Nissan Atlas F23 Workshop Manual

<COMBINED EDITION>
QUICK REFERENCE INDEX
GENERAL INFORMATION GI
MAINTENANCE MA
ENGINE MECHANICAL EM
ENGINE LUBRICATION & LC
COOLING SYSTEMS
ENGINE FUEL & EMISSION CONTROL SYSTEM EF&EC
ACCELERATOR CONTROL, FUEL & FE
EXHAUST SYSTEMS
CLUTCH CL
MODEL F23 SERIES
MANUAL TRANSMISSION MT
PROPELLER SHAFT & PD
DIFFERENTIAL CARRIER
FRONT AXLE & FRONT SUSPENSION FA
REAR AXLE & REAR SUSPENSION RA
BRAKE SYSTEM BR
STEERING SYSTEM ST
BODY BF
HEATER & AIR CONDITIONER HA
ELECTRICAL SYSTEM EL
Edition: July 1992

Printing: July 1992 (01)
Publication No.: SM3E-F3H1G0
NISSAN MOTOR CO., LTD.

© 1992 NISSAN MOTOR CO., LTD. Printed in Japan
All rights reserved. No part of this Service Manual may be reproduced or stored in a retrieval system, or transmitted in any
form, or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of
Nissan Motor Company, Ltd., Tokyo, Japan.
"fhis manual contains l'Raintenance anci'J:epair procedures for Nissan
roode I f=23andH41 series.
In order to assure your safety and the efficient functioning of the

vehicle, this manual should be.readthqroughly. It is especially impor-
tant that the PAECAUTIONSinthe'Glsection be completely under-
stood before sterth'lg any repairta.sk.
All information in .this manual is baseci on the latest product informa-

tionat the time of publication. The right is reserved to make changes in
specifications and methods at any time without notice.
Proper service is essential'for both the safety of the mechanic and the
efficient functioning of the vehicle. '
•The service methods i~ this Service Manuai are described in such a
5
mannerthet the service may be performed safely and accurately.

Service varies with the procedures used, the, skills of the mechanic and
the tools and parts available. Accordingly, anyone using service proce-
dures, tools or parts which are not specifically recommended by
NISSAN must first completely'satis'fy hi~self that neither his safety
nor the vehicle's safety will' be jeopardlz~d by the service method
selected.
~
.... NISSAN MOTOR CO., LTD.
Overseas Service Department
Tokyo, Japan
GENERAL INFORMATION
SECTIONGI
•
CONTENTS
PRECAUTIONS , ; ; , GI- 2
HOVV TO USE THIS MANUAL GI- 6
HOVV TO READ WIRING DIAGRAMS GI- 8
HOVV TO FOllOW FLOW CHART IN TROUBLE DIAGNOSES GI-11
IDE f\JTIFICATION INFORMA nON ; GI-14
LIFTING POINTS AND TOW TRUCK TOWING GI-24
TIGt-iTENING TORQUE OF STANDARD BOLTS GI-26
PRECAUTIONS
Observe the following precautions to ensure safe and proper

servicing. These precautions are not described in each individ-
ual section.
1. Do not operate the engine for an extended period of time

without proper exhaust ventilation.
Keep the work area well ventilated and free of any inflam-
mable materials. Special care should be taken when han-
dling any inflammable or poisonous materials, such as
gasoline, refrigerant gas, etc. When working in a pit or
other enclosed area, be sure to properly ventilate the area
before working with hazardous materials.
Do not smoke while working on the vehicle.
SGI285
2. Before jacking up the vehicle, apply wheel chocks or other

tire blocks to the wheels to prevent the vehicle from mov-
ing. After jacking up the vehicle, support the vehicle weight
with safety stands at the points designated for proper lift-
ing before working on the vehicle.
These operations should be done on a level surface.
3. When removing a heavy component such as the engine or
transaxle/transmission, be careful not to lose your balance
and drop them. Also, do not allow them to strike adjacent
parts, especially the brake tubes and master cylinder.
SGI231
4. Before starting repairs which do not require battery power,

always turn off the ignition switch, then disconnect the
ground cable from the battery to prevent accidental short
circuit.
SGI232
5. To prevent serious burns, avoid contact with hot metal

parts such as the radiator, exhaust manifold, tail pipe and
muffler. Do not remove the radiator cap when the engine is
hot.
SGI233
GI-2
PRECAUTIONS
6. Before servicing the vehicle, protect fenders, upholstery

an~ carpeting with appropriate covers.
Take caution that keys, buckles or buttons on your person
do not scratch the paint.
SGI234
7. Clean all disassembled parts in the designated liquid or

solvent prior to inspection or assembly.
8. Replace oil seals, gaskets, packings, O-rings, locking
washers,cotler pins, self-locking nuts, etc. with new ones.
9. Replace inner and outer races of tapered roller bearings
and needle bearings as a set.
10. Arrange the disassembled parts in accordance with their
aSsembled locations and sequence.
11. Do not touch the terminals of electrical components which
use microcomputers (such as electronic control units).
Static electricity may damage internal electronic comp~-
nents.
12. After disconnecting vacuum or air hoses, attach a tag to
indicate the proper connection.
13. Use only the fluids and the lubricants specified in MA
section, or their equivalents.
14. Use approved bonding agent, sealants or their eqUivalents
. Whenreqtlired.
15. Use tools and recommended special tools where specified
for .safeand efficient service repairs.
16. When' repairlng the fuel, oil, water, vacuum or exhaust
systems, check all affected lines for leaks.
17. DisposeOf'drained oil or the solvent used for cleaning parts
in.,an appropriate. manner.
~sbest()s~af~.ty,nstructions
;.(Based()n United Kingdom and Republic of
Ireland regulations)
This vehicle uses parts containing asbestos. Most are not haz-
ardous but Brake and Clutch linings can be. Consult the man-
ufactureror his agent for further details. When working with
these please obse'rve the "Garage Workers' Asbestos Code"
available through your Nissan Dealer, Local Authority or Health
and Safety Executive. In particular, work in a well-ventilated
place using, where possible, appropriate dust extraction
equipment, and avoid creating dust. Dampen all asbestos/dust
where possible' prior to machining, cutting, cleaning, etc. Use
only hand or .Iowspeed tools.
DlsposeofaH asbestos waste, wet rags, etc., in a closed con-
tainer.as.direqted by your local waste disposal authority.
GI-3
PRECAUTIONS
Engine Oils
Prolonged and repeated contact with mineral oil will result in
the removal of natural fats from the skin, leading to dryness,
irritation and dermatitis. In addition, used engine oil contains
potentially harmful contaminants which may cause skin cancer.
Adequate means of skin protection and washing facilities must
be provided.
HEALTH PROTECTION PRECAUTIONS

1. Avoid prolonged and repeated contact with oils, particu-
larly used engine oils.
2. Wear protective clothing, including impervious gloves
where practicable.
3. Do not put oily rags in pockets.
4. Avoid contaminating clothes, particularly underpants, with
oil.
5. Heavily soiled clothing and oil-impregnated footwear
should not be worn. Overalls must be cleaned regularly.
6. First Aid treatment should be obtained immediately for
open cuts and wounds.
7. Use barrier creams, applying them before each work
period, to help the removal of oil from the skin.
8. Wash with soap and water to ensure all oil is removed (skin
cleansers and nail brushes will help). Preparations contain-
ing lanolin replace the natural skin oils which have been
removed.
9. Do not use petrol, kerosene, diesel fuel, gas oil, thinners or
solvents for cleaning skin.
10. If skin disorders develop, obtain medical advice without
delay.
11. Where practicable, degrease components prior to handling.
12. Where there is a risk of eye contact, eye protection should
be worn, for example, chemical goggles or face shields; in
addition an eye wash facility should be provided.
(For the United Kingdom, see also HSE Cautionary Notice SHW
397 "Effects of Mineral Oil on the Skin".)
ENVIRONMENTAL PROTECTION PRECAUTIONS

Burning used engine oil in small space heaters or boilers can
be recommended only for units of approved design. The heat-
ing system must meet the requirements of HM inspectorate of
Pollution for small burners of less than 0.4 MW. If in doubt check
with the appropriate local authority and/or manufacturer of the
approved appliance.
Dispose of used oil and used oil filters through authorized
waste disposal contractors to licensed waste disposal sites, or
to the waste oil reclamation trade. If in doubt, contact the local
authority for advice on disposal facilities.
It is illegal to pour used oil on to the ground, down sewers or
drains, or into water courses.
The regulations concerning the pollution of the environment
will vary from country to country.
GI-4
....' PRECAUTIONS
Pre'c'aUtiohsfor Fuel
J3~~9Jin.~enQi.,n.~:.. > •.' . '. ..' .' ..•.•. " '., '.. ' .
F.9:r'Ajnga~o.r;e..~.Unl.~adecq.Qasoline of at.least9t9ct~n~(RON)
E#~pt.'Singapor~ ...• Lea~ecd gasolin~ of at .1~ast~1. oGtane
'(RbN) '" , " .
•,pi~.sel.en~i?~*: '...........•..• ."
blesel flJ.e~,Qf,<;l.boYe50c~t~ne
* 'If tW9 types. of dies~lfuel ~re •.ayanable, IJse.summer or
winter fuel properly cl(~Fordingto thecJolloWingtemp~rature
conditions. ..' . .
• Above -rc (20°F) SulTlmer type diesel .fuel
• rc .
Below ....;.
.. (20°F) Wi:nter type diesel ...fuel.
CAUTION:
• Do not use home:heatlng on,gasoUn!~or other alternate
fuels ..ln.Y,our dieselel:'l~lne.:Theuse of those can cause
'".;enghlei!tlamage. '
• Do not use summer fuel at temperatures below-7°C (20°F).
The cold temperatures will cause wax to form in the fuel.
Asaresult, It Ill~Y prevent the engine from running
smoothly; .'
• Do I1Qladdga,oline or other alternate fuels to diesel fuel.
Only under,the 'following conditlo ...smay you use diesel fuel
by mixing kerosene or regular gasoline (notp~~rniurn gas-
;oline) to prevent the fuelfl"omthickenin:g::~ue. tow.ax sep..
arittion: ": \ ' •......
If the summer .type di4itselfuells used at an ambient tem-
\", petatur,'below O°C(32°F)"lldd. kerosene or regular gaso-
Iinebut'lJQt more than 3'0% by 'volume.
If fhe wlnter!,!yp".dlesel fuel is used at an ambient temper-
ature below -15~.C'(5°F), add k.eros4itne01"regular gasoline
but not mO.rethan 30% by volume.
However, keep in m!l1d that there may be less engine out-
R,utpel"formance due'to the proportion of added fuel.
The use of kerosene for motor vehicles is not permitted in
some countries, e.g. U.K. Therefore, consult the authorities
before such mixtures are used.
HOW TO USE THIS MANUAL
1. A QUICK REFERENCE INDEX, a black tab (e.g... ) is provided on the first page. You can quickly
find the first page of each section by mating it to the section's black tab.
2. THE CONTENTS are listed on the first page of each section.
3. THE TITLE is indicated on the upper portion of each page and shows the part or system.
4. THE PAGE NUMBER of each section consists of two letters, which designate the particular section,
and a number (e.g. "BR-5") .
. 5. THE lARGE IllUSTRATIONS are exploded views (See below.) and contain tightening torques, lubri-
cation points and other information necessary to perform repairs.
The illustrations should be used in reference to service matters c,1Iy. When ordering parts, refer to
the appropriate PARTS CATALOG.
Example
rJ~'I~
Pad retai~~) 1jlit-.. n
'
54 • 64 (5.5 • 6.5 40 • 47)
~ ~ Main pin
\)
./ /'
/- m to sliding portion
Torque
member ./~
I
Outer shim
Piston ~
A : N.m (kg-m, ft-Ib)
SBR364A
6. THE SMAll IllUSTRATIONS show the important steps such as inspection, use of special tools,
knacks of work and hidden or tricky steps which are not shown in the previous large illustrations.
Assembly, inspection and adjustment procedures for the complicated units such as the automatic
transaxle or transmission, etc. are presented in a step-by-step format where necessary.
7. The following SYMBOLS AND ABBREVIATIONS are used:
Tightening torque 2WD 2-Wheel Drive
Should be lubricated with grease. MIT Manual Transaxle/Transmission
Unless otherwise indicated, use rec- AIC Air Conditioner
ommended multi-purpose grease. PIS Power Steering
Should be lubricated with oil. Tool Special Service Tools
Sealing point S.D.S. Service Data and Specifications
Checking point SAE Society of Automotive Engineers,
Always replace after every disas- Inc.
sembly. G.C.C. Gulf Cooperation Council
L.H., R.H. Left-Hand, Right-Hand L.H.D. Left-Hand Drive
FR, RR Front, Rear R.H.D. Right-Hand Drive
GI-6
HOW TO OSETNISMANUAL
8. The UNITS given in this manual are prima.rilyexpressedasthe SI UNIT (International System of Unit),
and alternatively expressed in the metric systemaIJd iIJ.the yard/pound system.
"Example"
Tightening torque:
59 - 78 N'm (6.0<';'8.0kg-m, 43 - 58 ft-Ib)
9. TROUBLE DIAGNOSES are inch,Jdedin sections dealing with complicated components.
10. SERVICE DATA AND SPECIFICATIONS are contained at the end of each section for quick reference
of data.
11. The captions WARNIN~ and CAVTION warn you of steps that must be followed to prevent personal
injury and/or damage to some part of the vehicle.
• WARNING indicates the pOSSibilityof personal injury if instructions are not followed.
• CAUTION indicates the possibility of component damage if instructions are not followed.
• BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful information.
HOW TO READWtRING DIAGRAMS
WIRING DIAGRAM
Symbols used in WIRING DIAGRAM are shown below,
Example
POWER SUPPLY
• This shows the
ignition switch
CONNECTOR
position In Which the
This shows that these connectors
system can be .
are white 6 terminal connectors.
operated .
•. See POWER .
SUPPLY ROUTING
in ELsectlonfor the
detailed Wiring
diagram.
SWITCH
This shows that continuity
exists between terminals CD
and @, when the switch is
turned to ON position.
SWITCH
WIRE COLOR CODING

B =
Black BR = Brown
BODY W =
White OR = Orange
~: MIT model LOCATION NUMBER GROUND R =
Red P = Pink
@: AIT model This number shows where the G =
Green PU = Purple
connector is located. See l =
Blue GY = Gray
t
ABBREVIATIONS
HARNESS LAYOUT in El
section. The number Is Identical
with the one in HARNESS
LAYOUT.
Y
lG
=
Yellow
=
Light Green
SB = Sky Blue
When the wire color Is striped, the base

color Is given first, followed by the stripe
I
I
color as shown below:
Example: llW =Blue with White Stripe
~@!~J
I: Instrument M:
harness Main harness
SGI543
SWITCH POSITIONS
Normally open Wiring diagram switches are shown with the vehicle in the fol-
---0
= 0---
lowing condition.
• Ignition switch "OFF".
• Doors, hood and trunk lid/back door closed.
• Pedals are not depressed and parking brake is released.
Normally closed
SEL764E
GI-8
HOW TO READ WIRING DIAGRAMS
Example CONNECTOR SYMBOLS

All. connector symbols in wiring diagrams are shown from
m
•
the terminal side.
m
Connector symbol 2
SGI362
Example • Male and female terminals

Connector guides for male terminals are shown in black
and female terminals in white in wiring diagrams.
Connector
Connector symbol
Female terminal
Guide
MULTIPLE SWITCH
Connector
Connector symbol The continuity oUhe multiple switch is identified in the switch
SGI363 chart in wiring diagram~.
Example
Continuity circuit of wiper switch

SWITCH POSITION CONTINUITY CIRCUIT
-SlY OFF 3-4
I
-R 0 'NT 3 -4,5 -6
-W/S B E 1 5 LO 3-6
-L/Y C(f) @2 HI 2-6
-B WASH t .6
--Y
Example: Wiper swltch in LO position

Continuity circuit: Redwire - @ terminal - @ terminal -Wiper switch (~- ~:
LO) - @ terminal - (f) terminal - Black wire
SGI365
GI-9
HOW TO READ WIRING DIAGRAMS
SUPER MULTIPLE JUNCTION (S.M.J.)

• The "S.M.J." indicated in wiring diagrams is shown in a
simplified form. The terminal arrangement should therefore
be referred to in the foldout at the end of the Service Man-
ual.
• The foldout should be spread to read the entire wiring dia-
gram.
Example
STARTING SYSTEM
o
STARTING SYSTEM SUPER MULTIPLE JUNCTION (S.M.J.)
Wiring Diagram Terminal Arrangement
Check
[]
o Check
~-
Super MUltiple Junction
(S.M.J.)
L--1
J
t
S.M.J.
Refer to last page
(Foldout page).
r-R B1 L----1
r- B
(Main harness)
DO BR~
(Instrument
+-+
harness)
BR---i
r---B (Main harness) (Instrument harness)
SEL653F
GI-10
HOW TO FOLLOWFLQWCHART INTROUB~I: DIAGNOSES
Example
m INSPECTION START
rITJN.G.
CHECK POWER SUPPLY. Check the following
1) Turn ignition switch "ON". items.
2) Checkvoltage.between terminal @ 1) Harness continuity
and ground. between crank angle
Battery voltage should exist. sensor and battery.
2) E.C.C.S. relay-1 (See
O.K.
page EF & EC-106.)
3) "SR" fusible link
~ 4) Power source for
a
E.C.U.
c DISCONNECT
ED (See page EF &

EC-104.)
5) Ignition switch
CHECK GROUND CIRCUIT.

N.G. Check the following
SGI562 1) Turn ignition switch "OFF". items.
2) Disconnect crank angle sensor har- 1) Harness continuity
ness connector. between crank angle
3) Check resistance between terminal sensor and ground
@ and ground. 2) Ground circuit for
Resistance: E.C.U.
Approximately on (See page EF &
EC-104.)
O.K.
NOTICE
The flow chart indicates work procedures required to diagnose
problems effectively. Observe the following instructions before
diagnosing.
1) Use the flowchart after locating probable caUses of a prob-
lem following the "Preliminary Check" •.or the "Symptom
Chart".
2) After repairs, re-check that the problem has been com-
pletely ~lIlTllnated.
3) Refer to.~~mponent Part~LocatlOI1 and Harness Layout for
the Sys~~~$.described I",.ea.ch..section for Identiflcationl
location of components 81'1c1l1arness connectors.
4) Ref~rtothe .Circuit Diagram fc>rQulck Pinpoint Check.
If you must check circuit continuity betwe~", hcuness con-
nectors,,",in)ore detail, such~s Yihen a sub..harness is
used, r~ferto Wiring Diagram and Harness Layout In EL
secUon..for id~ntification .of harness connectors.
5). When checking circuit continuity, ignition switch. $I1Quldbe
"OFF". .
6) Before checking voltage at connectors, check battery volt-
age.
7) After accomplishing the Dla9no~tic Procedures and Electri-
cal Components Inspectloll.,.ma~e sure that all harness
connectors are reconnected as it was.
GI-11
HOW TO FOLLOW FLOW CHART IN TROUBLE DIAGNOSES
HOW TO FOllOW THIS FLOW CHART

OJ Work and diagnostic procedure
Start to diagnose a problem using procedures indicated in
m enclosed blocks, as shown in the following example.
CHECK POWER SUPPLY.

+-- Check item being per-
1) Turn ignition switch "ON".
formed.
2) Check voltage between terminal @
and ground.
BaUery voltage should exist.
} Procedure, steps or
measurement results
[2] Measurement results

Required results are indicated in bold type in the corre-
sponding block, as shown below:
These have the following meanings:
Battery voltage --+ 11 - 14V or approximately 12V
Voltage: Approximately OV --+ Less than 1V
@] Cross reference of work symbols in the text and
illustrations
Illustrations are provided as visual aids for work proce-
dures. For example, symbol mindicated in the left upper
portion of each illustration corresponds with the symbol in
the flowchart for easy identification. More precisely, the
procedure under the "CHECK POWER SUPPLY" outlined
previously is indicated by an illustration m.
~ Symbols used in illustrations
Symbols included in illustrations refer to measurements or
procedures. Before diagnosing a problem, familiarize your-
self with each symbol.
Example Direction mark

View from terminal side A direction mark is shown to clarify the side of connector (ter-
Connector symbol
minal side or harness side).
Direction marks are mainly used in the illustrations indicating
terminal inspection.
~
Direction mark
~: View Irom terminal side ... T.S.
View from harness side

[:it • All connector symbols shown from the terminal side are
enclosed by a single line.
Connector symbol View from harness side •.. H.S.

~:
• All connector symbols shown from the harness side are
Double line enclosed by a double line.
Direction mark
Connector
~
SGI364
GI-12
HOW TO FOLl.oO""FLOWCHARTIN1ROU8L.E DIAGNOSES
Key to symbols signifying measurement.ll,C)l'{iproced"'f!!S\

Symbol Symbol explanation Symbol Symbol explanation
Check atter disconri~cHng the con-

A/C switch is "OFF".
nector to be measured. ~
CONNECT
Check after connectil1g1he.conl')ector
€) to be measured. ~
A/C switch is "ON".
(@-~ lrisert keY into jgnition switch.

~
REC switch is "ON".
Turn ignition switch to "OFF" posi-

REC switch is "OFF".
~ tion. ~
".',
00 Turn ignition switch to "ON" position.

~
DEFswitch is "ON".
00 Turn ignition switch to "START"

position: (jJ VENTswitch is "ON".
Turn .ignitiQI:'\'switch from "OFF" to Fan switch is "ON". (At any position
~ce "ACC" position. except for "OFF" position)
Turn ignition switch from "ACC" to "efj'2J4, F~n switch is "OFF".

~F ,'OFF" position.
TUrnjgnitiol') switch from "OFF" to Apply battery voltage directly to com-

~ "ON" position. pOlients~
TLrp ignilionswitchfroO;L':ON" \0
Drive vehicle.
"OFF"position.
Do not~tlirtengine,or.check ""ith.
Disconnect battery negative cable.
engine stopped.
Start engiri~:ior check wittl e'hgine

running.
',.', ,
, '
Release parking brake. Depress accelerator pedal.
Check after engine is warmed up sufc

Release acceleraforpedal.
C~H ficiently.
Voltageshould'be measured with a: Pin terminal check for S.M.J. type

voltmeter. E.C.U. connector.
~
n CJUNIT MCONIiIECTOR!I F.or details regarding the terminal
leJ Oircuit resistance shouldbetnea"

i.~1
...:~.•... E).-
.....'"
arrange!11ent,refer to the foldout
page.
tBJ sured,withan ohmrne.ter.
tal Current should be measured with an

ammeter.
GI-13
IDENTIFICATION INFORMATION
Model Variation
MODEL F23 SERIES
Destina- Class Model Transmis-
Engine
tion Wheelbase Rear body Rear tire l.H. drive R.H. drive sion
Steel SBK2LBF-KWH -
High-bed Cab &
chassis
SBK2LBF-KW2 -
Single
Steel SBK2LDF-KWL -
Low-bed Cab &
SBK2LDF-KW2 -
chassis
NA20S RS5W71C
Wood - SBK2RBF-MWU
Low & flat-
Cab &
bed
chassis
- SBK2RBF-MW2
Standard
Wood - SBK2RDF-MWU
Low & flat-
Cab &
bed
chassis
- SBK2RDF-MW2
Except .
Double
Europe Wood - SVN2RBF-MWU
Low & flat-
Cab &
bed
chassis
- SVN2RBF-MW2
TD25 RS5W81A
Wood - SVN2RDF-MWU
Low & flat-
bed Cab &
- SVN2RDF-MW2
chassis
Steel SBK4LBF-KWH SBK4RBF-KWH

High-bed Cab & NA20S RS5W71C
SBK4LBF-KW2 SBK4RBF-KW2
chassis
Long Single
Steel SVP4LBF-KWH SVP4RBF-KWH
High-bed Cab & TD27 RS5W81A
SVP4LBF-KW2 SVP4RBF-KW2
chassis
Steel SBK4LBF-KQH SBK4RBF-KQH
High-bed Cab & Single NA20S RS5W71C
SBK4LBF-KQ2 SBK4RBF-KQ2
chassis
Wood SVN4LBF-MQV -
Low & flat-
Cab & Double
bed
chassis
SVN4LBF-MQ2 -
For
Long
Europe Steel SVN4LBF-KQH SVN4RBF-KQH
High-bed Cab & TD25 RS5W81A
SVN4LBF-KQ2 SVN4RBF-KQ2
chassis
Single
Steel SVN4LDF-KQL -
Low-bed Cab &
SVN4LDF-KQ2
-
chassis
GI-14
Model Variation (Cont'd)
Prefix and suffix designations:
S BK 2 R B F F23 M W U
S Cabover J L Low-bed
V Low & flat-bed (Steel)
BK NA20S engine U Low & flat-bed (Wood)
VN TD25 engine H High-bed (Steel)
VP TD27 engine 2 Cab & chassis
2 Standard wheelbase W Except Europe

4 Long wheelbase Q For Europe
R Right-hand drive K 1.5t Single tire

L Left-hand drive M 1.5t Double tire
B Standard cab
D Double cab
F 5-speed manual transmission
GI.15
Model Variation (Cont'd)
MODEL H41 SERIES
Class Model
Desti- Rear Transmis-
Wheel- Cab Rear Engine
nation body Rear body L.H. drive R.H. drive sion
base width tire
width
Wood SVW2LBF-RWJ SVW2RBF-RWJ

High-bed Cab & Double
SVW2LBF-RW3 SVW2RBF-RW3
Stan- chassis
BD30 RS5W81A
dard Steel SVW2LDF-OWL -
Low-bed Cab & Single
SVW2LDF-OW3 -
chassis
Stan. Wood LWG2LBF-RWJ -
dard Wide High-bed Cab &
Stan- LWG2LBF-RW3 -
chassis
dard
Steel DWG2LBF-RWT DWG2RBF-RWT
Except High-bed Cab &
Stan- DWG2LBF-RW4 DWG2RBF-RW4
Middle chassis FD42
dard
East
Cab &
High-bed
chassis
SWG2LBF-RW3 -
Wood Double LWG4LBF-UWJ LWG4RBF-UWJ RS5R50A
Wide High-bed Cab &
LWG4LBF-UW3 LWG4RBF-UW3
chassis
Long
Wood UWH4LHF-XWJ UWH4RHF-XWJ
High-bed Cab &
UWH4LHF.XW3 UWH4RHF-XW3
chassis
Wide FD46
'Wood UWH5LHF-XWJ -
Super Stan-
High-bed Cab &
long dard UWH5LHF-XW3 -
chassis
Steel SVW2LDF-OKL -
Low-bed Cab & Single BD30 RS5W81A
SVW2LDF-OK3 -
chassis
Wood LWG2LBF-RKJ -
Wide High-bed Cab &
Stan-
chassis
LWG2LBF-RK3 -
dard
Stan- Steel DWG2LBF-RKT -
For dard High-bed Cab &
Middle
Stan- DWG2LBF-RK4 -
chassis FD42
dard
East
Cab &
High-bed
chassis
Double SWG2LBF-RK3 - RS5R50A
Wood LWG4LBF-UKJ -
Wide High-bed Cab &
LWG4LBF-UK3 -
chassis
Long
Wood UWH4LHF-XKJ -
Stan-
Wide High-bed Cab & - FD46
dard UWH4LHF-XK3
chassis
GI..16
:IDENiJ'lfIGAiJ'ION,INROR:MAiJ'ION
Model Variation (Gont'd)
Prefix and suffix designations:
S VW 2 L B 'F H4r R W J
S Cabover L Low-bed (Steel)

(Standard cab)
U Cabover J High-bed with
(Wide cab) straight frame
(Wood)
L Cabover (Standard T High-bed with high
cab, wide rear body) frame (Steel)
D Dump 3 Cab & chassis (High-
bed with straight
frame)
VW BD30 engine 4 Cab & chassis (High-
WG .FD42 engine ." bed with high frame)
WH FD46 engine .
Except Middle East
2 Standard wheelbase For Middle East
4 Long wheelbase ;
5 Super long wh~elb/:!.$e 2t Single tire
2t Single tire
2.75t Double tire
R Right-hand driv,e 3t Double tire
L Left-hand drive
B Standard cab
D Double cab
H Wide cab
F 5-speed manual
transmission
G'I-17
Identification Number
Vehicle identification plate
Vehicle identification number Vehicle identification number

(Chassis number, F23 model (Chassis number, H41 model
Outer surface of R.H. frame) Front right tire side)
SGI777
VEHICLE IDENTIFICATION NUMBER ARRANGEMENT

Model F23 series
Except Europe
S B 2 F23-XXXXXX
Body
__ J T---------vehicle serial number
S Cabover
Enginetype-------------' Model
B NA20Sengine
D TD25engine
E TD27engine
Wheelbase
2 Standardwheelbase
4 long wheelbase
GI-18
IQENTIFlc:ATION INFORMATIQN
Identiflcatiorf Number (Cont'd)
For Europe
_______T
• JN1 S B 2 F23 U
Manufacturer IT--.-----vehicle serial number

JN1 : Nissan vehicle
Stopgap (no meaning)

Body
S : Cabover-----------.-J Destination
U : For Europe
Engine type Model
B NA20Sengine
o TD25engine
Wheelbase
2 Standard wheelbase
4 Long wheelbase
Model H41 series

S A 2 H41 XXXXXX
Body J 1-c---------~:::e serial number

S Cabover (Standard cab)
U Cabover (Wide cab)
L Cabover (Standard cab,

wide rear body)
o Dump
Engine type
A B030 engine
C F042 engine
o F046 engine
Wheelbase
2 Standard wheelbase
4 Long wheelbase
5 Super long wheelbase
GI..19
IDI5NTIFIOATION .INFO RMATIO.N
Icf~"tmp;;ttiol1 Number (Co"t'd)
IDENTIFICATION PLATE
Europe Except Europe 1 Type approval number

2 Vehicle identification
number (Chassisnumber)
0 NISSAN MOTOR CO.,LTD.JAPAN 0 NISSAN MOTOR CO., LTD. JAPAN 3 Gross vehicle weight
TYPE 4 Gross combination weight
I Li\ I ~ ~ TIPO ill
Gross vehicle weight
ffi CHASSIS NO.
NO OE CHASIS
MODEL
ill + Gross trailing capacity
&, MODELO & (Weight)
5 Gross axle weight (Front)
0 & kg 0 0 ",,-COLOR TRIM
f 'I ~ COLOR GUARNICIDN &&. 0 6 Gross axle weight (Rear)
1-
ill kg .J:;"'-ENGINE
'Y;"'- MOTOR LfuLJ1 CC 7 Type
8 Body color code
2~ it kg ~ ';I ';/ 3 /'
7' :'7 ;;<.)"

TRANS" AXLE
TRANS., EJE Li1L11 9 Trim color code
PLANT
TYPE
TYP !L COLOA.TRlM
FAABE.POLST &:, & Ii~ PLANTA 10 Model
0 f & 0 a~ @l i:IJ.**~~U MADE IN JAPAN
11 Engine model
12 Engine displacement
SGI025 SGI316 13 Transmission model
14 Axle model
ENGINE SERIAL NUMBER

NA20S engine T025 and T027 engines
SG1779 SGI7BO
8030 engine
F'O~
/1 ~ ~~
I
::::l
SGI7B1
SGI782
GI-20
IDENTIFICATIONINF.ORMA'1!I.ON '--""$
Identif.ication Number (Cont'd)

MANUAL TRANSMISSION NUMBER
RS5W71C RSS\¥81A RSSRSOA
Dimensions
MODEL F23 SERIES
Wheelbase Standard wheelbase Lbhgwheelbase
Rear body Low-bed High-bed- .
OveraU 4,450 (175.2) 4,450 (175.2) 4,450' (175.2) 4,690(184.6) '4,690 (184.6) 4,690 (184!6y,H
length 4,430 4,430 (174.4)*1 4,430 4,610' .J 4,610 4,610
(174.4)*1 (174.4)*1 (181.5)*1 (181.5)*1 (181.5)*1
Overall width 1,6~5(q6.7) 1,69?(6{).7) 1,Q95(6El.Zt.. . 1,695(66.7) _..1,695(65.7) 1,695(66. 7).
Overall 1,980 (78.0) 1,960 (77.2) 1,980 (78.0) 2,005 (78.9) 1,990 (78.3) 1,976 (77.6)
height 1,970 (77.6)*1 1,970 (77.6)*3 1,970 (77.6)*1 1,990 (78.3)*2
1,970 (77.6)*1
1,960 (77.2)*1,*3
Front tread 1,410 (55.5) 1,410 (55.5) 1,410 (55.5) 1,410 (55.5) 1,410 (55.5) 1,410 (55.5)
Rear tread 1,380 (54.3) 1,280 (50.4) 1,380 (54.3) 1,380 (54.3) 1,280 (50.4) 1,380 (54.3)
Wheelbase 2,335 (91.9) 2,335 (91.9) 2,335 (91.9) 2,515 (99.0) 2,515 (99.0) 2,515 (99.0)
*1: Cab & chassis

*2: For Europe
*3: Double cab model
01-21
Dimensions (Conl'd)
MODEL H41 SERIES
Unit: mm (in)
Super long
Wheelbase Standard wheelbase Long wheelbase
wheelbase
Double
Body Standard Rear wide Dump Rear wide Wide
cab
Engine B030
I F042 B030 F042 F042 F046
Rear body High-bed Low-bed High-bed High-bed
Overall length 4,760 4,620 4,690 4,750 4,680 6,010 6,090 6,750
(187.4) (181.9)*1 (184.6) (187.0) (184.3) (236.6) (239.8) (265.7)
4,620 4,630 4,630 4,480 4,460 5,920 5,950 6,590
(181.9)*1 (182.3)*1*2 (182.3)*1 (176.4)*1 (175.6)*1 (233.1)*1 (234.3)*1 (259.4)*1
4,620
(181.9)*1*2
Overall width 1,695 1,695 1,695 2,015 1,695 2,015 2,015 2,015
(66.7) (66.7)*1 (66.7) (79.3) (66.7) (79.3) (79.3) (79.3)
1,855 1,855 1,995 1,955
(73.0)*1 (73.0)*1 (78.5)*1 (77.0)*1
Overall height 1,990 1,990 2,010 2,170 1,990 2,170 2,200 2,200
(78.3) (78.3)*1 (79.1) (85.4) (78.3) (85.4) (86.6) (86.6)
2,000 2,010 2,020 2,180 2,180
(78.7)*1 (79.1)*1 (79.5)*1 (85.8)*1 (85.8)*1
Front tread 1,400 1,400 1,430 1,400 1,400 1,400 1,675 1,675
(55.1) (55.1)*1 (56.3) (55.1) (55.1) (55.1) (65.9) (65.9)
Rear tread 1,245 1,245 1,430 1,430 1,245 1,430 1,490 1,490
(49.0) (49.0)*1 (56.3) (56.3) (49.0) (56.3) (58.7) (58.7)
Wheelbase 2,500 2,500 2,500 2,500 2,500 3,350 3,350 3,795

(98.4) (98.4)*1 (98.4) (98.4) (98.4) (131.9) (131.9) (149.4)
*1: Cab & chassis

*2: For Middle East
GI-22
Wheels and Tires

MODEL F23 SERIES
.
Except Europe For Europe
Single tire Double tire Single tire Double tire
Offset Offset Offset Offset
mm mm mm mm
(in) (ih) (in) (in)
Road wheel size Front 15 x 4-1/2K 35 15 x 4-1/2K 35 16 x 6J 35 16 x 6J 35
(1.38) (1.38) (1.38) (1.38)
Rear 15 x 5-1/2K 35 12x4J 94 16 x 6J 35 12 x 4J 94
15 x 5.50F (1.38) (3.70) (1.38) (3.70)
SDC*1 35
(1.38)
Tire size Front 6.00-15-6PR 6.00R15-8PR 205/75R 16C 205/75R 16C
6.00-15-8PR*2
Rear 7.00-15-8PR 155R12-8PR 205/75R 16C 155R 12C
7.00R15-8PR*1
7.00R15-10PR*1
7.00R15-12PR*1
Wheel nut Front 118 to 147 118 to 147 118 to 147 118t0147
tightening torque (12 to 15, 87 to 108) (12 to 15, 87 to 108) (12 to 15, 87 to 108) (12 to 15, 87 to 108)
N'm (kg-m, ft-Ib) Rear 118 to 147 118t0147
216 to 255 216 to 255
(12 to 15, 87 to 108) (22 to 26, 159 to 188) (12 to 15, 87 to 108) (22 to 26, 159 to 188)
*1: Option
*2: Models equipped with the TD27 engine
MODEL H41 SERIES

Standard wheelbase Long/Super long wheelbase
High-bed Low-bed High-bed
Offset Offset Offset

"
mm (in) mm (in) mm (in)
Road wheel size Front 16 x 5.50F SDC 115 (4.53) 15 x5.50F SDC 30 (1.18) 16 x 5.50F SDC 115 (4.53)
Rear 16 x 5.50F SDC 115 (4.53) 15X6.00GS 30 (1.18) 16 X 5.50F SDC 115 (4.53)
SDC
.
Tire size Front 6.50-16-10PR 7.00-15-10PR 7.00-16-12PR

6.50R16-10PR* 7.00R15-10PR* 7.00R16-12PR*
Rear 6.50-16-10PR 7.50-15-14PR 7.00-16-12PR

6.50R16-10PR* 7.50R15-14PR* 7.00R16-12PR*
Wheel nut Front 441 to 539 177 to 226 441 to 490

tightening torque (45 to 55, 325 to 398) (18 to 23, 130 to 166) (45 to 50, 325 to 362)
N'm (kg-m,ft-Ib)
Rear 441 to 539 177 to 226 441 to 490
(45 to 55, 325 to 398) (18 to 23, 130 to 166) (45 to 50, 325 to 362)
*; Option
GI-23
LIFTING POINTS AND TOW TRUCK TOWING
Garage Jack and Safety Stand

WARNING:
• Never get under the vehicle while It Is supported only by
the jack. Always use safety stands to support the frame
when you have to get under the vehicle.
• Place wheel chocks at both front and back of the wheels on
the ground.
CAUTION:
Place a wooden or rubber block between safety stand and vehi-
cle body when the supporting body is flat.
Garage jack points
Safety stand points

SGI793
Tow Truck Towing

CAUTION:
• All applicable local I~ws regarding the towing operation
must be obeyed.
• It Is necessary to use proper towing equipment to avoid
possible damage to the vehicle during towing operation.
Towing is In accordance with Towing Procedure Manual at
dealer.
• When towing with the rear wheels on the ground, release
the parking brake.
NISSAN recommends that vehicle be towed with the driving

(rear) wheels off the ground as illustrated.
SGI784
GI-24
LIFTING POINTS AND TOW TRUCK TOWING
Tow Truck Towing (Cont'd)
Model F23 series TOWING POINT
Front
Always pun the cable straight out from the vehicle. Never pun
on the hook at a sideways angle.
Do. not use for. towing

. Rear .
CE1108
Model H41series
Front;
GI-25
TIGHTENING TORQUE OF STANDARD BOLTS
Tightening torque (Without lubricant)

Bolt diam-
Grade Bolt size Pitch mm Hexagon head bolt Hexagon flange bolt
eter'mm
N'm kg-m ft-Ib N'm kg-m ft-Ib
M6 6.0 1.0 5.1 0.52 3.8 6.1 0.62 4.5
1.25 13 1.3 9 15 1.5 11

M8 8.0
1.0 13 1.3 9 16 1.6 12
1.5 25 2.5 18 29 3.0 22

4T M10 10.0
1.25 25 2.6 19 30 3.1 22
1.75 42 4.3 31 51 5.2 38
M12 12.0
1.25 46 4.7 34 56 5.7 41
M14 14.0 1.5 74 7.5 54 88 9.0 65

M6 6.0 1.0 8.4 0.86 6.2 10 1.0 7
1.25 21 2.1 15 25 2.5 18
M8 8.0
1.0 22 2.2 16 26 2.7 20
1.5 41 4.2 30 48 4.9 35
7T M10 10.0
1.25 43 4.4 32 51 5.2 38
1.75 71 7.2 52 84 8.6 62
M12 12.0
1.25 77 7.9 57 92 9.4 68
M14 14.0 1.5 127 13.0 94 147 15.0 108
M6 6.0 1.0 12 1.2 9 15 1.5 11
1.25 29 3.0 22 35 3.6 26
M8 8.0
1.0 31 3.2 23 37 3.8 27
1.5 59 6.0 43 70 7.1 51

9T M10 10.0
1.25 62 6.3 46 74 7.5 54
1.75 98 10.0 72 118 12.0 87

M12 12.0
1.25 108 11.0 80 137 14.0 101
M14 14.0 1.5 177 18.0 130 206 21.0 152
1. Special parts are excluded.

2. This standard is applicable to bolts having the following
marks embossed on the bolt head.
': Nominal diameter
Grade Mark
4T
7T
4
7
1T
M 6
Nominal diameter of bolt threads (Unit: mm)

Metric screw threads
9T 9
GI-26
MAINTENANCE
SECTIONMA •
CONTENTS
PREPARATION MA- 2
PRE-DELIVERY INSPECTION ITEMS MA- 3
GENERAL MAl NTENANCE MA- 4
PERIODIC MAINTENANCE (Except for Europe) MA- 5
PERIODIC MAINTENANCE (For Europe) MA- 9
RECOMMENDED FLUIDS AND LUBRICANTS MA-12
ENGINE MAINTENANCE -I NAI MA-14
ENGINE MAINTENANCE -I TOI MA-23
ENGINE MAl NTENANCE -I BDI MA-32
ENGI NE MAl NTENANCE - c:E:Q] MA-40
CHASSIS AND BODY MAl NTENANCE MA-50
SERVICE DATA AND SPECIFICATIONS (S.O.S.) MA-58
PREPARATION
SPECIAL SERVICE TOOL

Tool number Engine application
,
Tool name Description
NA TO SO FD
EG17650301 Checking cooling system
Radiator cap tester
adapter
X X X X
~ i
MA-2
PRE-DELIVERY' .INSPEC1"10N..ITEMS
Shown ,below are Pre..deliverylnspection Items required for the new vehicle. It is recommended that
necessary ite.ms other than those listed here be addedj paying due regard to the conditions in each
country.
Perform applicable items on each model. Consult text of this section for specifications.
UNDERHOOO~ engine off UNDERBODY'

o Radiator coolant level and coolant hose con. o Manual transmission/transaxle, tra.nsfer and
nections for leaks differential gear oil level
D Batteryfluid level,specific gravity andcondi- D Brake and fuel lines and oil/fluid reservoirs
tions of battery terminals for leaks
o Drive belts tension o Tighten bolts and nuts of steering linkage and
o Fuel filter for water or dusts, and fuel lines gear box, suspension, propeller shafts and
and connections for leaks drive shafts . '!
D Engine oil level and oil leaks D Tighten rear body bolts and huts (Models with
o Clutch and brake reserv6irfluid leVel and W06denbed only)
fluid lines for leaks
o Windshield •..and rear wind6Wwasherand ROAD TEST
headlamp cleaner reservoir fluid level
D C.lu~cnQperation
D Power steering reservoir fluid level a.hdhose
D Parking brake operation
connections for leaks
D Service brake operation
D Automatic transmission/transaxle shifttiming
ON .INSIDE AND OUTSIDE and kickdown
fX] Remove front spring/strut spacer (If applica- D Steering.control and returnability
ble) D Engine performance
o Operati6n' of a.1Iinstruments, gauges, lights D Squeaks and rattles
and accessories
D Operation of horn(s), wiper and washer EN(3INE OPERATING AND HOT
o Steering lock for operation
D Adjust idle mixture and speed. (and ignition
o Check air cond.itioner for gas leaks timing*1)
D Front and rear seats, and seat belts for oper-
o Automatic transmission/transaxle flUid .level
ation
D Engine idling and st6P knob6perati6n(Diesel
o All moldings, trims and fittings for fit and
only)
alignment .
o All window~ for operation and alignment
FINAL INSPECTION
o Hood, trunk lid, door panels for fit and align-
ment o Install necessary parts(Outsider1lirror, wheel
D Latches, keys and locks for operation covers, seat belts, mat, catpet6r mud fla.ps)
o Weatherstrips for adhesion and fit o Inspect for interior and exterior metal and
o HeadlClIl1Paiming paint damage
D Tighten wheel nuts (Inc. inner nuts if applica- o Check. for sPareti re, jaqk,. tools (wheel
ble) . chock), and Iiter~ture
o Tire pressure (Inc. spare tire) o Wash, clean interior andextedor
o Check front wheels for toe-in
o Install clock/voltmeter/room lamp fuse (If *1: I\IQtrequired on model!) with a direct ignitiQfl systeni
appl icat>le) 1Xl: Not applicable to this modeL
fX] Install deodorizing filter to air purifier (If
applicable)
[Xl Remove wiper blade protectors (If applicable)
MA-3
GENERAL MAINTENANCE
General maintenance includes those items which should be checked during the normal day-to-day
operation of the vehicle. They are essential if the vehicle is to continue operating properly. The owners
can perform the checks and inspections themselves or they can have their NISSAN dealers do them.
Item Reference pages

OUTSIDE THE VEHICLE
The maintenance items listed here should be performed from time to time, unless other-
wise specified.
Tires Check the pressure with a gauge periodically when at a service station, including
the spare, and adjust to the specified pressure if necessary. Check carefully for damage,
cuts or excessive wear.
Windshield wiper blades Check for cracks or wear if they do not wipe properly.
Doors and engine hood Check that all doors, the engine hood, the trunk lid and back door
operate properly. Also ensure that all latches lock securely. Lubricate hinges, latches,
rollers and links if necessary. Make sure that the secondary latch keeps the hood from
MA-56
opening when the primary latch is released.
When driving in areas using road salt or other corrosive materials, check for lubrication
frequently.
Tire rotation Tires should be rotated every 10,000 km (6,000 miles). MA-55
INSIDE THE VEHICLE
The maintenance items listed here should be checked on a regular basis, such as when
performing periodic maintenance, cleaning the vehicle, etc.
Lights Make sure that the headlights, stop lights, tail lights, turn signal lights, and other
lights are all operating properly and installed securely. Also check headlight aim.
Warning lights and buzzers/chimes Make sure that all warning lights and buzzers/chimes
are operating properly.
Steering wheel Check for change in the steering conditions, such as excessive free play,
hard steering or strange noises.
Free play: Less than 35 mm (1.38 in)
Seat belts Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters
and retractors) operate properly and smoothly, and are installed securely. Check the belt MA-56
webbing for cuts, fraying, wear or damage.
UNDER THE HOOD AND VEHICLE
The maintenance items listed here should be checked periodically e.g. each time you
check the engine oil or refuel.
Windshield washer fluid Check that there is adequate fluid in the tank.
Engine coolant level Check the coolant level when the engine is cold. MA-17, 25, 34, 42
Engine 011 level Check the level after parking the vehicle on a level spot and turning off
MA-19, 24, 33, 41
the engine.
Brake and clutch fluid level Make sure that the brake and clutch fluid levels are between
MA-50
the "MAX" and "MIN" lines on the reservoir.
Battery Check the fluid level in each cell. It should be between the "MAX" and "MIN"
lines.
MA-4
PERIODIC MAINTENANCE {Except for Europe)
The following tables show the normal maintenance schedule. Depending upon weather and atrnospheric
conditions, varying road surfaces, individual driving habits and vehicle usage, additional or more fre-
quent maintenance rnay be required.
Periodic maintenance beyond the last period shown on the tables requires similar maintc:mance.
Standard & The. First Free Services

DIESEL ENGINE
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, A = Adjust, C = Clean, 0 = Drain water and inspect.
MAINTENANCE OPERATION MAINTENANCE INTERVAL
Perform at the speci- Months 6 12 18 24 30 36 42 48 Reference

fied months or mile-
km x 1,000 10 20 30 40 50 60 70 80 page
age
whichever comes first. (Miles x 1,000) (0.6) (6) (12) (18) (24) (30) (36) (42) (48)
Engine compartment and under vehicle TD SD FD
Torque of manifolds & exhaust tube nuts I MA-23 MA-32 MA-40

Drive belts I I I I I MA-23 MA-32 MA-40
Engine anti-freeze coolant (Ethylene glycol base)
R R MA-25 MA-34 MA-42
(L.L.C.)
Engine coolant (Soft water) R R R R R R R R MA-25 MA-34 MA-42
Cooling system I I I I MA-26 MA-35 MA-42
Fuel lines I I MA-27 MA-36 MA-44
Air cleaner filter (Dry paper type)* C C C R C C C R MA-28 MA-36 MA-45
Air cleaner filter (Viscous paper type)* R R MA-28 MA-36 MA-45
Fuel filters (For in-line type injection pump)* R R MA-26 MA-35 MA-43,44
Fuel filters (Except for In-line type injection
D D D R D D D R MA-26 MA-35 MA-43,44
pump)*
Intake & exhaust valve clearance A A A A A MA-23 MA-32 MA-40
Injection nozzles See NOTE (1) MA-28 MA-37 MA-45
Idling speed I I I I I MA-29 MA-37 MA-46
NOTE: (1) If engine power decreases, black exhaust smoke is emitted or engine noise Increases, check and, If necessary,
adjust the fuel injection nozzle's starting pressure and the fuel spray pattern.
(2) Maintenance items with "*"
should be performed more frequently according to "Maintenance under severe driv-
Ing conditions".
MA-5
PERIODIC MAINTENANCE (Except for Europe)
Standard & The First Free Services (Cant' d)
GASOLINE ENGINE
Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, A = Adjust, C = Clean.
Perform at the specified Months 6 12 18 24 30 36 42 48 Reference

months or mileage km x 1,000 10 20 30 40 50 60 70 80 page
whichever comes first.
(Miles x 1,000) (0.6) (6) (12) (18) (24) (30) (36) (42) (48)
Engine compartment and under vehicle

Torque of manifolds & exhaust tube nuts & carburetor fixing nuts I MA-14, EM-14
Drive belts MA-15
Engine anti-freeze coolant (Ethylene glycol base) (L.L.C.) R R MA-16
Engine coolant (Soft water) R R R R R R R R MA-16
Cooling system I MA-17
Fuel lines MA-18
Air cleaner filter (Dry paper type)* C C C R C C C R MA-18

Air cleaner filter (Viscous paper type)* R R MA-18
Cyclone pre-air cleaner* MA-19
Intake & exhaust valve clearance Except Hong Kong & Singa- A A A A A MA-14
pore only
Carburetor Idle rpm & mixture ratio (Check mixture ratio only on
A A A A A A A A A EF & EC-25
models bound for areas affected by emission regulations)
Fuel fllter* R R MA-18

EGR control system Hong Kong & Singapore only I I EF & EC-51
Ignition timing A A A A A A A A EF & EC-25
Hong Kong & Singapore only I R I R MA-20

Spark plUgs
Except above R R R R MA-20
Ignition wires MA-21
Positive crankcase ventilation (P.C.V.) system MA-21
Vacuum hoses & connections MA-22
Vapor lines Hong Kong & Singapore only I I MA-22
NOTE: (1) Maintenance items with "*" should be performed more frequently according to "Maintenance under severe driv-
Ing conditions".
MA-6
PERIODIC MAINTENANCE •(Except for Eur0E!_e) _
Standard & The First Free Services (Cont'd)
CHASSIS AND •BODY
Abbreviations: I = Inspect and correct or replace as necessary, R Replace, T = Tighten, L = Lubricate.
Perform at the specified

Months 6 12 18 24 30 36 42 48 Reference
months or mileage km x 1,000 10 20 30 40 50 60 70 80 page
whichever comes first. (Miles x 1,000) (0.6) (6) (12) (18) (24) (36) (42)
(30) (48)
Engine compartment
Brake, clutch & steering gear fluid level & leaks I I MA-50, 52, 54
Brake f1uid* R R MA-52
Brake booster vacuum hoses, connections & check valve I MA-52
Power steering fluid & lines I MA-53
Under vehicle
Brake, clutch & Elxhaust systems I MA-50,52
Manual transmission & differential gear oil R R MA-50,51
Steering gear box & linkage, axle & suspension parts & propeller shaft
MA-51, 53, 54
(for damaged, loose & missing parts & lubrication)*
Nipples of kingpins* (H41 only) [ [ [ [ L L L L FA-31
Rear body bolts & nuts (Wooden bed model only) and body' mountings T T T T T BF-23, 26
Outside and inside

MA-53,55
Wheel alignment. If necessary, rotate & ~alance wheels
FA-7
Brake pads, disc & other brake components* MA-52
Brake linings, drums & other brake components* MA-53
Front wheel bearing grease FA-12,2O
Locks, hinges & latch L L [ L [ [ L L MA-56
Seat belts,buckles, retractors, anchors & adjuster I I MA-56
BR-10, 38, 42
Foot brake, parking brake & clutch (fOr free play'stroke & operation)
CL-5
NOTE: (1) Maintenanceitems with "*" should be performed rnore frequently according to "Maintenance under severe driv-
ing conditions". '
MA ..7
PERIODIC MAINTENANCE (Except for Europe)
Maintenance Under Severe Driving Conditions

The maintenance intervals shown on the preceding pages are for normal operating conditions. If the
vehicle is mainly operated under severe driving conditions as shown below, more frequent maintenance
must be performed on the following items as shown in the table.
Severe driving conditions

A ~ Driving under dusty conditions F - Driving in high humidity areas or in moun-
B - Driving repeatedly short distances tainous areas
C - Towing a trailer or caravan G - Driving in areas using salt or other corro-
D - Extensive idling sive materials
E - Driving in extremely adverse weather con- H - Driving on rough and/or muddy roads or in
ditions or in areas where ambient temper- the desert
atures are either extremely low or - Driving with frequent use of braking or in
extremely high mountainous areas
Maintenance operation: Check = Check and correct or replace as necessary.
Driving Maintenance Maintenance Maintenance Reference
condition item operation interval page
Engine all service
A B C D Engine oil & oil filter
Gasoline engine and FD series Replace Every 3 months or 5,000 km MA-19, 20, 41
diesel engine (3,000 miles)
Diesel engine except FD series Replace More frequently MA-24,33
Standard service
A Air cleaner filter
Dry paper type and cyclone Clean MA-18

pre-air cleaner
More frequently
All types Replace MA-18
A E Fuel filter Replace MA-18

Every 12 months or 20,000 km
F Brake fluid Replace (12,000 miles) MA-52
G H Steering gear & linkage, axle & Check MA-51 , 53, .54
suspension parts & propeller
shaft
G Nipples of kingpins (H41 only) Lubricate Every 3 months or 5,000 km FA-31

(3,000 miles)
A C G H Brake pads, discs & other brake Check MA-52
components
G Lock, hinges & latch Lubricate MA-56
A C G H Brake linings, drums & other Check Every 6 months or 10,000 km MA-53
brake components (6,000 miles)
MA-8
PERIODIC MAINTENANCE (For Europe)
The following tables show the normal maintenance schedule. Depending upon weather and atmospheric
conditions, varying road surfaces, individual driving habits and vehicle usage, additional or more fre-
quent maintenance may be required.
Periodic maintenance beyond the last period shown on the tables requires similar maintenance.
ENGINE OIL & MINOR SERVICES (Gasoline models)
Abbreviations: R = Replace, I Inspect. Correct or replace as necessary, A = Adjust
Months 12 24 36 48 60 72 84 96 Reference
Perform on kilometer basis or on month basis if not page
km x 1,000 15 30 45 60 75 90 105 120
driven 15,000 km (9,000 miles) within a year.
(Miles x 1,000) (9) (18) (27) (36) (45) (54) (63) (72)
[Engine oil service] Engine compartment and under vehicle

Engine oil (Use API SG oil only)* R R R R R R R R MA-19
Engine oil filter (Use Nissan PREMIUM type or equivalent)* R R R R R R R R MA-20
[Minor service] Engine compartment

Spark plugs R R R R R R R R MA-20
Idle rpm EF & EC-25
Drive belts (Except flat belt type) MA-15
Ignition timing A A A A A A A A EF & EC-25
NOTE: (1) Maintenance items with "*" should be performed more frequently according to "Maintenance under severe dri""
ing conditions".
ENGINE OIL & MINOR SERVICES (Diesel models)

Abbreviation: R = Replace
Months 6 12 18 24 30 36 42 48 54 60 66 72 78 84. 90 96 Reference
Perform on kilometer basis or on month basis if not
km x 1,000 5 10 15 20 25 30 35 40 45 50 55 60 65 70 .75 80 page
driven 5,000 km (3,000 miles) within half a year.
(Miles x 1,000) (3) (6) (9) (12) (15) (18) (21) (24) (27) (30) (33) (36) (39) (42) (45) (48)
[Engine oil service] Engine compartment and under vehicle

Engine oil (Use API CC or CD oil)* R R R R R R R R R R R R R R R R MA-24
Engine oil filter* R R R R R R R R MA-24
Drive belts (For tension) I (At the first oil change only) MA-23
ing conditions".
Abbreviations: R = Replace, I Inspect. Correct or replace if necessary, A = Adjust.

Months 12 24 36 48 Reference
Perform on kilometer basis or on month basis If not
km x 1,000 20 40 60 80 page
(Miles x 1,000) (12) (24) (36) (48)
[Minor service] Engine compartment

Intake & exhaust valve clearance A A A A MA-23
Idle rpm MA-29
Drive belts MA-23
Air cleaner filter (Viscous paper type) R R MA-28

Fuel filter R R MA-26
ing conditions".
MA-9
PERIODIC MAINTENANCE (For Europe)
MAJOR SERVICE (Engine)

Abbreviations: R = Replace, I = Inspect. Correct or replace if necessary.
Month 12 24 36 48 Reference
Perform on month basis or on kilometer basis if
km x 1,000 30 60 90 120 page
(Miles x 1,000) (18) (36) (54) (72)

Engine anti-freeze coolant (Ethylene glycol base) See NOTE (1) MA-16,25
Cooling system MA-17,26
Fuel lines MA-18,27
Air cleaner filter (Viscous paper type)* (Except TO series diesel engine) R R MA-18,28
w Carburetor idle mixture ratio (Except for Sweden) I EF & EC-25
a Fuel filter* R MA-18

if) Ignition wires (Except for Sweden) MA-21
w
~ Positive crankcase ventilation (P.C.V.) system MA-21
~ Drive belt (Flat belt type) MA-15

-0:
Cl Vacuum hoses & connections MA-22
--'w
wZ
[(3
-z
a Injection nozzles See NOTE (2) MA-28
ow
NOTE: (1.) Change at 60 months or 90,000 km (54,000 miles), then every 24 months or 60,000 km (36,000 miles).
(2) If engine power decreases, black exhaust smoke is emitted or engine noise increases, check and, If necessary,
adjust the fuel injection nozzle's starting pressure and the fuel spray pattern.
(3) Maintenance Items with "*"
should be performed more frequently according to "Maintenance under severe driv-
Ing conditions".
MAJOR SERVICE (Chassis and Body)

Abbreviations: R = Replace, I Inspect. Correct or replace if necessary, L = Lubricate, T = Tighten.
Month 12 24 36 48 Reference
Perform on month basis or on kilometer basis if
km x 1,000 30 60 90 120 page
(Miles x 1,000) (18) (36) (54) (72)
Brake, clutch & manual steering gear oil level & leaks I I I MA-50, 52, 54
Brake f1uid* R R MA-52
Brake booster vacuum hoses, connections & check valve I I MA-52
Power steering fluid & lines I I MA-53
Brake & clutch system I I MA-50,.52
Manual transmission/transaxle, transfer & standard differential gear oil R R MA-50,51
Steering gear & linkage, axle & suspension parts, propeller shaft &
MA-51, 53, 54
exhaust system*
Greasing points of steering linkage, propeller shafts & suspension L L L L MA-51, 53, 54
Body mounting bolts & nuts, & rear body bolts & nuts (Wooden bed model
T T T T BF-23,26
only)
Outside and inside

MA-53,55
Wheel alignment (If necessary, rotate & balance wheels)
FA-7
Brake pads, discs & other brake components* MA-52
Brake linings, drums & other brake components* MA-53
Front wheel bearing grease FA-12
Headlamp aiming
BR-10, 38, 42
Foot brake, parking brake & clutch (For free play, stroke & operation)
CL-5
Body corrosion Annually MA-56
Ing conditions".
MA-10
PERIODIC •.MAINTENANCE (for Eurol!!J_' _
MAINTENANCE UNDER SEVERE DRIVING CONDITIONS

The maintenance intervals shown on the preceding pages are for normal operating conditions. If the
vehicle is mainly operated under severe driving conditions as shown below, more frequent maintenance
must be performed on the following items as shoWn in the table.
Severe driving conditions F - Driving in high humidity areas pr in moun-
A - Driving under dusty conditions tainous areas
B - Driving repeatedly short distances G - Driving in areas using salt or other corro-
C - Towing a trailer sive materials
D - Extensive idling H - Driving on rough and/or muddy roads or in
E - Driving in extremely adverse weather con- the desert
ditions or in areas where ambient temper- - Driving with frequent use of braking or in
ature are either extremely low or mountainous areas
extremely high
Maintenance operation: Check = Check. Correct or replace if necessary.
Driving Maintenance Maintenance Maintenance Reference
condition item operation interVal page
Engine 011service
A B C D Engine oil
Gasoline engine Replace Every 7,500 km (4.500 miles) or MA-19
6 months
Diesel engine Replace More frequently MA-24
A B C D Engine oil filter
Gasoline engine Replace Every oil change MA-20
Diesel engine Replace Every sllcond oil change MA-24
Minor service
Diesel engine Replace Every 20,000 km (12.000 miles) _M_A_-2_8 _
A E Fuel filter or 12 months
Diesel engine Replace MA-26

MlIJor .servlce
Gasoline engine Replace MA-18
Every 12 months or 30.000km
A E Fuel filter
(18,000 miles)
Gasoline engine Replace MA-18
F Brake fluid Replace MA-52
A C G H Brake Pa.ds, discll & other Check MA-52
brake components
A C G H Brake linings. drums & other Check MA-53
Every 6 months or 15.000 km
brake components
(9.000 miles)
G H Steering gear & linkage. axle Check MA-51. 53. 54
& suspension parts. propeller
shaft & exhaust system
MA-11
RECOMMENDED FLUIDS AND LUBRICANTS
Fluids and Lubricants

Capacity (Approximate) Recommended Fluids/
Liter Imp measure Lubricants
Engine oil (Refill)
With oil filter change
NA20S 3.8 3-3/8 qt
TD25 & TD27 6.2 5-1/2 qt
Gasoline engine:
BD30 8.1 7-1/8 qt
API SG*1 for Europe
FD42 & FD46 9.6 8-1/2 qt
API SE, SF or SG*1 except for Europe
Without oil filter change
Diesel engine:
NA20S 3.5 3-1/8 qt
API CC or CD*1
TD25 & TD27 5.5 4-7/8 qt
BD30 7.4 6-1/2 qt
FD42 & FD46 8.3 7-1/4 qt
Cooling system (with reservoir)
With front and rear heater
NA20S 9.8 8-5/8 qt
TD25 15.3 13-1/2 qt
BD30 14.6 12-7/8 qt
With front heater
NA20S 8.8 7-3/4 qt
TD25 Single cab model 13.8 12-1/8 qt
Double cab model 14.1 12-3/8 qt
TD27 13.7 12-1/8 qt
BD30 Single cab model 13.1 11-1/2 qt
Double cab model 13.4 11-3/4 qt Anti-freeze coolant (Ethylene glycol
FD42 14.5 12-3/4 qt base) or soft water
FD46 15.2 13-3/8 qt
Without heater
NA20S 7.7 6-3/4 qt
TD25 Single cab model 12.8 11-1/4 qt
TD27 12.7 11-1/8 qt
BD30 Single cab model 12.1 10-5/8 qt
FD42 13.6 12 qt
FD46 14.3 12-5/8 qt
Manual transmission gear oil
RS5W71C 2.0 3-1/2 pt
RS5W81A 2.7 4-3/4 pt API GL-4*1
RS5R50A 4.0 7 pt
Differential carrier gear oil
C200 1.3 2-1/4 pt
H233B 2.0 3-1/2 pt
H260 4.3 7-5/8 pt API GL-5*1
H290 4.6 8-1/8 pt
H310 6.0 10-5/8 pt
Manual steering gear oil API GL-4*1
Power steering gear oil Type DEXROWM
Brake and clutch fluid DOT 3 (US FMVSS No. 116)
Multi-purpose grease NLGI NO.2 (Lithium soap base)
*1: For further details, see "SAE Viscosity Number".
MA-12
RECOMMENDED FLUIDS AND LUBRICANTS
SAE Viscosity Number

Outside Temperature Range Outside Temperature Range
Anticipated Before Next 011 Change Anticipated Before Next Oll Change
GASOLINE ENGINE Oil GEAR Oil
140
+40 +104 °C OF
90
+40 +104 -------
+30 +86
+15 +59
+10 +50 -
o +32
0
-10 +14
-10
-20
-30
-29
• Not recommended
for sustained high
75W BOW 75W-90
speed driVing
BOW-90
TlOO03
TlOO05
• For warm and cold areas: 75W-90 for trans-
• FOr warm and cOld areas: 10W-30 is prefera- mission of gasoline engine model, SOW-90for
ble for ambient temperature above -'-20°C differential carrier and 90 for transmission of
(-4°F). diesel engine model are preferable.
• For hot areas: 20W-20, 20W-40 and 20W-50 • For hot areas: 90 is suitable for ambient tem-
are suitable.
peratures below 40°C (104°F).
Outside Temperature Range
Anticipated Before Next 011 Change
DiESEL ENGiNE Oil
+30 +86 ---~---
+20 +68 0
+15 +59
~ ~
~
0 +32 ~
0
~
-10 +14 -
~
0
-20 -4 - '"
~
-30 -22 -
• Not recommended
for sustained high
speed driving
TI0006
• For cold and warm areas: 10W-30 is prefera-

ble for ambient temperatures above -20°C
(-4°F).
• For hot areas: 20W-40 and 20W-50 are suit-
able.
MA-13
ENGINE MAINTENANCE
Checking Tightening Torque

• Checking should be performed while engine is cold.
Manifold bolts and nuts:
Intake manifold
~: 16 - 21 N.m
(1.6 - 2.1 kg-m, 12 - 15 ft-Ib)
Exhaust manifold
~: 20 - 24 N.m
(2.0 - 2.4 kg-m, 14 - 17 ft-Ib)
Exhaust tube nuts:
~: 51 - 65 N.m
(5.2 - 6.6 kg-m, 38 - 48 ft-Ib)
Carburetor bolts:
~: 21 - 26 N.m
(2.1 - 2.7 kg-m, 15 - 20 ft-Ib)
Tighten in numerical order.
SMA595C
Adjusting Intake and Exhaust Valve Clearance

Adjustment should be made while engine is warm but not run-
ning.
1. Set No. 1 cylinder at top dead center on its compression
stroke, and adjust valve clearances (j), @, @ and @.
2. Set No. 4 cylinder at top dead center on its compression
stroke, and adjust valve clearances <ID, <ID, ([) and @.
Valve clearance:
Intake (j), @, <ID and @
0.30 mm (0.012 in)
Exhaust @, <ID, @ and ([)
0.30 mm (0.012 in)
Adjusting screw lock nuts:
~: 12 - 16 N.m (1.2 - 1.6 kg-m, 9 - 12 ft-Ib)
SMA596C
MA-14
ENGINE MAINTENANCE
Checking Drive Belts
Loosen
Adjusting bolt
Lock nut
A 16 • 21 (1.6 - 2.1, 12 - 15)
A : N.m (kg-m. ft-Ib)

pulley • : Check point
SMA597C
1. Inspect for cracks, fraying, wear or oil adhesion. If

necessary, replace with a new one.
2. Inspect drive belt deflections by pushing on the belt midway
between pulleys.
Adjust if belt.c;I.eflectionsexceed the limit.
Be.lt deflection:
Unit: mm (in)
... Used belt deflection
Deflection Deflection of
Limit after adjust- new belt
.. ment
Alternator
6-7 5-6
For Europe 11 (0.43)
(0.24 - 0.28) (0.20 - 0.24)
8 - 10 7-8
Exceptfor Europe 12 (0.47)
(0.31 - 0.39) (0.28 - 0.31)
10 - 12 8 - 10
Power steering oil pump 16 (0.63)
.... . (0.39 - 0.47) (0.31 - 0.39)
8 - 10 6-8
Gompresspr 13 (0.51)
(0.31 - 0.39) (0.24 - 0.31)
...
Applied pushing force 98 N (10 kg, 22 Ib)
Inspect drive belt deflections when engine is cold.
MA.15
ENGINE MAINTENANCE
Changing Engine Coolant

WARNING:
To avoid being scalded, never change the coolant when the
engine is hot.
1& ""'''';} "'3uJ "'3~ .-,-
1. Move heater "TEMP" control lever all the way to "HOT".
c
SMA598C
2. Open radiator drain plug at the bottom of radiator, and

remove radiator filler cap.
3. Remove reservoir tank, drain coolant, then clean reservoir
tank.
Install it temporarily.
• Be careful not to allow coolant to contact drive belts.
4. Remove cylinder block drain plug.

5. Close radiator drain plug and tighten cylinder block drain
plug securely.
6. Fill radiator with water.
7. Reinstall radiator filler cap.
8. Start engine.
9. Warm up engine sufficiently, then race engine 2 or 3 times
under no-load.
10. Stop engine and wait until it cools down.
11. Repeat step 2 through step 10 until clear water begins to
drain from radiator.
12. Drain water.
• Apply sealant to drain plug thread.
rPJ: 34 - 44 N'm (3.5 - 4.5 kg-m, 25 - 33 ft-Ib)
13. Reinstall reservoir tank.
14. Fill radiator and reservoir tank with coolant following step
6 through step 10.
Follow instructions attached to anti-freeze container for
mixing ratio of anti-freeze to water.
MA-16
ENGINE MAINTENANCE
Changing Engine Coolant (Cont'd)
Coolant capacity:
Unit: t (Imp qt)
Without heater 7.7 (6-3/4)

With heater 8.8(7-3/4)
With rear heater (Double cab model) 9.8 (8-5/8)
Pour coolant through coolant filler neck slowly to allow air in

system to escape.
15. If necessary, add coolant.
Checking Cooling System

CHECKING HOSES
Check hoses for proper attachment and for leaks, cracks,
damage, loose connections, chafing and deterioration.
CHECKING RADIATOR CAP

Apply pressure to radiator cap with cap tester to see if it is sat-
isfactory.
Radiator cap relief pressure:
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)
Pull the negative-pressure valve to open it. Check that it closes

completely when released.
CHECKING COOLING SYSTEM FOR LEAKS

Hose adapter Apply pressure to the cooling system with cap tester to check
for leakage.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
Higher pressure than the specified value may cause damage to
radiator.
SMA990A
MA-17
ENGINE MAINTENANCE
Checking Fuel Lines

Inspect fuel lines and tank for improper attachment and for
leaks, cracks, damage, loose connections, chafing and deteri-
oration.
If necessary, repair or replace faulty parts.
SMA803A
Changing Fuel Filter

1. Remove fuel filter from support bracket.
2. Loosen fuel hose clamps.
3. Replace fuel filter.
• Be careful not to spill fuel over engine compartment. Place
a shop towel to absorb fuel.
• Use a high-pressure type fuel filter. Do not use a synthetic
resinous fuel filter.
• When tightening fuel hose clamps, refer to "Checking Fuel
Lines".
Changing Air Cleaner Filter

Viscous paper type
The viscous paper type filter does not need cleaning between
renewals.
Dry paper type

It is necessary to clean the element or replace it at the recom-
mended intervals, more often under dusty driving conditions.
SMA532
To properly tighten wing nuts, position clamps at four places

and tighten wing nuts until they touch air cleaner. Then tighten
them three more turns.
SMA603C
MA-18
ENGINE MAINTENANCE @]
Checking Cyclone Pre-air Cleaner

Remove dust cover and check duct for dust clogging. Clean
away any dust.
SMA604C
Changing Engine Oil

WARNING:
Be careful not to burn yourself, as the engine oil is hot.
1. Warm up engine, and check for oil leakage from engine
components.
2. Remove drain plug and oil filler cap.
3. Drain oil and refill with new engine oil.
Oil grade: API SG for Europe
API SE, SF and SG except for Europe
SMA605C
Viscosity: See "RECOMMENDED FLUIDS AND LUBRICANTS"
in MA section.
Refill oil capacity (Approximate):
Unit: liter (Imp qt)
With oil filter change 3.8 (3-3/8)

Without oil filter change 3,5 (3-118)
CAUTION:
• Be sure to clean drain plug and install.withl1ew .washer.
Drain plug:
rPJ:
29 - 39 N.m
(3.0 - 4.0 kg-m,2~ - 29 ft-Ib)
• The refill capacity changes depending on the oil tempera-
ture anddrall1time; use these .values as a reference and
be certain to check with the dipstick when changing the oil.
4. Check oil level.

5. Start engine and check area around drain plug and oil fil-
ter for oil leakage.
6. Run engine for a few minutes, then turn it off. After several
minutes, check oil level.
SMA885B
MA-19
ENGINE MAINTENANCE
Changing Oil Filter

1. Remove oil filter with a suitable tool.
WARNING:
Be careful not to burn yourself, as the engine and the engine
oil are hot.
( SMAG06C
2. Before installing new oil filter, clean the oil filter mounting
surface on cylinder block, and coat the oil'ilter rubber seal
with a little engine oil.
SMA010
3. Screw in the oil filter until a slight resistance is felt, then

tighten an additional 2/3 turn.
4. Add engine oil.
Refer to Changing Engine Oil.
2/3 of a turn
Correct Checking and Changing Spark Plugs

1. Disconnect ignition wires from spark plugs at boot. Do not
pull on the wire.
Do not hold the cable.

SMA228C
2. Remove spark plugs with spark plug wrench.

3. Clean plugs in sand blast cleaner.
4. Check insulator for cracks or chips, gasket for damage or
deterioration and electrode for wear and burning. If they
are excessively worn away, replace with new spark plugs.
20.6 mm
(0.811 In)
SMA609C
MA-20
ENGINE MAINTENANCE [ED
Checking and Changing Spark Plugs (Cont'd)
Spark plug:
Make NGK
Standard type BPR5ES
Hot type BPR4ES
Cold type BPR6ES, BPR7ES
Side electrode 5. Check spark plug gap.

Gap: 0.8 - 0.9 mm (0.031 - 0.035 in)
It 6. Install spark plugs. Reconnect ignition wires according to

nos. indicated on them.
Spark plug:
to.J:20 - 29 N'm (2 - 3 kg-m, 14 - 22 ft-Ib)
SMA476
Checking Ignition Wires

1. Inspect wires for cracks, damage, burned terminals. and for
improper fit.
2. Measure the resistance of wires and check for intermittent
breaks.
Resistance:
Except for Europe
9.6- 22.4 kn/m (2.93 - 6.83 kn/ft)
F.orEurope
13.6 - 18.4kn/m (4.15 - 5.61 kn/ft)
If it exceeds the limit, repla.ce the ignition wire with a new one.
Checking Positive Crankcase Ventilation (P.C.V.)
System
CHECKING P.C. V. VALVE
With engine running at idle, remove ventilation hose from
P.C.V. valve; if valve is working properly, a hissing noise will
be heard as air passes through it and a strong vacuum should
be felt immediately when a finger is placed over valve inlet.
CHECKING VENTILATION HOSES

1. Check hoses and hose connections for leaks.
2. Disconnect all hoses and clean with compressed air. If any
hose cannot be freed of obstructions, replace.
MA-21
ENGINE MAINTENANCE
Checking Vacuum Hoses and Connections

Check vacuum hoses for improper attachment and for leaks,
cracks, damage, loose connections, chafing and deterioration.
Checking Vapor Lines

1. Visually inspect vapor lines for improper attachment and
for cracks, damage, loose connections, chafing and deteri-
oration.
2. Inspect fuel tank filler cap vacuum relief valve for clogging,
sticking, etc.
REFER to EVAPORATIVE EMISSION CONTROL SYSTEM
INSPECTION in EF & EC section.
Checking Exhaust Gas Recirculation (E.G.R.)

Control System
1. Start engine and warm itup sufficiently.
2. Make sure that the E.G.R. control valve diaphragm moves
with a finger when raising engine speed.
If it does not move, check vacuum lines, B.P.T. valve and
T.V.V.
Refer to EXHAUST GAS RECIRCULATION (E.G.R.) CONTROL
SYSTEM INSPECTION in EF & EC section.
MA-22
ENGINE MAINTENAiNCE

Ch~cking should be performed while engine is cold.
MANIFOLD BOLTS AND NUTS
Intake:
~:15 ':'20 N'm (1.5 - 2.0 kg-m,11 - 14 ft-Ib)
Exhaust:
~: •.25 - 29 N'm (2.5 - 3.0 kg-m, 18 - 22 ft-Ib)
EXHAUST TUBE NUTS

~: 51 - 65 N'm (5.2 - 6.6 kg-m, 38 - 48 ft-Ib)

ning.
1. Set No. 1 cylinder in top dead center on its compression
stroke, and adjust valve clearance CD, @, @) and CID.
stroke, and adjust valve clearance @, CID, rJ) and @.
Valve Clearance:
Intake CD , . @), CID and rJ)
0.35 mm (0.014 in)
Exhaust @, @, CID and @
0.35 mm (0.014 in)
tD.J: 15 - 20 N'm (1.5 - 2.0 kg-m, 11 - 14 ft-Ib)
Engine
front
SMA653C
Alternator Drive Belt Inspection

i A Adjusting bar
13 • 19 : Inspect for cracks, fraying, wear or oil adhesion. Replace
(1.3 • 1.9, 9 - 14) if necessary.
The bEtIts S.hoUld.not touch the bottom of th~pulleygro()ve.
2. Check drive belt deflection by pushing on the belt midway
between pulleys.
Adjust if belt deflections exceed .thelimit.
Unit: mm (in)
Used belt deflection

Deflection of
Deflection after
Limit new belt
adjustment
11 c 13 9 - 11
AlC compresSOr Alternator 20 (0.79)
(0.43 - 0.51) (0.35 - 0.43)
A Idler pUlley nut . , ....
6 -7.5 5 - 6.5
30-36 Air conditioner.cQmpressor 12 (0.47)
(3.1- 3.7,22 :' 27) (0.236 - 0.295) (0.197- 0.256)
Crank pulley 8 - 9.5 7 - 8.5
PIS pump Power steering oil pump 15 (0.59)
(0.31q~ 0.374) (0.276 -.0.335)
A Adjusting bolt
Applied pushing force 98N(10 kg, 22 Ib)
19 • 25 (1.9 • 2.6, 14 - 19)
Adjusting lock nut
25 - 31 (2.5 - 3.2, 18 • 23)
Check drive belt deflections when engin~il; cold.
T : Check point SMA613C
MA ..23
ENGINE MAINTENANCE
Changing Engine Oil

components.
2. Remove oil filler cap and drain plug.
3. Drain oil and fill with new engine oil.
Oil grade: API CC or CD
Viscosity:
See "RECOMMENDED FLUIDS AND LUBRICANTS"
in MA section.
Refill oil capacity (approximate):
SMA614C
Without oil filter change
5.5 {\ (4-7/8 Imp qt)
With oil filter change
6.2 {\ (5-112Imp qt)
WARNING:
• Be careful not to burn yourself, as the engine oil may be
hot.
• Be sure to clean and install all pan drain plug with washer.
Drain plug:
rPJ:
54 - 59 N.m (5.5 - 6.0 kg-m, 40 - 43 ft-Ib)
• The refill capacity changes depending on the all tempera-
ture and drain time; use these valves as a reference and
4. Check oil level.

5. Start engine. Check area around drain plug and oil filter for
any sign of oil leakage.
minutes check oil level.
SMA615C
Changing Oil Filter

1. Remove oil filter with a suitable wrench.
WARNING:
Be careful not to burn yourself as engine and engine oil is hot.
MA-24
ENGINE MAINTENANCE [lLJ
Changing Oil Filter (Cont'd)
2. Before installing new oil filter, smear a little engine oil on
rubber seal of oil filter and mounting surface on cylinder
block.
3, Install oil filter.
When installing oil filter, screw it in until a slight resistance is
felt, then tighten an additional 2/3 turn or more.
SMA010

WARNING:
To avoid the danger of being scalded, never attempt to change
the coolant when the engine is hot.
1. Set heater "TEMP" control lever all the way to "HOT" posi-
tion.
2. Open drain cock at the bottom of radiator, and remove
radiator cap.
3. Remove cylinder block drain 'plug located at left rear of

cylinder block.
4~ Drain coolant and then tighten drain plug securely.
Drain plug:
tDJ:
54 - 64 N'm (5.5 - 6.5 kg-m, 40 - 47 ft-II)
5. Fill radiator with water and warm up engine.
7. Repeat step 2 through step 5 two or three times.
8. Drain water.
SMA617C
9. Fill radiator with coolant up to filler opening.

Coolant capacity (With reservoir tank):
Unit: t (Imp qt)
. TD25 TD27
With front heater 13.8 (12-1/8), 14.1 (12-3/8)- 13.7 (12-1/8)
Without front heater 12.8 (11-1/4),13.1 (11-1/2)- 12.7 (11-1/8)
SMA182B
With front & rear heaters 15.3 (13-1/2)- -
-: Double cab models
system to escape.
MA-25
ENGINE MAINTENANCE [![]
10. Fill reservoir tank up to "MAX" level.
Reservoir tank capacity ("MAX" level):
Single cab models 1.0 t (7/8 Imp qt)
Double cab models 1.2 t (1-118 Imp qt)
11. Run the engine at approximately 2,000 rpm for about one
MAX.
minute.
12. Stop engine and cool it down, then refill the radiator and the
MIN.
reservoi r tank.
SMA412B

CHECKING HOSES
Check hoses for proper attachment, leaks, cracks, damage,
loose connections, chafing and deterioration.

Apply pressure to radiator cap by means of a cap tester to see
if it is satisfactory.
78 - 98 kPa
(0.78 - 0.98 'bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)

Hose adapter Apply pressure to the cooling system by means of a tester to
check for leakage.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
Higher than the specified pressure may cause radiator dam-
age.
Checking and Replacing Fuel Filter and Draining

Water
Be careful not to spill fuel In engine compartment. Place a rag
to absorb fuel.
REPLACING FUEL FILTER
1. Drain fuel and remove fuel filter sensor.
SMA618C
MA-26
ENGINE. MAINTENANCE ~
Water (Cont'd)
2. Remove fuel filter, using suitable tool.
SMA619C
3. Wipe clean fuel filter mounting surface on fuel filter bracket

and smear a little fuel on rubber seal of fuel filter.
4. Screw fuel filter on until a slight resistance is felt, thEm
tighten an additional more than 2/3 turn,
5. Install fuel filter sensor to new fuel filter.
6. Bleed air from fuel line.
Refer to Bleeding Fuel System In EF & EC section~
7. Start engine and check for leaks.
SMA010
DRAINING WATER
1. Loosen air bleeder cock offuelfilter cover (If equipped).
Air bleeder
cock
SMA620C
2. Loosen drain cock and drain water.

Loosening drain coc,k.4 to 5 turns causes water to start drain-
Ing. Do not removed(aln cock by loosening it excessively.
In the case of. a fuel filter cover not eqUipp~c1with an air
bleeder cock,if. water does not drain properly, move the
priming pump up .and down. .
3. Bleed air.
HE;lferto section EF & EC for fuel system bleeding instruc-
tions.
SMA621C
Checking Fuel System

Check fuel lines and tank for proper attachment, leaks, cracks,
SMAB03A
MA-27
ENGINE MAINTENANCE
Cleaning and Replacing Air Cleaner Filter

When cleanihg or replacing filter element, wipe off dust deposit
on inside face of air cleaner case.
VISCOUS PAPER TYPE

renewals.
SMA622C
SMA623C
DRY PAPER TYPE

Checking Injection Nozzle

WARNING:
When using nozzle tester, be careful not to allow diesel fuel
sprayed from nozzle to come Into contact with your hand or
body, and make sure that your eyes are properly protected.
1. Check initial injection pressure by pumping tester handle
one time per second.
Initial injection pressure:
Used Nozzle
9,807 - 10,297 kPa
(98.1 - 103.0 bar, 100 - 105 kg/cm2,
1,422 - 1,493 psi)
New Nozzle
10,297 • 11,278 kPa
(103.0. 112.8 bar, 105 • 115 kg/cm2,
1,493 - 1,635 psi)
• Always check initial injection pressure before Installing
new nozzle.
MA-28
Checking Injection Nozzle (Cont'd)
2. Check spray pattern by pumping tester handle onetime or
ij 3.
more per second.
~fe~~~~~
Ft~tternis not correct, clean injection nozzle tip or
Refer to INJECTION NOZZLE in EF & EC section.

• ~: Injection nozzle to cylinder head
54 - 64 N.m
(5.5 - 6.5 kg-m, 40 - 47 ft-Ib)
I Spill tube nut
Good Wrong
29 - 39 N.m
EF794A (3.0 - 4.0 kg-m, 22 - 29 ft-Ib)
Injection tube
20 - 25 N.m
(2.0 -2.5 kg-m, 14 - 18 ft-Ib)
Checking Idle Speed

Preparation
1. Make sure that injection timing is correct.
2. Make sure that injection nozzles are in good condition.
3. Make sure that the following parts are in good condition.
• Air cleaner clogging
• Glow system
• Engine oil and coolant levels
• Valve clearance
• Air intake system (Oil filler cap, oil level gauge, etc.)
4. Set shift lever in "Neutral" position. Engage parking brake
and lock both front and rear wheels with wheel chocks.
5. Turn off air conditioner, lights and accessories.
6. Make sure that idle control knob is turned fully counter-
clockwise and idle adjusting screw contacts accelerator
control lever.
MA-29
ENGINE MAINTENANCE
Checking Idle Speed (Cont'd)
INSPECTION
• Warm up engine until water temperature indicator points to middle of gauge .

• Attach tachometer's pick-up to No. 1 fuel injection tube.
In order to take accurate reading of engine rpm,. remove clamps that secure No.1 fuel injection tube.
Start engine.
Check idle Run engine at about 2,000 rpm for

speed. about 2 minutes under no-load.
SMA4068
Run engine for one minute at idle

speed.
Check idle speed.
IDLE SPEED:
700::1:50rpm
O.K. N.G.
Adjust idle speed by turning idle

~
speed adjusting screw.
END
• Race engine two or three times and allow engine to return to idle speed. If idle speed is not within
the specified range, check acceleration linkage for binding and correct it if necessary.
MA-30
ENGlNE MAINTENANCE
Checking Idle Speed (Conl'd)
I I (-.1\ 111m\ AIR C9NDITIONER EQUIPPED MODEL
1. Tum idle .control knob fully counterclockwise.
~~.~~~~
2. Mak~ cert(l.in tha~.the clearance between the actuator idle
control rod and the injection pump control lever is within
t~e specified limits .
. C,learan~e:2 mm (0.08 in)
3. Acljustid!e. speed to specified rpm without the air condi-
qClearance:
/ More than 2 mm tiOner operating.
-1 ft )~
8
SMA624C
4. Then~heck the idle speed when the air conditioner is oper-
atingand make sure it is correct.
Unit: rpm
Idle speed (Air conditioner "ON") 850::1::50
If not,. adjust itbyturning F.I.C.D. actuator stroke adjusting

screw.
MA ...31
ENGINE MAINTENANCE

Checking should be performed while engine is cold.
Intake:
~: 15 - 20 N'm (1.5 - 2.0 kg-m; 11 - 14 ft-Ib)
Exhaust:
~: 25 - 29 N'm (2.5 - 3.0 kg-m, 18 - 22 ft-Ib)
EXHAUST TUBE NUTS

~: 51 - 65 N'm (5.2 - 6.6 kg-m, 38 - 48 ft-Ib)

ning.
stroke, and adjust valve clearance (1), @, CID and CID.
2. Set No.4 cylinder in top dead center on its compression
stroke, and adjust valve clearance @, <ID, C1J and @.
Valve clearance:
Intake (1), CID, <ID and C1J
0.35 mm (0.014 in)
Exhaust @, @, CID and @
0.35 mm (0.014 in)
~: 15 - 20 N'm (1.5 - 2.0 kg-m, 11 - 14 ft-Ib)
Engine
front
SMA653C
Drive Belt Inspection

1. Inspect for cracks, fraying, wear or oil adhesion. Replace
Alternator if necessary.
Adjusting bar bolt
The belts should not touch the bottom of the pulley groove.
to.J 16 - 21
(1.6.2.1, 2. Check drive belt deflection by pushing on the belt midway
12 - 151 between pulleys.
Idler pulley nut Adjust if belt deflections exceed the limit.
~30.41 Unit: mm (in)
(3.1-4.2,
22 - 30) Used belt deflection
AIC compressor Deflection of new
Deflection after
Limit belt
adjustment
11 - 13 9 - 11
Alternator 20 (0.79)
(0.43 - 0.51) (0.35 - 0.43)
Air conditioner 6 - 7.5 5 - 6.5

12 (0.47)
compressor (0.236 - 0.295) (0.197 - 0.256)
Applied pushing
~ : N.m (kg-m, ft-Ib) 98 N (10 kg, 22 Ib)
force
... : Check point
Check drive belt deflections when engine is cold.
SMA180C
MA-32
ENGINE MAINTENANCE
Changing Engine Oil

1. Warm up. engine, and check for oil leakage from engine
componellts.
3. Draindil a~d fill with new engine oil.
Oil grade: API CC or CD
Viscosity:
See "RECOMMENDED FLUIDS AND LUBRICANTS"
in MA section.
Refill all capacity (Approximate):
Without all filter change
7..4t (6-112Imp qt)
With all filter change
8.H (7-118Imp qt)
WARt.UNG:
• Be careful "otto burn yourself, as the engine all may be
hot.
• Be sure to clean and install all pan drain plug with washer.
toJ:Drain plug
54 .. 59 N'm
(5.5 - 6.0 kg-m, 40 - 43 ft-Ib)
• The refill capacity changes depending on the all tempera-
tures and drain time; use these values as a reference and
be certain to check with the dipstick when changing the all.
4. Check oil level.

6. Run engine for.a few minutes, then turn it off. After several
Changing Oil Filter

1. Remove oil filter with a suitable wrench turning counter-
clockwise.
WARNING:
Be careful not to burn yourself as engine and engine all Is hot.
MA-33
ENGINE MAINTENANCE ~
Changing Oil Filter (Cont'd)
block.
3. Install oil filter.
When installing oil filter, screw it in until a slight resistance is
felt, then tighten an additional 2/3 turn or more.
4. Add engine oil.
SMA010

WARNING:
To avoid the danger of being scalded, never attempt to change
the coolant when the engine is hot.
1. Set heater "TEMP" control lever all the way to "HOT" posi-
tion.
2.. Open drain cock at the bottom of radiator, and remove
radiator cap.
3. Remove cylinder block drain plug located at left rear of

cylinder block.
4. Drain coolant and then tighten drain plug securely.
5. Fill radiator with water and warm up engine.
7. Repeat step 2 through step 6 two or three times.
8. Drain water.
Drain plug:
~: 54 - 64 N'm (5.5 - 6.5 kg-m, 40 - 47 ft-Ib)
SMA617C
9. Fill radiator with coolant up to filler opening.

Unit: C (Imp qt)
Single cab models Double cab models

With front heater 13.1 (11-1/2) 13.4 (11-3/4)
Without front heater 12.1 (10-5/8) 12.4 (10-718)
SMA1828
With front & rear heaters - 14.6 (12-7/8)

system to escape.
MA-34
ENGINE. MAINTENANCE (]QJ
10. Fill reservoir tank up to "MAX" level.
Re$ervoir tank capacity ("MAX" level):
Single cab models 1.0£ (7/8 Imp qt)
Double cab models 1.2 £ (1-1/8 Imp qt)
11. Run the engine at approximately 2,000 rpm for about one
MAX.
minute.
12. Stop engine and cool it down, then refill the radiator and the
MIN.
reservoir tank.
SMA412B

CHECKING HOSES
100seconne<::tioQS,
chafing and deterioration.

78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)
CHECKING COO.llNG SYSTEM FOR LEAKS

Apply pressure to the cooling system by means of a tester to
check for leakage.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
age.
SMA990A
Ch.eckingand Replacing Fuel Filter and Draining

Water
Be careful not to spill fuel in engine compartment. Place a rag
to absorb fuel.
1. Drain fuel and remove fuel filter sensor.
2. Remove fuel filter, using suitable tool turning counterclock-
Sensor connector
wise.
SMA626C
MA-35
ENGINE MAINTENANCE [!Q]
Water (Cont'd)
4. Screw fuel filter on until a slight resistance is felt, then
tighten an additional more than 2/3 turn.
5. Install fuel filter sensor to new fuel filter.
Refer to Bleeding Fuel System in EF & EC section.
SMA010
DRAINING WATER
1. Set a container under fuel filter.
2. Loosen air bleeder screw from the sedimentor cover.
Loosening drain cock 4 to 5 turns causes water to start drain-
ing. Do not remove drain cock by loosening it excessively.
In the case of a fuel filter cover not equipped with an air
bleeder cock, if water does not drain properly, move the
priming pump up and down.
4. Bleed air.
Refer to section EF & EC for fuel system bleeding instruc-
tions.
Checking Fuel System

Check fuel lines and tank for proper attachment, leaks, cracks,

When cleaning or replacing filter element, wipe off dust deposit
VISCOUS PAPER TYPE

renewal.
SMA628C
MA-36
(Cont'd)
D.RV PAPER TYPE

WARNING:
When using nozzle tester, be careful not to allow diesel fuel
sprayed from nozzle to come into contact with your hand or
body, and make sure that your eyes are properly protected.
Used nozzle
EF792A 18,143 . 18,633 kPa
(181.4 . 186.3 bar, 185 . 190 kg/cm2,
2,631 . 2,702 psi)
New nozzle
18,633 .19,614 kPa
(186.3 . 196.1 bar, 190.200 kg/cm2,
2,702 . 2,844 psi)
• Always check initial injection pressure before installing
new nozzle.
2. Check spray pattern by pumping tester handle one time or

more per second.
3. If spray pattern is not correct, clean injection nozzle tip or
replace it.
Refer to INJECTION NOZZLE in EF & EC section.
.. . •
I
Good Wrong
EF794A
Checking Idle Speed

Preparation
• Air heater system
• Valve clearance
• Air intake system
MA ...37
ENGINE MAINTENANCE [][]
6. Make sure that idle control knob is turned fully counter-
clockwise and idle adjusting screw contracts accelerator
control lever.
MA-38
ENGINE MAINTENANCE
INSPECTION
• Warm up engine until water temperature indicator points to middle of gauge .
• Attach tachometer's pick-up to No.1 fuel il'1jection tube.
In order to take accurate reading of engine rpm, remove clalTlPs ,that secure No. 1 fuel Injection tube.
Start engine.
Run engine at about 2,OOOrplTlfor

about 2 minutes under no-load.
SMA4068
Run engine for one minute at idle

speed .
•:!:lMA171C
Ch~ck idle speed.
IDLE SPEED:
700::l::50rpm
850::l::50 rpm (Air conditioner "ON")
O.K. N.G.
.. Adjust idle speed by turning idle

speed adjusting screw.
END
• Race engine two or three times and allow engin~ tOrE~turnto idle speed. If idle speed is not within
,he.spE!cifiedrang~, che~k.f'cceh!ration nnkage!or.bi~ding and correct it If necessary.
ENGINE MAINTENANCE

Checking should be performed while engine is cold.
Intake:
toJ: 14 - 18 N'm (1.4 - 1.8 kg-m, 10 - 13 ft-Ib)
Exhaust:
toJ: 39 - 49 N'm (4.0 - 5.0 kg-m, 29 - 36 ft-Ib)
EXHAUST TUBE NUTS
toJ: 51 - 65 N'm (5.2 - 6.6 kg-m, 38 - 48 ft-Ib)
Adjustment should be made while engine Is cold.
1. Set No. 1 cyl inder in top dead center on its compression
stroke, and adjust valve clearance <D, @, <ID and @.
2. Set NO.4 cylinder in top dead center on its compression
stroke, and adjust valve clearance @, @, (J) and @.
Valve clearance:
Intake <D, <ID, @ and (J)
0.4 mm (0.016 in)
Exhaust @, @, @ and @
0.4 mm (0.016 in)
toJ:
20 - 25 N'm
(2.0 - 2.5 kg-m, 14 - 18 ft-Ib)
Drive Belt Inspection

A Idler pUlley nut 1. Inspect for cracks, fraying, wear or oil adhesion. Replace
30 - 41
(3.1 - 4.2, 22 - 30) if necessary.
The belts should not touch the bottom of the pulley groove.
AIC compressor 2. Check drive belt deflection by pushing on the belt midway
Alternator
between pulleys.
A AdJusting bar bolt
16 - 21 Adjust if belt deflections exceed the limit.
(1.6 - 2.1, 12 - 15)
Belt deflection
\+ Used belt deflection
Limit
Deflection after
adjustment
Unit: mm (in)
Deflection of
new belt
13.5 - 15.5 11.5 - 13.5

(0.531 - 0.610) (0.453 - 0.531)
Alternator
AMounting 15 - 17 14 - 16
Air conditioner compressor 24 (0.94)
bolt/nut (0.59 - 0.67) (0.55 - 0.63)
46 • 61
(4.7 - 6.2, Applied pushing force 98 N (10 kg, 22 Ib)
34 - 45)
A: N.m (kg-m, ft-Ib) Check drive belt deflections when engine Is cold.
'If' : Check point MMA058A
MA-40
ENGINE .MAINTENANCE
Changing Engine Oil

WARNING:
Be careful. not to burn yourself, as the engine all may be hot.
components.
3. Drain oil and fill with new engine oiL
Oil grade: •.API CC or CD
Viscosity: See "RECOMMENDED FLUIDS AND
LUBRICANTS" in MA section.
MMA059A
Refill oil capacity (Approximate):

Without oil filter change 8.3 (7-1/4)
CAUTION:
• Be sure to clean and install oil pan drain plug with washer.
• Drain plug:
~: 54 - 59 N'm (5.5 - 6.0 kg-m, 40 - 43 ft-Ib)
• The refill capacity changes depending on the oil tempera-
ture and drain time; use these values as a reference and
4. Check oil level.
.r....
Refill oil
I to "H"
: level.
LOO not
overfill.
MMA060A
Changing Oil Filter

1. Remove oil filter with a suitable wrench.
WARNING:
Be careful not to burn yourself as engine and engine oil Is hot.
block.
3. Install oil filter.

Full flow oil filter;
When install oil filter, screw it in until a slight resistance is felt,
then tighten an additional 1/2 turn or more.
By-pass all filter;
When Installing at oil filter, screw it in until a slight resistance
is felt, then tighten an additional 2/3 turn .or more.
4. Add engine oil.
MA-41
ENGINE MAINTENANCE

WARNING:
To avoid being scalded, never change the coolant when the
engine is hot.
1. Move heater "TEMP" control lever all the way to "HOT".
2. Open radiator drain plug at the bottom of radiator, and
remove radiator filler cap.
3. Remove reservoir tank, drain coolant, then clean reservoir
tank. Install it temporarily.
MMA064A
• Be careful not to allow coolant to contact drive belts.
4. Remove cylinder block drain plug located at left rear of

cylinder block.
5. Close radiator drain plug and tighten cylinder block drain
plug securely.
6. Fill radiator with water and install radiator filler cap.
7. Warm up engine sufficiently, then race engine 2 or 3 times
under no-load.
9. Repeat step 2 through step 7 until clear water begins to
drain from radiator.
10. Drain water.
• Apply sealant to drain plug thread.
rPJ:20 - 29 N'm (2.0 - 3.0 kg-m, 14 - 22 ft-Ib)
11. Fill radiator and reservoir tank with coolant, following step
6 through step 8.
Unit: C (Imp qt)
FD42 FD46
With heater 14.5 (12-3/4) 15.2 (13-3/8)
SMA1828
Without heater 13.6 (12) 14.3 (12-5/8)

system to escape.
12. If necessary, add coolant.

CHECKING HOSES
MA-42
ENGINE MAINTENANCE
Checking Cooling System {Cant' d)
Radiator Cap relief pressure:
78 - 98 kPa
(0.78.-0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)
Pull the negative-pressure valve to open it. Check that it closes

completely when released.

Hose adapter Apply pressure to the cooling system by means of a tester to
check for leakage.
Testing. pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
Higher than the specified pressure may cause.darnage tc) radi-
ator.
SMA990A
Checking and Replacing Fuel Filter

Drain
support CHECKING. FUEL FILTER
screw
o Check fuel filter for fuel leakage, damage and other abnormal
signs.
+
Fuel filter Sensor
connector
MMA066A

Be careful not to spill fuel in engine compartment. Place a rag
to absorb fuel.
1. Remove fuel filter, using a suitable tool.
MA.43
ENGINE MAINTENANCE [£[]
Checking and Replacing Fuel Filter (Cont'd)
3. Screw fuel filter on until a slight resistance is felt, then
tighten an additional more than 2/3 turn.
Refer to Bleeding Fuel System in EF & EC section.
SMA010
Checking Sedimentor and Draining Water

DRAINING WATER
1. Set a container under sedimentor.
2. Loosen drain support screw on the sedimentor cover.
+
Fuel filter Sensor
connector
MMA066A

Loosening drain cock 4 to 5 turns causes water to start drain-
ing. Do not remove drain cock by loosening it excessively.
4. Bleed air.
Refer to EF & EC section for fuel system bleeding instruc-
tions.
Checking Fuel Lines

Check fuel lines and tank for improper attachment, and for
leaks, cracks, damage, loose connections, chafing and deteri-
oration. If necessary, repair or replace faulty parts.
MA-44
ENGINE MAINTENANCE
MMA069A
When cleaning or replacing filter element, wipe off dust deposit

VISCOUS PAPER TYPE

renewal.
DRY PAPER TYPE

Viscous paper type It is necessary to clean the element or replace it at the recom-
Dry paper type
MMA070A

WARNING:
When using nozzle tester, be careful not to allow fuel sprayed
from nozzle to come into contact with your hand or body, and
make sure that you eyes are properly protected.
1. Clean and check nozzles.
2. Install nozzle to injection nozzle tester and bleed air from
flare nut.

Used Nozzle
18,633 - 19,124 kPa (186.3 - 191.2 bar,
190 - 195 kg/cm2, 2,702 . 2,773 psi)
New Nozzle
19,124.20,104 kPa (191.2 - 201.0 bar,
195 - 205 kg/cm2, 2,773 - 2;915 psi)
• Always check initial injection pressure before installing
new nozzle.
MA ..45
ENGINE MAINTENANCE IT[]
Checking Injection Nozzle (Cont'd)
4. Check spray pattern by pumping tester handle one time per
second.
5. If initial injection pressure or spray pattern is not correct,
adjust or clean injection nozzle tip, or replace it.
• Refer to INJECTION NOZZLE in EF & EC section.
'---v /
Wrong Good
MMA072A
Checking Idle Speed

PREPARATION
1. Remove engine room cover. (Fixed cab type)
2. Tilt the cab. (Tilting cab type)
• Glow system
• Valve clearance
• Air intake system (Oil filler cap, oil level gauge, etc.)
MA-46
ENGINE MAINTENANCE
INSPECTION
• Warm up engine until water temperature indicator points to middle

of gauge .
• Lights, heater .fan and all accessori,es areaff.
Attach tachometer's pick-up to No. 1 fuel injection tube .

• In order to take accurate reading of engine rpm, remove clamps
that secure No. 1 fuel Injection tube ..
Start engine
Run engine at about 2,000 rpm

for about 2 minutes under
no-load.
Run engine for one minute at

idle speed.
MMA081A
Check idle speed
IDLE SPEED:
600+:° rpm
OK N.G.,
Adjust idle speed by turning idle

END speed adjusting screw.
Refer to "Adjustment".
• Race engine two or three times and allow engine to return

to Idle speed. If Idle speed Is not within the specified range,
check acceleration linkage for binding and correct ,If nec-
essary.
MA.47
ENGINE MAINTENANCE
ADJUSTMENT
Fixed cab type
1. Shut off engine.
2. Remove intake shutter, air heater, and auto-stop actuator
with bracket, then disengage accelerator wire.
3. Remove fuel filter without removing hoses, from bracket

and fasten to a body with a rope.
• Do not suspend fuel filter from hoses under its own weight
since hoses may be crushed.
4. Install air heater and intake shutter, then connect air duct.
5. Start engine.
• Run engine at idle for one minute.
6. Loosen lock nut, turn idle adjusting screw to adjust idle

speed and tighten lock nut.
Idle speed:
600+5~ rpm
MMA077A
MA-48
ENGINE MAINTENANCE ~
Checking Idle Speed (ConI' d)
7. Remove intake shutter.
8. Install fuel filter to its original position.
9. Install auto-stop actuator and connect accelerator wire.
• For accelerator wire adjustment, refer to "Accelerator Con-
trol System."
10. Install intake shutter and connect air duct.
Intake shutter bolt and nut:
toJ: 25 - 35 N'm
(2.6 - 3.6 kg-m, 19 - 26 ft-Ib)
Tilting cab type

Loosen lock nut, turn idle adjusting screw to adjust idle speed
and tighten lock nut.
Idle speed:
600+~orpm
AIR CONDITIONER EQUIPPED MODEL

1. Make certain that the clearance between the actuator idle
control lever pin and the injection pump control lever is
within the specified limits.
2. Adjust idle speed to specified rpm without the air condi-
tioner operating.
3. Then check the idle speed when the air conditioner is oper-
ating and make sure it is correct.
Unit: rprn
MMA07BA
Idle speed (Air conditioner "ON") 750:1:50
If not, adjust it by turning F.I.C.D. actuator stroke adjusting

screw.
MA-49
CHASSIS AND BODY MAINTENANCE
Checking Exhaust System

Check exhaust pipes, muffler and mounting for improper
attachment, leaks, cracks, damage, loose connections, chafing
and deterioration. .
SMA211A
Checking Clutch Fluid Level and Leaks

If fluid level is extremely low, check clutch system for leaks.
Max.
SMA642C
Checking Clutch System

Check fluid lines and operating cylinder for improper
attachment, cracks, damage, loose connections, chafing and
deterioration.
~
Q)-t)
SMA643C
Checking MIT Oil Level

Never start engine while checking oil level.
1. Check manual transmission for leakage.
2. Check oil level.
Filler plug
~: 25 - 34 N.m (2.5 - 3.5 kg-m, 18 - 25 ft-Ib)
SMA103
Changing MIT Oil

Oil capacity:
RS5W71C2.0£ (3-1/2 Imp pt)
RS5W81A 2.7t (4-3/4 Imp pt)
RS5R50A 4.0£ (7 Imp pt)
Drain plug:
~: 25 - 34 N.m (2.5 - 3.5 kg-m, 18 - 25 ft-Ib)
Oil grade: API GL-4
Viscosity: See "RECOMMENDED FLUIDS AND
SMA255A
MA-50
Checki.ng Propener Shaft

Check propeller shaft for damage, looseness or grease leak-
age.
Tightening torque: Refer to section PD.
SMA945B
Greasing Nipples of Propeller Shafts

Apply multi-purpose grease to nipples of propeller shafts.
SMA644C
Checking Differential Gear Oil

1. Check differential carrier for oil leakage.
2. Check oil level.
Filler plug:
C200
toJ: 39 - 59 N'm (4 - 6 kg-m, 29 - 43 ft-Ib)
Except C200
toJ: 59 - 98 N'm (6 - 10 kg-m, 43 - 72 ft-Ib)
Changing ..DiUerential Gear Oil

Oil capacity:
C2QO 1.3.(',(2-1/4 Imp pO
H233B 2.0 {; (3-1/2 Imp pt)
H260 4.3 {; (7-5/8 Imp pt)
H290 4.6 {; (8-1/8 Imp pt)
H310 6.0 {; (10-518 Imp pt)
Drain plug: .
toJ:59 ~98 N'm (6 - 10 kg-m, 43 - 72 ft-Ib)
Oil grade: API GL-5
SMA663C Viscosity: See "RECOMMENDED FLUIDS AND
MA~51
Checking Brake Fluid Level and Leaks

If fluid level is extremely low, check brake system for leaks.
Checking Brake System

Check brake fluid lines and parking brake cables for improper
attachment, leaks, chafing, abrasion, deterioration, etc.
Changing Brake Fluid

1. Drain brake fluid from each air bleeder valve.
2. Refill until new brake fluid comes out from each air bleeder
valve.
Use same procedure as in bleeding hydraulic system to
refill brake fluid.
Refer to section SR.
• Refill with recommended brake fluid "DOT 3".
• Never reuse drained brake fluid.
• Be careful not to splash brake fluid on painted areas.
Checking Brake Booster, Vacuum Hoses,

Connections and Check Valve
Check vacuum lines, connections and check valve for improper
attachment, air tightness, chafing and deterioration.
Checking Disc Brake

Check condition of disc brake components.
ROTOR
Check condition and thickness.
Standard thickness:
CL36VB 26.0 mm (1.024 in)
Minimum thickness:
CL36VB 24.0 mm (O.945 in)
SMA260A
CALIPER
Check operation and leakage.
SMA922A
MA-52
Checking Disc Brake (Cont'd)
PAD
Check wear or damage.
Standard thickness:
11.0 mm (0.433 in)
Minimum thickness:
2.0 mm (0.079 In)
SMA8478
Checking Drunt Brake

DRUM
Check condition and inner surface.
Drum repair limit (Inner diameter):
Refer to S.O.S.
SMA139
LINING
Check wearQr damage.
A Lining we~r limit (Minimum thickness):
2L28 & 2L30A
1.5mm (0.059 in)
2L328
3.2 mm (0.126 in)
SMA138
Balancing Wheels
Adjust wheel balance using the road wheel center.
Maximum allowable unbalance at rim flange:
40 g (1.41 oz)
Tire balancing weight:
5 - 60 g (0.18 - 2.12 oz)
Spacing 5 g (O.180z)
Checking Power Steering System Fluid and

Lines
• Check fluid level, when the fluid is cold.
MA-53
CHASSIS AND BODV MAINTENANCE
Cbeckll'l.gPQWerSteerlngSystel11Fluic:land
lines (Cont'd)
• C.h;eck Hnes. for improper attachment, leaks, cracks,
damag~, loose conn~ctions, chafing and d~t~rioration.
SST197C
Checking Steering Damper

Check steering d.amp~rfor damage and oil leakage.
SMA938A
Checking Steering Gear Box and Linkage

STEERING GEAR
• Ch~ck gear housing and boots for looseness, damage or
91'~l;lseleakag~.
• Ch~ck conn~ction with steering column for loos~ness.
STEERING LINKAGE
• Check ball Joint, dust cover and other component parts for
looseness, wear, dl;lmage or greas.e leakage.
Ore«sing Ste;ering Linkage

Apply mUlti~purpos.~grease to greasing points using suitable
gr~ase r,li:ppJ~s...
SMA939B
IF23] Tire Rotation
• • Single tire Low & flat bed
0=0
0-0
~.
Double tire
SMA665C
Wheel Nut Tightening Torque

F23-
U~it:~.m (l<!,tm~.ft~IB):
Front tire Rear tire
Single tire 118 - 147 (12 - 15, 87 - 108)
Double tire
11if.147 216 - 255
(12- 15,&7.108) (22 -26,159- 188)
H41
Unit: N"[!l (kg~I11'ft-Ib)
Front tire Pf~artird

Single tire 177.226(181.23,130- 166)
High bed & 441- 539

super low 441 - 539 (45 - 55, 325 - 398)
Double tire
,!1ow & flat (45;. 55, 325 - 398) 392 • 490
bed (40 - 50, 289 - 362)
CHASSIS AND BODY MAINTENANCAE
Body
LUBRICATING LOCKS AND HINGES
[JO
MMA052A
CHECKING SEAT BELTS, BUCKLES, RETRACTORS, ANCHORS AND ADJUSTERS

CAUTION:
1. If the vehicle Is collided or
overturned, replace the entire belt
Check belts for damage. assembly, regardless of nature of
accident.
2. If the condition of any component
Check function of buckles and tongues
of a seat belt Is questionable, do
Check anchors for when buckled and released.
not have seat belt repaired, but
loose mounting.
replaced as a belt assembly.
3. If webbing Is cut, frayed, or
damaged, replace belt assembly.
4. Do not spill drinks, 011,etc. on
Check retractors Inner lap belt buckle. Never 011
for smooth tongue and buckle.
operation. 5. Use a NISSAN genuine seat belt
assembly.
Anchor bolt
A 43-55
(4.4 - 5.6, 32 - 41)
Rear seat belt - Type II
Front seat belt
Rear seat belt - Type I
MMA053A
MA-56
CHASSIS AND BODV MAINTENANCE
Checking. Body Corrosion

Visually check the body sheet metal panel for corrosion, paint damage (scratches, chipping, rubbing,
etc.) or damage to the anti-corrosion materials. In particular, check the following locations.
Hemmed portion
Hood front end, door lower end, trunk lid rear end, etc.
Panel joint
Side sill of rear fender and center pillar, rear wheel housing of rear fender, around strut tower in engine
compartment, etc.
Panel edge
Trunk lid opening, sunroof opening, fender wheelarch flange, fuel filler lid flange, around holes in panel,
etc.
Parts contact
Waist molding, windshield molding; bumper, etc.
Protectors
Damage or condition of mudguard, fender protector, chipping protector, etc.
Anti-corrosion materials
Damage Of separation of anti-corrosion materials under the body.
Drain holes.
Condition of drain holes at door and side sill.
When repairing corroded areas, refer to the Corrosion Repair Manual.
MA-S7
SERVICE DATA AND SPECifiCATIONS
, .. '" ,-', , .. , -'
(s.o.s.)
Engine ..•.
Uedntenance - NA20S
INSPECTION 4ND ADJUSTMENT OU capacity (Refill capacity)
Unit: f, (Imp qt)
Valve clearance (Hot)
Wilh oil filter change 3.8 (3-'3/8)
Unit: mm (in)
Without oil filter change 3.5 (3-' 1/8)
Intake 0.30 (0.012)
Exhaust 0,30 ,(0.012)

Spark plug
Drive belt deflection Make NGK
Unit: mm ,(In)
------------+------------
Type
Used belt deflectio.n Standard BPRSES
Deflection Deflection of Hot BPR4ES

Cold BPR6ES, BPR7ES
ment
Plug gap mm (in) 0.8 - 0.9 (0.031- 0.035)
Alternator
6-7 5-6
For Europe 11 (0.43)
(0.24 - 0.28) (0.20 - 0.24)
Ignition wire
Except for 8 - 10 7-8 Resistance kQ/m (kQIft)
12 (0.47)
Europe (0.31 - 0.39) (0.28 - 0.31) Except for Europe 9.6 - 22.4 (2.93 - 6.83)
Power steering 10 - 12 8- 10 For Europe 13.6 - 18.4 (4.15 - 5.61)
16 (0.63)
oil pump (0.39 - 0.47) (0.31 -0.39)
8- 10 6-8
Compressor 13 (0.51)
(0.31 - 0.39) (0.24 - 0.31)
Idle speed
Unit: rpm
Applied pushing
98 N (10 kg, 22 lb)
force Standard Air conditioner "ON"
750:1:50 850:1:50
Coolant capacity (Refill capacity)

Unit: r (Imp qt) Tightening torque
Without heater 7.7 (6-3/4) Unit N'm kg-m ft-Ib
With heater 8.8 (7-3/4) Manifold bolts and nuts
With rear heater Intake 16 - 21 1.6 - 2.1 12 - 15

9.8 (8-5/8)
(DoUble cab moceJ)
Exhaust 20 - 24 2.0 - 2.4 14 - 17
Exhaust tube bolts and

51 - 65 5.2 - 6.6 38 - 48
Cooling system check nuts
Unit: kPa (bar, kg/cm2, psi) Carburetor bolts and nuts 21 - 26 2.1 - 2.7 15 - 20
Radiator testing pressure 157 (1.57, 1.6, 23)
78 - 98 (0.78 - 0.98,
Radiator cap relief pressure
0.8 - 1.0, 11 - 14)
MA ..58
Engine M,aintenance .-.- TD25 It T021
INSPECTION AND ADJUSTMENT Inlectionnoz:2:1e
Valve clearance (Hot) Injection pressure
kPa (bar, kg/cm2, pSi)
Intake and exhaust mm (in) 0.35 (9.014)
9,807 - 10;297
Used nozzle (98.1 .. 103.'0, 100- 105,
Drive belt deflection 1,422 - ':~93)
Unit: mm (in) 10,297 - 11,278
New nozzle (103.0 - 112.8, 105 - 115,
1,493 - 1,(35)
Deflection Deflection of
Umit alter adjust- new belt
. ment Idle speed
11 - 13 9 - 11 F.I.C.D. OfF f.Le.n.ON
(0.43 - 0.5t) (tl35- 0.43)
". Idle speed rpm 700!l:50 850:i:50
Air conditioner
12 (0.47)
6 - 7.5 5 6.5 -
compressor :.: -
(0.236 Q.295) (0.197- 0.256)
TIGHTENING tORQUE
Power steer- 8 - 9.5 '7 - 8.5
15 (0.59)
ing ell pump (U15 - 0.374) (0.276 - 0.335) Unit N'm kg-m It-Ib
Applied push- lntal<em'iihifol'd huttbelt 15-20 1.5-2:0 11-14
.:
98 N (10 kg, 22 "b)
ing force
Exhaustmaniloldnut 25 - 29 2.5 - 3.0 18 - 22
Inspect dtlve beUdeflections wken engine Iscokh
Alternator adjusting baT bb'n 13.19 1.3"Ul 9 - 14
Refill oil capacity (Approximate) IdleTpUlley hut

(A/C compressor)
Unit: C (Imp qt)
PIS oil pump adjusting bolt 19 - 25 1.9 - 2.6 14 - 19
Without oil filter change 5.5 (4-7/8)
PIS oil pump adjusting Ibcl< nut 25 - 31 2.5 - 3::1 18 - '23
Oil pan drain plug .' 54 - 5.5 - 8.'0 40 .. 43
Injection nazzle to cylinder

Refill coolant capacity (With reservoir tank) head
54 - 64 5.5 - 6.5. 40 - 47
Unit: C (Imp qt)
Spill tUbe nut 29 - 39 3.0 -4.0 22 - 29
TD25 tD27
mjection tube flare nut 20 - :25 2.0- 2.5 1" - if!
13.8 (12-1/8)
With front heater 13.7 (12-1/8) Vallie clearant'e adjusting
14.1 (12-318)*
Screw lock nut
12.8 (11-1/4)
Without front heater 12.7 (11-1/8) Cylinder block drain plug
13.1 (11-112)*
With front & rear heaters 15.3 (13-1/2)* -

*: Double cab models
Cooling system
Radiator cap relief pressure 78 - 98
kPa (bar, kg/cm2, psi) (0.78 - 0.98, 0.8 -1.0,11 -14)
Cooling system leakage testing

pressure 157 (1.57, 1.6, 23)
kPa (bar. kg/cm2, psi)
MA..'S
SERVICE DATA AND SPECIFICATIONS (S.D.S.)
Engin~ Maintenance - 8D30

INSPECTION AND ADJUSTMENT Idle speed
F.I.C.D. OFF F.I.C.D. ON
Valve clearance (Hot) 700:1:50 850:1:50
Idle speed rpm
Intake and exhaust mm (in) 0.35 (0.014)
TIGHTENING TORQUE
Drive belt deflection
Unit: mm (in) Unit N'm kg-m ft-Ib
Used belt deflection Intake manifold nut/bolt 15 - 20 1.5 - 2.0 11 - 14
Deflection Deflection of Exhaust manifold nut 25 - 29 2.5 - 3.0 18 - 22

Exhaust manifold cover
ment 3-6 0.3 - 0.6 2.2 - 4.3
bolt
11 - 13 9 - 11 Alternator adjusting
Alternator 20 (0.79) 16 - 21 1.6 - 2.1 12 - 15
(0.43 - 0.51) (0.35 - 0.43) bar bolt
Air conditioner 6 - 7.5 5 - 6.5 Idler pUlley nut
12 (0.47) 30 - 36 3.1 - 3.7 22 - 27
compressor (0.236 - 0.295) (0.197 - 0.256) (A/C compressor)
Applied push- Oil pan drain plug 44-54 4.5 - 5.5 33 - 40
98 N (10 kg, 22 Ib)
ing force
Injection nozzle bolt to
Inspect drive bell deflections when engine is cold. 44 - 49 4.5 - 5.0 33 - 36
cylinder head
Injection tube flare nut 20 - 25 2.0 - 2.5 14 - 18

Refill oil capacity (Approximate)
Valve clearance adjust-
Unit: C (Imp qt) 15 - 20 1.5 - 2.0 11 - 14
ing screw lock nut
Without oil filter change 7.4 (6-1/2) Cylinder block drain
54-64 5.5 - 6.5 40 - 47
With oil filter change 8.1 (7-1/8) plug
Refill coolant capacity (with reservoir tank)

Unit: C (Imp qt)
Single cab models Double cab models
With front heater 13.1 (11-1/2) 13.4 (11-3/4)
Without front heater 12.1 (10-5/8) 12.4 (10-7/8)
With front and rear

- 14.6 (12-7/8)
heater
Cooling system
Radiator cap relief pressure 78 - 98
kPa (bar, kg/cm2, psi) (0.78 - 0.98, 0.8 - 1.0, 11 - 14)
Cooling system leakage testing

pressure 157 (1.57, 1.6, 23)
kPa (bar, kg/cm2, psi)
Injection nozzle
Injection pressure
18,143 - 18,633
Used nozzle (181.4 - 186.3, 185 - 190,
2,631 - 2,702)
18,633 - 19,614
New nozzle (186.3 - 196.1,190 - 200,
2,702 - 2,844)
MA-60
SERVICE DATA AND SPECIFICATIONS (S.O.S.)
Engine Maintenance - F042 & F046

INSPECTION AND ADJUSTMENT Cooling system
Radiator cap relief pressure 78 - 98 (0.78 - 0.98,
Valve clearance (Cold) kPa (bar, kg/cm~, psi) 0.8 - 1.0, 11 - 14)
Intake and exhaust mm (in) 0.4 (0.016) Cooling system leakage

testing pressure 157 (1.57, 1.6, 23)
kPa (bar, kg/cm~, psi)
Drive belt deflection
Unit: mm (in)
Injection nozzle
Set deflection Injection pressure
Adjusted of new belt kPa (bar, kg/cm~, psi)
Limit
deflection
18,633 -19,124
22 13.5 - 15.5 11.5 - 13.5 Used nozzle (186.3 - 191.2, 190 - 195,
Alternator
(0.87) (0.531 - 0.610) (0.453 - 0.531) 2,702- 2,773)
Air conditioner 24 15 - 17 14 - 16 19,124 - 20,104
compressor (0.04) (0.59 - 0.67) (0.55 - 0.63) New nozzle (191.2 - 201.0,195 - 205,
Applied 2,773 - 2,915)
98 N (10 kg, 22 Ib)
pushing force
Inspect drive belt deflections when engine is cold. Idle speed

If engine is hot, check deflections in 30 minutes or more.
FJ.C.D. OFF F.I.C.D. ON
Refmoil capacity (Approximate) Idle speed rpm 600+050 750:1:50

With oil filter change 9.6 (8-1/2) TIGHTENING TORQUE

Without oil filter change 8.3 (7-1/4) Unit kg-m ft-Ib
N'm
Intake manifold nut/bolt 14 c 18 1.4 - 1.8 10 - 13

Refill coolant capacity Exhaust manifold nut 39 - 49 4.0 - 5.0 29 - 36
Intake shutter nut/bolt 25 - 35 2.6 - 3.6 19- 26
FD42 FD46
Alternator adjusting
16 - 21 1.6.2.1 12 - 15
With heater 14.5 (12-3/4) 15.2 (13-3/8) bar bo.lt
Without heater 13.6 (12) 14.3 (12-5/8) Idler pUlley nut

30 - 41 3.1 - 4.2 22 - 30
(A/C cOmpressor)
Oil pandrainplug 54 - 59 5.5 - 6.0 40 - 43
Injection nozzle sup-

25 - 29 2.5 - 3.0 18 - 22
port to cylinder head
Injection tube flare nut 20 - 25 2.0 -2.5 14 - 18
Valve clearance adjust.

20 - 25 2.0 - 2.5 14 - 18
ing screw lock nut
Rocker cover bolt 5 - 10 0.5 - 1.0 3.6 - 7.2
Cylinder block drain

20 - 29 2.0 - 3.0 14 - 22
plug
MA-61
SERVICE DATA A'NDSPECIFICATIOiNS {S.O.s.}
Chassis. and Body Maintenance

INSPECTION AND ADJUSTMENT 5- 60 (0.1il -2.12)
Tire balancing weight g (Ol)
Spacing 5 (0.18)
Clutch
Unit: mm (in)
Pedal height 172 - 177(6.77 - 6.97)

TIGHTENING TORQUE
Pedal free play Unit N.m kg-m ft-Ib
Backlash at clevis 1.0 - 2.0 (0.039 - 0.079) Clutch
F23 model 7 - 18 (0.28 -0.71)
At center of pedal pad
H41 model 12 - 21 (0.47 - 0.83)
Pedal stopper lock nut 12 - 15 1.2- 1.5 9 - 11
Master cylinder push

rod lock nut
8 - 11 0.8 - 1.1 5.8 - 8.0
Brake Manual transmission
Unit: mm (in) Drain and filler plugs 25 - 34 2.5 - 3.5 18 - 25
Disc brake Ditlerential carrier
Pad I=iller
C200 39 - 59 4- 6 29 - 43
Standard thickness CL36VB 11.0 (0.433) plug
Minimum thickness CL36VB 2.0(0.079) Except C200 59 - 98 6 - 10 43 - 72
Rotor
Drain plugs 59 - 98 6 - 10 43- 72
Standard thickness CL36VB 26.0 (1.024)
I=ront axle and front suspension
Minimum thickness CL36VB 24.0 (0.945)
Tie-rod lock nut 88 - 137 9.0 - 14.0 65- 101
Drum brake
Drum inner diameter repair limit Brake
2L28 281.5 (11.08) Air bleeder valve 7-9 0.7 - 0.9 5.1 - 6.5
L328 & D2L32B 321.5 (12.66) Stop tamp switch lock nut 12 - 15 1.2 - 1.5 9 - 11
2L30A & D2L30A 301.5 (11.87) Brake booster input rod lock
16 - 22 1.6 - 2.2 12 - 16
LT30B 296.5 (11.67) nut
DS22A 221.5 (il.72) Wheel and tire
Lining wear limit
Wheel nut
Except2L328 & D2L328 1.5 (0.059)
Front F23 Single tire 11il-147 12 - 15 87 - 108
2L32B & D2L32B 3.2 (0.126)
H41 Single tire 177 - 226 18 • 23 130 - 166
Pedal free height
169.0 - 175.0 Double tire 441 - 539 *245-55 325 - 398
F23
(6.65 - 6.89) Rear 1=23 Single tire 11il-147 12 - 15 87 - 108
169.0 - 174.0
H41 Double tire 216 - 255 22 - 26 159 - 188
(6.65 - 6.85)
Pedal depressed height H41 Single tire 177 - 226 18 - 23 130 - 166
[under force of 490 N (50 kg, 110 Ib) with Double tire 392 - 490 *1 40 - 50 289 - 362
engine running)
441 - 539 *245 - 55 325 - 398
F23 70 (2.76)
*1: Low and flat bed frame
H41 65 (2.56)
*2: High bed and straight frame bed
Parking brake
Number of notches [at pulling force
11 - 15
196 N (20 kg, 44 Ib))
Wheel and tire

Wheel balance
(Maximum allowable unbalance 40 (1.41)
at rim flange) g (oz)
MA ..62
ENGINE MECHANICAL
SECTIONEM.
CONTENTS
PRECAUTIONS .' , EM..; 3
PREPARA"rloN (NA, TD & BD, FD) EM- 4
I IHAI I
OUTER COMPONENT PARTS EM..; 14
COMPRESSION PRESSURE EM- 16
OIL PAN EM- 17
TIMING CHAIN EM- 19
OIL SEAL REPLACEMENT EM- 28
CYLINDER HEAD EM- 30
ENGINE REMOVAL EM- 41
CYLINDER BLOCK : , EM- 44
SERVICE DATA AND SPECIFICATIONS (S.O.S.) EM- 54
~ ~ITDI~ _
ENGINE COMPONENTS - Outer Parts EM- 60
CHECKING COMPRESSION PRESSURE (On-Vehicle Service) EM- 62
CYLINDER HEAD - Removal (On-Vehicle Service) EM- 64
CYLI NDER HEAD - Disassembly EM- 65
CYLINDER HEAD - Inspection EM- 66
CYLINDER HEAD - Assembly EM- 71
CYLINDER HEAD - Installation (On-Vehicle Service) EM- 72
OIL SEAL REPLACEMENT (On-Vehicle Service) EM- 75
ENGINE OVERHAUL EM- 80
ENGINE OVERHAUL - Disassembly EM- 81
ENGINE OVERHAUL - Inspection and Replacement EM- 84
ENGINE OVERHAUL - Assembly EM- 96
SERVICE DATA AND SPECIFICATIONS (S.D.S.) EM-101
I IBDI I
ENGINE COMPONENTS - Outer Parts EM-110
CHECKING COMPRESSION PRESSURE (On-vehicle service) EM-112
CYLINDER HEAD EM-113
CYLINDER HEAD - Removal (On-vehicle service) EM-114
ENGINE MECHANICAL
CYLINDER HEAD - Disassembly EM-115

CYLI NDER HEAD - Inspection EM-116
CYLI NDER HEAD - Assembly EM-121
CYLINDER HEAD - Installation (On-vehicle service) EM-122
OIL SEAL REPLACEMENT (On-vehicle service) EM-125
ENGINE REMOVAL EM-127
ENGINE OVERHAUL EM-129
ENGINE OVERHAUL - Disassembly EM-130
ENGINE OVERHAUL - Inspection and Replacement EM-133
ENGINE OVERHAUL - Assembly EM-145
_______________ IFDI~ ~
OUTER COMPONENT PARTS EM-156
COM PRESSION PRESSURE EM-158
01L SEAL REPLACEMENT EM-170
EM-2
ENGINE MECHANICAL
SECTIONEM.
CONTENTS
PRECAUTIONS .' , EM..; 3
PREPARA"rloN (NA, TD & BD, FD) EM- 4
I IHAI I
OUTER COMPONENT PARTS EM..; 14
COMPRESSION PRESSURE EM- 16
OIL PAN EM- 17
TIMING CHAIN EM- 19
OIL SEAL REPLACEMENT EM- 28
CYLINDER BLOCK : , EM- 44
SERVICE DATA AND SPECIFICATIONS (S.O.S.) EM- 54
~ ~ITDI~ _
ENGINE COMPONENTS - Outer Parts EM- 60
CHECKING COMPRESSION PRESSURE (On-Vehicle Service) EM- 62
CYLINDER HEAD - Removal (On-Vehicle Service) EM- 64
CYLI NDER HEAD - Disassembly EM- 65
CYLINDER HEAD - Inspection EM- 66
CYLINDER HEAD - Assembly EM- 71
CYLINDER HEAD - Installation (On-Vehicle Service) EM- 72
OIL SEAL REPLACEMENT (On-Vehicle Service) EM- 75
ENGINE OVERHAUL EM- 80
ENGINE OVERHAUL - Disassembly EM- 81
ENGINE OVERHAUL - Inspection and Replacement EM- 84
ENGINE OVERHAUL - Assembly EM- 96
I IBDI I
ENGINE COMPONENTS - Outer Parts EM-110
CHECKING COMPRESSION PRESSURE (On-vehicle service) EM-112
CYLINDER HEAD - Removal (On-vehicle service) EM-114
ENGINE MECHANICAL
CYLINDER HEAD - Disassembly EM-115

CYLI NDER HEAD - Inspection EM-116
CYLI NDER HEAD - Assembly EM-121
CYLINDER HEAD - Installation (On-vehicle service) EM-122
OIL SEAL REPLACEMENT (On-vehicle service) EM-125
ENGINE OVERHAUL - Disassembly EM-130
ENGINE OVERHAUL - Inspection and Replacement EM-133
ENGINE OVERHAUL - Assembly EM-145
_______________ IFDI~ ~
OUTER COMPONENT PARTS EM-156
COM PRESSION PRESSURE EM-158
01L SEAL REPLACEMENT EM-170
EM-2
PRECAUTIONS
Parts Requiring Angular Tightening

• Some important engine parts are tightened using a.n angu-
lar-tightening method rather than a torque setting method.
• If these parts are tightened using a torque setting method,
dispersal of the tightening force (axial bolt force) will be two
or three times that of the dispersal produced by using the
correct angular-tightening method.
• Although the torque setting values (described in this man-
. ual) are equivalent to those used when bolts and nuts are
tightened with an angular-tightening method, they should
be used for reference only.
• To assure the satisfactory maintenance of the engine, bolts
and nuts must be tightened using an angular-tightening
method.
• Before tightening the bolts and nuts, ensure that the thread
and seating surfaces are clean and then coated with engine
oil.
• The bolts and nuts which require the angular-tightening
method are as follows:
(1)Cylinder head bolts
(2)Connecting rod cap nuts for gasoline engine
Liquid Gasket Application Procedure

a. Before applying liquid gasket, use a scraper to remove all
traces of old liquid gasket from mating surfaces and
grooves, and then completely clean any oil stains from
these portions.
b. Apply a continuous bead of liquid gasket to mating sur-
faces. (Use Genuine Liquid Gasket or equivalent.)
Bolt hole • Be sure liquid gasket Is 3.5 to 4.5 mm (0.138to 0.177 in)
wide (for oil pan of gasoline engine).
• Be sure liquid gasket Is 2.0 to 3.0 mm (0.079to 0.118 In)
SEM371C
wide (in areas except 011 pan).
c. Apply liquid gasket to Inner surface around hole perimeter
area.
(Assembly should be done within 5 minutes after coating.)
d. Walt at least 30 minutes before refilling engine oil and
engine coolant.
EM..3
PREPARATION
SPECIAL SERVICE TOOLS

*: Special tool or commercial equivalent
Tool number
Description
Toot name
ST0501S000 Disassembling and assembling

Engine stand assem-
bly
(!) ST05011000
Engine stand
@ ST05012000
Base
KV10105001
Engine attachment
KV10113000 Installing valve oil seal

Valve oil seal drift
EM03470000* Installing. piston ass.embly into cylinder bore

Pi$ton ring compres-
sor
S116610001 Removing crankshaft pilot bushing

Pilot bushing puller
KV10111100 Removing oil pan

Seal cutter
WS39930000* Pressing the tube of liquid gasket

Tube presser
STt2070000*
Valve lifter
EM..4
PREPARATION
Tool number
Description
Tool name
ST13030001
Piston pin press
stand
KV10112100 Tightening bolts for bearing cap, cylinder head,

Angle w(ench etc.
COMMERCIAL SERVICE TOOLS

Tool. number
Descriptibn
Tool name
Pulley holder Holding camshaft p.ulley while tightening or loos-
ening camshaft bolt
51711650001* ,Fililtshing valve seat dimensions

Valve seat cl:J~ters.et
Piston ring expander Removing and installing piston ring
Valve guide drift Removing and installing valve guide
Intake & Exhaust

A. = 11.5 mm (0.453 In) dia.
B = 6.5 mm (0,256 In) dla.
EM.5
PREPARATION
Valve guide reamer Reaming valve guide CD or hole for oversize

valve guide @
Intake & Exhaust

D, = 8.000 - 8.018 mm (0.3150 - 0.3157 in) dia.
D2 = 12.175 - 12.196 mm (0.4793 - 0.4802 In) dla.
0,
Front oil seal drift Installing front oil seal
H
A = 70 mm (2.76 In) dla.
S = 55 mm (2.17 In) dla.
H = 15 mm (0.59 in)
L = 50 mm (1.97 In)
Rear oil seal drift Installing rear oil seal
H
A = 109 mm (4.29 In) dla.
S = 80 mm (3.15 In) dla.
H = 15 mm (0.59 In)
Chain stopper
Unit: mm (in)
EM-6
PREPARATION I TO & BO l
': Special tool or commercial equivalent
TD25 TD27 BD30
ST0501SOOO' Disassembling and
Engine stand assembly assembling
G) ST05011000
Engine stand
@ ST05012000 X X X
Base
KV10106500'
Engine attachment
X X X
KV11103200'
Engine sub-attachment
X X X
KV101092S0 Disassembling and

G) KV10109210' assembling valve compo-
Valve spring com- nents
pressor X X X
@ KV10111200'
Adapter
KV10107900' Disassembling valve oil

Valve oil seal pUller seal
X X X

X X X
ST11033000' Removing valve guide

Valve guide drift
X X X
KV11103900' Installing valve guide

Valve guide drift
X X X
EM..7
PREPARATION I TO & SO I

TD25 TD27 8030
ST11032000* Reaming valve guide
Valve guide reamer
8.0 mm (0.315 in) dia.
X X X
G) KV11101110 Removing valve seat

X X X
Valve seat remover
@ KV11103510
CD
Adapter (Intake) 2 @@@@(l)
@ KV11103520
Adapter (Exhaust)
@ KV11104910
X
Adapter (Intake)
@ KV11104920
X
Adapter (Exhaust)
@ KV11103610
X X
Adapter (Intake)
IJ) KV11103620
X X
Adapter (Exhaust)
G) ST15243000 Installing valve seat X X X
Valve seat drift
@ KV11103710 @@ X
Adapter (Intake)
@ KV11103720 X
Adapter (Exhaust)
@ KV11103810 ~ X X
Adapter (Intake)
@ KV11103820
Adapter (Exhaust)
A @@
X X
G) KV11104010 Removing and installing X X X

Cylinder liner tool cylinder liner
@ KV11104020
Adapter for remov-
ing @@@
@ KV11104700 X
Adapter for remov-
ing
@ KV11104110
ti,@ X X
Adapter for remov-
ing
@ KV11104030
Adapter for install-
ing
d X X X
EM03470000* Installing piston into cylin-

Piston ring compressor der
X X X
~
EM-8
PREPARATION I TO & BO I

Description
Tool name
TD25 TD27 8030
KV111033S0 Preventing crankshaft from
Engine stopper rotating
CD KV11103310
Stopper plate
@ KV10105630 x x x
Stopper gear
ST16610001 * Removing pilot bushing

x x x
KV111045S0 Removing cam bushing or

eam bushing replacer installing cam bushing
set
CD KV11104510
Replacer bar
@ KV11104520
Guide plate
@ KV11104530
Adapter
x x x
(1st bushing)
@ ST15243000
Drift
KV10109300* Preventing drive gear

Injection pump drive from rotating (VE-type)
gear holder
x x
KV11103000* Removing drive gear (VE-

Injection pump drive type)
gear puller
x x
WS39930000* Pressing the tube of liquid

Tube presser gasket
x x x
EM..9
PREPARATION I TO & eo I

TD25 TD27 8D30
ED19601000 Checking compression
Compression gauge pressure
x x x

adapter (for glow plug
hole) x x

adapter (for injector
hole) x x

adapter (for injection
hole) x
DK57914010 Removing and installing

Socket wrench (For injection pump assembly
timer round nut)
x
KV11226582 Removing injection pump

Timer extractor assembly
EM-10
PREPARATION

Tool number
Description
Tool name
ST0501S000* Disassembling and assembling
Engine stand assembly
G) ST05011000
Engine stand
@ ST05012000
Base
KV10106500*
Engine attachment
KV11105000*
Engine sub-attachment
G) KV10109210* Disassembling and assembling

Valve spring compressor valve components
@ KV10111200*
Adapter

ST17101000* Removing valve guide

Valve guide drift
ST17102000* Installing valve guide

Valve guide drift
EM-11
PREPARATION
Tool number
Description
Tool name
ST1711S000 Removing valve seat

Valve seat remover set
CD ST17111000
Valve seat remover
@ ST17112000
Adapter (Intake)
@ ST17113000
Adapter (Exhaust)
ST1712S000 Installing valve seat

Valve seat drift set
CD ST17121000
(Intake)
@ ST17122000
(Exhaust)
CDKV11104011 Removing and installing cylin-

Cylinder liner tool der liner
@ KV11105110
Adapter for removing
@ KV11105120
Adapter for installing
o
Q)
EM03470000* Installing piston into cylinder

Piston ring compressor
KV111052S0 Preventing crankshaft from

Engine stopper rotating
CD KV11105210
Stopper plate
@ KV11105620
Stopper gear
@ KV11105220 3
Bolt, washer, nut
ST16610001* Removing pilot bushing

EM-12
PREPARATION
Tool number
Description
Tool name
KV111055S0 Removing cam bushing or

Cam bushing replacer set installing cam bushing
(!) KV11105510
Replacer bar
@ KV11105520
Guide plate
@ KV11105530
Adapter
(1st bushing)
@ ST15243000
Drift
ED19601000 Checking compression pressure

Compression gauge
ED19600800 Checking compression pressure

Compression gauge adapter (for
injection hole)
OUTER COMPONENT PARTS
With EGR
16 - 21 (1.6 - 2.1, 12 - 15)
i ~
7
~16 - 21
(1.6 - 2.1, 12 • 15)
~
Al~
~ @~@)
/' /6 @ Ga.Sket ~ ~ 16 - 21 (1.6. 2.1, 12
15
)
CID~ /~
~ ,
0
0
0
1
G~k.t .:; ~ 16 - 21
(1.6 - 2.1,12 - 15)~ \

.,~
,
~ r¥~\:-,~
~~l~
6
~ 16~1
(1.6 - 2.1,7 I:~o (J ~ --""
Gasket ~
_~~ '~ ,@@o
12-15) ~--""' ~
~21-26 ~ L
\~ 16.21 / (2.1 - 2.7, 15 - 20) ~ 1
c~ (1.6 - 2.1, 12 - 15) @) @
~ 34 - 44 (3.5 • 4.5,
25-33
~ 16 - 19
(1.6 - 1.9, 12 • 14)=t:J~ ~
.
41 - 52
(4.2. 5.3, 30 - 38)
@
,
I
ill Power steering idler pulley @ V.v.T. valve @ B.C.D.D.

@ Power steering pump bracket @ EGR tube @) Oil filter
@ Carburetor CV Intake manifold @ Alternator bracket
@ EGR control valve @ Fuel tube @ Starter motor
EM-14
- ",.~~ 21 ."
(2.1 - 2.7, 15 - 20)
Gasket ~
~ 6-9
(0.6 - 0.9, 4.3 - 6.5)
~ ~0
Z
'~@
o~ //,~((l ~,
~ I~ -WV~\f9~
~ ~ ~20-24
~<:J (2.0 _ 2.4, 14 _ 17)
L ~ 18 - 25
~36-50
(3.7 - 5.1, 27 - 37)
(1.8 - 2.6, 13 - 19)
~ : N.m (kg-m, ft-Ib)
SEM403E
@ Distributor @ Compressor bracket @ Exhaust manifold

@ Oil level gauge
EM-15
COMPRESSION PRESSURE
Measurement of Compression Pressure

1. Warm up engine.
2. Turn ignition switch off.
3. Disconnect fuel cut solenoid valve connector.
4. Remove all spark plugs.
5. Disconnect distributor center cable.
6. Attach a compression tester to No; 1 cylinder.

7. Depress accelerator pedal fully to keep throttle valve wide
open.
8. Crank engine and record highest gauge indication.
9. Repeat the measurement on each cylinder as shown
above.
• Always use a fully-charged battery to obtain specified
engine revolution.
Compression pressure: kPa (bar, kg/cm2, psi)/rpm
Standard
1,187 (11.87,12.1,172)/350
Minimum
991 (9.91, 10.1, 144)/350
Difference limit between cylinders:
98 (0.98, 1.0, 14)/350
10. If cylinder compression in one or more cylinders is low,
pour a small amount of engine oil into cylinders through
spark plug holes and retest compression.
• If adding oil helps compression, piston rings may be worn
or damaged. If so, replace piston rings after checking pis-
ton.
• If pressure stays low, a valve may be sticking or seating
improperly. Inspect and repair valve and valve seat. (Refer
to S.O.S.) If valve or valve seat is damaged excessively,
replace them.
• If compression in any two adjacent cylinders is low and if
adding oil does not help compression, there is leakage past
the gasket surface. If so, replace cylinder head gasket.
EM-16
OIL PAN
~ Engine front Removal
@Ir~
~) ,j
@@@@@@@
o~~o~o~o~o~o~o~
J~~ .g o@
[
[@
1.
2.
Drain engine oil.
Remove oil pan bolts.
~J----> oeD
(j) ~".
0,---, o~o<----'::;o~o~ o~
L])
o{l;
@@@@@@@
Loosen in numerical order. SEM405E
3. Remove oil pan.

(1) Insert Tool between cylinder block and oil pan.
• Do not insert screwdriver, or 011 pan flange will be
deformed.
(2) Slide Tool by tapping its side with a hammer, and remove
qil pan.
Installation
1. Before installing oil pan, remove all traces of liquid gasket
from mating surface using a scraper.
• Also remove traces of liquid gasket from mating surface of
cylinder block.
2. Apply liquid gasket to inner sealing surface as shown in

figure.
• Be sure liquid gasket is 3.5 to 4.5 mm (0.138 to 0.177 in)
Cut here. wide.
Liquid gasket
]
SLC906
EM-t7
OIL PAN []!]
Installation (Cont'd)
7 mm (0.28 in) • Attaching should be done within 5 minutes after coating.
-j ~.
Inner
side
Groove Bolt hole

SEM909B
3. Apply a continuous bead of liquid gasket to mating surface

of oil pan.
• Use Genuine Liquid Gasket or equivalent.
4. Install oil pan.

• Install bolts/nuts in their reverse order of removal.
• Wait at least 30 minutes before refilling engine oil.
EM-18
TIMING CHAIN
toJ 137 - 157

(14 - 16, 101 - 116)
Tightening torque for front
'~
Front oil seal ~
L: 75 mm (2.95 in) and 65 mm (2.56 in)
~ 16 - 21 (1.6 • 2.1, 12 - 15)
L: 20 mm (0.79 in)
~ 6.3 - 8.3 (0.64 - 0.85, 4.6 - 6.1)
SEM406E
G) Cylinder head @ Front cover @) Oil pump drive gear

@ Timing chain (J) Water pump @ Crankshaft sprocket
@ Camshaft sprocket @ Crankshaft pulley @ Crankshaft
@ Chain guide @ Oil thrower @ Cylinder block
@ Chain tensioner
EM-19
TIMING CHAIN
POSITION FOR APPLYING LIQUID GASKET

Refer to "Installation" in "OIL PAN" for installing oil pan.
Front cover
Cylinder head
Unit: mm (in)
SEM407E
EM-20
TIMING CHAIN
CAUTION:
• After removing timing chain, do not turn crankshaft and
camshaft separately, or valves will strike piston heads.
• When installing sliding parts such as rocker arms,
camshafts, chain tensioner and oil seal, be sure to apply
new engine oil on their sliding surfaces.
• When tightening cylinder head bolts, camshaft sprocket
bolts, crankshaft pulley bolt and camshaft bracket bolts,
apply new engine oil to thread portions and seat surfaces
of bolts.
Removal
1. Open assist side engine cover.
2. Remove driver's seat and driver's side engine cover.
• Double cab model: Remove transmission inspection hole.
3. Remove air cleaner and air intake duct.
4. Drain coolant by removing cylinder block drain plug and
radiator drain cock.
5. Remove cooling fan and fan coupling.
6. Remove heater hose and radiator hoses.
7. Remove accel control wire.
8. Disconnect exhaust tube and exhaust manifold.
9. Remove P.C.V. hoses from rocker cover.
10. Remove all drive belts and pulleys.
11. Remove alternator and bracket.
12. Remove power steering oil pump and bracket from engine.
13. Remove vacuum hoses, fuel hoses, wires, harness, con-
nectors and so on.
14. Remove all high tension wires and spark plugs.
15. Remove rocker cover.

Q Engine
front
• Loosen bolts in numerical order as shown in figure.
@ @
0 (ID
l)
(-<r -9- )
TIl133J\i\J
O-..LY 0 CD
CID (j)
Loosen in numerical order.
SEM40BE
16. Set No. 1 piston at T.D.C. on the compression stroke by

rotating crankshaft.
EM.21
TIMING CHAIN [][]
Removal (Conl'd)
• Rotate crankshaft until key way on camshaft sprocket is in
top position.
17. Remove distributor.

Do not turn rotor with distributor removed.
18. Remove oil pump.
19. Remove camshaft sprockets.
20. Remove the bolt securing intake manifold to intake mani-

fold support.
21. Remove cylinder head bolts .

.,.A-, Engine • Bolts should be loosened In two or three steps.
~ front
22. Remove cylinder head with intake and exhaust manifolds.
SEM412E
EM-22
TIMING CHAIN
Removal (Cont'd)
23. Remove oil pan.
Refer to "Removal" in "OIL PAN".
24. Remove starter motor and set ring gear stopper, then
remove crankshaft pulley.
SEM980C
25. Remove front cover.
SEM413E
26. Remove timing chain guides and timing chain.
SEM414E
Inspection
Check for cracks and. excessive wear at roUer links. Replace
chain If necessary.
SEM984C
EM.23
TIMING CHAIN
Installation
1. Install crankshaft sprocket on crankshaft.
Crankshaft spr~Cket I
Oil pump '"::~ ~
\;~~~
C U Engine Front
SEM415E
2. Position crankshaft so that No. 1 piston is set at T.D.C.

(Keyway at 12 o'clock) fit timing chain to crankshaft
sprocket so that mating mark is in line with mating mark on
crankshaft sprocket.
3. Temporarily install cylinder head with new gasket. Position
camshaft so that keyway is set at 12 o'clock.
Punch mark
4. Install camshaft sprocket with mating mark on timing chain.
Camshaft sprocket
II
38 rollers
64 rollers
Crankshaft sprocket
Notch mark
5. Install timing chain and timing chain guides, and chain

tensioner.
• When installing R.H. timing chain guide, provide tension on
timing chain by pulling it inside. Make sur,e gap between
tensioner and tensioner bracket is 0 mm (0 in).
6. Remove camshaft sprocket, then loosen cylinder head

bolts.
• Insert chain stopper before removing camshaft sprocket so
that chain tensioner holds its position.
7. Before installing front cover, remove all traces of liquid
gasket from mating surface using a scraper.
cylinder block.
of front cover.
EM-24
TIMING CHAIN
9. Install front cover.
• Be careful not to damage cylinder head gasket.
• Wipe off excessive liquid gasket.
SEM413E
10. Install crankshaft pulley.

