts
Defective carburetor jet
the carbure
Dismantle
tor and check it
Improper
the level
Adjust
function of the float
and
check the needle valve
Uneven
Defective cylinder head
etc
Adjust
idling
Adjust
Improperly adjusted valve clearance
Excess
in
carbon
Ibe
combustion
Remove
the
head
and
get rid of the carbon
chamber
Damaged
it
valve
back fire
spring
fire
after
Replace
it
with
a new
one
EXCESSIVE OIL
CONSUMPTION
Oil leakage
Loose oil
Loose or
Tighten it
drain plug
damaged
oil pan
gasket
Renew
tighten
Loose or
damaged
chain
cover
gasket
Renew
tighten
ET
ll
Ibe
gasket
or
gasket
or
it
Ibe
it
ENGINE
Defective
oil
seal
in front
and
rear
of
Renew the oil seal
the crankshaft
Loose
or
damaged locker
cover
gasket
the
Renew
gasket
it
tighten
or
but not too
much
Improper tightening
Renew
of oil filter
the
tighten
gasket
and
with the pro
it
per torque
Loose
or
damaged oil
pressure
switch
Renew the oil
switch
Excessive oil consumption
Cylinder and piston
Overhaul
wear
and
Improper
location of
the
ring split
or
or
seizure of
the
cylinder
the
renew
Remount
it
piston
piston
the
rings
reversed assembly of it
Damage
pressure
tighten
or
Renew the
rings
Repair
rings
or
renew
the
piston and cylinder
Wear of
piston ring groove and rings
the
Renew
piston and
piston ring
Fatigue
of valve oil
seal lip
the
Replace
seal
lip
with a new one
Wear of valve
Renew the valve or the
stem
guide
In
Others
oil
mentioned
Previously
Engine overheat
POOR
designated
Use the
adequate quality of engine oil
FUEL ECONOMY
See the explanation
of the powet dectease
Exceeding idling
Others
Adjust
revolution
it
to
the desig
nated rpm
Adjust
Defective acceleration recovery
Fuel
it
Repair
leakage
or
connection
tighten
of
the
fuel
pipes
TROUBLE
IN
OTHER
FUNCTIONS
Decreased oil pressure
designated
Inadequate oil quality
Use the
Overheat
Previously
Defective
function of oil
pump
regulator
Dismantle
and
valve
ET l2
repair
oil
mentioned
the oil pump
or renew
it
ENGINE TUNE UP
Functional deterioration of oil pump
Repair
with
it
Renew it
Blocked oil filter
Increased
replace
or
new one
in
clearance
various
sliding
Dismantle
the
parts
and replace
parts with new
worn
ones
Blocked oil strainer
Clean it
Trouble in the oil gauge pressure switch
Replace
it
with
a
new
one
Excessive
wearon
the
Oil pressure decrease
Previously
mentioned
Exchange
the oil
sliding parts
Defective
quality
or
contamination of oil
proper one and
the element
Defective air cleaner
Change the element
Overheat
Previously
or
overcoal
Check the fuel
Decrease of oil pressure
Previously
Too small clearances
Reassemble
Overheat
Improper fuel
mixture
SERVICE JOURNAL OR BULLETIN
DATE
JOURNAL
BULLETIN
mentioned
Improper fuel mixture
Principally to cylinder walls
Seizure of sliding parts
or
No
PAGE
ET 13
sys tem
mentioned
with
the
designated
clearances
Previously
mentioned
Check the fuel
REFERENCE
SUBJECT
No
witI1
change
system
ENGINE
SERVICE JOURNAL OR BULLETIN
DATE
JOURNAL or
BULLETIN No
PAGE
No
REFERENCE
SUBJECT
ET 14
i
DATSUN
1800
I
SE RYICE
MANUAL
MODEL
I
t
r
SECTION
EM
ENGINE
MECHANICAL
G11
II
ENGINE
EM
1
ENGINE DISASSEMBLY
EM
5
INSPECTION AND REPAIR
EM
B
ENGINE ASSEMBLY
EM 22
SERVICE DATA AND SPECIFICATIONS
EM 31
TROUBLE DIAGNOSES AND CORRECTIONS
EM 36
GENERAL DESCRIPTION
NISSAN MOTOR CO
TOKYO
JAPAN
LTD
y
ENGINE MECHANICAL
GENERAL DESCRIPTION
CONTENTS
G18 ENGINE
EM l
CYLINDER HEAD
EM 3
CYLINDER BLOCK
EM 2
CAMSHAFT
EM 3
CRANKSHAFT
EM 2
VALVES AND VALVE ROCKER ARMS
EM 3
PISTONS AND CONNECTING RODS
EM 2
CAMSHAFT DRIVE SYSTEM
4
EM
MANIFOLDS
4
EM
G 18 ENGINE
The G 18 engine
stroke
is
85 x 80 mm 3
house with 1
815 c c
a
short stroke
346
x
3
110 8 c
150 in
1
bore
J
aluminum
x
SAE
displacement
maximum
From low to
by adoption of
new
mechanisms
such
fig
EM
as
tions
are
a
easily performed
cross
Gasoline with
standard octane value of 88 is used
an
Sectional view
EM
head which has
V
shaped valve layout a single
overhead camshaft and five journal crankshaft
It is sufficiently durable at high continuous
speeds and maintenance and inspection opera
output is 105HP at 5 600 rpm
this engine
high speeds
excellement
made
exhibits
performance
possible
and its
alloy cylinder
flow ports and
power
l
of G 18 engine
a
ENGINE
Oil sealing at the front end is
journal 112
accomplished by a lip type oil seal made of
highly durable acryl rubber and a flinger and
CYLINDER BLOCK
on
The
cylinder block is a special monoblock
casting with deep skirts and five bearing
support system
Rigidity is high and resist
ance
to
wear
excellent
Coolant
is
at the
rear
end by
means
of a graphite jute oil
seal
forced
through the space between cylinders to maintain
uniform
The
cylinder block temperature
passage for oil from the cylinder head is located
PISTONS AND
CONNECTING RODS
at the rear portion
The piston
is oval in
crown
is
full
a
cast aluminum
cross
slits
alloy
The piston
flat surfaced except for the cutout for
valves
and
made of
shape with
The piston pin is made of special steel
carburizing heat treatment
floating
system is used
rod to
connecting
the
is
piston and
A
applied
for
fitting
the
circlip
a
used at each end to limit the travel of the
is
piston
pin
oil
There
are
ring
The compression ring has
two
compression rings and one
a tapered
face and the entire surface is
plated with hard
improve the resistance to wear The
oil ring is equipped with a coil expander which
chrome to
boosts tension and functions to block the down
Fig
EM 2
Cylinder
flow of oil
block
The
during high speed operation
connecting rods are made of forged
carbon steel
ample strength
ing operation
CRANKSHAFT
The crankshaft is
is
provided with five
forging and
beariug journals and four
a
As
balancing weights
high rigidity and there
surfaces of the main
and the
carbon steel
a
result
are
weight
both the large
Bearings
it possesses
is little vibration
journals
located at
metal
The
I
are
cross
section
provides
To insure
made
good balancing
adjusting bosses
of three layer kelmet
and bushings of lead bronze with steel
backing
hardened by
o
tl
EM 3
Crankshaft
Fig
EM
2
are
and small ends
high frequency induction improving the resist
ance
to
wear
Highly durable threelayer
kelmet metal is used for main bearings
The
thrust bearings made of aluminum are located
Fig
dur
EM 4 futon and
connecting
rod
ENGINE MECHANICAL
The die cast aluminum alloy
cylinder
head
and results in
produces good cooling effects
excellent
and
strength
lightweight
qualities and
smooth combustion
Valve
chamber surfaces
is
layout
shaped and symmetrical
V
for intake and exhaust
used to obtain
good
Valve seats
cy
Cross flow ports are
intake and exhaust efficien
are
camshaft
The
CYLINDER HEAD
cast into the
cylinder head
is
special alloy casting
a
which has excellent resistance to
chill
are
plied
to
rocker
Lobes
wear
hardened and lubrite processing ap
obtain
arm
good
operation
Five
and camshaft
between
the
journals
are
employed and they receive the thrust by the
Bolts
front flange and cylinder head groove
with
threads
left hand
sprocket
are
used
to
attach
a
and the distributor drive gear to the
end of the camshaft
and special iron is used for intake valve seats
and 1113
chrome steel for exhaust valve seats
tos
cylinder head and cap surfaces are used
bearings without modification
The cylinder head gasket is made of asbes
which contains a steel net and is protected
by
a
Both
for camshaft
stainless steel grommet
VALVES AND VALVE
ROCKER ARMS
giving excellent
gas sealing effects
located
A rocker arm shaft is
of the camshaft
made
steel
of heat resistant
resistant steel is
on
each side
Intake and exhaust valves
Special
are
heat
used for the head of exhaust
valves and stellite is used for the valve seats
improving the resistance
temperature and speed
to wear a
A dual
high engine
valve spring
system is used to elevate the characteristic
frequency of the springs and insure the opening
The valve
and closing of valves at high speed
oil seal ring located at the top of the valve guide
blocks the downflow of oil
The rocker
arms
To im
special forged steel
prove resistance to wear tOughtelite processing
contact
surfaces
after
is
cam
applied to
are
Fig
EM S
made from
Lubrication is
carburizing heat treatment
oil
from
the jet in the
ejected
accomplished by
Cylinder head
stem of the rocker arm
CAMSHAFT
rf
rf1y
7
f
A
o
i
o
I
1
O
1
i
ff
f
Fig
EM 6
Camshaft
Fig
EM 3
EM
Rocker
arm
ENGINE
MANIFOLDS
The
intake
manifold
is
made
of
aluminum
alloy and is located on the right side of the
Coolant from the rear of the cylinder
engine
head
0 CJ
e nlJl
fJllll0
II
passes
intake
through
manifold
the riser portion of the
heating
this
portion
and is
returned to the water pump
0
The
o
No
o
grouped
I
exhaust manifold is made of cast iron
I No
4
and
together
No
2 No
The
3
cylinders
semi duel
are
system
which combines exhaust gas flow at the point of
exhaust pipe connection produces good exhaust
ing efficiency
EM 8 Valve
Fig
An oiled sheet is used for the intake
gasket
and steel filled asbestos for the exhaust
gasket
CAMSHAFT DRIVE SYSTEM
The camshaft is driven from the crankshaft
by
double
a
endless
row
reduction ratio of 2
ment
is
means
chain
1
accomplished
of the
adjusting
A
cover
The
chain
from
the outside
screw
at
a
and
by
attached to the
chain stop is located
chain tensioning end
vibration
roller
Chain tension adjust
serves
on
the
to eliminate
oil
jet at the top part of the
crank
sprocket provides active lubrication
holding chain elongation and sprocket wear to a
minimum
Fig
EM 1O Intake
Fig
EM ll Exhaust
manifold
oe
lie
6
Fig
EM 9
Camshaft
drive system
EM
4
manifold
ENGINE MECHANICAL
ENGINE DISASSEMBLY
CONTENTS
CLEANING AND INSPECTING
EM 5
DISASSEMBLY
EM 5
Disassembly of piston and connect
ing rod assembly
Disassembly of cylinder head assembly
EM 7
EM 7
CLEANING AND INSPECTING
Wash
thoroughly
the engine
Before washing
sembly
the alterna
and plug up the
starter
distributor and
tor
before disas
remove
carburetor airhorn to avoid any infiltration of
foreign
1
matter
The exterior of the
2
jacket
rust
Check
Cylinder block
Check the
engine
and bolts for breakage
covers
damage and loss
thoroughly
the water
for cracks and breakage
3
Clutch housing
4
Oil pan
Check for cracks
Fig
EM 12
Placing engine
engine stand
on
the
Check for excessive rust
6
Remove the clutch
7
Remove
the exhaust manifold and heat baffle
plate
DISASSEMBL Y
engine with transmission is placed on
engine carrier ST49770000 now
The disassembly procedure begins from this
The
the
condition
1 Remove the transmission
2
Disconnect
the
vacuum
the intake manifold water hose
hose
and
intake
manifold
to
oil
separator hose
3
Remove intake manifold with carburetor
Fig
4
Install the
engine
attachment
STa7200G18
Place the engine
8
Remove
remove
on
the engine stand
Removing
to
the cylinder block
5
EM 13
9
ST371
the fan blades
the water pump
Remove
the
heat hose and
00000
EM
5
rocker
exhaust
wnifold
At the
same
time
pulley and fan belt
cover
bypass hoses
hose
manifold
ENGINE
10
the
Remove
bracket
generator
and
oil
filter
11
Ing
Note Mounting bolts have left hand threads
the breather assembly by extract
Remove
from
upward
fitted to the guide
above
The
breather
take off the
removing the distributor drive gear
sprocket from the camshaft
is
with O ring pressed into the
16
cylinder block
Note
Remove the
cylinder head
assembly
as an
In addition to ten cylinder head bolts
6
two
are
chain
cover
mm
there
bolts fixing the
0 2362 in
the cylinder head
to
ff4lII
if
W IItf
1
r
c
if
f
t
y
t
0
Z
1Jtl
I
J
Fig
12
Remove
adjusting
EM 14 Breather
the water pump
arm
a
embly
v
and then pull out the crank pulley
washer
and
unscrew
puller
so
17
18
that it hooks in the
Remove the rocker cover
rubber
head
Turn
the engine upside down and
remove
Remove
the chain cover and remove the oil
flinger
V lIroove
the
Removing cylinder
the oil pan
ST44820llOO
Do not fit the puller
Remove
I
the
Note When the crank pulley cannot be easily removed
front
EM 16
Fig
nut
15
I
The generator
Flatten the lock
14
r
t
is removed at the same time
13
use 8
I
19
plug located
portion of the cylinder
head
on
Remove
the nut which holds the oil pump
sprocket in place
the chain in place
sprocket
the
Straighten
the locking washer of the camshaft bolt fixing
Pullout this sprocket
on
the distributor drive gear and camshaft sprocket
After
the camshaft and remove the bolt
to
Fig
EM IS
Removing camshaft sprocket
Fig
EM
6
EM 17
with
the crankshaft oil pump
Removing oil
pump
sprocket
ENGINE MECHANICAL
20
Remove the oil
removing
pump without
together with
the strainer
Note Two of the oil
mounting bolt
are
pipe
gu ides
timing chain
21
Remove the
22
Remove the crankshaft
23
Remove the chain tensioner and chain
24
Remove
and
assembly
rod
connecting
pump
piston
Disassembly of piston and
1
Remove the
piston rings
2
Remove the
piston pin clips
3
Pull out the piston pin
sprocket
connecting
stop
rod
as
semblies
Note
Keep
avoid
the
the
parts
for
cylinder arrangement
possibility
of
confusion
when
to
re
installing
EM I9
Fig
Removing puton pin
piston to 50 to 60 C
before extracting the piston pin
Hest
the
Note Make
sure
together
that disassembled
to preserve the
Disassembly
of
122 to
140 F
are
grouped
parts
original order
cylinder
assembly
1
Remove
and
the
rocker
camshaft
arm
head by removing
Fig
25
EM 18
Remove the
Removing puton assembly
Remove
and No
flywheel
Note
bearing
Do not hurt
or
bracket clamping nuts
5 bracket holes since the
fall from
damage the pipe guides since
cam
1
bracket
the rocker ann shaft when it
2
Remove the camshaft
3
Remove the cotters
and
ST47450000
Remove
shafts
is
removed
caps
positioning is accomplished by them
27
cam
arm
from the cylinder
Note Disused bolts should be inserted in the No
will
26
rocker
assemblies
the crankshaft and detach the main
springs
by using the special tool
disassemble
valves
and retainers
bearings
Note
Make
sure
that
bearings
are
grouped
to preserve
the original order
Note Make
sure
together
EM 7
that disassemble parts
to preserve the
are
original order
grouped
ENGINE
Fig
EM 20
Removing
rocker
assembty
Fig
EM 21
Removing valve pring
INSPECTION AND REPAIR
CONTENTS
PREPARATION FOR
INSPECTION
EM
B
EM
B
PISTON
Checking head mating face
Valve assembly
EM
B
CONNECTING ROD
EM
17
EM
9
CRANKSHAFT
EM
17
Valve
EM
9
BUSHING AND BEARINGS
EM 19
CYLINDER HEAD AND VALVES
springs
Boring of cylinder
EM
PISTON PIN AND PISTON RING
14
EM 15
Rocker arin and valve rocker pivot
EM l0
Measurement of main bearing
Valve
EM l0
clearance
EM 12
Measurement of connecting rod
CAMSHAFT AND CAMSHAFT BEARINGS
EM 12
bearing clearance
EM 19
Camshaft bearing clearance check
EM 12
Fitting bearings
EM 20
Valve timing check
EM 13
MISCELLANEOUS COMPONENTS
Camshaft alignment
EM 13
Crankshaft sprocket camshaft
EM 14
sprocket
EM 21
EM 14
Chain tensioner and chain guide
EM 21
Flywheel
EM 21
guide
Valve seat insert
check
CYLINDER BLOCK
How
to measure
cylinder
bore
PREPARATION FOR INSPECTION
1
Check the
cylinder head and the
block for traces of water leaks before
4
material
blowing
if all
the
oil holes
are
caustion
to
secure
proper
as
sembly
cylinder
Wash all the parts to clean them completely
of oil strains carbon deposits fur and sealing
Ascertain
every
EM 21
cleaning
2
3
Use
EM 19
CYLINDER HEAD AND VALVES
Checking
clear by
air into them
head
mating
1
Make
2
Measure the surface of the cylinder head
a
visual check for cracks and flaws
the cylinder block side
EM
8
face
for warping
If it
on
is
ENGINE MECHANICAL
found to be
the limit
beyond
affected
regrind the
grinder
designated below
surface
with
a
surface
lnab
99
t
o
o
3JI
0 2
1099
151
us 4
116
O
1
4
ull
Ext
8
f9
L
0 5
o
llo
015
11S
1I7
The
valve
face
EM 22
Checking
surface
the
0
valve grinder
Maximum
Less than 0 03 mm
sur
face flatness
a
cylinder head
Standard
Head
2
valve stem end surface
or
should be refaced by using
Fig
4
tO 1
7
EM 24 Intake and exhaust valve
Fig
2
2O 2
0012 in
0
0
1 mm
0039 in
Valve assembly
1
Check each of the intake and exhaust valve
assemblies
for
valve heads
or
valve
worn
stems
damaged
or
Correct or
if any excessive defects
are
deformed
replace
the
defected
EM 2S Valve
Fig
Note When
05
the
mm
valve
head
0 0197 in
or
grinder
has
been
reduced
to
less in thickness replace
the valve
Grinding
allowance
surface is 0 5
Valve
1
spring
the
EM 23
Checking
valve stem diameter
EM
9
0 0197 in
valve
or
stem
end
less
free length and the tension of
If the
the specified limit
Fig
the
spring
Measure
each
mm
for
measured
valve exceeds
replace the spring
ENGINE
Outer
Free
length
37
Valve closed
42 5 mm
41 4 mm
1 673 in
1 630 in
0 mm at 19 4
1 457 in
1 142 in
1 0
8 2
at 42
29 0 mm at 47
Valve open
Inner
6
kg
34 0 mm at 10 8
2 lb
2 4
at 23
26 0
at 22 5
kg
9 5 3 lb
at 104
1 339 in
1
mm
024 in
0
8
at 49
5
kg
1 1 lb
1 1
6 2
kg
4 lb
Check the deformation of each spring with a
Any springs with the deflection of 1 6
square
2
0 0630 in
mm
or more
must be
replaced
o
48
CDll
CIt
1
0
1
C
00
16 7
Q
Q
Q
N
EM 27 Guide intake
Fig
over
size
ci
CDll
60
Fig
Rocker
EM 26
arm
Checking
and
valve
spring
valve rocker
pivot
Check the valve rocker adjusting
the
cam
are
found replace them
contact for
damage
screws
and
If defects
or wear
Fig
EM 28 Guide exhaust
Intake valve
Valve
guides
Measure
guide
and
or
case
it
clearance
the valve
exceed the
parts
0
the
designated
stem
limit
between
the valve
Stem to
If the
clearance
clearance
replace
both valves and valve guide
is
clearance
valve stem
essential
has
or
to
been caused by
by
a worn
the worn
a worn or
Max
a
bent
clearance
valve guides
EM
lO
055
0 0010
tolerance
of above
0
size
Exhaust valve
0
04
mm
o
In this
determine it such
025
guide
aver
0
0
1 mm
0039 in
0016
o
0022 in
0
0
0 077
mm
0
0030 in
1 mm
0039 in
ENGINE MECHANICAL
Determining clearance
Precise measurement of clearance between
the valve
and the
stem
valve guide needs
the
aid of a micrometer and a telescope hole gauge
By using these gauge check the diameter of the
valve stem
places
in three
center and bottom
telescope hole gauge
bore
measuring at center
highest reading of valve stem
Inspect
valve
ance
bore
from
the two
gency expendient
guide and moved
which
point
exceeds
the
from
center diameter to
As
a
obtain
an
emer
valve is pushed in the valve
the
to
and the
left
right
at
tip deflects about 0 2 mm
it will be known that the
more
if its
0 0079 in
or
the
between
clearance
guide
diameter
valve guide clearance
to
valve
Subtract
measured to obtain its clear
guide
valve
in
stem
and
maxtmum limit of O
the
1
FM 30
0
0039
2
in
cylinder
Ream
temperature using
Note The
valve
rocker
the
of
should
moved
Generally
arm
wear occurs
be
Fitting valve guide
guide
the
mm
Fig
in
parallel with
a
large
head
side
reamer
hole at
guide
set
amount
02 mm
in this direction
0 0079 in
Standard
over
Replacement of valve guide
A
placed
1
valve guide found defective must
in the
Take
out the
and valve
a
2 ton
old
be
14 0
guide by
set
means
14 2
Cylinder head
14 018 mm
14
valve
0
0
guide
hole
551
o
of a press
ST49730000
siz e
re
manner
guide replacer
218
mm
559
552 in
o 560 in
under
be carried
This job may
temperatures but with better effect
pressure
out at room
at
following
room
ST49710000
Press the new valve
3
higher temperature
witb care
the
176
F
to
valve guides
The
into the
guide
hole
temperature of about
using valve guide replacer
cyiinder head
800 C
guide
will fit smoothly after heat
so that it
a
of 0 2
mm
0 0079 in
oversize diameter are available for service
Interference fit of
valve
guide
to
o
0
040
valve guide hole
4
fig
f M 29
Rf
ofJiflg
valve
Ream
using
guid
EM
ll
a
0
069 mm
o
0027 in
0016
the bore of the valve guide pressed in
valve guide
reamer
set
ENGINE
wide
intake
scrape
haust side 15
side by 150
60
and
ex
in order to
get prescribed width
After finishing
the correction
complete
the valve contact to the valve seat by doing lap
ping
Exhaust
a
Fig
EM 31
valve
Reaming
guide
Reaming
reamer
bore
8
set
ST497l0000
000 to 8
0
015
as
with the
Note As
the axis
EM 33 Dimension for seat correction
the
Check the valve seat inserts for any
of pitting at valve contact surface
seat
if
inserts
the
and
valve
seat
that
this
engine
are
replace
bearing clearance check
Check the
of some deformation of
pitching
are
the valve seat by
a
valve seat
cutter
plastigage
If the
scrape the seat by 450
cutter
after
clearance by measuring the dif
ference of the camshaft bearing inner diameter
and camshaft journal outer diameter or by using
ST49720000
Firstly
of
excessively
found at the valve contacting face of valve seat
correct
inserts
CAMSHAFT AND CAMSHAFT
BEARINGS
Camshaft
case
seat
evi
Valve seat correction
In
valve
into cylinder head by casting
ment of the valve seat cannot be done
dence
insert is worn out
3
new
Valve seat insert
valve
8
c
united
reseat
346
3150 to 0 3156 in
Correct the valve seat surface
valve guide
1
mm
Fig
5
8
b
e
Valve guide
316
wear
outruns
the limit
replace
as
the cylinder head assembly
if the width of the contacting face is too
0
Tightening torque
9 to 1 4
kg
m
6 5 to 10 1 ft lb
Standard
Wear limit
O 025
Clearance
0 075
0
o 0030 in
37
Camshaft
bearing
inner diameter
5
37
1 476
1
Fig
EM 32
Correcting
valve seat
477 in
45
1
474
Camshaft journal
outer diameter
525 mm
37
37
475 mm
1 475 in
EM
12
0
mm
0010
0
1 mm
0039 in
ENGINE MECHANICAL
Valve
timing check
If the camshaft shown
althougr
been
no apparent damage
operation troubles have
valve
some
the
in
detected
engine
compare
valve
timing data with the valve timing diagram to
see
whether the stroke beginning and end in various
cylinders
are
and retard
complying
with
specified advance
figures
Fig
EM 3S
bend
Checking camshaft
Valve rocker
Check the
valve
contacting surface
rocker
for
cracks
between
clearance
cam
rocker
shaft and etc
Fig
EM 34
Valve
Replace if
timing dingrom
If
wear
or
surface
I
GI8
I
I
2 0
b
250
58
Unit
found
are
found at
is
valve
the
replace
contacting
cam
In
rocker
heels of camshaft at the
case
check cam
time
Slight damages
of the valve
degrees
cracks
same
nibble
at cam
rocker and
cam
this
same
contacting surface
heel
can
be
cor
rected by oil stone
In
Camshaft
1
alignment check
CheCK the
cam
camshaft
surface for bend
defects
the
beyond
are
damage
limits
of clearance of rocker
rocker bushings
camshaft journal
wear or
case
and
is
excessive
shaft
replace the
and
worn
part
If the
replace
the
affected parts
Bend values
to the center
are
Clearance of
and
Standard
36 53
mm
1 438 in
rocker
O
0 01 mm
0 0004 in
0
mm
Rocker shaft
1 4l7in l
0020 in
17
0
O 03 mm
584 mm
6915
o
6922 in
0012 in
17 6
0
End play
07
Bushing
O 148 mm
0
inner
diameter
0028
17
0
EM
13
618
mill
693
o
o 0058 in
0 07
mm
0 0028 in
17 566
36 0 mm
0
052
0006
o
bushing
Limit
outer diameter
Camshaft bend
0 016
rocker shaft
journal
Cam height
Wear limit
Standard
expressed in terms of half
values of the readings obtained when the cam
shaft is given a turn with a dial gauge applied
2
694 in
ENGINE
CYLINDER BLOCK
1
Check visually
for
defects
such
as
cracks
10mm
and flaws
2
Measure the top face of the block
head
mating face
for warping
llit value
li
correct it
ceeds the
J
cylinder
If the warp
EB
ex
Fig
EM 37
Cylinder
bore
measuring position
Standard
0
035
0
mm
85 000
Cylinder bore
3
347
0014
Limit
0
0
2 mm
0079 in
0 in
Fig
EM 36
Checking cylinder
block
flatness
0
Ellipse taper
Standard
Difference of
Limit
0
each four
Less than
Surface flatness
0
0
3
or
cessive
tected
walls
4
wear
on
by
taper with
the
a
inder
If ex
taper and out of round
to the
limit
remove
are
the step at
gauge is
at
a
the like
measure
bore
in each
mm
machine
wear
reamer or
A bore
2
0079 in
in
the topmost portion of the cylinder by using
How to
0
are de
taper
cylinder wall rebore the cylinder
not excessive
ridge
0
05 mm
0020 in
for out of round
bore gauge
out of round
a
or
boring
When the
0
cylinder bore
10 mm
00039
0012 in
Measure the cylinder bore
excessive
O
03mm
02 mm
0008 in
0
top
direction A
cylinder bore
used
Measure the
middle
and
and B
as
Fig
cylinder
bore
Measuring cylinder bore
bottom points
illustrated and
record the measured values
Wear of the
EM 38
cyl
Boring of cylinder
1 When
is the
differehce
of the maximum and minimum value
other
time
EM
l4
any of the
cylinders
cylinders needs boring
must
be bored at
the
all
same
ENGINE MECHANICAL
2
Determine piston
oversIze
amount of wear of the
according
to
the
4
cylinder
Machine the cylinder bore
to
the determined
inner diameter
Note To prevent strain due to cutting heat bore the
Pis ton for service
Piston size
5
Outer diameter
Do not cut too much out of the
but cut 0 05
at a time
84 958
S T D
3
84 990 mm
345
3
85 220
250 S
85 470
750
3
7
S
125 0 S
85 970
85 990 mm
3 3846
3
86 220
86 240 mm
3
394
of
the
cylinder
care
bore
just
since it
is
Finish the treated cylinder bore
to
a
final
376 in
8
100 0
Measurement
finish bore by honing
85 740 mm
3 375
or so
expanded by cutting heat
