j

f
0
1

1R1 1M o
o
@ 7

r t

Jot

I 0

V
4
7
J
F

V 4
2
y

oomm llI IP J
c

ffi
DRAKE PUBLlSHERS INC

r
 DATSU O
RANGE 1969 1973

MAINTENANCE REPAIR

BY DRAKE AUTOMOTIVE EDITORS

Quick Reference Indel

MAINTENANCE TUNE UP 5 STEERING 91

ENGINE 21 REAR DRIVE SUSPENSION 95

ELECTRICAL SYSTEM 39 CLUTCH 99

FUEL SYSTEM 67 TRANSMISSION 107

COOLING SYSTEM 77 BODY WORK 115

BRAKES 81 SPECIFICATIONS 119

FRONT SUSPENSION 89

Tho purpose of this manual to provide the utomobila owner nd mechanic with
eference with which he perform normal ervice
source operations

We ndeavor to
rporato the late t manufacturing design changes nd upto date
specifications at the time of publication While ryeffort made to attain cy

the Publisher not be held Ipon ible for manufacturing changes typographical
rors or omissions

Upon ompiting the formation contained herein we have tried to be brief and
impls elying on the combination of photograph illustration nd l 1 to
te

make this manual elul tool

DRAKE
PUBLlSHERS ING
381 PARK AVENUE SOUTH

NEW YORK NY 1CXJ16

ISBN 87749 302 2

Published in 1973 by
Dlake Publishers Inc
381 Palk Avenue South
NewYolk N Y 10016

@Dlake Publishels Inc 1973

Printed in the United States of America

 able of Contents

MAINTENANCE TUNE UP CHARGING CIRCUIT DESCRIPTION 40

ALTERNATOR 41
VALVE CLEARANCE 6 Description 41
FAN BELT 6 Removal 41
ENGINE OIL 6 Installation 44
OIL FILTER 6 VOLTAGE REGULATOR 44
COOLANT 7 Descri ption 44
Nissan Long Life Coolant 7 Measure ofVoltage 45
COMPRESSION 7 Adjustment 47
Test Result 8 Charging Relay 48
BATTERY 8 ALTERNATOR 49
IGNITION TIMING 9 FUSES FUSIBLE LINKS 49
POINTS 9 EMISSION CONTROL DIAGRAMS 50
CONDENSER 9 DISTRIBUTOR 52
SPARK PLUGS 10 Construction 52
CARBURETOR 10 Disassembly 52
Idle Limiter Cap 11 Assembly 53
CHECKING ADJUSTING DASH IGNITION COIL 56
POT Automatic Transmission Only 11 Construction 56
Installed on Engine 11 Descri ption 57
DUAL POINT DISTRIBUTOR 12 SPARK PLUGS 5
Cap and Rotor Head 12 Descri ption 5
Point 12 Inspection 58
Phase Difference 12 Cleaning and Regap 58
TUNE UP GUIDE 14 TROUBLE SHOOTING IGNITION 58
TROUBLE SHOOTING 15 HEATER UNIT REMOVAL 59
TROUBLESHOOTING HEADLIGHT 62
TROUBLESHOOTINQ HORN 63
RADIO 63
ENGINE
Removal 63
TROUBLESHOOTING
DESCRIPTION 22
SPEEDOMETER 64
REMOVAL 23
TROUBLESHOOTING HEATER 65
INSTALLATION 24
DISASSEMBLY TROUBLESHOOTING RADIO 65
24
Pistons and NOISE PREVENTION CHART 66
Connecting Rods 2
Cylinder Head 27 FUEL SYSTEM
ASSEMBLY 27
Cylinder Head 28 AIR CLEANER ELEMENT 68
Piston and Connecting Rods 29 AUTOMATIC TEMPERATURE
Engine 30 CONTROL AIR CLEANER 68
OIL PUMP 36 AIR CONTROL VALVE 68
Removal 36 Idle Compensator 69
Installation 3 TEMPERATURE SENSOR 69
Removal 69
Installation 69
ELECTRiCAL SYSTEM FUEL PUMP 69
Removal and Disassembly 69
STARTER 40 Inspection O
Removal 40 Assembly 70

1
Table of Gontents

CARBURETOR 3 FRONT SUSPENSION

Removal 3
Disassembly 3 RECOMMENDATIONS 90
Float Chamber 74
ANTI DIESELING SOLENOID 74
Removal 4 STEERING
Installation 74
BOOST CONTROLLED STEERING GEAR COMPONENTS 92
DECELERATION DEVICE 74 RECOMMENDATIONS 92
Assembly and Installation 74 ASSEMBLY 93
Cleaning and Inspection 74 STEERING LINKAGE 93
JETS 5

REAR DRIVE
SUSPENSION
COOLING SYSTEM
SHOCK ABSORBERS 96
DRAINING FLUSHING Removal 96
78
WATER PUMP 78 Inspection 96
Removal Installation 96
78
Disassemb y DRIVE SHAFf 97
79
RECOMMENDATIONS 97
Inspection 79
Installation 79
THERMOSTAT 79
Removal and Installation 79 CLUTCH
RADIATOR 79
Removal and Installation 9 REMOVAL 102
Inspection 80 RELEASE BEARING 102
REPAIR 103
Refacing Pressure Plate 103
ADJUSTMENT 104
INSTALLATION 104
BRAKES
MASTER CYLINDER 105
Removal 105
MASTER CYLINDER 82
Removal 82
Disassembly 105

Installation Inspection 106

82
FRONT DISC BRAKE 82
Assembly 106
Installation 106
Description 82
BLEEDING CLUTCH SYSTEM 106
Removal 82
Disassembly 84
Inspection and Repair 84
Piston Seal Replacement 85 TRANSMISSION
Assembly and Installation 85
Pad Replacement 86 REMOV AL 109
REAR BRAKE 86 INSTALLATION III
Removal and Disassembly 86 4SPEED TRANSMISSION 113
Inspection 87 Removal and Installation 113
Assembly 88 RECOMMENDATIONS 113

2
 Table of Gontents

BODY WORK SPARK PLUGS 122

VALVES 122

FRONT FENDER 116 OIL PUMP 122

Removal and Installation 116 GENERAL 123

HOOD 116 ELECTRICAL 123

Removal and Installation 116 MANUAL TRANSMISSION 12

11 CARBURETOR 131
Adjustment
TRUNK LID 11 CLUTCH 134

Removal and Installation 11 ENGINE TORQUE INFORMATION 136

Torsion Bar Removal TUNE UP 138

and Adjustment 117 LUBRICANTS SAE 138

CAPACITIES PRESSURES 139
AUTOMATIC TRANSMISSION 140

SPECIFICA liONS PROPELLER SHAFT 144

BRAKE CHASSIS WHEEL

Sf ARTER 120 ALIGNMENT 146

NOTES 14
DISTRIBUTOR 121

a
llaiDteDlDce Tune up

VALVE CLEARANCE 6
FAN BELT 6
ENGINE OIL 6
OIL FILTER 6
COOLANT 7
Nissan Long Life Coolant 7

COMPRESSION 7
Test Result 8
BATTERY 8
IGNITION TIMING 9
POINTS 9
CONDENSER 9
SPARK PLUGS 10
CARBURETOR 10
Idle Limiter Cap 11
CHECKING ADJUSTING DASH
POT Automatic Transmission Only 11
Installed on Engine 11
DUAL POINT DISTRIBUTOR 12
Cap and Rotor Head 12
Point 12
Phase Difference 12
TUNE UP GUIDE 14
TROUBLE SHOOTING 15

I
IlaiDteDlDce TUDe up

VALVE CLEARANCE FAN BELT

Valve clearance adjustment is performed with Check for cracks or damage Replace if
the engine not running The initial adjust necessary
ment is made while the engine is cold
Adjust belt tension It is correct if detlection is
Remove the air cleaner Unbolt and remove 0 315 to 472
0 inwhen thumb pressure 122 0
the camshaft cover Each valve must be ad lbl is applied midway between fan and alter
justed with the valve completely closed that nator pulleys
is the rocker arm should be at the base
Ilowest point of the cam lobe Loosen the ENGINE OIL

locking nut and turn the adjusting screw until

the specified clearance is obtained as checked Check if oil is diluted with water or gasoline
with fuel gauge between the rocker arm and
a Drain and refill if necessary
oil
camshaft Straighten the locking nut Repeat
Notes
this procedure on each valve turning the
engine over bv hand to position each valve as a A milky oil indicates the presence of

necessary Temporarily replace the camshaft cooling water Isolate the cause and take

cover with two or three bolts and warm up the corrective measure

engi ne Remove the cover and recheck the

b An oil with extremely low viscosity in
valve clearance according to the warranty cer dicates dilution with gasoline
tilicates Readjust as necessary Replace the
camshaft cover using a new gasket if the old Check oil level If below the specitied level

gasket appears tlattened or broken Run raise it up to the H level

engine and check for leaks from the gasket

Engine oil capacity

including oillilterl

Valve clearance Maximum H leveli

Unit mOl in
41 U S qts
I
Intake 0 20 0 008
Minimum IL leveli
Cold
31 U S qts
Exhaust 0 25 0 010

OIL FILTER
Intake 0 25 0 010

Warm The oillilter is of a cartridge type

Exhaust 30
0 0 012

Ag 1 Adjusting valve clearance Fig 2 Drive belt tension

8
 llaiDteDlDce TUDe up

BoiHng point

Percent C0ncentralion

b
Sea level
0 Q

system
kem
i
2 I
coning
HeUUre
protection
FreeL

I060C lSOC SoF

3m 1240C 2SSor
2210F

I090C Inlle 61UF 3SoC 3IOP

50
228OF

Water lcity
cap

610 620 5to

6 0 U S gal S I U S 6 4t O U S gal
1 gal
Without heater
1 X Imper gal I 1 Imper gal I Imper gal

5
6 I Y s gal
U 60 t U S gal 6 81 1 U U S gal
With heater
I 1 Imper gal I i Imper gal
Imper gal

Check for oil leaks past gasketed flange If COMPRESSION

to
anv leakage is found retighten just enough
effec When it becomes necessary to check cylinder
stop leakage If retightening is no longer
tilter compression it is essential to remove an
tive replace as an assembly
spark plugs purpose of this test is to
The
When installing oiltilter tighten by hand determine whether there is excessive leakage

Note Do not overtighten oil filter lest past the piston rings head gasket etc To test
should the engine should be heated to the operating
leakage occur

temperature and throttle and choke valves

COOLANT opened

Cylinder compression in cylinders should not

Nissan Long Life Coolant be less than 80cf of the highest reading Dif
L L C is an ethylene glycol base product con

taining chemical inhibitors to protect the

cooling system from rusting and corrosion
c OF
The L LC does not contain any glycerine

ethyl or alcohol It will not evaporate or boil 0 32

away and can be used with either high or low

10 14
temperature thermostats It flows freely tran
sfers heat eniciently and will not clog the
20 4 I
The L L C
passages in the cooling system
I

I
must not be mixed with other product This 30 2
I
l
coolant can be used throughout the seasons of I
40 40 t
the year
t

Whenever any coolant is changed the cooling so 58

to 20 30 40 so

system must be tlushed and relilled with a EG001

new coolant Check the level Fig 3 Protection concentration

7
llaiDteDaDce Tune up

fClcnt comprc sion in two or more cylinder Full charge

Permissible
ll llalh indiL an
nte improperlv seated valve value
value
or hrokpll piston ring at 20ne 6SoF

Low ornpn ion in cYlinders result from

r
can climates
Frigid I 28

piqoll ring
oln Thi trouhle may usuallv
Tropical climates Over I 23
1
he i1 ol1lpanit rl bv excessive fuel
u mption
nn
Other climates Over I 10 126

1 R ult
If lindf 1 c ll1pre sion in one or more cvlin
ell l low a Illall quantity of engine oil
i pOll
into c ylinder through the spark plug holes
n
nd retest compression

II adding oil the compression

Iwlp pressure
Illl challn an t hat rings arc defective

II pn s ure tn low the likelihood is that

alve is sticking 01 seating improperly

II l linder compression in any two adjacent

dinder is low and if adding oil does not
help the compres ion this could be leakage
past the surface Fig 4 Testing compression pressure
gasketed
Oil and water in comhustion in any two ad
ja ent cylinder is low and if adding oil does
not help the compression this could be

I akage past the gasketed surface

Oil and water in comhustion chambers can
1 11 from this trouhle

nmpre ion prC Sl1re

p i at rpm

Standard 11350 c

Minimum 128 350

ET002

BATTERY Fig 5 Checking specific gravity of battery electrolyte

Check electrolyte level in each batterv cell

must be clean to prevent current leakage bet

Unscrew each liller and lluid
cap inspect
level If the lluid is low add distilled water to ween terminals and from positive terminal to
hold down clamp
bring the level up approximately 0 394 to
0 787 in above the plates Do not overlill In addition to current leakage prolonged ac
cumulation of acid and dirt on top of battery
Measure the specitic gravity of battery elec
trolyte may cause blistering of the material covering
connector straps and corrosion of straps After
Clean top of battery and terminals with a
tightening terminals coat them with
solution of baking soda and water Rinse 011
petroleum vaseline to protect them from
and dry wi h compressed air of
Top battery corrosion

8
 l1aiDteDIDce TUDe up

IGNITION TIMING full contact and that point dwell and gap are
correct Clean and apply distributor grease to
Check spark plugs and distributor breaker the earn and wick

points for condition

Note Do not apply grease excessively

Thoroughly wipe oIl dirt and dust from timing Point gap
mark on crank pulley and timing indicator on
and front cover 0 0177 to 0 0217 in

Warm up engine sufticiently Dwell angle

49 to 55 degrees
Install a timing light on No 1 cylinder spark
plug wire and install a tachometer
CONDENSER

Set idling speed to approximately 800 rpm

Clean outlet of condenser lead wire and check
Check ignition timing if it is 50 B T D l
for loose et screw Retighten if necessary
iBefore Top of Dead Center by the use of
Check condenser capacity witb a
capacit V
timing light
meter Condenser insulation resistance may
If necessary adjust it as follows
be also checked using a testcr by adjusting its

Loosen set screw to such an extent that range to large resistance value
measure

distributor can be moved bv hand When condenscr is normal the tester pointer

BT D C
swings largely and rapidly and moves
to 5
Adjust ignition timing gradually back to the intinite side When thc
Lock distributor set screw and make sure pointer does not stay still or it points zero in
thaI timing is correct resistance replacement is necessary

Ignition timing

5 t Retard side
1Z Advance side

POINTS

Check the distributor breaker points for ab

normal pitting and wear Replace if necessary
Make sure they are in correct alignment for

Fig 7 Checking ignition timing

Fig 6 Adjusting ignition timing Fig 8 Checking distributor point gap

llainteDance Tune up

Condeneer capacity Check ignition timing if neceesary adjust it to

the specillcations 15 800 rpm retard sidel
Hctard side 0 05 I F

Adjust idle adjusting screw so that CO per

Micro Farad
centage is 1 5 0 5
Advance oide 0 22 I F
Repeat the procedures as described in items 3
Micro Farad and 5 above so that CO percentage is
1
Condenser insulation resistance 5 0 5 at 800 rpm

5MlltMega ohms Caution

a On automatic transmission equipped

SPARK PLUGS
model check should be done in the D

Remove and clean range

plugs in a sand blast
cleaner Inspect each spark plug Make sure Be to brake and to
sure apply parking
that thev are of the heat range In
specitied lock both front and rear wheels witb
spect insulator lor cracks and chips Check wheel chocks
both center and ground electrodes If they are
b Hold brake pedal while stepping down
excessively worn replace with new spark
on accelerator pedal Otherwise car will
plugs File center electrode l1at Set the gap to
rush out dangerously
0 028 to 0 031 in using proper adjusting tooL
Tighten plugs to 110 to 15 0 ft lb torque On automatic transmission equipped model
make sure that the adjustment has been made
CARBURETOR with the selector lever in N position

Idle mixture And then check the specitications with the

adjustment requires the use of a

CO meter lever in D position Insure that CO per

When preparing to adjust idle
cent and idle speed are as tollows
mixture it is essential to have the meter
thoroughly warmed and calibrated
Idling rpm 650

Warm up engine sulliciently CO 1

percentage 50 5
Continue engine operation tor one minute at Readjust by turning in or out throttle ad
idling speed justing screw or idle adjusting screw if still
out
Adjust throttle adjusting screw so that engine
speed is 800 rpm 1 in N range tor automatic Notes
transmission L
a Do not attempt to screw down idle ad

EEOBO 2

Fig 9 Checking spark plug point gap Fig 10 Throttle and idle adjusting screws

10
 l1aiDteDlDce TUDe up

justing screw completely to avoid damage CHECKING AND ADJUSTING DASH

to tip which will tend to cause maIfunc
POT Automatic Transmission
tions only
Proper contact hetween throttle lever and
b After idle adjustment has been made
dash pot stem provides normal dash pot per
shift the lever to Not or plt range for
automatic transmission
lonnance Adju tmenl of the proper contact
can he made bv dash pot set screw
c Remove wheel chocks when running
If normal set can not be obtained between
Idle Limiter Cap dash pot stem and throttle arm rotate dash
Do not remove this idle limiter cap unless pot to the proper position
necessary If this unit is removed it is
necessary to re adjust it at the time of in
stallation To adjust proceed as follows Installed On Engine
It is necessary that the idling speed of engine
After adjusting throttle or idle speed ad
and mixture have been well turned up and
justing screws check to be sure that the
amount of CO
contained in exhaust gases engine it sufticiently warm

meets the estahlished standard Turn throttle valve by hand and read engine
speed when dash pot just touches the stopper
Install idle limiter cap in position making
lever
sure that the adjusting screw further turn 18
rotation in the CO RICH direction Adjust the position of dash pot by turning nut
until engine speed is in the range of 1 600 to
1800 rpm

C rburctor Then fasten loosened lock nut

h
topper
Make sure that the engine speed is smoothly
alation
reduced from 2 000 to t 000 rpm in about

three seconds
COlcan

limiter Jp

JIsoy1dle
ET031

Fig 11 Setting idle limiter cap

EE130

I Advanced break er point

2 Retarded breaker point
3 Pha difference

Fig 12 Dash pot adjustment Fig 13 Dual point distributor

u
l1aiDteDlDce uDe up

DUAL POINT DISTRIBUTOR Point gap

C 018 to z in
fi trihlltor has two breaker points located op
po itp each othl r with a phase ditlcrence as Dwell angle
hwn in Figure I
49 to 550
The ditl in be the
rence pha e can adjusted bv
If point gap IS adjusted by examining dwell
adju ting screw A phase dillerence of 7 crank
install distributor
angle on engine and
h
ilnf i adopted
proceed as follows
Th e two breaker points are placed parallel
Disconnect wiri ng harness of distributor from
in thp pi imarv ignition circuit The retarded
hreaker point when the relay is turned
engine harnes
ork
01 and the advanced breaker point works Using a lead wire connect B black of engine
wht ll lht 1C lav i turned OFF harness and B black of distributor harness
I advance side

ap lind Rotor lIead

Adjust dwell angle of advance side by
al and rotor hend must be inspected at
loosening point screw
ref iliaI inlervah I n addition remove cap and
e11 1Il t and carhon dc
duall sits from cap Disconnect lead wire from B t black of
lnd rotor Ii om time to time If cap is cracked distributor harness and then connect it to Y
0 i Ipaking replace with a new one vellowl of distributor I Retard side

Adjust dwell angle of retard side by loosening

Point
Standard gaps of both points are 0 0177 to point screw
0 0Z17 in If the gap is ot1 the standard ad After adjustment disconnect lead wire then
justment must be made by loosening point connect engine harness and distributor har
screwlS Gap gauge is required for adjustment ness securely
Roth must he checked from time to time
gap
Phase Difference
When point surface is rough take ot1 any To check phase dil1erence install distributor

irregularities with tine sand paper of No 500 on engine and proceed as follows
or tiOt or with oil slone
Disconnect wiring harness of distributor from
At this time grease must be supplied to engine harness
canHhaft and carn heel Do not applv ex
Using a lead wire connect B Iblackl of engine
cessively 1 When wear on each breaker point harness and B black of distributor harness
i noticeable replace points together with con
IAdvance sidel See Figure 15
tact an11

EE135

Fig 14 Checking of distributor breaker point gap Connecllead wire

Fog 15

12
 lIaiDteDance TUDe up

Spark timing sontrol system for Automatic T smission

Spark timing
Throttle SW

Advance ard
Ret

Engine start ON 0

Idling ON 0

Partial throttle opening ON 0

Wide throttle
opening OFF 0
and high speed rousing

Adjuster plate
set screws EEl38

EE136

Fig 18 Phase difference adjusting scale

Fig 16 Adjuster plate set screws

To correct further proceed as follows

Referring to Figure 6 turn out adjuster plate

set screw 12 to 2 turns The screw is located
at contact set on retard side

Using a notch in adjuster place as a hold turn

adjuster plate as required until correct delay
is ohtained Ignition is retarded when plate is
turned counterclockwise

Note Refer to graduations on breaker

Fig 17 plate to make One
adjustment easier

graduation corresponds to crankshaft

With engine idling adjust ignition timing by
angular displacement of 4 degrees
rotating distributor to specitications 112 800
rpm advance side Tighten adjuster plate set screws to secure the

Disconnect lead wire from B tblack of

adjustment
distributor harness and then connect it to Y Make sure that the ignition timing ofadvance
yellow of distributor harness IRetard side side is the specilications
With engine still idling check to determine After adjustment remove lead wire and con
that phase delay is 7 degrees in terms of nect wiring harness of distributor to engine
crank shaft angular displacement harness securely

