Nissan 1980 200Sx Repair Manual Service Datsun

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I DATSUN I

1980

DATSUN
200SX
i

rl1

SERVICE

MANUAL
J
A

I

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I
h

i
i

t

CI

o

IIV

INI55ANI
HlUM
lOco

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t

QUICK REFERENCE INDEX

DATSUN
200SX
Model

GENERAl INFORMATION

GI

MAINTENANCE

M

ENGINE MECHANICAL

E

COOLING SYSTEMS

ENGINE LUBRICATION

S J JO Series

FOREWORD
This service manual has been
for the purpose of

marily
personnel

in

providing

prepared pri

assisting

service

tion

All information

illustrations and

product

the time of

of

ENGINE REMOVAL

E

INSTALLATION

EXHAUST SYSTEMS

F

CLUTCH

C

MANUAL TRANSMISSION

M

AUTOMATIC TRANSMISSION

A

specifica

are

based

on

information available at

publication

model differs from

E

com

shooting

tions contained in this manual
the latest

EMISSION CONTROL SYSTEM

for main

procedures

adjustments
disassembly and assembly

ponents and trouble

iF

ENGINE CONTROl FUEL

removal and installa

tenance

ENGINE FUEL

effective service and

maintenance ofthe 1980 DATSUN 200SX
This manual includes

LC

the

If your DATSUN

specifications

con

PROPELLER SHAFT

DIFFERENTIAL CARRIER

P

tained in this manual consult your NISSANI
DATSUN dealer for information
The

right

is reserved to make

specifications

FRONT SUSPENSION

FRONT AXlE
changes

F

in

and methods at any time with

REAR AXLE

REAR SUSPENSION

R

out notice

NISSAN MOTOR

CO

BRAKE SYSTEM

B

STEERI NG SYSTEM

S

BODY

B

LTD

HEATER
@

t 979

NISSAN MOTOR CO

AIR CONDITIONER

LTD

Printed in Japan
Not to be reproduced in whole or in part without
the prior written permission of Nissan Motor Com
pany Ltd Tokyo Japan

H

ELECTRICAL SYSTEM

E

w

v
HOW TO USE THIS MANUAL
I

This Service Manual is

designed

as a

guide

for

servicing

cars

This manual is divided into 19 sections The first half of the manual presents sections which
the

engine

A

QUICK

and the second half presents sections which deal with the chassis and

REFERENCE INDEX is provided

on

body

Refer to this index

the first page

concern

along with

the

index of the particular section you wish to consult

The first page of each section lists the contents and

DATA AND SPECIFICATIONS
RVICr

SE

TROUBLE DIAGNOSES AND
manual

lists

the

likely

causes

are

gives

the page numbers for the

respective topics

contained in each section

CpRRECTIONS

are

also included in each section This feature of the

appropriate corrective

of trouble and recommends the

actions to be

taken
A list of SPECIAL SERVICE TOOLS is included in each section The

For information

assist you in performing repair safely accurlltely and quickly
obtain special service tools write to the following address
to

Moore
Kent

Moore
Kent

Corporation

29784 Little
RO eville

ack

tools

special service

of Canada

are

designed

concerning

how to

Ltd

2395 Cawthra

Michigan 48066

Mississauga

Ontario

Canada L5A 3P2

The
of

measurements

and

Unit

The back

given

in this manual

alternately expressed

cover

In the text the

are

primarily expressed with

in the metric system and in the

following abbreviations

Service Data

nd

J
f

Tightening TorQue

are

System

system

used

Specifications

LH

R H

MOrr AiT

The

captions CAUTION and WARNING warn
injury and or damage to some part of the car

left Hand

Right Hand

Manual Transmission Automatic Transmission

you of steps that must be followed to prevent

personal

IMPORTANT SAFETY NOTICE

The proper

performance

functioning

of the

of service is essential for both the

and

safetY

I

of the mechanic and the efficient

car

The service methods in this Service Manual
formed

safely

Special

service tools have been

use

yard pound

of the manual provides maintenance data for quick reference

s os

N

the Sl unit International

are

described in such

a

manner that the service may be per

accurately

designed

to

permit safe

and proper

performance of

service

Be sure to

them

Service varies with the

Accordingly
by NISSAN

anyone
must

jeopardized by

procedures

used

the skills of the mechanic and the tools and parts available

using service procedures tools or parts which are not specifically recommended
completely satisfy himself that neither his safety nor the car s safety will be

first

the service method selected

DATSUN 200SX

Model SIlO Series

SECTIONGI
GENERAL INFORMATION

CONTENTS
GENERAL VIE WS
MODEL VARIATION

IDENTIFICATION NUMBER
LIFTING POINTS AND TOWING

GI 2

TIE DOWN

GI 5

GI 3

TOWING

GI 5

4
GI
GI 5

PANTOGRAPH JACK

GI 5

GARAGE JACK AND SAFETY STAND

GI 5

SPECIAL SERVICE TOOLS

GI 6

TIGHTENING TORQUE OF
STANDARD BOLT

GI 6

GI

GENERAL INFORMATION

Genetal Views

GENERAL VIEWS
Hardtop
l

I
I

O

r
II

c

JI1

f

Po

Ll
1

r

dI

V

34S

S3 0

680

66 1

11

I

41

m

1

f

ll

I

lU

hF
LI

1 680

Unit

mm

1

11
53 O

J

990

39 0

t

I

ll
2 400

t

94 5

1

090 42 9

4
176

480

66 1

g
X

11

oi
345

J

L

1
r

1

I

SGIOO2

in

Hatchback

t
L

d

fT

c

I

iq
1 345

53 0

1 680

66 1

Ii

r

I

J

t

J J

L

r
I

bt

I

I

iL

J

t

uJJ

r

Il

IY
990

39 0

1

2 400
4 480

Unit

GI 2

mm

in

94 5
t

J

1
T

t

090

42 9

4
76
5GI003

GENERAL INFORMATION

Model Variation

MODEL VARIATION
Road wheel

Differential

Desti

Class

nation

Engine

Model

Transmission

carrier

mm

PLSIIOAEV

I

3N71B

KPLSIlOFEV

I

FS5W71B

KPLSllOAEV

I

3N71B

PLSIlOFEU

I

FS5W71B

I

3N71B

California
Hatchback
U S A

Hardtop
PLSllOAJ
iU

Hard top
Canada
Hatchback

5J 14

25

185

0 98

70 SR 14

I

Z20E

HI65B

KPLSllOFEU

I

FS5W71B

I

KPLSIIOAEU

I

3N71B

I

PLSllOFEN

I

FS5W71B

I

PLSllOAEN

I

3N71B

I

KPLSllOFEN

I

FS5W7IB

I

KPLSllOAEN

I

3N71B

Hatchback

California

in

FS5W71B

SIIOFEV
PI
Hardtop

Non

Tire size

Offset

Size

5 1 2JJ 14

25

185

0 98

70 SR14

35

T135

38
1

70D16 2

2
4 T

16

x

I

Aluminum wheel Option

2

Spare

tire

Prefix and suffix designations
K

K

I

Hatchback

I
J

o

Hardtop

P

Z20 engine

L

Left hand drive

P

L

SIlO

J

0

PST

LT

Sun roof Glass

S

Sport Luxury model

P

Power

R

Sun roof Steel

L

Rear window

C

Air conditioner

U

steering

wiper

California
Non

model for

U SA

0

means

V

California model

N

Canada model

E

E F l

F

Manual transmission

A

Automatic transmission

no indication

GI 3

IdentificationNiJmber

GENERAL INFORMATION

IDENTIFICATION NUMBER

EMISSION CONTROL
INFORMATION LABEL

CAR SERIAL NUMBER

PLATE

SGI004

CAR SERIAL NUMBER
K P

SlID

r

Hatchback

x

X

X X

X

X

I

Car serial number

Z20 engine
Model

ENGINE SERIAL

MANUAL TRANSMISSION

AUTOMATIC

NUMBER

NUMBER

NUMBER

ed

The engine seria number is stamp
on the left
side of the cylinder

block

The transmission seria number is
the front upper face of the
transmission case

stamped

on

The

plate

TRANSMISSION

transmission

is attached on the

of the transmission

serial

number

right hand side

case

I
Q
SGIOO6

4
GI

TM235

AT344

UftingPointsand Towing

GENERAL INFORMATION

LIFTING POINTS AND TOWING

Towing

Towing hook

hook

7

UL

I

IW

r
J

@
II 1I

Towing

Towing hook

hook

Jack up point for pantograph jack

@
A

point

for garage jack

@

Jack up

il
I

Supportable point

for

safety

PANTOGRAPH JACK

stand
SG 1007

b All
CAUTION

Always place
WARNING
a

6

Never get under the car while it
is supported only by the jack

Always

use

stands

safety

support frame when you have
get under the car

wood block between

safety stand and car body
supporting body with safety
Apply

to
to

a

in

the garage

jack

when

Canada

laws

Provincial

or

and

local laws

regarding the towing operation
obeyed
Before towing make sure that the
transmission axles steering system
and power train are in good order
If any unit is damaged a dolley
must be

stand
c

and safety

stand to the position indicated below
in a safe manner

must be used

b Place wheel chocks at both front

d

and back of the wheel

diagonally
opposite the jack position

State

applicable

If the transmission is

inoperative

tow the car with the rear wheels off

TIE DOWN

the

or

ground

with the

propeller

shaft removed
the

Apply

pantograph jack

nished with the
below

indicated

car

to

in

a

fur

FRONT SIDE

the position
safe

Use

manner

front

for

GARAGE JACK AND
SAFETY STAND
WARNING
When

carrying

sure

to

safety

stands
b When

of the

jacking up the rear front
car place the chocks at

the front

towing hooks for

tie down

rear

of the

wheels to hold them

front

towed with its front

the

ground secure the
a straight ahead
steering
with
the
position
ignition key
turned in OFF position
When towing an automatic trans

f

mission model

on

do not exceed 30
and
g

20 miles
brake
and set
parking

distance of 30 km

Release the

gearshift lever in Neutral
position before starting to tow the

CAUTION
a

a

its rear wheels
h 20 MPH
km

the

operations

with the garage jack be
support the car with

car is

on

wheel in

TOWING
out

When the
wheels

tie

REAR SIDE
Use rear

rear

towing hooks

down

t

a

e

car

towing
equipment to avoid possible dam
age to the car during a towing
operation
Towing is in accordance with Tow
ing Procedure Manual at dealer side
It is necessary to

use

proper

GI 5

Specia Service Too s
Tightening
1ueofStandardBolt
TO

GENERAL INFORMATION

SPECIAL SERVICE TOOLS
Special Tools play

The identification code of mainte

important

very

role in the maintenance of cars These
are

essential to the safe

speedy servicing
The working

nance

accurate and

tools is made up of 2

calletteIS and
The

times

listed in the

classify

digital
8

heading
tools

or

two

EMOOOOOOOO

Engine

alphabeli

Overhaul

ing Machine

figures

GGOOOOOOOO

General Gauge

letters roughly

LMOOOOOOOO

Garage

HTOOOOOOOO

Hand Tool

equipment

as

Tool

column under FLAT RATE TIME in
FLAT RATE SCHEDULE
based

puted

on

the

use

are

of

com

Special

Tools

STOOOOOOOO

Special

KVOOOOOOOO

Special Tool

Tool

TIGHTENING TORQUE OF STANDARD BOLT
Grade

Bolt

Bolt
or nut

size

or

nut diam

eter

4T

M6

60

M8

80

Tightening torque

mm

N

MI2

2 9

3 9

25
1

7 8

10 8 0 8

Ll

5 8

8 0

10

7 8

10 8 0 8

Ll

5 8

8 0

15

16

22

16

2 2 12

16

25
1

16

22

16

2 2

12

16

175

26

36

27

3 7 20

27

25
1

30

40 3 1

41 22

30

62 4 7

63 34

46

3 04 2 2
0

MI4

14 0

5
1

46

M6

6 0

10

5 9

6 9 06
18

M8

8 0

1 25

I

14

2 9

10

I

14

5
1

I
I

25

175
125
5
1

14 0

M6

6 0

1 8 10

13

35 2 6

3 6

26

26

36 2 7

3 7 20 27

I

45

61

I
L

50

68

1
5

76

103

7 7

M8

10

I

25
1

I

19

10

I
I
I

80

15

MIO

10 0
125

MI2

75
1

I

25
1

I

15

I

12 0

MI4

14 0

1

Special pam are

2

This standard is applicable to bolu having the

7 8

4

1
5

13

12 0

MI4

1

0 7 43
1 8 10

10 0

MI2

14
18

46

6 2 33

45

6 9 37

50

10 5 56

10 8 O
25

19

1

76

5 8

19

25 14

18

20

27 2 0

2 8 14

20

36

50 37

39

51

1
5

27 37

4 0

2 29
5

38

65

88 6 6

9 0 48

65

72

3
7

9 9 53

72

109

97
147

1
11

80

15 0 80

108

excluded

marks embossed

on

the bolt head

Grade

Mark

4T

4

7T

7

9T

9

GI 6

ft Ib

10

25
1

following

m

12 0

MIO

9T

kg

m

10 0

MIO

7T

Pitch

mm

Nominal diameter
M6

TT

Nominal diameter of bolt threads Unit
Metric

screw

threads

mm

DATSUN 200SX

Model S J J 0 Series

II
MAINTENANCE

CONTENTS
MAINTENANCE SCHEDULE
LUBRICATION

CHART

RECOMMENDED FUEL AND
LUBRICANTS

MA
MA

TRANSMISSION

2

MANUAL

4

AUTOMATIC TRANSMISSION
PROPELLER

MA

MA 23
MA 24

SHAFT AND

5

DIFFERENTIAL CARRIER

FUEL

MA

5

LUBRICANTS

MA

5

FRONT SUSPENSION

5

REAR AXLE

5

BRAKE

6

WHEEL AND TIRE

fVlA 29

6

STEERING SYSTEM

MA 33

9

BODY

MA 35

SAE

VISCOSITY NUMBER

APPROXIMATE REFILL
CAPACITIES
ENGINE MAINTENANCE
BASIC

MECHANICAL SYSTEM

IGNITION AND
EMISSION

FUEL SYSTEM

CONTROL SYSTEM

MINOR TROUBLE DIAGNOSES
AND CORRECTIONS
CHASSIS AND BODY
MAINTENANCE

MA

CLUTCH

SYSTEMS

AND

MA
MA
MA
MA

MA 14

MA 15

MA 23

SYSTEM

MA 23

MA 27
MA 28

HEATER AND AIR CONDITIONER
SERVICE DATA AND

MA 36

SPECIFICATIONS
ENGINE MAINTENANCE

MA 39
MA 39

CHASSIS AND BODY
MAINTENANCE

MA 23

MA 24

AND

REAR SUSPENSION

ENGINE CONTROl FUEL
AND EXHAUST

AXLE

MA 24

FRONT

SPECIAL SERVICE TOOL

MA 39
40
MA

MAINTENANCE

Maintenance Schedule

MAINTENANCE SCHEDULE
The following tabels list the periodic maintenance servicing required to
and good mechanical condition in DATSUN
The fint 1 600 km
and

ensure

000 miles service is one of the most important services
11

good emission
uired to

control

performance good engine performance

the maximum

nsurw

mission control

perfonnlnce

Iition
optimuin engine con

MAINTENANCE

OPERATION

MAINTENANCE

Periodic maintenance should be
number of kilometers miles

at

whichever

comes

performed

or

Kilometers

x

1 000

16

t2

x

1

0001

1

7

51

6

EMISSION CONTROL MAINTENANCE

60

72

t51

22 5

301

37 5

451

t8

24

3D

36

t2

@

So

NOTE

@

@
j

A
oil filter

111

R

R

R

R

RO

RO

RO

Engine coolant
Idle rpm

@

Fuel filter

So

Fuel lines hoses

piping connections

NOTE

Soo NOTE

Vapor

So

NOTE

6

MA

7

MA

8

121

MA 13

@

MA 14

@

MA

9

121

MA

9

R

MA t4

lines

MA t4
Abbreviations

A
I

NOTE

MA

I

Ignition wiring
induction v8lv filter

6

MA 13

131

Spark plugs

Air

MA

MA 12

etc

Air cleaner filter

rence

page

CALIFORNIA

@

Drive belts
uine
En

48

Ref
Miles

first

exhaust valve clearance

oil

INTERVAL

36

months

Months

Intake

24

If nhicla

under

A

Replace
replace if necessary

I nspect correct

conditions short distance driving extensive idling or driving in dusty conditions change
3
0
00 miles or 3 months whichever comes first
More frequent maintenance is required und
dusty driving conditions
If the vehicle is operated under extreme adverse weather conditions or in ar s where ambient temperaturas are either extremely
low or extremely high the filter might become clogged
In such an event replace the
filtimmmiatefy
COYIIto these re
D @ an @ are the maintenance intervals required by California Regulations @ limits the warranty
and R
the
uired mainUNInce intervals
placement InterYals
Other maintenance items and intervals are recommended by NISSAN MOTOR CO L TO

III

is

Adjust

sever

engine oil every 5 000 km

121
131
41

EMISSION CONTROL
Intake

exhaust valve clearance

Drjve bel

s

Engine oil

MAINTENANCE

CALlFORNIA
NON
A

1

oil filter

So

NOTE

R

R

Engine coolant
Idle rpm

A

I
R

151

A

R

R

R

R

mixture ratio

Idle rpm

A

A

A

A

Mixture ratio
Fuel

hoses

piping connections

Air cleaner filter

7

NOTE

161

R
A

A

R

Ignition wiring

I
Soo NOTE

61

R

A Adjust
I

MA 2

MA l0
MA

9

MA

9

MA 14
Abbreviations

81

8

MA l0

MA 14

Vapor lines

161
171

MA

MA t4

A

Spark plugS

51

7

MA 13
So

except Canada

6

MA

MA 13

etcJ

Ignition timing

Air induction valve filter

6

MA

MA l0

Soo NOTE

filter

Fuel lines

MA

If vehicle is

Inspect

RReplace
correct

replace if necessary

operated under senre conditions short distance driving extensive idling or driving in dusty conditions chenge
km 3 000 miles or 3 months whichner comes fitst
engine oil every 5
000
Mor frequent maintenance is required undar dusty
driving conditions
If the vehicle is opemed under extreme adverse weather conditions or in areas where ambient
temperatures are either extremely
filter
become
low or extremely high the
might
l In such IIn event replace the filter immeduty
dow
are
Maintenance items with
recommended by NISSAN MOTOR CO L TO
Other maintenance items Ifll required

MAINTENANCE

MAINTENANCE

MAINTENANCE OPERATION
Periodic maintenance should be
number of kilometers miles

at

whichever

comes

performed

or

Kilometers

months
Miles

x

1

x

1 000

000

Maintenance Schedule

INTERVAL

16

t2

24

36

48

60

72

III

17 5

It51

122 51

130

137 51

451

6

t2

t8

30

36

Reference
page

first
Months

24

UNDERHDOD MAINTENANCE
automatic transmission fluid

steering gear

Brake clutch

or

MA 23

leaks

cillevel

Air

vacuum

hoses

connections

R

MA 28
J7
MA

refrigerant leaks
I

lines

steering fluid

MA 28

check valve

conditioning system hoses connections

Power

R

R

Brake fluid
Brake booster

24

28 33

I

MA 33

UNDER VEHICLE MAINTENANCE
Brake clutch

exhaust systems for proper attachment leaks cracks

fuel

chafing abrasion deterioration

See NOTE

differential gear oil

Manual transmission

linkage suspension parts
Steering gear box
shaft for damaged loose
missing parts
Underbody

MA 23 28

etc

propeller 588 NOTE

MA 23 24

19

MA 24 27
10

34

flush and clean every 12 months

OUTSIDE

AND INSIDE

MAINTENANCE
MA 26

Rotate wheel

Disc

nspect wheel balance

position

wheel

deterioration

wear

Front wheel

Locks

See NOTE

MA 28

111

leaks
MA 25

bearing

hinges

hood latch

Seat betts buckles

See NOTE
anchors

retractors

brake parking

91

When

10

Steering linkage

towing

whichever

111

L

play

MA 23

operation
R

Replace

I

Inspect

28

Lubricate

L
correct

replace if necessary

whichever
change oil in differential gear every 48 000 km 30 000 miles or 24 months
96
000
km
60
000
miles
ball
should
be
front suspension
joint inspection
performed every

comes first

4 years

or

first

operated in areas using road salt or other corrosive materials inspect every 5 000 km 3 000 milesl

comes

MA 35
MA 35

trailer

comes

If vehicle is
whichever

a

L

L

adjuster

clutch forstroke free

brake

11

Abbreviations

NOTE

30

yJ

32

brake pads

other brake components for

Foot

alignment

or

3 months

first

The above charts show the normal maintenance schedule
Depending upon weather and atmospheric conditions varying road surfaces
individual driving habits and vehicle usage additional or ore frequent
maintenance may be required

MA 3

ctg
I

3

ZlmZ

z nm

Ic mJ
J obo 5Z 2 J

advers ambient extrme

km

such
In

ELCTROY

or

extrme wher clogltd
low

under

l
erel

in

operatd

or

cvehicle ondit

extrmely become fiImltedeiatlrv
lIre

the
If

wheat r temprau

filter

replICe

the

WINDOW FLUID FILTER

BATERY WINDSHEL REAR WASHER

either might the

i

AND

FUEL

@

STERING

OIL

POWER GEAR

@OILFTER @ENGIOL

driVng 000

TTRANSMIO RANSMIO
MANUL

1111t

6

condit s idling every comes
sevare enginewhic ev r
extnsive
or

oil

AUTOMIC

under

operatd

months
c
h
a
n
g
e
drivng

3

or

dvehicle luance condit s mi000les
i

high ev nt
IV

an

If

short dusty

3

@
@

diferntal

in

Month

@

@

mila

000

000

0 130

115

011

change

24
or

miles
000
30

lt
fll

cornel

km
000
411

trailer km000

24

towing every whicevr
lI

EV RY EV RY

48

1

L
@

When

6
or

6

road

GREAS
CHECK

liSl
fl

3 0j

ing

n

COLANT BEARINGn

QIQ

CHANGE

km

salt 000

UP

LUBRICATE

gear

ENGI E

ANTIFREZ

FLUIO

FLUIO

WHE L CLUTCH BRAKE
FRONT

OIL

GEAR

STERING

@
81

HINGES LATCH
LOCKS HO D

u

OIL@

ereai

every

onth

lt
fil

cornel

inspect whicevr

moperat d ateril month
in

GEAR

3

or

DIFERNTAL

cvehicle or sive 000mile
is

@

If

other

3

Recommended Fuel and Lubricsnts
Approximate Refill Capacities

MAINTENANCE

RECOMMENDED FUEL AND LUBRICANTS
FUEL
Use

an

unleaded

gasoline only of at

Under no circumstances should

a

least 91 research octane number Anti knock index 87

leaded fuel be used

ince this will damage the catalytic converter

SAE
VISCOSITY
NUMBER

LUBRICANTS
Remarks

Specifications

Lubricant

I

I

ENCEOIL

I I

APISE

Gasoline engine oil

211

ICM

I

I

I

JGIIf4l

t

0

r

lo

1
l

Further details refer
Transmission
Gear oil

and steering
Differential

Automatic T M and power
steering fluid

II

to recommended SAE

API GL4

viscosity chart

Type

I

rJ
v

API GL 5

DEXRON

I

I

l

I

r

I

I

NLGI No 2

I

I

I

I

Multi purpose grease

I

1

I

I

I

I

1

I

lithium soap base
I

1

r
I

Brake and clutch fluid

US FMVSS No 116

DOT 3

I
40

I

I
1

II
nII

Ethylene glycol base

Anti freeze

or

dri

I

1

TI

OlIl

T
Nut O

c
F

l 4Oll C11ll l l 101
11
Jl
Ch

APPROXIMATE REFILL CAPACITIES
us

liter

measure

Imp

measure

Hardtop

53

14gal

Hatchback

60

15 7 8

With heater

9 5

IOqt

8

Without heater

8 8

9 1 4qt

7 3 4 ql

With oil filter

4 1

4 3 8 qt

3 5 8qt

Without oil filter

3 9

4 1 8

qt

3 3 8 ql

M T

2 0

4 1 4

pt

3 1 2 pt

A T

5

5 7 8 qt

4 7 8 qt

Differential carrier

1

2 3 8 pi

2 pt

Power

12

11

I 1 8

Fuel tank

Coolant

Engine

Transmission

steering system

28
0

Steering gear

gal

4ql

II 5 8

gal

13 1 4

gal

3 8 qt

ql

5 8 pt

1 2 pt

Windshield washer tank

2 0

21 8 ql

13

Rear window washer tank

10

1 1 8 qt

7 8 qt

Air

conditioning system

Compressor
Refrigerant

oil

1 fOZ 9 0 oz
9

27
0
09

1

kg

20

4lb
2

4qt

5 fOZ 9 0
9
2 0

oz

2 41b

MA 5

Engine

MAINTENANC E

Maintenance

ENGINE MAINTENANCE
BASIC MECHANiCAL
SYSTEM

Valve clearance

Hod

CD @

Intake

0 30

mm

0 012 in

ADJUSTING INTAKE AND
EXHAUST

Exhaust

I

water

Using feeler

I

should be made while

between

ance

rocker

Start engine and

until

mm

10 012 i n

aEARANCE

Adjustment
engine is hot

0 30

@ j

VALVE

warm

up

points to the middle of gauge
stop engine

valve

stem

very

end

0

clear
and

arm screw

Feeler gauge should

engine

indicator

temperature

measure

gauge

with

move

No

1

earn

lobe

a

slight drag

SMA001

then

Valve clearance adjustment cannot
be made

while

engine

is in operation

2

Remove valve rocker cover

3

Set

cam

lobe points down

so

that

high point

Adjust ID ID @ and @ valves
using same procedure as for Step 3

of No I

@

@

Front

8M AQSO

D
kG
No

1

earn

lobe

2

ID
OO

If the clearance is not within spec

ified value loosen rocker

arm

turn rocker ann screw to

provide

tDf

nut and
SMA052

pro

per clearance

3

SMA005

Hold

rocker

tighten rocker

arm

arm

screw

and

nut
Valve clearance

Hod

Intake

@@

0 30 mm

Exhaust

ID ID

0 30 mm

0 012 in

When
starter

turning crankshaft
tension
remove high

from ignition coil

cable

5

Install valve rocker

cover

then turn it

Adjust clearance of half of
Adjust only CD @ @

valves

j

0 012 in

with

the

CHECKING AND
ADJUSTING DRIVE BELTS

and

valves

I
SMA051

Visually

inspect

for

should

not

cracks

or

damage
Th

CD

4

dl

Rocker arm nut
16

Front

o 1lJf Dt

1 6

DFJ

000
SMA049

12
4

2

m

2 2 kg

Check bell tension by

m

cified amount

16 ft b

Drive belt deflection
8

4

Turn crankshaft and set

high point

of No

touch the

pushing
by the spe

The belts should deflect

Recheck clearance

above
MAS

22 N

belts

bottom of the pulley groove

so

I cam lobe

that

points

12 mm

0 31

0 47 in

Applied prening forc
98 N

10

kg

22lb

MAINTENANCE

t

Engine Maintenance

J

ilJ

LoCk nut
Idler

puUey
Adjust
Loosen

Loosen to adjust

A

I t
Jr
f

Compressor pulley
Alternator

Crank

pulley
Checking point

Idler

pulley

of drive

belt deflection

Adjusting

bolt

Adjust
8MA053

3

belt tension

Adjust

as

follows

CHANGING ENGINE OIL

A

AND OIL

of

1

Start

until

securing bolts until
can be moved slightly

nator
tor

2

2

Loosen the upper and lower alter

Move the alternator with

range

Then

of gauge

An oil with extremely low
indicates dilution with

then

WARNING
a

prying

tighten

Be careful not to burn

yourself

as

the engine oil may be hot

Clean

plug

with washer

IiJ

Oil pan drain
20

29 N

2 0
14
4

I

1
1

pan

drain

plug
m

3 0 kg m
22 ft lb

Using Tool

1
Air conditioner compressor

install oil

and

3

the bolts

and power steering

viscosity
gasoline

Remove oil pan drain plug and oil

fiUer cap and allow oil to drain

the alterna

bar until the belt tension is within the

specified
securely

middle

milky oil indicates the presence
cooling water Isolate the cause

and take corrective measure

engine and warm up engine
temperature indicator

water

points to the
stop engine

Fan and alternator belt
I

FILTER

remove

oil fIlter

01

011 pump belts
Loosen the idler

2
belt

Adjust

the

tension is

pulley lock

adjusting

nut

bolt until the

within the

specified

amount

3

Tighten
securely

the idler

puUey

lock nut
E0036

SLC028

MA 7

Engine Maintenance

Wipe oil

5

with

MAINTENANCE

fIlter mounting surface

clean rag
6
Smear a little engine oil
gasket of new fIlter

When

a

ear
on

on

a

checking

on level

park the

level surface

W

rubber

F

v

O

SMA163

3

Drain coolant

flush

SMA010

4

completely

Then

cooling system

Close drain cock and

plug

5

Fill radiator with coolant up to
fIller opening observing instructions
7

Install

tighten
to tighten
8

oil

new

ONLY

mixing ratio of anti freeze

engine with new
mended engine oil referring

Cooling
recom

9 5

to RE

COMMENDED LUBRICANTS

6

COOLANT

qtl

Run

engine for

a

few minutes If

necessary add coolant

Capacity
WARNING
To BVoid the danger
scalded never attempt

lite4 3 8 US qt

5 8Imp qt
3
Without oil filter
lite4

3 8 Imp

capacity

lite 10 US qt

3 8 Imp
8

With oil filter

3 9

water

CHANGING ENGINE

Check oil level with dipstick

41

to water

the filter

Refill

Oil

attached to anti freeze container for

Hand

fIlter

DO NOT use a wrench

the coolant when the

7

of
to

being
change

engine

When

changing engine
equipped model

heater
TEMP

control lever at

Fill reservoir tank with coolant up
level

MAX

is hot
I

8 US qt
1

qt

to

coolant

on

heater

set

HOT

fully

position
I

Open drain

cock

at

bottom of

t

radiator and remove radiator cap

r

l

ild
rl

E0038

1

1xrC
Iv

rli

t III il
1

I

9

Start engine Check area around
plug and oil fIlter for any sign of

drain

I

8

4

CS015

CHECKING DiGINE
COMPRESSION PRESSURE

Run engine until it reaches oper
ating temperature Then turn it off
level If necessary add engine oil
8
MA

sign ofleakage

ll

10

Check oil

Install radiator cap

Check drain valve and plug for any

LOOSEN

oil leakage
Ifany leakage is evident these parts
have not been properly installed

and wait several minutes

CS021

2

Remove cylinder block drain plug
located at left rear of cylinder block

I
Warm up engine until water tem
perature indicator points to the middle
of gauge

MAINTENANCE
Remove au spark plugs
side for California models
2
3
at

4

on

one

Engine Maintenance

SPARK PLUG

IGNITION AND
FUEL SYSTEM

Resistor

Disconnect all harness connectors
Standard

REPLACING SPARK PLUGS

injector

Properly attach
spark plug

tester to

compression

a

hole in

cylinder

I

Disconnect

boot Do not

being tested

plug

spark

pull

the

o

built iJl

type
wire

at

wires

Standard

BP6ES

BPR6ES

BPSES

BPRSES

BP7 ES

BPR7ES

type
OK

N G
Hot

type

Cold type

4

Install

new

high

connect

All cable
their
SMAO

original

spark plugs

and

re

tension cables
are

marked

to

identify

locations

1 7

8MA042

iYJ

Spark plug
15

20 N
2 0

1 5
11
S

Depress accelerator pedal

to

open

throttle valve fully
6

Crank

engine and read gauge indi

2

Remove

spark plugs

with

m

kg m

14 ft Ibl

spark

plug wrench

cation

engine at about 350 rpm
Engine compression measurement
should be made as quickly as possi
Run

CHECKING IGNITION
WIRING

Visually check wiring for cracks
damaged and burned terminals
2
Using an ohmmeter measure the
I

ble
Compression pressure
kPa

kg

ps at rpm

em

resistance between

Standard

cable tenninal

on

the spark plug side and corresponding

1 177

12 0

171

350

electrode inside cap

Minimum

883 9 0 1281 350
in

cylinders

should not be less than 80

of the

7

Cylinder compression

highest reading
If cylinder compression
more

cylinders

is low

in one or

pour

a

small

quantity of engine oil into cylinders
through the spark plug holes and retest
compression
If

pressure

piston rings

Using feeler
spark plug gap

helps

the

chances

are worn

If pressure stays low

or

gauge

If it is not within
set gap

adding oil

sion

3

by bending

check

specified

new

range

Resistance

side ele trode

Less than 30 000 ohms
SMA 166

compres
are

that

damaged

valve may be

sticking or seating improperly
cylinder compression in any two
adjacent cylinders i low and if
adding oil doe not help the com
pression there is leakage past the
gasketed surface
If

Side electrode
Gap

08

0 9 mm

10 03t

0 035

1

if

sistanee

to

check

for

re

intermittent

brake

3

If the resistance is

limit

remove

cable

more

from

than the
cap

and

check the cable resistance only
If resistance is still more than the

Oil and water in combustion cham
bers can result from this problem

Shake the wire while measuring

SMA019

limit replace cable assembly
MA 9

Engine Maintenance

MAINTENANCE

ADJUSTlNGIDLERPM

Efl

ilrness cOiriecti ri

WARNING

Vacuum hoses

ADJUSTING IGNITION
TIMING AND
CHECKING MIXTURE RATIO
Non California models

Air intako system
etc
level gauge
Connect

2

a

Oil filler cap oil

ter

engine tacho

3

mode s

and

reanvheels

are

in

matic

checks should be carried out

whilo tho oi conditioner is

good order

Battery

ift lever is in

out while s

and

on

transmission

auto

equipped
that shift

modelsimake
P position
or
to pre
brake
pedal
depress

lever is in

equip

checks should be carried

peel modols

Ignition system

OFF

On automatic transmiuion

4

parking

with chocks

racing engine

b When

equipped

conditioner

apply

sure

Mako sure thauhofollowing parts

1

air

On

position

0

brake and block both front and

timing light in dieir proper pOsitions

Preparation

WIlen selector lever is shifted to

N

vent forward

O position

c

After tha

8of car
SUI
adjustment has been

made shift thelever
or

wheel

P

position
chocks

to the

and

N

remove

Maintenance procaclure
START

Start engine and wann up engine until water
temperature indicator points to the middle
of gauge

Open engine hood
Run engine at about 2 000
2

undet

1 Run engine

at

Di

E

for abou

load

no

idle speed

For Canada

I

rpm

I

For U S A

nnect

hose from air induction pipe

and amtall proper cap

on

air induction pipe

t

Race engine two or three times under no
load
Then run engine for one minute at idle

speed

Check idle speed
lransmiRion

M nuai

t
7oo

100 tpm

Autom ic
w
700

Transmission

100 rpm in

D

j

OK

I
YES

I
I

Adjust

MA l0

N

G

idle SPeed by turning idle opeed

adjusting

screw

j

b this maintenance operation at 1 600 km
1 000 miles service or rechecking idle
CO

INO

b

position

@

I
g@

MAINTENANCE

Engine Maintenance

@@

i

of

Check

t

ning
ir

20 B T D C

f

8

ing with

ignition ti

N

O K

f
1

G

r
ut
Adjust ignition timin g by turn g ditri
after loosening bolts which secure distributor

I

SMA059

I

Race erigine two

I

load then

r
a

When

measuring

into tail pipe
b

Use

CO

CO

iniert probe

I

1

or

three times under

engine

with

CO

00

idle speed

meter

If

1

t
3

than

OK

I Turn off engine and connect air induction
rhose to air induction pipe

at high
adjusting idle CO
altitude adjust to obtain following

When

Adjust CO
on

Unit

Altitude
600

t 200

2 000

4 000

1

200

1

4

000

6 000

Above

1 800

800

m

fdte 00
Race engine two or three times under
load then run engine at idle speed

2 7

by turning air by pass

adjusting

CO

remove

no

screw

blind plug

from air by pass screw
After adjustment install the plug
flow meter

Start engine

ft

SMA061

air flow meter

When

i

valua

on

air

r

3 8

I
5

0

Check idle speed
M

6 000
L

at

J

4 m 16 in
0
meter alter engine is fully
more

warmed up
e

CO

Check

Note

run

J

nu

1

Transmission
t
700

100 rpm

Automatic Tr nsmission
7

1

100 rpm

in

0

OK

position

I

N G

I

r

Adjust idle speed by turning
justing screw

SMA263
idle

speed

ad

L
l

END

MA ll

i
ntIine

M itit

MAINTENANCE

ance

ADJUSTING IDLE RPM
California models

WARNING
When selector lever is shifted to

a

0

Preparation
1
els

On air conditioner
checks

should

equiPPed

be

carried

while the air conditioner is
2

On automatic

ped models
out while

position

apply

parking

brake and block both front and
fear wheels with chocks

mod
out

b Whe

OFF

transmission

Ou position

on

transmission

models

equip

make

equipped

lever is in

N

depress

brake

vent

forward surge of car

After

c

the

or

auto

that shift

sure

and

checks should be carried

shift lever is in

racing engine

matic

P

position

pedal

adjlUtrDent

to pre

has been

made shift the lever to the
P

or

wheel

and

position

N

remove

chockS

Intenailce procedure

START

1
Start engine and warm up engine until water
temperature indicatQf points to the middle
of gauge

j
Open engine hood
Run engine about 2 000
2 minutes undeJ

rpm

8

SMA020

for about

load
no
SMA022

1
Run eDsine at Idle speed

1
Check idle speed
Maal
700

Bnsmiaion
Tl

100 rpm

Automatic Transmission
700

O

f

1

rpm

Un

D

position

I

dj

st idle

K

tG
IJg
JustJ

screw

1
END

MA 12

f

speed by turning idle speed ad

SMA263

I

MAINTENANCE
CHECKING

FUEL LINES

piping

Hoses

Engine Maintenance

connections

Fuel return pipe

etc

I
Check fuel line for leaks particu
larly around connection of fuel pipe

l

and fuel hose

Retighten loose connections and
replace any damaged or defonned
2

To

el tank

Fuel

pipe

rFue

parts

rbm f

fuel tan

damper

t

Fuel

Fuel pipe

pump

l

r

tr

btor

J

J

Jf 1j
W

Injector

W

W

SMA062

SMA034

CAUTION
fuel hose

after

clamp

a

00 not

b

loosening
Tighten high pressure rubber hose
clamp so that clamp end is 3 mm

reuse

from hose end

0 12 in

wider than other

portions

position
of clamp is flush With hose end
Tightening torque specifications
are

Same

the

for all

1
fl

screw

or

rubber

hose

J

tightening

ose

tact with

clamp

come

into

The fuel fIlter is

m
kg

1 1 ft Ibl

E F976

E F336A

I

con

2
ness

designed especially

Disconnect fuel pump

relay 2 har

connector with

runnin

engine

Relay bracket

with the EFI systerri It should

be replaced

as an

Follow the

I

m

0 15

adjacent parts

REPLACING FUEL
FILTER

use

07

8n ure

procedure

3

After

nect fuel pump

Unfasten

I

con

2 hamess connec

clamps

securing

fuel

fuel fIlter and disconnect fuel hoses
careful

engine

fuel hose release

lrtment
comP

not

to spill fuel over
Place

a

rag to ab

so b fuel

fuel pressure from fuel line to elimi

danger

relay

the

hoses to the outlet and inlet sides of

zero

Be

nate

crank

engine twice or three times
4
Turn ignition switch off and

2
below to re

CAUTION

disconnecting

stall

engine

tor

assembly

duce fuel pressure to

Before

f

clamps

1 5N

10 10

that screw does not

for

Fuel hose
1 0

clamps
When

3mmlo 12inl

SEF131

Start the engine
MA 13

Engine Maintenanpe
3

MAINTENANCE

Remove fuel mter

Remove

3

remove

air

cleaner

cover

and

Remove air induction valve case
from air cleaner and take out air in
duction valve fIlter Then instaIl new

air cleaner ftIter

air induction valve filter
I

When

V

to
so

replacing pay strict attention
which direction the valve i facing

that exhaust gas will not flow back

ward

tJl
SMA264
SMA065

4

To

instaIl fuel mter

reverse

the
4

order of removal

InstaIl air cleaner mter with

mark

UP

J

facing upward

1

REPLACING AIR CLEANER
FILTER
The viscous paper type air cleaner
filter

does

operation

not

require

deaning

any

between renewal

Disengage

air duct

SMA039

CHECKING VAPOR LINES
Check all hoses and fuel tank filler

leaks

cap for
I

I

Dsiconnect the

vapor

connecting carbon
1
SMA063

EMISSION CONTROL
S YSTEM
REPLACING AIR INDUCTION
VALVE FILTER

2

Disengage

Induction
duction

EAt

System

Exhaust

hose from

to

line
fuel

tank
2

Connect

3 way connector

a

manometer and a cock

lent 3 way carge cock
the vent line
3

Air

vent

canister

or an

a

equiva

to the end of

Supply pressure into the vapor
tIuough the cock little by

vent line

air in

little until pressure becomes to the

pipe

below

Leakage

test

3 923 kPa
15 75 in

4

Shut

pressure
400

mmll20

H20

the

cock

completely

and

leave it unattended

r
J

MA 14

SMA036

5

After

height
1

Air

2

induction valve
Air induction valve

3

Air induction valve rdter

4

Air

cleaner

5 minutes
2

of the

liquid

measure

case

Pressure variation
Less then
25

0245 kPe

mmH20

0 98

the

in manometer

inH201

Minor Trouble

MAINTENANCE

IY When
completely
zero

2

in

a

filler cap

3 923 kPII

short time

400

not

it

is the

cause

drop

mmH20

15 75

inH20

to

iller cap is

in a short time when

removed

and Corrections

does not close

the height should drop to

If the height does

zero

Diagnoses

of

a

staCfy

hose

AII

Check valve

Manometer

In case the vent line is stuffy the

Fuel filler cap

breathing in fuel tank is not thorough
thus causing insufficient
ly made
delivery of fuel to engine or vapor
lock

It must therefore be repaired

@

or

1

Carbon canister

replaced

EC091A

MINOR TROUBLE DIAGNOSES AND CORRECTIONS
Condition

Probable

CANNOT CRANK
ENGINE

OR

SLOW

Corrective action

cause

with proper grade oil

Improper grade oil

Replace

Partially discharged battery

Charge battery

Malfunctioning battery

Replace

Loose fan belt

Adjust

Trouble in charging system

Inspect

CRANKING

Wiring connection

on

starting

circuit

Correct

Malfunctioning ignition

switch

Repair

or

replace

Malfunctioning starting

motor

Repair

or

replace

Trouble shooting procedure
Switch

trouble in

on

starting

the starting motor with head

When head

lights

go off or dim

circuit

lights

ON

considerably

a

Check battery

b

Check connection and cable

c

Check starting motor

a

Check wiring connection between battery and starting

Whenhead lights stay bright

motor

b Check ignition switch
c

Check starting motor

MA

15

Minor TrrJUbleDiagnoses end
Correctiops

MAINTENANCE

Condition
ENGINE

WILL

Probable
CRANK

In this case the

NORMALLY

following trouble

Ignition system

BUT

causes

Corrective action

cause

WILL

NOT START

may exist

but in many

cases

ignition system

or

fuel system i1 in trouble

in trouble

Fuel system in troubk
Valve mecluznism does not work

properly

Low compression

procedure
plug fIrstly by following procedure
Disconnect high tension cable from one spark plug and hold it
about 10 mm
39 in from the engine metal part and crank the
0
engine
shooting
Trouble

Check spark

Good

spark

occurs

Check spark

a

plug

b Check ignition timing
Check fuel system
d Check revolution trigger signal
e
Check cylinder compression
c

No spark

Very high

occurs

Check the current flow in primary circuit

current

Inspect primary circuit

for short

Check distributor pick up coil operation
Check IC ignition system
ENGINE CRANKS

NORMALLY
WI

L

OT

Low or

no

cunenL

Check for loose terminal or disconnection in

BUT

5

Ignition system

primary

ART
in

circuit

Check for burned points
distributor pick up coil

Malfunctioning

Replace

trouble

Improper

air gap

Adjust

Leak at rotor cap and rotor

Clean

Malfunctiflning spark plug

Clean adjust plug gap

Improper ignition timing

Adjust

Malfunctioning ignition

Disconnection

connection

primary

circuit

revolution trigger

Malfunctioning
Fuel system

malfunction

or

disconnection

pulse

Repair

or

Damaged electronic fuel injection harness or
relay

Replace

Malfunctioning

Replace

to opera

ting sound

MA 16

Damaged control unit

Replace

Seized injector Usten to operating sound

Replace

Malfunctioning

air flow meter

Replace

Damaged

temp

Repl

sensor

unit

Replace
Supply

water

replace

replace

Replace IC ignition

Lack of fuel

Usten

or

Replace
41

IC ignition unit

fuel pump

replace

Replace

of high tension cable

Loose

Irregnlar

coil

or

ce

For inspection procedures for
electronic fuel injection sys
tern

components refer
Engine Fuel section

to

MAINTENANCE

Probable

Condition
Fuel system

Malfunctioning

malfunction

Dirty fuel f1lter
Dirty

Low

Replace
Clean

fuel tank breather pipe

Repair

Incorrect spark plug tightening

prellion

co

and Corrections

Replace

regulator

pressure

Diagnoses

Corrective action

cause

clogged fuel pipe

or

Clogged

Minor Trouble

or

damaged

and clean

Tightefl to

normal torque

or

replace gasket

gasket
oil

Improper grade engine

or

low viscosity

Incorrect valve clearance

Compression leak from valve
Sticky

Lap valves

seat

Correct

damaged

valve

Sticking

or

head

gasket

or

replace valve and valve guide

Replace gasket
Replace piston rings

defective piston ring

piston ring

or

Replace valve springs

springs

Compression leak at cylinder

Worn

Adjust

valve stem

Weak or

Replace with proper grade oil

Overhaul engine

cylinder

Trouble shooting procedure
Pour the

engine oil from plug hole and then
cylinder compression
Compression

measure

increases

Compression does

not

Trouble in cylinder

or

piston ring

Compression leaks from valve cylinder head
or head gasket

change

UNSTABLE
ENGINE

IDLING

Ignition system
in trouble

Engine

mechanical

Malfunctioning ignition system spark plug
high tension cable distributor IC ignition
unit ignition coil etc

Replace

Incorrect basic ignition timing

Adjust

Loose manifold and

Retighten bolts

cylinder

system in trouble

Incorrect valve clearance

Fuel system

Clogged

malfunction

Incorrect idle

head bolts

air cleaner f1lter

adjustme nt

Adjust
Replace

f1lte

Adjust

Damaged manifold gaskets

Replace gasket

Intake air leakage at

Repair

following points

or

replace

Dipstick
Oil filler cap
Blow by hoses
Intake air duct air flow meter to throttle
chamber etc

MA 17

Minor Trouble

MAINTE

DiagnolJts and Correctiom

Condition
Fuel system
malfunction

Probable

ANCE

Corrective action

cause

Damaged electronic fuel injection harness

Replace

sound

Replace

Seized injector Usten to operating

Malfunctioning
up

air

regulator During

warm

Damaged

Irregular fuel

electronic fuel

Replace
temp

compo
nents refer to

Engine
Repair

or

Replace

pressure

sys

tern

Replace

sensor

throttle valve switch

Low compression

IDLE

Replace

injection
unit

water and air

Malfunctioning

HIGH

inspection
procedures for

driving only

Damaged control

Others

For

replace

pressure

Fuel

Section

regulator

Previously mentioned

Malfunctioning

P C V valve

Check

Malfunctioning

E G R control system

COrrect

replace

or

or

replace

ENGINE
SPEED

Fuel system

Incorrect

malfunction

screw

adjustment

Malfunctioning

air

of idle speed

adjusting

regulator

Correct

Replace
For inspection procedures for air

regulator

refer to Engine Fuel section
Others

Throttle valve is opened

excessively

at

idle

IC D
F

Malfunctioning

Replace

Dragged accelerator linkage

Malfunctioning
VC V

Vacuum

Replace throttle chamber

Check and correct accelerator
Control

Valve

linkage

Check or replace if necessary

ENGINE POWER
BELOW NORMAL

Low compression

Ignition system
trouble

Fuel system
malfunction

in

Previously
Incorrect ignition timing

Adjust

Malfunctioning spark plugs

Clean adjust

Malfunctioning

Replace

distributor pick up coil

Throttle valve does not open

fully

or

replace plugs

Adjust

For

inspection proce

Damaged electronic fuel injection harness

Replace

dures

Seized injector Usten to operating sound

Replace

fuel

Malfunctioning

air flow meter

Replace

Malfunctioning

throttle valve switch

Repair

Irregular

MA 18

mentioned

fuel pressure

or

pressure

if necessary

fuel pipe

Replace

Dirty

clogged fuel ftIter

Replace

Fuel pwnp will not work properly

Replace

or

electronic

replace

Replace

Clogged

for

injection system
components refer to
Engine Fuel Section

regulator

if necessary

MAINTENANCE

Probable

Condition
Air intake system

Clogged

malfunction

Air

Minor Trouble

Diagnosessnd Corrections

Corrective action

cause

Replace filter

air cleaner filter

Replace gasket

leaking from manifold gasket

Repair

Intake air leakage at following points

or

replace

Dipstick
Oil ftller cap
Blow by hoses
air flow meter to throttle

Intake air duct

chamber
etc

Overheating

Insufficient coolant

Replenish

Loose fari belt

Adjust fan belt

Worn

or

Malfunctioning thermostat

Replace

Malfunctioning water

Replace

Clogged

or

Air in

pump

Flush repair

leaky radiator

Malfunctioning

Incorrect

Replace with

grade

proper

grade oil

Adjust

ignition timing

Malfunctioning

replace

Retighten each part of cooling system

cooling system
oil

or

Replace

radiator ftller cap

Improper engine

Othe

Replace

damaged fan belt

Replace

thermostat

octane fuel

Improper

octane fuel

Replace with specified

Improper

tire

Inflate to specified pressure

pressure

Adjust

Dragging brake

Adjust

Clutch slipping

Malfunctioning

E G R control system

Correct

or

replace

NOISY ENGINE
Car

knocking

Use

Overloaded engine

right gear

Disassemble

Carbon knocking

in

driving

cylinder

head and clean

car

bon

Mechanical

Timing knocking

Adjust ignition timing

Fuel knocking

Use

specified octane

Preignition misusing of spark plug

Use

specified spark plug

fuel

knocking

Crankshaft bearing

This strong dull noise increases when engine

knocking

is accelerated

misfire

by

on

To

each

the misfire

locate the

cylinder
this

place

cause

a

If the noise stops

cylinder generates

the

This is caused by worn or damaged bearings
or unevenly worD crankshaft Renew bear

ings and adjust

or

change crankshaft

Check lubrication system

noise

MA 19

MAINTENANCE

Minor Trouble Diagnoseund Corrections

Condition

Connecting rod
bearing knocking

Probable
This is

a

little higher pitched noise than the

Piston and cylinder

When you hear

noise

which

an

increases

overlapping metallic noise
its

magnitude

with

the

This may

cause an abnonnal wearing of
cylinder and lower compression which in

revolution of engine and which decreases

turn will cause a lower out put power and

engine is wanned up this noise is caused by
piston lUId cylinger To locate the place
cause a misfue on each cylinder

excessive

This

This may

noise

is

heard

place

cause a

This

noise

misfire

at each

on

be

may

damaged bearings
of sliding parts

highest

caused by

by

or

and

To locate the

each cylinder

An improper adjustment

the

worn

uneven

An excessive end

Wear
This

on

clutch

noise

on

or

of valve clearance

crankshaft

be heard

Replace

piston pin

a wear on

or

assembly

water pump with a new one

Adjust
the tension of chmn

Disassemble engine and
Renew

when

cause

piston pin hole

surface

pilot bushing

will

Overhaul engine

Adjust

play

consumption ofoil

Renew piston and piston pin

Noiseoftinringchmn

Others

bearings

this crankshaft bearing

lowest dead end of piston

Others

the case of crankshaft

as

each cylinder and if the noise diminishes

almost completely
generates the noise

Water pump noise

Same

and
also increases
knocking
when engine is accelerated Cause a misfue

crankshaft

on

Piston pin noise

Corrective action

cause

bushing

and

renew

adjust

main

bearing

drive shaft

clutch is

disengaged
ABNORMAL

COMBUSTION

backfire
on
run

after fire

etc

Ignition system
in trouble

Fuel system
malfunction

Improper ignition tinring

Adjust ignition timing

Improper heat range

of spark

Intake air leakage at

following points

plugs

Use

specified spark plugs

Repair

or

replace

Dipstick
Oil f1l1er cap
Blow
by

hoses

Intake air duct air flow meter to throttle
chamber
etc

Damaged electronic fuel injection harness

Damaged

MA 20

control unit

Replace

tern

air flow meter

Replace

Damaged

temp

Replace

sensor

inspection procedures

electronic

Malfunctioning
water

For

Replace

fuel

injection

components
Engine Fuel Section
J

refer

for
sys
to

MAINTENANC E

Condition
Defective cylinder head
etc

Probable

Improperly adjusted

v

valve clearance

alve spring

Adjust

after fire

backfire

E G R control

Malfunctioning

Others

Diagnoses and Corrections

Corrective action

cause

Excess carbon in combustion chamber

Damaged

Minor Trouble

system

Remove head and

Replace

get rid of carbon

it with a new one

Correct or

replace

EXCESSIVE OIL
CONSUMPTION

Oil

leakage

Loose oil drain plug

Tighten

Loose

or

damaged

oil pan gasket

Renew

gasket

or

tighten

it

Loose

or

damaged

chain

Renew

gaskei

or

tighten

it

oil

Damaged

seal

cover

gasket

front

and

in

rear of

it

Renew oil seal

crankshaft
Lo

e or

damaged

rocker

cover

gasket

Renew

gasket

or

it

tighten

but not too

much

Improper tightening of oil

fIlter

Renew

it with the proper

gasket and tighten

torque
Loose
I

or

damaged

oil pressure switch

Renew oil pressure switch

or

tighten

it

I

Cylinder

and

piston

Overhaul cylinder and

wear

Improper location of piston ring

or

reversely

Remount

renew

piston

piston rings

assembled piston ring
Renew

Damaged piston rings

rings

Repair
Worn

Others

POOR

piston ring

groove and

ring

r

Renew

renew

piston and cylinder

piston and piston ring

Fatigue ofvalve oil seal lip

Replace seal lip with

Worn valve stem

Renew valve or

Inadequate quality of engine oil

Use the designated oil

Engine overheat

Previously mentioned

a new one

guide

FUEL

ECONOMY

Engine

Previously mentioned

power

below normal

Fuel system
malfunction

it to the

Exceeding idling revolution

Adjust

Fuel leakage from fuel line

Repair replace
fuel pipes

Damaged

electronic fuel injection harness

Replace

Damaged

control unit

Replace

Malfunctioning

Damaged

air flow meter

air temperature sensor

Replace
Replace

For

designated
or

tighten the connection of

inspection

electronic
tern

rpm

fuel

procedures
injection

components

refer

for
sys
to

Engine Fuel Section

Malfunctioning throttle valve switch

Replace

Irregular fuel pressure

Replace pressure regulator if necessary

MA 21

Minor Trouble

MAINTENANCE

Diagnoses and Correctiom

Condition
TROUBLE

IN

Probable

Corrective action

cause

OTHER

FUNCTIONS

Decreased oil pressure

Inadequate

oil

Use the designated oil

quality

Overheat

Previously mentioned

Malfunctioning oil

pump

regulator valve

Disassemble oil pump and repair

Functional deterioration ofoil pump

Repair

Blocked oil f1lter

Renew it

Increased clearance in various

sliding parts

replace

or

Disassemble and

it with a new

replace

the

or renew

it

ne

worn

parts with

new ones

Excessive wear on the

sliding parts

Blocked oil strainer

Clean it

Malfunctioning

Replace

o

gauge pressure switch

Oil pressure decreases

Damaged quality

or

contamination of oil

it

with

a new one

Previously mentioned
the

Exchange

oil

with

proper

one

change element
Air

leakage

from air intake duct

Damaged

air cleaner

Overheat

or

overcoat

Improper fuel
Scuffing of sliding
parts

Change

or

replace

element

Previously mentioned
Check the fuel system

Decrease ofoil pressure

Previously mentioned

Insufficient clearances

Readjust

Overheat

Previously

Improper

MA 22

mixture

Repair

fuel mixture

to lIie designated clearances

mentioned

Check the fuel system

and

MAINTENANCE

Chassis and

Body Mainwnance

CHASSIS AND BODY MAINTENANCE
ENGINE CONTROL
FUEL AND EXHAUST
SYSTEMS

I

SYSTEM

stopper Then tighten lock nut

Check clutch system for proper at
tachment leaks chafing abrasion de
terioration

CHECKING FUEL AND
EXHAUST

CHECKING CLUTCH

Adjust pedal

Adjust pedal

2

height

pedal

with

free play with master
Then tighten lock

cylinder push rod
nut

etc

8

SYSTEM

Pedal free play means the following
total measured at position of pedal

Check fuel and exhaust systems for
condition connections and leaks

pad

Play

clevis pin
in pedal lever

due to

pin hole

Fuel system

Play

@j

and clevis

due to piston and piston

rod
b

nd

Depress

release

clutch pedal

over its entire stroke to ensure that

@
J

the clutch

ly

SMA101

smooth

linkage operates

without

squeak

noise

inter

ference and binding

MANUAL
TRANSMISSION

SMA034

CHECKING CLUTCH PEDAL
Exhaust system

HEIGHT AND FREE PLAY
Check clutch

play Adjust

Master

pedal height

CHECKING MANUAL
TRANSMISSION OIL LEVEL

and free

if necessary

Neyer

start

engine

while checking

oilleyel

ff

cylinde push rod
Pedal stopper

@

itner plug

r1

SMA 147

w

lotf

iLl

8

51

8

71

fl7 8
10

8

5 8

2 5

11 8

8

A

N

m

kg

m

Pedal height
168

J

5

Fill to this level
SMA 1 03

ft lb

completely

SMA102

H

174 mm

mm

Drain oil

H

Padal free play
SMA1QO

m

Ibl

TRANSMISSION OIL
I

FIOor
j
fl

kg

71

InSU1ator

level

35
25 ft

CHANGING MANUAL

CHECKING CLUTCH FLUID
LEVEL AND LEAKS

MAX

18

1 2

h

Add to

S

Lock nut

111
CLUTCH

4f

0 04

6 61

6 85 in

A

020 in

SMA104

MA 23

Chassis and Body Maintenance

MAINTENANCE

Refill transmission and check oil

2

level

CHECKING DIFFEREN11AL
CARRIER OIL LEVEL

CHECKINGAUTOMAnC
TRANSMISSION FLUID
CONDITION
Check fluid for contamination to
determine

the frictional

band

clutches

automatic

If fluid is very dark

smells burned

placemen

of

condition

transmission

etc

may

or

material
need

reo

t

Fill to this level
25ft lb

S MA10B

Oil capacity

CHANGING DIFFERENTIAL
CARRIER OIL

2 0 liten 41 4 USJit
31 2 Imp pt

Drain oil

I

CV

Oleck fluid for contamination

59
6

completely

98 N

10

m

72ft

m
kg

blL
AUTOMATIC

TRANSMISSIQN
CHECKING AUTOMATIC
TRANSMISSION FLUID

LEVEL
i

Place

selector

lever

in

W

I

Check under following conditions

I

Check fluid for smell

P

pARK position and idle engine
2

2

Maintain fluid temperature at 50

to80DC
2

SMA109

SMA107

Refill

differential

carrier

and

check oil level

122 to 176DF

Add oil if necessary
Use

fluid

only
having

tions

in

automatic
OEXRON

3N71B

transmission

identifica

automatic

trans

ER SHAFT
PROPELI

iSlion

AND DIFFERENTIAL
CAR IER
cv
CHECKING PROPELLER

Q

SHAFT

J

Check

propeller

shaft

replace

59

98 N

m

6

101qjm

43

lb
72ft

SMA11Q

if
Oil capacity

necessary

1 1liten 2
2 Imp pt

3 US pt
8

FRONT AXLE AND
FRONT SUSPENSION
Add to H level
Do not overfill

CHECKING FRONT AXLE
AND SUSPENSION PARTS
Oteek tube surfaces
fOJ denu or cracks

SMA106

MA 24

SMA231

Oleck tightening torque

I

Block

rear wheels

with chock and

raise front of car and then

with

safety

stand

support it

Refer to

lifting

MAINTENANCE
Points and Towing Section GI

4

2

grease

Shake each front wheel by hold
ing upper and lower surfaces of tires as
shown

Check

suspension ball joint for
ball joint dust cover

Chsssis and Body Maintensnce

Threaded portion of spindle

leakage and

Contact

for damage

surface

between

bearing washer and

wheel

outer

wheel

bearing
Hub hub cap and O ring
Grease seal lip

dl

nng

SMA111

Multi purpose
grease

Check suspension parts for loose
ness

wear or

Retighten

5

damage
all

loose

6
nuts

and bolts

or

to the

specified torque Refer to Sec
tion FA for tightening torque
Replace all worn parts as described
under Front Suspension Section FA

SMAl16

Remove wheel and tire assembly
Check front axle parts for crack

damage
Replace

worn

parts

Refer to Front Axle Section FA
7

3

Remove brake pads
Refer to section BR

8

Check wheel

point

Tighten wheel bearing
J 25
i

bearing

12 5
18

If there is any axial end play or if
wheel bearing does not smoothly turn

29N

nut

m

3 0 kg

m

lbl
22ft

adjust bearing to specifications
Replace worn or damaged bearings
Refer

to

Front Axle

Section FA

o
Strut upper end

SMAT17

4

Turn wheel hub several times in

both directions

to

seat wheel

bearing

correctly
SMAllS

3

oil

Check strut

leakage

or

Shock absorber

damage

for

ADjUSTING

WHEEL

BEARING PRELOAD
After wheel

placed

or

assembled

bearing
front axle

be

bearing preload

J

I

Before

sure
as

to

has been
has

Apply

pose grease

parts

reo
reo

adjust wheel

SMAllS

described below

adjustment

clean all parts to prevent
try of dirt
2

been

thoroughly
possible en

recommended

sparingly

to the

multi pur

following
5

Again tighten wheel bearing

nut

MA 25

MAINTENANCE

ChassiundBodyMainl11nance
6
in

Turn back wheel

bearing nut

with

9

In
Toe

otterpin

Spread

600
Measure toe in and make necessary
Use the following pro

adjustments

cedure when

making adjustments

I

Raise front of car and mark a base

line

across

the tread of left and right

wheels

Base line
F

Tumbac kA

Within600

SMA119

10

7

Fit adjusting cap and

A265

new

Install hub cap with

new

O ring

cotter

pin

SMA123

CHECKING WHEEL

2

ALIGN MENT

position

Set

3

Before

checking

be

ment

sure

to make a

sary

inspection of all front end parts

parallel

center line of

play
Suspension ball joint
Steering gear housing looseness

a

straight ahead
neces

adjustments

lines

Tire pressure
Wheel bearing axial

in

Measure toe in and make

front wheel

align
preliminary

wheels

and then lower front of car

to

body

at

frame

Steering linkage
8

Measure

wheel

bearing preload

and axial play

and connections

Shock absorber oparation

Tighten

each front axle and suspen

sion pam

Measure

car

height

when

not

loaded

Repair
tion

Toein

replace the damaged por
parts
or

or

o

2

Unladen
mm

12

Sid

slip

Out 1

900
Axial

1 b
Wh

new

at

14 7 N

10 7

1 5 kg

tion are preset at the
not be
1 5

3

31bl

If

US8 t parts

20

0 8 kg 0 4

n

datal

1 mmlm
In 0 012 in ftl

king pin inclina
factory and can

Toe in can be

the

length

adjusted by varying

of steering side rods

adjusted
camber

caster

clination alignment is

7B N

2
10

Reference

mm

Out 0 012 in

and kingopln

Camber caster and

1 hub bolt

parts

69

With

wh

O OS inl

inclination

ring prelo

As measured
With

Camber caster

0 mm 0 in

play

O

On both sides

0

or

king pin

not within

in

speci

fications check pertinent parts

1 8 Ib
SMA121

Repair

or

replace

as

necessary

Camber
40

50

Caster

1045

Repeat
rect

above

procedures

starting torque

MA 26

until

is obtained

cor

315

Kingpin inclination
7025

SOSS

SMA265

Chassis and Body Maintenance

MAINTENANCE
stopper pin of turning
radius gauge and then fully rotate
steering wheel to the right and left
2

Unladen
Fuel tank

radiator and engine oil

tank all full

Spare tire jack hand tools mats in
position
All tires inflated to specified pres

Turning angle

Remove

turning angle on inner wheel
make
and
necessary adjustments
measure

automatically be

ing angle

of outer wheel will
set

by adjusting

of inner wheel to

turn

specified

values

After adjustment

3

lock adjusting

lock nut

sure

All accumulation of mud

dirt and

road deposits removed from chassis
and underbody
If side rods have been disassembled
set the distance between lock nuts to
the

A

value

specified

to

prior

reo

assembling
FA632

REAR AXLE AND
REAR SUSPENSION
Front wheel turning
JJ

Toe
200

ut turns

Outer wheel
Sid

length

red

71 0 mm

Full turns

An

12 795 in

dels

wheel

147 N
Lock side rod bar lock nut
ball

On power steering

turning

joint

with

on

outer

respect

to

that

so

socket is 770

that

on

engine

at

10

CHECKING REAR AXLE
AND SUSPENSION PARTS

18 70

force

at

mo

cir

cumference of steering wheell of 98

ssn05

a

angle

When inner wheel

15 kg 22

33 Ib with

Inner wheel 330

rear

axle

parts for looseness

and

wear or

Retighten all loose
to the

specified

torque

suspension
damage

nuts and bolts

Refer

to

Sec

tion RA for

idle

Outer wheel 270

Check

350
290

tightening torque
Replace aU worn parts as instructed
under Rear Suspension Section RA

inner

socket
b

Make

that

sure

adjusting

bar

is

screwed in eam socket at least 25
mm

4

Check tightening torque

0 98 in

After correct toe in has been ob

tained tighten side rod bar lock nuts

Iil

78

98 N

8 0
58

m

10 0 kg

m

72 ft lb

Front wheel turning engle
I

Set wheels in straight ahead posi

tion and then move car foward until

front
gauge

wheels

rest

on

turn ng radius

properly

SMA129

MA 27

OIl1Sfisand Body Maintenance

MAINTENANCE

BRAKE SYSTEM

2

CIieck brake

3

Check for leaks

fluidleve

Pad

wear

liniit

CHECKING BRAKE FLUID
LEVEL AND LEAKS

1

CHECKING BRAKE BOOSTER
Add to

MAX

ll

VACUUM HOSES

level

coNNECTIONS

AND

I

A

TT

CHECK VALVE
PIId war limit tAt

1

Check condition of vacuum hoses

and connections

2

Check

vacuum

N22

2 mm 0 08 in

AN12H

2

mm

0 08 in

hoses and check

valve for air tightness

SMA266

pad

Section BR for

Refer to
SMA 130

re

placement
Rotor repair limit

If

fluid

level

i

extremely

low

check brake system for leaks

CHANGING BRAKE FLUID
I

SMA 125

Change brake fluid
Use

ing
Thi

procedure

same

to

IS

in air bleed

brake fluid in

change
ystem
operation should be done for one

wheel at a time Refer to Section BR

CHECKING BRAKE SYSTEM
I

Check

attachment

brake system fr proper
leaks chafmg abrasion

ROtor

deterioration etc
CAUTION
Never

10 5 mm

AN12H

8 6 mm

10 413 in
339 in
0
SMA267

brake fluid

reuse

because its

characteristic

is

chang2d by

tion

as

contains the

as

repair limit B

N22

well

oxidiza

foreign

CHECKING FOOT BRAKE

material and dirt

1

Check brake pedal free height and

free

play

Adjust if necessary
Brake b

t
CHECKING DISC BRAKE
I

Check

condition

of

disc brake

i

j

1

components

P

hl

0

SMA 133

Ck nut

l12

15

11 2
9

1 5

11

Lock nut

1I

1 16 22
2 12
6
1

16

I

Insulator

Air bleed valve

l6

9

O7
5 1
SMA131

MA 28

8 N
O

m

9kg

6 5ft lb

Refill until

new

3

fluid appears

beck pads for
SMA134

wear

X

Oteck caliper
operation and
inspect for

Floor

h

leaks
SMA140

l

N

m

kgm Ct tb

Chassis and Body Maintenance

MAINTENANCE

155

161

Pedal free
1

6 34 in

6 10

mm

play

stroke in

line at center of grip

Adjust

free

pedal

height

I

nut
free

Adjust pedal

play with brake
tighten lock

n
L

Then

booster input rod
nut

90

play

measured

total

mean

of

120 kg

I

100

WH024

3 94

0

0

mm

nl
7

SMA 142

8

2

pebbles

Remove

glass

any

or

in
other foreign material embedded

pad
Play due
hole in

Play
2

tread

t

l

Number of notches

pedal

Tire

I

3 54

the following

position

at

indicator

1

Lever stroke

Pedal free

wear

44 Ib

with

Then tighten lock

brake lamp switch

Tread

Pulling force

0 20 in

196N

1

straight

a

a

0 04

5 mm

Measure lever

h

height

Pedal free

to

clevis pin and clevis pin

pedal

lever

tire treads
Use

2

adjuster

to

adjust lever stroke

due to piston and piston rod

pedal

brake

Check

3

Check

tread and

cracks holes

separation

damage

or

Check tire valves for air leakage

4

depressed

side walls for

height
I

Tire Inflation
I

I

I
Lock

Check tire pressure If necessary
it to the specified value indi

adjust

t

fiU

cated in the label attached to the

d
v

also

found

in

Manual

Owner s

car
or

SMA143

S D S
Tire

DeprltSSllKl height

Mor

ln
thi

60

mm

2 36 in

SMA141

3
Bend parking brake warning lamp
switch plate down so that brake warn

ing light
If

depressed height i

below

specified value check brake system
leaks accumulation of a r or any

the

parking

on

comes

when ratchet

brake lever is moved back

be

at

notch and goes out when returned to

ab

its

easured

J

one

for

original

pressure should

when tire is cold

rireinflation

I

positi
on

pressure label

l

normality regarding component parb
master cylinder adju ier etc I and

make

the necessary

repain

WHEEL AND TIRE

I

CHECKING TIRE CONDITION
SMA268

Tire condition
1

Tires

tire

CHECKING PARKING BRAKE
I

Pull lever with

of force

specified

amount

are

provided

1 16

in tread

at

tread

six

depth

new

ones

2

After inflating tires valves should

When tires wear

be checked for leakage Whenever tire
pressure is checked be sure to tighten

them

valve caps firmly by hand to keep dust

and then marks appear
with

with

places around
circumference indicating 1 6 mm
indicator

wear

replace

and water

out

MA 29

MAINTENANCE

ChaS3is and BodyMainrenanaJ

Abnormal tire

wear

Radial tires
Correct

cording

abnormal

tire

ac

wear

Right

the chart shown below

to

front

Right

c
Probable

Condition

sides

Measure and

both

one

1

1
J

Repair

Left front

or

replace

Left

4

rear

WHEELS

axle and suspension

wear

SMA126

parts

1

1111

allll

side

lc
c
l

adjust

plessure

ar

Incorrect wheel camber

i

@

Corrective action

cause

Underinflation

rear

l
c

j ll

speed

Hard cornering

Reduce

Lack of rotation

Rotate tires

TIRE REPLACEMENT
Shoulder

wear

Measure and

Overinflation

CAUTION

adjust

Different types of tires Rich

pressure

If

lack of rotation

Rotate tires

may

Ii

ii ii

bias

Mind use of different types of tiies
can adversely affect car handling and

t

I

es

S murt not
tirl
bias belted and radial
be mixed under any cinumstances

cause

driver to lose control
i

I

When replacing

a

Center

wear

tire

Adjust

Incorrect toe

Feathered edge

toe in

j
l

Ii
I

Ii
t

1i
I
I

I

I

size and load carrying

ty

that with which the car WIS

as

load

different

Toein

l

b

or

out
toe

a

Do

wear

caster

replace
axle and suspension

Malfunctioning suspen

parts
Repair replace

sion

necessary reinstall

Unbalanced wheel

Balance

Repair

or

l

il

Ij m
1

I

Iij

or

11

I

I

lf
Out

I

f

1

serious accident

round brake

if

or

or

or

or

recommended
of

the

affect

ground

tire clearance

the

or

of diffarent

tires

ad

can

braking
body

ride

clearance

and sp et
tom8ter

calibration
It it recommended that new tires be

c

Rotate tires

Lack of rotation

or

and wheels other

1ead patterns

handling

replace

dons

wear

use

brands

to

Correct

and do

of different brandt

those

mixed

versely

drum

ll

mix tire

than

replace
Correct or replace

Other mechanical condi
Uneven

tires and wheels other

The use of tire

1

ll

1

Ii

only horten

tread patterns

fIll

j

or

than those recommeooed

lncorrect camber

I

will not

ti

not use

not

H

and

tire service life but may also resuh

I

o

The

size

capacity
in

II

capaci

when manufactUred

i

r

damaged

same

use of

1

worn or

replacement tire of the

a

aquipped

1
II 1

I

use

installed in pain on the same axle

replacing

When

SMA068

should

only

paired

be

one

tire

with the

it

most

tread to equalize braking traction
d

When

replacing original tires with
optional recom

those tires of 8n

TIRE ROTATION
1

Tires tend to

become

often

unevenly

after

Uneven

a

and

certain

tire

wear

results in tire noise which is

attributed to

30
MA

wear

unbalanced

running distance

etc

rear

axle gears

bearing

Front tires also tend

evenly

because of

mended size and of different diam

to wear un

ator

improperly aligned

tha speedometer must ba ra

calibrated

front wheels
2

Accordingly

to

equaliZe

tire

it is necessary to rot8te tires

cally

wear

periodh

To replace

1

safe

manner

Section

GI

a

tire with a

refe

to

jack

in a

lifting Points

for jacking up

Chassis and Body Maintenance

MAINTENANCE

Precautions whenuslng

WARNING

T

Never get under

car

while it is sup

Pe iodically check tire inflation pres
sure and always keep it at 60 psi

ported only by jack
Always use safety stands to support
side member of body construction
when you must get beneath

install wheel

To

nuts in criss

nuts

Align

412 kPa

with bolt

holes in wheel

car

and

evenly tighten nuts
each one a little
at

2

tighten

tire
spa

type

car at

than 80 km h

50 MPH

The

time

a

T type

only

wheel

speed faster

Do not drive

fpr

tire

spare

tempora ry

Dismount it and keep it

cross fashion

as

been

completed
with the

wash

spare

a

as
as a

spare

as

the standard tire repair has

soon

Do not enter into
SMA071

designed

is

use

automatic

an

T type

car

tire

spare

fitted
Do not attach

Tighten wheel nuts evenly

3
a

with

wheel wrench in criss cross fashion

SMA069

tightness
has been

Nn

600 milesl

in cases of

on

a

sharp

turn

or

apply

the brake suddenly while driving

the first 1 000 km

for

tire rotation etc

flat tire

Do not make

the aluminum wheel

also

tire chain

other cars

Be sure to check the wheel nuts for
after

a

Do not use the T type spare tire

As

soon as

with

a

the tread

new

wear

indicator

replace the

visible

becorries

repairing
Retighten

one

Mounting and dismounting

if necessary

tire

and

to

from the road wheel can be carried
out

Wheel nut
To install an aluminum wheel

ceed
I

as

pro

followS

Snugly tighten four

wheel is

nuts

after the

CAUTION
Two types of wheel nuts are used one
is designed for use with steel wheel
and the other for

positioned

in the

same manner

nary tin
Use of wheel balance is

Aluminum whee

use

with aluminum

wheel 00 not mix different types of

If the

car

wheels be

is

equipped

sure

wheel Never
aluminum
For aluminum

For steel

wheels

wheels

only

r

any

ordi

unneces

ary

CAUTION

for steel wheel

wheel nuts

as

with aluminum

to use the
on

us

wheel

wheel nuts

the r typ spare tire
the wheel nuts for
on

the

spare tire

wheel
The spare tire wheel may
axle and cause personal

only

come

injury

off the
if the

wheel nuts for aluminum wheels

C

used

on

are

the spare tire wheel

TIRE REPAIR

J
t

78

18 0
SMA070

58

98 N

m

10 0 kg
72 ft

Inspect

m

SMA234

Ibl

1
Be

careful

not

to

portion of bolt and

Slightly pull the

wheel

back

to

properly align

the nuts with bolt holes

in the wheel

and tighten the nuts

much

as

possible with

your

fingers

as

proce

repair or replace as necessary
Apply soapy solution or submerge

thread

tire and wheel or tube in water after

nut

and seat

inflating it to specified pressure
2
Inspect for leaks
3
Specially inspect for leaks around
valve or wheel rim and along tread
4
Note bead and rim where leakage

