QUICK REFERENCE INDEX DATSUN 280Z SERVICE MANUAL MODEL S30 SERIES ~ aa ae SOUL DL c a nan BF Cea BE OC 7 cy NISSAN MOTOR CO.,LTD,FOREWORD (C =) This service manual has been prepared for the purpose of assisting service personnel of authorized NISSAN/DATSUN dealers in providing effective service and maintenance of the 1977 Datsun 2802. Since proper maintenance and service are absolutely essential in satisfying the Datsun owners, this manual should be kept in a handy place for ready reference and should be carefully studied. This manual includes procedures for maintenance adjustments, minor service operations, Temoval and installation, and for disassembly and assembly of components, Some of these service operations require the use of Special Tools especially designed for effective performance of service operations. ‘The special tools are presented in the “SE” section. ‘AS you read through the maintenance procedures in this service manual, you will occasionally come across paragraphs headed NOTE or CAUTION. A NOTE is supplemental information that is important to a particular procedure. CAUTION warns of steps that must be followed to prevent personal injury and/or damage to some part of your DATSUN. The Quick Reference Index on the first page enables the user to quickly locate the desired section. At the beginning of each individual section is a table of contents, which ives the page number on which each major subject begins. An index is placed at the beginning of each major subject within the section. All information, illustrations and specifications contained in this manual are based on the latest product information available at the time of publication approval, Rights for alteration at any time of specifications and methods are reserved, Liability for any personal injury or property damage occasioned by the use of this service manual in effecting maintenance or repair of your Datsun is in no way assumed by Nissan Motor Co., Ltd. Accordingly, anyone using a service procedure or tool which is not specifically recommended by Nissan must first completely satisfy himself that neither his safety nor the car's safety will be jeopardized by the service method selected. NISSAN MOTOR CO., LTD. C TOKYO, JAPAN ) © 1976 NISSAN MOTOR CO, LTD. Printed in JapanDATSUN 280Z MODEL S30 SERIES in NISSAN} _ NISSAN MOTOR CO., LTD. TOKYO, JAPAN SECTION GI GENERAL MODEL VARIATION (DENTIFICATION NUMBERS APPROXIMATE REFILL CAPACITIES RECOMMENDED PETROL (FUEL) RECOMMENDED LUBRICANTS LIFTING POINTS AND TOWING INFORMATION GI 2 Gl 3 Gl 4General Information MODEL VARIATION = Differential cartier Destination Class Model Engine Transmission | rodel and gest ratio) e HLS30UV FAW7IB $4 R200 3.545 25 | 2seate 30FUV FSSWIL a3 -seater 2 HLS: "Ss iB BS 7 HLS3OAUV 3N7IB Rigo 3.545 ae &| GHLS30Uv FAW71B, as 3 R200 3.545 g | 2+2seater | 9] GHLS30FUV FSSW71B <4 ae 2 GHLS30AUV 3N71B RI80 3.545 fle HLS30U FAW7IB & R200 3.545 5 ‘2-seater HLS30FU FSSW71B fa HIS30A0 SN7IB RI80 3.545 3 g 128 28 GHLS30U Fawr, 38 . R200 3.545 3B” | 2+2scater | 3} GHLS30FU ESSW7IB 3 g 5 | _Guissoau 3N7IB R180 3.545 a HLS30UN FaW7iB g R200 3.545 aseater | 3] HLS3OFUN FSSWILB. 3 HLS30AUN 3N71B R180 3.545 é & GHLS30UN FaW7B R200 3.545 2+ 2seater GHLS30FUN FSSW7IB GHLS30AUN 3N7IB R180 3.545 *; Low altitude means nominally low altitude. GHLSIOFAUNVC Lo Air conditioner California model For Canada Por U'S.A. and Canada Automatic transmission model Manual S-speed transmission model. Left hand drive 28 engine 2+ 2 seater model G12General Information IDENTIFICATION NUMBERS ‘The unit and car numbers are stamped and registered at the factory The engine and car identification ‘numbers are used on legal documents, ‘These numbers are used for factory communication such as Technical Re- port, Warranty Claim, Service Journal and other information, CAR IDENTIFICATION PLATE ‘The car identification plate is located on the left hoodledge panel at the back of strut housing. ‘The plate contains the car type, engine capacity, maximum horse: power, wheelbase and engine and car serial numbers, Fig, GI-1 Car identification plate location CAR SERIAL NUMBER ‘The car serial number is stamped on the upper face of the left dash pane! and is broken down as shown in the following figure. HLS30-XXXXXX Fig. G12 Cor serial number location IDENTIFICATION NUMBER PLATE ‘The identification number plate is located on the upper surface of the instrument panel and can be seen from outside through the windshield glass. ‘The identification number consists of the car model and the serial number. (HLS30-XXXXXX) Fig. GI Identification number plate location ENGINE SERIAL NUMBER ‘The engine serial number is stamp- ed on the right side of the cylinder block. ‘The number is broken down as shown in the following Figure GL, Fig, GI-4 Engine serial number location COLOR CODE NUMBER LABEL ‘The body color code number label is attached to the top face of the radiator core support. M.V. S.S. CERTIFICATION LABEL ‘The MV.SS. certification label is affixed to the upper portion of the left lock pillar. cetifcaton label Fig, GI-6 M.V.S.S. certification label Tocation EMISSION CONTROL INFORMATION LABEL ‘The emission control information label is stuck on the inside panel of the hood, Vehicle