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N @J

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Jl

feU

lIDrnlli rnrnJW
CRAKE PU3 IS1

RS
i

fI

lII

DATSUN 1200
1971 1973

RANGE

MAINTENANCE

REPAIR

BY DRAKE AUTOMOTIVE EDITORS

Quick Referencelodel
TUNE UP

MAINTENANCE

89

STEERING
REAR DRIVE

ENGINEERING

13

ELECTRICAL SYSTEM

35

IGNITION SYSTEM

43

CLUTCH

FUEL SYSTEM

49

TRANSMISSION

103

COOLING SYSTEM

63

BODY WORK

111

BRAKES

67

SPECIFICATIONS

129

FRONT SUSPENSION

83

The
a

purpose of

reference

this manual

source

We endeavor to

specifications
the

Publisher

errors or

Upon

at

IS

with which

lOcorporate
the

time

to

provide

he

the

can

the automobile

perform

latest

normal

owner

service

99

and mechanic with

operations

manufacturing design changes

of publication While

cannot be held

every

effort

IS

and upto

date

made to attain accuracy

responsible for manufacturing changes typographical

omiSSions

compIling the information contained herein we have tried to be brief and

relvlng on the combination of photographs Illustrations and text to

Simple
make

93

SUSPENSION

thIS

manual

useful tool

DRAKE
PUBLISHERS INC
361

PARK

AVENUE SOUTH

NEW YORK NY 10016

ISBN 0 87 749 309 X

Pubhshed III 1973 by
DRAKE PUBLISHERS INC
381 Park Avenue South
New York N Y 10016

@Drake Pubhshers
Prmted

Inc 1973

the Umted States of Amenca

able of Contents
MAINTENANCE

TUNE UP

VALVE CLEARANCES

ENGINE OIL

OIL FILTER

COOLANT
COMPRESSION

BATTERY

IGNITION TIMING
DIstributor Breaker Pomt

DIsassembly
InspectIOn
RepaIr
AdJustmg Regulator
Assembly

32
33
33
33

ELECTRICAL SYSTEM
STARTER

36

Removal

37

Condenser

InstallatIOn

37

Spark Plugs

Trouble Shootmg

37

Carburetor
Idle LImIter Cap

Dash Pot

11

InstallatIOn

11

REGULATOR

model

10

automatic transmISSIOn

only

Carburetor Return

Sprmg

Fuel Filter

11
11

ALTERNATOR
Removal

14

REMOVAL

14

INSTALLATION

14

CLEANING

14

DISASSEMBLY

14

REPAIR

INSPECTION

PreparatIOn
Cyltnder Head
Valve Assembly
Valve Spnng

Camshaft

18
18
18

40

DISTRIBUTOR

44

ConstructIOn

44

Checkmg

and

Adjustment

SPARK PLUGS

DeSCriptIOn
InspectIOn

44

46
46
46

Cleamng

Regap

47

18
19

Valve Rocker Shaft

Valve LIfter

39
39

IGNITION SYSTEM

DESCRIPTION

INSPECTION

37
37

DeSCriptIOn
Trouble Shootmg

ENGINE

36

Rocker Arm

Push Rod
Camshaft

FUEL SYSTEM

19
20

Bearmg

Valve

Tlmmg
Cyltnder Block

20

FUEL FILTER

50

20

DESCRIPTION

50

21

REMOVAL

50

21

INSTALLATION

50

23

FUEL PUMP

50

Crankshaft

24

50

Bushmg

24

DeSCriptIOn
Testmg

PIston Piston Pm

Connectmg

LRmg
Plsto

Rod

Bearing
Crankshaft Sprocket
Camshaft Sprocket
Flywheel

Removal
25
25

ASSEMBLY

25

PrecautIOn

25

51

DIsassembly

InspectIOn
Assembly
CARBURETOR

52
52
52
52
52

25

DeSCription
Adjustment

26

Removal

58

Engme

26
32

DIsassembly
Cleanmg
InspectIOn
InstallatIOn
Assembly

58

OIL PUMP

Cyltnder

Head

PIston

ConnectIng

Removal

Engme

Rod

vehicle

32

53

59
60

labl8 of Contents

Jets

60

TlOuble

Shooting

FRONT SUSPENSION

60

DESCRIPTION
RECOMMENDATIONS
TROUBLE SHOOTING

f
I

85

COOLING SYSTEM
DESCRIPTION

64

WATER PUMP

64

Hemoval
InstallatIOn
THERMOSTAT

65

DESCRIPTION

90

65

RECOMMENDATIONS

90

65

TROUBLE SHOOTING

91

Removal

65

InspectIOn

65

Installation

65

RADIATOR

66

Hemovdl

66

InspectIOn

66

InstallatIOn

66

REAR DRIVE
SUSPENSION
REAR AXLE

94

DIFFERENTIAL

94

REAR SUSPENSION

95

REAR SHOCK ABSORBER

96

Replacement
InspectIOn

BRAKES

96
97

RECOMMENDATIONS

FRONT DISC BRAKE

68

BRAKE PAD

68

Replacement
InspectIOn

68

ReinstallatIOn

68

DESCRIPTION

70

CLUTCH PEDAL

CLUTCH

68

CALIPER
Removal

70

Removal

Disassembly
InspectIOn
Repmr
Reassembly

71

InspectIOn

71

ReinstallatIOn

ReinstallatIOn

74

REAR BRAKE

74

Removal

74

DIsassembly
InspectIOn
Reassembly

Hemoval

72

Dlsdssembly

InspectIOn
Reassembly

75
ReinstallatIOn

75

HAND BRAKE

75

Removal

InspectIOn

75
76

RemstallatlOn

77

ADJUSTMENT
Front DI

78

Brake

Brake Pedal

HeIght

Hand Brake

BLEEPIN

HYD

Adjustment
CLUTCH MASTER CYLINDER

RemstallatlOn
BLEEDING CLUTCH SYSTEM

TRANSMISSION

78

Rear Brake

AULIC

TROUBLE SHOOTING

STEERING

rM
SYs

78

4 SPEED TRANSMISSION

78

3 SPEED TRANSMISSION

79

TROUBLE SHOOTING

79

i
UIQM ATJC TRANSMJSSIQ

80

RECOMMENDATIONS

97

fable of Contents

SPECIFICATIONS

BODY WORK

HOOD

112

Removal

112

InstallatIOn

112

HOOD LOCK

112

Removal

112

Adjustment

112

LubncatlOn

114
116

TRUNK LID LOCK

Removal

Adjustment

116
116

SERVICE DATA

130

ENGINE

134

General SpeCificatIOn

134

Tlghtemng Torque

134

SpeCIficatIOn
Coohng System
Fuel System

135

Starter

142

Alternator

143

Regulator

144

Dlstnbutor

145

139
140

TRUNK LID TORSION BAR

116

DOOR CONSTRUCTION

117

IgnItIOn

WIRING DIAGRAMS

118

CLUTCH

146

BULB SPECIFICATIONS

120

NOTES

174

HEADLAMP

121

Cot

145

THERMOMETER AND
FUEL METER

122

OIL PRESSURE AND IGNITION

WARNING LAMPS

126

aintenIDce

TUDe up

Ii

ainteDaDee

TUDe up

VAL VE CLEARANCES

hot

Valve

clearance

while engme
To

IS

should be made

adjustment

stationary

adjust proceed

Start engme and

as

After

Checking
It until It IS heated to

operatIng temperature or at least more than

17S of engIne 011 temperature
then stop
engIne
Rotate crankshaft to

bnng

No

cylInder

In

top dead center on ItS compressIOn stroke

Remove valve rocker

cover

all

correctly tighten
adjustment

follows

run

should ue made whIle engIne IS

valves have been adjusted

Adjustment

and

valve

pOints while

clearance

engIne

IS

for

cracked

Replace

If defective

Adjust

the

belt

o 590

2 Intake valve of No 1

cylinder

3 Intake valve of No 2

cylinder

5 Exham t valve of No 3

AgaIn
4

Numbers in
10

cylinder

IS

In

damaged

V belt

If necessary

Belt

ENGINE OIL

011 capacity of engIne IncludIng 011 filter

Make
With

cylInder

parenthesis

top dead

agree with

center on ItS

Adjust follOWIng

4 Exhaust valve ofNo 2

6 Intake valve ofNo 3

7 Intake valve ofNo 4

gal

sure

Imp gal
III

Imp gal

that engIne 011

cooling

water or

refill the 011

lf necessary

Notes

presence of

IS

not detenorated

gasolIne

m1lky 011
cooling water

DraIn

indlcates

com

valves
Valve clearance

cylinder
Intake

cylinder

Hot

cylInder

8 Exhaust valve of No 4

0014 In

Exhaust

cylinder

Rg 1 AdJustmg valve clearance

tenSIOn

MInimum 5IB US gal

accompanY1Og sketch

pressIOn stroke

drive belt

or

In

MaXimum VB US

rotate crankshaft one turn so that No

piston

the

Capacity
1

ote

four

secure

still hot

1 Exhaust valve of No

those

follOWing

firmly to

deflectIOn when thumb pressure of 220 Ib IS

applied midway between pulleys 0394 to

to gaIn access to

at

adjusting

Check

valve operatIng mechamsm

Adjust

lock nut

Fig

2 AdJustmg dnve belt tension

and

aintenIDce

Find the

up

COOLANT

for necessary corrective

cause

une

action
b

Oil

dicates

Check 011 level If found below

to

in

extremely low viscosity

dllutton with gasoline

with

mark

on

mark

IS

gauge

of a

cartndge type

through gasketed flange

retIghten shghtly
leakage IS
sary replaLe filter as an assembly

Check for 011 leaks

found

any
nece

When

mstalhng

Note

Do not

leakage

an

011 filter

overtighten

IS

al

tammg

If
If

tIghten by

hand

011 fIlter

or

oil

base

ethylene glycol

chemical

coohng system

refill

OIL FILTER
The 011 filter

L LC

mhlbltors

from

to

product

con

protect the

rustmg and

corrosIOn

glycerme
ethyl or methyl alcohol It wIll not evaporate
or bOll away and can be used wIth either high
or low temperature thermostat It flows freely
transfers heat effiCiently and will not clog the
passages m the coohng system The L L C
must not be mIxed wIth other products ThiS
coolant can be used throughout the seasons of
The

L IC

does

not

con tam

any

the year
Whenever any coolant IS changed the coohng
system should be flushed and refilled wIth a
new

coolant Check the level

may result

COMPRESSION

Compression
Note

To

remove

all

pressure test

cylinder compression
spark plugs and hold tester fit
test

BOllIng pomt

Percent
concen

Sea level

tra lion

09 kg cm2

Freeze

coolmg

protectIon

sys

tern pressure

30

50

2210F

2550F

50f

2280 F

2610F

31oF

Fig 3 Checking engine 011 level

Oc OF
0

121

20141

30

21

I
401401
5015BI
10

20
I
EGOQl

Fig

4 Protection

concentration

104
ETO
Fig 5 Testing compressIon

pressure

TUDe up

aiDtenaDce

ting tightly

hole of

spark plug

cylin

der

top of battery and terminals With

solutIOn of

The tester is used to determme whether

cylinder

hold

can

whether there

rings

IS

or
compression
leakage past

excessive

etc

Test compressIOn wIth engme warm all spark

plugs removed and throttle and choke valve
No

cyhnder compressIOn should be

less than 80
of highest cyhnder s Excessive
variatIOn between cyhnders accompamed by
low speed missing of the cyllndel usually 10
dlcates a valve not properly seating or a
opened

blOken

pIston

though

umform

ThIs

Clean

may

be

preSsures

Low

ring

indIcate

may

accompamed by

baking soda and water Rinse off

and dry WIth compressed atr The top of bat
tery must be clean to prevent current leakage
between terminals and from poSItive termlndl
to hold down clamp
In additIOn to current

tery

corrOSIOn

of

terminals coat them

tightening
petrolatum vasehnel

straps
from

straps and

After

ac

the top of bat

of the material

on

bhstenng

connector

covering

With

cause

may

to

protect them

corrosIOn

even

worn

leakage prolonged

cumulatIon of aCId and dirt

IGNITION TIMING

rings

011

excessive

consumptIOn

Check

spark plugs

and dIstributor

breaker

pOints for conditIon

I

Test Conclusion

Thoroughly

If one

marks

cyhnders read low Inject about

one tablespoon
of engine 011 on top of the
plstons In low readmg cyhnders through
spark plug hole Repeat compressIOn check on
or more

on

wipe off dIrt and dust from

crank

Warm up engine

pulley and

front

tlmmg j

cover

suffiClently

these cy IInders
If compressIOn Improves
rings are defectIve

conSiderably

If compressIOn does not

Improve

stIcking
If two

or

valves

Fngld chmates

mdlcate low

mjectmg 011

on

the

compreSSIOn

com

pistons does

cause

may

Full

charge
at

value

68OF

are

seatIng Improperly

pressIOn and

PermIssIble
value

adjacent cyhnders

Increase

piston

not

be

TropIcal

chmates

Other clunates

Over 1 22

128

Over I 18

123

Over 1 20

126

cylInder head gasket leak between the cyhn

ders Engine 011 and coolant In cylInder could
result from this problem
CompressIOn

pressure

178 to 206 pSI at 350 rpm

I
BATIERY
Check

electrolyte

Unscrew
level
to

each

level

filler

If flUId level

bring

07874

In

Mea ure
trolyte

IS

10

each

cap

battery

and

cell

Inspect flUId

low add dIstilled water

level up to approximately 03937 to

above plates Do not overfill
P

illL gravlty

of

pattery

el

ET002

S Gheckmg
Flg

the speCific gravity of baltery

elec

trolyte
f

aiDteDaDce

Install

plug

timing lIght

WIre

and Install

No 1

on
a

cyhnder spark

Condenser msulatlOn resistance may be also

checked usmg

tachometer

to

Idhng ipeed

approximately

800 rpm

denser

IS

tester

large

to measure

Set

UDe

by adjusting

resIstance value

normal

the tester

ItS range

When

con

pomter swmgs

Check 19mtlOn tImmg If It IS 50BTDC Before

Top of Dead Center by the use of tlmmg

and rapidly and moves gradually back

the
Infimte
SIde When the pomter does not
to

hght

stay

If necessary
Loosen

iet

dlstnbutor
it
AdJu

adjust
screw

can

such

be moved

by

an

extent

that

Lock dlstnbutor set

IS

sure

correct

IgnitIOn tImmg degreel

50

IS

pomts

zero

reSIstance

necessary

MIcro Farad

Condenser InsulatIOn resIstance

and make

screw

It

or

Condenser capacIty
022 J F

hand

IgmtlOn tIming to 50BTDC

that tlmmg

still

replacement

It as follows
to

largely

5 Mn

Mega

ohms

Spark Plugs

B T DC

and clean plugs In a sand blast

Inspect each spark plug Make iure
that they are of the specified heat range In
ipect msulator for cracks and chIps Check
both center and ground electrodes If they are
excessIVely worn replace WIth new spark
plugs File center electrode flat Set the gap to
0031 to 0035 m USIng the proper adjustIng
tool Tighten plugs to 11 0 to 150 ft Ib torque
Remove
cleaner

Distributor Breaker Point

Check dlstnbutor breaker pomts for abnormal
pItting and wear Replace If necessary Make
wre

they

are

In

correct

ahgnment

for full

con

tact and that pOint dwell and gap are correct

Clean and apply dlstnbutor grease to cam and

WIck
Note Do not

apply

grease

excessively
CARBURETOR

Dl tI IbutOl
POint gap 0 018 to 0 022
Dwell

angle

49 to 55

In

Idle mixture
CO

degrees

meter

mixture

Condenser
Clean outlet ofcondenser lead WIre and check
for loose set screw RetIghten If necessary

Check

condenber

capacIty With

meter

capacity

It

thoroughly

adjustment

requIres the use of a

When preparIng to
IS essential to have

Idle

adjust

the meter

warmed and cahbrated

Warm up the engme

suffiCiently

ContInue engIne operatIOn for

der ldhng speed

one

mmute un

I
i
I
I

I
I

I
ETOQ4

Fig 7 Checking Igmllon timing

Fig 8 Checking dlstnbutor POint gap

up

aiDteDaDce

UDe

up

Throttle

sdJustlnl
screw

Fig 9 Checking spark plug gap

Idle

adjust

Inlscrew
Idle Itmlttcr
cap
4

10 Throttle

Fig

adjusting

screw

CARB

STOPPER

Stopper

and Idle

adjusting

screw

Adjust
speed

throttle

adjusting

800

1S

screw so

rpm

that engme
for

positIOn

automatic transmIssIOn

Check IgnitIOn tlmmg If necessary

the specIficatIOns

IgnitIOn timing 50
Adjust

Idle

tage

IS

800 rpm

adjusting

t0
5

Repeat

the

3 above

so

adjust

1t to

screw so

that CO percen

ff
5

adjustments

desctlbed

as

that CO percentage

In

t0
15

IS

steps
ff at
5

800 rpm
Cautions

On

automatic

model

equipped
the D position
brake

transmission

Fig

11

Setting Idle limiter cap

check must be done in

Be

sure

to

apply parking

and to lock both front

and

rear

wheels wIth wheel chocks

b Hold brake

pedal while stepping down

on accelerator pedal Otherwise car will
rush out dangerously

Notes

transmISSIOn

make

the

sure that

eqUIpped model
adjustment has been made

wIth the selector lever

And then
lever

In

and Idle

check the

In

posItion

specificatIOns

are as

follows

Idle rpm 650

cause

malfunctions

After idle

If necessary

10

PoSitIOn

t
5
0

or

position

for

wheel chocks before startmg

Remove

the

car

Do not
D

JI

automatic transmission

k
5

adjust by progIesslvely turmng

screw and Idle adJustmg
until correct adjustments are made

Cap

remove

necessary

to

stallatlon To

throttle adJustlng

Make

screw

satisfies the

sure

this Idle

If this

necessary
In

has been made

adjustment

shift the level to

Idle Limiter

CO percentage
with lever

down

with the

posItion Insure that CO percent

speed

screw

adjusting screw completely to

damage to the tip which will tend

avoid
to

On automatic

Do not attempt to

the idle

Unit

hm1ter cap unless

removed
It IS

IS

re adJust
It at the time
adjust proceed as follows

that the

percentage oLCO
specifications

of

In

contents

aiDtenuce

w be

certam

that

It

IS

TUDe up

correct

adjustment

Check to be sure that dash pot contacts stop

per lever when engme speed reaches 1 900 to
2 000 rpm
should be slowed down from 3 000 to

Engme

1 000 rpm within a few seconds

Readjust

dash pot or replace It with a

lflt falls to meet the above condItions

new one

Carburetor Return Spring

Fig

12

Check

Fuel strainer

throttle

damage

wear

found wIth
Install

Idle hmlter cap

sure that

the

rotatIOn

adJustmg
the

posItion

screw can

CO RICH

makmg

or

bound

sprmg for sign of

Discard spring If

any of above

excessIvely beyond

further turn

d1rectlOn

Fuel Filter

depoSIt

Dash Pot Automatic

cracked

return

squareness

use

Check

Transmission Model Only

Check operation of dash pot

or

It should not be

It IS also essenttal to check

for

a contammatlOn
and defection

All engmes use a

found to
be

IS

element

water

cartridge type strainer If 1t

defective
replace as an

assembly

r
u

IQgiDe
DESCRIPTION

Dram water from the radiator disconnect two

radIator

The A12 engme IS a 715 cu m In Ime over

head valve four cyltnder engine with 2874 m
bore
full

and

2 765

stroke

opened wedge shaped

ber

alummum

heads

bearmg crankshaft
dependable power

Removmg

feature

combustIOn cham

and
to

It

fully

turn

out

hoses

remove

four

radIator

stallatlOn bolts and remove the radiator

cables and hoses

Disconnect the

balanced

followmg

cables

hoses

and

wires

smooth

High voltage

cable

between Igmtton COlI and

distributor
Cable to the thermal transmitter

REMOVAL

Cable to the 011 pressure sW1tch

Removmg
Open
and

hood
Cable to the primary Side of the distributor

the hood

remove

Disconnect

remove

four mstallatlOn bolts

Cable to the startmg motor

the hood
the

battery

cable

from

Fuel hose

the ter

mmal

Removmg

Cable to the alternator

radIator

Heater hose for model With heater only

Fig

It

13 Sectional

view

of A 12 Engine

Bngine
WIres

for

choke

and

accelerator

operatIOn Will be carned

out more

The

easily by

removing the a1r cleaner

Lift up the engine toward the front

the engine

In

sequence

reverse

parts

and

of

Clutch

block

Check

cracks and

hOUSing

wire on

nght

On left hand dnve model

hydraulIc line from

the clutch slave

DIsconnect the clutch

WIre

at the

carburetor

thoroughly
breakage

the water

Check for cracks

011 pan Check for

Disconnecting clutch

up the

plug

horn to aVOid intrusIOn of foreign matter

CylInder
Jacket for

removal

model

air

The engine extenor

Check the covers and
bolts for breakage rust damage and loss

INSTALLA TION
Install

electncal

excessive

rust

hand dnve
DISASSEMBLY

disconnect

cylInder

JXlrtlOn ofthe

wIthdrawal lever

Mount engine
Remove

assembly

the engine

on

engine stand

mounting bracket R H

Side

Remove the exhaust front tube

Disconnect the the cable to the back up

Install the engine attachment

lamp
Mount the engine

SWItch

on

the stand

D1sconnect the speedometer cable

Remove the
Remove
carner

propeller

four

shaft

bolts used

In

the differential

SIde and Withdraw the propeller shaft

Remove the shift lever

Model With remote control shIft lever
Disconnect the remote control rod at the JXlr
tlOn of transmiSSIOn outer lever and remove
the remote control rod
Model With floor Sh1ft lever
Remove the boot
remove
In

the lever

WIthdraw the lock pin and

The operatIOn IS carned out

the passenger compartment

Fig 14011 pump removal

Model With automatic transmiSSIOn

Remove pinS from both ends ofthe cross shaft
and remove the shIft rod

Suspend the engine

With

wire

Remove the front engine mounting installation

nuts

Remove the

rear engine

mounting installation

nuts

When

removing the engine mounting in

nuts be sure to apply a Jack beneath

stallation

the transmiSSIOn
CLEANING AND INSPECTION
Clean the engine thoroughly before disassem
bly Before cleaning the engine remove the