TIRE

Size T135 70D16
2

the

smear

of nut with oil or grease

T TYPE SPARE

following

dure shown below If any defect is pre
sent

ed

tire

The T type spare tire is
emergency use only

occurs

designed

The spare tire can be used
for emergency situations

for

area

Wipe

water away

from

any

which leaks air bubbles and then

mark place with chalk

repeatedly

S

Remove

object

p uncture and seal the

which

caused

point
MA 31

MAINTENANCE

Chassis and Body Maintenance

a

When

repairing

B

puncture

tire repair kit furnished
dealer

by

use

8

WARNING

any tire

When

instructions pro

following

bead

vided with kit
b

If

puncture is too

8

damage

lome

6

to

or there

large

tire fabric

might

is

personal injury

repair

tire when

tire

to

ller

Ply

or

Worn

damaged bead

tread separation
fabric damage

wire

and then reinflate it

possibly resulting
sunal

Tires

or

psi

SMA074

If the tira is
LaterIII
S

in serious pl r

runout

A

and

tread

wear

ill

Lea thin
0 mm 10 039 in
1

injury

Aluminum wheel

Lea than
5 mm10 020 in
0

ence between
Diff

indicator
WHEEL INSPEcnON

etc

right and left la
btrel

runout
S

CAUTION
When
n

tire take extra

replacing

t to

tire bead

damage

rim

care

flange

and bead seat

U58

always

tire irons to force beads

wheel

use

tire

whenever tirei

7

Install tire

r

flange
rim

that

replacement

is

device

or

replace as
uy
necess
especially rim

Check wheel rim

flange and bead
tion

might

cracks
cause

for rust

seat

noting the following

air leaks

distor

on

Function

Install

valve

core

aOd

inflate

to

proper pressure CheC the loceting
rings of the tire to be sure they
show

around the

rim

flanges

a

Check valves

flating
c

or

sand from wheel

MA 32

efter

hand

tighten

valve caps

following

Wire brush

steel wool etc

firmly

3

detergent

tight

Wheel balance

Inspect wheel and

tire

for wheel

cloth ole

Examine wheel rim for lateral and

radial runout using dial gauge

taking

the

following points

into consideration
I

in
Neutral

radial runout

Wheel nuts will not stay

present
coarse

or

Air leaks through welds

balance and correct it if unbalance is

Aluminum wheel

tires

Be IUfe to

by

10rleakage

Excessive lateral

good seal

Steel wheel

both sides
b

Elongated bolt holes

Rim bead seets should be ct aned
with the

on

llOB In
O

Replace wheel when any of the
following problems occurs
Bent dented or heavily rusted

of

rim
a

O 02O in
Lea than

4

between tire bead and wheel rim
2
Thoroughly remove rust dust
oxidized rubber

items

I
2mm
0

other faults which

or

tubeless tire depends

moved

Aluminum

maximum tire life If any defect is

as

I
Do not

Lea then
5 mm
0

Inspect wheel taking care of the
following points in order to ensure
satisfactory steering condition as well
present repair

away from

B

rvnout

I wheel

damaged side wall

with

showing

stlinll over

overinflated the bead might break
tubeless

on

tire

Cracked

A

it Never inflate

inflating

pressure greater than 40

a

A

If beads fail to seat It that presRlre
deflate the tire lubricate it again

following

occurs
or

never

B

inflated

275kPa

Discard when any of the
Broken

being

snipS over safety hump it
break Thus to avoid serious

should be carried out by authorized

problems

B

while tire is

Correct

symptom

unbalance

of unbalance

when

wheel tramps and wheel shimmy
2
Balance wheel and tire

statically

end

dynamically

the

appears

as

both

MAINTENANCE
Ianeln

wheels

STEERING SYSTEM

WARNING
When balancing wheel and tire
the

car

be

SlIre

to

CHECKING STEERING GEAR
on

OIL LEVEL AND LEAKS

observe the

equipment manufacturers
tions carefully

instruc

Wheel

Cause

Symptom

static unbalance

Wheel dynamic unbalance

Wheel tramp
Wheel shimmy

of
unbalance
Corrective

Chassis and Body Maintenance

Wheel

Balance statically

Balance

action

Place

balance

shimmy

dynamically

Wheel shimmy

weights here

Check fluid reaks

o

o

Add fluid

SMA604

Wheel
tramp

Place balance

weights
here

o

CHECKING POWER
STEERING FLUID
AND LINES

leavy

I Mter stopping the engine

Location

check

oi11evel in reservoir
Wheel shimmy

Check

dipstick

SMA075

normal
COLD
a

Be

weights
b

on

place

used
steel

one

or

cold

Add recommended oil if necessarY

CAUTION
6f balance

is

temperature

ide when oil i

weights

each side

Two type

ide at

balance

correct

inner edge of rim

Do not put more than two
on

c

to

sur

HOT

on

operating

designed

weight
for

use

wheel and tha other for

are

00

not overfill

with
u

e

with aluminum wheel Do not mix

different types of balance weights
d

Properly
ti

Maximum allowable unbalanCl
rim flange
10 g 0 35
Bal

n

10
at

e

rebalance the wheel and

whenever puncture is repaired

I

at

c

1

UIllIfII

oz

Oil level should
be maintained

weight
35 2 120z
O
6Og
10 35 od interval

10 D

A
SMA076

within this range
SMA12

MA 33

Chassis and Body

2

Inspect

MAINTENANCE

UJJlce
Mainte

line condition and check

for leaks

Check for fluid

leaks
SMA190

CHECKING STEERING GEAR
BOX AND LINKAGE
Steerlna

aeer

box

Check parts for looseness wear or
damage Retighten if neccessary
Refer to Section ST for

tightening

torque

Steerlna Ilnkeae
Check parts for looseness

damag

wear or

Retighten if necessary

Refer to Section ST for tightening
torque
Check ball joints and idler
grease

arm

for

leakage

Check for any missing parts cotter
pins washer etc

34
MA

Q

Ch ck grease leakage

Check tightening torque

SMA 145

MAINTENANCE

Chassis and

Body Maintenance

BODY
LUBRICATING LOCKS

HINGES AND HOOD LATCH

Lubrication points

c

TlI

i

SMA191

CHECKING SEAT BELTS

BUCKLES RETRACTORS

ANCHORS AND ADJUSTER

O1eck retractors for smooth

operation

SMA232

MA 35

MAINTENANCE

is and Body Maintenance
Cha

HEATER AND AlII CONDITIONER
REFRIGERANT LEVEL

CHECKING
doors

Open

L

mum

2

Start the

3

Set air conditioner switch
ON

Set temperature

4

fully

engine

6

position

maxi

to

about five minutes
the

cold position

Judge according to

following table

Set blower to maximum speed
Checlc sight glass after the lapse of

5

to

lever

Amount of

refrigerant

Almost

no

Too much refrigenmt

Suitable

Insufficient

refrigerant

Check item
Almost

Temperature of high pressure
and low pressure lines

no

between

difference

high

side is
and low pressure
side is fairly cold

High pressure

side is
hot and low pressure
side is cold

High pressure side is
abnormally hot

The bubbles

Almost transparent
Bubbles may appear
when engine speed is

No

High

pressure

warm

pressure

and low pressure side
temperature

State in

Bubbles flow continu

sight glass

will

at

Bubbles
disappear am som

ously

seen

are

intervals of 1

2

seconds

bubbles

can

be

seen

raised and lowered

thing like mist will
flow when lIf iglrant

No clear differencr exists betwen thMe

is nearly gone

two

conditions

n

nl

r

High pressure side

system

abnormally

top compnssor im
mediately and con
duct

an

overall

The

glass

are

seen through the sight
bubbl
influenced by tha ambiant

Since the

temperature
hard

to

low

larger

it i

if

comparatively
below
20De
a

lightly

of refrigetant would

upplied aCCOrding to

ight glass

Be

u

to

chock

on

high

pressure sides
are nonnal

low

Both pres ures on high
and low pressure sides
are

abnormally high

Check fot gas leakage

Discharge refrigerant

repaiI alequited re
plenish and charge

from

the amount when it exceeds

68DF

serVice val
e of
low pressure side

b

i

appear
erant

ara

the

When
drier

2DoC

In higher temperatura the

bubble

ere
bubbl

possible that

amount

be filled

36
MA

up in

temperature

68d Fh

the

how

slightly

pressures

and low

system

ch k

a

Both

Both press re on high
and tow pressure sides

is

low

are

Repair

AC258

AC257

AC256

Pressure of

n

I

easy to show up
screen

clogged
en

if the

is normal

in

the

will

of refrig

In this case

the

outlet side pipe of tha raceiver drier
bacome considerebly cold

Engine Maintenance
inspection and adjustment
Refer to

receiver

tha bubble
emount

CHECKING COMPRESSOR
DRIVE BELT
for

MAINTENANCE

Chassis and Body Maintenance

CHECKING HOSES AND
PIPES

111

1

I I lI
Check heater
for

damaged

terference
parts

and

major

air conditioner

if

or

ing parts

possibility

there is the

check

co ressor

pipes If damage

encountering holes
affected parts

especially

adjoining
repair

minor

of

Carefully

Engine

due to in

pipes

is

damage

those affected hose
is

or

friction with

or

If

and

hoses

hoses

replace

and

a

the

o

pipes

thOle located CIOM to moy

Or

I

sharp edge of panel

I

L

Condenser

SMA233

CHECKING REFRIGERANT
LEAKS
Conduct

a

leak test with halide

or

electric leak detector whenever leakage

refrigerant is suspected and when
conducting service operations which
are
accompanied by disassembly or
loosening of connection fittings
of

Sampling
Flame

adjusting

tube

lines

MoIJor check point

I

Compressor
Compressor shaft seal
compressor by hand

rotate the

Flexible hose connections
Front and

rear head

gaskets

Service valve
2

Condenser
SMA150

Condenser pipe fitting
Condenser inlet and outlet pipe
connections
3

Refrigerant lines
Flared section of high pressure and

The

following

information

and

checking for leakage

cautions should be kept in mind when

low pressure flexible hoses
line connections
4

Evaporator housing
Inlet and outlet line connections
Expansion valve
Suction throttle valve

37
MA

MAINTENANCE

Chassis end Body Maint mance
If

a

halide leak detector is used

termine whether

or

not

de

there is gas

leaking by

the color of the flame

as

indicated in the chart below

If a gas leak is detecteil proceed

as

follows
I

Check torque on the connection
fitting and if too loose tighten to the

Propane type

Butane type

torque Oieck for

proper

gas

leakage

with a leak detector
NO

LEAK

Greenish blue

Pale blue

SMALL LEAK

Yellow

Bright blue

LARGE LEAK

Purple

Vivid green

2

If

leakage continues even after
fitting has been retightened dis
charge refrigerant from system discon
nect the
fittings and check it eating
face for damage Always replace even
the

if damage is slight
Che k compressor oil and add oil
3
if required
4

WARNING
a
Never inhale the fumes produced

by

combustion of J

since

they

b Never

use

are

toxic

halide torch in

where combustible
gas is present

38
MA

nt gas

or

a place
explosive

Since
ai
ed

refrigerant

mall leaks

gas is heavier than
be

easily detect
by placing sampling tube direct
can

around connection
sure

le

indication

king

i

noted at and

fittings it is
that refrigerant

and recheck for

ate and

charge

system

OFF SEASON MAl

ly below the check point
If eny trace of oil

Oiarge refrigerant

gas leaks If no leaks are found evacu

a

is

Even in the off season
compressor
once

idling

a

for

month

rpm

10 minutes

ANCE
turn
at

the
least

by running the engine

at

MAINTENANCE

Service Data and Specifications

SERVICE DATA AND SPECIACATIONS
Emission control

ENGINE MAINTENANCE

Unit

INSPECTION AND ADJUSTMENT
Basic

leakage

mm

in

es

mmH20 inH201

kPa

3 923

Supplied pressure

Vapor line

meclanlcal system

Valve clearance

system

Pressure variation

400

751

15

Less than 0 245

25 0

981

Cold

Hot

TIGHTENING TORQUE
Intake

0 30

10 Ot 2

0 2t

10 008

Exhaust

0 30

O Ot 2

0 23

10 0091

N

Unit

Fan

Alternator Air condi

22

t 6

22

12

t6

20

29

20

30

t4

22

8

steering oil pump

t210

Applied pressed force
N

3t

0 47

in

mm

I Spark plug

t5

20

15

20

tt

t4

Fuel hose

10

t 5

O tO

arm nut

Oil pan drain

tioner compressor and
Power

16

Rocker

Drive belt defle tion

ft Ib

m
kg

m

plug

clamp

07

0 t5

1

98110 221
kg lb
3 mm 0 12 in

Compression pressure
kPa kg cm2 psil rpm
t

Standard

t77lt2 0 17t1350
883

Minimum
At ambient temperature

h

9 0 t 281 350

l

@

After checking valve

200C 680F

Iso check it when engine is hot
engine is cold
within the Jpecifi
value
If it does not
if
it
remains
to

clearance while

Fuel hose

rudjunit

clamping position

EF335A

CHASSIS AND BODY
MAINTENANCE
Inition and fuel system

INSPECTION AND ADJUSTMENT

Spark plug

Clutch
Type
Standard

Hot type

Plug gap
in
mm

Cold type

Pedal

Unit

height

Pedal free

U S A

IStBnd

8P6ES

8P7ES

8P5ES

08

ard

I

Opti

0

8PR6ES

8PR5ES

ResUor

Canada

I

built in type
I

High tension cable resistance

ohm

Axial

I

Less than 30

Wheel

000

I

I

Califronhi models

models

ManuOl

t
8
tran

20 B T D
l
700

Automatic

lin

0

C

mission

tran

position

mission

I

l
8

20 B T D

700

60

B T D

700

100
C

l

at

idling speed

3i
No

t

air

C

tOO

Idle mixture
1

CO

C

100

60 B T O
700

tOO

01

bearing Pl eload

As measured at wheel hub bolt

Ignition timing idle speed and idle CO
california
on

0

inl
mm

play

1

I
I

t4

pBrts

N

Ikg lbl

9
6

With used part

N

Ikg Ibl

20

With

1

0 20

Front axle and front suspension

0 035

8PR7ES

10 04

9

0 03t

on

5

AU

play

inl

851
6

17416 61

t68

H

mm

Wheel

nBW

710 7

8
7

2
0

15 15

3 3

08 04

81
t

alignment

Camber

degree

Carter

degree

Kingpin inclination

Toe in

40

degree

Unladenl

o
0

SO

1045

3015

7025

8055

2

mm

12

10

On

0 08

inl

both sides

screw

is preset and

sealed at factory

Side

slip

Reference data

Out 1

mm

Out 0 012 in

In 1
In

mm m

0 012 in ftl

MA 39

MAINT NANCE

SpecialSi rvice Tool

Standard ide rod

mmlinl

Wheel rim lateral and radial

80
12

71 0

A

length

Front wheel

turning angle
turns IWhen inner
wheel i 200 I
degree

Difference between

out
Toe

end left lateral

Outer wheel

18

in
mm

02

10 020 02
0 020
10 008

1
2

Wheel balance

70

degree

turn

05

Less than 0 5

right

runout

Maximum allowable
Full

LeCs than 1 0 0 039

in
mm

runout

unbelance

Inner wheel

33 350

Outer wheel

270

Tire

29

at

im

to

ozl

gr

10 35

flange

balancing weight

gr

10

60 10 35 2 121
Spac ng to 10 351

loz

steering models wheel turning force lat circumference
147 N 110
15 kg 22 33 Ib with en
steering wheel of 98

On power

1

Steet wheel

of

2

Aluminum wheel

at

gine

Brake

idle

s

stem

Unit

mm

lin

TIGHTENING TORQUE
N22
Pad

wear

081
210

limit

Unit
AN12H

N

fb
ft

kg

m

2 10001
Clutch

Rotor

N22

10 5

AN12H

8 6 10 339

10 4131

Pedal

stopper lock

nut

Master

cylinder push

rod lock nut
Pedal

8
7

8
11

8
0

2
1

8
0

2
t

35

18

25

10

43

72

58

72

5 8

8 7

repair limit

16116 10

155

h

height

8
7

118

8 8 7
5

6 341
Manual transmission

Pede fre8

Pedal

play

5

a

depressed height

04
10

201
0

More than 60

Drain and filler

f2 36

Lever stroke
0

25

34

25

59

98

6

78

98

80

to O

69

88

07

O

12

15

12

1 5

9

11

16

22

6
1

22

12

16

78

98

80

Propeller shaft and dif
ferential carrier

Parking brake
0

plugs

8t

Differential carrier

pullirig

90

13 54

100

941
3

drain

t96N 120 kg 44lbll

Number of notches

7

and filler

plugs

Front axle and front

8

suspension

Side

rod lock nut

Brake system

Wheel and tire
Recommended

Air bleed vatve

Id tire inflation pressure

Brake

lamp switch

lock nut

7OSR14
t85

26 psi 1177

Tire size

Spare tire

not use

80

in

excess

of

rod

input

k nut

kmlh 150 MPHI
Wheel and tire

70DI6
T135
60 psi

1412 kPa

Tire prlSlure should be checked when tires

are

Wheel

nut

COLD

SPECIAL SERVICE TOOL
Tool number

Kent

Moore

ST19320000
125664

40
MA

No

65

kPaI
Brake booster

00

51

Tool

name

Oil fIlter wrench

SJ

to O

58

72

DATSUN 200SX

Model S

0 Series

ENGINE MECHANICAL

CONTENTS
ENGINE COMPONENTS
Outer parts
ENGINE COMPONENTS

CONNECTING
EM

2

MAIN

Body parts
ENGINE DISASSEMBLY

ROD

EM ll

CRANKSHAFT

EM l1

BEARING

AND

EM

3

CONNECTING

EM

4

MISCELLANEOUS COMPONENTS

EM

4

EM

4

EM

6

ASSEMBLING

PISTON AND

EM

6

CONNECTING

ROD

EM

6

ASSEMBLING

INTAKE MANIFOLD

EM 16

EM

7

ASSEMBLING

ENGINE

EM 16

CYLINDER HEAD

EM

7

SERVICE DATA AND

VALVE

EM

8

SPECIFICATIONS

EM

8

INSPECTION

TIGHTENING

PRECAUTION
DISASSEMBLING

ENGINE OVERALL

DISASSEMBLING PISTON AND
CONNECTING

DISASSEMBLING CYLINDER HEAD
INTAKE MANIFOLD

INSPECTION AND REPAIR

VALVE

SPRING

ROCKER ARM AND ROCKER

SHAFT

EM

8

GAMSHAFT AND CAMSHAFT

BEARIN

EM

8

EM

9

CYLINDER BLOCK
PISTON

PISTON PIN AND

PISTON RING

BEARING

ENGINE ASSEMBLY

EM lO

EM

12

EM 12
EM 14

PRECAUTIONS

EM 14

ASSEMBLING CYLINDER

ROD

DISASSEMBLING

ROD

HEAD

EM 14

EM 15

OVERALL

AND ADJUSTMENT
TORGUE

TROUBLE DIAGNOSES AND
CORRECTIONS
SPECIAL SERVICE TOOLS

EM 20
EM 20
EM 24

EM 25
EM 27

EngineComponenrs Outer parts

ENGINE MECHANICAL

ENGINE COMPONENTS

l34
I

Outer parts

44

5
3

4

5 25

33

IIigb temion coble

A
E

1
l

tube

Exhaust manifold
E

G R ValVe

l16
1
16

t2

Starter

l16
1

21

iti6

2

21
2 1
t5

motor

t
Intake manifold

12
157

16 87

116

Alternator adjusting bar
Fan belt

Intake manifold st y

J

29
3 0

39
4

0

22

P

C V valve

Oil pump

J
5 8
1

EM 2

11

N

m

tgm ft lb
SEM136

ENGINE MECHANICAL

ENGINE COMPONENTS

Engine Components Body

Body parts

Valve rocker

Valve

cover

rocker and shaft
@

bly

assem

Exhaust

tntake

Vatve cotter

9
eam shaft

If

16

22

16

2 2

parts

retainer

Spring

2

1

e

Rubber

Oil seal

plug

Spring

Camshalt

seat

snap ring

j

sprocket

Valve

Cylinder

If

head

69
1

bolt

18
0

gUide

Valve

8 0

51

Cylinder

at

58

head

Cylinder liner

Only for

service

Cylinder block

Front

l
cove

t51
t6
116

Drive

plate

151
16
116

Oil drain plug

If

20

29 2 0

If
3 0 14

22

N

m

kg

m

ft lb

EM137

EM 3

ENGINE MECHANICAL

EqgineDisas emb
y

DISASSEMBLY

ENGINE

Crankshaft pulley Use suitable tool
on air conditioner
equipped model

PRECAUTION
Arrange the disassembled parts

on

2 Power steering pump bracket and
throttle chamber stay if equipped
3
Intake manifold
mbly includ

the

parts stand in accordance with
their assembled locations sequence
etc

so

that the parts will be

sembled to

their

Place mating

reas

ing

water inlet water

let

vacuum

tie chamber and EFI parts

original locations

marks

water out

lnjecturs

fuel pipes air regulator etc

the parts if

on

pipes

tubes E G R valve throt

necessary

DISASSEMBLING
ENGINE OVERALL
SEMl39

MOUNTING ENGINE
STAND
ON
tK
WOi
at rear and

Starter

Remove engine

5

Remove

I

following parts

located

right side of engine

left side

parts

Distributor cap and high tension
cables

SEM 142

otor

Distributor

Transmission
Clut h

assembly

cover

KV30100100

using Tool

torque convertor
Intake manifold stays
or

Exhaust

manifold

duction

tubes

with

after

air

in

removing

4

E G R tube

And

follpwing parts

Alternator and its bracket

Oil f1Iter using Tool STl932ciOOO
Oil pressure switch

Engine mounting bracket

Spark plugs

2

Install

engine

attachment

cylinder

block

engine

the work stand

on

Then

mount

7

to

Remove engine bottom side parts
pump and oil pump drive

Oil

the

spindle
Gussets

SEM140

Compressor

ret
brac

if equipped

Oil level gauge
SEMl38

3

Drain out engine oil and coolant

Engine

Spark plugs
6
Remove engine right side parts
I Cylinder
block
PC V
to
valve
hose

REMOVING
4

OUTER

PARTS

Remove engine front side parts
Fan
Drive belts
Belt tensioner for

steering if
powI

equipped
Alternator

adjusting

Water pump
Vacuum tube

assembly

tot and canister

EM4

bar

for distribu

mounting bracket

REMOVING BODY PARTS

9

8

Remove oil pan and oil strainer
Remove valve rocker cover

10

Remove

1

Remove

cylinder

head assembly

camshaft

sprocket
slowly lower timing chain

and

Engine Disassembly

ENGINE MECHANICAL
2

Loosen

cylinder

ing rod and cap corresponding to
cylinder Care should betaken

head bolts in the

each

sequence shown

to

avoid wrong combination includ

ing bearing
13

Remove

flywheel

and end

plate

WARNING
When
not to

removing flywheel
drop it

be careful

SEM144

3

Remove

head to front
4

Remove

installed

cylinder

on

head from
If it

Turn crankshaft until No 1 piston
at

is

3

Slack side chain guide
Tension side chain guide

4

0 il thrower

5

Oil PUJlP

6

Crankshaft sprocket

follow the

car

instructions below
8

Chain tensioner

cover

cylinder head

When removing

engine

securing cylinder

bolts

1
2

TD C

on

its

sprocket

is hard
a

use

drive gear

extract crankshaft

to

suitable puller

compression

To

facilitate assembling

scribe

Remove crankshaft
Remove

operation

mark on timing chai

a

camshaft

sprocket

with

8

and

bearing

caps with

When

loosening main

bolts

loosen

from

bearing cap

outside

in

se

paint

before removal

quence
Use Tool to remoye center and

b

Support timing chain by utilizing
Tool between timing chains

c

main

bearings

stroke
b

14

1

main

bearing caps

rear

Keep them in

order
EM286

12

piston and

Remove

connecting

rod assembly

KVIOI041S0

connecting rod bearing
cap with bearing
2 Push out piston with connecting
rod toward cylinder head side
I

Remove

J

EM608

l
J1c
C

I

j

f

Remove rear oil seal

r

G 0

II

Remove front side

I

Front

2

Chain tensioner and chain

3

Timing chain

O EJ

II

parts

S7

cover

guide

4
Oil thrower oil pump drive gear
and crankshaft sprocket

8

Piston can

scraJiing
cylinder
b

be

easily removed by

carbon
with

Numbers are

a

off

top

scraper

stamped

on

T

face of

connect

@rb

EM1QO

EM 5

fTlbly
Sl
EngineOisa

Remove

3

ENGINE MECHANICAL

crankshaft

Remove main bearings

4

at block

DISASSEMBLING

3

Fuel and

CYLINDER HEAD

4

Fuel pressure regulator

5

Injectors

6

Throttle control cable bracket

side
15

Remove baffle

from

cylinder

plate

and steel net

block

1

Remove

shaft

rocker

assembly

vacuum

tube

assembly

together with securing bolts
a

Do

not

No 5

b

remove

brackeU

bolu at No 1
since

and

2

Remove

cooling system parts

rocker shaft

bracket and rocker will spring out
When loosening bolts evenly loosen
from outside in sequence

SEM145

DISASSEMBLING
PISTON AND
CONNECTING ROD
Remove piston rings with

1

a

ring

2

Remove camshaft

3

Remove valves

valve springs and

relating parts using

Too

1

Water outlet

2

Thermostat

3

Water

4

Water outlet

5

Semol housing

6

Water pipe

gallery

following emission con
system parts referring to Section

Remove

3
trol

EC

remOver

E G R control valve
Thermal

ST12070000

vacuum

valveS

Nota installed direction of inlet and

outletfor reassembly
Vacuum control valve
Positive crankcase ventilation valve
4

Remove

following

miscellaneous

parts
Fast idle control device

if

equip

ped
Plugs
Keep
2

Press piston pin out

and

using press

the

disassembled

parts

Vacuum connectors

in

Note installed direction of outl t

order
for

Too

mbly

r

Water temperature
5

Disassemble

body

ST13030001

DISASSEMBLING
INTAKE MANIFOLD
EM156

1

Remove

following

parts referring to
Keep
order

6
EM

the

disassembled

parts

in

I

Throttle chamber

2

Air

regulator

fuel

Section EF

system

sensors

intake

manifold

ENGINE MECHANICAL

lnspectionandRepair

INSPECTION AND REPAIR
CYLINDER HEAD

with

stem

places top
CYLINDER HEAD MATING

2

FACE
I

a

micrometer

a

three

Replacement of valve guide
To

1

Measure valve guide hore at center

using telescope hole

Make

in

center and bottom

gauge

old guides

remove

S111033000 and
2 ton pressure or

visual check for cracks and

Drive

them

a

Tool

under

toward

out

a

rocker

flaws

cover

2

facilitate the operation
2
Ream cylinder head valve guide
hole using Tool at room temperature

Measure the surface of cylinder

head

on

cylinder block

side

for

warpage
If

the

beyond

correct with a surface

Warpage

limit

specified
grinder

Reaming

F

of surface

T

0 004 int

limit 0 1 mm

Heated

use

press
hammer
a

h
10

1

will

12 196

0 4797

mm

0 4802 in

Mr

oP

j1

L

ItCil

head

bore

12 185
A

cylinder

@

C

I

d
SEM150

SEM152
SEM14g

3

Surface grinding li
The

grinding

it

3

cylinder block grinding is

Stem to

guide

B

0 2

mm

10 008 in

Expedient method
Pry valve in lateral

Valve

Measure

guide

the

with
clearance

and

valve

clearance exceeds

replace the
and

between
If the

stem

worn

parts
In

case

has been caused by

bent valve stem

or

by

a

amount

tion

a

Valve guide of 0 2
oversize

4

0 008 in

should be moved

until

mm

is

diameter

0 008 in

available

for

Refer to S D S

Ream

the

bore

using

1001

sur ace

with

STl1032000
in parallel

Generally

a

of wear occurs in this

Reaming

bore

8 000

018
8

large

0 3150

mm

0 3157 in

direC
5

Correct valve

new

valve gUide

it

as

seat

the axis

a worn
worn

is

Or

VALVE SEAT INSERTS

valve

Check valve
evidence

out

Precise method
diameter

of

for any
valve contact

inserts

seat

pitting

surface and reseat

Determining clearance

the

valve guide

into head

clear

guide

Measure

mm

new

both valve

or

this

essential to detennine if such

I

and

service

rocker arm

the specified limit

valve guide

ance

direction

deflection at stem end with

limit 0 2

on

guide

ring comes in contact with
cylinder head surface after heating
cylinder head to 150 to 2000C 302 to
3920F

Stem end deflection

VALVE GUIDE

press the

snap

dial gauge

limit

valve

clearance

limit 0 1 mm 10 004 in

measure

8

Fit snap ring

and

2

A

A

reading of

head

by the cylinder block
in
an
grinding
engine
Depth of cylinder head grinding is
of

the highest

ance

limit of cylinder

is determined

Depth

Subtract

valve stem diameter from valve guide
bore to obtain the stem to guide clear

at
or

replace

if worn

excessively

Correct valve seat surface with Tool
of valve

SEM151

and grind with a

grinding compound
EM

Inspection

and

ENGINE MECHANICAL

Repair

Valve seat insert of

5 min
0

0 020

in oversize is available for service

VALVE
I

Refer to S O S

Check each

exhaust

of the

valve for

worn

defonned valve head

J

or

replace

or

Correct

stem

the valve that is faulty

Refer to
2

or

and

intake

damaged

os
S

Valve face or valve stem end sur

face should betefaced by using

a

valve

grinder
Valve head margin
Limit 0 5 mm 10 020 inl

EM113

Grinding of valve stem end
Limit 0 5 mm 10 020 in

a

When
valve

guide

worn

valve

repa nng

seat

ROCKER ARM AND
ROCKER SHAFT

for wear beforehand

sign of

If

2

The Tool should be used with both
hands for uniform

anns

and shafts for

damage

and if

rocker

arm

worn

and

or

shaft

seat

b

wear or

excessively replace

Then correct valve

replace it

Check rocker

1

check

cutting

oil

Check

rocker

arm

clearance

between

and rocker shaft

Rocker arm to shaft clearance
0 007
EM111

vALVE
Replacement valve seat insert
I

Old insert

boring
machine

be

can

until it

out

deplh

removed by
The

collapses

stop should be set

that boring cannot

continue

the bottom face of the insert

so

beyond
recess

Select

a

Check valve spring for squareness
using a steel square and surface plate
S
more
If spring is out of square
than specified limit replace with new

CAMSHAn BEARING
CAMSHAFT BEARING
CLEARANCE
Measure the inside diameter of cam

ones

an inside dial gauge
and the outside diameter of camshaft

shaft bearing with

in

Out of square

S

Outer
suitable valve seat insert

mm

0 063 in

mm

10 063 inl

Limit 1 6

and check its outside diameter

journal
or

Limit 1 6

with

Camshaft

bearing

limit 0 1
recess

micrometer

If any

cylinder head assembly

center

Ream the cylinder head

a

malfunction is found replace camshaft

Inner

Machine cylinder head recess to
the concentric circles to valve guide
3

4

mm

0 0019 inl

CAMSHAn AND

SPRING

1

cylinder head
2

0 049

10 0003

mm

clearance

10 004 inl

at

temperature Refer to S O S
5
Heat cylinder head 10 a temper
ature of 150 to 2000C 302 to 3920 F
room

6

Fit inserl ensuring that it beds

the bottom
caulk
7

more

face

of its

recess

J

on

and

than 4 points

Valve seats newly fitted should be

cut or
at the

ground using

Tool ST1l65000l

specified dimensions

as

0

shown

iBEM29s

in S O S

8

Apply small
grinding compound

of

amount
to valve

contacting

face and put valve into guide Lap
valve against its seat until proper valve
seating is obtained Remove valve and
then clean valve and valve seat

8
EM

SEM154

fine
2

Measure the free length and the

tension of each spring If the
value exceeds the

Illeasured
limi I

re

CAMSHAFT ALIGNMENT
I

place spring
Refer to S

specified

s
O

and

Check camshaft camshaft journal
cam

surface for bend

wear or

ItJSPectionand Repair

ENGINE MECHANICAL

damage

If beyond the

specified

4

limits

replace the parts
bend value is

A

2

one half

the

of the

a

taper

out of round

or

at

the

If cyl inder
the wear limit

Camshaft bend
Total indicator

step

Undersize

readingl

mm

topmost portion of
ridge reamer or other

bore has worn

beyond

liner

cylinder
use

cylinder liners

are

avail

able for service Refer to S D S

in

10 0039

a

similar tool

dial gauge at center journal

limit 0 10

wear

cylinder using

total indicator reading obtained when
camshaft is turned one full revolution
with

When

is minor and within the limit remove

IntarferenC8 fit of cylinder liner
EM540

0 08 to 0 09 mm
0 0031 to 0 0035 in

Surface

grinding

limit

The grinding limit of cylinder block is
determined by the cylinder head

ing in an engine
Depth of cylinder

grind

head

grinding

is

of cylinder block

grinding

is

A

Depth
SEM156

8

Measure camshaft

3

the

beyond

cam

specified

replace

camshaft
Wear limit of com
0 25 mm

camshaft

Measure

4

in

play If
replace

specified limit
cylinder head assembly

beyond

the

camshaft

or

Camshaft end

limit 0 2

mm

Using

der bore

bore gauge measure cylin
for wear out of round or

a

to amount of wear of cylinder

Ovenize pistons are available for
service Refer to S D S
The size to which

2
be

bores

cylinder
clearance
piston to
diameter
skirt
A
piston

for taper and
around bores for out of round

honed

cylinders must
by adding

Measurement should

is

determined

the

to

Refer to S O S
of
Out

round

X y
A B

Taper

play

Determine piston oversize accord

ing
3

boring machine
be taken along
end

the same time

1

0 008 in

taper If those are excessive rebore
the cylinder walls by means of a

height

10 0098

0 2 mm

B

height If

limit

When any cylinder needs boring all
other cylinders must also be bored at

Determining bore size

limit
A

CYLINDER BORING

0 008 in

FA

T

J 1
zU

I

60

0 791
IiIL
12 361
I
III
A

I
t

flit
X
17
EM422

I
L

Unit

mm

SEM714

in

CYUNDER BLOCK
1

Visually check cylinder block for

cracks

or

flaws

EM126

Measure the top of cylinder block
for
cylinder head mating face

2

the
warpage If it exceeds
limit correct with a grinder

Warpage of surfaC8
limit 0 1 mm 0004 in

specified

Dimen ion

I

distance from center of
EM124

pinl

Approximately
20 mm 0 79 in
EM 9

In5PectionandRepair

ENGINE

MECHANICAL

Rebored size calculation
D

A

0 025

B

C

0 0002 to 0 0010 in

mm

where

D

Honed diameter

A

Skirt diameter

as

Piston

C

Machining allowance
0 02

to

to diilmeter

at upper or lower limit of ring travel

If ring gap exceeds
limit

t

wall clearance

the specified

replace ring

Ring

measured

B

Ring should be placed

l

I

0 005 to

A

gap

Limit 1 0

mm

0 039 in

0 0008 in

mm

l
J

l

EM641

Borin g

CAUTION
To prevenl strain due to
cuning
heat bore the cylinders in the order

a

of 2
41 3
b

Before
main

boring
bearing

tighten

any cylinder install
caps in place and

to the

specification so
crankshaft bearing bores

the

become distorted

not

boring

from

PISTON

PISTON PIN
AND PISTON RING

that
will
the

operation

PISTON

Do not cut too much

der bore at
0 0020 in
As

4

a

a

time Cut

or so

out

of cylin

only 0 05

in diameter at

final step

a

time

cylinders should

Measure the fmished cylinder bore
f round or
out

for

Refer to

since it is

cleaning

wear

bottom land of ring

Oean out oil slots in bottom

land of oil ring groove
2
Check for damage
wear

Replace

if such

b

is minor

Oversize piston

rings

for service

mm

mm

scratches and
a

0 5

are

available

0 020 inl

1 0

0 039 in oversize

fault is de

tected

PISTON PIN

tapered part

1

D S
S

PISTON RING

of a just machined
requires utmost care
expanded by cutting heat

Measurement
cylinder

useful in
groove

carbon scraper and a
The wire will be

a

steel wire

rnm

be honed to size
5

piston ring only is to be
replaced without cylinder bore
being corrected measure the gap at
the bottom of cylinder where the

Scrape carbon off piston and ring

I

grooves with

curved
3

When

8

bore

I
in

Check the fitting of piston pin in
piston pin hole to be such an extent
that it can be pressed smoothly by
fmger at room temperature This pis
ton pin must be a tight press fit into
connecting rod
to

Measure the side clearance of rings
grooves as each ring is installed

ring

If side clearance exceeds the speci
fied limit replace piston together with

piston ring
Side clearance

Measuring piston

cyllnder
to

Limit 0 1

mm

0 004 inl

clearance
6

This

clearance

can

be

checked

easily by using a feeler gauge and a
spring balance hooked on feeler gauge
measuring the amount of force re
quired to pull gauge oU t from between
piston and cylinder
Feeler gauge used

0 04 mm 0 0016 in

Extracting force
2 0
0 2

a

b

When

2

14 7 N
1 5

kg

0 4

measuring

EM129

3 3 Ibl

slOWly
2

gauge

to

200C 680F

with pis

ton

It is recommended that piston and

EM 10

Measure oil clearance between pis
pin and piston If it is excessive

replace piston pin together
cl

pull feeler gauge straight upward

cylinder be heated

ton

Measure

ring gap with

a

feeler

placing ring squarely in cylinder

using piston

Piston pin
0 006

to

piston

0 013

0 0002

dearance

mm

0 0005 in

Inspectionsnd Repair

ENGINE MECHANICAL

CONNECTING
I

CRANKSHA

ROD

If a connecting rod has any flaw

on

both sides of the thrust face and

the

large

end correct

or

replace

CRANK JOURNAL AND PIN
I

it

Repair
are

torsion

crocus

cloth

If bend

2

2

Check connecting rod for bend or
using a connecting rod aligner
or

correct or

torsion exceeds

the limit

replace

or

minor

faults

Check with

a

as

required

correct

If

with fme

micrometer

journals

of
out
and crank pins for taper and
round Measurement should be taken

replace

Bend and torsion

for taper and around

along journals
journals for

per 100 mm 3 94 in length
limit 0 05 mm 10 0020 in

of
out

round

If out of round or taper exceeds the
specified limit replace or repair
round X Y

of
Out

limit 0 03 mm

block and

0 0012 in

play

Taper A BI
0 0012 in

crankshaft
measure

at center

End

Limit 0 03 mm

A

Install

2

in

cylinder

crankshaft free end

bearing

play

limit 0 3 mm

10

012 inl

B

EM133

Install connecting rods with bear
ings on to corresponding crank pins
and measure the thrust clearance If

EP

I

3

EM767

the measured value exceeds the limit
replace such connecting rod
3

Big end play
Limit 0 6 mm 0 0024 in

After regrinding crankshaft finish

it to the necessary size indicated in the

REPLACING PILOT BUSHING

D S
S
under
by using an
adequate undersize bearing according

replace crankshaft
bushing proceed as follows

chart

to the extent of required

repair

To

I

rear

pilot

Pull out bushing using Tool

BEND AND END PLAY
I

Crankshaft

can

be

checked for

bend by placing it on V blocks and
using a dial gauge with its indicating

finger resting

on

center journal

Bend value is half of the total indi
cator

reading

obtained when crank

shaft is turned one full revolution
If bend exceeds the
When
select
tween

ozl

so

replacing conneCting
that weight difference

each

in the

cylinder

is within 7 g

rod
be
0 25

condition of piston and

connecting rod assembly

replace

or

specified

limit

repair

Bond
Total indicator
limit 0 10

reading

mm

0 0039 in

2

Before installing

thoroughly

a

new

bushing

clean bushing hole

EM 11

r

Inspection8ndRepair
3

ENGINE MECHANICAL

Insert

pilot bushing until distance
flange end and pilot bushing
specified distance A

2

Install hearing

between

with the bolts

is the

fied torque

Distance

rJJ

A

Main
44

40

14 5

mm

0 157 in

54 N

33

bearing
to the

tightened

MISCELLANEOUS

cap

speci

COMPONENTS

cap bolt

bearing

Approximately

and

CAMSHA

SPROCKET

m

I
5

Check tooth surface for flaws

m
kg

Replace sprocket if

wear

40 ft lb

or

any fault is

found
Do not turn crankshaft while

plastigage

is

the

Install sprocket
If runout

3

Remove bearing

pare width of

and cap

plastigage

Com

exceeds

the

specified

replace camshaft sprocket

Total indicator reading
Limit 0 1

0 004 inl

mm

clearance

bearing

Limit 0 12 0 0047 in

EM719

When

camshaft and

Runout

plasti

envelope

Main

careful

limit

at its widest

part with the scale printed in
gage

on

check for runout

inserted

being

2

installing pilot bushing be
damage edge of pilot

not to

bushing

and not to insert exceuiYely

MAIN BEARING
AND CONNECTING
ROO BEARIN

SEM157

MAIN BEARING
I

Thoroughly clean all bearings and

check for

scratches

melt

score

or

wear

value

replace bearing with an under
bearing and grind crankshaft
journal adequately
size

if any fault is

Replace bearings
detected
2

If clearance exceeds the specified

3

Refer to

Measure

bearing

clearan

D S
S

CHAIN

as

follows

Check chain for

plastigage to the width of
bearing and place it in parallel with
crank journal axis getting clear of the
I

Cut

a

oil hole

CONNECTING ROD BEARING
I

Measure

same manner as

rJJ

rod

Connecting
14

5

33
Sale

kg

cap nut

rod

Check for

place

bearing

dearance

ce

Refer to S D S

wear

and

Re

breakage

if necessary

FLYWHEEL
I

specified

bearing with an under
size bearing and grind the crankpin
adequately
repl

if faulty

0 0047 in

If clearance exceeds the

value

excessive

CHAIN TENSIONER
AND CHAIN GUIDE

m

40 ft lb

Limit 0 12 mm
2

EM 12

5 5

damage
Replace

above

54 N m

Connecting
Plastigage

bearing

at roller links

bearing

clearance in the

44

EM141

connecting rod

wear

Check

surface
wear

2

on

Repair

the

clutch

disc

contact

flywheel for damage
or

replace

or

if necessary

Measure runout of the clutch disc

contact surface with a dial gauge

exceeds the

specified

Ifit

limit replace it

ENGINE MECHANICAL

Total indicator

Check tooth surfaces of

3

Runout

reading

Limit 0 15 mm 10 0059 in

for flaws or

ring gear

It is

Inspection

and

Repair

good practice to renew oil
engine is overhauled

seal

whenever

wear

Replace if necessary
ReplaC8 ring gear at
2200C 356 to 4280F
FRONT

about

180 to

AND

REAR OIL SEAL
Check front

and

rear

Front

oil seals for

sealing lip or oil
leakage If necessary replace with a
new seal When installing a new seal
pay attention to its mounting direc
worn or

folded

l

F
1

over

Front
EM150

L
Rear

tion

EM

13

EngineAS3embly

ENGINE MECHANICAL

ENGINE ASSEMBLY
PRECAUTIONS
I

When installing

as

bearings

on

the

sliding part

be sure to

such

d

apply engine oil

sliding urfaces

2

Use

3

Be

new

packings and
to

oil seals

follow

specified
tightening torque and order
4
Apply sealant to the following
points
sure

c

Do not apply sealant too much

Front side of cylinder

1

Mating surface
top of front

Apply sealant

lock

at these

points

EM152

with front cover and

cover

a

When in
oil

4

Front and

rear

side of cylinder

head
with rubber

plug

valve

apply engine
lip of

valva stem and

Check whether the valve face i
from

c

foreign

sealant

uneven

at

springs are

of

I nstall valve

pitd1 type

spring with its
painted

free

matter

Inner and outer valve
an

Apply

taIling

the

valve oil seal
b

Mating surfaces

on

pitch side

narrow

cylinder head

id

Painted sid

111

c

Narrow

pitchwWlde Pltch

SEMl58

2

SEM202

Rear side of cylinder block

Each side
and each

of

rear main

corner

bearing

cap

2

of cylinder block

Make

up valve

rocker shaft

as

sembly
Cylinder block

Install rocker shaft bracket

Rear main bearing cap

rocker

10 79

O

I

i

4iR

Points to be applied with sealant
Unit

mm

in

spring on valve rocker
shaft observing the following

ASSEMBUNG
CYLINDER HEAD

gSI

N

EM151

I

valve

and

Install valve and valve spring
Set valve spring inner and outer

seat and valve oil seal
2

Install

valve

valve

spring

inner

valve spring retainer Com
press springs and fit valve spring collets
and outer

J

by using Tool

Oil seal

3

Bottom side of cylinder block

Step portions
faces
cover

mating

sur

cylinder block to front chain
and cylinder block to rear main

bearing
EM 14

at four

cap

tor 0

Inner spring

t1

Wf

Install above order

1

Rocker bracket

4

Spring

2

Rocker shaft

5

Rocker

3

Bolt

@

SEM160

SEM161

arm

Engine Assembly

ENGINE MECHANICAL
I

and the aid of Tool is necessary

Intake rocker shaft has identifi
slit

cation mark

on

front surface

exhaust rocker shaft does not
2

Both rocker shafts should be

sembled

that

so

front surfaces
are

punched

come

to

marks

pressing piston pin in con
necting rod apply engine oil to pin
and small end of connecting rod

When

but
e
Plae

upside

as
on

upside Marks

used to identify oil hole direction
Slits

SEM164

ST13030001

Mount valve rocker shaft

4
Intake

Front

Exhaust SEM162

lil

Rocker shaft bracket bolt
15

25 N

and

mark

I

provides

Be

a

identification

Similarly the one for No 2
cylinder provides mark 2
careful not to miss original

and No 4
4

11

identification marks

provided

on

Arrange
ing rod
the

18 ft lb
bolts

Tighten

that oil

so

gradually

big

right

jet

of connect

end is directed toward

side of

cylinder block

in two to

three stages outwardly from center
bracket
b

When
under

location of rocker shaft brackets For
this purpose

b

m

2 5 kg m

1 5
3
Valve rocker is same for intake
3
No
and exhaust and also No 1 and

SEM156

specified torque

en to the

0

cylinder

assembly

on cylinder head by accommodating
to knock pin of the head Then tight

tightening bolts make
cylinder head since

space
some

valves will open and interfered

are

each bracket and cylinder

t

head
EM151

A

Z

Marked

on

cylinder

head
c

Connecting rods
of

are

marked at side

big end for identifying the de

signated cylinder
2

Install piston rings
so
that stamped mark

Install
Z

a

v

Marked

on

brackets

SEM163

on

ring faces upward

5

After

assembling

Ll1IU

turn camshaft until No 1

TD C

on

its

piston

is at

is

chromium

plated

on

liner contacting face

head

r

Top ring

b

Second ring has larger taper surface
than top

compression stroke
c

ring

In the combined oil ring upper rail
is the same as lower one

To
from

prevent rocker shaft brackeu

slipping

out

of rocker shafts

insert bracket bolts any bolt will dol
into bolt holes of No 1 and No 5

ASSEMBLING
PISTON AND
CONNECTING ROD
I
Assemble pistons piston pins and
connecting rods of the designated cyl

inder

rocker shaft bracket

a

3

Mount

onto

placing dowellpin
top position

head
to

camshaft

cylinder

at front end

Piston

ing

pin

rod

is

and

pressed
fitting

4 9 to 14 7 kN
1 7 US ton

Marked side

r

1

101

into connect
force

0 5 to 1 5

is from
t

0 6 to

0 49 to 1 48 Imp tonl

EM158

EM 15

Engine Assembly

ENGINE MECHANICAL
4

ASSEMBLING
INTAKE MANIFOLD

Install lower main

bearings and

and tighten bolts to

caps

specified

torque
Assemhle in the
and

disassembly

reveorder

with

the

l
C

specified

When

Intake

33

main bear

m

5 kg

m

40 ft lb

thermostat and its

installing

When

emission

Apply sealant to each side of rear
main bearing caP and each corner
of cylinder block
Refer to Pre

a

Section LC
t
housing refer J
b

rear

ing cap

45

Manifold
a

side oil seals

to

Main bearing cap bolt
4454 N

Disassembling

to

Apply sealanl

Then install those into

of

torque if designated
Refer

4

control

installing
system parts and fuel system parts

b

tively

Arrange

the parts

so

J

n

I

cautions

refer to Sections EC and E F respec

S
f5

I

that tha arrow

EM724

mark on

bearing cap faces toward
engine
Prior to tightening bearing cap
bolts placo bearing cap in proper
position by shifting crankshaft in
the front of

c

ASSEMBLING
d

Tighten bearing cap bolts gradually
in separating two to three stages
and outwardly from center bearing

INSTALLING BODY PARTS
1

first place

In the
on

cylinder

mount

work stand

seal using Tool

rear oil

the axial direction

ENGINE OVERALL

block

Install

5

refer to engine

in sequence

and steel net

@

overall diSassembly
2

Install baffle

plate

3

Install crankshaft

1

Set

upper

main

CD

@

J

I

into crankcase

bearings

at

SEM166

the

proper portion of cylinder block
a

b

Only center bearing
flanged type
All
are

bearings
inter

a

a

@

No

type

Upper

as

rear

11 is
bearing

also

L

I

V

@

ill

the same type

same

d

is

No 2 and No 4

Front bearing

c

No 3

of

of oil to
e

After securing bearing cap bolts
ascertain

oil groove

that

crankshaft

b

Rear

ill

Upper

IT IT I a

ga
4
1

2

on

N2

H3

both

oil to main

peripherY

coating

of oil seal

outside

turn

wwer

p

Make

end

play

sure

that there exists proper

of crankshaft at center bear

ing

Install

l
C

Limit 0 3

mm

play
0 012 in

end

plate

and

fly

Flywheel fixing bolt
137

Crankshaft end

rear

wheel

14

101

157 N
16

kg

m

m

116 ft lb

HI

bearing

sides of cylinder

block and cap
3 Install crankshaft

EM 16

Also apply

SEM168

Apply engine

surfaces

to prevent scratches

Install oil seal with its dust seal lip
at

6

HS

give coating
sealing lip and

smoothly
Front

III III

shaft

to

and folded lip

No 5

lOwer bearings ara not
interchangeable Upper ones have

engine oil

mating

the

and

When installing oil seal

EM327

ENGINE MECHANICAL
When installing flywheel

foreign

or

matter

wipe oil

from

away

Arrange connecting rods

fitting

necting rod caps

surfaces
7

so

EngineAssembly

and con

that the cylinder

numbers face in the same direction

Install

with

pistons

connecting

rod

1 Install them into corresponding
cylinder using Tool

I

J

SEM167

4

3

EM544

Make

1

Chain tensioner

Refer to Inspection and Repair
8
Install cylinder head assembly

2

Slack side chain guide

3

through
Apply engine oil
Arrange so that

a

b

sliding parts

to

knock

the front mark on

piston head faces

to

Install

gasket

the front of

pin

1

block

cylinder

as

7

Thoroughly clean cylinder block

piston ring

as

Top ring

fi

J0

Piston pin direction

2

Oilring
expander

When

make

from

SUre

sur

head

that all

apart

valves

head of pistons

are

If necessary

screws

of rocker

ann

draw valves in

4
EM725

Temporarily tighten
Cylinder head bolt
20 N

two

center

m

2

bearing

kg

m

ITemporary

44

14 5
33

rod

54 N

bearing

ClIp nut

b

Final tightening should be carried
installing chain and front

faces

Install oil pump drive gear

large

chamfered

to

the

inner

so

side

that
faces

rearward
2

Install

chain

guide

to

cylinder

block
Set chain

camshaft sprocket

on

and crankshaft sprocket by aligning
each mating mark Then install
shaft sprocket to camshaft

cam

Camshaft sprocket bolt
118

a

oil

sprocket

Make sure that the mating marks of

12

Connecting

crankshaft

front

CfJ

14 ft lbl

caps

CfJ

a

3

bolt

CfJ

Install

crankshaft sprocket

installing cylinder

loosen adjusting
to

rod

mating

Turn crankshaft until No 1 piston
on its compression stroke

3

secon

connecting

sealant to

is at T D C

fJ

Oil ring lower ail

apply

face of cylinder block and head

Oil ring
upper rail

ll

not

1

Timing chain

pump drive gear and oil thrower

shown below

po

Install

accommodating

and head surface

c

2

by

of

Temion side chain guide
4 Oil thrower
5 Oil pump drive gear
6 Crankshaft sprocket

follows

engine
c

SEM169

that there exists proper
end play at connecting rod big end
sure

87

157 N
16

kg

m

m

116ft lb

out after

m

cover

5 5 kg m
b

40 ft lb

Do not

rotate

crankshaft and

shaft separately

cam

because valyes will

hit head of pistons
c

Always

use

new

cylinder

head

gasket

EM329

9

Install front side parts

SEM170

EM 17

ENGINE MECHANICAL

mbly
EngineA

Set timing chain by aligning its mat

a

b

Note that different

e

ing marks with those of crankshaft
sprocket and cemshaft sprocket on
the right hand side
Camshaft sProcket should be in
stalled by accommodating its No 2
hole to knock pin of camshaft

are

CiJ

length of bolts

Front

Install

12

used

rocker cover with

valve

gasket
bolt

cover

fl

Valve rocker cover bolt

Size M8
10

7 8

16 N

m

1 6

kg

1 0
7

12 ft

m

5 8

bl

9
3

9 8 N

0 4

1 0

Rocker

b
2 9

m
kg

bl

7 2 ft

6

Install crankshaft

fl

Crankshaft pulley bolt
118

157 N

112

16 kg

13

pulley

bolts

cover

should

be

fathian

cross
criss
new

rocker

cover

Install oil strainer and oil pan with

gasket

fl

m

Oil strainer bolt
10

m

116 ft lbl

87

m
kg

7 2 ft lbl

tightened in
Always use
saskat

m

m

1 0

a

Size M6
No 2 hole

9 8 N

8
0

16 N m

11 0

1 6

m
kg

12 ft lbl

7

Oil pan bolt

10
4

to the

5 9

specified

torque in several steps and in
the sequence shown below

Install chain guide and chain ten

sioner

fl

Tighten cylinder head bolts

Chain guide and tensioner bolt

43

0 6

1 0

m 4 3
kg

7 2 ft b

the

protrusion

tensioner spindle to 0
slack side chain

mm

of

chain

m

kg

m

2 ft lbl
7

Apply sealant to the designated
portions Refer to Precautions

b

Oil pan should be tightened in criss
cross

Adjust

1 0

a

98 N

5 9

9 8 N

0 6

c

0 in with

pattern

Always

use

new

oil pan

gasket

guide
INSTALLING OUTER PARTS
14

Install

following parts in the reo
disassembly and with
the specified torque if designated
Refer to Disassembling Outer Parts
verse

SEM172

fl

Cylinder head
69

78 N

7 0
51

order of

and S O S for tightening torque
I Engine bottom side parts

bolt

m

When

8 0

m
kg

tributor

58 ft lb

installing oil pump and dis
driving spindle in front cover

refer to Section LC
2

5

Install front

observing
a

the

cover

with gaskets

following

cover press
oil seal in the cover with dust

b

tions

designated

cylinder head
After engine

the

sealing

Refer

to

por

grease to

Check
tween

the

inl

neces

securing bolts and
ers

valve

at lower

nut

with wash

and center side

as

il

clearance to

referring

to

cold

Section

MA

Intake

21
0

Exhaust

height difference be
cylinder block upper face

0 0059

if

installing intake manifold to
previously set the

facilitate work

Precau

Its

dif

ference must be less than 0 15 mm

EM 18

retighten

Whe

lustrated

sealing lip

and front cover upper face

a

to front cover
has been operated for

Valve clearance

Apply lithium

Engine right side parts

tighten bolts securing

sary

of oil seal
d

to

specifications

tions
c

b

sure

I I Adjust

seal

lip at outside
alant to
Apply

Be

several minutes

Before installing front
new

a

At

Cold

mm

23
0

ambient

mm

0 008 in
0 009 inl

temperature

200C

680F
After engine has been assembled

finally adjust
fications

clearance to hot

speci

Temporarily set olts and

nut

SEM173

ENGINE MECHANICAL
b

When connecting

vacuum

pipes

re

fer to Section EC
c

When installing oil filter

refer to
15

Dismount engine in the reverse
order of mounting and install engine
right side and rear side parts remained

Section LC
3
a

b

DISMOUNTING ENGINE
FROM WORK STAND

Engine left side parts

with the

ENGINE TUNE UP
17

Referring

1
2

Valve clearance

gauge

que

specifications

tern

When installing high tension cable
clamp those

as

iIIustrat d

When
use

installing

clutch

finally

Warm up engine until water tem
perature indicator points to middle of

holes

distributor

Section MA

items

Drive belts deflection

porarilv tighten ignition timing ad
just screws at center of adjusting

installing

to

adjust following

specified torque if designated
Refer to Mounting Engine on Work
Stand and S
s for tightening tor
D

When

EngineAssembly

then adjust clearance

Valve clearance

assembly

Tool KV30100100

to

hot

IHotl

Intake 0 30 mm 0 012 in
Exhaust 0 30

mm

Fill engine oil and coolant to the
specified level after engine has been

3

Ignition timing

installed

4

Idle rpm

0 012 in

16

4

on car

Refer to Section MA

Engine front side parts

EM 19

ENGINE MECHANICAL

Setvice Data and Spec fication

SERVICE DATA AND SPECIFICATIONS
INSPECTION AND ADJUSTMENT

Valve seat
Seal insert dimensions

CYLINDER HEAD

Intake

Cylinder head

Unit

Limit

Head

01

rnm lin

surface flatness

I

xL

10 0041

Q

Valve guIde

Unit

mm

On

mm

in

l

I
I

EXHAUST

83

8

510 327

o

0 3551 dia

SEM177

45

t
r

Contacting face angle
2

310

Contacting width
W

INTAKE
Snap ring groove

r

Stendard

10

UtO

45 097
Standard
Outer diameter

11010 421

7

0 433
Service

Exhaust

intake

Il

10 409

04

11

10 4

0 417

il V
f

I

10 6

O 409

11 7755
45 597

45 613
1

Exhaust

1958

Unit

mm

Fir

1

I

c

EXHAUST

INTAKE

EM116

SEM118

C

Contacting width
12 023
0

0 4733

45

cr

mtactlng face angle

Service

St8ndari
i
Valve guide
Outer diameter

12 03412 223
0 47381
10 4812

12

234
0 48171

StaruWd

1 5

1 9

Standard

guide

Inner

diameter

8 000

d

8 01810

0 31571

3150

Outer diameter

Service

hole diameter

8

985

11 996

10 4718

0 4723

11

Interference fit of valve
0 027

0 049

1

2

12

85

10 4797

to

guide

clearance

Iln
I

40 597

40 613

1

t

5983

0 0019

Limit

Ex

Stem

end deflection

EM 20

0 1

0 0016

59891

0 4802

In

I

0 020 0053
10 0008 0OO21
0 040

57861

1

Unit
45

nsen

For

standard

For

service insert

0 004
For standard insert

0 073
0 0029

000

11 7717
45

Stem

40 096

196

guide
Standard

080

115779

essdiameter
Cylinder head seat m

0 0011

07S
O

0

Finished size
Cyhnder head valve guide

0 059

W
40

Valve

in

h

P
J IJ

1

776
1

11 1952

I

iJ

45 113

0

SEM175

4 10 6
10

0 0711

18 0 047

12

500

111913

45
1

mm

016

77231

45 516
1 79201

40 000 40 016
11 5748 1 5754

EX

0 2 10

OOSI

I

40

For service insert

500 40 516

11 5945

1

59511

in

ENGINE MECHANICAL
Interference fit of seat insert

Unit

Standard

0 081

In

Following data

Unit

0

0 0025

I

096

Standard

0 00381

Free

Ex
0 081

Service

height

0 113
0 00441

0 0032

I
I

49 7711 9594

Inner

44

mm

of seat

Unit

height

Exhaust

Intake

40 0

mm

tension

N

Y

L41

I

90

6

41

11638

r

8J

1 646

L

dia

Cut

l

o

mm

On

T
1

D

j

J

1

I

I

Rocker

arm to

shaft

0

0 049

007

0 0003

I

I I
I I
iln
In

Valve head
H

Ex

length

L

I
I I
Ex

Standard
42 0

11 654
38 0
1496
122

66tl

935

I

I

32 955

112967

nd

Camihaft

Ii

1

29741

center

O to

0 00391

0 2 10 008

pl

38 2
1

504

8

123 1

4 835

4 846

123 6

123 9
4 8781

14 866

32

mm

Limit

journal Total indicator
readi n91

42 2
1

cam

journal

Camihaft bend at
Limit

in

0 0019

Unit

Outer diameter of
shaft

mm

AND CAMSHAFT BEARING

Camshaft

L

I

10 075

Standard

I

clearance

SEM181

Valve

19

Standard

M

diameter

Inner

CAMSHA

H

61

2 2 0 0871

Unit

SEM180

Unit

19
3783

Outer

4801 dia

SEM179

VALVE

11

ROCKER ARM AND ROCKER SHA

37 6
1
1

31
61

35 0 87 18 91

108111 0
3783 24 31

1

189119
0
1 575 42

0

square

1
374
11 472

40

50 7

35 0

Ikg

Inner

I

i

I

226 23 01

1575

linllbl

I

1011 7362

lin lb

bled

in

mm

N

kg

in

mm

limit

Outer

Outer

Assem

Machining dimensions

to both intake and exhaust

ere common

0 00441

0 064

Standard

VALVE SPRING

in

0 113

10 0032

Service

mm

Service Dara and Specificstions

11

t
l
EM871

In

Valve stem
diameter

0

In
Cam

height

A

Ex

Valve fBee

angle

38 527
1

51681

Camshaft bearing

45 30

C

38 477
11 5148

0 25 0

Unit

Standard
Valve head margin
M

I

In

05

10 020

05

0 020

Inner diameter

Cemshaft

I

Grinding
stem end

of

valve

05

10 020

to

journal

bearing clearance

Oil clearance

33 000
112992

00981

mm

tin

Limit

33 025
1

3002

0 045 0 090
10 0018 0 0028

01

10 004

EM 21

ENGINE MECHANICAL

Service Datasnd Specifications

CYLINDER

BLOCK

PISTON RING AND PISTON PIN

PISTON

Cylinder block

Unit

io

f11m

Piston

Unit

1111
I

f

i

0

I

P

A

cr

Front

a

About 20

10 791

V

X

EM714

Standard

0 50

limit

Piston diameter

A

3

13 3459
85 465

10 01971

Oversize

035
34781

85 515
3 36671

13 3648

0 110 004

Surface flatness

1 00
85

Inner

diameter

000

13 3465

85 050
3 34841

3

38641

Side clearance of piston ring

Less than
round

86 015

85 965
3 3844

10 03941

Oersize

0 0081

02

Out of

Unit

mm

Unl

0 01510 00061

IX VI
Limit

Standard
Less than

Taper A B

Differene

Piston

to

0 01510

0 05

cylinders

0

cylinder

Feeler gauge

10 0081

025

0045

I
I
I

0 00181

0 040

Top ring

0 073
0 00291

10 0016

0 1
0
Second

ring

0

030

0 0041

0 063

0012

0 00251

Oil ring

ex

tracting force

N

with gauge

20

kg

thickness 0 04

0 0016

02

0 00201

10 0010

clearance

00061

Less then

in inner dia

meter between

mrn

85

985
84

Standard
EM422

bore

in

1J 120 10 791
1111
6012

A

Cylinder

rnm

14

Ring

710 2
3 31

gap

Ib

1

in

I

Wear limit

mm

in

Top ring

Oil

ring

ring

0 25

0 40

10 0098

01571
0

0 15

0 30

10 0059

0 01181

0 30
10 0118

0 90

Piston pin

s

Unit

mm

Limit

Standard

Second

Cylinder liner for

Unit

15 04

1 0 10

0391

0 03541

Unit

mmlin

in
Standard

40 10

1571

Undersize
45

Outside diameter

0

1711

Undersize
5

010 1971

Undersize

89 00
13 5039
89 50
13 5236
90 00
13 5433
0 08

Interference fit of cylinder liner

EM 22

0 0031

89 05
3 5059
89 55

I

Piston pin outside

di

3 6256

Piston pin hole diameter

90 05
3 54531

Piston pin

0 09
0 0035

I
I

20

993

20 998 0 8265

0 82671

21

001

21 008 10 8268

0 82711

meter

c lea

to

piston

0 006

0 01310 0002

0 00051

0 015

0 035 10 0006

0 oot41

ance

Interference fit of

pin to

piston

onnecting rod

c

ENGINE MECHANICAL
BEARING

CONNECTING ROD
Unit

1
torsion
3

I

rod bend

per 100

in

mm

Bearing clearence

I

or

0 03

mrn

0

00121

10 00201

0 05

I

94 inllength

Bid end

Unit

02

plev

03

0 008

0

mm

in

Limit

Standard

Connecting

ServiceOataandSpecifications

I

0 6 0 0241

0121

Standard

0 020
Main

bearing clearance

Connecting

rod

0

0 0008
0

beeting

062

0

0 0024

1210 00471

0 055

025

0 001 0

clearance

Limit

0 00221

Main bearing undersize

0 12

0 00471

Unit

mm

in

T

CRANKSHAFT
Unit

a

t1b
I

A

mm

lin

S

EM738

Bearing top
thickness

I
I
I
I

8
EM790

I
I
I

Journal diameter
Pin

diameter

A

54

B

942

49 961

S

42

of
Out

round

X

97

54 955 2 1631

49

974

43

0311 6917

2 16361

19670

1

96751

169411

V

1822

STD

10 0717

0 50

0 75

10 00981 Undersize

0 01971

Undersize

0 02951 Undersize

B
A

Taper

8

A

1

00

0 0394 Undersize

0 0767

I
I
I

2

072

0 0816

2 197
0 0865

2 322
0 0914

jou rnal

diameter

1835

54 942

0 0722

12 1631

2 1636

1 947
0 25

Cran k

T

1

54

955

54 692

54 705

0 07721

2

2

15371

2

54

2

14391

960

085

0 08211
2 210
0 08701
2

335

0 09191

2

1532

54

192

12 1335
53
2

455
54

442

1434

942

1237

54 205
2

13411

53 955
2

12421

o
EM715

Connecting rod bearing undersize
Standard

Taper of journal and

I
IOut
I

A S

pin

and

of round of

pin

Journal

X Y

Crankshaft bend Total
indicator

I
I

Less than
003
O Of

reeding

Pilot

bushing inserting

distance

0

00041

0 00121

0 03

10 00121

0 10

0 00391

Less than
0 05
0 05

Crenksheft free end plav

0 00041

less than
001

0 00201
O lB

03

10 0020

0 00711

40 0

Unit

Limit

1571

10 0121

J
I

I

I

I

I

I
I
I

493
1

STD

0 0588

0 25

0 50

0

00981 Undersize

0 01971

0 7510

Undersize

02951 UDdersize

1 618

10 0637

ciiameter

T

1 506

0 05931
1 631

49

49 711
1

1 743

1

49

0 0686

0

1868
0 0735

1881

0 07411

961

0 9670

0 06421

756
06911

Onl

Crankpin

Bearing top
thickness

rnm

9571
461

t 9473

49 211
1

9374

49 974
1

9675

49 724
1 95761
474
49
194791

49 224
193791

EM 23

Service

ENGINE MECHANICAL

DatallndSpecifications

MISCELLANEOUSCOMPONENH

Engine left side

Camshaft sprocket
Runaut

I

Total indf
mm

cator

Limit Q 1

in

0

I

004

readingl

Flywheel

I

Runout

frotsl

iodi
mm

N

Unit

Limit 0 15

in

10 0059

cator reading

Distributor support bolt

I

Exhaust manifold bolt

I

E G R tube

I

E A I

I

Air

and

3 9

m

78

ft lb

m
kQ
4
0

08

2 9

58

16

21

1 6

2 1

12

15

34

44

35

4 5

25

33

34

44

35

45

25

33

44

54

45

55

33

40

69

78

70

80

51

58

3 9

78

29

58

15

25

11

18

nut

tube

nut

nut

conditioner

cern

pressor bracket bolt

ENGINE TUNE UP
Engine top side

Valve clearance

Unit

1
Intake

I

Exhaust
At ambient

0

0

3010 012

0 21

30 10 012

0 23

temperature 200C 168

0 008

0 009

F

adjusted to cold specific tions
satisfy hot specifications and edjust again

Whenever valve clearances

check thd the clearances

in

Cald

Hot

I

mm

are

I

Cylinder

head bolt

I

Cylinder

head

I

Rocker shaft bracket bott

I

Camshaftsprocket

I

Rocker

I

Spark plug

I

Rocker

if necessary

COYer

to

front

4 08
0

bolt

bolt

bolt

cover

nut

arm

1 5

2 5

157

12

7 8

98

08

1 0

58

72

15

20

1 5

20

11

14

16

22

1 6

22

12

16

44

54

45

5 5

33

40

4454

45

5

33

40

10

16

10

1 6

7

12

98

06

1 0

43

7

20

29

20

3 0

14

11

15

1

1

5

8

43

58

44

5

9

32

118

87

16

116

TIGHTENING TORQUE
Engine bottom side

Engine front side
Unit

N

m
kg

m

ft lb

Front cover bolt
M8

16

1 0

1 6

7

9

9 8

04

1 0

2 9

7 2

5 9

98

06

1 0

43

72

5

9

06

1 0

43

7

10

M6

3

I

Chain

I

Chain tensionetr bolt

guide

bolt

9

8

12

I

Min bearing cap bolt

Connecting

t

Oil strainer bolt

10

Crankshaft pulley bolt

118

98

16
157

04

10

1 01 6

12

16

29

Oil pan

7

87

7 2

Gusset

drain plug

to

Flywheel bolt

I
1

Drive

16

1 0

1 6

7

12

I

Water outlet bolt

10

16

1 0

1 6

7

12

I

Intake manifold bolt and
16

21

1 6

2 1

12

15

AfT

39

59

40

60

29

43

Starter

20

29

20

3

0

14

22

29

39

3 0

40

22

29

I
I

adjusting

Engine mounting bracket
bo1t Same fot left side

EM 24

TI
M

Clutch

cover

bolt

T
M

Torque converter bolt

nut

to

2

22
11

43

side

plate bolt Arr

10

bar bolt

rear

I

Water inlet bolt

Alternator

5

116

I

bracket bolt

cylinder block

bolt

12

Engine right side

Alternator

59

Oil pan bolt

Engine

I

end

Oil pump bolt
3 9

M8

big

nut

Water pump bolt
M6

rod

I

motor

bolt

Transmission to cylinder
block

IT

157

14 0

t6 0

101

116

137

157

14 0

16 0

101

116

12

15

50

29

36

4 0

22

29

9

32

43

59

32

43

16

21

16

39

49

40

29

39

3

43

58

44

5

43

58

44

0

2 1

bolt

ransmission

bolt

137

to

gUet

Trouble Diagnoses and Corrections

ENGINE MECHANICAL

TROUBLE DIAGNOSES AND CORRECTIONS
Probable

Condition
I

Corrective action

cause

Noisy engine

Piston and connecting
rod knocking

Replace piston with pin

Seized piston pin

cylinder and replace piston

Recondition

Seized piston in cylinder

with pin

Replace ring

Broken piston ring

Realign

Improper connecting rod alignment

Knocking of crank
shaft and hearing

Timing chain

noise

rod

Seized

or

loose connecting rod bearing

Replace

Seized

or

loose main bearing

Replace

Bent crankshaft

Repair

Uneven wear of journal

Correct

Excessive crankshaft end play

Replace

Improper chain
Worn and or
Worn

Worn

and

tension

adjusting

chain

guide

and

or

Replace

Adjust

mechanism knocking

Worn rocker

Replace

bearing

Worn rocker face
Loose valve stem in

Water pump knocking

II

bearing

mechanism

Improper valve clearance

Replace
guide

Replace guide

Weakened valve spring

Replace

Seized valve

Replace

Excessive camshaft bearing clearance

Replace

Excessive axial play

Replace

Wom

Replace

earn

center

Replace
broken

Camshaft and valve

Camshaft knocking

replace

Replace

chain

sprocket
or

replace

cylinder

rod

Adjust

tension

damaged

or

and or recondition

or

gear

thrust

plate

Improper shaft end play

Replace

water pump

assembly

Broken impeller

Replace

water pump

assembly

Other mechanical troubles

Stuck valve

Improper valve clearance

Adjust

Insufficient clearance between valve stem

Clean stem

or ream

guide

and guide
Weakened
Seized

or

or

broken valve spring

damaged valve

Poor quality fuel

stem

Replace

Replace

or

clean

Use good fuel

EM 25

ENGINE MECHANICAL

TroubleDiagnosessndCorrections

Probable

Condition
Seized valve seat

Excessively worn
cylinder and piston

Corrective action

cause

Improper valve clearance

Adjust

Weakened valve spring

Replace

Thin valve head edge

Replace valve

Narrow valve seat

Reface

Overheating

Repair

Over speeding

Drive at proper

Stuck valve guide

Repair

Shortage of engine oil

Add

Dirty engine oil

Clean crankcase

or

replace

speed

replace oil

or

replace oil and oil filter

element
Poor quality ofoil

Use proper oil

Overheating

Repair

or

replace

Wrong assembly of piston with connecting

Repair

or

replace

rod

Improper piston ring clearance

Adjust

Broken piston ring

Replace

Dirty

Clean

air cleaner

Adjust

Mixture too rich

Engine

Drive at proper speeds

over run

Stuck choke valve

Clean and adjust

Overchoking

Start correct way

Faulty connecting

Shortage of engine oil

Add oil

rod

low oil pressure

Correct

Poor quality engine oil

Use proper oil

Rough

Bearing

Clean

oil passage

Clogged

Faulty crankshaft
bearing

Grind and replace bearing

surface of crankshaft

worn or

Replace

eccentric

Bearing improperly assembled

Correct

loose bearing

Replace

Incorrect connecting rod alignment

Repair or replace

Shortage of engine oil

Add

low oil pressure

Correct

Poor

quality engine

Crankshaft journal

Clogged
Bearing

oil

pasSage

worn or

Use

oil
worn or

of
out

in crankshaft

eccentric

Bearing improperly assembled
crankshaft
Eccentri

EM 26

or

bearing

round

or

replace

specified

Repair
Clean

Replace
Correct

Replace

oil

ENGINE MECHANICAL

SPECIAL SERVICE TOOLS
Tool number

Tool

name

Kent Moore No

KV30 100 100

Clutch aligning bar

KVlO105001

Engine attachment

ST050lS000

Engine stand assembly

126023

CD ST050l1000

Engine

126023 2

CVST05012000
126023 1

Base

stand

Special Service Tools

Special Service Tools

Tool number
Kent Moore No

KVIOlO39SO

ENGINE MECHANICAL

Tool

name

Valve guide

reamer set

125618

D

STlI08l000

125618 3

@ STlI032000
125618

@

2

STl1320000

Reamer

12

2 mm 0 480 in

dia

Reamer

8 0 mm

D
315
0

in

Drift

125618 1

dia

@
@

STl165000 I

Valve seat cutter set

STl6610001

Pilot bushing puller

123907

KVlOI05500
01
125640

Crankshaft rear oil seal
drift

M

EM03470000

EM 28

Piston ring compressor

DATSUN 200SX

Model S J J 0 Series

SECTION

LC

ENGINE LUBRICATION

COOLING SYSTEMS
CONTENTS
ENGINE LUBRICATION SYSTEM
LUBRICATION
01 L

CIRCUIT

PUMP

OIL PRESSURE

REGULATOR VALVE

OIL PRESSURE

RELIEF

COOLING SYSTEM
COOLING CIRCUIT
RADIATOR

THERMOSTAT
WATER PUMP

2

LC

2

SERVICE DATA AND

LC

3

SPECIFICATIONS

LC
LC

OIL FILTER
VALVE

TEM COUPLlNG

LC

LC

4
4
4

GENERAL SPECIFICATIONS
INSPECTION

AND ADJUSTMENT

TIGHTENING

TORQUE

LC

5

TROUBLE DIAGNOSES AND

LC

5

CORRECTIONS

LC
LC
LC

6

LUBRICATION

6

COOLING SYSTEM

7

SYSTEM

SPECIAL SERVICE

TOOL

LC

7

LC

8

LC

8

LC

8

LC

8

LC

9

LC

9

LC

9

LC 10

Engine

LubriCstion

ENGINE LUBRICATION

System

COOLING SYSTEMS

ENGINE LUBRICATION SYSTEM
LUBRICATION CIRCUIT

SLC021

j

I

Oil pan

Oil gallery in
cylinder block

Oil strainer

I
I

By pass passage

Oil pump

I

Regulator

valve

I

Intermittently

j

oiling portion
Oil passage

Oil filter

I

Pump drive gear

r

Relief valve

I
l
Main

I

aring

Con

ecting
bearing

I Connecting

f

rod

rod

I

II

II

I

l

Piston Pin pis
ton and cylinder
I

I

Oil J et

Timing

II

chain

Chain tensioner

I

I

I

Cylinder head
oil gallery

I

Center earn bracket

I

Rocker shaft

A
Rocker arm

I

Cam bracket

t
Cam surface

j
I Camshaft bearing I

t

I

Timing

chain

and front cover

I
S LC022

LC 2

ENGINE LUBRICATION

COOLING SYSTEMS

lfJ

OIL PUMP

Oil pump
6 9

5 1
1

cover

9 8 N

0 7

REMOVAL

Lubrication

Engine

System

bolt

m

1 0 kgm
7 2 ft lb

Remove distributor cap

2

crankshaft

Turn

piston

is at T D C

so

that No

1

41 Punch mark

its

compression
stroke by ascertaining the position of
distributor head rotor and timing mark
on

crank

on

Oil hole

a

Always replace with

b

Outer rotor should be assembled

a

new

gasket
so

th at the chamfered side faces to oil
pump

body

pulley

Remember position of

he rotor

E

L009

under above condition

California models

Using

3

a

gasket install oil
spindle assembly

new

pump and drive

J ii9

Front

SLC025

SLC074

Califomia
Non

models
4

sure

that the

spindle
securely
5
Tighten bolts securing oil

Front

INSPECTION

tip of the drive
fits distributor fitting hole

Make

Inspect the following for wear
damage
Pump body and cover
Pump rotors and rotor shaft
1

pump to

front cover

lfJ

Oil pump
11

15 N

111
8

2

mounting bolts
1 5

Ying
follo

m

kg

Using

a

Wear limit

m

11 ft lb

Rotor tip clearance

Install distributor cap

mm

Remove

oHpump body

with drive

CD

0 0079 in

Outer rotor to

body clearance

3

check the

Clearances

0 20
6

feeler gauge

or

0 50

DISASSEMBLY AND
ASSEMBLY

mm

V

0 020 in

spindle assembly

o

INSTALLATION
I

Make

sure

@

that distributor head

rotor is in the same

1

@1
EL032

position

as

it was

before removal of oil pump
2
Fill pump housing with engine oil
then align punch mark of drive spindle
with hole in oil pump