13
lJaiDteDance up
Tune

TUNE UP GUIDE

l litiun
1J nd fll1 1t 1T

1 t1illutl tirnmll e 5 IB T O C
dcgr

Dislrihlltol

I linl lJP in 0 5510

45100 0177 toO 02t7

Dwellanglc degree 49 to 55

retard side 0 05
C Id iCf
n
lpadty F
advance side 0 22

rlnd n er ilSiOulIl lanc MH 5

Idling ldjustmtnt
Manual Trnnsmission deg rpm
e 50 800 retard side
COil 1 t05
5

Automatic Transmission degree rpm 50 650 retard side 0 range

call t05
1 5

Dash pot 3djuslrnenl 1 600 to 1 800

pm

die
Anli ling solenoid tightening torque kg em lin Ib 35 to 55 30 to 48

Spark timing conlrol system

lluottle switch operating angle

L18 AfT degK e 350
L16 t5tO
MfT degree 400
Lib 620 AfT MfT 450
degree
Thermo switch operating
temperature or OF 5 to 13 4 to 55

of f a cO D
Adjustment operating pressure

R C 0 0 set pressure

AfT mmHg inHg t 20

480 t8 t 0 787
9

MfT mmHg inHg t 20

500 19 t
7 787
0

A T C Air cleaner

AT C Valve opening temperature Or OF 5

37 to 4S 100 to 1 8

H
 llaiDteDlDce TUDe up

TROUBLE SHOOTING

Condition Probable C rel tive elion

CANNOT CRANK Improper grade II with il

Repla proper grade
c

ENGINE OR StOW
DIscharged bat tery Charge ballery
CRANKING
Defective battery Replace

Loose fan belt Adjust

T wble in charge system Inspect

Wiring onnectiun trouble in Sl

Hting n Correcl

Detective igmllon switch Repair replace

tive
Defc lrter
st oloL Repair replace

T ouble shooting procedure starting cin uil

Switch on the starting motor with light ON

When light goes off dims nsiderably

k baltery
Che
b Check nnection and able

Check s aller olur

When light 51 s
bright
k wiring
Che cllOn between lt ery
h nd Slarter
OllH

h k starter switch
Chel
Check starter ulm

1
I
I

llaiDtelllDce IUD8 UP

Condition Probable cause Corrective action

Low or no current Check for loose terminal or disconnection

primary circuit
Check for burned points

Ignition system in Burned distributor point Repair replace

trouble
Improper point gap Adjust
Defective ondenser Replace
leak at rotor ap and rotor Clean eplace
Defective spark plug Clean adjust plug gap or
replace
Improper ignition timmg Adjust
Defective ignition oil Replace
Disconnection of high tension cable Replace
L005C connection or disconnection in Repair replace
primary Tcuit

Fuel system trouble la k of fue Supp1r

Dirty fuel strainer Replace
Dirty or
clogged fuel pipe Clean

Fuel pump will ot work properly Repair replace

Carburetor choke will 01 work properly Check tnd adjust

of float level Correct

Improper adjustment
Improper idling Adjust
Dirty or do ed carburetor Disassemble nd clean

Clogged breather pipe of fud tank Repair nd clean

Damaged dieseling
anti olenoid
Replace

Low compreuion Incorrect spark plug tightening or defective Tighten to normal or

replace gasket
torque
gasket
Improper grade engine it low viscosity Replace with proper grade oil

Incorrect valve clearance Adjust

Compression leak fromvaIve seat Remove cylinder head and lap valves

Sticky valve stem Correct replace alve nd lIve guide

Weak defective alve valve springs
springs Replace
Compression leak at
cylinder head gasket Replace gasket
Slicking or defective piston ing Replace pIston ngs

Worn piston ing cylinder Overhaul engine

Trouble shooting procedure

Pour the engine iI from plug hole nd then measure

cylinder compression

Compression increases Trouble ill cylinder or

piston ring
Compression does not change Compression leak from valve cylinder head
or head gasket

18
 llaiDteDlDce Tune up

Condition Probable cause Corrective action

IMPROPER ENGINE

IDLING

Fuelsyltem trouble Clogged or damaged carburetor jets Clean replace

Incorrect idle adjustment A1just
Clogged air cleaner Rplace element

Defective manifold gaskets or carbureto Replace gasket insulator

insulator

Improper float level adjustment Adjust

Low compreSlion i Previously mentioned

I
I
Others Incorrect valve clearance
Adjust
Extremely low revolution Adjust
Poor acceleration above 1 000 rpm Twin Loosen idling adjusting nuts about a half
carb turn

Defect or malfunction of the ignition system Replace

spark plug high tension cable breaker

point ignition coil etc

Incorrect basic ignition timing Adjust

Incorrect alve clearance Adjust

8C D D adjustment incorrect Adjust

Damaged vacuum control solenoid Replace
Sticked stall
anti
dash pot Replace

ENGINE POWER NOT

UP TO NORMAL

Low comprnsion Previously mentioned

Ignition syltem trouble Incorrect ignition timing Adjust

Defective spark plugs Clean adjust or
replace plugs
Defective distributor points Dress or
replace points Also check

condenser

Fuel system trouble Malfunction of choke system Adjust

Clogged fuel or
floating valve Clean
pipe
Dirty or
clogged fuel strainer Replace
Fuel pump will not work properly Repair or eplace
Clogged carburetor jets Disassemble and clean

Air ntake Replace element

syltem in Gagged air cleaner

trouble
Air inhaling from manifold gasket or
RepJace gasket
carburetor gasket

fl
IlainteDance TUDe up

Condition Probable cause Corrective action

Owrheating Insufficient coolant ReplenWt

Loose fan belt Adjust fan belt

Worn or defective fanbelt Replace

Defective thermostat Replace
Defective water pump Replace
or radiator Flush repair or
replace
Oogged leaky
Defective radiator mlct cap Replace
Retighten each part of cooling system
Air in cooling system
with proper grade oil
Improper e eoil grade Replace
Incorrect ignition timing Adjust
Defective carburetor lean mixture Overhaul carburetor

ooling
Owen Defective thermostat Replace

Othen Improper octane fuel Repbce with specified octane fuel

Improper tire pressure Inflate to specifted pressure

Dragging brake Adjust

Clutch dipping Adjust

NOISY ENGINE

Car knodting Overloaded engine Use right gear in driving

Carbon knocking Disassemble cylinder head and remove

carbon

Timing knocking Adjust ignition timing

Fuel knocking Use specified octane fuel

Preignition misusing of spark plug Use specified spark plug

Mechmicll kncdtinll

Crankshaft bearing ThU strong dull noise increases when engine This is caused by worn or
damaged bearings
knocking is accelerated To locate the place cause a or uneyen y worn crankshaft Renew

misflTe on each cylinder If the noise stop3 bearinp and adjust or change crankshaft
by the misfut this cylinder generates the Check lubrication system
noise

Connecting rod This is little than Same the of crankshaft bearinas

a
hisher pitched n9ise the as case

bearing knocking crankshaft knocking and also increases

when engine is accelerated Cause a misfue
on each
cylinder and if the noise deminiwi
almost completely this crankshaft bearing

generates the noise

Piston and cylinder When you overlapping metalic noise

hear This cause an abnormal of
an may wearing
noise magnitude with the and lower
which increases its cylinder compression which in

revolution of enaine and which decreases u turn will cause I lower out put power and
engiI e is warmed up this noi3e is caused by excessive consumption of oil
piston and cylinder To locate the place
cause amisfue on each cylinder erhaul engine

18
 IlaiDteDance TUDe ail

Condition Probable cause Corrective action

Piston pin noise This noise is heared at each ryighest and This may cause a wear on
piston pin or

lowest dead end of piston To locale the piston pin hole

place cause a misfire on ach cylinder Renew piston and piston pin usembly

Water pump noise This noise may be caused by worn

Replace water pump with a new one

the surface
damaged bearings or
by uneven

of iding parts

Others An improper adjustment of alve clearance Adjust

Noise of chain Adjust the tension of chain
timing
An excessive end play on ankshaft Disassemhle engine and new main bearing
Note This noise will be heared when clutch

is disengaaed

Wear on clutch pilot bushing Renew bush and adjust drive shaft
Note Uta noise will be hur when

clutch is disenpged

ABNORMAL

COMBUSTION
back fue after fire

run on etc

Improper ignition timing Improper ignition timing Adjust ignition timing

Improper heat range of spark plugs e

specified spaTk plugs

carburetor manifold gasket Replace them with new parh

system in trouble or
Fuel Damaged
back fire after fire

Defective carburetor jet Disas efnb e calburetor and check it

function of the noaL Adjust the level and check needle valve
Improper
Uneven idling Run on
Adjust

f8C1iYe
o eylinder hem Improperly adjusted valve clearance Adjust
Excess carbon in combustion chamber Remove head and gel rid of carbon

llaged
DaJ valve spring back fire after fire Replace it with a new one

EXCESSIVE OIL
CONSUMPTION

Oil I Loose oil drain plug Tighten it

Loose oil pan Renew gasket or

tighten it
or damaged gasket
Renew or
tighten it
Loose or damaged chain over
gasket gasket
Defective oil seal in front and rear of Renew oil seal
crankshaft

Loose or damaged locker cover

gasket Renew gasket or
tighten it but ot too

much

mter Renew and tighten it with the proper

fmproper tightening of oil gasket
torque

Renew oil pressure switch or tighten it

Loose or damag ed oil pressure switch

18
l1aiDteDIDce TUDe up

Probable cause Corrective action

Condition

and Overhaul cylinder and new

piston
Excessive oil Cylinder piston wear

consumption location of piston ring gap or Remount piston ings

Improper
reversely assembled piston ng

Renew rings
Damage piston rings

Repair or renew piston and cylinder

Worn groove and ing Renew piston and piston ring
piston ing
Replace seal lip with a new one
Fatigue of valve oil seal lip
Worn valve stem Renew valve or guide

of designated oil
Otben Inadequate quality engine oil Use the

Engine overheat Previously mentioned

POOR FUEL ECONOMY

See the explanation

of the power deerea

revolution Adjust it to the designated rpm

Others Exceeding idling
Adjust it
Defective acceleration ecovery
the connection of fuel
Fuel leakage Repair or
tighten
pipes

TROUBLE IN OTHER

FUNCTIONS

oil Use the designated oil

Oecreased oil pressure Inadequate quality
Overheat Previously mentioned
Defective function of il pump regulator Disassemble oil pump nd repair or enew it

valve

Functional deterioration of oil pump Repair or replace it with a new one

Blocked oil filter Renew it

Increased clearance in various sliding part Disassemble and replace the worn parts with
new ones

Blocked oil strainer Oean it

Troubles in oil gauge pressure switch Replace it with a new one

ExcessiYe wear on the Oil pressure decreases Previously mentioned

sliding pam Defective quality or contamination of oil Exchange the oil with proper and

change element
Defective air cleaner Change element
Overheat or overcoal Previously mentioned

Improper fuel mixture Check the fuel system

Scuffing of sliding Decrease of oil pressure Previously mentioned

PO to the clearances
lnsufficient clearances Readjust designated
Overheat Previously mentioned

Improper fuel mixture Check the fuel system

20
 IDgine
DESCRIPTION 22
REMOVAL 23
INSTALLATION 24
DISASSEMBLY 24
Pistons and Connecting Rods 27

Cylinder Head 27
ASSEMBLY 27

Cylinder Head 28
Piston and Connecting Rods 29

Engine 30
OIL PUMP 36
Removal 36
Installation 37

21
r
B DglDe

DESCRIPTION crankshaft to turn out smooth dependable

cast in single
power cylinder block is
The a

The L16and L18 engines feature a H C unit featuring deep skirting

chamber
valves wedge shaped combustion
5 bearing These engines are equipped with a single
alminum heads and fully balanced

EM256

Fig 19 Cross section view

22
 BngiD8

2 harreL downdraft carburetor that incor Disconnect thc fuel tube from the fuel pump

porates a special device to control emissiuns its hoses at

Ifequippcd with heater remove

engine attachment
Experience has shown that it is much easier
Disconncct accelerator control linkage and
to remove the engine with transmission as a
unit than to remove the engine only choke wire at the carburetor side
single
then be separated from the Disconnect the wirings for the starter alter
The engine can

transmission assembly n tor ignition coil oil pressure switch and

thcrmaI transmitter
REMOVAL and its
Hemove the clutcb operating cylinder
return spring
Scribe alignmcnt marks on hood around hood

hinges and remove hood from hinge Disconnect the speedometer cable Disconnect
tlat attaching plug connector from the reverse

Completelv drain the cooling system engme lamp switch

and transmission lubricant
Disconnect the shift rods and select rods and
Hcmove blow hy hosc ti om rocker cover and
t hen remove the s
cro shart a sembly bv
remove air cleaner shail bracket from the side
rcmoving the cross

Hemove the radiator grille memher

the Disconnect thc front exhaust tube from thc

Disconnect the battery cable and remove

battcrv off the car exhaust manifold

Disconnect the center tuhe from the rear tube

Take oil hoth upper and lower radiator hoses
by removing thc hosc clamps Then loosen the and remove the front tube pre mumer and
center tube assembly
lixing holts of the radiator and take it out in

sequence Disconnect the propeller shaft by disconncc

Note If equipped with automatic tran ting it from the companion tlange of the gear
smission remove the torque convertor carrier

cooling pipes from the radiator

Jack up thc transmission a little and thcn

fan and remove the rear engine mounting cross mem

Rcmove engine pulley
ber by removing the tixing bolts of the engine
mounting insulator mounting cross member
and hand brake cable clamp

Flg 20 Removing clutch operating cylinder Fig 21 Lilting engine

23
IDgine

Remove the
tixing bolts securing the front DlSASSEMBL Y

engine mounting insulators to cross member

Remove transmission from engine
Hook with cable or chain to the stringers
t hooks which are installed on the engine Thoroughly drain engine oil and coolant by

cylinder head one at the front and the other at removing drain plugs
the rear
Place engine assembly on the engine stand
At this lifting lower the jack placed under the
Remove fan and fan pulley
transmission gradually Idraw oil the
jack at
adequate stage hoist up engine observing the Remove engine mounting R H
tension of wire and adjusting the position of
Remove oil tilter
chain block so that the engine tilts in order to
make it cleared on the body At this lifting Remove oil pressure switch
take care that accessories installed on the
Install engine attachment to cylinder block
body side do not touch the engine and
transmission using bolt holes securing alternator bracket
and water drain plug
Set engine on the stand
INSTALLATION
Remove oil level gauge
Reverse the removal procedure but do not con Remove clutch assembly
nect any parts to the engine steadily until the
engine mounting insulators have been Remove high tension cable

replaced and power unit weight is taken by Remove spark plugs

them
Remove thermostat housing

Fig 22 Engine on ngine stand Fig 24 Removing manifolds

EM091

Fig 23 Removing thermostat housing Fig 25 Removing camshaft sprocket

24
 BDgiDe

Remove rocker cover Remove camshaft sprocket

Remove carburetor Remove cylinder head assembly Loosen bolts

from 1 to 10 as shown in Figure 26
Remove intake and exhaust manifolds
Note For the convenience of cylinder
Remove engine mounting L H
head replacement special tool Chain

Remove crank Stopper STt742000I is prepared to sup

pullev
port timing chain during the service
Remove water pump
operation By using this tool timing
Remove fuel pump marks on crankshaft sprocket and timing

Remove fuel pump drive earn

EM095
Fig 26 Cylinder head bolt loosening sequence

fig 29 Removing chain tensioner and timing chain

j 1r
r
Jp
I
k

EM096 W
Fig 27 Supporting timing chain Fig 30 Removing chain drive sprocket

Fig 28 Removing oil strainer and oil pump Fig 31 Removing piston and connecting rod assembly

21i
r
I

IDgine

EM1Q2

Fig 32 Removing flywheel Fig 36 Removing piston ring

STl651S000

ST I 3030001

J
EM103
EM099

Fig 33 Removing rear main bearing cap Fig 37 Removing piston pin

I
I

Fig 34 Removing rear oil seal

Fig 38 Removing rocker arm

EM105

Fig 35 Removing buffle plate and net Fig 39 Removing camshaft

28
 BDgine

chain will be unchanged So the work for Cylinder Head

aligning timing marks will be saved so Loosen valve rocker pivot lock nut and
much remove rocker arm by pressing down valve
spnng
Invert engine
Note Take care not to lose valve rocker
Remove oil pan and oil strainer
guide
Remove oil pump and its drive spindle
Hemove camshaft
Remove front cover
Note At this time take care not to

Remove chain tensioner damage camshaft bearings and cam

lohes
Remove timing chain
Remove valves
Remove oil thrower crankshaft worm gear
and chain drive sprocket Take care not to lose valve spring seat oil
seal valve collet and valve rocker guide
Hemove pistonand connecting rod assembly
Take otr connecting rod bearings and keep Note Be sure to leave camshaft bearing
them in order intact Because the bearing center is
liable to be out of alignment
Hemove tlywheel Be careful not to drop it

Remove main bearing caps

ASSEMBLY
Use special tool Crankshaft Main Bearing
Cap Puller ST1651S0000 to remove center
Precautions
and rear main bearing caps Keep them in or
Use thoroughIv cleaned parts Particularly
del
make sure that oil holes are clear of toreign
H emove rear oil seal matter

Remove crankshaft When installing sliding parts such as

Remove baffie plate and cylinder block net bearings be sure to apply engine oil to them

Use new packings and oil seals

Pistons and Connecting Rods
Remove piston rings with a ring remover Do not reuse lock washers that have been
removed
Pressall t piston pin

Keep the disassembled parts in order Keep tools and work benches clean

G
G

STl2070000

i
EM106
Exh aust
t
Intake EM107

Fig 40 Removing valve Fig 41 Valve components

rz
r
I

BDgme

Keep the necessary part and tools ready near

Using special tool Valve Lifter STt2070000
at hand et valve spring seat in po ition and tit valve

guide with oil seal

H ure to follow specitied tightening torque
a nd order Assemble valve in the order shown below

sealant alve inner and outer valve springs spring

Applying
retainer valve collet and valve rocker guide
U e ealant to eliminate water and oil leaks
Notes
requiring sealant
Part are

a Check whether the valve face is free

Front cover gasket Front side of cylinder
42 from foreign matter
hlock and cover gasket See Figure

42 b The L16 and LIS engines use double

Front cover Top affront cover see
Figure
type valve springs
Main bearing cap and
cylinder block Each
ide of rear main bem ing cap and each Valve rocker pivot assembly
corner

of cvlindl r hlock See Figure 43 Screw valve rocker pivots joined with lock
nuts into pivot bushing
Cylinder block Set portions at four mating
urlan o n lilldl r hloek to tront chain cover Camshaft assemblv
and ylindt 1 hlock to rpar main bearing capl
Set locating plate and install camshaft in
SrI j lgurl I
cvlinder head caretullv Do not
damage the
110 nut apply sealant too much
Not bearing inside The oblong groove of locating

l H ad
Cylind
Vain assemhly and valve spring

Points to be applied sealant

EM152

l EM153 Fig 44 Applying sealant ICylinder block

Fig 42 Applying scalant Front cover and gasket

20 to 25 mm
all
7 to 0 984 in
II
U I
I E

Points to
1 be appl ed sealant EM151
i
S

Fig 43 Applying sealant Main bearing cap and cylinder

block 45
Fig Installing valve

28
 Ingine

plate must be directed toward the front side of Install rocker arms lw pressing down valve

engl ne springs with a screwdriver

Install camshaft sprocket on camshaft and Install valve rocker springs

tighten it together with fuel pump cam to the

After assembling cylinder head turn cam
specilied torque shaft until No is at T D C its
piston on

Tightening torque compreHsion stroke

86 to 6 ft lb
Piston and Connecting Rod
At this time check camshaft end Assemnle n pins and connecting
play pistons pist
rods to the designated cylinder

Notes

a Piston is pressed into connecting rod

and fitting force is 0 5 to 1 5 tons and the
aid of special tool Piston Pin Press
Stand ST13030001 is necessary

When pressing piston pin in connec

ting rod apply engine oil to pin and small
end of connecting rod

b Arrange so thatoil jet of connecting lod

EM154
big end is directed toward the right side
of cylinder block
Fig 46 Installing camshaft sprocket

c Be sure to install piston in cylinders

with notch mark of piston head toward
the front of engine

EM155

Fig 47 Assembling cylinder head EM1S7

Fig 49 Assembling piston and connecting rod

gd

l
STl3030001

o
EM158

Fig 48lnstalling piston pin Fig 50 Installing piston ring

28
r
IDgiDe

I nstall piston rings Front bearing No 1 is also the same type

In tall top and second rings in
as rear bearing No 5 The difference is
right position that an oil hole is provided in the front
with the mal ked side
up
bearing
Top ring is chromium pIated on liner con
All bearings except No 1 bearing have an
tacting face and
interchangeability between upper
Second ring has larger taper surface than lower bearings
top ring
Applv engine oil to main bearing surfaces on

In the combined oil ring upper rail is the hoth sides of cylinder block and cap
same as tower one
Install crankshaft
I ix hearings on connecting rod and con nee
Install main bearing cap and tighten bolts to
ting Od
I cap
pecitied torque
Note Clean the back side of bearing
carefully Tightening tOl que

32 5 to 39 8 ft lb
Engine
The IIlst tep in engine assemblv is to bolt Notes
pecial tool Engine Attachment ST05260001
Apply sealant to each side of rear main
to right hand side of cylinder hlock In suc

cession install block in another tool

bearing cap and each corner of cylinder
special block shown in Figure 43
as
Engine Stand ST050tSOOO with engine bot
tom up Arrange the parts so that the arrow mark

Set main beal ings at the proper

on bearing cap faces toward the front of
portion of
cylinder block
engine
Prior to tightening bearing cap bolts
Install hatlle plate including cylinder block
place bearing cap in proper position by
net
shifting crankshaft in the axial direction
Notes
Tighten bearing cap bolts gradually in
Only center bearing No 3 is a flanged separating two to three stages and out
type wardly from center bearing in the
sequence as shown in Figure 52
All inter bearings No 2 and No 4 are the
same type After securing bearing cap bolts ascer

tain that crankshaft turn smoothly

Rear
Front ID CD @ J

fi ll m L
0 D D D D

liS
ga 14 113 112 III
@ @
EM159 60
@
Fig 51 Main bearings Fig 52 Torque sequence of cap bolts

30
 BogiDe

Make sure that there exists proper end play at Install side oil seals into main
rear bearing
cranksahft cap Prior to sealant to these
installing applv
seals
Crankshaft end play
Installrear oil seal using special tool
0 0020 to 0 007t in
Crankshaft Rear Oil Seal Drift STt5310000

Applv a lithium grease to sealing lip of oil

seal

Install rear end plate

Install tlywheel securely and tighten bolts to
specitied torque
Tightening torque
101 to 116 ft Ib

