TECHNIGAL INFCRMIATION DAIHATSU Charade DAIHATSU MOTOR CO, LTD. DAIHATSU MOTOR SALES CO, LTD, | NO. ECG10-7806-T1 FOR SOME EUROPEAN COUNTRIES |TECHNICAL INFORMATION Charade FOREWORD DAIHATSU hes put on ihe market the “DATHATSU CHARADE™ (Mode! G10), a now small-sized passenger car which has been de sd with an entirely new concept sas {o meer increasing demand for a resource saving, fusl-officient vehicle The “DAIHATSU CHARADE” is a passenger car with 2 refined, hatch-back styling, in 1 powerful engine has been combined with @ compactly DAIHATSU CHARADE" festuces excellent fusleconomy, ewy-operation and mult-purpese applications ssually in- voininess and running which a small-displacern Aesigned, light body. In this way, this versal herent in wagons alone, at the same time meeting performance,” that aro Une basis requirements for automobiles. We at DAIHATSU flunly believe that this compact et roomy Passenger ear will be favorably welcomed by all uses asa vehicle which has pioneered new field This “Technical Information” book contains the description and sammary of the new mechanism of the “DAIHATSU CHARADE” as well es its periodic mainten procedures. As for the information regarding servicing tiers, such as the removal/installaion, cisassernbly/reassembly and ropairs, consult the workshop menual for the DAIHATSU CHARADI DAIHATSU MOTOR SALES, CO., LTD.CONTENTS GENERAL INFORMATION ‘VEHICLE EXTERNAL VIEWS, VEIIICLE PERSPECTIVE DRAWING VEHICLE 4PLANE DIAGRAMS ENOINE PERFORMANCE DIAGRAM VEHICLE RUNNING PERFORMANCE DIAGRAM ‘VEHICLE MODELS CHASSIS SERIAL NUMBER & PATENT PLATE SUMMARY OF VEHICLE CONSTRUCTION SPECIFICATIONS ENGINE DESCRIPTION ENGINE SECTIONAL VIEWS ENGINE EXTERNAL VIEWS, THE ENGINE PROPER... VALVE ACTUATING MECHANISM. LUBRICATION SYSTEM COOLING S¥STEM, EUEL SYSTEM INTAKE AND EXHAUST SYSTEM. ENGINE ELECTRICAL SYSTEM ENGINE MOUNTINGS EXHAUST EMISSION CONTROL SYSTEM | POWER TRAIN DESCRIPTION CLUTCH TRANSMISSION DIFFERENTIAL... TRANSMISSION CONTROL MECHANISM. DRIVE SHAFTS FRONT AXLE SUSPENSIONS. FRONTSUSPENSION™ REAR SUSPENSION REAR AXLE TIRES AND DISC WHEELS STEERING BRAKES BRAKE LINE MASTER CYLINDER BRAKE HOOSTER PROPORTIONING VALVE (P VALVE) FRONT BRAKE 99 99 100 100 103, 107REAR BRAKE PARKING BRAKE PEDAL RELATED PARIS Roby is MAIN BODY BODY SECTIONAL CONSTRUCTION WEATHER STRIPS ° SILENCERS AND FLOOR MATS VENTILATION OF VEHICLE INTERIOR BODY APDGINIMENTS: ENGINE HOOD RELATED PARTS FRONT AND REAR DOORS RELATED PARTS. BACK DOOR RELATED PARIS BUMPERS ete RADIATOR GRILLE, OUTER REAR VILW MIRRORS AND GLASSES, MOULDINGS VEHICLE BODY COLORS. INTERIOR APPOINTMENTS, PRONT SEATS REAR SEAT SEAT BELTS. INSTRUMENT PANEL RELATED PARTS DOOR TRIMS INNER REARVIEW MIRROR TOWING HOOKS, JACK AND TOOLS BODY ELECTRICAL SYSTEM DESCRIPTION WIRING HARNESS USE BLOCK : BATTERY AND FUSIBLE LINK COMBINATION METER LIGHT GLOW-STATE WARNING SYSTEM. WARNING INDICATOR SYSTEM SWITCHES LIGHTING SYSTEM TURN SIGNAL FLASHER WER HEATER PERIODIC MAINTENANCE GENERAL INFORMATION CHECK AND ADIUSTMENT PROCEDURE ADJUSTING BRAKE DRUM-TO.LINING CLEARANCE ‘SERVICE SPECIFICATIONS TIGHTENING TORQUES WIRING DIAGRAMGENERAL INFO“ sid, GENERAL INFORMATION VEHICLE EXTERNAL VIEWS Fig. 1 Front View of Daihatsu CHARADE XG Fig. 2. Side View of Daihatsu CHARADE XTE =35‘VEHICLE PERSPECTIVE DRAWINGGENERAL INFORMATIC. | VEHICLE 4PLANE DIAGRAMS Fig. 4 4-Plane Diagrams of Mods] G10/ GENERAL INFORMATION ENGINE PERFORMANCE DIAGRAM HORSE POWER (PS) [DIN] comorsion Hato Nox, Horse Pane ENGINE REVOLUTION 29.051 5075/3500 rpm 21 h/2000 rom nem TORQUE (ko) FUEL CONSUMPTION (O/PS.H) Fig. 5 Engine Performance Diagram of Type CB-20 EngineGENERAL INFORM Gg ON PERFORMANCE DIAGRAM fore al reg Tat aver [fore] [nd ater | 7 Sed seer [Jano | mY fear j bh oi | 000 i —| 000 208 3 | & § 20% 3 3000 15% a 1000 I WO 20 30 40 BOG 70 €0 80 100 710 120 130 140 189 160 170180 90 Vehicle sped em/n Fig. 0 Vehicle Running Performance Diagram of Model GIO =ees /cENERAL INFORMATION VEHICLE MODELS Tansision vans Vente nomenetstace pati ‘Tae size Eine pe aia Spex] Shana rasriion 7 CHARADE XO [5 Spend Manvaltressmision GICEKD | pamaras “4Specd Manual wassnion | poth for font and year whch LSOGKD | pate gt eth for font and eu wheels | G59 Giocup | CHARADEXG [5 speed Manval wansnision| 155 SR GOSS | aan ‘Syst Neal ion G106 Gibkbe xte [spc Namal son Explanation of vehicle rode! code Vehicle modal codes stand forthe following, el] (ao) © flan fog fq} Steno | to cerca [ep x Gk rt G.....XTE TE: Initial for Touring E_ = Initial for Excellent J Ko... d8peed Manual transmission ‘Transmission specifications M...... SsSpeed Manual transmission Body configuration —— Vehisle model code (CHASSIS SERIAL NUMBER & PARTENT PLATE Patent plate Seat number ‘The serial number is stampod on the cow! panel at center gestion in the engine compartinen. |n addition, the patent plate is attacked to right side of the cowl pansl FIRST CHASSIS SERIAL NUMBERS G1o.so003s ~ ENGINE NUMBER STAMPED POSITION ‘The engine number is starnpod on the cylinder head atthe end sectionLE CONSTRUCTION engin. that isa water-cooled inderindine, SOHC, total dis 83ee engine, has beéa mounted yin the engine compartment, The ‘ean develop + maximum output of 5500 pm [DIN] with « maximum torque of 74 kg /3000 rpm (53.5 f1b/3000 ‘pm) [DIN] ‘With a view to attaining fueLeconomy and high output, the Type CB20 engine nas been | newly developed as « compuctly-bull, high performance engine with emphasis mainly placed on reduced mechanical oss of engine combustion efficiency, CB20 engine has employed a sealed blow-by gas cecizculating syste, yThe radiator & of the corrugated fin type featuring 4 good cooling tfciency. The uppor and Jower tanks are made of resin so as to seduce the wei 4 The cooling fan is the electrical ype which 45 controled by water temperatuce. When natural air flow through the radistor is sullen, the operation of the cooling fan is automaticaly stopped, thereby reducing ‘mechanical loss and fan sound level Power Train The cluich is of the mechanlcally-operated, dy, sngle-disc, digphrazm spring type. '* Fourspeed transmission and five speed trans: ‘mission have boen used, And all transmissions eniploy the ‘Toor shift control method. © The differential is constructed integral with the transmission, The final gear is a helical gear. And the final reduction ratio has been set a1 4.277. +* A barfield type constant velocity ball Joint is provided at cach end of the drive shaft. Suspensions and Wheels © The front suspension of the strut type ‘which employs an independent suspension by col springs © The rear suspension is of the fiveslink axle ‘type which is saspended with coil springs. ‘This uniquely-designed rear suspension has superior ground-contact characteristics and excellent riding comfort © Ticves of 155SR12 are standard equipment forall models. © ‘The Al'x 12 dice wheels have been used, Steering © The sicering sysiem J the rack and pinion type which Features sharp response and positive operation, The gear rstio has been seat 180, © The steering. shafl for all models $8 of the collapsible, impact-bsorbing type, Moreover, it is equipped with a steering lock mechanism, Brakes ©All models have been equipped with the diggonal, dual sysiem with a tandem master cylinder. © The font wheel uses the diss brake for all models All models have a brake booster and (wo P valves as standard equipment, ©The rear wheal uses tho leading and trailing type drum brake equipped with en avté- nate adjusting mechanism. # The parking brake system applies breking force to the two rear wheels by means of a wire cable Body A unique, hatel-back styling that is hes. suited for a family sedan hes been completed as the culmination of our long pursuit of the ‘most effective utilization of vehisle space by adopting a long wheelbase and a wide tread. GENERAL INFORMATIONGENERAL INFORMATION © The body constuction is of the wolded-mono- construction ‘The body has ample rigidity and strength without any waste portion so 2s to decrease the vehicle welght as much 2s possible © The body glaswescome in two different kinds: standard glass and coo! gess, depending upon models ‘The front windshield ses a $ mm (0:20 inch) thick, zone-tempered glass as standard equip. ment, and 5.7mm (0.22 inch) thick, Tamingted ess as en optional equipment, As for other slases, 4 min (0.16 inch) thick tempered glasseshave been used. © On Models XG and XT vehicles, a package ‘vay has been provided in the luggage com partment. Furthermore, the package tray is inteslinked with the openinglclosing of the hatchback dos, thus making loading) ‘unloading operations easier. Interior Appointments © The front seat is of the separate type. Or all models the front seat is equipped with = reclining mechanism and a seat sliding mochanism, Moreover, the front seat 38 pro vided with a height adjustable, insertion type ‘headrest on all models © The sear seat is of the bench type. On the Modet XO vehicle the rest seat Is the fixed ype, whereas on other models the rear seat lias @ seatback which can be Uted toward the front side. With the seatback tilted, the luggage compart: ‘ment will become one part of the vehicle passenger room, thus makingit possible to use the vehicle in the same way as with 9 wagon, © The three-point, continuous webbing type equipped with E.LR seat belt is installed on the front seat as standard equipment. © The walktoavall type floor mat is installed fn the asembly line, therehy making possible t0 ger a good appearance and fine finish, Furthermore, a gorgeous carpet is standasd equipment in the case of the Model XTE vehi Auris The healamps at ofthe twovound-shape- bulb type, Hach headlamp is fied with an cmaent ing which fears gary removal instalation The teat combination lamp is tae of resin boy in which the leases and hoasng ae in top to each other. Tt has employed 4 orzontalythrespiritoned, design which has 2 god vis ty. The: combination meter i composed of three spare fogetiaceis wha oncta ad ty ade, each meter having a refined dein. Besides, the combination meter sited wth a nomglare type glass. The centralized warning lamps are compactly located below the combination meter in over that the ativer may recognize immediately coven rng the cussing ony ralkneton, if it should occur. A lcgesied Fe block incorporating 9 say tas been proved in clove vicinity ofthe in strument panel where a umber of wing hamsies have tobe packed. A a etl he wiring wok has bon tationalzed great “The Model XTE veh s equipped with the Jump glowstale waming system which wil set off te buzzy Ifthe Ignition switch is turned OFF and the door is opened, whe the headlamps or the erence lamps ae sil ished “The intoducton ofthe mls ever switch (centralized, integral switch) has mede it posible 0 eiange all oitchesreguding the lightitg ger, wiper ad washes compactly at the sering colunn session, Consuenty th dive ea pert al vile offerte, even he buckles up his at bel {As rpuds the front windshield wiper stern, rectangularGENERAL INFORMATION XG vehicles are mounted ©The rear window dofogger standin equip- type wiper. In adation rent in th caso ofthe Model XTE vehi. E vehicle & equipped with he The heater is oF the indoor airjoutdoor ai type wiper. switching, hot-water spe. Faidow wiper and Sear window ©” Av forthe hor, «fit type hie pteba oem se standard equipment on the Movs ‘snl om all modal.(GENERAL INFORMATION SPECIFICATIONS VEHICLE SPECIFICATIONS > a Youle moaa Gee KD en ss eae) SMD) Kin o engine ow : Daplaerent ss = Kind of ful Cuatee | mane | 3860 3H85 Over gt mdm | tits, - een Oven with vm (hy 3, ;: ve ee ee a Wheelbase mm (inch) eee - - Devendony Frnt whet aan det) | 1900651.18) z i Trea jee atest ane — [Rearwiest mmaaem | 12400039) = i Misivu ound cewange am dgehd 16s Ea - ties unleaded] apn 60 Tater [bers ammdacty | 170006695) % a dimenionsFviaaxmamdacty | 1270 80.0) ‘oat Haight —mmdsem | 1130 aes) z z Footie ke | assay | = Sage [reraste —eumy | asses | sm0ussn | aseen 1 ea | e704 | orsaser7 | eo aan Wieatus Raine canst econ 7 = ae if Frontade aga) | SiS 7A) = = Soot [Rearaat’ gan et seo anism) = é Tos igi) | s0vo@29229 = = he ‘Menimum ped (estima ave) Z 3 re et lou (mp8) Peetomance : | Fes) is Moinen coniegmts mm) | year sitleay | — | Fontes tsesni2 Tide ea - - [Ree wet ‘Tose Other +— Tw isto | Front whee i eee aly Z ss glen? (oi) [Rear whos! [een -12-GENERAL INFORMATION =a Traine oe EE ‘Kind Gane Fee Mounting beaoa Front Cylinde: No, and anraneement 3-ovlindelndline, mounted transversely Combustion chamber p> ____Mukeaphere pe Vale mecha Bekchea overhead carcat Cylinder liner type Integra with cylinder block Boxe xsoke ‘a dk) T5R73(299 x28) Compresion rato 90 Compeion nesure Lfepm (kip) |__ a8 ~3500778~ 350) Gx ont Siro 6/5300 [DIN] van tomgue ‘gmlspm (Cetblpra) | 74/8000 2.573000) (DIN “Furs consumption ate _sipsh Gem) 210.6200), Traine dineasons ne Sab 58 x 36 {nth th chek] wen) | ai 8'435 00) ‘Sevie sng welsh atl) Bea) Number of Comproion ring 3 oars ores zi ey Open 2a Tbe ia Zee, tome om ‘Bane Nate ting da ae Oren 2° w80C Cow a ame, ——— am inch) p20 @0) an Gash) 020 (00079) Engine nodad fevolution speed ZZ oe 900 Dlowby ass ecioulting ys Shite | triste neitoa Ful forced eed method (i pam type | Trochoid type seem | one pe Fulvio ter gp, filer ape Fe Lubrication oll eapacity titer a | | Cooting method Water-cooled, eleciromotor type Radinor ome Cormtion type freed ccaation Goma areely [la Tie + ier pup pe _ Conta ty, bbe pe “Thennostat one 3 ane Wapetettree ~ [te in me imo 7 aiGENERAL INFORMATION jess agine ype aay. fr: “Zine pated stool set [118] ‘wake Capacity liter M ee inoet aa] Fase mate ae re) L Pelee a SSO perce =e | ame | uaattaia et | Aisin kogyo | ime == a oo ae ec Se aaron sneny| ena aay Choke valve type ae Manual type, butierfly-shaped valve | Aie-tuet eatio 15 Wie Voltage v ‘12 [Negative ground) pe Battery inition type | a = roo TD a a al fram Distributor type ‘Conventional type. | Becaker ey pe ‘Contact-point type Hl tee [o is advancing [Vacuum type (0/100, 12°/-400mmg ‘Manufacturor Nippon Denso | gue og pee ae a. Seen alts : eee a ‘Spark gap ‘mim (inch) 07 ~0.8 (0.028 ~0.031) | | aye NNIDD-SGL ae. [Capcity An 454M (20) i} [ae a eS") Alternator | Output vA 1245 all = Tg ea Te Starter ‘Output kW 12-08«2 | __| Mosifactarer ‘Nippon Denso ia Sie. Specification in (denote option equipment.GENERAL INFORMATION = ‘Vehice model ke ‘exo | oKG — iG (END) | GNC) Mechanism trom engi to trinsision aS © si Rediction ratio from engiae o irsmission 1.000 = = Wanatacucer Daikia whale a = Dry sisi die ele Tye Gane Geeninel Mechanically operated ‘a peaton method sy f ortictnee Aahiasteston : = } Dinwasion “ mm | ovtloxso =a Facing | LOwer a ximner a goer) | (6004-38302) Facing ata id Nos loge a Der fin! inch) cs) = Meters Metling [es ~ | Farwand Constantine ape = Te : ee ee Bois Seectstiineerre | = | [Operation method 1 Fioor sift type - | = | sree sonecsrnetoman | | = 2nd peat 2.150 (Syneheomesh), of Seles [164 Gyedvomety | = Gearrato ii i dings 0971 Syncvonedy | ~ 3 egaxt teh 0.35 ee | (Synthroes)] Revs weer 352 = Te Conwaioasleyee [=| Gear ype Hetiatwear ae | Resueon rato a Cobar =a Tene en ee Ceurtype nd atmber [Sige oytaas. a ae [obatienloe fof Teel ran lec 3013) zai rot | Cater i ie ol a ale Caster | e ais ‘nga acon apa | ie ae Tal andy | 1035) Poise aaa Tne Sane Stiseine ete el GENERAL INFORMATION ea = peer a ae ees — IGMGy va | Bestel ue aap eters tune | ye | rer as . - Front whoel Tubeless: = = “Saat ae : " : Sea piel mot, Type ———— Sane aa =4 I] [eaensge Spe lee nae a Otterdiamoter tm 380.13.0) 7 | et 1 tnt 1d Sel sMecring eel reqatied ‘Ouave! teem lok to lock Postion Rack end pinion aay = - fesemge = LE 222 Pere Fone 3 | = rosa Theft ee —— pt Steering ok pe ache 760 42.090 Binonions ac | Fromtwhest | gS PAIZO NIA s ap ores ae | im arya a0 T3049 z —_ eet Seah - ee Romwit | AU gapes | = Ade or pad fen =| ere idl eats eer seeniet | OCDs2Ge0x |. a pokes ete vie | eae Gene ee | Front whect | 164 (645) a or steve Shmster a romney | Rea wheel 180.59) = Es vigor pa SERRE |= weg | swat al: ae | isi Kon eae (ce Ses ene Toa | = a diameter int | __ 18.08 0.75 = a aeGENERAL INFORMATION Vetice moast Gre kD Ke eee teak (eb) ten) Seperated, nk i Sedum am «| mound oe, a FS yank ep Sods. 20.18, ote Pea grinder || Front whee arene | oe - filer tore aa a a oro | Rene hea 158706) = Nanunctrer | Nisin Keay a = Danke booster a ‘bre a z Rast oak Hearerube | Heatmen Inner Cu pit 1 i raking fore control device type Peake zi i Braking laces Phi ood ype cence ‘tant bre e = setae allan rotor ea = pone Ge Lit Mechaaiairovernted Typo ith rang ore a i Applied on ond wheal Wess wher broking force ae ear nels = : Noruetirer | Nitin Spinnin a e Diventine | 1730380080 | in del | 61x 138x016) i | ‘rea 500g) <2 pices x a e | ine int) | OS hea | Ta Tesla zi ib | Boke dram ahimerer_ mm dae) | 1800.09) = = E: oat weet Strut we I iE *emion WPS Tear whee aire | = Froai whee Shane. Coit sp e a ee whoo Satis Sea Vaiss | Ginerson WHE Irront whee | 292%9531318-695 = * is or (6AN3.73412.50°695) ire neta — Giecivetns tlre wna | 5000 0a87O-BH4 | 5 SFaincig| Gara s eT 30-884) iret - di Sala Dave — ang =z cS Shocksbocter [TM Ieesconie re Lope Gas sca, Doubteactng | | Rear wheat ae = z = Uskeontinaion S = =GENERAL INFORMATION Yetioe ode 7 en oe (oun (END) ] Mabie ceo | Te ~ | Eran: Sepate a e ae ae Rear: bench Naar Tron 2 Rea oun | Saunas, [D_ Feet: Soin pe 28 | Brotectxe | heaton Nunter Fronts 2 - i Monutecter | Nippon Seo z F “Eres, etter | Type vettine e pe i a oe cenlpped wih EL Tanber Treat 2 e [Maniac Pulsar = tsa 992 wih Head ete | Type iss ee ‘| bs Number Hanah nee = = = Fourdoor font jp eas ety sno. | EC = Z Monwtscer | Nippon pets etna | Frnt Zone wenrered pas | ype soos eee . ‘windshield — Laminated glass | glass, | = inves shea | Thee Ereny e Taovct) | 45-70028)0 tanefeturer | Npponpiite ge | Asis : Chases | Meare ee ee _|__ = pat naar oor | | asst Glass ter | ‘tied gsee | ere seme ae Giang” | xia |e senpert ds Supe 0 | ky ronda | toner oir : (Sarpontins | Shane wre Thsime Ee imtdncy) [0 4016) Side ‘Speatiemionsin |) denote opticnsl equipment,GENERAL INFORMATION raat ae “sie turn sigma mp Keite nv — sw © Clearance amp Keito 12v—sw. ‘| (es Tet NW Maoh a av saree a Rear tam signal lamp Keita “va pall a hy aNW ses yaw [License piste emp zy = 10W x2 a, 1v—10W) ~19-JP GENERAL INFORMATION Wein aaa crn ox. RG | = | (ou) 160) che ‘Manufacturer | Nippon Denso - € Qt | poe ember 1 ea re le iti itch sound 100 phons’ - [Nanuet Icke Koso > a i Type Glass. flexible type |e be ee be 41 8 mension at ecansan x carta ral 25151 1400R - + ie "nm ren) rea me Mamfiturer Toya ogy = a Vo | ee [De Gos.dcornmenyre | = | = Dracadorsiaad 60x20, : Sera es O70) = = | ‘om en) fa I aie Tara inne ‘laeamamy fndusty Conlide | 7 + De Notorisre Naber ont 2 =| Frome a Reet Fat poeta $0 tmes/inin, Pa 25 tacit 36800 | ont: $0 emeynin Snaiey Tesfonmanee rom 75 tee = | ene Sohne S1EA0 oak) dnemiten) Y 50 Smeynin, 19160u? ioe3einc) | ‘Tanaka instrnement ‘Manatee hate industry Co, Ltd, oa crt dows | Number Fiat? =| rene apnea washer T Prone YO0R40, Performance Fron: toome/t0 second, 1.26 = |. Toon | second 1.3e Manufactaror I Nippon Denso: = a Detter a : oo ee a a Prank st Pe Rear: Heating wire type Manuficteer Nippon Demo = 7 iE Estenion howsing a _ Speedometer | TYPE ‘eddy-current type Pestrmance — UA.Shm/A (24.89 37mm) z [oso a-Si) —u-GENERAL INFORMATION Vette modet ake cep KG — eat) ren IGNG) 2 | Nippon Dano : e q Eexemon hous eye pe porters se Posner wpe jee einer pe ear rato arp sigzl indicator lamp | Equipped Euulbped eke warning lap eve 3a =2=ENGINE ENGINE DESCRIPTION ‘The Model G10 vehicle is transversely mounted with the type CR20 gasoline ongine, that is a newly-designed, watercecled, seyele 3 Advantages of Cylinder Engine cylinder-infine, single overhead cam type, total displacement 993c¢ engine, (When Compared with a 4.Cylinder Engine with the Same Displacement) 1, The engine can be desinged compactly with seduced engine weight. . It is possible to reduce the number of neces. sary engine components, such as the pistons, connecting rods, crankshaft beatings, valves and so forth, thus resulting in dectessed mechanical loss, 3. The bore diameter of each eylinder can be Sel al a larger value, As a result, larger dia ‘meters of intake and exhaust valves become ‘Features in Engine Construction 1. The size of each sling part has bean designed as simall as possible, Consequently, the engine mechanical loss has been greatly seduced, 2. The intsoduction of the single overhead camshaft (SOHC) mechanism makes. it possible to arrange the valves in a Vee shape, ‘And the intake and exhaust ports have been so designed that they may have an in- dependent cross-flow construction, resulting in enhanced intake and exhaust efficiency. Besides, high output and fueleconamy of the engine have become possible because of the introduction of a polyspheic bastion chamber, 3. Each supporting section of the camshaft and. valve rocker shaft has become integral with the cylinder hezd. As a result, the number of necessary engine components has been re- duced, thus resulting in & compactly-con- structed engine, 4. A cogged belt has been employed to drive the camshait Therefore, the results are possible. Hence, the intake and exhaust efficiency can be improved, resulting in in- creased combustion power. 