Oil pump body
Outer rotor

5

Oil pump

2

6

3

Inner rotor and

7

Regulator valve
Regulator spring

shaft

8

Regulator

1

4

Gasket

LC026

I

cover

cap

Using a feeler gauge and a straight
edge check the following gap @ or
@ without gasket
3

LC 3

EngineLubricationSystem
Rotor to

straight edge

ENGINE LUBRICATION

@

OIL PRESSURE
REGULATOR VALVE

Less than
0 06 mm
Oi

pump

0 0024 in

body

to

straight edge

@

Less than
0 03 mm

0 0012 in

cover

should

satisfy

clearance
the

INSPECTION
Check

Then rotor side clearance rotor to
bottoni

COOLING SYS1 EMS

with gasket

valve

valve spring

assembly

and

sliding surface and
entire valve

replace

if necessary

following specifica

tion

S lC028

Wear limit
Rotor side clearance
0 20 mm

OIL PRESSURE
RELIEF VALVE

0 0079 in

INSPECTION

E L076

With oil f1lter rellloved check valve
for operation
Inspect for a

unit

cracked

or broken valve
If replace
Ilent is necessary remove valve by
prying it out with a screwdriver InstaII
a

new

valve in place by tapping it

N

S LC027

OIL FILTER
REMOVAL AND

INSTALLATION
Pump
serviced

rotors

and

separately
body are damaged

body

are

not

If pump rotors or
or

worn

replace

pump rotor set or entire oil pump as

sembly

LC4

When removing oil f1lter
When

installing

it

lightly

use

Tool

coat oil on

oil seal and fasten it by hand
Do

leakage

not

overtighten

may occur

filter

or

a

oil
5 LC029

ENGINE LUBRICATION

COOLING SYSTEMS

Cooling System

COOLING SYSTEM
COOLING CIRCUIT

Radiator to water pump

o

Water pump to cylinder block and heater

core

Cylinder block to cylinder head
1

Cylinder head

to

intake manifold

Thermostat to radiator
Radiator to reservoir tank

5 LC030

WARNING
To avoid serious
Radiator cap

F

never

Reservoir tank

when

of

t

cooling

hot Sudden release

system pressure is very

If it is necessary to remove Iadiator
cap when Iadiator is hot turn cap

Thermostat

A

L

counterclockwise to the fillt
stop After all pressure in the coo
ing system is released turn cap
passing the stop and remove it

slowly

Water pump

block

engine is

peRonal injury
cap quickly

dal1llerous

Radiator

Cylinder

Idiator
remove I

H

Heater

I

J

Thermostat

housing

t

f
Cylinder

head

l

Intake manifold

SLC031

LC5

ENGINE LUBRICATION

Cooling System

RADIATOR

COOLING SYSTEMS

Inspection
First

REMOVAL AND

tears

INSTALLATION

cleaning

I

Drain coolant into

a

clean

con

tainer
2
3

Remove air cleaner inlet pipe
Remove air duct with bracket

after loosening

clamps

ofradiator cap

check rubber seal

cracks
it

or

THERMOSTAT

cap for
deterioration after

Then

on

install

REMOVAL AND
INSTALLATION

radiator

cap on a tester If cap does not hold or
will not release at the
specified pres
sure

replace

1
When removing
drain coolant
partially and disconnect upper radiator

cap

hose at water outlet

Cap relief pressure
88 kPa

and screws at

0 9

kg cm2

2
13

psi

Install thennostat and water out

let

as

illustrated

portion illustrated

ET012

4

Disconnect

lower hoses
5

Remove

ing

screws

radiator upper and
and reservoir tank hose
radiator shroud attach

and

place

radiator shroud

close to engine
Radiator shroud can
be removed after removing radiator
6

On

sian

a

car

with automatic transmis

disconnect cooler inlet and outlet

lines from radiator
7

Remove radiator

8

Install radiator in the

2

SLC033

Jiggle valve

3

Gasket

2

Thermostat

4

Water outlet

Inspection of water leakage
With

radiator cap removed

apply

test pressure to radiator on a car

If

leakage

is

detected

repair

or

replace radiator
Leakage

test

157 kPa

INSPECTION
Inspect thennostat for the follow
ing and replace if
necesS3l
I Valve

pressure
1 6

nary

kg cm2

seating condition at ordi
It
should seat
temperature

tightly

23psil

2

Valve

opening temperature

maximum valve lift

and

Refer to SDS

reverse se

quence of removal and refill cooling
system with coolant to specified level

i
VJj

Refer to Section MA

INSPECTION
Inspect radiator cap
leakage using cap tester

1

and

water

I

y

SLC037
SLC034

Then check if valve closes at SOC

3

90F

below valve opening tempera

ture
It is necessary to check a new ther
mostat before

6
LC

installing

it in

engine

COOLING SYSTEMS

ENGINE LUBRICATION

PUMP

WATER

cf

N

m

kg

ln

ft Ib

Belt dcllcction

mm

DISASSEMBLY
Water pump is made of aluminum
bearing outer race is of a press

Cooling System

@

and its

in fN

M6

3 9

M8

10

kg Ib

9 810 4
16

10

7

1 0 2 9
16 7

21

121

fit type For this reason water pump
should not be disassembled

INSPECTION
Inspect pump assembly for the
following conditions and replace if

a

1210 31

0 47

98

10

22

Pump gasket
Always replace

necessary
I

Badly rusted

assembly
2

and

corroded body

or

vane
Water

Excessive end

play

or

roughness

fan
pump with

coupling

of bearings in operation
If excessive mechanical seal squeak
occurs

suitable

when

is

engine

pump seal

water

running

Fan belt

use

lubricant to
SLC035

prevent squeak

TEM COUPLlNG
DISASSEMBLY
The coupling is

so

designed

that it

cannot be disassembled

INSPECTION
Inspect
or

the

coupling for oil leakage

bend of bimetal

place

as a

pump

If necessary

reo

assemhly

t

C0077

1

Bi metal thermostat

4

2

Slide valve

5

3

ReseIVe chamber for

QFF

6

Bearing
Driving chamber for ON
Coupling part Labyrinth

Le

r

LUBRICATION

COOLING SYSTEMS

ENGINE
ServiceDataandSpecifications

SERVICE DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS

I

Oil pump

I

Oil

RADIATOR

Trochoid type

filter

Full flow and

cartridge type

CaP relief pressure

kPa

kg cm2 psi

Leakage

kPa

Ikg cm2 psi

test

pressure

88

0 9 13

157

116 231

Oil pressure relief valve
Valve

8
59

opening pressure
kg cm2 psH

0 60

kPa

I

Down

Redietor

6
10 7

THERMOSTAT

flow corrugated fin

1

and tube type

I Thermostat
I

13

0 75 8 5

I
I

Wax type

Water pump

Centrifugal type

coupling
Tem

Fen speed

at water

pump

speed 4000 rpm
oC OF
rp

Less

Unit

1

Standard

0 12

body
to

0 15

clearance

I

bottom

004
0 0016

cover

OIL PRESSURE

Max valve lift

oC Un oF I

I

mm

Fan belt

deflection

mm

lin

N

Ikg Ibl

0 21

I

llO831
0
0 08
0 00311

I

0 20

10 0079

0 50

0 197

0 20

1 00079

52 5 2

valve

Installed lengthl

spring

loed

8 1
34
in

N

7

9

77
3701

5

8 7 174

85 3

19 21

Ikg lbl

I

8

8 90
194

3t
O

12

10 31

0

98 10 221
471

m

m
kg

ft lb

I

mounting bolu

Oil pump

cover

bolts

Regulator valve cap

11

69

39

15

8
9
49

1

5
1

0 7

1 0

4

5

8

5 1

29

11

72

36

securing

bolt

343

pressure

kg cm2 psi rpm

N

Oil pump

Water pump

Regulator valve opening

8
LC

8 100
10 31 212

0671

Re ulator

kPa

8 95
10 31 203

170

76

TIGHTENING TORQUE

REGULATOR VALVE

length
jn
mm

mm

8811901

in

Unit
Free

1801
82

Wear limit

0 00471

10 0059

Rotor side clearance
rotor to

Tropical type

tom

oC OF

mm

type

Less then

tip clearance

rotor

opening

perature

Frigid

WATER PUMP

OIL PUMP

Outer

Valve

2 150 60 1401
than 1 650lbelow 50 122

INSPECTION AND ADJUSTMENT

Rotor

Standard

13 5

4 2 50

412

M6

39

Me

10

8
9

04

1 0

29

10

16

7

601 3 000
16

72

12

Trouble Diagnoses and Corrections

COOLING SYSTEMS

ENGINE LUBRICATION

TROUBLE DIAGNOSES AND CORRECTIONS
LUBRICATION SYSTEM
Probable

Condition

Oil leakage

Damaged
Oil

or

leakage

Corrective action

cause

cracked pump body

cover

from gasket and oil seal

Replace
Replace

Oil leakage from regulator valve

Tighten

Oil leakage from blind plug

Replace

Decreased oil

Lack of oil in engine oil pan

G orrect

pressure

Dirty oil strainer

Clean

Damaged

or

worn

quality

replace

replace

Replace

pump rotors

Replace

Malfunctioning regulator
Use of poor

or

or

engine oil

Replace

Warning light

Decreased oil pressure

Previously mentioned

remains

Oil pressure switch unserviceable

Replace

Electrical fault

Check circuit

Excessive backlash in pump rotors

Replace

on

engine running

Noise

COOLING SYSTEM
Probable

Condition
Water

leakage

Corrective action

cause

Damaged radiator seams
Leaks from heater connections

Repair
or

plugs

Repair

Leak from water pump shaft seal

Replace

Leak from water temperature gauge

Tighten

Leaks from gaskets or small cracks

Tighten
or

pump

or use

assembly

Nissan

Cooling System Sealer

equivalent

Loose joints

Tighten

Damaged cylinder head gasket

Replace
Check engine oil for contamination and refill
as

Water leakage

as

Cracked

cylinder block

necessary

Replace
Check engine oil in crankcase fonnixing
with water by pulling oil level gauge

Cracked
Loose

cylinder head

cylinder

head bolts

Replace
Tighten

LC 9

Special Service Tool

ENGINE LUBRICATION

Condition

Poor circulation

Corrosion

Probable

COOLING SYSTEMS

C arrective action

cause

Restriction in system

Check hoses for crimps and clear the system
of rust and sludge by flushing radiator

Insufficient coolant

Replenish

Inoperative

Replace

water

pump

Loose fan belt

Adjust

Inoperative thennostat

Replace

Excessive impurity in water

Use soft

clean water

rain water is satis

Cooling system should
ed thoroughly at least

be drained and flush

factory
Infrequent flushing

and draining of system

nent antifreeze

be used

Overheating

Malfunctioning
fan coupling

thennostat radiator cap and

twice a year Perma

Ethylene glycol base

throughout

the seasons of

a

can

year

Replace

Radiator fm choked with mud chaff etc

Clean out air passage

thoroughly by using

air

pressure from engine side of radiator
Incorrect ignition and valve timing

Dirty oil

and

Inoperative

Noise

in

Adjust

engine

Refill

water pump

Replace

Loose fan belt

Adjust

Restricted radiator

Flush radiator

Inaccurate temperature gauge

Replace

Impurity
Overcooling

sludge

in water

Malfunctioning

Use soft clean water

thennostat

Replace

Inaccurate temperature gauge

Replace

Squeak

Use suitable

at water pump mechanical seal

replace
Damaged

or worn water

pump

bearing

Replace

SPECIAL SERVICE TOOL
Tool number

Kent Moore No

STl9320oo0

Tool name

Oil filter wrench

125664

00

LC l0

as
as

water pump

pump assembly
pump aSsembly

seal lubricant

or

Model S J J 0 Series

DATSUN 200SX

SECTIONEF
ENGINE FUEL

CONTENTS
DESCRIPTION
EFI

SYSTEM

FEATURES

EFI SYSTEM OPERATION
FUEL
AIR

FLOW SYSTEM

FLOW SYSTEM

ELECTRICAL

FLOW SYSTEM

TION
INJEC

FUEL

CONTROL

FUEL INJECTION TIMING

INJECTION QUANTITY

FUEL

EF

2

DESCRIPTION

EF

4

PREPARATIONS FOR

EF

4

INSPECTION

EF

4

INSPECTION

EF

4

EFI

EF

5

EF

5

FUEL

EF

7

FUE L PUMP

EF 29

EF

7

FUEL

DAMPER

EF 29

EF

7

FUEL

FILTER

EF 29

FUEL
AIR

FLOW SYSTEM

FLOW

SYSTEM

ELECTRICAL

SYSTEM

SIGNAL

EF 24
EF 24

PROCEDURE TABLE

CIRCUIT

EF 25

DIAGRAM

EF 28

COMPONENT PARTS INSPECTION
PRESSURE

EF 29
EF 29

CHECK

EF 29

INJECTOR

EFI SYSTEM COMPONENT PARTS
CONSTRUCTION AND FUNCTION

EF 24

INSPECTION

EF 30

REGULATOR

EF 11

PRESSURE

EF 11

AIR

FLOW METER

EF 30

EF 13

AIR

TEMPERATURE SENSOR

EF 30

EF 15

AIR

EF 31

REGULATOR

THROTTLE CHAMBER

EF 31

EF 18

DASH POT

EF 31

EF 19

WATER

EF 19

THROTTLE VALVE

EF 20

VACUUM SWITCH

EF 20

ALTITUDE

EF 20

DROPPING RESISTOR

THROTTLE VALVE SWITCH

EF 20

RELAY

THROTTLE CHAMBER

EF 20

CONTROL UNIT

DASH POT

EF 21

CHECKING AIR LEAKAGE

VACUUM

EF 21

AIR

PRECAUTIONS FOR AN EFI
ENGINE

REMOVAL AND INSTALLATION
AND FUEL PIPE

INJECTOR

REGULATOR

PRESSURE
AIR

REGULATOR

WATER

TEMPERATURE

SENSOR

SWITCH

ALTITUDE

DROPPING

SENSOR

EF 21

RESISTOR

EF 21

EF 32

TEMPERATURE SENSOR

EF 33
EF 33

SENSOR

EF 33
EF 34

INTAKE

CHECKING

EF 32

SWITCH

EF 34
IN
EF 35

SYSTEM

FUEL

EF 35

HOSES

SERVICE DATA AND
SPECIFICATIONS

EF 36

CONTROL UNIT

EF 21

RELAY

EF 22

GENERAL SPECIFICATIONS

EF 36

AIR CLEANER

EF 22

INSPECTION AND ADJUSTMENT

EF 36

EF 22

TIGHTENING

AIR
AIR

FLOW

METER

TEMPERATURE

FUEL
FUEL

SENSOR

EF 22

FILTER

EF 22

PUMP AND FUEL DAMPER

EF 23

FUEL HOSE

ELECTRICAL SYSTEM INSPECTION

23
F
EF 24

EF 36

TORQUE

TROUBLE DIAGNOSES AND
CORRECTIONS
TROUBLE SHOOTING

EF 37

CHART

CHECKING AND ADJUSTING

EF 37
IDLE

RPM

IGNITION TIMING AND MIXTURE
RATIO

EF 43

Description

ENGINE FUEL

DESCRIPTION
SYSTEM DIAGRAM
fUEL UNE
VACUUM LINE
INPUT SIGNAL
OUTPUT SIGNAL

f

Fuel tank

i
I
r

J
ili
Fuelmter

t

essure

h

regulatm

Fuel pump

witch California modelA
Switching module
cu

Air

Air cleaner
Idle speed adjus ing screw

i

Ji t

dlJ

r
Ai

nwmei

0

1r

r

L

Air pipe

b y
pall

I

L

valve

inducti
ln

fj

Air temperature
semOl

ew

EA
tube

Oil pressure
switch

1

II

I
c

I

8j

8

a
J
IC
I
lliru

Fuel pump relay

ON

U

1ST
0

Ignition coil

I
Ih

Ignition switch

J
s

lt1
Control unit

California models
q

SEF081

EF 2

0i
i

Ci

I

TC

i
0

II

pump
yuel

pex
aIn
d

fue

model

oor
5en

AltiudeCalifornia

unit

contro
A
I

tot

f

tes1

Drop ing

wltchmodels

l
iforni

or

ternpetaW

n

Vacu m

re

ltCl

11

A

MI

Perature
tem

Wate sensot

EFI System

ENGINE FUEL

Openltion

SYSTEM

EFI

The Electronic Fuel Injection

EFI

system is used to control fuel supply
electrically in place of the conven

control

jector

tional carburetor system
to convert the

sensors

Various sensors

1

I

Electrical

I

Control unit

Electrical

I

Injector

engine

stored

are

sent to the

unit where the optimum in

open valve time

puted according

The EFl system employs various

types of

into electronic

operating conditions
signals These signals

to

period

the infonnation

For detecting engine operation

signal
For calculating optimum fuel injecti on

EFl system utilizes electronic
elements such as integrated circuits
The

ICs

is com

in the memorY for control

fuel injection quantity

FEATURES

of

resistors

thennistors

electrically controlling
fuel

etc

for

the amount of

injected corresponding

to

changes

Because of this

in

engine operations
use
of electronic components this
system is able to provide a quick
response to changes in operating con
ditions and serves to improve the
engine perfonnance and to reduce
fuel consumption and hannful gases

signal
For

injecting

fuel

EFISYSTEM OPERATION

FUEL FLOW SYSTEM
Fuel is sucked from the fuel tank
into the fuel pump

discharged

from which it is
under pressure As it flows

through the mechanical fuel damper
pulsation in the fuel flow is damped
Then the fuel is filtered in the fuel
filter goes through the fuel line and is
injected into the intake manifold cyl
inder branch from the

Surplus fuel
sure

regulator

is led

injector

through the pres

and is returned to the

The pressure regulator con
trois the injection pressure in such a
un

fuel tank

the pressure difference
between the fuel pressure and the in
manner

that

take manifold vacuum is

kPa

55
2

kg cm

always 250

J

J

3 psi
36
n

D

L

r
SEFQ83

4
EF

ENGINE FUEL

EFISystemOperation

AI R FLOW SYSTEM
Intake air from

the

air cleaner is

metered at the air flow meter

flows
Idle speed
adjusting

through the throttle chamber and into
the intake manifold and then flows

11

R

cleaner
0

through each intake manifold branch
into the cylinder
Air flow during
driving is controlled by the throttle

Throttle

valve located in the throttle chamber

chamber

During idling operation

Air

screw

A

AirflOwm ter
LA S

f

unit
i

the throttle

I

L

LAir by pass

Air pipe

valve is in the almost closed position

screw

and the air is led through the by pass
line between air pipe and throttle
chamber In this
suction air is

case

adjusted

the quantity of
by means of the

idle

speed adjusting screw During
warming up operation the air flow is
bypassed through the air regulator to
increase engine rpm

respondence

ELECTRICAL FLOW

SYSTEM
The suction air flow varies with the
movement
the

of the air flow meter

quantity

of fuel to

and

be injected

should be controlled correctly in

SEF084

cor

l

with

the

injector

air

present

flow In the EFI system the injection

control

pressure is held

mines

constant at 250 kPa

3 psi and the area
36
kg cm2
of the injector noule hole is also con
stant Therefore
the fuel injection
quantity can be determined by the

11

this

cording

55
2

open valve time

The

period

unit of the EFI system deter

pulse width duration

to information

ac

electrical sig

nals

from various types of sensors
thereby controlling the fuel injection
quantity

I

L

Vacuum switch California models

Switching module
Injector
Air flOW

o

Air

by

pass

Air

temperature

sensor

screw

I

f

s Control unit

SEF085

EF 5

ENGINE FUEL

EFI SystemOperation

SIGNALS FOR CONTROl

UNIT
An electrical

signal from

water

WATER TEMPERA11JRE
SENSOR

I

I

L

Opening of

AIR TEMPERATURE
SENSOR

IGNmON COIL
NEGATIVE
TERMINAL

H

Engme rpm

I

TIlROITLE VLAVE
SWITCH

throttle valve

IGNITION

of

mtake air

Starting
operation

SWITCHH

California models

intake air

H TempctalUIel

START position

VACUUM SWITCH

Quantity of

in

pulse computed

the control unit

Temperature of cooling

I

I

the duration of the

for computation The open vaIve tiJUe
period of the injector is controlled by

each sen

sor is introduced into the control unit

HI

take

manifOldl

vacuum

AIR FLOW
METER

H

ALTITUDE SENSOR
California modet

INJECTOR

H

Atmospheric
preuure

I

SEF169

engine

is detected

When starting the

CONTRDL UNIT

pump is

operated by the current
supplied through fuel pump relays

by monitoring both the generation
of the alternator and the engine oil

1 After the engine starts
the fuel pump continues to operate
using current supplied from fuel

moni
pressure Because of this dual
fuel
operation
toring system
pump

pump relay 2 monitoring the
gine revolution and fuel pump

en

tion even if one of these monitor

reo

units should fail

Fuel pump operation

2 and

IGNITION SWITCH

IGNrIlON SWITCH
START

IG

ENGINE REVOLUTION

lay

I

ALTERNATOR
l

TERMINAL

II

OIL rRf5SURE
SWITCH

I

fuel pump

I

ULAY

relay

I
fUEL PUMP

EF 6

I

EF37

1

some reason

2 receives the

en

gine stall signal and stops feeding
current thereby stopping the opera
tion of the fuel pump

FUEL PlJlIP RELAY

can

be assured

during engine

rota

If the engine stalls completely due

1

If the engine stalls for

r
FUEL pU
lp

engine

the fuel

Rotation of the

INDEPENDENT SIGNALS OF

to a malfunction
is

stopped

proves safety in
function

the

supply

offuel

at once this system iJU
case

of engine mal

ENGINE FUEL

Fuel

Injection

Control

FUEL INJECTION CONTROL
FUEL INJECTION TIMING

the basis for

as

tion but the

o

2400

1200

3600

I

I

1k

I

engine

tion

For providing this enrichment
control unit computes the quan

It

causes

total quantity of fuel to be

injected

from each

sent
m

I

I

i

71

Warm

fJ

in the full

or

tity of fuel to be added to the basic
injection quantity by using signals

l

Start of injection

the

the

1

f

c

8400

7200

example the
starting
throttle posi

fuel should be enriched when

v

10

4

6000

4800

Ignition point

sensor

enrichment

up

Fuel is increased according to the

cooling water temperature monitored
by the water temperature sensor This
enrichment is zero when the cooling
water temperature is above 40 to

104
engine has a repetitive four
stroke cycle suction
compression
exhaust Fuel injection
combustion
is made just prior 10 the beginning of
the suction stroke in each cylinder
The

4

situation

this

is

the

not

for the EFI system

same

The

fuel injectors

connected

in

parallel

are

electrically

in the control

unit All injectors receive the injection
signal from the control unit simul

taneously Therefore injection is made
independently of the engine stroke
cycle suction compression combus
and exhaust

tion
der

In the

injeCtion

engine

is

after receiving the ignition
the ignition coil two times

during

one

stroke

signal from

cycle

made

suction

into the cylinder but
is injected into the outside portion of

jected directly

Therefore

the air

fuel mixture is sucked into the cylin
der when the in take valve opens to
the

suction

stroke

In

which

is

quantity and the

enrichment

used

the

to

quantity

correct

basic

or

injection

various conditions

Intake air temperature

Fuel injection is increased accord

ing

to

tored

the intake air

Enrich

injection

quantity

quantity

temperature

400C

ment

INJECTION
engine

is above

104OF

Cold start

The

moni

the

Cold start

BASIC

temperature

air temperature sensor
enrichmen I is zero when the

by

intake air
Basic

injection

changed by

enrichment

This
Fuel

is

of idle contact

Ihat is

correspondence with the

in

ratio

OFF

is the

basic injection quantity
the basis of the injection

infonnation

rpm

enrichment
enrichment

providedes
ability in cold
weather with the ignition switch on
START during the cranking opera
improved

starting

created

tion and when the water temperature
is lower than 400C
1040F
The

vide

elapsed

and

load

information

state

are

by two signals which pro
for the rolation of the engine

One of these two signals is sent out
from the ignition coil that detects the

engine
signal

rpms
sent

The

from

other

one

is

which monitors the suction air quan
tity The injection quantity deter
mined by these

signals

is caIled the

basic injection quantity

temperature and cranking speed

Stsrt

enrichment

When the ignition switch is in the
START

operation

position
a

during cranking

constant amount of fuel

irrespective of the cooling
temperature

is increased
water

When

ENRICHMENT
The basic injection quantity

time and amount of this en

richment is detennined by the water

the

the air flow meter

other

the air fuel mixture is kept
outside the intake valve
strokes

injection quantity

of the

QUANTITY
is at

Fuel in this EFI system is not in

start

The fuel

600C

l400F

Enrichment

QUANTITY
sum

to

ON

once

compression combustion exhaust In
other words one injection of fuel
provides only half the fuel quantity
necessary for operation of one stroke
cycle of the engine

the intake Valve

FUEL INJECTION

cylin
four

made

The required fuel quantity
tained after fuel injection is
twice

the

Intake valve opens
SEF086

However

rota

is not controlled
For

by this factor alone

Crank angle

Cylinder

providing engine

injector

reaches
is used

Cold
zero

start

this

enrichment

START

enrich

ment will then occur

EF 7

FUtJllnjection

EXAMPLE

ENGINE FUEL

Control

OF FUEL INJECTION QUANTITY

Cold start
Intake air

temperature

DoC 320F

It

and

constant

AFTER

water

temperature rises from DoC
ehmenl

START
ch

llnitlon
Waler

1

lempcurcsensor

Thrbllle

COlD

switch

FULL

IDLE

FTER

Ignition

320 F

lw switch
i

nriehmen

Throltle ahe switch
r
I
vacuumswitcb

at
enrichrne

Iertemperaluresenlor

START
nridunent

IDLE

Throttle VlIlve tIIltch

QOLING WATER
orichm

TEMPERAnJRE
Witertemperalure

I

Ol
sen

I

chmenl

KE

RE

P R

IR

TA

AirtempcratureleDSOl
ic
Bots

luel

njection

quantity
Air

metcr

fio
Inition oil

Vcbide cooditioll

Janition

IWjlcb

Threl
e VlIlve

switch

Vacuum switch
California models
Water

OOe

temperature

Intake

200C

nor

6110FI

l04on

40 C

oGC 32oF

lemper iIturc

On California

600C 140oF

Full

models the

enrichment

ctinted

when the

vacuum

8

oC 11760F

lIo0e

ConSlant
17601

Const nt

switch

ON

when the

Full

throttle

contact is

ON

Hot restart
Intake air

temperature

at

Isoe

constant and
S90F

1F niliOn
W
t

r

water

temperature rises from 600e I400F

ehment

AFTER START

INTAKE AIR TEMPERAltlRE

ch

emperalure

Ilensm

FULL

vacuum

Ijl nilion

W

switdl

switch

i

ilch

ricbmcnt

telh

lIUl
mpcl

sensor

TluoltlevlIlYeswilCh

Air

enrichment

enrichment Throttle nlve

1

w
I

lemar

sie fuel

injeclion qUlrnlity

nometer
II

Air

Inilion

Vehicle condition

Ignilionswitch

nkinr

Vehicle
starling

Idlinl

ConstanHpecd drivina
ON

START
FULL

ThronlevoIhe
Vaeuum
California
WOItet

J ke
In

s

itch

ilch

cION

OFF

OFF

THROTTLE
rontac10N

OFF

OFF

ON

1odeb

empcnlure

F
800e
140l

600

176l
F

800C 117b 01IConst ntJ
ISoC

l ure
emper

On California models

8
EF

IDLE

the

Fun

enrichment

ctinted

ben the

vacuum

S90F

Constant

switch is

ON

when the

FuU

throttle

ntutis

ON

SEF344

ENGINE FUEL
After start
When the

from the

when

enrichment

ignition switch
ON

to

START

is turned

position

after cranking operation the start
enrichment becomes
or
cold start
zero

The

after

the

pedal

is

not

throttle valve switch

idle contact is

ON

to

provide

ad

ditional fuel injection

enrichment

The

enrichment

The
full
enrichment provides
smooth full throttle driving perfonn

California models
The
After Idle

enrichment

The

after

idle

enrichment pro

vides smooth acceleration when the

full

enrichment is activated

when the intake manifold

decreases

gradually as time passes finally be
coming zero and is detennined by
cooling water temperature

Full

ance

this

to

start

depressed

accelerator

enrichment is

after start

compensate for
sudden decrease in fuel quantity
provided

the

Fuellnjection Control

ac

celerator pedal is depressed to start the

below

inHg
ing is

3
21
or

kPa

vacuum

160 mmHg

is

30
6

when the throttle valve open

than 450

more

vehicle
The

after

idle

enrichment

gradually as time passes finally
becoming zero and is detennined by
cooling water temperature
creases

Idle

enrichment

When the

engine

is

idling

that is

models

California
Non

de

The

full

when the
more than

enrichment is activated

throttle

valve

opening

is

450

ENRICHMENT SIGNAL AND SIGNAL SOURCE CHART
Throttle valve switch
Water

tempera
Fuel

ture

sensor

Air

tempera
ture

sensor

enrichment

Cold start

Idle

Full
throttle

contact
contact

I

Vacuum

witch
California

switch

START

models

0

0

Ignition
coil
Remarks

negative
terminal

0

0

Start

After start

Ignition

0 1

0

1

Ignition switch
START

Idle

After idle

0

0

0

2

2

Idle contact

ON
0

Full

Warm up
Intake air

ON

0

OFF

0

0

0

temperature

9
EF

ENGINE FUEL

Fuel Injection Control

FUEL SHUT OFf
Fuel

is

off
shut

accomplished

dur

not

The

require fuel

graph

below shows

the

fuel

shut off tange

ing deceleration when the engine does

nmodels

Manual

Automatic transmission models

3 OC
3 000

S
e

1

2

600

@

I

2

@

0
0

2 200

1
S

9

600

s
e
2 200

Il
0

1 800

I

1

@

800

@
1

1 400

400

1
I

oooi

@

1 000

@

@
Cooling

temperature
at 80 C 1I6 F

Cooling

water

Fuel is shut off and fuel is
Deceleration from

zone

Deceleration from

rone

Deceleration from

zone

A

injected again

in tone

e

S

and

A

Deceleration from

zone

B1

A

is not shut ofT in

Engine
orue

driving

ALTITUDE COMPENSATION
California models
The density of ail

proportion

the

air fuel

high

becomes thin

to the altitude
ratio becomes

that

so

riche

t

altitude

The

altitude

compensator

is

a

device to correct air fuel mixture to
an

optimum ratio automatically

EF l0

rpm

zone

e

increased in order

S2

Idle switch ON

SEF095

temperature
1I6 F

Fuel is shut off and fuel is
injected again in zone C

injected again in zone en
Fuel is Dot shut off
Fuel is not shut off

zones

in zone A
C and B
fuel is shut off

etc

in

from zone B2

Deceltration from
Fuel

water

80 C

Fud is shut off and fuel is

D

Fuel is not shut off

e

Idle switch ON downhill

driving

zone

injected again in zone e

Engine rpm increased in order
of

Deceleration from

Ci

Fuel is shut off and fuel is
B

at

etc

Bl

and

downhill

A

Fuel is not shut off in
en

B2

z one

A

and

Bl

zones

in

fuel is shut off

ENG IN E FU EL

EFI

System Component

Parts Construction and Function

EFI SYSTEM COMPONENT PARTS CONSTRUCTION

AND FUNCTION

FUEL FLOW

SYSTEM

FUEL PUMP

Fuel pump

Battery

i
P
s

Outlet

Normal flow

Ignition

Relief valve actuated
due to

switch

clogged discharge

relay

Fuel pump

El

1
I

1

II

Oilpres ureswitch

I

IG Fuel
pump relay 2
Alternator

line

Normal

switch position
Nhene

ine

When

nline
opEration

opped
Allenulor

rmilUll

L

Inl

ON

011

OLlprclSurt
witch

Fuel
IGN SW

position

Fuel

1

Oil
Alternator

pump
prellure

No

No

generate

pressure

relay

pump
I

relay

ON

START

pump

2

II

Actuate

ON

Gentrate

Normal

ON

ON

Failure

NOllTUI1

ON

Actuak
Actuate

ON

atc
Gencr

Failure

ON

Actuate

lailure

Fwure

OFF

No

No

teneralt

prcuure

No
ON

actuate

No
OFF

OFF

actuate

SEF096

The fuel pump

employs

construction whe

e a

roller is directly

coupled

a

wet type

pump with

vane

to a motor

fIlled with fuel This construction pro
vides superior coupling characteristics
between

the pump

greater safety

and motor

and

in case of fire

RoUer

In the

pushed

vane

pump

outward by

the roller is
force

centrifugal

when the pump rotates and is pressed
against the outer wall This rotary

portion and surrounding wall are not
coaxial and pumping is perfonned
by the change in clearance between
the wall and the rotary portion Thus
when the clearance is large fuel is
sucked in when it decreases

fuel is

discharged
The

in the pump

is

to open when the pressure in
the fuel line rises over 294 to 44I kPa
5
4

kg cm2

43 to 64 psi

to malfunction in the pressure

due

system

valve prevents abrupt
drop of pressure in the fuel pipe when
The

Outlet
E F252A

stopping

operation the fuel pump is actuated
irrespective of the conditions of the
alternator and the engine oil pressure

swjtch
After starting the engirie the igni
the alternator
ON

tion switch is

and the engine oil pressure
switch is open through rotation of the
th reby actuating the fuel
engine

operates

pump

relief valve

designed
3 0 to

START position for cranking

to the

check
the

engine

If the alternator stops and the en
gine oil pressure decreases for some re
ason

the fuel pump

turned

relay

to

II

l is turned

pump is

relay

stopped through

switch remains in the
In this

manner

2 contact is

and the fuel pump
OFF Then the fuel

fuel

the

ON

supply

ignition
position

is cut off

for safety purposes when the engine

Operation

accidentally stops during driving

When the ignition switch is turned
EF l1

EFI 1

ENGINE FUEL

Component Parts Constroction and Function

FUEL DAMPER

solenoid

valve

driving pulse

principle

is

When

iI

to the coil built

applied
injector the plunger is pulled
the solenoid thereby opening the

into the
into

needle valve for fuel injection The
quantity of injected fuel is in propor
Fuel
outlet

tion

the

to

pplied

duration

of the

pulse

from the control unit

SEF099

SEF097

1

Injector lower rubber insulator
Injector lower holder

2
3
4

The

fuel

damper is provided to
suppress pulsation in fuel flow dis

charged

5

or

from

justment

the fuel pump No ad
is allowed on this damper

Change
sure

Injector upper rubber insula
Injector upper holder
Injector

in the pump

is monitored

discharge

FJectric terminal

pres

by the diaphragm

o

le

and spring which vary the volume of
the fuel chamber for suppressing pul

li

sation
11

f
I

Filter

FUEL FILTER
SEF098

R

Il

Fuel outlet

j

PRESSURE REGULATOR
To intake manifold

t

Fuel inlet
EF256A

chaniber

by the diaphragm

manifold

vacuum

air

the

the fuel

f1lter is

damper

is used to remove

placed

between

thereby

keeping

Air chamber

Diaphragm

tank

fuel

Fuel inlet

the

through
constant

return

side

differential

port

pressure

provides optimum fuel injection
every mode of engine operation

and the injector and

foreign

Intake

introduced into

differential pressure constant causing
excessive fuel to return to the
This

The fuel

chamber

is

in

matter in the

fuel Water in the fuel is collected at
the bottom of the f1lter

casing

SEF100

The pressure regulator controls the
pressure of fuel so that a pressure

INJECTOR
The

injector

receives

signal from the control

the

unit

pulse

and in

jects the fuel toward the intake valve
in the cylinder head
The

EF 12

injector

operates

on

the

difference of 250 kPa
3 psi
36

can

55
2

kPa kg
196
2 0
u
28
98
10
e
14

t

kgjcm

be maintained between

the fuel pressure and intake manifold
vacuum
The pressure regulator is
divided into the air chamber and fuel

em

psi
Fuel pressure
250 kPa 2 55 kg
36 6 si

I

0
98
10

Idling

em

tmospheric
D

e
CSSW

Foil
throttle

Ttme
ManiCotd
vacuum

14
E F258A

EN GIN E FU E L

E FI System

Component Parts Construction

and Function

AIR FLOW SYSTEM
AIR FLOW

METER

35

Ro
33

Damper plate

Helical spring

U
To intake

R

manifold

32
Potentiometer
R

IB

RJO
34
Air temperature

sensor

25

cleaner

From air

Terminal number
By pass port

Air temperature

fi

sensor

Potentiometer
To EFI

harness
EF441A

The

air

quantity

signal

flow meter

the

and sends

width

can

be detennined

for correct fuel injection by the injec
air flow meter is provided

The

tor

with

a

flap in the air passage As the
through the passage the flap

air flows

and its

rotates

angle

of rotation is

electronically monitored

to count the

air flow rate

specifically the angle of rota
flap is monitored by a
potentiometer provided inside as a
potential difference V When the flap
deflects along with a change in the
More

tion

of the

intake air flow rate

the terminal

mounted to the flap shaft slides

@
on

the variable resistor R from RI to R9

causing the voltage

across

tenninals

@ and@tochange
A

constant

voltage
and

@

is

across

Then the

VB

angle

where

AIR REGULATOR

able to rotate to

an

equilibrium

an

between

the air flow pressure and the return
coil spring can be main
lhe
of
torque

The

tained

damper plate
for the

flap

damper
are

so

disturbed by

a

terminal

and

chamber

provided as

Electric

damper

that the flap will not be

pulsation

in

manifold

during operation
The damper plate is interlinked
with the flap and as the flap rotates
the compensating plate rotates in the
damper chamber keeping a very small
vacuum

Shutter

clearance between the chamber wall

Sleeve

During idling operation when the
amount of intake air is extremely
small

Air outlet
rHeater

the air flows parallel with the

flap through the by pass port
the specified intake air flow

battery

terminals

@

air flow rate is

converted into the voltage ratio
V

The flap is

so

that

can

be

provided correctly

voltage VB

applied

control unit for computation

a

to the control unit so that the

pulse

base

measures

of intake air

signal

which in turn is sent to the

air

The air passage is provided with the
temperature sensor and the by pass
air by pass screw which
the idle mixture ratio

SEF101

port has the

regulates

The

air

regulator bypasses

the

throttle valve to control the quantity

EF 13

EN GIN E FU EL

ystBrn Component Pans Construction and Function

EFI

of air for

speed

the engine idling

increaSing

starting the engine at a bi
temperature of below 800C

metal

176OF
to the air

a

regulator

heater

are

I412
3

32 1 30

30
1 059

built in

When the ignition

switch is turned to the

START posi

engine running electric current
flows through the heater and the bi
metal as it is heated by the heater

e

to move and closes the air pas

The air passage
sage in a few minutes
remains cloSed until the engine is stop

21 5 759

20

2

706

l

16 5 583

10

or

hegins

COLD

curve

40

c

A bimetal and

on

Characteri5tics

when

353

a
0

88

2 5

Air inlet

0

g

20

0

20

40

60

80

4

32

68

104

140

176

Tempetature oe

FJ

and the bimetal temperature drops

ped

to below

0

800C 176OF

Initial bimetal temperature

200e

68

HOT

30

Idle speed
unit

UNIT

I A

adjusting

screw

Throttle valve remains closed dur

ing engine idling and the air required
for idling passes through by pass line
between air pipe and throttle chamber
Idle adjustment is made by the idle

speed adjusting

screw

at the

e

1 059

s

20

10

ri

o 177

2 5

8 8

I

g

4

2

6

8

10

1

Bimetal

2
3

Shutter
Heater
SEF102

Thne mmwU

1A S

j

unit

L

dicr

JFj

c

pi

AIR PIPE
the line be

The air pipe located
the air flow meter
on

tween

Intake manifold

and the

throttle chamber prevents the
ing of the intake air

A S unit
I

pulsat

THROTTLE CHAMBER
The

throttle chamber

located be

tween the air flow meter and the in
take manifold is equipped with a

dr

This valve controls the intake

valves

air flow

pedal

Airduc

in

response

to

accelerator

Air flow meter

movement
SEF106

The air passage is a two barrel type
which consists of a primary side and a

secondary side
on

A venturi is

provided

the primary

side

When

opening angle of the

the

ThIottle valve

witch

Primaty throttle valve

primary throttle valve reaches 350 the
secondary throttle valve will be

opened by

a

linkage

I
IH

which is connect

Secondary throttle valve

ed to the primary throttle valve
rotary shaft of the primary
throttle valve is connected to the
The

throttle valve switch

EF 14

J

SEF104

EN GIN E FU EL

EFI System Component Parts Construction and Function

DASH POT Automatic
transmission models
The dash pot is attached to the
The dash pot pre

Dash pot

throttle chamber

vents the throttle

valve from

closing

Air

abruptly and thus stalls the engine
The throttle valve will gradually reo
turn

the

to

during

idle opening

passage

Throttle
lever

position

Throttle

deceleration

L
h

valve

J
SEF105

ELECTRICAL SIGNAL
SYSTEM

WATER TEMPERATURE
SENSOR
CHARACTERISTICS CURVE

WATER TEMPERATURE
SENSOR
The water temperature

thermostat housing monitors
change in cooling water temperature
and transmits a signal for the fuel
enrichment to change the pulse dura
tion during the wann up period
I
The temperature sensing unit em

7 0

into the

ploys

a

6

TEMPERATURE
SENSOR

q

4
c

3

8

2

water

temperature

0

the

The

air

the

change

temperature

air

in the

and transmits

flow

sensor

meter

intake air
a

buHt

monitors

J

100 kn

t

I

SOOC 1220

1

I

6

1

31

0 2

rise

AIR TEMPERATURE SENSOR

680F

I

4
0

0

into

2 9 Jen at 200C

0 68

I
0

to

2 1
I

0

temperature range

decreases in response

IOoC l40F

kn at

8
AIR

The electrical resistance of the ther
mistor

I

I
114

10

thermistor which is very sensi

tive in the low

I

30
20

built

sensor

06

I

30
Air

22

temperature

sensor

L
20
4

0

20

32

68

40

60

80

104 140 176

Temperature Oc OF

SEF101

temperature

signal for the fuel

enrichment to change the pulse dura

Idl

contact

tion

The temperature sensing unit em
a thermistor which is very sensi

The

idle contact closes when the

ploys

throttle valve is positioned at idle and

tive in the low

opens when it is at any other position

temperature range
The electrical resistance of the ther

istor decreases in response to the air
temperature rise

The

idle

idle

contact

wann

up

for

compensates
and

after idle

en

richment and sends the fuel shut off

signal

Full throttle contact

THROTTLE VALVE SWITCH
The throttle valve switch is attach
ed

to

the throttle chamber and

tuates in response to accelerator
movement

ac

pedal

This switch has two sets

of contact points

One set monitors

the idle position and
monitors full throttle

the other set

position

The full throttle contact closes only
when the throttle valve is positioned at
full throttle
more than
45 degree

opening of the throttle valve

The

contact is open while the throttle valve
is at any other position

The

full contact compensates for
full enrichment

Full throttle
contact
SEF108

EF 15

EFI System

Component Parts Construction

ENGINE FUEL

and Function

VACUUM SWITCH
California models
The
for the

full

Terminal

switch

vacuum

Switching charact8ristics
compensates

ON

enrichment by controll

ing the intake manifold
switch consists of a

diaphragm

OFFj

and a microswitch
When the intake manifold vacuum

lowers

during

of the

back

3 kPa
21
160 mmHg 6 30 inHg

acceleration the tension
the

spring will push

diaphragm

and open the contact

microswitch

switching

j

This

vacuum

vacuum

This

will

signal to the control

an

Vacuum
decrease

Vacuum
increase

of the

the

cause

module to transmit

@ @

hn

Intake
manifold

Battery

ON

j
@

unit

uum

l

To control

unit

@
@

r

Switching

jule
mo

SEF217

ALTITUDE SENSOR

california

models

in

proportion

sensor

is

2 6

composed of

c

o

Altitude
m ft

changes

the position of the magnet installed
at the tip of bellows The magneto
resistance element senses the

signal

transmitted to the elec ronic
control unit and ihe injection duration
sensor

is

of the injectors is detennined to ob
tain the

optimum

air fue

ratio

by the

kPa
To
control unit

if
m
Magnet

control

The

connector

The
unit

essential

is

receiving
sensor

means

and the

connected to other

is

sensoIS

generate

an

electrical

the control

pulse Upon
signal from each
a

95 4
716
28 2

814
611
24 1

SEF113

SEF275

is controlled to
time period
provide an optimum quantity of fuel
according to the engine characteristics

The control unit consists

mainly

three integrated circuits fonned

on

of

the

printed circuit board This construe
tion provides superior control unit
reliability

unit generates a

pulse whose duration
EF 16

of a multi

EFI harness

role of the control

to

mmHg
inHgJl

valve

unit is connected to

by

800

5 906

j

Magneto resistance element

the EFI harness

1

J

electronic control unit

CONTROL UNIT

641

Atmospheric

position

from the altitude

500
1

pressure

Bellows

of the magnet and transfonns to the
electric signal
The electric

u

s
0

the bellows the magnet and the mag
neto resistance element At high alti
tude the bellows extends and

U

6

electronic control

unit

This altitude

curve

nn

signal

the

to altitude for

O1aracteristics

is a device to

sensor

m

This altitude

obtain the electric

injector

open

EF323A

EFI System Component Parts Construction and Function

EN G IN E FU EL

DROPPING RESISTOR
The

resistor

dropping

lower the

suitable for the
The

voltage
injector

source

is
to

used to
a

level

I I

resistor is connected

dropping

injector It reduces
voltage to approximately
1 4 of the source voltage These resis
tors protect the injectors from a1terna
tor voltage surges and from the effects
of other components in the vehicle s
in series with the

the

source

electrical system

Electric
tenninal

Resistor

tL
I

L

I

1

r

I

SEF114

RELAY

I

Battery

EFI relay
The EFI relay
electronic

serves

to activate the

fuel

injection
through the ignition switch

system

Dropping

I
81

I

l

1 and

Injector

I

o

5

Fuel pump relay

resistor

Fusible link

I

Control unit

1

IG

2

Ignition switch

SEF115

The

fuel pump relay serves to ac
tivate the fuel pump For 9peration of
the fuel pwnp refer to Fuel Pump

EFI

HARNESS

One wiring harness is used to con
lines between the control unit

nect

and the related major units
The 35
harness

unit

pin

is

and

connector of the EFI

connected to
runs

to the

ment

The

harness

units

the

air

valve switch
lator

ture sensor

jector

runs

flow

vacuum

altitude

the control

engine compart

sensor

dropping

to

meter

various

throttle

switch air regu
water tempera
resistor and in

etc

Battery supplies

power to

through fusible
designed especially for EFl
and control unit

Dropping resistor

injector

I

I

II I

Air flow meter

link

1

i

7

SEF116

EF 17

c p1

rn
I

lj
a
i

is

there fuel
i

when

suficentlY

n

mp1lcla
a
g
e
n
t
s
pump hose clamp

fuel

operate

antHrcez

fuel hose
iMJ reule fuel
use
in

not ruel not not
00

nO

00 Do

Tighten
rev

when
pedal

not
do

aC len staring

tot

ENGINE

afte1

car

dept S

EfI
en

not

EFl cvicng
AN

Do

dtatelY
Imrnt

ItarUPi

engine
up

or

i
l
5
p
e
c
t
i
n
g
FOR

leak

to

directly

when

v

avoid tight
to

a

carefulY

pOWe

point

PRECAUTIONS

unec arUY

meter ocnotur tero

bntery

fol wing

ke

should int

air

not

to

i

floW

ap lY

the

even

Do

tentlon

inlectan

Randle dalT ge Ther

air
in

clo

PaY
coil

conector extrme devlop
in

dam ge

an

in

55

harne cause
EFI

can

to
e

reulting

volt l thus
surge

91n
1

preventrec ption

em

to

to

due

10
t

e
t

rne

lhlesUes

of

operation

malfunctio degrade

igniton

groubantder

dIY off
rne

h

turn

end pl1Ita

ducnthecent

noise parts
a
d
j
c
e
n
t
con ect con ection EFt from sylten circuit EFt removing and
condesr EFl external Keep BefotO switch cable
poor high andtolCcir ut Keep away
Securely
A

ly

etc

h

an of Ie

bater

power

no
is

and

instaled along hatnes ththerate idling

as

bateic

disconect operating

is

is

is

olt
12

UJe

Alwl

1I

to

cable Efl iure engine

engine fceder fsitodme Maunike t whUe

reciv4anlt oposite

atempt whUe ante na
not

Qurce Do cable route control
i

a

If

interferen
e

ij

ENGINE FUEL

Removalsnd Installstion

REMOVAL AND INSTALLATION
INJECTOR AND
FUEL PIPE
1

Follow the

pressure
fold
5

procedure below

reduce fuel pressure to

to

regulator

to

intake

mani

jector

Remove boits securing fuel pipe

and

remove

Place

rag under

a

zero

connecting
ing of fuel

J

clamp on fuel in
injector from

fuel

fuel pipe

and pressure regulator

CAUTION
Before

Unfasten hose

8

fuel

pipe

injector when dis
to prevent splash

fuel hose release

disconnecting

elimi

fuel pressure from fuel line to

danger

nate

Start the

I

engine

Disconnect the harness connector

2

of fuel pump
is running

2 while the

relay

engine

Reibracket
SEF099

1

Injector lower rubber insulator

2

Injector lower holder
Injector upper rubber
Injector upper holder
Injector

3
4

i5
SEF119

SEF131

6

Remove

screws

securing fuel injce

tors

3

a

three times

or

Turn the ignition switch

5

Reconnect the harness connector

OFF

If the engine
pump

When

installing injector

install it
b

not start

no

check that

scratches or abrasion at

lower rutiber insulator and securely

of fuel pump relay 2

fuel

the order of removal

there are

4

w
1

install injector and fuel pipe

To

reverse

After the engine stalls crank the

engine two

9

insulator

to

remove

making

sure

it is air

For installation of fuel hose

tight
refer

Fuel Hose

connector

relay 2 I
a rness

and crank the engine for

bout 5 sec

conds
Then

the

turn

switch

gnition

INJECTOR RUBBER HOSE

OFF

2

Remove

ing parts and

or

7

connectors

Accelerator wire

Injector harness

connector

valve hose and air

VC

If necessary replace injector rubber

disconnect the follow
Remove

fuel pipe assembly

pulling

out

fuel

pipe

pressure

regulator

as an

injector
assembly

by

hose

proceed

as

follows

and
Removal

regulator

hoses
Air

regulator and

its harness con

nectar

Vacuum hose at the fuel pipe

con

nection end
Disconnect

3

fuel

feed

hose

and

fuel return hose from fuel pipe
Place a rag under fuel

pipe

to

pre

Socket

Y

20

mm

0

79 in

of fuel

vent

splashing

4

Remove vacuum hose

connecting

EF551

EF 19

ENGINE FUEL

Remolialand InstBllatioh

1

On injector rubber hose

off

a

20 mm

point approx

2

0 79 in

fuel pipe assembly

from socket end
2

Heat

15

3

soldering

minutes

iron

150 watt

for

To install pressure regulator
the order of removal

reo

verse

Cut hose into braided

reinforcement

from mark

to

For installation of fuel hose

socket

end

to

Do not feed
touches

Remove pressure regulator from

measure

soldering
injector tail piece

iron until

refer

3

Remove air pipe to facilitate

sensor

harness connector and then

re

move

water

by

5

To install water
r

it

AIR REGULATOR

reverse

the

sensor

t Ult

ture sen

of removal
Ordi
f

Be sure to
when

install

installing

washer

copper

watar

temperature

sensor

a

Be careful

b

plastic
ing iron
Never piece injector

damage

not to

connec1or

etc

socket

with solder

in

a

THROTTLE VALVE

vise when

SWITCH

rubber hose

disconnecting
3

temperatur

it counterclockwise

turning

Fuel Hose

CAUTION

reo

moval of water temperature sensor
4
Disconnect
water
temperature

Then pull rubber hose out with

hand

Installation
Clean

1

exterior

of

tail

injector

piece
2

Wet inside of

new

rubber hose

With fUel
3

Push

as

far

Disconnect

end

of rubber

hose with

as

Clamp is

they will go

not

necessary at this

2

3
air
4

con

nection

cable

ground

from

battery
Unfasten

hose and

hose socket onto injector tail piece by

hand

I

clamp
disconnect

Remove

each side of

on

hose

setscrews

and

remove

regulator
Disconnect

electric

connector

from air regulator

1

S

2

To

install air regulator

reverse

Disconnect battery ground cable
Disconnect throttle valve switch

harness

the order of removal

ector

co

CAUTION

3

After

valve switch to throttle chamber

properly connecting fuel hose
to injector check connec1ion for fuel
leakage

Remove

WATER

4

TEMPERATURE
SENSOR

toward you
5

Slowly pull throttle valve witch
To

reverse

6

PRESSURE
REGULATOR

securing throttle

screws

install throttle valve

witch

the order of removal

After installation

adjust position

of throttle valve sWitch
Refer

to

under the

Throttle

Valve

Switch

heading Component

Parts

Inspection
Fuel pipe assembly

THROTTLE
CHAMBER

I

2

SEF122

Disconnect
Remove

coolant
I

pipe

Remove

the

and pressure

sembly

fuel

injector fuel
regulator as an as

from the intake manifold Re

fer to Injector and Fuel Pipe for
moval

EF 20

reo

battery ground cable
radiator

by opening

drain

cap

Drain

plug

CAUTION
The coolant should not be

drained
has cooled off completely
Otherwise burns may be incuned
until it

battery ground cable

1

Disconnect

2

Remove hoses

tube and air duct

from throttle chamber
3

Disconnect

throttle

valve switch

harness connector
4

Remove

accelerator

wire

from

throttle lever
5

Remove

chamber

to

bolts
intake

throttle chamber

can

securing throttle
manifold
The
be removed

ENGINE FUEL
install throttle

To

6

verse

chamher

reo

2

Remove

3

one

replaced by

each time the

tle
throt

new

chamber is

To

install altitude

To

sensor

reverse

install dash pot

reverse

the

order of removal
4

After installation

adjust dash pot

touch speed Refer to Dash Pot under
the
heading of Component Parts

removed

5

the order of removal

chamber

the order of removal

Gasket should be

dash pot from throttle

Remova and Installation

Inspection
Throttle chamber

DROPPING
RESISTOR

VACUUM SWITCH

J
i

N

m

18

m
lkg
22

8
1

ft lbl
2 2 13

161

SEF128
SEF126

Do not adjust throttle valve stopper
screw

as

it

is

properly adjusted

SEF141

at

1

Disconnect

cable

ground

from

battery

factory

2

battery ground cable

Remove

air cleaner and air flow

I

Disconnect

2

Disconnect vacuum hose and har

Cleaner for removal

ness

connector from vacuum switch

3

3

Remove

switch

vacuum

from

bracket
4

meter

vacuum

switch

reverse

the order of removal

an

Refer to Air

assembly

Disconnect

harness

ing
5

dropping resistor
Remove dropping

connector

from
4

To install

as

resistor attach

screw

To

install dropping

resistor

re

verse the order of removal

ALTITUDE SENSOR
CONTROL UNIT
The control unit is mounted on the

DASH POT

left side dash panel

Dash

0

1

pot

Left side dISh

SEF323

panel

Throttle
chamber

IJ

1

SEF142

Disconnect

ground

cable

from

battery
2

Remove control unit
Refer to Control Unit for removal

3

Remove throttle chamber
Refer to throttle chamber for
moval

Remove altitude sensor

attaching
I

bolts
reo

4

Disconnect

from altitude

harness

sensor

connector

Turn

ignition switch

then disconnect

ground

OFF

and

cable from

battery
EF 21

ENGINE FUEL

Remoraland Instalstion

CAUTION
Before

disconnecting

3511in

connector

ignition

switch

connect

ground

be

0 FF

I

Oisconnect

and

remove

EFI harness at

2

turn

3

sure

to

and than dis

cable from

prevent control unit from

battery to
being dam

4

Remove LH dash side finisher
Pull lock lever back and discon

3

3S pin connector from

nect

Disconnect

relay bracket
Disconnect harness connector

2

Remove relay from relay bracket
To install relay reverse the order

meter

of removal

air ducts and hoses

air cleaner

connecting

and

air

3

Remove air cleaner cover

4

Remove

flow

bolts securing air fiow

meter

aged
2

DiSConnect battery ground cable

cable

battery ground

ham

S

Disconnect

and

remove

6

To install air flow meter

air

flow

cOnnector

meter
reverse

the order of removal

AIR CLEANER

control

unit
Remove bolt which

4

secures con

trol unit to LR dash side
remove

5

and

panel

control unit

To install control unit

reverse

the

AIR TEMPERATURE

order of removal

SENSOR
CAUTION
connector into
When inserting 35
pin
unit
be
careful
nol to bend at
control
break terminals

The air temperature

sensor

is built

into the air flow meter and cannot be
SEF132

removed
ment

as

necessary
I

ground

Disconnect

cable

from

a

single

unit When

replace

t mper ture 8eDSOI is
the entire air flow meter

of air

assembly should be rep

d

battery
2

air ducts and hoses

Disconnect

connecting

r

cleaner and

flow

r

meter

3

RELAY
The relays

Remove

I A
s

unit

air

from

cleaner
are

installed

on

the

relay

4

Remove bolts securing air cleaner
and detach air

to air cleaner bracket

bracket

cleaner with air flow meter
Inside

FUEL FILTER

an

as

as

sembly

relay brKket

5

Disconnect air flow meter harness

connector

6

Remove

air flow meter from air

cleaner Refer to Air Flow Meter for
removal
7

To install air cleaner reverse the

Fuel pump
telay l

order of removal

SEF130

AIR FLOW METER

Reduce fuel line pressure to zero
Refer to item I under the heading
I

Injector and Fuel Pipe
2

Relay bncket

Unfasten

clamps

securing

fuel

hoses to the outlet and inlet sides of
fuel fIlter and disengage fuel hoses

I

Be careful not to

I
l

gine compartment

spill

fuel over en

Place a rag to ab

sorb fuel

I

3

Remove fuel fIlter

4

To install fuel fdter

EF 22

the

order of removal
S

SEF131

reverse

For installation of fuel hose refer

to Fuel Hose

ENGINE FUEL

FUEL PUMP AND
FUEL DAMPER
1

Disconnect

c

0 12 in

cable

ground

Tighten high pressure rubber hose
clamp so thilt clamp end is 3 mm

from

from hose end

Reduce fuel line pressure to zero
Refer to item 1 under the heading In
2

jector and Fuel Pipe
3
Raise the rear portion of car with
a jack and block wheels
4
Temporarily clamp hose between

Type

Unfasten clamps and the suction
side of fuel pump and outlet side of
and

disconnect

SEF138

Be sure to receive fuel into

B

suit

as

instructed

Insert rubber hose until its

@

Type

@

onto

fuel pipe until

Type

Push

end

of rubber

hose

it contacts inner

If

Push end of

@

injector

rubber

hose onto fuel pipe until it is 28 mm

Clamps
1 0

able container

pressure fuel hoses into

bulge

fuel

hoses

into

adjacenl parts

positions

proper

ensure

come

end contacts unit

S

damper

their

high

clamp

not

helow

fuel tank and fuel pump

fuel

Insert

hose

does

screw

contact with

or screw

position wider than other portions
of clamp is flush with hose end
Tightening torque specifications are
the same for all rubber hose clamps

battery

tightening

d When
that

RemovalBnd Installation

1 5N

0 10

1 10 in

from end of

pipe

m

0 15

m 07
kg

1 1 f

lbl

Type

3

mm

@

end of

rubber hose

with hose socket onto unit
as

l

Push

10 12 in

far

as

necessary

li
II@

by

hand

they will go Clamp is
at

not

this connection

EF336A

To fuel tank

From fuel tank

n
6

Disconnect

fuel

n

harness

pump

connector

7

Remove

bolts which

bracket to body

lmp
p

secure

and

fuel pump and fuel damper

Fuel damper

fuel

remove

as

an

as

sembly from bracket
8

Fuel pump and fuel damper
be removed
9

To

install fuel

damper
10

reverse

pump

and

L

can

Fuel ftlter

@
fuel

the order of removal

For installation of fuel hose refer

to Fuel Hose
Fuel pipe

mblY

FUEL HOSE
Make
hoses

sure

are

that all low pressure fuel

fully

inserted and

are

ure
Pre

regulator

free

from undue strain before
When removing
pressure fuel hose

or

observe the follow

ing
CAUTION
a

Do not

reuse

fuel hose

clamps after

loosening
b

Clean dull and dirt from parts with
8d
compreS

I

clamping
installing high

air when

J

@

fJ
SEF139

assembling
EF 23

ENGINE FUEL

Electrical System Inspection

INSPECTION

ELECTRICAL SYSTEM
DESCRIPTION
Electrical system inspection

perfonned

by using

For

INSPECTION

the

To inspect the electrical system

be

can

EFI ANA

LYZER J 25400

CAUTION
When checking the electrical system
with EFI ANAL VZER be sure to use
the proper adapter harness

the

use

following procedures

use

RESISTANCE
MEASUREMENT

35 pin EFI harness connector installed
on car

I

Set circuit tester in the Ohm

range
2
Check

CAUTION

minals

Do not touch the circuit tester
If the analyzer is not available

refer to

Procedure Table

circuit tester

Continuity test can be
perfonnedeasily by measuring resist
ance and voltage between terminals of
a

items to be checked

Inspection

to any unnecessary

pin

connector

could

Doing

so

probe

and

Body ground

dam

cause

continuity between

@

@

Inspection Procedure

the 35pin

on

shown

ter

in the

table

should be

connecting unpainted

age to the circuit tester

R

mad

by

metal such

81

bolt

Resistance measurement

Fl
1

r

I

PREPARATIONS FOR

INSPECTION

r

VEHICLE PREPARATIONS
1

Turn ignition switch

tion SWilch is in the

0FF

Disconnect battery ground cable

3

Disconnect

lead wire from

connector

Arrange
can

be

uum

3

it hharness
sw

California models
so

that air flow meter

pushed manually

Disconnect

35

pin

EFI

connector from control unit

OFF

posi

tion
b Be
or

extremely careful
bend 35 pin when

terminal

EF 24

I

not to break

disconnecting

Connect the
connector

vacuum

and

switch har

disconnect the

hose in the line between the

vacuum

switch and the intake manifold
2

CAUTION
a
Before disconnecting EFI harness at
35 pin connector ensure that igni
tion swilch is in the

step 12 only for California models
ness

harness

After steps I through 11 above
been completed proceed to

have all

from air

cleaner side
6

U

S

tenninal of starter motor

DiscQnnect va

1

jj I

position

2

flap

i

II

CAUTION
Before disconnecting and connecting
electrical connectors ensure that igni

5

i

l8

position

4

l

L

OFF

to

B

1

Disconnect

the

switch and altitude

throttle

sensor

harness

valve
con

nectar

3

Check continuity when

sure

is

applied

no

pres

to vacuum switch

4

3 kPa
21
Apply a pressure below
160 mmHg
6 30 inHg to vacuum
switch by orally sucking port back and
check continuity

5

Bring

back

tude sensor
to their

vacuum

switch

a1ti

and throttle valve switch

original

condition

ENGINE FUEL

earth should be made by con

Set circuit tester in the DC Volt

1

DC
2

V

connect

battery ground

cable
3

Body
necting with unpainted

metal such as

bolt

range

Securely

8

body metal

tester to

VOLTAGE
MEASUREMENT

4

tester

Connect negative probe of circuit

Turn ignition switch

measure

7

to tenninal

probe

of circuit

shown in the

@

voltage

Turn

8

Contact positive

Electrical System Inspection

ignition switch

Connect

ON

and

in step 24

EFI

OFF

harness connector

to control unit
9

2

Connect

alternator

pin

con

nectar

Inspection Procedure table

10
its

Bring air flow
original condition

back

meter

to

Fl
2

I

I

2
6

INSPECTION

101

26

g

9
27

PROCEDURE TABLE

O

0

1811

HOW TO USE

L

l1
1
L13
U i
4

fJU

1

1

1

ured

After measuring compare meas
values with standard values to
whether

determine

I

IT

EF452A

circuits

malfunctioning or not
2
When a malfunctioning

parts

are

circuit is

located again check measurements in
volved in that circuit In this case

S

Inspection with ignition switch in
START position
1 Set ignition switch on START
and measure voltage in each step of
Inspection Procedure Table from 13 to
2

Turn ignition switch

3

Connect

lead

wire

6

measure

voltage

ON

and

in each step of nspec

tion Procedure Table from 16 to 22
2

Turn

3

Disconnect

4

OFF
to

S

ter

minal of starter roptor
and

Turn ignition switch

switch

ignition

oil

OFF

pressure

Set ignition switch
measure

voltage

Inspection
ON position

with

on

START

in step 1 S

igiIition

switch in

ignition switch
voltage in step 23

Turn

measure

ignition switch

ON

and

OFF

Turn

6

Connect oil pressure switch har

7

range

probe

are

Before
35

pin

connecting
connector

EFI harness at
ensure

tion switch is in the

that

0 FF

igni
posi

tion

inserting
control

securely

and

not to bend
con

they

positions

CAUTION

into

connector

Disconnect alternator 2 pin
nector
L and S terminals

circuit tester

to be certain

etc

set at proper

b When

S

ness

ignition switch

a

switch

harness connector

14

4

I

check

35 pin

unit

connector

insert

slowly
straight being careful
or break 35 pin termi

nals

EF 25

I
fo
I

mZ Cl Zm

C mr

valve

Judgment

tnrotle

c
o
n
e
t
r
Measurd value harnes

Disconet
2

switch

value

Standr vacum

2

Except Qand

Disconet

on

9kn

n

on

wn on on

n

unit

ration

J

op

flap

o ntrol

met r

from

Auxilary conetr aPuirflsohw
side

Be

Checktrminal
I

PROCEDU
INSPECTO

air

J
8

pin

A

35

Circuit tester range

TABLE

harnes clen er

EFI

terminal
US

or

or

2

1kO

above

above
680F 680F

34

from

pushed

32

deprcs5ed deprsed
Fully

Rel aied ully Rel ased

2

or

680P 20 C 680P 20 C
OC elow
2p
lOae Below
B

I

n

400 500
to

1kn 100 200

Below

2

n

to

Below
or

or

above

9kn

I

2

condit

above

I

side

n

kn kn

2St09n minatnaifkoeld

to

to to

at

ap lied

t6

3

can

port

IWitch

in

to

inHg
30
6

sucking

is

condit

oril y

No

hose

dbconet

IS IS

n

27

senor

IS

altiude
and

switch

26

21

v

harnes

air

switch

swilch

Conect senor

vacum switch source switch regulator
back terminal
power igniton and
i
g
n
i
t
o
n
Bring

stare

that

terminal
negative Arange
so

circuit

Inspection
Step
m T1 N

3

batery models

Disconet Californa
1

potenimr

circuit
and

met r resi tor

now

Air

slidng

vacum conetr
harnels

cir uit
and

1

model altiude

and

Canforla switch

switch

throtle

and

this

conet

vol p
batery

START
air

dfshtiy
drop

and

may

disconetg vAlotholusph
Earth

negative betwon unit betwen relay Before Body
models batery control pump
Circuit Bnd Circuit fuel Note
Californ Conect 131
E

I

12

below

conectira
a

Vacum

not
Is

elctrial

vavel
OFF

an

terminab

E

Igniton switch motor met r

flow

indcation

enlUfO

to

30 24

of

that

by

a

abnormality

n

o
igni

presu minHg orignal
preu re switch 160 switch their
vacu m
Ap ly
switch

conetr

flap

OFF

is

and

be

vacum bac

21

below

podtion

k

kPa

to

it ake

Batery

400

HoSO Iwn

manifold vacum

vot a

600

300 300

14

b

m Z G Zm T1 C m r

Judgment
Measured value

J

value

defl cts

Standr

voltage
Batery

Pointer

voltage

voltage

Batery

Batery

SY
O

Above

ov

positon
uOF

engi e

condit turni g
operation invole
Auxilary step

in
i

and

lIS

perfoming

E

E

j
A

conetr

met r
E

pin

Circuit tester range

Igniton switch

care

18

5

7

27

Exerci

28

CAUTION

21

v

v

START

ON

terin circuit Injector
mot r trig er
al

2

3

4

Injector Injector Injector

S

Inspection

coil

conetr

Check hames
a
1
t
e
r
switch
control cir uit igniton switch
and cir uits
relay pres u switch
b
a
t
e
r
y
and
relaysource models pump pres u
EFI
senIOr betw en fuel and and presu
POWC
Batery unjt Altiude Circuit switch nator opeforratIon

Conect

15

droping

17

oil

f

and

Californa

tor

16

2

oil

injce

at ery resi tor cir uits

stare Igniton
Step

21

16

19

20

21

alternao

22

oil

Disconet

pump

Disconet

v

fuel

ON

conetr
cir uitl

for
2

S

uL

pump

for
2

switch regulator relay switch switch regulator relay
igniton pump presure igniton pump
air

air

and fuel

and fuel

conetr
pin
2

dtemator

Batery relay Check operation Con ect Batery relay Check operation Con ect
2

23

1

2

24

L

I

an

not
is

and

this

conetrs

voltage
batery

terminals elctrial
and

harnes fuel cir uts
oil

Bring
2

ON

t

1

cirCu

alternao
2

r

t

21
I

indcation

terminab

flow
air

6

or

ensure

back

2

2

abnormality

that

to

in
I

Check

its

UL

1

switch

orignal igniton

S

it

terminals

condit

terminals

or

Be

g
l
I

below

conetig

slightly
drop

and

may

disconetg vAlothlotaugghe
Before

Earth
Body
E

a b

Note

1

m

N

s

0
i
1

mZ
I

Zm T1 C m r

SEF183

VACUM SWITCH Clforn modol

L

eQ

I

IGNTO

I

t
l

J
I

I

2

7

14 15

18 19 l21 24 2526278

9

10 32 33 34

FLOW
L AlA MET R

R
r

I

Jjln

14

11
CYLINOER
NO

131

121

INJECTOA

FUL

1O
11l

Jre

WATER

j

l

SENOR

SW

c

it

oo
37 38 40 4

f

DROPING RESITO

GROUND

Is

anaina operation

FUEL PUMP Whln
43

PUMP AV
Ei

RELAY F

DIAGRM

OFF

in

il

P
R
E
S
U
SWITCH engine nop ed
When
cp
cp
I

1

t

A

REI

OIL

ON

I

EFI

PUMP
FUEL RELAY

TEANOR

2

I

TCH

RT

SW 5TA

0

0

0

AL

0

ON

0

LAiterno terminal prul re switch
Oil

L

I

CIRUT

FUSIBLE LINK oc

EFI
mn

A

DLE

N

TEMP

R

THROLE VALVE
U
ALTIUDE SENOR Celforn models

0

l

111

TEMP

T
I

ex

e FUSE

BLE
FUS LINK

IGNTO

OFf
B

IG 1

IG

IGNTO SWITCH FUSIBLE LINK BATERY

0J
S
B

c

t

J

t

ENGINE FUEL

Component

Parts Inspection

COMPONENT PARTS INSPECTION
FUEL PRESSURE
CHECK

2

At idling

Approximately

3

206 kPa

Follow the procedure below

1

reduce fuel pressure to

to

zero

The

2 6 kg

Start the engine
Disconnect the harness connector

of fuel
is

pump relay

em2

37

exist If not

injectorCs

faulty

are

it

psi

If fuel pressure is not

replace
2

pedal

is

255 kPa

4

I

two

psi

Approximately

fuel pressure from fuel line to elimi

danger

30

accelerator

moment

connectors

injectors
Check continuity between the
terminals
Continuity sho ld

fully depressed

CAUTION
Before disconnecting fuel hose release
nate

kg cm2

12 1

electric

Disconnect

from

pressure

as

P

specified

and repeat

regulator

LJ

fuel pressure check
2 while the

engine

clogged

or

if necessary

running

Tf

If below the
for

assembly

or

specified value check
defonned fuel lines and

replace

fuel pump

as

an

check valve

r

Rel br cket
v

SEF144

FUEL PUMP
FUNCTIONAL TEST
L

After disconnecting alternator
terminal
tor

set

tion
SEF131

3

oil pressure switch connec
ignition switch at ON posi
or

Then make

sure

that fuel pump

4
5

two

or

Reconnect the harness connector

run

Start the engine and

run

it at idle

checked out OK

operating
2
All injectors are functioning prop
erly if click sound is heard at regular

eplace fuel

pump

intervals

OFF

of the fuel pump relay 2
2
Connect a fuel pressure gauge
between fuel pipe and fuel hose of fuel