3 366 in
85 720
S
6
machined requires the utmost
85 490 mm
3 365
cylinder bore
0020 in
346 in
3 356 in
S
0
mm
at a time
85 240 mm
355
3
500
of 2 4 1 3
cylinders in the order
Measure
liptic
or
3854 in
the finished cylinder bore
for el
tapered part
Note If the cylinder bore has
limit
use
3 395 in
worn
beyond
the wear
the cylinder liner
Undersize cylinder liners are available for service
Interference
fit of cylinder
block 0 08 to 0 09
3
By measuring piston
skirt side thrust face
to be installed at
and
clearance specification
adding
the
to
cylinder
piston
wear
the finish hone
iiner
0 0031 to 0 0035 in
mm
of
Cylinder
cylinder
liner for service
measurement can be determined
Outside diameter
400 U S
89 091
3
507
Inside diameter
89 126mm
83 5
84 5 mm
509 in
3287
3 327 in
3
PISTON PISTON PIN AND
PISTON RING
1
Check for seizing
Effect
a
scratches and wear
replacement when
such
a
defect
detected
G
Fig
Cylinder
EM 39
Measuring puton
bore to be treated
o 015 to 0 035 mm
0
dwmeter
A
Outer diameter of piston skirt
A
Piston
O
cylinder
clearance
mm
Hornning
allowance
B
C
A
0006 to 0 0014 in
C
B
030 to 0 050
0 0014 to 0
O 02 mm
0022 in
0 0008 in
Fig
EM
15
EM 40 futon
a
sembly
is
ENGINE
2
Measure the side clearance of rings in ring
Clearance
groove as each ring is installed
with
new
pistons and rings should be
as
follows
Fig
Note
a
EM 42
When the piston ring only is to be replaced
without
Fig
EM 41
ide
Measuring
measure
earonce
c
the cylinder
0 04
008mm
0 0016
002
0
0031 in
006mm
0
0008
0024 in
006mm
002
ring
0
0 0008
0
ailable for service
are
125 oversize
Limit
4
Oil
in minor
25 50 75 100
Standard
Second ring
wear
b Oversize piston rings
Side clearance
bore being corrected
the gap at the bottom of the cylinder
where the
Top ring
MetUuring ring gap
0
Imm
0
0039 in
o
Imm
0
0
relation to
in
pin If wear exceed
ing the limit is indicated replace such piston
pin together with the piston on which it is in
stalled
0039 in
01
0024 in
Measure the piston pin hole
the outer diameter of the
mm
0039 in
Standard
Interference fit
of piston pin
to
Ring gap
0
o
09
Limit
mm
0
pis ton
o
0035 in
Clearance
o
005 mm
0
0002 in
Clearance be
Standard
0 35
Top ring
0
055
0
0138
Limit
10
mm
0217 in
0
tween
pis ton
pin and con
nee ting rod
mm
0394 in
0 006
0
0 0l3mm
003mm
0002
o 0005 in
bushing
Second ring
o
3
0
0118
05 mm
1 0mm
0 0197 in
0
Piston
0394 in
2l 99l
pin
0
outer
o 35
Oil ring
0
0
0138
55 mm
0
1 0 mm
0217 in
0
diameter
o
Place
the ring
at
the
bottom
of the
ring
traveled part of cylinder bore in which it will
be used
Square ring in bore by pushing it into
position with
Measure
the
feeler gauge
the head
gap
between ends
as
of ring
listed
with
21987
Connecting
rod
21995
inner
diameter
EM 16
22 008
mm
0 8659
o
above
210mm
0 827
O 866 in
piston
bushing
piston
Gap should be
8661 in
0394 in
Piston pin hole
diameter of
3
22 Omm
8658
8664 in
0
0012 in
ENGINE MECHANICAL
CONNECTING ROD
1 If a connecting rod has any flaw within the
both sides of the thrust face and the big end
correct or
replace
it
Fig
44
EM
end end
Checking big
play
CRANKSHAFT
1
Check the
scars
biased
Repair
or
shaft journal
wear
and
2
EJI1 43
Check for bend
limit
correct
or
a
torsion
or
replace
for
o1
aligner
torsion using
or
If bends
ing rod aligner
the
Connecting
rod
pin
replace affected parts
UO
Fig
crank
and cracks
the
connect
exceeds
connecting
rod
Standard
0
110
0
0043
0
Big end end play
o
mm
100 mID
0
0 3
Fig
0 0118 in
0097 in
o 05mm
Torsion bend
per
246
Limit
0020 in
EM 4S Dimension
for crankshaft
measurement
Measurement of taper and out or round
Measure A B
0 Imm
0
Figure
0039 in
EM
46 by
or
a
X Y direction shown
in the
micrometer
y
x
3
In
rod
so
rods
oz
4
the
replacing
A
the
connecting rod select the
that the weight diference between new
and old
one
become within 6 gr
A
B
B
1
0 212
in unit weight
Install
connecting rods with bearing on to
crank pins and measure the
corresponding
thrust clearance
ceed the limit
If
the measured value
replace such connecting
ex
rod
Fig
EM
17
EM 46
Measuring point for crankshaft
ENGINE
Difference hetween A and B
Taper
Out of round
Difference between X and Y
Standard
Less than
Out of
Taper
Limit
o 01
round
mm
003mm
0 0004 in
0 0012 in
Check the crankshaft for bend
2
If the bend
specified value repair
the
exceeds
or
replace
the crankshaft
Fig
EM 48
Checking cronk haft
end
play
Wear limit
Standard
o 060
o
C rankshalt
end
0
play
192
03
mm
0024
0
mm
0118 in
o 0076 in
5
Check the main drive shaft pilot bearing
the
rear
Replace
of the crankshaft for
it
if
pilot bearing
Fig
EM 47
Checking cronkshaft
bend
tool
EM
defects
any
can
ST49700000
are
be removed
as
at
and damage
detected
The
wear
by using special
Figure
illustrated in the
49
clean
installing the pilot bearing
bearing hole and apply oil to the bearing
Before
Standard
Maximum
outer side then press the
Less than
C rank shaft
o
bend
03 mm
o
0 0008 in
Note
For measuring the bend
Bend values
are
half as
0
use
a
the
dial
gauge
05
Alter
a drift
After that
apply multi
0
into the hole
regrinding
bearing
quired repair
4
Install thE
and
the
measure
specified
071 oz
readings
a
its
to
PILOT BEARING
turn
the crankshaft
according
to
in
c
center
finish
the
lis ts
adequate
the
it
f
to
on
under
extent of
re
rl
crank shalt in the cylinder block
the thrust clearance
value
replace the
If it exceeds
center shims
fig
EM
18
into the
purpose grease
Un
the necessary size indicated
page EM 20 and by using an
size
pilot bearing
illustrated in the Figure EM 50 by using
2 grams
jou mal
3
as
dial gauge
much as the
applied
hole
0020 in
obtained when the crankshaft is given
with
the
M l9
I
Removing I ilol
bear llf
ENGINE MECHANICAL
16mm
r
0 236 in
PILOT BEARING
o
Q
t
Apply
Fig
EM SO
grease
Fitting pilot bearing
Note Be
BUSHING AND BEARINGS
of main
Measurement
clearance
1 Check all
tions
melts
2
Wipe off
and burrs
if any defects
oil and
dust
clearonce
by plastigage
turn the crankshaft when the
not to
is inserted
bearing
bearing and bushing for exfolia
scars
sure
plastigage
5
Replace bushings
Checking bearing
EM S2
Fig
are
especially
detected
the
rear
Remove the cap
and
meaure
compressed
the width of the
widest part with
plastigage
printed in the plastigage envelope
before removing it from the crankshaftor bear
ing
the
at its
scale
of
the bushing
Measurement
3
Set the main
bearing
on
of connecting rod
bearing clearance
the cap block
1
Measure
ance
the
connecting rod bearing clear
in the same marmer
4
Tightening torque
5 to 5
0
kg
m
32 6 to 36 2 ft lb
l
SCALE
Bearing oil clearance
Standard
i
Wear limit
OJ
o 03
Main
PLASTIGAG
o
bearing
0
clearance
o
Connecting
Fig
EM Sl
Plastigage
clearance
Cut a
Install the cap
getting clear of the oil hole
and tighten them together under the spec ilied
2
torque
specilied value
Tightening torque
10 to 11
kg
If clearance
sizes and
m
shaft
72 3 to 79 5 It lb
EM
19
mm
o
0
lmm
0039 in
0024 in
o
03
0
0012
rod
bearing
plastigage to the width of the bearing
and place it in parallel with the crank pin
4
06
0012
o 06 mm
o
0
lmm
0039 in
o 0024 in
proves
to be in excess of the
replace the bearing by under
consequently grind out the crank
journal
ENGINE
Fitting bearings
1
Set the
bushings
on
the main
Tighten to the
prescribed torque
cap and
bearing
bearing recess and install the
to
the
cylinder block bearing recess
bearing cap
then tighten the bolts to the specified torque
Main bearing cap tightening torque 10 to 11
the
kg
cylinder
m
block
Release the bolts
aher
tighten to the
prescribed torque
72 3 to 79 5 ft lb
Loosen the cap bolt on one side and Measure
the clearance between the cap and block
2
3
Ascertain that the clearance is
the
figures
the bearing
If
below
listed
it
is
within double
replace
not
Fig
Bearing
4
Handle
the
in
connecting rod bearing
4 5 to 5
kg
m
Standard
crush
bearing
0
bearing
0 04 mm
0
0016 in
tightening torque
0
Connecting rod
32 6 to 36 2 ft lb
0
bearing
Main
crush check
o
Main
cap bolt
Bearing
the
same manner
Connecting rod
M 53
004mm
0016 in
0
under size
Bearing size
Bearing thickness
2 485
S
T D
0
0978
26l2
505 mm
2
0
0986 in
2625mm
Crank journal diameter
55 971
55 990 mm
2
2
55
25 U S
0
50 U
S
75 U
S
100 U
S
Connecting rod bearing
1028
2
737
0
1078
2
862
0
1127
2
987
0
1033 in
2
750 mm
0
1083 in
2 875 mm
0
1132 in
3
1176
000 mm
0
1181 in
Bearing thickness
1 483
1
499
T D
25 U
2
721
2
184
174
2
164
mill
185 in
55 240 mm
54 971
2
195 in
55 490
2
55 221
2
in
55 740 mm
194
55 471
2
2Q43
175 in
54 990 mm
2
165 in
under size
Bearing size
S
0
2Q36
S
0
0584
1
609
1 622 mm
0 0633
1 734
mill
0590 in
0
0
1
0639 in
747
mm
50 US
0
0683
0
EM
0688 in
20
Crank
pin
49 975
1 967
diameter
49 991 mm
1 968 in
49 725
49 741 mm
1 9576
1 9582 in
49 475
49 491
1 9477
1
mm
9483 in
ENGINE MECHANICAL
1 857
872mm
1
0 0731
100 U
S
1
984
0
0781
0
0
1
0737 in
1 997
49 241
49 225
75 US
938
1
48 975
Dim
48 991 mm
1928
0786 in
mill
939 in
1
929 in
MISCELLANEOUS COMPONENTS
Crankshaft
sprocket camshaft
sprocket
defective
Replace
flaws
tooth surface for
1 Check
sprocket
if
and
wears
defects
any
are
found
2
Install the camshaft sprocket in position and
check
o 1
for
mm
run
0
out
0039
in
1f
it
is
found
replace
to
exceed
camshaft
the
sprocket
Fig
Camshaft
EM SS
drive
mechan
m
Flywheel
1 Check the clutch
flywheel
for
disc contact surface of the
damage
and
Repair
wear
or
replace if
2
Measure deviation of the clutch disc
surface with
mm
3
dial
a
0 0039 in
Check
flaws and
Note
necessary
replace
tooth
surfaces
1f
contact
exceeds
Fig
of the
ring
gear
Replace the ring
3560 to 3920F
gear
flywheel
at about
1800
When press the
to
3
Check the chain for damage
stretch at its
roller links
severe wear
Replace
a
Flywheel
Ring
gear
t
chain
J
Chain tensioner and
Check
for
wear
chain
guide
and breakage
Replace
if
Fig
necessarv
EM
2l
EM 56
2000C
pay attention to the direction
and
defective
for
ring gear
run out
camshaft
Checkifl
1
it
of the chamber on the teeth
EM S4
0
Replace if necessary
wear
into the
gauge
it
Fitting ring
gear
ENGINE
Front oil seal
Replace
are
ages
front
oil
seal if oil
found using
front
leaks
oil
or
dam
seal replacer
When install
oil seal
a new
pay attention to the
direction of the oil seal
ST49740000
LJ
i
Fig
EM S7
Replacing
oil seal
Fig
EM S8 Installation
of oil
seal
ENGINE ASSEMBLY
CONTENTS
PRECAUTIONS
EM 22
PISTON AND CONNECTING ROD
EM 24
CYLINDER HEAD
EM 22
ASSEMBLING OF ENGINE
EM 25
PRECAUTIONS
1
Use
thoroughly cleaned parts
check whether oil
holes
are
Particularly
clear
of
foreign
6
Be sure to follow
specified tightening torque
and orders where necessary
matter or not
2
In
installing sliding parts such
proceed after applying engine oil
required
as
to
bearings
them
CYLINDER HEAD
as
1
Set the valve
the
3
Use
new
packings
and oil seals
in
principle
Install
valve stem and
oil
4
valve
spring
put
the
oil
the seal
ring
cover over
the
seal ring
Keep tools and work benches clean and clear
of dust and oil stains
Note
Make
sure
that interference at the oil seal
is trom 0 3 to 0 7
5
position and then
seal ring onto the
seat in
Keep
near
the
necessary
parts
and
tools
ready
0 0118 to
It interference is less than 0 3
at hand
ring
EM
mm
22
or
the
cover
must
be
mm
replaced
ring
00276 in
the oil seal
ENGINE MECHANICAL
Assemble
3
rocker
seat
rocker
shaft
camshaft
the
bracket
valve
and spring on the valve
in the manner shown in Figure
spacer
62
EM
Note
a
The exhaust rocker shaft have the identifica
tion marks
but the intake rocker shaft does
not
b
Both rocker shaft should be assembled so that
hole points to the direction shown in
the oil
Figure
Fig
EM S9
EM 52
Interference of oi seal ring
Assemble the outer and inner valve springs
and retainer and mount the cotter by pressing
2
the
spring with
the
special tool
o
Go
o
0
EM 61
Fig
Rockershaft assembly
To prevent the camshaft bracket slipping
c
out
of the rocker shafts it is advisable to insert
bolts
bolt will do
any
1
of No
and
No
into the bolt holes
5 camshaft
sembly
Fig
EM 60
Assembling
valves
FRONT
REAR
Front
camshaft
bracket
Seat
2
Spring
Camshaft
bracket No
A
I
011 hole
LA
the
Center
camshaft
bracket
l
Install
rocker shaft oil hole
Fig
EH
hown
62 Detail of rocker
EM
3
Spring
B
I
10011
I
Indication mark
On Iront lace of
cker haft
Camshaft
bracket No
23
I
I
Rocker
the
I
Seat
shaft
figure
shaft assembly
Rea
CllmShllft
bracket
brackets
as
ENGINE
4
Mount the camshaft onto the head
valve rocker assembly
At
this time
the
align
the No
Note
nuts
the
punch marks
of the camshaft with the
flange
mount the
and tighten
on
a
piston to a temperature
600C
1220 to 1400F
piston pin can be installed by finger
50
the
the
Heat
of from
to
and
the
mark on
arrow
1 camshaft bracket
Fig
ettin
EM 63
Fig
camshaft
EM 6S
Pressing puton pin
b The assembling direction of the piston and
the connecting rod is shown in Figure EM 66
Note
a
the
Adjust
so that
adjusting
tip
screw on
of the screw is
the valve rocker
slightly
over
mark on the
6arrow
piston head is directed toward
the
engine
front
rocker
b Take sufficient care in
since the
tip of the
valve stem
tile
arrange so as the
ie
the
as
positioning
shown in
Correct
the rocker
bolt is apt to get out of
Figure
o
Arrow
mark
EM 54
Incorrect
0
Oil
jet
I
i
07
iI
y
J
I
I
I
c
hr
0
II
J
j
j
J
i
1
Fig
Fig
EM 64
Setting of rocker
EM 66
4ssemblillg piston
and
connecting
rud
arm
2
the
Install the piston pin clips
on
both sides of
piston pin
PISTON AND CONNECTING ROD
1 Assemble
necting
the piston
rod for each
piston pin
and
Note Use
con
new
installed
cylinder
EM
24
piston pin clips
as
shown
in
The clip
Fig EM 67
must
be
ENGINE MECHANICAL
TOOI
Crankshaft gap
Tool
fM 67
Fig
3
Installing dip
Install the piston ring with the punch
facing
EM 69
Fig
mark
3
Apply
a screw
block oil
up
Installing
hole
oil seal to
rear
sealing agent
on
and install to
plug
bearing
the
cap
cylinder
cylinder
the
block
4
bearings
Fix the
onto the
connecting
rod and
the connecting rod cap
4
Fix the main
and the
Note Make
sure
adheres
to
that no dust or other
the back of
foreign
matter
1
Place the cylinder block
2
Insert
the oil
seals
hold down
Then cut
by using
off the
the
the
on
the
5
same
engine
stand
the
cap
type bearings
install the
used
all
at
five
crankshaft
and
bearing
speCified tightening torque
Tightening torque 10 to 11 kg m 72 3 to
Tighten
the
to the
795 ft lb
bearing cap
special tool ST49750000
seal ends
with
Note
a
Apply liquid packing
or
a
equivalent
rear
bearing
to the
oil seal to
Installin
r1inder block
Fig
EM
25
FM 7U
Three bond
No
2
fitting surface of the
cap
Apply liquid packing
f M 68
are
and
rear
knife
Vig
cylinder block
caps
Lubricate all main bearings with engine oil
Then
into the grooves of
excessive
The
onto the
locations
ASSEMBLING OF ENGINE
cylinder block and
Note
bearings
bearing
bearings
here
Application of liquid packing
ENGINE
b Install the thrust washer
No 2 bearing
installed
that oil
so
9
both sides of the
on
channel
faces
to
Lubricate
the crankshaft
journals
and cylinder bores with engine
The thrust washer should be
the
the
oil
pistons
and
install
piston rod assembly
crankshaft thrust face
1
1
1
V
cc
Note
Install the piston rings
a
1
0
f
at
I
or
t
r
r
that their gaps
arrow
are
avoiding
piston
directions
mark
on
the top of the
piston
should face the front of the engine
J1
10
v
t
Install the connecting rod cap
I
0
t
Bolt
t
tightening torque
Fig
c
EM 71
Installing
Arrange the bearing
mark
faces toward
rear
bearing
rear
Note
cap SO that the
a
arrow
the front of the engine
bearing
cap side seal
cap side seal must
0 2 to 0 6 mm
0
to
kE
5 0
m
thrust washer
Install the caps to the connecting rod so that
the mark on the big end side faces to the
same
side
b After
Install the
4 5
32 6 to 36 2 ft lb
i
L
6
so
to each other is
piston pin axial
b The
r
l
356 F
the gaps face to the thrust side of the
I
1
1800C
project
0079 to 0 0236 in
The
torque
from
from
tightening
the bolt to the
bend the lock washer
as
specified
show
in
Fig EM 73
the
lower portion of the cylinder block
Note
Apply liquid packing
the
to
projecting tip
F
Fig
EM 72
Installing cap
EM
3
Illstallatiun
11 Install the oil jet
7
Install the
8
Install
engine
rear
of piston assembly
side seal
der block
plate
on
the front of the
cylin
Then install the chain tensi6ner and
stopper
bolts
using
to
new
the
After
flywheel
the specified
torque
tightening
lock
10 to
72
11
kg
12
the bolts
lock washer
Tightening torque
the
m
Install the crankshaft sprocket and
timing
chain
Note Align the timing mark of the chain with the
3 to 795ft lb
mark of the
EM 26
sprocked
ENGINE MECHANICAL
CAM
SPROCKET
TIMING
ADJUSTING
MARK
SCREW
f
CHAIN TENSIONER
Oil JET
CHAIN GUIDE
CRANK
SPROCKET
TIMING
Fig
EM 74
MARK
Timing
EM
27
mechanism
ENGINE
Install the
13
the
oil
Temporarily tighten
pump
mounting bolts
Note
Crank
or
Three Bond No 4
Apply sealing agent
equivalent onto the oil pump mounting surface
as
shown in
Figure
EM 75
Fig
Apply sealing agent
here
16
a
b
7
EM
pplicatinn ofliquid packing
sprockets
sprocket
pump
Tighten the
nut
securing
ivalent
is
Cut
off
portions
the oil
onto
located
the
of oil flinger
cover
the
Three Bond No 1
on
the back of the chain
between the
and
upper
of the
or
gasket
Ensure that the boss
cover
c
Install the oil pump chain together with the
two
Installation
Apply sealing agent
equ
Fig
EM 77
Install the chain
Note
14
pulley
timing chain
lower
projecting
gasket
to the pump drive shaft and bend
the lock washer
Note Adjust the tension of the oil
moving
the oil
pump
body
central
pump
with the
Then tighten
point
mounting bolt securely
the
chain by
the
pin
as
oil
pump
Vip
17
Install the
nut
to
the
EM 7Il
crankshaft
pullev and tighten the
specified
torque
tightenin
Then
bend the lock washer
Tightening torque
15 to 20
108
Fig
15
in
f M 76
4dj ting oil
EM
77
m
18
Install the oil strainer
19
Install the oil pan
20
Turn the
set
No
1
center
pump chain tension
Install the oil flinger in the direction shown
Figure
kg
5 to 144 6 ft lb
engine up side down and
cylinder piston to the Top dead
position of
EM 28
the
compression stroke
the
ENGINE MECHANICAL
Note a
the notch on the crank
Align
T
mark
ain
ct
the
on
pulley
to
the
cover
3
7
EM
9
22
mark
Timing
Pull
engine
when the
the timing chain does
since
cover
the
turned upward
was
not
timing
fall into the chain
chain
is
supported
with the rear boss of the chain cover
the chain will not
21
run
off the
timing
4
10
tightening
chain
from
urder
and set the chain
on
the
chain
the camshaft
onto the camshaft
Under
when the crankshaft is rotated
this condition
the
head
B
sprocket
making their mating marks meet each other
Then strike the camshaft sprocket with chain
cover
b Even
ou t
2
Cylinder
J M HI
Fig
Fig
5
6
23
Install
the
distributor drive
camshaft and tighten the
sprocket
bolt to
on
gear
the
the specified
torque
Tightening torque
Install the cylinder bead assembly
4
5 to 5
5
kg
m
32 6 to
39 8 ft lb
Note a
Apply sealing agent
or
the
onto
side of the head gasket
At this time
equivalent
cylinder
Then bend the lock washer
block
Three Bond No 4
make sure that
Note The camshaft bolt has left hand threal
s
the
EM 81
with
the
tightening torque applied
is several steps
Tightening torque
8 to 9
kg
m
57 9 to 65 1
lb
ft
Fig
24
FiJ
I fW
IWitf
W
dillaf rlwar
EM
29
fJI
Adjust the
Note
o
b
sealing agent has not entered into the
cylinder
Tighten in the manner shown in Figure
H
Inslalliag camshaft
rocket
I
valve clearance
Adjustment of valve clearance is made with each
cylinder set at the top dead center of the
ENGINE
compression
30
clearance
Specified
0 2
stroke
At room
0 0079 in
mm
for
temperature
intake
both
Install
the generator bracket and
alterna
tor
and
31
exhaust
Install the water pump pulley
fan blade and
fan belt
Note
The
fan
bolts
have
hole
a
After tightening the bolts
with
a
for
lock
wires
lock each two bolts
lock wire
32
Adjustment of fan belt tention
Adjust fan belt tension by changing
of the
alternator
to
establish
tension between the water pump
the position
the
specified
pulley
and the
alternator
Fig
Ref
25
EM 83
Adjusting
valve clearance
When warmed 0 25 mm 0 0 8 in
to the
Supply oil
oil
bath
of the
cylinder
head
26
Install the rubber
rear
plugs
Note Apply
sealing agent
Three Bond No 2
27
on
the
front
and
end of the cylinder head
Install the chain
Note Adjustment
the
to
rear
equivalent
or
adjusting
screw
of the chain tension
is
made
in
Rotate the crankshaft clockwise and establish
EM 84
Adju ting fan
33
Install the oil filter
34
Install the rocker
35
Install the distributor
Figure
EM
85
belt tension
hose
cover
controller and the rotor
in
the following sequence
a
Fig
rubber plug
so
are
that
in
the
vacuum
positions shown
Temporarily
tighten
lock nut
correct chain tension
b After
by
threading
hand
in the
adjusting
back it off 1 2
turn
screw
fully
and lock
with
the lock nut
c
As the width of
is 21
t0 3
6
the nut can be
flat of the lock nut
across
same as
that of the
tightened
or
spark
plug
loosened with the
spark plug wrench
28
Install the valve locker
29
Install the water pump
ing bolts of the
tain the
cover
One of the mount
water pump is
generator adjusting
also used to
re
arm
Fip
EM
30
EM 8S
J Qcation
of di tributor
rotor
the
ENGINE MECHANICAL
Note Apply sufficient oil
gear
Adjustment
of
the distributor
to
ignition timing
in the time of running in engine
or
driven
performed
after the
installed on the vehicle
engine
36
is
Install the gas
hreather
Note The clamp of the pipe i
tightened
in company
EM 86 Installation
Fig
with the exhaust manifold
Note Install
steel
37
Install the spark plug and connect the high
38
Install the exhaust manfiold
time
slinger
At the
surface of
the
39
Install the clutch
40
Remove the
oil
the
engine from
motor
switch
warning
pressure
engine
intake
engine
gasol ine
SERVICE DATA AND SPECIFICATIONS
GENERAL SPECIFICATION
4 in line
85
Bore and stroke
1
Displacement
Valve arrangement
Max
brake horse power SAE
Max
torque
80
x
mm
815 c
3
c
150 in
346 x 3
110
8 cu in
eHe
600 rpm
105 HP 5
15 9
1
Firing order
3
kg
m
115 ft lb
2
4
STD
Engine idle rpm
Compression ratio
600 rpm
Vacuum pressure of intake manifold at idle
More than 495
Oil pressure
4
8
3
7
1
5
5
13 000
mmHg
66
cm2
kgl
19 8
8
inHg
78 2 Ib
in2
rpm
TIGHTENING TORQUE
10
Main
bearing cap bolt
Connecting rod bolt
4
EM
3l
5
11
kg
m
72 3
5
kg
m
32 6
795
stand
manifold
tube etc
Cylinder arrangement
the
direction of the manifold
with carburetor starter
tighten them together
gasket with
grommet facing in
and install the transmission
same
install the heat shield plate and engine
and
manifold
exhaust
plate
the
tension cable
the
of exhaust manifold gasket
ft lb
36 2 It lb
mount
drain
ENGINE
Flywheel
bolt
10
15
Crankshaft nut
20
Cylinder head bolt
8
Camshaft center bolt
4
Spark plug
3
Oil fil ter center belt
2
8
1
5
Water pump blind
plug
Carburetor bowl set
Rocker
cover
sc rew
securing
screw
kg
11
9
5
5 5
4
3
2
2
o
15
0 2
o
33
0 4
m
kg
kg
kg
kg
m
kg
kg
kg
m
kg
72 3
79 5
108
144
5
ft lb
6
ft lb
m
57 9
65 1
m
32
6
39 8
ft
m
21 7
28 9
ft lb
3
23 2
ft
14
ft lb
20
m
10 9
m
1
m
24
1
5
ftlb
lb
lb
1 4
ftlb
29
lb
ft
LIQUID PACKING APPLICATION
fL
Cylinder block
Oil gallery blind plug
5
Intake manifold
Control valve
Angle
6
Block
gasket
installing surface
near
to oil
exit
Manifold heat pipe
Chain cover
tube connector
Oil pump
head
Expanision plug
Rubber plug Rear
3
gasket Cylinder block side
Cylinder
Expansion plug
Gas breather guide
Rear bearing cap fitting surface
Rear bearing cap side seal both ends
Cylinder
head
4
7
Rocker cover
Tapping screw of buffle plate installing
both sides
SPECIFICATION
a
Valve mechanism
Valve clearance
cold
In
o
25
mm
0
0098 in
Ex
o
25
mm
0
0098 in
Reference value
Hot
Valve head diameter
In
o
28
mm
0
011
in
Ex
o
28
mID
0
011
in
In
42
mm
1
654
in
Ex
35
mm
1
378
in
8
mm
0 3150 in
Valve stem diameter
In
Valve
In
116
4
mm
4
58
in
Ex
117
2
mID
4
61
in
mm
0
354
in
Outer
42 5
mm
1
673
in
Innter
41 4
IDm
1
630
in
Outer
29 0
mm
1
142
in
Innter
26 0
mm
1 024
in
Outer
37 0
mID
1
457
in
Innter
34 0
mm
1 339
in
Outer
4
5
mm
0
1772 in
Innter
6
25
IDm
0
2461 in
Valve
length
Ex
9
lift
Valve spring free
length
Valve spring loaded length
Valve spring assembling height
Valve spring effective wind number
EM
32
0
ENGINE MECHANICAL
Valve
spring
Outer
wire diameter
4 2
1654 in
mm
0
1142 in
2
Outer
27 5
mm
1 083
in
Inner
19 9
mm
0
733
in
In
48
mm
1 890
in
Ex
60
mm
2 362
in
In Ex
16
Valve guide inner diameter
In Ex
7
14
Valve
Valve
guide length
guide height
from
cylinder
head
Valve
guide
outer diameter
In Ex
Valve
guide
to stem clearance
In
7
2
Ex
In Ex
Valve guide interference fit
Max
In Ex
tolerance of above clearance
Valve seat
o
1
In Ex
Valve seat width
b
0
Innter
Valve spring coil diameter
9
mm
In
angle
mm
0
657
mm
0
2756 in
mm
0
559
o
025
0
055 mm
0
0010
0
0022 in
o
04
0
077 mm
0
0016
0 0030 in
o
040
0 069 mm
0
0016
0 0027 in
in
0 0049 in
mm
2
05
2 33 mm
0
0807
