RUICE

MANUAL
MODEL
J t 3 ,J t 5 & JI 6 SERIES
ENGINES

.-.

M
!,<.t-

NISSANMOTORCO.,LTD. i
17-1,Ginza6-Chome,
Chuoku,Tokyo104,Japan
,,/({..
?

SERVICE
MANUAT
MODEL
J13, J15 & J16 SERIES
EilGIIIES

NISSANMOTORCO.,LTD.
17l, Ginz8rchorne, Chuoku,Tokyo1Ot,Japan
I
FOREWORD

This servicemanualhasbeen preparedfor the purposeof assistingservicepersonnelof

of the ModelJ 13,
our ilistributorsand dealersin plovidingeffectiveserviceand maintenance
Jl5 and J16 SeriesEngines.

Sinceproper maintenanceand serviceare absolutelyessentialto satisfyour customers,

this lnanual should be read carefully.The following mattersshouldbe noted for effective
utilizationof this manual.

1. Pleaserefer to the following SERVICEMANUALS in addition to this manualfor

complete details of the car, becausethis manual describesthe information
concerningthe Jl3, J15andJl6 SetiesEngines
only.

o and Body
SERVICEMANUAL DatsunPick-upModel620 SeriesChassis
o SERVICEMANUAL Nisen HomerModelT20 SeriesChassisand Body
o and Body
SERVICEMANUAL ModelA32l Se esChassis

) All part namesin this manualconform to the PARTSCATALOGModel620, Model

T20 and Model A321, and only the genuineserviceparts listed in this PARTS
CATALOGmust be usedfor replacements.

3 . AII information, iUustrstionsand specificationscontainedin this manualare based

on the latestproductinformationavailableat the time of publicationapproval
4 . It shouldbe emphasized that thos€who use this manualareresponsible for revising
the contents according to the Service Journal and Se ice Data And Specilications
i$suedby the factory, which cany the latestfactory approvedservicingmethods
and methodsat any time are reserved.
5. Rightsfor alterationof specifications

NISSAN MOTOR CO, LTO

14. Gin2aSchom,ChuokuTokvo1O4,Japan
l
O I9?2 NISSAN MOTOR CO, LTD- Printcdin .ranan

f.".
MODEL
J 1 3 . J 1 5 & J16 SERTES 'i
HtGilEs
EngineGeneral

Fig. EGl Left Bidevieu for 620

fig:. Ee2 Left tide oieu fo. T2O

 EngineGeneral

SPECIFICATIONS

Engine nodel

Numberof cylinders,type 4, In line

Valve afiangemellt Overhead valve

Bore x stroke nrn (in) x 3.06) '78x82 (3.O7x 3.23)

73 ,17 .6 (2.87^ 3.06) 78 x 77.6(3.O1

DspLacem€nt c{ (cu in) 1,299Q9.3\ 1,483(90.5) |,s67(9s.6)

Compressionratio

Firing order t-3-4-2

Numberof
piston ngs

Numb€r
ofmainbearings

Capaciti€s 3.0(3X,2%\
liters(U.S.qt., 3 . 7( 3% , 3 X )
Imper,qt.)
4 . 4( 4% , 3 % \

VEHICLEREFERENCE
Ihis sectlon conteim the lnforma. manual of chassisand body for com- vehicleson which the Jl3, Jls and
tion rogarding engin€s only. Pleaso pl€te detailsof the vehlcles. Jl6 engin$areequipped.
refer io both thb manual and the The table that follows lists the

J13 J15 Jl6

620U PA32I N62OU 'r20u

R.H. drive A32l G62OU VPA32I cN520U T2OHU
U62OU KPA32I VT2OU
t 520 NL62O LT20
tn620 GN162O LT2OH
L.H. drive uL620 uNr-620
t-620'l NL62OT
tt]6207 GNL62OT
t
EngineGeneral
. RECOMMENDEDLUBRICANTS,
AND COOLANT
GASOLINE(FUEL)

RECOMMENDEDSAE
VISCOSITY NUMBER
Use the folowing grades of oil,
gasoline(fuel) and coolant.

10w

20w.20

30

GeafOil

90

-22 -4 14 32 50 68

TempemtweRangeAnticipated

t
t\
FG.A
 EngineGeneral

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IJ iINICNI
E
 E n g i n eG e n e r a l

RECOMMEl{DED
GRADE OF GASOLINE

Enginenodel OctaneNo. of gasoline

JIJ

J15 morethan85
Jl6

NISSAN LONG LIFE

cooLANT(L.L,c)
This L.L.C. is an ethyleneglycol
bas€product containingchemicalin-
hibiton to protectthe coolingsystem
from rusting and cor|os,on.L.L.C.
doesnol containany glycerine,ethyl
or melhyl alcohol.lt will not evapo.
rateor boil arrayandcanbeusedwith
either high or low temperature ther.
mostat.It flows fieely, hansfersheat
efficiently,and will not clog the pas.
sagesin the cooling sysrem.L.LC.
must not be rnixed with any olher
products.This coolant can be used
throughoutthe seasonsof the yearand
erchangeperiodis two yearsor total
runningmileage of36,000krn (24,000
milet.

0132)
Boilingpoint
-lo (t4t
0.9ks/cm,(13psi)
Sealevel -20 t4l
-30 \-221
3Oo/o l06oc(2230F) -lsoc (soF)
-40 {-40)
s0% ro9oc (228'F) t27oc(26roF) -35oC (-3loF)
.501-58)
10 20 30 ,rc 50

FiE. EG.3 Prctection .oncenndtion

UNIT SERIALNUMBERLOCATION
numbcrs.Thesenurnbersareindicated catedin an easy-to{eadposition.
unit identitication:engine and cllassis in the vehicleidentificationplate lo-

ENGINESERIAL J XXXXXX
NUMBER Jt5 X XX X X X
J16 XXXXXX
The engineserialnunber is stanp- ---T--
ed on the rear right sideof cylindel
block, at cylinderheid contactface. I
-tl-r-'-
SeeFigureBG-4.
The number is Fecededby the
I Serialnumber
ensinemodel,J(Jl3),lls or J15. Enginemodel Fig. EG-4 Engine @riol nunbet tedtian

EG.6
 E n g i n eG e n e t a l

PERIODICAL
INSPECTION
AND MAINTENANCE

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 SECTIONET

ENGINE
MODEL TUNE.UP
Jls, J15 & J15 SERTES
EilGnES

tt{0il{tTtJl{t-l|P "tT.2
SERI|ICT
OATA
AI{D'',,,'''..,'''
.' ..tT.9
sPECtflCATt0t{S
Tno|JsLr
D|AGI{0sts
AltD tTtI
c0RRtcTt0ils
sPtctAt
stnvtct
I00t tl.li
 EngineTune-up

ENGINE
TUNE-UP

CONTENTS
DESCF IPTo N . . . . . . . . R E P L A CN G A R C L E A N E RF L T E R
BASC MEC H A N I C ASLY S T E.M . EI.2 ( v s c o ur sY P E ). . . . . . . . . . . ET5
ADJUSTN G I N T A K E A N D E X H A I J S T C L E A N I N GO R R E P L A CN G A B C L E A N E F
V A L V EC L E A F A N C E S Er-2 F I L T E F1 D R YT Y P E,). . . . . . . , . . . E T5
CHECK N G A N D A D J U S TN G F A N F E P L A C I N GF U E L F L T E R ET5
BELT.. ET.3 C L E A NN G F I ] E L F I L T E R C O U P L E DW T F
BETIGNTENIN CGY L N D E FH E A D N U T S , E L E C T F TPCI I M P ......... ET5
MAN FOLD BOLTSAND NUTSAND A D J U S T N G C A R B U R E T O R . I D L ERP [ 4
L A R B - RT O o I L U F I \ ' \ U - S . . . ET.3 M XTURERATO ET5
( n L L K I N Gr N C N t L O I V D R5 0 \ . . . ET-3 C H E C KN G F U E L L I N E S ( H O S E SP, I PN G S ,
L U B R I C A T I NAGC C E L E B A T OLBN K A G E . . E T 4 C O N N E COT N S ,e r c . )F O B L E A K S . . . . . . . . ET-6
I G NT l O N S Y S T E .N. 4. . ET.4 L U B RC A N TA N D C O O L ] N G S Y S T E \ .4. . . . , . ET-6
C H E C K ] NB GA T T E R Y EI.4 REPLAC NG OIL F LTEB ,, ,,.... ET.6
C H E C K ] NA GN D A D J U S T I N GG NT I O N CHANG N G E N GN E O I L . , . , . . . . . . . . . . ET.O
T M | N G. . . . . C F ] E CN K G E N G I N EO L F O R L E A K S. . . . . ET.7
C H E C K ] ND G S T R I B U T OBBF E A K E R C H A N GN G E N GN E C O O L A N T . . . . . . . . . ET.7
P ON T . . . . ET,4 C N A N GN G E N G N E C O O L A N T( L . L C , ) . . , E T7
CHECK N G O R R E P L A C I NSGP A F K C F ] E C K I N GC O O L N G S Y S T E M F ] O S E SA N D
P L U G .S. . . . . . ET.5 CONNECTION FSO F L E A K S. , . , , , , , E 11
C N E C K I NA GN D C L E A NN G H G H C F A N K C A S EE M S S O N C O N T R O L
TENSION W F E S ,D S T RB U T O RC A P S Y S T E f .i ,4. . ,,. .. ET-8
AND ROTOR D E S CPFT | O N . . . . . . . . . . . . . . . . . . . . . . .E. T 8
G R E A S I ND GI S T RB U T O FS H A F TA N D C H E C KN G V E N T L A T I O N H O S E S
CAN4HttL ET,5 ( A L L T 2 OA N D A 3 2 ] N 4 O D E L S E F I E SA N D
r-UtLSVSTIv ET.5 O T H E B SO N t Y F O R A U S T R A A L ) ....,, ET.8

bc Inadcwhilc cngincis strLlonnry.

DESCRIPTION
li may be needlcssto say, howevef,
to restorcpowcr and perfonnrncelhnt
has leen lost though wea!, cotrosion,
or deteriorrtion, periodicnl mainte-
nanc€tenglnetune'up) ts n€cessary.
Ii is cven nore inportant that the
engine tune-up be done accurately
accordingto the maintcnancescheduLe
shown in the applicrble Owneas
Manual.
This clupter descrlbesaciual opel
ating proceduresfor the maintenance
operationofitens to be inspectcd.
BASIC MECHANICAL
SYSTEM
ADJUSIING INTAKE AND
EXHAUST VALVE
CLEARANCES
Valve clearanceadiustment shol d
To ,diust, procecdxs tbllows:
1 . S i a r t c n g i n €a n d r u n i t u n t i l i l i s
h c a l c dt o o p e r a t i n gt e m t e r a t u i eo, r r t
least,more thrn 80oC (1760F) of
e glnc oil tenrperatLrreithen slop
2. Rotatc orritshrft io bring No. 1
cylinder in iop dead center on its
3. Renove valve rocker cover lo ET09A
gain rcccss to valve operating mech- Fie. ET 1 AdjustinE udlDecteomnce
Adjust valvc cicarance at the ,1. Again,rotatecrankshaftoncturn
following four pojnts while engine is so lhat No. 4 piston is in top dead
sllll hot: center on its compressionstroke.
Adjustfollowinsvalves:
O ExhaustvalveofNo. I cylindcr
@ ExhaustvalveofNo.2 cylinder
e) Intrke valvcof No. 1 cylinder
htake valveof No. 3 cylinder
Or Inrakevalveof No. 2 cylinder @
lntakevalveofNo.4 cylinder
O
O Exhaust valveofNo. 3 cylindel
@ ExhaustvalveofNo. l cylinder
Adjushlent shouldbe mddewhiLe
engineis hot. Atler aI valvcshave
been ,djrsted correctly.tightenlock
Note: Nmbers in par€nthesisagree
with those in accompanyingsketch. nut fifmly to secufethe adjusiment.
Er2
 E n g i n eT u n e - u p

CHECKING
ENGINE
COMPRESSION
0 . 3 5i n m
Noter If this test is to be p€rformed,
( 0 . 0 1 4i n )
it shouldbe done wh€n plrgs are
remoYedfor seric€ during basic
tune-upprocedue.

CHECKINGAND ADJUSTING Unlesscheckh madefor worn rings

FAN BELT
With the engine switched off dnd
the hood u!. push th€ b€Lt gentiy
downward. You shoL d be able to
d e p r e s si t a b o u t i 0 ] n m ( l / l i n )
midway between fan pulley and
a l i c r n a t o rf u l l e y b y r f o r c e o f l 0 k g
( 2 2 . 0 l b ) . I f t h e f a n b e l t h a sb e c o m e
s l i c k t h r o L r s hw e a r , l o o s e nt h e f i x j n g
and ad.justnrsbolts. ard rnovc thc
aliernitor away tuonl the engine.This
will eli in!Le tho shck. Tighlcn thc
b o l 1 sa E d i i . r n d n r u k cs u r c t h r t L h c
b c L l h a s b c c n t i g h t c n c dc o f l e c l l y . I f
t i g h t c n e d c x c e s s i v c l yi t w i l l w e r r
rrpidly .lnd rlso ovcrlord lhe wrtet
p u r r p a n d r l l c n r a t o rb c a r i n g s .
Fln bcli dcflcction:
8 L o 1 2n n n
( 0 . 3 1 5 0r o 0 . 1 1 7 2i40
10k-s(22 !b)
Fig. ET's TiehteninEserruene
Tighieningtorque
Cylindcrhcadstudnut:
5.0 to 6.0 kg-nr
(36 ro 13 fflb)
Vdlverockcrshaftbrackel
2.0to 3.0kg-m
(i4lo 2? ftJb)
Whcnthe €ngincis wrm, lighton
thc bolts nnd nuts to r iorqu€0.5
kg n (3.6 ft lb) higherthnnthe specifi-
Intake and cxhausr nwrifold bolts
and nuts slrculd be tightened to the
or lbr the cnuseof low speed,con-
pressioncheckshouldnot be neces-
sary.
Fig. ET-4 Tejting comprc*ion
pressur.
Test comprcssion rvith enginc
wrrn1, r11 spark plugs rcmoved and
t h r o t t l c a n d c h o k e o p o n e d .N o . c y l -
inder compressionshouid be lessthun
80% of highest cylindefs. Exccssivc
variatjon betwe€n cylind€rs, ac-
companied by low sp€ed missing ol'
lhc cylinder or cylindcrs which are
]ow, usually indicatcs a valve not
proFrly sealing or a broken pislon
ring. Low pressures, ev€n thougll
uniform, may indicaieworn Iings.This
may be xccornpaniedby excessiveoil

FiE.ET-2 Adiustins fan belt Tighteningl0que:

Intake and enlaust manifold:
L7 to 2.3 kgin
(12 to 17ftlb) Il one of more cylinders read]ow,
CYLINDER
RETIGHTENING inject about one tabl€spoonof engine
HEADNUTS,MANIFOLD oil on top ofthe pistonsin low reading
cylinders through spa.k plug porl.
BOLTSAND NUTS AND
C{rburetor iNtallaiion nuts should Repeat compressionchcck on these
CARBURETORSECURING
be tjghteDed securely. Lcaks a1 this cylinders.
NUTS l[ If compression improves con-
xrca may crnse .ough idlc. surging.
Cyljnderheadnursandvalverockel deceleration fopping or deceleralion siderably,piston.ings are defective.
shaftbracketboltsl whistle. 2. If compressiondoesnot impfove.
Whenthe engineis cold, tightening ,ralvesar€ sticking or not sealingprop-
shouldbe madein severalstelsandin Tighreningtorque: erly-
the scquenccshown in Figure ET-3, Carburctornuts 3. If lwo adjacenicylindersindicate
starlingwith lhe centerand moving 0 . 8 t o 1 . 2k g - n low compressionand injecting oil on
(6ro9ft1b) pisions does not increasecompresslon,
ET3

the causcmay b€ a cylinderhead
gasketlcak between the cylinders.
Engine oi1 and coolanr in cylhder
couldresullfrom thisploblem.
Compression pressure
ks/cn2 (psi)at rpm
(r7r)/3s0
12.0
r0.0(142y3s0
LUBRICATING ACCELERATOR
LINKAGE
Apply a light coatof nn tipurposc
greascto ail slidinSor trictionsurfaccs
exceptball joints. The entife ljnkage
shouldbe rnspectcdwhclhcr or not
foot rcsl rctums to nornal hcight
smoothlywhenreleasing foot from ii.
This test shouldbc madcwith cngine
funning.Added careshouldbe takcn
in checkingitems that affect proper
linkagcfunclion.
IGNITIONSYSTEM
CHECKING BATTERY
Checkthe electrolyte
levelin each
battc!y cell.
l4 Unsct€w o&ch filler cr! and
inspect fluid icvel. lf the fluid is low.
add distiled walcr io bring the lcvcl
up approxinately 10 lo 20 mrn (0-394
to 0.787 in) abovethe plates.Do not
overfill.
2. Mexsure the specific gravity of
Fie. ET-' che.kine the specific
eruuitr of bdttery electrollte
EngineTune-up
vdue
Fully charged
Permissible
value
(at20oC,680F)
Frigid climatcs O\et 1.22 1.28
Tropicalclimates OverL 18 1.23
Otherclimates Over1.20
Clean the top of baltery and ter- Adjusi the tining to the specifi-
minals with a solution of bxkirg soda cations, tuming distributor body
and water. Rinse off and dry with loosenedsccuringbolt.
conpr€ssed air. Thc top of bxttery
must be clean to prevent currenl lerk.
age between temrindh rnd ho posi
tjve temrinal to hold.down chrrp.
In addition to currenl leakrge,
prolonged accumulation oi acid and
dirt on (he lop of battcry nray cduse
corrosjon of slmps. After tigfitening
teflninals, coa! thcm i!ilh petrolatunr
(vaseline)to protcct thcn fronr cor
Fig. ET-7 Atljusting ignition litning
CHECKINGAND ADJUSTING
IG ITION TIMING
Wiih disLriburor li']cdis-
vacuunr
connecled and vehicl€ opcrrlirg nt lanition timing (B.T.D.C/rpm)
normal idle sp€ed or below, set J l 3 ,J l 5 a n dJ l 6 8 0 / 6 0 r0y m
jgnjtion tiIning.
The iiming can be observedby Lhc
siatio|ary pointer ai frcnt covcr lnd
tle groovcson craikshaft pulley with
a d€vice called a slruboscopic light CHECKINGDISTRIBUTOR
(alsofefer.ed lo as a tining lighl). BREAKER POINT
Note that the pullcy groove is
gnduated 5o per scale division in
tern$ of the crank rngle. Thc to! dcad
center is locrted to lhc extrernelefl as
viewedfrom rhe inspeclor'sside.
Fie. ET 8 Che.hitc dkhibutor
potnr gdp
' - f
Fis. ET 6 Checkinqignitian timins
ET-4

Rernovedistdbulorcapandinspecr
burningor pitting.
pointsfor excessive
Replacepoints if necessary. Use a
point file to cleancontaclareaand
removescalefrom points.Adjustdis-
tributor point g!p. Filing is tbr
cleaningpurposesonly. Do not af
tempt to removeall roughness.Adjusi
distributordwel angleon rll engin€s.
Distributorpointgap:
0.45io 0.55nm
(0.o177 to o.o2l7in)
Dwe[ ansle:
49oto 55o
CHECKING OR REPLACING
SPARK PLUGS
Fig.ET-g Ch.chingsparhpluqgop
See tMt conect spark plugs are
us€d.Sparkplus rnsulatofs
shouldb€
ro preventpossible
thoroughlycleancd
Thoroushly clean lower insulator
and cavityby blast typeclcaner.Filc
bolh eleclrodcsilat Goundedsurfirccs
incrcasevoltagerequiredro fire pluBt
and set gap.Tightenplugs!o ldque.
Sparkpluggap:
J13
0.7 to 0.8 mn
(0.0276 to 0.031sin)
J 1 SJ, 1 6
0.8 to 0.9 nu
(0.0315 to 0.0354in)
Tightening torqxe:
1.5ro 2-0kg-m
(11 to 14 tt.lb)
CHECKING AND CLEANTNG
H|GH TENSTON W|RES,
DISTRIBUTOR CAP
AND ROTOR
Note: This op€rationis to be per'
formed while checkirg distributor
E n g i n eT u n e - u p
External surfacesol a[ parts of CLEANING OR REPLACII{G
secondafy be
systemmust cleaned to AIR CLEANER FILTER
reducepossibiliiyof voltage1oss.AI (DRY TYPE)
wires shouid be removedfrom dis- It is necessaryto clean the elemeni
tribuior ca! and coil so lhdt terminals or replace ii at the recomnended
canbe inspecl€daDdcieancd- Burned interval, nore often under dusty
or corrodedterninals indicatelhat driving condilions.
wifes were not fully seated,whioh
causes arcingbetweenend ofwire and REPLACING FUEL FILTER
terminal.Whenreplacingwiresin ter-
Check for a conianinated elernent,
minal, be surethey are fLllly sealed
before pushingrubber nipple down
overiow€r.Checkdistriburorrotor for
drmagc,anddislributorcapfor cncks.
GREASING DISTRIBUTOR
SHAFT AND CAM HEEL
Clcan and apply multi-purlose
grease
to camandwick.
Note: Do not apply greaseexces-
sively.
lE. ET'I1 Fuel sttainel
FUEL SYSTEM All engines us€ a cartljdge tYPe
shriner, so if r malfunction is
REPLACINGAIR CLEANER delecled,replaceasan assembly.
FILTER (VISCOUS TYPE)
The nif clerneruscsu wet papet CLEANING FUEL FILTER
lypc clerncr olcment (viscous lype). COUPLEDWITH EIECTRIC
As this elenrenl has becn manu- PUMP
faclured under speciNilreatmcnt, lhere
is ro need of cle ning until ii is
replacedwith a new one.Allhough the
cleaner clcment looks dirly, do noi
atlenrpl to clern. Thc clcaning peF
formanoe in con(antly maintained
though it looks contaminated.Cme
must b€ taken noi to injurc clcancr
Repl ce elemenl wiih a new one ar
recommended interval, norc often
Fis. ET 12 Replacingfuet putup
under dusty driving cordiiions. filt.r
Check for a coniamindtedliltel and
warer deposil. If filier is def€clive,
replaceit wiih a new one.
Also check packngs and o-rings, if
they rre defective, replace with new
ADJUSTING
CARBURETOR-IDLERPM
MIXTURE RATIO
is madeby throtlle
Idleadjustment
adjustscrewand idle adjxst screwafter
Fig. ET 10 Reptacinqdir.Ieaner engine is warmed !p. See Figure
filter ET-13.
ET.5

2 Throtucadjuslsrew
1. Checkto be surethal floatlevelis
correctwhilecngineis al idlespeed.
2. Usinga suitablescrewdriver, lLrn
out idle adjusl screwapproximately
two or threelurns,startingfrom fully
clos€dposition.Turn in throttleadjust
screwtwo or lhree lurns dnd stlrt
3. Turn out lhrottle adjust screw
genilyuntil specjfied
engineidl€speed
is approxinatelyobrained.
4. Turn in or out idie adjustscrew
until engine runs srnootNy at the
higheslspeed.
5. Turn oul throttle adjus! screw
until specified€rgine speedis ob-
tained.
6. Readjustjdle adjusl screwuntil
engineruns smootl y al the high€st
speed (ltith the highesl vacuum
reading).
7. Then, throttle ddjustscrewmusi
be bdjusledso ihdt enginespeedis 20
rpm fastefthanspecified.
8- Finaly, turn in idle adjustscrew
until specified
enginespeedis attained-
a. Items 7 and 8: B€st n€thod to
elininate carbor mononde in ex-
haustenission.
b. Do not att€mptto screwdown th€
idle adjust screw completely.ff
damageto the tip may resultwhich
will tend to csusenalfunctions.
E n g i n eT u n e - u p
For cabovcrtype tuck
assemblyusing oil Filtcl Wrench
ST1932000.Whcn installingan ojl
filter, fastenft on cylinderblock by
hand.
2. Thc oil filter elemenlshouldbe
re!lacedat reconn1cnded inteNah.
Notes:
a. Do not overtightenfilter, or oil
leikngemayoccur.
b. Whenassenblingoil the sealring
lightly.
Fig. ET t3 ldling adiBhnent
f i C E f l 4 R . , n u r L n +o i t / i | L . l
Jl3,JlsandJ16
CHANGINGENGINEOIL
l. Chcck if cngiic oil hrs bcen
Enginemanilbld d c l c r i o n r c db y l i v x d i n 8c o o l i n gw a l c l
o r g r s o l i D c .D n i n r n d r c i l l o i l , i f
speed
tumHg (inHg) 2. Drrinlig rs bcsl donc rlicr a good
run, whcn drc oil, being thoroughly
wrrn, will flow rerdily ir d freely xnd
CHECKINGFUEL LINES
xny forcign malter will bc hcld in
(HOSES,PTPTNGS,
CONNECTIONS,etc.)
FOR LEAKS Placeit hrgc bowl or olher shxilow
cont.riner undcr ll1c cngine. Then rc-
Checkfuel lines for loosecon-
move thc oil pan dr.rin !lug. Do this
nections,
cracks
anddeterior.rtion.
Re,
carefully. as ihe oil will bc hot and it
tighten
looseconnectionsi
if recessary,
will spufi out with somc force. AfLer
replace any damaged or defeciive
complerely drainins the dnLy oil off
sccurelyfephce the oit drain plug and
finally refill the engine jn thc usual
LUBRICANTAND "H" nark on thc
wry up to lhe
COOLINGSYSTEM dipslick. Mrkc surethrt the cm is on a
level surlioe wlnle drahing lnd fi1ling
REPLACING OIL FILTER
the €ngiic-
The oi1 filter is of .t full-flow
cadridge type. The on I'iller elementn
sealedin the containeras a unit. It can a. A nilky oii indicatesthe presence
b€ easily removed by lrrnd with a of coolingwater.
specialtool. Discover the cause for necessary
l Check for oil leaks at packing
flan8e. If any leakagejs discovered, b. An oil with extremelylow vismsity
lighten a iittle, or rellace o tilter suggestsdilution with grsoline.
 EngineTune-up

3. Checkoil levei,andif it is below samegradeup to the H level. CHECKINGENGII{EOIL FON

the specifi€d
level,replenish
oil of the LEAXS
Check cylinder head, front chain
cover,oil pan, rockercover,oil filter
gasket,etc. or other parts for si8n
of leakspast their gasketedsurfaces.
.If necessary,replace gaskets or
def€ctiveparts.After maintenance las
beendone,checkthereplaced partsto
seeif nayleaksoccur.

CHANGING ENGII{E COOLANT

FE. ET-15 Checkingenqineoil leuel
Scaleor sedimentaccumulated in
Oil c{pacity of ensine(includingoil filter) water jacket or radjatorharmsheat
radiation.Thoroughlyflushtho system
Maximum (H level) nfter opcningiwo drainplugs,(on€at
4 . 4L ( 4 % , 3 % ) the bottom of the radiatorand the
J13 (U.S.qt,,Irnp.qt.)
J15 other at the riglt sideof the cylinder
Jl6 Minimum (L level) block),until cleanwatercomesout.
(U.S.qt.,lmp. qt.)
3.41(3%,3) Alwaysusecleansoft waterin the
radiator,Whencold season arrives,
the

cooling systelhshouldbe protected

againstfreezingby a goodanti-ffeeze Botlingpoint
solution suchas NISSANLONO LIFE Percent Freez€
COOLANT, 0,9k8/cmz(13psi)
Sealevel cooling
system
To allow for expansionwhenhot,
the level,whencold,shouldbe visible
just below the liller neck, Do not 1050c 1240c -150c
30% (2230F) (25soF)
overfill the system. This coolant
(L.L.C) shouldbe changed everyrec-
1090c 127"C -3soc
ommended interval. 50% (228'F) (261'F) (-3loF)

GHANGING ENGINE
CIOLANT (L.L.C.)
o (32) In3pection of radlrtor cap
l{laarn long lif€ coolanl
" 1 0{ 1 4 1 Apply refercnce pressure [0.9
L.LC. is an ethylen€glycol base kg/crnz(13 psi)l to radiatorcap by
product containingchemicalinhibitors -20 (41
meansof a captesterto seeif it is in
to protect tne cooling system frorn -N t-221 goodcondition.Replacecapassembly
rustingand corrosion.The L.LC. does ifnecessary.
not contain any glycerine,ethyl or 40 {-40)
methyl alcohol. [t will not evaporat€
-50i-58)
or boil away and can be usedwith 10 20 30 4() 50
€iiher high or low temperature
thermosiat.It flows freely, tra$fe$ Fig. ET-16 Ptutection .orcehttution
heat effici€ntly, and wi not clog the
passagesin the cooling sj,stem.The CHECKING COOLING
L.LC. must not be mixedwith other SYSTEM HOSES AND
products.This coolant can be used CONNECTIONSFOR LEAKS
throughoutthe sealonsof the year-
lvheneverany coolant is changed, Checkcoolingsyst€mhosesand
the cooling systemshould be flushed fittings for loose connectionsand
andrefiIed\tith a newcoolant. deterioration.Retightenor replaceas
Checkthe level. Fie- ET-U TettinA rc.li4tor cap
 EngineTune-up

Cooling 3yatem prcssure test referencepressure[1.6 kg/cn2 (23 systemcomponents.

pstl to thp coolingsystembY means
With radiatorcaprenoved,aPPIY of a tester to checklor leaksat the

620 A32l T20

Withheater(u.S.qt.,Imp. qt.) 6 . 0 1( 6 % , 5 ) 6 . 5L ( 2 %, 1 % ) 8L(8X,1)

Withoutheatei(U.S.qt.,Irnp.qt.) s.4L(s%,4%) s . s 1 . ( D t , 1 % ) '7r, ('t%, 04)

rnodeiseriesand othersexported1o CHECKING VENTILATION

onlyAustralia. HOSES(ALL T2O AND
The controi systemconsistsof a 4321 MODEL SERIES
hosc connccledto the Yalverock€r AI{D OIHERS ONLY FOR
coverfrom ihe crrburetorair cleaner. AUSTRALtA)
This is feferred to as a "sealed
system"whichprovides an escapepath
gas
for the blow-by with no provision
for the intfoductionot ventihtionair l Cheokhoseand hoseconnections
ior leaks.
FiS.ET-18 ?atine cooling sytem Flow of blow-by gas is inducted 2. Disconnectall hose and blow
inlo th€ hoscby tlrc ncgativepressrr€ themout with compfessed ajr.
croatedwhen thc enginesucks th€ Il any hosecannot be madefteeol
freshair ihioughthe air cleaner. obstruclions,replacewith a new on€.
CRANKCASE The oil filler capandoil levelgauge
EMISSION CONTROL areof a sealedtype1l)preventblow-by
SYSTEM gasin cfankcss€ from escaping inlo the

DE3CRIPTlOT{
This systemis adoptedin all T20
andA32l

FE. ET 19 Sealedtrpe crdnhc$. uentilationslstem

ET.8
 EngineTune-up

SERVICEDATAAND SPECIFICATIONS
mm ain\

Iniake 0.35 (0.0138)

Hot
Exha st 0.35 (0.0138)

Fanbelt deflection (lnllb).......,.........

mnvkg 8 to t2lro(0.31
to0.47122)
Compression prcssure
Standad Rg/crn-$sr) at rpm (17r\13s0
12.0
Mlnlnum Kg/cm-$sr) at rpm (142y3s0
10.0

Batterylpeciflcgravity

Permfusible
valu€ FuUychargedvalue
(at20oC,68oF)

Frlgidclimatos O\er1,22 1.28

Tropicalcllrnates Overl.18 t.23

Other cllrnateg Over1.20 t.26

Ignitiontiming 8o/600
Distributorpointgsp 0.45to 0.55
(0.0177to 0.02I7)
Dwellangle 49to 55
Sprrkpluggap
J13 0.7to 0.8(0,028to 0.031)
J15,J16 0.8to 0.9(0.032to 0.035)

O capacityofengino (including oil flter)

J 1 3 J, l s a n dJ 1 6

4.4L (4%U-5.qt , 3%Imp. qt.)

3.4/ (3%U.S.qr, 3 Imp.qt.)

ET.9
 EngineTJne-up

Coolingsystem
Testingpressureof radiatorcap tg,/cln2(ps)......... ...... .........0.9 (13)
Testingpressureof coolhg gYstem
(psi) .... ..........
ks,/cm2 ..'....r.6Q3)

Watercapacity

620 A32l T20

With heater
(U.S.qt.,Inpiqt.)
6 . 0 L( 6 % , s x ) 6.sL(2%,
r%\ 8 L ( 8 X , 7)

Withoutheater 5.4L(5%,4%\ s . 5 L ( r xr,N ) 1 L (7%,6h' )

(U.S.qt,,lnp. qt.)

torque
Tighterung
headrtudnut
Cylinder
shaftbrackot
Rocker bolt
Manifoldnuk
Intake& exhaust
socuring
Carbur€tor nutd
Sparkplug

ET.IO
 EngineTune-up

AND CORRECTIONS
TROUBLEDIAGNOSES
Condition

CANNOTCRAIK lmpropergradeoil. Replacewith propergradeoil.

ENGINEOR SLOW Dischargedbattery. Charge
batlery.
CRANKING
Defectivebattery. Replace.
lrose fanbelt. Adjust.
Troublein charSesystem. Indpect.
wlring connectiontrouble in 8t&ting circuit. Corr€ct.
Defectivestarterswitch. R€pairor rcplace.
Defectivestartermotor. Repairor rcphc€.

(frouble-shootlng
procodure on stsrtingcircuit)
Switchon theshrtingmoto.with ltght 'ON."
whonllght 90e3off or dlrnsco8idonbly.

Check
bottery.
endcable.
b . Chcckconn€ctlon
Checkstsrtcrmotor.
Whcnlight strysbright.
Checkwlring conncctionbetweenbatt€ry and rtarter
motor.
b . Ch.ct strrterswitch.
Checkstlrtarmotor.