1

can

Attach the tip of a screwdriver to each
injector to ensure that it sounds while

three times

Turn the ignition switch

Engine

operating sound is heard If not check
all fuel pump circuits If all circuits are

After the engine stalls crank the

engine

OPERATING SOUND CHECK

Note

gine speed

FUEL DAMPER

however

increases

that

click

as

en

intervals

shorten

If noise from fuel pump is abnor

mally loud replace fuel damper

and

J

recheck for noise

J
1

ftIter

FUEL FILTER
If the

car is

operated under

adverse weather conditions

or

extreme
in areas

where ambient temperature is either

extremely

low or

extremely high

the

might become clogged In
event replace the fuel ftIter

fuel ftIter
such

an

l
1I

immediately

INJECTOR
Engine cannot
CONTINUITY CHECK
3

Start engine and read fuel pres

1

Disconnect

sure

gauge

battery

ground

cable

from

run

1
Crank the engine and check that
injectors produce operating sounds to
indicate operation

EF 29

ENGINE FUEL

ComponentParttlnspection
If

2

from

a

different sound is

particular

any

produced
that

injector

If

sound

no

is

If harnesses

@

resista
nce

the
and

@

between

The standard

heard from all

injectors check harnesses referring
Electrical System Inspection
4

Measure

tenninals

resistance is 200 to 500 ohms

injector is faulty
3

2

are

to

check

nonnal

operathm ofcontrol unit

EF327A

CHECKING RAP

PRESSURE

EF483A

inspection
3

While sliding flap
between tenninals

ance

and

0Cl

resist

@ and @
1aJl
t

If
0

ohm air flow meter is nonnaJ

@

Potentiometer

R

hand to

TlOMETER

CHECKING

@

t

RI

measure

resistance is at any value other

AIR FLOW METER

flap by

check that it opens smoothly without
binding If it doesn t it is out oforder

Refer to Fuel Pressure Check for

RO

open the

Fully

REGULATOR

EF318A

@

iJ

UlI

i I

LJ

R
SEF146

EF319A

@

AIR TEMPERATURE
SENSOR
CHECKING
I

I

Measure

terminals

the

resistance

@ and@

INUITY

Measure the outside air tempera

ture

between

2

The standard

Measure

minals

resistance is 100 to 400 ohms

@

resistance

between ter

@

air

and

meter connector

CHECKING INSULATION
RESISTANCE
Check insulation resistance between
the air flow meter body and anyone
of the tennin

s@ @ @and @

If

continuity exists the air flow meter is
EF482A

30
EF

out oforder

of the

flow

EN G IN E FU EL
3

The relationship between the out

side air temperature and resistance is
shown in the

following graph

4

AIR REGULATOR
Starting engine and pinch rubber

hose between intake manifold and air

regulator
SENSOR AND

WATER

MPERATURE
n
TEMPERATURE

AIR

Engine

SENSOR

warm

r

30

EJ
i
TC
2 1 to

2 9 k

3

at

warm

unchanged
OK

up

2

O

THROTTLE
1

Air

regulator

that

sure

smoothly

throttle

valve

when throttle lever is

manipulated

20oe

2

Make

sure

that by pass port is free

from obstacles and is clean
Do notadjust throttle valve stopper

lat2520Fl0oC

I

screw as

J

4
0

Make

moves

00

6SIo

g

If

operating properly

is

CHAMBER

6tFknl

I

then

and closes

opens

OK
remains

r 1 r i0

4

8

after

shutter to open

during

up

Engine speed

CHARACTERISTIC CURVE

decreases

speed

If shutter

smoothly it
not replace

Parts Inspection

screwdriver

flat b1ade

a

close

regulator

air

Pry

with
I

Component

it is

adjfactustoryed

l

0 3
0 2
0 1
O
0

I

OS
06
30

is opened during engine
thereby increasing quantity
of intake air causi ng engine speed to
increase Engine speed decreases when
passage is narrowed by pinching hose
Shutter

20
22

0

4 32

20

60

40

6S

SO

warm

104 140 176

Temperature Oc OF
EF334A

up

during

warm

shutter closes

If test results are far from the range
indicate
perature

in the
sensor

temperature
as an

graph

the air tern

remains
narrowed

is out of order The air

sensor

air flow meter

should

e

replaced

assembly

2

@

see

ana air flow meter body

ture

sensor

the air

tempera

is out of order The

up
F127

engine speed
is

passage
after

hose

Disconnect electric connector of
and

check

continuity

exist

If not

air

DASH POT
1

and visually

check to

if air regulator shutter opens

The shutter opening at a tempera
ture of 200C 680F is as shown in

Set

engine speed

rpm

Check the dash pot to make

that the
witli the
is

rod end

adjusting

or

sure

in contact

comes
screw

fully extended

when the rod

when

no

back

pressure is presentat the diaphragm

following figure

Adjusting screw
I

air

terpperature sc nsor and air flow meter
should be replaced as an assembly

1 500

to

under no load
2

Disconnect hoses from both ends

of air regulator

Check insulation resistance between
If continuity exists

unchanged
by pinching

regulator
Continuity should
regulator is faulty

RESISTANCE

warm

when

air

CHECKING INSULATION

After

up
warm

3

terminal

up

Therefore

Throttle lever

Air flow

rea

at

approximately
200C 6SoF

SEF149

Directioll of
movement
E F328A

hi metal

with

increasing temperature

3

If necessary

screw

so

adjust

the

that the rod end

contact with the

adjusting

adjusting

comes

into

screw

31
EF

ENGINE

CompOfJentParu Inspection

F1JEL

WATER
TEMPERATURE

CHARACTERISTIC CURVE
T

CHECKING INSULATION
RESISTANCE
Check

continuity

sensor

body

nals at

sensor

switch

position

with engine

of throttle valve
off

proceed

as

follows

SENSOR

1

To adjust

WATER TEMPERATURE SENSOR AND
AIR TEMPERA11JRE SENSOR

g

between

7

I
10L

the

U

I j I

010114 kn

lOoC 1401

al

j

8

and each of the tenni

When clearance

4

2 1 to 2 9

i

3

I

g 21

0

II
0
0
0

3

kn at lOoe

I
68 to

6tF
100 kn

I

aISOoC
1220FI

i
Ht

stopper

between throt
and throttle

3 mm
0

0 012 in

throttle valve switch position

that idle switch is changed from
to OFF
If clearance

I

A

screw

valve shaft lever is

adjust

j

6

tle valve

so

ON

between throttle valvo

stopper screw and throttle valve shaft
lever

is

speed

will become

3
0

0 012

mm

in

specified

engine

rpm

I

2r
u

gggL
30
1

1
20

22

4

0

20

32

68

40

60

80

104
140

176

Temperature DC COF
EF334A

2

If continuity exists

the

sensor

is

out of order

Shim

THROTTLE VALVE

SWITCH
CHECKING CONTINUITY
1

Dip the

tained

at

680F

sensor

into water main

temperature

a

800C

1760F

etc

of

ADJUSTING SWITCH
POSITION

200C

and read

its resistance

Disconnect throttle

valve switch

connector

2

Changing idle

Connect

minals

@

ohmmeter between ter

and

@

and make

sure

continuity eXists
3

rr
2

If the

spect

sensor

EF

32

o

@and@

CHECKING fULL THROTTLE

cONTAcT

changed

from

ON

to

N position under no load

1

Connect ohmmeter between ter

minals

@

continuity

and

@

and

make

sure

does not exist

EF329A

re

temperature is

not

t of order

between terminals

switch may be

A T

held within the range specified in the
graph the water temperature sensor
may be

ON

correspond
to
change
infinite ohms in resist

from 0 to
ance

switch from

throttle valve switch posi
tion with retaining screw so that idle
when engine speed is specified
idle rpm
70 rpm M T Neutral

resistance with

to the coolant

OFF

Adjust

OFF

r

to

o

i
SEF153

ENG INE FU EL
2

Depress accelerator pedal

to floor

Component Parts Inspection

Vacuum gauge

If continuity exists between tenninals

@

full throttle contact is

and

functioning properly

INSULATION

CHECKING

RESISTANCE

Resistance lkn

Voltmeter

1

I

I

ova

EB

o

Battery
12V

0

Regstan
30kn

o

1

SEF324

o

SEFl54

ALTITUDE SENSOR
Connect ohmmeter between engine
and tenninals @ @ and @ Ohm
meter

reading mould be infInite

I

Connect

the

lead wires

test

as

follows

i
Battery
12V

1

Remove

2

vacuum

Connect

Jf

SWITCH

VACUUM

III

switch

test lead

the

wire

as
0

follows
3

Voltmeter

4

SEF166

Measure the output voltage
Conditions

Output voltage

2

Measure the

No pressure is ap
plied to vacuum

Approximately
battery voltage

switch

3

If the

test

OK

results

the

speCification

43 and 38

output voltage

More thOriO 5V
are

altitude

not
sensor

the
is

43 and 37

No
No

2 cylinder
1

cylinder

The resistance should

mately 6 ohms

be approxi
O K

malfunctioning
Apply

a

pressure
3 kPa
21

below

160 mmHg
30
6

inHg

vacuum

OV

to

DROPPING

switch by

RESISTOR

orally ucking
port back

4

If the

Conduct resitance checks

test

specifications
malfunctioning

results

the

are

vacuum

not

the

switch is

ping resistor
points

between

43 and 41

No 4

43 and 40

No 3

the

cylinder
cylinder

on

drop

following

l
SEF155

EF 33

Cpmpopentp

N

5Per Von
ral

INE FUEL

RELAY
I

Disconnect

2

Remove relay from

EFI

3

battery ground cable

relay and fuel

pump

nu

Test

continuity

through

the

relay

following

relay

I
Normal

rp
d

Chcck terminals

1

I
f

j

@

Yea

@

@

No

Yes

@

@

Ya

No
iIt
Coritiilufty should ex
Continuity IhotiId not abt

IZVIliNct

Fuel pump relay 2

ppUed

CDond@

uololls

t

CoatiDuity

Tell resultl

Yes
No

aIIfIW

I

NDnIaI

c
a

llllilod
lkll

@
7

J
D

direct current iI

112V

condition

bet

1
2

chart

with an ohmmeter in accordance with

car

l

CD 00
@@

T
t

I

nau

y

y

No

No

j@

No

y

j@

y

YQ C
CO

@

0tndIaIIlt
No

y

cUII
nol alA

1inulll

ct
c

o
a

c

Ir

I

SEFl56

CONTROL UNIT

3 Use flat plate tenninals 3
in

CHECKING ELECTRIC
IGNAL TO INJECTORS

as

wide
male

0 8 mm
terminals

Inspection lamp as shown in
figure blow is required for thiS test

faces 2

thick

Place flat plate

terminals parallel with each
and keep distance between

I

0 12

mm

0 031 in

other
inside

The n secUre
terminals by wrapping insulation
tape or with suitable terminal body
2

mm

Disconnect injector harness

con

Connect inspection

tor harness connector

Starting engine

gine
ttic

to

injec

Make
1
2

inspection lamp as follows
Prepare 12V 3W lamp
Prepare socket and set lamp in it
34
EF

en

mitted to injectors
a

The engine should be cranked at a

speed of
b

more

IariSO
tJ

rpm

The control unit may fail to gener
ate

a

correct
low

pulse signal at an
battery voltage It is

recomm
nded

therefore

that

a

battery voltage of more than 9 volts
be applied
during the cranking
operation

E F353

cranking

regular interval If so elec
signals are being properly trans

excessiwely

lamp

or

check iitspection lamp to see if it

flashes at

0 08 in

nector

3

4

EN GIN E FU EL

CHECKING FUEL SHUT OFF
FUNCTION
1

2

3

lerator

Wann up engine sufficiently
Connect inspection lamp to injec

to

each

speed

and release

acce

respectively
pedal Check inspection lamp

below

Increase

zone

engine

speed

off
shut

Check inspection

lamp

3

3 000

m

els

@

6001

2

2 600

@

e

e

2 200

2 200

0

51

@

51
5

t

is off fuel

000

I

e
e

inspection lamp
operational

is

with engine

Manual transmission

Automatic transmission models

0

ill each zone as shown in chart

While

illumination

tor harness connector

Component Parts Inspection

800

c

1

800

@
1 400

t 400

Cooling
at

water

Make

sure

even

a

@

000

@
Cooling water temperature
at 800C 1760F

temperature

80C 1760F

CECKING AIR
LEAKAGE IN AIR
INTAKE SYSTEM
does not

1

@

1 000

slight air leak

Since

the

air

flow meter used

in

injection system
directly measures the quantity of in
take air to permit the supply of the
optimum fuel quantity for each cylin
the

electronic

fuel

der

occur

pay

particular atten
dipstick oil

tion to hose connections

filler cap etc
leaks

for any indication of air

Retighten
replace

any

loose

connections

damaged

or

and

defonned

any fuel hose whose
inner surface is deformed scratched or

parts

Replace

chafed
For replacement of high pressure
refer to Fuel Hose under the

When inspecting the electronic fuel

injection system

connections cracks or deterioration

fuel hose

CHECKING FUEL
HOSES

heading Removal and InstaUation

Check fuel hoses for leakage loose

EF 35

ENGINE FUEL

Service OatasndSpecificatiom

SERVICE DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS

I Design voltage
fuel

I

pump

Pressure

di

off
Cut

I

Airflow
meter

Dash pot T

12

V

Vacuum

switch
kPa

charge pressure

psi

Design current

A

Regulated

kpa

regulator pressure

I

cm2

t

294

44113 0
43 641

4 5

I

5 1

kgem

Altitude

ing

resistor

psi

Approx

rpm

Approx 21 3 kPa

vacuum when vacuum
switch is changed from OFF
to ON

Manifold

Output voltage

1 500

160 mmHg
6 30 i Hil

V

Above 0 5

fl

Approx 6

leos or

IDr

2SO 12 55 36 31

h speed
ou

Resistance
Per resistor

I

Design voltage

V

12

Design voltage

V

12

I

Air

regulator

Air flow quantitY

IAt 200C I68 FlJ
i

Control
unit

votteee

m

cuft

hr

19 0

I

611l

12

I

TIGHTENING TORQUE

W

15

I

I

W

140

V

Consumption wattage
At

idling

At full

throttle

J

I
I

Unit

Throttle chamber

A

I

hOSl

lp
clBn

N

lb
ft

m

8

18

22

1

1 0

15

0 1

2 2
0 15

Futtl hose clBr11ping position

INSPECTION AND ADJUSTMENT
fuel
B
pressul

kPa
A t dr1n9

measure

kg

em

Appro

206 12 1

Approx

255

301

3mmIO l2in

PII

iog point
between

The moment

fuel

eretor

filter

and

fuel

acce

pedal is

fully depre1sed

2

kPa kg Iem

2 6 37

PSI

pi

Fuel

Coil resistance

2

n

Q

35

injector
EF336A

Airflow

@

@

n

100

400

@

@

fl

200

SOO

@

@

fl

metar

Potentia
meter
resistance

Air

Except 0 and

tem

peratu re

tOOC t4OFI

At

kfl

10

114

kfl

2 1

9
2

kfl

0 68

1 0

sensor

water
tempera
At

200C 168OF

lUre
sensor

therml
tor re

At5OC t22F

sistance

Air

Heater

reQulstor

resistance

Throttle

coil

vaI

SWitch

EF 36

Specified idle

Engine speed
wh enl dll
is

to

70

SWltch

changed from
ON

25 90

n

OFF

rpm

in

rpm

Neutn

MfT in
tion

N

pasi

AfT

13

01

16
1

EN GIN E FU EL

Trouble Diagnoses and Corrections

TROUBLE DIAGNOSES AND CORRECTIONS
TROUBLE SHOOTING CHART
Save time by perfonning

The EFl system can be checked in

accordance with the

a

shooting
trouble

35

cially the

If any abnonnaIity is found in any
inspection item refer to the Inspec

flow meter connector

section and carry out further
inspection following the procedures

from corrosion and deformation

described therein

nect after

tion

Note

that

excepting
must be

component part
of the EFI system

any

some

replaced as

an

assembly

since no

found to be faulty

if it is

repairing

pin

are

sure

securely

Connector terminals

are

Pull all connecton off and

in

Failure to do so could result in damage
or cause fuel line

free

to the control unit

leakage
recon

inspecting terminals
the EFI system accurately
the intake air flow through an

CAUTION

Since

2

meters

air flow meter

will

cause an

resulting

is allowed

Before checking the EFI system be
to observe the instructions below

espe
air

connector and

chart

place

Inspection Instructlone

quick

check if all harness connecton

in

even a

slight

When

air leak

unit

air fuel ratio

improper
faulty engine operation

Checke before

inspection

oil ftller cap

nothing has

duct etc

I
a

been overlooked

The greatest problem source with
system of this type lies in the

connections between components

Condition

Engine will
or

hard

to

not start

nected
a

thorough inspec

EFI

disconnecting

or

or

that the

tom

ignition

any EFI
switch is

OFF
position and that the
battery terminal is discon

I

Removing

and

ins18l1ing
the
ignition switch
position will damage

connectors with the

tion for leaks should be made at the

Before attempting any test check
the following items to ensure that

enlUre

in the

due to excessive air
For this reason

connecting

harness connector to

left in the

dipstick blow by hoses

ON

control unit

air flow meter to throttle chamber air

Replace fuel

the ignition and start
are
satisfactory and the
ing systems
3

Make

battery

sure

is in

Probable

good

fonned
reuse

condition

hoses if

scratched

fuel hose

or

they

chafed

clamps

are

de

Do not

after removal

Check and corrective action

cause

Disconnect

Improper ignition system

high

tension

cable

from

one

spark plug and check for hot spark

start

Check for intake air leaks and repair

Intake air leakage at following points
P C V valve V C valve

dipstick

seal oil

or

replace if necessary

ftller cap blow by hoses
Air flow meter hoses and clamps
Manifold gaskets etc
Fuel pump does not work

Disconnect starter motor

S

temtinal and

ignition switch in START position
listen for fuel pump and pressure regulator
operating sound
If no sound is heard check fuel pump

con

trol circuit
Then

proceed

to the

following checks

Fuel pump
Alternator

L

terminal

Oil pressure switch
Fuel pump relays I and 2

Improper ignition signal input

Check ignition signal input

EF 37

Trouble

Diagnoses and ComJCtion

ENGINE FUEL

Condition

Probable

Malfunctioning

Check and corrective action

cause

EFI relay

or

control unit

injector

or

Connect

a

lead wire to ignition coil negative

terminal With ignition switch ON
attach
other end ofleadwire to engine body for a
short period and repeat it rapidly
listen to each injector sound with

a

screw

driver
Results
a

Injectors click every second
the following circuits

e

Water temperature

Air

break check

sensor

lJleter potent
signal cirelli t
regulator
0

r
ete

Start
Air

b

Injectors
ing

do not click check the follow

circuits

Control unit power input circuit
Ignition coil trigger input circuit
Control unit ground circuit
e

Problem in the following circuits

Vater temperature sensor
Air flow meter potentionietef
Start signal circuit

Poorly chaIged battery

circuit

Injector

Check each circuit Then proceed to

Com

ponent checks

Check charge circuit

Recharge battery if necessary

Engine starts then
stalls

Improper ignition signal input

Malfunctioning

EFI relay

injector

or

control unit or

Check ignition signal input
Connect

a

lead wire to ignition coil negative

terminal With ignition switch

ON

attach

other end of lead wire to engine body for
short period and repeat it rapidly
listen to each injector sound with

a

a screw

driver
Results
a

Injectors

click every second break check

fuel pump circuit
b Injectors do not click check the follow

ing circuits
Start signal circuit
Control unit power input circuit
Ignition coil trigger input circuit
Control unit ground circuit

Injector
Fuel pump does not work

circuit

With ignition switch in

ON

position dis

oil pressure switch harness
tor alternator L tenninal

connect

Listen for fuel pump and pressure
operating sound

connec

regulator

If no sound is heard check fuel pump
trol circuit

38
EF

con

ENGINE EUEL

Condition

Probable

Trouble

Dia9nosessnd Corrections

Check and corrective action

cause

Then proceed to the following checks
Fuel pump
Alternator

L

tenninal

Oil pressure switch
Fuel pump relays I and 2

Improper

wate temperature sensor circuit

Check

circuit

iI

Malfunctioning

air

regulator

Check air regulator and replace if necessary
Note

If these tests

Engine idles
cannot be

too fast

adjust

ed with idle speed

adjusting screw or en
gine idle is unstable

Improper

e an
intaJ

Malfunctioning

exhaust valve clearance

throttle valve

air

regulator

satisfactory prOceed

start

Adjust valve clearance

plate is closing when
and replace if necessary

Check that
released

Malfunctioning

are

Engine will not

to

To

check

air

regulator

throttle is

proceed

to

the

following steps
Start

engine

Pinch offhose to air

regulator

Results

al Ifidle speed drops perfonn circuit test
Ifno fault is found replace air regulator
b If idle speed remains high or unstable
perfonn the following checks
Check for manifold
at P CV

ing

vacuum

leaks includ

valve V C valve

dipstick

nd oil f1ller cap seals
If no problem is found perfonn the fol

lowing circuit tests
Throttle valve switch

idle contact and

full throttle contact
Va 9u urp switch
Air

rJ

temperature

sensor

Water temperature sensor
Control Jtit ground circuit
r

Air flow meter potentiometer
Air

Improper ignition

and fuel pump circuit

1

l

Engine misfIres

regwator

Ignition coil trigger input circuit
Control unit power input circuit
Inj ctor circuit
Then proceed to Component checks
circuit

Improper EFI harness

connectors

Check ignition circuit
Pull EFI harness connectors apart and check
for

looseness

groimd

circuits

and

corrosion

Do not

including

forget ignition

in

put lead
Improper fuel line

Check fuel line for blockage
Tank strainer
Fuel filter

Injectors
Fuel pipes

39
EF

Trouble

ENGINE FUEL

Oisgnosesand Corrections

Condition

Probable

Malfunctioning

Improper fuel

improper

Check and corrective action

cause

control unit

Tap control unit while driving to see if this
aggravates or aIleviates the problem If so
try another control unit
Perfonn fuel pressure test

pressure

EFI circuit

Perfonn all circuit tests
Then perfonn

Engine
volve

will not

re

Lor
t

f

ignition system

lack of

power

Malfunctioning

throttle valve

Component checks

Check IC ignition unit pick up coil and igni
tion coil
Make

sure

throttle

when accelerator is

Malfunctioning

air flow meter

Check air flow meter mechanical movement

Using

a

it opens

Improper

fuel line

plate is opening fully
fuI1ydepressed

finger push flap

smoothly

Check fuel line for

and

open

checking

that

fully

blockage

Tank strainer
Fuel fdter
Fuel pipes

Improper fuel pressure
Problem in the

followiIlg

Perfonn fuel pressure test
circuits

Ignition coil trigger input circuit
Control unit power input circuit

Injector

Check each circuit

Thin perfonn Component checks

circuit

Air flow meter potentiometer
Throttle valve switch idle contact and
full throttle contact
Vacuum switch
Air temperature sensor
Water temperature sensor
Altitude sensor
Air re

Hesitation
on

stumble

acceleration

ator and fuel pump circuit

Improper ignition system

Check ignition system

Malfunctioning

Check air flow meter mechanical movement
Using a finger check for smooth flap move

air flow meter

ment

Intake air leakage at

following points

Check for intake air leaks

P C V valve
V C valve

Dipstick and oil filler cap seals
Manifold gaskets
Air flow meter hoses etc

Improper fuel pressure

Perfonn fuel pressure test

Improper idle

Check idle

Improper

ll adjustment
CO

EFI circuit

Perfonn

complete circuit test
Components checks

Then perfonn

40
EF

ll if necessary adjust it
CO

ENGINE FUEL

Probable

Condition

Poor gas mileage or
CO reading too

high

or

ignition system

Diagnoses and Corrections

Check and corrective action

cause

Improper ignition timing

Trouble

Check ignition timing
Check ignition system for hot spark

Improper

Check

air cleaner f1lter

air

cleaner f1lter

and

replace

if

necessary

Improper fuel pressure

Perfonn fuel pressure test

Problem in the

Check each circuit

following circuits

Water temperature sensor
Air temperature sensor

Then proceed to Component checks

switch idle contact and

Throttle valve

full throttle contact
Vacuum switch
Air flow meter

potentiometer
regulator and fuel pump circuit
Injector cirellits
Air

Surge

Malfunctioning

air flow meter

Check air flow meter mechanical movement

Using

a

fmger

check

flap

movement

for

smooth operation
Intake air leakage at the following points
P

Check for intake air leaks

v valve
C

Dipstick

and oil ftller cap seals

Manifold gaskets
Air flow meter hoses etc

Improper fuel

Perfonn fuel pressure test

pressure

Improper idle CO

adjustment

Problem in the followirig circuits
Throttle valve switch

idle contact and

Check idle CO

if necessary adjust it

Check each circuit
Then proceed to Component checks

full throttle contact
Vacuum switch
Air flow meter

potentiometer

Control unit ground circuit
Air temperature sensor
Water temperature sensor
Altitude

sensor

Air

regulator and fuel pump circuit
Ignition coil trigger input circuit
Control unit power input circuit
Injector circuit
Backfuing

Intake air

leakage

at the

following points

Check for intake air leaks

P C V valve
V C valve

Dipstick and oil ftller

cap seals

Manifold gaskets
Air flow meter hoses etc

Improper fuel pressure
Improper idle CO

adjustment

nn fuel pressure test
Perf

Check idle CO

if necessary adjust it

41
EF

Trouble

Diagnoses

and Corrections

ENGINE FUEL

Condition

Probable

Problem in the
e

Check and corrective action

cause

folloWing

circuits

Throttle valve switch

Check each circuit

idle contact and

Then proceed to the

Component checks

fulllhrottle contact
Vacuum switch
e

Aidlow meter potentiometer
Air temperature sensor

e

Water temperature
Altitude sensor

e

Ignition

e
e

Afterfire
a

sensor

coil trigger input circuit
Control unit power input circuit

Injector

circuit

Problem in the following circuits

or

Throttle valve switch

g

Check each circuit

idle contact and

Then proceed to Component checks

fulllhrottle contact
Vacuum switch
e

Air flow meter

potentiometer

Air temperature sensor
Water temperature sensor
e

Injection circuit
START
signal input

COMPONENT

CHECKS

To be performed only after circuit tests
Control
Problem

Injector

Air

sound

regulator

will not start

Idle too high

Engine

or

rougli

misfires

Lack of power
will not rev

Hesitation

Poor gas
CO

too

replace

X

X

I

X

X

I

X

engine

I

X

Air flow meter

Fuel system

Flap

Resist

opera

ance

tion

means

X

X

Fuel pres

Injector

sure test

leakage

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

or

too

Engine surgAs

I

Backfiring

I

Afterbuming

I

42
EF

X

X

stumble

mileage
high

completed

unit

Relay
ment

Engine

are

I
I
I

X

EN GIN E FU EL

CHECKING AND
ADJUSTING IDLE
RPM IGNITION
TIMING AND
MIXTURE RATIO

discourage tlImpering
idle mixtu
adjus1ing
California model
steel blind
idle

it

Make

on

at

factory

So

of

the

lower

exhaust

the

Use

mixture

method

federal and

uling

below
or

California

b

with chocks

When

racing engine

matic

transmission

models

make
N

and

brake

depress

equipped

or

shift

that

Rife

lever is in

auto

on

P

position

pedal

to pre

vent forward RI rge of car
meter after it

CO

is

fully

c

After the

adjuS1ment

has been

made shift the lever to the
conditioner

air

equipped

or

checks should be carried out

P

position

and

N

remove

wheel shocks

OFF

while the air conditioner i

violate
or

On

models

other than

may

level gauge etc

d up
warm

emis

position

0

When selector lever is shifted to

rear wheels

oil

16 inl
4

shift lever is in

0
position apply parking
brake and block both front and

Connect engine tachometer and
timing light in their proper positions
insert
3
When
measuring CO
probe int tail pipe more than 0 4 m

5

Adjusting

a

2

sion
b

out while

WARNING

Oil filler cap

that case as directed by official in
to

following parts

intake system

Ai

routine maintenance except

spection

good
Battery

that the

order

gnition system

with the

blind plug should not be removed

during

sure

in

E F I harness connectors

is sealed withH

equip

1

e

plug attar adjustment

mixture

On automatic transmission

pad models checks should be carried

are

screw

Corrections

6

Vacuum hoses

To

Diagnoses and

Preparation

PRECAUTION
a

Trouble

other

tate and provincial laws

Inspection procedure
START

S

Start engine and warm up engine until waL
temperature indicator points to he middle
of gauge

Open engine
Run

engine

M

hood

at

about 2 000 rpm for about

2 minutes under

noload

SMA021
For

Canada

1

Run

engine

at

idling speed
I For

u S A

Disconnect hose from aii indUction pipe
and install proper cap on air induction

pipe

t
Race engine two or three times under no
load
e for one minute at idle
Then run e

speed

Check idle speed

MfT

700 z tOO rpm

AfT

700 t100 rpm Un

0

f

position

N G

O K

Adjust
justing

idle

speed by turning

spee4

ad

screw
I

@

idle

SMA263

@

@
43
EF

Trouble

eund
Diagno

ENGINE fUEL

Ctions
Cof1l

@

jiJ

@@

OIeck ignition timing with timing Ught
Cllifomia
Nol1

zo a T D C

a

6

Californil
ZO B T D C

J

OK

N G

Adjust ignition timing by turning distributor
aftedoosening bolts which secure distributor

I

I

I

SMA059

Race engine two or three times under
load then run engine at idle Ipced

0Ieclr idle
OK

I
Does engine

run

smoothly

f

r

YES

C
Non
t

11
3

CO with

CO
meter

liforni

C

0

less than 4

I

n

lifornia

N G

OIeck the following

Following hoses for proper connections
VaCWlm hoses
Blow by hoses
Air regulatOJ hOle
Air duct hoses
Canister purge hoses
Air leaks at throttle chamber mounting
and intake manifold

I

OK

Remove blind plug from air
on air flow meter
Californi
Steel

PUl
by

NG

I

SCItW

Correct

replace malfunctioning parts

California

models

I

models

plug

califomia
Non

or

Turn off engme and
air flow meter from

remove
cu

models

Rubber plug
canrornia
Noii
models
r

I

Note

Alter drilling be
remove

L

ure

dlaviDgs and

to

I

t

dUll
1

Race engine two or tluee times under
noload then run engine at idling speed

r

Drill a hoJi in steel plug wbich
seab air by pass screw and
remove

steel plug

Imta11 air flow meter on
Start engine and

engine until

warm

car

up

ter

temperature indicator pOints
to

@U
44
EF

@

e

middle of gauge

@

ENGINE FUEL
n

Only

for
owrOtnia
non
When adjUltina idle

models
CO

at

n

high

Adjust CO

I

I
I
iI

Altitude
600

1 200

2 000

4 000

1

1 800

200
4 000

6 000

Above 1 800
6 000

ft

CO

Idle

Idle CO
2 7

3 8

by turning air by pass

r
ai
flow meter

screw on

val
m

@

cp

altitude adjust to obtain foUowing
Unit

IN

1 3

1 0lI

IO

G

Not adjustable in this case
Comct or replace air flow meter or
other

K

SMA061

Install blind plug
California

malfunctioned parts of fuel

Calitom
Non

injection SYstem
5

Trouble Disgnosesand Correcrions

e

on

I

air flowmeter
HIM steel plug
Original rubber plug
California models

0
alifornia models

Non

Turn off engine and
from Cat

remove

air

flow meter

I
Insert

new steel plug
hed
fumi
as a service
part with its convex aide up into air by pass
screw Tap steel plug with suitable bar
thereby inltalling steel plug on air flow

meter

Air by pass

I

SE F 348

screw

Install air flow meter on Cat
Start engine and warm up engine until
water
temperature indicator points to the
middle of gauge

For U S A
For Canada
For Canada

I

For U

A
S

Turn off engine and connect air induction
hose to air induction pipe

I

t
J

Start engine

Race engine two or three times under
load then run engine at idle

no

L

L
Oleck idle speed
MfT
AfT

7OO

100rpm
1100 rpm
700

in 0

O K

position

I

N G

r

Adjust idle speed by turning idle speed ad
justing screw

END

45
EF

DATSUN 200SX

Model S r r 0 Series

SECTIONEC
EMiSSiON CONTROL SYSTEM

CONTENTS
EMISSION CONTROL DEVICES
DESCRIPTION
CRANKCASE EMISSION CONTROL
SYSTEM

EC

2

SPARK TIMING

EC

3

DECELERATION CONTROL SYSTEM

EC

5

CATALYTIC CONVERTER

EC 17

DESCRIPTION

EC

5

INSPECTION

EC

5

EVAPORATIVE EMISSION
CONTROL SYSTEM

EC19

GENERAL

lntake
I

EXHAUST EMISSION CONTROL
SYSTEM
DESCRIPTION
AIR INDUCTION SYSTEM
EXHAUST GAS
CONTROL

A IS l

RECIRCULATION

SYSTEM

EC

6

EC

6

EC

6

EC

9

E G R l

manifold

CONTROL SYSTEM

vacuum

control type

EC 15

EC1

DESCRIPTION

EC19

OPERATION

EC 20

INSPECTION

EC 21

SERVICE DATA AND
SPECIFICATIONS
TIGHTENING

TORQUE

EC 23
EC 23

a

io

li a

m
I

T

A

models
Can da

T

Im 3
lC
l
5 Z C 0 Z I0 0 r C
Cii C
l

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

M

T

models
Z20E SIlO

DEVICS

A

Californa

A
s
U

Non

for

T

M

I

T

CONTRL
EMISON

models

Californa
model

Engine

X

X

X

X

X

X

X

X

X

X

X

X X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

A

T

M

X

1
2

valve

3

Type Type Type
Type Type

model

A

Car

bar el
2

sy tem
sensor plug plugs control sy tem

senor switch

chamber valve switch temprau sensor
pipe flow temp ratue
r
e
g
u
l
a
t
o
r
Fresh
Throtle Throtle Vacu m Water Altiude
air

Air Air

2
I

met r

duct

B

Air

Air

for for

ignitor ignitor Water
IC

C
P

valve valve valve
T

T

T

V
V

V
V

P

ventilao

B

induction induction sy tem sy tem sytem convert crank se
temprau
air

IC

V

with with with

air

Exhaust Exhaust

R

R

R

G

G

G

E

E

E

Cat lyic Canister Positve
sy tem

Item inlet
Air
Pl

sy tem

Fuel
Air

sy tem

Igniton sy tem

S

R

I

G

A

E

sy tem

Catlyzer Evaport Crankcse ventilao sytem

EMISSION CONTROL SYSTEM

General DeScription

ENERAL DESCRIPTION
There

are

systems which
1

Closed

three types of control
are as

crankcase

type

2

follows

3
emission

Exhaust emission control system
Evaporative emission control

Periodic inspections and necessary
servicing of these systems should be

system

perfonned

control system

CALIFORNIA

to

keep

hannful emissions

to a minimum

MODELS
Vacuum control valve
lntake

Throttle chamber

Thermal

manifold

vacuum

valve

Airregulator

01IL

IT

11

1

en

I

I

T

i I

Airpipe

n

rr

i

J

u
Idle adjust

aew

f

umt

Distributor
Canister

Ported

vacuum

Distributor

Ported

vacuum

EG

c

j
ji

ri

Catalytic

tP

Venturi

r

f

o

I

Ii

lj f

A I

If

C
1

L
J

Ail cleaner

R

vacuum

Manifold

vacuum

Air
r

Canister purge

tube

Air induction valve

l

convert

Q

Secondary air

0

Carbon

Carbon monoxide hydrocarbon
dioxide gas water

Fuel tank vapor vent line
BEeoo

3
EC

General

EMISSION CONTROL SYSTEM

Cription
De

CALIFORNIA
NoN

MODELS For

U S A

Vacuum control valve
Throttlechamber

Thenn2

Intau
mmifOId

ftOUum

valve

G R ntve

Airregulator
P tube
B

Air pipe

H

r

il

n

0

ta

ell

b
I

f

i

1

II

I

I

I

I

raL
l

no

v

T

VV T Valve

1

1J

J
J

It

J

l

1

J

II

Sf

unit

t
II

Omister

C
t

r

Distributor

Fuel

R tube

J

u
ldIeadjusls

E G

I

b
f

C2Wytic cooverler
MalfIOr
1

t

dL

y

Air

vacuum

Distributor

Porled

vacuum

EG

Venturi

J

Canister purge

valve
mducti

Q

Secondary

air

Oirbon monoXide

1

Air

J

R

vacuum

Air

A I lube
E

f

Ported

cleaner

Q

tank vapor vent line

hydrocarbon

Carbon dioxide gas water
SECOO2

CANADA MODELS
Intake manif ld

acuum con

t

Throttle chamber

vacuum vaIve

E

n
M

pipe

1

I

i
J

J

Ji

kL

R
G

1

I

val

i
PT
B

val

II
I

R tube
E G

Ported vacuum

Ported
7

II

Idle adjust

saew

Y
t

gr

Distributor
Canister

t

21

vacuum

Distributor

EG

R

1
Air

r

JA

ta

r

rter
yticcon

Canister purge

Muffier

J
1 JF
1t

Q

sair
Exces

Carbon monoxide

9

hydrocarbon

Cubon dioxide gas water

Fuel tank vapor vent line
SECOO3

4
EC

Crankcase Emission Control System

EM ISSION CONTRO L SYSTEM

CRANKCASE EMISSION CONTROL SYSTEM

INSPECTION

DESCRIPTION
Tills system returns blow by gas to
both the intake manifold and air pipe
The

P

positive

C V

valve is

crankcase ventilation

provided

air is

The ventilating

to conduct

Under full throttle

crankcase blow by gas to the intake

manifold

manifold

draw the blow by

During partial throttle operation of

valve

the engine the intake manifold sucks
the blow by gas through the P C V

tube

the

condition

is

vacuwn

insufficient to
flow through the

and its flow goes through the
in the reverse diIee

connection

lion

On

valve

Nonnally the capacity of the valve
is sufficient to handle any blow by and
a small amount of ventilating air

then drawn

through the tube connecting air pipe
to rocker cover into the crankcase

cars

blow by

with

an

excessiveiy

of the

some

p C V VALVE AND FILTER
With engine running at idle

remove

the ventilator hose from P C V valve
if the valve is working a hissing noise
will be heard as air passes through the
valve and

a

strong

vacuum

felt

immediately when
placed over valve inlet

should be

finger

a

is

high

flow will go

through the tube connection
pipe under all conditions

to

air

Seal type oil level gauge
Flame arrester

iC

Intake manifold

v

J

l
r

R

T

J

L Air

pipe

Check hoses and hose connections

Disconnect all hoses
with compressed air
2

If any

C V valve

Steel net

1

for leaks

Throttle chamber

P

VENTILATION HOSE

cannot

be

dean

free

of

obstructions replace
Ensure that flame arrester is surely

Fresh air
Blow

hose

and

by gas

inserted in hose between air pipe and
rocker cover

SECOO4

ET277

EC 5

ExhaurtEmission Control System

EM ISSION

CONTROL SYSTEM

EXHAUST EMISSION CONTROL SYSTEM
DESCRIPTION
The exhaust emission control system is made up of following

Emission control system

Non California models

California models

TypeA
Air induction system

Type B

Air induction valve

Air induction valve

EA

E A

Type

tube
2

Thermal

vacuum

valve

Thennal

3 port

Catalytic

Catalyst

AIR INDUCTION
SYSTEM A I S
DESCRIPTION

designed

to send

exhaust manifold
caused

I

dary

seco

utilizing

A I
S

is

air to the
a

by exhaust pulsation

vacuum

in the

Thennal
2

vacuum

valve

port type

P T valve
B

V V T valve

vacuum

valve

Thennal

vacuum

valve

3 port type

A3

Type A I A3
Catalytic

converter

Catalytic

converter

converter

exhaust manifold

vacuum conditions

The exhaust pressure in the exhaust
manifold usually pulsates in response

be drawn into the exhaust manifold in
proportion to the vacuum

to

The air induction system

valve

port type
TYpe A I A3

type

Type A2

vacuum

3

E G R valve

3

VV Tvalve

Thermal

Type

E G R valve

3 port type
TYpe A2 A3

Spark timing control system

tube

Type 1

E G R valve

E G R system

Canada models

for U S A

the

opening and closing of the

exhaust valve and it decreases below

atmospheric pressure periodically
If a secondary air intak pipe is
opened to the atmosphere under

secondary

air can

Therefore the air induction system
reduces CO and HC emissions

A IS

in exhaust gases

The system consists

of two air induction valves
and hoses

a

filter

TypeA
Aircleaner

cy
Injector

n

II

Wf
E

l tube
A
SECOO6

EC 6

Exhaust Emission Control

EM ISSION CO NTROL SYSTEM

TypeB

Air

System

induction valve

Air cleaner
Filter

Exhaust
manifold

A

E

tube

SECOC

Air induction valve

case

The air induction valve

and

a

valve

case

attached to the air

is

fIlter

a

which

case

consists of two reed valves

Air induction valve
I

There

types of air induc
The type A is equip

two

are

tion valve cases

with two hose

installed

type

is below

on

B is

connectors and is

California models and the

equipped

and is installed

with

on

one connector

all

are

atmospheric

tive pressure

cleaner

ped

Two reed valves

installed in the

air cleaner When the exluiust pressure
nega

pressure

secondary

air is sent to

the exhaust manifold
When the exhaust pressure is above
valves
pressure the reed

atmospheric

prevent secondary

air from

being

sent

back to the air cleaner
EC921

Californla
non

models except Canada
TypeA
To exhaust

manifold

1
n

SEC009

Type

The secondary air fed from the air
valve
goes
through the

induction

Dlkwrtd
iillQl

O
M
Air filter

Air Induction pipe

EA

tube to the exhaust manifold

SEC059

Type A

B
To exhaust

rEAl

manifold

Z

Airinduction
valve

S ealmg
rubber

pipe

Air induction valve filter

From air
induction
valve

The air induction valve fIlter is in
1

LAirfi

stalled

at

cleaner It

er

SEC060

the

dust

side

of the air

purifies secondary

air to be

sent to the exhaust manifold

EC 7

Exhaust Emission Control System

EM ISSION CO NTROL SYSTEM
The air induction pipe

TypeB

can

then be

taken out Installation is in the reverse
sequence of removal

AIr induction
I

Disconnect air induction hose

air induction

E A I
pipe

hose to make
on

valve and fDter

pipe side
sure

the air induction

Suck

or

at

blow

that air flows only
pipe side

REMOVAL

TypeB

AND INSTALLATION

SEC016

Air Induction valve and filter
Remove the valve and fIlter

on

the

air cleaner The air induction valve and

valve fIlter

can

ly Installation

then be taken out easi
in the

is

reserve

se

2

quence of removal

Check

binding

air

induction

valve

for

damage At the same time
check fIlter for damage or plugging If
Filter should be
necessary replace
or

replaced periodically

in

accordance

with Maintenance Schedule

SECQ12

INSPECTION
Air Induction pipe

Preliminary Inspection

Remove nut securing the pipe to
the exhaust manifold At the same
time

remove

the

screws

bracket and rubber hose

EC 8

securing the

clamp

Check hose for looseness

damage

or

faulty

flatting

connections

each part for proper installation
nere
ry

replare

and
If

SEC016

EM ISSION CO NTROL

EXHAUST GAS

RECIRCULATION

DESCRIPTION
I

In
system

the

exhaust

part

a

gas

recirculation

fthe exhaust gas is

returned to the combustion chamber
to lower the

spark flaine temperature

SYSTEM

CONTROL

E G R

during combustion This results in a
reduction of the nitrogen oxide NOx
content in the exhaust gas
When the E G R control

open

some

Exhaust Emission Control System

from
then

exhaust

manifold

the

to

The exhaust gas is
controlled in quantity by the
chamber

E GR

of the exhaust gas is led

Type2

the

E GR

valve is

SYSTEM

valve

and is introduced into

the intake manifold

JJ

From air

pipe

JT

All

o

n
I

II
1

Throttle
chamber
venturi

1

II

Throttle
valve

Advance

EG R

oontrollinel

vacuum

port
r
Engine

coolant

E G R valve

v
J

L

t

L

Thermal

Thermal

Exhaust gas from exhaust

vacuum

vacuum

valve Type

valve

Type A2

A3

manifold

Type IL

D
l

SEC017

rom air

pipe

I

Air

0

II

venturi

I

1
Ad

ance

Throt e
chamber

It

controlline

Throttle
valv e
E GR
vacuum

port
Engine
coolant

E G R

valve

T0
r If
L

J

I

L

Thermal

Thermal
vacuum

Exhaust gas from exhaust manifold

vacuum

valve Type AI

uve Type A3
v
SEC018

EC 9

Exhaust Emission Control System

EM

ISSION CONTROL SYSTEM

Type 3
Air

I

I

I

ro
lL
LJ
I

Vacuum port

I

Engine coolant
r

L
Exhaust gu from exhaust manifold
SEC309

OPERATION
The operation of the system is

as

follows

Type 2
Water temperature

Oc

oF

Below 15

15
59

59

60

Type A2

Open

Leak

Closed

Type

valve

203

Closed

V V T valve

A3

Closed

Closed

Closed

203

Above 95

EC IO

vacuum

140

60 95

140

I Thermal

Open

Venturi

I
I

J
I

vacuum

Exhaust gas pressure

High

Low

High

High

Low

High

Low

Low

High

Low

High

High

E GR

Operation

control system

Closed
Not actuated

Low

High

Low

Low

High

Low

High

High

Low

High

Low

Low

High

Low

High

High

Low

High

Low

Low

Open
Closed

Slightly
actua ted

Open

Not actuated

Closed
Actuated

Open

Not actuated

Closed
Not actuated

Open

Exhaust Emission Control System

EM ISSION CONTROL SYSTEM

Type

I

Water temperature

Oc

eF

Type

140

Below 60

60

Thermal

V V T valve

valve

Type A3

Al

Venturi

Exhaust gas pressure

vacuum

High

Low

High

High

Low

High

Low

Low

High

Low

High

High

Low

High

Low

Low

High

Low

I

High

High

I
1

Low

High

Low

Low

control system

Operation

Closed
Not actuated

Open

I

Closed

Closed

203

Closed

Above 95

E G R

Closed

Open

95

140

vacuum

Open

203

Closed

Actuated

Open

Not actuated

Closed

Not actuated

Open

TYpe 3

1
Water

temperature
Oc em

Below

the

vacuum

122

engine

at

idle or at full

deactivate the E G R system

less of water
the thermal
valve

or

control system

Operation

Below 0 206

324
0

21

33 0 82

30
i

Above 0 206

324
0

21

33 0 82

30
1

Closed

Below 0 206

324
0

33 0 82

30
1

Open

Not actuated

Above 0 206

324
0

33 0 82

30
1

Closed

Actuated

Open
Not actuated

regard
temperature operation of

vacuum

21

Open

throttle the E G R control valve doses
to

E G R

Exhaust gas pressure
kPa mmHzO inHzO

valve

Closed

122
50

Above 50

With

Thermal

B P T valve

valve

and V

21

destinatiol For identification
is stamped
purposes the part number
on the recessed portion at the top of

Thermal

the valve

installed

and

car

It T

valve

vacuum

3 port type
thermal

Two

one on

valves

vacuum

intake manifold and the other

B P T valve

lower

side

are

the upper side of the

These

thennal

on

the

vacuum

valves detect the temperature of the

engine cooling

pushed

water The valve shaft is

or

up

down by the thennal

expansion force of wax which depends
on the temperature This action opens
E G R

control valve

The E G R

I

movement of the taper valve connect
ed to the diaphragm to which vacuum
is

applied

G d
I ID

control valve controls

the quantity of exhaust gas to be led
to the intake manifold through vertical

in response to the

I

ur

E GR

control

opened

or

vacuum

and

while

transducer

V

air from the

signal
the

V T

line is
venturi

valve

4

Valve

control valve construction

2

Diaphragm spring
Diaphragm

trolorifice and E G R valve

5

Valve seat

are

and type vary with transmission type

3

Valve

shaft

6

Valve chamber

E G R operation will not function

of the throttle valve
E G R

1

the

closed to the atmosphere

throttle chamber

vacuum

causes

line to be

vacuum

When the valve opens
introduced

SEC019

opening

and closes the valve which

exposed

to

the

con

diaphragm
atmosphere the

EC

Exhaust Emission Control System

EMISSION CONTROL SYSTEM

Thermal

Type A2
To E G R
control line

JQ

The

air cleaner

JQ
Orifice

pressure

valve monitors exhaust
activate

to

the

diaphragm

engine
thennostat housing It detects engine
coolant temperature by means of a
built in bi metal

tated exhaust gas varies with the posi

the

tion of the E G R

and opens or closes
pa ge in the thermal

vacuum

valve

E G R
per

the

to

control
valve

valve regulated by

passage is open

vacuum

the throttle chamber

applied

the amount of recircu

other words

the operating condition of the engine

When the

To distributor
advance
control line

PT
B

The
vacuum

controlling throttle chamber vacuum
applied to the E G R control valve In

vacuum

Q

8P T valve

2 port type thennal
is
mounted
on
the

valve

From

r

vacuum valve
type

port
2

signal

vacuum

is

diaphragm

valve to actuate the
the

connected to

ubber ClIp

To E G R
control1ine

of the

Air

dia

phragm

Wax

f

SEC020

Exhaust pressure

SEC20a

TypeAI
From
air cleaner
r

I

1

metal
Bi

1

REMOVAL
AND INSTALLATION

Spiing
SEC023

Q

n
I

To E G R
control line

E G

Ii controi

valve

and E G R tube
O

Venturi
j

IQ
To distributor
advance
control line

1

vacuum

V V T
The

transducer

1

valve
vVT

valve

of the

pressure

the

actuates

monitors

exhaust

diaphragm @

the

which

gas

and the

venturi vacuum which in turn activate

the

Remove

diaphragm 1 @

This valve

con

which

nuts

E G R tube and

secure

P tube to E G R
B

valve and disconnect tubes from valve
2

Disconnect

vacuum

hose

and

securing E G R control
valve to Intake Manifold The E G
R
remove

nuts

control valve

can

then be taken out

trols the throttle vacuum in order to
Wax

J

ctivate the E G R control valve

In other words
SEC021

TypeAJ
From air

c1eanCi

the amount of

reo

circulated exhaust gas varies with the
position of the E G R valve regulated

by the operating condition
engine

of the

Spring

Ii

1

Vatve

C

EG

R
control line

Control

E GR

control

ported

vacuum

orifice
Air bleed
1

Spark
advance
control

I

vacuum

CAUTION

line

T

Air pipe
Exhaust gas

t

Wax

SEC022

1
2

EC 12

Diaphragm
Diaphragm

pressu

3

Pay attention not 10 give damage
packing of E 6 R control valve

to

SEC024

Diaphragm

3

Installation

is

sequence of removal

in

the

reverse

EM ISSIONCONTROL SYSTEM
When installing

a

E G R valve

a new

Type A3

it is of the same type model
number and identification mark

verify
etc

l

as

that which was previo

Exhaust Emission Control System

slY

installed
b

Always

install

Thermal

a

vacuum

The thennal

gasket

new

SEC029

valve

vacuum

valve is made

of

plastic Consequently care should
be taken to avoid damaging it On
U S A
on

models two valves

are

V V T valve
1

located

V V T valve

the front side of the intake mani

2

rear

Canada models the valve is located

screws

which

on

the

3

Installation

secure

Disconnect

back

with

pressure

valve

can

then be taken

Disconnect
the

Then the valve

hoses

vacuum

thermal

J
i

B P T valve
3 7

out

valve

same

as

one

mounting screw

5 0 N

m

0 51

Q 38

one

B P T

kg m

3 7 ft lb

and
valve

vacuum

be removed

can

Installation

reverse

that the type

rm

part is the

new

former

2 7

unscrew

3

on

on

liter
2

the

the
f

co

that

from V V T valve

on

in

replacing

new

number
tube

is

sequence ofremoval
When

The V V T

Drain engine coolant about

tubes

Disconnect

the intake manifold
I

vacuum

V V T valve to bracket

The other is located under the
end of the intake manifold On

fold

4

Disconnect

the intake manifold One is located

on

SEC030

is

in

the

INSPECTION

reverse

sequence of removal
a

Be

sura

to

apply

the valve prior

to

installing

a

l

new

vacuum

and

Make

EG R

valve
b When

installing
valve

be

a

new
sure

system

Entire

sealer to threads of

thermal

SEC029

wipe

thorough visual check of
system If necessary
oil to facilitate inspection

a

control

away

If any hoses

that color

cracked

are

or

broken

replace

shape are correct
4

Type A2

Installation

is

in

the

reverse

sequence of removal
When

V V T

replacing the
verify

valve

that the type

with a new one

number on the noYi part is the same
that

on

J
i

V V T valve mounting

2

With

phragn
a

Of

fmger

3

With

EG R
crew

stopped

inspect

vacuum

c

up

ntrol valve

ds with

J

as

the former one

engine

E G R control valve for any indication
of binding or sticking by moving dia

engine
control

valve for

running
valve

nonn

and

inspect
thennal

1 operation

i

37

J

5 0 N

0 38

27

0 51

3 7

Place your finger on diaphragm of
E G R control valve to ensure that the

m

kg

m

valve functions

lb
ft

as

described below

SEC026

f
8P T
1

r

valve

Remove

tube

vacuum

on

the

B P T valve
2

Remove

screws

securing B P T

valve to the bracket
3

Disconnect

back

pressure

tube

from BP T valve
The B P T valve
SEe027

out

can

then be taken
SEC031

EC

13

1

Emission Co
Exhau

IM ISSION CONTROL SYSTEM

System

is

vacuuin

E

GR

vacuum

at

present

control

valve

the

end

side

E G R corit ol valve

of

hose

E G R

Dismount

control

valve

from engine

Apply

1

Type Al TypeA2

E G R control

vacuum to

valve referring to the following figure
If the valve moves to full position it is
nonnal
ER
G

control

will remain

valve

open for more than 30 seconds after
vacuum has cut off
SECOO2

When temperature of the engine

1

coolant is low
Below ISoC

S90F
California models

6001400F

Below

Non California modals
Below SOOC

1220F

I

Canada models
seC018

Make

sure

control valve

that E G R

when engine
increased from idle to 2 000

does not

I

ucsl

operate

speed

is

2 500

rpm
When temperature of the engine
coolant is high

Visually

2
Airregulatort

Above ISoC S90F

E GR

wrinkle

valve for

Canada

2

check

damage

or

control
deforms

lion

f

California models
Above 600C

1400F
Non California models

Above SOOC

1220F

Thermal

Canada models
1

Make

sure

that E G R

valve operates when engine
increased from idle to 2 000

control

speed

is

operate properly
Disconnect

one

end

valve side

of

connects

3 way

as

follows

KG R control

vacuum

h

which

connecter

2 000
Make

from idle to

2 SOO rpm
thennal
sure that

valve is closed

EC 14

speed

Dismount
C035

Before

vacuum

thennal

vacuum

valve

dismounting
engine

drain engine

coolant from
Ifvacuum pressure is either weak or
thermal
nonexistent
replace

Apply

vacuum

to thennal vacuum

vacuum valve Ifvacuum Pse ss lJe is
detected replace E G R valve

valve and check to be

If any difficulty is encountered in

ture as

mal

judging

the

condition

of any

inspection

check

questionable component
pendently as follows

inde

the

or

that ther

specified

Thennal

com

sure

valve opens or closes in
to engine coolant tempera

vacuum
c

ponent during above

and that throttle

valve

from engine

to

E G R control valve
Increase engine

J
V

2 SOO

rpm
If EG R control valve does not
2
check it

TV

vacuum

below
pa5Sage

vacuum

valve should open

temperature specified
the
vacuum
completing

close at

a

EMISSION CONTROL SYSTEM
Thermal

vacuum

valve

operating temperature

Exhaust Emission Control System

2

Apply

vacuum

above

pressure

0 785 kPa

Operating temperature

Type
Leak

80 mmH20
135
inH20
to V V T valve and check for leakage

Oc OF

Open

Applied model

Close

as

ed

Wax

60

Type AI

Wax
Type A2

95
203

140
15

59

Wax

Type A3
Bi metal

60

60

140

95

140

I

Below 60 140

Non California

Above 95

for U S A

203

Below 15
59

Above 95

Below 95

Above 50
122

I
1

replace

valve

California

203

203

shown below If a leak is discover

Apply

pressure

above

U S A

203

0 785 kPa
80

Below 50

Canada

122

3 15

aO
mmH

inH

OI

SEC038

Canada

CAUTION
Do not allow water to gel inside the
B P T valve

thermal Vllcuum valve

1

Disconnect

two

cuum

hoses

on

B P T valve

s A
U

2

Plug

one

of two ports of B P T

valve

Apply
50

pressure above 0 490 kPa

a

mmH20

valve and

197

orally

inH20

to B P T

suck back other port

of B P T

valve as shown below to
check for leakage If a leak is noted

replace

1OC1

valve

EC242

t

Apply pressure above

SEC036

V V T valve
1

0 490 kPII

50

mmH20

1 97

inH201
EC381

Apply

a

A

pressure above 1 961 kPa

200 mmH20

7

87 inH20

to V V T

valve and check it for leakage as shown
below Ifa leak is noted replace vaive

SPARK TIMING
CONTROL SYSTEM
DESCRIPTION
The spark timing control system is

designed
Apply vacuum above
t 1 961 kP
SEC037

200 mmH20

7 87 inH

to

control

the

distributor

advance under varying driving
conditions so as to reduce HC and
vacuum

OJ

NOx emissions

EC 15

EMISSION CONTROL SYSTE

ExhsustEmissionControlSystem
OPERATION
The

REMOVAL

operation of the system is

as

AND INSTALLATION

follows

Thermal
Thennal

Water temperature

Oc OF

AI A2

Type

vacuum

valve

Spark timing
control system

A3

Type

vacuum

valve

The thermal

vacuum

valve designs

exactly the

same as

those used in

are

the E G R control system
Below 15 59
15

60 59

60

95 140

140
203

Above 95 203

Closed

Closed

Actuated

Open

Closed

Not actuated

Closed

Closed

Actuated

Closed

Open

Not actuated

port
3

vacuum

Two

one on

valves

vacuum

side

engine

pushed

coo

thennal vacuum

These

valves detect the

ling

the

on

of the

temperature

II

up or down

J

distnbutor
or

vacuum

closed to the

From
A
rair cleaner

I

I Q

1

l

atmosphere

iQ

I

To distributor

a4vance
coIitrolline

When the valve opens the
signal line will open to the

vacuum

phere stopping the distributor
from advancing

vacuum

Ensure

that

vacuum

connected

to

hoses
their

are
con

19
controllme

I

the

line to be opened

I

2

Make

sure

that distributor vacuum

controller functions properly

by the thennal

causes

for removal

Entire system

properly

expansion force of wax which depends
on the temperature This action opens
and closes the valve which

control system

and installation procedures

iale

The valve shaft is

wa ter

Refer to

under the headirig

INSPECTION

are

the upper side of the

intake manifold and the other
lower

at

TypeAi

thennal

installed

engine

valve

type

instructions

EGR

This system does no1 operate with tha

Thermal

the

3

Set timing light

4

Check

thennal

vacuum

valve

beginning with a cold engine
1 Using a timing light check the
spark timing while temperature gauge
is in the C position

I

atmos

Wax

SEC021

TypeA2
To E G R
control line

TYpe A3

e

C

From
air cleaner

I

From

aircleaner

Spring

t1

ii
Valve

n

lQ

iiCE

SEC039

G R

control line

Q
Q

e
To distributor
advance

ce

a

timing light

ensure that

vacuum

vious position when temperature gauge
changes from the C position to the

line

middle position

i1i
I

3

Wax
Wax

SEC020

EC 16

Using

control

control line

i

2

the spark timing retards from its pre

SEC022

Wann up the engine until coolant

temperature gauge pointer moves to
middle position of scale Ensure that
the spark timing advances from its
previous position

Exhaust Emission ControJ System

EMISSION CONTROL SYSTEM
To check for

valve

proceed

as

operation of thermal
follows

from the 3 way connector through the
air hose and vacuum control valve To
the

enters
will

as

the air

manifold

vacum

consumption low

oil

keep

be

intake

maintained at less than the

specified level

Vacuum

Thermal vacuum valve

engine Inhale air from port of spark
timing control system and check to be
sure

If spark timing does not change
place thennal vacuum valve

To check for operating

Remove thermal vacuum valve from

SEC040

reo

or

that thermal

vacuum

valve opens

closes in response to its tempera

ture

VC V

control valve

proceed

as

follows
I

Disconnect

side

one

end Air regulator

of air hose connecting 3 way

connector to V C V

Make

2

sure

that

control

vacuum

valve operates when engine speed is
4 000 to idle
decreased from 3 500
on the hose end
finger

Place
Thermal

vacuum

valve operating temperature

If the intake manifold

3

Operating temperature Oc
Type

Wax

Wax

Type

Type A3

15

60

Above 95

00 not allow water 10 enter the ther
vacuum

140

203

the

at

vacuum

is

end of air hose

present
replace vacuum control valve
not

Below 15

59

Above 60

140

Below 95

203

DECELERATION

CAUTION
mal

59

F

Close

Open
Al A2

to

check for valve operation

CONTROL SYSTEM

Intake

valve

vacuum

manifold
control type

DESCRIPTION
The deceleration control system is

designed
fold

to control

vacuum

condition 59

under
as

the intake mani

decelerating driving

to

reduce the oil

con

CATALYTIC

CONVERTER
DESCRIPTION

sumption
The

catalytic

converter accelerates

the chemical reaction of hydrocarbons

and carbon monoxide

HC

OPERATION
This system is used to force air
directly into the intake manifold w en

preset
the
tained

vacuum

level has been at

thus preventing excessive in

creases in the intake manifold
SECQ36

during deceleration

CO

in

the exhaust gas and changes them into
CO
carbon dioxide
non hannful

Air

is

vacuum
directed

and

water

reaction

H O

This

process requires

chemical
the

amount of air which is induced
air induction valve
A I
S

Refer

This air is called

proper
y the

t the item

secondary

air

EC

7

Exhaust Emission ContrQl System

EM ISSION CONTROL SYSTEM

INSPECTION
Preliminary Inspection
check

Visually

L

Catalytic converter

condition

of all

component parts
including hoses
tubes and wires replace if
necessary
Refer to Air Induction System for

ft

inspection

Ci

MufIIer

converter
Whether

SEC043

normal

or

can

converter

is

be checked by

variation in CO

observing
The

catalytic
not

percentage

is as follows

checking procedure

Apply parking brake
OPERATION
Exhaust

stances due to

from

emitted

gas

contains

engine

in the combustion

mission

the

to reduce

designed

I

for

exhaust

2

this

exhaust manifold

and

air in

into

injected

to

the

SEC044

With this injection

of the secondary

HC

the

system

secondary aicisJed from the
duction valve and

air

carbon monoxide

dioxide CO

hannful
non

and water

The

CO

O

atmosphere

damage

SEe04S

Adjust engine idle speed Refer
Mjus
g Idle RPM for adjustment
Race engine
500
1
to 2 000 rpm

7

If CO percentage measured in step

Installation

is

in

the

reverse

8
6

con

If CO percentage measured in step
3
0
recheck Al S arid

AND INSTALLATION

Be

air induction valve

Then per

form inspection steps S and 6
9
CO
if
percentage is still over

CAUTION
a

careful

converter

not to

damage catalytic

when handling

b Newr wet

car

the catalytic

is over

replace

Jack up the

three times under no load

If idle

verter is nonnal

sequence ofremoval

I

converter

cracks

6 is less than 03

3

REMOVAL

or

6
Measure CO percentage at idle
speed After step S has been com
pleted wait for one minute before
making CO percentage measurement

contained in exhaust gas into carbon
dioxide and water before exhaust gas
to the

position

SWann up engine for about four
minutes at 2 000 rpm under no load

converter

discharged

for auto

speed increases readjust
it
to specified speed with throttle
adjusting screw

in

carbon

H

3

4

catalytic
further
cleans engine exhaust gas Through
catalytic action it changes residual
hydrocarbons and carbon monoxide

is

P

Visually check catalytic

two or

hydrocarbons

the exhaust gas are gradually oxidized
with oxygen 0
in the secondary air
and converted into

or

California models

the content of such substances in the
In

N

and

Shift gears
manual trans

combustion

chamber The air

induction system is

for

matic transmission

hannful sub

some

incomplete

gas

Neutral

into

catalyzer

with wa1er oil

3
0

step 8 catalytic converter is mal
functioning Replace catalytic con
in

verter

etc
and

place

securing

lower

6 3

shelter of catalytic converter
Loosen flange
bolts connecting

4 6

Apply

parking

brake

wheel chocks

fJ
2

Remove

catalytic

screws

converter to

front and

rear

exhaust tubes

Catalytic

converter

assembly

can

8 3 N

0 64

0 85

3 2
23

m
kg

converter bolt

42 N
4 3

m

m
kg

31 ft bl

models

Califomia
Non

m

6 1 ft lb

Catalytic
31

then be taken out
EC 18

Lower shelter bolt

I

VisuaIly check catalytic

for damage
2

or

Adjust engine

percentage

Refer

RPM and

Mixture

ment

converter

crack
idle

speed and CO
Adjusting Idle
Ratio for adjust

to

EMISSION CONTROL SYSTEM
3

Race engine

to 2 000 rpm

500
1

two Or three times under

make

centage

sure

that

no

specified

5

Wann up engine for about four
minutes at 2 000 rpm under no lmid
6
Measure CO percentage at idle

load and
CO

per

is obtained

4

Remove cap and connect air hose
to air induction v
a1ve
If idle

speed

to

specified speed
ing screw

Evaporative Emission Control System

speed

After step

pleted

wait

for

4 has

one

been

minute

8
S

before

increases readjust it
with throttle adjust

If CO percentage measured in step
over
3
0
recheck AJ S and

replace air induction valve Tlien
fonn inspection steps 4 and 5

per

9

3
0

com

making CO percentage measurement
7
If CO percentage measured in step
5 is less than
3
0
the catalytic con

is

If CO percentage is still

in

step

over

7

catalytic converter is mal
functioning Replace catalytic con
verter

verter is normal

EVAPORATIVE EMISSION CONTROL SYSTEM
DESCRIPTION

This

The

evaporative emission control
system is used to reduce hydrocarbons
emitted to the atmosphere from the
fuel system This reduction of hydro
carbons is accomplished by activated

system

is

made

up

of the

following
1

Fuel tank with

positive sealing filler

Vacuum signal line
Canister purge line

7

Vapor liquid

separator Hatchback

models

cap

charcoals in the carbon canister

S

6

2

Fuel check valve

3

Vapor

4

Carbon canister

Removal and installation of above

vent line

Pressure

components

are

described in Section

FE

Fuel Hller cap
Vacuum reliet

regulator

j

Vapor liquid separator

Fuelf1lter

HATCHBACK model OnlY
Fuel return line
Fuel check
valve

I

Fuel reed line

Z

Fuel tank

c

I

81

Fuel

danlper

J
Electrical
fuel pump

f

1

Fuel mjector

sending

unit

Fuel tank vapor vent line

Vapor storage
canister
Intake manifold
Canister
purge line
SEC046

EC 19

rr

Etlaporative Emission ContlOlSystrm

EMISSION CONTROL SYSTEM

OPERATION
Fuel vapors

tank

coals and stored there when the engine

directed to the carbon canis

char
ter which is filled with activated

the sealed fuel

from

are

is not

nmning

HARDTOP models

J111
Vacu1

POsitive Sea
lli1g gas cap
with aCllum relief valve

lline7
L

jFUel

LJ
I

vent

I

n

r

ri
Intake

vapor
line

Fuel che

ffil IlifOldJ
t
f fJ
ij

j
Freshair

L

Fuet vapor

Fuel tank

SEC041

HATCHBACK modeb

Vacuum signal line

tr

Yaporjliquid

L

7

G
I

separator

Purge control ialve

J

Fuel vapor

LJ
I

r

1

vent

line
sitive sealing gas

Fuel check

cap with vacuum
relief valve

Fixed orifice
I

Intake

manifold
J

Con tant purge
lice

i

Si
i
iji

S

ji

J

Fresh air
Fuel vapor

LFUe

tank

SEC048

EC 20

EM ISSION CONTROL SYSTEM
The canister retains the vapor until
purged by the air drawn through

it

3

Engine speed increases

To carburetor C
J
Ported vacuum

When the engine runs at idle the purge
control valVe is closed Only a small

To intake
manifold

the

amount

of purge

FUEL TANK AND VAPOR

VEfo T

Check all hoses and

2

intake manifold through the constant

the purge control valve opens
and the vapor is drawn into the intake
both

the

IDler

vent

vapor

canister

Connect

3 way

Fresh air

3

manometer and a cock
lent 3 way

to

line
fuel

a

cock

charge

connector
or

a

equiva

an

to the end of

the vent line
1

does not operate

4

Diaphragm
Pltrge control

2

Engine

the

carbon

F el vapor

fixed

orifice and the constant purge orifice

I

tank
fuel

iank

higher

through

Disconnect

Onnecting
C

purge orifice As the engine speed in
creases and the ported vacuum rises

manifold

LINE

cap

@

air flows into the

Control System

INSPECTION

is

purge line towards the intake
manifold while the engine is operaiing

Evaporative Emission

Constant fixed
orifice

4

Supply fresh
line

air

through

into the vapor
cock little by

valve

5

Activated carbon

vent

Fixed orifice

6

Filter

little until pressure becomes 3 923 kPa
400 mmH20 15 75 inH20

3

t

e

From
fuel
tank

3way connector

i

umuu
N

l

Air

Diaphragm

2

Purge control
valve

3

4

Check valve

11
fl

Fuel filler cap

@

Constant fixed
orifice

5

15 75 inH 2 0

mmH20

Manometer

SEC049

1

400

Cock

I
Fuel vapor

3 kPo

Carbon canister

Activated carbon

Fixed orifice
EC091A

Engine operates

5

at idle

Shut

the

cock

completely

and

leave it unattended
6

5 minutes
2

After

the

measure

in the manometer

of the liquid
Variation in height should remain

height
7
with

245
0

kPa

Iy made

livery

25

mmH20

It

thus

causing insufficient de
engine or vapor lock

of fuel to

must

therefore

be

repaired

or

replaced

0 98

inH20
8

When

filler cap does

completely

1

2
3

the

height

zero

in a short time

Fresh air

9

If the

Fuel vapor

zero
SEC050

Diaphragm
Purge control

4

Constant fixed
orifice

valve

5

Fixed orifice

6

Activated carbon
Filter

height

not

should

close

drop

to

CARBON CANISTER PURGE
does not

drop

to

in a short time when filler cap is
removed it is the cause of a stuffy

hose
In

case

breathing

the vent line is
in fuel tank is

stuffy the
not thorough

CONTROL VALVE
Check for fuel vapor
distributor

vacuum

leakage

in the

line at diaphragm

of carbon canister purge control valve
To check for leakage proceed as
follows

EC 21

Evaporative Emi

on

Control

Disconnect rubber

I

smem
in

nose

EMISSION CONTROL SYSTEM

he

Disconnect

I

thb l
ub

line between Tconnector and carbon

line between the

canister at T

engine and

2

Inhale

rubber

onnector
air

hse

into

running to

carbon canister and
is

no

the

opening of

vacuum

ensure

hole in

that there

leak

ber llooe

on

the

FUn TANK VACUUM
RnlEF VALVE

steel pipe of the

canister

Remove fuel filler
cap and

2

Force air into the opening of the
rubber hose which runs to tiJe carbon

canIster

and

ensure

that

there

functions properly
I
Wipe clean valve

are

housing

it

see

and have

it in your mouth
2
Inhale air A

leaks

slight resistance ac
cornpaniedby valve indicates that
valve is in good mechanical condition
Note also that by further inhaling air
the resistance should be

disappeared

as

valve clicks
3

If valve is clogged or if no resist
is felt replace cap as an assem

ance

bled unit

EF199

3

If there is

a

leak

remove

top

from purge control valve and
check for dislocated or cracked dia
cover

phragm
phragm
retainer

If necessary
kit

replace dia

which is made up oLa

r

SEC052

3

If there

purge

are

control

no

leaks

valve and
orifice

remove

check
for

the

If
purge
the
clean
constant
necessary
purge
constant

leak

orifir

diaphragm and spring
ET500

Cover

Diaphragm
Retainer

t

Diaphragm spring

FUEL CHECK VALVE
1
SEC053

Blow

air

through

connector

on

fuel tank side
A considerable resistance should be

felt at the mouth and

EF200

CARBON CANISTER FLTER
Check for
Element
bottom

body

the constant purge orifice of carbon
canister

as

To check the purge flow
follows

EC 22

portion of

a

contaminated element

can

be

of canister

on

Air flow should be smoothly direct
ed toward fuel tank

removed at

the

3

installed

car

not

on

air

engine side

I

If fuel check valve is suspected of
being properly functioning in steps
and 2 above replace

r

CARBON CANISTER
CONSTANT PURGE ORIFICE
Check the constant purge flow in
the intake manifold vacuum line at

a

flow be directed toward the engine
2
Blow air through connector

1
e

Q

ltank

tm
l

Evaporative fuel flow
Fresh air flow

proceed
EC090A

SYSTEM

EM ISSION CONTROL

Service Data and

Specifications

SERVICE DATA AND SPECIFICATIONS
TIGHTENING TORQUE
Unit

E G R

tube

N

securing

nut

34

m

44

m
kg
3 5

45

ft lb

25

33

Unit

V V T valve

I
18

mounting

N

m

kg

m

ft Ib

3 7

5 0

0 38

0 51

2 7

3 7

3 7

5 0

038

0 51

27

3 7

screw

E A I

tube

securing

nut

34

44

Less than
Thermal

vacuum

valve

35

45

Less than

25

33

Less than

P T valvo

mounting

screw

22

2 2

1

6

I Catalytic

converter bolt

31

42

3 2

43

23

31

EC 23

DATSUN 200SX

Mod 1 S II 0 Series

SECTIONER
ENGINE REMOVAL

INSTAllATION

CONTENTS
ENGINE REMOVAL AND

INSTALLATION
CONSTRUCTION

REMOVAL

INSTALLATION
ER 2

SERVICE DATA AND

ER 2

SPECIFICATIONS

ER 2

TIGHTENING

TORQUE

ER

5g

ER 5
ER 5

Engine

ENGINEREMOVAL

Removal and Installation

ENGINE

REMOVAL

INSTALLATION

AND INSTALLATION

CONSTRUCTION

Iii

87

30 40
3 1 4 1 22

8 7

19

Iii

44
4 5

54
5 5

33

0

Iii

1

N

m

m
Itg

40

3 1

31

Iii

30

1

22

30

42

3 2

ft b

4

4 3 23

31
SERD01

REMOVAL
It is much easier to remove

and transmission

as

single

a

engine

unit than

to remove them

separately After reo
engine can be separated from
transmission assembly

CAUTION
Before disconnecting fuel hose release
fuel pressure from fuel line to elimi