Fig 15 Thermostat hOUSing removal

II

Bngine
Remove the altel nator and engine mounting
bracket L H slde

Remove the rocker shaft

rods

assembly

Remove the crankshaft

Remove the

assembly

Remove
filtel

pulley

the 011 pump

Remove the high

dlstnbutor cap on
Remove the

together

tensIOn

With

cable

the 011

wIth

cylInder

head

and

push

Invert the engine

the

spark plugs

Remove the dlstllbutor assembly

Remove the carburetor
Remove the rocker

cover

Remove the

thermo
itat

houslllg

Remove the manifolds

Remove the water pump
Remove the fuel pump
Fig

18

Rocker shaft assembly removal

Y
w

Fig 16 Manifolds removal

Fig 19 Cylinder head bolts removal

Fig 17 Water

Fig

sequence

18

pump

removal

20 011 strainer removal

Bneine
Remove the 011

pan and 011 straIner

Remove the tImIng chaIn

cover

and the chaIn

tenSlOner

Remove

the

crankshaft
and
camshaft
WIth the timing chaIn

sprockets together

Rotate the engIne a quarter turn and remove

the piston and connectIng rod assembly Take
off the connectIng rod beatings at the same
tIme and keep them In order
Rotate the engIne
the flywheel
Remove the
seal

maIn

quarter

turn

and

cap and the

bearIng

remove

rear

011

Remove the crankshaft

Remove

the baffie

plate

and the crank

case

net

Remove the camshaft after

shaft

takIng off the cam

plate

Remove the valve tfter

Remove the piston rIngs With

Press out the piston pIn With

remover and an arbor press
Remove the valves USIng
Fig 21 Tlmmg cham

cover

removal

tlng
a

remover

piston

pin

valve tfter

Be careful not to lose valve sprIng seat 011 seal

valve collet and valve rocker sprIng

FIg 22 PIston and connectmg rod assembly removal

Fig

23 Rear 011 seal removal

FIg 24 Baffle plate and net removal

Fig

25 Camshaft plate removal

17

Bogioe

WAI CI

WAIl Cl

Fig 28 Checking the cylinder head surface

Fig 26 Valve components

Fig 29 CheckIng valve stem dIameter

FIg

27

Cylinder head

Secure proper

Cyhnder head surface flatness

MaxImum

Standard

Cylinder Head
Checking cylinder head mating face
VIsually check for cracks and flaws
Measure the surface of the

less than

Engme

o 0020

o 0039

cyhnder

cylinder

depoSits
pletely
M k
air

18

lr
s

parts

to remove 011

fur and other

foreIgn

stains

1at

all

block

The
carbon

matters com

hol Lare

clear

grinder

Blow

damaged

worn

valve caps and stems

valve If reqUIred
valve

face

should be refaced
Notes

against

Into them If reqUIred

surface

Assembly

assembhes for

for traces of water leaks before cleaning

Clean all

Check each of the Intake and exhause valve

INSPECTION AND REPAIR

head and

on

block SIde

ted surface wIth

Valve

Preparation
Check the cyhnder

head

cyhnder

for warping If It ex
ceeds the hmlt indIcated below regrind afTec
the

Al2

assembly carefully

or

by

Correct

valve
usmg

Deflection

or

end

valve

of

right

surface

gtlnder

seat

axis should be 0 0012 in

rr
ctnes

the

replace

or

stem
a

deformed

surface

or less

angle

and

out of round should be 0 0004 in or less

IBglne
Note

When

the

reduced to 0 0197 in

replace

or

for

seizure

and

for the valve

0 0197 in

or

stem

less

spring

wear

and repair

or

replace

as

required
Valve rocker

allowance

surface is

Valve

been

less in thickness

the valve

Grinding
end

head has

valve

arm

o 0008 to 0 0020

to shaft 011 clearance

III

Spnng specIficatIOns

Measure the free

and the tensIOn

length

of

each spnng If the measured value exceeds

the specIfied hmlt replace the sprlllg
deformatIOn with

for

Check each spnng

Free

1 831 In

length

Valve closed

square Any sprmgs w1th deflectIOn of 0 0630

III or more must be replaced

1 524 In

at 52 7 Ib

Valve open
Valve Rocker Shaft and Rocker Arm

I 19

Check the valve rocker shaft and rocker

Ll gE

cno
r

00

00

OtM

22

9E
o
NO

Bo
l

co
CX
171M

Be

22

11
N

at 1291b

in

III

arm

lit

cnM

Q
I

I
1

45 30
I

290

350

to

1 378

35 2dla
1386

to

1142

29 2 die

to

1501

to

INTAKE

EXHAUST

UNIT

EM
mm

lnl

Fig 30 The Intake and exhaust valves

Fig 32 Valve spring test

Fig 31 Valve grinder

Fig

33 Valve rocker shaft

lB

in1l
Bn

valve

When
rocker

by

contact

means

surface

of the

excessively m step
grinder or replace

arm IS worn

of a valve

valve
repair

ofthe valve rocker

arm IS

0 0197

In

or

clearance

bearmg

the camshaft

replace

bearmgs

IS

exceSS1ve

with

service

parts

allowance for valve contact surface

Grinding

If camshaft

less

Valve

Timing

If the

camshaft

although

some

has

no

apparent damage

valve troubles have been detec

Valve Lifter and Push Rod

Check the valve hfter for
bevel

edge
reqUIred

wear

and repair

contact

seizure

and

replace

or

Measure clearance between the hfter hole

Wear

Standard

as

1st
on

cyhnder block and valve hfter and

replace the valve hfter when clearance ex

hm1t

00015luOO024

the

2nd

00011 to 0 0020

ceeds the hmlt

Ot
Check the
and repair

push rod for bendmg

or replace as reqUIred

and

damage

clearance

3rd

00016 to 00025

o 0059

In

4th

00011 to 0 0020
Camshaft and Camshaft
Measure

bearing
Journal

Bearing

dIameter

mner

of the

5th

camshaft

00015 toO 0024

and outer diameter of the camshaft

1st
1 7257 to I 7261

Inner

2nd
1 7050 to 1 7060

diameter of
Standard

MaxlIDum

camshaft

3rd
1 6865 to 1 6868

beanng
m

4th

Valve hfter

I 6663 to I 6667

o 0059

hfter hole

o 0008 to 0 0020

5th

clearance

1 6243 to 1 6247

TDC
limit

0151010

Standard

003

00059
to

00012

DIRECTION

to

00027

EXHAUST

INTAKE

BDC

Fig 34 Camshaft bearing check

20

OF

ROTATION

0071010

Fig 35 Valve timing diagram

Bogioe
ted compare valve ttmmg data wIth the valve
ttmmg diagram to ensure that begmmng and

endmg
plymg
figures

of stroke
with

com

retard

and

out of round

or

remove

most

portIOn of

ridge

reamer or

Check for

Block

Check the
as

advance

specified

are

wear

wlthm the hmlt

the

head

cyhnder

for defects

v1sually

cracks and flaws

as

mmor

1S

and

the step from the top

cyhnder by

the

use

of

other slm11ar tool

Piston Piston Pin and Piston

Cylinder
such

cylmders

for all

When

seIzure

scratch and

Ring
wear

Replace

reqUIred
clearance of each

Measure the top of the cyhnder block cyhn

der head matmg face for warpmg If the warp

piston rmg
and ring groove WIth the piston rmg mstalled
Clearance of a new pIston and
on the piston

exceeds the hmlt correct 1t

p1ston

the

Measure
and

wear

of
out

walls

WIth

round

by

cyhnder

Measure Side

bore

If

bore

IS exceSS1ve

means

of

for out of round

gauge
rebore the

bormg

248

248

14

or

cyhnder

the rmg at the bottom of the rmg

traveled part of cyhnder bore m wh1ch It wlll
Place

be used

machme

Umt

wear

rmg should be as follows

degree

54

12

56

Wear

limIt

02mm
0 0079

In

MaxImum
Standard

Surface flatness

less than

tolerance

Fig 37 MeaSUring the cylinder bore

o 0039

o 0020

SAO

Distortion limIt

Standard

0 101010

0051010

00039 In
100020 In or less

Fig 36 Cylinder block surface check

Fig 38 Piston and connecting rod assembly

II

BogiDe
SIde clearance

Rmg gap
Standard
m

Top

rIng

Wear limIt

o 0079
0015 to 0 0027

2nd rIng

o 0079

00015 to 0 0027

Ot rIng

00015 to 0 0031

Standard

o 0079

Top

rmg

2nd rIng

o 0394

00079 to 0 0138

o 0394

00079 to 00138

o 0394

OtlrIng
00118 to 00354

EM131

EM129

22

Wear limIt

Fig 39 Side clearance measurement

Fig

41 Piston pin

Fig 40 Ring gap measurement

Fig

42 Measunng piston pin diameter

fitting

Bngine
of piston pm

Square

Flttmg

ends of rmg with feeler gauge

of the piston pm mto

the piston pm hole to such an extent that 1t
can be finger pressed at room temperature

It mto pos1t1on
rmg m bore by pushing
wIth the head piston Measure gap between

Gap

should be

Note

hsted above

When the
without

replaced
corrected
the

as

piston ring only is to be

the cylinder bore bemg

gap at the bottom of

where the wear is minor

measure

cylinder

b Overs1ze piston rings are avaIlable for

service 50 100 150 oversize
Measure the piston pm hole m relation to the
outer dIameter of the pm If wear exceeds the
hmlt
such piston pm together with

replace

the pIston

on

whIch It

IS

mstalled

Determme the

fittmg

ThIS piston pm rnust be

the connectmg rod

tight

press fitted mto

Rod

Connecting

If a connectmg rod shows any scratch or score

mark or IS pitted on both Sides of the thrust
face and the

large

Check for bend

rod

ahgner

hmlt correct

end correct

or

replace It

torsIOn usmg a

If bend
or

or

or

replace

torsIOn

connectmg

exceeds

the

the connectmg rod

replacing the connectmg rod select the

that weight difference between new and
rods IS wlthm 0 18 oz m umt weIght

When
rod
old

PI ton pill dldmeter

so

06869 to 06871
PIston pill

Standard

length

MaXimum

25681 to 5779

Connectmg rod bend

Piston pm hole dta
06874 to 0 6871

meter

or

tOrsIon

or

3 94

per

100

bend

mm

o 0020

length

o
torsIOn

o 0028 I

00391

PIston pm to piston
clearance

connectmg rod

MaXImum

BIg end play

Interference fit of piston

pm to

Standard

00002 to OOUr j

o 0008

00079 to 0 0118

U0157

EM133

FIg 43 Connecting rod ahgner

FIg 44 Big end play check

23

BogiDe
Llmtl

Standard
27 00
1910

to

0752

to

27 05

1063 to

Crankshaft free end

1910 to 19 40

1940

to

1 0651

0752 to 0

07641

7641

play

34 97

to 35

1 377 to 1
49951

to 49

11 9666

to

964 dl

44 961

1 9671

to

1 7701

ALL MAIN BEARING

o 0020 to 0 0059

00118

03

3791

44 974 dl

to

1 7706

ALL CRANK PINS

JOURNALS

UNIT

Fig

45

mm

Crankshaft

EM141

Taper

S tanddrd

MaXimum

o 0004

00012

Fig 46 Plasllgage

out of round

of uank Journal and

crank pm

Bend value is
when

tamed
once

half of the

o 0020

o 0006

regrInding

the crankshaft

and
Install connecting rods wIth bearings on to
the corresponding crank pinS and measure the
thrust clearance

If the measured value

replace

Check the crankshaft

biased

wear

Journal

and cracks

Repair

gauge

14

replace

or

ex

the crankshaft

When me8sJlring

jJ

ldtSe
nc

measure

rear

damage
Replace

and crank pin

Check the crankshaft for bend If the bend

Note

fimsh It to

repair

Check the
the

In

the

cyhnder

block

th the thruht clearance

main

drIve shaft

pilot beating

end of the crankshaft for

dial

It

Bushing

1f any defects

are

wear

at

and

detected

and

Check all

Bearing
bearIngs and bushings

melt

and burr

reqUired

ceeds the hmlt

Its

ex

such connecting rod

Crankshaft

as

to

size by uSing an adequate un

bearing according to the extent of

derSize

Install the crankshaft

replace

applied

journal

reqUIred

scars

ob

turned

the necessary

Crankshaft bend

for

is

MaxJmum
After

ceeds the hmlt

readmg

crankshaft

with the dial gauge

center

Standard

the

scar

Jlace
Rgj

bushings

If any defects

for

are

detected

Wipe off 011

the bushing

and dust

especially

Set the

bearing

the cap block

main

on

seIzure

the

rear

of

Ingine
Cut

plastIgage to the wIdth

place It m parallel with
gettmg clear ofthe 011 hole
1

of the

and

Install the cap on the

together with the

them

bearing

the crank pm

Install the camshaft

check

for

sprocket

Check the cham for

and stretch at ItS roller Imks

Ifdefective

Be

Remove

sure

not to turn the crankshaft

plastIgage

the cap

Replace

tooth

measure

Sprocket
surfaces

defective

excessive wear

Replace

cham

Flywheel

and

wIdth of the

and

the scale

Check the clutch diSC contact surface of the

flywheel for damage and wear Repair or

replace

Camshaft

If necessary

Measure deVtat10n of the clutch dISC contact

surface with

Sprocket
Check

damage

is Inserted

plastlgage at Its widest part wIth

printed tn the plastIgage envelope
Crankshaft

tn

Check the camshaft thrust deViatIOn If It IS

deViated replace the camshaft locatmg plate

36 to 43 ft lb

when the

00039

sprocket

Tlghtentng torque
Note

posItion and

If It exceeds

out

the camshaft

replace

assembly and tighten

specified torque

run

for flaws and

wears

sprocket

dial gauge

If It exceeds 0 0079

replace

1t

Check tooth surfaces of the ring gear for flaw

and wear
If necessary

Replace
Note

Replace

the

ring

gear at about 356

to 392 F

ASSEMBLY
PrecautIOn
EM148

Fig 47 Camshaft sprocket

out
run

check

Use

thoroughly

make

sure

cleaned

that 011 holes

parts
are

PartIcularly
foreign

cleal of

matter

When

mstalltng sltdmg parts

bearings be sure to apply engme 011
Use
Clearance limit
1

Standard

0 1 mm 00039
0 02 to 0 08mm
0 0008 to 0 0031 m

packmgs

new

such

as

to them

and 011 seals

Keep

tools and work benches clean

Keep

the necessary parts and tools

near

at

hand
Be

sure

to follow

specified tIghtemng torque

and orders

Cylinder
Assembly

Head
ofvalve and valve sprmg

Set the valve sprmg

Fig

48 Check

locatmg plate

thrust clearance

the valve

gUIde

seat

with the 011

poSItIon and fit

hp

seal

21

BDgiDe
Note

Make

sure

that the valve face

clear from

foreign matters

Piston and

Connecting

is

Rod

Assemble pIston piston pm and connecting

rod assorted accordmg to cyhnder number for
every

cylInder

Notes

P1ston

is press fitted to the

pin

connectmg rod tightly and fitting force is

from 1 to 3 tons When fitting piston pin

speCIal
Fig 49 Valve installatIon

tool must be used

When pressmg the piston pin into the con

necting rod apply engine oil to the pin
and the small end of the
b

Arrange

the

connecting

connecting

rod

so

rod

that the

oil Jet of the connecting rod large end is

directed toward the right side of the
block

cylinder

InstallIng piston

STl 303001

Install

the

pOSItIOns
EM156

Fig 50 Piston pin installation

so

rmgs

top and

second

that the marks

nght
upward
In

rings

are

faced

FIX bearings on the connecting

connecting rod cap

rod and the

Note Clean the back side of the

bearmg

carefully
Engine
Set the

cyhnder

block

on

the

WIth the engine bottom faced

Install the valve hfters
and

ft lb

FIg 51 Piston and connecting rod assembly

Assemble

the parts

In

order

valve sprmg

spnng retamer valve collet and val ve rocker

gUIde

28

stand

Install the camshaft

camshaft

by
plate tightemng torque

retain

Locate

the

workmg
upSIde

Fig 52 Installing camshaft locate plate

locate
IS

plate

2 9 to 3 6

Bogine
Note

Set

the

LOWER

mark

locate

plate

comes

to the

so

the

as

engine

Install the crankshaft

bot

Install the

tom side

bearmg cap
specified torque

bolts with
Set the

maIn

bearIngR

on

theIr posItIOns

on

Tlghtemng

the cylinder block

Notes

bearmg
b Two
of the
c

is

same

as

center

flanged type

bearmgs
type

lOner

The front

type
d

The

the

bearmg

No

Notes

are

IS

the

same

bearings except for No I bearing

interchangeable between upper and
lower bearings
on

Arrange the parts so

on the bearing cap
the front of the engine

bearIng

that the

mark

faced

IS

Prior

bolts

All

engIne OIl to the mam

torque

to tightening the bearing cap

place the bearing cap at a proper
posItIon by shlftmg the crankshaft in the

rear

axial direction

are

Apply

the

tighten

arrow

toward

bearmg No 1
bearmg No 5

and

36 to 43 ft Ib

for thrust force

No 2 and No 4

mam

Tighten the bearmg cap bolts gradually

in separatmg two to three stages and out
wardly from the center bearing
c

surfaces

both sIdes ofthe cyltnder block and cap

After

securing

ascertam

that

easily

rotated

Make

sure

the

the

bearing

cap bolts

crankshaft

that the crankshaft end

be

can

play

IS

correct

Crankshaft end play

o 0020 to 0 0059
InstalI the

rear

Install the
washers

Fig

53 Mam bearing caps

In

011 seal

flywheel securely USIng the lock

tighten the bolts with specIfied

and

torque

Tlghtemng torque
47 to 54 ft Ib

Rotate the engine a quarter turn and mstall

the piston rod assembly
Notes

Insert

the

pistons

in

the

corresponding cyhnders
b

Apply engine

oil to parts

as

required

Arrange pistons so that the F

the piston IS faced to the front
engine
c

on

d Install

avoIdIng
Fig

54 Crankshaft end play check

piston rings

to fit them

In

at

mark
of the

Y to each other
18

the thrust and pIston

pIn aXial directIOns

27

Bagine
Note

Arrange connecting rods and con

necting rod caps so that the cylinder num
bers

faced toward the

are

same

direction

Install the connectmg rod cap

Tlghtenmg torque
23 1 to 27 5 ft lb
Make

large
Big
Fig 55 ApplYing adhesive

sure

end

end

that end

IS

play

ofthe connectmg rod

correct

play

00079 to 0 0118
Install the camshaft and crankshaft

temporarily for adjustment

by usmg adJustmg washers
Install

the

tlmmg

cham

and

sprocket
Camshaft

sprocket tlghtemng torque

29 to 35 ft lb

L
FIg 56 Flywheel installation

FIg

Connecting rod cap installation

FIg

281

58

57 Piston and connecting rod assembly installation

Fig 59 Big end play check

sprockets
height

of the tooth

camshaft

Bogine
Notes

dIfference

HeIght

less than 0 0197

III

AdJustmg

Make

sprocket
sprocket key

0006

that the camshaft

sure

hole

dowel

dowel hole

washer

tluckness

in

are

and

key

and

crankshaft

line and both the

are

located down

ward

b Set the
marks

timing

meet

cham

with

making

those

of

its

mating

crankshaft

sprocket and camshaft sprocket

right hand side

at

the

Install the tlmmg cham tenslOner and tighten

the tenslOner bolts to a torque of 43 to 58
ft Ib
Install the crankshaft 011 thrower

Check the

spondle projection

temloner

Wear limit

Fig 60 AdJustmg sprocket tooth heIght

Spindle projection

IT
a
Match mark

8
Tlsnaft
0w 1

hol
0

Matohma

Key groove

Fig 63 Carn sprocket gear mstallatlon

Fig 61 Settmg cham

tt
I
f

Fig 62 Cham tensloner Installation

Fig

64 Checkmg the tension spindle projection

21

BDgiDe
Install the
front

cover

the front

new

011 seal to the front

011 seal should be

cover IS

Install the front

agent

The

cover

replaced

when

disassembled

applYing the seahng

gasket

cover

to both surfaces ofthe

The

of

uses

one IS

for the center nght SIde

and the other

IS

cyhnder

types

on

ItS head

36 to 5 1 ft lb
Install the ot strainer and the 011 pan uSing

Boltnumber

Dlaml

hh nlltilatlOn

tl
f

rJ

gasket

Apply seahng agent

gasket especIally on

the front and

rear

por

both surfaces of the

on

pt

lor

031111003189

CD

03492

to

0 3555

1M

ot

rhJ

tlOns of the 011 pan

FIg 65 Head bolt segment

011 pan

tlghtemng torque

2 9 to 4 3 ft lb
Invert
head

the engine

assembly

and

and Install

the

cyhnder

gasket

Apply sealing agent overall the

cylinder block surface Place the gasket
on It
and apply sealing agent to the
gasket top
Note

Tighten the cylinder

peclfied torque

head

bolts

to

the

Fig 66 Tlghtenmg sequence

Cylmder
bloLk

O rmg

Side
Stecl
heet

Sealmg

agent not required

Cylinder

head

Side
Jomt
sheet

Install WIthout

Remarks

Be careful

not

applymg sealing agent

because thIS SIde

WIth

sealing
J

30

damage the push rod Side

has prevIOusly been provIded

to

agent

in

for all other posItIOns The

nght Side has a I mark

bolt for the center

Tlghtemng torque

the

two

head

stallatIOn bolt

CYlmder head

ItI

o rtng To be mserted mto hole

Cylinder

h ad

gasket

Cylinder block

cylmder block

BDgiDe
40 to 43 ft Ib

TIghtening torque
Install the

push

rod
Intake

Install the rocker

the

ocker

haft

assembly

and

haft bracket bolts to the

at cold

tighten
specIfied

torque

Exhaust

Tightening torque

00138

In

at cold

00138

In

15 to 18 ft lb

TIghtening operation should be

made gradually 10 separating two or three
stages and outwardly from the center
Note

bracket
In tall the Intake and exhaust mamfolds

TIghtening torque
65 to 10 ft lb

AdJu

valve

clemance wIth

the

specIfied

dlmenblOn
Install the rocker

cover

and carburetor

assem

bly
In tdll the watel pump and thermostat

Tlghtemng

Fig 68 Valve clearance adjustment

tOl que

65 to 10 ft lb
Install the crankshaft

Tighten

the crank

pulley

pulley

bolt to the

specIfied

torque

TIghtenIng torque
109 to 116 ft lb

TlqhtCnlnq torque 15
109

to

to

16kg

116ltlb

Fig 69 Crankshaft pulley installation

Install the at pump with 011 filter

Install the alternator fan and fan belt
Install the fuel pump
Fig 67 Installation of Intake and exhaust manifolds

