Professional Documents
Culture Documents
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CRAKE PU3 IS1
RS
i
fI
lII
DATSUN 1200
1971 1973
RANGE
MAINTENANCE
REPAIR
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
operations
of publication While
cannot be held
every
effort
IS
and upto
date
omiSSions
Simple
make
93
SUSPENSION
thIS
manual
useful tool
DRAKE
PUBLISHERS INC
361
PARK
AVENUE SOUTH
@Drake Pubhshers
Prmted
Inc 1973
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
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
96
Replacement
InspectIOn
BRAKES
96
97
RECOMMENDATIONS
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
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
116
DOOR CONSTRUCTION
117
IgnItIOn
WIRING DIAGRAMS
118
CLUTCH
146
BULB SPECIFICATIONS
120
NOTES
174
HEADLAMP
121
Cot
145
THERMOMETER AND
FUEL METER
122
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
as
After
Checking
It until It IS heated to
bnng
No
cylInder
In
cover
all
correctly tighten
adjustment
follows
run
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
Make
With
cylInder
parenthesis
top dead
agree with
center on ItS
Adjust follOWIng
gal
sure
Imp gal
III
Imp gal
cooling
water or
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
tenSIOn
accompanY1Og sketch
pressIOn stroke
drive belt
or
In
MaXimum VB US
piston
the
Capacity
1
ote
four
secure
still hot
1 Exhaust valve of No
those
follOWing
firmly to
to gaIn access to
at
adjusting
Check
Adjust
lock nut
Fig
and
aintenIDce
Find the
up
COOLANT
cause
une
action
b
Oil
dicates
in
with
mark
on
mark
IS
gauge
of a
cartndge type
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
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
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
solutIOn of
cylinder
hold
can
whether there
rings
IS
or
compression
leakage past
excessive
etc
blOken
pIston
though
umform
ThIs
Clean
may
be
preSsures
Low
ring
indIcate
may
accompamed by
tery
corrOSIOn
of
tightening
petrolatum vasehnel
straps
from
straps and
After
ac
on
bhstenng
connector
covering
With
cause
may
to
protect them
corrosIOn
even
worn
leakage prolonged
IGNITION TIMING
rings
011
excessive
consumptIOn
Check
spark plugs
and dIstributor
breaker
Test Conclusion
Thoroughly
If one
marks
on
crank
Warm up engine
pulley and
front
tlmmg j
cover
suffiClently
these cy IInders
If compressIOn Improves
rings are defectIve
conSiderably
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
pressure
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
illL gravlty
of
pattery
el
ET002
S Gheckmg
Flg
elec
trolyte
f
aiDteDaDce
Install
plug
timing lIght
WIre
and Install
No 1
on
a
cyhnder spark
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
hght
stay
If necessary
Loosen
iet
dlstnbutor
it
AdJu
adjust
screw
can
such
be moved
by
an
extent
that
sure
correct
50
IS
pomts
zero
reSIstance
necessary
MIcro Farad
and make
screw
It
or
Condenser capacIty
022 J F
hand
that tlmmg
still
replacement
It as follows
to
largely
5 Mn
Mega
ohms
Spark Plugs
B T DC
they
are
In
correct
ahgnment
for full
con
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
When preparIng to
IS essential to have
Idle
adjust
the meter
suffiCiently
one
mmute un
I
i
I
I
I
I
I
ETOQ4
up
aiDteDaDce
UDe
up
Throttle
sdJustlnl
screw
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
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
sure
to
apply parking
and
rear
Notes
transmISSIOn
make
the
sure that
eqUIpped model
adjustment has been made
In
and Idle
check the
In
posItion
specificatIOns
are as
follows
cause
malfunctions
After idle
If necessary
10
PoSitIOn
t
5
0
or
position
for
Remove
the
car
Do not
D
JI
automatic transmission
k
5
Cap
remove
necessary
to
stallatlon To
throttle adJustlng
Make
screw
satisfies the
sure
this Idle
If this
necessary
In
adjustment
Idle Limiter
CO percentage
with lever
down
with the
speed
screw
avoid
to
On automatic
Do not attempt to
the idle
Unit
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
Engme
Readjust
new one
12
Check
Fuel strainer
throttle
damage
wear
found wIth
Install
sure that
the
rotatIOn
adJustmg
the
posItion
screw can
CO RICH
makmg
or
bound
any of above
excessIvely beyond
further turn
d1rectlOn
Fuel Filter
depoSIt
cracked
return
squareness
use
Check
or
It should not be
for
a contammatlOn
and defection
IS
element
water
assembly
r
u
IQgiDe
DESCRIPTION
and
2 765
stroke
ber
alummum
heads
bearmg crankshaft
dependable power
Removmg
feature
combustIOn cham
and
to
It
fully
turn
out
hoses
remove
four
radIator
Disconnect the
balanced
followmg
cables
hoses
and
wires
smooth
High voltage
cable
distributor
Cable to the thermal transmitter
REMOVAL
Removmg
Open
and
hood
Cable to the primary Side of the distributor
the hood
remove
Disconnect
remove
the hood
the
battery
cable
from
Fuel hose
the ter
mmal
Removmg
Fig
It
13 Sectional
view
of A 12 Engine
Bngine
WIres
for
choke
and
accelerator
out more
The
easily by
the engine
In
sequence
reverse
parts
and
of
Clutch
block
Check
cracks and
hOUSing
wire on
nght
WIre
at the
carburetor
thoroughly
breakage
the water
Disconnecting clutch
up the
plug
CylInder
Jacket for
removal
model
air
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
lamp
Mount the engine
SWItch
on
the stand
propeller
four
shaft
bolts used
In
the differential
the lever
With
wire
Remove the
rear engine
mounting installation
nuts
When
stallation
the transmiSSIOn
CLEANING AND INSPECTION
Clean the engine thoroughly before disassem
bly Before cleaning the engine remove the
II
Bngine
Remove the altel nator and engine mounting
bracket L H slde
assembly
Remove the
assembly
Remove
filtel
pulley
together
tensIOn
With
cable
the 011
wIth
cylInder
head
and
push
the
spark plugs
cover
Remove the
thermo
itat
houslllg
18
Y
w
Fig 17 Water
Fig
sequence
18
pump
removal
Bneine
Remove the 011
cover
tenSlOner
Remove
the
crankshaft
and
camshaft
WIth the timing chaIn
sprockets together
maIn
quarter
turn
and
bearIng
remove
rear
011
the baffie
plate
case
net
plate
cover
removal
tlng
a
remover
piston
pin
valve tfter
Fig
Fig
17
Bogioe
WAI CI
WAIl Cl
FIg
27
Cylinder head
Secure proper
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
foreIgn
stains
1at
all
block
The
carbon
matters com
hol Lare
clear
grinder
Blow
damaged
worn
face
should be refaced
Notes
against
surface
Assembly
assembhes for
head and
on
block SIde
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
the
replace
or
stem
a
deformed
surface
or less
angle
and
IBglne
Note
When
the
reduced to 0 0197 in
replace
or
for
seizure
and
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
III
Spnng specIficatIOns
length
of
for
Free
1 831 In
length
Valve closed
1 524 In
at 52 7 Ib
Valve open
Valve Rocker Shaft and Rocker Arm