4. The total eylinder surface area becomes smaller, thereby making it possible to reduce coollag loss. : 5. Engine vibrations inherent in a Seylinder engine can be counteracted by the in troduction of a balance shaft positive and quiet operation of the engine ang light engine weight 5. The center of the crankshaft i roughly aligned with the bottom of the cylinder block. thus making it possible to reduce the engine weight greatly. 6. Engine vibrations ané comparatively high sound level that are inherent in ordinary cylinder engines have been counterbalanced by employing a balance shat ‘The total cooling water capacity of the engine ‘has been decteased, resulting in easier Warming-up. Because of the resaltant reduced ‘cooling loss, the engine combustion efficiency hasbeen further improved In addition, an clectrical fan has been used, Hence, the engine mechanical loss and sound level have been further reduced, 8. The carburetor is of the twobarrsl type. ‘The fuelair mixture has been set at a com pparatively-lean value, thus resulting in further improved fuel consumption, = 22-ENGINE 2 Crankshaft Rotation Angles and Strokes of Each Cylinder seereniombeinen | ics oe we oe ww aw wa . cae = ee Pea) = = TOE Pee fez) (eet | sae saree (1 ery Sane Power: Exhaust | Yo2 | Sinn rx a) ear 8 om “Fig. ©. Relationship Between Cranksheft Rotat le, when the ptton of the No.1 reaches the cop dead center on the n alrcke, the No.2 cylinder i on the stroke. And the erankpin of the No.2 ' focated ata point 120° From the top Nio.tevinder fon Angle and Strokes of Each Cylinder dead center. Alto, the No.3 cylinder is on the exhaust stroke And the erankpin of the No.3 cylinder is located at a point 240° from the top dead center. Firing Order 12 Fig. 10 Shape of Crankshaft TeENGINE ENGINE SECTIONAL VIEWS Fig, 11. Lengthwise-Seotional View of Type CB20 Engine ==Fig, 12 Transverse Sectional View of Type CB20 Engine -BeENGINE ENGINE EXTERNAL VIEWS Fig. 13 Exteinal View of Type CB20 Engine ~6-‘block has been so constructed thet ‘and crankcase are integral cast iron [25 the four bearing type, the cfankshalt rigidity surface of the cylinder block is located 5 inch) below the center of the erank- sploying a so-called cylinder blosk-at- enter line separation type in which Dlock can be separeted into two halres at the crankshaft center line. Such ‘skes i possible co reduce the engine baeatly. has been exercised to shorten the of the cylinder block and to keop ‘ickness and height of water jacket 4 minimum level in order thet the head is mede of aluminum alloy ‘Eas an excellent high heat conductivity st woight feature. The combustion [s of the polysoherleal type. tn com= ‘with the piston whose top aurfzco is at, this combustion chamber provides ‘ares to got a better combustion. Head Gasket ylinder head gasket uses silicon-penetrated, lensity steel asbestos. In this way, the head Fig. 15 Cylinder Head He ENGINE Fig. 14 Cylinder Block fengine weight may be reduced 2s much as possible. As a result, the cooling water capacity hhas beea reduced. Hence, the time required for warming-up has been shortened, resulting in reduced cooling [oss, too, Moreover, the intake and exhaust ports are of the croseflow typo which features high efficiency, Each bearing section for the camshaft and rocker shaft 1s integral with the cylinder head, thereby making it possible to reduce the number Of necessary engine parts and to obtain 2 com- pact engine design, x msket has superior sealing charactotistics and distinctive durability.ENGINE Crankshaft This uni-construetion type ductile cast iron crankshaft has four bearings with a phase of 120 dogrees for three cylinders, The outer diameters of the Main journal and rankpin joumal are 42mm (1,654 inches) and 40mm (1.575 inches), respectively. Howevar, the widths of their beasings are comparatively small: 195mm (0.77 inch) and 18mm (0.71 inch), respectively, thoroby providing a reduced fiction resistance. Furthermore, for improved urability, these bearings employ. aluminum alloy. ‘The thrust force of the crankshaft is sustained by the No.3 journal. Two halves of alluminum alloy thrust washer are iastalled at the eylindsr block side alone s0 as to provide a proper thrust clearanes. A wide crankshaft beering cap holds ‘the above-described thrust washers so that they nay not be dropped. The balance shaft sections of the crankshaft mast be coordinated with the balance shafts that are described at the latter part of thie technical Information book. To this end, the balance ‘weight sections of the erankshaft have been so designed that they sre balanced with the half of the total weight of the reciprocating sections, uch as the pistons, the small ends of the connecting rods and so forth, in order that the engine vibrations inherent in a three-cylinder engine may be eliminated, Moreover, In order to attain a top-level accuracy, the crankshaft has deen accurately balanced by means of a balancing machine, after machining the circumference sections. , Crankshaft Specifications zi Bonn Nenjounatoue dimers | « OER, Gantpinjura outer dimer | «UTES ithe West |b, haley acrng or Washer © cranksnat: pulley @© Timing bolt pulley Norge © Timing bere outey © Timing bot pulley Farge ® aiancsshate drive sour B® key Slot spring pin Bash Crantsrel ears fat renisatt beering at raneshattenrat washers Striahe pin Flysmes!sttaching bot esees eset Fig. 16 Crankshaft Related Parts =bearings employ aluminum alloy Festure Curabilty. The same bear ‘used in common for No.I through f these bearingsinserts are pro- equate oil grooves so a8 to improve g durability Js attached to the crankshaft by & bolis which are spaced equally Sinle. Furthermore, a slotted pin sts ‘exactly at the corsect position in crankshaft. (0.16 ineh dia), Imma (0.039 jon timing mark Is provided at position on the periphery of the ‘ining mark is painted yellow for of wentitication. ei ring gear tooth nuraber Oil Seals and cear oll seals of the crankshaft are “1” with helix (spiral grooves) so as ENGINE Crankshoft Bearing Specifications ‘esting ier thisknes | 20mm (079 nok) eal srt wit Smm (0.971 ict) | Ovterdimnter | ‘Noterial | Fig. 17 Flywheel action which ovcurs when the crankshalt is tumed and which always forces the ail to flaw back into the inside of the engine. Hence, the il Leakage type “T" oll sexl has remarkable sealing ‘ol sesl utilizes the serew pumping __charactatistcs. Oil Seal Specifications em | tanerdiameter | Outer dismetee | Thickness | Oilseat Number 320mm 80mm ras aa cde rnc) as¥inetes) | (2M imam) | 9004211109 shonm Tom i0onm etches) QB iinches) | as inahy | 2004211025 (Crankshaft Front Oil Seal Fig. 19 Crankshaft Reur Oil Seal 9-ENGINE Pistons The piston is aluminum alloy. Ics overall height hhas been set at g comparatively small value of ‘60mm (2.36 inches). Moreover, the skirt section Of the piston is recessed in its pin dineetion in order that the friction Jos: and piston weight may be reduced. The skint section of ezch piston has two different sections; the twostage taper section and the straight section, so that smooth fiting with the eylinder wall may be cnsuted at all times, An ample clearance has been provided between the top surfuce of each piston and its exhaust & intake valves, Furthermore, the top of each piston is recessed in part so at to increase top clearance margin. Since the piston pins employ the connesting rod pres-fitting method, it is unnocessary to install 4 clip at each end of tho piston pin to retain the pin in place. Piston Rings ‘Those piston rings having a small width have been employed. Also, their tensions have reduced a much 2 possible in order that a minimum friction los may be achieved ‘The top ring and second ring are of the tapered face type, whereas the oil ring is of the com bination type so ss to obtain improved cil consumption. ‘The No.1 & No.2 pision rings bear a top mak at each top surface. Connecting Rods ‘The connecting rods are made of high rigidity carbon steel with a “I” shapederost section Particular attention hes been exercised so as to minimize the difforence in weight at the large and small ends between connecting rods. When sssembling connecting rods, make sure thot the side having the “55° mark of exch connecting rod faces toward the front side of the engine. Moreover, be certain that the side having 4 projected mark of each connecting tod cap aces toward the front side of the engine. Each connecting rod cap bears a code which Piston pin hole ier] “ci, coae ‘Outer ai, mating mark Frente Te, Fig. 20. Piston : Piston Specifications Tope Slipper ev: 7é.dram 99 inches) | 0.5mm (0.02in-h) 180mm inch) Outer diameter Psion pin ofset Pitoa pin disaster ra } TF 0.3 eg _/ (asgshape varies depend / ingupen manufacturer) 4 ors No.2 rine (Rina shop varie deponctng| il rng leombination syne) (Ring shooe vies deoending upon Fig. 21. Piston Rings Fig, 22 Connecting Rod Indicates the bore dismeter of the big end of the connecting rod —30-sod boarings employ aiminum “which have remarkable cortosion- feristics and superb durability. Head Cover nun die casting cylinder head cover curved surfaces. It features great ‘and distinctive antivibration effects is 2 ventilation bafile plate inside the head cover in order that any oll con- she blow-by gases may be separated, Housing um di costing distiibutor housing to the rear part of the cylinder € distibutor housing hss been con- fm such 2 way that it sustains the eam- 0 in its thrust direction. Furthermore, ation oll that has passed through ‘paris of the cylinder heed will lubricate tor driven gear, fusl pump lever and End Plate ie rear end plate comprises upper and Ik is attached to the rear part of ‘together with the transmisston case, type ignition timing mask is provided part of the engine rear end plate. “pen is mado of stee| sheet, For improved the oll pan has been provided with 2 ‘of ribs at various vital places, cesulting vibration and sound levels, fn, the oil pan strap has been welded with the off pan so that the oll pan fitted closely withthe cylinder block. to th oil pan gasket a rib has been at each curved section at the front and. in ovder to enhance further sealing ties. ENGINE ‘Beaving insert thickness | 1S (0.059 inch) 180m (Fined) Destng inert width Duiee dancer “Fam (1.69 ines) Matera ‘Aluminum allay =31- atte ote Fig. 23. Cylinder Head Cover Fuel pur pushrod inortien hele Distrioutor mounting Fuel pump mounting ation Fig 28 Distributor Housing Fig 25 Oil Pan ComponenisENGINE Balance Shaft While the engine i mnning, an imbalanced inertia force due to the piston's resiproeating movernents will be generated in euch eylincer, Im the case of a S-eylinder engine whose crank shaft has a phase of 120 degrees, the total sam imbalanced inertia force occurring in each cylinder will be counterbalanced among three cylinders, Nonetheless, parts of inertia forces generated at the No.l & No3 cylinders will ‘generate « moment about the No.2 cylinder. In order to alimnate this moment = sigale shaft balance shaft has been mounted in the eagine so that the engine durability and-riding comfort ‘may be further improved. Fig. 26 shows the contour of the balance shaft Which i turned by tho crankshaft drive peat at the same revolution speed as with the crank shaft but in the opposite direction, ‘A mating mark has boen provided on each gear to ensure the correct assembly. No oyinder Mement ZT Nozevitwer Fes Nc sae No. eytinger = te, Craniahare Betence shat. Rotating direction ‘When piston of No? evlinter rear 109 Sead center, foots in up and down follows Fee. 4¥, Momonts, oo, sro eountrbslance os fellows: Gy 23, Gy = Fig. 25 Schematic View of Balance Shait =32-ce Shaft Force in Single Cylinder Estudy has beon made as toa single & pecked up from among three combined force of the inertia the piston’s reciprocating move= inortis force generated by the Fe balance weight constitutes. the E iets force dhat 4s now occucting in ftuds of this imbalance inertia force the same, provided that the engine ged isconstant......0.060. 41 forve caused by piston reciprocat- mont force caused by the piston’s - ing movement varies a6 the crank- tums, When the piston reaches the vad center or the bottom dead conter, Tnertia force becomes the maximum, the direction is opposite.) Jet us designate the inertia force by the piston’s reciprocating move- Ameximum value) as /, the rotating E of the crankshaft as ¢. f varies in m of /-cosd , as the crankshaft force generated by crankshatt’s of the balance weight of the aft has teen set at 1/2 of the re ig sections, eg. the piston. There: “the balance wojght is always generat- p inertia force of 1/2 7, while the fis tuning, Jot us calculate the magnitude of sposte force F by combining the Forces as described in paragraphs | Supplement Referonee Information on Items *1 and #2 ENGINE Furthermore, this imbalance inertia fore is a Force that is tuming in the opposite direction at the sume revolution speed (angle) as with the crankshalt.....-.-cseeeseseeens *2 ‘Therefore, in the case of the cylinder engine whose crankshaft has a phase of 120 degrees, the imbalance inertia forces of the same magnitude are occurring at intervals of every 120degree phase and these forces are turning In the oppostie direction as with the cranks shaft. & 2 above. Also, let us establish is rot angle «. Moreover, let us designate the hosizontal component foice of F as Bx; the vertical component force of F as Fy. Since Fr is ‘equal to the horizontal component force of the Inertia force of the balance weight, the following equation can be established: Px-—1 sin? Moreover, singe Fy is equal to the dif ference between the inertia force caused by the reciprocating movernent and che vestical component force of the balance weight, the following equstion can be established: Fy= feos? hf cos} feosd Hence, the magnitude of F ean be doter mined as follows: Pov Feteby2 VERT SInETG Teos0)* SVT FRGin29+ cos9) =VEPSH EL colAs for the rotating angle @ can be asta- blished as follows: ec mtant BF tay APs Fy =tan-1(—tan?) Fig. 27. Imbalance Inertis Forces Imbalance Inertia Force in Three Cylinders Let us decompose those inertia forces of Fy, Fy ‘and F that are occurring in the three cylinders, in the Xaxis and Y-axis, respectively, so that the balance of the inertia forces in the three cylinders may be examined Here, it should be noted that the magnitude of those forces of Fy, F, and Fy is the seme, but the difference in their phases is 120 degrees Now, let us study the balance of inertia forces in the y-axis direction MF, ys ~ MF5 and, further more, Fy = Fy = Fs, the following equation can be established, indicating that there is equt libriam among the inertia forces. vit ya Inasmuch a yy 30 Let us proceed to study the balance of inertia forces in the x-axis direction, Inasmuch as x2 ate "3 Pa and, furthermore, F, = Fs, the following equation ccan be established, indicating that there is equi= Iibeam a8 far as the magnitude of inestia forces is concomed, X= Nevertheless, the pesition of x, differs from that of xs moreover, their divections are ‘opposite from each other, Hence, a moment about the y-axis has boon genorated and,ENGINE terbalance this moment, it atv the balance shaft to install a woight which can Consequently, the erankshaf{ and balance shaft inertia force G, a8, but in continue {0 rotate, maintaining the above don 25 well 9§ another weight described relationship in which the moment is se the same inertia force Gy as counterbalanced at all times. ‘opposite drsction. Their weights j reer pos <> saree Ne? Batence weit Fig, 28 Imbalance Inertia Forces SapENGINE VALVE ACTUATING MECHANISM Deseription The valve actuating mechanism is of the single featuring high rigidity and remarkable follow-up owshed camshaft (SOHC) in which « single characteristics over the entire operating. range. camshaft commonly used for intake and exhaust Furtheumove, large-sized valves that are arrangeé valves js located above the cylinder head. And ina Vee shape make tt possible to get an ex: ‘the camshaft is driven by a timing belt. cellent torque performance with 2 nearly fat ‘The camshaft is sustained by thiee bearings, curve. Fig. 20 Valve Actuating Mechanism = 38 —ENGINE ‘The cam lobe surfaces have been cltll cated ad camsha‘t that 18 located The sesults ate improved wear-resistant property. er heat is supported by three Furthermore, tho cam design features igh oF sx cam labs are provides ty. bh of the camshaft A gear for The crslobe's contours have been designed such Eibutor mounted at the war that they have remarkable fllowsup character Mhaft made of a spcil cast iron. ities over the erie operating range Wepeneat TDC ex cows 21° 4$s.50mm (9 tinde9) 5 65tmm © 26incH) 6654mn O2GrCH) 20mm O079inch) nm da. (o.d inchs) vp ig, 30 Valve Timing Ccemenat our No.2 Fee! pump cam \ \ l | \ i Camsnatt journal No EX Fig. 31 Camshaft =3-ENGINE ‘Timing Belt ‘The ‘timing belt for driving the camshaft is of the cogged belt. type which ensures smooth rotations and a very low sound level. The timing ‘belt contains cablacord 2s is Ingredient. Hence, it festures superior durability and can withstand even gruelling operating conditions Timing Belt Specifications ae Conaea att wpe elt with Osim) Pick ‘ember of ites % Timing Belt Pulleys The timing bolt pulleys are made of sintered alloy. There are two Kinds of the timing belt pulleys: one for the camshaft use and the other 's of the crankshaft use, Each timing belt pulley bears a mating mark so as to ensure the correct assembly of the related parts, as shown in Fig. 32, The abovesdescribed mating marks can be seen only when the timing belt cover has been re. moved. It should be noted, however, that the timing bel pulley at the cershaft side us another set of mating marks (timing belt check marks). by checking these mating marks, you can easily confirm the asiembling condition of the timing belt and the pesitioa of the top dead center. when the cylinder head cover is removed asindiceted in Fig. 33, Under this setting, the piston of the No.l cylinder is at tho top doad center. Furthermore, female serew holes (M 8) are pro- vided in the timing belt pulley at the erankshett side. In this way, the said pulley can be removed easily, by installing bolts into these female screw holes. ‘Timing Belt Pulley Specifications NoTE 1 The cablacord contained inthe ti superior ducsbiity agains tensile forces. Nevertles, it is very susepuble to breshage, when the belt it bent, resting in 2 greatly roduced siongth, Hence, be very careful to avoid bending the uiming belt Cate also should be exercised not to ot water or ois touch tho timing belt, forthe sorta nation due to these elements would cause the ciming belt's rabber to swell ing bolt has Tep deed canter aTpe 10° Timingrark | Timing beltcheck mark Mem | Gmikafiaie | Crnkiafe site ‘Tooth numbers, 40 20 D | tee 2am wah fc @9tnem | @sdinny Fig. 93 Timing Chock Marks — 38 —fensioner provides the timing Uadequate teasion in order that fay be ensured and the durabi- belt may be improved: can be adjust ensioner spring F the toller section of the timing ofthe maintenance-ice type by setting the st Valves land exhaust yaar are made of ‘aecl. For improved intake and ey, the diameters of the valve xd sections have boon set at com fe values, respectively. Further seal hai boon provided on each the intake and exhaust valves oll dropping, ‘Valve Specifications ENGINE ~ ARTE A Fig. 34. Timing Bolt Tensioner ‘The valve springs are made of chrome silicon steel, And these valve springs are of the equal pitched single spring type. To attain better following up characteristics during highspeed operation, the inherent vibrational frequency for these valve springs has been set ata comparative ly high valuo, Moreorer, siellite has been dapostied to. the ceshaust valve face as loaded gasoline measure Valve Spring Specifications trate | Estas Free eanth 7am (TORR yaar | ikea Hoght as void 349m (37k) co SRiakes | abe —— pe tt Bol Twi dcr “hs (.16nen 