emission control information label ia08 Fig. GI-7 Emission control information label location MANUAL TRANSMISSION NUMBER ‘The transmission serial number is stamped on the front upper face of the transmission case. Fig. GIS Body color code number label location aia Fig. O18 Manual trnemision number be locationGeneral Information AUTOMATIC TRANSMISSION NUMBER ‘The transmission serial number is stamped on the right-hand side of the transmission case, av3aa Fig. GI-9 Automatic transmission ‘number location APPROXIMATE REFILL CAPACITIES titers | Usmeaure | impor. mesure Fuel sank 6s "Peel ee Marval ansmision Engine cooling | model ie loa oat sytem "1 [awomai ‘transmission model ee ek eat Engine crankcase o 47 5 qt 4hqt doped | a7 | axp ae Transmission | Manus! ieee Sweet | 20 | xen Sipe Automat ss | sxe seat Ditferentiah [R200 ues zal ae tae R180 10 2Mpt 1% pt "I: Includes 0.8 liter (26US qf, Imp qt) for heater and 0.62 liter (3 qt, 44h) for reservar tank "2: Includes 0.7 liter (3 US qt, 96Imp qt) for oil filter RECOMMENDED PETROL (Fuel) Use an unleaded or low-ead Number) ‘gasoline with a minimum octane rating Of 91 RON (Research Octane leaded gasoline to protect the catalytic On California models, use only un- converter from contamination. oaGeneral Information RECOMMENDED LUBRICANTS RECOMMENDED SAE VISCOSITY NUMBER ENGINE O11 ___ Next OW Change’ Temperature Rags, Anticipated Before LUBRICANT SPECIFICATIONS 1 | Sab chasienion | Futhennore seer to i aoe SAE recommended vzoty Transmission 3 apt GLa oo 5 & APL OLS [ Aviomate Tarnaid | Type DEXRON | Multipurpose grease | NLGI2 Brake and clutch fuid | DOT 3 Antifiecce Permanent antifteeze Ethylene glycol bjse)General Information LIFTING POINTS AND TOWING JACK UP PANTOGRAPH JACK Place a jack under the posi where sill flange is cut for identifica- tion. Do not jack up other positions. i201 Fig. GI-10 Jacking point Notes: a. Never get under the car while it is supported only by the jack, Always use safety stands to support frame ‘when you have to get under the car. . Block the wheels diagonally by wheel chocks. Fig. GI-11 Wheel chocks and jack GARAGE JACK Notes: a. When jacking up the front of the ‘car, place the chocks behind the rear wheels to hold them, ', When jacking up the rear of the car, place the chocks at the front side of the front wheels to hold them, c. When carrying out operations with the garage jack, be sure to support the car with safety stands. ‘The front jacking point is center of front suspension member and rear is differential gear carter. Do not place a jack on the center portion of front suspension transverse link. Fig, GI-13. Rear jacking point SUPPORTABLE POINT Front supportable points for stand are both front side members. Rear supportable points are on both sides of front differential mounting cross- member. orz08 Fig. GI-14 Front supportable points as Fig. GI-18. Rear supportable points TOWING Cautions: It is necessary to use proper towing ‘equipment, to avoid possible dam- age to the car during a towing ‘operation. ‘Towing is in accordance with Tow- ing Procedure Manual at dealer side, b. All applicable State or Provincial (in Canada) laws and local laws regarding the towing operation ust be obeyed. ©. Only front hooks may be used for towing purposes. When front hooks are used for towing, remove front apron and front fender front to Prevent possible interference with towing rope, Note: Be sure to remove rear hooks before delivery of car If the transmission and rear axle are in good working order, the car may be towed with all the wheels on the road, If the transmission andjor rear axle are inoperative, the car must be towed from the rear with the rear wheels raised. When car is to be towed forward, connect a rope securely to hook at tached to front side member. See Figure GI-16. Before towing, make sure parking brake is released and transmission is in Neutral.General Information To prevent damage, remove front apron and front fender front ra06 Fig. GI-16 Front towing point Cautions: a, The ignition key must be turned to the OFF position and remain in the ignition. Do not remove the key during the towing operation, as this will lock the steering column and damage the lock mechanism. b. The car is equipped with a front towing hook as illustrated. How- ‘ever, this hook should be used only in an emergency situation, eg, to pull the car out of a ditch, a snowbank or mud. c. When towing, do not take up slack in the rope too quickly. Always pull the rope in a straight direction with respect to the hook. Do not apply force to the hook in side direction. It is illegal to tow a car on the highways with a rope, 4, MANUAL TRANSMISSION MODEL Before towing, make sure transmis- sion is in neutral gear. If rear axle or transmission is inoperative, car should bbe towed with its rear wheels off the ground, or propeller shaft must be removed, AUTOMATIC TRANSMISSION MODEL Car may be towed safely onits rear ‘wheels on the ground with select lever in “N” (Neutral) position at speeds of Jess than 30 km/h (20 MPH). However, propeller shaft must be disconnected for car must be towed on its front wheels on the ground under the fol lowing conditions: 1, Towing speed of more than 30 krnjh (20 MPH). 