I 19
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
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
arm IS
0 0197
In
or
clearance
bearmg
the camshaft
replace
bearmgs
IS
exceSS1ve
with
service
parts
Grinding
If camshaft
less
Valve
Timing
If the
camshaft
although
some
has
no
apparent damage
edge
reqUIred
wear
and repair
contact
seizure
and
replace
or
Wear
Standard
as
1st
on
hm1t
00015luOO024
the
2nd
00011 to 0 0020
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
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
20
OF
ROTATION
0071010
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
the
head
cyhnder
for defects
v1sually
as
mmor
1S
and
cyhnder by
the
use
of
Cylinder
such
cylmders
for all
When
seIzure
scratch and
Ring
wear
Replace
reqUIred
clearance of each
piston rmg
and ring groove WIth the piston rmg mstalled
Clearance of a new pIston and
on the piston
p1ston
the
Measure
and
wear
of
out
walls
WIth
round
by
cyhnder
Measure Side
bore
If
bore
IS exceSS1ve
means
of
gauge
rebore the
bormg
248
248
14
or
cyhnder
be used
machme
Umt
wear
degree
54
12
56
Wear
limIt
02mm
0 0079
In
MaxImum
Standard
Surface flatness
less than
tolerance
o 0020
SAO
Distortion limIt
Standard
0 101010
0051010
00039 In
100020 In or less
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
41 Piston pin
Fig
fitting
Bngine
of piston pm
Square
Flttmg
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
measure
cylinder
replace
the pIston
on
whIch It
IS
mstalled
Determme the
fittmg
tight
Rod
Connecting
large
ahgner
hmlt correct
end correct
or
replace It
torsIOn usmg a
If bend
or
or
or
replace
torsIOn
connectmg
exceeds
the
When
rod
old
so
06869 to 06871
PIston pill
Standard
length
MaXimum
25681 to 5779
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
Standard
00002 to OOUr j
o 0008
00079 to 0 0118
U0157
EM133
23
BogiDe
Llmtl
Standard
27 00
1910
to
0752
to
27 05
1063 to
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
o 0020 to 0 0059
00118
03
3791
44 974 dl
to
1 7706
JOURNALS
UNIT
Fig
45
mm
Crankshaft
EM141
Taper
S tanddrd
MaXimum
o 0004
00012
Fig 46 Plasllgage
out of round
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
replace
wear
Journal
and cracks
Repair
gauge
14
replace
or
ex
the crankshaft
When me8sJlring
jJ
ldtSe
nc
measure
rear
damage
Replace
Note
fimsh It to
repair
Check the
the
In
the
cyhnder
block
main
drIve shaft
pilot beating
dial
It
Bushing
1f any defects
are
wear
at
and
detected
and
Check all
Bearing
bearIngs and bushings
melt
and burr
reqUired
Its
ex
Crankshaft
as
to
derSize
replace
applied
journal
reqUIred
scars
ob
turned
the necessary
Crankshaft bend
for
is
MaxJmum
After
readmg
crankshaft
center
Standard
the
scar
Jlace
Rgj
bushings
If any defects
for
are
detected
and dust
especially
Set the
bearing
main
on
seIzure
the
rear
of
Ingine
Cut
of the
and
them
bearing
the crank pm
for
sprocket
Be
Remove
sure
plastIgage
the cap
Replace
tooth
measure
Sprocket
surfaces
defective
excessive wear
Replace
cham
Flywheel
and
wIdth of the
and
the scale
replace
Camshaft
If necessary
Sprocket
Check
damage
is Inserted
tn
36 to 43 ft lb
when the
00039
sprocket
Tlghtentng torque
Note
posItion and
If It exceeds
out
the camshaft
replace
run
wears
sprocket
dial gauge
If It exceeds 0 0079
replace
1t
Replace
Note
Replace
the
ring
to 392 F
ASSEMBLY
PrecautIOn
EM148
out
run
check
Use
thoroughly
make
sure
cleaned
parts
are
PartIcularly
foreign
cleal of
matter
When
Standard
0 1 mm 00039
0 02 to 0 08mm
0 0008 to 0 0031 m
packmgs
new
such
as
to them
Keep
Keep
near
at
hand
Be
sure
to follow
and orders
Cylinder
Assembly
Head
ofvalve and valve sprmg
48 Check
locatmg plate
thrust clearance
the valve
gUIde
seat
hp
seal
21
BDgiDe
Note
Make
sure
clear from
foreign matters
Piston and
Connecting
is
Rod
cylInder
Notes
P1ston
pin
speCIal
Fig 49 Valve installatIon
Arrange
the
connecting
connecting
rod
so
rod
that the
cylinder
InstallIng piston
STl 303001
Install
the
pOSItIOns
EM156
so
rmgs
top and
second
nght
upward
In
rings
are
faced
bearmg
carefully
Engine
Set the
cyhnder
block
on
the
ft lb
Assemble
the parts
In
order
valve sprmg
gUIde
28
stand
camshaft
by
plate tightemng torque
retain
Locate
the
workmg
upSIde
locate
IS
plate
2 9 to 3 6
Bogine
Note
Set
the
LOWER
mark
locate
plate
comes
to the
so
the
as
engine
bot
Install the
tom side
bearmg cap
specified torque
bolts with
Set the
maIn
bearIngR
on
theIr posItIOns
on
Tlghtemng
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
bearIng
that the
mark
faced
IS
Prior
bolts
All
torque
rear
axial direction
are
Apply
the
tighten
arrow
toward
bearmg No 1
bearmg No 5
and
36 to 43 ft Ib
No 2 and No 4
mam
surfaces
After
securing
ascertam
that
easily
rotated
Make
sure
the
the
bearing
cap bolts
crankshaft
be
can
play
IS
correct
rear
Install the
washers
Fig
In
011 seal
and
torque
Tlghtemng torque
47 to 54 ft Ib
Insert
the
pistons
in
the
corresponding cyhnders
b
Apply engine
oil to parts
as
required
on
d Install
avoIdIng
Fig
piston rings
to fit them
In
at
mark
of the
Y to each other
18
27
Bagine
Note
are
same
direction
Tlghtenmg torque
23 1 to 27 5 ft lb
Make
large
Big
Fig 55 ApplYing adhesive
sure
end
end
that end
IS
play
correct
play
00079 to 0 0118
Install the camshaft and crankshaft
the
tlmmg
cham
and
sprocket
Camshaft
29 to 35 ft lb
L
FIg 56 Flywheel installation
FIg
FIg
281
58
sprockets
height
of the tooth
camshaft
Bogine
Notes
dIfference
HeIght
AdJustmg
Make
sprocket
sprocket key
0006
sure
hole
dowel
dowel hole
washer
tluckness
in
are
and
key
and
crankshaft
located down
ward
b Set the
marks
timing
meet
cham
with
making
those
of
its
mating
crankshaft
at
the
Check the
spondle projection
temloner
Wear limit
Spindle projection
IT
a
Match mark
8
Tlsnaft
0w 1
hol
0
Matohma
Key groove
tt
I
f
Fig
21
BDgiDe
Install the
front
cover
the front
new
cover IS
agent
The
cover
replaced
when
disassembled
cover
The
of
uses
one IS
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
rear
por
on
pt
lor
031111003189
CD
03492
to
0 3555
1M
ot
rhJ
tlghtemng torque
2 9 to 4 3 ft lb
Invert
head
the engine
assembly
and
and Install
the
cyhnder
gasket
head
bolts
to
the
Cylmder
bloLk
O rmg
Side
Stecl
heet
Sealmg
Cylinder
head
Side
Jomt
sheet
Install WIthout
Remarks
Be careful
not
sealing
J
30
to
agent
in
Tlghtemng torque
the
two
head
stallatIOn bolt
CYlmder head
ItI
Cylinder
h ad
gasket
Cylinder block
cylmder block
BDgiDe
40 to 43 ft Ib
TIghtening torque
Install the
push
rod
Intake
ocker
haft
assembly
and
at cold
tighten
specIfied
torque
Exhaust
Tightening torque
00138
In
at cold
00138
In
15 to 18 ft lb
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
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
assembly
31
BBgiBe
Fig
70
Tlmmg mark
Fig
72
TrochoId