ENGINEWILL CRANK NORMALLY BUT WILL NOT START

In thls crr6, th€ following trouble crusesmay exist,but ln many casesiSnition tysternor fuel systemis in trouble,

IgnltlonVste,nnouble

Vabetn chadsmaoeraot uoth ptopetly

(Trolble-slwotlry prbcetute)
Chocksparkplugfirst by followinSproc€dure
Disconnocthigh temioncablefrcm one sparkplug andhold it
.bout l0 mm (0.3937tn) from dre€ngin€metalpsrt andcrank
theengine.

lfgoodspa.koccuru-

a. Checksparkplug.
b. Ch€ckignition tining.
c. Ch€ckfuel system.
d. Checkcylinder compre$ion.

If no sparkoccurs. Checkthe current flow in primary cncuit.

Veryhighcurrent. IrBpect for sho ed pdrnary circuit.

Checkbre.ter poht operation.

ET.lI
 EngineTirne-up

Condition Correctrve
action

Lworno cunent. Checkfor loos€terminalor disconnectionin

Checkfor burnedpoints.

Isnition Bum€ddistrlbutorpoint. Repairor replace.

rrouble Improper pointgap. Adjust.
Defective condinser. Replace.
laak at rotor capandrotor. Cleanor replace.
Defective sparkplug. Clean,sdjustpluggapor replace.
Improperignitiontiming. Adjust.
Defectlve ignitioncoil, Replace.
Disconneciion of hight€nsion
cable. Replace.
loose connoctionor disconnection in Repairor replace.
primarycircult.

Fuolwrtamtroubla Lackof fuel. Supply.

Dirtyfuelstniner. Replace.
fuel piFe.
Dirty or clogged Clean.
Fuelpumpwill notworkprcperly. Repairor rcplace,
Carburetor chokenrlllnotworkproperly. Checkandadjust.
Improper adjulimentof floatlev€I. Correct.
Irnpropcridllng. Adjust.
Dlrtyor cloSg€dcarburetor. Disassemble
rnd clean.
CloggedbreEtherpipeof fireltrnk. Repairandclean,

Incorrectsparkplug tlghtenlngor defective Tlghtento normaltorqueor replac€gssket.

gasket.
Improper gradeengin€oil or low vhcosity. Rephcewith propergradeoil,
lncorrectwlv€ clearance. Adjust,
Compression leakfromvalveseat. Removecylind€r headand lap !"ives.
Stlckyvalvestem. Corrector replacevah€ andvalveguide.
Weakor defectivevalYesprings. Replacevalv€springs.
Compression lo.k at cylind€rheadgasket. R€placegalk€t.
Stickingor defectivepistonrin8. Replacepiston rings.
Wo|npistonringor cylinder. Overhaulengjne.

(TroubleNhootingprocedur€)
Pour engin€oil into plug hole, and then meaiur€cylind€r
compressron.
Comprescjon
increases. Troublein cylinderor pistonring.
Compressiondoesnpt change. Compressionleaksfrom valve,cylinder h€ad
or headgasket.

EI-12
 EngineTune-up

Condition conectiveaction

ENGINE
IMPROPER
IDLING

Fu6l syrtemt.oublo Cleanor replace.

Adjust.
Replac€element.
Replacegasketor rnsulator.

Adjust.
Previouslymentioned.

Othsr! Adjust.
Adjust.

ENGINEPOWERNOT
UP TO NORMAL

Pr€viously
mentioned.

l0nlllonry3Fmtroubla Incorrectignltloniiming. Adjwt.

Defectivesplrk plugs, plu8t.
Cleln,adjustor reploce
distributorpoints.
Defective Dresr, or replace potnts. Also check

Fu6l rylt m roublr Malfunctionof cho*e syst€m. Adjust.

ClogSedfuelpipeor floatlngvalve.
Dirty or clogged fuel strainer. Replace.
Fuel pump will not work properly. ReFir or replac€,
Clogged carburetor jets. andcl.{n.
Dlsassemble
Throttlevrlvedo€snot openfully. Readjust.
.
Fu€lpumpout of adjustment, Runajqtt.

Cloggedair clean€r, Replac€element.

troub16 Air inhaling from rnanifold gasket Replac€gasket.

overheatins Insufficientcoolant. Replenish.

Loosefanbelt. Adjustfanbelt.
fanbelt.
Womor def€ctive Replace.
Defectiv€thermostat. Replac€.
Defectiv€water pump. Replace.
Cloggedor lealy radiator. Flush,rcpairor replace.

ET-13
 EngineTune-up

Condition action
Corrective

Defective
radiatorfiller cap. R€plac€.
Air in coolingsystem. R€tighteneachpartof coolingsystem.
Improperengineoil grade. with propergradeoil.
Replace
Incorrectignitiontiming. Ad.iust.
carbur€tor(leanmixtur€).
Defectiv€ Overhaul
carburetor.

Ovo.cooling Defective
thermostat. R€place.

Orh€rs Inproperoctanefuel. Replace

with specified
octanefu€l.
Imprcpertire pressure, pressure.
Inflateto specified
Draggine
brake.
Clutchslipping.

NOISYENGINE

Carknod(ing Overloaded
engine. Userightgearin driving.
Carbonkno€king. Disassernble
cylinder head and remove

Timingknocking. Ad.iustignitiontimtng.
Fu€lt(nocking. Usespecifi€d
octansfuel.
(misusinS
Preignition of sparkplug). sparkplug.
Usespe€ified

Moch6nic!l
knockins

Crankshaft
bearing Thh stronSdull nohe increas€s wh€nengine
knockinB. is accel€rat€d.'Iolocateth€ place,causea
misfireon eachcylind€r.lf the nois€stops
by the rnisfire,this cylinderg€nerat€s
the
This is causedby wornor drmagedb€anngs,
or un€v€nly worn crankshaft. Renew
bearings andadjustor chrngecranksllAft.
Ch€cklubricationsystem.

ConneciinSrod noisethanthe
This is a little highel-pitched Sameasth€ cac€ofcrankshaftbearings.
bearingknocking. crantshaft knocking, and aho incr€ases
whenengineis acc€lerated. Causea misfire
on eachcylinderand if the noisediminishes
alrnostcompletely,this crankshaftb€arin8
Senerates the noise.

Pistonandcylinder Whenyou hearan overlapping m€ralicnoise
which increasesits magnitudewith the
revolutionof engineandwhich decreas€sas
by
engineis warmedup, this noiseis caus€d
phton and cylinder.To locatethe place,
caus€a misfireon e3chcylinder.
This may cause an abnormal wearing of
cylinder and low€r compression which in
turn will causea lower out-put powerand
excessiveconsumptionof oil,
Overh.ulengine.

This noise is heard at each highestand This rnay causea weai on piston pin, or
lowest dead end of piston.To locatethe pistonpin hole.
place,causea misfueon eachcylinder. Renewpistonandpistonpin ass€mbly.

This noise may be causedby worn or waterPumPwith a newone.

Replace
darnagedb€arings,or by the unevensurface
of slidingparts.

ET.14
 EngineTune-up

Cotdition Probablecause Cofiectiveactlon

Othe$. An improper adjustmentof valv€cl€srrnce. Adjust.

Nois€of timing chain.
An exc$;ive €nd-playon crankshaft,
Note: Thir troire w l b€ h€ord when clutch
b direqaged,
Wearon clutch pilot busbing,
Adjust the tensionofchein.
Dsassembleengineand r€newmaln bearing.
Rene],bushand adjustdrive shaft.

Noter Thir noisewill be heardvhetr clutch

is dir.ngsged.

ABNORMAL
coMausTtott
(backflre, afterflre
ru["onetc,)

lmprop.lignitioniining Ift properlgnltlontlrnlng. Adjuit tgnltlontlning.

lnlproparheatftngeof sporkplugs. Usespeclned iparkplugs.

Fualryiofi troubla Danagedca6uretoror manifoldgasket, themwlth nowpart3.

Replace
Oackflre, afrcrnrc).
crrburltorjet.
Daf€ctlv€ Dlsr$€mblecarburetorandchecklt.
Inproperfunctionof th€float. valve,
Adjwt thelevel,andcheckne€dle
Un€venidling.(Runon) Adjust.

Drtrctlvacyllndarh.ad, lnprop€rlyadjultedr€lveclearance. Adj$t.

elc. Excorsorrbonin combustlon chlmber, Remowh6rdrnd g€trid of crrbon.
D&maged valvespring(backftle, after flr€). Replsceit wlth r n€iwon€.
EXCESSTVE
OtL
CONSUMPTION

Oll loakago Looseoil dralnplug. Tightenit,

loose or damagedoil pangasket.
loose or damagedchaincov€rgasket,
Defective oil seal in front and r€ar
crankslEft.
lrose or drmagedlocker covergasket.
otoil filter.
ImpropertighteninS
l-ooseor damagedoil pressur€switch.
Ren€wgrskct or tighten it.
Renewgasketor tightenit.
Ren€woil seal,
Renew gasket or tlghten il (but not too
rnuch).
Renewgasketand tight€n it with the p.op€r
torque.
Renewoil pr€ssur€switch or tiShtenit.

Exc4.ive bil Cylinderand pirton wear. Overhaulcylinder andrenewpiston.

tmproper location of piston riflg gap Remountpiston rings.
reverselyassembled piston ring.
Damagepiston rings. Renewrings,
Repairor ren€wpiston and cylinder.

ETIS
 EngineTune-up

Cofldition Probabl€cause Corrective

action

lvorn piston ring grooveanalring. Renewpiston andpiston ring.

Fatigueofvalveoil seallip. Replaceseallip with a new one.
Renewvalv€or guide,

Olhaas Inad€quetequality of engineoil. Usethe designatedoil.

Engineoverh€at. Predouslymentioned,

POORFUEL
ECONOMY

S.. thooel.oation
of lha porr€rdaqaaro

Olh.ri Bxceeding idllngrevolutlon. Adjult lt to the designatedrpm.

recovery.
Dcfectivescc€leration Adj$t it.
Fuelle.lag€. Repair or tighten the cormection of fuel
pipes.

TROUSLEIN OTHEN
FUNCTIONS

Dacr€rrd 9ll prot.un oil quallty.

Inadequate oll.
Usethedesignated
Overhest. mentioned.
Previously
Defectivefuncdon of oil pump regulator oil pumpandrepairor rcnewit.
Dis!$emble

Functionaldeterlor.tionof oil pump. R€pairor replaceit with a newo'Ie,

Blockedoil fllter. R6nowit.
Increasedcleannce in various sliding Par$, and roplate th€ worn partawith
Disass€mble

Blockedoil strainer. Cleanit.

Troubl6 in oil gaug€pressureswitch. Replaceit with a new one,

Ercr-lvo w6aron tho Oil pressuledecreases. Previously

mentioned.
.ldin0p.rtr Defectiv6qualily or contamlnatlonof oil. Exhangethe oil with porp€r olte andchsnge

Defective
air cl€n€r. Chaeelement.
Overheator overcoot. Previously
m€ntioned.
lmprope. fu€l nixture. Checkthe fuel syst€m.

Sdtffing of Ciding in oil pr€ssure.

Decr€ase Previouslym€ntioned.
partt Ineufficient cloarances. Readjurtto the designatedclearances.
Overheat. Previouslym€ntioned.
lnproper fuel ftixture. Checkthe fuel system.
 EngineTune-up

SPEC]ALSERVICETOOL
Tool rumb€r For Reference
Description
No. & use pageor
toolname Unit: rnm(in)
figure No.

l. sT19320000 This tool is usedto take oil filter out ofphce. In tightening All
the filter, do not uselhis tool, to proventoxcesrtightening. FisBT"l4
Oil filt€r models

120(4.1'

;
ET-I7
 SECTIONEM

ENGINE
rcDEL MECHANICAT
13, 1 6 SERIES
HGIIIES

0Et{ERAt"
0fscntP]t0il til. 2
il{Grilt
0tsAssti|Bt-Y tir.4
It{sPtcTt0l{
AN0 ... .. . tlt|-I
RtPAtR
tt{0liltASSIII|B|Y "' El'1.23
"'"diiirirt'frriiii
stRl|tctDAIA
Al{0 E1'r.2s
TR0UBLt
t)IA0
0SES...............
ru-2a
AilDC0nRtCTt0ilS
sPECtAt
SIRI||CE
T00tS ttl-38
l:
( '
EngineMechanical

GENERAL
DESCRIPTION

CONTENTS
J 1 3J, ] 5 A N D J 1 6 E N G I N E S EM2 CANISHAFT EM-3
CYLINDEHBLOCK EIV].3 ROCKERSHAFT EM.4
CFANKSHAFT Etvt-3 VALVE I\4ECHANISI\4 EM4
PISTON A N D C O N N E C T I NRGO D . EM3 ]\4ANIFOLDS EM.4
CYLINDER NEAD EM.3

J 1 3 , t 1 5 A N DJ 1 6
, rrENGll{ES
.. . mechanism
r. O.tt.V.typ" valve
, , r De€pski , cast'ironcylinderblock
with cast.incylinders
. Csst-hon cylinder head including
bathtubtype combustion chambers
. Fully counterbalancedcrankhaft
jourMls
with 3 mainbearing exlaust manifold ls equippedwiti the
. 2-banel,downdraftcarburetorfor
thorough air-fuelmixing Sinceth€ Jls is a bored.outversion
of the J13, and the Jl6 is a length-
The exhaust manifold is of semi. ened.veion of the Jl5. The way in
for the bonnettype
dualconstruction which they are serviced is seldom
models.For caballtype models,the different except that some iechnical
datemustbe adjusted.

Enginemejordrtr

BngineModel Jl3 Jl5 J16

Diiplacement cc (cu in) | 299(19.3) (90.5)

1,483 (9s.6)
1,557
Bore x stroko mm (il) 73x7't.6(2.81x 3n6) 78x 71,6 (3.0'lx 3,06) 18x 82Qn1 x 3.23)
Ratio
Compression 8.2 8,3 8.3

Isnition timins
-
B-.T-D,C.
rPm 8o/600 8Y600 8o/600

EIM.2

Fig. EM-l Croessectionaloieo (J16 enEine'bonnettlpe nodeb)
CYLINDERBLOCK
The crankshaftis a fully counter
baianced,3.bearingtype desjgnedto
turn out smooth,dependable pow€r.
Wate! is forced through the wrter
jackeh to depdve the cylindersof
unwanted combustion h€at. The
engineidertificationmarks"T0i" for
the Jls and Jl6 and "B34" for the
J13 areembossed on the right rearol
ihe engineblock.
Fic. EM-2 Cllinder bloch
CRANKSHAFT
The cranLshaftis of sp€cialsteel
forginSwith 3 main bearingjournals.
To providebalance,4 counterOal-
ance)weightsarc providedjust op'
posite t}Ie crants. The main bearing
joumalsand connectingrod joumals
(crank pins) are case hardened and
linished to extreme smoothnessfor
Engine Mechanical
cylinder walls are lubricatedby oil
squirtedfiom the oil jets locatedat
the corn€ctingmd big erds.
Fig. DM-4 Pi|ton
JGF Il5,ll5
0
increased wear resistance.
The crank.
shaft has drilled passages through
which oil can flow to the mainbear-
ingsto lubricateandat the sametime
K o -
The centermain
to cool the bearings. Fig. EM"5 Connectingrod
beadng is equipped ivith thrust
washersto take up end thnst of the
crankshaft.
CYLII{DER HEAD
The cylinderh€adis madeof steel
casting. It contains baihtub type
combustlon chambers. A specialsinte!"
ed alloy valveseatis installedon the
€xhaustvalve.It is press-fiit€d.
FE. EM-3 Crdnkshaft
PISTON AND
CONNECTING ROD
EM-345
The pistonsaremadeof aluminum
Fig. EM-6 Cylin.t r hed.l
aloy casting.Itis Autothermictype to
assurcperfectroundness whenheated
to operatingtemperature. The piston
pin is a full floaling fit to th€ piston
CAMSHAFT
while it is pr€ssfitted to the con- The camshaftis of specialste€l
necting rod snall end. The connecting casting and is supportedby 3 rnain
rod is a specialsteelforging.On the bearings.The cam lobes are cas€
J13, the piston pin is bolted to tlle hardened and finished to extreme
snall end to preYentit from wo*ing $noothness for inu€asedwear resist-
out of place during operation.The
:.
EIM.3
 E n g i n eM e c h a n i c a l

springtype, innerand outer.Only for MAI{IFOLDS

the A321models,the valv€springis of
single type. The valve oil seal iing is Cast-i.onmanifolds are used 1o
carrythe exhaustgases awayfrom the
cylindersand to admit fie ai.fuel
mixture to the combustionchambe..
The exhaustmanifoldis of seni-dual
constructionfor bonnettype mod€ls
and is equippedwith a heat control
valvefor caballtype models.Theseare
Iig. EM-7 CdnshLft bolted to the cylinderheadwirh the
gasketsinse(ed in between.The €x-
haust pipe is flangemountedto the
ROCKERSHAFT
Fie. EM-g Voluemechanism
The rockershaftis madeofcarbon
steel: it is also case hardenedfor
jncreas€d dumbility.The valverocker
arms are lubricatedby leakrgeof oil
from th€ oil passagedriled in the
rockershaft.

Fur bonnerryfc nrodel!

EM349
Fig. EM-8 Ro.ker shoft a$embly

VALVEMECHANISM
The valve train consistsof the
camshaft,pulh rod, v?iverockerarm,
and valve; motion h transmitted
throughthesefour partsin rhe order
listed.Th€ valvespringis of doubie Fi!. EM la Exhaust& Ihtohe manifods

ENGINEDISASSEMBLY

CONTENTS
P B E L I M I N A RCYL E A N I N G
AND PISTON
A N D C O N N E CNTG B O D EN/t,7
I N S P E CI T
NG EN,45 C Y L I N D E RH E A D EM.7
D SASSEI/]BLY El/l-5 V A L V E R O C K E RA S S E M B L Y EM.7
i

Et\,14
 E n g i n eM e c h a n i c a l
PRELIMINARY rcmoveoil filter, useOil Filter Wrench
CLEAIING AND sT19320000.
I1{SPECTING
Before disassembling engine,note
the fo owing:
l. Fu€l, oil or water may leakpast
cylind€r head and block. Prior to
disassembling,check cylinder head,
front chain cover,oil pan afld oil {ilter
gasketsand crankshaftand water FE. EM-14 Re ovingboterpunp
pump sealsfor signsof leatagepast
theirgasketed surfaces.
11. Back off bolts securingcarnk.
2. Checkcarburetorand fuel pump
Fig.EM-l1 EnEineonenginestand shaftpulleyin position:removecrank.
for condition;fuelhosesfor deteriora-
shaftpuney.
tion, cracksor leakageof fuel pasi
thei(jointedor conflectedsurfaces. 4. Removefan andfan pulley.
3. Removeeir cleaner,alternator, 5. Disconnect carburetor ffom
distributorand starter,and plug up intakemanifold.
carburetor air-hom add distributor 6. Remov€boih intakeandexbaust
hole to prevent entry of foreign maf manifoldsiogetllerwith gaskets.
ter.
4. Wipedudtandmud offengine.
5. Inspectblock,rockercover,front
chaincover,oil panandall otherouter
partsfor vbualdefectsandbrokenor
missingparts suchasboltsandnuh. EM35A

6. Test all pipings and electrical crcnhpuller

circuih for discontinuityor brokenor
&msgedinsulation.
DISASSEMBI.Y
To removeengin€ from vehicle,
rcfer to relatedtopic under "Engine
Removaland Installation"in Chassis
and BodySe iceManual,SectionER.
l. Removetransrnisslon from enBine
completewith clutch.
2. Thoroucldy drain €n8in€oil and
coolantbyremoving bottomplugs.
3. In succession, r€movethe follow"
rn8pa|ls:
. Hightensioncables
. Sparkptugs
. Rightenginemouniingbracket
. Oil filter bracket and oil filter
. Oil pressureswitch
. Oil levelgause
. Fanbelt
After above st€pshave been com-
plet€d, attach Engine Attachment
5T05280000to dght sid€of engine.
With the useof an overheadhoist and
lifting cable, hoist engine up away
frorn the engin€ cari€r and place it
down in Engirc StandSm501S000.
The engineattachment is commonto
the J13, J15 and J16 €ngines.To
Fig. EM-12 Bemouingintake dnd
eth.utt manifolds
1 . Removefuel pump.
Iig. EM-L3 Reno\inq fuel PumP
8. Back off bolts and removeleft
handenginemountingbracket.
9. Back off bolts securingwater
outlet; removewater outlet and i}Ier'
10. Removelrater pump together
withSasket.
EiTS
Fi.. EM'16 Removine
12. Applying suitablewrench,un-
screwboits which hoid timing chain
coverin place;take off covertogether
with gasket.
13. Remov€timing chainlensioner.
14. Back off bolh which secure
camshaftgear to camshaft;remove
camshaftwasher.At the sametime,
iake out oil thrower on crankshaft
side.
15. Removecamshaftand crank-
shaft gea6 with cham hung around
gearteeth-It is good practiceto use
CrankshaftCear Pullef 5T16530000.
FA.EM-16 Fenouing timing chain

16. Renove camshaftand cranl-
shaftkeysfro k€y,ways in gea( (two
for crantshaftandone for camshaft).
17. Straightcntabsof lock wishers
andbackoffbolis sccuring flywheelto
flanse erd of crankshaflrcar. Fiy-
wheel can dren be take oul. Be
carefulrot to drop it- At thissiagcof
disrssembly, removeenginerearplaie
togetherwith gasket.
18. Back off bolts which hold
rocker cover 10 the to! of cylinder
head; renove rocker coyer together
with gaskerundercover.
19. Back off valve rocker shaft
brrcket bolls ard cylinderherd stud
nuts in two or threeprogressilc sleps
ard in sequenceshown.
Fig. EM-17 Rocher shdft btochel
boLtdnd.cyliidet hcdd
trut loosenihg sequence
10. Tlkc off valvc rocker shan !s
semblyftorr cylinder head.
2 1 . L i f t o u t p u s hr o d sf r o m h o l e si n
c y l i n d c rh c a d .
22. Lift cylinder herd strright up
away irom cngineblock togetherwilh
saskct undcr hcad. Every caution
shouldbe taken not to damagethreads
of stud bohswhile head is beinglilled.
Fig. EM tB RPnaling.!Lindet hedd
23- Invert engnreblock 180" so that
oil pan is facing u!; renove bolts
which secureoil lan to engineblock.
Remove oit pan togetherwith Basket.
E n g i n eM e c h ainc a l
24. Rernove oil pum! with oi1 can be reinslaled in their original
sirainerassemblyand oil pump drive
sljndle by backingoff bolis which
Fig. EM-21 Withtlrouingpiston and
cannectinqrod oseftblr
Fie. EM-19 R.mouine oiLpump ond
oilpump driuespitdle 30. Rlck off bolls lolding crank-
slnll beuing c!ps to engine block
saddlcs:scprr te crps ofi srddles !o"
g c l h e r w i L h t h n r s l w a s h e r sa n d b e a r -
2 5 . F r € e c a n l s h a f tl o c a f i r g p h t c ; n l g s .l l i s n c c c s s a r1yo u s c C r r n k s h N l t
withdraw crmshaft towLlrd thc lio l M r n r B c a r i n g( l a p I ' u l l c rS f i 6 5 l l 0 0 0
of engine.When renrovi|8 shrft. cxcr. w h e n r e m o v i n gc c n t e ra n d r c i r b c a r i r g
c i s e c a r e n o t ! o d L u n a g cc r s h x J l
bcarings as woll rs crnr lobes, rvhich
w o L r l dm r k e t h e m u f i i f o r f L r ( | c l
Fig. EM 22 Rehauing rnaih
Deonhg caP
31. Renovc crankshrfl ald mair
Fig. EM-2a Withdnung conlshoft
bearings.Makesureto placeihern in
corfecl o.der ir pats fack, so-that
they can be instatledin their original
16. Pull oui valvclifters from block.
:7. Renovc ffont plate by backnrg
offbolts seou|ingii to engineblock.
18. Rotate engin€ block on engine
standfor easyaccessto pistons_
29. Remove bolts which hold con
necting rod caps ifl placet separate
connecting rod caps iogether wirh
bedring hserts. Push con ecting rod
and piston assemblyout to! of cyl,
inder with lr bar or hmdle end of a
hanner. Avoid danaging piston .ings
wher removingpiston and connecring
rcd. Phce all disassenbledparis in
paft rack in corect order so that rhey FE. EM'23 Remouine.runk\haft
ENrt.6

PISTOI{ AND
OONI{ECTIIIGROD,
l. Removepiton ringsfrom around
piston using Pislon Ring Expander
EM03500000.
Note: Exercise caution in renovirg
piston rings. Excessiverpreadingof
rings wil cau3edarnsgeand render
them unJit for furthe( servicedile
to br€akageor relaxedtemion,
FE. EM-24 Renouins pistot ring
2. Removeplston pin with Piston
Pln Prers Stand ST13060000under
pr€ss(Jl5 andJ16).
(J15,Jl
sTl3060000
Fig. EM-26 Eenoving piltton pin
(J16 ontl J16)
Engine Mechanical
3. Using suitable wrench, back off
bolt secuiingpiston pin in place.Using:
Pision Pin PiessStand 5T13040000,
removepin underpress(Jl3).
FE. EM-27 Renouing ualve
EM365
fE. EM"26 Remoolng pirton pin
bolt (J13)
VALVE ROCXER ASSEMBLY
Withdrawcotterpinr from€achend
ol rockerslnfti removevalverocker,
Note: Be sure to place removedpins
valve rocker bra4ket and sprlng ln
in conect ord€r in pad rack so that
orderListed.Therearmodbracketll,s
they csn be r€install€din ihe same
a s€tgcrewwhichlecureSrockershaft
pbtoff from which lhey ve.e re-
ln plsceto preventit frofi worklng
loosedu ngoperaiion,
CYLINDER HEAD
Compress valvespringswith Valve
Ufter 5T12070000. Removerubber A
Ws N
rings, valve colleh, springrotainers, \@ \
valve springs,valve oil seal rings
EM36?
(option) and valver.Placermoved
parh in correctorderin partsrackso Fig, EM-28 Dkastembling rccher
that they can b€ ninstrlled in their 6oemblr
odginallocations.
El\4-7
 Engine Mechanical

AND REPAIR
INSPECTION

CONTENTS
PREPARATION FOR NSPECTION .,,,... Et1 I c y L N D E BB O RN G . . . . . . . . . . . . . . EM'16
C Y LN D - R - f ^ D A \ D V A V t EM-8 P I S T O NP,] S T O N
PN AND
H E A DI V A TN G
C H E C K L NCGY L ] N D E R p t S T O NR T N G S . EM-17
E M 8 C O N N E C TR TOND G. . . . . . . . . . . . . . . . . ENI-19
v A - v r -^ , v B lY . . . . . . . . . ... E M 8 CFANKSHAFT .,.... EIV].19
V A t v r - | r r . FA \ D D U S H qOD..... Etvt-I B U S H I NAGN D B E A R I N.G .............. - E|\,,1-21
VALVI SPPING E[/]- 9 MEASUBE]\4ENT OF CONNECT NG ROD
ROCKEFARIV]AND VALVE B E A R T NCGL E A R A N C. E . . . . . . .. Etvt_2l
R O .< E c o t v o T EM-10 MEASUFEMEN OT F I \ 4 A I NB E A RN G
V A IV E C U I D f E M1 O CLEARANCE . . EM'21
VALVI SIAT EM,]2 FlrrlNG BEABNG " ev-zz
CAMSHAFT AND CAMSHAFT M I S C E L L A N E OCUOSf u 1 P O N E N T S , . ., . . , EM.23
B | - A B T N C . . . .. . EM.]3 C B A N K S H A FSTP F O C K EATN D
(AVS*A_ BEAE.NC G- ^ C A \ ' E . , EIV].13 C A M S H A FSTP B O C K E, T .,, ,,,,,,, EM.23
VA-VF TI\,1INC EM.14 C H A I NA N D C H A I NT E N S I O N E. B , . , . EM.23
C A I I S H AIL A I I C\ V t N EM-14 F L Y W H E .E. L. . . . . . . . . . . .. . . . . . . . . . EM'23
C Y L I N D EBF- O C < , EM.15 F R O N TC O V E FO L S E A L. . . , , , , . , , , , EM'23
NOWTO N4EASU FE CYLINDER
EM.15

PREPARATIONFOR Headsurfaceflatn€ss
INSPECTION
L Bciorc clcaning,checkfor signs Maximumallowable
standrrd mm (in)
ofwaterandoit Leaks in cylinderblock limit nun(in)
andhead.
2. Clean o and cafton deposits Transversc
warpage on
gasket
0.r(0.0039) 0.2(0.00?9)
from all parts.Th€y shouldbe clcan lhce
contacting
fromgaskero! sealant.
3. Cleana[ oil holeswith solvent Surface
Brindinglimii 1.5(0.0s9r)
ard dry with compressed air. Make
surethri lh€y arenot resiricted.

Surfacegrindinglirnit
CYLINDERHEAD The grindinglimit of cylinderhead
AND VALVE is availableby the cylinder block
grindingin an engine..
CHECKINGCYLINDERHEAD Depth of cylinderheadgrindingis
MATINGFACE
1. Make a visual checkfor cracks Depth of cylinder block grinding is

2- Measuretnc surfaceof cylinder Thelimit is fo owing;

head (on cylinder block side) for A+B= 2.0 mm (0.0784in)
waryage.If it is found to be beyond
the limit designated
below,regrindthe VALVE ASSEMBLY
affectedsurface grinder.
with a surface
Fig. EM 29 Checkikecrlinder h.dd
suta.e 1. Check each iniake and exhaust
EMA
 Engine Mechanical

valve for worn, darnagedor deformed VALVELIFTER AND

valvecap3or stems.Conector replace PUSH ROD

2. Valve face or valve ltem end Valve lilter

surfaceshouldbe refacedby usinga
valve8rinder. Check valve lifiers for excessive
Fig. EM30 Intahe and erhawt ualue wear on the face that contactswitl
cam lobe.The end that contactspush
rod shouldalso be smootl. Replace
Unit: mn (in) with new onesif wom beyondrepai..
Corroci valve lifter to lifter hole
34.8to 35.0
In. clearanceis 0.016 to 0.052 mm
(1.370to 1.378)
(0.0006to 0.0020in).
J13
299 to 30.1
Ex,
( 1 . 1 7t7o 1 . 1 8 5 )
valve head Pu3h rod
37.8to 38.0
In, l lnspect push rod tbr excessive
(1.488to 1.496)
wear on the face that contactswith
J16 valverockerbal end Gphericalface).
31.9to 32.1
The facethat contaclswith valvelifter
(1.2s6ro 1.264)
shouldalsobe smooth,replacing those
wom or damaged beyondrepair.
109.35to 109.65
In. 2. Checkpushrod for bendor twist
(4.30s1to 4.3169)
lvith a dial gaugeor on a surfaceplat€.
J13
to 10835
108.55
L Valvelength (42736to 4.28s4)

J15 In.& to 109.6s Unit: mrn(in)

109,35
Jt6 (4.30s1
to 4.3169)

Valvestem 8.680to 8.693

D In & Ex' (0 341'7to 0,3422')
diam€ter
0.2(0.00?9)
valveceatangle ln. & Ex. 45030'

Grinding allowance for the !"lve

sten €ndsurfac€is0.5 mm (0.0197
in) or les,
VALVESPR]NG
L Checkvalvespringfor squareness
usinga steeisquareandsurtac€plate.
If slring is out ofsquare"S" in Figure
8M.33 beyondspeciliedlimit, replace

Fig.EM 31 Medsuring
stemdbmeter

Note: Wh€nvalveheadhasb€enworn
down to 0.s mn (0.0197in) in
thickn€ss,replacethe valv€. FE. EM.32 Reetinding DstDefdce

Ell,l€
l' Engine Mechanical
I Valre sprin$Aecifi cations
A32l
J13,J15andJl6 J 1 3a n d J l 5
Valvespringlengtn Double
sprhgtrT,€ Singlespringtype
Outer nm (in) s2(2.U7)
Inner mm(in) s0(1.969)
47.r(r.8s4)
Valvespringpressedlength (valveopen)
Outer 'nm/ks(in/lb) 30.7 .8(r .2091l0s)
147
Inner mrn/ks(in/b) 30.'tl7o.6(t .2o91156)
(\.r30l4't)
28.712r.3
Valvespringassembled
height (r"tve ctose)
Orter rnm/ks(in/lb) .0(1.s3t164)
38.9129
lnner run/kg (in,{b) (1.0t6/?8)
38.9/3s.4
(t.453129)
36.9113.1
("S")
Outof square
Outer ftn (in) r.6(0.063)
Innor rnrn(in) 1.6(0.063)
1.2(0.047)

2. Measur€froe length and teNion
of eachspring.lf the messured value
€xceedsthe specified llrdt, replace
spdng.
lwiih pushrodshouldalsobe inspected
placing those worn or damaged
beyond llfiits. Correct oil clearance
betweenrockorarln and rocker ghaftis
0Ol io 0.05 mm (00004 ro 0,0020
m).
2. Check rocker arm for wear or
damageto the endthat contactswith
valvestemend.The facethat contacts
for roughness,Replaceil wom of
damaged beyondrepat.
the worn parieor both valveandvalve
guide.
In this case,it is esseniial
to doier.
nine if such s clearancehas been
cauledby e wom or bentvalvestemor
by a worn valveguide.