2. Car must be towed for a long distance (over 6 miles or 10 km), 3. Transmission isnot operating pro- erly, Caution: If car is towed on its front wheels on the ground, steering wheel should be secured to ‘maintain a straight ahead position, oi TIE-DOWN HOOK There are four tie-down hooks. ‘Two of them are located on front side ‘members, and the other two on rear panel. Front tiedown hook attached to either side member is also used as a towing hook. Note: When fastening chains to rear transverse link, wrap them around Tink to avoid interfering with any adjacent parts. Rear tie-down hook ‘c1308 Fig, GI-18 Rear tie-down hookDATSUN 280Z MODEL S30 SERIES [NISSAN] NISSAN MOTOR CO., LTD. TOKYO, JAPAN SECTION ET ENGINE TUNE-UP BASIC MECHANICAL SYSTEM | IGNITION AND FUEL SYSTEM EMISSION CONTROL SYSTEM SERVICE DATA AND SPECIFICATIONS TROUBLE DIAGNOSES AND CORRECTIONS i ET- 3 ET. § ET-10 ET-13 ET-14ea 30 32 33 34 35 37 38 3 40 ‘Purge control valve Carbon canister Vapor vent line Canister purge tne Carbon canister to 3.vay connector vacuum hose Fool filter Fuel fed rubber hose Fuel turn rubber hove ‘Thermal transmitter Thermotime switch ‘Water temperature sensor 3-way connector to distibutor vacuum hose ‘Antistall dash pot (Manual Transmission only) 3+vay connector throttle chamber vacuum hose ‘Throttle chamber Ile sped adjusting screw ‘Throttle chamber to air regulator rubber hose Throttle valve switch Throttle chamber to 3-way connector rubber hose Cold start vale Cold start valve to fuel pipe D rubber hose ‘Throttle chamber to thermal vacuum valve vacuum hose Air regulator ‘Heater housing to water pipe rubber hose Fuel pipe D ‘Thermal vacuum valve Air regulator to 3way connector rubber hose 3.way connector Fuel pipe D to fuel pipe A rubber hose ‘Thermal vacuum valve to vacuum delay valve vacuum hoee Pressure regulator to intake manifold vacuum hose 3-way connector to rocker cover rubber hose ‘Vacuum dob valve ‘Vacuum delay valve to BP. vale vacuum hose BPI. valve BPLT. vale to E.G.R, control valve vacuum hhowe EGR control vale ‘Thermal vacuum valve to BLP-T. valve Injector holder Injector Fue pipe C Fuel pipe A to fuel pipe C rubber hose Pressure regulator to fuel pipe C rubber hose Pressure regulator Pressure regulator to fuel pipe B rubber hose Rubber hos to water pipe * California models only Fuel pipe A to uel pipe B rubber hose Fuel pipe B **Non-Califomia models Fuel pipe A only ‘Heater housing to water pipe rubber hose Rubber hose to cylinder head water pipe aoe Fig. ET-1 128 engine eystem piping dn-eun, eu6ugEngine Tune-up BASIC MECHANICAL SYSTEM CONTENTS ADJUSTING INTAKE AND EXHAUST REPLACING OIL FILTER «oe. eceess era VALVE CLEARANCE 1.3 CHANGING ENGINE COOLANT era VALVE CLEARANCE «0... €T3 PERMANENT ANTI-FREEZE CHECKING AND ADJUSTING DRIVE COOLANT an eT Ss . £T-3 CHECKING COOLING SYSTEM HOSES FAN BELT...... : ET-3 AND CONNECTIONS i eral COOLER COMPRESSOR BELT .. ETS INSPECTION OF RADIATOR CAP... ETS RETIGHTENING CYLINDER HEAD BOLTS, COOLING SYSTEM PRESSURE TEST ETS MANIFOLD NUTS AND THROTTLE CHECKING VACUUM FITTINGS, HOSES, CHAMBER SECURING BOLTS ETA AND CONNECTIONS seeeee ETS CHANGING ENGINE OIL . ET4 CHECKING ENGINE COMPRESSION ETS TESTING RESULT ETS ADJUSTING INTAKE AND EXHAUST VALVE CLEARANCE Valve clearance adjustment cannot bbe made when the engine is in opera ton: 1, Loosen pivot locking nut and turn pivot screw until the specified clearance is obtained while engine is VALVE CLEARANCE cold. After adjustment, tighten pivot nut securely with special tool, and recheck the clearance. 2. Warm-up engine for at least several minutes and then stop. Measure valve clearance while engine is hot. If clearance is not within specifications, adjust. Unit: mm (in) Intake 0.20 (0.008) Cold Exhaust 0,25 (0.010) Intake 0.25 (0.010) Hot Exhaust 0.30 (0.012) 7 Fig. BT-2 Adjusting valve clearance CHECKING AND ADJUSTING DRIVE BELTS FAN BELT 1. Check for cracks or damage. Re- place if necessary. 2. Adjust fan belt tension. It is correct if deflection is 8 to 12 mm (0.315 to 0.472 in) when thumb pres: sure [10 kg (22 16)] is applied midway between fan pulley and alternator pul ley. ET emer Fig, ET-3 Fan belt tension COOLER COMPRESSOR BELT 1. Check cooler compressor belt for crack or damage. Replace if necessary 2. Adjust cooler compressor belt tension by turning idler pulley bolt in or out It is correct if deflection is 8 to 12 mm (0.315 to 0.472 in) when thumb pressure [10 kg (2 Ib)] is applied tnidway between crank pulley and cooler compressor pulley. G2). Fig. ET-4 Cooler compressor belt tensionRETIGHTENING CYLINDER HEAD BOLTS, MANIFOLD NUTS AND THROTTLE CHAMBER SECURING BOLTS Engine Tune-up Manifold nuts 8 mm (0.315 in) dia, bolt 1.4 t0 18 kgm (10.1 t0 13.0 fb) 10 mm (0.394 in) dia, bole 3.5 10 5.0 kgm 5 to 36 Feb) ‘Throttle chamber securing bolts Tightening torque: 15 to2.0kgm Cylinder head bolts. (11 to 14 ftp) Isttum: 4.0 kg-m (29 fulb) 2nd turn: 6.0 kgm (43 £16) Note: There are two types of 10M 3d turn: intake manifold securing bolts as 7.0 108.5 kgm shown in Figure ET-S, When in- G51 t061 ft-lb) stalling, do not confuse them, dimensions; Long bolt (amu): 40. mm (1.575 in) Short bolt ( qm J: 32:mm (1.260 in) Fig. BT-6 Tightening sequence of cylinder head bolts CHANGING ENGINE OIL 