0mm | Gem, ans oes" | coat | 3s lactone ume i P) tom | Ronn, (Coll outer disaster 29.4mmn (1.16inehes) ft) isfy |_ atime is a ete ee | Sorin onan Beige Shas —— —— er shaft uses a carbon stel tube. undergone heat treatments to get a — ee a stant property IE Se ay ferent kinds of rocker shalt: Foci Jntake valve use and the other for the use, The exhaust valve rocker shalt ite overall length. Furthermore, it passoge at 15 front end. This ci Jesed to lubricate the bearing journal the camshaft =39- Fig, 25 Valve Rocker Shar| ENGINE Moreover, on oil hole plug has been screwed into each shat far the purpose of locating the shaft the rear end of each valve rocker shaft. In 2s well as preventing the shaft from turning, addition, a roller pin tas been presctitted into Valve Rocker Arms The valve rocker aims are Installed on the two rocker shafis: one for the intake valve use and the other for the exhaust valve use. In these chrome steel valve rocker arms, the racket shaft fitting section incorporates 4 Teed bronze bush ing, while the pad susfues area is hard chrome plated, thereby increasing weavresistant property, Herd ebcern plating Valve Rocker Arm Specifications Rost Soetiatere Fig. 36 Valve Rocker Arm = 1 Pe | Vaive 20mm | 020mm Nahe carance (hot | contin) | (007m) =40-(beet i Balans aha] [Comsat ere Rare | [Rois as sain journals | Batance shat] news plates| [Cranks Tews ES TNO. Lead pi journals | OFT presure swig ia] ear (ase it pump Rel ae} = Cylinder walls Vane [atiatis 1 Naive wer] [Eng journals ] [Ceasar] Bae | [Cam gps | | surfaces on Crankshatt ace iit | =a Fig. 37. Schematic Diagram of Lubrication System Oli per Oil srsinerENGINE Description The lubrication system employs the fully forced feed . filtering method which has a great lubr- cating performance Im this fully-forced lubrication method, the oil is sucked from the oil pan with an oil pump. Then, the thussucked oil is filtered at an of filter Next, the lubrication oil i fed under a Oil eapaety (whol Manian of] par capacity Minimum oil pin capacity + il panyp relist valve opening pres Gi iter by-pass valve Spenine presare 17 ters 3.62 0.Skg/an* Glas ps 2kglem? | 228 pi) Pressurized condition to the principal com Porents, such as various beuring sections, gear sections and valve rockor shafts, and s0 forth. Oil Pump The oil pump is of the trachoid type. It is ‘mounted at the lower part of the cylinder block, ‘The oil pamp is driven by the balance shaft sprocket through the drive chein. ‘The oil pump has a builtin zelief valve. When the oll delivery pressure reaches 3.6kg/em? (51.2 psi), the rlieft valve will start functioning. ‘The Type CB20 and Type AB engines share the same oil pump drive shaft sprocket in common, Howover, it should be noted that the installing direction of the sprocket is different in these cngines. Tho sprocket must be installed in such ¢ way thet ‘the side bearing the embossed letter “COUT. SIDE” comes the front side (the side you can see), Sprecher 38 DI Pump Fig 99 Oil Pump Drive Shaft Sprocket (O11 Pump Specifications Tyre ‘Trocuotd gear Dovery output ‘40 Tier/min at tine when dln rry prestare end pump revolution speed ae 2kg/em! (28-4 pai) and 6O0zpm, respectively. al tcl nig at fie mien By pes Soe punp exouion sped ne 3kx/cin* (42.7 psi) and 2300rpm, respectively. a ia Delivery pressure of 3.6 + 0.Skg/cm? (51.2 +7.1 pai), with pump revolution Betefvabeoneing resi” | “peed ot MDtnsn enpun elena eas ea 0 Drive chain 6.35 i Eee oo Se -42—‘Tooth Number of Oil {E20 is of 2 dram (0.16 ineh) dias fs installed a the left slde of the Bieicnye /* 4s of the cartridge type which has a valve, It fs mounted onto the through en ol filter bracket. mn oll ows inside the oil filter, ‘by Fig. 42. However, in case that the Should be clogged, the relief valve ‘pushed open, thus permitting the adem 1125.6 neh) ENGINE Pump Sprocket 82.7 here Laine Fig. 40. Oil Level Gauge i finer (wnenpresue a Bese lw and utes doe Jehes Oto 1 2kaiemé Ol presure rites rede listed Fig. 41 Oil Filter Schematic Diagram ay pas wave Fito: amgENGINE COOLING SYSTEM. Description of Cooling System Fan motor —P® Radintor thermo-contea © To neater By-passhose From hes igntien switch Fig. 43 Schematic View of Cooling System The cooling system is a water-cooled, press lurizeé-citculation type. In this system, the radiator is cooled mainly by air flow developed by the forward motion of the vehicle, and is cooled forcibly by a fan motor (electric motor) for only a limited period of time ‘The cooling system includes the following com- ponents; the radiator, water pump, thermostat, various water jackets of the cylinder, cylinder head and intake manifold, water hoses connect ing these components to each other, radiator thermo control switch and fan motor. The radiator thermo coatrol switch operates the fan motor when the engine tomperatur exceeds a specified level of 98°C and stops the fan motor when the engine temperature drops below a specified level of 93°C, thus maintsining an ‘optimum temperature a all times, The radistor is the corrugated fin type. It features < remarkable cooling efficiency, al though its capacity is comparatively siall. The raliator cap is the pressurized type which main: tains the cooling system under a presiure of 0.9 keg/em? (128 psi. The water pump is of the centrifugal ype. The pump body is made of aluminum alloy s0 as to reduce the pump weight The thermostat Is the wax type Which is hasdly affected by the intemal pressure of the cooling passages. The racator thermo-control switch ts of the wax- sealing typeENGINE ‘equipped with a reservoir tank. As regaids the radiator installation method, the Js of the corrugated fin type rubber sections of the lower support boss have ent heat radiating charucterisies. been inserted. into the rubber tings, while the ower tanks and ratistor cap are upper sectlon has been attached to the upper ‘that the engine weight may be _baille plate by means of two bolts fe Fig. 44 Radiator Radiator Specifications (Specifications vary depending upon manulecturers.) Comsat te Das ier 303m! G63) 21,300 Real (09 = 01 skg/om? (12.82 2.4 0) Gore dimensions (hit x width x depth) 2350 x 310 « BP (13.78 1220 x1 26 ines)ENGINE Water Pump Water Pump Specifications Tie Corie oe, ice Deine outat ssplrelaton eed SHO Sn Rote date ea Re Pe date i ey Thesmostat, ‘This small-sized wax type thermostat is equipped with a jiggle pin which prevents over-cooling and tetanic =a ae Fig, 45 Water Pump ‘ensures smoother water eplenishment, ‘Thermostat Specifications Te Valve openine temperature ‘Valve fulbepening tape ure aes Wax type 100°C Varo ie | Not less than mn (0.31 inch) (100°C) Forced Cooling System ‘The forced cooling system consists of a radiator thormo-control switch and a fan motor, When the temperature of the cooling system reaches 98°C, the fan motor will be actuated auto- ‘matically, thus cooling the radiator forcibly When the temperature of the cooling system drops below 93°C, the fan motor will cease its operation. In this way, an optimum temperature for the engine can be kept at all tines, Fan Motor Specifications Tre | Rotating deciion Tolaiy-encosed ype, dliest arent printed creuit Rigi (4s viewed from div side) Revolution speed 2700 + 300eprm Curent 6740.78 —48 —fedistor thermo-contral themo-contral switsh, ex ‘Empersture rises, When the es 98°C, the expanding ®, tefron @, piston E Then, the snap plate Dwill fn the opposite direction, the movable contact point @) the stationery contact point ‘the ground circuit will be formed, fan motor. the water temperature Grops, ¢. Then, the contracting wax. ® B 10 push back the piston. temperature drops to 92°C, tho be deflected rapidly to the Consequently, the ground spied again, ENGINE Fig, 46 Radiator Thermo Control Switch Type Wax sealed type [ON temperature (OFF temperature were | Wenlifcation calor Gisen SieENGINE FUEL SYSTEM Carburetor The carburetor is of the two-barrel type. The cecbucetor hus been designed in such a way thet én optimum air-fuel ratio can be maintained always under varying operating conditions, by means of the diaphragm type secondary actuat- ing mechanism, sevondary slow mechanism end sinteted alloy air bleeder and so. forth. In addition 10 the abovedescrised features, the ‘ansfer from the primary system to the second: ary system can be carrid out vary smoothly. Choke opener Diaphragm (Secordtry throtte vale) Sobraid vake Thermestate vale Advance port Fig 47. Carburetor aeFig 48 Carburetor ScherENGINE Carburetor Specificati Engine tyne cpa0 | Ais horn Gang outer dn) eclcet am (nen) 58x63 (228 x 248) ba fee teltew Primary 187 (O71 0.28) Ventan(iaigt sam) mm (ined) Yenuuns& fa ose Secondary 3, | 25x80.98 031) iste oat Primacy 280.10) Troive bore dismerer mm (neh) ~ Secondary 02) Primary 0.81 0032) [ain jet dimer mo Giehy) 4 ‘Secondary 138 (0.054) Pama. 9.52 @020) Jets ‘Slow jet dismetes sim neh) —| Secondary 0.37 022) Power jet clameter ‘aim (inch) 0.40 0.016) Se ser fen [090 0005) ceca arn Seo A amin ul el alas de ASP ima eid | Fao recsipeaes: |_ SAS ndeGaa eeRTEERCST conaan am tet) | rae na Mot) o1n.0038 Falctoet e eam) j fans tin | Seater naar : valve (ineasuced from fully-closed position) Gegetey as lyeosedande eae 5 coapuaa: | naa ea) 7s Ker Fally-opened angle (aearee) 0 Tie ge gee evap ello ia Sor eater 93,0013) ed ey Cpa tees ciel yeteac a vias Coeeeoe i tartan Ee ae 7 i em ial sais ate et EEN To Dizphragm Type Carburetor ‘The carburetor for the use in the Type C320 engine is the diaphragm type in which the se condary throttle valve is actuated by the vacuum created at the primary and secondary ventura, ‘The introduction of such diaphragm makes it possible to get an optimum fuelair micture always under varying load conditions, Moreover, the transfer fiom the primary system to the secondary system can be made very smoothly, Explanation on principal mechanism n- 1. Diaphragm mechanism The diaphragm is inte:locked to the secondary throttle valve with a link, And the dia phiagm is actuated by the vacuum created at the primary and socondary venturi. Namely, as the vacuum at tho vontusi section incresses, the diaphragm will be pulled up. Then, the secondary throttle valve connected to the dia pluagmn by a link will open accordingly. 2, Secondary low-speed systemthis secondary slow-speed adequate airfuel mix ting range from the time cy throttle va begins ‘me when the openiag of the es approximately 10 degrees assistance furnished fiom the system, the tranefer from the primary system to the secondary system can be carried out without the occurrence of any uneven aicfuel mixture during this transient period. Consequently, ideal al fuel mixtures can be obtained at all times under varying operating conditions, result ing in increased engine output, ‘of the diaphragm type carburetor, mo need for providing a link to open the secondary throttle ‘ly. Nevertheless, in oder to “the secondary valve from being ith a delay because of the valve be- fo the bore or because of contact = the Kickaap mechanism fas been ‘When the opening of the primary exceeds $0 degrees, the kick sm opens foreibly the secondary anism idle mechanism is a device which 4g faster idle speed that is required engine warning-up period. choke valve is closed, the throttle {rests on the high spot of the fast idle ‘keeping the throttle valve open Consequently, 2 slightly increased ‘ean be oblained, choke button is pushed back upon fof the engine warming up, the ‘cam will be returned to the original ‘thus making the throttle valve free 44 result, a normal idling speed 1s Ser Fig, 49. Kick Up Mochaniia rote vive Fastiate cam Fig. 60 Fast [dle Mechanism ENGINEENGINE Power Piston. ‘The carburotor incorporates the power system. ‘This power system provides additional fuel-ar mixtures duting heavy load operations. Air Bleeder ‘When the fuel supply from the carburetor varies, it causes combustion fluctuation, cesulting in deteriorated duiveablity. In order to solve this problem, a multihole type air bleeder that fs made of sintered alloy has been installed in aes Fig 51 Power Piston. the emulsion tube et the carburetor primary sige so that the change in the fuel supply from the carburetor may be kept at a minimam level ‘and further finer fuel partieles may be ob tained. Sintred alloy Sreder Fig 52 Sintered Alloy Air Bleeder S82c,ENGINE ————————— ‘Byron (rubber ceburstor will deteciorste performancs and fuel valve has a rubber tip at ‘with the convontional meta the Byton tip needle valve has characteristics, thereby potential of the carburetor. Fig 63 Byton Tip-Equipped Needle Valve tic Valve (Hot idle compensator) fic valve is of the needle valve ing at a temperature of 50° to the temperature reaches 62.5°C, fan opening equivalent to a1 Smm ) dis. jet. ny maha ofc Fig 54 Thormostatie Vane valve (@ magnet valve) has been the slowsapeed system of the car int when the ignition switch i = the solenoid valve cuts of the fuel through the slow-specd system. In prevents the cecurtence of engine } Fig. 58 Solenoid Valve =83-ENGINE Fuel Filter The fuel fier is of the cartridge type. It is mounted at the dash panel Fuel Pump This diaphragm type fuel pump is installed at the driven via @ push rod by a lantsheet type cam Tear of the cylinder head. The fuel pump is that is screwed Into the end of the camshaft Fuel Pump Specifications ‘Type Diphiagm type ‘a ea qf | _Not ies than 880e Aescinalstngiod | @ Fig. 61 See Schematic View of Exhaust System on Model G 10 VehicleSYSTEM an external resistor hus that sttong and positive ‘be obtained at all mes. In {spite in winch the external ENGINE resistor can be by-passed only when the starter is cranking so as to ensure good ignition per: formance even during the cranking period has boon empleyed ‘Generator Roar CHG lem lace al sattery | Fig 62 Engine Electrical System log because the transition of alr fiom diaphragm of dashpot is controlled by VTV (Vacuum Transmitting Valve). Correspondingly the throttle valve gradually closes. When throttle valve is open and throttle lever cemains untouched on dashpot, dashpot is reset by diaphragm spring. Then air flows into the diaphragm in éashpot Choke Opener Description of Choke Opener This device is intended to reduce the emission of HC aad CO oven iffchoke knob remains pulled. Dathpot gradually returns the throttle valve to Idling position when decelerated from certain ‘opening position of throttle valve and prevents sudden change of negative pressure in intake ‘manifold, which causes decrease of HC emission PAT al | fl re A Ti 1 \ I \ es oe at Deshpot Fig 68. Operation ~62-ENGINE ‘Therefore diephiagm chamber in choke ric pressuse) and J-port are opener is exposed to atomospherie antl because BYSV (Biretsl choke valve resins closed, sng Valve) 1s riot operating. oxen ow K ‘owe SK —_ * F Negative esse Fig. 68 Operation (3) fom intake manifsld and choke valve get ‘opened (30 degree from complete closure.) feonnected 10 port Decause of by the Link, First idle cam move to second ‘of BYSV. Therefore dinphrogm rade because of the operation of choke ex temperature is warmed com. 1 (negative prossura) of BVSY is Ss subjected to the negative pressure open. iT eas AY Pes S ES Iovate manos evev SESE Atmosphere ES Neste ore Fig 69 Operation (2)ENGINE Description of BYSV BVSV is located In Inlet side for negqtive pre ssure of cheke opener and contrels this system by trensmitting vacuum in intake manifold and exposing positive pressure in response to cocling water temperature fir tnnako Geaner —manifote ay == choke opener Fig. 70 BYSY, —6h-Rehicle hes adopted the “EF” ne and front drive design, At the end of the cutput shaft is provided the shes with the fssion and S-speed trant- differential ring gear, theseby making it possible ssi case contains aso the ta educe the revolution speed and at the same put shaft ofthe transmission Tomes in two different kinds: final reduction gear whith Be that is integral with the tran time to inerease the torque. Then, the power Hows to the drive shafts equipped with bar-fleid fransmision case ts installed Sthe engine compartment. type constant velocity joints As a result, the at the engine flows via the drive shafts dive the front wheels. Geput shaft, various gears and out Fig. 71. Power Train 66 —POWER TRAIN CLUTCH ‘The clutch Is of the dry, single-ise, diaphragm spring type. Moreover, the clutch is operated by a cable whose method fesures positive operations and good serviceability. ‘The free travel of the clutch can be adjusted by” ring which ie changing the position of the “E inserted into the clutch outer eable af the clutch release lever section. a Fiyaheel Pressure plate cue die ch cbt Dl Clutch cover ever Wen Clutch release: pe brace 72 Chich Schematic Disgam Clutch Specifications ater Nolin Octe dimer a A) 16 (63) Lining ee eS 19 433) encase 7 Tacs ran Gre) 30.12 Shea See ea 160623) Dise Free thickness: mm (inch) 1.20.28) chai one na pear balsas 00) 20 6392) Cltchatle es Ovenleeth ne) —_ #0 5.1 —66——————— POWER TRAIN Description ‘Two kinds of transmissions are available: the 4+ speed transmission and Sespeed trasmission. All Forward gears employ the constantemesh type syachromesh method, The Uanstission is controlled by a control lever located on the floor. The control lever is not mounted directly con the transmission, Dutt is operated by remote control method. When designing the gear ratio of each gear, the ‘engine characteristics, cunning performance and uel economy have been taken thoroughly into consideration. With regard to the lubrication oll, SAESO ol! Transmission Specifications ‘which has smell agitating and slating resistance ‘has been used (On the S-speed transmission, the input and) output shafts have been extended toward th rear (the transmission case cover side) in ord that the Sth gear may be mounted additionally Hence, the differential, Second Gear ‘The power flows as follows: Input shaft > 2nd pear-> output sheft > differential Third Gear The power flows as follows: Input shaft ~ 3rd Bear > output shaft ~ differentia. Fig. 61 First Gear Fig 83. Third Gear ~12-POWER TRAIN Construction oO ae OOOO ORD ey, Input shate th oar thrust washer jth gear assersly ‘avd roller bearing “Tranumision hub sleeve Synchrcereh sifting ay Syrchrernonh sifting ey Sorina B syrenrenier eg ( Traremiasion ciate hub ip Transmssion hub sleeve stoner BABS 200% Fig 87 Synchromesh Mechanisin ‘The synchromesh mechanism consists of the Sth gear assembly @, dutch hub sleeve © synchronizer ring ®, clutch hub @and so forth. Fig, 87 indicstes how these parts sre bull (0 each other. Speedometer Gear The speedometer drive gear is pressfitted on the ear eral of the output shaft in the transmission case cover. (On the other hand, the speedometer shaft sleeve sub-assembly is insorted from the upper section fof the Lransmission cas: cover deep into the cover so that the drive gear meshes with the speedometer driven gear located at the tipend of the sleeve sub-assembly. In addition, two “O" rings are installed on the shaft sleeve sub-assembly so as to prevent float ing noise emanating from the gears as well as to onhance water-proof chareeteristics faye ‘The intemal spline provided Jaside the clutch nab is fitted with the external spline of the inpat shaft. In this wey, the power transmission takes place. Spasdometer able Soeedomater shaft paver #3 | vine war Gusput shalt Fig. 69 Speedometer Gearswhieh is Hcted inthe sot {is mounted on the shift & «setting bolt. And the end select shatt contacts the reverse fascembiy estricting pin sets the neutral Fig. 88 Gea control lever is selected toward the second side, the shifl & select shaft @ the direction of the arcow. Thus, the into the slot provided the comteo| lever Js shifted further first gear povition, the shift & select fusmed, causing the shift inner lever £0 xd the first gear side, As a result, the engage: to each other, we Y ty ve POWER TRAIN position and limits the axial movement of the shift & select shafl, Moreover, it also serves as @ Grain plug for the transmission eae. [As for the other end of the transmission case, an oil seal is provided co prevent of leakage from the case a everest am | 7 Shift Mecanism As for the reverse gear shifting, one end of the reverse shift am Gis feed in the slot in the reverse idier gear @). The other end of the re ‘verse shift rm is fitied in the groove provided in the aeverse shift fork @. When the control lever is shied into the reverse fork moves. pear position, first the reverse shit in the axial dizection, cuusing the reverse shift farm to be turned. As a rosult, the reverse idler oar willbe engaged HaePOWER TRAIN Interlocking Mechanism The interlocking mechanism prevents two ges from being engaged sinnlfaneousy. This rmechanism 8 composed of thee gearshift lek rolls, lage and smal, af shows in Fig. 90. A small roller 6 Tocated in the hole on the 316 & 4h gee shift for shaft. Largo roles ae located in holos provided inthe iansiaision case a the following places: ono between the reverse shift fore suatt and he Sl & th gearshift fork shalt and the other between the ist & 2nd gear shit foc shaft and the 3rd & Soh gear Shif fork shaft Each coller fits with the ext out sotion provided in the corsesponding shaft When the 1st & 2nd gear shift fore shaft is ‘moved inthe aval direction, a8 shown In Fig. 90, the large roller engaged with the cutout section of the shaft is pushed out, This causes the small Shift Forks Each shift fork is fixed securely on the corresponding shift fork shaft by means of = slotted spring pin Furthermore, at the side of the shaft there are recessed sections, against which 2 bal s tetained. ‘And this ball Is pushed up by @ compression speing that is fitted in the bore of the trans mmission case. In this way, the deteat feeling dur- ing the shifting process can be obtained. Also, the allowable movement of the shaft in the axial direction can be determined. 