SERVICE MANUAL NISSAN)QUICK REFERENCE INDEX GENERAL INFORMATION DATSUN 210 irae aH aT oH Model UMUC MTU CNA B310 Series Lalas chee FOREWORD NT De AL This service manual has been prepared pri- marily for the purpose of assisting service personnel in providing effective service and CATH DTM TANT eco maintenance of the 1981 DATSUN 210. STL aa ea LUN L tid This manual includes procedures for main- tenance, adjustments, removal and installa- Prt tion, disassembly and assembly of com- ponents, and troubleshooting. ime el All information, illustrations and specifica- tions contained in this manual are based on eMC ST the latest product information available at the time of publication. If your DATSUN soda dstrs fry ‘haw sifcatoas DN Gat Te tained in this manual, consult your NISSAN/ DATSUN dealer for information. Cea ENS 2 ee The right is reserved to make changes in specifications and methods at any time with- eae CR ae TT RA out notice UE) ‘s ay BLT AL a a roel h tN NISSAN MOTOR CO., LTD. Lae UL Le 1980 NISSAN MOTOR CO., LTD. Printed in Japan Not to be reproduced in whole or in part without HAL) the prior written permission of Nissan Motor Com pany Ltd, Tokyo, Japan/¢|__HOW TO USE THIS MANUAL D> This Service Manual is designed as a guide for servicing tars. D> This manual is divided into 19 sections. The first half of the manual presents sections which concern the engine, and the second half presents sections which deal with the chassis and body. DA QUICK REFERENCE INDEX is provided on the first page. Refer to this index along with the index of the particular section you wish to consult. D> The first page of each section lists the contents and gives the page numbers for the respective topics. D> SERVICE DATA AND SPECIFICATIONS are contained in each section. D> TROUBLE DIAGNOSES AND CORRECTIONS are also included in each section. This feature of the manual lists the likely causes of trouble and recommends the appropriate corrective actions to be taken. D A list of SPECIAL SERVICE TOOLS is included in each section. The special service tools are designed to assist you in performing repair safely, accurately and quickly. For information concerning how to obtain special service tools, write to the following address: Kent:Moore Corporation Kent-Moore of Conad, Ltd, 29784 Little Mack 2308 Cawthra Roseville, Michigan 48066 Mississauga, Ontario ‘Canada LSA 3°2 D> The measurements given in this manual are primarily expressed with the SI unit (International System of Unit), and alternately expressed in the metric system and in the yard/pound system. D> The back cover of the manual provides maintenance data for quick reference. D In the text, the following abbreviations are used: SDS. Service Data and Specilications LHRH. Left Hand, Right Hand Ds Tightening Torave MITLAIT: Manual Transmission, Automatic Transmission DP The captions CAUTION and WARNING warn you of steps that must be followed to prevent personal injury and/or damage to some part of the car. As IMPORTANT SAFETY NOTICE The proper performance of service is essential for both the safety of the mechanic and the efficient functioning of the car. The service methods in this Service Manual are described in such @ manner that the service may be per- formed safely and accurately. Special service tools have been designed to permit safe and proper performance of service. Be sure to use them. Service varies with the procedures used, the skills of the mechanic and the tools and parts available. Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by NISSAN must first completely satisfy himself that neither his safety nor the car’s safety will be jeopardized by the service method selected.GENERAL VIEWS MODEL VARIATION IDENTIFICATION NUMBERS ENGINE SERIAL NUMBER, MANUAL TRANSMISSION NUMBER AUTOMATIC TRANSMISSION NUMBER LIFTING POINTS AND TOWING GENERAL INFORMATION CONTENTS Gi 2 PANTOGRAPH JACK Gia GARAGE JACK AND SAFETY STAND Gi 6 TIE-DOWN Gi 6 TOWING . Gi 6“ SPECIAL SERVICE TOOLS Gl ‘TIGHTENING TORQUE OF 7 Gi STANDARD BOLT.General Information GENERAL VIEWS 1,300 (51.2) —~ k 1,580 (62.2) [He 1,365 (53 i Ties 63) Tee 785 5 1,330 6524) —t Go + 23002.) G19— > 190.068. 2door Sedan 1,300 (51.2) > — 1,580 (62.2) Ties T | os 16s 2340 921 iy aso iszey — + 130s (sia) 4190 165.0) nit: nm Gy * CamadsA12A engine model scioazGeneral Information Hatchback 1,300 (81.2) 1,580 (62.2)—$ = f = \ 1,335 652.6)" 1 160 [785 6.3) 1,065 | = G09 — 2340 02.1) 49 + 41.90 (165.0) $$ Fe 1,800 (51.2) = — 1,880 (622) —=| 1,335 (52.6)- 1,330 (524 — 2340 (92.1) — 4,260 (167.7) Unite mm (én) scio8a GiaGeneral Information MODEL VARIATION Dif] Road wheel Destination Class Model Engine ferential | size... offset] Tire size cartier_| mm (in) Lestorsv ‘AT2a| Faws6a | 4160 2door [| puastoRFv | Ais | Fssweoa | H50A Sedan Puasionav | Ais | L3N7IB | H150 Test 6.15.13-4PR a PLBSIOFV ‘Ate | FS5WGOA | HIOA E 4 Lubricate R= Repiece Depending upon weather and atmosphecc conditions, varying oad sue, {= repect, correc, lace necessary MASLUBRICATION CHART Lubrication Chart ~ MAINTENANCE iy UOT TSP Simon vou] @ Ten sousoa JOnayDINpr"ayiuoW E 40 [aT GOO E) uy pmerodo st 0031] @ ‘auana ue yons uy “p3860)9 a “ybiy Ajowanxe 40 mo} AJawes wet iva.qule 22049 ‘suanpe au wilecrkesill @1W0 wvao TWunauaasia NOISSIWSNYHA IWAN --—~—— - S NowssisNvuL | ‘SMWWOLAY-== = =~ ~. Ho1v1 a00H fewer @ @30NIH "4907 io aniona @ - -----} --| 2 ~}----- -110 uva ontusais waits woaniona ------L---L- = |--}------ cing anvua (sin) wainia tana @------+---} --- r-- (vavnvo) warts tans @):---- }--}-=--- -aims Houma ‘aint uansym moanim Cat +——_t_€9 ---- -: ontuvaa 133HM LNOws WV3U WOTSIHSONIM- --~--~f-—-f—-— - aaA10ui937a Avaiva-------4---40-- % C) come ANv 1009 antona SOIAWaS 3NILNOU Ei) 000'st/000'vz Awana oe 12310 © pa 3ONVHD 3 g ‘uiauip Aasnp sapun 4! soueuosujew usrMAINTENANCE = Recommended Fuel and Lubricants — Approximate Refill Capacities RECOMMENDED FUEL AND LUBRICANTS FUEL SAE VISCOSITY NUMBER Gasoline octane number (minimum) Gasoline fenaine eT TT TT. RON (R+M)/2 pe =i *US.A. and Canada er MPG models pit ‘Canada models Unleaded _ | except MPG leaded ss ‘The fuel filler opening is designed for use with an unleaded fuel gun nozzle diameter less than 21.3 mm (0.84 in}] only. Tabane Specifications Remake Gasoline engine of APL SE Tranmision | Further dts, fer to and scr apt ata recommended SAE Coca at scosty char Dilesnt ae OLS ‘Animate TM But ‘Type DEXKON Multipurpose grease | _NLGINo.2 Lithium soap base | Brake and ich Tad pots US FMVSS No. 116 Ethylene glycol base aan —- APPROXIMATE REFILL CAPACITIES Titer US measure_| Imp measure Fuel tank 30 T34/4gal | 11 gal at i a $9 Ga/aat S/aqt ck sows 33 sue a if necessary. 2, Before starting engine, fully open throttle valve and ensure that choke valve closes properly. CHECKING AND ADJUSTING CHOKE MECHANISM (Choke plate and linkage) (Canada) 1. Check choke valve and mecha nism for free operation, and clean or replace if necessary. Binding can result from petroleum gum formation on choke shaft or from damage 2. Before starting engine, fully open throttle valve and ensure that choke valve closes properly 3. Push choke valve with your finger, and check for binding, 4. Check to be sure that bi-metal cover index mark is set at the center of choke housing index mark as shown below.MAINTENANCE — Engine Maintenance Do not set bimetal cover index mark at any posi Dj | AZ \\\ ‘imetal cover index markil,. seteou CHECKING AUTOMATIC TEMPERATURE CONTROL AIR CLEANER (Canada) 1, Check that vacuum hoses (Intake manifold to. 3eway connector, 3-way connector to temperature sensor, S.way connector to idle compensator, temperature sensor to vacuurn moter) are securely connected in correct posi tion 2. Check each hose for cracks or dis- tortion. 3. Check A.T.C. system for function by proceeding as follows: Confirm that engine is cold before starting test. With engine turned off. Check position of air control valve, _—” smarng] Air control valve is in correct posi- tion if its cold air inlet is open and hot air inlet is closed, 4, Start engine and keep idling Immediately after starting engine, air control valve is in correct position if its cold air inlet is closed and hot air inlet is open. S. Check that air control valve gradually opens to cold air inlet side as engine warms up. When environmental temperature around, temperature sen- sor is low, allow more time for engine ‘warming up to facilitate smooth opera- tion of air control valve. If the above test reveals any prob- em in the operation of air contro! valve, carry out the further inspection described in Section EF REPLACING P.C.V. FILTER Remove air cleaner cover, and re- place filter. REPLACING P.C.V. VALVE (Canada) “Disconnect hose and replace P.C.V. (Positive Crankease Ventilation) valve. 