1. Cheek if oil is diluted with water or gasoline. Drain and refill oil if necessary. Fig, BT-5 Intake manifold securing bolt Notes: 8. A milky oil indicates the presence of cooling water. Isolate the cause and take corrective measure. '. Am ol with extremely low viscosity indicates dilution with gasoline, 2. Check oil level. If below the specified level, raise it up to the H level Engine oil capacity (including ol filter): Maximum (H level) 4.7 £(5 US at, 434Imp qt) Minimum (L level) 3.7£(3%US qt, 3M Imp qt) ers REPLACING OIL FILTER Oil filter i of & cartridge type, and can be removed with Oil Filter Wrench $T19320000, 1. Check for ol leaks past gasketed flange. If any leakage is found, re- tighten just enough to stop leakage. If relightening is no longer effective, replace filter as an assembly. 2. When installing oil filter, tighten by hand Note: Do not overtighten oil filter, lest leakage should occur, CHANGING ENGINE COOLANT PERMANENT ANTI- FREEZE COOLANT ‘The permanent antifreeze coolant is an ethylene glycol base product con- taining chemical inhibitors to protect the cooling system from rusting and corrosion. The antifreeze does not contain any glycerine or ethyl alcohol, It will not evaporate of boil away and ‘can be used with either high or low temperature thermostats. It flows freely, transfers heat efficiently, and will not clog the passages in the cooling system. The anticfreeze must not be mixed with other product. This coolant can be used throughout the seasons of the year, Whenever coolant is changed, the cooling system must be flushed and refilled with a new coolant. Check the coolant level See instructions attached to the anti-freeze container for mixing ratio of antifreeze to water, CHECKING COOLING SYSTEM HOSES AND CONNECTIONS Check hoses and fittings for loose connections or deterioration. Re- tighten or replace if necessary. INSPECTION OF RADIATOR CAP Apply reference pressure (0.9 kglem? (13 psi)] to radiator cap by means of a cap tester to see if it isEngine Tune-up satisfactory. Replace cap assembly if necessary. ero12 Fig. ET-7 Testing radiator cap COOLING SYSTEM PRESSURE TEST With radiator cap removed, apply reference pressure [1.6 kg/em? (23 psi)} to the cooling system by means ofa tester to detect any leakage. Water capacity (including heater and reservoir tank): Manual transmission model 10.3 liter (10% U.S. qt, 936 Imp. at) ‘Automatic transmission model: 10.1 liter (1O%US. gt, 8% Imp. qt) ressure test CHECKING VACUUM FITTINGS, HOSES, AND CONNECTIONS Check fittings and hoses for loose connections or damage. Retighten loose parts or replace parts that are not suitable for further use. CHECKING ENGINE COMPRESSION * To check cylinder compression, iis essential to remove all spark plugs” The purpose of this test is to determine ‘whether there is excessive leakage past piston rings, head gasket, etc. To test, engine should be heated to the opera ting temperature and throttle valve ‘opened. Cylinder compression in cylinders should not be less than 80% of the highest reading, Different compression in two or mote cylinder usually indi cates an improperly seated valve or broken piston ring. Low compression in cylinders can result from worn piston ings. This, trouble may usually be accompanied by excessive fue consumption. Fig. BT-9 Testing compression Pressure TESTING RESULT If cylinder compression in one or more cylinders is low, pour @ small quantity of engine il into cylinders through the spark plug holes and retest ‘compression. 1, If adding oil helps the compres- sion pressure, the chances are that piston rings are worn or damaged. 2. If pressure stays low, the likeli hood is that valve i sticking or seating improperly. 3. If cylinder compression in any two adjacent cylinders is low, and if adding oil does not help the compres- sion, there is leakage past the gasketed surface Oil and water in combustion cham- bers can result from this trouble, Compression pressure ke/em? (psifat epm: 11.5 to 12.5 (164 to 178)/ 300 to 400 IGNITION AND FUEL SYSTEM CONTENTS CHECKING BATTERY E16 CHECKING ENGINE IDLE RPM AND CHECKING AND ADJUSTING IGNITION MIXTURE RATIO... v7 TIMING . £16 DASH POT ADJUSTMENT : AND REPLACING SPARK (Manual transmission models only) er. lues cre CHECKING FUEL LINES (HOSES, CHECKING OPERATING PARTS OF PIPING CONNECTIONS, TC.) ET9 DISTRIBUTOR AND IGNITION WIRING ery REPLACING FUEL FILTER eT9 AIR GAP eT? CHECKING AIR REGULATOR HOSES .. ET9 DISTRIBUTOR eT? REPLACING AIR CLEANER ELEMENT ET9 HIGH TENSION CABLE er? CHECKING CABLE HARNESS AND CHECKING DISTRIBUTOR CAP ROTOR eT7 CONNECTORS ero ETSCHECKING BATTERY 1. Remove six vent plugs and check electrolyte level in each battery cell. If nocessary, pour distilled water, Fig. 7-10 Checking electrolyte level Engine Tune-up 2. Measure the specific gravity of 2. Thoroughly remove dirt and dust battery electrolyte, from crank pulley at timing mark location and front cover at timing indicator. 