-rtffi VALVEGUIDE
rig. EM-38 M.aludns sprw M€asureclearoncebetwoenvalve
EM36A
guide and valve!tem. If iie cleaonc€
Fig. EM.35 Intdke andexhoust uatue
exce€dsihe designaied limit, r€place
Euidedi,ne6iot,, ( for Sevice)

Valveguidedinensions(for Seryice)
Unit: ftn (in)

Valveguide 7.6to 7.A

Dr In. & Ex.
(0.299to 0.30?)
Fig. EM-34 Medsving spring t.tuio4
Valveguide 14.313to 14326
D2 In.& Ex.
outer diam€ter (0.s63sto 0.s640)
ROCKERARIII AI{D
VA.LVEROGKERPIVOT In. 47.6(r.874)
Valvesuide
L
l. Checkrockerarmfor signofwear length
oi damageto rocker slnft hole, r€. Ex. s6nQ.20s)
Et\4-10
 Engine Mechanical

- €mergencyexpedient, push (0.003ein). Max.alowabtedeflecxon

i valve guide and move to the
he right. If its tip deflects
0, mm (0.0079in) or more,
&drace betw€enstem and guide
tle maximumlimit of 0.1 mm
0.2nn (0.0079in)
Note: Valve should be moved in 3 0n m ( 1 . 1 8 1 i n )
paralel with rocker arn. (Gen€tal-
ly, a largeamountof w€aroccus in
this ditection..)

Fie- EM-36 Measutinq cledra\ce

betueen odluestem
an l vahreguide

E* luide s?ecilicstions

Intake Exhaust Wearlimit

14.2811o14.300
valve guidehole diameter mm (in)
(0.5622
to 0.5630)

Cuideto suidehole 0.013to 0.045

nrmllni
(0.000sto 0.0018)

Valvequideinner 8.732to 8.745 8.144$8.751

.. : mmtrn,
(0.3438to 0.3443) (0.3443to 0.3448)

Valvestemouter 8.680
to 8.693
.- mmttn,
(0,3411roO.3422)

0.039to 0.065 0.051to 0.077

Guideto stemclearance mm (in) 0.r0(0.0039)
(0.0015to 0.0026) (0.0020ro 0.0030)

R.pl.cem.nt of valva gulde 2. New guidesshouldbe installedto

t. To remov€old guides,usea drift
and drive them out of combustion
chamber sid€ toward rocker cover.
Heating cylinder head wil facilitate
Fig. EM-37 Drioing elue Ei.i.te
ort frcm crlintler heod
proper depth and ream€dto size of
nomal room temperatures. Standard (0.610!o0.626in)
diamet€!of hole io which guideis
fitted is 14281to 14.300mm (0.5622
ro 0.5630in).
3. Wheninstaling new guideswith
an arborpress,it is recommended to
heat cylioder head to about 80oC
(176oF).Then,pressthem into place
in valveguide holes from rocker cover
side. Guides must be installed to
proper depth so tlat height abov€
valvespring$at is 15.5to 15.9mm FA- EM-38 l@taUtne ualueSuide
(0.6t 0 to 0 .626in) asshownin Figure
EM-38. Int€rfer€nce between valve
guide and guide hole should be held
witlin 0.013to 0.045lnm (0.0005to
0O018in). 4. Ream the bore with valveSuide
pressedin, using Valve Guide Reamer
HTs6900870.
EIIIl
 EngineMechanical

Valveguideinner diam€ter
Unitl lnm (in) -! dia.

4.-"...s"
8]32 to 8.145
(0.3438to 0.3443)

8.744to 8.75'7
l"tC rios"
ls"
(0.3443to 0.34a3)
I'
Unit: mm(ir)
J13 J l 5 ,J l 6
tT569008?0
Intak€ A 40 (1.575) 40(r.s75)
B 34.5(1.358) 37.5(t.4'76t
C 32.2(t .268) 35.2(1.386)
0,2 to 0.4 0.2to 0.4
D (0.0079to 0.0157)
(0.0079 io 0.01s7)

Exhaust 32.s(r.280) 3 5( 1 . 3 7 8 )
B 29.4(1.t57) 31.6(1.244\
EM37] c 26.8(l.os5) 29.0(1.t42)
1 . 0t o 1 . 2 O.2to 0.4
FE. EM-39 Redninc uolvesuAe D (0.0079
(0.0394 to 0.0472) to 0.0157)

5. Correct valv€ seat surfacewilh
newvaiveguideasthe axis.
VALVE SEAT
when a valveseatis badlydamaged
or wom excessiv€ly to a poini wher€
pmper valvefunction is impaked,ii
nust be refac€dwith Valve Seat
CoutterST11600001. Valveseatinsert
of 0.5 mm (0.0197 in) oversizeis
availablefor service exhaustvalve.
in
Rogrlnding v.lve seatt
l- Wh€nvalveseat is found to be
wide b€yondspecificarions,
ir should
grinding
b€ narrowedwith a 45.d€gr€e
2. Width of valveseats,\ouldthen
be adjusted10 1.6 to 1.7 mm (0.053
to 0.067 in) by making upper and
lower cutsasshownin FigureEM42-
To do this, use a ls-degre€grinding
EM375
Fig. EM-41 Voloe sedt dime$io@
3. Apply snal amountoffine grind-
ing compoundto valvecontacting face
and put valveinto guide.Lap valve
aga,rst its seat until propei valve
seatingis obrained.Removevalveand
thencleanvalveandvalveseat.
Repleclng valvo Beal In.ort
1. Old in$it can be removedby
boring out until it collapses.The
machinedepth stop shouldbe s€t so
that boring cannotcontinuebeyond
the bottom fac€of the ins€rtrecess
in

ooo
cylinderhead.
2. Selecla suitablevalveseatinsert
sT1600001 andcheckits outsidediameter.
3. Machinecylinderh€ad recessto
ihe concentriccirclesof valveguide

x x o
c€nter so that insert will have th€

4. Reamthe cylinderheadrecess
at

Fig. EM40 value seot contactinq FE. EM42 Cti4ding uolue6eat 5. Pressins€rte$uring that it beds
face uith Srin lina cutter on the bottomfaceofits recess.
-12
Et\r
 Engine Mechanical

- 6. Valve seatsnewly fitted shouldbe 7. Lap valveagainstits seat,follow- CAMSHAFT AND

cut or ground at the specilieddirnen-
sionsasshownin Figur€8M41.
32,5?0ro 32.580
( 1 , 2 8 2t o 1 . 2 8 1 )d i a ,
2 6 . 8( r . 0 s 5 d
) ia.
Fie. EM.43 Standordethouttalue seat.lim2 rcn'
Cylirder herd r€c$s diametd
ingabovernentioned
procedure. CAMSHAFT BEARING
CAMSHAFT BEARING
35.0?0to 35,080 GLEARAI{CE
( 1 . 1 8 0t o 1 . 1 8 1 d
) ia.
Joumaldiameters shouldbe check-
ed with a micrometerand bearings
with an inside dial gauge.Measure-
ments should then be compared to
determinewhether bearlngsare worn.
29 (r.1,42tdi^, If found worn beyond 0.18 mm
(0.00?in), replacewith new ones.ln
.Ir5,J16 pr€ss-fittinga new bearing, make
certain that oil holes in block and
bearingareproperlyaligned.
: Unit: mm (in)

J13 J l 5 a n dJ l 6

32.500to 32.516 35.000to 35.016

For standard
insert
(l,2195ro 1,2802)(1.3780
to L3786)
Exhaust
For servic€
insert
33.00to 33.016 35.500 to 35.516
(1.2992to r.2998)(1.3976
to 1,3983)

fit nrn (in) I Exhaust| 0.054to 0.080(0.0021

Interference to 0.0031)

Crmshaftjournrl to beedngcleannct Unitr mm (in)

Frcnt Cenier Rear

journaldiameter 45.434to 45.447 43.891to 43.910 4l .218to 4l .231

Camshaft (1.?887 (r .7282to 1.7287) (1.6228to | .6233)
to 1.7892)

45.474 to 4s.484 43.948to 43.961 4l .257to 4l,267

Bearlnginnerdiameter (1,6243to | .6247)
(r ,7903to 1,1901) (1.7302to 1.7307)

0.027to 0.050 0.038to 0.064 0.026to 0.049

Beadngclearance (0.0015 (0.0010
(0.0011to 0.0020) to 0.0025) to 0.0019)

Bearingclearancelimlt 0.18(0.007r)

Camshaftjoumal to beirlng sp€cifications Unit: mm (in)

Beadng Camshaftjournal
Size Bearingthickness
position outer diameter

1 . 5 ?t o l 5 9 45.43to 45.45
Standard (0.0618to 0.0625) (1.7886to 1.7894)

o.25 1.69to l.?l 45.tab 45.20

(0.0098) (0.0665to 0.0673) (I ;7787to 1.779s)
Front
0.s0 1.82to I .84 44.93to 4495
Under size (o.o7r'7to 0.0724) (r.7689to 1.7697)
(0.0197)

o.75 l.94Io 1.96 44.6ato 44.70

(0o295) 64 ro O.0'7'72)
<O.O'7 (1.7s91
to 1.?s98)

EM-I3
 EngiineMechanical

Bearing Bearingthickness Camshaftj oumal

Size
position

1.57to 1.59 43.89to 43.91

St ndard (0.0618to 0.0626) (r ;1279to 1.128'7)

o.25 1.59to 1.71 43.64to 43.66

(0.0098) (0.0665to 006?3) ( 1 . 7 1 8 111.o7 1 8 9 )
Center
0.50 1.82to 1.84 43.39to 43.41
Und€rsize (1.7083to l.?091)
(0o197) (O.0117
roO.0724)

0.75 L94to 196 43.14to 43.16

(0o29s) (o.o764ro 0.0112) (1.6984to 1.@92)

1.57to 1.59 41.21to 41.23

Standard (0.0618to 0.0626) (t .6224to 1.6232)

0,25 L69to 1.?1 40.96to 40.98

(0.0098) (0.0665
to 0.0673) (1,6126
to 1.6134)
Rear
0.50 1,82to I .84 40,7| to 40.73
Under size (0.0197) (O.O117 (1.6028io 1.6035)
to 0.0724)

0.75 1.84to 1.96 40.46to 40.48

(0.0295) (0.0754to 0.0772) (1.s929to 1.s937)

VALVErl ll{G 3. Csmsh{ftendplay canbe check.

ed by lnstalllng camshaft, camshaft
This diagramwtll apply to a[ cyl. locatlng plate and cam$aft gear in
ind€rs,If any valveis found beyond their respectiveposiiions.Bnd play
speclfl@tiom,one possibilitylr that will thenbe indicatedwlth a dialgauge
cam lobe is worn or damag€dexc$- or a feelergaugB. If end play €xceeds
sively,calling for replacementof cam.
0.35mm (0.0138in), replacelocatinS
shaft. plate.

Fig. EM-44 VolveE ning dia$sm

& b d f

Jl3 244 244 t4 50 t2 52

J 1 5J, l 6 252 252 18 54 16 56

FE.EM46 Me6uing .omthoft end

CAMSHAFT ALIGI{MENT
1. Checkcamshaft,camshdtjournal
and cafi surfac€ for bend, wear or
damage.If ilefects are beyond limits,
replaceaffectedpafts.
2. A bent valve is one-half of the
reading obtain€d when camshaft is
tumed one tull revolution witll a dial
joumat.
gaugeapp&q(a th! .c,e!t-el Fig. EM45 Measurine .amshaft betd
Etv.14
 E n g i n eM e c h a n i c a l

Canshaft specificatioB

Standard

Canshaftbend nm (in) Lessthan0.03(0.0012) 0.05(0.oo2o)

J13 37.60lo37.70(1.4803
to 1.4842) 37.40(.1.4724\
Camshaftlobe hcight mn (in)
J15
3?.605io 37.650(1.4805
ro 1.4823) 37.3s(l.470s)
Jl6

endplay
Camshaft mm (in) 0.05to 0.29(0.0020
to 0.0114) 0.3s(0.0138)

CYLINDER BLOCK HOW IO MEASURE

CYLINDERBORE
1. Check flatnessof block gasket
surfacewith a straightedge and a A bore gaugc is used. Measure
feelergaugert lwo diagonaland five cylinder borc ri top, middlc and
positions.
longirudinal bottom positionstoward A rnd B
2. Plac€ ihe straigh! edse alons dnectionsas shorvnin FigureEM-49
diagonallinesof block planeand the ondrccordlhe measuredvalues.
longihrde,and inspectfor levelusinga
feelergauge.
Fig. EM-48 Measurihgcttin.ler bote

3. Usinga bore gauge,measure cyl-

Surface Lessthan inderborefor out.of-round
or tAper.lf
flatness 0.05 oufof'round or tap€r is cxcessive,
mm (in) (0.0020) r€borethc cylindcrwallsby melnsof
a boringmachine.Measurement should
be t ken along bores for iaper and
Surfacegrindinglinit around bores fof out.of'round.S€c
The grindinglimit ofcylinderblock FigureEM-49.
is availableby thecylinderh€adgrind-
ing in an cngine. Outof-round X.Y
Taper A-B
Depth of cylinderheadglindingis
U n i r :$ D ( i n )
4. Wl1enwear,trper or oui ot-round
Depihof cylindefblockSfindinsis is minor andwithin the limit, removc
"B"
the stcp at th€ topmostportion of
Thelinit is: cylinderusinga ridgereameror other
A+B=2.0inn(0.0784in) Fig. EM-49 Cllinler borc measwing
similartool. po$non3

Fie. EM-47 Chechinecrlindet bloch

Bytace
Et\,1-15
 E n g i n eM e c h a n i c a l

Cylinderbore sp€cifications

Standard

J13 J 1 5J, l 6

73.000io 73.050 77.950to 78.000

Innerdiameter
(2.8'740to 2.8760) (3.0689to 3.0709)
0.r5(0.005e)
Cyljnderbore
nm (in) Oufol-round 0.020(0.0008)

Taper 0.02(0.0008)
0.1(0.0039)
Diilerencecylinder
borebetw€encylindcrs mm (in) 0.02(0.0008)

CYLINDERBORING
L Whenany cylinderneedsboring, cording to the amount of wear of
all othercylindersmust alsobe bored 2. Detemine piston ovenize ac- cylinder.

pistonsspecifi
Ovelsize cations Unit: mm(in)

Jl3 Jl5,Jt6

Siandardsize 72.987lo 73.037

(2.8735to 1.8755) 77.935to 77.98s(3.0683
to 3.0703)

0.50(0.0r97) 73.467to 73.5L7 ().8924to I 8944) 78.415to 78.465(3.0872!o 3.0892)

Ov€rsiz€ .00(0.0394) 13.961ro 14.011(.2.9t21 ta 2.9140) 78.91s (3.1069

to 78.s65 to 3.1089)

1.s0(0.0s91) 74.461 (.2.9315

ro 74.517 to29337) 79.41sto 79.465(3.1266to 3.1285)

3. The sizeto which cylindcrsmust Note: To prevenistrah dueto cutting

be honedis determinedby adding1o heat,borethe cylindersin the oder
the laryestpistondiameier(at piston of 2-41-3.
skit in thrust directjon) piston-to-
9tt
a b o u t2 0 n m ( 0 . 7 8 7 4i n )
4. Do not cut too much out of
cylinderbore at one time. Cut 0.05
mm (0.0020in) or soai a time.
5. Measurementof cylinder boro
just machjn€d requires
the utmostcare
FiC.DM 51 MeosutihApbton Ekirt sinceit is expanded
by cuttingheat.
didneter 6. As a final sre!, cylindersshould
Reboredsizecalculation
D= -{ + B C = A + [ 0 - 0 0 5r o 0 . 0 2 5 7. Measure the finished cylinder
ffm (0.0002 to 0.0010 in)l borefor out-otuoundor taperedpart.
8. Measur€pistonto cylinderclear'
D: Honed diameier
Ar Skirt diametefasmeasured This cleamncecan be checked
B: Piston to-wxll clearance easilyby usinga feelerSaugeand a
C: Machinins alowanc€ [0.02 sping balancehookedon feelergauge,
Fig. EM-'0 Measutingpxton d.idtueter !m (0.0008 in)l measuringthe arnountof forcerequi!-
Efu'I.16
 E n g i n eM e c h a ni c a l

ed to pull oui gaugefrom beiween Note: ff cylinder bor€ h3s wom

pistonandcylinder. beyond the wear limit, us€{ylind€r
liner.
Undersizecylinderlinersare avail-
a. When measudg the clearanc€, able.
slowly pul the feelergaugestraight Interferenc€fit of cylind€r liner in
cylind€r block should be 0.08 to
that pislonand I
b. It is recommended 0.09mm (0.0031to 0.0035in).
cylinderbe heatedto 20oC(68oF).

Fig. EM 52 MedsurinEpiston fit

I
in cYlinder

JI5,Jt6

0.023to 0.043 0.025to 0.045

mn (in) (0.0009to 0.0017) (0.0010to 0.0018)

Fe€lerBauge
0.04(0.0016)
mm (in)

Exlractingforc€
kc0b) 0.s1o1.5(1.1to 3.3)

Cylind€rliner for service Unir: mm('n)

Jl3 J1 5 J, l 6

Oursid€diamete! Inncrdiame!€r Ouhidediameter

'77 ta 77.Os
4.0(0.ts7s) .OO 8L95 to 82.00
Undersizc (3.031sio 3.0335) (3.2254\o 3.2283)
'12.45 'l'l.45to'77.55
4.5(0.1772') 17.soto 1'1.SS to72.55 82.45to 82.50
Undersize (3.0512to 3.0531) (2.8524
to 2.8s63) (3.2461to 3.2480) (3.0492 to 3.0s31)

5.0(0.r969) 78.00to 78-05 82.95ro 83.00

Undersize (3.0709to 3.0728) (3.265'7
ta 3.2677)

Ring should be placed !o diamerer

PtsToN, P|STON P|NS at upper or lower limit of ring travel.

AND PISTON RII{GS

1. Removecarbonfrom pistonand
ling grooveswith a carbonscraperand
a curvedsteelwire. The wire will be
usefulin cleaning bottom landof ring
groove.Cleanout oil slotsin bottom
landof oil rins groove.
2. Checkfor damage,scratches and Fig. EM-5s Me$uriag ptston ring
wear. Replaceif such a defect is sitl. .ledtunce
detected-
3. Measur€the side clearanceof 4. Push ring inlo cylinder with a
rings in rhg groovesas each ring is piston so as ro place it squarely in
installed.Clearance with new pistons cylinder; measure ring gap with a
andringsshouldbe a!fo]1ows. feelergauge. FiC- EM-s! Meosuring ing Eop
E[/],17
 Engine Mechanical
Sidecleamnc€ Unit: rnm(in)
Notes:
a. l{hen piston dng obly is to be Standard
replnced, without cylindg bore Wearlimit
beitrg corr€cted,m€asurethe gapat Jl3, J15andJ16
th€ bottom of cytnder where the
Top dng 0.036to 0.076(0.0014to 0.030)
Properdng fit in ring grooYeis very 0.r (0.0039)
important for propet performance Secondring 0.036to 0.076(0.0014to0.030)
and long life. A sticky ring ca$es
blow"by ot oil.up, iesulting in
prenature wear on ring and cyl- Ring gap Unit: mm (in)
inder wall. ff it is too loose, this
acceleratB w€ar on sid€s of ring Standard
grooveto aggramt€ring play. Wearlimit
b. Oversizepiiton rings are available. J13 J l 5 ,J t 6
[0.5 mn (0,0197 in), 10 nn
(00394 in) orcruizel, 0.20to 0.33 0.20to 0.35
Top rlng
(0.0079xo0.0130)(0.00?9
to 0.0138)

0.20to 0.33 0.14to 0.29

dng
Second
(0.0079 1.0(0.0394)
to 0.0130)(0.0055to 0.01l4)

Oil ring
0.30to 0.90 0.3to 0.9
(0.0118io 0.0354)(0.0118
to 0.0354)

Ov€$izeplstonringout€ralitmeter Unit: mrn(in)

---------.-.'.--
113 Jl5,J15.

St.ndard 13.00(2.8740) 1't.95 (3.0689)

0.50(0,0197) 73.sO(2.8937) 78.4s(3.0886)

Over
size
1O0(0.0394) 14.00Q.9t34) (3.1083)
78.9s
1.s0(0.0591) 74.s0(2,933r) 19,4s(3.1279)

Fig"8M"66 Pitton pin fltti^e

5. Measurepiston pin hole in rela" 6. Determinethe fitting ol piston

tion to the out€r diameterof pin. lf
wear exceedstlle limit, replacepiston
pin tog€therwith piston on which it is
insta ed.
pin into piston pin hole to such an
€xtent that it canbe {inger press€dat
room temperature. This piston pill
must be a tight pr€ss fit into con-
n€ctingrod.
FiC. EM-56 Measwing piston pin
diametet

Etll,18
 Engine Mechanical

Unit: mm (in)

J13 J 1 5 J, l 6

Pistonpin outsidediameter 17.44'7to I7 .452(0.6869to O.6811) 20.993to 20.998(0.826sto 0.8267)

Pistonpin hole diameter 17.453 (0.68?lto 0.6874)

to 1?.460 21.001 (0.8268
ro21.008 to 0.82?1)

Pistonpjn to pistonclearance 0.001to 0.013(0.00004

to 0.000s) 0.003to 0O15(0.00012to 0.00059)

fit of piston
Interference 0.01sto 0O33(0.000s9
to 0.00130)
Bolt clamp
pin to connectingrod

CONNECTINGROD
J l 3 ,J l 5 a n dJ 1 6 Maximum
l. If a connecting rod hasany flaw
on bolh sidesof the thust faceand Connecting rod bend
it.
the largeend,corrector replace or torsion(per I 00
0.03(0o012) 0.1(0.0039)
mm or 3.94in length)
mm (in)

Connecling
rod big 0.20to 0.3
0.5(0o197)
endplay mm (in) (0.0079
to 0.0118)

EM133
Fig. EM67 Chechingrcd otign ent
2. Checkconnecting rod for bendor
torsion usingconnectingrod aligner.If
bend or torsion exceodsthe limit,
3. When replacingconnectigrod,
s€l€ct rod so that weiSht differ€nce
betwe€nnew and old onesis within 6
sr (0.2116oz),
4. lnstallconnectilgrodswit]bear"
ings on to conespondingcrnnk Pins
and measurcthe thrust clearance.If
the measuiedvalue€xceeds the limit,
replaceconnectingrod.
CRAI{KSHAFT
s
L Whenevercrarlshaft is remov€d J 1 3 J, l 5 3 8 . 8( 1 , 5 2 8 )
from engine, thor'
it shouldbe cleaned 41.00.646)
oughly in a suitablesolvent.Afier
cleaning,checkcrankshaft joumaland
crank pin for score,bias wear or 41.640to 41,652 dia.
( 1 . 8 7 5t6o 1 . 8 7 6 1 )
cracks.Repairor replaceas required,
If defectssre mjnor, dresswith fine 50.813to 50.825dia
crocuscloth, .0005102.0010)
2. Checkwith micrometerjournals
and crank pins for taperand outof'
mund. Measurement shouldbe talen
along joumals for taper and around
journalsfor out-of-round.SeeFigure
EM-59for detailedinformation.

Out-of-round x-Y 3 4( 1 . 3 3 9 )
Taper A.B
t 8 . 7( 0 , ? 3 6 2 )

/n tr-l
\l7I{
Fig.EM-59 Croftshdft andiourtul
.lime6ion

Ifjournalsor crankpinsaretapered
or out-of-roundbeyondlirnits;repiace

EM.lS

Fig- EM-60 MeasutiaCjou dl diometpr
3. Crankshafican
bend by piacingit
J 1 3 ,J l 5 a n dJ l 6
Taperandourof"round
ofjorunalandcrankpin
0.01(0.0004)
mm (in)
JI 3 ,J 1 5
Crankshaft
bend
(in)
mm
Noter When measurinS bend, us€ a
djal gauge.Bendvalueishaf ofthe
readingobtainedwhencrankshaft is
turned one full revolutionwith a
dinl guageattahcedto its center
journal.
4. After regrinding crankshaft,finish
it to the necessary
sizeindicaiedin dre
list on pag€EM-21by ushg an ade-
quate undersizebearingaccordingto
theextentof requiredrcpair.
5- After grindingjournalsor crank-
pins,crankshaftshouldbe checked for
end play-This canbe doneby instail.
ing shaft in engineblock with main
bearingsand bearingcapstorquedto
10 to l1 kg'rn (72 to 80 fi-lb).
Wilhout disiurbingabovesetting,bar
Crankshaftfreeend 0.05to 0.20
play mrn(in) (0.0020to 0.0079)
E n g i n eN 4 e c h a n i c a l
using a dial gaugewith its indicating
finser rcstingon centerjoumal.
Fig. EM 61 Chechingctunhshaftbend
Maximum
0.01(0.00r2)
Standard
0.0s(0.0020)
cranksluftas far €ndwiscas posiblc
and inserta feelcrgaugein cleanncc
bctwe€nbiock and centerrnainbear-
'nc.
Fig. EM 62 Chechinscrcnhshaftend
0 . 3( 0 . 0 1 r 8 )
Er\,1-20
If end play exceedsseflice limits
above, replace thrusi washerswith
thosethat give propercranlshafiend
ptav.
Thrusrwasherthickness
(upperandlowet mm (in)
2.235Ia 2.286
(0.0880to 0.0900)
2.286ro 2.337
(0.0900to 0.0920)
:.337to 2.388
(0.09:0 to 0.09210)
2.388io 2.438
(0.0940ro 0.0960)
6. At the rear end of crankshaft,
check crankshaft pilot bushing for
w c x r o r d a n a g e .R e p l a c ei t i l d c f c c ti s
To replace crnnkshaft rear pilot
b u s h i n g! r o c e e da si o L l o w s l
(l) PulL out bushins usins Pild
B u s h i n gP u l l € rS T l 6 6 l 0 0 0 l .
\ r'uuronn'
Fis. EM-63 Pulling out pilot
bwhing
(2) Before installing a new bushing,
rhoroughly clean bushing holc. Press
fit bushing so thai its heisht above
tlangecnd js 8.0 to 8.3 mn (0.315 to
0 - 3 2 7i n ) . D o n o t o i l b u s h i n g .
( 0 . 3 1 t o0 , 3 3i n )
Fig, EM-61 Presefitting netupilot
bwhirg
 E n g i n eM e c h a n i c a l

BUSt{t]{c Al{D w€ar,scorssor pitting,replacing

those (3) Loosen bolts securingcap in
BEARIl{G foundbeyondmaximu,nlinits. place.Compareflatlenedwidth with a
MEASUREMENT OF 2. Measurecleamncebetweencon- specialscalesuppliedwith the plas-
CON}IECTING ROD BEARING nectins rod journal and bearinsto ti8aseenvelope. If difference
between
CLEARANCE deternine jf it is within specified maximumand mirimun width in a
1. Checkconnecting
rodbearing
for limits. strip exce€ds 0.03 lnm (0.0012in), it
is an indicationlhal journal is wom
locally,callingfor furtherse.vice.
Brrring oil clearsnce Noter Do not tum crankshaftwith
plastigage
installed.
Maximurn
3. If measurement revealsthat oil
Connecting rod
0.011lo 0.052 clearanceexceeds0.10 mm (0.0039
ciearance(bigend) 0.10(0.0039)
(0.0004to 0.0020) in). usecorreclundersiz€
bearing.
mln (in)

To measureclearance,proceedas (2) Placea sirip ofplastisase lensth-

folows: wise on journal. Instal bearingon
(1) Before measuring,journah and joumal and right€nto 2.5 to 3,5 kg.m
bearingsshouldbe wiped cleanof oil (18to 25 frlb).

Connecting andjoumalspecifications
rod bearing
Unitr mm(in)

rodjoumal
Connecling
Bearing
rhickness
outerdianreter(crsnkpin)

L83 ro l 84 4l.64 ro4'7.65

Standard
(0.0720lo0.0724) (l.8756to 1.8?60)

0.08 1.8610L87 47.58to 41.59

(0.0031) (0.0732to 0.0736) (1.8732
to 1.8736)
0.l2 t.89 to l 90 4'7.51ro 4'7.53
(0.0047) (0.0744to 0.0748) ( 1 . 8 7 0 9 1Lo8 7 1 3 )

0.25 1.95to l.9a) 47.40ro1'7.41

(0.0098) (0.0768to 0.0772) (1.8661
!o 1.866s)
Undersize
0.50 2.08to 2.09 4'7.t4ra4'7.ts
(0.0197) (0.0819to 0.0823) ( l . 8 5 5r9o 1 . 8 5 6 3 )

0.75 2.2410o2.2r 46.90to 46.91

(0.0295) (0.0866to 0.0870) (l.8465to 1.8468)

1.00 2.33to 2.14 216.64to 46.65

(0.0394) (0.0917to 0.0921) ( 1 . 8 3 6 2r o 1 . 8 3 6 6 )

Note: Since bearinssare of precision
insert type, it is not necessaryto
file bearingcapsor to gdnd b€aring
surfac€swith an emery cloih to
conect b€aringclearance.
MEASUREMENTOF MAIN
BEARINGCLEARANCE
Thoroughly clean all beatings.
Check for scratches.
r€phcing those found beyond limits.

Etv-2l
 Engine M echanical

Bearingoil clearance Whennew bearingsare us€d,bear-

ins fit, or mor€ specifically,
oil clear-
anceshouldalwaysbe inspected. If if
exceeds0.10 mm (0.0039in) (maxi-
Main b€aring cl€arance 0.02to 0.05 mun), corr€ct undersize bearings
0.10(0.0039) shouldbe selected or journalsshould
mm (m) (0.0008to 0.0020i
be groundto fit next unde.size bear'
proceedasfollows:
To measureoil clearance, mgs.

