NISSAN SKYLINE MODEL R30 SERIES SERVICE MANUAL SUPPLEMENTQUICK REFERENCE INDEX aa CL ci} MAINTENANCE ul ati Tae Le fa ose R30 Series farina i This supplement contains information con- cerning necesary service procedures and ENGINE REMOVAL & INSTALLATION eR relevant data for the model R30 series face- a aM Te es All information, illustrations and specifica- tions contained in this supplement are based nce fon the latest product information available at the time of publication. If your NISSAN model differs from the specifications con- MANUAL TRANSMISSION Ll tained in this supplement, consult your NISSAN/DATSUN dealer for information, OU CRGEO SST n The right is reserved to make changes in specifications and methods at any time with- PROPELLER SHAFT & DIFFERENTIAL CARRIER PO ‘out notice. LANL FA Ue eae NA NLD ct PU RULS BR STEERING SYSTEM ---s--ss---0000 ve ST Ld ld NISSAN MOTOR CO.,LTD. Cate La tl) 1983 NISSAN MOTOR CO.,LTD. Printed in Japan Not to be reproduced in whole or in part without hie {he por written permsson of Nisan Motor Com ELECTRICAL SYSTEM us pany Lids Tokyo, apan. ece HOW. TO USE THIS MANUAL > This supplement is designed to give you the new service procedures, service data and specifications for the face-lifted model which has been in production since September, 1983. D> The supplement, however, does not contain some chapters which remain unchanged from the Service Manual “Model 30 Series (Pub. No.: SM2E-0R30GO)" > Follow the instructions below when using the Service Manual. See specified section titles in the QUICK REFERENCE INDEX of this supplement and check whether the background is black or white. 4 + Pea wise bneouieg on erica Gate STD |” Retr tothe already published Service Only the revised points are introduced in these Manusl(s) and.Technical Bulletin. chapters. IMPORTANT SAFETY NOTICE The proper performance of service is essential for both the safety of the mechanic and the efficient functioning of the vehicle, The service methods in this Service Manual are described in such a manner that the service may be per- formed safely and accurately. ‘Special service tools have been designed to permit safe and proper performance of service. Be sure to use them. Service varies with the procedures used, the skills of the mechanic and the tools and parts available. Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by NISSAN must first completely satisfy himself that neither his safety nor the vehicle's safety will be jeopardized by the service method selected.MODIFICATION NOTICE : Major modifications made in MODEL VARIATION ate as follows: © A model equipped with an L28S engine for general areas tas been adopted. © A model equipped with an L18S engine for general areas has been eliminated. © For Australia, L4N71B (Automatic transmission with lock-up mechanism) has been newly adopted. DIMENSIONS GENERAL INFORMATION Destination Except for Australia Australia, Body Sedan |Hatchback | Hardtop | Van Sedan |Hatchback Engine u20n | Laas] vas | taas | tess | i208 | tame | Lame Item Grade cox | ot | ox | or | crx | cox | ot | or 4,620 4,620 459s | sis) | 4620 | (gis) | 4620 | 439s | 4620 | 4620 Overalltength_ mm") ) i309) | aris | asia) | 4718} (1819) | (180.9) | C819) | (81.9) (135.91 (185.6941 1675 1675 1,665 | 65.9)*2 | 1,675 | 65.92 | 1675 | 1665 } 1675 | 1675 Overall width mm (in) | 5.6)63 | 1690 | 5.9) | 1690 | 5.9) | (65.6)%3) (65.9)*2] (65.942 (66.5)"1 (66.5)*1 1400! 1390 | 1390 | 1300 | 136 ' 1415 | 1390 | 1,390 Overall height mm iM) E51) | Gary | Gar | Gir | G37 | G57) | GAN | G42) ‘Wheelba 2610 | 2615 | 2615 | 201s | 2015 | 2615 | 2615 | 2615 eelbase mm (in) | (o2.8) | (103.0) | 03.) | (03.0) | (103.0) | (403.0) | (103.0) | (103.0) hi | to | tsio | isio [ taio | 140 Tiaio | ato | iio oat mm (in)} (55.5) | (35.5) | (35s) | G58) | G55) G55) | (S55) | G55) Tread R Gy) £59 | 1400 [1400 [140071400 [1390 | 1395 | 1,800 ear mmis)) ary | 3s. | Gs.) | Gt) | G51) | G47 | G49) | BS) Min. ground creas (iny | 175.69) | 16006.) | 160 (6.3) | 160 (6.3) | 160,66.3) | 1505.9) } 160 6.3) } 16066.3) ls00 (35.4) [900 (35.4) Front mm (in) 875 34.4)| 942. f900635.4){ 942 [o00 (25.4) 875 (34.4) 900 (35.4) 900 35.4) ryt @7. Overhang | 1,105 1,105 k y{ unio | 3s) | tins | G35) | ios | atta | tos | 10s eer mmm) | 437) | 1153 | 435) | 1153 | 3s) | 43.7) | Gas) | 435) Gas.ays | (as.ayr 7 For Middle East *T Models equipped with colored bumper GI-1 *3 Models equipped with black bumperMODEL VARIATION Model Road wheel Deste | Body [Grade Engine | Trans: [Differential |e ofiset | Tire size ration Linge ) Ri dive mvasion | carer |S . Shed ; ; 25(0.98)*1 |6.45-14-4PR px] pLinaove | wRs0vFU|1208 | c.g) 1190 et ee es Sedan 25(0.98)*2 MRSOHFU | cr MERSONF L2as R180 5 [ON Ditesonig[orsonat 3N7IB saps 2 NERSONF = ..28 (0.98)*1 < crx Lass. 200 / & [itardtop KNLRQOHF — FSSW71B S.1/2bxtg |!85/70HRI4 = GRIRGONFUT 25 (0.98)*2 30H | RMR3OM £ | watchback |r [RMLR OEY | 124s R180 & RMERIONA | RMR3OHAU SND _ oto ayes [845514488 Van cox |veLiRsove] = — | L208 jmp 9° | Shpannera [ISSR 73 Fssw 240% 708K 4 26 (0 9521851 70SR1543 = MR30HFEM S1/2HIx14 | 1g5/70HRI4 | Sedan 5 (0.98)*1 195/708 R143 2 - HAEM ANTIB é or MRSO) ime R180 SA/2Hx14 |b 9s/60R15- 3 - RMR30HFEM, FSSW71B 25 (0.98)"2| ggnie3 = | Hatchback 61x14 = __ | RMRSOHAEM LANTIB 25 (0.98)*2) 1: Steel road wheet "2: Option (Aluminum road wheel) *3: Option Prefix and suffix designations Lo K : Hardtop Us RH drive (Except for R: Hatchback Australia) Vi Ven M> For Australi + Sedan O: LM. drive B ! L20B engine Br EFL M>: L245 & L24E engine Os Carburetor N = 1285 engine F + S-speed manual trans mission Ls Lit drive OD: RH. drive —_ A's Automatic transmission J: 44k V + Custom Deluxe model a: 1RS Hs GT or GTX model 1: means no indication. GI-2APPROXIMATE REFILL CAPACITIES ENGINE MAINTENANCE Retightening cylinder head Checking and adjusting drive belts Maintenance procedure for L20B, L24S & L28S Maintenance procedure for L24E Replacing fuel filter MAINTENANCE CONTENTS Checking electric fuel pump filter and fuel filter (For Middle East) Checking fuel lines (Hoses, piping, connections, etc.) SERVICE DATA AND SPECIFICATIONS wos MA-1 Engine maintenance Chassis and body maintenance MA. 9 MA. 9 Mat MAI MAASAPPROXIMATE REFILL CAPACITIES APPROXIMATE REFILL CAPACITIES Liter Imp measure Fuel tank Except Van 65 14-1/4 gal Van 55 12-1/8 gal Coolant With heater 1208 85(75) 71/2 at 5/8.40) (Without heater) 124 & Las 9.0180) 7718 gt (7 ad) Reservoir nk 05 12a Engine With ol filter change L208, 38 3.3/8 qt L24& 128 50 43/8 gt Without oll iter change 1208 33 27/8 at 124 & 128 45 4aqt ‘Transmission MIT 4-speed 17 3pt Speed 20 Bj pt AT 35 7/8 at Differential carier Hi6se 1 2et ‘Sedan (11199) 1.0 13/4 pt Hardtop (R180) 10 13/4 pt Power steering system RED. 08 1.3/8 pt LHD. 10 13/4 pt Air conditioner system LB. drive ous 53floz Compressor oil RH, drive 0.20 7.0 floz Refrigerant 08-10kg 18-221 MA-2ENGINE MAINTENANCE ENGINE MAINTENANCE RETIGHTENING CYLINDER Units_mm (in) HEAD Adjust deflection of | Set deflection of Retightening should be done while en- used belt new belt ine is cold [approximately 20°C (68°F). 1208 |10- 1339-051) | 7-10(0.28-0.39) Alternator Tightening order 124.& 128 | 7-10(0.28-039) | 6-9(0.24-035) 2 : 0.43) | 6-9(0.24-03. ies ‘Aieconditioner t208__ | 8-11(031 -0.43) | 6-94 5) ®@ © 22 @| somes L24& 128 | 5-7(0.20-0.28) | 4-6(0.16-0.24) TFT FFF! Power steering oil bone 124& 128 [11 -14(0.43 -0.55) | 9-12(035 -047) ee 6 © 6 6 8)! Applied pushing fowe —N (kg, 1b) 98 (10,22) ®8 OHO OO 1, First loosen each cylinder head bolt slightly 2. Retighten cylinder head bolt. @:74-83Nm (75-85 kom, 54-61 feb) CHECKING AND ADJUSTING DRIVE BELTS 1, Visually “inspect for cracks or damage. The belts should not touch the bottom of the pulley groove. 2. Check belt tension by pushing. The belts should deflect by the specified amount, $ 16-22 116-22, 12-16). IS oll pump. an (os- 14, 58-80) OP + Nem (kgm, 4) 3. Adjust belt tension as follows: Fan and alternator belt 1. Loosen the upper and lower alter- nator securing bolts until the alterns tor can be moved slightly. 2. Move the alternator with a prying bar until the belt tension is within the specified amount. Then tighten the bolts securely. MA-3 Altemator @ 1208 26-50 g7-51, Crank pulley AIC compressor 27-37) 18-22 (15 -22,12-16) Air conditioner compressor and power steering oil pump belts 1, Loosen the idler pulley lock nut. 2, Adjust the adjusting bolt until the belt tension is within the specified amount. 3, Tighten the idler pulley lock nut securely.ENGINE MAINTENANCE MAINTENANCE PROCEDURE FOR L20B, L24S & L28S WITH “CO”-METER Timing indicator Star engine and warm up engine unt water temperature indicator points co the middle po fewpes of gauge, tv load, then run engine for one minute at Race engine two oF three times under no ing sped, q (Check idle speed, IDLE SPEED: rpm Trans ition) gary position) Engine 1208 700 ‘Check ignition Uming with timing ight Ignition timing (8.7.0.6. degree) t L208 & L24: 10° 2s: e (Cheek "CO" with “CO” meter [n a Adjust ignition timing by turning distibutor after loosening bolt Which secures distributor Idle “Cor 2% lox. NG. ‘Adjust ile “CO"% by farming ile | austin ser END MA-4WITHOUT “‘CO”-METER “Timing indicator as ENGINE MAINTENANCE START ‘Star engine and warm up engine uni water of gauge q lad, then run engine for one minute at idling speed. t ‘Check idle speed, [ILE SPEED: rem “rene sion! ye (AUT in” a position) Engine 208 700 = 0 ws 650 50 ize 650 350 Hong Kone Ox NG ‘Check ignition timing with timing Hest Tonition timing (8.7.0.6. degree) 10" a Ox. ‘Turn out idle adjusting srew approximate: Adjust engine peed by turning throttle ad isting serew. Engine speed: rom Race engine two or three times under no-—_[* ofr temperature indicator points tothe middle, -—=—=—}> ‘SMAa6S swaase ‘thrott jsting sere. Log ‘Adjust ignition timing by turning Aistibutor after loosening bolt which secures distributor. Trans inion | sayy 1208 700 650 Lz eo. a 650 Hong Kong ® MA-5ENGINE MAINTENANCE ® ee “Turn the idle adjusting serew until engine uns smoothly at highest speed a Does engine speed not raise in spite of uring ile adjusting sere ‘SMAI6? speed is obtained WWLe sre Mit: 650 AIT: 700 lin “N" position) MAINTENANCE PROCEDURE FOR L24E. CHECKING AND ADJUSTING IGNITION TIMING 1. On air conditioner equipped mod- inspections should be carried ‘out while the air conditioner is “OFF”. b. Inspection should be carried out while shift lever is in “Neutral” position. Be sure to engage parking brake and to lock both front and rear wheels with wheel chocks. 1. Warm up engine until water tem- perature indicator points to middle of gauge. 2. Race engine two or three times under noJoad, then run engine for one minute at idling. 3. Check idle speed. 