Install the dlstnbutor

assembly

31

BBgiBe

Fig

70

Tlmmg mark
Fig

72

TrochoId

Fig 71 Dlstnbutor mstallatlon

Notes

1 piston
compression

Set the No

dead center of the

Before

distributor

degrees from
the assembly

installation

to

its top

stroke

return

should
on

pump

60
approximately
Insert
regular position
meshing the distributor

rotqr

OIL PUMP

Its

installation
come

Fig 73011

the

drive gear and driven gear

After

Removal of 011 pump

the

Removal

distributor rotor

into contact wIth the mark

the rotor cap

fittmg

as

shown in the

Engine

Remove the front stabilIzer

Remove the

Figure
Install

the

distrIbutor

spark plugs and connect

to plug high tensIOn lead wire

the

Install the clutch

cover

Install the engme

tilatIOn hose

and crankcase

Dlsmount the engme from the

Install the engme mountmgs

32

body together

that the pump

ven

Take out

stand

with drIve

spmdle

IS

check to determme

defective

total of 2 bolts securmg the pump

cover to the pump

workmg

shield board

Disassembly
PrIor to dlsassembhng

assembly

shngers

splash

Detach the 011 pump

gear

Install the fuel hoses and tubes

in vehlCIe

Dram engme OIl

body

The outer and

mner

rotors and drive shaft can then be dlsassem

bled

Bngine
ApplYing a sUItable wrench
off the regulator valve
Note
use

spanner loosen

the valve

placmg

m a VIse

extreme care not to dIstort the pump

body
b

When

or

and

pull

Do not

securing

in the jaws

cover

shaft

the drive

out

pin

the drIven shaft and inner rotor

Adjusting

The shaft is press fitted to the rotor with

the pin calked

Inspection

and

Repair

FIg

the dIsassembled

Clean

wear

the dnve

and

scores

74

check

for

excessIve

the

follOWing

clearances
SIde clearance between outer and
rotors 0 0047

Tip clearance

In

or

below

00016 to 0 0047

o 7086

On inspecting the above dlmenslOns

mine the thickness of adjusting shim

deter

spring

length

Insert

valve

dIstance

In

the

body

and

measure

the

from the valve end to the spnng

contacting face inside the

plug

In

at compresslOn load 809 lbs

Assembly
Assembhng the
of disassembly

body

AdjustIng Regulator
In

0 7086

In

Clearance between outer rotor and

o 0059 to 0 0083

Regulator valve

ShIm thickness
Inner

Regul

The distance from the spring contacting face

inSide the valve to the valve end amounts to

shaft

rotor

and

rJ

rn

parts with cleamng

solvent and Inspect for defects

Inspect

Valve spnn

See

Figure

74

IS

chips

lint or dirt remain

sure

sure

gasket

no

the

traces

Note

Be

Be

011 pump

reverse

of

order

grinding

is not turned up and

dIscontinued

33

1
11

ty
J
r

4lI

j
it

r
t

Vi

rt
t
r

r
t

K
i

J
l

tf
l

i1

l
AP

I
it
8

l
jll

1ll
f
pJ

Bleatriall System
STARTER

I
2
3
4
5
6

Gl U

ne

oyer
Dmt
Shift h vu
ovcr
Dusll
Shift knr pm
Wlllh

Magndlf
t
f
Lntubr

1
8

Arlll

ot
Thru

to

Metal

it

Stoppu

12
13

L
w

w l

ht

hu

rdlP
Stoppt
toppu

Pinion

ture

18

Pmlon

15

Ovu

16

I KId lOll

20

17

Yok

11

dukb
rumuRl

h
Uru
l
Bru
b

19

ar
Rl

Through bolt

Fig 75 Exploded

view

of starting motor

ALTERNATOR

CD

@OO

@
EE031

Fig 76 Exploded

view

of alternator

Pulley assembly

Front beanng

Rotor

Rear beanng

Stator

Rear

Brush

Diode

10

Diode

11

Through bolt

on

cover

covet

assembly
t

plate assembly

cover

B1eetrical Iptem

Removal

Removal

battery ground

DIsconnect the

Disconnect the black and

Disconnect the negatIve

cable

yellow

DIsconnect two lead

from the

wIre

battery termmal

Remove two bolts used to

motor on the clutch

assembly

forward

secure

housing

and

Loosen the
the startmg

adjusting

bolt

Remove the alternator drIve belt

Pull the starter

remove

Remove the alternator installation bolt

Dismount the alternator from the vehIcle

the starting

motor

Installation

Installation
InstallatlOn

and connector from

wires

the alternator

magnetic sWitch termmal and black battery

cable from the

battery termmal

IS

InstallatlOn

the reversal ofremoval

1S

the

of removal

reverse

TROUBLE SHOOTING

Trouble IOlJlltHI

Troubles

lartlTlg

motor

Remedies

CaUlies

will not

operate
No mJgnetJl sWltdl

Defective bclttery

Rdttcry

operating sound

ry
Rcpldt bJlh
Measure

Over dlschargmg

speCific grJvlty

of

dnd

lrolyte
clcl

chJrge

ur

the

e
H

repl

battery
IgnitIon sWltLh

Defedlvc

orreLl

lontJd

Slartmg

lulty
F

Wiring
F

Magnetic

Magnetic SWitch
operating sound

Bdttery

Broken

SWitch

groundlllg

or

dlM onncdcd

dnnJture

or

Jble
t

Carrece

field coli cJble

Dekl

Correcl

mll3

or

shorted

senes

or

or

repldce

Replace

cod

FaulIy plunger slidmg

RepaIr or replace

Over

Measure

dlschargmg

of

IS

speCifiC gravity

electrolyte

charge

heard

Faulty

Clean and

M termmal connections

Rellghten

contact

or

and

If necessary

loose

terminal

replJt

RcpldCC
Rcpldce

Broken

Ig

CorrCl l

Broken brush pig tall

llVe

replJlc

Corrcll

lUlty battery groundmg

Broken
Starler

motor

or

wltdl

mllun

retighten

connectIOn

Wifing

Faulty

or

37

Bmetrlcal

Spt
Startmg motor

Shorted

Worn

armature

brush

or

or

field cOIl

Improper

Repair or replace
spring

Repair or replace

pressure
Contaminated
fective

commutator

or

de

brush

Faulty

repair

Replace

Armature contacted With

Insufficient

Faulty

plunger

pole

core

dimenSIOn

or

RepJlr or replace
AdjUst
ReplJee

contact

Brok en

The

or

Repair

connection

Seized metal

Magnetic SWitch

Cledn

mica

shorted shunt call

wire

Replace

motor

startmg

rotates

PinIOn gear does not

mtermech

with flOg

gear

Rmg gear

Worn teeth

ReplJee

Startmg

Weakened pinion sleeve sprmg

Replnee

Worn pmIOn teeth

Rcpldce

motor

FJulty

slldmg

plOlOJl

oft lever pill

Dropped

Pillion mtermeshes

Startmg

motor

Startmg

motor

lIlIan

ring gc
IS

tou

dlll1en

IOn

runnmg dutch

Adjust
Re

place

lT

roldles

Over

Battery

Jud pillion Intermeshes

With

over

tlve
Defel

Rep m

EXlhr plunger

with nng gc

RepJlr

but

slow

Improper

Wiring
IgnitIOn

Charge battery

dlscharglOg
or

lome termmdl

Improperly tightened
sWltl h

Sldelmg motor

Rough

Lontact

Shorted

connection

or

Repall l11d retIghten

Rellghten
RepJIr

or

replaLc

field cOIl

Repair

or

replace

I11sufficlCnt spnng

Repair

or

replace

urtJce

armdture

Worn brush

conLid

COil

or

pressure
Conldmmated
proper brush
DercLllVe

Lomrnutator

or Im

Repau

nllca

Repdlf or replace

Lack or metallubneallon
Armature Lontdcted With

38

Repair

LonldLl

pole

core

Repair

or

replace

llectrical Spt

When
set 10

OFf

FJuhy rctuflung

iIgwl tlcUhn

Repldce

the slJrl

motor

IIlg
I

Harting lWltch

do

MJgnclK

nut

Wltdl

Seiad

op

l
contJr

Shorted

Repldcc

011

Replace

Faulty plunger slidmg

StJflillg

motOr

Pillion does
nng gedr

Pinion

not

Replace

dlsengJge

from the

Repair

or

replace

smoothly

sphne

dot

110t

disengage

Repan

or

replJce

moothly
SCl7Cd pinIOn metal

Replace

REGULATOR

Description
The regulator basically consists of a voltage
regulator and a charge relay The voltage
regulator has two sets of contact poInts a
lower set and upper set to control alternator
voltage An at mature plate placed between
the two

sets

downward

or

of contacts
Vibrates

moves

The

upward

or

lower contacts

when clo ed

complete the field CIrCUIt dIrect

glOund and the upper contacts when
closed complete the field CIrCUIt to
ground
COl
through a resIstam e field
and produces
to

alternator output

POlnlsap

lower

Arm2fu1C

COfe

the

IS

SimIlar

In

constructIOn to

voltage regulator

When the upper contacts

warnIng

lamp goes

are

Crew

ap

The charge lelay

nt
CI

13

Yokeg
lp

Connecting

Yolce

AdJu

fln

Lock

nul

closed IgnitIOn

t
pnn

4mmlOlli15 nldll
SCrew

14
rcw

COlUlruci

RlaCI

15

Upper

voltage

I
Rlact

ulato

on

As for the constructIOn

IS

very SImIlar to the

the voltage regulator

charge relay as shown In

Figure 78
1

O
0

I
2
3
4

5
6

Point gap
Char
Clay

ConMctmg
Armature

FIg

View of removing cover

FIg

nl daa

Core ap
Yoke Jap

Yoke

AdJu

Voila

re

14

mm0

1575

dla

rew

llng
ere

b
EEOSJ

nl3el

pun

Cre

ulal0t l

IS

nfaC

te1

1
ontal

COfUtruclton of

cha

ay
rt

78 Structural view

81

Blectrical

Sptem
TROUBLE SHOOTING

Troubles

Not

output

Trouble

Causes

locatIon

Alternator

Remedies

Sl1ckmg brushes

Correct

or

brush and brush

replace

spnng

Duty brushes and slIp nngs

aean

Loose connections

RetIghten

or

broken leads

Replace
Open

stator coLI

Open

rotor

solder

the

DefectIVe dJodes

Replace

the dIOde

Shorted

Replace

the

rotor

Grounded

RepaIr

ternunal

Broken fan belt

FJulty voltage regulator pomt

connection

replace the stator

or

Replace

cotl

Shorted stator

Regulator

RepaIr

or

leads Ifnecessary

or

coLi

rotor

assembly

rotor

replace the

Replace

the

Replace

the belt

stator

Insulator

con

RepdU

01

replace

disconnectIOn of

Repdtr

or

replace

the

regulator

tact

WIring

Broken cable

chargIng

Low

output

Alterndtor

StIcking

or

CIH UIt

brushes

Correct

or

brushes If

replace

neces

sary
Low

brush spring

Correct

tenSion

replace brush

Clean

Duty slIp nngs

open

Replace

the

stator

rotor

Replace

the

rotor

DefectIVe dIOde

Replace

the dIode

Loose or worn fan belt

Rettghlen or replace

Improper voltage regulator adlust

Check

Pln

eratIOn

Partially
stator

shorted

or

ground

or

cod

Partially

shorted

or

grounded

c01l

Regulator

the
no

assembly
the

belt

voltage regulalor
rep

Jr

the

regulator

op
j

required

I
Wifing

Faulty voltage regulator pomt

t

ct

con

Repair

or

replace

Defective operation

Faulty chargmg

CUI Ult

lead

WIn

Re

olf or

e
rpla

connection

Loose baltery leririmaJ

Rettghten

3
t

t
J

t
iI

EXCCS

lVe

output

l lfculted
Short

Alterndlor

or

broken

Replace

the

Check

the

neutral

wife

Wife

Reguldtor

Impro
ment

er

voltdge regulator adJust

Defective operatIon
t

and

fa hon

ep

lf

required
Improper charge relay adjustment
detecttve operatIOn and or faulty

Check

the

9i

oPP

ator
reg

voltage
lor

replace

as

rw

charge relay operation

and repair or replace

as

requIred
1

pomt contact

1
P

I
1

i lC

r
A
1

fl

J
i

1
1

1k
4

of

401

rtI

tWf

P
pr
l

iltA
4

fl

i
r
l

JIA

ill
1

I
i

7lt
Ar
L

a
l

jj

lfI

lenition Sptem

TO STARTER

IGNITION
COI L

SECONDARY
COI L

BREAKER
r
7

POTNT

CAP
cr

tc

uToRI

battery Figure

76

shows IgmtlOn CirCUIt

dIstributor

of

high tension
part centrifugal ad

consists

voltage part SWitch off

vacuum
vancing
angle
part
mechamcal part and drlvmg part

advance

78 show the constructIOn and

and rotor head

new one

44

IS

covered wIth fine carbon

and dust Whenever crack or trace of

IS

Recommended the rotor head also be

wIth

a new

one

If excessively

replaced
damaged

When pomt surface IS roughened due to bur

nlng polish with a fine emery paper No 500
600

found

arm

or

011 stone When the point

on

the cap

replace

w1th

pivot
of

causes

pomt

receiver

and

cam

IS

surface

burnt point
msufficlent point

damaged

contact

defective condenser

worn

are

IS

the
For

Improper
gap

and

conSidered

The standard pomt gap IS 0 0177 to 0 0217 m

When gap IS devIated from the standard gap

adjust

Checking and Adjustment

Cap and rotor head must always be kept clean
to maintain good insulation durability since
high tensIOn voltage from IgmtIon cOil IS Im
posed on them SometImes inside of the cap
partIcles
leakage

diagram

excessively
replace When the POIn
replaced with a new one apply grease to

Construction

Figures 77 and
exploded view

Circuit

or

DISTRIBUTOR

The

ROTOR HEAD

SPARK PLUG

The IgmtlOn CirCUIt conSIsts of the distributor

IgmtIon cOli IgmtIon sWitch spark plugs
tensIOn cable and the

Fig 19 Igmtlon system

hIgh

Turn the shaft to

breaker

arm

where pomt gap

adjusting
ween

heel rides the

screw

contacts

posItIon where the

lug a posItIon

cam

IS maxImum

loosen the gap

apply a thIckness gauge bet

and adjust to the standard

pomt gap
When
SIOn

measurmg

apply

breaker pomt

sprmg

tensIOn

spring ten
gauge to the

breaker pomt and posItIon the sprmg tenslOn

gauge m right angle agamst the breaker arm

Ignition Iptem

Center carbon

Rotor head

Breaker plate
Condenser

4
5
6

FIxing plate
Housing

Side

Cap

Com

plug

10

Governor

11

Sh lft

l2

PIRIOn

werght

FIg 80 Structure D411 80

@
CID

l@Jtrf

CID

FIg

81 Exploded

View

cap

Aucmbly

cap

Assembly shaft

PlOlon

ID

Assembly clamp

of dlstnbutor

uembly
A

clamp

eam

Assembly weight

Spnng

Screw

Assembly

governor

governor

rotor head

10

Washer thrust

II

Assembly breaker plate

12

Set contact

13

Assembly

14

Assembly control

IS

Screw

16

AssembJy condenser

17

Screw

19

Assembly cap dJstnbutor

Assembly pomt carbon

20

Plate

21

Bolt

22

Housing

termmaJ
vacuum

fixing

80
D411

45

Ignition Sptem
The standard breaker pOint spring tensIOn
1 1 to 1 4 lb
If devIated

Replace

Performance

setting

proper

of

of condenser

ulatlOn

In

affected

IS

contaminatIOn
resIstance

by

Im

and reductIOn

Thus

pellOdlcal

eqlJ lred to maintain the outlet of

checking

lead

clean and to prevent et screw from

Checking the condenser capacIty IS

wire

loosening

checked USing a capacity meter It may be also

checked condenser Isolate resl tance USing a
tester
I

by adjusting

ItS

ange to measure

large

eSlstance value

When

pOinter

the condenser
SWings 1m

gradually

normal

gely and rapIdly

the tester
and

back to the Infimte SIde

pOinter does
reSIstance

IS

not

stay stili

replacement

IS

or

It

moves

When the

points Zero

necessary

SPARK PLUGS

IS

In

Description
The spark plugs are of the re
haVing 0 551 In threads and 0031

lster

Note

All

spark

installed

plugs

engme must be of the

number of heat range

same

on

an

brand and

Inspection
Remove

spark plug

by pulhng

wIre

on

boot

not on WIre Itself

Remove

spark plugs

Check electrodes

and

Inner

and outer

por

celams of
and the

plugs noting the type of depOSits

degree of electrode erO lOn Refer to

Figure 85
shght

Brown to gl

electrode

wear

aYlsh

depoSits and
spark

tan

indIcate correct

Fig 82 AdJusllng POint gap

Fig

84

Pnmary

terminal

Secondary

Cdp
Sprang

11i

gap

Normal

Fig 83 Measunng breaker POint spnng tension

type

to 0035

SIde

Prrmary

terminal

core

coil

Construction

Secondary COIl

Insulator 011

enter

10

Segment

II

Case

lore

Icnition Sptem

ttr

rJ
I

Carbon fould

JtOvcrmhgc

Life

Norm
Jl

Fig 85 Spark plug

plug

heat range

Carbon fouled Dry fluffy carbon depo

the

Insulator
slow

and

electrode

caused

by

nltlOn

too nch fuel mixture

speed dnvlng

In

lts on

mostly

were

cIty weak

dirty

aIr

Ig

cleaner

etc

It

IS

advIsable to

replace

WIth

plugs havmg

hotter heat range

011 fouled Wet black

depoSits

show

excesSive

oIl entrance Into combusllon chamber

through

rmgs and pIstons or excessIve clearance

between valve gUIdes and stems If the same
worn

condition

after repair

remams

use

hotter

plug

Install

spark plugs

WIth black

WhIte

or

hght gray msulator

brown spots and blUIsh
or

gray
burnt electrodes indIcate engme overheatIng
Moreover the appearance results from in
correct

IgnitIon tIming loose spark plugs low

guel

pump pressure
hotter plug etc

wrong selectIOn of fuel

adVisable to replace WIth plugs havmg

colder heat range
IS

and

torque

each

plug

to 11

to 15 ft Ib

Connect

Overheatmg

It

FIg 86 Settmg spark plug gap

spark plug

wires

Cleaning and Regap

Clean spark plugs In
cleaner

AVOId

sand

blast type

blasting Clean and

remove carbon or OXide depoSits
but do not
wear away porcelain
If depos1ts are too stub
born discard plugs
excessIve

After cleaning spark plugs

renew

firing

sur

face of electrodes With file mentioned above

After cleaning dress electrodes With a small

fine file to flatten the surfaces of both center

Then gap spark plugs to 0 030 to 0 035 In

uSing a round wire feeler gauge All spark
plugs new or used should have the gap

and Side electrodes

checked

gap to

specification

In

parallel

Set

spark plug

and

reset

by

bending

ground

electrode

II

v
1n

A
l

1
v

y
t

fJ

1r

1
t

ii

ruel Sptem
FUEL FILTER DESCRIPTION
The fuel filter

IS

of

cartndge type

It

Note Before
uses

paper element as traIner element which can

be checked for condItIOn from outsIde ThIS
filter cannot be cleaned
the

peclfied servICe
clogged or I estncted

Replace

Interval

01

In

fuel lines

use

remaining

fuel

disconnecting

container to receive the

lines

the filter at

INSTALLATION

If It becomes

InstallatIOn

IS

the

reverse

of removal

FUEL PUMP
REMOVAL
DIsconnect

Inlet and

fuel filter and

remove

outlet fuel hnes from

Description

fuel filter

The fuel pump

transfers

tank to the carburetor

to meet engine

In

gasoline

from

the

suffiCient quantity

requIrements

at any

speed

or

load
The fuel pump

IS

of the

diaphragm type

The fuel pump conSIsts of a

and link assembly
fuel

diaphragm

spnng

seal

body rocker
diaphragm

Inlet

and

fuel

outlet

valves

if

The

fuel

treated
EF005

diaphragm

rubber

whIch

gasohne held together

and a pull rod

Fig 87 Sectional view of cartridge type fuel filter

consists
IS

not

of

specially
by

affected

WIth two metal diSCS

Fig

arm

88 SchematiC

view

of fuel pump

Fuel Sptem
Testing

StatIc Pressure Test

A fuel pump
pressure

IS

operatIng properly when 1tS

Within specifications and
ItS
IS

capacIty
at all

IS
equal
speeds

to the engine

Pressure and capacity

two

tests

Be

engIne
tank when

With
sure

reqUIrements

must be determined

the pump
that there

conductIng

mounted
IS

on

gasohne

by
the
the

The

static

test

pressure

IS

conducted

as

follows
Disconnect the carburetor fuel line at the
buretor
Install the necessary

adapter

and

tee

car

fitting

to the fuel Ime and attach a SUitable pressure

gauge

these tests

Start and
The

engme at varymg

run

speeds

readIng

pressure

follOWing

on the gauge IS the static fuel

and thIS should remam wlthm the
Itmlts

2 61b sq m

Pressure below the lower hmlt IndlCates

treme wear
wear on

They
worn

seats

on

each

part of

one

ex

small amount of

working part

also md1cate

ruptured dIaphragm
warped dirty or gummmg valves and
weak dIaphragm return spring
or
a