1. Crankshaftjournalsand bearings Note Do not turn crankshaftwhile Note: Sincebearingsare of pr€cision

shouldbe wipedcleanof oil andalty plastigageis install€d. insert type, it is not n€cessaryto
oaherforeign materialssuch as dust file bea.ingcapsor to grind bearing
and dirt beforethey canbe neasu.ed surfa€€swith an em€ry cloth to
conectb€aringclearanc€.
2. Use plastigage, placingit length-
wise on joumal. lnstal bearingand
bearingcapin positionandtightento
10 to 11 kg.m(72 ro 80 ftlb) t€nsio..
3. Removecap and measurewidth
of plastigageflattenedby comparing
with a specialscal€print€d on plas. Fig.8M.65 Measwingmdin beoring
tigageenvelope,

Main bearingandjoumal specifications Unir: mm(in)

j ournaI
Crankshaft
Bcaringthickncss

1.822
to 1.83s 50.81
to 50.82
Standard (2.000
(0.o711roO.o722, to 2.001)

L947to 1.960 50.57to 50.59

0.25(000e8) (O.O'767
ta O.O7
72) ( l . 9 9 1t o 1 . 9 9 2 )

2.0721(l
2.085 50.31to 50.33
(0.0re7)
0.s0 (0.0816
to 0.0821) ( 1 . 9 8 0t7o l 9 8 1 s )
Undersize
2.197to 2.210 50.07 to 50.09
0.75(0.029s)
(0.086sto 0.0870) (t .9'7| to I .9'72)

2.322to 2.335 49.81to 49.83

1.00(0.0394)
(0.0914to 0.0919) (1.961to 1.962)

FIITING BEARINGS back surface is completely flush

Bearingsare manufaciuredwith
crush io nahe them fit snugly into
their bores.To measurelhis, proceed
1- Properlysetmainb€aringin mair
beadngcap recessor cylinderblock
2. Lock one sideof rhe bearingand
press i]Ie ofher side ti11ihe bearing
Pressweight:
abou!500kg (1,100lb)
3. Then,measure bearingc sh "H"
with a feelergauge.SeeFigureEM{6.
Th€ standardbearingcrush%lueis 0
ro 0.0smn] (0 to 0.0020in). Fig. EM-66 Cheching bedrinc crBh
EM22

MISCELLANEOUS
COMPONENTS
CRANKSHAFT SPROCKET
AND GAMSHAFT SPROCKET
1. Chcckcrankshaft and camshaft
sprockets
for wearor scores
onsprock-
et teeth. Replaceif wom or damaged
b e y o n dI i m i t s .
2. lnstall camshaft sprocket and
cleck to determinethat geafrur out is
held withfi 0.1 Jn'n (0.0039 in). If
CHAIN AND CHAIN
TENSIONER
i. Chcck chain for stcppcdw€ar,
scratchcsor othcr problcmsto roller
links.Replaceilnecessary.
2. Chcck chain tensioncrfor wear,
brerkag€or rny other defectswhich
would intcrfcrc wilh proper chrin
functbn. Replace if necessrry.
FLYWHEEL
1. Cheokring gcar. Ii found to bc
worn or danagedcxocssiycly,rcplace.
2. Clutch contactingface of fly-
wheelshouldbc smooth.lf it is wo|n,
d nagedo! roughcncdbcyondlimits.
PRECAUTION
C Y L\ D ' R A D .. . . . , . . .
P I S T OANN D C O N N E C T JFNOGD. . . , , , , .
PRECAUTION
Before dssemblingcnginc, obscrve
the fo]lowing precautions:
1. Clean all disasscnbledparls with
clean solvent- Al1 oil holes in crant-
shaft, camshaft.valverocker shaft. etc.
should be cleaned thorcugHy to re-
move all traces of grinding chips or
lint. Always use cleansolvent.
2. In genelal,uscd gaskets,packings
E n g i n eM e c h a ni c a l
3. Measure flywheel for run out.
This can b€ checkedwiih a dial gauge,
by iotaiing jl in either direction with
indicating finger resting on flywheel
facc la hest from center. If 'un out
exceeds0.05 mn (0.0020 in), replac€
flywhee1.
FiC.EM-67 Measurinqflydheel tun
Noter Removal and installationof
ringgearrequiresuseofa hydmulic
presr. It is also nec€ssaryto heat
ring gearas thh expandsit, thus
facililatingremoval0ndinstallation.
Do not heatring gearto morethan
300oC (572oF). To do so could
resultin inpaired hardness of ring
gerr.
ENGINEASSEMBLY
CONTENTS
EM 23 V A L V ER O C K ESRI ] A F TA S S E M B L Y , ,, .
EM 24 A S S E N 4 B LE
I NNG
G I N.E. , , . . , , , , . . - . . . . . .
EM 24
and oil sealsshoutd be rcplacedwith
3. Under no cncunsrances should
lockwashersbe reused.
,1. Place bolts. nuts and washers
back in their originrl parts or places
ffom which they were removed.
5. Most packings serve best when
Liquid packing is applied to iheif
sealingsurfaces.When designated,use
suitable liquid packing io elimjnate
EM.23
FROI{TCOVER
OIL SEAL
First check front cover of oil seal
for deflected wiping edge or oil
leakag€.If it is denec&d or the'e it
any sign ol oil teak,replacelvith a n€w
seal. When insraling a new sea1,pay
pariicular atlention to mounting direc
Fig. EM'68 InstaUineoil seal
Noi€s:
a. It is goodpnctice to renewoil serl
when€ver engin€is overhauled.
b. Apply lithiumgrease to wipingedge
of oil s€al.
EM.24
EN,1.25
possibiliiyof watcr, oil and gasleak.
6. Prior to assembling, all sliding
surfacesshouldbe oilcdlibera11y.
7. Propertighteningis essentialto
successful pefomancc of all vehicte
repairs.It is alsoimpodanlto lbllow
correctsequence of lighieningin pul-
ingup cylinderhead.Beon the aleriat
a]l tines to th€ amountof cleannce

8. Cleanliness of toolsor partssu€h
as work bench usedin makinga repan
is essential.When settingup a job
every pr€cautionshouldbe taken tiat
toolsor partsarefreeofdirt, mudand
oil. Do not work in dustandgrit, for
they are pdmary causeof w€ar in any
engine.
CYLINDER HEAD
Use Velve Lifter 5T12070000,1o
install intake and exhaustvalves,valve
springs, valv€ spring retainers, valve
colletsand rubber rings to cylind€r
hesdin the orderlisted.
Not$;
a. Do not intercha$ge\alvesbetween
cylind€rs,for th€lr slidingor seating
su acer haveundergonewearing-in
or hsve been hpped at s$lembly,
forning specific coniact with their
matingpart3.
b. Ch€ck to be sule thlt valv$ are
properly seatedon valveseatswith-
out for€rgn padicles stuck in be.
FE.EM-69 IrctauingDalue
PISTON AND
CONNECTINGROD
l. Heat pistonto 20oC (68oF);as-
sembleconnectingrod, piston pir and
pistonto8€therby hand.On the J13,
tiShten connectingrod s.nallend bolt
to 2.s to 3.s ks-m (18 to 2s ftlb)
usinga suitabletorque wrench.
Engine Mechanical
sT13050000o15.J16)
Iie. EM-70 ln6tdlli4Spitton p 1
EM365
Fe. EM-71 IiShteninssnotten4
bott ( 3)
EM32I
Fis.EM"72 Astemblingpietondnd
connectingrod
Notes:
a. For the Jls and Jl6 engine pbton
is pr€$ed into connecting rod, and
fitting forceis from 0.5 to 1.5tons;
the aid of Piston Pin hess Stand
ST13050000 (Jls, J16) or
STl30OO00(J13)b nec€ssary.
When pressingpiston pin in con-
n€ctingrod, apply engineoil to pin
and smallendof connectingrod.
b. A[ pistonsarc marftedwith a notch
in piston head and "F" ma*
around pislon pin hole. B€ sureto
install pistons in cylind€n with
thes€ markslacing toward front of
engrne.
c. Cotrnectingrod shouldbe instaled
with bottotn oil jet placrd on right
slle.
d. Do dot givedirect hanEn€rblows to
pidon pin whenfitting it hto place
in pi*on.
EM.24
2. To install pistonwith piston dngs
properly spacedarourd it, usePistor
Ring ExpanderEM035m000.BYery
€ution shouldbe taken that dngs are
not interchangedbetweenring groov€s
in piston.
Be sureto install compressionrings
with surfaces having marked end
towardpistonhead:
Notes:
a. Top ring is chromim-plated on
linercontactingface.
b. Secondring haslargertapersurface
than top ring.
c. In the combinedoil ring, upperrail
is the ssmeaslowerone,
EMI68
Fis. EM-73 ttutalling pbton rine
3. Installconnectingrod bushingin
btg end half and cap.M&kesurethat
dust and dirt arc not ca.ried ln bo-
lween iheir matingcl€aronce.
VALVE ROCKER SHAFT
ASSEMBLY
Install parts, as shown in'Figure
EM-74,in placeon rocker slEft; secure
with cotter pins on both €nals of
rocker shaft. Instrll set screwin hole
in rearmost bncket and tighien to
prevent shaft from working loose
duringoperation.
, b \
FiC.EM-74 ksembling Mlue rochq
shoft d*emblr
 Engine Mechanical

.ASSEMBLING 4. Cleanmain bearingshells,bearing Note: Apply liquid prcking to bearing

E1{GINE
l. The first step in €ngnrcassembly
is to bolt Engine Attaclunert
5T05280000 to dght hand side of
cylinder block. Next, instal anotlrcr
EngineStand ST0501S000 in block.
2. Thorougt y clean groove in oil
sealhousingof oankslBft rearbearing;
placeofl sealin groovewith finger and
thumb. Usine an oil seal replacer
Guide), lighdy tap with a harnmer
until oil seal is installed coffectly.
T.im seal flush with ends of housing
block. Install oil seal in rear bearing
saddlesand bearing caps. Place slpll
hrtves in b€arjng Naddlesin cylinder
blo€k; place other hlves in bearing
caps. Next, install thrust washerson
each side of center b€arh8. Make
ceriain that lug on eachhalf of shell
fits in a notch in bearing saddleand
bearingcap.
Notei Thrust washels should be in"
stauedwiih side oil gloov€sfacing
towaid outer sid€of bearingc$p.
saddletouching ends of r€{r main
b$ring csp.
7. tnstal rcar bearing side s€al and
front seal. Prior io installing, apply
aalhesiveto theseseals.B€ careful not
Xo damag€ sealing lips which could
result in oil leak.

FiE.8M.79 DtiuinSrcn be&ins

EM3A7
FE.8M.77 Mdin bedringcdps
dd beaing.

5. Liberally apply cleanengineoll to

EM3A5
Fig.EM-76 INtaUinE crunhahaftrc.r
oll eeol
3. Apply a light coat of engin€oil io
sliding surfccesof velve lifters; lnsert
lifters in holos in clinder block. To
inatell camshaft,be sureto coat sliding
surfacesof camslEft bushingswith a
Ilght cost of englno oll. Insert cam"
shaft in cylinder block from f$nt side
of €ngine, exercising carc not to
darnage camshaft bushtngs. Toque
locatingplate 1o 0.5 to 0.8 kg-rn(3.5
to 53 fdb) using a suitable torque
bearing shelk; place cranlshaft on
shellsin cylinderblock.
6. To instal main bearingcaps,be
rure that arrow mark in cap head h a
placedtowardlront of engine,Install
thrust lrasherson each sid€ of center
Fig. EM40 INto ing frcnt Beal
main bearingcap. Main bearingcap
bolis should be tightened In the
equenceasshownandin threeto four 8. Install engine rear plate and
st€psgraduaUy. After abovestepshave Sasketand tightenbolts to specifiod
been completed,checkto dotermine torque.
tlat cnnl(shaft tums fr€ely.
Mainbeadngcaptighteningtorque: 3.0 to 4.0 kg"m
10 to 1l kg-m 9/16" bolt
Q2 ro 29 rt.lb)
(72 to 80 ftlb)
09 to 1.5kg-rn
(6.5toll ft-lb)

9. Position fl]^vheel in place on

llange end of crantshaft; instull and
tighten attaching bolis to 4.0 to 5.0
EM4O4 ks-m (29 to 36 ftlb). Bend ends of
FiC. EM-78 Toryue equence of lockwash€rsup aSain$ sides of at-
Fig. EM-76 lastolling lo@tinA pldte cop bohs tachingbolts to secureinsta ation.
Elt4-25

Fig. EM-81 Installins flyuheel
Note: Always use new lockwashers
and tight€n them up againstbolts
10. Using Piston zung Compressor
EM03470000,install pistonsso they
are below top of cylinders.Notesin
inslallingpistons:
(1) Marking "F" in piston head F ie. EM-84 T iehtenine.onnecting tod
shouldbe placedtowardthe front ol
cngine.
11. lnstall engine fiont platc with
(2) Eachconn€ciingrod is number- gasket under jt and tighten bolls to
ed, beginingat the front of engine, specifiedtorque.
Pistonand connectingrod &ssemblies
shouldbe installedin respeclivecyl"
inder so that number on rod cor-
respond!with cylindernunber,
(3) Piston ring end gapsshouldbe
strggered l80o apad from €achoiher,
being careful not to locatc them in
thrustandpistonpin directions.
Se.6nd rinA_
Fig.EM 82 Pistoning diection
(4) Numberson connecting rod and
bearingcap must be on the sameside
with oiljets properlypoiried. Referto
Note "c" underihe paragraph "Piston
and ConnectingRod." Instan con-
nectingrod capswith light engineoil
on both joumal and bushingcontact-
ing surfaces. Draw tiem up to 2.8 to
3.5 ks-m (20 to 25 ftlb); insta pal
t nutsto secure the iflstallation,
4
Engine Mechanical
(2) After abovestephasbeencom.
pleted, instail crankshaft sprocket,
chainand camshaftsprocketwith their
markingsproperlyaligned.Oil sprock-
et t€eth and chain wlth liSht engine
oil. Tightencamshaftsprocketbolt to
4.0 to 5.0 kg-m (29 to 36 ft-lb) by
meansofa suitableiorquewrench,
F is. Elll-83 tnsLollingphton
Fig.EM-86 Aligningmothings
EM166
13. lnstall chain tensioner.Correct
cop proj€clion"L" ot spindleis bclow 15
mm (0.591 in). Rephcespindlewh€n
it is foundlo be overthisiimit.
0.5to 1.0kg-m
7116"bol\
(3.6 to 7.2 fr"lb)
0.9to L5 kg.m
l/2" bolt
(6.stollft.lb)
12. Installclankshaftsprocket, cam-
EM334
shaftsprockelandchainin t|e follow-
Fig.EM'87 In'ta|ing chaihtensionr
ingmanner:
(1) Insert keys in keyways.Tem-
porarily install both crankshaftand
14. Install oil ttuower in froni of
camshaftsprocketsand checkto s€c camshaflsprocketcorrectly.
thai th€y are flushwith eachother.If
differencein height falls below 0.5
mm (0.020 in), place a 0.15 mm
(0.00s9 in) washerund€r crankhaft
FE. EM-88 Imtalling oil thrcber
ls. Instal froni (chain)coverwith
gasketinsededin between.At this
Fie. EM-85 Meaturingspto.ket heiSht time, coat gasketsurfaceand Saskei
Etvl-26

contact surface of engirc block with
suitable liquid packing before in-
ita ing gasket.Apply a littuum grease
to wiping edgeof front cover oil seal.
16. Instal and tighten crankshaft
puley to 12 to 14 kg-m (87 ro 101
ftlb) torque.Be sureto bendlocking
tab of lockwasherto s€curethe in.
stallation.
EM396
Fig.EM'89 Irctalling uantuhaft puller
17. Insiall oil pump &ive spindle
and oil pump assemblywith gasket
placedunderthem.Correcttightening
is l 2 to 1.8kg.m(8.7to 13tulb).
EM397
Pig.EM-90 Intd ing oil pump
18. At ihis stage,oil pan shouldbe
installed io fianged end of engine
blockwith gasketinsertedin b€rween.
Tightening should be performed in
criss"crosspattemto 0.5 to 1.0kg-m
(3.6to ?.2 ft.lb) tension.
19. The next step in engine as-
sembly is to install cylinder head and
rockershaftassernbly.
(1) Positioncylinderhead in place
on top of engineblock.Do not fo4et
to install gasketb€tweenhead and
block.
Note: Coat gasket surfac€ of engine
block with suitable liquid paddng
before imtaling gasket.Also apply
Engine Mechanical
same liquid packing to cylinder
head on surfacein which pushrod
holesarc castout.
(2) Insertpushrods.
(3) Position rocker shaft assembly
on top of cylinderhed.
(a) Tiehten cylinder head stud nuts
andvalverockershaftbfacketboltsar
FiC- EM-92 A.ljuiting &lue-tdppet
Cylinderhead 5.0 to 6.0kg.m
(36 to 43 ftlb)
21. Instflll sidecov€r.Tightenbotts
2.0 to 3.0kg-m which hold it in plae to 0.4 to 0.8
(ls to 22 tulb) kg-m(2.9to s.8 ft-lb) torque.
22, lnstall water pump assembly
In tightening,note the followingi with gask€t placed under it. Coat
Tighteningshouldbe madein two gasket surfacewith suitable liquid
or ihree steps,finally torquingto peckingbeforeinstalling grsket.lnstall
specificrtions. and tightenattachingbolts to specifi.
Tightnessof nuts andbolts should cations.lt shouldbe between1,2 and
b€ rcchecked afier enginehasbeen 1.8kg.m(8.7to 13 ft.lb).
operatedfor severalminutes;if
necessary,reiighten,
IiR. EM-93 lwtalling wdt$ pump
EM39A
Fig.EM-qI T@htening sequence 23. Install thermostatand water
outl€t.Do nol forgetto insta gasket.
20. Afier valv€nappet clearnace has
been adjustedproperly, instat valve
rocker covei. Correct valvelappet
clearance is 0.35 mm (0.0138in) for
both intakeand exhaustvalveswhen
engineis hot. To achievethis, first set
clearanceto 0.35 mm (0_0138in)
when engineis cold.Afrer engjnehas
been assembled, run it for at least
sevenlminutesand recheckclearance,
€M4oO
For d€tails,referto 'Adjustingintake
Fig. EM-94 l6taUing thetmutot
and exhausi valve clearance" in ET on l uoter outlet
24- Coat cylinder block to fuel
pump mountiag fac€s with suitable
Intakeand liquid packing and position gasketon
Exiaust Valves fuel pump mounting lace of block;
instal pump and tighten to 12 to l 8
kg,m (8.7 to 13 ft-lb) tensionusing a
0.3s(0.0138) suitable torque wr€nch. Heat shield ,.
plate shortd be installedsimultan€ous- .:itL
1y. ::.i

Fis.EM 95 Installingfuelpump
25. Position intake and exhaust
manifoidson cylinder block; install
bolts which secure manifolds and
torqueto 1.7 to 2.3 kg-n (12 to 17
ftlb). Next, instal carbureto!and air
clean€r.Engineslingerandai! cleaner
suplort shouldalso be tiShlenedto'
getherwiih manifolds.
Notes:
r. Carburetor gasketshould
insulating
be installedwith notch facingup.
b. Extl" caution shouldbe takento
pr€ventdust and sbrasiYes from
enteringcarbur€tor.
C{$uretornutstighteningtorque:
0.8 to 1.2kg"m
(s.8ro 8.7 ftlb)
Fig. EM-96 Instdlling mdnifoU
Fie. EM-97 Iastollingcdtburetor
Engine lvlechanical
26. Instaflalternatorbrack€l,adjust-
ing bar, alternator,fan pulley,fan and
fan belt in that order.Then,checkto
b€ surethal deflectionof fdn belt is
held wilhin 8 to 12 mm (0.315 to
0.472 in) when thumb lressure is
appliedmidwaybelw€enpul€ys.
( 0 . 1 1 5 r0o0 . 4 7 2 4
ini
Fig. EM-98 Meosuringdeflection of
fon belt
sTr9s50000
Fig.8M.99 Mountinq ditection of distibutordtiue spindle
30. Instal spark !1ugs,hish tension
cabl€s,oil pressur€switch and oil level
gauge.
31. Insrall fuel pipes and vacuum
At]. pipes and hoses should be
clampedsecurely,being careful not 1o
allow them to interfere with adjacent
El\l -28
27. Position oil filter brackei in
place with gasLetplaced under it;
tightento 1.6 to 2.4 kg-n (12 to 17
ftlb) usinga suitabletorquewrench.
28. Fastenoil lilter on oi1 filter
Note: Do not overtighten
filter, ot oil
lskag€may occur.
29. lnstall distributorin the fofow-
(1) Brins No. I pistonin T.D.C.on
its comlression
stroke,
(2) Driv€ spindleshouldbe located
as shownby usingDistlibutorDrive
SpindlePullerST19550000.
(3) Install distribuior bracket and
Note: Be carefulnot to d(op drive
spindleinto oil pan.
or surounding pads.
32. Fill with engine oil to specified
level.
33. Using an overhead hoist and
lifting cable, hoist engine up away
fiom enginestandand ihen down onto
enginecanier. Instal clutch assenbiy,
stading motor and enginemountings.
 Engine Mechanical

SERVICEDATAAND SPECIFICATIONS
GENERAL SPECIFICATIOI{S
Jl5 J16
4 in line 4 irl lin€
Disphcernent 1t99 (79.3)
,cc(cuir) -.....-......... r,483(90.s) | ,56't(95.6)
Bore x stroke rnln(in) .........,.........
73 x 77.6 78x 71.6 18 x 82.o
(3O7x 3.06) (391 x 3.23)
o.H.v. o.H.v.
t-3-4-2
Engineidle speed rpm .........................
600 600 500
Cofirpr$sion ratio ..,......,......,..8.2 8.3 8.3
Otl capacity(lncludingoil fllt€r)
Llt6$(U.S.qt,,Lnp.ql) ..,,..,.. 3.4to 4.4(3%, 4% to 4%, 3%)

EM-29
 Engine Mechanical

TIGHTENINGTORQUE

Model Jt6

Cylinderheadstudnut
s.0to 6.0(36to 43)
kg-m (ftlb)

Rockershaftbmcketbolt
kg-m (ft-lb)
2.0to 3.o(14to 22)

Connecting
rod bigendnuts
ks.m(tulh) 2.8to 3.5(20to 2s)

Connecting rod smal endbolt

2.5to 3.s(18to 2s)
kg-m (ft-1b)

Flywheelfiing bolts
4.0 to 5.0 (29 to 36)
ks-m(tulb)

Malnbearingcapbolts
10to 1l (72to 80)
kg.m (fr-lb)

Camshaft sprocketbolt
4.0 to 5.0 (29 1o36)
kg-m (ft.lb)

Oil panbolts
0.5to 1.0(3.6to 7.2)
ks.m (ftlb)

Oil pumpbolts
1.2to 1.8(8,7to 13)
ks-m (ft.lb)

Oil pandrainplug
2.0to 3.0(14.5to 21.7)
kg"m(ftlb)

Locatingplatebolh
ks'm (f b) 0.5ro 0.8(3.6to 53)

Carburetor nuts
0.8to 1.2(s.8to 8.7)
kg-m (ftlb)

Manifoldnuh
1.7ro 2.3(12ro l7)
kg.m (ft.lb)

Fueipumpnuts
1.2to 1.8(8.7to 13.0)
kg.rn (ft.lb)

Crankpulleybolt
l2 to l4 (87to 101)
ks-m (ftlb)

Enginefront plate bolts

kg-m (ftlb)
7/16"bolts 0.5to 09 (36 to 5.5)
l/2" bolts 0.9to 1.5(6.5to 11)
Enginerearplate bolts
ks-m (ftlb)
9/16" bolts 3.0to 4.0(22to 29)
l/2" bolts 0.9to 1.5(6.5to 11)
 Engine Mechanical

Waterpunp bolts 1.2to 1.8(8.7to 13)

kg'rn (tulb)

Oil iilter bolt! r.6 to 2.4(12to 1'7

kg-m (ftlb)
)

Sidecoverbolt
0.4to 0.8(2.9to 5.8)
ks-m ({t"lb)

SPECIFICATIONS
Model J16

a) VehE mechanbm

Valveclo.rance(hot)
lntak€ andexhaust . 0.3s(0.0138)
mm (in)

Valveheaddia.
mm (in)
-Intake 349(r.3740) 37.9(1.492t)
-Exhaust 3 0 . (01 . r 8 l l ) 32.0(t.2s98)

Valvestemdia.
mm (in)
Intake andexlaust 8.680to 8.693(0.341?
io 0.3422)

Valvelength
mm (in)
-lntake 109.35to 109.55 (4.305to 4.31?)
(4.305to 4.31?) to 109.65
109.35

-Exhaust 108.55to 10835 109.35 (4.305to 4.317)

to 109.65
(4.274to 4,28s)

Valve springfree lengih

Inm (in) Model620,T20 (J13,Jls andJ16) ModelA32l (JI3,Jls)
-Outer 52 Q.047)
-Inner s0 (1.969) 47.r (r854)

Valve springpressured
length (valveopen)
mn/kg (in/lb)
-Outer 30.714'7.8 (t .209ll0s) 30.717O.6
28.7l2t .3(t .130147 O 2Ae1156)
Inner )

Valvespringassembled
height
(valveclose)
nrn/ks (in/lb)
Outer 38sl29n
Q.s3r164) 38I135A (t s3r 178)
Inne! 369113.r
(r.4ssl29)

Etv,31
 Engine Mechanical

Model Jl6

Valve spdngeffectiveturns Model520,T20 (J13,Jl5 andJl6) ModelA321(J13,Jl5)

mrn (in)
-Outer 4.s(0.1772) 3.7s(0.14'76)
Inner 6.s(0.2ss9)
Vaivespringwire dia.
mm (in)
-Outer 4.0(0.1s75)
' 4.s(0.r772)
Inner 2.8(0.1102)

Valvespringcoil dia.
mm (in)
-Outer 2s.2(0.992r) 2s.2(09921)
-Inner 18.4(0,7244)

Valveguidelength
nm (in)
.6 (1.874)
4'7
s6.0(2.20s)

Valveguideheightfrcm
heedsurface 15.5to 15.9(0.510
to 0.626)
rnm(in)

Valveguideinnerdia.
mm(n')
8.732to 8.745(0.3438
to 0.3443)
8.714to 8.751(0.3443
to 0.3/'48)

Valveguideouterdia.
mm (tn)
Intake andexlaust 14.313 (0.5535
to 14.326 to0.5640)

Valveguideio st€mclearance
mm (in)
-lniake 0.039to 0.065(0.0015
to 0.0026)
_Exlaust 0.051to 0.07?(0.0020
to 0.0030)

Valveguideinterferencefit
nJn (in) 0.013to 0.04s(0.000sto 0.0018)

Valve seatwidth
mm (in)
Intat€ andexiaust L6 to L7 (0.0630to 0.0669)

lntake andexiaust

fit
Valveseatinterference
lr)In (in)
0.054to 0.080(0.0021io 0.0031)

E[4-32
 E n g i n eM e c h a n i c a l

Model J16

b) canshaft and tinins chain

Camshaftendplay
0.05to 0.29(0.0020
to 0.0114)
mm (in)

Camshaftlobe height
6.15(0.242r)
mm (in)

Camshaft journaldia.
(standerdsize)
mn (in)
_F!ont 45.434to 45.441(l ;7887to I;7892)
-Center 43.89'lto 439lO(1.1282to | ,128'7)
-Rear 4l .218to 4t .231(1.622Ato | .6233)

Ca.rnshafibend
Lessthan0.03(0,0012)
mm (in)

journalto beartng
Camshaft

mm (in)
_Front 0.027to 0.050(0.0011
io 0.0020)
-Center 0.038to 0.064(0.0015
to 0,002s)
-Rear 0.026to 0.049(0.oo10
ro o.oo19)

Camshaftbearinginnerdia.
mm (in)
-Front 45.474 to 45,484(1,7903to 1.7907)
-Center 4.94a b 43.961 (1.1302 to 1,7307)
Rear 41.257Ia 4l .267(l .6243to 1,6247)

c) Rockerarm lev€rratio t.4

d) Connectingrod

Centerdistance
nrn (in) (s.51?)
t42.67 (5.s06)
13e.8s

Bearingmaterial F500 F770

(S.T.D.)
Bearinethickn€ss 83to 1.84(0.0720
to 0.0724)
mrn (in)

Bigendplay
0.20ro 0.30(0.0079ro 0.0118)
ffn (in)

Connectingrod bearingclearan
0.011to 0.052(0.0004to 0.0020)
mn (in)

Connectingrod bendor iorsion

(per 100lnm or 2.937in) l-e$ ihan0.03(0.0012)
nm (in)
 E n g i n eM e c h a n i c a l

Model J16

e) Crukshaft andnain bearing

Joumaldia.
s0.813to 50.825(2.0005
to 2.0010)
mn (in.)

Journaltaper& oulof,round
mm (in)
LEss
than0.01(0.0004)

Crankshaftfreeend play
mm (in)
0.05to 0.20(0.0020
to 0.0079)

Wearlimit of dittoedplay
mm (in) 0.3(0.01r8)

Crankpin dia.
mm (in)
47.640to 47.652(1.8756
ro |.8761\

Crankpin taper& oufof-round

nm (in)
Lessthan0,01(0,0004)

Mainbearingnaterial F770

Mainbearingtlickness(S.T.D.)
mm (in)
1.822to 1.835(O.0717
to 0.0722)

Mainbearingclearance
mm (in)
0.02to 0.0s(0.0008
to 0.0020)

Wearlimit of dittoedclealanc€
mm (in) 0.10(0.0039)

Cranlchaft bend
mm (in) Lessihan0.03(0.0012)

f) Piston

Pistondia. -S.T.D. '72987

to73.037
mm (in) (2.873s ??.935 (3.Q583
to 77.98s to 3.0763)
to 2.8755)

0.s0(0.0197) 73.467
to73.517
Oversize (2.8924
to 2.8944) ?841sto 78.46s
(30871ro3.0892)

1.00(0.0394) '73.961
ro 74.017
Oversize (2.9r2rta 29140) 78.915 (3.1069
to 78.965 to 3.1089)

1.5(0.0s91) 74.467ta 74.517 '79.415

Oversize to '79.465(3.1266
to 3.1285)
Q.9318to 29337)
Elipsedifference
nm (in) 0.07to 0.17(0.0028to 0.0067)
 E n g i n eM e c h a n i c a l

Jl6

Ring groovewidth
2.0(0.0787)
2.0(0,0781)
4.0(0.rs7s)
Piston to bore cl€arance 0.023to 0.043
mm (in) (0.0009to 0.0017) 0.025to 0.04s(0.0010
to 0.0018)

Pistonpin hol€ off-sei 0

mm (in)
0.95to L05 (0.0374
to 0.0413)

Pisionpin hoiediameter 17.453to 17.460

mrn (in) (0.6871to 0.6874) 21.001 (0.8258
to 21.008 to 0.8271)

g) Plstonpin

Pin dia. I7 .141to 17.452

rnn (in) (0.6869 to 0.6871) 20.993to 20.998(0,8265
to 0.8267)

Pin length 65.23to 65.48

mrn (in) (2,5681 66,40to 66.sS(2,6t42to 2.6240)
ro 2,5780\

Pistonpin to phton clearance 0.001to 0.013

mm (in) (0.00004 0.003io 0.015(0.00012
to 0.00059)
to 0.00051)

fit of pistonpin
Interfer€nce
to conneciingfod bushing Bolt clarnp 0.015to 0,033(0.0006
to 0.0013)
mm(nr)

h) Pistonring

Ringheight
rnrn(in)
-ToP (0.0781)
1.984
-Second (0.0781)
1.984

Sideclealance
nm (in)
-Top 0.036to 0.076(0.0014
ro0.0030)
-'Secord 0.036to 0.076(0.0014
to 0.0030)

Ringgap
rnm (in)
0.20to 0.33
(0.0079to 0.0130) 0.20to 0.35(0.0079
to 0.0138)
0.20to 0.33
(0.0079to 0.0130) 0.14to 0.29(0.0055
to 0.0114)
0.30to 0.90(0.0118to 0.03s4)
 E n g i n eM e c h a n i c a l

AND CORRECTIONS
T R O U B L ED I A G N O S E S
Condition
I. Noisy engin€
Knocking of crankshafl Loosemarnbearing. Reptace.
andbearing. Seized
bearing. Replace.
Bent crankshafi. Repairor replace.
wearofjournal.
UneYen Corr€ct.
cranLshaftend play.
ExcessiYe centerbearing.
Replace

Pistonandconnecting Loosebea.ing. Replace.

rod knocking Seizedbearing. Replace.
l,oosepistonpin. pin or bushing.
Replace
lrose pistonin cylinder. Recondition
cylinder.
Brokenpistonfing. Replace.
rod alignment.
Improperconnecting Realign.

Camslnftknocking lrose bearing. Replace,

axiaiplay,
Excessive bearingthrustplate.
Replace
Roughgearteeth, Repair.
Brokencamgear, Replace.

Timingchalnnoise Improperchaintension. Adjust.

chain.
Worn.nd/or damag€d Replace.
Replac€,
Wom and/or broken iension adjusting Replace.

andb€aliogclearance-
camshaft
Excessive R€plac€.

Camshaftand valve Improperyalv€clearance. Adjust.

nechanismknocking Wornadjustingscrew. Replace.
Replace.
Loosevalvestemin guide. guide.
Replace
valvesprinS.
Weakened Replac€.
valve.
Seized Repairor replace.

Waterpunp knocking Impropershafi€ndplay. R€place.

Brokenimpeller. Replace.

lI. Other mechanic{ltrcubles

Stickingvalve- Irnpropervalveclearance. Adjust.
Insufficientclearancebetweenvalve stem Cleanstemor r€amguide.
andguide.
Weakened
or brokenvalvespring. Replace.
Seizedor damaged valvestem.
Poor fuel quality.

EM.36
 EngineMechanibal

Cordition Probabl€cause Co(ective action

Seiz€dvalveseat Improper valveclearance. Adjust.

W€alcnedvalvespring. R€place.
Ihin valveheadedge. ReplacevalYe.
Na-ffowvalveseat. Relace.
Overheating Repairor replace.
OYerspeeding. Ddve within proper speed.
Stickingvalveglide. Repair.

Excessiv€iy
worn Shortage
of engineoil. Addor replaceoil.
cylinderandpiston Drty engtneoil. Cleancrankcese,
r€place
element,
Poorqualityof oil. Usedghtoil.
Overheating. Repair
or replace.
Fallty asseftblyof pistonwith conneciing Repair
or replace.
rod.
lrnproper fristonringcleerance. Adjusi.
Broken pirtonrlng, Replace.
Dirty alr clean€r. Clean.
Toorichrni\ture. Adjust.
Engineoverrun, Driveat properspeeds.
Stickingchokevalve, Cloan,nd adjust.
Overchoking. Startcorrectly,

Dofective Shortoge of engineoil. Md oil.

confl€ctirurod I-owoil pressurc. Correct.
Poorqualityof engineoil. Useright oil.
Roughsurfaceof crar*shaft. Gdndandreplacebearing.
Cloggdd oil passage. Clean.
Dearlng wearor eccentdcity, Replace,
Improper bearinga$embly. Conect.
loosebearing. Replac€.
Corur€cting
rod alignm€ntincorrect. Repairor replace.

Def€ctlvecranlshsft Shortageof engin€oil. Add or replace.

bearing l,ow oil pressurc. Correct.
Poor quality of engineoil. Useright oil.
Gankshaft journal wom or out-of-round. Repair.
Cloggedoil passage
in crankshaJt. Cl€an.
Bearing*'ear or ecc€ntricity. Replace.
Improper beadngassembly. Correct,
EccentriccranlGhaftor bearing. Replsce.

EM.37
 E n g i n eM e c h a n i c a l

SPECIALSERVICETOOLS

Description pageor
No- & Uniti mn (in)
figureNo.

1. sTo501s000 Thisenginestandassembly is usedfor disassembling

or assembling All PageEM-5
engineblock or differential carrierthroughout360' in all PaseEM-25
Enginestand
dir€ctions. Fis.EI{-l1
?ssembly
I
fsTos011000
J Ensinestand
l1ST05012000
Base

2. sTo5280000 Thisengine
attachmentis installedto enginestandST05015000 J13 PageEM-s
or assembling
in dhass€mbling engifle. J15 PageEM"25
Engine
J16 Fig.EM'lI

3. sT13040000 installingthe pistonpin.

For removingand Jt3 PageEM-?
PaseEM.24
Plstonpin
pressstand

sT13060000 Thistool is us€dwitha prcsgto drivepin into, or out oi, connecf Jl5 PageEM-7
ng rod. l\6 Fig.EM-25
Pistonpin
L2OA PageEM-24
20 (0.?87)dia
Fis.EM-70

120(4.72)S
2 0 ( 0 . 7 8 7 d) i a ;

EM.38
 Engine Mechanical

For Reference
Desc.iption
No. & paceor
Unit: rrun (in)
figurc No.

5. sT12070000 This tool is usedto compressvalvespringby the combinedaction Alt PageEM-7

Valvelifter of its carnandlever,therebyfaciliiaiing the removalor installation models P^geEM-24
of collect(for generaluse). Fig. E[,]-69

6. sTt1600001 This valves€atcutter setis usedto or refinish a valveseat. Jl3 PageBM.l2

Valveseat J15 Fig.EM42
J16
P

sEl93

't.
sTl6s11000 Thistool fuus€dto removeihe cepfrommeinboaring.When J13 PageEM.5
Crankshaft usingthistoo1,tuin itr adapterlnto thethreaded
holein maln J15 F|E,8M.22
malnbearing Desrulgcap. Jt6
cappurcr AI
L.
Series
2 5 0( 9 . 8 )

2 8 0( 1 r . 0 )

8. sT16530000 This tool is usedto rcmovecamshaftand crankshaftsean with Jl3 PageEM"s

Crankshaft chainhung aroundgearte€th. J15
gearpul€r J16
H20
H30

Elvl-39
 Engine Mechanical

Tool number For Reference

Descdpiion
No. & pageoi
Unjt: nu (in)
luure No.