11. Set NO.1 piston at T.D.C. on its compression stroke.
12. Install oil pan.

/l-, Engine Refer to "Installation" in "Oil PAN".
'v--' front
13. Tighten cylinder head bolts.
@ Tighten all bolts to 29 N'm (3 kg-m, 22 ft-Ib).
@ Tighten all bolts to 78 N'm (8 kg-m, 58 ft-Ib);
@ Loosen all bolts completely.
@ Tighten all bolts to 25 to 34 N'm (2.5 to 3.5kg-m, 18 to 25
ft-Ib).
SEM419E
Method A @ Method A: Turn all bolts 90 to 95 degrees clockwise with

Tool or suitable angle wrench.
Method B: If angle wrench is not available, tighten all bolts
to 74 to 83 N'm (7.5 to 8.5 kg-m, 54 to 61 ft-Ib).
Tightening torque N'm (kg-m, ft-Ib)

@ 29 (3,22)
@ 78 (8, 58)
@ 0(0,0)
@ 29:1: 5 (3:1: 0.5, 29.4:1: 3.6)

:Q 90~ degrees or
~ @
78:1:5 (8.0:1:0.5, 57.9:1:3.6)
e-
o.
::. 78
E (8,58)
Z
CD 29
E- (3, 22)
.E
01
c:
"2
CD
1: @
01
i=
SEM421E
E.M-25
TIMING CHAIN
14. Install cylinder head outside bolts.
15. Install intake manifold support.
16. Install camshaft sprockets.

Line up mating mark on timing chain with mating mark on
camshaft sprocket.
• Lock camshafts as shown in figure and tighten to specified

torque.
toJ: 137 - 157 N.m
(14.0 - 16.0 kg-m, 101 - 116 ft-Ib)
17. Install oil pump and distributor.

Refer to "Oil Pump" in Section Le.
18. Install rubber plugs as follows:

(1) Apply liquid gasket to rubber plugs.
• Rubber plugs should be replaced with rocker cover gasket.
• Rubber plugs should be installed within 5 minutes of apply-
ing liquid gasket.
EM-26
TIMING CHAIN []!J
Installation. (Cont'd)
(2) Install n.Jbberplugs, then move them with your fingers to
uniformly spread the gasket on cylinder head surface.
• Rubber plugs. should be installed flush with the surface.
• Do not start the engine for 30 minutes after installing rocker
cover.
N.G. Good
SEM753D
19. Install rocker cover.

/l-, Engine Rocker cover tightening procedure:
'v-' front (1) Tighten bolts (1) - @ in that order to 3 N.m (0.3 kg-m, 2.2
CID ft-Ib).
@ (2) Tighten nuts @ - @) - @ - (1) - @ - (f) - @ - @ - @ -
) @) - @ - (1) in that order to 7 to 11 N.m (0.7 to 1.1 kg-m,
"9-
'j]133J\i\J
I@ 5.1 to 8.0 ft-Ib).
21. Install parts in the reverse order of removal.
SEM428E
EM-27
OIL SEAL REPLACEMENT
VALVE Oil SEAL

2. Remove rocker shaft assembly.
3. Remove valve spring and valve oil seal with suitable tool.
Piston concerned should be set at T.D.C. to prevent valve from
falling.
4. Apply engine oil to new valve oil seal and install it with
Tool.
Valve oil seal ~
...J
Valve guide
Cylinder head
L: 19.6 - 20.2 mm
(0.772 • 0.795 in)
SEM429E
Oil SEAL INSTAllATION DIRECTION
Engine. Engine
inside .,. outside
FRONT Oil SEAL

1. Remove the following parts:
• Cooling fan and fan coupling
• Drive belts
• Crankshaft pulley
2. Remove front oil seal.
Be careful not to scratch front cover.
SEM997C
3. Apply engine oil to new oil seal and install it using a suit-
able tool.
EM-28
Oil SEAL REPLACEMENT
REAR OIL SEAL

1. Remove transmission. (Refer to MT section.)
2. Remove flywheel.
3. Remove rear oil seal.
Be careful not to scratch rear oil seal retainer.
SEM999C
4. Apply engine oil to new oil seal and install it using a suit-
able tool.
SEM001D
CYLINDER HEAD
~ ~~
Refer to "Installation" ~ . I - fP\ \
" "nMING CHAIN". ~ ~ ~L.I».
L-j ~ ~ \\ 0
~~.~
~~ .~.
D1\
I eJ~'
,,1\JIiJ.l ~
I
I
<>'~
~~(o ~
~~" ~\Y
~ - ~ ~ ~er to "Installation"
~ V in "TIMING CHAIN".
~ 137 - 157
(14 - 16, 101 - 116)
~: N.m (kg-m, ft-Ib)
SEM508E
(!) Oil filler cap @ Valve collet @ Camshaft bracket

@ Rocker cover (J) Valve spring retainer @ Camshaft sprocket
@ Rocker cover gasket @ Valve spring @ Camshaft
@ Rocker arm spring @ Valve spring seat @ Cylinder head
@ Rocker arm @) Valve @> Rocker shaft
EM-30
CYLINDER HEAD
CAUTION:
• When installing sliding parts such as rocker arms, cam-
shaft and oil seal, be sure to apply new engine oil on their
sliding surfaces.
• When tightening cylinder head bolts, camshaft sprocket
bolts and camshaft bracket bolts, apply new engine oil to
thread portions and seat surfaces of bolts.
• Hydraulic valve lifters are installed in each rocker arm. If

hydraulic valve lifter Is kept on its side, even when installed
N.G.
e •
•
in rocker arm, there is a possibility of air entering it. After
removal, always set rocke.r arm or valve lifter straight up,
or when laying it on Its side, have it soak In new engine oil.
Do not disassemble hydraulic valve lifter .
Attach tags to valve lifters so as not to mix thern up .
SEM430E
Removal
Remove cylinder head with intake and exhaust manifolds.
This removal is the same procedure as that for timing chain.
Refer to "Removal" in "TIMING CHAIN".
Disassembly
1. Rem9ve manifolds from cylinder head.
• Loosen bolts in numerical order as shown in figures.

SEM444E
EM ..31
CYLINDER HEAD ~
Disassembly (Cont'd)
2. Remove rocker shafts with rocker arms and camshaft.
/I--, Engine
"" front
• Bolts should be loosened in two or three steps.
CAUTION:
Keep parts in order so that they can be installed in their origi-
nal positions during assembly. (Install parts In their original
positions.)

SEM431E
3. Remove valve components with Tool.
SEM432E
4. Remove valve oil seal with a suitable tool.
Inspection
CYLINDER HEAD DISTORTION
Head surface flatness:
Less than 0.1 mm (0.004 in)
If beyond the specified limit, replace it or resurface it.
Resurfacing limit:
The resurfacing limit of cylinder head Is determined by the cyl-
inder block resurfacing in an engine.
Amount of cylinder head resurfacing is "A".
Amount of cylinder block resurfacing is "B".
The maximum limit is as follows:
A + B = 0.2 mm (0.008 in)
After resurfacing cylinder head, check that camshaft rotates
freely by hand. If resistance is felt, cylinder head must be
replaced.
Nominal cylinder head height:
98.8 - 99.0 mm (3.890 • 3.898 in)
CAMSHAFT VISUAL CHECK
Check camshaft for scratches, seizure and wear.
EM-32
CYLINDER HEAD
Inspection. (Cont'd)
CAMSHAFT RUNOUT
1. Measure camshaft runout at the center journal.
Runout (Total indicator reading):
Limit 0.05 mm (0.0020 in)
2. If it exceeds the limit, replace camshaft.
SEM926C
CAMSHAFT CAM HEIGHT

1. Measure camshaft cam height.
Standard cam height:
44.572 - 44.762 mm (1.7548 - 1.7623 in)
Cam wear limit:
0.25 mm (0.0098 in)
2. If wear is beyond the limit, replace camshaft.
SEM549A
CAMSHAFT JOURNAL CLEARANCE

1. Install camshaft bracket and tighten bolts to the specified
torque.
2. Measure inner diameter of camshaft bearing.
Standard inner diameter:
33.000 - 33.025 mm (1.2992 - 1.3002 in)
3. Measure outer diameter of camshaft journal.

St.andard outer diameter:
32.93S - 32.955 mm (1.2967 - 1.2974 in)
4. If clearance exceeds the limit, replace camshaft and/or cyl-
inder head.
Camshaft Journal clearance:
Standard
W
SEM012A
CAMSHAFT END PLAY

0.045 - 0.090 mm (0.0018 - 0.0035 in)
Limit
0.12 mm (0.0047 in)
1. Install camshaft in cylinder head.

2. Measure camshaft end play.
Camshaft end play:
Standard
0.070 - 0.148 mm (0.0028-0.0058 in)
\ \ Limit
0.2 mm (0.008 in)
EM-33
CYLINDER HEAD ~
Inspection (Cont'd)
CAMSHAFT SPROCKET RUNOUT
1. Install sprocket on camshaft.
2. Measure camshaft sprocket runout.
Limit 0.25 mm (0.0098 in)
3. If it exceeds the limit, replace camshaft sprocket.
VALVE GUIDE CLEARANCE

1. Measure valve deflection at right-angles direction to cam-
shaft. (Valve and valve guide mostly wear in this direction.)
Valve deflection limit (Dial gauge reading):
0.12 mm (0.0047 In)
2. If it exceeds the limit, check valve to valve guide clearance.

a. Measure valve stem diameter and valve guide inner diam-
eter.
b. Check that clearance is within specification.
Valve to valve guide clearance limit:
0.1 mm (0.004 in)
c. If it exceeds the limit, replace valve or valve guide.
SEM800A
VALVE GUIDE REPLACEMENT

1. To remove valve guide, heat cylinder head to 110 to 120°C
(230 to 248°F).
2. Drive out valve guide with a press [under a 20 kN (2 ton,

2.2 US ton, 2.0 Imp ton) pressure] or hammer and suitable
tool.
SEM151C
EM-34
CYLINDER HEAD
Inspection (Cont'd)
3. Ream cylinder head valve guide hole.
Valve guide hole diameter
(for .service parts):
12.175 - 12.196 mm (0.4793 - 0.4802 in)
4. Heat cylinder head to 110 to 120°C(230 to 248°F)and press

service valve guide onto cylinder head.
Projection "L":
17.9 - 18.1 mm (0.705 - 0.713 in)
Intake side Exhaust side
SEMOB9C
5. Ream valve guide.

Finished size:
8.000 - 8.018 mm (0.3150- 0.3157 in)
VALVE SEATS
Check valve seats for any evidence of pitting at valve contact
surface, and reseat or replace if it has worn out excessively.
• Before repairing valve seats, check valve and valve guide
for wear. If they have worn, replace them. Then correct
valve seat.
• Cut with both hands to uniform the cutting surface.
EM-35
CYLINDER HEAD []!J
Inspection (Cont'd)
REPLACING VALVE SEAT FOR SERVICE PARTS
I 1. Bore out old seat until it collapses. The machine depth stop
Recess diameter
should be set so that boring cannot continue beyond the
I bottom face of the seat recess in cylinder head.
2. Ream cylinder head recess.
Reaming bore for service valve seat
Oversize [0.5 mm (0.020 In)]:
Intake
41.500 - 41.516 mm (1.6339 - 1.6345 in)
Exhaust
SEM795A 36.500 - 36.516 mm (1.4370 - 1.4376 in)
Reaming should be done in concentric circles to valve guide
center so that valve seat will have the correct fit.
3. Heat cyli nder head to 110 to 120°C(230 to 248°F).

4. Press fit valve seat until it seats on the bottom.
5. Cut or grind valve seat using suitable tool at the specified

dimensions as shown in S.O.S.
6. After cutting, lap valve seat with abrasive compound.
7. Check valve seating condition.
Seat face angle "u":
45 deg.
Contacting width "W":
Intake
1.55 - 1.69 mm (0.0610 - 0.0665 In)
Exhaust
SEM892B 1.9 - 2.1 mm (0.075 - 0.083 in)
T (Margin thickness) VALVE DIMENSIONS

Check dimensions in each valve. For dimensions, refer to
11: S.O.S.
w"~
.4= .
When valve head has been worn down to 0.5 mm (0.020 in) in
margin thickness, replace valve.
Grinding allowance for valve stem tip is 0.2 mm (0.008 in) or
less .
EM-36
CYLINDER. HEAD
Inspection (Cont'd)
r s (Out-of-square)
VALVE SPRING
Squareness
1. Measure "8" dimension.
Out-of-square:
2. If it exceeds the limit, replace spring.
--------------«:SEM288A
Pressure
Check valve spring pressure.
Pressure: N (kg, Ib) at height mm (in)
Standard
664.62 - 749.55 (67.77 - 76.43, 149.43 - 168.53) at
35 (1.38)
Limit
More than 631.37 (64.38, 141.96) at 35 (1.38)
If it exceeds the limit, replace spring.
ROCKER SHAFT AND ROCKER ARM

1. Check rocker shafts for scratches, seizure and wear.
2. Check outer diameter of rocker shaft.
Diameter:
21.988 - 22.000 mm (0.8657 - 0.8661 in)
3. Check inner diameter of rocker arm.

Diameter:
22.023 - 22.041 mm (0.8670 - 0.8678 In)
Rocker arm to shaft clearance:
0.023 - 0.053 mm(0.0009 - 0.0021 in)
• Keep rocker arm with hydraulic valve lifter standing to pre-
vent air from entering it when checking.
SEM762A
Cylinder stoppe~ HYDRAULIC VALVE LIFTER

1. Check contact and sliding surfaces for wear or scratches.
SEM437E
EM.37
CYLINDER HEAD
Inspection (Cont'd)
2. Check diameter of valve lifter.
Outer diameter:
13.488 - 13.500 mm (O.5310 - 0.5315 in)
3. Check valve lifter inner diameter of rocker arm.

Inner diameter:
13.506 - 13.524 mm (O.5317 - 0.5324 in)
Standard clearance between valve lifter and rocker
arm:
0.006 - 0.036 mm (O.0002 - 0.0014 in)
Assembly
1. Install valve component parts.
• Always use new valve oil seal. Refer to OIL SEAL
Wide pitch
REPLACEMENT.
• Install valve spring (uneven pitch type) with its narrow pitch
side toward cylinder head side.
Narrow pitch • After installing valve component parts, use plastic hammer
to lightly tap valve stem tip to assure a proper fit .
•
Cylinder head side SEM638B
2. Install camshafts.
• Set key on camshaft at the top.
Engine
o front
SEM440E
3. Install rocker shafts with rocker arms.
~
SEM441E
EM-38
CYLINDER HEAD []K]
Assembly (Cont'd)
Tighten rocker shaft securing bolts in two or three stages.
/'--, Engine
'v-' front Set NO.1 piston at T.O.C. on its compression stroke and tighten
rocker shaft bolts.
~: 37 - 41 N.m (3.8 - 4.2 kg-m, 27 - 30 ft-Ib)
SEM442E
Installation
• This installation is the same procedure as that for timing
chain. Refer to "Installation" in "TIMING CHAIN".
• Install intake and exhaust manifolds with new gaskets.
• Tighten manifold bolts and nuts in two or three stages as
shown in the figures.
TIghten in numerical order.
SMA595C
• Models with hydraulic valve lifter:

Check hydraulic valve lifter.
a. Push plunger forcefully with your finger.
• Be sure to check it with rocker arm in its free position (not
on the lobe).
b. If valve lifter moves more than 1 mm (0.04 in), air may be
inside of it.
c. Bleed air off by running engine at 1,000 rpm under no load
for about 10 minutes.
d. If hydraulic valve lifters are still noisy, replace them and
SEM445E bleed air off again in the same manner as in step (c).
EM-39
CYLINDER HEAD []!J
• Models without hydraulic valve lifter:
8 Adjust valve clearance.
(1) Set NO.1 cylinder at top dead center on its compression
stroke, and adjust valve clearances (1), @. @ and @.
I
(2) Set NO.4 cylinder at top dead center on its compression

stroke, and adjust valve clearances 00, <ID, (f), and @.
Unit: mm (in)
COLD HOT
Intake 0.21 (0.0083) 0.3 (0.012)
Exhaust 0.23 (0.0091) 0.3 (0.012)
Whenever valve clearances are adjusted to cold specifications,

check that the clearances satisfy hot specifications and adjust
again if necessary.
SMA596C
EM-40
~
r.~ •.
16 - 2121 12 .1~
(1.• - .•
c~.
Instake manifold -0 ~_
supp.o rt .~ • . ~
~ 41 - 52 ~
@ !>
c/
(4.2- -38)
30 5.3, ~1.
I.~
~25 - 32
(2.6 - 3.3,
19 - 24)
~31.~~
(3.2 - 4.3,
23 - 31)
SEM446E
EM.41
ENGINE REMOVAL
WARNING:
a. Position vehicle on a flat and solid surface.
b. Place chocks at front and back of rear wheels.
c. Do not remove engine until exhaust system has completely
cooled off.
Otherwise, you may burn yourself and/or fire may break
out in fuel line.
d. For safety during subsequent steps, the tension of wires
should be slackened against the engine.
e. Be sure to hoist engine and transmission in a safe manner.
f. For engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTS CATALOG.
CAUTION:
• When lifting or lowering engine, be careful not to strike
adjacent parts, especially accelerator wire casing, brake
lines.
• In hoisting the engine, always use engine slingers in a safe
manner.
Removal
1. Remove transmission assembly. Refer to section MT.
2. Open assist side engine cover.
3. Remove driver's seat and driver's side engine cover.
• Double cab model: Remove transmission inspection hole.
4. Remove air cleaner and air intake duct.
5. Drain coolant by removing cylinder block drain plug and
radiator drain cock.
6. Remove cooling fan and fan coupling.
7. Remove heater hose and radiator hoses.
8. Remove accel control wire.

9. Disconnect exhaust tube and exhaust manifold.
10. Remove power steering oil pump and bracket from engine.
11. Remove vacuum hoses, fuel hoses, wires, harness, con-
nectors and so on.
12. Remove high tension wires.
13. Remove engine slinger and fuel pump.
14. Set a suitable jack under engine.
• Be careful not to damage oil pan.
15. Remove engine mountings and then slowly lower jack.
EM-42
ENGINE REMOVAL
Removal (Cont'd)
SEM447E
Installation
1. Temporarily install engine mountings and brackets to
engine.
2. Carefully raise the engine with suitable jack.
3. Installation is in the reverse order of removal.
EM-43
CYLINDER BLOCK
~6.3-8.3
. (0.64 - 0.85,
4
/ 4.6 - 6.1)
Rear oil seal ~
CID~
CID
,~ D
@
@~ ~~~o
~ I. \~
~j ~ 0 '\J
~ Refer to - . i1$\\ ~ ~ ~
(14.5 - 15.5,
"Assembly:' @ ~ U ~ ~ 105 - 112)
@~ \Iz., ~
o o~~~~
~ ~".~
V (4.5-5.5,
33 - 40)

~ 6.3 - 8.3
(0.64 - 0.85, ~ ~
4.6 - 6.1) ~
SEM448E
(!) Flywheel (J) Piston @ Main bearing

@ Rear plate @ Piston pin @ Main bearing cap
@ Rear oil seal retainer @ Connecting rod @) Oil strainer
@ Cylinder block @J Connecting rod bearing @> Oil pan
@ Piston rings @ Connecting rod cap @ Baffle plate and net
@ Oil rings @ Crankshaft
EM-44
CYLINDER BLOCK
CAUTION:
• When installing sliding parts such as bearings and pistons,
be sure to apply engine oil on the sliding surfaces.
• Place removed parts such as bearings and bearing caps in
their proper order and direction.
• When tightening connecting rod bolts and main bearing cap
bolts, apply engine 011to thread portion of bolts and seat-
ing surface of nuts.
Disassembly
PISTON AND CRANKSHAFT
1. Place engine on a work stand.
2. Drain coolant and oil.
3. Remove oil pan.
Refer to "Removal" in "OIL PAN".
4. Remove timing chain.
Refer to "Removal" in "TIMING CHAIN".
5. Remove pistons with connecting rod.
SEM744
CD @ 9 6. Remove bearing cap and crankshaft.

• Before removing bearing cap, measure crankshaft end
~-
o o ~
_I\~()~ o' play.

9L---J L--.-I ~ ~
• Bolts should be loosened in two or three steps.
o 0 000
o 0 000
J
[
~"s=J.~~
V-_o_~--
~ @ @ @ 4
Loosen in numerical order. SEM248C
Inspection
PISTON AND PISTON PIN CLEARANCE
• Confirm that the piston pin can be pushed into the piston
pin hole with your finger at room temperature.
1. Measure inner diameter of piston pin hole "dp".
Standard diameter "~p":
21.001- 21.008 mm (0.8268 - 0.8271 In)
SEM149B
2. Measure outer diameter of piston pin "Dp".

Standard .diameter lOOp":
20.993 - 20.998 mm (0.8265 - 0.8267 in)
3. Calculate piston pin clearance.
dp __Op = 0.008 - 0.012 mm (0.0003 - 0.0005 in)
If it exceeds the above value, replace piston assembly with pin.
SEM821B
EM-45
CYLINDER BLOCK rn!J
Inspection (Cont'd)
PISTON RING SIDE CLEARANCE
N.G.
Side clearance:
Top ring
0.040 - 0.075 mm (0.0016 - 0.0030 in)
2nd ring
0.030 - 0.063 mm (0.0012 - 0.0025 in)
Max. limit of side clearance:
0.1 mm (0.004 in)
If out of specification, replace piston and/or piston ring assem-
bly.
SEM024A
PISTON RING END GAP

Feeler
End gap:
gauge Top ring
0.24 - 0.43 mm (0.0094 - 0.0169 in)
2nd ring
0.42 - 0.66 mm (0.0165 - 0.0260 in)
Oil ring
0.20 - 0.69 mm (0.0079 - 0.0272 in)
Max. limit of ring gap:
1.0 mm (0.039 in)
SEM599A If out of specification, replace piston ring. If gap still exceeds
the limit even with a new ring, rebore cylinder and use over-
sized piston and piston rings.
Refer to S.O.S.
CONNECTING ROD BEND AND TORSION

Bend:
Limit 0.15 mm (0.0059 in)
per 100 mm (3.94 in) length
Torsion:
Limit 0.3 mm (0.012 in)
If it exceeds the limit, replace connecting rod assembly.
CYLINDER BLOCK DISTORTION AND WEAR

1. Clean upper face of cylinder block and measure the distor-
tion.
Limit:
0.10 mm (0.0039 in)
2. If out of specification, resurface it. The resurfacing limit is
determined by cylinder head resurfacing in engine.
Amount of cylinder head resurfacing is "A".
Amount of cylinder block resurfacing is "B".
The maximum limit is as follows:
SEM123C
A + B = 0.2 mm (0.008 in)
EM-46
CYLINDER BLOCK r:m
Inspection (Cont'd)
Nominal cylinder block height from crankshaft center:
227.40 - 227.50 mm (8.9527 - 8.9567 in)
3. If necessary, replace cylinder block.
--::;;- PISTON- TO-BORE CLEARANCE
619
I.'
l
I
\
Y
x ~l5l~
..
e..~-
1008
C')
I ....CO,..
I
!
1. Using a bore gauge, measure cylinder bore for wear, out-
of-round and taper.
Standard inner diameter:
86.000 - 86.030 mm (3.3858 - 3.3870 in)
Wear limit:
0.2 mm (0.008 in)
Ou.t-of-round (X - V) limit:
0.015 mm (0.0006 in)
Unit: mm (in)
Taper (A - B) limit:
SEM559E
0.010 mm (0.0004 in)
If it exceeds the limit, rebore all cylinders. Replace cylinder
block if necessary.
2. Check for scratches and seizure. If seizure is found, hone
it.
Piston grade number

• If both cylinder block and piston are replaced with new
ones, select piston of the same grade number punched on
cylinder block upper surface.
Engine
front
3. Measure piston skirt diameter.

Piston diameter "A":
Refer to S.O.S.
Measuring point "a" (Distance from the bottom):
14 mm (0.55 in)
4. Check that piston-to-bore clearance is within specification.
Piston-to-bore clearance "B":
0.025 - 0.045 mm (0.0010 - 0.0018 in)
5. Determine piston oversize according to amount of cylinder
wear.
Oversize pistons are available for service. Refer to S.O.S.
EM-47
CYLINDER BLOCK
Inspection (Cont'd)
6. Cylinder bore size is determined by adding piston-to-bore
clearance to piston diameter" A".
Rebored size calculation:
D=A+B-C
where,
0: Bored diameter
A: Piston diameter as measured
B: Piston-to-bore clearance
C: Honing allowance 0.02 mm (0.0008 in)
7. Install main bearing caps, and tighten to the specified
torque to prevent distortion of cylinder bores in final
assembly.
8. Cut cylinder bores.
• When any cylinder needs boring, all other cylinders must
also be bored.
• Do not cut too much out of cylinder bore at a time. Cut only
0.05 mm (0.0020 in) or so in diameter at a time.
9. Hone cylinders to obtain specified piston-to-bore clear-
ance.
10. Measure finished cylinder bore for out-of-round and taper.
• Measurement should be done after cylinder bore cools
down.
A B CRANKSHAFT
1. Check crankshaft main and pin journals for score, wear or
cracks.
x 2. With a micrometer, measure journals for taper and out-of-
round.
Main journal:
y
Out-of-round (X - V)
Taper: A - B Taper (A - B)
Out-of-round: X - Y Less than 0.005 mm (0.0002 in)
SEM316A Pin journal:
Out-of-round (X - V)
Less than 0.0025 mm (0.0001 in)
Taper (A - B)
Less than 0.0025 mm (0.0001 in)
3. Measure crankshaft runout.

EM-48
CYLINDER. BLOCK ~
Inspection (Cont'd)
~~h~~~tt
BEARING CLEARANCE
• Either of the following two methods may be used, however,
r
method "A" gives more reliable results and is preferable.
Method A (Using bore gauge & micrometer)
Main bearing
~\~2 ~ 1. Set main bearings in their proper positions on cylinder
\)#1 ~ block and main bearing cap.
c;;::? ~ Oil groove
Engine front
SEM560E
2. Install main bearing cap to cylinder block.

Tighten all bolts In correct order in two or three stages.
3. Measure inner diameters "A" of each main bearing.
4. Measure outer diameters "Om" of each crankshaft main

journal.
5. Calculate. main bearing clearance.
Main bearing clearance = A - Om
Standard:
0.024 • 0.056 mm (0.0009• 0.0022in)
Limit: 0.10 mm (0.0039in)
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any
bearing, grind crankshaft journal and use undersized bear-
ing.
(1) When grinding crankshaft journal, confirm that "L" dimen-

sion in fillet roll is more than the specified limit.
"L": 0.1 mm (0.0039in)
(2) Refer to S.O.S. for grinding crankshaft and available ser-
vice parts.
8. If crankshaft is reused, measure main bearing clearances

and select thickness of main bearings.
If crankshaft is replaced with a new one, it is necessary to
select thickness of main bearings as follows:
a. Grade number of each cylinder block main journal is
punched on the respective cylinder block. These numbers
Engine
front
are punched in either Arabic or Roman numerals.
b. Select suitable thickness of main bearings matched with
main journal grade numbers.
Journal grade number SEM266C

CYLINDER BLOCK []!J
Inspection {Cant' d)
Connecting rod bearing (Big end)
1. Install connecting rod bearing to connecting rod and cap.
2. Install connecting rod cap to connecting rod.
Tighten bolts to the specified torque.
3. Measure inner diameter "C" of each bearing.
4. Measure outer diameter "Dp" of each crankshaft pin jour-

nal.
5. Calculate connecting rod bearing clearance.
Connecting rod bearing clearance = C - Dp
Standard:
0.024 - 0.058 mm (0.0009 - 0.0023 in)
Limit: 0.10 mm (0.0039 in)
6. If it exceeds the limit, replace bearing.
7. If clearance cannot be adjusted within the standard of any
bearing, grind crankshaft journal and use undersized bear-
ing.
Refer to step 7 of "BEARING CLEARANCE - Main
bearing".
Method B (Using plastigage)

CAUTION:
• Do not turn crankshaft or connecting rod while plastigage
is being inserted.
• When bearing clearance exceeds the specified limit,
ensure that the proper bearing has been installed. Then if
excessive bearing clearance exists, use a thicker main
bearing or undersized bearing so that the specified bear-
ing clearance is obtained.
FLYWHEEL RUNOUT
Dial gauge Flywheel (M/T model)
EM-50
CYLINDER BLOCK
Assembly
PISTON
1. Assemble connecting rod and piston.
Cylinder No.
SEM512E
• Align the direction of piston and connecting rod.

• Numbers stamped on connecting rod and cap correspond
to each cylinder.
• After assembly, make sure connectin$l rod swings
smoothly.
KV101070S0
EM156
2. Set piston rings as shown.

Punchmark side up
(if mark is present.) CAUTION:
• When piston rings are not replaced, make sure that piston
rings are. mounted In their original positions.
• When piston rings are being replaced and no punchmark is
present, piston rings can be mounted with either side up.
SEM677C
Oil ring
• Top ring
expander 1li V • Oil ring
lit upper rail
Engine
;/
front
CRANKSHAFT
1. Set main bearings in their proper positions on cylinder
block and main bearing cap.
• Confirm that correct main bearings are. used. Refer to
"Inspection" of this section.
SEM560E
EM-51
CYLINDER BLOCK []T!
Assembly (Cont'd)
2. Install crankshaft and main bearing caps and tighten bolts
to the specified torque.
• Prior to tightening bearing cap bolts, place bearing cap in
its proper position by shifting crankshaft in the axial direc-
tion.
• Tighten bearing cap bolts. gradually in two or three stages.
Start with center bearing and move outward sequentially.
• After securing bearing cap bolts, make sure crankshaft
turns smoothly by hand.
SEM267C
3. Measure crankshaft end play.

Crankshaft end play:
Standard
0.050 - 0.150 mm (0.0020 - 0.0059 in)
Limit
0.3 mm (0.012 in)
If beyond the limit, replace bearing with a new one.
4. Install connecting rod bearings in connecting rods and con-

necting rod caps.
• Confirm that correct bearings are used. Refer to
"Inspection".
• Install bearings so that oil hole in connecting rod aligns
with oil hole of bearing.
5. Install pistons with connecting rods.

a. Install them into corresponding cylinders with Tool.
• Be careful not to scratch cylinder wall with the connecting
rod.
• Arrange so that front mark on piston head faces toward
front of engine.
b. Install connecting rod caps.

Tighten connecting rod bearing cap nuts to the specified
torque.
Connecting rod bearing nut:
(1) Tighten to 14 to 16 N.m
(1.4 to 1.6 kg-m, 10 to 12 ft-Ib).
(2) Turn nuts 60 to 65 degrees clockwise.
If an angle wrench is not available, tighten nuts
to 48.5 to 53.4 N.m (4.95 to 5.45 kg-m, 35.8 to
39.4 ft-Ib). .
EM-52
CYLINDER BLOCK em
Assembly (Conl'd)
6. - Measure connecting rod side clearance.
Connecting rod side clearance:
Standard
0.20. 0.30 mm (0.0079 . 0.0118 in)
Limit
0.30 mm (0.0118 in)
If beyond the limit, replace connecting rod and/or crank-
shaft.
7. Install rear oil seal retainer.

(1) Before installing rear oil seal retainer, remove all traces of
liquid gasket from mating surface using a scraper.
cylinder block.
SEM218D
(2) Apply a continuous bead of liquid gasket to mating surface

of rear oil seal retainer.
SEM219D
REPLACING PilOT BUSHING

8T16610001 1. Remove pilot bushing.
or suitable tool
2. Install pilot bushing.
•
Crankshaft side
M/T
SEM561E
EM-53
SERVICE DATA AND SPECIFICATIONS (S.D.S~)
General Specifications
Engine NA20S
Cylinder arrangement 4, in-line
Displacement cm3 (cu in) 1,998 (121.92)
Bore and stroke mm (in) 86 x86 (3.39 x 3.39)
Valve arrangement O.H.C.
Firing order 1-3-4-2
Number of piston rings
Compression 2
Oil 1
B.D.C.
Number of main bearings 5
EM120
Compression ratio 8.7
Model a b c d e f
Without hydraulic
240 232 2 50 19.5 40.5
valve lifter
With hydraulic
248 240 9 51 11 57
valve lifter
Inspection and Adjustment

ENGINE COMPRESSION PRESSURE VALVE
Unit: kPa (bar, kg/cm2, psi)/350 rpm Unit: mm (in)
Standard 1,187 (11.87,12.1,172)

T (Margin thickness)
Minimum 991 (9.91, 10.1, 144)
It
f.f~
Difference limit between cylinders 98 (1.0, 1, 14)
CYLINDER HEAD
Unit: mm (in)
D
Standard Limit
Less than
Head surface distortion 0.1 (0.004)
0.03 (0.0012)
l~ SEM188
Valve head diameter "D"
Intake 38.0 - 38.2 (1.496 - 1.504)
Exhaust 34.0 - 34.2 (1.339 - 1.346)
H Valve length "L"
121.72 - 122.32
Intake
(4.7921 - 4.8157)
123.30 - 123.80
Exhaust
(4.8543 - 4.8740)
Valve stem diameter "d"
SEM956C 7.965 - 7.980
Nominal cylinder head height:
Intake
H =98.8 - 99.0 (3.890 - 3.898) (0.3136 - 0.3142)
7.945 - 7.960
Exhaust
(0.3128 - 0.3134)
Valve face angle "a"
Intake 45°15' - 45°45'
Exhaust 45°15' - 45°45'
Valve margin "T"
Intake 1.3 (0.051)
Exhaust 1.5 (0.059)
Valve margin "T" limit M.ore than 0.5 (0.020)
Valve stem end surface grinding
Less than 0.2 (0.008)
limit
EM-54
Inspection and Adjustment (Cont'd)
Valve clearance Valve spring
Unit: mm (in)
Free height mm(in)
Hot Cold Pressure
Intake 0.3 (0.012) 0.21 (0.008) N (kg, Ib) at height mm (in)
Exhaust 0.3 (0.012) 0.23 (0.009) 664.62 - 749.55

Standard (67.77 - 76,43, 149.43 -
168.53) at 35 (1.38)
631.37 (64.38, 141.96) at 35

Limit
Hydraulic valve lifter (1.38)
Unit: mm (in) Out-of-square mm (in) Less than 2.3 (0.091)
Valve lifter outer diameter 13.488 - 13.500 (0.5310 - 0.5315)
Lifter guide inner diameter 13.506 - 13.524 (0.5317 - 0.5324)
Clearance between lifter and

0.006 - 0.036 (0.0002 - 0.0014)
lifter guide
Valve seat Unit: mm (in)
Cylinder head
H
D
• 35.6 (1.4021) • 30.6 . 30.8 (1.205 - 1.213)
.37.6 - 37.8 • 33.4 . 33.6 (1.315 • 1.323)

d (1.480 - 1.488) d
Contacting width (W); 1.55 - 1.69 (0.0610 - 0.0665) Contacting width (W); 1.9 - 2.1 .(0.075 - 0.083)
.: Machining data
SEM509E
Standard Service
Cylinder head seat recess diameter (D) In. 41.000 - 41.016 (1.6142 - 1.6148) 41.500 - 41.516 (1.6339 - 1.6345)
Ex. 36.000- 36.016 (1.4173 - 1.4179) 36.500 - 36.516 (1.4370 - 1.4376)
Valve seat interference fit In. 0.064 - 0.096 (0.0025 - 0.0038)
Ex. 0.064 - 0.096 (0.0025 - 0.0038)
Valve seat outer diameter (d) In. 41.080 - 41.096 (1.6173 - 1.6179) 41.580 - 41.596 (1.6370 - 1.6376)
Ex. 36.080 - 36.096 (1.4205 - 1.4211) 36.580 - 36.596 (1.4402 - 1.4408)
Depth (H) In. 7.7 - 7.8 (0.303 - 0.307)
Ex. 7.7 - 7.8 (0.303 - 0.307)
Height (h) 7.4 - 7.5 (0.291 - 0.295)
EM ...55
Valve guide CYLINDER BLOCK
Unit: mm (in) Unit: mm (in)
10
(0.39) 60 (2.36)
100 (3.94)
Exhaust side Intake side
Standard Service
12.023 - 12.034 12.223 - 12.234

Valve guide outer diameter
(0.4733 - 0.4738) (0.4812 - 0.4817)
Valve guide inner diameter 8.000 - 8.018

(Finish size) (0.3150 - 0.3157)
Cylinder head valve guide 11.975 -11.996 12.175 -12.196

hole diameter (0.4715 - 0.4723) (0.4793 - 0.4802)
Interference fit of valve 0.027 - 0.059

guide (0.0011 - 0.0023)
Standard Limit
SEM562E
Stem to guide clearance
0.020 - 0.053
Intake 0.1 (0.004)
(0.0008 - 0.0021) Distortion
0.040 - 0.073 Standard Less than 0.03 (0.0012)
Exhaust 0.1 (0.004)
(0.0016 - 0.0029)
Limit 0.1 (0.004)
Valve deflection limit
(Dial gauge reading) Height "H" (nominal) 227.40 - 227.50
(8.9527 - 8.9567)
Intake 0.12 (0.0047)
Cylinder bore inner diameter
Exhaust 0.12 (0.0047)
Standard Grade No.1 86.000 - 86.010
Projection length "L" 17.9 - 18.1 (0.705 - 0.713) (3.3858 - 3.3862)
Grade No.2 86.010 - 86.020

Intake manifold (3.3862 - 3.3866)
Unit: mm (in) Grade No.3 86.020 - 86.030

(3.3866 - 3.3870)
Distortion
Wear limit 0.2 (0.008)
Limit 0.15 (0.0059)
Out-of-round (X - Y) Less than 0.015
(0.0006)
Taper (A - B) 0.Q1 (0.0004)
Deference in inner diameter between

cylinders
Limit Less than 0.03 (0.0012)
Main journal inner diameter
Grade No. 0 58.645 - 58.654

(2.3089 - 2.3092)
Grade No.1 58.654 - 58.663

(2.3092 - 2.3096)
Grade No.2 58.663 - 58.672

(2.3096 - 2.3099)
EM-56
SERVICE DATA AND SPECIFICATIONS (S.O.S.) []KJ
CAMSHAFT AND CAMSHAFT BEARING PISTON, PISTON RING AND PISTON PIN
Unit: mm (in)
Piston
Unit: mm (in)
EM671
44.572 - 44.762
Cam height "A"
(1.7548 - 1.7623)
Wear limit of cam height 0.25 (0.0098)
Valve lift
Intake 9.5 (0.374)
Exhaust 9.5 (0.374)
Camshaft journal to bearing clearance

SEM750C
0.045 - 0.090
Standard Piston skirt diameter "A"
(0.0018 - 0.0035)
Standard
Limit 0.12 (0.0047)
85.965 - 85.975
33.000 - 33.025 Grade NO.1
Inner diameter of camshaft bearing (3.3844 - 3.3848)
(1.2992 - 1.3002)
85.975 - 85.985
32.935 - 32.955 Grade No.2
Outer diameter of camshaft journal (3.3848 - 3.3852)
(1.2967 - 1.2974)
85.985 - 85.995
Camshaft runout (T.I.R.*) Grade NO.3
(3.3852 - 3.3856)
Limit 0.05 (0.0020)
Service (Oversize)
Camshaft sprocket runout (T.I.R.*)
86.465 - 86.495
0.5 (0.020) Oversize
Limit 0.25 (0.0098) (3.4041 - 3.4053)
Camshaft end play 86.965 - 86.995

(3.4238 - 3.4250)
0.070 - 0.148
Standard
(0.0028 - 0.0058) "a" dimension 14 (0.55)
Limit 0.2 (0.008) 0.025 - 0.045

Piston clearance to cylinder block
(0.0010 - 0.0018)
*:Total indicator reading
21.001 - 21.008
Piston pin hOle diameter
Piston pin (0.8268 - 0.8271)
Unit: mm (in)
Piston pin outer diameter

20.993 - 20.998 Piston ring
(0.8265 - 0.8267) Unit: mm (in)
0.008 - 0.012
Piston pin to piston clearance Standard Limit
(0.0003 - 0.0005)
Side clearance
Interference fit of piston pin to connect-
ing rod bushing clearance 0.040 - 0.075
Top
(0.0016 - 0.0030)
0.D15 - 0.033 0.1 (0.004)
Standard
(0.0006 - 0.0013) 0.030 - 0.063
2nd
(0.0012 - 0.0025)
End gap
0.24 - 0.43
Top
(0.0094 - 0.0169)
0.42 - 0.66
2nd 1.0 (0.039)
(0.0165 - 0.0260)
0.20 - 0.69
Oil (rail ring)
(0.0079 - 0.0272)
EM-57
CONNECTING ROD
Unit: mm (in)
Om
147.95 - 148.05
Center distance
(5.8248 - 5.8287)
Bend [per 100 (3.94)]
Limit 0.15 (0.0059)
Torsion [per 100 (3.94)]
Limit 0.3 (0.012)
20.965 - 20.978 Op
Piston pin bushing inner diameter*
(0.8254 - 0.8259)
53.000 - 53.013 SEM954C

Connecting rod big end inner diameter
(2.0866 - 2.0871)
Out-ot-round X - V
Side clearance
Taper A - B
0.20 - 0.30
Standard
(0.0079 - 0.0118)
Limit 0.3 (0.012)
*: After installing in connecting rod
CRANKSHAFT EM715
Unit: mm (in)
Main journal dia. "Om"
54.942 - 54.955
Standard
(2.1631 - 2.1636) AVAILABLE MAIN BEARINGS
Pin journal dia. "Op"
49.961 - 49.974
Standard
(1.9670 - 1.9675)
Center distance "r" 43 (1.69)
Out-ol-round limit 01 journal and

pin (X - V)
Main journal 0.005 (0.0002)
Pin journal 0.0025 (0.0001)
Taper limIt (A - B)
Main journal 0.005 (0.0002)
Pin journal 0.0025 (0.0001)
Runout (T.I.R.*)
Standard Less than 0.025 (0.0010)

SEM560E
Limit Less than 0.05 (0.0020)
Free end play
Standard 0.050 - 0.150 (0.0020 - 0.0059)
Limit 0.3 (0.012)
*: Total indicator reading
EM-58
Main bearing size Connectingrod bearing size
Bearing top thick-

T Crank pin diameter
ness "T"
1.497 - 1.501 49.961 - 49.974

STD
(0.0589 - 0.0591) (1.9670 - 1.9675)
0.06 (0.0024) 1.527 - 1.531 49.880 - 49.935

Undersize (0.0601 - 0.0603) (1.9638 - 1.9659)
0.12 (0.0047) 1.557 - 1.561 49.820 - 49.875

Undersize (0.0613 - 0.0615) (1.9614 - 1.9636)
0.25 (0.0098) 1.622 - 1.626 49.690 - 49.745

Undersize (0.0639 - 0.0640) (1.9563 - 1.9585)
EM738
BEARING CLEARANCE
Unit: mm (in)
Grade Main bearing Standard 0.024 -0.056 (0.0009 - 0.0022)

No. on Bearing top thickness clearance
Crank journal diameter Limit 0.10 (0.0039)
the cyl- "T"
inder Connecting rod Standard 0.24 - 0:058 (0.0094 - 0.0023)
block bearing clear-
ance Limit 0.10 (0.0039)
0 1.829 - 1.833
Green (0.0720 - 0.0722)
Stan- 1 1.833 - 1.837 54.942 - 54.955 MISCELLANEOUS COMPONENTS

dard Yellow (0.0722 - 0.0723) (2.1631 - 2.1636) Unit: mm (in)
2 1.837 ~ 1.841
Camshaft sprocket runout
Blue (0.0723 - 0.0725) Less than 0.25 (0.0098)
(T.l.R. *)
0.25 (0.0098) 1.954 - 1.958 54.691 - 54.722
Flywheel runout (T.I.R.*) Less than 0.15 (0.0059)
Undersize (0.0769 - 0.0771) (2.1532 - 2.1544)
0.50 (0.0197) 2.079 - 2.083 54.441 - 54.472
Undersize (0,0819 - 0.0820) (2.1433 - 2.1446)
0.75 (0.0295) 2.204 - 2.208 54.191 - 54.222

Undersize (0.0868- 0.0869) (2.1335 - 2.1347)
1.00 (0.0394) 2:329 - 2.333 53.941 - 53.972