Fig 53 Checking crankshaft end play

Ij
Pi r ction

Fig 56 Installing piston rod assembly

Fig 54 Driving side oil seal

Fig 57 Piston ring direction

STl5310000

r
EM163

Ag 55 Installing rear oil seal Fig 58 Installing connecting rod cap

31
Bngine

Insert pistons in Turn crankshaft until No 1 piston is

corresponding cylinder using at

pecial tool Piston Ring Compres

or T D C on its compression stroke
EM03470000
Make sure that camshaft sprocket location
Notes notch and plate oblong groove are aligned at
their correct positions
Apply engine oil to sliding parts
When installing cylinder head make sure
Arrange so that the notch mark on piston
that all valves are apart from heads of
head faces to the front of engine
pistons
Install piston rings at 180 to each other
Do not rotate crankshatl and camshatl
avoiding their fit in the thrust and piston because valves will hit heads of
separately
pin directions
pistons
Install connecting rod caps
Temporarily tighten two bolts 1 2 shown in

Tightening torque Figure 60

lor Ll6 Tightening torque

23 to 28 ft lb 14 5ft lb

for LI8 Install cranksahll sprocket and distributor

drive gear and fIt oil thrower
33 to 40 ft Ih
Note Make sure that the mating marks of
Note Arrange connecting rods and con crankshaft sprocket faces to the front
necting rod caps so that the cylinder num
bers face in the same direction Install timing chain

Make sure that there exists proper end play at

connecting rod big end

Big end play

0 0079 to 0 0118 in

Install cylinder head assembly

Thoroughly clean cvlinder block and head sur

face

Do not apply sealant to any other part of

Fig 60 Tightening sequence
cvlinder block and head surface

J
f L
I Fuel pump drive eam

2 Chain guide
@61
Oj

Chain tensioner

Crank sprocket
ID

j
1
o

I s

6
earn sprocket
Chain uide

EM169

Fig 59 Checking big end play Fig 61 Installing timing chain

32
 BDgine

Notes Instal1 front cover with gasket in place

Make sure that crankshaft and camshaft Notes

keys point upwards Apply sealant to front side of cylinder

block and front gasket as shown in
Set timing chain by making its mating cover

marks align with those of crankshaft Figure 42

sprocket and camshaft sprocket at the Apply sealant only ta the top of front
right hand side There are forty twa chain cover as shown in Figure 42
links between twa mating marks of timing
Install front cover with head gasket in
chain
place
No 2 hole is factary adjusted When chain
stretches elcessiveIy adjust camshaft Check the height difference between

sprocket at No 3 hole cylinder block upper face and front cover

upper face Its difference must be less
Use a set Of timing marks and location
than 0 0059 in
hole numbers
Nate that different types of bolts are

Install chain guide to cylinder block

used
Install chain tensioner
Apply a lithium grease to sealing lip of oil
Note the protrusion of chain ten seal
Adjust
to 0 in
sioner spindle Tightening torque
Press new oil seal in front cover front cover
Size M8
oil seal should be replaced when front cover is
disassembled I 10 3151

7 2 to 11 6 ft lb

Size M6

10 236 in

2 9 to 5 8 ft lb

Install crankshaft pulley and water pump

then set No 1 piston at T D C on its com
pression stroke

Crankshaft pulley nut

Fig 62 Installing chain tensioner
tightening torque
86 8 to 115 7 ft lb

EM 172

Fig 63 Installing runt cover Fig 64 Front cover bolts

33
r

BDgine

Finallv tighten head bolts to the specitied Tightening torque

torque in three steps according to the 8 0 to 10 8 ft lb
tightening sequence as shown in Figure 60
Notes
Note that two
tvpes of bolts are used
Assemble oil pump and drive spindle
Tightening torque
making driving spindle mark face to oil
st turn pump hole

t2H 9ft lb Install oil pump together with drive spin

dle so that the projection on its top is
2nd turn

4 ft lb
43

3rd turn

47 0 to 61 5 ft lb

Notes
41
Be to two small bolts
sure tighten
After engine has been operated for
several minutes if necessary retighten

Install oil pump and distributor driving spin E LOO9

dle into front cover

Ftg 67 Setting distributor driving spindle

EM175

Fig 65 Installing crankshaft pulley and water pump Fig 68 Installing oil pump

8 0
A
o

0 A
B 0

B 0 0 B

0
8 o A

O 0
B A

EM176

FIg 66 Cylinder head bolts Fig 69 Adjusting valve clearance

at
 IDliD8

located in 11 25 am position At this time Install distributor assembly

tbe smaUer bow shape will be placed Install carburetor assembly and carburetor in
toward the front sulator with stamp facing upward Tightening
Do not forget to install gasket torque 3 6 to 7 2 ft lb

Install fuel pump water inlet elbow and front Install fuel pipes and vacuum hose

engine slinger in their positions All pipes and hoses should be clamped
Fuel pump tightening torque securely being careful not to allow them to in
terfere with adjacent or surrounding parts
Note Do not forget to instaU fuel pump
and packings inserted between Install thermostat housing thermostat and
spacer
spacer and block spacer and fuel pump water outlet in their positions Do not forget
to install gasket
Install oil strainer oil pan gasket and oil pan
Install rocker cover
Notes

Apply sealant to the step portions at four Note Bond gasket to rocker Cover using
mating surfaces as shown in Figure 44 sealant Then install rocker cover to

oil pan should be cylinder hea 1

Tightening performed
in criss cross pattern and finally to 4 3 to
Install spark plugs
6 5 ft Ib torque
Connect distributor to plug high tension lead
Adjust valve clearance to the specitied dimen
wire
Hons

Install engine mount bracket on left hand

Tightening torque side

36 2 to 4 ft lb
43
Install clutch assembly
Notes

First set clearance to the cold

specifications
After engine has been assembled run it
for at least several minutes finally adjust
the clearance to the warm specifications

Install rear engine slinger exhaust manifold

and intake manifold

Tightening torque
8 7 to 116 ft lb Fig 70 Installing manitolds

L16 and LIB

Intake 0 2 0 0079

Cold
Exhaust 0 25 0 0098
Valve clearance
mm in
Intake 0 25 0 0098
Warm
0 30 0 0118
Exha1
Jsr
IDgiDe

Tightening torque held within 0 315 to 472

0 in when thumb

pressure is applied midway between pulleys

8 7 to 15 9 ft lb
A pressed force is about 22 0 lb
Using an overhead hoist and lifting cable Install engine mount bracket right hand oil
hoist engine up away from engine stand and
filter oil pressure switch oil level gauge and
then down onto engine carrier Install alter water drain plug When installing an oil
nator bracket adjusting bar alternator fan filter fasten it on cylinder block by hand
pulley fan and fan belt in this order Then
check to be sure that deflection of fan belt is Note Do not overtighten filter or oil

Ieakage may occur

Pour engine oil up to specified level

OIL PUMP

Removal
Remove distributor

Drain engine oil

Remove front stabilizer

Remove splash shield board

Remove oil pump body with drive spindle
assembly
Fig 71 Installing clutch assembly

I
I
I
I

Front

ETOO7

Fig 72 Fan belt tension Fig 74 Setting drive spindle

Pumch mark

El009 E LO 11

Fig 73 Aligning punch mark and oil hole Fog 75 Installing oil pump

38
 BDgine

11 25 a m at
Installation on its top is located in position
this time the smaller bow shape will be
Before installing oil pump in engine turn

placed toward the front as shown in Figure

crankshaft so that No 1 piston is at T D C
74
Fill pump housing with engine oil then align
Ascertain whether the engagement is order or
punch mark of spindle with hole in oil pump
not by checking the top of spindle through
as shown in Figure 73
distributor fitting hole
Using a new gasket install oil pump and
that the projection Tighten bolts securing oil pump to front cover
drive spindle assembly so

1
B1ectrlcal IJStem

STARTER 40
Removal 40
CHARGING CIRCUIT DESCRIPTION 40
ALTERNATOR 41

Description 41
Removal 41
Installation 44

VOLTAGE REGULATOR 44
44
Description
Measure of Voltage 45

Adjustment 47

Charging Relay 48
ALTERNATOR
FUSES FUSIBLE LINKS 49
EMISSION CONTROL DIAGRAMS 50
DISTRIBUTOR 52
Construction 52

Disassembly 52

Assembly 53
IGNITION COIL 56
Construction 56

Description 57
SPARK PLUGS 57

Description 57

Inspection 58

Cleaning and Regap 58

TROUBLE SHOOTING IGNITION 58
HEATER UNIT REMOVAL 59
TROUBLESHOOTING HEADLIGHT 62
TROUBLESHOOTING HORN 63
RADIO 63

RerilQyal 63

TROUBLESHOOTING
SPEEDOMETER 64

TROUBLESHOOTING HEATER 65

TROUBLESHOOTING RADIO 65
NOISE PREVENTION CHART 66

39
Ileetrical IJStem

STARTER

@ fJ

l Y@O
i
L
e1l

13 Pinion
I ShiflleYerpin opper
2

3
Gur
hilt
ue

COftr IS
Pinion
tel runDinSclutch 1 e

5
Shiftlcvcr
Dusl
16
17
Field
Yo
coil
I
I
6 Masnetic switchAssy 18 Brulfl
7 Armature 19 Broth
8 Thrustw shcr 20 Brush sprinS
9 Metal 21 Brush holder Auy @@@@ @
10 Thrust washer 22 Metal EE007

II shcr 23 Rear over

Slopper
12 Slopperelipe 2 Throush bolt

Fig 76 Exploded view of starting motor

to operate all electrically operated units and

Removal
cable
to keep the battery fully charged
Disconnect battery ground
When the ignition switch is set to ON
Disconnect black wire with yellow tracer from
current flows from the
battery ground to
magnetic switch terminal and black battery
through the ignition switch
voltage regulator
cable from battery terminal of magnetic
IG terminal primary side contact point PI
switch
movable contact point P2 voltage regulator
Remove two bolts securing starting motor to terminal alternator F terminal
F ield
gear case Pull starter assembly forward and coil and alternator E terminal as shown in
remove starting motor
Figure 77 by full line arrow marks Then the
rotor in the alternator is excited On the other
Installation hand current flows from
battery to the
Installation is the reversal of removal warning switch
ground through the ignition
lamp voltage regulator L terminal lamp
side contact point P4 movable contact point
P5 and voltage regulator E terminal as
CHARGING CIRCUIT DESCmPTION
shown by dotted line arrow marks Then the

The
warning lamp lights
charging circuit consists of the battery
alternator regulator and necessary wiring to When the alternator begins to operate
connect these parts The purpose of this three phase alternating current is induced in

system is to con vert mechanical energy from the stator coil This alternating current is roc
the engine into electrical energy which is used tified by the positive and negative silicon

to
 IlectricalSptem

diodes The rectified direct current output comes into contact with secondary lIide contact
reaches the alternator A and E terminals point P3 Then the rotor current is shut off
and alternator output voltage is ased
decre im
On the other hand the neutral point voltage
reaches N and E terminals
mediately This action causes to separate
Inearly a half movable contact P2 from
of the output and current flows from secondary contact
voltage P3 Thus the vibration of the movable
N terminal to E
rapid
voltage regulator ter
P2
minaI
contact point or breaking and completing
or ground through the coil VCI as the rotor circuit maintains an alternator out
shown in Figure 78 by the dotted line arrow constant
put voltage
marks Then the coil VCl is excited and the
movable contact point P5 comes into contact
with voltage winding side contact point P6
ALTERNATOR
This action causes to turn off the warning
lamp and complete the voltage winding circuit
as shown by the full line arrow marks
Description
When the alternator speed is increased or the
voltage starts to rise excessively the movable Alternator Vehicle
contact point P2 is separated from the
side contact PI by the magnetic 510 and 610 models
primary LTl5005B
force of coil VC2 Therefore register Rl is except for Canada

applied into the rotor circuit and output SlOand610models

LTl60 19
voltage is decreased As the output voltage is for Canada

decreased the movable contact point P2 and

LTl35 13B 620 model
primary side contact PI comes into contact
once again and the alternator voltage in
creases Thus the rapid vibration of the
movable contact point voltage constant Removal
Disconnect negative battery terminal
When the alternator speed is further in
creased or the voltage starts to rise ex Disconnect two lead wires and connector from
cessively the movable contact point P2 alternator

r
I
I

T BlItt ry
1

r
I
t
I

i
J J

Alternator Voltage regulator

fig T7 Charging Circuit 1

tl
Ilectrical Sptem

r Ignition itch
r

ell
a
Btmery
Ii 8
c
0
T
5 0
E i
2

t
S
E
Ii
Cl
l
o

r
Ln J
Alternator Voltage regulator

fig 78 Olarging Circuit 2

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

Starting motor wiD Discharged batter Charge or

replace battery
ot operate Defective solenoid switch Olenoid switch
Repair eplace
Loose connections of terminal Clean and tighten terminal

Defective brushes brushes

Replace
Defective startina motor Remove starting motor and mab test

Noisy starting motor Loose securing bolt Tighten bolt

Worn pinion gear Replace pinion gear

Poor lubrication Fill in oil

Worn commutator Disassemble motor

Worn brushes Replace brushes

Starting motor Discharged battery Charge Or replace bartery

cranks slowly oose connection of terminal
l Clean and tighten terminal

Worn brushes Replace brushes

Locked brushes Inspect brush spring tension or
repair brush
holder

Starting motor Dirty or worn commutator Clean nd epalf

uanks slowly
Armature rubs field coil Replace assembly
Defective solenoid switch Repair or replace switch

Starting motor Worn pinion Replace pinion

operates but doe Locked pinion guide Repair pinion guide
not rank engine
Worn ringgur Replace ring gear

Starting motor will Defective solenoid switch Repair or replace solenoid switch

not disengage even

Defective gear teeth Replace defective gear
ignition switch is
turned off

t2
 I1ectricalSptem

I Pulley Slembly
2 Front
Front bearing
4 Rotor
5 Rear bearing
6 Brush IScmbly
1 RearcoVtr
8 Diode sel
plate aittmb y

9 Diode over

10 h bolts
Throu

Rg 79 Exploded View of LT 58 LT 135 138

150

I P ssemb y
ulley
Front over t
J Front bearing
4

5
Rotor
Rear bearin
J
9
6 Stator
7 Diode set pbtc embly
8 Rear
9 Brush embl
10 Diode

11 Through bolts
o

Rg 80 Exploded View of LT 160 19

a
Blectrical Sptem

I Fron beuing 4 Pulley

2 Rotor 5 Rear

J Stalor 6 Enca d diode

Rg B1 Sectional View ot LT 56 LT 135 136

150

I 5 Rear
Front bearinl
6 Brush holder ssembly
Rotor
7 eE121
3 Startor DiOde
4 Pulley

Flg 82 Sectional View of L T 160 19

Loosen bolt Installation

adjusting
Installation is the reversal of removal
Remove alternator drive belt
VOLTAGE REGULATOR
Remove parts associated with alternator from
Description
engine
The regulator consists basically of a voltage
Remove alternator from vehicle regulator and a charge relay The voltage
 B1ectrical Iptem

of contact points a
has two sets VOLTAGE REGULATOR
regulator
lower set and upper set to control alternator
voltage An armature plate placed between Measurement of VoItage
the two sets of contacts moves upward or Regulator voltage is measured with regulator
downward or vibrates The lower contacts assembled with alternator When measuring
when closed complete the field circuit direct voltage with regulator mounted on vehicle it
to ground and the upper contacts when is necessary to rotate engine at high speed
closed complete the field circuit to ground Connect DC voltmeter 05 30Vl DC ammeter
through a resistance field coil and produces 15 30Al battery and resistor 0 25 ohms
alternator output shown
with cables as

The charge relay is similar in construction to

Check to be sure that all electrical loads such
the voltage regulator discon
as lamps air conditioner radio etc are

When the upper contacts are closed ignition nected

warning lamp goes on

Before starting engine be sure to make short

circuit with a cable between fuse side ter

minal of resistor 0 250 and negative side
terminal of ammeter Failure to follow this
caution causes needle of ammeter to swing
violently and reversely resulting in a

8 damaged
Refer to the

regulator
dition
ammeter

following
and relative parts
chart to determine if
are in good con

Notes a Do not measure voltage im

after driving Do this while
mediately
regulator is cold
Fig 83 View of Removing Cover
b To measure voltage raise engine speed
gradually from idling to rated speed

EEOSA

10 10 Lock
1 Point Adjust pring I Pointglp Ul

2 lower II Coil 2 Cliugc day CI II Adjust spring

3 ArmillurC dir 12 Coil
12 3mm O 11l11 n
3 Cting
ConM e
4
Core ap screw 4 Armature J3 3mmlO lJ81 n di
S p
Yoke I 4 mm 0 1575 n di 5 Core gap screw

6 CnTl 6 Yoke gap 14 4mm di

I ifll pTin Crew 0 1575 n

1 Yoke 14 Conlact set 7 Yoke w

lju
At 15 8 Adju w
IS Contact
II
rlnlE cw Upper nber
ting set

J Lock 9
ul
Vultage egulator
a Corutruction of ollag relU14tOT b Uction
COfUt of chart rrlay

Ag 84 Structural View

tI
IlectricallJStem

GENERATOR

A CONNECTOR
E

WI RE HARNESS

Short ircuit h between

fuse side terminel and H
terminal of ammeter before
starting the operation

BATTERY V
RESISTOR FOR
MEASUREMENT AMMETER VOLTMETER
IDA IJOV

Rg 85 Measuring Regulator Voltage with Regulator on Vehicle

I Start engine
2 Rotate ngine at 2 500 rpm for several minutes

After racing for several minutes ammeter reading Afler for several minutes ammeter
racing
below SA reading
over SA

not available
FuUy charged battery available Fully charged battery
I 0 25 ohm resistor in series
Replace with fuUy charged battery I Connect a

2 Check to see if current falls below SA

I 1

Current falls below SA Current does nol fall below SA

and if current falls below

Recharge battery see

SA

T
I

Reduce engine speed to idling and then raise it to 2 500 rpm while observing needle of voltmeter

I 1
Needle of voltmeter held within limits shown in the below Needle of voltmeter out of limits shown in
table lhe following chart
Regulator functioning properly Regulator ou or order Have it repaired at

authoriled shop
 llectrical Iptem

Regulator model TLlZ 57 and TLlZ S8 HITACHI

Temperature oc oF Volta ge V

to 14 75 to 15 75

0 32 14 60 to 15 60

14
10 50 14 45 to 15 45

20 6S 30
14 to 15 30

30 86 14 15 to 15 15

104
40 14 00 to 15 00

c Voltagemay be approx 0 3 V higber

than the rated for two to three minutes af

ter engine is started or more specifically
when regulator becomes self heated
Measurements should then be made
within one minute after starting engine
or when regulator is cold

d The regulator is of a temperature com

pensating type Before measuring voltage 1 Contact set

be sure to measure surrounding tem 2 Thickness gauge

3 4mm O 1575in dia screw

perature and correct measurements ac
4 CIOsshead screwdriver
cording to the table in the left hand side
Ag 86 Adjusting Core Gap

Adjustment
As the result of above measurement when

regulating voltage is deviated from rated

value adjust regulator in accordance with the
following instructions

1 Inspect contact surface and if rough

lightly polish surface with fine emery paper
500 or 600
EE057
2 Measure each gap and adjust if necessary
I Thickness gauge
Adjust core gap and point gap in that order 2 3 mm 0 1181 in dia
No adjustment is required for yoke gap screw

3 Crosshead screwdriver
3 Adjusting core gap
4 Upper contact

Loosen screw 4 mm 0 1575 in diameter

Ag Adjusting Point Gap
which is used to secure contact set on yoke
and move contact upward or downward
See Figure 86 tact upward or downward adequately See
properly
Figure 87
4 Adjusting point gap
0 1181 diameter used
5 Adjusting voltage
Loosen screw 3 mm m

to secure upper contact and move upper con Adjust regulating voltage as follows

II
lIeetricalSptem

Loosen lock nut securing adjusting screw

Turn this screw clockwise to increase or coun

terclockwise to decrease regulating voltage

See Figure 88

Charging relay
is 8 to 10V EE058
Normal relay operating voltage as
U
I Wrench
measured at alternator A terminal Relay it
2 Cro ead screwdriver
self however operates at 4 to 5V 3 Adjusting screw

4 Lock nut
Use a DC voltmeter and set up a circuit as

shown in Figure 89 Fig 88 Adjusting Regulating Voltage

l Connect positive tenninal of voltmeter to regulator lead connector N terminal with negative terminal

grounded
Starl engine od keep it idle
3 Take voltmeter reading

aVail Below 5 2 Volts Over 5 2 Volts

l Check fm ntinuity b Pilot lamp remains lit Pilot lamp emainslit

terminals of Check fan belt tension Pilot ontact
tween N l lamp relay Oil
gulator and alternator If reet remove egulator points Qui of rdef
Alternator circuit defective od adjust as
necessary Replace 1tregulor
if continuity exists

Over 5 2 Valls

Pilot does 001 lit

lamp
Pilot lamp clay assembly is in good odition

TROUBLE DIAGNOSES AND CORRECTIONS Including alternator

Condition Probable cause CorrectiYe action

No Sticking brushes Correct or

replace brushes and brush springs
output
Qean
Dirty brushes and slip rings
Loose connections or broken leads Retighten orsolder connections
Replace leads if ecessary

Open stator winding Repair or

replace stator

Open rotor winding Replace rotor

diodes Replace diodes

Open
Shorted rotor Replace rotor

Shorted stator Repair or

replace stator

Grounded BAT terminaL Replace insulator

Broken ran belt Replace belt

t8
 IlectrieallJStem

Excessive Otltput Broken neutral wire color of wire is whitt Replace wire

Check regulator operation and repair or

Defective voltage regulator
replace as required
Poor of alternator and voltage Retighten terminal connection
grounding
regula tor E terminal

Broken ground wire color of wire is black Replace wire

Loose or worn fan belt Retighten or replace belt

Low output
Correct and if
Sticking brushes or
replace brushes springs
necessary

Low brush spring tension Replace brush springs

Defective voltage regulator Check egulator operation and repair or

replace as required
Clean
Dirty slip ngs

Partial short ground or

open in stator Replace stator

winding
Partially shorted or
grounded rotor winding Replace rotor

or defective diode Replace diode

Open

Noisy alternator Loose mounting Retighten mounting bolts

Loose drive puUey Retighten pulley correctly
Defective ball bearing Replace bearing