51277 If any hose cannot be freed of ob- structions, replace. 2. Confirm that flame arrester is positioned correctly in hose between rocker cover and air cleaner. 3. Connect all hoses and check hose connections for leaks. CHECKING VAPOR LINES 1, Check all hoses and fuel tank filler cap. 2. Disconnect vapor vent line con- necting carbon canister to fuel tank. 3. Connect 3-way connector, mano- meter and cock (or equivalent 3-way charge cock) to end of vent line. SMAi20 (CHECKING VENTILATION HOSES (Canada) 1. Disconnect all hoses and clean with compressed air. sMaiz2 4, Slowly supply fresh air into vapor vent line through cock until pressure reaches 3.923 kPa (400 mmH,0, 15.75 inll,0). 5, Shut cock completely. 6. After 21/2 minutes, height of liquid in manometer. 7... Variation in height should remain 0.245 kPa (25 mmli,0, 0.98 inH1,0). 8. When filler cap does not close completely, height should soon drop to zer0 measure MATEngine Maintenance - MAINTENANCE 9. If height does not soon drop to zero when filler cap is removed, the ceause is a clogged hose. Sway connector Carbon canister CHECKING FUEL TANK VACUUM RELIEF VALVE Remove fuel filler cap and insure it functions properly. 1, Wipe clean valve housing and place it in your mouth. 2. Inhale air. A. slight resistance caused by valve indicates that valve is in good mechanical condition. Note also that, by further inhaling air, the resistance should disappear as the valve clicks. 3. If valve is clogged, or if no resist: ance is felt, replace cap a8 an assem- bled unit 2.923 KPa (400 mm.0, 18.75 inllz0) Manometer If vent line is clogged, breathing in fuel tank is poor, thus causing insut- ficient delivery of fuel to engine or vapor lock. It must, therefore, be REPLACING CARBON CANISTER FILTER (Canada) oe canis ter aN repaired or replaced, Check vabe uel filler cap with vacuum rele valve Ecoa1A CHECKING VACUUM FITTING HOSES AND CONNECTIONS (Canada) Check fittings and hoses for loose connections or damage. Retighten loose parts and replace wom out parts Canada Distributor Ait induction valve 7500 MAS TN. Throttle opener servo diaphragm ‘Throttle opener vacuum~} contol valve To fuel EGR valve im, : To intake manifold ac. : To air cleaner ch. : To cylinder head ‘sMaet?MAINTENANCE - Engine Maintenance CHECKING FUEL LINES (Hoses, piping, connections, etc.) Check fuel lines for loose connec tions, cracks and deterioration. Re- tighten loose connections and replace any damaged or deformed parts. REPLACING FUEL FILTER Disconnect battery cable. Disconnect fuel hoses from fuel filter and replace it, Plug opon of fuel hose immediately after fuel hose has been removed from fuol filter. ud iter swans WP CHANGING ENGINE COOLANT WARNING: To avoid being scalded, never change the coolant when the engine ishot. When replacing engine coolant, set heater “TEMP” control lever to fully “HOT” position. 1, To flush system, open drain cock at bottom of radiator. Then thorough ly flush until clear water comes out, 2. Close drain cock. 3. Fill radiator with coolant up to filler opening. Follow instructions at- tached to anti-freeze container for ig ratio of anti-freeze to water. Coolant capacity: Without heater MIT 5.2 liters (5-1/2 US at, 4.5/8 Imp at) AIT 5.0 liters (5-1/4 US at, 43/8 Imp at) With heater M/T 5.9 liters (6-1/4 US at, 5-1/4 Imp at) AIT 5.7 liters (6 US at, 5 Imp at! 4, Run engine for a few minutes, and then check coolant level. If necessary add coolant up to filler opening. 5. Install radiator cap. 6, Fill reservoir tank with coolant up to “MAX” level. Min. level, sMaio7 7, Run engine for a few minutes, and check drain cock and plug for any sign of leakage. CHECKING COOLING SYSTEM, HOSES AND CONNECTIONS Check hoses and fittings for loose connections or deterioration. Retight- cen or replace if necessary. Inspection of radiator cap Apply pressure to radiator cap by means of a cap tester to see if it is satisfactory. Replace cap assembly if, necessary, tor eap relief pe 8 kPe (0.9 kglem?, 13 psd Cooling system pi With radiator cap removed, apply pressure to the cooling system by means of a tester to check for leakage ress 187 kPa (1.8 kglem?, 23 pail CHANGING ENGINE OIL AND REPLACING OIL FILTER 1, Start engine and warm it up until water temperature indicator points to middle of gauge, then tutn off engine 2. Remove oil filler cap and oil pan drain plug, and allow oil to drain. WARNIN( Use care as the engine sMai02 MASEngine Maintenance - MAINTENANCE ‘© A milky oil indicates the presence of cooling water. Isolate the cause and take corrective measure. ‘© An oil with extremely low viscosity indicates dilution with gasoline. 3, Using oil filter wrench, remove oil filter er275\ 4, After draining engine oil, wipe oil pan drain hole with a clean rag. 5. Clean and install oil pan drain plug with washer, B+ Ol pan drain plug 20-29Nm (2.0-3.0 kg-m, 14-22 ft-lb) 6. Wipe oil filter mounting surface with a clean rag, 7. Smear a little engine oil on rubber seal of new oil filter sMAgTO 8, Install new oil filter by hand. Do not use oil filter wrench to tighten the filter. 9. Refill engine with the appropriate new engine oil by referring to Recom- mended Lubricants. Check oil level with dipstick. Mato Oil capacity: With oil filter 3.2 liters (3-3/8 US qt, 2-7/8 Imp at) Without oil filter 2.7 liters (2.7/8 US qt, 2.3/8 Imp at) 10, Install ol filer cap and start en- sine 11. Check area around drain plug and cil filter for any sign of oil leakage. If leakage is evident, retighten or replace. 12, Run engine until water tempera- lure indicator points to middle of gauge. Then turn off engine and wait several minutes. Check oil level with dipstick. If necessary, add engine ol. When checking oil level, park: car ‘on a level surface. Oil evel SOY | X|| REPLACING SPARK PLUG 1. Disconnect spark plug wire at boot. Do not pull on the wires. 2. Remove spark plugs with spark plug wrench, sMaore 3. Install new spark plugs and re connect high tension cables. ‘Spark plug type | U.S.A. models | Canada models sun | PGES | ese vive [BPAEB TT | aenaese rees1 rest cotssvee| S°7ES". | goneese tones tmmin} (0039 04] (oast 0038 15-20 Nm (1.5 2.0 kg-m, 11-14 fb) REPLACING DISTRIBUTOR BREAKER POINT (Canada A12A engine models) Distributor point gap: 0.45 - 0.55 mm (0,018 - 0.022 in) Distributor dell angle: periarss Breaker st serow smasz2CHECKING IGNITION WIRING 1. Remove distributor cap together with high tension cables. 2. Check the resistance between cable terminal on the spark plug side and the corresponding electrode inside cap. 3. If the resistance is more than 30.000 chms, remove cable from cap and check the cable resistance only. IF resistance is still more than 30,000 ohms, replace cable assembly. CHECKING ENGINE COMPRESSION PRESSURE 1, Warm up engine until water tom perature indicator points to middle of gauge. 2. Remove all spark plugs. 3. Disconnect anti-ieseling solenoid valve connector. 4, Properly attach a compression tester to spark plug hole in cylinder being tested ers29| MAINTENANCE - Engine Maintenance 5. Depress accelerator pedal to fully ‘open throttle and choke valve. 6. Crank engine and read gauge indi- cation © Run engine at about 350 rpm. ‘© Engine compression measurement should be made as quickly as possi- ble. ‘Compression pressure: kPa (kg/em?, psi)/at rpm Standard 1,324 (13.5, 192/350 Minimum 1,226 (12.5, 178)/350 7. If cylinder compression in one or more cylinders is low, pour a small amount of engine oil into cylinders through the spark plug holes and retest compression. If adding oil helps the compression pressure, chances are that piston rings are worn or damaged. © If pressure stays low, valve may be sticking or seating improperly. ‘© If eylinder compression in any two adjacent. cylinders is low, and if adding oil does not help the com- pression, there is leakage past the ‘gasketed surface, Oil and water in combustion cham- bers can result from this problem. AFTER ENGINE WARM-UP ADJUSTING INTAKE AND EXHAUST VALVE CLEARANCE Adjustment should be made wi ‘engine is warm but not running. 1, Start engine and warm it up until water temperature indicator points to middle of gauge. Then turn off engine. 2, Remove valve rocker cover. 