9. sTr661000r Thjsiool is usedtopushpjlot bushour ofplace. J13 PageEM"20

Pilotbush J15 Fig.EM-63
puuer J16
Ll3
Lt4
L16
L18
L2OA,
G18

10. sT19550000 Thislool is usedto removeandinstalldistributordrivesDindle. J13 Pag€EM-28

Distributor J15 Fig.EM-99
drivespindle J16
puller

ll. EM03500000 Thistool is us€dto rcmoveandinstallth€pistonrings. AII PageBM-1

Pision ring mod€ls PageEM'24
expand€r

t2. EM03470000 This tool is usedto compresspiston ringswhile piston is being A| Pag€
BM-26
Phtonring insertedinto cylinder. inodels

EM40
 Engine Mechanical

Toolnumber For
Desqiption
No. & pa€eor
Unit: mm (in)
figure No.

sT19320000 This tool is usedto take oil filter out of plsce.In tightening All PegeEM-5
the lilt€q do noi usethis filter, to pr€ventoxcesstightening. models
Oil lilt€r

sE197

14. Irts6900870 Ihe reamerisusedfor finisldngtheboreof newguide, Jl3 Fig.EM.39

Vrlveguide J15 P6geEM.l1
ftamer J16

EM.4I
MODEL
J13, J15 & J16 SERIES
Iil0tilEs
 EngineLubricationSystem

ENGINELUBRICATION
SYSTEM
CONTENTS
I u B B t a A T tcot\c c u t T ............... EL-2 INSPECTION . -..... EL-3
o t l P U M .P. . . . _ . . EL.2 O I L P F E S S U RBEE G U L A T I NVGA L V E . . , , , , , EL-3
c E I V O V .A. .L. . . . . . . . EL-2 OILFILTER .. ,.,, EL4
t N sr A rI A I t o \ EL,2 O I L P R E S S URREEL 1 EVFA L V E . . . . , . . . . . . .- EL4
DISASSEV V BALN DA q S E \ , Y
4B. I - EL.2 OIL PRESSUW R EA F N I N S
G W I T C .N. . . . . . . . . EL-4

outerandinnerrotors,
The springloaded oil pressure
regu.
latingvalvelimits the oil pressure
to a
maximumof 5.8 kg/cm2(82.5psi) at
2,20Otprt.

REMOVAL
1. Drainenglneoil.
2. Rernove oil pan.
3. Remove oil pump body with
drlvespindleassembly.

INSTALLA'ION
1. Ustng a new gasket,lnstdl oll
pump and driv€ spindleass€mblyto
cylinderblockwith boltsandnut.
ELO34

FE. EL-l LubncatinS

circuit

LUBRICATION
CIRCUIT
The pressurelubrication of ihe
€ngineis accomplished by a trochoid.
type oil pump. This pump draws the
oil through the oil strainer into the
pump housing and then forces it
though th€ ful-flow type oil filter
into the mainoil gallery.A portionof
the oil is suppLiedto all cra*shaft
bearings,and is fed to the connecting
rod bearingsttuougl the dril€d pas"
sagesin the cranlduft. Oil inject€d
ftorn jet holes on conn€ctingrbds
lubricatesthe cylinderwallsandpiston
pins. Camshaftbearinglubricationis
made by carrying oil through oil pas-
sages from the cranl$lEft b€adng.
Timing clBin and chain tensioner
receivelubrication from tlle oiljet and
an additionaloil passagediveged from
the front cranlshaft bearing. Lubri-
cant is deliveredto the oil galleryin
th€ rockersbaft from the rearcrank-
shaftbearing.
Th€ valve mechanism,push rods
and valves, is tubricat€d tfuough oil
passeges in rockerarms.Cam profiles
of the camslHftis lubdcateddown
along push rods. Lubricating oil tien
returnsto the oil pan.
OIL PUMP
The oil pump is bolted to the
bottom of the cylinder block and
driven by the oil pump drive spindle
als€mblywhich is drivenby the helical
gearon the camshaft.
The oil pllmp assemblycoffists of
an oil pressurere8ulating valve md
Fig.EL-2 Instaingoil pump
2. Instal oil pan with a new gasket
in placeon cylinderblock.
DISASSEMBLY
AND ASSEMBLY
l Remove pump cover attaching
boltsandslideout pumprotors.
2. Removeregulatingcap,regulating
valveandspring,
3. Remov€ oil strainer from pump
4. Assembl€oil pump in tlle rcvene
order of disaeseflbly.

EL.2
 EngineLubricaiionSy$em
INSPECTION

lyash a[ parts in cleaning solvent

and dry with compressedair. Use a
brush to clean the insid€ of pump
housing and pressweregulatingvalve
charnber:Be sure a[ dirt and metal
particler are rcmoved.
1. Inspect pump body and covel for
craaksor exc$sivewear.
2. INpect pulnp rotors for daflage E!O13

3. Check inner rctor shaftfor loose- 3 Oui.r rotor to body

nessin pumpbody,
4. lfipect r€gulating!a1vefor wear 4 Rotorro botromcovo!
or sloring. cleahnco
Er-036 5. Check regulating spring to see FE. EL4 Cheching rctot cledftnces
that it k not wom on ih 3ide or
I Dr c gpindle collapsed.
2 Gasklt 6. Chec&&gulatingvalvefor free 8, Placea straightedg€,acrorsthe
3 Oil purn?body 8 RcgrlatorspriAr operatlonin thoborc.
9 Oil rrral|.l
faceofprmpasshowninFigursiEL4,
5Inn.!roto!dndBhaft ?. Uring a feeler gaugE,checktip Checkside clearinoe(outer to Inner
clearanceand outer rotoFto.body rotor) and grp b€tvoon body and
Ii'. EL-g Oll pump cl€arancesshownln FlguroBL4. stralghtedge.

Standard Woarllnlt

Rotor sldacleannce 0.04to 0,08

.
(outefto lnnerrotor,
mm tlnl
(0.0016to 0.0031)
0.2(o.oo8)
I,e3sth.an
Rotortip cl€annco tun (ln)
0.12(0.00{7) 0.2(0.008)

Outerrotor to bodv 0.15to 0.21

mmtlnl
(0.0059 0.5(0.020)
to,0.0083)
Rotorto bottoncover l,essth.n
. mm{llrl
0.04(0.0016) 0.2(0.00E)

Noter Outer and inner rotors rrc not OIL PRESSURE

s€rvic€dsepsrately.
lf oil pump body is damagedor
wom, rcplac€ tfie entire oil pump
assgnbly.
REGULATINGVALVE
The oil pressureregulatingvalveis
not adjustable.At the releasedposi-
tion, the r€lve permits the oil to
by-pass through the passagein the
pumP co!€r to the inlet side of the
pump. CheckregulatingyalvesprinSto
ensurethat springtensionis correct. FiA. EL-5 neguldting udlle
 Engine LubricationSystem

Specificationg

Oil pressure
at idling 1.0to 2.0
ke/cm,(pst ............................
(14.2to 28.4)

valYespring
Regulatins
Freelength 46.7(1.839)
mr' (in) ......................................
lnstalledlength/load mm/ks(in/lb) 39.01s.7
(.r.s3s
I t2.6)
Regularingvalveopening
2.8to 2.9
kg,ic'n,(psi)................................
(39.8to 41.3)

OIL PRESSURE OIL PRESSURE

OIL FILIER
The oil filter is of a cartridgetype.
The oil filter elementshouldbe re-
placed€very9,000 klTl(6,000 milet
of operation,with thc useofOjl Filtel
Wfench ST19320000.
WhenremovinS an oil filter, loosen
it after stoppingengineabout sevelal
minulesto drain out rh€ oil from oil
filtef to oil pan.
Whcninstallingan oil filter, fasten
it on cylinderblockby hand.
Note: Do not overtidl€n filter, or oil
leakagemayoccur.
RELIEF VALVE
The relief va1ve,localedin the oil
filler bracket,by-passes the oil into
the main gallerywhen th€ oil filtet
elementis €xcessively clogged.
With drain plug removed,check
valve for opefation, Inspect lor a
crackcdor broken valve.If replace"
ment is necessary, removevalveand
inslalla newone,
WARNING SWITCH
Thcoilwarningswitchis locatedon
right hand rear of cylinderblock and
wiredto the oil pfessure watninglighl
in the instrunrent
clustcr.
The wafninglight glowswhencver
lhc oil prcssurc
dropsbelow0.2 ro 0.4
kglcm2(2,8to 5.7 psi).
Priorto installingswitchto cylinder
block, be sure to apply conductive
seal€rio ilueadsofnew swtch,

I
2
3

Fig. EL-O Eemouincoil filter FiE. EL-z Retiefuatre

EL-4
 Engine LubricationSystem

SERVICEDATAAND SPECIFICATIONS
Oil pump
Studed Wearlimit
Rolor sideclearance
(outerto innerrotor) mrn (in) 0.04to 0.08 0.2(0.008)
(0.0016to 0.0031)
Rotor tip clearance mm (in) Lessthan0.12 0.2(0.008)
(0.0047)
Outerrotor to body clearance mm (1n) 0.15to 0.21 0.s(0,020)
(0.00s9to 0.0083)
Rotorto bottomcoverclearance mm (in) kss than0.04 0.2(0.008)
(0.0016)
Oil pressure
r€gulating
vatve

Oil pressurc
rt idling kg/cm, (psi) .. . . . 1.0to 2.0(142 to 28.4)
Regulaiing
valvespringl
Freelength rnrn (in) 45,7(r.839)
Installedl€ngth/load
valveopeningpre$ure
Regulating

torque
Tightening

Oil pumpmountingbolts
Oll pumpcoverbolts
wlve capnui
Regulating
Oil panmountingbolts

AND CORRECTIONS
TROUBLEDIAGNOSES
Condition Probablccaus€

Oil l€akag€ Damaged

or clackedbody cover. Replace.
f ron gask€t.
Oil leakag€ Replace.
from regulalorvalvc.
Oil leakage Tightenor replace.
from blindplug.
Oil leakage Replace.

ojl pressurc
Decreased t€ak ofoil in engineoil pan. Conect.
Dkty oil strainer. Cleanor replace.
or worn pumprotors.
Damaged Replace.
regulator.
Defective Replace.
Useofpoor qualiiyengineoil. Replace.

Warninglight remains oil pressure.

Decleased Previously
mentioned.
"on" - enginerunning
Oil pr€ssur€switchuns€rviceable
. Replace.
fault.
Blectrical Checkcircuit.

Noise in purnprotors.
backlash
Excessive Replace.

EL.5
 EngineLubricationSystem

SPECIALSERVICE.TOOLS

For Refer€nce
No. & Description pageor
tool name Unit: mm (in) on figure No.

sT19320000 This tool is usedto taLeoil frltor out of place.In iightening A1l Fig. EL6
the filtor, do not usethls tool to preventexcesstightening. models
oi1 filt6r Mencli

1 2 0m m ( 4 . t i n )

sEl€7

EL€
 S E C T I O NC O

cooHNG
MODEL SYSTEM
J13, J15 & J16 SERIES
E1{GilES

SYSTIl'l. . . . .
C00Ll1{G . . . .. c 0I -
sPECtftcATt0t{s c0.0
TRoUELE
0tA0t{0sEs
Al{D
c0Rntcil0ils c0-6
 Cooling System

COOLINGSYSTEM
CONTENTS

DESCRPTION co2 l N S P . C t . 0 NA \ D A D . I U S T \ , 4 F. N
. .T. . co4
COOLA\_ LFVEL co-3 TPFRI/OSTAT ........ co4
D F A I N I N GA N D F L U S HN G PI IVOVALA\D INSIAL .A I ION . , , . . co4
-!E
C O O L T NSCY S T E I. V ............. co,3 INSD-CT ON co5
WA_IF OU\,4O co-3 R A D | A T O .q_ . . . co-5
R T \ 4 O V A LA N D I N S A L L A T I O N . . - - . . co3 q C V O V ^A l \D lNclAlAl ON ..... co5
DISASS.VB.V A N D A S S \I 4 8 1 Y. . . . , . . co4 I N S PC I O N co-5

DESCRIPTION
The coolingsystemis ofa conven-
tional pressur€type. A cenirifugal
pump,installedon the cylinderblock,
servesto circulatethe coolant.The
pressuretype radialor filler cap is
installedon the radiatorand operates
the cooiing systemat high€r than
atmospheric pressure,
The higherpressure raise!lhe boil-
ing poini of the coolanttnd incr€ases
the coolingefficiencyof the radiator.
When the thermostatb closed,th€
coolantremainsin ihe cylinderh€ad
andblock for swift warmingup of the
engine.After it reachesnomal op"
eratingtemperature, the cooiant ci-
culatesthroughthe radiator.

nn]$q

coo32
FE. CO 1 CooIinEc$tem

co-2

COOLANTLEVEL
The coolant level should be
checkedand maintainedabove the
baffleplateofthe radiatoruppertdnl(.
Caution:To avoid s€riousperconal
injury, neverremoveradiatorcap
quickly*hen engineis hot. Sudden
releaseofcoolingsyst€mpressureis
n it is necessryto removeradiator
capwhen radiatoris hot, turn the
capslowlycounterclock\rise to the
first stop. After a[ pr€ssurcin the
coolingsystemis r€leased, turn cap
passing the stopandremoYe it.
."A
REMOVAL AND
IiISTALLATION
Removal
l. Drain coolantcompletelyinto a
2. Loosenbelt, andihenrenovefan
bladeandpu11ey
fron hub.
inlet hosefrom wxtcr
3. Disconnect
Cooling System
DRAININGAND
FLUSHING
THE COOLING SYSTEM
To drain the cooling systemj re-
move radiator crp, releasedfain cock
at the bottom of radirtor and drain
plug on the sid€ of cylinder block. If
the henter system is instailed, set
heaier temperature control !'dve to
olen position. After the coollnt is
drain€d completely, close drain cock
and plug and refill the sysl€m with
-n€
.Dl
@)
&V
Iig. CO-2 Etploded deu of uater pump
purnp.
.+. Rcnove pump assembly
andgas-
kci from cylindclblock.
waterpump,
Note: Prior to remoYing
cl€an the cooling system with
MSSAN CSC (Cooling System
Cleanet.
c03
WATER PUMP
The waterfu,.npis of a centrifugal
type, wtuchis mounredon the cylin-
der block. The fan and pulley ar€
bolted at the pulleyhub. The punp
shaftis sulpo(ed by a doublerow of
ball bearingspressfit.in the pump
body. A mechanicals€alis sentedln
ihe wat€r pump body betwe€nthe
van€andbearingassembly.
The pun! containsan impellerthai
turnson a steelshaftwhich rotdiesin
Theinl€t of the pump
the bal bearing.
is connectedto the radiator'slower
tl
1 BeadnSarsembly
2 Mechrnicalseal
3 Vlne
4 Lock wne
5 Pulleynub
6 covcr
7 Fan Fuuey
lnstallatlon
1. Be sureto clern the gaskelsur-
faccsin contactwilh pumpand cylin-
der b1ock.Always use new gasket
wheninsl lingpurnpassenbly.
2. Aftcr insiallingpump assembly,
fiI1coolingsystemdnd checktbr leaks
3. Instal fan pulley and fan blade.

and tighten fixing bolts securely.
4. lnstal fan belt and adjust for
DISASSEMBLY AND
ASSE'{ELY
DbaBselnbly
1. Removecoverand gas,kets from
purnpbody.
2. Removehub by usinga puller.ln
this case,be carcfulnot to damage
cast-iron
hub.
3, Carefullyremovecast-ironvane
by usinga puiler.
4. Pull out lock wire with a screw'
driver,and then take off bearingas-
s€mblyfrom pump body by usinga
pres9,
Note: Be sure to align b€aringass€m-
bly with a pressarbor, holding
pump body in a viseso as not to
dunagepumpair€mbly.
90.3to 90.7'in
(3,56lo 3.5?in)
FiC.CO3 Sectionaluieu ofudtet pump
INSPECTIONAND
ADJUSTMENI
InBpcctlon
Ifany of the followingconditionsis
found, replacedefectiveparts with
newones.
1. Washa[ partsexceptfor bearing
assemblyand rubber sealingpads in
Cooling System
5, Remove mechanicalseal f;onl
purnpbody.
Assembly
l. Instal bearine assembiyinto
pump body by appllng pressureto
outerrace,afterfitting mechanical
seal
into pump body. Be sureto usenew
sealwhenassembling wat€rpump.
2. Insert lock wire into the groove
of bearingthough th€ slit of punp
body to fix bearingassembly.
3. Install vane on shaft of bearing
assembly by usinga pressso that the
correctclearancc betweenthevanetip
and pump body is obraineda! show.
in FigureCO-3,
4. Instal hub on shalt of bearins
assembly by usinga pressso that the
distancebetweenlhe surfaces of pul-
I€y hub and pump coverbecomes the
specifiedvalue as shown in Figure
CO-3.This is very importantfor the
fanbelt operation.
(0.016to 0.024in)
Note: Bearingass€mbly is of a pe.ma-
nent seal€dand lubricatedtype and
must not be washed in cleaning
2. Inspeci respective component
partsfor cracks,or€xcessiyewear.
3. Inspect bearing assernblyfor
roughness or excessiv€
endplay.Clean
off rust or scaleon the shaft or outer
raceof b€aJing assembly.
co,4
4. Inspectmechanical
sealfor wear
or damage-
Adiu5tmcnt
Fan belt shouidbe kcpt adjusted
prop€rly at ali times. A tight belt
causeswear of alternaiorand water
1
pump bearings.A loose belt brings
about jmproperoperationof coolirg
fan,waterpurnpandof aiternator.
Checkthe frn belt slackbetween
alternatorand fan puley by a forceof
10ks (221b).
of fanbelt:
Slackn€ss
8 to 12nm (0.31to 0.47in)
lf adjustrnentis necessary,Ioosen
boli retainingalternatoradjustjngbar
to altefirato.,Movealiernatorioward
or awayfrom engineuntil ihe conect
tensionis obtained.
THERMOSTAT
A wax lellet type thermostatis
mountedin th€ th€rmoslathousingat
the cylinde!headoul1el.
The functioningof the thermostat
is to control ihe flow of coolant,
fscilitatingfast enginewarmup and
regulatingcoolant lemperaiure,The
ihermostaiis designedto open and
closeat predetermined temperatules
and,if not operalingproperly,should
be removedand testedas described
REMOVALAND
INSTALLAIION
1. Draincoolantpartialy.
2. Disconnecitop hose at water
ouUei.
3. Loosen two securingbolts and
then removewater outlei, gasketand
themoslat from thermostathousing.
4. After checkingtherno'stat,re,
instal with a new housinggasketin
p1ace.
5. Reinstallthermostat,gaskeiand
wateroutletand tbentightensecuring
bolts.
6. Replenishcoolantand checkfor
leaks.

INSPECIION
A stigked thefnostat wil prevert
tlrc cooling system from functioning
properly. If tl1e tlEmostat stick in
th€ open position,the enginewarms
up very slowly. [f the thermostat
sticks in the closed position,over-
heating will rerult. Therefore,the
tlEmostat should be inspectedfor
1. Submerge thermostat in hot
Vatveopeningtemperature
above8 mm at 95oC
Maximumvalvelift
Note: It is nec$saryto checka new
theftostat before imtalling it in
the engine.
RADIATOR
Theradiatoris a conventional down
flow typ€ havingthe top andbottom
tar*s to disiributethe coolantflow
uniforrnlythroughthe verticallube of
radiaiorcore.
Theradiatorfiller capis designedto
maintain a pre"set pressure [0.9
kg/cm, (13 psi)l aboveatmospheric
pressure,The reliefvalveconsisting of
a blow-off and vacuumvaive,helps
preventcoolsnt from boiling by giving
pressureto it, On the contrary,when
the pressure is reducedbelowatrnos-
pheric presswe,vscuumvalvealows
air to re-enterinto the radiatorpre-
ventingthe formationof Yacuumin
the coolingsystem.
Cooling Systdm
water soc (9oF) abovetfie tempera-
ture specified
in the folowingtable.
2. Put a mark on a screwdriverat
about8 n'Jn(0.3150in) from the tip,
and checkthe lift of valv€by inserting
thisscrewdver.
3. Now, placeihermostatin water
5oC (9oF) below the specifiedtem-
perature.Under the abovecondition,
valvesshouldbe closedcompletely. FE. CO-4l4spectingthetu@tdt
If ihemostat doesnot operateat
the above specifiedtemperature,it
mustbe replaced
because it cannot be
repaireal.
Standard For tropicalareas
82'C(180.F) 88'C (190'F) (l?0oF)
76.5oC
above8 mm at l00oc above8 mm at 90oC
(0.31sin at 2030F) (0.315in ai 212oF) (0.315in at l94oF)
NETUOVALAI{D
INSTALLAIION
l. Drain coolani completelyinlo a
cleancontainer.
2. Disconnectradiatortop andbot"
3. Removeradiator retainingboltt
and then removeradiatordownward
(the ModelsT20 andA32l) or upward
(theModel520).
4. Instel radiator in the reverse
sequenceof removal.
Also, inspect radiator for water
INSPECTION leakag€using the cap tester at a
Radjatorcapshouldbe ch€cked for pressureof 1.6kg/cm2(22.8psi).
working prersureat reSulartune-up
intervd. First, checkrubber sealon
cap for tear, cracksor deierioration
after cleaningit. Then,installradiator
capon a tester.Ifcapdoesnoi hold or
will not releaseat the specifiedpr€s-
fie- CO 7
If $e above defect is detected,
repaL or replace radiator.
co-5
 Co0ling System

SPECIFICATIONS
Model T20 620 L32l
Engine Jl6 Jl3& Jl5 Jl3& Jl5

Dmensiofl of core 330x446x49 33Ox446 x 32 300x488x49

(Height x Width x Thickne$) rnn (in) ( 1 3 . 0 x 1 7 . 6 x 1 . 9 )( 1 3 . 0 x 1 7 . 6 x 1 . 3 )( 1 1 . 8 x 1 9 . 2 x 1 . 9 )

ed tin andtu

Capworkingpresure kg/cm, (psi) 0.9(13)

pressure
Testing ks/cm?(pst 1.6(23)
watercaPacity liters 5 . 5( 1X , 1 X ) s.4(t%,t%) 6 . 3( t % , t % )
(u.S.sal.,Imper.sal.) ' 7 . 2( l
6.s (2 %, I N) 6.0(tX,t%) %,1 %)

Fanouterdia. [mm (in)] x No. ofblades 3a0(ll.a) z a 310(t2.2\x 4 340(13.4)

x4

AND CORRECTIONS
TROUBLEDIAGNOSES
Condition Correclive
action

Lossofwater Damagedradiatorseams, Repah.

wearin waterpump,
Excessive Replace.
of heaterhoses.
Lesksat connections Repair.
Leakat wat€ftemperaturegauge, Tighten.
Loosejoint!. Tighi€n.
Defectiverubberhoses. Replace.
D€f€ciiv€cylinderheadgasket. Replace.
dndrefill
Checkengineoil for contamination

cylinderblock.
Cracked Replace.
Pull out and seeengineoil levelgaugeto
checkfor waterin crankcase.
Crackedcylinderhead. Replace.
Loosecyiinderh€adbolts. TiBhten.

Overheating Defeciiv€thermostat. Replace.

Radiaiorfins chokedwiti mud, clEff, elc. Cleanout air passage
thorougllyby utingair
preslurefrom the enginesideofthe radirtor.
Incorrectignitionandvalveliming.
Dirty oil anddudgein engine. Refill.
waterpump.
Inoperative Replace.
Looselan belt. Adjust.
radiator.
Restricted Flushradiator.
Inaccurate gauge.
t€mperature Replace.
knpurityin water. Usesoftcleanlvater.
Cooling Systgm

co,7
MODEL
J13, J15 & J16 SERIES
Et{Gt1{ES
 EngineElectricalSystem

STARTINGCIRCUIT

The electricalsystemk a 12 volt Startingmotor Infomation on body electrical

sFtem. This sectionis subdividedinto systemssuch as lighting, instrum€nt,
the following subsectionsfor el€ctrical R€gulator and windshield wipers is deecribedin
parts which are required for engine Dstributor s€ction BODY ELECTRICAL in
opention. Ignitioncoil CIIASSISANP BODY.
. Battery Sparkplug

BATTERY
CONTENTS
RE\,4OVAL AND II\STALLATIO\ ,, ,, Ea-2 B A T T E R YF R E E Z I N G
.. EE.3
RETVOV . .A
. .L. . . . . . . EE.2 A D J U S T I NSGP E C I F G
I CF A V I T Y, . . , , . . , , , E E - 4
\STALLATION EE.2 C H A R G TCNTGR C U. .T. T. . . . . . . . . . . . . . . . . . . E
. E.4
ELECTROLY LE TE V EC L H E C,<, , , , , , , , TROUELEDIAGNOSES AND
S P E C TG
FRTC ATVYC H E C < . . . . . . . . . . EE-3 conREcTtoNs ....... EE-s

REMOVALAl{D
Itt|STALLATIOt{ ffi J=l=
@
l_r
REMOVAL
l Disconnect
tarminals.
andposltlve
negative

2. Renovenutsfiombatteryclamp;
#@
+
tal(eout clamps,

1r
3. R€move battery.

tI{sTAttAiflo
l. Install and tighten clamps 3€.
curely.
2. After clampshavebeen tightened,
cleanbatterycableterminalsand ap"
ply gr€as€ to retard formation of fig. EE-1 l$pecting electrolrte le@l
corrorion.

ELECTROLYTE
LEVEL CHECK
Ch€ck the electrolyte level in each l. Unscr€weachfiller aap and in,
battery cell onc€a month. spectfluid level,which canbe deter
mined by glancing into the cap
In caseof batterywitl fluid level
openings.SeeFigure EEI
lines, check to se€that the level is
Determine asshownbelow:
betweenthe upper and the lower lev€l
lines. Fig. EE-2 lupecAry electrclrte leuel
(uith te@l tines)

EE.2
 Engine Electrical System

lf the fluid levelis low, and distiled
water for each cell to raise the level
approximately l0 to 20 nm (0.394to
0.787 in) sbovethe plates.ln cale of
battery with l€vel lines, add distilled
$ater to the upper level. Do not
overfill.
SPECIFICGRAVITY
CHECK
Specificgra ty of batteryelectro_
lyte is testedby a hydrometer.
l. When measuring speclficgravlty,
place your eyes in line with scaleto
readhighestlevel(elecholytedsesat
edgedueto surfacetension)ofeleclro..
lyte. SeeFigureBB-3.
A corr€ction can ther be madeby The state of chargeof battery can
usingthe following formula: be determinedby the following tabl€s
Sro = St + 0.0007(t 20) if the specificgravity of electrolyte is
knorvn.Beforechecking,checkto be
S?o: Specific gravity ofelectrolyte sure tbat cells are filled to correct
correctedat 20oc (68oF) lev€1.
St: Specificgravity of electrolyte
at toc
t: Electrolytetemperature
.O
For example; A hydrometerreading 3
of 1.260 at 30oC (86oF) would be C
1267 whencorrected at 20oC(68oF), g
indicating fully clnrged battery. On L
the other hand,a hydrometerreading
ol 1.220at -IooC (14oF) would be
1.199whencorrected at 20oC(680F),
Ee002
FiE.EE-4 Relationbetueenspecific
indicatinga partiallychargedbattery. Ertoitr ond chotRinq condition
Conv.ttcdspscificgrdlty (S20)

sNffi
l-\ <t-h
E
[<

iL-F
iL-F
-'i

s
'6
-'j

:l ih-h

-u
--1=-l'--
L- tL
0
ffi
f"(T-l
1l 2a Ja "-ii --fr
Elecilolyk temprEtu,. roC)
FiE-EE-, ChanAesof Epecific ercuity in rcsponse to
electrolrte t?mp.tutur..hohg. (oC)

Fig-EE-3 CheckingspecificErcvity
2. If the stateofchargeof batieryis
607, full, or specific-gravityreadingis
below 1.20 las correctedat 20oC
(68oF)l, batieryrnustbe recharged or
batteryalectrolyte concentration must
be adjusted.
Add or subtractgravitypointsac'
cording to lrihether t}e electrolyte
temperatureis aboveor below20oC
(68"F) standard.
The gravity of electrolyt€ changes
0.0007 for every l"C (33.8oF)ten-
BATTERY FREEZING
Temperatures at whichbatteryelec-
trolyte l-reezesvary with acid con-
centrationor its specilicgravity.A
battery vrith an insufficient state of
chargewil freezeat low temperatures.
If specificgravity of a battery fails
below1.100,th€ indicationir tlat the
battery is completelydischargcdand
wili freezer€adilywhentemperatures
fall below freezingpoint. SeeFigure
EE{.
Note: Us€ extrerne caution to avoid
freezingbattery sinceit will usualy
ruin the battsy.
 EngineElectricalSystem

0 CHARGINGCIRCUIT
iEi!*-
- -i0 Baitery must be rechargedwhen
i -zo
tiiijh standard €lectroh/te.gravity reading
falls belorv 1.200wiih electrolj,'televel
E being satisfactory.If battery is quick-
& . ^
'6 chargedto bring it up to fuu charge,
-40 \
F ''{}} th€ operation should be cafiied out
with negativeterminal rcmoved.
I
!
-50
*ft\ Prior to charging,corroded termi
nals should be cleanedwith a brush
E -50 'ti\ and commonbaking-soda solution.In
E fi addition, the following items should
?i
-80 $f be oblervedduringrechaqingbatteryi

t . 0 0 L o 4 1 . 0 8 l . l 2 1 . 1 61 . 7 0 1 . 2 41 . 2 81 . 3 2 l. Be surethat elecirolytel6vel ls
Specific giady of electrolyo abovetop of eachplate.
2. K€ep removedplu$ in a safe
I'ig. EE.6 lrcezinc point ofelectrclyte location.
AD'U6II1{G SPECIIIC 3. Do noi allow electrolytetem-
perahrre togo over45oC(1l30F).
GRAVITY Whenlower,adddilutedsulphurlcacid 4. After recharging,check to be
Besureto checkelectrolyle speclfic lspecificgravityof which is 1.400at certainthat stsndardspecificgravity
gavity after firlly charglng battery. 20.c(68.F)l. doesnot excoed1.260 ht 20oC(680
Standardsp€cilicgravity b 1.260at Whenadjustin8speclJlcgravily,be F)l . Corr€ctioncsn be madeby add-
20oc (68oF). sure to conv€rtmeasured sp€cific ing disiilledwaierto collsasnecesrary.
Wh€nspecificg.avity i6 higherthan gravityto standard specific gravityat 5, Keep batt€ry away fiom open
the stlndrrd value,add distilled wster, 20oc(68oF). flamewhilolt l!being recharged.
6, After all vent plu$ have been
tlghtened, cleanupperfaceofbattery.
tp.cillc lrlvlty rl.40O

!g 2ao
t; 11
:E 18!

!E l::
€in
i6 go
El *
;F :3
r,?70r.?& r?90!.3o
t,2!J .Un r.?!0r.?60,
1,121
So.cllicrrlvlty llt 2ooc l68oFll

Fig. EE-7 Adjwtins specific gftuitr

EE-4
 EngineElectricalSystem
-TROUBLE DIAGNOSES AND CORRECTIOT{S

Battery is not chargedcorrectly.

l. Correctly adjustbelt tensionof alternatot.
2. Completeconnectionsin charglngsystem.
3. Securelyconnectbatterytelminals.

Lightingloadtest
1. MakeiurethatelectrolytelevellsconeCt.
(wlth ignltionsystemop€n).
2. Clankenginefor tlueeseconds
3. Turn on headlightoow beam)for oneminute,andthenmeasuespecilic
gravityof€achcellofbattery.