Improperly seated brushes Seat brushes correctly

Alternator Fuses and Fusible Links

r Qo wt Lou
Iu r tor N
tIi
E t
La
M
P re O lp t@C ftlor
N br

A p L320 Engine compartment

1 LS20 ight
L521
Mitllubillhi 2 500 24 5 PL521
AS203Al PUlO
WPLSIO
R Mit lbishi 2 SOO 24 5
AC1lli I2X2H 215@ LOO Engine compartment
high temp riht fender well

U20 Mitsubishi 2 500 23 SPL3II Inside glove lmpa

c nt
AS2030A2 SHL3ll

LIB Hitachi 500 22 L8ll0 Under instrumfttt panel Between battery

41
LTl30 KLBllO ight of steering column and alternA tor

24
1 Hitachi 2 500 34 HLSJO Under sh tray console At alternator
at starter
LTl45 35 5 000 45

AI2 Hitachi 2 500 24

LTl35 05 5 000 33

Morethan

41
IlectricalSptem

EMISSION CONTROL DIAGRAMS

IGNITION KEY

TO TJlIIUTO
OI

IGNmClC COIL

no DUAL PenNY
OlSTRI8UTOII

I
NEUTRAl QEAfl SWITQt
ANCED
UlCER

RETARDED
BREAKER

I
CLUTOt PEDAL

CARSURfTDR

LENOID

lr

MTCH DETECTING CLOSE THIIOTTLE IlO5lnON

Datsun emission control system manual transmission

IGNITION WITOI

TO OISTRIJUTOfI

ICHITlON COIL

BATTERY
DUAL IIOINT
AUTOMATIC
TRANSMISSION OISTRI8UTOII

l TAROED
R

Pat
KE

swtTQt DETlCTING DI CftN

nfROTTU POSlnON
SWITCH DETECTING CL
CIS

THROTTLE POSITION

Datsun emission control system with automatic transmission

50
 IIectricalSptem

1
FROM
CARBURETOR
AIR CLEANER
FROM
FUEL TANK

2
TO
CllAHKCAlI

VAPOR VENT LINE

FLOW GUIDE VALVE

The v lv opan
when the pr Ie
Ie over 0 4 in Hg

CV lIE

FUEL TANK

Datsun evaporative emission control system

51
IIectricalSpt

I
Battery

ReslSlor

To starter

C P

Retarded breaker point Rotor bead

Coo
L

1
n

DiStri IO

Fig 89 Ignition Systems Circuit Diagram

DISTRIBUTOR

CONSTRUCTION

Distributor model Applied engine

0410 66A LIS

0410 67 LI 6

The distributor for L1G and LIS engines has fig 90 External View of Distributor
two breaker located
points opposite to each
other with a phase difference as shown in

Figure 90 The distributor follows the conventional de

sign except for the dual points i e breaker

The difference in phase can be adjusted by
plate with contact points centrifugal advance
turning the adjusting screw
mechanism vacuum unit drive shaft and
A phase difference of 70 crank angles is adop 92 and 93 show
rotor Figures an exploded
ted Two breaker points which consists of ad view of the unit
vance and retard breakers are placed in par
a1Iel with each other in the primary ignition Disassembly
circuit To disassemble follow the below procedure
The retard breaker point works when the Take off cap and disconnect rotor head

relay is switched ON and the advance

Remove vacuum controller
breaker point works when the relay is swit
ched OFF See Fig 91 Remove contact set

12
 I1ectrical Iptem

and When is to be removed first remove set

Unscrew two contact breaker set screws cam

since shaft head is fastened by the

remove contact breaker assembly screw

screw to hold cam down Put matih mark

Pull knock pin out and disconnect collar to
across cam and shaft so that original com
remove the entire rotating parts
bination can be restored at assembly
When governor weight and spring are discon
nected be careful not to stretch or deform
governor spring
After disassembling apply grease to governor
weights

Assembly
Assemblv can be made in reverse sequence of
Refer to Figure 101 for
disassembly
replacement and reassembly of governor
spring and cam
Inassembling distributor use caution so that

rotorhead positioning tip at cam is set on

1 Advanced breaker point
hook side
2 rded breaker
Ret pomt governor spring circular
3 Phase difft rence

Then for governor spring A with

weight pin
FIg 91 External View of Dual Points circular hook comes in long rectangular hole

1 Center carbon 4 Condenser 7 Governor weight

2 Rotor head S Shaft 8 Cap
3 Breaker plate Contact 6 Hou ing 9 Side plug

Rg 92 Construction

13
I

iE1

asembly asembly a s e m b l y
asembly asembly asembly control asembly apoisemblny t asembly point embly point asembly point asembly
point
set

asembly asembly weight spring cap as

set
asembly head set
Advanced plate Bolt Retard wiLearde Advance wire Retard wiEarrteh
Shaft Colar Cam
J
23
Governo Governo Screw Rot r Breakr Contac Conectr Vacum Screw Condesr Screw Distrbuo Carbon Fixng Condesr
4 5678 9
10 II 12 13
for

14 15 16 17 18 19
for Screw
20 21
for Lead for
22 23

Distrbuo
of

1
i
I I

Compnets
7iJ
93
o
Flg

4
 IlectricalSJStem

EE07D EE074

Fig 94 Disassembling Vacuum Controller Fig 98 Removing Rotation Parts

EE075

Fig 95 Unscrewing Breaker Sets Screws Fig 99 Removing Carn

Q
s

b
i
EE141

Ag 96 Removing Contact Breaker

Fog 100 Exploded View

Also check to be sure that weight pin on

spring A is in slit in cam plate with a
clearance between the two at beginning and
end of governor operation
EE073 Meanwhile weight pin on opposite side comes

Fig fJ11 Removing Knock Pin in short rectangular hole

5
B1ectricalSptem

1 5

Shaft enter

I Governor Ieighl
2 Clearance fOl slart and

end of advancin angle

3 Rectangular hook
4 Governor printt R
5 am
plate
6 Weight pin
7 Circular hook
8 Gm ernuT
spring A
EE071 9 Rotor positioning tip

Ag 101 Setting Governor s Spring and earn

IGNITION COIL

1
2
CD
4

l rillliJr lnitlal
J Sl ndary 1
@ l It Tmin
Jp
C

4 Sprln
5 Side
@ h Primary III

7 S ndar il

8 In uhllllr HI

9 l nlcr
@ III Segment
II Case
EE143

Fig l02 Construction

18
 IIectricalSJStem

It does not leave clearance either at the start The resistor in the ignition coil circuit helps
and end of advancing produce strong sparks from starting to
high speed full power operation
With unit assembled check to be sure that

driven slit and rotor position tip 9 are set in The internal resistor limits to a maximum
current through the
the same direction See Figure 101 safe flow of the primary
coil and distributor contact points Thus it
After assembly check operation of governor
protects the contact points during slow speed
before installing it on engine
operation when they are closed for long inter
Ignition timing should be tested with unit vals
mounted on engine
The ignition coil and resistor should be han
dled as a matched set
IGNITION COIL

Description
The ignition coil is of an oil filled type The ig
nition coil case is filled with oil which has
SPARK PLUGS
good insulating and heat radiating charac
teristics
Description
The spark plugs of the resistor type
greater ratio between are
The ignition coil has a

the primary and secondary windings to step having 0 551 in threads and 0 0276 to 0 0315
in gap The inspection and cleaning should be
up the battery voltage to the high voltage to
made every suitable maintenance period If
cause stronger sparks to jump the spark plug
necessary replace
gap

The cap is made of alkyd resin which offers Note All spark plugs installed on an

engine must be of the same brand and

high resistance to electric arc and increased
insulation number of heat range

i l

Carbon fould
Normal

Life
Overheating

Fig 103 Spark Plugs

17
IlectricalSptem

Inspection fuel pump pressure wrong selection of fuel a

Remove spark plug wire by pulling on boot hotter plug etc

not on wire itself

It is advisable to replace with plugs having
Remove spark plugs colder heat range

Check electrodes and inner and outer por After cleaning dress electrodes with a small

celains of plugs noting the type of deposits fine file to flatten the surfaces of both center
and the degree of electrode erosion and side electrodes in parallel Set spark plug
gap to specification
Normal Brown to grayish tan deposits and
indicate Install spark plugs and torque each plug to 11
slight electrode wear correctspark
to 15 ft lb
plug heat range
Connect spark pi ug wires
Carbon fouled Dry fluffy carbon deposits on

the insulator and electrode were mostly

in
Cleaning and Regap
caused by slow speed driving city weak ig Clean spark plugs in a sand blast type
nition too rich fuel mixture dirty air cleaner cleaner blasting Clean and
A void excessive
etc
remove carbon or oxide deposits but do not

It is advisable to with plugs having wear away porcelain If deposits are too stub
replace
hotter heat range born discard plugs

Oil fouled Wet black deposits show excessive

oil entrance into combustion chamber through
worn rings pistons or excessive clearance
and
between valve guides and stems If the same
condition remains after repair use a hotter

plug

Overheating White or light gray insulator

with black bluish
gray brown spots and
or

burnt electrodes indicate engine overheating

Moreover the appearance results from in
correct ignition timing loose spark plugs low Fig 104 Selling Spark Plug Gap

TROUBLE SHOOTING IGNITION

Spark length Trouble location Causes Remedies

No sparks at all Distributor Defective insulation of condenser Replace

Breakage of lead wire low tension ide Repair

Defective insulation of cap and rotor head Replace

Point does at open close Repair

19nition coil Wire breakage short cuit of coil Replace with new ne

High tension cable Wire coming off Repair

Defective insulation Replace

I to 2 mm 0 0394 Distributor Point gap too wide Correcl

to 0 0787 in or
Clean
Oil sticking on
point
irregular
Point burnt too much Replace

18
 IlectricalSpt

T ublt Trouble location Cause Remedies

Less than 6 mm
Spark plugs Electrode gap too wide Correct or
eplace
0 2362 in
Too much carbon Clean or
replace
Broken neck of insulator
Replace
Expiry of plug life
Replace

Engine misses Distributor Dirty point Clean

Improper point gap Correct

leak of electricity of cap and olor head Repair or replace

Defective insulation of condenser
Replace
Defective arm Oil shaft

Defective spring of rm
Replace assembly
Breakage of lead wire Replace
Worn out or
shaky breahr plate Replace assembly
Worn out or
shaky distributor shaft Replace assembly

Ignitjo il Layer short circuit or of oferior quality with good

Replace one

High tension code Deterioration f insulation and leak of

Replace
electricity

Spark plugs Dirty Clean

Leak of electricity at upper porcelain Repair or

replace
nsulater

Engine causes Distributor Improper and advance timing Correct the fitting
knocking very off of governor
Coming or
breakage spring Correct or
replace
often
A pin or a hole of governor portion worn
Replace
out

Spark plugs Burnt too much Replace

Engine does not Distributor Improper and etarded timing Correct the fitting
give enough
Defective function of governor Replace assembly
power
Dirty point Clean

Point gap too narrow Correct

Spark plugs Dirty Clean

After cleaning spark plugs renew firing sur Disconnect connector of heater to engine well
face of electrodes with file mentioned above hot water pipe
Then gap spark plugs to 0 0276 to 0 0315 in
round wire feeler Remove defroster hose
using a
gauge All spark
plugs new or used should have the
gap Disconnect connector motor
checked and reset by bending ground
electrode Remove the two heater control wires at heater
unit

Remove the four bolts and take out ventilator

HEATER UNIT REMOVAL
Remove the four heater unit fixing bolts and
Drain out coolant
detach heater unit

18
 syste1ll

J
uJ
a E ii5
o
t03
2
A
t
3
1 t
J

h 8 tD

s
3
0

I
ft r
0

11 Ira il
1 I
111 11
I HP 4
II II lll
d C nIII
l
i

I
El
7J
O
oo lU1
lr
C
r
fuoO
J lJ
I
1 u

c
o

Ii J l Ii
Wt i
s
Tif r II E
L
l t
ir
l
I i l
ir Q l II ilt il
JI q c

1
J 1 I 1
II IS 1 11 l f
I
III C
I i ti II
1J lc
INi
yl
I
@ s3iiLI 1t I
I m II ii
I
1 1 J SI l
o II c

i
l
1

II I III r I
fiF E

z
I
II i
1 Ii lli I
l J2l
1 A
c

nnmm
m t

0
1 1 I
I
I IIiI
1 C
1
lI
I c f
dJ
r
rt o 1
l Itti1nT e E

t
L J
Ii i
III is
IC
I III C
0

I
lW 11 I I I l III
i c
J

r
W I
T J
Ii
I
Ji3r
I
l
ll

F
Xrf J
Ii r

I
l il e
r

I
rs
o

it 111
t
I
0
hill IF
u 5
I

aft
 IleCtricalSystem

P 1
Q

8
0
iii aa
o

1J
t
8 CD
a

1l

g
c
o

E
c

E
l
E
a

c cS

z
a c

is

rraa 1 8
Il
dl
It

ir
lf1l
t
g or

81
B1ectrical SpteJD

TROUBLE SHOOTING HEADLIGHT

Condition Probable cause Corrective action

Head lamps dim Partly discharged battery Charge battery

engine idling or
Defective cells in battery Replace battery
shut off
High resistance in circuit Check head lamp circuit including
light
ground connection

Make necessary repairs

Faulty sealed beam units Replace sealed beam units

Head lamps dim istance ci rcuit Check lighting circuit includ

High light
engine running ground connection

above idle Make necessary repairs

Faulty sealed beam units Replace sealed beam units

Faulty voltage control unit Test voltage control and generator

Make necessary repairs

Lights flicker Loose connections or

damaged Tighten connections and check for

wires in lighting ircuit damag d wiring

Light wiring nsulation damaged Check light wiring and replace or

producing momentary short tape damaged wires

Lights burn cut High oltage regulator setting Adjust voltage regulator
frequently Loose cOIUlections in Check
lighting circuitCor loose connections
circuit

LIght will not and correct

Discharged battery Recharge battery
light cause

Loose connections in lighting Tighten connections

circuit

Burned out bulbs Replace bulbs or sealed beam unit

Open or corroded contacts in light Replace lighting switch

ing switch

Open or corroded contacts in turn Replace turn and lighting

signal
signal and lighting switches switches

will Switch Replace switch

Slop lamps faulty
not light Wires broken disconnected or Make necessary repairs
loose

Bulb burned out Replace bulb

Loose connection poorly ground

or
Tighten loose connectIon or pro
od lamp body perly ground tamp body

Burned out fuse Check for shorts and replace fuse

Turning signal Faulty n sher unit Replace flasher unIt

lamps light with Burned out bulb
parking or tail lamp on Replace
out btinklng
that side

82
 IIectricalSJStem

Blinking on one Loose contact of bulb Make necessary repair

side too fast
Improper capacity of bulb
Replace bulb

Turn indicator mechanism

Faulty of turn signal Replace with new
parts
lever does not switch
return automati

cally

TROUBLE SHOOTING HORN

Condition Probable cause Corrective action

Horn does not F burned ut Replace fuse

operate
Improper mtaet uf horn bulton Check and repair horn button

Open circuit f harness Repair or replace harness

Improper mtaet of ch terminal Correct each terminal

Dead battery yharge battery

Improper contact of horn relay Correct

point

Open circuit or
rong ground coo
Replace or repair horn
nection of horn interior

Wear of horn point Adjust adjusting screw

Low volume Improper contact of fuse or 000 Correct contact

improper tone nector

Open circuit of harness Repair

Improper contact of horn point Correct horn point

Wear of horn point Adjust adjusting screw

Crack in diaphragm Rephlce horn

RADIO

Removal
HORN RELAY

Disconnect all connections

z
z
1 i
g ii Remove tuning knob
I8 I i
COIL
and volume control
knob
i i
2 2 IOINT

lI
BATTERY
L J Remove ashtray
Remove cluster lid
lid
by unscrewing four cluster

fixing screws

Separate cluster lid finisher board and radio

Ag 107 Horn Relay Wiring by unscrewing lock nuts

83
B1ectrical Spt
m

TROUBLE SHOOTING SPEEDOMETER

Condition Probable cause Corrective action

Speedometer does Improper setting of speedometer Correct setting

Dot cable union nut
operate

Broken speedometer cable Replace cable

Broken speedometer drive gears Replace meter

Defective speedometer Replace meter

of pointer Excessive bend in speedometer Correct cable installation or re

Swing
place cable
Broken speedometer drive gear Replace speedometer
Defective speedometer Replace speedometer
f
Unsteady pointer Improper setting of speedometer Correct setting
cable union nut

Defective speedometer cable Replace cable

Defective speedometer Replace speedometer

Excessive bend lack of lubricant

Strange sound Replace or
lubricate cable
eyncbronized and twist of meter cable inner wire

witbrunning Defective speedometer Replace speedometer

speed
Inaccurate Replace speedometer
indication of

pointer

Defective Improper gearing of second and Replace speedometer

odometer third gears in speedometer
Improper feed caused by deforma Replace speedometer
tion of pinion carrier

ry
1
Cil 1
@

@f

fig 108 Heater System

84
 IIectricalSpteJD
TROUBLE SHOOTING HEATER

Condition Probable cause Corrective action

Hot air does not

come out

Motor does Open or short circuit of feed Check and repair wiring harness
not harness
operate Defective switch Replace switch
Fan cannot be
Defective motor Replace motor
rotated
smoothly by
hand
Fin is clogged Clean fin
Hot air does
Slow rotation of fan
Dot come out Replace motor

although lesfJ

fan is
Looseness of fan stallation Repai r
rotating

Air temperature
is low

Hot wate r Defective water pump Repair water pump

does not
Bending or
clogging of connectir g Check or clean piping
circulate
hose

Defective hot water cock Repair

Air is left in the hose air out of hose

Purge
Water tem Defective thermostat Replace thermostat
perature is
low

Water leakage Defective water hose Replace water hose

rom heater
Loose clipping of water hose
Retighten clip
Defective cylinder head gasket Replace gasket

Improper soldering of heater core Solder leaking position

Defective Defroster hose is removed Correct connection

defroster
Bend break of defroster hose Correct
or or replace

Vibrating noise Looseness of heater BUpport Tighten completely

Looseness of each fixing screw
Retighten each screw

TROUBLE SHOOTING RADIO

Condition Probable cause Corrective action

Pilot lamp does Melt away fuse Replace

not light when
Improper connection of cable or Inspect and tighten
switch is on
connector

Broken pilot lamp Replace

Improper switch operation Repair or

replace

Pilot lamp lights Improper connection of antenna Tighten

but sound does
Improper connection of speaker Tighten
not come out
Improper circuit of radio itself Consult Service Shop of radio
manufacturer

85
B1ectrical I em

NOISE PREVENTION CHART

Condition Apparent cause Repair

Ignition system
Noise present synchronized High tension cord Do not worry about high tension cord
with engine revolution because anti noise cable is uBed

Ignition coil Keep choke wire away from ignition

coil far
as a8 P08 l
f
Set 0 5 IJ F condenser at primary side
B terminal of ignition coil

Note If the 6
COI is set at

ondary or primbraker side

engine will not p

Connect with bond wire between engine

and ignition coil locating area of body

Secure ground of ignition coil

Distributor Secure contact of carbon electric pole

and rotor

Eliminate excessive tips at rotor pole

cap pole scrubbing by driver
or

Check stagger veen

bet rotor and

starter

Charging system
Sound of alternating current Alternator Set 0 5 F condenser at charging
present terminal A

Note 00 not add mote condan r

If more conden is added alter

nator coil will be broken

hen pressing down or re Regulator Set 0 5 F condenser at B or Bat

leasing accelerator pedal terminal of voltage regulator

noise present

88
 Fuel Sptem

AIR CLEANER ELEMENT 68

AUTOMATIC TEMPERATURE
CONTROL AIR CLEANER 68
AIR CONTROL VALVE 68
Idle Compensator 69
TEMPERATURE SENSOR 69
Removal 69
Installation 69
FUEL PUMP 69
Removal and Disassembly 69
Inspection 70
Assembly 70
CARBURETOR 73
Removal 73
Disassembly 73
Float Chamber 74

ANTI DIESEUNG SOLENOID 74

Removal 74
Installation 74
BOOST CONTROLLED
DECELERATION DEVICE 74
Assembly and Installation 74
Cleaning and Inspection 74
JETS 75

81
raelSpt

AIR CLEANER ELEMENT When the temperature of suction air around

ThE air cleaner element is of viscous paper
a the sensor reaches 37SC IIOOF or above

type and does not require any cleaning until the sensor actuates to open the air control

replacement valve When the temperature of suction air

lote Do not brush or blast element around the sensor further rises and reaches
before replacement above 480C 11S0Fl the air control valve

completely opens prevent the entrance of

to
AUTOMATIC TEMPERATURE hot air and allows under hood air alone to be
CONTROL AIR CLEANER introduced into the carburetor See Figure
The automatic
temperature control air 111
cleaner is provided with a temperature sensor

and a vacuum operated valve The vacuum ac AIR CONTROL VALVE

ted upon the air control valve is controlled by
the sensor See Figure 109 The air control valve acts in the manner

described previously and the temperature of

If the temperature of suction air is low when
i
c ir a h sensor is always kept
the engine is running the air control valve
s n
IL e

at about 430C II 10oFl

closes the underhood air inlet and introduces
hot air through the cover which is installed on When the engine is operating under heavy
the exhaust manifold See Figure 110l load the air control valve fully opens the un

I Air nlet pipe

2 Vacuum molor s y

3 Temperature censor ass y

4 Hot rpipe
@ 5 Air ntrol alve

Ml
EC 6 Idle compresalor

Rg l09 Automatic Temperature Control Air Cleaner

To manifold
I

3 Diaphragmspring
4 Diaphragm
5 Vacuum hose

6 Air bleed valve I 6 Air b1cedvahrc

Airinlclpipe
Partwly open 2 Air ntrolvalvc fully open
Hot 7 7 Hot
Hot air pipe 3 Diaphrapn prins PJPC