Pressure

Fig

above the upper hmlt Indicates an

excessIVely strong dIaphragm that IS too tight

89 Pull rod removal

ThIS condItIOn reqUIres removal of the fuel

pump assembly for replacement or repair

Vlvc

PdlklOg

Retamer

4
5
6

Stre
p
ket
Ga

Screw

Washer prln

Rocker

10
II
12

13

Fig

llllh

Jrm

Rocker pm
ker
Ro

fm

pTln

Spdcer

14

Diaphragm assembly

15

Retiuner

16

Diaphragm

17

Washer

18

Nul

sprtng

5PIlllg

19

Washer

20

Ga ket

21
22

Spacer
Complete body

23

Connector anlet

24

Connector outlet

plalO

lower

90 Structure of fuel pump

51

Fuel Sptem
Capacity

Test

Check the

The capaclty test

plessure

IS

only when the statIc

specIficatIOns The capacity

IS

wlthm

used

test IS conducted as follows

valve

bly by

breath to

Check the

Place

Check the rocker

bUltable contamer at the end of the

In

Start the engme and

run

at 1 000 rpm

The pump should delIver 1 US pt

one mmute or less
If no
end

gasolme

of pIpe

pump

or

only

malfunctlOntng

worn

Check

Before removing the

the gas tank cap dIsconnect

both Inlet dnd outlet pIpes and blow through
pump

remove

them wIth
are

an aIr

hose to make

that

they

clogged

gas

sure

clear

Thl

wIll

tramer

elImmate

In

pOSSible

all

mahtIes

the fuel tank

Reconnect the pIpes

011

Remove

fuel

screwmg two
In

mounting

assembly

by

un

nuts and dIsassemble

the follOWing order

Take

gasket by

cap

emOVIng the cap

and

the

cap

body

new

from

by

Two valves

are

eaSIly

diaphragm diaphragm sprmg

body seal
lower
down
the
press
body

seal washer and lower

dIaphragm counter to the force of the

dIaphragm spring and while dOIng thIS cant
the dIaphragm so that the rectangular part m
the lower end of the pull rod IS unhooked from
the rocker

arm

IS

drawn up soon after the rocker arm

the
functIOn
of the
pump

The

carburetors

whIch

IS

deSIgned

lInk

These

IS
IS

of

downdraft

and bUIlt to

carburetors

as

Increase

to

reduce the

several

present

type
power

dIstinct

features of Importance to the car owners

A summary of features

Secondary
tie

lever

The

celeratIon

IS as

throttle valve

are

follows

operated by throt
power and good ac
IS

hIgh
gained With combmatlOn

of the

valve

Inspection

Acceleratmg

Check the

celeratIon

upper and lower bodIes for cracks

are

economy as well
ofexhaust gases

auxlhary

pump

released

the

the

poSItIOn the fuel

pipe connecting the fuel pump and the fuel

filter and operate the rocker arm by hand If

and fuel

body

pm

about 33ft above fuel level WIth

em1SSlon
remove

arm

Description

unscrewmg two

removed

lower

link rocker

arm

CARBURETOR

Take off the valve retainer

To

leakage

gasket

screw

screws

since

satIsfactory

Unscrew the elbow and the connector

valve retamer

wear

other components for any abnor

replace With new parts as

Lubricate the rocker

fuel
lower

off the

for

pin

Assembly
Assembly IS done In reverse order ofdisassem
bly For reassembly and remstallatlOn the
followmg matters should be noted

assembly

Separate the upper body and the

by unscrewmg the body set screws
I

portIOn

and

To test the functIOn

DisassenbIy
pump

at the

and lever pm before mstallatlOlI

Removal and
the

wear

requIred

Use

to the pump and rete t flow

arm

pm may cause

In

lIttle flows flOm open

pIpe IS clogged or the

for

dl m

contact With the camshaft

the fuel

cral ks

wear

Check the rocker

of fuel

for small holes

dIaphragm

and

of the

wear

ItS functIOn

examme

Disconnect the fuel p1pe at the carburetor

pIpe

for

assembly

valve and valve sprmg Blow the valve assem

pump

glves

excellent

ac

Fuel

mIxture

The power valve mechanIsm IS of a vacuum

actuated boost type and Improves hIgh speed

essentIal

IS

Warm up the engIne

throttle

porates

opener

control

system
The

diaphragm

servo

Incor

have the meter

to

warmed and cahbrated

thoroughly

drivIng
The

It

suffiCiently

ContInue engme operatIOn for

servo

der

dIaphragm helps open the throttle valve at a

decreasIng speed so as to reduce the emISSIOn
of hydrocarbons to a minImum

Sptem

one

mmute un

ldhng speed

Adjust
speed

throttle

adjustIng

800

IS

screw so

rpm

that engme
for

pos1tIon

automatic transmiSSIOn

dlesehng olen01d

An antI

IS

used

as

a means

Check

When the IgnItIOn

of preventIng dlesehng
In
the
fuel
IS
turned
ofT
key
passage Involved
the slow system IS closed and the fuel supply
IS

IgnItIOn

shut down completely

In

the

chok

mechanIsm

automatIc choke

IS

Adjust

electric

an

tage

used to

trol the choke valve

m

IgmtlOn
speCificatIOns

automatically con
operatIOn durIng the war

up of the engIne

makes

WIth

IS

so

are

qUIte

SImIlar

In

ap

CO

meter

When prepatlng to

adjust

model

poSItIon

On automatIc
check must be

Be

to

sure

apply

brake and to lock both front and

rear

down

rush out

make

that the

on

eqUIpped model
adjustment has been made

sure

With the selector lever

In

And then check

specificatIOns

of a

In

the

posItIon
With

the

pOSitIOn Insure that CO percent

speed

are as

follows

Idle rpm 650

Idle

for Automatic

for Manual transmISSion

Fig 91 External

eqUipped

the

that CO percen

accelerator

and Idle
use

50at 800

so

ns

b Hold brake

lever
requIres the

It to the

On automatIc transmiSSIOn

pearance
explaIned above except the dash
for
the
automatIc
transmISSion model
pot
as

Adjustment
Idhng Adjustment
Idle mixture adjustment

1 5

screw

pedal while steppIng

pedal OtherWise car Will
dangerously

stall at any operatIng conditIOn

These carburetors

adjust

wheels With wheel chocks

called dash pot that IS It

smooth deceleratIng WIthout engIne

eqUIpped

In

parkmg

The carburetor for automatic transmiSSIOn

adJustmg

transmiSSIOn

done

If necessary

tImlo 800 rpm

Idle

IS

tl

view

transmISSion

of carburetor

ruel Sptem

CO percentage

re

stallatIOn To
with lever

In

15

posltton

050

Make

adjust by progressively turmng

throttle adjustIng screw and Idle adJusttng
screw unttl correct adjustments are made
If necessary

Notes
the

Do not attempt to

Idle

adjusting
aVOid damage to the tip

screw

down

completely

screw

which will tend

b After idle

adjustment

shift the lever to UN

or

position

for

Remove wheel chocks before

starting

the car

Fuel Level

float

nccesbary

dIrectIOn

the float chamber to allow the

Into

comIng

measure

the

WIth

contact

shown

the needle

In

Figure

91

190

mm

approximately

IS

top float posltton IS correct The top

float pOSitIOn can be adjusted by bendIng float
0748

In

of the

Upon completIOn

adjustment

check fuel level WIth the attached level gauge

Cap

remove

CO RICH

Adjustment

valve and

seat

Idle Limiter
Do not

rotatIOn In the

When

automatic transmission

speClficattons

Install idle hmIter cap In poSItIOn makIng

sure that the adjustIng screw can further turn

Turn down
has been made

this Idle

If this

Unit

hmlter cap unless

removed
It IS

IS

Adjust
h

bottom float posItion

float

IS

cover

Throttle

Place the fast Idle

tmg
adJu
2

Idle

rcw
Ing
Idle hmlter

adJu
t

the fast idle

JustIng

Stopper

Illustratton

Figure
Idle

screw

In

Then

such

of the throttle valve

and

cam

Will

the second step of

adjust the fast Idle ad

arm

suew

screw

when the

Adjustment

Remove the bl metal

FIg 92 Throttle adjusting

the needle

In

Bend the float stopper

IS

Fast Idle

that clearance

0 0512 to 00669

fully raIsed
properly as reqUIred

so

between the float seat and

valve stem

on

way that the clearance

shown at

be the

rl1urdor

adjusting

topper

IH

Fig 93 Setting Idle limiter cap

Float

noalltopper

Float seat

Needle alve

Fig 94 AdJusting float level

In

speCificatIOns

92

screw

54

In

that the percentage of CO contents

sure

sattsfies the

to

to cause malfunctions

of

adJust it at the time

adjust proceed as follows

to

necessary

the
See

Fuel

FIg

95

Sptem

Adjusting fast d Ie

Choke val

uvm

stem

Vacuum break stew

Fig 96 Adjusting

vacuum

break

ruel Sptem

Clearance of throttle
valve

Engme

ill

revolutIon
rpm

Manual
I 750 to 2 050

o 0315 to 0 0346

transmiSSIOn

Automatic
2 650 to 2 950

00421 to 0 0461

transmISSIOn

Rubbu bJ nd

Fig 97 Adjusting choke unloader

Vacuum Break

Completely

Hold the choke valve

band

Choke Unloader Adjustment

Adjustment

close the choke valve

between

Completely

by stretching

choke

shaft

the rubber

stem with

In

In

1n

053

bending

51

body

and

Open

to 00449 to 0 0496
tar

the throttle lever unttllt

In

adjust

fully

opens

the clearance

the IllustratIOn between the choke valve

and the carburetor

ding

body

unloader tongue See

to 0 079

Figure

In

by

ben

94

and 0047 to

for automattc transrnlsslOn

vacuum break rod

rubber

phers

Under thiS condltton

for manual transmission

ring between the choke shaft lever and the

stattonary part ofthe carburetor

adjust the gap shown at

the 111ustratlOnl between the choke

valve and carburetor

by stretching

the

Under thIS condltton

8

Hold the choke valve

and

lever

btatlOnary part ofcarburetor

Grip the vacuum break

pull straIght fully

close the choke valve

car

by

Note

fully

Make

sure

that the throttle valve

opens when the carburetor is

moun

Fuel Sptem

ted

on

the

car

If the throttle valve fails to

the

fully
open
inoperative

unIoader

becomes

in
poor
resulting
engine is started

Note

Use

an

strument such

accurate

B1 metal

BL metal

Postllon the bl metal

Settmg
of bl metal

heater resistance
the

Install the bl metal

cover

buretor

that the resIstance

Make

sure

place

on

in

ac

celleration after the

Mea urement

measuring
bridge

as a wheatstone

mark

1S

cover

settmg

altgned

cover

at the middle

until the mdex

pomt ofthe scale

car

across

the termmal and the carburetor body IS m the

Measure the
range from 8 6 to 0 0 ohms
resIstance

without electnc current

through

the heater and at about 70 F

30

1 181

Connectml
Secondary

Fig 98 Settmg bl metal

cover

In

dlJ

26

rod

mm

I 024

Secondary

dlJ

throttle

vaJve

lms

COnnCl

throttle valve

lever

Pnmary

Throltle lever

Throttle chamber

Fig 99 AdJustmg mterlock opening Pnmary and

dary throttle valves

secon

Fig 100 AdJustmg dash pot

17

ruel S stem

Note

When

bl metal

somewhat

cover

after

choked

over

set

it clockwise

turning

slightly

Disassembly
The

main

primary

Jets and

and

needle

secondary

valves

Sides

are

both

on

accessible

from outSIde of the carburetor for disassem

Adjustment oflnterlock Opelntng of

Pnmary and Secondary Throttle Values
Open the pnmary Side throttle valve 48 from
and
measure
the
fully closed positIOn
GIn between the throttle valve and

clearance

chamber

throttle

mSlde wall

shown

as

level

shaft

take

out

pump

Remove rubber pipe from choke piston

out

servo

diaphragm

dlsturbmg

settmg

necessary so that

as

bend

secoridary

IS

hnk system operates

smoothly

Adjustment
only

and

In

dIaphragm

Back offtotal offive bolts which hold choke

the above

about to open Upon com

of the adjustment make sure that the

mlsszon

pump

lever and pump connectmg rod

Loosen off bolts secutlng

connectmg rod
throttle valve

Dash Pot

Remove

positIOn take

GIn 0 228

pletIOn

Remove throttle return sprmg

Figure 99

WIthout

bly

In

rods of starter system

posItion
take out choke chamber
remove

In removmg chamber
damaging float

exercise care

to aVOId

The pnmary and secondary emulsIOn tubes

can be disassembled by removmg the main air

AutomatIC Trans

bleeds

car

on

the indiVidual SIdes

It
necessary that the Idhng speed of engme
and mIxture have been well turned up and
IS

engme IS suffiC1

y warm

Turn throttle valve

by hand and read engme

when the da h pot Just touches the stop
per lever
speed

Adjust

the pOSitIOn of the dash pot

the nut until the engine

speed

IS

ij

by turnmg

In

the range

from 1 900 to 2 000 rpm

UII

Make

sure that the engine speed IS smoothly

leduced from 3 000 to 1 000 rpm within a few

econds
Fig 101 Removmg choke chamber and

servo

diaphragm

Removal
Remove the
DIsconnect
automatic

aIr

cleaner

the
choke

fuel

line

vacuum

harness and antl

line

dlesehng

solenOId harness from carburetor

Remove the throttle lever
Remove four nuts and washers retaining the
carburetor to the mamfold If necessary
LIft

the

carburetor

and

remove

from

the

llQt

mamfold
Remove and dlscard the

gasketcused

the carburetor and mamfold

between
Fig 102 Removmg emulsion tubes

Fuel Sptem
In removIng Injector weight
piston return
sptlng and ball care should be exercIsed to

prevent them from beIng scattered and lost

To check
IS

cover

the

accelerator

removed

pump

Be careful

the

It

pump

not to lose the

return spring and mlet valve

at the
lower part of the

bal
prOVided

piston

Do not

dUring

dIsassembly

remove

IS

preferable

unless

of removmg three set

cover IS a

sImple

matter

solenOId unless

to leave throttle valve mtact

otherWise

reqUIred

If throttle valve

be

must

dIsassembled to remedy a defect

secondary throttle valve must be Installed
wIth gap to be free
OtherWise

Removal of bl metal

dlesehng
change

antl

It IS necessary to

stable

formance Will

not

Idlmg

and slow

speed

per

be obtamed

screws

When It becomes necessary to take out float

pull shaft from float

dlsassembhng and reassembhng in

terlockIng hnks take care so that each
lInkage has a smooth action and that It IS not

Note

fitted

Under

no

In

C1rcumstances

should

any forced posltton

bl metaI

be moved with excessive force

this may cause a permanent set In
b1 metal making starting d1fficuIt
Since

The thlottle chamber

the

float

hamber

can

by

be detached from

removmg

three

set

Cleaning

and Inspection

Dirt gum water or carbon contammatIon m

or on the exterior movmg parts of carburetor
are

often

responsible

for

unsattsfactory perfor

mance

screws

For thiS
upon

effiCient carbureton depends

cleamng and InspectIOn whtle

reason

careful

servlcmg
Blow

all

pressed

passages and castmgs wIth com

and blow off all parts unttl dry

aIr

Note Do not pass drills

calibrated

enlarge

jets

or

wires

through

passages as this may

orifice and seriously affect car
or

buretor calibration

Check all parts for

EspeCially
Fig 103 Disassembling accelerator pump and bl metal

the

wear

Replace

followmg

matters

worn

part
he

should

noted

cover

1 Q

o
EC013

Fig 104 RemOVing throttle chamber

Fig

105 RemOVing throttle valve

18

Fuel

SJstem
Check float needle and seat for

Replace

wear

the assembly Ifworn

Replace
When

Check the throttle and choke bores

body and cover castIng for

throttle

In

wearor out

of round

the

If necessary

gaskets

terlock

hnk

and

needles for

Inspect
adjustIng
ndges Replace as reqUIred
Inspect gaskets

to ensure that

burrs

or

they do not ap
edges are not

pear hard or bnttle and that the

turned

or

detected

dIstorted

they

If any such condItIOn

must be

IS

replaced

and

If It

secreen screen

IS

dIstorted

or

cloggIng Clean
remaInS plugged

and

That

for loose

cluster

damage or
assembly

Ioosene

or

eXists

worn

If

parts

cluster

replace

Check the hnkage for operatIng condItion

Inspect

Into

the float

and

chamber

operate the throttle hver

gasohne InjectIOn from the acceleratIng nozzle

be

changed

them

and Installation

Assemble

and

Install

tIve

the

the carburetor
these

use

carburetor

In

sequence of dIsassembly and removal

So

and blow
bleed

they

Overflow

POSSible

Dirt

accumulated

on

Fuel pump pressure

Needle valve

ExceSSIve fuel
l

80

seat

may

should not

theIr numbers

the symptom

hsted to faclhtate

happens

qUIck

repaIrs

of engIne trouble It
that the completely effec

carburetor

seems

apparently

to

100

hIgh

Improper

troubles electnc system must be checked first

before adjusting the carburetor

Remedlc

Clean needle valve

RCpJlf pump

Lap

or

See above

Each

Clean

onsumptlon
bleed clogged

have

troubles when electnc systern IS defec

Therefore whenever the engIne has

causes

needle valve

and

are vanous causes

Fuel overflows
mam aIr

aIr on

sIze

TROUBLE SHOOTING

Troubles

are

care

air

emIssIon

Jets

performan

components

gasohne
or

on

emISSIOns

of carburetor troubles and remedIes for

sometImes

some

Assembly

the vehicle

Shootmg
follOWIng table

are

There

tlve

everse

on

why

ChangIng Jet

In the

the operatIOn of acceleratIng pump

gasohne

that all

so

Trouble

Check conditIOn of

IS

III vehICle

cause

causes

Pour

and

manufactured WIth utmost

them
Check

correctly
smoothly

performance depends

bleed

aIr

To clean them

replace

and

Jets
The carburetor

largely depends

for

In

be
components
components

related

Interlock hnks operate

ce

Check filter

the

careful not to bend or deform the

Reassembly carefully
Idle

reassembhng

and

dlsassembhng

replai

ruel Sptem

Possible

Troubles

Gauge plate adjustment

Choke valve does
Outlet valve

not

seat

Remedies

causes

Correct

mcorrect

adjustment

Adjust

open

of accelerator pump

1m

Lap

or

replace

proper
Lmked openmg of
too

Power

early

each

shortage

mam

Clean

Jet clogged

EaLh throttle valve does

Fuel pump

not

fully

Adjust

open

Repair

operated Improperly

Clean

clogged

uel stramer

Vacuum Jet

clogged

Clean

Power vdlve

operated Improperly

Adlust

Slow Jel

Improper IdlIng

Adlust

valve

secondary throttle

Fat h

Clean

dugged

Adlusl

thronle valve does not close

throttle

Secondary

valve

operated

Overhaul and dedn

Im

properly
h throttle valve shaft
Eal

Replace

wear

ReplaLe tlghtenlllg

Packing between mamfold and carburetor

defective

See the fust

Fuel overflows

Rough
eogme

engIne Idle

or

Idle

stop

adjustment

Incorrect carburetor
choke

miXture

Idle

Adjust

speed

Incorrect automatic

too fast

or

temperature control

malfunction

lugh

Ignition COIl

Trouble

Adjust

air

In

tUllIng

temperature control

automatlL

air

cable

In

PCV valve

Trouble

In

automatic

hIgh

Adjust

adjustment

throttle opener

Replace
choke

malfunctIOn of Igmhon

spark plug

replaLe IgllltIun system

Chel k throttle hnk and Lable

throttle lInk and cable

pomt Ignition Call

or

breaker

etc

Trouble

or

Adjust

of Igmtlon system

tenSion

Incorred throttle opener

Defect

dnd

cleaner

spark plug

Engme Idle

mixture

Adjust 19mtlon timing

tunmg

cleaner

JXInt

speed

settmg

Incorrect baSIC 1OIt100

Defect

Idle

Item

tenSion
elc

cable

stem

PCV vJlve

Adjust

auotmJtIL

Adjust

or

hoke

e
IgllltIun system
replac

breaker

81

Fuel I

em

Troubles

Engine hesitatIOn

RemedIes

POSSIble causes
Eal h

Jet slow Jet

mam

By pdss hole

die pdssage

Emulsion lube

Clean

Cledn

dogged

mcorrect

throttle

lube

lean

dogged

Idhng adlostment
Secondary

clogged

adjustment

Correct

valve

operated

1m

Overhaul and clean

properly
Car knock when

coastIng

Incorrect throttle opener

Trouble
Defect

or

PCV

AdjUstlhroltle

adjustment

Replace

valve

malfunction of Igmtlon system

spark plog

ugh

tenSIon

cable

Adjust

opener

PCV valve

or

replace IgJuhan system

breaker

pomt IgmtIon cod etc

EnglOe

does not

Fuel overflows

See the first

No fuel

Check pump fuel pIpe and needle valve

start

IdlIng adjustment
Fast Idle

adjustment

Damaged

dlesehng
antl

BI metal rod

82

mearrect

mcareeet

contact

solenoId

WIth

metal
bl

Correct

adjustment

Correct

adjustment

Replace
case

Item

Adlust

Cooling Sptem

Fig 106 Coolmg system

C0026

FIg 107 Water pump and front

cover

DESCRIPTION

FIg 1I1S Water pump removal

radiator w1th

pellet
coohng system IS of a closed pressure type
With hIgh coolmg capablhty Coohng water
resIstance free
water
through
flowmg
head
and
cyhnder
passages m the cyhnder
block IS mamtamed at adequate temperature
range at allo tlmes by means of an ample
capacIty water pump of a corrugated fin type

hIgh coohng efficiency

and of a

type thermostat

The

84

WATER PUMP

centrifugal type water

alumlpum d1e cast pump body

The water pump

WIth
pum
T he
cover

an

IS a

olute chamber
assembly

and

IS
a

bUIlt mto the front

high

pressure

seahng

GooliDI Sptem
mechamsm

leakage

pump
the
since

shrmkage

be

not

must

water

disassembled

Installation

bearings

are

fitted to their bores If any part

replace

of water pump is found defective

the

mstalhng

When

nOIse

The

Note

the water

adopted to prevent
completely

IS

and

adheSIve

Three Bond

thermostat
to

for preventIOn of water

packmg

stall the thermostat

apply

both SIdes of the

reverse

leakage

In

sequence of

removal

assembly

pump

Removal
Dram

coolmg

water

completely

Olher
Canadd

USA

Take the fan belt ofT the

Remove fan and

pulley
Valve opemng
temperature

pulley

Remove the water pump

177

to

16710

r8710

183

193

031 203

031 212

Installation
InstallatIOn

coun t nes

173

Valve lIft

IS the

reverse

of removal
O

oF

194
031

THERMOSTAT

pellet type

thermostat

IS

used

the water

outlet passage to control the flow of coolant

provldmg fast engme warm up and regulatmg
coolant temperature A wax pellet m the ther
mo tat
expands when heated and contracts
when cooled
a

to

piston

The
a

pellet

IS

valve and

connected
when the

through
pellet IS

WI

fL g
l
IL
JI

exerted agamst a rubber

pressure
and
the
valve opens As the pellet
dIaphragm
heated

IS

the contractIOn allows the sprmg to

cooled

1
I
I

IS

a
i
J

close the valve

EI
Removal
Dram

Thermostat

wa
r

outlet

Fig 109 Thermostat removal

coohng water

Remove radiator hose

Remove

water outlet elbow

Then take out

the thermostat

Inspection
To test the thermostat for proper operatmg
temperature submerg he umt m a contamer
of water Heat the water and observe the tem

perature
Measure

temperature

when the thermostat

valve Just starts rlsmg

If thermostat does not operate at the above

specIfied temperatures

It must be

replaced

FIQ 110 Thermostat inspection

81

Gooliol SJstem
RADIATOR
The radiator

IS

of a down flow type w1th an ex

on the top of tube sec

panslOn tank located

tlOn

Pressure
I

applted to the system and the

Incorporated In the radiator filler
controls the pressure at approximately 13
IS

eltef valve

cap

Ib sq

In

Removal
DraIn

cooltng

water

Fig 111 Radiator removal

DIsconnect radiator
and hose to the

reservOir

Detach the radiator

fiXIng

upper

hose

lower hose

tank

assembly by

removmg SIX

bolts
or

replace

the radIator

assembly

Inspection
Check for water
cap tester

88

leakage

If such defects

and cracks USIng a

are detected repair

Installation
InstallatIOn

IS

the

reverse

ofremoval

Brakes

Jl
I

r7
I

lip

Spnn

LVI

pm

hlm
5

lIJn ll

p lIJ

ih
Ih
Air

Rlt

11

k r
hlu
llmll

12
13

nn

8001
111

prill

lon

yhndu
PI

Ii

blolk

lon
L
lh

YOkl

15

Yoh

prm
pnn

Fig 112 Front diSC brake components

CYLINDER SIDE

DECOMPRESSION
exceeding the
elastic dISplacement IS
released with slipping on
Movement

the seal surf

Fig

Returns

elastIC

displacement of

the

seal

113 PIston seal automatic adjusting operation

Brake

FRONT DISC BRAKE

pad
Retalnl
pin

Clip

FIg 114 RemOVing retaining pm

Rigidity of the cahper IS high brake pedal

feehng IS adequate and the pad draggIng IS
mlmmlzed The padqs returned by elastIcity
of the piston seal When the pad IS worn the