Undersize (0.0917 - 0.0919) (2.1237 - 2.1249)
EM-59
ENGINE COMPONENTS - Outer Parts
Injection
pump
~30-36
(3.1 - 3.7,
22 - 27)
Blow-by hose
(3.1 - 3.7, 22 - 27)
~ Injection tube-
~20-25
2'0_2'5'
14 - 18)
~ ~'
Injection pump ~
(VE-type) ,
Oil cooler
~@
@
~59-69
(6.0 - 7.0, 43 - 51)
EM-50
ENGINE COMPONENTS _. Outer Parts
~ 3 - 6 (0.3 - 0.6, 2.2 - 4.3)
Oil filter bracket
-~
/ /"
<-~ a
~~~~
, ~Exhaust
./ manifold
Oilfilt~
Alternator adjusting bar

& engine slinger
Air conditioner compressor
~ ~ M10: 30 -36
~ (3.1 - 3.7, ~
'~-27)
. ~
~
~;{'- ~~~
~
L
~~-~ 29-39
~-1t----;. '?
~1--~~/tJ
(3.0 - 4.0, 22 - 29)
~ 30 - 36
~ 30-36
(3.1 - 3.7, 22 - 27)
~30-36
(3.1 - 3.7,
22 - 27) ~ : N.m (kg-m, ft-Ib)
SEM369E
EM-51
"""1;;,""","""" ""VIYI ...nl;;,~~lvl" ...nl;;,~~unl;;,
{On-Vehicle Service}
1. Warm up engine.
2. Remove glow plate and glow plugs.
3. Fit compression gauge adapter to cylinder head.

Compression gauge adapter:
~: 15 - 20 N'm
(1.5 - 2.0 kg-m, 11 - 14 ft-Ib)
4. Set no fuel injected condition.

• VE-type
Disconnect fuel cut solenoid wire connector.
5. Crank engine, then read gauge indication.
• Engine compression measurement should be made as
qUickly as possible.
Compression pressure:
Unit: kPa (bar, kg/cm2, psi)/200 rpm
Standard 2,942 (29.4, 30, 427)

Minimum 2,452 (24.5, 25, 356)
Differential limit between cylinders 294 (2.9, 3, 43)

pour a small quantity of engine oil into cylinders through
the glow holes and retest compression.
• If adding oil helps the compression pressure, chances are
that piston rings are worn or damaged.
• If pressure stays low, valve may be sticking or seating
improperly.
• If cylinder compression in any two adjacent cylinders is
low, and if adding oil does not help the compression, there
is leakage past the gasketed surface.
Oil and water in combustion chambers can result from this
problem.
EM-52
CYLINDER HEAD
Roker cover pi ate
Rocker cover
14.18) •
Rocke r cover gasket ~
Rocker shaft
f1
I
~
GIOWPIUg
15.20
Push rod
(1.5 - 2 .•0 11 - 14)
J
r-.
Cylinder head bolt
~ Refer to
installation f
~ cylinder head.
0
Cylinder head gasket.~
Cylinder head

SEM620B
EM-63
"'"'LII'IU.:;n n.:;Io\u - ntHIIUVClI
(On-Vehicle Service)
Removal
1. Set NO.1 cylinder at T.D.C. on its compression stroke.
2. Drain engine coolant from drain plugs on cylinder block
and radiator.
3. Remove blow-by hose and disconnect air cleaner air duct.
4. Remove alternator adjusting bolt.
5. Disconnect exhaust manifold from front exhaust tube.
6. Disconnect engine side water outlet hose, heater hose and
thermostat housing side water hose.
7. Remove fuel injection tube assembly and spill tUbe.
8. Remove injection nozzle holder and top nozzle gasket

using deep socket wrench.

10. Remove rocker shaft with rocker arms.
11. Remove push rods.
12. Remove cylinder head bolts in numerical order and remove

cylinder head.
Head warpage or cracking could result from removing in incor-
rect order.
Loosen in numerical order. SEM623B
EM-64
CYLINDER HEAD --- Disassembly
Disassembly
1. Remove following parts:
• Intake manifold
• Exhaust manifold
• Thermostat housing
• Alternator adjusting bar & engine slinger
• Glow plate and glow plugs
SEM6248
2. Remove valve component parts with Tool.
3. Remove valve oil seals with Tool.
4. Disassemble rocker shaft assembly.

a. Remove rocker shaft lock bolt.
b. Remove valve rocker and rocker shaft bracket.
If it is difficult to remove rocker shaft bracket, immerse rocker
shaft assembly in oil of 70°C (158°F) for a few minutes and then
remove bracket.
SEM6278
EM-65
CYLINDER HEAD - Inspection

Cylinder head distortion:
Standard
Limit
0.2 mm (0.008 in)
If beyond the specified limit, correct with a surface grinder.
Cylinder head height should be greater than 89.7 mm (3.531 in)
after surface has been ground.

• Valve guide clearance should be measured parallel with
rocker arm. (Generally, a large amount of wear occurs In
this direction.)
Stem to guide clearance:
Limit
Intake 0.15 mm (0.0059 in)
Exhaust 0.20 mm (0.0079 in)
Maximum allowable deflection
(Dial indicator reading)
Intake 0.30 mm (0.0118 in)
• To determine the correct replacement part, measure valve
stem diameter and valve guid~ inner diameter.
Valve stem diameter:
Standard
Intake
7.962 - 7.977 mm (0.3135 - 0.3141 in)
Exhaust
7.945 - 7.960 mm (0.3128 - 0.3134 in)
Valve guide inner diameter:
8.00 - 8.015 mm (0.3150 - 0.3156 in)

2.2 US ton, 2.0 Imp ton) pressure] or hammer, and suitable
tool.
SEM628B
EM-66
2. Press service valve guide onto cylinder head using suitable

KVlll03900
tool until the guide projects out 13 mm (0.51 in).

Finished size:
8.000 • 8.015 mm (0.3150 - 0.3156 in)
Contact width: VALVE SEATS

~' .... '0.083 ;01 Check valve for any evidence of pitting at valve contact surface,
and reseat or replace if worn out excessively.
\,..I O.K. • When repairing valve seats, check v.alve and valve guide
for wear beforehand. If worn, replace them. Then correct
valve seat.
ON.GONG
• The cutting should be done with both hands for uniform
cutting.
SEM024

1. Bore out old seat until it collapses or remove valve seats
with Tool.
Place a copper s.eatbetween contact surface of Tool and cylin-
der head.
2.. Place new valve seats on dry ice and allow them to cool for
five minutes.
WARNING:
Do not touch cpoled valve seats with bare hands.
3. Heat cylinder head to BO°C (176°F).
4. Install cooled valve seats on cylinder head with Tool.
EM-67
5 places 5. Stake exhaust valve seat at five places with punch.

When staking valve seat, select different places than those
staked before.

7. After cutting, lap valve seat with a lapping compound.
8. Check contact condition of valve seat.
COMBUSTION CHAMBER
Check combustion chamber for cracks and other damage. If
necessary, replace.
REPLACING COMBUSTION CHAMBER

Usually combustion chamber should not be removed.
1. Remove combustion chamber so that cylinder head cannot
be damaged.
SEM6338
2. Install combustion chamber.

• Identification of combustion chambers
Identification mark
Outer diameter "0"
(on combustion cham- Engine
mm (in)
ber)
2 T025
Identification
37 (1.46)
- TD27
mark
(1) Cool combustion chamber with dry ice for approximately 5

SEM599C to 10 minutes.
WARNING:
Knock pin
o Combustion chamber
Do not touch cooled combustion chamber with bare hands.
Align (2) Align combustion chamber knock pin with cylinder head
notch, and drive in combustion chamber with a soft ham-
mer.
3. Check amount of protrusion of combustion chamber.
Protrusion:
Standard
-0.05 to 0.10 mm (-0.0020 to 0.0039 in)
SEM6348
EM-68
CYLINDER HEAD - I"Sp_eC_I_iO_" I_T_D_1

it Check dimensions in each valve. For dimensions, refer to
fo~ S.O.S.
margin thickness, replace the valve.
te !~1
less .
.
SEM188A
VALVE SPRING SQUARENESS

Out-of-square "S":
SEM635B
VALVE SPRING PRESSURE LOAD

Refer to S.O.S.
VALVE LIFTER AND PUSH ROD

Valve lifter
1. Check valve lifters for excessive wear on the face.
2. Replace with new ones if worn beyond repair.
a. Valve lifter end should be smooth.
b. Valve lifter to lifter hole clearance:
Standard
0.030 - 0.073 mm (0.0012 - 0.0029 in)
Limit
Valve lifter outer diameter "A":
Standard
24.960.- 24.970 mm (0.9827 - 0.9831 in)
Cylinder block valve lifter hole dia~eter "8":
Standard
25.000 - 25.033 mm (0.9843- 0.9855 in)
EM-69
Push rod
1. Inspect push rod for excessive wear on the face.
2. Replace if worn or damaged beyond repair.
3. Check push rod for bend using a dial gauge.
Maximum allowable bend
(Total indicator reading):
Less than 0.5 mm (O.020 in)

1. Check valve rockers, brackets and rocker shafts for
scoring, wear or distortion. Replace if necessary.
2. Check clearance between valve rockers and rocker shaft.

If specified clearance is exceeded, replace affected valve
rockers or shafts.
Specified clearance:
Limit Less than 0.15 mm (O.0059 in)
Rocker shaft outer diameter "A":
Standard 19.979 - 20.000 mm (O.7866 • 0.7874 in)
Rocker arm inner diameter "8":
Standard 20.014 - 20.035 mm (O.7880 • 0.7888 in)
SEM027
3. Check rocker shaft bend at its center. If bend is within

specified limit, straighten it; and if it is greater than speci-
fied limit, replace rocker shaft.
Rocker shaft bend
Limit
SEM028
MEASURING CYLINDER HEAD TO VALVE DISTANCE

o Measure distance from cylinder head surface to intake and
exhaust valves. If specified distance is exceeded, replace
valve(s) or valve seat(s).
Specified distance:
Standard
Intake 0.20 - 0.75 mm (O.0079 • 0.0295 in)
~ Exhaust 0.23 - 0.77 mm (O.0091 - 0.0303 in)
00 Limit
)
Or-\
for intake and exhaust valves
EM-70
CYLINDERHEAD-. Assembly
1. Assemble rocker shaft component parts.
• Identification of rocker arms

Identification mark
Engine For use with
(on rocker arm)
B Intake
TD25 and TD27
C Exhaust
SEM373E

• Identification of valves
Identification mark
(on intake and exhaust valve) Engine
Intake valve Exhaust valve
2 B TD25
3 C TD27
• Always use new valve oil seal. (Refer to Oil SEAL

SEM926B REPLACEMENT .)
side toward cylinder head side.
Wide pitch
Narrow pitch
•
EM-71
CYLINDER HEAD - Installation (On-Vehicle Service)
1. Install cylinder head gasket.

• Identification of cylinder head gaskets
Identification cut hole
shape Inner diameter "d"
Engine
(on cylinder head mm (in)
gasket)
2 94.4 (3.717) TD25
1 97.5 (3.839) TD27

Grade number
a. When replacing only cylinder head gasket, install same
SEM600C
grade gasket as the one formerly used.
b. When replacing or repairing cylinder block, cylinder head,
piston, connecting rod and crankshaft, select gasket as fol-
lows:
(1) Measure piston projection.

Measuring points • Set each piston at its Top Dead Center. With piston held in
that position, measure its projections at two points.
• Calculate the average value of the two measurements.
• Determine the amount of projection of the other three pis-
tons.
(2) Select suitable cylinder head gasket which conforms to the
Engine
front
largest amount of projection of the four pistons.
Unit: mm (in)
Average values piston

SEM640B Gasket thickness Gasket grade number
projections
Less than 0.118
1.30 (0.0512) 1
(0.0046)
0.118 - 0.168
1.35 (0.0531) 2
(0.0046 - 0.0066)
More than
1.40 (0.0551) 3
0.168 (0.0066)
Make sure that No. 1 piston is at T.O.C. on Its compression

stroke.
2. Install cylinder head.

• Cylinder head identification mark
Identification number
(on cylinder head) Engine
Float mark Punch mark
2 4 TD25
2 - TD27
EM-72
3. Apply oil to the thread portion and seat surface of bolts and
tighten cylinder head bolts using Tool.
CAUTION:
• Tightening procedure
1st:
Tighten bolts to 39 - 44 N'm
(4.0 - 4.5 kg-m, 29 - 33 ft-Ib)
2nd:
Tighten bolts to 54 - 59 N'm
(5.5 - 6.0 kg-m, 40 - 43 ft-Ib)
Tighten in numerical order. SEM641B
3rd:
(1) Mark exhaust side of cylinder head and cylin-
der head bolts with paint as shown.
(2) Turn all bolts 90::l:10 degrees clockwise.
(3) Check that the paint mark of each bolt is facing
the front of the vehicle.
4. Apply engine oil and install push rods.

5. Install rocker shaft assembly.
Adjusting intake and exhaust valve clearance tentatively.
Refer to section MA.
6. Install rocker cover with rocker cover plate.

• Be sure the "F" mark on rocker cover plate faces upward
and is at the front end.
• When replacing rocker cover gasket, bend slit of rocker
cover baffle plate a little to hold the gasket. Do not twist
gasket.
7. Install glow plugs and glow plate.
EM ..73
8. Install new top nozzle gasket and injection nozzle.
9. Install spill tube and injection tube.
10. Connect thermostat housing water inlet hose and radiator

hose.
11. After assembling all disassembled parts, fill radiator and
engine with new coolant up to filler opening.
EM-74
OIL SEAL REPLACEMENT (On.;Vehicle Service)
Oil SEAL INSTALLING DIRECTION

• When installing a new front or rear seal, make sure its
mounting direction is correct.
Engine ~ Engine
inside ..,. outside
CRANKSHAFT FRONT Oil SEAL

1. Remove radiator shroud.
2. Remove cooling fan.
3. Remove drive belts.
4. Remove crank pulley.
5. Remove crankshaft oil seal.
• Be careful not to damage sealing surfaces of crankshaft.
6. Coat new oil seal with engine oil and install it in place.
CRANKSHAFT REAR Oil SEAL

1. Dismount transmission.
2. Remove clutch cover assembly.
3. Remove flywheel and rear plate.
4. Remove engine gusset and oil pan.
5. Remove oil seal retainer assembly, then remove oil seal.
VALVE STEM Oil SEAL

3. Remove valve spring.
'1... ---
4. Remove valve oil seals.

KV10107900
EM.75
OIL SEAL REPLACEMENT (On-Vehicle Service)
5. Apply engine oil to valve oil seal and install it in place.
C
E .-
.0..... ...
E~
co"l
"lt;
~e
EM-76
ENGINE REMOVAL
~
56
14A- -55 •• 32
43 -2 1
toJ ~:.~ ~~.3,
1
.)
19
o
.....
24)
~/~~
4-~
. .
~
Z ~
o@(
25 - 32
(2.6 - 33
.,
19 _ 24)
n -41'
~ 25 - 32
(2.6 - 3.3, 19 -
5~5_"7
24)
"."
,-.
43 - 55)
-
'4.4.5 .•• 32 - 41
'?%
'.
~~.
l"J 43 -'. n _41'
~ 25 - 32 _ 24) -./
(2.6 - 3.3, 19
~ : N.m (kg-m , ft-Ib)
SEM377E
EM-77
ENGINE REMOVAL
WARNING:
a. Situate vehicle on a flat and solid surface.
c. Do not remove engine until exhaust system has completely cooled off.
Otherwise, you may burn yourself and/or fire may break out In fuel line.
d. For safety during subsequent steps, the tension of wires should be slackened against the engine.
e. Before disconnecting fuel hose, release fuel pressure from fuel line.
f. Be sure to hoist engine and transmission in a safe manner.
g. For engines not equipped with engine slingers, attach proper slingers and bolts described In PARTS
CATALOG.
CAUTION:
• When lifting engine, be careful not to strike adjacent parts, especially accelerator wire casing, brake
lines, and brake master cylinder.
• In hoisting the engine, always use engine slingers in a safe manner.
Removal
I
Battery
1. Remove battery ground cable.

V SEM380E
2. Remove propeller shaft.

3. Raise front of vehicle using a jack.
4. Remove torsion bar spring.
5. Remove starter motor assembly.
6. Support transmission using a jack.
7. Remove rear member assembly from transmission.
8. Remove transmission assembly.
Refer to MT section.
9. Remove exhaust front tube assembly.
10. Remove engine hood.
EM-78
ENGINE REMOVAL
Removal (Coni' d)
Injection pump
fuel tube
SEM381E
11. Drain cooling water from engine and radiator.

12. Remove alternator assembly.
13. Remove power steering reservoir tank and power steering
pump assembly, then suspend steering pump from vehicle
body using wire.
(Do not remove piping from steering pump.)
14. Remove air compressor and suspend it from vehicle body
using suitable wire.
(Do not remove piping from compressor.)
15. Place a jack under engine.
16. Remove engine mount bracket from side frame.
Wooden
block
--
---
---
SEM382E
17. Remove engine assembly.
EM-79
ENGINE OVERHAUL
Oil pump
Camshaft
Spacer
Grommet cover
Timing gear c ase cover
Crankshaft
~ 167 - 177
(17.0 - 18.0,
Main bearing 123 - 130)
Oil pan
~7-9 ~
(0.7 - 0.9, <Q>
)
~b 5.1 - 6.5) ~ 54. _ 59~
Nom (kg-m,
Apply recom~ endedart: sealant
KP610-o0250) or equivalent. 40 _ 43)
(Nissan genUine p (55 - 6.0,
01 Keep In
. correct order.
SEM376E
EM-SO
ENGINE OVERHAUL --- Disassembly

1. Remove oil filter.
2. Place engine on work stand.
5. Remove cylinder head.
6. Remove oil pan.
SEM650B
8. Remove water pump.

9. Remove timing gear case.
SEM652B
If the timing case is hard to remove due to liquid gasket, pry it

off with a suitable tool at the cutout section.
SEM676B
10.
• VE-pump
Remove injection pump gear.
SEM653B
EM-81
ENGINE OVERHAUL - Disassembly
SEM6548
11. Remove idler gear and idler gear shaft.

12. Remove camshaft gear, camshaft and valve lifters.
SEM6558
13. Remove oil pump assembly.
14. Remove crankshaft gear.

16. Remove connecting rod caps.
17. Remove pistons.
18. Remove rear oil seal retainer.
EM-82
19. Remove bearing cap and crankshaft.

Place the bearings and caps in their proper order.
loosen in numerical order.

SEM6588
EM.83
ENGINE OVERHAUL - Inspection and Replacement
&~~
---: Measuring point
~
CYLINDER BLOCK DISTORTION
If beyond the specified limit, replace it.
Cylinder block distortion:
Standard
Limit
0.2 mm (0.008 in)
SEM038
CD~~
~:; CYLINDER LINER WEAR
1. Measure cylinder liner bore for out-of-round and taper with
a bore gauge. If beyond the limit, replace cylinder liner.
Inside diameter (With cylinder liner for factory):
r:tt
; I TD25
A 92.900 - 92.930 mm (3.6575 - 3.6587 in)
TD27
B 96.000 - 96.030 mm (3.7795 - 3.7807 in)
Refer to S.O.S.
Unit: mm (in) Inside diameter (With cylinder liner for service):
MEM042A TD25
92.925 - 92.970 mm (3.6585 - 3.6602 in)
TD27
96.025 - 96.070 mm (3.7805 - 3.7823 in)
Wear limit:
0.20 mm (0.0079 in)
Out-of-round (X - V) limit:
0.070 mm (0.0028 in)
0.20 mm (0.0079 in)
2. Check for scratches or seizure. If seizure is found, replace
cylinder liner.
3. Check amount of projection of cylinder liner.

Cylinder liner projection:
Standard
0.02 - 0.09 mm (0.0008 - 0.0035 in)
Deviation of each cylinder:
CYLINDER LINER
Replacement
1. Remove cylinder liner with Tool.
EM-84
ENGINE OVERHAUL -. Inspection and Replacement
2. Install cylinder liner with Tool.

SEM659B
PISTON TO CYLINDER WALL CLEARANCE

1. Measure piston and cylinder bore diameter.
Refer to S.O.S.
Measuring point "a" (Distance from the top):
70 mm (2.76 in)
2. Check that piston clearance is within the specification.
Piston clearance:
With cylinder liner for factory
0.05 - 0.09 mm (0.0020 - 0.0035 in)
SEM660B With cylinder liner for service
0.09 - 0.13 mm (0.0035 - 0.0051 in)
Check clearance between pistons and piston pins.
Clearance (B - A):
Standard
-0.003 to 0.012 mm (-0.0001 to 0.0005 in)
Limit
SEM424
PISTON. RING SIDE CLEARANCE

Side clearance:
Top ring
0.06 - 0.10 mm (0.0024 • 0.0039 in)
2nd ring
0.04 - 0.08 mm (0.0016 • 0.0031 in)
Oil ring
0.02 • 0.06 mm (0.0008 - 0.0024 in)
Top
0.5 mm (0.020 in)
2nd
0.3 mm (0.012 in)
Oil
0.15 mm (0.0059 in)
EM-8S
ENGINE OVERHAUL - Inspection and Rep_la_c_e_m_e_n_t I_T_o-1
PISTON RING GAP

Install piston rings in grooves on cylinder liner within a range
Upper surface of
cylinder block of 20 mm (0.79 in), as shown, before measuring piston ring
gaps.
Ring gap (With cylinder liner for factory):
Top ring
0.30 • 0.45 mm (0.0118 • 0.0177 in)
2nd ring
~~
Cylinder liner - T025
Unit: mm (in) 0.20.0.35 mm (0.0079 .0.0138 in)
SEM004E T027
0.50 - 0.65 mm (0.0197 .0.0256 in)
Oil ring
T025
0.15.0.35 mm (0.0059 .0.0138 in)
T027
0.30 - 0.50 mm (0.0118 • 0.0197 in)
1.5 mm (0.059 in)
Ring gap (With cylinder liner for service):
Top ring
0.40 - 0.60 mm (0.0157 - 0.0236 in)
2nd ring
T025
0.30 • 0.50 mm (0.0118 - 0.0197 in)
T027
0.60 - 0.80 mm (0.0236 • 0.0315 in)
Oil ring
T025
0.3 • 0.5 mm (0.012 • 0.020 in)
T027
0.40.0.65 mm (0.0157 • 0.0256 in)
Max. Iimit of ring gap:
J
1.5 mm (0.059 in)
MAIN BEARING CLEARANCE

Main bearing clearance:
Standard
0.035 • 0.087 mm (0.0014 • 0.0034 in)
Limit
1. Install main bearings to cylinder block and main bearing

cap.
Tighten all bolts in correct order and in two or three stages.
3. Measure inside diameter "A" of main bearing.
EM-86
ENGINE OVERHAUL .......Inspectionand _-_-I_T_D_l
Rep_la_c_e_m_e_n_t
4. Measure outside. diameter "Om" of main journal in crank-

shaft.
SEM413B
5. Calculate main bearing clearance.

CONNECTrNG ROD BEARING CLEARANCE

Connecting rod bearing clearanc.e:
Standard
0.035 • 0.081 mm
(0.0014.0.0032 in)
limit
Less than 0.15 mm (0.0059 In)
1. Install connecting rod bearing to connectirlgrod and cap.
2. Install connecting rod cap to connecting rCld.
Apply oil to the thread portion of bolts and seating surface of

nuts.
3. Measur~inside diameter "A" of bearing.
4. Measure outside diameter "Op" of pin journal in crank-
shaft.
Connecting rod bearing clearance = A - Op
SEM507A

Bend and torsion:
Limit
0.075 mm (0.0030 in)
per 100 mm (3.94 In) length
EM133
EM..87
ENGINE OVERHAUL -.Inspection .and .Rep_la_c_e_m_e_n_t I_T_o_1
CONNECTING ROD SMALL END BUSHING CLEARANCE

1. Measure inside diameter" A" of connecting rod small end
bushings.
2. Measure outside diameter "0" of piston pin.

3. Calculate connecting rod small end bushing clearance.
Connecting rod small end bushing clearance = A - 0
Bushing clearance:
Standard
0.025 - 0.045 mm (0.0010 - 0.0018 in)
Limit
0.15 mm (0.0059 in)
REPLACEMENT OF CONNECTING ROD SMALL END

BUSHING
1. Drive in the small end bushing until it is flush with the end
surface of the rod.
Be sure to align the oil holes.
2. After driving in the small end bushing, ream the bushing.
Small end bushing Inside diameter:
Finished size:
28.025 - 28.038 mm (1.1033 - 1.1039 In)
SEM062A
Out-ot-round x-v CRANKSHAFT

Taper A-B
1. Check crankshaft journals and pins for score, bias, wear or
cracks. If faults are minor, correct with fine crocus cloth.
2. Check journals and pins with a micrometer for taper and
out-of-round.
Out-of-round (X - V):
Standard
Less than 0.01 mm(O.0004 In)
Limit
0.02 mm (0.0008 In)
EM715
Taper (A - B):
Standard
Limit
0.02 mm (0.0008 in)
EM-S8
ENGINE OVERHAUL -- Inspection and Rep_la_c_e_m_e_n_t I_T_D_'
3. Check crankshaft runout.

Runout [T.I.R. (Total Indicator Reading)]
Standard
o .. 0.03 mm (0 .. 0.0012 in)
limit
0.10 mm (0.0039 In)
SEM662B
k:LLL
O.K. N.G. N.G. N.G.
SEF692A
5.8 - 6.0 mm 2. fnsertpilot bushing until distance between flange end and
(0.~~8 - 0.236 in) bushing is specified value.
Distance:
Approx. 5.8 .. 6.0 mm (0.228 .. 0.236 In)
Pilot bushing
SEM089
FLYWHEEL RUNOUT
less than 0.10 mm (0.0039 in)
SEM059A
EM ..S9
ENGINE OVERHAUL -Inspection and Rep_la_c_e_m_e_n_t 1_,._-o_1
FRONT PLATE
Check front plate for warpage. If not within the limit, make flat
or replace front plate.
Warpage limit:
0.2 mm (0.008 in)
SEM668B
GEAR TRAIN
Camshaft drive gear, injection pump drive gear, oil
pump gear, idler gear and crankshaft gear
1. If gear tooth and key have scratches or are excessively
worn, replace gear and key.
2. Check gear train backlash before disassembling and after
assembling.
Method A (Using dial gauge)
Method B (Using fuse wire)
SEM663B If beyond the limit, replace gear.
Backlash:
Standard
0.07 - 0.11 mm (0.0028 - 0.0043 in)
Limit
0.20 mm (0.0079 in)
IDLER GEAR BUSHING CLEARANCE

1. Measure idler gear shaft outer diameter.
SEM666B
2. Measure idler gear bushing inner diameter.

3. Calculate idler gear bushing clearance.
Bushing oil clearance:
Standard
0.025 - 0.061 mm (0.0010 - 0.0024 in)
, Limit
0.20 mm (0.0079 in)
SEM705
EM-gO
IDLER GEAR END PLAY

Measure idler gear end play between gear plate and gear.
Idler gear end play:
Standard
0.03 - 0.14 mm (O.0012 . 0.0055 in)
Limit
REPLACEMENT OF IDLER GEAR BUSHING

1. Use a suitable tool to replace bushing.
2. Ream idler gear bushing.
Finished size:
42.00 - 42.02 mm (1.6535 - 1.6543 in)
Idler gear shaft
Install idler gear shaft so that oil hole of shaft faces upward.
CAMSHAFT AND CAMSHAFT BUSHING

Camshaft bushing clearance
Measure inside diameter of camshaft bushing and outside
diameter of camshaft journal with a suitable gauge.
Clearance between camshaft and bushing (A - B):
Standard
0.020 - 0.109 mm
(O.OOOS . 0.0043 in)
Limit
SEM6698 Less than 0.15 mm {O.0059 in)
REPLACING CAMSHAFT BUSHING

1. Using Tool, remove camshaft bushings from the engine.
Some bushings must be broken in order to remove.
SEM106C
Carn bushing replacer set 2. Using Tool, install camshaft bushings as follows:
KV111045S0
~
Adapter
(1st bushing)
f' ~D,;ft
ST15243000
KV11104530
SEM9938
EM-91
(1) Install camshaft bushings in the order of "rear", "4th",

"3rd", "2nd" and "front". All bushings must be installed
from the front.
(2) Face the cutout upward and toward the front of the engine
during installation.
Q
Engine
front
SEM686B
(3) Rear camshaft bushing

a) Align the cutout of rear bushing with knock pin of replacer
bar before installation.
SEM995B
b) Insert rear bushing with replacer bar into the engine.

Install guide plate with bolt holes (on the "TD" mark side)
facing upper side of cylinder block. Tighten bolts.
c) Drive replacer bar until the alignment mark on replacer bar

is aligned with the end of replacer guide.
Remove replacer set.
After installation, check that oil holes in camshaft bushings
are aligned with oil holes in cylinder block.
EM-92
ENGINE OVERHAUL -Inspection and Rep_la_c_e_01_e_n_t I_!_D_I
Alignment mark to Rear bushing

@ surface
Knock pin
Replacer bar
@ Engine
Alignment mark line front
to @ surface
SEM601C
(4) 4th, 3rd and 2nd camshaft bushings

Install in the same manner as rear camshaft bushing.
Alignment mark to
@ surface 4th bushing
Engine
front
@
Alignment mark to
@ surface 2nd bushing
SEM602C
EM ..93
ENGINE OVERHAUL- Inspection and Rep_la_c_e_m_e_n_t 1 T_D_I
(5) Front camshaft bushing

Using 1st bushing adapter, position front camshaft bushing
so that oil hole in cylinder block is aligned with oil hole in
bushing.
3. Check camshaft bushing clearance.
4. Install new welch plug with a drift.

Apply liquid sealer.
liquid sealer
When setting 4th through 2nd bushings on replacer bar,

tape the bar to prevent movement.
SEM9998
EM-94
ENGINE OVERHAUL - Inspection ..and Rep_la_c_e_m_e_n_t I_T_o_1
CAMSHAFT ALIGNMENT
1. Check camshaft journal and cam surface for bend, wear or
damage.
If fault is b~yond limit, replace.
2. Check camshaft bend at center journal.
If bend is greater than specified limit, repair or replace
camshaft.
Camshaft bend
Standard
SEM670B Less than 0.02 mm (0.0008 in)
Limit
3. Measure camshaft end play between locating plate and

gear. If beyondJhe specified limit, replace camshaft locat-
ing plate.
CCimshCiftefid play:
Standard
0.08 - 0.28 mm (0.0031 - 0.0110 in)
Limit
4. Measure cillTl~haftcam height. If beyond the specified limit,

replace camshaft.
OJ cam
height
Cam height:
Standard
Intake
41.733 mm (1.6430 in)
Exhaust
41.900 mm (1.6496 in)
Limit
Intake
SEM037 Less than 41.20 mm (1.6220 in)
Exhaust
EM-95
ENGINE OVERHAUL - Assembly ----1 T_o_1
Leaf type PISTON

combustion
chamber
Assemble pistons, piston pins, snap rings and connecting rods.
a. Numbers are stamped on the connecting rod and cap cor-
Grade mark responding to each cylinder. Care should betaken to avoid
(Left direction) a wrong combination including bearing.
Engine
front
Matching mark
(Cylinder No.)
SEM672S
b. When inserting piston pin In connecting rod, heat piston

with a heater or hot water [approximately 60 to 70°C (140
to 158°F)]and apply engine oil to pin and small end of con-
necting rod.
c. After assembling, ascertain that piston swings smoothly.
SEM292
Install piston assembly.

CAUTION:
a. Stretch the piston rings only enough to fit them In the pis-
ton grooves.
b. Be sure the manufacturer's mark faces upward.
c. Identification of top piston ring and second piston ring.
White paint-/ Punch mark side up

identification mark (Both top and second
(2nd piston ring only) piston rings)
SEM005E
Identification Ring gap direction d. Install No.1 piston ring in such a way that its gap faces the
mark
(f027T only)
direction of the piston pin; and then install piston rings so
that their gap positioned at 180°to one another.
Top and 2nd ring

oil ring
EM-96
ENG.INE OVERHAUL - Assembly
CRANKSHAFT
1. Install crankshaft.
(1) Set main bearings in the proper position on cylinder block.
a. If either crankshaft, cylinder block Qr. main bearing is
reused again, it is necessary to measure main bearing
clearance.
b. Upper bearings have oil hole and oil groove, however
lower bearings do not.
(2) Apply engine oil to crankshaft journal and pin and install
crankshaft.
(3) Install main bearing caps.
Engine a) Install main bearing cap with the number facing the front of
front vehicle.
b) Apply engine oil to main bearing cap and cylinder block
contact surfaces.
c) Install rear oil seal assembly. Apply engine 9il to contact
surface of rear end oil seal and crankshaft.
SEM674B
(4) Install crankshaft thrust washer at the 4th journal frOm

front.
Install thrust washer so that oil groove can face crankshaft.
SEM057
(5) Tighten bearing cap bolts gradually in stages, starting from

two to. three separate stages, from center bearing and mov-
ing outward in sequence.
(6) Measure crankshaft free end play at NO.4 bearing.

Crankshaft free end play: .
Standard
0.055.0.180 mm (0.0022 • 0.0071 in)
Limit
0.4 mm (0.016 in)
If beyond the limit, replace No.4 main bearing thrust washer.
Refer to S.O.S.
EM..i97
i:NGINE OVERHAUL ~ A$sembly
::: ..• I (.. ;", '~"'",'" ",'., "f. ,.-l.; -"'~'.l
SEM063
2. Install pistons with con~ecting rods.

(1) Install them into corresponding cylinder using Tool.
• Be careflJl not tf) scratch ~ylin~r wall with connecting rod.
Engine • Apply engl~e qil to c::YH~derwfillI, piston filnd bearing.
front • The leaf ty~e f;O~bU~~i9,n ch,m~er on piston head must be
at ri~ht side of ~ngin!.
SEM453
(2) Install connecting rod bearing caps.
SEM678B
3. Measure connecting rod side clearance.

Connecting rod aiel! ch;tarance:
Standllrd
0.10 ~ 0.2~ mm (0.0039 ~ 9.0087 in)
Limit
0.22 mm (0.0087 in)
If beyond the limit, repl~ce connt,c;:ting rod ~nd/or crankshaft.
EM.98
[![]
:
GEAFl TRAIN
1. Set NO.1 piston at its top dead center.
2. Align each gear mark and install gears.
SEM665B
TIMING GEAR CASE

Installation
1. Before installing timing gear case, remove all traces of liq-
uid gasket from mating surface using a scraper.
AI~o remove traces of liquid gaSket from mating surface of
front plate.
SEM6801?
2. Apply a continuous bead of liqUid gasket to mating surface

of timing gear case.
----- Application POrtion .

ENGINE OVERHAUL - Assembly

wide.
• Attach timing gear case .to front plate within 10 minutes
Cut here after coating.
Lq ]
•
•
Wait at least 30 minutes before refilling engine coolant or
starting engine.
Use Genuine Liquid Gasket or equivalent.
Liqu id gasket
SEM683B
EM-100
SERVICEiDATAAND SPECIFICATIONS (S.D.S.)

COMPRESSION PRESSURE Valve guide
Unit: kPa (bar, kg/cm2, psi)/rpm Unit: mm (in)
Standard 2,942 (29.4, 30, 427)/200 Standard Service
Minimum 2,452 (24.5, 25, 356)/200 12.033 -

12.044
Differential limit between cylin- Valve guide outside diameter
294 (2.9, 3, 43)/200 (0.4737 -
ders
0.4742)
Valve guide inner diameter 8.00 - 8.015

CYLINDER HEAD (Finished size) (0.3150 - 0.3156)
Unit: mm (in)
12.000 -
Standard Limit Cylinder head valve guide hole 12.011
diameter (0.4724 -
Less than
Head surface distortion 0.2 (0.008) 0,4729)
0.07 (0.0028)
0.022 - 0.044
Interference fit of valve guide
(0.0009 - 0,0017)
VALVE
Unit: mm (in) Max. toler-
Standard
ance
T (Margin thickness) Stem to guide clearance
It
fa~
0.023 - 0.053
Intake (0.0009 - 0.15 (0.0059)
0.0021)
0.04 - 0.07
Exhaust (0.0016 - 0.20 (0.0079)
0.0028)
o
Intake 0.30 (0.0118)

L
SEM188
Exhaust 0.40 (0.0157)
~e T025 T027
Item
Valve spring
Valve head diameter
"0" Free length mm (in)
Painted white 52.04 (2.0488)

41.4 - 41.6 43.4 - 43.6
Intake
(1.630 - 1.638) (1.709 - 1.717) Painted yellow 52.3 (2.059)
36.9 - 37.1 37.9 - 38.1 Pressure height
Exhaust
(1.453 - 1.461) (1.492 - 1.500) mm/N (mm/kg, in/lb)
Valve length "L" 32.3/699.2 - 787.5
Painted white (32.3/71.3 - 80.3,
Intake
117 (4.61) 1.272/157.2 - 177.1)
Exhaust
31.81697.3 - 779.7
Valve stem diameter Painted yellow (31.8/71.1 - 79.5,
"d" 1.252/156.8 - 175.3)
Intake 7.962 - 7.977 (0.3135 - 0.3141) Assembled height
mm/N (mm/kg, in/lb)
Exhaust 7.945 - 7.960 (0.3128 - 0.3134)
42.3/287.3 - 330.5
Valve seat angle "u"
Standard (42.3/29.3 - 33.7,
Intake 1.665/64.6 - 74.3)
45' - 45'30'
Exhaust 42.31270.7
Limit
(42.3/27.6, 1.665/60.9)
Valve margin 'T" limit 1.0 (0.039)
Out of square mm (in) 2.0 (0.079)
Valve stem end sur-
0.2 (0.008)
face grinding limit
Intake
0.35 (0.0138)
Exhaust
EM ..101
SERVICE DATA AND SPECIFICATIONS (S.O.S.) [ill
VALVE LIFTER AND PUSH ROD CYLINDER HEAD TO VALVE DISTANCE
Standard Limit
24.960 - 24.970
Valve lifter outer diameter
(0.9827 - 0.9831)
Cylinder block valve lifter 25.000 - 25.033

hole diameter (0.9843 - 0.9855)
Valve lifter to lifter hole 0.030 - 0.073

0.20 (0.0079)
clearance (0.0012 - 0.0029)
Less than
Push rod bend (T.I.R.)* 0.5 (0.020)
0.3 (0.012)

SEM724C
Rocker shaft and rocker arm Standard Limit

Unit: mm (in) 0.20 - 0.75
Intake 1.25 (0.0492)
(0.0079 - 0.0295)
Standard Limit
0.23 - 0.77
Rocker shaft Exhaust 1.25 (0.0492)
(0.0091 - 0.0303)
19.979 - 20.00
Outer diameter (0.7866 -
0.7874)
Rocker shaft bend (T.I.R.)

o - 0.10 Less than
(0 - 0.0039) 0.30 (0.0118)
Rocker arm
20.014 - 20.035
Inner diameter (0.7880 -
0.7888)
0.014 - 0.056
Clearance between rocker arm
(0.0006 - 0.15 (0.0059)
and rocker shaft
0.0022)
EM.102
SERVICE .DATAAND SPECIFICATIONS ($.D.S.)
Inspectioni)nd Adjustment (Cont'd)
Valve seat
Unit: mm (in)
0,
SEM953C
TD25 TD27
Intake
42.535 - 42.545 44.535 - 44.545

Outer diameter "0,"
(1.6746 - 1.6750) (1.7533 - 1.7537)
Inner diameter "02" 36.4 - 36.6 (1.433 -1.441) 38.4 - 38.6 (1.512 - 1.520)
Diameter of seat "03" 39.7 - 39.9 (1.563 - 1.571) 41.7 - 41.9(1.642 - 1.650)
42.500 - 42.515 44.500 - 44.515

Cylinder head valve seat diameter
(1.6732 - 1.6738) (1.7520 - 1.7526)
Valve seat face angle "<\>" 89' - 90' 89' - 90'
Exhaust
Outer diameter "0,"
38.535 - 38.545 39.535 -.39.545

Standard
(1.5171 - 1.5175) (1.5565 - 1.5569)
38.735 - 38.745 39.735 - 39.745

0.2 (0.008) Oversize (Service)
(1.5250 - 1.5254) (1.5644 - 1.5648)
38.935 - 38.945 39,935 - 39.945

0.4 (0.016) Oversize (Service)
(1.5329 - 1.5333) (1.5722 - 1.5726)
Inner diameter "02"
31.4 - 32.1 32.4 - 33.1

Standard
(1.236 - 1.264) (1.276 - 1.303)
0.2 (0.008) Oversize (Service) 31.9-32.1 32.9 - 33.1

0.4 (0.016) Oversize (Service) (1.256 - 1.264) (1.295 - 1.303)
35.20 - 35.40 36.95 - 37.05

Diameter of seat "03"
(1.3858 - 1.3937) (1.4547 - 1.4587)
Cylinder head valve seat diameter
38.495 - 38.510 39.495 - 39.510

Standard
(1.5155 - 1.5161) (1.5549 - 1.5555)
38.695 - 38.710 39.695 - 39.710

(1.5234 -1.5240) (1.5628 - 1.5634)
38.895 - 38.910 39.895 - 39.910

(1.5313 - 1.5319) (1.5707 - 1.5713)
Valve seat face angle "<\>" 89' - 90' 89' - 90'
EM-:103
SERVICE DATA AND •SPECIFICATIONS (S.O.S.)
CAMSHAFT AND CAMSHAFT BEARING
----
Camshaft journal to
bushing clearance
[Oil clearance]
Camshaft journal
Standard
0.020 - 0.109
(0.0008 - 0.0043)
Unit: mm (in)
Limit
0.15 (0.0059)
diameter
50.721 - 50.740
Front -
(1.9969 - 1.9976)
50.521 - 50.540
2nd -
(1.9890 - 1.9898)
50.321 - 50.340
3rd -
(1.9811 -1.9819)
50.121 - 50.140
4th -
(1.9733 - 1.9740)
49.921 - 49.940
Rear -
(1.9654 - 1.9661)
Camshaft bend (Total Less than

0.06 (0.0024)
indicator reading) 0.02 (0.0008)
0.08 - 0.28
Camshaft end play 0.50 (0.0197)
(0.0031 - 0.0110)
EM671
Standard Limit
Cam height "A"
Intake 41.733 (1.6430) 41.20 (1.6220)
Exhaust 41.900 (1.6496) 41.40 (1.6299)
EM.104
$ERVICEDA,ltA ANllSPECIF1CATIONS(S.D.S.)
Insp~cti()nand Adjustment (Cont'd)
CYLINDER BLOCK AND CYLINDER LINER
Unit: mm (in)
20 (0.79)
SEM728C
TD25 TD27
Surface flatness (Without cylinder liner)
Standard Less than 0.05 (0.0020)
Limit 0.2 (0.008)
Cylinder bore of cylinder block
Inner diameter
95.900 - 95.920 99.000 - 99.020

Standard
(3.7756.3.7764) (3.8976- 3.8984)
Cylinder bore

Inner diameter
Standard
92.900 - '92.910 96.000 - 96.010

Grade NO.1
(3.6575 - 3.6579) (3.7795 - 3.7799)
92.910 - 92.920 96.010 - 96.020

Grade No.2
(3.6579 - 3.6583) (3.7799 - 3.7803)
92.920 - 92.930 96.020 - 96.030

Grade NO.3
(3.6583 - 3.6587) (3.7803 - 3.7807)
With cylinder liner for service

92.925 - 92.970 96.025 - 96.070
Inner diameter
(3.6585 - 3.6602) (3.7805 - 3.7823)
(Reference value)
Wear'limit 0.20 (0.0079)
Out-of-round (X - Y) Less than 0.070(0.0028)
Taper (A - B) Less than 0.20 (0.0079)
Projection "S" 0.02 - 0.09 (0.0008 - 0.0035)
Division of each cyli"der "S" Less than 0.05 (0.0020)
Interference fitcyli"denliner to block -{).01 to 0.03 (-{).0004 to 0.0012)
EM.105
Unit: mm (in)
....
--0---1
SEM427
TD25 TD27
Cylinder liner diam- 92.950 - 92.970 96.050 - 96.070

eter"D" (service)* (3.6594 - 3.6602) (3.7815 - 3.7823)
-Before installing in cylinder block
PISTON, PISTON RING AND PISTON PIN

Available piston
Unit: mm (in)
SEM778A
TD25 TD27
Piston skirt diameter "A"
Standard
92.840 - 92.850 95.940 - 95.950

Grade NO.1
(3.6551 - 3.6555) (3.7772 - 3.7776)
92.850 - 92.860 95.950 - 95.960

Grade No.2
(3.6555 - 3.6559) (3.7776 - 3.7779)
92.860 - 92.870 95.960 - 95.970

Grade No.3-
(3.6559 - 3.6563) (3.7779 - 3.7783)
"a" dimension 70 (2.76) 70 (2.76)
27.992 - 28.000 27.992 - 28.000

Piston pin hole diameter
(1.1020 - 1.1024) (1.1020 - 1.1024)
Piston to cylinder bore clearance
With cylinder liner for factory 0.05 - 0.09 (0.0020 - 0.0035)
With cylinder liner for service 0.09 - 0.13 (0.0035 - 0.0051)
-Grade NO.3 piston IS not provided as a service part.
EM.106
Il1spectionandAdjustment (Cont'd)
Piston ring CONNECTING ROD
------
Side clearance
Top
Standard
0.06 - 0.10
(0.0024 - 0.0039)
0.04 - 0.08
Un.it: mm (in)
Limit
0.50 (0.0197)
Center distance
Bend. torsion
[per 100 (3.94)]
Limit om5
Unit: mm (in)
156.975 - 157.025
(6.1801 - 6.1821)
(0.0030)
2nd 0.30 (0.0118)
(0.0016 - 0.0031) 27.997 - 28.005
Piston pin dia.
(1.1022 - 1.1026)
0.02 - 0.06
Oil 0.15 (0.0059)
(0.0008 - 0.0024) 28.025 - 28.038
Piston pin bore dia.
(1.1033 - 1.1039)
Ring gap
(With cylinder liner for fac- Side clearance
tory)
Standard 0.10 - 0.22 (0.0039 - 0.0087)
0.30 - 0.45
Top .. Limit 0.22 (0.0087)
(0.0118 - 0.0177)
0.20 - 0.35
TD25
(0.0079 - 0.0138) 1.5 (0.059)
2nd
0.50 - 0.65
TD27
(0.0197 - 0.0256)
0.15 - 0.35
TD25
Oil (rail (0.0059 - 0.0138)
ring) 0.30 - 0.50
TD27
(0.0118 - 0.0197)
Ring gap
(With cylinder Iimir for ser-
vice)
0.40 - 0.60
Top
(0.0157 -0.0236)
0.30 - 0.50
TD25
(0.0118 - 0.0197) 1.5 (0.059)
2nd
0.60 - 0.80
TD27
(0.0236 - 0.0315)
0.3 - 0.5
TD25
Oil (rail (0.012 - 0.020)
ring) 0.40 - 0.65
TD27
(0.0157 - 0.0256)
EM-107
CRANKSHAFT AVAILABLE MAIN BEARING
Unit: mm (in)
Bearing clearance
Unit: mm (in)
Main bearing clearance
Standard 0.035 - 0.087 (0.0014 - 0.0034)
Limit 0.15 (0.0059)
Connecting rod bearing clear-

ance
Standard 0.035 - 0.081 (0.0014 - 0.0032)
B Limit 0.15 (0.0059)
SEM100A
Main bearing undersize
----
70.907 - 70.920
Journal diameter "A" Unit: mm (in)
(2.7916 - 2.7921)
56.913 - 56.926 Crank journal diameter

Pin diameter "B"
(2.2407 - 2.2412)
Standard 70.907 - 70.920 (2.7916 - 2.7921)
Center distance "S" 46.00 (1.8110)
Undersize
Out-ot-round X - Y 0.25 (0.0098) 70.657 - 70.670 (2.7818 - 2.7823)

Taper A - B
0.50 (0.0197) 70.407 - 70.420 (2.7719 - 2.7724)
0.75 (0.0295) 70.157 - 70.170 (2.7621 - 2.7626)
1.00 (0.0394) 69.907 - 69.920 (2.7522 - 2.7528)
AVAILABLE CONNECTING ROD BEARING

Connecting rod bearing undersize
EM715 Unit: mm (in)
Taper ot journal and pin "A - B" Crank pin journal diameter
Standard 0.01 (0.0004) 56.913 - 56.926
Standard
Limit 0.02 (0.0008) (2.2407 - 2.2412)
Out-ot-round ot journal and pin Undersize

"X-Y" 56.663 - 56.676
0.25 (0.0098)
Standard 0.01 (0.0004) (2.2308 - 2.2313)
Limit 0.02 (0.0008) 56.413 - 56.426

0.50 (0.0197)
(2.2210 - 2.2215)
Crankshaft bend
56.163 - 56.176
Standard 0- 0.03 (0 - 0.0012) 0.75 (0.0295)
(2.2111 - 2.2116)
Limit 0.10 (0.0039) 55.913 - 55.926
1.00 (0.0394)
Crankshaft end play (2.2013 - 2.2018)
Standard 0.055 - 0.180 (0.0022 - 0.0071)
Limit 0.40 (0.0157)
EM-108
SERVICE DATA~~.P SPECI~ICATI0"lS(S.D.S.)
AVAILABLE THRUST WASHER MISCELLANEOUS COMPONENTS
Unit: mm (in)
Thrust washer undersize
Unit: mm (in) Gear train
Standard
- Thrust washer thickness Backlash of each gear
Limit
0.07 - 0.11 (0.0028 - 0.0043)
0.20 (0.0079)
Stamped mark A 2.275 - 2.325 (0.0896 - 0.0915) Flywheel
B 2.300 - 2.350 (0.0906 - 0.0925) Runout (Totarindicator read-

Less than 0.10 (0.0039)
ing)
C 2.325 - 2.375 (0.0915 - 0.0935)
Front plate
Oversize
Warpage limit 0.2 (0.008)
0.20 (0.0079) 2.475 - 2.525 (0.0974 • 0.0994)
0.40 (0.0157) 2.675 - 2.725 (0.1053 - 0.1073)
Tightening Torque
Engine o.uter parts Engine parts
Unit N'm kg-m ft-Ib ' Unit N'm kg-m fHb
Manifold nut/bolt Main bearing cap bolt 167 - 177 17.0 -18.0 123~ 130
Intake 13 -19 1.3 - 1.9 9 - 14 Connecting rod big end

78 - 83 8.0 - 8.5 58 - 61
nut
Exhaust 25 - 29 2.5 - 3.0 18 - 22
Crank pulley nut 294 - 324 30.,33 217 - 239
Injection pump fixing nut 20 - 25 2.0 - 2.5 14 - 18
Flywheel bolt 147 - 167 15.0 - 17.0 108,. 123
Injection pump bracket bolt (For
30 - 36 3.1~3.7 22- 27
VE type) Rear oil seal retainer
13 "19 1.3 - 1.9 9 - 14
bolt
Injection pump support bolt (For
19 - 25 1.9 - 2.5 14 - 18
VE type) , Timing gear Case
6-7 0.6 - 0.7 4.3 - 5.1
cover bolt
Injection pump bracket to support
30 - 36 3.1 - 3.7 22 - 21
bolt (For VE type) Timing gear case bolt 13 - 19 1.3-1.9 9 - 14
Injection nozzle to cylinder head 54-64 5.5 - 6.5 40 - 47 Timing gear case nut 13 - 19 1.3 - 1..9 9 - 14
Injection pump drive gear nut 59 - 6,9 6.0 - 7.0 43 - 51 Front end plate bolt 10 - 13 1.0- 1:3 7-9
Injection tube flare nut 20 - 25 2.0 - 2.5 14 - 18 , Camshaft gear bolt 44 - 49 4.5 -5;0 33-36
Spill tube with cap hut 29" 39 3.0 -4.0 22 - 29 Camshaft locating plate
4-6 0.4 - 0.6 2.9 - 4.3
bolt
Alternator bracket bolt 30 - 36 3.1-3.7 22 - 27
Idler gear shaft bolt. 25 - 35 2.6 - 3.6 19 - 26
Alternator toaQjusting bar bolt 16 - 19 1.6 - 1.9 12 - 14
Oil pump bolt 13 - 19 1.3 - 1.9 14
Alternator fixing bolt 30 - 36 3.1 - 3.7 22 - 27
Oil pan bolt 7- 9 0.1 - 0:9 5.1 - 6.5
Alternator ring connector bolt 29" 34 3.0 - 3.5 22 - 25
Oil strainer bolt 13 - 19 1.3"11.9 9.14
Alternator eye bolt 29 - 34 3.0 - 3.5 22 - 25
Oil pan drain plug 54.59 5.5 - 6.0 40-43
Starter motor to transmissiOn 39 - 44 4.0 - 4.5 29,33
Cylinder head bolt Refer to installation of cylinder head.
Dust cover bolt 13 - 19 1.3 - 1.9 9 - 14
Glow.plug 15 - 20 1.5 - 2.0 11 - 14
Idler pulley brac~etbolt 16 - 19 1.6-1.9 12 - 14
Rocker shaft bracket
Air conditioner compressor 20 - 25 2.0 - 2.5 14 - 18
bolt
bracket bolt
Rocker arm lock nut 15 - 20 1.5 - 2.0 11 • 14
M8 16-191.6-1.912-14
Rocker cover screw 1- 2 0.1 - 0.2 0.7 - 1.4
M10 30 - 36 3.1 -3.7 22 - 27
EM-t09
ENGINE COMPONENTS - Outer Parts
Timer assembly
, '~Adapter
~il pressure SWit~

Injection tube
'~'
lO@};J
~ ,";","," pump
~ 20-25
(2.0 - 2.5, ~ Oil pipe
14 - 18) ~ ~ 34 - 44 (3.5 - 4.5, 25 - 33)
~25-29
(2.5 - 3.0, 18 - 22) ~ : N.m (kg-m, ft-Ib)
SEM383E
EM-110
ENGINE COMPONENTS- Outer Parts
~ 3.6
I" - 0.'22-~3)\
Water pump
30_36
(3.1 - 3.7,
22 - 27)
~I
~ _ 0
(1.6 - 2.1,
/' '~12-15)
r:
/1" '~7J)
Fan
toJ 29 - 34
(3.0 - 3.5,
7-'
(0.7 - 0.9,
22 - 25)
5.1 - 6.5) Alternator
SEM384E
EM-111
CHECKING COMPRESSION PRESSURE (On-vehicle service)
1. Warm up engine.
2. Disconnect fuel spill tubes and fuel injection tube nuts.
3. Remove injection nozzle holder assembly using spanner
wrench.

toJ:
15 - 20 N.m
(1.5 - 2.0 kg-m, 11 - 14 ft-Ib)

• In-line type
Set control lever of injection pump at zero injection.
• Always use a fully-charged battery to obtain specified
engine revolution.
• In case of engine equipped with In-line type, depress accel-
erator pedal fUlly and crank engine.
quickly as possible.
SEM385E
Standard 2,942 (29.4, 3D, 427)
Minimum 2,452 (24.5, 25, 356)


pour a small quantity of engine oil into cylinders through
the injection nozzle holder holes and retest compression.
improperly.
• If cylinder compression In any two adjacent cylinders is
problem.
EM-112
CYLINDER HEAD
,
=/~9.11
'if (0.9 . 1.1, 6.5 . 8.01
Adjusting screw
Oi' fill" '" ~.~

I
I
Rocker cover
Push rod
Cylinder head bolt
r
~: Refer to "CYLINDER HEAD-
, .• •• ""01'''',, lO,-V,hi", S,,,.rel",
Cylinder head gasket~
Cylinder head
~ N'm (kg-m, ft-Ibl
SEM693C
EM.113
CYLINDER HEAD _. Removal (On-vehicle service)
1. Set No.1 cylinder at T.D.C. on its compression stroke.

and radiator.
3. Disconnect starter motor.
4. Disconnect propeller shaft joint.
5. Remove air cleaner and/or air duct.
6. Remove alternator adjusting bolt.
8. Disconnect radiator outlet hose and thermostat housing
water inlet hose.
9. Disconnect fuel hose.
10. Disconnect fuel spill tUbes and fuel injection tube nuts.
11. Remove injection nozzle holder and top nozzle gasket

using spanner wrench.


cylinder head.
rect order.
Engine
front
SEM697C
EM-114
CYLINDER HEAD ---Disassembly

• Intake manifold
• Alternator adjusting bar & engine slinger
3. Remove valve oil seals with Tool.

a. Remove rocker shaft lock bolt.
shaft assembly in oil of 70°C (158°F)for a few minutes and then
remove bracket.
SEM627B
EM-115
CYLINDER HEAD - l"sp_ec_t_iO_"_. 1_8_0_1
Standard
Limit
0.2 mm (0.008'in)
SEM648B

rocker arm. (Generally, a large amount of wear occurs In
this direction.)
Limit
Intake 0.15 mm (0.0059 in)
SEM586A Intake 0.30 mm (0.0118 In)
stem diameter and valve guide inner diameter.
Standard
Intake
7.962 - 7.977 mm (0.3135 - 0.3141 in)
Exhaust
7.945 - 7.960 mm (0.3128 - 0.3134 In)
8.00 - 8.015 mm (0.3150 - 0.3156 in)
EM030

tool.
EM-116
CYL.INDER HEAl) .-. Inspection [~J
KV11193900

Finished size:
8.000 .. 8.015 mm (0.3150 - 0.3156 in)
Contact width: VALVE SEATS

mm
.1 (0.083 inl
C1
Oheck valve for any evidence of pitting at valve contact surface,
O.K. • When repairing valve seats, check valve and valve guide
...
valve seat.
ON.GONG
cutting.
SEM024

1. aore out old seat until it collapses or remove valve seats
with Tool.
Place a copper seat between contact surface of Tool and cylin-
der head.
SEM722
2. Place hew valve seats on dry ice and allow them to cool for
five minutes.
WARNING:
Do not touch cooled valve seats with bare hands.
3. Heat cylinder head to 80°0 (176°F).
EM-117
CYLINDER HEAD - I"Sp_.eC_I_io_" I_B_D_1
5 places 5. Stake exhaust valve seat at five places with punch.

staked before.


it
fa~ o
S.O.S.
When valve head has been worn down to 0.5 mm (O.020 in) in
Grinding allowance for valve stem tip is 0.2 mm (O.OOBin) or
less.

s Out-of-square "S":
SEM635B

Refer to S.O.S.
EM113
EM-118
CYLINDER HEAD 4..IASp_e_c_ti_O_A I_B_D_'
aOCI<;ER SHAFT AND ROCKER ARM


rockers or shafts.
Limit
Standard
19.979.20.000 mm (0.7866 - 0.7874 in)
Rocker arm inner diameter "B":
SEM027 Standard
20.014 - 20.035 mm (0.7880 - 0.7888 in)
EM-119
CVLINDER HEAD - Inspection
3. Check rock.er shaft bend at its center. If bend is within

specified limit, s.traighten it; and if it is greater than speci-
Rocker shaft bend
Li.mit
less than 0.3 mm (0.012 in)
SI;M028

valve(s)!or valve se.at(s).
Specified distance:
Standard
Intake
~ 0.275 • 0.675 mm
)
00 (0.0108 • 0.026.6 in)
Exhaust
o~ 0..305 • 0.695 mm
(0.0120 • 0.0274 in)
Li.mit
Less tban 1.25 mm (0.0492 in)
fo.r intake and exhaust valves
CYLINDERHEAD-Assembly
• Identification of rocker arms

Identification mark
For use with
(on rocker arm)
B Intake
C Exhaust
SEM700C

• Alw;,lYs use rtew valve oil seal. (Refer to Oil SEAL
REPLACEMENT.)
Wide pitch • Install valve spring (uneven pitch type) with its narrow pitch
side toward cyfinder head side.
Narrow pitch
•
Cylinder head side SEM63aB
E1W-1'21
CYLINDER HEAD- Installation (On-vehicle service)

a. When replacing only cylinder head gasket, install same
grade gasket as the one formerly used.
b. When replacing or repairing cylinder block, cylinder head,
piston, connecting rod and crankshaft, select gasket as fol-
Engine
lows:
front
SEM701C
(1) Measure piston projection.

• Set each piston at its Top Dead Center. With piston held in
that position, measure its projections at two points.
• Calculate the average value of the two measurements.
• Determine the amount of projection of the other three pis-
tons.
(2) Select suitable cylinder head gasket which conforms to the
largest amount of projection of the four pistons.
Unit: mm (in)
/'----, Engine
~ front Average values piston Gasket thickness
SEM702C Gasket grade number
projections (nominal dimension)
Less than 0.44 (0.0173) 1.35 (0.0531) 1
0.44 - 0.49 (0.0173 -

1.40 (0.0551) 2
0.0193)
More than 0.49 (0.0193) 1.45 (0.0571) 3
Make sure that No.1 piston is at T.D.C. on its compression

stroke.

• Cylinder head identification mark
Engine
Identification number
front (on cylinder head)
Float mark Punch mark
82
I
SEM698C
EM-122
CYLINDER HEAD - Installation (On-vehicle service)
CAUTION:
Engine
front
1st Tightening bolts to 39 - 44 N.m
(4.0 - 4.5 kg-m, 29 - 33 ft-Ib)
2nd Tightening bolts to 54 - 59 N.m
(5.5 - 6.0 kg-m, 40 - 43 ft-Ib)
3rd (1) Mark exhaust side of cylinder head and cylin-
der head bolts with paint.
Tighten in numerical order. SEM703C (2) Turn all bolts 90::l:10 degrees clockwise.
(3) Check that the paint mark on each bolt is fac-
Ing the front of the vehicle.

Rocker shaft bracket bolt:
~: 20-25 N.m
(2.0 - 2.5 kg-m, 14 - 18 ft-Ib)
6. Install rocker cover with rocker cover gasket.
SEM705C
7. Install new top nozzle gasket and injection nozzle holder

assembly.
Injection nozzle holder:
~: 44 - 49 N.m
(4.5 - 5.0 kg-m, 33 - 36 ft-Ib)
EM-123
CYLINDER HEAD -. Installation (On-vehicle service)
8. Connect the spill tubes.

Glow plug:
~: 15 - 20 N'm (1.5 - 2.0 kg-m, 11 - 14 ft-Ib)
9. Install spill tube and injection tube.

Spill tUbe fixing nut:
~: 29 - 39 N'm
(3.0 - 4.0 kg-m, 22 - 29 ft-Ib)
Injection tube flared nut:
~: 20 - 25 N'm
(2.0 - 2.5 kg-m, 14 - 18 ft-Ib)
10. Connect thermostat housing water inlet hose and radiator

hose.
11. After assembling all disassembled parts, fill radiator and
EM-124
OIL SEAL >REPLACEMENT. (On.\t$hicleservICe)
OIL SEALINSTALUNGDIR;ECTIO:N
• When installing a newfrQnt arrear-seal, make sCIre its
mounting directianiscorrect.
Engine ~ Engine
inside .,. outside
Oil seal lip Dust seal lip
SEM715A
CRANKSHAFT FRONT OIL SEAL

5. Remove gear case cover.
6. Remove crankshaft oil seal.
7. Coat new oil seal with engine aHand tnstaH it in p;lace.
SEM709C
CRANKSHAFT REAR OIL SEAL

2. Remove clutch cover assembly ..
3. Remove flywheel and rear plate ..
5. Remove oil seal retainer assembly, then remove oil seal.
6. Coat new oil seal with engine oU and 1nstallit 1nplace.
SEM217B
VALVE STEM OIL SEAL

KV10107900
EM-125
OIL SEAL ..REPLACEMENT (On-vehicle service)
5. Apply engine oil to valve oil seal and install it in place.
/
Cylinder head or spring seat
SEM565E
EM-126
ENGINE REMOVAL
~43-55 \
(4.4 - 5,6,:;(32- 41) .•
/~ 25 -32
r .. X~ 25 -32 / ~ (2.6 - 3.3, 19 - 24)
, .. . ~\ \. (2.6 - 3.3, 19 - 24)
~~
;/~;~r~
~
I~X
,
.
~43-55
(4.4 _ 5.6, 32 _ 41)~
(~p
<-_~
'~~
'"V ~
~
~;
~
..
,
~
--- 0
32 - 41J
k 0 /.0
'"
\ ~~ ;:.; ~.6,32 - 41J
~25-32 a
(2.6 - 3.3, 19 - 24) @
~25-32
(2.6 - 3.3, 19 -24) 7
SEM389E
EM-127
ENGINE REMOVAL
WARNING:
b.Place chocks at front and back of rear wheels.
c. Do not remove engine until exhaust system has completely cooled off.
Otherwise, you may burn yourself and/or fire may break out in fuel line.
d. For safety during subsequent steps, the tension of wires should be slackened against the engine.
e. Before disconnecting fuel hose, release fuel pressure from fuel line.
f. Be sure to hoist engine and transmission in a safe manner.
g. For engines not eqUipped with engine slingers, attach proper slingers and bolts described in PARTS
CATALOG.
CAUTION:
• When lifting engine, be careful not to strike adjacent parts, especially accelerator wire casing, brake
lines, and brake master cylinder.
• In hoisting the engine, always use engine slingers in a safe manner.
Removal
1. Remove battery ground cable.
2. Drain cooling water from engine and radiator.
3. Tilt and lock the cab.
4. Remove front exhaust tube assembly.
6. Remove radiator assembly.
7. Remove alternator assembly.
8. Remove air compressor and secure it to vehicle body using
wire. (Do not remove piping from air compressor.)
9. Remove upper bolts from clutch housing.
10. Support transmission using a jack.
11. Support engine using a jack.
12. Remove nuts securing engine mount insulator to frame
bracket.
13. Remove engine assembly.
EM-128
ENGINE OVERHAUL
Oil pump
,'~ "- ~~} A4-6 (0.4-0.6,2.9-4.3)

"> ~ "-- Piston ring
~~ ~ ~~
Lrr
~
Camshaft gear
A 13 - 19 ~ Connecting rod
(1.3 - 1.9, 9 - 14) Snap ring ~ •
Timing gear case ~

Mating surface to timing Piston pin
l
gear case and front plate. Con~ecting rod
A 78 - 83 beanng
Front oil seal ~ (8.0 - 8.5, 58 - 61) ~
. case cover
Timing gear Oil jet _~ ~
A7-9 ~
(0.7 - 0.9, A 29 - 39
5.1 - 6.5) (3.0 - 4.0,
22 - 29)
Crankshaft
~C>:.:.,~.~. N ~
(30 - 33, ~
217 - 239)
Thrust washer
A 167 -In
(17.0 - 18.0,
123 - 130)
Main bearing
Oil pan
(DJ7-9
(0.7 ';0.9,
5.1-6.5)~ 0
N.m (kg-m, ft-Ib)
Apply recommended sealant
(Nissan genuine part: ~
KP610-00250) or equivalent.
*1 : Keep in correct order. ~~A54-59
(5.5 - 6.0, 40 - 43)
SEM387E
EM-129

5. Remove thermostat housing.
6. Remove alternator.
8. Remove oil pan.
SEM711C
Method B 9. Remove crank pulley.

(Using a wooden
Iblock)
Method A
(Using Tooll
______ KV111033S0
10. Remove timing gear cover.
SEM712C

SEM713C
If the timing case is hard to remove due to liquid gasket, pry it

off with a suitable tool at the cutout section.
SEM676B
EM-130
ENGINE OVERHAUL - .. Disassembly
13. Remove timer round. nut and spring washer using socket
wrench (DK57914010).
Refer to "Removal of INJECTION PUMP" in EF & EC sec-
tion.
14. Remove timer assembly using timer puller (KV11226582).

16. Remove camshaft gear, camshaft and valve lifters.
SEM655B
17. Remove oil pump assembly.

20. Remove connecting rod caps.
21. Remove pistons.
EM-131
ENGINE OVERHAUL -Disassembly
22. Remove rear oil seal retainer.
23. Remove bearing cap and crankshaft.

Place the bearings and caps in their proper order.
EM-132
ENGINE OVERHAUL ....-Inspection and.' Rep_18_c_e_rn_e_n_I l_B_D_1
~~Qtt
---: Measuring point
Standard
~ Less than 0.05 mm (0.0020 in)
Limit
0.2 mm (0.008 in)
~-(
~(~ SEM038
EB
,
~~Y
X
r~
eo
g
Itl
~
CYLINDER
1.
LINER WEAR
Measure cylinder liner bore for out-of-round and taper with
a bore gauge. /f beyond the limit, replace cylinder liner.
I
r
r
r
...
Inside diameter (With cylinder liner for factory):
\ \ 96.000 - 96.030 mm (3.7795 - 3.7807 in)
Inside diameter (With cylinder liner for service):
96.025 - 96.070 mm (3.7805 - 3.7823 in)
Refer to S.O.S.
Wear timit:
Unit: mm (in) 0.20 mm (0.0079 in)
SEM715C Out-of-round (X - V) Itmit:
0.070 mm (0.0028 in)
0.20 mm (0.0079 in)
cylinder liner.

Standard
0.02 - 0.09 mm
(0.0008 - 0.0035 in)
, Less than 0.05 mm (0.0020 in)
CYLINDER LINER
Replacement
1. Remove cylinder liner with Toot.
;'
\ . :
\ J'.'
--
't::
~ SEM849
EM-133
ENGINE OVERHAUL - Inspection and Rep_18_c_e_m_e_n_t I_B_D_1

SEM659B

Method A (Using micrometer)
Refer to S.O.S.
72.5 mm (2.854 In)
Piston clearance:
SEM660B
0.04 - 0.06 mm (0.0016 - 0.0024 in)
0.06 - 0.12 mm (0.0024 - 0.0047 in)

Check clearance between pistons and piston pins.
Clearance (B - A):
Standard
-0.003 to 0.012 mm (-0.0001 to 0.0005 in)
Limit
SEM424
EM-134
ENGINE OVERHAUL - .lnspection ...andRep_la_c_e_m_e_n_t 1_8_0_'
PISTON RING GAP

Install piston rings in grooves on cylinder liner within a range
of 20 mm (0.79 in), as shown, before measuring piston ring
gaps.
Ring gap (With cylinder liner for factory):
Top ring
0.30.0.45 mm (0.0118 • 0.0177 in)
til ~ 2nd ring
Cylinder liner' e 0.20.0.35 mm (0.0079 • 0.0138 in)
Unit: mm (in) Oil ring
SEM388E 0.30.0.50 mm (0.0118 • 0.0197 in)
1.5 mm(O.059 in)
Ring gap (With cylinder liner for service):
Top ring
0.40 • 0.60 mm (0.0157 • 0.0236 in)
2nd ring
0.30 • 0.50 mm (0.0118 • 0.0197 in)
Oil ring
0.40 • 0.65 mm (0.0157.0.0256 in)
1.5 mm (0.059 in)

Standard
0.035 .0.087 mm (0.0014 • 0.0034 In)
Limit
Less than 0.15 mm (O.00~9In)
EM ..135
1. Install main bearings to cylinder block and main bearing

cap.
Tighten all bolts in correct order and in two or three stages.
rPJ: 167 - 177 N'm
(17.0 - 18.0 kg-m, 123 - 130 ft-Ib)
3. Measure inside diameter "A" of main bearing.
4. Measure outside diameter "Om" of main journal in crank-

shaft.
SEM413B

CONNECTING ROD BEARING CLEARANCE

Connecting rod bearing clearance:
Standard
0.035 - 0.081 mm
(0.0014 - 0.0032 in)
Limit
nuts.
rPJ: 78 - 83 N'm
(8.0 - 8.5 kg-m, 58 - 61 ft-Ib)
3. Measure inside diameter "A" of bearing.

shaft.
SEM507A
EM-136
ENGINE OVERHAUL _. Inspection and Replacement

Bend and torsion:
Limit
0.075 mm (0.0030 In)
EM133

1. Measure inside diameter "A" of connectipg rod small end
bushings.
SEM781B
2. Measure outside diameter "0" of piston pin.

Connecting rod small end bushing clearance = A - 0
BU$hlng clearance:
Standard
0.025 - 0.045 mm (0.0010 - 0.0018 In)
Limit
0.15 mm (0.0059 in)
REPLACEMENT .OF CONNECTING ROD SMALL END

BUS.HING
surface of the rod.
Small end bushing inside diameter (Finished size):
30.025 - 30.038 mm (1.1821 - 1.1826 In)
SEM062A
Out-of-round X - Y CRANKSHAFT
Taper A - B
Check crankshaft journals and pins for score, bias, wear or
A B
Check journals and pins with a micrometer for taper and
out-of-round.
Standard
Less than O.Otmm (0.Q004 in)
Limit
0.02 mm (0.0008 In)
EM715
EM.137
ENGINE OVERHAUL - Inspection and Rep_la_c_e_m_e_n_t I_B_O_'
Taper (A - B):
Standard
Limit
0.02 mm (0.0008 in)
3. Check crankshaft runout.

Runout [T.I.R. (Total indicator Reading)]:
Standard
o • 0.03 mm (0 - 0.0012 in)
Limit
0.10 mm (0.0039 in)
SEM6628
RESURFACING OF CRANKSHAFT JOURNAL AND

CRANK PIN
When using undersize main bearings and connecting rod
bearings, the crankshaft journals or crank pins must be finished
LLLL
O.K. N.G. N.G. N.G.
to match the bearings.
R:
Crank journal
3.0 mm (0.118 in)
Crank pin
3.5 mm (0.138 in)
SEF692A, CAUTION:
• At the same time make sure that the surface width does not
increase.
• Do not attempt to cut counterweight of crankshaft.
CRANKSHAFT PILOT BUSHING

Crankshaft pilot bushing replacement
1. Pull out bushing with Tool.
EM-138
ENGINE OVERHAUL - Inspection and Rep_la_c_e_m_e_n_t .I_B_D_'
5.8 - 6.0 mm 2. Insert pilot bushing until distance between flange end and
(0,228 - 0.236 in) bushing is specified value.
Distance:
Approx. 5.8 • 6.0 mm (0.228 • 0.236 In)
Pilot bushing
SEM089
FLYWHEEL RUNOUT
Runout(Total indicator reading}:
SEM059A
FRONT PLATE
Warpage limit:
0.2 mm (0.008 in)
GEAR TRAIN
Camshaft. drive gear, injection pump drive gear, oi.1
pump gear, icller gear and crankshaft gear
worn, replace gea,r and key.
assembling.
If beyond the limit, replace gear.
Backlash:
Standard
0.06 - 0.12 mm (0.0024 • 0.0047 in)
Limit
0.20 mm (0.0079 in)
EM;'139
ENGINE OVERHAUL - Inspection and Rep_la_c_e_m_e_n_t I_B_O_I

SEM6668

3. Calculate idler gear bushing clearance.
Standard
0.025 - 0.061 mm (O.0010 - 0.0024 in)
Limit
0.20 mm (O.0079 in)
SEM705
IDLER GEAR END PLAY

Standard
0.03 - 0.14 mm (O.0012 - 0.0055 in)
Limit
Idler gear shaft bolt:
toJ:
25 - 35 N'm
(2.6 - 3.6 kg-m, 19 - 26 ft-Ib)

Finished size:
42.00 - 42.02 mm (1.6535 - 1.6543 in)
Idler gear shaft

Standard
0.020 - 0.109 mm
(O.0008 - 0.0043 in)
Limit
SEM6698 Less than 0.15 mm (O.0059 in)
EM-140
ENGINE OVERHAUL --Jnspectionand Replacement

1. Using Tool, remove camshaft bushings from the engine.
Some bushings must be broken in order to remove.
SEM106C
Carn bushing replacer set 2. Using Tool, install camshaft bushings as follows:
KV111045S0
I
Adapter
(1st bushing)
f ~ 0""
ST15243000
KV11104530
SEM993B
(1) Install camshaft bushings in the order of "rear", "4th",

"3rd", "2nd" and "front". All bushings must be installed
from the front.
(2) Face the cutout upward and toWard the front of the engine
during installation.
Q
Engine
front
SEM686B

a) Align the cutout of rear bushing with knock pin of replacer
SEM995B
b) Insert rear bushing with replacer bar into the engine.

Install gUide plate with bolt holes (on the "TD" mark side)
facing upper side of cylinder block. Tighten bolts.
EM.141
c) Drive replacer bar until the alignment mark on replacer bar

Alignment mark to
@ surface
Knock pin
Replacer bar
Engine
front
SEM601C
(4) 4th, 3rd and 2nd camshaft bushings

Install in the same manner as rear camshaft bushing.
Alignment mark to
@ surface
Engine
front
Q
Alignment mark to
@ surface
SEM602C
EM-142

so that oil hole in cylinder block is aligned with oil hole in
bushing.
4. Install new welch plug with a drift.

Liquid sealer
When setting 4th through 2nd bushings on replacer bar,

tape the bar to prevent movement.
SEM999B
EM-143
ENGINE OVERHAUL - Inspection and Rep_la_c_e_m_e_n_t '_8_0_'
CAMSHAFT ALIGNMENT
damage.
If fault is beyond limit, replace.
camshaft.
Camshaft bend
Standard
SEM670B Less than 0.02 mm (0.0008 in)
Limit

gear. If beyond the specified limit, replace camshaft locat-
ing plate.
Camshaft end play:
Standard
0.08 • 0.28 mm (0.0031 .0.0110 in)
Limit
SEM671B
4. Measure camshaft cam height. If beyond the specified limit,

replace camshaft.
~~m
~U1i9ht
Cam height:
Standard
17 mm (0.67 in) Intake
41.733 mm (1.6430 in)
Exhaust
41.900 mm (1.6496 in)
Limit
Intake
SEM716C Less than 41.20 mm (1.6220 in)
Exhaust
SEM717C
EM-144
ENGINE.QVERHAUL - Asseml)ly
Grade mark PISTON

Assemole pistons, piston pins, snap rings and connecting rods.
Engine a. Numbers are stamped on the connecting rod and cap cor-
front respondingto.each cylinder. Care should be taken to avoid
.C::? a wrong combination including bearing.
Matching mark
(cylinder No.)
SEM718C
b. When inserting piston pin in connecting rod, heat piston

with a heater or hot water [approximately 60 to 70°C (140
to 158°F)]and apply engine oil to pin and small end of con-
necting rod.
c. After assembling, ascertain that piston swings srnoothly.
SEM292
Install .piston assembly.

CAUTION:
a. Stretch thepist<)n rings only enough to fit them in the pis-
ton groovea.
b. Be sure the manufacturer's mark faces upward.
c. Identification of top piston ring and second piston ring.
White paint Punchmark side up

identification mark (Both top and second
(2nd piston ring only) piston rings)
SEM005E
d. Install No. 1 piston ring in such a way that its gap faces the
BD identification direction of the piston pin; and then install piston rings so
mark
that their gap positioned at 180°to one another.
Top and
oil ring
2nd ring
Engine
front
Piston grade number
SEM719C
ENGINE OVERHAUL- Assembly
CRANKSHAFT
1. Install crankshaft.
a. If either crankshaft, cylinder block or main bearing is
clearance.
crankshaft.
(3) Install main bearing caps.
Engine a) Install main bearing cap with the number facing the front of
front
vehicle.
y b) Apply engine oil to main bearing cap and cylinder block
contact surfaces.
c) Install rear oil seal assembly. Apply engine oil to contact
surface of rear end oil seal and crankshaft.
SEM674B
(4) Install crankshaft thrust washer at the 4th journal from

front.
Install thrust washer so that oil groove can face crankshaft.

two to three separate stages, from center bearing and mov-
Main bearing cap bolt:
~: 167 - 177 N.m
(17.0 - 18.0 kg-m, 123 - 130 ft-Ib)
Tighten in numerical order. SEM675B

Crankshaft free end play:
Standard
0.055 - 0.180 mm (0.0022 - 0.0071 in)
Limit
0.4 mm (0.016 in)
Refer to S.O.S.
EM-146
ENGINE OVERHAUL --- Assembly
SEM063

• Be careful not to scratch cylinder wall with connecting rod.
Engine
front • Apply engine oil to cylinder wall, piston and bearing.
• The leaf type combustion chamber on piston head must be
r:::? at right side of engine.

Connecting rod bearing nut:
toJ:78 - 83 N'm
(8.0 .. 8.5 kg-m, 58 - 61 ft-Ib)
SEM678B

Standard
0.10 - 0.22 mm (0.0039 - 0.0087 in)
Limit
0.22 mm (0.0087. ill)
If beyond the limit, replace connecti",g rod and/or crankshaft.
EM-147
ENGINE OVERHAUL - Assembly
GEAR TRAIN
Injection pump gear
(Z = 104) 1. Set NO.1 piston at its top dead center.
SEM321C
TIMING GEAR CASE

Installation
1. Before installing timing gear case, remove all traces of liq-
uid gasket from mating surface using a scraper.
Also remove traces of liquid gasket from mating surface of
front plate.
SEM680B

Tube presser of timing gear case.
WS39930000
SEM681B
----- Application portion SEM682B
EM-148
ENGINE OVERIi.AUl..-..As!temi;)ly

wide.
• Attach liming gear case to front plate within 5 minutes after
Cut here
~
...•••..•...•
J
l..iQuid gasket
•
•
coaling.
Wait at least 30 minutes before refilling engine coolant or
starting engine.
Use Genuine Liquid Gasket or equivalent.
SEM683B
EM-149

COMPRESSION PRESSURE Valve guide
Standard
Minimum
Differential limit between cylin-

ders
2,942 (29.4, 30, 427)/200
2,452 (24.5, 25, 356)/200
294 (2.9, 3, 43)/200

--------
Valve guide outside
diameter
Valve guide inner

Standard
12.033 - 12.044
(0.4737 - 0.4742)
Service
8.00 - 8.015
diameter
(0.3150 - 0.3156)
(Finished size)
CYLINDER HEAD
Cylinder head valve 12.00 - 12.011
Unit: mm (in) -
guide hole diameter (0.4724 - 0.4729)
----
Standard Limit Interference fit of 0.022 - 0.044
Less than valve guide (0.0009 - 0.0017)
Head surface distortion 0.2 (0.008)
0.07 (0.0028) Standard Max. tolerance
Stem to guide clear-

VALVE ance
Unit: mm (in) 0.023 - 0.053

Intake 0.15 (0.0059)
(0.0009 - 0.0021)
T (Margin thickness)
0.04 - 0.D7
Exhaust 0.20 (0.0079)
it (0.0016 - 0.0028)
f.~ o
Intake
Exhaust
Valve spring
0.30 (0.0118)
0.40 (0.0157)
Valve head diameter "0"
Intake
l
SEM1BB
43.4 - 43.6 (1.709 - 1.717)

-------
Free length
Painted red
Pressure height
mm (in)
Standard
53.4 (2.102)
Limit
Exhaust 37.9 - 38.1 (1.492 - 1.500) mm/N (mm/kg, in/lb)
Valve length "L" 31.8/751.2 72.8/311.9

Painted red (31.8/76.6, (72.8/31.8,
Intake 1.252/168.9) 2.866/70.1 )
117 (4.61)
Exhaust Out-of-square mm (in) 2.0 (0.079)
Valve stem diameter "d"
Intake 7.962 - 7.977 (0.3135 - 0.3141)
Exhaust 7.945 - 7.960 (0.3128 - 0.3134)
Valve seat angle "u"
Intake
45" - 45"30'
Exhaust
Valve margin "T" limit 1.0 (0.039)
Valve stem end surface grinding

0.2 (0.008)
limit
Intake
0.35 (0.0138)
Exhaust
EM-150
SERVICE DATA AND SPECIFICATIONS (S..D.S.)
VALVE LIFTER AND PUSH ROD Valve seat
-------
Valve lifter outer
diameter
Cylinder block valve

Standard
24.960 - 24.970
(0.9827 - 0.9831)
25.000 - 25.033
Limit
-
lifter hole diameter (0.9843 - 0.9855)
Valve lifter to lifter 0.030 - 0.073

0.20 (0.0079)
hole clearance (0.0012 - 0.0029)
D2
Push rod bend Less than
0.5 (0.020)
(T.I.R.)* 0.3 (0.012)

SEM953C
Rocker shaft and rocker arm Intake
-----
Rocker shaft
Outer diameter
Rocker shaft bend

Standard
19.979 - 20.00
(0.7866 - 0.7874)
0-0.10
Unit: mm (in)
Limit
Less than
Outer diameter "D,"
Inner diameter "D2"
Diameter of seat "D3"

44.535 - 44.545
(1.7533 - 1.7537)
38.4 - 38.6
(1.512 - 1.520)
41.7 - 41.9
(1.642 - 1.650)
44.500 - 44.515
(T.I.R.) (0 - 0.0039) 0.30 (0.0118) Cylinder head valve seat diameter
(1.7520 - 1.7526)
Rocker arm
Valve seat face angle "<I>" 89. - 91.
20.014 - 20.035
Inner diameter - Exhaust
(0.7880 - 0.7888)
39.535 - 39.545
Clearance between Standard
0.014 - 0.056 (1.5565 - 1.5569)
rocker arm and rocker 0.15 (0.0059)
(0.0006 - 0.0022)
shaft Outer diameter 0.2 (0.008) Over- 39.735 - 39.745
"D," size (Service) (1.5644 - 1.5648)
0.4 (0.016) Over- 39.935 - 39.945

CYLINDER HEAD TO VALVE DISTANCE
size (Service) (1.5722 - 1.5726)
Unit: mm (in)
32.9 - 33.1
Standard Limit Inner diameter "D2"
(1.295 - 1.303)
0.275 - 0.675 36.95 - 37.05
Intake 1.25 (0.0492) Diameter of seat "D3"
(0.0108 - 0.0266) (1.4547 - 1.4587)
0.305 - 0.695 39.495 - 39.510
Exhaust 1.25 (0.0492) Standard
(0.0120 - 0.0274) (1.5549 - Hi555)
Cylinder head
0.2 (0.008) Over- 39.695 - 39.710
valve seat diame-
size (1.5628 - 1.5634)
ter
0.4 (0.016) Over- 39.895 - 39.910
size (1.5707 - 1.5713)
Valve seat face angle "<1>" 89. - 90.
EM-151
SERVICE DATA AND SPECIFICATIONS (S.O.S.) [![]
Inspection an.dAdjustment (Conl'd)
CAMSHAFT AND CAMSHAFT BEARING CYLINDER BLOCK AND CYLINDER LINER
-------
Camshaft journal to
bushing clearance
[Oil clearance]
Standard
0.020 - 0.109
(0.0008 - 0.0043)
Limit
0.15 (0.0059)
20 (0.79)
Camshaft journal
diameter
50.721 - 50.740
Front -
(1.9969 - 1.9976)
50.521 - 50.540
2nd -
(1.9890 - 1.9898)
SO.321 - 50.340
3rd -
(1.9811 - 1.9819)
SEM721C
SO.121 - 50.140
4th -
(1.9733 - 1.9740) Surface flatness
49.921 - 49.940 (Without cylinder liner)
Rear
(1.9654 - 1.9661)
- Standard Less than 0.05 (0.0020)
Camshaft bend (Total Less than Limit 0.2 (0.008)

0.06 (0.0024)
indicator reading) 0.02 (0.0008) Cylinder bore of cylinder block
0.08 - 0.28 Inner diameter

Camshaft end play O.SO(0.0197)
(0.0031 - 0.0110) 99.000 - 99.020
Standard
(3.8976 - 3.8984)
Cylinder bore
Inner diameter
Standard
96.000 - 96.010
Grade No.1
(3.7795 - 3.7799)
96.010 - 96.020
Grade NO.2
(3.7799 - 3.7803)
EM671 96.020 - 96.030
Grade No.3
(3.7803 - 3.7807)
Standard Limit
Camheight "A" 96.025 - 96.070
Inner diameter
(3.7805 - 3.7823)
Intake 41.733 (1.6430) 41.20 (1.6220) (Reference value)
Exhaust 41.900 (1.6496) 41.40 (1.6299) Wear limit 0.20 (0.0079)

Out-of~round
Less than 0.070 (0.0028)
(X - Y)
Taper (A -8) Less than 0.20 (0.0079)

Projection "S" 0.02 - 0.09 (0.0008 - 0.0035)
Division of each cylinder "S" Less than 0.05 (0.0020)
Interference fit cylinder liner to -0.01 to 0.03
block (-0.0004 to 0.0012)
EM ..152
SERVICE OAT A AND SPECIFICATIONS (S.D.S.)
_________________ U_n_it_: m_m__ (i_n) Piston ring
------
Unit: mm (in)
Standard Limit
Side clearance
0.06 - 0.10
Top 0.50 (0.0197)
(0.0024 - 0.0039)
0.04 - 0.08
2nd 0.30 (0.0118)
(0.0016 - 0.0031)
......
--0-- ..
0.02 - 0.06
Oil 0.15 (0.0059)
(0.0008 - 0.0024)
Ring gap
(With cylinder liner for
factory)
0.30 - 0.45
SEM427 Top
(0.0118 • 0.0177)
Cylinder liner diameter "0"
96.050 - 96.070 (3.7815 - 3.7823) 0.20.0 ..35
(service)** 2nd
(0.0079 - 0.0138)
**Before installing in cylinder block
0.15-0.35
Oil (rail ring)
(0.0059 - 0.0138)
PISTON, PISTON RING AND PISTON PIN Limit 1.5 (0.059) 1.5 (0.059)
Available .piston Ring gap

(With cylinder liner for
Unit: mm (in)
service)
0.40 - 0.60
Top
(0.0157 - 0.0236)
0.30 - 0.50
2nd
(0.0118 - 0.0197)
0.30.0.50
Oil (rail ring)
(0.0118 - 0.0197)
Piston Pin
Unit: mm (in)
---- .
8030
29.993. - 30.000
Piston pin outer diameter
(1.1808 -1.1811)
Piston pin to piston -0.003 to 0.012

SEM778A
clearance (-0.0001 to 0.0005)
Piston pin to connecting
Standard rod clearance
Grade No.1
95.950 - 95.960 (3.7776 - Standard
0.025 - 0.045
3.7719) (0.0010 - 0.0018)
Grade .No. 2
95.960 - 95.970 (3.7779 - Limit 0.15 (0.0059)
3.7783)
95.970 - 95.980 (3.7183 -

Grade No. 3*
3.7787)
"a" dimension 72.5 (2.854)

29.997 -30.005 (1.1810 -
1.1813)
Piston to cylinder bore clearance
With cylinder liner for factory 0.04 - 0.06 (0.0016 - 0.0024)
With cylinder liner for service 0.06 - 0.12 (0.0024 .0.0047)
~Grade No. 3 piston is not provided as a service part
EM-t53
CONNECTING ROD AVAILABLE MAIN BEARING
Unit: mm (in)
Bearing clearance
156.975 - 157.025 (6.1801 -
Center distance Unit: mm (in)
6.1821)
Bend. torsion Main bearing clearance

[per 100 (3.94)] Standard 0.035 - 0.087 (0.0014 - 0.0034)
Limit 0.075 (0.0030) Limit 0.15 (0.0059)
30.025 - 30.038 (1.1821 - Connecting rod bearing clear-
Piston pin bore dia.
1.1826) ance
Side clearance Standard 0.035 - 0.081 (0.0014 - 0.0032)
Standard 0.10 - 0.22 (0.0039 - 0.0087) Limit 0.15 (0.0059)
.
Limit 0.22 (0.0087)

Main bearing undersize
-------
Unit: mm (in)
CRANKSHAFT
Unit: mm (in) Crank journal diameter
70.907 - 70.920
Standard
(2.7916 - 2.7921)
Undersize
70.657 - 70.670
0.25 (0.0098)
(2.7818 - 2.7823)
s
70.407 - 70.420
0.50 (0.0197)
(2.7719 - 2.7724)
70.157 -70.170
B 0.75 (0.0295)
(2.7621 - 2.7626)
SEM100A
69.907 - 69.920
70.907 - 70.920 1.00 (0.0394)
Journal diameter "A" (2.7522 - 2.7528)
(2.7916 - 2.7921)
56.913 - 56.962
Pin diameter "B"
(2.2407 - 2.2426)
Center distance "S" 51.00 (2.0079) Connecting rod bearing undersize
Unit: mm (in)
Out-of-round X- Y
Taper A - B Crank pin journal diameter
56.913 - 56.926
Standard
(2.2407 - 2.2412)
Undersize
56.663 - 56.676
0.25 (0.0098)
(2.2308 - 2.2313)
56.413 - 56.676
EM715
0.50 (0.0197)
(2.2210 - 2.2313)
Taper of journal and pin "A - B" 56.163 - 56.176
0.75 (0.0295)
Standard (2.2111 - 2.2116)
0.01 (0.0004)
Limit 0.02 (0.0008) 55.913 - 55.926

1.00 (0.0394)
(2.2013 - 2.2018)
Out-of-round of journal and pin
"x- Y"
Standard 0.01 (0.0004)
Limit 0.02 (0.0008)
Crankshaft bend
Standard o - 0.03 (0 - 0.0012)
Limit 0.10 (0.0039)
Crankshaft end play
Standard 0.055 - 0.180 (0.0022 - 0.0071)
Limit 0.40 (0.0157)
EM-154
AVAILABLE THRUST WASHER MISCELLANEOUS COMPONENTS
Unit: mm (in)
-----
Gear train
Unit: mm (in)
Backlash of each gear 0.07 - 0.11 (0.0028 - 0.0043)
Thrust washer thickness
Limit 0.20 (0.0079)
Standard
Flywheel
Stamped mark A 2.275 - 2.325 (0.0896 - 0.0915)
Runout
B 2.300 - 2.350 (0.0906 - 0.0925) Less than 0.10 (0.0039)
(Total indicator reading)
C 2.325 - 2.375 (0.0915 - 0.0935)
Front plate
Oversize
0.20 (0.0079) 2.475 - 2.525 (0.0974 - 0.0994)
0.40 (0.0157) 2.675 - 2.725 (0.1053 - 0.1073)
Tightening Torque
Engine outer parts Engine parts
Unit N'm kg-m ft-Ib Unit N'm kg-m ft-Ib
Cooling fan fixing bolt 7-9 0.7 - 0.9 5.1 - 6.5
Main bearing cap bolt 167 - 177 17.0 - 18.0 123 - 130
Air duct bolt and nut 13 - 19 1.3 - 1.9 9 - 14
Manifold nut Connecting rod big end
78 - 83 8.0 - 8.5 58.- 61
nut
Intake 15 - 20 1.5 - 2.0 11 - 14
Exhaust 25 - 29 2.5 - 3.0 18- 22 Crank pUlley nut 294 - 324 30 - 33 217 - 239
Injection pump nut 20 - 25 2.0 - 2.5 14 - 18
Flywheel bolt 147 - 167 15.0 - 17.0 108 - 123
Injection pump support
30-36 3.1-3.7 22 - 27 Rear oil seal retainer
bolt
13 - 19 1.3 - 1.9 9 - 14
Injection pump to support bolt
19 - 25 1.9 - 2.5 14 - 18
bolt Timing gear case bolt 13 - 19 1.3 - 1.9 9 - 14
Injection nozzle to cylin-
54-64 5.5 - 6.5 40 - 47 Timing gear ca.se nut 13 - 19 1.3 - 1.9 9 - 14
der head
Timer round nut 59 - 69 6.0 - 7.0 43 - 51 Front end plate bolt 10 - 13 1.0 - 1.3 7-9
Camshaft gear bolt 44 - 49 4.5 - 5.0 33 - 36
Oil filter bracket bolt 13 - 19 1.3 - 1.9 9 - 14
Oil cooler bolt 13 - 19 1.3-1.9 9 - 14 Camshaft locating plate
4-6 0.4 - 0.6 2.9 - 4.3
bolt
Alternator bracket" bolt 30 - 36 3.1 - 3.7 22 - 27
Alternator to adjusting Idler gear shaft bolt 25 - 35 2.6 - 3.6 19 - 26
16 - 19 1.6 - 1.9 12 - 14
bar bolt
Oil pump bolt 13 - 19 1.3-1.9 9 - 14
Alternator fixing bolt 30 - 36 3.1 - 3.7 22 - 27
Alternator ring connector Oil strainer bolt 13 - 19 1.3 - 1.9 9 - 14
29 - 34 3.0 - 3.5 22 - 25
bolt Oil jet (for piston) 29 - 39 3.0 - 4.0 22 - 29
Alternator eye bolt 29-34 3.0 ~ 3.5 22 - 25
Oil pan bolt 7-9 0.7 - 0.9 5.1 - 6.5
Starter motor to transmis-
39 - 44 4.0 - 4.5 29 - 33
sion Oil pan drain plug 54 - 59 5.5 - 6.0 40-43
Dust cover bolt 13 - 19 1.3 - 1.9 9 - 14
Refer to "CYLINDER HEAD - Installa-
Air conditioner com pres- Cylinder head bolt
tion (On-Vehicle Service)"
sor bracket bolt
M8 16 - 19 1.6 - 1.9 12 - 14 Rocker shaft bracket
20 - 25 2.0 - 2.5 14 - 18
M10 30 - 36 3.1 - 3.7 22 - 27 bolt
Air conditioner compres- Rocker arm adjusting
15 - 20 1.5 - 2.0 11 - 14
sor fixing bolt lock nut
M8 19 -25 1.9 - 2.5 14 - 18
Rocker cover screw 9 - 11 0.9 - 1.1 6.5 - 8.0
M10 30 - 36 3.1 - 3.7 22 - 27
EM-155
~ 14.18
(1.4 - 1.8,
10 • 13)
SEM249E
(j) EXhaust manifold cover <ID Oil level gauge @ Gasket

@ EXhaust manifold @) Heat shield cover @ Oil hose
@ Gasket @ By-pass oil filter @ Oil hose
@ Gasket @ Full-flow oil filter @ Alternator bracket
@ Oil pump assembly @ Oil cooler housing @) Alternator
@ O-ring @ Gasket @ Adjusting bar
(j) Oil pipe @ Oil cooler @ Tension pulley assembly
@ Gusset
EM.156
OUTERCOMpiONENT ,PARTS
r,
~.14
)
-18
(1.4 • 1.8, 10 - 13)
2
CD r
~
~44 .49
(4.5 - 5.0, 33 • 36)
CID
6!
@
~ 14 .18 @
(1.4 - 1.8,,, _
10 .13) ~
_;J
5
25-35
(2.&.3.6,
~ ~ 19.28)
.;:,1 '~~"'.1:B' 10 - 13)
'~~'4"8
(1.4 • 1.8, 10. 13)
SEM250E
CD Nozzle support @ Fan pulley @ Injection tube support

@ Nozzle holder assembly @ Bracket @ Injection tube
@ O-ring @ Oil tube @ Starter motor
@ Gasket @ Connector @ Cylinder block cover
@ Gasket @ Oil tube @ Gasket
@ Water outlet @ Gasket @ Intake manifold
(f) Thermostat @ Gusset @ Gasket
@ O-ring rubber @ O-ring @ Air heater
@ -Thermostat housing @ Injection pump assembly @ Gasket
@) Water hose
@ Bracket @ Intake shutter
@ Fan coupling
EM';'157
COMPRESSION PRESSURE
Measurement of Compression Pressure (On-

vehicle service)
1. Warm up engine.
2. Tilt the cab. (If cab is a stationary type, open engine hood.)
3. Install engine tachometer.
4. Clean areas around nozzle holders and lift off all nozzle
holder assemblies (one at a time) by turning them back and
forth using a wrench.

toJ:
15 - 20 N'm
(1.5 - 2.0 kg-m, 11 - 14 ft-Ib)

Set control lever of injection pump at zero injection.
• Depress accelerator pedal fully and crank engine.
quickly as possible.
Standard 2,942 (29.4, 30, 427)
Minimum 2,452 (24.5, 25, 356)


pour a small quantity of engine oil into cylinders thOrough
the glow holes and retest compression.
improperly.
• If cylinder compression in any two adjacent cylinders is
problem.
EM-158
CYLINDER HEAD
COJ Refer to
installation of
~ cylindr head.
~-~44 -49~
(4.5 - 5.0,
33 - 36)
@J
~~

SEM254E
G) OilfiHercap @ Valve spring (outer) @ Cylinder head bolt

@ Rocker cover @ Spring seat @ Push rod
@ Rocker cover gasket @ Valve lip seal @ Rocker shaft assembly
@ Adjusting nut @ Valve guide @ Nozzle gasket
@ Rocker shaft lock bolt @ Valve seat @ Nozzle oil seal
@ Adjusting bolt @ Intake valve @J Nozzle
IJ) Engine slinger @ Exhaust valve @ Nozzle support
@ Valve cotter @ Valve lifter @J Cylinder head bolt
@ Spring retainer @ Cylinder head gasket
@ Rocker shaft bracket bolt
@) Valve spring (inner) @l Engine slinger
EM-159
CYLINDER HEAD
Removal (On-Vehicle Service)

1. Set No.1 cylinder at T.D,C. on its compression stroke.
and radiator.
4. Disconnect radiator outlet hose and thermostat housing
water inlet hose.
SEM286E
/ )\..-/1, \
Revolution sensor installation}
hole notch I
I (
/:Ol. - --
o V-~I I~//
9 I goo, "~p
o IIJ~L
5. Remove fuel injection tube assembly and spill hose.
6. Remove nozzle supports.

7. Clean areas around nozzle holders and lift off nozzle holder
assemblies (one at a time) by turning them back and forth
with a wrench attached to the upper part of the nozzle
holder at the "width-across flats".
Be careful not to deform spill pipe.
8. Remove intake shutter, air heater and intake manifold.

EM-160
CYLINDER HEAD [£[J
Removal (On-Vehicle Service) (ConI' d)
cylinder head.
rectorder.

SEM257E
Disassembly
• Intake manifold
• Engine slinger
SEM258E

KV10109210
KV10111200
SEM260E

a. Remove rocker shaft. lock bolt.
shaft assembly in oil of 70°C (158°F) for a few minutes and then
(lI"C ~580F)l
remove bracket.
'( -!loC',>
i~_~~ ~_~_:_.~~:_~: ~~~~~I:
o~~ _ - -_
- -------
- - - -
~ . SEM261E
EM-1<61
CYLINDER HEAD
Inspection
Standard
Longitudinal direction
Transverse direction
Limit
SEM262E
0.20 mm (0.0079 in)

rocker arm. (Generally, a large amount of wear occurs in
this direction.)
Limit
Intake 0.15 mm (0.0059 in)
SEM586A Intake 0.30 mm (0.0118 in)
stem diameter and valve guide inner diameter.
Standard
Intake
8.970 - 8.985 mm (0.3531 - 0.3537 in)
Exhaust
8.935 • 8.950 mm (0.3518 • 0.3524 in)
9.000 - 9.015 mm (0.3543 - 0.3549 in)
EM030
EM-162
CYLINDER HEAD [£[J
Inspection (Cont'd)
ST17101000
tool.

SEM265E

Finished size:
9.000 - 9.015 mm (0.3543 - 0.3549 in)
r-Ji'Contact width:
mml~0B3I")
VALVE SEATS
Check valve for any.evidence of pitting at valve contact surface,
\,.J0.K. • When repairing v.alve seats, check valve and valve guide
valve seat.
ONOGONOG SEM024
cutting.
REPLACINGiVALVE SEAT FOR SERVICE PARTS

1. Bore out old seat until it collapses or remove valve seats
with Tool.
Place a copper seat between contact surface of Tool and cylin-
der head.
EM-t63
CYLINDER HEAD [fBJ
Inspection (Cont'd)
2. Place new valve seats on dry ice and allow them to cool for
five minutes.
WARNING:
ST1712S000 Do not touch cooled valve seats with bare hand.
3. Heat cylinder head to 80°C (176°F).
SEM268E
5. Stake exhaust valve seat at three places with punch.

staked before.

VALVE DIMENSIONS
S.O.S.
less.
L
SEM270E

S Out-at-square "S":
Outer
Inner
SEM635B
EM-164
CYLINDER HEAD
Inspection (Cont'd)
Refer to S.O.S.
VALVE LIFTER AND PUSH ROD

Valve lifter
1. Check valve lifters for excessive wear on the face.
2. Replace with new ones if worn beyond repair.
a. Valve lifter end should be smooth.
b. Valve lifter to lifter hole clearance:
Standard
0.030 - 0.065 mm (0.0012 - 0.0026 in)
Limit
Valve lifter outer diameter:
Standard
.19.955- 19.970 mm (0.7856 - 0.7862 in)
Cylinde{ block valve lifter hole diameter:
Standard
20.000 - 20.020 mm (0.7874 - 0.7882 in)
Push rod
1. Inspect push rod for excessive wear on the face.
2. Replace if worn or damaged beyond r~pair.
3; Check push rod for bend using a dial gauge.
Maximum allowable bend
Less than 0.5mm (0.020 in)

EM-1!65
CYLINDER HEAD LfQJ
Inspection (Cont'd)
rockers or shafts.
Limit
Standard
19.979 • 20.000 mm (0.7866 • 0.7874 in)
Rocker arm inner diameter "B":
SEM027 Standard
20.020 - 20.041 mm (0.7882 • 0.7890 in)
3. Check rocker shaft bend at its center. If bend is within

specified limit, straighten it; and if it is greater than speci-
Rocker shaft bend
Limit
SEM028

valve(s) or valve seat(s).
Specified distance:
Standard
Intake
1.30.1.86 mm (0.0512 • 0.0732 in)
)
Exhaust
C 0.98 • 1.58 mm (0.0386 - 0.0622 in)
~ SEM026 Limit
Intake
2.8 mm (0.110 in)
Exhaust
2.3 mm (0.091 In)
EM-166
CYLINDER HEAD
Assembly
°o~
e~-~
0.~'f~~
SEM272E

• Identification of valves
Identification mark
(on intake and exhaust valve)
!f\E~,"~C _____
•
In_ta_k_eo_v_al_ve I=_-==_ -==_ -==_ -=E=_xh=_a=_u=_~t=_v=_a=_lv=_e=_
Always use new valve oil seal. (Refer to Oil
-==_ -==_ -==_
SEAL
~ r SEM273E
REPLACEMENT.)
side (painted for identification) toward cylinder head side.
Wide pitch
Narrow pitch
•
Installation (On-Vehicle Service)

Ensure identification mark ("TOP") faces cylinder head side.
SEM274E
CAUTION:
1st:
Tighten bolts to 59 N.m (6.0 kg-m, 43 ft-Ib)
2nd:
Tighten bolts to 98 N.m (10.0 kg-m, 72 ft-Ib)
3rd:
Tighten bolts to 167 - 186 N.m
SEM275E (17.0 - 19.0 kg-m, 123 - 137 ft-Ib)
EM-167
CYLINDER HEAD [f[]
Installation (On-Vehicle Service) (Cont'd)
6. Install rocker cover with gasket.
Do not o"ertighten as this may cause oil to leak.

(:J Engine front
SEM278E
7. Install new top nozzle gasket and injection nozzle.

8. Align nozzle support to "width-across flats" of upper part
of nozzle holder.
9. Install spill hose and injection tube.
EM-168
CYLINDER HEAD I£[]
Installation (On-Vehicle Service) (Cont'd)
10. ConnecUhermostat housing water inlet .hose and radiator
hose.
11. After assemoling all disassembled part~, fill radiator and
EM-169
OIL SEAL REPLACEMENT
Oil SEAL INSTALLING DIRECTION

• When installing a new front or rear seal, make sure its
mounting. direction is correct.
Engine .. Engine
inside ..,. outside
CRANKSHAFT FRONT OIL SEAL (On-vehicle service)

5. Remove timing gear case .cover.
CRANKSHAFT REAR Oil SEAL (On-vehicle service)

2. Remove clutch cover assembly.
3. Remove flywheel.
4. Remove starter motor.
6. Remove flywheel housing assembly, then remove oil seal.
VALVE STEM Oil SEAL (On-vehicle service)

KV10109210
KV10111200
SEM260E
EM-170
Oil SEAL REPLA.eEMENT
5. Apply engine oil to valve oil seal and insta.lIit in place.

• Before installing valve oil. $eal, install valve spring seat.
C'
E- o
E~
.,0
....IIl
.... Spring
seat
, ...
lilt;
~e..
~ %
Cylinder head
SEM283E
ENGINE REMOVAL
~~.~ ~
. (2.5-3.6,J ~,
18 - 26)
,-:---
--:'wl
\ ~ ~71-90
{7.2 ••. 2, 52 • 67]
~~i
I
~51.65
(5.2 - 6.6, 38 - 48)
~!,a Gl
-~
V ~ 75 - 87
(7.6 - 8.9, 55 - 64)
(3)~---- e
~~75.87
(7.6 - 8.9, 55 - 64)
SEM313E
CD Engine mounting bracket @ Spring bumper rubber @ Engine slinger (front)

@ Engine mounting insulator @ Engine mounting member @ Engine slinger (rear)
EM-172
ENGINE REMOVAL
WARNING:
c. Do not remove engine until exhaust system has completely
cooled off. Otherwise, you may burn yourself and/or fire
may break. out in fuel line.
d. For safety during. subsequent steps, the tension of wires
should be slackened against the engine.
e. Be sure to hoist engine and transmission in a safe manner.
f. For engines not equipped with engine slingers, attach
proper slingers and bolts described in PARTSCATALOG.
CAUTION:
• While lifting 01' lowering the engine, be extremely careful
not to strike it against adjacent units or parts.
• In hoisting the engine, always use engine slingers in a safe
manner.
Fixed cab models Removal

/~ 1. Tilt the cab.
• If the Gab is a fixed type, proceed as follows:
1) Remove driver's seat.
2) Raise passenger's seat.
3) Disconnect shift lever.
( 4) Using a hoist, support the rear engine slinger.
2. .Drain engine coolant.
3. Remove vacuum hoses, fuel tubes, wires, harnesses and
connectors and so on.
4. Remove radi~tor shroud and cooling fan.
5. Remove drive belts and alternator. ........•.
6. Remove power steering oil pump and air C()nclition~rcom-
pressor without disconnecting pipes or' tubes.
7. Remove front exhaust tube.
8. Remove transmission from vehicle.
Refer toMT and A T sections.
9. Uft the engine arid remove engine mounting insulator nuts.
.If the cab is a fixed type, proceed as follows:
1) Remove one end of tie-rod ends.
2) Place a jack under the engine supporting the rear engine
SEM315E
slinger with a hoist.
3) Lift the engineand remove engine mountingi~~ul~tor,nuts.
4) Remov.~springl:>umper rubbers and remove engirie"m()unt
membeffi. - .
5) Remove oil filter.
10. Lifttheengineawa.y from engine compartment,b'eingcare-
furnot to stfik~itagairtst adjacent unitsorparts,thenlbwer
it onto workbench.
• If the cab is a fixed type, proceed as follows:
1) Remove chains from the engine.
2) Gradually IOWet jack until the engine is removed from
engine cOl1lpar;tment.Be careful not to strike it against
adjacent units or. parts during removal.
EM-173
ENGINE OVERHAUL
~ M12: 93 - 113
(9.5 - 11.5, 69 - 83)
Ml0: 72 - 83
(7.3 - 8.5, 53 - 61)
~ 265.284
(27 - 29,
195 - 210)
~
I 0
~14 - 21
(1.4 - 2.1, 10 - 15)
G) Cylinder liner @ Water pump @ Crankshaft

@ Camshaft @ Front gear case cover @ Crankshaft gear
@ Camshaft bushing @ Oil seal @ Crank pulley
@ Push rod @) Connecting rod bushing @ Oil strainer
@ Valve lifter @ Piston pin @ Gasket
@ Locating plate @ Snap ring @ Oil pan
(J) Camshaft gear @ Connecting rod cap @ Gasket
@ Camshaft gear plate @ Connecting rod bearing @ Main bearing cap
@ Idler gear shaft (lower) @ Thrust washer (lower)
@) Gasket @ Connecting rod bearing @ Main bearing (lower)
@ Front plate (upper)
@ Thrust washer (upper)
@ Idler gear @ Connecting rod
@ Main bearing (upper)
@ Idler gear plate @ Snap ring
@ Flywheel housing
@ Gasket @ Piston
@ Gasket
@) Front cover @ Piston ring
Cylinder block
@J Flywheel ~
@ Gasket @ Oil seal
EM-174
ENGINE OVERHAUL
Disassembly
1. Remove exhaust manifold.
ST0501S000 2. Remove alternator assembly.
5. Remove oil level gauge and guide.
6. Remove oil cooler and oil pump assembly.
8. Drain coolant and oiL
9. Remove fuel injection tube assembly and nozzle holder.
10. Remove intake manifold.
11. Remove injection pump assembly.
• Rotate crankshaft until NO.1 piston is set at TOO on com-
pression stroke. (At this point, match mark is aligned.)
• Looking through revolution sensor mounting hole, ensure

/ ) "----/ I , \ match mark on pump's drive gear tip is aligned with notch
Revolution sensor installation~
hOi'i/=ol= on timing gear case.

If timing mark is not aligned, No. 4 piston is set at TOC on
compression stroke. Rotate crankshaft again until No. 1 piston
o V-~I I~-// is set at TOC on compression stroke.
_ I gear stamp
,0 II J~L
• Remove oil pipe, bracket and flange mounting nut.
• Remove bolts securing pump to front of timing gear case.

• Remove.injection. pump assembly.
12. Remove oil pan and oil strainer.
EM;.175
ENGINE OVERHAUL [ill
13. Remove thermostat housing with by-pass hose.
14. Remove fan coupling and fan pulley.



20. Remove camshaft with gear and valve lifters.
• Remove camshaft locating plate.
• Bring crankshaft to upper side and remove camshaft.
• Remove valve lifters.
22. Remove front plate.
23. Remove flywheel and flywheel housing.

WARNING:
When removing flywheel, be careful not to drop it.
EM-176
ENGINE OVERHAUL [£[]
24. Remove piston and connecting rod.
• Remove connecting rod caps and bearing.
• Take piston and connecting rod out of cylinder head side.
Piston can be easily remov~d by scraping carbon off top face
of cylinder with a scraper.
25. Remove main bearing cap and crankshaft.

Place the bearings and caps In their proper order when
removed.
Donot hammer No.4 main bearing cap since it is provided with
a dowel pin.
26. Remove oil jet.

SEM296E
27. Remove piston ring.

When removing piston rings, be careful not to scratch piston.
28. Remove piston pin snap rings and piston pin.
SEM297E
Inspection and Replacement
t-g~w
- -- : Measuring point
Standard
" Less than 0.05 mm (0.0020 in)
). ~ Limit
0.2 mm (0.008 in)
'c;;;;trt~~q:,~=-~ Q
o \~ _ _ j2- SEM317E
CYlinder
liner inner CYLINDER LINER. WEAR
'&sn::-\
diameter stamp
1. Measure cylinder liner bore for out-of-round and taper with
-1-1 -,-[ a bore gauge. If beyond the limit, replace cylinder liner.
Standard inside diameter:
OMD.
0000 0000
0 0() Grade S
:0:0
108.000- 108.010 mm (4.2520.- 4.2524 in)
Grade M
108.010- 108.020 mm (4.2524 -4.2527 in)
- o 0
SEM520E:
Grade L
108.020- 108.030 mm (4.2527 - 4.2531 in)
Refer to S.D.S~
EM.177
ENGINE OVERHAUL [£[)
Inspection and. Replacement (Cont'd)
Wear limit:
co 0.020 mm (0.0008 in)
'" ,..,r::-
e .~ Out-of-round (X - Y) limit:
II)
~
I I
N
...,..,
N
Less than 0.025 mm (0.0010. in)
cyli nder Iiner.
/'
Unit: mm (in)
SEM318E

Standard
0.02 - 0.09 mm
(0.0008 - 0.0035 in)
CYLINDER LINER
Replacement
KV11104011
1. Remove cylinder liner with Tool.

II
I :..
1
" .. Adapter
I' .../.: KV11105120
SEM320E

Refer to S.O.S.
84 mm (3.31 in)
Piston clearance:
Standard
0.07 - 0.09 mm
SEM660B (0.0028 - 0.0035 in)
EM.178
ENGINE OVERHAUL [f[]
Inspection and Replacement (Cont'd)
Check clearanCe between pistons and piston pins.
Clearance (A -- B):
Standard
0.005- 0.025 mm (O.0002 ,; 0.0010 in)
SEM424
PISTON RING SIDE CLEARANCE

Side clearance:
Top ring 0.07 - 0.11 mm (O.0028 - 0.0043 in)
2rd ring 0.04 - 0.08 mm (O.0016 - 0.0031 in)
Oil ring 0.02 - 0.06 mm (O.0008 - 0.0024 in)
Top 0.5 mm (O.020 in)
2nd 0.3 mm (O.012 in)
Oil 0.15 mm (O.0059 in)
PISTON RING GAP

Standard ring gap:
Top ring
0.30 - 0.45 mm (O.0118 - 0.0177 in)
2nd ring
0.30 - 0.45 mm (O.0118 - 0.0177 in)
Oil ring
0;25 - 0.45 mm{O.0098 - 0.0177 in)
1.5 mm (O.059 in)

Standard
0.040 ....0.100 mm (O.0016 - 0.0039.in)
Limit
0.15 mm (O.0059 in)
Method A
1. Install main bearings to cylinder bl.ock and main bearing
cap.
2: Install main bearing cap to cylinder block.
Tighten aU bolts in correct order and in two or three stages.
Refer to. ASSEMBLY OF CRANKSHAFT.
3.ty1easure inside diameter "A" of maJnbearing.
EM-179
4. Measure outside diameter "Om" of main journal in crank-
shaft.
Refer to S.O.S.
SEM413B
Method B (Using plastigage)

CAUTION:
• Do not turn crankshaft or connecting rod while plastlgage
is being inserted.
• When bearing clearance exceeds the specified limit,
ensure that the proper bearing has been installed. Then if
excessive bearing clearance exists, use a thicker main
bearing or undersized bearing so that the specified bear-
ing clearance is obtained.
CONNECTING ROD BEARING CLEARANCE

Connecting rod bearing clearance:
Standard
0.045 - 0.111 mm
(0.0018 - 0.0044 in)
Limit
0.15 mm (0.0059 In)
nuts.
3. Measure inside diameter "A" of bearing.
shaft.
Refer to S.O.S.
SEM507A

Bend:
Limit
0.05 mm (0.0020 in)
Torsion:
Limit
0.075 mm (0.0030 in)
EM133
EM-180
ENGINE OVERHAUL [![]
Inspection and Replacement (Co nt' d)
1. Measure inside diameter "A" of connecting rod small end
bushings.
2. Measure outside diameter "D" of piston pin.

Connecting rod small end bushing clearance = A - D
Bushing clearance:
Standard
0.025 - 0.048 mm (0.0010 . 0.0019 in)
Limit
0.10 mm (0.0039 in)
REPLACEMENT OF CONNECTING ROD SMALL END

BUSHING
surface of the rod.
Small end bushing inside diameter:
Finished size:
36.025 - 36.041 mm (1.4183 . 1.4189 in)
SEM062A
EM-181
A B y CRANKSHAFT
1. Check crankshaft journals and pins for score, bias, wear or
x 2. Check journals and pins with a micrometer for taper and
out-of-rou nd.
Standard
Out-of-round X- Y Limit
Taper A - B 0.02 mm (0.0008 in)
SEM323E Taper (A - B):
Standard
Limit
0.02 mm (0.0008 in)
3. Check crankshaft bend.

Bend [T.I.R. (Total Indicator Reading)]
Standard
o - 0.03 mm (0 - 0.0012 in)
Limit
0.10 mm (0.0039 in)
RESURFACING OF CRANKSHAFT JOURNAL AND

CRANK PIN
When using undersize main bearings and connecting rod
bearings, the crankshaft journals or crank pins must be finished
LLLL
O.K. N.G. N.G. N.G.
to match the bearings.
R: Crank journal: 3.5 mm (0.138 in)
CAUTION:
Crank pin: 4.0 mm (0.157 in)
• At the same time make sure that the surface width does not
increase.
SEF692A • Do not attempt to cut counterweight of crankshaft.
CRANKSHAFT PILOT BUSHING
Crankshaft pilot bushing replacement
1. Pull out bushing with Tool.
EM-182
2. Insert pilot bushing until distance between flange end and
13.5. 13.9 mm bushing is specified value.
(0.531 - 0.547 In) Distance:
13.5 - 13.9 mm (0.531 - 0.547 in)
Pilot bushing
SEM326E
FL YWHEELRUNOUT
Ruriout (Total Indicator reading):
Less than 0.15 mm (0.0059 In)
SEM327E
FRONT PLATE
Warpage limit:
0.2 mm (0.008 in)
SEM328E
GEAR TRAIN
Camshaft drive gear, injection pump drive gear, idler
gear and crankshaft gear
worn, repl~ce gear and key.
assembling.
If beyond the limit, replace gear.
Backlash:
Standard
0.06 - 0.16 mm (0.0024 - 0.0063 In)
Limit
0.30 mm (0.0118 In)
EM.183
Inspection and Replacement {Cont'd}
SEM704

3. CalclJlate idler gear bushing clearance.
Standard
0.025.0.061 mm (0.0010 .0.0024 in)
Limit
0.20 mm (0.0079 in)
SEM705
IDLER GEAR END PLAY

Standard
0.03.0.14 mm (0.0012 . 0.0055 In)
Limit

Finished size:
42.00 • 42.02 mm (1.6535 • 1.6543 in)
Idler gear shaft

Standard
0.015.0.105 mm
(0.0006 . 0.0041 in)
Limit
0.13 mm (0.0051 in)
EM-184
ENGINE OVERHAUL
Illspectionand Replacement (Cont'd)
1. Remove rear plug.
2. Using Tool, remove camshaft bushings (Rear, 3rd and 2nd)

from the engine. Some bushings must be broken in order
to remove.
3. Using suitable tool, remove front camshaft bushing from

engine.
eam bushing 4. Using Tool, install camshaft bushings as follows:

replacer set
KV111055S0
Adapter.
(1st bushing)
r
~~Dmt
ST15243000
KV11105530 SEM335E
(1) Install camshaft bushings in the order of "rear", "3rd",

"2nd" and "front". All bushings must be installed from the
front.
(2) Ensure notches of all camshaft bushings face the front of
the engine and outward during installation.
Align cylinder block oil passage hole and bearing oil hole.
EM-t85
ENGINE OVERHAUL [![]
Inspection and Replacement (Co nt' d)
Align the cutout of rear bushing with knock pin of replacer
Insert rear bushing with replacer bar into the engine.

Install guide plates on cylinder block with "FD" and "UP"
marks facing outward and up. Tighten bolts.
Drive replacer bar until the alignment mark on replacer bar

Alignment mark to
@ surface
C
( ----
')
Guide plate
\0 Knock pin
J~~
'/~(_Y
, Alignment mark line
to @ surface
Replace bar
A Engine
Y front
SEM338E
EM-186
(4) 3rd and 2nd camshaft bushings
In~tall in .the same manner as rear camshaft bushing.
Alignment mark to
3rd bushing
@ surface
11111111111111111111111111111111111il. o
@
Engine
front
Alignment mark to 2nd bushing

@ surface
1 o o
1111 1111111111111111111111111111111111.
@ SEM339E

f so that oil hole in cylinder block is aligned with oil hole in
bushing.
SEM341E
EM ..187
ENGINE OVERHAUL
4. Install new rear plug with a drift.
When setting 3rd and 2nd bushings on replacer bar, tape

the bar to prevent movement.
SEM999B
CAMSHAFT ALIGNMENT
damage.
If fault is beyond limit, replace.
camshaft.
Camshaft bend
{Total indicator reading}:
Standard
0.02 mm {O.0008 in}
Limit
0.06 mm {O.0024 in}

gear. If beyond the specified limit, replace camshaft locat-
ing plate.
Camshaft end play:
Standard
0.05 - 0.25 mm {O.0020 - 0.0098 in}
Limit
0.3 mm {O.012 in}
SEM671B
EM-188
ENGINE' OVERHAUL [f[J
Inspectiol1 al1dReplacement (Cont' d)
4. Measuredal11shaft carn lJeight. If beyonetthe specifiecllimit,
replac~ camshaft.
..~~arn Cam height:
Ud~eight Standard
Intake and~il1aust
47.005 - 47.045 mm (1.8506 -.1.8522 in)
Limit
Intake and exhaust
46.6.95 mm (1.8384 in)
Assembly
PISTON
EngiM
front Assemble pistons, piston pins. snap rings and connecting rods.
a. Num~~rs'.are stamped on the connectirlg ro~.an~cap cor-
respondingto each cylinder . Care shQufd.be;tilkentC)avoid
a wrong combination Incl"d~nglJea~I~9; ..../ •••......•........•
b. When inserting pistQn pin in connecting rod; apply engine,
oil to pin and small ~ndof connecting rod.
Cylinder No. stamp c. After assembling, ascertain that piston swings smoothly.
SEM298E
CornblnaUonof cylinder bore grade and.piston grade:

Piston grade (service)
Weight 5
stamp
Outer M Sor M
diameter
grade L M
stamp
Replaced cylinder liner 5 or M
SEM307E
Install piston ring.

CAUTION:
a. Stretch the piston rings only enough to fit them in the pis-
tong ...ooves~ •. .'. •.. • ...• '. ...• •.
b. Be sure the manufacturer.'s ma~kfaces upw.rd.
SEM299E
Front mark c. Install No.1 piston ring in such a way that its gap faces the
directic:nlof the piston pin; and.then install piston' rings so
that their gap positioned at 1809 to one another.
... ..
Piston pin direction SEM300E
EM-189
ENGINE OVERHAUL [!Q]
Assembly (Cont'd)
CRANKSHAFT
o;"r 1. Install crankshaft.

a. If either crankshaft, cylinder block or main bearing is
Oil hole clearance.
c. Install bearings with notches aligned. Install upper bearing
with oil hole aligned.
(J Engine front crankshaft.
(3) Install main bearing caps in numerical sequence.
a) Ensure arrow marks on main bearing caps face the front of
the engine during installation.
b) Apply engine oil to main bearing cap and cylinder block
contact surfaces.
SEM302E
(4) Install crankshaft thrust washer at the 4th journal from

front.
Ensure machined (glossy) side of thrust washer faces crank pin
during installation. Install thrust washers of the same thickness
on the upper and lower ends.

two to three separate stages, from center bearing and mov-
After tightening cap bolts, ensure crankshaft moves smoothly.

SEM304E

Crankshaft free end play:
Standard
0.06.0.16 mm (0.0024 • 0.0063 In)
Limit
0.4 mm (0.016 in)
Refer to S.O.S.
EM-190
Assembly (Cont'd)
• When replacing the upper thrust washer, push out the
former one by new one as shown.
SEM063

EM03470000
• Be careful not to scratch cylinder wall with connecting rod.
• Apply engine oil to cylinder wall, piston and bearing.
• While aligning notches, Install upper and lower bearings.
Ensure the bearing with a groove is on the connecting rod
side, and the bearing without a groove is on the cap side.
• Install pistons with the FRONT mark (on their heads) facing
the front of the engine, while checking cylinder Nos.

Standard
0.10 • 0.30 mm (0.0039 • 0.0118 in)
Limit
0.60 mm (0.0236 in)
If beyond the limit, replace connecting rod and/or crankshaft.
GEAR TRAIN
1. Set NO.1 piston at its top dead center.
°
°f::9E
EM-191
SERVIGE pArA. AND SPECIFICATIONS (S.D.S.)

COMPRESSION PRESSURE VALVE
Standard 2,942 (29.4, 30, 427)/200
Minimum 2,452 (24.5, 25, 356)/200
Differential limit between cylin-

294 (2.9, 3, 43)/200
ders
CYLINDER HEAD
------
Cylinder head distor-
sion
Longitudinal direc-
tion
Standard
Less than
0.10 (0.0039)
Unit: mm (in)
Limit
SEM270E
Valve diameter "D"

0.20 (0.079)
Transverse direc- Less than
Intake 48.4 - 48.6 (1.906 - 1.913)
tion 0.05 (0.0020)
Exhaust 39.4 - 39.6 (1.551 - 1.559)
89.9 - 90.1
Cylinder head height -
(3.539 - 3.547) Valve length "L"
Intake 128.65 - 129.25 (5.0650 - 5.0886)
Exhaust 129.7 - 130.3 (5.106 - 5.130)
Valve stem diameter

"d"
Intake 8.970 - 8.985 (0.3531 - 0.3537)
Exhaust 8.935 - 8.950 (0.3518 - 0.3524)
Valve face angle "a"
Intake 60" - 60"30'
Exhaust 45" - 45"30'
Valve margin "T" limit
Intake
0.5 (0.020)
Exhaust
Valve stem and surface

0.2 (0.008)
grinding limit
Intake
0.40 (0.016)
Exhaust
EM-192
SIERVICEDATA AND SPECIFIC~:rI()NS(S.D.S~)
Inspection.andAdjustment (Co nt' d)
Valve guide VALVE LIFTER AND PUSH ROD
Valve guide outside diam- 14.040 - 14.053 ~ Standard Limit

etar (0.5528 - 0.5533)
19.955 - 19.970
Valve lifter outer diameter 19.90 (0.7835)
Valve gUide inner diame- (0.7856 -0.7862)
9.000 - 9.015
ter
(0.3543 - 0.3549) Cylinder block valve lifter 20.00 - 20.02
(Finished size) -
hole diameter (0.7874 - 0.7882)
Cylinder head valve guide 14.000 - 14.018
Valve lifter to lifter hole 0.030 -0.065 Less than 0.20
hole diameter (0.5512 - 0.5519)
clearance ,(0.0012 - 0.0026) (0.0079)
Interference fit of valve 0.022 - 0.053
Less than
gUide (0.0009" 0.0021) Push rod bend (T.I.R.)" -
0.50 (0.020)
Standard Max. tolerance
~ *: Total indicator reading
Stem to guide clearance
" 0.015 - 0.045

Rocker shaft and rocker arm
Intake 0.15 (0,0059) Unit: mm (in)
(0.0006-0.0018)
0.05 - 0.08 Standard Limit

Exhaust 0.20 (0.0079)
(0.0020 -0.0031)
Rocker shaft
19.979" 20.000
Outer diameter
Intake 0.30 (0.0118) (0.7866 - 0.7874)
Exhaust 0.40 (0.0157) Rocker shaft bend (T.I.R.,. 0,03 (0.0012) . 0.05 (0.0020)
Projection length 15.0 (0.591) Rocker arm
20.020 - 20.041
Inner diameter
Valve spring (0.7882 - 0.7890)
Clearance between rocker 0.020" 0.062

Free length mm(in) 0.20 (0.0079)
arm and rocker shaft (0.0008 - 0.OP24)
OuteT standard 5/l.9 (2:319)
Inner standard 59.5 (2.343)
Pressure height CYLINDER HEAD TO VALVE DISTANCE

mm/N (mm/kg, in/I b) Unit: mm (in)
31.2/591.4 - ,658.0 (31.2/60.3 - 67.1,

Outer
1.228/133.0 - 148.0)
28.2/235.4 - 260.9 (28.2/24.0 - 26.6,

Inner
1.110/52.9 - 58.7)
Assembled height
mm/N (mm/kg, in/lb)
43.5/288.3 - 329.5 (43.5/29.4 - 33.6,

Outer standard
1.713/64.8 - 74.1)
40.5/125.5 - 139.3(40.5112.8 - 14.2,

Inner standard
1.594/28.2 - 31.3)
SEM724C
Out of square mm(in)
Standard Limit
Outer 2.6 (0.102)
Valve distance
Inner
'. 2.1 (0.083)
Intake
1.30 - 1.86
2.8 (0.110)
(0.0512 - 0.0732)
0.98 - 1.58
Exhaust 2.3 (0.091)
(0.0386 - 0.0622)
EM-193
SERVICE DATA AND SPECIFICATIONS (S.O.S.) [fQ]
Valve seat CAMSHAFT AND CAMSHAFT BUSHING
Unit: mm (in)
-----
Camshaft journal to bush-
ing clearance
[Oil clearance]
Camshaft journal diameter

Standard
0.015 - 0.065
(0.0006 - 0.0026)
Unit: mm (in)
Limit
0.13 (0.0051)
57.535 - 57.555
No.1 -
(2.2652 - 2.2659)
57.335 - 57.355
No.2
(2.2573 - 2.2581)
-
57.135 - 57.155
No. 3 -
(2.2494 - 2.2502)
56.935 - 56. 955

No.4
(2.2415 - 2.2423)
-
SEM785B
Camshaft bushing diame-
Outer diameter 50.046 - 50.056 ter
"D1" (1.9703 - 1.9707)
57.570 - 57.600
No. 1 -
Inner diameter 41.9-42.1 (2.2665 - 2.2677)
"D2" (1.650 - 1.657)
57.370 - 57.400
Diameter of seat 47.9 - 48.1
NO.2
(2.2587 - 2.2598)
-
"D3" (1.886 - 1.894)
57.170 - 57.200
NO.3 -
Intake Diameter of seat 43.9 - 44.1 (2.2508 - 2.2520)
"D4" (1.728 - 1.736)
56.970 - 57.000
Cylinder head
No.4
(2.2429 - 2.2441)
-
50.000 - 50.016
valve seat diam-
(1.9685 - 1.9691) Camshaft bend (Total indi-
eter 0.02 (0.0008) 0.06 (0.0024)
cator reading)
Valve seat a 30' - 30'30'
0.05 - 0.25
face angle Camshaft end play 0.3 (0.012)
/3 60' (0.0020 - 0.0098)
Outer diameter 41.046 - 41.056

"D1" (1.6160 - 1.6164)
Inner diameter 34.35 - 35.05

"D2" (1.3524 - 1.3799)
Diameter of seat 39.1 - 39.3

"D3" (1.539 - 1.547)
Exhaust Diameter of seat 36.1 - 36.3

"D4" (1.421 - 1.429)
SEM671
Cylinder head
41.000 - 41.016 Standard Limit
valve seat diam-
(1.6142 - 1.6148)
eter Cam height "A"
Valve seat a 45'.45'30'

Intake
47.005 - 47.045
46.695 (1.8384)
face angle (1.8506 - 1.8522)
/3 70'
47.005 - 47.045
Exhaust 46.695 (1.8384)
(1.8506 - 1.8522)
Camshaft bushing
Unit: mm (in)
Bushing thickness
Standard 1.495 - 1.515 (0.0589 - 0.0596)
Under size
1.620 - 1.640 (0.0638 - 0.0646)
0.25 (0.0098)
Under size
1.745 - 1.765 (0.0687 - 0.0695)
0.50 (0.0197)
Under size
1.870 - 1.890 (0.0736 - 0.0744)
0.75 (0.0295)
EM-194
CYLINDER BLOCK AND CYLINDER LINER Unit: mm (in)
Unit: mm (in)
70
(2.76)
SEM311E
FD42 FD46
Cylinder liner diameter 108.020 - 108.050
----- SEM563E "D" (service)* (4.2527 - 4.2529)
*Before installing in cylinder block

FD42 FD46
Nominal cylind~H block 294.95 - 295.05 316.65 - 316.75 PISTON, PISTON RING AND PISTON PIN
height (11.6122 - (12.4665 -
(From crankshaft center) 11.6161) 12.4704) Piston
Surface flatness (Without Unit: mm (in)
cylinder liner)
Standard less than 0.05 (0.0020)
Limit 0.2 (0.008)
Cylinder bore (Without cyl-

inder liner)
Inner diameter 111.000 - 111.022 (4.3701 - 4.3709)
Cylinder bore (With cylin-

der liner)
Inner diameter
Standard SEM778A
Grade S 108.000 - 108.010 (4.2520 - 4.2524)

FD42 I FD46
Grade M 108.010 - 108.020 (4.2524 - 4.2527) 107.920 - 107.929
Grade S
Grade l (4.2488 - 4.2492)
108.020 - 108.030 (4.2527 - 4.2531)
107.930 - 107.939
Wear limit 0.020 (0.0008) Grade M
(4.2492 - 4.2496)
Out-of-round 107.940 - 107.950
less than 0.020 (0.0008) Grade l*
(X-V) (4.2496 - 4.2500)
"a" dimension 84 (3.31)
Taper (A - B) less than 0.025 (0.0010)
36.005 - 36.018
Projection "S" 0.02 - 0.09 (0.0008 - 0.0035) (1.4175 - 1.4180)
Deviation of each Piston to cylinder liner
less than 0.05 (0.0020) clearance
cylinder "S"
Standard 0.070 - 0.090 (0.0028 - 0.0035)
Interference fit cylinder
-0.03 to -0.028 (-0.0012 to -0.0011) Service 0.091 - 0.120 (0.0036 - 0.0047)
liner to block (Service)
* Gradel piston is not provided as a service part.
Combination of cylinder bore grade and

piston grade
Cylinder bore grade Piston grade (Service)
S S
M S or M
l M
Replaced cylinder liner S or M
EM-195
Piston ring CRANKSHAFT
---------
Standard Limit
Side clearance
0.07 - 0.11
Top 0.50 (0.0197) S
(0.0028 - 0.0043)
0.04 - 0.08
2nd 0.30 (0.0118)
(0.0016 - 0.0031)
0.02 - 0.06
Oil 0.15 (0.0059)
(0.0008 - 0.0024)
Ring gap
0.30- 0.45 SEM312E

Top
(0.0118 - 0.0177) 77. 920 - 77. 940
Journal diameter "A" Standard
0.30 - 0.45 (3.0677 - 3.0685)
2nd 1.5 (0.059)
(0.0118 - 0.0177) 64.925 - 64.945
Pin diameter "B" Standard
0.25 - 0.45 (2.5561 - 2.5569)
Oil
(0.0098 - 0.0177) FD42 57.5 (2.2638)
Center distance "S"
FD46 63.0 (2.4803)
Piston pin
Unit: mm (in) Out-of-round X- Y
Taper A - B
---------
Piston pin outer
diameter
Standard
35.993 - 36.000
(1.4170 - 1.4173)
Limit
-
Piston pin to piston 0.005 - 0.025
clearance (0.0002 - 0.0010)
-
Piston pin to con-
0.025 - 0.048
necting rod bushing 0.10 (0.0039)
(0.0010 - 0.0019)
clearance
EM715
CONNECTING ROD
----
Taper of journal an~ pin Standard 0.01 (0.0004)
Unit: mm (in) "A- B" Limit 0.02 (0.0008)
FD42 FD46
Out-of-round of journal Standard 0.01 (0.0004)
178.775 - 178.825 194.975' - 195.025 and pin "X - Y"
Clearance distance Limit 0.02 (0.0008)
(7.0384 - 7.0403) (7.6762 - 7.6781)
Standard o - 0.03 (0 - 0.0012)
Connecting rod bend Crankshaft bend
[Per 100 mm (3.94 in) Less than 0.05 (0.0020) Limit 0.10 (0.0039)
length)
0.06 - 0.16
Standard
Connecting rod twist- Crankshaft end play (0.0024 - 0.0063)
[Per 100 mm (3.94 in) Less than 0.075 (0.0030)
Limit 0.40 (0.0157)
length)
Piston pin bore diam- 36.025 - 36.041

eter
AVAILABLE MAIN BEARING
(1.4183 - 1.4189)
Big end play Bearing clearance

Unit: mm (in)
Standard 0.10 - 0.30 (0.0039 - 0.0118)
Limit 0.60 (0.0236) Main bearing clearance
Standard 0.040 - 0.100 (0.0016 - 0.0039)
Limit 0.15 (0.0059)
Connecting rod bearing clear-

ance
Standard 0.045 - 0.111 (0.0018 - 0.0044)
Limit 0.15 (0.0059)
EM-196
~ERVIGEDAT A AND SPECIFICATIONSi(S.D.S.)
Inspection and .Adlustment (Cont' d)
Main bearing undersize AVAILABLE THRUST WASHER
----
Stangard
Undersize
0,25 (0.0098)
Crank journ~ldiameter
Unit: mm (in)
77.670 - 77.690 (3.0579 - 3.0587)

.
77.920 - 77.940 (3.0677 - 3.()685)

Standard
Stamped A
Thrust washer thickness
Unit: mm(in)
2.965 - 2.995 (0.1167 - 0.1179)

0.50 (0.0197) 77.420 - 77.440 (3.0480- 3.0488) mark
B 2.930- 2.965 (0.1154 - 0.1167)
0.75 (0.0295) 77.170 - 77.190 (3.0382 - 3.0390)
C 2.900 - 2.930 (0.1142 - 0.1154)
1.00 (0.0394) 76.920 - 76.940 (3.0283 - 3.0291)
Oversize
0.20 (0.0079) 3.150 - 3.200 (0.1240 - 0.1260)

0.40 (0.0157) 3.350 - 3.400 (0.1319 - 0.1339)
Connecting rod bearing undersize
----
Standard
Undersize
0.25 (0.0098)
Unit: mm (in)
Crank pin journal diameter
64.925 - 64.945 (2.5561 - 2.5569)
64.675 - 64.695 (2.5463 - 2.5470)

MISCELLANEOUS COMPONENTS
Gear train
Backlash of each
gear
Unit: mm (in)
0.06 -0.16 (0.0024 - 0.0063)
0.50 (0.0197) 64.425 - 64.445 (2.5364 - 2.5372)

Limit 0.30 (0.0118)
0.75 (0.0295) 64.175 - 64.195 (2.5266 - 2.5274)
Flywheel
1.00 (0.0394) 63.925 c 63.945 (2.5167 " 2.5175)
Runout (Total indi-
Less than 0.15 (0.0059)
cator reading)
Front plate
EM-197
SERVICE DATA AND SPECIFICATIONS (S.O.S.) II[]
TIGHTENING TORQUE Engine internal parts
Engine outer parts Unit N'm kg-m ft-Ib
Main bearing cap bolt 167 - 172 17.0 - 17.5 123 - 127
Unit N'm kg-m ft-Ib
Crank pulley nut 490 - 539 50-55 362 - 398
Water outlet bolt 14 - 18 1.4 - 1.8 10 - 13
Flywheel bolt 265 - 284 27.0 - 29.0 195 - 210
Water pump bolt 14 - 18 1.4 - 1.8 10 - 13
Front cover bolt 14 - 18 1.4 - 1.8 10 - 13
Oil cooler M8 14 - 18 1.4-1.8 10 - 13
bolt Front end plate bolt 14 - 18 1.4 - 1.8 10 - 13
M10 25 - 35 2.6 - 3.6 19 - 26
Camshaft gear bolt 44 - 59 4.5 - 6.0 33-43
Oil cooler pipe 14 - 18 1.4 - 1.8 10 - 13
Oil pump bolt 14 - 18 1.4-1.8 10 - 13
Front cover to injection
14 - 18 1.4 - 1.8 10 - 13
pump bracket Oil pan bolt 14 - 21 1.4 - 2.1 10 - 15
Injection pump bolt and Oil pan drain plug 54 - 59 5.5 - 6.0 40-43
14 - 18 1.4-1.8 10 - 13
nut
Oil strainer 14 - 18 1.4 - 1.8 10 - 13
Injection nozzle support
25 - 29 2.5 - 3.0 18 - 22 1st 59 6.0 43
bolt
Cylinder
2nd 98 10.0 72
Injection tube flare nut 20 - 25 2.0 - 2.5 14 - 18 head bolt
3rd 167 - 186 17.0 - 19.0 123 - 137
Alternator bracket bolt 46 - 61 4.7 - 6.2 34-45
Rocker arm shaft
Alternator to adjusting 34 - 39 3.5 - 4.0 25 - 29
16 - 21 1.6 - 2.1 12 - 15 bracket bolt
bar bolt
Valve clearance adjust-
Starter 2 places 64 - 74 6.5 - 7.5 47 - 54 20 - 25 2.0 - 2.5 14 - 18
ing screw lock nut
motor bolt 1 place 59 - 69 6.0 - 7.0 43 - 51
Camshaft locating plate
34 - 39 3.5 - 4.0 25 - 29
Thermostat housing 14 - 18 1.4 - 1.8 10 - 13 bolt
Intake manifold 14 - 18 1.4 - 1.8 10 - 13 Connecting rod big end

113 - 118 11.5-12.0 83 - 87
nut
Exhaust manifold 39 - 49 4.0 - 5.0 29 - 36
Rocker cover bolt 5 - 10 0.5 - 1.0 3.6 - 7.2
Air heater and intake
25 - 35 2.6 - 3.6 19 - 26
shutter Oil jet (for piston) 29 - 39 3.0 - 4.0 22 - 29
Idler gear shaft 34 - 39 3.5 - 4.0 25 - 29
Idler gear 10 - 18 1.0 - 1.8 7 - 13
Flywheel M10 72 - 83 7.3 - 8.5 53 - 61

housing M12 93 - 113 9.5-11.5 69 - 83
EM-198
ENGINE LUBRICATION &
COOLING SYSTEMS
SECTIONLC
CONTENTS
•
PRECAUTIONS AND PREPARATION LC- 2
~ ~ ~INAI I
ENGINE LUBRICATION SYSTEM LC- 3
ENGINE COOLING SYSTEM LC- 7
I I TOI~~ ----'
ENGINE LUBRICATION SYSTEM LC-11
COOLING .SYSTEM ; , , LC-18
I IBOI I
ENG INE LU BRICA TION SYSTEM , LC-24
COOLING SYSTEM LC-30
I IFOI I
ENG INE LUBRICATION SYSTEM LC-35
COOLI NGSYSTEM LC-42
SERVICE DATA AND SPECIFICATIONS (S.O.S.) - NA, TO, BD, FD LC-47

PRECAUTIONS AND PREPARATION
t.iq,Qid,; Ga$~~t. AppliQClti;Ql;'I.P(QQedu(e

a. Bef.ore applying liquid gp'sket, use a scraper to remove all
. .'~'
traces of old liquid. gasket from m.a.ting,surface and groove,
, .. .. • Inner and then.completely clean aOYoil stains from these areas.
.. i ... side b. Apply a contin.uous. beaq of liquid gasket to mating SUf-
~;~;~ .•......................................•......
n.................... , faces. (l,)se Genuine l;..iquidG.asket or equivalent.)
• ee SUfe liquid gasket i.s3.5 to 4.5 mm (0.138 to 0.177 in)
wide (for oil pan of gasoline engine).
• Be sure liquid gasket is 2.0 to 3.0 mm (0,079 to 0.118 in)
"",ioe (in areaS except oil pan).
SEM371C
c. Apply liquid g.a.sketto inner surface around hole perimeter
area.
(Assembly should be done within. 5 minutes after coatin.g.)
d. Wait at least 30 minutes before refilling engine oil and
engine coolant.
Sp~cial Service TQQIS

*: 8pecial tool or, commercial equivalent
Tool number Engine applic;ation

Description
Tool name NA TD SD FD
8T25051 001*
Oil pressure gauge
x X X. X
8T25052000* Adapting oil pressure gauge

Hose tocylinq~r block
X X X X
EG17650301. A<:lElptingradiator cap tester

R~Qiator c;aptesJE1r to radiator filler nec;k.
aQapter X: X X X
ENGINE LUBRICATION SYSTEM
Lubrication Circuit
.... ' Oil gallery in cylinder block
+- --- By-pass passage

.. "1
...- - - - Intermittently oiling portion
__ ~~..J
<;:=:J Oil passage
~--l Pump drive gear
_ ...J
SLC836A
LC-3
Oil Pressure Check

WARNING:
• Be careful not to burn yourself, as the engine and oil may
be hot.
• Oil pressure check should be done in "Neutral" gear posi-
tion.
1. Check oil level.

~ <:=J Front Oil pressure switch 2. Remove oil pressure switch.
Oc:==O==Oc::::::::::::;O=O
SLC821A
3. Install pressure gauge.

4. Start engine and warm it up to normal operating tempera-
ture.
ST25051001 5. Check oil pressure with engine running under no-load.
Approximate discharge pressure

Engine rpm
Idle speed More than 78 (0.78, 0.8, 11)
3,000 324 - 461 (3.24 - 4.61, 3.3 - 4.7, 47 - 67)
SLC825A
If difference is extreme, check oil passage and oil pump for oil
leaks.
6. Install oil pressure switch with sealant.
LC.4
Oil Pump
DISASSEMBLY AND ASSEMBLY
Drive spindle
Gasket ~
Pump body
Gasket .~
Pump cover
Regulator
valve set
~ : N.m (kg-m. ft-Ib)
SLC822A
CAUTION:
• Always replace with new gasket.
• When removing oil pump, turn crankshaft so that No.1 pis-
ton is at T.D.C. on its compression stroke.
~Punch • When installing 011pump, align punch mark on drive spin-
mark dle and oil hole on oil pump.
.... Oil
hole
OIL PUMP INSPECTION

Using a feeler gauge, check the following clearances:
Unit: mm (in)
Rotor tip clearance G) Less than 0.12 (0.0047)
Outer rotor to body clearance @ 0.15 - 0.21 (0.0059 - 0.0083)

Side clearance (with gasket) @ 0.04 - 0.08 (0.0016 - 0.0031)
• If the tip clearance CD exceeds the limit, replace rotor set.

• If body to rotor clearances (@, @) exceed limits, replace
SLC026 oil pump assembly.
LC-5
Oil Pump (Cont'd)
SLC732
REGULATOR VALVE INSPECTION

1. Visually inspect components for wear and damage.
2. Check oil pressure regulator valve sliding surface and
valve spring.
3. Coat regulator valve with engine oil and check that it falls
smoothly into the valve hole by its own weight.
If damaged, replace regulator valve set or oil pump assembly.
SLC851A
4. Check regulator valve to oil pump cover clearance.

Clearance:
@: 0.040 - 0.100 mm (0.0016 - 0.0039 in)
If it exceeds the limit, replace oil pump assembly.
Oil PRESSURE RELIEF VALVE INSPECTION

Inspect oil pressure relief valve for smooth movement and
damage by pushing the ball. If replacement is necessary,
remove valve by prying it out with a suitable tool.
Install a new valve by tapping it in place.
Oil Jet (For timing chain)

INSPECTION
Make sure that the holes are not clogged. Clean them with a
wire if necessary.
Drive oil jet into cylinder block with punchmark facing up.
LC-6
Cooling Citt:Uft
To heater core ---
QThermostat open
... Passage In cylinder head
.. Thermostat closed
St:08:37A'
Water Pump
~ Uquid gasket
Water pump
SLC824A;
CAUfION:
• When te movlngwatetpumpasseh1b'ly, beeatefttl'ffot flo
i vet
C'oolanton timingchein.
• Watetpump cannot be d'isassembfei and should Ibe
replacedasa uhit.
• Afterinstaning water pump,cortnecth'()seand 'damp
securely, then cheCk for leaks usirtg radcfator icaptester.
ENGINE COOLING SYSTEM ~
Water Pump (Cont'd)
REMOVAL
1. Drain coolant from. radiator and cylinder block.
2. Remove radiator shroud and cooling fan.
3. Remove drive belts for compressor, power steering pump
and alternator.
4. Remove water pump pulley.
INSPECTION
1. Check for badly rusted or corroded body assembly and
vane.
2. Check for rough operation due to excessive end play.
SLC857A
INSTAllATION
1. Before installing water pump, remove all traces of liquid
gasket from mating surface of water pump using a scraper.
cylinder block.
SLC826A

of water pump.
3. Install any parts removed in reverse order of removal.
SLC827A
LC-8
ENGINE COOLING SYSTEM
Thermostat
REMOVAL AND INSTALLATION
1. Drain engine coolant.
2. Remove upper radiator hose.
3. Remove water outlet, then take out thermostat.
4. Before installing thermostat, remove all traces of liquid

gasket from mating surface of each part using a scraper.
of each part.
SLC829A
6. Install thermostat with jiggle valve facing upward.

• After installation, run engine for a few minutes, and check
for leaks.
• Be careful not to spill coolant over engine compartment.
Use a rag to absorb coolant.
SLC767
INSPECTION
1. Check valve seating condition at ordinary room tempera-
tures. It should seat tightly.
2. Check.yalve opening temperature and maximum valve lift.

Standard Frigid type Tropical type
Valve opening temperature
82 (180) 88 (190) 76.5 (170)
°C ("F)
More than More than More than
Max. valve lift
8195 81100 8190
mml"C (inI"F)
(0.311203) (0.311212) (0.311194)
3. Then check if valve closes at 5°C (9°F) below valve open-

SLC343 ing temperature.
lC-9
EN'GIN:E COOLING SYSTEM
, , _.,' , .- , -,' .. _. ,_,,""- •.. - .. --".
Radiator
ReMOVALA,ND 'INSTALLAT:JON
1.R'elTl'ov:e :enginec0v:er.
2. Orajtlc00lantfr0mradiator.
3. Dlsc'onnect,radiatorupper and lower hoses.
4. Remove radiator.
5. After repairin'gor replacing 'f",lJrdiator
,install any part
rem0vedinreverseorae,ror removal.
WhenfUUngrad'iator with coolant,referto MA section.
.~/Radiat()fUpperbradket
~Radiat()f cap ~ .., . Radiatorsnroud(Upperl
/'
~~u •• '" h'"
'---af!
,,'
~Mounting rubber
Radiator
Lower hOse a:
Radiator Uppersupporl
SLC830A
Cooling Fan
Fan coupling
DISASSEMBL v AND ASSEMBLV
~-; N'm (kg-m, h-tbl SLC322A
INSPECTION
Check fan coupling for rough operation, oil leakage or bent
bimetal.
SLC072
LC.10
ENGINE lUBRICATION SYSTEM
lubrication Circuit
Oil cooler
assembly
Oil jet (for piston & cylinder)

Oil jet (for gear train)
Note: 4.:.:.;.:.::.:.:.:.:.:.;.) Oil gallery in cylinder block
~- -:~By-pass passage
~ Oil passage
_ Return to oil pan
Engine oil cooler -- ---{ Regulator valve 1----
_U
I
Oil pan
SLC868A
lC-ll
Oil Pressure Check (On-vehicle service)

WARNING:
be hot.
tion.
1. Check oil level.

2. Remove oil pressure switch.

ture.
5. Check oil pressure with engine running under no-load.

Engine rpm
294 - 392
3,000
(2.94 - 3.92, 3.0 - 4.0, 43 - 57)
leaks.
Oil pressure switch:
tDJ: 10 - 13 N.m (1.0 - 1.3 kg-m, 7 - 9 ft-Ib)
LC-12
Oil Pump
SLC020A
Oil PUMP .IN.$PECTION

1. Inspect pump body, gears and drive shaft for wear and
damage.
2. Using a feeler gauge and fuse wire, check the following
clearances.
Gear sid.e clearance:
Gear backlash:
SLC873A
3. Measure inside diameter "A" of bushing.

A: 13.012 - 13.098 mm (0.5123 - 0.5157 In)
LC-.13
ENG1NE LUBRICATION SYSTEM [!Q]
on Pump (Cont'd)
4. Measure outside diameter "B" of drive gear shaft.
B: 12.974. 12.992 mm (0.5108 • 0.5115 in)
5. Calculate oil pump bushing oil clearance.
on pump bushing oil clearance: A - B
Standard
0.020.0.124 mm (0.0008.0.0049 in)
If it exceeds the limit, replace oil pump bushing or entire oil
pump assembly.
SLC969
SlC965
ENGINE. LUBRICATION. SYSTEM
Oil filtef bJacket
Oil pump
relief valve
~ •.: N~m (,kg-m. fH>)
Of,l PUMP REUEF VAlVE I,NS;PECTION

1. \lisl:JaJly insJ:)ect cornpon,ents for wear and damage.
2. G.oa1'r'EltHef",a:I""~,,Vv:ith enginElt eil and check that it falls
smoothly into tne va,liVe,hQle,by its ow'" wei~ht.
If d'amaged, replace QH I'wmp rei iet valve set.,
OIl. Fil TlJ'tl R~ll.Ef~VALVE I,NSPECTION

1,lJspect oi I ti Iter rei iet val.ve for smooth movement and damage
by p>t,ls/:ting tne baJi.
, If.,damage,d, lieplace oil filter bracket assembly ..
ENGINE lUBRICATION SYSTEM
Oil Cooler
O-ring~
Regulator valve
- Oil cooler element

SLC809A
OIL COOLER RELIEF VALVE INSPECTION

Inspect oil cooler relief valve for smooth movement and dam-
age by pushing the ball.
If damaged, replace oil cooler relief valve set.
Install spring so that the smaller diameter side faces the valve.
SLC518

If damaged, replace regulator valve set.
lC-16
ENGINE LUBRICAflON SYSTEM
Oil Jet
INSPECTION (For gear train)
wire if necessary.
Oil jet has to be instam~d with all hole facing crank gear and
idler gear.
INSPECTION (For pistoll)

1. Push cut-off valve of oil jet bolt with a clean resin or brass
rod and make sure that cut-off valve moves smoothly.
2 Make sure that the oil jet passage is not clogged. Clean
with a wire if necessary.
When installing oil jet, direct oil jet nozzle toward cylinder head
side and align all jet's locating pin with hole on cylinder block.
011 jet bolt:
tDJ: 29 - 39 f'1I'm
(3.0 - 4.0 kg-m, 22 - 29 ft-Ib)
LC-t7
COOLING SYSTEM
Cooling Circuit
Water pump assembly
Radiator
~7
Thermostat
housing
t
•
,
Water pump
t
Water outlet
f
Engine oil cooler
,
Cylinder block
t
Thermostat
Cylinder head
<lll :.:, Thermostat: Closed
SLC869A
LC-18
COOLING ..SYSTEM ~
Cooling System Inspection

CHECKING HOSES

Apply pressure to radiator cap by means of a cap tester.
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11- 14 psi)

check for leakage.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
age.
SMA990A
lC-19
COOLING SYSTEM
Water Pump
REMOVAL AND INSTALLATION
Drain coolant from drain plugs on cylinder block and radiator.
Cylinder block drain plug
(Use proper sealant):
~: 20 - 29 N.m
(2.0 - 3.0 kg-m, 14 - 22 ft-Ib)
SMA617C
SLC810A
CAUTION:
• When removing water pump assembly, be careful not to get
coolant on drive belt.
• Water pump cannot be disassembled and should be
replaced as a unit.
• After installing water pump, connect hose and clamp
securely, then check for leaks using radiator cap tester.
INSPECTION
vane.
SLC979 '
LC-20
COOLING SYSTEM [![]
Water Pump (Cont'd)
SLC244
3. Check fan coupling for rough operation, oil leakage or bent

bimetal. .
The Water pump and fan coupling cannot be disassembled and
.should be replaced as a unit.
SLC245
LC..21
COOLING SYSTEM
Thermostat
r~ 13 -19 (1.3.1.9,9 -14)
~~~ 13 - 10 ~.3 -1 •••• - 14)
~ Water outlet
~~~ml
~ jiggle valve
//-1 '
~. ~Jwater temperature
¥.- .
~13.19~
(1.3 • 1.9, ". e
0 ~ sensor (Glow)
~20.29
, 9 _ 14) , ~ l) l)
I~ 0
.~
-/ ./'_
~
(2.0 - 3.0,
14-22)
~13-19~/
(1.3 - 1.9,
9 -14)
'7;' ~~:7'
~
/"" '- W.m,mmpe"'~
sensor
R,"",,,. ~ ~20.29
(2.0.3.0,
~ 13 - 19 (1.3 - 1.9, 9 • 14) 14 - 22)
Thermostat
~ : N.m (kg-m, ft-Ib) housing
SLCB11A

for leaks.
Place a rag to absorb coolant.
INSPECTION
1. Check for valve seating condition at ordinary temperatures.
It should seat tightly.
2. Check valve opening temperature and maximum valve lift.
Tropical type Standard type
76.5 (170) 82 (180)
.C CF)
Max. valve lift
8/90 (0.31/194) 8/95 (0.31/203)
mml'C (inI'F)
SLC343
3. Then check if valve closes at SOC(9°F) below valve open-

ing temperature.
LC ..22
COOLlNGSVSTEM
Radiator
-,~To engine
thermostat housing
ReServoir tank
Radiator shroud
-----.:..::,.
Radiator hose (Lower)
SLC813A
Lubrication .Circuit
Note: <11.: .....:,:.:.:.:.:.:....:,:.:1Oil gallery in cylinder block ~ Oil passage
---- - By-pass passage ___ Return to oil pan
Oil pan
SLC874A

WARNING:
• Be careful not to burn yourself, as the engine and all may
be hot.
• 011 pressure check should be done in "Neutral" gear posi-
tion.
1. Check oil level.

ture.
Engine rpm
294 - 392
3,000
(2.94, 3.92, 3.0 - 4.0, 43 - 57)
If difference is extreme, check all passage and all pump for all
leaks.
011 pressure switch:
~: 10 - 13 N.m(1.0 - 1.3 kg-m, 7 - 9 ft-Ib)
LC-24
ENGINE LUBRICA'TION SVS'TEM
Oil Pump
SLC020A
OIL PUMP INSPECTION

1. Inspect pump body, gears and drive shaft for wear and
damage.
2. Using a fee.ler gauge and fuse wire, check the following
clearances.
Gear side clearance:
Less than 0.13 mm(0.0051 in)
Gear backlash:
SLC873A
3. Measure inside diameter "A" of bushing.

A: 13.012 • 13.098 mm (0.5123 • 0.5157 in)
LC.25
ENGINE.LUBRICATION SYSTEM [ill
Oil Pump (Cont'd)
4. Measure outside diameter "B" of drive gear shaft.
S: 12.974 . 12.992 mm (0.5108 - 0.5115 in)
5. Calculate oil pump bushing clearance.
Oil pump bushing oil clearance: A - S
Standard
0.020.0.124 mm (0.0008 . 0.0049 in)
Limit
0.15 mm (0.0059 in)
If it exceeds the limit, replace oil pump bushing or entire all
pump assembly.
SLC969
SLC965
LC-26
ENQINELUBRICATIONSYSTEM
Oil Filter. Bracket
O-ring ~
rOil filter bracket
Shield plate
011 pump
relief valve
~ 13.19
(1.3 - 1.9,
9.14)
Ollfilter~

~ 13 - 19 (1.3 - 1.9, 9 - 14)
MLC034A
Oil. PUMP RELIEF VALVE INSPECTION

2. Coat relief valve with engine oil and check that it falls
sr,noothlyintoW~.valve hole by its own w~ight.
If damaged, replace oil pump relief valve set.
Oll.FllTER FlEUEFVAlVE INSPECTION

Inspect oil filterr~liefvalve for smooth movement and damage
by,pllshing the ball.
If damaged, replace oil filter bracket assembly .
.LC-27
Oil Cooler
O-ring~
Regulator valve
- Oil cooler element

~29-49
(3.0 - 5.0, 22 - 36)
~ : N.m (kg-m, ft-Ib) SLC815A

Inspect oil cooler relief valve for smooth movement and dam-
Install spring so that the smaller diameter side faces the valve.
SLC518

LC-28
ENGINE> LUBRICATION SYSTEM
Oil.J.et
INSPECTION (For gear. train)
wire if necessary.
Oil jet has to be installed with oil hole facing crank gear and
idler gear.
INSPECTION (For piston)

1. Push cut;.off va.lve of oil jet bolt with a clean resin or brass
rod Ei,ndmakesure that cut-off valve moves smoothly.
2. Make sure that the oil jet passage is not clogged. Clean
When installing oil Jet, direct oil jet nozzle toward cylinder head
side and align .oil jet's locating pin with hole on cylinder block.
Oil.jet bolt
~: 29 - 39 N.m (3.0 - 4.0 kg-m, 22 - 29 ft-Ib)
LC~29
COOLING SYSTEM
Cooling Circuit
Radiator
\7
Thermostat
housing
Engine oil cooler

Water pump
t {}
Cylinder block
,
Water outlet
Thermostat
t
Cylinder head
SLC870A

CHECKING HOSES
Check hoses for proper attachment, leaks, cracks, damage.

Apply pressure to radiator cap by means of a cap tester.
78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)

check for leakage.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
age.
SMA990A
LC-30
COOLING SYSTEM
Water Pump
REMOVAL AND INSTAllATION
Drain coolant from drain plugs on cylind~rbl()ck and radiator.
~: Cylinder block drain plug
(Use proper sealant)
20 - 29 N.m (2.0 - 3.0 kg-m,14 - 22 ft-Ib)
SMA617C
SLC816A
CAUTION:
replaced as a unit.
INSPECTION
vane.
SLC979
LC ..31
COOLING. SYSTEM ~
Water Pump (Cont'd)
2. Check for rough .operation due to excessive end play.
SLC244

bimetal.
The water pump and fan coupling cannot be disassembled and
should be replaced as a unit.
SLC245
LC-32
COOLING SYSTEM
Thermostat
A13 . ,. ~~ - 1.', • . ")SO

wm"~~t~
Thermostat >==--= ~
CoM"t"~ ~Co"_"
~ 13.19
(1.3 • 1.9, 9 • 14)~
V
I
~~ -
a
--, SJ~~
9o~~_~
>J"'. \I
. '~'''@~
/' 0 \ ..Water temperature se.nsor

~~ 20.29 (2.0.3.0,14.22)
~ 13.19 Water temperature sensor
(1.3 • 1.9, 9 • 14) ~~5 • 25 (1.5 .2.5, 11 .18)
Thermostat housing
~: N.m (kg-m. ft-Ib) SLC817A

for leaks.
THERMOSTAT HOUSING
Thermostat housing identification
SLC328A
INSPECTION
Tropical type Standard type
Valve opening temperature °C CF) 76.5 (170) 82 (180)
Max. valve lift mmtC (intF) 8/90 (0.311194) 8/95 (0.31/203)

SLC343
ing temperature.
LC-33
COOLING SYSTEM
Radiator
To engine
thermostat housing
'"
''01 To engine water
outlet
Radiator
hose (Lower) ;;:- ~
~e(upper)
Reservoir tank
Radiator
shroud (Upper)
Radiator
Air guide
Radiator shroud (Lower)
SLC818A
LC-34
FD
Lubrication Circuit
---- --- \--

;t
r-------------------~--- ---1--------.----,
:::====::::>
I l I
Oil passage I
I I
--_ Bypass passage I I
I I
__ ... ~. Oil gallery I I
__ - -~ To oil pan Oil filter element
Relief valve
I
(full flow) I
---.. Intermittent lubrication point I
Oil cooler element . I
I
____ ._J I
I
I
I
I
I
, Fuel inject/on pump Vacuum pump
I I I
I I 'I I I I I
I I I I I I
Valve lifter I I I I I I I
L---~-----__L------L-----_L--j---~---i L _
SLC773A
LC-35
ENGINE LUBRICATION SYSTEM I FD I

WARNING:
be hot.
tion.
1. Check oil level.


ture.
Engine rpm
Idle speed 69 (0.69, 0.7, 10)

2,000 294 (2.94, 3.0, 43)
3,200 392 (3.92, 4.0, 57)
leaks.
Oil pressure switch:
~: 10 - 13 N.m (1.0 - 1.3 kg-m, 7 - 9 ft-Ib)
LC-36
Oil Pump

SLC776A
G) a-ring @ Relief valve @ Gasket

@ Oil pipe @ Valve spring @) Driven gear
@ Gasket (J) Gasket @ Cover
@ Case & driven gear assembly @ Plug
INSTAllATION
• Temporarily tighten oil pump, then connect oil pipe.
CAUTION:
When assembling, make sure to align marks on drive gear and
driven gear.
SLC327
Oil PUMP INSPECTION

1. Inspect pump body, cover, gears and drive shaft for wear
and damage.
2. Check driven gear shaft and driven gear hole clearance. If
clearance is not within the specified range, replace gear or
case.
Driven gear shaft and driven gear hole clearance:
0.04 . 0.09 mm (0.0016 . 0.0035 in)
SLC322
LC-37
Oil Pump (Cont'd)
3. Check gear side clearance. If clearance is not within the
specified range, replace gears.
Gear side clearance:
0.06 - 0.11 mm (0.0024 - 0.0043 in)
4. Check gear tooth clearance. If clearance is not within the

specified range, replace gears.
Gear tooth clearance:
0.08 - 0.14 mm (0.0031 - 0.0055 in)
SLC325
5. Check gear backlash. If backlash is not within the specified

range, replace gears.
Gear backlash:
0.16 - 0.26 mm (0.0063 - 0.0102 in)
6. Check relief valve sliding surface and valve spring. If relief
valve seat is scratched or its movement is not smooth,
replace damaged parts.
SLC326
OIL PUMP RELIEF VALVE INSPECTION

2. Coat relief valve with engine oil and check that it falls
If damaged, replace oil pump relief valve set.
LC-38
Oil Filter Bracket
.q
@~
A : N.m. (kg-m, ft-Ib)
SLC778A
G) Gasket @ Oil filter relief valve @ Oil filter (for by-pass)

@ a-ring @ Oil filter (for full flow) @ Heat shield cover
OIL FILTER RELIEF VALVE INSPECTION

Inspect oil filter relief valve for smooth movement and damage
by pushing the ball.
If damaged, replace oil filter bracket assembly.
LC-39
Oil Cooler
SLC787A
G) Oil cooler element @ Gasket @ Valve spring

@ Gasket @ Plug @) Gasket
@ Regulator valve (J) Oil pressure switch @ Plug
@ Valve spring @ Relief valve (for oil cooler) @ Oil cooler housing

Q Inspect oil cooler relief valve for smooth movement and dam-
Install spring so that the smaller diameter side faces valve.
SLC518

LC-40
Oil Jet
INSPECTION (For gear train)
wire if necessary.
Oil jet has to beinstalle4 with all hole facing crankshaft gear
and camshaft gear.
INSPECTION (For piston)

1. Push cut-off valve of oil jet bolt with a clean resin or brass
rod and make sure that cut-off valve moves smoothly.
2. Make sure that the oil jet passage is not clogged. Clean
When installing all jet, direct oil jet nouletoWiilrc:l cylinder head
side and align all jet's locating pin with hole on cylinder block.
011 jet bolt:
tDJ: 29 - 39 N'm
(3.0 . 4.0 kg-m, 22 . 29 ft-Ib)
LC-41
COOLING SYSTEM I FD I
Cooling Circuit
To radiator
/'
From radiator
Radiator -__--= =::':1..... R_es_e_rvo_ir_t_an_k

__ -'
Water pump
Thermostat
Water outlet
~::.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.:.j Thermostat: Closed
SLC781A
LC-42
CHECKING HOSES
looSe connections, chafing and deterioration.

78 - 98 kPa
(0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2, 11 - 14 psi)
CHECKING COOLING SYSTEM FOR lEAKS

check for leakage.
Testing pressure:
157 kPa (1.57 bar, 1.6 kg/cm2, 23 psi)
CAUTION:
age.
SMA990A
Water Pump
Drain coolant from drain plugs on cylinder block and radiator.
Install water pump gasket with silicone-printed side facing

water pump.
SLC777A
LC-43
Water Pump (Cont'd)
1~
(0.6 • 0.7, 4.3 • 5.1)

SLC783A
G) Gasket @ Fan pulley @ Cooling fan

@ Water pump @ Fan coupling
CAUTION:
replaced as a unit.
INSPECTION
vane.
SLC784A

bimetal.
LC-44
Thermostat
i A 14 -18
(lA -, ... " - f3'
~CID----O .~
~
V'~ 0 't, 8 ~
.~0i1 ~" ~
4
~~SIiI'-v---,
/~?y'~.
0
(
7
A 14 - 18
(1.4 • 1.8, 10 - 13) V /"-~' / <.,/ ~--\@
CID rJ
SLC785A
CDWater outlet @ Thermostat housing (J) Water temperature sensor

@ Thermostat @ Heater connector @ Gasket
@ Gasket @ Thermosensor
• After installation,run engine for a .few minutes, and check
for leaks.
INSPECTION
Frigid type Standard Tropical type
82 (180) 82 (180) 76.5 (170)
'c rF)
Over Over Over
Max. valve lift
10/95 10/95 10/90
SLC343 mmtC (inrF)
(0.39/203) (0.39/203) (0.39/194)
*Frigid type is equipped with jiggle valve.

ing temperature.
LC ..45
Thermostat (Cont'd)
Intake manifold side
- • Install thermostat housing on cylinder head with silicone-
printed side facing the housing.
Silicone printed
SLC786A
Radiator
Front
SLC850A
G) Reservoir tank @ Radiator mounting bracket @ Clip

@ Radiator stay rJ) Radiator mounting bracket @ Radiator upper shroud
@ Baffle plate @ Baffle plate @ Radiator upper hose
@ Radiator mounting sleeve @ Radiator stay @ Radiator lower hose
@ Radiator rubber mounting @) Radiator lower shroud
LC-46
.SERVICE DATA AND SPECIFICATIONS (S.O.S.)
Engine Lubrication System

Oil pressure check Oil pump inspection
Unit: mm (in)
Engine Approximate discharge
rpm pressure kPa (bar, kg/cm2, psi) Rotor tip clearance Less than 0.12 (0.0047)
Idle speed More than 78 (0.78, 0.8, 11) Outer rotor to body
0.15 - 0.21 (0.0059 - 0.0083)
3,000 324 - 461 (3.24 - 4.61,3.3 - 4.7,47 - 67) clearance
Side clearance (with gasket) 0.04 - 0.08 (0.0016 - 0.031)
Regulator valve inspection

Unit: mm (in)
Regulator valve to oil pump

0.040 - 0.100 (0.0016 - 0.0039)
cover clearance
Engine Cooling System

Thermostat
Tropical
Standard Frigid type
type
Valve opening tempera-

82 (180) 88 (190) 76.5 (170)
ture 'C ("F)
More than More than More than

Max. valve lift
8/95 8/100 8/90
mml"C (inI"F)
(0.31/203) (0.31/212) (0.31/194)
lC-47

Oil pressure check Tightening torque
Engine Approximate discharge pressure Unit N'm kg-m ft-Ib
rpm kPa (bar, kg/cm2, psi)
Oil pump fixing bolt 13 - 19 1.3 -1.9 9 - 14
Oil cooler securing bolt 13 - 19 1.3 - 1.9 9 - 14
3,000 294 - 392 (2.94 - 3.92, 3.0 - 4.0, 43 - 57)
Oil filter bracket fixing bolt 13 - 19 1.3 - 1.9 9 - 14
Oil filter shield plate 13 - 19 1.3 - 1.9 9 - 14

Oil pump inspection Oil jet bolt (for piston) 29 - 39 3.0 - 4.0 22 - 29
Unit: mm (in)
Oil pump relief valve 29 - 49 3.0 - 5.0 22-36
Gear side clearance Less than 0.13 (0.0051)
Oil cooler short valve 29 - 49 3.0 - 5.0 22 - 36
Gear backlash Less than 0.30 (0.0118)
Regulator valve 29 - 49 3.0 - 5.0 22 - 36
Oil pump bushing
Less than 0.15 (0.0059)
clearance
Oil pump bushing inside

13.012 - 13.098 (0.5123 - 0.5157)
diameter
Drive gear shaft outside

12.974 - 12.992 (0.5108 - 0.5115)
diameter
Oil pump bushing oil clear-

ance
Standard 0.020 - 0.124 (0.0008 - 0.0049)
Limit 0.15 (0.0059)

Thermostat Tightening torque
Tropical type Standard type Unit N'm kg-m ft-Ib
Valve opening temperature 76.5 82 Water pump

'c ('F) (170) (180)
M8 13 - 19 1.3 - 1.9 9 - 14
Max. valve lift 8/90 8/95
M10 30 - 36 3.1 - 3.7 22 - 27
mml'C (inI'F) (0.31/194) (0.31/203)
Thermostat housing bolt 13 - 19 1.3 - 1.9 9 - 14
Water outlet bolt 13 - 19 1.3 - 1.9 9 - 14

Radiator
Unit: kPa (bar, kg/cm 2
, psi) Fan securing bolt 7-9 0.7 - 0.9 5.1 - 6.5
Cylinder block drain plug 20 - 29 2.0 - 3.0 14 - 22

78 - 98
Cap relief pressure
(0.78 - 0.98, 0.8 -1.0,11 -14) Water temperature sensor 20 - 29 2.0 - 3.0 14 - 22
Leakage test pressure 157 (1.57, 1.6, 23)
LC-48
SERVICE. DATA AND SPECIFICATIONS (S.O.S.)

Oil pressure check Tightening torque
Engine Approximate discha.rge pressure Unit N'm kg-m ft-Ib
rpm kPa (bar, kg/cm2, psi)
Oil pump fixing bolt 13 - 19 1.3 - 1.9 9 - 14
Idle speed More than 78 (0.78, 0.8,11)
Oil cooler securing bolt 13 - 19 1.3 - 1.9 9 - 14
3,000 294 - 392 (2.94 - 3.92, 3.0 - 4.0, 43 - 57)
Oil filter bracket fixing bolt 13 - 19 1.3 - 1.9 9 - 14
Oil jet bolt (for piston) 29 - 39 3.0 - 4.0 22-29

Oil pump inspection
Oil pump relief valve 29 -.49 3.0 - 5.0 22 c 36
Unit: mm (in)
Oil cooler short valve 29 - 49 3.0 - 5.0 22 - 36
Gear side clearance Less than 0.13 (0.0051)
Regulator valve 29 - 49 3.0 - 5.0 22 - 36
Gear backlash Less than 0.30 (0.0118)
Oil pump bushing oil

clearance
Standard 0.020 - 0.124 (0.0008 - 0.0049)
Limit 0.15 (0.0059)
Oil pump bushing

13.012 - 13.098 (0.5123 - 0.5157)
inside diameter
Drive gear shaft out-

12.974 - 12.992 (0.5108 - 0.5115)
side diameter

Thermostat Tightening torque
Tropical type Standard type Unit N'm kg-m ft-Ib
Valve opening temperature 76.5 82 Water pump

°c rF) (170) (180)
M8 13 - 19 1.3 - 1.9 9 - 14
Max. valve lift 8/90 8/95
M10 30 - 36 3.1 - 3.7 22 - 27
mmrC (inrF) (0.31/194) (0.31/203)
Thermostat housing bolt 13 - 19 1.3 - 1.9 9 - 14
Radiator Water outlet bolt 13 - 19 1.3-1.9 9 - 14

Unit: kPa (bar, kg/cm2, psi) Fan securing bolt 7-9 0.7 - 0.9 5.1 - 6.5
78 - 98 Cylinder block drain plug 20 - 29 2.0 - 3.0 14 - 22

Cap relief pressure
(0.78 - 0.98, 0.8 - 1.0,11 - 14)
Water temperature sensor 20 - 29 2.0 - 3.0 14 - 22
Leakage test pressure 157 (1.57, 1.6, 23)
LC-49

Oil pressure check Oil cooler inspection
Unit: kPa (bar, kg/cm2, psi)
Engine rpm
kPa (bar, kg/cm2, psi) Standard
Idle speed 69 (0.69, 0.7, 10) Regulator valve opening 402 - 481
2,000 294 (2.94, 3.0, 43) pressure (4.02 - 4.81, 4.1 - 4.9, 58 - 70)
3,200 392 (3.92, 4.0, 57) Oil cooler short valve 177 - 216
opening pressure (1.77 - 2.16,1.8 - 2.2, 26 - 31)
Oil filter short valve open- 88 - 108

Oil pump inspection
ing pressure (0.88 - 1.08,0.9 - 1.1, 13 - 16)
Unit: mm (in)
Gear side clearance 0.06 - 0.11 (0.0024 - 0.0043)
Gear backlash 0.16 - 0.26 (0.0063 - 0.0102)
Gear tooth clearance 0.08 - 0.14 (0.0031 - 0.0055)
Driven shaft and driven gear

0.04 - 0.09 (0.0016 - 0.0035)
hole clearance

Thermostat Radiator
Unit: kPa (bar, kg/cm2, psi)
Tropical
Frigid type Standard
type 78 - 98
Cap relief pressure
Valve opening temper- (0.78 - 0.98, 0.8 - 1.0, 11 - 14)
ature 82 (180) 82 (180) 76.5 (170) Leakage test pressure 157 (1.57, 1.6, 23)
'c ("F)
Over Over Over
Max. valve lift
10/95 10/95 10/90
mml"C (inI"F)
(0.39/203) (0.39/203) (0.39/194)
"Frigid type is equipped with jiggle valve.
LC-50
ENGINE FU.EL &
EMISSION CONTROL SYSTEM
SECTION EF& Ee
CONTENTS
PREPARATION (NA, TO, BD & FD)
~ ~INA~I
EF &~C- 3
~
•
ENGINE AND EMISSION CONTROL OVERALL SYSTEM EF & EC- 13
CARBURETOR EF & EC- 22
MECHANICAL FUEL PUMP EF & EC- 41
ELECTRIC FUEL PUMP CONTROL SYSTEM EF & EC- 42
IGNITION CONTROL SYSTEM EF & EC- 43
IGNITION CONTROL SYSTEM - Distributor. EF & EC- 46
EXHAUST EMISSION CONTROL SYSTEM EF & EC- 49
IDLE COMPENSATOR EF & EC- 53
EVAPORATIVE EMISSION CONTROL SYSTEM EF & EC- 54
CRANKCASE EMISSION CONTROL SySTEM EF & EC- 55
SERVICE DATA AND SPECIFICATIONS (S.O.S.) EF & EC- 56
~ ITD~I _
INJECTION SYSTEM EF & EC- 60

INJECTION PUMP EF & EC- 61
INJECTION NOZZLE EF & EC- 98
BLEEDING FUEL SYSTEM EF & EC-103
SOLENOID TIMER EF & EC-105
START Q ADJUSTMENT LEVER EF & EC-108
QUICK-GLOW SYSTEM EF & EC-110
FUEL CUT SYSTEM EF & EC-118
CRANKCASE EMISSION CONTROL SYSTEM EF & EC-119
SERVICE DATA AND SPECIFICATIONS (S.O.S.) EF & EC-120
~ IBD'-I ~
INJECTION SYSTEM EF & EC-142

INJECTION PUMP EF & EC-143
INJECTION NOZZLE EF & EC-190
FUEL FILTER EF & EC-197

FUEL HEATER SYSTEM EF & EC-198
AIR HEATER SYSTEM EF & EC-201
~ ~IFD I ~
BLEEDI NG FUEL SYSTEM EF & EC-271
EF & EC-2
ENGINE FU.EL &
SECTION EF& Ee
CONTENTS
PREPARATION (NA, TO, BD & FD)
~ ~INA~I
EF &~C- 3
~
•
ENGINE AND EMISSION CONTROL OVERALL SYSTEM EF & EC- 13
CARBURETOR EF & EC- 22
MECHANICAL FUEL PUMP EF & EC- 41
ELECTRIC FUEL PUMP CONTROL SYSTEM EF & EC- 42
IGNITION CONTROL SYSTEM EF & EC- 43
IGNITION CONTROL SYSTEM - Distributor. EF & EC- 46
EXHAUST EMISSION CONTROL SYSTEM EF & EC- 49
IDLE COMPENSATOR EF & EC- 53
EVAPORATIVE EMISSION CONTROL SYSTEM EF & EC- 54
CRANKCASE EMISSION CONTROL SySTEM EF & EC- 55
SERVICE DATA AND SPECIFICATIONS (S.O.S.) EF & EC- 56
~ ITD~I _
INJECTION SYSTEM EF & EC- 60

INJECTION PUMP EF & EC- 61
INJECTION NOZZLE EF & EC- 98
SOLENOID TIMER EF & EC-105
START Q ADJUSTMENT LEVER EF & EC-108
QUICK-GLOW SYSTEM EF & EC-110
~ IBD'-I ~


~ ~IFD I ~
BLEEDI NG FUEL SYSTEM EF & EC-271
EF & EC-2
PREPARATION
SPECIAL SERVICE TOOL

Destination
Tool number Hong Kong
Description General
Tool name Europe and Singa-
areas
pore
KV10108300
Idle adjusting
screwdriver x x
EF & EC-3
PREPARATION

VE-type injection pump
Adjusting device on vehicle
Tool number
Description
Tool name
KV11229352
Measuring device
(Set length of plunger
spring)
G) KV11229350
Holder
@ KV11229360
Nut
@ KV11229370
Pin
@ KV11254410
Dial gauge
Disassembling and assembling tools
Tool number
Description
Tool name
G) KV11244852
Universal vise
@ KV11244872
Bracket
@ KV11244792
Bracket
KV11229072
Insert device
KV11214110 For delivery valve

Socket wrench
KV11214270 For ~overnor pivot

Socket wrench
EF & EC-4
PREPARATION
Tool number
Description
Tool name
KV11214260 For regulating valve

Socket wrench
KV11214250 For distributor head plug

Socket wrench
KV11215842
Governor shaft adjusting
device
KV11229542
Feed pump holder
"MS" measuring device

set
G) KV11229110
Block gauge
@ KV11241920
Dummy shaft
@ KV11229830
Rod
KV11229752 For high altitude compensator

Block gauge
KV11229762 For hi,gh altitude compensator

Block gauge
KV11229042
"K" & "KF" measuring
device
KV11222090 For drive shaft

Oil seal guide
EF & EC-5
PREPARATION
Adjusting device on pump tester
Tool number
Description
Tool name
KV11281036
Fixing stand
KV11242442
Coupling
~
KV11282815 For timer advance angle
(fg ((@
Measuring device
KV11205032 For pipe length: 840 mm (33.07 in)
r
Injection pipe
KV11229462 For disassembling of regulating valve

Extractor
KV11229522 For assembling of regulating valve

Insert device
U
KV11257802 For Bosch type EF8511-9A
Nozzle holder
KV11257800 For Bosch type DN12SD12T

Nozzle
tj
EF & EC-6
PREPARATION

Injection nozzle
Tool number
Description
Tool name
KV11289004
Nozzle cleaning kit
G) KV11290012
Box
@ KV11290110
Brush
@ KV11290122
Nozzle oil sump scraper
@ KV11290140
Nozzle needle tip
cleaner
@ KV11290150
Nozzle seat scraper
@ KV11290210
Nozzle holder
(J) KV11290220
Nozzle hole cleaning
needle
KV11292210
Nozzle centering device
KV11290632
KV11290620
Nozzle seat scraper
EF & EC-7
PREPARATION I BD&FD I
In-line type injection pump
Tool number Description Engine application
Tool name BD FD
G) KV11244852
Universal vise
@ KV11244872
Bracket
@ KV11244782
Bracket
KV11226512 For flyweight

(DK57926512)*
Extractor
x x
KV11231612
(DK57931612)*
Tappet clamp X X
KV11231410
Tappet holder
X X
a
DK57914010 For timer round
X X
Socket wrench nut
KV11214240
Socket wrench X
KV11242442
iP
Coupling X
KV11242462
Coupling X
DK57916542 For use with cou-

Spanner piing
X X
*: These tools have two different tool numbers. If these S.S.T.s are required, place an order using KVxxxxxxxx.
EF & EC-8
Tool name BD FD
DK57923580 For press-fitting
DK57923590 plate plug
DK57923600
Drift
x X
D: DK57923580 17.95 mm (0.7067 In) dla.

DK57923590 21.95 mm (0.8642 In) dia.
DK57923600 25.95 mm (1.0217 In) dia.
Special tool For timer
G) KV11216432
(DK57916432)*
Timer wrench
@ KV11232020
(DK57932020)*
Timer spring support
@ KV11226582
Timer extractor
@ KV11224190 ~(j)
EJ--@
(DK57924190)*
~
Nut
@ KV11224180 X
(DK57924180)* @
Guide ~
@ KV11224170
(DK57924170)*
Guide bolt
(J) KV11224162
~@
(DK57924162)*
Base ~
KV11226692 For timer

Timer extractor
KV11231250
Tappet holder
X X
KV11215010 For flyweight

(DK57915010)* X X
Special wrench
EF & EC-9

Tool name SD FD
KV11221012
(DK57921012)*
Tappet insert x x
KV11221562
Plunger insert
x X
DK57913532 For adjusting gov-

Wrench ernor shaft
X X
DK57913540 For adjusting idle

Wrench spring
X X
DK57913362 For adjusting

Special wrench torque cam
X X
KV11257802
Nozzle holder
X X
KV11257800
Nozzle
KV11282618
a For control rack
X X
(DK05782618)*
Measuring device X
X
KV11257805
Injection tube
X X
EF & EC-10
Tool name SD FD
KV11205781
Securing stand x
KV11281035
Securing stand x
KV11282617
Adjusting device
KV11284019
Timer coupling
~
. KV11284051
Timer coupling
KV11284022 For use with timer
@
Driving device coupling
KV11282433 For plunger pre-

Measuring device stroke
X X
~
KV1128413 For camshaft end
Measuring device play
DK57976310 For locking con-

Lock screw trol rack
X X
EF & EC-11

Injection nozzle
Tool name BD FD
KV11289004
Nozzle cleaning kit
G) KV11290012
Box
@ KV11290110
Brush
@ KV11290122
@ KV11290140
Nozzle needle tip cleaner x x
@ KV11290150
Nozzle seat scraper
@ KV11290210
Nozzle holder
(J) KV11290220
Nozzle hole cleaning needle
KV11292210
Nozzle centering device
x X
KV11290632
X X
KV11290620
Nozzle seat scraper
X X
EF & EC-12
ENGINE AND EMISSION CONTROL OVERAL.L SYSTEM
..Engine and Emission Control System

Application
on Hong Kong and Singa-
Europe General areas
System pore
Automatic choke X X -
Idle-up control system * X X X

Fuel cut control system X X X
Mixture by-pass control system * X X X
Thermal vacuum valve
X X -
(T.V.V.)
Vacuum delay valve

X X -
Ignition control system (V.D.V.)
Vacuum switch & vac-

uum control solenoid X - -
valve
1 stage diaphragm - - X
Distributor
2 stage diaphragm X X -
Boost Controlled Deceleration Device (B.C.D.D.) X X -
Exhaust Gas Recirculation (E.G.R.) control sys-

- X -
tem
Idle compensator X X .. X
Evaporative emission control system - X -
Crankcase emission control system X X X
X: Available *: These systems are operated by the same solenoid valve.

-: Not available
EF & EC-13
ENGINE AND EMISSION CONTROL OVERALL SYSTEM
Engine and Emission Control Parts Location
V.v.T. valve
(Models with E.G.R.)
E.G.R. control valve

(Models with E.G.R.)
Idle-up solenoid valve
(Mixture by-pass solenoid valve)
Fuel cut solenoid valve
F.I.C.D.
(Models with
air conditioner)
T.v.v. (Models for Europe

and models with E.G.R.)
Carburetor
harness
connector
SEF795M
EF & EC-14
ENGINE AND EMISSION CONTROL OVERAll SYSTEM
System Diagram
MODELS FOR EUROPE
ec- Q)
.... >
o lU
o >
E:E
::> 0
::> c
o.!!!
~g
...
i
c
~ .... "0
::>
Q) E 00
0-
:28 - lii Q)
~'O~
u.CI) >
t\j
::>
Q) c
... lU
.2::i:
lU -
o
S
mo
a. ...
.c
°C
Ec
Q) 0
tj
o
t- 0
SEF796M
EF & EC-15
System Diagram (Cont'd)
MODELS WITH E.G.R.
SEF797M
EF & EC-16
System Diagram (Cont'd)
MODELS WITHOUT E.G.R. FOR AREAS OTHER THAN EUROPE
...
~c:
0)
Q.
0)
-
E
0
:E 0
g
c:
o
o
E::J
«s::::::-
... as
0) ::J
Q.c:
E as
O)~
1--
.c. .c.
o 0
:2j
() 1Il
SEF798M
EF&EC-17
Circuit Diagram
EF & EC-18
ENGINE. AND EMISSION CONTROL OVERALL SYSTEM
Circuit Diagram (Conl'd)
w @
l.3 CONDENSER
o.~~ ~~'u:~'
(!)
Z
> .... > HW L -D
a: a:
a: ;;J, ~~o W:J 0
a > ~
w W:JH WUl H
!-c t-o --'>-0 >-Ul a
....Jo..W . oxz w ~ ....
w UlW zw
:=>H .. cnHW --' >-I :EI ow>
W:E a: u~ a:I
:J:J :J a.~B >-I
t-u
...
~w :JU
:J!-c
a:o..u
W !-c
U....J....J
HO«
z
a
lJ..0.. tIl ...JIJJ .:> (I) ot-
a:
«
U
~a
1.L(J)
tlJ~(I)
...J...J(I)
lIt-!
I3
1-(1)
0:::£
t-o
::::>I.
<tU
UH
«3:
>Ul
3:....JH
OH3:
o..OUl
lJ..Ul>
B/W -0,
BIY -{JJ
B/W--(]9) H
I-
H-l
oM. S~~ lC1 (T) "!
@ ~
L 0
ZH
(!)O
HU
ru_
e..
v ~
C ~ ~ ~ ~
a
@
~@ nw?l@
.....
+'
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C
e..
a
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00 IDeo mx~
@)W @@W @Ef Ef B7Y~
a
0
v
e..
~lD
lD ;:C~ ~~8i ~
,3:: 3:
..1'-
lD Q) @ ~~
--'
~ lD B/W=tf
a. EU
L.e E
.....0 a
ro~ 0 DISTRIBUTOR
o~ a
!-cOO !-c
a:
B/R
B/R
-flLn
--=:'f JLJ~
rn-I:MlI ~ L..:..:..:J
__ ~
a
Ul
@ ~
@@
0000
..... 00
OOV EU W~Rj IW~R
fIlC
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g.e c v
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!:!L.c
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:EOO
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a..
+,Qi'
B --9J iB- B
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:Ja:ZW
____
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«00«
UZ-l-l
000)
.roro >UUl>
-:J..., a.
:Eo+'
.-I-'.~
Ul a
e..u
v...,
@
~ 't~ [;5-
+'
C
v_
EOO
:000
e..v
+,C
@ ~
file.. BR/W~_!-c
B/W ~W>-
a: cro
!::!.e W/R gi5:5
-ocj B/W :JIW
«ua:
lijUJ
Qi Qi
-0 -0 Ql Ql:5
0 0 c. g- .~
E E :>
5.!!!
e
ci q UJ UJQl
::C ::r; (; 0"8
.J a: u. u.E
Q@@~
RlBI~II
:;I
B
B/R
B/W
RIB
0 .~
_
_
...... H
lD
.'"' .• j1~'~
'!!!3
HOI-
a
Z
I-
wcr:J
@
I a.
U WE
>- (!)ro
H a:. _ a:...,
3: W(!) . «
Ul 3:ZC IO)
Uc .....
zB
a
OHO
a.. t-.r-! Ec
• :J +' oe..
He.. :>:: 00
>-0 U 00: Q) Lro
H
A+' 00
lJ..~
ZU ....J>-
(!)U tIlL-l....J
H« vo..w
W .....
o..
Ulv:Jc
::J
lJ:.-
a: en'n
SEF746M
EF & EC-19
Vacuum Hose Drawing

MODELS WITH E.G.R.
3-way
connector
T.v.v. (For distributor)
13
To canister
(Vacuum line) ¥' ¥' ~
To canister
(purge line) 11 10
Vacuum
gallery T.v.v.
Vacuum
(For E.G.R.)
connector
SEF840M
G) Distributor to vacuum gallery @ Vacuum gallery to vacuum gallery

@ Vacuum gallery to vacuum gallery @ Vacuum gallery to vacuum gallery
@ Vacuum gallery to air cleaner @ Vacuum gallery to 3-way connector
@ Vacuum gallery to carburetor @ 3-way connector to E.G.R. control valve
@ Vacuum gallery to vacuum connector @l 3-way connector to V.V.T. valve
@ T.V.V. (for E.G.R.) to vacuum gallery
@ V.V.T. valve to vacuum gallery
(J) T.V.V. (for E.G.R.) to vacuum gallery
@ Vacuum gallery to vacuum gallery
@ Vacuum connector to vacuum gallery
@ T.V.V. (for distributor) to vacuum gallery
@ Carburetor to vacuum gallery
@l Carburetor to vacuum gallery @) Vacuum gallery to vacuum delay valve
EF & EC-20
Vacuum Hose Drawing (Cont'd)
MODELS FOR EUROPE
Vacuum control
solenoid valve
Vacuum
delay valve
~
Front
B.C.D.o.
Vacuum
connector
Vacuum switch
SEF841M
CD Distributor to vacuum gallery @ Vacuum connector to vacuum switch

@ Vacuum gallery to TV.V. @ Vacuum connector to vacuum gallery
@ Vacuum gallery to vacuum gallery !JJ Vacuum gallery to vacuum control solenoid valve
@ Vacuum connector to vacuum gallery @ Vacuum control solenoid valve to vacuum delay valve
MO.DELS WITHOUT E.G.R. FOR AREAS OTHER THAN EUROPE
Air cleaner
SEF842M
CD Distributor to vacuum gallery

@ Vacuum gallery to carburetor
@ Vacuum connector to vacuum gallery
EF & EC-21
CARBURETOR
.~(@) 0
~ 1.0 - 3.4 ~-~ ~~ 2 - 6 (0.2 - 0.6, 1.4 - 4.3)
(0.1 - 0.35,
0.7 -2.5)
J'~
l ~2 - 6
o \;;
(0.2 - 0.6,
1.4 - 4.3) ~: N.m (kg-m, ft-Ib)
SEF799M
G) Choke chamber @ Primary slow air bleed @ Fuel cut solenoid valve
@ Accelerator pump lever @ Step jet @) Throttle valve switch
@ Power jet @) Idle-up jet @) Auto choke heater
@ Secondary main jet @ Vacuum break diagram (Automatic choke model)
@ Primary main jet @ Diagram for secondary system @ Fast idle cam
@ Accelerator pump piston @ Idle-up solenoid valve (Automatic choke model)
(J) Primary slow jet (Mixture by-pass solenoid valve) @ Throttle chamber
EF & EC-22
CARBURETOR
Construction
Secondary main nozzle Injection nozzle Choke valve
Secondary main air bleed'1

Secondary slow .air bleed'2
Primary main air bleed'1
Accelerator pump piston
Primary slow air bleed
Fuel needle valve
Primary slow
Fuel filter economizer air bleed'2
Vacuum
piston
Inlet check ball
Secondary main jet Primary slow jet
Step jet
Idle adjuslting screw
Step hole
Secondary throttle valve
Primary throttle valve
Idle-up nozzle
Idle~up air bleed'2 Primary main air bleed'1
Primary slow air bleed
Primary slow jet
Primary slow economizer
air bleed'2
Fuel cut
solenoid valve
Fuel cut control system

Idle-up control
solenoid
(Mixture by-pass
solenoid valve)
Idle-up control system

(Mixture by-pass control system)
'1: This air bleed cannot be removed from small venturi.
'2: This air bleed cannot be removed from carburector.
SEF020N
EF & EC ..
23
CARBURETOR
Major Service Operation

The perfectly adjusted carburetor delivers the proper fuel and
air ratios at all speeds for the particular engine for which it was
designed.
The carburetor should be maintained in its original condition
and will continue to deliver the proper ratios.
To maintain accurate carbureting through passages and dis-
charge holes, extreme care must be taken in cleaning.
Use only carburetor solvent and compressed air to clean all
passages and discharge holes. Never use wire or other pointed
instrument to clean or carburetor calibration will be affected.
REMOVAL
Remove carburetor from engine, taking sufficient care to the
following:
PRECAUTIONS:
a. When disconnecting fuel lines, do not spill fuel from fuel
pipe.
b. When removing carburetor, do not drop any nut or bolt into
intake manifold.
c. Be careful not to bend or scratch any part.
CLEANING AND INSPECTION
Dirt, gum, water or carbon contamination in or on exterior mov-
ing parts of a carburetor often results in unsatisfactory perfor-
mance. For this reason, efficient carbureting depends upon
careful cleaning and inspection while servicing.
Before assembling and installing the carburetor, blow all pas-
sages and castings with compressed air and blow off all parts
until dry.
Do not pass drills or wires through calibrated jets or passages
as this may enlarge orifice and seriously affect carburetor cal-
ibration.
Disassembling Carburetor Harness Connector

When replacing fuel cut solenoid, throttle valve switch, auto-
matic choke heater (choke chamber assembly) or idle-up sole-
noid (mixture by-pass solenoid) , it will be necessary to disas-
semble carburetor harness connector.
1. Remove rear clip.
SEF099H
2. With a small screwdriver, tilt lock tongue and, at the same

time, push out terminal.
CAUTION:
• When extracting terminal, do not pull wire harness. Always
push the top of terminal.
• Take care not to damage seal boot at the bottom of termi-
nal.
• Do not let oil or gasoline adhere to seal boot.
EF & EC-24
CARBURETOR
Checking and Adjusting Idle Speed, Ignition

Timing and Mixture Ratio
CAUTION:
a. Idle mixture ratio is adjusted at factory and requires no
further adjustment. If It becomes necessary to adjust It,
proceed with the following steps.
b. Do not attempt to screw the idle adjusting screw down
completely. Doing so could cause damage to tip, which in
turn will tend to cause malfunctions.
c. After adjusting idle speed and mixture ratio, be sure to
check items below, and if necessary, adjust them.
(1)F'astidle adjustment
(2)F.I.C.D. adjustment
PREPARATION
1. Make sure that the following parts are in good order.
• Battery
• Ignition system
• Fuses
• Vacuum hoses
• Air intake system
(Oil filler cap, oil level gauge, etc.)
• Engine compression
• Throttle valve
2. On air conditioner equipped models, checks should be car-
ried out while the air conditioner is "OFF".
3. When measuring "CO" percentage, insert probe more than
40 cm (15.7 in) into tail pipe.
4. Turn off headlamps, heater blower, rear defogger.
5. Keep front wheels pointed straight aheacl.
6. Use idle adjusting screwdriver (KV10108300)when adjust-

ing idle adjusting screw (Automatic choke model).
WARNING:
Depress brake pedal while racing the engine to prevent forward
surge of vehicle.
SMA075C
EF & EC-25
CARBURETOR ~
Timing and Mixture Ratio (Cont'd)
START
Visually check the following:

• Hoses and ducts for leaks
• Electrical connectors
• Gasket
• Throttle valve operation
Slart .'.". aod wa<m It ,p .,tII

wal., I.m~
perature indicator points to normal operat-
ing temperature.
/-,
I--V
H~~
C
o (£)
TEMP.J:
SMA059C
Open engine hood.
Race engine (2,000 - 3,000 rpm) 2 or 3 min-

utes under no-load, and then run engine at
idle speed.
Check idle speed.
Idle speed:
750::1:50 rpm
SEF835M
O.K.
Disconnect distributor vacuum hose @ and Adjust idle speed by

install a plug to vacuum hose. ~ turning throttle
adjusting screw.
Check ignition timing at idle speed.
Ignition timing: degree B.T.D.C.

3::1:2
O.K. N.G.
Adjust ignition tim-

ing by turning dis-
tributor.
Connect distributor vacuum hose.
EF & EC-26
CARBURETOR ~
@
<ID @
~
Race engine (2,000 -
3,000 rpm) 2 or 3 times
under no-load, and then
run engine at idle
speed.
!
Adjust idle speed by
turning throttle adjust-
ing screw.
Idle .speed: rpm

750:l::50
!
Confirm ignition timing
at idle speed. (Except Clean or replace
SEF835M for Europe) vacuum hoses.
Ignition liming: degree

B.T.D.C.
3:l::2 (For Europe) I
10 :l::5 (Except for Check distributor
Europe) vacuum hoses.
O.K. N.G.
~ Without "CO"-meter @
I
With "CO"-meter
!
Check "CO"% at idle
speed.
Idle "CO": %
1.0:l::0.5
!O.K. N.G.
END
I
Adjustidle
"CO"% to
1.0:l::0.5% by
turning idle
adjusting screw.
J
SEF982M
EF & EC-27
CARBURETOR ~
@
CAUTION: Turn out idle adjusting screw approxi-

Do not attempt to screw the mately two turns, starting from fully
idle adjusting screw down closed position.
completely. Doing so could
cause damage to tip, which
in turn will tend to cause
malfunctions.
SEF835M
Adjust engine speed by turning throttle

adjusting screw.
Engine speed: rpm

800:1::50
Turn idle adjusting screw until engine

runs smoothly at highest speed.
Engine speed Engine speed

does not rise. rises.
Adjust engine speed by turning idle

adjusting screw clockwise.
Idle speed : rpm

750:1::50
END
SEF982M
EF & EC-28
CAR.BURETOR
Fuel Le"el
INSPECTION
Disconnect ignition wire between dis-

tributor and coil.
Disconnect fuel cut solenoid connector

of carburetor.
Check primary main nozzle to ensure N.G. Check needle valve for
that no fuel is discharging while crank- looseness or sticking. If
ing engine for approximately 3 sec- necessary, repair or
onds. replace.
Adjust fuel level.
O.K.
Check that acceleration pump nozzle N.G.

SEF547G injects fuel when throttle valve is
.- opened .
e
Nozzle I
O.K.
END
Accelerating
i\
pump piston
~p ~~.
,,,""
::1
-------- -
r,
II
~
'-. "
_OJ
Primary Outlet check valve

side
SEF548G
• If necessary, use Tool (1612501MOO)to visually check fuel

level as follows:
1. Disconnect inlet fuel hose from carburetor, and plug open-
ing.
2. Start engine and wait for it to stop.
3. Install Toolan carburetor, as shown.
Be careful not to spill fuel.
4. Connect inlet hose to carburetor.
5. Start engine. Visually check fuel level.
If out of specification, adjust by bending float seat and float
stopper.
EF & EC-29
CARBURETOR ~
Fuel Level (Cont'd)
ADJUSTMENT
1. Remove carburetor from engine.
2. Remove choke chamber from carburetor.
3. Turn choke chamber upside down, and fix it horizontally.
4. Raise float fully, then lower it slowly until float seat contacts
needle valve, and in this position, check height "H1".
Height "H1":
4.8.5.8 mm (0.189 - 0.228 in)
If out of specification,
adjust by bending float seat. Make sure
needle valve slides smoothly on float seat.
SEF537G
5. Lower float slowly until float stopper contacts carburetor,

and in this position, check height "H2".
Height "H2":
47.5 - 48.5 mm (1.870 - 1.909 in)
If out of specification, adjust by bending float stopper.
6. Install choke chamber and then place carburetor on engine.
7. Perform "FUEL LEVEL INSPECTION".
SEF674G
Automatic Choke
MECHANICAL CHECK
1. Before starting engine, fully open throttle valve and ensure
Automatic that choke valve closes properly.
choke relay 2. Push choke valve with your finger to check for smooth
movement.
Automatic choke
SEF838M
3. Make sure bimetal cover index mark is aligned with center

of choke housing index mark.
4. Check wiring connection, and start engine.
5. After warming up engine, ensure that choke valve is fully
open.
If not, check automatic choke circuit and heater.
SMA855A
EF & EC-30
CARBURETOR ~
Automatic Choke (Cont'd)
ENTIRE SYSTEM
Do not attach test leads of a circuit tester to those other than
designated.
1. Start engine.
2. Check voltage between terminal @ and ground, with

[1t engine running.
CONNECT Voltage: Approximately 9 - 12V
II) If no voltage appears, check the following items.
• Automatic choke relay
• Automatic choke circuit
• Fuse
SEF823M
AUTOMATIC CHOKE CIRCUIT

1. Disconnect automatic choke relay and then connect a suit-
able jumper wire between terminals CID and @.
Carburetor 2. Disconnect carburetor harness connector.
Automatic choke
relay harness
Eta
4
harness
connector
3. Turn ignition switch "ON". Check voltage between carbu-
retor harness connector terminal @ and body ground.
Voltage: Approximately 12V
connector If N.G., check or repair the harness.
~
SEF825M
AUTOMATIC CHOKE RELAY

Check relay for proper operation.
AUTOMATIC CHOKE HEATER

1. Disconnect carburetor harness connector.
~
DISCONNECT
2. Check continuity between choke heater connector terminal
18 @ and choke housing.
Continuity should exist.
SEF826M
EF & EC-31
CARBURETOR
Fast Idle
AUTOMATIC CHOKE MODEL
1. Warm up engine.
2. Set fast idle arm on 2nd step of fast idle earn.
3. Check fast idle speed. .
Fast idle speed (at 2nd cam step):
2,800::l:100 rpm
Make sure that engine is completely adjusted (idle speed, igni-
tion timing, etc.) before checking or adjusting fast idle speed.
4. If out of specification, remove carburetor and make fast idle

adjustments as follows:
1) Place fast idle arm on 2nd step of fast idle earn, in the same
manner as in step 2. above.
2) Adjust clearance "A" between primary throttle valve and
inner carburetor wall by turning fast idle adjusting screw.
Clearance "A":
Models for Europe
0.80::l:0.07 mm (0.0315::l:0.0028 in)
Models with E.G.R.
0.57::l:0.07 mm (0.0224::l:0.0028 in)
5. After adjusting clearance "A", install carburetor on engine
and check engine speed.
Following installation, do not attempt further adjustment of
clearance "A" even if fast idle speed is Incorrect.
MANUAL CHOKE MODEL

Check clearance "A" between primary throttle valve and inner
wall by pulling choke lever completely.
Clearance "A": 1.30::l:0.15 mm (0.0512::l:0.0059 in)
If out of specification, adjust it by bending choke connecting
rod.
EF & EC-32
CARBURETOR
Fast Idle (Cont'd)
-------l/ChOke
Choke lever ; /-.11, .valve
~: :.~
, \
)
(
"A"
SEF067
Vacuum Break
AUTOMATIC CHOKE MODEL
1. When engine is cold, close choke valve completely.
2. Apply vacuum to vacuum break diaphragm with a handy
vacuum pump.
Approximately -53.3 kPa
(-533 mbar, -400 mmHg, -15.75 inHg)
Vacuum break
diaphragm
SEF827M
3. In this condition, check clearance "R" between choke valve

and carburetor body.
R,
~ Temperature Clearance R mm (in)

CD
() .C ("F) Models for Europe Models with E.G.R.
<: R2
1.50:1:0.12 1.74:1:0.15
~
CD Below 5:1:4 (41 :1:7.2) R1
13 (0.0591 :I: 0.0047) (0.0685:1: 0.0059)
Above 165:1:4 3.10:1: 0.44 2.79:1:0.30
R2
(62:1:7.2) (0.1220:1: 0.0173) (0.1098:1: 0.0118)
5 :t4°C 16.5 :t4°C
(41 :t 7.2°F) (62 :t 7.2°F)
Temperature T SEF022N 4. If out of specification, adjust "R" by bending tongue.
EF & EC-33
CARBURETOR ~
Vacuum Break (Cont'd)
MANUAL CHOKE MODEL
1. When engine is cold, close choke valve completely.
2. Apply vacuum to vacuum break diaphragm with a handy
vacuum pump.
Approximately -53.3 kPa
(-533 mbar, -400 mmHg, -15.75 inHg)
3. In this condition, check clearance "R" between choke valve
and carburetor body.
Clearance "R":
1.6 - 1.9 mm (0.063 - 0.075 in)
SEF016N 4. If out of specification, adjust "R" by bending rod.
Accelerator Pump
1. With engine stopped, make a visual check of the accelera-
tor pump connecting rod and lever.
• If they are bent or twisted, replace them.
SEF443K
2. Turn the throttle lever and make sure that fuel is smoothly
injected from the injector located in the primary port.
• If the accelerator pump is not functioning properly, check
the pump piston.
Replace it if necessary.
SEF052D
Fast Idle Control Device (F.I.C.D.)

1. Warm up engine sufficiently.
2. Check idle speed.
Idle speed: 750:!: 50 rpm
3. Turn air conditioner switch and fan switch "ON", and check
idle speed.
Idle speed: 850:!: 50 rpm
4. If out of specification, adjust idle speed by turning adjust-
ing screw.
INSPECTION
Apply vacuum to F.I.C.D. with a handy vacuum pump.
Rod of F.I.C.D. should pull out.
EF & EC-34
CARBURETOR
Fast Idle Control Device (F.I.C.D.) (Cont'd)
F.I.C.D.SOLENOID VALVE
1. Disconnect F.I.C.D. harness connector.
2. Check continuity between terminals.
If N.G., replace P.I.C.D. solenoid valve.
m m
SEF500L
Idle-up Control System

This system prevents poor battery charging and erratic idling
Idle-up
when power steering oil pressure switch is operating.
solenoid In this system, the proper fuel is added when solenoid valve
valve attached to carburetor is in the "ON" position.
SEF828M
Idle-up solenoid valve INSPECTION

(Mixture by-pass solenoid valve)
Idle-up control solenoid valve (Mixture by-pass solenoid
valve)
1. Connect solenoid valve connector to battery.
2. Check "click" sound from solenoid valve when battery is
connected and disconnected.
3. If no sound is heard from solenoid valve, replace with a
new one.
1) Disconnect harness from harness connector.
2) Remove solenoid valve from carburetor.
3) Install new solenoid valve. After replacement, check that
solenoid valve is in.good condition.
Power steering oil pressure switch

~Di8T~ 1. Disconnect power steering oil pressure switch harness
connector.
m 2. With engine running, check continuity between terminals.
Condition Continuity
Steering wheel being turned Yes
Steering wheel not being turned No
If N.G., replace power steering oil pressure switch.

SEF830M
EF & EC-35
CARBURETOR
Fuel Cut Control System and Mixture By-pass

Control System
FUEL CUT CONTROL SYSTEM
Description
The fuel cut control system is designed to reduce He emission
and to promote good fuel economy during deceleration.
FUSIBLE
LINK
8
r iDLE-upSOLENCiib------,
CARBURETOR
I VALVE (MIXTURE :
>-
a:
W
I BY-PASS SOLENOID VALVE) I
l- Z 1 I
I- o 3
- « H I 1
III I-
W::J
I I
Z...J I THROTTLE VALVE SWITCH I
HOI- I I
From ignition coil (!»H I I
(Via resistor) 13 ZWZ 2
Wa:::J I
1
1 .:: JI
7
CLUTCH SWITCH
SEF748M
Clutch switch*1 Throttle switch*2 Engine speed Fuel cut control system
OFF OFF Over 2,150 rpm Operates*3
Except above condition Does not operate
*1: Clutch switch ON: Clutch pedal is depressed.

OFF: Clutch pedal is not depressed.
*2: Throttle switch ON: Throttle valve is open.
OFF: Throttle valve is closed.
*3: Fuel cut solenoid is OFF and the fuel to the engine is cut.
EF & EC-36
CARBURETOR ~
Control System (Cont'd)
MIXTURE BY-PASS CONTROL SYSTEM
Description
The mixture by,.pass control system is designed to reduce He
emission and.to prevent after burn.
FUSIBLE
LINK CARBURETOR
fToCE-=-UpsoTENOTo-----l
8
IVALVE (MIXTURE I
1BY-PASS SOLENOID VALVE)I
1 1
Z 3
o
H I I
J-.,- I I
w:::> I THROTTLE VALVE SWITCH I
Z...J
HOJ-.,- I 1
From ignition coil (!»H I I
(Via resistor) 13 zwz 2 1
wec:> I
I -=_I J
7 CLUTCH SWITCH
SEF811M
Mixture by-pass control sys-

Clutch switch*1 Throttle switch*2 Engine speed
tem
OFF OFF 1,100 - 2,150 rpm Operates*3
Except above condition Does not operate
*1: Clutch switch ON: Clutch pedal is depressed.

OFF: Clutch pedal is not depressed.
*2: Throttle switch ON: Throttle valve is open.
OFF: Throttle valve is closed.
*3: Mixture by-pass solenoid is ON and additional mixture gas is supplied.
EF & EC-37
CARBURETOR ~
OPERATION CHECK
mFOO 1. Start the engine and warm it up until choke valve is fully
tiS ..
open.
2. Check the voltage between engine revolution unit harness
terminal and body ground in the conditions shown below.
!~
I
I
I
""----
SEF988M
Fuel cut control system
Terminal No.
Condition Engine speed Voltage (V)
(f> e
Clutch pedal is not depressed Over 2,150 rpm Body Battery voltage (11 - 14V)
@
Throttle valve is closed Engine speed is idle speed ground OV
Mixture by-pass control system
Terminal No.
Condition Engine speed Voltage (V)
(f> e
Clutch pedal is not depressed 1,100 - 2,150 rpm Body OV
@
Throttle valve is closed Engine speed is idle speed ground Battery voltage (11- 14V)
INSPECTION
Throttle valve switch
1. Start engine and warm it up until choke valve is fully open.
2. Stop engine and disconnect carburetor harness connector.
3. With choke valve fully open, check the continuity between
terminal <ID and ground.
Accelerator pedal not depressed: Discontinuity
Accelerator pedal depressed: Continuity
If N.G., replace or adjust throttle valve switch.
EF & EC-38
CARBURETOR ~
Throttle valveswUch adjustment
If throttle valve switch is replaced or removed, it is necessary
to install in proper position, following the procedure shown
below:
1; Remove carburetor from engine.
2. Install throttle valve switch on carburetor.
3. Adjust clearance "B" by bending adjusting plate when
switching the continuity of throttle valve switch ON to OFF
while closing throttle valve gradually.
Clearance "8": 0.25 • 0.45 mm (0.0098 • 0.0177 in)
"8"
SEF928M
Clutch switch
1. Disconnect harness connector for clutch switch.
2. Check the continuity between terminals @ and @.
ChAtch p~dal is not depresse<:l: Discontinuity
Clutch pedal is depressed: Continuity
Clutch
switch
SEF925M
Fuel cut solenoid valve

1. Connect solenoid valve connector to battery.
2. Check "click" sound from solenoid valve when battery is
connected and disconnected.
3. If no sound is heard from fuel cut solenoid valve, replace
with a new one.
1) Disconnect harness from harness connector.
2) Remove fuel cut solenoid valve from carburetor.
3) Install new fuel cut solenoid valve.
After replacement, start engine and check that fuel cut solenoid
is in good condition.
Mixture by-pass solenoid valve

Refer to "Idle-up Control System".
EF & EC-39
CARBURETOR ~
Engine revolution unit
Engine revolution unit is installed on the driver's dash side.
CONNECT
Check input and output signals for each terminal of engine
revolution unit as shown.
£) 1. Disconnect the connectors of clutch switch.
2. Start the engine and warm it up until choke valve is fully
~ open.
SEF926M
Check terminals Circuit tester

Condition
+ - Range Reading
Ground (J) - n on
Battery @ - Battery voltage (11 - 14V)
Ignition signal @ - Approx. 9 - 13V
Release the accelerator pedal Approx. battery voltage

Fuel cut solenoid @ Body fully at above 2,500 rpm. (11 - 14V)*1
ground V Approx.OV
Engine speed is idle speed.
Release the accelerator pedal
Approx. OV*2
fully at 1,100 - 2,150 rpm
Mixture by-pass solenoid @
Approx. battery voltage
Engine speed is idle speed
(11 - 14V)
*1: Until engine speed is under 2,150 rpm

*2: Until engine speed is under 1,100 rpm
EF & EC-40
MECHANICAL FUEL PUMP
Fuel Pump
The fuel pump is a mechanical type and is mounted on the cyl-
inder head. The end of the pump lever rests on the camshaft.
q When the camshaft rotates, the lever moves in a reciprocating
From fuel motion to deliver fuel from the fuel tank to the carburetor.
filter
SEF735H
Operation
1. Flush pump by immersing it in a fuel bath and operating
rocker arm several times.
2. Drain fUel from fuel pump. Then block off the inlet port and
BlOCk"
check that pump arm does not move.
3. Remove your finger from the inlet port and listen for a suc-
tion sound which will confirm that sufficient suction was
produced.
SEF743H
4. Block off outlet port and return port. Once again operate
rocker arm. After air pressure has been built up, confirm
that pressure remains for two or three seconds after.
5. Put a finger over outlet port and again build up pressure in
pump. Then slJbmerse pump in a fuel bath and check for air
leaks.
WARNING:
Before starting to work on any part of fuel system, disconnect
ground cable from battery. When disconnecting fuel hoses, use
a. container to catch fuel remaining in hoses.
SEF744H
Suitable blind plug Fuel Pressure

1. Disconnect fuel return hose and plug with a suitable blind
plug.
2. Disconnect fuel feed outlet hose and connect fuel pressure
gauge between fuel pump and carburetor.
3. Check fuel pressure with engine running at various speeds.
Fuel pressure:
24.5 - 34.3 kPa
(0.245 - 0.343 bar, 0.25 - 0.35 kg/cm2, 3.6 - 5.0 psi)
If out of specification, check for fuel filter clogging or
improper fuel pump operation.
EF & EC-41
ELECTRIC FUEL PUMP CONTROL SYSTEM
Component Parts Description

ELECTRIC FUEL PUMP
The fuel pump, which tS located in the front of the fuel tank, is
a electromagnet type pump.
l Fuel tank
SEF806M
Inspection
[:tI CioT 00 FUEL PUMP COMPONENT CHECK
1) Make sure that ignition switch is "OFF".
(ffi) 2) Disconnect fuel pump harness connector.
3) Check continuity between terminals.
SEF829M
FUEL PRESSURE CHECK

WARNING:
a. Keep flammables away during the test.
b. For safety, the test must be completed in as short a time
as possible.
1. Connect a suitable fuel pressure gauge.
2. Check fuel pressure.
Fuel pressure (Approximately):
21.0 - 26.0 kPa (0.210 - 0.260 bar,
0.214 - 0.265 kg/cm2, 3.05 - 3.77 psi)
If fuel pressure or fuel quantity is extremely low, check if
fuel filter is clogged.
EF & EC-42
IGNITION CONTROL SYSTEM
Wiring Diagram
IGNITION SWITCH
'- OFF ACC ON ST
1 Cl 0
2 6 0
3 0
4 [Instrument fJ42\@C7
5
W ~j~
harness)
W/_L ~
~
~ B/W
tl fr22\
2 3
5 4
\.51
~~
0.---: ~
I G1
+J Q) 3= \::J
~;im
[Chass is
harness)
~.~ ~.Q
g!s ~ ~
,,--'
n
3:>- >-3:
"J(" "
CIlCIl
II
W
II UJ
o Z
f- W
::J o
(Il z
H o
II u
f-
UJ
OJ H
RESISTOR
....
C 0
0)
c
OJ
FUSIBLE o
BATTERY f-
SPARK PLUG IGNITION
LINK COIL
SEF747M
System Description
Ignition timing is controlled by two systems built into the dis-
tributor to meet varying conditions during engine operation:
1) Governor advance system
Advances ignition timing in response to engine speed.
2) Vacuum advance system
Advances ignition timing by compensating for combustion
speed delay when intake vacuum is high.
Models without
Models for Models with E.G.R. for areas
Europe E.G.R. other than
Europe
Control vacuum
Intake manifold of carburetor Control vacuum
Vacuum source
vacuum Intake manifold of carburetor
vacuum
The thermal vacuum valve is located on the front side of intake

manifold. Ignition timing is advanced during engine warm-up
for improved performance.
The vacuum switch and vacuum control solenoid valve are
installed in the vacuum control line to the distributor. The vac-
uum switch detects intake manifold vacuum and lets the vac-
uum control solenoid.valve operate. Ignition timing is advanced
during deceleration for improved performance.
EF & EC-43
System Description (Cont'd)
OPERATION
Models for Europe
Engine coolant temperature T.V.V.
Vacuum advance
'c ('F) Between @ and @ Between @ and @
Below 20 (68) Close Open Fully advanced'
Above 20 (68) Open Close Normal
, Ignition timing is prevented from retarding suddenly by V.D.V. when depressing accelerator pedal.
Intake manifold vacuum Vacuum control solenoid

Vacuum switch Vacuum advance
-kPa (-bar, -mmHg, -inHg) valve
Below 76.0 (760, 570, 22.44) ON ON Fully advanced
Above 76.0 (760, 570, 22.44) OFF OFF Not advanced
Models with E.G.R.

Engine coolant temperature T.V.V.
Vacuum advance
'C ('F) Between @ and @ Between @ and @
Below 50 (122) Close Open Fully advanced'
Above 50 (122) Open Close Normal
, Ignition timing is prevented from retarding suddenly by V.D.V. when depressing accelerator pedal.
TVV. Component Parts Description

THERMAL VACUUM VALVE (T.V.V.)
This thermal vacuum valve is mounted on the front side of the
intake manifold. It detects engine coolant temperature and
opens or closes the vacuum passage in the thermal vacuum
valve.
SEF964M
v.ov. VACUUM DELAY VALVE (V.D.V.)

The vacuum delay valve is installed in the vacuum control line
to the distributor. This valve prevents ignition timing from
retarding suddenly when the throttle valve is opened rapidly .
From •
carburetor
To •
distributor
SEF984M
Component Parts Inspection

Remove T.V.V. from engine.
Blow air from @ port and check to be sure that TV.V. opens
or closes in response to its temperature.
CAUTION:
Do not allow water to get inside the T.V.V.
SEF965M
EF & EC-44
Component Parts Inspection (Cont'd)
Between @ and @ Operation of T.V.V.
1_1
Valve Unit: .C CF)
Models for Europe Models with E.G.R.

T1 15 (59) or more 45 (113) or more
:~: nm
T2 20 (68) 50 (122)
I
I
I
I
T, T,
Water temperature roc (OF)] SEF985M
Between @ and @
Valve
~:~ 1'---_1_ I
I
I
!
T, T,
Water temperature roc (OF)] SEF986M
VACUUM DELAY VALVE

1. Blow air from the port of the distributor side. The valve is
in good condition if the air flows through the valve.
2. Try again from the opposite side of the valve. The valve is
in good condition if the .air flow resistance is greater than
in step 1 above.
CAUTION:
Be careful to avoid entry of oil or dirt into valve.
VACUU M SWITCH
~Di(Y~ 1.
2.
Disconnect vacuum switch connector.
Check continuity between terminals.
m 3. Apply vacuum to vacuum switch port with a hand vacuum

pump.
Applied vacuum -kPa (-bar, -mAlHg, -inHg) Continuity
Below 76.0 (760, 570, 22.44) Yes
Above 80.4 (804, 603, 23.74) No
SEF830M
If N.G. replace vacuum switch.
VACUUM CONTROL SOLENOID VALVE
Check air passage continuity.
Air passage continuity Air passage continuity
Condition
between @ and <ID between <ID and @
12V direct current sup-

Yes No
BATIERY ply between terminals
No supply No Yes
@ If N.G., replace solenoid valve.
EF & EC..45
IGNITION CONTROL SYSTEM - Distributor
MITSUBISHI make
~
@~
(J)
~~
@
Models without E.G.R. for
areas other than Europe
r$ @
~@~
@ C)
SEF834M
(i) Cap a,sembl, ~ @ Breaker @ Shaft

@ Rotor head (j) Dust seal @ Housing
@ Reluctor @ Cam assembly @ O-ring
@ Pick-up coil @ Governor spring @ Collar set
@ IC ignition unit @ Governor weight @ Vacuum controller
EF & EC-46
Disassembly
Carefully observe the following instructions during disassem-
bly.
• Put a matchmark across cam assembly and shaft so that
original combination can be restored at assembly.
• Inscribe a match mark across spring and mating parts so
that spring can i:)e replaced in its original position during
assembly.
Be careful not to stretch or deform governor spring.
Distributor Component Check

CAP AND ROTOR HEAD
1. Check cap and rotor head for dust, carbon deposits and
cracks.
2. Measure insulation resistance between electrodes on igni-
tion coil and spark plug sides on cap.
Insulation resistance:
More than 50 MQ
Insulation resistance • Less than specified value ... Replace.
tester
SEL656B
CHECKING AIR GAP

Check air gap between reluctor and stator.
Air gap:
0.25 - 0.5 mm (0.0098 . 0.0197 in)
Stator
• Stator set screw

SEF023N
VACUUM ADVANCE
1. Connect vacuum pump gauge to vacuum controller and
gradually draw a vacuum while watching breaker plate
movement. Check for smooth operation with no evidence of
binding.
2. Turn breaker plate right and left to check for freedom of
movement.
SEF465K
GOVERNOR ADVANCE
Turn head of cam assembly counterclockwise, release it, then
check that it returns smoothly to the original position.
SEL657B
EF & EC-47
Assembly
Carefully observe the following instructions.
GREASE POINT
Apply high-temperature grease to:
• Governor spring
• Frictional surface of governor weight
• Frictional surface of breaker plate
• Vacuum control shaft
• Cam assembly head
INSTAllATION OF GOVERNOR
Governor
spring Install governor springs, governor weights and cam assembly
to drive shaft as shown in figure.
SEF487G
EF & EC-48
EXHAUST EMISSION CONTROL SYSTEM
Boost Controlled Deceleration Device (B.C.D.D.)

DESCRIPTION
The function of the B.G.D.D. is to open the by-pass hole of the
carburetor slightly during deceleration. During deceleration,
the air-fuel mixture ratio becomes unbalanced and norma'i com-
bustion cannot continue. Thus, a great amount of unburned
hydrocarbons are emitted. The B.G.D.D. supplies additional air
into the intake manifold to balance the air-fuel mixture ratio and
prevent such unburned hydrocarbons .from being emitted.
OPERATION
Intake manifold vacuum
B.C.D.D. operation
-kPa (-mbar, -mmHg, -inHg)
Below 81.3 (813, 610, 24.02) Actuated
Above 81.3 (813, 610, 24.02) Not Actuated
INSPECTION AND ADJUSTMENT

1. Disconnect idle compensator vacuum hose.
2. Gonnect vacuum gauge to idle compensator vacuum hose.
3. Start engine and observe vacuum gauge while engine rac-

a: Maximum negative pressure
ing.
Negative a b: Operating pressu re
/' c: Idling pressure 4. If B.G.D.D. is in good condition, vacuum gauge will follow
pressure
the pattern shown in the figure at left.
Set
pressure -- ---- Set pressures are .shown in step 5.
Idling
pressure
Time
Characteristic curve of B.C.D.D.

EC502
5. If it does not react as described above, adjust operating

pressure.
1) Remove rubber cap on B.G.D.D.
2) Racing engine, turn adjusting screw until the specified set
pressure is obtained.
B.C.D.D. set pressure (at sea level):
-81.3 kPa (-813 mbar,
-610 mmHg, -24.02 inHg)
EF & EC-49
EXHAUST EMISSION CONTROL SYSTEM ~
Boost Controlled Deceleration Device (B.C.D.D.)
Adjusting screw (Cont'd)
a. Turning adjusting screw one quarter rotation will cause a
change in operation pressure of about 2.7 kPa (27 mbar, 20
mmHg, 0,79 inHg).
b. Do not fit tip of screwdriver tightly into screw slot.
• Turn clockwise to reduce operating pressure.

• Turn counterclockwise to increase operating
pressure. ET037
Boost Control Valve {B.C. V.)

Apply
vacuum
(Models without E.G.R. for areas other than
pressure Europe)
INSPECTION
Apply vacuum pressure below -81.3 kPa (-813 mbar, -610
mmHg, -24.02 inHg) to B.C.V. and check the operation. If N.G.,
replace valve.
SEF923M
Exhaust Gas Recirculation (E.G.R.) Control

System
r \
OR
-
Carburetor
SEF832M
OPERATION
Engine coolant V.V.T. valve
Thermal vacuum E.G.R. control sys-
temperature Exhaust gas pres-
valve" Venturi vacuum Operation tern
°C tFl sure
Below 50 (1221 Closed Anv condition Not actuated
Low
High
Closed Actuated
Above 50 (122) Open High
Low
Low Open Not actuated
EF & EC-50
EXHAUST EMISSION CONTROL SYSTEM
Component Parts Description

E.G.R. CONTROL VALVE
The E.G.R. control valve controls the quantity of exhaust gas to
be led to the intake manifold through vertical movement of the
taper valve connected to the diaphragm, to. which vacuum is
applied in response to the opening of the throttle valve.
SEF632B
T.V.V. THERMAL VACUUM VALVE (T.V.V.)
..•.•
=,.
Thermal vacuum valve detects engine coolant temperature by
means of a built-in bimetal, and opens or closes the vacuum
passage which controls E.G.R. system.
O-ring
Bimetal
Spring
SEF858H
E.G.R. control VENTURI VACUUM TRANSDUCER (V.V.T.) VALVE

ported vacuum
The V.V.T. valve monitors the pressure of the exhaust gas
I
,. Carburetor which actuates the diaphragm @ and the venturi vacuum
venturi which in turn activate the diaphragm @, <ID. This valve con-
vacuum
trols the carburetor throttle vacuum in order to activate the
E.G.R.controlvalve.
3 Air filter
When replacing the V.V.T. valve with a new one, verify that the
t 4 Diaphragm type number on the new part is the same as that on the former
Exhaust gas pressure 5 Diaphragm one.
1 Control orifice 6 Diaphragm
2 Air bleed 7 Spring
SEC069
Inspection
SYSTEM INSPECTION
1. Make a thorough visual check of E.G.R. control system. If
necessary, wipe away oil to facilitate inspection. If any
hoses are Cracked or broken, replace.
2. With engine stopped, inspect E.G~R.control valve for any
indication of binding or sticking by moving diaphragm of
control valve upwards with a finger.
3. Race engine (2,000- 3,000 rpm) under no-load, and place a
SEcm finger on the diaphragm of E.G.R. control valve to check for
valve operation.
Water temperature The diaphragm of E.G.R. control
°C (OF) valve
Below 50 (122) Does not move
Above 50 (122) Moves
If N.G., check vacuum hose for air leakage and T.V.V.
EF&EC-51
EXHAUST EMISSION CONTROL SYSTEM [@
Inspection (Cont'd)
E.G.R. E.G.R. CONTROL VALVE
control valve
Apply vacuum to E.G.R. vacuum port with a hand vacuum pump.
E.G.R. control valve spring should lift.
SEF820F
V.V.T. VALVE
Apply vacuum pressure to V.V.T. valve and check it for leakage
as shown. If a leak is discovered, replace valve.
-
SEF922M

Remove T.VV. from engine.
Blow air from @ port and check to be sure that TV.V. opens
or closes in response to its temperature.
CAUTION:
Do not allow water to get inside the T.V.V.
SEF861H
Operation of T.V.V.
I
Valve
Unit: DC CF)
40 (104) or more
~~ --------j 50 (122)
1----
I
I
I
T, T,
Water temperature 1°C (OF))
SEF862H
EF & EC-52
IDLE COMPENSATOR
Idle Compensator
The idle compensator is basically a thermostatic valve which
introduces air directly from the air cleaner to the intake mani-
.j fold to compensate for abnormal enrichment of mixture in high
idle temperatures and to stabilize the engine. The idle compen-
sator is installed on the air cleaner.
Orifice
n
To intake manifold
Air cleaner J SEF861A
Inspection
1. Remove air cleaner.
''== 2. Suck on hose to make sure neither idle compensator
Orifice opens.
SEF751H
Idle compensator opening temperature

Intake air temperature
Bimetal function
°C (OF)
Below 50 (122) Fully closed

55 - 60 (131 - 140) Closed or open
Above 60 (140) FUlly open
3. Direct warm air to idle compensator with a heat gun.

And measure operating temperature of idle compensator.
• Place thermometer as close as possible to idle compensa-
tor sensor.
4. Idle comp.ensator is in good condition if airflow opens idle
compensator when it reaches operating temperature.
• Take care not to bend or damage bimetals of idle compen-
s,ator.
EF & EC-53
EVAPORATIVE EMISSION CONTROL SYSTEM
Description
Purge control valve
..
Activated
carbon canister
Filter ... Fuel vapor
~ Purge air
<;:::::J Outside air
SEF833M
The evaporative emission control system is used to reduce

hydrocarbons emitted into the atmosphere from the fuel sys-
tem. This reduction of hydrocarbons is accomplished by acti-
vated charcoals in the carbon canister.
Q@ Inspection
CARBON CANISTER
Check carbon canister as follows:
@ : Blow air and ensure that there is no leakage.
CID : Blow air and ensure that there is leakage.
SEC424A
EF & EC-54
CRANKCASE EMISSION CONTROL SYSTEM
Description
P.C.v. valve This system returns blow-by gas to both the intake manifold and
air cleaner.
Th~ positive crankcase ventilation (P.C.V.) valve is provided to
conduct crankcase blow-by gas to the intake manifold.
During partial throttle operation of the engine, the intake man-
ifold sucks the blow-by gas through the P.C.V. valve.
Normally, the capacity of the valve is sufficient to handle any
blow-by and a small amount of ventilating air.
The ventilating air is then drawn from the air cleaner, through
the hose connecting air cleaner to rocker cover, into the crank-
case.
Under full-throttle condition, the manifold vacuum is insufficient
to draw the blow-by flow through the valve, and its flow goes
through the hose connection in the reverse direction.
On vehicles with an excessively high blow-by some of the flow
will go through the hose connection to the air cleaner under all
conditions.
~ Fresh air
.. Brow-by gas
SEF808M
Engine not running

Cruising
or backfiring
Idling or Acceleration
-~.~ SEC559A
Inspection
P.C.V. VALVE
With engine running at idle, remove ventilation hose from
rocker cover; if P.C.V.valve is working properly a hissing noise
will be heard as air passes through it and a strong vacuum
shoUld be felt immediately whenafillget is placed over hose
inlet.
If N.G., check ventilation hose first.
If hose is O.K., replace P.C.V. valve.
UEF011
VENTILATION HOSE
VENTILATION HOSE
ET277
EF.&EC-55
Hong Kong and Sin-
Destination Europe General areas
gapore
21M304-181 21M304-081 21M304-161

Carburetor model
21M304-191*1 21M304-091*1 21M304-171*1
Throttle chamber bore P 30 (1.18)

mm (in) S 34 (1.34)
Large venturi diameter P 23.7 (0.933)

mm (in) S 30 (1.18)
P #102 .#104
Main jet Standard
S #170
P #55
Main air bleed*2
S #60
P #40 #44 #40

Jet and air bleed Slow jet
S #110
size
P #70*3
Slow economizer air bleed
S -
P #190
SloW air bleed
S #80*3
Power jet #45
Choke type Automatic choke Manual choke
Fast idle speed rpm 2,800:l: 100 -

Fast idle adjustment
(At 2nd cam step) 0.80:l:0.Q7 0.57:1:0.07 1.30:1:0.15
Clearance "A" mm (in)
(0.0315:1: 0.0028) (0.0224:1: 0.0028) (0.0512:1: 0.0059)
1.50:1:0.12 1.74:1:0.15
Clearance "R/'
Vacuum break (0.0591 :I: 0.0047) (0.0685:1: 0.0059) R: 1.6 - 1.9
adjustment mm (in) 3.10:1:0.44 2.79:1:0.30 (0.063 - 0.075)
Clearance "R2"
(0.1220:1: 0.0173) (0.1098:1: 0.0118)
B.C.D.D. operating pressure

-81.3 (-813, -610, -24.02) -
kPa (mbar, mmHg, inHg)
B.C.V. operating pressure -81.3 (-813,

- -
kPa (mbar, mmHg, inHg) -610, -24.02)
Idle speed Normal 750:1:50

rpm Air conditioner: ON 850:1:50
Idle CO% 1.0:1:0.5
P: Primary S: Secondary #: 1/100 mm

*1: Models with power steering
*2: This air bleed cannot be removed from small venturi.
*3: This air bleed cannot be removed from carburetor.
EF & EC-56
SERVICE DATA AND SPECIFICATIONS (S.O.S.).

IDLE COMPENSATOR IGNITION TIMING
Unit: °C ("F)
Hong Kong
Europe General areas
Idle compensator partially and Singapore
55 - 60 (131 - 140)
opens 3°:1:2°
Type 1*1
Idle compensator fully opens Above 60 (140) B.T.D.C.
3°:1:2° 10°:1:5°
Type 11*2
B.T.D.C. B.T.D.C.
IGNITION COIL
*1: Type I: Distributor vacuum hose disconnected and pluged
Primary resistance *2: Type II: Distributor vacuum hose connected
Approx. 1
[at 20°C (68°F)] o
Secondary resistance DISTRIBUTOR SPARK AND ADVANCE
Approx. 10
[at 20°C (68°F)] kO CURVE
Hong
MECHANICAL FUEL PUMP Europe
Kong and
China
General
Singa- areas
Fuel pressure 24.5 - 34.3 (0.245 - 0.343, 0.25 - Advance curve pore
kPa (bar, kg/cm2, psi) 0.35, 3.6 - 5.0)
Vacuum advance
Type A*1 Type B*2 Type C Type C
curve
ELECTRIC FUEL PUMP Governor advance
Type I Type I Type II Type III
curve
Fuel pressure 21.0 - 26.0 (0.210 - 0.260, 0.214-
kPa (bar, kg/cm2, psi) 0.265, 3.05 - 3.77) *1: Type A-1 operates when intake manifold vacuum is below
-76.0 kPa (-760 mbar, -570 mmHg, -22.44 inHg)
Type A-2 operates when engine coolant temperature is below
20°C (68°F).
DISTRIBUTOR *2: Type B-2 operates when engine coolant temperature is below
50°C (122°F).
Firing order 1-3-4-2
Rotating direction Counterclockwise
Air gap rnm (in) 0.25 - 0.5 (0..0098 - 0.0197)
Cap insulation resistance MO More than 50
Rotor head insulation resis-

More than 50
tance MO
EF & EC-57
Type A-1 Type B..1
Measure at 300 rpm Measure at 300 rpm
J15'
Q)
~
01
26.7 (267, 20(l, 7.87) x 6°
I
x lr
54.0 (540, 405, 15.94)
I
~ 10° 12.0 (120, 90, 11.5 (115, 86, 3.39)
Q) 3.54) x 0.5° x 0.5°
C>
c :.:::::.:.:.:.:.:.:.:.:.:.:::::.'
'"o
Q)
•..:.:.:.:.:.:.:.:.: .
~
"0
0°
B'" 5
:; a
:J
.0
'C
a 76 A
80.0 .0 13.3 26.7 40.0 53.3 66.7 80.0
'C
iii '(800, (133, (267, (400, (533, (667, (800,
iii
C5 (760, 600, C5 100, 200, 300, 400, 500, 600,
570, 23.62) 3.94) 7.87) 11.81) 15.75) 19.69) 23.62)
22.44)
Vacuum -kPa (-mbar, -mmHg, -inHg) • Vacuum -kPa (-mbar, -mmHg, -inHg) _
SEF989M SEF991M
Type A-2 Type B-2
Measure at 300 rpm Measure at 300 rpm
~ )15
0
C, 18.4 (184, 138, 5.43) x 4°

Q) 10°
~
Q) Q)
C> C>
c c
5°
'"
Q)
0
'"
Q)
o
c c
'"
>
"0 0°
'"
>
al
21.6 (216, 162, 6.38) x 2°
'"5 5
10.7 (107, 80, 3:15) x ("':1.5°)
:; a :; a 13.3 26.7 40.0 53.3 66.7 80.0
.0 13.3 26.7 40.0 53.3 66.7 80.0 .0
:s (133, (267, (400, (533, (667, (800, E (133, (267, (400, (533, (667, (800,
'" C5'"
100, 200, 300, 400, 500, 600, 100, 200 300 400, 500 600
C5 3.94) 7.87) 11.81) 15.75) 19.69) 23.62) 3.94) 7.87) 11.81) 15.75) 1969) 23.62)
Vacuum -kPa (-mbar, -mmHg, -inHg) - Vacuum -kPa (-mbar, -mmHg, -inHg) •
SEF990M SEF992M
Type I
Set to 0° at 300 rpm
2,150 x 12°
o 1,000 1,500 2,000 2,500 3,000
Distributor (rpm) •
SEF994M
£&ii: Distributor control zone.
EF & EC-58
SERVICE DATA AN.D•.SPECIFICATIONS (S.O.S.)
Type C
Measure at 300 rpm
- 13.3 (133, 100, 3.94) x (_1°)
o 13.3 26.7 40.0 53.3 66.7 80.0

(133, (267, (400, (533, (667, (800,
100, 200, 300, 400, 500, 600,
3.94) 7.87) 11.81) 15.75) 19.69) 23.62)
Vacuum -kPa (-mbar, -inmHg, -inHg) _
SEF993M
Type II
Set to 0° at 300 rpm
(;
'5
.c
.;::
(j)
is o 500 1,000 1,500 2,000 2,500 3,000
Distributor (rpm) ~
SEF995M
Type III
!
g>
<1l
f15
0
10°
2,150 x 12°
Set to 0° at 300 rplTi
<1l
<.>
~ 5°
al
(;
'5
.c
.;::
(j)
is o 500 1,000 1,500 2,000 2:500 3,000
Di:;tributor (rpm) ~
SEF996M
B: Distributor control zone.
EF .&>EC-59
INJECTION SYSTEM
CAUTION:
• Disassembly and assembly of the injection pumps should be done only In service shops authorized
by NISSAN or by the pump manufacturer.
• The pump tester is required for servicing the pump.
• Before removing fuel injection pump from vehicle, check closely to make sure that it is definitely
malfunctioning.
VE-TVPE INJECTION PUMP
Fuel System
ype 1
--- ---
Fuel return passage
Priming pumR
t Fuel filter
t Injection
nozzle
-
t Fuel tank
SEF382F
Type 2
FRCS
-
Priming pump
Fuel return passage
Fuel
tank
t
SEF491F
EF & EC-60
INJECTION PUMP
Removal
1. Remove injection tube.
Cover the injection nozzle assembly with a plug to prevent dust
entry.
2. Disconnect fuel cut solenoid wire connector.
3. Remove accelerator wire and disconnect overflow hose,

fuel inlet hose, fuel return hose and actuator hose.
4. Remove injection pump drive gear cover.
5. Mesh injection pump drive gear with idler gear at "Z" mark
so that NO.1 piston is at top dead center (T.D.C.).
EF&EC ..61
INJECTION PUMP l.!!U
Removal (Cont'd)
6. Remove injection pump drive gear nut with lock washer
and pull out the drive gear using a puller.
CAUTION:
Do not attempt to crank engine after removing Injection pump
drive gear.
7. Remove injection pump fixing nuts and injection pump sup-

port bolts.
8. Remove injection pump with injection tubes.

Disconnect injection tube from pump once it is removed.
Installation and Adjustment

1. Confirm that No.1 piston is set at T.D.C. on its compression
stroke.
2. Install injection pump.

(1) Temporarily set injection pump so that the flange of pump
is aligned with aligning mark on front end plate. Use a new
gasket.
(2) Install injection drive gear over the key.
tDJ:59 - 69 N'm (6 - 7 kg-m, 43 - 51 ft-Ib)
Coat key with grease to prevent it from falling into timing gear
case. Make sure that "Z" marks or injection pump drive gear
and timing gear case are at "punch mark and align line".
EF & EC-62
INJECTION PUMP [![]
Installation and Adjustment (Cont'd)
(3) Apply a continuous bead of liquid gasket to mating surface
of timing gear case cover.
• Be sure liquid gasket Is 2.5 to 3.5 mm (0.098 to 0.138 In)
wide. .
• AUachtiming gear case cover to timing gear case within 5
minutes after coating.
• Wait at least 30 minutes before refilling engine oil.
(4) Tighten injection pump nuts.
liquid gasket
tDJ: 20 - 25 N.m (2.0 - 2.5 kg-m, 14 - 18 ft-Ib)
SEF6261 (5) Install injection pump supports.
tDJ: Support to cylinder block
30 - 41 N.m
(3.1 -4.2 kg-m, 22 - 30 ft-Ib)
Support to injection pump
19 .. 25 N.m
(1.9 - 2.5 kg-m, 14 - 18 ft-Ib)
PLUNGER LIFT ADJUSTMENT

1. Loosen injection pump mounting nuts and mounting
bracket bolt.
2. Remove plug bolt from distributor head and install dial
gauge.
3. Plunger lift measurement and adjustment.
(1) Turn crankshaft counterclockwise 20 to 25 degrees from No.
1 piston at T.D.C.
(2) Find dial gauge's needle rest position at step (1) set
position, then set the gauge to zero.
(3) Turn crankshaft clockwise until NO.1 piston is set at T.D.C.
(4) Read dial gauge indication.
TD25:
0.71:1:0.02 mm (0.0280:1:0.0008 in)
(equivalent to 6° B.T.D.C.)
TD27:
0.65:1:0.02 mm (0.0256:1:0.0008 in)(equlvalent to 5°
B.T;D.C.)
(5) If it is not within the above range, turn pump body until it
comes within standard range.
a. If indication is smaller than the specified value, turn pump
body counterclockwise.
b. If indication is larger than the specified value, turn pump
body clockwise.
4. Tighten injection pump securely.
tDJ: Injection pump fixing bolt
19 - 25 N.m (1.9 - 2.5 kg-m, 14 - 18 ft-Ib)
Injection pump to mounting bracket
30 - 41 N.m (3.1 - 4.2 kg-m, 22 - 30 ft-Ib)
EF&EC-63
INJECTION PUMP L!!!..J
5. Disconnect dial gauge and reinstall plug bolt with new
washer.
tDJ:
14 - 20 N'm (1.4 - 2.0 kg-m, 10 - 14 ft-Ib)
6. Connect injection tubes.
2
tDJ:
Flare nut
20 - 25 N.m (2.0 - 2.5 kg-m, 14 - 18 ft-Ib)
7. Bleed air from fuel system.
IDLE AND MAXIMUM SPEED ADJUSTMENT

CAUTION:
a. Do not remove sealing wires unless absolutely necessary.
b. Disturbing full-load adjusting screw will change fuel flow
characteristics, resulting in an improperly adjusted engine.
Readjustment of fuel injection pump should be done using
a pump tester.
c. If maximum speed adjusting screw is turned in direction
that increases control lever angle, engine damage may
result.
Throttle control wire adjustment
Refer to "Adjusting accelerator pedal and cable" in section FE.
Idle speed adjustment

1. Refer to section MA for idle adjustment.
2. Make sure that clearance between the actuator idle control
rod and fuel injection pump control lever is within the spec-
ified range.
Clearance:
More than 2 mm (0.08 in)
SMA624C
EF & EC-64
INJECTION PUMP ~
Maximum speed adjustment
Maximum speed adjusting screw is retained by sealing cap and
need not be adjusted under normal circumstances. However, if
it becomes necessary to adjust it, the following procedure
should be followed:
1. Start engine and warm it up until coolant temperature indi-
cator points to middle of gauge.
2. Connect tachometer's pick-up to No. 1 fuel injection tube.
To obtain accurate reading of engine rpm, remove clamps that
secure No. 1 fuel injection tube.
3. Depress accele.rator pedal fully under no load and, at this
point, read the tachometer indication.
Maximum engine speed (Under no-load):
T025 :
5,000 ~~~ rpm
T027 :
5,100 ~~~ rpm
4. If indication is lower than specified maximum engine

speed, turn maximum speed adjusting screw counterclock-
wise 1 or 2 rotations. Then depress accelerator pedal to
floor under no load and,at this point, read indication.
5. If indication is still lower than specified speed, repeat step
4 above until specified engine speed is reached.
6. After adjustment, tighten lock nut securely.
7. Seal with a sealing wire or install a sealing cap.
SEF6271
Disassembly
PREPARATION
• Before performing disassembly and adjustment, test the
fuel injection pump and note test results.
• Prior to beginning disassembly of fuel injection pump,
clean all dust and dirt from its exterior.
• Disconnect overflow valve and drain fuel.
• Clean work bench completely, removing all foreign matter.
• Collect only those service tools necessary for disassem-
bling and reassembling.
• Be careful not to bend or scratch any parts.
EF & EC-65
INJECTION PUMP
Without high altitude compensator
(For without solenoid timer)
...
(l)
s
...
E
z
~
..c
E
(l)
U)
...II'i
...:
c:i
It)
e......
It)
SEF694M
EF & EC-66
~
.E
Ol
I
u.
~c
8
E
Z
.2:"-
.0
E
Q)
III
~
CD
c?
,..-
o
."
,..e.
SEF695M
EF & EC-67
INJECTION PUMP
Disassembly (Conl'd)
With high altitude compensator
SEF696M
EF & EC-68
INJECTION PUMP
Block gauge for,"MS

KVl1229110
H
\v
~2,
adjustment
Block gauge (With high altitude compensator) KVl1229752
~:;';~::;:'~~1~02~;~;1~d
.'.. ft..
,
BIOOk ,KV,11229762
Dial gauge
KVl1229352 {
A,djusting device
~ (For governor shaft)
o,mmY.~' . KVl1215842
KVl1241920
Adjusting device
KVl1229830
e
•9 ,
Socket wrench
(For regUlating valve)
KV11214260
~ Oil seal guide

(For drive shaft)
~ KV11222090
CGi
t • ''''' pomp hold"
KVl1229542
~
Socket wrench (For pivot bolt)
Socket~ch\ KVl1214270
(For head plug) Dial gauge
~
KVl1214250 (For measuring plunger lift on car) KV11229352 SEF5571
1. Remove pump cover.

(1) Remove nut, spring washer, spring seat and spring from
control lever.
SEF409A
(2) Draw matching marks on control lever and control shaft.

Matching marks
SEF410A
(3) Remove compensator cover.
SEF411A
EF & Ee-59
INJECTION PUMP
Disassembly (Coni' d)
(4) Remove bellows and adjusting shim.
(5) Remove E-ring, then remove spring seat and spring.
(6) Loosen nut.
(7) Remove governor cover plugs.
(8) Remove governor cover.

a. Remove sealing wire and idle and maximum speed adjust-
ing screws.
EF & EC-70
pUMP
INJECTIQN ....
b. Remove governor cover fixing bolts and screws.
Use hexagon wrench.
c. Remove full-load adjusting screw.

d. Remove governor cover, by holding control shaft with Tool
(KV11229072)and lifting governor cover.
Do not tap control shaft with a hammer.
(9) Rerhove high altitude compensator parts.

a. Remove plugs.
b. Remove lever pin and lever using a suitable drift and a
plastic mallet, by tapping it from the right-hand side
(viewed from the drive side).
c. Remove plUg and pin.
SEF420A
d. Remove retainer, sleeve and washer.

Use a suitable screwdriver to remove retainer.
SEF421A
EF & EC;.71
INJECTION PUMP
e. Remove nut and adjusting rod.
f. Remove bushing.

(1) Remove nut, spring washer, spring seat and spring from
control lever.
(2) Check matching marks on control lever and control shaft.
(3) Remove pump cover.

Lift and separate governor cover from control shaft, while
holding control shaft with Tool (KV11229072).
Do not tap control shaft with a hammer.
EF & EC-72
INJECTION PUMP
2. Remove control shaft from tension lever.
\
3. Remove governor shaft with Tool (KV11215842).
L.oosen locknut by turning it counterclockw.lse.
4. Remove.governor sleeve, washer and flyweight, along with

flyWeightholder,)hen remove washer and shims.
5. Remove plug with Tool.
EF & EC-73
INJECTION PUMP [![]
6. Remove delivery valve holder, spring, delivery valve and
gasket.
Distributor head has letters (A, B, C, D) stamped on it. Remove
lettered parts in alphabetical order and arrange neatly.
7. Remove fuel-cut solenoid valve.

Be careful not to drop the spring and armature.
8. Remove distributor head.

Be careful not to drop the two support springs and guide pins.
SEF475
Control sleeve
9. Remove plunger assembly.
Lift plunger, along with control sleeve, shim, spring seat,
plunger spring, washer and shim.
SEF476
10. Insert Tool (socket wrench) and loosen left and right gov-
ernor pivot bolts.
SEF032A
EF & EC-74
INJECllONPUMP [![]
Dis.assemblytCont'd)
11. Remove governor pivot bolts and lever assembly.
Avoid pulling on start spring and start Idle spring.
12. Remove.shim, cam disc, spring and driving disc.
~Shirn
earn disc
I--spring
$ Driving disc
SEF478
13. Remove.clip and pin.
14. Move adjusting pin to center of roller holder, as shown.

INJECTION PUMP
DiSassembly (Cont'd)
15. Lift out roller holder with rollers without tilting.
Be careful not to drop rollers.
SEF037A
16. Remove drive shaft.

a. Rotate drive shaft until keyway faces the top of Injection
pump.
b. Remove drive gear side key.
c. Attach Tool (011seal guide) KV11222090 onto drive shaft to
prevent keyway from damaging 011seal.
d. Be careful not to scratch inner surface of fuel injection
pump body.
e. Be careful not to drop the key.
SEF483
17. Remove speed timer cover, O-ring, shims, spring, piston
\~oo
@az",
and slider.
@az",~OI
_ r;; r Spring
, 0 •
, [ --------
-J
~
~g
SEF513
18. Remove regulating valve with Tool.
19. Loosen the two screws from feed pump cover.
EF & EC-76
INJECTION POMP [![]
20. Remove cover and feed pump assembly as a unit.
1) Insert Tool (feed pump holder) into fuel injection pump
housing.
2) Turn..injection pump upside down, as shown.
3) Rempve cover and feed pump assembly as a unit.
KV11229542 a. If cover and feed pump assembly are hard to remove or
stuck l1'Iid\Vay,strike the pump body lightly.
b. Do notchange positions of vanes.
SEF487
Inspection
1. Wash all parts completely.
2. Replace worn or damaged parts.
3. Control edge of plunger must be sharp and contact sur-
faces must not exhibit any noticeable running tracks. If the
condition is not good, replace plunger.
4. Check for height of all rollers.
Difference in maximum and minimum roller height should be
less than 0.02 mm (0.0008in).
SEF504
Assembly
Always replace the following service parts as assembly units.
• Distribut()rhead, control sleeve and plunger
• Feed pumpassembly (pump impeller al'ld vanes with
eccentric ring)
• Plunger spring kit
• Roller assembly
• Flyweight kit
• Governor lever assembly
Larger side Smaller side PREPARATION

Dip all movable parts and O-rings in test oil, thehclean.
1. Setfeed pump cover, rotor with vanes, and. ring on
Tool
(feed pump holder).
1) Align the three holes in feed pump cover and ring.
Feed pump
2) Do not change positions of vanes. .•......•
cover 3) Holes A and B in ring are not equally spaced to inner wall
of ring.
SEF505
2. Install feed pump cover, rotor with vanes, and ring to pump
housing.
Be careful to install ring correctly. If left and right are reversed,
fuel will not be discharged from feed pump.
SEF341F
EF & EC-l.l
INJECTION PUMP [![]
Assembly (ConI' d)
When fuel injection pump rotates in direction lOR"
The following description applies to fuel injection pumps that
rotate in direction lOR".
3. Turn fuel injection pump 180°, and remove Tool
(KV11229542).Tighten screw to retain pump cover.
a. When tightening screws, be careful not to scratch inner wall
of pump housing.
b. After tightening screws, make sure that rotor with vanes
moves smoothly.
SEF507
4. Make sure that drive shaft and gear are assembled

properly, as shown.
~ Side view of gear

m=J::::COJ
SEF342F
5. Install drive shaft to housing while key in drive shaft

engages with key groove in rotor.
a. Before installing drive shaft, attach Tool KV11222090(oil
seal guide) onto drive shaft.
b. Be careful not to scratch oil seals and inner wall of hous-
ing.
6. Set drive shaft's nail parallel to timer.

7. Install roller and holder.
a. Do not interchange roller positions. If they are
Interchanged, refer to Inspection for correction.
b. Make sure that washer is situated outward of rollers.
8. Align holder and timer adjusting pin holes.
EF & EC-78
INJECTION PUMP [![]
Assembly (ConI' d)
9. Install timer piston and slider as a unit.
a. Make sure that hole In slider faces towards roller holder.
b. Make sure that concave hole In piston Is on same side as
return hole.
10. Insert timer adjusting pin into timer piston slider, and
secure with retaining pin and clip.
Make sure that timer piston moves smoothly.
SEF042A
11. Install Ftimer, using a 0.6 mm (0.024 in) thick shim, then
\. Slider
(iston install timer spring, shim, O-ring, and cover, in that order.
\
f\---
~Shim
rSpring
Refer to S.O.S. for timer spring adding/shims.
• 0 I ~ • a. Use at least one shim on each side of timer spring.
, [~~ b. Use shims that were selected during bench test.
~g
SEF513
~8 -9.N.m
12. Install regulating valve.
(0.8 - 0.9 kg-m, Be careful not to scratch O.rlng~.
5.8 - 6.5ft-lb)
SEF514
13. Install driving disc with its concave side facing up.
SEF043A
EF & EC-79
INJECTION PUMP [![]
Assembly (Cont'd)
14. Measurement of plunger spring set length (dimension
"KF")
Dimension "KF" is the distance between the end face of the
distributor barrel and the end face of the plunger.
(1) Install distributor head, as shown.
• Do not Insert shim into "A" portion before measuring.
<D Spring seat

@ Plunger spring
@ Guide pin
@ Distributor head
@ Distributor barrel
@ Spring seat
(])
Washer
@ Shim
@ Plunger
SEF697M
(2) Install Tool (measuring device) and set dial gauge so that
it can compress 0 to 10 mm (0 to 0.39 in), and reset to zero.
KV11229042
SEF419
(3) Apply force (not enough to compress plunger spring) to

plunger's bottom in axial direction, and measure dimension
"KF: with dial gauge, as shown.
EF & EC.80
INJECTION PUMP lID
Assembly (Cont'd)
(4) Determine the shim to be used by calculating difference
between standard and measured dimensions.
Standard dimension "KF":
5.7 - 5.9 mm (O.224 - 0.232 in)
[Example]
When measured (dial gauge reading) value is 5.2 mm,
5.7 mm - 5.2 mm = 0.5 mm (shim thickness to be used)
a. When there are no shims available of a thickness which

matches specified dimensions, use slightly thicker shims.
b. Use selected shim with distributor head In step 14-(3)
above.
c. Use the same size shim on each side of distributor head.
d. Shims are available in seven different thicknesses.
Refer to S.O.S.for adjusting shims.
15. Adjustment of plunger dimensions (Measurement of dimen-

sion "K")
Dimension "K" Is the distance from the end face of the distrib-
utor barrel to the end face of the plunger top, when the plunger
is at the bottom dead center position.
(1) Install parts as shown.
a. Do not Install "spring" on driving disc.
b. When inserting plunger and shim Into cam disc, make sure
that drive pin is situated In groove at bottom of plunger.
CDDrive shaft (J) Spri ng seat

@ Driving disc @ Shim
@ Shim @ Distributor barrel
@ Spring seat @ Washer
@ Plunger spring (j]) Shim
@ Guide pin @ Camdisc
SEF370F
(2) Using a dial gauge, measure dimension as shown.

KV11229042
a. Rotate. drive shaft so that plunger is set at bottom dead
center.
b. Securely mount distributor head with screws.
SEF044A
EF & EC-81
INJECTION PUMP ~
Assembly (Cont'd)
Shim (3) Determine shim to be used by calculating difference
between measured (dial gauge reading) value and stan-
dard dimension "K", and position that shim on plunger's
bottom.
"K" =3.2.3.4 mm
(0.126.0.134 in)
a. When measured value is greater than standard dimension
"K", use a thicker shim.
b. After shim has been positioned, measure dimension again
to ensure that it is correct.
SEF519 c. Shims are available in 25 different thicknesses.
16. Install spring in top of driving disc, then install cam disc
and shim.
Make sure cam disc drive pin and drive shaft key way face
upwards.
17. Install governor lever.

Avoid pUlling on start spring and start idle spring.
18. Install plunger assembly.

a. Make sure control sleeve is installed with Its small hole
facing spring seat side.
SEF522
EF & EC-82
INJECTION. PUMP ~
Assembly (Cont'd)
b. Insert ball pin for governor lever into hole in control sleeve
(shown by arrow).
19. Apply a coat of grease to guide pin, shim and spring seat,
and attach these parts to distributor head.
20. Install distributor head.

a. Always face support spring toward governor lever.
b. Be careful not to drop spring.
c. Make sure that ball pin for governor lever isinserted prop-
erly illto hole in control sleeve.
d; After installing. distributor head, make sure that plunger
spring is at guide pin In spring seat.
SEF524
21. Tighten distributor head.

Distributor head bolts:
rPJ:
10- 14N.m(1.0 - 1.4 kg-m, 7 - 10ft-lb)
SEF046A
.. . ... ..
22. Attach flyweight assembly.
Lock nut~
rmling When Installing governor shaft, be careful not to scratch
Governor
Sh"" ~
7 Sh;m
O-rings.
~ VVasher
~ Flyweight
~L ~ assembly
Shim
~ Governor sleeve
SEF5621
EF'&EC-83
INJECTION PUMP
Assembly (Cont'd)
SEF031A
23. Adjust dimension "L".

"L":
1.5 - 2.0 mm (0.059 - 0.079 in)
L~m"'I". Lock nut:
l- '~ ~: 17 - 22 N'm (1.7 - 2.2 kg-m, 12 - 16 ft-Ib)
SEF500
24. Measure axial play of flyweight holder. If it is not within

specified range, adjust it by means of shims.
"L":
0.15 - 0.35 mm (0.0059 - 0.0138 in)
Shims are available in 5 different thicknesses.
Refer to S.O.S. for adjusting shims.
25. Measurement of dimension "MS" (for determining starting

amount of fuel injection)
Dimensions "MS" is the distance between closing plug and
start lever.
Collector
lever
SEF856
(1) Remove lock nut and governor shaft with Tool

(KV11215842).
EF & EC-84
INJECTION PUMP
Assembly (Coni' d)
(2) Install Tool (dummy shaft) at governor shaft position.
(3) Install Tool (dial gauge) with rod.
(4) Install Tool (block gauge) to pump housing.

KV11229752 KV11229752 is for pump with high altitude compensator.
SEF424A
KV11229110 Is for purnp without high altitude compensator.
EF & EC-85
INJECTION PUMP ~
Assembly (Cont'd)
(5) Push governor sleeve against flyweight. Hold governor
sleeve in that position and set dial gauge to zero.
(6) Push tension lever until it touches stopper pin. Back gov-
ernor sleeve up until start lever touches tension lever. At
this point read dial gauge.
MS: Refer to S.O.S.
(7) If dial gauge indication is not within this range, replace

closing plug and adjust dimension "MS" to that range.
g Closing plugs are available in 8 different lengths.
;:;" \oCkin cap
Refer to S.O.S. for adjusting closing plugs .
.;.:.: >~'t~
....•............• :............•...................
~~::::.:.:
Closing plug
SEF538
26. Install control lever shaft.

Apply a coat of grease to lever shaft end.
27. Install governor cover.

(1) Position adjusting rod bushing so that its height above
upper surface of governor cover is within specified range.
L = 20.5:1: 0.5 mm
(0.807:1: 0.020 in)
Ensure that holes in adjusting rod bushing and governor cover
are aligned properly.
/, SEF428A
EF & EC-86
INJECTION PUMP ~
Assembly (Cont' d)
(2) Install. adjusting rod.
(3) Install washer and nut.
(4) Tighten nut.
~: Adjusting rod bushing lock nut
25 - 34 N.m (2.5 - 3.5 kg-m, 18 - 25 ft-Ib)
a. Prevent adjusting rod bushing from rotating by locking its
nut.
b. If nut and bushing rotate together, bushing height above
upper surface of governor cover is insufficlent~
(5) Install washer, sleeve and retainer.
(6) Install pin.

Ensure that pin moves smoothly when adjusting rod is moved
up or down.
(7) Install lever.

Usea suitable bar asa guide to properly install lever.
EF &.EC-87
INJECTION PUMP
Assembly (Cont'd)
Ensure that lever moves smoothly when adjusting rod Is moved
up or down.
(8) Check clearance between block gauge and lever.

If not within specifications, change the pin.
Clearance:
0.1 mm (0.004 in)
Refer to S.O.S. for pins.
(9) Install governor cover.
(10) Install control lever.

Align aligning marks of speed control lever and control lever
shaft.
(11) Install spring seat, spring and E-ring.

(12) Install adjusting shim and bellows.
(13) Install compensator cover.
EF & EC-88
INJECTION PUMP ~
Assembly (Cont'd)
(1) Install pump governor cover with Tool (KV11229072).
(2) Install speed control lever assembly.

Align matching marks of speed control lever and control lever
shaft.
28. Install plug with new O-ring with Tool.

Always replace plug with a new one.
Plug:
~: 59- 78 N.m (6.0 - 8.0 kg-m,43 - 58 ft-Ib)
29. Install plug bolt with a new gasket.
SEF055A
~44 - 54 N.m 30. Install fuel cut solenoid valve with .Tool.
(4.5 - 5.5 kg-m, 31. Install delivery valve.
33 - 40 ft-Ib) KV11214110
a. Always use new washers.
b. Make sure that delivery valve is reinstalled in its original
position.
EF&EC-89
INJECTION PUMP
Test
PREPARATION
Nozzle KV11257800
Nozzle holder KV11257802

2
Nozzle starting pressure kPa (bar, kg/cm , psi) 14,711 - 15,201 (147.1 - 152.0, 150 - 155, 2,133 - 2,204)
Nozzle tube
KV11205032
Inner dia. x outer dia. x length mm (in)
2.0 x 6.0 x 840 (0.079 x 0.236 x 33.07)
Fuel feed pressure kPa (bar, kg/cm2, psi) 20 (0.20, 0.2, 2.8)
Fuel (test oil) ISO 4113 or SAE Standard Test Oil (SAE J967d)
Fuel temperature .C ("F) 40 - 50 (113 - 122)
Rotating direction Right (observed from the drive shaft)
Injection sequence 1-3-4-2
Special tools for testing injection pump
Insert device ~
KV11229522
M
U
Nozzle holder
KV11257802
-.,> ~- ~~'-"
Extractor
ES
LcouPling
KV11242442
\
KV11205032
Measuring device for pump timer stroke
KV11282815
~
SEF698M
1. Pour test oil into fuel injection pump.

Test oil should be ISO 4113, SAE Standard Test Oil (SAE J967d)
or its equivalent.
SEF950
EF & EC-90
INJECTION PUMP
Test (Cont'd)
2. Install fuel injection pump to pump tester.
3. Connect necessary piping.
CDFuel supply inlet from pump tester

@ Overflow valve
CID
Coupling
@ Fixing stand
SEF378F
4. Make sure that governor shaft is properly installed.

Adjust dimension "L".
"L":
1.5 - 2.0 mm (0.059 - 0.079 in)
Governor shaft lock nut:
tDJ: 17 - 22 N'm (1.7 - 2.2 kg-m, 12 .. 16 ft~lb)
SEFSOO
5. Run fuel injection pump as follows:

(1) Maintain test oil in tank at 45 to 50°C (113 to 122°F).
(2) Set control lever at "full speed" using a spring.
Set maximum speed adjusting screw in position shown, by
turning it c.ounterclockwise.
(3) Furnish. specified voltage of 12 volts to fuel-cut solenoid
valve to activate it.
8-9mm
(4) Rotate fuel injection pump by hand to see if it moves
(0.31 - 0.35 in) smoothly.
Maximum speed adjusting screw (5) Rotate fuel injection pump at 300 rpm to make sure that all
SEF569 air inside pump chamber is discharged through overflow
valve.
(6) Set feed oil pressure at 20 kPa (0.20 bar, 0.2 kg/cm2, 2.8
psi).
(7) Run fuel injection pump at 1,000rpm for ten minutes.
If fuel leakage, fuel injection failure or unusual noise is noticed,
immediately stop pump tester operation and check fue.1injec-
tion pump for abnormalities.