3. Rotate crankshaft, 4, Set No, 1 cylinder in fop dead center on its compression stroke, and adjust valve clearance @),@, @ and ©. 5, Set No. 4 cylinder in top dead center on its compression stroke and adjust valve clearance @, @, @ and ® Valve clearance (Hot): Intake and exhaust 0.35 mm (0.014 in) Step 1 O@®_ © CULT Froat Step 2 (1) Loosen valve rocker adjusting screw lock nut and tum adjusting serew until clearance is obtained. (2) After adjustment, tighten Lock nut and recheck clearance. specified @ + Adjusting screw lock nut 16-22Nm (1.6 -2.2 kgm, 12-16 feb) MAAEngine Maintenance - MAINTENANCE ADJUSTING IDLE RPM (U.S.A. and MPG models) Preparation 1. Connect engine tachometer in its proper position. 2, On air conditioner equipped models, the air conditioner system should be “OFF”, 3. Apply parking brake and block both front and rear wheels with chocks. Maintenance procedure WARNIN( a. Inspections should be carried out while shift lever is in “D’ position on automatic transmis: sion equipped models and in “Neutral” on manual transmis- sion equipped models. 1. On automatic transmission e- quipped models, racing the en- gine should he carried out while shift lever is in “N” or “P” posi- tion and brake pedal should be depressed. . After adjustment has been made, shift the lever to “N" or “P” (start__) sure that Start engine and warm it up until water tempers ture indicator points to middle of gauge and en engine speed is below 1,000 rpm. + ‘Open eval ——— ine hood. ‘Run engine at ile speed for 2 minutes, Race engine (2,000 - 3,000 spm) 2 or 3 times under no-load, and run engine at idle speed + ‘Check idle speed. IDLE SPEED Aza, AeA rr 7003450 rm ANd MIT 650 509mm AIS. A/T 650.450 rpm (in “D" position) Ox. NG. ‘Adjust idle speed by turning throtie adjusting CD ) maraADJUSTING IDLE RPM, ADJUSTING IGNITION TIMING AND CHECKING MIXTURE RATIO MAINTENANCE ~ Engine Maintenance 2. Connect engine tachometer and tuming light in their proper positions. 3. On air conditioner equipped models, the air conditioner system WARNING: a. Inspections should be carried out while shift lever is in “D”” position on automatic transmis ete OEE sion equipped models and in (Canada models except MPG models) de Abeer paring, Fame a Mace “Neutral” on manual transmis- sion equipped models. Preparation chocks. b. On automatic transmission e quipped models, racing the en- gine should be carried out while shift lever is in “Nor “P” posi- tion and brake pedal should be depressed. ©. After adjustment has been made, shift the lever to “N or “P” position. 5. When measuring “CO” percent age, insert probe more than 40 cm (157 in) into tail pipe 1, Make sure that the following parts are in good order. Ignition system ‘¢ Engine oil and coolant levels Valve clearance Maintenance procedure START ‘Start engine and warm it up until water temper ‘ure indicator points to middle of gauge and ensure that engine speed is below 1,000 rpm. 1 ‘Tum off engine and open engine hood, t Disconnect air induction hose from air pipe and Install eap on air pipe. i ‘Start engine and run itat lle speed for 2 minutes, =a Is this maintenance interval 1,600 km (4,000 miles)? NO ‘Race engine (2,000 - 3,000 zpm) 2 or 3 times under nodoad and ran engine at idle speed. ‘Cheek ignition timing. IGNITION TIMING (8.7.0. A128 MIT 21022" Ais MT 542° AIS AIT 522° Gn postion! Ox, NG ® ® © ® MaAa3Engine Maintenance - MAINTENANCE g © “Adjust ignition timing by turning distributor, ¥ ‘Race engine (2,000 3,000 pm) 2 03 times under rnodoad, and run engine at idle speed. t | IDLE SPEED M/T 700+ 60 rpm ‘AIT 650 £ 50 rpm lin “D” positon) ‘Adjust idle speed by turning throtile adjusting serew, ‘Race engine (2,000 - 3,000 rpm) 2 or 3 times tunder nodosd, and run engine at idle speed, t (Check idle "CO", IDLE “com wr 2e1 AT 21 (in "D" position) Ox] NG ‘Adjust idle "CO"% by turning idle adjusting screw. Refer to NOTE for idle limiter cap. = Fate limiter cap 11 wot remove le iter ca unes \puccany- I his eap crenered ice necesy 10 adjust a he time of instalation a folows 1 After adjusting thot or ile speed Aiatng sees check that he le CO" satis the specications. 2. Ina mite api postion, teting see that dreads stew urn 1/8 rotation in he “CO- 1 1 1 ' 1 ' ! ' i ' Carburetor \itennbeat i ' t i i “Turn off engine and connect al induction hose to air pipe. Y Start engine, ¥ t ‘Race engine (2,000 3,000 rpm) 2 or 3 times under nodoad and run engine at idle speed direction. zr ae cOrnich ye ~ DLE SPEED soll rotation) MIT 700 50%0m \ {AIT 650 3 500m (in “D" postion) betes! OK, NG. Adjust ide speed by turning throttle adjusting N1s0_4 Mle limiter ap END. MataMAINTENANCE - Minor Trouble Diagnoses and Corrections MINOR TROUBLE DIAGNOSES AND CORRECTIONS Condition Probable cause Corrective action CANNOT CRANK — | Improper grade ol. Replace with proper grade oil ENGINE OR SLOW Discharged batter ange bate CRANKING ¥ - Saree Faulty battery. Replace Loose fan belt Adjust. Malfunction in charging system. Inspect Wiring connection loose in starting circuit Correct. Faulty ignition switch. Repair or replace Foulty starting motor, Repair or replace (Troubleshooting procedure on starting circuit) Switch on the starting motor with light “ON”. ‘When light goes off or dims considerably, a, Check battery. b. Check connection and cable. ©. Check starting motor. When light stays bright 2. Check wiring connection between battery and starting motor b. Check ignition switch. . Check starting motor. ENGINE WILL CRANK NORMALLY BUT WILL NOT START In this case, the following trouble causes may exist, but in many cases ignition system or fuel system isin trouble. Ignition system in trouble Fuel system in trouble Valve mechanism does not work properly Low compression (Trouble-shooting procedure) Check spark plug first by following procedure Disconnect high tension cable from one spark plug and hold it about 10 mm (0.39 in) from the engine metal part and crank the engine, Good spark occurs. a. Check spark plug. b. Check ignition timing. . Check fuel system. 4. Check cylinder compression. No spark occurs. Check the current flow in primary circuit. Very high current. Inspect primary circuit for short Check breaker point operation (except tran- sistor ignition system). Low or no current. Check for loose terminal disconnection in primary circuit. Check for bumed points. MAISMinor Trouble Diagnoses and Corrections ~ MAINTENANCE Condition Probable cause Corrective action, Ignition system out of order Fuel system out of order Low compression Burned distributor point Improper point gap. Faulty condenser. Leak at rotor cap and rotor. Faulty spark plug, Improper ignition timing. Faulty ignition coll Disconnection of high tension cable. Loose connection or disconnection in primary circuit Lack of fuel. Dirty fuel filter. Dirty or clogged fuel pipe. Fuel pump will not work properly Carburetor choke will not work properly. Improper adjustment of float level. Improper idling. Dirty or clogged carburetor. ‘Clogged breather pipe of fuel tank. Malfunctioning anti-dieseling solenoid valve. Malfunction of fuel shut-off system, Incorrect spark plug tightening or faulty gasket Improper grade engine oll or low viscosity. Incorrect valve clearance. Compression leak from valve seat. Sticky valve stem. Weak or damaged valve springs. Compression leak at cylinder head gasket Sticking or damaged piston ring Worn piston ring or cylinder. (Trouble-shooting procedure) Pour the engine oil from plug hole, and then measure cylinder compression. Compression increases. Compression does not change. Repair or replace. Adjust. Replace, Clean or replace. Clean, adjust plug gap or replace. Adjust. Replace. Replace. Repair or replace. Supply. Replace Clean, Repair or replace. Check and adjust Correct Adjust. Disassemble and clean Repair and clean, Check for loose terminal or wire harness. Check for loose vacuum hose and harness connections. Adjust or replace if necessary. Tighten to normal torque or replace gasket. Replace with proper grade oil Adjust, Remove cylinder head and lap valves. Correct or replace valve and valve guide. Replace valve springs. Replace gasket. Replace piston rings. Overhaul engine, Malfunctioning cylinder or piston ring. Compression leaks from valve, cylinder head or head gasket. MateMAINTENANCE - Minor Trouble Diagnoses and Corrections Condition Probable cause Corrective action IMPROPER ENGINE IDLING Fucl system out of order Low compression Othe Clogged or damaged carburetor jets Incorrect idle adjustment. Clogged air cleaner