88

piston operating stroke Increases shpplng oc

curs on the plston
seal surface and thus
clearance

IS

adjusted automatIcally

Brakes
r

Moreover

squeahng

In

order

shIm

IS

to

prevent

Inserted behind the

brake

for

pad

and every 3 000 miles thereafter

after the first 6 000 miles

wear

Clean the brake

BRAKE PAD

or

pad

driVing

With carbon tetrachloride

gasohne

Replacement
Jack up front UnIt of the vehicle and
the front wheel

remove

When 011 and

the
to

from the retaining pin and sup

the
brake
porting
pad remove the retaining
and
COil
pin
spring
Remove

clip

spring and Withdraw the

and shim With a pair of phers

Unhook the
brake

pad

hanger

Note When the brake

not

the

pad IS
pedal

depress the brake

piston will come out

removed do
or

otherWise

grease IS

heavIly

replace

the

or

stlcked

on

deformed due

pad

With

new

one

When thickness of the friction material

IS

less than 0 0630

total

pad

thIckness

replace

In

IS

Replace

less than 0 2402

pad
when

In

Replace pads as a set Replacement

only one position may cause uneven

Note
at

brake

It

effect

pads

IS

recommended

be made

that

periodically

Check the rotor

Clearance between the brake

adjusted automatically

pad or
overheating

rotation of

Inspection

or

when deteriorated

and rotor

pad

Check the brake

IS

pad

Reinstallation
Clean the

calipers

and piston

pad installing

parts
Do not

Note

apply

not to

on

mineral oil

Be careful

the rotor

the pIston Into the

be Installed

Depress
new pad
Note

use

oil

cyhnder

so

that

can

Note that brake fluid may over

the reservoir It is recommen

flow from
ded

that

loosening

operation

be

carried

out

by

the breather to release brake

fluid
Fig

115

WIthdraWing brake pad and shIm

Fig

116

b The

piston

hand

But

be easily pushed in by
pushed excessively the

can

if

DepreSSion piston A and B Into cylinder

88

Brakes

groove of pIston goes insIde of seal as

shown in Figure 117 and the seal will be

damaged When the piston is pushed

cesslvely mto the cylinder remove
brake assembly disassemble It push
the piston to the arrow direction
shown in Figure 117 and reassemble

ex

When the

pedal
pad In

as

CALIPER
Removal
Remove the brake
DIsconnect

cyltnder

pOints the

Apply
which

so

rotor forward

arrow

mark

rotating directIOn

the COIl
IS

spring to the retaining pin

distanced from the atr bleeder

111

PlSton seal

Normal position

the brake

the posltton

out

pad and antt squeal shim assemble

squeal spring and retaining pin and
ecure them with cltp
that the

depress

the

the anti

the shim

Installed

IS

several tl mes so as to settle down the

Install

Install

pad

pad

the brake tube

Remove the strut

assembly

from the wheel

and knuckle

so as

cahper assembly

installatIOn bolt

Remove the

cahper assembly

installatIOn bolt

and separate It from the strut assembly

I
Fig 119 RemOVing strut assembly and knuckle

Fig

117 Piston pushIng

FIg 118 Arrow mark

78

on

In

posllIon

shim

arm

to ease removal of the

installatIOn bolt

arm

stallatIon bolt

Fig 120 RemOVing caliper assembly Installallon bolt

in

Brakes

DIsassembly

Remove the bIas nng from the piston A

Remove mud and other contamInations from

the

caLiper

as

before dlsa

embly

DraIn bl ake fluId flOm the wheel

Loosen

pistons

the

bleeder

aIr

sembly
cylinder

and

A and B Into the

the
depres
cylInder See FIg

125
Secure the
head with
then

be

yoke
a

In

vIse

hammer The

removed

from

and tap the

yoke
cylinder body can
the yoke
When

remOVIng the cylinder body be careful not to

allow the piston A comIng out from the cylIn

Remove the

nngs and boots from

retaInIng

the pistons A and B

and

Depress

remove

the piston from the

cylin

der
Remove the piston seal from the
Note

Remove

w1th
not

fmgers
damaged

so

the p1ston seal carefully

that the cylinder wall is

Remove the
from the

cylinder

prIng and

yoke
yoke

bias sprIng

yoke

der

Inspection
Thoroughly

and

Repair

clean all dIsassembled parts

check them for the follOWIng Items

and

Note

use

When

alcohol

cleaning

rubber

parts

brake fluid If rubber parts

wIth mmeral Oil they will

or

cleaned

are

be

detenorated

Calzpers
If the

cylInder

replace
foreIgn
der
FIg 121 TapPing yoke head

If the

so

damaged
replace

cylinder

damaged
wall

IS

or

worn

rusted

or

cylIn

carefully polIsh wIth fine emery

that the cylInder wall
IS
not
If rusted or roughened excessively

Pad
See paragraph

IS

matters are accumulated on the

wall

paper

wall

covenng

replacement of pad

PIston

Replace

If

unevenly

worn

damaged

and

or

rusted
I

Note The
Thus

rusted

piston slidmg

do not
or

use

foreign

surface is

plated

emery paper although

matters are sttcked on

the sliding surface

Q
Fig

122

Retamlng

nng

Cylinder body and piston

Boot

Seals

Prlmanly replace both pIston

whenever overhauling

and dust seals

Brakes

Note

The

Ieakmg
reason

seal affects not only

piston return For this
replace the piston seal even If the

piston

LImIt of I

econdltlOntng lotOl

In

thlcknes
l

but also

damage IS

minor

o 3307

In

DeflectIOn ofthe rotor

Below 0 0012

In

Rotor
Check the rotor

and

If It shows

cesslvely out of round

ditIOnIng by machInIng
normal
and

condItIOns such

excessIve

deflectIOn

Standard rotor
03740

and

requIred
l

as

crack

replace

cOl e

forth

so

ex

recon

If any ab
ltortlOn
dl

the rotor

Reassembly
Apply the rubber

grea
le

to

cylinder

bore and

Install the pIston seal

Insert the bIas rIng to pIston A so that the
roundl
lh
portIon of bIas ring comes to the bot
tom of pIston

thlckne
ls

In

A
PISTON A

Fig 123 MeaSUring deflectoon of diSC

Fig

72

124

Installing bias ring

mto

piston A

Fig

125

Piston A and B

Fig

126

Installing boot

PISTON B

Brakes

Note Be careful not to confuse the

piston

A with B

Apply

rubber grease

tlon of

hghtly

Insert

p1ston and

to the

shdlng

When

the

piston

be

careful not to insert too far

Install the boot and
Install

so

that the

piston A COinCide

Install the bias spring to yoke so that the bias

spring comes to the aIr bleeder Side of cyhn
der
the brake grease to the
portIOn of cylinder

groove of bIas nng of

wIth the

projected portIOn of yoke

as shown In Figures 127

Apply

retaining nng

yoke

that the

par

the piston Into the

insertmg

so

spnng faces to diSC

and 128

cyhnder
Note

Install

yoke

cyhnder

groove

of

With
groove

the

yoke
hghtly

spring
correct

Inserted

poSitIOn

yoke shdlng
to

cylinder

of the

spnng so that the groove of biaS spring

Cides With yoke

bias
COin

YOKE SPRING

Fig

127

Installation of yoke spnng

Fig 128 InstallatIOn of yoke spnng 2

Fig 129 Correctmg bias spnng POSItion

Fig

130 Measunng startmg torque

73

Brakes

Fig

Assemble the
ping the

Apply
slIding

and

cylIndel body
yoke lIghtly

the

brake

grease

131

Rear brake construction

yoke by tap

air

fully

to

the

yoke

bleeder

the

calIper assembly

pad
the hydraulIc
torque of diSC

remove

IS

the brake drum

Remove

In

reverse

DIsconnect

the brake tube from

completely

measure

bleed

the rotatton

Remove the dust

plates

The

In

removed

eaSily

Ib

At the hub bolt

345

Tightening torque
CalIper assembly installatIOn

bolt

33 3 to 44 1 ft lb
Brake tube flare nut connected to wheel

cylIn

der 108 to 13 0 ft lb
REAR BRAKE
Removal and

Disassembly

Jack up the rear slde of the vehicle support

With a stand and remove the wheel

74

the shoe

remove

the

the wheel

adjusting shims and

cylInder can then be

cover

wheel

Starting torque
780

and

cylinder

Installed

line and

the cleVIS

spnng

retainer and retUl n spnng

brake shoe assembly

sequence of removal
After the

pull

return spnng

Remove

Reinstallation
Reinstall

Wire

pin from the rear wheel lylInder lever and

disconnect the hand brake wIre Remove the

groove of cylInder

Install the

Loosen the hand brake

Flg 132 RemOVing hand brake vme

Brakes

the

Remove
Wire dla

free

length

Load

housing

length

the

o 0787

4 69

III

sIde

33 4lb

5 22

28

bolt from the

flange

the

remove

brake disc

actIve turns

Cylmder

adjuster assembly

Remove the

Return spnng dimensIOns

can

00787

2 736

sIde

3 020

III

axle
The

together

wIth

axle shaft

rear

Inspection
For the

19 6 lb

rear

axle shaft

then be removed

rear

brake inspectIOn the instructIOns

for front drum brake

Adjuster

rear

Reassembly

20

apply

and Reinstallation

semble and
Rea

reinstall

sequence of dl

reverse

noting the follOWing

Measure the wheel

the

matter

cylinder shdlng

and make

136

Figure

In

Note When

sure

resistance

as

shown

that the

In

slIding

range from 4 409 to 15432 Ib

sliding

improper
smoothly

IS

shoe does not return

Tighten

In

and removal

With the brake tube dIsconnected

resIstance

brake

rear

assembly

the brake

the brake diSC installatIOn bold

flange

bolt 10 8 to 14 5 ft Ib

T1ghten

adjuster assembly

the

installatIOn bolt

116to 159ft Ib
HAND BRAKE
1

Brake moes

Shoe

retamer

Removal
Loosen the

Fig 133 Rear drum brake

turn buckle

adjusting

separate the front cable from the

nut

and

rear cable

CYLINDER SIDE

306
1 205

jE
58 2 283

1192

469

FREE LENGTH
ADJUSTE R 51 DE
12

11
UNIT

Fig 134 Removmg brake disc

Fig

0433
mm

0472

2
42 1654
69 5 2 736
FREE LENGTH

135

75

Brakes

Remove the lock

plate

located

front of the turn buckle

Immediately
the clip

remove

the passenger compartment SIde

nect the front cable

III

Remove the hand brake lever

III

the lever

and discon

nected

toward

cover

Remove

wIth the front cable

assembly
the

passenger

con

compartment

SIde
Remove

the

hanger strap installatIOn bolt

plate from the axle hOUSIng

withdraw the lock

bracket umt and disconnect the

Loosen

the

strap

hanger

the

separate

parts

Into

and bracket

cylinder

lever SIde brake cable

Note Do not
the cable

umt

nut

washer

rear

remove

and

nut

hanger strap

DIsconnect

the dust

but leave it

cable

the wheel

cover

installed

from

on

the

cable

Inspection
Check the cable for

Spong balancer

Wheel

tlve

cyhnder

Replace

FIg 136 Measunng slidIng resistance

1
2

Hand brake It

ver

able

Clip

Lock

6
7

plate

FIg

78

condlttons
If

and

shdIng part

Turn hUlkle Hand brake

Han

adJU

Return sprmg

hr

CabJc
abk

damage and other

replace If reqUIred

er

trap

10

Cable shank

II

Hand brake lever

137 Hand brake construction

IS worn

lover

defec

excessively

Brakes
Make

sure

that the hand brake lever

operated smoothly
and teeth

are

can

be

and that the ratchet

not worn

pawl
unusually or damaged

With the hand brake lever

pulled depress the

push button and make sure that the pawl
disengages the teeth when the push button IS
depressed 0 1969 to 0 2362 In completely
Make

sure

damaged

or

that the cable dust

cover

warped

1S

not

Reinstallation

Remstall the hand brake

ofremoval notmg the
Be careful

not

to

reverse

damage

or

tW1St

TIghten
nectmg
When
sure

the

hanger strap

and the cable

adJustmg

rear

brake shoe clearance be

shdmg parts

MIL G 2108

or

sufficIently

w1th multI purpose

G10924l

o
buckle

con

nut to 5 8 to 7 2 ft lb

to loosen the mner cable

grease

turn

the dust

cover

Grease the

FIg 138 Removing

sequence

folloWIng matters

Fig 140 Disconnecting

housing

cable

rear

Lock

from

plate
rear

axle

j
0

O
I
i

Ii

j
0

V
2

Fig

139

Front cabl
Cover

Removing

CI

H nd brok

hand brake lever

Ye

I
Fig 141

Dust

cover

Hanger strap

washer

Bracket

Hanger strap mounted

on rear

axle hOUSing

77

Brakes

ADJUSTMENT

Rear Brake
Jack up the vehicle and

Front Disc Brake

Ordinarily

adJu

tment

IS

requIred

not

pad and rotor IS

adjusted automattcally by elasttclty of the
because clearance between

pIston seal

ApplYing

remove

the wheel

your hand and tool from reverse side

of the brake diSC

ttghten

the brake

adjuster

clockWise up to such an extent that the

brake shoe comes Into contact With the brake

wedge
drum

adjuster wedge properly so that

IS separated from the brake
drum slIghtly
Return

the

the brake shoe

Turn the brake drum

and If the brake shoe

Interferes the brake drum

dition

sure

iJ

depress

readjust In ad
pedal and make
operates effecttvely and

the brake

that the brake

correctly

Loosen the stopper up to such extent that the

brake pedal stopper IS separated from the pedal

el

arm

Brake Pedal

Height
height of the brake pedal head from
the dash panel and adjust the adjusting shim
between the brake master cylInder and dash
panel so that height IS 5 65 In
Measure

FIg

142

AdJustmg

rear

brake shoe clearance

F
J

1
I

r
BRAKE MASTER

CYLINDER

tI

I
05mmlOQ197
10 0315

THICKNESS 08mm
16mm

100630

nl
0

11

r
l00

Fig 143 Brake pedal adjustment

78

Brakes

Adjusting

shIm thickness for selectIOn

LImIted stroke

o 0197

In

535

00315

In

The

o 0630

In

standard posItIon 8 7
lever fulcrum

Note

When

be

adjusting

Jusbng sh1ms having

sure

to use ad

th1ckness for

same

upper and lower brake master

IOstallahon bolts

Upon completIOn of adjusting

ment tighten the stopper down
tent that heIght of the pedal
pO 0787 In and tighten the lock
Free travel of the brake
0591

tn

and the stroke

shIm

adjust

to such an ex

head
nut

pedal

4 72

IS

cylinder

IS

5 57

becurely

IS

0 197

to

Stroke

term

Note

Readjust

reaches

the

In

Turn the turn buckle

properly and adjust
hand brake lever operatmg stroke
correctly so
that operatmg stroke IS 3 091 m 16 notches at
operatIng force of 243 to 331 Ib
com

pletIOn

of

adjustment

be

sure

to

Upon
tIghten

the

lock nut
of the

adjustment

the hand brake lever and make

wheels

are

not

braked

Normal btroke
3091

Fig

In

the

hand brake stroke when it

hmited

stroke

5 35

in

10

BLEEDING HYDRAULIC SYSTEM

BleedIng the hydrauhc brake system deserves
much attentIOn

As

air

IS

servICe

as

It IS an e senttal factor for

brake operatIon

matter of fact

lIkely

durmg

the brake

serVice

to creep Into the CirCUIt WIth the

IS

altered and the

brake pedal becomes spongy at the travel end

Bleedmg

should be carned out at first WIth

the master

then from

cylmder

lIne from the master

cylmder

the

longest

and then fimsh

up With the shortest

Always clear away any dirt around

cylinder reservoir cover before
removing cover for any reason Never
depress pedal while brake drums are
Note

Upon completIOn
rear

from

above the hand brake

result that the flUId actIon

Hand Brake

heIght

means

notches

regular

In

10 notches

tn

6 notches

144 AdJusting turn buckle

sure

release
that the

master

removed unless bleeder valve

Top

up

the

reservOIr

master

flUId of the recommended

Fig

145

Connecting Vinyl

IS

open

cyltnder

With

type

hose to air bleeder rear

79

Brakes

Wipe the bleeder screw and from

Thoroughly
any mud

hole

IS

Attach
bleeder
a Jar

Conduct

dust present so that the outlet

free from foreign matter
or

hose

VInyl
Dip

screw

contaInIng

to

the

Note

the wheel

cyhnder
VInyl hose In

the end of the

some

In

aIr

FlUid

withdrawn

When the master

the wheel

pedal fully depressed loosen

exhaust air and rettghten
screw qUIckly
screw

the

brake flUId

operatIons

comes

brake flUId

near

pedal slowly

out from
out

the

above

Air

When

WIll

no

replaced
cylinder which
the master cyhnder
or

Ordinarily
following

stIll eXists

atr

Rear left

but

screw

is dIsassem

cylinder

conduct air

the

the bleeder

bleeding
again for

refilling

times

With the brake

come

in

operation should not be used

the bleeder

Repeat
longer

cyhnders

Check the reservoir for fluid level

bled

Return the brake

other wheel

on

during bleeding operation

brake flUId

Depress the brake pedal two to three

and keep the pedal fully depressed

the bleeder

bleedIng

same manner

air

bleeding

bleeding

is

performed

It appears whIte due to aIr bub

Rear

Front left

right

Do not return the brake

retightening

the bleeder

pedal

screw

TROUBLE SHOOTING

Spongy pedal

Probable

Au

In

poor

qualIty

Use of
which

Pedal Yields under

shght

15

to

flu d wIth

or use

of

bOilIng pomt

Ihoroughly
e md bleed the
ho

Replace

filler cap
a

Vdcuum

through

vent
In

hole

master

rear

wIth the

Change
bleed

low

promotes

In air

detenoratlOn

system

spectlied

brake

flUId dnd

system

clogged

Tins

Clean

cylinder

that

system

filler

reserVOIr

cap

and

bleed

the

seal

Detenorated check valve

Fit

ExterIlalleaks

Check

a new

check valve and bleed the system

pressure
master

cylInder

cyhnder

for leaks

Master

cyhnder

leaks through pnmary cap

Overhaul

master

plpmg and wheel

and make necessary

pairs

80

dellon

brake flUid

brake

too

Bleed

ReservOir

suckS

Corretttve

cause

brake lines

Swollen hose due

in

sequence

Front

right

In

ble

Condition

on

is located most

cyhnder

re

before

Brakes

Excessive pedal

System hds

not

Bleed the

been bled

travel

system

shoe

Improperly adjusted

clearance

Adjust

FlUid level

cylinder IS too low

Full up wIth

master

In

Bleed the

Thermal expansIOn of drums due

hea

to Qver

clearance
brake flUId

specIfied

system If requIred
to

Allow drums

lImngs

lmg

todrum

off Check brake shoe

cool

and drums

Replace damaged parts

All b rakes

drag

drum
lnsuffiuent shoe to
Weak shoe

return

Brake shoe

return

Seized

One brake

drdgs

master

Loose or
Weak

damaged

wheel

SerVJce

bedfmgs

unhooked

or

the spnngs

Adjust pedal height

free travel

cylinder piston

broken

return

Replace

springs
no

cledrance

Adjust

clearance

brake

shoe

the

cyhnder

master

pISton

and bleed the

Adjust

Of

the

syslem

wheel

replace

repla

beanngs

Replace spnng

spnngs
between brake shoe

InsuffiCient clearance

Adjust

brakes

and drum

Unbalanced brdkes

Grease

or

011

Clean brake mechamsm repldce hnmg and

hnmgs

on

of grease

cause

correct

or

011

getllng

on

Lmmg
Seized piston

In

wheel

cylInder

the wheel

SerVIce

cyhnder and bleed

the

system
Tires

lted
mtl

Improperly

Loose wheel

bearing

Front suspension

Inflate

tires to

Adjust

wheel

pedal

Grease

mud

or

tter
w

on

Lmmgs

Full

area

of

Immgs

not

Lontaclmg drums

or

drums

Clean

Dust

on

drums

or

oIl

Replace

adlust

all

front

sus

and dry hrongs

or

shoes

Reface drums and mstall

SLOTed brake drums

squeak

Remove

es
brak

Brake chatter

and

components

replace

pressure required
poor

bearing

Thoroughly check

faulty

pensIOn

Excessive

correct pressure

soLled Immgs

Remove

and

clean

new

IImngs

drums

thoroughly

ElImmale oIl leak

squeal
Weak

shoe

Drum

out

Worn

Itmngs

return

springs

of round

Check spnngs and replace

Turn drums

on

as

required

lathe

Replace hrungs

II

J
t

f1J

lr

Jtt

V
t
T

lfr

Yr

t7

1 1
1

lQ

t
t

pront

Suspension

Strut

Strut mounllng

Upper

mounting

5
6

tlOVU
DU
ton rod
ool

Hub

Fig

embly
t
b

mbly

10

pring

Irut

bearing

at
r
pnng o
Oumpu rubblf

Qj

Insulator

5pmdh

II

Ball JOint

12

Trd

1 J

Tln lon rod

14

StJblluLr

15

SU

nwu
link

p mIOn mlmbt r

146 Front axle and suspension assembly

I

DESCRIPTION

overall

forward

movements

The front suspensIOn IS of

shock absorber and spIndle

Ingle

Unit

whIch

IS

strut

are

type The

combIned to

the COIl

supported by
by the transverse

the

to

lInear

spnng at the upper end and

rearward

lInk at the lower end

slOn

The

spIndle

Installed

IS

strut outer caSIng

A ball JOInt

by

on

means

the bottom of the

the

spIndle The ball JOInt and the transverse

lInk lower lInk are connected and they are
fitted to the suspensIOn member
rubber
b shIng
The
shock
mechanism