700 rpm ‘Automatic Transmission 750 rpm (in “N" position) If necessary, adjust idle speed to the specified rpm by turning idle speed adjusting screw attached to throttle chamber, “Turn in idle adjusting serew until engine idle ‘Nor For Hong Kong smaras| 4, Check ignition timing with a ® Yes ‘Not Except Hong Kong If necessary, adjust ignition timing by turning distributor after loosening bolt which secures distributor. timing light. Ignition timing ‘Manual Transmission 10° B.T.D.C./700 rpm Automatic T ion CHECKING AND ADJUSTING 10° B.T.D.C./750 rpm IDLE RPM AND MIXTURE {in “N" position) RATIO. CAUTION: Idle mixture ratio is adjusted at factory and requires no further adjustment. If it becomes necessary to adjust it, proceed with the fol- lowing steps. bb. Before disconnecting and connect: ing EFI component parts harness connectors, ensure that ignition switch is in “OFF” position, MA-6ENGINE MAINTENANCE OH rae’ ———————— ‘a. On air conditioner equipped mod- b, Inspection should be carried out while shift lever is in “Neutral position. Be sure to engage pa brake and to lock both front and rear wheels with wheel chocks. &. When checking idle mixture ratio {CO percentage), make sure that the following parts are in good order. Battery Ignition syster Engine oil and coolant levels Fuses EFI component parts EFI harness connectors Hoses il filler cap and ol level gauge Valve clearance, engine compres- sion (with “CO” meter 1. Adjust idle speed and ignition timing, referring to Checking and Ad: justing Ignition Timing, 2. Check “CO™ with “CO”.meter at idling speed. Idle “CO”: 1.0% or lower 3. If specified idle “CO"% is not ob- tained, adjust idle mixture ratio as de- scribed below. (1) Turn ignition switch to “OFF” position, (2) Disconnect throttle valve switch hharness connector, (3) Connect a lead wise, between ter- minals No. 24 and No. 30 of throttle valve switch harness connector. suaorral a. The idie mixture ratio of EFI car is set s0 lean that “CO"% remains almost unchanged when adjustment is made under normal condition, ‘Therefore, when adjusting idle mi ture ratio, to distinguish variation in "CO"%, a full enrichment must be temporarily given to idle mix ‘ture setting to make it richer. b, Make lead wire as follows: Use flat plate terminals 3 mm (0.12 in) wide, 0.8 mm (0.031 in) thick ‘as male terminals. Place flat plate terminals parallel with each other ‘and keep distance between i faces 2 mm (0.08 in), Solder lead ‘wire to each terminal and wr insulation tne around soldered portion. (4) Warm up engine sufficiently, race engine two ot three times under no- load, then run engine for one minute at idling speed. (8) Adjust “CO"% to altitude at measured point by turning air by-pass screw on air flow meter. MA-7 Altitude Tale COs Ms ull enrichment) 0-600 | (0-2,000) Ae 600 1,200 900 "4,000) At 1,200 - 1,800 (4000 - 6,000) 57% ‘Above 1,800 (6,000) | 97” 1 Al by-pass screw: Turning counterclockwise — Leaner ‘Turning clockwise — Richer b. When adjusting ““CO"%, remove blind plug from air by-pass screw. After adjustment, install the plug on air flow meter. (6) Stop engine and remove lead wire and connect connector back to throttle valve switch. (7) Check idle speed. If necessary, ad- Just it to specifications (8) Check “CO%” if it is within specifications. (Without “CO”-meter) Altitude of measured point; {600 m (2,000 ft) or less 1. Adjust idle speed and ignition timing, referring to Checking and Ad- Jjusting Ignition Timing. 2. Turn ignition switch to “OFF” position, 3. Disconnect throttle valve switch harness connector.ENGINE MAINTENANCE 4. Connect 2 lead wire between ter minals No. 24 and No. 30 of throttle valve switch harness connector. ‘The idle mixture ratio of EFI car is set so lean that “CO'% remains almost unchanged when adjustment is made under normal condition, Therefore, when adjusting idle mixture ratio, to distinguish variation in “CO"%, a full enrichment must be temporarily given to idle mixture setting to make it richer. 5. Warm up engine sufficiently, race engine two or three times under no- load, then run engine for one minute at idling speed. 6. Adjust mixture ratio with engine speed set at maximum by turning air by-pass screw, When adjusting mixture ratio, re move blind plug from air by-pass serew. After adjustment, install the plug on air flow meter. 7. Stop engine and remove lead wire and connect connector back to throt- tle valve switch 8. Check idle speed. If necessary, ad- Just it to specifications, Altitude of measured point; £600 m (2,000 ft) or more 1, Adjust idle speed and ignition tim- ing, referring to Checking and Adjust- ing Ignition Timing 2. Turn ignition switch to “OFF” position. 3. Disconnect water sensor harness connector. 4, Connect resistor between. termi- nals of water temperature sensor har ness connector. temperature Swagzaa— hamess connector Resistor smazit a. The idle mixture ratio of EFI car is sat so lean that “CO” percentage re- mains almost unchanged when ad- justment is made under normal con- dition, Therefore, when adjusting le mixture ratio, to distinguish variation in “CO” percentage, a cer- tain amount of enrichment must be ‘temporarily given to idle mixture setting to make it richer, b. When adjusting idle “CO”, select proper setting corresponding to alti- ‘tude as mixture ratio varies accord- ing to altitude, Accordingly, resis- ‘tor should be made to suit measur- ed altitude mt, [Romane m (ft) pote cet eyo ney | 8 MA-8 6. Set up resistor as follows. 1) Prepare snap connector plug, snap ‘connector socket, lead wires and resistors shown in above table. 2) Solder lead wire to connector. 3) Solder resistor to side opposite to connector and wrap insulation tape around soldered portion. CAUTION Be careful that hands or harnesses are ‘not caught in cooling fan. 5. Start engine, race engine two or three times under nodoad, then run engine for one minute at idling speed. 6, Adjust mixture ratio with engine speed set at maximum by turning air by-pass screw. When adjusting mixture ratio, re move blind plug from ai screw. After adjustment, plug on air flow meter. 7. Stop engine and remove resistor. ‘Then reconnect EFI harness as it was before. 8, Check idle speed. If necessary, ad- just it to specifications. REPLACING FUEL FILTER L208 & 24 (Except for Middle East)CHECKING ELECTRIC FUEL PUMP FILTER AND FUEL FILTER (For Middle East) CHECKING FUEL LINES (Hoses, piping, connections, etc.) L208 & L24 (Except for Middle East) ENGINE MAINTENANCE L28& 124? jf Fuel return Ful feea Power steering models ‘To ful From fuel tank 4 ve Fuel filter Electrical fuel pump MA-9ENGINE MAINTENANCE 24 & L.28 (For Middle East) Fue return solenoid ‘To fuel tank rom fuel tank Fuel iter lectical fuel pump sMasz0a Fuel renum solenoid ‘To fuel unk PB + > ++ +4 7 + From atk a8 oe tt poate testi fn pump MA-10ENGINE MAINTENANCE SERVICE DATA AND SPECIFICATIONS SERVICE DATA AND SPECIFICATIONS INSPECTION AND ADJUSTMENT Basic mechanical system Intake 0.25 (0.010) Hot Voter clearance Exhaust 0.30 (0.012) con in Intake 0.20 (0.008), cous" | Exhaust (0.25 (0.010) Drive elt deflection Refer to MAS. kPa (bar, kg/em?, psi) 6? NT, 1A, ‘These values are massured when engine is cold and ambient temperature is 20°C (68°F) Alter checking valve learance while engine is cold, also hack them when engine ie Met tose if they remain with In the specified range. If they do not readjust them, Ignition and fuel system susoayn | BS os os seem Tt ve van om case os, as oes Prsibutr Dwell angie degree 35° -41" 49° - 55" MA-11SERVICE DATA AND SPECIFICATIONS ET (e 28 Lae L208 ~. Exceot Hoceteang | Mona Kena Tontion timing and | Manual transmission models 8/650 10° 650 10"/700 10°/700 ile speed ‘Automatic vansmission models 7.0.6. degree/tom | fn position! - roreso | 10%1700 1/750 - 39% "CO" % at ialing speed eo ~ oy (ith oir - enrichment) Type NBO Voltane v 2 Capacity AH EJ Beutery Pesmissive ; Etectroly-| value 70 te gravity atz0"¢ | Fully {ee"F)) | charged 126 value TIGHTENING TORQUE Unit Nm kom feo Cylinder head bot vacaa [75-05 | S461 ma | 16-25 | 15-26 | 11-18 Bolt Manifols mio] s4-aa | 35-45 | 25-33 Nut 12-16 | 12-16 | 9-12 26-36 a exnaust | 124.128 27-37 | 20-27 tbe L208 20-25 | 20.25 | 14-18 ‘Carburetor nut 8-7 | as-07 | 36-81 Pivot lock nut 49-59 | 60-60 | 36-43 (il pan drain lug 20-20 | 20-30 | 14-22 Spork plug 16-20 | 16-20 | 11-14 Fugt hose clamp (1248) | 1.0-1.5 [0.10-0.15 | 07-14 ene (0.12 in) Fusl hose clamping postion. craven MA-12SERVICE DATA AND SPECIFICATIONS CHASSIS AND BODY MAINTENANCE INSPECTION AND ADJUSTMENT clutch {Units mm (ind Pedal height "H” 146-156 (5.75 6.18) Pedal tree play “ 1-3 (008-012) Floor carpat Brake nits mm tind 146 - 156 (6.75 -6.14) Free play “A 1-3 (0004-0.12) RHO. Depressed height “4” L208 engine More than 100 (3.94) Under force of 490N L24 engine More than 95 (3.74) (50 kg, 1101) with CHO. engine running] 1208 engine More than 105 (4.13) [24 engine More than 100 (3.94) Floor carpot 22h insulator ath insulator a Hs Pad fee height AA: Ped fee travel ‘Dash floor panel Male sheet SMASsCA hh: Pedal free height H: Depressed height ‘Dh floor pas Differential carrier (Model R200) SMAsa7A Oiteapscity ia about iter (Imp pe) 1a aaa) MA-13.ENGINE MECHANICAL SERVICE NOTICE © The L28S engine is now installed in models destined for the Middle East © Crankshaft pin journal diameter and connecting rod pin diameter have become engine model. Refer to $.D.S. for details © The L18 engine has been eliminated. maller on L24E EM-1TIGHTENING CYLINDER HEAD BOLTS ‘© Tightening order 124.& 128 1208 ENGINE MECHANICAL © Tightening procedures (1) Tighten all bolts to 29 Nem (3.0 kg-m, 22 fttb), (2) Tighten all bolts to 78 Nem (8.0 kgm, 58 ft-lb), {3) Loosen all bolts completely. (4) Tighten alt bolts to 29 Nem (3.0 kgm, 22 fib). (8) Tighten all holts to 74 to 83 Nm (75 to 85 kom, 54 to 61 feb) or if you have an angle wrench, turn all bolts 90 degrees clockwise, ‘a, After engine has been operated for several minutes, retighten if neces- sary. b When performing normal mainte- ind inspection, first loosen each cylinder head bolt slightly, ‘then tighten to a torque of 74 to 83 Nm (75 to 85 kgm, 54 to 61 ftlb), (This should be done when engine is cold). EM-2SERVICE DATA AND SPECIFICATIONS SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT Engine model ize | uzae | czas] 1208 CYLINDER HEAD Unit: em kn) ‘ylinder 7 “aint ‘erangement Sinting tine Standora Tinie Displacement 2,753 2393 1,952 oad surface flatness Less than 3. fem? fev int | (167.99) (146,02) cian 0.05 (0.0020) (0.008) Borexstroke | 86x79 3x 737 | 85x86 mm{in) | (339%3.11) | (9.27 x 2.902) | 13.95 x 3.39) VALVE Valve one, Units mem find Firing order 624 13.42 ‘ Number of piston rings a {Compression 2 ow 1 Number of o ‘main bearings 7 5 Comereion 26 39 as ——- sem Engine mode! rr 124 & 1208, Valve head aiameter “D" Iotake 44.0(1.792) | 42.01.6548) Exhaust 35.0 (1.378) Valve length“ mar 116.05 - 116.65 (4.5689 - 4.5925) Exhaust 117.05 - 117.65 (4.6083 - 4.6319) Valve stem diameter “a Intake 7.965 - 7.980 (0.3136 -0,3142) Exhaust 7,945 - 7.960 (0.3128 0.9134) ‘Valve seat angle 4500 Valve margin ume 0.5 (0.020) ‘Valve stom end surfoce Finding Himit 8 (0020) Valve clearance Hot {*Cold) Intake 0.26 10.010) {0.20 (0.00811 Exhaust (030 (0.012) (0.26 (0.0101) EM. “Cold Used as approximate values during engine sssombly, clasrances should ultimstely be acted to tho above hot values, refer ta Section MA for procedures, 3SERVICE DATA AND SPECIFICATIONS 0 ernment Oe Valve spring Valve guide —_— Unis: em (in Free height enfin) ‘Outer spring 49.98 (1.9677) ‘Standare Serves Inner serng “44.85 (1.7657) Valve guide 12028-12.034 | 12.223. 