4

Turn the

5

Reconnect tJie harness connector

of fuel pump rel y 2

danger

nate

F nd

moval

WARNING
a
Place wheel chocks in front of
front wheels and in rear of rear

I

Start the engine
2 Disconnect the harness connector
of fuel pump
relay 2 while the en

gine

is

sure

to hoist

engine

up transmission in

a

and

safe

protect
2

You

not

remove

Relay bracket

destined

battery
3

jack

fire may break

man

the

out

on

FoUow the procedure below

in

reduce fuel pressure to
ER 2

zero

to

battery

to

for

r

aquipped

California
this

facili

mod ls

remon

tho

operation

location of hood

hood to facilitot

hinges

correct reinsta

lotion

SEF131

fuel line

I

to

Drain engine coolant
Remove hood

4

until the exhaust system
has completely cooled off
Otherwise you may burn your
or

the negative

On air condition

engine

self and

uBI

body

Disconnect

Mark tho

should

shCll ld b

co

cable

nero
C

r

car

running

wheel
b Be

ignition switch OFF

3

After the engine staUs crank the

engine

two or three times

CAUTION
Have an assistant help you

so as

to PII

vent

damage

5

Remove aU wires and hoses where

to

body

indicated by the
below

arrows

in the

figure

ENGINE REMOVAL

INSTALLATION

Engine

Removs and In tallation

1
r

I
Yr

p

t

u

1

J

o

0

o

SER003

Air conditioner equipped

2

models
Remove compressor foUowing the
procedures below

I

Remove
To

drive belt

compressor

remove

this belt

idler puUey nut and

loosen both

adjusting

Ne er d
sor

shown

work is

models
Remove

gas from compres

ilCherge
repair

while service

as

being

foUowing
I

power

steering oil

pump

the procedures below

Remove oil pump drive belt
loosen both
remove this belt

To

performed

idler puUey nut and

bolt

fi

P

Power steering equipped

Remove compressor

Place removed compressor
below

adjusting

bolt

III

9

qa

ey nut

5
a

1
I

djUS ing

11

l

n

I
AOO

ER 3

Engine
2

ENG INE REMOVAL

Removal and Installation

INSTALLATION

Remove oil pump
Place removed oil pump

as

shown

below
Never drain oil from oil pump while
sorvice repair

rk i

being perfonnod

SER010

g

Disconnect

9

Disconnect

wire and

Mk
ar mgp

I

speedometer cable
down

inhibitor

Plug
housing

shift solenoid

switch wire

1
SER024

open holes in rear extension
hown

as

AfT

only
Remove transmission control link

6

age as foUows

1

Manual transmission

Attach suitable wires to engine
sIingers and raise engine using a hoist
to take the weight off front and rear
12

E

iW

33

10

Disconnect

vacuum

hose

AfT

mount insulators

only
2

Automatic transmission
WARNING

BeforB raising engine try loosening
or three times to make

wires two
sure

I3

it is safe to do

Remove

support

Remove clutch operating cylinder
propeUer shaft

II

Remove

7

radiator

and

radiator

front exhaust tube and

shroud
Place marks
On air
dels

ER 4

conditioner

remove

equipped

oil cooler ho

mo

fora
tion

on

remo al to

propeller

facilitate

haft be

reinstall

body
to

so

engine mounting
aUaching bolts

rear

14

Remove

front

engine

mounting

ing
InstaU in the

Raise engine and transmission and

remove

them from

car as

a

reverse

moval observing the

electrical

that

WARNING

reo

are
heme

be

raising engine

especially
against ad

jacent parts

Set engine and transmission

on an

engine stand

Refer

correcdy
3

When

When

installing

first

secure

rear

engine support bracket to rear mount
ing insulator
2
Refer to pertinent section when
installing and adjusting any parts
Adjust accelerator control system
Refer to Engine Control System
Section FE for adjustment

Pump Belt Adjustment
ST for adjustment

to

Section

installing

exhaust front tube

exhaust manifold be

on

I

for checking and adjust

drive belts

InstaU power steering oil pump and
adjust belt

be lure to check

connected

careful not to knock it

16

order of

foUowing

single unit
When installing

When

tion MA

INSTALLATION

bolts
15

ServiceDataandSpecifications

INSTALLATION

ENGINE REMOVAL

sure to

instaU

gasket
4
When reinstalling the hood foUw
ing engine instaUation be sure that it
a new

is

properly

centered and that hood

lock operates securely Refer to Hood
Section BF

for adjuslment

Add the correct amount of engine
coolant
5

InstaU air conditioner compressor
and adjust belt

6

Refer to Engine Maintenance See

transmission fluid

For automatic transmission mod
els add the same amount of automatic
as

was drained

SERVICE DATA AND SPECIFICATIONS

TIGHTENING TORQUE
N

Unit

m

m
kg

ft Ib

Front

engine support bracket to cylinder block

30

40

3 1

41

22

30

Front

engine support bracket

31

42

3 2

43

23

31

Front

mounting insulator to body

31

42

3 2

43

23

31

44

54

45

5 5

33

40

19

25

19

2 6

14

19

09

12

65

87

09

12

65

8 7

Compressor

to

to

mounting insulator

bracket

Steering oil pump

to

bracket

Rear

mounting insulator to transmission

8

Rear

mounting insulator to mounting member

8

118

8
11

14

31

2 0 2 6

14

19

3 1

22

30

Mounting member

to

body

20

42

2

Exhaust maniflold

to

exhaust tube

20

25

operating cylinder to engine

30

40

Clutch

4 3

4 1

ER S

DATSUN 200SX

Mode

S 110 Series

SECTIONFE
ENGINE CONTROL FUEL
EXHAUST SYSTEMS

CONTENTS
FE 2

INSPECTION

FE 6

ADJUSTMENT

FE 2

INSTALLATION

FE 7

REMOVAL

FE 3

INSPECTION

FE 3

REMOVAL

FE 9

INSTALLATION

FE 3

INSPECTION

FE 9

INSTALLATION

FE 9

ENGINE CONTROL SYSTEM

FUEL SYSTEM
REMOVAL

4
FE
FE 5

EXHAUST SYSTEM

FE S

GII

EngjneControISyltem

ENGINE CONTROL

FUEL

EXHAUST SYSTEMS

ENGINE CONTROL SYSTEM

Adjusting bet
Ptdal
o 2

free
mm

nut

play
0

0 08 in

arm

Iii

frPedaI

t

2 9
0 3
2 2

3 9
0 4
29

Pedal arm
brlcket

j

aI t etum
PlUIll

Iii

N

m

kg

m

ft

lb

SFEQ01

ADJUSTMENT

a

Depress

ACC

to

RATOR

WIllE

accelerator pedal to make

its

linkage moves lIDootItly
jamming or dragging re
lease pedal to make lure it returns
to its original position smoothly
Check to see if throttle valve fully
when accelerator pedal i
open
completely depressed and if it
Iura

without

Adjust accelerator pedal free play
specifICation using adjusting nuts
b

returns
c

Pedal

to

necessary
mined

SFEOO3

FE 2

idle

height

when

adjustment
since its height

by stopper

releasad
i

not

is deter

ENGINE CONTROL

INSPECTION

REMOVAL

I

ACCELERATOR WIRE
I

Loosen

Engine Control System

EXHAUST SYSTEMS

FUEL

adjusting

Check pedal return spring for rust

fatigue

or

damage

if

Replace

neces

sary

lock nuts and

cases
Check accelerator wire
socket and fastening locations for rust

2

disconnect accelerator wire from car

buretor

damage or looseness Repair or replace
if necessaiy

INSTALLATION
instaU

To

the

reverse

order

of

removal
SFE155

a

Check accelerator controrparts for

improper contact
jacent parts
2

Remove

toward

nylon coUar by pushing

wire

accelerator

end

wire

and
from

b

it

ann

ACCELERATOR PEDAL
Remove

nylon collar

tip of pedal

c

remove

pedal

by removing pedal
ing 01t

arm

arm

scratch its

or

On automatic transmission models

depress accelerator pedal
su

arm

Then

ad

inner wire

and discon

nect accelerator wire from

any

When connecting accelerator wire
be careful not to twilt

disconnect

pedal

with

assembly

bracket retain

on

that

when

and t

t

kickdown

throttie
push

alve is

rod mo

to

make

switch turn

fully open
properly

r

SFE154

3

Remove

and extract

pedal stopper bracket
accelerator wire toward

EF156

passenger compartment

FE 3

rl
I

llm s C
l C
l
llC
m ZG Zm n o z l0 o r T1 C m r ll mX J Ic C

m r en enI mi
m
m Itg

unit

fHb

8

pate
I

k
c

0
1

check
Fuel

tank uge
uel

18N

1

fHb

13

4

14

tank
Fuel

ing
O

1

10

m

kg

Iii

m
N

Iii

hose
fil er
vol Fuel

hoae

outlet
Fuel

hOle

fetum
Fuel

Hatchback

tube

outlet
Fuel

tube tulx

return
Fuel

Enporatin

Hardtop
cap

fil er
Fuel

tube

ho

fil er

Ventilao

Fuel

hole

fil er
Fuel
II m Q Qom

mJ

o

ENGINE CONTROL
Evaporation

REMOVAL

Fuel filler

EXHAUST SYSTEMS

FUEL

Fuel

System

hose

hose

Hardtop

WARNING
When
sure
a

replacing
to

put

with
c

Be

in

sign

sure

Be

INFLAM

CAUTION

a

MABLE
b

fuel line parts be
the following

observe

asphyxiator

an

sure

to disconnect

cable before

ground
operations
d

workshop
workshop

furnish

to

Put drained fuel in

battery
conducting

an

explosion

container and put

proof
securely

lid

on

FUEL TANK GAUGE UNIT
5

bolts which

Remove

tank in

secure

fuel

place and dismount fuel tank

battery ground cable
protector from luggage

I

Disconnect

2

Remove

compartment and disconnect harness

FUEL TANK

for fuel tank gauge unit Also

1

Remove

rubber grommet

2

Drain fuel

3

Remove

battery

and extract fuel lank gauge unit

the

remove

for

connector

Turn lock plate counterclockwise

3

protector from luggage

compartment and then
foUowing parts
Harness

cable

ground

frofuel tank

fuel

remove

tank

gauge unit
Ventilation hose

18N

Evaporation hoses

SFE012

m

3ft lb

1 4

Hatchback

Fuel filler hose

Hardtop
Harness connector

Ventilation

hose

RESERVOIR TANK
Hatchback

FUEL FILLER TUBE AND

I

Remove

battery ground

2

Remove

protector from

compartment
speaker and

Also
side

cable

luggage
R H

remove

lower

flnisher

nnector

A
HatchbackrHai
b1J neiS

Ventilation hose

HOSE
I
Disconnect battery ground cable
2 Drain fuel if fuel overfloWs when
disconnecting both fuel filler tube and

hose

o

Open fuel filler lid

3

o

filler

cap

and

remove

remove

fuel

fuel
fIller

attaching bolt
l

G

i

o

SFE010
SFE013

1

4

Remove the foUowing parts from

I

j

2

underside offloor
Fuel outlet hose

3

Fuel return hose

then

Remove evaporation
remove

reservoir tank

hoses

and

uel filler

p
SFE016

FE S

Fuel

4

ENGINE CONTROL

System

Remove fuel filler tube and hose

as

Hardtop

follows

Hardtop
Disconnect

1
fuel
2

k
al

9

Remove protectors from

Remove

cl1eckvalve

D

fuel filler hose from

underside of floor

compartment
tion hose

EXHAUST SYSTEMS

FUEL

luggage

and disconnect ventila

fuel check valve bracket

and then extract both fuel filler tube
SFEO

and hose

FUEL PUMP

DAMPER

AND FILTER
Refer

Section EF

to

INSPECTION
FUEL TANK
Check fuel tank for cracks
mauon
Ifo

Hatchback
Remove

protectors from luggage
compartment Also remove rear speak
er

and side lower fmisher from

side
cc

of

mnect

luggage

compartment Dis
evaporation hoses ventilation

and then

remove

Fuel tubes

1

110

as an assem

er do not disconnect any
How
fuel line unless absolltely necessary

Disconnect

Drain fuel from fuel tank

3

Loosen

t

Plug

be

I

FUEL TANK GAUGE

prevent

fuel
fuel

hose

UNIT

Refer to Fuel Tank Gauge Unit Jor

inspection Section EL

batlery ground cable

I
2

Fuel filler
filler

serviced

bly

disconnect

1

are

fuel

arid hose

defor

FUEL TUBE

fuel filler tube

hose and fuel filler hose from
tank

right

or

ecessary
replacl

hose
tube

and

tube

entry of dust

clamps
each

at

openi ng
or

and
end

FUEL FILLER TUBE
AND HOSE

Inspect aU

to

dirt while

cracks

hoses and

fatigue sweating

or

tubes

for

deteriora

tion

removing

Replace

any hose

or

tube that is

damaged

FUEL CHECK VALVE
Refer

to

Fuel Check Valve

for

inspection Section EC

SFE018

FUEL TUBE

Replact
ed

rusted

any fuel tube 1hat is crack

coUapsed

or

deformed

FUEL CHECK VALVE
Remove

fuel check valve

as

fol

lows
Remove

protectors from

luggage

compartment Disconnect fuel check
valve from evaporation hose
6
FE

4

Remove fuel tube

clamps

and fuel

pump bracket from underbody Re
move fuel tubes and fuel
pump as an
assembly Leave brake tube on under

body

FUEL PUMP FUEL DAMPER
AND FUEL FILTER
Refer to Fuel

Pump

Fuel

Damper

and Fuel Filter for component parts
inspection Section EF

ENGINE CONifROL
b

INSTALLATION

Observe the foUowing notes and refer
Fuel Pump
Fuel
to Fuel
Filter

Darnper aod Fuel
aod instaUation

GJ

for removal

18 N m

1 4
10

1 8 kg

e

clamp

tighten excessively
ing

ecurely

on

und

Failure

Do not twist

or

and evaporation

to the
urfe of fuel tube
Do not kink or twist ole and tube

when

are

Run the
at

e

ge from around hose

connections
ventilation

engine

and check for leak

connection

tank

filler

has been

Failure

to

routed

hoses

Be sure to

with clips

them

smash

securely

Fuel tank

gauge unit
When installing fuel tank gauge
unit align tlle projection of fuel
tank gauge unit with the notch in

Fuel tank
fuel

they

retain
f

when they are routed
d

result in lea

r

to follow

FueISysll1

this caution could result in damage

Install
m

13ft lb

Install ho

c

Section EF

Fuel tank retaining bolt
14

a

Hose

Fasten fuel tube clamp

body

InstaU any parts of the fuel system
order of removal
in the
reverse

EXHAUST SYSTEMS

FUEt

etter

hose

mounted

follow

this

in

fuel

place

rule could

fuel tank and
sure

tighten

it

ecurely Be

to install fuel tank gauge unit

with Q

ring

in

place

ecurely Do not
to

avoid damag

hose

FE 7

C m r Ii mX I

o Zl
Do r

m Zc Z m

11
l
I

m

C

J Jlm

J

f f m3

J Iic f

8 2

1l

7
8

8
8
8
0
7
5

mountig
mutner

1

b

8

H

Iii

2
1

7

ft

8

m

8
8
8
0
5

kg

1fJ7
l

m
N

Rear

Iii

7
8

8
5

2
1
8
0

ounli 8

8

H

j

8
7

bond

Iii

fj

IUmer

murtle

I

op er

Exhaust

7
8

8
5

rUbJer 8l12
H

RiIl8

8
8
7

0

convert
Catlyic

7
7
8

11

81

Lower mountlos bncket

8

0

7

flermo

Iii

gg

I

mu

Up er raCket

4

tube

inulatOJ

ePaust heat

mu er

82

tir18

23

Front lower

1

58

31l

1i
1

@

5
6
9
0 3

4

32
9
0 2
2

LIii tube

@
7
8

8
5
82

11

1

8
8

exhau
Front

6
3

2
2
5
9

0

4

3
9

0

2

Iii

0

7

Iii

m0

m Co

ENGINE CONTROL

EXHAUST SYSTEMS

FUEL

ExhBustSystem

REMOVAL

INSTALLATION

FRONT TUBE

the reverse order of removal

1

ifl

InstaU the exhaust system parts in
Remove catalytic converter lower

shelter

Exhaust manifold to front
tube nuts
26

31 N

m

3 2

kg

2 7
20

m

23 ft lb

Front tube mounting bracket
SF E026

nuts

7 8

11 8 N m

0 8

1 2

5 8

kg m

8 7 ft lb

Catalytic

converter

attching

bolts
31

42 N

3 2

31 ft lb

23

EXHAUST MUFFLER

m

4 3 kg m

Rear muffler
L

lift up

car with a

2

Remove

frame hoist
converter lower

catalytic

7 8

shelter
3

2

Remove

bolts

or

nuts

attaching

front exhaust tube to exhaust mani
fold and front tube mounting bracket
Front tube can then be removed

11 8 N

0 8

Remove

bolts attaching exhaust

1 2

5 8

muffler to catalytic converter remove
rear muffler mounting nut and rubber

insulator

m

kg

m

8 7 ft lb

Muffler band stopper attaching
bolts

Dismount
exhaust muffler
rings
through underbody and rear axle case

7 8

11 8N m

0 8

1 2 kg m

5 8

ift

8

Muffler

lb
bracket B

mounting
11 8 N m

7 8
0 8

1 2

5 8

kg m

8 7 ft lb

hieiil plate ecuring

Heet
bolt
I

2 9
Exhaust muffler

1

SFE025

mounting

nut

4 9 N

0 3

U

0 5

m

kg m

3 6 ft lb

2 2
SF E027
a

Keep sufficient clearance between
exhaust

system

components

and

underbody adjacent parts
b

Replace
verter
one

c

CATALYTIC CONVERTER
Remove catalytic converter lower
shelter and

remove

catalytic

INSPECTION

converter

converter when
b

Never wet
water oil

damage catalytic
handling

to

catalytic
m

Check

muffler

cmcks damage

converter with

Replace

any

or

and

tubes

for

inStallation

After

is

sweated

and

con
new

that

mounting

rubbers

are

If any

of the above part

or

free from undue stress
i

not

excessive noise

vibrations may be transmitted to

the car body

damaged

beyond limits
2
Replace bracket and hanger rub
ber parts that are cracked fatigued or

catalytic

check

brackets

installed properly

corrosion

parts that

for

when removed

mounting

I

CAUTION
a
Be careful not

ga ket

and for front tube with

d

With

engine running check

connection
and

entire

for

all tube

exhaust gas leaks

system

for

unusual

noises

FE 9

NG N

CON

ROL fU

L

E1

S

AUS S

II
II
a

e
q
o

E

fj

1

1

jj

oJ

a
j

6
P
A
Q

9

1

a

Q

O
j

e

SFI

Mode

DATSUN 200SX

S II 0 Series

SECTIONCL
CLUTCH

CONTENTS
CL

HYDRAULIC CLUTCH CONTROL
l

CLUTCH

PEDAL

Ci 2

CLUTCH

MASTER CYLINDER

CL

OPERATING CYLINDER
CLUTCH

CLUTCH

SYSTEM

CLUTCH UNIT
CLUTCH
RELEASE

DISC AND COVER

BEARING

2

SERVICE DATA AND
SPECIFICATIONS

9

CL 11

clli

CL

4

t

5

INSPECTION AND ADJUSTMENT

CL 11

CL

5

TIGHTENiNG

CL11

C

7

CL

7

CL

9

Refer to Section MA

Clutch

TORQUE

TROUBLE DIAGNOSES AND
CORRECTIONS

CL12

SPECIAL SERVICE TOOLS

CL14

for

CHECKING CLUTCH PEDAL HEIGHT AND FREE
PLAY

CL

GENERAL SPECIFICATIONS

LINE

BLEEDING

PILOT BUSHING

2

Hydraulic

utJ
C

CLUTCH

h Conrrol

HYDRAULIC CLUTCH

CONTROL

CLUTCH PEDAL

rD

REMOVAL
1

Remove instrument lower cover

Pry

2
is

I nstall

Co

Q

l

clevis

pin

left

of
sa

curaly
d

I nstall

return

Figure

off snap pin and take out clev

pin

tha

on

clutch pedal and attach snap pin

shown in

spring

as

on this

page

G
2

After

assembly adjust
play

clutch ped

aI height and free
Refer

0
o
SC

l002

Checking Clutch Pedal

to

Height and Free Play Section MA

tV

Pedal rtoppar lock nut
11 8N m

B
7
10 8

12 kg m
8 7 ft lbl

5 8
3

INSTAllATION
I
SCLOOl

Install clutch

pedal

in reverse

or

der of removal

Observe foUowing
1

li ring

1

Return

spring

a

3

Oevi pin
4 Stopper bolt
5

Apply
al return

to boss of clutch
grea

spring

ped

and fiih rum pin

Outchpedal

3

Remove stopper bolt
Remove E ring on fulcrum pin
then remove clutch pedal and return

CLUTCH MASTER
CYLINDER

4

spring

REMOVAL

INSPECTIoN
the

Inspect
nonnalities

SCL003

foUowing

Remove snap pin from clevis pin

2

Pull

3

Disconnect clutch tube

4

Remove master

out

clevis

pin
cylinder

parts If ab

found repair

are

I

or

replace

the affected parts
I

Clutch

pedal bushing D

fulcrum pin
wear

V

and E ring

deformation or

at boss

@

for

b

Firmly attach

E

ring

to

fulcrum

pin

damage

Clevis pin

@

for

wear or

@

formation
4

or

Return

damage

Cl 2

or

clutch switch

@

a

container
to

Use of rags

is also

keep adjacent parts and

dean

CAUTION
When

for de

fatigue

disconnecting

dutch tube

use

suitable flare nut wrench
Never

for

disconnecting clutch tube be
recei
draining clutch fluid

damage

damage
spring

into

area

and snap pin @ for any deformation
3
Pedal @ pedal pad j and pedal
stopper

to

suggestad

Bushing iJ p
fitted If it shows
sign of abnonnality replaca pedal as
sembly
2

When
sure

or
SCL0Q4

use

adjustable

an open end wrench
wrench

or

CLUTCH

Hydniulic

Clutch Control

DISASSEMBLY

ir

Reservoir band
Lock nut

lii7

Return

1

Iii 7
8

118

0 8

12

118

8

0 8

12

5 8

8 7

spring

5 8

8 7

Stoppetbol

Iii

N

m

m fHb
kg
SCL005

I

Remove dust

cover

and take off

stopper ring

for
CAUTION

the

clearance

between

bore

Never detach reservoir If it is removed
for any

If

wear

reason

discard it and install

and piston exceeds
cylinder
specified value
replace piston as
sembly or master cylinder assembly

new one

Cearance between cylinder
bore and piston
Le

than 0 15

mm

0 0059 in
3

Check

condition

and dust cover

after disassembly

INSPECTION

t1

4
SCLOO6

CAUTION

Then

can

be taken out

the

push rod and stopper

wash all parts of master
be

To clean

or

cylinder

clean brake fluid must

used
2

Never

gasoline

use

of piston cup
Always replace them

mineral oils such

and kerosene

rubber parts of the

Check aU

recesses

openings

and

internal passages to ensure that they
are clean and free from foreign matter

as

It will ruin the

hydraulic system

Loosen stopper bolt and take it

3
out

4

The piston spring seat and

spring

return

can be taken out

Discard piston cup and

ust cover

Check cylinder bore and piston
for score or rust and if fo nd replace

ASSEMBLY

1

2

Check cylinder bore

and piston

I
Apply
sliding part

grease to cylinder
and piston cup

body

CL3

CLUTCH

h Control
Hydraulic C1u t

Install piston

2

assembly

to

cylinder
CAUTION

body

To clean
Be

careful

not

damage piston

to

cylinder

cup
4

that master

sure

Never USe mineral oils such is

cylinder
I

operates normally
Make

sure

thai piston

maximum siroke

1 5

1 1

parts of the hydraulic system

fTI

0 3

k9

for

m

When

master

of

disconnecting

clutch tube

cylinder

removal

in

Observe

Never

use

adjustable

or

Cearance between cylinder bore
and piston

Bleed air

out

of hydraulic system

Refer to Bleeding Clutch System

Adjust pedal height and pedRl

play Refer

free

Checking Clutch Pedal
HeiRht and Free Play Section MA
to

Master cylinder

HCUring
7 8

2
1

8
5

to

Remove

2

18 N

er
oj

cover

of piston cup
Always replace them

after disassembly
heck bleeder holno be surnhat

DISASSEMBLY

m

I

Remove dust

2

Remove

cover

and

push rod

piston and piston

cup as

ASSEMBLY

assembly

m

reverse

3
11 8N
1 2
8 7 ft

Assemble

Discard piston cup and dun cover

m
kg

13ft b

5 8

Check condition

and dust

Remove bleeder

operating cylinder in
disassembly Observe

order of

following

screw

Push rod lock nut

08

3

it is clean

m
kg

1 8

7 8

mm

0 0059 in

ating cylinder
4
Remove operating cylinder

an

11

less than 0 15

dis

dash panel

8 7 ft bl

1 5

then

spring

engage hose from bracket
3
Remove clutch hose from

Clutch tube flare nut
15

lock

nut

11 8 N

0 8

I

m

Prior

m
kg

pis10n

bl

install

to
in

cup

assembly

dip

a

clean brake fluid

new

To

piston cup on piston pay
particular attention to its direc ion
2
Dip cylinder nd pis10n in clean

CAUTION
When

wear

and piston is more than the
specified value replace piston or oper
ating cylinder assembly

foUowing

2

replace

and piston
If clearance between cylinder

bore

use

an open end wrench
wrench

and piston

and if found

Check cylinder bore

for

suitable flare nut wrench

INSTALLATION
order

score or rust

2

2 2 ft
lb

InstaU clutch

Check cylinder bore

I

sc L001

m

CAUTION

reverse

gasoline

It will ruin the rubber

smoothly

29N

0 15

and kerosene

can move

bolt

Stopper

I

wash all parts of operating
be

clean brake fluid must

used
Make

5

or

connecting dutch

tube

use

brake fluid before assembly

Tool

GG94310000
I
J

When

pi by
in9

tightening

flare

nut

hold
CL222

hand to prevent it from twist
1

Push rod

2

Dwt

3

Piston spring
Piston

4

5

cover

INSTALLATION
Install operating cylinder in

Piston cup

6

Operating cylinder

7

Bleeder

screw

Bleed air thoroughly from clutch

hydraulic system

OPERATING

Clutch System

CYUNDER

8

INSPECTION
REMOVAL
clutch tl be flare nut
the bracket on side member
L

lo9sen

4
Cl

at

parts and
or

damage

replace

all

disassembled

parts which are

worn

Refer to

When

operating cylinder

from

or

installed

without

on

is

Bleeding
r

moved

elutch hou

disconnecting clutch
operating cylinder loos
en bleeder scrow so that push rod
moves lightly
ing

Visually inspect

reverse

order of removal Observe foUowing

hose from

CLUTCH

b

Exercise care not to warp
clutch

hose

Be

clutch

hose

away

sure

or

from

twist

install

to

exhaust

tube

pipe by hand

nut

hold

prevent it

from

flare

tightening
to

clutch hose from oper

Remove

ating cylinder
4

mas

Clutch Control

CAUTION
When

Disconnect clutch tube from

tightening

flare nut

Tool

use

GG94310000

cylinder

ter

When

c

3

Hydraulic

5

Remove clamp

to dash

fixing

clutch tube

panel

twisting

CAUTION
When

clutch tube

connecting

use

Tool

INSTALLATION

GG94310000

opening ends of hydraulic
any foreign matter
before making connections
the

Wipe

Bleeder

i
l

screw

8 8 N

6 9

line

0 7

0 9

m

kg

Operating cylind

r

10

clutch

2

housing securing bolts
30

40 N

3 1

3

m

30 ft lb

22

i
l

Clutch hose to operating
17
1 7

21 N

m

2 1

kg

Fix

with

m

41 kg

to

master

flare nut

clutch

tube

clamp
Then tighten

dash

to

panel

15

18 N

m

1 8

kg

cylinder
Use

or

air has entered it

Remove cap of reservoir and top
with
recommended brake fluid
up

13 ft lb

with a

new

must

I

m

Install clutch hose

2

hydraulic clutch system

The

disconnected

1 5
t1

SYSTEM
be bled whenever clutch line has been

cylinder

m

BLEEDING CLUTCH

flare nut

Clutch hose to master

cylinder

15 ft lb

12

clutch tube

I Connect
cylinder with

6 5 ft lb

5 1

Install clutch tube

I

m

remove

to

gasket

in

on operating
place

gasket

Clutch hose to operating

i
l

cylinder
17

2 1

1 7

CLUTCH UNE

12

I

21 N

m

kg

m

o

15 ft lb
SC LoDe

INSPECTION
Check

3
tube and hose

clutch lines

for evidence of cracks deterioration

or

other damage Replace if necessary
If leakage

at

occurs

joints retighten and if
place damaged parts

or

to

bracket

pipe by

re

4

When

disconnecting

clutch tube

use

use

adjustable

open
wrench
an

end wrench

i
l

clutch hose

at

tube

clutch

Disconnect

bracket

on

side

nut and

ber

11

2

Remove lock

spring

from bracket
gage hose

then disen

Check

line and
tween

6

so

that

screw

outlet

of

operating

hole is free

tighten

any

Place the other end of it in

a

con

tainer filled with brake fluid

it

Flare nut

or

memo

bleeder

screw

from

Connect clutch tube to hose with

1 5

from

from

cylinder

clutch hose

15

5
I

from

foreign material Install
bleeder hose vinyl hose on bleeder

suitable flare nut wrench
Never

nut

clean mud and dust

Exercise care not to warp or twist

flare

CAUTION

flare

hand to prevent it

hold

twisting
b

Thoroughly

2

tightening

When

a

REMOVAL

end of hose with

bracket Install lock spring fixing hose

around

necessary

Engage opposite

18 N
1 8

m

kgm

13 ft lb
distance

adjacent

between clutch

parts

especially

be

hose and exhaust tube

Bleed air out of hydraulic sys1em
Refer to Bleeding

for adjustment

Clutch System

J
SCL009

CL 5

CLUTCH

Hydraulic Clutch Control

3

Have

pedal

a

co

two or

worker

pedal depressed fully
screw

to

depress clutch

three times

bleed

air

With clutch

loosen bleeder
out

of clutch

system

4

Close

bleeder

ly with bleeder
6

Repeat

screw

two

or

as

closed

l
G

69

I
I

ilr

j

y
CJy

0 7
5 1

SCL010

0 9

Pay

containing

bleeder

in

runs

solid

a

without air bubbles

close attention to clutch fluid

leve

in

reservoir

during bleeding

operation
d

Add brake fluid

up

m

to

f

h

to

tl

reservoir only
leyel

qo

not

overfill

m
kg

6 5 fHbl

Depress and release dutch pedal

several tim s

then

hydraulic leaks
Brake fluid

at

a

check for external

connections

containing

air i

Do not

use
re

brake fluid drained

during bleeding operation
care not to
splash

b Exercise
fluid

white

and has visible air bubbles
c

on

exterior finish

damage the paint
tightening flare

When

GGg4310000

6
CL

air

no

screw

CAUTION
7

a

@

8 N

of

stream

no

Bleeder screw

Brake fluid
out

vinyl hose

three times

dlll

b

c

steps 3 through 5 until

air bubble shows in the

CD Depress pedal

quickly

screw

clutch pedal is on down stroke
S
Allow clutch pedal 10 return slow

nut

as

brake
it will

use

Tool

CLUTCH

Clutch Unit

CLUTCH UNIT
CLUTCH DISC AND COVER

SCLOll

REMOVAL

Be sure to turn them out in a crisscross

Remove transmission from engine
Refer to Removal Section MT
I

2

fashion

solvent to remove dirt and grease
before making inspection and adjust
ment

Insert Tool into clutch disc hub

Flywheel end

pressure

Check friction surface of

@

and

plate

Ilywheel

plate for scoring or
roughness Slight roughness may be
smoothed by using fine emery cloth If
surface is deeply scored or grooved
the part should be replaced
pressure

Clutch disc assembly

Inspect clutch disc for
4

Remove

clutch

disc

and

cover

assembly

facings

loose

rivets

worn or

and

oily

broken

or

loose torsional springs
I

3

Loosen

cover

time

to

bolts

Ilywheel

attaching
one

clutch

turn each at

a

until spring pressure is released

INSPECTION
Wash all disassembled parts except
disc assembly in suitable cleaning

If facings are oily disc should be
replaced In this case inspect trans
mission

front

cover

bushing engine rear oil
points for oil leakage

oil

seal

pilot

seals and other

CL 7

C1Ul1h Unit

2

CLUTCH

The disc should also

when facings
down

the

to

are

worn

be replaced

locally

mm

10 016 inl

A

facing

Less than 0 3

mm

10

012 inl

Clutch

II I

ril
Q

assembl

Check end surface of diaphragm
spring for wear If excessive wear is

l

I

cover

1

l

found replace clutch
2
Measure
height

l

F

Less than 0 4

specified limit

Wear limit of

c

Backlash

or worn

I

A

cover

of

SCL018

assembly
diaphragm

springs as outlined below
I

Place Tool ST20050100

on

Tool

ST200500 10 and then tighten clutch
CL336

cover

assembly

on

base plate by using

Also
unevenness
of diaphragm
spring toe height should be wilhin the
specified limit

Tool ST20050051

Unevenness of
toe

Less than 0 5

Check disc plate for runout when
ever the old disc or a new one is
3

If runout

exceeds the

specified

or

repair

0 020 in

If unevenness of

diaphragm spring
height
beyond specified value
adjust
Tool
spring
height with

jST20050100

ST20050010

value at outer circumference of facing

place

mm

ST20050051

installed
4

diaphragm spring

height

toe

1

disc

A

ST20050240

@

Runout limit

3

total indicator reading
Less than 0 5 mm 0 020 in
R

CL 151

from hub center
95 mm 3 74 in

Measure

2

CAUTION
When

repairing disc plate never hold it
forcibly with pliers or bend it exces
siveIy otherwise facing will be dam
aged

points with

A

height
vernier

a

several

at

caliper depth

Inspect thrust rings for wear or
damage As these parts are invisible
from outside shake cover assembly up
and down
to
listen for chattering
noise or lightly hammer on rivets for a
slighily cracked noise Any of 1hese
noises indicates need of replacement as
a complete
assembly

gauge

Oiaphragnt spring height
31 6

11

33 6

244

A

mm

1 323inl

INSTALLATION
I

Apply

a

light

coat of grease

c1uding molybdenum

in

10
disulphide

transmission main

drive gear splines
Slide clutch disc on main drive gear
several times

Remove clutch disc and

wipe off excess
by disc hub
CL

l

12

Take special care to prevent grease

SCL014
or

oil from

2
Check fit of

5

disc

sion main drive gear

hub

ontransmis

splines for smooth

If splines are worn clutch disc
main drive gear should be replaced

sliding
or

that

backlash exceeds the specified
value at outer edge of clutch disc

8
CL

height
beyond specified
height

A

with

necessary

sembly

and

of spring end
value

Tool

replace

dju

t

ST20050240
clutch

cover

lll
spri

getting on

cluteh

faeing

Reins1a11 clutch disc and clutch

cover

If

pushed off

lubri
cant

assembly

Support

assemblies

cover

clutch disc
with

Tool

KV30100100

1

Be

ure

as

wheel

and

dry

to

keep

disc

faeings fly

pressure plate clean

and

CLUTCH
Hold bearing inner
outer race

race

applying

while

bearing rotation
noisy replace bearing
it

KV30100100

If the

and rotate

pressure to
is

rough

or

4

main

Transmission

mall

A

mount of

tho

to

Assemble

sleeve

using

out on

release

a

bearing

on

clutch
should

Each bolt
turn at

I

l

assembly
tightened one

cover

be

applied

too

it wilt run

the friction plltes when hot re

lulting in damaged clutch disc facing

3

l
Install

If

points

press

CL340

3

gear

hould be

gre

bov

much lu ricant is

I

drive

splines Use grease including molybde
num disulphide

coatad

INSTALLATION

Clutch Unit

j

After

lubricating

drawal lever

assembly

install

with

release bearing and sleeve

in

position

Connect them

with holder spring

time in a crisscross fashion

a

Clutch cover bolt

til

16

21 N

1 6
12

m

2 1 kg

m
u

15lt lb

4

Remove clutch

5

Reinstall

SCL015

aligning bar

transmission

Refer

to

Section MT

Installation

Do not depress outer race
2

Before

cate the

SMT010

during assembly lubri
following points with a light
or

coat of multi purpose grease

1

RELEASE BEARING

Inner groove

of release bearing

sleeve

4

Reinstall

Installation

transmission

Refer to

Section MT

REMOVAL
Remove transmission from

1

engine

Refer to Removal Section MT
2

holder

Disconnect

from

spring

bearing sleeve
3
as

Remove release

bearing and sleeve

assembly from transmission

an

front

case

PILOT BUSHING

L

cover

Take

4

clutch release bearing out
bearing sleeve using a universal

from

puller

and

a

REMOVAL
SCL016

suitable adapter

I

Remove transmission from

engine

Refer to Removal Section MT
2

2

Contact

surfaces

of withdrawal

Remove

assembly

clutch

Refer

to

lever lever ball pin and bearing sleeve
3
Bearing sleeve sliding surface of

Cover for removal

transmission case front cover

shaft with TooL

3

Remove

disc and cover
Clutch Disc and

pilot bushing

in crank

CLt45

INSPECTION
Check for abnormal
tact

wear on con

surface of withdrawal lever

pin and

bearing

sleeve

ball
SMT016

CLOSS

9
CL

CLUTCH

OutdWnit

INSPECTION

Distance

for fit in bore

pilot bushing

Check

4 0

mm

A

3

0 157 inl

cover

inner

bushing

for

surface

of

pilot

roughness or bell
mouthed condition If pilot bushing is
When
worn
or
damaged replace
bushing

is

Do not oil

4

bushing

damaged be
main

sure to

drive

gear

check
at

When
careful

inserting pilot bushing be
to d amage edge of pilot

not

bushing

the

time
A

Pilot bushing

INSTALLATION
1
Before installing a new bushing
thoroughly clean bushing hole
2
Inser1 pilo1 bushing until distance
A

between

bushing

CL10

is

disc

and

clutch

to Clutch Disc

flange

end

specified distance

and

Install transmission

staUa1ion

wear

transmission
same

clutch

assembly Refer

and Cover for installation

of crank5haft
Check

InstaU

pilot
EM719

Section MT

Refer

to

In

Service Data and Specifications

CLUTCH

SERVICE DATA AND SPECIFICATIONS
a
UTCH DISC

GENERAL SPECIFICATIONS

I

aUTCH CONTROL SYSTEM
Hydraulic

of clutch control

mm

In

I

200CBL

Model
Wear limit

I Type

Unit

offacing

surface to rivet

03

10 0121

0 5

10 0201

I

hood

Runout limit

I

aUTCH MASTER CYLINDER
Distance of

Ilnnar

nout checking point
from the hub center

81
15

15 88

mmOn

diameter

at outer

spline

0 4 10 016

edge of disci

adjustable
Non

TV

aUTCH DISC

Facing

size

Outer die

0
2

x

Inner die

x

Thickness
mm

87
17

inl

130
x

Unit

I

C200S

x

5 12

3 5
x

Model

31 6

I
I

200CB L

Type

aUTCH COVER

mm

lin

111161

17 46

jn
mm

Inner diameter

I

Maximum backlash of

I

aUTCH OPERATING CYLINDER

9513 741

0 1381

Dioph ag m spring ho ght

Unevenness of

33 6

11 244

diophragm spring

toe

13231

Less than 05

0 020

height

PILOT BUSHING
Thickness of disc assembly
8 50

9 20
10 3346 0 36221

in

Free

mm

Installed

mmUnl

76

Number of torsion

I

80

10 299

Inserted distance of

TIGHTENING TORQUE
C200S

Type

Ikg

3 923

lb

INSPECTION AND

1400 882

Pedal stopper bolt lock

I
I

Maner

ADJUSTMENT

Pedal free

play

AU

168

174

5

in
mm

16 61

I

and

pilton

cylinder push cd

cylinder stopper

cylinder securing

10 04

0

Clutch fube flare

201

cylinder bore
mm Unl

I

Loss than 0 15

10 0059

Push rod lock nut

I

Dporating cylindor

j

bleeder

78

11 8

08

12

58

8 7

7 8

11 8

08

12

5 8

87

15

2 9

0 15

1

2 2

78

118

08

1 2

58

8 7

15

8
1

03

I

Lessthan 0 15 10 00591

Operating cylinder

18

11

13

78

118

08

12

5 8

87

6 9

88

0 7

09

5 1

65

30

40

3 1

4 1

22

30

17

21

7 2 1
1

12

15

16

21

1 6

12

15

lecuring bolt
to

operating

cylinder securing

J

15

screw

Clutch hose

Clearance between cylinder bore
and piston
mrn in

nut

I

aUTCH OPERATING CYLINDER

I

ft Ib

bolt

6 85

aUTCH MASTER CYLI NDER
Clearance between

m

nut

in
mm

H

kg

lock nut

Master

height

m

nut

aUTCH PEDAL
Pedal

N

Unit

Master

I
l

1571

0 315

aUTCH COVER

N

4 0 10

6

springs

Full load

pilot bushing
mrn in

I

Clutch

cover

nut

securing

2 1

bolt

CL 11

I

CLUTCH

TroUble DiagnosesBnd Corrections

TROUBLE DIAGNOSES AND CORRECTIONS
aUTCH SLIP

Slipping of clutch may be noticeable when any of the following symptoms
I Car will not respond to engine speed during acceleration
2
Insufficient car speed
I Lack of power during uphill driving
4
Increasing of fuel consumption
Some of the above conditions may also be attributable to
ing the problem

If slipping clutch is left unheeded

wear

and or

is encountered

during operation

engine problem First determine whether engine

overheating

will occur

on

clutch

facing

to

or

clutch is

such an exten1that it is

no

caus

longer

serviceable
TO TEST FOR SLIPPING CLurCH proceed

as

follows

Inspection
Insure that parking brake is engaged Disengage clutch and shift transmission
gears into TOP Gradually increase engine
speed while simultaneously engaging clutch If engine stops while clutch is being engaged clutch is functioning properly If
car

does not

move

and the engine does not slop clutch is
Probable

Clutch facing hardened
Clutch

or

facing excessively

slipping
Corrective action

cause

wet with oil

worn

Repair

or

Replace

Replace

transmi

Diaphragm spring weak
Flywheel

or

or

damaged

pressure plate warped

Particles in return port of master
Piston fails to return to its

Clutch tube deformed

or

cylinder
original posi1ion

crushed

replace

iLengine
faulty

ion oil seal is

Replace
Repair
Clean

or

or

replace

replace faulty paris

Replace

aUTCH DRAGS

Dragging clutcl

is particul r1y noticeable when shifting
gears especially into low gear
TO TEST FOR DRAGGING CLUTCH proceed to inspection

Inspection
Disengage clutch and shift gears into Reverse Shift gears into Neutral gradually increasing engine
mission shift gears into Reverse If noise is heard while
gears are being shifted clutch is dragging

CL 12

speed After a short inter

CLUTCH

Probable
Clutch disc hub splines

worn

or

Trouble Diagnoses and Corrections

cause

Corrective action

rusted

Replace
coat

Oil leakage at master cylinder operating cylinder tube

or

hose

Bleed air

Insufficient pedal stroke

Adjust

Clutch disc

Replace

or

warped

Diaphragm spring fatigued
Piston cup deformed
Lack of grease

facing

Clutch

on

wet

or

remove

rust

and

Replace faulty parts

Air in hydraulic system

runout

or

with grease

Replace
04

damaged

Replace

pilot bushing

Coat with grease

with oil

Replace

Replace

if

transmission oil seal is

engine

faulty

CLUTCH CHATTERS
Clutch chattering is usually noticeable when
Probable
Oil

on

car

is

just rolled off with clutch partially engaged

cause

Corrective action

facing

clutch

Replace

Diaphragm spring fatigued
Clutch

Replace

hardened

facing

Replace

Clutch facing warped
Pressure

plate

Repair

worn or

Engine mounting loose

warped
or

or

replace

Replace

rubber deteriorated

Tighten or replace

Clutch facing rivets loose

Replace

NOISY CLUTCH
Probable
Release bearing sleeve damaged
Pilot bushing

worn

Clutch

rivets loose

Disc

facing

jammed

or

or

cause

improperly

Corrective action

lubricated

Replace

damaged

Replace

Replace

plate cracked

Replace

Clutch disc torsion springs

fatigued

Replace

RABBIT HOPPING CLUTCH
When

rabbit

hopping of clutch
fully depressed

occurs

car

will not rol1 off smoothly from

a

standing

star1 or clutch will be

engaged be

fore clutch pedal is

Probable
Oil

On

clutch

Clutch facing

Flywheel

cause

facing
worn or

pressure

Corrective action

Replace
rivets loose

plate warped

Mounting bolts on engine
Diaphragm spring fatigued

Replace

or worn

Replace

or power train loose

Tighten

Replace

CL 13

Special Service Tools

CLUTCH

SPECIAL SERVICE TOOLS
Tool number

Tool

name

Kent Moore No

KV30100100

Clutch aligning bar
CLJI

ST20050100

1

2

Distance piece

@
ST200500 10

Base plate
@

39
ST20050051

Set bolt

ST200S0240

Diaphragm spring adjusting

STI 661 000I

Pilot

wrench

bushing puUer

123907

o

n

GG94310000

Flare nut torque wrench
lII1A
IIIIlII

CL14

DATSUN 200SX

S II 0 Series

Mode

MANUAL TRANSMISSION

CONTENTS
MT

2

REPLACEMENT OF

REMOVAL

MT

2

SERVICE DATA AND

INSTALLATION

MT

2

SPECIFICATIONS

REMOVAL AND INSTALLATION

5 SPEED TRANSMISSION

BEARINGS

MT16
MT16

3

INSPECTION AND ADJUSTMENT

MT

6

TIGHTENING

TRANSMISSION CASE

MT

7

FORKS AND FORK RODS

MT

8

GEARS AND SHAFTS

MT

9

REAR

FSsW71B
EXTENSION

REPLACEMENT OF

OIL SEALS

MT14

MT16

GENERAL SPECIFICATIONS
MT

Model

MT14

TORQUE

TROUBLE DIAGNOSES AND
CORRECTIONS
SPECIAL SERVICE TOOLS

MT17

MT18

MT22

MANUAL TRANSMISSION

Removal and Inrtallation

REMOVAL AND

INSTALLATION

REMOVAL

3

When installing
to

sure

I

Disconnect battery ground cable

2

Remove accelerator
Jack up

J
or

support
anI

car

safety stands

on

Use

a

sliding

linkage

Make

sure

be

its

weight
hydraulic hoist

Control lever

open pit if available

4

control lever

multi purpose grease to
parts as shown below

apply

Bushing

that safety is insured
Grease

Disconnect front exhaust tube

coating
TM335

Grease

coating
12

Loosen rear

ing

nuts

engine

mount secur

CD tempobirily

crossmember

mounting

and

nuts

Striking guide

SMT142

remove

00
4

Remove filler

plug

and fill 1rans

mission with recommended gear
the level of 1he plug hole
Oil

oiI
o

capacity

2 0 liten
41
5
5

Disconnect

back up
if so

from

7

Remove

Refer to

gear

iJ
I3

propeUer shaft

Propeller

Shaft

Section

to

opening in rear extension
oil from flowing out

prevent

14

Remove bolts

securing

1ransmis

sion

from the

Remove clutch operating cylinder

CAUTION

9

Support engine by placing

Take care in

under oil pan with

a

wooden

block

used between oil pan and jack

jacks and slide transmis
ffom engine and

rearward away

8

jack

not to

18

m

5
3

m
kg

25 ft lb

engine

mission with

remove

a

34 N

5
2

Then support the engine and trans
up

plug

25

Remove starter motor

sian to

for removal

Plug

Filler

cable

speedometer

sealant to threads of filler

and instaU filler plug to transmis

sionc

lamp
equipped switches

Disconnect

Apply

plug

reverse

Top and O D

6

PO

wires

2Imp I
ll

P1
lJ

6

Tighten bolts securing
engine

transmis

tion to

iJ @

car

43

58 N

4 4

@

dismounting transmission
strike any adjacent parts and

kg

32

43 ft bl

25

35N m

26
19

main drive gear

m

9
5

3

81qjm

28ft lb
A

CAUTION
00 not place jack under oil pan drain

INSTALLATION

plug

Install

the

transmission in reverse

order of removal paying attention
10

Support

transmission wi1h

a

trans

mission jack

surfaces of engine

H
I

the foUowing points
I
Before installing
rear

to

clean mating
plate and trans

mission case

Remove console

box

Refer to

Console Box Section BF for removal
2
Place transmission control lever in
neutral position and
control lever
MT 2

remove

E ring and

2

Before

instaUing

lightly

apply

grease to spline parts of clutch disc
and main drive gear And also apply
grease to moving surfaces of control

7

lever and striking rod

tial lubrication

Lubricate oil seal lip and bushing
extension with gear oil for ini

on rear

3

ZC

r I

Z CJl 3 en CJl o Z
I

i
aI

iiig

Cl It

l

OJ
JJ C1I e
C1I
en m m C f0 Z en 3 en en 5z 3 o Q 1

lb
ft

15

m

12

leal
Oil

seal
oil
to

oil

kg

1
2

E

m
N

6

1

17

21

Iii

12

gear

3
2

Ap ly

6

1

23
25

22
14
0

18

bolts

5

of

3
5
0

2

2

switch

Neutral

25
18

3

34

29

pll 8

20

Fil er

Iii

22
14
0
3

Bearing

0
f

to

5
2

seal nt
Ap ly

34

plug 25

Drain

Iii

plate
14
0

Adapter

3

20

on Iii

5
3

2

2

29

25

Iii

thread

0

witch

2

29

gear 20
J
i

rTOP

lampowS
Revet

22
14
0
3

0
2

cover

Front

29
20

Iii

3

l

5 speed

ModeIFS5W71BJ

lTlissiof1
Trafl

MANUAL TRANSMISSION

3rd main gear

SnaPrinB
Main

drive gear ball bearing
Washer

Snap rinB
Apply gear oil
bearq

to

needle

3rd 11 4th synchronizet hub

Pay attention

pread spring

to

its direction

Shifting imert

r
G

1st a 2nd

synchronizer hub

2nd main gear

123

CounterJbaCt lock nut

ifJ

98

127

10 0

13 0 12

counter

94

geu

Apply gear oil to
needle bearing

Counter front bearing

Snap ring

Woodruff key

Reverse idler throt washer

Shim
Refer to transmission

Reverse idlet sear bearing

case

for assembly

Reverse idler shaft

Iii

N

m

kg

m

ft b

SMT040

4
MT

MANUAL TRANSM ISSION

5 speed Transmission

Model FS5W71BJ

Striking guide
E rinB

r rJ

O

StoPper guide pic
ControlleYer

spri
plUS
Apply locking sealer

Lock pin

Apply

gear

J fRetum

oil to O

to

Retrun

pri

plunger
Return

j

checking

SPriDl

Iii

7

8

5 8

thread of bolt

9 8 O g

10

7 2
Check ball pl1lll

Apply locking sealer
to thread

25

14

2 5

19

Check

t

Check prins

of bolt

18

1
@

prins

Check ball

bushing

qeontrol ever

0

J

5

Controlleverb ahUw

Interlock baD

Retainins Pin
3m

4th Cork

rod

Reverse

OD shift Cork

Ioterlock baD
3m

4th shift Cork

Iii

19
19

25
2 5 14

18

Iii

lm k8

m

lb
Ct

SMT150

MT 5

54peed

fTJission
TT8Il

REAR

ModeJ FS5W71B

MANUAL TRANSMISSION

EXTENSION

DISASSEMBLY
I

@NEur

2

Wipe off dirt and grease
Drain oil

3

Remove 0 0

gear

1

switch

if so

equipped
4

4
W

@

Remove E ring and stopper guide

In

pin
SMT006

SMT007

5

INSPECTION

InstaU plunger return spring and

return

spring plug

Clean with solvent and check for

I

cracks

cavities

or

by

means

of dyeing

test
TM337

2

Check mating surface of

tension for small nicks

rear ex

projection

or

sealant
If fesr extension
5

Remove return spring plug retum
spring and plunger from rear exten

pla it
bushing

and

rear

bushing
as

is worn or

an a
ssembly

extension

of

housing

sion
SMT041

ASSEMBLY
I

Stand transmission

case

assembly

wooden plates of more than 20 rom
0 79 in thick

on

Clean mating surfaces of adapter
plate and rear extension
3
Apply sealant to mating surface
of adapter plate

1

PlUJl8O

2

Return spring

3

Return

spring plug

2

6
Apply sealant to stopper guide
pin then instaU stopper guide pin and
E ring
7

SMT003

InstaU 0 0

gear

switch

that

gears

if

so

equipped
8
6

Make

sure

smoothly
Remove

rear extension

SMTOOS

4

InstaU

I

Se gears at Neutral

2

Turn

rear

extension

striking guide

as

foUows

counterclock

wise

3
7

Remove lock pin and then
striking rod
6
MT

remove

4

Set

striking guide at Neutral
Aligh end of striking lever

cutout portion of fork rod

with

9

Install drain

Iil

25
2 5
18

34 N

plug

m

35
lbl
25 ft

fD
kg

operate

MANUAL TRANSMISSION

TRANSMISSION
CASE

6

INSPECTION
Clean with solvent and check for

1

2

DISASSEMBLY
1

Remove

rear

extension

Rear Extension for
2

ing

Remove dust

Refer

sion
to

pits by means of dyeing test
Check mating surface of transmis
case for small nicks projection or

shim as foUows
Measure

1

A

height

sealant

disassembly
cover

Fit main drive bearing snap ring
Select countershaft front bearing

7
cracks or

Transmission Model FS5W71B

speed
5

release bear

ASSEMBLY

and withdrawal lever

clean mating surfaces of adapter

1

2
en

I

and transmission case

plate

Stand transmission

plates

case

on

wood

of more than 20 mm O 79 in

thick
3

Apply sealant

transmission

to

mating surface of

TM371

case

2

Select

1

Tranlmission

2

Counter gear front bearing

3

Counter gear

a

shim

case

A

of thickness

measured
Counter geer front

3

Remove

Detach

front

cover

countershaft

and gasket

front

bearing

him

Refer to S O S

bearing

shim
4

Remove main drive bearing snap

ring
Slide gear assembly onto adapter
plate by lightly tapping with a soft
4

8

hammer

Clean

cover

9
r

surfaces of front

mating

and transmission

Apply

grease

to

case

shim selected to

tain it on front cover

10

Lubricate seal lip and main drive

shaft with gear oil then instaU
gasket and front cover

new

II

Apply sealant to threads of
through bolts and tighten them to
transmission case

5

Separate transmission
adapter plate

case

from

5
tates

Make certain

that mainshaft

roo

freely
Iii

111

21 N

m

11 6 2 1 kg m
12 151t lbl
rmrl

12
TM153

SMT014

Apply

a

light

SMT015

coat of multi pur

pose grease
MT 7

XpeerI Transmission

Mode

FS5W71BJ

MANUAL TRANSMISSION
ASSEMBLY
I

rC

Fork rod
1st l 2nd

InstaU dust

cover

to Rear Extension for

fork rod

then

2nd

with retaining

secure

pin

Chect baD

@

Assemble Rear Extension

4th and

Fl

release bearing

and withdrawal lever
14

3rd

2nd

Rev shift forks and 1st

Interlock
ball

SMT016

13

InstaU 1st

QD

ED

Refer

TM198A

assembly
Drive out retaining pins

6

2

InstaU

3

InstaU 3rd

secure

2

two

interlock

4th

fork rod

baUs
then

with retaining pin

FORKS AND FORK
RODS
DISASSEMBLY
Drive out fork rods and

7
1

Remove

rear

extension Refer

Rear Extension for
2

disassembly

Remove transmission

to Transmission Case for
3
4

to

disassembly

SMT019

interlock baUs and check baUs
Be

Refer

case

remove

check

careful
balls

not to

and

lose

four

4

three

3

interlock

balls

Set up Tool on adapter plate
Place above assembly in a vise

4

InstaU

5

InstaU O D

fork rod

two

then

2

interlock

baUs

Rev shift fork and
secure

with

retaining

pin
INSPECTION
Clean with solvent and check for
wear

scratches projection damage

other faulty conditions

part which is

Replace
worn or darnaged

or

any

TM754

one
5

Remove

check springs
MT B

check

baU

plugs

6
6

and
SMT137

InstaU

springs

check

baIls

and

check

TRANSMISSION

MANUAL
7

Apply locking sealer
ball plugs and install them

dl

19

Model FS5W71B

5 speed Transmission

check

to

25 N m

1 9
14

2 5 kg

m

18 ft lb

TM398

TM757

S
Remove counter

6

drive

gear

snap

gear and

Drive out counter 0 0

bearing

ring
Draw out counter drive gear with

7

main drive gear

a

Check ball

2nd fork

rod

plug for 1st
longer than that

for

is

shift fork rod and 3rd

Rey

4th fork

rod
b

To insure that interlock
installed

properly

plunger

slide 3rd

is

4th

fork rod and operata the other fork
rod Make lure that the gear except
3rd

or

4th gear does not

8

Apply gear oil
faces and check to

to
see

operate correctly and
gaged smoothly
9

m

sh

all sliding

are

Remove
When drawing out main drive gear

en

b

Refer to
transmissio

Install

spacer

1hat shift rods
gears

case

n

ful not to drop

mbly
bearing and
car

baulk

edle

pilot

Install

Refer

extension

rear

ring

snap

idler shaft

and

remove

from

reverse

reverse

idler

gear
7

ring

Remove

rings steel ball
bearing

snap

speedometer gear

Transmission Case for assembly
10

Remove revene counter gear and

6
sur

and

to

Rear Extension for assembly

3rd meln geer
Remove

I

ring

snap

and

thrust

washer
2

GEARS AND SHAFTS

Draw out 3rd

4th

synchronizer

and 3rd gear

f
I
DISASSEMBLY

KV32101330

o D
Mein drive end counter

Remove rear

xtension

Remove transmission
Remove

Refer to

forks

case

Refer

disassembly

and

fork

rods

Refer 10 Forks and Fork rods for dis
Measure g

r

end play

Refer

to

Mesh 2nd and

draw

out

reverse

counter front

gear

bearing

3rd main gear Refer to

Gears and Shafts for disassembly
Measure 0 0

3

ge

r

to Gears and Shafts for
4

Mesh 2nd and

mainshaft

on

nut

then

8

Remove

washer

end play Refer

mainshaft

reverse

synchronizer

and

nut

main

gear

thrust
00

D gear
O

inspection

reverse

gears

Re

counter gear nut and

and loosen these nuts

Remove counter gear nut

Gears and Shafts for inspection
S

Remove

lease staking

assembly
4

TM760

drive gears
for disassembly
2

disassembly

to Transmission Case for

3

geer

drive and counter

Refer to Gears and Shafts

Rear Extension for

2

reverse

Remove main

1

drive geer
1

end

geer

Removed nuts should be discarded
nd should not be reused

1st end 2nd mein geer end
counter
I

Draw

together
rear

end

eer

out

mainshaft

with counter gear

assembly
by tapping

of mainshaft and counter

gear

MT 9

siJeed Trantmiision Model FS5W71B
5

lRANSMISSION

MANUAL

Hold front of mainshaft assembly
by hand being careful not to drop

Synchronizer

counter

plier

gear

I

wiih

circlip

Remove

mainshaft

Tighten

0 D

specified
play to
specified

ring

snap

band
Remove
syncbro
ring
brakes anchor block and thrust block
2

limit

and

insure

thai

lock

nut

tneasure

to
end

is within

it

limit

If end play is not within specified
limit disassemble and check parts

I

for condition

J

Replace any part which
damaged

is worn or

4

I

iEndPmY

INSPECTION

rT

W1
TM

Bearing
Mainshaft
I

Thoroughly clean bearing and dry

with
2

1 st gear and needle
Be

careful

bearing

not

to

teel ball

Press ou1 1st gear rnainshaft bush

ing together with 2nd gear and
2nd synchronizer
Wlliin priising oiirliii liing
mainshaft by hand

air

CIJE

CAUTION

lose

retaining thlUlt washer
3

compressed

Remove thrust washer steel baU

o

bushing

081 notto

Do not allow the

bearings

to

spin

SMT025

Because it will damage the race and
balls Turn them slowly by hand
Standard end play

1st

1st lI88r

q2
holif

3
0

drop it

lm
tD
0 0134

0106
0

inl

2nd gear
0 12

H

0 19

0 0047

r

mm

0075
0

in

3rd gar
0 13

037 mm

10 0051 0 0146 in
00
5thl gear
0 10
TM372

0 11 mm

0 0039

0 0061 in

Reverse idlar gear
0 50 mm

05
0

ST30031000
2

When

worn
TM049A

of
out

with

a

race

and baU surfaces

are

balls

are

rough

or

round

or

or

when

rough replace

0 0020

0 0197 inl

bearing

new one

Replace needle bearing if worn or
damaged
3

I

Synchronizer

Replace

deformed

lat a 2nd and 3rd a 4th
Disassemble

Baulk ring
baulk ring if found to be
or otherwise dam

cracked

aged excessively

synchronizer
Gears snd ahafts
I

G

chips
2

Q
sleeve

Check all gears for excessive
or

cracks

as

required

Check shaft for bending

wear

d

worn

spline if

crack

necessary

replace
3
Shifting insert

Measure gear end play
It is necessary to measure end

before
SMT02A

MT10

replace

wear

disassembling

play

mainshaft and

after reassembling mainshaft

SMT026

MANUAL TRANSMISSION
2

Place baulk ring in position

on

nizer

While holding baulk
gear as far as it will go

ring against
measure

gap

between baulk ring and outer gear
If the clearance is smaUer than

Place

bearing

new

on

adapter plate and tap

Standard

Mainshaft
mm

0 0630 in

0 0472

coupling

sleeve

on

them

Adapter plate
Dowel pin

B8Ulk ring to glar clearance

1 60

put

mainshaft

dowel pin

limit discard baulk ring

1 20

hub

synchronizer hub

Adapter plate
I

slots in syncliro

inserts in three

ing

ASSEMBLY

gear cone

wear

Transmission Model FS5W71B

speed
5

2

places

bearing7

1fU11

Wear limit
Lathan 0 8 mm
0 031 in

Unit

mm

in
SMT027

idler shaft

2

Insert

3

InstaU bearing retainer

reverse

Synchronizer
Position

synchronizer

ring

band

thrust block and anchor block

brake
on

G D

overdrive clutch gear install circlip

SMT140

JH

D

rjeU
ShlftlnB Insert
Band brake

if

excessively
unevenly deformed or damaged

Replace

worn

worn

Anchor block

Tighten each
points

4

screw

then stake it

at two

I

I
r

J

L

Thrust block

InstaU counter

5

Oil seals
1

or

seal if spring
to

2

bearing with

a

seal if sealing lip

is out of

I

position Refer
1st

with shaft if necessary
as

set

replace

oil seal

I
2

2nd and 3rd

Assemble 2nd

gear needle

2nd gear baulk ring
chronizer assembly

Synchronizer

of Oil Seals

Check the oil seal lip contacting

a

1st and 2nd main Bear

is

cracked Also discard oil

Replacement

and shaft

rear

soft hammer

Replace oil

deformed

TM449
A

SMT064

4th

Assemble coupling sleeve and hub
Position spread springs and shift

ring

I st gear

1st
I st

bearing

2nd syn
gear

baulk

bushing needle bearing

1st gear steel baU
mainshaft

and thrust washer

on

MTll

MANUAL TRANSMISSION

ission Model FS5W71B

PeedTrsn
5

Before

Sle8I

installing

thru t washer apply

gr

boll

a to

2

and

Press counter gear into adapter

Be RU

plate

tham

ring

to

align

of baulk

with inserts

Apply gear oil to mainshaft pilot
bearing and install it on mainshafl
2

KV31100401
TM358

2

Set Tool and place

assembly on
For counter
rever
id

e

adapter plate

it

gear and

For mainshaft and
rever
idler shaft

shaft

TM

3

Position needle bearing 3rd main
baulk ring and 3rd
4th
gear
synchronizer assembly on the front of
mainshaft
Assemble
hub

IoU

ID
koles

O

J

paying

3

main

InstaU

drive

gear

with

counter drive gear
3rd4th

synchronizer

Assembfe counter driy

attention to its direction

paying

gear

attention to its direction

f31100401
lJ
for

reverie

idler shaft
TM438

Front
Front

3

Press

mainshaft

assembly

to

adapter plate
Vl
SMT031
SMT065

4

Install thrust washer on mainshaft

and secure it with snap

ring of proper
1hickness that will minimize clearance

4

Press

counter

drive

gear

onto

counter gear

of groove in mainshafl
KV3H00401

Mainshaft front snspring

ST23860000

Refer to S O S
TM439

3rd main and counter 8ear
I
are

Tap
seated

new

woodruff keys until they

securely

KV31100400

n

cHOJ

L

Main

drive

gear and counter drive

gear should be handled as a matched
set When

TM441

replacing

8S 8

drive 8ear
1

MT12

Install baulk ring

main driva gear or
to

replace

set of main drive gear and

nter

counter drive gear

Main drive and counter

TM442

be

sure

driva gear

Counter drivege ar snap ring
on

synchronizer

Rafer to S O S

MANUAL TRANSM ISSION
5

Secure

counter

drive gear with

a

Assemble O O
hub

snap ring that will minimize clearance
of groove in countershaft

reverse

synchro nizer

paying attention

to

Conversion of torque

its direc

tion

Mode FS5W71S

5 speed Transmission

Mainshaft nut should be
to

doing
read

tightened

with Tool When

specified torque
so

the amount of

on

wrench

torque

needle

to be

be

should

modified according to the foUowing
chart
Front

If

167 N

137
14

17 kg

101

m

m

123 ft lb

C

ST22520000
0
o

TM366

TM297A

b
Press counter gear

6

Main

00

and countor 0 0

gear

goor should be handled

front bearing

as a

motch

ed set

onto counter gear

When

replacing

counter

place

3

be

gear

set

a

as

counter

ST22360002

0 0

main 0 0

sure to

of main 0 0

5

re

and
e

0 0 gears

Assemble

S z
counter

reverse

gear

u
c

Vi

u

and

u

1O

147

C

temporarily
InstaU bearing

1

Upp

s
u

c

00

135 1

TM443

ASSEMBLY

u
80

and

reverae

reverse

counter

spacer

bearing
spacer needl
idler gear spacer and snap ring
ring

i

11

04

66

0 5

0 8

0 7

gear

After front side is assembled

I

semble

J

o

o
0

90

gear

limitll ne7

0 it

e

O D

r

uun

it

KV31100400

n

rr

Lm f

O lOm
33 ft
0

gear and

overdrive counter gear
4
Assemble new mainshaft nut

tighten

f1

m

as

2

5
1

2

0

snap
reverse

5
ft

SMT034

6

Mesh 2nd and

tighten
er

reverse

gear

and

mainshaft lock nut and count

gear lock nut

7

Stake

mainshaft

lock

counter gear lock nut with

a

nut

and

punch

Fr

I

I

w

J
L

ST22520000

Iii

TM451

137

114 0
101

2

Assemble

nizer

hub

O D

reverse

reverse

gear

mainshaft

ing

a

steel baU

rear

123ft

to it

lbl
SMT044

gear

side Before instaU

apply grease

m

17 0 kgm

synchro
aD

bushing needle bearing O D gear
assembly steel baU and thrust washer
on

167 N

iJ

Counter gear lock nut
98

127 N m

10 0

72

13 0

94 ft

lbl

kg

m

8

Measure gear end

Gears and Shafts for

play Refer

to

inspection
MT13

5
s
peed Transmission Model FS5W77BJ

FIt

9

shaft

MANUAL TRANSMISSION

soap ring then assemble main

rear

bearing

5

Remove front

6

Remove oil seal

Ier
CO

3

Apply

coat

of gear oil to oil seal

surface then drive

new

seal into place

ST223500i

TM068A

10
rear

Fit thick snap ring to mainshaft
beapng to eliminate end play

Mainshaft

bearing

rear

snap

7

Apply

of gear oil 0 oil seal
new seal into
place

coat

4

surface then drive

InstaU

PropeUer

propeller

shaft

Refer to

Shaft Section PD for instal

lation

ring

Refer to S O S
ST23800000

II

Assemble soap rings steel baU and
speedometer drive gear

PreS

InstaU forks and fork rods Refer
to Forks and Fork Rods for assembly
13

InstaU transmission

Transmission Case
14

InstaU

rear

case

REPLACEMENT OF

Y
Z

12

BEARINGS

o

J

Refer to

MAIN DRIVE AND

oV

assembly
for

7

extension

Rear Extension for

Refer

COUNTER FRONT

to

80

assembly

1
SMT036

2

8

Lubricate seal lip and main drive

9

Install front

cover

Remove

main

drive

gear

snap

ring and spacer
3

shaft with gear oil

REPLACEMENT OF
OIL SEALS

Remove main drive and counter

drive gear Refer tb Gears and Shafts
for disassembly

Remove main drive bearing

in reverse order

of removal

FRONT COVER OIL SEAL
It is necessary to remove transmis

sion unit from

car

Replace

oil seal

as

REAR EXTENSION

follows
Remove

Rear
transmission

Refer to

sion

2

Wipe offdirt and grease

I

3

Drain oil

PropeUer

4

Remove dust

cover

release bear

extension

oil

seal

can

be

replaced without removing transmis

RemovaL

ing and withdrawal lever

OIL

SEAL

Replace
Remove

oil seal as follows

propeller shaft Refer

Shaft

Section PD

for

to

TM349

reo

movaL
2

Remove oil seal

4

Press

new

main drive

bearing

Press

SMT037

MT14

SMT038

MANUAL TRANSMISSION
5

Place main drive bearing spacer

on

main drive

bearing

CAUTION

and secure main

When

bearing with thicker snap ring
that wiD eliminate end play
drive

Main drive gear snap

Refer
6

to

shaft

hold

pressing out bearing gear
by hand so as not to drop it

ring

S OS

Mesh 2nd and

Model FS5W71B

5 speed Transmifi1iion

III
reverse

gear

Countenhaft

then

rear

draw out counter front bearing

bearing

I
TM754

I
11

5

main drive

Remove

drive gear

and counter

Refer to Gears and Shafts

TM351

for disassembly
6

Remove

reverse

main gear

Refer

to Gears and Shafts for
TM398

disassembly
7
Draw
mainshaft assembly
out
together with counter gear by tapping
end of main shaft

rear

and

counter

gear
7

Press counter gear front bearing

onto counter gear

front of meinshaft essembly

Hold

by

hand

counter

being careful

not

drop

to

gesr

Press counter

11

onto

12

InstaU

mainshaft

bearing

onto

adapter plate
13

I nstaU

bearing

two

Tigh1en
points

15

Install

14

retainer and

bearing

retainer with reverse idler

at the cut out

ST23860000

bearing

rear

adapter plate

portion of

and stake

align
shaft

the shafl

each

screw

at

KV31100400

n

TM442
TP 347

8
drive

InstaU
gear

main drive and counter
Refer to Gears and Shafts
8

for assembly

Remove

bearing

retainer

drive gear
for

16

main

drive

assembly
InstaU

reverse

main gear

Gears and Shafts for

17

MAINSHAFT AND
COUNTER REAR
1

Remove

rear

Rear Extension for
2

4

rear

case

assembly

extension

Rear Extension for

Refer to

Refe

to

assembly

extension Refer to

disassembly

Remove transmission

to Transmission Case for
3

SMT039

InstaU

Refer to

assembly

InstaU transmission

Transmission Case for
18

and counter

Refer to Gears and Shafts

case

Refer

disassembly

Set up Tool on adapter plate
Place above assembly in a vise

9

Replace mainshaft bearing by

MAINSHAFT REAR AND
new

one

10

ing

Press out

countershaft

rear

bear

COUNTER REAR END
Refer to Gears and Shafts for disas

sembly and assembly
MT15

MAN UAL TRANSMISSION

Service Data sndSpecificatiom

SPECIFICATIONS

SERVICE DATA AND
GENERAL SPECIFICATIONS
Transmission model
No

of

INSPECTION AND ADJUSTMENT

FS5W71 B

GEAR END PLAY

Unit

mm

in

5

speed
1

Synchromesh type

to

FS5W718

4th Warner

5th Servo

Shift type

3

5

L
r
2

4

1 st main gear

0 27

0 34

0 0106

2nd main gear

0 12

0 19

00047

3rd main gear

0 13

0 3710

5th main gear

0 10

Rev idler gasr

005

0 0134
00075

0051

0 01461

0 17

0 0039

0 00671

0 50

0 0020

0 0197

R

aEARANCE BETWEEN BAULK RING AND
GEAR
Unit

Gear

All models

ratio
1st

3 321

2nd

2077

3rd

308
1

4th

1

5th

0 864

Rev

3 382

I

Standard

I

Wear limit

120

1

60 10 0472
0 810

0 06301

0311

000

AVAILABLE SNAP RING
Number of teeth

Drive

22

1st

33

2nd

28

3rd

26

5th

19

Rev

36

Drive

31

1st

1

Counter

2nd

19

shaft

3rd

28

5th

31

Rev

15

Mainshett

Main drlv

Rev idler shaft

s

Thickness
1 73

1 80

1

er

mm

b erlns

in

0 06811

10 0709

87 0 0736

Part number
32204 78005
32204

78000

32204 78001

1 94

0 07641

32204

2 01

0 07911

32204 78003

2

0810 0819

32204

78002

78004

23

Speedometer gear ratio

lB 6

Malnsheft front
Oil

capacity

II US pt

Imp

pt

12

0 4 14

3 121
Thickness

MT 16

rnm

mm

in

Part number

14 0 055

32263

E9000

15

10 0591

32263

E9001

16

0 063

32263 E9002

in

Service Data and Specifications

MANUAL TRANSM ISSION
Maln haft

rear

Thickness

mm

end besrlna

lin

1 0 043

TIGHTENING TORQUE
Part number

1

32228 20100

I
I

Transmission installation

I

Transmission to

I

Gusset

I

Crossmember

I

Rear

I

Rear

I
I

Transmission

I

Gear

I

Bearing retainer to

1 2 0

0471

32228 20101

1 3 0

0511

32228 20102

14 0

0551

32228 20103

Counter drive aear

Thickness

mm

Part number

lin

1 4 0 055

32215 E9000

1 5 0 059

32215

16 0

E9oo1

32215 E9oo2

0631

AVAILABLE SHIM
Counter front bearlna

Unit

mm

operating cylinder

Clutch

to

D

transmission

to

to

@

I

TM371

3 42
0

3

Counter gear

4

Shim

Thickness of shim

3 51

1346

Counter gear front

0 1

0

0041

body

mounting insulator

mounting insulator

3 1

41

22

30

43

58

44

59

32

43

25

35

19

26

31

42

3 2

43

23

31

31

42

32

43

23

31

31

42

32

4 3

23

31

16

21

16

2 1

12

15

29

39

3 0

40

22

29

16

23

16

2 3

12

17

2 6

rear

case

to

extension

motor to

Starter

transmission

assembly

adapter plate

bearing

17 0

101

127

10 0

13 0

72

94

16

21

16

2 1

12

15

16

21

16

2 1

12

15

137

Counter gear lock

98

167

nut

to

case

cover to
case

Filler

plug

25

34

25

35

18

25

Drain

plug

25

34

25

3 5

18

25

20

34

20

35

14

25

09

1 2

6 5

19

2 5

14

04

05

2 9

2 0

3

14

08

1 0

Ball

pin

Striking lever lock nut

88

Check ball

19

11 8

Part number

32218 E9000

123

14 0

Mainshaft lock nut

case

0 13821

3 6

extension

reaf

transmission

2

40

crossmember

Front

A

to

Rear extension

j

30

transmission

transmission

Transmission

engine

ft b

m
kg

m

in

A

1

N

Unit

plug

Speedometer sleeve

39

25

49

8 7

18

3 6

installation
3 32
0
3

3 41

1307

22

3 31

0 1268
3 12

0 13431

02

10 0081

up
Back

03

0 012

0 4 0 016
3

02

E9002

Return

lamp switch
spring plug

20

7

8

29

98

0

58

22
72

32218 E9003

0 1264

3 11

0 1189

32218

0 1303

3 21

0 1228

32218 E9001

0

12241

92 3 01
0 1150 0 11851

05 0

0201

2

0 6 0 024

32218 E9004

32218 E9005

MT17

Correctiofl

TroubleDiagnosesa

MANUAL TRANSMISSION

TROUBLE DIAGNOSES AND CORRECTIONS

Noise

Check level and color of oil

Level color

I

N G

Level and color OK

L
Add replace oil If oil leaks

repair

cause

Check noise

I
NOise does

not

stop

Noise stops
0

OK

Shift gears and loco te which
gear

position makes

noise

I
Noise in Neutral

Noise in position other than
Neutral

I
Disengage clutch
if noise

see

to

stops

I
Noise does

not

Noise stops

stop

Noise outside transmission

Noise in transmission Noise may

Check engine and dutch

be caused

etc

torque
Adjust engine idle speed

Noise

by

variations in

engine

L
occurs

in

a

specific

position and peaks at
specific engine rpm and

gear

Noise occurs in all

positions
except Neutral and peaks at
a specific car speed

High roaring noise occurs in
all positions and peaks 8t
specific engine rpm

stops with gears in TOP

1

Noise source appears to be
located in differential

Noise appears to occur in
transmission Disassemble
and check gear in which
noise occurs for

surface nd

meshing

bearings

carrier Check differential

Noise occurs while

carrier and eliminate cause

gears

L
shifting

and or

occurs

when stroking
shifting gears

of noise

l
Moving parts couplings

bearing

Refer to 1he section

Faulty

Synchromesh Mechanism
MIlS

Noise

further after

1
Replace gear

nizing

I

1

position

Gears grate while synchro

gears etc

interfering

of transmission
with other parts

Gear jumping

ctions

DiTroubl
sgnoseundCoeir

MANUAL TRANSMISSION

of mesh

out

L
Locilte

position where

gears

jump

out

of mesh

Check for free play in control lever

Shifting

is

accomplished

without

problems

Check interference of control lever with
console and check rubber boot of control
lever for

fatigue
K
O

N G

I
Adjust

or

replace

Check for fatigue play etc
and

mounts

engine

rear

front

on

I
N G

Adjust

or

OK

replace

Problem may be inside transmission

Disassemble and check transmission

Check end play of jump out

gear

I
End

End play excessive

Replace

play O

Check for engaging damage

or

I
OK

wear

Replace

or wear on

coupling sleeve synchronizer hub and clutch
gear of main gear

Damage

K

Check for

wear or

fatigue

breaks

or

damage

on

on

check ball and

check spring

I
Damage

or

Replace

Wear

or

O K

wear

Check for

wear

ball groove

deformation

Replace

deformation of fork rod

or

OK

Check for
nizer and

play of
mainshaft splines
wear or

jump
out

synchro

I
Wear

or

No wear or

play

Replace

Check for

wear or

play

damage

on

bearings of main

shaft and countershaft Replace if

worn

MT19

Trouble Disgnoseund CDrrections

MANUAL TRANSMISSION

Faulty synchromesh mechanism
Noise occurs while

shifting

gears

Locate position where improper synchro

meshing

occurs

L

Check

disengaging of clutch Refer to
Clutch Drags Section CL for trouble
diagnoses and corrections