EF& EC-91
INJECTION PUMP
Test (Cont'd)
ADJUSTMENT
Preadjust full-load delivery
If equipped with high altitude compensator, remove high alti-
tUde compensator cover, bellows and adjusting shim.
1. Set control lever at "full speed" using a spring.
Set maximum speed adjusting screw in position shown, by
turning it counterclockwise. Refer to step 6-(2) in Preparation.
2. Furnish specified voltage of 12 volts to activate fuel-cut
solenoid valve.
3. Rotate fuel injection pump at 1,100 rpm, and measure
amount of fuel injection.
Standard fuel injection:
Refer to S.O.S.
Full.load
4. If fuel injection is less than standard, adjust it with full-load
adjusting screw adjusting screw.
Turn adjusting screw clockwise to increase fuel injection.
Adjustment of feed pump pressure

1. Repeat steps 1 and 2 outlined under "Preadjust Full-Load
Delivery" heading.
2. Measure feed pump pressure at specified fuel injection
pump rpm.
Refer to S.O.S.
a. When measured pressure is lower than specifications.

Push in plug that is driven into regulating valve body.
Be careful not to push plug in too far.
r\
'---Regulating valve
r \.:::::Y SEF571
EF & EC-92
INJECTION PUMP
Test (Co nt' d)
b. When measured pressure is higher than specifications.
Remove regulating valve from fuel injection pump, and disas-
semble regulating valve using Tool (KV11229462).
spring-j
Piston-o
Spring-IIiD
ring
SEF572
Drive plug out until it is flush with end face of regulating valve.
Plug Install spring, piston and spring ring, in that order, to regulat-
ing valve.
Make sure that spring ring is flush with end face of regulating
valve body when it is pushed in.
SEF573
Attach regulating valve to fuel injection pump.

Regulating valve:
~: 10 - 13 N.m (1.0 -1.3 kg-m, 7 - 9 ft-Ib)
Adjust supply pump pressure to specifications. Refer to step
2-a.
Spring ring
Regulating valve
SEF637
AdJustment of .speed timer

1. Repeat steps 1 and 2 outlined under "Preadjust Full-Load
Delivery" heading.
2. Remove cover from high-pressure side (side without
spring) of timer, and attach Tool (KV11282815)to that side.
3. Measure timer piston strokes at specified fuel injection

pumprpm indicated below.
Refer to S.O.S.
EF & EC-93
INJECTION PUMP ~
Test (Cont'd)
4. If timer piston stroke is not within specified range, remove
cover from low-pressure side of timer and adjust piston
stroke by adding shim(s).
a. Refer to S.O.S.for timer piston stroke adjusting shims (ser-
vice parts).
b. Make sure that at least one shim is used on each side of
timer spring.
SEF575
Adjustment of fuel injection under full-load

1. Set control lever at "full speed" using a spring.
solenoid valve.
3. Measure fuel injection at each specified fuel injection pump
rpm.
Refer to S.O.S.
4. If fuel injection is not within standard range, adjust it using

full-load adjusting screw.
Adjustment of fuel injection during idle

1. Pull spring until control lever touches idle speed adjusting
screw.
solenoid valve.
3. Measure fuel injection at specified fuel injection pump rpm.
Refer to S.O.S.
Idle speed 4. If fuel injection is not within specified range, adjust using
adjusting screw idle speed adjusting screw.
SEF079K
EF & EC-94
INJECTIONPU MP
Tesl(Conl'd)
a. Tightening this screw will increase fuel Injection amount.
b. Make sure that control lever angle (a) Is set at the speci-
fied range.
a: Refer to S.O.S.
If control lever angle Is not within specified range, adjust it
by repositioning control lever on control shaft. (One serra-
tion pitch: 15°)
After control lever has been repositioned, be sure to mea-
sure amount of fuel injection at Idle speed again.
SEF080K
Adjustment of fuel injection during start

1. Set control lever at "full speed" by pulling spring.
2. Furnish specified voltage of 12 volts to activate fuel..cut
solenoid valve.
3. Measure fuel injection at specified fuel injection pump rpm.
Refer to S.O.S.
4. If fuel injection is lower than standard, check, "MS" dimen-
sion. Refer to step 25 for Injection Pump Assembly.
Adjustment of fuel. injection at maximum pump rpm

solenoid valve.
3. Measure fuel injection at specified fuel injection rpm.
Refer to S.O.S.
4. If fuel injection is not within standard range, adjust using

maximum speed adjusting screw.
a. Tightening screw will decrease fuel Injection.

b. Make sure that .control lever angle (P) Is within the speci-
fied range.
~: Refer to S.O.S.
SEF082K
EF & EC-95
INJECTION PUMP ~
Test (Cont'd)
ADJUSTMENT OF HIGH ALTITUDE COMPENSATOR
1. Install bellows and adjusting shim.
2. Install a vacuum pump.
Check that there is no vacuum leakage.
SEF440A
3. Measure fuel injection volume.

1) Below 2,000 m (6,562ft)
0 250 500 750 1,000 1,250 1,500 1,750 2,000

m (It)
(0) (820) (1,641) (2,461) (3,281) (4,101) (4,922) (5,742) (6,562)
Item
~
21.2 - 22.5 18.3 - 19.6 15.3 - 16.7 12.4 - 13.7 9.5 - 10.8 6.9 - 8.3 4.4 - 5.7 1.9 - 3.2
Applied vacuum
(212 - 225, (183 - 196, (153 - 167, (124 - 137, (95 - 108, (69 - 83, (44 - 57, (19 - 32, 0
kPa (mbar,
159 - 169, 137 - 147, 115 -125, 93 - 103, 71 - 81, 52 - 62, 33 - 43, 14 - 24, (0,0,0)
mmHg, inHg)
6.26 - 6.65) 5.39 - 5.79) 4.53 - 4.92) 3.66 - 4.06) 2.80 - 3.19) 2.05 - 2.44) 1.30 - 1.69) 0.55 - 0.94)
Fuel injection pump

1,000
rpm
Standard fuel injection

mf (Imp fI oz)/ 29.4 - 33.4 (1.03 - 1.18)
1,000 stroke
2) Above 2,000 m (6,562ft)

2,250 4,000
(7,382) (13,124)
Fuel injection pump rpm 1,000
Standard fuel injection 28.4 _ 32.5 27.4 _ 31.5 26.5 _ 30.5 25.5 _ 29.6 24.5 - 28.6 23.6 - 27.6 22.7 - 26.7 21.7 - 25.7
mf 1~~~b :Itr~~~ (1.00 - 1.14) (0.96 - 1.11) (0.93 - 1.07) (0.90 - 1.04) (0.86 - 1.01) (0.83 - 0.97) (0.80 - 0.94) (0.76 - 0.90)
EF & EC-96
INJECTION PUMP ~
Test (Cont' d)
4..11 fuel injection is not within the standard range, increase
or decrease the adjusting shims.
Refer to S.D.S.for bellows adjusting shims.
SEF441 A
Measurement of overflow amount

2. Furnish specified voltage of 12 volts to activate fuel cut
solenoid valve.
3. Measure fuel overflow at specified fuel injection rpm.
Fuel overflow:
43 - 87 m-C
(1.51 - 3.06 Imp fI oz)/1 0 sec. at 1,100 rpm
SEF580
Operation check of fuel-cut solenoid valve

When engine is idling and fuel cut solenoid valve current is
OFF, be sure there is no injection. This check has to be done
for approx. 5 seconds.
EF'.&EC-97
INJECTION NOZZLE

1. Remove injection tube assembly.
2. Remove spill tube assembly.
To prevent spill tube from breaking, remove It by gripping noz-
zle holder.
3. Remove injection nozzle assembly using deep socket

wrench.
4. Install injection nozzle in the reverse order of removal.
toJ: Injection nozzle to cylinder head
54 - 64 N'm
(5.5 - 6.5 kg-m, 40 - 47 ft-Ib)
Spill tube nut
29 - 39 N'm
(3.0 - 4.0 kg-m, 22 - 29 ft-Ib)
Injection tube flare nut
20 - 25 N'm
(2.0 - 2.5 kg-m, 14 - 18 ft-Ib)
a. Nozzle gaskets should always be replaced.
b. To prevent spill tube from breaking later, spill tube nuts
should be tightened gradually In sequence.
Refer to BLEEDING FUEL SYSTEM.
DISASSEMBLY
1. Loosen inlet connector while keeping nozzle top from turn-
ing.
SEF785
Inlet connector ~
2. Arrange all disassembled parts in order shown at left.
Adjusting Shim\
Nozzle spring ~
Spring seat '"
Spacer , ~~
Nozzle~ ~
needle _~ }
Nozzle
assembly
At.~NO. zzle body
~ Nozzle holder
'e~ Nozzle washer
Nozzle gasket
SEF425F
EF & EC-98
INJECTION. NOZZLE
INSPECTION
Thoroughly clean all disassembled parts with fresh kerosene or
solvent.
• If nozzle needle is damaged or fused, replace nozzle
assembly with a new one.
• If end of nozzle needle is seized or excessively discolored,
replace nozzle assembly.
• Check nozzle body and distance piece for proper contact.
If excessively worn or damaged, replace nozzle assembly
or nozzle holder assembly.
• Check distance piece and nozzle holder for proper contact.
If excessively worn or damaged, replace nozzle holder
assembly.
• Check. nozzle spring for excessive wear or damage. If
excessively worn or damaged, replace nozzle holder
assembly.
CLEANING
1. Clean nozzle assembly using the Nozzle Cleaning Kit.
SEFB2B
2. Portions which should be cleaned are indicated in the left

figure.
Adjusting shim
Nozzle holder
Spring seat
Spacer
Injection hole
SEF426F
3. Remove any carbon from exterior of nozzle body (except

wrapping angle portion) by using Tool.
SEFB30
EF &I:C-99
INJECTION NOZZLE
4. Clean fuel sump of nozzle body using Tool.
SEF831
5. Clean nozzle seat by using Tool.

This job should be performed with extra precautions, since
efficiency of nozzle depends greatly on a good nozzle seat.
KV11290150
SEF832
6. Clean spray hole of nozzle body by using Tool.

To prevent spray hole from canting, always clean it by starting
with inner side and working towards outside.
KV11290220
SEF833
7. Decarbon nozzle needle tip by using Tool.
SEF834
8. Check needle for proper position.

(1) Pull needle about halfway out from body and then release
it.
(2) Needle should sink into body very smoothly from just its
own weight.
(3) Repeat this test and rotate needle slightly each time.
If needle fails to sink smoothly from any position, replace both
needle and body as a unit.
SEF835
EF & EC..100
INJECTION NOZZLE
ASSEMBLY
Assemble in the reverse order of disassembly.
rPJ:
Inlet connector to nozzle holder
29- 49 N.m
KV11292210 (3.0 - 5;0 kg-m, 22 -"~6 ft-Ib)
TEST AND ADJUSTMENT

WARNING:
SEF967
make sure that your eyes are properly protected with goggles.
Injection pressure test
f.IarenUt.
EF791A
2. Pump the tester handle slowly (one time per second) and
watch the pressure gauge.
3. Read the pressure gauge when the injection pressure just
starts dropping.
Used
9,807 • 10,297 kPa
(98.1 - 103.0 bar, 100 - 105 kg/cm2,
1,422 - 1,493 psi)
New
SEF672A 10,297 • 11,278 kPa
(103.0 - 112.8 bar, 105 - 115 kg/cm2,
1,493 - 1,635 psi)
New nozzle is required to always check initial injection pres-
sure.
4. To adjust injection pressure, change adjusting shims.

a. Increasing the thickness of adjusting shims increases ini-
tial injection pressure. Decreasing thickness reduces initial
Adjusting shim pressure.
b. A shim thickness of 0.04 mm (0.0016 in) corresponds
approximately to a difference of 471 kPa (4.71 bar, 4.8
kg/cm2, 68 psi) in initial injection pressure.
SEF427F
EF .•••
& EC..101
INJECTION NOZZLE
Leakage test
1. Maintain the pressure at about 981 to 1,961kPa (9.8 to 19.6
bar, 10 to 20 kg/cm2, 142 to 284 psi) below initial injection
pressure.
2. Check that there is no dripping from the nozzle tip or
around the body.
3. If there is leakage, clean, overhaul injection nozzle or
replace it.
Good Faulty
SEF674A
Spray pattern test

1. Pump the tester handle one time per second.
2. Check the spray pattern.
3. If the spray pattern is not correct, clean injection nozzle or
replace it.
,
\
, \
I
Good Wrong
EF794A
EF & EC-102
BLEEDING FlJEL SYSTEM
BLEEDING FUEL SYSTEM (Engine on vehicle)

Air should be bled out of fuel system when injection pump is
removed or fuel system i.s repaired.
Protect pump and engine mounts from fuel splash with rags.
If engine will not start after bleeding air, loosen Injection tubes
at nozzle side and crank engine until fuel overflows from Injec-
tion tube. Tighten Injection tube flare nuts.
If the engine does not operate smoothly after it has started,
race it two or three times.
Up and down
VE.pump with air vent screw
• MethodA
t @ 1.
2.
Loosen the air vent screw <D.
Move the priming pump @ up andd.own until no further
air-bleed comes out of the air vent screw <D.
3. Tightentheair vent screw <D.
4. Move the priming pump @ upand downl..mtil there is sud-
denly more resistance in the movement.
• Method B
SEF430F
1. Loosen the air vent screw <D.
2. Move the priming pump@ up and down until no further
air-bleed comes out of the air vent screw <D.
3. Tighten the air vent screw <D.
Without solenoid timer 4. Loosen injection pump air bleeder screws or magnet valve
of with solenoid timer and priming pump.
SEF702M
EF&.EC-103
BLEEDING FUEL SYSTEM
With solenoid timer
SEF704M
CHECKING PRIMING PUMP

• VE pump
Before checking priming pump, make sure that fuel filter is
filled with fuel.
1. Disconnect fuel return hose.
Place a suitable container beneath hose end.
2. Pump priming pump and check that the fuel overflows from
the hose end. If not, replace priming pump.
SMA618C
EF & EC-104
SOLENOID. TIMER
DESCRIPTION
To improve startability, a solenoid timer is used on models for
Europe and cold areas. Its purpose is to advance fuel injection
Fuel
timing in relation to coolant temperature for a certain period
inlet ....... after starting the engine.
This timer is controlled by the signal from the glow control unit.
The glow control unit sends a signal to activate the advance
mechanism of the fuel injection pump during cold starting.
SEF419F
OPERATION
Part of the fuel in the return line returns to the fuel injection
pump inlet, when the solenoid timer is OFF. When cold starting,
the solenoid timer comes ON to stop the return of fuel to the
inlet. This increases the fuel pressure in the fuel injection pump
so that fuel injection timing advances. The duration of fuel injec-
tion timing advance varies with changes in coolant tempera-
ture.
SEF914H
(sec.) The advance duration of fuel injection timing is 30 seconds

Ui
2l. 30 (constant) when coolant temperature is be.low 10°C (50°F).
~ Above 10°C .(50°F),fuel injection timing does not advance.
~
0)
<:
"E
:;:;
<:
o
~ CIl
:~
CIl-
E ~ o -20 0 10 20 40
t=~ (-4) (32) (50) (68) (104)
Coolant temperature °C(°F) SEF421F
TYPE A Timer characteristics

cj The following figures show the differences in fuel injection tim-
ci 8.0° ing in relation to engine speed when the solenoid timer is both
.-:
e:!- ON and OFF.
O)
<: 5.2° When the solenoid timer turns ON, fuel injection timing
"E
:;:; advances approximately 5°. Thus, cold engine starting in cold
<:
0 weather is greatly improved.
~
CIl
:5' 0
a;
:> Engine speed rpm
u..
SEF705M
EF & EC-105
SOLENOID TIMER
TYPE B
Type of fuel injection timing:
u
ci ______ T_D_2_5 I-----T-y-F 2-:- -----
.-:
!:!!. go p A
Cl
TD27 TypeB
c
"e:;=
c
--------------------------
o
13
Q)
20
:5' 0
Qi 800
"
u. Engine speed rpm
SEF706M
INSPECTION
1. Disconnect solenoid timer harness and check for "clicking"
sound from solenoid when battery is connected and discon-
nected.
If solenoid has malfunction, replace it.
After checking, reconnect the connector.
CD: For fuel cut

solenoid valve
00: For solenoid
timer
SEF423F
2. Disconnect water temperature sensor harness connector.

3. Start engine and check voltage between terminal <ID and
ground.
Battery voltage should exist for 30 seconds after starting
engine.
If not, check harness and glow control unit.
SEF424F
EF & EC-106
SOLENOID TIMER
Timer piston stroke (Using pump tester)

Measure timer piston strokes at specified fuel injection pump
speed when solenoid timer is on and off.
Refer to Service Data and Specifications (S.O.S.) of Injection
pump.
EF & EC.107
START Q ADJUSTMENT LEVER
Disassembly
1. Attach injection pump to bracket using two bolts.
2. Remove control lever by removing nut after marking the
installation position.
3. Remove nut and washer from the tip of lever shaft and then
remove start Q adjustment lever, spring, washer and
O-ring.
4. Remove lever shaft and washer from the inside of gover-
nor cover.
Inspection
1. Check that lever shaft's sliding surface is not worn,
scratched or damaged excessively and that lever shaft's
flange is not bent, worn or damaged excessively.
Replace lever shaft if defective.
2. Inspect the other parts carefully. If they are damaged, worn,
rusted or bent excessively they must be replaced.
Reassembly
During reassembly of a fuel injection pump equipped with start
27.7 (1.091) Q adjustment lever, a block gauge must be used to determine
the start Q adjustment lever installation position.
I~
~) 27.7 (1.091)
Unit: mm (in)
MEF452B
1. Using block gauge, ensure that the distance from the inside
Lever flange
face of cover to the tip of lever flange is 27.7 mm (1.091 in).
Maintain lever shaft in this position.
MEF453B
2. Install start Q adjustment lever on lever shaft so that start

Q adjustment lever contacts (or almost contacts) the under
side of the adjusting bolt base.
Then, fix start Q adjustment lever on lever shaft using
washer and nut.
If start Q adjustment lever can not be installed as described
above, use start Q adjustment lever with differently pha~ed
serrations.
MEF454B
EF & EC-108
START QADJUSTMENT LEVER
Adjustment
Start Q adjustment lever functions to adjust the fuel injection
quantity at starting.
Starting
Adjust adjusting bolt on the normal operating side so that the
starting injection quantity is as specified.
Refer to S.O.S.
EF & EC.109
QUICK-GLOW SYSTEM
Schematic
BATTERY
FUSIBLE FUSIBLE
LINK LINK
IGNITION SWITCH
OFF ACC ON 8T
GLOW
FUSE INDICATOR
CO
FUSE
TIMER SOLENOID
GLOW
CONTROL GLOW GLOW
UNIT RELAY-1 RELAY-2
FUSIBLE
LINK
ALTERNATOR DROPPING
RESISTOR
GLOW PLUG
~ For cold areas
@ Except ~
Number [J' ..For cold arears
0 ...Except for @)
cold arears
8EF812M
EF & EC-110
QUICK-GLOW SYSTEM
Wiring Diagram
..... OJ
I I
GLOW CONTROL UNIT
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SEF813M
EF &.EC-111
QUICK-GLOW SYSTEM
Description
----- When not cranking

••••• When coolant temperature is over 50°C (122°F)
ST[ _~ When driving over 20 km/h (12MPH)
s--r----.~------------
00000
Ignition switch O~~ [
Indicator ONe -..hl

OFF 0-1 I
Relay-1 o~~[ -..1...... : L ,~I _
I-TLI
Relay-2 ON --~-I--.-'--a-a-
OFF [ -..1....... : :..... ----3ai
20 km/h,t
Vehicle speed 10 km/h
I I' T
s
~I T. I
sensor 0 km/h I
II
I: r .....
Solenoid
(Injection timing ON
advance) ... For OFF [ I I
Europe model only .. j
I
-----fr ~ U
Solenoid ON T4
(Injection timing OFF [ : I I
~::-~::~! ;-: .....

~:rv~~~~~~";~~:ft
..1....:.: ".'- "'-

•
Elapsing time
SEL360M
When coolant temperature is lower than 50°C (122°F), the relay-1 and the relay-2 are turned on at the
same time that the ignition switch is turned on. From this time, the "high-level" electric current flows
through the glow plugs and heats them up quickly. After T 1 seconds have passed, the control unit turns
off the indicator. The relay-1 automatically turns off after it has been on for T2 seconds or the cranking
time, whichever is longer.
The solenoid valve (for advance injection timing) is turned on at the time that the ignition switch is turned
to "START". The relay-2 remains on for T3 seconds and the solenoid valve remains on for T4 seconds
after the ignition switch has returned to "ON" from "START". The relay-2 allows the "low-level" cur-
rent to flow through the glow plugs. The solenoid valve advances injection timing. These features
improve the combustion performance of the engine after it has started.
When the coolant temperature is higher than 50°C (122°F), the relay-2 is turned on only during engine
cranking.
When the coolant temperature is higher than 10°C (50°F), the solenoid valve is turned on only during
engine cranking.
T1: approx. 2 - 6 [sec.] (Varies with coolant temperature and glow plug terminal voltage.)
T2: approx. 3 - 11 [sec.] (Varies with glow plug terminal voltage.)
[When coolant temperature is below 50°C (122°F).] ... For Europe
T3: approx. 600 [sec.]
model only
[When coolant temperature is below 50°C (122°F), varies with cool-
T3: approx. 60 - 180 [sec.]
ant temperature.] ... Except for Europe model
o [sec.] [When coolant temperature is over 50°C (122°F).]
T4: approx. 30 [sec.] [When coolant temperature is below 10°C (50°F).]
o [sec.] [When coolant temperature is over 10°C (50°F).]
T5: approx. 30 [sec.]
• When the ignition switch is repeatedly turned "ON" and "OFF", T2 becomes shorter.
EF & EC-112
QUICK-GLOW SYSTEM
Terminal voltage Check

12
10
GLOW LAMP CHECK (TYPE 1)
Turn ignition switch ON and measure the time that glow lamp
stays lit.
j
c Approx. 1 - 10 seconds
6. 4
(The time will vary according to glow plug terminal
~ 3.5
2
1.8
voltage and water temperature.)
o
-40-25-40 0 20 40 80 80
(-40)(-13)(-4)(32) (68) (104) (140) (176)
Water temperature °C (OF)
SEF716M
GLOW CONTROL CHECK (TYPE 1)

[At.water temperature below 50°C (122°F)]
Pre-glow control check
Turn ignition switch ON and measure glow plug terminal volt-
age.
Battery voltage should appear for 2 to 13 seconds*, and then
half of battery voltage for the next 30 seconds.
* (Varies with glow plug terminal voltage)
The time will be shortened if Ignition switch Is OFF for only a
brief period.
14
Therefore, when measuring the time, leave ignition switch OFF
for more than 5 minutes, and then turn it ON.
12
11
10
~ 8
.S'" 6
I-
4
2.4
2
o
9 9.5 10 11 12 13
Glow plug terminal voltage (V) SEL230K
After-glow control check

600 -+--------..,
Turn ignition switch to START and run engine, then measure
glow plug terminal voltage.
- For cold areas model -
Half of battery voltage should continue for more than 2 minutes.
(If vehicle speed is above 20 km/h (12 MPH), glow plug termi-
nal voltage should drop to OV.)
o '-----,-------f--
0(32) 50 (122)
Watertemp.oC(oF)
SEL486M
GLOW CONTRO.L UNIT CIRCUIT CHECK (TYPE 1)

Power supply circuit check
Turn ignition switch ON and check voltage between terminal @)
and body ground.
SEL232K
EF& EC-113
QUICK-GLOW SYSTEM
Check (Cont' d)
Ground circuit check
Check continuity between terminal @ and body ground.
SEL233K
Glow-relay check
Normally this glow relay is open.
Ohmmeter
SEL927J
Water temperature sensor check

Disconnect water temperature harness connector and measure
resistance.
Coolant temp .• C rF) Resistance kQ
-25 (-13) 19
0(32) 5.6
20 (68) 2.5
40 (104) 1.2
Alternator "L" terminal check

Start engine and check that voltage between terminal @ and
body ground is more than 5V.
SEL236K
Speed sensor signal check

While running vehicle, check that voltage between terminal @
and body ground is deflected.
SEL237K
EF & EC-114
QUICK-GLOW SYSTEM [![]
Check (Conl'd)
SOLENOID VALVE CONTROL CHECK
1. Connect test lamp to glow control unit as shown.
2. Disconnect the harness connector from starter motor "S"
terminal.
3. Make sure that test lamp comes on when ignition switch is
turned to ON. (For Europe model only)
Make sure that test lamp comes on when ignition switch is
turned to START. (Except for Europe mOdel)
4. Measure the time the test lamp stays lit when ignition
Test lamp (3AW) switch is turned to ON from START.
SEL361M Time the test lamp should stay lit.
Below 10°C (50°F):Approx. 30 seconds
Over 10°C (50°F): 0 second
START SIGNAL INPUT CHECK

1. Turn ignition switch OFF.
2. Disconnect harness connector from the starter motor's "S"
terminal.
3. Check terminal voltage between @ and @ when the igni-
tion switch is at "START".
Voltage: approx. 12V
Voltmeter SEL362M
Check
7
6 GLOW lAMP CHECK (TYPE 2)

~
,..: Turn ignition switch ON and measure the time that glow lamp
~ stays lit.
,5
c
9
Approx. 1 - 10 seconds
E
j
0-
(The time will vary according to glow plug terminal
voltage and water temperature.)
-35 -2$-15 0 10 40 60
HI1)(-13)(5) (32)(50) (1041'(140)
Water temperature °C (OF)
SEF717M
GLOW CONTROL CHECK (TYPE 2)

[At water temperature below 50°C (122°F)]
Pre-glow control check
Turn ignition switch ON and measure glow plug terminal volt-
age.
Battery voltage should appear for 2 to. 13 s~col1ds*, and. then
half of battery voltage for the next 30 seconds.
* (Varies with glow plug terminal voltage)
EF & EC-115
QUICK-GLOW SYSTEM
Check (ConI' d)
15 The time will be shortened if ignition switch is OFF for only a
brief period.
Therefore, when measuring the time, leave ignition switch OFF
10 for more than 5 minutes, and then turn it ON.
T, (S)
o 9.5 11 13 15
Glow plug voltage (V) SEF718M
10 After-glow control check

9 Turn ignition switch to START and run engine, then measure
8
glow plug terminal voltage.
7
6
- Except for cold areas model -
T, (S) 5 Half of battery voltage should continue for 1 to 3 minutes*.
4 * (Varies with water temperature.
3
If vehicle speed is above 20 km/h (12 MPH), glow plug ter-
2
minal voltage should drop to OV.)
1
SEF719M
GLOW CONTROL UNIT CIRCUIT CHECK (TYPE 2)

Power supply circuit check
Turn ignition switch ON and check voltage between terminal (J)
and body ground.
- +
SEF720M
Ground circuit check

Check continuity between terminal @ and body ground.
SEF721M
Glow-relay check
Normally this glow relay is open.
Ohmmeter
SEL927J
EF & EC-116
QUICK-GLOW SYSTEM [m:J
Check (Cont'd)
Water temperature sensor check
Disconnect water temperature harness connector and measure
resistance.
Coolant temp. °C (OF) Resistance kn
-25 (-13) .
19
o (32) 5.6
20 (68) 2.5
40 (104) 1.2
START SIGNAL INPUT CHECK (TYPE 2)

2. Disconnect harness connector from the starter motor's "S"
terminal.
3. Check terminal voltage between @ and CD when the igni-
Voltage: approx.12V
SEF722M
EF&EC-117
FUEL CUT SYSTEM
Wiring Diagram
IGNITION SWITCH
ON Dr START
tUP
3: FUSE BLOCK
~ (Refer to "POWER
SUPPLY ROUTING"
in EL sect ion.)
S.M.0. FUEL CUT

[Refer to last page SOLENOID
L-
(Instrument
harness)
(Fo ldout
B/W
@
G
page) .]
@
B/W ----
(Chass is
harness)
B/W -@ @-
tC2Q\ tEl'
B/W ---
(Eng 1ne
room
B/W -8J
'E7'
\..!:.!...)
€-E1
VALVE
.
=
~ \....'::.:..J harness)
SEL814M
EF & EC-118
DESCRIPTION
Fresh air ---_
Blow-by gas_ The closed-type crankcase ventilation system is utilized as a
crankcase emisslon control system.
Air control valve
The closed-type crankcase emission control system prevents
blow-by gas from entering the atmosphere and keeps the inter-
nal crankcase pressure constant.
During the valve operation, the blow-by gas is fed into the
intake manifold by the air control valve.
This is activated by the internal rocker cover pressure. When
the intake air flow is restricted by the throttle chamber, the
internal rocker cover pressure decreases. At this point, the
crankcase emission control valve keeps the internal rocker
cover pressure constant so that air or dust is not sucked in
around the crankshaft oil seal.
SEF432F
INSPECTION
Air control valve
2. Remove control valve from rocker cover.
3. After plugging the center hole with adhesive tape, check
that air flows from inlet by blowing air from outlet and that
air does not flow by inhaling air.
SEF060B
VENTILATION HOSE
2. Disconnect all hoses and clean with compressed air.
If any hose cannot be freed of obstructions, replace.
SEC692
EF.& EC-119
Injection Pump
PUMP NUMBERS
Applied model
Engine Destination Part No. Pump assembly No. Remarks
F23
For Singapore
16700-30N10 104740-7360
with servo valve timer
General areas 16700-30N11 104740-7201 For standard models
16700-30N13 104740-7221 With high altitude compensator

TD25 0
16700-21T17 104740-7660 For cold areas with servo valve timer
16700-21T12 104740-9782 With servo valve timer

Europe For Portuguese Republic
16700-3T700 104745-4020
with servo valve timer
16700-11800 104740-7870 For standard models
TD27 General areas 16700-1T801 104740-7880 0 For cold areas
16700-11802 104740-7890 With high altitude compensator
INSPECTION AND ADJUSTMENT Use of adjustment value and adjusting shim

when installing injection pump.
General specifications
Dimension "KF" mm (in) '--5-.7---5-.9-(0-.2-2-4---0-.2-32-)--
Maximum engine TD25 engine 5,000~1~ rpm
speed TD27 engine 5, 100~1~ rpm
Injection timing
Engine Plunger lift mm (in)
0.71 :l:0.02 (0.0280:l:0.0008)

TD25
(equivalent to 6' B.T.D.C.)
0.65:l:0.02 (0.0256:l:0.0008)
TD27
(equivalent to 5' B.T.D.C.)
"KF"
SEF638
Part number Thickness mm (in)
16882-V0700 0.5 (0.020)
16882-V0701 0.8 (0.031)
Adjusting shim ("A" 16882-V0702 1.0 (0.039)

position) 16882-V0703 1.2 (0.047)
16882-V0704 1.5 (0.059)
16882-V0705 1.8 (0.071)

SEF692M
16882-V0706 2.0 (0.079)
EF & EC-120 .
Injection Pump (Cont'd)
Dimension "KF" mm (ind 3.2 - 3.4 (0.126 - 0.134) Axial play of flyweight hqlder
0.15 - 0.35 (0.0059 - 0.0138)
"L" mm (in)
"K"
SEF639
SEF047A
Adjusting shim ("6" position)
Adjusting shim
Thickness Thickness
Part number Part number
mm(in) mm (in) Part number Thickness mm (in)
16884-V0700 1.92 (0.0756) 16742-R8100 1.96 (0.0772) 19208N0700 1.05 (0.0413)
16884-V0701 2.00 (0.0787) 16742-R8101 2.04 (0.0803) 19208-V0701 1.25 (0.0492)
16884-V0702 2.08 (0.0819) 16742-R8102 2.12 (0.0835) 19208-V0702 1.45 (0.0571)
16884-V0703 2.16 (0.0850) 16742-R8103 2.20 (0.0866) 19208-V0703 1.65 (0.0650)
16884- V0704 2.24 (0.0882) 16742-R8104 2.28 (0.0898) 19208-V0704 1.85 (0.0728)
16884-V0705 2.32 (0.0913) 16742-R8105 2.36 (0.0929)
16884-V0706 2.40 (0.0945) 16742-R8106 2.44 (0.0961) TD25 0.9 ~ 1.1 (0.035 - 0.043)
Dimension "MS" mm (in)
16884-V0707 2.48 (0:0976) 16742-R8107 2.52 (0.0992) TD27 0;8- 1.0 (0.031-0.039)
16884-V0708 2.56 (0.1008) 16742-R8108 2.flO (0.1Q24)
16884-V0709 2.64 (0.1039) 16742-R8109 2.68 (0.1055)
16884-V0710 2.72 (0.1071) 16742-R8110 2.76 (0.1087)
16884-V0711 2.80 (0.1102) 16742-R8111 2.84 (0.1118)
16884-V0712 2.88 (0.1134) ...
Dimension "L" mm (in) I 1.5 - 2.0 (0.059 -0.079)
SEF856
Adjusting closing plug (without solenoid timer)
Part number Length mm (in)
16268-R8100 3.10 (0.1220)
16268-R8101 3.30 (0.1299)
16268-R8102 3.50 (0.1378)
16268-R8103 3.70 (0.1457)
SEF500 16268-R8104 3.90 (0.1535)
16268-R8105 4.1Q (0.1614)
16268-R8106 4.30 (0.1693)
16268-R8107 4.50 (0.1772)
EF & EC-"121
Pin Bellows adjusting shim
Pin (block gauge and lever clearance) Part number Thickness mm (in)
Part number Length mm (in) 19275-W3300 0.2 (0.008)
19276-02NOO 24.6 (0.969) 19275-W3301 0.3 (0.012)
19276-02N01 24.8 (0.976) 19275-W3302 0.4 (0.016)
19276-02N02 25.0 (0.984) 19275-W3303 0.7 (0.028)
19276-02N03 25.2 (0.992) 19275-W3304 1.0 (0.039)
19276-Q2N04 25.4 (1.000) 19275-W3305 1.5 (0.059)
Closing plug TIGHTENING TORQUE

Adjusting closing plug (with solenoid timer) Unit N'm kg-m ft-Ib
Part number Length mm (in) Distributor head to
10 - 14 1.0-1.4 7 - 10
19207-V0700 2.3 (0.091) pump housing
19207-V0701 2.5 (0.098) Plug to distributor head 59 - 78 6.0 - 8.0 43-58
19207-V0702 2.7 (0.106) Delivery valve to dis-

44-54 4.5 - 5.5 33-40
tributor head
19207-V0703 2.9 (0.114)
Pivot pin to pump hous-
19207-V0704 3.1 (0.122) 10 - 13 1.0 - 1.3 7-9
ing
19207-V0705 3.3 (0.130) Regulating valve to
10 - 13 1.0-1.3 7-9
19207-V0706 3.5 (0.138) pump housing
19207-V0707 3.7 (0.146) Control shaft to control

7 - 10 0.7 - 1.0 5.1 - 7.2
lever
Injection pump drive

Shims (Service parts) 59 - 69 6.0 - 7.0 43 - 51
gear nut
Timer piston stroke adjusting shim (without solenoid timer)
Injection pump fixing
19 - 25 1.9-2.5 14 - 18
Part number Thickness mm (in) bolt
16880-V0700 0.6 (0.024) Injection pump to

30 - 36 3.1 - 3.7 22 - 27
mounting bracket
16880-V0701 0.7 (0.028)
Feed pump cover to
16880-V0702 0.9 (0.035) 2-3 0.2 - 0.3 1.4 - 2.2
pump housing
16880-V0703 1.0 (0.039)
Speed timer cover to
6-8 0.6 - 0.8 4.3 - 5.8
16880-V0704 1.2 (0.047) pump housing
16880-01T00 2.4 (0.094) Governor shaft lock nut 17 - 22 1.7-2.2 12 - 16
Overflow valve 20 - 29 2.0 - 3.0 14 - 22
Timer piston stroke adjusting shim (with solenoid timer) Maximum and idle
speed adjusting screw 6-9 0.6 - 0.9 4.3 - 6.5
lock nuts
16880-43G10 0.1 (0.004)
Full-load adjusting
7-9 0.7 - 0.9 5.1 - 6.5
16880-43G 11 0.2 (0.008) screw lock nut
16880-43G 12 0.25 (0.0098) Fuel cut solenoid valve 15 - 25 1.5 - 2.5 11 - 18
16880-44GOO 0.5 (0.020) Plug bolt 14 - 20 1.4 - 2.0 10 - 14
16880-44G01 0.75 (0.0295) Adjusting rod bushing

25 - 34 2.5 - 3.5 18 - 25
lock nut
16880-43G13 1.0 (0.039)
16880-43G 14 2.0 (0.079)
EF & EC-122
SERVICE DATA AND. SPECIFICATIONS (S.D.S.)
Injection Pump (Conl'd)
INJECTION PUMP CALIBRATION DATA
Pump rotation: Clockwise-viewed from ~rIVJ
TD25 ENGINE MODEL side
[
Injection pump assembly No. 104740-7360
Pre-stroke: -
Part No. 16700-30N10
Charge air press

Pump speed Difference in delivery
1. Setting Settings kPa
rpm mt (Imp II oz)
(mbar, mmHg, inHg)
1- 1 Timing device travel 1,100 2.4 - 2.8 mm (0.094 - 0.110 in) -
402 - 461 kPa (4.02 - 4.61 bar,
1- 2 Supply pump pressure 1,100
4.1 - 4.7 kg/em', 58 - 67 psi)
-
Full-load delivery without 45.3 - 46.3 mt
1- 3 1,100 3.0 (0.11)
charge air pressure (1.59 - 1.63 Imp II oz)/1,000 st
FUll-load delivery with charge
air pressure
- - - -
4.5 - 8.5 mt
1- 4 Idle speed regulation 350 2.0 (0.07)
(0.16 - 0.30 Imp fI oz)/1,000 st
41.5 - 45.5 mt
1- 5 Start 300
(1.46 - 1.60 Imp fI oz)/1,000 st
-
10.1 - 14.1 mt
1- 6 Full-load speed regulation 2,500
(0.36 - 0.50 Imp fI oz)/1,000 st
, -
2. Test specifications
2 - 1 Timing device N=rpm 1,100 1,700 2,300
mm (in) 2.3 - 2.9 (0.091 - 0.114) 4.3 - 5.5 (0.169 - 0.217) 6.0 - 7.0 (0.236 - 0.276)
2-2 Supply pump N=rpm 1,100 1,700 2,150
kPa (bar, kg/em', psi) 402 - 461 (4.02 - 4.61, 549 - 608 (5.49 - 6.08, 647 - 706 (6.47 - 7.06,
4.1 - 4.7, 58 - 67) 5.6 - 6.2, 80 - 88) 6.6 - 7.2, 94 - 102)
2-3 Overflow delivery N = rpm 1,100
mt (Imp II oz)/10 sec. 43:0 - 87.0 (1.51 - 3.06)
2- 4 Fuel deliveries
Speed control lever Pump speed Fuel delivery Charge air press Difference in delivery 3. Dimensions
rpm mt (Imp II oz)/ kPa (mbar, mt (Imp fI oz)
1,000 st mmHg, inHg)
End stop 1,100 44.8 - 46.8 K 3.2 - 3.4 mm (0.126 - 0.134 In)
(1.58 - 1.65) KF 5.7 - 5.9 mm (0.224 - 0.232 in)
600 41.4 - 45.4 MS 0.9 - 1.1 mm (0.035 - 0.043 In)
(1.46 - 1.60) BCS -
2,150 36.0 - 40.2 Control lever angle
(1.27 - 1.42) - - a 50 - 58 degree
2,300 28.3 - 37.3
Va 10.7 - 14.2 mm (0.421 - 0.559 in)
(1.00 - 1.31)
2,500 9.6 - 14.6 P 31 - 41 degree
B 9.3 - 12.9 mm (0.366 - 0.508 in)
(0.34 - 0.51)
2,700 Below 5.0 (0.18) 'Y -
C -
Switch OFF 350 0(0) - -
Magnet valve
Idling 350 4.5 - 8.5
(0.16 - 0.30) - -
450 Below 3.0 (0.11)
2-5 Solenoid Max. cut-in voltage: 8V
Test voltage: 12 - 14V
EF & EC..123
Injection Pump (Confd)
Control lever angle measurement position
Measure the control lever angles (a, ~) at hole "A".
SEF699M
Starting injection quantity adjustment

Adjust the starting injection quantity using the adjusting bolt (as shown in the figure).
Adjusting lock nut
15 - 18.5 mm
(0.591 - 0.728 in)
Adjusting lever Adjusting bolt
SEF700M
EF & EC.124
SERVICE DATA AND SPECIFICATIONS. (S.D.S.)
TD25 ENGINE MODEL
J
Injection pump assembly No. 104740-7201 pump rotation: Clockwise-viewed from driV
Part No. 167oo-30N11 side
~Pre-stroke: -
Charge air press

rpm mf (Imp fI oz)
(mbar, mmHg, inHg)
1- 1 Timing device travel 1,700 4.7 - 5.1 mm (0.185 - 0.201 in)
..
-
549 - 608 kPa (5.49 - 6.08 bar,
1- 2 Supply pump pressure 1,700 -
5.6 - 6.2 kg/em', 80 - 88 psi)
Full-load delivery wit~out 45.3 - 46.3 mf
1- 3 1,100 3.0 (0.11)
charge air pressure (1.59 - 1.63 Imp fI oZ)/1,Ooo st
Full-load delivery with charge
air pressure
- - -
4.5 - 8.5 mf
(0.16 - 0.30 Imp fI oz)/1,Ooo st
45.0 - 80.0 mf.
1- 5 Start 100
(1.58 - 2.82 Imp fI oz)/1,OOO st
-
10.1 -14.1 mf.
(0.36 - 0.50 Imp fI oz)/1,Ooo st
-
2 - 1 Timing device N = rpm 1,100 1,700 2,300
mm(in) 2.0 - 3.2 (0.079 - 0.126) 4.6 - 5.2 (0.181 - 0.205) 6.0 - 7.0 (0.236 - 0.276)
2-2 Supply pump N = rpm 1,100 1,700 2,150
kPa (bar, kg/cm2, psi) 402 - 461 (4.02 - 4.61, 549 - 608 (5.49 - 6.08, 647 - 706 (6.47 - 7.06,
4.1 - 4.7, 58 - 67) 5.6 - 6.2, 80 - 88) 6.6 - 7.2, 94 - 102)
mf (Imp II oz)110 sec. 43.0 - 87.0 (1.51 - 3.06)
2 - 4 Fuel deliveries
rpm mf (Imp fI oz)/ kPa (mbar, mf (Imp fI oz)
End stop 1,100 44.8 - 46.8 K 3.2 - 3.4 mm (0.126 - 0.134 In)
(1.58 - 1.65) KF 5.7 - 5.9 mm (0.224 - 0.232 in)
600 42.4 - 46.4 MS 0.9 - 1.1 mm (0.035 - 0.043 in)
(1.49 - 1.63) BCS -
(1.26 - 1.41) - - a 50.0 - 58.0 degree
2,300 28.3 - 37.3
Va 10.7 - 14.2 mm (0.421 - 0.559 in)
(1.00 - 1.31)
2,500 9.6 - 14.6 P 31 - 41 degree
B 9.3 - 12.9 mm (0.366 - 0.508 in)
(0.34 - 0.51)
2,700 Below 5.0 (0.18) 'Y -
C -
Switch OFF 350 0(0) - -
Magnet valve
Idling 350 4.5 - 8.5
(0.16 - 0.30) - -
450 Below 3.0 (0.11)
EF & EC-125
Measure control lever angles (a, ~) at hole "A".
SEF699M
EF & EC-126
TD25 ENGINE MODEL
J
Injection pump assembly No. 104740-7221 Pump rotation: Clockwise-viewed from driV
Part No. 16700-30N 13 side
[ Pre-stroke: -
Charge air press

rpm mf (Imp fI oz)
(mbar, mmHg, inHg)
1- 1 Timing device travel 1,700 4.7 - 5.1 mm (0.165 - 0.201 in) - -
549 - 608 kPa (5.49 - 6.08 bar,
5.6 - 6.2 kg/em', 80 - 88 psi)
- -
Full-load delivery without 45.3 - 46.3 mf
1- 3
charge air pressure
1,100
(1.59 - 1.63 Imp fI oz)/l,OOO st
- 3.0 (0.11)
FUll-load delivery with charge

air pressure
- - - -
4.5 - 8.5 mf
1- 4 Idle speed regulation 350
(0 ..16 - 0.30 Imp fI oz)/l,OOO st
- 2.0 (0.07)
45.0 - 80.0 mf
1- 5 Start 100
- -
10.1 - 14.1 mf
(0.36 - 0.50 Imp fI oz)I1,OOO st
- -
37.9 - 40.9 mf -21.9:1:0.7 (-219:1:7,
1- 7 A.C.S. adjustment 1,100
(1.33 - 1.44 Imp fI oz)/l,OOO st -164:1:5, -6.46:1:0.20)
-
2 Test specifications
2 - 1 Timing device N = rpm 1,100 1,700 2,300
mm (in) 2.0 - 3.2 (0.079 - 0.126) 4.6 - 5.2 (0.181 - 0.205) 6.0 - 7.0 (0.236 - 0.276)
2-2 Supply pump N=rpm - 1,700 2,150
kPa (bar, kg/em', psi) 549 - 608 (5.49 - 6.08, 647 - 706 (6.47 - 7.06,
5.6 - 6.2, 80 - 88) 6.6 - 7.2, 94 - 102)
2-3 Overflow delivery N=rpm 1,100
mf (Imp II ~z)/10 sec. 43.0 - 87.0 (1.51 - 3.06)
rpm mf (Imp fI CJz)/ kPa (mbar, mf (Imp II oz)
1,000 st mmHg,lnHg)
End stop 1,100 44.8 - 46.8 - K 3.2 - 3.4 mm (0.126 - 0.134 in)
(M8 -1.65) KF 5.7 - 5.9 mm (0.224 - 0.232 in)
600 42.4,46.4 -21.9:1:0.7 MS 0.9 - 1.1 mm (0.035 - 0.043 in)
(1.49 - 1.63) (-219:1:7, BCS -
1,100 37.4'41.4 -164:1:5, Effective 0.958 - 0.998 mm
(1.32 - 1.46) -6.46:1: 0.20) stroke (0.0377- 0.0393 in)
2,150 35.8 - 40.0 - Control lever angle
(1.26 - 1.41)
2,300 28.3 - 37.3 - - a 35.5 - 43.5 degree
(1.00 - 1.31) Va 24.3 - 28.7 mm (0.957 - 1.130 in)
2,500 9.6 - 14.6 - P 31 - 41 degree
(0.34 - 0.51)
B 9.3 - 12.9 mm (0.366 - 0.508 in)
2,700 Below 5.0 (0.18) -
Y -
- C -
Switch OFF 350 0(0) - -
Magnet valve
Idling 350 4.5 - 8.5
(0.16 - 0.30)
- -
450 Below 3.0 (0.11)
EF& EC.;127
SERVICE DATA AND SPECIFICATIONS (S.O.S.) L!!!J
Full-load fuel injection quantity and A.C.S. adjusting procedure at high altitudes
1. Full-load fuel injection quantity adjustment
(1) Remove the A.C.S. cover, the bellows and the adjusting shims.
(2) Perform all adjustments as described in the adjusting specifications, except for A.C.S. adjustment.
2. A.C.S. adjustment
(1) Attach the A.C.S. cover, the bellows and the adjusting shims.
(2) At a pump speed of 1,100 rpm and referring to the graph below, use the shims to adjust the fuel
injection quantity decrease quantity according to the altitude.
____ Adjustment limit
::: : :: :: Inspection limit
o
r\\ \
,
(0)
\ .\ \
\'
\.\ \..
ti \. \"~..
."
5
8 ~\
0. (0.2)
~
.....
N
0
\~ .\ ~\
-=Co ~~'
~\,~
~ \~\ ~ ,
~ i','\.".
C>I
E 10
"
Q)
III
os
l!!
(0.4) ~ 1'\:"
0
Q)
'0.- I'\,l'\:r..
'~ 1'\,
't:l
~
E
os
:J
tT
c
0 15
'~.,~'" I"
~ K ',-
"\!'~
"~ f"
"'~
~Q)
(0.5)
E
'0.- \1'\,
"
20
(0.7)
o (0) 1,000 2,000 3,000 4,000

(3,281) (6,562) (9,843) (13,124)
Altitude m (ft)
101.3 89.6 79.4 70.1 61.6

(1,013, 760, (896,672, (794,596, (701,526, (616, 462,
29.92) 26.46) 23.46) 20.71) 18.19)
Atmospheric pressure kPa (mbar, mmHg, inHg)
SEF701M
EF & EC-128
InjectionPurnp (Cont'd)
Measure the control lever angles (a, /3) at hole "A".
SEF699M
EF& EC...129
1025 ENGINE MODEL
fP.ump rotation: Clockwise-viewed from drivel
Part No. 16700-21T17 !-sIde J
1. Test conditions
1- 1 Nozzle: 105780-0000 (NP-DN12SD12T) 1- 4 Injection pipe: 2 x 6 x 840 mm (0.08 x 0.24 x 33.07 In)
1- 2 Nozzle holder: 105780-2080 (EF8511/9) 1- 5 Fuel oil temperature: 45+50 .C (113 +"o.F)
Nozzle opening pressure: 14,711 +4900 kPa (147.1 "';,4.9 bar;
1-3 1-6 Supply pump pressure: 20 kPa (0.20 bar, 0.2 kg/cm2, 2.8 psi)
150+50 kg/cm2, 2,133+7'0 psi)
Charge air press

Pump speed Difference In delivery
rpm mt (Imp II oz)
(mbar, mmHg, InHg)
SIT ON: 3.9 - 4.7 mm (0.154 - 0.185 In)
2- 1 Timing device travel 1,100
OFF: 2.4 - 2.8 mm (0.094 - 0.110 in)
-
SIT ON: 441 - 520 kPa (4.41 - 5.20 bar,
4.5 - 5.3 kg/cm2, 64 - 75 psi)
2-2 Supply pump pressure 1,100
OFF: 343 - 402 kPa (3.43 - 4.02 bar,
-
3.5 - 4.1 kg/cm2, 50 - 58 psi)
45.3 - 46.3 mt
2-3 Full-load delivery 1,100
(1.59 - 1.63 Imp II oz)/1,Ooo st - 3.0 (0.11)
4.5 - 8.5 mt
2-4 Idle speed regulation 350 2.0 (0.07)
(0.16 - 0.30 Imp II oz)/1,000 st
45.0 - 80.0 mt
2-5 Start 100
(1.58 - 2.82 Imp II oz)/1,Ooo st
-
10.1 - 14.1 mt
2-6 Full-load speed regulation 2,500
(0.36 - 0.50 Imp II oz)/1,Ooo st
-
3. Test spedfi- Solenoid timer ON OFF

cations
3 - 1 Timing N = rpm 1,100 1,100 1,700 2,300
device mm (In) 3.8 - 4.8 (0.150 - 0.189) 2.3 - 2.9 4.3 - 5.5 6.0 -7.0
(0.091 - 0.114) (0.169 - 0.217) (0.236 - 0.276)
3-2 Supply N = rpm 1,100 1,700 1,100 1,700 2,150
pump
3-3 Over-
kPa (bar,
kg/cm2,
N = rpm
psi)
441 - 520 (4.41 - 5.20,
4.5 - 5.3, 64 - 75)
1,100
I 579 - 657 (5.79 - 6.57,
5.9 - 6.7, 84 - 95)
343 - 402 (3.43 - 4.02,
3.5 - 4.1,50 - 58)
481 - 539 (4.81 - 5.39,
4.9 - 5.5, 70 - 78)
569 - 628 (5.69 - 6.28,
5.8 - 6.4, 82 - 91)
flow delivery mt (Imp II oz)/ 43.0 - 87.0 (1.51 - 3.06)

10 sec.
3 - 4 Fuel injection quantities
Speed control Pump speed Fuel delivery Charge air press Difference In delivery 4. Dimensions
lever position rpm mt (Imp fI oz)/ kPa (mbar, mt (Imp fI oz)
Max. speed 1,100 44.8 - 46.8 K 3.2 - 3.4 mm (0.126 - 0.134 In)
(1.58 - 1.65) KF 5.7 - 5.9 mm (0.224 - 0.232 In)
600 42.4 - 46.4 MS 0.9 - 1.1 mm (0.035 - 0.043 In)
(1.49 - 1.63) BCS -
2,150 38.5 - 40.0 Pre-stroke -
(1.36 - 1.41) - - Control lever angle
2,300 28.3 - 37.3
a 50 - 58 degree
(1.00 - 1.31)
Va 10.7 - 14.2 mm (0.421 - 0.559 in)
2,500 9.6 - 14.6
(0.34 - 0.51) II 31 - 41 degree
2,700 Below 5.0 B 9.3 - 12.9 mm (0.366 - 0.508 In)
(0.18) y -
C -
Switch OFF 350 0(0) - -
Magnet valve
Idling 350 4.5 - 8.5
(0.16 - 0.30)
450 Below 3.0 - -
(0.11)
EF & EC-130
Measure the control lever angles (a, f3) at hole "A".
SEF699M
If there is no designation in the specifications for the Solenoid Timer's ON-OFF position, then the posi-
tion should be regarded as OFF.
EF & EC-131
TD25 ENGINE MODEL
Injection pump assembly No. 104740-9782 ~p.ump rotation: Clockwise-viewed from drivel
Part No. 16700-21T12 LSlde J
1. Test conditions
1-1 Nozzle: 105780-0000 (NP-DN12SD12T) 1- 4 Injection pipe: 2 x 6 x 840 mm (0.08 x 0.24 x 33.07 In)
1- 2 Nozzle holder: 105780-2080 (EF8511/9) 1-5 Fuel oil temperature: 45"'(,5 °C (113 "'(,9 OF)
Nozzle opening pressure: 14,711 +g90kPa (147.1 +o•.9bar,
1- 3 1-6 Supply pump pressure: 20 kPa (0.20 bar, 0.2 kg/cm2, 2.8 psi)
150"'(,5 kg/cm2, 2,133+~' psi)
Charge air press

rpm mt (Imp II oz)
(mbar, mmHa, inHal
SIT ON: 3.9 - 4.7 mm (0.154 - 0.185 in)
2 - 1 Timing device travel 1,100 -
OFF: 2.4 - 2.8 mm (0.094 - 0.110 in)
SIT ON: 441 - 520 kPa (4.41 - 5.20 bar,
4.5 - 5.3 kg/cm2, 64 - 75 psi)
OFF: 343 - 402 kPa (3.43 - 4.02 bar,
-
3.5 - 4.1 kg/cm2, 50 - 58 psi)
48.0 - 49.0 mt
(1.69 - 1.72 Imp fl oz)/1,OOO st
- 3.0 (0.11)
4.5 - 8.5 mt
2-4 Idle speed regulation 350 2.0 (0.07)
(0.16 - 0.30 Imp fl oz)/1,Ooo st
45.0 - 80.0 mt
2-5 Start 100 -
(1.58 - 2.82 Imp fI oz)/1,000 st
10.1 - 14.1 mt
(0.36 - 0.50 Imp fI oz)/1,000 st
-
3. Test specifi- Solenoid timer ON OFF

cations
3 - 1 Timing N = rpm 1,100 1,100 1,700 2,300
device mm (in) 3.8 - 4.8 (0.150 - 0.189) 2.3 - 2.9 4.3 - 5.5 6.0 - 7.0
(0.091 - 0.1141 10.169 - 0.217) (0.236 - 0.276)
3-2 Supply N = rpm 1,100 1,700 1,100 1,700 2,150
pump kPa (bar, 441 - 520 (4.41 - 5.20, 579 - 657 (5.79 - 6.57, 343 - 402 (3.43 - 4.02, 481 - 539 (4.81 - 5.39, 569 - 628 (5.69 - 6.28,
kg/cm2, psi) 4.5 - 5.3, 64 - 751 5.9 - 6.7, 84 - 951 3.5 - 4.1, 50 - 581 4.9 - 5.5, 70 - 781 5.8 - 6.4, 82 - 91)
3-3 Over- N - rpm 1,100 1,100
flow delivery mt (Imp fI oz)/ 43.0 - 87.0 60 - 103
10 sec. (1.51 - 3.06) (2.1 - 3.6)
(Without O-rinal
3- 4 Fuel injection quantities
Speed control Pump speed Fuel delivery Charge air press Difference in delivery 4. Dimensions
lever position rpm mt (Imp fI oz)/ kPa (mbar, mt (Imp fl oz)
1,000 st mmHg, inHal
Max. speed 1,100 47.5 - 49.5 K 3.2 - 3.4 mm (0.126 - 0.134 in)
(1.67 - 1.74) KF 5.7 - 5.9 mm (0.224 - 0.232 in)
600 45.1 - 49.1 MS 0.9 - 1.1 mm (0.035 - 0.043 in)
(1.59 - 1.73) BCS -
2,150 38.5 - 42.8 Pre-stroke -
(1.36 - 1.51) Control lever anale
2,300 28.3 - 37.3
- - a 35.5 - 43.5 degree
(1.00 - 1.31) Ya 24.3 - 28.7 mm (0.957 - 1.130 inl
2,500 9.6 - 14.6 ~ 31 - 41 degree
(0.34 - 0.51) B 9.3 - 12.9 mm 10.366 - 0.508 inl
2,700 Below 5.0 'Y -
(0.18\ C -
Switch OFF 350 0(0) - -
Maanet valve
Idling 350 4.5 - 8.5
(0.16 - 0.30)
450 Below 3.0
- -
(0.11)
EF & EC-132
Injection Pump. (Cont'd)
Measure the control leVer angles (at ~) at hole "A".
Va = 24.3 - 28.7 mm (0.957 " 1.130 in)
SEF906H
If therei~"0 designation in the specifications for the Solenoid Timer's ON-OFF position, then the posi-
EF&EC-133
1D27 ENGINE MODEL
P.ump rotation: Clockwise-viewed from driV
Injection pump assembly
Part No.
No. 104740-7870
1670D-1T800 side
UPre-stroke: - J
Charge air press
rpm mt (Imp II oz)
(mbar, mmHg, inHg)
1- 1 Timing device travel 1,700 4.7 - 5.1 mm (0.185 - 0.201 In) -
549 - 608 kPa (5.49;- 6.08 bar,
5.6 - 6.2 kg/cm2, 80 - 88 psi)
-
1- 3 1,100 3.0 (0.11)
charge air pressure (1.75 - 1.79 Imp fI oz)/l,Ooo st
air pressure
- - -
5.3 - 9.3 mt
(0.19 - 0.33 Imp II oZ)/l,OOO st
45.0 - 80.0 mt
1- 5 Start 100
-
32.2 - 36.2 mt
(1.13 - 1.27 Imp II oz)11,000 st
-
. Test soecillcations
2 - 1 Timing device N =
rpm 1,100 1,700 2,150 2,550
mm (in) 2.0 - 3.2 4.6 - 5.2 (0.181 - 0.205) 6.0 - 7.2 (0.236 - 0.283) 6.8 - 7.8 (0.268 - 0.307)
(0.079 - 0.126)
2-2 Supply pump N =
rpm - 1,700 2,150
kPa (bar, kg/cm2, psi) 549 - 608 (5.49 - 6.08, 647 - 706 (6.47 - 7.06,
5.6 - 6.2, 80 - 88) 6.6 - 7.2, 94 - 102)
2-3 Overflow delivery N =
rpm 1,100
mt (Imp fI oz)/10 sec. 43.0 - 87.0
(1.51 - 3.06)
Speed con- Pump Fuel delivery Charge air press Difference in delivery 3. Dimensions
trollever speed mt (Imp fI oz)/ kPa (mbar, mt (Imp fI oz)
rom 1,000 st mmHa, inHa)
End stop 1,100 49.3 - 51.3 K 3.2 - 3.4 mm (0.126 - 0.134 In)
(1.74-1.81) KF 5.7 - 5.9 mm (0.224 - 0.232 In)
600 48.8 - 52.8 MS 0:8 - 1.0 mm (0.031 - 0.039 in)
(1.72 - 1.86) BCS -
(1.36 - 1.51) - - a 51.5 - 59.5 degree
2,350 31.7 - 36.7 Ya 24.3 - 28.7 mm (0.957 - 1.130 In\
(1.12 - 1.29) P 31 - 41 degree
2,550 5.6 - 14.6 B 9.3 - 12.9 mm 10.366 - 0.508 in)
(0.20 - 0.51) Y -
2,700 Below 5.0 (0.18\ C -
Switch OFF 350 0(0) - -
Magnet
valve
Idling 350 5.3 - 9.3 - -
(0.19 - 0.33)
450 Below 3.0 (0.11)
2-5 Sole- Max. cut-in voltage: 8V
noid Test voltage: 12 - 14V
EF & EC-134
Measure control lever angles (a. ~) at hole "A".
Ya = 24.3 - 28.7 mm (0.957 - 1.130 in)
SEF906H
EF.& EC.135
1027 ENGINE MODEL
P,ump rotation: Clockwise-viewed from driV
J
Part No. 16700-1T801 side
U
Pre-stroke: - .
Charge air press

rpm mt (Imp" oz)
(mbar, mmHg, inHg)
SIT ON: 3.9 - 4.7 mm (0.154 - 0.185 in)
1- 1 Timing device travel 1,100
OFF: 2.4 - 2.8 mm (0.094 - 0.110 In)
SIT: Solenoid timer -
SIT ON: 441 - 520 kPa (4.41 - 5.20 bar,
4.5 - 5.3 kg/em', 64 - 75 psi)
OFF: 343 - 402 kPa (3.43 - 4.02 bar,
-
3.5 - 4.1 kg/em', 50 - 58 psi)
1- 3 1,100 3.0 (0.11)
charge air pressure (1.75 - 1.79 Imp" oz)/l,OOO st
air pressure
- - -
5.3 - 9.3 mt
(0.19 - 0.33 Imp" oz)/l,OOO st
45.0 - 80.0 mt
1- 5 Start 100
(1.58 - 2.82 Imp" oz)/l,OOO st
-
32.2 - 36.2 mt
(1.13 - 1.27 Imp" oz)I1,OOO st
-
2. Test specifications Solenoid timer ON OFF

2 - 1 Timing device N - rpm 1,100 1,700 1,100 1,700 2,550
mm (in) 3.8 - 4.8 5.7 - 7.3 2.3 - 2.9 4.3 - 5.5 6.8 - 7.8
(0.150 - 0.189) (0.224 - 0.287) (0.091 - 0.114) (0.169 - 0.217) (0.268 - 0.307)
2-2 Supply pump N - rpm 1,100 1,700 1,100 1,700 2,150
kPa (bar, 441 - 520 579 - 657 343 - 402 481 - 539 569 - 628
kg/em', psi) (4.41 - 5.20, (5.79 - 6.57, (3.43 - 4.02, (4.81 - 5.39, (5.69 - 6.28,
4.5 - 5.3, 64 - 75) 5.9 - 6.7, 84 - 95) 3.5 - 4.1, 50 - 58) 4.9 - 5.5, 70 - 78) 5.8 - 6.4, 82 - 91)
2-3 Overflow deliv- N = rpm 1,100
ery mt (Imp" oz)/ 43.0 - 87.0 (1.51 - 3.06)
10 sec.
Speed control Pump speed Fuel delivery Charge air press Difference in delivery 3. Dimensions
lever rpm mt (Imp fl oz)/ kPa (mbar, mt (Imp II oz)
End stop 1,100 49.3 - 51.3 K 3.2 - 3.4 mm (0.126 - 0.134 in)
(1.74 - 1.81) KF 5.7 - 5.9 mm (0.224 - 0.232 In)
600 48.8 - 52.8 MS 0.8 - 1.0 mm (0.031 - 0.039 In)
(1.72 - 1.86) BCS -
(1.36 - 1.51) - - a 51.5 - 59.5 degree
2,350 31.7 - 36.7 Va 24.3 - 28.7 mm (0.957 - 1.130 in)
(1.12 - 1.29) P 31 - 41 degree
2,550 5.6 - 14.6 B 9.3 - 12.9 mm <0.366 - 0.508 in)
(0.20 -0.51) Y -
2,700 Below 5.0 (0.18) C -
Switch OFF 350 0(0) - -
Magnet valve
Idling 350 5.3 - 9.3
(0.19 - 0.33) - -
450 Below 3.0 (0.11)
2-5 Solenoid Max. cut-In voltage: 8V
EF & EC-136
Measure control lever angles (a, P) at hole "A".
Ya = 24.3 - 28.7 mm (0.957 - 1.130 in)
SEF906H
If there is no designation in the specifications for the solenoid timer's ON-OFF position, then the posi-
EF& EC-137
1027 ENGINE MODEL
Injection pump assembly No. 104640-7890 Pump rotation: Clockwise-viewed from drivel
Part No. 16700-1T802
[ side J
1. Test conditions
1- 1 Nozzle: 105780-0000 (NP-DN12SD12T) 1-4 Injection pipe: 2 x 6 x 840 mm (0.08 x 0.24 x 33.07 in)
1- 2 Nozzle holder: 105780-2080 (EF8511/9) 1- 5 Fuel 011 temperature: 45 +g °C (113 +g OF)
Nozzle .opening pressure: 14,711 +490 kPa (147.1+4.9 bar,
1- 3 1- 6 Supply pump pressure: 20 kPa (0.20 bar, 0.2 kg/cm2, 2.8 psi)
150+5 kg/cm2, 2,133+71 psi)
Charge air press

Pump speed Difference In delivery
rpm mt (Imp fI oz)
(mbar, mmHg, InHg)
2 - 1 Timing device travel 1,100 2.4 - 2.8 mm (0.094 - 0.110 in) - -
402 - 461 kPa (4.02 - 4.61 bar,
4.1 - 4.7 kg/cm2, 58 - 67 psi)
- -
49.8 - 50.8 mt
(1.75 - 1.79 Imp fI oZ)/1,000 st
- 3.0 (0.11)
5.3 - 9.3 mt
2-4 Idle speed regulation 350
(0.19 - 0.33 Imp fI oZ)I1,OOOst
- 2.0 (0.07)
45.0 - 80.0 mt
2-5 Start 100
(1.58 - 2.82 Imp fI oZ)/1,000 st
- -
32.2 - 36.2 mt
(1.13 - 1.27 Imp fI oZ)/1,000 st
- -
39.7 - 42.7 mt -21.901:0.7 (-21901:7,
2-7 A.C.S. adjustment 1,100
(1.40 - 1.50 Imp fI oZ)/1,OOOst -16401:5, -6.4601:0.20)
-
3 - 1 Timing device N=rpm 1,100 1,700 2,150 2,550
mm (in) 2.3 - 2.9 (0.091 - 0.114) 4.3 - 5.5 6.0 - 7.2 (0.236 - 0.283) 6.8 - 7.8 (0.268 - 0.307)
(0.169 - 0.217)
3-2 Supply pump N = rpm 1,100 1,700 2,150
kPa (bar, kg/cm2, psi) 402 - 461 (4.02 - 4.61, 549 - 608 647 - 706 (6.47 - 7.06,
4.1 - 4.7, 58 - 67) (5.49 - 6.08, 6.6 - 7.2, 94 - 102)
5.6 - 6.2,
80 - 88)
mt (Imp fI oz)/10 sec. 43.0 - 87.0 (1.51 - 3.06)
3 - 4 Fuel injection quantities
Speed control Pump speed Fuel delivery Charge air press Difference In 4. Dimensions
lever rpm mt (Imp fI oz)/ kPa (mbar, delivery
1,000 st mmHg,lnHg) mt (Imp fI oz)
Max. speed 1,100 49.3 - 51.3 - - K 3.2 - 3.4 mm (0.126 - 0.134 In)
(1.74 - 1.81) KF 5.7 - 5.9 mm (0.224 - 0.232 In)
600 48.8 - 52.8 -21.901:0.7 (-21901:7, MS 0.8 - 1.0 mm (0.031 - 0.039 in)
(1.72 - 1.86) -16401:5, -6.4601:0.20) Control 1.03 - 1.07 mm (0.0406 - 0.0421 in)
1,100 39.2 - 43.2 - sleeve's
(1.38 - 1.52) effective
2,150 38.7 - 42.9 - sl.
(1.36 - 1.51) Control lever angle
2,350 31.7 - 36.7 -
a 50 - 58 degree
(1.12 - 1.29)
Va 10.7 - 14.2 mm (0.421 - 0.559 In)
2,550 5.6 - 14.6 -
(0.20 - 0.51) 13 31 - 41 degree
2,700 Below 5.0 (0.18) - B 9.3 - 12.9 mm (0.366 - 0.508 in)
y -
C -
Switch OFF 350 0(0) - -
Magnet valve
Idling 350 4.8 - 9.8 - -
(0.17 - 0.34)
450 Below 3.0 (0.11)
3-5 Solenoid Max. cut-In voltage: 8V
EF & EC-138
Measure the control lever angles (a, ~) at hole CIA".
Va = 10.7 - 14.2 mm (0.421 - 0.559 in)
.SEF699M
EF & .EC.139
SERVICE DATA AND SPECIFICATIONS (S.O.S.) ~
Full-load fuel injection quantity and A.C.S. adjusting procedure at high altitudes
1. Full-load fuel injection quantity adjustment
(1) Remove the A.C.S. cover, the bellows and the adjusting shims.
(2) Perform all adjustments as described in the adjusting specifications, except for A.C.S. adjustment.
2. A.C.S. adjustment
(1) Attach the A.C.S. cover, the bellows and the adjusting shims.
(2) At a pump speed of 1,100 rpm and referring to the graph below, use the shims to adjust the fuel
injection quantity decrease quantity according to the altitude.
____ Adjustment limit
::: : : =:: Inspection limit
o
(0) \\ \
\ \\
\' ",
u;
8
0.
5
(0.2)
-,~,.,.
\.\ \.,
\ \."
~
......
\~ ,\'
,~
i\'
~ ~\
;;:::
1-,
~
Q.
'\~ \~ ,
0<
1"- ..
""- '""-
E \~ '
10
Q) .\~
(0.4)
81
~
(,)
Q)
"0
'~ ~~ ..
"~
~c:
<II
::3
0" '" ~ '.
'~-,1"- "'\: '"
"-
""-1"-'
c:
0 15 ~ ~.
ti (0.5) ,.~
Q)
£'
'~ I'"
'~ "
20
(0.7)
0(0) 1,000 2,000 3,000 4,000

(3,281) (6,562) (9,843) (13,124)
Altitude m (ft)
101.3 89.6 79.4 70.1 61.6

(1,013, 760, (896,672, (794,596, (701,526, (616,462,
29.92) 26.46) 23.46) 20.71) 18.19)
Atmospheric pressure kPa (mbar, mmHg, inHg)
SEF701M
EF & EC-140
Injection Nozzle
INSPECTI.ON AND ADJUSTMENT
Injection nozzle assembly
Used New
Initial injection pressure 9,807 - 10,297 10,297 -11,278

kPa (bar, kg/cm2, psi) (98.1 - 103.0, (103.0 - 112.8,
100 - 105, 1,422 105 - 115, 1,493
- 1,493) - 1,635)
Thickness Part number

mm (in) (for service)
0.1 (0.004) 16613-43GOO
0.2 (0.008) 16613-43G01
0.3 (0.012) 16613-43G02
0.4 (0.016) 16613-43G03

Initial injection pressure
adjusting shim 0.5 (0.020) 16613-43G04
0.52 (0.0205) 16613-43G05
0.54 (0.0213) 16613-43G06
0.56 (0.0220) 16613-43G07
0.58 (0.0228) 16613-43G08
0.8 (0.031) 16613-43G09
TIGHTENING TORQUE
Unit N.m kg-m ft-Ib
Inlet connector to noz-

29 - 49 3.0 - 5.0 22 - 36
zle holder
Injection nozzle to cyl-

54-64 5.5 - 6.5 40 - 47
inder head
Spill tube nut 29 - 39 3.0 - 4.0 22 - 29
EF.& EC.141
INJECTION SYSTEM
CAUTION:
• Disassembly and assembly of the injection pumps should
be done only in service shops authorized by NISSAN or by
the pump manufacturer.
• The pump tester Is required for servicing the pump.
• Before removing fuel injection pump from vehicle, check
closely to make sure that It Is definitely malfunctioning.
Fuel System
IN-LINE TYPE INJECTION PUMP
Injection
t nozzle
I'
Fuel filter
(With fuel heater and
without fuel heater vehicle)
Overflow valve connector

Sedimentor
SEF6661
EF & EC-142
INJECTION PUMP
Removal
1. Disconnect fuel spill tubes and remove injection tube nuts.
Cover the delivery holders of the Injection pump and injection
nozzle assembly with a clean rag to prevent dU$t entry.
2. Disconnect engine control wire from injection pump assem-
bly.
3. Disconnect the following hoses and tubes.

• Fuel feed pump hoses
• Fuel inlet tube
• Fuel overflow tube
• Fuel injection pump lubrication tube from feed pump side.
4. Disconnectoil tube from timing gear case cover.

5. Remove timing gear cover.
6. Mesh injection pump drive gear with idler gear at "Z" mark
or injection pump drive gear and timing gear case at "point
mark and alignment mark" so that No. 1 piston is at top
dead center (T.D.C.).
7. Install Tool DKS7914010(socket wrench) and remove timer

round nut with lock washer.
EF694A
EF&EC-143
INJECTION PUMP ~
Removal (Cont'd)
8. Pull out the timer assembly using Tool KV11226582(timer
puller).
CAUTION:
Never attempt to crank engine after removing injection pump
drive gear.
9. Remove injection pump support.

SEF6691

1. Install injection pump.
(1) Temporarily install injection pump and align it with align-
ing mark on front end plate. Use new gaskets and lock
plate.
(2) Install timer assembly through the key.
Coat key with grease to prevent it from falling into timing gear
case.
Make sure that "Z" marks match or injection pump drive gear
and timing gear case are aligned at "point mark and alignment
mark".
EF & EC-144
INJECT.ION PUMP ~
(3) Secure timer assembly with lock washer and round nut.
tDJ:Round nut
59 ~69N.m
(6;0 ...7.0 kg-m, 43 - 51 ft~lb)
(4) Install timing gear case cover with new gasket.
(5) Install oil tube.
(6) Tighten injection pump nuts.
tDJ:20 ~25 N.m
(2.0 ~2.5 kg-m, 14 ~18 ft~lb)
(7) Install injection pump support.
SEF851M tDJ:30 ~36 N.m
(3.1 ~3.7 kg-m,22 ~27 ft~lb)
INJECTION TIMING ADJUSTMENT

1. Turn crank pulley in standard rotating direction and set No.
1 piston at injection timing mark located before T.D.C.
Select the right Injection timing mark on crank pulley.
2. Remove all injection tubes.
SEF670r
3. Remove No. 1 lock plate and delivery valve holder, and

then pull out delivery valve stopper (if so equipped), deliv-
ery valve spring and delivery valve.
SEF920A
4. Install delivery valve holder without delivery valve spring,

delivery valve stqpper or delivery valve.
EF&EC ..145
INJECTION PUMP ~
5. Connect test tUbe to the No.1 delivery valve holder.
6. Loosen the four nuts and one bolt securing injection pump
to timing gear case and injection pump support, then tilt
injection pump assembly fully toward engine side.
SEF671I
7. While feeding fuel by operating priming pump, slowly tilt

injection pump outward until fuel flow from No.1 injection
tube stops.
8. Fix injection pump in the position where fuel flow stops.
SEF6721
9. Check whether or not the injection timing marks of injection

pump and front plate are aligned. If not aligned, stamp a
new mark on front plate.
SEF924A
10. Remove NO.1 test tube and delivery valve holder.

11. Install delivery valve spring, delivery valve stopper, deliv-
ery valve holder and delivery valve.
Delivery valve holder:
~: 39 - 44 N.m
(4.0 - 4.5 kg-m, 29 - 33 ft-Ib)
12. Install injection tubes, new timing cover gasket and timer
cover.
Coat new timing cover gasket with sealant.
13. Connect governor hoses, fuel hoses and engine control
SEF6841 wire.
14. Bleed air. Refer to Bleeding Fuel System.
CAUTION:
a. Do not remove sealing wires unless absolutely necessary.
b. Maximum speed adjusting screw is retained by sealing
wire and need not be adjusted under normal circum-
stances. However, if it should become necessary, adjust it
with the screw. After adjustment, always wind up with seal-
ing wire.
EF & EC-146
INJECTION PUMP ~
Refer to "Adjusting accelerator pedal and cable" in Section FE.
Idlea<ijustment
Refer to section MAfor idle adjustment.

Maximum speed adjustment screw is retained by sealing wire
and need not be adjusted under normal circumstances.
However, if it should become necessary to adjust it, the follow-
ing procedures should be followed:
1. Start engine and warm .ifup until coolant temperature indi-
2. Connect tachometer's pick-up to No. 1 fuel injection tube.
To obtain accurate reading of engine rpm, loosen clamp that
secures No. 1 fuel injection tubes.
SEF6731
3. To obtain maximum speed, turn the adjusting screw in
either direction while fully depressing accelerator pedal.
Maximlim engine speed
(Under no-load):
4,300 ~15:0 rpm
5. Seal it with a sealing wire.
Altitude Compensator (Engine on vehicle)

Altitude
cOmpensator 1. Remove altitude compensator from bracket.
2. Disconnectvacuum hose and remove bracket from injec-
tion pump.
3. Install altitude compensator in the reverse order of
removal.
SEF6741
INSPECTION
1. Check for loose connections.
2. Checl<for altitude compensator movement.
If it does not move, contact a service shop. authorized by the
pump manufacturer.
SEF6751
EF & EC-147
INJECTION PUMP ~
(Cont'd)
ADJUSTMENT
The following describes the procedure for adjusting the RLD
type governor equipped with an altitude compensator.
This section explains only the adjustment procedure of the alti-
tude compensator.
CAUTION:
The altitude compensator must be adjusted at sea level.
Select a suitable pushrod so that L, = 11:t0.5 (0.433:1:0.020)

Adjusting
screw Pushrod CD L, Governor
cover
Pushrod @
"Lz" :/'
Adjust clearance to approx. 1.5 (0.059)
Unit: mm (in)
(Using adjusting screw)
SEF6761
1. Altitude compensator inspection

Measure the distance (dimension L2) between snap ring
assembled with push rod (!) and housing. If dimension L2
is outside the specified range, adjust using the adjusting
screw after removing altitude compensator cap nut and
loosening lock nut.
2. Checking push rod protrusion
Check the following items before attaching spacer to gov-
ernor cover.
(1) Fix speed control lever in maximum speed position. Next,
operate injection pump at the specified speed.
(2) In this condition, use calipers to measure the protrusion
(dimension L1) of push rod @ from the end face of the
governor cover when the specified control rack position is
obtained.
If dimension L1 is not within the specified range, replace
push rod @ so that L1 is as specified.
Refer to S.O.S. for adjusting push rods @.
3. Adjustment after altitude compensator assembly

Secure control lever at maximum speed position and oper-
ate injection pump at the specified speed.
(1) In this condition, "supply negative pressure"* P1 to the
altitude compensator's atmospheric chamber. Rotate the
altitude compensator housing to adjust control rack posi-
tion to R1.
Check that fuel injection quantity 01 is obtained at this
point.
SEF6771
EF & EC-148
INJECTION PUMP .~
0, m Q (Imp fl oZ)/1,OOO st
(Cont'~)
I (2) Next, decrease the negative pressure of the altitude com-
I
I pensator's atmospheric chamber to less than P2' and then
c:: I
o I increase it to P2 and check that control rack position is R2,
E I
Check that fuel injection quantity O2 is obtained at this
III
8. R, --+-----
I I point. Always measure the negative pressure in an
""o~ I I
increase direction (direction of the arroW).
II II
eE o *CAUTION:
o P, P, The following explains the relationship between negative pres~
()
Negative pressure -
sure as shown in the figure and absoluttil,pressure.
MEF912D
Zero point (i.e. the intersection of the axes) in the figure equals
absolute pressure at sea lever [101.3 kPa (1,013 mbar, 760
mmHg, 29.92 inHg)].
In. relation to the negative pressure for example, the change
from O.to Pl on the horizontal axis in the figure is an increase
h'l negative pressure.
However, in terms of absolute pressure, the above equals a
reduction i.nabsolute pressure from 101.3 kPa (1,013 mbar, 760
mmHg, 29.92inHg) to the point 101.3 kPa (1,013 mbar, 760
mmHg, 29.92 inHg) - Pl.
In other words, ah increase in the negative pressure is actually
a decrease in absolute pressure. "Supply negative pressure"
means "reduce the pressure" .
Ef&EC ..149
INJECTION PUMP
Disassembly
Delivery valve holder

LJti" Lock plate
~39. 44
(4.0 - 4.5,
29 - 33)
~ 7.9
(0.7.0.9,5.1.6.5)
Bearing cover
Oil seal ~
Bearing
Shim
I
Rook p"'"
Control sleeve /
A L~
Upper spring seat /" ~
Screw
Spring../' ~
Lower spring seat ~

(For plunger pre-stroke adjusting shim)
Guide
Shim
Pin~~~1
Bushin~~
~
II ev
r---~...,
I
:
/Tappet
Roller
assembly
~ ~(J I
L- -rll-=:;---/J
~
Plug
~ 54 • 74 (5.5 . 7.5, 40 - 54)
~ N'm (kg.m, ft.lb)
SEF852M
EF & EC-150
INJECTION PUMP
PREPARATION
• Before performing disassembly and adjustment, test fuel
injection pump and note test results except when testing is
impossible.
• Prior to beginning to disassemble fuel injection pump,
• Be careful not to mix parts of different cylinders.
Special tools for disassembling and reassembling injection pump
KV11242442~.
KVl1231250fi ~"... ())
DK579140~
~.l
.\@Y.
111215010
~
.~ ~KV11226582
~2215"
SEF6791
1. Drain injection pump oil.

2. Attach injection pump with Tool (KV11244852,KV11244872
and KV11244782).
SEF6801
3. Remove feed pump and cover plate.

4. Check backlash between control rack and control pinion.
Refer to Inspection.
SEF681I
EF & EC-151
INJECTIONPU MP
5. Install Tool KV11242442(coupling).
SEF6821
6. Turn coupling with Tool OK57916542until tappet is raised

to T.O.C. for each cylinder.
SEF6831
7. Turn coupling until tappet is raised to T.O.C. for each cyl-

inder and then install Tool in tappet holder hole.
8. Check camshaft end play.
9. Remove mechanical governor cover, diaphragm cover,
diaphragm, flyweight and governor housing.
Refer to Governor for removal.
10. Remove plug and bearing cover.
SEF707M
SEF581F
11. Draw out camshaft.
SEF582F
EF & EC-152
INJECTION PUMP ~
Disassembly (Cdllf'd)
12. Remove Tool KV11231250 by pushing tappet with Tool
KV11221012.
CAUTION:
Be careful not to damage housing plug hole threads.
13. Withdraw tappet assembly with Tool KV11231612from cam-

shaft chamber by loosening Tool KV11221012.
SEF708M
14. Remove plungers together with lower spring seat with Tool.
CAUTION:
Layout plunger and plunger barrel in order in a pan of kero-
sene or solvent. Do not touch plunger with hand. .
15. Remove plunger spring, upper spring seat and control

sleeve assembly.
16. Remove lock plate.

17. Re(T1ovedelivery valve holder and then remove delivery
valve holder spring, and delivery valve stopper.
SEF930A
EF & EC.153
INJECTION PUMP ~
18. Remove delivery valve.
19. Remove plunger barrel by pushing it from below.
20. Remove cap, bolt and nut on control rack.
SEF932A
21. Remove control rack guide screw and then draw out con-
trol rack.
~ ~ ~
J J Wh'I;721A
~
Inspection
Pump housing
1. Inspect for damage, cracks, etc.
If excessively damaged, replace it with a new housing.
2. Check plunger barrel drum surface for proper contact with
plunger barrel seating hole. Also, check for damage or
cracks. Replace with a new plunger and plunger barrel as
required.
3. Measure tappet to housing clearance. If worn beyond wear
SEF585F limit, replace tappet or housing.
Tappet to housing clearance (A-B):
Limit
0.2 mm (O.008 in)
EF & EC-154
INJECTION PUMP ~
Inspection (Cont'd)
Camshaft
1. Measure cam profile for uneven or excessive wear. If
excessively or unevenly worn, replace camshaft with a new
one.
2. Check for damage, cracks, etc.
If excessively damaged, replace it with a neW one.
3. Measure camshaft end play by pushing camshaft from
timer end so as to move camshaft in shaft direction.
Camshaft end play:
Standard
SEF7421 O.• O.O~mrn (0 • 0.0008 In)
Limit
0.1 mm (0.004 In)
If camshaft end play is over limit, adjust as follows:
(1) .Remove bearing inner race from camshaft.
(2) Based upon end play measurement, increase or decrease
adjusting shims.
Refer to S.O.S. for camshaft end play adjusting shims.
Use the same shim thickness on each end.
(3) Re-install bearing inner race on camshaft.
Bearings
Check for wear or discoloration. Replace with a new one as
required.
Plunger and plunger barrel
The operation of the plunger should be checked based on the
results of fuel injection volume measurement.
Oil-tightness check
1. Thoroughly clean plunger barrel in clean kerosene or sol-
vent.
2. Tilt it to approximately 60•. Then, let plunger slide down
through barrel, making sure that plunger slides smoothly.
Repeat this procedure by turning plunger to ..various
positions, making sure that plunger slides smoothly in any
of the positions.
When replacement is required, replace both the plunger
and plunger barrel as a set.
EF724A
EF & EC-155
INJECTION PUMP ~
Inspection (Co nt' d)
Delivery valve
Air-tightness check
1. Thoroughly clean delivery valve and delivery valve seat in
clean kerosene or solvent.
2. Place finger over lower part of valve seat, lightly depress
delivery valve with your finger tip, and make sure that valve
springs back when released. If valve falls to valve seat, it
is not operating properly due to excessive piston wear.
Replace with a new valve and valve seat assembly as
required.
CAUTION:
The above procedure is not necessary if the delivery valve has
a variable retraction type piston.
This type of piston will not return after your finger is released
(this Is not a malfunction).
Tappet
Tappet
Inspect tappet, roller, roller bushing, and pin for wear or dam-
Tappet guide ~ __ .-Ji) age. Replace with new components as required.
Roller end play limit:
RolI~ Pl"~.t., 0.20 mm (0.0079 in)
ROII~b""';"~
Roller
SEF587F
Control rack and control sleeve assembly

1. Inspect control rack for bending and damage.
Repair or replace with a new control rack as required.
2. Measure control sleeve to plunger lug clearance. If worn
excessively, replace control sleeve or plunger.
Control sleeve to plunger lug clearance (A-B):
Limit
0.12 mm (0.0047 In)
A
EF727A
3. Measure backlash between control rack and control pinion.

Backlash between control rack and control pinion:
limit
0.30 mm (0.0118 in)
Spring
Inspect plunger and delivery valve springs for damage and
squareness.
SEF7431
EF & EC-156
INJECTION PUMP
Assembly
Clean parts thoroughly and apply a thin coat of engine oil to
rotating and sliding parts.
Assemble injection pump in the reverse order of disass~mbly.
Note the following items.
1. Set plunger barrel in position,witll hole in barrel aligned
c o with dowel pin of housing.
@
o
@0
SEF935A
2. Install delivery valve,

3. Install delivery valve spring, delivery valve stopper (if so
equipped) and delivery valve holder,
(OJ: 39- 44 N'm
(4.0 - 4.5 kg-m, 29 - 33 ft-Ib)
SEF6841
4. Install lock plates.

5.
(1) Set the control rack so that marks on both sides are same
distance "A"frorn each end of pump housing.
(2) Adju~tbolt length and tighten lock nut.
(3) Then instl;ill c.ontrol rack guide screw.
6. Install control sleeve assembly with slit of control sleeve

facing straight up. Then install upper spring seats and
plunger springs.
SEF975M
7. Install plunger together with lower spring seat by using

Tool with plunger alignment mark facing upward (cover
side of pump housing).
Do not use plunger with a barrel from a different cylinder.
KV11221562
EF& EC-157
INJECTiON PUMP BD
Assembly (ConI' d)
8. Install tappet assembly by reversing the removal proce-
dure.
9. Install camshaft with larger diameter end toward timer.

10. Install governor housing and then adjust camshaft end
Larger diameter end play.
11. Install screw plug on bottom of pump housing.
Seal the plug with sealant.
toJ: Screw plug
54 - 74 N'm
(5.5 - 7.5 kg-m, 40 - 54 ft-Ib)
SEF709M
12. Remove tappet holder.

13. Install flyweight and mechanical governor cover in that
order.
Refer to Governor for installation.
14. Install control rack cap, cover and feed pump.
15. Install timer.
toJ: Round nut
59 - 69 N'm
(6 - 7 kg-m, 43 - 51 ft-Ib)
EF & EC-158
DISASSEMBLY
Snap
0d ring
r:::...'~)~t4!
Spring
~~
f,~\
/4, c.\,~ Carn plate
Screw \~'1\C(
~,/(')~ -1'
. ~Shaft
.dr:t~ Spring
I Lever
Snap ring
~
~Lever
.cSr:ap ring
Cap
SEF853M
EF & EC-159
INJECTION PUMP ~
Governor (Cont'd)
1. Attach injection pump with Tool KV11244852 (Universal
vise) and then remove feed pump and cover plate.
2. Install tappet holders (KV1123150)by turning coupling.
3. Remove control lever return spring and spring bracket.
SEF707M
Plate plugs (three types) are used at five locations. To remove

plate plugs during disassembly, push a screwdriver tip through
the center to make a hole and pull out the plate plug. When
doing this, be careful not to damage the inside surface of the
governor cover.
To install plate plugs when assembling, use Tools DK57923580,
DK57923590and DK57923600.
4. Remove the governor shaft plate plug, then loosen the lock
nut with Tool.
SEF7t1M
5. Remove the idling spring plate plug, then remove the lock
nut with Tool. Next, use a Phillip's head screwdriver to
remove the idling assembly.
SEF713M
EF & EC-160
INJECTION PUMP ~
Governor (Cont'd)
6. Loosen the seven governor cover mounting bolts, then
remove the governor cover assembly. Be sure to put an oil
pan under the governor to catch I.ubricating oil.
SEF506F
7. Remove start spring from rack connecting link.

8. Remove rack connecting link nut from control rack.
9. Remove snap ring fastening sensor lever.
I
SEF6871
10. Remove fulhload set lever.
SEF6881
11. Remove guide p.lug on opposite side of full-load set lever.

12. R.emoveU-type lever and sensor lever.
13. Remove fuH..,loadcontrol shaft together with spring.
EF&EC ..161
INJECTION PUMP ~
Governor (Cont~d)
14. Remove bolt fastening stop lever and remove stop lever.
SEF6901
15. Remove round nut fastening flyweight with Tool

KV11215010.At this time, prevent camshaft from turning
with Tool DK57916542.
SEF691I
16. Extract flyweight from camshaft with Tool KV11226512.
SEF6921
17. Remove bolt and screw fastening governor housing to

pump housing. Remove spring eye at the same time.
SEF6931
18. Remove governor housing from pump housing by lightly

tapping governor housing with mallet or plastic hammer.
19. As the governor shaft is screwed directly into the cover,
loosen and remove it together with the governor springs.
SEF507F
EF & EC-162
INJECTION PUMP @J
Governor {Coni' d)
20. Remove snap ring and then remove rod from torque cam.
SEF6941
21. Remove snap ring connecting torque cam and remove

torque cam.
SEF6951
22. Remove plug which holds the shaft sUPRortingthe tension

lever assembly in place. .
23. Extract shaft.
SEF113B
24. Extract tension lever assembly.

25. Extract guide lever together with collar. Extract cancel
spring at the same time.
SEF114B
26. Remove nut fastening control lever and remove control

lever.
) SEF115B
EF& EC-163
INJECTION PUMP ~
Governor (Cont'd)
27. The lever assembly consists of the parts shown at left and
is connected by a snap ring.
SEF508F
28. When rod for adjusting torque cam of tension lever or

spring is to be replaced, loosen nut and remove it with Tool.
SEF117B
Press INSPECTION
1. Flyweight
• Check pin and holder bushing for wear. If worn excessively,
Adjusting
shim replace with a new one.
• Check slider for uneven wear or scorching. If necessary,
replace with a new one.
Shifter
• Remove burrs from contact surface of flyweight at spring
Suitable
guide
washer location.
• Check screw threads for damage. If necessary, repair or
SEF976M 2. Tension lever assembly
• Check tension lever shaft for abnormal wear or seizure.
• Check governor spring seat pin for wear.
• Check torque cam rod for bending and screw threads for
damage.
• Check shifter pin for abnormal wear and bearing for sei-
zure or wear.
Replace damaged parts as needed.
To disassemble tension lever assembly for parts replacement,
proceed as follows:
a. Remove left and right snap rings from shifter pin and with-
draw shifter pin.
b. Remove snap ring which holds sleeve to bearing.
c. Press out shifter bearing guide.
3. Guide lever, rack connecting link and floating lever.
Check guide lever, rack connecting link and groove width
of floating lever for excessive play or wear. Replace worn
or damaged parts.
4. Governor housing and cover
• "Pressed-in" locks
Check pins for bending or damage. Repair or replace dam-
aged parts or entire assembly.
• Check tension lever shaft bushing for wear.
EF & EC-164
INJECTION PUMP ~
Governor {Co nt' d}
• Check screw threads for abnormalities. If necessary, repair
or replace with new ones.
5. Sensorleverand torque cam
• Check for abnormal wear on pawl at tip end of sensor lever
and surface of torque cam. Replace sensor lever and/or
torque camas required.
• Check sensor lever fork for uneven wear.
• Check torque cam rod pin and pin hole for wear. Replace
worn parts.
6. Governor shaft
Check for proper operation of governor shaft, governor
housing, spring seat, etc.
7. Control lever assembly
Chec.k control lever shaft, bushing and supporting lever for
abnormal ities.
8. Springs
Check springs for bending, rust formation or damage. If
necessary, replace with new ones.
ASSEMBLY
Assembly is in the reverse order of disassembly. Observe the
following:
Do not reuse old gaskets, oil seals, O-rings and snap E-rings.
Always install new ones.
1. Governor housing and flyweight.
(1) Place gask(:)t between governor and pump housings and
then install spring eye. Tighten all seven bolts equally in a
~
n\ crisscross fashion.
(2) Install full-load set lever, U-type lever, sensor lever and
SEF121B
connecting link in that order.
(3) Connect hook of start spring to connecting link pin.
(4) Install key. into groove on camshaft, install flyweight and

tighten nut with Tool KV11215010 while holding camshaft
with appropriate TooL
rPJ:Flyweight
49 - 59 N'm
(5 - 6 kg-m, 36 - 43 ft-Ib)
EF&.EC-165
INJECTION PUMP @]
Governor (Conl'd)
2. Governor cover assembly
(1) Shifter
When shifter is assembled to sleeve assembly, the sleeve
is pressed against the flyweight holder so that the lift of the
flyweight becomes O.It should be adjusted using an adjust-
ing shim so that distance L1 from the governor housing
surface to the center of the pin hole of the shifter is 29::1:0.2
mm (1.142::1:0.008in).
L, =29:t: 0.2 mm Refer to S.O.S. for shifter distance adjusting shims.
(1.142:t:0.008 in) A functional difficulty will occur if the dimension L1 is not
FG0117 within specifications:
a. Too large a value of L1 causes the flyweights to open too
wide, allowing the slide to come off the sleeve and rub on
the contacting surface of the sleeve. This wear is indicated
by a surface offset.
b. Too small a value of L1 prevents the flyweight from moving
and making maximum lift.
(2) Assemble shifter assembly to tension lever.
3. Governor cover internal parts

(1) Installation of control lever and floating lever
a. Insert control lever assembly into place on inside of gover-
nor cover. To facilitate insertion, apply a coat of grease to
upper oil seal and surface of lever shaft.
b. Install floating lever on supporting lever with chamfered
side (mark "[J~[J") of fork facing down.
(2) Installation of tension lever and guide lever
a. Connect upper rod of tension lever to torque earn. Tighten
lock screw.
b. Place left and right collars between tension lever and guide
lever, and insert tension lever shaft into collars.
(3) When cancel spring for integrating the guide lever with the
tension lever is built in, it is convenient to use a screw-
driver with a grooved blade.
SEF1238
EF & EC-166
INJECTION PUMP ~
Governor (Conl'd)
4.
(1) Install spring seat and governor spring onto governor shaft.
Then install governor shaft into governor cover through
spring seat on upper end oftension lever.
Spring seat on each side of governor spring should be
installed with its graded portion facing the spring.
(2) Temporarily tighten nut on end face of governor shaft
located inside governor cover.
(3) After plug of tension lever shaft is pressed in governor
cover, coat periphery of plug with screw lock. Unless screw
lock is applied, lubricating oil may leak out.
5. Fitting governor to pump

(1) Have control rack side of supporting lever pulled out toward
governor housing, and then mount sleeve. Insert ball joint
(on control rack side) into slot of floating lever, then insert
governor shaft into governor housing. This makes it easier
to attach governor cover assembly to pump.
(2) After installation of the governor cover assembly, check the

following:
1) Ensure the governor shaft can be moved smoothly by
hand.
If governor shaft movement is difficult, loosen the seven
bolts of the governor cover, slide the governor cover
until the governor shaft center is aligned with the guide
screw hole center, and then retighten these bolts.
2) Check that the control rack moves smoothly when oper-
atingthe control lever.
CAUTION:
Should the control rack movement be difficult, remove the gov-
ernor cover assembly and determine the cause.
EF & EC-167
INJECTION PUMP
Test
PREPARATION
Injection pump test conditions
Nozzle KV11257800
Nozzle starting pressure kPa (bar, kg/cm2, psi) 17,162 (171.6,175,2,489)
Injection pipe
KV11257805
2.0 x 6.0 x 600 (0.079 x 0.236 x 23.62)
Fuel feed pressure kPa (bar, kg/cm2, psi) 147 -157 (1.47 -1.57,1.5 -1.6,21 - 23)
Fuel temperature °C (OF) 40 - 45 (104 - 113)
Rotating direction Clockwise (observed from the drive shaft)
KV11282433
KV11257802
KV11282617
~19
KV11205781
SEF943M
EF & EC-168
INJECTION PUMP ~
Test (Cont'd)
1. Remove fuel feed pump and cover plate.
2. Remove timer drive gear and attach coupling KV11284019.
3. Install fuel injection pump on the bed of tester with Tool

KV1120S781.Then attach pump to timer.
4. Connect coupling to tester drive shaft with coupling disc.
5. Connect flexible hose from tester to injection pump.
6. Bleed air from injection pump.
ADJUSTMENT
Adjusting injE!ction timing
1. Adjust No.1 injection timing.
(1) Remove delivery valve holcler, delivery valve stopper,
delivery valve spring and delivery valve for No.1 cylinder.
(2) Install Tool KV11282433and set NO.1 tappet to bottom dead

center (B.D.C.) position and set dial gauge at "0".
EF & EC-169
INJECTION PUMP ~
Test (Cont'd)
(3) Rotate camshaft (pump tester) clockwise, and measure the
lift of 1st plunger when fuel flow from Tool (measuring
device) pipe stops.
Pre-stroke:
KV11282433
Refer to S.O.S.
Lower
spring seat
Beginning-of-injection position
B.D.C.
MEF432E
2. If pre-stroke is not within specification, adjust injection tim-

ing. .
(1) Rotate camshaft until earn reaches top dead center (T.O.C.)
position.
(2) Insert Tool (plunger spring holder) between lower spring
seat and tappet.
SEF595F
(3) Remove adjusting shim and adjust shim thickness so that

desired prestroke can be obtained. Adjusting shim thick-
ness varies in 0.05 mm (0.0020 in) steps.
3. Adjust No.2 to No.4 cylinder injection timing.
(1) Set NO.1 cylinder to injection start timing position, and set
angle scale on tester flywheel at "0.".
(2) Turn tester flywheel to the angle shown below, and make
sure that fuel flow from test nozzle stops.
If pre-stroke (injection timing) is incorrect, adjust the timing
SEF596F by following step 2.
Cylinder No. 1 3 4 2
Injection
89°30' - 179°30' - 269°30' -
starting 0
90°30' 180°30' 270°30'
angle
EF & EC-170
INJECTION PUMP ~
Test (Cont'd)
4. Check top clearance.
For shim-type tappet adjustment pump:
With shim-type tappet, top clearance cannot be measured.
Confirm that camshaft rotates smoothly by manually rotat-
ing camshaft slowly.
Adjusting injection volume

1. Attach Tool (measuring device) to driven side of control
rack.
SEF6991
2. Setting the "0" point position of control rack..

(1) Screw in governor shaft fully, and hold control lever at
idling position.
SEF714M
(2) Raise pump speed gradually until it reaches point @,

where governor spring stops operating. Then, push rack
R.
fully in the "fuel decrease" direction. The position where it
stops moving is the control rack's "0" position.
Pump speed.(rpm)----. SEF510F
(3) Set indicator of measuring device's dial gauge to "0".

a. Unless injection pump is driven at above speed, "0" posi-
tion cannot be obtained even If front end of control rack Is
pressed hard.
b. If front end of control rack is pushed without driving injec-
tion pump, this may cause damage to links.
EF& EC...171
INJECTION PUMP ~
Test {Co nt' d)
3. Remove control rack guide screw and install Tool
DK57976310(lock screw) to fix control rack on pump hous-
ing.
CAUTION:
Tighten Tool (lock screw) by hand.
EF746A
4. Set fuel feed pressure.

Fuel feed pressure:
147 - 157 kPa(1.47 - 1.57 bar,
1.5 - 1.6 kg/cm2, 21 - 23 psi)
5.
(1) Measure injection volume for each cylinder at rated pump
speed and control rack position.
Injection volume:
Refer to S.O.S.
(2) Compute allowable imbalance of fuel injection volume.
Allowable imbalance =
~j.~t~n ~~:~ _ (Mean injeCtiOn)

( ume for each volume
plunger
x 100
Mean injection volume
Allowable imbalance:
Refer to S.O.S.
6. Adjust injection volume so that specified injection volume

and allowable imbalance are obtained.
(1) Loosen control pinion clamp screw.
SEF7011
(2) Place suitable tool into hole in control sleeve and adjust by
~ rotating control sleeve.
Decrease (3) After adjustment is completed, tightly secure pinion set
---------- screw.
(4) Remove lock screw from control rack and reinstall guide
screw.
7. Install diaphragm housing and governor spring.
EF748A
EF &EC~172
INJECTION PUMP
Test (Cont'd)
GOVERNOR
Adjustment
The following adjustment tests must be carried out.
1. Adjustment of injection timing and injectioh quantity of
injection pump.
2. Setting the "0" point of control rack
3. Idling adjustment
4. Adjustment of governor spring contact
5. Setting the full-load position of control rack
6. Checking the maximum controlled speed
7. Checking the idling speed limit for warm-up run
PREPARATION
Before adjusting governor, the following preparations must be
made:
1. Add a prescribed amount of lUbricating oil to governor
chamber and chamber of injection pump.
2. Run in tester. After run-in operation, check that governor
operates satisfactorily.
3. Remove lock nuts for idling spring and governor shaft.
4. Loosen full speed set bolt, idle set bolt and full-load set
bolt.
Setting the "0" degree point of adjusting device

1. Referring to figure showing the top view of the adjustfng
deVice, set the angular scale in the position shown, truing
it with the square, and tighten the lock nut below the lever.
2. Align the center pin of the adjusting device to the axis of the
control lever shaft. This is accomplished by displacing the
scale-carrying top pa.rtof the device.
Control
lever shaft
SEF133B
Setting "O"point position of control rack

rack.
SEF6991
EF&EC-173
INJECTION PUMP ~
Test (Cont'd)
2. Screw in governor shaft fully, and hold control lever at
idling position.
SEF714M
3. Raise pump speed gradually until it reaches point @,

where the governor spring stops operating. Then, push the
:s Ra
rack fully in the "fuel decrease" direction. The position
S Rb where it stops moving is the control rack's "0" position.
e
.g
1
~
!
Nb
80.100
Pump speed (rpm)-..
SEF510F
4. Set the indicator of the measuring device's dial gauge to

tion cannot be obtained even If front end of control rack Is
pressed strongly.
b. If front end of control rack is pushed without driving Injec-
Precaution for adjustment of governor

Rf,
Rf,
1. Fixing control rack
Rf
Rf.
In fixing control rack when adjusting injection quantity of
Rf,
Rf,
injection pump, control lever is fixed in the idling position,
Ra'
Ra
injection pump is accelerated to above 500 rpm, control
Rb
R,
lever is manipulated to the full speed position,control rack
Rd
Rg
is positioned in the full-load position + about 3 mm (0.12
R, in) by full-load stopper and control rack is controlled, to be
fixed to each control rack position to obtain injection quan-
Na Ni Nb Nj Nb' Ns NI Nc Nk
tity.
Pump speed (rpm),~
SEF514F 2. When operating control lever to the full speed position, first
increase pump speed to above 500 rpm at the idling lever
position.
3. Always fix adjusting nut for adjusting torque cam with lock
screw.
EF & EC-174
INJECTION PUMP ~
Test (Cont'd)
Adjustment of idle spring
Rs
.S Rb
1. Adjustmentof idling lever position
E Control lever is fixed to the position where it comes in
E Ri contact with idle stopper bolt, and length of projection of
.~ Rh,
... idle stopper bolt is adjusted so that control rack position Rs
.&Rh 2
may be obtained at a pump speed of N = 80 to 100 rpm.
~ (This length is fixed.)
U
~
SEF7021
SEF7031
2. Maintain pump speed at Nb and screw in idle spring

assembly. When rack position is Rb, tighten lock nut [tight-
ening torque: 25 - 29 N'm (2.5 - 3 kg-m, 18 - 22 ft-Ib)].
SEF715M
-==-_::~
SEF517F
3. Increase pump speed until control rack position is at Ri and

then check that pump speed is Ni.
If the pump speed Ni is not as specified, adjUst by altering the
shim thickness.
Refer to S.O.S. for Idle spring adjusting shims.
EF &.EC-175
INJECTION PUMP ~
Test (Cont'd)
4. Adjustment of the governor springs
(1) Maintain pump speed at Nh1 and adjust the amount the
governor shaft is screwed in [tightening torque of nut: 10 -
15 N'm (1.0 - 1.5 kg-m, 7 - 11 ft-Ib)] so that the rack position
is Rh1•
(2) Check that control rack position is Rh2 when pump speed
is Nh2. If it is not as specified, replace governor springs
with new ones.
SEF716M
Idle adjustment
1. Decrease pump speed to Nb' and adjust idling setting bolt
so that control rack will be at position Rc. Then lock the nut.
SEF7031
JRa'
,g
E
E Rc
c:
.g
';;;
8-
,:,t
<l
~ 0
~
8
:: 80-100
Nb'
-
Pump speed rpm
SEF524F
2. Further decrease pump speed to 80 to 100 rpm, and make

sure control rack is positioned at Ra'.
3. Check that control lever angle is as specified with adjust-
Pin
ing device (KV11282617).
Control
lever shaft
SEF133B
Adjustment of full-load rack position

1. With pump speed maintained at Nf, temporarily set control
lever at the position where lever contacts maximum-speed
setting bolt.
SEF7051
EF & EC-176
INJECTION ..PUMP ~
Test (Cont'd)
2. Adjust maximum-speed setting bolt so that control rack
begins moving toward fuel decrease direction at a pump
speed of Ng. Then, lock maximum-speed setting bolt with
the nut.
SEF7061
E"t
E
E
c:
.g
';;;
0
C.
.:>!.
U
e
e...
c:
0
U
SEF527F
3. Adjust full-load setting bolt so that control rack position is

Rf when pump speed is Nf.
When full-load setting bolt is turned clockwise, the control rack
position value decreases.
SEF7371
Adjustment of torque earn

1. Using Tool (special wrench), adjust adjusting nut so that
control rack position is Rf4 when pump speed is Ni. Lock
adjusting nut with a lock screw.
Torque carn adjustment can be performed at a pUmp speed of
either Nk rpm or Ni rpm, whichever is convenient.
Pump speed rpm

SEF530F
EF & EC ..177
INJECTION PUMP ~
Test (Cont'd)
2. Decrease pump speed to Nj minus approximately 100 rpm,
;g t Rf s then increase it to Ng to ensure that torque cam stroke is
E Rf 3 within the specified range. If torque cam stroke is not as
E Rf
specified, readjust full-load setting bolt and torque cam. If
g Rf2
this adjustment cannot be performed to obtain the specified
:~ Rf I
control rack position, replace torque cam.
8-
~
~
et: Nj-100
0
8 Pump speed rpm

SEF531F
Before installing a new torque cam, be sure stamped mark is

same as number given In service data.
3. Next, increase pump speed from Nj minus approximately

100 rpm to Ng, then make sure pump speed is as specified
for each control rack position. If pump speed is not as
specified, torque cam has not been adjusted properly.
Readjust it. If torque cam cannot be adjusted to obtain the
specified pump speed, replace torque cam.
SEF532F
4. Measure fuel injection quantity at each of the adjusting

;g t points as specified (Le., the fuel injection characteristics for
full-load). If fuel injection quantity is not as specified, adjust
E
E full-load setting bolt and torque cam adjusting nut carefully.
c:
Lock the nut and bolt after adjustments .
.....
.2
'
8-
~u
~
e... 0
8c: Pump speed
---
rpm
SEF533F
If this adjustment is not executed properly, specified fuel injec-

tion quantity cannot be obtained. There will be decreased
engine output and black smoke may be produced.
EF & EC-178
INJECTION PUMP ~
Test (Cont'd)
ADJUSTMENT OF MAXIMUM SPEED CONTROL
1. Lock control lever when it contacts maximum~speed setting
bolt.
2. With pump speed maintained at Ng, adjust maximum-speed
setting bolt so that control rack begins moving from Rf3 in
fuel decrease direction. Then, lock the bolt with the nut.
]t
EAt.
E
o ~Ng
Pump speed rpm
SEF535F
3. Checking the speed drop

c Gradually increase pump speed and make sure pump
E speed is Nh when control rack reaches Rg.
EAt.
c
...
,2
'en
8-
-t~ Ag
e...c
8
SEF536F
4. Increase pump speed further to make sure control rack

reaches 0 mm (0 in).
5. Check that control lever angle is as specified with the
adjusting device.
SEF537F
6. Installation of plate plugs

After adjusting governor, check that there is no damage to
the inside surfaces where governor cover plates are press
fitted. In addition, remove as much oil as possible from
inside.
(1) Push in new plate plugs, and drive them securely into place
with Tools.
(2) After press-fitting each plug, thoroughly coat the outside
surface with suitable adhesive.
SEF717M
EF & EC-179
INJECTION PUMP
Test (Cont' d)
ADJUSTING CONTROL RACK LIMITER
Stop pump and fix control rack at rack limit position. Then
remove control rack measuring device.
After that, adjust L (distance between pump end surface and
bolt head end) so that it is the same as the depth of the control
rack cap, then fix the lock nut.
FG0143
Feed Pump
After installing feed pump bleed air from system.
FEED PUMP TEST

1. Suction test
(1) Attach a hose [2 m (7 ft) x 8 mm (0.31 in) dia.] to the feed
pump suction port and insert the other end into a container.
Fuel oil container must be approximately 1 meter (3 feet) below
suction head of feed pump.
(2) Operate the injection pump at 100 rpm.
(3) Fuel must be discharged within less than 40 seconds.
SEF7081
2. Priming pump test

(1) Fully loosen the priming pump's screw cap.
(2) Operate priming pump using the screw cap, at 60 to 100
strokes per minute.
(3) Fuel must be discharged in less than 25 strokes.
SEF7091
3. Capacity test
(1) Place discharge hose in a measuring cylinder.
SEF7101
EF & EC-180
INJECTION PYMP ~
Feed Pump (Cont'd)
(2) OperateJnjection pump and check supply rate, referring to
the following table:
Supply rate
Pump speed
me (Imp fI oz)/15 sec.
100 rpm More than 60 (2.11)
500 rpm More than 340 (11.97)

1,000 rpm More than 405 (14.26)
1,500 rpm More than 430 (15.14)
4. Feed pressure measurement

(1) Connect a hose between feed pump discharge port and the
pressure gauge.
(2) Operate injection pump at 600 rpm.
(3) Ensure that feed pump maintains a feed pressure of 333 to
412 kPa (3.33 to 4.12 bar, 3Ato 4.2 kg/cm2, 48 to 60 psi).
SEF7111
5. Air tightness test

...
- - 0
..
.. ----
_
(1) Plug feed pump discharge port using a suitable plug .
(2) Apply 196 kPa (2.0 bar, 2 kg/cm2, 28 psi) air pressure to
suction port.
(3) Immerse feed pump in a container of fuel oil, and check for
air leakage. There must be no air leakage .
SEF550F
EF &EC~181
INJECTION PUMP
Feed Pomp (Cont'd)
INSPECTION
Priming pump
Feed pump housing
SEF718M
Feed pump housing

1. Check the check valve seats. If they are damaged or exces-
sively worn, replace housing.
2. Check push rod hole. If hole is excessively worn, replace
housing.
Check valve and check valve spring
1. If seat of check valve is excessively worn or scarred,
replace check valve with a new one.
2. If check valve spring is damaged or permanently stressed,
replace valve spring.
Piston and piston spring
1. If periphery of piston is excessively worn or scarred,
replace piston with a new one.
2. If piston spring is damaged or weakened, replace valve
spring.
Tappet assembly
1. Tappet
If periphery of tappet is worl1 or scarred, replace it with a
new one.
EF & EC-182
INJECTION PUMP lliJ
Feed. Pump (Cont'd)
2. Tappet roller
If periphery of tappet roller is excessively worn or scarred,
replace it. with a new one.
Roller to pin clearance:
limit
0.30 mm (0.0118 in)
Tappet roller outside diameter:
Wear limit
14.9 mm (0.587 in)
Timer
REMOVAL
1. Remove timing gear case cover.
2. Mesh injection pump drive gear with idl~r gear at "Z" mark
or injection pump drive gear and timing gear case at
"punch mark and align line" so that No.1 piston is at top
dead center.
SEF6681
3. Remove timer round nut with Tool.

4. Remove timer assembly by screwing in Tool.
DK57914010
SEF946M
5. Remove timer assembly using Tool (timer extractor).
KV11226582
SEF947M
INSTAllATION
1. Mesh injection pump drive gear with idler gear at Z-mark,
or injection pump drive gear and timing gear case at "point
mark and alignment mark" and then align gear to key way
of injection pump camshaft while turning crank pulley.
2. Secure timer assembly with lock washer and round nut.
toJ: Round nut
59 - 69 N'm
(6 - 7 kg-m, 43 - 51 ft-Ib)
3. Install timing gear case cover with new gasket seal.
EF&EC ..183
INJECTION PUMP ~
Timer (Cont'd)
ADJUSTMENT
1. Install stroboscope, using cover plate bolts, so that syn-
chronizer lever attachment is applied to tappet.
2. Operate fuel injection pump, turn "ON" switch of strobo-
scope illuminating dial (angle scale) on flywheel, and mea-
sure angular change based on variations in pump speed.
If tester does not have a dial (angle scale):
(1) Attach a dial to timer coupling and mount a pointer on
tester drive shaft.
(2) Operate fuel injection pump and turn stroboscope "ON" so
SEF570F as to illuminate dial.
3. If advance angle is not within specified range, adjust by
changing timer spring shims.
a. When injection timing Is retarded, decrease shim thick-
ness.
b. When injection timing is advanced, increase shim thick-
Adjusting ness.
shim
Timer advance curve:
Refer to S.O.S.
Flyweight holder
EF789A
DISASSEMBLY
Thrust washer
Adjusting shim
Washer
Lock plate ~
A98 -1n
(10 - 18, 72 - 130~
SEF854M
EF & EC..184
INJEGTION PUMP ~
Timer (Cont'd)
1, Clamp the base of inserter (KV11224162) in a vise.
2. Mount guide bolt (KV11224170) on the base.
3. Set timing device assembly so that flange inserter base's

two knock pins enter holes in flyweight holder.
4. Remove the six bolts and remove injection pump drive gear
from liming devIce flange.
5. Flatten lo~k washer locking lock nut.
SEF7141
6. Remove loCk nut, and then remove lock washer, washer,

shim .and bearing.
SEF7151
7. Insert a screwdriver under timing device flange pin and

remove timing device flange by lifting it up.
ponot losetiming~eVice spring or shil1'l'
SEF7161
EF& EC-'185
INJECTION PUMP
Timer (Cont'd)
8. Remove flyweights from flyweight holder.
SEF7171
9. Carefully clean disassembled parts to remove all oil and

dirt.
INSPECTION
Timing device springs
Replace entire set if bent or worn.
Flyweight holder
Replace flyweight holder if tapered parts, key slot or flyweight
pins are abnormally worn, or flyweight pin welds are cracked.
SEF7181
Flyweights
Replace if pin holes or curved surfaces are worn.
SEF7191
Timing device flange

Replace if abnormal pin wear or pin weld cracks are found.
Injection pump drive gear
Replace if abnormal gear tooth wear is found.
Do not reuse the lock washer. Always replace a new one.
SEF7201
EF & EC-186
INJECTION PUMP
Timer (Cont'd)
Bearing
Replace if abnormally worn.
SEF7211
ASSEMBLY
1. Install flyweight holder on the base.
2. Mount flyweights on flyweight holder pins.
SEF7221
3. Insert timing device springs into flyweight holder pin seats;

then insert supporters (KV11232020)under timing device
springs and position flange ends of timing device springs
upward.
SEF7231
4. Mount timing device flange on flyweight holder.

At this time flyweight holder's key groove and aligning
mark on outside edge of the flange must be aligned.
SEF7241
5. Mount guide (KV11224180)and nut (KV11224190)on guide

~Nut bolt.
l~G"~'
SEF7251
EF& EC-187
INJECTION PUMP ~
Timer (Cont'd)
6. Use timer wrench (KV11216432)to rotate timing device
flange to compress timing device springs. Hold it in this
position.
7. Disengage supporters from beneath both ends of timing
device springs.
SEF7261
8. Compress timing device springs further and, when timing

device flange pins contact curved surfaces of flyweight,
slowly tighten bolt to push timing device flange down.
SEF7271
9. Insert a screwdriver under timing device springs and pry

timing device springs into timing device flange seats.
SEF7261
10. Install thrust washer, shim, washer, lock washer and then
lock nut on flyweight holder.
11. Tighten lock nut to the specified torque.
~: 98 - 177 N.m
(10 - 18 kg-m, 72 - 130 ft-Ib)
SEF7291
12. Use a feeler gauge to ensure clearance between washer

and shim is as specified. If not, adjust by changing shim
thickness.
Specified thickness:
0.02 - 0.1 mm (0.0008 - 0.0039 in)
Refer to S.O.S. for timer flange to washer clearance adjusting
shims.
SEF7301
EF & EC-188
INJECTION PUMP [![]
Timer (Conl'd)
13. Bend lock washer' to fix lock nut.
14. Check timing device performance using a pump test stand
and then install injection pump's drive gear.
SEF731I
EF&EC ..189
INJECTION NOZZLE

1. Disconnect injection tube flare nuts.
2. Remove spill tubes.
3. Remove injection nozzle holder supports.

4. Install injection nozzle holder assembly in the reverse
order of removal.
toJ: Injection nozzle holder bolt
to cylinder head
44 - 49 N'm
(4.5 - 5.0 kg-m, 33 - 36 ft-Ib)
20 - 25 N'm
(2.0 - 2.5 kg-m, 14 - 18 ft-Ib)
• Nozzle gaskets should always be replaced.
DISASSEMBLY
1. Loosen inlet connector while keeping nozzle top from turn-
ing.
Adjusting shim
Nozzle spring
1 Pin
Spring seat
Spacer
Nozzle needle
Nozzle assembly
Retaining ~29 - 39 N.m
nut (3.0 - 4.0 kg-m, 22 - 29 ft-Ib) SEF843M
INSPECTION
solvent.
EF & EC-190
INJECTION. NOZZLE

assembly.
• Check nozzle spring for excessive wear or damage. If
assembly.
CLEANING
1. Clean nozzle assembly using Tool (Nozzle Cleaning Kit).

figure.
Adjusting shim
Nozzle spring
Spring $eat
Spacer
Nozzle needle
Nozzle assembly
Retaining nut
SEF6371

SEF6381
EF & .EC-191
INJECTION NOZZLE
KV11290122
SEF6391

KV11290150
Cleaning area
SEF6401

To prevent spray hole from canting, always clean It by starting
with Inner side and working towards outside.

it.
own weight.
If needle falls to sink smoothly from any position, replace both
SEF641 I
EF & EC-192
INJECTION NOZZLE
ASSEMBLY
toJ:
Retaining nut
29- 39 N'm
(3.0 -4.0 kg-m, 22 - 29 ft-Ib)
If nozzle body is not installed properly, tool cannot be removed
and nozzle body may be damaged.
TEST AND ADJUSTMENT
WARNING:
from nozzle to come int.o contact with your hand or body, and

flare nut.
SEF6421
starts dropping.
Used
18,143 - 18,633 kPa
(181.4 - 186.3 bar, 185 - 190 kg/cm2,
2,631 - 2,702 psi)
/1\\ New
SEF6431 18,633 - 19,614 kPa
(186.3 - 196.1 bar, 190 - 200 kg/cm2,
2,702 - 2,844 psi)
New nozzle is required to always check initial injection pres-
sure.
EF &. EC..193
INJECTION NOZZLE
4. To adjust injection pressure, change adjusting shims.

a. Increasing the thickness of adjusting shims increases ini-
tialinjectlon pressure. Decreasing thickness reduces initial
pressure.
b. A shim thickness of 0.010 mm (0.0004 in) corresponds
approximately to a difference of 147 kPa (1.47 bar, 1.5
kg/cm2,21 psi) in initial injection pressure.
Shim
SEF6441
Leakage test
pressure.
around the body.
Retaining
nut
replace it.
Good No good
SEF6451
Spray pattern test

1. Pump the tester handle one time per second.
replace it.
•
I •
•
I
Good Wrong
EF794A
EF & EC-194
BLEEDING FUEL SYSTEM (Engine on vehicle)

Air should be bled out of fuel system when injection pump is
removed or fuel system is repaired.
If engine will not start after bleeding air, loosen injection tubes
at nozzle side and crank engine until fuel overflows from Injec-
tion tUbe. Tighten injection tube flare nuts.
In-line pump
CAUTION:
Wipe up any fuel discharged while bleeding air during each
step.
• Step 1: Sedimentor air bleeding
1.. Turn priming pump counterclockwise.
2. Loosen air bleeder screw.
3. Move priming pump up and down until no further air comes
out of air bleeder.
4. Tighten air bleeder screw.
SEF6461
• Step 2: Fuel filter air bleeding
1. Loosen fuel inlet and fuel outlet connectors.
out of overflow valve connector.
3. Tighten overflow valve connector.
rPJ:Connectors
25 - 29 N.m
(2.5 - 3.0 kg-m, 18 - 22 ft-Ib)
Fuel outlet
connector SEF977M
• Step 3: Fuel injection pump air bleeding

1. Loosen fuel overflow valve connector.
rPJ:
Overflow valve connector
25 - 29 N.m
(2.5 - 3.0 kg-m, 18 - 22 ft-Ib)

2. Loosen fuel inlet valve connector.
out of fuel inlet valve and fuel overflow valve connector.
4. Tighten inlet valve and overflow valve connectors.
rPJ: Valve connector
25 - 34 N.m
(2.5 - 3.5 kg-m, 18 - 25 ft-Ib)
SEF6491
EF &.EC-195
• Step 5: Fuel injection tube and spill tube air bleeding

1. Loosen injection tube nuts of injection pump delivery
valves and nozzle holders.
2. Loosen fuel filter spill tube overflow valve connector.
3. Move the priming pump up and down until no further air
comes out of the injection tube nuts.
4. Tighten the injection tube nuts.
toJ:20 - 25 N'm
(2.0 - 2.5 kg-m, 14 - 18 ft-Ib)
5. Tighten the fuel filter overflow valve connector.
toJ:25 - 29 N'm
(2.5 - 3.0 kg-ml 18 - 22 ft-Ib)
EF & EC.196
FUEL FILTER
Overflow Valve
In-line pump
Attach a pressure gauge to fuel filter discharge port, and check
valve opening pressure by operating priming pUJnp.lfpressure
is not within range of 98 to 137 kPa (0.98 to 1.37 bar, .1.0to 1.4
kg/cm2, 14 to 20 psi), replace overflow valve.
SEF6521
EF&EC ..197
FUEL HEATER SYSTEM
Fuel temperature sWitc~ DESCRIPTION

Fuel heater system is designed to improve startability at low
atmospheric temperatures for H40 models destined for cold
areas.
This system prevents fuel filter from clogging with fuel wax.
SEF6531
Fuel temperature switch Oil pressure switch*
From fuel ... ....... To injection pump

tank
OFFo Ignition
switch
Fuel filter assembly
*Oil pressure switch

is fixed on left side
of engine block.
SEF411F
BATTERY IGNITION SWITC H

ON or START
~ FUSE BLOCK
~ (Refer to "POWER SUPPLY
I ROUTING" in EL section)
OIL PRESSURE
SWITCH
(Chassis harness) ~ (Instrument harness)
~@
rEt-oD-G/B
~
rm:;i~;~Imil:~~;:~""
~ (Instrument sub
G/R
BIG
W/BID
<@l
co
i@
BODY GROUND
TI JI.
Heater switch
FUEL HEATER SEF6221
EF & EC-198
FUEL HEATER SYSTEM
5(41) Fuel heater operation arn OPERATION

u Fuel heater system operates when fuel temperature switch and
o
e 0(32)
oil pressure switch are on.
a OJ
!
...~ -5(23)
'ii
u..='
o 98 196
(0,0,11.0,1, (2.0, 2,
Engine 0) 14) 28) 43)
oil pressure kPa (bar, kg/em' , psi) SEF541D
INSPECTION
Lead wire
1; Connect a lead wire, as shown, between terminals of fuel
temperature switch.
After checking, reconnect

the connector
SEF553D
2. Run engine at about 1,000rpm. After several minutes, make

sure that fuel heater is hot.
Be careful not to burn yourself.
SEF6551
3. If fuel heater does not operate, check fuel heater system as

follows.
Fuel heater
1. Check continuity for fuel heater.
2. If fuel heater has malfunction, replace fuel filter bracket.
SEF6561
Oil pressure switch

1. Run engine at about 1,000 rpm.
2. Check continuity for oil pressure switch.
3. If oil pressure switch has malfunction, replace it.
Cylinder
block
SEF414F
EF& EC.199
FUEL HEATER. SYSTEM
Fuel heater relay

t. Check fuel heater relay operation.
2. If fuel heater relay does not operate, replace it.
Harness
Check harness and fuse continuity.
EF & EC-200
AIR HEATER. SYSTEM
CAUTION:
Before starting work, be sure to turn ignition switch "OFF" and then disconnect battery ground cable.
Schematic
@ : For cold areas

FUSIBLE
@ : Except for cold areas
FUSIBLE
LINK LINK @ : Except for Australia
IGNITION SWITCH
Sf ON Ace Of'
IG
S
• AIR
w ~ HEATER
3
IL
RELAY.2
0 AIR
HEATER
CONTROL
CD UNIT
0
@
0
AIR
WATER HEATER
TEMPERATURE
SENSOR
ALTERNATOR
SEL055N
EF ••& .EC,201
AIR HEATER SYSTEM
Wiring Diagram
EX
0::
...
W
w
::0
z
o
~
z
iD
::0
o
u
o @
0
u B/R~ H$$fl'~ ;5
EX B/y~lm B/Y x
w B/Ytj
B/R
~,,~
Y/R~@Y
B @
[ilJ1
0::
w/Rm~Eaw
BR/RifjI~ Ijj-BR/R wB
«
~
..
E"
.J:
..
.~
.J:
~aS=C)WATER TEMPERATURE
!:!. SENSOR
a..
::l
@ @
.. ~'mm' X
w
@
en
M
B~I.!3
0
Z
::l
0
>
0
0
~R------Lw-R-8gR lD
@@ 3:
0
3:0::
~
x
u
!: ..
nr ?
".2
w
~
Z CIlZ
lD
o rr::i
i=
Z >
0::
£! ~ ......
W
«
9 ~
B"
lD
SEL056N
EF & EC-202
AIR HEATER SYSTEM I B030 ,
Trouble-shooti ng
Engine fails to start or is hard to start.
Check fuel level, fuel supplying system, starter motor, etc.
O.K.
Check that air heater harness and

N.G. Correct.
connectors are installed properly.
O.K.
Turn ignition switch OFF for more than 10 seconds.
Check if heater pilot lamp comes on within a few seconds of turning the ignition switch ON.
*1 (Next page)
Check for a burned out bulb. N.G.

Replace bulb.
O.K.
Go to "Power supply circuit check"

N.G. Check harness between fuse and
for heater control unit.
heater control unit.
O.K.
Go to "heater pilot lamp control

N.G.
check". Replace heater control unit.
O.K.
Check short circuit on harness between

ignition switch and heater pilot lamp.
EF.& EC-203
AIR HEATER SYSTEM
Trouble-shooting (Cont'd)
(From previous page)
*1
Go to "Air heater check". N.G.

Replace air heater.
O.K.
Check heater relay.

N.G.
Refer to "Air heater relay check". Replace air heater relay.
O.K.
Go to "Start signal input check". N.G. Check harness between air heater control unit
and ignition switch.
O.K.
Go to "Pre-heating control check". N.G.

Replace air heater control unit.
O.K.
Check harness between

• Air heater control unit and air heater relay
• Air heater relay and air heater
The combustion performance of the engine

after it has started is not good.
Check air heater relay.

N.G.
Refer to "Air heater relay check". Replace air heater relay.
O.K.
Go to "After-heating control check". N.G.

Replace air heater control unit.
O.K.
Check harness between air heater control unit

and air heater relay.
EF & EC-204
AIR HEATER SYSTEM 18030 I
When the ignition key is ON, the
heater pilot lamp remains on and
does not go off.
O.K.
Go to "Water temperature sensor cir-

N.G.
cuit check".
O.K.
Go to "Water temperature sensor". N.G.
O;K.
Replace water
temperature sen-
sor.
Check harness between heater con-

trol unit and water temperature sen-
sor.
Go to "heater control unit control

check". Replace heater control unit.
O.K.

heater control unit and heater pilot lamp.
AIR HEATER SYSTEM
Inspection
CAUTION:
Before starting work, be sure to turn ignition switch "OFF" and
then disconnect battery ground cable.
AIR HEATER FUNCTIONAL CHECKS (On-vehicle service)
1. When engine is cold, turn ignition switch from OFF to ON
to check that air heater pilot lamp comes on.
2. With ignition switch ON, listen to check air heater relay
operates for a certain period of time, the time correspond-
ing to an increase in cooling water temperature.
3. Touch air heater with your hand to check that it is warm.
Do not repeat above checks since battery may run down.
AIR HEATER CHECK (On-vehicle service)
Type I (12V) Type II (24V)
~
o r------. 0
B B A
0,
!
~jf'
E=J::-:
c I o
•
oL J 0
:~
A
A
SEL125N
1. Turn ignition key ON and measure air heater terminal volt-

Type! Type II
age.
m ------- ------Lir
m heater
2.
Terminal voltage: Battery voltage (Approx. 12 or 24V)
Check that continuity exists between heater terminals.
Type
Between terminal
check point
Continuity
connector
A-B Yes
Type I (12V)
CoD Yes
Ignition switch: ON. Type II (24V) A-C Yes

SEF180N
EF & EC-206
AIR HEATER SYSTEM ~
Inspection (Cont'd)
AIR HEATER RELAY CHECK (On-vehicle service)
• Turn ignition switch ON and measure air heater relay ter-
minal voltage.
Terminal voltage: Battery voltage (Approx. 12 or 24V)
*: Figure shows vehicle equipped with 12-volt battery.
SEL126N
• If N.G., check continuity between terminals as shown in the

Continuity ....... O.K.
No continuity... N.G. figure.
12V or 24V D.C.

SEL 127N
WATER TEMPERATURE SENSOR

• Check resistance of water temperature sensor.
Resistance as shown in the figure below.
EF &.EC-207
AIR HEATER SYSTEM
Inspection (Cont'd)
Resistance (kn)
20 (68) Approx.2.5
80 (176) Approx.0.33
SEF062F
POWER SUPPLY CIRCUIT CHECK

Disconnect harness connector from air heater control unit and
perform voltage check and continuity check.
Voltmeter terminals Ignition switch position
(+) H OFF ACC ON

Battery voltage
(J) @ OV OV
(approx. 12 or 24V)
SEL181N Ohmmeter terminals

Ignition switch OFF
(+) H
@ Body ground Continuity exists
WATER TEMPERATURE SENSOR CIRCUIT CHECK

• Check continuity between terminals @ and @.
Measure resistance to temperature approximately as
shown in "Water temperature sensor".
SEL 182N
EF & EC-208
AIR HEATER SYSTEM lliJ
Inspection (Cont'd)
CIRCUIT TO ALTERNATOR'S "L" TERMINAL CHECK
2. Disconnect harness connector from heater control unit.
3. Disconnect harness connector from the alternator's "L" ter-
minal.
4.. Check terminal voltage between @ and @ when the igni-
tion switch is turned to ON.
Volta.ge:
Battery voltage (approx.12 or 24V)
Ignition switch: ON
SEL183N

2. Disconnect harness .connector from the starter motor's "S"
terminal.
3. Check terminal voltage betweend)and @ when the igni-
Voltage:
Battery voltage (approx. 12 or 24V)
Ignition switch: START

SEL184N
HEATER PILOT LAMP CONTROL CHECK

2. Leave harness connector joined to heater control unit.
3. Connect test lamp to heater control unit as shown.
4. Turn ignition switch to ON and measure the time the test
lamp stays lit.
Time the test lamp should stay lit.
Type I (12V):
Type II (24V):
(Varies with water temperature)
EF & EC.209
AIR HEATER SYSTEM 00
Inspection (Cont'd)
PRE-HEATING CONTROL CHECK
lamp stays lit and the voltage between the terminals.
Between termi-
Type Time Voltage
nal check points
8-4 Approx. 0 - 20
Test lamp (3.4W) Type I (12V)
11 - 4 seconds
Ignition switch: ON Battery voltage
Approx. 0 - 18
Type" (24V) 11 - 4
seconds
SEL 186N
AFTER-HEATING CONTROL CHECK

terminal.
turned to START.
4. Measure the time the test lamp stays lit and the voltage
between the terminals when ignition switch is turned to ON
Test lamp (3.4W) from START.
Between ter-
Type minal check Time Voltage
Engine is funning. points
Water temperature;
Type I • Below 20°C (58°F)
(12V) Battery voltage should
Approx. 0 -180 sec-
exist when water tem-
11 - 4 onds (Varies with
perature is below
water temperature)
Type" 20°C (58°F).
• Over 20°C (58°F)
(24V)
o seconds
SEL 187N
EF & EC-210
FUEL CUT SYSTEM
Wiring Diagram
t
UP
FUSE BLOCK ~
(Refer to "POWE:R ;;,
SUPPLY ROUTING"
in EL sect ion.)
8.M.c!.
[Refer to last page
FUEL CUT
m
(Fo ldout page) .]
SOLENOID
(Instrument
r-r-harness)
B,W ~ B,W
(Chass is harness)
1 B,W =B ~
VALVE
(For auto stop
actuator)
I I @ @ (ill)
m m
m
@~
BODY GROUND BODY
GROUND
SEF818M
EF & EC-211
DESCRIPTION
Fresh air ---_
Blow-bygas_ The closed-type crankcase ventilation system is utilized as a
crankcase emission control system.
Air control valve
The closed-type crankcase emission control system prevents
blow-by gas from entering the atmosphere and keeps the inter-
nal crankcase pressure constant.
During the valve operation, the blow-by gas is fed into the
intake manifold by the air control valve.
This is activated by the internal rocker cover pressure. When
the intake air flow is restricted by the throttle chamber, the
internal rocker cover pressure decreases. At this point, the
crankcase emission control valve keeps the internal rocker
cover pressure constant so that air or dust is not sucked in
around the crankshaft oil seal.
SEF432F
INSPECTION
Air control valve
2. Remove control valve from rocker cover.
3. After plugging the center hole with adhesive tape, check
that air flows from inlet by blowing air from outlet and that
air does not flow by inhaling air.
SEF060B
VENTILATION HOSE
2. Disconnect all hoses and clean with compressed air.
If any hose cannot be freed of obstructions, replace.
SEC692
EF & EC-212
SERVICE DATA AND SPECIFICATIONS (S.D.S~)
Injection Pump
PUMP NUMBERS
Applied model
Engine Destination Part number Pump number Remarks
H41
16700-0T860 101493-9090 Without high altitude compensator

BD30 General areas 0
1670o-0T861 101493-9130 With high altitude compensator
INSPECTION AND ADJUSTMENT Standard Limit

mm (in) mrr;t (in)
General specifications .
Thickness
Part number
Injection timing B.T.D.C. 14° mm (in)
0.2 (0.008) 16741-T8272
MaXimum engine speed
0.25 (0.0098) 16741-T8273
0.3 (0.012) 16741-T8260
Injection pump 0.35 (0.0138) 16741-T8274
0.4 (0.016) 16741-T8261
Standard Limit 0.45 (0.0177) 16741-T8275
mm(ir:t) mm(in) 0.5 (0.020) 16741-T8262
Push rod protrusion of altitude 10.5 - 11.5 0.55 (0.0217) 16741-T8267
corr;tpensator (0.413 - 0.453)
-
0.6 (0.024) 16741-T8263
0.02 - 0.062 0.65 (0.0256) 16741-T8268
Pump housing to tappet clear-
(0.0008 - 0.20 (0.0079) 0.7 (0.028) 16741-T8264
ance
0.0024) ~ 0.75 (0.0295) 16741-T8269
0.02 - 0.08 0.8 (0.031) 16741-T8265
Control sleeve to plunger lug Plunger Pre-stroke adjUsting
(0.0008- 0.12 (0.0047) 0.85 (0.0335) 16741-T8270
clearance shim
0.0031) 0.9 (0.035) 16741-T8266
0-0.02 0.95 (0.0374) 16741-T8271
Camshaft end play 0.10 (0.0039) 16741-99006
(0 - 0.0008) 1.0 (0.039)
Control rack to pinion backlash 0.15 (0.0059) 0.30 (0.0118) 1.05 (0.0413) 16741.99012
Less than 1.1 (0.043) 16741-99008
Pump rpm = 1.471 N 1.15 (0.0453) 16741"99013
- 1.2 (0.047) 16741-99009
Control rack 0 (150 g, 5.29
oz) 1.25(0.0492) 16741-99014
sliding res is-
1.3 (0.051) 16741-99010
tance Less than
Pump rpm = 1.35 (0.0531) 16741-T8276
1,000
0.490 N - 1.4 (0.055) 16741-99011
(50 g, 1.76 oz)
1.45 (0.0511) 16741"T8277
Injection interval
(cam angle)
89°30' - 90°30' - 1.5 (0.059) 16741-99015
1.55 (0.01310) 16741-T8278
Injection starting timing 3.15-3.25
1.6 (0.063) 16741-99016
(pre-stroke: plunger lift from (0.1240- - .
Push rOd
B.D.C.) 0.1280)
length Part number
Thickness
Part number mm(in)
mm (in)
95 (3.74) 19329~Z9018
0.10 (0.0039) 16716-SS009
96 (3.78) 19329"Z9019
0.12 (0.0047) 16716-99010
97 (3.82) 19329-54T65
0.14 (0.0055) 16716-99011
98 (3.86) 19329-54T66
0.16 (0.0063) 16716:99012 Altitude compensator adjusting
Front 99 (3.90) 19329-54T67
0.18 (0.0071) 16716-99013 push rod
100 (3.94) 19329-54T68
0.30 (0.0118) 16716-99401
101 (3.98) 19329-54T69
0.50 (0.0197) 16716-99014
102 (4.02) 19329-54T60
1.00 (0.0394) 16716-99402
102.5 (4.04) 19329-54T61
Camshaft end 0.10 (0.0039) 16741-37500 103 (4.06) 19329-54T62
play adjusting 0.12 (0.0047) 16741-37501 103.5 (4.07) 19329-54T63
shim 0.14 (0.0055) 16741-37502 104 (4.09) 19329-54T64
0.16 (0.0063) 16741-37503
0.18 (0.0071) 16741-37504
Rear 0.30 (0.0118) 16741-37506
0.50 (0.0197) 16741-37505
0.70 (0.0276) 16741-Z9001
1.00 (0.0394) 16741-Z9000
1.40 (0.0551) 16741-37509
2.40 (0.0945) 16741-Z9005
EF& EC-213
Injection Pump (Co nt' d)
Governor Timer
Standard Limit Timer flange to washer clear-
mm (in) mm(in) ance (Lock plate to thrust
0.02 - 0.10 (0.0008 - 0.0039)
washer clearance)
Shilter pin hole to 28.8 - 29.2
- mm (in)
housing surface (1.134 - 1.150)
Thickness
Thickness Part number
Part number mm (in)
mm (in)
0.1 (0.004) 16822-37500
0.2 (0.008) 19342-90001
Timer spring adjusting shim 0.3 (0.012) 16822-37501
0.3 (0.012) 19342-90002
0.5 (0.020) 16822-37502
0.4 (0.016) 19342-90003
0.5 (0.020) 19342-99118 0.10 (0.0039) 16826-99007
Shilter distance
1.0 (0.039) 19342-90004 0.12 (0.0047) 16826-99000
adjusting shim
1.5 (0.059) 19342-99119 0.14 (0.0055) 16826-99001
2.0 (0.079) 19283-0n03 Timer flange to washer clear- 0.16 (0.0063) 16826-99002
3.0 (0.118) 19283-0n04 ance adjusting shim 0.18 (0.0071) 16826-99003
4.0 (0.157) 19283-0n05 0.20 (0.0079) 16826-99005
0.30 (0.0118) 16826-99006
0.1 (0.004) 19283-Z9012
0.50 (0.0197) 16826-99004
0.2 (0.008) 19283-Z9013
0.25 (0.0098) 19283-Z9014
Idle spring adjusting
0.3 (0.012) 19283-Z9016
shim TIGHTENING TORQUE
0.5 (0.020) 19283-Z9017
0.8 (0.031) 19283-Z9018 Unit N'm kg-m It-Ib
1.0 (0.039) 19283-Z9015
Injection pump
Feed pump Injection pump fixing nut 20 - 25 2.0 - 2.5 14 - 18
Delivery valve holder 39 - 44 4.0 - 4.5 29 - 33

Standard Wear limit
Screw plug 54 - 74 5.5 - 7.5 40-54
Roller to pin clear- 0.04 - 0.08
0.30 (0.0118)
ance mm (in) (0.0016 - 0.0031) Bearing cover bolt 7-9 0.7 - 0.9 5.1 - 6.5
Roller outer diame- Adapter:

15.0 (0.591) 14.9 (0.587)
ter mm (in)
M14 20 - 29 2.0 - 3.0 14 - 22
300 me (10.6 Imp fI oz) or more within 15
Oi I feed rate M18 39 - 49 4.0 - 5.0 29 - 36
seconds at a pump speed of 1,000 rpm.
Overflow valve 20 - 29 2.0 - 3.0 14 - 22
Discharge should occur within one minute
Pumping capacity (60 seconds) with a pump speed of 100 Eye bolt 20 - 29 2.0 - 3.0 14 - 22
rpm and intake head of 1.0 meter (3.3 It).
Control rack gUide screw 4-6 0.4 - 0.6 2.9 - 43
The time required to develop an oil feed
Feed pump fixing nut 5-7 0.5 - 0.7 3.6 - 5.1
pressure of 157 kPa (1.57 bar, 1.6 kg/cm2,
Oil feed pressure
23 psi) with a feed pump speed of 600 rpm Governor
should be within 30 seconds.
Flyweight round nut 49 - 59 5.0 - 6.0 36 - 43
Operate the priming pump at a rate of 60
Pumping capacity Timer
to 100 strokes per minute and verify that
(priming pump)
pumping is started within 30 strokes. Round nut 59 - 69 6.0 - 7.0 43 - 51
Lock nut 98 - 177 10 - 18 72 - 130
Drive gear fixing bolt 59 - 69 6.0 - 7.0 43 - 51
EF & EC-214
INJECTION PUMP CALIBRATION DATA (Pump parts No. 16700-0T860;16700;'OT861)
Injection timing
Pre-stroke: No.1 plunger 3.2:l: 0.05 mm (0.1260:l: 0.0020 in)
Injection order:1 --- 3 , 1 4 , 1 ---2

90":l: 30' 180":l: 30' 270":l: 30'
Plungers are numbered Irom the Drive side.
Tappet clearance: Bolt adjustment type; More than 0.3 mm (0.012 inO lor all cylinders.
: Shim adjustment type; Manually rotate the camshaft 2 to 3 times and conlirm that it rotates smoothly.
Injection quantity
Rack position Pump speed Injection q'ty Max. var bet. cyl
Adjusting point Fixed Remarks
mm (in) rpm mt (Imp II oz)/1,OOOstrokes (%)
- 11.5 (0.453) 1,000 52.0 - 55.2 (1.83 - 1.94) :l:2.5 Rack
Approx. Basic
H 350 6.1 - 9.1 (0.24 - 0.32) :l:15 Rack
9.5 (0.374)
A 11.5 (0.453) 1,000 52.5 - 54.7 (1.85 - 1.93) - Lever
B 11.3 (0.445) 1,900 51.2 - 55.2 (1.80 - 1.94) - Lever
i - 100 64.0 - 74.0 (2.25 - 2.60) - Lever Control rack limit
Timing advance specification

Pump speed (rpm) Below 950 900 1,900
Advance angle (deg.) Start Below 0.5 Finish 4.5 - 5.5
EF&EC ..215
Governor adjustment I Full load adjustment
Control rack limit
I 11.9 (0.469)
11.15 (0.4390)
11.5 (0.453)
I
---..,---~-
---J.._~_+_+
A
E I I I I
E 11.4 (0.449) ---~---~-rT--------~- B
c:
~ 11.3 (0.445) ---~---~~-~--------t~----t
I I I I I I I I
~ 110 +0.97 ---T--_+-L~_--------I~_- __~-L__-
~ . -1.02 I I: I I I I: I
~ (0 4331 + 0.0382 ) I I I I I I I I I
. ~.0402 I I I I I I I I I
e"E ---+---~-+~---------+-~---~-~---~
I I I I I I I I
o
() 8 3+0.10 I : I I I I I I I
. ~.12 I I I I I I I I
I II I I I I I I I
(0.3268 +0.0039) I I I I I I I I
~.0047 I I I I I I I I I
o Below 250 620

(sqO) (700)
Pump speed (rpm) _
@SEF847M
Idling adjustment
I
:5 (04331
11 0
11.5 (0.453)
+0.49
. ~.70
+0.0193)
-;. ~.0276
E Approx. 9.5
c: (0.374)
,g 9.5 (0.374)
.~ 7.0:t 0.09
~ (0.2756 :t 0.0035)
~ 53 +0.21
. ~.20
e"E (02087 +0.0083)
8 . ~.0079
o 1,200
Pump speed (rpm) •
@SEF848M
EF & EC-216
SERVICEPATA AND SPECifiCATIONS (S.o.S.)
Speed control lever angle Timing setting
At No. 1 plunger beginning of Injection

38° :t3" B.T.D.C.: 14°
Idling
Full-speed
Approximately 100°
<3ear mark "ZZ"
SEF844M SEF845M
For high altitude compensator model
53.6 :t 1.1 m Q (1.89:t 0.04 Imp fl oZ)/1,000 st

11.5
(0.453)
I
I
I
;[ I
E I
E I
c:
o
:;:::
I
'iij I
o I
a.
I
"""~ I 36:t1.6 m Q
I (1.27 :t 0.06 Imp fI oZ)/1,000 st
eE 10.5
(0.413) ------~----------------
o I I
u
I I
I I
I I
I I
I I
I I
95.0:t2.7 61;6:1:0.7
(950:t 27, (616:t 7,
713 :t 20, 462:t 5,
28.07 :t 0.79) 18.19 :t 0.20)
Negative pressure kPa (mbar, mmHg,inHg) SEF846M
EF & EC-217
Injection Nozzle
INSPECTION AND ADJUSTMENT TIGHTENING TORQUE
Injection, nozzle assembly Unit N'm kg"m ft-Ib
Used New Injection nozzle assembly

Initial injection pres-
18,143 - 18,633 18,633 - 19,614
sure Inlet connector to nozzle
(181.4 - 186.3, 185 - (186.3 - 196.1, 190- 29 - 49 3.0 - 5.0 22 - 36
kPa (bar, kg/cm2, psi) holder
190, 2,631 - 2,702) 200, 2,702 - 2,844)
Thickness Part number Injection nozzle holder bolt
44 - 49 4.5 - 5.0 33 - 36
mm (in) (for service) to cylinder head
0.50 (0.0197) 16614-54TOO Injection tube flare nut 20 - 25 2.0 - 2.5 14 - 18
0.525 (0.0207) 16614-54T01
0.55 (0.0217) 16614-54T02
0.575 (0.0226) 16614-54T03
0.60 (0.0236) 16614-54T04
0.625 (0.0246) 16614-54T05
0.65 (0.0256) 16614-54T06
0.675 (0.0266) 16614-54T07
0.70 (0.0276) 16614-54T08
0.725 (0.0285) 16614-54T09
0.75 (0.0295) 16614-54T10
0.775 (0.0305) 16614-54T11
0.80 (0.0315) 16614-54T12
0.825 (0.0325) 16614-54T13
0.85 (0.0335) 16614-54T14
0.875 (0.0344) 16614-54T15
0.90 (0.0354) 16614-54T16
0.925 (0.0364) 16614-54T17
0.95 (0.0374) 16614-54T18
Initial injection pres-
0.975 (0.0384) 16614-54T19
sure adjusting shim
1.00 (0.0394) 16614-54T60
1.025 (0.0404) 16614-54T61
1.05 (0.0413) 16614-54T62
1.075 (0.0423) 16614-54T63
1.10 (0.0433) 16614-54T64
1.125 (0.0443) 16614-54T65
1.15 (0.0453) 16614-54T66
1.175 (0.0463) 16614-54T67
1.200 (0.0472) 16614-54T68
1.225 (0.0482) 16614-54T69
1.25 (0.0492) 16614-54T70
1.275 (0.0502) 16614-54T71
1.30 (0.0512) 16614-54T72
1.325 (0.0522) 16614-54T73
1.35 (0.0531) 16614-54T74
1.375 (0.0541) 16614-54T75
1.40 (0.0551) 16614-54T76
1.425 (0.0561) 16614-54T77
1.45 (0.0571) 16614-54T78
1.475 (0.0581) 16614-54T79
1.50 (0.0591) 16614-54T80
Fuel Filter
Type Full-flow, paper type filter Unit N'm kg-m ft-Ib
Overflow valve opening Fuel filter

98 - 137
pressure
(0.98 - 1.37,1.0 - 1.4, 14 - 20) Lead line connector bolt 25 - 29 2.5 - 3.0 18 - 22
EF & EC-218
INJECTION SYSTEM
CAUTION:
• Disassembly and assembly of the injection pumps should
be done only in service shops authorized by NISSAN or by,
thE!pump mal1ufacturer.
• Tbe pump tester is required for servicing the pump.
closely to make sure that it is definitely malfunctioning.
Fuel System
IN-LINE TYPE INJECTION PUMP
Injection nozzle
Fuel
filter
MEF815Q
EF & EC..219
INJECTION PUMP
CAUTION:
• Disassembly and assembly of the all injection pumps
should be done only in service shops authorized by NIS-
SAN or by the pump manufacturer.
• The pump tester is required for servicing the pump.
closely to make sure that it is apparently malfunctioning.
Refer to Trouble-shooting in MA section.
Removal
1. Disconnect battery ground cable.
2. Remove injection tubes.
Cover the injection nozzle with a plug to block the entry of dirt.
3. Disconnect the following wire and hoses.

• Manual fuel excess wire
• Fuel hoses
• Oil feed pipe
• Fuel inlet tube
• Fuel outlet tube
4. Remove injection pump fixing bolts.

5. Take out injection pump with bracket.

1. Align front cover and crank pulley mark for setting No. 1
piston at T.D.C.
EF & EC-220
INJECTION PUMP [£Q]
2. Injectionpump
(1) Align front cover mark and pump drive gear mark:
(2) Tigl'lten injection pump fixing bolts.
[OJ: . Injection pump bracket to front cover
to -
14 - 18 N'm (1.4 - 1.8 kg-m, 13 ft-Ib)
'M.ake suretbe injection timing marks on Injection pump and

bracket, and bracket and front plate are aligned.
3...lnstall injection tubes .
. 4. Connect fuel hoses, injectiQn tubes and manual fuel excess
wire.
Ble~d air. Refer to Bleeding Fuel System.
INJECTION TIMING INSPECTION

1. Erisurethat match marks on injection pump and bracket
and those on bracket and front plate are aligned, respec-
tively.
Rotate flywheel in normal direction of operation until the

TOGmark (long mark) on flywheel perimeter is aligned with
pointer.
At this point, ensure No. 1 piston is set at TDC on compres-
sion stroke.
MEFB22D
3.; Remove No.1 injection tube.

4. Remove No. 1 delivery valve assembly. Remove delivery
valve \spring and delivery valve stopper from delivery
valve', then install delivery valve.
MEFB23D
EF&'EC ..221
INJECTION PUMP [£[].
5. While operating priming pump, rotate flywheel.
• Rotate flywheel in normal direction of operation until fuel
delivery starts and then stops. At this point, check that short
fuel injection timing mark (short mark) on flywheel perim-
eter is aligned with pointer.
• If timing mark is not aligned, adjust Injection timing.
INJECTION TIMING ADJUSTMENT

1. Rotate flywheel in normal direction of operation until fuel
injection timing mark (short mark) on flywheel perimeter is
aligned with indicator.
2. Loosen four nuts and one bolt securing injection pump to
the bracket, then tilt injection pump toward engine side.
3. While operating priming pump, slowly tilt injection pump

outward until No. 1 delivery valve starts and then stops
delivering fuel. At this point, secure injection pump.
~: Injection pump to bracket
34 - 39 N'm (3.5 - 4.0 kg-m, 25 - 29 ft-Ib)
4. Ensure match marks on injection pump and bracket are

aligned. If not, scribe new match mark on injection pump.
:::-:,..
MEF827D
5. Remove NO.1 delivery valve holder.

6. Install delivery valve spring, upper seat, and delivery valve.
~: Delivery valve holder
39 - 44 N'm
(4.0 - 4.5 kg-m, 29 - 33 ft-Ib)
7. Install injection tubes.
8. Connect fuel hoses and engine control wire.
9. Bleed air. Refer to Bleeding Fuel System.
EF & EC-222
INJECTION PUMP [fQJ
Installation and Adjustment (Co nt' d)
CAUTION:
a. Do not remove sealing caps unless absolutely necessary.
b. Maximum speed adjusting screw is retCiinedby sealing cap
and need. not be adjusted under normal circumstances.
However, if it should become necessary, adjust it with the
screw. After adjustment, always install a sealing cap on the
lock nut.

Refer to "Adjusting accelerator pedal and cable" in FE section.
Idle adjustment
Refer to section MA for idle adjustment.

Maximum speed adjustment screw is retained by sealing wire
and need not be adjusted under normal circumstances.
However, if it should become necessary to adjust it, the follow-
ing procedures should be followed:
1. Start engine and warm it up until coolant temperature indi-
2. Connect tachometer's pick-up to No.1 fuel injection tube.
To obtain accurate reading of engine rpm, loosen clamp that
secures No. 1 fuel injection tubes.
3. To obtain maximum speed, turn the adjusting screw in
either direction while fully depressing accelerator pedal.
Maximum engine speed
(Under no-load):
FD42 engine 3,650 rpm
FD46 engine 3,350 rpm
5. Install a sealing cap on the lock nut.

1. Remove altitude compensator from bracket.
2. Disconnect vacuum hose and remove bracket from injec-
tion pump.
3. Install altitude compensator in the reverse order of
removal.
EF&EC-223
INJECTION PUMP [£[]
(Cont'd)
INSPECTION
1. Check for loose connections.
2. Check for altitude compensator movement.
If it does not move, contact a service shop authorized by the
pump manufacturer.
ADJUSTMENT
The following describes the procedure for adjusting the RLD
type governor equipped with an altitude compensator.
This section explains only the adjustment procedure of the alti-
tude compensator.
CAUTION:
The altitude compensator must be adjusted at sea level.
Select a suitable pushrod so that L, = 11:t 0.5 (0.433:t 0.020)
Adjusting
screw
Pushrod CD L, Governor
cover
Pushrod @
.. L," /
Adjust clearance to approx. 1.5 (0.059)
Unit: mm (in)
(Using adjusting screw) SEF6761
1. Altitude compensator inspection

Measure the distance (dimension L2) between snap ring
assembled with push rod <D and housing. If dimension L2
is outside the specified range, adjust using the adjusting
screw after removing altitude compensator cap nut and
loosening lock nut.
2. Checking push rod protrusion
Check the following items before attaching spacer to gov-
ernor cover.
(1) Fix speed control lever in maximum speed position. Next,
operate injection pump at the specified speed.
(2) In this condition, use calipers to measure the protrusion
(dimension L1) of push rod @ from the end face of the
governor cover when the specified control rack position is
obtained.
If dimension L1 is not within the specified range, replace
push rod @ so that L1 is as specified.
Refer to S.O.S.for adjusting push rods @.
EF & EC-224
INJECTION PUMP
(Cont'd)
3. Adjustment after altitude compensator assembly
Secure control lever at maximum speed position and oper-
ate injection pump at the specified speed.
(1) III this condition, "supply negative pressure"* P1 to the
altitude compensator's atmospheric chamber. Rotate the
altitude compensator housing to adjust control rack posi~
tion to R1.
Check that fuel injection quantity Q1 is obtained at this
poillt.
(2) Next, decrease the negative pressure of the altitude com-

0, m Q (Impfl oz)/l,ooO st
. pensator'satmospheric chamber to less than P2, and then
I
I increase it to P2 and check that control rack position is R2.
c : ~ 0, mQ (Imp fl oz)/ Check that fuel injection quantity Q2 is obtained at this
o I 1,000 st
point .. Always measure the negative. pressure in an
~
8. R, ---+-----
I
increase.direction (direction of the arrow).
-"
~
I
I
*CAUTION:
I
ec I T~e follo""in9 explains the relationship between negative pres-
o P, P, sure as shown in the figure and absolute pressure.
o
()
Negative pressure - Zero point (i.e. the Intersection of the axes) in the figure equals
kPa (mbar, mmHg, inHg) MEF912D absolu.e pressure at sea level [101.3 kPa (1,013 mbar, 760
mmHg,29.92.inHg)].
In relation to the negative pressure for example, the change
from 010 Pl on theh()rizontal axis in the figure Is an increase
in negative pressure.
Howevf!r, in terms of absolute pressure, the above equals a
reduction in absolute pressure fro~101.3 kPa (1,013mbar, 760
mmHg, 29.92 inHg) to the point 101.3 kPa (1,013 mbar, 760
mmHg,29.92 inHg) - Pl.
In other words, an increase in the negative pressure is actually
a decre~se In absolute pressure. "Supply negative pressure"
means ".'reduce the pressure".
EF & ECr225
INJECTION PUMP
Disassembly
cqJ: N.m(kg-m, ft-Ib)

MEF832D
(f) Delivery valve holder @) Bearing cover @ Lower spring seat

@ O-ring @ Oil seal @ Shim
@ Delivery valve stopper @ Bearing @ Roller
@ Delivery valve spring @ Shim @ Plug
@ Gasket @) Ring @ Gasket
@ Delivery valve @ Woodruff key
@ Cover
(J) Plunger & plunger barrel @ Camshaft
@ O-ring
@ Lock plate @ Tappet assembly
@ Ring
@ Eye bolt @ Guide
@ Shim
@ Adapter @) Pin
@ Control rack @ Bushing @ Bearing
@ Screw @ Rack pinion @ Adapter
@ Pump housing @ Control sleeve @ Overflow valve
@ Bracket @J Upper spring seat @ Gasket
@ O-ring @) Spring @ Eye bolt
EF & EC-226
INJECTION PUMP
PREPARATION
• Before performing disassembly and adjustment, test fuel
injection pump and note test results except when testing is
impossible.
• Prior to beginning to disassemble fuel injection pump,
• Be careful not to mix parts of different cylinders.
Special tools for disassembling and reassembling injection pump
KV11231250.=>o
~. KV11215010
V11242462
d\)
..... ~
DK57916542
~"2265'2
MEF833D
1. Drain injection pump oil.

2. Attach injection pump with Tool (KV11244852,KV11244872
and KV11244782).
3, Remove feed pump and cover plate.

4. Check backlash between control rack and control pinion.
EF& EC-227
5. Remove timer assembly and install Tool KV11242462(cou-
pling).
Refer to Timer removal.
Tool
MEF836D
6. Turn coupling with Tool OK57916542until tappet is raised

to T.O.C. for each cylinder.
7. Turn coupling until tappet is raised to T.O.C. for each cyl-

inder and then install Tool in tappet holder hole.
8. Check camshaft end play.
9. Remove mechanical governor cover, diaphragm cover,
diaphragm, flyweight and governor housing.
Refer to Governor for removal.
10. Remove plug and bearing cover.
11. Draw out camshaft.
EF & EC-228
INJECTION PUM.P [£Q]
Disas.sembly(Cont'd)
12. Remove Tool KV11231250 by pushing tappet with Tool
KV11221012.
CAUTION:
Be careful not to damage housing plug hole threads.
MEF206E
13. Withdraw tappetassembly with Tool KV11231612from cam-

shaft chamber by loo~ening Tool KV11221012.
14. Remove plungers together with lower spring seat with Tool.
CAUTION:
Layout plunger and plunger barrel In order In a pan of kero-
sene or solvent. Do not touch plunger with hand.
15. Remove plung~r spring, upper spring seat and control

sleeve assembly.
16. Remove lock plate.

17. Remove delivery valve holder and then remove delivery
valve holder spring, and delivery valve stopper.
00(0
~ MEF841D
EF&EC ..229
INJECTION PUMP [![]
18. Remove delivery valve.
19. Remove plunger barrel by pushing it from below.
o
MEF821A
20. Remove cap, bolt and nut on control rack.
MEF822A
21. Remove control rack guide screw and then draw out con-
trol rack.
~l1l1l1ill!mi"
MEF823A
Inspection
Pump housing
1. Inspect for damage, cracks, etc.
If excessively damaged, replace it with a new housing.
2. Check plunger barrel drum surface for proper contact with
plunger barrel seating hole. Also, check for damage or
~ cracks. Replace with a new plunger and plunger barrel as
B required.
3. Measure tappet to housing clearance. If worn beyond wear
limit, replace tappet or housing.
Tappet to housing clearance (A - B):
Limit
0.2 mm (0.008 in)
EF & EC-230
INJECTION PUMP ~
Inspection (Cont'd)
Camshaft
1. Measure eam profile fQr uneven or excessive wear. If
excessively or unevenly worn, replace camshaft with a new
one.
2. Check for damage, cracks, etc.
If excessively damaged, replace it with a new one.
3. Measure camshaft end play by pushing camshaft from
timer end so as to move camshaft in shaft direction.
Camshaft end play:
Standard
o - 0.02 mm (0 - 0.0008 in)
Limit
0.1 mm (0.004 in)
If camshaft end play is over limit, adjust as follows:
(1) Remove bearing inner race from camshaft.
(2) Based upon end play measurement, increase or decrease
adjusting shims.
Use the same shim thickness on each end.
(3) Re-install bearing inner race on camshaft.
Bearings
Check for wear or discoloration. Replace with a new one as
required.
Plunger and plunger barrel

The operation of the plunger should be checked based on the
results of fuel Injection volume measurement.
Oil-tightness check
1. Thoroughly clean plunger barrel in clean kerosene or sol-
vent.
2. Tilt it to approximately 60°. Then, let plunger slide down
through barrel, making sure that plunger slides smoothly.
Repeat this procedure by turning plunger to various
positions, making sure that plunger slides smoothly in any
of the positions.
When replacement is required, replace both the plunger
and plunger barrel as a set.
EF & EC-231
INJECTION PUMP IT[]
Inspeclion(Cont'd)
Delivery valve
Air-tightness check
1. Thoroughly clean delivery valve and delivery valve seat in
clean kerosene or solvent.
2. Place finger over lower part of valve seat, lightly depress
delivery valve with your finger tip, and make sure that valve
springs back when released. If valve falls to valve seat, it
is not operating properly due to excessive piston wear.
Replace with a new valve and valve seat assembly as
required.
CAUTION:
The above procedure is not necessary if the delivery valve has
a variable retraction type piston.
The type of piston will not return after your finger Is released
(this Is not a malfunction).
Tappet
w-
Tappet
Inspect tappet, roller, roller bushing, and pin for wear or dam-
age. Replace with new components as required.
Tappet guide _--0
Roller end play limit:
Roll" PIO~l, 0.20 mm (0.0079 in)
Roll" bo",' .. ~
Roller
SEF587F
Control rack and control sleeve assembly

1. Inspect control rack for bending and damage.
Repair or replace with a new control rack as required.
2. Measure control sleeve to plunger lug clearance. If worn
excessively, replace control sleeve or plunger.
Control sleeve to plunger lug clearance (A - B):
Limit
0.12 mm (0.0047 in)
A
EF727A
3. Measure backlash between control rack and control pinion.

Backlash between control rack and control pinion:
Limit
0.30 mm (0.0118 in)
Spring
Inspect plunger and delivery valve springs for damage and
squareness.
EF & EC-232
INdECTIONPUMP
Assembly
Clean parts thoroughly and apply a thl.n coat of engine oil to
rotating and sliding parts.
Assemble injection pump in the revers.e order of disassembly.
Note the following items.
1. Set plunger barrel in position, with hole in barrel aligned
o with dowel pin of housing.
@
o
EF729A
2. Install delivery valve.

3. Install delivery valve spring, delivery valve stopper and
delivery valve holder.
~:39 -44.N'n,'1
(4.0 -4.5 kg-m, 29 - 33 ft-Ib)
EF702A
4. Install lock plates.

5..
(1) Set the control rack so that marks on both sides are same
di.stance "A" from each end of pump housing.
(2) Adju~t bolt I~ngth and tighten lock nut.
(3) Then.install control rack guide screw.
6. Install control sleeve assembly with slit of control sleeve

~ Spring seat
facing straight up. Then install upper spring seats and
plunger springs.
o
o
SEF975M
7. Install plunger together with rower spring seat by using

Tool with plunger alignment mark facing upward (cover
side of pump housing).
Do not use plunger with a barrel from a different cylinder.
EF&EC-233
INJECTION PUMP ~
Assembly (Cont'd)
8. Install tappet assembly by reversing the removal proce-
dure.
MEF20SE
9. Install camshaft with larger diameter end toward timer.

10. Install governor housing and then adjust camshaft end
Large diameter end play.
11. Install screw plug on bottom of pump housing.
Seal the plug with sealant.
(OJ: Screw plug
54 - 74 N.m (5.5 - 7.5 kg-m, 40 - 54 ft-Ib)
Timer side
MEF843D
12. Remove tappet holder.

13. Install flyweight and mechanical governor cover in that
order.
Refer to Governor for installation.
14. Install control rack cap, cover and feed pump.
15. Install timer.
(OJ: Round nut
59 - 69 N.m (6 - 7 kg-m, 43 - 51 ft-Ib)
EF & EC-234
INJECTION PUMP
Governor
DISASSEMBLY
(j)
~@
~,!
MEF844D
CD Limiter @ Spring seat @ Tension lever

@ Lever @ Governor spring @ Spring
@ Cap @ Link @ Guide lever
@ Spring @ Woodruff key ~ Snap ring
@ Shim @) Flyweight assembly @!) Cam plate
@ Collar @ Lock washer @ Rod
(J)Lever @ Round nut @!) Spring
@ Adapter @) Sleeve @ Screw
@ Lever @ Shim @ Lever
@> Spring @ Shaft @ Bracket
@ Shim
@ Snap ring @ Plug
@ O-ring
@ Spring @ Shaft
@ Plug
@ Lever @ Gasket
@ Bracket
@ Lever ~ Governor cover
@ Shaft
@ Spring @ Bracket
@ Spring
@ Lever @ Bracket
@ Lever
@) Lever
@ Snap ring @) Spring assembly
@ Shifter @ Screw
@ Gasket
@) Governor housing @ Snap ring @ Plug
@ Shaft @ Pin @ Shim
EF & EC-235
INJECTION PUMP ~
Governor (Cont'd)
1. Attach injection pump with Tool KV11244852 (Universal
vise) and then remove feed pump and cover plate.
2. Install tappet holders (KV11231250)by turning coupling.
3. Remove control lever return spring and spring bracket.
Plate plugs (three types) are used at five locations. To remove

plate plugs during disassembly, push a screwdriver tip through
the center to make a hole and pull out the plate plug. When
doing this, be careful not to damage the Inside surface of the
governor cover.
To install plate plugs when assembling, use Tools DK57923580,
DK57923590and DK57923600.
4. Remove the governor shaft plate plug, then loosen the lock
nut with Tool.
MEF846D
5. Remove the idling spring plate plug, then remove the lock
nut with Tool. Next, use a Phillip's head screwdriver to
remove the idling assembly.
EF & EC.236
INJECTION PUMP ~
Governor .(Cont'cI)
6. Loosen the seven governor cover mountin~ bolts, then
remove the governor cover assembly. Be sure to. plJt an oil
pan under the governor to catch lubricating oil.
7. Remove start spring from rack connecting link.

8. Remove rack/connecting link nut from control rack,
9. Remove snap ring fastening sensor lever.
10. Remove full-load set lever.
11. Remove guide plug on opposite side of full-load set lever.

12. Remove U-type lever and sensor lever.
13. Remove full.load control shaft together with spring.
EF & ••EC-237
Governor (Cont'd)
14. Remove bolt fastening stop lever and remove stop lever.
15. Remove round nut fastening flyweight with Tool

KV11215010. At this time, prevent camshaft from turning
with Tool DK57916542.
16. Extract flyweight from camshaft with Tool KV11226512.
17. Remove bolt and screw fastening governor housing to

pump housing. Remove spring eye at the same time.
18. Remove governor housing from pump housing by lightly

tapping governor housing with mallet or plastic hammer.
19. As the governor shaft is screwed directly into the cover,
loosen and remove it together with the governor springs.
EF & EC-238
Governor (Cont'd)
20. Remove snap ring and then remove rod from torque cam.
MEF859D
21. Remove snap ring connecting torque cam and remove

torque cam.
22. Remove plug which holds the shaft supporting the tension
lever assembly in place.
23. Extract shaft.
24. Extract tension lever assembly.

25. Extract guide lever together with collar. Extract cancel
spring at the same time.
26. Remove nut fastening control lever and remove control

lever.
EF& EC",239
INJECTION PUMP [f[]
Governor (Cont'd)
27. The lever assembly consists of the parts shown at left and
is connected by a snap ring.
SEF508F
28. When rod for adjusting torque cam of tension lever or

spring is to be replaced, loosen nut and remove it with Tool.
MEF863D
Press INSPECTION
1. Flyweight
Adjusting
• Check pin and holder bushing for wear. If worn excessively,
shim replace with a new one.
• Check slider for uneven wear or scorching. If necessary,
Shifter replace with a new one.
Suitable
• Remove burrs from contact surface of flyweight at spring
guide washer location.
• Check screw threads for damage. If necessary, repair or
SEF976M
2. Tension lever assembly
• Check tension lever shaft for abnormal wear or seizure.
• Check governor spring seat pin for wear.
• Check torque cam rod for bending and screw threads for
damage.
• Check shifter pin for abnurmal wear and bearing for sei-
zure or wear.
Replace damaged parts as needed.
To disassemble tension lever assembly for parts replacement,
proceed as follows:
a. Remove left and right snap rings from shifter pin and with-
draw shifter pin.
b. Remove snap ring which holds sleeve to bearing.
c. Press out shifter bearing guide.
3. Guide lever, rack connecting link and floating lever.
Check guide lever, rack connecting link and groove width
of floating lever for excessive play or wear. Replace worn
or damaged parts.
4. Governor housing and cover
• "Pressed-in" locks
Check pins for bending or damage. Repair or replace dam-
aged parts or entire assembly.
• Check tension lever shaft bushing for wear.
EF& EC-240
INJECTION PU MP [!QJ
Governor (Cont'd)
• Check screw threads for abnormalities. If necessary, repair
or replace with hew ones.
5. Sensor. lever and torque cam
• Check for abnormal wear on pawl at tip end of sensor lever
and surface of torque cam. Replace sensor lever and/or
torquecam as required.
• Check sensor lever fork for uneven wear.
• Check torque cam rod pin and pin hole for wear. Replace
worn parts.
6, Governor shaft
Check for proper operation of governor shaft, governor
housing, spring seat, etc.
7. Control lever assembly
Check control lever shaft, bushing and supporting lever for
abnormalities.
8. Springs
Check springs for bending, rust formation or damage. If
necessary, replace with new ones.
ASSEMBLY
Assembly is in the reverse order of disassembly. Observe the
following:
[)o not reuse old gaskets, 011seals, O-rings and snap E-rings.
Always install new ones.
1. Governor housing and flyweight
(1) Place gasket between governor and pump housings and
then install spring eye. Tighten all seven bolts equally in a
crisscross fashion.
(2) Install full-load set lever, U-type lever, sensor lever and
connecting link in that order.
(3) Connect hook of start spring to connecting link pin.
(4) Install key into groove on camshaft, install flyweight and

tighten nut with Tool, KV11215010while holding camshaft
with appropriate Tool. .
to.]: Flyweight
49 - 59 N'm
(5 - 6 kg-m, 36 - 43 ft-Ib)
EF&EC.241
Governor (Cont'd)
2. Governor cover assembly
(1) Shifter
When shifter is assembled to sleeve assembly, the sleeve
is pressed against the flyweight holder so that the lift of the
flyweight becomes O.It should be adjusted using an adjust-
ing shim so that distance L1 from the governor housing
surface to the center of the pin hole of the shifter is 29:t: 0.2
mm (1.142:t:0.008 in).
L, =29:t 0.2 mm
Refer to S.O.S. for shifter distance adjusting shims.
(1.142:t 0.008 in) A functional difficulty will occur if the dimension L1 is not
FG0117 within specifications:
a. Too large a value of L1 causes the flyweights to open too
wide, allowing the slide to come off the sleeve and rub on
the contacting surfaceof the sleeve. This wear is indicated
by an uneven surface.
b. Too small a value of L1 prevents the flyweight from moving
and making maximum lift.
(2) Assemble shifter assembly to tension lever.
3. Governor cover internal parts

(1) Installation of control lever and floating lever
a. Insert control lever assembly into place on inside of gover-
nor cover. To facilitate insertion, apply a coat of grease to
upper oil seal and surface of lever shaft.
b. Install floating lever on supporting lever with chamfered
side (mark "c~c") of fork facing down.
(2) Installation of tension lever and guide lever
a. Connect upper rod of tension lever to toque cam. Tighten
lock screw.
b. Place left and right collars between tension lever and guide
lever, and insert tension lever shaft into collars.
(3) When cancel spring for integrating the guide lever with the
tension lever is built in, it is convenient to use a screw-
driver with a grooved blade.
SEF123B
EF & EC-242
Governor (Cont'd)
4.
(1) Install spring seat and governor spring onto governor shaft.
Then install governor shaft into governor cover through
spring seat on upper end of tension lever.
Spring seat on each side of governor spring should be
installed with its graded portion facing the spring.
(2) Temporarily tighten nut on end face of governor shaft
located inside governor cover.
(3) After plug of tension lever shaft is pressed in governor
cover, coat periphery of plug with screw lock. Unless screw
lock is applied lubricating oil may leak out.
5. Fitting governor to pump

(1) Have control rack side of supporting lever pulled out toward
governor housing, and then mount sleeve. Insert ball joint
(on control rack side) into slot offloating lever, then insert
governors haft into governor housing. This makes it easier
to attach governor cover aSsembly to pump.
(2) After installation of the governor cover assembly, check the

following.
1) Ensure the governor shaft can be moved smoothly by hand.
If governor shaft movement is difficult, loosen the seven
bolts of the governor cover, slide the governor cover until
the governor shaft center is aligned with the guide screw
hole center, and then retighten these bolts.
2) Check that the control rack moves smoothly when operat-
ing the control lever.
CAUTION:
Should the control rack movement be difficult, remove the gov-
ernor cover assembly and determine the cause.
EF & EC-243
INJECTION PUMP
Test
PREPARATION
Injection pump test conditions
Nozzle KV11257800
2
Nozzle starting pressure kPa (bar, kg/cm , psi) 17,162 (171.6, 175, 2,489)
Injection pipe
KV11257805
2.0 x 6.0 x 600 (0.079 x 0.236 x 23.62)
Fuel feed pressure kPa (bar, kg/cm2, psi) 147 - 157 (1.47 - 1.57, 1.5 - 1.6, 21 - 23)
Fuel temperature .C ("F) 40 - 45 (104 - 113)
Rotating direction Clockwise (observed from the drive shaft)
KV11282433 rDK57976310
KV11257802
KV112577~
~
~~1_
KV1~
KV11284022
~KV1123141O
~. ~KV11281~
~KV11284051
'MEF867D
EF & EC-244
INJECTION PUMP
Test (Cont'd)
1. Remove fuel feed pump and cover plate.
2. Remove timer assembly.
Refer to Timer removal.
3. Install fuel inJection pump on the bed of tester.

4. Attach the Tool KV11284051(coupling) to the injection pump
camshaft.
• At this time, both the camshaft and coupling shaft key
groove must face in the same direction.
MEF913D
5. Replace the cover of timer flange with an adjusting plate.

Adjusting plate The adjusting plate is a Tool that is incorporated in Tool
KV11284022(driving device).
Timer flange
MEF914D
6. Attach the timerto Tool KV11284022(driving device).
7. Lubricate the center plug hole and the screw plug hole of
Tool with engine oil (Viscosity of SAE 20).
Amount: approx. 400 mt (14.1 Imp fl oz)
EP& EC-245
INJECTION PUMP [![]
Test (Cont'd)
8. Connect the driving device to the pump test stand's fly-
wheel.
MEF917D
9. Fix the reflecting plate for stroboscope on the outside of the

coupling.
10. Connect flexible hose from tester to injection pump.

11. Bleed air from injection pump.
ADJUSTMENT
Adjusting injection timing
1. Adjust NO.1 injection timing.
(1) Remove delivery valve holder, delivery valve stopper,
delivery valve spring and delivery valve for NO.1 cylinder.
(2) Install Tool KV11282433and set NO.1 tappet to bottom dead

center (B.D.C.) position and set dial gauge at "0".
EF & EC-246
INJECTION. PUMP [£[]
Test (Cont'd)
(3) Rotate camshaft (pump tester) clockwise, and measure the
lift of 1st plunger when fuel flow from Tool (measuring
device) stops.
Pre-stroke:
KV11282433 Refer to S.O.S.
Pre-stroke
Lower
spring seat
Adjusting
shim
Beginning-of-injection position
B.D.C.
SEF606G
2. If pre-stroke is notwithin specification, adjust injection tim-

ing.
(1) Rotate camshaft untilcam reaches top dead center (T.D.C.)
position.
(2) Insert Tool (plunger spring holder) between lower spring
seat and tappet.
MEFB70D
(3) Remove adjusting shim and adjust shimthicknes~ so that

desired prestroke can be obtained. Adjusting shim thick-
ness varies ihO.05 mm (0.0020 in) steps.
Refer to S.O.S. for. adjusting shims.
3. Adjust NO.2 to No. 4 cylinder injection timing.
(1) Set No.1 cylinder to injection start timing position, and set
angle scale on tester flywheel at "0°".
(2) Turn tester flywheel to the angle shown below, and make
sure that fuel flow from test nozzle stops.
If pre-stroke (injection timing) is incorrect, adjust the timing
by following step 2.
Cylinder No. 1 3 4 2
InjeCtion starting 89°30' - 179°30' - 269°30' -

0
angle 90°30' 180°30' 270°30'
EF & EC-247
Test (Cont'd)
4. Check top clearance.
For shim-type tappet adjustment pump:
With shim-type tappet, top clearance cannot be measured.
Confirm that camshaft rotates smoothly by manually rotat-
ing camshaft slowly.
Adjusting injection volume

rack.
~~
t~~
~
MEF872D
2. Setting the "0" point position of control rack.

(1) Screw in governor shaft fully, and hold control lever at
idling position.
MEF873D
(2) Raise pump speed gradually until it reaches point @,

where governor spring stops operating. Then, push rack
R. fully in the "fuel decrease" direction. The position where it
Rb
stops moving is the control rack's "0" position.
Nb
80.100
Pump speed- ,rpm ----. SEF510F
(3) Set indicator of measuring device's dial gauge to "0".

tion cannot be obtained even if front end of control rack is
pressed hard.
b. If front end of control rack is pushed without driving Injec-
EF & EC-248
Test (Cont'd)
3. Remove control rack guide screw and install Tool (lock
screw) to fix control rack on pump housing.
~ CAUTION:
Tighten Tool (lock screw) by hand.
J G
DK57976310~
MEF874D
4. Set fuel feed pressure.

Fuel feed pressure:
147 - 157 kPa (1.47 - 1.57 bar,
1.5 - 1.6 kg/cm2, 21 - 23 psi)
5.
(1) Measure injection volume for each cylinder at rated pump
speed and control rack position.
Injection volume:
Refer to S.O.S.
(2) Compute allowable imbalance of fuel injection volume.
Allowable imbalance =
~;:~t~n
";~:
) Mean )
( umefor each
plunger
-
(
injection
volume
x 100
Mean injection volume
Allowable imbalance :
Refer to S.O.S.
6. Adjust injection volume so that specified injection vol.ume

and allowable imbalance are obtained.
(1) Loosen control pinion clamp screw.
MEF875D
(2) Place suitable tool into hole in control sleeve and adjust by
rotating.control sleeve.
(3) After adjustment is completed, tightly secure pinion set
screw.
(4) Remove lock screw from control rack and reinstall guide
screw.
7. Install diaphragm housing and governor spring.
~
MEF876D
EF& EC-249
INJECTION PUMP
Test (Cont'd)
GOVERNOR
Adjustment
The following adjustment tests must be carried out.
1. Adjustment of injection timing and injection quantity of
injection pump
2. Setting the "0" point of control rack
3. Idling adjustment
4. Adjustment of governor spring contact
5. Setting the full-load position of control rack
6. Checking the maximum controlled speed
7. Checking the idling speed limit for warm-up run
PREPARATION
Before adjusting governor, the following preparations must be
made:
1. Add a prescribed amount of lubricating oil to governor
chamber and cam chamber of injection pump.
2. Run in tester. After run-in operation, check that governor
operates satisfactorily.
3. Remove lock nuts for idling spring and governor shaft.
4. Loosen full speed set bolt, idle set bolt and full-load set
bolt.
Setting "0" point position of control rack
KVl1282618
1. Attach measuring device to driven side of control rack.
2. Screw in governor shaft fully, and hold control lever at

idling position.
MEF873D
3. Raise pump speed gradually until it reaches point <ID,

where the governor spring stops operating. Then, push the
R.
rack fully in the "fuel decrease" direction. The position
where it stops moving is the control rack's "0" position.
Pump speed rpm----.

SEF510F
EF & EC-250
INJECTION PUMP [E[]
Test (Cont'd)
4. Set the indicator of the measuring device's dial gauge to

tion cannot be obtained even if front end of control rack is
pressed strongly.
b. If front end of control rack is pushed without driving injec-
R,
iIJJ Precaution for adjustment of governor
Rf,
Rf,
1. Fixing control rack
Rf
Rf.
In fixing control rack when adjusting injection quantity of
Rf,
Rf,
injection pump, control lever is fixed in the idling position,
Ra'
R,
injection pump is accelerated to above 500 rpm, control
Rb
R,
lever is manipulated to the full speed position, control rack
Rd is positioned in the full-load position + about 3 mm (0.12
Rg
R, in) by full-load stopper and control rack is controlled, to be
fixed to each control rack position to obtain injection quan-
Na Ni Nb Nj Nb' Ns Nt Nc Nk
tity.
Pump speed rpm ----. ~5EF514F
2. Wtren operating control lever to the full speed position, first

increase pump speed to above 500 rpm at the idling posi-
tion.
3. Always fix adjusting nut for adjusting torque cam with lock
screw.
Adjustment of Idling spring

t Rs
1. Adjustment of idling lever position
l: Rb
E Control lever is fixed to the position where it comes in
E Ri contact with idle stopper bolt, and length of projection of
..8.
,~ Rh,
'in
Rh2
idle stopper bolt is adjusted so that control rack position Rs
may be obtained at a pump speed of N = 80 to 100 rpm.
~<.> (This length is fixed.)
~
e 0 Nb Ni Nh, Nh2
~ 80 _ 100 Pump speed rpm
-- SEF7021
MEF877D
EF & EC-251
INJECTION PUMP [f[]
Test (Cont'd)
2. Maintain pump speed at Nb and screw in idling spring
assembly. When rack position is Rb, tighten lock nut [tight-
ening torque: 25 - 29 N'm (2.5 - 3 kg-m, 18 - 22 ft-Ib)].
MEF878D
-=-_::~
SEF517F
3. Increase pump speed until control rack position is at Ri and

then check that pump speed is Ni.
If the pump speed Ni is not as specified, adjust by altering the
shim thickness.
4. Adjustment of the governor springs

(1) Maintain pump speed at Nh1 and adjust the amount the
governor shaft is screwed in [tightening torque of nut: 10 -
15 N'm (1.0 - 1.5 kg-m, 7 - 11 ft-Ib)] so that the rack position
is Rh1.
(2) Check that control rack position is Rh2 when pump speed
is Nh2- If it is not as specified, replace governor springs
with new ones.
Idle adjustment
1. Decrease pump speed to Nb' and adjust idling setting bolt
so that control rack will be at position Rc. Then lock the nut.
EF & EC-252
INJECTION PUMP
Test (Cont'd)
c
o
";::;
"iii
8-
~<J
~ 0
-.ce..
o
u
80-100
Nb'
-
Pump speed rpm
SEF524F
2. Further decrease pump speed to 80 to 100 rpm, and make

sure control rack is positioned at Ra'.
3. Check that control lever angle is as specified.
Adjustment r~ck position.

of full-load
1. With pump speed maintained at Nf, temporarily set control
lever at the position where lever contacts maximum~speed
setting bolt.
2. Adjust maximum-speed setting bolt so that control rack

begins moving toward fuel decrease direction at a pump
speed of ..Ng. Then, lock l1Jaximum-speedsetting bolt with
the nut.
MEF828D
:st
E
E
c
0
:E
IS
Co
~
<J
~
g 0
Nf_Ng
c
0
U Pump speed rpm
SEF527F
EF&.EC-253
Test (Cont'd)
3. Adjust full-load setting bolt so that control rack position is
Rf when pump speed is Nf.
When full-load setting bolt is turned clockwise, the control rack
position value decreases.
Adjustment of torque cam

1. Using Tool (special wrench), adjust adjusting nut so that
control rack position is Rf4 when pump speed is Ni. Lock
adjusting nut with a lock screw.
Torque cam adjustment can be performed at a pump speed of
either Nk rpm or NI rpm, whichever Is convenient.
E
E
c
...
.2
1
.>I.
U
f?
e...c
8
NiNk
--
Pump speed rpm
SEF530F
2. Decrease pump speed to Nj minus approximately 100 rpm,

g t Rts then increase it to Ng to ensure that torque cam stroke is
E Rt 3 within the specified range. If torque cam stroke is not as
E Rt
specified, readjust full-load setting bolt and torque cam. If
g Rt
l
2
this adjustment cannot be performed to obtain the specified
Rt 1
control rack position, replace torque cam .
.>I.
U
f?
e
---
0
E Nj-100
8 Pump speed rpm
SEF531F
Before installing a new torque cam, be sure stamped mark Is

same as number given In service data.
EF & EC-254
INJEOTION PUMP [£Q]
Test (Oont'd)
3. Next, increase pump speed from Nj minus approximately
c:
:=
t RfRf s 100 rpm to Ng, then make sure pump speed is as specified
E Rf for each control rack position, If pump speed is not as
E Rf. specified, torque cam has not be adjusted properly. Read-
g Rfl
just it. If torque cam cannot be adjusted to obtain the spec-
';;
';;;
o
Co
ified pump speed, replace torque cam.
~
~
~ 0
E Nj _ 100 Nj Nk N, N. N4N~
8 N3
Pump speed rpm
SEF532F
4. Measure fuel injection quantity at each of the adjusting

~t points as specified (Le., the fuel injection characteristics for
full~load). If fuel injection quantity is not as specified, adjust
E
E full-load setting bolt and torque cam adjusting nut carefully.
c
o
';;
Lock the nut and bolt after adjustments.
';;;
8-
~
"
E
~
.... 0
c
8 Pump speed rpm
SEF533F
If this adjustment is not executed properly, specified fuel injec-

tion quantity cannot be obtained. There will be decreased
engine output and black smoke may be produced.
ADJUSTMENT OF MAXIMUM SPEED CONTROL

1. Lock control lever when it contacts maximum-speed setting
bolt.
2. With pump speed maintained at Ng, adjust maXimum-speed
setting bolt so that control rack begins moving from Rf3 in
fuel decrease direction. Then, lock the bolt with the nut.
MEF828D
c t
E
E
c
0
';;
';;;
0
Co
~
E"
~
.... 0
_Ng
c
0 Pump speed rpm
U
SEF535F
EF &.EC-255
Test (Cont'd)
3. Checking the speed drop
c
E
t Gradually increase pump speed and make sure pump
E Rf3 speed is Nh when control rack reaches Rg.
c:
...
.Q
';;;
8.
.><
u Rg
~
~
...
c:
0
U
SEF536F
4. Increase pump speed further to make sure control rack

reaches 0 mm (0 in).
5. Check that control lever angle is as specified.
6. Installation of plate plugs

After adjusting governor, check that there is no damage to
the inside surfaces where governor cover plates are press
Plate plug
fitted. In addition, remove as much oil as possible from
inside.
(1) Push in new plate plugs, and drive them securely into place
with Tools.
(2) After press-fitting each plug, thoroughly coat the outside
surface with suitable adhesive.
ADJUSTING CONTROL RACK LIMITER

Stop pump and fix control rack at rack limit position. Then
remove control rack measuring device.
After that, adjust L (distance between pump end surface and
bolt head end) so that it is the same as the depth of the control
rack cap, then fix the lock nut.
Feed Pump
After installing feed pump bleed air from system.
EF& EC-256
Feed Pump (Cont'd)
FEED PUMP TEST
1. Suction test
(1) Attach a hose [2 m (7 ft) x 8 mm (0.31 in) dia.] to the feed
pump suction port and insert the other end into a container.
Fuel oil container must be approximately 1 meter (3 feet) below
suction head of feed pump.
(2) Operate the injection pump at too rpm.
(3) Fuel must be discharged within less than 40 seconds.
2. Priming pump test

(1) Fully loosen the priming pump's screw cap.
(2) Operate priming pump using the screw cap, at 60 to 100
strokes per minute.
(3) Fuel must be discharged in less than 25 strokes.
3. Capacity test
(1) Place discharge hose in a measuring cylinder.
(2) Operate injection pump and check supply rate, referring to

the following table:
Supply rate
Pump speed
mt (Imp 11 oz)/15 sec
100 rpm More than 60 (2.11)
500 rpm More than 340 (11.97)
1,000 rpm More than 405 (14.26)
1,500rpm More than 430 (15.14)
4. Feed pressure measurement

(1) Ccmnecta hose petween feed pump discharge port and the
pressure gauge.
(2) Operate injection pump at 600 rpm.
(3) Ensure the feed pump maintains a feed pressure of 333 to
2
412 kPa (3.33 to 4.12 bar, 3.4 to 4.2 kg/cm , 48 to 60 psi).
EF&EC-257
Feed Pump (Cont'd)
5. Air tightness test
- (1) Plug feed pump discharge port using a suitable plug.

(2) Apply 196 kPa (2.0 bar, 2 kg/cm2, 28 psi) air pressure to
suction port.
(3) Immerse feed pump in a container of fuel oil, and check for
air leakage. There must be no air leakage.
SEF550F
INSPECTION
Priming pump
EY'bo"~
Adapter
~O-ring
Feed pump housing
MEF20BE
Feed pump housing

1. Check the check valve seats. If they are damaged or exces-
sively worn, replace housing.
2. Check push rod hole. If hole is excessively worn, replace
housing.
Check valve and check valve spring

1. If seat of check valve is excessively worn or scarred,
replace check valve with a new one.
2. If check valve spring is damaged or permanently stressed,
replace valve spring.
EF & EC-258
Feed Pump (ConI' d)
Piston and piston spring
1. If periphery of piston is excessively worn or scarred,
replace piston with a new one.
2. If piston spring is damaged or weakened, replace valve
spring.
Tappet assembly
1. Tappet
If periphery of tappet is worn or scarred, replace it with a
new one.
2. Tappet roller
If periphery of tappet roller is excessively worn or scarred,
replace it with a new one.
Roller to pin clearance:
Limit
0.30 mm (0.0118 In)
Tappet roller outside diameter:
Wear limit
14.9 mm (0.587 in)
Timer
REMOVAL
Refer to INJECTION PUMP Removal.
2. Remove timer round nut with Tool while locking timer gear
securely.
3. Remove timer assembly using Tool.
EF.& EC-259
INJECTION PUMP ~
Timer (Cont'd)
INSTALLATION
1. Secure timer assembly with lock washer and round nut.
toJ: Round nut
59 - 69 N'm
(6 - 7 kg-m, 43 - 51 ft-Ib)
2. Install injection pump assembly.
Refer to INJECTIONPUMP Installation and Adjustment.
ADJUSTMENT
1. Install stroboscope, using cover plate bolts, so that syn-
chronizer lever attachment is applied to tappet.
2. Operate fuel injection pump, turn "ON" switch of strobo-
scope illuminating dial (angle scale) on flywheel, and mea-
sure angular change based on variations in pump speed.
If tester does not have a dial (angle scale):
(1) Attach a dial to timer coupling and mount a pointer on
tester drive shaft.
(2) Operate fuel injection pump and turn stroboscope "ON" so
MEFBB9D as to illuminate dial.
3. If advance angle is not within specified range, adjust by
changing timer spring shims.
a. When injection timing is retarded, decrease shim thick-
ness.
b. When injection timing is advanced, increase shim thick-
ness.
Timer advance curve:
For clockwise Refer to S.O.S.
rotation
(shoulders
decline to
the left) Adjusting shim
MEF919D
EF & EC-260
INJECTION PUMP
Timer ..(Cont'd)
DISASSEMBLY
Round nut
~59-69
(6 - 7, 43 - 51)
Timer flange
(fi9 Timer spring
~ : N.m (kg-m. ft-Ib)

SEF145B
1. Remove gear.
SEF146B
2. Extract flyweight assembly by removing snap ring.

3. Remove large and small cams.
SEF147B
EF& EC..261
Timer (Cont'd)
4. Separate flange from timer flange by removing snap ring
and shims.
5. Disassemble timer spring by removing snap ring after com-

pressing timer spring.
INSPECTION
Carefully check all disassembled parts for deformities, rust or
damage.
Replace damaged parts as required.
Flange
Replace damaged parts if excessive play exists.
Also repair if pin does not slide smoothly.
Repair or replace affected parts if screw threads are damaged.
Timer flange
Check tapered section and key grooves for abnormalities. If
worn or damaged, replace timer flange.
Repair or replace affected parts if outer periphery of timer
flange and bore into which large cam is inserted are scratched
or worn. (Bore should be checked for wear by inserting large
cam.)
Large and small cams

Replace large and/or small cams if excessive clearance exists
on their frictional surfaces, or repair if rough friction is evident.
Flyweight
Replace affected parts if excessive play exists between hole in
large cam and flyweight pin (press-fit).
Springs
Replace springs if they are fatigued or deformed.
EF & EC-262
Timer (Conf'd)
Other parts
Replace pilot pin if it is bent or worn on mating surfaces of snap
ring.
Discard snap rings and O-rings and install new ones.
Replace affected parts if sealing lips of oil seals .are damaged
or if there is any oil leakage at or around oil seats.
ASSEMBLY
1 Attach fl~nges to timer flange and hold it with washer and
snap ring.
Ensure.that both the key groove on timer flange and align-
ment line .on outer periphery of flange face in the same
direction.
SEF150B
2. With timer flange attached to flange, make sure clearance

between flange and washer is within 0.02 to 0.1 mm (0.0008
to 0.0039 in) range.
If it is not within specified range, replace shim with suitable
one.
3. Install large and small cams on timer flange while key
groove on timer flange and alignment line on flange are
aligned with each other.
0.05 - 0.2
(0.0020 - 0.0079)
Unit: mm (in)
----r--- SEF151B
L 4. Attach spring to flyweight.

Measure distance "L" between center of flyweight pins.
Next, rotate large cam until distances between center of
bore in large cam and rotational centers of timer flange are
equal on both the teft and right sides. Then, install flyweight
assembly.
SEF152B
SEF153B
EF& EC-263
INJECTION PUMP
Timer (Conl'd)
View from cover side SEF154B
5. Adjust thickness of cover until clearance between it and

flyweight is within 0.05 to 0.2 mm (0.0020to 0.0079in) range.
6. Install snap ring.
7. Insert gear with its chamfered bore side toward timer and
align alignment mark on flange (or key groove on timer
flange) with alignment mark on gear.
toJ: Gear bolt
8 - 12 N.m
(0.8 - 1.2kg-m, 5.8 - 8.7 ft-Ib)
EF & EC-264
INJECTION NOZZLE

1. Dis.connect injection tube flare nuts.
2. Remove inje.ction tubes and spill tubes.
3. Remove injection nozzle holder supports and injection noz-

zle assembly.
• Using a wrench, remove Injection nozzle by rotating It back
and forth.
4. Installilljectibn nozzle holder assembly in the reverse
order of removal.
to:J: Injection nozzle holder support
to cylinder head
25 - 29 N'm (2.5 - 3.0 kg-m, 18 - 22 ft-Ib)
20 - 25 N'm (2.0 - 2.5 kg-m, 14 - 18 ft-Ib)
• Nozzle gaskets should always be replaced.
5. Bleed air trom fuel system
DISASSEMBLY
1. Loosen nozzle retaining nut while keeping nozzle top from
turning.
EF.&EC-265
INJECTION NOZZLE
INSPECTION
solvent.
assembly.
• Check nozzle spring for excessive wear or damage. If
assembly.
CLEANING
1. Clean nozzle assembly using Tool (Nozzle Cleaning Kit).

figure.
Adjusting shim
Nozzle spring
Spring seat
Spacer
Nozzle needle
Nozzle assembly
Retaining nut
SEF6371
EF & EC-266
INJECTION NOZZLE

KV11290122
SEF6391

KV11290150
=. :
Cleaning area
SEF6401

To prevent spray hole from canting, always clean It by starting
with Inner side and working towards outside.
EF&EC-267
INJECTION NOZZLE

it.
own weight.
If needle fails to sink smoothly from any position, replace both
SEF641I
ASSEMBLY
toJ: Retaining nut
29 - 39N'm
(3.0 - 4.0 kg-m, 22 - 29 ft-Ib)
If nozzle body is not installed properly, tool cannot be removed
and nozzle body may be damaged.
TEST AND ADJUSTMENT
WARNING:

flare nut.
EF & EC-268
INJECTION NOZZLE
starts droppi,ng. . . .
InltlalinjE!ption pressure:
Used
18,633 • 19,12~.kr~ ..'
(186.3 • 191.2iJ)al';'190 • 195 kg/cm2,
2,702 - 2,773 psi)
New
SEF6431 19,124 - 20,104 kPa
(191.2 - 201.0 bar, 195 - 205 kg/cm2,
2,773 - 2,915 psi)
New nozzle Is required to alwaysicheck initial Injection pres-
sure.
4. To adjust injectioh pressure, change adjusting shims.

a. Increasing the thickness of adjusting shims increases Ini-
tial injection pressure. Decreasing thickness reduces initial
pressure.
b. A shim thickness of 0.01>i1)m\(0.0004in) correspqr'lds
approximately to dlfferenceof147kPa (1.47.bar,1.5 kglcm2,
21 psi) In initial injection pressure.
SEF6441
EF& '.E
. C-269:
INJECTION NOZZLE
Leakage test
pressure.
around the body.
Retaining
nut
replace it.
Injection
nozzle
Good No good
SEF6451
Spray pattern test

1. Pump the tester handle one time per second or more.
replace it.
, y
I
Wrong Good
MMA072A
EF & EC-270
BLEEDING. FUEL SYSTEM (Engine on vehicle)

Air. should be bled out of fuel system when injection pump is
removed or fuel system is repaired.
If engine will. not start after bleeding air, loosen injection tubes
at nozzle side and crank engine until fuel overflows from injec~
tion tube. Tighten injection tube flare nuts.
In~line pump
CAUTION:
Wipe up any fuel discharged while bleeding air during each .
step.
• Step 1: Sedimentor air bleeding
1. Remove cap covering priming pump from injection pump.
2. Turn priming pump counterclockwise.
3. Loosen air bleeder screw.
out of air bleeder.
MEF892D 5. Tighten air bleeder screw.
• Step 2: Fuel filter air bleeding
1. Loosen fuel inlet and fuel outlet connectors.
out of connector.
3. Tighten connector.
toJ: Connectors
21 ~ 30 N'm
(2.1 ~3.1 kg~m, 15 - 22 ft-Ib)
Fuel outlet
connector
t MEF893D

toJ: Overflow valve connector
25 - 29 N'm
(2.5 ~3.0 kg-m, 18 ~22 ft-Ib)

2. Loosen fuel inlet valve connector.
out of fuel inlet valve and fuel overflow valve connector.
4. Tighten inlet valve and overflow valve connectors.
toJ: Valve connector
25 - 34 N'm
(2.5 - 3.5 kg~m,18 ~25 ft-Ib)
EF & EC-271
• Step 5: Fuel injection tube and spill tube air bleeding

1. Loosen injection tube nuts of nozzle holders.
2. Loosen fuel filter overflow valve connector.
3. Move. the priming pump up and down until no further air
comes out ofthe injection tube nuts.
4. Tighten the injection tube nuts.
~: 20 - 25 N.m
(2.0 - 2.5kg-m, 14 - 18 ft-Ib)
5. Tighten the fue.1filter overflow valve connector.
~: 25 - 29 N.m
(2.5 - 3.0 kg-m, 18 - 22 ft-Ib)
EF & EC-272
FUEL FlLTER
Overflow Valve
Attach a pressure gauge to fuel filter discharge port, and check
valve opening pressure by operating priming pump. If pressure
is notwithinrangeof 108 to 147 kPa (1.08 to 1.47 bar, 1.1 to 1.5
kg/cm2, 16 to 21 psi), replace overflow valve .
.. From fuel tank

MEF896D
EF&eC-273
FUEL HEATER SYSTEM
Fuel temperature switch DESCRIPTION

Fuel heater system is designed to improve startability at low
~
atmospheric temperatures for models destined for cold areas.
~ This system prevents fuel filter from clogging with fuel wax.
MEF897D
Fuel temperature switch Oil pressure switch*
From fuel ~ -.. To injection pump

tank
OFF 0 Ignition
switch
*Oil pressure switch

is fixed on left side
of engine block.
SEF411F
EF & EC-274
FUEL HEATER. SYSTEM
IGNITION SWITCH
ON or START
S.M.c!. FUEL HEATER

[Refer to last page RELAY
~:~I~I
(Fo ldout page) .]
15A B/W -- B/W G B/W
@ @)
(Instrument
harness)
@@
@@
(ChaSSis
• UP harness) @)@ FUEL HEATER
@)@.-----~
FUSE BLOCK HEATER
(Ref er to "POWER SUPPLY
ROUiING" in EL section.) G~B =B 6="""=J
FUEL TEMP.
--m W
SWITCH
FD BR BR FD JlYR =tj tV=1

OIL PRESSURE @@)
SWITCH
~[J-BR GD Standard cab
1~ (ill) @
@
Wide cab
FD engine
w @ BD engine
BODY GROUND
SEF822M
II.
5(41) Fuel heater operation area OPERATION
'L.
(.J
Fuel heater system operates when fuel temperature switch and
o
~ 0(32)
oil pressure switch are on.
.....
:l
&
E -5 (23)
l!!
1i
:l
II.
o98 196
(0,0, (1.0, 1, (2.0, 2,
Engine 0) 14) 28) 43)
oil pressure kPa (bar, kg/em' , psi) . SEF541D
INSPECTION
1, Connect a read wire, as shown, between terminals of fuel
temperature switch.
After checking, reconnect

the connector
SEF553D
EF & EC-275
FUEL HEATER SYSTEM
2. Run engine at about 1,000rpm. After several minutes, make

sure that fuel heater is hot.
Be careful not to burn yourself.
3. If fuel heater does not operate, check fuel heater system as

follows.
Fuel heater
1. Check continuity for fuel heater.
2. If fuel heater has malfunction, replace fuel filter bracket.
Oil pressure switch

1. Run engine at about 1,000 rpm.
2. Check continuity for oil pressure switch.
3. If oil pressure switch has malfunction, replace it.
SEF414F
Fuel heater relay

1. Check fuel heater relay operation.
2. If fuel heater relay does not operate, replace it.
Harness
Check harness and fuse continuity.
EF & EC-276
AIR HEATER SYSTEM
CAUTION:
Before starting to work, be sure to turn ignition' switch "OFF"
and then disconnect tJattery ground cable. '
Description
Normal operation
Ignition switch left "ON". An air heater system is installed to preheat the intake air and
Ignition switch turned between make it easy to start the engine. An after-heat system is also
"ON" and "OFF" repeatedly.
used to stabilize the combustion after the engine has started.
PREHEATING
Cranking When the ignition switch is turned to "ON", the pilot lamp will
.. 8T
Ignition ON
8T
r------, ON illuminate. Current flows through the air heater via relay. After
a specified period of time, relay turn off and then the pilot lamp
switch OFF
goes out; however, current continues to flow through the air
Pilot ON
lamp OFF
heater via relay.
ON
CAUTION:
Relay OFF a. T2 and T1 are varied according to engine coolant tempera-
ture.
b. Relay will not activate when the temperature of the engine
Air heater
.... - ...... coolant is higher than 10°C (50°F).
temperature '.
Time-
MEF906D
AFTER-HEA TING
When the ignition switch is returned to "ON" from "START",
relay is kept on for the after heat time T1-
CAUTION:
a. T2 Is varied according to engine coolant temperature.
b. Relay will not activate when the temperature of the engine
coolant is higher than 10°C (50°F).
cj
w
(J)
(j 14 ~ 14
(J)
~ 12 ;:; 300
~ 12
--::;10 ..= 10
w
~(240)
t- 8 :2 8 t= 200
w
:2 6 t= 6 t;;:
t-
t=
D..
4 ;5 4 ~ 100
:2 2 Ji= 2 d:. 60
w
:5 0 g: 0 ~
u.
0
-25 -20 0 20 40 -25 -20 0 20 30 40 < -20 0 20 30 40
(-13) (-4) (32) (68) (104) (-13)(-4) (32)(68)(86)(104) (-4) (32)(68) (86)(104)
Coolant temperature °C (OF) Coolant temperature °C (OF) Coolant temperature °C (OF) MEF907D
EF&EC-277
AIR HEATER SYSTEM
CAUTION:
Before starting work, be sure to turn ignition switch "OFF" and then disconnect battery ground cable.
Schematic
FUSIBLE
LINK
AIR
HEATER
RELAY
AIR
ENGINE HEATER
TEMPERATURE
SENSOR
SEF819M
EF & EC-278
AIR HEATER SYSTEM
Wiring Diagram
f-
<O:-.J
ffi~
WO
Icr: ~C"')""<::rLn ......
a:~~ ~
HOZ
<O:U::J
cr:
W
f-
W
::E
Z
o
H
f-
<0:
Z
H
CO
::E
L
o
U
Not used
S.M.J.
[Refer to last page
(FaIdout page) .]
BR/R E1 BR/R
,
a:
l.L.
To CHARGE R E5 R
W/R A14 W/R
warning lamp W/L 03 W/L
B 016 B
cr:= ~
Wl.!l •
3:ZC (f)
OHO (f)
Q..~'rl Q) (f)
= ::J .... C (f)
::L 00 L Q)
Uocr:Q) co C
0.... (f) .c: L
-.J >- co
COL-.J.-J .... .c:
Q)D..W c
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SEF820M
EF& EC-279
AIR HEATER SYSTEM
Trouble-shooting
Engine fails to start or is hard
to start.
Check fuel level, fuel supplying system, starter motor, etc.
N.G. O.K.
Correct. Check that air heater harness and connectors are N.G. Correct.
installed properly.
O.K.
Turn ignition switch OFF for more than 10 seconds.
Check if heater pilot lamp comes on within a few seconds of turning the ignition switch ON.
~
I~ ---~ *1 (Next page)
Check for a burned out bulb. N.G. Replace bulb.
O.K.
Go to "Power supply circuit N.G. Check harness between fuse

check" for heater control unit. and heater control unit.
O.K.
Go to "heater pilot lamp control N.G. Replace heater control unit.

check".
O.K.
Check short circuit on harness

between ignition switch and heater
pilot lamp.
EF & EC-280
AIR HEATER SYSTEM
(From previous page)
*1
Go to "Air heater check". N.G. Replace air heater.
O.K.
Check heater relay. N.G. Replace air heater relay.

Refer to "Air heater relay check".
O.K.
Go to "Start signal input check". N.G. Check harness between air heater control unit and
ignition switch.
O.K.
Go to "Pre-heating control check". Replace air heater control unit.
O.K.
Check harness between

• Air heater control unit and air heater relay
• Air heater relay and air heater
The combustion performance of the engine after it

has started is not good.
Check air heater relay. N.G. Replace air heater relay.

Refer to "Air heater relay check".
O.K.
Go to "After-heating control check". N.G. Replace air heater control unit.
O.K.
Check harness between air heater control unit and air

heater relay.
EF& EC-281
AIR HEATER SYSTEM
Trouble-shooting (Conl'd)
When the ignition key is ON, the heater pilot lamp
remains on and does not go off.
O.K.
Go to "Water temperature sensor cir- N.G. Go to "Water temperature sensor". N.G.

~
I
cuit check".
O.K.
O.K.
Replace water tem-

perature sensor.
Check harness between heater control

unit and water temperature sensor.
Go to "heater control unit control N.G. Replace heater control unit.

~
I
check".
O.K.

heater control unit and heater pilot lamp.
EF & EC-282
AIR HEATER SYSTEM
Inspection
CAUTION:
Before starting work, be sure to turn Ignition switch "OFF" and
then disconnect battery ground cable.
AIR HEATER FUNCTIONAL CHECKS (On-vehicle service)

1. When engine is cold, turn ignition switch from OFF to ON
to check that air heater pilot lamp comes on.
2. With ignition switch ON, listen to check air heater relay
operates for a certain period of time, the time correspond-
ing to an increase in cooling water temperature.
3. Touch air heater with your hand to check that it is warm.
Do not repeat above checks since battery may run down.
AIR HEATER CHECK {On-vehicle service)
A
B
D c
MEF901D
1. Turn ignition key ON and measure air heater terminal volt-

..fF.ill / Air heater age.
~ connector
Terminal voltage: Battery voltage (Approx. 24V)
2. Check that continuity exists between heater terminals.
Between terminal check point Continuity
A-C Yes
Ignition switch: ON
MEF902D
Ef&EC.;283
AIR HEATER SYSTEM [fQJ
Inspection (Cont'd)
AIR HEATER RELAY CHECK (On-vehicle service)
1. Turn ignition switch ON and measure air heater relay ter-
minal voltage.
Terminal voltage: Battery voltage (Approx. 24V)
m
~ Air heater side
connector
i)~
+ -
MEF903D
• If N.G., check continuity between terminals as shown in the

figure.
MEF904D
WATER TEMPERATURE SENSOR

• Check resistance of water temperature sensor.
Resistances are shown in the figure next page.
EF & EC-284
AIR HEATeR
L
SYSTEM
'
Inspection (Cont'd)
Temperature °c (0 F) Resistance (kO)
20 (68) Approx.2.5
80 (176) Approx. 0.33
SEF062F
POWER SUPPLY CIRCUIT CHEC~

Disconnect harness connector frorftair heater control unit and
perform voltage check and continuity check.
..
Voltmeter terminals Ignition switch position

(+ ) H OFF ACe ON
..
Battery "olt-
(J) @ OV OV age
(approx. 24V)
Ohmmeter terminals
Ignition switch OFF
(+) H
@ Body ground Continuity exists
SEl181N
WATER TEMPERATURE SENSOR CIRCUIT CHECK

• Check continuity between terminals @ and @.
Measure resistance to temperature approximately as
shown in "Water temperature sensor check".
SEl182N
EF& EC..285
AIR HEATER SYSTEM [£[]
Inspection (Cont'd)
CIRCUIT TO ALTERNATOR'S "l" TERMINAL CHECK
2. Disconnect harness connector from heater control unit.
3. Disconnect harness connector from the alternator's "L" ter-
minal.
4. Check terminal voltage between @ and @ when the igni-
tion switch is turned to ON.
Voltage:
Battery voltage (approx. 24V)
Ignition switch: ON SEL183N

DISCONNECT ~
• Turn ignition switch OFF.

'ID ~ 2. Disconnect harness connector from the starter motor's "S"
terminal.
3. Check terminal voltage between <D and @ when the igni-
Voltage:
Battery voltage (approx. 24V)
Ignition switch: START

SEL 184N
HEATER PilOT lAMP CONTROL CHECK

lamp stays lit.
Time the test lamp should stay lit.
EF & EC-286
AIR HEATER SYSTEM [£[]
Inspection (Cont'd)
PRE-HEATING. CONTROL CHECK
lamp stays lit and the voltage between the terminals.
Between terminal
Time Voltage
check points
CONNECT
Test lamp (3.4W) 11 - 4 Approx. 0 - 18 seconds Battery voltage
E)
~ Engine is running. AFTER-HEATING CONTROL CHECK

terminal.
turned to START.
4. Measure the time the test lamp stays lit and the voltage
between the terminals when ignition switch is turned to ON
from START.
SEL 187N Between ter-
minal check Time Voltage
points
Water temperature;
• Below 20°C (58°F)
Approx. 0 - 180 seconds Battery voltage should exist
11 - 4 (Varies with water tem- when water temperature is
perature) below 20°C (58°F).
• Over 20°C (58°F)
o seconds
EF & EC-287
FUEL CUT SYSTEM
Wiring Diagram
IGNITION SWITCH
ON or START
t
UP
FUSE BLOCK ~ ~
(Refer to" POWER ;;, \.!.:.V
SUPPLY ROUTING"
in EL sect ion.)
S.M ....!.
.=E!J
[Refer to last page
(Fo ldout page) .] FUEL CUT
(Instrument
~
I I
harness)
8/W
@
8
F16
D16
@
8 .---~1---
(Chass is
8/W -------
harness)
8/W --0, ~
8 --D'
(ill)
IIJ-t::::::::J
SOLENOID
VALVE
(For auto stop
actuator)
!D !D
@f1@
!D
BODY GROUND BODY

GROUND SEF821M
EF & EC-288
SERVI.CE<DATA AND SPECIFICATIONS (S.O.S.)
Injection Pump
PUMP NUMBERS
Applied model
Engine Destination Part number Pump number Remarks
H41
167000T021 101493-9150 Without high altitude compensator

FD42 General areas 167000T022 101493-9160 0
With high a,ltitude compensator
167000T023 101493-9170
167000T310 101493-9180 Without high altitude compensator

FD46 General areas 167000T311 101493-9190 0
167000T312 101493-9200
INSPECTION AND ADJUSTMENT Thickness

Part number
mm (in)
General specification
0.20 (0.0079) 16741-T8272
Injection timing B.T.D.C:W 0.25 (0.0098) 16741-T8273
0.30 (0.0118) 16741-T8260
Maximum engine FD42 engine 3,650 rpm
0.35 (0.0138) 16741-T8274
speed FD46 engine 3,350 rpm 0.40 (0.0157) 16741-T8261
0.45 (0,0177) 16741-T8275
0.50 (0.0197) 16741-T8262
Injection pump
0.55 (0.0217) 16741-T8267
Standard Limit 0.60 (0.0236) 16741-T8263
mm in 0.65 (0.0256) 16741-T8268
0.70 (0.0276) 16741-T8264
0.75 (0.0295) 16741-T8269
0.20 (0.0079) 0.80 (0.0315) 16741-T8265
Plunger pre-stroke
0.85 (0,0335) 16741-T8270
0.12 (0.0047) adju.sting shim
0.90 (0.0354) 16741-T8266
0.95 (0.0374) 16741-T8271
0.10 (0.0039)
1.00 (0.0394) 16741-99006
Control rack to pinion 1.05 (0.0413) 16741-99012
0.30 (0.0118)
backlash
1.10 (0.0433) 16741-99008
Pump rpm
Control 1.15 (0.0453) 16741-99013
=0
rack sliding 1.20 (0.0472) 16741-99009
Pump rpm
resistance
== 1.000 1.25 (0.0492) 16741-99014
Injection interval 1.30 (0.0512) 16741-99010
89'30' - 90'30'
cam an Ie 1.35 (0.0531) 16741.T8276
Injection starting timing
3.15 - 3.25 . 1.40 (0.0551) 16741-99011
(pre-stroke: plunger lift
(0.1240 - 0.1280) 1.45 (0.0571) 16741-T8277
from B.D.C.
Thickness 1.50 (0.0591) 16741-99015
Part number 1.55 (0.0610) 16741-T8278
mm in
0.10 (0.0039) 16716-99009 1.60 (0.0630) 16741-99016
0.12 (0.0047) 16716-99010 PUsh rod length
0.14 (0.0055) 16716-99011 Part number
mm (in)
0.16 (0.0063) 16716-99012
Front 95 (3.74) 19329~29018
0.18 (0.0071) 16716-99013
0.30 (0.0118) 16716-99401 96 (3.78) 19329-29019
0.50 (0.0197) 16716-99014 97 (3.82) 19329-54T65
Camshaft 1.00 0.0394 16716-99402 98 (3.86) 19329-54T66
0.10 (0.0039) 16741-37500 19329-54T67
end play Altitude compensator 99(3.90)
0.12 (0.0047) 16741-37501
adjusting adjusting push rod 100 (3.94) 19329-54T68
0.14 (0.0055) 16741-37502
shim 0.16 (0.0063) 16741-37503 101 (3.98) 19329-54T69
0.18 (0.0071) 16741-37504 102 (4.02) 19329-54T60
Rear 0.30 (0.0118) 16741-37506 102.5 (4.04) 19329-54T61
0.50 (0.0197) 16741-37505
103 (4.06) 19329-54T62
0.70 (0.0276) 16741-29001
1.00 (0.0394) 16741-29000 103.5 (4.07) 19329-54T63
1.40 (0.0551) 16741-37509 104 (4.09) 19329-54T64
2.40 (0.0945) 16741-29005
EF&EC.289
Governor Timer
Standard Limit Clearance between washer and 0.02 - 0.1
mm (in) mm (in) flange mm (in) (0.0008 - 0.0039)
Shiller pin hole to 28.8 - 29.2 Clearance between cover and 0.05 - 0.2
housing surface (1.134 - 1.150)
- flyweight mm(in) (0.0020 - 0.0079)
Thickness
Part number
mm (in)
TIGHTENING TORQUE
0.2 (0.008) 19342-90001
Unit N'm kg-m II-Ib
0.3 (0.012) 19342-90002
Injection pump
0.4 (0.016) 19342-90003
Injection pump to pump
0.5 (0.020) 19283-99118 34 - 39 3.5 - 4.0 25 - 29
bracket
Shifter distance
1.0 (0.039) 19342-90004 Delivery valve holder 39 - 44 4.0 - 4.5 29 - 33
adjusting shims
1.5 (0.059) 19283-99119 Screw plug 54 - 74 5.5 - 7.5 40-54
2.0 (0.079) 19283-0n03 Injection pump bracket to
14 - 18 1.4 - 1.8 10 - 13
3.0 (0.118) 19283-0n04 front cover
4.0 (0.157) 19283-0n05 Bearing cover 7-9 0.7 - 0.9 5.1 - 6.5
0.10 (0.0039) 19283-Z9012 Governor
0.20 (0.0079) 19283-Z9013 Flyweight round nut 49 - 59 5.0 - 6.0 36-43
0.25 (0.0098) 19283-Z9014 Timer

Idling spring adjust- Round nut 59 - 69 6.0 - 7.0 43 - 51
0.3 (0.012) 19283-Z9016
ing shims
0.5 (0.020) 19283-Z9017
0.8 (0.031) 19283-Z9018

Injection pump calibration data:
This data will be introduced in the Technical Bul-
1.00 (0.0394) 19283-Z9015
letin later or refer to CALIBRATION STANDARD
published by ZEXEL.
Feed pump
Standard Wear limit
Roller to pin clearance 0.04 - 0.08

0.30 (0.0118)
mm(in) (0.0016 - 0.0031)
Roller outer diameter

15.0 (0.591) 14.9 (0.587)
mm (in)
300 mt (10.6 Imp II oz) or more

Oil feed rate within 15 seconds at a pump speed
of 1,000 rpm.
Discharge should occur within one

minute (60 seconds) with a pump
Pumping capacity
speed of 100 rpm and intake head
of 1.0 meter (3.3 II).
The time required to develop an oil

feed pressure of 157 kPa (1.57 bar,
Oil feed pressure 1.6 kg/cm2, 23 psi) with a feed
pump speed of 600 rpm should be
within 30 seconds.
Operate the priming pump at a rate

Pumping capacity of 60 to 100 strokes per minute and
(priming pump) verify that pumping is started
within 30 strokes.
EF & EC-290
Injection Nozzle
Injection nozzle assembly Unit N'm kg-m ft-Ib

Used New
Initial injection pres- Nozzle retaining nut 29 - 39 3.0 - 4.0 22 - 29
18,633 - 19,124 19,124 - 20,104
sure (186.3 - 191.2, (191.2 - 201.0, Injection nozzle support to
kPa (bar, kg/cm2, psi) 190 - 195, 195 - 205,
25 - 29 2.5 - 3.0 18 - 22
cylinder head
2,702 - 2,773) 2,773 - 2,915
Thickness
Part number
mm (in)
0.50 (0.0197) 16614-54TOO

0.525 (0.0207) 16614-54T01
0.55 (0.0217) 16614-54T02
0.575 (0.0226) 16614-54T03
0.60 (0.0236) 16614-54T04
0.625 (0.0246) 16614-54T05
0.65 (0.0256) 16614-54T06
0.675 (0.0266) 16614-54T07
0.70 (0.0276) 16614-54T08
0.725 (0.0285) 16614-54T09
0.75 (0.0295) 16614-54T10
0.775 (0.0305) 16614-54T11
0.80 (0.0315) 16614-54T12
0.825 (0.0325) 16614-54T13
0.85 (0.0335) 16614-54T14
0.875 (0.0344) 16614-54T15
0.90 (0.0354) 16614-54T16
0.925 (0.0364) 16614-54T17
Initial injection pres- 0.95 (0.0374) 16614-54T18
sure adjusting shim 0.975 (0.0384) 16614-54T19
1.00 (0.0394) 16614-54T60
1.025 (0.0404) 16614-54T61
1.05 (0.0413) 16614-54T62
1.075 (0.0423) 16614-54T63
1.10 (0.0433) 16614-54T64
1.125 (0.0443) 16614-54T65
1.15 (0.0453) 16614-54T66
1.175 (0.0463) 16614-54T67
1.200 (0.0472) 16614-54T68
1.225 (0.0482) 16614-54T69
1.25 (0.0492) 16614-54T70
1.275 (0.0502) 16614-54T71
1.30 (0.0512) 16614-54T72
1.325 (0.0522) 16614-54T73
1.35 (0.0531) 16614-54T74
1.375 (0.0541) 16614-54T75
1.40 (0.0551) 16614-54T76
1.425 (0.0561) 16614-54T77
1.45 (0.0571) 16614-54T78
1.475 (0.0581) 16614-54T79
1.50 (0.0591) 16614-54T80
Fuel Filter
Type Full-flow, paper type filter Unit N'm kg-m ft-Ib
Overflow valve opening Fuel filter

108 - 147 (1.08 - 1.47,
pressure
1.1 - 1.5, 16 - 21) Lead line connector bolt 21 - 30 2.1 - 3.1 15 - 22
EF & EC-291
ACCELERATOR CONTROL, FUEL &
EXHAUST SYSTEMS
SECTION FE
CONTENTS
ACCELERATOR
FUEL SySTEM
EXHAUST
CONTROL
SYSTEM
SYSTEM
'" '"
, ,
;
; FE-2
FE:4
FE-6
..
ACCELERATOR CONTROL SYSTEM
CAUTION:
• When removing accelerator cable, make a mark to indicate lock nut's Initial position.
• Check that throttle valve opens fully when accelerator pedal Is fully depressed and that It.returns to
Idle position when pedal Is released.
• Check accelerator control parts for Improper contact with any adjacent parts.
• When connecting accelerator cable, be careful not to twist or scratch Its Inner wire.
Fleturn spring ~«(I~,

cover ,l I
j ~ 12 _ 15
(1.2 _ 1.5,
9-11~/
u
~A:J
~".h.I.
:
) ~~12-15 '
/'\ (1.2 - 1.5, I
9 - 11) 11
~ 9.3 - 10.8 (0.95 - 1.1, 6.9 - 8.0)
~ Accelerator rod
Accelerator cable
Accelerator rod stopper bolt
(Models without exhaust brake)
~ : N.m (kg-m, ft-Ib) Accelerator switch

(Models with exhaust brake)
SFE308A
Adjusting Accelerator Pedal and Cable

Idle control knob 1. Loosen accelerator cable fixing bolt.
(Diesel models) 2. Return idle control knob fully. (Diesel engines)
IT
:: 3. Adjust L1 (Extruded screw height of stopper bolt or accel-
erator switch) to the following:
L1: 7.5 mm (0.295 In)
For reference: Accelerator pedal angle (8) will become 48
degrees for gasoline models and 45 degrees for diesel
models.
4. Install cover on extruded screw end.
5. Tighten accelerator cable fixing bolt returning accelerator
cable by 1 to 2 mm (0.04 to 0.08 in) from position that
accelerator cable is extended fully.
6. Adjust accelerator pedal stopper bolt so that space
between accelerator pedal and stopper bolt end becomes
o to 1 mm (0 to 0.04 in) when accelerator pedal is fully
depressed.
Accelerator
rod stopper
bolt (or
Pedal stopper bolt accelerator
sWitch)
SFE309A
FE-2
ACCELERATOR CONTROL SYSTEM
Lock nut Fixing Accelerator Cable End

~ 8.11 N.m
(0.8 - 1.1 kg-m, GASOLINE ENGINE MODELS
5.8 - 8.0 ft-Ib)
1. Loosen lock nut, and put accelerator cable bracket to mid-
die of thread length.
2. Tighten lock nut holding adjusting nut.
SFE248A
FE.3
FUEL SYSTEM
WARNING:
• Do not smoke while servicing fuel system. Keep open flames and sparks away from work area.
• Be sure to furnish workshop with a CO2 fire extinguisher.
CAUTION:
a. Put drained fuel In an explosion-proof container and put the lid on securely.
b. Disconnect battery ground cable.
• When installing fuel check valve, be careful of Its designated direction. (Refer to section EF & EC.)
• Always replace O-ring and clamps with new ones.
• Do not kink or twist tubes when they are being Installed.
• After Installing tubes, run engine and check for fuel leaks at connections.
Fuel Tank
F23 (50 Q tank)
~43-59
(4A.'~'~)
When removing fuel tenk,

remove front bracket from frame.

SFE310A
Pin
/1
V.
/i I uel tank bracket
@-Nut
Fuel tank ~ ~5 - 9 (0.5 - 0.9, 3.6 - 6.5)
band
Lock nut
~: N.m (kg-m, ft-Ib) ~ 20 - 23 (2.0 - 2.3, 14- 17)
SFE312A
FE-4
FUEL SYSTEM'd
Fue I Tank (Cont )
H41
No. 3 position
Breather tube
No.4 position
Sub fuel tank

(If so equipped)
Main fuel tank
~ 9 - 11 i No. 2 position
~~/Q
~''<lC~0.F
6032-43) ..
Nut ~,,,' 43
Iaok
- 59band
(4.4 •- .. , No. 3 position
(0.9 • 1.1--------., ""' Nut ~-.II 11 M. 8.0)bracket for
M • 20&"...... ./ , lC!l 9 _ 11 (0.9. .,
1
n
~.
Lock nut 2314
('.0- -23 .• -17)
61 - 81
V~'...-- .
0
ue
I tank valve
main fuel tank
ro
lC!l 45-60)
(62 - &~ "~ Lock out
~20-23(. ... '.3. 14 • 17)
FE.-S
EXHAUSTSVSTEM
CAUTION:
• Always replace exhaust gaskets with new ones when reas-
sembling.
If gasket is left on flange surface, scrape off completely as
shown at left.
• With engine running, check all tube connections for exhaust
gas leaks, and entire system for unusual noises.
• After installation, check to ensure that mounting brackets
and mounting insulators are free from undue stress. If any
of the above parts are not installed properly, excessive
SFE180A
noise or vibration may be transmitted to the vehicle body.
Arrangement
F23
~ 11 - 15
l
(1.1 - 1.5, 8 -~1)
'~\ ~51-65'
~
0 \
(5.2 • 6.6, 38 - 48) ,
~~ I \
For diesel engin'e
~,~
~51_~ / ~
1~
(5.2-6.6'~
r-' 11 - 15 (1.1 - 1.5,8 - 11)

25 - 31 (2.5 - 3.2, 18 - 23)
r
~ 4-7
(0.4 - 0.7, 2.9 - 5'1)~ ~
~ 4-7
-fit: f'il..J ~ @Izz, (0.4 - 0.7,
..--.-
J:~-.@1l
,~-B
~__ 2.9 - 5.1)
(
/ ~ ~=h1: ---
I
L'---------"',
0
P
7~~ l
4 - 7 (0.4 - 0.7, 2.9 - 5.1)
~ 51-~(~'-6'. 38-48, ~' ~
~ 9 - 13 (0.9 - 1.3, 6.5 - 9.4)~ ~

SFE314A
FE-6
H41
20-22
@)
~
,~.1M.
mol 9 - 12
1.2, as - 8.", _
'~ cl~
~-, ~
~-~r~r1\\,,~
1
U\ I \
I
mol 51 - 65
~-.01 (5.2 _ 6.6, 38 - 48)
~ 25 - 31 (2.5 -'3.2, 18 - 23)
.J .
~
mol 20 - 22
~~-.01 (2.0 _ 2.2,14.8 - 16.2)
~
V~-.01 mol 32 - 38 24 _ 28)
(3.3 - 3.9, ~
________
mol 51 - 65 (5.2 - 6.6, 38 - 4~ • ~ 32 _ 38 _ 28)
r
~-.01 ~ . (3.3 _ 3.9, 24
mol 20 - 22
~-.01(2.0 _ 2.2, 14.8 - 16.2~
Long
Wheelbase ~ : N.m (kg-m, ft-Ib)
models only
SFE315A
FE-7
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
CLUTCH
SECTloleL
CONTENTS
PRECAUTIONS AND PREPARATION CL.2
CLUTCH SYSTEM CL- 3 ~
INSPECTION AND ADJUSTMENT CL- 5 ~
HYDRAU L1C CLUTCH CONTROL CL- 6
CLUTCH RELEASE MECHANISM CL-10
CLUTCH DISC AND CLUTCH COVER CL-12
SERVICE DATA AND SPECIFICATIONS (S.D.S.) CL-15
Precautions
• Recommended fluid is brake fluid "DOT 3".
• Be careful not to splash brake fluid on painted areas.
• When removing and installing clutch piping, use Tool.
• Use new brake fluid to clean or wash all parts of master
cylinder, operating cylinder and clutch damper.
• Never use mineral oils such as gasoline or kerosene. It will
ruin the rubber parts of the hydraulic system.
SBR820B
WARNING:
After cleaning the clutch disc, wipe it with a dust collector. Do
not use compressed air.
Preparation
*: Special tools or commercial equivalent
Tool number
Description
Tool name
ST20050010 Inspecting diaphragm spring of clutch cover

-:-::_ .
Base plate
.<".. @» -.:.-
. - <- : - :.- ..
~
ST20050100
Distance piece
GG9431 0000 Removing and installing each clutch piping

Flare nut torque
wrench
ST20600000* Installing clutch cover and clutch disc

Clutch aligning bar
ST20050240* Adjusting unevenness of diaphragm spring of

Diaphragm spring clutch cover
adjusting wrench
COMMERCIAL SERVICE TOOL

Bearing puller Removing release bearing
CL-2
CLUTCH SYSTEM
~9.3-10.8
(0.95 - 1.1, 6.9 - 8.0)
/ ~ ~ 20 _ 23 ~ 12 - 15 (1.2 - 1.5, 9 - 11)
fl (2.0 _ 2.3, Clutch switch
14 - 17) or stopper bolt
".~/,~>"
~ ~~ "- ,{
:\
'J
Clutch master cylinder
L.H. model
o CM," ",d" F -.~-. J
Q
rJ,~
I ~ 9.3 - 10.8
(0.95 - 1.1,
m~
Return spring F~ ~
Fl' _
'J W
Clevis pin-
Booster
8 - 12 (0.8 - 1.2, 5.8 - 8.7)
<or 6.9 _ 8.0) u crum pin &O.IiI IIilOIiI
! I Clutch cover
Clutch disc
~~'~ Dust cover
t..,-,..
(0.95 - 1.1,
6.9 - 8.0)
Clutch hose
Clutch operation cylinder
Withdrawal lever
H41 model
~17 - 20
-'!./'"Hose (1.7 - 2.0, 12 - 14)0
Washer ~~ W .Air bleeder
I ~6 - 10 (0.6 -
B030' :; 1.0, 4.3 _7.2)washer~~(f".t
engln~' Washer~ ,"J'!J
o 6)-" . •
F23 model , "J -----------.___.,/

~ 12 -15
o -r - Air bleeder
(1.2 - 1.5,
- --~6 -10
9 - 11) Air bleeder
(0.6 - 1.0,
~ 6 -10
4.3 - 7.2)
(0.6 - 1.0,
4.3 - 7.2)
m (Q: Apply lithium-based grease including molybdenum disulphide.

SCL532
CL-3
CLUTCH SYSTEM
Vacuum Hose Layout
Brake booster ~
0"10" bOO~"~"
Vacuum tank
Brake side
check
valve
.. Brake
SCL555
CL-4
AdjustillgiClutch Pedal
1. Adjust pedal height with pedal stopper or clutch switch.
[ Lock nut
Pedal height "H":
172 - 177 mm (6.77 .. 6.97 in)
~ 8 -11 (0.8 - 1.1, 5.8 - 8.0) 2. Adjust pedal free play with master cylinder push rod. Then
tighten lock nut.
Pedal free play "A":
F23 model 7 - 18 mm (0.28 - 0.71 in)
H41 model 12 - 21 mm (0.47 - 0.83 in)
[Backlash at clevis 1.0 - 2.0 mm (0.039 - 0.079 in)]
Pedal free play means the following total measured at position
of pedal pad:
• Play due to clevis pin and clevis pin hole in clutch pedal.
3. Make sure that clevis pin can be rotated smoothly.
If not, readjust pedal free play with master cylinder push
rod.
~ : N'm (kg-m. ft-Ib)
SCL534
Bleeding Procedure
Bleed air according to the following procedure.
Carefully monitor fluid level at master cylinder during bleeding
operation.
1. Top up reservoir with recommended brake fluid.
2. Connect a transparent vinyl tube to air bleeder valve.
3. Fully depress clutch pedal several times.
4. With clutch pedal depressed, open bleeder valve to release
air.
SCL203
5. Close bleeder valve.
6. Repeat steps 3 through 5 above until brake fluid flows from
J J air bleeder valve without air bubbles.
Position for
new clutch disc
Clutch Disc Wear Indicator Plate
- FD42, FD46 engines only -
Check that withdrawal lever reaches the position that requires
clutch disc replacement.
When installing a new clutch disc, reset wear indicator plate.
/\ SCL543
HYDRAULIC CLUTCH CONTROL
Clutch Master Cylinder
Reservoir tank
Reservoir
~~
~ ~R~'~;'bMd
~
Cylinder body
m@ Rubbing ('5/ ~~15_18
(1.5 - 1.8,
Reservoir tank cap
~"'J ~
~ surtace
to piston
~ '\ ~ 11 - 13)
Piston aSSembIY~.
..
@'~r
""- assemblYA;
~ ()
I
Dust cover", "\JIJT . Return

spring I Packing~
.
"~ ~@. ~
~ Push rod
m@ Contact surtace to piston
• Apply brake fluid
CI when assembling.
eVIS~ assembly ~
CJ Stopper Valve stopper
~ 1.5 - 2.9
G Q) Stopper ring ~ (0.15 - 0.3, 1.1 - 2.2)
Lock nut • Remove this stopper,
~ 8 - 11 when removing piston and
m@: Apply rubber grease. (0.8 - 1.1, 5.8 - 8.0) return spring.
SCL537
DISASSEMBLY AND ASSEMBLY

• Push piston into cylinder body with screwdriver when remov-
ing and installing valve stopper.
• Align groove of piston assembly and valve stopper when

installing valve stopper.
Groove
SCL214
CL-6
Clutch Operating Cylinder
~ 12 - 15 (1.2 - 1.5, 9 - 11)
Washer ~
NA20, T025, T027, B030 engines
Operating cylinder
lEal @ : Apply rubber grease.

SCL538
INSPECTION
• Check rubbing surface of cylinder for wear, rust or damage.
Replace if necessary.
• Check piston with piston cup for wear or damage. Replace
if necessary.
• Check dust cover for cracks, deformation or damage.
• Check piston spring for wear or damage. Replace if neces-
sary.
CL-'7
Clutch Booster
SCL546
INSPECTION
Hoses and connectors
• Check condition of vacuum hoses and connections.
• Check vacuum hoses and check valve for air tightness.
Check valve
• When pressure is applied to the clutch booster side of
check valve and valve does not open, replace check valve
with a new one.
[ ~Q~
:cuum pump (
side
- Clutch booster
side
SCL539
• Pay attention to its direction when installing check valve.
-Q] ~-~
~- To clutch
To vacuum pump booster
SCL535
CL-8
Clutch Booster (Cont'd)
ADJUSTMENT
Output .rod length:
Length "A"
1.3 - 1.6 mm (0.051 - 0.063 in)
SCl540
If amount of adjustment required exceeds 0.5 mm (0.020 in),

reaction disc may have either been dislocated or fallen off.
Replace clutch booster assembly.
• Adjust input rod length before installing clutch booster to

vehicle.
Input rod length:
Length "8"
121 - 127 mm (4.76 - 5.00 in)
B
SCl136
CL-9 ..
CLUTCH RELEASE MECHANISM
rm~:~""-/
Holder spring
,~
lEI (b)---
lEI CQ : Apply lithium-based grease including molybdenum disuJphide.

SCL326

• Install retainer spring and holder spring.
SCL217
,
• Remove release bearing.
CL145
• Install release bearing with suitable drift.
SCL222
CL-10
CLUTCH RELEASE MECHANISM
INSPECTION
• Check release bearing to see that it rolls freely and is free
from noise, crack, pitting or wear, Replace if necessary.
• Check release sleeve and withdrawal lever rubbing surface
for wear, rust or damage. Replace if necessary.
LUBRICATION
• Apply recommended grease to contact surface and rubbing
surface.
Too much lubricant might cause clutch disc facing damage.
Pack this recess
• m<!): Apply Iithium-based grease including

molybdenum disulphide. SCL223
CL-11
CLUTCH DISC AND CLUTCH COVER
Clutch cover
SCL547
Clutch Disc
INSPECTION
• Check clutch disc for wear of facing.
Wear limit of facing surface to rivet head:
0.3 mm (O.012 In)
• Check clutch disc for spline backlash and facing runout.

Maximum spline backlash {at outer edge of disc)1
Runout Iimitl
Distance of runout check point (from hub center):
Refer to S.O.S.
• Check clutch disc for burns, discoloration or oil or grease
leakage. Replace if necessary.
SCL221
INSTALLATION
• Apply recommended grease to contact surface of spring
portion.
Too much lubricant might damage clutch disc facing.
CL-12
Clutch Cover and Flywheel

• Set clutch cover and Tools.
• Check height and unevenlless of diaphragm spring.
• Set T mm (T in) feeler gauges. on distance pieces
(ST20050100)when checking diaphragm spring height.
Unit: mm (in)
Clutch cover
D240K D260K D275K D300K
model .
Feeler
0.2 0.2 0.4 1.4
gauge thick-
(0.008) (0.008) (0.016) (0.055)
ness "T"
Diaphragm
37.5 - 39.5 41 - 43 44 -46 44 - 46
sp[ing height
IIA." (1.476 - 1.555 ) (1.61 - 1.69) (1.73 - 1.81 ) (1.73-1.81)
• Replace if diaphragm spring height is not within specified

range.
• Check thrust rings for wear or damage by shaking cover
SCL541
assembly and listening for chattering noise, or lightly ham-
mering on rivets for a slightly cracked noise. Replace
clutch cover assembly if necessary.
• Check pressure plate and clutch disc contact surface for
slight burns or discoloration. Repair pressure plate with
emery paper.
• Check pressure plate and clutch disc contact surface for
deformation or damage. Replace if necessary.
• Adjust unevenness of diaphragm spring with Tool.

Uneven limit:
D240K, D260K and D275K 0.7 mm (0.028 in)
D300K 1.0 mm (0.039 in)
FLYWHEEL INSPECTION
• Check contact surface of flywheel for slight burns or discol-
oration. Repair flyWheel with emery paper.
• Check flywheel runout.
Refer to sec EM.
SCL468
CL-13
Clutch Cover and Flywheel (Cont'd)
• Insert Tool into clutch disc hub when installing clutch cover
and disc.
SCL261
• Tighten clutch cover fixing bolts.

Bolt • Tighten bolts in crisscross order as shown in illustration, in
two steps.
Tightening torque:
First step
D240K, D260K and D275K
20 N.m (2.0 kg-m, 14 ft-Ib)
D300K
34 N.m (3.5 kg-m, 25 ft-Ib)
Final step
SCL447 D240K, D260K and D275K
22 - 29 N.m (2.2 - 3.0 kg-m, 16 - 22 ft-Ib)
D300K
37 - 47 N.m (3.8 - 4.8 kg-m, 27 - 35 ft-Ib)
SCL542
CL-14
F23 H41
Applied model 1.5 Ton 2 Ton 2.75 Ton 3 Ton
NA20S TD25
I TD27 BD30 FD42 FD46
Clutch control system
Type of clutch control Hydraulic
Clutch master cylinder
Inner diameter mm (in) 15.87 (5/8)
Clutch operating cylinder
Type Non-adjustable
Inner diameter mm (in) 17.46 (11/16) 19.05 (3/4)
Clutch booster
Type - *M45
Diaphragm diameter mm (in) - 114.3 (4.50)
Clutch disc
Type 240TBL 260TBL 275TBL 300TBL
Facing size mm (in)
Outer diameter 240 (9.45) 260 (10.24) 275 (10.83) 300 (11.81)
Inner diameter 150 (5.91) 160 (6.30) 160 (6.30) 180 (7.09) 190 (7.48)
Thickness 3.5 (0.138) 3.5 (0.138) 3.5 (0.138) 4.0 (0.157)
Thickness of disc assembly
7.8 - 8.2 8.0 - 8.4 7.8 - 8.2

Installed (0.307 - 7.8 - 8.2 (0.307 - 0.323)1 (0.315 - (0.307 - 9.0 - 9.4 (0.354 - 0.370)1
mm (in)/N (kg, Ib) 0.323)/4,904 3,923 (400, 882) 0.331)/4,904 0.323)/5,394 5,884 (600, 1,323)
(500, 1,103) (500, 1,103) (550, 1,213)
Clutch cover
Type D240K D260K D275K D300K
4,511 (460,
Full-load N (kg, Ib) 3,923 (400, 882) 5,884 (600, 1,323)
1,014)
* option
CLUTCH PEDAL CLUTCH DISC
Pedal height "H*" 172 - 177 (6.77 - 6.97) Model 240TBL 260TBL 275TBL 300TBL
Pedal free play Wear limit of facing

0.3 (0.012)
surface to rivet head
Backlash at clevis 1.0 - 2.0 (0.039 - 0.079)
Runout limit of facing 0.7 (0.028) 1.3 (0.051)
At center of pedal pad "A"
Distance of run out
F23 model 7 - 18 (0.28 - 0.71) 115 125 132.5 145
check point (from
(4.53) (4.92) (5.22) (5.71)
H41 model 12 - 21 (0.47 - 0,83) the hub center)
*: Measured from surface of melt sheet to pedal pad Maximum backlash

1.1 1.2
of spline (at outer 1.0 (0.039)
(0.043) (0.047)
edge of disc)
CL-15
CLUTCH COVER CLUTCH BOOSTER
Model D240K D260K D275K D300K Output rod length "A" 1.3 - 1.6 (0.051 - 0.063)
Diaphragm 37.5 - 39.5 Input rod length "8" 121 - 127 (4.76 - 5.00)
41 - 43 44 - 46 44.46
spring (1.476 -
(1.61 - 1.69) (1.73 - 1.81) (1.73 - 1.81)
height 1.555)
Uneven
limit of dia-
phragm 0.7 (0.028) 1.0 (0.039)
spring toe
height
CL-16
MANUAL TRANSMISSION
SECTIONMT
CONTENTS
PREPARATION MT - 2
ON-VEHICLE SERVICE MT- 8
REMOVAL AND INSTALLATION MT-10
GEAR CONTROL MT-11
~ I Model RS5W71C ~I ~
MAJOR OVERHAUL MT-14
DISASSEM BL Y MT -17
INSPECTIO N MT -20
ASSEMBLY MT-22
~-----------_I Model RS5W81A ~I ~

DISASSEM BL Y MT -33
REPAI R FOR COM PONENT PARTS MT -38
ASSE M BL Y MT -44
I I Model RS5R50A I I
DISASSEM BL Y MT-51
REPAI R FOR COM PONENT PARTS MT-55
ASSE M B LY MT -71
SERVICE DATA AND SPECIFICATIONS (S.O.S.) MT-76

PREPARATION I RS5W71C I
Special Service Tools - For RS5W71C
Tool number Description

Tool name
ST2381 0001 Fixing adapter plate with gear assembly
Adapter setting plate
KV321 01330 Removing overdrive mainshaft bearing

Puller
KV31100401 Pressing counter gear and mainshaft

Transmission press stand
ST22520000 Tightening mainshaft lock nut

Wrench
ST23540000* Removing and installing fork rod retaining pin

Pin punch
ST30031 000* Removing 1st gear bushing

Puller Removing main drive gear bearing
ST23860000* Installing counter drive gear

Drift
a: 38 mm (1.50 In) dla.

b: 33 mm (1.30 In) dla.
ST22360002* Installing counter gear front and rear end bear-

Drift ings
a: 29 mm (1.14 In) dla.

b: 23 mm (0.91 in) dla.
MT-2
PREPARATION I RS5W71C I
Special Service Tools - For RS5W71 C (Cont'd)
': 8pecial tools or commercial equivalent
Tool name
8T22350000' Installing 0.0. gear bushing

Drift
a: 34 mm (1.34 In) dla.

b: 28 mm (1.10 in) dla.
~
8T23800000' Installing front cover oil seal

Drift
a: 44 mm (1.73 in) dia.

~ b: 31 mm (1.22 In) dia.
8T33400001' Installing rear oil seal

Drift
a: 60 mm (2.36 in) dia.

b: 47 mm (1.85 in) dia.
8T30720000' Installing mainshaft ball bearing

Drift
a: 77 mm (3.03 in) dia.

b: 55.5 mm (2.185 In) dia.
8T30613000' Installing main drive gear bearing

Drift
a: 71.5 mm (2.815 in) dia.

b: 47.5 mm (1.870 In) dla.
8T33200000' Installing counter gear bearing

Drift Installing 3rd & 4th synchronizer assembly
a: 60 mm (2.36 In) dia.

b: 44.5 mm (1.752 In) dla.
Commercial Service Tool - For RSSW71C

Puller Removing counter bearings. counter drive

and 0.0. gears
MT-3
PREPARATION I RS5W81A I
Special Service Tools - For RS5W81 A
': 8pecial tools or commercial equivalent

Tool name
8T22530000' Installing mainshaft bearing
Adapter
KV32101100' Removing and installing retaining pin for shift

Pin punch fork rod
8T30031 000' Removing counter gear front bearing

Puller
8T22360002' Installing counter gear rear end bearing

Drift
a: 29 mm (1.14 In) dla.

b: 23 mm (0.91 In) dia.
8T22452000' Installing mainshaft bearing
Drift
a: 45 mm (1.77 In) dla.

b: 36 mm (1.42 in) dla.
8T30600000' Installing front cover oil seal
Drift
a: 36 mm (1.42 In) dla.

b: 31 mm (1.22 In) dla.
8T30720000' Installing rear oil seal
Drift
a: 60 mm (2.36 In) dla.

b: 44.5 mm (1.752 In) dia.
Commercial Service Tool - For RS5W81 A

Bearing stopper Removing mainshaft rear end bearing
T:
iil 50 (1.97)
: 60 (2.36)
il ::10LI
70 (2.76) 11--110 (4.33)='-1
183 (7.20) 10 (0.39) Unit: mm (in)
MT-4
PREPARATION I RSSRSOA I
Special Service Tools - For RS5R50A
Tool name
____ a _____
KV321022S1* Removing D.D. gear bushing
Bushing hook set Removing 3rd gear bushing
(i) KV32102211* Removing high gear bushing
Bushing hook
@ KV32102221*
Spacer
@ KV32102240*
Spacer
@ KV32102231*
Bolt (M12)
@ KV32102250* a: 75 (2.95) dia. a: 55 (2.17) dia. a: 55 (2.17) dla.
b: 59 (2.32) dia. b: 42.2 (1.661) dia. b: 40.2 (1.583) dia.
Bolt (M8) c: 15 (0.59) Unit: mm (in)
KV32102400* Installing D.D. gear bushing

Counter gear stopper
49 (1.93)
40 (1.57)
15 (0.59) Unit: mm (in)
KV32102501* Installing mainshaft bearing

Mainshaft stopper Installing D.D. main gear
Installing mainshaft rear end bear-
ing
Unit: mm (in)
KV32101100* Removing and installing retaining

Pin punch pins to striking lever, reverse shift
fork and reverse fork rod bracket
KV31100300* Removing and installing retaining

Pin punch pin for reverse check assembly
ST25420001* Installing sub-gear components

Clutch spring compressor
MT-5
PREPARATION I RS5R50A I
Special Service Tools - For RS5R50A (Conl'd)
Tool name
ST30031000* Removing 0.0. main gear
Puller Removing main drive gear bearing
ST30613000* Installing main drive gear bearing

Drift Installing 0.0. synchronizer cone
a: 71.5 mm (2.815 In) dia.

b: 47.5 mm (1.870 In) dia.
ST33200000* Installing 3rd gear bushing

Drift Installing 3rd & 4th synchronizer
assembly
Installing counter gear front bearing
Installing counter gear rear bearing
(Use with KV40100630)
a: 60 mm (2.36 In) dla.
b: 44.5 mm (1.752 In ) dia.
KV40100630* Installing counter gear rear bearing
Drift (Use with ST33200000)
a: 67.5 mm (2.657 In) dia.

b: 44 mm (1.73 In) dla.
c: 38.5 mm (1.516 in) dla.
ST33210001* Installing front cover oil seal
Drift
a: 44 mm (1.73 in) dla.

b: 24.5 mm (0.965 In) dia.
ST22452000* Installing 0.0. gear bushing

Drift Installing 0.0. main gear
Installing mainshaft rear end bear-
ing
a: 45 mm (1.77 In) dia.

b: 36 mm (1.42 In) dia.
ST30720000* Installing rear oil seal
Drift
a: 77 mm (3.03 in) dla.

b: 55.5 mm (2.185 In) dia.
MT-6
PREPARATION I RS5R50A I
Commercial Service Tools - For RS5R50A
Puller Removing companion flange
Removing mainshaft rear end bearing
Removing 0.0. synchronizer assembly
Removing 0.0. gear bushing
Removing 0.0. main gear
Removing mainshaft bearing
Removing reverse synchronizer hub
Removing 3rd & 4th synchronizer hub
Removing 3rd gear bushing
Drift Installing reverse synchronizer hub
Installing 1st & 2nd synchronizer hub
Installing mainshaft bearing
a: 48.6 mm (1.913 in) dla.

b: 41.6 mm (1.638 In) dla.
e: 410 mm (16.14 In)
MT-7
ON-VEHICLE SERVICE
Replacing Rear Oil Seal

REMOVAL - RS5W71 C
1. Pull out propeller shaft. - Refer to section PD.
2. Remove oil seal.
INSTALLATION
1. Install oil seal.
• Before installing, apply multi-purpose grease to seal tip.
2. Install propeller shaft. - Refer to section PD.
SMT463C
REMOVAL - RS5W81A
I 1. Pull out propeller shaft. - Refer to section PD.
2. Pull out companion flange.
(
SMT331C
INSTALLATION
1. Install rear oil seal.
• Before installing apply multi-purpose grease to seal lip.
2. Install companion flange.
3. Tighten nut to the specified torque.
SMT016C
REMOVAL - RS5R50A
1. ReJTlovepropeller shaft. - Refer to section PD.
2. RemOvecenter brake drum.
3. Remove mainshaft nut.
SMT998A
MT-8
ON~VEHICLE SERVICE
Replacing Rear Oil Seal (Cont'd)
5. Remove center brake assembly.
SMTOO1B
INSTAllATION
1. Install rear oil seal.
Before installing apply multi-purpose grease to seal lip.
SMT016C
2. Install center brake assembly.

4. Tighten nut to the specified torque.
5. Install center brake drum.
SMT017C
MT~9
Removal
• Remove shift cable and select cable .

• Remove speedometer cable .
• Remove center brake cable. - Refer to section SA.
• Remove starter motor .
• Remove exhaust front tube. - Refer to section FE (only for
H41 model)
• Remove clutch operating cylinder .
• Remove propeller shaft. - Refer to section PD.
SMT332C
• Remove torsion bar spring. - Refer to section FA (Only for
F23 model).
• Support manual transmission with a jack .
• Remove rear mounting bracket.
• Remove transmission fixing bolts .
• Remove transmission from engine .
• Support manual transmission with jack while removing it.
Installation
@ M/T to enigne
o Engine to M/T • NA20S engine model
Tightening torque
Bolt No. C mm (in)
N'm (kg-m, ft-Ib)
39 - 49 (4.0 - 5.0, 29 - 36) 60 (2.36)
2 39 - 49 (4.0 - 5.0, 29 - 36) 65 (2.56)
3* 18 - 22 (1.8 - 2.2, 13 - 16) 25 (0.98)
4 29 - 39 (3.0 - 4.0, 22 - 29) 35 (1.38)

SMT333C
*: With nut
• T025, T027 and 8030 engine models
Tightening torque
Bolt No. t mm (in)
N'm (kg-m, ft-Ib)
1* 39 - 49 (4.0 - 5.0,29 - 36) 110 (4.33)
2 39 - 49 (4.0 - 5.0, 29 - 36) 60 (2.36)
CD 3 25 - 34 (2.6 - 3.5, 19 - 25) 110 (4.33)
<:> M/T to engine 4 18 - 22 (1.8 - 2.2, 13 - 16) 20 (0.79)

Engine (gusset) *; With nut
8 to M/T
• F042, F046 engine models

Tightening torque
Bolt No. t mm (in)
N'm (kg-m, ft-Ib)
77 - 98 (7.9 - 10, 57 - 72) 65 (2.56)
MT-10
GEAR CONTROL
F23-RS5W71 C Select lever

KnOb
tr toJ 13 • 16
(1.3 - 1.6,
V
Boot
9 - 12)
.. Select cable assembly
I Control device
rnI 25 _ 31
.-. (2.5012. "023)\.
Lock plate
toJ 25 - 30
(2.5 - 3.1,
18 • 22)
Z,o" (1.3 - 1.6,

9 - 12)
toJ 25 - 30
(2.5 - 3.1,
18 - 22)
SMT335C
F23-RS5W81A
~25.31 1
(2.5 - 3.2,
18 - 23)
'",,--
Select cable assembly
~ 13.16
(1.3 - 1.6,
9 - 12)
toJ . N.m (kg-m, ft-Ib)

SMT336C
MT-11
GEAR CONTROL
H41-RS5W81A, RS5R50A
~ 25 - 31 (2.5 - 3. ,.
Boot
~
\
rU oot
S; I ~
(~
.
BraCket
r
Retainer
Return spring
Boot
r
Control device ~25 - 31 ~ .
18 • 231
(2.5 - 3.2, 18 - 23)
-~
~ , ,
~(~ ..
'-~62 - 78
(6.3 - 8.0,
~~~ 46 - 58)
l!:
Cross shaft assembly
~ 25 - 31 '",-
~_~ (2.5 - 3.2, 18 - 23)
jdw ..,.., ~25-31 '-,
~ 25 - 31 (2.5 - 3.2, 18 - 23) ~
(2.5 - 3.2, Shift cable assembly ~
18 - 23) ,
Select cable assembly