filter. Damaged manifold gaskets or carburetor insulator. Improper float level. Loose air hoses or air-fuel mixture hoses of carburetor Malfunctioning carburetor choke Malfunctioning A.B. valve. Malfunctioning automatic temperature con- trol air cleaner. Inoperative idle compensator. Carbon canister purge line hose damaged or disconnected Stuck E.F.E, valve shaft, Incorrect valve clearance. Extremely low revolution, Malfunction of the ignition system (spark plug, high tension cable, ignition coil, etc.) Incorrect basic ignition timing. Malfunction of choke valve or linkage Malfunction of vacuum motor, sensor or hoses of air cleaner. Incorrect idle adjustment. (Clogged air cleaner filter. Malfunction of idle compensator of air cleaner. Malfunction of E,G.R. control valve. Loose manifold and cylinder head bolts. Dragged accelerator linkage Incorrect idle adjustment, Malfunction of T.O.CS. system or throttle opener. Malfunction of speed switch and harness. Stuck dash pot stem or clogged air orifice, Dragged fast idle cam. Clean or replace, Adjust Replace element, Repl ce yasket or insulator, Adjust Check for loose connections Cheek and adjust Cheek for loose connection of vacuum hose. Check air temperature sensor and vacuum motor. Check for connection of idle compensator hose or replace idle compensator. Connect or replace. Repair. Previously mentioned. Adjust Adjust. Replace Adjust. Lubricate or clean. Check for loose hoses. Replace system com- ponents if necessary. Adjust idle speed, Replace. Replace, Clean or replace, Retighten bolts. Check and correct accelerator linkage. Adjust idle speed. Check for loose vacuum hose and harness connections. Adjust, replace if necessary. Cheek for loose connection. Repair or re place if necessary Clean or replace, Repair. MAt7Minor Trouble Diagnoses and Corrections ~ MAINTENANCE Condition Probable cause Corrective action ENGINE POWER NOT UP TO NORMA! Low compression Ignition system out of Fuel system out of order Air intake systom out of order Emission control Overcooling Incorrect ignition timing, Damaged spark plugs. Wom distributor points. Malfunction of T.C.S. Malfunction of V.D.V. Malfunction of choke system. Clogged fuel pipe or floating valve. Dirty or clogged fue! filter. Fuel pump will not work properly Clogged carburetor jets Malfunction of altitude compensator. Malfunction of A.T.C. air cleaner. Clogged air cleaner. Air inhaling from manifold gasket or carbu- retor gasket Malfunction of E.G.R. valve, Malfunction of V.V.T. valve. Stuck E.P.E. valve shaft. Malfunction of air-fuel mixture ratio control system, Insufficient coolant, Loose fan belt, Worn or oiled fan belt Inoperative thermostat. Worn water pump. Malfunction of fluid coupling. Clogged or leaky radiator. Worn radiator filler cap. Air in cooling system, Improper engine oil grade. Incorrect ignition timing. Clogged carburetor (lean mixture). Inoperative thermostat, Previously mentioned. Adjust. Clean, adjust or replace plugs. Dress or replace points. Also check con. denser, Check and correct Check and replace Adjust. Clean. Replace. Repair or replace. Disassemble and clean. Cheek or replace. Check or replace. Replace element. Replace gasket. Check and replace. Repair or replace Repair. Check and replace Replenish. Adjust fan belt. Replace, Replace. Replace, Replace. Flush, repair or replace. Replace. Retighten each part of cooling system. Replace with proper grade cil. Adjust Overhaul carburetor. Replace. MA18MAINTENANCE - Minor Trouble Diagnoses and Corrections Condition Probable cause Corrective action Others Improper octane fuel Replace with specified octane fuel Improper tre pressure Inflate to specified pressure. Dragging brake Adjust Clutch sipping. Adjust. NOISY ENGINE (car knocking Overloaded engine Use right gear in driving Carbon knocking Disassemble cylinder head and remove car bon. Timing knocking ‘Adjust ignition timing. Fuel knocking. Use specified octane fuel Preignition (misusing of spark plug) ‘Use specified spark plug. Mechanical kno Crankshaft bearing | This strong dull noise increases when engine | This is caused by worn or damaged bearings, knocking is accelerated. To locate the place, cause a | or unevenly worn crankshaft, Renew bear Connecting rod bearing knocking Piston cylinder noise Piston pin noise Water pump Others misfire in each cylinder. If the noise stops by the misfire, this cylinder generates the noise. ‘This isa little higher-pitched noise than the crankshaft knocking, and also increases when engine is accelerated. Cause a misfire in each cylinder and if the noise diminishes almost completely, this crankshaft bearing generates the noise When you hear an overlapping metallic noise which increases its magnitude with the revolution of engine and which decreases as engine is warmed up, this noise is caused by piston and cylinder, To locate the place, cause a misfire in each cylinder. This noise is heard at each highest and lowest dead end of piston. To locate the place, cause a misfire in each cylinder. ‘This noise may be caused by worn or dam- aged bearings, or by the uneven surface of sliding parts. An improper adjustment of valve clearance. Noise of timing chain, ‘An excessive end-play on crankshaft, Noisy E.P-E. valve shaft, Surging A.T.C. air cleaner vacuum motor. will be heard when clutch is This noi disengaged. ings and adjust or change crankshaft. Check lubrication system. ‘Same as the case of crankshaft bearings. ‘This may cause an abnormal wearing of cylinder and lower compression which in turn will cause a lower out-put power and excessive consumption of cil. Overhaul engine. This may cause a wear on piston pin, or ton pin hole. Renew piston and piston pin assembly. Replace water pump with @ new one. Adjust. ‘Adjust the tension of chain. ‘Adjust the tension of chain or replace. Disassemble engine and renew main beating, Repair or replace. MatoMinor Trouble Diagnoses and Corrections ~ MAINTENANCE Condition | Probable cause Corrective action Wear on clutch pilot bushing. Renew bushing and adjust drive shaft. This noise will be heard when clutch is disengaged. ABNORMAL, COMBUSTION (Backfire, afterfire, run-on, etc.) Improper ignition timing Fuel system out of order Faulty cylinder head, ete, Improper ignition timing, Improper heat range of spark plugs. Damaged carburetor or manifold gesket. (backfire, afterfire) Clogged carburetor jet Improper function of the float. Uneven idling, Improperly adjusted T.O.CS. set pressure Malfunction of anti-dieseling solenoid valve Malfunction of auto-choke Improperly adjusted valve clearance. Excess carbon in combustion chamber. Damaged valve spring (backfire, afterfire). Adjust igntion timing Use specified spark plugs Replace them with new parts. Disassemble carburetor and check it. adjust the level, and check needle valve Adjust. Adjust. (Check or replace. Adjust. Adjust. Remove head and get rid of earbon, Replace it with a new one, Others Malfunction of A-T.C. air cleaner, ‘Check for loose vacuum hoses. Replace if necessary. Inoperative anti-backtfire valve Replace, EXCESSIVE OIL CONSUMPTION Oil leakage Loose oil drain plug. Tighten it Loose or damaged oil pan gasket, Renew gasket or tighten it. Loose or damaged chain cover gasket. Renew gasket or tighten it. Wom oil seal in front and rear of crankshaft. | Renew oil seal. Loose or damaged rocker cover gaskes, Renew gasket or tighten it (but not too much). Improper tightening of oil filter. Renew gasket and tighten it with the proper torque, Loose or damaged oil pressure switch. Renew oil pressure switch or tighten it Excessive oil Cylinder and piston wear. Overhaul cylinder and renew piston. consumption Improper location of piston ring gap or reversely assembled piston ring Damaged piston sings, Wom piston ring groove and ring. Fatigue of valve oil sea lip. ‘Worn valve stem, Remount piston rings. Renew rings, Repair or renew piston and cylinder. Renew piston and piston ring, Replace seal lip with 2 new one. Renew valve or guide. MA-20MAINTENANCE — Minor Trouble Diagnoses and Corrections Condition Probable cause Corrective action Others Inadequate quality of engine oil Use the designated oil. Engine overheat. Previously mentioned. POOR FUEL ECONOMY ‘See the explanation of the power decrease Others Exceeding idling revolution. ‘Adjust it to the designated rpm. Inoperative acceleration recovery. Fuel leakage. Malfunction of T.O.CS. Malfunction of A.T.C. air cleaner, Adjust it, Repair or tighten the connection of fuel