0
0917 in
90
Ex
Camshaft and timing chain
Camshaft end play
Cam
36 53
height
Camshaft journal diameter
0
Camshaft bend
01
o 07
0
0
0 0058 in
0028
1
journal
to
bearing
clearance
438
37 45
37 475 mm
1
1 475
474
0
mm
in
in
0004 in
37 525 mm
1 476
Camshaft
148 mm
mm
37 5
Camshaft bearing inner diameter
c
in
1
477 in
o
025
0
075
0
0008
0
0030 in
mm
Connecting rod
140
Center distance
o
Big end end play
0
o
Connecting rod bearing clearance
Connecting rod bend
EM
33
05
5
mm
110
0 246
0043
0
mm
0020 in
o 03
0
06 mm
0
0
0024 in
0012
in
0097 in
0
mm
51
ENGINE
Connecting rod bearing under
size
1
S T D
483
0
1
25 U S
1 499 mm
0
0584
609
0
1734
1
967
857
1
75 U S
0
1
100 U S
d
0
1
872
0731
984
0
081
688 in
0
1
1
49 491
1
938
0786 in
1
mm
939 in
48 991 mm
928
1
mm
9483 in
49 241
48 975
997 mm
mm
1 9582 in
49 225
mm
0737 in
0
49 741
9477
1
mm
968 in
1 9576
49 475
1747 mm
0683
1
49 725
mm
00639 in
50 US
0
59 991
49 975
0590 in
622
1
0633
pin diameter
Crank
Bearing thickness
Bearing size
1
929 in
Crankshaft and main bearing
Less than
Journal taper and out of round
o
01
Crankshaft free end play
Wear limit of ditto clearance
Less than
Crank pin taper and out of round
Main
bearing under
060
0
0
0024
0 0008 in
mm
0 0118 in
o
mm
0 0004 in
01
485
0
0
2
50 US
0
2
100 U
S
737
2
2
2
mm
1033 in
750 mm
0 1083 in
2 875 mm
1127
0 1176
0986 in
625
0
1078
987
505 mm
0
1028
862
0
2
0978
2 612
S
o
03
0
0
0012
0 0024 in
1
06 mm
0
mm
0039 in
Crank journal diameter
Bearing thickness
2
75 U
mm
size
T D
25 U S
192
o 3
o
Beadng size
S
0004 in
o
Main bearing clearance
Wear limit of ditto clearance
0
mm
0
3
1132 in
000 rom
0
1181 in
Crankshaft bend
Less than
EM 34
55 971
2
55 721
2
194
55 471
2
184
55 221
2
174
54 971
2
0
55 990 mm
2036
164
02
2
2043 in
55 740
2
mm
195 in
55 490 mm
2
185 in
55 240
2
54 990
2
mm
mm
175 in
mm
165 in
0
0008 in
ENGINE MECHANICAL
e
Piston
Piston diameter
84 968
85 0
o
diElf elirpencese
Ring grove width
Top
2 0
Second
2
0
Oil
0
4
4
ring side clearance
0020
0
0012 in
0
0012
0
0004 in
03
0
0012
ill
0
0004 in
05
0
03 mm
0
03
0
01 mm
0
0
Second
Oil
Top
Second
Oil
Ring height
0
Top
2
2
Oil
4
Piston pin interference fit of piston pin
to
piston
Clearance between piston pin and
rod
connecting
bushing
Piston pin outer diameter
Piston pin hole diameter of piston
Connecting
rod
bUshing
inner diameter
EM 35
mm
0
0787
0
0787
0
1575
0035
0
0
0014
0 0022 in
55mm
0
04
0 08 mm
0
0016
0 0031 in
0
02
0 06 mm
0
0008
0 0024 in
0
02
0
06
0 0008
0
0024 in
0
35
0
55 mm
0
0138
0
0217 in
0
3
0
5 mm
0
0118
0
0197 in
0
35
0
55 mm
0
0138
0
0217 in
01
0 03
0
Second
346 in
0
0
Top
Ring gap
3
0 0157 in
mm
Piston to bore clearance
Piston
3 345
mm
0
mm
0787
01
0 03 mm
0
01
0
03
mm
0
0787
0
1575
mm
0
0004
0
0012 in
0
0004
0 0012 in
0
0004
0
0012 in
o
0
09
0
0
0035 in
mm
0
003
O 013 mm
0
0001
O 0005 in
21991
220mm
0
0 8661 in
8658
21 987
21 996 mm
0
0 8660 in
8656
21995
22 008 mm
0
0 8664 in
8659
ENGINE
TROUBLE DIAGNOSES AND CORRECTIONS
I
Correction
Cause
Trouble
Noisy engine
bearing
Loose main
Burnt
Knocking of
Replace
Replace
bearing
replace
Bent of crankshaft
Repair
Uneven wear of
Regrinding
or
crankshaft and
bearing
Too much end
Loose
Burnt
journal
play
of crankshaft
bearing
Replace
bearing
Replace
Piston and
cting
kno cking
conne
rod
piston
in
Loose
Too
Camshaft
knocking
rod
alignment
is not made
Replace
gear
Timing chain
noise
Wear of
damage
Adjust
of chain
Replace
Replace
sprocket
adjusting
Replace
Clearance of camshaft and bearing too
Replace
Wear or
thrust
Repair
Chain tension not adequate
Wear and
and repair
Replace bearing
teeth of gears
cam
Disassemble
breakage of
tension
mechanism
big
Camshaft and
valve mechanism
Valve clearance not correct
Adjust
Wear of
Replace
adjusting
screw
Wear of rocker face
Loose valve stem in
knocking
Water pump
knocking
or
Replace
bearing
Broken
bushing
Replace
big axial play
Rough
or
bearing
Recondition cylinder
cylinder
Broken piston ring
Connecting
center
Replace pin
Loose piston pin
Loose
Replace
Replace
Replace guide
guide
Yielded valve spring
Replace
Burning of valve
Mention later part
End play of shaft
Replace
Broken impeller
Replace
EM
36
plate
replace
ENGINE MECHANICAL
Trouble
II
Correction
Cause
Other mechanical trouble
Adjust
Not correct valve clearance
Small
of
clearance
valve
stem
with
Clean stem
or ream
the
guide
guide
Sticked valve
Yielded
Biting
or
or
broken valve spring
Replace
of valve stem
Replace
damage
Use
Not correct valve clearance
Adjust
Yielded valve
Replace
Thin valve head
Burnt valve seat
Replace valve
edge
N arrow valve seat
Refacing
Overheat
Mentioned
Drive
speed
Over
of
engine
oil
9heck
day
every
Clean crankcase
oil
Dirty engine
right
Repair
Sticked valve guide
Shortage
clean
good fuel
Bad fuel
spring
or
replace oil filter
element
Use
Overheat
Mentioned
Wrong assembly of piston with
necting
Repair
or
replace
ring
Adjust
wear
of cylinder and
piston
Replace
Broken piston ring
Dirty
Clean periodically
air cleaner
Too rich mixture
Adjust
Engine
Drive
over run
Clean and adjust
Overchoking
Start correct way
of
Check oil daily
engine oil
Refer
Low oil pressure
Defective
rod
right
Sticked choke valve
Shortage
connecting
con
rod
Not correct clearance of piston
Exceseive
right oil
Inadequate oil
Not
adequate engine
oil
Use
Grind and replace bearing
Rough surface of crankshaft
Clogged
Wear or
right oil
Clean
oil passage
eccentricity of bearing
EM
37
Replace
ENGINE
Wrong assembly of bearing
Defective
connecting rod
Loose
Repair
bearing
Replace
Connecting rod alignment
Shortage
is not made
of engine oil
Repair
or
replace
Check every day
Low oil pressure
Mentioned
Not adequate engine oil
Use
right oil
Wear or out of round of crankshaft
Defective
crankshaft
bearing
journal
Clogged oil passage
Wear or
in crankshaft
eccentricity of bearing
Wrong assembly of bearing
Clean
Replace
Repair
Not concentric crankshaft or
beariug
Replace
SERVICE JOURNAL OR BULLETIN
DATE
JOURNAL
BULLETIN
or
No
PAGE
No
REFERENCE
SUBJECT
EM
38
1
1
1
1
1
t
i
f
DATSUN
1800
I
a
I
SERVICE
MANUAL
MODEL
SECTION
EL
ENGINE
LUBRICATION
SYSTEM
G18
ENGINE
NISSAN MOTOR CO
TOKYO
JAPAN
LTD
LUBRICATION SYSTEM
EL 1
ENGINE
lUBRICATION SYSTEM
LUBRICATION
SYSTEM
CONTENTS
DESCR IPTION
EL 1
LUBRICATION
EL 2
OIL
CIRCUIT
EL 3
Assembly
OIL
PRESSURE
Specification
RELIEF
VALVE
of relief valve
EL 3
ELA
PUMP
EL 2
Description
EL 2
FILTER
ELA
Removal
EL 2
Disassembly
EL 5
Installation
EL 2
EL 5
Disassembly
EL 2
Inspection
Assembly
Inspection
and
OIL
repair
1 itI
I
EL 5
OIL WARNING SWITCH
EL 3
J llbrif aliofl
8
irr uit
EL 5
CIlMifW
DESCRIPTION
The
lubricating system
type system
and is
is Pressure
feed
functional components
composed of highly efficient
EL
ance
l
1
e
high
suited for high perform
out put and
high speed running
ENGINE
LUBRICATION
Oil
inlet
CIRCUIT
6
from the oil
pan
body by removing
four
attaching bolts
then delivered by oil pump through the
gallery
to the inlet side of the full flow oil
filter and to the main oil
main
The
crankshaft
in the
oil
main
Installation
gallery
gallery
supplies oil
to
the
Installation
bearings and drilled passages
crankshaft direct oil from main
bearings
In
connecting rod bearings
Oil injected from jet holes on connecting
rods lubricates the cylinder walls and piston
pins
The oil
oil
through
lubricates the timing
jet located
Furthermore
inder
head
near
reversal of removal pro
this
adjust the
case
pump drive chain as shown in
tension
of the oil
Figure EL
2
lubricant
main
oil
chain
the chain
is
supplied
gallery
through the camshaft bracket
bearing
a
distributed from the cylinder block
gallery
the
is
cedure
to
front
Remove the oil pump
oil pumps
through the
and tube to the inlet side of the oil
screen
pump
oil
drawn
is
to
rocker
cyl
shaft
and the camshaft
cylinder head are fed directly
from this gallery
The rocker arm and valve
are lubricated by the oil
through the rocker arm
on
the
gallery from the cylinder head
main oil
gallery
rocker shaft
Fig
OIL
EL 2
Ten
ioning
oil pump drive chain
PUMP
Description
The
Disassembly
oil
pump assembly is installed to the
cylinder block by four bolts and driven by the
rotor chain in the crankshaft
The oil pump is
The oil pressure is
gear type
regulated by
the regulator valve to 4 55 to 4 85 kg cm2 65 4
a
to 74 0 lh
Isq
in
Removal
1 Drain engine oil
2
Remove the distributor
3
Remove the cylinder head
crankshaft
pulley
assembly
fan belt
and oil pan
4
Remove the chain
5
Remove the oil pump sprocket with the oil
cover
with oil
flinger
Fig
pump
crankshaft
sprocket
and
the oil
EL 3
Dwsembly
of
oil pump
pump
drive chain
1 Separate
EL
2
the
body
cover
from the oil
pump
i
ENGINE LUBRICATION SYSTEM
body by unscrewing
four
take out the drive gear
securing bolts and
assembly and idler gear
from the pump body
2
Take
and spring by removing
out the valve
the relief valve plug
InspeCtion and repair
1 Clean the disassembled parts with cleaning
solvent
2
Inspect the drive
and
3
shaft for excessive
wear
scores
EL S
Fig
InspectiDn of clearunce
Check the following
Assembly
O
1
Assembly
O 5 mm
1
0 0039
0
0195 in
cedure
2
Gear backlash
is
a
reversal of disassembly pro
Side clearance between
016
O
15
0006
O
0059 in
016
O
1 mm
0006
O
0039 in
O
O
gear and body
0
mm
In this
case
the mark dotted on gear should
be faced to the oil pump body
cover
Clearance between drive
O
shaft and body
0
Clearance between
drive shaft and body
02
O
1 mm
00078
O
0039 in
0
016
O
1
0006
O
0039 in
cover
0
Clearance between
idler gear and
idler shaft
0
mm
Fig
EL 6
Dotted mark
of pump gear
OIL PRESSURE RELIEF
VALVE
The oil Iressure relief valve is not adjust
the valve
At the released po ition
able
permits that oil is by passed through
on the pump body to the oil pan
Check the relief valve
Fig
EL 4
ImpectiDn of
pring
EL 3
passage
dimension to
ensure that it has not lost its tension
backltuh
a
ENGINE
Specification of
relief
valve
Free
length of
spring
Pressured
64 0
66 0 mm
2
2
51
60 in
length
50 mm at 7
of spring
1
96 in
at 17
4 55
Opeuing pressure
64 7
2
8
9
7
kg
21 4Ibs
4 85
kg crn2
69 0 Ibs sq in
Oil pan
Fig
Et 7
Relief
valve
OIL FILTER
o
Fig
EL 8
Oil
Oil filter is of foil flow type and the element
replaceable whicb is mounted to the cylinder
block at the right hand side by two bolts
The oil fed by oil pump is filtered by oil
is
filter and supplied to main
Filter
set
element
is
set
filter
The
cover
by
filter
body
is
center shaft
mounted
The oil
filter
to
the
by
pass valve
is located in the filter cover
If the pressure difference between inlet and
gallery
outlet
between the element
lb I sq in
by clogging of filter element the
released valve permits oil to be by passed then
spring and the retainer
EL 4
of
oil
filter reaches O 8
kg cm2
11 38
ENGINE
the pressure of oil
to main
supplied
lUBRICATION SYSTEM
gallery
is
avoids the engine
specified level
trouble caused by pressure dropping
kept
at
Loosen
the
separate the
oil
cover
center
filter
shaft
is a reversal of disassembly pro
Assembly
cedure
Note
Disassembly
1
Assembly
It
a
When tightening the filter body
by
and
2 8
torque
and body
bolt
center
tighten with
3 2
to
m
to
20 25
kg
the cover
the
specified
to
23 15
Ibsq in l
2
off
Take
upper
retainer and set
3
Remove
and draw
by
lower
element
retainer
b The
spring from the body
pass valve
plug
gasket
from the
filter body gasket and center shaft
oil
be
should
in case of
cover
replaced
with
one
new
reassembling
valve spring and
off valve washer
valve in sequency
OIL WARNING SWITCH
Inspection
the
following specifications
Free
warning switch is located on right
cylinder block and wired to an
indicator lamp in the instrument cluster
The
Check the by pass valve spring according to
54 5
length
2
Pressured length
14
49 0 mm
hand
The
56 0 mm
2
20 in
oil
center of
low pressure
oil pressure
lb
1 93 in
JOURNAL
BULLETIN
or
No
PAGE
No
below
5
REFERENCE
SUBJECT
EL 5
0
sq in
SERVICE JOURNAL OR BULLETIN
DATE
drops
light glows
whenever the
kgl cm2
7
11
ENGINE
SERVICE JOURNAL OR BULLETIN
DATE
JOURNAL
BULLETIN
or
No
PAGE
REFERENCE
SUBJECT
No
EL 6
t
l
l
J
f
SERVICE
MANUAL
MODEL
SECTION
CO
COOLING
YSTEM
Gll
ENGINE
CI
NISSAN MOTOR CO
TOKYO
JAPAN
LTD
COOLING SYSTEM
Co l
COOLING SYSTEM
COOLING SYSTEM
CONTENTS
DESCRIPTION
COo
WATER
CO 2
Removal
Removal
CO 2
Inspection
Disassembly
Inspection
CO 2
Installation
PUMP
THERMOSTAT
CO 2
FLUID COUPLING
Lubrication
CO 3
CO 3
4
CO
CO 4
CO 4
RADIATOR
CO 3
Removal
CO 5
CO 3
Inspection
CO 5
SPECIFICATIONS
CO 5
DESCRIPTION
The
cooling system
is
a
temperature range at all times by
ample capacity water pump of a
fin
corrugated
type radiator with high cooling
closed pressure
adequate
Cooling
type with high cooling capability
flowing through resistance free water passages
in the cylinder head and block is maintained at
water
Fig
COol
Cooling
means
of an
efficiency and
system G 18 engine
CO I
a
pellet type thermostat
ENGINE
WATER PUMP
The water pump is a
with
volute
an
aluminum
chamber
and
assembly
nism
is
is
a
adopted
water pump
pump body
built into the chain
high
to
centrifugal
die cast
pressure
cover
Fig
leakage
CO 2
equlpped
vertor
thoroughly
water pump with
The
sealing mecha
prevent the water
and noise
The
for
or
fluid coupling will be
the models with the torque
the
CO
air conditioner and for U S A
models
Water pump and chain
cover
Removal
1 Drain cooling water completely
3
Remove fan and
2
4
Remove the water pump
Take the fan belt off the
pulley
pulley
Disassembly
By reason of an aluminum make the water
pump body is preferably not to be disassembled
Inspection
Pump body
o
Replace
it if it has
badly rusted
or
corroded
vanes
o
Fig
CO 3
Replace it if
noise or
Water pump removal
CO 2
it grows up excessive
squeak
beariug
with the engine running
COOLING SYSTEM
Note To prevent
squeak
use
Nissan CSP
Cooling
Protector
System
Prior
a
the
installing
to
Nissan CSC
pump
Cooling System
it
clean
with
it
After
reassembly
filled with silicon oil of exactly 11
cu in
using an injection syringe
an
overhaul
must
5 c c
be
0 702
Cleaner
FLUID COUPLING
the
In the models with
the
air
fluid
to
conditioner
coupling
maintain
torque
converter or
the U S A
and
is combined
models
a
with the water pump
to
cooling efficiency and
orevent
power loss at high speed operation
Cl
Fig
Note
Carry
A
COoS
Fluid
lubrication
coupling
injection slowly
out oil
binding agent
to
to
help air escape
be used in assembling
Three Bond No 1
In
CO 4
Fig
Fluid
coupling
If
Wash the
Note
coupling
take care so that
from
for interior
exceed 5
in
a
gelatinized
oil
a
phenomenon of oil thickened into a semi solid
form
Change such oil because thickened oil
At the
will make bearings and grooves sticky
time
same
examine the condition of seal and
bearing thoroughly
the
A blackened seal and bear
requires the replacement of
pump body assembly
ing due
to
0 305 cu in
c c
pellet type
seizure
passage
thermostat is used in the water
to
control
forces
to
cooled
open
the
valve
the contraction allows
lication
Lubl
Removal
Silicon oil is to be used
If
a
malfunction and oil
in the fluid
coupling
leakage
remove
are
1
Drain
2
Remove radiator hose
cooling
water
detected
the water pump for
Co3
the
flow of coolant
providing fast engine warm up and regulating
A
wax
coolant temperatures
pellet in the
thermostat expands when heated and contracts
when cooled
The pellet is connected through a
to
a
valve
and when the pellet is heated
piston
is
exerted
against a diaphragm with
pressure
the valve
1
re
the
THERMOSTAT
A
and
coupling installed in
case
away
gasoline
Check for seizure
be
The quantity of oil to be replenished must not
outlet
2
can
cleaning
gasoline in this
rubber seal will be kept
coupling
the
oil
engine
a
disassemble the
of water pump
with
plenished
or
malfunction due to foreign matters
detected
to
deteriorated
oil
are
sticking due
1
this type
As
a
the
pellet
spring
is
to close
ENGINE
3
Remove
water
take
Then
outlet
out
the
Valve open
thermostat
800 C
temperature
valve lift
Max
1 50 C
above 8
mm
0
17SO F
2
70 F
at 900 C
315 in
at 1940 F
Installation
1
In
Bond
both sides
to
tion of water
2
apply binding agent
of the packing for
installing
Three
preven
leakage
Install by the removal procedure in
reverse
RADIATOR
The radiator is a conventional side flow type
with
sight glass
The
valve
Fig
CO 6
system is pressurized and the relief
incorporated in the radiator filler cap
the
controls
Thermostat removal
o
9
kgl cm2
pressure
12 8 lb
I sq
at
approximately
in
Inspection
To
test the
temperature
of
thermostat for proper operating
submerge
Heat
water
the
the
unit in a container
and
water
observe
the
temperature
I
Measure
1
mostat
the
wben
temperature
valve just starts rising
the
S
ther
c
Fig
For
oil
the
cooler
CO 8
models
to
cool
the
If adiator removed
with
torque converter the
torque converter oil will
be combined with the radiator
Fif
Provide
marking
8
mm
CO 7
Thermostat
screwdriver with
at
a
0 315 in
point about
from
the
inspection
Inspect
by
in
rting
marked screwdriver
at
the
C
9Cf
1940F
tip
2
Measure the
maximum lift of the thermostat
valve
Fig
CO
4
CO 9
Radiator with oil couler
COOLING SYSTEM
Removal
cooling
1
Drain
2
Disconnect
water
the
radiator
hose
upper
and
lower hose
3
Detach
the four
1
4
the
fixing
Sight
radiator
assembly by removing
bolts
glass
can
be
removed
by
turning
counter clockwise to clean it
Inspection
Fig
If the radiator requires
CO lO Radiator shroud
ing
1
Also
frequent top ups
the trouble must be traced to
the radiator shroud is combined with
the radiator in the models with the torque con
verter or the air conditioner and the U S A
ing
evaporation from
result of a clogged radiator
Excessive water
as
a
Defective
safety
Replace the
3
Loose hose
4
Leaky
valve
on
x
width
x
clamps
water
core
334
thicknees
13
x
Tighten clamps
pump shaft seal
465 x 38 mm
15 x 18 31 x 1 50 in
Type
Corrugated
Radiator fin spacing
2
3 mm
Cap working
0
9
3
1 t
Water
Clean
radiator filler cap
SPECIFICATIONS
height
overheat
cap
the water pump
Dimensions of radiator
of the follow
causes
the radiator
2
model
one
pressure
capacity
CG 5
0
fin type
091 in
kg cm2
3
3 U
12
S
8 lb
Isq
quart
in
Replace
ENGINE
SERVICE JOURNAL OR BULLETIN
DATE
JOURNAL
BULLETIN
or
No
PAGE
No
REFERENCE
SUBJECT
CQ 6
I
1
1
t
f
i
DATSUN
1800
SECTION
l
SERVICE
EF
FUEL SYSTEM
MANUAL
MODEL
G11
ENGINE
411
NISSAN MOTOR CO
TOKYO
JAPAN
LTD
AIR CLEANER
HI
FUEL STRAINER
HI
FUEL PUMP
H
2
CAilBURHOR
H
B
FUEL SYSTEM
AIR CLEANER
DESCRIPTION
4ir cleaner
EF 1
Fig
of
C 18
ell
for single
carburetor
ine
The air filter element used is viscous paper
type element and does not require any cleaning
ragardless
at every 40
of contamination until
000 km
24 000 miles
it
of
replaced
operation
is
Note
Never
treat
blasting
the
element by
before the time for
brushing
or
replacement
FUEL STRAINER
DESCRIPTION
The
fuel strainer is of the cartridge
A fiber mat is used as a strainer element
strainer
should
be
exceed 40 000 km
replaced
at
type
This
intervals not to
24 000 miles
REMOVAL
Disconnect
and
the
fuel
the inlet
strainer
and outlet fuel
assembly
is
pipes
easily
t
Fig
EF 2
Sectional view
fuel
removed
EF l
strainer
of cartridge type
air
ENGINE
SERVICE REFERENCE
This fuel strainer has
carburetor
the strainer
should not be removed
is full
ed
or
no
pet cock
lines
cleaned when the tank
unless absolutely necessary
place
the
tube
at
therefore
and fuel pump
If requir
the rear of the strainer
above the top of the fuel tank
Fig
EF 3
Cartridge
type fuel strainer
FUEL PUMP
CONTENTS
DESCRIPTION
EF 2
REMOVAL
EF 7
CONSTRUCTION
EF 3
DISASSEMBL Y
EF 7
OPERATION
EFA
INSPECTION
EF 7
EF 6
ASSEMBLY AND INSTALLATION
EF 7
TESTING
TROUBLE
DIAGNOSES AND
EF 6
CORRECTIONS
DESCRIPTION
1
No vapor lock in torrid zones
2
Starts
The fuel pump is of the electric
ing of
a
contact
mechanism
type consist
solenoid relay
pump mechanism and a strainer unit
This is located in the center of the
as
as
the
ignition
swi tch is turned on
spare
wheel house in the trunk compartment
This electric pump presents several distinct
features
pumping immediately
Built in type filter keeps dust out and adds to
pump and engine life
3
4
follows
EF 2
Reduced power consumption
FUEL SYSTEM
Coil
Piston
Strainer
Fig
2
Solenoid relay
solenoid relay is constructed
The
trated in
EF 4
Electric fuel pump
@
contact
EP
type
3
a
follows
1
Contact mechanism
the
pump
contact
consists
relay
solenoid
of
mechanism
as
a
pump
Its details
strainer unit
as
In
fuel
mechanism
mechanism and
9
6
are
shown
is
below mounted
above
on
and
a
the frame
to each
with
cylinder g a driving coil tj is mounted
concentrically and the coil @ is surrounded by
a
leakage type solenoid relay covered by iron
yokes @ and an end yoke Ql
is connected
An arc suppressing resistor Q
in parallel to the driving coil
this
in
end of
reciprocating
located inside
plunger
a
motion
cylinder
of
a
@ indicated
by the dotted line the holder makes an oscilat
ing motion in the direction of the arrow as
shown
Accompanying with the oscilating
a point arm @
at
motion of tbe magnet holder
of
the
magnet
tached to the horizontal part
holder
A
moves
up and
down
that
the contact
come
into contact
so
Wattached to its end will
relay stay q to make switching
The arc suppressing resistor and conden er
are connected in parallel to the contacts A and
BOO fixed
on
brass cyl
plunger spring
Encircling
EF 5
vertically
illus
W
magnet A 2 and B @ are attached
a
L shaped magnet holder D
The magnet holder is mounted on a relay stay 0
by means of a hinge @ in such a way that along
Figure
as
the hollow iron
damper spring
CONSTRUCTION
The
EF
Figure
Inside the
plunger @ which at its
lower part is connected to a piston @ by means
of a connecting rod iJJ can freely slide and is
attacbed so that it is pushed up between a
inder
Fig
Contact mechanism
EF S
the
Fig
B
EF 3
EF 6
Solenoid
relay
ENGINE
3
mechanism
Pump
This unit is constructed
EF
Around
8
filter
side
P
of
C
magnet
the
is
riJ
filings
iron
strainer
is
wire
a
and
concentrically
mounted
fixed
8 using the seal
i
lower end
to
of
the
on
the
a
fine
any
filter
glass
a
the frame l by
on
Figure
netting
frame
remove
the
Enclosing
i
shown in
as
frame
is attached
2
under
the
a
band
packing
OPERATION
1
20
Operation
of
electromagnetic
unit
Before
as
the
operating the fuel pump
stays pushed up inside the cylinder
plunger
the plunger spring il
mounted
the
on
u
9
by
frame
1
magnet
the magnet A
on the end of the
holder fof the contact mechanism is
attracted
to
mounted
22
on
the
cylinder
the
horizontal part of the
and the
holder L is pressed downward
f ig
As
IF
necting rod
is
mechanism
shown in Figure EF 7
connected to
It
rump
the
plunger
hole
freely
the
piston
through
10
z
the
is
1
When
An
turning
con
z
of the frame
inlet valve
fJ
B
jjl
fitted in the
so
that it
is
provided
can
A
contact
ing coil
the plunger
4
contact
A
on
the
the battery
contact
B
ij
yoke
arm
if
electromagnet
Then
is attracted downward
against
act as
l
the
lower end
switch
engine
point
magnet
making
8
IIJ
t
arm
ground and this current makes the driv
slide
at the
the
coil
driving
cylinder
and B
current flows from
electric
il
mounted in the
central
between contacts A r
point
an
plQunger
spring
i
and
given
potentiai
energy by the plunger spring pressure
Strainer unit
As
the
9
1
plunger
down
moves
the distance
r
between the plunger ill and the magnet A
increases and the
attractive force
of the
I
magnet
I
A
1l
becomes
Thus
zero
the
at
force working between the magnet B
the yoke 1 becomes
predominant
tractive
I
and
drawing the magnet
B
to
ac
the
yoke
disconnect the contacts At and B
@
2 When
rated
i
5J
rW
the contacts
the
A
driving coil
magnetic force
gradually pushed
and
and
7
B
loses
J
the
ilT
and
oBi
are
sepa
its electro
is
plunger
position held prior
potential energy of the
When the plunger
plunger spring pressure
the
reaches the
position held prior to
operation the distance between the plunger
to the operation
@ t
10
and
contacts
the
up to the
by
the
magnet
A
the contacts A 1 and B
that
Fig
fF 8
Fuel strainer
is
it
returns
described above
EF 4
2
to
the
decreases
A i is drawn to the plunger
ill
and
becOlnes connected
the
original
state
as
FUEL SYSTEM
Thereafter
plunger
ing motion
this
is repeated and the
regular reciprocat
engine switch A remains
goes up gradually to the position held prior
to the operation as the contacts A C1J and B @
process
carries
on
while the
a
becomes disconnected
Figure
on
tion
EF ll
of the
inside
the
closes
the
surface of the connecting rod
val ve opens
thus
cylinder
discharge
These
processes
upper
spherical
and the inlet
the fuel flow into
allowing
simultaneously
the
shown in
the its
as
with
contacts
as
at the upper por
opening
piston
wall
Then
1
and
2
with
are
its
repeated
continuously
Note
The number of operations of the fuel pump
is
is empty
full
the
to
pump
needle
the
Fig
EE 9
Operation of
2
above in respect of the opera