12.234 - | ‘Outer diameter (0.4733 -0.4738) | 10.4812 0.4817) Pressure height imiN vk, it) Valve guide 29,51480.5 Inner diameter 8,000 -8.018 (0.3150 - 0.2157) uree spring (29.5/4900, 1.161/108.0 [Finished size] 24,5/250.1 (Cylinder head waive 11,985-17.996 | 12185-12196 Inner sorina (24.5/25.5, 0.965/56.2) guide note lameter (04718 -0.4723) | (0.4799 - 0.48021 ‘Assembled height oniN roi, 3) Outer spring Out of square (5°) me lin) Outer Taner spring 1.210.087) 40,0/208.9 8.071206 (950/123, 1378/27.1) 2.2 10.0871, (40.0/21.3,1.575/47.0) EM. 4 Interference fi of valve Stem to guide clearance Intake (0.0008 0.0021) 19.0006 = 0.0021) | Exhaust ‘avi deletion limit (0.027 - 0.049 (0.0011 - 0.0019) ‘Standard 0.020 - 0.053 0.040 - 0.073 12.0016 - 0.0028) Max. tolerance 101 (0.008), (02 (0.008),SERVICE DATA AND SPECIFICATIONS Valve seat “vo en it INTAKE 0 Le Standars y ; Standard xk / U8 A LNe baa 1s cose) 280 (1.490) — 388 888) eee - erie Lane ir 620) aa 4 senaas 43.8 (1,724) dia. Meet Oversize 45,500 - 45,516 (1.7913 - 1.7920) aia. [0.510.020 Teynnder head) 04 (ore) 15 a hes oo) 45.500 AS Sie Pia 1.7020 i {Cylinder hae seuss | 418 1.0 a 43.8 (1,724) dis, EXHAUST SEMz26 Standard 128 ns (o.osen) 34,6 (1.362) dia. - 39.0 (1.535) di 8 (te) Seer oy) 97800>97,816 9 4766-14770) da 4 BT y S077 Teter ea sewaea | | Ro 10.016), Roa 19 ote) a ‘ears ws 2 (0.501 _ 246 (1.262) dia sewaa7 (200 11.538) i F388 PS ge AB Ne) Se .s00 45 6 1 19 1.7920) dn ‘yinge ad Vaeun [intake | 00081-0179 (.0002- 0.0048) seM28e interference fit | exaust | 0.064 - 0,096 (0.0025 - 0.0038) EM-5SERVICE DATA AND SPECIFICATIONS CAMSHAFT AND CAMSHAFT BEARING Unit: mm tin) ‘Standard | Wox tolerance Camshatt journal vo 0.038-0.067 bearing clearance (0.0015-0.0026) | _%" (9.008 Inner ameter of "48.000 - 48016 ‘eomahalt Beseing (1.8898 - 1.8904) - ‘Outer diameter of "47.949. 47,962 a ‘camshatt journal (1.8878. 1.8983) ‘Camshaft bend ‘ess then (urd 0.02 (0.0008) | 08 (0.0020) Camshaft end play 0.08 -0.38 (0.003 -0.0150) CYLINDER BLOCK Units mm tind eras ‘Model [__28 a] toe Surfce Hotness Standard than ewes Les than 0.05 (0.0020) Wear tit 0.19 0.0089) (0 2aE & Mod) us | uzas | WSS ‘lind bore 18,.000- | 83.000. | 35.000 ‘Cam neigh “A Inner aiameter soso | ose | 95.080 3995- 3aesa- | @.2677- | (33465. 40.00 3.3878) | 3.297 | 334a4) Innake (ne sme | 2095" | 4020- urotround OY Less thon 902 (0.0008) qos. | (15728. | (1.5866 Taper (88) Les then 0.02 (00008) ‘tos | 15748) | 15886) Exhaust os Diflerene in inner 5866 siameter between Les than 0.05 (0.00201 - evlinoors Wear iit of cam eight 0.15 (0.0088) Pion wevinaer —_—— et irre 0.026 -0.088 (0.0010 -0.0018), ‘Valve timing TT {Cylinder finer for service Unit: mm tind 28 tae | toe Outer dameter of evlinger ner for serves 9000. | 87.00- | 99.00 mao 400157) 8005 | eros | esas Undersize .5433- | (34252- | (3.5039 _ Units dere sass) | 34272) | 3.5059) efetetate tt s50- | e7s0- | eso. 45 (017) voss | 375s | 9955 eS ze | oo [2 | as | 4 | Undersize 3.5620. | saaa9. | 3.5206 Las zo | 22 | 8 | a | 10 | 60 axeso) | 3.4ese) | a.s2s6) tae arzoe | 2 | 20 | | o | 4 | e100. | e800. | 90.00 500197) 1.05 | aos | 2005 Undersize (3.5827- | (sases | (a5e33 seas) | 34865) | 3.5450) EM-6SERVICE DATA AND SPECIFICATIONS PISTON, PISTON RING AND PISTON PIN Piston eure Unit: am ae Lae Laas 208 a 95,965 - 66.05, . 94.965 85.015 Stondar 5.985 86.015, 82.965 - 83.015 13.2663 - 3.2683) ee ee ona 95,985 - 86.095 (04 985 85.095 mon ste Stamaarg | 05988 -960005, 62,985 - 69.095 (3.2671 - 3.2691) eg35 86.035 ameter “A” | Oversize 98.065-86.515 85.465 - 85.515 yess 06 (0.020) | 88485-88515, 89.465 89.515 (3.2860 - 3.2860) Se ses 26.965-67 018 15.965 -86.015 1000s) | S8965°87 015, 83,965 - 88.016 (3.3057 - 5.3077) err * dimension ‘About 20 0.79) 21001-27008 | 20003-20012 Piston pin hole sameter eee oo 21.001 - 21,008 (0.8268 08271) Piston clearance to evinderbioek 0.025 -0.048 (0.0010. 0.00789 Piston ring Piston pin Uni: ram Gn) Units tom in 128, L245 Siondera , Lae (208 Limit laa 26% | 208 uton pin out diomewer | 19995-20.000 | 20.999 20.998 " (0.772-0.7874) | (0.8265 0.8267) Side clearance x - 0.040 - 0.078 Zeton pla to piston 0.008 - 0.012 0.0003 - 0.0005), Top (oto 0073 Jo 10008) clearance 0030. | 0020 Inerference fit of piston | 00017-0038 | 0.015-0.033, “ 06s | ‘0070 Bin to connecting rod | (0.0007 0.0015) | (0.0006 0.0013) on (0.0012. | jooo12- |" 904 0.0028) | 0.0028), oa Combined ~ Fine ov 0.25-0.40 Tor ° (0.0098 -0.0157) _|1-2 (0.099) 015-030 2nd (0.0059: 0.0118) |*-0 (0039) Vain 03-08 OF ait ina (0012-0035) _ {1-0 (0039) EM. 7SERVICE DATA AND SPECIFICATIONS CONNECTING ROD CRANKSHAFT unit: mm tind Unit: me tin ‘ode (28 ] ae | v2es | L208 - ize | wae | zs | L208 130.35 146 ‘center distance 13995 | r93 45.28 | ig ony so08 = “om 94.982 54.955 99.955 ‘Bend, Torsion ‘Sele Tepe. “On (21631-2.1636) (2.3590 [per 100 rm (3.94 i) 2.3608) Standord Las than 0.025 (0.00101, —_— ere s9.961- [44.961 Limi (0.05 (0.0020) in journa da. "0p 4974 | 44.974 | 49,961 -49.974 - ' "11.9670 -t1.7701 -| (1.9670 - 1.9675) 720.965 -] 19.965 1.967) | 1.7706) hi ove ti 20.978 | 19.978 | 20865-20978 ‘ston pin ove cin (0.8754 .|(0,7960.-| (0.8254 0.8259 ve 39,0) wa 43,00 ‘cece’ |o.7688) ‘Genter distance “+ eraser | 388800480 | tap Big ond play Outofround OY) Stonderd 02-03 (0.008 -0.012) and taper (AB) —_———— stoncars Less than 0.01 Limit 06 (0.024) aes | of" Rano — Limit 10.03 (0.00121, Bend (T.1F.] ‘Standard Les than 0.08 (0.0020), 0.10 (0.0039) Free ond play Srandacd 0.05 -0.18 (0.0020 - 0.0071) Umit (030 (0.0178) Pilot bushing insert Hot Approximately 4.0 (0.187) om Dp ema? Ouratround XY ‘Taper a8 ews EM.SERVICE DATA AND SPECIFICATIONS BEARING Connecting rod bearing undersize Units mm tnt Bearing clearance Unies mm Gin] ran pin Journal diameter Sanaa Time (2He (28, L285 a 208 Tan bearing clearance Senders ‘aaast-aao7e | 4061-40074 vont vas wearing | 0020-0.082 (9.7701 1.7706) | (1.9670 1.9678) * | (0.0008 - 0.0024) ‘aagor-aaare | 42001-0914 (096 (0.0028) Undersize Inter & center 0.020 - 0.075 / Unde (1.7678 - 1.7683) | (1.9646 - 1.9651) bearing 10.0008 0.0030) eee Lene 0.12 (0087 ‘aaeay -aagse | a0ea) 49.58 Connecting rod besring (012 (0.0047) Undersize | 19 7654. 1.7669) | (1.9622 1.9628) 0010-0082 grasa | 44711-44720 | 49.711-40.726 L28e (0.9004 - 0.0020) 028.00 ) Unders (1.7603 - 1.7608) | (1.9571 - 1.9576) 020 0086 deine | 48861-44476 | 49061-0474 LB, 1245.8 1208 | «0909 9.9026) 050(0.0197) Undersize | 14 7504 1.7509) | (1.9672. 1.9478) ‘aaziv-4e.z26 | 49.211. 49.228 (0-75 (0.0295) Undersize | (1 7496 1.74114 | (1.9974 - 1.9379) Main bearing under " Unit: mm (ind 41,00 40,0394) Undersize | 43:961-43.974 | 48.961 - 48.974 (3207 -1.70%2) | (1.9276--1.9281 rank main journal dameter 28 & C24 208 ena si.982- S405 | 59.942. 69.955 : eiest-2tece | (29508 23800) MISCELLANEOUS COMPONENTS lo Unit men tn s#.652-54.705 | 59.692. 59,708 0.25 10.0088) Undersize | (21592. 2.1597) | (2.950% - 2.806) Camatat sro, Les than 0.1 (0.008) saa2. 64.455 | 69442-60455 — 0.60 (0.0197) Undersize | (> s4zq..2.1499) | (2.3402. 2.34071 Fernie ind Less than 0.15 (0.0059) 4.192. 68.208 | 69.192. 69.205 ——— 0.75 (0.0298) Undersize | (9 1395. 2.1361) | (2.3908 - 2.3309) “ganna | 53982,59955 | 50.062. 50.056 1.00 (0.0394) Undersize | 19.4997. 2.1242) | (2.3205- 2.3211) EM-9TIGHTENING TORQUE SERVICE DATA AND SPECIFICATIONS ac ve [em [ew einveringcapvor | aaa | a5-a8 | 99-40 Themmovainowing | ta-z0 | 12-20 | 9-14 oomsine wade | cg | ance | sana a vo se Aywnesborw | 197-157 |rea-te0 [101-16 Orpreswresendng |g. 4e | 1918 | 712 Drive plate bolt (A/T) | 137-157 |14.0- 16.0 | 101-116 ontorevich Anerorbaster | 99-89 | 40-60 | 29-40 wav | 20-29 | 20-80 | 14a ron" Tweens | v216 | vate | oi corpo SMS | 20-9 | 20-a0 | 14-22 me | 5-10 | o-10 | 36-72 Engine mounting Cylinder heed Refer to page EM-2. brecket ae [owe | 2® exinareesrotont |g. | op-sa | sa-sos Cararate montorre | gp [06-10 | 4a.72 Poorbuningvar | 70-118 | 60-120 | 68-07 Pot ack nt wes) | 60-60 | 26-09 Camsiaeeproskerton | 127-147 [190-780 | 98-108 hain ude bot e109 | os-t0 | «ava Grain wrsionervor | 6-10 | 08-10 | 43-72 Feel pump nt wie [tie | Orpump bot wis puis | en nao | ab-29 | 20-00 | aa wer nomo Fear | 1216 | a216 | 9-2 we si | as-t0 | a0-72 ais pump uleysua | 6-10 | 08-40 | 48-72 Wort bot toi | to-8 | 7-12 [Berkouiersa [veer | v216 | ernie | Oierine bat woe | tone | 7-72 tear bo oi | obta | aava Gieandainoig | 20:20 | 20-00 | wart uchcom [om | 20-00 | 20-30 | wae vot [RE eat | teas | vais Ronco | 1016 [10-16 | 7-12 Sea pe 1520 | v8.20 | ve [ Mi0bolt*| 34-44 | 35-45 | 25-33 enol boreeon | v5.25 | 18-28 | 11-18 wenn | W216 [vase | ov [ater ove woe | to18 | 72 forteSERVICE NOTIC! ENGINE LUBRICATION & COOLING SYSTEMS ‘The L28 engine is now installed in models destined for the Middle East, and its service data is the same Gg as that of the L24 engine, ‘The L28 engine is equipped with an oil cooler. ‘The cooling circuit has been modified on the L24E engine on models destined for Australia due to the hot water type of throttle chamber. The engine for hot areas equipped with air conditioner has a condenser fan, Refer to section HA for details Lc-1ENGINE LUBRICATION SYSTEM ENGINE LUBRICATION SYSTEM LUBRICATION CIRCUIT —L28 engine— Note: <== # Oil galery in cylinder block = ~ By pass passage = 1 Oil passage Oi! pumo, ~ ¥ i filter | Regutatrvave it site fale ale Oil cooler relief vaive Oil cooler Cylinder head Main bearing oil gallery Crankshaft Camshaft bracket ‘Connecting rod Camshaft bearing bearing o a Conneeting rod Camshaft ft 1 il strainer Piston and Rocker arm ose evlinder wall Oil pump Timing chain drive gear [Chain tensioner and sprockets stcrsoENGINE LUBRICATION SYSTEM OIL PRESSURE RELIEF VALVE When removing oil filter, check valve unit for operation, Inspect for @ cracked or broken valve, If replace- ment is necessary, remove valve by prying it out with a screwdriver, Install a new valve in place by tapping it. sucsi0 OIL COOLER serene U7 Cee one Writ _ telt ave lay wim 7) sett valve = Eyl ieaites Se Sy I =e 9) | REMOVAL 3. Remove oie. 1 Drain coolant 4. Remove oil cooler assembly. 2. Remove coolant hoses Lc-3 5. Remove O-ring from bracket. INSTALLATION Install oil cooler in the reverse order of removal. Always use now gasket. 1 + Oil cooler fixing bolt 16-21Nm (1.6 -2.1 kgm, 12-15 ftlb) Aftor installing, run engine for a few ‘minutes, and check for leaks.ENGINE COOLING SYSTEM ENGINE COOLING SYSTEM COOLING CIRCUIT — L24E engine —SERVICE DATA AND SPECIFICATIONS SERVICE DATA AND SPECIFICATIONS ENGINE LUBRICATION SYSTEM GENERAL SPECIFICATIONS ENGINE COOLING SYSTEM GENERAL SPECIFICATIONS Tubrication method Presed fod How Coving method Watercooling, freed circulation Ok pump twee “Trochois ype Water pump type Centitugal Oi Finer ee Ful flow and earrdge wpe ‘Thermostat type Wax-pelet Oitcapeciy ——-tlimpat 208 | Waa Le Radiator type Corrugated fn and tube With ot iter 386s) | 501638) Cooling tan Fan di. x No. of blades without ol iter aa07e | asl ‘mm tind 350 13.78) x4 L208 380 (14.96) x 8 with INSPECTION AND ADJUSTMENT fui coupling it pump Units nm ind 380 (13.78) x4 £385 118.16) x7 With Rotor tp clearance Less than 0.20 (0.0079) Lae temperature coupling"? “410 (16.141 x8 With Ouwr rotor t body clearance @ | Less than 0.50 (0.0197), temperature couping’3 Rotor to straight edge (@) Less than 0.06 (0.00241 Coolant capacity & limp at) 208 24a LB Oil pump body to straightedge @ | Less shan 0.03 (0.0012) with heater 857172) | 901778) Without heater 751650 | 800) Fesorvoir tank 05 1172) “1: Modes for hot areas and models equipped with air conditioner "2: Models for hot ares, models equipped with sir eonditioner or ower steering and Australia models *3: Models with air conditioner for hot areas, models equipped with air conditioner or power steering for Middle East and ‘Australia models with sir conditioner or power steering. INSPECTION AND ADJUSTMENT Water pump an bale dtiection {applied force 98 N mm tin) |8-12(0.31-047 (10a, 201) Thermostat ‘stondard | Tropical Fegidtyp0 ‘vee | vee | toe TIGHTENING TORQUE ature seer | eaten | 22190) | 7650170) Max. va ite anoo | ara | 8/90 eit Nm [kom | fb mmrctinrry — | (031212) | 10317203) | (031198 St pumemovnting | yyeys | at-as | att (it pump cover bolt 710 | 07-10 | 51-72 Radiator Pa tone, kalen?, Regulatorvatvecso | 99.49 | 40-50 | 29-36 {Cap etiet pressure 88 (088, 0.9, 13) Oi pan drain og 20.29 | 20-30 | 14-22 Leakage tent presure 187 (187, 16,23) Lc-5SERVICE DATA AND