--------
RS5W81A
A: N.m (kg-m, ft-lb)

SMT337C
Shift Cable Adjustment

RS5W71 C, RS5W81 A and RS5R50A:
Ensure select cable is connected to control device when adjust-
ing shift cable.
1. Separate control device and shift cable.
2. Insert 3 mm (0.12 in) dia. pin into hole on control device
stopper and align device knob with Neutral position.
3. Align cross-shaft (on transmission side) with Neutral posi-

tion.
~Front
1, 3, and 5 2, 4, and reverse

speed positions positions
Neutral position
SMT339C
MT-12
GEAR CONTROL
Shift Cable Adjustment (Cont'd)
4. Adjust shift cable (length) so that control device is aligned
with shift cable ball joint.
Shift cable
SMT340C
RS5W71C Select Cable Adjustment

Neutral position The "Neutral" position refers to the position in which the con-
trol lever is held upright by tension of the control device's
select return spring.
Ensure shift cable Is connected to control device when adjust-
ing select cable.
1. Separate control device and select cable.
!1 and
2. Ensure control lever is set to "Neutral".
2-speed
position 3. Align select lever (on transmission side) with "Neutral".
SMT341C
4. Adjust select cable (length) so that control device is aligned

with select cable ball joint.
Select cable
SMT342C
MT-13
MAJOR OVERHAUL I RS5W71C I
Case Components
'"
C'i
.,;
11)'
d ...
N
,'<I' o
ll:I'e. C'i
~
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.
en C7! •
......
- ...
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-0
r::
Ol
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rl g.
r::
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~
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, ::::
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r:: ~o
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~ al
.~
r::
~ ...
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I-
..:
C'ilf)
~=a
• .0
SMT197C
MT-14
MAJOR OVERHAUL I RS5W71C I
Gear Components
Spread spring n
Snap ring
Main drive gear
*~~ ~ Mainshaft ball bearing
so'P'::~~~b~
ball bearing
:J "-- 'cd & 4th '" mo'o g."l D~

. ~~{I j
Main drive gear
synchronizer
spri,ng insert~
1 ~~
N
Needle bearing
Baulk nng~~~ ~Baulk ring
2nd main gear ~

~ '5,
/' Malnshaft 0
Snap ring
d'
* ~~
Steel ball ~ ~ lock nut ~ m:~~s~I~~ bearing
Steel roller Dh~.

(2WD mOd~l)m
(y
~ qf3J
Washer
~g:.~
With~~t
*
_1~~.0, Snap ring
T~~~)
~
~~fj~
I~ ~
I
Steel ball 0 ~::;~~V:hin~ ~ ~

~ ~ ~ S~eedometer
~ ~~ dnve gear
0.0. (5th) main gear~ ~ 0 ~ "~ Thrust washer
Baulk nng ~" ~ ~ Roller bearing
. -/
-/ Reverse main gear \
1fi!!!!f!JJ~ 3Y3
~
Countershaft
rear end bearing
~~~~;ginsert~
insert spring
0.0. (5th) synchronizer
~
~~
~ 'Y Reverse counter gear
:-\
~~~
MJ
~,h'b * --;;;~ ''''N' "'""'" g~ -~<rfll
JS) ~ ~
L
Apply gear 011to gears, shafts,
• I
Insert retainer
Woodruff key~
"1e
\
~Q
Cou~ter rear
beanng
. ~~
(;r:>~
Overdrive counter gear
(10.0 _ 13.0, 72 - 94)
Snap ring ~
synchronizers, and bearings when assembling.
* : Select with proper thickness.
~
~ \ L ~~ ~
Reverse idler
* : Pay attention to its direction.
Snap ring
~
* ~--.....
~.
~
~~
~~
\
({)
-Counter
drive gear
~
Counter gear
* \
~~L
L \L
~ ~ thrus.t washer
Reverse Idler gear beanng
Reverse idler gear