2, FiveSpeed Transmission Basically, the S.speed transmission has the same construction as with the 4-speed transmission. However, the Sth gear fork is mounted on the reverse shift fork shaft. Therefore, the reverse shift mechanism for the Speed transmission differs from that for the 4speed tansmission, a5 indicated in Fig. 92, ame Reverse ett Raver ail Treva 5 La CX Large rater Sal ‘shift fork Fig, 90. Interlocking Mechanism rolles fitted in the hole provided in the 310 & 4 gear shift fork shaft to be pushed toward 1 reverse gear side, Consequently, neither the ‘& 4th gear shift fork shaft nor the roverse shi fork cha‘t can move avially, thus preventing 1 ‘ro gears from being engaged simultancously. ee 2rd 8a ar rd eh gear atitefore PNT shite fork sate \ ee ot slote spine oi “rani eeee TOY spring Fig 91 Shift Fork Shaft over shear Ss sinoartomk YO {fewer in wren Fig, 02 Gear Shift Mechanismshift fosk shakt Dare reverse shift arm head fox gear shitt head @. Further it fork shat is hich the roverse shi |Gear Shitting Period lever i shifted to th fhe setting os described in Fig. 93, her with the Sth & reverse gear Sabatt D moves in the srrow-headed pin will be dropped fata. the slot fe the 31d & th peor sit Cork shaft Dbecoming feee from the reverse shift the arm maintains its pretent the Sth gour fork (@) moves toward sie As 2 cesult, the transmission is h pear postion. se Gear Shitting Period ‘control lever is shifted to the reverse om the seiting as described 3" Brogernar wilh the Sth & re ft D) moves inthe arrow the pin sh Fork férecion © gis movement, the pin © Sot proved inthe 338 4th gears Then the pin Gah i ito the on of the arm). Te pn contin fa the atowhsaded diction, ont sin toe tumed counter eoskws the tansmison {ssc int the 1 position POWER TRAIN Fig. 94 Daring Fifth Gear Shifting Penod Poiod Fig 98 Daring Reverse Gear Shifting =7=(01. MECHANISM ission is controlled by a shift lever jssion of the Model G10 fnsid2 the engine compart. se control method in which fat the floor is connected 10 shift lever Dis operated toward the Aieecton. the conicl shaft © is pulled ta the snowheaded diction by the ‘crank (D) that is fitted in the recessed Iocited athe Hottom of the shit ees the shift & select shaft @is pulled fn the arrose dteton through & select conteal levers No.2 @and that ae fixed at the end of the shat. the selecting opetation lakes place. ca the shilt lever is operated toward 2 Seber bl rane Fig. 97 Transmission Conteo! Mechanisra POWER TRAIN the stansmision with levers aad shafts, 0s Indicated in Fig. 97, las been employed Furthenmore, the floos support No.1 and the shift & select shalt support are mounted on the transmission case 3) Contr sate "Be saan ie Jp evteteas J? reaest / sides Fleer euppare Ne? the shifting aeection, the como shaft is waned im the arrow-headed digestion by the shifting intermediate fever @)that is attached to the shift lever retainer @). At the same time, the shift & select shaft is tomed in the arrow-headed dlte- ction through the control levers No.2 and No.1. ‘As a rout, the shifting operation takes place. In this way, the sleeting and shifting operations for each gear position can be carried out proper y “maPOWER TRAIN 2. Five Speed Transmission ‘The shift pattern for the S-speed transmission hnas beon arranged in sych a way that the Sth gear is located opposite the reverse gear on the scme selecting line. Hence, ¢ wrong operation proof mechanism has been provided in the shift & select shaft support, thereby making it impossible for the driver to move the shift lever from the Sth gear position pean lever Nest directly 10 the reverse gear position The shift to the reverse gear position must be Fig. @B Schematic View af Wrong Operation» made after retuming the shift Jever first to Proof Mechanism the neutral position, Operation of Wrong Operation Proof Mechanism (1) Neutral When the trensmission isin nowtea, the shift & select control lever@is located apart from the reverse restricting cam Q). There- fore, the wrongoperstion proof méchenism is inoperative Hence, the seleting and shifting operations for the 1, 2nd, Sed gears or 4th gear ean be performed independent of the wrong- operation proof mechan, (2) Fifth Gear When the transmission is selected toward the Sth gear position from the setting as in- dicated in Fig. 99, the lever) pushes the cam@ in the arrow-headed disection. Con- sequently, the selecting 10 the sth peer positon takes place. (See Fig, 100.) Next, when the (ausmision is. shifted toward the Sth gear position, the cam is pushed out by the tension of the com pression spring @). As a result, the cam will Fig, 700 Fifth Gear Postion Fit imo the cutout section provided in the lover. -80-sion is shifted toward the from thesSth gour posi if in the lover D may However. inasmuch as the sh the reverse resuicting pin Heer can not he shifted to the d in the cutout fever is rewined once to the nism assumes the as indicated in Fig. 100, Under the ca ‘of the lever while the selecting the mec never Fit into the out seer position i taking place the gut position twunsmission is shifted 81 POWER TRAIN Fig. 107 Reverse Gear Fosiian As is evident from the foregoing, the trans mmission hus hoon fo designed that no shifting can be made from the 5th gear position Ghezily 10 the reveise gear positionPOWER TRAIN DRIVE SHAFTS ‘Outboard joint ea Inver race i shaft sup rng (im Boot cue Boot bend Inboard joint Outer rece Fig. 102 A barfield type constant velocity joint has been. employed at each end of the drive shafts, thersby ‘making it possible to smoothly transmit power 10 the front wheels. ‘The constant velocity joint located at the tire side of the drive shaft is called the outboard Joint (BY), and it compensates for the variation in operating ange. On the otter hand, the constant velocity joint located at the differential sile is called the inboard joint (DOJ), and it compensates for the variation in operating angle fas well as in the axial movement of the drive shaft Drive Shaft Tho splines on the inner races of both oute and inner board joints are connected with the sume drive shaft. Moreover, each end is fixed securely with a snap ring, ‘There are six balls in the recessed sections on the inner race and cage, one cach. These six balls fare encased in the outer cate (outboard or in: board). The inside of the joint is filed with: grease containing molybdenum — disulphi (NLGI, No.2 LIWITHMOS2), Furthermore, the joint is covered with boot to protect the intctior sections. Drive Shaft Specifications Dave a ry iam G236 maka er eat es 3b G20 ihe) Maximum atone Invosre 23 degrees, tithele Siboere Riss Sele gms “nwantaFsealed NIG, No LNTTHNOS? —60~ 30g tives eit {om Maid ard oxbeard sides) -82-POWER TRAIN (Ushio aquinpes with Otte Brake D oi ses) 2 acta wl bearing 5) Steer kruekle Drive safe (outbowetl Fig. 108 Front Axle Jeutboard drive shaft also serves as a front The splined section of the drive shaft is fitted thereby via the bearing supporting the load with the front axle hub. Morcorer, a castle nut spplied tothe frent wheel with a washer retains the end of the drive shaft. ‘oti! ball bearings are ‘stalled inse the ‘In addition, a cotter pin is provided to prevent cose hat is integrel with the steering the castle nut from becoming lose. Aso, a oil seal is provided at exch The brake drum or the front disc in the case of Sof these hearings es smeans to prevent inv vehicles equipped with dise brake is attached to gon of water or dust imto the bearing cose ‘the axle hub by means of four attaching bolts, -a-POWER TRAIN Appendix Chart “The table helow contains a list of principal parts in which the specifications for the 4-speed transmissi ‘mounted on the Madel (10 veficle differ from those specifications for the 4-speed transmission mount ‘on the Model L40 vehisle (September, 1977, onward) Past nomendatre ‘Trasmision case assembly ‘Chtch cover avembly Chtek diseassembiy Cute seloass vor sob aston Datput shat related parts ‘Both upper and lower cass) Main diforences Contour of luteh houses differs. Droiure plate capciiy and installing Jad characteristics ter ‘Capacity and thleknescat time of fee state differ. Contour of lever and it installing direction differ “Tooth numbers cf output sift gear and Sed gear dior, Speedometer scar Different ring pear Tooth numbers of both drive gear and driven gear ctier, Tooth aumber of gor dif List of Bearings np shaft bourne ‘Radi pal beat Specl produ: (20-112AC3) ‘Radial ball beacing (Output share bearing eee ‘Nese roller bearing with ciowaing, provided wih knocking ok for turn prevention, Ist gear bearing Needle rollor bearing 2ad gear bearing ‘Newale yolles beating “th gear baurins ‘Newilerotir bearing unequal pith Suh gear veins ‘Neale role bering Differential Nearing adil bal bearing (Clutch lens being “Angle bal acing = BbNSION “ sion fs of the independent strut ‘eonsists of the stock absorbers, coil Following are some of the features of steering Enuckles and so i, Light Weight and fewer consum- Be swe of the suspension is small, the fom can be utilized in the most driving stabilty and bility, because the unsprung weight confor, front suspension is very small and the bushes incorporated inside the attach Sections of the lower anns provide “com. characteristics t0 a certain degree in fore-and-aftditection. t for the toein, no other adjustment ssary for the front suspension, Also, of the sesion needs no hubrication sures a good serviceability 10+ shows the construction of the front maintenance-free type, the Moorer. Coil ring Bae Shock sbecrar Ss knuckle suspension, The movements of the front wheels in the upanddown direction are trensmitied to the coil sorings via the steering knuctles Simultaneously, the front shock absorbers are expanded or compressed, thus providing damy- ing forces during their robound and compression strokes, Incidentally, © load applid to the front wheel 's transmitted t0 the shock absorber via the steering knuckle in the upper part. Then, this load is further through the suspension support rubber bushes t0 the body fender apron which finally supports such load. On the other hand, in the lower part, the load 48 applied 10 the tower am, Then, it is trans mitted win the bracket to the body which finally supports such load. * The compliance characteristics in the fore and aft ditection denote the front sus- Penson’s followingup performance in its fronteandewear diveetion, They ure determined. by the elasticity of the rubber bushes, ee transmitted Fig, 10 Fronts — 86 pension SUSPENSIONSNSION “ sion fs of the independent strut ‘eonsists of the stock absorbers, coil Following are some of the features of steering Enuckles and so i, Light Weight and fewer consum- Be swe of the suspension is small, the fom can be utilized in the most driving stabilty and bility, because the unsprung weight confor, front suspension is very small and the bushes incorporated inside the attach Sections of the lower anns provide “com. characteristics t0 a certain degree in fore-and-aftditection. t for the toein, no other adjustment ssary for the front suspension, Also, of the sesion needs no hubrication sures a good serviceability 10+ shows the construction of the front maintenance-free type, the Moorer. Coil ring Bae Shock sbecrar Ss knuckle suspension, The movements of the front wheels in the upanddown direction are trensmitied to the coil sorings via the steering knuctles Simultaneously, the front shock absorbers are expanded or compressed, thus providing damy- ing forces during their robound and compression strokes, Incidentally, © load applid to the front wheel 's transmitted t0 the shock absorber via the steering knuckle in the upper part. Then, this load is further through the suspension support rubber bushes t0 the body fender apron which finally supports such load. On the other hand, in the lower part, the load 48 applied 10 the tower am, Then, it is trans mitted win the bracket to the body which finally supports such load. * The compliance characteristics in the fore and aft ditection denote the front sus- Penson’s followingup performance in its fronteandewear diveetion, They ure determined. by the elasticity of the rubber bushes, ee transmitted Fig, 10 Fronts — 86 pension SUSPENSIONSSUSPENSIONS Suspension Lower Arms ‘The suspension lower arm is welded integrally ‘with the strut bar. It is so constructed that the span in its fore-and-aft disection is comparative. ly large, thus making it possible to effectively support any Jateral load applied to the lower ann, ‘The lower arm is attached to the bracket through strut bar cushions at its front end; through a lower arm bush at its cear end. ‘As regards the ruhher bushes incorporated inside ‘Strut Bar Brackets and Lower Arm Brackets ‘The strut bar bracket is attached to the front cross member and side cross member, while the ower arm bracket Is attached to the dash cross the attaching sections of the jower arm, th have been glven a certain degree of corapli ‘characteristics in their fore-and-aft dizection as to improve further driving comfort, at seme tlme giving due consideration to stabil maneuverability, too. As for the inner sleeve of the lower erm bu their hoth ends are knurled so 2s ta prever inner sleeve from tuming together with rubber bush and aut, et, member and side cross member, by means attaching bolts, utilizing the rigidity of the whol body. Stu bar bracket stu bat ‘suut bar cushion ‘Suspension loner arm Lower arm bracket Imer sleeve of lower ann ba Lowa arm bush Fig. 105 Installation View of Lower Arm —83-| joint is of the maintenance-free gan not be disassembled Since itis the suspension lower arm proper, t section alone can be not removed 1 seat is accial sesin treated with oi fe a more durable form of lubtice- xshion rubber (rubber spring) te- Jing-away tongue and the tightness of sud Jubricant, the Dall Joine is Billed with grease, and & sealed with a dust sion Supports suspension! support has been so har the front shock absorber is suse ‘with 2 ball bearing chat Is connected to pron through a robber cushion with ching bos. ore, 4 front spring bumper made of hnas been prosided inside the front spring seat in onder to absorb impacts ducing rebound stroke as well 3s 10 prevent an ke of the shock absorber coved sealing characterises, a dist seal ‘of polyurethane sponge has been installed ball bearing section In order to prevent agession, SUSPENSIONS Salud J, Dusreone onesies Fig 106 Sectional View of Lower Ball Joint Skepersion support PB co-eram nny won Bo oa Fig 107 Crow Section of Front Suspension Support -a7-NSION son is of the five-ink axle 1yp= sts of the shock Absorbers, coil axle beam, lower & upper control contro) rod and so forth. This tear system has the following features wheelbase is posible, Space between jean be nied effectively, since no pro- Saft or ifferential located here of the FF system, driving comfort owing to reduced welght, thanks to the introduction opening type axle beam whieh features feeight. ‘movement of the axle beam is controled Be lows ip and floating of the wheels during ‘nd upper contro) arms. Hence acceleration or deceleration period xe smaller, compared with the com. sal leaf spring ¢ype suspensions. Shack serber Lateratconvat roe Axle beam Fig. 108 Rear Suspension 4. (improved lateral suspension because of the adoption of a lity of the whole rear lateral contrat rod. 109 shows the construction of the rear suspension, Loads applied fo the wheel in the up- and-down direction are sustained by the coil spring through the axle beam, Simultancously the shock absorber Is expanded or compressed thus providing a damping force during its com pression of rebound strokes. Loads in the fore-ané-aft direction are supported by the lower and upper control arms, whereas Iateral loads are supporied by the lateral control sod via the axle boam. Also, with a viow (0 reducing sound and ‘vibration levels, the installation bracket located at the front ends of the lower snd upper controt ans has been provided on the boly at such place whee the body sighity 1s maximum,SUSPENSIONS REAR AXLE Rear Axle Beam . The axle beam is msde of a 3.2mm (0.13inch) thick steel sheet having a hat type cross section. Its design allows light construction. Besides supporting loads as on sxle, tho sear axle beam hhas been given adequate rigidity, thus making it possible to absorb twisting loads. Hence, the displacement of each of the right and left wheels can be absorbed when the subber bushes and axle beam are twisted. As 4 result, the elasticity of the axle beam can provide a closer contact of the wheels with the ground Furthermore, the brake tube and parking cable are routed inside the axle beam. Lower Control Arms and Upper Control Arms The upper and lower control arms are made of steel tube. Primarily they sustain Toads in the foreandaft direction. In adittion, they restrict the movement of the axle beam. Rubber buthet are presifitted into eack end of these control ans, Esch ond is attached to the oly or the axle beam, respectively, through a shock 5 pexiny BEEPS (Cremation pine es oom A | Rear axo pale Upper contral am bracket Fig 170 Rear Axle Beam bracket. [As for the inner sleeve of the mbber bush, it ha undergone Knurling machining so 2¢ to prevent the inner sleeve from turing together with the rubber bush and mut, ete. Morvover, the front rocket sorves as a transport hook to be used dung tae new car transport, ey Lat conto rod gir | vaca om co Lemar contol se srmbrosker [> ausnes \ Lower control arm ‘Upper contra arm bracke: Ty Loner atiching section ofehosk absorber \ ante bear Fig. 111. Installation View of Lewer & Upper Control Arms -30-Rod control rod is made of « 2 3x (0.09 steel sheet having a USshaped cross This lateral contro] rod sustains lateral by providing an adequate lateral the roar suspension Tposhes ur provided in each end of the tro] rod. Bach end is attached to the the axle bear Bearings Seenard to the rver avle hearings, radial are used at the Inboard and out sides, one each, Moreover, the inboard is equipped with o sealing plate so that say enter into the inside of the brake eating Is of the oxdinary type Pear ane earing inne eine Fig. 12 Lateral Control Rod ralal ball bearing. The cear whoel greae retainer cap prevents any grouse from flowing to the outside, Furthesmoce, retainers for lovating the bearings are provided between both bearings as well ss between the inboard basring and the backing one each, plate respective Faia bal bearing (outer! L | ‘ear whee grease retaine cae I Fig. 113. Sectional View of Rear Axle Bearing Related Parts —o- SPENSIONS ]SUSPENSIONS Boo eh i . Z ~S cut tr } | wn Fen shock sorter bracket | FD, seegn Fear spring burr Rear spring uoper sent Fig 114 Installation View of Rear Shock Absorber AND DISC WHEELS List of Specifications for Ties and Dise Wheels Tir prewire AFM? (os | Gade ew [purine oan sd pursuant [x0 [xe [xt Stee rail tbetess | 158812 w7aiy o}|olo ) | sit be 1g58R12 17atay ale|- wheel ae aan ole [ordinary ani eo fle [Decoration aut ° ab ovearent| OStaaterd AOpri0n tubeless ties ore standard on all nodes With regard to radial tires, all of them ine tube-instlled-tives, radial tubeless tires couporate steel cons s0 at to improve further ‘m0. ties ate avalable as optional equis. ‘wearresistant characteristes 93 -SUSPENSIONS Disc Wheels The dise wheel is of the 41" 12 type in winich the amount of offset is $0 mm (1.97 inches). ' Other disc wheels have different amounts of pif'set. Hence, make sure to use dist wheels designed exclusively for the Model G10 whicles. Ss Wheel Hub Omaments The newly-designd wheol hub omament has been introduced, (The Model XO vehicle is excluded) Fig, 118 Wheel Hub Omament Hub Nuts [As for the hub nuts, the Model XTE vehicle employs decoration nuts, whereas the Models XO and XG vehicles employ ordinary type nut, iesystem fs he rack and pinion type wes simple construction 2nd shacp An impact da orbing type teeing svat 99 all models. 