Air inlet 8 Temperature censor 4 Diaphrqrn 8 Temperature llsor

K
I pipe
5 Vacuum hoses b1
2 Air control ly ECOO7 ECOOB

Hg l10 Hot Air Delivery Mold During Cold Engine fig 111 Underhood Air Delivery Mold lOuring Hot
Operation Engine Operation
 FuelSptem

derhood air inlet to obtain full power regar Note Use care not to damage sensor

dless ofthe temperature around sensor

Connect hoses to their proper positions See
This control of carburetor air temperatures Figure 115
allows leaner carburetor calibration with ac

companying reduced emissions than conven FUEL PUMP

tional controls and also eliminates carburetor

icing Removal and Disassembly

Remove fuel pump assembly by unscrewing
Idle Compensator two mounting nuts and disassemble in the
The idle compensator is essentially ather following order
mostatic valve to compensate for excessive
enriching of the mixture as a result of high
idle temperatures When the under the hood

temperatures are high the bimetal located in 1 Pipe

the air cleaner is heated by intake hot air and 2 Catch
lifts the valve to open This pennits additional 3 Fixed with
ad hesivc
fresh air that is properly calibrated by the 1 4
4 Hose
mm 0 055 in dia orifice compensates for the 5 Tab
increased richness of into the intake manifold 6 CHp
and the air fuel mixture in order to maintain 7 GaSket

smooth idle engine operation Ag 112 Removal 01 Sensor

The idle compensator thermostatic valve par

tially opens at 650C l490F and fully opens

at 750C l670F

Never attempt to disassemble this unit since

it is sealed for tightness and properly adjusted
for valve timing

TEMPERATURE SENSOR

Removal
Flatten tabs of clip with pliers Ag 113 Installing Sensor
Pull off hoses

Note Note the respective positions of

hoses from which they were removed
Take off sensor and clip

Installation
Install sensor and gasket assembly In the
proper positions See Figure 113
Insert clip Be sure to hold sensor at its
correct position in Fig 113 to avoid damage
See Fig 114

Press fit clips into pipe while straightening

tabs Ag 114 Inserting Clip

81
aelSpteI l
l

Separate upper body and lower body by un during this operation not to damage
screwing body set screws diaphragm or oil seal
Take off cap and cap gasket by removing cap Drive out rocker arm pin by using a press or

screws
hammer

Unscrew elbow and connector

Inspection
Take off valve retainer by unscrewing two Check upper body and lower body for cracks
valve retainer screws and two valves are
Check val ve assembly for wear on valve and
easily removed
valve spring Blow valve assembly with
To remove diaphragm press down its center breath to examine its function
against spring force With diaphragm pressed
Check diaphragm for small holes cracks or
down tilt it until the end of pull rod touches
wear
the inner wall of body Then release the
diaphragm to unhook push rod Use care Check rocker arm for wear at the portion in
contact with camshaft

Check rocker arm pin for wear A worn pm

may cause oil leakage

Check all other components for any abnor
malities and replace with new parts if
necessary

Assembly
Reverse the order of disassembly Closely ob
serve the following instructions

Ag 115 Connecting Hoses Use new gaskets

1 OutIetvalve

2
Diaphragm
3
Diaphragm spring
4 Inlet valve
5 Rocker arm

fig 116 Schematic View ot Fuel Pump

70
 uelSJStem

Lubricate rocker arm rocker arm link and

rocker arm pin before installation

To test the function proceed as follows

Position fuel pump assembly about 3 3 ft

above fuel level of fuel strainer and connect a

pipe from strainer to fuel pump

Operate rocker arm by hand If fuel is drawn

up soon after rocker arm is released fuel
Ag 117 Removing Pole Rod pump is functioning properly

1 Fuel pump cap

2 Cap gasket
3 Valve packing Ass y
4 Fuel pump valve Ass y
5 Valve retainer
6 Diaphragm Ass y
@ 7 Diaphragm spring
8 PUU rod

9 Lower body seal washer

10 Lower body seal

11 Inlet connector

12 Outlet connector
13 Rocker arm spring
14 Rocker arm

15 Rocker arm side pin

16 Fuel pump packing
17 Spacer Cuel pump to
EF008 cylinder block

FIg 118 Structure of Fuel Pump

71
 I

ble d ble d tube hole valve

air airjet jet

9
i

S S S
emulsion throtle
main slow slow main bypas
S S S S

15 16 17 18 19 20 21

ble d ble d
air air

slow gOW jet

I
st
2nd
hole valve
throtle
slow bypas main smal
noz le venturi Carbueto
of

89
P P P P S

3
S

View
10 II 12 t 14

tube
Sectional
venturi noz le 119

valve valve smal main ble d aic

emulsion Fig

Float Float Choke Primary Primary Main Primary

1 2 34 56 7

of
do
1
9
c

I
i
 Fuellptem

CARBURETOR Remove pump lever and pump rod

Remove cam connecting rod

Removal
Remove air cleaner Remove thermostat cover by unscrewing three
set screws
Disconnect fuel and vacuum lines from car

buretor

1 Needle valve
Remove throttle lever
2 Stopper plate
Remove four nuts and washers 3 Filter
retaining car
4 Filter l
buretor to manifold
screw

Life carburetor off manifold S Nipple

Remove and discard the gasket used between

carburetor

necessary

Disassembly
and manifold
y
Replace it if

o11 @

ET040
Do not remove throttle plates 122
Fig Removing Filter
Carburetor assembly

Remove throttle return spring from primary

side

w
o

@
I Chock chamber
CID
ET041
ET038
2 Thermostat cover
1 Ventui 4 3 Pump lever
Secondary
2 Main air bleed 5 4 Throttle return spring
Primary
3 Emuleion take 5 Pump rod

Rg 120 Removing Thermostat Rg I23 Removing Venturies

2 ET039
EF134

fig 121 Removing Diaphragm Chamber Flg 124 B C D D Securing Screws

73
aelSptem
l

Remove choke chamber by unscrewing four After inotalling anti dieseling solenoid leave
et screw and remove throttle return spring carburetor more than 12 hours without
from secondary side operation
Separate float chamber and throttle chamber After replacement is over start engine and

by unscrewing four set screws check to be sure that fuel is not leaking and
that anti dieseling solenoid is in good con
Float Chamber
dition
Remove diaphragm chamber assembly and Notes a Do not allow adhesive getting on

diaphragm chamber gasket valve Failure to follow this caution would

Remove fast idle and counter result in improper valve performance or

cam cam spring
lever clogged fuel passage

Remove filter set b In installing valve use caution not to

screw nipple filter needle
valve and stopper hold body directly Instead use special
plate
tool tightening nuts as required
Remove cylinder plate pump cover piston
c After installing a new solenoid check
piston return spring and inlet valve by un
to be certain that there is
screwing two set screws
no leakage
cracks or otherwide deformation
Remove injector spring and outlet valve
BOOST CONTROLLED
Remove small venturies main air bleeds and
DECELERATION DEVICE
emulsion tubes from primary and secondary Remove B C D D by unscrewing three
sides 1
securing screws Do not unscrew three
B C D n 2
Remove slow jet and slow air bleed assembly scrcw

Remove When installing after screwing three

primary and secondary main jets
securing screws 1 rescrew three BC D D
Remove level gauge cover float chamber
assembly screws 2 in order to prevent the
level gauge rubber seal float shaft colour and
warp of B C D D body
float
Tighten torque
Remove power valve 17 to 35 in lb

Remove return plate sleeve fast idle lever

and throttle lever Assembly and Installation
spring hanger
Follow disassembly and removal procedures in
reverse
ANTI DIESELING SOLENOID
Removal if necessary
Replace gaskets
Solenoid is cemented at factory
In disassembling interlock link and related
Use a pair of pliers to loosen body out of
components be careful not to bend or deform
position
any of components
Installation Careful will smooth
reassembly rest9re
Before installing a solenoid it is essential to of all interlock parts
operation
clean all threaded parts of carburetor and
solenoid Supply screws in holes and turn Cleaning and Inspection
them in two or three pitches Dirt gum water or carbon contamination in
or on exterior moving parts of a carburetor
First without disturbing the above setting
all
are often responsible for unsatisfactory perfor
coat exposed threads with adhesive the
mance For this reason efficient carburetion
Stud Lock ofLOCTITE or equivalent
depends upon careful cleaning and inspection
Then torque screws to 30 to 48 in lb while servicing

R
 ruel IJStem

Blow all passages and castings with com Check filter screen for dirt or lint
pressed air and blow oft all parts until dry
Clean and if it is distorted or remains
Note Do not pass drills or wires through
plugged replace
calibrated jets or passages as this may
Check linkage for operating condition
enlarge orifice and seriously affect car
buretor calibration Inspect operation of accelerating pump Pour
fuel into float chamber and make throttle
Check all parts for wear If wear is noted
lever operate And check condition of fuel in
defective parts must be replaced Note
the following jection from the accelerating nozzle
especially
Push connecting rod of diaphragm chamber
and block passage of vacuum by finger And
when connecting rod becomes free check for JETS
leakage of air and damage of diaphragm
The carburetor performance depends on jets
Check float needle and seat for wear If wear
and air bleeds That is why these components
is noted assembly must be replaced
must be fabricated with utmost care To clean
Check throttle and choke shaft bores in throt them use cleaning sol vent and blow air on
tIe chamber and choke chamber for wear or them Larger inner numbers stamped on the
out of roundness indicate
jets larger diameters Accordingly
Inspect main and slow jets with larger numbers
idle adjusting needle for burrs or
Such provice richer mixture and the smaller num
ridges a condition requires replacement
bers the leaner mixture Inversely the main
Inspect gaskets to see if they appear hard or and slow air bleeds which are for air to pass
brittle or if edges are torn or distorted If any make the fuel
through leaner if they bear
such condition is noted they must be larger numbers and the smaller numbers the
replaced richer fuel

71
GaoUDI Sptem
DRAINING FLUSHING 78

WATER PUMP 78
Removal 78

ssembly 79
Dis
Inspection 79
Installation 79

THERMOSTAT 79
Removal and Installation 79
RADIATOR 79
Removal and Installation 79

Inspection 80

1
Cooling Sptem

JJ

CiJ @

C0013

FIg 125 Cooling System

DRAINING AND FLUSffiNG The pump contains an impeller that turns on

a steel shaft which rotates in the ball

To drain the cooling system remove the bearings and the volute chamber is built in
radiator cap release the drain cock at the bot the front cover assembly The inlet of the
tom of the radiator and drain plug on the pump is connected to the radiator lower tank
right side of the cylinder block If the heater by a hose
system is installed set the heater temp
erature control valve at open Removal
position
Drain coolant into a clean container
After the coolant is drained completely close
and refill the system Loosen four bolts retaining fan shroud to
the drain cock and plug
with clean water radiator and remove shroud

WATER PUMP

Thwater 1ump is of a centrifugal type

which is mounted on the engine front cover
The fan and pulley are bolted at the pulley
hub

The pump shaft is supported by a double row

ball bearing press fit in an aluminum die cast

pump body The bearings are

permanently
lubricated and sealed to prevent loss of
lubricant and entry of dirt fill 126 Removing Water Pump

78
 Cooling IJStem

Loosen belt then remove fan blade and pulley

from hub

Remove five bolts pump assembly and gasket

from front cover

Disassembly
The water pump body is made of aluminum
and its bearing outer race is press fit For this
reason the body shaft bearing should not be
disassembled
fig 127 Removing Thermostat

Inspection
for the following
Inspect pump assembly con

ditions and replace it if necessary Loosen two securing nuts and remove water

rusted corroded body assembly and outlet gasket and thermostat from ther
Badly or
mostat housing
vane

in
Excessive end play or roughness of bearings After checking thermostat satisfactorily
in
stall replacing with a new housing gasket
operation
Reinstall water outlet and tighten securing
Installation nuts
Make sure to clean the gasket surfaces on coolant and check for leaks
Replenish
pump and front cover Always use new gasket
when installing pump assembly Be sure to
RADIATOR
tighten bolts uniformly

Fill cooling system and check for leaks at The radiator is conventional down flow type
a

pump having the top and bottom tanks to distribute

the coolant flow uniformly through the ver
Install fan pulley and fan blade and tighten
tical tube of the radiator core
fixing bolts securely Install belt and adjust
for proper tension The mdiator filler cap is designed to maintain
a pre set pressure 09 kglem2 13 Ib sq in

THERMOSTAT above atmospheric pressure The relief valve

consists of a lf1
bIow valve and a vacuum

A wax pellet type thermostat is mounted

in valve It helps to prevent coolant loss from
the thermostat housing at the cylinder head boiling for by raising the pressure on the
water outlet adjacent to the inlet manifold coolant On the contrary as the pressure is

The function of thermostat is to control the reduced below atmospheric pressure the
flow of coolant facilitating fast engine warm vacuum valve allows air to enter
re the

up and regulating
coolant temperature The radiator preventing the formation of vacuum

thermostats are designed to open and close at in the cooling system

and if not
predetermined temperatures The bottom tank on cars equipped with the
opemting properly should be removed and
automatic transmission inoorplrates an oil
tested as listed below
cooler for the transmission fluid

Removal and Installation

Removal and Installation
Drain coolant partially
Drain coolant into a clean container
Disconnect radiator hose at water
upper
outlet Remove front grille

19
GooUDI SJStem

I emove bolts retaining radiator from radiator

side support3 and radiator upwards

remov

Install radiator in reverse sequense of

removal

Inspection
Iadiator cap should be checked for pressure at

regular tune up intervals First check rubber

seal Oil cap for tears cracks or deterioration
after cleaning it Then install radiator cap on
Ag 128 Radiator for Manual Transmission a te ter If cap docs not hold pressure or will
not release at thp proper pressure replace
cap

Disconnect radiator upper and lower hoses Also in pect radiator for water leakage using
On a vehicle with automatic transmission a cap tester unde applying a pressure of 17
disconnect cooler inlet and outlet lines from lblsq in If uch the defect is detected repair

radiator or replace radiator

80
 Brakes

MASTER CYLINDER 82
Removal 82
Installation 82
FRONT DISC BRAKE 82
Description 82
Removal 82
Disassembly 84
Inspection and Repair 84
Piston Seal Replacement 85
Assembly and Installation 85
Pad Replacement 86
REAR BRAKE 86
Removal and Disassembly 86
Inspection 87
Assembly 88

II
Brakes

MASTER CYLINDER hydraulic pressure from the master cylinder

out of the
forces the piston of wheel cylinder
Removal caliper bore and thrusts inner pad forward un
Remove the clevis pin connecting the push rod til it contacts disc and simultaneously pushes
with the brake pedal and disengage the reaction force F These forces
outer pad by
master
cylinder from the pedal cause rotating moment which increases reac

tion force F This is called self energizing ac

Disconnect the brake tube from the master
tion In this SC brake it is around 50
cylinder
As pad wears movement of piston is in
Screw out master cylinder fixing nuts and than
creased and when seal is deflected more
remove the master cylinder from the dash
its elastic deformation piston wiil slide out
board
ward causing slip between seal and piston
thus assuring constant clearance between pad
Installation
and disc
Installation is a reversal of the removal

procedure but the following operation should Removal

be added Jack up the vehicle and support it on stands
and remove the wheel
Adjust the pedal height by changing the push
rod length of the master cylinder Disconnect the front brake hose from the
Bleed air out of the master cylinder brake tube

Note Plug up the brake tube with a

wooden peg to avoid spilling fluid during
FRONT DISC BRAKE
work on caliper

Screw out the bolts the to the

Description fixing caliper
knuckle flange and the caliper
Figure 130 shows the relation of forces remove

working As brake pedal is depressed assembly

t Push rod ass

y
2 Dust cover

Ii 3

4
Stopper ring
Piston ass
y A
I 5 PistOn ass1y 8
6 Secondary piston cap
7 Pbton

8 Primary piston cap

j
I 9 Master cylinder body
6

@7cf I 10 Reservoir band ass

y

11 Reservoir

lY 12

13
Reservoir

Filter
cap ass1y

4
Y
0 14 Bleeder screw

15 Check valve spring

16 Check valve ass
y

17 Valve cap gasket

18 Valve cap

Fig I29 Tandem Master Cylinder

82
 Brakes

3
I
2

9
11

6
1 Cylinder
2 Pi ton eal

3 Wiper eal
4 Eletainer

5 Piston

QD1 6

7
Clip
Shim

8 Pad

@ 9 Caliper plate
10 Torsion ipring
11 Cotter pin
12 Nut

13 Washer
I
10 14 Support bracket
15 Hold down pin
16 Pivot pin
17 bracket
Mounting
17 18 Spring

Fig 130 Front Disc Brake

FIg 131 Sectional View ot Front Disc Brake

83
I lk

Remove the spindle nut and the disc hub and

separate the rotor from the hub assembly

Disassembly
Remove the anti rattle clip from the caliper
plate and then pick up the pad

Remove the tension springs and pull the cylin

der out ofthe caliper plate
To take out piston apply air or hydraulic
rubber
pressure from inlet hole Remove the
seal from the groove on the cylinder Remove
the retainer and wiper seal and then it can be

easily taken out

Inspection and Repair

Ag 132 Removing Front Brake Hose Check the cylinder assembly for oil leakage
and any damage and replace the cylinder
assembly if any abnormal condition is detec
ted on it

Note Unlike the wheel cylinder cup of

drum brakes the
piston seal of SC type
disc brake has three important functions
sealing retracting piston and automatic
adjusting If pistonseal is damaged
replace whole cylinder assembly as a unit
However if it is necessary to replace

piston seal replace wiper seal at the

same time When pads are replaced two or
three times cylinder assembly or seal

should be replaced though they still seem

to be in good condition

Ag 133 Removing Caliper Assembly

fig 134 Removing Brake Disc Fag 135 Removing Piston

M
 Brakes

Check the for and crack replace if it Clean the piston Check that no damage exists
pad wear

is damag ed or become worn to less than 0 04 on piston surface Insert the piston Take care
in in thickness Inot including the metal that the relieved position of the piston faces

pivot pin Insert fin t two inches gently

hacking plate
and it
avoiding tilting
Check the caliper for damages replace
if any damag e is detected and Installation
Assembly
Check the rotor and if it shows score ex Clean the mounting surface and disc surface

ccssive out of roundness and so forth recon Attacb the disc to thc hub

ditioning by machining is required Install tbc bub to tbe knucklc pindle

in thickness is 0 331
Limit of reconditioning lnsc t the piston into the cylinder till the face

or piston hl ad hecomes almost flush with the

tn

Standard rotor thickness 0 0394 in j ace of the I ptailwt of the wiper seal

Install the cylindcr into the caliper platc and

Kunout of the rotor should be less than 0 0048
in total indicator reading seCure in place bv two tor ion springs

If ahnormal condition such as crack emble the hold down pin spring wa her
an

distortion or excessive run out is detected and nut in this order to support bracket

r place the rotor

lnsert a cotter pin to the nut

Sccurc the mounting bracket and caliper plate

Piston Seal Replacement washer
with the pivot pin washer spring
If oil leakage is found on the piston seal it
and nul in that ordcr Tighten nut complete
hould bc replaced paying attention to the
and set a cotter pin
following points
Pry up and hold down bracket by a screw
Aftcr disassembly rinse the cylinder borc
drh and hook up to the upper end of the
with brake fluid Insert new seal into the to
mOll Ilt i ng bracket Turn tbe caliper platc
groove taking great care not to damage the slide
mak sure that it can smoothly
seal Attach the wiper seal Apply a thin
Install the calipcr assembly to the knuckle
coati ng of specified grease to the cylindcr
hol flange

Fig 136 Measuring Runout of Disc Ftg l37 Assembling Piston Seals and Retainer

85
Brakes

Attach a shim to inner pad for noise proof and Loosen the bleed screw Pull the caliper plate
heat insulation outwards outward of chassis Push the piston
in by 0 lIS to 0 157 in
Be sure to set the inner pad first Draw the

caliper plate enough toward inside toward Outer pad is loosened and can be easily pulled
center of chassis Insert lower cuts on both out

ends of the pad into the mounting bracket

Draw the caliper plate inwards and remove
and then push the pad until the pad contacts

the
inner pad Wipe exposed surface of the piston
piston
thoroughly Push the piston enough into the
Draw the caliper plate toward outside Insert cylinder bore Insert new pad into the caliper
upper cuts and center indentation of outer pad plate
into the caliper plate REAR BRAKE
Attach the anti rattle clip Be sure the direc
tion coincides as indicated by the sticker on Removal and Disassembly
the clip Jack up the vehicle and support it on stands
and remove the wheels
Pad Replacement
The clearance between the pad and rotor is

adjusted automatically
Check the pad for wear after the first 6 000
miles and every 3 000 miles and thereafter

Pad thickness is easily checked by removing

the anti rattle clip When linings become
worn to less than 0 04 in in thickness not in

cluding the metal backing plate replace all

pads
Note Always replace the pads in full sets
of four using genuine parts
Remove the road wheel Remove the anti rat
tie clip from the caliper plate Fig 139 Pushing Pin

Fig 138 Removing Anti Rattle Clip Fig 140 Removing Pad

88
 Brakes

@i
c
J

r
jj
i

Fig 141
ectional View of Rear Brake

Release the parking brake and disconnect the Inspection

cross rod from the lever of the rear wheel Drums If they show score excessive out of

cylinder roundness and so forth reconditioning by

machining is required
Remove the brake drum
Drum inside out of
Remove the return springs and then take out
the brake shoe assemblies roundness below 0 0020 in

Disconnect the brake tube from the wheel Nominal inner diameter

cylinder of the drum is 8999 in

Remove the wheel cylinder by removing com Limit of reconditioning
ponents as in the order of dust cover plates
and adjust shims then it is ready to be in diameter is 9 040 in
removed from the brake disc
Linings If shoe linings are incompletely
The wheel cylinder is easily disassembled by seated soiled or greasy or deteriorated due to

removing the snap ring and dust cover excess heating repair or replace them If the
thickness of the lining is found less than
Remove the adjuster assembly 0 0591 in replace it

Remove the brake disc Notes a If oil or is found in

grease

1
8
Brakes

Fig l42 Sectional View of Rear Brake

linings clean thoroughly with carbon When the wheel cylinder is overhauled it is
tetrachloride or gasoline recommendable replace cups even if ap
to

b After
parently they are in satisfactory conditions
lining installation and bonding and they must be replaced if deformed due to
grind the lining face to a diameter equal
damage crack corrosion and ageing
to that of the brake drum

Check and adjust cams for their smooth

Assembly
operation Assemble in the reverse order of disassembly

Springs If
they are considerably weak
Be careful not to smear the brake linings with
replace them
oil or grease
Check the brake disc for distortion
Apply grease thinly to the sliding areas such
Check the bore of the wheel cylinder for wear as shoes and discs cam adjuster stud and

sign of rust and damage spacer

If the clearance between the cylinder and the Adjust the shoe clearance and bleed the

piston exceeds 0 0059 in replace them hydraulic system

88
rroDt Suspension

1 Stnrt mounting insulator

2 Coil spring
3 Strut assembly
4 Suspension cross member

5 bilizer
St

6 Tension rod

7 Transverse link

8 Steering knuckle ann

5 6 7

Ag 143 Front Suspension Assembly

RECOMMENDATIONS

U to the need for a large number of special mended that repairs to the front end be left to
and
lonl alignment equipment it is recom a completely equipped shop