continues the
Turning the engine
piston
very
t connected
quickly
switch A
plunger spring
upper portion of the
on
the
very fast drop
inlet
as
valve it
In
2
The
inside wall of the
discharge
closes
and
it
moves
piston
its
therefore
given
Fig
E f 10
Pump operation
the
and the
TESTING
upward
is
Open
the
shown in Figure EF 10 and
piston M lowered
energy by
the
the number of the pump
of the
this movement
fuel contained between the piston
inlet valve
of
After the
@ drop
pressure
becomes open due to the reaction to
the
reduced
closed
the
number
makes the
the plunger
to
against
114
IJ
the
is one per five or six seconds
lr
owing to these forces
reciprocating motion
direction of the power and
1
Then
is
operates
thus
1j
electromagnetic unit the fuel pump
utilizes the power of the electromagnet and the
force
of the
plunger spring in the opposite
piston
becomes
up and
Operational principle
tion of the
the
that
increases in
valve
pump unit
described
As
rises
pressure
the fuel at its
quantity
needle
the
operations is
valve
operation
discharges
the fuel
decreases
almost stops
@
pump
As
carubretion
discharge
the
the
contained
quantity
When the carburetion
carburetor
rate
close
fuel
the
governed by
inside the
1
Disconnect the fuel hose at the pump outlet
2
Connect a suitable hose
potential
the plunger spring pressure
and
EF 5
r approximately
6 mm
ENGINE
0236 in
0
inner diameter
to the pump outlet
J
not
lie
If
the
proper
diameter
is
small
too
delivery capacity
can
even if the pump functions
With
3
the
hose
than the pump
in one minute
If
more
or
gasoline
no
open end
as
than 15 seconds
3
c
I
only
a
little flows from
Poor
grounding
Poor
grounding of battery
Incorrect or loose
wiring
Trouble in carburetor
follow the following
2
When
fuel
the
does
pump
not
operate and
discharge fuel
TROUBLE DIAGNOS IS AND
In
CORRECTIONS
a
fuel
this
pump
is
cause
Check it
as
of the trouble lies in
follows
found to be faultly
If the current flows this will be indicated by
1
Remove the fuel pump from the vehicle
2
Connect the
fuel pump to
and operate it
the
case
the pump
check it in the following procedure
charged
charges
causes
follows
or
diagnosi s
When
r
clogged piping
of the pipe with the pump operated
if the pump does not work
othe
Incorrect connection of inlet or outlet or
24 U S
less
or
pump but in some
Voltage drop of battery
higher position
c
fuel
be obtained
operate the pump and check the
The capacity should be 1 400
pts
not
following
properly
outlet in the
delivery capacity for
4
the
the
Check other units for possible
unit
Note
in
sparks
The
a
battery properly
at the terminal
to see if the pump dis
and
fueL
is the
cause
motion
plunger
Therefore
remove
or
piston binding
disassemble
in
the pump
any dust inside
If the current does not flow
The
the
breaking of
a
coil
or
lead
Therefore replace the fuel pump with
a new
unit
3 When the
t
is
cause
wire
fuel pump discharges only
quantity of
fuel
The
is
cause
a
trouble in the inlet valve
small
dis
charge valve the malfunction of packings or
Therefore disas
choking of filter mesh
Close
semble
the
pump
and
make
the necessary
servicing
REMOVAL
1
Fig
EF II
Pump operation
2
1
When the fuel
pump operates and
discharges
fueL
In
this
case
the
Remove two bol ts retaining fuel pump
to floor
cause
of the trouble does
Remove two bolts retaining fuel pump to fuel
pump cover
3
Disconnect the lead wire
4
Disconnect fuel hoses
EF 6
cover
panel
FUel SYSTEM
5
Gently
the inlet
press
valve
down the plunger and
packing
cylinder
and
remove
plunger
assembly
Note The electric unit cannot
it
is sealed
placed
as a
be disassembled
If it is defective
complete
since
it must be re
unit
INSPECTION
1
Fig
EF 12
Fuel pump
cover
Wash the
strainer
filter and gasket with
gasoline and blow dust off with a blast of
air
When cleaning the parts
check the fil ter
and gasket
If defective
replace it
clean
removal
Note
Filter must be cleaned every 20 000 km 24 000
miles
2
Wash the plunger
clean
air
and
gasoline
piston
and blow
and inlet valve with
dust off with a blast of
Check the smooth operation of the cylinder
If it is noted defective replace
piston
them
Fig
EF 13
Fuel pump removal
3
Insert
the
plunger assembly
into the
cylinder
of the electric unit
down
the
DISASSEMBLY
shows
1
Loosen the screws of the
2
Remove the strainer
strainer seal and
locking
spring
a
that
must be
locking band
strainer
If
contacts
Move the assembly up and
clutter sound is heard it indicates
are
the
normally operated
If not
electric unit is defective
it
and
replaced
filter
band
ASSEMBLY AND INSTALLATION
3
Remove the snap
4
Remove
ring
Follow
the four
screws
of the yoke
and take
off the electric unit
cedure
in
necessary
EF 7
the
disassembly
reverse
and removal pro
Replace
the
gaskets
if
ENGINE
CARBURETORS
CONTENTS
DESCRIPTION
EF
8
Adjustment of
EF
8
the accelerati ng pu mp
Primary system
Secondary system
EF
8
Float system
EF 14
Removal
EF 14
Disassembly
EF 14
Cleaning
STRUCTURE
AND OPERATION
EF 11
ADJUSTMENT
Idling adjustment
Fuel level adjustment
interlock valve
EF 15
Adjustment of interlock opening of
primary and secondary throttle valve
EF 16
DESCRIPTION
are
Model
draught type
type manufactured by
of the two barrel down
DAK 340
is of the
solex
the mTA CHI
Model
00034C is of the strongburg
type
manufactured by the NIHON KIKAKI and instal
led on the exhaust emission control engine
Each
carburetor
manual and automatic
has
two
amount of
D3034C carburetor
EF 16
EF 17
EF 17
and
Assembly
EF 17
inspection
EF 20
and installation
EF 21
JETS
opening
The carburetors
injection
MAJOR SERVICE OPERATIONS
EF 14
Adjustment of starting
the
variations
for
transmissions
EF 21
TROUBLE
DIAGNOSES AND
CORRECTIONS
EF 21
SPECIFICATIONS AND SERVICE DATA
EF 23
STRUCTURE
OPERATION
AND
These carburetors consist of the primary
system for normal running and the secondary
The float system
system for full load running
which the primary and secondary systems use
in common
the secondary switch over mecha
nism
the starting
mechanisln
accelerating
mechanism etc
are incorporated
For
model
D3034C
mechanism
val ve
speed
drive
is
carburetor
provided
better
a
fuel
the power
make high
cut off valve is
to
attached to cut fuel supply when the ignition key
is
switched off
vided to
Carburetor
model
screw
DAK340
IA
lvIanual transmission
DAK340
2A
Automatic transmission
lB
1
engine with manual
Primary
EF 15
which
Exhaust emission control
2B
engine
movement
a
certain
of the idle
adjust
is limited in a certain range
main
Fuel flows
transmission
D3034C
the
Primary system
Exhaust emission control
D3034C
control the emissions under
So that
level
Application
and a idle limitter is also pro
passes
with automatic
out
transmission
The
as
through
comes
system
in
shown in Figures EF 14 and
the main jet
from
mixing
through the emulsion tube
into
the
venturi
multiholed
main
through
nozzle
and is pulled
the main nozzle
insures
atomization of fuel and a low fuel
EF 8
with air
the main air bleed and
a
proper
consumption
FUEL SYSTEM
Model DAK340 Carburetor
20
7
5242322
21
Primzry
1
I
6
Needle
7
Float
air bleed
8
S Emuhion ub
13
P Main air
jet
9
SMainjet
14
PMain
15
Economi7 er bleed
I
lin
SM
2
S Small
3
S
4
S Slow
5
5 Slow air bleed
Main
10
S
lIve
S
12
By pass hole
Throttle valve
Choke
FigEF
14
aIve
hleed
d
16
P
17
Slow
18
19
20
Slow jet
Mainjer
21
P
22
Idlelimitter
P Slow air hleed
23
Idle hole
Air
24
P
Level gauge
25
P Throttle
omizer
By pass hole
alve
Sectional view
Model D3034C Carburetor
21
23
34
33
I
32
I
3029
31
25
2
Soooo
1
Float
Olive
Vacuum
piston
3
P Slow
4
Slow jet
5
Slow
omizcr
6
P
bleed
slow
bleed
7
Air
13
8
P Main ilir bleed
14
Pump weight
Discharge check
9
PMain
I
15
S Small
PSmall
nturi
17
S
18
19
10
I
Choke
12
Pump
alve
zlc
20
Fig
21
alve
Pump plunger
28
P Throttle
Inlet check
29
Idle port
alve
23
SMainjet
30
Slow port
24
Diaphragm spring
31
Idle
Step air bleed
25
32
P main jet
Pump
Step jet
26
Diaphragm
Step port
33
Powerjet
27
Idle port
34
Float
un
Main air bleed
EF IS
m
Sectional view
EF 9
adjust
alve
w
ENGINE
2
Idling and slow system
The throttle valve is opened at
a
small angle
speed running with a
large negative pressure prevailing down stream
This negative pressure
of the fuel system
acts on the slow speed system equipped with a
when
and in slow
idling
Through this action fuel
measured through the jet seciion of the slow jet
assembly located immediately behind the main
economizer
slow
are
is
coming from the
air
jet and
further mixed with air
bleed
through
the
chamber through the inlet valve into the space
under the piston
When the throttle valve is
the piston goes down
and fuel is forced
opened
valve
The
injector
inder not only
in
position
economizer
opening the outlet
out
through the
spring in the cyl
the smooth movements of
serves
to
place inlet valve
that the piston goes down quickly
so
and fuel is forced out
through
This mixture
coming from the slow
slow
return
piston
assures
the linkage but also
economizer bleed
mixed in the emulsion hole
air
is closed
shown in Figures EF 16 and EF 17
from
the float
the piston goes up and fuel flows
the
injector
Model D3034C Carburetor
and
7
The atomized mixture is supplied to
atomized
from the idle hole and by pass hole
As a result
via the slow speed system line
the engine
there is
an
excellent linkage between the slow
system and
speed
resultant
stable
and the
system
speed performance is
the
main
slow
ensured
3
mechanism
Accelerating
Carubretor
Model DAK340
L
Pump
2
Pump
3
4
d
5
Inlctvalve
6
Valve
Float chamber
7
Outlet valve
Pump plilnger
8
P
etum
spring
weight
throttle wlve
2
4
During accelerating
EF 17
Fig
Starting mechanism
Pull the choke button to close the choke valve
fully
rich
1
Main air bleed
zIe
choke valve is opened at
matically
eturn
spring
Main
6
3
Pump njector
7
Outlet valve
4
Piston
8
Throttle valve
ensures
the
The
type
carburetor is
accelerating
throttle valve
equipped
mechanism
with the piston
linked
engine
to
the
When the primary throttle valve
EF lO
adequate angle auto
overchoking and
prevents
which
an
smooth engine
is
being
pe rformance
warmed up
While
it increases in
releasing the choke
button an optimum engine speed can be obtained
the primary
With the choke valve closed fully
speed
During accelerating
a
the
When the engine is started
engine qui ckly
Piston
2
Fig
This provides a
engine
it possible to start the
making
5
Inlet valve
EF 16
then start tbe
mixture
at
steps
and
by
throttle valve is caused to open at
suited for starting
through
a
an
angle
best
link mechanism
FUEL SYSTEM
5
Dash pot mechanism
the
through
main
nozzle
promotes
the
fuel
atomization
only for
Model
Carburetors
andD3034C
DAK340 2A
Automatic
with
equipped
2B
Trans
2
mission
This
with
interlocked
the
primary
through a link mechanism
is exclusively installed on
converter
torque
stall
dash pot
throttle
valve
carburetor is equipped with
would
that
equipped with
a
intended to prevent engine
otherwise result from quick
is
application of the brake immediately after the
from the quick release of the
car
ran
or
accelerator
after
pedal
giving
The
only
near
full
speed
stem
a
1
800 to 2
throttle
shown
in
throttle
lever
Figure
000 r p
m
strikes
the
EF 18
valve in its fully closed state
small
in
engine
dash pot
making
valve
primary
gradually
keeping the engine running
Secondary switch
the
and
open
Fuel air
of
the
EF 21
tube
in the
system
is
system
mixture
main
jet
same
pulled
the
functions
air bleed and
emulsion
in the
manner as
out
through the
primary
main
nozzle
into the small venturi
Due
system
to the
double
vacuum
venturi
of the secondary
causes the
shown in Figures EF 19 and
secondary throttle valve
open until the
chamber is connected to the atmosphere
I
0
L
j
r
L
Ln
6
Fig
18
not
primary throttle valve opening
51
fuel consumption
during normal operation is not excessive
During high speed running as the vacuum at
the diaphragm is
the
venturi
is
increased
pulled against the diaphragm spring force and
then secondary throttle valve is opened
The
atmospheric side in the diaphragm
the higher velocity air current passing
5
of these
diaphragm
reaches approximately
produced by
main
and the composite
actuates the
As the linkage
to
main
mechanism
secondary throttle valve is linked to the
diaphragm which is actuated by the vacuum
A vacuum jet is pro
created in the venturi
of
the
at
each
vided
primary and secondary
venturies
Secondary system
Secondary
over
The
jets
1
idling
valve is closed
throttle
primary
the
system may cor
system of the
and slow
primary system
The system aims in the proper filling up of
the gap when fuel supply is transferred from
the primary system to the secondary one
The
step port is located near the secondary throttle
3
angle
to
respond
pressure
When the
of this
construction
a
The dash pot which
cars
Step system
Dash pot mechanism
EF ll
1
Lock
2
Choke wire
3
Dash pot
4
Throttle lever
5
Throttle chamber
6
Throttle valve
ut
arm
ENGINE
Model P AK340 Carburetor
z
Model DAK340 Carburetor
6
2
1
w
i
5
4
I
5
j
S
2
Diaphragm
J
jet
4
Fig
Diaphragm
Diaphragm
5
Diaphragm
6
Vacuum
ad
EF 19
low
at
Vacuum jet
4
Diaphragm chamber
5
Diaphu gm ad
P Vacuum jet
6
jet
J
Full throttle
S
Diapmilgm chamber
chamber
chamber
Primary
Primary
1
1
I
Secondary
I
Seoondary
Vacuum
6
If
1
speed
Diaphragm
EF 20
Fig
Full throttle at
high speed
Model D3034C Carburetor
6 7
2
3
4
89 10
5
I
20
21
22
r
30
31
I
29
28
2
1
25
1
24
Primary
1
Vacuum
2
P
3
Slow jet
4
SI
5
P
6
AU
piston
Slow air bleed
amner
Slow air bleed
on
7
P
Main air bleed
8
P
Main
9
P
ill
Sm
d
nturl
13
Discharge check valve
19
Pump plunger
25
511llottlevalve
14
S Small venturi
20
Inlet check valve
26
P l11rottle valve
Idle port
IS
S Main air bleed
21
S Main jet
27
10
Choke nlvc
16
Step air bleed
22
28
Slow port
11
Pump
d
17
Pump
23
Diaphragm spring
o
phngm
29
Idle
12
Pump weight
18
Stepjet
24
Step port
30
P
arm
31
Fig
EF 2
Full throttl
EF 12
at luw
speed
adjust
Mainjcr
erjcr
ll
PO
screw
FUEL SYSTEM
Model D3034C Carburetor
20
21
22
31
30
29 2B
26
271
1
Primary
1
Vacuum
piston
P Slow
bleed
3
Slowjct
4
Slow
5
P
6
Au
7
P Main
8
P
9
10
omizer
Slow air bleed
air bleed
I
Main
I1
PSm
Choke
uri
alve
Fig
24
25
Secondary
lie
11
Pump
12
Pump weight
alve
2l
SMainjet
22
Diaphragm spring
23
Diaphragm
13
Discharge
check
14
S
Small
nturi
24
Step port
15
S Main air bleed
25
S Throttle
alve
16
Step air bleed
26
P
alve
17
Throttle
Pump airm
27
Idle port
18
Step jet
28
Slow pon
19
Pump plunger
29
Idle
20
Inlet check
30
PMainjet
31
Powcrjet
EF 22
illve
Full throttle at
EF 13
adjust
high speed
w
ENGINE
Float system
Fuel level adjustment
There is only
float
one
carburetor systems
chamber while two
and
primary
Model DAK340
A
provided
are
Fuel fed from
the filter
ber
the
fuel pump flows through
valve into the float cham
and needle
Carburetor
secondary
fuel level is
constant
maintained
the
by
float and needle valve
A constant fuel level is maintained by the
2
float and needle valve
Because
of the
air
vent
type of
the float
3
chamber ventilation
the fuel consumption will
not influenced by some dirt accumulated in the
air cleaner
The
needle
is
valve
made of special hard
steel and will not wear for all its
long
considerably
use
1 5
H
ADJUSTMENT
1
Float
2
Flo 1
mm
o
D591
SRt
3
Float stopper
4
Needle
alve
Idling adjustment
Idling adjustment
adjust
is
screw and idle
As
for
the
emission control
required
made
adjust
by the
throttle
engines equipped with Nissan
system special adjustment is
detail
method is
as
follows
the float
gange line
ing the float
three
the
idle
adjust screw approximately
starting from the Mly closed
turns
position
Screw
in
the
throttle
adjust
start the engine
two or three turns and
screw
Screw
out
the throttle
adjust
until the engine is about to rotate
the
3
H mm
stroke
the gap
between the
seat to
H
mm
it
Figure EF
is required
of the needle valve
Screw
in
runs
Readjust
the
idle
23
So
as
smoothly
the
valve stem and the float
with the float fully lifted up
1 5 mm
0
00591 in
gently
unevenly after
screw
tbe
at the
throttle
screw
engine speed
Repeat these operations until
speed of apprOximately 550
a
to
drop
smooth
the
engine
has
been
down the idle
adjust
rpm
attained
Note
Do not attempt to
screw
completely
which will tend to
screw
to avoid
cause
damage
to the
tip
Fig
malfunctions
EF 14
EF 24
the
adjust
bending the float stopper
adjust screw until
highest speed
If
by bend
engine speed gradually drops
engine
4
adjust
seat as shown in
effective
H
2
with the level
level is properly set
float level is not correct
Approximately
1 Give
adjustment
If the fuel level is in accord
the
adjusting
Fuel level
DAK340 carburetor
Therefore refer to page EC OO for
Ordinal
EF 23
Fig
screw
Adjustment of float
seal DAK340
by
FUel SYSTEM
Adjustment
valve
of
startinl interlock
opening
Model D3034C Carburetor
in
J
J
Fig
EF 2S
Adjustment of float
stopper DAK340
3
Model D3034C Carburetor
1
If the fuel level is in accord with the level
J
If
gauge line the float level is properly set
the float level is not correct
adjust it by the
L
L
gaskets between the body and needle seat
Never adjust it by the float hunger
Approxi
mm
0
02756
in
is
7
clearance
mately
required
as
shown in Figure EF 26
1 Choke levcr
Fig
2
Choke valve
3
Connecting rod
EF 27
4
Connecting lever
S
Throttle lever
Adjustment of starting
opening
interlock
I
Model DAK340 Carburetor
5
4
3
40
1
Float
Float valve scat
Fig
EF 26
3
Floatvalve
4
Adjusting gasket
5
Stopper
Fuel level
adjustment
Throttle chanber
D3034C
Fig
EF 15
EF 28
G1
Throttlevlltve
Adjustment of starting interlock opening
ENGINE
The choke valve at a full close
for
14
angle
DAK340
model
D3034C
for
link mechanism
after
retor
model
and
Model D3034C Carburetor
auto
optimum
13 50
for
engine through
a
As for model DAK340 carbu
reassembly
rod for
the
starting
interlocked opening
necting
position
opens the throttle valve at an
matically
in
or
a
check
on
bend the choke
angle
adjustment
that
so
fully
a
the
closed
EF
Figure
28 to 1 1 mm
Adjustment
primary
0
0433 in
of interlock
and
lr
J
choke valve will bring the clearance Gl shown
in
I
I
con
0S
openin
secondary throttle valve
of
i
1
50DIsof
1 1
Model DAK340 Carburetor
2
I
i
600
1
i
L
1
S Throttle
2
S
f
Fig
oo
Figure
arm
JGL
Connecting lever
5
50
Throttle chamber
link
4
Return
Throttle
plOlte
Adjust pl2te
3
EF
comes
EF 29
the primary
shows the
to
primary throttle
When the adjust plate fixed
throttle
valve is open
60
it
@
@
the point
where the
contact with the stopper
connecting lever
The
linkage between
throttles
distance
wall
between
the
operates
the
by bending
0 3937 in
the
point
in
permitting
actuating
primary and
properly if
throttle
of the throttle chamber
38 mm
is
is detached
the secondary system to start
ondary
Throttle nm
5
P
Throttle valve
shows the
When the
primary
to
primary throttle
primary throttle
throttle valve is open
contact
of the
with the connecting
injection
accelerating
amount
pump
acceleration
injector during
by selecting a fitting hole
ature
But
the pump
be controlled
can
of the pump arm
of the middle
according
position
to the temper
select the proper position of the hole
shown in the table
sec
the
amounts
Position of
Injection
the hole
Inner
per
O tic
c
one
O
amount
Tempera ture
stroke
0366cu in
Below
C
32Of
to
The
@
the hole
Ordinarily
should be used
valve and inner
G2
fuel amount forced out from
The
contact with the
connecting lever at
When the throttle valve is further opened
comes
P
D3034C carburetor
Figure
7
of the
EF 29 Mudel lIAK HO carburetur
valve opened 60
to
Link
4
lIve
Adjustment
Fig
30
fixed to the
it
3
EF 30 Model D3034C carburetor
valve opened 50
I
4
ctum lever
Primary
Secondilry
1
arm
Throttle
adjustment is made
of the adjusting plate
EF 16
Hddle
Outer
0 4
c
c
O 2c
c
O 0244
O
ell
D122eu
in
in
O
C
3O
Above
C
3O
32
F
86
S6OF
as
FUel SYSTEM
MAJOR SERVICE OPERATIONS
The
perfect carubretor
delivers the proper
all speeds of the
gasoline
for
which
it
was designed
particular engine
at
disassembling
regular inter
By completely
vals
which will allow cleaning of all parts and
air
and
the
passages
original
for
ratios
carburetor
condition
and
it
be returned to its
can
will then deliver the
proper ratios as it did when new
Accurate
charge
require that
passages and dis
extreme care be
Use
carburetor solvent
calibration
holes
taken in cleaning
of
only
n
compressed air to clean all passages and
Never use wire or
passage discharge holes
other pointed instrument to clean as calibration
and
fF 3
Fig
inkage
removal
of carburetor will be affected
5
Remove four
fixing
screws
end take off choke
chamber
Removal
1
Remove air cleaner
2
Disconnect
fuel line
vacuum
line and choke
choke heat
wire in case of auto choke
from
Q
carburetor
3
Remove the throttle lever
4
Remove
J
o
four
nuts
and
washers
retaining
carburetor to manifold
5
Lift carburetor off manifold
6
Remove
Fig
and discard carburetor to manifold
gasket
EF 32 Choke chamber removal
6 Remove stop pin and four
Separate
throttle
fixing
chamber
screws
from
chamber
Disassembly
Carburetor
Model DAK340
A
l
o
1
Carburetor assembly
primary throttle
1
Remove
2
Remove
E
necting
rod
3
Remove
necting
4
Remove
return
ring and take off
split
pin and take
0
spring
and
con
off choke
con
pump
rod
Fig
secondary throttle
return
EF 33
Throttle chamber removal from
floal
spring
EF 17
i
chamber
float
ENGINE
2
Choke chamber
chamber
packing
gasket
cover
level gauge
rubber
and float
0
il
c
r
G
Fig
EF 34 Choke chamber
Fig
1
Remove two
arm
4
3 Remove choke shaft and choke valve
5
spring
4 Remove
choke lever and choke lever spring
by taking off the clip
1
Float chamber
Remove
three
fixing
diaphragm
and diaphragm
screws
cover
and
take
Remove
filter
fixtng
and
screw
take
off
Remove needle valve
6 Remove
7
chamber
disassembly
nipple and filter
2 Remove two screws and take off choke valve
3
EF 36 Float chamber
and take off choke wire
screws
fixing
screws
and take off cyl
cover
return
spring and inlet valve
piston
cover
pump
piston
Remove
pump
off
two
inder
injector fixing screw and take off
injector injector spring and outlet
valve
diaphragm spring
8
Remove
primary main
9
Remove
secondary
air bleed
main
air
bleed
and
emulsion tube
It
10
Remove
three
fixtng
screws
and take off
small venturi
C
I
A
f
4Jl
GL
0
I
0
1
0
0
Fig
EF 3S
Dinphragm
2 Remove three fixing
chamber and gasket
3 Remove
four
fixing
chamber
screws
screws
disassembly
and
0
j
l
I
diaphragm
and take off float
EF 18
Fig
EF 37 Float chamber
disassembly
FUel SYSTEM
11
Remove
and secondary slow jets
primary
and slow air bleeds
12
Remove
and
4
se
drain
condary
plugs and take
main
off
jets
Throttle chamber
1
Remove throttle
2
Remove idle
3
Remove
spring
return
e
adjust
adjust
screw
take
and
spring
and spring
throttle
lever
lever
nut
two
and
screw
sleeve
hunger
connecting
plate and adjust plate
4 Remove
fixing
off
screws
Fig
and
take
off
and
take
off
primary tnrottle valve
5
Remove
6
Remove
Remove
3 Remove
EF 39 Air horn
pump
secondary
rod
slow
jets
primary
two
fixing
screws
throttle valve
fl
b
secondary throttle shaft
Fig
tPo
EF 40 Removal
4 Remove
J
i
primary
of jets
and
c
b
and venturies
secondary
parts
Q
or
@
Fig
EF 38 Throttle chamber
duassembly
PO
p
A
Model D3034C Carburetor
1
and
small venturies
primary throttle shaft
secondary
7
v
primary
starting connecting rod from choke
lever and accelerating pump connecting rod
Remove
Fig
2 Remove three screws and air horn
EF 19
EF 41
Removal
of linkage parts
linkage
ENGINE
5
Remove
three
fixing
diaphragm chamber
and diaphragm
screws
cover
and
off
take
r
diaphragm spring
a
ai
4
ceO
f F 44 Float chamber di
Fig
a
embly
l
9
Remove
fuel inlet
strainer
and float valve
seat
Fig
EF 42
Diaphragm
chamber diw
10
Remove main
11
Remove two
embly
cut
6 Remove
three
fixing
screws
jets
fixing
screws
and take off fuel
off valve
and diaphragm
chamber and gasket
float
7 Separate
chamber
from
throttle
chamber by removing three fasteners
o
P
o
EF 45 Fuel cut
Fl
Cleaning
Dirt
and
gum
inspection
water or carbon contamination
in or on the exterior
Fig
retor
EF 43 Float chamber removal from throttle
are
carhuretion
8
Remove
chamber
three
cover
check valve
screws
glass
and
take
gaskets
a
carbu
For
depends
this
upon
reason
careful
efficient
cleaning
and
inspection while servicing
off float
float
moving parts of
often responsible for unsatisfactory
performance
chamber
oJ valve
and
1
Blow
pressed
EF 20
all
passages
and
air and blow off all
castings with
parts until dry
com
FUEL SYSTEM
Note Do not pass drills
jets
this
as
passages
or
enlarge orifice
may
be
link and related components
interlock
ful not to bend
affect carburetor calibration
seriously
and
Reassemble
the
reassembling
and
1isassembling
In
wires through calibrated
or
care
deform any of the components
all interlock links operate
or
that
so
smoothly
Check all
2
defective
pecially
parts for
If