1 piston
compression
Set the No
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
the
Removal
distributor rotor
fittmg
as
shown in the
Engine
Figure
Install
the
distrIbutor
the
cover
and crankcase
32
body together
Take out
stand
with drIve
spmdle
IS
check to determme
defective
workmg
shield board
Disassembly
PrIor to dlsassembhng
assembly
shngers
splash
in vehlCIe
body
mner
bled
Bngine
ApplYing a sUItable wrench
off the regulator valve
Note
use
spanner loosen
the valve
placmg
m a VIse
body
b
When
or
and
pull
Do not
securing
in the jaws
cover
shaft
the drive
out
pin
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
deter
spring
length
Insert
valve
dIstance
In
the
body
and
measure
the
plug
In
Assembly
Assembhng the
of disassembly
body
AdjustIng Regulator
In
0 7086
In
Regulator valve
ShIm thickness
Inner
Regul
shaft
rotor
and
rJ
rn
Inspect
Valve spnn
See
Figure
74
IS
chips
sure
sure
gasket
no
the
traces
Note
Be
Be
011 pump
reverse
of
order
grinding
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
cable
yellow
from the
wIre
battery termmal
assembly
forward
secure
housing
and
Loosen the
the startmg
adjusting
bolt
remove
the starting
motor
Installation
Installation
InstallatlOn
wires
the alternator
battery termmal
IS
InstallatlOn
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
Dekl
Correcl
mll3
or
shorted
senes
or
or
repldce
Replace
cod
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
replJlc
Corrcll
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
Faulty
plunger
pole
core
dimenSIOn
or
RepJlr or replace
AdjUst
ReplJee
contact
Brok en
The
or
Repair
connection
Seized metal
Magnetic SWitch
Cledn
mica
wire
Replace
motor
startmg
rotates
with flOg
gear
Rmg gear
Worn teeth
ReplJee
Startmg
Replnee
Rcpldce
motor
FJulty
slldmg
plOlOJl
Dropped
Pillion mtermeshes
Startmg
motor
Startmg
motor
lIlIan
ring gc
IS
tou
dlll1en
IOn
runnmg dutch
Adjust
Re
place
lT
roldles
Over
Battery
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
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
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
alternator output
POlnlsap
lower
Arm2fu1C
COfe
the
IS
SimIlar
In
constructIOn to
voltage regulator
lamp goes
are
Crew
ap
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
Figure 78
1
O
0
I
2
3
4
5
6
Point gap
Char
Clay
ConMctmg
Armature
FIg
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
replace
spnng
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
connection
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
Replace
the
stator
rotor
Replace
the
rotor
DefectIVe dIOde
Replace
the dIode
Rettghlen or replace
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
ct
con
Repair
or
replace
Defective operation
Faulty chargmg
CUI Ult
lead
WIn
Re
olf or
e
rpla
connection
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
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
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
dIstributor
of
high tension
part centrifugal ad
consists
advance
new one
44
IS
a new
one
If excessively
replaced
damaged
found
arm
or
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
adjust
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
hIgh
breaker
arm
adjusting
ween
screw
contacts
cam
IS maxImum
pomt gap
When
SIOn
measurmg
apply
breaker pomt
sprmg
tensIOn
spring ten
gauge to the
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
@
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
12
Set contact
13
Assembly
14
Assembly control
IS
Screw
16
AssembJy condenser
17
Screw
19
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
checking
lead
wire
loosening
by adjusting
ItS
ange to measure
large
eSlstance value
When
pOinter
the condenser
SWings 1m
gradually
normal
the tester
and
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
same
on
an
brand and
Inspection
Remove
spark plug
by pulhng
wIre
on
boot
Remove
spark plugs
Check electrodes
and
Inner
and outer
por
celams of
and the
Figure 85
shght
Brown to gl
electrode
wear
aYlsh
depoSits and
spark
tan
indIcate correct
Fig
84
Pnmary
terminal
Secondary
Cdp
Sprang
11i
gap
Normal
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
plug
heat range
Insulator
slow
and
electrode
caused
by
nltlOn
speed dnvlng
In
lts on
mostly
were
cIty weak
dirty
aIr
Ig
cleaner
etc
It
IS
advIsable to
replace
WIth
plugs havmg
depoSits
show
excesSive
through
condition
after repair
remams
use
hotter
plug
Install
spark plugs
WIth black
WhIte
or
gray
burnt electrodes indIcate engme overheatIng
Moreover the appearance results from in
correct
guel
pump pressure
hotter plug etc
and
torque
each
plug
to 11
to 15 ft Ib
Connect
Overheatmg
It
spark plug
wires
AVOId
sand
blast type
renew
firing
sur
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
peclfied servICe
clogged or I estncted
Replace
Interval
01
In
fuel lines
use
remaining
fuel
disconnecting
the filter at
INSTALLATION
If It becomes
InstallatIOn
IS
the
reverse
of removal
FUEL PUMP
REMOVAL
DIsconnect
Inlet and
remove
Description
fuel filter
transfers
In
gasoline
from
the
suffiCient quantity
requIrements
at any
speed
or
load
The fuel pump
IS
of the
diaphragm type
diaphragm
spnng
seal
body rocker
diaphragm
Inlet
and
fuel
outlet
valves
if
The
fuel
treated
EF005
diaphragm
rubber
whIch
consists
IS
not
of
specially
by
affected
Fig
arm
88 SchematiC
view
of fuel pump
Fuel Sptem
Testing
A fuel pump
pressure
IS
capacIty
at all
IS
equal
speeds
to the engine
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
gauge
these tests
Start and
The
engme at varymg
run
speeds
readIng
pressure
follOWing
2 61b sq m
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
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
51
Fuel Sptem
Capacity
Test
Check the
IS
IS
wlthm
used
valve
bly by
breath to
Check the
Place
In
run
at 1 000 rpm
gasolme
of pIpe
pump
or
only
malfunctlOntng
worn
Check
remove
them wIth
are
an aIr
hose to make
that
they
clogged
gas
sure
clear
Thl
wIll
tramer
elImmate
In
pOSSible
all
mahtIes
011
Remove
fuel
screwmg two
In
mounting
assembly
by
un
Take
gasket by
cap
and
the
cap
body
new
from
by
Two valves
are
eaSIly
arm
IS
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
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
are
economy as well
ofexhaust gases
auxlhary
pump
released
the
the
and fuel
body
pm
em1SSlon
remove
arm
Description
unscrewmg two
removed
lower
link rocker
arm
CARBURETOR
To
leakage
gasket
screw
screws
since
satIsfactory
valve retamer
wear
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
portIOn
and
DisassenbIy
pump
at the
Removal and
the
wear
requIred
Use
arm
pm may cause
In
for
dl m
the fuel
cral ks
wear
of fuel
dIaphragm
and
of the
wear
ItS functIOn
examme
pIpe
for
assembly