4. Connect engine tachometer and oer es onde war ans oe oe Eee bene eee ae Seer eee ae ae Full charge value Caution: When selector lever is shifted [at 20°C (68°F)] to “D” position, apply parking brake and block both front and rear Frigid climates Over 1.22 1.28 ‘heels with chocks. Tropical climates Over 1.18 123 6. Check ignition timing with a timing light to ensure that it is ad- Other climates Over 1.20 1.26 justed to specifications indicated in the chart below. Clean top of battery and terminals with a solution of baking sode and water. Rinse off and dry with com- pressed air. Top of battery must be clean to prevent current leakage be- tween terminals and from positive tetminal to hold-down clamp. In addition to current leakage, prolonged accumulation of acid and dirt on top of battery may cause bistering of the material covering con- nector straps and corrosion of straps. After tightening terminals, coat them with petrolatum (vaseline) to protect them from corrosion, Cautions: a. If it becomes necessary to start the engine with a booster battery and jumper cables, the booster battery voltage must not exceed 12 volts, or the control unit of the fuel injection system and other electric ‘components will be damaged, If the battery cables are discon- nected, they should be tightly clamped to the battery terminals to secure a good contact. CHECKING AND ADJUSTING IGNITION TIMING 1, Check spark plugs for condition. je Ignition timing Manuel transmission 10° B-T.D.C,/800 rpm Automatic transmission (in “D” position) | 10° B.T.D.C,/700 rpm If necessary, adjust it a follows. (1) Loosen set screw until distribu- tor can be moved by hand, (2) Adjust ignition timing to specifi- ol cations, ) Lock distributor set serew, and ~~ ‘make sure that mings correct. . Nee Fig. ET-18. Ignition timing indicator CHECKING AND REPLACING SPARK PLUGS 1, Remove and clean plugs in a sand blast cleaner. Inspect each spark plug. ‘Make sure that they are of the specifi- ed heat range. 2. Inspect insulator for cracks or ‘chips. Check both center and ground electrodes. 3. If they are excessively worn, re- Fig, ET-12 Adjusting ignition timing place with new spark plugs. ETS4. Spark plug gap: For US.A. 1.0to 11mm (0.039 t0 0.043 in) For Canada 0.7008 mm (0.028 to 0.031 in) Tightening torque: 1.5 to 2.0 kgm (11 to 14 feb) £080 Fig, BT-14 Checking spark plug aap CHECKING OPERATING PARTS OF DISTRIBUTOR AND IGNITION WIRING AIR GAP Standard air gap is 0.2 to 0.4 mm (0.008 to 0.016 in). If the gap is off the standard, adjustment should be made by loosen- ing pick-up coil screws. Gap gauge is required for adjustment. Air gap: 0.2 10.0.4 mm (0.008 to 0.016 in) Fig, ET-15 Measuring alr gop Remove rubber cap from tip end of rotor shaft, Check grease and, if neces: sary, add, To remove pick-up coil, remove two pick-up coil assembly se. ‘curing sctews and core screws clamp- ing primary lead wire. Install new pick-up coil assembly in reverse se- quence of removal Engine Tune-up Fig. ET-16 Removing pick-up coit DISTRIBUTOR Check the centrifugal mechanical parts for loose connection, sticking of spring, or excessive or Local wear. If found to be in good condition, then check advance characteristics using a distributor tester. For test procedure and reference data, refer to Distributor in Section EE. If vacuum advance unit fails to operate properly, check the following items and correct as necessary: 1, Check vacuum inlet for leakage at connection. If necessary, retighten or replace. 2. Check vacuum diaphragm for air Teak, If leak is found, replace diaphragm. 3. Inspect breaker plate for smooth ‘operation, If plate does not move smoothly, this may be caused by sticky steel balls or pivot. Apply grease to steel balls or, if necessary, replace breaker plate as fan assembly. Refer to Section BE, Distributor, as regards vacuum advance characteristics. HIGH TENSION CABLE Use an ohmmeter to check resist- tance on high tension cables. Discon- rect cables from spark plugs and re- move distributor together with hi tension cables. Do not remove cables from cap. Connect the ohmmeter be- ‘tween cable terminal on the spark plug side and the corresponding electrode inside cap. If the resistance is more than 30,000 ohms, remove cable from cap ‘and check the cable resistance only. If resistance is still more than 30,000 ohms, replace cable assembly. er? Fig. BT-17 Checking high toncion cable CHECKING DISTRIBUTOR CAP ROTOR Note: This operation is to be per formed while checking distributor points. Inspect distributor cap for cracks and flash over. External surfaces of all parts of secondary system must be cleaned to reduce possibility of voltage loss. All wires should be removed from dis- tributor cap and coil so that terminals can be inspected and cleaned. Burned or corroded terminals indicate that wires are not fully seated, which causes arcing between end of wire and terminal. When replacing wires at ter- minal, be sure they are fully seated bbefore pushing rubber nipple down over tower. Check distributor rotor for damage, and distributor cap for eracks. Apply grease through the top of distributor shaft. CHECKING ENGINE IDLE RPM AND MIXTURE RATIO Cautions: ‘2, On automatic transmission models, checks should be performed with the lever shifted to the “D” posi- tion. Be sure to engage parking brake and to lock both front and rear wheels with wheel chocks. b, Depress brake pedal while accelera- ting the engine to prevent forward surge of ear. ¢. After idle adjustment has been made, shift the lever to the “N” or “p” position and remove wheel chocks.Engine Tune-up Idle mixture inspection requires the 4. Check ignition timing, If neces: use of a CO-meter. Before attempting _sary, adjust it to specificaticns. to check idle mixture ratio, itis essen- tial to have the meter thoroughly warmed up and calibrated 1, Warmup engine until water tem. erature gauge registers operating tem- perature, 2. Race engine (1,500 to 2,000 rpm) two or three times under no load, then idle engine for one minute. 