pipes. Adjust Check and replace PROBLEMS IN OTHER FUNCTIONS Decreased oil pressure Excessive wear on the sliding parts Souffing of parts Inadequate oil quality Overheat. Wom oil pump regulator valve. Functional deterioration of oil pump, Blocked oil filter. Increased clearance in various sliding pats. Blocked oil strainer. Malfunctioning oil gauge pressure switch Oil pressure decreases. Improper quality or contamination of oil. Oil pressure decreases. Improper guality or contamination of oil Damaged air cleaner. Overheat or overcool Improper fuel mixture, Decrease of oil pressure. Insufficient clearances. Overheat. Improper fuel mixtu Use the designated oil, Previously mentioned. Disassemble oil pump and repair or renew it Repair or replace it with a new one. Renew it. Disassemble and replace the worn parts with new ones. Clean it Replace it with a new one, Previously mentioned. Exchange the oil with proper one and change element. Previously mentioned. Exchange the oil with proper one and change element. Change element. Previously mentioned. ‘Check the fuel system. Previously mentioned, Readjust to the designated clearance, Previously mentioned. Check the fuel system MA2tChassis and Body Maintenance — MAINTENANCE CHASSIS AND BODY MAINTENANCE ENGINE CONTROL, FUEL AND EXHAUST SYSTEMS CHECKING FUEL AND EXHAUST SYSTEMS Check fuel and exhaust systems for condition, connections and leaks. Fuel system marae sMara7 CLUTCH CHECKING CLUTCH FLUID LEVEL AND LEAKS “Add to “MAX” level SMAt00 Ma22 CHECKING CLUTCH SYSTEM Check clutch system for proper at- tachment, leaks, chafing, abrasion, de- terioration, etc. smaror CHECKING CLUTCH PEDAL HEIGHT AND FREE PLAY Check clutch pedal height and free play. Adjust if necessary. 1. Adjust pedal height with pedal stopper. Then tighten lock nut. 2. Adjust pedal free play with master eylinder push rod. Then tighten lock nut 2, Pedal free play means the following total measured at position of pedal pad. © Play due to clevis pin and clevis, ppin hole in pedal lever. © Play due to piston and piston rod b. Depress and release clutch pedal over its entire stroke to ensure that ‘the clutch linkage operates smooth. ly without squeak noise, inter ference and binding. MANUAL TRANSMISSION CHECKING MANUAL TRANSMISSION OIL LEVEL Never start engine while checking oil level. «Master evlinder push rod \ [Pedal stopper ® : Nom (ke-m, feb) ‘smaio2 Pedal height ““H 143 - 149 mm (6.63 -5.87 in) Pedal free play “A”: 1-5 mm (0.04 - 20 in) (25-3Skgem, Fillto this level 16-25 feb) ‘sMAI03 CHANGING MANUAL TRANSMISSION OIL 1. Drain oil completely, Pains —] 25-290 We | Bsctbiem| Yt asians), —_— ‘SMA706MAINTENANCE — Chassis and Body Maintenance (25-39 Nm \a (25-40 kgm, 18-29 fo) aa or Oil capacity: FSSW6OA (A14 and A15 5-speed) FAWS6A (A12A 4-speed) 1.2 liters (2-1/2 US pt, 2-1/8 Imp pt) FaW60L (A15 4-speed) 1.3 liters (2-3/4 US pt, 2-1/4 Imp pt) AUTOMATIC TRANSMISSION CHECKING AUTOMATIC TRANSMISSION FLUID LEVEL 1. Check under following conditions. (1) Place selector lever in “P” (PARK) position and idle engine. (2) Maintain fuid temperature at 50 to 80°C (122 to 176°F). 2. Add oil, if necessary Use only automatic transmission fluid having “DEXRON” identifica- tions in 3N718 automatic trans- mission. Add to “H” level Do not overfill CHECKING AUTOMATIC TRANSMISSION FLUID CONDITION Check fluid for contamination to determine condition of automatic transmission. If fluid is very dark or smells burned, the frictional material (clutches, band, ete.) may need re- placement, ‘Cheek fuid for smell sMai07 PROPELLER SHAFT AND DIFFERENTIAL CARRIER CHECKING PROPELLER ‘SHAFT Check propeller shaft, replace if necessary, Check journals for | swear or damage. (Cieck tightening| torque, @ 24-32Nm (2.4-3.3 kam, 172A SMAga6 CHECKING DIFFERENTIAL CARRIER OIL LEVEL 50-98 Nm (6-10 kgm, 43-72 feb) Fill to this evel suman CHANGING DIFFERENTIAL CARRIER OIL 1. Drain oil completely. @ 59-98 Nm (6-10 ko-m, 43 -72 Fb) 2. Refill differential carrier and check oil level. 43-72 ft) smario| Oil capacity: 0.9 liters (1.7/8 US pt, 1-5/8 Imp pt) FRONT AXLE AND FRONT SUSPENSION CHECKING FRONT AXLE AND SUSPENSION PARTS 1. Block rear wheels with chocks and raise front of car, and then support it with safety stand, Refer to Lifting MA-23,Chassis and Body Maintenance - MAINTENANCE Points and Towing (Section Gl). 2. Shake each front wheel by hold: ing upper and lower surfaces of tires as shown SMAINY Check suspension parts for loose ness, wear, or damage. Retighten all loose nuts and bolts to the specified torque. Refer to Sec- tion FA for tightening torque. Replace all worn parts as described under Front Suspension (Section FA). sMant2 3. Check strut (Shock absorber) for oil leakage or damage. |) swans MA24 4, Check suspension ball joint for grease leakage and ball joint dust cover for damage: ‘© Threaded portion of spindle ‘© Contact surface between wheel beating washer and outer wheel bearing ‘¢- Hub, hub cap and O-ring 4 Grease seal lip. 5. Remove wheel and tie assembly. 6. Check front axle parts for crack or damage. Replace worn parts. Refer to Front Axle (Section FA). 7. Remove brake pads. Refer to section BR 8, Check wheel bearing, If there is any axial end play or if wheel bearing does not smoothly turn adjust bearing to specifications, Replace worn or damaged bearings. Refer to Front Axle (Section FA). Manis ADJUSTING WHEEL BEARING PRELOAD ‘After wheel bearing has been re- placed or front axle has been assembled be sure to adjust wheel bearing proload as described below. 1. Before adjustment, thoroughly clean all parts to. prevent possible en- try of dirt 2. Apply recommended multi-pur- pose grease sparingly to the following parts. Mult-purpose ease point sMante 3. Tighten wheel bearing nut # 29-34Nm pee (30-35 22-25% ha 4. Turn wheel hub several times in both directions to seat wheel bearing correctly. 'S. Again tighten wheel bearing nut.MAINTENANCE ~ Chassis and Body Maintenance 6. Tum back wheel bearing nut 90° 9. Spread cotter pin. 7. Fit adjusting cap and new cotter pio, sMaiz0 8, Measure wheel bearing preload and axial play. smarts (As maasurad ot whee! hub bolt): Excopt Cansea 1.2 liter models With new parts Loss than 17.8 N (1.2 kg, 2.6 tb) With used parts 1.67-7.75 N (0.17 -0.79 ig, Canada 1.2 liter models With new parts Less than 13.7 N (1.4 kg, 3.1 Ib) With used parts Less than 6.9 (0.7 kg, 1.5 ta) Repeat above procedures until cor- tect starting torque is obtained. 10. Install hub cap with new O-ring. CHECKING WHEEL ALIGN MENT Before checking front wheel align- ment, be sure to make a preliminary inspection of all front end parts. Tire pressure Wheel bearing axial play Suspension ball joint Stoering gear housing looseness at frame Steering linkage and connections Shock absorber operation © Tighten each front axle and susper sion parts (© Measure car height (when not loaded) ‘© Repair or replace the damaged por- tion or parts. Camber, caster and king: Inclination Camber, caster and king-pin inclins- tion are preset at the factory and can- not be adjusted. If camber, castor or king-pin clination alignment is not within speci fications, check pertinent parts. Repair or replace as necessary. Except Canada 1.2 liter models: Camber 0° - 1°30" Caster Sedan & Hatchback 1°40" - 3°10" Wagon 1°55 - 3°25" ‘Kingpin inclination 7°50" -9°20" Canada 1.2 liter models: Camber 25" - 1°05" Caster 140"-3°10" Kingpin inclination 7°40'-9°10" Toe-in Measure toe-in, and shake necessary adjustments. Use the following pro- cedure when making adjustments 1, Raise front of car and mark a base line across the tread of left and right wheels. 2. Set wheels in a straight-ahead position, and then lower front of car. 3. Measure toein and make neces- sary adjustments, Lines parallel to centerline of body — smaraa| Front 8 Toe-in (Unladen): Except Canada 1.2 liter models Toein (Unladen) 1- 3mm (0.04 - 0.12 in) 6°30" - 20" (On both sides) Canada 1.2 liter models Toe-in (Unladen) 0- 2:mm (0- 0.08 in) 0 13° (On both sides) MaA25Chassis and Body Maintenance ~ MAINTENANCE. Toesin can be adjusted by varying the length of steering side rods. sMaz6s “Uniaden” @ Fuel tank, radiator and engine oil tank all full fe. Spare tite, jack, hand tools, mats in position. © All tires inflated 10 specified pres. sure, @ All accumulation of mud, ditt and road deposits removed from chassis and underbody. If side rods have been disassembled, set the distance between lock nuts to the specified value “A” prior to re assembling. “A dimensior Except Canada 1.2 liter mods ‘315 mm (12.40 in) Canada 1.2 liter modots 340 mm (12.20 in)