2 oF the mvintenance-iree type in mse is factory-soaled. Furthermore, th ar hss bees! so Uesghied as (0 ensure = snd dustproof chaructoristies, — 95 py making ita maintenance-free type. Fig system. The sotational movernent of the sta 117 shows the construction of the steering main shaft is convertad Into the lateral move: meat by the rack & pinion type steering gear Then, this lateral movement stzers the front wheels through tke steering rack ene, tie 1011 cendsand steering Knuckle ars steering specications Gare Rack & pnw Gear rt = {Gana iene final Tuaning gts loners. Owes] | aim sora Tae Ibeh te ik ae Wieslouter | poqa 14 9oiache) AnmpactabSo7bBE | Siaquard on all models Steering rack housing Fig 117 Schematic Diagram of Steering SystemSTEERING Steering Main Shaft Assembly Tho stacring main shaft assembly consists of the steering main shaft No.1 and the steezing main shaft No2. And these two components are attached to each other by presslitiing of poly-acetal resin Moreover, the energy absorbing tube made of a thinwall aluminum tube has been provided between the main via No.1 and the main shaft No.2 in order that impacts may be ab- sorbed gradually in the event of collision. If an impact load should be applied to the steor- jing whee! in the event of accident, the main shaft No.1 would begin sliding inside the main shaft No.2, although the main shait No.1 must overcome the resistance of poly-acctal resin the mating section with the main shaft No.2. Simultaneously, the impact load is applied to energy absorbing tube via a colar welded 10 main shaft No.1, As result, the energy abso ing tube is compressed, thereby absorbing impact energy. In alcion, the sessing loce system fs stands ‘on all models, This steering lock system hs bs So designed thatthe lock bars dropped int t froove provilee in the main shaft collar, th locking the steering. system, when the key pullec out after seitig the key at the "LOCK" position Stooring main shoft No.1 Energy abserbing tube Sweering main shaft No? Fig, 118. Steering Main Shaft Assembly 96 —Geer Assembly 1g gear assembly consists of a stering fa steering rack, a steering Tack housing ng rack ends, ring pinion hat seven helical gear ceeth is supported by two necale bearings ore, the steoring rack as 29 helical sh. And the stescing rack is sipported by alloy bush and 2 rack gulde, Each sl face is lubricated by molybdenum dts ithium-base grease, Deck side of the stoosing rack is pushed via guide by 2 staring rack guide patch compression spring in order that the stecr- ck may be pushed always against the pinion surfaces by a force of an optimum tude cour Gia teeing ry |__ 80) takteoneenhe | Serpermtacit te menonn GRE Compeeson soins Rack pies | Racktrone ase to rootheumber |) sreenna Incidentally, the self amount of the steering rack is controlled by a bol for adusting the rack guide The “T" type ell seal has been installed at the pinion insertion section of the steering rack housing. Furthesmore, 2 rack boot has been provided at each end of the steering housing In this way, this completely sealed type steering gear assembly can prevent the ingression of water and Gust, thereby amsking it ¢ maintenance-free type. Moreover, the sieering gear hes been designed in sich a way that the trapped sir can move through aps between the stosring housing and the rack, as the véck boots at both ends expand br contracts, during the steering rack operation owes Nese bearing Fock sue mark tor rc be ne pinion Finan Se 00h, | sesrngrack en Pack quid adjusting al Steering Gest Spesiiestions 8 | pene Lange chews ease Moiybocmom dius tnuunrbase | Fig. 119 Steering Gear Asombly a7‘Steering Rack Ends and Tie Rod Ends Each steering rack end is composed of a rack fend ball joint and @ tie 10d. Since these two parts are assembled by complet staking, they can not be disassembled As regurds the ball joint, its ball seat is of the smaintenane: fee type jn which lithium grease 1s factory-sealed. Hence, it is impossible to dis- assemble the bal joint. Furthermore, the tie rod has @ hexagonal cross section, thus making the tuming angle aj ‘ment or toe ia adjustment operations easier [As for the tie rod end ball joint, Its of maintenance-frce type in high lithium gr 1s factory-sealed, Hence, it is: impossible disassemble the ball joint sections Pathe: lis ball stud section is attached to the stec ‘knuckle am with a castle nut ‘Steering rack hoot steering te roa en \ \ ) a i} Comoteely Sted Rack ond ons, Fig. 120. Cros-Section of Stecsing Rack End Steering Whee! ‘The steering wheel is the bar type whose outer diameter is 380mm (14.96inches), The whole hhorn bar serves as the horn button. ‘The steering wheel proper Is made of poly: propylene. The steering wheel comes in two different colors: Dlack and light brown, Either color is used depending upon the color of the vehicle Interior so as to provide a better matching With regard to the color of the steering wheel fomnament, green colar isiused for the black steet- ing wheel, whereas gold color is used for the light ‘brown steering wheel = 98 Fig, 121 Steering WheelStewed device KE LINE Drake Line is 4 with « tandem master evlinder mining the brake line routing, careful of the duabsystem type dete derarion has been paid as to saety. brake line has empleyed diagonal routing Sh is connecting the right front wheel der to the laft rear whee! cylinder and the front wheel cylinder to she sight rear wheel der, As for the routing inside the vehicle [stweroarhetl interior, che brake line topether with the tel line is routed along the side memeber, Also, as regards to Ue routing at the underfloor section, the brake tube is protected by a polyethylene, heatvontracted tube. In addition, for farther enhanced sufoty a protector has been provided at each critical point so a5 t0 avoid sny damage to the brake line due to contact with the ground or stones bouncing from the road. aRAKES jode| G10 vehicles use the Following broke specifications, epending upon modes, Brake Specifications Beatie Gale NO, XG. XTE ae a a XO, XG _XTE ais ise T Te Tandem 7 ae Yin 1903 Tipe ae goreaumees) — 2snm rane Ret (ont Eaomasic thal 472m Sete Whos! [ots ‘ea Vacuum boner | ovine 1s.87mm © bre toa echanial ype wih bore foe Peck eskng bre broke fore Spel 22 Brake Tine —99 Fig.BRAKES MASTER CYLINDER The master cylinder for all models sahee tandem vided i the illor tank. ‘ype, with the font disc brake. Moverover, the Also, the master eylinder for all models has brake fluid level warning switch has been pro- equipped with 2 brake booster. Master Cylinder Specifications SE | oe Ie Di ore dame 3.03 (0215) ee I Sap] Fits tank capacity ) Senna eh section Siroke [isias9) BRAKE BOOSTER The brake booster has an aluminum diecast at tho time when the brake system begios # body. It Incorporates the jumping mechanism operate, In this way, a smoother brth ‘heh can slightly radueo the braking foxce only application has heen obtained Brake Booster Specifications hem Gade XO, XG, XT wonoare ey atin Kone | 23) ‘Nishia Kogyo tee sie | soe a Type Direct acting lsateneaee kay | 70054) fective droke amcinety | 3403 [Gude veboopentig ote soa 3p Daa RT antes Toe Fig. 123 Sectional View of Mester Cylinder with Booster = 100—Booster Jumping Mechanism brake booster jumping mechanism utilizes clasticty of rubber piece which is fused onto rezction plate in oider to slightly reduce the tion Anstances where the brake booster s equipped ‘no jumping meckanism, when the brake jal is depressed and the operating rod moves aud, immedictely the vacwam passage will be ‘ked by the control valve, thereby opening atmospheric passage. Reaction force at mater hiner ie Q BRAKES ‘braking force only at the time when the brake system hegins to operate. Asa realt, a smoother braking application has been provided. Consequently, the piston aso moves forward and a force indicated in Fig. 124 wil be applied to the reaction lever. As a rosult, as the piston ‘moves forward, the reaction force at the master ceylindes will be sustained at the operating rod side. _ Feree by vu 0-00 Ccomatvave Goeratng ros “eae pede moplesion force In instances where the brake booster isequipped ‘with the jumping mechanism, the brake booster functions in the same way as with the brake Dooster without the jumping mechanism, until the stmospheric passage is opened. However, as ‘the piston moves forward, no force is applied to ‘the operating tod while the reaction force from ‘the master eylnde is small, because te reaction. force from the master cylinder which is applied tp the point © of the reaction lever with the Fig, 124 Diagram Showing Operation of Jumping Mechanism (1) point A of the power piston as its fulerur will bo sustained at the point B by the elasicity of fa rubber pisce provided on the reaction plate. In this way, the applying force of the opersting rod must oversome first the tension of the control valve setum spring, before the brake system stasts its function. As a result, the braking force at the time when the brake system starts functioning wil be reduce. =101-Brak’ Fig. 125 Diagram Showing Opera When the brake pedal is further depressed under this setting, the rubber pisce provided on the reaction plate will be more compressed. Finally, the operating rod receives the Full reaction force Operating ved Return spring tion of Jumping Mechanism (2) from the master eylinder via the point D of the Power piston, in the same manner as with the brake booster equipped with no ju mechanism Fig. 120 Diagram Showing Operating of Jumping Mechanism (3) = 102 —> Tht tcc of eperatina vod (ts) Fig 127 Brake Booster Performance Curve /ORTIONING VALVE (P VALVE) froportioning vale hus been provided on wheels, compared with the increase rate in the Jes with the front die brake. iydraulic pressuie applying to the front wheels. proportioning valve reduces the increase In this way, further stabilzed brake application inthe byGraulic pressure applying to the rear has been provided From SG Iyetaulc presure (ler?) Nester evingor (halo) oe Fig 123. P Valve and P Valve Performance Curve = 103Operation 1, Condition in which pressure corfirol valve (piston) is stationary When Pa, @ hydraulic pressure from the master cylinder, is 30 kglem? or lest, F, that 48 a force working in the right direction exerted by the spring is groater than Fp that is 4 frove working in the left direction exerting upon the piston caused by PA. As a result, i piston is stationary, Under thls state, ‘master cylinder passage @ is disectly nected with the rear wheel cylinder pass ® . Namely, the hydraulic pressure from master cylinder can be applied directly to # rear wheel eylindors, From ster ovine Y oreorwteet cytincer Passoge bomeen ind is erupted From mestr evinder o | Te rear wheal cylinder Fig, 129 Condition in Which Pressure Control Valve (Piston) is Stationary 2. Point where pressure control valve (piston) begins to move witen Pa reaches 30 kg/em?, Fe that is a force working on the piston is balanced with F, that is a force exerted by the spring. Furthermore, when the hydfaulie pressure at @ increases, Fz overcomes Fi, therby moving the piston to the left direction ‘This piston moves until it contacts the lip seal section. As a result, the passage hetween and @ ts interrupted ‘The following is explanation on this movernent of the piston, using pertineat values at respective sections, Spring force Fy = 11.6 kg - 104 - Master cylinder hydraulte pressure PA= 30 kefom? ‘Area receiving pressure that intends to ‘move piston to left ditsetion: (Sy in Fig, 131) =F «0.70? =0,385 om? ‘As fs evident from the foregoing, Fs, a f Which tends fo move the piston to the left direction, is computed as follows: Fy =Pa x8; = 30x 0.385 = 11.6 kg When F; equals to F), balance is obtained. However, when PA increases slightly, the piston Is moved, thereby interrupting the passage between (®) andTo rear wheel evlinder Fosse between From mae eyindse TSGRS ENE @ interapees © “Foret wea ener Fig. 190. Point Where Pressure Control Valve (Piston) Bogins 10 Move 3. Condition in which pressure is controlled: When PA exceeds 30 kgfom?. the hydraulic pressure atthe left side ofthe piston becomes greater than that at the right side of the piston, ‘The following relationship. is es tablished among PA, PB thet is « hydraulic pressure applying to the rear wheel cylinder and Fr Pox S:=Pa(S—$:) +8) ‘Tae following s explanation 2s to how the nent valuse pressure is controlled, using per at respoctive sections 26 indicated in Fig. 128. Spring force F, = 11.6 kg Let us essume that tho master eylinder hhydoue pressure Pa = 60 keer rea receiving pressure thet intends to rao piston tole (SinFig. 13 S.=-B xD} =I x08? -088ten? Area recesng peiure that atends 10 more plsion to ht leeton (Ging. 131) = 105 - S =, -$, =0.554~ 0385 01169 em? Pb, the hydraulic pressure epplying to the rear wheel cylinder, can be caleulated using the Jolfowing formula. Pax, =Pa(S— 8+ Fi pow PAXS +R: . 60x0.169+ 11.6 Sa 0 =39 kglem? ‘The foregoing caleulation shows thet Pa, the hycranlic pressure applying to the rear wheel cylinder, is reduced to 39 kglom?, whereas the master cylinder hydraulic pressure Pa is Fig. 128 i the procure control velve por. formance diagram which shows to what extent the hydraulic pressure is controlled, ‘using typical valuesBRAKES @ Fig 131 Condition 4, Condition in which pressure control valve (piston) is returning to original position: If the brake pedal is released under @ con dition in which 2 prossure exceeding 30 ke/ em* is applied to the sectien @ , the pressure at the section @) drops to 0 kg/cm? However, 4 pressure exceeding 30 kg/em? is still applied to the section ®) . Hence, the piston Is pushed to the leit side, As a result, the section @ is not connecteé with the section ® . (Under this condition, the force pushing the piston 10 the left direction, Py =Po x S: = 30 x 0.554= 16.6 ke, Therefore, this force of Fy is greater than Fy ‘Which Pressure Control Valve is Functioning that Js 11.6 kg. Consequently, the section () js nol connected with the section B) .) However, when the hydraulic pressue at the section @ diops to O kglem?, the difference in pressure between the section @and @ will cause the lip seal to be deflected. As result, the pressure at the section ) will decrease, for its pressure escapes to. the section @). Then, the spring tension Fy over comes the pressure at the section B), thus moving the piston to the right side, In this way, the section @) will be connected with the section (B to each other. From master oplinser @ @ To rear whos! Fip. 132 Condition in Which Pressure Control Valve (Piston) is Returning to Osiginal Position = 106 =BRAKES INT BRAKE + Dise Brake (Models XO, XG and XTE Vehitles) “Aishin made Type “B™ alse brake hus been employed, Front Dis: Brake Specifications X0,XG,XTE, Grade] x0,x6, TE | om [resane rime] ape i | Se | tapes [as ine Resin molded |e G4) exintertor ciara ent) 47-620.87) 75.0382.000.0 | Pai cimensions a Peettaibikaes) mam Cinch) [C2 99%, 6320.39) ats crossecton AA Fig, 193, Dise Brake = 107BRAKES REAR BRAKE ; The rear brake is of the Jeading and trailing type equipped with an automatic brake shoe clearance adjusting device (which will be operated during the parking brake operation) For simplified construction, the rear wheel cylinder is of the sliding cylinder type which incorporates enly one piston. When the braking force is applied end the brake shoe is pressed aguinst the brake drum by means of the wheel cylinder piston, the resction force of the piston will cause the wheel cylinder proper to slide on the backing plate, until the wheel cylinder proper pushes the brake shos at the ‘opposite side. Asa result, the wheel is braked, permease | one [ee ae fe ee ee ee EeeeES aaa | 100) lketpeaett jenna | [HEENERRTan mm ane [CROPS [EEO | aren io \ ~ 108 -Operation of Automatic Adjuster i ‘The automatic brake shoe clearance adjusting device is actuated only when the parking brake is operated. A spring is attzched 10 the parking brake bell crank, as indicated in Fig. 135, This spring locks the adjuster, by holding the tooth surface of the aljuster. Beslds this locking operation, the adjusing lock spring will eauso the adjuster’s notch to be advanced, when the parking brake is pulled out, since the one end of the spring ie secured atthe bell crank. ‘When the brake shoe-to-drum clearance is within PARKING BRAKE ‘The parking brake is of the mechanical type with tho braking force applying to both rear wheels, ‘The parking brake cable pasos through the vehicle inside, Then, it is routed outside the vehielo, starting from the seat riser, And the right inner cable is brenched from the equalizer pro- the specified value, the movement of the spring Js not large enough to advance the adjuster by cone notch. Convssaly, when the brake shoe-o- drum clearance has exceeded the specified value due to wom brake lining, the operating angle of tho bell crake bocomes larger. Conssquentiy, the movernent of the spring, 100, will become Jerge enough to advence the adjuster by one oteh, thus making it possible te msintain the shoe‘o-irum clearance at the specified level at al times vided on the axie beam, In this way, the ends of parking brake cable are connected to the wheels at the right and left sides, respectively, Furthesmore, the parking brake cable can be adjusted by tho clavises located at each end of the parking brake cables. Parking brat ver Parking brake Fig 135 Parking Brake Lever and Cables = 109 -BRAKES PEDAL RELATED PARTS e The pedals are of the pendant type. ‘The pedal- related specifications, soch as the. distance between pedals, height, leverage satio and so Pedal Related Specifications Vehisle moa All models em eaaiibaat cate 200 (7.87) mined) Bases 200 1787) 136 Pedal levers ratio tt 450 [stoke men(inch| 140 631) ; is~20 fey 0297 ihe Free travel samnch) Is | (ok ba, rake ling engine ‘nine peioa Fewween itch pecalend | 1084.13) Brake podat Distance between peas nen) Been ra pedal ni Seeker | 110632) pecal forth, have been determined so that the pedals may be operated easily. Pedal heignt Fig, 136 Pedal Related Parts ~10-PEDAL RELATED PARTS ‘The pedals are of the pendant type. The pedal related specifications, such ss the distance between pedals, height, leverage ratio. and so Pedal Related Specifications All modes 2000.87) 200.87) | Podalveraze ratio 135 (531) 101331) 1s~30 0.89 its) [Free tase! min(inch) running period ‘imnch)| Betwesa brike) (ooh a ae (Gig ine 105 44.13) 110433) forth, have been determined so that the pedals may be operated easily. ~110-Booy BODY SECTIONAL CONSTRUCTION : ‘Body Sealer For imptoved rustproof and waterproof characteristics, body sealer in sufficient quantity has been applisd to each of various joint sections and hemming sections of the body sheets. lisse of back door Fig. 138 Diagram Showing Body Sealer Applying Points airesony WEATHER STRIPS |As for the door weather strips, the hollow type which can provide superior sealing becaue of its wider ‘body contact surface hes been employed Fig. 198 Configuration of Weather Strips =13-SILENCERS. A lacgessized dash panel insulstor is installed af the passenger room side of the dash panel in coder to prevent the engine noise from being ‘transmitted directly into the vehicle interior. With regard to the sound-proof mossuzes for the floor section, asphalt silencer sheets are affixed over the floor sections. In addition, floor silencer pads which are made of linen-woven feit ere placed on the abovecdescribed asphalt silencer sheots. NOTE: On the Model XTE vehicle, the floor silencer pad is integral with the floor carpet ‘Luggage comparemenetloor mat Flocesienest pad (10mm) Fig 140 Silencers and Floor Mats FLOOR MATS Both front and rear floor mats are of the wal-to- wall type which provides a better appearance of the vehicle interior. Moreover, these floor mais are secured by the seats and seuff plates, thereby preventing the displacement of the floor mats. For Ma Species le ‘Luggage compartment floor mat Vinyl l Carpet =14=‘VENTILATION OF VEHICLE INTERIOR (Fresh Air System) ‘A positive ventilation system has been employed. throug those ventilators that are located at both Fresh air is introduced into the vehicle interior sides as well as at the center of the dash panel through the uit sections provided in the cowl Then, the vehicle intotior air will be discharged top panel to the qutside through the discharged ports The thusintroduced fresh air enters into the provided at the back doar inside pan, heater proper and is sent into the passenger room Fig, 141 Frosh AirSystem Fig, 142 Back Door Inside Panel =118-BODY APPOINTMENTS ENGINE HOOD RELATED PARTS ‘The engine hood is the rear arm hinged type in which the front end can be lifted. And the hood Wil be supported by a bar at its raised position. To provide better ventilation and cooling characteristics in the engine compertment, louver slits have been provided in the engine hood at its right and left sides. ‘The hood lock is of the ratchet type. The hood foci cable is routed together with the wiring hhamess through the inside of the right fender panel, In this way, tho number of the passing: through holes in the dash panel has been re duced. Consequently, the level of noises which are transmitted from the engine to the passenger oom has been decreased. Moreover, such routing Of the hood lock cable has provided a better appearance of the engine compartment, Hose lock Fig 143 Hood Lock Diagram FRONT AND REAR DOORS RELATED PARTS A thick sheet metal has boon used for the doors in order that the safety may be enhanced, Furthermere, the door opening angles has been sot at 63° in the case of the front door; 68° in the case of the rear doors so that entry and exit can be made easily, For enhanced sefety, the outside handle is pro. tected by a cover. Fig. 144 Diagram Showing Door Relaied Parts =116—9 Check Mechanism door check mechanism hast been newly scoduced. This mechanism makes it possible to fin the door at any desitable position over range between the halfopened position and the fully-opened postion, This unique feature provides easy entrance/oxit of the vohile especially at those nasrow places. 