3. Check idle speed. If necessary, ad just it to specifications. Engine speed: Manual transmission: 800 pm Automatic transmission (in “D” position): era0s 700 rpm, Fig. BT-18 Adjusting idling speed Ignition Manual transmission 10° B.T.D.C/800 rpm Automatic transmission. (in “D” position) 10° B.T.D.C,/700 rpm 5. Check CO percentage with CO meter, Specified CO percentage is as follows: {le mixture ratio (CO percentage) California models: CO= 0.5% max. NonCalifornia models: CO= 1.0% max. Note: When checking idle mixture ratio (CO percentage), make sure that the following parts are in good onder. © Battery © Ignition system Engine oil and coolant levels Fuses © EFL © ELF. harness connectors () Remove connector of throttle © Hoses valve switeh harness, . OU fer cap aad ol evel pps (2) Ensrt a leadg wire to the ter Rite clearance, engine compres. nina of connectors @ and ® sion Note: When adjusting idle CO per ‘centage at altitudes 750 m (2,500 ft) or more for California models, be sure to disconnect altitude switch connector. Refer to pages EF-1S and EF-64. ETB If specified idle CO percentage is ‘ot obtained, adjust as follows: 6. Idle Mixture Setting Procedure (dle mixture ratio adjustment) Note: The idle mixture ratio of elec- tronic fuel injection car is set so {ean that it is not appropriate to use CO% as an indicator of mixture ratio, Therefore, in order to adjust ‘le mixture ratio with convention- al CO analyzer, a certain amount of enrichment must be temporarily siven to idle mixture setting to make it richer. To enrich the idle mixture, the full load enrichment is forced to func- tion by making a short circuit in that enrichment circuit. The actual procedure to be followed is illus: trated below. 1 Air Mow ineter 2 Aiery-pace sew 3. Tivottle chamber 4 Throttle valve switch 5 Connector of throttle vale switch hamess 6 Leading wie era62 Fig. ET-19 Idle mixture ratio adjustment (3) Adjust idle CO to the shitude Specifications by turning. ait by-pass Notes: 4. Remove plastic blind plug. from by-pass screw of air flow meter. b. Tum air by-pass screw clockwise to obtain rich mixture; turn it coun. terclockwise to obtain lean mix- ture.Engine Tune-up dle CO specifications: (full enrichment) Altitude 0 t0 600 m (0 to 2,000 ft) {600 to 1,200 m (2,000 to 4.000 tt) 1,200 to 1,800 m (4,000 to 6,000 ft) Above 1,800 m (6,000 ft) [dle CO % (full enrichment) 3.3% 41% 5.1% 6.7% (4) Remove the leading wire and connect the harness back to the throt- te valve switeh, Note: After adjusting idle CO per centage for California models. re- place altitude switch connector in its original position. (9) Install a new rubber plug (fur- nished as a service part) on air flow meter ers6a Fig, ET-20 Rubber plug (oy Check CO percentaye if it is wahin specifications le mixture ratio (CO percentage): California models CO = 0.5% max, Non Calionia models CO= 1.044 mix. DASHPOT ADJUSTMENT (Manual transmission models only) Make sure that the clearance be tween idle setserew (preset at th. factory) and throttle lever is 19) mnt (0.0748 in). Use shinm(s) or suitable jauge to measure the clearance. dlearance of 1.9 mm (0.0748 in) be- tween these two points corresponds te 2,000 engine rpm under no toad. Check that the dashpot rod end closely touches throttle lever wi Frosh at > Blow-by gas P.C.V. VALVE Check P.C.V. valve in accordance with the following method With engine running at idle, remove the ventilator hose from P.C.V, valve If the valve is working, a hissing noise will be heard as air passes through the valve and a strong vacuum should be felt immediately when a finger is placed over valve inlet. Replace P.C.V. valve in accordance with the maintenance schedule, VENTILATION HOSE 1. Check hoses and hose connec: tions for leaks. 2. Disconnect all hoses and clean with compressed air. If any hose cannot be free of obstructions, replace, Ensure that flame arrester is surely inserted in hose between throttle ‘chamber and rocker cover. CHECKING EVAPORATIVE EMISSION CONTROL SYSTEM FUEL TANK, VAPOR LIQUID SEPARATOR AND VAPOR VENT LINE 1. Check all hoses and fuel tank filler cap. PCY. valve Stoel net Baffle plate Fig, ET-25. Crankease emission control system 2. Disconnect the vapor vent line ‘connecting carbon canister to vap. liquid separator. 3. Connect a 3.way connector, a ‘manometer and a cock (or an equiva: lent 3-way charge cock) to the end of the vent lin. 4. Supply fresh air into the vapor vent line through the cock little by little until pressure becomes 368 mm#l20 (14.5 inH20). 5. Shut the cock completely and Teave it unattended, 6. After 2.5 minutes, measure the height of the liquid in the manometer. 