80
 Steering
STEERING GEAR COMPONENTS 92

RECOMMENDATIONS 92

ASSEMBLY 93

STEERING LINKAGE 93

81
Steering

STEERING GEAR COMPONENTS

1
0

1
Steering ar
ge housing 5 Shim worm
bearing 9 Ass y bearing steering worm

2 Shaft steering sector 6 0 ing housing cover 10 Ass y nut ball

3 Cover sector shaft 7 Camp jacket column II Assfy column steering

4 Screw adjurting roller shaft 8 Ass y bearing column

Fig 144 Steering Gear Components

RECOMMENDATIONS

Due to the nepd for a large number of special mended that repairs to the steering com
tooJ
and al ignment equipment it is recom pOllenb be left to a completely equipped shop

82
 Steering

ASSEMBLY

Tightening orque I 8 2 5 13 0 18 1 ft Ib
kg m

Tightening torque 1 8 2 5 kg m 13 0 18 1 ft lb orque 1 8 2 5 kg m 13 0 18 1ft Ib

Select the lhiml thatthr c1 arance

0 01 0 03 0 0004 0 0012

1
t17mm 1
6 693 i
r J
d IBIJ I
i
J
f
M thod of the gear assembly
Apply greue
here when
II BEARING PRE LOAD ADJUSTMENT
auembling
I l Adjust the thickn u of the worm
adjust ahim thou the of tbe whrel
rque steering ames

be 0 to 6 0 kg em 55 83 1 before the sector lhaft fiaed

GtarumE
II 1 Place the tor ah
5h the al point
Tigbtening 2 AdJun the location of the tor 5haft by turning the that the 5ha ft
adju t crew os ctor ad
torque
th ball hit ch ther
12 5 14kg m

3 Lock the adjult with the lock

90
ew
mporarily
101 ft Ib
4 Move the gear for Iera imel from the mak
ide of the Beu arm E nd turn
The rtandard distance
smoothly
between the bottom of
5 After this backl uh the op of the s
t OIl ar arm should be brtweeD 0 O 1 mm 0 0 0039
tlw T groove Ild the the uual point
of the
lurfac housing 6 If the backlash more tban O 1 0 0039 th funher
mm
I ew
adjust 5Crew IIId
peat the
the uml p itlOD th es of 2 5 til within the ndard
proce ome figure
7 the
Finally adjust by 1 8 1 6 turn nd lock firmly with the lock

lll OILING

Apply it MP90 about O 33

sear liter5 4U
3 S pu S 8lrnper pli
IV STANDARD flACK LASH

The backlash should be 0 the ldius 22 75 0 896 of the

mm sector pitch when tbe backlash
the al 0 ad the
point turning angle of the sectOr haft O

Ag l45 Sectional View of Steering Gear

STEERING LINKAGE

Fig l46 Front Bottom View of Steering Linkage on Vehicle

83
Bear Drive Suspension
SHOCK ABSORBERS 96

Remvval 96
Inspection 96
Installation 96
DRIVE SHAFT 97
RECOMMENDATIONS 97

85
Bear Drive SuspensiOD

I
1
I
6 5

1 Suspension member 7 Spring seat

B Shock absorber
2 Suspension arm

insulator 9 Drive shaft

3 Member mounting
10 Differential mounting member
4 Differential mcunting insulator
Coil 11 Differential carrier
5 spring
6 Bumper rubber

Fig 147 Rear Axle on Suspension

Installation
SHOCK ABSORBER
Installation uf the shock absorber is the rever

al ofthc procedure given for rcmoval

Removal
Open the trunk and remove the trunk finisher

assembly
Remove the double nuts which fasten the up
absorber to the body
per end of the rear shock

Remove the shock absorber from its lower

mounting bracket on the axle housing

Inspection
Test the shock absorber and replace if

necessary

Check for oil leakage and cracks Also check

the shaft for straightness

Inspect the rubber bushings for damage

cracks and deformation Replace the parts if Ag 148 Installation of Rear Shock Absorber Upper
End
necessary

88
 Bear Drive Suspension

DRIVE SHAFT

Drive shaft 6 Boot band 11 Flange yoke

2 Drive shaft ball 7 Snap ng 12 Oil ea

3 Ball spacer 8 Sleeve yoke 13 Needle bearing

4 Drive shaft stopper 9 Sleeve yoke plug 14 Snap ing
5 Rubber boot 10 Spider journal

Rg 149 Drive Shaft

RECOMMENDATIONS

necessary it is recommended that the

Due to the large number of special tools overhaul of the differential be left to a
required and the advanced knowledge properly equipped shop

87
 Olutch

REMOV AL 102

RELEASE BEARING 102

REPAIR 103

Pressure Plate 103

Refacing
ADJUSTMENT 104

INSTALLATION 104

MASTER CYLINDER 105

Removal 105
105
Disassembly
Ins pection 106

Assembly 106

Installation 106

BLEEDING CLUTCH SYSTEM 106

81
Clutch

JJ
FL Y WHEEl

RING GEAR

12

II
1 11

1 Clutch disc 8 Bearing sleeve

2 9 Clutch elease bearing

Clutch cover
assembly with plate
3 10 Bearing sleeve bolder spring
4 Bolt 11 Dust cover

5 Lock washer t2 Return spIing

6 Clutch withdrawal lever 13 Withdrawal lever push

7 Retainer t4 Lock nut

spring

Rg 150 Outch Diaphragm Spring Type

M
 Olutch

o
N

1 N

1 17 Retainer pring
Clutch disc 9 Release lever

10 Relea tevet 18 Seasing sleeve

2 Clutch assembly e at

3 Clutch cover 11 Lock nut 19 Clutch eleue bearing

4 SUre
Pre plate t2 Release lever support 20 Bearing deeve holder spring
bolt 13 21 Dun cover
S Prelllure plate Retaining spring
14 22 Return pring
6 Eye bolt pin Bolt
7 Pre sure
fpring IS Lock washer 23 Lock nut

8 rlU e retainer 16 Clutch withdrawal lever 24 Withdrawal lever push nut

PreJ spring

F1g 151 Clutch Coil Spring Type

101
11 uteb

REMOVAL Remove the completely and lift

screws the

the the
clutch assembly away from the flywheel
Remove transmission assemblyTrom
Note Be sure not to soil with grease or oil
engine
the surface of the disc
al Diaphragm spring type

Fully insert a special tool Clutch aligning Bar RELEASE BEARING

ST20600000l on the clutch disc hub spring to
support the clutch Replace if there is rough spot or wear on the
release lever control surface or if the inside
Ib Coil spring type
wear causes too much play
Temporarily lock the release lever with the
release lever stopper If it is
judged that the remaining grease is not
enough iJe
ausc of the lCJlkage place the
Note If the release lever stopper is not
bearing
placed under each levers the release
lever will be over Ioaded with excessive If the clearance between the transmission

force when the clutch assembly is front cover and the inside diiuneter of the

removed sleeve is more than 0 5 mm 0 0197 in or

there is step wear at the contacting surface

Loosen the six bolts which are holding the
with the withdrawal lever replace or repair
the at a
cover assembly to flywheel a turn

selection until the spring Replace if there is excessive wear or defor

time by diagonal
pressure is relieved mation

E
E

N
II E
E
0

N o
E
E
E
E
E
E

i i
o 0

i01
I

7 Bmm

r4H1
mm

52 m

Rg 152 Clutch Cover Assembly Diaphragm Spring Typel

102
 Glatah

mm

E
E

lD
lD
N

Rg l53 Clutch Cover Assembly Coil Spring Type

Ag l54 Removing Release Bearing Fig 155 Installing Release Bearing

REPAIR The refacing limit is 1 0 mm 0 0394 in from

specifiedstandard di mension
Refacing Pressure Plate
The pressure plate can be refaced if the sur If it needs to be cut more than 1 0 mm 0 0394

face is rough or has uneven wear In this case in the unit must be replaced After refacing
the tension of clutch springs working on the the out of flatness should be less than 0 1 mm

plate will be weakened 0 0039 in

pressure

103
Clutch

Note In case of the diaphragm spring Replace the height finger and pillar by the
type the pressure plate should not be clutch actuating mechanism and actuate the
refaced at any times clutch several times by operating the handle

Note This will enable the parts to settle

Replacing Release Bearing down on their knife edges
Removing the bearing
Replace the height linger and recheck the
Remove the bearing by using universal puller
height of the release levers checked for run
the bearing in out as near the edge as possible if the error
Pressing
is more than 0 020 in adjust until it is true
There are two types of the release bearing
within spec limit
Specification of both bearings is quite the
same but particular attention is required INSTALLATION
because of different construction when in
stalling the bearing into the bearing sleeve as friction facings free
It is important to keep
follows from oil or grease

Diaphragm spring type Release

a Place the discassembly on the flywheel with
Bearing Fitting press fit the bearing in place the longer chamfered splined end of the disc
on the bearing sleeve with the force of 400 kg
assembly towards the transmission
880 Ibs applied at the outer race as shown in
Set the position of the disc assembly by a
Fig 155
dummy drive shaft which fit the splined bore
of the disc assembly hub and the pilot bearing
ADJUSTMENT of the flywheel

Tighten six bolts which are holding the clutch

Screw the center pillar into the base plate and
cover assembly to the flywheel a turn at a
slip the high finger over the pillar
time by diagonal selection
Adjust the
height of the release levers by Note There are two dowels on the
screwing unscrewing the eye bolt nuts un
or
to locate the clutch cover
til the height when rotated just contact the
flywheel

highest point on the tip of the release lev r

Ag 156 Adjusting Release Lever Height Fig l57 Actuating Clutch

104
 Olutch

O@ Q 1J

I Cylinder 9 seat 17 Piston

Spring Hopper
2 Return 10 Valve
spring rtem stop 18 Stopper ring
3 Pi ton 11 19 Boot
Stopper gasket
4 Secondary 12 Calket 20 Oil reservoIr
cup ing
S Piston cup 13 Pwh rod 21 Reservoir band
6 Supply valve eat 14 Pwb Od bead 22 Reservoir cap
7 Supply valve Item IS Weld 23
Dut Cap seal
8 Supply valve spring 16 Lock nut 24 Pipe Ie at

Ag l58 Clulch Master Cylinder

Remove the dummy shaft after these bolts are MASTER CYLINDER
fully tightened

Tightening torque should be 11 to 16 lb ft Removal

Remove the clevis pm installed at the push
Remove the clutch aligning bar Irelease lever
rod
stopperl
Disconnect the clutch hose from the master
Refit the release bearing and transmission
cylinder and drain out the fluid
case

Remove the securing bolts and take off the

Note In assembling a clutch disc be sure
master
to small amount of
cylinder assembly from the car
apply Multipurpose
grease MILG 2108 or 10924 to the disc

splines Neglecting this caution will result Disassembly

in clutch slippage Remove the filler cap and drain out the fluid

105
Clutch

Pull back the rubber boot and remove the Assembly

snap ring and then the push rod and ring can This accomplished by reversing the
is
be removed disassembling procedure but the following
Unscrew the piston stopper screw and remove
points should be observed
the piston assembly completely Prior to assembly piston cup should be soaked
in brake fluid Install piston cup taking care it
The piston assembly can be separated by lif
is correctly faced
ting the spring seat edge over the shouldered
end of the piston Coat well brake fluid to cylinder and piston
and assemble them

Inspection
Prior to inspection all parts should be cleaned Installation
orwashed Installation is a reversal of the removal

Note To clean wash all parts of master

procedure but the following operation should
or
be added
cylinder operating cylinder and pipings
clean brake fluid must be used Never use Adjust the pedal height by changing the push
mineral oils such as gasoline and rodlength
kerosene etc as to do so will ruin the rub
Bleed air out of the hydraulic system
ber parts of the hydraulic system To do
so will ruin the the hydraulic parts of the

hydraulic system
BLEEDING CLUTCH SYSTEM
Check cylinder and piston for abnormal one
sided wear and damage and replace if found
Remove the bleed screw dust cap of the
If the clearance between cylinder and piston is operating cylinder open the bleed screw ap
more than 0 005 in replace cylinder proximately three quarters of a turn and at
tach a tube
immersing the open end into a
Renew piston in
principle
cup when
disassembled It must also be replaced when
clean receptacle containing a small amount of
brake fl u id
swell wear deformation due to fatigue and

damage etc are found Fill the master cylinder reservoir with the
recommended fluid and by using slow full
Damaged dust cover oil reservoir and cap
strokes pump the clutch pedal until the fluid
etc should be replaced
entering the container is free from air bub
Piston spring and inlet valve spring must also bles
be replaced when they are broken or weak
Screw up the bleed screw on a down stroke of

Replace clutch hose and tube if any abnormal the pedal remove the bleed tube and replace

signs of damage or deformation are found the dust cap

108
 TraDsmissioD

REMOV AL J09

INSTALLATION III

4 SPEED TRANSMISSION 113

Removal and Installa tion 113

RECOMMENDATIONS 113

l
lO
TraDsmissioD

11

I
I
i

Fig 159 3Forward Speed Transmission

Ll

Fig l60 4Forward Speed Transmission

108
 Transmission

FIg 161 3Forward Speed Transmission

REMOVAL

When removing the transmission from the

vehicle it is necessary to follow the undermen

tioned procedure
Jack up the vehicle and support it with four
stands If available a hydraulic hoist or open
pit can be utilized

the hand brake wire at the

Disconnect
shown in Figure 163
equalizer pivot as

Loosen the two exhaust center pipe clamps

with center
and turn the premuffier complete
to theleft as shown in Figure 164 This
pipe
will allow sufficient room for the propeller
shaft to be removed

Remove the propeller shaft by disconnecting

the four securing bolts at the companio n

flange of the gear carrier Seal the end of the

rear extension housing to prevent oil leakage
FIg I62 Underside of Vehicle

108
Transmission

Disconnect the speedometer drive cable from

the adapter in the transmission extension

housing See Fig 165

Disconnect the lower shift rods from the shift

levers and remove the cross shaft assembly
from the transmission case See Fig 166

Remove the clutch operating cylinder from

the clutch housing

Support the engine with a jack placed under

the oil pan Do not locate the jack under the

Fig 163 Disconnecting Hand Brake Wire

Fig 166 Disconnecting Remote Control Linkage

Rg 164 Removing Propeller Shaft

Cable Fig 167 Detaching Clutch Operating Cylinder

Ag l65 Disconnecting Speedometer

no
 Transmission

oil pan drain plug To prevent damage to the Lower the jack supporting the engine to in
oil pan insert a wooden block between the pan cline the engine in a rearward direction This
and jack will allow sufficient room for the transmission
to be removed
Remove the two bolts attaching the tran
smission to the rear engine mount Place a Remove the starting motor and the bolts at
jack under the transmission and remove the
taching the clutch housing to the engine
four bolts fixing the rear engine mounting Lower the jack gradually and withdraw the
cross member to the body transmission

INSTALLATION

Installation of the transmission is the reversal

of the procedure given for removal However
attention should be given to the following
points

Notes a Fill the transmission with the

recommended gear oil MP 90

Oil capacity 45
0 U S gal
b Adjust the clutch operating cylinder at
the push rod so that the play at the with
drawaI lever will be 0 087 in

Fig 168 Cross Member Removal

Fig 169 4 Forward Speed Transmission

lD
Transmission

AUTOMATIC lISSION
TRANS

@ CID @ CID @ @ @ @ j @
i

if
rT 1
L J
L

L J
II

I I
@ @ @ @ @ @ @ F @ @

AT260

I Transmission II Governor
case
Tightening torque CT of
@T 0 5 to 0 7 kg m

2 Oil pump 12 Output lihafl bolts and nuts 3 6 to 5 1 ft Ib

3 Fronl clutch 13 Rear ion
exlen h 2 0 to 2 5 kg m

4 Band brake 14
@T 4 to 5 kg m

Oil pan 14 to 18 f Ib
29 to 36 ft Ib
5 Rear clutch 15 Control valve h 3 to 1 8 kg m
1
6 Front
@T 14 to 16 kg m

planetary gear 16 Input shaft 4 to 13 ft

9 lb
101 to 116 ft Ib
7 Rear planetary gear 17 Torque converter @T 0 6 0 8 kg m
to @T 55
0 to 0 75 kg m

8 One way clutch t8 Converter 4 0 to 5 4 ft Ib

housin1 4 3 to 5 8 ft Ib
9 Low Reverse brakC 19 Drive plate
10 Oil distributor
@T 0 25 to 0 35 kg m

1 9 to 2 5 ft Ib

Fig 170 Cross Sectional View of 3N71 B Automatic Transmission

U2
 Transmission

4 SPEED TRANSMISSION
port is securely placed between the upper sup
port plate and rubber insulator on one hand
Removal and Installation and the lower support plate and rubber in
Removal and installation of the 4 forward sulator on the other

speed transmission are similar to the

procedure given for the 3 speed transmission
However the 4 speed transmission is of the RECOMMENDATIONS
floor shift type therefore in addition to com

pleting the operations described in the section Due to the complexity of setting up a

covering the 3 forward speed transmission it disassembled transmission as well as the

will be necessary to remove the shift lever special tools necessary it is recommended
from the control lever bracket On the 4 speed that internal repairs be left to a fully equip
transmission the rear engine mounting sup ped shop

U3
 Bod Work

FRONT FENDER 116

Removal and Installation 116

HOOD 116

Removal and Installation 116

117
Adjustment
TRUNK LID 117

Removal and Installation 117

Torsion Bar Removal

and Adjustment 117

U5
Bod Work

FRONT FENDER HOOD

Removal and Installation Removal and Installation

Remove the radiator grill head light and Open hood and place a protective cover over
head light finisher the front fenders to prevent damage to pain
ted areas
Remove all bolts securing the fender and then
remove the fender Scribe the location of the hinge straps
Ipenci
on under surface of hood
Installation of the fender is the reversal of the
for removal Replace the bolts attaching the hinge to the
procedure given
hood With the aid of a helper remove the
hood

Fig 171 Removing the Fender Fig 173 Removing the Hood Support Rod

ENCH

BOW
1

fill 172 Removing the Hood fig 174 Removing Trunk Lid

U8
 Bod ork

Uing screw driver as shown in Figure 173 Adjustment

remove the hood support rod from the support To adjust the hood release the hinge attaching
bracket bolts and move the hood to the desired

position After the adjustment has been made

Installation of the hood is the reversal of the
tighten the hinge bolts
procedure given for removal However align
the hinges within the scribe marks
TRUNK LID

Removal and Installation

Open trunk lid and place a cover over the rear

fenders and rear panel to protect them from

damage to painted area

With the aid of a helper remove the trunk lid

attaching bolts and remove trunk lid See Fig

174

Torsion Bar Removal and Adjustment

Remove torsion bar fixing wire then using a
screw driver as shown in Fig 175 remove the
torsion bar

The tension of the torsion bar can be adjusted

by changing the location of the bar with the
use of a screw dri ver
Rg 175 Removing the Torsion Bar

5
r
s
Alo

cd
1 4
II
EGf
i

t
j I
1

4
Outside handle

Out ide handle rod

Clip
Pull knob

6
Ie r 5 uOJtcheon

Spring clip
J

I
I

III
cs
J
10
1 I
1 7 Inside handle
8 I
IN
111
I
8 Remote ontrol
1 J
7 9 Lockass y
i
10 Striker

10 11 Key cylinder
12 Bell crank
0

Rg 176 Door Lock Mechanism

117
Bod Work

1 Froot door glass

z
2 Bottom channel

3 Front egulator ass

y
4 Regulater handle
3
S RaUer guide
6 Stopper
7 Connecting clip
8 Nyloo washer

9 Rear docx glass

10 Rear egulater ass
y

Fig 177 Window Regulator

U8
 Specifications
STARTER 120
DISTRIBUTOR 121
SPARK PLUGS 122
VALVES I
OIL PUMP 122
GENERAL 123
ELECTRICAL 123
MANUAL TRANSMISSION 127
CARBURETOR 131
CLUTCH 134
ENGINE TORQUE INFORMATION 136
TUNE UP 138
LUBRICANTS SAE 138
CAPACITIES PRESSURES 139
AUTOMATIC TRANSMISSION 140
PROPELLER SHAFT 144
BRAKE CHASSIS WHEEL
ALIGNMENT 146
NOTES 147

D8
Specifications

STARTER

Model LI6 and LI8engines

HITACHI S1l4 IOJP HITACHI SII4 126M

Type For manual transmission For utomatic transmiuion

12 Volts
Voltage

10KW 1 KW
Output

Slarling current Voltage Less than 430 amps 6 Volts Less than 540 amps 5 Volts

No load Less than 60 amps 12 Volts

rent Voltage

No load starter revolution pm More than 7 000 More than 6 000

Shift type of pinion gear Magnetic shift

Number of teeth on
pinion gear 9

Number of teeth on
ring gear 120

Weight lb 5 1 10 42 5 8 12 8
g

SPECIFICATIONS AND SERVICE DATA

Specifications
Model
Item o58
LTI50 LTI6019 LTlJ5 1J8

510 and 610 models except 510 and 610 models

AppliLable to 620 model
for Canada for Canada

Mak er HITACHI

N lminal ating 12V SOA 12V 60A 12V 35A

Ground polarity Negative

120
 Specifications
DISTRIBUTOR

SPECIFICATIONS AND SERVICE DATA

Distributor type D1O 66A 0410 67

Make HITACHI

Applied engine Ll8 610 Ub Qand

S 6Q
vehicle

order 1 42
Firing

Rotating direction Counterclockwise

Ignition timing degree SO B T D C

Idling adjustment

MIT 5u 800 rpm

AfT 5Uj6S0rpm
0 range

vel angle degree 490 to 550

Condenser capacity p F

Advanced isde 02 to 0 24

Retarded side O t 15
05

Phase difference 70 at k ngle

ldegree

All distributors

Point gap in
mm 45100
0 55 0 9177 to 0 7
02

AJvauccd ld Retarded side lcqllyl

Point lb
kg 0 50 to 0 65 I 1010 I 43
pTt ssure

lower pari 1 in r 430 to I 440 41 94

0 to 48
0 8
Shaft Jlll
di eT

in 450 to 4Ml 0 4402 to 4 09

0
in inner diameter
J1011

hp hafl nd hOll in 001 In O G3R 0 0004 h 0 00 5

lram
Ic p wren il1g
Repair limit h arilnre in 0 1 0003 I
10

0005 00002
in H O JI50 1
Shaft diameter upper pi
t1l4
O 0 0006

H 000 It x 1115 lUISO ltl 1 156J

C III ti lllcter in 0
0015 II fi
J 9 D002 tu 0 0 11
C1c nam e nc lIl cro shllf lrod un mmfin