IS

bUIlt

A COIl

SIngle

These
umt

are

through

rubber

adopts

are

type
system

suspensIOn

IS

changed
adopted

used

connectIOn

so

The

tor

In

thiS

that the strut

between

both

Side

absorber

the strut outer caSIng

apphed between the upper

Thus

thiS

suspensIOn

mechanism

absorbs

shocks toward all directIOns Into the chaSSIS

effectively

and

effiCIently

the tensIOn rod ab

sorbs forward and backward shocks the strut

absorbs

vertical

shock

and

the

transver

In

components

assembled

to

fitted to the chaSSIS frame at

their upper part through the thrust beanng

M eover
the 1ransverse hnk supports the

84

shape
ngldltles

stabilIzer

se

lInk absorbs shock

sprIng IS
sprIng seat fitted to the upper end of the
piston rod and spring seat welded to the outer
caSIng

through
bushIng

struts

attached to the lower part of

IS

bar

strut

WIth whICh the forward and

maIntaInS

of weldIng

backward

of the tensIOn rod fitted

frame
sls
cha
rubber
The

bushIng
non

by

and

means

applIed

toward

SIdeway

RECOMMENDATIONS

Due to the need for

tools and

large

number of speCial

ahgnment eqUIpment

It IS recom

mended that repairs to the front end be left to

a

completely

pped

shop

Suspension

Pront

j
I

i
I

t I

I
l

c aj

ll l l

hf
11

t
r

FIg

Cross sectIonal

147

vIew

Drum type brake

of front axle

TROUBLE SHOOTING

Probable

CondltJOn

Vibration

steenng

Vibration
ratIOn

shock

and

of

shimmYing

Loose connectIOn of the

ser

parts and rubber coupling parts

wear

of

part of hnkage and VIbration of

front wheels are In many cases trans
each

to

nottceable
road

au

Unbalance

defectIve rubber couplIng and

mitted

Improper

pressure of

wheel

the

steenng wheel ThiS

when

travellIng

over

IS

very

and

Corrective

cause

Adjust

tIre

deformatIon

of

road

wheel

Unevenly

Correct
or

worn

hre

or

action

the

unbalance

replace

insufficient

Replace

front

Adjust

or

ttghten

IIghtemng
Improperly adlusted

or

worn

wheel

or

tIghten

beanng

rough
Faulty wheel alignment

Adlust

85

Pront

Suspension
When the

Shock
Img

over

roads

bumpy

steenng linkage
steering wheel

the

Shlmmymg

are

play

transnutted

IS

This

Worn

travel
of the

to

especially

IS

travellmg rough

able when

front

fronl wheels

the

which

specific speed

IS

when

occur

tlghten

Replace
gear

steenng

steenng hnkage

Replace

Worn suspensIOn ball

Jomt
E

backlash

xcesslve

due

Replace
improper ad

to

attamed

beanng

beanng
or

spnng

loose

strut

Check

clamp

rectly

or

driVing

wheel

over
to

swerves

Note

or

left

With hands

flat road

nght

Improper

off

the

ficlent

steering

the vehicle

gently

rear

also be the

cause

dealing With

Replace

or

repdlT

cor

relighlen

In

of

pressure

of wheel
of

height

Correl t the unbaldnle

tire

or

msuf

Adjust

or

tighten

nuts

nght and left

lIre

Replace

tlTes

treads

A defective

and therefore

au

hghtenmg

Difference

lefl

or

and

loose mstdllatJon bolts

Unbalance ofvehtcle level

pulls to right

Adjust correctly

weakened column

MalfunctIOn of shock absorber inSIde the

Vhen

defective p uts

Justment of the ret uner parts

Worn column

VehIcle

Rellghten

housmg
Wear of

Abnormal VIbratIOns of the

hnkage

Insufficiently

bushmgs

notice

road

suspensIOn group and lhe whole

sleenng

transverse hnk

fittmg

see

the

suspenSion

may

Incorrect adjustment

of tillS trouble
also the
rear

wheel

chapter

suspenSion

or

abraSIOn of

front

Adjust

or

Collapsed

or

tWisted front sprmg

Repldcc

Incorrect wheel

alIgnment

Adjust

Incorrect brake

adjustment bmdmg

Adlusl

Worn rubber

for transverse link

Repl ne

Deformed steering linkage and suspensIOn

Repldc
e

and

replalc

beanng

bushmgs

rod

tensIOn

lInk
Unbalanced vehicle level

InstabilIty of vehIcle

Improper

au

Worn rubber
and

pressure of

bushmgs

Incorrect wheel

or

tire

for

Adjust

tmnsverse

Imk

AdlU

rod

tensIOn

Worn

Correcl the unbdJdlKe

alignment

deformed

Adjust

steenng hnkage and

Replace

suspensIOn link
Incorrect

Stoff

steering wheel

checking

up

procedure

Jack up fronl wheels

g

88

nd

ra

steenng gear

AdJusl
Correcl

Improper

Adlust

pun ties
o

andk

of

Deformed unbalanced wheel

au

InsuffiCient

detach the steenng

ste

adjustment

pressure of
lubricants

lire

or

sleenng linkage

steenng Imkage

nuxmg

or

Im

exceSSively

or

e
replaf

msh grease
Repl
place the pa rt

or re

Front

If

IS

lIght

check

stecrmg hnkage and

suspension groups
If

It
I

hectvy

chl ck

StIff

or

dJmaged

5llspenslUn bJII

Jomt

or

SuspeDsion
RcplJce

lack of gTcelse

sleermg geM wd

stcermg column groups

Worn

whed

ReplJLL

dJtnJged steering gedf Jod bearmg

ReplJLc

lIKorrcctly

01

ddJuSICd

Worn

Inorrectly
Deformed

Inorrcct

adjusted teenng

JdJu

wheel

strut

Damaged

or

AdJusl

gear

steering Imkage

Damaged

rod

Replace

alignment
upper end

stiff piston

Adlust
bearmg

or

shock

Replace
dbsorber

turn

Adlusl

Incorrectly adjusted steenng gear housmg

Adjust

Worn

Replace

h
sWlh

signal
play

Replace

the strut

Interference of steenng column Wllh

Excessive steering wheel

or

bCJfIll g

steenng lmkage

Improperly fitted
1n orrectJy

gear box

adjusted

Worn

trdl1Wcrs
e

wheel

hnk

Retighten

bearIng

dnd

tensIOn

Adjust
rod

Replace

f1ttlllg bmhlOgs
1

NOises

Improper

lIT

pressure of

Adlusl

lire

InsuffiCient lubncatmg 011 and grease for

lOn b t11
suspen
or

then

Loose

Jomt and steermg hnkage

breakage

Replemsh
od

and

lubncatlOn

grease

or

re

place
bolt
Imkage and

teermg gear

Retighten

suspension groups
Defective

shock

absorber

mslde

the

Replace

slrut

Defective wheel

Worn

bearmg

Replace

sleenng Imkage

Worn

transverse

hnk

Replace
and

tenston

rod

Replace

fiUmg bushmgs
Broken collapsed rod sprmg

Replace

Loose strut

Retighten

mountmg Insulator tJghtemng

nuts

Grating

tire

nOise

Improper

aJf

pressure of

Incorrect wheel

Adjust

tlfe

alIgnment

Deformed knuckle

spmdle

Adjust
and

suspensIOn

Replace

linkage

81

Front

Suspension
Jumping of disc wheel

Improper

air

pressure of

Adjust

hre

Unbalanced wheels

Adjust

Defective shock absorber

Replace

DefectIve

Repldce

tlfe

Deformed wheel

Replace

rim

I
ExcessIVely

or

partially

worn tIre

Improper

au

pressure of

Incorrect wheel

tlfe

alIgnment

Adlusl

DefectIVe wheel beanng

Replace

Incorrect brake

Adjust

adjustment

Improper lire sluflmg

rolahon

Rough and Improper driVing

88

Adlust

manner

Adlusl
Dnve

more

gen

tly

i
1
f

tc

J
I

If

IJ

l
t

4i

1
J
i

rf

f
lo

d
rr

tt4

l
f
r
lf

0
1

0
9

ij

it

Ir

ij

Steering
DESCRIPTION

mtles

and

replenIsh

recommended

011

as

reqUIred
The steering
ball type

gear

These

dlmg

ystem

box and

The steetlng linkage should be greased up

WIth wheel bearing grease every 30 000 mtles

of

reclrculatmg
parallelogram linkage

consIsts

y tems gIve good respon e light han

utmost durabIlity
Moreover the

RECOMMENDATIONS

and

teermg linkage

IS

rubber sy tem Idler

from the wheel

eqUIpped
arm

With

torsIOn

Due to the need for

whIch absorbs shock

tools and
mended

Steenng gear housing

Cover ector haft

Shaft

Shim

anng

Camp Jacket

column

Suew

sector

adjusting

roller hdft

Fig

80

that

ponents be left

Check the lubricant of gear box every 6 000

steeling

148

worm

large number
alignment eqUIpment It

Steering gear coriiPon rrts

repairs
to a

to

IS recom

the steering

com

completely eqUIpped shop

Assembly olumn steering

t
mbly bearmg steering l
Assembly ut ball
As

of specIal

orm

SteeriDg
TROUBLE SHOOTING

Probable

ConditIon

lIeavy steering

Low

tIre

Corrective

cause

pressure

orreet front wheel

In

altgnmcnt

Innate

tires to

Adjust

to

FITm

stllkmg

of

the ball

Jomt and

strut

steering gc H and b dl jomts

or

bdll jomt

WOln

replace

recommended pressure

speclficatJono

Lubricate

Lack of lubricant

action

Replace

beanog

Improper adjustment
gcar

and

Adjust

or

steermg hnkJge

LubrlcJte with

beanng

Incorrect front wheel be mng

Loose

Adjust

ddJustment

or

Loose

to

one

side

adjustment of ddJust

Incorrect

lITe

pre

replace

nuts to

Inflate

sure

to

and

Inspect

Incorrect front wheel

beanng adjustment

Adjust bearings

Deformation

or

to

proper torque

front WhlCI

corred

alignment

Replace

umts

Improper

and

Adjust brakes

ddJustment

Weak front suspensIOn

If any

recommended pressurc

dhgnment

brdke

pdrts

worn

recommended torque

Adjust

nut

Incorrect front wheel

Unequal

reqUired

as

TIghten mountmg bolts

steermg gCdf housmg mountIng

Incorrect

bearing grease

replace

Inspect

connectIOns

tighten

Pull

repldce

housmg

H Hd lock1l1g of column

Loose steenng

damage of steering

fittmg of

sus

Check

correct

or

replace

pensIOn

Steermg shock

Incorrect front wheel

Loose front wheel
Loose
verse

beanngs

steering lmkage connectIOn and

adjustment of ball nut

Wheels out of balance

correct

front wheel

alIgnment

Adjust bearings
trans

Inspect
tighten

lmk

Incorrect

Inspect and

ahgnment

Adjust

Inspect

replace
nuts to

worn

proper

steenng

and

correct

parts

If any

and

torque

gear

wheel

e
balanl

81

i
1

f
J1J

JI
it

Jil
r
k

rt

f
t

83
t
u

o
J

d
lo

U
f
i
M

At

1
rd

i il

lear Drive

Suspension

FIg 149 Sectional

REAR AXLE

The

axle

ear

axle

hOUSIng

hou Ing It IS

19

of

IS

press steel

light

In

weight

tly strong
ding loads

to wIthstand all

The

wheel

rear

IS

IS

IS

sufficlen

torsIOnal and ben

with

of

presealed
bearIngs
frequent lubncatIng ser

no

However when the

reqUIred

reInstallatIOn
the

and

are

dIsassembled the wheel

packed

BanjO

axle

bearings should

be

grease pnor to the

lpproved
beIng careful

an

rear

not

to

damage

sealing rubber
DIFFERENTIAL

The gear carner IS made of light and strong

alumInum alloy metaLand hYPOld bevel gear
IS used

of

rear

A le

SPdlU

holft

3
4

c1 beanng
Whl
Whcd be mng

Oll

Hcanng

Axle

BrJ ke drum

ollar

al

adjust

hlOl

C
a

axle

Adjust dnve pInIOn bearIng preload wIth

and pInion height
non adjustIng type spacer
and Side bearIng adjustment wIth spacer
shlm

MIllimeter standardIzatIOn stili

all the

screw

adjustment

types Therefore
vice

type The
type

f10atIng
sem1

vIew

I
2

remaInS

for

threads of thIS Unit Therefore

figures stamped

on

screws

JustIng shIms washers dIfferentIal

case

ad

dnve

In accor
pInIOn and carner are In millimeters
dance with the millImeter standardIzatIOn of

parts
The proper lubncatlOn to the gear hOUSIng IS
neCessary otherWIse It would shorten the

durability
troubles

of
The

the

gear

lubncant

each 3 000 miles and

and

cause

other

should be checked

replenished

each 30 000

miles
The

luJ

ncan
ks hould be draIned and

at the end of the first 600 miles to

refilled
eltm1l1ate

Bear Drive

Suspension

TIghtening torque
12 to 11 kg m 86

It beii
contact pattern means that
ange of 2 3 to 3 4 from the tip
Backlash
IS
no
load
tooth nder

of the
010 to 015mm

Tlghtemng
60

to

70

00039

to

00059

Plmon be nng

lve
O

matenal

ad ustlng shims

Left

Ide T1

jA

Right

SIde T2

from

breaking

the

sump

which

Dlfferentlallubncant

should be changed at least every 30 000 m11es

ConsIderatIOns

It

IS

should

be

given

to

the

HI

hYPOld

prohibited

adjust

spacer

plmon adlustlng
N
HxO 011

washer
0 2 mml

001

001

0200

0 200

E lmml

mml

carner

springs telescopIc hydrauhc

and rubber bumpers

shock absorbers

rear sprmg center pm 1S ofT set 4 33 m

toward the front from the center of the sprmg

The

ThIS

matters

Nommated

nut

lb
ft

Drive gear

Fig 150 Sectional view of dIfferentIal

follOWing

1229

with

results from

to

torque of drlve gear bolt

kg m 434 to 506 ft Ibl

TIghten by tapping bolt head

hammer
a 0 lkg 1 4 lb

loose

correct

the

any

of dnvt pmlon

IS

done to reduce sprmg wmd up and to

arc while the rear wheel sWings

decrease the

gear 011 must be used

through Thereby

to use any gear 011 of dIfferent

of

the

rear

m1n1mlzmg the

suspensIOn

POSSibilIty
effecting vehlCle

stablhty

VISCOSity

It

The

same

brand must

always

The standard 011 capacity

IS

be selected

damp deVices are used

axle hOUSing to the sprmg
Iso

about 0 198 US

gal

for

attachmg

the

The leaf sprmgs shock absorbers and rear

axle housmg are mounted on rubber bushings
REAR SUSPENSION

at each end to
the

Rear suspensIOn consists of

serm

elhptlc

leaf

minimIZe nOIse

transmiSSIon

passenger

to

the

and VibratIOn of
car

body

and

compartment

85

Suspension

Bear Drive

3
4

16

ll
Lx

111111

hJ ddl

hOl k oIh orbu

Ji

H md brah

ldr

8rdk

ho

Torqw

Hound

bumplf

prill
It

Fig

151

arrl

10

hr

lrL

Rear suspension

Fig 152 Removing the shock absorber lower end

REAR SHOCK ABSORBER

Fig 153 Removing shock absorber

upper

Remove the lower end of the

rear

ber from the sprmg seat

Replacement
Jack upcthe center of the rear axle
port the axle housmg with stands

88

and sup

See

E ll1ove the rear shock

located under the

rear

sea

bracket

shock absor

FIgure

152

absorJ
l lpstalhng
back

nut

Bear Drive

Install

rear

shock

absorber

reverse

cracks

and

shock

absorber

and

Replace

replace

If
Due to

necessary

Check for

leakage
straightness
Inspect

deformatIOn

RECOMMENDATIONS

Inspection
the

exceSSIve

the defectIve parts If necessary

equence of removal

Test

Suspension

the

rubber

cracks and the shaft for

the

reqUIred

It

necessary

overhaul

bushmgs

for

damage

large

and

of

number of

the
IS

the

advanced

specIal tools
knowledge

recommended
differential

be

that
left

the
to

properlv equipped shop

97

Clutch

CLUTCH PEDAL

DESCRIPTION
The clutch
prIng

IS

sIngle dry

type clutch

clutch

cover

provided

diaphragm

plate

pressure

are

diaphragm

rIngs The clutch diSC IS

WIth rIveted plates on both surfaces

and

sprIng

dIsc

The major components

wire

and cot bprIngs arranged In a hnk The COIl

whIle engagIng the
prIngs absOl b shock
clutch

smoothIng

and

softemng

dre

sleeve and WIthdrawal lever

used to control clutch engagement and

bearIng

disengagement
Each part of the clutch assembly IS secured
With rivets Therefore when a trouble IS un

replace
assembly

correctable
a

new

the clutch

Remove the return sprmg

Loosen the lock nut of the master cyhnder
push rod and disconnect the push rod end
Remove the lock nut and washer of the
shaft and remove the pedal lever

assembly

With

Inspection
Thoroughly

clean all disassembled parts

and

wear

Pedal head rubber

9353
30
3682

1181

00004

il

f
g

0
O
l
ll

00

it
11

l
I

lt NN
to
lt

If

I
I

I
I

lIGHTENING TORQUE

5 to 2 2 kg m
108 to 159ft lbl

UOIt

FIg 154 Construction of clutch

100

check them for

carefully
damage and other abnormal conditions
RepaIr or replace them With new ones If
reqUIred
dlcated below

Return sprIng

pedal

clutch

engagement
Release

Removal

mm

Inl

Clutch

Adlustmg shun
Part number

ThIckness

mm

00630
Clutch
30

mm

pedallrte
1181

tl
aY

00315

05

00197

nllSgre
Ch

Fig 155 P edal height adjustment

l
1

f
J
vy

Snap

ring

Dust

over

Push rod

Clutch piston
Piston

W
Il

Spring

Inlel valve

@
0

pnng

Inlet valve

Spnng

Ji

retamer

Shun
Inlet valve release pm

Body
011 reservoir

to

@
@

011 reservou cap

Fig 156 Clutch master cylinder

101

Clutch

pnmanly whenever
cyhnder IS dIsassembled It must
also be replaced when wear or deformatIOn
due to fatIgue or damage IS found

Pedal lever bush

Fulcrum

pedal

the pIston cup

Replace

the master

etc

pIn

Remstallation
Reinstall the clutch

pedal

In

reverse

sequence

ofremoval

Check the dust

thIckness
to use shIms

Ule

haVIng

same

thIckness

for both upper and lower

adjust the pedal stopper properly so that

pedal pad height IS 557 In and secure the

Next
the

pOSitIOn WIth lock

Note

two

Grease if

places

matters

The pIston cup should be soaked In brake flUId

Install the pIston cup
before reassembly

carefully

so

brake flUId

rod from the cleVIS

Remove

the

master

ecunng

suffiCIently

to the

the

master

cyhnder

of removal

cyhnder

sequence

assembly
adjust

and

Adjust the pedal heIght by changmg

rod length
Bleed air out ofthe hydrauhc system

Removal

cylinder

correctly faced

In

as

follows

CLUTCH MASTER CYLINDER

and draIn flUid

IS

Reinstallation

reqUired

DIsconnect the clutch lIne from

that It

and pIston and assemble them

reverse

push

new

cylInder assembly In
dIsassembly notIng the

of

sequence

follOWIng

ReInstall

DIsconnect the

replace With

Reassemble the master

Apply

sure that chaSSIS grease has

been applied to the CG marked portions

found

IS

filler cap

deformatIOn If

Reassembly

nut

Make

or

one

reverse

Be

reservOIr

damage

abnormal condItIOn

Adjustment
Adjust pedal pad heIght to 565 In Without
stopper The adjustment IS made by selectmg
and
shlm s
haVing adequate
applYIng