pump
glves
excellent
ac
Fuel
mIxture
essentIal
IS
throttle
porates
opener
control
system
The
diaphragm
servo
Incor
to
thoroughly
drivIng
The
It
suffiCiently
servo
der
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
IgnItIOn
In
the
chok
mechanIsm
automatIc choke
IS
Adjust
electric
an
tage
used to
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
rear
down
rush out
make
that the
on
eqUIpped model
adjustment has been made
sure
In
specificatIOns
of a
In
the
posItIon
With
the
speed
are as
follows
Idle
for Automatic
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
adjust
eqUIpped
In
parkmg
adJustmg
transmiSSIOn
done
If necessary
Idle
IS
tl
view
transmISSion
of carburetor
ruel Sptem
CO percentage
re
stallatIOn To
with lever
In
15
posltton
050
Make
Notes
the
Do not attempt to
Idle
adjusting
aVOid damage to the tip
screw
down
completely
screw
b After idle
adjustment
or
position
for
starting
the car
Fuel Level
float
nccesbary
dIrectIOn
comIng
measure
the
WIth
contact
shown
the needle
In
Figure
91
190
mm
approximately
IS
In
of the
Upon completIOn
adjustment
Cap
remove
CO RICH
Adjustment
valve and
seat
Idle Limiter
Do not
rotatIOn In the
When
automatic transmission
speClficattons
Turn down
has been made
this Idle
If this
Unit
IS
Adjust
h
float
IS
cover
Throttle
tmg
adJu
2
Idle
rcw
Ing
Idle hmlter
adJu
t
JustIng
Stopper
Illustratton
Figure
Idle
screw
In
Then
such
and
cam
Will
arm
suew
screw
when the
Adjustment
the needle
In
IS
Fast Idle
that clearance
0 0512 to 00669
fully raIsed
properly as reqUIred
so
valve stem
on
shown at
be the
rl1urdor
adjusting
topper
IH
Float
noalltopper
Float seat
Needle alve
In
speCificatIOns
92
screw
54
In
sure
sattsfies the
to
to cause malfunctions
of
to
necessary
the
See
Fuel
FIg
95
Sptem
Adjusting fast d Ie
Choke val
uvm
stem
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
Vacuum Break
Completely
Adjustment
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
In
adjust
fully
opens
the clearance
ding
body
to 0 079
Figure
In
by
ben
94
and 0047 to
rubber
phers
by stretching
the
and
lever
car
by
Note
fully
Make
sure
moun
Fuel Sptem
ted
on
the
car
fully
open
inoperative
unIoader
becomes
in
poor
resulting
engine is started
Note
Use
an
strument such
accurate
B1 metal
BL metal
Settmg
of bl metal
heater resistance
the
cover
buretor
Make
sure
place
on
in
ac
Mea urement
measuring
bridge
as a wheatstone
mark
1S
cover
settmg
altgned
cover
at the middle
car
across
through
30
1 181
Connectml
Secondary
cover
In
dlJ
26
rod
mm
I 024
Secondary
dlJ
throttle
vaJve
lms
COnnCl
throttle valve
lever
Pnmary
Throltle lever
Throttle chamber
secon
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
clearance
chamber
throttle
mSlde wall
shown
as
level
shaft
take
out
pump
out
servo
diaphragm
dlsturbmg
settmg
necessary so that
as
bend
secoridary
IS
smoothly
Adjustment
only
and
In
dIaphragm
mlsszon
pump
connectmg rod
throttle valve
Dash Pot
Remove
positIOn take
GIn 0 228
pletIOn
Figure 99
WIthout
bly
In
In removmg chamber
damaging float
exercise care
to aVOId
AutomatIC Trans
bleeds
car
on
It
necessary that the Idhng speed of engme
and mIxture have been well turned up and
IS
engme IS suffiC1
y warm
Adjust
speed
IS
ij
by turnmg
In
the range
UII
Make
econds
Fig 101 Removmg choke chamber and
servo
diaphragm
Removal
Remove the
DIsconnect
automatic
aIr
cleaner
the
choke
fuel
line
vacuum
line
dlesehng
the
carburetor
and
remove
from
the
llQt
mamfold
Remove and dlscard the
gasketcused
between
Fig 102 Removmg emulsion tubes
Fuel Sptem
In removIng Injector weight
piston return
sptlng and ball care should be exercIsed to
cover
the
accelerator
removed
pump
Be careful
the
It
pump
bal
prOVided
piston
Do not
dUring
dIsassembly
remove
IS
preferable
unless
cover IS a
sImple
matter
solenOId unless
otherWise
reqUIred
If throttle valve
be
must
Removal of bl metal
dlesehng
change
antl
It IS necessary to
stable
formance Will
not
Idlmg
and slow
speed
per
be obtamed
screws
Note
fitted
Under
no
In
C1rcumstances
should
bl metaI
float
hamber
can
by
be detached from
removmg
three
set
Cleaning
and Inspection
often
responsible
for
unsattsfactory perfor
mance
screws
For thiS
upon
reason
careful
servlcmg
Blow
all
pressed
aIr
enlarge
jets
or
wires
through
buretor calibration
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
18
Fuel
SJstem
Check float needle and seat for
Replace
wear
Replace
When
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
turned
or
detected
dIstorted
they
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
Inspect
Into
the float
and
chamber
be
changed
them
and Installation
Assemble
and
Install
tIve
the
the carburetor
these
use
carburetor
In
So
and blow
bleed
they
Overflow
POSSible
Dirt
accumulated
on
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
Remedlc
RCpJlf pump
Lap
or
See above
Each
Clean
onsumptlon
bleed clogged
have
causes
needle valve
and
Fuel overflows
mam aIr
aIr on
sIze
TROUBLE SHOOTING
Troubles
are
care
air
emIssIon
Jets
performan
components
gasohne
or
on
emISSIOns
sometImes
some
Assembly
the vehicle
Shootmg
follOWIng table
are
There
tlve
everse
on
why
ChangIng Jet
In the
gasohne
that all
so
Trouble
Check conditIOn of
IS
III vehICle
cause
causes
Pour
and
them
Check
correctly
smoothly
performance depends
bleed
aIr
To clean them
replace
and
Jets
The carburetor
largely depends
for
In
be
components
components
related
ce
Check filter
the
Reassembly carefully
Idle
reassembhng
and
dlsassembhng
replai
ruel Sptem
Possible
Troubles
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
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
Secondary
valve
operated
Im
properly
h throttle valve shaft
Eal
Replace
wear
ReplaLe tlghtenlllg
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
or
breaker
etc
Trouble
or
Adjust
of Igmtlon system
tenSion
Defect
dnd
cleaner
spark plug
Engme Idle
mixture
tunmg
cleaner
JXInt
speed
settmg
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
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
properly
Car knock when
coastIng
Trouble
Defect
or
PCV
AdjUstlhroltle
adjustment
Replace
valve
spark plog
ugh
tenSIon
cable
Adjust
opener
PCV valve
or
breaker
EnglOe
does not
Fuel overflows
No fuel
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
C0026
cover
DESCRIPTION
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
and of a
type thermostat
The
84
WATER PUMP
WIth
pum
T he
cover
an
IS a
olute chamber
assembly
and
IS
a
high
pressure
seahng
GooliDI Sptem
mechamsm
leakage
pump
the
since
shrmkage
be
not
must
water
disassembled
Installation
bearings
are
replace
the
mstalhng
When
nOIse
The
Note
the water
adopted to prevent
completely
IS
and
adheSIve
Three Bond
thermostat
to
packmg
apply
reverse
leakage
In
sequence of