,
~~~r~~~r front
Shim * --n~
~
~~ \ \ SUb-gear
Sub-gear spring *
:'l .
Snap nng ~
Reverse idler shaft
Reverse idler thrust washer
Sub-gear bracket
SMT346C
MT-15
MAJOR OVERHAUL I RSSW71C I
Shift Control Components
g
.0
c:
"a
Cl
c:
Cl
:l
a.
~-- 'iij "C
.0
.lo<
'"
l!!
.s ~
0
Gl
.E
.c :;:;
U .c
<Il
"C
...
0 .c
~
c:
"a ~ o!l
.E
Cl .c
c:
~ ~
:~ o!l
'i
a: ~
SMT021C
MT-16
DISASSEMBL Y I RS5W71C I
Case Components
1. Remove rear extension.
2. Remove front cover, gasket, shim of countershaft front
bearing, and snap ring of main drive gear ball bearing.
SMTOll
3. Separate transmission case from adapter plate.
TM753
4. Remove front cover oil seal.

Be careful not to damage front cover mating surface.

1. Set up Tool on adapter plate.
2. Remove striking rod from adapter plate.
3. Remove check ball plugs, check springs, and check balls.
SMT454C
4. Drive out retaining pins. Then drive out fork rods and
remove interlock balls.
MT ..17
DISASSEMBL Y I RS5W71C I
EndPlaY Gear Components
Gear
1. Before disassembly, measure each gear end play.
• If end play is not within the specified limit, disassemble and
check parts.
~M.;,.....", . • Replace any part which is worn or damaged.
bushing Gear end play: Refer to S.O.S.
2. Mesh 2nd and reverse gear, then draw out counter front
bearing with suitable puller.
3. Remove snap ring and then remove sub-gear bracket, sub-
gear spring and sub-gear.
SMT174A
4. Draw out counter drive gear with main drive gear assem-
bly with suitable puller.
• When drawing out main drive gear assembly, be careful not
to drop pilot bearing and baulk ring.
5. Remove snap ring and draw out 3rd & 4th synchronizer and
3rd gear.
6. Disassemble parts at rear of adapter plate as follows:

a. Release staking on countershaft nut and mainshaft nut and
loosen these nuts.
Mainshaft nut: Left-hand thread
SMT546A
b. Pull out 0.0. counter gear and bearing with suitable puller.
c. Draw out reverse counter gear and spacer.
d. Remove snap rings from reverse idle shaft, and draw out
reverse idle gear, thrust washers and reverse idler gear
bearing.
SMT547A
MT-18
DISASSEMBLY I RS5W71C I
Gear Components (Cont'd)
e. Remove snap ring and pullout overdrive mainshaft
bearing, then remove snap ring.
f. Remove mainshaft nut.
g. Remove speedometer drive gear and steel ball.
h. Remove thrust washer, steel roller, roller bearing and
washer.
i. Remove 0.0. main gear, needle bearing and baulk ring
(0.0.).
j. Remove 0.0. coupling sleeve, shift inserts and shifting
insert springs.
SMT456C k. Remove counter gear by tapping rear end of counter gear.
I. Press out 0.0. gear bushing, insert retainer and 0.0. syn-
chronizer hub.
Press
SMT514C
7. Remove thrust washer, steel ball, 1st main gear and nee-
dle bearing.
Be careful not to lose steel ball.
SMT383A
8. Press out 1st gear mainshaft bushing together with 2nd

main gear with Tool.
Then remove 2nd gear needle bearing.
9. Remove main drive gear bearing.

a. Remove snap ring and washer.
b. Remove main drive gear bearing.
MT-19
INSPECTION I RS5W71C I
• Check contact surface and sliding surface of fork rods for
wear, scratches, projections or other damage.
*
* *
~
SMT075C
Mainshaft and gear Gear Components

GEARS AND SHAFTS
• Check shafts for cracks, wear or bending.
• Check gears for excessive wear, chips or cracks.
SMT550A
Shifting insert SYNCHRONIZERS

• Check spline portion of coupling sleeves, hubs and gears
for wear or cracks.
• Check baulk rings for cracks or deformation.
• Check shifting inserts for wear or deformation.
• Check insert springs for deformation.
SMT427C
MT-20
INSPECTION I RS5W71 C I
Baulk ring to • Measure wear ofbaulk rings.
gear clearance a. Measure clearance between baulk ring and gear.
Clearance between baulk ring and gear:
Refer to S.O.S.
If the clearance is smaller than the wear limit, replace baulk
ring.
SMT140
BEARINGS
• Make sure bearings roll freely and are free from noise,
crack, pitting or wear.
MT-21
ASSEMBLY I RS5W71C I
Mainshaft ball bearing in adapter plate Gear Components
1. Install bearings into case components.
Counter rear bearing in adapter plate
SMT205C
2. Assemble adapter plate parts.

• Install oil gutter on adapter plate and bend out on rear side.
Upper
l}
Q
Front
• Install bearing retainer.

a. Insert reverse shaft, then install bearing retainer.
b. Tighten each screw, then stake each at two points.
SMT053C
MT-22
ASSEMBLY I RS5W71C ,
Gear Components (Conl'd)

3. Install main drive gear bearing.
a. Press main drive gear bearing.
b. Install main drive gear spacer.
c. Select proper main drive gear snap ring to minimize clear-

ance of groove and install it.
Allowable clearance of groove:
0- 0.13 mm (O - 0.0051 in)
Main drive gear snap ring:
Refer to S.O.S.
4. Assemble synchronizers.
• 1st & 2nd synchronizer
SMT054C
• 3rd & 4th synchronizer

J Shifting insert
\
\
Coupling
sleeve
Spread spring
Synchronizer hub
SMT055C
• 0.0. synchronizer
Q L Reverse main gear

Front a
0.0. (5th) synchronizer ~
hub ta:P SMT095A
MT-23
5. Install front side components on mainshaft.
a. Assemble 2nd main gear, needle bearing and 1st & 2nd
synchronizer assembly, then press 1st gear bushing on
mainshaft.
b. Install 1st main gear.
\
1st gear
thrust washer
\
SMT518C
c. Install steel ball and 1st gear washer.

Apply multi-purpose grease to steel ball and 1st gear washer
before Installing.
SMT403A
6. Install mainshaft and counter gear on adapter plate and

main drive gear on mainshaft.
a. Press mainshaft assembly to adapter plate with Tool.
KV31100401
SMT519C
b. Press counter gear into adapter plate with Tool.
SMT520C
c. Install 3rd main gear and then press 3rd & 4th synchronizer
assembly.
Press
• Pay attention to direction of 3rd & 4th synchronizer.
SMT521C
MT-24
d. Install thrust washer on mainshaft and secure it with main-
shaft front snap ring.
Select proper snap ring to minimize clearance of groove in
mainshaft.
0- 0.18 mm (0 • 0.0071 in)
Mainshaft front snap ring:
Refer to S.O.S.
e. Apply gear oil to mainshaft pilot bearing and install it on
mainshaft.
TM441
f. Press counter drive gear with main drive gear with Tool.
Press
ST23860000
KV31100401
SMT522C
• Pay attention to direction of counter drive gear.
SMT620A
g, Install sub-gear components.

(1) Install sub-gear and sub-gear bracket on counter drive gear
and then select proper snap ring to minimize clearance of
groOve In counter gear.
Allowable .clearance of groove:
o . 0.18 mm (0 • 0.0071 in)
Counter drive gear snap ring:
Refer to S.O.S.
LSUb~ear
L Sub-gear spring
Sub-gear bracket
SMT528A
(2) Remove sn~p. ring, sub-gear bracket and sub-gear from
counter gear.
(3) Reinstall sub-gear, sub-gear spring and sub-gear bracket.
h. Install selected counter drive gear snap ring.
TM366
MT-25
i. Press counter gear front bearing onto counter gear.
ST22360002
KV31100401
SMT523C
7. Install rear side components on mainshaft and counter

gear.
a. Install reverse idler gear to reverse idler shaft with
spacers, snap rings and needle bearing.
Front
b. Install insert retainer and 0.0. synchronizer to mainshaft.

• Pay attention to direction of hub.
&(11l/})
Q
Front
~
0.0. (5th) synchronizer ~
hub ~ SMT095A
c. Install 0.0. gear bushing with Tool.

d. Install 0.0. main gear and needle bearing.
e. Install spacer, reverse counter gear and 0.0. counter gear.
• 0.0. main gear and 0.0. counter gear should be handled
as a matched set.
f. Install washer, roller bearing, steel roller and thrust
washer.
g. Tighten mainshaft lock nut temporarily.
• Always use new lock nut.
h. Install countershaft rear end bearing with Tool.
SMT212C
MT-26
ASSEMBLY I RSSW71C I
8. Mesh 2nd and reverse gears, then tighten mainshaft lock
nut with Tool.
SMT213C
c • Use the left chart when deciding the reading torque.

(Length of torque wrench vs. setting or reading torque)
9. Tighten countershaft lock nut.
• Always use new lock nut.
L m (ft)
0.10 m
(0.33 h) N'm
(kg-m)
(h-Ibl 157
(16)
(110)
147
CIl (15)
I"!
o
;, (100)
c:
~CIl
a:
(,) (90)
(80) 108
(11)0.4 0.6 0.7 0.8
, I Im
(1.5) (2.0) (2.5) (h)
L: Length of torque wrench
SMTOO4A
Mainshaft 10. Stake mainshaft lock nut and countershaft lock nut with a
punch.
11. Measure gear end play. For the description, refer to DIS-
ASSEMBLY for Gear Components.

Fork rod
(1st & 2nd)
1. Install shift rods, interlock plunger, interlock balls and
check balls.
Fork rod
(3rd & 4th)
Interlock plunger
Interlock
Check ball ball
SMT992
MT-27
Shift Control Components (Cont'd)
a. 1st-2nd shift fork
SMT969
b. 3rd-4th shift fork
c.O.D.-reverse shift fork or reverse shift fork.
SMT991
Case Components
1. Install front cover oil seal.
• Apply multi-purpose grease to seal lip.
SMT236C
2. Apply sealant to mating surface of transmission case.
SMT061C
MT-28
Case Components (Cont'd)
3. Slide gear assembly onto adapter plate by lightly tapping
with a soft hammer.
4. Install main drive bearing snap ring.
5. Apply sealant to mating surface of adapter plate.
SMT062C
Striking rod
6. Set shift forks in neutral position.
7. Install striking lever onto adapter plate and align striking
lever with shift brackets.
Shift bracket
8. Install rear extension.
9. Fit main drive bearing snap ring.
SMT8018
A: Distance from bearing

10. Select counter front bearing shim.
surface to transmission Counter front bearing shims:
case Refer to S.O.S.
11. Install gasket.and front cover.
1 Transmission case
2 Counter gear front bearing
3 Counter gear
TM371
MT-29
MAJOR OVERHAUL I RS5W81A I
Case Components
~
{50" ~.;og bon t:. { 1
19 - 21 (1.9 - 2.1, 14 - 15)
Gear shift
housing assembly
Gear shift housing

gasket ~
Filler plug 0
~ 25 - 34 (2.5 - 3.5, 18 - 25) ~

rJ Thread of plug ~
Front cover oil seal ~

mSeallip
Front cover gasket ~
Drain plug
~25 - 34
(2.5 - 3.5, 18 - 25)
~ Thread of plug
PT.a. cover
\ gasket ~
PT.a. cover
--Y:
~
r-
19 - 21 (1.9 - 2.1, 14 - 15)
(Self sealing bOlt~)
%~
'54072{M-7.3.40~
_ ___________-
___________
eM'h hO",;09~__
2'32 4' 0
- (3.3 - 4.3,
24 - 31)
0.0. gear case gasket ~ ~ 16 - 21

(1.6 -2.1, 12 - 15) rJ : Apply recommended sealant (Nissan Genuine
Bearing retainer part: KP610-00250) or equivalent.
SMT348C
MT-30
Gear Components
Needle bearing~
3" m,lo 9'M\ ~

Mainshaft spacer
Main drive gear ball bearing
Snap ring
~ '" N"'dI, b'M;", b",h;"\ ~\J
~l. sn~p nng
Pilot beanng
*
Shifting insert
Synchronizer ~ r'\'!;
IJ~ ~
1st main ge~
/'
~
Baulk ring~~_-«l
""
\ t\... ~ 196 - 392 N.m Cotter pin ~
(20 - 40 kg-m, ~
2nd main gear~ ~~ Spread spring 145 - 289 ft-Ib)
Needle bearing ~~ Washer
Oil seal ~
Mainshaft end bearing
o Mainshaft spacer
0-- Steel ball
Snap nng ~ ./ 0 (3 Synchronizer .
L 0 Spread spring {j3
Mainshaft ~ Coupling sleeve .. ~
Needle bearing~~ Reverse idler ~
Apply gear oil to gears, shafts,

0.0. (5th)
synchronizers, and bearings when assembling.

. .
""m,, b",h;"'~
Counter rear beanng~\?sy[J
~
~
~~
Jt$@~ ~ ,....
\
.
\
lSl"""'. @_ront
Reverse idler
thrust washer
• Se"" ~th p"p" th"k .. ". ~~ l N"'" b'M;",
~~ ~ Reverse idler gear B
lSl ~ Needle bearing
.. ~ Reverse idler gear A
Reverse idler thrust washer
~ Snap ring *
SMT349C
MT-31
~18 - 25
,,/ (1.8 - 2.6,
Gear shift housing V 13 - 19)
~GaSket~
~
- 0
@
i
Shift Pin\ ~)\
~ ~
Shift shaft n :
Shift lever
/~ ~ ~~
'(()
Oil seal
Select shaft
0
~8.8 - 11.8
. (0.90 - 1.2,
\6.5 - 8.7)
~~
Lever Pin~ () 0
Select lever
~. J;R~'" 'hift lock b~hi",

.., '-M, \ •
.. .\~~- O"~ 00'"
Retaining pin ~
'" _ \ ~rJ78 - 98, .. - 10,5& -72)
0.0. 15th)-R~,re 'hift I~ . \ ~ Snap ring
Reverse shift fork
~ Retaining pin ~
Check ball
/Check plug
#11
~16 - 22 (1.6 - 2.2, 12 - 16)
1st-2nd shift fork

Check spring
1st-2nd fork rod
~ Retaining pin
-b~'-""'
3rd-4th shift fork ~ D.O. (Slh( 'hift lo,k
Pin
0.0. (5th) shift fork

3rd-4th fork rod 0.0. (5th) fork shaft
SMT350C
MT-32
DISASSEMBLY I RS5W81A I
Case Components
1. Remove transmission outer parts.
2. Remove shift control components, clutch housing and
p.T.a. cover.
SMT351C
3. Remove mainshaft nut.

SMT352C
CD Check ball plug ~ 16 - 22 N.m Shift Control Components

@ Check spring (1.6 - 2.2 kg-m,
@ Check ball 12 - 16 ft-Ib) 1. Remove check ball plug, then the check balls.
1st-2nd shift rod 2. Using Tool, remove retaining pins from 1st-2ndand 3rd-4th
Interlock plunger Transmission case shift fork rods and a.D.-reverse shift rod, then remove shift
forks.
3. Remove 1st-2nd, 3rd-4th and a.D.-reverse shift rods, then
remove shift forks.
O.D.-reverse
shift rod Ensure shift rods are set to "Neutral" before removal;
Interlock pin 4. Remove interlock plunger, pin and lock ball.
Interlock ball
3rd-4th shift rod Be careful not to lose check balls, interlock plunger and inter-
lock balls.
/"
KV32101100
SMT353C
MT-33
5. Remove E-ring from clevis pin and remove 0.0. shift fork.
6. Remove reverse shift fork shaft lock nut, then remove

reverse shift fork and fork shaft.
Gear Components
1. Before disassembling gear components, measure end play
and backlash of each gear.
• If end play or backlash exceeds specifications, disassem-
ble and check related parts.
Specifications: Refer to S.O.S.
2. Remove front cover and gasket.

3. Remove snap ring from rear of counter gear and remove
0.0. synchronizer assembly, 0.0. shift fork and 0.0.
counter gear as a unit.
4. Using a puller, remove mainshaft rear end bearing.
SMT359C
0.0.
synchronizer
assembly
Snap ring
SMT360C
MT-34
DISASSEMBL V I RS5W81A I
Gear Components {Cont'd}
5. Remove 0.0. fork shaft and bracket.

6. Remove bearing retainer.
0.0. fork shaft and bracket are tightened together with bearing
retainer.
SMT362C
7. Remove spacer and 0.0. main gear.

If 0.0. main gear is hard to remove, use a puller.
8. Remove snap ring from rear end of reverse idler shaft.
9. Remove reverse idler shaft.

• Remove reverse idler gears (main and counter), needle
bearings and thrust washers.
MT.35
10. Attach Tool to front end of counter gear and hammer it to
drive counter gear rear bearing out of transmission case.
11. Leave removed counter gear inside transmission case.
Work with gear notch facing down.
SMT366C
12. Remove main drive gear from transmission case.
13. Remove attachment and hammer front end of mainshaft so

that a thin iron plate (used as a pad) can be placed between
mainshaft bearing and transmission case. Remove main-
shaft bearing.
SMT368C
14. Remove retainer from mainshaft bearing.
SMT369C
MT-36
DISASSEMBLY I RSSW81A I
15. Prepare an attachment as shown in figure at left and attach
it to transmission case. Hammer rear end of mainshaft until
clearance between mainshaft and counter gear at 2nd gear
is eliminated.
72 (2.76
183 (7.20)
28 (1.10)
10 (0.39)
I-
Unit: mm (in)
SMT370C
16. Remove mainshaft assembly from transmission case.
SMT371C
17. Attach a puller to counter gear rear bearing and drive out
\Counter rear bearing and 0.0. gear bushing as a unit.
gear 18. Remove counter gear.
fear bearing
\
0.0. gear bushing
SMT372C
MT-37
REPAIR FOR COMPONENT PARTS I RS5W81A I
Main Drive Gear
DISASSEMBLY
1. Remove main drive gear snap ring and spacer.
2. Press out main drive gear bearing.
INSPECTION
Gears and shafts
SMT459
Bearings
cracks, pitting or wear.
ASSEMBLY
1. Press main drive gear bearing.
ST30613000
2. Install main drive gear spacer.
SMT525C
3. Select proper main drive gear snap ring to minimize clear-

ance of groove.
o - 0.15 mm (0 - 0.0059 in)
Refer to S.O.S.
4. Install selected snap ring on main drive gear.
SMT426A
MT-38
Mainshaft and Gears
Press
DISASSEMBLY
1. Remove spacer and steel balls from mainShaft.
2. Using a press, remove 1st gear, needle bearing, bushing
and 1st-2nd synchronizer assembly as.a unit.
3. Remove 2nd gear and needle bearing.
SMT373C
4. Using snap rin.g pliers, remove 3rd-4th hub snap ring.
5. Using a press, remove 3rd-4th synchronizer assembly, 3rd

gear and needle bearing.
Appropriate drift
SMT375C
INSPECTION
Baulk ring clearance
Baulk ring • With baulk ring pushed against cone, measure clearance
between baulk ring and gear. If it is less than
specifications, replace with newbaulk ring.
Gear and shaft

SMT376C
• Check contacting surfaces of mainshaft, main drive gears,
counter gears, etc. for damage, flakes, abnormal wear,
dents, bends or damage, and replace as necessary.
SMT377C
MT-39
Mainshaft and Gears (Cont'd)
Counter gear
SMT378C
Synchronizer
g
Shifting insert
Inspection
1. Replace coupling sleeve, synchronizer hub and insert if
their contacting surfaces are broken, abnormally worn or
damaged.
2. Ensure coupling sleeve and synchronizer hub move
smoothly. If they do not, check and replace parts as neces-
sary.
SMT379C
3. Replace baulk ring if its cam surface is broken, abnormally

worn or damaged. Also check insert and replace if faulty.
~=={,==
SMT380C
ASSEMBLY
1. Install 1st-2nd synchronizer and 3rd-4th synchronizer
spread springs as shown in figure at left.
2. Ensure coupling sleeve and synchronizer hub move
smoothly. If they do not, check and replace faulty parts.
SMT381C
3. Install 3rd gear and needle bearing onto mainshaft.

4th gear side 3rd gear side 4. Align 3rd-4th synchronizer assembly as shown in figure at
left, and install onto mainshaft, then press into place.
Front
Machined surface
~
SMT382C
MT-40
SMT383C
5. Select and install suitable snap ring from those listed

below, so that 3rd-4th synchronizer hub end play at main-
shaft groove is within specifications.
SMT384C
6. Install 2nd gear and needle bearing onto mainshaft.

7. Using figure at left as a guide, install 1st-2ndsynchronizer
2nd gear side
assembly onto mainshaft, then press it and 1st gear as a
unit.
Front ~
SMT385C
SMT386C
8. Using a screwdriver, install 1st gear bushing, then install

1st gear needle bearing.
SMT387C
MT-41
9. Apply grease to steel ball and install it and spacer on main-
shaft as a unit.
SMT388C
Counter Gear Front Bearing

DISASSEMBLY
• Attach Tool to bearing inner race and remove bearing
ST30031000
using Drift.
SMT526C
ASSEMBLY
• Attach Tool to bearing inner race and press bearing into
place.
SMT390C
Case Components
FRONT COVER OIL SEAL
Removal
• Remove oil seal.
Installation
~press
• Apply multi-purpose grease to oil seal lip before installing.
MT-42
Shift Control
INSPECTION
1. Check contacting surfaces of shift rod and shift fork for
••••••
~-~~~
wear, bends or damage, and replace as necessary.
SMT356C
2. Check to ensure shift fork pawl widths (at coupling sleeve

frictional parts) are within specified limits.
Q
H At ;"p.ct;oo
When new
Wear on both sides I Wear on one side
SMT357C
MT-43
ASSEMBLY I RS5W81A I
Gear Components
1. Install reverse idler gears (main and counter), needle
bearings, thrust washers and reverse idler shaft in trans-
mission case as shown in figure at left, then select and
install suitable snap ring so that reverse idler gear (main)
end play is within specifications.
• Install thrust washer with oil sump (concave) side facing
Reverse idler the gear.
gear (main)
Needle bearing SMT393C
2. Install counter gear in transmission case.
SMT394C
3. Install mainshaft assembly in transmission case.
4. Install Tool to front side of transmission case to support

mainshaft.
5. Install main bearing onto mainshaft by lightly hammering

bearing inner race.
Ensure bearing outer race is properly installed in bore in trans-
mission case.
SMT397C
MT-44
6. Remove ST22530000(Mainshaft stopper) from front side of
transmission case.
7. Apply transmission fluid to pilot bearing and install on
mainshaft.
8. Press front bearing into bore in counter gear, then press

rear bearing and 0.0. gear bushing into place.
Ensure bearing outer race is properly installed in bore in trans-
0.0. gear bush
mission case.
SMT399C
9. Tighten bolts which secure bearing retainer, 0.0. fork shaft

and bracket to specifications.
Two lower retainer mounting bolts are flat-head types.
SMT400C
10. Install 0.0. gear and spacer on m(:ilnshaft.

11. Install bearing on the end of mainshaft by lightly hammer-
ing bearing inner race.
SMT401C
12. Install 0.0. counter gear and needle bearing on counter

gear bushing.
13. Attach shift fork to 0.0. synchronizer assembly and install
them onto counter gear bushing.
14. Select and install suitable snap ring so that 0.0. synchro-
nizer hub snap ring clearance is within specifica.tions.
0.0. synchronizer
assembly
SMT402C
MT-45
ASSEMBLY I RSSW81A I
15. Install front cover and gasket on transmission case, then
tighten mounting bolts to specifications.
~: 20 - 27 N.m (2.0 - 2.8 kg-m, 14 - 20 ft-Ib)
SMT403C
16. Shift forks and shift rods

a. Apply grease to reverse fork shoe, then install reverse fork
~lO~"~
on reverse idler gear while aligning it with groove on idler
gear.
b. Temporarily install reverse shift fork shaft by tightening
Reverse shift fork shaft lock nut.
SMT404C
c. Install a.D.-reverse shift fork and a.D.-reverse shift rod.

0.0. -reverse shift fork d. Install a.D. shift fork on a.D.-reverse shift rod, secure with
O.D.-reverse shift rod clevis pin and E-ring.
SMT405C
CD Check ball plug ~16 - 22 N.m

e. Install interlock pin and interlock ball in transmission case.
CV Check spring (1.6 - 2.2 kg-m, f. After installing 3rd-4th shift rod, install interlock plunger
CID Check ball 12 - 16 ft-Ib) and 1st-2nd shift rod in that order.
1st-2nd shift rod
Interlock plunger Ensure each gear is shifted to "Neutral" during installation.
g. Install both check ball and check spring and tighten check
ball plug to specified torque.
h. Using Tool, drive each shift fork retaining pin into place.
SMT353C
MT-46
Gear Components (Co nt' d)
Lock nut i. Adjust reverse shift fork shaft (previously installed) so that
~ 78 - 98 N.m dimension "i" is within specifications, then tighten lock nut
securely.
.....( ~~~°ft~:t Specifications ("i" dimension):
0.5 mm (0.020 in)
Q size
Reverse shift fork shaft
SMT407C
17. Install rear extension.
SMT408C
18. Install transmission outer parts.

a. Install center brake components.
b. Install companion flange.
c. Tighten companion flange nut to the specified torque.
SMT986A
d. Install p.T.a. cover and gasket.
e. Install gear shift housing assembly and gasket onto trans-

mission case.
Always use new bolts at position @ as they are self- seal-
ing bolts.
SMT976A
MT-47
MAJOR OVERHAUL I RS5R50A I
Case Components
- 21 (1.9 - 2.1,14 - 15) ~.@

~19
(Self sealing bolt ~ ) 1 Gear shift
housing assembly
,
Gear shift housing gasket ~
Filler plug
~ 25 - 34 (2.5 _ 3.5, 18 _ 25) a a
IEIP1ug thread ~ \
Front cove.r oil seal ~ 1
mSeal lip
Front cover gasket ~
Drain plug
~ 25-34
(2.5 - 3.5, 18 - 25)
~ Plug thread
P.T.O. cover gasket ~
~ 32 - 42 (3.3 • 4.3, 24 - 31)
Low & high switch

~ 20 - 29 (2.0 - 3.0, 14 - 22)
~ Switch thread
~ 57 - 72 (5.8 - 7.3, 42 - 53)

(Self sealing bolt ~ )
~ 16 - 21
(1.6 - 2.1, 12 - 15) ~ : Apply recommended sealant (Nissan Genuine
Bearing retainer part: KP610-00250j or equivalent.
SMT409C
MT-48
Gear Components
SMT410C
MT-49
Shift Contro I Components
...
~
u
Cl
c:
"iij
~
o
L:.
~
en
SMT074C
MT-50
DISASSEMBLY I RS5R50A I
Case Components
1. Remove transmission outer parts.
2. Remove shift control components, clutch housing and
p.T.a. cover.

4. Remove center brake components.
SMT847A
Gear Components
1. Pull out mainshaft rear end bearing.
2. Remove speedometer drive gear and steel ball.
SMT984A
3. Check 0.0. counter gear end play.

Gear end play:
Refer to S.O.S.
• If not within specification, disassemble and check contact
surface of gear to hub, washer, bushing, needle bearing
and shaft.
Feeler gauge
SMT982A
MT-51
4. Remove counter gear rear snap ring.
5. Pull out the following parts.

• 0.0. counter gear
• 0.0. synchronizer assembly with 0.0. shift fork and rod.
6. Pull out 0.0. gear bushing.

KV321022S1 7. Remove bolts securing bearing retainer and then remove
bearing retainer.
SMT840A
8. Pull out 0.0. main gear.
SMT856A
9. Remove mainshaft assembly, main drive gear assembly,

counter gear assembly and reverse idler gear components.
a. Remove mainshaft bearing snap ring.
b. Pullout mainshaft bearing.
SMT857A
MT-52
c. Support mainshaft with hoist.
d. Remove bolts securing front cover and then remove .front
cover.
e. Rernove counter gear front bearing outer race.

Tap rear end of counter gear lightly before removing bearing.
f. Remove counter gear rear bearing outer race.

Tap front end of counter gear lightly before removing bearing.
g. Put counter gear assembly on bottom of transmission case.
SMT859A
h. Remove main drive gear assembly.

Set cutting portion of clutch gear on main drive gear to upper
side.
SMT860A
i. Remove mainshaft assembly.
SMT861 A
MT-53
DISASSEMBL Y I RS5R50A I
Gear Components (Co nt' d)
j. Remove counter gear assembly.
SMT862A
k. Remove lock plate of reverse idler shaft and then remove

reverse idler gear, washers, needle bearings and shaft.
SMT863A
MT-54
REPAIR FOR COMPONENT PARTS I RS5R50A I
Main Drive Gear
DISASSEMBLY
1. Remove main drive gear snap ring and spaCE:}r.
2. Press out main drive gear bearing.
INSPECTION
Gears and shafts
SMT459
Bearings
ASSEMBLY
1. Press main drive gear bearing.
2. Install main drive gear spacer.
3. Select proper main drive gear snap ring to minimize clear-

ance of groove.
o ~0.15 mm (O - 0.0059 in)
Refer to S.O.S.
4. Install selected snap ring on main drive ge~r.
MT-55
1st, 2nd and reverse main gear Mainshaft and Gears
DISASSEMBL Y
1. Before disassembly, check 1st, 2nd, 3rd and reverse main
gear end play.
Gear end play: Refer to S.O.S.
• If not within specification, disassemble and check contact

surface of gear to hub, washer, bushing, needle bearing
and shaft.
2. Remove 3rd & 4th hub snap ring.

3. Pull out 3rd main gear together with 3rd & 4th synchronizer
assembly and 3rd gear needle bearing.
4. Pull out 3rd gear bushing.

5. Remove 2nd main gear and 2nd gear needle bearing.
Puller
KV32102211
+
KV32102231
SMT839A
6. Pull out reverse synchronizer hub.

7. Remove reverse main gear and reverse gear needle bear-
ing.
Puller
8. Remove 1st & 2nd hub snap ring.
SMT910A
MT-56
9. Press out 1st main gear together with 1st & 2nd synchro-
ni.zer assembly.
SMT528C
INSPECTION
Gears and shafts
• Check shafffor cracks, wear or bending.
• Check coupling sleeve for wear or damage.
SMT912A
Synchronizers
Shifting insert
for wear or cracks.
t
SMT387A
SMT026
Baulk ring to • Measure clearance between baulk ring and gear.

gear clearance Clearance bet~eenbaulk ring and gear
Unit: mm (in)
Standard Wear limit

1st 1.00 - 1.45 (0.0394 -.0.0571)
2nd 1.1 - 1.5 (0.043 - 0:059)

0.7 (0.028)
3rd & main drive 1.00 - 1.45 (0.0394 - 0.0571)
Reverse 1.00 - 1.45 (0.0394 - 0.0571)

SMT140
MT-57
Bearings
SMT418A
Coupling sleeve ASSEMBLY
.--=----- 1. Assemble synchronizers .

1st & 2nd synchronizer
• Shifting insert
Shifting insert
• Opening of shifting insert springs must not be aligned with
each other.
3rd & 4th synchronizer
Coupling
sleeve
Shifting insert
SMT078C
Synchronizer hub Reverse synchronizer

Shifting insert
Coupling sleeve • Pay attention to direction of synchronizer hub, shifting
inserts and coupling sleeve.
• Open parts of shifting insert springs must not be aligned
with each other.
Front V
SMT277B
MT-58
2. Press reverse synchronizer assembly together with
reverse main gear and reverse gear needle bearing.
• Pay attention to direction of reverse synchronizer hub
assembly.
3. Install 1st main gear and 1st gear needle bearing.
SMT529C
4. Press on 1st & 2nd synchronizer assembly.

1st baulk ring and 2nd baulk ring are different.
Drift • Press
~ 2nd baulk ring
~
1st baulk ring
SMT530C
Front 5. Select proper 1st & 2nd hub snap ring to minimize clear-
{) ance of groove,
1st & 2nd hub o • 0.13 mm (O. 0.0051in)
snap ring 1st & 2nd hub snap ring:
Refer to S.O.S.
6. Install selected snap ring on mainshaft.
SMT469C
7. Install 2nd main gear and 2nd gear needle bearing.

8. Press on 3rd gear bushing.
9. Install 3rd main gear and 3rd gear needle bearing.
ST33200000
SMT531C
MT-59
10. Press on 3rd & 4th synchronizer assembly.
Pay attention to direction of synchronizer assembly.
11. Select proper 3rd & 4th hub snap ring to minimize clear-
ance of groove.
o . 0.1 mm (0 • 0.004 in)
3rd & 4th hub snap ring:
Refer to S.O.S.
12. Install selected snap ring on mainshaft.
SMT918A
13. Install reverse coupling sleeve.

Pay attention to direction of coupling sleeve.
14. Measure 1st, 2nd, 3rd and reverse main gear end plays as
the final check - Refer to "Disassembly".
SMT966A
Counter Gear
DISASSEMBLY
1. Remove sub-gear components.
a. Remove sub-gear snap ring.
b. Remove sub-gear, sub-gear bracket, sub-gear spring and
steel ball.
Counter gear front Counter gear rear 2. Pull out counter gear front and rear bearing inner race.
bearing inner race bearing outer race
Puller
SMT924A
MT-60
REPAIR FOR COMPONENT PARTS RS5R50A
Counter Gear (Cont'd)

INSPECTION
Gears and shafts
• C.heckshafts for cracks or bending.
Bearings
• Make sure bearings roll freely and are free from noise.
SMT925A
Shifting insert
Synchronizer
for wear or cracks.
t
SMT026
• . Measure clearance between baulk ring and gear.

Clearance between baulk ring and gear
Unit: mm (in)
Standard Wear limit
0.0. 1.00 - 1.45 (0.0394 - 0.0571) 0.7 (0.028)
Counter gear front Counter gear rear ASSEMBLY

bearing Inner race bearing outer race
1. Press on counter gear front and rear bearing inner race.
MT ..61
Counter Gear (Cont'd)
2. Install sub-gear bracket on counter gear and then select
proper sub-gear snap ring to minimize clearance of groove.
o . 0.15 mm (O . 0.0059 in)
Sub-gear snap ring:
Refer to S.O.S.
SMT927A
3. Install sub-gear, sub-gear spring, sub-gear bracket, steel

ball and selected snap ring, while compressing sub-gear
spring.
• Pay attention to direction of sub-gear spring.
• Apply mUlti-purpose grease to steel ball.
Mainshaft Low Gear and Counter Low & High

Gear
DISASSEMBL Y
Mainshaft low gear
1. Remove low gear snap ring and then remove low gear
spacer and low gear pilot bearing.
2. Press out low gear front bearing.
Counter low & high gear

• Press counter low & high gear front bearing.
SMT536C
MT-62
REPAIR FOR COMPONENT PARTS RS5R50A I I
Gear (Cont'd)
INSPECTION
Gears and shafts
~ • Check shaftsfor cracks, wear or bending.
• Check coupling sleeve for wear or damage.
~
SMT932A
Shifting insert Synchronizer

for wear or cracks.
• Check baulk rings for cracks or deforrnation.
Baulk ring to • Measure wear of main drive, 1st and 0.0. baulk rings.
gear clearance Clearance between baulk ring and gear:
Refer to S.O.S.
It the clearance is smaller than the wear limit, replace
baulk ring.
SMT140
Inner baulk ring • Measure wear of 2nd and 3rd baulk ring.
'\ 2nd inner baulk ring a. Place baulk rings in position on synchronizer cone.
?Jr":'b¥=' b
c.
While holding baulk rings against synchronizer cone as far
as it will go, measure dimensions "A" and "B".
Clearance: Refer to S.O.S.
If dimension "A" or "B" is smaller than the wear limit,
replace baulk ring.
ST3OO31DllO~ OJo""lI""M
~ST30031000
SMT308C
Outer baulk ring
(
SMT042B
MT-63
REPAIR FOR COMPONENT PARTS RS5R50A I I
Gear (Cont'd)
It.oo~ •
a.
b
Measure wear of reverse baulk ring.
Place baulk ring in position on reverse cone.
While holding baulk ring against reverse cone as far as it
will go, measure dimension "A" with dial indicator.
Dimension "A":
Standard -0.1 to 0.35 mm (-0.0039 to 0.0138 in)
Reverse~ Wear limit 0.7 mm (0.028 in)
baulk ring c. If dimension "A" is larger than the wear limit, replace baulk
ring.
SMT424A
Bearings
• Check bearings roll freely and are free from noise, cracks,
pitting or wear.
SMT41BA
ASSEMBLY
.8T30613000
Mainshaft low gear
1. Press on low gear front bearing.
2. Install low gear pilot bearing and low gear spacer and then
install low gear snap ring.
SMT929A
Counter low & high gear

• Press on counter low & high gear front bearing.
c-
-=-==1- -
I
SMT53BC
MT-64
DISASSEMBLY
1. Remove top cover, top cover gaskets and shift lever guide
plate.
SMT946A
2. Remove gear shift housing cover.
3. Remove select lever snap ring. Then remove select lever

and plane washer.
4. Remove cross shaft set screw. Then remove cross shaft,

spring case assemblies, ring stoppers and operating lever.
5. Remove reverse lamp switch, neutral switch, check plugs,
check springs, check spring guide and check balls .
•
Pull out SMT949A
6. Remove shift rod caps.
SMT95'oA
MY-65
7. Drive out retaining pins from striking lever, reverse shift
fork and reverse fork rod bracket.
8. While pulling out striking rod and reverse fork rod, remove
striking lever, striking interlock, 1st & 2nd, 3rd & 4th and
reverse shift fork and reverse fork rod bracket.
SMT951A
9. Drive out retaining pin from reverse check assembly and

KV31100300 then remove reverse check assembly.
SMT952A
10. Remove slide ball bearings.
INSPECTION
• Check contact surface and sliding surface for wear
scratches projections or other damage.
ASSEMBLY
F'~
"
s=;;:: ~
, .L-
:&:J 1. Install slide ball bearings.
Q) Slide ball bearing

Drift
SMT470C
MT-66
REPAIR FOR COMP.ONENT PARTS I RS5R50A ,

2. Assemble reverse check.
Reverse check earn
SMT956A
3. Install reverse check assembly and then install retaining

KV31100300 pin.
SMT952A
4. Install 1st & 2nd, 3rd & 4th and reverse shift fork onto gear
shift housing.
5. Install striking rod into hole of 1st & 2nd and 3rd & 4th shift
fork, striking lever and striking interlock.
Pay attention to direction of striking rod.
•
Insert
6. Install reverse fork rod into hole of reverse shift fork and
reverse fork rod bracket.
7. Set striking lever as shown in illustration.
Front
Pay attention to
direction.
SMT957A
8. Install retaining pins into striking lever, reverse shift fork

and reverse fork rod bracket.
SMT951A
MT-67
9. Install shift rod caps by tapping them lightly.
• Apply recommended sealant to mating surface of shift rod
caps.
• Apply multi-purpose grease into shift rod caps.
SMT959A
10. Install reverse lamp switch, neutral switch, check balls,

check springs, check plugs and check spring guide.
• Apply multi-purpose grease to check balls and contact
point of neutral switch to striking rod.
• Spring for reverse check is shorter than the other spring.
• Apply recommended sealant to threads of check plugs and
switches.
SMT960A
11. Set operating lever, spring case assemblies and ring stop-
pers on gear shift housing cover and then install cross shaft
onto hole.
12. Install cross shaft set screw.
SMT961A
13. Check clearance between ring stopper and operating lever.

If not within specification, replace ring stopper.
Allowable clearance:
0- 0.3 mm (0 - 0.0012 in)
Ring stopper:
Refer to S.O.S.
14. Remove cross shaft set screw.
15. Reinstall cross shaft set screw.
• Apply multi-purpose grease to pilot portion of screw.
• Apply recommended sealant to screw thread.
SMT962A
MT-68
16. Install select lever into gear shift housing cover and then
install select lever snap ring.
SMT948A
17. Install gear shift housing cover onto gear shift housing.
Always use new bolts at position @ as they are self-sealing
bolts.
SMT964A
18. Install shift lever guide plate, top cover gaskets and top
cover.
Always use new bolts at position @ as they are self-sealing
bolts.
SMT965A
Case Components
FRONT COVER Oil SEAL
Removal
SMT941A
Installation
• Apply multi-purpose grease to oil seal lip before installing.
MT-69
REPAIR FOR COMPONENT PARTS I RSSRSOA I
Case Components (Cont'd)
REAR OIL SEAL
Removal
SMT944A
Installation
• Apply'multi-purpose grease to oil seal lip before installing.
SMT945A
MT-70
ASSEMBLY I RS5R50A I
Gear Components
1. Install reverse idler shaft, thrust washers, needle bearings
and gear.
• Pay attention to direction of reverse idler gear and wash-
ers.
2. Install lock plate of reverse idler shaft.
3. Settle counter gear assembly on bottom of transmission

case.
SMT866A
4. Place mainshaft assembly on top of counter gear assembly

and then support it with hoist.
• Align matching portion of counter gear and sub-gear tooth

to upper side.
5. Install main drive gear assembly by tapping front end of it

lightly.
• Set cutting portion of clutch gear on main drive gear to the
upper side.
MT-71
6. Install counter gear front bearing outer race by tapping it
lightly while holding counter gear assembly.
• Pay attention to direction of bearing.
SMT869A
7. Install counter gear rear bearing outer race by tapping it

lightly while holding counter gear assembly.
8. Remove hoist from mainshaft.
9. Install a.D. gear case components.

a. Install Tool onto transmission case.
SMT967A
b. Install a.D. gear bushing.

c. Remove KV32102400(Counter gear stopper).
10. Install front cover.

• Always use new bolts at position @ as they are self seal-
ing bolts.
11. Install clutch housing.
SMT295B
MT-72
12. Install Tool onto transmission case.
Turn adjusting bolts to eliminate clearance between 3rd main
gear and transmission case.
o
~ AdjUsti~bOlt
~ SMT070C
13.. Stand transmission case assembly on two wooden blocks

placed under clutch housing.
14. Install mainshaft bearing without snap ring to prevent it
from damaging transmission case.
15. Install mainshaft bearing snap ring.
16. Install 0.0. main gear.

• Pay attention to direction of main gear.
17. Remove Tool KV32102500 (Mainshaft stopper)
SMT872A
o 18. Install bearing retainer and then stake 4 torx bolts at two
points.
MT-73
ASSEMBLVl RS5R50A I
19. Assemble 0.0 ..synchronizer onto 0.0. counter gear.
0.0. coupling sleeve
• Pay attention to direction of shifting Inserts and 0.0. cou-
pling sleeve.
SMT071C
20. Install 0.0. counter gear with 0.0. synchronizer assembly,

0.0. shift fork and rod.
21. Install 0.0. synchronizer cone and washer.
22. Select proper counter gear rear snap ring to minimize

groove clearance, then install it.
Allowable groove clearance:
o . 0.15 mm (0 • 0.0059 In)
Counter gear rear snap ring:
Refer to S.O.S.
23. Measure 0.0. counter gear end playas the final check -
Refer to "Disassembly".
MT-74
24. Install steel ball and speedometer drive gear.
25. Install mainshaft rear end bearing.
Case Components
1. Install rear extension and then tighten fixing bolts.
Always use new bolts at position @ as they are self sealing
bolts.
@
SMT971A
2. Install center brake components.

• Mesh 2nd and reverse gear before tightening.
SMT986A
4. Install p.T.a. cover and gasket.
SMT458C
5. Install gear shift housing assembly and gasket onto trans-

mission case.
Always use new bolts at position @ as they are self- seal-
ing bolts.
SMT976A
MT-75
F23 SERIES
NA20S T025
Engine T027
Europe Except Europe Option
Transmission model RS5W71C RS5W81A
Number of speeds 5
Sync~hromesh type Warner
1 3 5 1 3 5
1 1
Shift pattern
1-I~-1 1-I~-1
2 4 R 2 4 R
Gear ratio
1st 4.220 4.220 5.429 4.222 5.038
2nd 2.455 2.540 2.796 2.370 2.595
3rd 1.467 1.641 1.651 1.440 1.531
4th 1.000 1.000 1.000 1.000 1.000
0.0. 0.821 0.821 0.820 0.825 0.761
Reverse 3.657 3.657 6.544 4.622 6.073
Number of teeth
Mainshaft
Drive 21 21 21 24 22
1st 36 36 38 38 38
2nd 29 30 31 32 31
3rd 26 28 26 27 26
0.0. 21 21 22 26 22
Reverse 36 36 37 32 37
Countershaft
Drive 32 32 36 32 35
1st 13 13 12 12 12
2nd 18 18 19 18 19
3rd 27 26 27 25 27
0.0. 39 39 46 42 46
Reverse 15 15 12 12 12
A* 26 26 26
Reverse idler gear 21 21
B* 21 20 21
Oil capacity £ (Imp pt) 2.0 (3-1/2) 2.0 (3-1/2) 2.7 (4-3/4)
*: Reverse idler gear unit consists of two gears A and B.
MT-76
SERVICE DATA AND SPECIFICATIONS (S.cD.S.)
General Specifications (Cont'd)
H41 SERIES
Engine BD30 FD42, FD46
Transmission model RS5W81A RS5R50A
Number of speeds 5
Synchromesh type Warner
l-I~
1 3 5
Shift pattern
2
II 4 A
Gear ratio
1st 5.038 5.099
2nd 2.828 2.863
3rd 1.652 1.588
4th 1.000 1.000
0.0. 0.761 0.752
Reverse 6.073 4.862
Number of teeth
Mainshaft
Drive 22 24
1st 38 43
2nd 32 39
3rd 27 34
0.0. 22 20
Reverse 37 41
Countershaft
Drive 35 37
1st 12 13
2nd 18 21
3rd 26 33
0.0. 46 41
Reverse 12 13
Reverse idler A* 26
27
gear B* 21
Oil capacity f (Imp pt) 2.7 (4-3/4) 4.0 (7)
*: Reverse Idler gear unit consists of two gears A and B.
MT-77
SERVICE DATA .ANO SPECIFICATIONS (S.O.S.) I RS5W71C I
GEAR END PLAY Mainshaft rear end bearing
Unit: mm (in)
Allowable clearance 0- 0.14 mm (0 - 0.0055 in)
1st gear 0.31 - 0.41 (0.0122 - 0.0161)
Thickness mm (in) Part number
2nd gear 0.11 - 0.21 (0.0043 - 0.0083)
1.1 (0.043) 32228-20100
3rd gear 0.11 - 0.21 (0.0043 - 0.0083)
1.2 (0.047) 32228-20101
0.0. gear 0.24 - 0.41 (0.0094 - 0.0161)
1.3 (0.051) 32228-20102
Counter gear 0- 0.16 (0 - 0.0063)
1.4 (0.055) 32228-20103
Reverse idler gear 0.05 - 0.50 (0.0020 - 0.0197)
Counter drive gear

CLEARANCE BETWEEN BAULK RING AND
GEAR Allowable clearance 0- 0.18 mm (0 - 0.0071 in)
Unit: mm (in) Thickness mm (in) Part number
Standard 1.4 (0.055) 32215-E9000
1st & 2nd 1.20 - 1.60 (0.0472 - 0.0630) 1.5 (0.059) 32215-E9001
3rd & main drive 1.20 - 1.60 (0.0472 - 0.0630) 1.6 (0.063) 32215-E9002
0.0. 1.20 - 1.60 (0.0472 - 0.0630)
Wear limit
AVAILABLE SHIMS
1st & 2nd 0.80 (0.0315)
Counter front bearing
3rd & main drive 0.80 (0.0315)
Unit: mm (in)
0.0. 0.80 (0.0315)
A: Distance from bearing

AVAILABLE SNAP RINGS surface to transmission
case
Main drive gear bearing

1 Transmission case
1.73 (0.0681) 32204-78005 2 Counter gear front bearing
3 Counter gear
1.80 (0.0709) 32204-78000
1.87 (0.0736) 32204-78001 MT371
1.94 (0.0764) 32204-78002 Thickness of

"A" Part number
2.01 (0.0791) 32204-78003 shim
2.08 (0.0819) 32204-78004 4.52 - 4.71 (0.1780 - 0.1854) Not necessary
4.42 - 4.51 (0.1740 - 0.1776) 0.1 (0.004) 32218-V5000
4.32 - 4.41 (0.1701 - 0.1736) 0.2 (0.008) 32218-V5001

Mainshaft front
4.22 - 4.31 (0.1661 - 0.1697) 0.3 (0.012) 32218-V5002
4.12 - 4.21 (0.1622 - 0.1657) 0.4 (0.016) 32218-V5003
4.02 - 4.11 (0.1583 - 0.1618) 0.5 (0.020) 32218-V5004
2.4 (0.094) 32263-V5200
3.92 - 4.01 (0.1543 - 0.1579) 0.6 (0.024) 32218-V5005
2.5 (0.098) 32263-V5201
2.6 (0.102) 32263-V5202
MT-78
SERVICE DATA AND SPECIFICATIONS (S.D.S.) I RS5W81A I
GEAR END PLAY AND BACKLASH SHIFT FORK PAWL WEAR LIMIT
Unit: mm (in)
Service limit Pawl width
Gear End play Back lash Item (Shift fork pawl width) (when new)
mm(in) mm(in)
0.20 - 0.35 0.05 - 0.22
1st main gear 1-2 shift fork 8.7 (0.343), min. 9.7 - 9.8 (0.382 - 0.386)
(0.0079 - 0.0138) (0.0020 - 0.0087)
0.20 - 0.35 0.05 - 0.22 3-4 shift fork 6.7 (0.264), min. 7.7 - 7.8 (0.303 - 0.307)
2nd main gear
(0.0079 - 0.0138) (0.0020 - 0.0087) 5th shift fork 6.7 (0.264), min. 7.7 - 7.8 (0.303 - 0.307)
0.10 - 0.50 0.05 - 0.22 If only one side of shift fork pawl Is extremely worn, service limits
3rd main gear
(0.0039 - 0.0197) (0,0020 - 0.0087) should be 9.2 mm (0.362 in) (1-2 shift fork) and 7.2 mm (0.283 in) (3-4
shift fork), respecllvely.
0.0. counter 0.10 - 0.25 0.05 - 0.22
gear (0.0039 - 0.0098) (0.0020 - 0.0087) AVAILABLE SNAP RINGS
Reverse idler
0.05 - 0.30 0.05 - 0.25 Main drive gear snap ring
gear (Counter)
(0.0020 - 0.0118) (0.0020 - 0.0098)
A
Reverse idler 0.05 - 0.25
0.50 (0.0197) Thickness mm (in) Part number
gear B (0.0020 - 0.0098)
1.6 (0.063) 32205 J2000
1.7 (0.067) 32205 J2001

1.8 (0.071) 32205 J2002
GEAR
1.9 (0.075) 32205 J2003
1st, main drive and 0.0. baulk ring
Unit: mm (in) Input shaft 5th synchronizer hub
Standard Wear limit
1.25 - 1.80
1st & 2nd 0.8 (0.031) Thickness mm (in) Part number
(0.0492- 0.0709)
1.4 (0.055) 3270886401
0.90 - 1.80
3rd & main drive 0.5 (0.020)
(0.0354 - 0.0709) 1.5 (0.059) 3270886402
1.25 - 1.80 1.6 (0.063) 3270886403

0.0. 0.8 (0.031)
(0.0492 - 0.0709)
1.7 (0.067) 3270886404
Mainshaft 3rd & 4th synchronizer hub Reverse idler gear and counter gear snap
ring
Allowable clearance o - 0.05 mm (0 - 0.0020 in)
Thickness mm (in) Part number Allowable clearance o - 0.2 mm (0 - 0.008 in)

1.52 (0.0598) 3220408000 Thickness mm (in) Part number
1.59 (0.0626) 3220408001 1.30 (0.0512) 3228586403
1.65 (0.0650) 3220408002 1.55 (0.0610) 3228586401
1.71 (0.0673) 32204' 08003 1.90 (0.0748) 3228586402
1.77 (0.0697) 3220408004
MT-79
SERVICE DATA AND SPECIFICATIONS (S.O.S.) I RSSRSOA I
GEAR END PLAY 3rd & 4th hub snap ring
Gear End play mm (in) Allowable clearance o - 0.10 mm (0 - 0.0039 in)

1st main gear 0.20 - 0.48 (0.0079 - 0.0189) Thickness mm (in) Part number
2nd main gear 0.20 - 0.60 (0.0079 - 0.0236) 1.95 (0.0768) 32348-0H10
3rd main gear 0.20 - 0.45 (0.0079 - 0.0177) 2.00 (0.0787) 32348-0H11
2.05 (0.0807) 32348-0H12
0.0. counter gear 0.20- 0.47 (0.0079 - 0.0185)
2.10 (0.0827) 32348-0H13
Reverse main gear 0.20 - 0.44 (0.0079 - 0.0173)
2.15 (0.0846) 32348-0H14
2.20 (0.0866) 32348-0H15
GEAR 1st & 2nd hub snap ring
1st, main drive and 0.0. baulk ring Allowable clearance 0- 0.13 mm (0 - 0.0051 in)
Unit: mm (in) Thickness mm (in) Part number
2.05 (0.0807) 32348-0HOO
Standard Wear limit
2.15 (0.0846) 32348-0H01
1.0 - 1.5
1st 0.7 (0.028)
(0.039 - 0.059)
1.0 - 1.5
Main drive
(0.039 - 0.059)
0.7 (0.028) Sub-gear snap ring
1.0 - 1.5
0.0. 0.7 (0.028)
(0.039 - 0.059) Allowable clearance o - 0.15 mm (0 - 0.0059 in)
1.0 -1.5
Reverse 0.7 (0.028) Thickness mm (in) Part number
(0.039 - 0.059)
2.35 (0.0925) 32348-0H20
2.50 (0.0984) 32348-0H21
2nd and 3rd baulk ring
2.65 (0.1043) 32348-0H22
Unit: mm (in)
2.80 (0.1102) 32348-0H23
Outer baulk ring
B
Counter gear rear snap ring

1.35 (0.0531) 32204-01 T1 0
1.45 (0.0571) 32204-0H11
Inner baulk ring 1.55 (0.0610) 32204-0H12

1.65 (0.0650) 32204-0H13
1.75 (0.0689) 32204-0H14
SMT044B 1.85 (0.0728) 32204-0H15
Dimension Standard Wear limit
0.6 - 1.0 AVAILABLE RING STOPPER
A
(0.024 - 0.039)
0.2 (0.008)
0.75 - 0.95 1st & 2nd ring stopper
B
(0.0295 - 0.0374
AVAILABLE SNAP RINGS Identification

Length mm (in) Part number
color
Main drive gear snap ring
13.15 (0.5177) 32812-0H03 White
13.35 (0.5256) 32812-0H04 Black
13.55 (0.5335) 32812-0H05 Brown
Thickness mm (in) Part number 13.75 (0.5413) 32812-0H06 Green
1.75 (0.0689) 32204-0HOO 13.95 (0.5492) 32812-0H07 Orange
1.85 (0.0728) 32204-0H01 14.15 (0.5571) 32812-0H08 Yellow
1.95 (0.0768) 32204-01 T02 14.35 (0.5650) 32812-0H09 Pink
2.05 (0.0807) 32204-0H03 14.55 (0.5728) 32812-0H10 Blue
2.15 (0.0846) 32204-01T04
MT-80
PROPELLER SHAFT &
DIFFERENTIAL CARRIER
SECTIONPD
CONTENTS
PREPARATION PD- 2
PROPELLER SHAFT PD- 7
ON-VEHI CLE SERVICE (Fi nal d rive) PD-12
REMOVAL AND INSTALLATION (Final drive) PD-13
'--- ~I Model C200 ~I ~

FI NA L DRIVE ,.................................................................................................. PD-14
DISASSEM BL Y PD-15
INSPECTIO N PD-18
ADJUSTMENT PD-19
ASSE M B LY PD-25
~ I Model H233B and H260 ~I ~

FINAL DRIVE PD-30
DISASSEM BLY PD-31
INSPECTI ON PD-35
ADJUSTMENT PD-36
ASSEM BLY PD-40
~ ~ __ ~I Model H290 and H310 _I _

FINAL DRIVE PD-46
DiSASSEMBLy PD-47
INSPECTI ON PD-52
ADJ USTM ENT PD-53
ASSEM BLY PD-57
SERVICE DATA AND SPECIFICATIONS (S.D.S.) PD-61

PREPARATION
Special Service Tools

Tool number Unit application

Description
Tool name C200 H233B H260 H290 H310
ST0501S000 Mounting differential
Engine stand attachment
CD ST05011000
Engine stand
@ ST05012000 X X X X
Base
ST06340000 Mounting final drive

X
Differential attachment
ST06350000
X
ST06240000
X
KV38108100
X
KV38104700* Removing and installing

Drive pinion flange propeller shaft lock nut, X
wrench and drive pinion lock
ST31530000' nut
Drive pinion flange X
wrench
ST31620001*
wrench
ST31590000*
wrench
ST31570000*
wrench
ST32580000* Adjusting side bearing

Diff. side bearing preload and backlash
adjusting nut wrench (ring gear-drive pinion)
X
PD-2
PREPARATION
Special Service Tools (Conl'd)

Description
Tool name C200 H2338 H260 H290 H310
ST32530000*
Diff. side bearing x
adjusting nut wrench
ST32570000*
Diff. side bearing x
Diff. side bearing

x
KV381039S0 Selecting pinion height

Drive pinion setting adjusting washer
gauge
G) KV38103910
Dummy shaft
@ KV38100120 x
Height gauge
@ KV38100140
Stopper
ST3125S000 Selecting pinion height

Drive pinion setting adjusting washer
gauge set
G) ST31251000
Drive pinion height
x
gauge
@ ST31181001
Dummy shaft
ST3124S00Q.
Drive pinion setting
gauge set
G) ST31130000
Drive pinion height
x
gauge
@ ST31241000
Dummy shaft
ST3116S000
Drive pinion setting
gauge set
G) ST31161000
Drive pinion height
gauge
x x
@ ST31162000
Drive pinion clamp
PD-3
PREPARATION
Special Service Tools (Cont'd)
': Special tool or commercial equivalent

Description
Tool name C200 H233B H260 H290 H310
ST3090S000. Removing and installing

Drive pinion rear inner drive pinion rear inner
race puller set cone
G) ST30031000' CD X X X
Puller A: 79 mm (3.11 in) dia.
B: 45 mm (1.77 in) dia.
@ ST30901000' C: 35 mm (1.38 In) dla.
Base
ST3002S000' A: 110 mm (4.33 in) dla.
B: 56 mm (2.20 In) dla.
Drive pinion rear inner C: 46 mm (1.81 In) dia.
race puller set
G) ST30021000' X X
Puller A
@ ST30022000'
Base
ST3127S000 Measuring pinion bear-

Preload gauge ing preload and total
G) GG91030000' preload
Torque wrench
@ HT62940000'
Socket adapter
CD---Q =6=0 X X X X X
(3/8") @-~
@ HT62900000'
Socket adapter CID~
(1/2")
. ST3306S001 Removing and installing
Ditt. side bearing differential side bearing
puller set inner cone
G) ST33051001' X X
Puller A: 28.5 mm (1.122 in) dia.
B: 38 mm (1.50 In) dia.
@ ST33061000.
Adapter
ST0237S000 A: 40 mm (1.57 in) dla.
B: 50 mm (1.97 In) dia.
Diff. side bearing
puller set
G) ST33051001' X
Puller
@ ST02371000' A
Adapter
KV381031SO A: 43.5 mm (1.713 in) dia.

~ B: 58 mm (2.28 In) dla.
Ditt. side bearing CJ
B
puller set
G) ST33021000' X X
Puller
@ KV38103110'
Adapter
ST32501000 Selecting side bearing
8
Weight block adjusting shim
PD-4
PREPARATION

Description
Tool name C200 H2338 H260 H290 H310
KV38102000 Selecting side bearing

Master gauge adjusting shim
[21.0 mm (0.827 in)]
8 x
ST33230000* Installing side bearing

Ditt. side bearing drift inner cone
x
A: 51 mm (2.01 In) dla.
B: 28.5 mm (1.122 In) dia.
ST30611000* Installing pinion rear

Drift bearing outer race
x x x
I
X X
A: 79 mm (3.11 In) dia.
B: 59 mm (2.32 in) dia.
A
ST30613000* Installing pinion front

A: 71.5 mm (2.815 in) dia. X X X

B: 47.5 mm (1.870 in) dla.
~ A

X
A: 89 mm (3.50 in) dia.
B: 79 mm (3.11 In) dia.
~ A
KV38100600* Installing side bearing

Side bearing spacer spacer
drift
~A
X
A: 8 mm (0.31 In)
B: 42.5 mm (1.673 in) dla.
PD-5
PREPARATION

Description
Tool name C200 H2338 H260 H290 H310

Diff. side bearing drift inner cone
X
A: 52 mm (2.05 in) dia.
B: 34 mm (1.34 in) dla.

Side bearing puller inner cone
adapter X
A: 43 mm (1.69 In) dia.
B: 33.5 mm (1.319 in) dia.
ST01550002* A: 65 mm (2.56 In) dia.

B: 40 mm (1.57 In) dla.
Side bearing puller X
adapter B
ST02371000' A: 50 mm (1.97 in) dia.

B: 40 mm (1.57 in) dia.
Side bearing puller X
adapter ~
A
KV38103200* A: 68 mm (2.68 in) dia.
B: 43.5 mm (1.713 in) dla.
Side bearing puller X X
adapter
KV38103110* A: 58 mm (2.28 in) dia.
B: 43.5 mm {1.713 in) dia.
Side bearing puller X X
adapter
ST30720000* Installing front oil seal

Gear carrier front oil
seal drift A: 77 mm (3.03 in) dia. X X X X
B: 55 mm (2.17 in) dla.
A: 114 mm (4.49 in) dia.

B: 60 mm (2.36 in) dia.
Gear carrier front oil
seal drift X
PD-6
PROPELLER SHAFT
Model2S71H
~ 55 - 65 N.m
(5.6 - 6.6 kg-m,
;/!<l 41 - 48 ft-Ib)
,/
J"",' "''''''\.
Snap ring * \t b
~ I
@......~"-. I
81"",,,'~k' .• /. /'.!,
o @
o @l
Journal
*: Adjustment is required.
SPD172A
Model 2F80B, 2F100H and 3F100H

~ : Do not reuse. Replace with new part.
SPD173A
PD-7
PROPELLER SHAFT
On-Vehicle Service
PROPELLER SHAFT VIBRATION

If vibration is present at high speed, inspect propeller shaft
runout first.
1. Raise rear wheels.
2. Measure propeller shaft runout at points indicated below by
rotating final drive companion flange with hands.
Unit: mm (in)
Propeller shaft 2F80B

2S71H 2F100H 3F100H
model 3S71H
Measuring point
A 155 (6.10) 162 (6.38) 285 (11.22) 280 (11.02)
A c B 165 (6.50) 172 (6.77) 485 (19.09) 475 (18.70)
B C 185 (7.28) 192 (7.56) 285 (11.22) 280 (11.02)
beanng ~ Jo'm,' 3. If runout exceeds specifications, disconnect propeller shaft

~"~', , at final drive companion flange; then rotate companion
flange 180 degrees and reconnect propeller shaft.
A B C SPD729
Runout limit: Refer to S.O.S.
4. Check runout again. If runout still exceeds specifications,
replace propeller shaft assembly.
5. Perform road test.
APPEARANCE CHECKING
• Inspect propeller shaft tube surface for dents or cracks.
If damaged, replace propeller shaft assembly.
• If center bearing is noisy or damaged, replace center bear-
ing.
SPD102
Removal and Installation

• Put matchmarks on flanges and separate propeller shaft
from final drive.
• Draw out propeller shaft from transmission and plug up

Transmission
rear end of transmission rear extension housing.
SPD359
PD-8
PROPELLER SHAFT
Inspection
• Inspect propeller shaft runout. If runout exceeds
specifications, replace propeller shaft assembly.
SPD106
• Inspect journal axial play.

If the play exceeds specifications, replace propeller shaft
assembly.
Journal axial play: Refer to S.O.S.
SPD874
Disassembly
CENTER BEARING
1. Put matchmarks on flanges, and separate 2nd tube from 1st
tube.
2. Put matchmarks on the flange and shaft.
3. Remove locking nut with Tool.

Tool number:.Refer to PREPARATION.
4. Remove companion flange with puller.
SPD170A
5. Remove c~nterbearing with Tool and press.

Tool number: ST30031000
PO-g ...
PROPELLER SHAFT
JOURNAL
1. Put matchmarks on shaft and flange or yoke.
2. Remove snap ring.
..
:
.
'.
m .
~:"
r---
.:.
3. Remove pushed out journal bearing by lightly tapping yoke
with a hammer, taking care not to damage journal and yoke
hole.
SPD732
4. Remove bearing at opposite side in above operation.

Put marks on disassembled parts so that they can be rein-
stalled In their original positions from which they were
removed.
SPD131
Assembly
CENTER BEARING
• When installing center bearing, position the "F" mark on
center bearing toward front of vehicle.
• Apply a coat of multi-purpose lithium grease containing
molybdenum disulfide to the end face of the center bearing
and both sides of the washer.
PD-10
PROPELLER SHAFT
Assembly (Coni' d)
• Stake the nut. Always use new one.
• Align matchmarks when assembling tubes.
JOURNAL
1. Assemble journal bearing. Apply recommended multi-pur-
pose grease on bearing inner surface.
When assembling, be careful that needle bearing does not fall
down.
2. Select snap ring that will provide specified play in axial

direction of journal, and install them (Refer to S.O.S.).
Select snap rings with a difference in thickness at both sides
within 0.06 mm (0.0024 in).
3. Adjust thrust clearance between bearing and snap ring to

zero by tapping yoke.
4. Check to .see that journal moves smoothly and check for

axial play.
Axial play: Refer to S.O.S.
SPD874
PD-11
ON-VEHICLE SERVICE (Final Drive)
Front Oil Seal Replacement (Model H233B,

H260, H290 and H310)
CAUTION:
For final drive models using collapsible spacer (C200), bearing
preload must be adjusted whenever companion flange is
removed. Therefore, final drive overhaul is required.
2. Loosen drive pinion nut.
Tool number: Refer to PREPARATION.
PD237
3. Remove companion flange.
5. Apply multi-purpose grease to cavity at sealing lips of oil

seal. Press front oil seal into carrier.
6. Install companion flange and drive pinion nut.
7. Install rear propeller shaft.
Tool number: Refer to PREPARATION.
SPD73lJ
Rear Cover Packing Replacement (Model C200)

1. Drain gear oil.
2. Remove rear cover and rear cover packing.
3. Install new rear cover packing and rear cover.
4. Fill final drive with recommended gear oil.
PD-12
REMOVAL AND INSTALLATION (Final drive)
Removal - C200 -
Insert plug into transmission after removing propeller shaft.
2. Drain gear oil.
3. Remove brake tube and parking brake cable. Refer to BR
section.
4. Remove rear axle case assembly. Refer to RA section.
5 Draw out axle shafts. Refer to RA section.
SPD174A
Installation - C200 -
1. Install axle shafts. Refer to RA section.
2. Install rear axle case assembly. Refer to RA section.
3. Install propeller shaft.
4. Fill final drive with recommended gear oil.
Removal - H233B,H260, H290, H310 -'

• Remove propeller shaft.
Insert plug into transmission after removing propeller shaft.
• Remove axle shaft.
Refer to RA section.
CAUTION:
• Be careful not to damage spline, sleeve yoke and front oil
seal when removing propeller shaft.
Installation - H233B, H260, H290, H310 -

• Fill final drive with recommended gear oil.
SPD123
Final drive assembly

Filler plugrJ
H233B ~59 - 98(6 - 10, 43 - 72)
: ~54 - 64 (5.5 - 6.5, 40 - 47)\
H260 : ~54 - 64 (5.5 - 6.5, 40 - 47)
H290 : ~ 54 - 64 (5.5 - 6.5, 40 - 47)
H310 : ~ 78 - 98 (8 - 10, 58 - 72) \Q)
Drain plug rJ
~59 - 98 (6 - 10, 43 - 72)
H233B, H260 and H290: Gasket ~

~: N.m (kg-m, ft-Ib) H310:rJ liquid gasket
SPD247A
PD-13
FINAL DRIVE (Model C200)
Gi
.s:::.
.. ;;:
.... tl
Q)
(J)
al
....
al
Q)
.s:::.
(J) 2 Ol
al
;;: -E Q)
OJ
E
I
.E cr:
Q)
(J)
al
..
....
Q)
.s:::.
0
OJ
E
e
(J)
~
~ is
tl
2
CIOo>
N -E
CIO_
.... .::: ....
.... al
.s:::.
al
Q)
~ (J)
Ol
CIO
0> .; Q)
"C
co
U)
ui
II'i ]j
E
c
Ci5
.... C 0
..... Q)
'c
.... U) Gi a::
to M !t=
cO c Cl
c;)
U)
f;l
.... ....
e 0>
(II
CIO 6'
..... <D ....
D~ Olo>
l')
l')
ui
:J U)
II'i
c.'
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:t
i1;
SPD248A
PD-14
DISASSEMBL V (Model C200)
Pre-inspection
Before disassembling final drive. perform the following inspec-'
tion.
• Total preload
1) Turn drive pinion in both directions several times to set
bearing rollers.
2) Check total preload with Tool.
Tool number: ST3127S000
Total preload: Refer to S.O.S.
Tool • Ring gear to drive pinion backlash.
SPD241
Check backlash of ring gear with a dial indicator at several
points.
Ring gear-to-drive pinion backlash:
Refer to S.O.S.
• Ring gear runout

Check runout of ring gear with a dial indicator.
Feeler gauge • Tooth contact

Check tooth contact (Refer to Adjustment).
• Side gear to pinion mate gear backlash
Measure clearance between side gear thrust washer and
differential case with a feeler gauge.
Clearance between side gear thrust washer and differ-
ential case:
Refer to S.O.S.
SPD198
Differential Carrier
1. Remove rear cover and rear cover gasket.
2. Put matchmarks on one side of side bearing cap with paint
or punch to ensure that it is replaced in proper position
during reassembly.
Bearing caps are line-bored during manufacture and should be
put back in their original places.
SPD714
PD-15
DISASSEMBLY (Model C200)
Differential Carrier (Cont'd)
3. Remove side bearing caps.
SPD202
4. Remove differential case assembly with pry bar.
SPD193
Keep the side bearing outer races together with their respec-
tive inner cones - do not mix them up.
SPD745
5. Remove drive pinion nut and pull off companion flange.

Tool number: KV381 04700
SPD204
6. Remove drive pinion with soft hammer.

7. Remove front oil seal and pinion front bearing inner cone.
SPD206
PD-16
DISASSEMBL Y(Model C200)
Differential Carrier (Conl'd)
8. Remove side oil seal.
9. Remove pinion bearing outer races with a brass drift.
PD349
10. Remove pinion rear bearing inner cone and pinion height
adjusting washer.
Tool CD Differential Case

1. Remove side bearing inner cones.
To prevent damage to bearing, engage puller jaws in grooves.
Tool number:
CD ST33051001
3~Groove @ ST33061000
Be careful not to mix up the right and left bearings.
<5 (0 0
00 o .'
~
~ SPD254A
2. Loosen ring gear bolts in a criss-cross fashion.

3. Tap ring gear off the differential case with a soft hammer.
Tap evenly all around to keep ring gear from binding.
4. Separate differential case.

Put match marks on both L.H. and R.H. differential cases.
PD-17
INSPECTION (Model C200)
Ring Gear and Drive Pinion

Check gear teeth for scoring, cracking or chipping. If any dam-
aged part is evident, replace ring gear and drive pinion as a set
(hypoid gear set).
Differential Case Assembly

Check mating surfaces of differential case, side gears, pinion
mate gears, pinion mate shaft, thrust block and thrust washers.
SPD648
Bearing
1. Thoroughly clean bearing
2. Check bearings for wear, scratches, pitting or flaking.
Check tapered roller bearing for smooth rotation. If
damaged, replace outer race and inner cone as a set.
SPD715
PD-18
ADJUSTMENT (ModeIC200)
To avoid confusion while calculating bearing shims, it is abso-

lutely necessary to stay with the metric system. If you measure
anything in inches, the results must be converted to the metric
system.
Drive Pinion Height

1. Prepare Tools for pinion height adjustment.
(1) Dummy Shaft (KV38103910)
@ Height Gauge (KV38100120)
<ID Stopper (KV38100140)
@ Feeler Gauge
2. To simplify the job, make a chart, like the one below, to
organize your calculations.
LETTERS HUNDREDTHS OF A MILLIMETER
H: Head number
N: Measuring clearance
3. Write the following numbers down the chart.

H: Head number
SPD542
4. Set Tool (Dummy shaft) as shown at left and tighten drive

pinion nut carefully to correct preload of 1.0 to 1.3 N'm (10
to 13 kg-em, 8.7 to 11.3 in-Ib).
Tool: KV38103910
SPD756
PD-t9
ADJUSTMENT (Model C200)
Drive Pinion Height (Cont'd)
5. Attach Tool (Height gauge) to gear carrier, and measure
the clearance "N" between the height gauge and the
dummy shaft face.
Tool: KV38100120
6. Substitute these values into the equation to calculate the
thickness of the washer.
If value signifying H is not given, regard it as zero and calcu-
late.
T (Thickness of washer) = N - (H x 0.01) + 3.00
Example:
SPD757 N = 0.23
H = 1
T = N - (H x 0.01) + 3.00 = 0.23 - (1 x 0.01) + 3.00
(1) H , , , 1
x 0.01
+ 0.01
(2) N '. 0.23

-(+0.01)
0.22
(3) 0.22
+3.00
3.22
:. T = 3.22
7. Select the proper washer (Refer to S.O.S.).

If you cannot find the desired thickness of washer, use washer
with thickness closest to the calculated value.
Example:
Calculated value ... T = 3.22 mm
Used washer ... T = 3.21 mm
Side Bearing Preload

1. To simplify the job, make a chart like the one below to
lETTERS HUNDREDTHSOF A MilLIMETER
A - left housing
B - Right housing
C - Differential case
D - Differential case
E - left side bearing
F - Right side bearing

H - (+) or (-): ring gear
G - Spacer measurement
PD-20
Side Bearing Preload (Cont'd)
2. Write the following numbers down in the chart.
A & B: Figures marked on gear carrier.
SPD707
C & D: Figures marked on differential case
H: Figure marked on ring gear
SPD576
G: This is thickness of side spacer.
3. Measure how far under the standard thickness

[21 mm (0.83 in)] the side bearings are.
It will require tools shown to the left.
<D Weight Block (ST32501000)
@ Master Gauge (KV38102000)
CID Base Plate
@ Dial Indicator
PD-21
4. Place the outer race of the opposite side bearing to be
measured.
5. Place a weight block on that outer race, and a master
gauge on that block.
Tool number:
CD ST32501000 (Weight block)
<ID KV38102000 (Master gauge)
6. Adjust dial indicator scale to zero.
Tool CD
7. Carefully slide master gauge block and weight block out
from under dial indicator.
SPD256A
8. Lubricate side bearing and place the bearing outer race

and inner cone to be measured on the opposite side outer
race.
If the bearing assembly is placed on the base plate, the bear-
ing width cannot be accurately determined due to its cage
being in contact with the base plate.
SPD050
9. Place weight block on side bearing.

10. Slide dial indicator on weight block.
SPD591
11. Turn weight block a few times to ensure that bearing is

properly seated.
12. Read dial indicator.
• Normal indication:
0.10 - 0.30 mm (0.0039- 0.0118 in)
• If the needle fluctuates erratically then bearing is either
dirty or defective and should be cleaned or replaced.
13. Measure both bearings in the same way and write the left
side bearing measurement next to "E" and the right side
bearing measurement next to "F".
SPD051 14. Substitute these values into the equation to calculate the
thickness of the shim.
PD-22
ADJUSTMENT (Model C200}
If values signifying A, B, C, D and H' are not given, regard them
as zero and calculate.
• When spacer is located on ring gear side
Left side:
T1 = (A - C + D) x 0.01 + E - G + 10.03
Right side:
T2 = (B - D) x 0.01 + F + 2.03
• When spacer is located opposite to ring gear
Left side:
T1 = (A - C + D) x 0.01 + E + 2.03
Right side:
T2 = (B - D) x 0.01 + F - G + 10.03
Example:
A = 1 G = 8.09
8 = 2 E = 0.15
C = 2 F = 0.17
D = 3
• When spacer is located opposite to ring gear,

Right side:
Left side: T2 = (8 - D) x 0.01 + F- G + 10.03
T1 = (A - C + D) x 0.01 + E + 2.03 = (2 - 3) x 0.01 + 0.17 - 8.09 + 10.03
= (1 - 2 + 3) x 0.01 + 0.15 + 2.03
(1) 8 2
(1) A 1 -0 ....................... ............................. -3
-C -2 -1
-1
+0 +3 (2) -1
2 x 0.01
-0.01
(2) 2
x 0.01 (3) -0.01
0.02 +F +0.17
0.16
(3) 0.02
+E + 0.15 (4) 0.16
0.17 -G -8.09
-7.93
(4) 0.17
+2.03 (5) 10.03
2.20 -7.93
:. T1 = 2.20 mm 2.10-
:. T2 = 2.10 mm
15. Select the proper waShers (Refer to S.O.S.).

If you cannot find the dEJsired thickness of shims, use washers
with the total thicknes.s closest to the calculated value.
PD-23
Tooth Contact
Checking gear tooth contact pattern is necessary to verify cor-
rect relationship between ring gear and drive pinion.
Hypoid gear set which is not positioned properly in relation to
one another may be noisy, or have short life or both. With a
pattern check, the most desirable contact for low noise level
and long life can be assured.
1. Thoroughly clean ring gear and drive pinion teeth.

2. Sparingly apply a mixture of powdered ferric oxide and oil
or equivalent to 3 or 4 teeth of ring gear drive side.
3. Hold companion flange steady by hand and rotate the ring

gear in both directions.
Usually the pattern will be correct If you have calculated the shims correctly and the backlash Is correct.
However, In rare cases you may have to use trlal-and-error processes until you get a good tooth contact pattern.
The tooth pattern Is the best Indication of how well a differential has been set up.
Heel contact Face contact Toe contact Flank contact
~~
To correct, increase thickness of pinion To correct, reduce thickness of pinion
height adjusting washer in order to bring height adjusting washer in order to make
drive pinion close to ring gear. drive pinion go away from ring gear.
Conect tooth ~_ / ~t=,,-
When adjustment Is completed, be sure to wipe

off completely the ferric oxide and 011or their
~
equivalent. ~
SPD007
PD-24
ASSEMBLY (Model .•C200)
Differential Case
1. Measure clearance between side gear thrust washer and
differential case.
Clearance between side gear thrust washer
and differential case (A - B):
Refer to S.O.S.
The clearance can be adjusted with side gear thrust washer
(Refer to S.O.S.).
2. Apply gear oil to gear tooth surfaces and thrust surfaces
and check to see they turn properly.
SPD656
3. Install differential case L.H. and R.H.
4. Place differential case on ring gear.

5. Apply locking agent [Locktite (stud lock) or equivalent] to
ring gear bolts, and install them.
Tighten bolts in a criss-cross fashion, lightly tapping bolt head
with a hammer.
6. Press-fit side bearing inner cones on differential case with

Tab I.
Tool number:
CD 5T33230000
@ 5T33061 000
PD-25
ASSEMBLY (Model C200)
1. Press-fit front and rear bearing outer races with Tools.
Tool number:
@ ST30611 000
@ ST30621 000
CID ST30613000
Pinion
front bearing
outer race
SPD258A
2. Select pinion height adjusting washer, referring to Adjust-

Adjusting
ment.
washer
3. Install pinion height adjusting washer in drive pinion, and
press-fit rear bearing inner cone in it, with press and Tool.
Tool
4. Place pinion front bearing inner cone in gear carrier.
EilI
SPD581

seal. Install front oil seal.
SPD557
PD-26
6. Place drive pinion bearing spacer, drive pinion bearing
adjusting washer and drive pinion in gear carrier.
Collapsible spacer SPD222
7. Insert companion flange into drive pinion by tapping the

companion flange with a soft hammer.
--=
SPD708
8. Tighten pinion nut to 127 N.m (13 kg-m, 94 ft-Ib).

/
The threaded portion of drive pinion and pinion nut should be
free from 011 or grease.
9. Tighten the pinion nut by very small degrees until the spec-
ified preload is achieved. When checking the preload, turn
the drive pinion in both directions several times to set the
bearing rollers.
Pinion bearing preload: Refer to S.O.S.
This procedure will have to be repeated if:
• Maximum preload is achieved before the minimum pinion
nut torque is reached.
• Minimum preload is not achieved before maximum pinion
SPD241
nut torque is reached.
10. Select side bearing adjusting washer.
Refer to Adjustment.
11. Install differential case assembly with side bearing outer
races into gear carrier.
PD..27
ASSEMBL V (Model C200)
12. Insert left and right side bearing adjusting washers in place
between side bearing and carrier.
SPD558
13. Drive in side bearing spacer with Tool.

Tool number: KV38100600
14. Align matchmarks on bearing cap with that on gear carrier

and install bearing cap on gear carrier.
15. Measure ring gear-to-drive pinion backlash with a dial indi-

cator.
Ring gear-to-drive pinion backlash: Refer to S.O.S.
• If backlash is too small, decrease thickness of right shim
and increase thickness of left shim by the same amount.
If backlash is too great, reverse the above procedure.
Never change the total amount of shims as it will change the
bearing preload.
16. Check total preload with Tool.

When checking preload, turn drive pinion in both directions
several times to seat bearing rollers correctly.
Tool
SPD241
PD-28
• If preload is too great, remove the same amount of shim
from each side.
• If preload is too small, add the same amount of shim to
each side.
Never add or remove a different number of shims for each side
as it will change ring gear-to-drive pinion backlash.
17. Recheck ring gear-to-drive pinion backlash because
increase or decrease in thickness of shims will cause
change of ring gear-to-pinion backlash.
SPD561
18. Check runoutof ring gear with a dial indicator.

• If backlash varies excessively in different places, the vari-
ance may have resulted from foreign matter caught
between the ring gear and the differential case.
• If the backlash varies greatly when the runout of the rrng
gear is within a specified range, the hypoid gear set or dif-
ferential case should be replaced.
19. Check tooth contact.
Refer to Adjustment.
20. Install rear cover and gasket.
PD-29
FINAL DRIVE (Model H2338 and H260)
2-pinion type (H233B) Pinion mate shaft

Thrust block
r
Pinion mate gear
Pinion mate thrust washer
[ ~ Differential case
Side bearing cap
Ring gear
4-pinion type (H233, H260)
Differential case R.H.
Side bearing
~ 93 - 103
(9.5 - 10.5, 69 - 76)
Differential case L.H.
Side bearing
e
Drive pinion
rear bearing ~ ~ Side bearing adjuster
Inner Outer .
I
cone
~ race ~Side bearing cap
Differential carrier
~~
Drive pinion
front beari ng l@ :'/~\
I Hypoid gear set
I I
Inner Outer
~ H233B : 93 - 103 (9.5 - 10.5, 69 - 76)
cone race
H260 : 78 - 98 (8 - 10, 58 - 72)
Differential case couple bolt

~ H233B : 64 - 74 (6.5 - 7.5, 47 - 54)
H260 : 39 - 54 (4.0 - 5.5, 29 - 40)
Ring gear bolt

~ H233B : 132 - 152 (13.5 - 15.5, 98 - 112)
H260 : 196 - 226 (20 - 23, 145 - 166)
: 196 - 284 (20 - 29, 145 - 210) ~ : N.m (kg-m, ft-Ib)

H260 : 167 - 245 (17 - 25, 123 - 181)
* :Adjustment is required.
SPD176A
PD-30
DISASSEMBLY {Model H233B and H260}
Pre-inspection
Before disassembling final drive, perform the following inspec-
tion.
• Total preload
1) Turn drive pinion in both directions several times to seat
bearing rollers correctly.
• Ring gear to drive pinion backlash
SPD149
points.
Refer to S.O.S.

• Tooth contact
Check tooth contact, referring to Adjustment.
Clearance between side gear thrust.washer and
differential case: Refer to S.O.S.
1. Mount final drive assembly on Tool.
Tool number:
H233B ST06340000
H260 ST06350000
PD-31
DISASSEMBLY (Model H233B and H260)
during reassembly.
SPD249
3. Remove side lock fingers and side bearing caps.
4. Remove side bearing adjuster with Tool.

5. Remove differential case assembly with a pry bar.
Be careful to keep the side bearing outer races together with

their respective inner cones - do not mix them up.
SPD011
PD-32
Tool 6. Remove drive pinion nut with Tool.
Tool number:
H233B ST31530000
H260 ST31620001
SP0012
8. Take out drive pinion together with pinion rear bearing

inner cone, drive pinion bearing spacer and pinion bearing
adjusting shim.
SP068?
9. Remove front oil seal and pinion front bearing inner cone.
10. Remove pinion bearing outer races with a brass drift.
SP0563
~------- 11. Remove pinion rear bearing inner cone and drive pinion
adjusting washer.
SP0018
PD-33
Tool CD Differential Case

To prevent damage to bearing, engage puller jaws in groove.
Tool number:
H233B (1) ST33051 001
@ ST33061 000
H260 (1) ST33051001

@ ST02371 000
Be careful not to confuse left and right hand parts.
SPD022

3. Tap ring gear off differential case with a soft hammer.
SPD024
4. Drive out pinion mate shaft lock pin, with punch from ring
gear side (2-pinion type differential case).
5. Separate differential case. (4-pinion type differential case)

Put matchmarks on both L.H. and R.H. differential cases.
PD-34
INSPECTION (ModelH233Band H260)

Check gear teeth for scoring, cracking or chipping.
If any damaged part is evident, replace ring gear and drive
pinion as a set (hypoid gear set).
2-pinion type Differential Case Assembly

mate gears, pinion mate. shaft, and thrust washers.
Bearing
1. Thoroughly clean bearing.
SPD715
PD..35
ADJUSTMENT (Model H2338 and H260)
To avoid confusion while calculating bearing shims, it is abso-

lutely necessary to stay with the metric system. If you measure
anything in inches, the results must be converted to the metric
system.
Drive Pinion Height

1. Prepare Tools for pinion height adjustment.
~~
<D Height Gauge (H233B ST31251000)
(H260 ST31130000)
@Dummy Shaft (H233B ST31181001)
(H260 ST31241000)
(IDSpacer [thickness: 2.50 mm (0.0984 in)]
@ Feeler Gauge
2. To simplify the job, make a chart, like the one below, to
~ ~~
lETIERS HUNDREDTHS OF A MilLIMETER
H: Head number
D': Figure marked on dummy shaft

S: Figure marked on height gauge
N: Measuring clearance
3. Write the following numbers down the chart.

H: Head number
SPD542
D': Figure marked on dummy shaft
SPD759
PD-36
ADJUSTMENT (Model H233B.and H260)
DriveP.inion Height (Co nt' d)
S: Figure marked on height gauge
SPD760
4. Place pinion rear bearing inner race and Tools on gear

carrier.
~ SPD230A
5. Attach Tool (Height gauge) to gear carrier, and measure

the clearance between the height gauge tip and the dummy
shaft face.
SPD231A
PD-37
AOJUSTMENT(Model H233B and H260)
OrivePinion Height (Cont'd)
6. Substitute these values into the equation to calculate the
thickness of the washer.
If values signifying H, D' and S are not given, regard them as
zero and calculate.
T (Thickness of washer) = N - [(H - D' - S) x 0.01] + 3.05
Example:
N = 0.30
H = 2
0' = -1
S = 0
T = N - [(H - 0' - S) x 0.01] + 3.05
= 0.30 - [(2 - (-1) - 0) x 0.01] + 3.05
(1) H 2
-0' ..................................... .................................... -(-1)
3
-S -0
3
(2) 3
x.0.01
0.03
(3) N 0.30
-0.03
0.27
(4) 0.27
+3.05
3.32
:. T = 3.32
7. Select the proper washer (Refer to S.O.S.).
If you cannot find the desired thickness of washer, use washer
with thickness closest to the calculated value.
Example:
Calculated value ... T = 3.32 mm
Used washer ... T = 3.33 mm
PO-38
ADJUSTMENT (Model H233B •andH260)
Tooth Contact
Gear tooth contact pattern check is necessary to verify correct
relationship between ring gear and drive pinion.
Hypoid gear set which are not positioned properly in relation to
one another may be noisy, or have short life or both. With the
pattern check, the most desirable contact for low noise 'level

SPD005
3. Hold companion flange steady by hand land rotate the ring

SPD695
Usually the pattern wlll be correct I(.you have calculated the shhns correctly and the backlash Is correct.
However, In rare cases you may have to use trlal.and~error,J)ro~esses until you get a good tooth contact pattern.
Heel contact Face contact Toe contact .Flank contact
~~
drive pinion close to ring gear. drive pinion go away from ring gear,
h.'__ =_/~~
off completely the ferric oxide and 011or their ~
equivalent. ~
SPD007
PD-39
ASSEMBL V (Model H233B and H260)
Differential Case - 4-pinion type -

differential case.
and differential case (A - B): Refer to 5.0.5.
The clearance can be adjusted with side gear thrust
washer. (Refer to S.O.S.)
SPD656

with a hammer.

Tool.
Tool number:
H233B GD 5T33190000
@ 5T33081 000
H260 GD 5T01550002
@ 5T02371000
PD-40
ASSEMBLY (ModelH23~Band H260)
DifferentialCase- 2-piniontype -
1. Install side gears, pinion mate.gears, thrust washers and
thrust block into differential case.
2. Fit pinion mate shaft to differential case so that it meets

lock pin holes.
SPD553
3. Adjust clearance between rear face of side gear and thrust

washer by selecting side gear thrust washer. Refer to
S.O.S.
Backlash of side gear: Refer to S.O.S.
SPD828
4. Install pinion mate shaft lock pin with a punch.

Make sure lock pin is flush with case.
5. Apply oil to gear tooth surfaces and thrust surfaces and

check that they turn properly.
SPD322
PD-41
ASSEMBLY (Model H233B and H260)
Differential Case - 2-pinion type - (Cont'd)
.,
::: ....•
.
~
~
6. Apply locking sealant to contacting surfaces of ring gear
and differential case, then place differential case on ring
gear.
SPD600
7. Apply locking sealant to ring gear bolts.

8. Install new lock straps and ring gear bolts.
• Tighten bolts in a criss-cross fashion, lightly tapping bolt
head with a hammer.
• Then bend up lock straps to lock the bolts in place.
SPD032

Tool.
Tool number:
H233B GD ST33190000
@ ST33081 000
H260 GD ST01550002
@ ST02371000
SPD257A
1. Press-fit front and rear bearing outer races with Tools.
Tool number:
H233B GD ST30611000
@ ST30621 000
<ID ST30613000
H260 GDST30611 000

@ ST0150001
<ID ST30613000
~f
/\
Pinion front
~ bearing outer race
SPD260A
PD-42
2. Select drive pinion adjusting washer, referring to Adjust-
Adjusting
washer
ment.
3. Install drive. pinion adjusting washer in drive pinion, and
press-fit pinion rear bearing inner cone in it with press and
Tool.
Tool Tool number: ST30901000
4. Place pinion front bearing inner cone in gear carrier.
)
r
J~
~o I
SPD581

seal. Install front oil seal.
SPD160
Drive pinion bearing spacer

6. Install drive pinion bearing spacer, pinion bearing adjust-
ing shim and drive pinion in gear carrier.
7. Insert companion flange into drive pinion by tapping the

companion flange with a soft hammer.
SPD697
PD..43
8. Tighten pinion nut to the specified torque.
The threaded portion of drive pinion and pinion nut should be
free from oil or grease.
Tool number:
H233B 5T31530000
H260 5T31620000
SPD040
9. Turn drive pinion in both directions several times, and mea-

sure pinion bearing preload.
Tool number: 5T31275000
Pinion bearing preload: Refer to S.O.S.
SPD149

11. Position side bearing adjusters on gear carrier with

threads properly engaged; screw in adjusters lightly at this
stage of assembly.
Tool number:
H233B 5T32580000
H260 5T32530000
12. Align mark on bearing cap with that on gear carrier and
install bearing cap on gear carrier.
• Do not tighten at this point to allow further tightening of side
bearing adjusters.
SPD265
PD-44
ASSEMBLV(Model H233Band H260)
13. Tighten both right and left side bearing adjusters alter-
nately and measure ring gear backlash and total preload at
the same time. Adjust right and left side bearing adjusters
by tightening them alternately so that proper ring gear
backlash and total preload can be obtained.
Refer to S.O.S.
SPD246

several times to set bearing rollers.
SPD149
14. Tighten side bearing cap bolts.

15. Install side lock finger in place to prevent rotation during
operation.
16. Check runout of ring gear with a dial indicator.

• If the backlash varies greatly when the runout of the ring
gear is within a specified range, the hypoJdgear set or dif-
17. Check tooth contact (Refer to Adjustment).
SPD247
PD-45
FINAL DRIVE (Model H290 and H310)
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SPD178A
PD-46
DISASSEMBLY (Model H290 and H310)
Pre-inspection
Before disassembling final drive, perform the following inspec-
tion.
• Total preload
1) Turn drive pinion in both directions several times to seat
bearing rollers correctly.
SPD149 • Ring gear to drive pinion backlash
points.
Refer to S.O.S.
SPD246

SPD247
• Tooth contact
Check tooth contact, referring to Adjustment.
Clearance between side gear thrust washer and
differential case: Refer to S.O.S.
1. Mount final drive assembly on Tool.
Tool number:
H290 ST06240000
H310 KV38108100
PD-47
DISASSEMBLY {Model H290 and H310}
Differential Carrier {Cant' d)
during reassembly.
SPD249
3. Remove side lock fingers and side bearing caps.
4. Remove side bearing adjuster with Tool.

Tool number:
H290 5T32570000
H310 (Refer to PREPARATION.)
5. Remove differential case assembly with a pry bar.
Be careful to keep the side bearing outer races together with

their respective inner cones - do not mix them up.
SPD011
PD-48
DISASSEMBLY (Model H290and H310)
6. Remove drive pinion nut with Tool.
Tool number:
H290 ST31590000
H310 ST31570000
SPD012
SPD686
8. Remove oil seal from drive pinion bearing cup.

9. Remove bearing cup from differential carrier.
SPD179A
10. Remove drive pinion and sleeve from differential carrier by

hammering the drive pinion end via drift (copper rod).
SPD180A
11. Press drive pinion out of sleeve.
PD-49
DISASSEMBLY (Model H290 and H310)
12. Using tool, press rear bearing inner cone out of drive pin-
ion.
()
()
()
I+----------a~ SPD182A
13. Using a drift, drive bearing outer races out of drive pinion.
SPD183A
14. To remove drive pinion bearing (for replacement), remove

plain washer, then remove pinion bearing from carrier
using a hammer and copper drift.
SPD184A
Differential Case
To prevent damage to bearing, engage puller jaws in groove.
Tool number:
CDST33021 000
@ KV381 0311 0
SPD261A
PO-50
DISASSEMBLY (Model H290and H310)
Differential Case (Cont'd)
Be careful not to confuse left and right hand parts.
SPD022

3. Tap ring gear off differential case with a soft hammer.
SPD024
4. Separate differential case.

Put matchmarks on both L.H. and R.H. differential cases.
PO-51
INSPECTION (Model. H290 and H310)

Check gear teeth for scoring, cracking or chipping.
If any damaged part is evident, replace ring gear and drive
pinion as a set (hypoid gear set).
Differential Case Assembly

mate gears, pinion mate shaft, and thrust washers.
SPD177A
Bearing
1. Thoroughly clean bearing.
SPD715
PO-52
ADJUSTMENT.(Model H290.and H310)
Pinion Height and Drive Pinion Bearing Preload

Adjustment
Adjustment of the pinion height can be made by adjusting shim
and spacer to be installed between the rear bearing inner race
and the drive pinion head.
In regards to drive pinion bearing preload, the adjustment can
be made by selecting pinion adjusting spacer and washer.
For this type of differential carrier, drive pinion bearing preload
should be adjusted similar to the way pinion height is adjusted.
1. Press"'fit front and rear bearing outer race onto drive pin-
ion sleeve using Tool.
SPD262A
2. Install bearing inner race and drive pinion sleeve on Tool.

SPD263A
3. Tighten nut until turning torque is in the specified range.

Tighten it HUle by little because there are no washers and
spacers between front bearing and rear one.
Drive pillion flange turning torque: Refer to S.O.S.
Example 1 4. Turn drive pinion sleeve upside down and place Toolan it.
Then measure clearance B.
Tool number:
CD 5T31161000
CID 5T31162000
Value B:
In example 1, value B can be determined by adding minus "-"
B to measured clearance B; in example 2, measured clearance B
itself is value B.
Example 2 Adjustment (Cont'd)
• Press 5. Remove Tool from drive pinion flange .

Install bearing inner race (gear side), drive pinion sleeve,
pinion adjusting washer and spacer, bearing inner race,
companion flange spacer and companion flange.
SPD467
6. Hold companion flange with Tool and tighten pinion nut.

Tool number:
Refer to PREPARATION.
SPD266A
7. Measure drive pinion bearing preload.

Drive pinion preload: Refer to S.O.S.
If preload is not in the specified range, replace pinion
adjusting washer and/or spacer with another one.
Preload is too large ~ Change to a thicker one.
Preload is too small ~ Change to a thinner one.
8. Thickness of pinion height adjusting shim can be calculated
by the following equation.
T = 1.25 + (H - A) x 0.025 + B
Where:
SPD469 T: Required thickness of shim
H: Figure marked on drive pinion head
A: Figure stamped on differential carrier flange
B: Value measured in step 4
PO-54
Adjustment (Cont'd)
The required thickness of shim shou.ldbe the nearest one to the
calculated value.
SPD470
Tooth Contact
Gear tooth contact pattern check is necessary to verify correct
relationship between ring gear and drive pinion.
Hypoid gear set which are not positioned properly in relation to
one another may be noisy. or have short life or both. With a
pattern check, the most desirable contact for low noise level

SPD005
3. Hold companion flange steady by hand and rotate the ring

SPD695
PO-55
Tooth Contact (Cont'd)
Usually the pattern will be correct If you have calculated the shims correctly and the backlash Is correct.
However, In rare cases you may have to use trlal-and-error processes until you get a good tooth contact pattern.
Heel contact Face contact Toe contact Flank contact
~~
drive pinion close to ring gear. drive pinion go away from ring gear.
Cone" tooth , .... " / V-t--=:,

off completely the ferric oxide and 011or their
equivalent.
SPD007
PO-56
ASSEMBLY (Model H290 andH310)
Differential Case
differential case.
and differential case (A - B):
Refer to S.O.S.
The clearance can be adjusted with side gear thrust
washer. (Refer to S.O.S.)
SPD656

with a hammer.

Tool.
Tool number:
CD KV381 03200
<ID KV381 0311 0
PD-57
ASSEMBLY (Model H290 and H3l0)
1. Insert drive pinion rear bearing outer race into bore in car-
rier using a hammer and copper drift.
2. Secure rear bearing outer race using plain washer.

3. Remove companion flange. Install gasket and cup on drive
pinion sleeve and secure with bolts.
4. Install selected pinion height adjustment shim(s) on carrier

flange surface.
Align oil hole on carrier with oil hole on sleeve during instal-
lation.
5. Install sleeve and drive pinion assemblies on carrier.
SPD188A
6. Using tool, install oil seal on drive pinion cup.

Charge oil seal lips with chassis grease.
Tool numbers:
H290 KV381 02550
H310 KV38102450
PO-58
ASSEMBLY (Model H290 and H310)
7. Using Tool, tighten pinion nut to specified torque.
Tool numbers:
H290 ST31590000
H310 ST31570000
\
SPD190A

PD383
9. Position side bearing adjusters on gear carrier with

threads properly engaged; screw in adjusters lightly at this
stage of assembly.
Tool number:
H290 ST32570000
H310 (Refer to PREPARATION.)
10. Align mark on bearing cap with that on gear carrier and
install bearing cap on gear carrier.
• Do not tighten at this point to allow further tightening of side
bearing adjusters.
SPD265
11. Tighten both right and left side bearing adjusters alter-
nately and measure ring gear backlash and total preload at
the same time. Adjust right and left side bearing adjusters
by tightening them alternately so that proper ring gear
backlash and total preload can be obtained.
Ring gear-to-drive pinion backlash: Refer to S.O.S.
PO-59
ASSEMBLY (Model H290 and H310)
several times to set bearing rollers.
SPD149
14. Tighten side bearing cap bolts.

15. Install side lock finger in place to prevent rotation during
operation.
16. After adjusting gear backlash, measure distance between

left and right bearing cap end surface using gauge. If it is
less than specifications, equally tighten left and right
adjustment nuts; if it is greater, equally loosen.
The above distance must be measured to ensure side bearing
preload is within specifications and bearing caps are free from
interference with axle case.
Standard distance between cap-end surfaces:
H290 282.8 - 282.9 mm (11.134 - 11.138 in)
H310 302.7 - 302.8 mm (11.917 - 11.921 in)
17. Check runout of ring gear with a dial indicator.

• If the backlash varies greatly when the runout of the ring
gear is within a specified range, the hypoid gear set or dif-
18. Check tooth contact (Refer to Adjustment).
SPD247
PD-60
SERVICE OATAANO SPECIFICATIONS (S.D.S.)
Propeller Shaft
GENERAL SPECIFICATIONS
F23 series
Long wheelbase models
Wheelbase Standard
I Long Standard Long
Engine type NA20S TD25

I TD27
Transmission type RS5W71C RS5W81A
Rear tire Double Single Double Single
Final drive type C200 H233B C200 H233B
Propeller shaft model 2S71H 2F80B
Number of joints 2
Coupling method with transmission Sleeve type
Types of journal bearings Solid type (Disassembly type)
Shaft length (Spider to spider) mm (in) 750 (29.53) 770 (30.31) I 925 (36.42) 745 (29.33) 920 (36.22)
Shaft outer diameter mm (in) 75 (2.95) 75 (2.95)
H41 series
Wheelbase Standard Long Super long
Engine type BD30 FD42 FD46

I FD42 FD42
Transmission type RS5W81A RS5R50A RS5R50A RS5R50A
Rear tire Single

I Double Double Double Double
Final drive type H260 H296 H310
Propeller shaft model 2F80B 2F100H 3F100H
Number of joints 2 3
Coupling method with transmission Flange type
Type of journal bearing Solid type (Disassembly type)
Shaft length (Spider to spider)
1st mm (in) 865 (34.06) 870 (34.25) 780 (30.71) 1,225 (48.23)
2nd mm (in) - 960 (37.80) 960 (37.80)
Shaft outer diameter mm (in) 75 (2.95) 82.6 (3.252) 82.6 (3.252) 82.6 (3.252)
SERVICE DATA
Propeller shaft model 2S71 H, 2F80B
I 2F100H, 3F100H
Propeller shaft runout allowance mm (in) 0.6 (0.024)
Journal axial play allowance mm (in) 0.02 (0.0008) 0.03 (0.0012)

I
PO-61
Final Drive
GENERAL SPECIFICATIONS
F23 series
TD25
Engine type TZ3 TD25 TZ3 TD27
Option
Rear tire Double Single
Final drive type C200 H233B
Number of pinions 4 2 4 4
Gear ratio 4.375 4.111 5.875 5.571 5.143
Number of teeth
Ring gear 35 37 41 39 36
Drive pinion 8 9 7 7 7
Oil capacity t (Imp pt) 1.3 (2-1/4) 2.0 (3-1/2)
H41 series
Engine type BD30 FD42 FD42 FD46
Vehicle model - Rear wide Dump
Payload 2-ton 2.75-ton 3-ton
Wheelbase Standard Long
Rear tire Single Double Double
Others - Standard Standard Option Standard Standard Option Standard Option
Final drive type H260 H290 H310
Number of pinions 4 4
Gear ratio 5.857 6.143 5.571 5.857 5.857 5.857 6.167 5.571 5.857
Number of teeth
Ring gear 41 43 39 41 41 41 37 39 41
Drive pinion 7 7 7 6 7
Oil capacity t (Imp pt) 4.3 (7-5/8) 4.6 (8-1/8) 6.0 (10-5/8)
PD-62
Propeller Shaft
Available snap rings
2571H
Thickness mm (in) Color Part number
1.99 (0.0783) White 37146-01GOO
2.02 (0.0795) Yellow 37147-01 GOO
2.05 (0.0807) Red 37148-01 GOO
2.08 (0.0819) Green 37149-01 GOO
2.11 (0.0831) Blue 37150-01GOO
2.14 (0.0843) Light brown 37151.01 GOO
2.17 (0.0854) Pink 37152-01 GOO
2.20 (0.0866) No paint 37153-01 GOO
2F80B
1.99 (0.0783) White 37146-C9400
2.02 (0.0795) Yellow 37147-C9400
2.05 (0.0807) Red 37148-C9400
2.08 (0.0819) Green 37149-C9400
2.11 (0.0831) Blue 37150-C9400
2.14 (0.0843) Light brown 37151-C9400
2.17 (0.0854) Black 37152-C9400
2.20 (0.0866) No paint 37153-C9400
2F100H, 3F100H
1.95 (0.0768) White 37146-61502
1.98 (0.0780) Yellow 37147-61502
2.01 (0.0791) Red 37148-61502
2.04 (0.0803) Green 37149-61502
2.07 (0.0815) Blue 37150-61502
2.10 (0.0827) Light brown 37151-61502
2.13 (0.0839) Pink 37146-61503
2.16 (0.0850) Gold 37147-61503
2.19 (0.0862) Black 37148-61503
2.22 (0.0874) No paint 37149-61503
PD-63
SERVICE DATA (C200) Drive pinion adjusting washer (C200)
Final drive model C200 Thickness mm (in) Part No.
Drive pinion bearing preload adjusting 3.09 (0.1217) 38154-P6017

Collapsible
method 3.12 (0.1228) 38154-P6018
Drive pinion preload 1.1 -1.7 3.15 (0.1240) 38154-P6019
(With front oil seal) N'm (kg-em, in-Ib) (11 - 17, 9.5 - 14.8)
3.18 (0.1252) 38154-P6020
1.4 - 3.1 3.21 (0.1264) 38154-P6021
Total preload N'm (kg-em, in-Ib) (14 - 32,
3.24 (0.1276) 38154-P6022
12 - 28)
3.27 (0.1287) 38154-P6023
Side bearing adjusting method Shim
3.30 (0.1299) 38154-P6024
Backlash
3.33 (0.1311) 38154-P6025
0.13-0.18 3.36 (0.1323) 38154-P6026
Drive pinion to ring gear mm (in)
(0.0051 - 0.0071)
3.39 (0.1335) 38154-P6027
Side gear to pinion mate gear 3.42 (0.1346) 38154-P6028
0.10 - 0.20
(Clearance between side gear to differ-
(0.0039 - 0.0079) 3.45 (0.1358) 38154-P6029
ential case) mm (in)
3.48 (0.1370) 38154-P6030
Ring gear runout limit mm (in) 0.05 (0.0020)
3.51 (0.1382) 38154-Pl3031
3.54 (0.1394) 38154-P6032
Side bearing adjusting shim (C200)
3.57 (0.1406) 38154-P6033
Thickness mm (in) Part No. 38154-P6034
3.60 (0.1417)
2.00 (0.0787) 38453-N3100 3.63 (0.1429) 38154-P6035
2.05 (0.0807) 38453-N3101 3.66 (0.1441) 38154-P6036
2.10 (0.0827) 38453-N3102
2.15 (0.0846) 38453-N3103 Side gear thrust washer (C200)
2.20 (0.0866) 38453-N3104
Thickness mm (in) Part No.
2.25 (0.0886) 38453-N3105
0.775 (0.0305) 38424-E3000
2.30 (0.0906) 38453-N3106
0.825 (0.0325) 38424-E3001
2.35 (0.0925) 38453-N3107
0.875 (0.0344) 38424-E3002
2.40 (0.0945) 38453-N3108
0.925 (0.0364) 38424-E3003
2.45 (0.0965) 38453-N3109
2.50 (0.0984) 38453-N3110
2.55 (0.1004) 38453-N3111
2.60 (0.1024) 38453-N3112
PO-54
Final Drive
INSPECTION AND ADJUSTMENT (H233B) Drive pinion preload adjustment
Ring gear runout Drive pinion bearing preload adjust-
Adjusting shim and spacer
ing method
Ring gear runout limit mm (in) 0.08 (0.0031)
Drive pinion preload
N'm (kg-em, in-Ib)
Side gear adjustment
1.2 - 1.5
Without front oil seal
Side gear backlash (12 - 15, 10 - 13)
(Clearance between side gear to 0.15 (0.0059) or less Available drive pinion preload adjusting shims
differential case) mm (in)
Available side gear thrust washers
Thickness mm (in) Part number 2.31 (0.0909) 38125-82100
1.75 (0.0689) 38424-T5000 2.33 (0.0917) 38126-821 00
1.80 (0.0709) 38424- T5001
2.35 (0.0925) 38127-82100
1.85 (0.0728) 38424- T5002
2.37 (0.0933) 38128-82100
Drive pinion height adjustment 2.39 (0.0941) 38129-82100

Available pinion height adjusting washers 2.41 (0.0949) 38130-82100
Thickness mm (in) Part number 2.43 (0.0957) 38131-82100

2.58 (0.1016) 38151-01JOO 2.45 (0.0965) 38132-82100
2.61 (0.1028) 38151-01J01
2.47 (0.0972) 38133-82100
2.64 (0.1039) 38151-01J02
2.67 (0.1051) 38151-01J03 2.49 (0.0980) 38134-82100
2.70 (0.1063) 38151-01J04 2.51 (0.0988) 38135-82100

2.73 (0.1075) 38151-01J05 2.53 (0.0996) 38136-82100
2.76 (0.1087) 38151-01J06
2.55 (0.1004) 38137-82100
2.79 (0.1098) 38151-01J07
2.82 (0.1110) 38151-01J08 2.57 (0.1012) 38138-82100
2.85 (0.1122) 38151-01J09 2.59 (0.1020) 38139-82100

2.88 (0.1134) 38151-01J10 Available drive pinion preload adjusting spacers
2.91 (0.1146) 38151-01J11
Length mm (in) Part number
2.94 (0.1157) 38151-01J12
2.97 (0.1169) 38151-01J13 4.50 (0.1772) 38165-76000
3.00 (0.1181) 38151-01J14 4.75 (0.1870) 38166-76000

3.03 (0.1193) 38151-01J15 5.00 (0.1969) 38167-76000
3.06 (0.1205) 38151c01J16
5.25 (0.2067) 38166-01JOO
3.09 (0.1217) 38151-01J17
3.12 (0.1228) 38151-01J18 5.50 (0.2165) 38166-01J10
3.15 (0.1240) 38151-01J19

3.18 (0.1252) 38151-01J60 Total preload adjustment
3.21 (0.1264) 38151-01J61 Total preload 1.7 - 2.5
3.24 (0.1276) 38151-01J62 N'm (kg-em, in-Ib) (17 - 25, 15 - 22)
3.27 (0.1287) 38151-01J63
0.15 - 0.20
3.30 (0.1299) 38151-01J64 Ring gear backlash mm (in)
(0.0059 - 0.0079)
3.33 (0.1311) 38151-01J65
Side bearing adjusting method Side adjuster
3.36 (0.1323) 38151-01J66
3.39 (0.1335) 38151-01J67
3.42 (0.1346)
Ring gear runout
38151-01J68
3.45 (0.1358) 38151-01J69 H260 0.08 (0.0031) or less
Ring gear rear face
3.48 (0.1370) 38151-01J70 runout limit H290 0.08 (0.0031) or less
3.51 (0.1382) 38151-01J71 mm (in)
H310 0.08 (0.0031) or less
3.54 (0.1394) 38151-01J72
3.57 (0.1406) 38151-01J73
3.60 (0.1417) 38151-01J74
3.63 (0.1429) 38151-01J75
3.66 (0.1441) 38151-D1J76
PD-65
Final Drive (Conl'd)
Side gear adjustment H290
0.15 - 0.2
----------'"T'"----------
H260
(0.0059 - 0.0079)
0.Q7 (0.0028) 38154 T8000
Side gear backlash 0.05 - 0.3
H290 0.10 (0.0039) 38154 T8001
mm (in) (0.0020 - 0.0118)
0.20 (0.0079) 38154 T8002
0.15-0.2
H310
(0.0059 - 0.0079) 0.50 (0.0197) 38154 T8003
Available side gear thrust washers H310

H260, H290 Part No.
Thickness mm (in)
Thickness mm (in) Part No. Right side Left side
1.55 (0.0610) 3842461500 0.10 (0.0039) 38155 Z5010 38155 Z5005
1.60 (0.0630) 3842461501 0.15 (0.0059) 38155 Z5011 3815525006
1.65 (0.0650) 3842461502 0.50 (0.0197) 38155 Z5012 38155 Z5007
0.5 (0.020) 3815525008

H310 1.0 (0.039) 3815525009
1.54 (0.0606) 3842490010 Drive pinion preload adjustment

1.57 (0.0618) 3842490011 H260
Drive pinion bear- Adjusting washer and
1.60 (0.0630) 3842490012 H290
ing adjustment spacer
1.63 (0.0642) 3842490013 H310
1.66 (0.0654) 3842490014 1.4 - 1.7

H260
(0.14 - 0.17,1.0 - 1.2)
1.69 (0.0665) 3842490015
1.8 - 2.4
H290
Drive pinion pre- (0.18 - 0.24, 1.3 - 1.7)
Drive pinion height adjustment
load (oil seal 1.3 - 2.0
Available pinion height adjusting washers installed) Old bearing (0.13 - 0.20,
N'm (kg-m, ft-Ib) 0.9 - 1.4)
H260 H310
2-3
Thickness mm (in) Part No. New bearing (0.2 - 0.3,
2.60 (0.1024) 3815382101 1.4 - 2.2)
2.63 (0.1035) 3815382102
2.66 (0.1047) 38153 82103 Available drive pinion preload adjusting
2.69 (0.1059) 3815382104 shims
2.72 (0.1071) 38153 82105 H260
2.75 (0.1083) 38153 82106
2.78 (0.1094) 3815382107
2.31 (0.0909) 3812582100
2.81 (0.1106) 38153 82108
2.33 (0.0917) 3812682100
2.84 (0.1118) 3815382109
2.35 (0.0925) 3812782100
2.87 (0.1130) 3815382110
2.37 (0.0933) 3812882100
2.90 (0.1142) 3815382111
2.39 (0.0941) 3812982100
2.93 (0.1154) 3815382112
2.41 (0.0949) 3813082100
2.96 (0.1165) 3815382113
2.43 (0.0957) 38131 82100
2.99 (0.1177) 3815382114
2.45 (0.0965) 3813282100
3.02 (0.1189) 3815382115
2.47 (0.0972) 3813382100
3.05 (0.1201) 38153 82116
2.49 (0.0980) 3813482100
3.08 (0.1213) 38153 82117
2.51 (0.0988) 3813582100
3.11 (0.1224) 3815382118
2.53 (0.0996) 3813682100
3.14 (0.1236) 38153 82119
2.55 (0.1004) 3813782100
3.17 (0.1248) 38153 82120
2.57 (0.1012) 3813882100
2.59 (0.1020) 3813982100
PD-66
SERVICE DATA AND SPECIFICAT,IONS(S.D ..S.) -
Final Drive (Co nt' d)
H290 H310
Thickness mm (in) Part No. Thickness mm (in) Part No.
1.7000 (0.0669) 3812990008
3.81 (0.1500) 3812561500
1.7250 (0.0679) 3812990009
3.84 (0.1512) 3812661500 1.7500 (0.0689) 3812990010
1.7750 (0.0699) 3812990011
3.87 (0.1524) 3812761500
1.8000 (0.0709) 3812990012
3.90 (0.1535) 3812861500 1.8250 (0.0719) 38129.90013
1.8500 (0.0728) 3812990014
3.93 (0.1547) 3812961500
1.8750 (0.0738) 3812990015
3.96 (0.1559) 3813061500 1.9000 (0.0748) 3812990016
1.9125 (0.0753) 3812990807
3.99 (0.1571) 38131 61500
1.9250 (0.0758) 3812990017
4.02 (0.1583) 3813261500 1.9375(0.0763) 3812990808
1.9500 (0.0768) 3812990018
4.05 (0.1594) 3813361500
1.9625 (0.0773) 3812990809
4.08 (0.1606) 3813461500 1.9750 (0.0778) 3812990019
1..9875 (0.0782) 3812990810
4.11 (0.1618) 3813561500
2.0000(0.0787) 3812990100
2.0125 (0.0792) 3812990811
2.0250 (0.0797) 3812990101
2.0375 (0.0802) 3812990812
2.0500 (0.0807) 3812990102
2.0625 (0.0812) 3812990813
2.0750 (0.0817) 3812990103
2.0875 (0.0822) 3812990814
2.1000 (0.0827) 3812990104
2.1125 (0.0832) 3812990815
2.1250 (0.0837) 3812990105
2.1375 (0.0842) 3812990816
2.1500 (0.0846) 3812990106
2.1625 (0.0851) 3812990817
2.1750 (0.0856) 3812990107
2.1875 (0.0861) 3812990818
2.2000 (0.0866) 3812990108
2.2125 (0.0871) 3812990819
2.2250 (0.0876) 3812990109
2.2375 (0.0881) 3812990900
2.2500 (0.0886) 3812990110
2.2625 (0.0891) 3812990901
2.2750 (0.0896) 38129 90111
2.2875 (0.0901) 3812990902
2.3000 (0.0906) 3812990112
2.3125 (0.0910) 3812990903
2.3250 (0.0915) 3812990904
2.3375 (0.0920) 3812990905
2.3500 (0.0925) 3812990906
2.3625 (0.0930) 3812990907
2.3750 (0.0935) 3812990908
2.3875 (0.0940) 3812990909
2.4000 (0.0945) 3812990910
2.4125 (0.0950) 3812990911
2.4250 (0.0955) 3812990912
2.4375 (0.0960) 3812990913
2.4500 (0.0965) 3812990914
2.4625 (0.0969) 3812990915
2.4750 (0.0974) 3812990916
2.4875 (0.0979) 3812990917
2.5000 (0.0984) 3812990918
2.5125 (0.0989) 3812990919
2.5250 (0.0994) 3812991000
2.5375 (0.0999) 3812991001
2.5500 (0.1004) 3812991002
2.5623 (0.1009) 3812991003
2.5750 (0.1014) 3812991004
2.5875 (0.1019) 3812991005
2.6000 (0.1024) 3812991006
PD.67
SERVICEDAT A AND SPECIFICATIONS (S.O.S.)
Final Drive (Cont'd)
Available drive pinion preload adjusting T~tal preload adjustment
spacers 1.7 - 2.5
H260
H260 (0.17 - 0.25, 1.2 - 1.8)
Thicknessmm (in) Part No. 2.5 - 3.4

H290
(0.25 - 0.35, 1.8 - 2.5)
4.50 (0.1772) 3816576000 Total preload (oil seal
installed) 1.0 - 1.7
4.75 (0.1870) 3816676000 Old bearing (0.10 - 0.17,
N'm (kg-m, ft-Ib) H310
5.00 (0.1969) (side 0.7-1.2)
3816776000
bearing 1.5 - 2.5
preload) New bear-
(0.15 - 0.25,
H290 ing
1.1-1.8)
Thickness mm (in) Part No. H260 0.15 - 0.20 (0.0059 - 0.0079)

Ring gear backlash
22.25 (0.87:60) 3816561500 H290 0.20 - 0.28 (0.0079 - 0.0110)
mm (in)
22.50 (0.8858) 3816661500 H310 0.20 - 0.28 (0.0079 - 0.0110)
22.75 (0.8957) 3816761500
23.00 (0.9055) 3816861500
PD-68
," . FRONT. AXLE &
FRONT SUSPENSION
SECTIONEA
CONTENTS
PRECAUTIONS AND PREPARATION . FA- 2
FR6f..iTAXLEAf,i6' FROf..ifSu.SPE~SI6N ,..; .. FA~
ON-VEH ICLE' SERVICE ,..;;;.•....
~ ; ~ FA.,.5
FRONT AXLE - (F23) .. FA-11
FRONT AXLE - Wheel Hub and Rotor Disc, Drum Brake (F23) .. FA-12
FRONT AXLI; - Knuckle Spindle (F23) FA-16
FRONT AXLE - (H41) : ., :';, .. ": ,,/',' c', ." \.::': :" ;""
FA..18
FRONT AXLE - Wheel Iiub and Knuckle SpincHe (H41) .. fA;J9
FRONT SUSPENSION -(F23) .. FA-23 IZII' .
FRONT SUSI?ENSION -(H41) .. , FA-31

SERVICE DATA AND SP~CIFICATIONS (S.O.S.) FA-34
Precautions
• When installing rubber parts, final tightening must be car-
ried out under unladen condition* with tires on ground.
*: Fuel, radiator coolant and engine 011full. Spare tire,
Jack, hand tools and mats In designated positions.
• Use Tool when removing or Installing brake tUbes.
• When removing each suspension part, check wheel align-
ment and adjust if necessary.
SBR500
Preparation

Description
Tool name F23 H41
ST29020001 Removing ball joint for
&
Gear arm puller knuckle spindle
X X
HT72520000 Removing tie-rod outer

Ball joint remover end
-- .-"'=Z:
X X
• PAT.P
~ ~~
KV401021 SO Installing wheel bearing

Bearing race drift outer race
X -
~
KV40105400 Removing or installing
-=- -a-
Wheel bearing lock nut <J> wheel bearing lock nut
wrench \I II
X -
GG94310000
\ t1
Removing and installing
Flare nut torque wrench brake piping
X X
FA-2
FRONT AXLE AND FRONT SUSPENSION
F23
When Installing each rubber part, final tightening

must be carried out under unladen condition"
with tires on ground.
" Fuel, rlldlator coolant and engine 011full.
Spare tire, jack, hand tools and milts In
designated positions.
CAUTION:
When removing suspension member, take
care not to place engine load on body.
Suspension member
asSembly
SFA399B
FA..3
FRONT AXLE AND FRONT SUSPENSION
H41
When installing each rubber part, final tightening

" Fuel, radiator coolant and engine oil full.
Spare tire, Jack, hand tools and mats in
~L"f 'P"09
SFA400B
FA.4
ON.VEHIClESERVICE
Front Axle and Front Suspension Parts

.~heckfronfaxle and front suspension parts for looseness,
cracks, wear or other damage.
(1) Shake each front wheel.
SMA525A
F23
;(2) .Makesurethat cotter pin is. insetted.
(3) Retighterkall nuts and bolts to the specified torque.
,'rR4iJfer
l; to FRONT SUSPENSION.
CheeR'.front axle and front suspension parts for wear,
craCks or other damage. .
H41
F23
• Checlcshockabsorber forbilleakageor 'other damage.
H41
SFA403B
ON-VEHICLE SERVICE
Front Axle and Front Suspension Parts (Cont'd)
F23
• Check suspension ball joint for grease leakage and ball
joint dust cover for cracks or other damage.
SMA241
F23
• Check ball joint for vertical end play.
Upper ball Joint:
1.6 mm (0.063 in) or l.ess
(1) Jack up front of vehicle and set the stands.
(2) Clamp dial indicator onto transverse link and place indica-
tor tip on lower edge of brake caliper.
(3) Make sure front wheels are straight and brake pedal is
depressed.
(4) Place a pry bar between transverse link and inner rim of
road wheel.
(5) While pushing and releasing pry bar, observe maximum
dial indicator value.
(6) If ball joint movement is beyond specifications, remove and
recheck it.
SFA303A
Front Wheel Bearing

• Check that wheel bearings operate smoothly.
• Check axial end play.
Axial end play: 0 mm (0 in)
• Adjust wheel bearing preload if there is any axial end play
or wheel bearing does not turn smoothly.
SFA404B
Drum
SRA006
FA-6
ON-VEHICLE SERVICE
Front Wheel Bearing (Cont'd)
PRELOAD ADJUSTMENT
F23
Refer to FRONT AXLE - Wheel Hub .and Rotor Disc, Brake
Drum.
F41
Refer to FRONT AXLE - Wheel Hub and Knuckle Spindle
Front Wheel Alignment

Before checking front wheel alignment, be sure to make a pre-
liminary inspection.
PRELIMINARY INSPECTION
1. Check the tires for wear and proper inflation.
2. Check the wheel runout for outside and inside.

Wheel run out average
[(Outside runout value + Inside runout value) x 0.5]:
Radial runout limit mm (In): 0.8 (O.031)
Lateral runout limit mm (in): 0.8 (O.031)
3. Check the front wheel bearings for looseness.
4. Check the front suspension for looseness.
5. Check the steering linkage for looseness.
6. Check that the front shock absorbers work properly by
using the standard bounce test.
F23
7. Measure vehicle height (Unladen): H = A - B mm (in)
Refer to S.O.S.
(1) Exercise the front suspension by bouncing the front ofthe
vehicle 4 or 5 times to ensure that the vehicle is at a proper
height.
(2) Measure wheel alignment.
Refer to Wheel alignment on S.O.S.
(3) If wheel alignment is not as specified, adjust vehicle pos-
ture.
SFA4638 Refer to Wheel alignment on S.O.S.
(4) Adjust wheel alignment.
Refer to Wheel alignment on S.O.S.
CAM BER, CASTER AND KINGPIN INCLINATION

Before checking camber, caster or kingpin Inclination, move
vehicle up and down on turning radius gauge to minimize fric-
tion. Ensure that vehicle is in correct posture.
• Measure camber, caster and kingpin inclination of both
right and left wheels with a suitable alignment gauge and
SFA894 adjust in accordance with the following procedures.
FA-7
ON-VEHICLE SERVICE
Front Wheel Alignment (Cont'd)
Camber (Unladen):
Camber Refer to S.O.S.
Kingpin inclination (Unladen):
Refer to S.O.S.
o
SFA895
Caster
Caster (Unladen):
Refer to S.O.S.
ADJUSTMENT
F23
Both camber and caster angles are adjusted by increasing or
decreasing the number of adjusting shims inserted between
upper link spindle and frame.
Before removing or installing adjusting shim(s), be sure to.

Frame bracket
place a jackunder lower link.
Adjusting shim standard thickness:
2.9 mm (0.114 in)
r;u.
Adjusting shim
• Do no.tuse three or more shims at one place.
• When installing shim B, always face the pawl towards spin-
Shim thlC. kness
dle and insert them from bracket side. Use only one shim
1.0 (O.039) ina place.
1.6 (O.063) • Total thickness of shims must be within 9.6 mm (0.a78 in).
3.2 (O.126)
• Difference of total thickness of the front and rear must be
Unit: mm (in)
SFA4078 within 4.8 mm (0.189 in).
• Determine thickness and number of shims necessary for
adjusting camber and caster, in accordance with the follow-
ing graph.
FA ..S
ON~V&HIC:E.E':'se:RVlce
",;, 'i'ii{lirbntlWheel i,Alignment (Cont'd)
Examples:
Camber adjustme(lt
• Adjust camber' by installing or removing the same nUl\lber of
front and rear shims.
• Adding a 1 mm (0.04 in) thick ;;;him increases the camber by
12'.! .
Caster adjustment.);..,> ..•. , ' ",.' ,
• When the front shim thi9~.pess is fmm (0.04 in) greater t~<l~.
the rear, the caster and;eamberare increased by 24'a(ld .6t
respectively; when it is.1mm (0,04 in) less than therea.f, they
are decreased by 24' a(l'd 6'. . , .
SFA408B
'i,TOE..iIM f3
".~
1..• ~~.rki;~I~~~~:;I'ineacrbss"ttie tread. 'j • .
:i;f'Aft~r;I?~.~~hlg'ifrontof ve~icl~" ~qy,~' it up'i~d down ~O.e.I~mi-

nate friction, and set ste~rlng Wt!e~.1in straight ahead\po~ltlon.'
) ".~ ,', ~. 1fX}' ,"" • V
t\,Jli ",L'~
,;l,tc.;>~.".
! j n
L
P
''<Ii'"'' '
SMA123
',2.fi,:e,tq!eas.ure.toe. in. ,
i .;; ii' i' .
?"1.:;,:.1 (, ",.<,' ,i / ,"., __ ' .,.-.,,_. .\
Measure distance "A" and i

"B~~atthe $~me height as hub,cen-
i' ;/ ' ~-\ / ,-" " \, " \
ter. i i, ,,;
Toe-In:
Refer to 5.0.$.
Front
Toe-in = A - B
t:) e
e Total toe-in angle = 2
SFA234A
3. Adjust toe-in by varying, fhe'Te,ngfholsfeeringtie-rods.

(1) Loosen clamp bolts or I<;>ck nuts':>,'
(2) Adjust toe-in by turnlngJhe left',and righttie-rodtubes an
equal amount. ... \ ..
Make sure that the tie-r~d bar.~te\screWedi~to the, tie"rod
tube more than 35 mm (1'.38i,n)-:' , \<;,~ .
Make sure that the tie.ro~s ~r~;,l~~,sa~elel'1gt~: ..'
(3) Tighten clamp bolts or lock ntlts,then:tQrquitthem.
SFA409B
ON-VEHICLE SERVICE
Front Wheel Alignment (Cont'd)
FRONT WHEEL TURNING ANGLE

1. Set wheels in straight ahead position and then move vehi-
cle forward until front wheels rest on turning radius gauge
properly.
SMA127
2. Rotate steering wheel all the way right and left. measure
A B turning angle. '
Wheel turning angle: Refer to S.O.S.
t
Front
A: Inside
B: Outside
SFA898
3. Adjust by stopper bolt if necessary.
FA-10
FRONT AXLE (F23)
Disc type
Baffle plate
Wheel hub m (Inner side)

m
Drum type :r"'''
outer
~tta
bearing outer race
b .. ri"" Ell
Washer
~
Adjusting cap
lock nut
~34.39
A 118.147 (3,5 • 4.0, 25 • 29)
(12 • 15,
87 • 108)
SFA413B
FA."
FRONT AXLE - Wheel,HUij and. Rotor>Disc, Brake Drum (F23)

• Remove brake drum. (Drum brake)
•.•• ~emov~ brake saliper assembly (Disc brake).
Brake hose does not .need to be disconnected from brake cal-
iper. Be careful not to depress brake pedal, or piston will pop
out.
Make sure brake hose is not twisted.
• RemoV(ilhub cap and remove cotter pin, adjusting cap.

• Remove wheel bearing locknut with suitable tool.
• Remove wheel hub assembly from knuckle spindle.

Be careful not to drop outer bearing.
• Remove torsion bar spring.
Refer to FRONT SUSPENSION.
• After installing wheel hub and wheel bearing, adjust wheel
bearing preload.
Preload Adjustment
Adjust wheel bearing preload after wheel bearing has been
replaced or front axle has been reassembled.
Adjust wheel bearing preload as follows:
1. Before adjustment, thoroughly clean all parts to prevent
dirt entry.
2. Apply multi-purpose grease sparingly to the following
~ Multi-purpose parts:
grease point • Rubbing surface of spindle
• Contact surface between lock washer and outer wheel
SFA406B
bearing
• Hub cap (as shown at left)
• Grease seal lip
FA..12
FR.GtJ'fzAXlE.:--<Wheel Hub and Rotor Disc, Brake Drum (F23)
Preloild .Adjustment (Cont' d)
3, Tighten whe.el bearing lock nut to the specified torque.
toJ:34 -39 N'm (3.5 - 4.0 kg-m, 25 - 29ft~lb)
SFA889
4. TUliOwhe.el)llJ ..bseveral times in both directions to seat

wh.eel bearing correctly.
5. AgaJn tighten wheel bearing lock nut to the specified
torque.
toJ: 34 - 39 N'm (3.5 - 4.0 kg-m, 25 - 29ft-lb)
SFA890
With castle nut 6. Turn p.ackwhe.elbearing lock nut 45 degrees.
....~1""'r~
..•. h •..•.
"' .....
Fit adjl,Jstiogcap and new cotter pin, Align cotter pin slot by
loos.ening nut 15 degrees or less.
SMA120
.8., Measurew:he.el bearing preload and axial end play.

Wheel bearing preload
(As measured at wheel hub bolt):
Starting torque
0.7 - 1.1 N'm (0.07 - 0.2 kg-m,0.5 - 1.4 ft..lb)
Spring balance indication
9.8 - 27.5 N (1.0 - 2.8 kg, 2.2 - 6.2 Ib)
Repeat above procedures until correct bearing preload is
obtained. .
FA-13
FRONT AXLE - Wheel Hub and Rotor Disc, Brake Drum (F23)
Preload Adjustment (Cont'd)
9. Spread cotter pin.
10. Install hub cap.
SRA417
Disassembly
• Remove inner grease seal.
• Remove bearing outer races with suitable brass bar.
FA858
Inspection
Thoroughly clean wheel bearings and wheel hub.
WHEEL BEARING
• Make sure wheel bearing rolls freely and is free from noise,
WHEEL HUB
• Check wheel hub for cracks by using a magnetic explora-
tion or dyeing test.
Assembly
• Insert bearing outer race until it seats in hub with suitable
tool.
• Insert bearing inner race until it seats in hub with suitable
tool.
~ SFA414B
• Apply multi-purpose grease to each bearing cone.
Multi-purpose
grease point
SFA406B
FA-14
FRONT AXLE __ Wheel Hub.and Rotor Disc, Brake Drum (F23)
Assembly (Cont'd)
FA781
• Pack grease seal lip with multi-purpose grease, then install

it into wheel hub with suitable drift.
FA-15
FRONT AXLE - Knuckle Sp_in_d_le
__{F_2_3} _
Removal
• Separate tie-rod from knuckle spindle with Tool.
Install stud nut conversely on stud bolt so as not to damage
stud bolt.
SFA840
• Separate knuckle spindle from ball joints.

(1) Loosen (not remove) upper and lower ball joint tightening
nuts.
(2) Separate knuckle spindle from upper and lower ball joint
studs with Tool.
During above operation, never remove ball joint nuts which are
loosened In step (1) above.
Tool: ST29020001
ST29020001
SFA485B
(3) Remove ball joint tightening nuts.

Support lower link with jack.
(4) Remove knuckle spindle from upper and lower links.
Inspection
KNUCKLE SPINDLE
• Check knuckle spindle for deformation, cracks or other
damage by using a magnetic exploration or dyeing test.
FA-16
FRONT AXLE- ...>
KnuckleSp_in_d_le_<_F_23 _
Installation
• Install knuckle spindle to upper and lower ball joints with
lower link jacked up.
CAUTION:
Make sure that oil or grease does not come into contact with
tapered areas of ball joint and knuckle spindle and threads of
ball joint.
• After installing knuckle spindle, adjust wheel bearing pre-

load. Refer to Preload Adjustment in FRONTAXLE - Wheel
hub and Rotor Disc, Brake Drum.
FA-17
FRONT AXLE {H41}
'\:""'''.~ nlj-l"l14 . 18(1A. 1.8, 10 • 13)

Washer ~ ~ ~ "- Spindle upper plate lEI
/' :~ King pin lEI
'\,~~ 392 _ 490 (40 _ SO, ~ Shim lEI
o '\ 'L 289 - 362) Thrust:&o
bearin~
Knuckle spindle
~Z
0 ~SPindle lower plug ~
/ ~ ~ Brake
~ , ~um Double tire vehicles
' Grease '_______ (fg~ ..... lEI
~?
seal ~ , Wheel hub (Inner side)
@
/
Inner bearing m ~ ~ @..----.. Outer bearing outer race m
(
I /;
Inner bearing ,
outer race lEI mol ~ --OiiJ ~ Outer bearing lEI
~-.,j 118 - 157 / tb"""-d
'~ Single tire vehicles (12 - 16, 87 _ 116) '" Spindle nut ~ ~ Washer
& ~ 70 -74
Inner bearing D
Inner bearing
outer race m
'We e,0
(g}. ~~
ceO-ring
/ ~:~USting
Cotter pin ~
~
Wheel hub lEI (Inner side) e' Hub cap ~ lEI (Inner side)
~ : N.m (kg-m, ft-Ib) Brake drum
SFA418B
FA-18
FRONT AXLE _. Wheel Hub and Knuckle Spindle (H41)
Removal - Wheel Hub

• Remove brake drum.
washer
• Remove hub cap, O-ring, cotter pin, adjusting cap, spindle
nut and washer, remove wheel hub assembly from knuckle
Spindle nut spindle.
~ o ~~Adj"'ti"g ,~
COO"
PI:~jJ~
Hub cap SFA419B
Removal -Knuckle Spindle

1. Using a suitable tool, remove tie-rod and drag link from
knuckle arm.
2. Remove wheel hub assembly from knuckle spindle.
Spindle upper plate

~ 16 - 21 N.m .
\!!~.~
:l-"'t
3. Remove spindle upper plate, loosen kingpin lock nut, then
remove kingpin lock pin by lightly hammering the nut.
(1.6 - 2.1 kg-m, . K" "
4. Using a copper rod and hammer, drive out kingpin and
12 _ 15 ft-Ib) ~~. Ing pin spindle lower plug in the upper direction.
Axle center 5. Remove knuckle spindle from the axle center, then remove
JI7 ·
---...... ----u
Shim~~
o~
c;:J Knuckle spindle
6.
thrust bearing and adjustment shim(s).
Remove knuckle arm cotter pin and nut securing knuckle
arm to spindle, then separate knuckle arm and knuckle
------'----
~
:::/
~ 0 0 0 Spindle lower
spindle using a press.
L Thrust bearing ,/ plug
CAUTION:
- Kingpin lock pin @ SFA421B
Be careful not to drop thrust bearing.
Installation - Knuckle Spindle

1. Install knuckle spindle, thrust bearing and adjustment
shim(s) on the axle center as a unit. At this point, adjust
kingpin's axial end play using shim(s) intheO.02 to 0.1 mm
(0.0008 to 0.0039 in) range.
FA-19
FRONT AXLE - Wheel Hub and Knuckle Spindle (H41)
Installation - Knuckle Spindle (Cont'd)
Part No. Thickness, mm (in)
400320TOOO 0.10 (0.0039)

400320T001 0.15 (0.0059)
400320T002 0.20 (0.0079)
400320T003 0.25(0.0098)
400320T004 0.30 (0.0118)
2. Using a copper rod and hammer, drive kingpin into place;

install lock pin and tighten lock nut.
3. Install spindle lower plug on the lower side of kingpin.
CAUTION:
After driving spindle lower plug, clinch the plug at three points
equally spaced over its circumference.
4. Tighten spindle upper plate's bolts.
5. Using a grease gun, grease kingpin.
6. Install knuckle arm and knuckle spindle.
Preload Adjustment
1. Charge the shaded section (see figure at left) of wheel hub
assembly with grease and install on knuckle spindle.
2. Sparingly apply grease to both surfaces of the wheel bear-
ing nut and washer and tighten wheel bearing nut to spec-
ified torque.
~: 69 - 74 N'm (7.0 - 7.5 kg-m, 51 - 54 ft-Ib)
Multi-purpose 3. Turn hub back and forth two or three times until wheel
grease point bearing is settled down.
4. Loosen wheel bearing nut until it is loose enough to turn by
SFA406B
hand, then tighten again.
~: 39 - 44 N'm (4.0 - 4.5 kg-m, 29 - 33 ft-Ib)
5. Turn hub back and forth again so that wheel bearing is
settled down.
6. Tighten wheel bearing nut to specified torque.
~: 39 - 44 N'm (4.0 - 4.5 kg-m, 29 - 33 ft-Ib)
7. After settling down wheel bearing, check to ensure hub's

rotation starting torque and axial end play are within spec-
ifications. If not, repeat torque and/or end play adjustments,
starting with tightening wheel bearing nut.
Rear double-tire model:
Rotation starting torque (As measured at wheel
hub bolt):
6.9 - 29.4 N (0.7 - 3.0 kg, 1.5 - 6.6 Ib)
SFA488B
FA.20
FRONT AXLE -. Wheel Hub and Knuckle Spindle (H41)
Preload Adjustment (Cont'd)
Rear..~lngle~.tlre model:
Rotation starting torque (As measured at wheel
hub.bolt):
7.8 - 35.3 N (0.8 - 3.6 kg, 1.8 -.7.9 Ib)
Axial end play: 0 mm (0 In)
8. Install adjusting cap over wheel bearing and adjust so that
cotter pin holes are aligned. If cotter pin holes are not
aligned, loosen wheel bearing within 15°, max. until the
holes are aligned.
Allowable maximum wheel bearing back-off angle: 15°
CAUTION:
Ensure wheel bearing is too tight to be rotated by hand.
9. Apply grease to inner wall of wheel hub cap. Using a drift,
install hubcap onto hub.
Wheel. Hub Bearing

CAUTION:
After either wheel bearing is disassembled, replace both wheel
bearings as a set.
DISASSEMBL V
• Remove inside wheel bearing outer race, grease seal and
outside wheel bearing outer race.
CAUTION:
• Cotter pin must not be r,used.
• Grease seal must not be. reused.
SFA4258
Inspection
Thoroughly clean wheel bearings and wheel hub.
KINGPIN
• Check kingpin for wear or cracks. Replace if necessary.
WHEEL BEARING
cracks, pitting or wear. Replace if necessary.
WHEEL HUB AND KNUCKLE
• Check wheel hub for cracks by using a magnetic explora-
tion or dyeing test. Replace if necessary.
FA-21
FRONT AXLE - Wheel Hub and Knuckle Sp_in_d_le_{_H_4_1} _
Assembly
• Insert inside and outside bearing outer races until they seat
in hub with suitable tool.
SFA943
• Pack hub and hub cap with multi-purpose grease.

Coat O-ring with multi-purpose grease.
FA861
• Apply multi-purpose grease to each bearing cone.
FA781
• Place inner bearing in hub and install a new grease seal,

coating sealing lips with multi-purpose grease, then install
it into wheel hub with suitable drift.
SFA747
FA-22
FRONTStJSPENSION (F23)
When installing each rubber part, final tightening

" Fuel, radiator, coolllnt and, engille oil ,full.
Spare tire,jack, hand tools and mats in
Washer ~~ 71 - 103
Upper link bushing washer (7.2 - 10.5, 52 - 76)
Bushing \ \
~ 108 - 147 Washer ~~

\
"
\ ~ ~
~~
(11 - 15, 80 - 108) ~~'-."".t~~
~",f1~' ~
Upper link spin,d,
Ie,~~
~~
~
, .~
.''-."".
U.~
~
~ ~
'~
Adjusting shil11
0
rf~ Upper link
22 - 26
(2.2-2.7,
16 - 20)
~ 7",1- 1,03 (72.' 10.5;~~ '" • '." ',' ~

52 - 76) • \1
d
~~
upper
~ 103 • 147 (11 • 1~ SO • 103)J. ' ' ;\Y '" ball
}0;0I
J/ ., , 78 - 98
0' 58-72)
c
Knuckle arm \
Knuckle spindle ,\
:-~ 16 - 22 (1.6 - 2.2, 12 - 16)
Washer L!~ Bushing

,
/ (i3\ ~
!------(11
108 - 127
- 13, 80 - 94)
00 0 0 , (AnChor arm m~
I \ Anchor~
bolt
~ 79 -103
[ (8.1 - 10.5,
~B~:~~6rubber'
~
~
'~59-76)
\~, \ ~EIl /1'-'" n
.68(" ••••• .,.5O,
~
(6.3 - 7.8, 46 - 56)
54 - 71
(5.5 - 7.2, 40 - 52)
~
' ,
,
Lower link spindle

"\
/
'1/)"-'/-/vV~J
.~
'/
118 - 157 (12 - 16, 87 - 116) ~' :::,/ Torque arm
~ {;;",h;'9 ~~:.. (~~"\=

~
\
~~9\\])j
Spacer
Tension rod
~ 108 - 147
(11 - 15, 80 - 108)
/~L I ~\
'-
Lower link
Cott" ,;,
~
t:i
118 - 191 (12 - 19.5, 87 - 141)
~: N.m (kg-m. fHb)
SFA466B
FA-23
FRONT SUSPENSION (F23)
Shock Absorber
When removing and installing shock absorber, do not allow oil
or grease to come into contact with rubber parts.
INSPECTION
Wash all parts, except for nonmetallic parts, clean with suitable
solvent and dry with compressed air.
Blow dirt and dust off of nonmetallic parts with compressed air.
• Check for oil leakage and cracks. Replace if necessary.
• Check piston rod for cracks, deformation or other damage.
• Check rubber parts for wear, cracks, damage or deforma-
tion. Replace if necessary.
Torque arm Anchor arm Torsion Bar Spring

REMOVAL
• Apply matchmarks between torsion bar spring, torque arm
and anchor arm.
SFA4278
___ • Measure anchor bolt protrusion length.
----
SFA4288
• Pull out anchor arm rearward, then withdraw torsion bar

spring rearward.
FA-24
Torsion Bar Spring (Conl'd)
• Remove torque arm.
INSPECTION
• Check torsion bar spring for wear, twist, bend and other
damage.
• Check serrations of each part for cracks, wear, twist and
other damage.
• Check dust cover for cracks.
INSTALLATION AND ADJUSTMENT

Adjustment of anchor arm adjusting nut is in tightening direc-
tion only.
Do not adjust by loosening anchor arm adjusting nut.
1. Install torque arm to lower link.
2. Coat multi-purpose grease on the serration of torsion bar
spring.
3. Place lower link in the position where bound buffer clear-

ance "C" is O.
Clearance "C": 0 mm (0 in)
Lower
link
SFA549
4. Install torsion bar spring.

Be sure to install right and left torsion bar springs correctly.
Rear
SFA854
FA-25
Torsion Bar Spring {Coni' d)
5. Set anchor arm.
• Align mounting nut with the anchor bolt protrusion (mea-
sured during removal), and tighten.
• To adjust vehicle posture, tighten or loosen anchor bolt.
Before tightening anchor bolt, always turn it once in the
direction that loosens, then tighten as required.
• After vehicle posture adjustment, tighten anchor bolt lock
nut to specified torque.
tcl]: 108 - 127 N'm (11 - 13 kg-m, 80 - 94 ft-Ib)
Ensure vehicle is empty before tightening anchor bolt.
-----
SFA431B
6. Bounce vehicle with tires on ground (unladen) to eliminate

friction of suspension.
t
Measure vehicle posture "H".
H = A - B mm (in) (Unladen)
Refer to S.O.S.
Exercise the .front suspension by bouncing the front of the
vehicle 4 or 5 times to ensure that the vehicle is at a proper
height.
Measure vehicle posture ... Dimension "H".
(Refer to Wheel alignment on S.O.S.)
If height of the vehicle is not as specified, adjust vehicle
posture.
Check wheel alignment if necessary.
If "H" dimension is not within the specified value, readjust
vehicle posture using anchor arm adjusting nut.
Upper Link
REMOVAL
• Remove shock absorber upper fixing nut.
FA-26
Upper Link (Conl'd)
• Remove bolts fixing upper ball joint on upper link.
• Remove upper link spindle fixing bolts.
SFA918
INSTALLATION
• Tighten LIpper link spindle with camber adjusting shims.
• After fitting, check dimensions "A" and "B".
A.: 110 mm (4.33 in)
B: 32 mm (1.26 in)
SFA919
• Install upper ball joint on upper link.

• Install shock absorber upper fixing nut.
• Tighten upper link spindle lock nuts under unladen condi-
tion with tires on ground.
• After installing, check wheel alignment. Adjust if neces-
sary. Refer to Front Wheel Alignment of ON-VEHICLESER-
VICE.
SFA920
DISASSEMBLY
• Press out upper link spindle with. bushings.
FA688
INSPECTION
• Check upper link spindle and rubber bushings for damage.
• Check upper link for deformation or cracks. Replace if nec-
essary.
FA-27
Upper Link (Conl'd)
ASSEMBLY
• Apply soapsuds to rubber bushing.
• Press upper link bushing.
Press bushing so that flange of bushing securely contacts end
Upper link
bushing
surface of upper link collar.
Upper link
SFA102
• Insert upper link spindle and inner washers.

Install Inner washers with rounded edges facing Inward.
• Press another bushing.
Press bushing so that flange of bushing securely contacts end
surface of upper link collar.
• Temporarily tighten nuts.
Tension Rod
• Remove fixing nuts on lower link and frame.
• Install tension rod.

Make sure that bushings and washers are installed properly.
Final tightening of rubber parts must be carried out under
unladen conditions with tires on ground.
INSPECTION
• Check tension rod for twist and deformation. Replace if
necessary.
• Check rubber bushing for cracks, wear or deterioration.
FA-28
Lower Link
• Remove shock absorber lower fixing nut.
• Remove torsion bar spring. Refer to REMOVAL of Torsion
Bar Spring.
• Remove tension rod fixing nut. Refer to REMOVAL AND
INSTALLATION of Tension Rod.
• Separate lower link ball joint from knuckle spindle.

Refer to FRONT AXLE - Knuckle Spindle.
• Remove front lower link fixing nut.
SFA922
• Remove bushing of lower link spindle from frame with suit.,

able tool.
• When installing bushing, apply soapy water on bushing.
• After installing lower link, adjust wheel alignment and vehi-
cle height. Refer to Front Wheel Alignment of ON-VEHICLE
SERVICE.
SFA872
INSPECTION
lower link and lower link spindle
• Check lower link and lower link spindle for deformation or
cracks. Replace if necessary.
lower link bushing
• Check bushing for distortion or other damage. Replace if
necessary.
FA-29
FRONT SUSPENSION {F23}
Upper Ball Joint and Lower Ball Joint

• Separate knuckle spindle from upper and lower links.
Refer to FRONTAXLE - Knuckle Spindle.
INSPECTION
• Check ball joint for sWinging force "A".
Refer to S.O.S.
If turning torque A is not within above specifications,
replace ball joint assembly.
• Check ball joint for turning torque "B".
Refer to S.O.S.
If turning torque B is not within above specifications,
replace ball joint assembly.
• Check ball joint for vertical end play "C".
'-------~---
SFA858A
---.J
Refer to S.O.S.
Replace ball joint if movement is beyond specifications.
• Check dust cover for damage.
Replace dust cover and dust cover clamp if necessary.
FA-30
FRONT SUSPENSION (H41)
When Installing each rubber part, final tightening

must be carried out under unladen condition'
• Fuel, radiator coolant and engine all full. ~ 93 - 108
Spare tire, Jack, hand tools al'ld mats In (9.5 - 11, 69 - 80)
~ 93 -'08 (9.5-11." -.r /~ 19 -25

rei (1.9 - 2.6,
e 14 - 19)
@3
@3
.~
Shock absorber
~ ~'~60'.]6
~/ (6.1 - 7.7, 44 - 56)
c:'
Grease nipple m
~ 167 - 196 (17 - 20, 123 - 145)
Stabilizer
Bushing-Q@;
BraCket~
~25-29
P~-3U-~
SFA4688
FA-31
FRONT SUSPENSION ••(H41)
Shock Absorber
When removing and installing shock absorber, do not allow oil
or grease to come into contact with rubber parts.
INSPECTION
Wash all parts, except for nonmetallic parts, clean with suitable
solvent and dry with compressed air.
Blow dirt and dust off of nonmetallic parts with compressed air.
• Check for oil leakage and cracks. Replace if necessary.
• Check piston rod for cracks, deformation or other damage.
• Check rubber parts for wear, cracks, damage or deforma-
tion. Replace if necessary.
Leaf Spring
REMOVAL
1. Remove shock absorber lower end nut and U-bolts.
2. Remove shackle nuts.

3. Remove shackle plate and shackle.
4. Remove front pin mounting bolt and nut.

5. Remove front pin.
FA-32
t=RONT$ljSPEN$ION (H41)
Leaf Spring (Cont'd)
INSTALLATION
• Apply soapsuds to rubber bushing.
• Install shackle and front pin, and finger tighten the nuts.
• Tighten U-bolt mounting nuts diagonally.
Tighten U-bolts so that the lengths of all U-bolts under spring
pad are the same.
Final tightening of rubber parts must be Carried out under
unladen conditions with tires on ground.
INSPECTION
• Check leaf spring for cracks. Replace if necessary.
• Check front bracket and pin, shackle, U-bolts and spring
pad for wear, cracks, straightness or damaged threads.
• Check all bushings for deformation or cracks. Replace if
necessary.
Stabilizer Bar
REMOVAL
• Remove stabilizer bar connecting bolt and a clamp bolt.
INSPECTION
• Check stabilizer bar for twist and deformation.
• Check rubber bushing for cracks, wear or deterioration.
INSTALLATION
Stabilizer
clamp • Install bushing outside paint mark on stabilizer.
SFA426B
FA.33
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FA-34
SERVICE DATA AND. SPECIFICATIONS (S.O.S.)
SHOCK ABSORBER - F23/H41
F23 H41
Payload 1.5-ton 2-ton

I 2.75-ton
I 3-ton
Rear tire , Single Double Single I Double
Wheelbase ,
- - Standard
I Long
Cabin width - - Standard I Wide
Diameter mm (in)
A 54 (2.13) 54 (2.13)
B 45 (1.77) 45 (1.77)
A B A B
~~-
$-
SFA4898
~-=-E4-~"
STABILIZER BAR - H41
Applied model All
Stabilizer bar diameter mm (in) 30(1.18)

WHEEL ALIGNMENT (Unladen*1)
F23 H41
Payload 1.5-ton 2-ton 2.75-ton 3-ton
Rear tire Single Double Single Double Double
Wheelbase Long Standard

I Long Standard Long Long
Cabin width Standard Standard Standard Wide
Camber degree -0'25' to 0'35' O' - l'
Caster degree 0'15' - 1'15' I 0'30' - 1'30' 2'25' - 3'55' 2'45' - 4'15' 2'25' - 3'55'
Kingpin inc.lination degree 8'55' - 9'55' . 11'30' - 12'30' "
Camber, c.aster, and kingpin

inc.lination differenc.e between 45' 30'
both sides degree
Toe-in
Radial tire
0-2
A-B mm(in)
(0 - 0.08)
o - 2 (0 - 0.08) 1 - 3 (0.04 - 0.12)
Total angle 29 degree 0' - 10' 5' - 15'
Front wheel turning angle

degree
Inside 32' - 34' 35' - 37" 39' 40' 38' 45'
Outside 26' - 28' 28' - 30' 30' 29' 28' 33'
FA-3S
WHEEL ALIGNMENT (Unladen*1)
Vehicle posture (F23)
Lower link spindle center
Lower arm pivot height (H) 139 - 145 (5.47 - 5.71)
mm (in) - ~~
SFA709
*1: Fuel, radiator coolant and engine oil full. Spare tire, jack, hand tools and mats in designated positions.
KNUCKLE SPINDLE AND CENTER AXLE BALL JOINT (F23)

(H41) Upper ball joint Lower ball joint
Clearance between kingpin and Swinging force "A"
bushing 19.6 - 122.6 9.8 - 39.2
(Measuring point:
(2.0 - 12.5, (1.0 - 4.0,
Limit mm(in) 0.1 (0.004) cotter pin hole of
4.4 - 27.6) 2.2 - 8.8)
ball stud) N (kg, Ib)
Standard mm (in) 0.020 - 0.055 (0.0008 - 0.0022)
1.0 - 4.9
28.000 - 28.021 Turning torque "B" 1.0 - 3.9
Bushing inner diameter mm (in) (10 - 50,
N'm (kg-em, in-Ib) (10 - 40, 8.7 - 34.7)
(1.1024 - 1.1032) 8.7 - 43.4)
Clearance between knuckle spin- Vertical end play
Less than 0.1 (0.004) 0.1 - 1.0 0.1 - 1.0
dle and center axle mm (in) Iimit"C"
(0.004 - 0.039) (0.004 - 0.039)
mm (in)
Spindle shim
40032 - 30TOO 0.7 (0.0276)

40033 - 30TOO 0.8 (0.0315)
40034 - 30TOO 0.9 (0.0354)
40035 - 30TOO 1.0 (0.0394)
WHEEL BEARING
Model F23 H41
Wheel bearing lock nut
Tightening torque N'm (kg-m, ft-Ib) 34 - 39 (3.5 - 4.0, 25 - 29) 69 • 74 (7.0 - 7.5, 51 - 54)
Retightening torque after loosening wheel

bearing lock nut 34 - 39 (3.5 - 4.0, 25 - 29) 39 - 44 (4.0 - 4.5, 29 - 33)
N'm (kg-m, ft-Ib)
Return angle degree 45" Max. 15"
Wheel bearing starting torque
Rear double tire 6.9 - 29.4 (0.7 - 3.0, 1.5 -

6.6)
As measured at wheel hub bolt N (kg, Ib) 9.8 - 27.5 (1.0 - 2.8, 2.2 - 6.2)
Rear single tire 7.8 - 35.3 (0.8 - 3.6,1.8 -
7.9)
Axial end play mm (in) 0(0)
FA-36
REAR AXLE &
REAR SUSPENSION
SEOTIONRA
CONTENTS
PRECAUTIONS AND PREPARATION RA- 2
REAR AXLE AND REAR SUSPENSION RA- 5
ON-VEHicLE SERVICE RA- 7
REAR AXLE (F23) ;;. RA- 9
REAR AXLE (H41) ; RA-16
REAR SUSPENSION (F23) RA-20
REAR SUSPENSION (H41) RA-21
SERVICE DATA AND $PECIFICATIONS (S.O.S.) RA-25
Precautions
• When installing rubber parts, final tightening must be car-
ried out under unladen condition* with tires on ground.
*: Fuel, radiator coolant and engine 011full. Spare tire,
jack, hand tools and mats in designated positions.
• Use Tool when removing or installing brake tubes.
• When removing each suspension part, check wheel align-
ment and adjust if necessary.
SBR820B
Preparation
Tool number
Description
Tool name
GG94310000* Removing or installing brake piping

Flare nut torque wrench
KV40101000* Removing rear axle shaft

Axle stand
ST36230000* Removing rear axle shaft

Sliding hammer
ST38020000* Removing wheel bearing lock nut

Bearing lock nut wrench
:J:~~
HT72480000* Removing wheel bearing
Rear axle shaft bearing puller
ST37840000* Installing rear axle shaft

Rear axle shaft guide
@
RA-2
Preparalion( ConI' d)
Tool number
Description
Tool name
KV40105400' Removing or installing wheel bearing
Wheel bearing lock nut wrench lock nut
COMMERCIAL SERVICE TOOLS

F23
Bearing outer race inserter Installing outer bearing's outer
race (double-tire model)
A: 46 mm (1.81 in) dla.
Bearing outer race drift Installing inner bearing's outer

race (double-tire model) or
installing wheel bearing (single-
tire model)
A: 79 mm (3.11 in) dia.

B: 59 mm (2.32 in) dla.
Grease seal drift Installing grease seal (double-

tire model)
A: 96 mm (3.78 in) dia.
Oil seal drift Installing oil seal (single-tire

model)
A: 49 mm (1.93 in) dia.

B: 41 mm (1.61 in) dia.
Grease seal drift Installing grease seal (for H233B)

(single-tire model) or installing
wheel bearing
A: 82 mm (3.23 In) dia.

B: 60 mm (2.36 in) dla.
Grease seal drift Installing grease seal (on C200

final drive) (single-tire model)
A: 76 mm (2.99 In) dia.
RA-3
Preparation (Cont'd)
H41
Bearing outer race Installing outer bearing's outer
race
A: 89 mm (3.50 in) dia.
Bearing outer race drift Installing inner bearing outer

race
A: 99 mm (3.90 In) dla.
Grease seal drift Installing grease seal
A: 77 mm (3.03 In) dia.

B: 55.5 mm (2.185 in) dia.
Grease seal inserter Installing grease seal
A: 46 mm (1.81 In) dla.

B: 110 mm (4.33 In) dla.
Metal bush drift Removing or installing metal

bush
A: 29.5 mm (1.161 In) dla.
RA-4
REAR AXLE AND REAR SUSPENSION
F23
Rear spring shackle
Leaf spring
SRA544A
RA..5
REAR AXLE AND REAR SUSPENSION
H41
Standard full floating type

Shock absorber Rear spring shackle
Leaf spring
Rear wide semi-floating type

Rear spring shackle
Shock absorber
SRA576A
RA-6
ON-VEHICLE SERVICE
Rear Axle and Rear Suspension Parts

Check rear axle and rear suspension parts for looseness, wear
or damage.
• Shake each rear wheel to check for excessive play.
• Retighten all nuts and bolts to the specified torque.

Tightening torque: Refer to REAR SUSPENSION.
• Check shock absorber for oil leakage or other damage.
Wheel Bearing
AXIAL END PLAY
1. Check that wheel bearings operate smoothly.
2. Check axial end play.
Axial end play:
Refer to S.O.S.
SRADD6
RA-7
ON-VEHICLE SERVICE
Wheel Bearing (Conl'd)
Starting torque
1. Rotate wheel hub two or three turns in each direction (for-
ward and reverse), attach spring balance to a hub bolt on
wheel hub. Check starting torque wheel hub.
2. If measured value is outside specification, check wheel hub
bearing.
F23 (Double tire only)
Rotation starting torque:
2.1 - 3.4 N'm (0.21 - 0.35 kg-m, 1.5 - 2.5 ft-Ib)
Spring scale indication (at hub bolt location):
SRA545A
24.5 - 40.2 N (2.5 - 4.1 kg, 5.5 - 9.0 Ib)
H41
0.7 - 3.3 N'm (0.074 - 0.339 kg-m, 0.5 - 2.5 ft-Ib)
Single tire vehicle
7.8 - 35.3 N (0.8 - 3.6 kg, 1.8 - 7.9 Ib)
Double tire vehicle
7.8 - 32.4 N (0.8 - 3.3 kg, 1.8 - 7.3 Ib)
RA-8
REA.R AXLE (F23)
Components
F23
Single tire
Semi-floating type
!
Double tire
Full-floating type
I
.rnk",:m~' ~4;;::
...
~lIDl
t J . _"hOb~f7fJ~"'~~4_5
Knuckle
~c~
~ @~
..
IE! Outer
---.I
b::~:9 nut
J /' )
"'G> 'rD (0.4 - 0.5, 2.9 - 3.6)
spindle ~ rrl'l Lock washer ~ ~ 57 - 75

~-.0184- 98 ~.-.l:II 0 (5.8 - 7.6,
(8.6 - 10, 62 - 72) ~..... il seal @ 42 _ 55)
Baffle plate Axle shaft
SRA577A
RA-9
REAR AXLE (F23)
Removal - Single tire models

1. Disconnect parking brake cable and brake tube.
2. Remove brake drum.
3. Remove nuts securing wheel bearing cage with baffle
plate.
4. Draw out axle shaft with Tools.

When drawing out axle shaft, be careful not to damage oil seal.
SRAO03
5. Remove oil seal.

Do not reuse oil seal once it is removed.
Always install new one.
6. Bend out tangs on lock washer with a screwdriver.
SRA104
7. Remove bearing lock nut with Tools.
SRA728
RA-10
REAR AXLE (F23)
Rembval- Single tire models (Cont'd)
8. Remove wheel bearing together with bearing cage and baf-
fle plate from axle shaft.
HT72480000
o
0
0
(> 0
()
SRA729
9. Remove grease seal in bearing cage with suitable bar.
SRA105
10.• Remove wheel bearing outer race with a brass drift.
Removal-. . Double tire models

1. Remove axle shaft tightening bolt.
2. Slowly slide axle shaft being careful not to damage oil seal
lip.
3. Remove oil seal.
4. Loosen screws and remove lock washer from rear wheel
bearing lock nut.
5. Remove. rear wheel bearing lock nut with Tool.
SRA547A
REAR AXLE (F23)
Removal - Double tire models (Cont'd)
6. Remove wheel hub assembly.
SRA548A
7. Remove inner bearing.

8. Remove oil seal.
SRA549A
9. Remove inside wheel bearing outer race, grease seal and

CAUTION:
Be careful not to drop wheel bearing. Grease seal must not be
reused.
SRA550A
Inspection
AXLE SHAFT
• Check axle shaft for bending, cracks, damage, wear or
deformation. Replace if necessary.
WHEEL BEARING
AXLE CASE
• Check axle case for deformation or cracks. Replace if nec-
essary.
Installation - Single tire models
1. Install wheel bearing outer race with suitable tool.
2. Install a new grease seal in bearing cage.
After installing new grease seal, coat sealing lip with multi-
purpose grease.
Final drive model:
H233B
Outer diameter: 82 mm (3.23 in)
C200
Outer diameter: 76 mm (2.99 in)
SRA551A
RA-12
REAR .AXLE(.F23)
Installation .._. ..Single tire models (Cont'd)
3. Install wheel bearing inner race with a brass drift.
Coat each bearing Cone.with multi-purpose grease.
4. Install plain washer and a new wheel bearing lock washer.

5. Tighten wheel bearing lock nut with tool.
Fit. wheel bearing lock washer lip in wheel bearing lock nut
groove correctly by tightening locknut. Be sure to bend it up.
6. Install a new oil seal with suitable tool.

After installing new oil seal, coat sealing lip with multi-purpose
grease.
7. Apply multi-purpose grease to recess on end of axle case.

8. Apply gear oil to the spline of axle shaft. Coat seal surface
of axle shaft with multi-purpose grease (as shown left).
~ : Lubricating portion
SRA756
9. Adjust axial end play.

10. Select end shims.
Standard thickness: 1.5 mm (0.059.in)
Axle case end shim: Refer to S.O.S.
Do not insert end shims .between case. seal and bearing cage.
RA-t3
REAR AXLE (F23)
Installation - Single tire models (Cont'd)
11. Insert axle shaft with Tool as a guide.
When inserting axle shaft, be careful not to damage oil seal.
12. Measure end play of axle shaft.

SRA012 Axial end play:
Servicing both side axles
On first axle (right or left)
0.4 - 1.6 mm (0.016 - 0.063 in)
On second axle
0.02 - 0.15 mm (0.0008 - 0.0059 in)
13. If axial end play is not within the specified limit, reselect
axle case end shims.
While adjusting axial end play, be careful not to damage oil
seal.
SRA006
Installation - Double tire models

1. Install outer race of outer bearing using suitable tool.
SRA552A
2. Install outer race of inner bearing using suitable tool.
SRA553A
3. Install grease seal using suitable tool.
SRA554A
RA-14
REAR AXLE (F23)
Installation - Double tire models (Cont'd)
4. Pack hub with recommended multi-purpose grease.
Grease point
SRA555A
5. Coat each roller bearing and inner race with recommended

multi-purpose grease.
a. Install wheel hub into axle case.
b. Install inner race of outer bearing.
c. Temporarily tighten lock nut.
SRA556A
6. Using Wheel Bearing Lock Nut Wrench, tighten lock nut to

specified torque.
~: 167 - 196 N'm (17 - 20 kg-m, 123 - 145 ft-Ib)
(1) Turn hub back and forth two or three times to settle down
wheel bearing.
(2) Loosen lock nut so that it can be rotated by hand.
(3) Tighten wheel bearing lock nut to specified torque.
(4) Turn hub back and forth again two or three times.
(5) Loosen wheel bearing nut until its screw hole is aligned
with lock washer. (Loosen to a maximum of 22.5°.)
SRA557A Do not over return angle.
(6) Using a spring scale, measure if hub's rotation starting

torque is within specifications. If it is not, loosen wheel
bearing nut and adjust rotation starting torque again.
2.1 - 3.4 N"m (0.21 - 0.35 kg-m, 1.5 - 2.5 ft-Ib)
24.5 - 40.2 N (2.5 - 4.1 kg, 5.5 - 9.0 Ib)
SRA558A
7. Coat sealing lips with recommended multi-purpose grease,

install a new oil seal.
RA ..15
REAR AXLE (H41)
Components
H41
SRA578A
Removal
1. Remove axle shaft tightening bolt.
2. Slowly slide axle shaft being care not to damage oil seal
lip.
3. Remove oil seal.
4. Loosen screws and remove lock washer from rear wheel
bearing lock nut.
SRA546A
5. Remove rear wheel bearing lock nut with Tool.
SRA547A
RA-16
REAR AxtE ..(H41)
Removal (Cont'd)
6. Removewhe.el:dflub assembly.
SRA548A
7. Remove inner bearing.

8. Remove grease seal.
SRA549A
9. Remove inside wheel bearing outer race, grease seal and

CAUTION:
Be careful not to drop wheel bearing. G.rease seal must not be
reused.
SRA550A
Inspection
AXLE SHAFT
• Check axle shaft for bending, cracks, d~m~ge,wear or
deformation. Replace if necessary.
WHEEL BEARING
• Make sure wheel bearing rolls freely and is free Jrom noise,
cracks, pitting or we~r.
AXLE CASE
• Check axle case for dElformation or cracks. Replace if nec-
essary.
RA-17
REAR AXLE (H41)
Installation
1. Install outer race of outer bearing using suitable tool.
SRA552A
2. Install outer race of inner bearing using suitable tool.
SRA553A
3. Install grease seal using suitable tool.
SRA554A
4. Pack hub with recommended multi-purpose grease.

Grease point
SRA555A
5. Coat each roller bearing and inner race with recommended

multi-purpose grease.
a. Install wheel hub into axle case.
b. Install inner race of outer bearing.
c. Temporarily tighten lock nut.
SRA556A
RA-18
REAR AXLE (H41)
6. Using Wheel Bearing Lock Nut Wrench, tighten lock nuttb
specified torque.
toJ: 167 -196 N'm (17 - 20 kg-m, 123 - 145 ft-Ib)
(1) Turn hub back and forth two or three times until wheel
bearing is settled down.
(2) Loosen lock nut so that it can be rotated by hand.
(3) Tighten wheel bearing lock nut to specified torque.
(4) Turn hub back and forth again two or three times.
(5) Loosen wheel bearing nut until its screw hole is aligned
with lock washer. (Loosen to a maximum of 22.5°.)
SRA557A Do not over return angle.
(6) Using a spring scale, measure if hub's rotation starting

torque is within specifications. If it is not, loosen wheel
bearing nut and adjust rotation starting torque again.
0.7 - 3.3 N'm (0.074 - 0.339 kg-m, 0.5 -.2.5 ft-Ib)
Spring scale indication starting torque
(at hub bolt location):
Single tire
7.8 - 35.3 N (0.8 - 3.6 kg, 1.8 - 7.9 Ib)
Double tire
SRA558A 7.8 - 32.4 N (0.8 - 3.3 kg, 1..8 - 7.3 Ib)
7. Coat sealing lips with recommended multi-purpose grease,

install a new oil seal.
RA-19
REAR SUSPENSION (F23)
F23
~ 127 - 157
j@-i'"
~~~ 127 - 157
(13 - 16, 94 - 116)
(13 - 16, 94 - 116)

~ Rear spring shackle
plate
Leaf spring
I
[I '
I'kl
!I -~_~Front pin
, I ~16 - 22
I . . (1.6 • 2.2, 12 • 16)
~ 46 - 62
(4.7 • 6.3, 34 • 46) ---@~
~...0))
~f 1 1
~
Shock ,.:~~. ~ Lower rear spring pad
absorber'/ ~~-:- j
/,\~~
~46-62
(4.7.6.3, 34 - 46) ---4
%~ tJJ
~
~
. ~ 167 - 196 (17 • 20, 123 - 145)
Single tire (Low and flat bed) Double tire (All vehicles)
r Bumper rubber
~1~-3-'1:
:@,j
Shock absorber
SRA579A
RA-20
REAR SUSPENSION (H4t)
H41
Shock absorber
~
~- .. 46
(4.7- -6263
., 34 - 46)~<R.@..U _ \..&
~
35 - 47
(3.,6 - 4.8,
26 - 35)-n
,U-bolt
n ~/
Rear spring shackle pin
6Q '
k
~bUShlng
Rear rubber
type
/if'>-
~r~s~hackle
f1<..~,
Rear spring
p.ln.ear
R
. sp.ring
''''ok'. p'''' pieS

~ , ~ , "
~ ~ I ~ Grease
~ c/ . llY ~ 12£:::&,.. nrp .
~
upper seat I ~ 93 _ 108. )
~-.. 127
(13 -- 16,
257
94
_ 116)~@
o ~-". .1 69 _ 80
~-~t (9.5 - 1 , . type '. '...
?:7:7J~
AH' -, ""'.'.g ngmetal bushing
~ ~""
ta, .... ,,". "". @!Q ' , '.
F~"I m. , .taI '''hl", 93 _ 108q,~~. I
I
C.
'----...
'----.. ~
Aoo' ","". spm ,_, (95, 11, , '""" /
lEI eO ' ") ,
A...
67
ring Imot pi'
Grease nipple S
23 ' 145)
R bber lJushing
"
">::JI 'ft!./9-'
~ 1 - 196 (17 - 20, 1 F~ot .. bber bushing type

~:N.m (kg-m , ft-Ib)
Double fire e
Double tire d High frame type Straight frame typ
High bed an ...
D~~.
€:~II ~ <:
I
m"".,
t
'retyp. ~
A .. '
---""'Q
""',
,LJi!l? "" .' ./ . ;p
.
,'.".,.
' '.
C,l-
• ..' .
'. ..... L..., • V
""t_._ ... ...
~
SRA580A
RA-21
REAR SUSPENSION (H41)
Shock Absorber
• Remove shock absorber by disconnecting upper and lower
end.
INSPECTION
• If oil leakage, cracks or deformation occurs, replace shock
absorber assembly.
• If rubber bushings are cracked or deformed, replace rub-
ber bushings.
Leaf Spring
1. Disconnect shock absorber lower end, and remove U-bolts.
2. Disconnect spring shackle.
SRA704
3. Disconnect front pin.
SRA705
RA-22
Leaf Spring (Cont'd)
INSPECTION
• Check leaf spring for cracks. Replace if necessary.
• Check front bracket and pin, shackle, U-bolts and spring
pad for wear, cracks, deformation or damaged threads.
• Check all bushings for deformation or cracks. Replace if
necessary.
Make sure that front bushing is properly installed.
INSTALLATION
1. Apply soapsuds to rubber bushing.
2. Install spring shackle and front pin, and finger tighten the
nuts.
3. Install spring pad and nuts under leaf spring or axle case.
4. Tighten U-bolt mounting nuts diagonally.
Tighten U-bolts so that the lengths of all U-bolts under spring
pad are the same.
5. Install shock absorber, and finger tighten the nuts.
All same length
SRA727
6. Remove stands and bounce the vehicle to stabilize suspen-

sion. (Unladen)
1
SRA703
7. Tighten spring shackle nuts, front pin nuts and shock

absorber nuts.
Press Metal Bush

Suitable
tool REMOVAL AND INSTALLATION
H41
Bush
1. Remove bush using suitable tool.
Leaf
spring
SRA561 A
RA-23
Metal Bush (Cont'd)
Press 2. Install bush using suitable tool.
Leaf
spring
SRA562A
Bumper Rubber
F23
• Make sure front mark is set toward outside of vehicle as
shown at left.
H41
• Make sure out mark is set toward outside of vehicle as
shown at left.
Outside
SRA564A
RA-24
SIi.FlVICE DATA AND SPECIFICATIONS (S.O.S.)
1 I
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RA-26

WHEEL BEARING
F23
Applied model Single tire
16 inch
Wheel bearing axial end play mm (in) 0.02 - 0.15 (0.0008 - 0.0059)
Final drive model
C200 H233B
Shim thickness Shim thickness

Part number Part number
(C200) (H233B)
Rear axle case end shim thickness mm (in) 0.05 (0.0020) 43086 P0110
0.07 (0.0028) 43087 P0110 0.10 (0.0039) 43036 C8000
0.10 (0.0039) 43088 P0110 0.20 (0.0079) 43089 T0400
0.15 (0.0059) 43086 B9500 0.25 (0.0098) 43088 T0400
0.20 (0.0079) 43089 P0110 0.50 (0.0197) 43087 T0400
0.50 (0.0197) 43090 P0110 1.00 (0.0394) 43086 T0400
1.00 (0.0394) 4303601GOO
F23 H41
Applied model Double-tire Single-tire Double-tire
15 inch Low- and flat-bed 17.5 inch

I 16 inch
Wheel bearing axial end play mm(in) 0- 0.08 (0 - 0.0031) 0(0)
Wheel bearing nut
Tightening torque N'm (kg-m, ft-Ib) 74 - 83 (7.5 - 8.5, 54 - 61)

167 - 196
Retightening torque (17 - 20, 123 - 145) 49 - 54 (5.0 - 5.5, 36 - 40)
after loosening wheel bearing lock nut
Return angle degree - Max 22.5'
Wheel bearing starting torque 2.1 - 3.4

0.7 - 3.3 (0.074 - 0.339, 0.5 - 2.5)
N'm (kg-m, ft-Ib) (0.21 - 0.35, 1.5 - 2.5)
24.5 - 40.2 7.8 - 35.3 7.8 - 32.4

At wheel hub bolt N (kg, Ib)
(2.5 - 4.1, 5.5 - 9.0) (0.8 - 3.6, 1.8 - 7.9) (0.8 - 3.3, 1.8 - 7.3)
STABILIZER BAR - H41 model

Applied model All (option)*
Stabilizer bar diameter mm (in) 30 (1.18)
*: Except for 2-ton single tire (Wide cab vehicle) and dump vehi-
cle.
RA-27
BRAKE SYSTEM
SECTIONBR
CONTENTS
PRECAUTIONS AND PREPARATION BR- 2
CHECK AND ADJUSTMENT BR- 3
AIR BLEEDING BR- 4
BRAKE HYDRAULIC LINE BR- 5
CONTROL VALVE BR- 7
BRAKE PEDAL AND BRACKET BR- 9
MASTER CYLINDER ; BR-11
BRAKE BOOSTER , 6R-13
VACUUM PIPING BR..,15
VACUUM PUMP BR-18
FRONT DRUM BRAKE (2L28, 2L30A and 2L32B) BR-20
FRONT DISC BRAKE (CL36VB) BR-24
REAR DRUM BRAKE (DS22A, LT30B, D2L30A and D2L32B) BR-28
CENTER BRAKE - Parking Drum Brake (DS18 and DS20HC) BR-37 •
PARKI NG BRAKE CONTROL BR-41 : •
EXHAUST BRAKE SYSTEM BR-44
SERVICE DATA AND SPECIFICATIONS (S.D.S.) BR-47
When you read wiring diagrams:

.. Read GI section, "HOW TO READ WIRING DIAGRAMS".
• See EL section, "POWER SUPPLY ROUTING" for power distribution circuit.
When you perform trouble diagnoses, read GI section, "HOW TO FOLLOW FLOW CHART
IN TROUBLE DIAGNOSES".
Precautions
• Use brake fluid "DOT 3".
• Be careful not to splash brake fluid on painted areas; it may
cause paint damage. If brake fluid is splashed on painted
areas, wash It away with water immediately.
• To clean or wash all parts of master cylinder, disc brake
caliper and wheel cylinder, use clean brake fluid.
• Never use mineral oils such as gasoline or kerosene. They
will ruin rubber parts of hydraulic system.
• Use Tool when removing and installing brake tube.