I

N G

Repair

or

replace

O K

Problem may be inside transmision
Disassemble and check transmission

1

Measure baulk ring
clearance
to
gear
Refer to Baulk Ring for inspection
Clearance
N G

Clearance

K
O

l
Check for

Replace baulk ring

area

w

ar on

of baulk

chamfered

ring

I
Chamfered

Chamfered

area worn

area

not

worn

1
Replace
Check

tapered
Improper

contact

cone

1

pattern of baulk ring and
ofclutch gear

contact

Proper

l
Replace baulk ring

l
Check spread spring for any
break or bending

I

Spread spring
broken bent

Spread spring not broken bent

1
Replace

contact

Check for

1
wear

deformation

of insert
Refer to Shifting Inset for

inspection

MT 20

MANUAL TRANSMISSION

Trouble Diagnoseund Correction

Difficult gear meshing shifting
Shift gears up and down while operating
see if gears shift smoothly

car to

Shift gears while engine is OFF
OK

I

N G

Check for proper installa

Check engine idle

tion of control lever

OK
I

O c

N G

Check for improper dis

Adjust
Repair

or

speed

I

N G

engaging of clutch

replace

Check for improper oper
ation of clutch operating

cylinder

master

cylinder

I
Operation
N G

OK

Operation
I

Repair clutch

Check lubrication oil level
and color

N G

I
OK

Add replace oil

I
Check for smooth shifting while
car

is

operating
OK

N G

Instructs customers in correct

shifting method

Problem may be inside transmission Remove trans
mission from car disassemble it and check it for source
of difficult

meshing shifting

of gears

L
Check

operation of striking rod

Repair

or

Ox

I

N G

Check operation of fork rod

replace

1

Check for
N G

K
O

Scratched bent

L
Replace

Check gear end faces and gear bores
for any sign of
If detected

stickingjamming
replace faulty parts

possible

Replace

bent fork rod

or

scratched

case

I
Check engaging of hub

pling

cou

sleeve clutch gear etc

I
MT 21

Special Service Tools

MANUAL TRANSMISSION

SPECIAL SERVICE TOOLS
Tool number

Kent Moore

No

ST2381000l

Tool name

Adapter setting plate

125693

9

KV311 00300

Fork rod pin punch

ST30031000

Bearing puUer

125733

1

KV311 004 n

Transmission press stand

Lo

rQ

OJ

rUoLh
ST23860000

Counter gear drift

ST22360002

Bearing drift

125679

ST22520000

Wrench

ifi
ST23800000

Transmission drift

125691

KV32 101330

Bearing puUer

ST22350000

Mainshaft

125678

MT 22

bearing

drift

MANUAL TRANSMISSION

Special

Service Tools

Tool number
Kent Moore No

ST33400001

Tool

name

OU seal drift

126082

MT23

DATSUN 200SX

Mode

SECTION

S 110 Series

AT

AUTOMATIC TRANSMISSION

CONTENTS
DESCRIPTION

AT

2

HYDRAULIC CONTROL UNIT AND
VALVES
HYDRAULIC CONTR

L CIRCUITS

MINOR ADJUSTMENTS
REMOVAL AND INSTALLATION
TRANSMISSION ASSEMBLY
MAJOR OVERHAUL OPERATIONS
SERVICE

NOTES

AT

3

AT

5

FINAL ASSEMBLY

44
AT

TROUBLE SHOOTING AND
DIAGNOSES

AT51

PRELIMINARY CHECKS

AT 25

Prior to road testing

AT 28

DIAGNOSTIC ROAD

AT 28

PRESSURE

AT30

STALL TESTING

AT 51
TEST

TESTING

AT 52
AT 54
AT 55

SERVICE DATA AND

FOR

DISASSEMBL Y

AT31

SPECIFICATIONS

AT 52

DISASSEMBLY

AT31

SPECIAL SERVICE TOOLS

AT 53

COMPONENT

PARTS

AT 34

Description

AUTOMATIC TRANSMISSION

1

DEScRIPTION
The 3N7l B transmission is

a

fully

consisting primarily of
a 3 element hydraulic
torque converter
and two planetary gear sets
Two
clutches a
inultiple
disc
multiple
disc

FLUID RECOMMENDATION

automatic unit

brake brake band and

one

Use

DEXRON

type

automatic

arrangementa

transmission fluid only
IAPO AUTOIlATle TllAIISIIISSlOll CO lTO

X

MODEL

way clutch

provide the friction elements

Identification of number

NO

necessary

23
01

7601234

to obtain the desired function of the

planetary gear sets
hydraulic control system is used
operate the friction elements and

two

A
to

automatic shift controls

IDENTIFICATION NUMBER
Number designation

Stamped position
The plate is attached to the right
hand side of transmission

TORQUE CONVERTER

case

7601234

L

The torque converter is attached to
the crankshaft through a flexible drive

Serial

Month of

Heat generated in the torque
converter is dissipated by circulating

plate

the transmission fluid through
to water

an

1

Jan

X

production
2 Fob

Oct

Y

on
Lat

type cooler in the radiator

N01

no

Z

Dec

denoting
figu

tho year A

lower tank
The welded construction of the

production

mber forthe month

DJ

tor

prohibits disassembly or
service unless highly specialized equip
que converter

AT344

ment is available

Tightening torque T of bolts
and nuts

@
1

Transmission

2

Oilpump

3

Frorit clutch

4

Band

5

Rear

6

Front planetary gear
Rear planetary gear

7

G

if
8

One way clutch

14

9

Low

IS

10

Reverse brake
Oil distributor

Oil pan
Control valve

16

1npot shaft

brake

11

JQvemor

17

Torque

clutch

12
13

Outputshaft

18

Converter housing

Rear extension

19

case

oonverter

Driplate

N

m

m
kg

fHb

@
@
@

T 39

49 4

T

157 14 16 101 116
54 4 5 5 5 33 40

@

T

5 9

7 8

@

T 4 9

6 9

137

T 44

5

0 6
0 5

T

20

25

@T
@ T
CD T

13

l8 LJ

2 0

29

36

0 8 4 3
0 73 6

5 8

5 1
2 5 14 18
18 9 13

4
5

7 4

0 55

0 75 4 05 4

2 5

3 4

0 25

0 35 1
8

2

5

AT312

AT 2

AUTOMATIC TRANSM ISSIO N

Control Unit and Valves

aulic
Hydi

HYDRAULIC CONTROL UNIT AND VALVES

hydraulic

The

or

automatic control

system is comprised of four 4

groups the pressure supply system
the pressure regulating system the
flow control valves

and the

FLOW CONTROL VALVES

Pressure modified valve

Manual valve

the mainline pressure regulator valve in
lowering mainline pressure during high

basic

friction

elements

The manual valve is moved manual
the

ly by

car

operator to select the

different drive ranges

pressure supply

The
of

a

SUPPLY SYSTEM
system consists

gear type oil pump driven

by

the

engine through the torque converter
The pump provides pressure for aU
hydraulic and lubrication needs

shifts the
second

ing
sure

tle pressure to work

shift valve automaticaUy

1 2

The

transmission from first to
from second to first depend

or

speed light load conditions such as
steady speed cruise Governor pres
sure
working against a spring opens
the valve which aUows modified throt

1 2 Shift valve
PRESSURE

pressure modifier valve assists

The

upon governor and throttle pres
along with accelerator position

solenoid downshift

valve

See

against the pres
regulator valve spring lowering
mainline pressure Lower operating
pressure under light load reduces oil
sure

and

temperature

increases

transmis

siOli life

Hy

Drive 2

draulic Control Circuits

Throttle back up valve
2 3 Shift valve

The

PRESSURE REGULATOR
The

VALVES

shift valve automatically

2 3

shifts the transmission from second
The pressure regulating valves con
trol the output pressure of the oil

top

pump

pressure

or

gear

pending

from top

up governor
or

The
trols

pressure

mainline

regulator

valve

pressure
for the

based

throttle opening
operation of
the band clutches and brake
Governor valve
The

valve

gulated

pressure

based

to the

shifi valves

tranSffi ts
on

re

speed
upshifts

car

to control

and downshifts

vacuum

throttle valve transmits

regulated pressure
load

vacuum

based

on

engine

This pressure controls

the pressure regulator valve Also this
pressure is applied to one end of the
shift valves in opposition to governor
pressure

Timing valve

For 23 shifts

a

restrictive orifice

slows the application fluid to the front
clutch while the slower reacting band
to release

allowed
2 3

hard
load
run

or

3 2

Second lock valve

This

prevents

The

second lock valve is used

to

bypass the 1 2 shift valve to
the band apply pressure in

maintain

tion

as an

The valve is also used
for the

pass ge

apply
I

pressure

2

posi

1 2 shift valve
in

D

oil

band

D

and

Range

a

shift Under heavy

however the engine will tend to
during the 2 3 or 3 2 shift

away

therefore a 2 3 timing valve
using throttle and governor pressure is
used to bypass the restrictive orifice
during such heavy load conditions
pause

Vacuum throttle valve
The

2 3

is

governor

Range

con
on

line pressure when the manual valve is
shifted either to 2 or I range

See Hydraulic

Drive 3

Control Circuits

back up valve assists

and throttle

accelerator position sole

noid downshift valve

Pressure regulator valve

to

second de

to

throttle

the vacuum throttle valve to increase

which acts

on

the other end

of the shift valves controlling
and downshift speeds

upshift

CLUTCHES AND BAND

SERVOS
The

Solenoid downshift valve
The
activated

solenoid

downshift

electrically

celerator is

floored

valve
the

when

causing

a

downshift from top to second
fi st

or

low
is
ac

forced
top to

second to first gear depending

upon car speed

governor pressure

servo

reverse

hydraulicaUy
brake and
and

prake

spriT
1g
released

pistons of

the clutches

brake and band
to

apply

moved

engage
the band The clutch

pistons

tension

are

the clutches

are

released

and band

by spring

tension

by

piston is
and hy

draulic pressure

AT3

Hydl7lUlic Control Unit

and Valves

AUTOMATIC

TRANSM ISSIO N

Control valVe

rTil

SV
J

AT094

1

4
AT

Pressure regulating valve
Manual valve

6

Vacuum throttle valve

2

7

Throttle

3
4

lst 2nd shift valve
lnd 3rd shift valve

8

Solenoid down shift valve
Second lock v8Ive

5

Pressure modifier valve

9
10

up
back

2 3 timing valve

valve

AUTOMATIC TRANSMISSION

Hydraulic Control Unitsnd

Valves

Oil Channels in Case Front Face

OIL CHANNEL

IDENTIFICATION
The circuit numbers shown in each

Hydraulic Control Circuit are classified
as follows according to the function
Pressure source of the line

7

Operating line pressure for
friction elements
12 3 4 5 6 8 9

Auxiliary
Torque

line pressure

13

converter pressure

Governor pre

ure

10 1112

14

15
AT106

Throttle system pressure
16 17 18

19

Oil Channels in Case Face

Oil Channels in Oil Pump

90
o

r

Oil pump discharge hole 7

Governor pressure 15

Oil pump discharge hole 7

i
Torque

Torque converter pressure 14
q Rear clutch pressure 1
Front

converter

pressure l4

Servo

0

LOiiJ

o

Front

a

clutch

pressure 11

rr
U

0

0

10

Servo tightening
pressure 9

Governor feed pressure 1
1

I

lnl

Low
I

0

o

i

release

pressure

clutch
pressure 1
Rear

clutch pressure 11
unm
P suction hole

J

fj

0
0

P

0
sucti

Jj
e

reverse

brake pressure

12f

J
AT107

AT10S

MECHANICAL OPERATION
In the 3N71 B automatic transmission each part

operates

as

shown in the foUowirig table at each gear select position

Gutch

Low

Band servo

One

Gear
way

reverse

Range

ratio

Front

Rear

Park

brake

Operation

Release

clutch

Parking
pawl

on

on

Reverse

2 182

on

on

on

Neutral

Drive

Dl

Low

D2

Second

1458

D3

Top

1000

Second
12

Second

I

Low

2

The low

reverse

brake is

458
2

on

on

on

on

on

on

1458

on

on

1458

on

on

on

458
2

applied in

on

1

on

on

range to prevent free wheeling when

coasting

and allows engine

braking
AT 5

AUTOMATIC TRANSMISSION

Hydraulic Control Cirtuirs

HYDRAULIC CONTROL CIRCUITS
P

RANGE

I
a
rking Mechanism

PARK

Power flow
In

P

range

the

shifl

linkage

actuated parking pawl meshes in

splined

movement of the car
is

a

gear

to the output shaft

preventing
When the engine
reverse

brake is

applied by pressure from the
Uve
v
passing through the 1

manual

running the low and

2

shift

valye
F

Locr

11
AT086

Fluid flow
Manual Valve

4

Downshift Valve

13

2nd 3rd Shift valve

1st 2nd Shift Valve
Throttle Back up Valve
5

Ist 2nd Shift Valve

12

I
y

6
AT

1ottle Back up Va ve
h
Low

Reverse Brake

I

AUTOMATIC TRANSM ISSION
P

Oil Pressure Circuit Diagram

park

range

11
r

conv
t

TorQu

j
O

ro

Oi

I

r

rIf

h

c

E

@1

rl j

01

IY

10

j

9
I

l

I

JJI

14

Drain
01

I

II

1

1

J

1

r

r

Throttl
drain
1

volv

x

fir

lL
p

13

16

I

I

l
l

LLl
I r

1

lubricati

t

olu

oL

Front

0

gm

oIll

II

lubrication

o

0

h

J
I

Slllt

r

cooler

Rnt

nh

I

0

TIC Oil

Hydraulic Control Circuits

1
1
C
1

JLSII J
2Z

1J

x

IE 2no
vol
x

P

Ii

ur

otor

2
t
Sh

II
I
I ck

@

I

II

r3

6

J ji

mino

1

J

l
CD

3 d

15

II

II

I

I

I

j

I

I

I
II
Monuol
YOI

xn

ru
Not
llrr Itr

Mork d

Lin

X ort

prulUr

droin

lGoy

Gornor
I

ro

t
con
lI

rnor

fud pt
r

Secondory
lOlv
Qovunar

Primo
OO

lIOr

olv

lpr1U1lI1

Torqu
Th

I
I

pr

t
r

r

pr

r

AT455

AT 7

AUTOMATIC TRANSMISSION

Hydraulic ContrrJI Circvits
R

RANGE

Mechaitical

REVERSE

Power flow
With

the

transmit

selector

lever

in

applied

Rear gear set

Output

to

Input through front
clutch

clockwise

engine
torque
connecting shell to the

the

Sun gear

The clockwise rotation ofthe

gear

Range

R

through
sun

R

Front gear set

the front clutch is

range

Operation during

causes

the

planet

gears

Held

by low

reverse

brake

to

rotate counterclockwise With the low

and

reverse

brake holding

carrier

the

the

rear

internal gear
to the output shaft
turns
counterclockwise in a reduction ratio

planet
splined

rear

AT329

Front clutch

of approximately 2 18 to I

Low

ON

reverse

brake

ON

N

Front clutch

ON

Rear clutch

OFF
ON

Low and reverse brake
Brak band servo
way
One

OFF

Pressure

release

Overrunning

clutch

AT085

Fluid flow

Manual Valve

4

Downshift Valve

I3

2nd 3rd Shift Valve

L

Ist 2nd Shift Valve

Throttle Back up Valve
5

Ist 2nd Shift Valve

12

I

y
6

Pressure

L

Regulator

Throttle Back up Valve
Low

Reverse

Valve

2nd 3rd Shift Valve

10

Band Servo Release Side
II

8
AT

Brake

1

Front Clutch

AUTOMATIC TRANSM ISSIO N
Oil Pressure Circuit Diagram

R

Hydraulic Control Circuits

Reverse

range

broil
l
ton

Torque

rt

Front
r

I

0

Brok
band

RlOr
h

h

l

I

trJI

I

J
12

kill

TIC Oil

l

r

cr volu
reOlollalnil

1

Oil cool

JUI
I

i

01

l
U

T I
Oral

1

1

IL J

11

LL l

ThMII

drain
val

h

fi
ID

l

I

T
24

Ool

l

r

rl

6

I

jJ

x

x

G9

lxjJ
CD p

2nd 3rd
olv

@

i

M

liming

O

uff

k

II

r

L

Jr

ator

I

J

II
n ui

1

1

U lr

I

vci
r
u

No
lrto

L

fm

r

Markld
Lin
G av

X

Torqu
Th ronl

prn

1

Go rnor
ure

COMut

pr

l

dfoin

preuur
rnor

l

r

un

ud

pr

ur

Secondory
go rnOI lGlv

x
Primor
go itlr

1
01

ll
prl

AT456

AT

9

Hydraulic Control

RANGE

N

Cirwiu

AUTOMATIC TRANSM ISSION

NEUTRAL

Power flow
In
are

in use

elements
ange no friction
thus no power is trans

mitted to the output shaft

AT10

AUTOMATIC TRANSM ISSIO
N

Oil Pressure Circuit Diagram

N

Hydraulic Control Circuits

range Neutral

F
ll
Torql

conv

rt

e

Front
lItCh
r

Oil

1i

x

I
12

I

Bond

X

@

YO

Vacuum

Throtllt
bacll up
wolv

Ihrottl
oh
Oi

I

cooler

i1t

OIY

I
RIO

I

ealia

4

flL

i

1t

r1I

T11

I

Drain
101

11

Front
t
lubricaf
Drain

own

01

1

18

Orifice
chlcll
fol a

1

I

L
Throttle
drain

t

I

11
101

rI5

6

10

c

o
Z2

I

I

II

t1J

x

x

JI

fLx

5
l
J

Xl

r

II
CD

P
otor

21

IV

ilL @

6

d lock

frO

6

II
II

I
I

II

dl

t 2
ShiflIllGIY

I
I

r

OI

@

jULj

Not

I
I

on drain
Worked

lint prUSUft Go

ud

rnor

pr

nur

OOv
G
nI
tI

ft

o

no

Torqu
Th

rottl

nor

Slcondar
01

Primory
00

rnor

vol

prlssure
conyut

p

ur

pnn

r

AT457

AT11

AUTOMATIC TRANSM ISSIO N

Hydraulic Centrol Circuits

D

RANGE

Mechanical Operation

LOW GEAR

Power flow

Front

With the shift selector in

D

during

61

Range

Rear gear set

gear set

low

Output shaft

engine torque is transmitted
through the applied rear clutch to the

gear

Held

in1ernal gear of the fron1 gear set The
clockwise rotation of the front inter
nal gear
to

front

sun

driving the

com

carrier is

splined

10 the

output shaft This causes the planet
gears to drive the sun gear instead of
around the

sun

causes

rotate

the

rear

clockwise

clutch holding the
the rear

planetary

planet

With the
rear

to

reai gear

set

gear set

one

AT330

sun

gears

planet

Input from front
Output

This

gear

counterclockwise rotation of the
gear

way

gear counterclockwise The

planetary

walking

one

the fron t planet gears

causes

rotate clockwise

pound

by

clutch

to

way

carrier

gears turn the rear

internal gear and outpu1 shaft clock
wise in a reduction ratio of
approxi

mately

46
2

to I

Front clutch

OFF

Rear clutch
Lo

and

ON

reverse

Brake band

brake

servo

One way clutch

OFF
OFF
HOLDING
AT081

Fluid flow

Manual Valve

Governor Valve

15

Pressure Modifier Valve

2nd 3rd Shift Valve
Ist 2nd Shift Valve

2nd 3rd
Ist 2nd Shift Valve

J
2

Second Lock Valve

3

Second Lock Valve

L
AT12

Rear Clutch

Orifice Check Valve

2nd 3rd Shift Valve

Timing

Valve

AUTOMATIC TRANSM ISSIO N
Oil Pressure Circuit Diagram

D1

range

Hydraulic Control Circuits

Low gear

Front
cluleh

Rlar
cl utch

Brake
bond

Low
r

v

Q

nd
brake

1

Oi I pump

t
1

Torqu

rl
ean

2

t
L

ur

t

6

Bond

I b

I

r

Pres

1

o

1

ervo
7

I
3 Shill

OI

It

rlQulo1 or
valv

l

1
Throttle
sur
pr

J

t

t

@
I

1

lint

s

pr

Governor

Torque

Throttle

Governor
pressure

ur

pre sure

conyerter pressure

prlssure
AT446

AT13

RANGE

D

AUTOMATIC TRANSMISSION

Control Circuim

Hydraulic

2ND GEAR

MechariicaI Operation

Power flow
D

Io

applied
and

sun

D2 Range

Front gear set

Rear gear set

the brake band is

range

to

dtiring

hold the connecting sheU
gear

stationary

torque through the

applied

Engine

rear clutch

is delivered to the internal gear of the
front gear set in a clockwise rotation

Clockwise rotation of the internal gear
causes

the

around the

walk
planet gears to
stationary sun gear in a

clockwise direction

This

causes

the

output shafl which is splined to the
front planet carrier to turn in a clock
direction with

wise

a

AT331

reduction ratio

of about 146 to I

Front clutch

OFF

Rear clutch

ON

LOw

and revelSe biake

Ike band
llr

OFF
ON

servo

One way clutch

OFF
AT079

Fluid flow
As

car

increase
on

the

speed and

governor pressure

the governor pressure acting
end of the
1 2 shift valve

Manual Valve

force of the 1 2 shift

the

and line pressure This
aUows the 1 2 shift valve to move to

and

overcomes

the

valve spring

Governor Valve

15

upshift position which
pressure through the 2nd
on

directs line
lock valve

to the brake band

Pressure Modifier Valve

2nd 3rd Timing Valve
2nd 3rd Shift Valve

Ist 2rid Shift Valve
Ist 2nd Shift Valve

8

Second Lock Valve

9

Band Servo

Apply

4
2

3

Rear Clutch

I

Second Lock Valve

I

Second Lock Valve

L Orifice Check Valve
AT 14

2nd 3rd Shift Valve

Side

AUTOMATIC TRANSM ISSIO N
Oil Pressure Circuit Diagram

D2

range

2nd gear

Front
clutch
Oil

Hydraulic Control Circuits

Brake
ba nd

Reor
clutch

Low and
revers

broke

pump

F

t
J
f

Tor q ua
conYerter

I

tl
Pressure
r

oulator

valve

2

hjf

llvOIV

t

u

1Itrrr 1ltrrr 1Itrrr

P RND21

t

r

l

t

Throttl e
pressure

It
j

@

Govern or
pressure

Line

pressure

Gover

or

Torque

Throlll

pressure

converter

pressure

prellur
AT448

AT15

Hydraulic Control Circuits
t

D

RANGE

3RD

AUTOMATIC TRANSM ISS10 N

GEAR

Mechanical Ojleiation

Power flow
In

on

range

transmitted
The

clutch

Rear gear set

Front gear set

both

turns

the

Input through front

is

engine torque

through

front

during D3 Range

and

clutches

rear

internal

gear of the forward gear set clockwise

Output

clutch turns the sun gears in a
clockwise direction also With both the

shaft

The

clutches

rear

internal gear and the sun gear of the
forward gear set turning in the same
direction at the same speed the planet
gears are locked in
as a

position and turn
splined to

A T332

unit The output shaft

the forward
ratio of I

planet

carrier turns at

Front

a

clutch

ON

Rear clutch

ON

I

N

Il
AT083

Front clutch

ON

Rear

ON

Low

clutch
and reverse brake

Brake band

OFF
OFF

servo

One way clutch

Presswe release

OFF

Fluid flow
Governor pressure increases to the
point that it can overcome the com
bined

forces

pressure

and

of spring and throttle
move

the 2nd 3rd shift

Manual Valve

valve

When

the 2nd 3rd shift valve

pressure passes through the
valve lands to the 2 3 timing valve and
opens

on

to

apply

Governor Valve

the

front

15

clutch

release the brake band The
in D
was

or

direct drive

car is now

the rear clu tch

already applied

and

Pressure Modifier Valve
2nd 3rd

Timing

Valve

2nd 3rd Shift Valve
lst 2nd Shift Valve
Ist 2nd Shift Valve

J

Rear Clutch

8

Second Lock Valve

9

I

2

Second Lock Valve

3

Second Lock Valve

Ii

Band Servo

Apply

Side

i
I

Band Servo is released

t

LOrifiCe

Check Valve

I

2nd 3rd Shift Valve

42nd 3rd Timing Valve
AT16

10

TIBand

Servo Relea

II

I Front

Clutch

1

Side

I

AUTOMATIC TRANSM ISSIO N
Oil Pressure Circuit Diagram

Fronf
clutch
Oi

Rear
clutch

Brake
bond

Low and
rever

brake

pump

0

1

t
JI

Bond

t

JJ

To rq
c anYlrter
ue

1
y W r

r

t

l
Pressure
re QU lator
valve

sY

if
t

tr
PRN021

t
I
Throttle
pressure

Ya

Il

t

Iv

t

@

i

t

Governor
pressure

lo

L in

Cirruit3

3rd gear

D3 range

I

Hydraulic Control

pressure

Governor

IIDJWq

Torque

Iijp
I

Throlll

pressure

eonv

rter pr

ur

AT449

preuur

AT 17

Hydraulic Control Circuits

AUTOMATIC TRANSMISSION

RANGE KICKDOWN

D

To achieve
3rd to

2nd

a

forced downshift from

the car

speed

be

must

under approximately 100 km h 60
MPH
from 2nd to 1st it must be
under approximately 50
h 30
km
MPH FuUy depressing the accelerator

pedal energizes the
noid

downshift sole

which opens the solenoid down

shift valve Oil pressure is then exerted

against the shift valves Between 50
and 100
h 30 and 60 MPH this
km
pressure wiD close the 2nd 3rd shift
valve against governor pressure and the
car

downshifts

below 50

When the

car

h 30 MPH the
km

speed

is

I st 2nd

shift valve will be closed and the 1rans
mission

will be in 1 st gear

speed and

As

car

governor pressure increase

the shift valves automaticaUy reopen

AT IS

AUTOMATIC TRANSM ISSIO N
Oil Pressure Circuit Diagram

Torqul

rl

conv

D

range kickdown

Front
Iutch
r

shift valves in 2nd gear position

Rlor
ClutCh

SD

Oil

p

RI

1

all COOler

V

I

ro

I

J

O

lID

i

Vacuum
throttl

i

It

01

II

N

hlbri cot ion

8

t

d

I
3r

r

0

o

y

J1

TIC on
rog o

Hydraulic Control Circuits

i

i1

I
01

lI

S

m
U

I

j

lu
own

I
I

14

Oraln
vohl

I

oz
n
Front
lubriCQtif

8

l

i

18

d

16

Yol

W

Throttle
drain
10
1

I

X
J

l
@Z

I
Hmu

C

u

J
JI

X

g 2nd

3rd

1

1Qto

Hot
IIo

U

L

I

I

GOY

B
pul

r

N

23

Tr
Ol

1

yol
l

@
PRND2

I

f

Worbd l
Lin

I

2 d

lJlu r

t

ore

flU

Th r011l

Oroln
Govlrnor fud

r

pr

lt
Tor4
v

r

limine

a vI

ii
D

3n Shift
I
Yol

5

j

J

1

Jr

Z2

11

L

pr
c

on

pr

I
r

p

uunl
Primor
rrror yo
90

u

Y

pr sure

ur

AT458

AT19

Hydraulic Control CilCuil
2

RANGE

The

range

lock he

upshifts

2

2ND

AUTOMATIC TRANSMISSIO N

GEAR

position

Fluid flow

is used to

in 2nd gear preventing
downshifts under any con

car

or

Power flow in

D1

pressure

opens

the

the

second

against spring pressure

flows to

Power flow

in

yalve

opening the valve and aUowing pres
from

manual

lock

As

valve

this valve

opens pressure then passes to apply
the band servo Line pressure also

ditions

as

Line

2

the throttle back up valve

to

sure

pass

into

the

line of the

throttle valve

thus assuring adequate
throttle pressure even during decelera
The downshift solenoid valve is

tion

passage for line pressure to
lock the 1 2 and 2 3 shift valves
used

as a

range is the same

range

Governor Valve

Manual Valve

Pressure Modifier Valve

15

2nd 3rd Timing Valve
2nd 3rd Shift Valve

L

Is1 2nd Shift Valve

lst 2nd Shift Valve

Rear Clutch

I

2

Second Lock Valve

4

Solenoid Downshift Valve

Band Servo Apply Side

9

13

I

3rd Shift Valve

t2nd

1st 2nd Shift Valve

Throttle Back up Valve

17

Vacuum Throttle Valve

16 Pressure Modifier Valve
2nd 3rd Shift Valve

2nd 3rd Timing Valve
Throttle Drain Valve
Pressure

AT 20

Regulator

Valve

AUTOMATIC TRANSM ISSIO N
Oil Pressure Circuit Diagram

Torqvt

conv r1

2

range

2nd gear

Rlor
r

r

r

l
r

I

Oil cooler

12

it

v

9

@
Vacuum
Ihrottlt
01

10

ll

boc k

up

downall

ft volv

yolv

14

t
6

f

Drain
olv
Front
lubricatit
Drain volv

Hydraulic Control Circuits

I I

WI

Throttl
drain
01

I

l r

11

13

l
1

@2nr3rd

Shift
01

1

In

II

22

i

x

x

1

J
Q

21

6
6

II

Pr or
Iau otor
01 1

Manual
I

@
P

No

worktd
lint

l
i
1

JA

S

X

pr

Gatnor
Torque

Th rottl

or

ur

droln
l

p U
con

pt

f

R

t d

o rnor

pr

urel

Primory
nor volvl
QO

l
Ur

pt
fI

r

AT459

AT 21

Hydraulic
1

AUTOMATIC TRANSMISSION

Control Circuiu

RANGE

The
lock the

upshifts
to

the

moving

vents

I

range
car

in

position is used to
1 st gear preventing any

1

position while
high speeds the

the car is
transmis

sion will not shift into fIrst gear until
car

speed slows

km h 30 MPH

Manual

to

approximately

1

alYe

Manual pressure

passing through

1 2

shift valve

preventing

valve closed

to

hold the

rear

gear

as

along with applying addi
tional c1 sing pressure to the 1 2 shift
valve

in D

15

Pressure Modifier Valve
2nd lnl Tuning Valve
2nd lrd Shift Valve
lst 2nd

Shift Valve

2nd Shift Valve

jRear Clutch I
4

Solenoid Downshift Valve

13

lrd Shift Valve

t2nd
Ist

2nd Shift Valve

Throttle Back up Valve
5

Ist 2nd Shift Valve

12

lbrottle Back up Valve

I
FluId flow
Manual Valve

Low

Ii Reverse Brake

I

l gear
2n
1

Governor Valve

15

Pressure Modifier Valve
2nd 3rd Timing Valve
2nd lnl Shift Valve
1st 2nd Shift

1st

j
4

2nd Shift Valve

Rear

Clutch

8

Val

Second Lock Valve

91

I

Solenoid Downshift Valve

13

lrd Shift Valve

t2nd
1st

Throttle

up
Back

Valve

17

1

2nd Shitt Valve

Pressure Modifier Valve
2nd lrd Shift Valve

3rd
2nd Timing Valve
Throttle Drain Valve
Pressure Regulator Valve
5

AT 22

1 2 up

band is applied

Governor Valve

to lst

a

shift Manual pressure passing through
the downshift valve locks the 2 3 shift

planet carrier providing engine
braking Power flow in I is 1he same

to

Low gear

The power flow in I differs slight
Iy from D in that the low and reverse
set

50

Instead i1 will shift

Fluid flow

the 1 2 shift valve is used to close the

Power flow

If the selectorJever is moved

at

I
as governor pressUre pre
the 1 2 shift valve from closing

second

LOW AND 2ND GEAR

bt 2ndShiftValve

Band

Servo

Apply Side

I

Hydraulic Control Circuits

AUTOMATIC TRANSM ISSIO N
II

Oil Pressure Circuit Diagram

Low gear

range

La

and

br

Torqul

Srok
bond

Rlor
cllutth
C

r
con

C

Et
IJI
u

p

II

j
Jir

I

r

9
I

10
I

II

I

1

f

yo

I

1 1 XII

OIUOld

ll
vol

downlhlft
lol

r

i
i

1

J

c

Ij l

Front
lubriCG
ltc

tu

I

Throttl
back up

1
01

1

Rlor lubricalion

Drain

1@ 12
Vacuum
throttl

CI

1

I

i

o

t

cooler

Oroln Yol

o

J

I

11

con

m

oPhrogm

ThroW
drain
vol

Ie

I

16

X

wr

1

I

@2nct 3rd

D

Shift
val

ft

II
m

I
x

rl

CD P

u
UI

otor

II
I

11

n

f

lr

j
ij

dX

N

1

d

ooo

X

Lin prusur
G
3
0
A

ov

rnor

Torqul
Th

oltl

pr

Goy

rnor

tud pr

un

Secondory
Qov rnor

01

jl

J
Primory
nor
90 Ie r

1
101

t
ul

converler

preure

pre
ure

AT460

AT 23

AUTOMATIC TRANSMISSIO N

Hydraulic Control Circuits

jjPressure

12

Diagram

Circuit

range

2nd

gear
La

and

broil
Torqu

rt

an
c

Front
clufeh
r

R

or

uum

hro

oot ol
m

tuteh
J
TIC Oil
re9U

pt

6

b

u

Olloro I

Oil cool

t
1

17

2

oB

Th
t1
bocll up
101

0

I
l

oro
l

Rlor lubrication

n

JI

I

II

II

Iii

4

Orain
0
01

JJ

III
IItIOl1

downahi

11i

g

tyol

FrOnt

11

lub icotic
Or ain

1

01

1

I

Throttl
drain

f

1
101

1

L

3tdSllift
@2n
101

10

r

S

@2nd
vol

I

ldI

3

zo

1

tJJ

r
I

uro

I
Sh

ii

Pr
D nou
otor

I

3rdliminv

It
I

i

r
l
u

L

I

r

I

vol

6
Manual

2
PRND2

Not

Mork d
Lute
Goy

U
T

T

Th

X

on

pru
rnOt

rquI
otll

prlS

n

f1

drain
Gov

d

pt

urt

S
90t

pr

I

w

rnor

U

COn

p

I

condor
YQlv

ftOI

PtimOI
Q 0Vllnol

olv

lur

nut

AT461

AT 24

AUTOMATIC TRANSM ISSION

Minor Adjustments

MINOR ADJUSTMENTS
the transmission to downshift

KICKDOWN SWITCH
Kick down

ADJUSTMENT

switch

upper post of
pedal inside the car

When the pedal
click

can

be

pedal bottoms

the

part

throttle

7

The kickdown switch is located at
the

on

DIAGNOSIS

accelerator

Switch can be heard

clicking

and the

transmission still does not kickdown

fuUy depressed a
heard just before the

Check

out If the click is not

for available current

is

using

the
a

continuity

continuity

of

the switch
Also check

tester

heard loosen the locknut and extend
the switch until the pedal lever makes
contact with the switch and the switch

SA TOO 1

The

car

upshifts

and 110 km h

clicks

approximately 65

at

40 and 70 MPH

only

The kickdown switch may be internal

ly shorted
Do not allow the switch to make
contact

This would cause

too soon

ed

there

When the switch is short
is continuity

through

the

switch in any position

Wiring Diagram

re

t

mO

1

BATTERY

FUSIBLE

R

LINK

o

ST

t CC

ON

WB

OFF

BW

J
6

8

J

D

rIl
I

r

r

iDf
W

BW

IGNITION ANO
ACCESSORY RE

WR

1J

IGNITION SWITCH
MAIN HARNESS

rJ

WB

Q
lIl

o

0

O

O
0

0

0

q o

0

0

l
U

O
0

O

O

Ul

0000

O
J
O

D
l

D

0

0

O

Q

0

UI

D

O

FUSE BLOCK

I

G

J

I

rOl
E
No

S

2

G1 0

J

iO

8

DOWNSHIFT

SOLENOID

I

I

K1CKDOWN

SWITCH
SEL490

AT 25

Minor

AUTOMATIC TRANSM ISSIO N

Adjustmentt

INHIBITOR SWITCH

current to pass from the starter

ADJUSTMENT

when the lever is placed in the
The inhibitor switch has two major
It allows the back
up lights

N

functions
to

placed
as

a

wires should have

lever is in the

or

tester may be used to

continuity

con1inuity when the
Nfl positions

and

R B

wires should

have continuity when the shift lever is

check the inhibitor switch for proper

in the reverse range It also acts
neutraJ safety switch allowing

P

Red and black

range
A

illuminate when the shift lever is

only
p

moved to

R

range

operation
The

black and yeUow

two

B

Y

Wiring DIagram

00

00

BACK UP LAMP R H

gg
ii

RB

RB

00

B

8

o
BODY HARNESS

BO
BACK UP LAMP LH
R

W
E

O

a
B

TTE

5T

WR

ON ACC Off

we

J J I11LBw J
rr w

g g

1

0

6

BW

W

2
c

IGNITION AND
ACCESSORY R

lJ

IGNITION SWITCH
W
MAIN

ii

O

U

ii

ii

ii

0

0

0

0

0

0

o

0

Q

0

Q

N

0

0

r

o

0

0

o

I

o

o

o

r

FUSE BLOCK

Lw

I

a

m

BY
B

t

BR
LW

I

r

HARNESS

co

III

Ii

INHIBITOR RELAY

flfj@
s
J

Dl
l

C BR

ENGINE
No 2
M

l

HARNESS

q

G Do
oo
RB

on
oU

we c
J CJO
LW

J

STARTER MOTOR
INHIBITOR

SWITCH
SEL491

AT 26

AUTOMATIC TRANSM ISSIO N
I

Place the manual valve in Neutral

2

R

F

Remove the

ROD ADJUSTMENT

I
screw

as

I

illustrated

1

The
Grommets

mine

nJ4I

c

1

Lock nuts

vacuum

SAT099

D

3

Loosen the attaching bolts

4

Using

3

aligning pin move the
the pin falls into the hole

in the rotor

can

properly aligned

shift
and

and

remove

at
dia

phragm from transmission case
2
Using a dep1h gauge measure
Be sure vacuum throttle
depth L
is
valve
pushed into valve body as far

possible

3

depth with chart
length rod

L

Check

below and select proper

and

P

safety

Range

measure

1

posi

be sure you

P

in

If you

are

Depth

L

feel full detent when shift lever is

placed

hose

vacuum

diaphragm

locknut

Recheck
tions As a

that the correct

range

Tighten

an

switch until

D

is

move

Disconnect

as

range

Loosen locknuts and

is in

is essen1ial

It

J
Front

Place shift lever in D

car

its

length rod be installed
I

lever until

and the

diaphragm rod help deter
the shift patterns of the transmis

sion
r

diaphragm

vacuum

length of

2

Adjustments

VACUUM DIAPHRAGM

N D

position

vertical

Minor

unable to

adjustment grommets may
damaged and should
be replaced
make

an

be badly

worn or

SAT002

5

6

Tighten the attaching bolts
Recheck for continuity If faulty

replace

MANUAL LINKAGE
ADJUSTMENT
adjustment of the manual
an important adjustment of

the auto

shift lever

Range

I

tic transmission

from

the

P

range

to

the detents in each range

adjustment

the

range

or

is

Vacuum

throttle valve

mm

in

Part number

29 5

161
1

31932

XOlO4

10295

10453

30 0

181
1

31932

XOIOO

2705

1 0492

1 0650

5
30

1 201

31932

XOlO2

15
27

1 0689

310

1220

31932

XOIOI

10098

26 15

26 55

26 65
Over

brake

Proper

results in smooth
2nd and 2nd

adjustment
to

band

shifting

adjustment

3rd

Although the
it is im
simple
very
use an
accurate torque

Loosen locknut

im

2

Torque band
N

m

servo

3

Back off band

two

complete

servo

piston

stem

turns

between 1st

is

I

ft lb

5

10256

26 05

I5
to

Diaphragm rod
Valve body side plate

XOI03

25 65

12

4

31932

the

linkage needs

3

142
1

1 0059

portant

Transmission

29 0

55
25

wrench

If the detents cannot be felt

pointer indicating the

Rod length

in

mm

Under

Move the

you should be able to feel

properly aligned

L

BRAKE BAND ADJUSTMENT

linkage is

Note

rod selection

diaphragm

Measured depth

the switch

The

Vacuum

seated valve body
case wall

1
2

piston

2 to 15 kg
1

m

CAUTION
00 not back off EXCESSIVElY

adjusting

stem

fall out of

place

as

Tigh1en locknut

stem to

4

9 to II

20 N

m

ing band

2

kg

servo

m

on

anchor block may

to

approximately

14 ft lb

piston

stem

while hold

stationary
AT 27

AUTOMATIC TRANSMISSION

Removal and Installation

REMOVAL AND INSTALLATION
TRANSMISSION
ASSEMBLY
When

dismounting

tran

I

from

on

to the

the

a

CAUTION
Do not
automatic

foUowing points
dismounting the transmis
rigidly inspect it by using the
Troublneg
shooti

mount it

Chart

and

dial gauge rested

converter

housing

0 020 in

mm

dust

Remove bolts securing torque

converter to drive

it is necessary
the transmission with

the

plate

QOOOO

tightening torque indicated

another table do Dot exert

on

dis

Detach

12

cover

a

Maximum allowable runout
0 5

and when mounting ob

utmost care

serving

under the oil

jack

of

only when

Dismount

2

the

pan drain

pay attention

car

Before

sion

place
plug

eating fInger
against plate

exces

sive force
AT268

2

line up notch in torque converter

REMOVAL
In

with that in oil pump
the

dismounting

transmission from

a

automatic

proceed

car

as

foUows
I

InstaUation of torque converter

Before

removing

inscribe chalk maria
that they

Disconnect battery

cable

ground

torque converter

may

original positions

be

on

two

replaced
assembly

at

parts

so

Be extremely

careful not to put undue stress

parts when installing torque

on

converter

in their

from terminal
2

Jack up car and support it
We
recommend
safety stands

hydraulic hoist

on

a

open pit be utilized

or

if available
Observe

all

safety regulations
Remove propeUer shaft

3

Plug

up the

tension

to

opening

prevent

in the rear ex

oil from

flowing

out

13

Remove

rear

engine

mount

ingbolts
14

Remove starter motor

15

Remove bolts

securing

transmis

sion to engine After removing these
bolts support engine and transmission
with

jack and lower the jack graduaUy

until transmission

can

Disconnect front exhaust tube

5

Disconnect

selector

lever

range

Plug up openings such as
ing pipe oil co ler tubes etc

car

oil charg

at

inhibitor switch
Disconnect

vacuum

When conneCting torque converter
measure distance
A

to be

Disconnect wire connections

7

3

to transmission

from manual shaft
6

ATl16

be removed and

take out transmission under the

4

se

curing bolts and crossmember mount

CAUTiON
Take

vacuum

diaphragm

tube

and wire

from

care

certain

that they

are

correctly

assembled
when

dismounting transmis
adjacent parts

sion not to strike any

Distance

A

More than 21 5

connee

mm

0 846 in

tions at downshift solenoid
8

Disconnect

from

speedometer

9

Disconnect oil

10

Disconnect

A

INSTALLATION

charging pipe

oil

cooler inlet and

outlet tubes at transmission
II

cable

rear extension

case

Support engine by locating

a

jack

under oil pan with a woden block used
between oil pan and jack Support
transmission by means of a transmis
sion jack
AT 28

InstaUation of automatic transmis
sion

on car

is in reverse order of re

moval However observe the

foUowing

installation notes
Drive

plate tUnout

Turn crankshaft
measure

one

fuU turn and

drive plate runout with indi

ATl17

AUTOMATIC TRANSM ISSION
Bolt converter to drive plate

4

Align chalk
both

marks

painted

across

After converter is installed rotate

sure

without binding
6

Pour

recommended

automatic

transmission fluid up to correct level

ough
7

oil charge pipe
Connect manual lever to shift rod

Operation

should be carried out with

manual and selector levers in
8

N

Connect inhibitor switch wires

not

I

Refer to pages AT 26 and 27 for
Inhibitor Switch

b

Adjustment

Inspect and adjust switch

as

it

positions

should

is in

R

positions

lamp

should

page
gine Idle

AT52 for

Checking En

D

12

Check to be

sure

that line pressure

is correct To do this

refer to page

AT 54 for Line Pressure Test

also light

placed

when selector lever is

in

R

13

Perform staU test

as

described in

page AT 55

position
Check fluid level in transmission

IO

For detailed

procedure

see

page AT

51
11

Move

lever

selector

positions to be

sure

through

aU

that transmission

operates correctly
engine

hand

through

whenever it has to be removed for

and to

service

felt

brake

idling
setting

at

the above
above

N

and

Back up

into

when selector lever is

be started when lever

2

and

brought

P

With
a

be

should

in

that transmission rotates freely

time transmission is shifted
See

Starter

operation only

crankshaft several turns and check to
be

ation

parts during disassembling pro

cesses

5

Check inhibitor switch for oper

9

Removal and Installation

N
R

to

applied rotate
disturbing

Without
move

D

to

selector lever
2

to

I

A slight shock should be

by hand gripping selector each

AT 29

Major

OlllHhaul

Operations

AUTOMATIC TRANSMISSIO N

MAJOR OVERHAUL OPERATIONS

Input
Torque

shaft

converter

Needleb

reftTsebraJce

Bearing

race

Needle bearins
L

Needle bearing

Output abaft
Oil chaIJing pipe

c

iI

Speedometer pinion
Valve

body

L

otIl
et

L Parking

mechanism

SAn01

AT 30

AUTOMATIC TRANSMISSIO N

Major Overhaul Operations

SERVICE NOTES
FOR DISASSEMBLY
proceeding

Before

with

dis

assembly thoroughly clean the outside
of the transmission It is important to
prevent the internal parts of the trans
mission from becoming contaminated
by dirt or other foreign matter
Disassembly should be dne in a
clean work area
Use a nylon cloth or paper towel
for wiping parts clean Common shop
rags can leave lint that might interfere
with the transmission s operation

4

Unscrew and

remove vacuum

phragm diaphragm

rod and a

dia

Remove control valve

7

body

ring
of

Bolts

used

3

different

lengths are
identify

Care must be taken to

individual bolt lengths and locations
Remove

DISASSEMBLY
1

Remove torque

transmission fluid
extension

and

converter

drain

through end of

place

manual valve from

valve

precaution to prevent valve
from dropping out accidentaUy
body

as a

rear

transmission on

TooL
SA T006

5

Remove

speedometer lock plate
Remove speedometer

bolt

retaining
pinion

SAnoa

8

Loosen band

piston
steIl
piston stem to
prevent front clutch drum from drop
ping out when removing front pump
locknut

2

Remove converter

housing

servo

and tighten

SAT102

6

its
pan and inspect
of
any foreign
analysis

Remove oil
An

contents

matter can indicate the types of

prob

lems to look for If the fluid is very
SAT003

dark

smells burned

eign particles
clutches
men
A

or

band

may

tacky film

need replace

that will not

wipe

clean indicates varnish build up which
3

Unscrew

and

solenoid and a ring

remove

downshift

can cause

valves

SATOOB

contains for

the frictional material

servo

and clutches to

stick and may inhibit pump pressure

9

Remove input shaft from pump
Attach Tool to pump and remove

pump

Do not

aUow front Clutch to
AT31

Major Olll1rhaul Operations

come

out of

AUTOMATIC TRANSMISSIO N

position and drop

onto

floor
Take care that shaft is not inserted
backward

during reassembly

I

AT124

SAT012

15
To

brake Iin inus from
peeling do not stretch the

prevent

cracking

or

flexible band unnecessarily Before
moving the brake band elwaYI
it with a clip as shown in the

re

secure

figure

Back out

servo

ajtaching

carefuUy
band

about haIf way
bolt

apply

servo

Using

band

air gun
loosen

to

pressure

Remove band

an

servo

retain

ing bolts and puu band servo

be

low
Leave the

Remove

10

front

washer and bearing

clutch

thrust

race

moving the

clip

i

fter

ition

ra

brake band

Flexible

type

bend I
nk

oW

Unit

mm

in

157

16

ApprOXimately

SAT106

2

0 08 dia wire clip

Remove

planetary carrier
planetary carrier

rear

snap ring and

rear

SAT010

13
II Back off band servo

piston

stem

Remove pump thrust bearing and
thrust washer

rear clutch

to release band

17

SAT013
SAT011

14

Remove

planetary
12

Remove brake band strut Brake

band front and

rear

may be removed

together

32
AT

clutch assemblies

rear

rear

clutch hub

front

carrier and connecting sheU

clutch thrust bearing front plane

tary carrier thrust washer and thrust

bearing

Remove

output shaft

s

ap

ring

AUTOMATIC TRANSM ISSIO N
18

Remove

rear

Major Overhaul Operations

connecting drum

with internal annulus gear

SAT020

SATon

25

Remove

Be

22

careful

not

to

lose parking

pawl spring and retainer washer
19
a

Pry off

one

screwdriver

low and

one

reverse

inner

clutch

way

low and

thrust washer

return

race

spring and spring thrust

return

ring

end of snap

ring with
ring from
brake assembly while

Remove snap

reverse

applying plier force

o

in direction of

arrow

01

L
C

r

Remove outpu1 shaft with gover

23

and

Tilt

extension

remove

housing

low and

11

AT021

air gun with a

an

tapered

rubber tip carefuUy apply air pressure
low and reverse brake
to
remove

piston

nor

20

Using

l
J
0

CJ

0

O

26

I

J
EiL

upward

reverse

brake

clutch assembly

SAT022

24

Remove

governor thrust

washer

and needle bearing
Remove

attaching
21

Remove

rear extension

Tool

one way

clutch inner

hex head slotted bolts

race

using

27

Pry off

snap

ends of

parking

remove

the

lever

shaft lock nut

plate @

and

rings

@

CD

from both

brake lever

@

and

Back off manual
and

parking

remove

rod

manual

ID
AT 33

AUTOMATIC TRANSMISSION

MsjorOverhaulOpsrstions

6

1

Using

edge

a

feeler gauge and

measure

and pump

straighf

clearance between gears

cover

Standard clearance
0 02

0 04 mm

0 0008

0 0016 in

Replace if the clearance exceeds
0 08

u

AT133

28

Remove

inhibitor

manual shaft by

cming

0 0031 in

SAT024

and

switch

loosening

mm

two

se

bolts

3
Inspect gears and aU internal
faces for faults and visible wear
4

sur

Measure clearance between outer

gear and crescent

Standard

e
dearanc

0 14

0 0055

COMPONENT PARTS
The transmission consists of many
parts that are quite alike in

c1

yet machined
When

oIerances

e

parts be

sure

part rack

so

to

to

mm

0 0083 in

Replace if the clearance exceeds

small

construction

21
0

25
0

mm

0 0098 in

very
7

disassembling

they

can

be put back in

general

purpose

vent before

non

inspection

Gaskets seals

0 16 mm

0 0016

0 0063 in

flanunable sol
or

reassembly

be

very

to

tests whenever

it

0 04

Replace

and similar parts should

replaced It is also
perform functional
is designated

0 16

mm

Of

important
SAT025

if

the clearance exceeds

0 0063 in

course

it is

good practice

place aU seal rings during

l
OIL

Remove

front

pump gasket and

O ring
Inspect pump body pump
shaft and ring groove areas for wear

Measure clearance between outer

gear and pump

20
0

0 0020

Replace
25
0

w

mm

if the clearance

exceeds

0 0098 in

housing
AT 34

cover

Sealring
w

4

11

I

AT1

5

SAT023

8

Mount pump

pump

Remove pump

reo

1earance

yw

mm

0 0079 in

up pump
2

to

overhaul

housing

Standard dearance
0 05

an

J

PUMP
5

I

between seal

groove

Standard clearanca

the unit in their proper positions AU
parts should be carefuUy cleaned with
a

Measure clearance

ring and ring

place them in order iD

from pump

cover to
SAT026

housing

gears

on

housing in

Tool Set

with inner and outer
it

and instaU pump

pump housing
assemble oil pump

Temporarily

AUTOMATIC TRANSM J
Totar indicator reading
Less than 0 07 mm

SJON
10

Tighten pump securing bolts
specified torque

0 0028 in

Oil pump

b

t

housing

to

to

oil pump

cover

1

5 9

t

0 6
4 3

Recheck

AT166

and

9

Major Overhaul Operations

Set run out of the cover to within

7 8 N m
8 kg
0

m

5 8 ft lb

run

out

Replace

Q ring

gasket

0

ST25580001

specified total indicator reading

AT264

FRONT CLUTCH

ring
O

retainer

Spring

Dish plate
Driven plate steel plate
Drive plate

riction plate

Snap ring
SAT086

35
AT

AUTOMATlG TRANSMISSIO N

Major Overhaul Operstions
Using

1

a

screwdriver

remove

driplate thickness

Standard

large

50
1

clutch retaining plate snap ring

1 65 mm

0 0591

0 0650 in

J

L

C

S

0 79

Cut off hatched portion

seal
ATl48

and instaU inner seal and piston
illustrated Be careful not to

as

stretch seals during installation
Neyer
lubri

4

Remove

spring

snapring weak
and warped

Lubricate clutch drum hub and

seals

in

wear on

coil springs

spring retainer

20

mm

broken

or

J

Unit

Check for

7

1

retainer

a

mbl

clutch

dry Iways
thoroughly

to its components

and

springs

Remove clutch plate assembly

2

SAT031

SAT029

AT1S0

9
For easy removal of piston from
drum mount clutch on pump Use an

3

clutch

Compress

remove

springs

and

snap ring from spring retainer

Assemble piston

careful not

to

air gun with

damaged during instaUation After in
stalling turn piston by hand to ensure

a tapered rubber tip to
carefully apply air pressure to loosen
piston from drum

aUow seal

being

5

that there is

no

to

kink

or

become

binding

SAT030

6
When
toe

tips

wheel

AT 36

Tool
of

th

is

to

legs

b
with

used

cut

grinding

Check clutch drive plate

wear or

must
in

facing

for

darnage Drive plate thickness

no1 be less than 1 4 mm

0 055

10

Reassemble spring

ReinstaU soap ring Be
properly seated

and retainer

sure

snap ring is

AUTOMATIC TRANSMISSION
13

Measure

tainer

clearance

plate and

snap

between

re

Major Overhaul Operations

REAR CLUTCH

ring

Specified clearance
1 6

2 0 mm

0 063

0 079 in

try other retaining
un
plates having different thicknesses
is
obtained
til correct clearance
If

necessary

Available

retaining plate

Thickness

II

Install dish plate with dish facing

outward

mm

Part number

in

10 6

0 417

31537 XOIOO

10 8

0 425

31537 XOIOI

110

433
0

31537 X0102

112

0 441

31537 XOI03

0 449

31537 XOI04

II 4
116

31537 X0105

0 457

AT153
1

Rear

2

Piston

3

Dished plate

4

Coil

5

6

Snap ring
Spring retainer
8 Snap ring
9 Drive plate
10 Driven plate

clutch drum

7

spring
Retaining plate

Service procedures for
are

essentially the

front

same

with the foUowing

clutch

retainer plate and snap
0 8

1 6

0 031

install driven

then

plate
plate

a

drive

plate

plate

steel

check

Service

Data

and

Specifications for proper quanti1y of
plates Now install retainer plate and
snap

SA

ring

mm

0 063 in

T034

friction

and repeat in this order until
correct number of plates has been
instaUed

ex

clearance betWeen

Specified

Now

clutch

those for

ception

SA T033

12

rear
as

ring

14

Testing front clutch
With front clutch assembled

pump

cover

direct

a

jet

on

oil

of air into

hole in clutch drum for definite clutch

operation
SAT035

Test

rear

clutch

AT152

1

Snap ring

2
4

Retainer plate
Drive plate Friction plate
Drive plate Steel plate

5

Dish plate

3

III

AT157

AT37

AUTOMATIC

Maior Overhaul Operations
LOW

TRANSMISSIO N
band friction material for

Inspect

REVERSE BRAKE

wear

spots

If cracked

chipped

or

burnt

the

replace

apparent

are

band

Piston

Spring thrust ring
Low and

reverse

Return

return

spring

tluust washer

SAT036

Dishplatc
Driven plate Steel plate

components for
wear
Rep ace piston
other
and
aU
a rings
components as
Check band

Drivc platc Friction plate

servo

and scoring

Retainer plate

Snap ring

necessary

SAT094

Examine low and

reverse

brake for

DriY 4l plate thickness

damaged clutch drive plate facing
and worn soap ring
Check drive plate facing for wear or

Standard

damage if necessary replace

Allowabl

1 90

2 05 mm

10 0748

0 0807 in

limit

1 8 mm 10 071 in

Test piston return spring for weak
ness Discard if it is too weak

GOVERNOR
BRAKE BAND AND BAND SERVO
3

To control valve

I

Gornot
15

prc

z

1
2

Anchor end pin
Band strut

3

Apply

4

Release

5
6

Return spring
Band servo piston stem

7

Band

8

Servo retaines

9

Brake band assembly
Trammission case

10

servo

4
From control valve
Linc prcssur
I
J

piston

ATQ90

AT290

AT 38

11

1

Primary governor

4

2

Secondary governor
Governor valve body

5

3

Oil distributor
Output shaft

Major Overhaul Operations

AUTOMATIC TRANSM ISSIO N
governor and check
valves for indication of burning or
Disassemble

Governor valve sprIng chart

scratches Inspect springs for weak
ness

burning

or

Replace parts

as

Free

necessary and reassemble
I

Do not interchange components of

secondary

and

primary

governor

valves

length
As

installed

I

m

Lm

0

Wire dia

SAT039

Assemble governor

D

oil distribu

on

tor

l
t

Governor valve body

to

oil

distributor

aOlriMI

IIlI1

SAT038

No of

Outer

Wire dia

Valve spring

mm

Primary

in

0 45

governor

0 0177

Secondary

0 70

governor

0 0276

active

coil dia

in
mm
8 75

length

coil

mm

5 0

218

planetary

carrier

3445
0
5 5

9 20

25 1
0 988

0 3622

Clearance

cannot

be

Check

clearance

washer and

between

planetary

a

feeler
Standard clearance
0 70 mm

0 20

0 0079

Replace
080

mm

mm

in

7 5

0 295

N

kg

lb

2 109
0 215

10 5

10 788

413
0

100

474
0

426
2

that have been damaged by over
heating wiD have a blue discolora

rI

is

pinion

carrier with

Load

Length

tion

1

divided into its individual components
If any part of the component
faulty replace the carrier as a unit

in

0 858

PLANETARY CARRIER
The

InstaUed

Free

1

J
In

AT167

0 0276 in

if the clearance exceeds

0 0315

in

Check

darnaged

planetary
or

worn

gear

sets

for

gears Gear sets

SAT040

AT 39

AUTOMATIC TRANSMISSION

MajorOverlJaulOperations

CONTROL VALVE BODY

relief check valve

The valve body contains many pre
cision parts and

requires

they

can

in the

4

extreme care

when parts are removed and serviced
Place removed parts on a parts rack so
be put back in the valve

related

sleeve

aod plug and second lock valve

aod spring Place each loose part

Remove

regulator

side

valve

plate

spring

A

pressure

spring

seat

rack to retain

correct

on

sequence of

a

as

sembly

body

positions and sequences
Care will also prevent springs and smaU
parts from becoming scattered or lo t
L

and

baU

springs

same

Spring

seal

Spring

Remove oil strainer aod its attach
nuts and bolts

ing screws

II

L

Side plate

A

SAT041

2

Disassemble

SA T042

valve

body

and

it

remaining attaching bolts and nuts to
carefully separate lower body separa
tor plate and upp r body

5

Remove

ide

plate

timing valve and spring
tle

valve

B

2nd 3rd

vacuum

throt

thro1tle back up valve and

2nd

spring
spring

aod

the kickdown valve and

Place each loose

part

on a

rack

to retain sequence of assembly

3rd timing valve

HT61000800

Spring

AT168

a

9

9

J

Q

J IOIi

c

a
I

io

9I

J

19uDdI

L
uii

I

1
l

I
AT1 9

Throttle back up valve
3

valve body separation do
not scatter or lose orifice check valve

During

servo

40
AT

orifice check valve and thro11le

down
Kick

vaive
Side plate

B
SAT043

AUTOMATIC TRANSM ISSIO N
6

Remove

modifier

side

valve

shift valve

C

plate

Manual

pressure
2nd 3rd

and spring

spring and plug and
spring

valve

I st

mission

2nd shift valve and

Place each loose part

on a

valve

body

removed when

was

removed from trans

was

Include

inspection

Major Overhaul Operations

valve

in

subsequent

and service sequence

rack to

retain sequence of assembly

1fu

h

d@4tt

nib
fkq T
AJ

1

It

2M

J

35t1t

L
i

w

ml

k

w

l

Mw

i1 Wip j1 11

I

jtltwmJ

iiJU
PbEH1 1
Jt

bOdY

111

@n

sary

Scratches

cause

oil to

I

valves assembled with close tolerances
into precision bores of the valve body
If inspection reveals excessive clear
ances

0 03mm

0 0012 in

or

rather than attempt rework
If one or more valves are sticking
from varnish deposits or burns resulJ

ing from deteriorated oil or overhea1
ing you may be able to clean the
valves and valve bodies

use

very fme type
of cutting material Never use emery
croeus

cloth

scratch

cloth which is

Always

as

is

it

the

too

bo

valves

Scratches

can

of varnish

or

or

and

valve

lead to future

foreign matter

can

bores

deposits

0

nnn

0

Spnng

0

0

0
1

oo
0

3rd shift valve

Slde plate

I

SAT046

e

I

A

During cleaning do not remove the
sharp edges of the valve When edges
rounded or scratched entry is pro

are

vided for dirt

or

foreign

matter

to

work into the sides of the valves and

10 Check oil passages in upper and
lower valve bodies for varnish deposits
Or

otber damage that would
movement Check thread

ed holes and related bolts and screws
for stripped threads replace as needed
II

Test valve springs for weakened

load condition

Spring

Refer

to

Valve Body

Chart for spring specifications

hinder valve movement
The valves may be cleaned using
alcohol
bodies

or

lacquer

thinner The valve

be dip cleaned with a good
carburetor cleaner or lacquer thinner
can

Valve body spring chart

Do not leave valve bodies
in carburetor cleaner
minutes

Rinse parts

SUbmerged
longer than five
thoroughly and

Free length

dry
I

As installed

I

Lubricate all
matic

a

coarse

nDllD
o

0

g

more

between the valves and the valve body
bores replace the en1ire valve body

can

o

Pressure modifier valve

impair valve

newly manufactured valve body
manufactured
precision
represents

marks

Co

scratches

A

score

correct oil passages

o

SAT044

inspection

bypass

Plug

nd

Precaution for

or

vun

C

11
A

for
separator
plate
damage Replace if neces

Spring

Spring
2 n d shif t valve

or

and result in system malfunction

1 II

I

Check

scratches

j

Lower valve

1 it

9

parts in clean auto
transmission fluid before reas

sembly

l

7

Check valves for signs of burning
Replace if beyond clean up
8

Check oil strainer for general
Replace if necessary

dition

i5

O

r ij

0

Wire dia

con
SAT039

41
AT

Major Overflaul Operations

Valve

spring

AUTOMATIC TRANSM ISSIO N

Wire dia
mm

in

Outer coil
dia
mm

Manual detent

3
1
0 051

Pressure regulator valve

12

0 047
Pressure modifier valve

04
0 016

1st

2nd shift valve

0 6
0 024

2nd

3rd shift valve

0 7

0028
2nd

3rd timing valve

0 7
0 028

Throttle back up valve

0 8
0 031

Solenoid downshift valve

55
0

0 0217
Second lock valve

0 55
0 0217

Throttle relief check valve

09
0 035

in

3
7

InstaUed
No of
active coil

15

13

5

16

18

15

14

12

36 0

22 0
0 866

16

0 2185

5
6

32 5

1 417

0 2185
55
5

41 0

280
1

0 287
5 55

32 0

1 614

0 244

3
7

18 5

260
1

0 272

6 2

43 0

0 728

0 260
6 9

4
32

1 693

331
0

6 6

in

276
1

0 461

4
8

mm

33 5
319
1

14

0 256

26 8
1055

Load

Length
mm

0 287
7
11

Free length
in

26 5

N

53 9

1 043

5

9 0

28 62

10

354
0
16 0

0 630
17 0
0 669

27 0
1 063

18 8

0740
5
12
492
0

210
0 827

19 0
0 748

12 1

5
27

5
23
0 925

kg lb

1
0

0 2

6 129
0 625 1 378
13 73

I

40 3 09

39
5
0 55 1
21

18 83
1 92 4 23

5 88
0 60 1
32
5 88

060

32
1

2148
2 19 4 83

Orifice check valve
0 23
0 0091

Servo orifice check valve

42
AT

5 0

0 197

12

15 5

0 610

5
11
453
0

0 10
0 01 0 02

AUTOMATIC TRANSM ISSIO N
12

Assemble side plate A group of
into lower valve body Reins1aU

side

parts

Sid

plate and fmger tighten

side

screws

Major Dverhsul Operations

plate C group

in same manner as

A group

Assemble side pla1e B group and

Pia

talA
Pressure

llat
regl

Pressure

Spring

Cl

r

seat

J@
U

sleevei

regulator plug

Second lock valve

Upper valve body

Manual valve

SAT095

13

cD

Tighten

screws

Side plate
2 5

valve

3 4 N

0 25
1 8

to

body

15

Install upper and lower valves

cD

Upper snd lower VBlves

m

0 35

kg

2 5
m

3 4 N

0 25

2 5 ft lb

1 8

m

0 35

kg

m

2 5 ft lb

Reamer bolt
4 9
14

Install orifice check valve

6 9 N

0 5

valve

3 6

spring 1hrottle relief valve spring and
steel ball in valve body

m

0 7 kg m
5 1 fNb

AT173

Orifice check valve
ST25160000

16

cD

Install oil strainer
Oil strsiner to valve
2 5

fO

25

1 8

0 35

kg

AT430

m

2 5 ft lb

The manual valve
the valvB

body

3 4 N m

body

is inserted into

when the latter is in

stalled in the transmission

43
AT

Majo OverhaulOperations

AUTOMATIC TRANSMISSION

FINAL ASSEMBLY

bearing bearing
O ring seal ring

installing assembling needle

When

race
use

ring and
the foUowing

snap

iUustration

procedures

as

a

guide

to instaUation

and locations

F

Q

gE
do

0

a
0
c

2
Q
u

Co

e

Q
0

c
5

8

O
Q

i
d

Q

C

QC

e

8

C

S

oU

ll

0
3

e
oS

Q
u

Co

@

e

cii

r

1

ll

Ji

a8
Q

a 5

H

Q
U

Q
U

e

e
C

S
d
@
Co

a

j
Q
U

@Q

1

5

zj
8

e

I

l

f

il

d
Q
U

e

S

e

C

C

a
Q

f

Co

cii

5

a

s 8
z

t

S

e
Co

IS

SA T099

44
AT

AUTOMATIC TRANSMISSION
I

with the fmal

proceeding

Before

it is im

assembly of all components
portant to verify that the case housing

be

can

used

rear

of case

WARNING
Check that return spring is centered

Have
tray available with clean trans
mission fluid for lubricating parts
a

jeUy

slotted

start hex head

bolts into inner race from

and parts are clean and free from dust
dirt and foreign matter use air gun

Petroleum

Align and

4

Major Overhaul Operations

on

before tightening

race

to

washers during installation All
seals and rings should have been

secure
new

installed

before

beginning

final

as

semb ly

Tighten

J
G

the bolts

One way clutch inner race to
transmission

case

13

m

18 N

1 3
9

1 8

m

kg

13 ft lb
7

Using an air gun with a tapered
tip check low and reverse
brake operation

I

I

i

l
7

rubber

i

i

lfiu

ST25570001
ST25490000
GG91060000
SAT047

2

Lubricate

reverse

piston

and

instaU

and

low

into the case

Install steel dished pla1e first then

5

steel and friction plates

retaining plate

and snap

and

fmaUy

ring

8

InstaU governor thrust washer and

needle bearing

3

InstaU thrust
thrust

spring

clutch inner

ring piston

washer

and

return

one

way

race

6
Oe

JGOC

o

clearance

j

GOo

0
v

c
Co

cl

tainer

IIU
l

0

1

f9

JP
r

r

completely

c

o
o

o

After low and

been

o

II

s

ISTOZl

between

plate

reverse

brake has

assembled

snapring

measure

and

re

If measurement exceeds

specifications it can be adjusted by
replacing retainer plate with one of a

9

different thickness

sembly

Low and reverse brake clearance
0 80

1 25 mm

0 0315

0 0492 inl

Slide
on

distributor as
governor
shaft
from fron1 of
output

shaft Install shaft and governor dis
tributor into case using care not to

damage distributor rings
45
AT

Major Overhaul Operations

AUTOMATIC TRANSMISSION

V

D CO
c

a

j

10

InstaU

way

clutch

one

way sprag

outer

race

into one

attached

Install mapring

13

on

shaft

16

Adjust front end playas foUows

to

connecting drum
Arrow on sprag must face front of
transmission

Front end p1aY

1

JLv

r

l J CC

j
14

Secure thrust bearing and thrust

washer with petroleum jeUy and instaU
rear

planetary

carrier

SAT091

InstaU

connecting drum with
sprag by rotating drum clockwise using
a slight pressure and wobbling to aIign
plates with hub and sprag assembly
Connecting drum should now be free
to rotate clockwise only This check
will verify that sprag is correctly in
II