OIl

cover

and clutch lIne for

the

push

the master
BLEEDING CLUTCH SYSTEM

bolts and

remove

the

from the vehIcle

cyhnder assembly

Remove

the bleed

screw

dust cap from

the

operatIng cyhnder

DIsassembly
Pull back the dust

cover

and

remove

three
the snap

The stopper push rod pIston assembly

pnmary cup and return sptlng assembly can
be removed
rIng

Inspection
Thoroughly

clean all

parts With brake flUId

before InspectIOn
Check

the

wear or

When

clearance

pIston

IS

cyhnder

102

cyhnder
damage Replace

more

piston

for

uneven

If required

between

the

than O 0059

In

cylinder
replace

bleed

approximately

screw

quarters of a turn Attach

tube

Immer

SIng the open end mto a clean contaIner which

contaInS a small amount ofbrake flUId
Fill the master

cyhnder

reservOIr

With the

recommended flUId

Depress
keepIng
and

and

the

Open

Remove the filler cap and draIn flUId

the
It

pedal qUIckly while

retighten the bleed screw
return slowly
Repeat thiS

clutch

down

allow It to

flUId entenng the

pumpIng actIOn unttl the
contaIner IS free from air bubbles

and

Screw up the bleed

the

the

pedal

remove

the dust cap

screw on a

the

bleec

1
t1

down stroke of
nd

rel1lace

Transmission

lransmission

Idler shaft and front sIde of the transmiSSIOn

FOUR SPEED TRANSMISSION

case

The transmiSSIOn
smISSIOn case

and

rear

assembly

whIch

assembly

gear

the

rear

rear

end

Moreoyer

cons1sts of tran

contams

supports the other ends

mam

extensIOn

shaft

The gear
the gear

The cast Iron adapter plate supports each end

of the mam sO aft counter shaft and reverse

assembly
assembly

supports

extensIOn

can

be dIsassembled With

Installed

on

the

plate

1T

Fig 158 F4W56 gear tram

Fig 157 R3W56 gear tram

iir
j

lkv
If
r
v

rn
J

li
I

rr

Fig

11M

159

F4W56 transmisSion

the

J
I

Jo
J

adapter

Iransmission

THREE SPEED TRANSMISSION

Fig 160 R3W56 transmisSion

TROUBLE SHOOTING

Symptom
Difficult

to

sure

shift

possible

cause

tIve actIOn
Correc

mtermesh gears

Causes for difficult gear

gear

and

lever

IS

heavy

that the clutch

shlftmg
and

It

are

IS

classIfied to troubles concernmg the control system md transmlSSlUn When the

difficult

operates correctly

and

to

shift ge us clutch disengagement mdY also be unsmooth First make

Inspect the transmiSSion

105

Transmission

Worn gears

shaft and

Inufficlcnt

Defective

Gear

slips

or

to

loose

worn or

Repair

shdmg pdll

or

mesh

thiS trouble

cases

when the control

system
be

IS

occurs

defectIve
out

weakened front and

rear

must

when the Interlock plunger check ball and

In thiS

earned

trouble shootmg

Cd

carefully
engme

the trouble

cannot

be

Worn check hall and

or

or

weakened

IS worn or

spnng

corrected by repldtlllg gt

It should also be noted that gear

slips

out

to

vlbralIon

Replal c

Replalc

broken sprmg

weakened

or

RepI

Worn

damaged beanng

Repldce

damaged

Repldlc

or

or

therefore

and

of mesh due

Worn fork rod ball groove

Worn

drs

mounts

mterlock plunger

or

replal c

Replace

damaged synchronIzer

out of

generated by

Repl llc

heanng

operatmg stroke due

In the most

Worn

or

gear

e
H

NOise

When
gears

nOIse

It

occurs unoer

may

Inoufllclenl

Judged

or

engine

that the

Idling and stops whde the clutch

nOIse

IS

from the

IS

ldlgsedeng

or when

nOI

Olcurs

Add od

1mproper lubncant

or

replace

oIl

Ollleaklllg due

Worn

to

defectIve 011 seal md

beanng High hummmg

occurs at

gasket clogged breather

Damaged beanng Cychc knockmg sound

108

etc

alllo

Clean

or

Replace

high speed

occurs

while

shlftmg

ltrSanSmlIUnl

at

low

speed

Replace

Worn each

sphne

Replace

Worn each

hushmg

Replace

replace

With

deSignated

Transmission

AUTOMATIC TRANSMISSION DESCRIPTION

Ii

AT270

lllll

II

l
O

12

OUllJllt

011 pump
1 runl dUlth

13

KlJT

B H1d brJkl

14

Re

15

011 p Jll
lIT01

Rldr

h
du

plJllctJry

ronl

pIJIJC

IJ

ry j

lJr

16

Input

lLr

11

JYdutdt

lW

011 dl

l
RlVlr

holtl

Jkl
bl

19

Dm l

6 5

15

n
l1
11

T
lIh

147

11l

@I

plJh

nbulm

Flg 161 CrosssectIonal

view

tn
to

15

III

11n

8
i

HI

07

to

II

01

20

@I

I 310 I 8

055toO

to

194
40

CDT

2 5

14toHn

541

16

tu

16

hl

41u5

01

Ihl

29101fll

111
11

lu

II

Illllt

10
li

tlvt

ItlrllUl

hkl1lllj
Ih kl

01

llhlOIl

rllT

OIll
9
10

II
h llt

lr
rn

2S
I

013

05

5
4

to U l
to

2 iJ

of 3N71B automatic transmIssIon

107

Transmission

AUTOMATIC TRANSMISSION
The model 3N71B automatic transmiSSIOn

fully

automatic Unit consisting

3 element

hydrauhc torque

planetary gear
a multiple

ches

a one

Two

sets

elements reqUired
tlon of the two

The two

planetary

ward ratIOs and

gear ratIOs

IS

pnmanly

multiple
a

disc clut

band brake and

provide

the fnctlon

to obtain the deSired

planetary

Rg 162 Idenllflcatlon number

fun

gear sets

gear

sets

one reverse

fully

of

converter and two

disc brake

way sprag clutch

IS

give three for

of the

Changing

automatic

In

relation to

vehicle

speed and engine torque Input

Vehicle speed and engine mamfold vacuum
Signals are constantly fed to the transmiSSIOn
to prOVide the proper gear ratIO for maximum
effiCiency and performance at all throttle
openmgs

The Model 3N71B has

P R N D

SIX

selector poSitIOns

speed

Park pOSitIOn

put shaft

to the

posItively locks the

transmiSSIOn case by means

out

of

lockmg pawl
rollmg either directIOn
to

prevent the vehicle from

at any vehicle

gear and

remain

IS reduced to

second until vehicle

approximately

speed

25 to 31 MPH

1 range posItion prevents the transmiSSIOn

from shlftmg out of low gear ThiS IS par
tlcularly benefiCial for mamtamIng maximum

brakmg

operation

IS

when continUOUS

low

gear

deSirable

The torque converter

constructIOn and

can

assembly

of welded

IS

not be dlssassembled for

service

ThiS pOSitIOn should be selected whenever the

dnver leaves the vehicle
The engme may be started

selected

and the transmiSSIOn will shift to second

engine
p

range can be

FlUld Recommendatwn
Use

Park pOSition

automatic

DEXRON

flUid

transmiSSIOn

IdentificatIOns

only

haVing

the 3N71B

automatic transmiSSIOn

Reverse range enables the vehicle to

be operated m a reverse direction

Neutral pOSitIOn enables the engine to

be started and run Without dnvIngthe vehicle

driVing

Drive range IS used for all normal

conditions Dnve range has three gear

denttficatwn Number
Stamped posttwn
The plate attached to

the

rIght hand Side

Figure 161

of

transmission case as shown m

denttficatwn of number arrangements

See Page 109

ratios from the startmg ratIO to direct dnve

2

range

dnvIng onshppery
be used for engine

prOVides performance
surfaces

2 range

can

for

brakmg

2 range can be selected at any vehicle

speed
and prevents the transmlsslOn from shifting

out of second gear

108

RECOMMENDATIONS

also
Due

to

the

compleXity

of

setting

up

disassembled

transmissIOn

special tools
thaL nternal
ped shop

necessary It IS recommended
epalrs be left to a fully eqUip

as

well

as

the

Transmission
AUTOMATIC TRANSMISSION IDENTIFICATION
Model code

JAPAN AUTOMATIC

I0

TRANSMISSION CO

LTD

MODEL

XOIOO

NO

2412345

Unit number

NlIlllher deSignatIOn
2412145

Sendl productIOn
number for the monfh
Month of
X

LJ

Oct
t

production
Y

Nov

Pel

Ure denotmg
fll

the yedf

A D

108

f J
li

i
j

11

t
r

t
t

if

j
f

1
1
j
r

t
i

t2

tf

Or 1
AZ

111

j
c

t
l
1

j t
l
1t

JH

1i

of

tI

1
N
J

j1
t

l
f
1

Bod Work

with the fender top and clearance between the

HOOD

and fender IS aligned evenly toward

overall circumference of the hood when the
hood

Removal
hwld washer hose at the
WInd

connect the
DI
nozzle

hood

IS

closed
HOOD LOCK

In order to protect the hood from damaging

place rag In hoth Ide of the hood rear end
loosen the hood

hinge

installatIOn bolts

and

remove the hood

UPPOl tIng It from both SIdes
Two
shown
In
the follOWing figure
as

workers

are

Removal
Remove

the

radiator

stallation bolts

and

remove

Disconnect the hood lock

the

hood

removal carefully

In

so

in

the male Side of

the hood lock

required

Installation
Install

the

loosen

gnlle

reverse

sequence

that the hood

IS

of

Side of the hood lock

from the female

wire

and

remove

the female

Side of the hood lock

flush
Remove

three

screws

and

the hood

remove

lock control lever

Adjustment
Centermg the

Hood Lock

The male Side

o 118

In

hook lock

adjusting

IS

with

prOVided

stroke toward left and

nght

Sides of the vehicle and the female SIde with a

0118 In adjustIng stroke toward front and
rear

Sides

of the

stallatIOn bolts and

vehicle

align

the

Loosen

the center

correctly

FIg 163 Removmg hood hmge

Dov tall bolt

Dovetail bolt

31

Spong
Sarety

retammg
Ii

il

7JjHood
Fig 164 Removmg hood

U2

Fig 165 Hood lock mechamsm

catch lever

Spnng
lever

nut

hmaJc lever

lod

in

control

Rubber grommet

Bod Work

Adjusting
Operating

Hood Lock Control Lever

Force

When the control lever operatmg force IS ex

ceSSlve loosen the dove tail bolt retammg nut
2

Increase

dove tall bolt 1

mstalled

length

and reduce tensIOn ofthe spring

Tightening torque
Dove tall bolt retaining nut
108 to 18 1 ft lb
Fig 166 Removing male Side of the hood lock

DovetaIl bolt lock nut

Ttghtenlllg

FIg

167

Removing female Side ofthe hood lock

FIg 169 Section

Fig

168 Removing hood lock control lever

Fig

10

torque

view

mm

1 5

to

2 5

m
kg

1108

to

18 1 It Ib

of hood lock

0079

10

0 236 on

170 Checking free play of hood panel

U3

Bod Work

J
t

3
G

iJ

7
Fig 171 Adjusting dove tall boll
A

5 Omm

O 197

85

0335

mm

Fig 172 Safety catch lever positIOn

AdJustmg Hood TIghtness

After clOSIng the hood panel completely push
the center of the front portIon of It by hand
and check whether there IS a free play of
o 079 to 0 236
If It

IS

LUBRICATING POINT

In

out of the above mentIOned range ad

length of the dove tall bolt 1 to In

Just the
ie
crea

After

or

decrea
ie

adJustIng

retaInIng
Notes

nut to

tighten the dove tall bolt

above the tIghtenIng torque

When

note the

inspecting the
following matters

Check to be

tensIOn ofthe sprIng

sure

hood

lock

that dove tail bolt

retaining nut 2 is tightened securely

specifIed tightening torque

Fig 173 Lubncatlng POints

with

b Check catcher of the

safety catch lever

spring 3 for weakness
and break If the spring is broken the
hood may be unlocked and rapidly open
du ring driving
for

wear

and the

Check the female lever for smooth and

correct

operation

and the

spring

for

weakness and break

If

the

smoothly

female

lever

engaging

1M

disengaged

Measure the dimension

dimension

should be

more

to

check

The dimension

than 0 335 in

Lubrication
When check

or

adjust

the hood lock lubricate

pIvOt catcher and return sprIng 3 of the

4
Also
thoroughly
safety catch lever
the

does
stroke

dove tail bolt wilLbeoreduced

be

the

not

with

move

the

and it may

lubricate the lever of the hood lock femel

focsmooth
173

allc1

orr

ioperatIon Se

ylgur

Bod Work

1
Trunk lJd
Trunk lid lock

FIg

uieI1lbly

174

Trunk hd

Hmge

weathentnp

fixII18

pin

Trunk lid

Stnker

hmzc
sembly

Trunk lid and hinge construction Sedan

@
Oosed poSItion
RaUtlon center of

ill

trunk hd

Trunk

hd

Iungo

Trunk lid torsion

bar
Rear Waist connector

Fig 175 Installing torsion bar

U5

Bod Work

TRUNK LID LOCK

Coupe
adju tmg engagement between the lock
adjust stnker poSitIOn toward left
tmg stroke 02362 m
right Sides
adju

When
Removal
Loosen

and stnker
tallatlOn

bolts

tl Iker and lock from the

Remove the leaf

hd lock

chp

and

remove

the

body

and lock

lu ed to secure the trunk

cylmder on the body

cylIndCl

and

and

remove

the

pOSitIOn for vertical directIOn

justmg stroke 03 50

ad

Tlghtemng torque

trunk lId lock

fixmg bolt

Lock and stnker

45 ft lb

o 87 to

Adjustment
Sedan

TRUNK LID TORSION BAR

When

adjustmg engagement

and

tnker

properly

set

adjust

890

and

statlOnanly and
poSitIOn
Adjustmg
nght SIdes dIrectIOn IS

the lock
stnker

stroke toward left and

0

between the lock

03150

toward

vertical

The

mdlcated

dIrectIOn

as

tallIng

torsIOn

installing

the torsion bar

torsIOn bar wrench

VAN

J
j

l
tl

11

II

Back door

hUlle

tomon

bOT

BlCk door

hmge

Back door

Back door lock rod

Lock

Stnker

Stnker shun

Back door side

dovetad
9

Side

10

Back

II

Ag 176 Back door and hinge constructions

U8

bar

are

follows

Note When
a

of

procedures

dovetl1l
door

tllm

bumper
Back door
bumper plate

te
u

Bod Work
DOOR CONSTRUCTION

0
f

@
f

ID
I

W
@Y

I tCl
@

FIg

177

GllUs

Weatherstnp

run

rubber

Door panel

Weathentnp

Weatherstnp

Seal

Door fmlsh

Door

bumper rubber

Door

gla

spICer

screen

stopper

10

oraln hole cover

II

Doorgllss

12

Glazmg

13

Bottom channel

14

Outer

I S

Door upper

hmge

16

Door lower

hinge

rubber

moulding

Front door construction

Dw
I

Glass

Partition

Partition sash

Door panel

We

Doorbumper rubber

Seal

Door fintsh

Door comer

10
11

run

rubber
athentnp
we

therstrlp

screen

Klass

Door lass
Jter
O

moulding

12

Glass

13

Glazmg

14

Bottom channel

15

Door upper

16

Door lower hinge

17

Dram hole cover

18

Door

19

run

rubber

rubber

hinge

glasstopper
Wcatherstnp

Fig 178 Rear door construcllon

U7

fi

Gu

G1

t4ual

UI

ie

0
l

cat

3
a

J
G

Jl

E
1

i
t

lj

It

U
8

1l
3

I
i

p
t g

UMlt
U
t
1

tEAtt
R

mode

transmi on
automatic

for

diagram
Wifing
1SO
fIg

UfOR

Efl
fII

M
O

t
l
t

@ f1
t

1tO

H
Rlt
PA

a
P

Vo
I
I

Jo

Bod Work

BULB SPECIFICATIONS

Headlight

umt

Duectlonal and
SIde marker
LIcense

parking light

Speclflca tlons

SAE Trade Number

2V 50 40W

60 2

2V 23 8W

1034

8W
2V

67

2V 7 5W

89

light

plate light

light
TaIllight
Stop brake light
Turn sIgnal light
Back up lIght

Rear combination

2V 23 8W

2V 23 8W
2V 23W
2V 23W
2V

Meter

Illuminating lamp

WIper

Washer Illumination

lamp

Heater control Illumination

lamp

Ignition warmng light

Turn

signal

Headlight

indicator

beam indIcator

all pressure warning

Brake warning
Room

120

light

light

light

light

lIght

7W

1034

073

12V 3 4W

58

2V 3 4W

57

12V 17W

2V

7W

2V

7W

61

2V 17W

16

2V I 7W

2V lOW

If

fuse

detect cause

Corectwe

tlon

ac

the

requtred

fused repaH replace

as

When

RepaIr

Inspection

and and

the

as

the

RepaIr

If

IS

If

and and

When

contact

fuse

contact the contact

the

fuse

for

Check faulty

Check cable

test

the

fuse
the

termInal

contact
fuse

Blown

contact

Def ctive

dIm er dIm er
off

lmpro er Def ctIve

BI

1M
do

anW

l ead

CondItiOn

lamps hght

An not

Conduct

Check

sWItch

Faulty con ector

off

contact

contl u

sWitch sWitch

hghtlng hghtlng

or

ty

the

CO

sWItch

faulty

test

con ector

Check faulty

Conduct

Check

for

for

con ector contiUIty

contact

fusIng

for

for

block

Proba le cause

as

and

fusIng

and

ethOd

r
e
q
u
n
e
d
requHed lighting fused repair replace dIm er def ctWe
def ctWe
RepaIr

and

wlute
of

the

sWitch replace

fuse
c
a
u
s
e
d
e
t
e
c
t
SWitch replace the the

hght high beams

not both loW

1h

does

for and

meter contact requlted

be
a

the

If

le
Correctl

actlon

after

regulator With

con

cor

cause

Corect

the

Replace rectiUg fused tact

It

the

When regulator replace With

to

voltage comb ed
The

the

IS

thermo ter smgle voltage defctlve together thermo ter

unit

IS

together

cable

tReplacehermo ter

and

If

unproper repair

fuse

the

l
twee

Check

With

for

and

and

excsIVelY

fUSing
of

MethOd lnspectlon

for

fuse
the

cause
P
r
o
b
a
l
e
met r

contact

Thermo ter

con

Dam

Impro er

regulator contaopenct

or

voltage

fuse

voltage

DefctIVe Impro er lmpro er

ken

Defec aged

nectlOn

thermo ter

do

thermo ter

Both

meter
fuel

operate

Both

and not
1

cable

Wire

heat

fused

IVe

off

regulator consteaiczted contact

groundi g

or

Meter
Bro and

and

conditon

operates

Meter

U
Blov

fuel

shghtly

operates

Check Improper

oa

II

or

meter Inac u
fuel
and

mdlcate rately

ther

thet
the

place
Re

t anst1

place
Re

t1

t ansm

momet r

place
Re

ace
p
Re

tt

deuect yel

lte
owlw

the

does t ansmlt er rounded

ye

deUects
pot1

tansmltetounded

the

t1

cates aftet

lt On

l1

ble

the

even

tS

tS

t et
sttl

etet

thermot1
Def ctlve Def ctIVe

thetmal

themO et

t a1

thetrnal

Def ctIVe

Def ctIVe
tnUl mum
tet

themo et
lermotnetet
f

off

petature
tem

Smt et

t a1

the

tt

tS

al

moves

Itton
l

tutned
off potntet
wh
e
n
p
o
t
n
t
e
r
t
h
e
t
1
c
a
bl
e
potntet
the sWitch
t
u
t
n
e
d
lt1
the
the whe1 wht e
al

tet

SW

to

not

whe1

malUmut

loW tch

owl

omet

mal
tS

ca

thet

the

ttet

the

the

tUet

the

thet

perate
o

not

the does

potl
the

maJ
petatute
tem

cates

10a

iii

from

thermal

defctive

to

cable break

cable

repalI

and and

tile

thermal
t
h
e
r
m
o
r
e
q
U
i
r
e
d
g
r
o
u
n
d
m
g
a
b
o
u
t
c
o
n
t
a
c
n
u
t
e
r
Replace transmiter Check

the

If

Replace

for

the

to

as

the the

IS

cable SOoC

serVIcable transmIter
IS

the

reSIstance thermal cable

thermo

a
p
r
o
x
u
n
a
t
e
l
y
thermo ter thermo teampcrtautuael
thermo yeUowlute grounde Uldcates 12 0F through tempratue
IS