wear
wear
parts
following
is noted
Note es
be replaced
must
JETS
the
The carburetor
1
Check float
the
noted
is
wear
and
needle
seat for
must
assembly
If
wear
be
Check
them
and
throttle
throttle
body and
choke
in
for wear or
castings
cover
bores
shaft
out of round
the
Such
ridges
needles
adjusting
to see if
gaskets
Inspect
if the
edges
or
If
such condition
bleeds
they
appear hard or
torn or distorted
are
noted
is
they
must
be
it
is
screen
for dirt
distorted
or
cluster
remains
or
output to meet
plugged
clusters
If
damage
assembly
for
loose
or
main
smaller
looseness exists
or
worn
replace
Check the linkage for operating condition
7
Inspect
in
the operation of accelerating
the
gasoline
in
the injection condition of the
bring
and block
And
check the
when
leakage
a
the limited sacrifice of
slow
air
bleeds than
should
the
meet
regularly
purpose
jets
or
or
slow
consumption
slow jets
or
air bleeds
use
smaller main
and that should
satisfactory result
And the check
gasoline
from the
rod
the passage
free
of
air
of
diaphragm
of
by
AND CORRECTIONS
vacuum
connecting rod
and tbe damage of
In
causes
There
no
defect
troubles
electric
reverse
quick
various causes of
seems
that the carburetor which
apparently
system
must
EF
21
have
to
system
whenever the engine
be checked
starting carburetor adjustment
if necessary
repairs
engine troubles
when electric
Therefore
Follow the disassembly and removal proce
are
sometimes happens
has
Assembly and installation
following table
them are listed to facilitate
It
Replace the gaskets
the sympioms and
of carburetor troubles and remedies for
the
the
diaphragm
dure in
cite
when increase in output is desired at
main
a
To
becomes necessary
TROUBLE DIAGNOSES
Push in the connecting
finger
or
meet the
pump
accelerating nozzle
chamber
at
and
must be carried out
limited sacrifice of fuel
the
to
air
make
through
float chamber and
the
make the throttle lever operate
8
leaner
slow
frequent light load operation use
jets or slow jets or larger main
This
specified
Inversely
larger
6
car
when it
fuel
economize
air bleeds
Put
and
above directions in mind
with the
air bleeds
Check venturi
parts
condition of the
Clean
lint
replace
5
main
designated jets
of
Replacement
to
if
the
numbers
for air to pass
are
practical example
Check filter
and
which
service
replaced
4
them
on
the fuel leaner if they bear larger numbers
the smaller numbers the richer fuel
brittle
any
air
blow
the
Inversely
mixture
ment
3
smaller
the
and
or
requires replace
condition
a
for burrs
and
gasolir e
use
clean
To
care
Larger numbers siamped on the jets indicate
Accordingly main and slow
larger diameters
jets with larger numbers provide richer mix
ture
3 Inspect
utmost
with
fabricated
are
placed
2
and air bleeds
re
performance depends on jets
why these components
That is
is
some
defective
has troubles
first before
ENGINE
Troubles
Overflow
Excessive fuel
consumption
Possible
Remedies
causes
Dirt accumulated on needle valve
Clean needle valve
Fuel pump pressure too high
Repair
pump
Needle valve seat improper
Lap
replace
Fuel overflow
See above item
Each main jet
slow jet too large
Each main air bleed
or
Replace
Clean
clogged
Choke valve does not fully open
Adjust
Outlet
Lap
pump
valve
of
accelerator
of
secondary
seat
improper
Linked
opening
Adjust
throttle valve too early
Power shortage
Each main jet
Each
throttle
clogged
valve
Clean
does
not
fully
Adjust
open
Improper idling
Fuel pump operated improperly
Repair
Fuel strainer clogged
Clean
Vacuum jet clogged
Clean
Air cleaner
Clean
clogged
Diaphragm damaged
Replace
Power valve operated improperly
Adjust
Slow jet
Clean
clogged
Each throttle valve does not close
Adjust
Secondary throttle
improperly
Overhaul and clean
valve
Each throttle valve shaft
Packing
between
operated
Replace
worn
manifold carbu
Replace packing
retor defective
Manifoldl carburetor
tightening
im
Correct
tightening
proper
Fuel overflow
Engine hesitation
Each main jet
See the first item
slow jet clogged
By pass hole
idle passage
Emulsion tube
clogged
clogged
Clean
Clean tube
Clean
EF 22
FUEL SYSTEM
Idling adjustment
Secondary throttle
improperly
Engine does
not
start
Correct
incorrect
valve
operated
adjustment
Overhaul and clean
Fuel overflows
See the first item
No fuel
Check pump
fuel pipe and needle
valve
Gauge plate adjustment incorrect
Idling adjustment
Fast idle
incorrect
adjustment
incorrect
Bimetal rod in contact
with bimetal
Correct
adjustment
Correct
adjustment
Correct
adjustment
Adjust
case
SPECIFICATIONS AND SERVICE DATA
r
D3034C
OAK 340
model
Item
30
34
30
34
1 1811
1 3386
1 1811
1 3386
Outlet diameter
mm
in
29 x 9
23
Venturi diameter
mm
in
Se condary
Primary
Se condary
Primary
0
9055
1 1417 x
28 x 16 x 8
23 x 14 x 7
0
9055 x 0 5512
0 0354
0
x
1 1024 x O
2756
x
O
11155
102
11119
II 165
Main air bleed
11220
II 100
II
60
II
80
Slow jet
II
II
II
50
II
80
Slow air bleed
11130
Main
jet
90
11100
in
0
160
x
II 220
II 150
1 6
1 4
Slow economizer
mm
48
0
0551
063
1 2
Economizer bleed
mm
in
mm
in
0 0472
o 5
Power
Weight
jet
kg
lbs
0 0197
2
5
2
9
5
5
5
87
EF 23
6299
3149
ENGINE
Main
jet
variation
ModeIDAK340
Jet
Altitude
Primary
Note Jets for
be
000 ft
1
000
m
3
300 ft
2
000
m
6
2
000
m
6
000 ft
3 000
m
10 000 ft
3
000 m
10 000 ft
4
000 m
13 300 ft
Secondary
115
160
112
155
108
150
model D3034C carburetor should not
changed because of
the
special calibration
for emission control
SERVICE JOURNAL OR
DATE
JOURNAL
BULLETIN
BULLETIN
REFERENCE
or
No
PAGE
No
SUBJECT
EF 24
l
t
L
DATSUN lt
1800
t
J
SERVICE
MANUAL
MODEL
SECTION
EC
EMISSION
CONTROL
SYSTEM
G11
ENGINE
GENERAL DESCRIPTION
EC 1
POSITIVE CRANKCASE VENTIlATION SYSTEM EC 1
NISSAN MOTOR CO
TOKYO
JAPAN
LTD
EXHAUST CONTROL SYSTEM
EC 2
EMISSION CONTROL SYSTEM
GENERAL DESCRIPTION
There are
tow
be controlled
sions
the exhaust
and
emissions
types of
are
controlled by
are
controlled by
of these
Crankcase
emissions
use of the Positive
intervals
to
assure
a
at the
cleaner
performing
longer lasting engine and
almost complete elimination of air pollution
better
of the Nissan Air
use
servlCmg
out
systems should be carried
recommended
Exhaust emis
Crankcase Ventilation System
sions
Injection System N A I S
Periodic inspection and required
emissions that must
These are the crankcase emis
POSITIVE CRANKCASE VENTILATION
sysTE M
CONTENTS
DESCRIPTION
EC 1
TESTING
EC 2
EC 2
PERIODIC SERVICE
DESCRIPTION
Crankcase emissions
of the
so
are
use
with valve
called combination system
controlled by intake manifold
to
controlled by
vacuum
and tube
This system provides
air cleaner device
Carburetor
air
for the return of blowby gases to both the in
take manifold and carburetor air cleaner
the
e
cleaner
o
6
During part throttle operation of the engine
intake manifold sucks the crankcase blowby
the
through
gases
variable
orifice
tapered plUnger type
Normally the capacity of the valve
under these
ficient
blowby plus
The
air
clean
of
amount
is
valve
II
is suf
to handle
of
u
the
ventilating
air is then drawn from the
the
carburetor
the tube connection
Under
vacuum
adequate
ventilating
side
through
an
conditions
o
air
cleaner
into the crankcase
full throttle conditions
the manifold
insufficient to draw the blowby flow
and the blowby flow goes
through the valve
through the tube to air cleaner in the reverse
In cars having
direction
excessively
high
the
will
tube
some
of
the
flow
through
blowby
go
cOlmection
to the
carburetor air cleaner under
all conditions
The control
valve
was
shown to be capable
of operating longer with much less
Fig
EC 1
Positive crankcase ventilation
part throttle operation
clogging
EC
l
c
ENGINE
TESTING
lith
engine
ventilator hose
valve
as
air
vacuum
is
working
is
passes
should
placed
over
the rocker
Replace
the
remove
cover
hissing noise will be heard
through the valve and a strong
be felt immediately when a finger
the valve inlet
with a
new
1
Check hoses and hose connectors for leaks
2
Disconnect ail
If the
a
If valve is plugged
it
idle
at
running
from
do not attempt to clean
compressed
If any hose
3
Once a year
Positive
or
Check
for
function
proper
of
ncase
cra
ventilation control valve
at 20 000 km
Crankcase
should be serviced
be freed of obstructions
cannot
with new hose
replace
valve
PERIODIC SERVICE
the
hoses and blow them out with
air
12
000 miles
Ventilation
If the val ve is found defective replace with
System
new
a
assembly
follows
as
EXHAUST CONTROL SYSTEM
CONTENTS
DESCRIPTION
EC
2
EC
3
DIAGNOSIS AND TESTING
Engine driven air pump
EC
4
Diagnosiasl
gener
Air
injection
Engine modifications
EC
5
Diagnosis air pump
EC 12
EC
7
Testing
EC 14
Recommended annual maintenance
EC
8
EC
8
Air pump
EC
8
Drive pulley
EC 11
Anti backfire valve
EC 11
SERVICE
Check valve
EC 11
SPECIFICATIONS
NISSAN
AIR
INJECTION SYSTEM
into each exhaust port
REMOVAL AND DISASSEMBLY
Air
gallery pipe and injection
EC 11
EC 12
EC 12
exhaust system
SETTING IGNITION
TIMING
IDLE SPEED
ADJUSTING
PROCEDURE
nozzles
MIXTURE
EC 17
MAINTENANCE
EC 17
General maintenance
EC 18
Periodic recommended maintenance
EC 19
DATA
AND
EC 20
DESCRIPTION
The
Nissan Air
is
Injection System
air pollution
reduce
N
A IS
and carbon
designed
by
engine exhaust tailpipe gases by treating the
unburned hydrocarbons and carbon monoxide as
they are expelled from the combustion cbam
to
bers into the exhaust manifolds
ing
pump
driven
by
the
engine
caused
A sealed bear
chemical
exhaust
air
distributes and injects clean filtered air into the
A
exhaust
are
air
port of each cylinder
Here the clean
combines with the unburned hydrocarbons
EC 2
an
pump
valve
at
high temperatures
producing
a
in a
treated
below the maximum allowable level for
The
pollution
include
tion
compresses
monoxide
reactions
elements of the N A I S
air cleaner
a
check
and related
a
belt driven air injec
valve
an
anti backfire
connecting tubes
and hoses
special calibrated carburetor and distributor
also used with the air injection system
EMISSION CONTROL SYSTEM
Fig
EC 2
Model CI8
Engine
NISSAN AIR INJECTION SYSTEM
Air pump
Relief
valve
Carburetor air cleaner
Vacuum sensing line
Special
catibratad
carburetor
Fig
EC 1
Nissan air
EC 3
injection system
ENGINE
N A I S
is
basically an air injection sys
engine modifications to
with
combined
tem
increase its effectiveness
The basic elements of the
system
goes to an anti backfire valve and then to a
check valve
which prevents exhaust gas from
air
the
pump in the event exhaust mani
entering
fold
are
than
greater
air
The compressed fresh air is injected
1
Engine driven
air pump
2
Air
3
Engine modifications
4
Recommended annual maintenance
injection nozzle
into each exhaust port
injection
or in the case of an inoperative pump
pressure
injection
is
pressure
valve has been installed to
in the exhaust
popping
the throttle is closed at
a
system when
coast
high speed
Controls which have been incorporated to
reliable system operation include
fire valve and a check valve
The air injection pump receives clean air by
connected to a fitting on the
of a hose
means
This
signed
rotary
to
vane
type
pump has been de
draw the air in and
air flow with
quiet operation
produce
The
maximum
A fresh air line
from the air injection pump is routed
so
that it
injection pump is a positive dis
type which is permanently
and requires no periodic mainte
placement
vane
lubricated
nance
Vane
Relief valve
The die
EC 4
Stripper
Sectional view
aluminum air pump assembly
cast
attached to the front of the engine is driven by
an
air pump drive
hub
are
relief valve
visible
vanes
on
belt
A
rotor shaft
drive
and intake and exhaust tubes
the
carbon shoes
pump
exterior
assure
anti back
air
Housing
Fig
an
air pump
drEngiivenne
underside of the carburetor air cleaner
an
to the exhaust ports
An anti backfire
eliminate
through
A rotor
of air
the
EC 4
rotating
unit of the pump
in the center of the
pin
The rotor located
The
pump is belt driven
freely around the off center pivot
and follow the circular shaped pump bore
vanes
The
and shoe springs make up
pump
rotate
vanes
housing
produce
intake
three
chambers
compression
and
in
the
exhaust
EMISSION CONTROL SYSTEM
Side seal
Ball bearmg
I
j
I
Pulley
hub
Needle bearing
V
Vane shaft
Rotor ring
Needle bearing
EC S
Fig
Each
completes
vane
pumping cycle
a
a tube
connected to the air
The air is sealed between the
cleaner
into a smaller
and moved
sion
After
the
compression
The
cavity
vanes
then
vanes
a section of the
the vane
its
again
pumping
cycle
encloses
in
provide
compression
in the rotor
of
sliding
interior
are
both
a
are
from slots
to
permit
the air cavities
Leaf springs
the follower side of the shoes
into the rotor is
small holes in the end
sealed
exhaust
seal the rotor
compensate for shoe
further
vanes
designed
and
vane
articulation
exhausted
cover
a
small
lUlit is
a
steel ring
rear
bearing and the
front
and
bearings which support
The front bearing
types
rear
and the
The
needle
bearings
bearing type
greased for life
needle
bearing uses
bearings are the
All bearings have been
rear
hub
the housing
and
to
wear
by the
This ring prevents the
at high r p m
and also
holds the
ball bearings
Air
injection
The
and
spreading
and
rotor are of two
transition from intake
support the
vanes
behind
leaking
quiet
The
uses
pre
pre set value
into
the intake
The shoes
the
from
a
leaks
carbon seal
the
to exhaust
Carbon shoes
two
a
positions
to
The relief valve
machined
grooves
located
cavities
Air
rotor from
Continuing
cavity
if the pressure exceeds
Metering
which
the
a seat
and a pressure setting
function is to relieve the exhaust air
Its
wall
pass
enters the intake
to confine the air
carbon seal is exhausted through
front
pass
spring
plug
cavities
pump
bolted to the rotor end
the
located in the exhaust cavity
loaded
the
cover
Air that
the
housing that separates
the exhaust and intake cavities
cycle
repeat
and end
off the housing
to
The plates also seal
attached to each end
are
hole in the housing
the compres
cavity
air pump
Completing the rotating
stripper
to
vanes
of
area
exhaust
flow
in every
Air is drawn into the
revolution of the rotor
intake cavity through
Sectional view
through
The rotor is
by flexible carbon seals which
EC 5
into each exhaust
fresh air from the air pump is
into the individual
exhaust ports of the
port
injected
cylinder
head in the vicinity of the exhaust port
Pressurized
air
is
transmitted
through
hoses and air distribution manifold
A schematic of the exhaust port is shown in
Figure EC 6
In addition to air
have
been
injection
incorporated to
system operation
as
follows
certain controls
assure
reliable
ENGINE
Air
injection
Air
Fig
EC 6 Air
injection
nozzle
gallery pipe
into exhaust port
Anti backfire valve
This valve is controlled by intake manifold
vacuumvand is required to prevent exhaust sys
tem
baClUires during deceleration
During
deceleration
is too rich to
Dis
hlfVltllir
check
to
yalve
the mixture in the intake manifold
burn and ignites when combined
with the injected air in the exhaust manifold
The
anti backfire valve is
air delivered
to the exhaust
used to shut off
system during
the
first pre determined period of deceleration
so
that backfires
are
nlet
prevented
A schematic of the
shown in Figure EC 7
The
By pas air
to
ir pump
anti backfire
valve
is
anti backfire valve inlet is connected to
the air pump
discharge
line
one
of the outlets
to the
check valve and the other to the air pump
sucticn line
Since the valve action can have a deleterious
effect
set
on
under
backfire
emission reduction
its
operation is
ce restriction
BaI
orifice
fine compromise between adequate
suppression and minimum emission
a
effects
Fig
EC 6
EC 7
Sectional view
of anti backfire
valve
EMISSION CONTROL SYSTEM
If the valve does not work properly
or
backfire
Engine modifications
emission deterioration will result
Check valve
The
Air
Inj
ection
System includes
engine
modifications necessary
haust
hydrocarbons
and
to
some
reduce
carbon
ex
monoxide
concentrations
Carburetor
In
consideration
engine
ness
drive
feeling
equipped
with
Ignition
performance
fuel
the GIS
for this
with
narrow
of air injection effective
engine
ignition distributor
is
used
Check
check valve
the
valve is set between the air pump and
air
injection
distribution manifold
When
system
exceed
pressure
will at high speed
the air
belt fails
air
or
will
pressure
backing
exceed
up exhaust gas
entering
the
exhaust
injection
the
air
manifold
pressure
as
it
when the air pump drive
injection nozzle
of the exhaust gases
in
and
air
is in the
path
the exhaust manifold
injection
pressure
which is prevented from
system by the
check valve
different
system
is
timing
a
engines without
retarded
by
13
degrees
Idle
the air injection nozzle
It prevents a back
flow of exhaust gas
it passes air
Normally
into
ignition
with the Air
with
provided
exhaust emission control
Idle
of
is
special calibrated carburetors
advance curve from that used on
EC 8 Sectional view
system
to tolerance for fuel flow
Injection System
Fig
and
distributor
The
an
economy
speed
The
idle
Specifications
mission
speed
are
is
set
700 r p
equipped vehicles
automatic transmission
Ee
r
at
m
a
higher
r
p m
for manual trans
and
650 r p m
for
equipped vehicles
Ref
I
F
Carburetor idle mixture
On
equipped with the Air Inje ction
System
slightly rich adjustment of the idle
mixture is required
cars
whicb
closes it off
Cooling system
A
used
Air pump relief valve
cavity of the air
pump
plishes the following functions
the
exhaust
emission
control
and
cooling
system will be
heat
rejection
at
without
system
Cooling system changes such as larger fans
higher fan speeds are incorporated
accom
affecting
s
effec
Fluid fan coupling
tiveness
Hold the increase
engine
idle caused by retarded ignition timing
The air pump relief valve is mounted in the
discharge
modified
due to increased engine
in maxtmum exhaust gas
The
Minimize horsepower losses
larger fans
A fluid fan
temperatures to a minimum
resulting
air injection into the exhaust system
Protect the pump against excessive
increase fan noise
coupling
is used on Air
Injection
equipped engines
When the engine speed rises
to
some
predetermined speed the fluid fan
from
back
coupling
is activated and therefore reduces fan
noise and fuel
pressures
EC 7
consumption
ENGINE
Spark plug
Projected electrode type spark plugs are
employed on all of Nissan s emission controlled
engines
Recommended annual maintenance
For the continued proper
performance
Nissan Air
must be
InjectionSystem
performed
details
The
of
annual
described in chapter
of the
annual maintenance
maintenance
are
MAINTENANCE
REMOVAL AND DISASSEMBLY
The
exhaust emission control
system should
not be removed generally and full
inspection
must be done prior to removal
3
Remove
Air pump
Removal
that
pin with
up
then
special
assure
remove
retain rotor ring to rotor
wrench
hexagon
from
by carefully tap
cover
reassembly and
screws
tool
six
using
STECP
20000
air
housing
pump
Note Generally manufacture already gives coincidence
cover
2
housing end
vicinity of
cover
Scribe rotor ring and side of rotor to
proper
hoses
end
Removing
ping on
large dowel
plastic hammer and lifting straight
4
1 Disconnect
EC 9
Fig
PROCEDURE
Remove
marks
bolt securing air pump to belt ad
on
both rotor
ring
and rotor
justing bar
3
Remove bolt securing air pump to mounting
bracket and
4
remove
Remove air pump
air pump drive belt
assembly
from car
Periodic service
Since the
nent
is
bearings
type lubrication
in the pump have perma
maintenance
periodic
no
required
the
Every 4500 km 3000 miles
belt tension should be inspected and adjusted
Note
Mask the
washing
Disassembly of
1
Remove
remove
holes in the
two
end
cover
when
the car with steam cleaner
air pump
four
Fig
pulley
drive
hub
bolts
EC 10
Remolling
rotor
ring
and
5
pulley from hub
Remove rotor
ring and side carbon seal from
rotor
2
Clamp
air
shown
in
housing end
Note
pump
drive
Figure
EC
cover
Never clamp
on
hub
9
and
in
a
vise
remove
as
6
four
If it
is necessary to
replace
out of rotor
rear
bearing
it
be pressed
ring on a press
using support for disassembling rotor ring
STECP 20001
and attachment
special tool
may
bolts
the aluminum housing
EC
8
EMISSION CONTROL SYSTEM
for
needle
pushing
bearing
special tool
STECP 20002
Note Support rotor ring carefully to avoid distortion
EC 13
Fig
Fig
EC 11
Removing
rear
rotor
Removing relief
valve
bearing
10
further
No
should
disassembly
be
at
temped
7
Remove vanes from rotor
8
Remove three sets of carbon shoes and three
shoe
springs using pair of
nose
pliers
tweezers or needle
Cleaning inspection Iubrication
Cleaning
Clean
rear
bearing and
vane
hub bearings
in petroleum solvent
Clean carbon dust from pump housing and
rotor
Note
assembly with
Do not use
an
air hose
cleaning solvent
on
pump
and rotor assembly
t8
w
i
1
00
8
Fig
9
If it
use
EC 12
Removing
is necessary to
bridge
cial tool
for
carbon shoe
replace the relief valve
pulling
out relief valve
STECP 20004
and standard
spe
puller
EC 9
Fig
EC 14 Air pump
components
housing
ENGINE
all
Inspect
s
vanes
for
parts
and roughne
we ar
chipping
scoring
quiet and efficient
carbon seal is scored
ensure
If especially
operation
replace with
The
operation
to ten miles wear in
require five
may
In the event a slight squeaking
running time
still persists the vehicle should be run through
In
two or three full throttle shift points
s
All damaged parts must be replaced to
side
initial
squeaking during
Inspection
most cases five to ten miles will be sufficient
new
for wear in
one
Carbon dust may be present in the housing
and is usually
an
indication of normal
wear
4
rear
bearing
and
be lubricated with
must
such
grease
as
260
or
bearing
side of
each
service
are
already packed
to
Insert three shoe
Note When
with
will
grease
pump
pump drive hub between
vanes
that
deeper
of
springs
positioned
properly
are
be flush
they
The
below rotor surface
or
will
portion of spring
be
against
the
shoe and ends will be against wall of shoe slot
1 Place air pump housing in
Assemble
into the
springs
so
vane
shoe slots
curved
Assembly of air
positioned
the
must
its
adequate lubrication
high melting point
9
on
chamfered end of shoe faces to
high melting point
a
ANDOK
ESSO
Work grease into each
Note Bearings for
2
shoe
carbon
Note Each carbon shoe
hub bearings
vane
5
equivalent
insure
one
every vane
Lubrication
The
Insert
vise
clamping
6
jaws
correctly
s special tool
5
a
on
If rear bearing
may
dummy shaft
tachment
STECP 20005
for
0
The
bearing
0
0315 in
below
end
bearing
8 mm
ring surface
only
lettered
on
and support rotor
7
in
bearing
ring using at
needle
bearing
a new
STECP 20003
should be about
Note Press
into rotor
pressing
special tool
rotor
removed
was
pressed
be
Pos tion
new
ring
surface
to prevent its distortion
carbon seal
on
rotor
ring
so
that holes line up
8
Position
rotor
9
Apply
rotor
ring
3
Place
vane
remove
Note
a
Vane
thread
Pack in
into rotor
vane
Installation of
a
as
Remove
housing
indexing
that one
tion pump may result in
set
vanes
material to six rotor
locking
screws
2
and tighten them
2 to 3
to
6 lb ft
vane
shaft into
cover
on as
vane
bearings
Do
this will distort vane
Do not
bearing and
11
cover
in air injec
chirping
Ibft
or
EC
Seat end
or vane
cover
bolt adjacent to
ESSO ANDOK 260
new vane
on
dummy shaft from vanes and start
end cover assembly into position
not force
hub bearing with high melting
point grease such
b
10
ssembly
a
making sure
against housing stripper
dummy shaft at this time
vanes
is
EC IS
that scribe marks
so
and side of rotor line up
ring retaining
30 to 50 kg cm
Fig
ring
lO
to
bearing alignment
housing and starting with
large
dowel torque four end
bolts to 100 to 130 kg
Remove from vise
cm
7
2 to 9 4
EMISSION CONTROL SYSTEM
12
Insert
relief valve
hole
With
into housing mounting
protective plate over valve tap
hammer
with
valve
until
shoulders
check the valve operation and inspect all hoses
and hose connections for leak
on
housing
Check valve
1
Disconnect the air
2
Remove the check valve from the air
holding
pipe
a
000
gallery
the flange of air gallery pipe with
wrench
Note a Take care not to
damage
the air
gallery pipe
b No further disassembly should be done
3
T
M
hose
supply
Installation
of check valve
reversal of
is
procedure given for removal
Note
Before installation apply the anti seize com
No 250 at the
PLATE
LED
pound such as
a
screw
b
Tightening torque
to 10 5
9 0
kg
m
65 to
76 Ib ft
Fig
EC 16
Specinl
tool
4
Note Care
be observed
must
of air pump
to
prevent distortion
After installation check the valve
hoses and
hose connections for air leakage
housing
Air
Set silencer to relief valve
13
gallery pipe and
injection nozzles
by hand
It
Installation of air pump
Installation of air pump is reversal of pro
cedure
for
given
removal
noting
following
points
Adjust the belt
mm
kg
0
315
1 5 to 2
Note