2, Cushion ‘Stopper cushion Fig. 145 Svetional View of Door Check Mechanism Operation ‘The lever moves through the check mechanfsmn body es the door opens or closes, Then, the shoes, 00, move in the up-and-down direction along the lever curved surface. The reaction force fof the rubber piece which occurs during the above-described movement will provide an adequate amount of sliding resistance between Door Locks On both front and rear doors, the fork-type- plantin method has been adopted. Furthermore, ‘the locking lever type (lock button type) inside lock mechanism has been employed. * ‘The fork-type-plant-in method door lock mechanism roprosents 0 lode mechar which the inner lever is fork-shaped and it is installed in such a way that it is recessed in the shoe and lever, As result, the door ean be retsined at any desrabl postion Furthermore, when the door travels as far as i wil go, the check cae (mechanism body) comes in contact withthe stopper cushion, as indicated in Fig, 145. In this way, the opening position of «he door can be eontoled. the door This lock michanism features robust construction since the reaction foree is divided (0 Wo components in this design, Morover, its safety has been enhanced because of the loop- shaped striker. Also, the weight of the locke ‘mechanism has been reduced, thanks to the introduction of s resin body. Ins.cenanate Leching over Fig. 148 Schematic Diagram of Door Lock Mechanism -1W7-BODY Rear Door Safety Lock Mechenism Tn addition to the locking lever type - mechsnism (push-button type) as with the front door, the inside lock mechanism on the rear door has incorporated a child safety mechanism. When this child safety mechanism is operated, the rear door can not be operated even if child ‘ampers the inside handle inadvertently. Nevertheless, the rear door can be opened from the outside by operating the outside handle, even if the child safety mechs Window Regulators The front window regulator is the X arm type, whereas the rear window regulator employs the single lift arm type, Fig. 149 Rear Window Regulator -118=BACK DOOR RELATED PARTS ‘The back door is of the single-sheet, pop-up type. ‘The height of the back door at its saised position i 1740mm (68.50 inchss) above the ground. (he back door assumes an angle of 75°, when fully opened.) And its width is 1090mm (42.91 inches). Such a wide opening provides easy access to the insde of the vehi. With repaid to the back door stay, « small-sized ‘marscaled type stay has been employed. The stay of this type hes no projected portions, opy Inasmuch 2s the package tray is interlocked With the opening/closing of the back door, the lugeage room can be used with ease, (excluding ‘the Model XO vehicle) Furthermoe, the wire hamess and washer hose are routed through the quarter pans! at the sight for left side: In addition, the hamess and hose are protected by s rabber beliows tube, Abo, for improved rear visibility, a rear wiper thas been mounted on the Model XTE vehicle, Fig. 150 Back Door Related Paris, =19-Bopy Back Door Lock . The back door can be unlocked by means of the key. And the door can be locked, while holding the door lightly. ae Lec stiker 0 L Fig. 157 Unlocking — Locking Operstion Locking L. When the back door is loweied, the lock striker pushes the lock hook, causing the lock hook to be tured in the amow-headed direction of @ about the ® axis, 2. As the back door is lowered further, the lock ‘hook continues to tum, uatil the lock hook Unlocking 1. When the back door key is tumed to the tight, the lock ratchet lever will be pushed in the arrow-headed direction of @. Then the contact surfuce of the lock hook will -120~ Fig 182 Locking — Unlocking disengages from the lock mtchet. Whea the Tock hook has traveled to such a point where it no longer contacts the lock ratchet, then the lock hook engsges with the lock ratchet, thereby locking the back door completly (See Fig. 152.) become disengaged, thus setuming the lock mechanism to the prelocked condition, as shown in Fig, 151Bopy Back Door Lock 5 ‘The back door can be unlocked by means of the key. And the doot can be locked, while holding the door lightly. allan Lock nook Lock striker Fig 151 Unlocking — Locking Oper Locking 1. When the back door i lowered, the lock Striker pushes the lock hook, causing the lock hook to be tumed in the arrow-headed {direction of B about the ® axis, 2. As the back door is lowered furthes, the lock hook continues to turn, until the lock hook Unlocking |, When the back door key is tumed to the right, the lock ratchet lever will be pushed in tho sow-headed direction of @. Then the contact surfaco of the lock hook will ~ 120 ~ Lock ratchet Fig. 152 Locking — Unlocking isengages from the lock ratchet, When the Tock hook hes traveled to such a point where it no longer contacts the lock ratchet, then the look hook engages with the lock ratchet, thereby locking the back door completely. (See Fig. 152.) become disengaged, thus retuming the lock Mechanism to the presiocked condition, 1s shown in Fig, 151Luggage Room Trim Related Parts To provide better appearance, the inside of ‘the Ingoage room has been lined with resin trim panels Exch trim panel is secured, except some places, by means of plastic clips which will not rust (Plastic) Fig. 153 Luggage Room Tum Panels BUMPERS Rubber side extension bumpers have been in- stalled at both sight and left sides of ezch of the front and rear bumpe In this way, damage to the bumper corners can be minimized in the ‘event of touching other ebjects, Furthermore, the installztion of bumper filer ‘has beuutified the vehicle epposranco, (exclud- ing the Model XO vehicle), Also, the bumper guard pad is standard on the ‘Model XTE vehicle, Bureer aembly Slee exons unpeefilor fe Fig. 154 Bumper (Standard Equipment) 11BoDv RADIATOR GRILLE AND HEADLAMP ORNAMENT RINGS All models share che same radiator grille which is of the three-piece type The headlamp ornament ring is ofthe snapping-ia type which features eusy removal/installation Fig 155 Radiaior Grille and Headlamp Omament Rings OUTER REARVIEW MIRRORS GLASSES ‘The side door glass is a curved glass having 2 radius of 1600R so as to get a roornler vehicle interior. Glass Specifications Has in{ are options ee mae _ ae Polke sone logtened eat ay Windshisi lae FDiam (0-20) Se ea {Laurea plate 51 rarn CCA ABCAD Yr ed planed 5.7 min (8,2 Zinc) | 2 ‘Ordinary toughened glass Heat ray absorbing tyne toughened ion doo: las ‘Brum (eich) gio SbCl) ‘Reerduor gis he ame ave Thee ore Rear door quarto The sme above The we above ‘Tae same above Heat my absorbing | Heat ray absorbing type toughened se doer she {ype toughened sla with defogger” glass with Geogset = Fle (.16inch)) =m (0..5inen) -12-soDy ‘MOULDINGS Beck door mouicing {eneept Model KO} Wirsis6 moulding (erteat Moget xo} oot rip moulding Boor eu ple Fig. 157 Mouldings Fender Liners AA fender liner made of polyethylene (PE) has ‘boon installed ot each front fender in order that the inside of the fender mey not be corroded or ‘may not emanate noises becuase of grit or mud that fk most likely bounced by the tire ducing the vehicle running Fig 188 Fender Liner -13-s0Dy VEHICLE BODY COLORS A total of six different colors are swailable four colors in solid group aad ‘wo colors in metallic group. The threecoat painting method has beea em: ployed on all colors. In the case of the metallic colors, 4 clear coat has been applied so. as to provide a better peinting finish as well es to reduce the maintenance expense Poppy White Camelia Red Saffron Yellow Grass Green Blue Metalic Silver Moon Stone Metallic i Grate nero im clare xo xe ate Vere body eter ES | Teer White ak @ Siaslaee Coase ak 3 rs ae Suihcn Yow ce ° eo Gass Green Lent brow © ° © Be setae black ° oO ° ‘Siver Moon Stone Metalic enero 6 3 @ ‘Vehicle Color Mixing Ratio * Made by KANSAT PAINE CO. LID, COLOR NO. COLOR NaN FRINARY COLOR NINING RATIO ww 7 en 13st OXIDE eLLoy | small amount m0 pony WHT Tol DEEP GREEN’ ral aout 140) DEEPRLACK ral amount 1564 INDIAN RED | Sian 6 14g) ROZANORENGE = Iss INDIAN RED > 16 CAMELLIA RED 158 INDIAN » 1B Avo Whe 1 16) ROYAL YFLLOW a git SArFRON YELLOW 2 ss sarmonveiiow | 181 AUrowute B 13st OXIDE YELLOW é 1651 DEEPGREN sal nt isis DEUPGREEN # 152) ROYAL YELLOW = aes RAS GUEEN U3 AUTO WHITE u Mo DEEPELAcK sal noun 167 FRESH BLUE ~ 480 125 ROVAL viocer 30 0 BLUE METALLIC Hot MeTALTICHASE 50 1202 SUNNETALLIC BAS 15 190 Denruuaex sna stont 122 suNeTALLiC Base 1% 1s SIEyER Moon srove | Ifht SEVAnTSaS 3 ue Hop DEEP BLack sou anouat ~ 1INTERIOR APPOINTMENTS FRONT SEATS On all models separate eats a reclining device are standesd equipment. The recliner has been so constructed that it Is integral with the seat rail 0 as to increase strength. ‘The sest cushion has beon designed in such a way Racine Fig. 159 Front Seat Froat Seat Specifications thet it can provido a smooth deflection when seated. resulting in excellent seating and riding comfort. The headrest is of the adjustable, insertion type. kom eh [ain seat _Ostiaiy bathe | Ventlative Seat tiirganount | 160mm (30inche) | Recining device | Equipped | ‘Hated: |) Tasetonaype | XTE REAR SEAT The rear seat is of the bench type on which two Persons can seat, It uses molded urethane. The seat eushion is the comercut type where both ends of the rear seat are rounded, thoreby making it possible for passengers to make easier entrance and ext Fig, 160 Rear Seat = 125 -eoby Forward-Tilting Type Sestback (Except Model XO) * When the seatback is tted forward, the vehicle interior and luggage roam can be util in « {nterior will become integral with the luggage most effective way Toom. Consequently, the spece of the vehicle Fig. 161 Forward-Tilting Type Rea: Seatback SS nhock =~ Forward Tilting Procedure To unlock the seatback, operate the lever hancle Jocated at each seatback stopper on the right and left sides of the package tray. After releasing the lock, tit the seatback forward SEAT BELTS The three-point, continuous webbing type equipped with EL.R sout belt is standard equipment The retroctor is recessed inside the center piller, thereby making the foot area moze specious, Fig. 163 Front Seat Belt ~ 126—INSTRUMENT PANEL RELATED PARTS The instrumont panel conssis of the instrament core, safety pad, meter cluster and glove com partment, ets. The instrument penel has been so ited that the projected area ts. small, while the leg space is lacge, Furthermore, the visibility has been further improved by the anowly-d panel On the instrurent panel wie arranged three round-shaped meters side by side, And the wem- ied configuration of the instrument ing lamps are located below the center of the ‘meter cluster inorder that the centralized control of the wasning lamps, e.g. monitoring of buint out bulbs, may bo performed effectively and effortlessly. Moreover, the centralized, in- tegral type switch has been employed, further enhancing the safety and oasy-operation In addition, the suspension type console box Is available a8 optional equipment Meter euster Center senior Clore comoarment Fig. 164 Ash Receptacle The ash cecepiacle 1 of the (wostage-pulling out type. It should be pulled cut two stages when It is removed for the purpose of cleaning The rear ash receptacle is incorporated into each of the rear door trim panels at the right and eft sides. As a result, the space at the reir seat can he utilized effectively Tnsirument Panel Fig 165 Removing Front Ash Receptacle -127-sopy DOOR TRIMS Both front and rear doors come in two different With regard 10 the pull handle, itis avalable in specifications: the semi-trim and fulktrim specifi-. two kinds. A large-sized, deluxe type pull handle cations. They are selected depending upon grades is mounted oa those vehicles having full-tr of wehicle modals speviications, (Front! Som trim specifications [Models XO & XG) Pull handle Fulbtrin specications (todo x7) Pullnarde Ach mesptace Fia, 166 Door Trims Package Tray (Except Model XO) ‘The openingjclosing of the package tray is easly. Hence, it ie possible to use the luggage {interlocked with the opening/closing of the back __ room effectively in other way, as required. door NOTE: Make saze not to place heavy objects or Also, the package try can be removed very: lrge articles on the package tray. Fig, 167 Package Tray, - 128Bopy INNER REARVIEW MIRROR Sa A large-sized inner misror has been eraployed <0 as to provide an improved rear visbility, Dropable Construction 1. The inner rearview mirror is incorporated into Seeing the 1oom lamp body through a resin catch { reanentch Uh Swirer fom imo boss Inside the resin ch is installed a snep ring Which always exeris 2 force to expand the resin catel to the outer periphery. 3. If an impact should be applied to the rearview Fig 168 Drapabla Construction of Inner Reatview Misr mirror, the snap ring would be compressed, thereby dropping the micror from the room lamp body. Other Interior Appointments D Rew enistgrip (Models XG & XTE 8) Rosrawist rip (Med XG & XTE) @ Front asst orp (Except Mosel XO) ‘Gpnter ila nnoe trim Model XT} 3) @ Sunvsor (Diver's set side — Allmodels Front ollarinnar tim (All rece) ‘Condor seat ris — Except Model XO) Fig, 169 Other Interior Appointments = 129ey TOWING HOOKS Towing hooks have been provided at both right ‘and left sides of the front side of each vehicle Fusthermore, a towing hock hes been located at the center part of the roar side of each vehicle When the towing is to be made, make certsin to Use these towing hooks. CAUTION: Under no circumstances, should a towing rope be attached (0 the ave heam, (Front si) ar eda Fig. 170. Towing Hooks ieerece) JACK AND TOOLS sg ae ref the paorapt type. Thuja These aching polns are located at four points Jack handle end too! bag are positioned inside the spare tite house provided in the lasgage com: partment, The pantograph type jack must be set only at thow specified jacking points Fig 171, Jock aad Tools —130— lunder the rocker panel at its front and reer Points on the right and left sides. These jack setting points are notched for the purpose of identification so that you may readily find them, zee setting pointe— WODY ELECTRICAL SYSTEM DESCRIPTION With emphasis placed on the driving comfort and safety, & wide vaslety of equipment has been installed on the Model G10 vehicles. As repards the wing rolated parts, «relay built in fuse block has been newly introduced, theceby making it possible to reatrange and rationalize the wiring work. Also, with 4 view to further improving vehicle functions and ts safety, the following pieces of equipment have been pro- vided: the light glow-stste warning system, intermittent wiper, rear wipes, semfiransstor- led tsher unit and so forth Furthermore, whet designing the heater (OPTION), special considesation has been paid WIRING HARNESS BODY ELECTRICAL SYSTEM 40 a8 fo ensure easy combination with the air conditioning unit. As for the venation. i has been constricted fn sich way tat all ic mst enter the heater unit, In this way, this forced ‘ype ventilting method ensures comforable airconditioning tall times The contraized warning lamps ae located com- pectly on the instrament cluster panel in oxder that the deer may readily know whether or not there is any malfvaction in respective system, Moreover, the multiuss lever switch has town employed 50 that each sviteh of to light. ing systom may be operate effrtesly Enlorged View of Tnstnamant Pape! Related Parte Hepilamp barre ron x Pedal bracket For un sonal switch For tap ismp a Dermer fe Fuse look Enlarged View of Flee Binet Bolted Parte Fig 172 Wiring Harness = 131--ODY ELECTRICAL SV: EM, FUSE BLOCK The wiring routing in clos vieinity of the in Strament panel has been rede so that all main Wiring harnesses are connected to the fuse block concentratedly, thus making it possible to arrange thes> wiring harnesses in order. Thea, these wiring hamesses aro routed to respective systems, In this way, the wiring hamesse¢ have been acranged ideally, at the sume time providing = better appearance, Besides, the following parts have been built nto the fuse block compactly: the tum signal flasher lant, taillight alarm buzzer and stop lamp failure telay, Also, the centralized giound method has been employed to give excellent pround coae Conreste stom coal Connected tem | A | ee-sonced io op tmp sien we | | Dreatyaonnsted meat I 5 Directly-connected to headlamp harness (right) 1 | Directiy-connected to multiaase lever switch | € | Disesiy-connectes to headlamp harness ef | | Stop mp Fara clay D_| Dieetyssnreciad oreo nes det) | | Tallignt am bunser [ © | Divesty-connestea to rear harness M [Tura vem fisher “il F | Directly-coanected to instrument harness ==” Lo Fig, 174 Fuse Block Diggrem -132-BATTERY AND FUSIBLE LINKS ‘A IDV, 4SAH battery is mounted on the let side inside the engine compartment, The battery features compact size and: light weight which have been made possible by the improvement in the separator materia) and their configuration Furthermore, to protect die wiring hamesses, fusible links have beea provided between the battery and the headlamp circuit as well as between the battery and the fuse block, one each, COMBINATION METER The combination meter consists of three meters Which are srranged in lin hosizoatally, On all models a nonzeflecting type glass has been employed in order to avoid glare. Moreover. - 4 / / Noga TE: wehoreter Fig 178 Combination Moter Incorporating Three Round Metsre > 2 s00¥ ELE ‘TRICAL SYSTEM Fusible ink Fig. 176 Battory and Fusible Link the combination motes has been designed so that the metets, meter glasses, meter casees and meter bodies, etc. can be removed or installed very casly, by means eine Fig 177 Schematic View of Combinetion Meter = 133-20DY ELECTRICAL sysrew LIGHT GLOW-STATE WARNING SYSTEM ‘The Model XTE vehivie is equipped with the Tight glow-state warming system which will set ‘ff alarm signal in the ovent that the diver has failed to turn off the light control switch (except the parking lamp switch). When the door is opened while the light control ST en BaEn Fae i Fuse nk | Fuse (Te) Tal Side lamp slic Bostery Ese Jamos Tat amos is re ri UPd Lares lampe es Fig. 178 Wiring Citcuit of Light Operation |. When the ignition switch, side lamp switeh and door switches are turned ON, the current fom the battery flows as follows: the fusible link ~ ignition switch ~ fuse tail Nght alarm buzzer (temminal ©) D, — coll L > terminal ®) = door switches > ground Gnder this setting, the buzzer contact points are held open by the magnetic force of the nergized coll L. As a result the buzzer will not set off aay alarm, 2. When