— Cc Right reat a—c> Left fron! Left reat 4 WHEELS Right front Right rear Left rea S WHEELS Radial Tire Right from Right roar e254 co=c> Len tiont Left rear 4 WHEELS Right Front Right reat SS, eS Left rear | Loft front 5 WHEELS = smazse TIRE REPLACEMENT CAUTION: Different types of tires, such as bias, bias belted and radial tires, must not be mixed under any circumstances. Mixed use of different types of tires can adversely affect car handling and may cause driver to lose control Ma-30 a, When replacing a worn or damaged tire, use a replacement tire of the same size and load carrying capaci- {ty as that with which the car was equipped when manufactured. The use of different size and/or load capacity tires will not only shorten tire service life but may also result, ina serious accident, b. Do not use tires and wheels other ‘than those recommended, and do ‘not mix tires of different brands or tread patterns. The use of tires and wheels other than those recommended or the mixed use of tires of different brands or tread patterns can ad versely affect the ride, braking, handling, ground clearance, body- to-tire clearance, and speedometer calibration, ¢, It is recommended that new tires be installed in pairs on the same axle, When replacing only one tire, it should be paired with the most tread, to equalize braking traction. 4. When replacing original tires with ‘those tires of an optional recom- ‘mended size and of different diam- eter, the speedometer must be re- calibrated, 1, To replace a tire with a jack in a safe manner, refer to Lifting Points (Section GI) for jacking up. WARNING: Never get under car while itis sup- ported only by jack. Always use safety stands to support side member of body construction When you must get beneath car. To install wheel, tighten wheel nuts in eriss-eross fashion, smaos9 Aluminum wheel To install an aluminum wheel, pro. ceed as follows: 1, Snugly tighten four nuts after the wheel is positioned. (-Serew nut onto [ub to SMADI0 2. Slightly pull the wheel back to properly align the nuts with bolt holes in the wheel, and tighten the nuts as ‘much as possible with your fingers. Align nuts with bolt / holes in wheel and evenly tighten muts each one a litle smaont 3. Tighten wheel nuts evenly with a wheel wrench in criss-cross fashion.MAINTENANCE — Chassis and Body Maintenance Wheel nut CAUTION: Two types of wheel nuts are used; one is designed for use with steel wheel and the other for use with aluminum wheel. Do not mix different types of wheel nuts. Foraluminum For stet ‘wheels only wheels only ~ ® 78-99N-m (80. 10.0k9m, 58 G SMAI91 Be careful not to smeat thread ed portion of bolt and nut, and seat of nut with oil or grease, TIRE REPAIR Inspect tire, following the proce dure shown below. If any defect is pre sent, repair or replace as necessary 1. Apply soapy solution or submerge tire and wheel or tube in water after inflating it to specified pressure. 2. Inspect for leaks. 3, Specially inspect for leaks around valve or wheel rim and along tread 4, Note bead and rim where leakage occurs, Wipe water away from any area which leaks air bubbles and then mark place with chalk. 5. Remove object which caused puncture and seal the point, a. When repairing a puncture, use = tire repair kit furnished by any tire dealer, following instructions pro: vided with kit. b. If a puncture is too large or there is some damage to tire fabric, repair should be carried out by authorized tire dealer. 6. Discard when any of the following problems occurs © Broken or damaged bead wire © Ply or tread separation. © Wom fabric damage on tubeless tire Cracked or damaged side wall e Tires with tread wear indicator showing, ete CAUTION When replacing tire, take extra care not to damage tire bead, rim-flange and bead seat. Do not use tire irons to force beads away from wheel rim-lange; that is, always use tire replacement device whenever tite is removed. 7. Install tire, noting the following items: ‘a. Install valve core and inflate to proper pressure. Check the locating rings of the tire to be sure they show around the rim flanges on both sides. bb, Check valves for leakage after in- ‘lating tires. cc. Be sure to tighten valve caps firmly by hand, WARNING: When, while tire is being inflated, bead snaps over safety hump, it might break. Thus, to avoid serious personal injury, never stand over tire when inflating it, Never inflate to a pressure greater than 40 psi (275 kPa. If beads fail to seat at that pressure, deflate the tire, lubricate it again, and then reinflate it. If the tire is overinflated, the bead might break, possibly resulting in serious per- sonal injury. WHEEL INSPECTION Inspect wheel, taking care of the following points, in order to ensure satisfactory steering condition as well as maximum tive life. I any defect is present, repair or replace as necessary. 1. Check wheel rim, especially rim flange and bead seat, for rust, distor- tion, eracks or other faults which might cause air leaks. Function of tubeless tire depends on a good seal between tire bead and wheel rim 2. Thoroughly remove rust, dust oxidized rubber or sand from wheel rim. Rim bead seats should be cleaned with the following, Steel wheel: Wire brush, coarse steel wool, etc. Aluminum whee Neutral detergent, cloth, etc. 3. Examine wheel rim for lateral and radial runout, using dial gauge smaoze Latoral runout (A) and radial runout (B) ‘Stool whoo! Phi wa 7ea5¢ ss Less than 1.0 mm (0.089 in) WRI eee es Less than 1.2 mm (0,087 in) Aluminum wheel... .. . Less than 0.5 mm (0.020 in) Difference between right and lat lateral runout: Stool wheel... es... Less than (0.5 mem (0.020 in) Les then (0.2 mm (0.008 in) Aluminum wheat. 4. Replace wheel when any of the following problems occurs. © Bent, dented or heavily rusted Elongated bolt holes Excessive lateral or radial runout Air leaks through welds Wheel nuts will not stay tight Wheel balance Inspect wheel and tire for wheel balance and correct it if unbalance is present, taking the following points into consideration. 1. Correct unbalance when the symptom of unbalance appears as wheel tramps and wheel shimmy 2. Balance wheel and tire both statically and dynamically. MAIChassis and Body Maintenance ~ MAINTENANCE. Balancing wh WARNING: When balancing wheel and tire on the car, be sure to observe the equipment manufacturers instruc tions carefully. Cause Wheel static unbalance | Whee! dynamic unbalance ‘Symptom | 4 Wheel tamp | of oo, Wheel shimmy unbalance Conrective Balance statially Balance dynamically action Place balance Wheel shimmy weghisbe Fae inane went in eaey tay Location” Wesatiog: Wel img | suaors Balance weights ‘Maximum allowable unbalance at tien flange: 10g (0.35 02) Balance weight: 10 -60910.35 -2,12 02) 8810-9 (0.36 02) interval sMao7e Masa b. Be sure to place correct balance ‘weights on inner edge of rim. Do not put more than two weights ‘on each side. Two types of balance weights are used; one is designed for use with steel wheel and the other for use with aluminum wheel. Do not mix different types of balance weights. Properly rebalance the wheel and tire whenever puncture is repaired. STEERING SYSTEM CHECKING STEERING GEAR OIL LEVEL AND LEAKS 5 Check ui aks CD + Add nui. sMasosCHECKING STEERING GEAR BOX AND LINKAGE Steering gear box © Check parts for looseness, wear or damage. Retighten if neccessary Refer to Section ST for tightening torque © Check for any missing parts (cotter pins, washer, etc.) Steering linkage © Check parts for looseness, wear or damage, Retighten if necessary. Refer to Section ST for tightening torque. ‘* Check ball joints and idler arm for grease leakage MAINTENANCE - Chassis ano Body Maintenance SMAn4S Ma.33Chassis and Body Maintenance - MAINTENANCE BODY LUBRICATING LOCKS, HINGES AND HOOD LATCH We Be {td (iatehck an Wagon) § ae r ' —_- | fa oh Side stoppars (Hatchback and Wagon) ae ww oie Ste sma3e2 CHECKING SEAT BELTS, BUCKLES, RETRACTORS, ANCHORS AND ADJUSTER ‘Check belts for damage. ‘Check anchors for loose mounting. UE Check retractors for smooth operation. 4-door a ‘Chock buckles and tongues oy function when buckled Check: comfort clips for and released. function, an MA34MAINTENANCE ~ Chassis and Body Maintenance HEATER AND AIR CONDITIONER CHECKING REFRIGERANT LEVEL 1. Open doors fully 4, Set temperature lever to maxi- about five minutes, Judge according to 2. Start the engine, mum cold position. the following table. Set air conditioner switch 10 5. Set blower to maximum speed. “ON” position. 