SPECIFICATIONS TIGHTENING TORQUE nit Nim kom fell Wioter pump bol MG. 410 04-10 29-72 me 106 10-16 7-12 Woterpump pulley sud 6-10 06+ 1.04.8-7.2 Thermostat housing 208 12-20 12-20 9.14 Lraa.ze 16-20 16-20 12-14 Water outlet bolt 1208 12-20 12-20 9.14 L248 L28 16-20 16-20 12-14 LC-6ENGINE FUEL SERVICE NOTICE : © The 1285 engine is now installed in models destined for the Middle East. Its fuel system is the same as, that of the L24S engine bound for Hong Kong, Refer to S.D.S, for details. G On the L24E engine, only the location of the idle adjusting screw has been changed. ‘Two electric fuel pumps have been used on the L28S engine for the Middle East. Refer to section FE, A fuel return solenoid has been adopted on L245 & L28S engines for the Middle East. Refer to section FE, EF-1ENGINE FUEL ELECTRIC FUEL PUMP & FUEL FILTER (L288 engine for the Middle East) L388 124, FUEL RETURN SOLENOID (1.245 & L28S engine for the Middle East) Refer to FE section, EF-2SERVICE DATA AND SPECIFICATIONS SERVICE DATA AND SPECIFICATIONS CARBURETOR 28 Engine L208 8 Except for Hone Kore | __ Hong Keng Carburetor mode ‘OC F340.20 BAF342.30 DAH342-90 ‘DAHO42.97 Primary 3011.18) 32 (1.26) Outer diameter mom tn} Secondary 34 (138) Primary 23091) 25 098) 26 (102) Venturi ameter mm fin) Secondery 30 (1.18) 28 (1.201 9211.28) Primary 105 #128 #132 Main jet Secondary 180 #200 100m Primary #103 #125 #128 (8.30010) Secondory 155 #195 zoom Primary #8 wit #128 Mainjet (65008) Secondary #150 #190 for sttitude 3,009 Primary “97 #118 wat Fe (890011) Secondary #145 #105 “000m Primary 94 #4 “7 (13.2007) Secondary #140 #180 Primary #80 #240 #20 #240 Main air bleed Secondery #60 #70 #80 Primary #8 #46 52 #50 Slow jet < ‘Secondery #70 #90 #100 Primary #165 #210 #230 Sow air bleed Secondary = #50 #50 Power iet #0 #70 60 #80 Fuel level adjustment mm tin) ‘Gap between float and carburetor 850335) bay “H Gi ecu va stoma oat sx 13-17 10.051 -0.967) ‘Autohoke bimetal sting = ‘Center of index mark Fast ile ejustment rm find 1481.62 180-194 ‘Gap between throttle valve and My | At 2nd cam step: 1.05 1.20 (0.0817 0.0472), ero a (0.0583-00638) | (0.0709- 0.0768) 3.010.118), T 3000.18 ‘Vecuum break adjustment mm fin) Tealow 18°¢ tar 28° Gap betwen choke valve and - (50°F) (82°F) carburetor body "8 4.36 (0.1797 436 (0.1717) ‘Above about [ax 36°c 20°C (68°F) (or Fil EF-3SERVICE DATA AND SPECIFICATIONS ta Engine L208 v8 Exceat for Hong Kong Hong Kong ‘Carburetor mode! oFS40:20 DAF42.30 DAH342-30 DAHsa237 ‘Choke unioader edlustment mm iad ‘Gap between choke valve and. - 4.1.4.7 (0.161 -0.188) carburetor body "C" Inerlock opening of primary and 688-788 72-82 82-92 72-82 sezondary throttle valve'"G" mm (ia) | ©.2709 -0.3102) (0.283 -0328), (0.323 -0.362) (0283 - 0.328) wit ~ Bash pot adjustment (without loading) "em - 1.400 1,800, mn ina at 1,400 1,800 1.400 - 1,800 EF-4ENGINE FUEL ENGINE CONTROL SYSTEM DIAGRAM -L24e— und yang, EB] eufis nding us ynduy uy wane, oun fon SEFaO4A EF-5EMISSION CONTROL SYSTEM SERVICE NOTICE : ¢ The emission control system for the L28S engine is the same as that for the L24S engine for general areas. The B.C.D.D, system for the L24E engine has been modified. * The emission control system, except for the above, remains the same. Refer to the DATSUN MODEL R30 SERIES Service Manual EC-1GENERAL DESCRIPTION GENERAL DESCRIPTION Fane as |e Ls 1208 Destination Hong Kong Middle East Australia General areas | Hong Kong and fem psn ares Cranks emision contol system x x x x x Bont contol Eshaustemision | gecieation deve | — x - x - | (B.C.D.D.) Eaportve ison contol xem z x - = : 1X Avslabie > Notable ‘L248 for Australia Flame arrester Carbon canister I Fu ck valve Fuel tank Fuel ler cap] Seal type ol evel gauge Mutter: B.CDD. control valve \. \8.c.0.p. control solenoid valve Inhibitor switch (A/T models Speed detecting switch (M/T models) secassa| EC-2EXHAUST EMISSION CONTROL SYSTEM EXHAUST EMISSION CONTROL SYSTEM BOOST CONTROLLED DECELERATION DEVICE (B.C.D.D.) FOR L24E ENGINE (Australia) 1124 for Hong Kong Ignition switch BCD. control L24E for Australia 13 Vacuum chamber! rom alr duct ‘manifold BODY GROUND EC-3 t mer fomivave 18 Vaca cot 1 ‘Spend detecting switch Air passage 15 Vacuum chamb how 10 nh Diggit 16. Vaso pee (Eni: ONCEOrMT) 4 Awcontlvabe 17 Secon te “oreo: ON 30 ude costo. 19 Coating i De ovary Mintwarposor 29 Sats mat Dupin 31 nate mols secoul Tau fow amTToW IT user ceed : all = Moy cer) Lod 80.0, conrnoL puree |e Ale, Hong Kons) @: ArT models @: MIT modets secsesalEXHAUST EMISSION CONTROL SYSTEM INSPECTION Entire systom Generally, it is unnecessary to adjust the boost control valve. If it should be- come necessary to adjust it, the proce- dure is as follows: This adjustment should be carried out with the automatic transmission lever in the “N position, Prepare the following tools (1) Tachometer to measure the engine speed while idling (2) A vacuum gauge and connecting pipe Connect rubber hose between ‘vacuum gauge and intake manifold as shown, Say comer ASIEN 2, Warm up the engine until itis heated to operating temperature Then adjust the engine at normal idle setting. (Refer to the item “Idle Adjustment”) 3. Run the engine under no-load. In crease engine speed to 3,000 to 3,500 pm, then quickly close throttle valve 4. At that time, the manifold vacu- um pressure will change as follows: 1) It will abruptly ise up to —80.0 KPa (800 mbar, ~600 mmiig, ~23.62 inkig) or above. 2) It will decrease gradually 10 a cer {ain level and stay there fora while. This is so called operating pressure 3) In most cases, it will drop to idling pressure 7 Maximum negative presure bi: Operating pressure Negative fa © Idling pressure prewure set pressure Taling pressure Characteristic curve of B.CD.D. THRE 5. Check that the B.C.D.D. operating, pressure is within the specified range Unit: KPa (mbar, mmHg, nk) Atmospheric pressure 101.3 (1,013,760, 29.92) 80.0 (800, 600, 23.62) 6. If it is lower or higher than the specified level, turn the adjusting screw in the following direction until correct adjustment is made. Adjusting serew: Lower corsition Counterclockwise Higher condition Clockwise ~® Eca19A, T Adjusting nut 2 Lock spring EC-4 Operating pressure =62.752.7 (627427, ~470220, -18.5020.79) 453027 (-453427, —340+20, —13.3920.79) 7. Race the engine and check for adjustment. 8. If it is lower than the set level, tum the adjusting screw until correct, adjustment is made. 9. Race the engine and check for ad- justment. If engine speed cannot be decreased to ‘dling when checking B.C.D.D. oper. ating pressure, proceed as follows. 10, (1) Tur adjusting screw counter. clockwise so that B.C.D.D. operating pressure is on high vacuum side, 2.7 KPa (27 mbar, 20 mmHg, 0.79 inHg) away from the specified value. (2) Turn adjusting screw 1/4 of a turn clockwise so that B.C.D.D. operating pressure drops by 2.7 kPa (27 mbar, 20 mmt¥g, 0.79 inklg). If BLC.D.D. operating pressure cannot bbe observed clearly even in step 10(1), proceed as follows: ML. (1) Turn adjusting screw counter- clockwise so that B.C.D.D. operating pressure is on the high vacuum side 6.7, KPa (67 mbar, 50 mmHg, 1.97 inHg) away from the specified value, (2) Turn the adjusting screw 1/2 of a turn clockwiseSERVICE DATA AND SPECIFICATIONS ‘The B.C.D.D. operating _pressur should be correctly set within the specified range after the above adjust ‘ments, even if the engine speed cannot bbe decreated to idling. B.C.D.D. control solenoid 1. Check BCD.D. contro! solenoid harness for continuity. (1) Disconnect B.C.D.D, control sole- noid harness connector. (2) Turn ignition switch “ON and check voltage. | Never use ammeter or amplifier may be damaged, b. On automatic transmission models, shift in “N" position while check is being made. (3) When a voltage of approx. 12 volts is indicated, conteol citcuit is in good condition. Tf not, the amplifier (M/T model) or inhibitor switch (A/T model) may be damaged 2. Check BC.D.D. control solenoid operation (1) Remove both hoses and harness. (2) Operate the solenoid valve using the battery to determine if air flows theough the valve propery. f oid valve Switch: ON Switeh: OFF - la - i seas SERVICE DATA AND SPECIFICATIONS INSPECTION AND ADJUSTMENT B.C.D.D. 3.6.0.0, operating pressure [Om (OF, L286 for Australie 28 tor Hong Kong (vel and 101.3 KPa (1,013 mbar, 780 mmHg, 29.92 inte), exmosphere pressure] Pa (mbar, mmHg, inHg) 74, EC-5 62.7227 (627227, ~470:20, 0 (746-20, =1850:0.79) 60:15, 22.05:0.59)SERVICE NOTICE : ENGINE CONTROL, FUEL & EXHAUST SYSTEMS © Two electric fuel pumps have been used on L285 engine for the Middle East. © A fuel retum solenoid has been adopted on L248 & L28S engines for the Middle East. FUEL SYSTEM ELECTRIC FUEL PUMP & FUEL FILTER (L28S engine for the Middle East) 128 & 124 FUEL RETURN SOLENOID (L24S & L28S engine for the Middle East) = 6 Sutretor™ I i 5 To fuel tank “/ “ Plunger, Plunger guide From carburetor FE-1FUEL SYSTEM IGNITION swt ON or START FUSE BLOCK T- wm Bw ‘SPEED DETECTING switch FUEL RETURN SOLENOID, 8.6.0.0. CONTROL AMP. ‘ew— 8. ‘aly wy foe RH, dea sds) Lowe toaco.. solenoid a seFoesa| OPERATION Fuel return solenoid ‘The fuel return solenoid valve controls the amoust of fuel returning to fuel tank, for stability of engine at idle Solenoid] Rewen Vehisespeed | “vate | orice Below 10 K/h (esx) on Open ‘Above 10 kei bore 1 rr | Closed Speedometer INSPECTION ms Control circuit Below 10 km/h 1. Confirm that each wire connector (6 MPH) of control circuit is securely connect ed. Also check fuse 2. Remove combination meter lens. 3. Tum ignition switch to “ON”, ‘usm speedometer needle by finger and check voltage between terminals of hhamess side connector for fuel return solenoid. (6MPH) ing switeh may Above 10 km/h Voltage between terminal rv ov IfN.G,, the amplifier or speed detect bbe damaged. FE-2 1. Apply 12 volts between terminals ‘of connector for fuel return solenoid. 2. Ensure that solenoid valve clicks when intermittently electrified. 