2

Front clutch

5

Transmission

thrust

6

Oil pump ga5Ket
Oil pump cover

washer

3

Oil pump cover
Front clutch

4

Rear

7

bearing

case

race

clutch

stalled and operative

I
SATOSS

Assemble front and

Install

rear

planetary

clutches

internal gear front planetary
carrier and connecting sheU Secure
thrust

15

rear

front

bearings

with

petroleum jeUy

carrier snap

ring
This snap ring
clutch drum snap
are

using

correct

sufficient spaco
int drum

InstaU

46
AT

rear in1ernal

gear

thinner than

ring

size
to

groove

drum forward a

12

is

far

so

8

ba sure you

If you have in

install

snap ring
pull connecting
as possible
This

will

give

anco

to install drum nap

I
4

you sufficient groove clear

ring

SATOS7

AUTOMATIC TRANSM 15510 N
2

Install assembly into transmission

caSe Check that parts are properly
before
with
seated
proceeding

from

face of clutch drum to top of

thrust bearing

race

dilliension

B

6

Major Overhaul Operations
thrust

Install

Measure

washer

pump

from top of oil

shaft to thrust

washer dimension D

measurements

L fffi

I

llV
Oil

@
SAT05S

3

l
sing a

seven

dial gauge

inch base

hub thrust

or

caliper with
from

measure

bearing

SAT061

1

Depth

2

Front clutch drum

3

Rear clu tch drum

4

Thrust

pumpU

SAT096

gauge

bearing

a

rear

dimen

race to case

sion A

0 004

mm

end

front

3

A

Difference between dimension

7
0 1

in B

and

C D

is

play and must be within

specified value

cID

Specified

@
1

SAT059

2

Dial gauge
Front clutch drum

3

Transmission

4
5

Bearing race
Thrust bearing

6

Rear clutch drum

0 5

shaft

to

0 020

top of oil pump
installed
dimension C
gasket

Measure

5

from

case

Front

0 031 inl

end

with front

1

front end play

0 8 mm

play

can

be

adjusted

clutch thrust washers

of

different thickness

c

G

k

Available front clutch thrust washer
I

Thickness

I

ty

oilPump
SAT063

fU
4

Assemble

front

drum assemblies
l1at

on

bearing

together

bench Be
is

and

rear

properly

Part number

S
I
0 059

31528 XOlO6

7
1

0 067

31528 XOl05

19

075
0

31528 XOIOO

2 1

0 083

31528 XOIOI

3
2

0 091

31528 XOI02

5
2

0 098

31528 XOlO3

106
0

31528 XOI04

2 7

clutch

hub thrust

seated

in

0

17

and lay them

sure rear

mm

Measure

III

SAT064

Adjust

total end

playas

follows

This adjustment is seldom required
because this type of thrust bearing and
47
AT

Major Overhaul Operations

will normally show very little

race

We

wear

also have

0 0197 in

standard taler

a

of 0 25 to 0 50

ance

However

mm
we

0 0098 to
present

are

18

Install brake band band strut and

band

servo

Lubricate

Orings

servo

before installing Care should be taken
to

checking procedure

correct

ing

AUTOMATIC TRANSMISSION

avoid

damaging
mbling

O rings when

21

Mount

oil

pump gasket
petroleum jelly

with

pump

pump to transmission

case

on

oil

Align

and install

re
n

j

i
C1l

E

i

Tott

r

SAT069

Jf

play

22

SA T092

Front clutch
thrust
2

5

washer

6

3

Oil pump cover
Front clutch

4

Rear

7

Transmission

case

Oil pump ga5ket
Oil pump cover
be aring

19

Install

and

torque the

bolts Loosen piston

rfl

retainer

stem

9
4

9N
6

3 6

0 7

Meamre

structions in

Measure

structions in

5

step

using

under

12

5 1 ft b

1 5

m

m
kg

11 ft bl

Piston stem lock nut
15

39N

in

11

4 0

m
kg

29 ft lb

N 16
GG91060000

Difference

AQ I
end

15 N

1 2

above
3

secure

Piston stem

m
kg

1 5

C

Jue
specified v

full turns and

dimension A using in
2
and 3
steps 1
dimension

installed

Back off two

under No 16 above
2

correctly

that brake

Torque piston

9

1

sure

tern to

rfl

m

race

5
0

is

strut

with lock nut

Servo piston retainer bolt

clutch

band Make

Adjust

band

mm

between

0 004 in

dimension

and C is total

and it must be within speci

play

fied value

Specified
0 25

total end

play

0 50 mm

0 00980 0197 inl

If difference
0 008 in
ance

A2
Q

Jletwen

and C is not within taler

select proper size oil pump

bearing

ST25490000
mm

cover

race

20

not

mm

servo

SAT070

brake

band and strut from falling out Do

Available oil pump
Thickness

Finger tighten brake band
stem enough to prevent

piston

in

cover

bearing

adjust

bnlke band at this time

race

Part number

12

0 047

31556 XOlOO

14

0 055

31556 XOIOI

16

0 063

31556 XOI02

18

0071

31556 XOI03

20

0079

31556 XOI04

2 2

0 087

31556 XOl05

23

Before

tion of valve

proceeding with installa
body assembly perform a

fmal air check of all assembled

ponenjs

have not overlooked
bolts

or

sembly
48
AT

This will

ensure

that

com

you

tightening of any
damaged any seals during as

Major Overhaul Operations

AUTOMATIC TRANSMISSIO N
Air check

Q

point

Rear extension to transmission

29

case

I11ent and install

20

25 N

2 0
14

m

2 5 kg

dl
m

Check pump

44
4 5

18 ft Ib

33

54 N

m

5 5

kg

to

transmission align

converter

housing

m

40 ft Ibl

n

1

Band

2

Rear clutch 1

servo

Front

apply 9

clutch 11
release

3

Band

4

Governor feed 1

5

Low

servo

reverse

SA T014

10

brake 12

Install control valve body Be

27

valve

manual

Using an air gun with a tapered
rubber tip perform air checks
4

is

in

alignment

sure

with

selector pin

30

Before

installing

phragm valve

measure

vacuum

depth

in which it is inserted

This

ment determines correct rod
ensure

proper

dia

of hole

measure

length

to

performance

u

o

tK

o oo1
SAT078

28

Tighten control valve body attach

ing bolts
25

Check

spring

that

and

parking pawl

washer

are

correctly

pin

assembled

dl

5 4

1

74N

0 55
4 0

m

0 75 kg

m

6

vary in

c

l

0

length

Note seated valve body
Transmission case wall

3

Vacuwn

5

diaphrngm
Diaphragm rod
Valve body side plate

6

Vacuum

4

5 4 ft Ibl

Control valve body

2

attaching

throttle valve

bolts

Care must be taken to

ensure

that each

correct

hole

bolt is returned to

o

0

1

o

2

o

SAT073

26

Install

rear extension

49
AT

AUTOMATIC TRANSM15510 N

Major Overhsul Operations

Throttle modulator valve rod selectioo
L

Measured depth
Under

55
25

J 0059

25 65

26 05

1 0098

15
26

55
26

26 65

Over 27 15

31

Install

vacuum

in

Rod

length

in

mm

Part number

29 0

142
1

31932 XOI03

1 0256

5
29

161
1

31932 XOI04

0295

1 0453

30 0

l81
l

31932 XOlOO

10492

1 0650

5
30

201
1

1

27 05

mm

1

0689

diaphragm

1

310

34

31932 XOI02
0
22

31932 XOIOI

Install inhibitor switch Check for

proper

operation

circuit

tester

in each range

using

a

Refer to Minor Adjust

ment

37

SAT082

check bushing contact

Before installing down shift sole

32

check to

noid

Carefully inspect torque converter

for damage Check converter hub for
grooves caused by hardened seals Also
area

verify that it is oper
Use a hot lead and

ating properly
ground to check solenoid

35

Before

alignment

installing
and

oil

pan

check

operation of control

lever and
Blow

parking pawl engagement
mechanism with air to clean

Make fmal check to be
are

sure

all bolts

installed in valve body

38

A

Lubricate oil pump lip seal and
before installing con

converter neck
verter

Install converter
converter is
33

Install down shift solenoid

pump drive gear

L

@J
E

F

SATOS1

50
AT

properly

36

Install oil pan with

tfl

Oil pan
4 9
0 5
3 6

to

new

gasket

transmission ease

6 9 N
0 7

m

kg m

5 1 ft Ibl

being

sure

that

meshed with oil

AUTOMATIC TRANSMISSION

Trouble

shootingsndDiagnoses

TROUBLE SHOOTING AND DIAGNOSES
sian front

1 Converter housing

PRELIMINARY
CHECKS Prior to

Rubber O ring of oil pump housing
Oil pump housing oil seal transmis

road testing

The

customer

much information

should
as

supply

as

includ

possible

any unusual characteristics
accompany the
lcaoimnpt

ing

Bolts of converter

f CD

Verify customer complaint

that

seal

Crankshaft oil seal

I

housing

to case

I

8

1 II

1
IL

Fluid level

1

I II

To properly check l1uid level
Place car on a level surface

chocks in place and
brake securely
parking
apply
3 Warm up engine on fast idle
4 Return engine to curb idling speed
5 Slowly
selector
move
the gear
through tlie entire shift pattern
and return it to park
6 Remove the dipstick clean it and
replace it fully in the filler tube
7 Quickly remove it again and read
2

I

I
I

wheel

Put

O

If

filse

the level
2
L

dipstick indi
cates the transmission is approximate
ly 0 4 liter 7 8 US pt 3 4 Imp pt
low Add only clean Dexron transmis
The

sion l1uid

mark

or

on

the

Transmission and

rear

extension

Junction of transmission and

rear

Vacuum

if

diaphragm and downshift

solenoid

extension

Speedometer pinion sleeve

Oil cooler tube connectors

Rear extension oil seal

Oil pr

ssure

o

inspection ports

equivalent

Fluid leakage
To detect
I

Raise

car

2

Clean

area

3 Start

place
wait

a

suspected of leaking
engine apply foot brake
gear

a

l1uid leak

selector in drive

and

few minutes

4

Stop engine

5

Check for fresh leakage

I

If the transmission breather is

8US

pected
I

Raise car

2

Clean the

3

Run the car at

4

Check the breather for fresh leak

area

around the breather

highway speeds

age
To aid in locating leaks

following list of seals and

use

gaskets

the
SAT104

AT 51

TroublfHhootingand DilJgnoses

AUTOMATIC TRANSM 15510 N

Fluid condition

pIAGN STIC ROAD

Transmission fluid color and tex

TEST

from

trouble shooting When checking l1uid
level examine the transmission l1uid

preliminary

and note its color

earlier If the

Some

fonns

common

and odor

texture

of contami

nation are listed below
I

With

a

coolant leak

in radiator
Water Contami

water

through filler tube

entering
breath

or

er

Fluid

light

to

dark

brown and tacky Oxidation
or

road

Underfilling

specific

conditions
g steep
e

neutral

plied

the Symptom Chart on page
It may be necessary to repeat

sections

of the test under different

throttle conditions
full throttle

g light
After completing the

road test

compare the test results to
Trouble
lIIe
shooting Chart on page
AT 56

Idling speed
0

full throttle

Range 2
Manually shift

Prior to road testing check engine
oil and coolant levels and fill

as neces

sary

in

2

park position

gear selector through all
detent

clicks

should

with the range indicator

52
AT

move

or

Symptom

button and slowly

ranges

the
The

correspond

park

the

mission

should

regardless of

from
ty

P

Mark all results on the

Drive

shift

enough

to

R

the

speed
re

or

gear

engine

Range I
Manually shift the gear selector
I

creases

Note

re

lts

shift

however

quality

downshift

to
It

im

to 2nd gear and downshift

gear as road speed de
Accelerate and decelerate in
1st

1st gear to determine engine braking
Note results
The transmission should not
into 1st gear from

0

shift

range if tha car

road speed is above approximately 50
km h 30 MPHI

Chart

to

in 2nd

remain

car

car

Reverse

Manually

depress
move

In

the gear selector to

range
slippage hesita
tion or abnormal condition The trans

should be locked in position unable to
roll

Shift linkage
Start

and neutral

ranges

other

Check for

2

mediately
again to

and start the engine Stop the engine
and repeat the procedure in all other

or

conditionS

5

L

range

noise

slippage

or

ROAD TESTING

Place the gear selector in P

Engine 011 and coolant levels

detent

for

If necessary
drive the test sequence under different
throttle openings e g light medium

range

range

ap

shifts and in all gear ranges Note shift
quality and timing km h MPH

should

Park Range

are

no move

Drive Range
Manually shift the gear selector to
ran e 0 and note shift quality
Drive the car through all automatic

6

tions

bands

or

4

Engine Idle

700 i 100 rpm

clutches

volutions Note

Check and adjust idle to specifica

selector

gear

and note quality In

ment Note results

medium

e

Overheating

at

no

abnormal

on

N

and there should be

check

or

Over

select

pressure
a

shift the

to

Follow the test sequence as out
lined in this section and mark the

AT 59

Coolant leak

3 Varnished

and

gauge

a

P

hills freeways etc

results

nation

Road

vacuum

If the customer has

complaint

odor

2 Milky Pink Fluid

And also install

car

similar to those described

Slight engine

the

car

in the

gauge

Worn friction material
an

a

perform

outlined
inspections
is not equipped with
tachometer install a portable tacho

suitable

burned odor

Without

Prior to road testing

tneter

Dark or Black Fluid

Neutral

Manually

in transmission

aid greatly

ture can

3

the gear

selector

and note shift quali
car

detect

in

reverse

slippage

abnormalities Note results

or

long
other

7

Record line pressure and governor
pressure at each range and at each
throttle

vacuum

in accordance

with

the pressure testing described below

AUTOMATIC TRANSM 15510 N

shooting
Trouble

and

Diagnoses

Car speed and line pressure when shifting gears
Intake manifold vacuum
kPa

mmHg

Kiekdown

o

Propeller shaft

km h MPH

0

3
13

Car speed

Gearshift

inHg

100 3 94

Full throttle

0

O2

60

0

0

107

115

0

0

105

97 65

0

0

53

0

O2

23

31 14

O2

0

63

70 39

0

0

32 25

20

O2

0

I

I

40

68 38

45

18

II

54

42

1 970

2 220

3 480

3730

3 410

3 160

1720

1470

19

750

1 000

44

2 040

2 290

1 300

1 050

66

33

7

46 33

Line pressure

revolutions rpm

71
60
28

II

350

29

1750

kPa

530
5 4

441
4 5

300

1181

I

I

54

46

33

29

1 750

1 500

549

500
1

549
5 6

Car speed
v

where

can

be calculated by the

0 0307 x

Np

1

2 x

following

rx
x

Car speed

Propeller

RF

Final gear ratio 13 700

0

Tire effective radius

its diameter

01905xNp

V

Car speed

Np
RF

Propeller

r

m

64

87

706
7 2 80

102

706
7 2 80

102

formula

rpml
185nO SR14 0 301
a

m

circle

2xll xrxNPx60
x

360
63

MPH

shaft revolution
Final gear ratio 3 700
Tire effective radius

in

The ratio of circum
to

6 1

3 141

RF
where

598

km h
shaft revolution

The ratio of circumference of

v

100

1 000

V

to

7 0 77

Np x 60

x

RF

Np

r

686

600

5 6
40 0

kgem2 psi

its diameter

rpm

18SnO SR14

85
11

in

of a circle

3 14

53
AT

shooting
Trouble

AUTOMATIC TRANSMISSION

iagnoses

8m

Shift schedule

Full

1

Kickdown range

throttle

1
13 3

E

l

I
I

I

I

0

r
3

112

1

40 0

e
E

E

I

300 11 81

I

I

I
I

d
0

5

3

I

200 7 87

c

S

t3

I

26 7

f

2 t

1t2

2Y3

2

000 3 94

2

3
53

I

OO 15 75

I

I
I
I
I

66 7

19 69

500

c

0

1

500

1

000

2

500

2

000

Propeller shaft revolution

kmfh

0

10

MPH

PRESSURE
3N71 B

30

40

20

10

70

60

TESTING

transmission

is

At

30

4

3 500

000

rpm

80

90

100

120

130

140

line

50

40

60

70

80

SAT105

idling

pro

Range

vided with three pressure test ports
Only two are useful for transmission
trouble shooting

50

3 000

I

Car speed

The

20

500

Pressure

and

Line pressure kPa kg cm2 psi

R

412

549 4 2

5 6 60

80

D

314

373

3 8 46

54

2

588

1 147

314

373

Governor Pressure
3 2

ST2505S001

6 0

3 2

117

85

3 8 46

166

54

At tall test

AT454

1

Line pressure

2

Governor pressure
Servo release pressure

3

Range

Line pressur

kPa

R

1402

D

971

1 089

9 9

1 000

1 147

10 2

1 089

9 9

589
1

kg cm2 psi
16 2 203

3
14

1
11

141

230

158

LINE PRESSURE
2

117 145

166

I

Install pressure gauge to line pres
sure port
When shift lever is in 0
2

971

1
11

141

158

1

install pressure
range
to
and
when in R
gauge
port CD
or

range install pressure gauge to port

shown above
can

be

seen

pressure at

@

Locate the gauge so it
by driver Measure line

idling and at stall

Key points of pressure testing
al Pressure

test

rise

2

Road test car and note pressure
under different throttle conditions

54
AT

in

cre

bl

Pr ur

at

idle

pressure
under

Look for
as

car

a

are

teady

speed

in

light load

drop b

tween

hould

not

kg cm2

15

drop
hift

point

exceed
p n

kPa

98
Ex

i

1 0

pressure

may indicate an internal leak at a

servo or

clutch seal

Trouble

AUTOMATIC TRANSMISSION
Cut back point
The

is gradually increased

rotation

cut back

point

indicates

stall

a

point

The car

point

shaft

put

point where line pressure changes from
high to low value a output shaft

rotation

speed and

out

that cut back

at

Quickly note the
speed and immediately

mmHg

kPa

Car

speed

km h

MPH

vacuum

inHg

Stall revolution

0 0

Place shift lever in

6

rpm

40

48 25

30

1 310

20

28 13

17

660

1 950 rpm

revolutions

Propeller shaft

repeat
o

release throt

tle

1 650

Intake manifold

stall

engine

5

indicated in chart below

as

are

from

shootingandOiagnoses

above

1 560

range

910

volution in

test

R

range and

same

in

as

D

If stall test indicates proper stall

100

3
13

3 94

D

no

range

re

further tost

ing is necessary

GOVERNOR PRESSURE
STALL TEST ANALYSIS

CAUTION
Install pressure gauge to governor
it
pressure port Locate the ga ge so
I

can be seen

by

a

should

driver

added

and note pressure at
different road speeds Gov mor pres

b

directly with road speed
and should always be less than line

c

2

Road test

sure

Transmission and

car

increases

pressure

d

Run

alwavs

engine

fluid levels

be checked and fluid

needed

as

proper

warm

During

test

up

wide open for
Do Not test

Satisfactory results
rear

clutch

of transmission

at 1 200 rpm to attain

engine

I

indicates

hold

never
more

throttle

than 5 seconds

more than two gear
ranges without driving car to cool
off engine and transmission

torque

apd

converter are

0

in

one

sprag

flutch

functioning

2

Stall revolution in

0 range

of testing

The
3

rear

Stall

above

clutch is faulty

revolution

in

R

specified revolution

clutch operation
ance

band

converter
and

holding
one

way

engine perform
only be per

A stall test should

formed

as

a

last resort because of the

high l1uid temperature it generates and
the excessive load it places on the
engine and

STALL TEST PROCEDURE
1

be
2
3
in
4
to

Install
seen

by

a

tachometer where it

driver

during

Converter
can

0

0

faulty

range

1St

test

slipping
properly

clutch is

sprag

or

engine

is not

faulty
performing

Set hand brake and block wheels
Start engine and
D

place

car

Apply foot brake
wide open

If converter sprag clutch is frozen

shift lever

range

throttle

and accelerate
Do not hold

throttle open longer than five seconds

transmission

Stall revolution in

is

range
for

gear is below specified revolution

effective method

clutch and

to rque

ability

an

1st

gear is above car specified

4

The stall test is

of

pro

perly

range
Low and Reverse Brakes are

STALL TESTING

range

way clutch

will have poor

mance

slipping
or

If

car

60 km h

high speed perfor
sprag

clutch is

sluggish

up to 50

converter

will be

30 or 40 MPHl

1

AT 55

AUTOMATIC TRANSM IS ION

Troubleshooting Bnd Diagnoses

CHART

TROUBLE SHOOTING

J
arranged in order of
probability Perform inspections
starting with number one and work
ing up Circled numbers indicate

c

E it
c

S
s

o e
e fe

EEo

P

Nn

i

J
Ur

J5

oS
2

c
0

J

t

S

c

R
Q

C

S

f

tCI

0

o

0

tIf

e
f

I

0

l

O

0

Sf
0

ag
t

c

M

4

aOClO
a

r

u

t

co

d
does not start in

Cf7

E
Eib

13

ii

J

2

a

CO

that the transmission must be
removed from the car

s

L

s

ti

fi

e

0

Numbers are

Engine

OFF CAR

ON CAR

Cir

t

0

OIl

Jsou
E

i8 cSg

c

jl

5fJ

l
t

fi

t

fj
l

f

J

g

CO

cE

Ct

E

GJ

0

e

1
I
CI

0

and

starts in range other than

N

C

M

3C5C5

It

I

3

2

p

Transmi sion noise in

P

N

and

S

0 c

ranges

Engine

00

11

ra

E

cfJB

o

i

s

f

@

2

ranges

when changing into P
gear does not dis
out of P
when
shifted
engage
range
Car

moves

range

Car

or

runs

N

in

V

I

parking

3

I

range

Car will not run in R range but
2 and I ranges
in 0
Clutch slips Very poor acceleration

2

runs

Car braked when shifting into

3

2

6

5

R

@
J
@@

4

@

321

@

@

CID

@

range

Sharp shock
D

in

shifting from

N

to

Car will not
runs in
2

run

in

0

and

Clutches
in

or

4

2

3

4

5

6

3

5

7 4

5

4

@@

D
@

2 3

56874

@

@

2 3

56874

range but
ranges

R

I
2
Car will not run in D
ranges but rims in R range
Clutch slips Very poor acceleration

brakes slip somewhat

tarting

I

2

I

2

@

3

2

range

6

@

3

3

2

No creep at all
Failure to change gear from
2nd

I st

Failure to change gear from
3rd

2nd

I

to

to

gear change point from
2nd from lnd to 3rdu

a

Gear change directly from
3rd occurs

1st

to

I

2

3

5

@
@@

@

3

I

@
D

4

6

2 4

IN CAR

AT 56

@

I

Excessive creep

Too high
1st to

7

CID

@
OFF CAR

@

AUTOMATIC TRANSM 15510 N

Troubleshooting and Diagnoses

OFF CAR

ON CAR

f
o

i

ff
l

Je
or

J0
U
g

o

to

Too

sharp

2nd

a

g

I

0

E

t

Almost no shock
in

or

e

E

or

B

3

Ei

0
c

o

g
C5tE

v

o

3

3

5

4

3

4

6

8

7

5

123

4

6

8

7

5

2

5fj
c

fj

or

0 i5

1

5

shock in change from

2

N
3

g

4

I

o

it

0

E

0

d

u

fJ E
0 0

S

0

c

r

S

s
388

iJ
ct

@

3

@

3rd

to

slipping

u

Jt rJJ

a shock in change from
2nd

ii

c
o
a

f1

0

a

tJ

t

o s

6
1st

Ei
e

0

rJ

e

If

0

E

Too sharp

5

i

that the transmission must be
removed from the car

fi

S

s
Numbers are arranged in order of
probability Perform inspect ons
starting with number one and work
ing up Circled numbers indicate

tf

clutches
1st

change from

I

to

2

@

@

2nd
no shock or slipping
change from 2nd to 3rd
Engine races extremely

Almost

in

Car braked by gear change from
lst to 2nd

2

Car braked by gear change from
to
2nd
3rd

3

2

7

6

Maximum

speed not attained

I

Acceleration poor
Failure to

3rd

change

2

4

gear from

@

Failure to change gear from 2nd
to
1st or from
3rd to lst

3

CID

j

8

CD@

346152

CD

5

j

I@
@I
@@@I@

2

346

2nd

to

5

@

@

@
@

Gear change shock felt during
deceleration

by releasing

I

2

3

4

5

6

CD

I

2

3

4

5

6

CD

4

5

3

5

6

2

4

accelerator pedal
Too
to

high

a

2nd

change point from
from

2nd

to

3rd

1st

I

Kickdown does not operate when
depressing pedal in 3rd within

kick down

car

2

3

@

Kickdown operates

or engine over
depressing pedal in 3rd
beyond kick down car speed limit

runs

CD

speed

when

I

Races extremely or slips in changing
from 3rd to 2nd when depress

2

6

7

4

@

@

5

3

CD@

@

@

ing pedal

r

ON CAR

I

OFF CAR

AT 57

ble
Trl shooting

and

AUTOMATIC TRANSM IS IO N

S
OiagnOSJ

ON CAR

OFF CAR

1
n
n

Numbers

arranged in order of
probability Perform inspections
starting with number one and work
ing up Circled numbers indicate

2

r

0

are

e

fi

E
f

that the transmission must be
removed from the car

g
0

ii
o
f

lO
I

i
f

e

5

2

IV

g

E

run

in any range

Transmission noise in
I

and

R

D

2

6

0
t

c
0

gag
io
J

I@

2

ranges

2

4

2

3

5

3

@

6

@

763

@@

u
tl

o

rt

641

5

IV

8

6 5

E2

CVID

I

@

I

cEo

@I
@

gj
e

II
@

range

Gear
or

rl

lI
C

f
0

0
0

S

2

Failure to change from 3rd to
2nd when changing lever into
2

c

3

E
0
r

601JitSJi
Car will not

2

G

c

eo

8E

t

0

C

fi
v
c
0
c

9

o

0

0

tiC

t

J
C

c

G

e

IV

g e

tl

1iO

0

IV

Q

a

S
l

E

e

a

0

J

Q

change from

from

2nd

2nd

3rd

to

to
in

1st

I

to

2

range
No shock at change from
2 range or engine races

123

4

5

7

8

extremely
Failure to change from 3rd to
2nd when shifting lever into
I

4

2

4

5

@

range

Engine brake does
in

1

Gear
or

2

@

not operate

531

range

change from

from

2nd

to

1st

to

3rd

in

2nd
I

2

@

range

Does
to

not

1st

change from

in

1

large shock changing
2nd

to

st

2nd

range

I

4

2

from

in

6

7

3

3

range

Transmission overheats
Oil shoots out during operation
White smoke emitted from
exhaust pipe during operation

3

3

4

5

6

I

I
I

I
I

6

8 7

5

2

7

8

4

@@

2

I@@@

Offensive smell at oil charging

ON CAR

@

@I

I
I

@

I @@I@@@I@

2

pipe

AT 58

5

4

2

I

I@

@@@
@

@I

OFF CAY

I

@

@

@

@

I@

AUTOMATIC TRANSM 15510 N

Troubleshooting and Diagnoses

ROAD TEST SYMPTOM CHART

SHIFT QUALITY

Z

I

S2
I
t
l

8

l

g
0

z

I

g
o
t

I

PARK
RANGE

R

I

I

I

I

I

I

I

I

I

I

RANGE

I

I

I

II

I

I

I

I

I

I

I

Man

I

ENG

IN
I Man

R N

shift

START

shift N D

lIst

I

I

I

I

I
I

I

I

I
I

I

I

I

I

I

I

I

I
I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I
I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

I

Auto shift 2 3

I

I

3rd

I
I

I

I

I

I
I

I

I

I

I

2 1

I

I

I

I

I

I

I

I

I

I

I

I
I

I

I

I

I

I

I

2 1

I

I

0 1

I

I

I
I
I

I
I
I

I
I
I
I
I

I

Kickdown

3 2

I

Decel

I

Kickdown 2 1

j

0 2

I

Acceleration

I

I
I

L

I

3 2

I Man shift
I 2nd
shift
I
I Man shift

I

I
I
I

Decel

I

I
I

I

Man

RANGE

2

I
I
I

COMMENTS

u

I
I
I
I
I

I
D

RANGE

I

2nd

RANGE

2

Auto shift

t

0
t

5

HOWING

I

l

is

0
Z

I

t

e

t

I

shift P R

I

if
f

x

r

REVERSE

N

I

ENG START

Man

RANGE

1

I

x

e

Engine

Braking

I
I

I
I
I

I

I

i
AT 59

AUTOMATIC

TroublNhoovng and Diagnoses

TRANSM 15510 N

TROUBLE SHOOnNG GUIDE FOR 3N71B

Order

AUTOMATIC

TRANSMISSION

Test item

Checking

Procedure

Oil level gauge

Check gauge for oil level and

leakage

before and after each

test
2

Downshift solenoid

Check for sound of operating solenoid when
accelerator pedal fully with ignition key ON

3

Manual linkage

Check by

shifting

into

P

R

D

res ing
dep

2

and

I

ranges with selector lever
4

Inhibitor switch

5

Engine idling

Check whether starter operates in N and P ranges only
and whether reverre lamp operates in R range only
Check whether idling rpm

rpm

6 Vacuum pressure of

vacuum

pipe

7

Check whether
17 72

mmHg
increasing

Operation

in each range

vacuum

in

inHg

meet

standard

pressure is more than 60 0 kPa

450

idling and whether it decreases with

rpm

Check whether transmission engages positively by shifting
N
D
2
N
and N
R range
while idling with brake applied

8

Creep of car

Check whether there is any creep in D

I

and

R

ranges

Stall test

I

Oil pressure before testing

Measure line pressures in D

I

2

and OR

range while

idling
2

Stall test

Measure engine rpm and line pressure in
R ranges during full throttle operation

D

2

and

Temperature of torque converter oil used in test should be

l000C

from 60 to

2120Fl

140 to

i

e

sufficiently

warmed

up but not overheated

CAUTION
To cool oil between each stall test for
R
more

idle

ranges
engine
than 1 minute in

i

e

P

0

rpm at about

2

200
1

T and
rpm for

range Measuremenl time

must

shifting

2nd

not be more than 5 seconds

Road test

3

Oilpressure

1

Slow acceleration

after testing

as

Check

Ist2nd

2nd

Same

car

3rd

Same

1st

o kPa

2nd

2nd

60
AT

3rd
down
Kick

3rd

2nd

rpm in

up 1st

3rd range while running with lever in
range and engine vacuum pressure of about
3 kPa
13

Quick acceleration

3

speeds and engine

range and 2nd

mmHg
2

item I

as

3 94

100

inHg

item I above
0

0

mmHg

0

except with engine vacuum pressure of
inHg ie in position just before

kickdown

operation
or

2nd

1st

Check whether th

kickdown operates and

delays while running at 30 40 50 60 70
37 43 MPH in Os
range

measure

h 19
km

the time
25 31

Trouble shooting and Diagnoses

AUTOMATIC TRANSMISSION

Procedure

Test item

Order
4

Shift down

Ds

02

5

speeds and engine rpm in shifting down from 3rd
1st sequentially
while coasting with accelerater
pedal released in D3 range and engine vacuum pressure of
about 60 0 kPa 450 mmHg 1772 inHg
Check

D1

car

2nd

Shift down

Check for shifting down D

D

further for shifting down I

12 11

shifting

the lever into

I

released and the engine
o inHg

while driving

and engine braking after
range with the accelerator pedal
I

vacuum

at

and engine braking and

I

pressure of 0 kPa

about 50 km h

0 mmHg

30 MPH

in

D3

range

6

Shift down

Check for quick shifting down 0

0

after shifting the lever into

2

50 km h 30

MPH

in

0

2

2 and engine braking
driving at about

range while

range

Also check for locking of the transmission in 2nd gear ratio

regardless of car speed
7

11
8

Check for failure

Shift up
l

acceleration when

12

starting

in

range

Shift up or down when start

Check the transmission for not

ing in 2

acceleration

range

9 Parking

Abnormal shock oil leakage

or

shifting

move on

grade

2

during

range

when

shifting

to

range

Enter into record conditions observed
as

up or down

deceleration when starting in

Confirm that vehicle will not
P

Others

of the transmission to shift up during

gear noise

during these

tests such

abnormal clutch noise and acceleration per

formance

AT 51

Service Datund

AUTOMATIC TRANSMISSION

Specifications

SERVICE DATA AND SPECIFICATIONS
General specifications

I

Automatic transmission
3N718
Reo
2 0

Transmission
gear fatio

I

cl

t

08

in

mm

1 6 0 031

0 063

2 458

st

Thickness of retain
2nd

ing plate

1458

I Top

1000

I

2

Reverse

182

Oexron

I
Low

type

5 5 liters

12 7 8 US qt
torque

2 8

I

e

15 7 8 US qt 4 7 8 Imp qtl
Approximately 2 7 liters

capacity

mm

835

10 32871

Un

Number of drive plates

Automatic transmiuion fluid

Oil

Oil

5

plates
Clearance

l

5

plates

Number of driven

model

Stall torque ratio

Number of drive

5

Number of driven

5

plates
Clearance

mm

80 125
0

lin

10 0315

verse

Thickness of

brake

retaining plate

Thickness

0 04921

Part number

in
mm

Imp qt
7

converter

Specifications and adjustment

810 3071

31667 X0500

8 0 10 315

31667 X0501

8 2

10 323
8AI0 33tl

31667 X0502

8 6 10 3391

31667 X0504

8 8 10

31667 X0505

31667 X0503

346

Brake band

Automatic transmission

Piston size

assembly

Big dia

64

2 52

Small dia

40 1157

mmlin

Model code number

X2305

Torque

converter assembly
Stamped mark on the
TIC

Control valve

assembly
Stamped mark on strainer

G

LRJ

Governor assembly
Number of drive

plates

I

3

Stamped mark
governor

Number of driven

on

35

body

3

plates
Clearance
Front
clutch

mm

Thickness of

retaining plate

in

1 6

2 0 0063

Thicknesi

Part number

mmOnl
10

610 4171

10 8

10 4251

110

31537 X0100

31537 X0101

10 433
t1 210 44t

31537 X0103

114

31537 X0104

116

62
AT

0 0791

10 449
10 457

3t537 X0102

31537 X0105

Stall revolution

I

Stall revolution

rpm

1

650

1

950

AUTOMATIC TRANSM 15510 N

Specisl Service Tools

Tightening torque
N

Unit
Drive

plate

to

137

m

ft Ib

m
kg

157

14 0

16 0

116

101

plate

to

torque

39

40

49

50

36

29

Converter

housing

39

49

40

50

29

36

converter

44

54

4 5

5 5

33

40

case to

20

25

2 0

2 5

14

18

transmission

69

05

0 7

3 6

51

ca

Servo
to

9
4

69

Oil pump

0 5

0 7

Piston stem lock

clutch inner

transmission

12

15

1 5

body

I

v

lv

upper valve

36

5t

2 9

3 9

0 3

04

22

29

49

6 9

05

07

36

5 1

5

713

06

0 8

43

5 8

69

0 5

0 7

36

5 t

29

39

30

40

22

29

29

49

3 0

50

22

36

14

2 1

10

15

08

11

513

to

to

9

to

49

case

pipe

body

to

case

15

39

1 5

4 0

11

t3

18

13

18

9

29

13

case

plug oil pressure
nspecticn hole

Support actuator
parking rod nserting

to

5 4

74

0 55

0 75

40

5 4

2 5

34

0 25

0 35

18

25

14

78

21

10 8

8 0

to rear

extension

case

Turn back two
Lo

0 7

11

9

positionl
transmission

05

Test

nut

transmission

Control valve

lower

housing

transmission
12

way
One

69

5 1

36

adjusting band brake

race to

2 5

case

when

stem

9

0 35

cover

Oil cooler
Piston

18

4

Manual shaft lock nut

piston retainer

transmission

to

Inhibitor switch
49

0 25

body

oil pump

extension

to

34

oil distributor

housing

Transmission

valve

ft Ib

m
kg

25

bolt

Governor valve

case to

Transmission

Oil pen

Nut forcontrol valve

Oil strainer

to

engine

Nm

plate to control
body

reamer

converter

rear

Side
valve

crankshaft

Drive

Unit

body

to

turns aftar

tightening

body

SPECIAL SERVICE TOoLs
Tool number

Tool

name

Kent Moore No

ST07870000

Transmission

case

stand

ST07860000
125607

ST25850000

Sliding

hammer

125721

GG91060000

Torque wrench

GG930 10000
J25703

AT 53

Special Service Toofs

Tool number
Moore
Kent

AUTOMATIC TRANSM 15510 N

Tool

name

No

ST25420001

Clutch spring compressor

ST2542000Q
126063

ST25320001

Snap ring

remover

125710
o

ST2557000 I

Hex head extension

ST2557000Q
J25718

ST25490000

Socket extension

ST255 1200 I
125713

HT62350000

Spinner handle

ST25160000

Torque driver

ST25580001

Oil pump assembling gauge

Q

125719

HT6 I 000800

Hexagon wrench

j
ST2505S001

Oil pressure gauge set

125695

c
64
AT

DATSUN 200SX

Model S rJ 0 Series

SECTIONP D
PROPELLER SHAFT
DIFFERENTIAL CARRIER
CONTENTS
ASSEMBL Y

PD

9

PD

2

DIFFERENTIAL CASE

PD

9

PD

2

DIFFERENTIAL CARRIER

PD l0

PD

2

PD

3

SIDE

PD

3

PINION

PD

3

PD

3

PROPEUER SHAFT
Model

3S63A

GENERAL INSPECTION

PROPELLER

SHAFT

REMOVAL AND

VIBRATION

INSTALLATION

INSPECTION

PROPELLER

SHAFT

RUNOUT

YOKE AND SLEEVE

FLANGE
JOURNAL

AXIAL

YOKE

PLAY

REPAIR

CENTER BEARING

DIFFERENTIAL CARRIER
Model

PREPARATION

FOR

DISASSEMBLY

REMOVAL
PRE DISASSEMBLY
TOOTH

INSPECTION

CONTACT

DISASSEMBLY

FINAL

PD 11

BEARING

ADJUSTMENT

PD l1

HEIGHT ADJUSTMENT

PD 13

VERIFICATION

PD 15

SERVICE DATA AND
SPECIFICATIONS

PD 16

PD

3

PD

3

PD

3

PD

5

PD

6

PD

6

GENERAL SPECIFICATIONS

PD

6

SERVICE

PD

6

PD

7

PROPELLER

SHAFT

PD

GENERAL SPECIFICATIONS
SERVICE

Final drive

H165B

ADJUSTMENT

16

PD 16

DATA

PD 16

TORQUE

PD 16

DIFFERENTIAL CARRIER

PD 16

TIGHTENING

PD 16

DATA

TIGHTENING

PD 16
PD 17

TORQUE

TROUBLE DIAGNOSES AND
CORRECTIONS

PD 17

DIFFERENTIAL CARRIER

PD

7

DIFFERENTIAL

PD

B

PROPELLER

PD

9

DIFFERENTIAL CARRIER

PD 1B

SPECIAL SERVICE TOOLS

PD 19

INSPECTION

CASE

SHAFT

PD 17

1

1ft

PropellerSheft

Model

PROPELLER SHAFT 8 DIFFERENTIAL CARRIER

3S63A

PROPELLER SHAFT
Model
3S63A

Propeller shaft

Locking nut
Flange nut type

b245

Companion flange

U

a

coat of

and

217

Nut and washer type
if 196 235

containing molybdenum disulfide
the end face of the center bearing

grease
to

30

181

lithium

PUIJlOse
muIti

294

25

Washer

Apply

2nd tube

20

both sides of the washer

VI

24

145

ill
fJ

174

24
4
2
17

Center bearing
Install center bearing
ffiuk

toward front of

32
3 3
24

F

with
car

Center bearing
support

Propeller lhaft
1st tube

V
if

32
2
17

fJ

N

m

kg

m

4

3 3
24

ft tb
S

GENERAL

PROPELLER SHAFT
VIBRATION

INSPECTION

To

Inspect propeller shaft tube surface
for dents
If

or

cracks

damaged replace propeller
center

damaged
If

and

correct

shaft

is

center

noisy

or

bearing

journal is damaged or worn
place propeller shaft assembly

re

Remove

foreign

proceed as

undercoating and other

material which could

shaft balance

upset

and check shaft vibra

tion by road tesi
2
If shaft vibration is noted during
road test disconnect propeUer shaft at
differential carrier companion
rotate

companion

and reconnect

PD 2

an

follows
I

bearing
replace

check

unbalanced propeller shaft

assembly
If

PD11

flange

propeller

flange

180 degrlies

shaft

3

Again check shaft vibration

If

VIbration still persists replace propel
ler shaft assembly

PROPELLER SHAFT

DIFFERENTIAL CARRIER

PropellerShaft

Mode

3S63A

REMOVAL AND
Connecting
portion

INSTALLATION
I

Put match marks on

Cushion

l1anges and

separate propeller shaft from differen
tial carrier

c

c r

SPD10B

SPD124

REPAIR

INSPECTION

CENTER BEARING

PROPELLER SHAn RUNOUT
Inspect propeller shaft runout If
specifications replace
propeller shaft assembly

I

Put match marks on

separate 2nd tube from

l1anges and

1st tube

ronout exceeds

2

Remove

center

bearing bracket

I I
1 roS

Runout limit

@

06

mm

0 024 in

c

KO

itM

I

SPD109

J

SPD106

2

Put

match

marks on the

l1ange

and shaft

m

3

propeller shaft from

Draw out

transmission

and

of transmission

plug

rear

up

rear

extension

end

housing

FLANGE YOKE AND SLEEVE
YOKE
If l1ange yoke and sleeve yoke are
damaged or worn replace propeller
shaft assembly

Q

aU

o

t

Plug

3

Remove

SPD110

locking nut with Tool

SPD105

SP0107

4

To install

reverse

procedure using

the foregoing

reference

marks in
JOURNAL AXIAL PLAY

removal
Install

the

center

bracket with the
cushion

bearing

contact

facing upward

on

the

surface of the

Inspect journal for axial play if
play replace propeller shaft

there is

assembly
PD 3

Model

PropellerShsft
4

Remove

PROPELLER SHAFT

3S63A

companion l1ange with

puller

6
to

Install

new

center

DIFFERENTIAL CARRIER
bearing Be

install center bearing

with

sure

8

Tighten locking

nut

using Tool

OF

mark toward front of car

Apply

L

a

coat

of multi purpose lith

iuin grease

containing molybdenum di

sulfide

to

the end faoe of the cente

bearing

and both sides of the washer

SP0116

l
C

Cent

baring locking nut
r

Ntit

Flange nut type
Remove center

5

bearing

245

with Tool

25

and press

181

294 N
30

m

m
ka

217 It lb

and

196
20
145

wash
type
235 N
24

m

m
ka

1741t

bl

@

SPD125

7

1 iLsP0113
Care should be token when
Tool in

press

to

line of Tool is
fixture

make

right angle

of press

Tool from

sure

This

is

to

liC

the center bearing Align the mark

companion flange
companion flange
the

10

Align the

on

and install the

support
prevent

9

bending

OK

Stake the nut

setting
parting

that

to

9
Insert the washer into the end of

N

G

f

center bearing
Washer

Companion flange
Locking nut
SPD115

I

Ji
Support
fIxture

4
PD

and 2nd tubes

mark and connect

1st

Jo

0

ni
i
a

S

l
t1

l0

l
I
J

i
m

Jl

on 1

JtJ

t

00

oJ

c0

Q

n S0

S

O

st

diP
inll
de
S

43
36
59

10 11

Outct

5

49
@

511

8

ace

p
te

tu

tial

Lock

oeatIDS

6

J@111911

side

taCe

a

MY

a

DJ

l
i1

Side

Olfter 1 case

adiustifl

l
sbin

oet rni tW

es

tnict
t

hatt

mate
nWP
y

6
n
n

nllSOllt

ir

011

set

t

lfl
R

inl

I

IffW

18
II

tn
ill

0
I

0

K13005
YI Bac

o

l

e

Dti

e
CD

ace
te1

J

ble
et

er

b
inln

t
s

llht
ne

Vil on

nesS

UStinS Det n thick
ad

wot
p

race ft

inII

Drive

waYtp

p

col1

15

Jacet
S

18
5
3

outer

ca

34

5

15
@

1

to 10
P

on

1

in

vep ON
I

btained

0

et

Gas

11

Hatt
Yt
lreplace

10
O

43
HI
u

Ie

a

oil

replace

front

aY
A

Corvaniot

l
ll1

11

valuen

1
8

00

1

P

ue

1
6

to Ct
l1
19
ad g
1 10
13

@

dl

L

of

u
l

plte

as ern
ftna1

0

un

1

Ditfel nt catiet

ty

iI

M
t

Differential Carrier Final drive

Model

H165B

PREPARATION FOR

llnce
Cleal

I

REMOVAL

it

Jack up

a

rear

of

car

and support

by placing safety stands under

axle case
2

referring

Remove drain

ferring

rear

0 10

Check backlash of ring gear with
dial indicator at several points If it is

not within
to

specification

adjust

SIDE BEARING

it

20
0

mm

llO39 00078 inl
10

re

ADJUST

MENT

to section GI

plug

DIFFERENTIAL CARRIER

PRE DISASSEMBLY
INSPECTION

DISASSEMBLY
I

PROPELLER SHAFT

and drain gear

oil
Backlash
0 13

0 18

10 0051

mm

SPD004

0 0071

inl

TOOTH CONTACT
Gear tooth contact pattern check is
necessary to

SP 0002

verify

correct

relationship

between ring gear and drive pinion
Hypoid gear set which are not posi
tioned
short

SPD121

properly
life

or

may be

both

noisy

With

a

or

have

pattern

check the most desirable contact for
low noise level and

long

life can be

as

sured

3

Remove propeller shaft and

axle shafts

rear

Refer to Section RA for

removal and plug up rear end of
mission rear extension housing

tran

2

Check runout of ring gear with a
dial indicator If it is over specifica

hypoid gear set
case should be replaced
tion

or

differential

excessively

in

different places the variance may have
from

I

Thoroughly clean ring

gear

and

drive pinion teeth
2

When backlash varies

resulted

Check

Sparingly

powdered
alent

to

3

apply

mixture of
or equiv
of ring gear drive
a

ferric oxide and oil
or

4 teeth

foreign

side
matter

caught

between ring gear and differential case

SP0105
I

Runout limit

0 04 mm
10 0016 in
4

Loosen bolts securing differential
carrier to rear axle case and take out

SPD003

3

differential carrier

Hold companion

hand and rotate the

Mount differential C3rrieron Tool

5

SPOOD5

flange steady by
ring gear in both

directions

3

Check tooth contact

referring to

TOOTH CONTACT
4

Check backlash of side gear
Using
thickness gauge measure clearance
between side gear and differential case
a

If it

adjust
washer
6
PD

it

is

not within specification
by selecting side gear thrust

Refer to S

s
O

SPoooa

PROPELLER SHAFT

DIFFERENTIAL CARRIER

Oifferent sl Carrier

Finsl drivel

Model H1658

Adjustment

H

F

I contact

Toe contaCt

ce contact

To correct increase thickness of pinion
height adjusting washer in order to bring
drive

pinion

close to

ring

Flank cont8ct

To correct

reduce thickness of pinion
height adjusting washer in order to make
drive pinion go away from ring gear

gear

c

V
Correct tooth

conae1

SPD007

Remove side

2

DISASSEMBLY

bearing

caps

DIFFERENTIAL CARRIER
1

Put

match mark

on

one

side bearing cap with paint
to ensure that it is

replaced

or

side

of

punch

in proper

position during reassembly
Bearing caps

bored
line

are

during

manufacture and should be put back
in their

1W

original place
SP 0009

3

Using

a

pry bar

remove

differen

tial case assembly

1

Be careful to keep the side
08

together with inner

outer

races

don

mix them up

bearing
race

SP0011

PD 7

Differential Carrier Final drive

4

Remove

drive

pinion

nut

Model

PROPELLER SHAFT

H165B

with

DIFFERENTIAL CARRIER
DIFFERENnAL CASE

TooL

I

Remove

side bearing inner

race

with TooL
To

prevent

damage

to

engage

puller paws with

careful

not to

confuse

bearing
groaBe

left and right

hand parts

S

1
SPD012

5

Remove

ST3305100l
SPOOl

8

Remove

race

using

a

pmlOn

bearing

outer

brass drift

companion l1ange with

puller
SP0020

SPD017

9

1

SPD014

ij

Remove

drive

collapsible

SPD021

Pull out
a

rear

bearing

inner race

press and Tool

Care should be taken when
Remove

6

drive

pinion with soft

hammer

ST3305200Q

from

pinion

10
with

spacer

setting

Tool in press to maka sura that parting
line of Tool is a
fixture

of

press

right angle

to

This is to

support
prevent

bonding Tool

SPD022

Soft hammer

2

Remove

out lock

bolts in a

SP0018
OK

N

ring gear by spreading
straps and loosening ring gear
cross
criss

fashion

G

lie

a

Remove oil seal by prying up with
large screwdriver and remove front

pinion bearing
Do this
seal

inner race

carefully

so

of screwdriver with

8
PD

as not to

bore with screwdriver
a

rag

scratch

Cover end

Support
fIXture
SPD023

3

Tap ring

gear off gear case

Differential Carrier Final drive

DIFFERENTIAL CARRIER

PROPELLER SHAFT
using

Assembly should be done in the
reverse order of disassembly
while
making any necessary inspections and

@

ring

e

gear from binding

adjust
1ents

@@

@4S

PRECAUTION
a
Arrange shims and washers
stall them correctly

e
@

SPD026

b

d

SPD024

Clean

Drive out

mate shaft lock

pinion

with Tool from

pin

ring gear side

disassembled

pletely
Repair or replace
faulty parts
When
gear
gear

replacing

replace

parts

any

8

new

on

and

Pack recommended

multi purpose
between lips

com

damaged

pinion

in

bearings
bearing caps are installed
Apply gear oil when installing
bearings

or

DIFFERENTIAL CASE
Install

I

drive

with

clean the surfaces

grease inlo cavity
when fitting oil seal

INSP CTION
I

Thoroughly

to

which shims washers

c

4

H1658

ASSEMBLY

a

soft hammer

Tap evenly all around to keep

Model

or

ring

hypoid

set

pinion

mate

gears

side

gears and thrust washers into differen

tia

case

2

Fit pinion mate shaft

3

Adjust

clearance

between

rear

face of side gear and thrust washer by
selecting side gear thrust washer Refer
to S D S

O
Draw out

5

rota e
case

pinion

and

pinion
mate

remove

mate shaft

gears

out

II

tt
SP0027

and

of the

Feeler

5

B

c

side gears and thrust

washers

are

The

removed

using

@Frontoilseal
ID Collapsible spacer
@ Lock strap

O 20mm

0 0039
0 0079 in

Insta l pinion mate shaft lock pin

4

CD Gasket

0 10

5P0029

following parts should be
replaced by new ones each time they

2

Clurance

a

punch

Make

sure

lock pin

is flush with

case

@
SPD122

Put

washer

marks

in their original

they

on

were

and

gears

so that they

can

positions

removed

thrust

be reinstalled
from which
SP0028

5P0030

PD 9

Differential Carrier fFinaldrive

5

Place ring gear

and install

new

on

Model

PROPEbLER SHAFT

H 65B

differential case

lock straps and bolts

Tighten bolu in a
cross fa
crisl
lightly tapping bolt head with

DIFFERENTIAL CARRIER

DIFFERENTIAL CARRiER

5

I

seal into carrier

Press fit

outer

races

front

and

rear

bearing

using Tools

Using Tool carefully fit

Make

shion
a

of

hammer
Then bend

lure

carrier

grease into

up lock straps to lock

a new

oil

oil seal is flush with end

and

apply

cavity

purpose
multi
d

lips

the bolts in place

Iii

7S

IS O

L

58

gSN

72 ft

l

m

10 0

kG

bl

A

ST33400001

SP 0035
1

SPDQ37

2

Select

washer

height

pmlOn

referring

adjusting

to PINION HEIGHT

Install

washer

toward gear
6

Select

shims

side

referring

bearing
to

SIDE

adjusting

inner

race

height

pinion

in

drive

using

adjusting
bevel

pinion

and press fit

in it

Place a new collapsible spacer on
drive pinion and lubricate rear bearing
with gear oil
and insert it in gear
6

ADJUSTMENT
3

iI

side

carrier
rear

bearing

press and Tool

BEARING

ADJUSTMENT
7

Install the shims behind each bear
on the bearings
using

ing and press
Tool

SP003S

7
it
4
SPD033

Lubricate front

oil and place

bearing with

gear

PD IO

companion flange by tapping
with

it in gear carrier

ST33052000
SPD034

Install companion l1ange and hold
firmly Insert drive pinion into

SPD045

a

soft hammer

its head

PROPELLER SHAFT
8

DIFFERENTIAL CARRIER

Hold companion l1ange with Tool

and

temporarily tighten pinion

until there is no axial

nut

10

Install differential

and side

assembly

nut are

free

and install side bear

bearing

Tap
mer to

from oil or grease

on

8

tions

soft ham

side

case

of specifica

out

is

preload

bearing shims of proper

side

thickness should be installed

settle it in the carrier

The
with

the cap with

differential

bearing
gear carrier is replaced or
when the ring gear backlash or side

ing cap
pinion and pinion

H165B

Model

or

Ascertain that threaded portion of
drive

the

When

miter races into dif

bearing

ferential carrier

play

case

Differential Carrier Final drive

cap should be installed
marks put 8t disassembly

bearing

the

aligned

Required Tools

D Weight Block
@Master Gauge
@ Base Plate
@ Dial Indicator

ST32501 000

SP 0040

j@R

@
9

Tighten pinion nut by degrees to
specified preload while checking

the
the

preload with Tools

When checking preload

drive

IiJ

49

36

59 N

D

m

0f

60

kg m
431t IOI

pinion in both directions several times

If

bearing rollers

set

I

tl
5 0

turn

ST33741000

@

SPD048

l
SPD044

I

Thickness of shim

lated by
Preload

II

ADJUSTMENT

with oilMan
07
7

SIDE BEARING

10

6 1

Left side

1 0Nom
cm
kliJ
8 7in lb

T

Right

side

Drive pinion nut
137
14
101

294 N
30

kg

8

T2
x

0

0 01

O

H

0 20

E

I

H
0 09

F

I

m

m

217 ft Ib

by using the
collapsible spacer
So here if an over preload results from
excessive turning of the pinion nut
the spacer should be replaced by new
preload

permanent

be calcu

L

Side

CAUTION

bearing

To avoid any confusion while calcula
ting it is absolutely necessary to stay
with metric system

CAUTION
The

C

0 01

x

I

J

A

I

ADJUSTMENT

can

following equation

is achieved

If you measure

set of

Side bearing
SPD046

adjulting

shim

anything

in inches the

results should be converted into the
metric system

one

PO tt

Differential CarrierfFinal drivel

Model

DIFFERENTIAL CARRIER

PROPEllER SHAFT

H7658

Where

T

o

Left side

H

T2
Right side
o

o
0

A

U
o

E

G

mm

o

Left
l

Side

Bearing

B
Stamped on differential
carrier

F
Differences between width
of left E or right F

mm

c

Right Side
Bearing

side bearing and standard width

D
Stamped

on

differential

A B

cue

a

C D and H

unit ofl 100

are

mm

dimensional variations in

against each standard value
SPD126

2

Measure values E and F

I

Attach

a

race

dial indicator to the base

plate
2

the

outer race

of the op

posite side bearing to be measured
3
Place a weight block on that outer
and

master

a

gauge

on

that

biock
Then
to

e

the

Place

race

and inner

the opposi

zero

weight
assembly

with

the dial indicator scale
its

tip

on

block

If the bearing
the

base

be measured

plate

on

that

its cage

The indication should be Ear F

on

being

Left

bearing

Right

ide bearing

E

ide bearing

F

embly i placed on
bearing width

the

cannot be accurately determined
to

adjust

race to

side outer race and place

due

in contact with the

base plate

the master

gauge

speOS1

Measured
outer

3

race

Substitute

equation

ST3 501000

these values

into the

to calculate the thickness of

the shim
SP0Q49

Oppo

ite

outer

race

side

If value
H

are not

ignifying A
given regard

B

C

0 and

them as zero

and calculate
5

4

Remove

weight block
PD 12

the

master

Place the

gauge

bearing

and
outer

Turn

to settle it

the

bearing several

limes

and then read the indica

tion of the dial indicator

After as

preload
tion

embly

end

check to

backla h

If not readjust

ere

ee

that

pecifica

PROPELLER SHAFT

DIFFERENTIAL CARRIER

Differential Carrier Final drive

H165B

Model

PINION HEIGHT

Example

ADJUSTMENT
2

A

I

H

B

2

E

l1
O

C

2

F

0 20

D

3

Left side
T

A

0 20

E

2

3

1

0 20

I

Right side
B
T2

xO OI

H

0

C

D

0 09
xO OI

2

A

I

C

2

0

3

I

I

3

2

0 09

20
0

2

11
0

xO 01

H
F

B

2

D

3

I

SP0056

2
When

3

drive

2

be
4

4

2

3
x

0 04
0 04

3

4

0 03

3

adjust

to

be made
be

bearing

hypoid
or

gear set
carrier

gear

the pinion

of the

height

pinion height

by adjusting the washer

installed

between

the

rear

inner rice and the drive pinion

head

0 03
0 09

0 24

0 06

0 24

4

Pinion height adjusting
washer

0 06

11
0

F

20
0
0 26

035
T

0 01

0 20

E

to

the

bearing

Adjustment

0 01

x

replacing

pinion

sure

can

2

Hiit
l

I
H

2
H

I

xO OI

035mm

T

0 26mm
SPD051

Select the proper shims

4

Refer to

SO S
If

you

find

cannot

thickness of shims

use

the

desired

shims

Required Tools

that

so

the total thickness is the closest to the

j Height Gauge
CV Dummy Shaft
ID Feeler Gauge

calculated value

Example

Left side

ST31942000

Right side
T

Calculated value

35
0

mm

Calculated value

T2

0 26

Thickness
0 20

I

0 20

0 10

x

I

10
0

x

I

Total thickness

L

Used shims

Quantity
x

Thickness

07
0
0 05

0 05
35
0

mm

Quantity
x

3

0 21

x

I

0 05

Total thickness

0 26

j

CV

mm

Used shims

0 05

ST31141 000

r

mm
SPD058

PD 13

Oifferential Csrrier Final drive

I

Thickness

of washer

can

Model

CAUTION
To avoid any confusion while calculat
ing it is necessary to stay with the
metric

r
N

H

0

Sl

x

0 011

2 98

I

DIFFERENTIAL CARRIER

be cal

culated by following equation

T

PROPELLER SHAFT

H165B

thing
I

system
in inches

If you measure any
the result should be

converted to the metric system

Where

@

T

n

D

3

mm

s

N

mm

H
H D and S

are dimensional

unit of 1 100

variations in a

against each standard

mm

value

SP 0127

2

Assemble

bearing

inner

Dummy shaft
race

and

fit

4

on rear

it

into

Substitute
to

equation

carrier

these values into the

calculate the

thickness

of the washer
If value
not

given

Sigilifying H
regard them

0 andS are
8S

zero

and

calculate
After
tooth

readjust

ST31141000

3

Attach Height Gauge to carrier
a
feeler gauge measure the

Using

clearance between the height gauge tip
and the dummy shaft face
PO 14

SPD061

essembly

contact

is

check to see that
correct

If

not

PROPELLER SHAFT

DIFFERENTIAL CARRIER

Example

Differential Carrier Final drive

FINAL VERIFICATION
N

35
0

H

4

D

S

Check backlash of ring gear with

If prelOad i
same amount

a

If

dial indicator
same

N

great

H1658

remove

the

of shims to each side

preload

i

mall

too

add

the

amount of shims to each side

3
Never

O

amount

T

too

Model

H

0

S

0 01

x

add

or

different

remove

of shims to each side or

gear beckla h will be

ring

changed

2 98
35
0

4

0 01

x

I

0

3

2 98

H

4

0

3
I

S

0
I

2

I
0 01

x

00
3

N

35
0

If backlash is too small decrease
thickness of left shim and increase

thickness of right shim by the

same

amount

3

If backlash is too great
above procedure

dial indicator

0 01

Never add

36
0

5P0031

or

remove

amount of shims

or

reverse

the

Check runout of ring gear with

a

from the total

bearing preload

will be changed
4

36
0
2 98
34
3
T

34
3

SP0003

5

Select the proper washer

Refer

to S O S
If

If backlash varies excessively in dif

you

find

cannot

the

desired

SPD066

ferent places

the variance may have

thickness of washer use washer SO that

resulted from

thickness

between the ring gear and the differ
entia case

is the closest to the calcu

late value

foreign

caught

matter

If the backla h varies greatly when
2

Example

Check side bearing preload
Hook the tip of a spring balancer

on a

Calculated value
Used washer

T
T

33
3

3 34 mm
mm

ring

gear bolt

the runout of the ring gear is within a

pecified

range

differential

Check the preload by

rotating resistance in

a

mea

uring the

backlash

4

case

the

hypoid gear set
replaced

or

should be

Finally check for

tooth contact

pattern
Refer to TOOTH CONTACT
Preload
At

ring gear bold

14 7

26 5 N
11 5 2 7 kg
3 3 6 01bl

U ually the pettern will be correct
if

have

you

correctly

However
will

you
proce

calculated

the

and the backla h i
in extremely

have to

use

until you get

correct

rare cales

trial
a

hims

nd error

good tooth

contact pattern
The

SPD067

pattem

i

indieation of how well

a

ha

tooth

the

best

differential

been et up

PO 15

PROPELLER SHAFT

ServiceDataandSpecifications

DIFFERENTIAL CARRIER

removed

fl

Then fill with gear oil

Recommended

referring

Lubricants

Differential carrier fixing bolt

to

25

Section

34 N

m

3 5

kg

2 5

MA

m

25 ft Ibl

18

Drain and filler plugs
59
6

98 N

m

10

m
kg

43

72 ft b

Gear oil capacity
1 1 I ita rs

ngrdler

SPDOOS

318
2

US pt 2 Imp

Oil level
5

Install the differential

ptl

carrier in

the car

Gasket should be replaced by
one

new

SPD123

each time the differential carrier is

SERVICE DATA AND SPECIFICATIONS
PROPELLER SHAn
GENERAL

DIFFERENTIAL CARRIER

SPECIFlcATIONS

Unit

Model

Number of

Coupling

3S63A

I

3

I

joints

method with transmiSsion

Distance

Sleeve type

Model

H1658
Rigid axle suspension

TVpe

Banjo typo

I

Ring gear pitch dianleter

I

Gear ratio

Disassemblv type

I

Number of teeth

1st

3201 2 601

I

Oil

2nd

730

tst

75 0 2

9531

2nd

50B

0001
2

yokes

63

Type of journal bearing

2 481

Shell type
Non

Shaft lenQth
Spider to spider

GENERAL SPECIFICATIONS

in

mm

28

mm

Unl

t65 6

3

700

Ring gear drive pinion

2

cepacity

US pt

50

10
37

Imp pt

1

3 8 21
2

741

SERVICE DATA
Shaft

outer

diameter

Drive

pinion bearing adjusting mathod

Drive

pinion preload with front oil seal
N

SERVICE

I

DATA

Unit

mm

in

I

Side

cm
kg

in lb

0 7
7

10

method

bearing adjusting
Drive

Propeller shaft runout limit

m

Collapsible spacer

pinion

to

0 6 0 0241

0

6 t

8 71

Shim

ring gear

0

jn
mm

3

005
0

0

8

0 00711

Backlash
Side gear

to

Unit

I

Center bearing

Nut

24

m

fHb

m
kg

32

24

33

17

245

294

25

30

8

ridwashertvpe

196

235

20

24

45

8

8

to bracket

bearing preload

0 9

12

2 6

40

65

217

74

8 7

Side bearln

PD 16

case

mm

at

in
in

0

kG lbl

0

10 0039

0 04

ring gear bolt

25

39

I

0 00791

0 00

14 7
1 5

0 20

29

mm

inl

61

26 5

27 33

shim
Part No

005

0 00201

38453

28500

0 07

0 00281

38454

28500

0 10 00391

38455

28500

0 00791

38456

28500

0 50 10 0 971

38457

28500

020
9

adjustin

Thickness

0
Center bearing bracket
body

differential

mm

Ring gear nmout limit
Side

24

side gear

locking nut

Center bearing support

to

pinion mate gear

N

nut
tvpct

Flange

I
I

N

Flange yoke to com
pani on flange

to

Clearance

TIGHTENING TORQUE

6

01

DIFFERENTIAL CARRIER

PROPELLER SHAFT
Pinion height adjusting
Thickness

mm

Thickness

Part No

38424

04101

8424

08000

885 10 0348
0

38424

08001

035 10 04071

38424

08002

38424

08003

09 10 12171

38154 U 1500

0

785 10 0309

3

12 10 12281

38154UI501

0

835 10 03291

0

38154

12401

Ut502

3

181O t252

38154 U1503

3

21 10 12641

38154 U1504

3

2410 12761

38154 U1505

1

0

330

0 1299

38154U1507

3 33

10 13111

38 154

l1508

38154

U1509

12871

3 36 10 13231

3

38154 U1514

13821

38154 U1515

54 10 t394

38154 UI516

6010 14171

38154 UI517

3 63 10 14291

38154 UI518

3 66 10 14411

38154 U1519

Drive

I Ring

U1513

38154

3 57 10 14061
3

I

38154Ut612

10 1370
0

Unit

38154 U1511

3 4510 13581

3 51

10 04671

TIGHTENING TORQUE

38154UI510

0 1335

3 42 10 1346

3 48

1 185

38154U1506

327

3 39

Corrections

Part No

in

mm

3

3 15

sesand
Diagno

Side gear thrust washer

washer

in

Trouble

pinion
ge

r

N

m

294

137

nut

bolt

ft Ib

m
kg
14

30

101

217

78

98

8

10

58

72

I
I

Side beari ng cap bolt

49

59

5

6

36

43

Drain and filler

59

98

6

10

43

72

I
I

Companion flange

24

32

24

33

17

24

25

34

25

35

18

25

plugs
to

propeller 5h8ft
Difforential
rear

axle

TROUBLE DIAGNOSES AND

co

io

to

case

CORRECTIONS

PROPELLER SHAFT
Probable

Condition
Vibration during at

Worn or damaged journal

medium or

Unbalance due to bent

high speed

Corrective action

cause

Repla
prol eller shaft assembly

n
beari
or

dented

propeller

shaft assembly

Replace propeller

shaft

propeller

Worn

transmission

Damaged
U

center

dercoatiIg

Retighten

shaft installation

Loose

rear

extension bushing

Repl

bearing

or

mud

Replace

he shaft

on

ausing

j

ace

Clean up shaft

unbalance

Replace propeller shaft assembly

Balance weights ntissing
Worn

starting or noise
during coasting on
propeller shaft

Worn sleeve

or

or

whistle

Replace propeller

spline

shaft assembly

Loose joint installation

Replace propellei shaft assembly

center

or

t 10

Dust

cover

Damaged

on

center bear
Repla

bearing or insulator

ntissing bolts
body

brac

transmission

Whine

and mainshaft

Retighten

Loose

noise

yoke

Loose propeller shaft installation

Damaged

Scraping

Replace propeller shaft assembly

damaged journal

Knocking sound during

sleeve

at

center

bearing

yoke rubbing

on

Replace

Straighten

rear extension

ference

bearing

Replace

center

or

tighten

g

bolts

out dust cover to remove inter

center

bearing

1

0

17

DIFFERENTIAL CARRIER

PROPELLER SHAFT

Diagnoses and Corrections

Trouble

DIFFERENTIAL CARRIER
When

differential carrier is

of being noisy

pected
make

a

a

thorough

it is advisable to

test

whether the noise

road surface exhaust universal
joint propeller shaft wheel bearings
engine transmission or differential
tites

sus

to detennine

originates

carrier Noise which

in the

Probable

Condition
Noise

on

drive coast

places

be corrected

cannot

ment

or

by adjust

of parts in dif

replacement

ferential carrier

originates in other
Corrective action

cause

Supply

Shortage of oil

oil

gear

Rebuild

carrier

gear

if

necessary

and l1oat

tooth contact

Incorrect tooth contact between ring gear

Adjust

and drive

gear set

pinion

Incorrect backlash between ring gear and
drive

or

replace

the

hypoid

replace the hypoid gear

set if necessary

pinion

Seized up

backlash

Adjust

or

damaged ring

or

gear and drive

Replace the hypoid gear

set

pinion
Seized up damaged

pinion bearing and faulty parts

broken drive pinion

Replace

the

or broken side bearing

Replace

the side bearing and faulty parts

or

bearing
Seized up

damaged

clamp bolts
bearing cap etc
Loose

Noise

on

turn

Seized up

pinion

or

damaged

holding ring gear

or

broken side gear and

Replace faulty parts

damaged

or

broken side gear and

Replace faulty parts

Pinion mate gears too

tight

on

their shaft

Incorrect backlash ring gear

pinion

or

Replace faulty parts

drive
to

Adjust

backlash

side gear to pinion mate gear
or case

Worn rear axle shaft and side gear

breakage

replal

Excessive backlash

Worn gears

or

specified torque and

to

mate gear thrust washers

pinion

Seizure

Clamp them
faulty parts

mate gear

Seized up

Knocking sound
during starting or gear
shifting

nuts

spline

Replace

worn

parts

Replace

worn

parts

Pinion bearing under preload

Adjust preload

Loose drive pinion miL

Replace

Loose boltS and nuts such as ring gear bolts

ReplaCe faulty parts

Shortage ofoil

or use

or

tighten bolt
or

lighten bolts

Replace faulty parts and

of unsuitable oil

use

recommended

gear oil

Adjust

Excessively small backlash
Incorrect

Severe

adjustment
due to

vice
ser

improper use

of bearings
an

damaged

out
Worn

front oil seal

mally

worn

excessive loading

required

Replace faulty parts

or

or

as

ring gear bolts

improperly

bruised dented

or

slide face of companion

driven
abnor

Replace faulty

l1ange

Loose filler

Tighten

or

drain plug

damaged

breather

parts

or

tighten

bolts

Replace damaged oil seal Repair l1ange
sandpaper or replace if necessary
Replace

or

as

Replace faulty parts

Damaged gasket

Clogged

PD 18

geats

replace

of clutch

Loose bolts and nuts such
Oil leakage

or

backlash and

Repair

or

replace

with

PROPELLER SHAFT

DIFFERENTIAL

CARRIER

Special Service Tools

SPECIAL SERVICE TOOLS
Tool number

Kent Moore

No

ST050 I SOOO

Tool

name

Engine stand

126023

CD ST05011 000

Engine stand

126023 2

@ST05012000

Base

126023 1

ST0636000l

ST3003S000
125733

CD

ST30031 000

Diff attachment

Drive

puller

pinion

feaf

bearing inner

race

set

Puller

125733 1

@ST30032000

Base

125733 2

ST30611000
125742 1

ST30613000
1257423

ST30701000
125742 2

ST3114S000

Drive

pinion bearing

outer race

drift bar

Drive
race

pinion

rear

bearing

Drive pinion front
race

outer

drift

bearing Quter

drift

6

Drive pinion setting gauge set

See 125269 01

CD ST31141000
@ST31942000

Height

gauge

Dummy shaft

PD 19

Special Service Tools

PROPELLER SHAFT

DIFFERENTIAL CARRIER

Tool number

Kent

Moore No

ST3127S000

Tool

name

Preload gauge

See 125765

CD GG91030000
CV lIT62900000
@ lIT62940000

Torque

wrench

Socket adapter
Socket

1

adapter

2

1

3 8

t

o
e

ST31530000

Drive

pinion l1ange wrench

125774

ST32501000

Weight block

125407 3

ST33051001

Diff side bearing

ST33052000

Adapter

puller

125797 1

5J
ST33400001

Oil seal

fitting tool

126082

ST33741000
See 125407 1

KY311 00300

KY38102100
125803

PD 20

Master gauge
5 mm 0 728 in
18

Solid punch

Diff side

bearing

drift

8

Model S 110 Series

DATSUN 200SX

SECTION
FRONT AXLE

FA

FRONT SUSPENSION

CONTENTS
FRONT AXLE AND
FRONT
USPENSION
FRONT AXLE
FRONT SUSPENSION
SPRING

TENSION

AND STRUT ASSEMBLY

ROD AND STABILIZER

TRANSVERSE
LOWER

LINK

BAR

SERVICE DATA AND
SPECIFICATIONS

FA

2

FA

3

GENERAL SPECIFICATIONS

FA 12

FA

5

INSPECTION

FA12

FA

5

TIGHTENING

FA 9

AND

BALL JOINT

FA10

SUSPENSION CROSSMEMBER

FA ll

Refer to Section MA

AND ADJUSTMENT
TORQUE

TROUBLE DIAGNOSES AND
CORRECTIONS
SPECIAL SERVICE TOOLS

Front Axle and Front Su pen ionl

for

ADJUSTING WHEEL BEARING PRELOAD
CHECKING WHEEL ALlGNMENT

FA 12

FA13

FA 14
FA 17

FRONT

lFProntensi
AxleandFronnrSu

FRONT SUSPENSION

XLE

FRONT AXLE AND FRONT SUSPENSION

Wheel alignment
Camber caster and kingpin are preset
factory and cannot be adjusted
The car requiresonly toe in and car

at

adjustment

pouure
Toe in 0 2

00

mm

to

0

0

08 in

0012

RefeI to section MA fot Wheel Alignment

J

25
25

34
3 5 18

J

25

59

74
6 0 7 5 43

Strut

54

mounting

insulator

Dust

J

covet

21

16

2 1

16

12

Coil SPrinll

J

62

7S

6 3

76

46
Strut

bly

Suspension croumember

Stabilizer bar

BaUjoint

Tension rod bracket

l
J

50

78

98

8

10

58

rod

To body

link

Vcue
Tranl

6 1

37

31

rame

44

72
Wheel bearing
Do not overtighten wheel bearing nuts
can cawe wheel bearing seizure

as

this

Axial play 0 mm 0 in
Preload As measured at wheel bolt with used parts
2 0 7 8 N 0 2 0 81rg 0 4 1 8 lb
When measuring bearing preload do not include

dragging

resistance with brake pads

Refer to Section MA for Adju linB Wheelllearing Preload

FA 2

31 42
3 2 4 3 23

60

5 1

J

J
llion
Te

J

N

m

m
Irg

lb
ft

SFA

9

FRONT AXLE

FRONT SUSPENSION

Front Axle

FRONT AXLE

seal

We
Inner

@

wheel bearing

Cotter Pin

Baffle

plate

@

38

@j

L

LWheelhub

@innerside

Washer

Wheel bearing nut
Adjust wheel bearing preload
Hub cap
Refer to Section MA for
inner side
Adjusting Wheel Bearing Preload

lD

@

@g

N

m

kg

m

ft lb

Multi purpose grease point
SFA120

REMOVAL

4

Work off hub cap

CAUTION
I

Block

and raise front

port it
Section

wheels with

rear

of

car

for

Be careful not to

and then sup

with safety stands
GI

chocks

Lifting

Refer to

Points

and

7

Towing
2

Remove wheel and tire

3

Remove caliper

to

Section BR for

drop

wheel

bearing

wheel

bearing

Screwdriver

outside

Separate

inner race and washer

assembly
assembly Refer
removal

8

Separate brake

9

Remove

rotor and hub

O riJ11

5

Pry

adjusting

off

cotter

cap

and wheel

pin take
bearing

out
nut

Cotter pin must not be reused

6

Remove

wheel

hub

with

disc

brake rotor

outer

race

inside
grease

wheel

bearing

seal and outside

outer race

CAUTION

CAUTION
Make
not

sure

twisted

Be careful not to

brake hose is secured and
FA258

Grease seal

wheel

bearing

mud not be

reused

drop

FA 3

FRONT SUSPENSION

FRONT AXLE

FronrAxle

I
1

11

1

@

I
III

Y

5
2

Pack hub and hub

commended
Coat

cap with

purpose
multi

oring

Multi
purpo
point

grease

SFA 124

SFA126

Fix brake rotor to hub

re

grease

with

recommended

multi purpose grease

38 ft Ib

INSPECTION

Thoroughly

dean

bearing

and each

part and dry with compressed air
Wh

q

1 bearing

When

make

l
O

race

noise

rough or
bearing assembly
worn

or

cage

or

roller sufaces

cracked

are
out

pitted

fround replace
MuIt

purpo
grease point

Wheel hub
Check
means

dyeing

SFA125

wheel hub for

cracks by
6

of magnetic flaw detecting or
test
replace if necessary
3

Knuckle aplndle
check wheel hub

Also

replace if

cracked or damaged When thread
damaged replace strut assembly

Sparingly

apply

recommended

multi purpose grease to each part
Threaded portion of spindle
Coat

mended

each bearing
purpo
multi

Bearing

with reCom

washer to

bearing

contact

ing face
7
Put hub assembly on spindle and
then install washer and wheel bearing

gr

is

nut
8

Greaae aeal
If grease leakage is detected during
removal

sembly

even

to

bearing

9

Install hub cap

with a ring

10

brake

Install
Roter to

caliper assembly

Section BR for installa

tion
II Install wheel and tire

cD

78
8 0
58

INSTALLATION
Install

front

axle in

the

reverse

I

Install

bearing

outer

Tool until it seats in hub

4
FA

4

Place inner bea i
J
n in hub and
a new grease seal coating seal

install
race

with

on

hub

if it appears good

order ofremoval as follows

preload

Section MA for adjUlt

ment

grease seal
grease seal at every disas

replace

Replace

wheel

Adjust
Roter

ing lips
PO

with recommended

gr

pur
multi

98 N

m

10 0 kg
72 ft Ibl

m

FRONT SUSPENSION

FRONT AXLE

Front Suspension

FRONT SUSPENSION

Croamember auembly

J
I
Stabilizer bar

or

i

t

J
I

60
51
6 1

e

6 3 76
1 46 55

J4454
1

J
I

t

72

60

5 33

45

Z

Tension rod

e

bracket

J

tf

J
I

L

42

31
3 2

4

Ten

3

t

31

23

I

i

2

J
I

N

m

kg

m

12

42

3 2

25

t

bIY

I

6

23

10 0

link

J
I
J
XI

3 5 18

34

I

J
I
55

54

n

Transverse

31

25

43

7 5

To body

b
U

tI

8

J
I

f8

50

3744

J
I

75

74

6 0

25

J
62

59

4

1
15

J
I

3

50

ft Ib

J
brI

j

Balljo

g3

nta

9
9

53

72

sembly

60

5 1

31

1
oS

37

6 1

SFA128

44

SPRING AND STRUT ASSEMBLY
J
I
Gland packing

rstruI
I
I

ShoCk
O
b

ber

packing

59 74
6 0 7 5
43

kit

J
I

54

3

ton rud

uldebusllIng

25
18

with dust seal

sPring

upper seal

G

Inner cylinder

Bound bumper rubber

Strut outer casing

Strut kit

DUSI

1

bearing

nut

Adjusting cap
Atterpin

9

fr
f r
J

m

u1alor

Mounting bearing

kit

I

N

3 5
25

Mountingin

Lock nut
Washer

J
I

34

2 5

C

Onng

m
kg

Service parts

ft b
SUUt packing kit

Shock absorber kit

Strut kit

I

cover

SPring

J
J
I

V

50

60

5 16 1
37

44

SFAl29

FA 5

FRONT AXLE

FrontSuspension

FRONT SUSPENSION

REMOVAL AND

Dust seal

INSTAllAnON

Spring

upper seat

Bound

bumper

Block

rear

wheels with chocks and

raise

front of car and then support it

with

safety

stands

rubber

Coil spring
Dust cover

Refer to Section

GI for Ufting Points and

Towing
assembly
Remove brake tube and caliper

CAUTION

Remove wheel and tire
3

Refer to

Front

Disc Brake

Pay

Section

A pply

BRl
Remove

4

hub

bearing if necessary
5
Separate knuckle

and

wheel

3

Remove gland packing with Tool
Retract piston

arm

from strut

GJ

Strut to
25

lower end

hoodledge

34 N

2 5
18

3 5

53

pushing

it

down until it bottoms

m
kg

97 N

ST35500001

J

m

9 9 kg

A

J

Strut to knuckle arm

7 3

rod by

m

25 ft Ibl

72

damaga piston

sealing material
SFA132

wheel

attention not to

rod

m

72 ft Ibl
KV48100301

DISASSEMBLY

r

When disassembling strut assambly
extra

caution

should

be

exercised
FA209

to

prevent dirt and dust from entering

strut

Set

SFA130

up Tools on strut

assembly

Compress spring just for enough

permit turning

of strut

to

4

Remove

ring
O

casing and draw

out

from top of

outer

guide bushing

in

mounting

sulator by hand

6

strut

Support

assembly with

a

suitable stand
7

HT7t730000

Remove strut upper end

SFA135

ST35652001
SFA133

5

Lift out piston rod together with

cylinder
2

Remove lock

piston

nut

from top

of

rod

Draw out strut assembly from

9

Install strut and spring assembly

car

to

J

piston rod guide innlr
are adjusted
provide precilion mating surfaces

cylinder

SFA 31

8

Piston rod

LX

and bottom valvl

Ind should

be hlndled IS I matched

it

Lift out

in reverse order of removal

CAUTION
Make

sure

brake hose is secured and

not twisted

When
arm

installing steering

to

the

strut

assembly

apply

suitable sealing material to portion
indicated in figure
FA 6

SFA134

knuckle

Separate following parts
Strut mounting insulator
Strut mounting bearing

FA275

FRONT SUSPENSION

FRONT AXLE
thoroughly from

Drain l1uid

6

cylinder

and outer

inner

Strut mounting insulator

Inner diameter
Inner

casing

cylinder

30 02

30 10

1 1819

FrontSuspension

if

Replace

rubber to

cemented

mm

metal portion

1 1850 in

melted

are

or

Rubber parts should also be

cracked

replaced

if deteriorated
Guide bushing
r

Strut mounting bearing

Replace if inspection
normal

noise

reveals ab

excessive

or

rattle

in

axial direction

iJ

SFA136

ASSEMBLY
Before assembly clean away all dirt

operation

Thi

i

very

important

since performance of strut varies with
amount

Maximum

to

prevent any possible entry of dirt
into strut assembly

runout

Inner cylinder
Less than 0 2

of fluid filled within strut

mm

I

0 008 in

Install

strut

assembly

Tool

on

KV4810030 I
2

cylinder

INSPECTION
parts except for noome
tallic parts clean with suitable sol
vent and dry with compressed air
and dust off of

dirt

non

metallic parts using compressed air
8

at

If oil leaks part

piston rod and gland

check

the

packing
problem

to

If oil

leakage

welded

portion

of

correct

cause

of

occurs

on

outer

strut

O

If

hock absorber itself is malfunc

tioning replace as shock absorber
kit including pillion rod cylinder
bottom valve and guide bushing