the ignition switch is tured OFF and the side lamp switch and door swliches are fumed ON, the current from the side lamp switch further Hlows as follows, because the 134 ‘witeh i tumed ON and the ignition switch is tumed OFF, the tal light alarm buzzer will be set off, thus reminding the driver of the fact ‘that the lights are still glow. The tall light alarm buzzer above has been i eorporated into the fuse block. for neal bee | FReer Tiont Rear Front Boor itches Glow State Warning System buzzer contact poinis are now closed: the tail light alam burzer (terminal @ + D, = buzzer contact points P ~ coil L > terminal ® ) + door switches > ground. Consequently, the buzzer contact poins P will be opened by the megnetic force of the coll L However, at the moment when the buzzer contact points P are opened, the current is interrupted, thus demagnotizing the coil L, Consequently, the buzzer contact points P will be closed again. The above-described operation is repeated ‘and the buzzer will continuo to set off alarm signalsWARNING INDICATOR SYSTEM The centralized warning indicator lamps heve been auranged mpactly at the center pact of the instrament cluster finish panel Because of this centralved monkoring system, the driver ccan readily know as to whether any malfunction ‘hich may prevent safe, normal driving is present in the vehicle's functional systems The warniag indicator systern 1s composed of those waning lamps for those states of stop lamp bulb bumingout, charging; oll pressure and brake, ote. BODY ELECTRICAL SYSTEM Fig, 179 Watning Indicator Lamps OO % ex how bale i 3 PEE | 2 HIME af ‘Saprinp Fature ay, ae Stop laine Fig, 180 Warning Indicator Lamp Clreuit Checking Waring Lamp Bulbs for Buming Out 1. Tum ON the ignition switeh and check to see ‘whother all warming lamps go of, fall warn ing lamps are glow, it indicates thet these lamps ate functioning propedy, ‘Undor this sotting, the circuits ere formed as follows EA Battery = fusible link — ignition switch = fue block +E bulb > regulaior terminal L > contact point Pe > ground, 8% Hettery > fusible link = ignition switch = fuse block > i bulb = ol prosture switch = ground, = 188-CTRICAL SYSTE $5 batery > tusble tink ignition mitch > fuse block > $5 bulb stop lamp falue relay [terminal @), Ds, termine @] = regulator terminal L > contact point ~ ground, (© Batiory ~ Ful ink ~ ignition swten > fuse block =p pu1d Dy ~ regal tor teminal L > Contact point Pr = round. (©) Ratwry > fusible link ~ ignition switch * fuse block > (B) bulb > D, + regula. tor terminal L~ contact point PE rod 2, Start the engin by turing the ignition pic & tho START positon. And ensre that all wearing lamps go out, If all waminglanps ace aot glow, i incvates that thes lamps ane funetioningpropesy 8: OS Warn laps After the engine has stared by turning the ignition switch tothe START postin, i the allemator it generating current propety, the regulator point will be switched from PE: to Pb, As a result, the curentgenorated by the aerator will each the regulator termina 1 Operation of Warning System 1. Ol pressure warning syitem Any drop in oll presse can be detected by the ol pressure switch, After the engine as tated, i the oil pressure reaches the specified of pressure, the oll presse switch will be opened, ths interrupt ing. the circuit. Consequently, the wasaing lamp will go out. When the oil pressure drops below 0.ske/em? (7px, the of! pressure switen will be closed and the warning lamp wil go on, thus telling the driver that the ofl pressure is abnormally low. 2. Charging state waraing system Tf the charge warning lamp remains off, i indicates thatthe charging systom is function. ing property = 136 - throat the points Pn, hereby ang the potenti tthe eminal L Consequenty, no amen Now tough ech vary lan of the EB and. 3 ing lip oF te of ar a Albi. signe insitatiiptuttngtag inion svitch to the START postion, i tho bake Mud lel is the spoited value do sb ncn wong baste Il sith is opeate). Th bia wening lee etigsau Seca AEG The cs tasshetea by ely a lution swish to the START poston, af the acting bake yer Is retuned tthe cut pain, the brake wing ang eae Alex the engite has sae by turning the ire al pistiis & ai a soma bel, te of pies sich willbe opened, Consequently, (io ol aig Wp In this way. each wa. and 3 will remain ignition switch to the START postio: If the altemator should fail to generate current, the current from the battery would be grounded through the regulator point PE Consequently, the weraing lamp will g0 of, thus tolling the driver that the charging system is not functioning properly, Parking brake warning lamp ‘This waining lamp will remind the driver that the parking brake is still on, in order that the vehicle may not be moved off while the parking brake is still applied When the parking brake lever is pulled out, the brake warning switch will be closed. As a result, the waming lamp goes on, thus re. minding the driver that the perking brake is still on,4, Brake flvid warning lamp If the brake Auld level should érap below the specified level fie. below the hal? of the ‘whole capacity), the brake warning level 5. Stop lamp burning-out warning system If the stop lamp bulb should be buint out, the wacning lamp would glow, when the brake CTRICAL SYSTEM switch would be closed. Consequently, the warning lamp goes on, thus telling the driver that the brake fluid level is abnormally low. podal is deprossad uring the engine running, In this way, the warning lamp tells the driver ‘that tho stop lamp has failed viarning luntion switch use (Rugutator Forib ink Tipe {| Stop tam Weta SHINE, (ren) Gr— stop lam ye Oe repitnor | on Fig. 181 Wirlag Choult of Stop Lamp (1) In caso that all stop lamp bulbs are normal: When the brake pedal is depressed, the ccucrent I, from the fuse further flows as follows: the stop lamp switch + stop lamp failure relay (terminal © eurrent coil L, + terminal ) roune. Ase result all stop lamps will goon, stop lamps — = 137 Failure Indicstor System (1) Under this sotting, the rood switch P i closed by the magnetic force caused by the enosgized coil Ly. Hence, the current jg flows as follows; Ry > reed switch P > terminal + ground, Consequently, no base current flows through T, ‘As a result, Tr is not conducting. There- fore, the wataing lamp remains offBODY ELECTRICAL SYSTEM Wering tem Ignition switeh Fave Ai step lomo |--—}----- S109 lamp Fig. 182 Wiring Circuit of Stop Lamp Failure Indicator Sysiem (2) In case that one stop lamp bulb has been burnt out: When the brake pedal is depressed, the jcusrent 1; flows in the same way as the all stop lamp bulbs would be normal. Nevertheless, the load is very small, since ne stop lamp bulb is bumt out. Hence, Only a current of a smell magnitude flows through the collLy Asa result, the magnetic force caused by the energized coil Ly will decrease to such an extent it no longer hold the reed switch in a closed stste, Consequently, the cunrent 1 Moves as follows: the stop lamp failure relay (Ry > Dy > Tr > = 138- terminal ()) > ground. In this way, the current i, becomes the base current of Tr, Asa resilt, Trbecomes conductive ‘Then, inasmuch as Tr is conducilag, the current iz Hows as follows; the warning lamp ~ stop lamp fallure relay (terminal ©> R, = Tr terminal @ ) + ground. In this way, the waming lamp goes on ‘The current coll L: has been provided in the systom in order that the operation of the reed switeh P may not he affected by the chango in magnotic force of the current coll 1; due to voltage vatiation,SWITCHES Multi-Use Lever Switch (Centralized Type Switch) ‘The Model G10 vehicles have employed the smulisuse lever switch in which all switches to be used frequently dusing the operation are centtalized at the steering column ection in BODY ELECTRICAL SYSTEM pres that the driver, even when he buckles up his seat belt, may operate all switches effortless y, Hara warning sonal siteh “Torn signal sites urn me azar seh ght contol itch Ligh conto! sich eres ner ster EE A af Fig 183 Multsise Lever Switch = 138BODY ELECTRICAL SYSTEM Light Control Switch ‘The light contol switeh incorporates each lamp. switeh for the side lamps, headlamps and parking lamps ‘The light control switch can be operated with a lever provided at the right side of the steering column, The headlamp switch has a comparatively large contact-soint capacity. Therefore, no. light control relay is installed in the headlamp circuit Moreover, the headlamp circuit uses the switch ground methed. Front Wiper & Washer Switch The wiper & washer switch has been bull into the end of the tum signal lever mouated st the left side of the sicering coluran section, The wiper switch is operated by turning the end of the lever, whereas the washer switch is porated by deprossing the end of the lever, Furthermore, the intermittent type wiper has been instslled on the Model XTE vehicle Rear Wiper & Washer Switch (Model XTE) The rear wiper & washer switeh: is of the seesaw type. It is located below the instrument panel at its right side The wiper switch is tumed ON when It i de proseed, When the switch is depressed one more stage yn this setting, the washer will be operated. Furthermore, when the switch is deprasced further from the wiper switch OFF postion, the washer alone will be operated, Rear Window Defogger Switch (Model XTE) The rear window defogger switch is of the seesaw type. It i located below the instrument panel, at its right side. Waren the rear window defogger switch is turned ON by depressing the switel too, wil go on ont carte sen Hf Fig. 184 Light Control Switch Fig. 187 = 140- Wiser thd source Resrineons cofaeger swith Rear Window Defogger SwitchBODY ELECTRICAL SYSTEM LIGHTING SYSTEM. Headlamps and Front Combination Lamps ‘The headlamps have employed round-dhaped stalled very easly forthe purpose of photometric bull ype. ajusiments, ete Moreover, « headlamp omament ring is fitted in ‘The front combination lamp incorporates 2 tucn each headlamp sas t0 provide a better signal lamp, a clearance lamp and a parking lamp, appearance, This headlamp omament ring Tas Tt features excelent visibility. been so designed that It can be removed and in ‘Side Tum Signal Lamp The side turn sgnal lemp has a wedge-shaped lens Moreover, the sile turn signal lamp body fsvalle 0 that It may provide improved visibility from of soft resin Ie Has such a construction that the the front or rear diceetion atthe side ‘housing is integral withthe packing Rear Combination Lamps ‘Thi resin rear combination lamp har been so Tamp whose housing is divided equally into three designed that the housing {¢ integral with the sections. It features emaikable vsfiliy lens. It is largesized, square type combination Fintan aa” ag wae Farad seaming lar clewanca orp ae main any eras piste arp Spal Berra Fig 188 Lamps on Front and Rear Sides Lamp Specifications specication in @__) denotes option Frontlimp: | Goler | Fanetion | Watoge]] Rearlanps | Color | Function | Wattage ie | Urns beam, ay || Rear tinier | Orange |Baetan, | Headlamp |eelow)] lower barn Tow || Binp SM | Ose» | Fasted waning) 22 Tront tn sea Front ara, Orne | Fe 21W ner Ere 1} stopitat ia ls aw sg | Stop, ta ny white | Clerane ew | | sie tann sien Side wu zac ra sw || buckaptamp | wate | Backup amp use | once | Se sxwplimp | whe | Backup amp | 21W eauigeamsl ois ae em ite | Eisen ate 5 Foon tay | Whe | Reon mp vow | i wake | PSE sows -1t-BODY ELECTRICAL SYSTEM TURN SIGNAL FLASHER ‘The tur sighal Masher Is the sei-transistorized type which features positive and stable functions, Indicating Performance in Event of Tum Signal Lamp Failure (Reference information) romenslture ‘Troubie nate Daring nora Tadiator hn Turn pel lamp (Oper sreuit on tm inal lamp roto ae) [lashing speed exsved 12 tines min Side tur signal hay open oecned (Open ciel Instr amp lashing speed inereases by more than. ots an lashing sped increases by more than Sin (Note) Phshing speod may dizhly rary depending upon conditions Tum Signal & Hazard Lamps Operation 1. When the tum signal switch is tumed OFF Even if the turn signl sviteh is tuaned OFF, the current iy from the batery flows as follows: B-> Ry > Ry > Ts +E. Asaseslt, Try, becomes ON, while Ts becomes OFF. When Tr, becomes ON, the current lp Noas in the following path: B-* Ri > Trs > Cr Try > E, On the Other hand, the eurent Furetra) Tettionwwitch Fue ‘ibe Hata site Fig 189 Wirlng Dagiara of Tuan Signal Flasher System () i flows in the following path: B > coll > RG + C; > Tr > E. Hence, the condenser Cy is charged by these two curtants. When the condenser C, has been charged fully, the cunents i and bp cease to ow. And this condition continues until the tum signal switch is tamed ON. Tinker = 12-—— Operation of Transistors PNP Type... In the caso of transistor of this type, when the base current flows from the emitter to. the base, the transistor is conducting ‘between the emitter and the collector, thus allowing the collector current to. flow through this path, yor PNP Trnsintor NPN Type... In the cate of transistor of this type, when the base current flows from the base fo the emitter, the tran sistor is conducting between the collector snd the emitter, thus llowing the collector current to flow through this path © 8 ©) Collsetor Rey ues RL aarear Type NPN Transitor ECTRICAL SYSTEM 2. Whon the turn signal switch is tamed ON: If the (usm signal switch is turned ON from the foregoing condition, the potential at the terminal © will become nearly equal to the ground potential. Consequently, the base voltage of Tr, will drop, thereby turning Tr, off. When Try is tumed off, Tr, is turned on, allowing the current ig to flow through the following path: B > coll + Tr, +E. Asa result, the contact points P will be closed Thea, the current is of a large amount flows a8 follows: B> Ry > terminal ©) > switeh = lamp > ground. In this way, the lamps will glow. Inasmuch as Tr, has been turned on, the electric charge will begin to discharge as the current ig flows in the following parth C1 >Re > Ty >Re C1 While C, is discharging, the base current of ‘Tr; will become negative because of the drop in voltage across Ry. In this way, Try remains off, wherease Trs remains on, Consequently, the tum signal lamps remain lighted, a5 long as Tia Is turned on. Hazard aiteh (7 Turn sera) aga $n TIT Fig. 190 Wiring Diagrain of Turn Signal Flasher System (2) = 143 -BODY ELECTRICAL SYSTEM, 3. Whon the tur signal lamps remain OFF: When C; has completed its discharge, the base voltage of Try will inereuse, theceby tuen ing Tr, on. When Try is tamed on, Try is turned off. As 4 result, the currant passing through tke reley col! is interrupted, thus opening the contact points P, Consequontly, the tura signal lamps 0 out When Ts, is tumed on, the following two ‘currents flow 25 the base current of Tr, in respective paths: jo, the current ig, B+ Ry 9 Tr > Re + C) > Th +E, and the current is, B> coll > Ry >C) > TH > E, In this way, C, will be charged by these two sumrents off; and The lamps remain off, until Cy is charged Tully. When C, has been charged completely, Tr wil be turned off and Try will be turned fon. As 2 result, the lamps go on again. The abovedesctibed operations are repeated and ‘he tura signal lamps continue to flash. Teriten Saitoh muse ie (Wiper) swter Hen etch a Tama Toa Fig. 101 Wiring Diagram of Tum Signal Flasher Systema (3) 4, When one bulb (22W) is burat out: IF one bulb (23W) of the tum signal lamps i burt out, the curent passing through Ry ‘during the light-on period will be reduced to hha. As a result, the voltage drop due to Ry decreases, at the same time increasing the emitter yoltage. Consequently, Tr; will be turned on. When Try is tumed on, (inder this condition, Try is turned on), cuztent flows ia the follow Ing path: B+ Ry > Tr) Rs > By + Try ~E. Then, the voltage at one side of C, will rise by a voltage caused by divided voltages Of Re and Re. Asa result, the discharge at Cy = 144 takes plece only until « voltage cuased by divided voltages of R; and R,, is obtained; in this case where one bulb has faled, wheres the discharge at C, takes placo until the voltage drops 10 the ground potential during the normal operation. Consequently, Tris tumed on, before C, ean completa its cise charge Furthermore, since the charging operation of Cy is started before Cy has compleied its discharging operation, C, will resch its Fully. churged state for a short period of time Consequently, the fashing speed increase:BODY ELECTRICAL SYSTEM f Fae Ten) Remar oi “Tarn signal 5. When the hazard waining lemps are funetior= $0 does the current lamp. However, the flash ing: ing speed remains almost unchanged. The hazard warning lamps operate in the same Also, even if one bulb has failed, the flashing ‘way as with tho turn signal lamps speed during the hazard lamp operation ‘The number of operating Lamps increases and ‘romans the same, Hagaea aah Feat) Furie nk Tera siona | teh Fig 193, Wiring Diagram of Tum Signal Plasker System (3) = 145 -BODY ELECTRICAL SYSTEM WIPER ‘The Models XO and XG vehicles are equipped with the two-speed wiper motor: the Model XTE, the twospeed and intermittent type wiper Front Windshield Wiper ‘The pivot section ofthe front windshield wiper is Taperserrated, And the sido hinge method hos been used (© conmect the wiper blade to the wiper acm, In acition, the wiper arm is fited with @ wiper arm cover. {In addition, the rear window wiper is standard on the Model XTE vehicle, ‘The wiper motor hes heen installed inside the cowl top panel. The service hole covers have been provided for the purpose of maintenance service. ‘The washer tank hat been so consiructed that the tani is integral with the impeller section. Wiper Motor Spciieations piace Cee S )During =| Notoaa | ptalian | SO*Pm pert Vghspees | 752S:pm a Se eS ee (S6.8lache39) ai FLIPS Ee CT NS ma Fig. 194 Front Windshield Wiper Intermittent Type Wiper ‘The Mode! XTE vehicle is equipped with the intermitient type wiper motor which will be very handy in those weathers, such as when is is. ing or raining lightly. Operation of Intermittent Type Wiper When the wiper switch is set at the intermittent ‘operation position marked 2s “INI,” the wiper starts to function ata ate of one time at intervals of 310 $ soconds, Diner switch [Tavemnitent operation NT" wiperrety filo Fl rT F 36-65, 01 ~09 see. Fig, 195, Diagram Showing Operation oF Intermittent Type Wiper ~ 6When the ignition switeh is turned ON, while the wiper switch is wimed OF: With the ignition switch set at the ON postion, a voltage is apolied to the terminal B of the relay. However, since. the ground terminal 5 not grounded, no current flows through the coil L. As a result, the relay - ‘mains inoperative When the wiper switch i set at “LOW positon: The current fows 38 follows: the ignition Switch — wiper motor — wiper switch — E ‘Thus, the wiper motor continues to turn. When the wipor switch is set at “HIGH™ position: The current flows as follows: the ignition ‘switch ~ wiper motor>wiper sviteh QE. Fig. 196 Wiper Wiring Diagram: Thus, the wiper motor continues to turn at high speed. BODY ELECTRICAL SySTER Jonson Ly Wiper motor Fare i lenition switeh | NOTE: Functions ofeach of nds and condensers (Dane.o Dy + Countersmetsire tor nepitive pulses in power supply Hee D, «To present reverse curent from, ‘wiper clay tema (8) Di fi Te ‘praveat erg operation ‘caused by voltage variation To dliminate influnee by sountereecttomatve forse coil ‘odetermine internat tine To prevent wrong operation ssa by nos To bob counterelectro motive ice of cou Fig. 197, Wiring Disgram of Intermittent Type Wiper (1) 147 ~El BODY ELECTRICAL SYSTEM 4. When the wiper switch i set at the inter. mittent position masked as “INT,” sil: taneously Trz is tumed on by the bise current. Consequently, the exciting current ip flows pasting through the coil L. ‘Then, the contact points P will be pulled and the current is will cause the wiper motor to start turning ata low speed, At the moment when the wiper motor begins to tum, 2 path is formed between the terminal © and the terminsl ©. Consoquently, the current ig begins to flow. In this way, the condenser C, will begin to be charged to Positive potential, 2s indicated Fig. 198. When Cy has been charged only a litle, the Potential at the point A ie high and Tey is turned off Wiper rainy Wiper meter Fig 198 Wiring Diagram of Intermittent Type Wiper (0) 5. As C, is charged gradually, the eursent ly de- creases, at the same time dropping the potential at the point A. As a result, Tr will be turned on. At the sane tle, the potential at the point B rises and Tr, is turned off, Consequently, the contact points P will be