3. If a click is not heard, replace solenoid valve,CLUTCH SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS CLUTCH vIsc CLUTCH PEDAL Peaainegmw”_wmtad)_48T66TBB Om Ege ae peda ten ploy "Am in) 1-3 (008-032) Tos vase Foca so utr Ie ax 2 Os Thickness mm (in) 886 x * 0.138) Thickness of dae atsembly Free min) 825-895 (0.9248 -0.3524 ‘At load 3.923 N (400 ka, 882 1b) ram Lin) ‘Number of tortion soringe 6 76 -8.0 (0.299 -0.315) CLUTCH COVER Engine Les Type 226s Full load Nika, 11 4,904 1600, 1,103) Floor exroet Dash insulator H: Pedi free height 1A: Pedal free tauel Dash floor panel ‘SMASBOA CL-1MANUAL TRANSMISSION SERVICE DATA AND SPECIFICATIONS GENERAL SPECIFICATIONS No.of sheed Synehromesh 6 Sut yee Gear ratio —_____ | ‘Number of teeth Maingate Drive 2 ie 33 and 2 Sra 6 Se 2 Bow 36 Gountershate Drive m et \4 2nd 2 ee 2 bon a4 Rew 15 Revers idiershoh cis ws Oieapesivy Eline oo) (CIS: Mesh to counter gear MIS: Mash to mainshaft gear MT-1MODIFICATION NOTICE : AUTOMATIC TRANSMISSION Anew L4N71B fully automatic ¢ransmission has been added to the vehicle for Australia. It is equipped with overdrive and a lock-up mechanism. DESCRIPTION OF L4N71B (With Overdrive) HYDRAULIC CONTROL UNIT AND VALVES (L4N71B) HYDRAULIC CONTROL CIRCUIT (L4N71B) : ON-VEHICLE SERVICE (L4N71B) Control valve assembly Replacement of extension oil seal Parking components Governor valve assembly inhibitor switch adjustment Manual linkage adjustment Vacuum diaphragm rod adjustment Downshift solenoid Kickdown switch adjustment Overdrive control system AT. 4 AT: AT AT. AT. AT. aT. AT. AT-10 . AT-10 AT-10 AT AT-12 Comonar CONTENTS REMOVAL AND INSTALLATION (LAN71B) Transmission assembly MAJOR OVERHAUL OPERATIONS. (LaN71B) Service notes for disassembly Disassembly Component parts Final assembly TROUBLE-SHOOTING ANDO DIAGNOSES (L4N71B) Preliminary checks {Prior to road testing) Diagnostic road test Pressure testing Stall testing Road test symptom chart SERVICE DATA AND SPECIFICATIONS AT-1 T13 ATA AT-16 AT-I8 ATAB AT-21 AT. “Gg AT43 ATAS AT 4a AT-46 AT-46 AT-S2 AT55DESCRIPTION OF L4N71B (\ ith Overdrive) DESCRIPTION OF L4N71B (With Overdrive) The L4N71B transmission is a fully automatic unit consisting primarily of 23 element hydraulic lock-up torque converter and three planetary gear sets, Thee multipledisc clutches, a multiple-dise brake, two brake bands, and one-way clutch provide the ‘tic: tion elements necessary to obtain the esired function of the three planetary rarsets A hydraulic control system is used to operate the friction elements snd autor ‘matic shift controls. LOCK-UP TORQUE CONVERTER, The lockup torque converter is at tached to the crankshaft through flexible drive plate and serves 10 di- rectly couple the turbine runner and pump impeller through the lock-up piston which is controlled by the Toek-up control valve. Heat generated i the torque converter is dissipated by circulating the transmission uid through an oilto-vater type cooler in the radiator lower tank. The welded construction of the tor que converter probibits disassembly or service unless highly specialized equip- ment is avaiable FLUID RECOMMENDATION Use “DEXRON” type transmission Huid only, automatic IDENTIFICATION NUMBER ‘Stamped position ‘The plate is attached to the right hand side of transmission case, Number designation 2601234 Serial production ‘number for the month Month of prodvetion 1 dan, 2: Fob. X: et, Vs Now, Lat figure denoting ‘the year (A.0.) FLUID REFILLING POSITON Identification of number arrangements Wea auToATC ANSMISIN o,LID| MODEL X8707 NO. 2601234 —_ AT-2DESCRIPTION OF L4N71B (With Overdrive) FLUID LEVEL 1 Drive the ear several miles (Kilo- meters) to bring the transmission up co nocmal operating, temperature. [50 to 80°C (122 10 176°F)} 2. atk the car on a level surface. 3. Put wheel chocks in place, apply parking brake securely and leave the engine running 4. Slowly move the gear selector through the entire shift pattem, and return it fo park 5, Remove the dipstick, clean it, and replace it fully in the filler tube, 6, Quickly remove it again and read the level. 1p the fluid at the proper level. © Overfiling may blow off the fluid during high-speed driving © Underfiling may cause the clutches ‘to slip, and finally break them, The “L” mark on the dipstick indi cates the transmission is approximate ly 4 liter (3/4 Imp pt) low. Aad only clean Dexton transmission fluid (or equivalent). 1 Converter housing 2 Torque converter Intermediate shaft 2nd band brake 3 Oilpumpassembly 9 _Highzeverse clutch (Front) 4 OD. planetary gear 10 Forward clutch (Reat) 5. Direct clutch LL Pront planetary gear 6 Drum support 12. Rear planetary gear Oneevay elute Low & reverse clutch ‘Teansmision case Govetnor valve assembly Rear extension Outpue state AT-3 wo @ 9 20 Control valve assembly 21 Oil pan 22 O.D. band brake B oD.case 24 Input shartHYDRAULIC CONTROL UNIT AND VALVES (L4N718) HYDRAULIC CONTROL UNIT AND VALVES (L4N718) Control valve 1 Pressure regulating valve 2 Manual valve 3. 2nd-3rd shit vate 4 st-2nd shift valve 5. Pressure modifier valve 6 Brd-tth shift valve 7 Vacuum throttle valve 8 Throttle back-up valve 9 Solenoid down shift vave 10 Second lock valve Lock-up control valve ant 0.0. cancel valve Spring oo in 0. cancel ae, Y — \ EE f 2a 9t m= | L sareoe AT-4HYDRAULIC CONTROL UNIT AND VALVES (L4N71B) O1L CHANNEL ponents are located in the areas shown Oil channels which connect com- below. Ot chans in off pump (Oil pump cover side (Oil pump HSG side Drain Ct pump dscarze hole Lore convener in pressure (or toskn) sara satsoa i channels in transmission case Front Yace side Lower face side * pomp dicharae hole Front OD bration Fora ch ea pres | pServo apply pressure i pump dichare ote Higheevere teh | [pte sre tit abe To Sut hit valve | - Governor pressure (To contrat valve) ED CO; REE / pressure “Torque converter pressure \_\-Forward clutch (Rear) pressure \- oi pump suction hole ‘sarsos| “_fihveverse clutch (Front) pressure satsoa) Oil channels in O.D. case Oil pump suction ho Te Highaevense ditch] oo (Front) pressure Forward clutch aHYDRAULIC CONTROL UNIT AND VALVES (L4N71B) il channels in drum support Oil channels in converter housing Governor pressure it pump, suction hole /— Highzeverse ‘lutch (Frond) presure Leorward ettch (Rear) pressure Front & 0.0. lubrication From34 sirtvabe! — Cowpump discharge Hole | arses [Dect ciuteh pressure MECHANICAL OPERATION In the L4N71B automatic transmis. the following table at each gear select sion, each part operates as shown in postion ign ind servo onward | Low & | 2ed band servo Direct | OP Parts | seyere [Forward] Low & | Zedband se Lone way | parking tame | Stet a Taos cn | SUED | Yves swan | sot ply | Release | ane rake | Apply | Release Park on | (on) | ON ON ON | Reverse ON | (ON) | ON | ON oN on Neutral ON | (ON) | ON ° oN | (on) | oN on on (Low) Rm on | (om | on oN on (Second) D D, Crop) on | on | on | on | on (on) | on oe on on | on on) | or (0.0) fon) ) oN Second on} (ony | ON ON ON a teconay | ON | (OND | ON oN on 4 tt on | (on | on on | on on (Low) i ‘The low & reverse brake is applied in “11” range to prevent free wheeling when coasting and allows engine braking. AT-6HYDRAULIC CONTROL CIRCUIT (L4N71B) HYDRAULIC CONTROL CIRCUIT (L4N71B) “IN” range (Neutral) High 20. Feverse Forward Low & “torque converter saretl | pace 0,0. band Vacuum rd: ‘transmission case, make sure that a“ > control lever can be moved to all i wwe EROS fe RORTER \ positions LSE) \ 6. Install kickdown solenoid and ws Wea yy) vacuum diaphragm & rod. shi ‘Make sure that vacuum diaphragm rod does not interfere with side plate of control valve Downshit solenoid 7. Install new gasket and oi pan. @ib-7Nm (0.5 -0.7 kgm, 3.6 -5.1 feb) 3. Remove control valve assembly (remove seven bolts), 8. Secure clamps of governor tube and oil cooler tubes. 9. Refill automatic fluid. transmission 4. Disasemble, inspect and resem: REPLACEMENT OF bie contol vale sssombly. Refer to EXTENSION OIL SEAL page AT-32 for Control Valve Body u 5. Install control valve assembly. 2 Separate propeller shaft. Remove oil seal, AT-8 3. Apply coat of DEXRON to oil seal surface, then deive new seal into 4. Coat sealing lips with vaseline, then install propeller shaft. Refer 10 Propeller Shaft for instalation, PARKING COMPONENTS 1. Drain oil by removing oil pan, 2. Separate propeller shaft 3. Separate speedameter cable from transmission, then remove speedo: meter pinjon.4, Support transmission with a jack and wooden block, then remove rear ‘mounting bolts. 5. Remove rear extension bolts, then draw out rear extension with rear mounting. isarsia—— 6, Remove control valve assembly. Refer to Control Valve Assembly. 7. Inspect and repair parking com- ponents. Refer to Parking Mechanism for inspection, 8. Install control valve assembly. Refer to Control Valve Assembly for ‘onvehicle service. 9, Install rear extension with rear mounting. @): Rear extension to transmission case 20-25 Nm (20-25 kgm, 14-18 fib) Rear mounting to body 59-78 Nom (6.0.8.0 kg-m, 43-58 feb) 10, Install speedometer ‘pinion and cable. 11, Install propeller shaft, Refer to Propeller Shaft for instalation, 12. Install oil pan with new gasket. ON-VEHICLE SERVICE (L4N718) il pan to transmission case 5-7Nem 108 -0.7 kam, 3.6 -5.1 ftlb) 13. Refill uid. automatic transmission GOVERNOR VALVE ASSEMBLY 1. Drain oil by removing oil pan. 2. Remove rear extension with rear mounting. Refer to Parking Compo- rents. 3, Remove governor valve assembly. 4, Inspect and repair governor valve assembly. Refer to Governor for inspection. 5, Install governor valve assembly. 5-7 Nm (05 -0.7 kom, 3.6 -5.1 ftlb) 6. Install extension with rear moune in. Refer to Parking Components. 7. Install ol pan with new gasket. @ : Oil pan to transmission case 5-7 Nem (08 -0.7 kar 3.6 -5.1 ftlb) INHIBITOR SWITCH ADJUSTMENT ‘The inhibitor switch has two major functions. 1 allows the back-up lights to illuminate when the shift lever is placed in the reverse range, It also acts AT-9 as a neutral safety switch allowing cur- rent to pass front the starter only when the lever is placed in the “P" or “N” range, A continuity tester may be used to check the inhibitor switch for proper ‘operation, © Check continuity at “N “R ranges. lsarsis ‘© With control lever held in Neutral, ‘turn manual lever an equal amount in both directions to see if current flow ranges are nearly the same, (Current normally begins to flow before manual lever reaches a angle of 1.5 in either direction.) HF cuerent flows outside normal range, or if normal flow range is out of specifications, properly adjust ins hibitor switeh, 1. Place the manual valve in Neutral (rerticat position). 2. Remove the screw as illustrated.ON-VEHICLE SERVICE (L4N71B) 3. Loosen the attaching bolts. 4. Using an aligning pin, [2.0 ‘mm (0.079 in) dia.) move the switeb until the pin fas into the hole in the roter, S. Tighten the attaching bolts equal- @: Inhibitor switeh to transmission 5-7Nm (05-07 kgm, 3.6 6.1 felb) 6. Recheck for continuity. If faulty, replace the swe MANUAL LINKAGE ADJUSTMENT ‘The adjustment of the manual linkage is an important adjustment of the automatic transmission, Move the shift lever from the “P” range to “Range 1°, You should be able to feel the detents in each range. If the detents cannot be felt oF the pointer indicating the range is im- properly aligned, the linkage needs adjustment, PRND » 2, Grommets. Lock nats A088] 1. Place shift lever in “D™ range. 2. Loosen locknuts and move shift lever until “D” is properly aligned and car is in “D” range. 3. Tighten locknut Recheck “P” and “Range 1” posi- tions. Asa safety measure, be sure you can fee! full detent when shift lever is placed in “P”. If you are unable to make an adjustment, grommets may ‘be badly worn or damaged and should be replaced. VACUUM DIAPHRAGM ROD ADJUSTMENT ‘The vacuum diaphrogm and the length of its diaphragm rod help deter. ‘mine the shift patterns of the transmis. sion. It is essential that the correct length rod be installed. 1. Disconnect vacuum hose at vacuum diaphragm and remove dia phragm from transmission case. ‘Vacuum diaphragm rod selection Measured depth “L” mim (in) Under 25.55 (1.0059) 25.65 - 26.05 (1.0098 - 1.0256) 26.15 + 26.55 (1.0295 - 1.0453) 26.65 - 27.05 (1.0492 - 1.0650) Over 27-15 (1.0689) DOWNSHIFT SOLENOID 1. Disconnect downshift solenoid harness, 2. Remove downshift solenoid and O-ring. Catch oil dropping out of the hole, 3. Cheek to verify that downshift solenoid is operating properly. If faulty, replace it with a new one, AT-10 2. Using a depth gauge, measure depth “L", Be sure vacuum throttle valve is pushed into valve body as far 4s pose, 3. Check “L” depth with chart below and select proper length rod ‘sarooe Note seated valve body ‘Transmission case wall Diaphragm rod ‘Vaive bay side plate Vacuum thyotte valve Rod length mm (in) Pact number 29.0 (1.142) 31932 - X0103, 29.5 (1.161) 31932 - X0104 300 (1.181) | 31932 - X0100 30.5 (2.201) 31932 - X0102 31.0 (1.220) 31932-0104 4. Apply coat of DEXRON to O- ring, and install O-ring and downshift solenoid. 