to
0
2 Ib
tension so that it has 8 to 12
472
in
of slack under 7 to 10
of load
1
remove
manifold
injection
without
Lubricate around the screwed portion of the
injection nozzle with engine oil
adjusting bar
nut
screwed
plug
injection nozzle
to
And then
pump
the
Remove
gallery
supply
to
exhaust
housing
pulley
Loosen the air
difficult
the
If damaged
it will result in fra
damaging
tures or leakage
Therefore the removal of the
air gallery pipe and injection nozzle should be
done only when they are damaged
2
1
very
from
air
Do not pry on the die cast pump
Dri ve
is
nozzles
remove
the air
connecting
air
exhaust manifold
gallery
from
the ex
haust manifold
and bolt to relieve the belt tension
Note
2
Remove the drive
pulley attaching
a
Apply engine
in
bolts
oil
The
removal
the
screwed
portion
work
b Take care not to
Anti backfire
to
several times during the above sequence
damage other
correct parts
valve
of
the
anti backfire
valve
No
further
requires disconnecting the hoses
After installation
disassembly should be done
EC
3
Insert
a
hard wire with hooked
tip through
the injection nozzle and hook nozzle with it
then
ll
remove
and
ENGINE
the
Check
4
fractures
air
gallery
Clean the
leakage
or
and
nozzle
air
Tighten the screwed plug connecting the air
gallery to injection nozzle exhaust manifold to
for
6
injection
nozzle with wire brush
a torque
0 to 6
of 5
Note Before
5
At the time of installation
nozzles must
pound
the air injection
0
kg
installation
such
m
36 to 43 ft lb
apply
the anti seize
LED PLATE
as
No 250
com
at
the
screw
be correctly positioned into the
7
exhaust manifold
Check the engine running
DIAGNOSIS AND TESTING
Diagnosis general exhaust system
A
preliminary
Diagnosis
Guide
ed below
is includ
Trouble
Excessive
backfire
as
an
Possible
in
Anti backfire valve
exhaust
disconnected
system
Defectibe
or
or
or
system
line collapsed
mulfunctioning
on
anti backfire valve
mixture
adjustment
air distribution manifold
Improper carburetor adjustment idle speed
mixture
choke setting etc
Rough engine idle
plugged
leaking
Defective check valve
burned
ex
cause
vacuum
Improper carburetor fuel
Air supply hose baked
aid in trouble shooting the
haust emission control
idle fuel
Improper initial ignition timing
Intake
line
Enginesurges
at all
Improper carburetor adjustment idle speed
speeds
air pump drive belt
choke
Drive belt
Seized
or
On
solting
idle fuel
etc
improperly adjusted
failing
Misaligned
Diagnosis
vacuum
at the anti backfire valve vacuum chamber
mixture
Noisy
leak at the anti backfire valve
vacuum
or
or
air pump
defective pulleys
air pump
car
1
Noise
external
cause
in
Under normal
pitch
as
see
that it rotates and check
belt for proper tension
Air injection pump is not completely noise
less
Check pump to
conditions
noise
2
rises
loose
engine speed increase
If excessive noise is heard
Check hoses
to
leaking
insure
or
that
they
following
steps should be taken
3
EC
12
not
touching other parts of
car
the
are
Check relief valve for escaping air
EMISSION CONTROL SYSTEM
Noise
internal
2
cause
Inspect carbon seal
This seal should not
show holes caused by
1 Vane noise
A chirping
or
squeaking
monly associated
bore
housing
cracked
noise is most com
with
Vane
noticeable at low speed
is
chirping
from
in
rubbing
vanes
3
With
rear
moved
mittently
Additional
wear
in time may eliminate this
If additional
condition
not eliminate
sembled
wearin
is
time does
Bearing noise
A rolling sound
this
This
sound
bearing noise
noticeable at all speeds
necessarily indicate bearing
not
failure
However
objectionable level
replaced
Off
4
will be
but does
if noise
bearing
pull
out vanes
bearing
Vane
re
failure
by absence of grease or
Inspect vane shaft to confirm
bearing
failure
All
should be square
indicates
or
also indicated
vanes
2
be broken
ring and carbon seal
rotor
caked grease
pump must be disas
and carbon shoes replaced
chirp
vanes
or
A failed seal must be replaced
most
and is heard inter
rear
wear
Such condition commonly results
andlor vane bearing failure
be
Remove
corners
Broken
edges
of
vanes
require
replaced
shoes
carbon
and
inspect surface
Small grooves in shoes are
contacting vane
normal
chipped or broken shoes require
Broken shoes indicate impro
replacement
per assembly of shoe springs
Damaged
shoes must be replaced and springs must be
properly installed
increases to
may have to be
car
1 With pump removed from
car
rotate drive
5
hub in jerks three quarters of turn forward
and
one
ness
or
not failure
If rough
quarter of turn backward
rear
cover
bumps are felt remove
Trouble
Inoperative
Possible
pump
Carbon dust may be present on vanes and in
This is indication of normal wear
housing
air on
parts
Remove carbon dust
in
Remedies
cause
Trouble in pump
Replace with
Excessive slackness of drive belt
Adjust
new
pump
drive belt tension to specifi
ed data
Insufficient
delivering
Damaged
vane
hub
Replace defective parts
bearing
air
Air leakage
Abnormal noise
Worn vane
Replace
worn
parts
Worn carbon shoe
Replace
worn
parts
Worn side seal
Replace
worn
parts
Leakage from
or clamps
hoses
connectors
Ammend
or
tighten
Replace if necessary
Leakage from relief valve
Replace relief valve
Stick of air pump
Replace with
Slackness of drive belt
Adjust
in
or
new
assembly
drive belt tension
accelerating
Leakage
from hoses
by blowing
question
connectors
clamps
EC
13
Retighten
or
replace
ENGINE
It should
Testing
The following procedures
are
tion
recommended
Prior to performing
the exhaust
control
mined
the
that
system
engine as a
Die conne ct the
prope rly
it
must
unit is
the
engine
1
original posi
when released
500 r p m
or
increase the
and
watch
and start the
engine speed
for
the check valve
at
not be any
flutter
disconnected
hose
Slowly
leakage
be deter
exhaust
The valve may
leakage
at idle
vibrate
to
exhaust gas
There should
but this is
speeds
normal due to the exhaust pulsations
functioning
hi the
manifold
anti backfire valve
Plug the anti backfire
sensing hose
valve vacuum sensing hose to close the passage
fe
Lea
1
diagnosis of
any extensive
the valve seat
V
checking andlor verifying
components of the exhaust emission control
The engine and
system are operating properly
all components must be at normal operating
temperatures when the test are performed
that the various
for
return to the
freely
against
vacuum
to the intake manifold N
ing
the engine
the N A I S
A
a
can
the
be performed at the
same
engine until
it
reaches
a
Operate the engine until
operating temperature
b
Inspect all
time
normal
ovbious
Inspect all
hoses
obvious leaks
fore checking
c
Disconnect
and
and
connectors
hose
correct as
supply
hose
necessary be
at
c
the
check
reaches normal
connections
correct
them
for
before
anti backfire valve operation if
Accelerate
the
the throttle
to
operating
valve
d
and hose
and
leaks
it
necessary
for
the valve operation
air
hoses
checking the
operating temperature
b
recom
it
Anti backfire valve test
the air pump test
Operate
replace
reinstall all
parts
This test
If the check valve does not meet the
mended conditions
After check
IS
normal operation
Check valve test
as
g
in neutral
engine
close rapidly
satisfactorily
system backfire
when
allowing
The
valve is
no
exhaust
occures
Visually inspect the position of the valve
It should be
plate inside the valve body
lightly
positioned
against
the
valve
seat
away from the air distributor manifold
e
Insert
a
probe
into the valve
connection on
the check valve and depress the valve plate
J i
d
f
8
Inli ba
If a further check is
the
by
pass hose
EC 17
Check valve lest
EC
14
lest
valvf
necessary
disconnect
to air pump suction line at
the anti backfire valve
fig
kfirc
EMISSION CONTROL SYSTEM
e
Open
and close the throttle valve
air flow
finger
is
felt
for
felt
is
line
continuously
Disconnect the vacuum
manifold
Insert a suitable
it
one
by
a
Air pump test
a
more
plug
air
b
two
sensing
hose
ing
from the
c
valve
idle
d
speed
the case the vacuum
ed with the valve
varies
excessively from
sensing
hose is connect
the
proper and it should be
the air
supply
Install
hose
connections
for
necessary before check
pump
a tachometer
500 r p
m
following order
1
To air pump
Air pump test gauge
STEep 20006
4ir pump le 1
gauge
EC 15
as
engine and slowly
To pressure gauge
9
and
hoses
replaced
0
reaches normal
Check the air pump belt tension and adjust to
to 1
valve function is not
Fig
it
specifications
in the hose and fasten
securely
If engine
Inspect all
leaks and correct
replaced
the anti backfire
at
or
than
Operate the engine until
operating temperature
the valve is function
the valve should be
seconds
intake
second to
If air flow is not felt
ing properly
f
a
If
at the anti backfire valve outlet to the
air pump suction
flow
half
rapidly
on
the
Start the
engine
engine speed
increase the
Check
the
air pump in the
ENGINE
AIR PUMP TEST
Check for the air leakage of relief valve with
engine speed at 1 500 r p m
No
leaky pressure
Leaky
is felt
pressure is felt
Disconnect the air supply hose at the anti
backfire valve
Plug up it
Check the air leakage of relief valve with
engine speed
at 1 500
No leaky pressure is felt
Leaky
p
m
pressure is felt
Insert the open pipe end of the test gauge adaptor in the air supply
hose to the check valve at the anti backfire valve
Relief valve is stuck
Replace with
r
new one
Clamp the hose securely
With engine speed at 1 500 r p
observe the
m
the test gauge special tool
STECP200006
Air pressure
Plug
Air pump and relief
valve are functioning
again
produced
less than 3 4 psi
more
up the relief
Air pump is func
than 3 4
psi
tioning properly
valve and observe
properly
pressure
the pressure
Air pressure
Replace relief
Disconnect and plug the air hose to the air pump suction
line at the anti backfire valve
With
engine speed at
produced at the test
1 500 rp
gauge
m
special
valve
observe the pressure
tool
STECP200006
Aire pressure
Air pump is
functioning
properly
Replace
pump
I nspect air leakage
from anti backfire
or
repair air
Air pump is
functioning
properly
Inspect air leakage
from anti backfire
valve hose or hose
connections
valve
hose or hose
connections
EC
16
at
EMISSION CONTROL SYSTEM
SETTING IGNITION TIMING
ADJUSTING IDLE SPEED MIXTURE
Note Care
ann
shaft
arm
that
be taken
must
should
never
adjust
throttle shaft
the
pressed by
be
the throttle
screw
Engine tune up must be done according to
Specifications with necessary equipments
Nissan
recommended
The
following procedures
are
recommended
1 Install the air cleaner
2
Warm
engine thoroughly with the
position
the
up
transmission in neutral
3
7f
it
ignition tachometer and timing light
Connect
If the
rNote
4
car
is
sure the
make
mission
the
Turn
shaft
throttle
clockwise
trans
dash pot does
not
ITHROTTLE
throttle closing
interfere with
counter
with automatic
equipped
so
adjust
arm
screw
that the tip of it does not
Fig
touch the throttle shaft arm
EC 20 Model D3034C carburetor
Note If you set
Set
5
for
the idle
throttle adjust
ing
at 700
speed
r
screw
at 50 A T D
650
p m
p
r
CO meter
m
speed and mixture by using
the followin
procedure should be
idle
done after above item 3
adjusting the
and adjust the ignition tim
transmission
automatic
SHAET
ARM ADJUSTSCREW
by
a
Disconnect the air supply hose at the check
valve
C
Insert
a
suitable plug in the check
valve inlet
Adjust the idle adjust screw and throttle
adjust screw until the most satisfactory 700
b Set the speed
6
r
650 r p
p m
m
throttle
for automatic transmission
is obtained
engine speed
timing
Adjust
c
7
Turn
idle adjust
the
screw
to
leaner mixture until the point where the engine
idle speed begins to drop
r
for richer mixture
counter clockwise
screw
one
turn
one
and a half for
r
p m
the
engine
timing
at 700 r
adjust
speed
f If the
by adjusting
Check the ignition
speed
700
r
p
screw
Timing should remain at 50 A
p m
W A T D C at 650 r p
m
clockwise
the throttle
so
throttle shaft
p
650
m
r
p
650
at
rp m
Timing
at
700
r
for
m
by turning the
throttle adjust screw
50A T O C
at
idle
should
p m
50
for automatic trans
T D
m
C
shaft
arm
adjust
supply hose
at the check valve
engine speed changes adjust the engine
at
700
transmission
rp m
650
r
p
m
for automatic
by turning the throttle adjust
screw
for
MAINTENANCE
To
Turn
r
the ignition timing
Connect the air
650
at
automatic transmission
10
p m
mission
for automatic transmission
the throttle
and
screw
A T OC
e
Set
700
at
remain
automatic transmission
9
and
r
by adjusting the
adjust ignition
O C
1
6 0
adjust
adjust
screw
650
p m
the percentage of the carbon monoxide
d Check
Turn the idle
r
automatic transmission
p m
8
700
0 5
10
approximately
adjust
50A T
at
for
clockwise
at
for automatic transmission
screw
that the tip of it just touches the
that
arm
months
EC 17
make certain that exhaust emissions
maintained
at a low level
inspection
or
be
basically
every 20 000 km
are
it is recommended
12
made
every
000 miles
12
ENGINE
Whichever
occurs
Best
first
engine operation
and minimum exhaust emissions will be obtained
with
regular
services
and
inspections
recommended
at these interval
General maintenance
1
Carburetor check
Check the
cifications
as
choke setting and adjust to spe
required
carburetor idle mixture
Proper
adjustment
imperative for best exhaust emission control
Refer to the article given in
Setting ignition
timing and adjusting idle speed and mixture
is
Fig
2
EC 22
Spark plug
check
Distributor check
adjusting tool
Spark plug should
be
replaced
every 20 000 kIn 12 000 miles
4
Fig
EC 21
check
otributor
Di
Check the distributor
cam
dwell
and
angle
point condition and adjust to specifications or
Check the ignition timing
replace as required
and adjust it to the specification
Clean and apply distributor grease to the
Use
Breaker points should be replaced at inter
vals not to exceed 20 000 kIn
Spark plug
Remove
cleaner
12 000
miles
clean
EC 23
an
secondary
plug
and
ohmmeter
install
plugs
in
Inspect each spark plug
a
sand
Make
blast
Connect
the
both center and ground electrodes
15 000
worn
0 90
mm
If they
replace with new spark plugs
Set
are
File
the gap to 0 80 to
0 0315 to 0 0355 in
using the proper
electrode flat
to
check
Remove
the
resistance
on
cable from spark
proper
adaptor between
Remove the distributor
plug
cap
cer
plug adaptor
center
tension cable test
cap from the distributor with secondary cables
Do not remove the cables from the
attached
tain that they are of the specified heat range
Check
Inspect insulator for cranks and chips
badly
High
cables
cable and spark
test
and
Fig
cam
and wick
3
cable test
High tension
inside the
the
between
corresponding
If resistance
cap
is
the spark
electrode
more
than
the cable from cap and
check cable resistance only
If resistance is
still
ohms
ohmmeter
and
more
assembly
EC 18
remove
than
15 000
ohms
replace
cable
EMISSION CONTROL SYSTEM
5
Test
the
accurate
rections
bring
an
or more
with temperature
as
of these
cor
recommended
required
tightening
and clamps with
and
cable terminals
coat
the battery posts
posts
clamps
light
grease to retard
intervals
to
assure
a
correc
tions
N A IS
Interval
Item
1
Engine
Check ignition timing
every
12 000
tune up
3
Check spark plugs
000
Replace spark plugs
12 000
Check high tension cables
12 000
Check for pitting and
wear
of distributor breaker points
3
000
12 000
Replace distributor breaker points
Apply grease
to distributor rotor shaft
12 000
Apply grease
to distributor cam and wick
12
Replace carburetor
2
3 000 M
3 000
Check engine idling
Engine
Crank
case
air cleaner element
000
24 000
emission control
Check hoses and hose connections for leaks
12 000
Check for proper function of crankcase ventilation control
12 000
valve
3
Exhaust emission control
Check for proper function of air pump
12 000
Check for proper function of relief valve
12 000
Check for proper function of checkvalve
12
000
Check for proper function of anti backfire valve
12
000
Check air
gallery
and nozzle connections for leake
Check hoses and hose connections for leake
12 000
12 000
3
Check air pump belt tension
EC
cleaner
longer lasting engine and
almost complete elimination of air pollution
better performing
fluid upto proper level
battery
inspection and required servicing
system should be carried out at the
Periodic
Specific gravity should
Add mineral free water
Clean
After
with
battery specific gravity
hydrometer
be at least 1 220
to
Periodic recommended maintenance
Battery check
19
000
ENGINE
SERVICE DATA AND SPECIFICATIONS
Type of crankcase
Type of
emission control
exhaust emission control
Carburetor
Closed type
Nissan Air
Injection System
Make
NIHONKIKAKI
Model
D3034C
Type
Downdraft dual throat
Barrel
Primary
Bore
30
mm
Secondary
dia
1 181 in
Large
venturi
23
0
Small venturi
1st
7
2nd
mm
mm
0
16
dia
551 in
dia
0
mm
Slow jet
II 50
II 80
Main air bleed
II 60
80
Emulsion hole
O 5
Slow air bleed
1st
dia
10 020 in
150
1 6 mm dia
Power jet
II 50
Cushion jet
11120
Air jet
11150
Power system
Vacuum
x
5
9
Piston
100 gr
ffim
40 gr
0
0
140
vacuum
0 063 in
dia
acting type
dia
Vacuum
0
354 in
220 lbs
0882 Ibs
110 mm
Hg
dia
31 mm
8
6 mm
5
51
Accelerator pump
Piston
14
Pump discharge
1
O
2
c
c
0 0122 cu
in
2
0
4 c
c
0 0244 cu
in
3
0
6 c
c
O 0366 cu
in
Pump nozzle
dia
220
Slow economizer
Actuating
5
11160
2nd
piston
spring
Power valve spring
x
dia
5 mm dia
0
dia
020 in
dia
dia
630 in
11155
mm
dia
315 in
11102
0
dia
8 mm dia
dia
jet
Main
dia
1 102 in
dia
276 in
0
28
dia
mm
14
1 339 in
dia
mm
906 in
0
34 mm dia
dia
O
EC 20
mm
dia
5 mm dia
0
551 in
0 020 in
dia
dia
1 22 in
0 339 in
4
33 in
Hg
EMISSION CONTROL SYSTEM
P
Main nozzle
3 mmdia
2
0
S
2
dia
0906 in
8
mm
dia
0 110 in
dia
Throttle valve
Fully closed angle
P
10
S
Idle opening
Approximately
20
5
Choke valve
Distributor
Fully closed angle
Throttle opening at full
10
choke
13 5
Make
HITACHI
Model
D423
BP 6E
Spark plug
Air pump
Model
ECP 200 1A
Capacity
200
c
Irev
c
Air pump pulley ratio
120
120
1 00
Relief valve opening pressure
4 2
mAq
Type
Air
by
Model
DV54
Duration time
1 3
1 7 sec
Type
AMC
type
6
psi
Antibackfire valve
Check valve
Opening
Cooling
fan
coupling
Pulley
ratio
Tune up data
x
blade
5
at 500
91 in
14 57 in
370 mm
no
Fan
Revolution ratio
Fan
15 mAq
type
19 7 in
Hg
Hg
Aq
Spider
Type
Outer dia
Fan
o
pressure
pass
120
W IPump
rpmlwater
103
700 rpm
650 rpm
49
at O
Spark plug
angle
55
0 0315
gap
Choke setting
Manual
CO
6 0
percent setting
EC 2l
3
300
4 000
A T D C
Idle
Distributor dwell
4
1 17
5
p m
x
pump rpm
Basic timing
r
dia
6
0
5
02 in
0355
in
of point gap
0 go
0
0
YY
at the pump disconnected
ENGINE
TIGHTENING
TORQUE
air pump bracket to
Nut
cylinder head
to bracket
Bolt
adjusting bar
Bolt
air pump to bracket
Nut
air pump to
Nut
A B
Nut
vacuum
plug
0
hose
lamp
sensing
to rocker
2
40
O
air
to
gallery
5
exhaust
0
6
36 2
9 0
0
kg
m
43 4 It lb
10 5
kg
m
75 9 ft lb
SLACKNESS
8
12 mm
7
10
kg
0
315
1 54
O
472 in
2 20 lb
of slack under
of load
SERVICE JOURNAL OR BULLETIN
DATE
65 Kg m
4 7 ft lb
9
65 1
BELT
m
c
Check valve to air gallery
DRIVE
kg
COver
valve to bracket
manifold
AIR PUMP
40
174 It lb
adjusting bar
cover
Screwed
2
11 6
valve bracket to rocker
A B
Screw
1 60
JOURNAL or
BULLETIN No
PAGE
No
REFERENCE
SUBJECT
EC 22
f
i
1
t
DATSUN
1800
r
a
a
I
a
I
SERVICE
MANUAL
MODEL
t
t
SECTION
EE
ENGINE
ELECTRICAL
SYSTEM
G11
ENGINE
STARTING CIRCUIT
1
STARTING MOTOR
1
CHARGING CIRCUIT
EE 12
ALTERNATOR
EE 14
R GULATOR
EE 26
IGNITION CIRCUIT
NISSAN MOTOR CO
TOKYO
JAPAN
LTD
30
DISTRIBUTOR
EE 30
IGNITION CDlL
EE 40
SPARK PLUGS
EE 41
ENGINE ELECTRICAL SYSTEM
STARTING CIRCUIT
The
electrical system operates
following
1
sections which
Starting
motor
Information
wipers will be
pertain
12
to
This
volts
section
manual is subdivided into the
of the
engine electrical
3
Alternator
2
pertaining
to
on
such as the
body electrical
lighting
5
Ignition coil
4
Regulator
circuit
instrument
Spark plugs
and
windshield
found in section BE
STARTING MOTOR
CONTENTS
running clutch assembly
SPECIFICATION
EE
1
Over
DESCRIPTION
EE
2
Brush holder
OPERATION
EE
2
Pinion
CONSTRUCTION
EE
3
Magnetic switch assembly
REMOVAL
EE
3
DISASSEMBLY
EE
3
7
EE
8
EE
8
ASSEMBLY
EE
8
TEST
EE
8
EE
8
EE
9
EE
9
5
Performance
EE
5
Diagnosis of
Field coil
EE
5
Magnetic
EE
6
SERVICE
Brush
EE
6
TROUBLE
EE
6
CORRECTIONS
assembly
for ground
metal
test
test
switch
Brushes and brush lead wire
Armature
test
bearing
case
EE
spri ng tension
assembly
test
EE 10
DATA
DIAGNOSES AND
EE 11
SPECIFICATION
HITACHI S114
Type
104
Voltage
12V
Output
1 0 KW
Starting current voltage
Less than 480
Lock torque
More than 1 15
Amps
kg
m
Less than 60
Amps
No load starter revolution
More than 7
000 rpm
Shift type of pinion gear
Magnetic shift
No load current
voltage
EE
l
7
EE
Terminal
CLEANING AND INSPECTION
EE
6V
8 31 ft lb
12V
ENGINE
Number of teeth
on
pinion gear
9
Number of teeth
on
ring
120
gear
Weight
5
3
11 68 Ibs
kg
DESCRIPTION
The starting system permits the engine to be
cranked by turning the ignition switch to
While the ignition switch is turned to
position
I
start
the
Klsition
starts
continues
running
on
its
then the starting motor current is
power
opened and
motor
starting
operation until the engine
own
1
start
the
13
disengaged by turning
the ignition switch on to
ON
This
position
motor
an
utilizes
enclosed overrunning
starting
clutch
and the
type
compound motor as
described
motor
is
The
following
mounted onto the
solenoid
switch
11
12
10
is
yoke
1
Stationary
2
Series
J
Ignition switch
10
Solenoid
II Pinion sleeTe
5
Shunt
12
Armature
6
Plunger
13
Movable
7
Return
H
Battery
Fig
oil
and
spring
EE 2
Closing
movable
of
also
cuts
the
8
Shift lever
9
Drive pinion
Ring gear
spring
ntactor
motor circuit
Starting
the
causes
solenoid
ntact
oil
contacts
stationary
and
the motor to crank the engine
out
the
series
eoil of the
shunt
magnetic pull of the
coil
being sufficient to hold the pinion in mesh after
the shifting has been performed
After the cranking
switch is
Fig
EE l
5114 104
coil
turned to
and
ON
demagnetizes against
when the
position
the
the
shunt
ignition
series
coil
then
the return spring actuates the plunger to return
to
OPERATION
When
start
series
the
and
of the
switch
ignition
position
current
shunt
coils
magnetize the solenoid
into
the
lever to
with
solenoid
the original position
motor
so
that
is
turned
on
flows through
it
plunger
is
pinion and
means
the
pulled
The
operates the shift
the
of the
over
running clutch is designed to transmit
driving torque from the motor armature to the
ring gear but permit the pinion to over run the
armature after the engine has started
the drive pinion into engagement
flywheel ring gear and then closes the
move
solenoid switch
EE
consequently stops the
positive meshing and demeshing
ring gear teeth are secured
The
by
running clutch
over running clutch
a
shift
leve
r
to
employs
slide the pinion along the armature shaft and
into
or out of
mesh with the ring gear teeth
to
of the solenoid and
The
More
2
over
ENGINE ELECTRICAL SYSTEM
CONSTRUCTION
Shift
Gear
Shift IsvBr
case
Dust
Magnetic
Dust
cover
llking
O
000
switch
ass
y
Armature
cover
Thrust washer
Stopper clip
Stopper
washer
ij 6
r
@o@
Over
Plmon
stopper
@
Thrust washer
running clutch
Pinion
I
Th rough bolt
Metal
Bruslle
Yoke
B
Brush
Rear
Brush holder
Brush
ass
cover
y
spring
Magnetic switch terminel
Fig
EE 3
5114 104
Construction
REMOVAL
1
Disconnect the
Disconnect
from
the
battery ground cable
black
wire
with
yellow
the magnetic switch terminal
battery
cable
from
the
magnetic
tracer
and black
battery
terminal
U
2
to
Remove two bolts
securing the starting motor
the clutch housing
forward and remove
Pull starier
starting
I
li
assembly
motor
I
o
DISASSEMBLY
1 Loose
the nut securing the connecting plate
Remove
magnetic switch M terminal
screws
securing magnetic switch and
remove magnetic switch assembly
to the
three
EE
Fig
EE 4
Removing magnetic
embly
3
witch
ENGINE
2
Remove
two
through
bolts
and brush
cover
5
assembly
Remove
the
pillIOn
stop
end of the armature shaft
ring
side
firstly
and
remove
clutch
push
then
the
at the
To remove the stop
stop ring to the clutch
removing the snap ring
ring with the overrunning
the
after
stop
Withdraw
assembly from
located
ring
the
over
running
clutch
the armature shaft
U
tU
Fig
3
Remove
EE 5
the
Removing
the brush
cover
yoke assembly by hitting lightly
with a wooden hammer
oeo
Fig
EE B
Removal
of the
over
running
clutch
assembly
6
Dissolder
the brushes
using
a
iron and remove each brush
Fig
4
EE 6
Withdraw
Removing
the
thc yoke assembly
armature
assembly
and shift
lever
R
i
i
o
Fig
EE 7
Removing the
and hift lever
armature
assembly
Fig
EE
4
EE 9
Removing
bru h
soldering
ENGINE ELECTRICAL SYSTEM
Field coil
Check the
field coil insulation
lation of the coil is
be
Connect
or an
continuity
the test probe of
If the tester
Removing
a
circuit tester
ohmmeter to field coil terminals