Specificgravityof eachcell is lels Specificgroviiy of somecella ia Specificgravityof eachcellIsabove

than1,200. above1.200but the otle$ show 1.20.
l. Wh€nspecific gravitycsnnotbe. lower
sp€cificgravity.
raisedabove1.200by charglng,
thebatteryIr defective.
Unbalance
is within 005 Unbalanceof spedfic gravity be-
l. DischarSedbattery. Charge it tweencellsexceed!005.
lnd repeatllghtingloadt$t. l. B.tteryisdefective.

ld wllhln 005.
Unbalance Unbalanceof speciflcgrevlty be.
l. Baiteryls satisfactory. tw€€nc€lls€rrceeds
0.05.
l. Battery
is defective;

f

D - S C oD r O \
OPERATION
c o N st c . .- o \
F.[/OVAI A\D \S-a tA tO\ ... ...
D < ^ . ) t t v B t\
c r f a \ ' \ - A \ D \ J P tC t O \ . . . . . . . . . .
_FF\4
\A1 .,.
F t l - L DC O t '
...
B R U S H L SA \ D B R J S -
B D L I C SHP R . \ ' T F N S O \ . . . . . . . . . .
^ D \ r A T U o a 5 _ t V BY t
( _u - c - a J 5 : \ 4 8 Y .
-fq
BRUShHO_DrB ' oc Gqou\D
DESCRIPTION
Thefunctionofthe startingsystem,
consislingof the battery, ignilion
sw'tch,sta(in8 molor and solcnoid,is
to crank the engine.Tbe electrical
OPERATION
Whenthe ignition swilchis turned
tully clockwiseto the START posi-
tion! batt€ry current flows through
"series" and "shunt"
coils of the
solenoid.magnetizingthe sol€noid.
The plungeris pull€dinto the solcnoid
so that il operaiesrhc shift ievcr to
move the drive pinion into the fly,
wheel fing gear.Then the solenojd
switch conracrscloseafr€r the drive
pinion is partially engaged with the
ringgear.
Closingof the solcnoidswitchcon-
tacts causesthe molor to crank the
engjneand also cut out rhe'\eries"
Engine ElectricalSystem
STARTINGMOTOR
CONTENTS
P ] N I O NC A S EB E A R ] N GM E T A L , . , , , . , . E E . 9
E E 6 MAGNET1C S W I T C HA S S E M B L Y, . , . , , , , E E 9
A S S E I \ 4 B 1 Y . .. .. .. . . . . . . . . . . . . . . . . . . . . E E -9
T E S T . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . _E. E .to
PERFOFN4AN TE CS E T. . . _ . . . . . . . . . . . . . . . E E - ] O
E E .8 DIAGNOSE O SF T E S T. . . . . . . . . . . . . . . . . . . E E - I O
EE 8 M A G N E T I CS W T C H A S S E N I B L T YE S T
., EE.IO
EE 8 S E F V I C ED A T A A N D S P E C I FC A T O N S , , . , E E 1 ]
AD W R EE.8 S E R V I CDEA T A. . . . . . . . . . . . . . . . . . . . . . . . E E _ 1 1
E E 8 SPECC I FA T I O N. S_ . . . . . . . . . . . . . . . . . . . . .E E t 2
.TBOUB
..... .. EE.8 LE DIAGNOSES AND
E E 9 C O R R E COTN S
. . . . . . E E1 3
EE.9
energyis suppliedfron thc ba$ery, coil bccomeszefo. The relurn spring
the solcnoidcompletesthe oircuit to then actuatesthe shift lever rvhich
operrte the startingrnotor, and then puilsthe plungcr,andallowsit to opcn
the motor carricsout the actualcrdnk. the solcnoidswitch conraols.Conse-
ingof the enginc. quenlly,thestartingnrotorstops,
a,
@
o
3 Shilt l.vcr
4 Ovclrurning ctutcll
@ @
I Stdtionrry contlct 8 Shill tevel
2 Sericscoil 9 Drivc pinion
FiE. EE-8 Sectionaluiew of startinemotor 3 lAnition switch 10 Rinr scrr
4 Solcnoid 1l linion slccvesprins
5 Shuntcoil 12 Annarurc
6 Plunecr l3 MovableoontdrLr
7 Relurn sprins t4 Brttcry
coil of the solenoid,the nagneric pull
of thc "shunt" coil beirB sufficient to Fig, EE-g SLartiag molar cncuit
hold thc pinion in mesh aftcr thc
shifling has beenperforned- More positjvemcshingand dcrncsh
A f t e r t h e e n g i n es t a r t sr u n D i i g , l h e ing of the pinion and the rins gear
d.iver feleasesthe ignition key and it tccth are sccured by mcans of the
automatically retuins to the ON posi- overiunning clutch. Thc over-running
clutch ernploys a shift lcvcr to slide
This breaks the solenoid circuit so the pinion akrng thc annrt!rc shaft,
thal revene currcnl flows th.ough th€ into or out of mesh with ihe ringgear
serics coil. and the magnetic fi€ld teeth. The over-running clurch is de-
builds up in fte direciion in whjch the sgned to transmit driving torque from
plunger nrovesbnck. As this happcns, the motor armature to rhe ring gear,
the resullant force of the ma-qnetic but pen it lhc pinion ro ovelrun the
fields in rhe shunt coil and rhe series a f m a t u r ea f t e r t h e e n g i n eh a ss r l r r e d .
EE-6
 EngineElectricalSystem
CONSTRUCTION

Magnelicswiich terminal

I 6 Piniol' u Shifl lever

2 Bneh t 2 M4neticswitchassembly
3 t3
t4
5 15
EE'63

FE.EE-10Erptodeduieuof ato'iingnotor

REMOVALAND 2, Loosennut used io securecon-

INSTALLATION nectingplste to magneticawitch"M"
Disconnectbatterygroundcable, terminal.R€movetwo scr€ws usedto
L
Dirconnectblack wire wiih yellow secwe magneticswitch, and remove
magneticswitchassembly.
tracerfrom magn€ticswitcht€rminal,
and black batterycablofrom battery
terminal of magjleticswitch.
2. Removetwo bolts securingstart"
ing motor to gear case,Pull starter
a$emblyforwardandrenovestarting
Fie. 8E.13 Renouing rcdr cov.r ond
3. lnstall startingmotor in reverse

DISASSEMBLY 4. Withdrawthe amature assembly

1. Remov€th€ brushcoverandtake and dift lever.
out thebrush.
/\
#
Fig- EE-12 Removingmogneticsaitch
ossemblr

td 3. Removetwo tbroughbolts and

then remove rcar cover and yoke
Fig.EE 11 n assemblyby lighdy tapping with a Fig. EE-i4 RemouingsnLlue
woodenmalletor plasticmallet. dwmblr .nd shift lerer
EE.1

5- Remove pinion stopper from
amature slaft end. To remove
stopper,Iirst, push the stopperto
clurch side. After removingstopper
clip, remov€stopp€r togethei with
over-ruruing clulch. Withdraw ov€F
running clutch assemblyfrom arma'
ture shalt.
Fis.EE-15 RenoulngooeHunni^8
clutcha$enbly
CLEANINGAI{D
II{SPECTION
Cleanall disassembledparts,but do
not use greasedissolving solventsfor
cleanlngover-running clutch,armature
assembly,magneticswitch assembly
and field coils llnce such a solv€nt
woulddhsolvegrease packedin clutch
mechanism andwoulddamage coilsor
oth€rinsulaiors,
Check them for excessivedamage
or weaf,andreplaceifflecesssry.
TERMI AL
Check terminal for damage and
wear,andreplaceifnec€ssary.
FIELD COIL
Checkfield coil for insulation.If
the insulationof coil is damagedor
worn,il shouldbe r€plac€d.
T..tlng fi.ld Goil for
conthuity:
Cornect tlle probe of a circuit
lester or an ohmmeterto field coil
positive(+) terminaland positive(+)
brushholder.
If testershowsno conduction,
iield
circuitor coil is open.
EngineElectricalSystem
Fig. EE-16 Conti.uity test of field coil
To.tlng ti.ld ooll tor Stound r
Place one probe of circuit tester
onlo yoke and the other onto field
coil lead(positiv€terminal).
If very litde resistance
is read,field
coilis ground€d.
EE170
!tE, LL-LI t'rou^o tesl ol letd cot
Flald coll t.rtcr for short!
Unsolderthe connecred portionof
each coil and proceedas mention€d
If a detectivecoil is found, it
stlouldbe replac€d.
BRUSHES AND BRUSH
LEADWIRE
Check the surface condition of
brushcontactandwearof brush.If a
loosecontactis found, it shouldbe
replaced.
If brush is wom and its lengthis
lessthan 9-5 nn (0.374in). r€place.
Checkthe connectionof lead clip
andleadwire.
Checkbrushholdersandspringclp
to s€ethat they are not d€formedor
bent, and will properlyhold brushes
against the commutator.
If brushes or brush holden are
dirty, theyshouldbe cl€aned.
EE.8
BRUSHSPRINGTEI{SIOI{
Check brush springtensionby a
springscaleas shownin FigureEE-18.
The readingshodd be 0.8 ks 0.81b).
Replacespdngif tensionis lowerthan
0.7kg (i.5lb). _
Fig,EE-18 Impectionof brurhsping
tentton
ARMAIURE ASSEMBLY
Checkexternalappearanc€
of arna.
tureandcommutator,
L M€asurearmaturestlaft fof bend
by a dial gauge.Replacearmature
shaft if the bend exceeds0.08 mn
(0.c031'n).
EEOl9
Fie.88.19 tnipectionof amatwe
Bhaftfot b.nd
2. lnspectcommutator.If the sur-
faceof commutatoris rough,it must
bc sanded lightly with a No.500
emery cloth. Commuiatormust be
ch€ckedalso for outof-round.If tl€
out4f-round is'more ttan 0.2 mm
(0.0079in), or ihe depthof insulating
mica is lcssthan 0.2 mn (0.0079in)
frcrn commulatorsurtace,commuta-
tor (arnalure)shouldbe turn€don a
lathe,so that the out-of-roundis less
tllan 0.05 rnm (0.0020in). Insulating
mica shouldalso be undercutso that
the depth of it is 0.5 to 0.8 rnm
(0.019? to 003ls in).
The wearhnit of commutatordi-
ameteris 2 mm (0.0787in). If com-
mutatoris beyondrepair,r€place.

- Note: It is recornrnendeilto rephce
commutator as an assemblyif wofn
or damag€d.
3. lnspecl solderedconnectionof
amature lead and comrnutator.If
loogeconn€ctionis found, soldertl
usinSrorlnflux,
4. Armaturetestfor ground
Usinga clrcuittester,placeonetest
probe onlo ,rmrture shaft and oth€r
onto eachcommutatorbar,
If tesler showsconductive,arma-
ture h gfoundedandmustbe replaced.
FE. EE-22 Amatute test forercund
5. Check armature for short by
placingit on armatufeterierGrowler)
with a piece of iron over armature
core, rotaiing armature.If the plate
vibmtes,armatureis shorted.
Engine Electrical$ystem
EE02O
Fie. EE-20 hlspectio| of commutatot
for out.of-tound
EE 0 2 1
Fig. EE-21 Uidercutting insuldting mico
EE023
FiE.EE-23 Armdhte test for
short cicuit
6. Check amature for continuity by
placing probes of tester on two seg_
menh side by side. If tesrer showsno
conduction,the circuil is open.
OVER.RUTI{Il{GCLUTCH
ASSEiIBLY
Inspect pinion ,isembly and screw
sleeve.Screwsle€vemust slidefreety
alongarmatur€shaft splines.If damage
is foud or resistanceis felt when
sliding,it must be repaired.Inspect
pinion teeth If excessive bbing is
found on teeth,it $ould be replaced.
Flywheel ring gear also must be in-
@@0
Fiet EE"24 O|ettunninA clutch
. ar3enbtr
BRUSI{ HOLDERTES'
FOR GROUI{D
Usinga circuittester,placeonetest
prooe onto negativesidebrushholder
and anotllet onto positive side. If
testershowsconduciiod,brushholder
h shortedto ground.Replacean insu-
latoror brushholder.
EE172
FiE.EE-26 Grou4.I test of brushhotdel
PII{IOI{ CA3E BEARIiG
IIIETAL
Inrpectbearing
metaifor wearor
side play. lf the cl€arancebetween
bearingmetal 0nd annstur€shaft is
morethan0.2 mm (0,0079in), replace
metal. Pressin a new bearingand
adjustthe cl€{nnce to 0.03 to 0.lO
nun (0.0012 to 0.0039 tn). Bearing
metalshouldbe pressed in so that th€
end of the bearingmetalis flushwith
IIIAGNETIC SWITCH
ASSEMBLY
Inspectmagnetic switchcontacts.
If
a rough welding is found on the
contact,it shouldbe repair€d.
ASSEMBLY
Reassemble startingmotor in re-
versesequence of disassembly.
wlen assenbling, be sureto apply
greaseto gear case and r€ar cover
bearingnetal, andapplyoil to pinion
sligltly.

TEST
PERFORMANCETEST
Startingmotof shouldbe subjected
to a "noload" lest wheneverit has
been overhauledto ensurcthat its
performance will be salisfactorywhen
installedon engine. Starting motor
shouldalsobe subjected to testwhen
the causc of abnornal operation is to
v.llN.1$
DIAGNOSES OF TEST
l. Low speedwith noload andhigh
currenadraw may resull from the
followinBcauses.
(l) Tisht,dirty or wom bcadrss.
(2) Bentarmalufeshafior loosened
fi€ldprobe.
(3) Shortedarmatur€;
Cheokarmatur€further.
(4) Aground€d armature or fieldl
a. R€moveinput terninal.
b. Raise two negativesidc brushes
from commutaior.
c. Using a circuil tcsle!, place one
pfobe onio input terminaland the
d. If testerindicatesconduction,rais€
the other 1wo brushesand check
field and armatureseparutely10
deierrninewhether field or arma-
tureis grounded.
EnginerElectricalSystem
be determined.A bri€f outline of th€ 3. Low current draw and low no'
test is givenbelow. load speedwould causehigh internal
resistance due to loose conneclions,
defectiveleads,dirty connutator and
tloJo.d teit
causeslistedon itern2-(3)-
. Connect stailing motof in series
with specified (12 volrs) battefy and
an ammeter capable of indicating
I ,000 amperes.
Specified current draw and revolu-
tion in this test is shown in
"speci-
MAGNETIC SWITCH
ASSEMBLY TEST
A ri'rrr
[ig. EE-27 Circuitofmagneticsuitch
osemblyt6t
li the slarting molor check is
"OK," checkmagneticswitchassem-
Fig.EE-26 No-loadt$l bly. Connoctcablesbctwe€n"nega-
live" battery terminaland starting
motor "M" terminal,"posiiive" bar
2. Failurcto opcralcwith high cuF
tery terminal!nd startingmotor "S"
renl draw nrayresullfrom the follow-
terninal conn€cling ignitionswitchin
ingilcms,
series asshownin FigureEE-27.
(l) A sroundedor open field coil:
Wiih ignilion switch on, measule
Inspcot thc connectionrnd lrrce
lhc gap '2" betweenpinion front
circuitby, circuilteslcr.
cdgeandpinionstopper-
(2) Aunaturecoil docsnot opcrale:
lnspect commutatorfor excessivc
burning.In thiscase.arcmay occuron
defectiveconnnulaiorwhen motor is ( 0 . 0 1 1t8o 0 . 0 5 9 i1n )
operatedwilh noload.
(3) Burnedoui comnutatorbar:
Wcakbrushspringtension,broken
brushspring,rubberbush,thfust oul
of mioa in commuiatoror a loose
contactbetweenbrushandcommula-
tor would causeburned-outcommutr-
FiE. EE-28 Medsuring gap "1. '
EE-10
 EngineElectrioatr
System
.SERVICEDATAATD SPECIFICATIONS
SERVICE EATA

BrushI€ngth
ftn (in)
W€arlimit mm(in)
6.s(0.256
in)
Brulhspringtension ks0b) 0.80.8)
Commutator

_ Outerdiarneter mrn(in)
Wearlimit tun (in)
Taperlimit nm Qn)
Depthof mica
Wear
limit rnrn(in)
0.2(0.0079)
Repairaccuracy nrn (in)
0.5to 0.8(o.Ol97
roO.O3l
S)
Clea$ncebetween
armaturo
rhsft andbearing
Wearlimit run (in)
0.2(O.OO79)
Ropaireccuracy mn (ln)
0.03to 0.1(0.0012
to O,OO3
Armatureshafidiameter
Pinionside nm (in)
l3 (0.s12)
Rearend rnm(in)
r r.5(0.453)
Wear
limit rnln(in)
0.1(0.003e)
Bendlimit mrn(in)
0.08(0.0031)
Capt.r" bctwe€nl,inionfront edle
andpinionstopper rnm(in)
1.5(0.0118to0

E€.l1
I--.;ji-
 EngineElectricatSystem
SPretFrcAflol{s . 1:1,

v l2
..................................-.........................,.....

l2
v .....................,....,..............................,.,,...,.
le$ than 60
morethrn7,000

0.9(6.5)
kFn (ft-lb) ....................................................

Magnetig
switch
h Sedos
coilr$lstsnce . ...... . 0.33[at20'C(68oF)
Shuntcoilrcsist.nc€ .......,.,.1.36lat 20oC(68oF)]

EE.12
 EngineElectricalSystem

TROUBLEDIAGNOSESAND CORRECTIONS

Condition Probablecause

Startingmotorwill not Chargeor replacebattery.

oP€rate. Defectivesolenoidswitch.
Looseterminalconnections.
Defectivebrulhes.
Defectivestartingmotor.
Repairor replacesotenoidswitah.
Cleanand tighien termin.l.
Replace
brushes.
Removestartingmotorandtest.

motor.
Noirystarting Looresecuring
bolt. Tightenbolt,
Wompiniongeal. plnlongear.
Replace
Poorlubricaiion. Add oil.
Disassemble
motor.
Wombrushes, brushes.
Replace

Starting
motor Disclurged
battery. Chargeor replace
battery.
slowly.
crenl<s Looseconnection
of terminal. Cleanandtightenterminal.
Wombrushes. Replaccbrush€s.
Lockedbiushes. lnspectbrushspringtenslonor rePa brush
holder,
Dirtyworncommutator, Cleanandreprir,
Armaturerubsfieldcoil. Replaceassembly.
Defective
solenoldswitch. Repairor replace
swltch.

Shrtingmotor Wornpinion plnion.

Replace
butdoesnot
operates Lockedpinionguide. pinionguide.
Repair
crankengine.
Wornringgear. Replace
ringgear.

motorwill not
Startin8 Defectivelolenoid switch. Repairor replacesolenoldswitch.
dk€ngageev€n Defectivegeart€eth. ReplacedefectiYegeor.
whenignltlonswitch
isturnedoff.

The chargingcircuit consistsof the
battery, alternator, regulator and
necessary wiring to connect these
parts. The puryoseof tlus systemis to
convert mechanical eneryy from the
engineinto elecirical €nergy which is
usedto operateall electricauy operat-
€d unitsand to k€eptle batteryiuly
cnaryeo.
When the ignition s'ivitch is set to
"ON," currentflowsfrom the battery
to groundthroughthe ignitionslvitch,
voliageregulatorIG terminal,primary
"P1," movable
side coniact point
contactpoint "P2," voltageregulator
"F" terminal,altenator"F" terminal,
"E" telminal,
field coil and alternator
as shownin Fture EE-29bY ful line
a[ow marks.Then the rotol in the
alternatoris excited. On the other
hand,currentflows ftom the batterY
to groundtfuoughthe ignitionswitch,
"L"
warninglamp, voltager€gulator
terminal, larnp side contact Point
"P4," movablecontact point "P5,"
andvoltageregulator"E" terminal,as
shown by dott€d line arrow marks.
l t -
EngineElectricalSystem
CHARGING
CIRCUIT
Then,the warninglamplights. "P2" is separatedfron the prirnary
side contact "P1" by the magnetic
. llhen the alternator begins to "VC2." Therefore,
operate,three-phase alternatingcur. forc€ of coil
"Rl"
rent is inducedin the staiorcoil. This rcgistor is appliedinto therolor
altematingcurrentis rectifiedby the circuitandoutputvoltageis decreased.
positiveand negativesilicon diodes. As the outputvoltageis decreased, the
"P2" and
The rectified direci curreni output movable contact point
reachesthe alternator"A" and .,E' primarysidecontact"P1" comesinto
contactonceagain,aod the altemator
On the other hand, the neutral voltage increases.Thus, the rapid
point voltagereaches"N" and "E" vibntion ofthe movablecontactpoint
"P2," maintainsan alternatoroutput
telminals(nearlya half of th€ output
voltage), and cunent flows from
voltageregulator"N" t€rminnlto "E ' Whenthe alternalorspeedis furthel
.ermjnal or ground throughthe coii increased or the voltagestarts1o rise
"VCl" as lhown in
FigureEE-30by €xcessively,the movablecontactpoint
"P2" comes into contact
the dottedlinearrowmarks.Then,ihe with
coil "VCl" is excited, and the secondarysid€ contact point "P3."
movablecontact point "P5" comes Then,the rotor currenlis shutoff and
into contrct 'rith vollagewindingside alternatoroutput voltageis d€cr€ased
contactpoint '?6," Thisactioncauses immediately.This action causesio
io turn off th€ warninglump and separatemovabl€contaci "P2" from
compleiethe voltagewindingcircuit, secondarycontact "P3." Thus, the
asshownby the full linearrowmlrks. rapidvibrationof the movableconlact
When ihe alternatorspeedis in. point "P2" or bleaking and com-
deasedor the voliagestarls to rise plelingthe rotor circuit maintainsan
excessiv€ly, the movablecontacipoinl altematoroutputvoltageconstant.
I E
-l
ii
I"
I
I
i
Fie. EE-29 Chdteinscncuit (I)
EE-I4
 EngineElectricalSystem

_l
l-_----_--_-- lgnition sq

Almaturc
= Battery
T
.E.i

L_____-
-____- -i
F.A
rt:
I
Altolnator

I,ig. EE-30 Chdrsits circuit (n)

ALTERNATOR

CONTENTS
DESCF IPTION EE,15 T N S P E C T TOOcN B R U S H.............
REI\4OVAL AND INSTALLATION EE.16 SPRINGPRESSURE TEST. . . . . . . . . . . . . . . . EE , ] 9
D'SASSEIVIBLY . ,,,, E E .6] ASSE[,481V ........... E E .9]
]NSOECTIO AN D B E P A I R EE.17 A L T E R N A TTOEFS T , , . . , . . , , , . , . . . . EE.19
F O T O BI N S P E C T T O N EE.17 SERVICEDATA AND SPECIFICATIONS EE.21
TNSPECTTON OF STATOB. . . . . . . . . . . . EE.18 SERVICEDATA
INSPECTIO ONF D i O D E 8E.18 S P E CI C
F ATIONS EE21

DESCRIPTION like a one-wayvalvefor electricityso

that chargingcunentpasses easilybur
reve$e curent h shut out. In this
Alternator Applied engine tlternator, six diodes (lhree negative
and three positive), are installed in
LTt35-13B J13,Jl5 andJ16 positive and negativepiates as an
asernbly.
LTr5045 Jl3, Jls andJ16(Option) Packlypesilicondiodesareusedin
this aliernato..Thes€diodesare di-
rectsolderedat their tips, and con-
structed *ith positive and negative
In the alternator,
a magnetic Iieldis smallfi€ld curent- Output currentis conjunction. They aremountedon the
producedby the rotor which consists generatedin the amatur€ coilslocated iwo plates which combhe the func,
of alternatorshaft, field coil, pole in the. stator- The stator has ihree tion of heatdissipating plafeandposi.
pieces, and slip rings, The slip .in8s windings and Seneratesthree.phase tive/negaliveterminalsand are light in
pr€ssedin the shaft conduct or y a alternatiogcurrent.Silicondiodesact w€ighlandeasyto service.
EE.15
 EngineElectricalSystem

o
oo@

I
t

r@o@
2
l

r--------------
0tr --J t0
I
7
8
9 Diode serplale asenbly

@ .."",
FE. EE-31 Etploded uieu of altendtor

DISASSEMBLY
L Removepulley nut, pulley rim,

I
-D!U^ I
@ffi
@oo
I
2
3 FiE-EE33 RemouinEpuller and fan

Fig. EE'32 Sectiotul Dieb of altenatol

REMOVALAl{D 2. Rernove brush holder fixinS

INSTALUTTION
l- Disconnect negativebattery ter-
minal.
2- Disconnect two lead wires and
connectorfrom alternator.
3. Loosenadjustingbolt.
4. Removealternatordrivebelt.
5- RemoYeparts associatedwith
alternalorfrom engin€.
6. Rernovealtemato.from vehicle.
7. Installaliernatorin reve6€order
EE.16
scr€ws, and remove brush holder
cover.Removebrushholder forward,
and remove brusheslogelh€r with
brustrhotder.
Note: Do not disconnect"N" termi
nal fron stator coil l€adwire.

I
II
I
I Fig-EE'34 Remouing
brush
3. Loosen and remov€ throu8h
bolts.Separatefront coverwirh rotor
from rear coverwith statorby lightly
tappingfront bracketwith a wooden
mallet.
o!@:ir*l
Fig. EEAS Sepatutingfront cover
uith rotor frcm rcar couer
4. Removethree se1 scrcwsfrom
bearingretainer,and separateroior
from front cover.
! @@
rig. EE-36 Remoui/tgrotor
5. Pull out rea. bearingfrom roror
assemblywith a press or bearing
puller.
Engine ElectricalSystem
Fig. EE 37 Pulling out of rcar
Fie. EE-4o Inspectinsaltemator
ROIOR I]{SPECT|O
Iig. EE'38 Pullingout of rcar
bedrins(II) 1. Conduction lestof rotorcoil
Apply teslerbetw€enslip ringsof
6- Renrovedjodecov€rfixiogscrew,
rotor as shown in Figurc 8E.41. lf
and removediode cover.Disconncct
threestatorcoil leadwiresfrom diode thefe is no conduction,discontinuity
terminalwith a soldering of fieldcoil mayexist.Whenreshtance
iron.
7. Remove"A" terminalnut and h approximalely 4.4O at normalambi-
diode installalion nut, and femove ent lemperature, conditionis $tk,
diodeassembly. factory.
O
lr
f\ ,, }ir, 4\^u, )r
\J I 'r l.!'
"':q f " ,,'
I Djodc a$ehbly
2 Diode cover
Iig. EE-41 Conductiont6t of
Fig. EE-39 RemouinEdiode Nembly
rotor coil
Not€: Use c,5rein handling diode as-
s€mbly to prevent an undue stress
2. Ground lesl ofrolor coil
Check conduclion betweenslip ring
and rotor core. If conduction exish,
INSPECTIOI{AI{D replace rolor ass€rnbly,becausefield
REPAIR coil or slip ring rnay be gfounded.
Removeattematorfrom vehicleand
apply lester between lead wire F
(whitewith blacklracer)andleadwire
E (blackcolot.
Whenthe resistance is approximate-
ly 5s,,the conditionofbrushandfield
coil is satisfactory-
Whenno conduc
tion existsin brush or field coil, or
whenresistance diff€rsrcmarkabtybe
tween those parts. disassenbleand Fig. EE 42 Testinqrotor coit for
grcund
EE.]7

INSPECTIOIIOF SIATOR
l. Conduclion test
Stalor is normal when ther€ is
conduction between individual stator
coil terminals. When there is no con-
duction between individual terminals,
cableis broken.
Replacewith stator assembly.
FiE.EE-43 Testingstatorfor
conduction
2. Groundtest
If eschlead wire of armaturecoil
(includingneutralwirc) is no! conduc-
tive with stutol corc, condition is
{ie.EE 45 ConductiDe.lir.ctio^ af.Iio.te
Diodeinstalledon O plate is a posi-
tive diode which alows currenlflow-
ing from terminalto @ plale only.In
other words, curreni does not flow
from G) plateto tenninal.
EngineElectricalSystem
saiisfactory.Il there i3 conduction
stato.coil is grounded.
Fig.EE'.14 Testitrgstator for
Eround
INSPEC'ION OF DIODE
Pefform a conduction lest on
diod€s in both direclions,using an
ohmmeter.A totil of six diodesare
used;threeare mountedon th€ posi-
tiv€ O plste, and other threeare on
ihc negativeO plate.The conducijon
lest should be performedon each
diod€,betweenlhe teminnl andplate.
(
Fig. EE 16 tnspectin' needti@ dio.te
EE.I8
Diode installedon O plate is a
negalivediode which alows cu(eni
flowing from O Plale to terminal
only. In olher wods, currentdoesnot
flow from termiralto O plate.
dio.le
FE EA47 ln|pe.tne negatiDe
If cuncnt flows towardboth posi-
tive rnd negativedirections,diodc is
lf 0urron!flowsin the
short.circuited.
samedhectiononly, diodc is in good
condilion.If ihereis a defectivediode,
rcplaceall diodesGix diod€t as an
ass€mbly.(See below table.) Th€se
diodesafeunsewiceable.

Testprobeofa circuittester
o o
O plate
terminal
O plate
O plat€
@ plate
I]{SPECTIONOF BRUSH
Check movemenlof brush and if
movementis unsmoolh,checkbrush
holderandcleanit.
Checkbrushfor wear.If it is worn
SPRIIIG PRESSURETEST
With brushproj€ct€dapproximai€-
ly 2 mm (0.078? in) from brusl'
holder,measurebrush springpressure
by the use of a springbalance.Nor.
mally, the rated pressureof a new
brush springis 255 to 34s g (9.0 to
12.2 oz).
Moreover,when brush is worn,
pressure d€creases
approxinately209
(0.7oz) p€r l mm (0.0394in)wear.
Fie. EE 50 Meosurina slnng Praure
EngineElectricalSystem
Conduction
G) plate o
terminal
O plate
terminal o
O plate o
O plate
Fig.EE-48 lnspectingdiode6
down to Iessthan the specifi€dlimit, rnsulatin8bush 4 Sratorcoil leadwirc
replace
brushassembly. Redi cover 5 A tqhinat bolt
Diodeasonbly 6 Diodecovcr
Checkbrush pig tail and,if found
defective,
replace. Fie.EE-61Sectionot
oieuof diode
o\d A terminol
3. Tightenpulley nur with tighien-
ing torqueof 350 ro 400 kg-cm(301
to 344 inlb), Whenpulley is tighn
ened, make lure that deflectionof
V.groove h lessthan0.3 mm (0.01l8
n,r,
Fie.5E-49 Brwh uear limit
ASSEMBLY
Reassemblealternatorin ihe reverse
sequence
of disassemblynotingfollow-
mgmarrcrs:
Fie. EE-52 Tiehteningpulley nut
l. When solderingeachstaior coil
Ieadwire to diodeassembly rerminal,
carry out the operationas fast as
possible.
2. Wheninstallingdiode"A" termi"
nal, insta insulatingbush and insu- ALTERNATORTEST
latingtub€corectly. Before conducting an alternatoi
test,make surel}Iar the baitery is fully
charged-
To conduct a test, it i! n€cessary to
use a 3o-volt voltneter and suitable
Set up a test circuit as shown in
Figure EE-53 and tesr alrernarorin the
manner indicated in th€ flow chart
EE.I9
 Engine ElectricalSystem

l. Disconnectconnectonat altemator-
2. Connectonetestprobefrom voltmeterpositiveterminalto "N" terminaloi "BAT" terminal.Connectt}Ieother
testprobetoground.Makesurethat voltneterregisters batteryvoltage.
3. Tum on headlights
andswitchto MainBeam.
4. Startengine.
5. Increase
enginespeedgraduallyuntil it is approximately
I ,l 00 rpm,andtaketh€ voltmeterreading.

Measured value:Below12.5volts Measuredvalue:Over12.5volts

Altemator is defective.Removeand checkit Alternatoris in goodcodition.
for colldiiion.

a. Do not run engin€at more than

1,100rpn rvhiletestis beingcon-
duct€donaitemator.
b. Do not raceengine.

?iE. EE-63 T6tin9 altemdtor

EE.20
 EngineElectricalSystem

SERVIGE DATA A]{D SPECIFICATIONS

SERVICE DATA
- LTIJ5.t3B,LTl50-05>

Statorcoil
Resistaftep€r a phase 0.17lat 20oc(58oF)]
Rotorcoil
Registance 4.4 [at20oc(68eF)]
Brustl
Br:ush
length 14.5(0.571)
Wearlimit 1(0.27s6)
Springpressure 0.25to 0.35
(0.5sto 0.7?)
Slipring
Outerdfumeter 31(t.220)
Reduction
limit l (0.0394)
Repairaccuracy 0.05(0.0197)

SPECIFICAT|Ol{3

Item LT135.l3B LT150-05(Option)

Make HITACHI HITACHI

Nominalriting l2v-35A t 2v-50A
Groundpola.ity Negatlve Nogativ€
Revolution 1,000
to 13,500rpm I ,000to 13,500
rpm
Minimum revolution underno load LessthanI ,000rpn L€ssthanI ,000rpm
Outputcurreni 284 (14V,2,500rym) 37.5A(14V,2,500rpm)
Pulley ratio 2.25 2.25
Appliedregulatormodel TLtZ-61 TL\Z4l
 EngineElectricalSystem

REGULATOR

CONTENTS
D F S ' RP T I O N .. EE.22 C I A R G I N BCF L A Y , , ,
MEASUREMENT OF REGULATOR S F V ' E D A T AA N D S P I C| I C A T I O N S, . EE 26
VOI TACt EE23 T R O U E L ED I A G N O S EASN D
ADJUSTIVTNT EE.24 C O F c - C T I O \(S1 l d 1 9 " I e r . d r o .r .' . . . . . . . EE27
V O L T A CR| I - C U I A T O
. .B
...........

DESCRIPTION
The regulatorconskisbasicaliyofa
voltageregulatorand a chargerelay.
The voltaSeregulatorhas two setsof
contactpoinls,a lowef sel and upper
rct, to control alternatorvoltage,An
armatureplateplacodbc|weenthe two
lets of conlacts,noves upward or
downwardor vibrales,The lowercon-
tacts,whenclosed,completethe field
cirouitdifect to ground:andthc uppel
conlacts,when closed,completethe
field circuitto groundthrougha resh!
ance(field coil), andproducesalterna.
IOf OUIpUL
The chargerelay is similarin con-
structionto thevoltageregulator.
Whenthe uppercontactsarcclosed,
ignilionwarninglampgoeson. 2

EE146
Regulatofmodel Appltcdengjn€ Appliedaliernator
Fig. EE-54 Vietr ofrcmovins couer

TLt2.6) J l 3 ,J l 5 a n dJ 1 6 LTt35.l38
As for construction, the voltage
LTl50-05 (Option)
regulalor is very similar to the charge
relayasshownin Figure8E.55.

10
ll 2
l2 l 12 Co
l 3 3 m n ( 0 , 1 1 8 1 i nd)i a .
l3 5
6 t 4 4 m m ( 0 . 1 5 7 5i i ) d i a .
l4 1
l5 8
9 VoltJgeregulatorconlact
(b) Co$truction of chaqe rclay
(a) construction of uoltagerecutotor
Fig. EE 55 Stuctutol uieu of rclay

EE.22
 Engine ElectricalSystem
.MEASUREMENT
OF REGULATOR
VOLTAGE

Regulatorvoltageis measured with

regulatorassembled with altemator.
Whenmeasuringvoltagewith regulator
mountedon vel cle,it is necessary to
Shortcircuitlere (letween
rotateengineat highspeed. fus iide lerminaland(-)
Connect DC voltmeter(15-30V), t€ininalof anmebt befit€
DC ammeter(15-30A),battery and
resfutor(0.25f,,) witll cablesasshown.
1. Checkto be surethat all electrical
Ioadssuchaslamps,cooler,radio,etc.
aredhcoftrected.
2. Beforestartingenginejbe sureto
(10A) (30v)
make short circult with a cablebe-
tween fuse side terminal of resistor
(0.25Q)and negative EEO55
sideterminalof
amneter.Failureio follow this cau- ti9. EE-66 Meatutingrceulatoruoltogeuith regulatoron uehicb
tion cauresneedle of ammeterto
swingviolentlyandreversely, rcsulting 3. Refer the following chan to partsarein gooalcondition:
in a damaged ammeter. determineif regulator and relaiive

l. Startengine,
2. Rotateengineat 2,500rpm for several
minutes.

After racingfor severalminuies,ammeterreading After racing for severalminuteg,ammeter

- below5A. reading- over5A.