100 the
a

the

and

When

when plied

The

the

the

to

transmIter

thermo

slightly

above

thermal

The

contact
cable

thermo does operate rately

defl cts yelow

pOUlter umt

pOUlter the

grounde The through

met r

tank

fuel

DefCtlve

Defctive

Fuel

Fuel

operate
not

ter

II

Ii

above

umt

The

ter

mdoes spectlon

met r meter

ac U

With

not

does
not

defl ct

The tank

the

DefctIve Improer

Defctive

IS

when cable

lower
1
9
d
1
c
a
t
e
s
UlSpeCtlOn

IS

the

the

than

normal

fuel new

Replace wut Replace

ap

me one

tank

trans bemg poor faulty

II

IIa Iia

me

tank

defctive

fuel

the

the

Replace Unit Replace

from

the

cable met r
the

If

ter

place

Replace

the

fuel

Re

to

fuel

cable break

and and

to

groundtg

for

Unit

met r

Check the tank

in

level

about contac reqwred

being po r faulty repaIr
as

the

Full

Igmtlon
below
the

lowers when

off

mdIcates
stIli

In

above

and

level

ap hed
half cable

the

not the

the

35

IS

to

IS

cable

pOinter level

the

The half

fuel

spection The slIghtly level

contac

met r

Unit

met r

tank

fuel

tank

fuel

cable

Defctive

Defctive

Defctive

Defctive

Improer

umt

po

func

pOInter Full

met r

mdl
The

cates sItion

actual

I
n
d
t
c
a
e
s
yelow
than
r
e
S
I
s
t
a
n
c
e
through Indtcaes taUninkt grounde does through met r lower
a

turned
pomter
pomter
pOinter the
The empty sWitch The pOSItion pectIon The when
Imut

indcate above

IS

Fuel

ImtIporonesly
13en

oa

ta

COfe

CorectIV

after

action

the

bulb

fila

hght

out

fuse

fused
the

pres

replace

011

burnt

the

lf

as

and

not yel oW
does sWitch

fusing
for

of

MethOd tnSpeCtlOn

gpres urerounde

lamP

fuse

15

contact warnt g

the

Check faulty

the

sWitch

oil

IS

cable

oil

when black

The

pres

pres ure

the the
on

when
e
X
i
s
t
s
level

engine

tnspectlOn

engine

oil

ou

bghts
lamp

sWitch

Replace sure

Add

through

bght

and

01

ment reqUIred Replace Sure

Check for

Replace tlng cause

the

pres

the

011

warnt g above inspect system

The

Cont Ulty

Check

the

or

contact

lamps

faulty

warni g

or

Ptoba le cause

fuse

igniton

Blown

and

warn

pres ure conditon presure

not

Broken faulty

Defctive

the

lamp amp when

The

19I1tlOn

engine

IS

oil

pres ure

of

Lack

Oil

not

does

sWItch ON

hght

oil

toO

IS

does

Oil ing

Oil

contact

lamp cable

off

loW

pres ure

bulb

sure

belng

sWitch

swltch

filament

sWltch operated

pres ure

Oil

Defctive

the

wlule being

IS

lamp
The

to

out
go

engtne operated

set
Il

II

II
II
II
II

Jl

ll

as

for

re

replace

bulb

filament

as

or

the out

replace

it

Repair requIred Check burnt and qUired

and

light

con the and ON

fusmg

not

for

does

regulator grounde

fuse

lamp

contac

the

voltage disconetd

IS

set
IS

sWitch

sy tem

chargin
the

1
8
m
t
l
O
n
when nector white Inspect

pdot the

Check faulty

to

IS

cable

The

41

red

the

4t

fJ

or

contac
fuse

hght contac

off

out

Blown
does when

wanu g
Igmtion lamp

sy tem

bulb

or

6i

filament

faulty

lamp hght

IgDlton

The Dot the

Ii

cable

chargm

Burnt faulty

Faulty

to

does

when

lamp

out

set
IS

switch ON

IS

engme

go

The not

tA

stared

the

j
11G
f

ir

j olv
i

ct
I

rV

ffl

tl

to

t
1

p
f

t
Toi

tf

l1

jr
J

H
ti

1k

wli

in

r
7

Io
i

lJj
j

if

t
r

JIi

t
r

f
tj

f
l

ql

1J

5
I

fi

f
i

l tl
j

1
r

fo

Ji

l
r
II

if

ft

51lm

lllIllIII
h

Jl

t1SJ

fr

rtl
y

1
I

t
I

Xr
A

t
it

i
r

8
l

c
ct

l
t

Cf

lf

li

4t
Y
l

A
o

ft
r

jB

A
r

To

1
7

orn
c

1
t

Ai

ft

Specifications

ICATIONS
RECOMMENDED LUBRICANT SPECI f

SpeCificatiOnS

Item

SAE ClaSSIfIcatIon
GasolIne engme 011

SD or SE

Remarks
Furthermore refer

Transmission
and

API

GL4

API

GLS

steenng
l

Dlfferenllal
Automallc

TIM

NLGI2

clutch flUId

OOT3

Antifreeze coolant

130

Type DEXRON

grease

MultIpurpose
Brake and

flUId

Long LIfe Coolant

to

SAE recommended VISCOSity

table See Page GI 5

LIthIUm soap base

Specifications

SERVICE DATA AND SPECIFICATIONS

1 vpc

RCl

Ieertng wheel dldl1lCler

Od

JpJuty

mm m

400

L US

024

Imp pt

pI

wheel

iteenng angle

outer
heel

hllttal

20

111

to

10 7X7

to

0 JX4

10

69 4

10

2S

worm

shulls

OS 0 0197

mm m

turnmg torque of

column
le

16
111111

kness of
thl

tJJ d ud

beaTIng

211

1
43

IImer

Ieermg wheel

PIdY

ulatlllg bdll type

15 I

ClrrJtm

assembly

Hance

sedor

uf

kg

ddJustmg

SLrew

cm

oz
lIl

20

to

5 0 27 X

to

shaft

Length of side rod

mm

005

nun

Ill

296 8

0 0020
1169

TlghteolOg torque
Steenng wheellol k
t d unp
po

Steenng
1

pO

to

dlu

If

to

I 0 5 8 107

ilhIlJlcp

kg

to

18

kg

Ill

I ft Ih

o8

10

I 0 S X

L If

III ge

lI1g
hOll

over

hOUI

Side

Idler

to

to

to

13

kg

Ill

ft Ib

1 5

to

25

10810 18 I

kg

Ill

ft Ih

10

28

12 3

kg m ft Ih

nut

drill

I1MIIl

nut

kg

ft Ih

kg

Ill

ft Ib

kg

mltt Ih

kg

kg

kg

Ill

201030
14

10

20 2

14510217

101

bar
I 9

to

26

13 7

5 7 106 3 4

to

18 8

2 1045 6

stde l1lJlO bar bolts Jnd

nuts

nuts

51dc rod hJf

108

hou holh

nut
nul

stud

hnlt

lIl

plllllJIl

In

holts

IIl

lf

rew

IfI 10

Jlld
holt

III
B

I 7

15

Idler dflll
arm

35

08

10

10

ft Ih

llImn hole

30

Ill

edM

Ihl

kg m ft Ih

lrtng

ft

steermg

hrH

IllImn

Ill

lct holts

tdt

kg

nul

k
IOl nuts

ft Ib

191026

ft Ib

30

ft Ih

XOlo 100

to

13710188

0 21 7

to

36 2

57810723

I3l

Specifications

SERVICE DATA

Valve clearJnce
Intdke

IHot

exhaust
Fan belt

tensIOn

Cyhnder

1st
2nd
Re

035

0014

In

035

0014

mm

In

10

15

kg Ib

kg m

bolts

to

0 394

to

0 591

turn

Hot

40

to

4 5

29

to

33

55

to

6 0 40

to

43

60

to

6 5 43

to

47

o 5

to

I 0 36

to

7 2

Spark plugs

I 5

to

2 0 II

to

14

including od filter

capacIty of engine

Maximum

L US gal Imp gal

33

Mmlmum

L US
gal

Imp gal

23

10

US gal Imp gal

42

Water

capacity of coohng system

Wllhout heater

W th heater

L US

CompressIOn

pressure

at

1 4 IJi
49

gal Imp gal

125

kgcm2 PSI

rpm

Ji

to

145

78

to

Battery specific gravity

Permlsslble value

Fully charged
at

FrigId

climates

Tropical

clImates

Other climates

132

22

09toI4 65toI0

nuts

Carburetor nuts

ad

10

ft Ib

turn

l1ghtemng torque

Mamfold

In

mm

Cold

Tlghtemng torque
head

mm

value

20 C 68 F

rlver I 22

128

Over 118

123

Over I 20

126

206

350

Specifications

IgnItIon tlmmg degree

50

BTDC

Dlstnbutor
POInt gap

mm

Dwell angle

degrees

Condenser capacIty
Condenser insulatIon

04510055

49

MIcro Farad

lF
J

Mil

reSiStance

Mega

hms

to

0018 to0022

55

022
5

Spark plug
Cdp

mm

Idle CO Idle
Manual

speed

transmissIon

Automatic
Dash

08to09 003IlO0035

lO

transmission

Irpm

I 5 iO

51800

Irpm

I 5 iO

51650

10

pOSItIOn

pot

Settmg englOe speed

Throllle opener

Settmg

at sea

vacuum

Thermo

sSltranSfonfiI

speed

no

load

SWitch
to

Temperature

hIgh

to

mmHg

10

Hg

500

mmHg

10

Hg

48010520
1 650

rpm

diaphragm full stroke

from low

2 000

level

Automatic transmission

Servo

10

pressure

Manual

Sell 109 englOe

1 900

rpm

mm

540

to

19 7 to
18 9

to

213
20 5

1 850

5 01969

nses

oc

above 5 41

Flow gUIde valve

Operating

pressure

mmHg

10

Hg

10 04

133

Specifications
ENGINE

GENERAL SPECIFICATION

4mlme

Cylinder Jrrangement

Displacement

ce

Bore and stroke

mm

eu

71

73

71 5

70

2 874

Valve

arrangement

Over head

Fmng

order

Engine

Idle

rpm

ratio

011 pressure

Hol

al

2 756

vdlve

42
3

800

Manual

650m

Compresc lon

transmiSSIOn

Automatic transrmsslon

85

2 000 rpm

kg em Ib

sq

30

to

3 5 43

10

50

TIGHTENING TORQUE
Uml

Cyhnder head bolts

CQnnedmg

rod

nuts

Flywheel bolls
Main bearing cap

10

6 0 40

10

43

32

to

3 8 2310

28

651075 471054
bolts

50

10

6 0 36

to

43

Camshaft gear bolts

40

10

4 8 29

10

35

011 pan bolts

o4

to

0 6 2 9 1043

Ot pump bolts

1 I

to

I 7 80

10

011

o9

to

I 4 65

to lO

stramer

Crank

134

5 5

bolts

pulley

bolts

J5

to

16

108

to

12

116

kg

ft Ib

Specifications

SPECIFICATION

Valve mechamsm
Valve clearance

Hot

mm

035

0 0138

Exhaust

035

0 0138

Intake

025

0 0098

Exhaust

025

00098

Valve clearance

Cold

mm

Valve hedd diameter

Valve

stem

Intake

mm

ln

Intake

35

I 378

Exhaust

29

dIameter

mm

Intake
Xh
Valve

HlSl

length

Illm

0 3144

to

0 3134

10235

length
lenglh

spnnpssembled height
t1ve
effcl

wire

diameter

spnngcoil diameter

Valve

gUide length

Valve

gUIde height from

mm

10

mm

kg

mm

to

4 030

to

4 041

10265 4030

to

4 041

465

kg

lb

lb

1831

302 585

387 239

I524

129
199
527

50
mm

em

4100 01614

111m

111

26

mm

10

53

mm

18

111m

I039
2 087

head

surface
UHler

3128

8 5 0 3346

turns

Valve

gUide

to

7 960 0

10235 to 102 65

V dive sprmg loaded

Valve

7 985 0 3138

to

lUst

Valve spong tree

Valve spnng

to

l xh

IIUll

Valve spnng

7970
7945

Intake

vJlve lIft

V dive

142

lhameter

0 709

Intake

8015 t08000

Exhaust

8015

031561003150

t08000 03156to03150

13

Specifications

V dve

gUIde

ouler

diameter

mm

tn

Intake

12044 to 12033

12044

04737 1004733
JU51
Xh

Valve

Valve

Valve

Valve

V live

gUide

to stem

dearance

Cam haft and

to

0045 0 0006

to

00018

Exh lUSf

0040

to

0 070

0 0016

to

0 0028

mm

Jntake

I 3 0 0512

Exhaust

I 8 0 0709

angle

gUide

Intake

450

Exhaust

450
mm

IntJ ke

o 064 to

0096 0 0025

to

Ixhaust

0064

0 096

0025

to

0 0038

Intake

0022 100044 0

0009

to

0 0017

Exhaust

0022

0009

to

0 0017

mterference

fit

mm

to

to

0 044

lImmg cham

Camshaft end play

mm

o 02

Camshaft lobe 11ft

mm

565

Camshaft Journal diameter

mm

43

to

2nd

43

42

283

783

I6844
4th

42

783

I 6647
5th

Camshaft bend

mm

Camshaft bearmg lOner d13meter

1st

41

208

6224

to

to

43 296

to

10

I 6849

42

to

to

46
7

42 796

to

to

I 7242

296

1 6652

41 221

to

I 6229

0015 0 006

mm

0 0008

783 1043796

I7041
lrd

0 08

0 222

I7237

43843

I7261

0038

1st

138

0 4733

0015

mterference fit

sed t

to

Inldke

seat width

seat

mm

12033

to

04737

to

43

to

833

1 7257

to

00031

SpecificatioJls

2nd

43 333

to

I 7060
3rd

42 846

4th

to

to

42 333

to

41

268

Rocker

arm

lever ratio

I 6865

42

323

I 6663

to

41258

to

J 6247

7050

42 836

J 6868

J 6667
5th

43 323

to

1 6243

to

142

Connect 109 rod

Center

e
dlstan

mm

121 47to 121 53

47812

Be H1ng thll kne

BIg end end pldY

to

4 7788

10

J 0594

mm

021003 00079100 0012

500

I 508 0

0591

mm

to

less than 04 0

016

Connecting rod bearlllg

e
c1eardnc

Connectmg rod bend

Crankshaft and

0020

to

1010

10

mm

005

mm

49 951

to

010 0 0020

to

J 9666
taper and

Crankshaft end
MaXimum
end

out

of round

play

service

ll1mt of

play

Crank pin dIameter

mm

mm

005

Mam beanng clearance

MaXimum

beanng

service

clearance

Crankshaft

to

to

0 0020

0 039

bend

964

19671

to

0 0012

00020

0 15

10

0 0059

crankshaft
00118

mm

03

mm

44 97410 44 961

Crankpm taper and out of round

beanng thickness

49

to

less than 003

Main

0008

maIO beanng

Journal diameter

Journal

0 050 0

mm

10

7706

to

7701

less than 0 03 0 0012

to

00719

0008

to

mm

0020 to 0 062

mm

tn

015

00059

mm

0015

to

835

to

827 0 0722

mm

0024

hmlt of mam

0 05

0 0006

to

l
0002

f Piston

137

Specifications

11 lOlIll1l111def

Jml
tJIH

111m

72967

to

28727
OWL Me

mm

73467

to

2 8924
Over

lIe

100

nnn

73967

150

mm

In

to

dlfferenle

RJIlg groove

PI

IUII to

Ith

2 8944

74 017
2

74467to74517
to

2 9337
0004 to 0 0012

lop

20 0

2nd

2 0 0 0787

at

40 0 1575

hure dedram e

9140

00110003 0

mm

mm

73 517

to

29318

Ilhp

2 8 47

to

29121

OverSJle

73 017

to

mm

mm

0787

0023100043 00009

to

00017

gl Piston pm
Pill dlJllleter

17447

to

0 6869
PlIl

length

Piston

pm

to

piston de uJIH e

lOt

ton

if
t vf plston pm

0 6871

6523

to

65 48

2 5681

to

15779

mm

10

0006

to

0008 00002

to

0 0003

to

00013

to

200C

I
680F

Lonnedmg
0 034 0

0017

to

20 0

0787

2nd

20 0

0787

at

40

0007

rmg

helghl
Rill

mm

lop

ilde dedranLe

mm

01575

Top

004 to 0 07

0 0016

to

0 0027

2nd

00410007 0 0016

to

0 0027

004 toO 08 0 0016

to

0 0031

01

mm

lp
Rmgg

138

to

an

111m

hu
hmg

6869

6871

mm

at

IIIlt rterenLe

17452 0

to

Top

02

to

0 35

0079

to

0 0138

2nd

o2

to

0 35

0079

to

00138

01

03

to

090 0 0118

10

0 0354

l
iJ

lk
t

looIo

fj

11
1

v
f

26
I

32

344 135

330

13

14

type

t
13

fm

Corugate

v
S
0

t
09

335

49

SYTEM

sq

mm

mm

hoC
cat
K

Imp
qt

cm2

US

kg

heater

radI tor Width

ff

spacmg cap city presure with

workIng cap city

of

DimenSIOs

qt

Ib

Thicknes

core

471
6

098

In

COLING

Height
Type

Raditor RadItor

Cap

It

fm

1f

Water

It
i

It

A
r

t
fj

ir

Ii l

JJ
0

1mycar

Specifications
SPECIFICATIONS AND SERVICE DATA
Make

NGK

Model

BP5ES

Screw dla

ze

Plug

Reach

mm

14

mm 10

gap

Tlghtemng torque

kg m ft

lb

HITACHI

19

l46PW
0 55

0 75

o 8 to 0 9

0 031

15t025

11 Oto 150

10

0 035

FUEL SYSTEM

Carburetor model

Apphed

DCH3064 for ManuallransrnlSSlon

DCH306 5 for Automalle transmisSIon

englOe

Type

Downdraft

Outlet dIameter
Venturi

diameter

Primary

Secondary

10m

10

26

024

30

1 181

10m

10

20

0 787

26

I 024

95

MamJet
MalO air bleed

fI

Slow let

fI

Slow

alf

bleed

140

80

fI

43

fI

215

HO

level

50
100

Power Jet
Float

80

60
H

mm

lO

18

to

20

0 709

to

0 748

r
r

1
J

1l
II

Interlock opening of primary wd

sCl

Throttle valve opening 48

ondary throttle valve

mill

eI
58 0

Ul

81

Auto choke
raclldle sclllllg dCdrdllLC

080

to

0 88

0 0315

to

0 0346

107

to

1 17

0 0421

to

0 0461

drhurelor

lrdnsmlSS10n

mill

trdnMlll

clearance

Jrburetor body
BI metal

10

transml SIOn

AutomatlL
Choke unloader

hoke vdlve and

body

Manudl

Ill

AUttJl1ldtlC

Vawurn brcdk gap between

l

111m

Mdlludllfdnsmlsslon

JOn

to

1205

to

I 115

260 0 0449

to

00496

004741000526

between choke valve and

mm

c
rCSlstan

I 140

In

00791

201

ohms

86

mm

05 00IQ7

to

90

Aleteralor pump
I oJCl tor hole
Return spring

mm

Fuel pressure

kg em

WClght

78

Ibfm
pSI

x3mplc

15

ts
replC

1 00
15

2 15

018 2 6
28 6 2

kglb

Manual transmISsion

29 639
f

mm

0 0846

AutomatIc

transmIssIon

dIameter

IHI
d
lw

1i

2
1

c
iJ01

if

J
l

lQ

Specifications

STARTER

Au tOP1allc

Mdnual
T
Make

and type

TransmJsslon

lrJaSJonnsmJ

HITACHI S114

Nommal output

KW

System voltage

12

kg Ib

46

Weight

87M

10

HITACHI S 114 I S6
10
12

10 I

S 4 119

No load
Tennmal voltage V

12

Current

less

12

RevolutIon

rpm

more

less than 60

than 60
than 7

000

more

than 6 000

Load
Tennmal voltage V

63

Current

less than 420

Torque
Sluftmg type
Number

142

kg

ft Ib

of pmlOn gear

of teeth

on

pinion gear

more

63

than 0 9 6 S

MagnetiC
9

shift

less than 420

mare

than

MagnetiC
9

1 0 72

shift

Specifications
ALTERNATOR
Make and
NonunaJ

HITACHI LTl3S 13B

type

12 35

VA

output

NegatIve ground

Pole

Revolution
No

load

rpm

000 to 13 500

mmunum

revolu bon

rpm

less than I

Output

A V rpm

more

current

than 28 14 2 500

75
34

kg lb

Weight

000

TLI Z 57

Applied regulator

APPROXIMATE REFILL CAPACITY

USA

Dter

Fuel tank

Sedan

40

10

Coupe

38

10

Coohng system

gal

8Y

gal

gal

gal

qt

without heater

42

yt

qt

qt
pi

X
X

qt
qt

2X

ql

t
054

IX

pt

Manual

t
12

2X

pt

2X

Automatic

5X

qt

4X

ql

pI

IX

pI

pi

pt

27

Transmission case

Steenng gear box

measure

49

Od filter

case

lmp

with heater

Od pan

Dlfferenttal

measure

55

o 75 t
024 L

H3

Specifications

REGULATOR

tgl
VOIt

gulJtur

Model

HITACHI TLlZ 57

RegulJLlIlg voltage
Jnd

lt cry
h

do

with fully

regulator

IlwJrd

cod resistance

Voltage

Rotor coli

msertmg resIstance

coil

Voltage

Smootlung

charged

faced

senes

143

10 5 at

10

resistance

resistance

to

15 3

al

20

200C

68

680F

31

40

Core gap

mm

Poml gap

mm m

03to04 00118toOOI57

Release voltage

42 to 5 2

Voltage

378

o6

to

0 0236 to 0 0394

Charge relay

COlI resIstance

termmal

200C 680F

Core gap

mm

0810 I 0 00315

Pomt gap

mm

04 to 0 6 0 0

Standard

144

at

at

to

0 0394

57 to 0 0236

temperature gradient

0015 V

oC

1
r

ill

j
f

f
c

dii

DISTRIUTOR

Ij

llle

Ai

Make and

type

80
D412

D4 I

89
2
fI

forManual

for

Transmission

Fmng

order

Rotatmg
Dwell

directIOn

Condenser

42
3

49

I1F

capacity

o 20

42
13
Counterclockwise

550
to

49

0 24

o 20

550
0 24

to

IGNITION COIL

MJk e mu

lVpc

voliJge

llY
Pllll1

park gJp

mm

HANSHIN

HITACHI

H5 152

C6R 601

12

12

more

than 7

more

1 an

028
l lIlllJry

itdnLe
reSI

Seu1ndJry
l

tlrllJl

Applied

at

rcc
lc lllll e

resistor Jt

20o
Jt

680F
Oo 68f F

20068uF

7I
i

Transmission

Counterclockwise

angle

Automapc

028

I7 to

17

to

I 43

Kn

112

to

168

112

13

I 43
J

ftSISlor

to

I 7

RC 15

13

to

to

168

I 7

5560R 1510

t
l

1
h

J
t

r1

I
r

iF
U
M

JL

ti
A

jy

LIo

rt

Url

JJf

oj

11

Specifications
CLUTCH
HydraulIc clutch
Clutch

Mechamca clutch

release lever

Release

bedTlng todlaphragm

spnng

withdrawal lever clearance

o7

I 4

to

00276

DIaphragm spring

to

flywheel height

29t031

I 142

09 to I 2

mm

0 0551

to

00354

In

mm

to

0 0472

In

mm

to I

220

In

autch dIsc

Facmg

Size

Outer did

inside dl3

thIckness

180xl25x35mm

709 x 4 92
Total

fnctlOn

Thickness

264

area

4092 sq

cm

In

In

76t080mm
02992

Compressed

Number of tOrsIOn sprmg

mlOJlJlum

3150

In

to

0 2756

In

depth of CIvet head

from facmg surface

Allowable facmg

to

67t070mm
02638

out
run

03

mm

0118 In

05

mm

0197

radIUS

Allowable free play of spline

autch

0 140

of disc assembly

Free

Allowable

85

In

at

3 346

mm

In

04mm 001571n

pedal

Pedal hClght when not depressed

1415

mm

5 57 m

1365

to

1465

54 to 5 8

Free travel of pedal head

I 181
30mm

In

to

ISmm

0433

PreSSing strenglh
Master

cylindtr

Master

between

full

stroke

diameter

maximum

1587

58

mm

015

mm

1905

mm

In

0059

In

0 750 m

15t022kg m
108to

to

I83
83kg

mng torq
Clutch assembly sccuTlng bolt

He

23 81b

clutch

Operating cylInder dIameter

8i
r

kg

clearance

cyhnder and piston

Operating cyhnder

108

clutch

cylinder

Allowable

at

159ft Ib

mm

In

0 591
b

In

Vltl
r

@1rmml IB

vf

t
f

i IICi

@ @

tr
j

f
j

Jt
o
il

rl

IRINGANDREFINISHIiilG
bY EB Weston

AUTOBODYREP
l

deeply into the illghly cqmp tit1ve auto body repair trade Every possible ph e 1S
and explaIneg in hght of the correct repair techniques and tools to be used to return a damaged

Tills book delveS

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Topics such as construction matenals welding hand tools and auto body
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