6. Check sight glass after the lapse of = Amount of Feftigerant | stmost na refrigerant Insufficient Suitable Too much refrigerant ‘check jem Temperature of high pressure Almost na ditierence | High pressure side | High pressure side | High pressure side i aie low presse lines hecween high pressure | warm and low pressure | hot and fow pressure | abnormally hot and low presure side | side whaiy cold. | se cold temperature, State ight glass Bubbles flow continu | ‘The bubblesare wen | Almost transparent. | _ No bubbles can be sen ously, Bubbles wi at intervals of 12 Bubbles may appear dimppear and some- | seconds when engine speed is ‘hing ike mist will taised and lowered. ‘low whan refrigerant [No clear difference exists betwen these two conditions, C286 cas case Pressure of system High pressure sige is | Both presure on high | Both pressures on high | — Both pressures on high abnormally low and low pressure sides | and low pressuse sides | and low pressure sides are slightly low. are normal are abnormally bigh Repair. ‘Stop compressor im- | Check for gas leakaue, Discharge refrigerant mediately and con- | repair as required, re- from service valve of duct an overall plenish and charge low pressure side check. system, 8, The bubbles seen through the sight ‘the amount when it exceeds 20°C CHECKING COMPRESSOR lass are influenced by the ambient (68°F). In higher temperature the © DRIVE BELT temperature. Since the bubbles are bubbles are easy to show up. Refer to Engine Maintenance for hard to show up in comparatively. When the screen in the receiver low temperatures below 20°C drier is clogged, the bubbles will SPSS Sa (68°F), it is possible that a slightly appear even if the amount of refrig- larger smount of refrigerant would rant is normal. In this case, the be filled, if supplied according to outlet side pipe ofthe receiver diet the sight sass Be sure to recheck becomes considerably cold. MA.35Chassis and Body Maintenance ~ MAINTENANCE CHECKING HOSES AND PIPES Check heater and air conditioner for damaged hoses or pipes due to in- terference or friction with adjoining parts, If damage is minor, repair those affected hose or pipes. If damage is major and if there is the possibility of encountering holes, replace the affected parts. Carefully check hoses and pipes, especially those located close to mov- ing parts or sharp edge of panel. CHECKING REFRIGERANT LEAKS. Conduct a leak test with halide or electric leak detector whenever leakage of refrigerant is suspected and when conducting service operations which are accompanied by disassembly or loosening of connection fittings Major check points (2) Compressor ‘© Compressor shaft seal (rotate the compressor by hand) Flexible hose connections Front and rear head gaskets © Service valve (2) Condenser ‘© Condenser pipe fitting ‘© Condenser inlet and outlet pipe connections (3) Refrigerant lines Flared section of high pressure and low pressure flexible hoses. © Line connections (4) Evaporator housing Inlet and outlet line connections ‘© Expansion valve © Suction throttle valve MA36 Engine TF Compreton L condenser Receiver drier smazaa Copper reaction plate Burner lame adjusting ins. Flame adjuster 3 Gas bombe cet ‘The following information and cautions should be kept in mind when checking for leakage# If ahalide leak detector is used, de- termine whether or not there is gas MAINTENANCE ~ Chassis and Body Maintenance leaking by the color of the fame, as cated in the chart below. Propane type Butane type NO LEAK Greenish blue Pale blue SMALL LEAK Yellow Bright blue ee LARGE LEAK | Purple |__ Vivid green EEE EEL CO WARNING 4. Never inhale the fumes produced by combustion of refrigerant gas since they are toxic. b, Never use halide torch in a place where combustible or explosive 42s is present. ‘© Since refrigerant gas is heavier than air, small leaks can be easily detect 2d by placing sampling tube direct ly below the check point, If any trace of oil is noted at and found connection fittings, it is a sure indication that refrigerant is leaking. If a gas leak is detected, proceed as follows 1. Check torque on the connection fitting and, if too loose, tighten to the proper torque. Check for gas leakage with a leak detector 2. If leakage continues even after the fitting has been retightened, dis- charge refrigerant from system, discon- nect the fittings, and check its seating face for damage. Always replace even if damage is slight 3. Check compressor oll and add oil if required, 4. Charge refrigerant and recheck for 2s leaks. If no leaks are found, evacu- ate and charge system. OFF-SEASON MAINTENANCE Even in the offseason, turn the compressor for 10 minutes at least once a month by running the engine at idling rpm. MA37Service Data and Specifications 5.0.8.) ~ MAINTENANCE SERVICE DATA AND SPECIFICATIONS (S.D.S.) ENGINE MAINTENANCE Ignition and fuel system INSPECTION AND ADJUSTMENT Spark plug. Basi ic mechanical system Tyee ae Valve clearance mm (in) Hot cold" ‘Standard | Hot tre | Cold type | ™ nh wei oss ior) | 028 0070) oreee in A1us | gosesrr | apacsrr | erresty | 122.7 Exhaust 0.35 (0.014) | 0.25 (0.010) and Cansds| pepses-i1| BPR4ES-11| BPRGES-17 e rs moc BERGES 1] Goes ron, Atararr and At Cede oso preioe aioaer tewcon | arnses | opnaes | senses | foost mm (in), Boe Saar MPG) 0.035) ; : SS ae Siac ed ies a 1 ed nue ated Ignition timing, idle speed (B.T.D.C. aes 32 degree/rpm) and idle “CO"% Wo ter oth oS car E an] cencmera) Withous oi iter 22, = (2-7/8, 2-3/8) AIZA wit *7-£2°/700 £50 |1042°/700450 Goon nab Sey wr ar aaa eat S 2.(US qt, Imp at) a sh is ho fre MT > saz" 00380 wi (5-1/2, 4-5/8} | (6-1/4, 4-3/8) AR dake tes we a.) wan me At | -saztesos0 | sez°esoaso seg (614, 52141 Wea peenier , 109,18) veo" ewes || a ie lon? si oF inv ae faa re 157 118,20) ee (ha : * Measure with distributor vacuum hose disconnected and vacuum ‘Compression pressure {hoes plogged up, kPa (kg/em2, psil/rpm standard 1.324138, 100/980 Hinman 1296 02.5, 17880 "sddaioh Goubra evene: * At ambiont tomporature 20° (68°F). After checking valve Units Pa nmttg0, in} clearance while engine i cold, also check it whan engine is hot 10400 fit romains within the specified value. If it doesnot, Vapor fine readjust it leakage test Supplied presure | 3.923 (400, 15.75) Pressure variation | Less than 0.245 (25, 0.981 TIGHTENING TORQUE Unit Nm kom tek Valve rocker adjusting 1-22 | 18-22 | 12.16 \ pan érain plug 20-29 | 20-30 | 14.22 Spark plug 15-20 | 15-20 | 1-14 MaA38MAINTENANCE - Service Data and Specifications (S.D.S.) CHASSIS AND BODY MAINTENANCE INSPECTION AND ADJUSTMENT Clutch Units mm int eda height “H™ 143.149 (5.63 -5.87) dal fee play “A” 1-5 (004-020) Front axle and front suspension Brake Pedal Height Freeplay Deprassed height Units rom find 143-149 (6.63 - 6.87) | 1-81008-0.20) More than 70 (2.76) Dise brake ad wear limit 1.810.063), Rotor repair iit | 84 (0.331) Drum brake Lining wear timit (0.052) rum repair limit 208.5 (8.05) Parking brake Lover stroke (at pulling widows aie force: 196N (20 kg, 44 1b)) Except Conede Conad ‘Number of notches | 7-Bnotehes | 12 tiermodels | 1.2iter medale —_ = = [Axial piay mm tind 010) Whee! bearing preload ] (As measured at wheel ub bol | With new parts Less than Neg. t0)] 72226 | ae tia an With used parts 1.7-7.710.17- | Less hon Nita, tb) | 0.79,04-1.7) | 6.9107, 151 Whe! signment ‘Cambor 0-190" | 25". 1208" Wheel and tire 1840" -3°10" Fecommended cold tre inflation pressure al (kPa) caster 1955°-3°25" | 1940"-3%10" Wegon 241170) 19519/6.164134PR | 26 (180) ..Wogon rear Kingpin inclination | 7950°-9°20" | 7940". 9°10" wheel only Tire size 13mm 0-2mm 6.00-1249R dian (0.04-0.12in) | (0-0.08 in) 1s55R13 24 (170) Terk Gat 6:30" - 20° 0-13" 175/70SR13 (On both sides) | (On both sides) ‘Tire presure should be checked when tires are COLD. Stondacd side vod toa A am Gy | 28849240) | 310412.20) 13 in| Less tan 1.0 0.0391 Fret wee sng Weel rim taterat | stot whee! Ne ee ane fed out 12in| Less than 1.2 (0.047) inner wheel is 20°) ‘Aluminum wheel | Less than 0.6 (0.020) Outer whee! 193° Difference between | Stee! whee! Less than 0.5 (0.020) Full urns (On power Fight an oltre stoering models, steer runout mm fin) | Aluminum wheet | Less than 0.2 (0,008) ing power i 98 to 147 N10 0 18 ka, 22t0 Whee! balance 3 1b) with engine (Maximum sllowsble unbalance 100.35) turned on and standing at Fim flange) or (ox) sul] Inner wheet 30° - 422 419 -45° 10-60 Tire belancing weight ‘ar tor) (039-2.121 Outer whee! 31-122 -35-1/2° | 33.1/2°-37-1/2° Spacing 10 (0.38) MA39Soecial Service Tool - MAINTENANCE TIGHTENING TORQUE Unit Nm xem | tel Ccluren Pedal stopper locknut | 8-12 | 08-1.2 | 68-87 [Mastareylinder push Sees 8-12 | 08-12 | 58-87 Manual transmission Drain and flr plugs | 25-39 | 25-40 | 18-29 Propeller shett end differential eaerior Propels shat to companion flange bors] 74°92 | 24-38 | 17-24 Differential carrier drain and filter pugs | 92°98 | 6-10 | 43-72 Front oxle and front Whee! bearing nut za-a¢ | 30-35 | 22-25 Side rod lock nut 7-98 | 80-100 | 68-72 Brake ‘Air bleed valve 7-9 | 07-09 | 61-68 Seshaboomer loose | ngsaa: |i 4ieeaca® |! 