circuit
EE IO
it should
replaced
Field coil test for
Fig
damaged
If the insu
worn
or
or
shows
no
conduction the field
coil is open
brush holder
o
0 liAr
Fig
o
@
EE 12
Field coil test for
000
Place
the
Fig
EE 11
Field coil te t for
yoke
one
continuity
ground
probe of the circuit
tester onto
and the other on to the field coil lead
positive terminal
Disassembly
If very little resistance is
coils
are
read
the field
grounded
CLEANING AND INSPECTION
Clean all disassembled parts
grease
over
dissolving
running clutch
netic switch
solvents
for
armature
but do not
use
cleaning
the
assembly
assembly and field coils
since
mag
such
in
a solvent would dissolve the grease packed
and
would
the
the clutch mechanism
damage
coils
or
other insulators
Check them for excessive damage
and they should be replaced
or wear
if necessary
Terminal
Check for damage
and
wear
and replace if
Fig
necessary
EE
5
EE 13
Field coil te t
for ground
ENGINE
Field coil test for short
Dissolder
the
section
connecting
of each
coil and proceed to the same mentioned above
If a defective coil is found it should he
replaced
Brushes
and brush lead
Check the
surface and
condition
of the brush
of the brush
wear
tact may be found it should be
If the brush in its
0 4921 in
mm
wire
contact
If a loose
con
replaced
is less than 12
length
5
replace it
Check the connection of the lead clip and
lead wire
Check hrush holders and spring clip to
that
they
properly
are
deformed
not
or
bent
see
Fig
or
brush holders
haft
armature
bend
dirty
are
2
Inspect the
tension
spring
with
lightly
Check the brush spring tension hy
a
tator
spring
reading
If
Replace the spring
if the tension is lower than 0 7 kg 1 54 lbs
0
shown in Figure EE
14
The
should he O 8 kg 1 761bs
must
the
a
is
No
00
less
than
is
should
0
the
less
wear
2 mm
In
pection of
brush
it
0
insulating
0 0079 in
is
0
05
0
mm
be also under cut
from
O
5
to
O
it
spring
and the commutator
the
armature
shaft
for bend by
a
shaft if the
Fig
EE
6
so
8 mm
If the commutator is be
replace
Check external appearance of the armature
Measure
the
0020 in
Armature assembly
1
mica
from
ten ion
dial gauge
Replace the armature
bend exceeds 0 08 mm 0 0031 in
2 mm
limit of the commutator diameter is
0 0787 in
yond repair
EE 14
than
more
0197 to 0 0315 in
The
Fig
than
depth of
commu
the commutator armature
mica should
Insulating
that
is
mm
commutator surface
be sanded
The
also for out of round
the depth of the
0 2
must
sandpaper
out of round
or
If the surface of
it
rough
be checked
0079 in
is
commutator
commutator
the
as
pection of
for
they should be cleaned
scale
In
hold hrushes against the commutator
If the brushes
Brush
EE 15
but will
EE 16 In
pection of
commutator
ENGINE ELECTRICAL SYSTEM
S Ej
Correct
Fig
3
EE 17
Incorrect
Undercutting
Inspect the soldered
lead and commutator
is found
in
ulating
connection
mica
Fig
of armature
If the loose connection
solder it using rosin flux
6
Check
EE 19 Armature test
armature
probes of tester
on
If the tester shows
hort
for
for continuity by placing the
two segments side by side
no
conduction
the circuit is
open
4
Armature test for
Using
on
to
ground
a circuit tester
armature
place
shaft and other
one
on
test
probe
to each com
running clutch assembly
conductive
armature is
the
pinion
and
assembly
screw
Screw sleeve must be freely slid along
sleeve
If the tester shows
the
Inspect
mutator bar
grounded
Over
armature
If damages
shaft splined
are
found or resistance would be felt when sliding
Inspect the pinion teeth
it must be repaired
and must be replaced
rubbing would be found on the
The flywheel ring
teeth it should be replaced
must
be
inspected
also
gear
If excessive
1
Fig
5
EE 18 Armature test for
Check armature
for shorts
by placing
and with hack
armature
tester
armature
core
vibrates
armature is shorted
ground
rotate armature
saw
Fig
on
blade
the
Using
on
to
brush
EE 7
OeO
EE 20 Over
running
a
circuit tester
rear cover
holder
ground
place
and another
If the
mbly
clutch
Brush holder test for
over
If saw blade
ji
tester
on
test probe
positive side
one
to
shows
conduction
ENGINE
the brush holder is shorted to
an
insulator
or
has been
Replace
ground
brush holder
mance
perfor
satisfactory when installed to the
overhauled to
will be
ensure
that its
The
starter
motor
should also be
engine
subjected to these tests when the cause of ab
A brief
normal operation is to be determined
outline of the two tests is given below
Noload test
starting motor in series with
the specified 12 volts battery and an ammeter
capable of indicating 1 000 amperes
Connect the
Specified
current draw
these test are shown in
EE 21
Fig
Brush holder test
and revolution in
specification
for ground
Switch
Pinion
Starter
bearing metal
case
motor
Inspect the bearing metal for
clearance
If the
play
0
mm
a new
between
shaft is
metal and the armature
wear or
the
more
the metal
0079 in
to o 10 mm
0039 in
B
bearing
than 0
2
E
Press in
replace
bearing and adjust the clearance
0 0012 to O
s
side
to 0 03
The bear
ing metal should be so pressed In that the end of
the bearing metal would be equal to gear case
Voltmeter
Ammeter
end plane
Magnetic switch assembly
Fig
If a
Inspect the magnetic switch contacts
rough welding be found on the contact it should
be repaired
EE 22
No load test
ASSEMBLY
Assembling
is a reversal of the
disassembly
Torque
test
procedure
When assembling
rear
the
determine the
and apply light
bearing metal and pinion
case
cover
Torque testing equipment should be used to
torque the motor will develop
grease in the
coat of oil to the rear
pack
A
high
should
specified voltage
TEST
no
Ioad
starter
and
a
motor should
lock torque
carrying variable
resistance
at the
starting
motor may be
obtained since a small variation in the voltage
will produce a marked difference in the torque
Performance test
The
current
be connected into the circuit so that the
be subjected to
development
Specified power
a
test whenever it
EE
shown in Figure EE
8
voltage and torque
23
are
ENGINE ELECTRICAL SYSTEM
Performance
1
curve
A
grounded
or
open field coil
trace the
Inspect the connection and
by a circuit tester
2
0
g
The armature coil does not operate
Inspect
GI
oE a EjDI
l
Is
circuit
the commutator for excessive burned
In this case
out
arc
may occur
on
defec
0
tive commutator
a
12 000
1 2
12
10 000
1 0
10
8 000
08
8
6 000
06
6
4 000
04
4
with
no
when the motor is operated
load
3 Burned out commutator bar
Weak brush
spring
the commutator
commutator
2 000
02
2
0
0
0
or
would
broken
tension
spring
brush
out of mica in
thrust
rubber brush
loose contact brush and
a
cause
to burn
the
com
mutator bar
300
200
100
0
400
3
Low
torque
low current draw and low
load speed would
Current flow A
due to
caU6e
loose connections
defective leads
commutator and causes listed on item 2
4
High
would
Fig
EE 23
5114 104
no
dirty
3
load speed with low developed torque
cause
field coil
no
high internal resistance
grounded field coil
Replace the
check for improvement in per
and
fonnance
of test
Diagnosis
1
with no load
speed
Low
draw may result from
and
current
high
Magnetic switch assembly
followings
1
Tight dirty
2
Bent armature shaft or loosen field
or worn
test
bearings
probe
Ignition
switch
3 Shorted armature
Check armature further
4
A
ground
armature
B
of field
Remove copper connector
Remove
negative
side brush and insulate it from the commuta
tor
before
inspection
place one probe
tester
and
another
indicates
brushes
2
or
Failure
rear
on
and
to
check
fields
armature that is
to
operate
may result from
with
BMS
circuit
If the tester
other
remove
determine
a
insulated terminal
cover
conduction
separately
fields
on
Using
and
whether
two
it
Starter motor
Battery
armature
is the
grounded
high
Fig
current draw
EE 24
Circuit
test
followings
EE
9
of magnetic
switch
a
embly
ENGINE
OK
check
Connect
jumper
If the starting motor check is
the
magnetic
switch
assembly
cables between the
negative
hattery terminal
and the starting motor M terminal the posi
tive
battery terminal and the starting motor
S
as
terminal connecting ignition switch in series
shown in Figure EE 24
With the ignition switch
between the
pinion
on
measure
front
edge
the gap
and
the
pinion stopper
EE 25
Fig
urement
Me
of gap
SERVICE DATA
S114
104jl
Armature shaft diameter
pinion
Armature shaft diameter
rear
side
0
032
0
050
11 0
mm
0
mm
0
0 032
0 050
Amendment limit of shaft diameter
O
1 mm
Amendment limit of shaft bent
0
08
0
0
Amendment limit of dittoed clearance
0 2
Outer diameter of commutator
35 0 mm
Wear limit of commutator diameter
2
Brosh
18 5
length
Wear limit of dittoed
length
remaining hrosh should
03
0
mm
Brush spring tension
0 8
Front bracket metal inner diameter
11
Rear cover metal inner diameter
11 5
0
0012
0039 in
j
0787 in
0
0
7283 in
2362 in
0
4921 in
018
0
0
0007
mm
0
4331
mm
0
4528
021
I0
0
1 76 Ibs
kg
0
EE
m
1 3780 in
mm
mm
4528
0 0020
0079 in
0
mm
12 5
ill
0039 in
1 rom
0 mm
6 0
be more than
O
0020
0 0031 in
mm
Clearance between shaft and bush
0013
0
0 0013
11 5
end
0
4331
in
0008
in
L
ENGINE ELECTRICAL SYSTEM
TROUBLE DIAGNOSES AND
CORRECTIONS
Possible
Troubles
Starting
not
motor will
operate
Remedies
causes
Discharged battery
Charge
Defective solenoid switch
Repair
or
replace
the
battery
the
replace
or
solenoid
switch
Loosen
conne ctions
of the
ter
tighten
Clean and
termin
i1
the
minal
Defective brushes
Replace the brush
Defective starting motor
Remove
the
starting
motor
and
make test
Loose
Noisy starting
securing
Tighten the
bolt
motor
Starting motor
cranks slowly
Worn pinion gear
Replace the pinion gear
Poor lubrication
Fill in oil
Worn commutator
Disassemble the motor
Worn brushes
Replace
Discharged battery
Charge
Loose connection
of the terminal
motor
operates
does
or
replace the battery
Worn brushes
Replace the brush
Locked brushes
Inspect the
Dirty
but
the brush
Clean and tighten the terminal
repair
Starting
bolt
or
worn
commutator
brush
spring
Disassemble the motor
Defective solenoid switch
Repair
Worn
Replace the pinion
or
replace
the switch
Locked pinion guide
Repair the pinion guide
engine
Worn
Replace the ring gear
Starting motor will
not disengage even
Defective solenoid switch
crank
not
the
the
ignition switch
is turned off
ring gear
Repair
or
replace
the
switch
Replace the defective gear
Defective gear teeth
EE ll
or
Clean and repair
The armature rubs the field coil
pinion
tension
the brush holder
solenoid
ENGINE
CHARGING CIRCUIT
The
charging circuit includes the battery
regulator and necessary wiring to
energy
to
alternator
connect
system
these
is
to
The
parts
convert
just
of
purpose
this
from the engine
all
supply
keep
the
into electrical
energy
units
electrically operated
and
battery fully charged
enough mechanical
SPECIFICATIONS
Alternat
Regulator
or
AS2030B 1
AS2040P
RQA22208
Item
Item
Applied engine
GI8
G18
Maker
MITSUBISHI
MITSUBISHI
Nominal output
14 V
14 V
Pole
N egati ve
N egati ve
ground
ground
1
1
Applied alternator
option
AS2030Bl
AS2040P
30 A
000
G18
Maker
MITSUBISHI
Type
Tirril type
000
12 000
Revolution
Applied engine
40 A
Constant voltage
12 000
Element
rpm
relay and pilot
lamp relay
rpm
No load
Less than
minimum
1
revolution
1
voltage
Constant
000 rpm
relay
30 A
Output
Less than
000 rpm
current
14 V
40 A
5 000 rpm
5
3 contact
type
14 V
No load
000 rpm
regulating
14 3
voltage
Pulley
ratio
When
2
04
2
l20
the
on
ignition switch is turned
battery to ground through
the ignition switch voltage regulator IG termi
nal
movable
primary side contact point PI
contact point
P2
voltage regulator IF ter
alternator
alternator
arrows
E
F
terminal
terminal
as
field coil and
shown by the heavy
exited
ground through
C
68
F
current flows from
the
ignition switch
warning lamp voltage regulator L terminal
movable contact
lamp side contact point P4
P5
and
voltage
point
regulator E terminal
Then the warning
as shown by dotted arrows
lamp
Then the rotor in the alternator is
EE
On the other hand
the battery to
15 3 V
000 rpm
4
04
current flows from the
minal
point
12
turns
on
ENGINE ELECTRICAL SYSTEM
When the alternator
phase
begins
to
operate
by the magnetic force of coil
is inserted
Rl
register
in the field circuit and output voltage is de
As the output voltage is decreased
creased
and primary
the movable contact point
P2
PI
in
comes
contact once again
side contact
side
three
alternating current is induced in the
This alternating current is rectified
armature
by the positive and negative silicon diodes
This
rectified current of direct current output comes
and
E
B
terminal
between the alternator
EE
Figure
Therefore
and the alternator
26
On the other hand
comes
PI
contact
VC2
between
the neutral
and
N
voltage
increases
rapid vibration of the movable contact point
or inserting and removing the resistance
P2
point voltage
nearly a
Et terminal
voltage and this causes to flow
current from voltage regulator N terminal
E
terminal or ground through the coil
the
field
alternator
circuit
maintains
half of the output
in
the
alternator output voltage to constant
to
VCl
the
When
Then
shown by the dotted arrows
and the movable con
VCl
is excited
as
coil
further
comes in contact with voltage
P5
point
This action
winding side contact point P6
causes to turn off the warning lamp and com
plete the voltage winding circuit as shown by
the
contact
point
P2
with
output voltage
speed
is
voltage starts to go further high
point P2 comes in
secondary side contact point
is decreased
immediately
breaking and completing the field circuit main
output voltage to constant
r
I
I
I
I
c
E
j
I
l
Armature
co
I
I
1
I
t
I
c
is
c
I
I
I
I
2
I
I
Field
e
I
I
I
coil
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
J
Lu
I
J
I
J
L
Voltage regulator
Alternator
Fig
EE 26
Charging
EE
13
circuit I
T Battery
I
I
o
I
I
This
separate movable contact P2
P3
from secondary contact
Thus the rapid
the
contact
of
movable
vibration
point P2 or
tains an alternator
is separated from primary
I
increased
action causes to
When the alternator speed is increased or
voltage starts to go too high the movable
contact
the
or
alternator
Then the field current is shut off and alternator
arrows
n
the
an
at last the movable contact
tact
the heavy
the
Thus
ES
c
0
1
r
ENGINE
i
r
I
I
I
I
I
Ell
Armature
c
I
2 0
00
L
C
0
t
c
i
Battery
T
L
c
Field
t
e
I
o
coil
l
e
I
I
I
I
I
Voltage
Alternator
Fig
EE 27
regu lator
Charging
circuit 2
ALTERNATOR
CONTENTS
DESCRIPTION
EE 14
REMOVAL
EE 15
OISASSEMBL Y
EE 18
DIODE
REMOVAL
EE 20
Inspection
Spring pressure
INSTALLATION
EE 21
Inspection of output
DIODE
INSPECTION AND REPAIR
EE 21
Inspection of
Inspection of
diode
EE 22
diode with tester
EE 23
of brush
EE 24
EE 24
test
EE 24
EE 25
ASSEMBLY
Rotor inspection
EE 21
I n case of AS2030B 1
EE 25
I nspection of stator
EE 22
I n case of AS2040P
EE 25
DESCRIPTION
Different from the DC generator
nator
turns
the magnetic
and
three phase
alter
fixes
the
produced by the
small field current
ated
The
in
armature
stator
has
charging
rotor which consists of alterna
current
field coil
pole pieces and slip rings
The slip ring pressed in the shaft conducts only
a
act like
In the alternator a magnetic field is
armature
tor shaft
pole
an
Output
coils
current is gener
located
three windings
in the
alternating
one
way valves for
current
is
passes
shut out
diodes
are
used
tives
and
these
In
electricity
easily
this
and generates
six diodes
system is also basically
in principle
EE 14
but
so
that
reverse
alternator
six
three negatives and three posi
are
positive and negative heat sink
stator
Silicon diodes
current
same
installed
voltage
to D
C
in
control
system
ENGINE ELECTRICAL SYSTEM
2
6
11
7
B
12
13
9
10
1
Brush
S
Pulley
8
Rm
2
Brush holder
6
Brush
9
Stator
J
Rotor
7
Ball br aring
Ball
sscmbly
10
ssembly
Front
11
Heat sink
12
Positive diode
13
Negative diode
ssembIy
bearing
Fig
EE 28 Schematic view
AS2030Hl
REMOVAL
1
Disconnect the
2
Remove two
negative battery
terminal
leads at the alternator and
4
Remove the alternator drive belt
5
Remove the bolts which retain the alternator
6
Remove the alternator from a car
con
nector
3
Loosen the
adjusting bolt
Fig
ni 29
Fig
4S2030H I
EE
15
EE 30
AS2040l
ENGINE
Pulley assembly
I
Rotor assembly
Front hearing
Bearing retainer
Slip ring
3 Diode
Through bolt
Brush
Rear
cover
Fig
Brush
EE 31 Alternator
EE
cover
assembly
16
AS2030PI
assembly
ENGINE ELECTRICAL SYSTEM
Pulley assembly
Front cover
Rotor assembly
Front
bearing
Slip ring
cfIi
Connector
Rear bearing
EBDiode
eDiode
Heat sink assembly
f ig
EE 32 Alternator
EE
17
assembly
101
AS20
p
ENGINE
DISASSEMBL Y
1
Unscrew the
through bolts
j
Fig
EE 36
Drive end hou
hou
Fig
EE 33
Removal
of through
3
bolt I
ing
ing sepamled
and diode end
Vise the rotor of the drive end
sembly carefully
Remove the pulley
not to
nut
housing
as
injure the rotor
pulley
rim
fan and the
spacer
Fig
2
EF 34
Separate
Remuval
of through
the diode end
end housing assembly by
bolt
2
housing from the drive
means
Fig
of two drivers
f f 37
embling
Dua
the rotor
eooo
i
Fig
EE 35
Separating of diode end
from drive end housing
hou
ing
Fig
EE
18
EE 38 Removal
of pulley
ENGINE ELECTRICAL SYSTEM
4
Remove the rotor from the drive end
assembly
slightly
by
with
the
hitting
end
drive
housing
housing
a mallet
6
Pull out the
assembly
puller
rear
using
an
bearing
arbor
from
press
the
or
rotor
bearing
I
c
Z
I
L
r
1
II
rr
I
N
J
a
L
I
I
1
1
I
L
11
1
Ii
EE 39 Removal
Fig
5
Remove
three
using
set
an
the
bearing
screws
and
retainer
push
Fig
of rotor
out
Pulling
EE 42
of
out
rear
bearing
I
by unscrewing
the bearing
arbor press
0
iL0Qi
I
C
Fig
A
r
l
0
o
7
To
EE 43
separate
Fill
Removal
of bearing
the
out
of
stator
rear
bearing
from the diode end
disconnect the negative three
diodes from three coil lead wires and each lead
soldering
retainer
diodes by
melting
solder with
iron
i
1
h
I
t
Fig
EE 4l
Pulling
out
2
housing assembly
wire between
EE 40
Pulling
Fig
of bearing
EE
19
EE 44 Removal
of stator
a
ENGINE
8
Remove the brush cover
by unscrewing
each
setscrew
Disconnect
solder
N
terminal lead
wire
by melting
then the diode end and the stator can be
separated
l
I
tfl
v
fJI
4
Fig
EE 47 Removal brush holder
4S2040P
10
Disassemble the brush holder
Dissolder lead wire F
wire E
EE
Fig
s
4
Diode end and stator
black color
black white
color
lead
and the brush holder wires
negative and positive
using
a
soldering
iron
separoled
Note There
Note When
goes
the
internal
up over
1500C
lose its function
to 200W
temperature
3000F
so use
of
the
a
at
100W
on
the soldered
Remove
from
screw
the
kinds of diode
is marked with
marked with
black
same manner as shown in
the heat
rear cover
sink and
Positive
and
red figure
the bottom of the diode and the negative
diode is
portions
9
two
are
Negative
The positive diode
diode will
the electric iron
for around 2 seconds
diode
figure
in
the
Figure EE 48
the brush holder
by unscrewing each
set
Be careful not to lose small parts such
as screws
washers and
hushings
Red
Fig
or
EE 48 Diode
Black figures
identification
DIODE REMOVAL
To
remove
a
diode
support the heat sink
Fig
I f 16
Removal
of
bru h holder
using
AS2030Bl
EE
20
an
arhor press
use
a
suitable tool to
and push the diode out
as
shown in Figure EE
by
49
ENGINE ELECTRICAL SYSTEM
AND REPAIR
INSPECTION
Remove the alternator from the vehicle and
put the tester between the lead wire F
white
color
black
and the lead wire E black color
When the resistance is approximately 5 to 60
the condition is all
right
not to
injure the mounting
bore of the frame
the
lt
he
Rotor
inspection
or
1
ink
Conduction test of field coil
As shown in Figure EE 51 put the probes of
the
circuit
rotor
Fig
EE 49
will be open
Removal of the diode
mately
Do
not strike
damage
the
diode
as
the
no
conduction
rings
shock may
of
the field coil
When the resistance is approxi
4 47 0 at normal room temperature
condition is all
Note
between the slip
tester
If there is
the
right
the other diodes
DIODE INSTALLATION
Support
the heat sink with a suitable tool and
then press the diode into the heat sinks
the tool
@
which fits
over
by using
the outer diode edge
A portion
Press
mounting
down
perfectly
B portion of the diode
not
the
diode
into
bore of C portion to the lower
be taken out with
a
Replaced
the
edge of
diode should
force smaller than 15 kg
33 Ibs
fig
2
Check
J
or
Ai
Fig
EE 50
Installation
Condudion
the
core
I
test
of field
conduction between slip
If the conduction exists
assembly because in this
slip ring must be grounded
rotor
I
l
5
coil
Ground test of field coil
rotor
i
f
case
ring and
replace
field coil
j
of
the diode
fig
EE
21
J 52
f
I round k
offield
mil
ENGINE
3
Inspection of
rotor
neutral wire is not conductive with stator
eccentricity
the condition is all
Check the eccentricity of rotor
Figure EE 53 using a dial gauge
Repair
0
10
or
rom
0
as
replace if the eccentricity
right
shown in
is
over
0039 in
Fig
Fig
EE 53 In
EE 55 Ground te t
of diode
Inspection
pection of rotor eccentricity
Using lamp and battery
1
Positive side diode
Connect the battery
Inspection
the terminal BAT
of stator
If the neutral
the lead wire N
is all
white color
wire of stator
white color
lead wire of armature
connected
negative terminal with
battery
at rear cover and the
with connector N terminal
shown in Figure EE 56
terminal
positive
1 Conduction test
each
core
as
Lamp in the circuit will light
to
is conductive with
coil
the condition
right
Fig
EE 56
Inspection of po
itive
side diode
Fig
EE 54
Conduction
t t
Nextly
connection
2
G round test
If each lead wire of armature coil
including
EE
if
is
lamp
made
does
not
light
reversely as
the positive
Figure EE 57
good working condition
22
when
shown
side diode
is
the
in
in
ENGINE ELECTRICAL SYSTEM
EE 57
Fig
Inspection of positive
EE 59
Fig
side
2
Negative
Connect
hattery negative terminal
connector N terminal
of diode
Inspection
side diode
the
Inspection of negative
side diode
diode
white color
There
with
and the bat
tery positive terminal with connector E terminal
black color as shown in Figure EE 58
with tester
are two kinds
Figure
EE
ed its
polarity
figures
on
60
of diodes
as
shown in
Each diode can he descriminat
by
color
the
each diode
as
of the
printed
follows
Lamp in the circuit will light
Cu rrent flow
Red figUre
Current flow
ack
figUre
DIode
terminal
M
Positive diode
Fig
Negative diode
EE 60 Diode
Check diode resistance
Fig
EE 58
Inspection of ncgative
side diode
as
shown in Figure EE
When
one
other shows
Nextly
nection is
EE
59
if
lamp does not light when the
made reversely
the negative
ing condition
as
a
tester
in
61
side shows low resistance and the
high
resistance
the diode condition
is all right
con
If both sides
shown in Figure
side diode is in
using
a current flow direction and a reverse direction
circuit and
good work
be
EE
23
a
are
low
if both sides
open circuit
there will be
are
infinite
In both cases
a
short
there will
replace diode
ENGINE
Spring
Place
and
a
suitable block
press down
spring
on
holder
to
the
1
holder
weight
brush
block
0
mm
The
than
0
hlock
The
spring
77 Ibs
0
kg
2
the
the
If the
44 Ibs
0
it
Diode te t
EE 6l
of
Check the movement
is
from
subtracted
be 0 35 kg
small
sinks in the
height
in
of brush
Inspection
movement
platform scale
with brush and
until brush
0394
reading
is
pressure
Fig
on a
holder
shows the spring pressure
pressure should
replace
test
pressure
unsmooth
brush
and
if the
check hrush holder and
clean it
The
0
standard
512 in
7 mID
length
If brush
0 276 in
of brush
wore
is
13
off smaller
mm
than
replace the brush with
new
Fig
one
Inspection
The
EE 63
of
Spring
pre
oure
te t
output
procedure
of output
inspection
is
as
follows
1
Remove the alternator
connect
r7
13
mm
wiring
3
Drive the
mm
4
the
Bru h
wear
limit
its
mm
length
13
512
AS2040P
with
motor
until
and
in
the ammeter
Izero
Turn off the
speed of
switch Kl
the alternator
and further increase
until the voltmeter
20
0
The specified
revolution when the voltmeter
indicates 14 volts is approximately 1 100 rpm
787
6
in
Make the load resistance the maximum and
turn the switch K2 on
Wear limit
7
mm
0
alterna1ure
speed gradually
indicates 14 volts
5
AS2030B 1
Brush
64
Turn the switch Kl on and excite the rotor
indicates
EE 62
from the vehicle and
shown in Figure EE
2
crease
Fig
as
0 276
14
0
552
7
Raise the load current
in
resistance
EE
24
gradually
by decreasing
the load
and increase the alternator
ENGINE ELECTRICAL SYSTEM
the
Then
speed
alternator
8
output voltage
Read the output current when the revolution
of alternator is 5
should be kept to 14 volts
9
Note I ncreasing the alternator speed would
cause
000 rpm
The specified current should be
to
increase the output
as
follows
AS2030Bl
more
than 30
Ampere
AS2040P
more
than 40
Ampere
KI
K2
CD
c
10nSOA
Ammeter
Load resistance
Voltmeter
Battery
Fig
Note Use the
battery charged
EE 64
Circuit