Fully charged
batteryavailable. Fully charged
batt€rynot available.
L R€place'rvithfully chargedbattery. l. Connecta 0.25Qresistorin series.
2. Ch€ctto seeifcurrent fallsb€low54.

Curcnt falh below5A. Currentdocsnot fall below5A.

Recha'ge
bdtre'yandseeifcuflenrfailsbelow5A.

Reduceenginespeedto idling and then raiseit to 2,500 rpm while observingneedleof voltmeler.

Needle ol voltmeter held within lirnits shown in the iable Needleofvoltmeterout of limitsshownin the
followinBchart.
Regulatorfunctionhgproperly. ReSulatorout of order. Haveil repaireda!

ADJUSTMENT
VOLIAGE REGULAIOR
As the resultof aboYeneasure-
ment,whenregulating voltaged€viates
ftom ratedvalu€,adjustregulatorin
accordancewith the followinginstruc-
l. lnspect contact surface,and if
rough, lightly polish surfacewith fine
emerypaper(#500or 600).
2. Measureeach!ap, and adjustif
necessary. Adjust coregap analPoint
gap in that order.No adjustmentis
requiredfor yoke gap.
3. Adjustingcoregap
Loosenscr€lr [a mm (0.15?5in)
diameter] which is us€d to secure
contactseton yoke,andmovecontact
upward or downwardproperly. S€e
FigureEE.57.
2 screw,Turn this screwclockwiseto
3 4 mm (0.1575h) dh. scles
Ctossh€adsqewdrivo! EEo66
Fi'.8E.57 Adjwting core$ap
Engine ElectricalSystem
4. Adjustingpoint gap
Loosenscrew [3 mm (0.1181in)
dian€terl used to secureuppercon-
tact, and moveuppercontactupward
or downwardadequately. SeeFigure
EE,58.
I
2
3
Fi8- EE-59 AdjBting requlotineuoltoge
1
2 3 m n ( 0 . 1 l 8 li r ) d i r . 6 c r o w
3
UDDe! contart
Fig. EE-58 Atljusting point gdp
5. Adjustingvoltage CI{ARGII{GRELAY
Adjust regulatingvoltage as fol-
Normalr€layoperatingvoltaSeh 8
Loosenlock nut securingadjusting to 10V asmeasured at alternator"A"
terminal. Relay itself, however,op.
incresse,or counierclockwiseto de. eratesat 4 to 5V.
crease,regulatingvoltage.SeeFigure Use a DC voltmeter,and set up a
EE.59, circuitasshownin FigureEE-60.
EE.24
 EngineElectricalSystem

l. Connect positiveterminal of voltmeter to regutatorlearl conn€ctor..N,,

lerminal with negativeterminal
gromded.
2. Start engineandkeepit idle.
3. Takevoltmeter r€ading.

0 Volt B€lolr5.2 Volts Ov€r5.2Volts

1. Checkfor continuitybetlveen (Pilot lamp remainslit) (Pilotlarnpremains
"N" teminals lit)
of regulatorard l. Ch€ckfan belt tension. Pilot lamp relay coil ot contact
altornatot, 2, If conect, remove regulator pointsout of ord€r.
2. Alternatot circuit dofectlve if andadju8tasnecesssry. Replace regulator.
continuity exirts.

Over5.2Volts
(Pilotlempdoesnot light.)
PilotIamprelayossembly
ia in goodcondition,

L (WR) IG (WL)
F(WB)

E (B)

fig. EE40 T$trng chaEingrcW

t *
EngineElectricalSystem

SERVICE DATA AND SPECIFICATIONS

Voltag€regulator
Mod€l 'tLtz4l

Regulatingvoltage
(with fuly chargedbattery) V 13.8to 14.8
Voltagecoil resistance O 10.3lat 20oc (68"F)]
Rotor coil insertingresistance O 10
Voltageco_ilseriesr€sistance O
Smoothingresistance O 4l
Corcgap
Pointgap
Charge
rclay
Releasevoltag€ V 8 1ol0 at "A" terminal
Voltagecoil rclistrnce O 3l .9 lai 20oC(68oF)]
Coregap n.'Jn(in) 0,8to 1.0(0.0315 to 0.0394)
Pointgap mm (in) 0.4100.6(0.015? to 0.0236)

EE.26
 Engine ElectricalSystem

TROUBLE DIAGNOSESAND CORREGTIONS(lncludingalternator)

Condition

No output Stickingbrushes. Corr€ctor replacebrushes

andbrushsprings.
Dirty brushes
andsliprings. Clean.
LooseconnectioNor brokenleads. Retightenor solderconnections.
Replaceleadsif necessary.
Openstatorwinding. Repairor replacestator.
Openrotor winding. R€place
rotor.
Opendiodes. Replace
diodes.
shortedrotot. Replace
rotor.
Shortedstator. Repa or replacestator,
Crounded"BAT" terminsl. Replace
lnsulator.
Brokenfsn belt. Replace
belt.

Excessive
output Brokenneutralwire(colorofwtre tNwhite.) R€place
wire.
Defective
voltageregulator. Check regulator of'eratlon and repair or
rcplaceasrequired.
Poor gioundingof alternatorand voltage Retightentermlnalconnection.
regulator"E" terminol,
wire (coloror wire h black.).
Brokenground Replace
wire.

Low output l-oos€

or womfanbelt. Retight€nor replacebelt.
Sticking
brushes. Correct or replacebrushesand springsif
necessary.
Lowbrushspringiension. Replace
brushspringr.
Delective
voltage
regulator. Check regulatorop€rationand repalr or
rcplaceasrequired.
Dirtysliprings. Clean.
Psrtialshort,gound, or open in stator R€place
stator.
Mnding.
shodedor grounded
Partially rotorwinding. Replace
rotor.
Openor defectivediode. Replace
diod€.

Noisyalternator Loor. mountinS. Retightennountingbolh.

Loosedrive pulley. R€tighten
pulleycorr€ctly.
Defeciivebal beariry. Replace
bearing.
brushes.
Improperlyseated Seatbrushes
correctly.

EE.21
 Engine ElectricalSystem

DISTRIBUTOR
CONTENTS
rB .c ro\
coNS EE.28 A D V A N C E I T l E C HNA r s t !.1. .s. . . . . . . . . . . . EE,3O
.
C N T T K \ CA N DA D I U S T V | N
......... EE.29 D I S A S S E I V ] B LAYN D A S S E I / ] .B. L . .Y. . . . . . . .
c A PA \ D C O OP q c A D .......... EE29 D SASSEMBLY EE.31
POt\T .......... EE.29 A S S E M B .L.Y. . . . . . . . . . . . . . __ . . . . . . . . . . . E E3 2
c o N D\ r' r q EE30 S E F VC E D A T AA N D S P E C I F I C O AT N S . . . . . E E3 3

CONSTRUCTION
The distributorconsistsol breaker
Distributor lnodel Applied engine plate wilh contacipoints,centrilugrl
advance mechanism,vacuum unit,
D4l l-68 drive shaft. and rotor. Figure EE-61
and 62 showa seclionalview of the
D4t3-84
unit.
D4l1.81 J15

I
2
l

8
9

Fig. EE 61 Constructian
 Engine Electrical System

I
6
t

ll Lcodwirea3smbly
l2 Roto!ttead.lsenbly
13 Cond.nsia$embly
l4 Tcrninalasrnbly
15 Yacuuncontrolarsembly
16 Capa!!€trbly
l? Calbonpoiitassehbly
8 BF.ker plalc asmbly
19 Oring
10 Edth vLe as!.,nbly

FE. EE-62 Conponenttof .Jbtributot

CHECKINGAND
ADJUSTMEl{T
CAP AI{D ROTOR HEAD
Cap and rotor head must be in-
spected at r€8ular intervals. Every
5P00 km (3,000miles)of operstion,
remove cap and clean all dusi and
carbond€positsfrom capandrotor.If
cap is crack€d or is leating, replace
POITI
Standardpoint gapi! 0.45 to 0.55 paper (No.500 or 600) or with oil
nn (00177 to O-O2t7in). In casesize
is off the standaid,ad.iustmertis made At t}Iistime,greasemustb€applied
by looseningpoint screws.Gtp gauge to camshaftheadand camheel.
is requircdfor adjustment. When wear on breaker points is
Point gap must be checked every noticeable, replace points together
sp00 kln (3,000niles) of operation. with conlact arm. To replac€,proceed
When point surfaceis rough, take
off any irr€sularities with fine sand-
EE.29
 Engine ElectricalSystem

F
fig. EE-65 Disosemblinscontdct
arn dad contactPoinl
3 Prnnalylcadtcrminrl

point gaP
Fig.EE-64 Madsuting
First turn out sel screwsI to 1,5
lurnsat conlactarmandprnnary lead
Fig, EE'63 Breaher
wireconnectionjusl farenough
to full
out prinary leadteaninal.
Ref€ningto Figrre1.i1.63,
unscrcw
two contact sct lixnrg screwsand
While holdirrgcontactrnn by iin-
gers,pu]l out contactseltowardyou
by raisinSit slightly.Contrct point
and alm can lhen be rcmovedt0-
gelher.
Installnew contactponrtrnd anrl
assemblyin rcverscsequ€nceof r€-
moval.Coatcrnr hccl andcamshaft
headwilh a lightcoating
ofgrc sc.
CONDENSER
Satisfactoryperformanc€of con-
denserdcpends oo capacityanddegree
of insulation,requiringatt€ntionto be
sure that terminalsare cl€anand set
Chccking ofcondenser ismad€by a
capa.itytester.Thk canalsobe made
by n circuit testerwith its rangcsstto
high reshlancereirding.Wh€nneedle
of tester swingsviol€ntly and then
movesback to infinite gradually,it is
an indicationthat condensor is in good
If n€€dlcshows ny steadyrcading
or if it regist€rs
zero,the likelihoodis
that translbrmeris out of order,call-
ingfor replacemenl.

ADVANCE MECHANISM

<Pe.fo,rnances>

2A

2050x1
9
2050x1
Bro
5 205(Jx?. .l:

0
65{t;2.1
J1 t?st6,,,
500 1000 1500 2000 2500 1000 0 150 200 250 300 350 ,1110
Distribniorrolriion Gpr) VacuunGrnHg)

Fie. rF.66 Pcr[armon.ectru. lor Mo.lel Dd I I 6A

EE.30
 Engine ElectricalSystem

3 1 0 310

1000 1500 2000 2500 100 150 200 250 300 350
(rpnt
rotation
Distribulor vacuumCmmHg) E E1 7 5
Fig. EE'67 P.tfotnance cutuefot Mo.tel D413.84

810 310

1000 1s00 2000 2500 r0o 150 200 250 300 350
(ryn)
Diltibrto!roldtion VacuumCnnHs)

Fie.EE-68Petormdnce.utuefor ModelD4| I-81

<Vacuum sdvancemechanism <Centrifugaladvance DISASSEMBLYAND

parts>
mechanical
If vacuumodvanc€mechanism failg
to operateproperly, check for the
followingitemsand correctth€ trou-
ble asreq ired.
l. Check vacuumifllet for signsof
leakage If necessary,
at its connection.
retightenor replacewith a newone.
2. Checkvacuumdiaphragmfor air
leak.
If leakis found,replacediaphragm
3. Inspectbreakerplaaefor smooth
If plate doesnot movesmoothly,
this condition could be due to sticky
steel bslls or pivot. Apply greas€to
steel balls or, if necessary, replace
breakerplateasan assenbly.
parts>
rnechanicai ASSEMBLY
When causeof enginetlouble is
tracedto centrifugal advance m€chani-
DISASSEIIIELY
cal part,us€dhtributortesterto check
its characteristic. follow the proce-
To disassemble,
$,hen nothinS is wrong with its
characteristic,conc€ivable causesare l. Takeoff capanddisconnect
rotor
def€ctiveness or abnormalwearing-out
of driviflSpartor otherpart. 2, Removevacuumcontroller,
Do not disass€mble it. In cas€of
impropercharacteristic, removeon-off
switch part and check closelycam
assembly, govemorweight.shaft and
Sovernor sprng.elc.
Whencentrifugal advance mechani-
cal part is reassembled, be sure to
check advancecharacteristic by dis' d
d
Fie. EE 69 Dins@mblirq odcuud
contrcUer

EE31
 EngineElectricalSystem

3. Rlmovecontactbreaker. 6. mrcn caln is to be removed,first ASSEMBLY

Referto PageEE,30,whencontact remove set scrcw since shalt head is Assemblycan be made in reverse
fasten€dby the screwto hold cam
sequenceof disassembly.Refer to
down.Put natch markacrosscamand

s
Figurc 8E,75 for replacementand
t shaftso that originalcombinationcan reassemblyof govemor spring and
be restoredat assembly.
7. Whengovernorweightand spring
are disconnected, be car€fulnot to
stretchor deformgovernorsping.
applygrease
After disassembling, to
governorweights.

Fig.88.70 Renoving contact set

Fi|- EE-74 Renouing con

Fig.88.71 Renovingcontdctbrcaker

4. When contact br€aket is disas-

sembled,be cafefulnot to lose steel
balls between breaker sprtng and
plate.
brea.ker
5. Pull knock pin out and dhcon-
necl collar to removethe entire ro-
talng Frts-

' I2
8 Govenorspins{A)
3 9 Rotorpositio.inglip
FA. EE-72 Remouingknochpia
5
Fig. EE-75 Settinggouemorspringand @m

Fig.EE-73 Renodag rototioh parts

EE.32
 EngineElectricalSystem

SERVICE DATA AND SPECIFICATIONS

SERVICE DATA

< All distributofs>

Pointgap rnm(in) 0.45to 0.s5(0.0177to 0.0217)

kc 0b) 0.s0to 0.65(1.10to 1.43)
shaft dia'neter(lowerpart) rnm(in) 12.430to 12.440(0.4894 to 0.4898)
Housinginnerdiameter nm (in) 12.450to 12.468(0.4902 to 0.4909)
Clearanceb€tweenshaft andhousing nnr'(in) 0.010to 0.038(0.0004 to 0.0015)
Repairlirnit of clearance mm(in) 0.08(0.0031)

Shaftdiameter(upp€rpart) nJn (in) x- :9-!9! ,6 -- -9!!9?1

--,,.6 -0.0006
0_014
CaIninnerdiameter mm(in) 8.000to 8.015(0.3150
to 0.3156)
Clearance
beiweenshaftandcam mrn(in) 0.005to 0.029(0.0002
to 0.0011)
Weightpivot diameter mm(in) (0
4.972to 4.990 ,1959to 0.1965)
Weightholedianeter mm(in) 5.000to 5,018(0.1969
to 0.19?6)
betweenpivot andhole
Clearance mm(in) 0.01to 0,046(0.0004
to 0.0018)

SPECIFICATION3
Distributortype D411.68 D4r3-84 D{ I l.8l

Make HITACHI HITACHI HITACHI

Appli€dengine Jl3 Jl5 Jt6
Firingorder 1-3-4-2 1"3.4.2 1.34.2
Rotatingdirection Counterclockwis€ Counierclockwise
Ignitiontiming(B.T.D.C.) degree-rpm 80/600 8'/600 8o/600
Dwell angle degre€ 49o to 55o 49oto 55o 49oto 550
Condenser
capacity !F 0.2OIo 0.24 0.20to 0.24 0.20to 0.24

EE.33
 EngineElectricalSystem

COIL
IGNITION

The ignition coil is of an oil-filied

type. The ignition coil caseis filled
with oil whichhasgoodinsulating and
heatradiating characteristics-
High sparkingvoltageis produced
from startingto enginehighrevolution
by the exlernalresistorwhich is used
in the ignitioncoil cncuit for 6R'200.
(Extefnalresistorb not equippedfor
C1Z-200.)The internalresistorlimih
to a maximumsafeflow ofthe prirna-
ry currertthroughthe coil anddistrib-
utor contactpoints.Thus,it pfotects
the contactpointsduringslow speed
operationwhen th€y ar€ closedfof
longintervals. 2 Se.ondary
teiminal
3 Cap
4 Spring

10 Seg'nen1
ll Casc

FE. EE.76 Construction

SPECtFtCATtOttS
Makeandtype...............-. HTTACHI(6R.200) HITACHI(cr2-200)
Prinaryvoltage v ......................_....._........................
12 12
Sparkgap nn (jn) ..........................
. .. .. . ......Morcthan? (0.2756) Morethan7 (0.2756)
Primaryresislance
at 20oC(68oF) o ...................................................
1 . 5t o 1 . 7 4.2It)3.4
Secondary
resistance
at 20"C(68oF) KO 9-5lo l l.6 9tol1
Externalresistor O ..........-..-..................-....................
t.6

8E,34
 EngineElectricalSystem

SPARKPLUG

CONTENTS

D E S CPRT I O N .,..... EE,35 SERVICE D A T A A N D S P E C IC

F A T I O N S. . . . , E E . 3 6
NSPECTION ........ EE-35 TROUBLE D I A G N O S EASN D
N D B E G A PNPG . . . . , , , , , . . . . . E E . 3 5
C L E A N I NAG C O R R E COTN S -...., EE'36

DESCRIPTION Overhealing:Whiteor light grayinsu- spafk plugs,low fuel pump pres-

The sparkplugsare of the resistel lalor with black or gray brown sure, wrong selectionof fuel, a
typ€.having14 mm (0.551in) threads spots and bluis,hburnt electrodes hotterrangeplug,€lc.
and0.8 to 0.9 nm (0.031to 0.035tn) indicat€engineoverheating. More- to replacewith plugs
It is advisable
grp. Insp€ctionandcleaning shouldbe over, the appeuanceresultsfrom havingcolderheatrange.
rnadeerery 10,000km (6,000miles), incorrect ignition timing, loose
and replacement shouldbe carriedout
.vcry 20,(Imkrn ( l2,000milet,
Note: A[ sFrft phgs install€d on an
eo8ine,must ba of the samebrand
atrdheat nog€.

l1{sPECTtOl{
l. Removesparkplug wire by pull.
ingon boot, not on wir€ itrelf,
2. Remov€sparkplugs.
3. Ch€ck electrode!and inner and
outer porcelainsof plugs,noting the
type of depositsand the degreeof
€lectrodeerosion.Referto FigureEE-
77.
Lifc
Normal: Brown to grayish{an de.
posih afld slight electrodewear E€079
indicate correct spark plug heat Fie. EE-77 Spothplug
nnge.
Caronfouled: Dry fluffy carbonde- 4. Afl€r cleaning,dresselectfodes type cleaner.Avoid €xcessiveblasting.
positson the insulatorand elec- with a smaufine file to flatlcn ule Clean ard remove carbon oi oxide
trode are mostly causedby slow surfacesof both centerand sideelec- deposih, but do not wear away porce-
speeddrivingin city, weakignition, trodesin parallel.Setsparkpluggapto lain. If deposiis are too stubborn,
too rich fuel mixture, dirty air specification. discardplugs.
cleaner,etc. 5. Instal spark plugs and torque After cl€aning spark plugs, renew
to replacewith pluSs
It is advisable ezchplugto 1.5to 20 kg,m(l t to 14 fir'ns surface of electrodeswith file
havinghotterheatrange. fl,rb). mentioned above. Th€n gap spark
Oil fouled: Wet black depositsshow 6. Connectsparkplugwires. plugs to 0.8 io 0.9 mm (0.031 to
excessive oil enlranceinto conbus- 0.03s in) using a round wire feeler
tion chamber through worn rings gauge. A[ spark plugs new or used
and pistons or excessiveclearance should have the gap rhecked and reset
betweenvalveguidesand stems.If
CLEANINGAND by bendinggmund electrode.
the samecondition renainsafter REGAPPING
repair,usea hotterplug- Cleansparkplugsin a sandblast
EE.35
 EngineElectricalSystem

fie. EE-78 Setting 6pdrhplug Eop

SERVICE DATA AND SPECIFICATIOI{S

Modelandmal@ BP-sES.
NGK
L46PW;HITACHI
Size(screw
dia.x reach) mm(in) ......................... la x 19(0.551x 0.748)
....................
Pluggap mm(in) ..........,,.,,....,..... 0.8to 0.9(0.031ro 0.035)
.............,,.,..,
Tightening
torque kg-m(ft-lb) ...............-... ....................
1.51o2.0(l1to14)

TROUBLEDIAGNOSESA1{DCORRECTTOI{S
l. Whenenginedoesnot start, high t€nsion cable from spalk plug, After checkinSthis, repair as neces'
Ifthere is no houblein fuel system, startingengineand obsefvingcondi. sary.
ignition system should be checked. tion of sparkthat oc.ursbetween
high
This canb€ easilydoneby d€laching a tensioncableand sparkplugterminal.

SparkIength Troublelocation Probablecause Corrective

action

No sparksat all Distrbutor Defectiveinsulationof condenser. Replace,

oflead.wireon low tensionside,
Breakage Repair.
insulationofcap androtorhead.
Defective Replace.
Pointdoesnot openor close, Repair.
Ignitioncoil Wirebreakage
or shorlcircuitof coil. Replace
with a n€wone.
HEh tensioncable Wirecomingoff. Repair.
D€fcctiveinsulation. Replac€.

I to 2 nm (0.0394 Distributor Pointgaptoo wide. Correct.

to 0.0?87in) or Oil stickingon point. Clean.
irregular.
Pointburnt too much. Replace.

Lessthan 6 mln Sparkplugs Electiodegaptoo wide.

(0.2362in) Cleanor replace.
Brokenneckof insulator. Replace.
Expirationof pluglife. Replace.

'2.
f,rhcn enginetums over but does
not run sxnootl y.
In this cas€,there are many caus€s
EngineElectricalSystem
rcsulting from tlre ignition systemand spection of ignition syst€mshould be
other engin€conditions not related tb
igntion. Therefore, first complete in-

Trouble Troublelocation Probablecause Corrective

action
Enginemisses. Distributor Dirty point. Clean.
Improperpointgap. Correct.
IJak of €lectricityof capandrotor.head. Repairorraplace.
Defectiveinsulationof condens€r. Replace.
Defectivearm. Oil straft.
Defective
springolaIm. R€plaaeassembly.
Breokrge
ofleadwire. R€place.
Womout or shakybreakerplate. Replace
assembly.
Wornout or shakydistributorshaft. Replaceassembly.
lgnitloncoil L,ayer$ort circuitor useofinferior quality. Replace
with goodone.
Hight€nsioncode Deterlorationof insulation and leak of Replace.
elechicity.
Sparkplu8s Dirty. Clean.
L€ak ol electricityat upper porcelainlnsu- Repairor replace.
lator.

Engineknocks Distribuior Improperandadvance timlng, Correctthe fi ing,

veryoften.
Coming off or breakageof governor
sprjng. Cprr€ctor replace.
A pin or a holeof govefiorportionworn Replace.

Sparkplugr Burnttoo much, R€place.

Bnginedoesnot Distributor Improperandretarded timing. Correci tlle fitting.

give€ndugh
power. Defective
functionof Sovemor, Replace
assembly.
Drti point. Clean.
Pointgaptoonarrow. Correct.
Sparkplugs Drty, Clean.
MODEL
J13, J15 & J16 SERIES
HtGtltES

DESCRIPTION
The air cleaneris a dry tapertype.
DESCRIPIION
Th€ fuel strain€ris a cartride€
type.
It usespaperelementas strainerele-
ment whichcanbe clrcckedfor condi,
tion f-romthe outside.This strainer
shouldbe replacedevery20,000km
(12,000 milet und€f normal coodi,
tions.SeeFigureEF-i.
FUELPUMP.MECHANICAL
DESCR PTION
INSPECTION
FUEL PU[/4P
TESTING
STAT]CPRESSURE
DESCRIPTION
The fuel pump transfersgasoline
fron th€ tank to the carburetorin
sufficient quantity to meet engine
requirements at anyspeedor load-
The luel punps usedon the model
Jl3 and J15 enginesar€ of the dia-
phragmtyp€.
The firel punp consistsof a body,
rocker arm and link assembly,fuel
diaphrag'n,fueldiaphragm spring,s€al,
inletandoutletvalves.
The fuel diaphragmconsistsof
speciallytrcatedrubber,which is not
a11bc1ed by gasoline,held togeiher
wii}I two metaldiscsanda pull rod.
Enginetuel
AIR CLEANER
It should be cleaned and replaced
periodically.Availabieasan option is a
vrscouspaper type air cleane.el€ment
FUEL STRAINER
IiE. EF-l Sectiondluieu of
cdrttidgetype fuel jttuiner
CONTENTS
CAPACITYTEST
EF-2 FEMOVALAND D SASSEMBLY
ASSENIELY
INSPECTION
l. Cheok upper body and lower
2- Check valve asscmblyfor wear of
valve and valve spring. Blow valve
assembly by breath to examine its
3. Check diaphragmfor snaU holes,
4. Check rocker arm for wear at the
poriion in contact with the camshafi-
5. Check rocker arm pin for wear
sinceaworn pin nay cauk oil leakage.
6. Check all other componentsfor
any abnormalities and rcplace wirh
new partsas requrcd.
which doesnot rcquneany cleaning,
regardless
of contamination,
until it is
replaced period.
in the designated
REMOVAL
Disconn€ctinlet and outier fuel
lines from fuel strainer,nnd remove
Note: Befor€disconnecting fuel tiner,
use a containerto receive the
remainingfuel in lines.
EF.3
EF.3
FUEL PUMP TESTING
A luel punp is operatingproperly
when its pressureis within specifi-
calionsand ih capacityis equalto the
engine'sr€quir€nents at all speeds.
Pre$ure and capacity must be
d€terminedby two tests, wiih the
pumpnounted on rhe enSine. Besure
that thereis gasolirein the tanl wher
conduciing thesetests.
STATIC PRESSURE TEST
The staticpressure
test is conducr
l Disconnectca$uretorfuel lineat

2. Instal the necessary adapterand
"tee" fitiing to
fuet ljne and atracha
suitablepresNregauge.
3. Start ensineand run at varying
4. The readingon gaugeis the static
fuel prcssureaod this shouldremain
within thefolowinglimits.
Jl3 Engine
0.18ks/cm2(2.56psi)
J15Engine
0.2t kslcm2Q.9g psi:)
Pressurebelow the lower limit
indicaaes exlremewearon onepartor
a small amount of wear on €ach
workingpart.
This may alsoindicatea ruptured
diaphragm,worn, warped, dirty or
gummingvalvesand seatsor weak
diaphragm rehlln spring. Pressure
above the upper limit jndicaresan
excessively strongdiaphragmthrt is
too tight.
This conditionrequifesr€movalof
fuel pump assemblyfor replacement
I
2
1
4 Fuel pun? vrlve a$embly
5
6
7
9
l0
lt
I2
1 3 Rocter arn sidespa€r
l4
t5
t 6 Rockerdn sid€Da€r
t1
EngineFuel
CAPACITY TEST REMOVALAND
DISASSEMBLY
The capacitytestis usedonly when
the siaticpressure is within specifica- Removefuel pump assembiyby
tions. The capacirytest is conducted unscrewingtwo mountingnuts and
asfollows: disassemblc in the folowingorder.
l. Disconnectfuel pipe at carbu- i. Separateupper body and lower
body by unscrewing body serscrcws.
2. Placea suitablecontainerat the 2. Take off cap and cap gasketby
€ndofpipe. removing capscrew.
3. Start enginernd run at 2,000 3- Unscr€w elbowandconnector.
4. Take olT the valve retainerby
4. On rnodel Jt3 ongine,pump unscrewlng two screws, andtwo valves
shoulddeliyer400 cc (24.4 cu in) of
fuelin oneminuteor less. 5. Pressdowndiaphragncounterio
thc force of djaphragmspdng and
On nlodelJl5 engine: unlockthe rcctangular prrt ir the low
1,200cc (73.2cu in) end of pLrllrod from rockcrann.Then
r€movediaphrrgm,djapl agm spring
If no gasoline,
or only a littlc flows andlowerbody sealfrcm lowerbody.
from open end of pipe, frlel pip€ is 6. Dive ou1rockerarmph by press
clogg€dor pump is malfunctioning.
Belbre removingpump, removegrs
tank cAp, disconn€crboth inlet and
outlet pipesand blow throughthem
vrith an air hose ro makc sure th l
th€y are clear. This witl elirni ato
possiblecloggedgas s|lainer in fuei
tank. Reconnecipiposto pump and
EFI6A
FE. EF.2 Rehoual of pull rod
F
Fig. EF 3 Sttucturc of fuet puap
EF3
 Engine Fuel

ASSEMBLY 1. Usenewgasket. abovefuellevelwith a pipeconnecting

Assemblyis done in reverseorder
of disassenbly.For reassembly and
rcinstallation,the fo owing matiers
2. Lubricaterockerarm iink, rocker
ann pin and lever pin before instal-
3. To testthe function,positionfuel
pumpassembly nboui I meter(3.3ft)
fuel pump and fuel strainerand oper-
ate rocker arm by hand. If fuel is
dfawn up soon after rocker arm is
reieased,the function of purnp is

FUELPUMP-ELECTBIC

CONTENTS
DESCBIPTION ,,,.,,. EF.4 DISASSE[/]8LY AND ASSEMBLY EF.6
O P E F AOTN .....,,,, EF . 4 DSASSEMB . .L. .Y. . . . . ........ EF-6
T 8 SNTG................ ........... . E. F 5 .
A S S E M B. L. .Y. . . . . . . . . . ..... .. EF-6
T B O U B L ED I A G N OSS A N D NSPECT .
ON . . . . . . . . . . . . . . . . . . . . . ....... EF'6
COFRECTIONS ,,.,,. E F5

DESCRIPTION
The Silicon Transistortype fuel
pump consislsof transistot,diodes
solenoid, pump mechanism and
I Diapltngm
This hanshrorfuel pump pr€s€nts
severaldislinclfe turesasfollowsI 3 Diodc
l- No vaporlookin torridzones.
2. SlrrLspunrpinginmediatclyas
th€ ignitionswilchis turnedon.
3. Builtin filter and magnetkeep
out dust and iron filingsof fuel,and 9 FiLlet
add to pump and enginelite. See
FigureEF4.

Fig. EF-4 CoBttuctioh of luel pump

OPERATION

I
2
3

5
'7
8
9
10

Fuel pump circuit .tiagam


: (2) As the transhtor is cut off, the
Wllen the ignition switch is tumed
on, cun€nt flows thrdugh the con and
resistorO to the transistor.
The current furtler incrcasesin
strengthas it passesthrough the signal
coil.
Whenthe curent flows through tlrc
main coil, there is then a rnagnetic
pull, pulling the pluager against the
force of the return spdng.
Men the pl nger is so pulled
down, revefte cuffent beginsto flow
through the sigral circuit, cutting off
the traNistor.See FiguresEF"3 and
EF4.
(1) Suctionstroke
When current flows through the
maln coll, this causesthe plungerto be
pulled down by the mrgneiic force. As
this takes place, fuel pushesup the
outlei valveand entersthe top end of
the plunger,FigureBF-s.
Iie. EF-6 Suctionsiohe
Engine Fuel
plunger is puslrcd up by the retum
spring, forcing fuel out. Then ule
pluager sucks up fuel at the bottom
end of the plung€r through the inl€t
valve.SeeFigureEF'7.
FE,EF-7 Dbchdqesiohe
The samesequenceof eventstakes
placeto continuesupplyingfuel to tlle
engme,
Theseprocesses@ and @ are
repeatedcontinuously,
TESTING
fuel hoseat pump
1 Dkconnect
outi€t.
2. Connecta suitablehoselapproxi-
mately6 nm (0.0236in) tnnerdta-
meter]io thopumpoutlet.
Nore: If th€ diam€rerfutoo smrll, th€
Foper deliv€ry caFcity c{n not be
obtain€d €ven if putrrp functions
properly.
3. With th€ hoseoudet in the higher
position than pump, operate PumP
and check the delivery capacity for
morethanl5 seconds.
4. Tlle capacityshouldbe I,400 cc
(853 cu in) in oneminuie or l€ss.
If no gasollne,or only a little flows
from open end of pipe with pump
operated,or if pump doesnot work,
follow the following diagnosis.
Notesr
a. Do not connect battery in rcvene
poladiy, 13thls would dunagc han.
sbtor cLcuit and dilabl€ the pump.
b. Do not let the pipe fal, a3 tt m8y
damagethe electronlccomponenk.
c, Do not rpply overvoltage,(max.
l.E V) Ovdvoltage shrtlng by
qrdck chrryeor overvoltagerurmiig
would detedorate ot d.mrg6 elec-
trcnic components.

TROUBLE DIAGNOSESAI{D CORRECTIOI{S

Condltion Corrective
action

Fuelpumpfallsto Termoalsor connections loose. Retighten.

operarc. Rust on terninals or groundingmeial. Clearl.
Frozenliquid in plungprstick or pump. Cleanplungerassembly.Replacepump if
plungeris stuckor seized.

Fuel pump falls to Cloggedfilter. Cleanpumpinterior.Cl€anand,ifnecessary,

disclargesufficient
flo\li. lnsufficient fuel. Replenish.
lnsufficient fuel Fuelhosedbconnected.
dischargeduring Air in fuel hosethroughconnections Apply a coating of end sealinScompound to
h4h speedtraveling. connections, and retighten.
lnw float level
Hoseneckeddown or bent. Checkand correct.
at idling.
Fuel tank breather tube beni or necked

Wealenedretum spring. Replace.

EF.5
 Engine Fuel

Condition

Air sucked through connection (fuei hose Apply a coatingof end sealingcornporlndlo
morefrequentlylhan and f'rel pump joint). connection,andretigit€n.
undernormalcondition. Fuel hose(on suction side)bent. Checkandcorrect.
Cloggedshainer. Cleanor replacestrainer.

Rattling noise Mounting bolts loose. RetiShten.