7. Vatiation of height should remain with 25 mml120 (0.98 inH120). -way connector Cock Aire Manometer Carbon canister 8. When filler cap does not close completely, the height should drop to ze10 ina short time 9. If the height does not drop to zero in a short time when filler cap is removed, it is the cause of a stuffy hose Note: In case the vent line is stuffy, the breathing in fuel tank is not ‘thoroughly made, thus causing in- sufficient delivery of fuel to engine ‘or vapor lock. It must, therefore, be repaired or replaced. 368 mmil20 (14.5 inH20) Vaporsiquid separator Fuel filler cap eons Fig. ET-26 Checking evaporative emission control system eratCARBON CANISTER PURGE CONTROL VALVE Check for fuel vapor leakage. in the for vacuum Hine, at diaphiragen af cadbon eanister purge control valve To check for leakage, proceed as follows: ssconnect rubber hose, in the ne. between T-connector and eashon cr at T~~onnector 2. inhale air into the opening of wher hose running to vacttim hole in canister and ensure that there ers 'T-27 Checking carbon canister urge control valve Engine Tune-up 3. If there is a leak, remove top cover from purge contiol valve and check for dislocated or cracked dia. phragm. If necessary, replace dia. aihragm kit (which i made up of a ‘eiainer, diaphragm and sping). 2 Diapheagm ae spine Fig. £128 Carbon canister purge control valve CARBON CANISTER FILTER Check for a contaminated element. Llement can be removed at the vottom of canister installed on car badly ET12 os & we : SN yl Fig. E1-29 Replacing carbon canister filter FUEL TANK VACUUM RELIEF VALVE Remove fuel filler cap and see that it functions properly. 1. Wipe valve place it in your mouth 2. Inhale ait, A stig resistanes ae companied ay valve indicates that valve isin good mechanical condition, Note also that, by further inhaling sit the resistance’ shoult disappear with valve clicks 3. IT valve is clogeed, or if no re- sistance is felt, replace cap as an assembly, 7 a gs ising clean and C370 Fig. ET-30 Fuel filler capEngine Tune-up SERVICE DATA AND SPECIFICATIONS Ignition timing and idling speed Manual transmission degree! apm 10° B:.D.C/800 oa degree/rpm 10° B..D.C/700 Valve clearance cold Intake sn in) . 0,20 (0.008) Exhaust vom ing oS 0250010) Hot Intake som (in). «0:25 (0.010) Exhaust sim tin - 030(0.012) Bett tension Fan and alternator sm (in 8 t0 120315 0 0472) Aur con gompressor som tin) 810 12(0.315 0472) Pressure gb 10 (22) is applied Compression presse at 300 to 400 rpm Standard fem? (PS) 125.0178) Minimum egfem? (PSI) nnsnnnnnen 11.5 (164) Radiator cap reliet pressure kgfem? (Psi) canoer sonesnnnrer 09 (13) Cooling system Leakage testing pressure Pe eee 1623) Battery specific pravty at 20°C (68°F 1 1.26 Distibutor Ae gap mm (in) 0.2 to 0.4 (0.008 to 0.016) Spark plug Gap mm (in) « . For USA, 1.0 t0 1.1 (0.039 to 0.043) For Canada 0.7 t0 0.8 (0.028 to 0.031) Checking “CO” percentage at idling speed California models % ss 0.5 ma Non California models Seems LTS Dash pot Setting engine speed TBM arenes 2,000 Tightening torque Cylinder head bolts Ist turn kgan (fb). se 4.929) 2nd turn gsm (ftb) — ss 6.0(43) 3rd turn kg-m (fb) oe 7.0 0 8.5 (51 10 61) Manifold nuts kgm (ftlb) 8 mm (0.315 in) dia. bolt; 1.4 to 18 (10.1 to 13.0) 10 mm (0.394 in) dia. bolt; 3.5 to $.0 (25 to 36) 15 to2.0(11 to 14) 155 to 2.0(11 to 14) Throttle chamber securing bolts kgm (Ft 1b) .. ‘Spark plugs gem (Ub) on eT43Engine Tune-up TROUBLE DIAGNOSES AND CORRECTIONS Condition Probable cause Corrective action CANNOT CRANK Improper grade oil, Replace with proper grade oil, ENGINE OR SLOW | Partially discharged battery. Charge battery. ae Malfunetioning battery. Replace. Loose fan belt Adjust Trouble in charge system, Inspect. Wiring connection trouble in starting circuit, | Correct. Malfunctioning ignition switch Repair or replice, Malfunctioning starter motor Repair or replace, (Trouble-shooting procedure on starting circuit) Switch on the starting motor with head lights “ON”. When head lights go off or dim considerably, 4. Check battery . Check connection and cable, ©. Check starter motor When head lights stay bright, 4. Check wiring connection between battery and starter motor. Check ignition switch. ©. Check starter motor ENGINE WILL CRANK NORMALLY BUT WILL NOT START in this case, the following trouble causes may exist, but in many cases ignition system or fuel system isin trouble, Ignition system in trouble Fuel system in trouble Valve mechanism does not work properly Low compression (Trouble-shooting procedure) ‘Check spark plug firstly by following procedure Disconnect high tension cable from one spark plug and hold it about 10 mm (0.39) from the engine metal part and crank the engine, ee a. Check spark plug, . Check ignition timing, ©. Check fuel system. 