returned (© the original position. ‘This curation time when Tr, ie tuned on is the intermittent operating time, It is about 0.5 second. (This duration time is cepresonted by T, in Fig. 195.) When the eontact points P fare returned to the original position, the current ty in Fig. 198 dees net flow eny longer. the wiper continues to tum by the current ig, because 8 current path is formed between the torminal © and the terminal ©, until the wiper motor travels up to the wiper automatic stopping position, When Try is turned on, the base current ig will cause the condenser C, to be discharged NOTE: The curzont ig is not strong engough to pull the contact points P, Nevertheless, motor Winer relay Wipermater ri Winer switch = 148 Fig. 189, Wiring Diagram of Intermittent Type Wiper 3)©. When the wiper motor reaches the automatic Stopping position, a current pet & Formed between the csminal @) and the terminal @ through the contact points provided inside the wiper motor, thereby permitting. the current fy 10 flow. Consequently, electrical braking is applied to the wiper motor, In this way, the wiper motor can be stopped immediately. Oa the other hand, the con denser C; will soon hegin to. be charged by the current is from the opposite direction BODY ELECTRICAL SYSTEM As Cy is charged, the base current ig of Tr: will decress2, Then, Tr, is turned off and Trp | tumed on. In this wey, the wiper motor fetus t0 the original position. Then, the Wiper motor begins to operate again at @ low speed, This duration time when Try is tumed on is the intermitient rest time. It is about 4 feconds. (This dumtion time is represented by Ta in Fig. 195) Wiper motor qe Wiberenich| Hoe Fig 200 Wiring Diagram af Iniermittent Type Wiper (4) Rear Window Wiper (Model XTE) ‘The rear window wiper has been so designed that the link mechanism is built inside the wiper ‘motor. And this wiper motor is mounted on the back door inner panel. Furthermore, 2 bag type washer tank is located inside the right deck sido trim of the luggoge compartment. Wiper Motor Spesifastons Rindor maser Nosnad oelating Frequency Noroae owilaiing nuke [ Feit iene 49~ 64 gylelmin 10s Fig. 201 Rear Window Wiper & Washer Installation Diggram -149-BODY ELECTRIC: HEATER The heater is the indoor/outdoor air switching lype hot water heater ‘The forced type ventiltion method his been ‘employed to ventilate the vehicle interior in fonder that comfortable ventilation may be assured at all times, even when the vehicle is stopped or iti involved ina traffic jam, This forced type ventilation system has been 30 designed that, when the ventilation outlet port switching lever is set at the FACE position, the blower motor will automatically start tuming at a low speed. In this way, fresh outdoo: air that hus not routed the heater radiator can be discharged into the va In order to ensure comfortable ventilation, the seatilation outlet poris aie located on the top of the instrument panel cluster aswell as om high places at both ends of the instrument panel On the Mode! XTE vehicle, the indicator lamp i located above the instrument panel so as to illuminate the heater control panel lo intorios. x Mierositen ‘Heater Specifications 1.202 Schematic View of Heater Indoor airoutdaor wer revolution eed 25 ae ee a 2a 7200 Power consumption wm | @ Standard votage v a -150-Heater Control Meckarism 1, Hester blower switch: It is possible to re ulate the ar flow over three stages. This lever controls opsning/dlosing of the indoor ais/outdoor air switching lever. 2, Indoor sis/outdoor a switching lever 3 Outlet port switching lever: This lever controls openinglelasing of the FACE/FOOT switching damper and the FOOT/DEF switel BODY ELECTRICAL SYSTEM ing damper. Also, when the lever is set at the FACE position, the micro switoh actuster the blower motor which will start turning, thus performing forced ventilation, Temperature regulating lever: This lever ‘which is interlocked with the wator valve will perform teruperatuze regulation, tower snten on Blonar switch ON iets vl opened Bons switch ON WO ————————— —— lower sich OW Wee aie opens Pay Fig. 203 Schematic View of Heater Contial System -151-BODY ELECTRICAL sySTEM Examples of Heater Settings 1. Heating wile Inyoducing auteoor air 2. Heating wile reccculating indoor air 3. Heating that keeps Tuco area cool, while foot When the switching levec@ is set at a mids point of tho BI-LEVEL range, the outdoor ait sent from the blower willbe divided into two streams, for the FACE/FOOT switching damper is set at a mid-position. Then, one aie stream is routed to the hoater radiator where the air avream is heated. In this way, the hheated air is blown to the foot area of the driver On the other hand, the other air stream will = 152= 62) be blown tough the ventiator cutet ports, while mainaiving the outdoor temperstare, since it has rot routed through the heater ratiator. In this way, comfortable heating will be assured, keeping fee aren cool while foot aes warm. Furthermore, when the saitching lever @ io moved within the BLLEVET range toward the FACE postion, the air fow blown through the ventilator outlet ports wil IncreaseBODY ELECTRICAL SYSTEM Fig. 205 4. Dofroster (Demisting front windshield) Fig 207 Example of Heater Setting (4) 5. Forced wntating Even if the blower svitch i set ab the OFF position, whon the outlet port switching lever @ ss moved to the FACE poston. ste bloner rotor will start functioning, thersby sending the outdone air into the vehicle interior. Unvor this setting, the FACE/FOOT switching damper closes the asia for the hoster radiator. As 4 result, the fresh outdoor air will be blown through the ventilaicr outlet ports into the vehicle interior. Moreover, when the blower switch is pro [gresead to the seconé stage oe the third stage, the outdoor air will be furnished in a greater quantity Fig. 208 Example of Fozeed Ventilator Setting = 183 -BODY ELECTRICAL SYSTEM It should be noted thet the foregoing ex- planation ‘on the forced ventilation system Aiffer between those vehicle equipped with a hheater and those vehicles equipped with no heater. = 154 In the ease of those vohicles equipped with 20 Heater, no healer control mechsnism is pro- Nided. They are equipped with a blower ‘switch alonePERIODIC MAINTENANCE, GENERAL INFORMATION 1. When carrying out overhaul, inspection ‘and adjustment operations and so forth, make certain to use fender caver and seat covers prior to starting operations. . Ensure that only the specified bolts and ruts be used Moreover, where specified, make sure to employ 2 torque wrench to torque bolts and nuts to specifications 3. Make sure to use only geruine automotive parts for every replacement operations 4, For increased work efficiency and im- GENERAL SERVICING INSTRUCTIONS, 5. When only the front part of vehicle or 6. When you are going to jack up vehicle PERIODIC MAINTENANCE proved accuracy tools sfectivoly. be sire to utilize special only the rear part of vehicle is jacked up, be sure co place chocks at the wheels correctly in order to insure safe operation, and place rigid racks undernecth the Vehicle, be certain to follow the carjacking and rigid setting instructions as illustrated below, Jacking Point ates y oN Fig. 208 Jzcking Pont at Front End NOTE: When pla beam, special ing jack undemeath the axle te should be excercised not to damage it Rigid Rack Setting Point Rigid rack setting point is sot underneath the body at 4 points of left and right AS reinforcement is spotowalded on the setting point in order to increase strength, be sure not to support a place other than rigid rack setting point. = 188 = Fig. 210. Jacking Point st Rear End Fig. 211 Rigid Rack Setting PointPERIODIC MAINTENANCE Moreover, when lifing the car with a two-post lit, support it with rigid rack setting points (4points). Caution on Operation Fig. 212 Two-Post Lift Fig. 218 1, Be cortsin to Keep your hands away from tho fan motor, especially when the engine is running Even If the fan Is stands, Iis danger, since the fan motor rotates in accordance with coolant temperature 166 — Fig. 214 2. Be careful not to drop or damage the loctrical components.When removing the resistive rd, pull out it with cap section held, never pull the resistive cord by holding cord seotion: Whea installing the esistive cond, insert it securely after bleeding the cep. When using a timing light, be sure not to damage the resistive cord with a wire etc, When connector itself, never pull the wiring harness by holding wiring harness section, Care should be paid to ensure that no open removing the connector, pall the circuit or poor contact of the wing harness is present, and make sure it again after operation has boon completed The connector equipped with lock inserts securely until clicking sound occurs, And make sure that itis locked secuedly, by pl ing it lightly, When inserting the tester probe into the wire coupler, tho tester probe should be inserted from the rear side of the wire coupler so as ‘ot to damage the torminal When performing steam clesning, patticuler attention must be pald to ensure thet no water is appliod directly to the clectrical ‘components, especially ignition system. DIC MAINTENANCE - 17PERIODIC AINTENANCE 7, Particular attention must be paid +0 ensire that lead wires and vacuum hoses are clamped securely or they are not interfered with any other components or they are connected ‘without being pulled tightly, 9. Ensure that deflection of “belt is adjusted. Specified deflection of “V" belt 110 13mm (0.43 to 0.51 inch) [with a force of Skg (17.61b)] Reference information If any difficulty should be encountered in pushing the “WV” helt, aveasuze deflection at the time when pulling up the “V" bei If this measurement is within above specif cations, it indicates tha! deflection of “V" bolts satisfactory 10. The engine adjustment should be carried out securely Prior to Inspection Tachometer As the commercially-available tachometer is not provided range for 3.cylinders, read the engine revolution speed following instruction given below. 1. If the tachometer is the type which picks up engine revolution speed from primary circuit, actual engine revolution speed for 3 or Sno lina eames on real ine ys tat inversion ef line B, In case of RH. unit Fig, 240 With regard to RAL umit, ity symmetry ‘with LHL unlt -170-Function of Instruments Checking Function of Warning Lamps 1, When the engine switch is moved to the “ON’ Position, the warning lamps should go on, 2. Next, after the engine has fred, the warning Tamps should go aut NOTE: The (@) waming lamp remains on, ‘while the parking brake lever Is applied (Checking Operation of Brake Fluid Remaining Amount Warning System 1. Turn te ignition swtieh to the ON" position, 2. While the reservoir tank cap is being pulled up agracally, if the (C) wasning lamp goes on, it inidcates that the brake Quid rem: ning amount warning system is functioning properly, NOTE 1. Muke sure that the brake Mul level is Within the specified range 2, Be very careful not to spill the brake fluid, -m- PERIODIC MAINTENANCE IANA IE el=[alol= 242, -Brake Fiuld Remaining Amount Warning SystemSERVICE SPECIFICATIONS SERVICE SPECIFICATIONS 2 Cylinder head ren ‘Specified yale | Allowable lini] Kemarks 00, Clinder head lower gasket surface ditortion sam Gn aay 5 O10, Manifold gasko: surfer dtostion am Gn any 1-18 rate | oi ~ 0071) a ne Seve with sam net ae Extaast | (039 071) = Seatansie a = * ‘nm Gn os Resession allowable ini co) firm ‘Valve guide bush Tien ‘Speciiod valve | Allowabl tnt] Remarks 949 = 9.070, 9, aus | roots ~ D023) | (0.0035) ‘Vale stomto-bush cleanse ram inch) 1.045 = 0075 19, Estawot | ois ~ Dodsof | (05089) Valves ten Specified Value | Allowable in] Remasks “10718 | tawke | (089 ~ 0.071) r= seat wet sm Gach) —— i= Exhawet | (9 933~ D7) m= Seat anal = = 02-15 Tnwake | (9.038 ~ 9059) ‘Yale ead stock thickness ‘nm dat . Bahaaat | og 258 Ao osha | aes Trak | 685 ~ 5960. 6820 rake [0.2734 ~ 0.2740) | (0.2728) ‘Yabo stom outer dhunetcr ‘am (act) Exhaust | 62807 8955 210 oan 0278) | (03720) ==‘SERVICE SPECIFICATIONS Valve spring = er Specified value | Allowable lk] Remarks =e | TER er oy Pose eth mmirei)| 8) ese F io Loneth iste mnie] go) 3 7 Te 299 | Tendon esinstalled san] 3, ey | 7 1s, Ontaquuteness sim (inch) = cot) | ‘Valve cocker shaft and Rocker arm lem ‘Spevifiod value | Allowstie limit] Remake D016 ~ 0.060) 0.09 Rosker sheftevoster arm elerance nn Gnd [tens enna] cm | Cylinder block ite Speciied vale 5] Allowable limit] Remus us Top gasket surface distortion in (inch) = Ruta alee e 010, our sam (ch) ries (Oyliader bore t | ovvorromenes taper mm acy | coos Piston, piston pin and piston ring Tem Specitiet vale [Allowable rit [Remasis E an DOSS = O68 4 Pisomtocvlindercleamace mum ane) |g 90fS= O85 | atta) @in~04 70 | Compression Nod andNO2 p79 ~n.a1s7| (0.0276) | [Fad exp mm finch) er ne n2~09 130 (00079 = 10324) | (0.0812) Pitan rng 9.03 ~ 0.07 0.12 reese caub12~ 0.0026 | (asios7y Side ciearance mu: inch) ee cess = case cao 0008 ~ 0.0024) | _(@.b047) 75945-15976 Fiston outer diameter am Gach) | F800 = 2991, = ‘005 ~ 0.011 Pisconorison pin clearance cre Gineb | p03 ~ 9.0904) my -173-SERVICE SPECIFICATIONS Connecting 0d : om Splice Aloabh nema ed ofa pe nm 6.94 ch om] | eatin This o per 100mI © 98 ache) he ey 5 aa9=00% | a7 Conosting bingo char tn] HEQ= BREE | Ay 15-0999 | 090, big dat hatre om dats] HB =B2| HATE Cranksatt Tm Secs wae Aloabe ai Rema canst mc om dn aoe ‘Uneven wear of jour on ene) oe com~o08 | om aka beg earn cm dan] 4029~ 288] Ey ‘sao =o200 | 020 babes tas smn (inch) ig gnc ~ 0.0087). (0118) Balance sate en es ee | om=013. | om Test ore meg MEER || Re ‘aes ~006 | __o10 Tas eae oleae sn oer | aS = BOE | (RlB) Comsat Tem Spediiedvalie | Alowable Unie [Remake a9s-909, | avo Thess acs smn (inet) (9 9930 ~ 00114) 0.0157), acca~a97 | 300 ‘am bve nei vom into] ESE Pash |b) omit eta taba) ‘ait aa G40, 3 codoie=Bea5)| — etteds Const cog cremate ‘ac =014 39, ia comss~batss)| «thers ta oug~011 6, cote =Bedes | cat -1%4—SERVICE SPECIFICATIONS Tinving bolt pulley Tem Specified vale | Atowable nit] Renate a eae 1004 | 119.50 Peiley onter diamicter eel [4.7189 ~ 47260) (7165) ram tinen) al é 92-8, 2920 meeaey (23331 ~ 2.5370) (23307) Manifold Trem Species vale | Aliowable lini] Remarks Inks manifold gasket eae distortion tam (oe obey Exhaust anol prt ease diteton tum (Hed oats | Flywheel ten Specified valve | Allowable ni] Remarks =a. eee | rivsiesiniaet eee, cluch Tie Specitea ake | Allowable ak [Ranarks Dita etvesn ee Teta 1) ~ 05 fers Heit mm nen e - 5 ted pet is} 84 Sines edges fant is~30, | Preeti! mm Goel) 383% | Thane nmin) diy | Atice lana: oe ite ase | ott» Deo oie 13 es, ning wear mine] — ohn BSA tents feng ate -178~Transmission snd Differenti Guartuin | antond St geartuk one dant mm dhs] 3882" 83, | aL, [ert twa] ABz Aion | ifn iene aah | at en | asso | | For am ce gab Adben | ohn Geos | am eg = Bim |_ bo er iia namie | gilts nde] cats» | ciety _tbatereconmst rice iat rm det ee _@tiso ‘Shift ner eer groove width rma (at | dee ache) | tena ‘Shift furk-to-hub Meeve groove clearance rut Cnet | (4.0095 = G.otom) | co.nz 96) ‘Synchronizer ringto-gear clearance amined) ASS ~ by | codion Dust inner anater rim nen] SQ F807 | AEDS Rowse te | ou ar em Dustin clarnce vam orem] QO 88, | OA0R Rios dit inom nel aidame mine || ROL | ae Reverse shift arm-tc-reverse suit fork clestane> TAG gates caw enis Carer dn Bot ee Bunz | Sa ne dew sonic] MEO S| i |_| -176—SERVICE SPECIFICATION: Steering oe Spaifed wae ae Dilfreses no aa canter | Beeman sine Ditech oa str Per Boece a ak Tol) | | eee Hiei ina ee wer ested sn ie ant sigan = . Ditterences in left Innere Tring 4 saale Disferences in eft oweraue | mar aps Sua ene an t ae a ton mmo | gab hare) 5 >| mag~oua | Brean [sacap aman | RP Om aD Ber Im @.28%) Sanog wast pay eee Wits 10 039 Stecring wheet | Pash re), TaGEa aE ‘ tee Nemes a: Tomine fox tg 08) | Mo mere unt (242) Reese " s [uién the vehicie | ete Brake Pel ids a oe Fie ret mm mtd | bigs OLR O18 Tee m Grey CBB, ee AT EAD Ma lp hoe opera Drake pdt No an 20 4.72) Payee ieee PON ee eer mnt cetee abi 7 is: applet and while engine is. and dash panel haha ==VICE SPECIFICATIONS Frout brake ‘ a Seletvke | Albabeiai |) Remmts [eee inc, alk nmawen) | 3 oy co ds ; Raroot mma | ei Rear brake Tm Speed whe | Alowale tia Tats Whsleyinderianeramneer mmc) | BT, = es aay co Dra ing eines nadia) | @idy ait, =178—SERVICE SPECIFICATIO TIGHTENING TORQUES s Table of general standard bolt tightening forque aed tightening torque ken Kind diameter Pitch ——_—__—_ B pst Stanord value] Tightening range 6 |r G47 3.4) | a= 07, 28= Sy al THC 8) | Lo 460 72~ 116) 10 | 135 239163) | 19~ 31 C1R7~ 24) is in | us 244153) | 18 $0 (130~ 217) ; 12 | 129050) | a40( 318) | 35- 55¢283~ 998) (RPE ora TEE |: 35~35(83~ 98) F oveataae 2 | 17 | 30- S00 217~ 352) a ) B fas 3836.7) | 45~ 700 325~ 50.4) iw 1S: 6.33 45.8) | 5.0~ 80¢ 37.9) is [2 593429) | 47= 7.7¢440~ 357) 6 J is 9.57( 69.2) | 15~110( $82~ 796) is | 2 9.10 65.8) | T1~106¢31.4~ 162) cst orc 5 | 96~ 09 ole 166 (120) | 15= 23, w fiz 337( 284) | 3.0~ 45( 7 wo | as 320231) | 27~ 42, (alt pearing mark of $ ut | Lsasoy | 6606477) | 50— .0¢ ioe a2 15 5.84 ( 5.0~ 7.0 ( (Giang et pat nuriber n | 5.601( 4.8 6.8 (34.7~ 49.2) OPP ER Bo fas 7634552 | 68~9.0( 1.0~ 681) wo} as 9.50687) | 13~11.0( 542~ 79.9) ice a #90 (644) | 2.0-10.5 ( 30.6~ 789) i | as 1436039) | 120~17.0 868~1230) a= |e 13538 (98.2) 15.3 $32~1183) isi ot 3.) O91 43> 63) a es 156 ( 120) 22) 108~ 15.) Boll bearing mark of 6 ay | 10 | Ls 337 (244) 45(217~ 325) Gott read } w | 43 3.2023.) 42 19.5~ 30.9) (Egle of prs oumber 12 | 13sasey | 640¢ 477) 40 ( 36.2~ 379) HOCO« 12 us 5.84 (42.2) 7.0 36.2~ 50.6) | 13s S61 (40.5) 68 (347~ 49.2) 6/4 095 69) 12 38> 8) 8 | 12 220159) | 20~ 3.0 (143-217) wo | 125 430325) | 40~ Ss(280~ 308) 1 4s 4200LD | 37~ 32 268~ 376) (a ane mark of 7 at ) 2 1.25 (SO) $80 ( 63.7) 7S~10.8 ( $4.2~ 75.9) = coke ley 298 ( $63) | 10~ 90 s96~ 6.1) (Exgmele of part numer | i 748 (54.1) | 60~ 85 434~ 615) 6 Jas TOIT (736) | 3.0~120¢ 57.9— sa) of 45 1267( 91.6) | wn.0~150( 72.3—10R's} ud? 1.86 ( 85.) | 9.5~140 ( 68.7—101.3) us WIS 0388) | 15.0230 (108.5166) io 18.11 C310) | 14.0~220 101.3~1591) NOTH: Boone TTT ap 0 Example Bor 62) ‘Lofoittangth below FEET 4 stands for mark bearing at bolt head tea(onn GQ) Crt ow ose pe tnacc shew Pieler of bolt (d) mm 20 sands for lengh blow hea Slandard tightening torque degots value when Ughtning the mails ade of ee 4 case tha the materials omer than sel made are iene, hes oF tes sash a vibration lad ees spolcd to Dol, strdand tightening torque shculd be change ss Tegeen ~173—SERVICE SPECIFICATIONS Luts kem fe) Tiamat Tieng Tone line sks elader a otify Cylinder block » crankshaft bearing cp (Cyndeyhlosk x balnse that nat pts (Cotes nea x manifold (lindas head = spa pag (Cilinde head + head cover Crantshat « Aywheet CCranhsna « cramisnatt puley Connecting wo connecting od cap CConstafe conta tnn, lt plley | Je camsiate fat pump ase sare Timing bet tensioner x eybnder block sn eter les 2923 6 pan x evince bieck 29251) ‘Ope ata pg 35735 (il panne x cylinder book (il pump drt shat sprocket il pemp eotae Balance shat gear cover ylnder block Distbutor Housing + cylinder Bock Foal pipe x fusl pump ue pipe x carburetor Disithuor « dbirbutorhewsing aos 159) sea steiner pln 1015 : eer @2-116) ~ 180 —al el Clutch and Transmission : SERVICE SPECIFICATION Unit: keen (re) “Tightening component Transmission eslinder blosk Output shaft foragon aut Input shaft tesagon aut |For $-se2ds transmission] Transmiison aso [upper] [ower] Transmission ease intermatite plate Tiehtening torques 30~70 (662505) 60-70 (34 ~ Sits) 12~22 G15) Net Foreepeeds ‘rananaen) a 70 34505) wR Bott Foe Sapeds 100~ 120. (23863) min 38755 O83 38a) Drain plas Revese restrict pin 3.0 ~ 5.0 Bleeder pve adeup lnp snitch oie, > 8-10 1 Speedometer seve lock plate 1 Ditferenta sing wear Cured cover (Catch release lever x release lever yoke Sift and seoct shalt shift fame lever Fiver support No.l x tramsmision ease Bolt40~ 5.0 Nur20 = 2.01 Shift and selet shat support transmlision case o7~11 Lever lock pin (51-80) 10-16 Shit rm pivot 2-16) ~181-ee SERVICE SPECIFICATIONS Driveshaft and Front uapension aie Reni) "isn compo Ticino Laver Wate x Bay aay Strut barbracket x body Lower arm x lower ann bracket Lower nm x strut bar teacket Lower arm bal joint » scoring enue Pron’ shock absorber piston rod suspension support Swspension support body Fron shock absorber x stering knuckle Steering kaucHle x alse brake sent cover Diireshatt front axe hut 9.0~ 120 (és = 868) Diss wheel x front ave hab —182—