WARNING:
Clean brake pads and shoes with a vacuum dust collector to
minimize the hazard of airborne asbestos or other materials.
GG9431 0000
SBR820B
Preparation
Tool number
Description
Tool name
GG9431 0000 Removing and installing each brake

Flare nut torque wrench piping
KV991V0010 Measuring brake fluid pressure

Brake fluid pressure
gauge
BR-2
CHECK AND ADJUSTMENT
Checking Brake Fluid Level

• Check fluid .level in reservoir tank. It should be between
Max. and Min. lines on reservoir tank.
• If fluid levelis extremely low, check brake system for leaks.
• When brake warning lamp comes on even when parking
brake lever is released, check brake system for leaks.
MIN
SBR849B
Checking Brake Line

CAUTION:
If leakage occurs around Joints, retighten or, if necessary,
rQpl~ce damaged parts.
1. Check brake Iines (tubes and hoses) for crack~, d~teriora-
tioll or other damage. Replace any damaged parts.
2. Check for oil leakage by fully depressing brake pedal while
engine is running.
Chclnging Brake Fluid

CAUTION:
• Refill withllew brake fluid "DOT 3".
areas, wash it away with water immediately.
1. Connect a vinyl tube to each air bleeder valve.
2. Drain brake fluid from each air bleeder valve by depress-
ing brake pedal.
3. Refill until new brake fluid comes out of each air bleeder
valve.
Use same procedure as in bleeding hydraulic system to
refill brake fluid. Refer to "Bleeding Procedure" in "AIR
BLEEDING" .
AIR BLEEDING
",....'- -.. Bleeding Procedure

- =----
CAUTION:
• Carefully monitor brake fluid level at master cylinder dur-
---./
------ •
ing bleeding operation.
Fill reservoir with new brake fluid "DOT 3". Make sure it is
full at all times while bleeding air out of system.
• Place a container under master cylinder to avoid spillage
of brake fluid.
SBR995
1. Connect a transparent vinyl tube to air bleeder valve.

2. Fully depress brake pedal several times.
3. With brake pedal depressed, open air bleeder valve to
release air.
4. Close air bleeder valve.
5. Release brake pedal slowly.
6. Repeat steps 2. through 5. until clear brake fluid comes out
of air bleeder valve.
• Bleed air in the following order .
Left rear brake
SBR992
Right rear brake
Left (ront brake
Right front brake
BR..4
BRAKE HYDRAULIC LINE
Model equipped with L.S.V.
Three-way connector
~ Mounting bolt
8 - 11
(0.8 - 1.1, 5.8 - 8.0)
Flare nut
15 - 18
Brake hose
(1.5 - 1.8, 11 - 13)
~ Mounting bolt
5 - 7 (0.5 -0,7, 3.6 ~ 5.1)
Flare nut
Front
,15 - 18 (1.5 - 1.8, 11 - 13)
Brake booster Load sensing valve (L.S.V.)

~ Mounting bolt
17 - 21 (1.7 - 2.1, 12 - 15)
Flare nut
15 - 18 (1.5 - 1.8, 11 - 13)
Three-way connector
Mounting bolt
~ 5 - 7 (0.5 - 0.7, 3.6 - 5.1)
Flare nut
15 - 18 (1.5 - 1.8, 11 ••13)
Model equipped with proportioning valve
Front brake
Brake hose
Three-way connector
~ Mounting bolt
Front
8 - 11 (0.8 - 1.1, 5.8 - 8.0)
Fiare nut
15 - 18 (1.5 - 1.8, 11 - 13)
Brake booster
Master cylinder
_ : Primary line
== :~
Secondary line
: N.m (kg-m, ft-Ib)
o : Flare nut
• : Connecting bolt
SBR240C
BR-5
BRAKE HVDRAULICLINE
Removal
CAUTION:
• All hoses must be free from excessive bending, twisting
and pulling.
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid from each air bleeder valve by depress-
ing brake pedal.
3. Remove flare nut securing brake tube to hose, then with-
draw lock spring.
4. Cover openings to prevent entrance of dirt whenever dis-
connecting hydraulic line.
Inspection
Check brake lines (tubes and hoses) for cracks, deterioration or
other damage. Replace any damaged parts.
Installation
CAUTION:
• Refill with new brake fluid "DOT 3".
1. Tighten all flare nuts and connecting bolts.
Flare nut:
!:OJ: 15 - 18 N'm (1.5 - 1.8 kg-m, 11 -13 ft-Ib)
Connecting bolt:
!:OJ: 17 - 20 N'm (1.7 - 2.0 kg-m, 12 - 14 ft-Ib)
2. Refill until new brake fluid comes out of each air bleeder
SBR820B
valve.
3. Bleed air. Refer to "Bleeding Procedure" in "AIR
BLEEDING".
BR-6
CONTROL VALVE
Load Sensing Valve

a. Have a driver sit in the driver's seat and one person sit on
the rear end. Then have the person on the rear end slowly
get off the vehicle. This is necessary to stabilize suspen-
sion deflection.
b. Attach a lever to the stopper bolt.
Length "H":
For Europe: 202 mm (7.95 in)
Except Europe
Single tire: 182 mm (7.17 in)
Double tire: 148 mm (5.83 in)
• Adjust spring length by moving eye bracket while pushing
lever toward A,
2. Connect tool to air bleeders of front and rear brakes on

either L.H. and R.H. side.
SBR821B
3. Bleed air from Tool.
SBR284A
4. With one person aboard depress brake pedal until master

cylinder oil pressure reaches 4,904 kPa (49.0 bar, 50
kg/cm2, 711 psi). Hold brake pedal in that position and read
rear brake oil pressure on pressure gauge indicator.
Rear brake pressure:
Single tire
1,079 - 2,059 kPa
(10.8 - 20.6 bar, 11 - 21 kg/cm2, 156 - 299 psi)
Double tire
1,079 - 2,059 kPa
(10.8 - 20.6 bar, 11 - 21 kg/cm2, 156 - 299 psi)
BR-7
CONTROL VALVE
Load Sensing Valve (Cont'd)
5. Depress brake pedal until master cylinder oil pressure
reaches 9.807 kPa (98.1 bar. 100 kg/cm2, 1,422 psi). With
brake pedal held in that position, read rear brake oil pres-
sure on pressure gauge indicator.
Rear brake pressure:
Single tire
1,765 - 2,746 kPa
(17.7 - 27.5 bar, 18 - 28 kg/cm2, 256 - 398 psi)
Double tire
1,765 - 2,746 kPa
(17.7 - 27.5 bar, 18 - 28 kg/cm2, 256 - 398 psi)

CAUTION:
• Replace damaged Linkage Load Sensing Valve as an
assembly.
Double tire Single tire

~34-39
(3.5 - 4.0, 25 - 29)
Air bleeder
~ 6 - 8 (0.6 - 0.8, 4.3 - 5.8)
L (1.7 - 2.1, 12 - 15)
SBR242C
• Tighten all flare nuts and bolts.

tDJ:15 - 18 N'm (1.5 - 1.8 kg-m, 11 - 13 ft-Ib)
• Bleed air. Refer to "Bleeding Procedure" in "AIR
BLEEDING".
BR-8
BRAKE PEDAL AND BRACKET
Removal and .Installation
~ 9.3 -10.8
(0.95 - 1.1, 6.9 - 8.0)
Snap ring
~ 20 - 23 (2.0 - 2.3, 14 - 17)

\
Brake pedal
SBR243C
Inspection
Check brake pedal for following items:
• Brake peda.l bend
• Clevis pin defOrmation
• Crack of any welded portion
o • Crack or deformation of clevis pin stopper
SBR997
BR..9
BRAKE PEDAL AND BRACKET
Adjustment
Lock nut Check brake pedal free height from dash reinforcement panel.
~ 16 - 22 (1.6 - 2.2. 12. 16) H: Free height
Refer to S.O.S.
~, 0: Depressed height
Refer to S.O.S.
.J Under force of 490 N (50 kg, 110 Ib)

with engine running
C1, C2: Clearance between pedal stopper and threaded
Stop lamp switch
end of stop lamp switch and A.S.C.O. switch
o~C~ and A.S.C.D. switch
C, ~ 12 -15 0.3 - 1.0 mm (0.012 • 0.039 in)
I (1.2 -1.5. 9 - 111 A: Pedal free play
I
\ 1.0 - 3.0 mm (0.039 - 0.118 in)
Floor carpet
Melt sheet
~ : N'm (kg-m, ft-Ib)
SBR153A
If necessary, adjust brake pedal free height.

1. Loosen lock nut and adjust pedal free height by turning
brake booster input rod. Then tighten lock nut.
Make sure that tip of input rod stays inside of clevis.
SBR824B
2. Loosen lock nut and adjust clearance "C1" and "C2" with
stop lamp switCh. Then tighten lock nuts.
3. Check pedal free play.
Make sure that stop lamps go off when pedal is released.
4. Check brake pedal's depressed height while engine is run-
ning.
If depressed height is below specified value, check brake
system for leaks, accumulation of air or any damage to
components (master cylinder, etc.); then make necessary
repairs.
BR..10
MASTER CYLINDER
Reservoir tank
~ '~
R.,,~, "p~ /
O-ri~ ~J
Oil strainer
~ s.e.condary Piston~. .
NO ~
assembly •
~~
,j)'~ ~ ""',de, b'"
~ Primary Piston~
assembly
Secondary return spring

t:; Stop", "p~ ,f ~
SBR244C
Removal
CAUTION:
Be careful not to splash brake fluid on painted areas; It may
cause paint damage. If brake fluid Is splashed on painted
areas, wash It away with water Immediately.
1. Connect a vinyl tube to air bleeder valve.
2. Drain brake fluid frorneach air bleeder valve, depressing
brake pedal to.empty fluid from master cylinder.
3. Remove brak~ pipe flare nuts.
4. R~move master cylinder mounting nuts.
Disassembly
1. Bend claws of stopper cap outward.
BR41
MASTER CYLINDER
2. Remove piston assemblies.
If it is difficult to remove secondary piston assembly, gradually
apply compressed air through fluid outlet.
3. Draw out reservoir tank.
SBR939A
Inspection
Check for the following items:
Replace any part if damaged.
Master cylinder:
• Pin holes or scratches on inner wall.
Piston:
• Deformation of or scratches on piston cups.
Secondary piston Assembly

1. Insert secondary piston assembly. Then insert primary pis-
ton assembly.
• Pay attention to direction of piston cups In figure at left.
Also, insert pistons squarely to avoid scratches on cylinder
Primary piston
bore.
SBR012A
2. Install stopper cap.

Before Installing stopper cap, ensure that claws are bent
inward.
3. Push reservoir tank seals.
4. Push reservoir tank into master cylinder.
Installation
CAUTION:
1. Place master cylinder onto brake booster and secure
mounting nuts lightly.
2. Fit flare nuts to master cylinder.
3. Tighten mounting nuts.
~: 8 - 11 N'm (O.8 - 1.1 kg-m, 5.8 - 8.0 ft-Ib)
4. Tighten flare nuts.
~: 15 - 18 N'm (1.5 - 1.8 kg-m, 11 - 13 ft-Ib)
BLEEDING" .
BR-12
BRAKE BOOSTER
On-vehicle Service
OPERATING CHECK
• Depress brake pedal several times with engine off, and
check that there is no change in pedal stroke.
• Depress brake pedal, then start engine. If pedal goes down
slightly, operation is normal.
SBR002A
AIRTIGHT CHECK
OK N.G. • Start engine, and stop it after on~or two minutes. Depress
brake pedal several times slowly. If pedal goes further
down the first time and gradually rises after second or third
time, booster is airtight.
• Depress brake pedal while engine is running, and stop
engine with pedal depressed. If there is no change in pedal
stroke after holding pedal down 30 seconds, brake booster
is airtight.
SBR365A
Removal
<@
toJ : N.m (kg-m, ft-Ib)
toJ 8 - 11 (0.8 - 1.1, 5.8 - 8.0) /
SBR245C
BR.;;13
BRAKE BOOSTER
Removal (Cont'd)
CAUTION:
• Be careful not to deform or bend brake pipes, during
removal of booster.
Inspection
OUTPUT ROD LENGTH CHECK
1. Supply brake booster with vacuum of -66.7 kPa (-667 mbar,
-500 mmHg, -19.69 inHg) using with a handy vacuum pump.
2. Check output rod length.
Specified length:
M215T, M195T, G23 or M23
10.275 - 10.525 mm (0.4045 - 0.4144 in)
SBR281A
Installation
CAUTION:
• Be careful not to deform or bend brake pipes, during instal-
lation of booster.
• Replace clevis pin if damaged.
• Take care not to damage brake booster mounting bolt
thread when installing. Due to the acute angle of
installation, the threads can be damaged on the metal sur-
rounding the dash panel holes.
1. Before fitting booster, temporarily adjust clevis to dimen-
sion shown.
2. Fit booster, then secure mounting nuts (brake pedal bracket
to brake booster) lightly.
3. Connect brake pedal and booster input rod with clevis pin.
4. Secure mounting nuts.
5. Install master cylinder. Refer to "Installation" in "MASTER
CYLINDER".
BLEEDING".
BR-14
VACUUM PIPING
NA20S engine model

To brake ;~er
~u8
(vacuum hose
~
Check ~valve
~~
~~.
To i~take
manifold
Vacuum tank
~
c
l~
T025 and T027. engine models
8.6 - 127
J:'("H.~6A.6A1
•
To actuator
(Exhaust brake)
if' "' 4'pump n

•
~ ~vacuum lJ
( - j>~
~ I
W~ ~
~~ Vacuum hose j~
~ ~ (Built in check valve) .~ ~
r~ ~ @1
~~ &tC==::::---
.~
8030, F042 and F046 engine models
To brake booster
~~ ,~vacuum hose
~ .. f!j,1:/ (Built in check valve)
~....12.,J Vacuum tank

~~o~~~~h~
(0.88 - 1.3,
6.4 - 9.4)
~ ~
?
t@)
/j~ f~4'
To actuator
(Exhaust brake)
~•
a
v~""mh:r~~
"'" ~ ~""m pump
,/ _ i~
~---j)
~~ff0
Vacuum hose j ..A
(Built in check valve) IUY
~ : N.m(kg-m, ft-Ib)
SBR246C
BR-15
VACUUM PIPING
Removal and Installation (Cont'd)
CAUTION:
When installing vacuum hoses, pay attention to the following
points.
• Do not apply any oil or lubricants to vacuum hose and
check valve.
• Insert vacuum tube into vacuum hose as shown.
----------r~
-----------~~------------
Connect hose until it contacts
protrusion on vacuum tube.
SBR225B
• Install check valve, paying attention to its direction.

For gasoline engine
•
Brake
booster
side
•
Intake manifold or
vacuum pump side
SBR247C
CAUTION For diesel engine
~
.. ENG.
Inspection
HOSES AND CONNECTORS
Check vacuum lines, connections and check valve for
airtightness, improper attachment, chafing and deterioration.
CHECK VALVE
Manifold side
Check vacuum with a vacuum pump.
Connect to
Vacuum should exist.
booster side
Connect to
Vacuum should not exist.
engine side
• Brake booster side
SBR248C
BR-16
VACUUM PIPING
Inspection (Cont'd)
Booster side
Engine side
Arrow indicates
engine side
SBR826B
VACUUM WARNING SWITCH

Test continuity through vacuum warning switch with a vacuum
pump.
Vacuum condition Continuity

26.7 kPa (267 mbar,200 mmHg, 7.87 inHg) or less Yes
33.3kPa (333 mbar, 250 mmHg, 9.84 inHg) or more No
SBR827B
BR-17
VACUUM PUMP
~ 29 - 34 (3.0 - 3.5, 22 - 25)~
~ 0
~
Check valve
g
o
Pump hOUSing~
Vane~ &"'l
Rotor~V
~""g (::~:;~
\J~
f~ Q ~:~f
O-ring (Large)~
~ 6 - 7 (0.6 - 0.7, 4.3. - 5.1)-~/ L~ 29 - 34 (3.0 - 3.5, 22 - 25)

SBR325C
• Drain oil from vacuum pump before removal.

Manually rotate fan belt clockwise to discharge any oil which
may have accumulated In vacuum pump.
• When inserting vane, take care that vane does not get on
Pump vane guide of center plate.
~' housing • Install vane so that its round surface faces pump housing.
\l) .Id. • After installing vacuum pump assembly on alternator, apply
5 mf, (0.2 Imp fl oz) of engine oil into vacuum pump assem-
bly. Then, make sure that pulley of alternator can be
smoothly rotated by hand.
SBR896
Inspection
PUMP
• Check for wear or scratches on mating surfaces of rotor
and vacuum pump housing and of rotor and center plate. If
wear or scratches are noted, replace those parts.
• Check for wear or scratches on vanes. If necessary,
replace.
TO engine
A: 12.5 - 13.5 mm (0.492 - 0.531 In)
SBR828B H: 25.0 mm (0.984 In)
BR-18
VACUUM PUMP
Inspection (Cont'd)
BD and FD engines
A: 20.0 - 21.0 mm (0.787 - 0.827 in)
H: 46 mm (1.81 in)
• Check rotor shaft for wear. If necessary, replace.

• Check valve locations. If necessary, replace.
• Check inner diameter of vacuum pump housing. If
necessary, replace.
TD engine
B: 57.0 - 57.1 mm (2.244 - 2.248 in)
BD and FD. engines
B: 77.0 - 77.1 mm (3.031 - 3.035 in)
SBR829B
• Check valve operation. Check that valve operates smoothly

when slightly pushed. Replace if necessary.
Checking valve operation
SBR194
• Check for air leakage with 98 to 490 kPa (1.0 to 4.9 bar, 1 to
5 kg/cm2, 14 to 71 psi) of air pressure. Replace if necessary.
Air.
Checking air leakage of valve
SBR195
VACUUM
1. Install vacuum gauge.
2. Run engine at 1,000 rpm or more.
3. Check vacuum.
Specified vacuum:
93.3kPa.(933 mbar, 700 mmHg, 27.56 inHg)or
more
BR-19
FRONT DRUM BRAKE (2L28, 2L30A and 2L32B)
Model2L28
toJ108 - 147
Q (11 - 15, 80 - 108)
Front of vehicle
toJ108 - 147
Front of vehicle (11 - 15, 80 - 108)
lEI @ : Rubber grease point
• : Lubricating point (Brake grease)
SBR253C
CD Shoe hold pin @ Piston cap @ Back plate

@ Brake tube @) Locking spring @ Adjust hole plug
@ Bleeder @ Return spring @ Toggle lever
@ Bleeder cap @ Brake shoe @ Lock plate
@ Adjuster screw @ Shoe hold spring seat @ Wave washer
@ Adjuster @ Shoe hold spring
@ Retainer ring
(J) Boot @ Shoe hold spring retainer
@ Spring
@ Piston @) Wheel cylinder assembly
BR-20
FRONT DRUM. BRAKE. (2L28, 2L30Aand2L32B)
Removal
WARNING:
Clean brake lining with a vacuum dust collector to minimize the
hazard of airborne asbestos or other materials.
CAUTION:
Make sure parking brake lever is released completely.
1. Relea$.eparki!'lg brake lever fully, then remove drum.

If drum is hard to remove, the following procedures should be
carried out.
a. Remove plug. Then shorten adjuster to make clearance
between brake shoe and drum as shown.
b. When adjuster is turned in direction of arrow stamped on
back plate, brake shoes expand.
c. Tighten the two bolts gradually .
.2. After removil'lg shoe hold pin, remove retainer.

3. Remove brake shoe with spring from wheel cylinder anchor
side. .
Inspection"';"" .Wheel Cylinder

• Check wheel cylinder for leakage.
• Check for wear, damage and Iclose conditions.
Replace if any such condition exists.
BR-21
FRONT DRUM BRAKE (2L28, 2L30A and 2L32B)
Wheel Cylinder Overhaul

~ ~
Pay attention so as not to scratch cylinder when installing pis-
tons.
rJj) e '
~~I~
-w t'
'0A SBR258C
Inspection - Drum
Maximum inner diameter:
2L28 281.5 mm (11.08 in)
2L30A 301.5 mm (11.87 in)
2L32B 321.5 mm (12.66 in)
Out-of-roundness:
0.06 mm (0.0024 in) or less
SBR022A
• Contact surface should be fine finished with No. 120 to 150

emery paper.
• Using a drum lathe, lathe brake drum if it shows scoring,
partial wear or stepped wear.
• After brake drum has been completely reconditioned or
replaced, check drum and shoes for proper contact pattern.
Inspection - Lining
Check lining thickness.
A
Standard lining thickness:
2L28 6.0 mm (0.236 in)
2L30A 7.6 mm (0.299 in)
2L32B 7.7 mm (0.303 in)
Lining wear limit (A):
2L28 & 2L30A 1.5 mm (0.059 in)
2L32B 3.2 mm (0.126 in)
SBR021A
Installation
1. Apply brake grease to the contact areas shown at left.
SBR260C
BR-22
FRONT DRUM. BRAKE (2L28, 2L30A and 2L32B)
.. . Installation (Cont'd)
2. Install all parts.
3. Check all parts are installed properly.
Pay attention to direction of adjuster.
4. Install brake drum.
5. When installing new wheel cylinder or overhauling wheel
cylinder, bleed air. Refer to "Bleeding procedure" in "AIR
BLEEDING" .
SBR261C
BR-23
FRONT DISC BRAKE (CL36VB)
@~ 17-20 f{D, @
(1.7 - 2.0, 12 - 14)/ ~"",
~
~m~ :P.B.C. (Poly Butyl Cuprysil) grease
\1.9' or silicon-based grease point
m@ : Rubber grease point
~ @ : Brake fluid point SBR250C
G) Main pin (J)

Copper washer @ Piston seal
@ Pin boot @ Pad @ Piston boot
@ Washer @ Pad retainer @) Piston
@ Torque member @)Brake hose @ Outer shim
@ Inner shim @ Air bleeder @ Main pin bolt
@ Union bolt @ Air bleeder cap
Pad Replacement
WARNING:
Clean brakes with a vacuum dust collector to minimize the
CAUTION:
It is not necessary to remove connecting bolt except for disas-
sembly or replacement of caliper assembly. In this case, sus-
pend cylinder body with wire so as not to stretch brake hose.
1. Remove master cylinder reservoir cap.

2. Remove lower pin bolt.
BR-24
FRONTDISCBRAKE< (CL36VB)
Pad Replacement (Cont'd)
Cylinder 3; Opencylir:u:lEilCbodyupward. Then remove pad retainers,
body and inner and outer shims.
Outer Standard pad thickness:
11 mrn (0.43 in)
Pad wear limit:
2.0 mm (0.079 in)
• Carefully monitor;brake fluid level because brake fluid will
ret.urn to reservoir when pushing back piston.
Pad
Removal
WARNING:
Clean brake pads with a vacuum dust collector to minimize the
Remove torque member fixing b()lts and connecting bolt.

It is not neces$ary toremovecon~ecting bolt exc~et for disas-
s~mbly .or.replacement of caliper assembly. In this: case, sus-
pend. caliper assembly with wlre.;so as not to stretch brake
hO.$~.
Disassembly ....
1. Remove piston seal with a screwdriver.
SBR252C
WARNING:
Do not place your fingers in front of piston.
CAUTION:
Do not scratch or score cylinder wall.
2. Push out piston with dust seal with compressed air.
3. Remove piston seal with a suitable too./.
SBR772
BR-25
Inspection - Caliper
CYLINDER BODY
• Check inside surface of cylinder for score, rust, wear, dam-
age or presence of foreign objects. If any of the above
conditions are observed, replace cylinder body.
• Minor damage from rust or foreign objects may be elimi-
nated by polishing surface with a fine emery paper.
Replace cylinder body if necessary.
CAUTION:
Use brake fluid to clean. Never use mineral oil.
PISTON
CAUTION:
Piston sliding surface is plated. Do not polish with emery paper
even if rust or foreign objects are stuck to sliding surface.
Check piston for score, rust, wear, damage or presence of for-
eign objects. Replace if any of the above conditions are
observed.
SLIDE PIN, PIN BOLT AND PIN BOOT
Check for wear, cracks or other damage. Replace if any of the
above conditions are observed.
Assembly
1. Insert piston seal into groove on cylinder body.
2. With piston boot fitted to piston, insert piston boot into
groove on cylinder body and install piston.
Piston seal 3. Properly secure piston boot.
SBR574
Installation
CAUTION:
1. Install caliper assembly.
Do not forget to install washers.
2. Install brake hose to caliper securely.
3. Install all parts and secure all bolts.

BLEEDING" .
BR-26
Inspection - Rotor
RUNOUT
1. Secure rotor to wheel hub with at least two nuts (M12 x
1.25).
2. Check runout using a dial indicator.
Make sure that wheel bearing axial end play is within the spec-
Ifications before measuring. Refer to section FA.
Maximum runout:
0.07 mm (O.0028 In)
SBR019B 3. If the runout is out of specification, find minimum runout
position as follows:
a. Remove nuts and rotor from wheel hub.
b. Shift the rotor one hole and secure rotor to wheel hub
with nuts.
c. Measure runout.
d. Repeat steps a. to c. so that minimum runout position
can be found.
4. If the runout is still out of specification, turn rotor with
on-car brake lathe ("MAD, DL-8700", "AMMCO 700 and
705" or equivalent).
THICKNESS
Thickness variation (At least 8 positions):
Maximum 0.01 mm (O.0004 in)
If thickness variation exceeds the specification, turn rotor with
on-car brake lathe.
Rotor repair limit:
CL36VB .24.0 mm (O.945 In)
BR-2.7
REAR DRUM BRAKE (DS22A and L130B)
DS22A
~
@ : Brake fluid point
r:::2
Front of vehicle
m @ : Rubber grease point
• : Brake "grease point
~ : N'm (kg-m, ft-Ib) SBR262C
CD Shoe hold pin @ Bleeder screw @ Retainer @ Cable guide

@ Back plate @ Wheel cylinder @) Shoe guide plate @ Return spring
@ Anchor block @lSpring @ Return spring @ Spring seat
@ Strut @ Piston @)Adjuster cable @) Shoe
@ Pin @ Boot @ Adjusting lever @ Toggle lever
@ Wave washer @ Piston cup @ Adjuster
@ Spring
!J) Bleeder cap @ Shoe hold spring @ Return spring
LT30B
~ 6 - 11 (0.6 - 1.1, 4.3 - 8.0)
~ @ : Brake fluid point

IE! @ : Rubber grease point
.. : Brake grease point
~ : N.m (kg-m, ft-Ib) SBR263C
CD Shoe hold pin @ Spring @ Adjuster @ Shoe hold spring

@ Plug @ Piston cup @) Boot @ Retainer
@ Back plate @l Piston @ Piston @ Adjuster spring
@ Check plug @ Boot @) Piston cup @) Return spring (upper)
@ Spring @ Retainer ring @ Wheel cylinder @ Return spring (lower)
@ Shoe (leading side) @ Operating lever @ Adjuster lever
!J) Air bleeder @ Shoe (trailing side) @ Spring seat
BR-28
REAR. DRUM BRAKE (DS22AandLT30B)
Removal
WARNING:
CAUTION:
1. Release parking brake lever fully, then remove drum.

LT30B
Wheel
If. drum is hard to remove, thefollowlngproceduresshoul~be
cylinder
.carried out.
a. aemove plug. Then shorten adjuster to make clearance
Adjuster
SBR264C
DS22A;;, ...•
Adjuster
spring
b. Tighten the two bolts gradually.

c. DS22A:
After removing wheel bearing, remove brake-drum with
wheel hub.
Refer to section RA for wheel hub.
Bolts
(M8 x 1.25) SBR020A
-- LT30B .......,...
2. After removing shoe hold pin by rotating push retainer,
remove leading shoe then remOve trailing shoe.
Remove spring by rotating sl10es in direction arrow.
3. Remove adjuster.
BR ..29
REAR DRUM BRAKE (DS22A and LT30B)
Removal (Cont'd)
LT30B
4. Disconnect parking brake cable from operating lever.
Be careful not to damage parking brake cable when separating
it.
-DS22A-
2. After removing shoe hold pin, remove secondary shoe then
remove primary shoe.
3. Remove adjuster.
Adjuster
spring
4. Disconnect parking brake cable from operating lever.
SBR269C
5. Remove retainer ring with a suitable tool. Then separate

toggle lever and brake shoe.
SBR093B
Inspection - Wheel Cylinder

• Check wheel cylinder for leakage.
• Check for wear, damage and loose conditions.
SBR816B
BR-30
REAR DRUM BRAKE (DS22A and .LT30B)

Pay attention so as not to scratch cylihder when installing pis-
tons.
SBR215B
Inspection - Drum
DS22A 221.5 mm (8.72 in)
LT30B 296.5 mm (11.67 ill)
Out-of-roundness:
0.03 mm (0.0012 in) or less
SBR022A
• Contact surface should be fine finished with No. 120to 150

emery paper.
• Using a drum lathe, lathe brake drum if itshows scoring,
Inspection- Lining
A
Stand.~rdIinillg thickness:
DS22A 4.65 mm (0.1831 in)
LT30B 6.1 mm (0.240 in)
1.5.mm (0.059 in)
SBR021A
Installation
Always perform shoe clearance adjustment. Refer to
"Adjustment" in "PARKING BRAKE CONTROL".
Fit operating lever to brake shoe with retainer ring.
LT30B:Tralling side
DS22A: Secondary side
BR-31
REAR DRUM BRAKE. (DS22A and L130B)
LT30B 2. Apply brake grease to the contact areas (indicated by
arrows and hatching) shown at left.
SBR271C
DS22A
SBR272C
- LT30B-
3. Shorten adjuster by rotating it.
• Pay attention to direction of adjuster.
Wheel Screw Depression
Left Left-hand thread Yes

Right Right-hand thread No
SBR217B
4. Connect parking brake cable to toggle lever.

Pay attention tp direction of adjuster.
BLEEDING" .
SBR279B
-DS22A-
FrontQ CAUTION:
Pay attention to adjuster assembly direction since stamped
mark and. wheel locations differ for left-hand and right-hand
brakes.
Wheel Screw Depression
Left Right-hand thread Yes

m Drum Brake Grease
(KRF10-000s) Right Left-hand thread No
SBR273C
BR-32
REAR DRUM BRAI(I::. (DS22Aand l T30B)
4. Connect parking brake cable to toggle lever.
DS22A
Pay attention to direction of adjuster assembly.
8. When, inl:italling new wheel cylinder, bleed air. Refer to
"Bleeding procedure" in "AIR BLEEDING".
SBR274C
BR.33
REAR DRUM BRAKE (D2L30A and D2L32B)
3 I
Front of vehicle rRJ 108 - 147 (11 - 15, 80 - 108)
rRJ : N.m (kg-m, ft-Ib)
m @ : Rubber grease point
• : Brake grease point
~ @ : Brake fluid point
SBR275C
G) Shoe hold pin ,@) Piston @ Return spring

@ Brake tube @ Dust boot @ Brake shoe
@ Bleeder cap @ Piston cup @) Shoe hold spring retainer
@ Air bleeder @ Adjuster lever @ Shoe hold spring
@ Piston cup @ Lock plate @ Shoe hold spring seat
@ Piston @) Wave washer @ Wheel cylinder assembly
(J) Dust boot @) Retainer ring @ Back plate
@ Adjuster screw
@ Spring @ Adjust hole plug
@ Adjuster
Removal
WARNING:
CAUTION:

carried out.
a. Remove plug. Then shorten adjuster to make clearance
BR-34
REAR DRUM BRAKE (D2L.30A and D2L32B)
Removal (Cont'd)
b. Tighten the two bolts gradually.
Bolt
(M1QX1.25)
SBR277C
2. Remove shoe hold pin by rotating shoe hold spring

retainer.
3. Expand.shoe anchor side, remove brake shoe with return
spring.
Shoe
setting
SBR278C
Inspection-. Wheel Cylinder

• Check Wheel cylinder for leakage.
• Check for Wear,damage and loose conditions.

Pay attention so as not to scratch cylinder when in~talling pis-
tons.
SBR280C
Inspection _. Drum
D2L30A 301.5 mm (11.87 in)
D2L328 321.5 mm (1'2.66in)
Out-of~roundness:
0.06 mm (0.0024 in) or less
SBR022A
BR-35
REAR DRUM BRAKE (D2L30A and D2L32B)
Inspection - Drum (Cont'd)
• Contact surface should be fine finished with No. 120to 150
emery paper.
• Using a drum lathe, lathe brake drum if it shows scoring,
Inspection - Lining
A
D2L30A 7.6 mm (0.299 in)
D2L32B 7.7 mm (0.303 In)
D2L30A 1.5 mm (0.059 In)
D2L32B 3.2 mm (0.126 In)
SBR021A
Installation
Always perform shoe clearance adjustment. Refer to
"Adjustment" In "PARKING BRAKE CONTROL".

3. Install 'brake drum.
BLEEDING".
BR-36
CENTER BRAKE
@ (DS18H TYPE)
I DS20HC TYPE I
.",- ---~1....... ...
" '" .....

.....
•/
\
A~
0')
0-\)'"'))'"'))"') 'j I
,"
0
/
.......
...... ","
.. '
..
'" /
-- ---
------ @
.....
( A \
" .... ' ,.,I '~
~(((I?
@ @
CD Shoe hold pin @ Conical washer @ Retainer spring

@ Back plate @ Parking lever @ Retainer
@ Retainer ring @) Adjuster spring @ Strut return spring
@ Parking brake cable @ Adjuster @ Strut
@ E-ring @ Brake shoe @l Shoe guide plate
@ Rubber @ Shoe return spring
@) Shoe return spring
(J) Retainer ring @ Strut
Removal
WARNING:
Clean brakes with a vacuum dust collector to minimize the
carried out:
a. Remove plug.
b. Insert screwdriver through plug hole.
c. Turn adjuster to make clearance between brake shoe and
drum.
BR-37
CENTER BRAKE
Removal (Cont'd)
d. Fit two bolts to the drum as shown and tighten gradually.
SBR392A
2. After removing shoe hold pin, retainer, remove spring by

rotating shoes.
Be careful not to damage parking brake cable when separating
it.
3. Remove adjuster.
4. Remove strut.
5. Disconnect parking brake cable from parking lever.
SBR285C
6. Remove retainer ring with a suitable tool. Then separate

toggle lever and brake shoe.
Toggle lever
SBR947A
Inspection - Drum
DS18H 181 mm (7.13 in)
DS20HC 204.5 mm (8.05 in)
SBR383A
BR-38
CENTERB.RAKE
Inspection- Lining
A
DS18H 4.0 mm (0.157 in)
DS20HC 5.1 mm (0.201.in)
1.5 mm (0.059 in)
SBR021A
DS18H Strut
Installation
parking spring 1. Fit parking lever to brake shoe with retainer ring.
Pay attention to retainer ring direction.
Conical washers are not used with DS20HCtype.
Parking lever
SBR286C

~.
/' ..~ 01'0'70'.\..

i/:.00 >oojJ

4. Connect parking brake cable to parking lever.
Vehicle front 5. Install all parts.
SBR949A
BR ..39
CENTER BRAKE
DS18H
7. Install brake assembly.
Measure drum inside diameter. Turn adjuster so that out-
side diameter of the middle part of the brake shoe is 0.35
to 0.55 mm (0.0138to 0.0217 in) less than drum inside diam-
eter.
8. Install drum.
SBR289C
DS20HC
SBR290C
Shoe Clearance Adjustment

1. Remove adjuster hole plug, and turn down adjuster wheel
with a screwdriver until brake is locked.
Make sure that parking control lever is released completely.
2. Return adjuster wheel 5 to 6 latches.
3. Install adjuster hole plug, and make sure that there is no
drag between shoes and brake drum when rotating drum.
4. Adjust parking brake cable. Refer to "Adjustment" in
-~ "PARKING BRAKE CONTROL".
Expand
SBR383C
Breaking in Drum and Lining

Carry out following procedures to bed down parking brake
when stopping effect of parking brake is weakened, or brake
shoes and/or drums are replaced.
1. Drive the unloaded vehicle on a safe, level and dry road.
2. Depress the release button of parking brake lever, then pull
the lever with a force of 98 N (10 kg, 22 Ib).
3. While holding the lever, continue to drive the vehicle for-
ward 100 m (328 ft) at approximately 35 km/h (22 MPH).
4. While holding the lever, drive the vehicle in reverse 10 m
(33 ft) at approximately 10 km/h (6 MPH).
5. Repeat steps 1 through 4 two times and then repeat only
step 4 one more time.
BR-40
PARKING BRAKE CONTROL
DS22A and LT30B rear brake models

Front parking cable
~ 4.9 - 6.5
(0.5 - 0.66,
3.6 - 4.8)
~4.9 - 6.5
\4.9 .. 5
(0.5 - 0.66, 3.6 - 4.8)
=====,=<---'1'1
05
. • o:~...,
~ 4.9 - 6.5 (0.5 - 0.66, 3.6 - 4.8)
Lock nut
~ 4.9 - 6~5
(0.5 - 0.66,
3.6 - 4.8)
D2L30A and D2L32B rear brake
&(
-
~,
~
~~-~
I~:~~
~ 4.9 - 6.5 (0.5 - 0.66, 3.6 - 4.8)
-
warning~ ,
lamp ,
switch < '
~~10 - 13 (1.0 - 1.3, 7 _ 9) _1~.3, 7 - 9)
~ 25 _ R,eta~'ner ring
6CB
31 (2.5 - 3.2,18 - 23) ~
E-nng 7
e2~ @// '
IB i ~"'0 (;
~ 25 - 31 (2.5 - 3.2, 18 - 23) ~

1. ~51-65
25 - 31 (2.5 - 3.2, 18 - 23)

Rear parking cable
(5.2 - 6.6, 38 - 48)
SBR291C
BR..41

DS22A AND LT30B TYPE
1. Disconnect rear parking cable from adjuster.
2. Remove brake drum and brake shoe then remove parking
cable from operating lever.
Refer to section RA.
==
Q Front
SBR292C
3. Remove cable tightening nuts and cable.
D2L30A AND D2L32B TYPE

Adjusting nut II/ 1. Loosen adjusting nut.
I' I~ Refer to section PD.
3. Remove brake drum and brake shoe.
4. Remove rear parking cable from center brake lever.
5. Remove front grille and front grille upper.
Refer to section SF.
6. Remove control assembly.
7. Remove parking cable assembly.
Inspection
1. Check control lever for wear or other damage. Replace if
necessary.
2. Check wires for discontinuity or deterioration. Replace if
necessary.
3. Check warning lamp and switch. Replace if necessary.
4. Check parts at each connecting portion and, if deformed or
damaged, replace.
Adjustment
On models equipped with center drum brake, perform shoe
clearance adjustment before adjusting parking brake control.
BR-42
Adjustment (Cont'd)
1. Adjust clearance between shoe and drum as follows:
a. Pull parking brake lever several times until clicking sound
does not occur from rear brake.
b. Release parking brake lever and loosen adjusting nut.
c. Depress brake pedal fully.
2. Loosen lock nut @, rotate adjuster CID.

3. Tighten lock nut @.
SBR032A
4. Pull control lever with specified amount of force. Check

lever stroke and ensure smooth operation.
Number of notches: 11 - 15
5. Bend parking brake warning lamp switch plate so that
brake warning light comes on when ratchet at parking
brake lever is pulled "A" notches and goes out when fully
released.
Number of notches: 1
BR...43
EXHAUST BRAKE SYSTEM
A ~9-12N.m
(0.9 - 1.2 kg-m, 6.5 - 8.7 ft-Ib)
(?
.~
Orifice
Vacuum tank 2,000 (122.04)
V~""m pomp
,, ,,
-----~!
Intake shutter
Refer to EF section
for adjustment.
Check valve
Vacuum tank 4,000 (224.08)
Unit: cm' (cu in)

SBR322C
Exhaust Brake Unit

Adjustment for exhaust brake valve clearance
Stopper used when 1. Measure and average clearance A and B.
fully closed
Adjusting bolt
2. If the average is not within the specified value, adjust the
Fully
clearance by adjusting bolt.
closed
Average of clearance A and B:
F042 and F046 engine model
0.35 - 0.5 mm (0.0138 - 0.0197 in)
B030 engine model
SBR323C 0.45 - 0.60 mm (0.0177 - 0.0236 in)
SBR324C
BR.44
EXHAUST .BRAKE SYSTEM
Wiring Diagram
CAUTION: Before starting to work, be sure to turn ignition switch "OFF" and then disconnect battery
ground cable.
COMBINATION
EXHAUST METER
BRAKE
SWITCH @ Wide cab
EXHAUST BRAKE
310----@--029
GD Standard cab
@ FD en,gine
@ BD en,gine
~
t
UP
.J CD "'~ FUSE BLOCK

CD (Refer to "POWER SUPPLY
ROUTING" in EL section.)
S.M.J.
(Instrument [Refer to last pa,ge (Chassis
harness) (Foldout pa,ge) .] harness)
L/Rffi4 L/R
B 01& B
B/W F16 B/W
(ill) @)
3: CD 3: CD a: 3:a:
CD CD '-'- .......
co, ....... '-'-CD
CD a: .J a:.J .J.J
CD
@)M @:@)l$J @)~
@@~ ~
@@
BODY GROUND
ACCELERA TOR
SWITCH
CLUTCH
SWITCH
mill
NEUTRAL
SWITCH EXHAUST
~
EXHAUST
BRAKE
MAGNETIC
@
BODY
GROUND
BRAKE VALVE
CUT RELAY
SBR321C
Function
Item Exhaust brake unit
Exhaust 'Exhaust Exhaust
Accelerator Clutch Vacuum solenoid Intake shut-
brake brake cut brake mag-
Exhaust switch switch Vacuum Atmosphere ter valve
switch relay netic valve
brake passage passage
Transmis-
Accelerator Clutch sion shifted
pedal pedal into any
Operating ON Open Closed Fully closed Fully closed
released released other but
(ON) (ON) Neutral
(ON)
Fully open Fully open
Not operating Anyone of the above switches is OFF. Closed Open (Not operat- (Not operat-
ing) ing)
When exhaust brake switch is turned "ON", pilot lamp illumi-

nates to indicate that exhaust brake system is ready.
During deceleration, when accelerator pedal is released with-
out depressing clutch pedal, exhaust brake vacuum solenoid
turns ON to open vacuum passage. Vacuum pressure is then
applied to exhaust brake unit's diaphragm to fully close exhaust
brake magnetic valve. Intake manifold shutter valve is also
closed.
BR..45
EXHAUST BRAKE SYSTEM
Function (Cont'd)
Exhaust gas discharge from combustion chamber becomes
restricted, increasing piston exhaust discharge pressure (back
pressure) and thus producing increased engine "braking" dur-
ing exhaust stroke.
*. Exhaust brake unit'svalve is installed so that when it is fully
closed, exhaust gas flows through a slight clearance of
approximately 0.45 to 0.6 mm (0.018to 0.024 in) on the BD30
engine, and 0.35 to 0.5 mm (0.014 to 0.020 in) on the FD42
engine. With exhaust brake lever switch turned ON, exhaust
brake unit is fully closed even during idle. This may cause
erroneous engine rotation when starting a cold engine or
during engine operation when exhaust brake switch is ON.
On FD42and FD46-series engines, when the transmission is
in Neutral, turning exhaust brake lever switch ON does not
activate exhaust brake unit.
BR..46
SERVICE DATA AND. SPECIFICATIONS (S.O.S.)
BRAKE UNIT
F23
Applied model
1.5-ton
NA20S, TD25 NA20S, TD25, rD27

Engine
Double tire Single tire
Front brake
Brake model CL36VB 2L28
Cylinder bore diameter mm (in) 68.1 (2.681) 28.57 (1-118) x 2
Pad or lining mm (in) 268.7 x 60 x 6.0

130 x 52.5 x 11(5.12 x 2.067 x 0.43)
Length x width x thickness (10.58 x 2.36 x 0.236)
Drum inner diameter or rotor mm (in)

236 x 26 (9.29 x 1.02) 280 (11.02)
outer diameter x thickness
Rear brake
Brake model DS22A LT30B
Cylinder bore diameter mm(in) 17.46 (11/16) 22.22 (7/8)
Lining or pad mm (in) 230 x 60 x 4.65 295.2 x 60 x 6.1

Length x width x thickness (9.06 x 2.36 x 0.1831) (11.62 x 2.36 x 0.240)
Drum inner diameter or rotor outer diameter

220 (8.66) 295 (11.61)
x thickness mm(in)
Master cylinder
Cylinder bore diameter mm (in) 25.40 (1)
Control valve
Proportioning valve
Valve model L.S.V. (Built into master cylin-
der)
Split point
(Variable) x 0.15 (Variable)
kPa (bar, kg/cm2, psi) x reducing ratio
Brake booster
Booster model M195T *G23 or M23
Diaphragm diameter
Primary mm (in) 205 (8.07)

230 (9.06)
Secondary mm (in) 180 (7.09)
Recommended brake fluid DOT 3
*: Option
BR..47
BRAKE UNIT
H41
Applied model
2-ton 2.75-ton 3-ton
BD30 BD30 FD42 FD42 FD46

Engine
Single tire Double tire
Front brake
Brake model 2L30A 2L32B
Cylinder ~ore diameter mm (in) 28.57 (1-118) x 2 28.57 (1-1/8) x 2
293.2 x 75.0 x
Pad or lining mm (in)
7.6 (11.54 x 335.1 x 75.0 x 7.7 (13.19 x 2.953 x 0.303)
Length x width x thickness
2.953 x 0.299)
Drum inner diameter or rotor mm(in)

300 (11.81) 320 (12.60)
outer diameter x thickness
Rear brake
Brake model D2L30A D2L32B
Cylinder bore diameter mm (in) 26.99 (17/16) 26.99 (17/16)
293.2 x 75.0 x
Lining or pad mm (in) 7.6
335.1 x 75.0 x 7.7 (13.19 x 2.953 x 0.303)
Length x width x thickness (11.54 x 2.953 x
0.299)
Drum inner diameter or rotor

300(11.81) 320 (12.60)
outer diameter x thickness mm (in)
Master cylinder
Cylinder bore diameter mm (in) 26.99 (17/16) 26.99 (17/16) 26.99 (17116) 26.99 (17116)
Control valve
Valve model Proportioning valve (Built into master cylinder)
Split point
(Variable)
, kPa (bar, kg/cm2, psi) x reducing ratio
Brake booster
Booster model M195T M195T M215T
Diaphragm diameter
Primary mm(in) 8 (0.31) 8 (0.31) 9 (0.35)
Secondary mm (in) 7 (0.28) 7 (0.28) 8 (0.31)
Parking drum brake
Brake model DS18H DS20HC
Lining
196.0 x 35 x 4.0 196.0 x 35 x 5.1

Width x thickness x length mm (in)
(7.72 x 1.38 x 0.157) (7.72 x 1.38 x 0.201)
Drum inner diameter mm (in) 180 (7.09) 203 (7.99)
Recommended brake fluid DOT 3
BR-48

FRONT DISC BRAKE FRONT DRUM BRAKE
Brake model CL36VB Brake model 2L30A 2L32B 2L28
Pad wear limit Lining wear limit
Minimum thickness mm (in) 2.0 (0.079) 1.5 3.2 1.5

Minimum thickness mm (in)
(0.059) (0.126) (0.059)
Rotor repair limit
Drum wear limit
Maximum runout mm (in) 0.07 (0.0028)
Maximum inner diameter 301.5 321.5 281.5
Minimum thickness mm (in) 24.0 (0.945)
rtlm (in) (11.87) (12.66) (11.08)
Radial runout mm (in) 0.08 (0.0031) or less
Out-ol-roundness mm (in) 0.06 (0.0024) or less
REAR DRUM BRAKE

F23 H41
Brake model .. DS22A LT30B D2L30A D2L32B
Lining wear limit
Minimum thickness mm (in) 1.5 (0.059) 1.5 (0.059) 3.2 (0.126)
Drum wear limit
Maximum inner diameter mm (in) 221.5 (8.72) 296.5 (11.67) 301.5 (11.87) 321.5 (12.66)
Radial runout mm (in) 0.05 (0.0020) or less 0.08 (0.0031) or less
Out-ol-roundness mm (in) 0.03 (0.0012) or less 0.06 (0.0024) or less
CENTER BRAKE ... H41 BRAKE BOOSTER

Unit: mm (in)
Maximum vacuum leakage
Brake model DS18H DS20HC (15 seconds after engine is
3.3 (33, 25, 0.98)
stopped)
Lining wear limit
Minimum thickness 1.5 (0.059)
10.275 - 10.525
Output rod length mm (in)
Drum repair limit (0.4045 - 0.4144)
Maximum inner diame- Input rod length mm (in) 130 (5.12)

181.0 (7.13) 204.5 (8.05)
ter
Brake shoe adjustment

CHECK VALVE
Returning notches 8 - 10
Maximum vacuum leakage
[15 seconds after 66.7 kPa (667
PARKING BRAKE F23 mbar, 500 mmHg, 19.69 inHg) 1.3 (13, 10, 0.39)
Brake model DS22A I LT30B

pressure is applied]
Number 01 notches when
warning lamp switch
comes on
Number 01 notches
[When pulled under lorce 11 - 15
01 196 N (20 kg, 44 Ib)]
BR-49
BRAKE PEDAL VACUUM PUMP
Free height "H" F23 169 - 175 (6.65 - 6.89) Engine TO engine BD and FD engines
mm (in) H41 169 - 174 (6.65 - 6.85) Pump vane length 12.5 - 13.5 20.0 - 21.0
"A" mm (in) (0.492 - 0.531) (0.787 - 0.827)
Depressed height
F23 70 (2.76)
[Under force of 490 N Pump vane width
25 (0.98) 46 (1.81)
(50 kg, 110 Ib) with "H" mm (in)
engine running]
H41 65 (2.56) Vacuum pump hous-
mm (in) 57.0 - 57.1 77.0-77.1
ing inner diameter
(2.244 - 2.248) (3.031 - 3.035)
Clearance between pedal stopper and "B" mm (in)
0.3 - 1.0 (0.012 - 0.039)
threaded end of stop lamp mm (in)
Pedal free play mm (in) 1 - 3 (0.04 - 0.12)
SBR039A
BR-50
STEERING SYSTEM
SECTIONS.,
CONTENTS
PRECAUTIONS AND PREPARATION ST- 2
ON-VEHICLE SERVICE ST- 4
STEERING WHEEL AND STEERING COLUMN ST- 8
MANUAL STEERING GEAR (Model: VB66K, VB70K) ST-12
POWER STEERING SYSTEM (Model: PB66A, PB70A) ST-17
POWER STEERING GEAR (Model: PB66A, P870A) ST-19
POWER STEERING OIL PUMP ST-27
STEERING LINKAGE ST-31
SERVICE DATA AND SPECIFICATIONS (S.O.S.) ST-36
1111
Precautions
• Before disassembly, thoroughly clean the outside of the unit.
• Disassembly should be done in a clean work area. It is important to prevent the internal parts from
becoming contaminated by dirt or other foreign maUer.
• When disassembling parts, be sure to place them in order on a part rack so they can be reinstalled
in their proper positions.
• Use nylon cloths or paper towels to clean the parts; common shop rags can leave lint that might
interfere with their operation.
• Before inspection or reassembly, carefully clean all parts with a general purpose, non-flammable
solvent.
• Before assembly, apply a coat of recommended A.T.F.* to hydraulic parts. Vaseline may be applied
to O-rings and seals. Do not use any grease.
• Replace all gaskets, seals and O-rings. Avoid damaging O-rings, seals and gaskets during installa-
tion. Perform functional tests whenever designated.
*: Automatic transmission fluid
Preparation
Description
Tool name Manual steering Power steering
ST27180001 Removing steer-
Steering wheel puller ing wheel
x x
HT72520000 Removing ball

Ball joint remover joint and swivel
joint x x
ST29020001 Removing pitman

Steering gear arm arm
puller
x x
KV48101200
Lock nut wrench
x x
KV481 04200
End cover wrench
x
KV481 01400 Adjusting and

Adjusting plug wrench tightening lock
nut x
ST-2
Preparation (Cont'd)
Description
Tool name Manual steering Power steering
ST3127S000 Measuring turn-

(i) GG91030000 ing torque
CD--fJ:::::r=. ~~~
Torque wrench
@ HT62940000
Socket adapter ~ x x
@ HT62900000
Socket adapter ~
KV481 00301 Steering gear is

Strut & steering gear- installed.
box attachment
x x
ST27091 0000. Measuring oil

Pressure gauge pressure
KV481009S0 Installing oil seal

Oil seal drift set
(i) KV48100910
Drift
@ KV48100920
Adapter
x
@ KV481 00930
Adapter
KV481 00700 Adjusting worm

Torque adapter bearing preload
x x
COMMERCIAL SERVICE TOOL

Unit application
Manual steering Power steering
Boot band attachment Installing boot
band
x x
Unit: mm (in)
SST671A
ST.3
ON-VEHICLE SERVICE
Checking Steering Wheel Play

• With wheels in a straight ahead position and check steer-
ing wheel play.
Steering wheel play:
35 mm (1.38 in) or less
• If it is not within specification, check backlash of steering
gear, tie-rod outer and inner ball joints.
SST618A
Checking Neutral Position on Steering Wheel

O.K. N.G.
Pre-checking
• Verify that the steering gear is centered before removing
the steering wheel.
Checking
• Check that the steering wheel is in the neutral position
when driving straight-ahead.
• If it is not in the neutral position, remove the steering wheel
and reinstall it correctly in the neutral position.
SST146C • If the neutral position is between two serrated teeth, loosen
tie-rod lock nut and move tie-rod in the opposite direction
by the same amount on both left and right sides to compen-
sate for error in the neutral position.
Checking Front Wheel Turning Angle

• Rotate steering wheel all the way right and left, and mea-
sure turning angle.
Turning angle:
Refer to section FA for S.O.S.
SMA127
Checkir:-g and Adjusting Drive Belts

(Power steering)
• Refer to section MA for Drive Belt Inspection.
ST-4
ON-VEHICLE SERVICE
Checking Fluid level (Power steering)

Check fluid level.
Fluid level should be checked using "HOT" range on dipstick
at fluid temperatures of 50 to 80°C (122 to 176°F) or using
"COLD" range on dipstick at fluid temperatures of 0 to 30°C (32
to 86°F).
CAUTION:
• Do not overfill.
• Recommended fluid is Automatic Transmission Fluid
''DEXRON™,, type.
SST280B
Checking Fluid leakage (Power steering)

Check lines .for proper attachment, leaks, cracks, damage,
1. Run engine at idle speed or 1,000 rpm.
Make sure temperature of fluid in oil tank rises to 60 to 80°C
(140 to 176°F).
2. Turn steering wheel right-to-Ieft several times.
3. Hold steering wheel at each "lock" position for five sec-
onds and carefully check for fluid leakage.
CAUTION:
SST621A
Do not hold steering wheel at lock position for more than fifteen
seconds at a time.
4. If fluid leakage at connectors is noticed, loosen flare nut
and then retighten.
Do not overtighten connector as this can damage O-ring,
washer and connector.
Bleeding Hydraulic System (Power steering)

1. Raise front end of vehicle until wheels clear ground.
2. While adding fluid, quickly turn steering wheel fully to right
and left untiLit lightly touches steering stoppers.
CAUTION:
Do not hold steering wheel in lock position for more than fifteen
seconds.
Repeat steering wheel operation until flUid level no longer
decreases.
3. Start engine.
Repeat step 2 above.
• Incomplete air bleeding will cause the following to occur.
When this happens, bleed air again.
CD Generation of air bubbles in reservoir tank
@ Generation of clicking noise in oil pump
CID Excessive buzzing in oil pump
S'T-5
ON-VEHICLE SERVICE
Bleeding Hydraulic System (Power steering)
(Cont'd)
In steering while the vehicle is stationary, or when moving
wheel slowly, fluid noise may be caused in the valve or oil
pump. This type of fluid noise is inherent in an integral power
steering system, and it will not affect performance or durability
of the system.
Checking Steering Wheel Turning Torque

(Power steering)
1. Pa'rkvehicle on a level, dry surface and set parking brake.
2. Bring power steering fluid up to adequate operating tem-
perature. [Make sure temperature of fluid is approximately
60 to 80°C (140 to 176°F»).
Tires need to be inflated to normal pressure.
3. Check steering wheel turning force when steering wheel

has been turned 360° from neutral position.
Steering wheel turning force:
Model PB66A
24.5 . 29.4 N (2.5 - 3.0 kg, 5.5 . 6.6 Ib)
Model PB70A
39 N (4 kg, 9 Ib)
SST714A
ST27091 000 Checking Hydraulic System (Power steering)

Before starting, check belt tension, driving pulley and tire pres-
sure ..
1. Set Tool. Open shut-off valve. Then bleed air. (See "Bleed-
ing Hydraulic System".)
2. Run engine.
Make sure temperature of fluid in tank rises to 60 to 80°C
(140 to 176°F).
WARNING:
Warm up engine with shut-off valve fUlly opened. If engine is
SST834
started with shut-off valve closed, oil pressure in oil pump will
increase to relief pressure, resulting in an abnormal rise in oil
temperature.
3. Check pressure with steering wheel fully turned to left and
right positions.
ST-6
ON-VEHICLE SERVICE
Checking Hydraulic System (Power steering)
(Cont'd)
CAUTION:
Do not hold steering wheel at lock position for more than fifteen
seconds.
Oil pump pressure:
PB66A
7,649 - 8,238 kPa (76.5 - 82.4 bar,
78 - 84 kg/cm2, 1,109 - 1,194 psi) at idling
PB70A
B030 engine
8,630 - 9,219 kPa (86.3 - 92.2 bar,
F042 & F046 engines
9,121 - 9,709 kPa (91.2 - 97.1 bar,
4. If oil pressure is below the standard, slowly close shut-off
valve and check pressure.
• When pressure becomes standard, gear is damaged.
• When pressure remains beyond standard, pump is dam-
aged.
5. If oil pressure is higher than the standard level, pump ,is
damaged.
CAUTION:
Do not close shut-off valve for more than fifteen seconds.
6. After checking hydraulic system, remove Tool and add fluid
as necessary, then completely bleed air out of system.
ST..7
STEERING WHEEL AND STEERING COLUMN
~ 16 - 19 (1.6 - 1.9, 12 - 14)

Horn pad
Hole cover
SST058C
STEERING WHEEL
• Pull out horn pad.
SST060C
• Remove steering wheel with Tool.
ST-8
STEERING WHEELAND STEERING COLUMN
• When installing steering wheel, apply multi-purpose grease
to entire surface of turn signal cancel pin (both portions)
and also to horn contact slip ring.
SST626A
• Install steering wheel on column shaft in a straight-ahead

position.
• After installing, turn steering wheel to make sure it moves
smoothly and that the number of turns from the straight-
ahead position to left and right locks are equal.
STEERING COLUMN
• When installing steering column, finger-tighten all lower
bracket and clamp retaining bolts; then retighten them
securely. Make sure that undue stress is not applied to
steering column.
• When fitting steering lower joint, be sure tightening bolt

faces cutout portion perfectly.
SST189C
ST-9
Disassembly and Assembly
Combination switch
Steering lock
toJ 6.4 - 7.4 N.m~

(0.65 - 0.75 kg-m,
4.7 - 5.4 ft-Ib) "'@
Column shaft assembly
Lower joint assembly
SST062C
• When disassembling and assembling, unlock steering lock

with key.
• Ensure that rounded surface of snap ring faces toward
bearing when snap ring is installed.
• Install snap ring CD before inserting shaft into jacket tube.
SST428A
• Install snap ring on upper shaft with tool.

Upper shaft
SST628A
ST-10
Disassembly and Assembly (Cont'd)
• Steering lock
a) Break self-shear type screws with a drill or other appropri-
ate tool.
SST741A
b) Install self-shear type screws and then cut off self-shear

type screw heads.
Self-shear screw
SST742A
Tilt mechanism
• Tilt type
After installing steering column, check tilt mechanism oper-
Steering wheel
center
ation.
Tilt
L1: 15 mm (O.59 in)
L2: 45 mm (1.77 in)
Telescopic
La: 10 mm (O.39 in)
L4: 20 mm (O.79 in)
SST064C
Inspection
• When steering wheel can not be rotated smoothly, check
the steering column for the following matters and replace
damaged parts.
(1) Check column bearings for damage or unevenness. Lubri-
cate with recommended multi-purpose grease or replace
steering column as an assembly, if necessary.
L (2) Check jacket tube for deformation or breakage. Replace if
necessary.
• When the vehicle is involved in a light collision, check
SST065C
dimension "L". If it is not within specifications, replace
steering column as an assembly.
Column length "L":
448 mm (17.64 in)
ST-11
MANUAL STEERING GEAR (Model: VB66K, VB70K)
Worm shaft to rubber coupling

~ 24 - 29 (2.4 - 3.0, 17 - 22)
Align the groove in worm shaft with
the bolt hole in rubber coupling flange
yoke, and press coupling bolt through
the cutout portion of worm shaft.
~ST29020001 Gear housing to frame

~ 88 - 98 (9 - 10, 65 - 72)
• Install pitman arm.
Align four grooves of gear arm serrations with
four projections of sector shaft serrations, Sector shaft to pitman arm
and install and tighten lock washer and nut.
~ 235 - 265 (24 - 27, 174 - 195)
SST068C
Lock nut
~29 - 39
(3 - 4' 22 - 29)~ ~Filler plug P'n'l
~-.. 15 - 25 (1.5 - 2.5, 11 - 18)
~44-54~ "''\ \-\

(4.5 - 5.5, @ i~sector ' Bearings
33 - 40) v ~ shaft cover
o-GaSket~
Adjusting plate ~ j
Sector shaft adjusting screw--\
L-----
Steering gear housing
Oilseal~~
~~ /~ 235 - 265 ~ : N.m (kg-m, ft-Ib)

Spring washer ~ (24 _ 27, 174 - 195)
SST190C
ST-12
MANUAL STEERING GEAR {Model: VB66K, VB70K)
Disassembly
1. Place steering gear in a vise with Tool.
2. Set worm gear in a straight-ahead position.

3. Remove sector shaft with sector shaft cover.
CAUTION:
a. When pulling sector shaft out, be careful not to damage oil
seal or associated parts.
b. Set worm gear in a straight-ahead position.
c. Do not remove sector shaft needle bearings from steering
gear housing. If necessary, replace gear housing assem-
bly.
4. Loosen adjusting plug lock nut with Tool.
SST085
5. Draw out worm gear with worm bearing.

CAUTION:
a. Be careful not to allow ball nut to run down to either end
of worm.
Ends of ball guides will be damaged if nut .Is rotated until
it stops at end of worm.
b. Do not detach ball nut from worm shaft assembly.
If necessary, replace entire unit as an assembly.
c. Do not remove sector shaft needle bearings from steering
gear housing.
SST086 If necessary, replace entireg~ar housing as an assembly.
Assembly and Adjustment

Fill space between sealing lips of new sector shaft and adjust-
ing plug oil seals with multi-purpose grease.
WORM BEARING PRELOAD

1. Fit worm gear assembly with worm bearing in gear hous-
ing.
SST088
ST-'13
MANUAL STEERING GEAR (Model: VB66K, VB70K)
Assembly and Adjustment (Cont'd)
2. Adjust worm bearing preload with Tools.
CAUTION:
• Always adjust worm bearing preload by turning adjusting
plug In "tighten" direction.
• Rotate worm shaft a few turns in both directions to settle
down worm bearing and measure preload.
Worm bearing preload (without oil seal):
0.20 - 0.59 N'm
(2.0 - 6.0 kg-em, 1.7 - 5.2 In-Ib)
SSTOB9
3. Apply suitable sealant around lock nut inner surface.
KV48101200
4. Tighten lock nut using Tools.
5. After tightening lock nut, check worm bearing preload to
make sure it is within specification.
SST091
~o_-;~c
- - -~
Lm (ft)~
0.1 m
(0.3 ft)
lft.lbl NomIkt-ml
(2101 "'(30)
12001 "'1211
271 (281
11901
211(271
.r 11801 255 t261
245 (26.
111701 2361241
{:. H801 226(23)
216 (22)
U (150)
2061211
fT4DI
196(201
1130) 186 (191

177 (181
11201
167 (171
157(161 0.3 0.4 0.6 0.6 0.7 0.8

I
11.01
SST30BA
ST-14
MANUAL STEERING GEAR (Model:.VB66K,VB70K)
Assembly and Adjuslmenl (Conl'd)
STEERING GEAR PRELOAD AND BACKLASH
1. Set worm gear in a straight-ahead position.
Cart!fully Insert sector shaft In place, using care not to scratch
oil seal.
2. Adjust adjusting screw until sector shaft just contacts ball
nut. Temporarily tighten lock nut.
3. Lubricate contacting portion of sector shaft and ball nut with
gear oil or bearing grease.
4. Tighten ..adjusting screw further to increase worm gear

preload, and I.ockwith lock nut.
Preload increment:
0.2 - 0.6 .N'm (2 - 6 kg-em, 1.7 - 5.2 In-Ib)
CAUTION:
• Always adjust steering gear preload by turning adjusting
screw In "tighten" direction.
• Rot~te wor"" gear a few turns In both directions to settle
down steering gear.
SST309A
5. Turn worm gear several times by hand to properly break in

worm bearing.
6. Check steering gear pr:eload. If not within specification,
readjust it.
SST310A
7. Drive oil Seal into place.

Before pressing oil seal, coat seal contacting face of oil seal
with gear fluid.
8. Meas.uretotal preload.
Steering gear total preload (With oil seals):
New parts
0.83 - 1.23 N'm
(8.5 ~ 12.5 kg-em, 7.4 - 10.9 In-Ib)
Used parts
0.59 - 0.98 N'm
(6.0 - 10.0 kg-em, 5.2 - 8.7 In-Ib)
ST-15
MANUAL 5TEERINGGEAR (Model: VB66K, VB70K)
Assembly and Adjustment (Cont'd)
9. Check backlash.
Measure backlash at pitman arm top end in straight-ahead
position.
Backlash (in straight-ahead position):
New gear: 0.1 mm (0.004 in) or less
Used gear: 0.3 mm (0.012 in) or less
SST030
Inspection
Wash clean all the disassembled parts in solvent and check for
condition.
SECTOR SHAFT
1. Check gear tooth surface for pitting, burrs, cracks or any
other damage, and replace if necessary.
2. Check sector shaft for distortion on its serration, and
replace if necessary. Also check gear housing for deforma-
tion.
STEERING WORM ASSEMBLY

1. Inspect ball nut gear tooth surface, and replace if pitting,
burrs, wear or any other damage is found.
2. Ball nut must rotate smoothly on worm gear. If found too
tight, assembly should be replaced. Check rotation of ball
nut as follows:
(1) Move ball nut to either end of worm gear, and gradually
stand worm shaft and ball nut assembly until ball nut moves
Moves downward downward on worm gear under its own weight.
under own weight (2) If ball nut does not move freely over entire stroke, replace
SST098 assembly.
Be careful not to damage ball nut guide tube while check is
being made.
CAUTION:
Be careful not to allow ball nut to run down to either end of
worm.
BEARING
1. Inspect worm bearing for wear, pitting or any other dam-
age. Replace as required.
When replacing worm bearing, replace it as a set of bearing
and outer race.
2. If sector shaft needle bearings are worn or damaged,
replace as an assembly of gear housing and bearings.
OIL SEALS
• Always replace oil seal which has once been removed.
• Replace oil seal if sealing lip is deformed or cracked.
• Replace oil seal if spring is fatigued or dislocated.
5T-16
POWER STEERING SYSTEM (Model. 'PB66A, PB70A)
MODEL F23 A
NA20S engm
. e model Reservoir tank ..
~ 49 - 69 36. 51)
(5.0 - 7.0,
.
TD25 an d TD27 engme models
~ 39 - 51 (4.0 - 5.2, 29 - 38)
~ Copper washer
View from A
.. 9 parts
ealing parts can bembly.
replaced . The remalnln
O"~ lh" '~d
must be rep a
~ M~" "'9" U
d In a place a
CAUTION: should be performe
•. possible.
D"H_~ Id be cleaned befo ~
Hands shou Be sure to u
•• ~m'~. ,"01'.
sednylon or pape
D
b. e a rag. ft Ib)
o not us (kg-m, _
c. ~: N.m
SST066C
ST-17
POWER STEERING SYSTEM (Model: PB66A, PB70A)
MODEL H41
8030 engine model

~ 49 - 69 (5.0 - 7.0, 36 - 51)
s.
F042 and F046 engine models
~39-49
(4.0 - 5;0, 29 - 36)
View from A
Accelerator wire
FrontQ
View from B
Only the sealing parts can be replaced. The remaining parts

must be replaced as an assembly.
CAUTION:
a. Disassembly should be performed In a place as clean as
possible.
b. Hands should be cleaned before disassembly.
c. Do not use a rag. Be sure to use nylon or paper cloth.
SST067C
ST-18
POWER. STEERING GEAR {Model: PB66A, PB70A}
Steering Gear
. ~
@_---;1))
235 - 265 (24 - 27, 174 - 195)
Pitman arm
Lower joint
~
o ~
0@)
:b.~
toJ
~
24 • 29 (2.4 - 3.0, 17 - 22)
Copper washer
.-\e~
y- - @~ toJ 31. 51
e 'ZJ -~ ~. (4.0 - 1.2, 29.31)
Steering gear
Cotter Pln_="""'"j~
. I
toJ 88 - 137
(9.0 - 14, 65 - 101)
toJ 27 - 40
toJ sa • 98
(2.8 - 4.1, 20 • 30) (1.0 - 10,
toJ : N.m (kg-m, fl-Ib) 66 - 72)
SST070C
Removal
Before removing, clean exteriors or gear housing and 011 pump
with steam and dry with compressed air.
1. Remove high-pressure and low-pressure pipe connectors.
2. Remove lower joint.
3. Detach pitman arm from drag link with Tool.
4. Remove.pitman arm tightening nut.

5. Remove pitman arm from steering gear assembly with
Tool.
6. Remove steering gear tightening bolt and steering gear
Pitman arm
assembly.
SST191C
ST-19
POWER STEERING GEAR (Model: PB66A, PB70A)
Pitman arm Installation

1. Install pitman arm to steering gear assembly.
2. After installing, completely bleed air out of system.
Refer to "Bleeding Hydraulic System" in "ON-VEHICLE
SERVICE".
Power Steering Gear Component
Gear housing
SST075C
Disassembly
1. Place steering gear assembly in a vise.
2. Set up a preload gauge and adapter at worm shaft
serrations, then turn steering wheel to the left and right
repeatedly until fluid no longer flows out of the two holes.
3. Set worm shaft in neutral.

Neutral is in the middle of the two lock positions.
Model: PB66A
A: 34.5. - 38.
B: 34.5. - 38.
Model: PB70A
A: 45. - 48.5°
B: 45° - 48.5°
Center Sector shaft
serration
SST077C
ST.20
POWER STEERING GEAR (Model:<PB66A, PB70A)
Sector shaft
4. Loosen sector cover tightening bolts about 5 mm (0.20 in).
Then, lightly tap end of sector shaft with a plastic hammer
or the like until it is slightly driven out. Remove the bolts
and sector cover.
SST078C
5. Draw out sector .sl:1aft.

Knock out end of sector shaft approximately 22 mm (0.87 in).
22 mm (0.87 in)
SST079C
6. Connect aToll of plastic film to sector shaft.

Plastic film:
Thickness 0.1 mm (0.004 in)
Length x width
200 x 200 mm (7.87 x 7.87 in)
7. Pull out sector shaft by hand.
Simultaneously pulling out sector shaft so that bearings will not
drop into housing.
SST080C
8. Remove oil seal.
9. Remove adjusting screw lock nut.

10. Remove sector cover and sector shaft.
SST082C
ST-21
POWER 8TEERINGGEAR (Model: PB66A, PB70A)
a. Remove O-ring.
b. Remove U-packing.
CAUTION:
• Be careful not to scratch sector cover and needle bearing
when removing U-packlng.
• Needle bearing cannot be disassembled and, If damaged,
replace sector cover assembly.
SST083C
Worm shaft
11. Remove gear housing cover.
SST084C
12. Remove end cover lock nut.
13. Remove end cover using end cover wrench.

a. Remove worm bearing, outer race, inner race by hand.
b. Remove worm shaft from worm gear housing.
SST087C
8T-22
POWER STEERING GEAR (Model: PB66A, PB70.A)
c. Remove oil seal of gear housing cover together with ball
bearing using suitable tool.
CAUTION:
• When worm. assembly is removed, piston may turn and
come off under its own weight. Hold piston to prevent it
from turning.
• Take care not to damage teflon ring at piston end when
removing.
SST088C
Inspection
SECTOR COVER ASSEMBLY
• If needle bearing (built into sector cover) is scratched or
uneyenly worn, replace sector cover assembly.
SECTOR COVER
• If sector cover is dented or scratched, or if gear teeth at
bearing location are broken, replace sector shaft.
• If gear (teeth are broken, replace sector cover and ball
screw unit, or any other faulty part as necessary.
• Check for adjusting screw axial play. If it exceeds
specifications, replace adjusting plate.
Axial play: 0.1 mm (0.004 in)
WORM SHAFT
• If worm shaft, ball and/or rack piston is worn or damaged,
replace WOrmshaft.
• I.fmain shaft does not properly rotate (due to flaking of ball
screw rolling surface), or if rack teeth are cracked, replace
worm shaft.
WORM BEARING
• If bearing balls, outer race or inner race are faulty, replace
worm bearing.
GEAR HOUSING COVER BALL BEARING
• If ball bearing is abnormally worn or does not spin
smoothly, replace ball bearing.
GEAR HOUSING
• If needle bearing is scratched or al:mormally worn, replace
gear housing assembly.
• If the contact surface of the gear hOlJsing cover, sector
cover O-ring or end cover O-ring groove are damaged,
replace gear housing.
Assembly
Worm shaft
Before il'1stalling oil seal, U-packing, O-ring, apply mUlti-pur-
posegrea~e to lips.
1. Install O-ring.
~ O-ring
SST089C
ST.23
Assembly (Cont'd)
a. Install oil seal, ball bearing to gear housing cover.
b. Apply a thin coat of vaseline to new O-rings prior to their
installation.
Be careful not to install wrong a-rings as some of them resem-
ble in size.
c. Using a drift and hammer, drive oil seal and ball bearing
(as a unit) into bore in gear housing cover.
SST090C
2. Insert worm shaft into gear housing.

CAUTION:
• Apply a thin coat of A.T.F. inside gear housing and piston
before insertion.
• Be sure that teflon ring at piston end is not damaged dur-
ing insertion of gear housing. If it is damaged, replace
entire assembly.
• Be sure that teflon ring settles in its correct position.
3. Install housing cover to gear housing and gradually tighten
housing cover bolts.
4. Apply a coat of A.T.F. to O-ring (located at the end of gear

housing), then install worm bearing inner race on worm
shaft. Drive worm bearing into bore in end cover.
Ensure worm shaft starts to rotate properly. then tighten
end cover until starting torque is within specifications.
0.3 - 0.7 N'm (0.03 - 0.07 kg-m, 0.2 - 0.5 ft-Ib)
5. Using Lock Nut Wrench, tighten lock nut to specified torque.

~: 177 - 226 N.m
(18 - 23 kg-m, 130 - 166 ft-Ib)
6. Using Preload Gauge and Adapter, measure worm shaft

KV481 00700
rotation starting torque to see if it is within specifications.
If it is outside specifications, loosen lock nut and end cover,
then retighten as required.
0.3 - 0.7 N.m (0.03 - 0.07 kg-m, 0.2 - 0.5 ft-Ib)
SST092C
ST-24
POWER STEERING GEAR (ModeJ: PB66A, PB70A)
Assembly (Coni' d)
7. Using Drift [0.0.: 60 mm (2.36 in)], drive oil seal into bore
in gear housing (at sector shaft location) until it is flush with
gear housing.
SST093C
146 mm (5.75 In) 8. Rotate worm shaft by hand until it is in the center of its
travel.
Center of
worm shaft SST094C
Sector shaft
9. Install U-packing and O-ring to groove of sector cover.
10. Install adjusting screw and adjusting plate (as a set) to

sector shaft.
11. Install sector shaft to sector cover assembly.
• Using a standard screwdriver, turn adjusting screw coun-
terclockwise until it almost touches the bottom of the sec-
tor cover, then back it off one complete turn.
Temporarily tighten adjusting screw lock nut.
12. Insert sector cover assembly and sector shaft in gear hous-
ing.
CAUTION;
Be careful not to damage oil seal when installing sector shaft.
• Rotate worm shaft fully counterclockwise and clockwise to
check if it makes 5 or 4 complete rotations in each direc-
tion. If it does not, then check rack piston and sector shaft
for proper engagement.
ST-25
Assembly (Conl'd)
13. Measure worm shaft starting torque:
a. Use Preload Gauge and Adapter for measurement.
b. Align incomplete serration section of the sector shaft as
shown in figure at left.
- - - )) Incomplete sector
~ shaft serration
SST077C
14. Tighten sector cover mounting bolts to specified torque.

a. Apply a coat of multipurpose grease to inner surface of dust
cover, then install gear housing cover side and sector shaft
side.
SST096C
b. While rotating worm shaft approximately 1/4 turn counter-

clockwise and clockwise from the Neutral position, tighten
adjusting screw until starting torque is within specifica-
Lock nut
~ 29 - 39 N.m
tions.
(3.0 - 4.0 kg-m, Neutral is in the middle of the two lock positions.
22 - 29 ft-Ib)
Starting torque:
1.0 N'm(0.10 kg-m, 0.7 ft-Ib) or less
c. After adjusting the starting torque, tighten adjusting screw
lock nut to specified torque.
SST097C
ST-26
POWER STEERING OIL PUMP
Disassembl y and Assembly

NA20S T02 T027
engine' mOd:'ls NA20S
engine ~~ 16 - 21
models ~ if (1.6 - 2.1, 12 - 15)
only I ~
l Pulley
ef
Rubber plug
::-- .......-::
~ 14 - 18 Reservoir tank
(1.4 - 18
10 - 13) ,
~"'~
~ ~ ~ or"Vieshaft ~
~~O-ring
lEI Oil seal o~
~ ~
_~_ ,~/~ ~ 0
~y\ ~' ~ C-"o,
..•..•.•.•
~'~."ro~ c" L
7'~~~'o'''''''' 5.)
.
.:.J.
Spring
V~~~~
~
(moo ,pool,
., ...'. .,' .. . .. Front ho uSing
' 0'Ischar
• •. ~ 5""0' ""
na-ngo 000",_
~ . '000' 0-", (7A- 8.', 51 - 58'
~ Outer O-ring
Front Sl'd eplate
COJ : N.m (kg-m, ft-Ib)
8030, F042 and F046 engme

. models
I BD30 Engine I ~ 14 - 18 (1.4 - 1.8, 10 - 13)
5'01'00 ooo",~:~ Oil ~.ElI ~.~

~~::::~. ~ 54 - 68(5.5 - 6.9, 40 - 50)
~ O-ring ------0
'.~ )k<
~O' 0
Front hOUSingJt0
Spring
I
ce>o ""./ ~~"
•Flow control Pulley
val" .( ,
~ ~ ~ I<.>r. . ve malnsp
1(0
X ~ ~
Z. ~~..
~ Outer O-rin Discharge 001)
'm,"'" p"" '~ IS\(I' - ~. """"octo< ~ .. - ".

Rot:;t ~- \J~ "I' i Spring n ';.".
~~~'
eam ring ~ ~ _
III "'-.....~ '0"" 0-" . -58,
51- 8A,
~~~~ \.;:-: ~\E;~~. ' ~. o,... ,oor.~.. ~w~

~ ~\~~ tp,;C-v.oe I~l f, ~ "-w.!.~-ri~
~ R.~ ~:,:.. ,"01'00 """"ioi~ ~ ~~~~<i~
~ 21 _ 35 (28 ' 00 • .: ,~~ 0''' 'hofl .
n" _58(5'
~ (8030 en~in~)3.6, 20 _ 26) ~~
,0 ,/ ~ • Spacer
,.~Sprlo,
1'D42 Md 'D46
- ~~ 00"00'
'" - <3)
',oot hoo,'o, FD42 Englne~.~F1~
,,"
• ""'tr~""'"
COJ 49 _ 59 (main.. spool)
., - 43)
FD.46Engine . ('2J (5.0 - 6 0 36
Discharge
connector ~ '. N.m (kg-m, ft-Ib)
SST099C
ST-27
Pre-disassembly Inspection
Disassemble the power steering oil pump only if the following
items are found.
• Oil leak from any point shown in the figure.
• Deformed or damaged pulley.
• Poor performance.
SST984A
Disassembly
CAUTION:
• Parts which can be disassembled are strictly limited. Never
disassemble parts other than those specified.
• Disassemble in as clean a place as possible.
• Clean your hands before disassembly.
• Do not use rags; use nylon cloths or paper towels.
• Follow the procedures and cautions in the Service Manual.
• When disassembling and reassembling, do not let foreign
matter enter or contact the parts.
1. Remove snap ring, then draw drive shaft out.

Be careful not to drop drive shaft.
Extension bar
Drive shaft
SST010B
2. Remove oil seal.

Be careful not to damage front housing.
3. Remove connector.
Front housing
Be careful not to drop control valve.
SST036A
ST-28
POWER5TEERING 011.. PUMP
Inspection
Inspect each component part for wear, deformation, scratches,
and cracks. If damage is found, replace the part.
Assembly
1. Assemble oil pump, noting the following instructions.
a. Make sure O-rings and oil seal are properly installed.
b. Always install new O..rings and oil seal.
c. Be careful of oil seal direction.
d. Cam ring, rotor and vanes must be replaced as a set if
necessary.
e. Coat each part with A.T.F.when assembling.
2. After installing spring A, install front side plate.

CAUTION:
Be careful not to scratch front side plate during installation.
Otherwise, performance degradation, seizure or oil leaks may
result.
SST100C
Reer housing side 3. Pay attention to the direction of rotor.
4. When assembling vanes to rotor, rounded surfaces of

vanes must face cam ring side.
Flat portion
SST843A
5T-29
Assembly (Cont'd)
5. Insert pin @ into pin groove CD of front housing and front
side plate. Then install earn ring <ID as shown at left.
0,
t Front housing side
Rear housing side
SST497A
ST-30
STEERING LINKAGE

MODEL F23
Cotter Pin
l ~ 88 - 137 (9.0 - 14, 65 - 101)
~ 88 - 137
Cotter pin ~ Drag link
'\~ ..~' ~ ~ - 137 (9.0 - 14, 65 - 101) \~cotter
.~. (9.0 - 14, 65 - 101) Connector rod pin ~

(Swivel joint) \1
Tie-rod ,
~@ 0) 0 I
/ . ~
Relay lever assembly ~ 52 _ 62 ~I'
(5.3 - 6.3,38 - 46~I:-----"'~
Rear stopper bracket ~ 88 - 137 ~
(9.0 - 14, 65 - 101)
r:2
Front
Cotter pin ~
~ : N.m (kg-m,fNb)
SST101C
1. Remove cotter pin from tie. rod, then separate knuckle arm
from tie rod using a suitable tooL
2. Using asuitable tool, separate tie rod, relay rod, relay lever
assembly, idler assembly and drag link at ball joints.
ST-31
STEERING LINKAGE
3. Using Tool, separate drag link from Pitman arm at ball joint.
4. Remove front stopper bracket and rear stopper bracket