5. Connect downshift solenoid har- ness. 6. Refill fold. automatic transmissionON-VEHICLE SERVICE (L4N778) KICKDOWN SWITCH ADJUSTMENT ‘The kickdown switch is located at the upper post of the accelerator pedal, inside the car, When the pedal is fully depressed, « click can be heard just before the pedal bottoms out. If the click is not heard, loosen the focknut and extend the switch until the pedal lever makes ‘contact with the switch and the switch clicks. Kickdown switch ‘downsitt solenoid SATGOT Do not allow the switch to make contact too soon. This would cause ‘the transmission ta downshift on part throttle. transmission still daes not kickdown: Check the continuity of the switch using a continuity tester. Also check for available current, The car upshifts at approximately 55 and 90 km/h (34 and 56 MPH? oniy: The kickdown switch may be internal- ly shorted. (When the switch is short: fed, there is continuity through the switeh IGNITION SWITCH ONor START ‘Reler @ POWER SUPPLY ine stim kicxoown swiren ruse aLock rk 1 1 owe om [FT 1 g 7 Booy GROUND y—] (Engine room harness) AT-11 “7 bE (Engine harnets No.2! ownsHieT SOLENOID ow “ty yy sarois|ON-VEHICLE SERVICE (L4N718) OVERDRIVE CONTROL SYSTEM 0.0. indicator lamp vs well ws whan ignition switch is ON (and engine wien itis ruraing in 0.0. postion IGNITION swiTCH ONorSTART Refer POWER SUPPLY in EL section Front on wore Fuse_eLock x Sl me _ SiH Ht onstA T q vi8 —e ow. 0.0. INDICATOR Pes ane 0.0. 1noIcator soov SwircH 2 crouno ond b 0.0. canceL SOLENOID L—vie y "OG {Engine room hanes) (Engine harness No sare 0.0. CONTROL SWITCH & 0.0. 0.0, CANCEL SOLENOID Inspection INDICATOR LAMP Location Confirm that clicking sound is heard Location This switch including O.D. indicator switch Is located in center console box. when power is applied, \nspection saress| sats20| ey \ T= LO GE itch “ON” & cone AT-12REMOVAL AND INSTALLATION (L4N71B) REMOVAL AND INSTALLATION (L4N71B) TRANSMISSION ASSEMBLY When dismounting the automatic transmission from a car, pay attention to the following points: 1, Before dismounting the transmis sion, rigidly inspect it by using the “Troubleshooting Chart”, and dis- mount it only when itis necessary. 2. Dismount the transmission with ‘utmost care; and when mounting, ob- serving the tightening torque indicated ‘on another table, do not exert exces- sive force REMOVAL In dismounting the automatic transmission from a car, proceed as follows: 1. Disconnect battery ground cable from terminal 2. Disengage torsion shaft from ac- celerator linkage (gasoline engine only) 3. Jack up car and support it on safety stands. We recommend a hydraulic hoist or open pit be utilized, if available. Observe all safety regulations 4. Remove propeller shaft Plug up the opening in the rea tension to prevent oil from flowing out. 5. Disconnect front exhaust tube. 6. Disconnect selector range lever from manual shaft. 7. Disconnect wire connections. at inhibitor switch. 8. Disconnect vacuum tube from vacuum diaphragm, and wire connec tions at downshift solenoid, 0.D. sole- noid and O.D. indicator switch. 9. Disconnect speedomerer from rear extension. 10. Disconnect oil charging pipe. 11. Remove oil cooler inlet and outlet tubes. cable Plug up openings such as oil charg: ing pipe, oil cooler tubes, ete. 12. Support engine by locating a jack under oil pan with a woden block used deiween ofl pan and jack. Support transmission by means of a transmis- sion jack. CAUTION: Do not place the jack under the engine oil pan drain plug. 13, Remove gussets 14. Detach converter housing dust cover. Remove bolts securing torque ‘converter to drive plate. Before removing torque converter, inseribe chalk marks on two parts so that they may be replaced in their ‘original positions at assembly. 15, Remove rear engine mount se- curing bolts and crossmember mount ing bolts. 6, Remove starter motor. 17, Remove bolts securing transmis- sion to engine, After removing these bolts, support engine and transmission with jack, and lower the jack gradually until transmission can be removed and take out ¢ransmission under the vehi- ale, CAUTION: Do not drop torque converter from transmission. ‘Take care when dismounting transmis. sian not to strike any adjacent parts, AT-13 INSTALLATION Installation of automatic transmis sion on vehicle isin reverse order of re- moval, However, observe the following installation notes. f. _Drive plate runout Turn crankshaft one full turn and ‘measure drive plate runout with indi- cating finger of a dial gauge rested against plate. Maximum allowable runout: 0.5 mm (0.020 in} 2. Installation of torque converter Refill with automatic transmission ‘uid. Fluid capacity: Approximately 2.0 liters (1-3/4 Imp at? Line up notch in torque converter with that in oil pump. Be extremely careful not to put undue stress on parts when installing torque converter, 3. When connecting torque converter to transmission, measure distance “A” to be certain that they are correctly assembled.REMOVAL AND INSTALLATION (L4N71B) Distance “A": ‘More than 35 mm (1.38 in) Straight edge 4. Bolt converter to drive plate ‘Align chalk marks painted across both parts during disassembling pro- cesses. 5. After converter is installed, rotate crankshaft several turns and check to be sure that transmission rotates freely without binding. 6. Pour recommended automatic transmission fluid up to correct level through oi charge pipe. 7. Connect manual lever to shift rod, Operation should be carried out with ‘manual and selector levers in “N” 8. Connect inhibitor switch wires a Refer to page AT-9 for inhibitor Switch Adjustment. b. Inspect and adjust switch as above whenever it has to be removed for service. 9. Check inhibitor switch for oger- ation: Starter should be brought into ‘operation only when selector lever is in “BY and “N” positions (it should not be started when lever is in “D”, “2,1 and “R™ positions) AT-14 Back-up lamp should also light when selector lever is placed in “R™ position, 10. Check fluid level in transmission, For detailed procedure, see page AT- 3 1), Move selector lever through all Positions to be sure that transmission operates correctly. With parking brake applied, rotate engine at idling, Without disturbing the above setting, move selector lever through “N” to “D”, t0 2", t0 “1” and to “R". A slight shock should be felt by hand gripping selector each time transmission is shifted. Refer to section MA for Checking Engine Idle. 12. Check to be sure that line pressure is correct. To do this, refer to page AT-46 for Line Pressure Test 13. Perform stall test as described in page AT-46,REMOVAL AND INSTALLATION (L4N71B) Notes AT-15MAJOR OVERHAUL OPERATIONS (L4N718) MAJOR OVERHAUL OPERATIONS (L4N71B) Tightening torque Nom (kgm, ft) @ 39-49 (4.0 -5.0, 29-36) ™ Input shaft Gasket Converter housing rewoneey ‘Thvust “om Gasket Intermediate Ze ‘ZS Pi nt 8 < ‘Accumulator ©.D. band & ee mee 6 LS oe sarsi9 AT-16MAJOR OVERHAUL OPERATIONS (L4N718) OD. brake 7 Phra waster at Direct clutch assembly 0. planetary gear assembly. Connecting shell Ys “Q Lay sng pa \ a a Whe. x ee BE ae LGoserar este assembly Manat shat Oil distributor Manval sue - Beating Parking ro. Downshift solenoid Disp rod—— rep e 2nd band , brake ev assem & : ~ vacuum digphrsem oe ~ D. indicator switch az De | = - - (Kickéown) Dy > Ds - - 530-686 + 2. . Py Da | 84-91(52-57) 2.870 3,120 (5.30 - 6.86, 5.4-7.0, 77 - 100) | 530. 686. Dy > Dy 38-46 (24-29) 1,320- 1,570 (5.30..686,5.4-7.0,77-100) > 539 - 598 Pi > Dy | 20:anteD. 1680-930 (5.39 - 5.98, 5.5 -6.1, 78-87) . $39 598, Di +s | 54-61. G4-38) 1,860-2,110 G23 298, 55-6.1,78-87) 539-598 Dy +d, | 87-95(54-59) | 3,020-3,270 5 . ” 46.7 (467, 350, 13.78) BP Soe ss on Tes Dy + Ds | 35-61 (34-38) 1,830- 2,080 (5.39598, 55 -6.1,78-87) . 539-598 Ds + D, | 29-36(18-22) 1,000 1,250 (5.39 .5.98, $5 -6.1, 78-87) 530.598 Dp > Dy | tne 18(7-11) 350-600 6539-598, 55 -6.1,78-87) 20.0 (200, 150,591) |), > 549-706 (Full throttle) hh M 39-47 (24-29) (5.49 - 7.06, 5.6 - 7.2, 80 - 102) ali, > > 549-706 80.0 (800, 600, 23.62)| 1, A 39-47(24-29) 1,350 - 1,600 (6.49 -7.06, 5.6 -7.2, 80-102) Shift schedule Kickdown range aif? 2s 2 2 sacs. ae) ie = 2870007 3 | 200,7.87)) 4 400.00, af Soo. 113%) 27 59.1633, 1875) Propeller shaft revolutions (rpm) 0 10 2 30 40 50 69 70 0 9 190190 p_19 29 39 _49 so 6p __79 99 9% o 70) i : ‘Vehicle speed kmh (MPH) saton7 AT-45TROUBLE-SHOOTING AND DIAGNOSES (L4N71B) PRESSURE TESTING ‘The LAN7IB transmission is provided with two pressure test ports. Only fone is useful for transmission trouble- shooting. ana seri release piessure_ga594 LINE PRESSURE 1, Remove engine rear mounting. Disconnect both line pressure and servo release pressure plugs and, in Ueir places, attach pressure gauges. 3. Install vacuum gauge. 4. Check levels of engine cooling water, engine oil and automatic trans- mission fluid. Add as necessary, to reach the specified level. 5. Warm up engine until engine oil and automatic transmission fluid reach operating temperatures. Fluid temperatu 50 - 80°C (122 - 176°F) 6. Place wheel chocks at all wheels, and firmly engage parking brake 7. Measure line pressure at idle and at stall point wile depressing, brake pedal fully. Anidle Range Line pressure kPa (bar, kaler® | 412-589 (4.12-5.49, 4.2 $6, 60-80) 314-373 (3.14-3.73,3.2-3.8, 46 -54) 588-1,147 2 | (s.88-11.47, 6.0- 11.7, 85 - 166) 1) 3ie373 G.14-3.73,3.2-3.8, 46-58) At stall point Line pressure kPa (bar, ke/em?, ps) 1402 - 1,589 (14.02 5.89, R | 1b.3- 162, 203-230) | 971-1,089(9.71 - 10.8, 9.9. 11.1, 141-158) 2 | 991 13809.91-1138, 101-116, 144-165) 1 | 971 1,08909.71 10.89, 99- 11.1, 141-158) Key points of pressure testing are: a) Pressure at idle: Look for a steady rise in presure as car speed in creases under light load. AT-46 b) Pressure drop between shift points should not excoed 98 kPa (0.98 bar, 1.0 kglem?, 14 psi). Excessive pres: sure drop may indicate an internal leak at servo or clutch seal, Cut-down point ‘The cut-down point indicates a point ‘where line pressure changes from high to low value as output shaft rotation is sradually increased ‘om “stall” point. ‘The car speed at that cut-down point are as indicated in chart below. Tntake mani i Propeller idm “thom, ‘tone ami, v.00 | atc iaso. 1430 weasa | 20-27 100, 3.94) z.17) | 80°930 STALL TESTING ‘The stall test i an effective method of testing clutch and band holding ability, torque converter oneway clutch operation, and engine per- formance. A stall test should only be performed as a last resort because of the high fluid temperature it generates and the excessive load it places on the engine and transmission, test, never hold throttle ranges without driving ear to coo! off engine and transmission, STALL TEST PROCEDURE 1, Transmission and engine fluid levels should always be checked and fluid added as needed. 2. Run engine at 1,200 rpm to attain proper warm-up.TROUBLE-SHOOTING AND DIAGNOSES (L4N71B) 3. Set parking brake and block wheels, 4, Install a tachometer where it can bbe seen by driver during test. 5. Start engine and place shift lever in “D” range. 6. Apply foot brake and accelerate to wide-open throttle, Do not hold throttle open longer than five seconds. 