diagram for output inspection
in full up to the normal
capacity
ASSEMBLY
In
5
of AS2030Bl
case
Assembly
However
cedure
1
Install
Insert
push
pro
rings
brush holder and brush
come
all
iron
parts
wire
have
been
assembled
then brushes
and slip
in contact
it
the
two
two
brush
holder to
securing
diode
end
brushes to the brush holder and
against spring tension
brushes by an iron
EE
the
screws
Secure the
Figure
I ran wire
of AS2040P
case
housing by
2
the
disassembly
an
should be installed at the last procedure
cover
In
is a reversal of
the
After
remove
wire as shown in
65
3
Install the stator to the diode end housing
4
Join
together
both
end
housings
by
Fig
three
EE 65
Installation
AS2040P
through bolts
EE
25
of
brush holder
ENGINE
REGULATOR
CONTENTS
EE 26
INSTALLATION
EE 26
ADJUSTMENT
EE 26
TROUBLE
EE 27
CORRECTIONS
Check of regulated voltage
EE 27
Adjustment of gap
Adjustment of voltage
REMOVAL
EE 29
DIAGNOSES AND
EE 29
INSTALLATION
7
Installation
is
reversal of removal pro
a
cedure
B
9
ADJUSTMENT
In
2
it
is
the temperature
necessitated to
of the
3
is
regulator
according
compensated regulator
measure
cover as
varied
the temperature
the
to the
regulating voltage
surrounding temper
ature
6
In this
5
0001P
4
or
case
use
cylindrical
shown in Figure EE
1 Movable
2
3
ntact
Secondary
Secondary
uppon
side
ntact
ide
ct
5
Primary side
ntact
6
Primary side
ntact
7
ntact
Fig
thermometer with
90196
putty
67
upport
support
MoyabIe
the thermometer
EE 66
Spring
8
Bimetal
9
Armature
Regulator
2
The voltage regulator RQA2220B is temper
that the
ature
compensated
copes
with the climatic variations and two units
are
so
housed in the regulator box
lator relay and
a
by
a
on
the use of bi
J
voltage regu
pilot lamp relay
of temperature fluctuation
is minimized
charging voltage
The effect
their relay setting
metal spring
REMOVAL
To remove the
the
6 way
voltage regulator
multiple
connector and
securing the regulator to the
bulkhead of the engine room
screw
1
Thermometer
2
Cylindrical thermometer
disconnect
remove
the
Fig
longitudinal
EE 67
Measuring of regulator
temperature
EE
26
cover
as
ENGINE ELECTRICAL SYSTEM
Check of
1
regulated voltage
Connect the
shown in
B
battery almost charged
Figure EE 68
in full as
8
B
Voltage regulator
Connector
A
Ammeter
V
Voltage meter
Wire harness
Fig
temperature of regulator
2
Measure the
as
shown in Figure EE
3
5
Raise
000
the
rpm
EE 68 iUeler and indrument connection
cover
67
alternator revolution to 4 000 to
engine
revolution
1
960
to 2 450
of gap
Adjustment
The gap adjust values of the constant voltage
relay and the pilot lamp relay must be as
follows
rpm
When the
4
charging
current
is
less than 5
ampere and the voltage of this time is within the
limit of Figure EE
it is all
69
right
Air gap
G2
16 0
15 5
Stopper
I
l
15 0
I
1
114
Frame
5
14
Point gap
13 5
20
10
0
20
10
Regulater
cover
Fig
t
30
ratur
40
C
50
G3
60
Fig
EE 69
EE 27
EE 70
RQA2220B
ENGINE
ROA22208
O
Gl
0
1 1
O
O
8
1 2
contact
O
0472
support
G2
relay
0
0315
3
0
4
0
0118
O
0157
0
1 1
in
rom
0433
Movable
voltage
Constant
8
0315
O
G2
g2
gap
G3
Primary
contact
gl
0
0295
Pilot lamp
O
relay
g2
0
in
rom
relay
0
0 0433
9
I3
the same
0354
0 0472
0 75
11
0295
0 0433
Accordingly
type
and G3 g3
gap
12
and the pilot
voltBge regulator
are
justing method is also the
Adjust these gaps in
g2
support
G3
Fig
g3
The
75
EE 72
4djusting
gap
lamp
the ad
same
order
if these
are
G2
g1
of specifi
of Gl
out
cations
Back gap
GI
or
gl
Loose the armature
the position by
sliding
hinge
screw
and adjust
the armature
Fig
Point gap
EE 73
G3
or
Adjusting
G2 g2
gap
g3
Adjust the gap by bending the secondary
support as shown in Figures EE 72 and
contact
EE
Fig
Top air
Adj ust
tact
EE
gap
EE 71
G2
or
Checking
Gl
gl
g2
the gap by bending the movable
supports
as
74
shown in Figures EE
con
72 and
73
Fig
EE
28
EE 74
Adjusting
G3
g3
gap
ENGINE ELECTRICAL SYSTEM
of
Adjustment
voltage
Adjust the voltage by bending
Bending
Bend upward to heighten adjust
and down
value and downward to lower adjust value
the stopper up
direction
H ighten
voltage
I Lower voltage
Fip
EE 75
Adjusting
the
Fig
voltage
FE 76
Adjusting
the
voltage
TROUBLE DIAGNOSES AND CORRECTIONS
No
Remedies
Causes
Troubles
Free
Sticking brushes
output
replace
brush
and
brush
spring
Clean the brushes and slip rings
Dirty brushes and slip rings
Loose
connections
broken
or
Open
stato
Open
rotor
solder connection
r
Repair
winding
or
replace the
Replace
the rotor
Open diodes
Replace
the diodes
Shorted rotor
Replace the
Shorted stator
Repair
Grounded
winding
BAT
Broken
or
stator
rotor
replace the
stator
Replace the insulator
terminal
Replace the belt
Broken fan belt
output
or
Replace leads
leads
Excessive
Tighten
color
neutral point wire
Replace
the wire
of wire is white
Check the
Defective voltage regulator
Poor grounding of the alternator
and voltage
regulator
E
termi
nal
EE
29
regulator operation
Tighten the terminal connection
ENGINE
Broken ground wire
color of wire
Replace the
wire
is black
Low output
Loose or worn fan belt
Tighten
Sticking brushes
Free
or
replace the
replace
belt
brushes and spring
if necessary
Low brush
spring
Defective voltage
tension
Replace the
Check the
regulator
stator
spring
regulator operation
Clean the slip ring
Dirty slip rings
Partial short
brush
ground
or
open in
Replace
the stator
winding
Partial short
or
ground
of rotor
Replace the
rotor
winding
Open
Noisy alternator
diode or defective diode
Loose
Replace the diode
Tighten mounting bolts
mounting
Loose drive
Tighten pulley
pulley
Defective ball bearings
Improperly
Replace
seated brushes
the
bearing
Seat brushes
properly
IGNITION CIRCUIT
The
ignition
circuit includes the distributor
tension cable and the
ignition coil
ignition switch
spark plugs
high
battery
DISTRIBUTOR
CONTENTS
SPECIFICATIONS
CONSTRUCTION
EE 31
AND OPERATION
CHECKING AND ADJUSTMENT
Cap
and rotor head
Centrifugal advance mechanical
EE 31
EE 35
part
EE 34
DISASSEMBLY AND ASSEMBLY
EE 36
EE 34
Disassembly
EE 36
Point
EE 34
Assembly
EE 38
Condenser
EE 34
SERVICE
Vacuum advance mechanical part and
switch
on
off part
EE 35
EE
30
DATA
EE 39
ENGINE ELECTRICAL SYSTEM
Applied engine
Distributor model
D416
57
GI8
D423
53
G18
with
emission control
Fig
system
EE 77 D4l6 57
SPECIFICATIONS
Make
0416 57
0423 53
HIT ACHI
HITACHI
G18
Applied engine
G18
with emission
control system
1
Firing order
2
1
Counter clockwise
Rotating direction
80
Ignition timing
Dwell
3 4
B
600
T D
550
49
angle
Condenser capacity
I
F
0
C
20
0 24
3
4 2
Counter clockwise
50
A T D
600
490
C
550
0 20
0 24
475
550
Start rpm
Centri
11 50
1
Maximum
fugal
400
16 5 2 800
degree
Advance
11
50
1
23 50
000
2 600
rpm
charac
Start
teristic
Vacuum
mmHg
80
Maximum
degree
6
200
30
120
80
400
rpm
1 2
kg lbs
Weight
50
80
2
646
1 2
2
646
CONSTRUCTION AND OPERATION
Figure
EE
gasoline engine
78
shows
ignition diagram of
Functionally the distributor
consists of high tension
voltage
part
switch off
EE
part
centrifugal advancing angle part
vacuum
advance mechanical part and driving part
Figure
31
EE
79 and EE
80 show its structure
ENGINE
Ignition switch
Ignition
plug
engine
o
Condenser
Battery
o
o
o
Primary coil
Distributor
Ignition
Fig
EE 78
coil
Ignition diagram
D4l6 5
D423 53
5
2
10
1
ntroller
Vacuum
5
Rotor head
Condener
6
Breaker head
10
C p
J
Contact
7
Governer weight
11
Cubon
4
C
8
Oil seal
12
Shaft
13
Pinion
em
m
Fig
EE 79
9
Structure D4l6 57J
EE
32
Knock
pin
point
r VI VI m 3
m ZG Z m mr m
A o ai
6
0
S
o
ring Washer
Vi
nion
P
o
Condesr
seal seal
Oil
Dust
contrle
Vacum
Clip
moC@
t1
I
Shaft
Iii
f1il
OO
plate
G
Break r
@
G
II
spring
set
erner
Cam
Go
O@
l
f
J
wire
arth
E
Contac
head
Rot r
1
Cap
t
1
1
t
l
t
l
t
jt
t
j
I
ENGINE
CHECKING AND ADJUSTMENT
Cap and
Clip
clean to
head
rotor
aIld
point are also to he replaced with
replacement is as undermentioned
rotor
maintain
head
First loosen
be kept
always
durability
must
insulation
good
high tension voltage from ignition coil is
Sometimes
inside of cap
imposed on them
since
contact
line
once
cleaning
in it month
is
required by gaso
the
cap
it
must
be
1 5
to
turns
of screw at
and primary lead wire connection
arm
notice not to
however
case
excessively
As
in
from
Figure
82
EE
bar
stem
hold
and
In this
loosen the
Refer to Figure EE
shown
stopper
Whenever crack or trace
leakage is found on
replaced with a new one
of
1
part to pull out primary lead terminal
and rotor head is covered by only fine carbon
powder and dust
by
Details for
screw
82
off
take
the
contact
the
point by fingers and pullout toward you elevat
The both contact point and con
ing it a little
tact arm can be disconnected
When
contact set
together
is connected
do just
opposite order
Apply slightly grease on
both arm pivot receiver and surface of cam
new
in
Point
Standard
mm
0
size of
0177 to O
the standard
point gap
0217 in
In
is
0 45 to
case
0 55
size is off
required by loosen
Gap gauge is required for
adjustment
is
ing point
However without gap gauge it can
adjustment
be adjusted by holding down the contact arm of
screws
which the stopper is 0
5
mm
0
0197 in
thick
As for those with tungsten point point gap must
be checked at every 4 000 km 2 500 miles run
When surface of the point is not smooth
sand
paper No
must
be
ceiver
or
600
and surface of earn
is
new one
or
applied for smoothing
be supplied to both
must
grease
point
500
remarkable
it must
In this case
oily
fine
whetstone
At this
time
pivot re
In case wearing of
be replaced with a
arm
ill
contact arm and contact
Fig
EF 82
Duassembling
contact
ADJUSTER
the contact
point
of condenser
setting and insulating condition
checking
SellE
required
is
wire and to
meter
checked
EARTH TERMINAL
measure
denser
condenser
by
EE 8l
Breaker
clean the outlet of lead
screw
resistance
normal
points
and
34
value
tester
by
capacity
it
can
indicator
gradually
Zero in resistance
be
range to
When con
moves
swings
back to
In case the indicator never
is out of order and must be
EE
from loosening
made
is
capacity meter
tester by adjusting
its
large
is
the infinite
it
depends on the
Thus
frequent
Without
largely instantly
or
to
prevent set
of
Checking
Fig
and
Condenser
Performance
SET
arm
stays
the transformer
replaced with
ENGINE ELECTRICAL SYSTEM
and 2
Vacuum advance mechanical part and
switch on off part
Vacuum advance
is to
replace
is as follows
Solution for 3
1
characteristic
Moving side
of breaker
three steel balls
2
Moving
pivot
I
plate
for each
Do these balls work
10
it with a new one
is
supported by
up and down side
smoothly
side of breaker
is to rotate with
plate
receiver of fixed side
Does this pivot receiver move
In case of
j
be sure to put in 3 steel
assembly
balls for each up and down side and to apply
5
grease
61 5
0
o
500
300
200
nwnHg
Vacuum
Centrifugal advance mechanical
part
When cause of engine trouble is traced to
centrifugal advance mechanical part use dis
Fig
n 1l3
D416 57
tributor
When
tester
conceivable
normal
to
is
nothing
check
wrong
causes
wearing
of driving part
take off switch
characteristic
1
check closely
0 400
0
cam
assembly
on
or
ab
others
or
In case of
So do not disassemble it
1a
characteristic
defectiveness
are
out
characteristic
its
with its
improper
off part and
governor weight
shaft and governor spring etc
In case centrifugal advance mechanical part
400
5
is
reassembled
characteristic
by
be
sure
check
to
advance
distributor tester
os
o
o
200
Vacuum
300
400
Centrifugal advance characteristic
500
mmHg
20
Fig
Ef 1l4
Check whether
operates
or
not
D423 53
vacuum
17 5
advance mechanism
5
1
by operation indicator attached
0
to vacuum advance mechanism
Followings
non
are
the
causes
considered
2 800
g
for
10
operation
5
1
Leakage of
vacuum
air due to
incomplete fastening of
inlet
o
o
2
3
Leakage
due to defective
Fixed side
and
diaphragm
moving side
of
1
500
500
Oiatributor rotation
breake
r
2
000
rpm
plate
is sticked
Solution for 1 is to make complete
fastening
EE
Fig
35
EE 85
D4l6 57
2
500
000
3
ENGINE
25
3
I
r
20
1
I
Take off contact breaker
Refer to page EE
contact set is to be
34 when
disconnected
I
1
JI t
5
1
251
f
05
ro
i
I
t
5
0
o
4
1
o
OiRributor
500
rot
EE 86
Fig
2 000
Hon
500
2
3000
rpm
D423 53
ft
DISASSEMBLY AND ASSEMBLY
Fig
Disassembly
When
distributor
is
disconnected
EE 88 Removal
of contact
set
from
of distributor and rotor head
position
engine
for
housing must
be
well
remembered
or
place
Disassembly is
no
marked
If
is
distributor
set
to
wrong
operation become possible
be made in the following order
1
Take off cap and disconnect rotor head
2
Take off
vacuum
to
controller
4
t
Fig
l
4
When
off
o
V
clip
breaker
contact breaker is disassembled
to
breaker
disconnect
spring and breaker plate
between breaker plates
er
5
Pull knock
whole
plate
take
fixed
vacuum
pin and
rotation
as
well
as
those
disconn6ct gear to
part
However
pull out
before pulling
on gear
and shaft or
remember the relation between coupling direc
out
Duassembly of
of contact
Be careful not to lose steel balls between break
o
EE 87
Removal
putting down moving breaker plate
0
o
Fig
EE 89
controller
put
tion and
EE
36
counter
mark
setting groove of
cam
rotor head
ENGINE ELECTRICAL SYSTEM
6
When cam is disconnected
first
hold
mark
on
tion with
Fig
EE 90 Removal
In this case also
down
cam
take off set
shaft head is fastened by
since
and shaft
cam
or
screw
screw
remember the rela
ignition timing
of knock pin
Fig
7
EE 92 Removal
of cam
When governor weight and spring
be careful
connected
not to
are
dis
stretch or deform
When disassembly
governor spring
completed apply grease to weight pivot
the
Fig
EE 9l Removal
to
put counter
of rotation part
8
Figure
EE
93 shows the
exploded
o
l
L
f
0
of
I
i
r
r
c
h
Fig
EE 93
Exploded
EE
view
37
D4l6 57 D423 53
6
view
is
ENGINE
Assembly
Refer to Figure EE
In case of
way of
reassembly
do it
in
just
reverse
disassembly
ment
and
94 at the time of
reassembly of
governor
replace
spring
earn
Governor
weight
Carn
Clearance for start and
end of advancing angle
plate
Weight pin
hook
Rectangular
Circular hook
Governor
8
spring
Governor
Rotor
Fig
At the time of assembly
at
is
to
A
and
start
weight
pin
side
It does
checking
is
completed
Be
sure
ignition timing after
Adjustment
must
tributor point at
ram
Fig
EE 95 Point pressure test
posi
for
clearance at
Meanwhile
comes
set
to
in
advancing
it
to
engine
advance characteristic and
performance
and
short
not leave clearance
at the start and end of
assembly
positioning tip
governor
weight pin
advancing
opposite
rectangular hole
either
Then
to
It leaves
of
end
on
set
A
with circular hook comes in
governor spring
long rectangular hole
the
Setting of governor spring
rotor head
be
tioning tip
spring circular hook side
carn
EE 94
spring
When
after
confirming
make adjustment of
this
be made to let off the dis
degree
position of upper dead
point of first cylinder compression of engine
EE
38
and
ENGINE ELECTRICAL SYSTEM
Fig
EE 96
Point gap
measure
SERVICE DATA
All distributors
Point gap
0
45
0 55 mm
Point pressure
O
50
O 65
Shaft diameter
kg
0
0177
1 10
O 0217 in
1 43 Ibs
0 010
lower
12 45
pari
mm
0
0 018
Housing
inner diameter
12 45
mm
0 010
Amendment limit of clearance
O 08 mm
Shaft diameter
8
0 038 mm
0
mm
0
0 014
3150
0 015
mm
0
0
Clearance between shaft and
O
cam
Weight pivot diameter
5
Weight hole diameter
5
O
005
0
010
0
028
0
018
315 0
029mm
EE
39
m
0004
0
0
0
0002
0
0006
0
0006
0015 in
m
m
0
0002
O
0
1969
0 0010
0
mm
O 01
0007
0011 in
0 0004
mm
0
m
0007
1969
0
Clearance between pivot and hole
0
m
0 0031 in
0 005
8
0008
0
Clearance between shaft and housing
Cam inner diameter
0004
0
0 4902
0
upper part
0
0 4 9 02
020
m
0
0
046 mm
0 0004
O
0018
n
i
ENGINE
IGNITION COIL
The ignition coil is
SPECIFICATION
HANSHIN
e
Model
HM 12F
Item
Applied
engine
G18
a
oil type
HP5 10E
oil and water
d from dust
HP5 10E
GI8 with emis
sian control
system
Primary voltage
12
12
V
Spark gap
mm
more
in
Primary
6 0
than
more
6
2362
0
1
than
2362
2
resis
3
tance at 20 C
3
8
3
8
0
Secondary
4
resis
11 2
tance at 20 C
11 2
16 8
16 8
5
15
6
16
KO
17
DESCRIPTION
18
7
19
8
30
1
I
I
Vig
11 9
HM
20
9
10
21
tV
1
Secondary
3
4
HPS lOE
Contact
51
40
Washer
D
Seal
14
IS
C p
Washer
16
Secondary
17
Primary
rminal
Solder
6
Guide
7
Secondary ube
18
Outside iron
8
Primary tube
19
Primary
9
Insulator
20
Secondary
Case
21
Oil
Fig
EE
spring
12
5
10
EE 98
rmi ml
rmianI
Primary
fig
and
Dirty ignition coil is
pitch type coil HM 12F
not available because it generates high voltage
The case and cap should be cleaned and protect
ng
EE 99
truc
Con
ion
ate
pl
ulating paper
il
il
mpS lOE
ENGINE ELECTRICAL SYSTEM
I
I
i
ui
ll
r
DIIT
o
OIDT
EI
100
Fig
T
Characteristic
CUniC
SPARK PLUGS
CONTENTS
SPECIFICATION AND SERVICE
EE 41
INSPECTION
DATA
EE 41
CLEAN AND REGAP
DESCRIPTION
EE 41
TROUBLE DIAGNOSES AND
PERIODIC SERVICE
EE 42
CORRECTIONS
42
EE
EE 43
EE 44
SPECIFICATION AND
SERVICE DATA
RING
NGK
BP
Item
Applied engine
G1S
x
screw
ach
6E
B
CENTER
EL
ECTRODE
REACH
GAP
6E
with emission
Gl8
control
Size
NGK
diameter
mm
in
system
14
0 5S
19
x
0 75
14
0 55
TERMINA
x
x
NUT
19
0 75
A
INSUI
T
Plug
O
gap
mm
Torque
kg
in
m
ft lb
8 O 9
0 03h O 03S
1
10
0
0
7 0 8
0 031
028
5 2 0
I
8 14 5
10
5 2 0
8 14 5
Fig
EE
41
EE lOl
CrosHcction
of Sf ark plug
BP 6f
ENGINE
PERIODIC SERVICE
Too
seat
lean
actual
time
Periodically
depending on
operating conditions
plugs should he removed
fo cleaning inspection and regapping
Broken insulators
are usually the result of
improper installation or carelessness when
Broken upper insulators
regapping the plug
usually
result from
outside blow
moisture
is
Spark plug life
accordingly
spark
To
and
insure
should
plugs
affected to
conditions
operating
a
large
extent
life
varies
plug
peak
cleaned
000 km
12
at
conditions
000
hot
may be due to
cessive gap
Dirty
or
dirty
leaded plugs
penetrate
the
result
as
high speed
heavy loads
but
may be evident
red brown yellow
or
blistered oxide deposits
on
the
plugs
from the
plug operating
operation
or
under
faulty ignition
plugs which
piston rings
should
always
he replaced
by
or
over
will also result in carbon deposits
cold
too
are
Red
brown oxide deposits and a consequence of
use of leaded fuel
usually result in spark
or
the
failure under
plug
severe
The oxides have
no
eration
as
operating conditions
adverse effect
on
plug
op
they remain in a powdery
state
But
under high speed or hard pull the
powder oxide deposits melt and form a heavy
long
as
glaze coating
acts
on
the
insulator which
Fig
EE 102
Normal
when hot
good electrical conductor allowing
current to follow the deposits and short out the
as
a
plug
Excessive gap
usually
speeds
be
plugs
of low mileage
indicates the engine is operating at
high
or loads that are
consistently greater
than normal
being
wear on
or
used
the result
combustion
and gasket
the spark
that
a
plug
In addition
of
gases
due to
which is too
electrode
hot
wear
is
may
plug overheating caused bv
leaking through the threads
insufficient
plug gasket
compression of
dirt under the gasket
EE
or
The
too
extremely
the gap adj ustment by bending the ground side
electrode
Spark plugs with hroken insulators
deposits are usually the result of slow speed
driving and short runs where sufficient engine
operating temperature is seldom reached
Worn
oil
encountered in sustained periods
The black
rich carburetion and spark
soon
When regapping a spark plug to
avoid lower insulator hreakage
always make
ex
plugs
black carbon deposits
or an
fracture
broken insulator
leaded
or
or
may
such
of
they frequently fajl
Faulty plugs
are evident in a number of
ways such as wasting
loss of speed
hard starting
power loss
gas
and general poor engine performance
in addition to normal
Spark plug failure
wear
will
wrench
carelessness when regapping and generally are
visible
In fajrly rare instances
this type of
break
operation
fitting
Broken lower insulators usually result from
and
diriy plugs may give satisfactory
idling speed hut under operating
or
poor
cracked insulator may not
fracture is usually just below the crimped part
miles
Worn
a
of shell and may not be visible
performance
be checked
every 12 months or 20
regapped
The
make itself evident immediately
INSPECTION
by
carburetion will also result
in excessive electrode wear
Fig
42
EE 103
Wet
ENGINE ELECTRICAL SYSTEM
Fip
EE 104
Overheating
I
EE 107
Fig
Life
CLEANING AND REGAP
Clean
spark
abrasive type
be of the
Use
same
round
a
plugs
thoroughly
using
an
All spark plugs must
cleaner
make and number
or
heat range
feeler gauge to adjust the spark
plug gaps
Note
Before
In
adjusting
9ap
file center electrode flat
adjusting spark plug
gap
never
electrode which extends through
Always
Fig
EE 105
Fig
EE 106
Overheating
2
Overheating
3
make
bend center
porcelain
adjustments by bendin9 ground
side electrode
Fig
EE
43
E 108
center
Measuring spark plug
gap
ENGINE
TROUBLE DIAGNOSES AND
CORRECTIONS
1 When the
engine does
If there is
no
not stari
trouble in the fuel system
ignition system should be checked
This
ing motor and observe the condition of the
sparks that occur between the high tension cord
and cylinder hlock
After checking this use
the
can
he
easily done by detaching the high tension cord
from spark plugs start the engine by the start
Spsrk
No
sparks
the proper countermeasures
Trouble location
gsp
at all
Distributor
Remedies
Causes
Defective insulation of condenser
wire on low ten
Breakage of lead
Replace
Repair
sian side
Defective
insulation
of
cap
and
Replace
rotor head
Ignition coil
Point does not open or close
Repair
Wire
Replace with
breakage
or
short circuit of
coil
High
1
2 mm
0
0394
0 0787 in
tension code
Distributor
or
irregular
Wire
new
one
coming off
Repair
Defective insulation
Replace
Point gap too wide
Correct
Oil sticking
Clean
on
point
Point hurnt too much
Layer short
Replace
Replace with good
circuit
one
Less than 6 mm
Spark plugs
Correct
Electrode gap too wide
or
re
place
0 2362 in
Clean
Too much carbon
Broken
neck
of
porcelain
or
replace
Replace
insulator
Expirty of plug
2
When
the
engine
rotates
but does
not run
this
case
causes
are
many and varied
EE
it
life
is
Replace
difficult to point to the right
cause
considering the ignition system only
special attention to the following points
but
smoothly
In
and
s
44
pay
ENGINE ELECTRICAL SYSTEM
Spark
Engine
Trouble location
gap
misses
Distributor
very often
Remedies
Causes
Dirty point
Correct
Improper point gap
Correct
Leak
of electricity
of
cap and
Clean
or
replace
rotor head
Defective insulation of condenser
Defective
insulation of lead wire
Replace
Correct
of condenser
Defective
Oil the shaft
arm
Defective spring of
Correct
arm
or
re
place
Near
breakage of lead
Worn out and
Worn
out
Correct
wire
shaky breaker plate
and
shaky distributor
Correct
Correct
shaft
Ignition coil
High
tension code
Layer short circuit
ferior quality
Deterioration
of
or use
of in
Replace with good
one
insulation
and
Replace
leak of electricity
Spark plugs
Clean
Dirty
Electricity leak
at the upper por
or
replace
Clean
celain insulator
Engine cause
knocking very
Distributor
Improper and advance timing
often
Coming off
nor spring
or
Worn out a
pin
nor
Engine does
give enough
not
Correct
the
fit
or
re
the
fit
ting
breakage
of gover
Correct
place
or a
hole of gover
Replace
portion
Spark plugs
Burnt too much
Replace
Distributor
Improper and retarded timing
Correct
ting
power
Defective function of governor
Correct
Dirty point
Correct
Point gap too
Spark plugs
Correct
Clean
Dirty
EE
narrow
45
ENGINE
SERVICE JOURNAL OR BULLETIN
DATE
JOURNAL or
BULLETIN No
PAGE
No
REFERENCE
SUBJECT
EE
46
f
DATSUN
t
1
i
SERVICE
MANUAL
MODEL
SECTION
SE
SERVICE
EQUIPMENT
Gll
ENGINE
NISSAN MOTOR CO
TOKYO
JAPAN
LTD
ENGINE TOOLS
SE 1
SERVICE EQUIPMENT
ENGINE TOOLS
Tool number
ST49700000
Tool name
Pilot bush
Figure
Note
puller
Valve
guide
reamer
4
8mm
ST49710000
Valve
guide
reamer
set
Valve
for
guide reamer
cylinder head
14 2 mm
II
ST49720000
Valve seat cutter
Gi
g
IN
43
mm
dia
45
deg
IN
43
mm
dia
30
deg
EX 36
mm
dia
45
deg
Pilot
Cross bar
Valve guide replacer
set
Valve
guide replacer
Use when
qT
drawing
out
the guide
ST49730000
U sewhen
Valve guide replacer
the
pressing
in
guide
Use for
Spacer for valve
guide replacer
e
getting the
specified length when
pressing
SE
l
in the
guide
ENGINE
Tool numbe
ST49740000
Tool name
Front oil seal
Note
Figure
replacer
Rear oil seal drift set
Rear oil
seal drift
t
c
ST49750000
Stand for
rear
oil
seal drift
ST49760000
Engine slinger
ST49770000
Engine
ST37200G18
Engine attachment
If
carrier
SE
2
1
SERVICE EQUIPMENT
Tool number
ST37100000
Tool
Note
Figure
name
Engine stand
SERVICE JOURNAL OR BULLETIN REFERENCE
DATE
JOURNAL
BULLETIN
or
No
PAGE
SUBJECT
No
SE 3
ENGINE
SERVICE JOURNAL OR
DATE
JOURNAL or
BULLETIN No
PAGE
BULLETIN
No
REFERENCE
SUBJECT
SE
4
INISSANI
Printed in Japan Publication No 48331 30330250