4. Check revolution trigger signal, . Check cylinder compression, No spark occurs. Very high current, ‘Check the current flow in primary circuit Inspect primary cireuit for short Cheek distributor pick-up coil operation, Check transistor ignition system, ET14Engine Tune-up Condition Probable cause Corrective action Ignition system in trouble Low or no current. Malfunctioning distibutor pick-up col Improper air pup. Leak at rotor cap and rotor. Malfunetioning spark plug, Improper ignition timing Malfunctioning ignition coil Disconnection of high tension cable. Loose connection or disconnection in primary circuit. Irregular revolution trigger pulse. Malfunctioning full transistor ignition unit. Check for loose terminal or disconnection in primary ciroutt. ‘Check for burned points. Adjust. Clean or replace. Clean, adjust plug gap ot replace. Adjust. Replace. Replace. Repair or replace, Replace transistor ignition control unit, Replace. ENGINE CRANKS NORMALLY BUT WILL NOT START uct systom. ‘malfunction ‘Low compression Lack of fuel, Damaged electronic fuel injection harness or relay. Malfunctioning fuel pump (Listen to opera- ting sound). Damaged control unit. Seized injector (Listen to operating sound). Seized cold start valve. Malfunctioning air flow meter. Damaged water temp. sensor. Malfunctioning pressure regulator. Dirty fuel strainer. Dirty or clogged fuel pipe. Clogged fuel tank breather pipe. Incorrect spark plug tightening or damaged sasket. Improper grade engine oil or low viscosity Incorrect valve clearance ‘Compression leak from valve seat. Sticky valve stem Weak or damaged valve springs. Compression leak at cylinder head gasket Supply. Replace, Replace. For inspection procedures for electronic fuel injection sys- fem components, refer to ‘engine fuel section, Replace. Replace. Replace. Replace. Replace, Replace. Replace. Clean. Repair and clean. ‘Tighten to normal torque or replace gasket. Replace with proper grade oll. Adjust, Remove cylinder head and lap valves. Correct or replace valve and valve guide. Replace valve springs. Replace gasket. ETSCondition Engine Tune-up Probable cause Corrective action Low compression Sticking or defective piston ring. Worn piston ting or cylinder, (Trouble shooting procedure) Pour the oylinder c Compr engine oil from plug hole, and then measure sompression, cession increases. ‘Compression does not change. Replace piston rings. ‘Overhaul engine. Trouble in cylinder or piston ring, Compression leaks from valve, cylinder hea or head gasket. UNSTABLE ENGINE IDLING Ignition system Engine mechanical systom in trouble Incorrect idle adjustment Malfunctioning ignition system (spark plug, high tension eable, air gap, full transistor ‘ignition unit, ignition coil, etc.) Incorrect basic ignition timing. Loose manifold and cylinder head bolts, Adjust Replace, Ajust. Retighten bolts. Incorset valve clearance Aus. Fast syst Clogged air leaner fs. Replice element mmalfunetion Damaged manifold gaskets. Replace gasket, Intake air leakage at following points: Repait or replace. Dipak Oi filler cap Blow.hy hoes Intake air uct air Row mete 0 throtle chamber. Damaged electronic fost injection harness, | Replace, j Seized injector (Listen to operating sound), | Replace. 1 eee Malfunctioning air regulator (During warm- | Replace (na up driving only) ieeciital aye Damaged contol unit Replace tem compos Damaged water and air temp. sensor. Replace. nents, refer to Malfunctioning throttle vale switch Repair or replace oo | Damaged atte switch Replace ae Irregular fuel pressure. Replace pressure regulator. ) Others {_Mufuntoning E.G, contol ve, Clean or replace HIGH ENGINE Dragged accelerator lnk. (heck and correct accelerator Ikape. IDLE SPEED Malfunetioning B.C.D.D. system Matfunctioning air regulator. eT16 If engine idling speed rises above 1,800 10 2,000 rpm, the cause may be a malfunctioning B.C.D.D. system, Check B.C.D.D. system, Repair or replace if necessary. Replace. For inspection procedures for air regulator. refer to engine fuel section.Condition Engine Tune-up Probable cause Corrective action HIGH ENGINE Incorrect adjustment of idle speed adjusting Correct. IDLE SPEED screw. For inspection procedures, refer to throttle chamber section. ENGINE POWER NoT UP TO NORMAL Low compression Previously mentioned. Ignition system in Incorrect ignition timing Adjust, ‘rouble Malfunetioning spark plugs. Clean, adjust or replace plugs. Malfunctioning distributor pick-up coil Dress, or replace points. Also check condenser. ENGINE POWER BELOW NORMAL For inspection procedures for Fuol systom Throttle valve does not open fully. Adjust. electronic fuel mattun Damaged electronic fuel injection harness Replace, injection sys tem compo- | Seized injector (Listen to operating sound), | Replace. a ee Malfunctioning air flow meter. Replace Engine Fuel Malfunetioning throttle valve switch. Repair or replace.) Section, Air intake system ‘malfunction Overheating Irregular fuel pressure. Clogged fuel pipe, Dirty or clogged fuel strainer. Fuel pump will not work properly. Clogged air cleaner. Air leaking from manifold gasket. Intake air leakage at following points: Dipstick Oil filler cap Blow-by hoses Intake air duct-air flow meter to throttle chamber ete, Insufficient coolant. Loose fan belt. Worn or damaged fan belt. Malfunetioning thermostat. Malfunctioning water pump. Clogged or leaky radiator. “Malfunctioning radiator filler cap. Air in cooling system. Improper engine oil grade. Incorrect ignition timing, Replace pressure regulator if necessary. Replace if necessary, Replace. Replace, Replace element. Replace gasket. Repair or replace. Replenish, Adjust fan belt, Replace. Replace, Replace. Flush, repair or replace. Replace. Retighten each part of cooling system. Replace with proper grade oil Adjust. ery