DISASSEMBLYAND 2. Whenrenovingplunger,take out Nolesi

ASSEMBLY
DISASSEMBLY
l. Removecoverwith wrenchand
take out cover gasket,magnel,and
filter from pumpbody,
spfingretainerfrom plungertube.
3. Then, take out washer,O.ring,
inlet valve,returnspringand plunger
from tube.SeeFigureEF-8,
Note: Do not disass€mble
€leclronic
compon€nts.If neces$ry,r€plac€
Take crre not to deformtrbe as it
h thin.
a. A$€mbl€ plung€r, return spring,
inlet valve,O-ring,washerand set
springretrinerin thisorder.
b. Assemblefilter, gasketsnd cov€r
with magnet.
c. Tight€ncoverwith wr€nchto the
stopp€r.

INSPECTIOt{
lf Wrshfilter andstrainerwith clean
casolineandblow dustoffwith a blast
ot air. Whencleaningth€ parts,check
filter andSasket.If defective,
replace.

Noter Filter must be cleaned every

10.000km (6,000mil€s).

2- Washplunger,plungertube and
7 Oiine inlet valvewith clean gasoline,and
blow dust off with a blast of air.
Checkthen for wearanddefect.
If tley are found defeciive,
replace
12 Body

Fig. EF-8 Explotlettlieu of fuet punp 3. lnsert plunger assenbly inio

ASSEMBLY
Belore asscmbly. clean all parts
with ga$ljne and compressedair con,
pletely.
plunger tube of body and apply
Notes: electriccurren!to it.
If gasket or filter is def€ctive,re- Movethe assembly up anddown.
placeit with a new one. If the assembly doesnot move,it
b . Especialy cleanmagnetand cover shows that the electric unit is defec-
for defect. tive,andit mustbe replaced.
EF-6
 Engine Fuel

TWO-BARREL
CARBURETOR
CONTENTS
DI SCRIPTON EF. I A C C E L E R A TPOUFN T P . . . . . . . . . . . . . . . . .E. F . -13
c A R B U q r t oTRV P -. . . . . . . . . . . . . . . . J E TA , I R B L E E De ,t c .. . . . . . . . . - . . . . . . . . . E F l 3
s - I F U ILu R l A N D O P E q A T j O N . . . . . . . EF,7 [ / ] A J OSRE R V T COEP E R AOTN - . . . . . . . . . . E F - l 3
P R I I V A RS YY S T I M, , , . EF.8 R E M O V A L . . . . . . . . . .. .. . . . . . . . . . .E F - 1 3
S E C o N D A FSYY SL l l . . . . . . . . . . EF.11 DISASSEIVIBLY . . . . . . . . . . . . . . . . . . . . . . . . . . EF-13
AD-US]MtN] E F] 1 C L E A N I NAGN D ] N S P E C T |.O. .N. . . . . . . . . E F1 7
IDiINCAD,USIMLNT. E F1 1 A S S E M B LAYN D I N S T A L L A T I O. .N. . . . . . . E F l j
TUT- LEVLL ADJUSTMENT E F . ]1 J E T .S. . . . . . . . . . . . .. .. .. . . . . . . . . . . . . . . .E. F . -17
ADJUSTIIIENT OF INTERLOCK SERVICE D A T AA N D S P E C I F I C A T I O. N . .S
.. EF,1B
OPENING OF PRIMARY AND TROUBLEDIAGNOSES AND
S F C O N D A FT Y H R O T _ LVEA L V E S .,...... EF-12 CORBECTIONS ..,... EF-19
ADJUSTN,,IENT OF STARTING
I N f T R L O CVKA L V EO P E N I \ G .. . .. ... EF,12

As almost all the mechanisms of

DESCRIPTION thesecarburetonarequitesimilar,the
general explsnatlon dpplies to all
TYPE
CARBURETOR exceptfor minorvariations,
Theseare downdrafttypesand are
Carburetor
type Appliedengine bodynumber
Car.s designedto ircrease power and fuel
economy.
2t4282-124 GN62OU
N62OU, These carburetorspresentsev€ral
distinctfeaturesof importanceto ih€
NL620,GNL520,
214282-r32 J15wlth manual 1'NL620,
NL52OT, A summaryof featuresis as fol-
transnrisrion GNL62OT
a The secondary switchover systemis
PA32l.WA321, the mechanical throttle valvetype
214282-141 CKPA32t whichusesthe auxiliaryvalve.
. The power valve mechsnism, so-
T2OU,VT2OU,T2OHU calledvacuumpistontype, affords
214282-t11 J16with manual highspeedpeformance.
LT2O,LT2OH . Accele.ating pump gives excellent
214282-l8l

214260-t22 520U,G620U,
U620U
STRUCTUREAND
J13with nanual L620, LG620,UL620, OPERATION
214260-t32 L620T,uJ620'l
These carburetors consist of tlle
primary system fbr normal running
214260.111 A32I
andthe secondary systemfor full load
running.
The float systen which is com-
*The diff€.encss h performance are explained in the fo owing specification table.
mor y usedby primary rnd secondary
systems,the secondaryswitchover
mechad$n, the startingmechanisn,
acceleratingmechanism,etc- are also
attached.
On thesecarbur€tor,both primary
and secondarysystemsadopt zedth
stromberg typenozde.
EF.7
 F n g i n eF u e l

(a
T
:

,6
l:l Sccondaryslos air blecd 23
14 l,rimrry hdn rirbleed 24
15 trinruy nrin nozrlc l5
(Prirhdy $tr{ll venturi) 26
l6 2l
t7 28
? Outlct chcokvalvc a o c r e t o r p u m Pn o z z l c 29
8 Acccl*!t$ pun! piJto! l 9 SccondaryDrin nozzlc l0
( S c c o n d d ys n l d l l ! c n t ! r i ) li
l0 Prir{ry slo{ xtr blccd 2(J Sccondfy nuin !n b[cd J 2 Sccondrrythroltlc valve
ll 33
22
Fk. u-FI S.ctionol tieu of cdrbLre tor

PRIMARY SYSTEM ldlina and slow syslem

Primary gy5teln Dudrg low enginc spccd, asshown

The prnnary systenris of zenith
slrombergtype. Fuel flows as shDwn
in FigureEF-10throughthc mrin jet,
niting with air which conesin flom
the main ajr blecdand passesthrough
the cmulsiontube, and is pu ed out
into the small venturi through the
mainnozzle-Du€ Lothe smallventuri,
the highervelocityair curfentpasslng
tluoughthe nrainrlozzlcpromotesthe
in FigurcEF,l l, fuel flowsthmgh
th€ slowjel, lnixnrgwith airconnring
from the lst slowair bleed,rnd passes
$rough the siowc.onomizerjet,again
mjxingwith iir comingffom rhe 2nd
slow air bleedand thcn is puled oul
into the enginethroughthc idlo hole
(or the idle nozzle)andby-pass hole.
Mode1.2t4282.111 and -l8l arc
equipped wjth the idle nozzle as
Fig. EF-11 Idlinganl610b sy3tem
slown in FigurcEF-12.Throughthis
nozzle, idling mirrufc is further
alomizedby air streamb.low throule
valveandensures stableidliig

Fig. EF l0 Prinary main stst.m Fie. EF-12 ldL nozzlesrstem

EF€
 Engine Fuel

The lst slow air bleed on ihe bureto$ is differentfrorn othertypes Slow economizersystemis useful
2 1 4 2 8 2 - 1a
7n1 dl 8 l (Jl6) type car- (Jl s andJ13). to obtainsmoothdeceleration
ai high

J15,113'iype

Fie. EI'-13 lst stou dit bleed

Accslerrting mechanlsm

Theca$utetoris equt!pcdwitl the

piston typc accelerating nrechanism
linked to the throttlevalvc.Whcnthe ii
primary throttle valve, shown in
Figure EF-14, is closed,the piston
gocsup, and fu€l llows lionr thc flo:r!
chamb€rlhroughdrc inlet valvejnto
the spaceunder the piston.Whcnthe
lhrotile valve is opcncd,the pisror
gocsdown, openingthe outlct valve,
il
and th€n fu€l is stray€d againstthc
sidcwall of the snall venturi.broken
up inro small dropleis,and suppljcs
additionalfuel to errich the air-fucl
lrixture. Thc dnounr of fuel io be
sprayedcan be adjustedby ohanging
the positionof thc pump rod on rhe
pumpam.

2 Clip

Startint m€chanism
Pull the chokeknob io closerhe
choke valve fu1ly, then srart the
engine.This providesa rich mixrure,
naldng it possibl€to startlhe engine
quickty Whenthe cngineis srarted,
the chokevalveis openedat an ade
quate angle automatically, ivhich
prevents overchoknre and ensures
smooth engineperfomance.
While the engine is being wanned
up, it increas€sin s!€ed dr steps,and
by reteasing rhe choke knob an
EF.9
FiE.Et 14 Acceletutionntechanisa
optimum engine speed can b€ ob-
lained. With ihe chok€ valve closed
fully. ltle prinary throttle valve is
causedto open througl a link nech-
anism at an ,ngle besl suited for
starting.
 E n g i n eF u e l

r j-!
ql.
)
<J (
-"t
)

A: I d t n s ( o r T n r o t t l ec L o s d )
!
B' : Iast idle (or Throttlc opcncd)

EF196 To.1lhif6ld
Fig. EF-15 8tafti\g mechanism FE.EF-16 Pouerodllemechonbm

Powot velva mechahlgm the vacuumbelowlhe throtilevalveis Throttle valvG

ioweredduring full load or rccelera-
The power valvemechanism,so. Thc primaryihrottle valveopemles
iion the spring pushesthe vacuum
callcdvacuumpistontype,ulilizesthe pistondownward,openingthe power tluough 80o for the Jl5 and Jl6
vacuurnbelowth€ throltlc valve.When €ngrne,an0dJ_rorrrr engrne,
valve1ofurnhhfu€I,
the throttlc valve is slightly opened Th€ sccondarylhrottle vaiveopcr-
Thc powervalvecomesinto func-
duing light load running, a high alcsthrough 70o for Jl5. Jl5 AndJl3
lion wheDthc vacuumis 115to 145
vacuumis createdin the intakemani- mmHg(4.531o5.71inHg)for thcJ1s cngine,
fold. This vacuumpulls the vacuun ard I l0 to 140 11is connected to the chokevalve,
engineandJ16engine,
piston upward against th€ springJ acceleralorpump throughihe system
mmHg(4.33to 5.51inHs)for theJl3
leavingthe powervalveclosed,When ergin€, linkagc.The designis suchthat when
th€ primarythrottle valveh opencd
s0o (Jls, Ji6), or s30 (Jl3), the
sccondary throttlevalvestarlsto open.
T|es€ ar€ op€nedfully at thc same
Secrisun lil-21
/.
f

50"( r 5,.116)
5 3 "( J l 3 )

7 0 o( J1 5 ,J 1 6r n dI l 3 ) 8 o o( J t s ,J 1 6 )
83'(Jt3)

2 o o( J 1 5J, 1 6a n dJ l 3 )
1 o o( J 1 5J, r 6 )

I
2
l

FiC. EF-17 Throttle lalte

EF.1O

.SEOOI{DARY SYSTEM
Secondary sy3tem
The secondarysystemis of zenith
strombergtype. Air-fuel mixture pro.
duced by tle functions of &e main
jet, mainair bleedand emulsiontube,
in the sarnemarner as in the primary
system, is puled out into the small
venturi tfuough the main nozzle.
The structure is akflost ihe sameas
the primary-side, but ventudandjeXs
are different. Take carc not to as-
sembleimproperly.
Flg. EF-18 Secondory noin atten
3t.p .yrt.m
The construction of this sFtem
maycorespond to thedowsyst€m of
the pdmarysystem.Thissystemalrns
at the proper filling up of t]le gap
when fu€l supplyis transfefiedfrom
the prtnary systemto the secordary
one.The stepport is locat€dnearthe
secordarythrottle valveedgein its
fully closedstate.
Enginefuel
Secondary Bwltchover
machari3m
As the linkage, shown in Figure
EF-l?, cau!€sthe secondary throttle
valve not to open urtil the primary
tfuottle valveopeningreachesapproxi
mately50o (J15, J16), or 53o (Jl3),
fuel consumption duringnolmal oper.
ationis not excessive.
When the primary throtde valv€
opening reacheswider position than
50o (15, J16), or s30 (Jt3), the
au\iliary valvefureadyto open.
The auxiliary valve, shown in
Figuie EF.17, is a specialy shaped
buttetlly valv€ and is eccentrically
mountedabovethe throttlevslve.Itis
connected to the valve arm which
incorporates a weight.Thevrlveopens
and closesautomaticallyto provide
the correctair.fuelratio.
Flo.l ryatsm
The float systemconsistsof a floai
chember,a floet and a needlevalveas
rhown, Fuel from the fuel pump
ent€rsthrough the fuel strainerand
noedlevalveinto the float chamber,
Thls wlll causethe float to moveup,
pushingthe needlevalv€into the valve
s€at.As the result,the fuel inlet is
closed,so that no fuel can enter,As
the fuel level lowe$, the float moves
down and opensthe fuel inlet, thus
maintaining ille level constant.Since
the needlevalveis spflngloaded, it is
hardly influencedby extenal forces
due to vibraiions (float) when driving
on roughroad,
The float chmber is v€ntedinto
the carburetoran horn and doesnot
open to the atmosphere.In other
words,air pressure is the samein the
float chamber and air hom. This
eliminatesthe effect of a cloggedair
cleaner,which otherwisewould ble€d
too much fuel due to inoeasedmani-
fold negativepressur€.
1u Checkto be surcthat float levelis
cofi€ct whjle rurning engine at idle
speed.
2. Using a suitable screwddYer
stariing from tully closed position,
turn oux idle Edjust screw approxi-
nately 2 (J15) or l%(lt6) or
2%(J13)tur . Tum in tirottle adjust
screw two or three tums and start
engine.
3. Turn throttle adjust soew gendy
in or out untll speclJledenglne idle
speedis approximatelyobtained.
4. Tum idle adjust screwin ol out
uniil engine runs smoothly at the
htghestipe€d.
5, Tum out ihroiile adjust screw
until speclfled engine rpeed is ob.
tained.
6, Readjust idle screw until €ngine
nrns smootl y at the highest speed
(wtth hig.hestvacuumreading).
7. Repeat ihes6 operstionsuntil
smooth and specifiedenginespeed
(600 rpm or .bove) is obtalnodand a
conc€ntrationof 3% CO has been
obtained.
FUEL LEVEL ADJUSTMEI{T
A constant fuel level is maintained
by float andballvalve.lfthefuel Ievel
k in accordwitl levelgaugeline,float
levelis properly set.If float level ls not
correct, adjust it by bendinSfloat arm
asslbwn in FisuroBF-21.

ADJUSTMENT
IDLING ADJUSIMENI
Idlingadjustmentis madeby throt-
Fig. EF-19 Secontlary step clstem tle, adjustscrewrnd idleadjustscrew.
EF.lI
 Enginefuel
Figue EF-23 stlows that pdmary
ttuottle valveopens50o (J1s, J16)or
53o (J13). mer primary throxtle
valve opeff 50o or 53o, connecting
link is contacted with riSlrt hand end
of a groove on primary tluoitle arm
(A).
When throttle valve further opens,
secondsry ftrotde valve beguN to
open. Linkage between primary and
secondarytirottles *ill operateprop-
erly if clearancaGt beween ihrotde
valve end lnner wall of tfuottle cham-
I Slairer ber, amounts to specificatio as
2 BaUwr!€

Gl dimention
mm (mJ
FE. EF-20 FueIleuelddiwhnent
5.89(0.27r)
lifted up by bendingfloat atopPer.
*H: I O mm (0.0394in) 6.89(0.27t)
6.45(0.254)

Adjwtmentis madeby bending

connocting
lin*.

AD'U3TME'IT OF STARTIXG
PE. EF-21 ?Ioot.n odjuatnett INTEFLOCX VALVE OPENING
Adjwtmentshouldb€ performed
Appioxim.tely *ll mm h rcquired wlth chokevslvefully closed.Without
for effectlv€ltrok€ of boll valve.So dbturbing {bove settlng, check to
adjuit grip blt*een valve stem and EFOlA
determlne lf cloarance between
float arm to *H mm with flost fully trig, EF-22 Floot stoppet adjustmant prlnary throttlo valveand innerwall
of throttle chamberis held within
specifiedljmlts. Allo geeif openinS
oPEt{tr{G
oF
SECO]IDARY
VALVES
t*****^"f''-.r,
AD'USTMENIOF II{TERLOCK
angleof primorythrottlovalveis 1?o
(Jls,Jl3)or 19o(J16).
If necessary,bend choke con"
nectinglod as requiredso that cl6ar-
ance"C2" fallswithin specifiedtoler-
ances,asshownin.FiguftEF-24.

1?"(!15,J13)

5 o o( J t 5 , J 1 5 )
53o (J13)

(seeFig. EFl5)
tie. EF-24 Me@ing startiie
Fb. EF-23 Adjusrte interloch openine tuterloch nolre openina
EF.12
 E n gi n e tuel
AGCELERATOR
PUMP If th€ tlueadsof the parts and oiher
it
G2 dimention fitting parts of rhe throttle shaft and
Acceleratorpump can be checked
mm (in) chokeshaft are roo tight, cleanrhem
w'th enginestationaryandair cleaner
well with gasolinebefore assembting
remov€d. To testpump,op€nthrottle
1.33(0.0s2)
valve fuly at a stretch and seehow
1.s7(0.062) All the parts of these carburetors,
much fuel pump wifl feed. Be sureto includiq the small ventud, €an be
1.03(0.041) repeatthis procedurel0 to 20 times disass€mbled
and careshouldbe taken
to obtainaveragereading: to identify very sirnilar parts for rhe
primary side and for the secondary

men disassembling rhe carburetor,

Holein pumparm it is easyto dividethe work into the
nearthe pump arm shaft following six Sroups.
l. Linlegesand rod arouddthe car-
0.72cc
0.6 cc 2. Acceiemtor pumpparts.
3. Air hornparts.
0.6 cc
4, Bodyparts.
Dependingon position of connecting 5. Floatparts
rod in holesin pumparm.
6. Flangeparts.
Among the abovegroups,the float
anq acceleratorpump parts are rel.
atively easy to djsssenble inde-
JET,AIR BTEED,ETC. REMOVAL pendently.

All jets, air bl€edholeaetc.,should

be cleanedwith rpprovedsolventand
checked for cloggingand stgn of
damage. Th€y shouldneverbecleaned
with wires, for this will enia4e th€
oPenrngs,
MAJOR SERVICE
OPERATION
The perfectca6uretordeliversthe
properair andfuelratiosfor alt speeds
of the particr ar enginefor which it
was designed.By conpletely disas- DISASSEMBLY
sembling at reguiar intewqh, which
will aliow cleaning of atl pans and
passages, the carburetorcanbe rctum-
ed to its original condition and it wifl
then deliver the proper ratios as it did wellfittedto thenuts,screws
To maintain the accuratecalibra.
tion of pas$g€sand dischafgeholes,
extreme care must be taken in clear-
ing. Use only carburetor solv€nt and
compressedair to clean all passages Replacethe d€fectiveparts with new
anddischarge holes.Neverusewire or
other pointed insrrument to clean as
the calibration of ca$ureror wil be
L Removesir cleaner
2, Disconnect the lacuumpipecon.
nectingto thedistributor,
3. Disconnect fueliine.
4. Removethroiile end chokewtrc.
5. Removefour nuts and washers
retainingcarburetor Llnkrgo part.
to manifold.
6. Life carburetor offmanifold. l. Takeoff ihe clip at thepumparm
7. Removethe gasketusedbetween anddisconnect the pumpconnecting
calburetorandmanifold.R€plac€ it, if roo xom thepdmarythrorrletever.
2. Disconnect the starting con.
nectingfod fron th€ startingthrottle
lever.
G€n6ral inglructlonr
Usewtenchesand driversof siz€s
andjers,
to avoiddanageto them.
The smal parts disassembled or
rernovedshould b€ kept aranged ac-
cording to the individual systemand
be checked for werr and damage.
Clean a[ the parts with gasoline,
blow air though tlle $nall holesin the
iil
partsanddry them by air.
i
EF.I3 riii
 Enginefuel

I Cotterph (1 dia.)
2 Plainwasler(4 dia.)
3 Rod slring

5 Erins (4 dja.)

8 Slarlinglev€rconnccting
roal
9 Eiins (1.9dia.)

EF2O1
Fig. EF-26 Lithaee pa .lba$emble

Acc.l.rrtlnS Purnp pumpplungerassenbly canbe taken the ball inlet valve by removing the
the linkagethe
By disconnecting out. Takeout the pumPskainerand rtrainerclip.

I AceleratorPumPPston
2 Clip
l

EF205

Fig.El-26 Removatol occeletutingpumb

Afu horn
the air hom to the body, the choke
By taking off three bolts holding wire hold€r,air hom, clalllpetc.,and
EF.I4
 Engine Fuel

I
. 2
3

5
6
' 18
' 9
o'oiir""e'.qp
10 rh'ottturuqmjprtnr
rEf206
PE.EF-27 Aenowl of ai hon

Note: Th€ vdcuumpiston arsembly
for.the potfu!Jet,thFrchokrlslve,
thc choke shgft, chdkeleverand
rpdrg are indall€dlh th€ air hom
rssernbly,
_,,r :
B€c{r€fulnot to damsgethem,and
do not removethen fton air hom.
Body
1. By tlkiog off threebolts which
hold the body to the flange,th€ body
it r€movod. TVo of these bolts ar6
tightenedfrom th€ body sid€ and one
id from-th€ flangeside.

I B9dv
2
3

FE.E?-28

2. Renovethe jetsandan bb€djets

installed on the upper surfaceof the moving the slow paslageplug at the lst slow an bbed phg at the wall of
body. upp€r surfaceoftne body, the slowjet th€ primary sidebody, the lst dow aif
Model 214282-171,181, by rc- is taken out and then by removingthe bl€edjet is tal(en out.
EF.15
 Enginetuel

I Plug
2 Garkei

4 outlet klle (Ba[)

6 Se@nilsryslowai! bleedjet
7 Piindy main6ir blee.ljet
8 Pdhary small@ntlri

10 Primaryb4e venturi
lt Se@ndary nah dr bLedjel
12 S.condary sm.llEntud
13 Casker
l4 SopJet
l5 St p lir Ue.djet

EF2OS
FE,8F.29 Remoualof iat etc.

3. By refilovirlgthe pump passage
phg, the pumpweightandthe purnp
oud6tvalveOall) &e takenout.
Do not rcmovotte pump nozzle
Ilxedinto thebody.
4. R€movethe small venturl bY
takingoff two screws.
5. Be careful not to dsmag€the
valvettp of the powerjet valveas.
$mbly with theddver.
6. Tal€ off the mainjet aftet re-
movlngth€ mainpassage plug at the
bottomsurface of thebody.
Flo.t
1. Loosenthreescrewsholdingthe
levelgaugeglassandiakeoff thefloat.
At float plr, thete ls a collar for
keeplogfloet position.
Pay atlentlon to the stnallr€lated
partswhichmay comeoff at r€movrl
of thefloat,
2. Removeih€ bolt holding the
union nipple,by removingthe nipplo,
thebellr.lve s€atlr removed.

FlanSe
Primaryeide
1. Removeidle edjust sr$w afld its
spring. By taking off the prtrnary
throttle shaft nut, the thrcttle shafi
lever, the ihrotde shaft arm and the
starti[g throttle leverarc remov€d,
I Fuel niplle et rcrew
2 Plain walhor (8 dia)
2. R€movethe plug ofprimary slow
3 F@l nippl€ port.
3. Model 214282.1'l| , I8l, take off
5 Float%lw seal the idle nozzle and its gasket after
6 Float varve removingthe idle nozzleplug.
8 Level SauBe@wr
4. Do not r€mov€th€ primary throt
9 Floal cltdber gastet ile valve and ttuottle shaft from
l0 I?rel9.lge flange.
11 Rubt er seal

EF2o9
gie. EF30 Reno@l of float

EF.I6

l. By taking off the throttle lever
set screw,the secondary throttlelevet
and the spring ar€ removedfrom the
secondarythrottl€s,\aft.
@. -.>..-
N.y
I The carbur€tor performance
2 5 Secondary
3 Secondaryihrottle lewr
Fig.8F.32 Remoualof flonse(seconddrN)
Note: In the flang€, two throttle
valvesareinstall€d.
Be careful nol to damag€them and
do not renor€ them frorn flange.
Otherwise, stable idling and slow
sp€ed p€rformance will not be
obtained.
CLEANING AND INSPECTION
Dirt, gun, waterorcarboncontam-
ination in or on the exterior moving
parts of carburetorare often rcspon- mattersshouldbe checked:
sible for unsatisfactoryperformance.
For this reason,efficient carbu-
retion dependsupon carefutcleaning 2- Check throttle and choke bore
and inspeciionwhile servicing.
Engine Fuel
3. Inspectidle adjustingscrewfor
A*
\<'--l/-:\
burrsor ddges.R€place asrequired.
Inspect gaskets whether they
appearhard or brittle, or whether
\- \, edgesaretorn or distorted.Ifanysuch
\t \\a -
tr
condition is detected,they must be
replaced.
Check filter screen for clogging.
Cleanand replaceif it is dhtortedor
@ remairsplugged.
Checkventuriclustersfor loos€or
2 wom parts. If damageor looseness
l exists,r€placeclusterassembly.
Checklinlage for operatingcondi,
5
tion.
6
7 Idle adjustinE screw spring Inspect .the operaiion of ac-
eF210 celeratingpump. Pour gasolineioto
Fiq.EF.31 Redouatof flance(Primory) float chamberand operatethrotue
2. Removethe plug of the second-
ary stepport. Ch€ck condition of gasolinein"
3. Do not removethe secondary jectionfrom accelerating nozzl€. l,r
throttlevalve,its shaft,auxilialyvalve
andit, shaftassembly from flange, ASSEMBLY AND l
INSTALUITION ii
Assemble
in reverse
and instalithe carburetor
sequence
Replace
ofdisassembly
gaskets,
if necessary.
and ti
Whendisassembling and assembling
interlocklink andr€latedcomponents,
be carefulnot to bendor deformth€
Reassenble carefullyafldcorrectly
so that all int€rlock links operate
li
$noothly.
JETS
throttL returnspring depends on jets andair bleeds.Thafis
EF211
why these componenisare manufac-
turedwith utrnostcare.
Blow all passages and castings wiih ' To cleanthem,usecleaning
solvent
compressed air and blow offa paris and blow air on them.Larger nunbers
until dry. stampedon the jets indicatelarger
diameten.Accodingly,mainandslow
Note: Do not pass drills or wir€s jet with largernumbersprovidericher
through calibrated jets or passag€s mixturc, and the smaller numbers
as this may enlarge orifice and provide the leanerrnixtur€-
seriously affect carburetor calibIa- Inversely, the main and slow air
bleed,which air passes illrough,makes
fuel mixrureleanerif they bearlarger
Checkall parts for wear.Replace numbers, andthe smalernurnbers the
wom parts. Esp€cialythe fo owing richer fuel mixture.
Replac€meni of designatedjets to
l. Check float valve (ba[) and seat
for wear.Replaceassembly,
if wom.
meet the sefliceconditionof the car,
must be carriedout with the above
dnectionsin mind.To cite a practical
i
example,when it becomesnecessary
EF.17 I
 EngineRrel

to economize fuel at the limited
sacrifice of output to meet frequent
liSht-loadoperation, use smaler main
jets or slow jets, or larger main air
bleedsor slow air bleedsthan regularly
specified. use larg€r main jets or slow jeh, or
This shouldmeet the purpose. smaller main air bl€€ds or slow air
Invenely, when increasingoutput bleeds. This will bring a satisfactory
at the sacrifice of fuel consumption, rcsult.

SERVICE DATA AIID SPECIFICATIOI{S

Carburetormodel 214282.t24,
t32, I4l 214282-11
1, 181 132,17|
214260.122,

Applied engine J15 J16 It3

Prlmary I Secondary Prinary Secondary Prlrnary Secondary

Inlet diam€ter mm (ln) 65(2.559) 6s(tr.559) 6s(2.5s9)

Oudetdirrheter fiun (in) 28(r.r.02) 32(1,.260) 28(1.rO2) 32(t260)
Venturi diameter
Lalge rnrn(in) 2r (0.827) 27(1.063) 23(0.905) zg(r.riz) 20(O.187) 27(r.063)
Medlum rffn (in) 1 4 ( 0 . s s l )14(o.ss
l) 14(0.5s1) 14(0.5s1)

smalr run un, 8 (0.315) 7 (0.276) 7 (0.276) 7 (0.276) 8 (0.31s) 7 (0.276)

Mrln nozzle mm (in) 2.2(0.087) 2.5(0.098) 2.3(0.091) 2.5(0.098) 2.3(0.091) 2.s(0.098)

Mainjet # 100 # lso # 102 f 160 #88 # l4s

Slowjet t46 t70 f46 t60 #48 f70
Mainair bleed f50 i60 #50 #60 #60 #80
lst slow air bleed # 100 # r00 il 100
2nd slow air bleed # 200 # 22O t 200 # 200 # 240 r90
PowerI€t #4s # 45 #s0
Float lever inrn (in) 21.5(0.846) 2r.sI ).846) 2r.s(0.846)

uppor surfaceofbody)

Fuel pr€ssur€ kelcr"2 (ps) 0.24(3.4r4) o.24(.\.414) 0.18(2.560)

1
Throtde valveclos€dangle 100 200 200 70 I 200
I I
Secondarythrottle valve
50" 50 53'
openingangle

Chokevalveclosedangl€ too 10 too

(exarnple) # 200 rcpresents 200/100= 2.00 mm (0.0787)diarneter

EF-18
 Engine Fuel

TROUBLE DIAGNOSESAND CORRECTIONS

In the folowing table, the troubles.It sometimeshappensthat defective.Th€refore,whenevertlle

symptonsand causesof carburetor i}Ie completelyeffectivecarbur€tor €nginehastroublesthe el€ctricsystem
troublesand remediesfor them are seems apparently to have some mustb€ checkedfiIst beforeadjusring
listedto facilitaiequickrepairs. troubleswhen the electricsystemis
Thereare variouscauses of engine

Condifion Probable
cause

Overflow Dirt accumlated

on float valye. Cieanfloat valve.
Fuelpumppressure
too highfloat valyesear Repairpump. Lap or replace.

Excessive
fuel
improper.

Fueloverflow. S€eabove.
i
consumption Eachmainjer,slowjet too large. Replace.
Eachmainair bleedclogged. Clcan.
Chokevalvedoesnot open. Adjust.
Outlel valveseat of accelerator
pump im. l,ap.
proPer.
Linkedop€ningof secondary
ihrottle valve Adjust.

Pow€rshortage Eachmainjetclogged.
Eachthrotllevalvedoesnot fuly open.
Clean.
Adjust.
fi
Fuelpumpoper ted improperly. Repair.
Fuelstrainerclogged. Clean.
Vacuumjet clogged. Clean.
Air clean€rclogged. Clean.
Powervalveoperating
improperly- Adjxsl.

Improperidling slowjet clogged. Cl€an.

Each lhrottle valvedoesnot close.
Each throltle valveshaft wedr. Replace.
Packingbetwee, nanilbld/cafburcior defec, Replacepacking.

Manifold/carburetortighiefling improper. Corect tightening.

Seethe first it€m.

Enginehesitation Eachmainjet,slowjet closged. Clcan.

By-prsshole,idlepassage
clogged. C1ean.
Emulsioniube clogged. Clean.
Idlingadjustment
Secondary
incorrect.
throttlevalveandauxiliaryvalve overhaulandclem. i
i
EF.]9 I
 Engine Rlel

Enginedo€snot stari S€€tlrc fust iteft.

Ch€ckpump,fuel pipeandfloatvElv€.
Cofiectrdjuhnbnt.
' Correctadjustrnent.
Overhaul, cleon.

EF.2O
MODEL
Jt3, J15 & J16 SERTES
BEilES
 Service Equipment

EOUIPMENT
SERVICE
GENERAL
SPECIFICATIONS CLASSIFICATION OF SPECIAL TOOL
SpecialTools play Yeryimportant Classification
role in the maintenanceot cars.
These are essentialto the safe, ac_
curat€andspe€dY seNicing.
The working limes listed in llrc lnspecrion
andminor
column under FLAT RATE TIME in repair
FLAT RATE SCHEDULE are com-
pured based on the use of Special Generaldisassembly
It_
Tools. Th€ ideniificalion code of andassembly
maintenrncctools is made uP of 2
alphab€tical letters and 8"digitai Sp€cialdisassembly
I]I,
ligures. andassembly
The headingtwo lctters roughly
tooh or equipments
classifies as: A. lmporlant c. Minorunit disassembly
a. Exclusivewith no aliemative ll. ceneraldisassembty andassembly
5T00000000: SpecialTool a. Ceneral djsassemblysuch as
b. Partslikely will be damasedif
8M00000000i EngineOvcrhauling rcpairedwithoutspecialiool. engin€, differential, transmis.
Machinc sion.
c. Gauges
Ill. Specialdhassembly and assembly
B, General a. Dhassemblyof exclusiveparts
a. To €aseservicing such as automalictransmission
I. Inspection andminor repair and€lectricalaccessories
a. lnspectionandmaintenance b. Specialwork suohasbofine.
b. Unit replacement c. Workveryrarelyrequired

TOOL LIST
Tool Number Tool Nrme Class Remark

Engine
sTo501s000 Enginestandassembly Former
toolNo.sT05010000
f--
I
srosortooo Enginestand
t- ST05012000 Base
sTo5280000 Engineattachment 5
sTl1600001 3 Forner tool No. ST11600000
sT12070000 Valvelifter 5
sT13040000 PiStonpin pressstand 2 For J13engine
sT13060000 Pistonpin pressstand 2 ForJl5 andJl6 engines
sT16511000 Crankshaftmain bearingcappuiler 2
sT16530000 Crankshaftgearpuler 5
sT16610001 Pilot bushpdler 3 Formertool No. ST16610000

ri sT19320000
sT19550000
Oil filter wrench
Distdbutor drive spindlepuler
I
2

il 8M03470000 Pistonring compressot 2

|n
l,{
ti
8M03500000 Pistonringexpander 5