7. Quickly note the engine stall speed and immediately release throttle Stall revolution: 1,800 - 2,100 8. Shift select lever to “N* 9. Run engine at 1,200 rpm far at least one minute, allowing it to cool off. 10. Perform stall tests in the same manner as in steps 5 through 9 with select lever in “2”, “1” and “R", respectively. STALL TEST ANALYSIS 1, Satisfactory results in “D” range indicates forward clutch (Rear), direct clutch, high-reverse clutch (Front), one-way clutch of transmission, and one-way clutch of torque converter, are functioning properly. Drange test, NG, Stall revolution is Too high D/C, RIC or OWE. slips 1 range test Ox, NG. OW. sips D/C or RIC slips - Rerange test ox, RIC dips z 6 DIC slips Teg low Lockup clutch is dragging, converter one-way clutch is faulty (slipping), or engine is not performing properly. Ox, / range test no] Stal evolution is AT-47 ‘The analysis diagram is shown below. ‘The abbreviations are: F/C — High-reverse clutch (Front) R/C Forward clutch (Rear) D/C — Direct clutch L& R/B — Low and reverse brake O.W.C. ~ One-way clutch ® r Too high F/C or L& RIB slips Perform road tests to determine whether F/C or L & R/B slips When shift select lever jin Sno No engine braking L& R/B slips Effective engine braking | FIC dips -— Too low Lock-up clutch is dragging, converter one-way clutch is faulty (slipping), or engine is ot performing properly, If converter oneoway clutch is frozen, ‘ar will have poor high speed perform ance. If converter one-way clutch is slipping, car will be sluggish up to 50 ‘F 60 km/h (30 or 40 MPH.TROUBLE-SHOOTING AND DIAGNOSES (L4N71B) TROUBLE-SHOOTING CHART rl CAR} Numbers are arranged in order of probability. Perform inspections starting with number one and work ing up. Circled numbers indicate that the transmission must be removed from the ear. OFF CAR. ing Piping I, svitch and wiring Tater motor brake inspection Reary (Front) check batt Transmission one-way cluteh High-reverse clutch igheverse clutch (Front) Park Tnkage }O.D. Band brake Pn band brake Low and reverse brake Transmission aie check Oi pump Otel Vacuum disphragin and Kickdown solenoid, Engine iting rpm Tine pressure [Control vale Governor Band servo Oil quality = | lonition switchand-3 Engine adjustment, Forward catch OW pasage ak 1 | Range select tin v2] w | inhibitor switen and wi ranges. [Engine doesnot statin “N", [Engine starts in ange other than “AN” and “P eS “Transmission noise in “P* and “N° ranges. 1 ‘Car moves when changing into “P” range or parking gear 1 doesnot disengage when shifted out of “P" rane, cle = (Car runs in *N range : {Car will not run in “R” range (but runs in “D" "1" ranges), Clutch slips. Very poor acceleration, & oS = e (Car braked when shifting into “R™ range, wee ef 5 ‘Sharp shock in shifting from “N” to “D” range. we [2d (Car will not run nD" range (but runs in“ R ranges), (Car wil not ran in “D", “1, “2° ranges (but runs in @ a “R range). Clutch ships. Very poor acceleration P2.jo. [4 5-|. 63). O@.|.. .1@. - and 1 ‘Clutches or brakes slip somewhat in starting 12.[6. Exoesive creep. . No creepat al Fallre to change gear from "Ist to “2nd” : Failure to change gear from "2n Failure to change gear from "3rd" to ‘Too high a gear change point from" 2nd” to "31d from “3d” to Ath Gear change directly from 1st” to "3rd occurs. wee. fe Gear change directly trom “2nd to “4th” occurs. . AT-48TROUBLE-SHOOTING AND DIAGNOSES (L4N71B) J¢——— on car: OFF CAR——>} 2 5 3 Numbers are arranged in order of 3 g 3 probability. Perform inspections # i mae Sarting with number one and work- a2 f] es BB ing up. Circled numbers indicate ie . 4.2) 3 that the transmission must be gels 2 2 is] Hf a5 removed from the car. ose 3 2] 23/23) « 5/5 23/2 84/2. 2 24(923/22 3 4/; Self 2 s/f 5 2/23 3/3 2 Ezz sls 22 Bee(e fle 2 e293 i]2 = elk 2 3]2 2 2/5 2 Bale Sle 2 F/2 2 5/2 § sla 2 3/22 a/g iS 25/2 5 cle 8 2/85 Ela 2 2/5 4 3/8 8 Elz Too sharp a shock in change from “ Ist" to “2nd”. 1 2/4. 5). 3.f. . ®.|. : “oo sharp a shock in cane from “2nd” t0 “3 i]. 2 [3.3/4 off ‘Too sharp a shock in change from "3rd" to “4th”. 1 2.13. 5/4. ®. + “Almost a shock oF clutches slipping in change from “Ist” to 75 oa ines 123). 4.]6. slr s @.|. 0. ‘Aimost no shock or sipping in change from “2nd” to “3 3 > Engine races extremely fast. 123). 4./6. 8/75 @). [Almost no shock oF sipping in change from "3d to 4th 123). 4./6. 875 -|@- |. (Cr braked by gat change fom “Ist” 19 "2nd .-[2.-[-1.]. a). ol. a). (Cr brake by gat change from “2nd” to 3rd" fa. 2[- 1]. .-[- oO... (Car braked by gear change from “3rd” to “ath”. f2. 1.J@. @. . : Maximum speed not attained, Acceleration poor. 12 43[7. 6). 3a]. oa). dal Fallre to hange ger fom "4° t0 “Sr 1... [3 4.|s2./@ ®. Fall to hange gar fom “Sr t0 “2nd” and from “ath to oe ne 1 34 6/52.]..al@@. : Failure to change gear from “2nd” to “Ist” oom 3 ; pacls2 > al fae : so -fe@.f. al. (Gear change shock fet daring deceleration by releasing Sexy Sane sos rajaa.[s6.|. Too high a change pint from "4h" 19 "31, From "Sad 0 ; eee eee 12/3 4.|56 : ®. Kickown does not operate when depressing pedal in “31d o.|.4 within kickdown car speed, . a1 as ae @ O- Kickdown operates or engine overruns when depresing pedal © in"3rd” beyond kickdown ear speed limit. ste 386.174]. Os of @.]. Races extremely fast or slips in changing from “4th to "3 t when depresing pedal anne Ho * .2./4. 6/53 Jo. ao. .|. @. 19) Races extremely fst or pin changing from "3" 0 "2nd > a when depressing pedal. 24/4. 6153. 4 7 AT-49TROUBLE-SHOOTING AND DIAGNOSES (L4N71B) Numbers are arranged in order of probability. Perform inspections Starting with number one and work- ing up. Circled numbers indicate that the transmission must be removed from the cai |}*-—@ 8 Ca ——_— FF caR ———9] ragm and piping em Vacuum di Engine idling atch clutch (Front) ‘OD. band brake ih (Rear) 2nd band brake Torque converter, one-way clutch Transmission one-way’ Patk linkage Goremnor Band sero O.D.itaicator switch Direst clutch Forward Highevene Low and reverse brake [Oi pump Planetary gear (O.D. cancel vae 5 | Oi passage leak (Car will not run in any range. 1 | Range solect linkage w |Line pressure ©» | Transmission air check 1 Control valve & |Oitquaity é Transmission naie in “D",“2", “I and anges. Failure to change from “3rd” to “2nd ‘hen changing ever into “2” range Gear change from "2" to “Ist” or from "2nd" to “Sed” in “2” range, No shock at change from “1” to "2" range rengine races extremely Failure to change from “3rd” to “2nd” ‘when shifting lever into “1” range. 45/763... .]..@.0.|.@. Engine brake doesnot operate in “1” range (Gear change from “Ist” to “2nd oF ftom Sets wo Samia “1” rsge Does not change fom “2nd” to Let in pees Large shock changing from “2nd” to™“1st™ in "I" range, ‘Transmission overheats * - Ba) Oil shoots out during operation. White smoke. «emitted from exhaust pipe during operation, gal. . .J. .@]. wa ‘Offensive smell at oil charging pipe 2. . ..@@aoloaelooo). “Transmission shifts to overdrive even if 0.0, cancel switch is turned to “ON”, | T Lamp inside O.D. cance switch does not slow even if jgnition switch is turned to “ON” (engine not started) Lamp inside 0.D, cancel switch does not low even if transmission i shifted to 0.D. Sy Refer to the next page. AT-50TROUBLE-SHOOTING AND DIAGNOSES (L4N71B) Jeon car oF cok : ‘Numbers are arranged in order of 8 probability. Perform inspections 2 Starting with number one and work. a ing up. Circled numbers indicate § £/% that the transmission must be dgjsfti/s removed from the car ei 2/z/#/#/é a 3 Ble & = eye el tle] 8s Ble e/s/ils a] E/E] Ele/e/2)2/)2 Elsie lFlelile Torque converter is not locked up 2[3|®|9|/6|o/6 Lock-up piston slip 11/@/|® @|®@ Lock-up point is extremely high or low 1/2 ® Engine is stopped at RD. 2 and 1 ranges ®/o ‘Transmission overheats 1 @|® ®|®@ AT-51TROUBLE-SHOOTING AND DIAGNOSES (L4N718) ROAD TEST SYMPTOM CHART SHIFT QUALITY g/é g/ 8 f/e g/é COMMENTS ENG. START HOLDING Men shift PR REVERSE, Man. shift RN ENG. START N Ist Auto shift 1-2 2nd Autoshit 23 Sed Auto shit 24 4th in lockup “OFF” pe RANGE ‘Auto shift Lockup “OFF (4) Lock-up "ON" (4) {th in Look-up "ON" ‘Auto dift Lock-up (@) Lookup “OF Dee 43 Kickdown 43 Deel. 32 Kickdown 32 Deeel 2 Kickdown 21 Man shift D2. RANGE ong Man. sift 24 as Man. shift D-1 RANGE “Acceleration Engine Braking AT-52TROUBLE-SHOOTING AND DIAGNOSES (L4N718) ‘TROUBLESHOOTING GUIDE Order Test item Procedure Checking 1. Oil level gauge Check gauge for oil level and leakage before and after each test 2. Downshift solenoid Check for sound of operating solenoid when depressing accelerator pedal fully with ignition key “ON” 3, Manual linkage Check by shifting into “P", “RY, “NY, “DY, "2" and ranges with selector lever. 4. Inhibitor switeh Check whether starter operates in “N" and “P” ranges only. and whether reverse lamp operates in “R” range only. 5, Engine idling rpm. Check whether idling pm meet standard, 6. Vacuum pressure of vacuum | Check whether vacuum pressure is more than 60.0 kPa (600 pipe. mbar, 450 mmblg, 17.72 inHg) in idling and whether it de- ‘creases with increasing rpm. 7. Operation in each range. Check whether transmission engages positively SN? "DP, ONT 82" SNM SD and SNP while idling with brake applied. 8. Creep of car. (Check whether there is any creep in “D", “2”, ranges. Stall test 1. Oil pressure before testing Measure line pressures in “D”,“2", 1” and “R™ range while idling. 2. Stall test. Measure engine rpm and line pressure in “D”, “2”, “1” and “R™ ranges during full throttle operation. ‘Temperature of torque converter oil used in test should be from 60 to 100°C (140 to 212°F} i-e., sufficiently warmed up but not overheated. CAUTION: To cool oil between each stall test for “D”, "2", "1" and “R™ ranges, , ie., rpm at about 1,200 rpm for more than 1 minute in “P’ Measurement time must not be more than 5 seconds. 3. Oit pressure after testing Same as item 1. Road test 1, Slow acceleration, ‘Check car speeds and engine rpm in shifting up Ist > 2nd, Ist 2nd 2nd + 3rd range and 3rd > 4th range and when torque conver 2nd-+ 3rd ter is locked up while running with lever in “D” range and 3rd ath engine vacuum pressure of about 13.3 kPa (133 mbar, 100 ‘mmHg, 3.94 ils). 2. Quick acceleration, Same as item 1 above except with engine vacuum pressure of Ist 2nd 0 KPa (0 mbar, 0 mmHg, infig) (ce., in position just before and + 3rd kickdown). 3. Kick-down operation, Check whether the kickdown operates and measure the time Ath -» 3rd, 3rd > 2nd delays while running at 30, 40, $0, 60, 70, 100 kh (19,2: ‘or 2nd Ist 31, 37, 43, 62 MPH) in “Ds” of “D,” range AT-53TROUBLE-SHOOTING AND DIAGNOSES (L4N71B) Order Test item Procedure 4, Shift down, Check car speeds and engine rpm in shifting down from 4th Dy >Ds>D, > Dy + 3rd + 2nd + Ist (sequentially) while coasting with ac celerater pedal released in “D,” range and engine vacuum pres sure of about 60.0 kPa (600 mbar, 450 mmHg, 17.72 inHg). S. Shift down, Check for shifting down Ds + 12 and engine braking, and Dy? h further for shifting down 1; + 1, and engine braking after shifting the lever into “I” range with the accelerator pedal released and the engine vacuum pressure of O kPa (0 mbar, 0 ‘mmHg, 0 inkig) while driving at about 50 kmn/h (30 MPH) in “D3” range. 6. Shift down, Check for quick shifting down Ds + 2 and engine braking, Dy +2 after shifting the lever into “2” range while driving at about 50 km/h (30 MPH) in “D3” range. Also, check for locking of the transmission in 2nd gear ratio regardless of car speed. 7. Shift up, Check for failure of the transmission to shift up during hol acceleration, when starting in “1” range 8, Shift up or down when start- | Check the transmission for not shifting up or down during ing in “2” range acceleration or deceleration, when starting in “2” range. 9. Parking; Confirm that car will not move on grade when shifting to “P* range. 