removal
assembly
pump
Removal
Dram
coolmg
water
completely
Olher
Canadd
USA
pulley
Valve opemng
temperature
pulley
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
to
piston
The
a
pellet
IS
valve and
connected
when the
through
pellet IS
WI
fL g
l
IL
JI
IS
cooled
1
I
I
IS
a
i
J
EI
Removal
Dram
Thermostat
wa
r
outlet
coohng water
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
specIfied temperatures
It must be
replaced
81
Gooliol SJstem
RADIATOR
The radiator
IS
Pressure
I
eltef valve
cap
Ib sq
In
Removal
DraIn
cooltng
water
reservOir
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
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
CYLINDER SIDE
DECOMPRESSION
exceeding the
elastic dISplacement IS
released with slipping on
Movement
Fig
Returns
elastIC
displacement of
the
seal
Brake
pad
Retalnl
pin
Clip
88
IS
adjusted automatIcally
Brakes
r
Moreover
squeahng
In
order
shIm
IS
to
prevent
brake
for
pad
wear
or
pad
driVing
gasohne
Replacement
Jack up front UnIt of the vehicle and
the front wheel
remove
clip
Unhook the
brake
pad
hanger
the
pad IS
pedal
removed do
or
otherWise
grease IS
heavIly
replace
the
or
stlcked
on
deformed due
pad
With
new
one
total
pad
thIckness
replace
In
IS
Replace
pad
when
In
Note
at
brake
It
effect
pads
IS
recommended
be made
that
periodically
adjusted automatically
pad or
overheating
rotation of
Inspection
or
when deteriorated
and rotor
pad
IS
pad
Reinstallation
Clean the
calipers
and piston
pad installing
parts
Do not
Note
apply
not to
on
mineral oil
Be careful
the rotor
Depress
new pad
Note
use
oil
cyhnder
so
that
can
flow from
ded
that
loosening
operation
be
carried
out
by
fluid
Fig
115
Fig
116
b The
piston
hand
But
be easily pushed in by
pushed excessively the
can
if
88
Brakes
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
111
PlSton seal
Normal position
the brake
the posltton
out
depress
the
the anti
the shim
Installed
IS
Install
Install
pad
pad
assembly
and knuckle
so as
cahper assembly
installatIOn bolt
Remove the
cahper assembly
installatIOn bolt
I
Fig 119 RemOVing strut assembly and knuckle
Fig
78
on
In
posllIon
shim
arm
installatIOn bolt
arm
stallatIon bolt
in
Brakes
DIsassembly
caLiper
as
before dlsa
embly
pistons
the
bleeder
aIr
sembly
cylinder
and
the
depres
cylInder See FIg
125
Secure the
head with
then
be
yoke
a
In
vIse
hammer The
removed
from
yoke
cylinder body can
the yoke
When
Remove the
retaInIng
Depress
remove
cylin
der
Remove the piston seal from the
Note
Remove
w1th
not
fmgers
damaged
so
Remove the
from the
cylinder
prIng and
yoke
yoke
bias sprIng
yoke
der
Inspection
Thoroughly
and
Repair
and
Note
use
When
alcohol
cleaning
rubber
parts
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
Pad
See paragraph
IS
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
Q
Fig
122
Retamlng
nng
Boot
Seals
Brakes
Note
The
Ieakmg
reason
piston
LImIt of I
econdltlOntng lotOl
In
thlcknes
l
but also
damage IS
minor
o 3307
In
In
Rotor
Check the rotor
and
If It shows
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
thlckne
ls
In
A
PISTON A
Fig
72
124
mto
piston A
Fig
125
Piston A and B
Fig
126
Installing boot
PISTON B
Brakes
piston
A with B
Apply
rubber grease
tlon of
hghtly
Insert
p1ston and
to the
shdlng
When
the
piston
be
so
that the
piston A COinCide
wIth the
Apply
retaining nng
yoke
that the
par
insertmg
so
cyhnder
Note
Install
yoke
cyhnder
groove
of
With
groove
the
yoke
hghtly
spring
correct
Inserted
poSitIOn
yoke shdlng
to
cylinder
of the
bias
COin
YOKE SPRING
Fig
127
Fig
73
Brakes
Fig
Assemble the
ping the
Apply
slIding
and
cylIndel body
yoke lIghtly
the
brake
grease
131
yoke by tap
air
fully
to
the
yoke
bleeder
the
calIper assembly
pad
the hydraulIc
torque of diSC
remove
IS
Remove
In
reverse
DIsconnect
completely
measure
bleed
the rotatton
plates
The
In
removed
eaSily
Ib
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
74
the shoe
remove
the
the wheel
cover
wheel
Starting torque
780
and
cylinder
Installed
line and
the cleVIS
spnng
sequence of removal
After the
pull
return spnng
Remove
Reinstallation
Reinstall
Wire
groove of cylInder
Install the
Brakes
the
Remove
Wire dla
free
length
Load
housing
length
the
o 0787
4 69
III
sIde
33 4lb
5 22
28
flange
the
remove
brake disc
actIve turns
Cylmder
adjuster assembly
Remove the
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
Adjuster
rear
Reassembly
20
apply
and Reinstallation
semble and
Rea
reinstall
sequence of dl
reverse
the
matter
cylinder shdlng
and make
136
Figure
In
Note When
sure
resistance
as
shown
that the
In
slIding
sliding
improper
smoothly
IS
Tighten
In
and removal
brake
rear
assembly
the brake
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
turn buckle
adjusting
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
0433
mm
0472
2
42 1654
69 5 2 736
FREE LENGTH
135
75
Brakes
plate
located
Immediately
the clip
remove
III
III
the lever
and discon
nected
toward
cover
Remove
assembly
the
passenger
con
compartment
SIde
Remove
the
the
strap
hanger
the
separate
parts
Into
and bracket
cylinder
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
1
2
Hand brake It
ver
able
Clip
Lock
6
7
plate
FIg
78
condlttons
If
and
shdIng part
Han
adJU
Return sprmg
hr
CabJc
abk
er
trap
10
Cable shank
II
IS worn
lover
defec
excessively
Brakes
Make
sure
operated smoothly
and teeth
are
can
be
not worn
pawl
unusually or damaged
sure
damaged
or
cover
warped
1S
not
Reinstallation
not
to
reverse
damage
or
tW1St
TIghten
nectmg
When
sure
the
hanger strap
adJustmg
rear
shdmg parts
MIL G 2108
or
sufficIently
G10924l
o
buckle
con
nut to 5 8 to 7 2 ft lb
grease
turn
the dust
cover
Grease the
sequence
folloWIng matters
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
Ye
I
Fig 141
Dust
cover
Hanger strap
washer
Bracket
on rear
axle hOUSing
77
Brakes
ADJUSTMENT
Rear Brake
Jack up the vehicle and
Ordinarily
adJu
tment
IS
requIred
not
pIston seal
ApplYing
remove
the wheel
ttghten
the brake
adjuster
wedge
drum
the
sure
iJ
depress
readjust In ad
pedal and make
operates effecttvely and
the brake
correctly
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
F
J
1
I
r
BRAKE MASTER
CYLINDER
tI
I
05mmlOQ197
10 0315
THICKNESS 08mm
16mm
100630
nl
0
11
r
l00
78
Brakes
Adjusting
LImIted stroke
o 0197
In
535
00315
In
The
o 0630
In
standard posItIon 8 7
lever fulcrum
Note
When
be
adjusting
sure
to use ad
th1ckness for
same
tn
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
pletIOn
of
adjustment
be
sure
to
Upon
tIghten
the
lock nut
of the
adjustment
are
not
braked
Normal btroke
3091
Fig
In
the
hmited
stroke
5 35
in
10
As
air
IS
servICe
as
brake operatIon
matter of fact
lIkely
durmg
the brake
serVice
Bleedmg
the master
then from
cylmder
cylmder
the
longest
Upon completIOn
rear