Weight pivot diamctlo in

mm 4 972 104 990 0 1959100 1 5

n in 5 000 10 5 018 0 1 9 to 0 1976

Weighl hole diameter
Clcilr mce b lw n i ot and hole tnm ill 0 01 tnO 046 0 0004 tv O OOI

121
SpecificatioDS
SP ARK PLUGS

SERVICE DATA AND SPECIFICATIONS

Make NGK

Model B6ES

Applied engine and Ll8

Size screw dia x

in
mm
reach
Ll6 14

0 55
x

0 7 to 0 8
19
x 0 75

in
Plug gap mm
0 028 to 0 031

1 5 to 2 5
Tightening torque
kg m ft lb 11 0 to 15 0

VALVES

In 42 Qtn42 2 654fO 1 661

lib

Ex 33 0 to 33 2 1 299 10 1 307
H Valve head diameter
nun in
In 42 01041 2 1 654 10 1 661
LIB

Ex 35 01035 2 1378101386

In 114 9 to 115 2 4 535

524104
L Valve length lI6

in
mm LIB
Ex 115 7 116 0 4 555 567
104
to

lI6 In 7 965 to 7 980 0 3136 to 0 3142

Valve stem diameter
D
in
mm LIB
Ex 7 945 107 960 0 3128 100 3134

a Valve seat angle In Ex 45030

OIL PUMP

i lth
I ning turque
Oil pump mounting bolts kg m ftIb 1 to 15 8 010 II

Oil pump cover bolts kg m fl Ib 0 7101 0 5 1 to 72

alve fl Ib 4 5 29 26
Cap nut regulator kg m to to

Specifications
Oil preuure at idling kg cm Ib in 0 8102 8 1110 40

Regulator valve spring

Free length mm in 5 2
52 067

Pressured length mm in 34 8 I 370

Regulator valve opening pressure kgcm Ib n 5t05

3 0 501071

122
 Specifications

GENERAL SPECIFICATIONS
Li6 Li8
Model

4 in line
Cylinder arrangement
1 595 62 80 770
1 108 01
Displacement cc cu in

in 83 737 3 2677 2 9016 85 78 3 3465 3 0709

Bore and stroke mm

OH C OH C
V31ve ngemenl
1 4
Firing rder I 4 2
i

Engine iule rrlll

MIT 800

A T 650 in l range

85
Compression l 111

I
Engine idle fold lHg inllgl
at idle TPIll I
BO c
M T Ih

AIT 390 4 in
15 N 1ge

Oil pressure em

psi 35104 0 49 8 to ill 9

Varm 000 rpm
kg
at

M T MalHI 11 rransllil n AIT Automatk Transmission

STARTING MOTOR SPECIFICATIONS

Distributor Specifications
h

flcut CUrr N L d N pi DWtrilu lorCr1Iln 1

f Sprint p v AtI u

Hum T llen D C1W Cur t

S t 1 IltaTt E
lb PI t1@ ND fIjq
JI O
oJ HD

67 61 MII ubl hI 1 1 2 1 00
ME rla
J Hitachi 50 11 15@ 3 4
97 6 9@
66 6 HiluM 1 51 00 2400 13
411 53 4
5 114 2

6667 MIt hl 51 00 LI6 Hitachi 4 1O@ 5 9 9@

114 IA 01lh5ll 1 500 4
12

19 72 Hltochl 1 51
L2 Hitachi 4 J 9 5
6@ 5@
114 103
D60652 1 000 96
1 912 Hlt chl 1 511

5 1t4 122 At2 Hitachi 550 12 5@ 98 65@

72 HII ehl 151 42 412
1 63 2 100 13 8
71
S 114 1I7L

DISTRIBUTOR SPECIFICATIONS

C lllrlr II Dnu1 VD U
AdII
IAd

n
Pol t Dw srlnll
F full
DI trlbut 0 T II SIDrI Inl Inch Ad
y M I AIIIII n

V hll 01
Inllln rlNo IlIe D
O e @ @ @ cuu D

SIDrt euuftl
pm pm pm @V
Itn

12@ 6
6
97 I D407 51 0 dll 1 1 41 1
16@ 475 5 12

55O
4DO 1100
021 5054
l
Mltfu
hl
5r6

1 6 J D411 53 01
50 55 I 1 411 11 15@ 41 5 6
@ IJ

OU 2400

4Q7
1 n 6
0 4955 1 1411
O@ @10 10@n
020 40000 1 00

1 72 l I 04105 011 4 1 1 1 1
4 IO@ @ @ 12

022 OGO 1500

1
7i
Wi L 24 D I2 52 016 1 1 1 411 @14 @11
02Q 00 100 1400

1200 D412 011 4955 11 1 4 12 5@ @9 9

5@ 12
55 1200 00
021

d t d with S I
ID J cuu dVDII cII x

123
Specifications

Electrical Specifications Battery and Starter

1 1l U T StGTt T

ModTl
l od rut No L Tut

V to oI A V T Ao V V
111 i
Wi
I Tn 1 1 b LUI1tJ
U
f

A A NA NA
P 60 12 e X A A N A N N

El 50 12 P 500 8 0 7 7 60 11 7 000 NA

G X A 12 Po 500 9 5 0 60 7 OIXl A

40 50 12 XA NA NA 60 12 7 000 31
Neg
9 5 NA N o N A
R 40 SO 12 Xeg 500 fL5

6 000 30
50 12 500 60 7 2 60
V20 Xeg
60 7 000 28
Ll6 50 60 PLSlO 12 eg 480 6 0 79 12
WPL510 10 50
1 520 40 50 60
i L521 LS21

L24 A 12 460 6 0 10 1 60 12 5 000 9

Xeg

XA 12 420 6 3 6 5 60 12 7 000 31
A12 Xeg

Ltssthan fore than

Electrical Specifications AC Regulator

trul Rd V R
tA6
i CACTI
4IM c s Ai 1 CouG A i G P d R OI
I
Go
G G G J Yoolt
p Gap rfJ i i
i J i i i

044 12
U J 48 044 028 036 032 040 012 016 NA
G fiuubishi 32
0 032
RLA l

01614 15
litsum hi 032 043 o32 147 032 043 028 035 032 039 012
RL2220B5

R Mit uhishi 032 043 032 047 032 043 028 035 032 035 012 015 14 15
RL 2B

U20 035 047 030 043 32

0 047 032 043 012 01613 5 14 5
liIslIhishi 030 043
RU220B5

012 01614
LIB Hitachi 1m 020 024 016 020 035 039 032 047 15
TL l li

L24 Hihlt hi tn2 039 016 024 024 019 012 01614 315 3
TI 1 Z 7 @50F
0 12 016 24 024 039 012 016 14 315 3
Hitachi 032 039
TLI Z 37 50F

i hl
HiJ t t ltlllatOT a left TLIZ 111
it

V Left illl t lClllatllr right TLlZ 17

it
XOTF d left letennilloo with the tenninals Illlm
Rillhl t J ltor
glll s pluJI
t1 wllwlITU

124
 Specifications

hlClemodel
b O 1I6
Appli Int tlIO L1RI SIOllln
Item

HS 15 HITACHI 6R 1
Mau rldtype HANSHIN HS IS I HANSHIN

60R
St SIO
ApplIed resister RC IS

voltage V
Ptimu

Sparkpp mm in nIOrt Ihl n7 0 1756

PlimlloiY ll
hl Ce
n 17
1 1 4J
fC I68 F

conduy Kn 11 lb 8
10 8OF
f

Extern
n LJ J7
OCthaoF

Light Bulb Specifications

Wdlag Mlld l v
u

50 42 up
Baclc 15
UlO Headlights
21 6 License plate 8
Front paning turn
216 M p 5
Stnp tlil turn 8
L 10 Side rker
plate
lnstrument panel 8
15 520
1 Headlilthn 37 5 50
flasher ming light 50
Headlights 31 5 SO 25 8
PLUO Fr mt parking turn
31 5 Tail top 25 8
B 25
Parldng Rear turn backup
Turn 25 License plate B
License plate 8 Interior B
Interior light 5
Backup 25
1 5
Warning lights L521 Headlights 37 5 50
Instrument 5 PLS21 37 5
Front turn parking 25 B
SPL310 HeadliRhts 50
TilU top 25 B
Front parking turtI 25 5
2 l6 Irtun 25
Tail stop
B clcup 25
LictrlIeplate 8
Interior 6
In rior 6
15 L seplate 8
nll
Instrumr warning
Inspection lamp B PL5lO Headlights 37 5 50
Radio I WPLSlO 37 5
31 5 50 Front parking bun 25 8
PUll Headlighu
37 5 T i1 tum 25 B
RUll
StOP 25
Side marken 8
ckup 25
Tail 8
8 License plate B
License plate
25 Interior 10
Stop
25 HLS3Q
Backup Headligh 50
Interior 5 Side marker tum 2311
Fog 35 Side marker license 75
pI
te
Inspection B Tall 7
Parling B Stop 23
Turn 25 l Reartun 23
J
Instrument ckup 23
Warning 15 Instrument J
warning glove
50 40 compartment clock
SPUll Headlight Four way Suhet 23
SRL3Il Front turn parking 25 S
P B
Stop tail turn 28 B

125
Specifications

WIRING DIAGRAMS

III
CD COOlI

o 0

Lr

PLSIO utomatic transmwion

l
r

G
JIrII

I t
II
n
11
COLOIlCODE

11 I
iil jll 1 i I
t4L
cnm
w

JlI 1
i
1 7 Jfrdll
V
11 IF 11111I 1 II IJ
n
I
I

r I
l
i I o
i
r III l I
r

j i r
I

I i d 71 a
1rtJ
r e

l J
3l
u
Jo f
r c 11 7lI
tl A
II L l
L
I
f
l a
f
DPTlONAL EQU PMEm

1 10 ltomatic trarumission

126
 Specifications

CO COOl

PL510 standard traosmiuion

MANUAL TRANSMISSION

APPLICATION Of TRANSMISSION MODELS

Type of Transmission Applied Model edome r gear Final gear atio

1
R3W65L
N510 S V NL510 S V
19 5 4 375
3 Forward speed JNL510S lot 3 263
JN510SU
Column shift 2nd IS45
P510 SlV PL510 Sl 1715 3 900
Warner 3rd 1000
type synchromesh
WP510U WPL510 Rev 17 5 3 S99
3 355

F4W63L

f
P510 S TV JNL510 S T lot 3382

PL510 S T 2nd 2 013

IS 5 3 700
N510TU 3rd 1312

P510TKU PL510TK 4th 1000

4 ro
Fmw peed RPL510SWTV PL510TV Rev 3 364

I
FloofS uft
F4W63L
Warner type synchromesh
ht 3657
WP510TU 2nd 177
16 5 3 700
WPL510T 3 d 1 419 I
I
4th 1000

Rev 3 63R i

127
I

Specifications

Manual Transmission Ratios

V I FiN s Tli Tel 1i u Rn

1 60 900 1562 1 000 No N 3 015

1 00 6
L320 94 301 173 No 6

1 000 None 3 638

L520 3 657 2 177 1419

1726 1 000 No 6 462

941 3 009

1 419 1 000 None 3 636

521
PL 3 657 177
2

No NOM 4 125
PUlO 518
3 1725 100

3 197 1725 100 No N 125

1 490 1 000 N 5 159

3 945 94

3 945 403
2 1490 1 000 No 5 159

PL411 3 197 1 725 1000 N e None 4 5

12

3 94 2 40 1 49 100 None 5 159

2 1 000 None 3 638

3 657 177 1419

RL411 3 382 2 013 1312 1 000 None 3 365

SPL311
PL510

SPJ
110 3 515 140
2 1 328 1000 None l7
5

SRL311 2 957 1858 1311 1 000 65 2 922

419
1 1 3 638
PL510 3 657 2 177 000 None

None 3 634
3 382 2 013 1312 1000

3 382 2 013 1312 1 000 N 3 634

420
1 3 164
HLS30 3 549 2 197 1 000 None

2 957 1 857 1 311 1 000 852 922

1404 3 640
LHllO KLBllO 3 757 2 169 1 000 None

CD L60 transfer cue ratiOl 2 264 1 nd I I

Condition Probable cause CorrectivE ction

1
Loosened bolts such as side nange id Tighten thebolts to specified torque
retainer or
gear camero

Defective gasket or aring Replace defective parts with ew nes

Loose tiller or drain plug Tighwn the plug

Clogged or
damaged breather Repair or
replace

128
 Specifications

SERVICE DATA AND SPECIFICATIONS

Nominal diameter of ring gear mm in 160 6 30

Gear carrier material Malleable cast iron

Gear ratio number of teeth

3 700 37 10
with AfT mQdel for
U S nd Canada

111
4 37 9

Drive pinion preload adjusted by Shim

e Pinion
Dri

Preload kg em in lb
without oil seal to to
7 10 61 8 7
with oil seal
S to 11 7 0 to 9 6
At ompanion flange bolt hole kg Ib
without oil seal 20 to 2 9 4 to 4
6
withoil seal 2 3 to 3 2 5 1 to 7 1

Thickness of pinion height adjusting washer

mm in 3 09 0 1217
3 12 0 1228
3 15 0 1240
3 18 0 1252
3 21 0 1264
3 24 0 127S
3 27 0 12S7
3 30 0 1299
3 33 0 1311
3 3S 0 1323
3 39 0 1335
3 42 0 134S
3 45 0 135S
48
3 0 1370
3 51 0 1382
3 54 0 1394
3 57 0 1406
3 60 0 1417
3 63 0 1429
3 6S 0 1441

129
Specifications

Thickness of pinion bearing adjusting spacer

and washer mm in

5S 2 2 2t26
Spacer
56 4 2 2205
56 S 2 2283

56 8 2 23S2
57 0 2 2441
57 2 2 2520

Washer 2 59 0 10201
2 57 0 1012
2 55 0 1004
2 53 0 09961
2 51 0 0988
49
2 0 0980
47
2 0 0972
45
2 0965
10
43
2 0 0957
41
2 0 0949
2 39 0 0941
2 37 0 0933
2 35 10 0925
2 33 0 0917
2 31 10 0909

Side gelr and pinion mate

Thickness of side gear thrust

washer mm in Q to 0 80

0 0295 to 0 03151

0 80 to 0 85

0 0315 to 0 03351

0 85 to 0 90

0 0335 to 0 03541

Backlash in pinion mate and side

gear or clearance between ide gear

and thrust washer mm in 0 1 to 0 2

0 0039 to 0 0079

Ring ar

Backlash between ring gear and

drive pinion mm in 0 1 to 0 2

O 0039 to 0 0079

Runnut of reat ide of iog gear

mm in Less than 0 05 10 0020
gear

Thickness of side retainer adjusting

shim mm in 0 20 0 0079
0 25 10 00981
0 30 0 0118
40
0 0 0158
0 50 10 0197

Side bearing standard with mm in 20 0 0 7874

130
 Specifications

Carburetor Specifications
r f
f l
I
U
t
I
C

Ir t
l
il 1 h i l

P SO
Leo 880

Pwlth
nission

LBO

EI 079 75eD
PUIO

El 145 750
320
1

J 85@
520
1

J 850
PUll

with N A

emission

control
L52ll
L501

R 1
950

R with 23 M 39 with Jrl

emisrion 5 M 70
38W i
95
control with 6
38W

U20 87
SU 950

UOO s
M nll t

Sole

U20 32 N i1with 8 87
with uion
emi 46W 5 N 25 950
with 46W 7

LIB 071 87
PL510 D
95

LIe 071 87 ISO

with emwion 95 13
lrol

L24 23 N 21 rrT
wth 079 950
emialon
control
HLS30

At2 71
with 78CD
emission
control
UllO
nJlllO

From
@ SOIt chamber top to fuelleYel

131
 CDft Nt ft 8

l i

l t

tIn
E

14 14 14 14
i e

45
I
1 024

55 0
40
I
55

3 il r

2nd
i
l l 210 100 220 2nd 120 100 220 2nd 120 100 40
2 tWsce
I ec sec
4Hlt

Specifatons
0f
5
2 B B
tS B 48
48 48

el 60

Carbueto
l
ii 70 80 BO BO 60 60

ec
ICf sec
h 135 9B 115 96 15C1 90 14 92 140

c
827 0241 827 024
1 788 061
788 06 1

f 0l 42 81 102 81 022 1 022 LlSO

1
102 1
1 1 1 1 180 1

r M D2630A
M
4A

Hitachi VC42 Rochest 7015 3 Imgle throat downraft Nihonki kakl 2D3OCE dual thrOlt downl1ft Nlhonkl kat 2D3OC dUll throat downraft Niho ki hln D2630A dUIlI thm downraft Nihonlia blu downNt
t

dual thro

i
f
l

P L60 Pwlth eml contrl LOO El PUlO El 1

320 J 520
1 J PlAl

tI
 CD P n 8

400 131
1
1

5
16 16 I1
4
13 6

011 020 020

60 100 JIM
092

11
ec

180 100 C ISO 100 220 100

200 100
ec
3
46 18 see 48 16 5O
41 100 6

071
138 157
255 118 083 110
106 118

240 120 C 240 I

C BO 8 S

100 14

sec ll5 155 C

f 1I1 1969 1
5 1970 A 96 135
16
96 130

35 155 315 pnm 216 SL2 2nd

315 512 pnm 315 433 551 710 nJ
4
2
0

945 U02 787

7
01 394 456
1
C 900 1
I01 1

62 1

605 2 200 260 c

L81 024 1
i 495 495 81 74
1
1 l1 C
1 101
1 1
1 181
02 1 1
l 180
1 10
5 7 6
8
DAF328
6
HJB38W

Ilderaft Hitachi HJG46W HJC46W type Ilderaft Hitachi DAF328 dual throat downraft Hitachi auto DAF328 DAF328 PL521 Hitachi HJG46W ASU tyPsiderlh HitlChl DC 306 throat downrah
f
Ildedr
aft choke
PHH twm du

Hitacln DCA306 throat downraft

l dUIil

Hitachi HJB38W SUtypeIlde raft Hitachi HJB38W SUtype Ide rah HitachI HJ46W SUtype Mikunil SoJex f StI
itd

cont
with emlD n control
16
puna with emiSIOn with enul on control HLS30 AI2 with emis on COTltrol LBlIO KLBlO
Rwith emluon control
24
with emJslon contml 5
1 L5U R
U U U 1 16
1 1

i
 CDat ft 8

P
frpl
05
1 1 98 1
18
0 580
111 2
for
PlA r RIAl JIO 80
l

I2
1

98 98 98 39 5 18
1

A
I j

Vo J

1
5
A A 10 60 lts
8
88 N 68 N
0

without
1

15 34 00 57
bl
0
B 5
46
5
stop 8 5

Z 11 020 020 020 020 020 020

020 020 020 020
M
Irnl pl 1
g

d Ii
012 012 012 012 012 012 012 012 012 012
lftM 1I
d

A
A
N
N e
e e e B 9 e e

Specifatons
c

339 31
4
A
lI

tI
I
7 we 338 358 333 N 339 31
4 339 354 127 350 299 315
N
laid

X
D X X XX X X XX X XX

fiJlI
I
J aX 9X MX 00 87 12X 87 76 81 12X 87 UX 87 12X 87 5 86X 90 A 00 92 A
IO B 14 14 13 14
Xd 12

Clutch
f 1
1
1 75 15 1

a5 N N
75 1S 7S 75 7 740
D

O XU

i
5
226 32 I
00 04 011 A
N
91 01
1 2 I
77
1
98 OI
1 I
77
1 14 1
1
211
R 2 2 2 22 i

1
r

tlww
4

99
6pr1 190 US6 176 41 7
1 178 56 101 179
6@1
1S
qUo 78 @1
15 87 1 I587 99
@1
1

17 00
l
I

180 A
N 132 @1 I 1 169 @J 2 92 2 161 l
1

diaphr
gm

c roll pring roll

ag
Prh

i1

spring i1

spring spring il
pring diaphrgm sprina roll sprinl dlaph1 J pbralJ
LS21
y
LOO Eady L320 Lo
L320 PLUO PUl RUll SPL310 SPL31 SRL31 PUIO WPL510 510 WPL510 15IO PL021 lHlOA LBlO uBlO

i
 Specifications

SERVICE DATA AND SPECIFICATIONS

Pressure

Free
spring
length 3 mm 2 0 0 in
I I

l 14Din AJ7 l Ib I
Fitted length load 29 2 mm 44 kg
100 1m 0 196tl 9 7 ill
Qut of right angle
Allowable min spring force l j f
I
h release lever
Clut
Release bearing ta diaphragm spring
release lever clearance 1 2 1 j mm 0 04i O ll j 1I

J
l O 10m 1 o O l
Hl
Diaphragm spring ta flywheel height t

O i
0 0 1 9ti8 t O 019
in J
Release lever ta flywheel height in

Clutch disc
ze
Facing
Outer dia x inside dia thickness 1 O
200 mtu

7 H7 120 x O tO
I in

Total friction area 362 12 6 11 i02

Thickness of disc assembly
8 6 9 0 nm 0 38G
J O 1 in
Free
7 6 7 9 IllIl1 0 3012 O lU
31 in I
Compressed
Material HITACHI HT50S 17 AKEBOXO A50

Number of torsion spring G

Allowable min depth of rivet head

from surface 0 3 0 Ollb in
facing mm

Allowable facing ron out O mm 0 0197 in

Allowable free play of spline 0 4 rom 0 0157 in

Pressure platlll
Allowable refacing limit 10 mm 0 0394 in

Clutch pedal
Pedal when not depressed 182 7 17 in R H
height
207 1m 8 1 0 in L H

Freestroke of pedal head 2 mm 0 1 in

98

Pressing strength at full stroke L kg 33 Ib

Master cylinder clutch

15 87 mm il 8 in
Dia master cylinder
Allowable max clearance between
0 3
1 0 0051 in
cylinder and piston mm