10. ©.D. control switch operation. | Confirm that transmission will not shift to overdrive while running with O.D. cancel switch ON. 11. OD. indicator lamp. Confirm that O.D. indicator lamp glows when ignition switch is ON (engine not started), and that it goes off as soon as ‘engine is started. Confirm that lamp glows when transmission is shifted to O.D. and driven in “D” range with O.D. cancel switch OFF, Others Abnormal shock, ol leakage. Enter into record conditions observed during these tests such ‘a gear noise, abnormal clutch noise and acceleration per- formance. AT-54SERVICE DATA AND SPECIFICATIONS SERVICE DATA AND SPECIFICATIONS General specifica ‘Applied model 28 ‘Automate transmission mode! ani Formard cuten (Rear) ‘Ropied model Lee ‘Number of drive plater 6 ‘Number of driven pater 6 Stall torque ratio 20:1 Clearance mm (in) 08 1.8 (0,081 - 0,058) “Thickness of retaining plate ‘Transmission gear ratio rm tin 4-80 (0.1890) 1 2842 2nd 1.542 Low & rovers brake Top 11000 ‘Number of drive plates 5 00. 086 Number of driven plater 5 Reverse 2.400 Clearance ‘mm in) 0,80. 1.05 (0.0818 - 0.0819) Thickness of retaining plate Thickness on ‘Automatie transmission fuid| mm (in) Part pumber "Depa Lae 7.810.307) 31667-x0500 capacity ters (61/8 Imp at 8.0 (0.215) 31667-0507 * 7.0 thers (678 iy at) 82 (0.323) 31667-xos02 4 (0.231) 31667-x0503, 8.6 (0.339) 31667-xo504 ‘Applied model Lae 88 (0.346) 31687-xo505 ‘Automatic transmission assombly 2d brake band Model code numer xs719 Piston size mim fin Big dia. 64 2.62) “Torque converter assembly Smal di aotisn ‘Stamped mark on the TIC ou (0.0. brake band High-reverseeluten (Front) Parone vm (inl ‘Number of drive plates 3 ‘indie 60 12.96) ‘Number of driven plates 5 Smita, Seura2) Cletrance mm (iol 1.61.8 (0,063 0.071) Thickness of retaining plato THICKNESS par number Control valve assembly rm (in) ‘Stamped mark on strainer oAaN.A, 5.010.197) 31867-x2900 5.2 0.205) 31567-x2901 Governor asembiy 54 (0.213) 31567-x2902 ‘Stemped mark on governor a 5.6 (0.220) 31567-x2003 body 5.8 (0228) 31967-x2908 6.010.296) 31867-x2905 6.210.248) 31867-x2006 Direct eluted (LAN71B) Stall revolution Number of drive pater 2 Number of erie plates 2 ‘Applied model eo Clearance mm (in) _ 1.6 - 1.8 (0.063-0.071) Thickness of retaining plate Thickness Stal revolution om 1,800 - 2,100 vreaess part number 560.220 31567-x2903, 5.810.228) 31567-x2004 6.0 (0.236) 31567-x2905, 620.288) 31567-x2008, 6.4 (0.252) 31567-xB600, 6.6 (0260) 31567-xe601 68 (0.268) 31867-x2800 7.0 (0276) 31867-x2801 AT-55Tightening torque (L4N7 1B) SERVICE DATA AND SPECIFICATIONS On ween One = i “ om Lower valve body to 25-34 0,25-0.35 18-25 ‘Transmission installation upper valve body Dive pte to 97-187 140-160 101-16 Ob savopinon fo 10-18 Tt Cente fener to 00. cse Orie pate ororqve 39-49 «40-50 29-98 0.0. stem (when p10 07-10 st-72 cone schsting bad brake Converterhowingto 39-49 «40-50 29-98 Obstemiocknut = 18-38 18-40 11-29 sroin Sideploteconvol «28-34 025-035 18-25 Fear mounting bracket 31-42 32-49 23.31 vel body ‘ansmission Nut for control valve 5-7 05-07 36-51 Feormouningbrcket 31-42 «32-43 28.38 eee tomer nor Citrine oiower «8-40-04 22-28 Feormoening member 69-78 60-80 43-88, wah boy tebey - Goverorievebedy!o 6-7 05-07 36-84 Component par sion remmioncaw to 44-84 A5-55 33-40 Tranmisin ase Oiloumerousnate «6-8 «06-08 45-58 silpon co ‘Transmission case to 20-28 20-25 14-18 <= Traramision Inhibtorswitcho «6-78-07 6-84 Oil pan transmission 5-7 05-0.7 36-51 vesi oie Moral shatlocknut 29-38 «30-40 22-29 2nd servo piston 79 07-09 51-65 Oil cooler pipe to 29-49 90-50 22-36 eae ae trams coe rion cove Ten pi (olpremme 14-70 14-21 10-18 ‘2nd piston stem (when 12-15. “12-15 9-11 inepection hole) Suing band broke) Suppor stustor a1 og-n1 80-80 ‘2nd piston stem lock nut 15-39 18-40 11-29 Ioana inserting Oneway clutch mer 18-18 13-18 9-13 pase torr ‘me Dru suport a 7907-08 51-65 oven Con vahe body to 64-78 055-075 40-54 itarsmision case * Turn back two turns after tightening, AT-56PROPELLER SHAFT & DIFFERENTIAL CARRIER MODIFICATION NOTICE : ‘A.3S63A type propeller shaft has been adopted on all models. An R200 type final drive has been adopted on the L28S engine model. PD-1DIFFERENTIAL CARRIER (Type R200) DIFFERENTIAL CARRIER (Type R200) 99-118 (9.0- 120, 65-87), @:Nm Using locking agent [Locktte (stud lock) ot @) 196-246 (19-22, 137-159)DIFFERENTIAL CARRIER (Type R200) REMOVAL 1, Jack up rear of vehicle and support on safety stands. Drain gear oil 2. Disconnect propeller shaft at com- anion flange. 3. Remove drive shafts, 4. With differential cartier jacked up, remove diff, mounting insulator nuts, 5. Loosen off four fitting bolts that hold differential carrier onto suspen- sion member. 6. Pull off differential carrier back: ward together with jack. ‘After carrier assembly is removed, support suspension member on a stand to prevent its insulators being twisted or damaged. Note: Do not place the center of suspension member on the stand before removal operation. Other wise, it will be difficult to extract the gear carrer assembly. PRE-DISASSEMBLY INSPECTION Differential carrier should be in- spected before parts except rear cover ate removed from it These inspections are helpful in finding the cause of the problem and in determining necessary corrections. 1, Using three 45. mm (1.77 in) spacers, mount carrier on Diff. Attach- ment KV38100800. srosia 2. Remove rear cover: 3. Visually inspect parts for wear or damage. 4. Rotate gears checking for any roughness which would indicate dam- aged bearings or chipped gears. Check gear teeth for scoring or signs of abnormal wear. Measure prelosd of drive pinion. ST31278000 poas0 5. Set up 2 dial indicator and check the backlash at several points around ing gear Ring gear-to-drive pinion backla 0.13 -0.18 mm (0.0051 - 0.0071 in} 6. Check gear tooth contact with a mixture of recommended powder and oil For the tooth contact pattern, see page PD, PD-3 DISASSEMBLY 1. Put match marks on ‘side bearing ‘caps and carrier. 2. Loosen side bearing cap bolts and remove bearing caps, 3. Using Slide Hammer HT72400000 lift differential case assembly out Terence gy poe Note: Care should be taken not to confuse the left and right hand bearing caps and bearing outer races so that parts may be installed to the original position 4, Loosen drive pinion nut, holding companion flange with Drive Pinion Flange Wrench $T31520000 and pull off companion Mange using a suitable puller.DIFFERENTIAL CARRIER (Type R200) 8, Extract drive pinion from carrier using a press, Take out drive pinion together with rear bearing inser race, ‘bearing spacer and adjusting washer. 6. Remove oil seal. Note: Oil seal must not be reused. 7: Remove pilot bearing together with pilot bearing spacer and front bearing inner race using Pilot Bearing Drift KV38100401. SB / Kv38100401 poses 8. Remove side oil seal. Note: Oil seal must not be reused. 9, Hold rear bearing inner race with Puller $T30031000 and extract om drive pinion with a press 5130031000 10, To remove front and rear bear- ing outer races, put a drift to race surface, and withdraw them by tap- ping the top of drift with a hammer. DIFFERENTIAL CASE 1. Extract bearing using Differential Side Bearing Puller ST3306S00! (set of $T33051001 and ST33061000), 8733051001 Note: a. Securely attach puller to bearing inner race, utilizing two grooves in erential case b. Be careful not to confuse the left and right hand parts, PD-4 2. Remove ring gear by loosening ring gear bolts. Note: Loosen bolts diagonally. 3. Punch off pinion mate shaft lock pin from ring gear side using Sold Punch KV31 100300, Note: Lock pin is eaulked at pin hole ‘mouth on differential case. Do not punch it off forcibly without checking how it is caulked. 4. Draw out pinion mate shaft and remove thrust block, pinion mate geats, side gears and thrust washers. Note: Put marks on gear and thrust washer so that they can be re- installed in their original positions from which they were removed. INSPECTION ‘Thoroughly clean all disassembled parts, and examine them to see that they are worn, damaged or otherwise faulty, and how they are affected. Repair or replace all faulty parts, whichever is necessary. 1, Check gear teeth for scoring, cracking or chipping, and make sure that tooth contact pattern indicates correct meshing depth. If any damaged part is evident, replace parts as re- quired Note: Drive pinion and drive gear are supplied for replacement as a set, therefore, should either part be damaged, replace as a set. 2. Check pinion mate shaft, thrust block, and pinion gears for scores and signs of wear, and replace as required. Follow the same procedure for side gears and their seats on differential 3. Inspect all bearing races and rollers for scoring, chipping or evidence of excessive wear. They should be in tiptop condition such as not wom and with mirrorslike sur- faces. Replace if there is a shadow of doubt on their efficiency, as an incor rect bearing operation may result in noise and gear seizure,DIFFERENTIAL CARRIER (Type R200) 4, Inspect thrust washer faces. Small damage can be corrected with sand- paper. If pinion mate to side gear backlash (or the clearance between side gear and thrust washer) exceeds the specified value, replace thrust washers. Pinion mate-to-side gear backlash: Less than 0.15 mm (0.0059 in) 5. Inspect cartier and differential cease for cracks or distortion. If either condition is evident, replace faulty parts 6. Asa general rule, oil seal should be replaced at each disassembly. ASSEMBLY AND ADJUSTMENT Assembly can be done in the re- verse order of disassembly. Adherence to the following directions for ad. justment and usage of special tools enable to obtain 4 perfect differential operation, PRECAUTIONS IN REASSEMBLY 1. Arrange shims, washers and the like to install them correctly. 2. Thoroughly clean the surfaces on which shims, washers, bearings and bearing retziners ate installed 3. Thoroughly clean oil from ring gear bolt and its hole and contacting surfaces of ring gear and differential case with “Locktite Lacquic Primer” or equivalent. 4. Apply gear oil when installing bearings, 5. Pack recommended multi-purpose grease into cavity between lips when fitting oil seal ASSEMBLY OF DIFFERENTIAL GEAR CASE 1. Assemble pinion mates, side gears, thrust washers and thrist block in differential case. 2. Fit pinion shaft to differential case so that it meets lock pin holes. 3. Adjust side gear-to-pinion mate backlash or adjust the clearance be- tween the rear face of side gear and thrust washer, If above procedure is not effective with existing washer, try with other washers jon mate geor-to-side gear backlash: Less than 0.15 mm (0,0059 in) 4. Lock pinion shaft lock pin using punch after itis secured in place. 5. Apply oil to gear cooth surfaces ‘and thrust surfaces and check that they turn properly 6. Place differentia! case_on ring sear 7. Apply a small amount of locking agent locktte (Stud lock) or equiva Tent] to bolt holes of ving gear, and install sing gear bolts, CAUTION: «a. Use only genuine drive year bolts. 1, Tighten bolts in crisscross fashion lightly tapping sround bolt heads with @ hammer 7. When measure bearing width using Master Gauge KV38102000 and Weight Block 832501000 prior to installation, replacing side bearing, PD-5 ‘Standard bearing width: 21.0 mm (0.827 int svasonom Ns 8. Press fit side bearing inner eace on differential case with Diff, Side Bear ing Drift KV38100300 and Adspter 5133061000. KV38100300 ADJUSTMENT OF DRIVE PINION PRELOAD Adjust drive pinion preload with spacer and washer between front and rear bearing inner caces, regardless of thickness of pinion height adjusting washer. This adjustment must be carried ‘out without oll seal inserted, 1. Press fit front and rear bearing outer races into gear carrier using Drive Pinion Outer Race Drift Set $T30611000, $T30613000 and $T30621000. ‘S306 11000 and 8730613000 Rear. $T30611000 and 8730621000 Front 2. Insert rear bearing inner race into Dummy Shaft KV38100110.