from
heIght
means
notches
regular
In
10 notches
tn
6 notches
sure
release
that the
master
Top
up
the
reservOIr
master
Fig
145
Connecting Vinyl
IS
open
cyltnder
With
type
79
Brakes
Thoroughly
any mud
hole
IS
Attach
bleeder
a Jar
Conduct
hose
VInyl
Dip
screw
contaInIng
to
the
Note
the wheel
cyhnder
VInyl hose In
some
In
aIr
FlUid
withdrawn
the wheel
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
come
in
the bleeder
Repeat
longer
cyhnders
bled
other wheel
on
brake flUId
the bleeder
bleedIng
same manner
air
bleeding
bleeding
is
performed
Rear
Front left
right
retightening
the bleeder
pedal
screw
TROUBLE SHOOTING
Spongy pedal
Probable
Au
In
poor
qualIty
Use of
which
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
Fit
ExterIlalleaks
Check
a new
pressure
master
cylInder
cyhnder
for leaks
Master
cyhnder
Overhaul
master
pairs
80
dellon
brake flUid
brake
too
Bleed
ReservOir
suckS
Corretttve
cause
brake lines
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
Full up wIth
master
In
Bleed the
to Qver
clearance
brake flUId
specIfied
system If requIred
to
Allow drums
lImngs
lmg
todrum
cool
and drums
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
free travel
cylinder piston
broken
return
Replace
springs
no
cledrance
Adjust
clearance
brake
shoe
the
cyhnder
master
pISton
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
hnmgs
on
of grease
cause
correct
or
011
getllng
on
Lmmg
Seized piston
In
wheel
cylInder
the wheel
SerVIce
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
or
shoes
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
squeal
Weak
shoe
Drum
out
Worn
Itmngs
return
springs
of round
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
14
StJblluLr
15
SU
nwu
link
p mIOn mlmbt r
DESCRIPTION
overall
forward
movements
Ingle
Unit
whIch
IS
strut
are
type The
combIned to
the COIl
supported by
by the transverse
the
to
lInear
rearward
slOn
The
spIndle
Installed
IS
A ball JOInt
by
on
means
the
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
between
both
Side
absorber
Thus
thiS
suspensIOn
mechanism
absorbs
effectively
and
effiCIently
vertical
shock
and
the
transver
In
components
assembled
to
84
shape
ngldltles
stabilIzer
se
sprIng IS
sprIng seat fitted to the upper end of the
piston rod and spring seat welded to the outer
caSIng
through
bushIng
struts
IS
bar
strut
maIntaInS
of weldIng
backward
frame
sls
cha
rubber
The
bushIng
non
by
and
means
applIed
toward
SIdeway
RECOMMENDATIONS
large
number of speCial
ahgnment eqUIpment
It IS recom
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
of front axle
TROUBLE SHOOTING
Probable
CondltJOn
Vibration
steenng
Vibration
ratIOn
shock
and
of
shimmYing
ser
of
to
nottceable
road
au
Unbalance
mitted
Improper
pressure of
wheel
the
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
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
tire
or
msuf
Adjust
or
tighten
nuts
lIre
Replace
tlTes
treads
A defective
and therefore
au
hghtenmg
Difference
lefl
or
and
pulls to right
Adjust correctly
weakened column
Vhen
defective p uts
VehIcle
Rellghten
housmg
Wear of
hnkage
Insufficiently
bushmgs
notice
road
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
Repldcc
Incorrect wheel
alIgnment
Adjust
Incorrect brake
adjustment bmdmg
Adlusl
Worn rubber
Repl ne
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
alignment
deformed
Adjust
Replace
suspensIOn link
Incorrect
Stoff
steering wheel
checking
up
procedure
88
nd
ra
steenng gear
AdJusl
Correcl
Improper
Adlust
pun ties
o
andk
of
au
InsuffiCient
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
suspension groups
If
It
I
hectvy
chl ck
StIff
or
dJmaged
5llspenslUn bJII
Jomt
or
SuspeDsion
RcplJce
lack of gTcelse
sleermg geM wd
Worn
whed
ReplJLL
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
Adjust
Worn
Replace
h
sWlh
signal
play
Replace
the strut
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
then
Loose
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
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
Replace
DefectIve
Repldce
tlfe
Deformed wheel
Replace
rim
I
ExcessIVely
or
partially
worn tIre
Improper
au
pressure of
Incorrect wheel
tlfe
alIgnment
Adlusl
Replace
Incorrect brake
Adjust
adjustment
rolahon
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
of
reclrculatmg
parallelogram linkage
consIsts
RECOMMENDATIONS
and
teermg linkage
IS
eqUIpped
arm
With
torsIOn
tools and
mended
Shaft
Shim
anng
Camp Jacket
column
Suew
sector
adjusting
roller hdft
Fig
80
that
ponents be left
steeling
148
worm
large number
alignment eqUIpment It
repairs
to a
to
IS recom
the steering
com
of specIal
orm
SteeriDg
TROUBLE SHOOTING
Probable
ConditIon
lIeavy steering
Low
tIre
Corrective
cause
pressure
altgnmcnt
Innate
tires to
Adjust
to
FITm
stllkmg
of
the ball
Jomt and
strut
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
Adjust
ddJustment
or
Loose
to
one
side
adjustment of ddJust
Incorrect
lITe
pre
replace
nuts to
Inflate
sure
to
and
Inspect
beanng adjustment
Adjust bearings
Deformation
or
to
proper torque
front WhlCI
corred
alignment
Replace
umts
Improper
and
Adjust brakes
ddJustment
If any
recommended pressurc
dhgnment
brdke
pdrts
worn
recommended torque
Adjust
nut
Unequal
reqUired
as
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
beanngs
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
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
with
of
presealed
bearIngs
frequent lubncatIng ser
no
reqUIred
reInstallatIOn
the
and
are
packed
BanjO
axle
bearings should
be
lpproved
beIng careful
an
rear
not
to
damage
sealing rubber
DIFFERENTIAL
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
screw
adjustment
types Therefore
vice
type The
type
f10atIng
sem1
vIew
I
2
remaInS
for
figures stamped
on
screws
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
and
cause
other
should be checked
replenished
each 30 000
miles
The
luJ
ncan
ks hould be draIned and
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
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
shock absorbers
The
ThIS
matters
Nommated
nut
lb
ft
Drive gear
follOWing
1229
with
results from
to
loose
correct
the
any
of dnvt pmlon
IS
decrease the
through Thereby
of
the
rear
m1n1mlzmg the
suspensIOn
POSSibilIty
effecting vehlCle
stablhty
VISCOSity
It
The
same
brand must
always
IS
be selected
about 0 198 US
gal
for
attachmg
the
at each end to
the
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
Ji
H md brah
ldr
8rdk
ho
Torqw
Hound
bumplf
prill
It
Fig
151
arrl
10
hr
lrL
Rear suspension
upper
rear
Replacement
Jack upcthe center of the rear axle
port the axle housmg with stands
88
and sup
See
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
equence of removal
Test
Suspension