tightening bolt.
MODEL H41
Pitman arm
~~~
Front
392 - 490 (40 - SO, 289 - 362) #E '---~o
Cotter pin ~7
c1: (.?--
~
/'"
~Cotterpin~
If
Drag link ~ 235 - 265
~ 88 • 137
(9.0 - 14,
65 - 101) V/
I
1)' j t:r~~\(
Z~.> ~>" c., ~, f'....
d,... '
C~tter pin ~ ~
\ ~~
~ Cotter pin
<!) ',~:', 6(---_ ~ 88 - 137
~s,~ ..? I C-",,- / (9.0 - 14
Knuckle arm
,(
"':::. .... \.~
~_... //) ((CF
l:'1 ~
/',/
....
~ A/"
£ "'::: ;:;::?' ~/ -
1",-""
, ~ 392 - 490
I ~--~ ) __%;:>~, -'>
~/
(40 - SO, 289 - 362)
"J'- ' ..
{/
/ /'
Cl
\.,~/
~ 64 _ 78
(6.5 - 8.0, 47 - 58) !!J Tie-rod
~
~
Knuckle arm
~ ... 78 ('~ • M. 47 • 58)/ ~ : N.m (kg-m, ft-Ib)
SST106C
ST-32
STEERING LINKAGE
1. Remove tie-rod from knuckle arm using Tool.
2. Remove knuckle arm and drag link from Pitman arm using
suitable tool.
SST108C
Disassembly
IDLER ARM ASSEMBLY AND RELAY LEVER ASSEMBLY
• Apply coat of multi-purpose grease to bushing.
• Press bushing into idler or relay lever body, and insert
shaft of idler relay lever bracket carefully until bushing
protrudes.
RELAY ROD AND TIE-ROD - F23 and H41

1. When tie-rod ball joints and tie-rod bar are separated,
adjust tie-rod length correctly.
Adjustment should be done between ball stud centers.
L: Standard
Refer to S.O.S.
2. Lock tie-rod clamp nut so that ball joint on outer ball stud
is as follows with respect to that on inner ball stud.
40 mm (1.57 in) or more CAUTION:
Make sure that tie-rod bars are screwed into tie-rod tUbe more
SST109C
than 40 mm (1.57 in).
STEERING LINKAGE
Ball joint Inspection

~A BALL JOINT AND SWIVEL JOINT
~B 1. Check joints for play. If ball or swivel stud is worn and play
in axial direction is excessive or joint is hard to swing,
t c replace as a complete unit.
Swinging force (Measure point: Cotter pin hole) "A":
Ball joint
Refer to S.O.S.
~ Rotating torque "B":
SFA858A Refer to S.O.S.
Axial end play "C":
Swivel joint o mm (0 in)
2. Check condition of dust cover. If it is cracked excessively,
~B replace dust cover.
t c
a.
b.
When replacing dust cover, be careful not to damage it.
Lubricate joint with multi-purpose grease, if necessary.
SFA817A
c. When installing boot band with *commercial tool, be care-

ful not to overexpand it.
* Refer to PREPARATION.
CAUTION:
Tie-rod
assembly Commercial tool Be careful not to apply grease or oil to taper of joint.
Dust cover
SST670A
IDLER ARM ASSEMBLY AND RELAY LEVER ASSEMBLY

• Check rubber bushing of idler arm for breakage, wear or
play, and if necessary replace.
• Lubricate idler arm assembly and relay lever assembly
with recommended multi-purpose grease, if necessary.
When lubricating, refer to BALL JOINT AND SWIVELJOINT.
DRAG LINK AND TIE-ROD

Check tie-rod and cross rod for breakage, bend or crack, and
replace with a new one if necessary.
ST-34
STEERING LINKAGE
Inspection (Cont'd)
STEERING DAMPER
Check for oil leakage and measure damping force of damper,
and replace if necessary.
Damping force:
at 0.3 m (1.0 ft)/sec
1,942 N (198 kg, 437 Ib)
... Extended direction
1,775 N (181 kg, 399 Ib)
... Compressed direction
FIXING LOCATION
• Check fixing location (nuts and cotter pins) for looseness,
play or breakage.
• When looseness or play is found, check for wear on tapered
portion of joints, gear arm of .idler arm.'
• When reassembling each joint, use new cotter pins.
ST-35
Model F23
Applied model 1.5-ton
Steering model Manual steering Power steering

Steering gear type VB66K PB66A
Rear tire Single tire
I Double tire Single tire
I Double tire
Steering overall gear ratio 22.5 - 25.5 22.6
Turns of steering wheel
(Lock to lock)
3.52
I 3.83 3.38
I 3.67
Steering column type Collapsible, tilt, non tilt
Model H41
Applied model 2-ton 2.75-ton 2-ton 2.75-ton 3-ton
Handle L.H.D. - R.H.D. L.H.D. L.H.D. - - -
Steering model Manual steering Power steering
Steering gear type VB70K PB70A
Rear tire Single Double Single Double
Steering overall gear

25.0 - 28.0 22.0
ratio
Turns of steer- Tire

7.00-15 6.50-16 7.00-16 7.00-16 7.00-15 6.50-16 7.00-16 7.00-16
ing wheel size
(Lock to lock) 5.0 5.0 4.9 4.8 4.2 4.2 4.0 4.7
Steering column type Collapsible, tilt, non tilt

GENERAL STEERING COLUMN
Steering wheel axial play Applied model All
0(0)
mm (in)
Steering column length "L"
448 (17.64)
Steering wheel play mm (in) 35 (1.38) or less mm (in)
Movement of gear housing

:1:2 (:1:0.08) or less
mm (in)
L
SST110C
ST-36
SERVIC.EDATAANDSPECIFICATIONS.(S.D.S.)
STEERING GEAR AND LINKAGE Model H41
Model F23
Ball joint
Ball joint
4.32 - 50.41
Swinging force Drag link Swinging force Tie-rod (0.44 - 5.14,
5.9 - 64.7
Measure point: Measure point: 0.97 - 11.33)
Relay rod (0.6 - 6.6,
cotter pin hole cotter pin hole
1.3 - 14.6) 5.10 - 59.14
N (kg, Ib) Connector rod N (kg, Ib) Drag link (0.52 - 6.03,
Drag link 1.15 - 13.30)
0.3 - 3.4
Sliding torque
Relay rod (0.03 - 0.35, Tie-rod 0.3 - 3.4
N'm (kg-m, ft-Ib) Sliding torque
0.2 - 2.5) (0.03 - 0.35,
Connector rod N'm (kg-m, ft-Ib)
Drag link 0.2 - 2.5)
Drag link
Axial end play Tie-rod
Axial end play mm 0(0)
Relay rod 0(0) mm(in)
(in) Drag link
Connector rod
Tie-rod standard 7.00-15 1,180 (46.46)
Relay rod standard length "L'.' mm(in) 6.50-167.00-16 1,165 (45.87)
length "L" - 669 (26.34)
mm (in) Tie-rod
L
Relay rod
Ball Swivel joint

joint
~ 64 - 78 N.m
(6.5 - 8.0 kg-m, 47 - 58 ft-Ib)
More than
SST112C
~ 25 - 28 N.m 40 mm (1.57 in)
(2.5 - 2.9 kg-m, 18 - 21 ft-Ib)
SST111C
Swivel joint
MANUAL STEERING GEAR (Model: VB66K,
VB70K)
Sliding torque 0-3.4
N'm (kg-m, ft-Ib) (0 - 0.35, 0 - 2.5)
Relay rod Worm bearing preload
Axial end play
0(0) (Without oil seal) 0.20 - 0.59 (2.0 - 6.0, 1.7 - 5.2.)
mm (in)
N'm (kg-cm, in-Ib)
Steering gear preload

(With oil seal)
Relay lever assembly and idler assembly N'm (kg-em, in-Ib)
0.83 - 1.23
New parts
Relay lever assem- (8.5 - 12.5, 7.4 - 10.9)
Sliding torque bly Less than
N'm (kg-m, ft-Ib) 4.9 (0.50, 3.6) 0.59 - 0.98
Used parts
Idler assembly (6.0 - 10.0, 5.2 - 8.7)
Spring scale indi- Relay lever assem- Backlash at pitman arm top end
bly Less than (in a straight-ahead position)
cation
35.3 (3.6, 7.9) mm (in)
N (kg, Ib) Idler assembly
New gear 0- 0.1 (0 - 0.004)
Used gear 0- 0.3 (0 - 0.012)
Oil capacity t (Imp pt) Approx. 0.7 (1-1/4)
ST-37
POWER STEERING SYSTEM (Model: PB66A,
PB70A)
Steering wheel turning force (at (PB66A)

360' from neutral position and 24.5 - 29.4 (2.5 - 3.0, 5.5 - 6.6)
circumference of steering wheel) (PB70A)
N (kg, Ib) 39 (4, 9) or less
(PB66A)
7,649 - 8,238
(76.5 - 82.4,
78 - 84,1,109 - 1,194)
at idling
(PB70A)
Oil pump pressure BD30
kPa (bar,kg/cm2, psi) 8,630 - 9,219
(86.3 - 92.2,
88 - 94, 1,251 - 1,337)
FD42, FD46
9,121 - 9,709
(91.2 - 97.1,
93 - 99, 1,322 - 1,408)
Fluid capacity Approximately 900 - 1,000

mt (Imp fl oz) (31.7 - 35.2)
Normal operating temperature

60 - 80 (140 - 176)
'C ('F)
Steering gear turning torque

N'm (kg-em, in-Ib)
(PB66A)
360' position from straight- 0.7 - 1.2 (7 - 12, 6.1 - 10.4)
ahead position (PB70A)
0.4 - 1.2 (4 - 12, 3.5 - 10.4)
Backlash at pitman arm top end

(in a straight-ahead position) o - 0.1 (0 - 0.004)
mm(in)
End play (Between sector shaft

0.01 - 0.03 (0.0004 - 0.0012)
and adjusting screw) mm (in)
ST-38
BODY
SF
CONTENTS
GENERAL SERVICING (Including all clips and fasteners for using this model) BF- 2
BO 0 YEN 0 ........ ...... ...... ........ .... ....... .. .. .......... .. .. .... .. .. ........... ....... .... ... .. .......... ......... ......... BF- 4
CAB TILT MECHANISM BF- 5
000 R ........... ..................................................... B F- 7'
INSTRUMENT PANEL . BF- 9
INTERIOR AND l:XTERIOR (In EXTERIOR, including "Weatherstrips") BF-11
SEAT ; " BF-19
M I R ROR BF-21
CAB AND REAR BODy BF-22
BODY ALIGNMENT " " BF-27
* For seat belt, refer to MA section.
•
GENERAL SERVICING
Precautions
• When removing or installing various parts, place a cloth or padding onto the vehicle body to prevent
scratches.
• Handle trim, molding, instruments, grille, etc. carefully during removing or installation. Be careful
not to soil or damage them.
• Apply sealing compound where necessary while installing parts.
• When applying sealing compound, be careful that the sealing compound does not protrude from
parts.
• When replacing any metal parts (for example body outer panel, members, etc.), be sure to take rust
prevention measures.
Clip and Fastener

• The following numbers and symbols correspond to clips and fasteners in BF section.
• Replace any clips and/or fasteners which are damaged during removal or installation.
Symbol
Shapes Removal & Installation
No.
Removal:
Remove by bending up with
flat-bladed screwdrivers.
SBF256G SBF367B
s."...
~
~
Removal:
Pull up by rotating.
SBF137B
SBF115B
Removal:
Remove with a flat-bladed
screwdriver or pliers.
t~eb:t
SBF257G
-.~ SBF292C
BF-2
GENERAL SERVICING
Clip and Fastener (Cont'd)
Symbol
Shapes Removal & Installation
No.
Push center pin to /
catching position. .... •
(Do not remove
center pin by hitting it)
Installation:
SBF258G SBF708E
Removal:
Holder portion of clip must be
spread out to remove rod.
SBF768B SBF770B
Removal Installation
Rotate 45°
I'm'
,
to remove.
Removal
SBF145B SBF085B
SBF260G
BF-3
BODY END
• When removing clip or fastener, refer to "Clip and Fastener".
Body Front End

• Bumper finisher: It is made of plastic, so do not use excessive force and take care to keep oil away
from it.
REMOVAL - Front bumper assembly
(j) Remove the six nuts (three on each side) from left and right bumper stay.
@ Remove bumper assembly.
@) Disconnect left and right fog lamp harness connectors or headlamp cleaner hoses from nozzle.
@ Remove clips~and bolts from bumper fascia.
@ Disassemble reinforcement, seal rubber and bumper fascia.
C--~--J
@Headlamp
cleaner
nozzle
@ Fog lamp
* : Bumper assembly mounting nuts

MBF831A
BF-4
CAB TILT: MECHANISM
CabT:ilt Operation Force Adjustment
Cab rear mounting
Front
MBF832A
1. Remove front lower grille.

* 14\ mm\ \ (0.55'-----.J
In) 2. Tilt the C;:l.t> up.
or 18 mm(0.71 In)
\ Nut@
CAUTION:
When the cab is'tilted down, do not attempt to make adjust-
me.nts s!ncEtt()rslon bar's torque acts on anchor arm adjust-
mentboltand nut.
3. Loosen,bolt @ (refer to figure at left) just enough to be
turned by hand. (To perform work safely, do not remove the
bolt.)
4. Loos~n;l}ut @.
5. Turn adjustment bolt CID to adjust the force required to tilt
the cab.
• Turn the bolt clockwise to reduce the force.
• Turn the bolt counterclockwise to increase the force.
• One complete turn of adjustment bolt changes the force by
:l::29N(:l::3kg, :l::7Ib) ..
6. Ensure adjustment bolt CID is in contact with the end of
anchor arm. .
* Adjustment bolt protrusion: 14 mm(0.55 in) (stanc;Jardcab)
and 18 mm (0.71 in) (wide cab) 2.. Referenceyalue
7. Ensure anchor arm is inserted into and in close contact

with hole in hinge bracket.
8. Tighten bolt @ and nut CID to specified torque.
9. Tilt the cab up and down to ensure that:
• The cab does not drop under its own weight when it is tilted
at an angle of 40° - 45°.
• The cab is well balanced.
Anchor arm--
MBF835A
BF-5
CAB TILT MECHANISM
Tilt Lock Adjustment
o d) Unlock tilt handle.

CAUTION:
When tilt handle is "locked," do not attempt to make adjust-
ments.
@ Loosen two adjustment nuts (located at the right of rod).
CID Move rod until main lever lock pin is in contact with left and
right brackets.
@ Tighten the two rod adjustment nuts on trunnion.
CAUTION:
Do not tighten adjustment nuts if rod is tWisted.
BF-6
DOOR
Front Door
• When removing front door, it is better to remove front corner panel first.
• After adjusting door or door lock, check door lock operation.
Door glass sub-channel

Door glass regulator
adjustment
assembly
Rear lower sash
@rc--_O-o
m~. 0
~~
~~1.~
(0.52 " 0,66,
~~
~".26 ."
(2.1 - 2.7,
15 • 20)
I;]l
Striker adjustment
t [YIII.
Holder
(~ l0I
~21
l
- 26
(2.1 - 2.7,
15 - 20)
.. ~ ',="
~ I, \()
Doorh;",. I I~ I
~ : N.m (kg-m,ft-Ibj
MBFB42A
BF-7
DOOR
Rear Door
Double Cab
• After adjusting door or door lock, check door lock operation.
Door glass
sub-channel
adjustment \
Rear lower sash
\
Outside handle
adjustment Fa
\ I
~~5.1 - 6.5
(0.52 - 0.66,
3.8 - 4.8)
Door glass regulator

assembly
Striker adjustment
Ii]
I
Holder
Rod
MBF843A
BF-8
INSTRUMENT PANEL
CAUTION:
a. Disconnect ground terminal from battery in advance.
b. Be careful not to scratch pad and other parts.
c. These parts are made of plastic. Excessive force will damage them.
REMOVAL - Instrument panel assembly
CD Remove steering column cover.
@ Remove oil reservoir tank lid.m
@) Remove engine c;ontrol knob.
@ Remove cluster lid A.1i)
<ID Remove combination meter assembly.
@ Remove meter cover.
([) Remove ventilator right side duct.
@ Remove ventilator left side duct.
@ Remove cluster lid C.(;]
@) Remove A/C or heater control and radio.
@ Remove center box finisher.1!]
@ Remove center box.
@ Remove instrument panel finisher.1!I
@ Remove pocket deck.
@ Remove glove box lid.
@ Remove glove box.
@ Removednstrument panel finisher.1!I
@) Remove ashtray.
@) Remove ashtray outer.
@) Remove instrument panel assembly.
SF-9
Bolt (Hexagon wrench)
@
*(
b
. Instrument panel assem bly mounting

* . bolts and nut~ H drive model.
This figure shows ..
MBF844A
BF-10
INTERIOR AND EXTERIOR
Interior
SIDE AND FLOOR TRIM - Passenger room
CAUTION:
Wrap the tip of flat-bladed screwdriver with a cloth when removing metal clips from garnishes.
Removal - Body side trim

CD Remove sun visor.
CID Remove rearview mirror.
<ID Remove interior lamp assembly.
@ Remove windshield upper garnish.
@ Remove assist grip.
@ Remove front pillar garnish.
(f) Remove body side welt.
@ Remove roof side garnish.
@ Remove seats.
@> Remove seat belt anchors.
@ Remove fluorescent lamp.
@ Remove back window glass.
@ Remove plastic nut and roll up back panel trim.
@ Remove back panel garnish.
@> Remove lock pillar garnish.
@) Remove kick plates.
(jJ)
--@
@
Plastic nut
_ : Double-faced adhesive tape
MBF845A
BF-11
Interior (Corlt'd)
DOOR TRIM
Removal - Door trim
CD Remove lock knob.
<.ID Remove .inside seal.
<ID Remove inside handle escutcheon. (Rear door)
@ Remove pull handle.
CID Pullout regulator handle.
CID Lift out door finisher. (Front door)
([) Remove door finisher. (Rear door)
Front door Rear door (For double cab)
MBFB46A
BF-12
Interior (Cont'd)
ROOF TRIM
Removal - Headlining
Single cab model:
<D Remove part of headlining from corner and gradually peel headlining off.
Double cab model:
<D Remove screws and roof bow.
@ Remove headlining by peeling it off, starting with middle portion.
Headlining
Headlining adhesive
1
1
Single cab model
Double cab model
MBF847A
BF..f3
Exterior
Double cab
Single cab
MBF848A
BF-14
INTERIOR AND EX~ERIOR
Exterior (Cont )
(1) Front upper finisher
Upper finiS~hr
bracket
Upper Side\ ' I
finisher ~
Bolt
Front upper finisher
@ Front grilie
Grommet
Grommet
Front upper grille
Fron t lower grille
MBF866A
BF-15
Exterior (Cont'd)
CID Front corner panel
After removing front combination

lamp and upper side finisher
Front corner panel
MBF867A
@ Front window & Back window
t!1----GlaSS
,, '
MBF856A
BF-16
E](t~rior (Cont'(t>
@ Body side welt
Outside y ~,
MBF850A
CID Door outside molding

Front door Rear door
~. :\ Door, outside
I molding
[:T~]
--=-=
Molding
Door panel
Section
MBF853A
BF ..-17
Exterior (Cont'd)
(J) Front step
Slide
to remove
step finisher
Step mat
MBF855A
BF-18
S.EAT
• When removing or installing the seat trim, handle carefully it to keep dirt out and avoid damage.
Front Seat
~43-55
(4.4 - 5.6, 32 - 41)
~ : N.m (kg-m, fl-Ib)
MBF857A
BF.19
SEAT
Front Seat (Cont'd)
PASSENGER SEAT
~21-26
(2.1 - 2.7,
15 - 20) ~
7
I
~
.J
~1-26
(2.1 - 2.7, 15 - 20)
,
MBF854A
Rear Seat - Double Cab
~43 - 55
~ (4.4 - 5.6, 32 - 41)
r--_____ T
-------. ] ,
~43_55
1
• . (4.4 - .... 32 - 41J
~
MBF858A
BF-20
MIRROR
OutsideMi rror
BF-21
CAB AND REAR BODY
Cab B()dy
• Remove following parts in engine room at least.
(1) Main harness and other wiring harness
• Disconnect steering shaft, brake and clutch line in engine compartment.
• Remove following parts under body at least.
(1) Transmission and transfer control levers
(2) Hand brake control lever and cable
(3) Main harness, other wiring harnesses and heater hoses
MBF860A
Rear Body
• Remove following parts at least.
(1) Rear combination lamp and license plate lamp harness
MBF861A
BF-22
CAB AND REAR BODY
Cab Body MoOnting - Rigid cab type

When removing, be sure to replace bolts and nuts (sealant applied bolts or self-lock nuts have been
adapted for all mounting).
Single cab Jouble cab
[]
Rear cab
mounting
Front cab mounting Second
cab
mounting
Front cab
Third cab
mounting
mounting
~ : N.m (kg-m, fHb)
m H41 model F23 model
-----
Front
@
~~ 118 - 137 (12.0 - 14.0, 87 - 101) I

~~ 75 - 87 (7.6 - 8.9, 55 - 64)
Front
J
Front
~75-87 .
(7.6 - 8.9, 55 - 64)~
MBF862A
BF..23
CAB AND REAR BODY
Cab Body Mounting - Tilt cab type
~E
~D
L.H. side
Front
Front cab mounting

View A Detail B
1m Cab mounting lever bush
Bolt
toJ 77 - 98 (7.9 - 10,
57 - 72)
i c;b~(m -, Pin of shock absorber
D~'
Nut
i@
~
toJ75 - 87 fill
(7.6 - 8.9, 55 - 64)
View C Bolts
toJ 108 - 137 (11.0 - 14.0, Nuts toJ 15 • 19 (1.5 • 1.9, 11 • 14)
80 - 101) m Torsion bar
serration
Nuts
A 75 - 87 (7.6 - 8.9,
Nut toJ 20 - 24 (2.0 - 2.4, 14 - 17)
55 - 64)
00 cD!
toJ : N.m (kg-m, ft-Ib) Nut toJ 75 • 87 (7.6 - 8.9, 55 - 64)
Bolts toJ21 - 26 (2.1 - 2.7, 15 - 20)
Rear cab mounting

View D View E
Front
Nut
toJ 25 - 31
(2.5 - 3.2,
18 - 23)

Nuts A 51 - 65
(5.2 - 6.6, 38 - 48)
SBF814G
BF-24
CAB AND REAR BODY
Rear Body Mounting
For F23 rear body For H41 double cab
i 11
~ ~
~.
~ I '
~ I
~Shim ~Shim
I I
rr '1:----
~Insulator
@
tjC ~Insulator
+--ff,=
~,1
Bolt protrusion allowance: Bolt protrusion allowance:

4.6 - 5.4 mm (0.181 - 0.213 in) 4.6 - 5.4 mm (0.181 - 0.213 in)
For H41 single cab first mounting
Other mounting
U bolt slipper

U bolt
MBF851A
BF..25
CAB AND REAR BODY
Rear Body Frame (Wood)
CAUTION:
Supporting points differ between
models.
@ Guard frame lower member, @ Side rail, floor and bolster @ Rear rail, floor and bolster
floor and bolster
~A
@ @
~ 13.16
(1.3 - 1.6, 9 - 12)
Guard frame lower & upper member Side gate board, Rear gate board _ @ Rear fender stay and bolster
and header board----------= "'-
~ ~ ~ 9 -13
(0.9 - 1.3,
6.5.9.4)
SBF876G
BF-26
BODY ALIGNMENT
• When a tram tracking gauge is used, adjust both pointers to equal length and check the pointers and
gauge itself to make sure there is no free play.
• When a measuring tape is used, check to be sure there is no elongation, twisting or bending.
• Measurements should be taken at the center of the mounting holes.
• An asterisk (*) following the value at the measuring point indicates that the measuring point on the
other side is symmetrically the same value.
Single cab Double cab

(Standard/wide)
Unit: mm
Single and Double cab

( ) dimension show for wide cab model.
Measuring
Dimension
point
pOints@~ Points @.@
@,@ @-@ 1.400
@,@
@-@ 1;446
@,@
(fj).(fj) @-@ 1;452
CD. CD @-@ 1;468

@.C]) 1;4 74
@-@
(f)-CD 1,645
@-@ 1;474
(fj)-(fj) 1,584
CD-CD 1;474
Points @ • @ t Points (EJ. CD @-C]) 1,584
Single wide cab
Meas!Jring
Dimension
point
@-@ 1,700
@-@ 1.746
@-@ 1,752
@-@ 1,768
@-@ 1,774
... (EJ- CD 1.945
SBF761G
BF.21
BODY ALIGNMENT
Underbody
MODEL F23 SERIES MEASUREMENT
Rear
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MBF838A
BF-28
BODY ALIGNMENT
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Rear
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MBF841A
BF ..29
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MBF852A
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BF-31
BODY ALIGNMENT
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MBF864A
BF-32
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MBF868A
BF-33
BODY ALIGNMENT
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SBF762G
BF-34
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MBF869A
BF-3S
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MBF870A
BF-36
BODY ALIGNMENT
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MBF849A
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SBF760G
BF-38
HEATER &
AIR CONDITIONER
SECTIONH.
CONTENTS
PRECAUTIONS ;...... . '" HA- 2
DESCRIPTION - Overall System . HA- 5
DESCRIPTION - Refrigeration System ; HA- 8
PREPARATION HA- 9
DISCHARGING, EVACUATING, CHARGINGANDiCHECKING HA-15
SERVICE PROCEDURES HA-27
LUBRICATION OIL -Checking and Adjusting HA-33
COMPRESSOR - Model DKS-16H (ZEXEL make) ; HA-35
DIAGNOSES - Overall System ;: ; HA-37
TROUBLEDIAGNOSE9 - Manual Air Condition~r.t HA-46
SERVICE DATA AND SPECIFICATIONS (S.D.S;) . HA-70

• Read GI section, "HOW TO READ WIRING DIAGRAMS" .
• See EL section, "POWER SUPPL~ ROUTING" for power distribution circuit.
When you perforlJlt.~ouble diagnoses, read GI s~ction, "HOW TO FOLLOW FLOW CHART
IN TROUBLE DIAGNOSES".
•
PRECAUTIONS
Precautions for the Handling of Refrigerant

• Do not release refrigerant into the air. Use your refrigerant
recycling equipment to capture the refrigerant every time
you need to discharge an air conditioning system.
'4 ~~\ Freon gas

The release of refrigerant into the air can cause damage to
the Earth's ozone layer.
'\ '\\\
"\
RHA576C
Do not release. No Direct Heat

Goggles
on Container
Avoid Open Flame

Gloves
RHA475C
• Always wear eye protection when working around the system.

• Always be careful that refrigerant does not come in contact with your skin.
• Keep refrigerant containers stored below 40°C (104°F)and never drop from high places.
• Work in well-ventilated area because refrigerant gas evaporates quickly and breathing may become
difficult due to the lack of oxygen.
• Keep refrigerant away from open flames because poisonous gas will be produced if it burns.
• Do not increase can temperature beyond 40°C (104°F) in charging.
• Do not heat refrigerant container with an open flame. There is a danger that container will explode.
CAUTION:
• Do not use steam to clean surface of condenser or evaporator. Be sure to use cold water or com-
pressed air.
• Do not use compressed air to clean out a contaminated A/C tube or hose. Shake the line over a clean,
white paper towel. If it contains obvious moisture or contaminants, replace it. Do not blowout the
line with refrigerant.
• Do not use manifold gauge set whose press point shape is different from that shown. Otherwise,
insufficient evacuating may occur.
• Do not over-tighten service valve cap.
• Follow the manufacturer's instructions for discharging into your refrigerant recycling equipment.
HA-2
PRECAUTIONS
Precautiol"lsforRefrigerant Connection
WARNING:
Make sure all refrigerant is dischargedjinto the recycling equipment and the pressure in the system is
less,than atmospheric. Then gradually loosen the discharge side hose fitting and remove It.
CAUTION:
When replacing orCleaningretrigerant cycle components, observe the following.
• Do not leave compressor on its side or upside down for more than 10 minutes,' as' compressor oil
willent~r Id~r>re~~ur~c~~'11l6er.
• When connecting tubes, alWays use a torque wr,enchand a back-up wrench.
• A,fter disconnectingtu~e~~plu~. aU operlings inlmedlatel}f to r>revent,,~ntranceof dirt. and moisture.
• Wh~n installinganair ~ondUionerin the vehicle, the pipesrnust be connected as the final stage of
the operation. The seal caps of the pipes and other components must not be removed until their
removal is required for connection.
7
• B fore instamr1ganra!rco~diti()~~rCOI1lP()nent that ~as been stored in ,aco()1location toa vehicle
that has been exposed to the hot sun, leave the component as It is for some time in a hot location
wit~ its seal cap unremoved. This step is necessary to preventcondensatioll of moisttireinside'the
cold component. . .
• Thoroughly remove moisture from the refrigeratiollsystem before charging the refrigerant.
• Always replace used O-rings.
• When connecting tube, apply lubrication oil to portions shown in illustration. Be careful not to apply
oil to threaded portion.
• O-ring must be closely attached to inflated portion of tube.
• After inserting tube into union until O-ring is no longer visible, tighten nut to specified torque.
• After connecting line, conduct leak test and make sure that there is no leakage from connections.
When the gas leaking point is found, disconnect that line and replace the O-ring. Then tighten con-
nections of seal seat to the specified torque.
O-ring
Apply lubrication oiL
N.G.
N.G.
Inflated portion
O.K.
SHA525D
HA-3
PRECAUTIONS
Precautions for Servicing Compressor

• Attach a blind plug to the suction port (low pressure) and discharge port (high pressure) of the com-
pressor to prevent oil from leaking out and dust from getting inside.
• Do not keep the compressor in the upside down position or laid on its side for more than 10 min-
utes.
• When replacing or repairing compressor, be sure to remove oil from the compressor and check the
oil quantity extracted.
• When replacing with a new compressor, be sure to remove oil from the new compressor so that the
quantity of oil remaining in the new compressor Is equal to the quantity collected from the removed
compressor. See the section "lUBRICATION Oil".
• Pay attention so as not to allow dirt and oil to attach on the friction surfaces between clutch and pul-
ley. If the surface is contaminated with oil, wipe it off by using a clean waste cloth moistened with
thinner.
• After completing the compressor service operation, be sure to rotate the compressor shaft more than
five turns in both directions by hand to equalize oil distribution Inside the compressor, then run the
compressor for about one hour by.idling the engine.
• When the compressor magnet clutch has been replaced, be sure to check the magnet clutch for nor-
mal operation by applying voltage to the clutch.
HA-4
DESCRIPTION-.. ••Overall System
Control Operation
Intake lever
Air control lever
Air conditioner
switch
Temperaturt:!
control lever
SHA669D
FAN LEVER
This lever switches the fan ON.and OFF, and controls fan speed.
AIR CONTROL LEVER

This lever allows you to select the outlet air flow.
TEMPERATURE CONTROL LEVER

This lever allows you to adjust the temperature of the outlet air.
INTAKE LEVER
l? position:
Outside air is drawn into the passenger compartment.
(JJ position:
Interior air is recircul.ated inside the vehicle.
AIR CONDITIONER SWITCH

Start the engine, set the fan lever to the desired position (1 to 4) and push the air conditioner switch to
turn ON the air conditioner. The indicator light will come on when the air conditioner is ON. To stop the
air conditioner, push the switch again to return it to the original position.
The air conditioner cooling function operates only when the engine is running.
HA..5
DESCRIPTION - Overall System
Compo nent Layout
Side defroster
duct Center defroster duct
i
I
Side defroster d uct
Side ventilator
duct
Side ventilator
duct
For wide cab models only
Heater
unit
Intake unit
SHA670Q
HA-6
DESCR.lPTION --- Overall System
.,Air Flow
Floor
Ventilation
Floor and defroster
Gyro ventilator
Defroster
door
Evaporator
Air mix door
Bi-Ievel Defroster
Outside
air
@ To floor
.. : Air passed through heater core
~ :Mixedair .. +~
~ : Air not passed through heater core
SHA807D
HA-7
DESCRIPTION - Refrigeration System
Refrigeration Cycle
REFRIGERANT FLOW
The refrigerant flows in the standard pattern, that is, through the compressor, the condenser, the liquid
tank, through the evaporator, and back to the compressor.
The refrigerant evaporation through the evaporator coil is controlled by an externally equalized expan-
sion valve, located inside the evaporator case.
FREEZE PROTECTION
The compressor cycles on and off to maintain the evaporator temperature within a specified range. When
the evaporator coil temperature falls below a specified point, the thermo control amplifier interrupts the
compressor operation. When the evaporator coil temperature rises above the specification, the thermo
control amplifier allows compressor operation.
REFRIGERANT SYSTEM PROTECTION

Dual-pressure switch
The refrigerant system is protected against excessively high or low pressures by the dual-pressure
switch, located on the liquid tank. If the system pressure rises above, or falls below the specifications,
the dual-pressure switch opens to interrupt the compressor operation.
Fusible plug
Open at temperature above 105°C(221°F),thereby discharging refrigerant to the atmosphere. If this plug
is melted and opened, check the refrigerant line and replace liquid tank.
~ High-pressure ~ Low-pressure
gas liquid
f....::::.;:l High-pressure ';::;:;,::::;::;;::]

Low-pressure
liqUid gas
s
o
Outside air
U t
. Condenser
Blower motor
•
Expansion valve
Dual-pressure switch SHA504D
HA-8
PREPARATION
Tool number
Description
Tool name
KV99232022 Removing clutch disc
Clutch disc puller
KV99235140 Removing and installing shaft seal

Shaft seal remover
and installer
KV994C1552 Charging refrigerant

Charge nozzle
KV99231 01 0 Removing shaft nut and clutch disc

Clutch disc wrench
KV99233040 Removing pulley

Puller pilot
KV99234160 Installing pulley

Pulley installer
KV99267420 Installing shaft seal

Shaft seal guide
KV99235160 Removing lock nut

Nut wrench
HA-9
PREPARATION
Commercial Service Tools

Manifold gauge Discharging, evacuating and charging
refrigerant
SHA899C
Additional valve Discharging, evacuating and charging

refrigerant
SHA898C
Charging hose Discharging, evacuating and charging

refrigerant
SHA897C
Adapter valve Discharging, evacuating and charging

refrigerant
Thermometer and Checking temperature and humidity

hygrometer
Etched-stem
type
thermometer
SHA900C
Vacuum pump Evacuating
RHA575B
Gas leak detector Checking refrigerant leaks
RHA577B
HA.10
PREPARATION
Commercial Service Tools (Cont'd)
Charging cylinder Checking amount of refrigerant and
charging refrigerant
RHA57BB
Weight scale Checking amount of refrigerant
[[fi) I
RHA579B
Refrigerant recycling Capturing and recycling refrigerant

equipment
SHA732C
Forcletails of such handling methods, refer to the Instruction

Manual attachecl to each of the service tools.
Low pressure HANDLING METHOD AND STRUCTURE

compound gll.uge
Manifold gauge
The manifold gauge is .usedto meGJ,suretheoperating'pr~ssure
accurately in tlie high pressure and low pressure Iines,>ofthe
refrigerating system. .. ..
The high pressure gauge measlJres frort).-101.3 kP{l.(....
1,013
mbar, -760 mmHg, -29.92 inHg) to 2,94? kPa (29.4ibar, 30
kg/cm2, 427 psi), and the low pressure gauge measures gener-
ally from -101.3 kPa(-;-1,013mb{lr, -760 mmHg,-29.92inHg) to
1,471 kPa (14.7 bar, .15kglcm2, 213 psi)~
CAUTION:
C • Whe~ installing the gauge to the refrigerating system, use
Inner valve
incorporateo ..
utmost care not to mistake high pressure and low pressure
Center joint (A): line. connections. (Wrong connections will lead. toa dam-
Use for evacuating. aged gauge.) . . . ,.• .•.. . .,;!
High pressure side joint (8):
• Befor.e.evacuating, confirm. thatth~.SJaugeh:Il;~'.Cl,,..egative
Connect to high pressure side service vll.lve
of refrigeratillg system. pressure scale. (If not, the gauSJe)vHlbe ~a.p~'ge(l.)
Low pressure side joint (C):
Connect to low pressure side service valve
of refrigerating system.
Refrigerant joint (D):
Use for charging refrigerant.
SHA044D
HA-11
PREPARATION
Charging hose
1. Completely tighten high pressure valve, low pressure valve
and vacuum pump valve cocks of gauge manifold.
2. Connect charging hoses to high and low pressure lines.
3. Connect charging hose fitted with valve core to charging
cylinder.
4. Connect vacuum pump hose to vacuum pump.
High and low pressure hoses are color coded to prevent wrong
connection.
High pressure line hose Red
Low pressure line hose Yellow
Vacuum pump hose Blue or green
CAUTION:
• Check each hose for cracks. If found, discard the hose.
• Do not use any hose if bulges are found.
• Check the rubber packing. If any deterioration or cracks are
found, replace It with a new one.
RHA5818
Installing the adapter valve

Install the adapter valve to each of the high pressure and low
Opens
•
pressure service valves so that air purging from the charging
hose can be omitted. This also ensures that refrigerant leakage
upon disconnection of the hose can be prevented.
1. Before connecting the adapter valve to the on-vehicle ser-
vice valve, turn the adapter valve handle fully counterclock-
wise to retract the pin.
CAUTION:
On-vehicle service Check the packing for any sign of deterioration or cracks. If any
valve RHA5858
abnormality is found, replace it with a new one.
2. Connect the charging hose to the adapter valve.
Turning the handle clockwise will cause the on-vehicle service
valve pin to be pushed open by the adapter valve pin, thus
opening the refrigerant passage.
Turning the handle counterclockwise will close the passage.
Before removing the adapter valve from the on-vehicle service
valve, be sure to fully turn the handle counterclockwise to shut
off the refrigerant passage.
HA-12
PREPARATION
Vacuum pump
The vacuum pump is used to purge air and moisture from the
inside of the refrigeration system by evacuation, thereby ensur-
ing proper functioning of the air conditioner system.
Check the vacuum pump to see that the vacuum pump capac-
ity is greater than -100.0 kPa (-1,000 mbar, -750 mmHg,
-29.53 inHg).
RHA5878
Vacuum pump performance check procedure

1. Connect the vacuum gauge to the system.
Vacuum gauge 2. Run the. vacuum pump, and check to see that the needle
o to -101.3 kPa
(0 to -1,013 mbar, pointers of the gauge manifold and vacuum gauge move
o to -760 mmHg, smoothly, indicating a similar value.
o to -29.92 InHg) 3. After running the vacuum pump for two or three minutes,
read the vacuum gauge. The measured value indicates the
capacity of the vacuum pump.
Connecting nipple
SHA501D
Gas sampling adapter Gas leak detector

Detecting section The gas leak detector is used to check whether the refrigera-
tion system is leaking. The features of this gas leak detector are
listed on the next page.
Handling instruction
Gas name plate
Power Isensitivity selector switch
L.E.D. lever meter
RHA5898
Type Detection ability Features

• Easy handling
Discharge type • Medium se.l1sitivity
3 - 50 g (0.11 - 1.76 oZ)lyear
(Suction type) • Each point needs tow or more sec-
onds for detection.
Electrical
• High sensitivity
Positive ion
• High price
emission type 2 g (0.07 oZ)lyear
• Warm-up time is needed because a
(Suction type)
heater is incorporated .
1 kg (2 Ib)/month; if 13.3 kPa • Can be used easily in refrigerant
Other simple checking method: (133 mbar, 100 mmHg, 3.1:14inHg) charging operation.
Change in vacuum when evacuating change in vacuum is detected in 10 • Detection ability is very low with vac-
minutes. uum gauge in gauge manifold.
HA ..13
PREPARATION
• Leakage inspection of a refrigeration system needs a sen-
sitivity greater than 20 g (0.71 oz)/year.
• The actual amount of leak is estimated at 5 to 10 times the
detected amount.
• Insufficient cooling may be felt if leakage exceeds 150 to
200 g (5.29 to 7.05 oz).
Temperature gauge
Use to check the air conditioner performance. An etched stem
type thermometer may be used. A hygrometer must also be
used because the air conditioner performance depends on the
humidity.
Gauze
Water Etched-stem
tank type
Wet and dry bulb thermometer
hygrometer
RHA590B
Scale
Measure the weight of the refrigerant to determine how much
the refrigerant is charged.
Weight
scale
RHA602B
Charging cylinder
The charging cylinder is used to correctly measure the amount
of refrigerant to be charged.
Features
• With the charging cylinder, the operator can measure cor-
Scale rectly the amount of refrigerant to be charged into the sys;'
cover
tem.
• Change in the refrigerant volume due to a change in tem-
perature and pressure can be supplemented, and this
ensures correct charging of refrigerant.
Sight
Connect glass CAUTION:
manifold • Never attempt to carry the charging cylinder containing
gauge.
refrigerant.
• Do not put the charging cylinder in a hot place. If the tem-
perature and pressure of the refrigerant in the cylinder
increase, the' safety valve will be pushed open and the
refrigerant will be released into the atmosphere.
• Do not expose the cylinder to the direct sunlight.
• Do not over-charge the refrigerant so that it exceeds the
maximum limit of the cylinder.
• Do not charge the cylinder with more refrigerant than is
RHA674B needed.
HA-14
DISCHARGING,.EVACUATING,CHARGING<ANDCHECKING
Work Procedure
Install the service tools.
Discharge refrigerant into recy-

cling equipment.
Recycle refrigerant if tank l3epairor replace parts.

becomes full.
Evacuate the unwanted air in

charging hoses.
Evacuating (over 5 minutes).
I Cheek. air tightnes_s_. H Repair .
............•.......
....•••..J O.K~
Evacuating (over 20 minutes),
Charging [app:rox. 2009

(7.050z)).
Preliminary refrigerant leak N.G.

check.
OK
Charging [specified amount
- 200 g (7.05 oz)].
Check for refrigerant leaks. N.G.
O.K.
Check amount of refrigerant and

operation of AIC system.
Recover refrigerant in charging

hoses.
I Remove service tools.
HA-t5
DISCHARGING, EVACUATING, CHARGING AND CHECKING
Setting of Commercial Service Tools
----~
Adapter valves
connected to service
- valve low and high
High pressure---
service valve
~
~
Low pressure ~
service valve
Charging hose
(yellow)
Connect charging cylinder

or refrigerant recycling
equipment.
Charging cylinder "1:If a 13.6 kg (30 Ib)

Refrigerant container of refrigerant is
container used a weight scale will
~ be needed.
For evacuation This scale is to determine
Connect the amount of refrigerant
manifold that is used.
gauge 2: Transfer refrigerant from
~ a 13.6 kg (30 Ib) container
Vacuum pump to a charging cylinder,
and measure the amount of
refrigerant.
SHA894C
WARNING:
Discharge only into your recycling equipment. Do not release refrigerant into the air.
HA-16
.DISCHARGING, EVACUATING, CHARGING AND CHECKING
Setting of Commercial Service Tools (Conl'd)
<....:::::> ~ 1. Install adapter valve to each of high pressure and low pres-
sure service valves.
Opens Before connecting adapter valve, turn adapter valve handle
• fully counterclockwise to retract pin.
2. Connect charging hoses to adapter valves and connect vac-
uum hose to vacuum pump.
3. Run vacuum pump and open additional valve and both
valves on ga.uge manifold set.
4. After evacuating unwanted air in gauge set, close addi-
tional valve and stop vacuum pump.
RHA585B 5. Disconnect vacuum hose from vacuum pump and connect
it to refrigerant recycling equipment.
Gauge manifold
Vacuum Compressor
pump
SHA893C
Compressor Discharging
Low pressure
gauge High pressure gauge WARNING:
From Discharge only into your recycling equipment.
evaporator To condenser
Do not release refrigerant into the air.
Use only authorized refillable refrigerant tanks for your recy-
cling equipment.
High pressure valve Use of other tanks could cause personal injury.
Refrigerant
recycling
equipment Additional valve REFRIGERANT RECOVERY
SHA890C 1. Connect vacuum hose to refrigerant recycling equipment
and open additional valve and adapter valves.
Refrigerant tank 2. Open both valves of manifold gauge set. Make certain
refrigerant tank "Gas" and "Liquid" valves are open.
3. Plug unit's power cord into a suitable AC outlet and turn on
"Main Power" switch.
4. Turn on "Recovery" switch.
5. Depress "Start" switch. Compressor will start. Compressor
will shut off automatically when recovery is complete.
Watch for pressure rise to above 0 kPa (0 bar, 0 kg/cm2,
o psi) within two minutes. If this occurs, repeat this step.
SHA891C
HA-17
Discharging (Cont'd)
6. To drain AIC system oil accumulator, open "Accumulator
Air purge
Oil drain valve
Pressurizing" valve for approximately 15 seconds to allow
valve
some compressor discharge pressure back into accumula-
Accumulator
tor. Close "Accumulator Pressurizing" valve and open "Oil
pressurizing valve Drain" valve slowly and drain accumulator. Do not allow
Tank accumulator to completely depressurize. When oil stops
draining, close "Oil Drain" valve. Be sure to replace oil in
Oil bottle AIC system before servicing.
7. Turn off "Recovery" switch.
I SHA892C
8. When recovery tank is full, trip switch at the bottom of
weight platform will de-energize compressor and "Tank
Full" light will come on. Recycle refrigerant in tank before
Refrigerant tank removing.
REFRIGERANT RECYCLING
The recycling of reclaimed refrigerant is essential in order to
assure that the refrigerant which meets the standards is
re-used.
For maximum efficiency, full tanks ,of recovered refrigerant
should be recycled. As required, tanks containing a minimum
of 3.6 kg (8 Ib) of refrigerant can be recycled.
SHA891C
For greatest efficiency, recycling full tanks of refrigerant is rec-
ommended.
1. Make certain both valves on recovery tank are open.
2. Turn on "Recycling" switch. Recycling solenoid will be
energized.
Moisture
indicator
3. Depress start switch. Compressor will start, and "Recycling
On" light will come. Refrigerant will be seen going through
moisture indicator at start up. The sight glass will not com-
pletely fill with refrigerant.
4. Allow the station to operate until moisture indicator turns
green. If moisture indicator does not turn green after 40
minutes, remove and replace filter.
SHA895C 5. After recycling for approximately 5 minutes, check air
purge indicator. If green pointer on air purge indicator
leads red pointer by more than 10 psi (2 small divisions),
bleed tank through air purge valve on the back of unit until
Air purge both pointers are equal. Repeat as necessary.
indicator
Red
needle
SHA896C
HA-18
DISCHARGINGr EVACUATING,. CHARGING AND CHECKING
Low pre~sure Evacuation

gauge
From -.. EVACUATION. PROCEDURE
evaporator condenser
-0 1. Completelyjighten low pressure and high pressure adapter
valves.
2; Open highand ..IIDwpressure valves of manifold gauge set
and additional valve.
High pressure valve 3. Run vacuum pump.
Additional (open)
valve Vacuum
(open) pump
SHA952C
4. Perform evacuation for more than five minutes to stabilize

the vacuum inside the system. Check to ensure that the low
pressure gauge indicates -98.6 to -101.3 kPa (-986 to
....,t,Ot3mbar,-740 to-760 mmHg, -29.13 to .,...29.92
inHg).
5. Shut off high and low pressure valves and additional valve.
7
CHECKING AIRTIGHTNESS
1. Shutoff high and low pressure valves and additional valve,
Low pressure
gauge and leave the system as it is for 5 to 10 minutes.
2. Make sure that the needle of low pressure gauge will not
move back toward atmospheric pressure side (gauge pres-
sure 0).
If any reverse movement Is noted, It Indicatespo()rsystem air-
tightness. Service the system .untll airtightness Is complete. If
pressure changes appro". 13.3 kPa (133 mbar, 100 mmHg,
3.94 inHg) In 10 minutes,the refrigerant in the system will be
exhausted in about one month.
EVACUATION
If no abnormality is found dui"ingairtightness check, perform
evacuation again for more than 20 minutes.
1. Run vacuum pump.
To To high 2. Open high and low pressure valve and additional valve.
vacuum pressure
pump service 3. Evacuate for more than 20 minutes.
valve
High pressure
4. Close high and low pressure valves and additional valve.
valve cock
[HI] (close)
SHA954C
Charging Refrigerant
SETTING OF CHARGING CYLINDER
1. Make sure that inlet and outlet valves of charging cylinder
are closed.
Outlet 2. Slowly open liquid line valve of refrigerant tank.
valve 3. Slowly open inlet valve of charging cylinder.
(slowly
open) The refrigerant will flow into the sight glass of charging cylin-
Inlet valve der as Inlet valve is opened.
(slowly open)
RHA677B
HA-19
Charging Refrigerant (Cont'd)
Vent valve 4. Slowly open upper vent valve to release pressure from
(slowly open) charging cylinder. While doing so, continue charging until
required amount of refrigerant is reached.
The refrigerant volume changes with temperature and pres-
sure. It is necessary to charge refrigerant with a little more than
required amount (indicated on sight glass).
5. Close inlet valve and upper vent valve of charging cylinder.
RHA678B
6. Turn on heater switch (charging cylinder is provided with

a heater).
The refrigerant charging time can be reduced by heating refrig-
erant to increase its pressure. In this case, do not allow the
pressure in cylinder to rise higher than 1,030 kPa (10.30 bar,
10.5 kg/cm2, 150 psi). (If pressure rises above this level, turn off
the heater.) The pressure in the charging cylinder can be mea-
sured by upper pressure gauge.
RHA679B
SETTING OF FLOW METER

1. Rotate charging cylinder main body until scale for R12 is at
the correct position on sight glass.
2. Read charging cylinder pressure gauge.
3. Rotate charging cylinder so that scale of charging cylinder
agrees with pressure value indicated on pressure gauge.
RHA580B
HA-20
CALCULATING CHARGING AMOUNT OF REFRIGERANT
1. Record the amount of refrigerant in the sight glass before
charging.
2. Subtract the required amount of refrigerant(charge quan-
tity specifiedforthe vehicle) from theamountof refrigerant
Sigl]t glass recorded in step 1. Charge refrigerant into the system until
Refrigerant level the remaining value equals to the value indicated on the
before charging sight glass.
-1Specified amount
• of charge
Example:
Level in sight glass: 3 Ib 8 oz
Charge specification (from service manual) 2.0 - 2.4 lb.
Calculate charge quantity into Ib and oz as follows: 1 Ib = 16
Refrigerant I.evel
after charging oz, and 0.1 Ib = 1.6 oz, so that 2.0 Ib = 32 OZ, 2.4 Ib = 32 +
(4 x 1.6) =32 + 6.4 = 38.4, round off to 38. Therefore our
charge quantity will be between 32 and 38 OZ, or 2 Ib 0 oz to 2
Ib6 oz. Subtract '2 Ib 6 oz from level in sight glass (3 Ib 8 oz)
= 1 lb '2 oz.
This will be our ending point.
Ifaflow rneteris not available, the amount of charged refriger-

ant also can be determined by subtracting the weight of the
canister measured after charging from its weight measured
before charging.
RHA602B
~
tfT~~~ L I PRELIMINARY CHARGING OF REFRIGERANT
I 1. Open outlet valve of charging cylinder.
2. Slowly open high pressure side valve of manifold gauge to
charge refrigerant from the high pressure side.
...
.... 0 3. Close high pressure valve after charging approx. 200 g
:::: (7.05 oz) refrigerant.
....
CAUTION:
I RHA682B
The refrigerant in charging cylinder is kept in liquid state, so
the refrigerant should be charged from high pressure side. Do
not start engine with high pressure valve kept open.
HA-21
DISCHARGING, EVACUATING, CHARGING ANDCH.ECKING
PRELIMINARY CHECK FOR REFRIGERANT LEAKS
1. Make sure that the gauge manifold valve is closed.
2. Check for refrigerant leak from each connector in the sys-
tem using the leak detector.
At this point, the pressure in the system is not high. Only large
amounts of refrigerant leak due to loose pipe joints, etc. can be
detected.
CHARGING REFRIGERANT
RHA601B 1. Slowly open high pressure valve of manifold gauge, and
charge calculate amount of refrigerant in "CALCULATING
CHARGINGAMOUNT OF REFRIGERANT".
CAUTION:
The refrigerant in charging cylinder is kept In liquid state, so
the refrigerant should be charged from high pressure side. Do
not start engine with high pressure valve kept open.
2. Close high pressure valve of manifold gauge.
3. Make sure that the calculated amount of refrigerant
remains in sight glass.
4 Close charging cylinder outlet valve.
S Turn off heater if it is on (when using heater equipped).
Inspection for Refrigerant Leaks

WORK PROCEDURE
To facilitate inspection for refrigerant leaks, establish the fol-
lowing conditions:
• Start engine.
• Run air conditioner.
• Set blower fan control to MAX.
• Set temperature control to FULL COLD.
• Run the refrigerant system for more than S minutes after
setting the above-mentioned conditions (to circulate refrig-
erant through the system).
Refrigerant leaks should be checked immediately after stop-

ping engine, beginning with high pressure line, using a gas
, leak detector. This is because the pressure in high pressure
line drops gradually after refrigerant circulation stops while the
,I pressure in low pressure line rises gradually as shown in the
graph at left. Leaks can be detected easily when pressure is
----~,-'-\;:~u~e-~
,
low
pressure line
high.
t Time
Compressor stops.
RHA604B
HA-22
Inspection for Refrigerant Leaks (Cont'd)
To prevent detecting errors, make sure that there is no refrig-
erant vapor or tobacco smoke in the vehicle vicinity. It is also
necessary to shield vehicle from wind so that leaking refriger-
ant is not blown away.
Example:
Cooling unit
INSPECTION POINTS
Low-pressure
High-pressure (Su~tiOn) Check carefully each tube joint. To check, wipe the portion to
(Discharge) service valve be checked with waste cloth, and move tester probe all around
service valve the joint.
Compressor
Check shaft seals and bolt holes, and also around magnet
clutch.
Liquid tank
Check pressure valve, safety valve and fusible plug mounts.
Service valve
Check all around service valves.
Ensure that valve core is not loose.
Service valve caps, must be attached to valves (to prevent
leak). ....
Also check that there are no foreign objects inside caps.
Inside of cooling unit

RHA608B
To check, insert leak tester probe into drain hose immediately
after stopping engine. (Keep probe inserted for more than 10
seconds.) !
HA-23
Confirmation of Amount of Charged Refrigerant

The amount of refrigerant charged into the system can be
observed through the sight glass by watching the flow of the
refrigerant and by reading the high pressure and low pressure
manifold gauges under the following conditions:
CONDITIONS
• Doors:
Close completely.
• Window glasses:
Close completely.
• Intake door position:
RECIRC
• Mode door position:
VENT
• Blower fan:
HI
• TEMP control:
Optional [Set so that intake air temperature is 30 to
35°C (86 to 95°F).]
• AIR CON switch:
ON
• Engine speed:
Approx. 1,500 rpm
WORK PROCEDURE
Engine speed: Approx. 1,500 rpm
After warming up engine, adjust intake air temperature to 30 to 35°C (86 to 95°F).
Wait until high pressure is stabilized at approx. 1,471 kPa (14.7 bar, 15 kg/cm2, 213 psi).*1
*1: Cover the entire condenser until the required pressure is indicated.
Check the sight glass of the refrigerant system.*2

Touch the high and low pressure tubes of the
system to get an idea of the temperature.
*2: Refer to sight glass inspection.
Check to see whether the refrigerant If white clouding or bubbles are found:
is free of white clOUding and bubbles.
O.K.
Recover the refrigerant from the AIC system.

Recharge the system to specification using an
accurate refrigerant measuring device.
I Charged amount of refrigerant is O.K.
HA-24
I)I$CHARG'~G,e"ACUATING,C ...ARGING AND Cl:leCKING
Confirmation of Amount of Charged Refrigerant
(Cont'd)
OVercharged, or
APP(9prillte Refrigerant is insufficient Almost no refrigerant
air in system
Temperature of high and High pressure side is hot High pressure side is No difference is felt High pressure side is very
low. pressure pipes while low pressure side is warm and low pressure between high and low hot.
cold. side is s.omewhat cold. presser sides.
Flow of refrigerant viewed Mostly transpacrent. Bubbles are always flow- Nothing is visible. If overcharged, no bub-
through sight glass Occasionally some bub- ing. Refrigerant is .cloudy. bles are seen. If there is
bles are seen when air in the system, large
engine rpm is increased bubbles are seen.
or decreased.
Pressure Normal high pressure: Both high and low pres- High pressure value is Both high and low pres-
1,373 - 1,765 kPa sure values are insuffi- very small. sure values are exces-
(13.7 - 17.7 bar, cient. sive.
14 - 18 kg/cm2,
199 - 256 psi)
Normal low pressure:
147 - 294 kPa
(1.47 - 2.94 bar,
1.5 - 3 kg/cm2,
21 - 43 psi)
Action to take Bubbles may be gener- Add refrigerant after Check the refrigerant sys- Stop the compressor and
ated when the liquid tank checking for leaks. tem. extract excessive refriger-
strainer is clogged, or ant. If air is found,
when the expansion valve evacuate, then charge the
is opened excessively. specified amount of refrig-
erant.
CAUTION:
The condition of bubbles seen through the sight glass as well
as the intake and discharge pressures are influenced by the
ambient temperature, wind velocity, weather, and by the air
temperature in front of the condenser, etc.
HA-25
DISCHARGING, EyACUATING, CHARGING AND CHECKING
Removal of Commercial Service Tools

1. Completely loosen adapter valves of low pressure and high
pressure lines.
2. Close additional valve and remove center hose from charg-
ing cylinder.
3. Connect center hose to refrigerant recycling equipment.
4. Open additional valve and both valves on gauge manifold.
5. Capture refrigerant in charging system.
6. After recovering refrigerant, remove adapter valves from
on-car service valves.
Compressor
Low pressure
gauge
From
evaporator To condenser
High pressure valve

Refrigerant
recycling
Additional valve
equipment
SHA890C
HA-26
SERVICE PROCEDURES.
Refrigerant Lines
• Refer to "Precautions for Refrigerant Connection" on page
HA-3.
FD ENGINE FOR H41 MODEL
[AJ
[1]]~
~
~
~[]] Cooling unit
[1]
For wide cab

models
High-presslJre
(Discharge)
service valve
liquid tank
D (Tightening torque)
D D (Wrench size)
D (O-ring size)
[AJ 10 - 20 (1.0 - 2.0,7 - 14)
~ 15 - 25 (1.5 - 2.5, 11 - 18)
[Q 20 - 29 (2.0 - 3.0, 14 - 22)
[Q] 22 - 27 (2.2 - 2.8, 16 - 20)
[g] 18 - 24 (1.8 - 2.4, 13 - 17)
lEI 12 -14 (1.2 -1.4,9 -10)
SHA671D
HA-27
SERVICE PROCEDURES
Refrigerant Lines (Cont'd)
BD ENGINE FOR H41 MODEL
[AJ
[1]][H]
[aJ
~
~[ZJ Cooling unit
~
High-pressure
(Discharge)
service valve
Condenser
DD (Wrench size)
D (O-ring size)
[AJ 10 - 20 (1.0 - 2.0, 7 - 14)
~ 15 - 25 (1.5 - 2.5, 11 - 18)
[Q 20 - 29 (2.0 - 3.0, 14 - 22)
[Q] 22 - 27 (2.2 - 2.8, 16 - 20)
lEJ 18 - 24 (1.8 - 2.4, 13 - 17)
[EJ 12 -14 (1.2 -1.4, 9 -10)
SHA672D
HA-28
SERVICE PROCEDURES
TO ENGINE FOR F23 MODEL
High-pressure
(Discharge)
service valve
[AJ
~ [JJ !6l Compressor
~ ~~
U1J
Liquid tank
D D (Wrench size)
D (O-ring size)

[AJ 10 - 20 (1.0 - 2.0, 7 - 14)
!6l 15 - 25 (1.5 - 2.5,11 - 18)
[g 20 - 29 (2.0 - 3.0, 14 - 22)
[QJ 22 - 27 (2.2 - 2.8, 16 - 20)

[g] 18 - 24 (1.8 - 2.4, 13 - 17)
lEI 12 - 14 (1.2 - 1.4, 9 - 10)
SHA808D
HA-29
SERVICE PROCEDURES
NA ENGINE FOR F23 MODEL
High-pressure
(Discharge)
service valve
Compressor
liquid tank
[A]
[j]][I] o (Tightening torque)
[aJ DO (Wrench size)
o (O-ring size)
[A] 10 - 20 (1.0 - 2.0, 7 - 14)
~ 15 - 25 (1.5 - 2.5,11 - 18)
[Q 20 - 29 (2.0 - 3.0, 14 - 22)
[Q] 22 - 27 (2.2 - 2.8, 16 - 20)
lEI 18 - 24 (1.8 - 2.4, 13 - 17)
IE] 12 - 14 (1.2 - 1.4,9 - 10)
SHAB09D
HA-30
SERVICE PROCEDURES
Compressor Mounting
FO ENGINE
~ : N.m (kg-m, ft-Ib) SHA673D
BO, TO ENGINE
~ 18 - 24 (1.8 - 2.4, 13 - 17)
~ 35 - 47 (3.6 - 4.8, 26 - 35)
~ : N.m (kg-m, ft-Ib) SHA674D
HA-31
SERVICE PROCEDURES
Compressor Mounting (Cont'd)
NA ENGINE
Compressor
rRJ : N.m (kg-m, ft-Ib) SHA675D
Belt Tension
• Refer to MA section.
Fast Idle Control Device (F.I.C.D.)

• Refer to EF & EC section.
HA-32
LUBRICATIONOIL-- Checking and. Adjusting
Lubrication oil
SUNISO 5GS or equivalent
Maintenance of Oil Quantity in Compressor
The oil used to lubricate the compressor circulates through the
system with the refrigerant. Whenever any component of the
system is replaced or a large amount of gas leakage occurs,
add oil to the compressor to maintain the specified amount.
If oil quantity is not maintained properly, the following malfunc-
tions may result:
• Lack of oil: May lead to a seized compressor
• Excessive oil: Inadequate cooling (thermal exchange
impeded)
Checking and Adjusting
Adjust th~ oil quantity according to the flowchqrt shown below,
START
Yes
Can oil return operation be performed? Perform oil return operation, proceeding as follows:
• AIC system works properly .
• There is no evidence of a large amount 1. Start engine, and set the following conditions:
of oil leakage. • Test condition
Engine speed: Idling to 1,200 rpm
No A/C or AUTO switch: ON -
Blower speed: Max, position
Temp, control: Optional [Set so that Intake air temperatl,lre is
25 to 30°C (77 to 86°F).]
2, Next Item Is for V-5 or V-6compressor. Connect the manifold
gauge, and check that the high pressure side pressure Is 588 kPa
(6 kg/cm2, 85 psi) or higher.
If less than the reference level, attach a cover to the front face of
the condenser to raise the pressure.
3. Perform oil return operating for about 10 minutes.
Should the compressor be replaced? 4. Stop engine
CAUTION:
No Yes
If excessive 011 leakage Is noted, do not perform the 011 return opera-
tion.
@
(Go to next page.)
Yes
Is there any part to be replaced? After replacing any of the following major components of the system,
(Evaporator, condenser, liquid tank orin be. sure to add the correct amount of oil to the system.
case there is evidence of a large amount Amount of oil to be added
of oil leakage.)
Oil to be added to svstem
Part replaced Ratio Remarks
No Amount of oil mt (Imp II oz)
(%)
Evaporator 45 - 75 (1.6 - 2.6\ 30 -
Condenser 30 - 50 (1.1 - 1.8) 20 -
Add if compressor
Liquid tank 15 - 25 (0.5 - 0.9) 10
is not replaced.'1
In case of refriger- 30 - 50 (1.1 - 1.8) - Large leak
ant leak - - Smallleak'2
Carry out the AIC performance test.
*1: If compressor is replaced, addition of oil is included in the flow
chart.
*2: If refrigerant leak is small, no addition of oil is needed. "Ratio" in
this table indicated the ratio of added oil to the overall amount of
oil needed in the system.
HA-33
LUBRICATION OIL- Checking and Adj_us_t_in_9 _
Checking and Adjusting (Cont'd)
@
1. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure oil discharged into the recovery/
recycling equipment.
2. Remove the drain plug (for V-5, V-6 or DKS-16H compressor) and drain the oil from the "old" (removed) compressor
into a graduated container, and record the amount of oil drained.
3. Remove the drain plug and drain the oil from the "new" compressor into a separate, clean container.
4. Measure an amount of the new oil equivalent to that drained from the "old" compressor, and add this oil to the
"new" compressor through the drain plug or suction port opening.
5. Measure an amount of the "new" oil equivalent to that recovered during discharging, and add this oil to the "new"
compressor through the drain plug or suction port opening.
6. Torque the drain plug.
V-S or V-6 compressor: 18 • 19 N'm (1.8 • 1.9 kg-m, 13 - 14 ft.lb)
DKS-16H compressor: 14 - 16 N'm (1.4.1.6 kg-m, 10.12 ft-Ib)
7. If the liquid tank also needs to be replaced, add an additional 20 mC (0.7 Imp fl oz) of oil at this time.
Do nol add Ihls 20 mC (0.7 Imp fl oz) of oil If only replacing Ihe compressor.
011 adjusting procedure for compressor replacement
DO 00
Recovery Old New

IRecycling compressor compressor
equipment
!".,,,,d ~'""t 1 "'00", ~'""' Drain oil

from new
r-----------------~ compressor
I I into clean
I I
I
I "X"
+ "Y"
mQ
I
I
container
I mQ I
L J
Reinstall
"X" mQ + "y" mQ New
of new 011 oil
•
New
compressor ------
.- - - - - - - - - -.,
I Add an additional
~-----
:
: 20 m Q (0.7 Imp fl OZ)I
I of new 011 when reo :
L ~a:I~9_1~~d_t~n~ _ J
SHA968D
HA-34
COMPRESSOR-. MOd~I[)KS-16H]ZEXEl.rnake)
Screw
~ 5 - 6 (0.5 - 0.6, 3.6 - 4.3)
Pulley
Shaft nut
~ 14 -16
(1.4 • 1.6, 10 • 12)
SHA132D
Compressor Clutch
REMOVAL
• When removing shaft nut, hold clutch di~c with clutch disc
wrench.
• Using clutch disc puller, clutch disc can be removed eas-

ily.
• Bend down pawl of lock wa~her.

• When removing pulley, remove Jock nut with nut wrench.
HA..35
COMPRESSOR-. Model DKS-16H (ZEXEL make)
Compressor Clutch (Cont'd)
• Remove the pulley by hand. If difficult, use puller pilot.
INSPECTION
Clutch disc
KV99233040 If the contact surface shows signs of damage due to excessive
heat, the drive plate and pulley should be replaced.
Pulley
Check the appearance of the pulley assembly. If the contact
SHA805D surface of the pulley shows signs of excessive grooving due to
slippage, both the pulley and drive plate should be replaced.
The contact surfaces of the pulley assembly should be cleaned
with a suitable solvent before reinstallation.
Pulley Coil
Clutch disc
Coil
Check coil for loose connection or cracked insulation.
~
SHA703B
INST ALLATION
KV99234160 • Install the key in the keyway on the compressor drive shaft.
• Install the coil to compressor (lead wire up) and tighten the
mounting screws.
• Install the lead wire into the holder correctly.
SHA806D
• Install lock washer and nut with nut wrench.

~Shim(S) • Bend one pawl of the lock washer up against the nut to
prevent the nut from loosening.
SHA705B
• Check to ensure that the clutch clearance is between 0.3 to

0.6 mm (0.012 to 0.024 in). Adjust the clearance using
shim(s) as necessary.
BREAK-IN OPERATION
When replacing compressor clutch assembly, do not forget
break-in operation, accomplished by engaging and disengag-
ing the clutch about thirty times.
Break-in operation raises the level of transmitted torque.
SHA707B
HA-36
DIAGNOSES - Overall' SY_SI_e_I'1'l_' _
How to Perform Trouble Diagnoses for Quick

and Accurale Repair
WORK FLOW
CHEC_K_IN_' 1 ..-- I Reference item

---l .
LISTEN TO CUSTOMER COMPLAINT AND
CONFIRM BY PERFORMING OPERATIONAL
CHECK.
Can be Cannot be
confirmed confirmed
EDUCATE CUSTOMER ON
CORRECT OPERATION OF
SYSTEM.
LISTEN TO CUSTOMER COMPLAINTS AND Symptom Chart

CONFIRM. (See page HA-46.)
INVESTIGATE ITEMS YOU SHOULD CARRY Symptom Chart

OUT RELATED TO EACH SYMPTOM. (See page HA-46.)
ELIMINATE GOOD SYSTEM(S)/PART(S). Preliminary Check

(See,.pages HA-47 - 48.)
• Diagnostic CHECK MAIN POWER SUPPLY AND GROUND Main Power Supply and Ground Circuit
Procedure(s) CIRCUITS. Check
(See pages HA- (Seej:ll:lge HA-56.)
56 - 65.)
• Circuit Diagram
for Quick
Pinpoint Check ELIMINATE GOOD Harness Layout for A/C System
(See page HA- PART(S)/HARNESS(ES)/CONNECTOR(S) (See pages HA-49 - 50.)
51.) ELECTRICALLY.
Malfunctioning Malfunctioning
harness(es)1 partes)
connector(s)
I REPAIR.
I Electrical Components Inspection
(See pages HA-66 - 68.)
~
N.G.
FINAL CHECK
CHECK OUT
HA..37
DIAGNOSES - Overall System
Operation Check
The purpose of the operational check is to confirm that the
system is as it should be. The systems which will be checked
are the blower, mode (discharge air), intake air, temperature
decrease, temperature increase and AIC switch.
CONDITIONS:
Engine running and at normal operating temperature.
PROCEDURE:
1. Check blower
1) Slide fan lever to 1.
Blower should operate at speed 1.
2) Then slide lever to speed 2.
3) Continue checking blower speed until all speeds are
checked.
4) Leave blower on speed 3 or 4.
SHA676D
2. Check discharge air

1) Slide air control lever to -; position.
2) Confirm that all discharge air comes out of face vents.
3) Slide air control lever to,J position.
4) Confirm that discharge air comes out of face vents and foot
vents.
J
5) Slide air control lever to ... position.
6) Confirm that discharge air comes out of foot vents, with
some air from defroster vents.
7) Slide air control lever to PI position.
SHA677D 8) Confirm that discharge aIr comes out of foot vents with
some air .from defroster vents.
9) Slide air control lever to C\iW position.
10) Confirm that all discharge air comes out of defroster vents.
3. Check recirc
1) Slide intake lever to c::iD position.
2) Listen for intake door position change (you should hear
sound change slightly).
SHA678D
HA-38
DIAGNOSES _.. Overall System
Operation Check (Cont'd)
4. Check temperature decrease
1) Slide temperature control lever to full cold.
2) Check for cold air at discharge air outlets.
•
Temperature control
lever
SHA679D
5. Check temperature increase

1) Slide temperature control lever to full hot.
2) Check for hot air at discharge air outlets.
Temperature
control lever
SHA680D
6. Check AIC switch

Move fan lever to the desired position (1 to 4). and press air
conditioner button to turn ON air conditioner.
Indicator light will come on when air conditioner is ON.
SHA681D
HA-39
Performance Chart
TEST CONDITION
For Auto Air Conditioner, before conducting performance test,
disconnect ambient sensor harness connector and make short
circuit using jumper cable.
Testing must be performed as follows:
Vehicle location: Indoors or in the shade (in a well venti-
lated place)
Doors: Closed
Door window: Open (Front driver side only)
Hood: Open
TEMP.: Max. COLD
Discharge Air: Face Vent
REC switch: (Recirculation) set
FAN speed: 4
Engine speed: 1,500 rpm
Time required before starting testing after air conditioner
starts operating: More than 10 minutes
TEST READING
Recirculating-to-discharge air temperature table
Inside air (Recirculating air)

at blower assembly inlet Discharge air temperature at center ventilator
Relative humidity Air temperature DC CF)
% DC CF)
20 (68) 1.0 - 3.5 (34 - 38)
25 (77) 4.5 - 7.0 (40 - 45)
50 - 60 30 (86) 8.5 - 11.0 (47 - 52)
35 (95) 12.0 - 14.5 (54 - 58)
40 (104) 16.5 - 19.0 (62 - 66)
20 (68) 3.5 - 6.0 (38 - 43)
25 (77) 7.0 - 9.5 (45 - 49)
60 - 70 30 (86) 11.0 - 13.5 (52 - 56)
35 (95) 14.5 - 17.0 (58 - 63)
40 (104) 19.0 - 21.5 (66 - 71)
Ambient air temperature-to-compressor pressure table
Ambient air
High-pressure (Discharge side) Low-pressure (Suction side)
Relative humidity Air temperature
kPa (bar, kg/cm2, psi) kPa (bar, kg/cm2, psi)
% DC ("F)
726 - 902 127 - 177
20 (68)
(7.26 - 9.02, 7.4 - 9.2, 105 - 131) (1.27 - 1.77, 1.3 - 1.8, 18 - 26)
912 - 1,128 157 - 206

25 (77)
(9.12 - 11.28, 9.3 - 11.5, 132 - 164) (1.57 - 2.06,1.6 - 2.1, 23 - 30)
1,108 - 1,353 186 - 235

50 - 70 30 (86)
(11.08 - 13.53, 11.3 - 13.8, 161 - 196) (1.86 - 2.35, 1.9 - 2.4, 27 - 34)
1,295 - 1,589 216 - 275
35 (95)
(12.95 - 15.89, 13.2 - 16.2, 188 - 230) (2.16 - 2.75, 2.2 - 2.8, 31 - 40)
1,491 - 1,824 245 - 314

40 (104)
(14.91 - 18.24, 15.2 - 18.6, 216 - 264) (2.45 - 3.14, 2.5 - 3.2, 36 - 46)
HA-40
DIAGNOSES - Overall$yst~m
Performance Test Diagnoses

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AA-41
DIAGNOSES.- Overall. System
Performance Test Diagnoses (Cont'd)
TROUBLE DIAGNOSES FOR ABNORMAL PRESSURE
Whenever abnormal pressure of high and/or low sides. of the system is noted, diagnosis must be con-
ducted by using a manifold gauge. The large-line zone on the gauge scale (see illustrations.) shown in
the following table refers to the standard (normal) pressure range for the corresponding pressure side
(high or low). Since the standard (normal) pressure, however, differs from vehicle to vehicle, refer to
the "Ambient Temperature-Pressure Characteristics" chart.
Gauge indication Refrigerant cycle Probable cause Corrective action

Both high and low-pressure • Pressure is reduced soon Excessive refrigerant charge Reduce refrigerant until spec-
sides are too high. after water is splashed on in refrigeration cycle ified pressure is obtained.
IAl condenser .
• No bubbles appear in sight
glass when pressure is
reduced.
Air suction by radiator or Insufficient condenser cooling • Clean condenser.
condenser fan is insufficient. performance • Check and repair radiator
! or condenser fan as neces-
G) Condenser fins are sary.
clogged.
@ Improper rotation of radi-
ator fan or condenser fan
• Low-pressure pipe is not Poor heat exchange in con- Evacuate repeatedly and
cold. denser recharge system.
AC359A • When compressor is (After compressor operation
stopped high-pressure stops, high pressure
value quickly drops by decreases too slowly.)
approximately 196 kPa !
(2.0 bar, 2 kg/cm2, 28 psi). Air in refrigeration cycle
It then decreases gradually
thereafter.
Engine tends .0 overheat. Engine cooling systems mal- Check and repair each
function. engine cooling system.
• Areas near low-pressure • Excessive liquid refrigerant Replace expansion valve .
pipe connection and ser- on low-pressure side
vice valves are consider- • Excessive refrigerant dis-
ably cold compared with charge flow
areas near expansion valve • Expansion valve is open a
outlet or evaporator. little compared with the
• Plates are sometimes cov- specification .
ered with frost. !
G) Improper thermal valve
installation
@ Improper expansion valve
adjustment
HA-42
DIAQNPSES """'";
OveraIISY$tf!1l1
Pertor'manceTest Diagnoses (Cont'ct)
Gauge indication Refrigerant cycle Probabll'l. Gause Corrective action
High-pressure side is too Upper side of condenSl'lr l:ind High-pressure tUlJe or parts • Check and repair or
high and low-pressureside<is highcpressure side are hot, located between.compressor replace malfunctiClning
too low. however, liquid tank is not so and condenser l:ire clogged parts.
[6J hot. or crushed. • Check compressor oil for
contamination.
AC360A
High-pressure side is too low High and low-pressure sides Compressor pressure opera- Replace compressor.
and low-pressure side is too become equal soon after tion is improper.
high. compressor operation stops. !
tQl Damaged inside compressor
packings
No temperature difference Compressor;discharg.e. Rep1l:ice compressor.

between high and low-pres- capacity does not change.
sure sides (Compressor~troke is set.at
maximum.)
AC356A
Both high- and low-pressure • There is a big temperature Liquid tank inside is clogged • Replace liquid tank
sides are too low. difference between liquid a little. • Check compressor oil for
IQI tank outlet and inlet. Outlet contamination.
temperature is extremely
low .
• Liquid tank inlet and expan-
sion valve are frosted.
• Temperature of expansion High-pressure pipe located • Check and repair malfunc-
valve inlet is extremely low between liquid tank and tioning parts.
as compared with areas expansion valve is clogged. • Check compressor oil for
near liquid tank. contamination .
• Expansion valve inlet may
be frosted .
• Temperature difference
occurs somewhere in high-
AC353A pressure side
HA-43
Both high- and low-pressure There isa big temperature Expansion valve closes a lit- • Remove foreign particles
sides are too low. difference between expansion tle compared with the specifi- by using compressed air.
[Q] valve inlet and outlet while cation. • Check compressor oil for
the valve itself is frosted. L contamination.
CDImproper expansion valve
adjustment
@ Malfunctioning thermal
valve
@ Outlet and inlet may be
clogged.
Areas near low-pressure Low-pressure pipe is clogged • Check and repair malfunc-
pipe connection and service or crushed. tioning parts.
valve are extremely cold as • Check compressor oil for
compared with areas near contamination.
expansion valve outlet and
AC353A evaporator.
Air flow volume is not Evaporator is frozen. Replace compressor.
enough or is too low. L
Compressor discharge
capacity does not change.
(Compressor stroke is set at
maximum length.)
Low-pressure side some- • Air conditioning system Refrigerant does not dis- • Drain water from refriger-
times becomes negative. does not function and does charge cyclically. ant or replace refrigerant.
~ not cyclically cool the com- L • Replace liquid tank.
partment air. Moisture is frozen at expan-
• The system constantly func- sion valve outlet and inlet.
tions for a certain period of L
time after compressor is Water is mixed with refriger-
stopped and restarted. ant.
AC354A
HA-44
DIAGNOSES- Overall ..System
Low-pressure side becomes Liquid tank or front/rear side High~pressure side is closed After the system is left at
negative. of expansion valve's pipe is and refrigerant does not flow. rest, start it again in order to
!El frosted or dewed. ! confirm. whether or not prob-
Expansion valve or liquid lem is c.aused.by water or
tank is frosted. foreign particles .
• If the problem is clue to
water, drain water from
refrigerant or replace
refrigerant.
• If it is due to foreign
particles, remove expan-
sion valve and remove
them with dry and com-
pressed air .
• If either of the above meth-
AC362A
ods. cannot correct the
problem, replace expan~ion
valve .
• Replace liquid tank .
• Check compressor oil for
contamination.
HA-45
TROUBLE DIAGNOSES- Manual Air Conditioner
Contents
Symptom Chart HA-46
Preliminary Check HA-47
PRELIMINARY CHECK 1
(A/C does not blow cold air.) HA-47
PRELIMINARY CHECK 2
(Noise) HA-48
Harness Layout for AIC System HA-49
Circuit Diagram for Quick Pinpoint Check HA-51
Wiring Diagram HA-52
Main Power Supply and Ground Circuit Check HA-56
Diagnostic Procedure 1
SYMPTOM: Blower motor does not rotate HA-56
SYMPTOM: Magnet clutch does not engage when A/C switch and fan switch are ON HA-59
SYMPTOM: Sub-condenser fan motor does not rotate HA-62
Electrical Components Inspection HA-66
Control Linkage Adjustment HA-68
Symptom Chart
DIAGNOSTIC TABLE
Main Power
Prelimi- Supply and
Diagnostic
PROCEDURE nary Ground Cir- Electrical Components Inspection
Procedure
Check cuit
Check
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AIC does not blow cold air. 0 f) f) 0 0 0 0 0 0 0 0 0 0 0 0 0

Blower motor does not
0 f) 0 0 0 0 0 0 0
rotate.
Magnet clutch does not

engage when AIC switch 0 f) 0 0 0 0 0 0 0 0 0
and fan switch are ON.
Noise 0
Sub-condenser fan motor
0 0 0 0 0 0 0 0 0
does not rotate.
O. f): The number means checking order.

0: As for checking order, refer to each flow chart. (It depends on malfunctioning portion.)
HA-46
TROUBLEDIAGNQSe:$ -, ,l\I1anijal Air"Col1ditiol1er
Preliminary Check
PRELIMINARY CHECK 1
Ale does not blow cold air.
N.G.
DOES AIR FLOW FROM VENTS? IS BLOWER MOTOR OPERAT-
Condition ING NORMALLY?
• Ignition switch and AIC switch
are ON. Yes ~NO
• Move fan lever to ON (1 to 4)
position. CHECK
• Air control lever is in VENT BLOWER
mode and temperature control MOTOROPER-
lever is in full cold position. ATION.'
Go to biag.
O.K. nos tic Proce-
dure 1.
CHECK COMPRESSOR BELT TEN- N.G. CHECK COMPRESSOR OPERA- CHECK FOR EVAPORATOR
SION. TION. COIL FREEZE UP.
Refer to MA section. Remove intake unit. Check if
O.K. evaporator freezes.
N.G. O.K.
N.G. O.K.
(Freeze up) (Does not
freeze up)
Adjust or CHECK REFRIGERATION CYCLE CHECK VENTI-

replace com- PRESSURE WITH MANIFOLD LATOR DUCT
pressor belt. GAUGE CONNECTED. FOR AIR
Refer to Performance Chart. LEAKS.
,. O.K.
~ N.G. ,
CHECK SIGHT GLASS. Go to Perfor" CHECK THERMO CONTROL

Refer to "Confirmation of Amount mance Test AMP. OPERATION.
of Charged Refrigerant" Diagnoses. Refer to Electrical Components
described in DISCHARGING, Inspection.
EVACUATING, CHARGING AND
CHECKING. N.G.
,
O.K. N.G.
CHECK FOR CHECK EXPANSION VALVE.

REFRIGERANT Refer to Performance Test Diag-
LEAKS. noses.
Go to Diagnostic Procedures 2.
,';
CHECK AIR MIX DOOR ADJUST" O.K. CHECK EVAPORATOR OUTLET

MENT. AIR TEMPERATURE.
Refer to DOOR CONTROL. Refer to Performance Chart.
.
N.G.
CHECK THERMO CONTROL

AMP. OPERATION.
Refer to Electrical Components
Inspection.
HA-.i47
TROUBLE DIAGNOSES - Manual Air Conditioner
Preliminary Check (Cont'd)
PRELIMINARY CHECK 2
Noise
Check where noise

comes from.
Expansion Refrigerant line

valve
Replace expan- Replace com-

sion valve. pressor.
The line is fixed The line is not

directly to the body. fixed.
Fix the line with rubber

or some vibration
absorbing material.
The belt vibration is Side of belt is worn

intense. out.
Readjust belt tension. The pulley center

Refer to ENGINE MAIN- does not match.
TENANCE in MA sec- Readjust the pulley
tion. center.
HA-48
TROUBbEDIAGNOSES - Manual AirCondiUoner
Harness Layout for Ale System

H41 MODEL
Air conditioner switch

harness connector @ Air conditioner relay
Fan switch harness
harness connector @
connector@
I u J
Blower motor
1/; harness connector
Blower motor
@
III
Blower resistor
harness connector @
Compressor
harness connector
@)
harness connector ~
SHA738D
HA.49
Harness layout for A/C System (Cont'd)
F23 MODEL
Air conditioner switch harness connector @

Air conditioner relay
Fan switch harness harness connector @
connector @
(I [=--=
Sub-condenser
fan relay harness
connector@
Blower motor
nhermo control amp. harness connector @
I harness connector @ Blower relay Blower motor
If'
Sub-condenser Blower resistor
fan relay harness connector @
harness connector @
Dual-pressure
switch
SHA739D
HA.50
Circuit Diagram for Quick Pinpoint Check

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SHA827D
HA-5~
Wiring Diagram - Heater
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I
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(l)1--
U W ......
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3:
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Z w
ZO L/Y
o
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harness) ~_ D===O WO
x
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UlU W/L 30A H:::<::
H« (f)Z
D===O ::JH
LL-l
SHA695D
HA..52
TROUBLEDIAGNOSES-. Manual Air Conditioner
Wiring Diagram - Heater (Cont'd)
a:c
F23 MODEL
wa:
0- B -
a: 3: 0
«01-
W-JO INDICATOR I
a: [In,: U
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£ B -rn--!I' Oa:
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r-1 U
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Y
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I-ffia:fjil @ = ....
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t!)U LL
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0..+J
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a: ~I'~
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o harness)
o..c
:;: .r-1
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W~R =llJJ ffi
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SHA694D
HA.53
Wiring Diagram - Manual Air Conditioner
H41 MODEL
...
I I
U
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'" ~
H
-~ en
Z
""
~ lJ..
IN "' ... "'Sl r---I£!

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t-
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SHA737D
HA-54
Wiring Diagram - Manual Air Conditioner
(Cont'd)
F23 MODEL
...
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I I
U
t-
H
OJ
~
- ~
~
- ,,/£: ~ LL
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a:
o
t-
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a:
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I
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.....
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U
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3:
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a.+, ::ED..., Z
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CfJOl
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CfJ 0
en LU
a: Ol ..... D===O W
W..J '1-0 ..J
lD
3:W
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[5-
D===O H
a.e W/R
CfJ
= ...-t ;:)
~ LL
U 0=
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lDLH
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COt-
W'I-;:)
CfJCOO
;:)a:a:
LL- U)(j)
..... en
[:
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c:iS~
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D-W/L
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H.;..J...J
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W/L-cn~I'~
g
00.00 ~
U
ffi (!) (!) @ o

Z
>-;:)
I~
lDZZt-
g;O~G=F~=Be:~
'eI- B
B --[ID-lh
@
8~
lDC!l
Vl8~~ (Ale sub-harness)
SHA736D
HA.55
Main Power Supply and Ground Circuit Check

POWER SUPPLY CIRCUIT CHECK FOR AIC SYSTEM
Check power supply circuit for air conditioning system.
Refer to "POWER SUPPLY ROUTING" In EL section and Wiring
Diagram.
Flowchart
INCIOENT
No. SYMPTOM: Blower motor does not rotate.
1 Fan fails to rotate. [j] • Perform PRELIMINARY CHECK 1 before referring to the
2 Fan fails to rotate at 1-speed. (2J following flow chart. ~
3 Fan fails to rotate at 2-speed. [3] <ID
Check if blower motor rotates properly ~
4 Fan fails to rotate at 3-speed. ~ at each fan speed. <ID
Conduct checks as per flow chart at [3]
5 Fan fails to rotate at 4-speed, ~ left. @
(2J
<ID
(Go to HA-58.)
[j]
N.G.
CHECK BLOWER MOTOR CIRCUIT. Disconnect blower relay.
Disconnect blower motor harness con-
nector.
L
Does battery voltage exist between
Blower motor
connector@
"cfi' 2 3 4
blower motor harness terminal No. G)
and body ground?
O.K.
Note
CHECK BLOWER MOTOR
CIRCUIT BETWEEN
BLOWER MOTOR AND
= BLOWER RELAY.
SHA740D
Check circuit continuity
between blower motor
Ii)
\Lf Blower motor
co~nector @
harness terminal No. G)
and blower relay harness
terminal No. @.
[lI [ill @
(Go to next page.)
DISCONNECT [iJ
Blower relay connector @
EO L CHECK POWER SUPPLY FOR BLOWER
RELAY.
N.G.
CHECK POWER SUPPLY
CIRCUIT, 10A FUSE AT
Does battery voltage exist between FUSE BLOCK and FUS-
~ blower relay harness terminals No. @, IBLE LINK.
@ and body ground? (Refer to "POWER SUP-
SHA741D PLY ROUTING" in EL
O.K. section and AIC ELEC-
w Blower relay TRICAL CIRCUIT.)
~ connector@
L/Y w=ITJ ~ °i~Y Note:

(f)
(Go to next page.)
If the result Is N.G. after checking circuit continuity, repair harness or con.
nector.
SHA742D
HA.56
TROUBLE DIAGNOSES .- Manual.AirConditioner
Diagnostic Procedure 1 (Cont'd)
•
f3T5l
[IFIT]
Blower relay Note
connector
@
B [ill CHECK BODY GROUND CIRCUIT FOR
BLOWER RELAY.
Check continuity between blower relay
harness terminal No. G) and body
= ground?
SHA743D
O.K.
T~
[it Dio Replace blower relay.
[ill
Blower motor
connector@
Check circuit continuity between blower N.G. Reconnect blower motor

motor harness terminal No. @ and harness connector.
SHA744D
body ground?
Resistor O.K.
connector @
EiliillJ! CHECK BLOWER MOTOR.

(Refer to Electrical Components Inspec-
R tion.)
+ -
N.G.
~. ~D' 2.34 Replace blower motor.

=
SHA745D iii
CHECK BLOWER MOTOR CIRCUIT N.G. Disconnect blower motor
Blower motor
~.Oi8T Iftn.OFF
~
R.~sistor
connector
BETWEEN BLOWER MOTOR AND
RESISTOR.
and resistor harness con-
nector.
@ Does battery voltage exist between
connector@
resistor harness terminal No. G) and
EiliillJl body ground?
R
O.K.
R
Note
SHA746D Check circuit continuity
between blower motor
harness terminal No. @
and resistor harness ter-
minal No. G).
@
(Go to next page.)
Note:
If the result is N.G. after checking circuit continuity, repair harness or con-
nector.
HA..57
Dia.gnostic Procedure 1 (Cont'd)
.~~
Fan switch
@
connector
10] ~ @
CHECK RESISTOR AFTER DIS-
CONNECTING IT. [3]
R
(Refer to Electrical Components
<ID
Inspection.)
~ f4l <ID
O.K. !N.G.
i
SHA747D Replace resistor.
D
Reoo""ecl 'osl'lo' h3l"e" CO"-
Fan switch
connector @
~
IS 18~
DISCONNECT ~
nector.
0]
7fr~i=~"1'1
'"
R/G,W Y 1Ql"
~ w/y,G R ,
III
body ground?
~~[3]~~~[5].
CHECK FAN SWITCH CIRCUIT.
each fan switch harness terminal and
Terminal No.
Flow chart No. Voltage
SHA748D EFJ e
2- ~
~ @
~ 4 15rJ Fan switch
connector @
4 (])
Body ground
Battery volt-
age
.2 ~
B
O.K. N.G.
~ [3]
~ [5]
D Note
Check circuit continuity between fan
switch and resistor.
SHA749D
Terminal No.
Fan switch con- Resistor con- Continuity
nector nector
~ ~
(]) ~ Yes
@ @
~ (])
CHECK FAN SWITCH AFTER ~ Replace fan switch.

DISCONNECTING IT.
Inspection.)
O.K.
II Note
Check circuit continuity between
fan switch harness terminal No.
@) and body ground?
Note:
If the result Is N.G. after checking circuit continuity, repair harness or con-
nector. .
HA-58
TROUBLE DIAGNOSES-- Ma.nuaIAirCo.nditioner
Compressor Diagnostic Procedure 2

connector
°i5 00 SYMPTOM: Magnet clutchdoesl"l0tengage when Ale

T
[ffiJ ~~~; @B ~ switch and fan switch are ON.

• Perform PRELIMINARY CHECK 1 before referring to the
Ivl .~O~ following flow chart.
FD engine: B
Except FD Ii)
engine: W/L
CHECK POWER SUPPLY FOR COM- N.G. CHECK AIC RELAY
SHA750D PRESSOR. OPERATION.
Disconnect compressor harness con- Does battery voltage
nector. exist between AICrelay
Does battery voltage exist between harness terminal No. @
+ - compressor harness terminal No. (!) and body grounc;l?
and body ground?
O.K. N.G.
rOO!
W/L
AIC relay
connector @
O.K.
Check.magnet clutch coil.
OK
SHA751D Replace magnet clutch.

Refer to COMPRESSOR - Model DKS-
Compressor 16H (ZEXEL make).
connector
m H41:@
F23: @) AIC relay
connector Disconnect AIC relay harness connec-
[ill @ tor.
FD engine:B
W/L [U1l1]
Except FD
engine: W/L [iIDi5
T
00 iii
Check circuit continuity between AIC
relay harness terminal No. @ a,nd
.Note Ii]
CHECK POWER SUPPLY
FOR AIC RELAY.
SHA752D
compressor harness terminal No. (!). Disconnect AIC relay
• harness connector .
DqE!s battery voltage
exisfbetween AIC relay
AIC relay
harness terminals No.
connector@
L/Y @, @ and body
ground?
~ L/Y
O.K. N.G.
@ CHECK POWER SUPPLY

(Go to next page) CIRCUIT, 10A FUSE AT
SHA753D
FUSE BLOCK.
(Refer to "POWER SUP-
PLY ROUTING" in EL
section and AIC ELEC-
TRICAL CIRCUIT.)
Note:
nector.
HA.59
II H41 model
connector ~
CHECK AIC RELAY. N.G. Replace AIC relay.
LIW tion.)
A/C relay
L/W connector
O.K.
@
CHECK DUAL-PRESSURE SWITCH. N.G. Replace dual-pressure
SHA859D
(Refer to Electrical Components Inspec- switch.
tion.)
II F23 model ~ DISCONNECT t1F.t\\
Dual-pressure
switch connector @
~ -10 ~ O.K.
Note
~~ A/C relay
1 connector[l~
relay harness terminal No. (1) and
{
eM ~.
@"
J "e
dual-pressure switch harness terminal
No. @.
O.K.
SHA754D
N.G.
Thermo
[J,~d] ~ Di(Y~ CHECK POWER SUPPLY FOR THERMO
CONTROL AMP.
Disconnect thermo control amp harness
CHECK POWER SUPPLY
CIRCUIT, 10A FUSE AT
FUSE BLOCK.
control
connector. (Refer to "POWER SUP-
amp.
L/Y
[:YJ Does battery voltage exist between PLY ROUTING" in EL
connector
+ - thermo control amp harness terminal section and AIC ELEC-
@
No. @ and body ground? TRICAL CIRCUIT.)
O.K.
SHA755D
CHECK THERMO CONTROL AMP. N.G. Replace thermo control
(Refer to Electrical Components Inspec- amp.
Thermo control amp.

connector @
~ Di(Y~ tion.)
O.K.
A/C switch connector
@ Note
Disconnect AIC switch harness connec-

tor.
switch harness terminal No. @ and
thermo control amp harness terminal
SHA756D
No. (1).
O.K.
@
(Go to next page)
Note:
nector.
HA.60
TROUBLE DIAGNOSES -' Manual Air Conditioner
Ale switch Fan switch

connector @ connector @ CHECK AIC SWITCH. N.G'Replace AIC sWitch.
~j,~d] ~415EJ
tion.)
Inspec-
'"{--8_1'" SHA757D
O.K.
Note
CHECK AIC SWITCH CIRCUIT

o BETWEEN AIC SWITCH AND FAN
SWITCH.
Fan switch
connector @ Disconnect fan switch harness connec-
rwO:;;~T tor.
[ill ~ 'liiV
switch harness terminal No. @ and fan
switch harness terminal No. @.
O.K.
= CHECK FAN SWITCH. N.G. Replace fan switch.

SHA758D
tion.)
O.K.
o Note
Check circuit continuity between fan

switch harness terminal No. @ and
body ground?
Note:
If the result Is N.G. after checking circuli continuity, repair harness or con.
nector.
IotA-61
Sub- ~ SYMPTOM: Sub-condenser fan motor does not rotate.
condenser ~J~
fan motor • Perform PRELIMINARY CHECK 1 before referring to the
connector following flow chart.
o
I H41 model
Note
SHA759D N.G.
CHECK POWER SUPPLY FOR SUB-
CONDENSER FAN.
---.. Disconnect sub-con-
denser fan relay.
.
Disconnect sub-condenser fan harness Check circuit continuity
~Sub-
~Oi~Y~ connector.
between sub-condenser
fan relay harness termi-
~1~ condenser sub-condenser fan motor harness ter- nal No. @ and sub-con-
fan motor minal No. G) and body ground? denser fan motor har-
W/R
connector
@
W/R
Sub-
dID
condenser
O.K.
ness terminal No. G)?
O.K.
fan relay
connector
[!J Note
SHA760D
Check circuit continuity between sub-
condenser fan motor harness terminal
Sub- ~
~Oi8T~ No. @ and body ground?
O.K.
condenser ~rJl
fan motor
connector B
[ill Replace condenser fan.
@
Ii]
~
N.G.
CHECK POWER SUPPL Y FOR SUB-
CONDENSER FAN RELAY.
----.- CHECK POWER SUPPLY
CIRCUIT, AT FUSIBLE
SHA761D Does battery voltage exist sub-con- LINK.
denser fan relay harness terminal No. (Refer to "POWER SUP-
• @ and body ground? PLY ROUTING" in EL
Sub-condenser
fan relay
l2iI 0ijT ~ O.K.
TRICAL CIRCUIT.)
connector @
[Y]
&W/L
~ + - Ii Note

condenser fan relay harness terminal
No. G) and body ground?
SHA762D ~ O.K.
@
(Go to next page)
Note:
Sub- If the result Is N.G. after checking circuit continuity, repair harness or con-
condenser B r-r\l nector.
fan relay ~
connector
@
~OijT~
SHA763D
HA-62
TROUBLE DIAGNOSES - Manual ..AirCondilioner
Note
Sub- W/L N.G.
CHECK SUB-CONDENSER FAN RELAY Disconnect AIC relay.
condenser
fan relay
connector
(=)
8
OPERATION.
Check circuit continuity
between sub-condenser
@ sub-condenser fan relay harness termi- fan relay harness termi-
nal No .• @ and body ground? nal No. @ and AIC relay
SHA764D harness terminal No.
O.K.
@?
~Di5T~
AIC relay Replace sub-condenser fan relay. CHECK AIC RELAY
Sub-
condenser
connector @
~
~
fan relay
connector
W IL ltiMlliJ OPERATION.
Refer to I!J in Diagnos-
tic Procedure 2.
@
W/L
Note:
SHA765D nector.
HA.63
fa
F23 model
Sub- ~
condenser \\,)~
fan motor
connector Note
@ CHECK POWER SUPPLY FOR SUB- N.G. Disconnect sub-con-
CONDENSER FAN.
f---+ denser fan relay.
Disconnect sub-condenser fan harness Check circuit continuity
connector. between sub-condenser
Does battery voltage exist between fan relay harness term i-
SHA759D sub-condenser fan motor harness ter- nal No. @ and sub-con-
minal No. CD and body ground? denser fan motor har-
Sub- Sub- ness terminal No. CD?
condenser condenser O.K.
fan motor fan relay O.K.
connector connector
o [;]
"~~'J
Note

condenser fan motor harness terminal
No. @ and body ground?
O.K.
SHA766D
Replace condenser fan.
~Oi()T~
Sub-
condenser
fan motor
connector
~
~tJ!
[ill
Ii]
•
CHECK POWER SUPPLY FOR SUB-
CONDENSER FAN RELAY.
N.G.
f---+
CHECK POWER SUPPL Y
CIRCUIT, AT FUSIBLE
B
Does battery voltage exist between LINK.
sub-condenser fan relay harness term i- (Refer to "POWER SUP-
nal No. @ and body ground? PLY ROUTING" in EL
O.K.
TRICAL CIRCUIT.)
SHA761D
Ii
• Note
~Oi8T~ Check circuit continuity between sub-

condenser fan relay harness terminal
No. CD and body ground?
00 ~ O.K.
WIG Sub-
condenser
@
fan relay (Go to next page)
~ connector
Note:
[lJ'E](ill)
If the result is N.G. after checking circuit continuity, repair harness or can.
SHA767D
nectar.
Sub-
condenser
fan relay
connector B
(ill)
SHA768D
HA.64
@
Sub-
condenser W/L Note
fan relay
connector + - CHECK SUB-CONDENSER FAN RELAY N.G. Disconnect AIC relay.
@) OPERATION. Check circuit continuity
Does battery voltage exist between between sub-condenser
sub-condenser fan relay harness termi- fan relay harness termi-
= nal No. @ and body ground? nal No. @ and AIC relay
SHA769D harness terminal No.
O.K.
@?
~Oi8T~ O.K.
Sub- Replace sub-condenser fan relay. CHECK AIC RELAY

_~ condenser OPERATION.
[IFjJJ fan relay W/L ~ Refer to (;J in Diagnos-
connector Ale relay
tic Procedure 2.
@) connector
W/L @
Note:
If the result is N.G. after checking circuit continuity, repair harness or con-
Continuity should exist. SHA770D nector.
HA.65
TROUB.LEDIAGNOSES. - Manual Air Conditioner
Electrical Components Inspection

DUAL-PRESSURE SWITCH
High-pressure side line pressure
Operation Continuity
Decreasing to 177 - 216

(1.77 - 2.16, 1.8 - 2.2,26 - 31) Does not
Turn OFF
Increasing to 2,452 - 2,844 exist
(24.5 - 28.4, 25 - 29, 356 - 412)
Increasing to 177 - 235
(1.77 • 2.35, 1.8 - 2.4, 26 - 34)
Turn ON Exists
Decreasing to 1,373 - 1,667
(13.7 - 16.7, 14 - 17, 199 - 242)
THERMO CONTROL AMP.

Evaporator outlet air temperature Thermo amp.
Tester
.C ("F) operation
Decreasing to 3.0 - 4.0 (37 - 39) Turn OFF Battery voltage
Increasing to 4.5 - 5.5 (40 - 42) Turn ON Approx.OV
Dual-
pressure
switch
TIt
2 1 3
ACC
AIC switch
=
SHA772D
AIC RELAY AND BLOWER RELAY

Check circuit continuity between terminals by supplying battery
voltage to coil side terminal of AIC relay, or blower relay.
HA-66
TROU.BLE[)IAGNOS ..ES.- Manual Air ••CondUioner
'1i1~qtriqaICompQnents Inspection (Cont'd)
FAN SWITCH
Check continuity .between terminal at each position.
POSITION
TERMINAL
@
@
@
@
SHA773D
@)
@
BLOWERI\IJOl'OR.
Confirmsmo()tnrotaHon of the blower motor.
• Ensyr!3 thaLthere. is no foreign matt~rs irls.ide the intake
uniL .
BLOWI;R, RESISTOR
Gh!39kcqntinyiJy b~t\J\leenterminals.
SHA775D
A/CSWIT.CH
Check continuitY/between terminals.
".~.' ....'•..2
".'i.'....'."'.•'..... ' ••:' ..•...•.
'•."." ••. :.•. . '.. :••...•..•
•.•••, •.•..•••..•.•..•••.•.••.••
. •.•
: .....•.. ~.••••••..••..•.•....•..•....••..•..........•
• 3 ". Q
1
SHA776D
HA..67
Electrical Components Inspection (Cont'd)
SUB-CONDENSER FAN RELAY
H41 model
voltage to coil side terminal of condenser relay.
SHA777D
F23 model
voltage to coil side terminal of condenser relay.
SUB-CONDENSER FAN MOTOR

Sub-condenser
fan motor ~ Di~T 1. Disconnect sub-condenser fan motor harness connector.
2. Supply sub-condenser fan motor terminals with battery
connector ~ 'liiv
voltage and check operation.
~ Sub-condenser fan motor should operate. If N.G., replace sub-
condenser fan motor.
SHA969D
Control Linkage Adjustment

AIR CONTROL CABLE
• Move air control lever to ~ position.
Set side link in DEF mode.
Pull on outer cable in direction of arrow and then clamp it.
After positioning control cable, check It operates properly.
WATER COCK CONTROL ROD

• When adjusting water cock control rod, first disconnect
temperature control cable from air mix door lever and then
adjust control rod. Reconnect temperature control cable
and readjust It. (Refer to next Item.)
1. Set air mix door lever in full cold mode.
2. Pull control rod of water cock in direction of arrow so as to
make clearance of about 2 mm (0.08 in) between ends of
rod and link lever and connect the rod to door lever.
After connecting control rod, check It operates properly.
HA-68
TROUBLEDIAGNO.SES<~ Manual Air Conditioner
Control Linkage Adjustment (Cont'd)
TEMPERATURE CONTROL CABLE
• When adjusting ventilator door rod and defroster door rod,
first disconnect air control cable from side link.
Reconnect and readjust air control cable.
• Move temperature c;ontrol lever to max. COLD position. Set
air mix door lever in full cold mode. Pull on outer cable in
direction of arrow and then clamp it.
After positioning control cable, check it operates properly.
INTAKE DOOR CONTROL CABLE

• Move intake lever to ~ position.
Set intake door lever in REC mode.
PUll on outer cable in direction of arrow and then clamp it.
After positioning control cable, check It operates properly.
HA..69
COMPRESSOR LUBRICATION OIL
DIESEL-KIKI make DIESEL-KIKI make
Model Model
DKS-16H DKS-16H
Type Swash plate Type SUNISO 5GS

3
Displacement cm (cu in)/Rev. 167 (10.HI) Capacity ml', (Imp II oz)
37.0 x 25.8 Total in system 250 (8.8)

Cylinder bore x stroke mm (in)
(1.457 x 1.016)
Amount of oil which can be
190 (6.7)
Clockwise drained
Direction of rotation
(viewed from drive end)
Compressor (Service parts)
250 (8.8)
Drive bell A-type cha.rging amount
REFRIGERANT
Type R-12
kg (Ib) H41 model: 0.6 - 0.7 (1.3 - 1.5)

Capacity
F23 model: 0.5 - 0.6 (1.1 - 1.3)
COMPRESSOR
ENGINE IDLING SPEED (When AIC is ON.) Model DKS-16H
• Refer to EF & EC section. Clutch disc-pulley clearance
0.3 - 0.6 (0.012 - 0.024)
mm (in)
BELT TENSION
• Refer to Checking Drive Belts (MA section).
HA-70
ELECTRICAL/SYSTEM
sectroN,El.:
• Read GI section, "HOW TOREAD\,WIRING DIAGRAMS".
CONTENTS'
HARNESS CONNECTOR . .. ;; El:~ 2
ST ANDARDIZSD RELAy ; ~........................................................... .. EL~ 3
POWER SUPPLY ROUTING EL- 5
BATTERy ;; ;.. EL- 8
ST ARTI NG SYSTEM , 6L- ..16
CHARGING SYSTEM EL- 28
COMBINATION SWITCH .. EL- 41
HEADLAMP - Witho.ut Daytime Light Sy~teqri and Dim-dip Lamp System EL- 43
HEADLAMP - Day!iOle Light System -/.... EL- 45
HEADLAMP - Dinf:"~iP Lamp System - c.•• ~ ;... .. E~~ 47
HEADLAMP :..... . 'EL- 49
EXTERIOR LAMP .. EL.. 51
INTERIOR LAMP ; EL';;' 61
METER AN D GAUGES EL- 63
WARN ING LAM PS AND BUZZER EL- 68
WI PER A.ND. W.ASHER EL- 74
HORN, CIGARETTE LIGHTER, CLOCK EL- 81
AUDIO EL- 82
AU DIO AND POWER ANTENNA EL- 86
LOCATION OF ELECTRICALUNITS EL- 88
HARNESS LAYOUT .. ':." ;;., .".:.C:........................................................... EL- 92
SUPER MULTIPLE JUNCTION (S.M.J.) EL-109
WlalNG DIAGRAM REFERENCE CHART
IGNITION SYSTEM, QUICK-GLOW SYSTEM, AIR HEATER SYSTEM, FUEL HEATER EF &. EC SECTION
all
EXHAUST BRAKING SYSTEM BR SECTION
HEATER AND AIR CONDITIONER' tlA'SEC110N
HARNESS CONNECTOR
Description
HARNESS CONNECTOR
• All harness connectors have been modified to prevent accidental looseness or disconnection.
• The connector can be disconnected by pushing or lifting the locking section.
CAUTION:
Do not pull the harness when disconnecting the connector.
[Example]
LIFT PUSH
PUSH
PUSH
PUSH
(For combination meter) (For relay)
SEL769D
EL-2
STANDARDIZE.D RELAY
Description
NORMAL OPEN, NORMAL CLOSED AND MIXED TYPE RELAYS
Relays can mainly be divided into three types: normal open, normal closed and mixed type relays.
NORMAL OPEN RELAY NORMAL CLOSED RELAY MIXED TYPE RELAY

Flows Flows
Does not • •
u..u. flow'Q
= Does no~
flow
0
.....
3:
(/)
I I I
BATTERY BATTERY BATTERY
Flows
Z
• Does not
flow Q
Does not
flow c:>
0 = Flows
.....
3:
(/) L L
SW 1 BATTERY SW 1 BATTERY SW 1 BATTERY
SEL881H
TYPE OF STANDARDIZED RELAYS

1M 1 Make 2M 2 Make
1T 1 Transfer 1M.1B 1 Make 1 Break
1M 2M
1M
2M
1T lM.1B
1T
SEL882H
EL-3
STANDARDIZEDRElAV
Description (Cont'd)
Type Conne.ctor symbol

Outer view Circuit Case color
and connection
1T BLACK
BLUE
1M or
GREEN
=
2M BROWN
1M.1B GRAY
SEL883H
El-4
POWER SUP,PLV••.
ROUTING
Wiring Diagram
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SEL789R
EL.5
POWER SUPPLY ROUTING
Wiring Diagram (Cont'd)
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SEL790R
EL-6
POWER SUPPLVROUTING
Fuse
a. If fuse is blown, be sure to eliminate cause of problem
b~fore installing new fuse.
b. Use fuse of specified rating. Never use fuse of more than
specified rating.
c. Do not inst~1Ifuse in oblique dir~ction; always insert it into
fuse holder properly.
d. Remove fuse for clock if vehicle is not used for a long
O.K. Blown period of time.
SEL945J
Fusible Link
A meltedjusible link can be detected by visual inspection. If its
condition is questionable, use circuit tester or test lamp.
CAUTION:
a. If fusible link should melt, It Is possible that critical circuit
(power supply or large current carrying circuit) is shorted.
In such a case, carefully check and eliminate cause of
problem.
b. Never wrap periphery of fusible link with vinyl tape.
Extreme care should be taken with this link to ensure that
it does not come into contact with any other wiring. harness
or vinyl or rubber parts.
EL-7
BATTERY
CAUTION:
a. If it becomes necessary to start the engine with a booster
battery and jumper cables, use a 12-volt booster battery.
b. After connecting battery cables, ensure that they are tightly
clamped to battery terminals for good contact.
c. Never add distilled water through the hole used to check
specific gravity.
How to .Handle B$ttery

METHODS OF PREVENTING OVER-DISCHARGE
The following precautions must be taken to prevent over-dis-
charging a battery.
• The battery surface (particularly its top) should always be
kept clean and dry.
If the top surface of a battery is wet with electrolyte or
water, leakage current will cause the battery to discharge.
Always keep the battery clean and dry.
SEL711E
• When the vehicle is not going to be used over a long period

of time, disconnect the negative battery terminal. (If the
vehicle has an extended storage switch, turn it off.)
SEL712E
• Check the charge condition of the battery.

Periodically check the specific gravity of the electrolyte.
Keep a close check on charge condition to prevent over-
discharge.
SEL442D
EL-8
BATTERY
)CHECKINGELECTROL VTE LEVEL
WARNING:
Do not allow battery fluid to come in contact with skin, eyes,
fabrics, or painted surfaces. After touching a battery, ..donot
touch or rub your eyes until you haveth()roUghly washed' your
hands. If the acid contacts the eyes,~ldnorcl~thing, immedi-
ately flush with water for 15 minutes arid seek medical atten-
tion.
Normally the battery does not require a..dditional water.
However, when the battery is used under severe Qonditions,
adding distilled water may be necessary during the battery life.
TOmaintain s.erviceapility, a perforated line has been added to
the.:p.a,tterycaution label.
lfthe eleQtrplytelevel is low, remove label at perforated

line.
RefnovetrreceH ..plug using a suitable tool.

Addgi$tilledWa.ter up to the MAX level.
Cell plug
__ Normal. battery
..SUlPHATION ..
Charging voltage ----- SUlPhated..baft.ery.

.
When .ab.atteryha~been left unattended for a long period of
time,andhas a specific .gravit,y of less than 1.100, it will be
t .--',------- Charging voltage cornplete(y discharged, resulting in sulphation on the cell
~ pl~tes,.,; ..
Compared wiiha battery discharged under normal conditions,
Charging current
the current flow in a "sulphated" battery is not as smooth
t Charging-current
although its voltage is high during the initial stage of charging,
as shown in the figure at the left.
Duration of charge
SEL709E
BATTERY
Read top level SPECIFIC GRAVITV.CHECK

with scale
1. Read hydrometer and thermometer indications at eye level.
SEL442D
• When electrolyte level is too low, tilt battery case to raise

Hydrometer it for easy measurement.
meter ~
n
Thermo- ..........
SEL710E
2. Convert into specific gravity at 20°C (68°F).

Example:
• When electrolyte temperature is 35°C (95°F) and specific
gravity of electrolyte is 1.230,converted specific gravity at
20°C (68°F) is 1.240.
• When electrolyte temperature is O°C (32°F) and specific
gravity of electrolyte is 1.210, converted specific gravity at
20°C (68°F) is 1.196.
Converted specific gravity (S20)
-30 -20 -10 0 10 20 30 40 SO

(-22) (-4) (14) (32) (SO) (68) (86) (104) (122)
Electrolyte temperature °C (OF)
SEL042D
EL-10
BATTERY
Battery Test and Charging Chart

Chart I
VISUAL INSPECTION
e Check battery case for cracks or bends.
e Check battery terminals for damage. N.G.
elf the difference between the max. and min. level is within 10 mm (0.39 in), electrolyte levels in cells
are O.K.
O.K.
T
Replace battery.
CHECKING SPECIFIC GRAVITY
Refer to "Specific Gravity Check".
SLOW CHARGE *
Refer to "A: Slow CAPACITY TEST
STANDARD CHARGE QUICK CHARGE
Charge". Refer to "Chart II".
Refer to "B: Standard Refer to "C: Quick
Charge". Charge".
N.G.
CAPACITY TEST
Refer to "Chart II". Ready for use
CAPACITY TEST
Refer to "Chart II". e Mount battery again
and check loose ter-
O.K. N.G.
minals. Also, check
other related circuits.
Ready Replace
for use battery.
CHECKING SPECIFIC GRAVITY QUICK CHARGE
Refer to "Specific Gravity Check". Refer to "C: Quick
Charge".
eTime required: 45 min.
RECHARGE CAPACITY TEST

Refer to "C: Quick Charge". Refer to "Chart II".
elf battery temperature rises above 60°C
(140° Fl. stop charging. Always charge O.K. N.G.
battery when its temperature is below
60°C (140°F). Ready Replace
for use battery.
CAPACITY TEST
Refer to "Chart II".
O.K. N.G.
T
Ready Replace
for use battery.
* "STANDARD CHARGE" is recommended in casethat the vehicle is in storage after charging.

BATTERY
Battery Test and Charging Chart (Cont'd)
Chart II
• Check battery type and

detllrmine the specified
current using the following
table.
Fig. 1 DISCHARGING CURRENT

(Load tester)
Test using battery
Test using load tester. Type Current (A)
checker.
28B19R(LI 90
34B19R(L) 99
46B24R(L) 135
Follow manufacturer's Read load tester voltage
55B24R(L) 135
instructions to check and when specified discharging
determ ine if battery is current (Refer to Fig.l) 50D23R(L) 150
serviceable. flows through battery for 55D23R(L) 180
15 seconds. 65D26R(L) 195
O.K. N.G. 80D26R(L) 195
75D31R(L) 210
Ready for use Go to next step.
95D31R(L) 240
95E41R(L) 300
130E41R(L) 330
Ready for use Go to next step.
SEL697B
EL-12
BATTERY
Battery Tes,t<andCharging Chart (Cont'd)
A: SLOW CHARGE
Fig.2 INITIAL CHARGING CURRENrSETTING (Slow charge)
:i:i :i :i..
~~ a: a:
MM
M
:;;:
NN
o w
00 g
Determine initial char!lingcurrent from
OLtl
LtlLtl
Ltl
.... -
specific gravity referrirtg to Fig. 2.
4.0 5.0 7.0 8~0 9.010.0 14.0
Below 1.100
(A) (A) (A) (A) (A) JA) (A)
• Charge battery. • Check battery type and determ ine the specified current using the
.Checkchargingvoltalle 30 minutes after table shown above.
sfartingthe battery charge;
• After starting charging, adj u$1:mentof charging current is not
necessary.
"T
Fig.3 ADDITIONAL CHARGE. (Slowcharge)
O.K.
N.G. Below 1.150
I 1
ioo I 1200 1.240
Replace battery.
Continue to charge for
12 hours.
Charge for 5 hou rs Charge for 4 hou rs Chargefor 2 hours
at initial charging at initial charging at initial charging
current setting. current setting. current sehing.
CHECKING SPECIFIC'GiRAVITY
Refer to "SpeCific Gravity check".
Go to "CAPACITY TEST".
CAUTION:
Conduct additional charge as per a. Set charging current to value specified in Fig. 2. If charger
Fig 3, if necessary. is not capable of producing specified current value, set its
charging current as close to that value as possible.
b. Keep battery away from open flame while it is being
charged.
c. When connecting charger, connect leads first, then turn on
charger. Do not turn on charger first, as this may cause a
spark.
d. If battery temperature rises above 60°C (140°,F),stop charg-
ing. Always charge battery when its temperature is below
60°C (140°F).
EL-13
BATTERY
Fig.4 INITIAL CHARGING CURRENT SETTING

B: STANDARD CHARGE
(Standard charge)
TYPE :J:J :J:J :J:J :J:J :J :J:J :J

~~ ~~ a:
CON. a: a:
CllCll
~~
oq- oq- MM <D<D
a:
M
~~ ...... :it
VERTED mm NN
alai
NN
00
NN
00 0
Moq-
ow W
0
Determine initial charging current from SPECIFIC
ClOoq-
NM
<Dill
oq- III 15:8 III 0
<DClO
III
"
III III
CllCll ...
M
specific gravity, referring to Fig. 4. GRAVITY

~
1.100 -1.130 4.0 (A) 5.0 (A) 6.0 (A) 7.0 (A) 8.0 (A) 9.0 (A) 13.0 (A)
1.130 -1.160 3.0 (A) 4.0 (A) 5.0 (A) 6.0 (A) 7.0 (A) 8.0 (A) 11.0 (A)
Charge battery for 8 hours. 1.160-1.190 2.0 (A) 3.0 (A) 4.0 (A) 5.0 (A) 6.0 (A) 7.0 (A) 9.0 (A)
1.190 - 1.220 2.0 (A) 2.0 (A) 3.0 (A) 4.0 (A) 5.0 (A) 5.0 (A) 7.0 (A)
• Check battery type and determine the specified current using the table
shown above.
CHECKING SPECIFIC GRAVITY
• After starting charging, adjustment of charging current is not necessary.
Refer to "Specific Gravity Check".
Conduct additional charge as per

Fig. 5, if necessary.
Fig.5 ADDITIONAL CHARGE (Standard charge)
Above 1.240
Charge for 3.5 hours Charge for 2.5 hours Charge for 1.5 hours
at initial charging at initial charging at initial charging
current setting. current sett ing. current setting.
CAUTION:
a. Do not use standard charge method on a battery whose specific gravity is less than 1.100.
b. Set charging current to value specified in Fig. 4. If charger is not capable of producing specified
current value, set its charging current a$ close to that value as possible.
c. Keep battery away from open flame while it is being charged.
d. When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as
this may cause a spark.
e. If battery temperature rises above 60°C(140°F),stop charging. Always charge baUery when its tem-
perature is below 60°C (140°F).
EL-14
BATTERY
C: QUICK CHARGE Fig.6 INITIAL CHARGING CURRENT SETTING AND
CHARGING TIME (Quick charge)
::J ::J ::J::J::J ::J

a: a:
222
a: a: a:
::J::J::J
a: a: a: iririr a:
CJ) CJ)
~ ~ 'It 'It M
N N N
M
N NN
lDlD
;:).M'; :;;
Determine initial charging current setting and W
ID III IDID 0 0 0 0 OOw 0
charging time from specific gravity, referring
co 'It
N M
co ltl 0 .ltlltl 0 ,...
ltlltl ltl M
'It ltl ltl ltlCOIll CJ)CJ)
to Fig. 6.
10 (A) 15 (AI 20 (A) 30 (A) 40 (A)
1.100 - 1.130 2.5 hours
1.130 - 1.160 2.0 hours
Charge battery 1.160 -1.190 1.5 hours
1.190-1.220 1.0 hours
Above 1.220 0.75 hours (45 min.)

• Check battery type and determine the specified current using the table
shown above.
• After starting charging, adjustment of charging current is not necessary.
CAUTION:
a. Do not use qUick charge method on a battery whose specific gravity is less than 1.100.
b. Set initial charging current to value specified In Fig. 6. If charger is not capable of producing spec-
ified current value, set its charging current as close to that value as possible.
c. Keep battery away from open flame while it is being charged.
d. When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as
this may cause a spark.
e. Be careful of a rise In battery temperature because a large current flow Is required during qulck-
charge operation.
If battery temperature rises above 60°C(140°F),stop charging. Always charge battery When Its tem-
perature is below 60°C (140°F).
f. Do not exceed the charging time specified in Fig. 6. Because if the battery Is charged over the
charging time, it can cause deterioration of the battery.
Service Data and Specifications

Europe Except Europe
Applied model
NA20 TD25 NA20 TD25,27 BD30 FD42, 46
Type 55D23R 130E41R 34B19R 95E41R 95E41R 55D23R*

Standard
Capacity V-AH 12-60 12-110 12-33 12-100 12-100 12-60
Type - 55D23R 130E41R 75D31R* 95D31R*

Option
Capacity V-AH - 12-60 12-110 12-70 12-80
* Models equipped with two batteries.
EL-15
STARTING SYSTEM
NA engine Wiring Diagram
S.M.0.
[Refer to last page
IGNITION SWITCH (Foldout page) .J
I" OFF ACC ON ST
1
2
3
4
....Q.
....Q.
u
2...
~ rfff ~~~
----- ----- W/R.~ .. D14
W/R ~
•.W/R
W/R ---
(Chassis
5 2... lfr (Instrument @ @ harness)
harness)
@)EUBJ
@EtiBl a: E
"
~ 0
0
L.._
U)
Q)U)
n
CQ)
.,.. C
QlL..
a: crn
~ !:!:!£
~ c;
nb
FUSIBLE
LINK
BATTERY
SEL791R
TO engine
S.M.0.
[Refer to last page
IGNITION SWITCH (Fo ldout page) . J
"OFF ACC ON ST
rn4J. ..m=
1 0
2
3
4
~
~ L
rr W/R
-----
W/R -----
W/R fiJ14
W/R D1
W/R
W/R
5
2-
:!.... ~ (Instrument @ @
harness)
(Chassis
harness)
W -tl Ii-
@D @
W I
I
(Engine room
harness)
"FR
@~
BODY
GROUND
n
FUSIBLE
LINK
FUSIBLE LINK BOX
-
BATTERY
STARTER
MOTOR
SEL792R
EL-16
SIARTINGSYSTEM
Wiring Diagram (Ccml'd)
BDengine
IGNITION SWITCH (InstrumeQt

harness)
fi41\
•.
~
,@ (Chass is harness)
:=rn
"'- OFF ACC ON ST
1 0 .0
2
W
W/R'
Jr
0 .• W,
/R ffiD14.' WI.R
3 2
4 3.•.•
4 ~ 5' '" • '"B~16B 00 • '" .••. •
Il
15
S',M.J., ,.
II
IDID
[Refer to last page
~.. ...... (Foldoutp,g,)] .••..•
: •• ~
~'-'!
(])@ @)~
BODY .GROUND
@<fr
E
n o
o
L~
00
aJOO
CaJ
-r-!C
OlL
~ ceo
D 181:
ID
"FA
D ~"", ....; ••••••• ,i,',.,.o

~ ~ •.'.•••
""Jt;
FUSIBLE
@ LINK BOX BATTERY
BODY
GROUND
STARTER RELAY
SEL793R
FQ ~ngine
. ... ,.~ ]
t [
•. , "'
FUSE BLOCK
(Referto,."pOWER
STARTER
RELAY
UP
I
,.~~
~
0::>
;. SUPPLY Rq~:ING".)
@n"r.n..,i.,
-D" "0-'-
W~R=8JGJ
":>"'
J...•
W W -{]2)
---&!
«.' • = •".
.i'
W/L W/L -{]2)
IGNITION SWITCH., (tnstrument (Sub,-
•• . harness)
1
OFF ACC ON ST
W/L' . B/W F16
(~Ii}' harness)
2 Q'
3
4
0
~_
rn4J.. .,." ~~E ••," '. ",' • ~;;E
':-'.' _~' ', .., _ . B
0 3
0 1 4
016
W/L
B SUB-STARTER
5 ..•..•• @ @) SWITCH
R/B-(), ~l
W/R.-QJ,0~
..••.•. '. • [ReferSt~'~ast
."'"' (Fo Idout page)
, B/W-o@......
@'H@ (Chass is
R/B)d. •
=
.'
NEUTRAL
harness) SWITCH
@ Wide cab
STARTER
MOTOR @
BODY
GROUND
SEL794R
STARTINGSVSTEM
STARTING SYSTEM TROUBLE-SHOOTING
"' .r:...
c:
g'
--
tJ
E
.~
...a.
o
...
tJ
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c: c:
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c: U en "8-
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c:
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c: .~g' .~
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:> III
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~ 0 ., ., ... U
.,... ~ tJ
., Q.'" ~ ....
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0
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.r: .,
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tJ
III
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~
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t:.
0c:
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z E ....,...E ...., .r:.~
.,... ....,
:>
~ >... 0
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tJ
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c:
>- .= ~~ 0
:-ec: ......>
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(ij
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0 c: .r: "0
u c: ... ... a
en'" ...
0
'"
EL-18
M3T38482
Adjusting plate .
Plate thickness.
o 25 (0.0098) I
0
'50
'. (0.0197) Magne t'IC switch assemb y
Through-bolt
l_ ~
~ ~ • • 131 3 5.8 - 9.4)
(0.8- " ~ 3.4 - 7.4 75 2.5 _ 5.4)
~~
Rear cover
Sleeve bearing Gear case
'gEl@
Sleeve beann
m@ Thrust washer Brush H
Brush holder
Stopper clip
Pinion stopper Brush spring
, , m (in) Pinion assembly
Unit. m ft-Ib) ,
~ : N.m (kg-m, rease POints
EI@: High-temperature g SEL775R
M2T78681
mol 12.7 - 16.7 ~8 -13

~-~ (1.30 • 1.70, (0.8 - 1.3,
9.4 • 12.3) 5.8 - 9.4)
Magnetic SWI
'tch assembly
t.~@J(j
I L P;o;oo~""b~
L P;o;oo"000" J
'
Pinion shaft assembly
Reduction gear
Washer
Center bracket
SEL778R
EL-19
STARTING' SYSTEM
Construction (Cont'd)
5114-607C
Dustcover~
toJ 6.4 - 7.8
(O.65 - 0.80, \
4.7-5.8) ~
Armature
@~ m@
Pinion assembly
Gear case. () \ Dust cover
Pinion stopper
metalE!@ ]
Housing
Field coil
Unit : mm (in) Rear cover metal m@

toJ : N.m (kg-m, ft-Ib) Yoke
E! @ : High-temperature grease points
SEL776R
513-1068, 126, 127
Clutch assembly Torsion spring
~ 7.4-9.8
(0.75 - 1.00,
Gear case 5.4 - 7.2)
toJ 6.4 - 7.8
(0.65 - 0.80,,,
4.7-5.8) ~
d)"""
.. ~.
fJ"~'
Be~ing
. 0
retainer
Pinion shaft
Unit: mm (in)
Thrust washer "A" Brush (+)
~: N'm (kg-m, ft-Ib)
E! @ : High-temperature greasepoints
SEL125D
EL-20
SlABTING'"SYSl\EM
Construction (Cont' d)
524-08
Adjusting plate
I\c:tjust difference " Q "
~Iale ~~ickness:0.5 (0.020)
. 0.8 (0.031)
Bearing retainer
Unit : mm (in) Field coil

m@: High-temperature grease points SEL777R
525-303
Rear cover
Pinion gear assembly

m@ : High-temperature grease point SEL855R
EL..21
STARTING. SYSTEM
Construction (Cont'd)
S114-527A
Adjusting plate
Plate thickness:
0.5 (0.020)
0.8 (0.031)
~
Through bolt
~ 0 ~4.9 - 6.4
(0.50 - 0.65,
Thrust washer 3.6 • 4.7)
Pinion assembly
Pinion stopper
~ Pinion stopper clip
~ 6.4 • 8.3 (0.65 • 0.85,
4.7 • 6.1)
Gea~," .... ~@))\U .' :. ElIA@,~, .... mb~
~ ~ Brush holder assembly

Armature assembly
Thrust washer
Unit : mm (in) \ Yoke assembly
~ : N.m (kg-m, ft-Ib) \ Center bracket
m @ : High-temperature grease points
SEL033S
From battery Magnetic Switch Check

• Before starting to check, disconnect battery ground cable.
• Disconnect "M" terminal of starter motor.
1. Continuity test (between "S" terminal and switch body).
• No continuity ... Replace.
SEL555E
2. Continuity test (between "S" terminal and "M" terminal).

• No continuity ... Replace.
SEL556E
EL-22
STARTING SYSTEM
Non-reduction gear type Pinion/ClutchCheck

~ 1. Check to see if pinion locks in one direction and rotates
smoothly in the opposite direction.
• If it does not lock (or locks) in either direction or unusual
resistance is evident ... Replace.
SEL630B
SEL825R
2. Check pinion movement.

• If it is hard to move, apply grease or,if necessary,
replace.
3. Check ball bearing.

Spin outer race of ball bearing to ensure that it turns
smoothly without binding .
• Abnormal resistance ... Replace.
4. Inspect pinion teeth.

• Replace pinion if teeth are worn. or damaged. (Also
check condition of ring gear teeth.)
5. Inspect reduction gear teeth.
• Replace reduction gear if teeth are worn or damaged.
(Also check condition of armature shaft gear teeth.)
EL-23
STARTING SYSTEM
Brush Check
BRUSH
Check wear of brush.
Wear limit length:
Refer to "Service Data and Specifications,"
• Excessive wear ... Replace.
SEL014Z
Non-reduction BRUSH HOLDER

gear type 1. Perform insulation test between brush holder (positive
side) and its base (negative side).
• Continuity exists ... Replace.
2. Check brush to see if it moves smoothly.
Ohmmeter • If brush holder is bent, replace it; if sliding surface is
dirty, clean.
SELB2BR
Field Coil Check

1. Continuity test (between field coil positive terminal and
positive brushes).
• No continuity ... Replace field coil.
Ohmmeter
Positive terminal
SELB29R
2. Insulation test (between field coil positive terminal and

yoke)..
• Continuity exists ... Replace field coil.
Positive terminal
SEL 103E
EL-24
STARTINGS¥STEM
Armature Check
1. Continuit.y.t
... •.•'est
N0 continuity. (between tw
• ... RePlace~ segments side by side).
SEL625B
2. Insulation test (bet

• Continuity eXist;~~~:~~~e~ommutator bar and shaft).
SEL104E
3. Checkcomm
• Rou' ..ua.tor t surface.
> / .' gh .....$and lightly with No. 500 - 600 sandpaper.
Check.diameter of
Commutator m' ~ommutator.
I",mum d'
Refer to "Se' lameter:
L rVlce Data
ess than specified val
d
an Specifications".
ue ... Replace.
Et-25
STARTING SYSTEM
Armature Check (Cont'd)
Undercut procedures 5. Check depth of insulating mold from commutator surface.
• Less than 0.2 mm (0.008 in) ... Undercut to 0.5 to 0.8 mm
(0.020 to 0.031 in)
~-
0.5 - 0.8 mm
RO~031lnJ
Correct
/-File
~ Comm"".,
EE021
Assembly
GREASE POINT
• Rear cover metal
• Gear case metal
• Center bracket metal
• Frictional surface of pinion
• Moving portion of shift lever
• Plunger of magnetic switch
• Reduction gear
PINION PROTRUSION LENGTH ADJUSTMENT

Switch
rT
: Battery
....L..
Non-reduction gear type
With pinion driven out by magnetic switch, push pinion back to
remove slack and measure clearance "t" between the front
edge of the pinion and the pinion stopper.
Clearance "t":
Refer to "Service Data and Specifications".
Clearance "Q"
SEL299E
Adjusting plate • Not in the specified value ... Adjust with adjusting plate.
Dust cover thickness .'
0.5 mm (0.020 in)
0.8 mm (0.031 in)
SEL633B
EL-26
STARTINGSVSTEM
Assembly (Co nt' d)
Reduction gear type
Compare movement" t" in height of pinion when it is pushed
out with magnetic switch energized and when it is pulled out by
hand until it touches stopper.
Movement "t":
"Q"~-
SEL027Z
• Not in the specified value ... Adjust by adjusting plate.
SEL573B
Service Data and Specifications (S.O.S.)

STARTER
S114-607C M3T38482 S114-527A S13-106B I S13-127 S13-126 S24-08' M2T78681 S25-303'
MITSUB- MITSUB-
Type HITACHI HITACHI HITACHI
ISHI ISHI
Non-reduction Reduction
Applied model
NA20 T025 (27) I TD25 B030 F042 (46)
General Europe General I Europe General & Middle East
System voltage V 12 12 24 24 12
No-load
Terminal voltage V 11.5 11.5 11.0 11.0 23.0 23.0 22.0
Less than Less than Less than Less than Less than Less than Less than
Current A Less than 100
60 60 90 160 90 65 100
More than More than More than More than More than More than More than
Revolutions rpm More than 3,900
7,000 6,500 2,950 4,000 3,100 4,250 3,800
Minimum diameter of 31.4 32.0 31.4 36.6
39 (1.54) 35.5 (1.398)
commutator mm (in) (1.236) (1.260) (1.236) (1.441)
Minimum length of brush 11.5 11.0 10.0
11 (0.43) 9.0 (0.354) 11 (0.43)
mm (in) (0.453) (0.433) (0.394)
17.7 - 21.6 13.7 - 25.5 17.7-21.6 26.5 - 32.4 24.5 - 34.3 29.4 - 38.2 28.4 - 35.3
Brush spring tension
(1.8 - 2.2, (1.4 - 2.6, (1.8 - 2.2, (2.7 - 3.3, (2.5 - 3.5, (3.0 - 3.9, (2.9 - 3.6,
N (kg, Ib)
4.0 - 4.9) 3.1 - 5.7) 4.0 - 4.9) 6.0 - 7.3) 5.5 - 7.7) 6.6 - 8.6) 6.4 - 7.9)
Clearance of bearing
Less than
metal and armature shaft
0.2 (0.008)
- - - - -
mm (in)
Clearance ''C'' between 0.3 - 2.5 0.5 - 2.0 0,3- 1.0
pinion front edge and (0.012 - (0.020 - - - - (0.012 -
pinion stopper mm (in) 0.098) 0.079) 0.039)
Movement "f." in height 0.5 - 2.0
0.3 - 1.5 0.3 - 1.0
of pinion assembly - - - (0,012 - 0.059) (0.012 - 0.039)
(0.020 - -
mm (in) 0.079)
, : Option
EL-27
CHARGING SYSTEM
Wiring Diagram
ID ID
C C
.M .r-!
0) 0)
c C
ID ID
<t0
Z I-
x a: x a:
,
CI:
LL
x
" "
III X
" "
III X
WO
(,
T 0 N A -llD
CI: lD
W H::'::
I- [J:==:[] rJJZ
W ::JH
~ [J:==:[] LL-l
Z
0 W/R
I,~
H
I-
<t W
Z
H
lD
~
0
u S.M.J.
[Refer to last paQe
W-{)
(Faldout paae). J
W/R~W/R
W/R~W/R
en
@ @
en
ID
c
L
rn en
.I::. en
...., (I)
B/W NA c
G C
(I)
E
:J
L
rn
.I::.
@ @
CI:=
Wt!J
L
...., .....en
3:Z en en
OH c en
Q.I- !:! rn
::,::
0
= ::J .I::.
UaCI: oS z
0....,
-l >-
lDL-l
(l)Q.
W ....Q.
rJJ(I)::J
::JCI:rJJ E
LL~ a
a
L~
en III
IDen
C(I)
.....c
O)L
crn
.I:!:!..I::.
I
U
I- t-
en
H
3:
rJJ
Z u
o u
H
« fa
I-
H
Z
~
t!J /- ClJl"l ",10
H
SEL795R
EL-28
CHARGING SYSTEM
:>:::>-
lIlU«
...JW...J
::lIW
lIlUIX
cr:
<.!l "-
X
IX
W
t-
W
~
,
Z
o
H
t- IX
« LL
Z
H x
III
~ S.M.J. WO
[Refer to last p age -.JlIl
o III
U (Foldout page) .] H:>:::
(f)Z
G
W/R~W/R
o 0 ::lH
LL...J
W/L~W/L W/L - ~
H
IX=
W(!)
~Z
OH
a..t-
@ @
W -
W
=
:>::: 0
UOIX
O+J
::l
[ W ---aI ~Ilt::
>-
IX
W
...J >- «
III e......J III
GlQ..
W ..... Q.. enen
(f)Gl::l
::lIX(f)
LL~
Gl
C
enen
e... Gl W/L
rn C
.c e...
G rn
+J .c
C >-- B
Gl
E
:J
'-
....UJ
UJ
UJ Cl
-
<...>
Cl
+J rn
en .c
C
H B W f--
III III
~
<...>
.
W/R
cr:
"-
x .....
F <...>
B D
~ X III
E x !Xl
o
~
t=EJ
@~ wE@ o
e...~
aJUJ
CGl
en
@~ Cd
I
U
t-
H
~
tii @~ tEf1@ .... C
Ole...
crn
~..t: ~ ~
(f) tjU I'-' x !Xl
E
Z
o
!:3n
<{
0
0
H
t- '-~
H
Z
(!)
~
1/..- C\J C'l""1fJ
Gl
C
....... .M
Gl
C I I Glen
CGl
en
.... C
Ol Ol
H C C Ole...
Gl Gl crn
o 0
~.c
LL III
SEL796R
EL-29
LR1S0-430T
Rear bearin
Do not reuseg bea .
Replace with a new
rtngone.
after remov a I.
~ 3.1 - 3.9
.-=i
(0.32 " 040
2.3 - 2.9) ,
Oil seal
Do not reuse .1 ~. RefertoB R
- ~ for vacuum section
~ @ @ <ll@;;
seal aft er removal.
01
service infor~ua~~n.
(i) 0 <ll@ ~6.7

@ @ ~ (0.6.07
~. ~3" ~;)'
~ Vacuum pump'
~ 3.1 - 3.9
~ 3.1 - 3.9
(0.32 - 0.40 , 2 .3 - 2.9) \0 lode assembly
Rear cover (0.32 - 0.40 , 2 .3 - 2.9)

SEL779R
LR23S-S02B , LR240-S02B
Pulley assembly
~
Front b eartng
. ret .
3.1 • 3.9 alner
!
(0.32 - 0.4,
2.3 - 2.9)
Stator
~83 - 98
(8.5 - 100
61-72)"
I.e.voltage
regulator assembly
Diode assembly Vacuum pump assembly
~: N.m (kgom, ft-Ib) SEL856R
EL-30
A:5;TO;1;O;76~=======~C]H~A~R~G~.I;N~G~
~__________
....~SV;~ST~E;.M~~ Construction (Cont'd)
~
-
Bearing retainer
Bearing
Front cover
CO.J 3.9 - 5.4 N.m

. kg-m
(0.40 - 055
2.9 • 4.0 Jt-Ib) ,
I.C. regulator
assembly
PUlley assernbly
Stator
SEL760R
A5T01094
Bearing retainer
Bearing
~ Front cover
~-~ 3.9 - 5.4 N.m

.
(0.40 - 055 kg-m
2.9 - 4.0 ft-Ib) ,
I.C. regulator
assembly
Stator
SEL781R
EL..31
CHARGING SYSTEM
nt'd)
Construction (Co
LR225-412T, LR235-404T
Front bearing t
. er
bearing retain 040 2.3 _ 2. 9)
Fron n3.1 - 39. (0.32 _ . ,
Front cover ~-.. Rotor .
Rear beanng baring after

Do not reuse e ith a new one.
remova.I Replace w
1Il
n 83-98
~- .. (8.5 - 10.0, Stator
61 - 72)
V
~29-34
(3.0-3.5,
@ 22-25)
@ 7
~0~6.0.7,
~~U.5.'1
~
~@O.cir
~
o 0
~00~
@
Diode assembly
Vacuum pump assembly

Do no t reuse oil seal
~ : N.m (kg-m, ft-Ib) after removal.
SEL857R
EL-32
CHARGINGSVSTEM
Trouble ..shooting
Before conducting a.n alternator test, make sure tha, the battery is fully charged. A 30-volt voltmeter and
suitable test probes are necessary for the test. The alternator can be checked easily by referring to the
Inspection Table.
Before starting trouble-shooting, inspect the fusible link.
WITH Ie REGULATOR With alternator side l terminal
grounded, internal short occurs Burned-out
@ when + diode is short-circuited. bulb. Replace
and Proceed
Ignition Disconnect to "@'
switch "ON" connector(S,
(Check light l) and ground
for operation) llead wire Damaged IC-RG,
Connect con-
(Check light Replace
nector (5, Ll
for operation) I and ground F
Engine idling I terminal
(Check light I (Check light
for operation)
I for operation)
: (MITSUBISHI
I~a~e~ DamAacgeGd
IC-RG
Dimlight
or ...
light fl ickers
Bright light --JDamaged A.c.G.I.
light "ON" --_I 1_. .
Contact positive lead (+) of voltmeter on B
terminal and negative lead (-) to l terminal.
Engine idling
(Measure the
More than 0.5V - -I Damaged A.c.G.1
_.------.
voltage across /-----
"B" and "l" less than 0.5V - -- _O_._K_. _
Engine speed: terminals)
1,500 rpm
lighting
switch "ON" Engine speed: Damaged IC-RG,
(Check light 1,500 rpm
1) Use fully charged battery Replace
for operation)' (Measure B
2) Light Charge warning light terminal volt-
A.C.G. Alternator parts except IC regulator age)
IC.RG IC regulator
Make sure "S" Engine idling
O.K. IC-alternator is in good condition terminal is con- lighting
3) When reaching "Damaged A.C.G.", remove nected correctly switch "ON"
alternator from vehicle and disassemble, inspect (Check light
for operation)
and correct or replace faulty parts
4) *Method of grounding F terminal (HITACHI make
only)
Gasoline engine model
Diesel engine model
Contact tip of wire with brush and attach
Remove vacuum pump and connect tip
wire to alternator body.
of wire with brush and attach wire to
alternator body.
Brush lift wire
.~ ..
~V"oom'pomp "CO'"
5) Terminals "S", "L", "BAT" and "E" are marked
on rear cover of alternator.
SEL056Z
EL..33
CHARGING SYSTEM
WITH VOLTAGE REGULATOR
Set up a test circuit as shown in figure and test alternator in
manner indicated in flow chart below:
1. Disconnect connectors at alternator.
2. Connect "BAT" terminal to "F" terminal.
3. Connect one test probe from voltmeter positive terminal to "BAT" terminal. Connect the other test probe to ground.
Make sure that voltmeter registers battery voltage.
4. Turn on headlights and switch to High Beam.
5. Start engine.
6. Increase engine speed gradually until it is approximately 1,100 rpm, and take the voltmeter reading.
I I
Measured value: Below 12.5 volts Measured value: Over 12.5 volts
Alternator is run-down. Remove and check it for Alternator is in good condition.
condition.
a. Do not run engine at more than 1,100 rpm while

test Is being conducted on alternator.
b. Do not race engine.
SEL251B
Ohmmeter Disassembly
ROTOR SLIP RING CHECK
1. Continuity test
• No continuity ... Replace rotor.
EL-34
CHARGING SYSTEM
Disassembly ..(Coni' d)
Ohmmeter 2. Insulator test
• Continuity exists ... Replace rotor.
3. Check slip ring for wear.
Slip ring minimum outer diameter:
[MITSUBISHI BRUSH CHECK

make] 1. Check smooth movement of brush.
• Not smooth ... Check brush holder and clean.
2. Check brush for wear.
• Replace brush if it is.worn down to the limit line.
SEL631D
3. Check brush lead wire for damage .

• Damaged ... Replace.
2 mm (0.08 in) 4. Check brush spring pressure.
Measure brush spring pressure with brush projected
approximately 2 mm (0.08 in) from brush holder.
Spring pressure:
• Not within the specified values ... Replace.
SEL035Z
[HITACHI make] STATOR CHECK

To test the stator or diode, you must separate them by unsol-
dering the connecting wires.
CAUTION:
Use only as much heat as required to melt solder.
Diodes will be damaged by excessive heat.
SEL587A
[MITSUBISHI make]
Long nOse pliers
used as a heat sink
SEL054D
EL...35
CHARGING SYSTEM
1. Continuity test
• No continuity ... Replace stator.
2. Ground test
• Continuity exists ... Replace stator.
SEL 109E
EL-36
CHARGING SYSTEM
Diode Check
MAIN DIODES
• Use an ohmmeter to check condition of diodes as indicated in chart below.
• If any of the test results are not satisfactory, replace diode assembly.
Ohmmeter probes
Continuity
Positive $ Negative e
Positive diode plate Diode terminals Yes
Diodes check (Positive side)
Diode terminals Positive diode plate No
Negative diode plate Diode terminals No
Diodes check (Negative side)
Diode terminals Negative diode plate Yes
[MITSUBISHI make] [HITACHI make]

Positive side
Negative diode plate
Ohrnmeter
~--
SEL767D SEL319E
Negative side
SEL320E
EL-37
CHARGING SYSTEM
Diode Check (Coni' d)
[HITACHI make] SUB-DIODES
• Attach ohmmeter's probe to each end of diode to check for
continuity.
• Continuity is N.G.... Replace diode assembly.
SEL593A
[MITSUBISHI make]
SEL910A
Assembly
• When soldering each stator coil lead wire to diode assem-
bly terminal, carry out the operation as fast as possible.
WHEN SOLDERING BRUSH LEAD WIRE

[MITSUBISHI make]
• Position brush so that its wear limit line protrudes 2 mm
(0.08 in) beyond end face of brush holder.
2mm
(0.08 in)
SEL632D
[HITACHI make]
(1) Position brush so that it extends 11 mm (0.43 in) from brush
holder.
SEL595A
EL-38
CHARGING SYSTEM
Assembly (Co nt' d)
(2) Coil lead wire 1.5 times around terminal groove. Solder
outside of terminal.
When soldering, be .careful not to Jet solder adhere to insulat-
After soldering, ing tube as it will weaken the tube and cause it to break.
place insulating tube
on terminal.
1 mm (0.04 in) SEL596A
Amount of protrusion: RING FITTING IN REAR BEARING

Fix ring at the position
• Fix ring into groove in rear bearing so that it is as close to
O~~'~lnimumprotrusion.
the adjacent area as possible.
I
~/''''.~....
I ..
"'",
\.\
~
,- \ . 1-'
Ere,m,;,
", ,~ .:,'" .... '.,,/'
groovy
Rear bearing
SEL044Z
Gasoline engine models REAR COVER INSTAllATION

(1) Before installing front cover with pulley and rotor with rear
cover, push brush up with fingers and retain brush, by
inserting brush lift into brush lift hole from outside.
After installing, remove wlrefor brush lift.
(2) After installing front and rear sides of alternator, pull brush
lift by pushing toward center.
Do not pull brush lift by pushing toward outside of cover as it
will damage slip ring sliding surface.
SEL045Z
Diesel engine models

Use serration cap (Attach vinyl tape)
to prevent scratching oil seal
SEL046Z
EL-39
CHARGING SYSTEM
Service Data and Specifications (S.O.S.)

ALTERNATOR
Type
A5T01076 I A5T01094 LR150-430T LR225-412T* LR235-404T* LR235-502B LR240-502B*
MITSUBISHI HITACHI
NA20 TD25 (27) B030 F042 (46)

Applied model
General I Europe
General &
Europe
General & Middle East
Nominal rating V-A 12-50 12-50 24-25 24-35 24-35 24-40
Ground polarity Negative
Minimum revolutions under

Less than Less than
no-load (when 14, 27 volts are Less than 1,300 Less than 1,000 Less than 950
1,000 950
applied) rpm
More than More than More than More than

Hot output current
More than 10/1,300 More than 42/2,500 811,300 13/1,300 13/1,300 13/1,300
(when 14, 27 volts are applied)
More than 40/2,500 More than 50/5,000 21/2,500 30/2,500 30/2,500 33/2,500
Alrpm
25/5,000 35/5,000 35/5,000 38/5,000
Regulated output voltage

14.1 - 14.7 14.4 - 15.0 28.0 - 29.0
V
Minimum length of brush

8.0 (0.315) 6.0 (0.236) 6.0 (0.236)
mm(in)
3.138 - 4.315
Brush spring pressure 2.305 - 3.383 1.47-3.14 0.922 - 3.276
(320 - 440, 11.29 -
N (g, oz) (235 - 345, 8.29 - 12.17) (150 - 320, 5.29 - 11.29) (94 - 334, 3.32 - 11.78)
15.52)
Slip ring outer diameter

22.1 (0.870) 30.6 (1.205) 33.6 (1.323) 30.6 (1.205)
mm (in)
Rotor (Field coil) resistance n 3.1 - 3.8 - - -

*: Option
EL-40
COMBINATION SWITCH
Combination Switch/Check
FRONT WIPER
AND WASHES
A \
-.
/
OFF
IJ#
WASH
LIGHT
/_----.JA'------\ TURN INT
A
, B
~
2ND
1ST
U N
~
ON
EXHAUST
BRAKE ."
4r
LO
~
C fJ
OFF
D
HI
-----------------1
r--------------
I
I
I
-----------'1 I
I I
i
I I
I I
I
I 1 6 9 127 : 12151 ~61
I
I
I (R.H.O.
except
model:
for :
I
(L . H .0.) _~~_.~:~_:.U
LJ~_._~~~_L_ (L.H.D.)
(Horn) _~~~~:::~ .J (Rear fo,g)
(Front wiper and washer.
Exhaust brake) (Li,ght in,g and Turn s i,gna 1)
LIGHTING SWITCH
FRONT WIPER AND
WASHER SWITCH HORN SWITCH ~ OFF 1ST 2ND
AS CA S~
....... OFF INI LO HI WASH
5 ~~~ TURN
rI3 0
0 6 ~~~~ SIGNAL
14 0
15
7 SWITCH
~ 8
~~I?I~
II
16
17 9 ~
18 10
11
12 ~~
!d
~
EXHAUST 25 ~ ~
BRAKE 26 !d
SWITC.H
fif3 g I
SEL797R
EL-41
COMBINATION SWITCH
Replacement
Lighting switch • Each switch can be replaced without removing combination
r~ switch base. .
0=, A J
o:~) ?fI1
l_
~
-~~~\'r
~ rr.l~
O=~ --
Wiper and
Switch base washer switch
SEL728R
• To remove combination switch base, remove base attach-

ing screw.
EL-42
HEADLAMP
-. Without Daytil'l1eUght System and Dil'l1-dipLamp SY$JE!m>.-
.•
Wiring Diagram
LIGHTING SWITCH COMB INA TI ON
~ OFF 1ST 2ND METER
AB CA BC A BC
5 R.H.D. model for Europe
6 ~ HIGH BEAM and L.H.D. model
7 34~33 R.H.D. model except
B 7129 6 1 16917
~ for Europe
9 ~ ~
~
10118 5 2
• 3
3 5 81110
2 • Except @
10
11
12 ~ ~ ~ R.H.D. model for Europe
25 ~
26 ~
.!:i
a:l~
, .......
Ira: "
Q)...J
3([
>-C!l
..............
a:oc
R/Y
HEAD LAMP R.H. RIG
~
(Instrument
harness)
HEADLAMP L.H.
RIS
• R/W
B
~ W/S
R E
~
0)
,0)
a:
0)
;r ,
3:
a:
0) 0)
ti
@@
FUSE BLOCK
(Refer to "POWER
SUPPL Y ROUTI NG" .)
JOINT CONNECTOR BODY GROUND

SEL798R
EL-43
- Without Daytime Light Slstem and Dim-dip lamp Slstem-
Wiring Diagram
c1
,...,
,....~
m~.
WID
.... (")C\J
o
R/W
W
W/B ..JI---
RIL ' r--
R/Y o
@ Ba:
m
RIG
S.M.J.
[Refer to last page
~~.
1f'
.... C\J(") R/Y (Foldout pagel .] B -{]9)-jI' t!l
>-
WID
R/L a: o
o W/B s o
'en W/B W/B (J)(J) lD
"B 016 B en .rl(J)
"9 R/W (J)CP
RIB I..J RIB F10 R/B..J (J)C
roL
Lro
I
U aU
I-- ZOJ
19I;:;tg~~ tg (ill) @) 2.c
H C\I<t
3:
en U ~
OJ
t!l .....
Z
H IJ..
I-- IJ..OJ
I a<t
t!l
H
-.J I.t: lOW "CO cno-ru
...............
+J
C
CP~
El/J
>- ::Jl/J
a: LCP
w +JC
(J)L
I-- RIG
I-- R/Y cro
« tj.c
lD
a::
Wt!l
3:Z
OH
0..1--
: ::J
~ 0
UQa:
O+J
-.J >-
lDL-.J
cpo..
w-....o..
encp::J
::Ja:en
LL~
a:
0..
4
«
-.J
o
«
w
I
HEADLAMP L.H.
SEL799R
El-44
HEADLAIVIP ..'!"'7" Daytim~. Light.:System-
Operation
After starting the engine with the lighting switch in the "OFF"
position, the headlamp low beam and clearance, tail, license
and instrument illumination lamps automatically turn on. Light-
ing switch operations other than the above are the same as
conventional light systems.
Engine With engine stopped Wi.th engine running

OFF 1ST 2ND OFF .. 1ST 2ND
Lighting switch
A B C A B C A B C A B C A B C A B C
High beam X X 0 X X 0 0 X 0 X X 0 X X 0 0 X 0
Headlamp
Low beam X X X X X X X 0 X 0 0 0 X X X X 0 X
Clearance and tail lamp X X X 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
License and instrument illumina-
X X X 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
tion lamp
o : Lamp "ON"
X : Lamp "OFF"
C : Added functions
Schematic
IGNITION SWITCH
START
CHARGE
WARNING
LAMP
DAYTIME LIGHT UNIT
r1rn51
~
I I
10 :s: (D :s: (D
0 H 0 H :::Ea:
-.J I -.J I «0
wt-
0-
l!l«
:::E u
To clearance. license. « IH
-.J. (DO
tail and illumination 0
HZ
IH
lamps «I
ALTERNATOR w
Ia:
SEL800R
EL-45
HEADLAMP - Daytime Light System -
Wiring Diagram
a:=
WUl
3:Z
OH
0..1-
= ~
:<: 0
Uoa:
O+J
...J !>-
I (])L...J
U Q)o..
I- W'l-o.. a:
H OOQ)~ "-
3:1- ~a:oo
lL~ 3: (IJ
00 a: (IJ
« Q)
ZI- G e
000 L
H ro
I-L .c::
HO
Z
UlZ .....(IJ
HO (IJ
(IJ
ro
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2
>-
a:
W 15A R
l- 15A RIG
I- 5 R/V
«
(])
+J
e
Q)~
E(IJ
::J(IJ
To sma 11 lamps LQ)
+Je
To CHARGE warning lamp (lJL
ero
!:j.c::
I
U
I-
H
3:
00
Z
o
H
1-1-
Ha:
Z«
Ull-
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I
:r::
a: ...J
0.. Q.
:::;: :::;:
« «
...J ...J
o o
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W W
I I
SEL801R
EL-46
HEADLAMP-.- Dim-dipLamp_S_y_s_te_m_
..•_•._.· _
Operation
When ignition switch is in the "ON" position with the lighting
switch in the "1ST" position, the headlamp low beam comes on
dimly to function as a clearance lamp. Lighting switch opera-
tions other than the above are the same as conventional light
systems.
Ignition switch OFF or ACC ON
OFF 1ST 2ND OFF 1ST 2ND
Lighting switch
A B C A B C A B C A B C A B C A B C
High beam X X 0 X X 0 0 X 0 X X 0 X X 0 0 X 0
Low beam X X X X X X X 0 X X X X X X X X 0 X
Headlamp
Dim-dip (Low
X X X X X X X X X X X X 0 0 X X X X
beam)
Clearance, tail, license and illumi-
X X X 0 0 0 0 0 0 X X X 0 0 0 0 0 0
nation lamps
o : Lamp "ON"
X : Lamp "OFF"
C : Added functions
Schematic
FUSE
5 6
DIM-DIP LAMP UNIT
~r9it01
QNlID tilll
10 I I
3: UJ 3: UJ :::EO:
0..
0 H 0..
0 H <to
:::E -.J I :::E -.J I WI-
<t <t tD<t
-.J -.J U
0 0 IH
<tI <tI UJO
W W HZ
IO: I-.J IH
SEL802R
EL-47
HEADLAMP - Dim-dip_L_a_m_p_S_y_s_te_m _
Wiring Diagram
CI:=
Wt!l
3:Z
OH
CLt-
::<:
= ='
0
WOCI:
O+J
-l >-
I ClJL-l
W QlCL
t- W'+-CL
H (/)Ql='
3:t- ='CI:(/)
(/)(1: IJ..-
<l:
zt- A G
O(/)
H
t-L
HO
Z
t!lZ
HO
>-
CI:
W R
t- RIG
t- R/Y
<l: (jJ
ClJ en
Ql
c:
L
co
.r::
+J
t-
c:
H....-----, Ql
Z E
R/W :J
=' G/W L
RIB +J
CL en
~ ~ B
c:
I~j~
<l:
-l ~
g.
o
~
ItO
1Il!'-
CU lD
G
R/L
H R/W
o '--_--' RIB
@ ~
B ;D9H11 ffi
j B~llb
@ ~
I I
I i'\[;:;
U aU
ZID CI: -l
t-
CU<l: ~~ r;~ ~~
H
3: ~~ ~ ~ ~~ CL
~
CL
~
(/) t-U <l: «
UlID -l -l
t!l .... <1: o o
Z <l: <l:
H IJ..U W W
t- u..1D I I
I 0<1:
t!l
H
-l
j, IIltO !'-co OJ~::: C\.ILIHD
.... C\JC\J
SELB03R
EL-48
HEADlAMP
Bulb Replacement
The headlamp .is a semi-sealed beam type which uses a
Rubber replaceable halogen .bulb. The bulb can be replaced from the
cap engine compartment side without removing the headlamp body.
• Grasp onlythfi! plastic base when handling the bulb. Never
PUSH to
remove touch the glass envelope.
1. Disconnect the battery cable.
2. Disconnect the harness connector from the back side of the
bulb.
3. Turn the bulb retaining ring counterclockwise until it is free
from the headlamp reflector, and then remove it.
4. Pull off the rubber cap.
5. Remove the headlamp bulb carefully. Do not shake or
rotate the bulb when removing it.
6. Install in the reverse order of removal.
CAUTION:
• Do not leave the bulb out of the headlampreflector fOr a
long period of time as dust, moisture, smOke, etc. may
enter the headlamp body and affect the performance of the
headlamp. Thus, the headlamp bulb should not be removed
from the headlamp reflector until just bef.ore a replacement
bulb is to be installed.
Aiming Adjustment
When performing headlamp aiming adjustment, use an aiming
machine, aiming wall screen or headlamp tester. For operating
instructions of any aimer, it should be in good repair, calibrated
and used according to respective operation manuals supplied
with the unit.
If any aimer is .not available, aiming adjustment can be done as
follows:
For details, refer to the regulations in your own country.
CAUTION:
a. Keep all tires inflated to correct pressures.
b. Place vehicle and tester on one and same flat surface.
c. See that there is no-load in vehicle (coolant, engine oil
filled up to correct level and full fuel tank) other than the
driver (or equivalent weight placed in driver's position).
LOW BEAM
Left and right adjusting screw
1. Turn headlamp low beam on.
2. Use adjusting screws to perform aiming adjustment.
• First tighten the adjusting screw all the way and then make
adjustment by loosening the screw.
Lt,,,
(I 0
Up and down adjusting screw
if "'" SEL730R
El-49
HEADLAMP
Aiming Adjustment (Cont'd)
"H": Horizontal a. Adjust headlamps so that main axis of light is parallel to
center line center line of body and is aligned with point P shown in
of head lamps
illustration.
b. Figure to the left shows headlamp aiming pattern for driv-
ing on right side of road; for driving on left side of road,
aiming pattern is reversed.
c. Dotted lines in illustration show center of headlamp.
"H": Horizontal center line of headlamps
"WL": Distance between each headlamp center
"L": 5,000 mm (196.85 in)
"C": 65 mm (2.56 in)
Height of
Vertical centerline lamp centers
ahead of head lamps
~ = ACCEPTABLE RANGE
SEL2541
EL-50
EXTERIOR. LAMP
Clearal'lce.,lic::ense, Tail and Stop Lamps/Wiring

Diagram W
I-
<t
z z
Q) 0 o
0- H W " .a H
E
E
Q)
+.l
rn
0
L
:J
w
I-
<t
Z
H
-.J
H
<t
I-
0..
0
I-
00 W
o:~
00
Z
wo..
I-
<t
Z
H
-.J
H
<t
I-
0..
o
I-
00
Q) >. (I) I- U::E (I)
Q) +.l rn Q) L ::EI: <t H<t • .' III ::EI:
rn 0- 0 -.J -.J-.J
0- O' 0.. O'
0 >. +.l 0 'I- ucr: U-.J
L rn .e L
:J 0) :J +.l .cr: 0.. cr:o..
W +.l .r< W 0- <t::E <t::E
.e M Q) Q) w<t w<t
L 0) LM () 0- a:-.J a:-.J
0 .r< Q) OQ) X 0
'I- M E 'l-Ll Q) L
.r< 0 :J
M +.l Q) ME M W
>. Q) Q)
tWl
~~.~ ro Ll Ll Q) L
o -.J +.l Ll 00 0 0- 0
E >. E E 0 LL
ro +.l I: L
+.l Ll :J :J +.l -'>-
0 O-.J .......... 1Il
~ 0-
Q) .e .e
0 W 0-
Q) (!)(.!l
:r:; ()
X
+.l +.l I:Ll
.r< .r< 'C
I: L
0
0
X N E
-.J W ~ ~ cr:ro cr: LL W
>- ~-'
III ...............
(.!J (.!J(.!J
>-
a:
w
l-
,
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(I)
0.. >- rnrn

a: :J III ..... .r< rn
(.!J
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UJC
roL
.ero
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@
~mlm
--------- B ~II
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00
m
-:JU
G/W
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w
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C
Q)~
+.l
-:J M 0-
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• ro ,ro
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EUJ
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muw o
I: +.lC 00 0
(!) LLl
UJL
H cro Q)M ~~>-
-.J .!:j.c '1-0 ......................
m
~ ~.G/W Q)LL (.!J(.!J(.!J
w -' 5~
[I] ffiG/W
::E
H 0
1-1-
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<tz
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R U RN
a: .....
~ ~
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~
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(.!J (.!J (.!J (.!J-' (.!J
l8it8 ~J z
$ z
$
I:
0 0
U oU @p,! ,,?:i P=<1r; H H
I- zm
H C\J4:
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00 I-U
(I)m
Elm ffilj l-
<t
Z
H
(I)
W
U
Z
~
I-
<t
Z
H
(I)
(!) ::E <t 0.. ::E
.....4: OI: OI:
Z U a: ::E U
H LLU a: <t <t -.J
l- LLm w -.JI I-
I: I- -.J U
(!) 04: zo.. U 0..1- zo..
mO~ru O::E OH O::E
H
-.J ~ '[HD f'-ro ................. a:<t
LL-.J I-~ a:<t
LL-.J SELB04R
0000
El.-S.1
EXTERIOR LAMP
Clearance, License, Tall and Stop Lamps/Wiring
Diagram (Cont'd)
REAR COMBINATION REAR COMBINATION
LAMP R.H. LAMP L.H .
.Q
ro / "- / "-
0
E ...J eL eL ...J ...J eL eL ...J
"0 Ol
H 0 0 H H 0 0 H
L +J « f- f- « W « f- f- «
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W
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H
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OH 3- ,, ~/
0:« f-
LL...J CflCfl
FRONT COMBINATION LAMP L.H.
SEl805R
EL.52
EXTERIOR lAMP
Back-up lamp;and Back Buzzer/Wiring Diagram
REAR COMBINATION
LAMP R.H.
t FUSE BLOCK
(Refer tq "POWER
~
UP SUPPLY ROUTING".)
(Instrument
I harness)
[Refer S.M.J.
to last page
(Foldout page) .]
rn
@)~
~
..
-
@~
.o---r-l
RIB ---{], BACK
'---
G/W-[Y ~ BUZZER
(Chassis
harness) (Tai1
har ness) REAR COMBINATION
LAMP L.H.
III III
........(!) C!l ........
c: c:
0 . Buzzer can operate independently
of lighting switch position.
BACK-UP @ . Buzzer doesn't operate when
LAMP (Engine lightlngswltch "TURN ON- .
SWITCH harness) @~ @ NA engine
BODY @ TD engine
~l8=R~B GROUND
SEL806R
El-53
EXTERIOR LAMP
Back-up Lamp and Back Buzzer/Wiring Diagram
(Cont'd)
IGNITION SWITCH
ON or START REAR COMBINATION
LAMP R.H .
.~'B~-upl
t FUSE BLOCK
(Refer to "POWER r-- From lighting switch
UP SUPPLY ROUTING".) (Instrument LG/W ~ a:
I harness) G/W ---cI-----%--
,'Bf ~
U
, l-W
@'"
GJ ~8
, ZZ
~ @u~
B
[Refer S.M.0.
to last page ;:
(Foldout page) .] ~ BACK-UP
LAMP
BACK-UP ~ '" WR/B-o~
LAMP
SW=ITCH
~
.
@@
(Chassis-lll
rO-- harness) G/W -[}, ~ BACK
~ LQ- R~B
--------R/B RIB RIB-D' 'O-L.J BUZZER
(Tail
m':'B~-upl
harness)
@: 'Wide cab
@: Standard cab III
REAR COMBINATION
0 .. Buzzer can operate independently LAMP L.H.
of lighting switch position.
@ .. Buzzer doesn't operate when
lighting switch "TURN ON".
BODY
GROUND
SEL807R
EL-54
EXTERIOR LAMP
Front Fog ..Lamp/Wiring Diagram
FRONT FOG
@ L.H.D. model with c: LAMP SWITCH
standard cab o
R
.M
@ Except @ +'
co
c:
'M
E
::J
......
E
...... Ol
@m
~
t
UP
.M+'
00
0;>,
1-00
a: FUSE BLOCK
(Refer to "POWER
SUPPL Y ROUTING" .)
FRONT FOG
LAMP R.H.
(E) B 6=LJ!1Y
Ol
OJ
co~
Cl.'
+' Ol
OJ
...J
>'
~@)
(Instrument
harness)
@o@ lD
BODY
:r:
....J
0..
~~il
fl
LlJ
22
Oll.L..
~
>'
@)
GROUND
::;:
« fE~ ~ (Chass is
....J
(!) harness)
o
l.L..
I- B ~ BODY
Z
o @ J. GROUND
a:
l.L..
SEL808R
EL-55
EXTERIOR LAMP
Rear Fog Lamp/Wiring Diagram
REAR FOG
COMBINATION METER LAMP SWITCH LIGHTING SWITCH
REAR FOG
LAMP RELAY OFF 1ST 2ND
REAR FOG ABCABCA C
290---&--024 25
26
~
~
~ T T
~
,
>-
~
...1)-...J>-
~
.JO: 3
W W
0: 0:
lD
0: ""
a:a:era: "
0:3
lD'
(!)
,0:
3
0:'
3 0: ,
3
(!)
FUSE BLOCK
(Refer to "POWER
SUPPL Y ROUTING" .)
(Instrument
harness) lD lD
@)
aD
lD~
QU
S.M . .J.
[Refer
(Fo ldout
to last
page)
page
.J
@t1@
BODY GROUND
CD
QD
L.H.D.
R.H.D.
REAR FOG
model
model
@lD~ LAMP R.H. QD

(Chassis (Ta i 1
R6Y=9~
harness) harness)
I
REAR FOG
LAMP L.H. CD
lD R6Y=9~
@)@)
BODY
GROUND
SEL809R
EL-56
EXTERIOR LAMP
Turn Signal and' Hazard Warning Lamps/Wiring

Diagram
For Europe Z Z
0 0
H H
.g; l-
«
Z
H
I-
«
Z
H
!D !D
~ ::EI
0
::EI
0
0:. UO: U..J
llHD 0:0- 0:0-
3:Z «::E «::E
OH w« w«
0-1- O:..J O:..J
= ::J
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uoo:
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tl)0-
W'+-O-
ff)tl)::J Ui'
::J0:ff)
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.... ~
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W "
t!l
coco
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lD
I- 10A RIB t:;.e

I-
«
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I-
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8~~
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rii Vi
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ZO-
I-
ZO-
O::E O::E
0:« 0:«
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SEL810R
EL..57
EXTERtOR LAMP
Turn Signal and Hazard Warning Lamps/Wiring
Diagram (Cont'd)
Except for Europe
z z
o o
H H
f- f-
~ <l:
Z
Z
H H
OJ OJ
::EI ::EI
O. 0'
uC[ u-.J
C[=
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OH W<l: W<l:
O-f- C[-.J C[-.J ri ri
= :::J Q) Q)
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uOC[ 0 0
O+J E E
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OJL-.J
Q)O- 0 0
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cnQ):::J
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Q)
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LL~ ro a: -.J C[
>- '- ro riC
L '- ro
C[ C!J _rl C!J
W coco
f- 10A RIB t::..c
f-
~
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Q@
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W
f- . ~ . ~ UlUl
-rlUl
W
:r:t!t'.l
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C[ -.J - UlC
-'"
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o
H
f-
z
a:
~
z
a:
~
.cCO
~.c @ o
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B ------e::@---il'
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00
Z OC[
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Q)-
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LQ)
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CCO
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00
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W/R B~II OJ(!)
G/R -.J
G/B
@
ro a:
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C!J C!J
C
o z Z
-rl
o o
H H
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co <l: <l:
C Z Z
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OI OI
NH U. U.
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C[
f-
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f-Ul O::E O::E
c[<l: c[<l:
LL-.J LL-.J
SEL811R
EL-58
EXTERIOR LAMP mil
Turn Signal and Hazard Warning Lamps/Wiring
Diagram (Cont'd)
REAR COMBINATION REAR COMBINATION
.. ~ ..e
+J
-rl
~
LAMP R.H. LAMP L.H .
~
.a r1.Q
CI:: ro ro
Wt!J
3Z
o -gorcm
Ql
OH .a u Eu\dl
Qt--- ro L L
: oro'ro+J
='
~
UOCI:
0 u ou Q.
Ql C 'CQl
O+J uroIroo
-l >- .r! ~ "+.I X
CDL-l $:CfJ-lUlW
QlQ
W,+-Q
CfJQl='
='CI:UJ
LL~ OJ OJ a: a:
" OJ OJ" " OJ OJ"
>-
CI:
'" '" '" '"
W
t--- 10A RIB
t---
<{
CD
Ul
Ul
Ql
t--- OJ a: r1C o
ZH Z
""
"''''
-M
roro
t:...e
"-
B -C@--jl' @ >-='
00
85~ OCI:
~~.•c8
CDCfJ
CDC!l
::>:<{
O-l
ULL
UlUl
-rl Ul
OJ a: UlQl
CI:
W
~ ""
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Z
II'~"
t--- ..ero 0
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t---
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a: a: GIR
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CD
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l$@
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W/R
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J::I'11@8
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c;-u =' a:
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ffi "'"L
B
ZZt--- Z
CI:t!JH IT: S
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CD Ql
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W/R L
G/R ...J
ro
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LQl
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cro
tj.c
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C
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r1E
r1Ql
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CI:U
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u,
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Ul NH lJ.. CI:
0>- <{3 a t---
t---Ul IUJ /.--< CIJ(T} "fIXLD ZQ
0::>: ,---------~/
CI:<{
LL-l
FRONT COMBINATION
LAMP L.H. SEL812R
EL-59
EXTERIOR LAMP
Test lamp (27W) Combination Flasher Unit Check

,
,I,-' • Before checking, ensure that bulbs meet specifications.
• Connect a battery and test lamp to the combination flasher
unit, as shown. Combination flasher unit is properly func-
tioning if it blinks when power is supplied to the circuit.
Battery
SEL 122E
Bulb Specifications
Wattage
[1=23 ] mil
12V 12V 24V
Headlamp (Semi-sealed beam)
High/Low 60/55 60/55 75/70
Front combination lamp
Clearance 5 5 5
Turn 21 21 25
Front fog lamp - 23 25
Rear combination lamp
Stop/Tail 21/5 21/5 25/10

Turn 21 21 25
Back-up (Standard cab) 21 21 25
Back-up lamp (Wide cab) - - 25
License plate lamp 10 10 12
Rear fog lamp 21 - -
Interior lamp 10 10 .
10
EL-60
INTERIOR LAMP
Illumination/Wiring Diagram
COMBINATION METER
METER ILLUMINATION
380----&----042
a:: 220----&----021
W(!)
~Z
OH
D..~
: ::>
::.::
UOa:
0
[lHE] ~
0...,
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CD L...J
Q)D..
W'+-D..
UlQ)::>
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>-
a:
w
~
LL-
R F
B
B
I:~
o
II@
o
II \::J
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0
a:
(!)
>-
0
~ 0
CD
<l: R H
CD
g~w
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0
H
~
<l:
I >-Z
<l:H
G/W::::EEl
EE3==(ID
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w 8 a:::E:
1-::>
I...J
Ul Ul...J
~Ul~ ,,(>1 Ul <l:H
~G~W ll.. Q)
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O~ ..-1CUPl'Oif C
a:<l: L
LL...J co
L
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c:
Q)
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HZ
ZZ
00
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000
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Q) <l:<l:
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0 ...J 0.
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C\J<l:
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..., 0. 0 0.
00 I-U >- 0 '+- 0
(/)lll
(!) ....<l:
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0)
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H lJ...U
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Q) co
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0)
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0. L 0 L rl
I a<t .rl Q) o 0 X 0
(!) rl E L '+- Q) '+- 0)
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lCl<D t"-lD m~:::~ Q) ....,
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W rl rl rl
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L
Q)
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lJ...I ~ ~ LL W a: a: ...J W ~
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a:
SEL813R
EL-61
INTERIOR LAMP
Interior Lamp/Wiring Diagram
t
UP
FUSE BLOCK
(Refer to "POWER
a: a:
SUPPL Y ROUTING" .)
I "-
INTERIOR LAMP
F-o~HIO
DOOR SWITCH
'" (Instrument harness) (Room lamp harness)
([) F23 mode1

@ H41 model
SEL814R
EL-62
METER AND GAUGES
Combination Meter
o o
\\1111,
,\
........2 3" ,
....
' 1 X1000r/min 4""
o
~8 = 0 0 5\ o
~lBBBB68:~
o 1 ~ @J~@)OO~CK)~~
o DDDo~orn
@ : Diesel engine model

~ : For Middle East
22 38 14 17 24 31 34 36 41 Dropping 13
res istor (24V)
a:
0
(fJ
z
w
(fJ
C!l
0 C!l Z
z z W W Z H
0
H
I--
0
H
I--
:r: :r: C!l
0
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«
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W
Q.
(fJ
H
Z
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a:
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a:
w I--
« «
-.J a: IL a: « a:~
«:E 3: I-- -.J @
lD
z z z z a: W W 3: W a:w W
a:
H H
a: a: « :r: lD -.J a: :::Ea: :::E WC!l W @ lD
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::J ::J I-- I-- a: W :r: H WN ::IN :r: «« a: 3: :>:: -.J I-- I--
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Q.
a: ::J W
(fJ
H
H H :r: > (fJlD >lD I-- 0 U C!l lD IL IL
21 42 16 29 33 35 39 19 20 27 8 3023 12 3 28 2 10 25 9 2618
SEL815R
EL-63
METER AND GAUGES
Tachometer, Temp. and Fuel Gauges/Wiring

Diagram
l"l
C\J
'>
'<l"
0
l"l
0: ~ TEMP.
W O)L
I- co
W .....
+'
::E 0.00
0.."" (Xl
Z 000
o LQ)
H
OL (;\~
I-
<1
Z :~'IOffi
H
co
::E
o
B ~II @ro
......
0
U co
+'
c
Q)~
EOO
:JOO
LQ)
+'C
OOL
crn
Q)
0)
~.c
rn,..,
0.'
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000)
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3: 3:'"
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>- <!l<!l
...L..J @
"J .....0.
::ED+'
. +' :J
0:= C/) 0
<!l <!l W(!) Ll:l
3:Z Q) .....
OH '1-0
0..1- Q)lJ...
= ::J 15-
;x:
uoo:
0 o
O+' r5
-l
COL-l
Q)o..
r
@
CT") 00
(...) 00:
COc.!l
W'l-o.. 00
C/)Q)::J 00
::JO:C/) Q)
lJ...- C
L
rn
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I .....00
U 00 0:
I- 00 W
H rn l-
3:1- .c I-
C/)O:
<1 ~ -lH
<1::E
ZI- ::EC/)
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H
I-L
W<1
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1-1-
Z
(!)Z
HO
0..
0: '- Z
L 0 co o
Q)
H
+'
Q)
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e=o
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0 Z-lO
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(!»Z
Q) Q) 0
l:l l:l rn .....c .....c .....c .....c '- '-
c.!l (!) ZWW
WO:(I)
0 0 +' 0) 0) 0) O)-l -l E
E E C C C o 0:
.c Q) Q) Q) o W
(Y] .... .....
+' o~~~
co co L~ l-
I-
C\J '<l" <1 0 0 00
lJ...I 3: Z I- co lJ... Q)OO -lH
cQ) <1::E
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O)L
Y/W-[]~I' ::E(I)
O:Z
crn W<1
(9@@@@~@;'" C\J
!:!:!.c Ia:
1-1-
SEL816R
EL-64
METER AND GAUGES
Inspection/Fuel Gauge and Water Temperature

Gauge
o INSPECTION START
Q 0 0 0
o
CHECK POWER SOURCE. N.G. Check the following

o
1) Turn ignition switch "ON". items.
2) Check voltage between terminal @ 1) Harness continuity
and ground. between battery termi-
~@ r;;1t1=t=t=I=I;:::::;::I=I;;l1l BaUery voltage should exist.
O.K.
nal and combination
meter
is ~
2) Ignition relay
3) Fusible link and fuse
4) Ignition switch
Voltmeter
CHECK GAUGE OPERATION. N.G. Repair or replace gauge.

SEL731R 1) Turn ignition switch "ON".
2) Connect terminals CID (Fuel), ~
(Temp.) and ground with wire for
less than 10 seconds.
3) Check operation of gauge.
Gauge should move smoothly to fult
scale.
OX
-
@ : Fuel gauge Check harness continuity between com- N.G. Repair or replace.
@ : Water temperature gauge
SEL732R ponent and combination meter <ID (~).
O.K.
o CHECK COMPONENT. N.G. Repair or replace.

o 0 o 0
o Check gauge units and harness. Refer to FE section. (Fuel
Refer to "Fuel Tank Gauge Unit Check" tank gauge unit)
and "Thermal Transmitter Check".
O.K.
Reinstall any part removed.
INSPECTION END
@,@ + -
@ : Fuel gauge
@ : Water temperature gauge
SEL733R
EL-65
METER AND GAUGES
Fuel Tank Gauge Unit Check

• For removal, refer to FE section.
Check the resistance between terminals (G) and (E).
Resistance value
Ohmmeter Float position mm (in)
(Q)
(+) H F23 H41 F23 H41
52 60 Approx. Approx.
*3 Full
(2.05) (2.36) 5-7 4-6
147.5 176
G E *2 1/2 30 - 36 30 -36
(5.81) (6.93)
243 304.5
*1 Empty 80 - 90 80-90
(9.57) (11.99)
*1 and *3: When float rod is in contact with stopper.
Empty
SEL734R
Fuel Warning Lamp Sensor Check

• It will take a short time for the bulb to light.
Test lamp
3AW ON
Test
lamp
3.4W
OFF
Sensor
Battery
SEL735R
Thermal Transmitter Check

Check the resistance between the terminals of thermal trans-
Ohmmeter mitter and body ground.
~I
Water temperature Resistance
60e (140°F)
0
Approx. 70 - 90n
100 e (212°F)
0
Approx. 21 - 24n
SEL233P
EL-66
METER AND GAUGES
Ohmmeter
on Pressure Switch Check
Check the continuity between the terminals of oil pressure
switch and body ground.
Oil pressure
Continuity
kPa (bar,kg/cm2, psi)
More than 10 - 20 (0.10 - 0.20,

Engine start NO
0.1 - 0.2, 1.4 - 2.8)
Less than 10 - 20 (0.10 - 0.20,

Engine stop YES
0.1 - 0.2, 1.4 - 2.8)
Speedometer Cable Removal and Installation
.. PUSH
TO CONNECT
After disconnecting speedometer cable end from transaxle,
push speedometer cable so that combination meter is pushed
into passenger compartment. Disconnect speedometer cable
end from combination meter as shown in the figure at left.
~
PRESS "
TO DISCONNECT SEL4168
Vehicle Speed Sensor Signal Check

• A vehicle speed sensor is built into the speedometer.
1. Turn speedometer slowly using a small screwdriver.
2. Check continuity of vehicle speed sensor circuit.
Continuity exists two times for each turn ... O.K.
[I
~-
Rt=~
~@
Ohmmeter
~
SEL736R
EL-67
WARNING LAMPS AND BUZZER
Warning Lamps/Schematic
SEAT BELT
SEAT BELT
I' TIMER AND
BUZZER
FILTER FUEL
= FILTER
0 I'
SENSOR
0
BULB
CHECK
RELAY@
I
u W
I- 00
H ::J
3:1- lJ..
OOCI CHARGE
<l:
Zl-
000 I' ALTERNATOR
H
I-L
HO
Z
t!lZ
HO G
0 0
w
00
::J
lJ..
AUTOMATIC
CHOKE RELAY @
FUEL
I'
FUEL TANK
GAUGE UNIT @
OIL
I OIL PRESSURE
• SWITCH
...,
(/)
co
PARKING BRAKE
I' SWITCH
w
Q)
.....
1J
1J
-rl BRAKE VACUUM
Q)
:::>: ..., SWITCH
C 1J (/)
Q) -rl C co
c 0) co W BRAKE
-rl
0)
C
Q) Q) Q)
BRAKE FLUID
..... ..... c c. ..... I' LEVEL SWITCH
Q) llJ llJ Q) 0 1J
1J 1J C L 1J
0 0 ..... -rl ;:J -rl
E E Q) ..... w :::>:
(/) 0
(Y) <rl Q) (/) L L
C\J "<T -rl co 0 0
lJ.. I 0 t!l lJ.. lJ..
SEL817R
EL-68
Warning Lamps/Wiring Diagram
IT:
W(!)
3:Z
OH
Q.I-
I : ::l
U ::<: 0
I- UOIT
H 0....,
3:1- -l >-
en IT CDL-l
« VQ.
ZI- W .....
Q.
oen enV::l
H ::lITen
I-L lJ...-
HO
Z
(!)Z
HO
>-:Jt cr: :Jt cr:

.....................
CO ..............
mm:Jt m:Jt
TON A
(.!l cr: :Jt

(j) CO, OJ ........ ........
lIJ ...J :Jt OJ
V
I';'
TO
e
--•
L
ro
I
CHARGE Q .c
C'l lIJ
.rl
lIJ
lIJ
FILTER@ ro
IT 10 .c
W
(IJ
2
l-
iel'
II'~
W S
::E S.M.J.
Z SEAT [Refer to last page
0
BELT@) (Foldout page) .J
H
C'l
I- ..... (J)
« B 016 B
Z
H c L/G 1313 L/G c
CD BRAKE ....a/w Fe B/W ....
::E ~ W/R A14 W/R
i
0 Y/B Al1 Y/B
U
Y/W
OIL
~
0
B/W @ @ m m cr:
Y/B ..... ..... .....
>- >- :Jt
lIJ
lIJ
V
e
L
ro
.c
...., m
..... OJ
..... cr:
.....
e >- >-:Jt
v
H
(!) E E
::J o
a
L
...., L~
~WQ~
::<:::<:.1-.
IT«H =. D-B/W lIJ lIJ
«IT 3: e VlIJ
ev
Q.CDen !:! C
.r-l
I' O)L
em OJ
!!:!..c .....
>-
6
v v
v
c.
~.~
[]J
1._. @~
:l:::~~
e e 0
.rl .rl L aJ~ffi •.•...
::J
~, IT
0) 0)
e e W I-WN . o
v v «::EN I-
«
0
I-
«
Z
L
0
lJ...
WH::l
enl-CD
v o
CD
IT
::lI
enu
en I-
Z
IT
W
-lWH I-
HIT3: -l
OQ.(/) «
@@@)
SEL818R
EL-69
DIll
~ ~-----_...!~~~~~~;A~N~D~.B~U~Z~Z~E1Rira;ira;T;"i([Cc:co:nntr
WARNING LAMPS
Warning Lamps
IWiring Diagram
0:=
Wl!J
3:Z
OH
CLI-
= :J
::<: 0
U 00: ::<:>-
(J)u<t
3+'>- ...JW...J
t
(J)L...J :JIW
l;
lllCL
W'+-CL :::EI
cnlll:J CL W:JU 0:
:JO:cn :J ::<::JI- o
lL- <tUH I-
0:<t3: <t
(J»cn Z
0:
I' W
I-
...J 0
rrr9l <t Z
~~f@3:
'-
m
Cl
~
3:
Cl
(l)
WO...JU
::<:HWI- I~
<t:J>H
O:...JW3:
rn= B/W
B
(J)lL...Jcn
0:
+' o
en I-
cu <t
r; W Z
III 0:
"0 III III :::EI W
o C III H W:JU I-
E ..... C "0 ::<::JI- ...J
..... "0
<tUH <t
OJ
g>i 0:<t3:
~ ~ III L
(J»CIJ
:r; 0 o 0
...J (J) lL lL
SEL819R
EL-70
WARNING lAMPS AND BUZZER
VACUUM WARNING Warning Buzzer/Wiring. Diagram
COMBINATION METER
VACUUM WARNING BUZZER
1o-i~~13 IGNITION SWITCH

ON or START
ffiHE] ~
VACUUM BUZZER
CANCEL RELAY
~. ~:;:J
VACUUM
SWITCH
G 10A
~[c}-Y/R .
PARKING FUSE BLOCK

BRAKE (Refer to "POWER
SWITCH SUPPLY ROUTING" .)
~[c}-B/R
SEL822R
120 KM/H SPEED WARNING
COMBINATION METER
SPEED VEHICLE
WARNING SPEED
IGNITION SWITCH BUZZER SENSOR
e:::
ON or START
41~
t
UP
FUSE BLOCK
(Refer to "POWER
t!l SUPPL Y ROUTI NG" .)
(Instrument harness)
III III
@@
BODY
GROUND
SEL821R
EL-71
Warning Buzzer/Wiring Diagram (Cont'd)
LIGHT AND SEAT BELT WARNING
LIGHTING SWITCH COMBINATION METER
IGNITION SWITCH
5 ON Dr START SEAT BELT
6
7 13 o----@--o 9
B
g=ElB
9 2
10 11
11
•
12
t
~ UP
c::o:IfIJ
~ a:
I a: a: (!) (!) FUSE
(Refer
BLOCK
to "POWER
SEAT BELT J(!) LJj:C IL y:c IL SUPPLY ROUTING" .)
TIMER AND
BUZZER
4:IG~W ~
[] .
7 2
B 3
BIG
Y~W
Y
(Instrument harness)
tttE EEEI= ~ (!)

"-
<D
~ (f) F23 mode 1
SEAT BELT SWITCH @ H41 mode 1
@M@
<D <D
BODY GROUND DOOR

SWITCH
SEL820R
EL-72
Diode Check
• Check continuity using an ohmmeter.
• Diode is functioning properly if test results are as shown in
the figure at left.
SEL901F
Vacuum Warning Buzzer Check
Vacuum warning
buzzer
BATTERY
SEL737R
Test lamp 3.4W Seat Belt Timer and Buzzer Check

Seat belt warning
Connect as shown in the figure at left.
@ ... Test lamp comes on about 6 seconds and buzzer oper-
ates.
@ and CID ... Test lamp comes on about 6 seconds.
Battery SEL738R
Light warning
• Connect as shown in the figure at left.
• If buzzer sounds when connected to terminal ([) and bat-
tery ground, seat belt timer and buzzer is normal.
Battery
SEL739R
EL-73
WIPER AND WASHER
Front Wiper and Washer/Wiring Diagram

L.H. model
FRONT WIPER AND

WASHER SWITCH
,"'13- OFF0 INT LO HI WASH
14 0 0
15
16 0
17 0 0 0
18
IGNITION SWITCH
ACC or ON
(Instrument
harness)
F L/R 15A
a: CD
"
...J...J
15A
FUSE BLOCK
(Refer to "POWER
CD CD
FRONT WIPER
WASHER AMPLIFIER
MOTOR
F23 model
H41 'model
@@
BODY GROUND FRONT WIPER MOTOR
SEL823R
EL-74
WIPER AND WASHER
Front Wiper and Washer/Wiring Diagram
(Conrd)
R.H. model
FRONT WIPER AND

WASHER SWITCH
"'- (ff INT LO HI WASH
13 0
14 0 0
15
16 1 1 1 15
17 0 0 0 14 1
18 0
• IGNITION SWITCH
ACC or ON
3>- <D
................JlIlOC ....... (Instrument
--'<!l --'
harness)
F L/R 15A
a:<D
""--'
--' 15A
FUSE BLOCK
(Refer to "POWER
<D <D
FRONT WIPER
WASHER AMPLIFIER
MOTOR F23 model
H41 model
@@
BODY GROUND FRONT WIPER MOTOR
SELB24R
EL..75
WIPER AND WASHER
Headlamp Washer/Wiring Diagram
IGNITION SWITCH
ACC or ON
HEADLAMP
WASHER
SWITCH
~Ed=tj~-l-_-L/R 15A
(Instrument
harness)
FUSE BLOCK
S.M.J.
[Refer to
(Fo ldout
last
@~
page
page) .]
W
•
~
lL.
(Refer to "POWER
SUPPLY ROUTING".)
@~
HEADLAMP
WASHER RELAY
(Chass is harness) (Sub-harness)
r----- W:L CD, LD W:L

'------If----- LIB =S!1 ~ LIB
@)
a:
3:: 3::'-
3::
HEADLAMP
~ WASHER MOTOR
~ III
U =8~
G
!~ FUSIBLE
LINK
@)
~
BODY GROUND
SEL830R
EL-76
WIPER AND WASHER
Wiper Removal and Installation

• Before removal, turn wiper sWitch OFF.
c:::::c ====~====~~
@
I Spacer
~ ~ Seal rubber
~~-~---~ \)
i0- ~
, -&}
,~'>b '-~
Wiper link
SEL741R
REMOVAL
1. Remove wiper arm.
2. Remove lock nut, spacer and seal rubber.
3. Remove instrument assembly. (Refer to "Instrument
Assembly" in BF section.)
4. Remove left and right front deflector ducts and side vent
ducts. (Refer to "Heater" in HA section.)
5. Using a screwdriver, pry off Wiper link from motor arm.
CAUTION:
Be careful not to deform wiper link during removal.
6. Remove wiper motor-to-amplifier harness connector.
7. Remove bolts securing motor bracket.
8. Remove motor arm.
9. Remove wiper motor from bracket.
10. Remove wiper amplifier from bracket.
11. Remove wiper link.
INSTAllATION
To install, reverse the above removal procedures. Be sure to
adjust wiper arm after installation.
El-11
WIPER AND WASHER
Wiper Removal and Installation (Cont'd)
Wiper .link
SEL744R
Adjustment
1. Prior to wiper arm installation, turn on wiper switch to oper-
ate wiper motor and then turn it "OFF" (Auto Stop).
2. Lift the blade up and then set it down onto glass surface to
set the blade center to clearance "C" or "0" immediately
before tightening nut.
3. Eject washer fluid. Turn on wiper switch to operate wiper
motor and then turn it "OFF".
4. Ensure that wiper blades stop within clearance "C" or "0".
Standard cab Wide cab
lie" mm (in) 45 - 55 (1.77 - 2.17) 55 - 65 (2.17 - 2.56)
liD" mm (in) 45 - 55 (1.77 - 2.17) 55 - 65 (2.17 - 2.56)
• Tighten windshield wiper arm nuts to specified torque.

tD.J: 17 - 23 N'm (1.7 - 2.3 kg-m, 12 - 17 ft-Ib)
L.H.O. models R.H.O. models
'5 '6 '5

All the diameters of these
circles are less than 60 (2.36)
'7 'S 'S '7
Standard cab Wide cab
*1: 265 (10.43) *1: 280 (11.02)

*2: 245 (9.65) *2: 250 (9.84) Clearance "C" ~~
*3: 260 (10.24) *3: 310 (12.20) h (Driver's side) ~ @
*4: 235 (9.25) *4: 275 (10.83) ---~
*5: 140 (5.51) *5: 263 (10.35)
\.:- i _'
-===~i?-'~J
*6: 125 {4.92) *6: 252 (9.92) ~
*7: 345 (13.58) *7: 495 (19.49) Clearance "0"
*8: 310 (12.20) *8: 514 (20.24) (Passenger side)
Unit: mm (in)
SEL740R
EL-78
WIPERANO.WASHER
Adjustment (Cont'd)
• Before reinstalling wiper arm, clean up the pivot area as
illustrated. This will reduce possibility of wiper arm loose-
ness.
SEL024J
Washer Nozzle Adjustment

,Suitable tool
• Adjust washer nozzle with suitable tool as shown in the
figure at left.
Max. adjustable range: 10°
Nozzle hole bore diameter

0.8 mm (0.031 In)
SEL745R
Check Valve
• A check valve is provided in the washer fluid line. Be care-
ful not to connect check valve to washer tube in the wrong
From
reservoir
tank
..0
c~ ,.m. ,fo To
nozzle
direction.
0"
SEL411H
Wiper Amplifier Check

1. Connect as shown in the figure at left.
2. If test lamp comes on when connected to terminal <ID and
battery ground, wiper amplifier is normal.
BATIERY
SEL746R
El.-79
WIPER AND WASHER
Washer Tube Layout

Front washer
SEL747R
Headlamp washer
Headlamp
washer tank
Headlamp
washer nozzle
SEL748R
EL-80
HORN, CIGARETTE LIGHTER, CLOCK
Wiring Diagram
HORN
RELAY
t
UP
FUSE BLOCK
II-----1L-J
<!l ~ al ~
........0...... ~ :J (Refer to "POWER
r
SUPPL Y ROUT ING" .)
[ReferSt~'~ast page all
HORN (Fo ldout page) .]
11'-1 gcg~~AL
rrolD-
vy
G ~ G G G
(Chass is
harness)
'C6'
~
I"Jij\
~
<!l
"-
al
(Instrument
harness)
1Il..J
T~~
al al
HORN
SWITCH
CIGARETTE
@@
LIGHTER BODY GROUND SEl831R
HORN
RELAY
I
[[=
W(!)
~z
OH
0..1-
= =:!
:::<: 0
UO[[
O+J
....J
CDL....J
>- t
UP
(~f:'i;i"i~
QlQ.
S.M.oJ. ~ W'l-Q.
(J)Ql=:!
[Refer to last page
cyo- ,
~<!l~ =:![[(J)
HORN HIGH IJ..-
DIGITAL
CLOCK
HORN LOW
<!l
(Instrument
harness)
1'~~
rroo-
"-
al
al..J
vy -=-
(Chassis
harness)
HORN al III
SWITCH
CIGARETTE
@@
M
LIGHTER BODY GROUND SEL832R
EL-81
AUDIO
Wiring Diagram
With Cassette Player (12V)
(Sub-harness)
W/R
;,1I:~---------:::I
DR/L
W/L
W/R
DR/Y
B/W
OR
DR/Y
B/W
OR
o
H
o
«
0:
I
W/L
DRIL
0:
DRIB
(Not used) «
W
>-
«
o WIG Ul
Ul II
Z
Z
W
Q)
01-
..J C OZ
0.. LIB L 0:«
R/W m
W L:
l- I
I-
t;/EL t;/ELII~~~
.0
I
W ::J
(f)
(f)
DRIB DRIB R/W
~
« OR 0
u
LIB --------- LIB BR
----t-----
1
R/W --------- R/W G/W
'-------' WIG WIG
D
Q)
Ul
::J
+-'
o
b
D
Q)
Ul
::J
+-'
rl ..... o
Q) Q) Z
D D
0 0 ..... .....
E E Q) Q)
D D
0 0
0 0 E E
I I CD ....
..J 0:
C\J
l.L..
'<t
I
+-'
c
Q)~
@ ~~
EUl
::JUl
LQ)
B~llffi
Q)@@@ +-'C
UlL
cm B ~II>-
o
!:::,-L:
@ 16
0:,
3: Q)@ >->- Q)@
0: "
!DO:
~@@ E
Q)
+-'
~@@
Ul
~~ ;>,
Ul
~ ~
10A BR F 3:
I C!l>-
0:, I
I
0:
0:
c
0
-.-1
"
!DO:
..J
U +-'
I- Ul Ul
H Ul m Ul
3: Q) c Q)
-.-1
(f) C C
Z L E L
ZO 10A BR H m ::J
..... m
0 L:
HL
..... L:
1-0 ~ 3:
L -.-1
C!l>-
L
H 0:, 0 0
zu 0:=
W(!)
0: 0
9
0
I- "
!DO:
9
0
.~
(!)u
H«
::.:::
3:Z
OH
0..1-
= ~
0
6J 6J
~!~!
uoo: 0: 0:
O+-' W W
..J >- ::.:::
CDL..J
Q)o..
W'l-o..
(f)Q)~
~O:(f)
l.L..~
OI OI
O' O'
00: O..J
SEL833R
EL-82
AUDIO
Wiring .Diagram(Cont'd}
With Cassette Player (24V)
W/Gj}
E~~ Ici'R';W Y
G/WI
BRB'Y. 0 o
(Sub-harness) H
OR • o
DRIB R/W R/W «
OR/L R/Y R/Y a:
'g~
W/L B/Y B/Y
W/R . R R
a: (Not used)
w (jj' «
>- Ul
2w
«
OC Q) 11
-.J e ot-
Q. L
rn oz
R/W
.c: a:«
.
~ ~~
W
t- I
t-
W ~~~E ~~E~ r--.==R
m- B/Y .Q
:J
g
[!2
~ ~
~~
BR =-ED
D. • BR/Y
B~IY~
~~;=- -=-=--=-=~--=-=~-t=--=-=--=-=--=-=--=-=---=~;!JG/W -
RESISTOR
I
~~~=8J w=Eh
rl rl
Q) Q)
-0 -0
a a
E E
0 0
I I
-.J a: +J
e
Q)-
@ ~
-ym-+ ffi
EUl ::J
:JUl B
Q@ LQ)
+Je
UlL
ern B ~I'>-
o
::;.c:
@~
E
Q)
+J
Ul
>-
Ul
a:~ I I
a: e
a: a -.J
I .rl
U +J
t- Ul Ul
Ul rn Ul
H
3: Q) e Q)
.rl
(J) e e
L E L
Z :J
ZO 10A BR rn rn
o .c: rl
rl
.c:
HL .rl
t-o L L
H a a a
zu a:" a a
(')u w(') 9 t-
9
H« 3:Z
OH
Q.t-
" ::J
6J 6J
~.!~.!
::<: 0
uoa:
O+J
-.J >-
OJL-.J
Q)Q.
W,+-Q.
(J)Q)::J
::Ja:(J)
LL~
OI OI
O' O'
oa: 0-1
SEL834R
EL-83
AUDIO
Without Cassette Player (12V)
«
Z
I' i1:i
01-
oz
([«
I
B~Y
o R/Y .:><:
R/W 0
H
Ol
o [J
.:><: "0
«
([
G/B 0
B Ol Ol
BR "0 +J
+J
G/W Ol Ol
rl rl +J [J)
Ol Ol +J [J)
en
[J)
"0
0
E
"0
0
E
rl
Ol
rl
Ol
Ol rn
[J) 0
[J)
Ol "0 "0 rn +J
Ie 0 0 0 ::J
W DL
l- ::Jrn
0 0 E E 0
B
.... .c.+J .c.
*
I- f:!!..c.
BR r r (Y) +J
'<t ..... .....
W
(f)::it. [J G/W C\J
(f)U -.J ([ lJ... r 3: 3:
«w
uo
Q@@@~~
~rr
......................
0:
« a:a:ID
z ( C 0 )
z +J
e
W
01- Ol~
oz
([«
E[J)
::J[J)
LOl
~~~
+Je
I' [J)L
ern
tj.c.
t I @~
o R/W 0
H
o
« • B
L
([
B z--J B~II~
BR
G/W B ~II>-
RIB .[)
@~
"0 E
Ol Ol
[J) +J ~ Q @ rr Q @
::J [J)
>-
[J)
a:,
a: . . .. "
IDa: .. . .
+J
0
z e
.....0
~@@ ~@@
+J 1Ij1il ~ 1Ij1il
rn ~
a:,~
c <.!lr
o BR <D- .....
E a: r "IDa: r
r ::J ([ -.J
U rl
I- rl
H ..... [J)
[J)
[J)
[J)
3: Ol Ol
(f) 0
I- e e
Z L L
zo 10A BR @- rn rn
o .c. .c.
HL
1-0
H
~ a:,~ L <.!lr L
ZU
(!)U
([=
W(!)
a: 0
0 "
IDa: 0
0
H« 3:Z
OH
a. I-
=
::it.
::)
0
6J 9
6J 9
UO([
! !
O+J
-.J >- ([
.. g; lD L-.J
Ola.
([
W
::it.
W
::it.
w ..... a. « «
(f)Ol::) w W
::)([(f) a. a.
lJ...- (f) (f)
([ ([
or or
o. O.
0([ O-.J
SEL835R
EL-84
AUDIO
Without Cassette Player (24V)
0:
W
I-
0:
W
>
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o
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SEL836R
EI..-85
AUDIO AND POWER ANTENNA
Antenna Trimmer Adjustment (Mechanical

tuning type)
The antenna trimmer should be adjusted in the following cases.
• Fading and weak MW (AM) reception.
• After installation of new antenna, feeder cable or radio
receiver.
Before adjusting, be sure to check harness and antenna feeder
cable connectors for proper connection.
1. Extend antenna completely.
2. Turn radio on, and turn volume control to increase speaker
volume.
3. Tune in the weakest station (barely audible) on dial at the
range around 14 (1,400 kHz).
4. Turn antenna trimmer to left or right slowly, and set it in the
position where reception is strongest.
CAUTION:
Do not turn antenna trimmer more than one-half turn.
Location of Antenna
SEL749R
EL-86
AUDIO AND; POWER ANTENNA
NOTE
EL-87
LOCATION OF ELECTRICAL UNITS
Engine Compartment
Qi
-0
ro Q)
c:
0
~
co '0> E
c: (Y)
-0 OJ C'l
(5 Qi
u 0 -0 !:!:.
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c: ~
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SEL837R
EL-88
LOCATION OF ELECTRICAL UNITS
Passenger Compartment
L.H. model
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Q)
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iii
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Cll
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U 16' ::J ~ ::J
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as
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0
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co := I
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LL iii (j) a:
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u
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SEL838R
EL.89
lOCATION OF ELECTRICAL UNITS
Passenger Compartment (Cont'd)
R.H. model
:u
Ea;-
".j:i c.
+-,0
«5::;
.ow
+-' ...
ctl 0
Olu.
Cfl_
a;-
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15
C
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Ol
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SEL839R
El-90
LOCATION OFE.LECTRICAL UNITS
Rear Body
~1
~I
'--------- I
----- I
SEL840R
EL-91
HARNESS LAYOUT
L.H. model Outline
Engine room harness (TO engine)
Room lamp harness
Door harness R. H.
Instrument harness
SEL841R
R.H. model
Engine room harness (TO engine)

Tail harness
Door harness R. H.
Door harness L. H.
SEL842R
EL-92
HARNESS L:.AYOUT
...OuHine (Cont'd)
LH. model
Engine room harness (FD engine)
Engine room harness (SD engine)
Room lamp harness
Tail harness
(Standard cab) SEL843R
R.H. modEi,
SEL844R
HARNESS LAYOUT
Instrument Harness
...
L.H. model
EL-94
HARNESS LAYOUT
Instrument Harness (Cont'd)
Qi "E
:0- "0 ro
.s:::. ro 0 ""C
c:
~ro
~ :0-
0 E .!!! w
(J) (J) Q;
al ro "0 ;: 00 (J) .,.;
Qi 0 N
c: .~ J: .;; '5 I!! N
'51
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c: E ro .;; 0. ~
(J) "0
c: .~ 0(J) Qi
Cl
c:.s:::. E~
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c:
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00
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SEl845R
EL-95
R.H. model
"0
c:
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ill
EL-96
MARNESS1 ..AYOUT
Instrument Harness (Cont'd)
1)
ttl al
Q) Q) (J .os:.
C
05 C
05 "E
~
.c
C C ttl
al "0 Ol
al C,J::;
C 0- ....(J
al Q) (ii .os:.
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C
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gj al '"'"alC E .J
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,It;
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(ii
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w
:J
~
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al ,J::; :E- ~ E
(ii O> :i 0
~ "0
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(ij .J 0 ;0
I
:i C !:!:.
:J
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al "0
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SEL846R
EI:::-97
HARNESS LAYOUT
Engine Room Harness

NA engine
SEL847R
Elo.98
HARNESS LAYOUT
Engine RbomHarness (Conl'd)
TO engine
.>It.
~
@@@~
"" C\l C\l
(.) (.) (.) .0
000
"1ij
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.~
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c:
I-I-I-U- "c.
c-
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o
SEL848R
EL-99
HARNESS LAYOUT
Engine Room.Harness (Cont'd)
BD engine
SEL849R
EL-100
HAFlNESSLAY0QT"
Engine Room Harness (Cont'd)
FD engine
,,/ '-
ljle
<5
Ul',
c:
Ql
C:", ,,00
Ql .... ;
J:: J:: 00 ~
.B
"~
Ci .8
E
~
"~
al
c:
:8:J "E
Ql
:=: :J ...
,to
00 00 00 Q;
1ii c:
~ Ol
c: ~
:J
Ql
J:: 0
(5
> jg
0.
E
0 :J
00 "c 00
00
00 ~ 2
Qj
@@@ ...1ii ~ ~
0 0 0
c:
Q;
00
0.
0
(ij
3: l!!
0. .2
Ul
0
~
0.
Ql
c: E c:
lii
E "0, Q; "0,
0 c: J:: c:
Ql
l- I- I- ~ <5 !:!:. <5 !:!:. () W I- W
SEL850R
EL-101
HARNESS LAYOUT
Chassis Harness
EL-102
HARNESS LAYOUT
Cha.ssis Harness. (Cont'd)
c
o
:s
j
(I)
c
'o.=:
c c
[I
'8
l5
15
~ ~
£ L...__ ~ .J
SEL851R
EL~103
EL.104
HARNESSI ..AYOUT
Chassis Harness (Cont'd)
..
Q) Q) Q)
c: c: c:
'5 OJ '5 '5
c: > c: c
OJ tii :0- OJ OJ
>
0
~ u Q)
u '"
OJ >-
Q) 0;,"0'
c: Q) ~' !bi
Q) .<: OJ ~ c: "0
'" '5 c: in
~ c: '5
'" '"'"
Q) at Ql c: > c: '5
c: c: c: '5 ~;;: c: tii Cl c: ~ OJ c: OJ OJ
> '5 0 OJ c:
'5 '01> '5> c:
c: c: c: OJ
'" E "0 E 0 >- u'"
OJ
~ .!b. .<:~ .<:
0 (;;
OJ OJ
0 0 c !b.
(])
0 E .!!! '0 OJ fQ.
c: -'t:. '"
~ -'t:.OJ Q) .!!!.
>- I
.c .c
I
!b. !:!::- \!::.

::l
::l
Cl OJ
c: eQ; Q; e
c:
'5
'r:: '0 .c 1il 1il .c c: l!!' ~
~ ::l ::l
"0 ~ '" '"
~ > '" >- >-
@@@
0 0 0
E
~
OJ
'"
::l
'5
-'t:.
e 0 g
't5 OJ OJ 't5 OJ
OJ ~ c:i ::l .<: .<: ::l ~iOJ'
'"
.<: Qi Qi .<:C£.<: '"
'" .~
Q;
t ~'" ~'"
0 0
l- I- I- <{ Z III
)(
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::l )(
W ~ c75 l- I-
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U
~.~
U
N N;~
uu:u,
... ~
U
N
U
M
0
M
0
Qi
"0
o
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1Z
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c:
(;;
.<:
"0'
c: .c
::l ::l
eClU'"
'-
c:~<{
000
J: III I-
SEL853R
EL.,*105
HARNESS LAYOUT
Chassis & Tail Harness
~l
===1I
'------------
-------I
SEL852R
EL.106
HABN&SS'~.I.$AYi9l;)'f,
Chassis & Tail Harness (Cont'd)
""CJ
[
C
::J
o
L
OJ
:>-
""CJ
o
CD
If J
1°
b_-======:
Q)
c
'5
c
:c
11l
Ql
C\I
0 '<t
0
Q)
Q) ~ !:!:.
c "0
c '5 c iO'
.c '5 c ....
£ c Ql Ql 'c:J ~ ~
'~ 0
0 u. (;
"5
x CIl lD ~ Ql iO' 0
0 a. ~ .c Ol
:J
CIl
c ~ ~Ql
.c E
~ ~c (; £ 11l Ql
CD !!!
~ -
11l
"0 '~
Ol CIl
~C ~ tti .c
Ul
,:@g E ~ .cQl tl
.. ~~
Ul
G) Ql
CD .l!l
~:J (jj
'i= :J
C
Ql :0 :0 I- ~
t: 11l
III
.c
'(ii '(ii 0 g Ql :J
(jj (jj .c
:J :J X
:J
lD u. ~l-lD ~ Z u. u. u. w
Ul
'iii "
.. .. .. .. .. .. ..
g@@@@@@@@@~@
:c
11l
:c
11l
0 0
:c
11l
:c
11l 'E
~
"0
0 0 11l
"0
c: C Ql
"0
Ql
"0
c
E
0
:J
~ ~ ~ ~
:i :i :i :i
c: a.
Ql ci ci :c .J .J
E 0 11l
a. a.
:J x a. a. 0
e. !!:!.a. E E
.E!! .E!!
Ql
"0
E E
.E!! .E!!
a.
E E c c c c
.E!! .E!! 0 0 ~ 0 0
:a;c ~ a. ~ ~C
~Ql CD
"0
Ql
tti tti
Ql
.f: E c
c N
C :0 .c .E!! :0 :0
:J 0. 0. E E E
c
0
N
:J
.c
e Ol
Ql Ql
""CJ
Ql
E
0 0
0
a. 0
:J 0
0 0
Ii@) 0
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c
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CIl CIl
~ iii iii
iii iii 0 Ql
C
CIl
:J
0 I
..
Ql
G)
'0 11l 0 ...J .~
0 ..., "0 Ql Ql 11l c: Ql
c:
...J Z c: c: lD
,~
C lD lD
.. .. .. .. .. .. .. ..
I-
III .. .. .. ..
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EIl!1GJ
',',:".
il' .... ,
>,"
.0,".
'/'.
HARNESS LAYOUT
NOTE
EL.108
!"$&' (")*+$)& ,"-.*+/- !"#$#%#&
!"$&' (")*+$)& ,"-.*+/- !"#$#%#&
*2345671 03376824269
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Nissan Atlas F23 Workshop Manual

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<COMBINED EDITION>

QUICK REFERENCE INDEX

REAR AXLE & REAR SUSPENSION RA

HEATER & AIR CONDITIONER HA

Edition: July 1992

NISSAN MOTOR CO., LTD.

In order to assure your safety and the efficient functioning of the

All information in .this manual is baseci on the latest product informa-

mannerthet the service may be performed safely and accurately.

Observe the following precautions to ensure safe and proper

1. Do not operate the engine for an extended period of time

2. Before jacking up the vehicle, apply wheel chocks or other

4. Before starting repairs which do not require battery power,

5. To prevent serious burns, avoid contact with hot metal

6. Before servicing the vehicle, protect fenders, upholstery

7. Clean all disassembled parts in the designated liquid or

HEALTH PROTECTION PRECAUTIONS

ENVIRONMENTAL PROTECTION PRECAUTIONS

A : N.m (kg-m, ft-Ib)

WIRE COLOR CODING

When the wire color Is striped, the base

Example CONNECTOR SYMBOLS

Example • Male and female terminals

Continuity circuit of wiper switch

Example: Wiper swltch in LO position

SUPER MULTIPLE JUNCTION (S.M.J.)

ED (See page EF &

CHECK GROUND CIRCUIT.

HOW TO FOllOW THIS FLOW CHART

CHECK POWER SUPPLY.

[2] Measurement results

Example Direction mark

View from harness side

Connector symbol View from harness side •.. H.S.

Key to symbols signifying measurement.ll,C)l'{iproced"'f!!S\

Check atter disconri~cHng the con-

(@-~ lrisert keY into jgnition switch.

Turn ignition switch to "OFF" posi-

00 Turn ignition switch to "ON" position.

00 Turn ignition switch to "START"

Turn ignition switch from "ACC" to "efj'2J4, F~n switch is "OFF".

TUrnjgnitiol') switch from "OFF" to Apply battery voltage directly to com-

Start engiri~:ior check wittl e'hgine

Release parking brake. Depress accelerator pedal.

Check after engine is warmed up sufc

Voltageshould'be measured with a: Pin terminal check for S.M.J. type

leJ Oircuit resistance shouldbetnea"

tBJ sured,withan ohmrne.ter.

tal Current should be measured with an

Steel SBK4LBF-KWH SBK4RBF-KWH

2 Standard wheelbase W Except Europe

R Right-hand drive K 1.5t Single tire

F 5-speed manual transmission

Wood SVW2LBF-RWJ SVW2RBF-RWJ

S Cabover L Low-bed (Steel)

Vehicle identification number Vehicle identification number

VEHICLE IDENTIFICATION NUMBER ARRANGEMENT

Manufacturer IT--.-----vehicle serial number

Stopgap (no meaning)

Engine type Model

Model H41 series

Body J 1-c---------~:::e serial number

U Cabover (Wide cab)

L Cabover (Standard cab,