Tightening torque
Clutch assembly securing bolt 2 2 Gkg m 17 IS S lb
ft

135
Specifications

ENGINE TORQUE

n lBS

Op elle
200 I I
Ii
112 5 0I 32
5
CI1 heo ns I ls lu n lu
nettu J
1
l n

c cti 1
i3 i i 5 19
2 5 239

l 119
J
216
b h 7 O 54 2 JIe 75 9

I
Ma 1 S 4 32 5 5
ri
It
cap

h ft 2 9 J4 7 30 2 U 2 43 4
C I

1o 1t

011 U 9ii
i2 2 91 05 1

I
u
b oli3 2
5 1 I IS 2

I 6 5 5 7 S U

10 1

15 7 UO 7
lil15 130
e nk uUay
boll

PISTONS PINS RINGS CRANKSHAFT BEARINGS

h lI End 0 I d B lnlll I
I Motna rlng
I

i
I
h ck Inch

M r I 1
I
hto
Y I
CI 01 Shott 8 in Shoff Il n h t Shft
I C
101111 h ck Jilek tn CI o cI 01 Cl u h

I
I Inch Inch B I 1

i N Inch

966
i ooa
I 1 67 1 1 0 1 9n 0005 1
013 002
0131
2 360
001 T 1 2 04 001
0016 010 012 0027
01

012
2 47 1
U 20 0012 T 1 2045 0013
012
010 012 0024 0021 I
016

012

1 L I 1 12 1 7 a 2 161 1
001

121 I
009

015
012 0026 002 012

i 1
012
L U T 1 12 1 67 0001 1 4
001
012 0026 0021 012
009

01S

012

1 012 617 1 770 1 1 967 1

1970
721 0017 014 035 0024 011

138
 Specifications

VALVE ADJUSTMENT

I V I
L h V
AIIIII Vol
1 Clearenc

to
SteDl

Inch D h lI
M cI S
V o

lnl lt ll Intah bh IIII Inteke bh

h lll bh feu @l

00 00 00 0 4 014
014 ur21 @ 1l
19
IOut r 64@ 1 00

001 014 0 114

@ t
1 001 004

l
0 Q17G
I @ 1 00

160 172 00 0 14 034

U 20 OO QUIl 0004 002
@

l @
210 @
00

I
5@ 1
o 001 00 0312 il2
o
oliID ut 1fw
l
19 72 L 4 OtOIl
11l r 56@ J
tb 00

00 0 3112
197072 L 24
OiG 0 120 Out 90100
IS
004

4o 5@1

I 1200 0 14 In@II001
00
00 00 0 12 0 112

j Enlllneh t

ENGINE

GENERAL SPECIFICATIONS

I I M

I
Y d I ll nm 1I1 Ma T Ne
r
Dltpl CeI Cl
8 k H P fl t OIlP

I
un
l 1e Inch R l
fn Inch C nd
ce @ plll @ pm

I I
n 2100
2 174 J OSS 19 21 7 @ 5200 @ 2040
I
196
6

I n nS 1299 2 I 0
4000 5
196661 4U 2 30 97 22 0
@ 6000 103 @
17 3
6 9 U9S I

1
0 2 433 3 261 U0 92 SU b @ 00 3040

I I
17 2 n
09 U 125
@ 6000

5 1 b 131@ 100

150@ 000

2600 0
97 I 9 @ 00 100@
I
71 2 2 902

113 2 73 76 1595 I
2 0 1 @4400 lo4 60
1
1 2 2 2 902

1 3 2 n76 U92 151@56OO1

4000 42 50
@ 000 70 @
I
1200 74 2 756 71 5 0

j 12 11 117H
7 I 96 @ 00
I
100
@ noo 5 60

I
1972 1 16 2 26 2

U2 72 76 1595 I
2 02 14 1 1 151 @ 4400 5 60

I
l 4
1 2

12 2 n 7 n 2 @S6OO1 4000 4 50
1200 2 74 2 7 71 5 0 @ 6000 70 @
IT1 6t 7 11171

137
Specifications

TUNEUP SPECIFICATIONS

I I SI II Dbtrlbvt 11I1I tllI TI

h

I
I Ihll
e PlrI l

Y M 1 T 1 ell 04 0 M k
G D S

I
d

I
1
Inch G A e fTDC L e N
Elllln
Rch D

1 66 61 I J 027 03 0 022 SO 55 1 2 4 vlley

671
0 012 40
3 It I vll
031 0U

I 11
I

I U 2Q
027
027 01 016 020
st

ltlt
MI
61

IS
hI

11 4 1
1 vlley
n
1 72 I 1 16 031 035 017 022 1 55 I 1 42

on 017 0211 55 11 3 4 2 7 n
191072 DO o
1
I l 24 0311 035 Olt D20 t 35 41 I 3 62 pvn 75

20 with S I
B

ADJUSTMENT OF IDLING

the normal idling setting

Adjust ngine at

Engine idling Idlin liming

0 1
rpm ldeg e relard side

M Tvehicle 800 1 BlOC

5 15 5
0

A Tvehicle io
650 D mge 511 BTlX 15 5
0

Recommended Lubricants SAE

T r U4 T o tI
Or

F 1IA inc il IOW 30 IOW 10 1lI 30 IOW 10

API lOW IOW O lOW 40 IOW 40
dl il nall n W 20 lOW 20 20W 4 0
IS ilSE 10

carOil jIJ 0 90 140

API
1 Ili tion
iJ
f1 EI l fPS

40W Ily Icmpcrutures

he used for 00
hi h speeds

138
 Specifications

Capacities and Pressures

Wttd l l1iru RA t
U tln lli T t Yo Cool d
ur azi
r
ke ON Pc T f s u rul e
t a f
R pt m
11 f ql d l u

fl r 0 Hi
i qtf
Wi WiLl M A e
PiJi T Filt

UI
S s

LBO 36 S A 4 20 2 6 front 19 0 5 2 NA NA

nd rear

PlAID 33 30 3 8 20 10 8 5 4 NA 6

SIL1W 4 2 4 6 1 8 113 6 9 NA 4 6

A u R 4 7 2 2 110 5 7 N A 6
PIAlI

HUll A J 5 4 3 19 110 7 1 NA 4 6

S1 11 1 1 A 4 3 4 6 2 0 11 4 8 3 4 4 6

Slt1
111 1 3 54 20 11 1 90 3 43 13

SI 111 11 7 5 5 4 2 0 11 4 90 4
3 4 3 13

ithtwlJ
twin I hoke
rhuretors

1 8 5 A A
L 12O 32 43 18 93 7 N N

6
i20
L L521 3 8 32 42 17 10 8 5 9 1 25
2

1 L51O 52 4 4 6 4 IL4@ 11 1l9 68 16 3 4 13

7 2 with
heater

WlL51D 6 21 11 9 68 2 6 4
3 1
5 2 4 4 IIA@
7 2 with
heater

2 6 4
3 11
PL521 4 36 42 17 10 8 68
7 4 with
heater

HLS30 4 7 43 32 32 12 8 2 1 15 9 8 5 44
1 3 1 1

LBllO NA 29 43 16 L1 57 NA 13

Q8 pb
4 witllollt power takeoff 7 8 rll trnnder
@ 1 5 pts uil Oler

138
SpecilicatioDS

AUTOMATIC TRANSMISSION

V t
al pring h rl

In lalled
1 10 d
No ul free
i Jla
tliJ length
I pfll11 II Load
mm in length
linl
mmOn lb
q

13 6 0 15 0 3 4 5
26 5
lallllal Uh lIl
O OSI 1 1O Jb2 1276 1043 12

I 10 5 13 0 43 0 23 5 2 8
SSllrt
Prl gULHllT to 04nl 004134 1693 0 925 62

004 X O 5 0 18 5 90 0 1
Prssute Jdificr
0 728 0 3543 02
10 01571 10 31501

06 6 0 16 0 32 0 16 0 0 625
1st Id shill
OO 36 10 162
2 260
1 0 630 4
1

0 7 6 2 18 0 410 17 0 140
d 3rd shifl
1 614 0 669 3 1
0 02761 0 24411

0 7 5 15 0 32 5 27 0 0 55
ud 3rd timing 0 01761 0 2165 1280 1063 12

08 65 14 0 36 0 18 8 192
Throttle k Ip
10 0315 10 2559 1417 0 740 4 2

0 55 50 12 0 22 0 5
12 0 60
Sulenoid downshift
10 0217 0 1969 0866 492
0 3
1

55
0 5 0 16 0 5
33 210 0 60
und
Se k
lo 3
1
0 0217 0 1969 319
1 0 827

09 5 6 14 0 26 8 19 0 2 19
Throttle elief
0 0354 0 2205 1 055 0 748 48

4 8 15 0 5
21 5
11 om
02
Orifice check 453
0
10 078 0 1890 0 846 0 02

3
8 5 0 218 75 0 215
45
0
Primary governor 0 858 0 2953 0 5
0 0177 0 3268

07 55 25 1 10 5 10
1
8
5
Secondary governor
0 0276 0 3346 0 988 0 413 24

140
 SpecifiCations

SERVICE DATA AND SPECIFICATIONS

General specifications

Torque converter

Type SYllImelrit l1 J e1emc 1t I lge

Sl
phJx llfl
Ut
onverter ollpling

Stall torque alia 0

Transmission

Type J speed lorward ld lI

sp d r r l iT

pl lIletal Jin
lr

Control elements Multiple disc clutch

Band brake
diMulstipcle brah
One way clutch

Gear ratio 1st 458

2 d 1458
3rd 1000
Reverse 18

Selector positions P ParkJ The transmission

plal cd llo
lIlr IL Till llpl
shaft is fixed Thl19inc illl bl qarku
R Reverse Backward
N Neutral The transmission t utral TI1 I ill
b
slarlc4
o Drive
Up or downshillS ltom tlly
lIil hI IU tr llll bl
nd and
lOp
2 d lock Fixed at ld
I Lock up Fixed allow downshifls tWill J

Oil pump

Type 11Ilernally I
termeshing l1
11
p l ar
pUlllp
Number of pump

Oil
AUlOlllath transmissiOll fluid Dl rull
IYlk

Capacity 5 5 liters 57 8 U S qls 4718 Imp qls 1

Approxil
JTdy 7 Iill rs I 7S U S lS
qh
Imp qts in torque r
T1c

Hydraulic control system Controlled by detecting Ih nep ati e prc sllle

of intake manifold and the YOhllioll speed It
output shafl

Lubrication system Fon ed lubrkation by an Iii pump

Cooling system Water coo

edbya Ixili JfY
culaliOlHypc
cooler located at the dialOr

HI
Specifications

Specifications and adjustment

Automatic transmission nsembly

Model code number X0400

Torque converter assembly

the 16 8
tamped mark on TIC

Front lutch

Number of drive r1ates

3
Number of driven plates 3

Clearance in
mm 1 6 to 1 8 0 0630 to 0 0709

Thickness of retaining plat in

mm 10 6 0 417

10 8 425
0

110 0 433
112 0441

114 0 449

116 457
0

Rear clutch

Number of drive plates

4
Number of driven 4
plates
Clearance mm in 1 0 to 5 0 039
1 to 0 059

Thickness of retaining plate in

mm 4 8 0 189

IttW reverse hrake

Number of drive plattos 4

Number of driven plates 4

Clearance 0 80 to 105 0 031 to 0 041

in
mm

Thickn s of retaining plate mm in 118 0 465

12 0 472
0

12 2 0 4S0

12 4 0 488
t2 6 0 496

12 8 504
0

Brake band

Piston size mm in

dia 64 520
2
Big
Small dia 40 575
1

Control valve assembly

mark strainer E
Stamped

Governor assembly
35
Stamped mark on
governor body

142
 Specifications

Engine idling and stall revolution

Engine with emission control device

olution 650 D position

Idling rC
rpm at

800 al N position
Stall revolution pm I 800 to 2 000

Tightening torque kg m ft lb

14 0 to 16 0 101 to 6
Drive plate to nhhaft

Drive 40 to 5 0 00 u16
plale to torque verter

Converter housing to ngine 40 to 5 0 30101c

Transmission case 40 to 5 0 30 t 1 1hl

0 comelIer housing
Transmission ase to extension 0 to 5 i
I In IX

Oil pan to transmission case 0 5 to 0 7 3 61 II

Servo retainer to transmission case 5 tnO

0 3 1
1
piSlon
Piston stem when band brake 1 210 I 5 87 to IU i1
adjuting
1 5104 0 11 to 9
Piston stem lock ut

One way clutch nner ace to transmission case 13 to 18 941013

Control valve to transmiiSion 0 55100 75 40 to 4

5
body ase

Lower vain 0 75 to 0 35 19102 5

body to upper valve body
Side control valve 0 25 to 0 35 19 to 5
2
plate to body
Nut for oOlrol valve reamer bolt 05 to 07 36 to 5 1

Oil strainer to lower alvc body 0 25 to 0 35 19 to 5

2

Governor alve body to iI distributor 5 to 0 7

0 3 6105 1

Oil pump oil pump 06 to 08 44 to 5 8

housing to COVeT

Inhibitor switch to transmission case 5 to 0 7

0 3 6105 1

Manual shaft lock ut 30 to 40 22 to 29

lock nut for oil cooler pipe connector to transmission case 30 to 5 0 22 to 36

Oil cooler pipt 07 to J 5 0 to 79

onnecting nut
Test oil pressure 14 to 1 1010 15
plug inspection hole
to 08 to 11 5 8 to 79
Suppor actuator parking rod inserting position extension

Oil s5
0 to 0 75 40 In 4
5
charging pipe to ase

Dust ver to converter 055 100 75 4 0to 5 4

housing
Selector range lever to manual shaft 30 to 0 tll II

08 tu 0 5 10
Selector rod lock nut

1 6 to tI to tt
Control lever boll

0 1 ItJ 4
0 610 I
Control lever bracket to floor

0 0 h O S I t I I 1
COfltlOj lever knob to evel

Turn back two turns after lightening

143
Specilications

PROPELLER SHAFT

SERVICE DATA AND

SPECIFICATIONS

Propeller shaft Length ut diD x dia mm in

For Sedan 1 080 63 5 60 3

42 5 25 4
2

For Wagon 1 242 75 0 71 8

48 9 x 30 28

Axial play of the spider journaJ 0 08 mm 0 0315 in

Sleeve yoke spline to mainshaft o 0 08 mm 0 0 0031

lash limit 05 mm 0 0197

Spline wear

Maximum out
run of propeller shaft 06 mm 0 0236

Spider journal diameter wear limit 0 15 mm 0 0059 j

Pennissible unbalance

35 0 486 in oz at 5 800 m
Dynamic cm
gr p

Thickness of available snap rings

Standard white 2 00 mm 0 0787 in

Oversize yellow 2 02 mm 0 0795

I 2 04 mm 0 0803 in

green 2 06 mm O OSll in

blue 2 08 mm 0 0819 in

brown 2 10 mm 0 0827 in

colorless 2 12 mm 0 0835 in

pink 2 14 mm 0 0843 in

Tightening torque
Fixing nuts of flange yoke to 20 2 7 kg m

companion flange 14 20 nIb

144
 Specifications

kg m ft Ibl
Tightening torque
Drive 17 to 20 122 9 to 144 6
pinion ut

Ring gear bolt 7 to S 50 S to 57 8

Side etainer rolt 0 9 to 1

2 6 5 to S 7

Side flange fix bolt 1910 2 6 13 7 10 18 8

Rear cover fix bolt 19 to 2 6 13 710 lS S

Rear 6 to 8 43 410 57 S
cover to mounting member lock nut

Differential carrier to uspension member fix bolt 5 to 7 3S 2 10 50 6

Differential to drive shaft fix bolt 5 to 6 36 2 to 4

43

Differential mounting member elf lock nul 7 to 10 50 6 to 72 3

propeller shaft fix bolt 2 0 to 2 7 14 5 to 19 5

Companion flange to

Oil dram nd filler plug 4 to 6 28 9 to 43 4

liter DS 08 7 8 3 4
Oil i y ahOllO
Ipal qt Imper qt

ethods
djll tiltg
Variation umbers o pressed by mm GO

Oummv shaft u

I Dri pinion adjusting formula T W

S
N

O OlJ
H D

02

I A C Gl D
Side bearing adjusting formula Tl

I 0 01 0 76 E

L
T2 B D G2

0 01 0 76 F

145
Specifications

Brake Specifications
C i Bore nJ D
S
LM rti J

w r R
r R Mu ur
u
c
Ii
C n

F t R

115
1 60 Drum Drum 1000 1 000 USO 11 5

KA i A
Drum 875 1000 93ll
PIAW Drum
1000 93ll S A
SPL310 Drum Drum 875 NA

9 0
PL411 Drum Drum 875 1 000 93 9 0

875 2 000 9 1
HUll Dbl Dmm

750 125 1
81 11 2 9 tJ
SPL311 Dbc DrUllI

5
12 11 2 l ll
SRLl11 l i1 l Dnllll 750

10 0 10 0
320
1 Drum DrUIll 77 77

i50 10 0 10 0
520
1 L521 rnm
I Drom 750 750

tln 9 1 9 0
PL510 Di1c Drum 750 000

000 l U3 9 1 9 0
WPL5lO Disc Dn m 750

KA 10 0 10 0
PL521 Drum Drum KA

Disc Dnnn 875 2 125 875 10 7 9 0

HLS30

8 4 8 0
LBllO KLBllO Disc Drum 688 1894 688

Chassis and Wheel Alignment Specifications

Mod C W rlAIa

u T KilO W Pi
w r tf CukT IIq J C r k
i o bd R
U
ill lio 1 0
g Wltul w

1 Rur B JIII
q
f f
S d
t ll Ii

166 45 2S 25 32
UlO M 54 B 55 3 30 1 30 12
7 15

WL60 98 4 54 B 55 3 1 30 1 30 12 16 6 45 2S 25 32
7 15

PUlO 93 8 47 5 47 0 1030 1030 00 13 6030 3B 28036

5PL310 89 8 47 8 47 1 1030 1026 06 13 6034 38 28036

PUll 93 7 75 47 2 0 1045 06 136015 38 28036

RU11 93 7 47 5 47 2 0 1045 13 6015 3B 28036

311
5P1 89 8 50 47 2 1 30 1025 08 12 6035 36016 29020

5RL3ll 89 8 50 47 2 30 1025 08 12 6035 36016 29020

L320 97 2 46 1 46 7 3 30 1 30 08 126 34 29030

L520 99 B 49 2 49 9 SO SO 105O 1 20 08 12 6 34 29 30

35 478 3839 22030

510
P1 95 3 50 4 50
3030

510
WP1 95 3 50 49 6 1 10 12 24 7050 3B 39 2203
3030

WI 99 B 49 2 49 9 3 SO 50 I oSO 1020 08 126 34 29 30

PWI

j
HLS3O 90 7 83 3 83 0 5
202 2055 20 1020 50 os 20 11040 13
32 31024
3025 12040 32024

LBllo JLBllO 90 0 48 8 49 0 40 040 1 10 35 5

103 OOS 1 24 7oSS 42 3537

i Uo
ooded

148
s

o
r
 r cif
1

1
If
7 C Ju
i
J fIT7L7 7JrwF
wM
lifftrf
u tI 4 1
UJ

AUTO BODYR IRING AND REFINISIUNG by B B Weston

This b delves deeply highly ompetitive auto body
into the ir tf
rep ide Every possible phase is
discus light of the correct repair techniques and tools to be used to return a damaged
and eXplained in
auto to likenew condition Topics such at n materials welding hand tools and auto body
constrocti
design are just a few of the major areas clearly explained in this text Designed to serve as a shop mahual
for auto body men and as a reference tool for the owners of auto repair shop s it is a must for any well
equipped school shop or library
SBN 030
87749 9 58 95

MTOR RACING THE GRA X GltEA1 bY 13arrie Gill

Banie Gill the internationally famous r ej ert has created a book that offers portraits of ten
c ntenders for the honor f being the gre iver
dr of t1iem all Graham
Jill tirIing M s J en
dt ryIanuel
Ju@ FangJQ Ienny n
Huh lt ikl Hawthorn JunClm k Jack Brabham Bruce McLaren df E
nd Jackie Stewait Eaclimim is disCjlssed ii1 this book by the o knew 1llm th e
writerS best and
s
sport
h shiueCi his triumphs agedies Tl book will
give t
evet racing enthusiast a fresh ly and
liv
SIde look at some ofthe world s most cOIof W
and courageous sPfirtsmen
t SBN 87749 229 8 5 95 II

1 lof y
rJbTI AeBESSORIESIDE
RE5l Edward J Mezo
c
U by
liiI
il teitieatis e on the latest autom ccessory developments and l8iring
rej adjustment and
di oslJm1Jtho s for the imtomobile Qwner anll theprofessionaI mechanic
li Hters cloc
t
r lC
dj s o
c1nditi b e reIease signals cigare
lwmdiftsow and
c
eIe i
c s tum sign l
4
Ysl1ers a There
eters
mdl
at ii p w r t power
voted to controls for the
speedqm eId
wmdshi nd Wipers 1

9tl
sl 11 handicapped
eve1 l a s n

l87749
SB 128 3 paper 1 i
9

ELECTRO

This book Contains

JD1 b CP
JECTS
lcore
FOR CAR AND GARAGE by R M Marston
S

fsimple and very useful electric devices that can be made at home for the car
N 87749 129 1 3 95

ij f
T

and garage ldeil

fncl are circuits for the car that warn of danger from ice arid overheating an autoinatic
dshieId
wi rtqntrol
wipe and an automatic sidelight switch Two projects that will be Of great help in the
garage are a e
f atiilgbattery charger and a speed control for electric drills
Each project described by ll d and easily understandable instructions and ilustrateq by clear
it is
diagrams All necessary components ate listed fot each device This book wilI l e ofgreat value to all car ti
owners meMtanics and electricians
SBN 87749 32 1 5 95
L
li

TUNING YOuRBIUTISH SPORTSCAR by Charles Williams

This bOOK will liel t ers of British made cars tune them for maximum power and speed TUNING
YOUR BRITIS ORTSCAR gives a non technical but practical guide to how f8InllY cars can be made
to behave mpre liKe sport cars An added feature is a list of major Americ8n suppliers of the British IlUide
auto parts discuss in this book TUNING YOUR BRITISH SPORTSCAR is profusely illustrated with

many photos and grams

iJii

SBN 87749 165 8 7 95