the
rubber
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
97
Clutch
CLUTCH PEDAL
DESCRIPTION
The clutch
prIng
IS
sIngle dry
type clutch
clutch
cover
provided
diaphragm
plate
pressure
are
diaphragm
and
sprIng
dIsc
wire
smoothIng
and
softemng
dre
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
assembly
With
Inspection
Thoroughly
wear
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
100
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
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
@
@
101
Clutch
pnmanly whenever
cyhnder IS dIsassembled It must
also be replaced when wear or deformatIOn
due to fatIgue or damage IS found
pedal
Replace
the master
etc
pIn
Remstallation
Reinstall the clutch
pedal
In
reverse
sequence
ofremoval
thIckness
to use shIms
Ule
haVIng
same
thIckness
Next
the
two
Grease if
places
matters
carefully
so
brake flUId
Remove
the
master
ecunng
suffiCIently
to the
the
master
cyhnder
of removal
cyhnder
sequence
assembly
adjust
and
Removal
cylinder
correctly faced
In
as
follows
IS
Reinstallation
reqUired
that It
reverse
push
new
cylInder assembly In
dIsassembly notIng the
of
sequence
follOWIng
ReInstall
DIsconnect the
replace With
Apply
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
the
push
the master
BLEEDING CLUTCH SYSTEM
bolts and
remove
the
cyhnder assembly
Remove
the bleed
screw
the
operatIng cyhnder
DIsassembly
Pull back the dust
cover
and
remove
three
the snap
Inspection
Thoroughly
clean all
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
tube
Immer
cyhnder
reservOIr
With the
recommended flUId
Depress
keepIng
and
and
the
Open
the
It
clutch
down
allow It to
and
the
the
pedal
remove
screw on a
the
bleec
1
t1
down stroke of
nd
rel1lace
Transmission
lransmission
case
The transmiSSIOn
smISSIOn case
and
rear
assembly
whIch
assembly
gear
the
rear
rear
end
Moreoyer
cons1sts of tran
contams
mam
extensIOn
shaft
The gear
the gear
assembly
assembly
supports
extensIOn
can
be dIsassembled With
Installed
on
the
plate
1T
iir
j
lkv
If
r
v
rn
J
li
I
rr
Fig
11M
159
F4W56 transmisSion
the
J
I
Jo
J
adapter
Iransmission
TROUBLE SHOOTING
Symptom
Difficult
to
sure
shift
possible
cause
tIve actIOn
Correc
mtermesh gears
and
lever
IS
heavy
shlftmg
and
It
are
IS
difficult
operates correctly
and
to
105
Transmission
Worn gears
shaft and
Inufficlcnt
Defective
Gear
slips
or
to
loose
worn or
Repair
shdmg pdll
or
mesh
thiS trouble
cases
system
be
IS
occurs
defectIve
out
rear
must
earned
trouble shootmg
Cd
carefully
engme
the trouble
cannot
be
or
or
weakened
IS worn or
spnng
corrected by repldtlllg gt
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
drs
mounts
mterlock plunger
or
replal c
Replace
damaged synchronIzer
out of
generated by
Repl llc
heanng
In the most
Worn
or
gear
e
H
NOise
When
gears
nOIse
It
occurs unoer
may
Inoufllclenl
Judged
or
engine
that the
nOIse
IS
from the
IS
ldlgsedeng
or when
nOI
Olcurs
Add od
1mproper lubncant
or
replace
oIl
Ollleaklllg due
Worn
to
occurs at
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
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
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
107
Transmission
AUTOMATIC TRANSMISSION
The model 3N71B automatic transmiSSIOn
fully
3 element
hydrauhc torque
planetary gear
a multiple
ches
a one
Two
sets
elements reqUired
tlon of the two
The two
planetary
IS
pnmanly
multiple
a
disc clut
provide
the fnctlon
planetary
fun
gear sets
gear
sets
one reverse
fully
of
disc brake
IS
Changing
automatic
In
relation to
vehicle
SIX
selector poSitIOns
speed
Park pOSitIOn
put shaft
to the
out
of
lockmg pawl
rollmg either directIOn
to
at any vehicle
gear and
remain
IS reduced to
approximately
speed
25 to 31 MPH
brakmg
operation
IS
when continUOUS
low
gear
deSirable
can
assembly
of welded
IS
service
selected
engine
p
range can be
FlUld Recommendatwn
Use
Park pOSition
automatic
DEXRON
flUid
transmiSSIOn
IdentificatIOns
only
haVing
the 3N71B
automatic transmiSSIOn
driVing
denttficatwn Number
Stamped posttwn
The plate attached to
the
of
range
dnvIng onshppery
be used for engine
prOVides performance
surfaces
2 range
can
for
brakmg
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
HOOD
Removal
hwld washer hose at the
WInd
connect the
DI
nozzle
hood
IS
closed
HOOD LOCK
hinge
installatIOn bolts
and
workers
are
Removal
Remove
the
radiator
stallation bolts
and
remove
hood
removal carefully
In
so
in
required
Installation
Install
the
loosen
gnlle
reverse
sequence
IS
of
wire
and
remove
the female
flush
Remove
three
screws
and
the hood
remove
Adjustment
Centermg the
Hood Lock
In
hook lock
adjusting
IS
with
prOVided
nght
Sides
of the
vehicle
align
the
Loosen
the center
correctly
Dovetail bolt
31
Spong
Sarety
retammg
Ii
il
7JjHood
Fig 164 Removmg hood
U2
catch lever
Spnng
lever
nut
hmaJc lever
lod
in
control
Rubber grommet
Bod Work
Adjusting
Operating
Increase
mstalled
length
Tightening torque
Dove tall bolt retaining nut
108 to 18 1 ft lb
Fig 166 Removing male Side of the hood lock
Ttghtenlllg
FIg
167
Fig
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
U3
Bod Work
J
t
3
G
iJ
7
Fig 171 Adjusting dove tall boll
A
5 Omm
O 197
85
0335
mm
IS
LUBRICATING POINT
In
Just the
ie
crea
After
or
decrea
ie
adJustIng
retaInIng
Notes
nut to
When
note the
inspecting the
following matters
Check to be
sure
hood
lock
with
wear
and the
correct
operation
and the
spring
for
the
smoothly
female
lever
engaging
1M
disengaged
should be
more
to
check
The dimension
than 0 335 in
Lubrication
When check
or
adjust
does
stroke
the
not
with
move
the
and it may
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
@
Oosed poSItion
RaUtlon center of
ill
trunk hd
Trunk
hd
Iungo
U5
Bod Work
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
chp
and
remove
the
body
and lock
and
and
remove
the
justmg stroke 03 50
ad
Tlghtemng torque
fixmg bolt
o 87 to
Adjustment
Sedan
When
adjustmg engagement
and
tnker
properly
set
adjust
890
and
statlOnanly and
poSitIOn
Adjustmg
nght SIdes dIrectIOn IS
the lock
stnker
03150
toward
vertical
The
mdlcated
dIrectIOn
as
tallIng
torsIOn
installing
VAN
J
j
l
tl
11
II
Back door
hUlle
tomon
bOT
BlCk door
hmge
Back door
Lock
Stnker
Stnker shun
dovetad
9
Side
10
Back
II
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
II
Doorgllss
12
Glazmg
13
Bottom channel
14
Outer
I S
Door upper
hmge
16
Door lower
hinge
rubber
moulding
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
17
18
Door
19
run
rubber
rubber
hinge
glasstopper
Wcatherstnp
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
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
lamp
signal
Headlight
indicator
beam indIcator
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
as
When
RepaIr
Inspection
and and