1248 rod lock nat Master eyliner push pect 16-22 | 16-22 | 12-16 Winee! ane ire Wheel nut 72-98 | 80-100 | 58-72 SPECIAL SERVICE TOOL Tool number (Kent-Moore No.) | Tee!name 819320000 Oil filter wrench (325664) MasoENGINE MECHANICAL CONTENTS ENGINE COMPONENTS eM. 2 BEARING ENGINE DISASSEMBLY EM. 3 MISCELLANEOUS COMPONENTS PRELIMINARY CLEANING AND ENGINE ASSEMBLY INSPECTION EM. 3 PRECAUTIONS, DISASSEMBLY EM. 3 CYLINDER HEAD PISTON AND CONNECTING ROD EM. 4 PISTON AND CONNECTING ROD CYLINDER HEAD EM. 5 ENGINE ASSEMBLY INSPECTION AND REPAIR —EM-5 SERVICE DATA AND PREPARATION FOR INSPECTION EM. 5 SPECIFICATIONS (S.D.S.) CYLINDER HEAD AND VALVE EM. 5 GENERAL SPECIFICATIONS CAMSHAFT AND CAMSHAFT BEARING .. EM 7 INSPECTION AND ADJUSTMENT CYLINDER BLOCK EM 7 TIGHTENING TORQUE PISTON, PISTON PIN AND TROUBLE DIAGNOSES AND PISTON’ RING EM-9 CORRECTIONS CONNECTING ROD EM-9 SPECIAL SERVICE TOOLS CRANKSHAFT EM. 9 M10 Mat M12 M12 EM12 M12 EMaA3 E18 EM8 EMA8 EM.22 M.23 EM-26Engine Mechanical ENGINE COMPONENTS 9 Camshatt 10 Timing chain 11 Front cover 12 Water pump Fig. EM-1 Engine ComponentsEngine Mechanical PRELIMINARY CLEANING AND INSPECTION Before disassembling engine serve the following items: 1. Prior to disassembling, check ‘outer parts for sign of leak past their sasketed surfaces 2. Check carburetor and fuel pump for condition: fuel hoses for deteriora tion, cracks oF otherwise leakage of fuel past their jointed or connected surfaces 3, Wipe dust and mud off engine 4. Inspect outer parts for visual faults and broken or missing paris such, as bolts and nuts. 5. Check piping and electrical cir cuits for deterioration, breaks: fittings, discontinuity or insulation. DISASSEMBLY To remove engine from car, refer to Section ER for Removal 1. Remove starting motor, then re rove transmission from engine. 2. Remove clutch assembly. 3. Remove alternator, fan belt, alter- nator bracket and alternator adjusting bar 4. Remove idler pulley, compressor belt and idler pulley bracket. (If s0 equipped) Note: Loosen idler pulley mut and belt adjusting bolt in that order. \~ Adjusting bolt Sewage Fig. EM2 Removing Idler Pulley, Compressor Belt and Idler Pulley Bracket ENGINE DISASSEMBLY 5, Remove compressor and compres: sor bracket. (IF so equipped) 6. Remove fan, fan spacer or fan coupling and pulley. 7. Remove oil level gauge 8. Remove distributor cap and high tension cables as an assembly. 9. Disconnect distributor vacuum line from distributor and remove dis: tributor. 10. Disconnect fuel line from carbu- retor 1, - Remove fuel pump and fuel line. 12. Remove water outlet and thermostat. 13, Remove engine mounting brack- et RH. 14. Remove oil pump and filter as- sembly Mae ELo«s Fig. EM-3 Removing Oil Pump 15. Remove spark plugs 16. Install Engine Attachment KV10102500 to cylinder block using engine mounting bracket RH. attach- ing studs, fuel pump attaching studs and alternator bracket attaching bolt holes 17, Mount engine on Engine Stand 'ST0S01S000, ems? Fig. EM-4 Engine Mounted on Engine Stand ems. 18. ct. 19. Disconnect ait, vacuum blow-by hoses from air cleaner. 20. Remove air cleaner and air cleaner brackets, 21. Remove vacuum control valve assembly and bracket as a unit, Remove engine mounting brack- and. 22. Remove carburetor and baffle plate 23. Remove E.G.R. control valve 24, Remove P.C.V. hose (Pipe con nector to control valve). 25. Remove intake and exhaust manifolds. Fig. EM-5 Removing Manifolds 26, Remove rocker cover. 27. Loosen valve rocker adjusting nuts and tum adjusting screws out to disengage push rods. Then evenly loosen rocker shaft bolts. 28. Remove rocker shaft assembly. masa Fig. EM-6 Removing Rocker Shaft Assembly 29. Withdraw push rods, and keep them in correct order. 30. Loosen cylinder head bolts a little at time in the sequence shown, in Fig, EM.7, and remove cylinder headEngine Mechanical eMasa Fig. EM-7 Cylinder Head Bolt Loosening Sequence Fig. EM-8 Removing Cylinder Head Note: Do not pry between head and block as gasket surfaces may be+ ‘come damaged. 31. Invert engine. 32, Remove oil pan and oil strainer. 33, Invert engine. 34, Remove water pump. 35, Remove crank pulley and timing chain cover. emass Fig. EM-9 Removing Timing Chain Cover 36. Remove oil thrower and chain tensioner. 37. Loosen camshaft sprocket bolt and remove both sprockets and timing chain, 38. Remove connecting rod caps and push piston and connecting rod assemblies out of the bores, Fig. EM-10 Removing Piston and Connecting Rod Assembly Note: Numbers are stamped on con- necting rod and cap corresponding to each cylinder. Care should be taken to avoid wrong combinati including bearing. 39, Remove flywheel and rear plate. WARNIN When removing flywh not to drop it. 1, be careful 40. Gradually loosen main bearing cap bolts in two or three stages and. remove caps, ease Pig, EM-11 Main Bearing Cap Bolt Loosening Sequence 41. Remove rear oil seal 42. Lift out crankshaft, 43, Remove main bearings from block and bearing caps. 44, Remove baffle plate and steel net. Fig, EM-12 Removing Baffle Plate ‘and Steel Net eM4 45, Remove camshaft plate. Careful- ly remove camshaft by pulling it to- ward the front of engine, mast Fig, EM-13 Camshaft Plate 46. Remove valve lifters and keep them in osder. PISTON AND CONNECTING ROD 1, Remove piston rings with a ring Fig. EM-14 Removing Piston Ring 2. Press out piston pin with Piston Pin Press Stand KV10105300 emoa Fig. EM-15 Removing Piston Pin Note: Keep disassembled parts in order.Engine Mechanical CYLINDER HEAD 1. Using Valve Lifter $T12070000, compress valve spring and remove valve collet. 2. Release Valve Lifter and remove spring retainer, spring, oll seal, spring seat and valve, emae2 Fig, EM-18 Removing Value Place valve components in order. © WU @a (sO Mos Fig, EM-17. Valve Components Note: Take care not to lose valve spring seat, oil seal, valve collet, and valve rocker guide. INSPECTION AND REPAIR PREPARATION FOR INSPECTION 1. Before cleaning, check for signs of water and oil leaks. 2. Clean oi! and carbon deposits from all parts, They should be clean from gaskets and sealant 3. Clean all oil holes with solvent and dry with compressed air, Make sure that they are not restricted. CYLINDER HEAD AND VALVE CHECKING CYLINDER HEAD MATING FACE L. Make a visual check for cracks and flaws 2. Measure surface of cylinder head (on cylinder block side) for warpage. If beyond designated limit, correct surface with a surface grinder. Warpage of surface: Less than 0.1. mm (0,004 in) Fig EM-18 Checking Cylinder Head Surface Note: Surface inding limit The grinding limit of cylinder head determined by the cylinder block ‘grinding in an engine. Depth of cylinder head grin isa” Depth of cylinder block grinding is"B* The limit is as follows: A+ B=0.2 mm (0.008 in) VALVE 1. Check each of the intake and exhaust valve for worn, damaged or deformed valve caps or stems. Correct oor replace the valve that is faulty, For standard size of valve, refer to Service Data and Specifications. 2. Valve face or valve stem end surface should be refaced by using a valve grinder. Note: When valve head has been worn down to 0.5 mm (0.020 in) in thickness, replace the valve. Grinding allowance for valve stem end surface is 0.5 mm (0.020 in) or Fig. EM-19 Regrinding Vole Face EMS VALVE SPRING L. Cheek valve spring for squareness using a steel square and surface plate If spring is out of square “S” more than specified limit, replace with new Out of square ("S" Less than 1.6 mm (0.063 in) SSS SSSSSSSSSran Fig, EM-20 Measuring Spring ‘Squareness 2. Measure the free length and the tension of each spring, If the measured value exceeds the specified limit, re- place spring, Refer to Service Data and Specifica tions )) J} Se Fig. EM-21. Measuring Spring Tension ema