the
as
the
RepaIr
If
IS
If
and and
When
contact
fuse
fuse
for
Check faulty
Check cable
test
the
fuse
the
termInal
contact
fuse
Blown
contact
Def ctive
dIm er dIm er
off
BI
1M
do
anW
l ead
CondItiOn
lamps hght
An not
Conduct
Check
sWItch
off
contact
contl u
sWitch sWitch
hghtlng hghtlng
or
ty
the
CO
sWItch
faulty
test
con ector
Check faulty
Conduct
Check
for
for
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
1h
does
for and
be
a
the
If
le
Correctl
actlon
after
regulator With
con
cor
cause
Corect
the
It
the
to
voltage comb ed
The
the
IS
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
Defec aged
nectlOn
thermo ter
do
thermo ter
Both
meter
fuel
operate
Both
and not
1
cable
Wire
heat
fused
IVe
off
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
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
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
pOUlter the
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
ap
me one
tank
II
IIa Iia
me
tank
defctive
fuel
the
the
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
in
level
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
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
Check for
the
pres
the
011
Cont Ulty
Check
the
or
contact
lamps
faulty
warni g
or
Ptoba le cause
fuse
igniton
Blown
and
warn
not
Broken faulty
Defctive
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
and
light
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
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
to
Specifications
1 vpc
RCl
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
15 I
ClrrJtm
assembly
Hance
sedor
uf
kg
ddJustmg
SLrew
cm
oz
lIl
20
to
5 0 27 X
to
shaft
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
nuts
nuts
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
33
Mmlmum
L US
gal
Imp gal
23
10
42
Water
Wllhout heater
W th heater
L US
CompressIOn
pressure
at
1 4 IJi
49
125
kgcm2 PSI
rpm
Ji
to
145
78
to
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
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
at sea
vacuum
Thermo
sSltranSfonfiI
speed
no
load
SWitch
to
Temperature
hIgh
to
mmHg
10
Hg
500
mmHg
10
Hg
48010520
1 650
rpm
from low
2 000
level
Automatic transmission
Servo
10
pressure
Manual
1 900
rpm
mm
540
to
19 7 to
18 9
to
213
20 5
1 850
5 01969
nses
oc
above 5 41
Operating
pressure
mmHg
10
Hg
10 04
133
Specifications
ENGINE
GENERAL SPECIFICATION
4mlme
Cylinder Jrrangement
Displacement
ce
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
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
40
10
4 8 29
10
35
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
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
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
Valve
7 985 0 3138
to
lUst
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
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
mm
o 02
mm
565
mm
43
to
2nd
43
42
283
783
I6844
4th
42
783
I 6647
5th
Camshaft bend
mm
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
e
dlstan
mm
47812
to
4 7788
10
J 0594
mm
500
I 508 0
0591
mm
to
less than 04 0
016
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
mm
mm
005
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
49
to
Main
0008
maIO beanng
Journal diameter
Journal
0 050 0
mm
10
7706
to
7701
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
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
ff
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
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
sCl
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
body
Manudl
Ill
AUttJl1ldtlC
111m
Mdlludllfdnsmlsslon
JOn
to
1205
to
I 115
260 0 0449
to
00496
004741000526
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
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
than
MagnetiC
9
1 0 72
shift
Specifications
ALTERNATOR
Make and
NonunaJ
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
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
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
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
3150
In
to
0 2756
In
to
67t070mm
02638
out
run
03
mm
0118 In
05
mm
0197
radIUS
0 140
of disc assembly
Free
Allowable
85
In
at
3 346
mm
In
04mm 001571n
pedal
1415
mm
5 57 m
1365
to
1465
54 to 5 8
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
kg
clearance
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
Topics such as construction matenals welding hand tools and auto body
of
the
Y
fe
major areas clearly exp a ned in tills text Des1gned to serve as a shop manual
well
must
for
men and as a reference tool for the owners of auto repair snops 1t is a
auto to
hke new
des1gn
Just a
are
conchtion
any
body
equ1pped school
for auto
shop
hbrary
or
SBN 87749
030
8 95
t
r
THEGRANnPRIX GltEATS by
internationally famous racmg expert
MOTOR RACING
the
Barrie Gill
Barne Gill
has created
contenders for the honor of bemg the greatest dnver of them all
book that
Graham Hdl
p
f
portr ts Of te
Moss
Jochen
Strrhng
of
j
offers
FangIO Denny Hulme Mike Hawthorn Jun Clark JaCk Brabham Bruce McLaren f
and J ckie tewart Each man IS chscussed in tills book by the spons writers who knew hun the best and
who shared h1s triumphs and trageches Th1S book WIll gIve every rac1ng enthus1ast a fresh lively and
min e look at some ofthe world s most colorful and courageous sportsmen
Rmdt Juan Manuel
tMOTIVE
REPAIR
GUIDE by
Edward J
if
i
f
Ort
complete
ller
oV
conchtio
air
ors
even a
spec1al
seats
SOl
I
f
LECrRONIC
nj
PRO
Tills b60k cOntains a oore
and
rh
garage
Included
are
WIndsilleld
R M Marston
SWItch
be of
owners
j
lk
q
132
J
f
a h p in the
automatic sldelight
projectll
WIl
Twc
battery charger and a speed control for electric dnlls
by luc1d and easily understandable instructions and dlustrated IlY
diagrams All necessary components are listed for each device Tills book will be of great value to
per
garage are a self regulating
Each project 1S descnbed
11
i hv
y
that
J1
and very useful ilectnc devices that can be made at homeifbt the car
anautomatiC
for tHe car that warD of danger from ice and overheating
contro
and an
of simple
circuits
f J1
erqi I li
1
3 95
1 J
3 pap
tPt
I
j
f rt
i
tiinI slgnal
and WIpers
There
l
t i
electnc clocks
inchca
1t
and
adJustment
i
f
ei
1
r
on
ll
I
Mezo
treatise
duiinoslsmeth6ds
RiES
CESS
i
q
95
r
j
clear
all
car
595
l
f
help
owners
by
Charles Williams
ofj
rit1sh made cars tune them for maxunum power and sPeOO TUNING
gives a non technIcal but practical gu1de to how famdy cars can be made
AI added feature 1S a hst of major American suppliers of the British made
to behave more h
te
port cars
auto
parts d1Scussoo
many
photos
and
diagrams
t
r
1
f
381 P
ARKAVENUESQUTH
cp
N Y
N Y 10016
7 95