Y
SFA137

rod

piston

defoffilation

for

other

Re

kit

and O ring

or

replace

Pour
U

19 975

e

F LUI 0

correct
NISSAN
or

amount

of

fluid

GENUINE STRUT

equivalent

mm

0 7860

0 7864 in

325 m2

Maximum runout

gland packing

new

3

SFA139

Capacity

Oring and

fluid

Replace with

f

cracks

damage
place shock absorber kit
Inspect threads for cracks or ot her
damage Replace shock absorber
or

Rod diameter

Gland packing

M

Piston rod

19 965

inner

Piston rod

cYlinder

Inspect

and

shock absorber kit

pring

casing replace strut assembly
b

r

Oil oozing out at and around gland
packing does not call for strut
maintenance

rod

piston

t

Wash all

Blow

Install

Less than 0 1 mm

11 0 US 110z
0 004 inl

11 4

Imp

11 ozl

with fresh l1uid

whenever strut is disassembled

Inner cylinder and
outer casing

Inspect inner cylinder and outer
casing for cracks deformation or
other damage As for inner cylin
der

replace

for

outer

shock absorber kit As

casing

replace

strut
SFA138

assembly
FA 7

Suspension

Front

Place

4

FRONT AXLE

FRONT SUSPENSION
Tighten gland packing

7

guide bushing

1

ST3SS00001
Guide

shing
bu

LJ

Cylinder

fl98

118 N

12kg

10
72

m
m

87ft
FA280

4

SFA140

SFA143

10

strut

Reinstall

Toot

on

KV48 10030 I

Lubricate

5

sealing

lip

gland

of

LorIw
f

packing

c

1L

1tch

Compress coil spring

u

ing Tool

HT71730000

Lm ft

O 1m
0 3ftl
11

108

80

o

E

98

10 12

o

88 9 65

Converted torquel
p

B
o

78

8 58

SFA14S

o
0

3

12

o

SFA141

Be

careful

packing using

not to damage

Tool

sealing

N

q ft lb

m

L

8

coil
on

pring with Tool
spring lower seat of

strut
0 3

SFA144

lip

up

HT71730000

59 6 43

u
Install gland

6

Set

0

0 4

10

5

06
m

5
1

from

trut

Lubricate

parts

indicated

in

figure

2 0

Effective length of torque wrench

Remove

13

ft

Tool

KV48100301
After the above steps have been
completed air should be removed

9

from shock absorber syst

m

Repeat above procedure

everal

timal 10 that air will ba bled out from
strut

thoroughly

al

hown

48
SFA1

SFA142

279
FA

FA 8

At

FRONT AXLE
14

Mount following part

as

FRONT SUSPENSION

Front

Suspension

shown in

figure

Coil spring

G

Lock nut

Mounting

insulator

c

mi

Bear ing With dust Seal

spnng

eat

Bound bumper rubber
Dust

I

Sprmg
I

I

d

SFA149

Place

pnng

In

seat
po

ilton

Spnng InstallatIon

cover

TENSION ROD AND

STABIUZER BAR

Hf71730000

LJ

e
KV48100301

braCketlj
rl1

SFA147

Stabilizer

IV

42

31
3 2

4 3

23

To tension

IV
Install

bound

bumper

rubber

44

in

place to prevent piston rod from
falling by its own weight
Install mounting bearing so that it
points in correct direction
15 Tighten new piston rod self lock
in

nut

cJO
In

54

4 5

5 5

40

33
To

411

rod bracket

Tension rod

J

tension rod

bracket

Transverse link

IV

16
16

IV

l

N

m

kg

m

J

IV

50
5 1

37

I

60
6 1

44

t1
A

21
2 1

1215

ftIb

SFA150

IV

59

i6
43

74N
0

1

m

5k

54 ft Ibl

Remove under

cover

Set load of car

Uvd

If correctly

painted
can

be

on
seen

installed

white mark

stabilizer bushing

seat

from both sides of car

Always install

the stabilizer which

has the while mark on it on the left
transverse link
FA148

When

installing a bushing do
to project beyond the

allow it
face

area

Do

not

washers
16

Remove

strut

Tool

HT71730000

on

not
sur

of lhe washer
allow the
to

grease oil

come

bushings

and

in contact with

soapy water etc

assembly

After

in position
spring seatl
greduelly

placing spring

between upper and lower

release eompreaor

FA 9

Front

FRONT AXLE

Suspension

FRONT SUSPENSION
7

White mark

Separate following parts
Ball joint

I

Left side

1IT72520000

only

r

White mark
Both sides

knuckle

arm

using

press

SFA155

Stabilizer position

SFA152

to

4

strut

Separate

knuckle

lower

end

to
FA712

arm

CD
I

Unk

bushing

using

to

transverse

link

Set Tool ST36720000

SFAl53

washer

1

Tluust

2

Tension lod bracket
Tension rod

3

4

Collar

5

Bu

hins

5

Remove

following

from

parts

transverse link
I

Balljoint

I

Stabilizer

TRANSVERSE UNK

rG
f

Tension rod

SFA159

AND LOWER
BALL JOINT
8

reverse

moval noting the

following

I

I

vtJ

Front

6
SFAl54

Remove

transverse

link

from

crossmember

Wh n

instelling
spindle insert it
suspension crOS3
To

port it
Section

ear

I

car

with safety
GI

for

and then

curb

Lifting

I

Refer to

tand

Points

Remove wheel and tire

Separate
using Tool
3

FA 10

weight with

tire

on

Make

mating

ure

urfeof bu h
end

is clean end free from oil
gre

up

Install tren
set Tool

e

link bushing

u

ST36720000

and

tfl

Towing
2

first

hould be carried

Finel tightening

ing

wheels with chocks

front of

link
transye

ground

INSTAllATION

and raise

tremver
link

crossmember
I

REMOVAL AND

Block

re

from rear lide of

instell

out lit

I

order of

temporerily tighten nuts securing
tren
ve
link spindl which con
neeu transven link to suspension

SFA1511

9

Install transverse link and lower

ball joint in the

72

assembly

knuckle arm to side rod

Knuckl
17 3

SFAl58

erm

97 N

to strut
m

9 9

53 72

ni
kg
lb
ft

IISIllmbly

ing

FRONT AXLE
joint to knuckle

Ball

120 N

97
9 8

Ball

install

m

is

88 ft Ibl

joint to

50

transvene

60 N

5 1

grease

completely

and

plug

remove

in

grease

Pump

122 kg m

71

lubricate

To

arm

FrontSuspension

FRONT SUSPENSION

nipple
slowly until

its

place

old grease

forced out After greas

ing reinstall plug

link

m

6 1

m
kg

44 ft Ibl

37

Transverse link to crossmember
62

75 N
7 6

16 3
46

When

m

kg

used

m

so

55 ft lb

a

that grease is

new

grease gun is

pressure
high

operate the grease gun carefully
grease does

and

injected slowly
not

out

come

from

6

Raise up engine
Support weight of engine

the clamp ponion

load from
7

to remove

engine mounting
suspension crossmember

Remove

from body frame

INSPECTION

Transv

SUSPENSION
CROSSMEMBER

link

rs

Check for signs of cracks

distor

damage Replace if
are beyond

tion or other

any of above conditions

REMOVAL AND

INSTALLATION

repair
Ifrubber bushing shows evidence of
cracking replace with a new one

I

Bl6ck

wheels with chocks

rear

and raise front of

car

and then sup

port it with safety stands
Section

GI

for

Refer

to

Points and

Lifting

8

Towing

Ball Joint
BaIl

joint
factory and

assembled

is

at

the

2

Remove wheel and tire assembly

3

Remove under cover

f

cannot be disassembl

or

40

31

42 N m

3 2

20
17

4 3 kg

Crossmember

m

Bolt

kltcm

3 2

7 8N

23

m

Nut

80 kg em
69 in Ibl

Check conditional dust

found

to

beyond

use

be

cracked

replace

cover

Lubricate ball

body

frame

m

4 3

kg

m

31 ft Ibl

sidesl

72 N

m

7 3

kg

m

53 ft Ib

excessively

ball joint with

a

4

Remove

crossmember

new one

3

44

If

to

42 N

Both

60
6 1

2

m

Center

31

87 in Ibl

Used parts
2 0

insulator to

crossmember

23 31 ft Ibl

9 8 N
100

m
kg

Engine mounting

is pro

New parts

35

m

7 6

55 ft Ibl

46

Turning torque
3 9

75 N

6 3

lower than

specifications and ball joint
perly lubricated replace

Crossmember to transverse link
62

Check ball stud turning torque
with nut in place on ball stud
ed

If excessively higher

Install suspension crossmember in
order of removal

reverse

joint with

recom

link

transverse
Refer

to

from

Link and Lower Ball joint

Separate suspension

INSPECTION

Tran vene

crossmember

mended multi purpose grease regular

S

ly

from engine mounting insulator

Check suspension crossmember for
evidence of deformation or cracking if
necessary

replace
FA l1

FRONT SUSPENSION

FRONT AXLE

Service OstBsndSpecifications

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS

INSPECTION AND ADJUSTMENT

COIL SPRING

WHEEL ALIGNMENT

1
Dimension
DxL

d

Right

12 2
386

Color

Spring

identification

constant

I

degree

Caster

degree

045

3015

Kingpin inclination

degree

1025

S055

mm

erem 1
5 12

50

1716 N
Pink 1

392
5 12

2 0

0

0 081

75
1

Yellow 2

98

mm

kg mm

0 12

2

degree

130

10 480

in

in
Toe

White 2

Front wheel
12 2

Lah

40

Camber

5 201

steering

1

30

0 480

With power

Unladen

Inside

330

350

3

Outside

270

290

3

turning ngle
Full

turn

degree

0Iblin

5 43

Front wheel

200

Inside

out
Toe

2 2

Without

x

power

30

0 480

steering

turns

x

White 2

5 12

1

5 20

d x 0 xL

Free

18

Outside

70

length

mm

lin

mm

x

Coil diameter

mm

in

2

On both sides

3

On power

in

engine oil full
designed position

Tankful of fuel radiator coolant and

Spare tire jack hand tools

Wire diameter
x

degree

Cream 1

3S6

wheel
98

mats

in

steering models

turning

147N

tat circumference of steering wheel of
33 Ibl with engine at idle

force

10

15 kg 22

WHEEL BEARING

STRUT

I Shock

MBLY
ASSE

Wheel

bearing axial

absorber type

0

HYdraulic
N

I

Shock absorber fluid

l

Piston rod diameter

mQ US

fl

OZ

Imp

ozl

mm

in

110

kg

114
Wheel

19

19

965

975

bearing nut
tightening torque

mm

Return

0 7864

in

30 10
11 1819 1 1850

mm

N

in

172

16 77

gre
se

11 0 hI

see

22

With
m

an
kg

m

3 0 18

600

degree

new

Stroke

t 0 3

2 5

30 02

cylinder inner

diameter

Damping force

29

m

lbl
ft

angle

I

m

25
fl

325

10 7860

linneI

01

in

mm

play

I
I

Expansion
N

588 tOO 132

k9 lb

N

m

0 10
cm
kg

Wheel

J43 135 77

741

lbl
in
1

used

N

083

14 0 S 5 3 5

With

kg Ibl

Compression

0 39

gro

bearing

se

in

10

lbl

0 44
45 09

3

91

l

starting
With

torque

new

N

69

At

grease

Ik9 lbl

fO 7

14 7

wheel

seal

usad

N

20

grease

Ik9 lb

10 2 0 8 04

1 5 1 5

33

hub

bolt

STABILIZER BAR

I

Bar diameter

FA 12

mm

in

t9

10 75

With

se

t

7B
18

FRONT AXLE

FRONT SUSPENSION

ServiceOataandSpecifications

LOWER BAlL JOINT
N

m

New

39

kg
parts

in

98

em

100 35

140

Ibl

871

Turning torque
N

Used

m

kg
parts

20

7 8

120

80

em

Ibl

17

691

TIGHTENING TORQUE

I
I

Hub

I

Wheel hub

I

Disc brake

I

Rotor

I

Strut

I

Strut

I

to

I

nut

I

78

98

I

38

52

25

hub

hoodledge

to

Piston rod

sei

Iocklng

N

m

I

kg

8

I

ft Ib

m

10

I

58

72

I

28

38

3 9

5 3

34

2 5

3 5

18

25

59

74

60

75

43

54

9B

118

10 0

U2

87

72

97

7 3

9 9

53

72

72

97

7 3

9 9

53

72

54

98

5 5

10 0

40

72

nut

Gland

Strut

packing
to

Caliper

I

Unit

knuckle

to strut

Knuckle

arm

Knuckle

arm to

ball

arm

joint

side rod

12 0

I

FA 13

FRONT AXLE

Diagnoses and Corrections

JlTroeu

TROUBLE

FRONT SUSPENSION

DIAGNOSES AND CORRECTIONS
Probable

Condition
shock and shimmy of steering

Vibration
wheel

Loose connection

of each part

of each part of Iini age cause vibra
tion of front wheels and
steering wheel
wear

vibration This is very noticeable when

trav

When the front wheels

Shock

wom tire

Unevenly
ening ofwheel

insufficient

or

tight

imbal

Correct

the

ance or

replace

Replace

tighten

or

nuts

Improperly adjusted

front wheel

wom

or

Adjust

or

tighten

bearing

elling on rough road
travelling
the steering

are

bumpy roads the play of
linkage is transmitted to the steering wheel
This is especially noticeable when travelling
on

on

Adjust

tire pressure

Imbalance and deformation of road wheel

Vibration
and

Improper

Corrective action

cause

rough road

Shimmy Abnormal vibration of the front
suspension system and the whole steering
linkage which occurs at specific speeds

Faulty wheel alignment

Adjust

Wom transverse link

Replace

bushings

Insufficiently tightened steering gear hous

Retighten

ing
Wear of steering linkage

Replace faulty

Wom suspension ball joint

Replace

Excessive backlash due

to

improper adjust

parts

Adjust correctly

ment of the steering gear box

Damaged idler
Worn column

Replace

arm

bearing
or loose

bearing spring

column

Replace

or

retighten

inside the

Replace

or

retighten

weakened

clamp

Malfunction of shock absorber
strut or loose installation bolts

Correct

Imbalance of carlevel

the

imbal

ance

Car pulls to right
When drivin

wheelan
to
A

right

or

Improper

left

with hands off the steering

flat road

the

car

gently

swerves

left

lII ellSion
may also b8 the
of this problem and therefore 188 also

faulty

caUI8

a

or

rear

Sectinn RA

tire pressure

ening ofwheel
Difference in

insufficient tight

or

Adjust

or

tighten

nuts

wear

and tear of

right

and left

Replace

tires

tire treads
Incorrect

adjustment

abrasion of front

or

Adjust

or

replace

wheel bearing

Collapsed

or

Replace

twisted front spring

Adjust

Incorrect wheel alignment
Incorrect brake adjustment
Worn rubber bushings for

Adjust

binding
link and

Replace

and transverse

Replace

transverse

tension rod
Deformed

steering linkage

link and tension rod
Imbalance of car level

Correct
ance

FA 14

the

imbal

FRONT AXLE

Probable

Condition

Corrective action

cause

Adjust

tire pressure

Improper

Instability of car

Trouble Diagnoses and Corrections

FRONT SUSPENSION

bushings for

Worn rubber

transverse link and

Replace

tension rod
Incorrect wheel
Worn

deformed

or

Adjust

alignment
steering

linkage and

Replace

gear

Adjust

transverse link

adjustment of steering

Incorrect

Deformed

Checking

up

procedure

Insufficient lubricants
in

Jack

up front

gear

arm

and

wheels

detach the steering

operate the steering wheel

and

Stiff

box

mixing impurities
excessively worn

or

or

ball

damaged suspension

or

joint

or

Replenish
replace

or

grease

the part

Replace

lack of grease

light check steering linkage
suspension parts
If it is heavy check steering gear and
ing column parts
If it

steering
steering linkage

gear

replace

Adjust

tire pressure

Improper

Stiff steering wheel

Correct or

unbalanced road wheel

or

is

and
Worn
steer

or

Worn

incorrectly adjusted
damaged steering

or

Replace

bearing

gear and

Incorrectly adjusted steering

bearing

Replace
Adjust

alignment

Replace

mounting bearing
shock absorber

Replace

Interference of steering column with turn

Replace

Damaged

or

stiff piston

or

in the strut

piston rod

swi tch

signal

Adjust

Incorrectly adjusted steering gear housing
Worn

adjust

Adjust

gear

Incorrect wheel
strut

or

Replace

Deformed steering linkage

Damaged

Excessive steering wheel play

wheel

Replace

steering linkage

Improperly

Retighten

fitted gear housing

Adjust

Incorrectly adjusted wheel bearing
Worn transverse

link and tension rod bush

Replace

ings
Noises

Improper

Adjust

tire pressure

Insufficient lubricating oil

and grease for

suspension baU joint and steering linkage

or

their breakage
Loose

steering

gear bolts

linkage and

sus

Replenish

lubrica

ting oil and grease
or replace
Retighten

pension parts
Faulty shock absorber inside

the strut

Replace

Faulty wheel bearing
Worn

gear

Replace

tension rod bush

Replace

steering linkage and steering

Worn transverse link and

Replace

ings
Broken

or

coUapsed coil spring

Replace

FA 15

Trouble DiagnmsundCorTfICtions

FRONT AXLE

FRONT SUSPENSION

Condition

Probable

Corrective action

cause

Loose stabilizer bar installation bolts and

Retighten

nuts
Loose strut to

Grating tire noise

Improper

hoodledge installation

nuts

tire pressure

Adjust

Incorrect wheel alignment
Deformed knuckle

spindle

Retighten

Adjust
and

suspension

Replace

linkage
Jumping of disc wheel

Improper

tire pressure

Adjust

Faulty shock absorber

Replace

Faulty

Replace

tire

Deformed wheel rim

Excessively or partially

worn tire

Adjust

Imbalanced road wheels

Improper

tire pressure

Replace

Adjust

Incorrect wheel alignment

Adjust

Faulty wheel bearing

Replace

Incorrect brake

Adjust

adjustment

Tires not rotated

Rotate

tires

commended

at

val

Rough and improper driving manner

FA 16

Drive

more

re

inter

gently

FRONT AXLE

FRONT SUSPENSION

Special Service Tool

SPECIAL SERVICE TOOLS
Tool number

Kent Moore No

KV401021S0

CD ST35325000
@KV40102110
@KV40102120
@KV40102130
CID KV40 102140
@KV40102150

KV48100301

Tool

name

Bearing

outer race drift set

Drift bar
Drift A
Drift B

V

V

Screw A
Screw

B

Screw C

Strut and steering gear

housing

I

attachment

J
HT71730000

Coil spring compressor

ST35500001

G land

packing wrench

125825

ST35530000

Gland packing

guide

125827

tL
HT72520000

Ball joint

ST36720000

Transverse link

125847

remover

bushing replacer

3
t
ST35652001

Clamp

o
FA 17

DATSUN 200SX

Model SIlO Series

SECTIONRA
REAR AXLE

REAR SUSPENSION

CONTENTS
REAR AXLE
REAR AXLE
AXLE ASSEMBLY

REAR

RA

2

SERVICE DATA AND

RA

2

SPECIFICATIONS

RA

2

REAR AXLE SHAFT AND WHEEL
BEARING

GENERAL

SPECIF ICA TIONS

INSPECTION
RA

3

REAR SUSPENSION

RA

5

TROUBLE

REAR SUSPENSION

RA

5

RA

6

CORRECTIONS
SPECIAL SERVICE TOOLS

RA

6

RA

7

RA

7

STABILIZER
SHOCK
COIL

BAR

ABSORBER

SPRING

UPPER

LINK AND LOWER

LINK

TIGHTENING

AND ADJUSTMENT
TORGUE

RA

8

RA

8

RA

8

RA

8

RA

9

DIAGNOSES AND

RA lO

GII

REAR AXLE

RearAxle

REAR SUSPENSION

REAR AXLE
REAR AXLE

REAR AXLE ASSEMBLY
Removal and Inatallatlon
Oil w

Block front wheels

Install using oil seal
drift KV40100300

Place stands

Support under differential
garage jack

carrier with

BeuiDg coner
Installed by
force of 29
3
Rear axle

cue end

5t 3 3
49

3 0

shim

a

ing

p

49 kN
I

5 5 US ton

Imp

I

ton

0 075 0 0030
Thickne
0 150 0 0059
0 225 0 0089
0 300 0 0118

A

I

L
Breather
72 Filler PI

lteatherCOP
1l

2

Remove stabilizer

bar

Refer to

Stabilizer Bar for installation

4
72

1

SAA013

It

I
SAA017

3
Rear

J22
C

axle

cue end

shim

to

26
2 2

J
C

2 7 16

section

hydraulic

20

78 98
8 10 58

Disconnect
PO

When
tubes

Ax1ease

I

for

line and

shaft

Refer
brake

removal

parking brake cable

CAUTION

BeuiDg

72

propeller

removing
use

or

installing

brake

Tool GG94310000

II
Axle shafl

Bearingcol1ar
Bearing spacer

Gap

fiJ
Aal shaft

fIanse side

Beerin8
ide

f
1r

W
J

C

w
0iI

C

Gap

C 0

0 1

J
C

0

N

Unit

0 004

m

kg

rom

m

ft Ib

SAA014

RA 2

t

ec

in

SRA018

REAR AXLE
4

2

Disconnect shock absorber lower

end

on

REAR SUSPENSION
Disconnect

Rear Axle

parking brake

cable

and brake tube

each side

When removing shock absorber low
er

end from

bracket

absorber and
to

lift

it

squeeze shock

right above

out

accommodate embossment

inside

bracket

F
p

c

7

I

i

y

II
I

I

Release jack and pull it out

I

Remove caliper and rotor
nuts securing baffle plate

3

Re

move

l

RA485

It
Installation is in
R

A486

reverse

order of

removal
Refer

Upper

to

Link

and Lower

Link for installation of upper link and

4

Draw out axle shaft

lower link
Rear

5
on

Lower

jack and

remove

coil spring

axle shaft

In p ction

each side

Check axle
tion

jf

or

case

for yield deforma

cracks and replace if necessary

REAR AXLE SHAFT AND
WHEEL BEARING
SAA026

R
I

mov

1

nd dl

Block front wheels

Remove

rear

wheel

mbl
Place stands
5

Remove oil seal

4
6

Raise

jack

to

previous position

Disconnect upper link and lower link
at axle case side

A

SAA027

RA 3

REAR AXLE

Rear Axle

REAR SUSPENSION

6

Cut collar with cold chisel Take

care

not to

damage

2

Press

bearing collar by

new

of 29 to 49 kN

axle sheft

a

load

Gap

3 to 5 ton 3 3 to 5 5

US ton 3 0 to 4 9

Imp

Ion

C

less than 0 1

mm

0 004 in

Ions

i

Shim thickness

d

W
Baffle plate

IIII

II
SRA028

AA559
SRA030

7

Remove wheel

bearing and

collar
3

Install oil seal

tween

L

packing cavity

sealing lips with

Rear axle case end

be

Refer

recommended

to

him

S OS

multi purpose grease
6

l
AA492

Measure end play of axle shaft

KV40100300

SAA031

Inspection

SAA032

Check axle shaft for straightness
cracks

damage

wear or

distortion

Check lip of oil seal for damage de
formation

or

wear

Check bearing for

4

Insert

outer
wear

or

damage

move

I

Install

fer

ide

wheel
haft

bearing

facing

bearing

axle

shaft into axle
purpose grease

to

case

90 mm

l1ange

and

bearing

is 70 to

2 76 to 3 54 in

with seal

facing

0 40 mm

0 0020

fl

25 N m

2 0

CD

ollie

14

2 5 kg

m

18 ft lbl

Oil drain and filler

flange

1

59

98 N

6 0

9 AJ

J
CD

70

90mm

12 76

SRAQ29

r

54
3

RA560

1

Bait

4

Rear axle shaft

5

3

Bame plate

6

Adapter plate
Bearing spacer
Wheel bearing

5

Rear axle

2
3

Rear axle shaft gune ST37840000
Rear axle case

4

Oil seal

gap

shaft

between wheel

bearing and axle tube end by selecting
shim

m

1 8

m

kg

m

13 ft lb

17

20 N

1 7
12

C

kg

Brake 3way connector fixing bolt

1

Adjust

18 N

11

Wheel
2

10 0

Brake tube flare nut

1 5
in

plug

m

72 ft Ibl

43

15
A

4
RA

0 0157 in

Differential gear carrier fixing
20

flange Insert

ido

0 05

nut

spacer with cham
haft

Axial end play

the

periphery of bearing collar Re
guide when distance A be

tween axle

Assembly and Installation

axle

applying multi

m

kg m

14 ft Ibl
nut

78
8 0
58

2 0

98 N

m

10 0

kg

72 ft Ibl

m

REAR SUSPENSION

REAR AXLE

Rear

Suspension

REAR SUSPENSION
REAR SUSPENSION
dl

15

20

5
1

2

0 11

14

@

e
e

e1

1

Coil Spring
l D color
YeUow

Purple

Shock absorber

Upper link
8

0 51

bolt

58

dl

3 7 50
0 38 0 51
2 7 3 7

Lower link

bushing
Replaceable
or installed
by a pressing force of
39 69 KN 4 11
4 4 7 7 US ton
39
6 9 Imp ton

Removed

78

Differ in length

7

0

8 0 51

58

Differ in length from upper link bolt

from upper link bolt

2 1

dl16

21

16

2 1

12

dl

12

N

15

m

kg ft lb
SAA033

AA 5

Rear

REAR AXLE

Suspension

REAR SUSPENSION

STABILIZER BAR

Inspection

Remoyal

Check stabilizer bar for evidence
of deformation or cracks replace if

Inspection
Test shock

I

Remove stabilizer bar

Check

rubber

P

fI

parts

they
replace if necessary

be

to

deteriorated

are not

Check for oil leakage and cracks
Also check shaft for bending

sure

cracked

or

Inspect

stabilizer bar

b

InstJ U

rubber

fining
c

on

Install

dam

Re

being careful
COIL SPRING

confuse right and left sides

not to

bushings for

place parts if necessary

Installation
Install

rubber

cracks and deformation

age

a

absorber and compare
in S O S

specifications given
Replace if necessary

necessary

2

II

with

bushing

with metal

Remoyal end Installation

axle case lide

bolt

SRA017

I

attaching

that bolt is inside the

bushing

so

car

Block front wheels

Place stands

Support under differential
garage jack

carrier with

L

Front
21

SRA016

11 6 2 1

2

IV
IV

N

m

kg

m

2111 6 2 1

16

Disconnect shock absorber lower

end

12

ft Ib
SRA035

SHOCK ABSORBER

C

s

Remoyal and Installation
Disconnect upper end

I

LIV6

C
14ft

SRA038

lbl

1

fl ilr

SAA038

L7 0

8 0 kg

m

51

3

58 ft lbl

T

c

In

2

lturggage
unk

room

Disconnect lower end

SRA037

md remme

i

r

shock absorber
I

Squeeze shock absorber and lift it
out

right

above to accommodate em

bossment inside bracket

6
RA

t

t

I

r

RA486

L7 0

Lower

coil springs

IY
ml

78N

80 kg

m

jack slowly
on

each side

51

and

58 ft lbl

remove

REAR SUSPENSION

REAR AXLE
Inspection

mation
Test

or

defor

cracks

spring and

Check for signs of cracks
tion

compare with

fications given in S D S
Check all rubber parts for

speci

other

or

distor

Replace

damage

a

if

Securing

bolts for

use

with lower

link differ in length from those for
upper link If used wrong securing
bolts cannot be tightened securely

beyond repair
b

wear

cracks damage or deformation Re
place if necessary

Suspension

Installation

Inspection

Check coil spring for yield

Rear

When
one

Bushing replacement
For lower link only

installing

make
then

upper

end of upper link
sure

tighten

that
link

link

install

link
on

car

body

is level

and

securely Next

in

stall the other end of link on axle

UPPER LINK AND LOWER
LINK

If rubber bushing shows evidence of

Upper

Removal

link

Remove

It

upper

link

by removing bolt
is

possible

to

assembly alone from

or
on

lower

link

place

as

bushing is secured by

assembly

an

as

securely tighten link while
ground
When installing lower link securely
tighten link while tires are on
tires

adhesion and cannot be removed

alone

side and

cracks replace it using Tool
c

Re

are on

ground

necessary

each end

remove one

til

link

CAUTION

car

Shock absorber lower end
69

00 not tap end face of bushing direct
ly with a hammer as deformation may
result in loose bolt

7 0
51

7 0

pressing

51

or

installed by
69 KN

4

71 4 4

69
7 0

7 7 US ton
39

69

kg

m

58 ft Ibl

78 N

m

8 0

kg

51

nut

m

58 ft Ibl

Lower link

a

force of

39

m

8 0

Upper link fixing bolt and
69

Removed

78 N

fixing

78 N
8 0

nut

m

kg

m

58 ft Ibl

Imp

ton

KV40101420

RA495

LI

g
lr

BUshing

KV401O

j

t
47 a
w
SRA039

RA 7

REAR AXLE

ServireDataandSpecifications

REAR

SERVICE DATA

SlJSPENSION

AND SPECIFICATIONS
REAR AXLE

GENERAL SPECIFICATIONS
SHOCK ABSORBER

I

Maximum

I

Stroke

length

Unit

L

mm

End

in

play

mm

146

5 75
Thickness of

10 0020

mm

0 01571
Part

n

umber

075
0

10 00301

43036

0 1SO

10 00591

43036 H5oo1

0 225

10 00891

43036 HS002

0 300

10 01181

43036 H5003

H5000

xle

rear

end shim

case

L

C

OAO

Thickness

120 67

525

0 05

On

0
SRA090

COIL SPRING

I

Wire diameter

I

Coil diameter

mm

in

90

13 541

I

Free

mm

in

362

14

mm

length

I

Effective

I

Spring

10 010

in

3941

251

TIGHTENING

turns

Unit
constant

N

17

mm

kg

mm

Ib

178 99

46

inl

71

Yellow

1

N

Broke tube flare

Identification color

nut

m

15

18

m
kg
15

8
1

ft Ib

11

13

Brake

caliper fixing bolt

38

52

39

5 3

28

38

Baffle

plate fixing

22

26

2 2

2 7

16

20

ut

PurPle
Propeller shaft to

com

Refer

panion flange connecting

ll0

Wheel

nut

Drain and filler

SHOCK ABSORBER
SHOCK ABSORBER DAMPING

I

Expansion

N

kg lbl

I

Compression

N

kg Ib

FORCE

490

245

686

at

03

50

402

25

PO section

m

70

41

plugs

78

98

80

10 0

58

72

59

98

60

10 0

43

72

20

25

20

2 5

14

18

15

20

15

2 0

11

14

69

78

7 0

80

51

58

RA040

INSPECTION AND ADJUSTMENT

I

to

nut

5

RA B

TORQUE

7 75

11 0 hIls

110

154

55

901

I
I
I

Differential carrier

I
I

Upper link fixing bolt

69

78

7 0

8 0

51

58

Upper link fixing

nut

69

78

7 0

80

51

58

I

Lower link

nut

69

78

7 0

80

51

58

axlll

case

to

nut

Shock absorber upper
end

nut

Shock absorber lower
end

nut

fixing

REAR AXLE

REAR SUSPENSION

Trouble

Diagnoses and Corrections

TROUBLE DIAGNOSES AND CORRECTIONS
When

rear

axle and suspension is
is advis

suspected of being noisy it
able to make thorough test
mine

whether the

noise

to

shaft

bearings

transmission
engine
suspension
Noise which originates in other
places cannot be corrected by adjust
ment or replacement of parts in the

deter

originates

in the tires road surface exhaust pro

Condition
Noise unusual sound

peller

wheel

Probable

Tighten
Tighten

securing bolts loose
or

and

case

rear

suspension

of oil

leak

there is any damage
breather

or

first check if
restriction in

Corrective action

One

Lack oflubricating oil

In

cause

Loose wheel nuts
or more

rear axle

or

grease

Faulty shock absorber

to

Lubricate

specified torque

as

required

Replace

Incorrect adjustment of

rear

axle shaft end

Adjust

play

Damaged
Worn

or worn wheel

spline portion

of

bearing

rear

axle shaft

Replace
Replace if necessary

Loose journal connections etc

Tighten

Unbalance of wheel and tire

Balance

Damage
bushing

of the rubber parts such as link
shock absorber mounting bush

to

torque

Replace damaged parts

ing
Faulty propeller shaft journal

Breakage
Instability in driving
This problem is also
related to the front

Replace

of coil spring

Damaged

Tighten

link rubber

bushings

also refer to

the FA section

Replace

Incorrect wheel alignment

Adjust

Spring

Replace

Oil

leakage

wear

Damaged oil seal on

rear axle

shaft

to

specified torque

Replace

Worn shock absorber

suspension For trouble

diagnosis

propeller shaft assembly

Replace

Loose wheel nuts
rear

as a

Replace

Oil leakage from the differential carrier

Replace parts as required

Damaged

Replace

grease sea of rear axle shaft

RA 9

Special Service

Tools

REAR

REAR AXLE

SUSPENSION

SPECIAL SERVICE TOOLS
Tool number

Tool

name

knt Moore No
GG943 I 0000

Flare nut torque wrench

KV4010I0OO

Rear axle stand

J

1
25604

ST36230000

Sliding

hammer

J 25840

bearing puller

lIT72480000

Rear axle shaft

ST38210000

Wheel bearing collar press stand

25869
1

J

KV40100300

Rear axle oil seal drift

J 25405

ST37840000

Rear axle shaft

guide

@
KV40l0l4S0

CD

Link rubber bushing drift

KV4010141O

Drift

V KV40101420

Drift

@

KV40101430

Base

@

KV40101440

Ring useless

RA I0

h

Model S II 0 Series

DATSUN 200SX

SECTIONBR
BRAKE SYSTEM

CONTENTS
DESCRI PTION
SERVICE BRAKE
BRAKE
MASTER
BRAKE

PEDAL
CYLINDER
HYDRAULIC

BLEEDING

LINE

HYDRAULIC SYSTEM

NP VALVE
FRONT

DISC

BRAKE

N22

FRONT DISC ROTOR
REAR DISC

BRAKE

REAR DISC

ROTOR

AN12H

BR

2

BR

3

BR

3

BR

4

PARKING

BRAKE

SERVICE DATA AND
SPECIFICATIONS

BR 14
BR 16
BR 16

5

BR

5

GENERAL SPECIFICATIONS

BR 18

BR

6

INSPECTION

BR 18

BR

6

TIGHTENING

BR

9

BR 13

to

BOOSTER

BR

BR lO

Refe

BRAKE

PARKING BRAKE

Section MA

AND ADJUSTMENT
TORQUE

BR 1B

BR 19

TROUBLE DIAGNOSES AND

CORRECTIONS
SPECIAL SERVICE TOOL

Brake

System

BR 20
BR 22

for

CHECKING FOOT BRAKE
CHECKING PARKING

8RAKE

a

BRAKE SYSTEM

ription
CH

DESCRIPTION

way
3

Pulling

Brake

connector

hrake lever

hOle

Front disc brake

SBR001

The brake system is
controlled

dual

line

operates independently

a

hydraulically
type

on

which

front and

rear wheels

The

BR 2

brake

assist

device

is

a

power

The

rear

engine

rear

disc

a

pressure control

brakes

brake is

with

a

mechanically operated parking

brake mechanism

vacuum

The NP valve is
device for the

booster

which utilizes

intake manifold

The

pad clearances of the front and
automatically adjusted

rear brakes are

equipped

BRAKE SYSTEM

Service Brake

SERVICE BRAKE
BRAKE PEDAL
R H

f
Input rod

rod lock nut

Input

SnaPrin

l16
i

22

16

2 2

i7 8
l
0

i7 8
l

10 8

5 8

10 8 0 8

1 5 8

8 0

1

8

8 0

t

12

0

10 8

8

1 5 8

8 0

Pin

l7
i

8

11 8

0 8

2 5 8
1

Pedal bracket

8 7

LH

Itf
ring
E

i7 8
l

10 8

0

8

1 58

l13
ki

18

3
1

13

8 9
1

Return spring

t
l

Brakelamp witCh
Lock nut

l12
i
Pedal

Be

sure

to

from LH

l
i

N

m

insert
side

kg

m

Brake

Remove

2

pedal bracket assembly
M T only
clevis

from

00

brake

O@

damage c

Check

Check return springs for fatigue
Check clevis for deformation

clevis pin be careful
ip of the clevi pin

brake

pedal

for

bend

and crack at welded part

o

not to

I
2
3

pedal
When removing

11

9

SBR120

pedal

Disconnect

15

fHb

o

with brake

12

Lubricating
point

pedal

REMOVAL
I

15

stopper

I

@II

lf

INSTALLTION
I

Apply coating

of recommended

multi purpose grease to sliding portion
and return coil spring
2

Adjust brake pedal after installa
completed Refer to Section
MA for adjustment
tion is

lil
SBR122

Fulcrum pin
7 8
0 8
5 8

INSPECTION
3

Remove fulcrum pin Brake pedal
then be taken out

16

Check brake pedal for the following
items

servicing

as

necessary

1 6
12

bolt

1 1

kg m

8 0 ft lb

Input rod lock

SBR121

can

fixing

10 8 N m

nut

22 N m
2 2

kg m

16 ft lb

3
BR

Service Brake

BRAKE SYSTEM

MASTER CYLINDER

piston
H

return

spring

Secondary pilton

Reservoir cap

Fillet

Reservoir

pilton
Prim
Primary piston return spring

teek

Yalve

88 8 0

tfJ
88

8 0

9 0 58

6 9

9 0 58
8 8 0 7

65
0 9 5 1

6 5

J
l

N

m
ii

m

65

ft Ib

SBA009

DISASSEMBLY
The brake master

cylinder

Secondary piston

is avail

able
no

only in TOKICO make There is
interchangeability of repair kits or

component part between NABCO and
TOKICO makes
When

replacing

tha

component part

repair

kit

or

rtain tha brand

Primary piston

of the brake master cylindar body Ba
sure to
part of the same make as

SBR011

SBR013

the former ones
I

Pry off stopper ring
3

Disassemble piston assembly
5

Unscrew

plugs for disassembling

check valve

L

Secondary piston

Primary piston

assembly

uembly
a

INSPECTION
I
2
SBR012

Clean all parts in a brake l1uid
Check the parts for evidence of

abnoimal wear or damage
Check piston
cylinder
to

3

clear

ance

2

Remove

stopper

and secondary

piston

then be taken out

4
BR

screw

Primary

assemblies

can

4

Remove piston cups and discard
them

Piston

linder clearance

Less than 0 15 mm

0 0059 in

BRAKE SYSTEM

ASSEMBLY

2

Brake tube

Lock

I
a

Replace piston
with new

b

to

packing

ed

ones

Iiding

Install bleeder

valve

With brake

hose

on

pedal fully depress
and allow

brake pedal to return Repeat bleeding
operation until no air bubbles show in

urface of ports

contact

bleeder

open bleeder valve to exhaust air

Then close bleeder valve

braka fluid or rubber gre

Apply
to

and

cups

spring

SelYice Brake

focilitata aaembly of master cyl

hose

inder
a

J
i

Chock

01

78

plug

0

88

8 0

on

m
N

9 0

b
SBA006

m
kg

c
a

After

installation

bleed

brake

is

system

completed
Refer

painted

h br ka fluid

pla

areas

Brake fluid

containing

air is white

and contain air bubbles

65 ft Ibl

58

Be careful not to

Brake fluid
out

of

to
stream

containing

bleeder

valve

no

in

air runs
a

solid

free of air bubbles

Bleeding Hydraulic System

BRAKE
HYDRAULIC LINE

BLEEDING

HYDRAULIC SYSTEM

Check brake lines tubes and hoses
for evidence of cracks deterioration or
other

damage

parts
If leakage

Replace

a

faulty

any

at

occurs

tighten
joints
replace faulty parts

end

if

or

Do not mix

two

different

recom

brand

braka fluid
b

Ie

with

1
Top up reservoir
mended brake l1uid

INSPECTION

around

C refully monitor brake fluid le el
at

master

cylinder during bleeding
SBR003

operation

necessary
c

Do not reuse drained brake fluid

r

REMOVAL AND
INSTALLATION
To

remove

flare nuts

3

brake tube

on

disconnect

both ends and

retainers and

Bleed

J
i

Air bleeder

0 7

CAUTION

tubes

removing
use

5 1
or

in

the

following

se

Rear wheel

remove

clips

6 9

When

air

quence Master cylinder
Front wheel

installing

8 8 N

I

e

m

0 9 kg

m

6 5 ft Ibl

brake

Tool GG94310000

SBROOS

To remove brake hose

l1are

first

remove

hose

securing brake tube to
then withdraw lock spring

Next

disconnect

nut

the

Do not twist brake ho

other side
e

BR 5

Service Brake

BRAKE SYSTEM
Do notdisassemble NP val e

NP VALVE
If

wheel
e Front
cylinder
Front

Brake tube f1ere nut
15

18 N

11 5

wheel

m
kg

13 ft Ibl

11

cylinder

m

1 8

NP waive to body
3 9

4 9 N

m

4 0 5 Irg m
0
2 9 3 6 ft lbl

SBROO1

N22

FRONT DISC BRAKE

J12
i

9 9 53

91 1 3

72

a1
Dustse
Piston eal

Replace

at

Apply

each disassembly

cfuc

bJake grease

Cy1inder body

r

ainingring
aet

You holder
II
Minimum thickness

D

10 5 0 413

Installed by pressing force
196 294N
20 30 leg 44 66 Ib

I

Yoke

1

Spring

rupj

21

16

2 1

12

15

Pad
WeaJ limit

1

J
i
Unit

J
6
BR

2

0 08

N

m
rom

m
Ieg
in

lb
Jt

SBA014

BRAKE SYSTEM

PAD REPLACEMENT

CAUTION

clip Remove pad pins
holding springs with finger
I

Service Brake

Remove

Piston
hand
of

easily pushed in by

be

can

groove

piston

if

piston is pressur
point
moved
piston seal will be

seal At this
ed

far

inside of

will go

piston

too

pushed

but if

or

pushed
assembly
caliper
and disassemble it Then push piston
out in direction shown by arrow
Assemble it again referring to the
following
If

damaged
in too

far

piston

has been

remove

Piston seal

2

Y

Piston B

Normal

SBA015

2

POSitiOn

Detach pads
Do not push too far

CAUTION
After
brake

removing pads do
pedal or pistons

BR780

depress
will jump

not

out

REMOVAL

4

Install

inner

pad

I

Disconnect brake tube

2

Remove

to

Pull yoke

outer side

SBRG16

Open bleeder valve Push piston
piston in until dust seal
of
piston B coincides with
groove
end surface of retaining ring on dust
3

B

SBA230

outer

seal
5

caliper assembly

Install outer pad
Coat

the

following points with

recommended

pad grease
Cylinder body to pad clearance
Pad pin to pad clearance
Pad pin holes of cylinder body
Do not grllll8 friction face of pIId

Then install

pad ftxing parts

pre

viously removed
BR 7

Service Bl1lke

BRAKE SYSTEM

Piston seal

Remove pads
Remove

fIXing

bolt and separate

Gripper and

Remove piston seal

4

DISASSEMBLY

each d

must

be

replaced

at

bly

Check for

oke holder
cracks

wear

damage Replace

or

other

if any fault is detect

ed

yoke and cylinder body

01

ASSEMBLY
I

D

SBR020

Apply rubber

seals taking

BR740

or brake

grease

to seal grooves and seals Install
care

not to

l1uid

piston

damage them

INSPECTION
CAUTION
Use bfllke fluid to clean Never use

J

minefllloil

BA741

Cllnder

SBR021

bod

I Check inside surface of cylinder
for
2

Remove

yoke holder

retaining
rings and dust seals from both pistons

score

rust

wear

damage

presence of foreign substance
surface fault i
detected

or

If any

replace

cylinder body
2
MinoJ damage from
Just
of
foreign sub tances may be eliminated
by polishing surface with a fme emery
cloth If damage is major cylindCJ

Dust seal

assembly

must be

replaced

2

Apply

rubber

grease

brake

or

l1uid to sliding portions Insert pistons

CAUTION

Iniert piston

A in direction shown

arrow

Q1 and

shown

by BrroW 02

piston

by

B in direction

Yoke
Check for

wear

B

cracks

or

damage Replace if any fault
8R742

i

other

not to

detect

ed

When inserting pistons
insert too far

Replacement
b

Instan

Refer

of

Push out pistons from cylinder

to

Pad

for assembly

piston A

10

that its

groove coincides with
3

be careful

yoke

yoko

groove

cylinder

PIston
Check piston for

score

rust

tonA
wear

presence of foreign sub
any fault is detect

damage

or

stances

Replace if

PistonB

1

ed

t
CAUTION
Piston

sliding surface is plated 00 not
with
polish
emery paper eveil if rust or

foreign
SBR019

BR B

surface

matter

is sticked

on

sliding

I

Q2

BRAKE SYSTEM

3

Install dust seal and clamp

secure

CAUTION

ly with retaining ring
a

Apply
grease
1

When

recommended
to

disc

brake

sealing surface of dUlt

b

Be careful not to deform dust seal

c

Wipe off

excess

Brake

Vice
Se

grease with alcohol

pressing yoke inlo yoke holder
to insert yoke vertically so as
not to crack or chip yoke holder If
yoke holder is damaged or pl8uing
force is out of specification replace
be

su re

with

a new one

i

n

Preaing force
196
20
44

I

SBR232

294 N
30
66

kg

Ibl

Rotor repair limit
Maximum runout
Total indicator
center

reading

at

of rotor pad contact

su rface

0 12 mm

0 0047 in

SBR022

Pariille lism

3
BR959

4

Install yoke holder to piston A

Apply a
gripper to yoke
coating of 1 soap water to inner wall
of gripper and drive in collar
Install

6

Install pads Refer to Pad Replace

ment for installation

ll
F

L

T

FRONT DISC ROTOR
SBR233

REMOVAL AND

INSTALLATION

Rotor

repair limit
Maximum parallelism

Refer to section FA

Circumferential direction
0 07 mm

0 0028 in

BR745

INSPECTION
I

Sliding surface

4

If there are cracks or considerable

Install yoke to yoke holder and
supporting end of piston B press yoke
into yoke holder by using press or

chips repair

hands

Measure mnout

5

2

or

Standard thickness

replace

12 5

Runout

Adjust

Thickness

wheel

bearing

correctly

Rotor

mm

0 492 inl

repair

limit

Minimum thickness
10 5 mm

0 413 in

BR 9

2
I

C1l

m en

aIII IIa a It n m aII

en lm 3

III
I

IIz

NZ
I

in

mm

Pring

Retainer CyUnder

r

Unit

Return

body

A

lever

Tog le

Ipring
I

Yoke

cover

Spring

ke

thicknes
Rotor

Minmu

spring
lueal
Anti

339
0
6
8

grease

Retain g

to

Shim
Pad

limit 063

0

Wear

6

1

J
o

instaling

brake
when
ap ly sides

rins

sure
Be

both
to

SBA037

BRAKE SYSTEM
PAD REPLACEMENT
I

Service Breke

Nissan silicone based grease or

equiva

lent

Remove

clip Remove pad pins
holding springs with finger

Silicone based greasing points
Friction surface of yoke and cyl
inder

LL

body

Cylinder body pad pin hole
Then install

pads fIxing

parts pre

viously removed

REMOVAL
I

5

Disconnect brake tube

Install pads and shims

SBR03B

Position outer

piston

so

that por

tion of cutout is level and install pad
by aligning this portion with protru
2

Detach

pads

sion at back of

and shims

CAUTION
After

pad

Align

ss
removing peds do not
dep
pedel or pistons will jump out

breke

SBA041

Ie I
I

4

J
Ie

2

1
J

D

Remove

caliper assembly

rf
Jrr

r
7

BR191A

1111

6

1

Coat the following points with

re

commended pad grease

3

Retract outer piston into cylinder

body by turning it clockwise and push
ing it in Be careful not to demell8
dust seal

I

I

Cylinder body to pad clearance
Y oke to pad clearance
Pad pin to pad clearance
Pad pin to bracket clearance

SBRD42

8

Do not grease friction face of pad

DISASSEMBLY

b

Be sure to

I
Separate cylinder
yoke by pushing it

apply pad

grease

to

both

sides of shims

body

from

Fllt blade screwdriver

1

BR173A
SBR234

4

Move yoke until clearances to in

stall pads

are

equal with

between rotor and yoke

a

lever

placed

2
are

Check that the

following points

coated with silicone based grease

2

Remove retaining rings and dust

seals

BR II

BRAKE SYSTEM

ServiceBrake

Replace

dust seal

at

each di

m

6

Disassemble

piston by

outer

re

moving snap ring B

bly

Snap rilll

BAlBOA

Piston

SBA043

SBR045

2

Engage

square

with push rod
3

Drive

pushing

out

outer

piston assembly
piston in

by

key plate
7

Disassemble

moving snap rings

inner

piston by

hole in

Also engage

in concave in

key plate
convex

in

piston

re

A and C

Snap ring

remover

SBR048

SBRD46

3

Install spring

cover

4

Remove piston seals
Replace piston seal
sembly

8
at

each

di

Remove hand brake

by removing

return

Remove dust seal and

toggle lever
spring and nut

and snap

seat

ring

spring spring

A with suitable

press and drift

cam

Nut

tt

Return spong

Drift

Toggle lever

8

LDust
Caml

SBA044

5

Disengage piston assembly
turning inner and outer pistons

SBA235

seal
4

When

SBR047

gle

by

installing parking brake tog
assembling piston turn
direction parking brake opera

lever after

cam

in

tes

ASSEMBLY
I

Before

assembling

apply

thin

coat of rubber grease to the following
e
Groove in push rod and new O ring

Strut ends
Oil seal
Piston seal
Inside of dust seal

Securely
direction
BR 12

install oil seal in

specified

Toggle lever

BRAKE SYSTEM
5

Apply

rubber grease

or

brake l1uid

II

REAR DISC ROTOR

the following points with

silicone based grease
Frictional surfaces of yoke and cyl

to seal grooves and seals

6

Coat

Install piston seals

Service Brake

REMOVAL AND

inder

body
Cylinder body pad pin hole

INSTAUATION
Remove

caliper and

rotor can

be

taken out

fi

o

INSPECTION
Sliding surface

I

If there
2

7
to

8

Apply rub ber grease
sliding portions

Apply

Diameter

insert
arrow

pad

brake l1uid

wheel

bearing

correctly

contact surface

l

the figure shows Then

piston
piston assembly

considerable

Measure runout at the center of rotor

rubber grease to one hole
of
1 5 mm 0059 in
as

outer

or

or

replace

or

Runout

Adjust

SBA044

cracks

are

chips repair

H

in direction of

1

SBR243

I

Silicone based greasing point

rl

12

1

Yoke

2

Cylinder body

3

Assemble

Pad pin

yoke and cylinder with

retainer

j

out

l
on

Inne

Rotor

QI

repair

limit

Maximum runout

YOke

Total indicotor

Retainer

pi

center

of rotor

reading at
pad contact

surfacel

fJ

0 15

3

Di
1 5

m
mm

0 0059 in

mm

Parallelism

r

0 059 in

L

SBR049
r

SBR245

13

Install pads Refer to Pad

Replace

ment for installation
9

Install

dust seals and clamp

se

curely with retaining rings
10

INSTAUATION

fl

Install yoke spring

Coliper fixing
3 9

28
After

pedal

SBR050

Rotor

5 3 kg m

installation

few times to

pad

check

for

to rotor

oil

repair

limit

Maximum parallelism

38 ft Ib

brake

Circumferential

depress brake
properly adjust
clearance

leakage

and

When brake

stroke is constant brake

pad to
rotor clearance is properly adjusted It
will be automatically adjusted by
depressing brake pedal
pedal

BR181A

bolt

52 N m

38

0 07
4

mm

diroctionl

0 0028 in

Thickness
Sblndard thicknou
9 6 mm

378
0

in

Rotor repair limit
Minimum thickness
8 6 mm

0 339 in
BR 13

Service Brake

BRAKE SYSTEM

BRAKE BOOSTER

D

Cheek valve
Pisto

j

IJp hngm

I
Valve

turn

spring

11

0

Fins rJ

Fulcrum

plate

l
Front meD

I
ID
SBR059

2

engine and increase engine
speed Stop engine when vacuum is
66 7 kPa
500 mmHg 19 69 inHg

INSPECTION

Air tight test
1

Connect

a

No load

vacuum

Start

3

If

than
the

vacuum

the
cause

following

gauge between

pressure drops more
value
correct

specified
in

accordance

with

the

chart

check valve and brake booster
Maximum vacuum
15 seconds after

leekege

engine

3 3 kPa

25 mmHg 0 98 inHg

60

J

coo

SBR216

Probable
Air

leakage

Air

leakage

Air

leakage between

Air

leakage

saRD D

Corrective action
check valve

Inspect

output rod seal

at valve

valve body and seal

plunger

Damaged piping or joints

BR 14

J
76

cause

at check valve
at

HI

Replace

brake booster

seat

Repair

or

replace

as an

assembly

is

stopped

Service Brake

BRAKE SYSTEM
Under loed

Air tight test

Maximum vacuum

as

toppedl

after engine i

15 second

Keep brake pedal fully depressed
Following procedures are same

Operetlng test

leakage

25

for noload conditions

Connect

1

3 3 kPa

brake
0 98 inHg

mmHg

line

an

oil pressure gauge to

connection

at

on

master

cylinder
2

Install

force

pedal

a

gauge

on

brake pedal
Probable

Corrective action

cause

speed until
Air leakage at check valve

Inspecl

check valve

kPa

500

gistered

Damaged diaphragm

Replace

Air leakage at poppet assembly seat and
valve body

an

brake booster

With a

as

a

vacuum

19 69 inHg

mmHg

on

engine

pressure of 66 7

vacuum

pressure

is reo
gauge

steady vacuum pressure of 66 7
mmHg 19 69 inHg measure

500

kPa

assembly

and increase

Start engine

3

oil pressure with respect to each
operating force

pedal

Relationship between oil pressure
pedal operating force is illustrated
Fig If test results are not as speci

and
in
4

pressure is applied to the
brake booster side of check valve and

Check velve
Remove check valve

When

valve does

n

valve with

new one

a

check

brake

in

manner

dition

check

replace

open

fied

booster

for

described

con

under

before removal of this

Inspection
unit

Also check brake line for evidence
M T

of l1uid leakage

model

de

Lc

With cooler

ManVifOI

1

Determine whether source of pro

j

SBR061

@

is

valve

Before you reach a final conclu

brake

booster or

always inspect check valve fint

sion

Brake booster side

in

check

blem

SBR063

Apply

2

a

vacuuin pressure of 26 7

200 mmHg

kPa

port

7 87

of check valve

inHg
the

on

to the

brake
11 770 120 1 710

booster side

M

10 190
e
Manifold side

e
e

I
110 1 500

9 810 100 1
8

830 90 1 280

1

850 80 1 140

6 860

10

1

4

900 50 710

u

ii

If

S
u
M

Brake booster side
SBR062

0

3 920 40

510

2 940

30 430

960

20 280

1

jj

1

000 I

5 880 60 850

980 10 140

l

f
I
I

L
r

I

jf

66

tfl

J

I

J

td J
o

I I

1 961
200 441

981

100 221
Rod operating force N

If

I

I

II

420 I

kg

lb

pressure drops more
the
than
specified value in 15 seconds
3

replace

vacuum

check valve with

a new one

8
0
0

Maximum vacuum

of check 01

leakage

0

mmHg

6

6

6

Pedal operating force N kg Ib

1 3 kPo
10

0

SBR074

0 39

inHg
BR 15

S8rvics Brake

BRAKE SYSTEM
Check length

REMOVAL
To

the

remove

brake booster

9 75

following points

r

AH

Langth

detach

10 00 mm 10 384

0 394 in

j
u
B
BR110A

1

1
BR109A

S8A064

INSTAllATION

IiJ

M

cylinder
7 8

2

If length is

tions

not

replace brake

within

10 8

specifica

58

booster assembly

10 8
ADJUSTMENT

58

Input rod length

PV

rod length

seno

cannot

be

Adjust
adjusted

as

output rod thread portion is secured

by

Length

length by turning clevis

10 8 N

5 12 in

12

body

m

1 1 kg m
80 fHbl

22 N

11 6

8

130 mm

Ibl

Input rod lock
16

brake booster

1 1 kg m
8 0 ft

Brake booster to
7 8

Output

to

10 8N m

2

nut

m

kgm

16 fHb

adhesion

PARKING BRAKE
PARKING BRAKE
REMOVAL
Control lever and front cable
Front cable
Remove console box

Disconnect harness connector
move

Re

control lever

SBA066
SBR067

BR 16

BRAKE SYSTEM
2

Remove

grommet

rubber

and

lock plate Disconnect cable adjuster

CAUTION
Be careful

not to deform or

L

damage

control lever

Front cable

pin
r

t

Brake

Parking

are

clevis

pin and

l

cotter

available as Hrvice parts

IJ

SBRQ73

SBA068

Rear cable

INSPECTION

Disconnect cable
Remove
3

Pull front cable out into driver

s

lock

adjuster
plate and strap

or

cable clamp

Check control lever for

I

other

compartment

wear

2

Replace

3

Check wires for discontinuity

worn

or

fatigued spring

Replace

deterioration

or

if necessary

damage Replace

if

or

necessary

4

Replace malfunctioning warning
light or switch
5

Check parts at each connection
and if found deformed or damaged

replace
INSTALLATION
SBR071

When installing front cable to

SBA069
u

I

specified

Apply

elevis

a

pin

end cotter

coat of grease to

le r

pin

sliding

contact surfaces
If necessary

separate front cable
from parking brake lever by breaking
pin and replace front cable
4

2
rear

Remove lock

cable

cotter

pin

from

plate

and disconnect

lever by

removing

Adjust parking brake system after
completed Refer to Sec
tion MA for adjustment
2

installation is

BR 17

Service OataandSpecifications

SYSTEM

lAKE
Bf

SERVICE DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS

I

J

Type

BRAKE BOOSTER
Maximum

DiscN22

vacuum

Cylinder inner die

mm

Pad

mm

in

53 98

kPa

Width

x

thickness

x

lin

52 9 x 9 7

Output rod length

76 2

x

2 083 x 0 382

length

3

x

Rotor

I

Type

I

Cylinder inner die

I

Pad

I

IMa
I

ter

Brak

die

outer

in

mm

mm

x

thic

ness

in
in

xlength

Rotor outer dia

cyljnde

253 5

A

9 75

mmlin

10 00

0 3839

0 39371

S

mmlin

130

5 12

9 98

Disc AN12 H

mm

Width

3 3 25 0 981

0001
Input rod length

I

after

mmHg inHg

2 1 8

Front

Rear

leakage 15 s8cond

engine iutopped

mm

inner die

40

I

42 0 x 10 3
1 654

x

0 406

in

269

in

22 23

mm

r

4611 5929

booster type

x

r
IW

56

x

8

2236

7

8

P75

J

I

NP valve

Split point
kPalkg cm2 psi

25

452
2

reducing

J

10 59

356

x

B
r

BR109A

04

8Rll0A

ratio

INSPECTION AND ADJUSTMENT
BRAKEPEDAL

CHECKYALYE
Maximum

Unit mm in

26 7 kPa

I
I

I

Pedal

play

5

8

Depressed height
Pedal

height

d

0 201

0 04

More than 60

h

155

t6t

2

6 10

is

leakage 15 seconds after
mmHg 7 87 inHg pressure

vacuum

200

kPa

applia
tJ

13

36
6 34

DISC BRAKE
Unit

PARKING BRAKE

1

Pulling force

I Number of

I

N

kg Ibl

in

N22

196 20 441
7

mm

mm

in

Type

notches

Stroke

to 0 391

mmHg inHg

90

8

100 3 54

AN12H

Item

I

3 941

Pad

wear

limit
2 0 0079

Minimum thickness
Rotor

repair limit

Maximum
I

unout

0 1210 0047

16 10

0631

0 15 10 0059

MASTER CYLINDER
Maximum palallelism

I

N8ble
Allo

clearance between

cylinder and piston

BR 18

Less than

mmOnl

0 15

0 0059

I

Minimum thickness

0 07 0 00281
10 5 0 413

8 6 0 339

BRAKE SYSTEM

Service Oat1l and Specifications

TIGHTENING TORQUE
Unit

N

Brake tube flare

nut

15

18

15

18

11

13

17

20

t2

t4

7
0

9
0

5 1

65

17

20

I

Air bleeder valw

69

88

Fulcrum pin fixing bolt

78

10 8

08

11

5 8

8 0

Brake booster to

7B

10 8

OB

11

5 8

8 0

16

22

12

16

I
I

I

to

body

shell

16

ver

Mascylinder

to

22

7 8

10 8

0 8

11

5 8

80

78

10 8

0 8

11

5 8

80

broke

booster
IIXI

Front disc

per

bolt

Front disc

rotor

I

72

97

7 3

9 9

53

72

36

52

3 9

5 3

28

38

38

52

3 9

5 3

28

38

20

fixing

bolt
Rear disc

caliper fixing

bolt

Baffle plate fixing bolt

I

ft Ib

m

Brake hose connector

Flange

I

kg

I

I nput rod lock nut

I

m

Brake lamp switch lock

22

26

2 2

2 7

18

12

15

1 2

1 5

9

17

20

1 7

2 0

12

14

2

3 6

11

nut

way
3

connectOr

NP valve to

body

bol t

39

49

4 05
0

9

BR 19

BRAKE SYSTEM

Trouble Diagnoses and Corrections

TROUBLE DIAGNOSES AND CORRECTIONS
Condition

Excessive pedal travel

Low

brake

Probable

cause

l1uid level

or

Corrective action

master

empty

Fill and bleed

as

necessary Test for source

of leakage by examining aIllmes and

cylinder reservoir

connec

tions
in master

Leakage

Overhaul master

cylinder

cYlinder

Deteriorated check valve

Replace check valve and bleed system

Air in system

Bleed system

Faulty brake adjustment

Adjust pad

Inspect

to rotor

clearance

auto

adjuster operation
Excessive lateral
loose

or

worn

play

disc

on

wheel bearings

caused by

Replace

or

adjust faulty parts

steering

or

parts

Spongy pedal

Low fluid level in master

JoP with fluid and inspect fa leakage

cylinder

Air in system

Correct

Faulty brake adjustment

Adjust pad to rotor clearance Inspect
adjuster operation

Reservoir filler cap vent hole

SwaDen hose due

to

auto

Clean and bleed system

clogged

deterioration

necessary

as

or use

of

Replace hose and bleed system

poor quality hose

Distorted brake moes
or

Soft

or

braking effect

excessively

worn

swaDen caliper seals

Use of

Poor

or

Replace faulty parts

cracked brake drum

a

Drain hydraulic system
and replace ail seals

brake l1uid with too low

boiling

l1ush with alcohol

Replace with specified brake fluid and bleed

point

system

Fluid leakage in brake line

Check master

cylinder piping and caliper for

leaks and repair
Low

brake

fluid level

or

empty

master

Fill and bleed

as

necessary

cylinder reservoir
Bleed system

Air in brake lines

Grease oil mud

or water on

Clean brake

pads

of problem
Deterioration of pads

Replace

Local fit of pads

Shave

Pads excessively

worn

Master cylinder

Or

caliper assembly

or

and check for
mechani

cause

Replace pads

replace

Replace
in poor

Repair

or

replace

conditions
Frozen

or

seized caliper pistons

on

disC

Disa semble caliper and free up

brakes

Binding

BR 20

mechanical linkage at brake

pedal

Free up as

required

a

required

BRAKE SYSTEM

Condition
Unbalanced brakes

Probable

Improper

Inflate to correct pressure

adjustment of pad

auto

Diagnoses and Corrections

Corrective action

cause

tire inflation

Improper

Trouble

to rotor

Readjust

clearance

Grease oil mud

or

water on

pads

Clean brake mechanism and check for
of problem Replace pads

Mud in rotor

Clean

Deterioration ofpads

Replace

Excessive

Replace

wear

of pads

Caliper cylinder in poor condition
Looseness of caliper
Scored

or

cause

assembly securing

bolts

round rotor

of
out

Repair

or

replace

Fasten

or

replace

Recondition

or

replace

rotor as

required

Check for improper pad contact with rotor
and grind pad if necessary

Brakes fade

Brakes drag

Incorrect adjustment of wheel bearings

Adjust

Incorrect

Adjust

adjustment

of wheel

Brake l1uid has too low

alignment

boiling point

Drain and flll system with approved l1uid

Use of improper pads

Replace

Brake rotor is

of
out

replace

or

round

Repair

or

replace

Hydraulic connections master cylinder and
caliper cylinders are corroded or damaged

Repair

as

necessary

Bleed screw is open

Close

Pedal linkage is
ment

binding

or

output rod adjust

is too long

screw

as

necessary

and bleed system

Lubricate linkage
for condition and

check pedal

adjust

return

output

rod

spring

as neces

sary

Master

cylinder compensator part

is

ob

Blowout

foreign

structed

air

Seized master cylinder piston

Disassemble

matter with

master

cylinder

compressed

and

replace

piston Bleed system
Poor pad condition

Clean and repair

Poor caliper cylinder condition

Repair

Deformation of piston cups

Replace

Poor condition of

Replace piston seals

caliper

because of faulty

or

replace

piston seals
Excessive ronout of rotor

Turn rotor

Hand brake will

Check and repair

not

return

on

lathe

Clogged

master cylinder return port

Clean

Clogged

brake lines

Check and clean

Incorrect adjustment of wheel bearings

Improper pad

to

rotor clearance

No free travel in brake

pad

return

Adjust

or

or

replace

repair

Adjust

Adjust pedal height

BR 21

SpeciafService Tool

BRAKE SYSTEM

Condition

Brake chatters

Probable

Groove

or

Corrective action

cause

round rotor

of
out

Loose or bent support

Grind

plate

or

Tighten
torque

Distorted pads

Brake squeal

Dirty

Bend support
or

required

plate bolts
replace plate

as

to

specified

necessary

Replace pads

scored rotor

or

Glazed

pads

as

support
or

Replace

Grease or brake fluid on

replace

Blowout assembly with compressed air
refmish rotor

plate

Replace faulty

contaminated

or

unit

Grind pad to eliminate glaze If it doesn t

pad

replace pad
Pedal pulsates

Lateral

roDout

of brake

rotor

is excessive

Check with dial indicator

turrting disc by

hand Ifrunout exceeds specification
or
replace disc
Excessive
rotor

Rear lock
under

light brake

variation

in thickness

of brake

surfaces

Improper tire

Rear lock
under

heavy brake

as

required

Check and adju t

Excessive wear of tires

Check and replace

pedal force

Faulty

Measure around disc face with micrometer

Replace disc
pressures

NP valve

Replace

Improper

tire pressures

Check and adjust

Excessive

wear of tires

Check and

pedal force

replace

Poor front braking effect
Grease oil mud

or

water on

Clean

pads

or

Excessive wear pads

Replace

Local fit pads

Shave

Master cylinder

or

caliper cylinder

in

or

Repair

poor condition

SPECIAL SERVICE TOOL
Tool number
Kent Moore No

GG943 10000

Tool

name

Flare nut torque wrench
u

I

BR 22

repair

replace

replace

or

replace

DATSUN 200SX

Model SIlO Series

SECTIONST
STEERING SYSTEM

CONTENTS
STEERING SYSTEM

ST

2

SERVICE DATA AND

STEERING WHEEL AND COLUMN

ST

3

SPECIFICATIONS

STEERING WHEEL

3

INSPECTION AND ADJUSTMENT

ST 21

ST

4

TIGHTENING

ST 22

ST

6

ST

STEERING COLUMN

STEERING GEAR

3

ST

STEERING LOCK

Collapsible type

Model

VRB47l

POWER STEERING GEAR
Model

I P S

ST 21

GENERAL SPECIFICATIONS

56l

AIiID Oil PUMP

ST 10

STEERING LINKAGE

ST 19

TORQUE

ST 21

TROUBLE DIAGNOSES AND
CORRECTIONS

ST 23

SPECIAL SERVICE TOOLS

ST 25

a

50

lTIr

Cl
Iti

Wi

fft

gteaoil

46
46

36

38
I

8

8

of

21

end

2
5

8

Vlbe l

Ste lng

3
5

dam

thaft

or

d to
snou

to

wil

notpole

IID
bea

omer nO shaft
sttik column tuu StIl dtne dle uUl cancel
not
DO

1

ste rin

ltefu
c

a

age

ith
W

co fie

age

umntube

case

direction

ap lied

eo

to

bt1

fotc

ll

utJ

4

35

tube

bendin5 column

40
3

et
jael

frame
haft ternbW
wor1 62 bOdY
nllpt
a

coupUns
lbCl
tlU

n

603

6

5

0

45
0

n Wheninsu
lins

4ue in

Ste ing

101 35
c
0

e

co

ef
Ne

3

0
5

2

do

l
a

S
ttt

in

29

3

n8
tcet

not

a

be

at

3

P
ap

ste 1

UI

m
di

SST

pO

3

5

5

39 10

I1L 52
l

teerl Vv

0

51

52

cer

Purl

m

fod

62

4

49

g
1

3

MoIti

tj

ctOS

22

@

and

0

rm

1

a

0

IY

3
69
1C
n

t

29 to

tad

Side

lon
t

I
r

@

i1
s
ll

et
bracl
B

OS
mount

28

8

24

1

8

column

haft

11

46

tub

38

IY

0

18

Ste B

2

bly

31

3

S

12

9

I

tod

tad

9

tat le
503

10

4

Ste til

3

52

S

tad

r

42

81m

141

40
1I
V

0
0

em1M

pte

98

tOd
SId

gnuc

idle

1

I

and
aun

1

1JVI

0

3

d

tad

d

00

69 eaI
29

dote rit iscon ect

be

S

t

Il

To

cOlumn

1

Q

lleJ
ro

fif4
inatl1

l ing

d

nd

St

and

lle
ca

ttlnS emovlng gtound

meel

0

54

pipins

l Il
g
1l

de

5

18

ann

0

pipins

uto

nt11l

5

KnUc
0

ol

22

ute
10

and

98

0

rod

eto

e

3

hot
s

0
8

d
nuc

54
J

bOdy

and
arm

5

51

12

0

Side 9s

tame

2

ClOS

0

atm

5

3

0

58

nd

0

23

56L 62 bOdY

055

40

6

u

12

COvel
dutt

altetY
Eacb
When l

nl

STEERING SYSTEM

Steering

Wheel and Column

STEERING WHEEL AND COLUMN

I

STEERING WHEEL

Remove

steering wheel

using

Tool

8T27180001
2

REMOVAL

Remove

steering

column

shell

cover

Disconnect battery ground cable
Remove horn pad and steering

I

2

y

wheel nut

1

Upward

SST069

Igi
Install steering wheel

2

shaft

in

a

straight

on

ahead

Ii

column

position

SST072

SST067

3
a

4

Break self shear type screws with
drill

or

other

Remove

appropriate
screws

and

tool

disconnect

steering lock
3

Remove

steering

wheel

using

Tool

Self shear type

CAUTION
Do not strike end of steering column
shaft with a hammer Striking shaft
will damage bearing or column shaft

screw

SSTU70

Tighten steering wheel

3

J n
l

51 N
52

13B
27

nut

m

kg

m

38 ft lb

Screw

SST073

80001

INSTALLATION
Align steering lock hole in steering
column tube with mating portion of
steering 10cL
I

SST071

SST068

2

Install

screws
screw

After installing

4
bJm

wise

it

clockwise

screws

and self shear type

and then cut off self shear type

heads

steering wheel

and

counterclock

for catch or

checking
operation

drag

Also

check horn

V
INSTALLATION
Inltall
reverse

ltaering wheel in the
order of removal Observe the

STEERING LOCK

following instructions
I
Apply grease to sliding portions

REMOVAL
Before
connect

removing steering

V
Self shear

screw

lock dis
SST074

battery ground cable
ST3

STEERING SYSTEM

Steering Wheel and Column

Collapsible

STEERING COLUMN

tYPe

Steering column asRmbly
Never in any
stress be
in axial

case

applied

should undue

to

steering

column

fJ

37

direction

51

3 8

When installing do not apply bending
force to steering column

S
k

Steerinj

Cn
Jacket

fJ

tube bracket

3 4

44

To dash

0 35

tte

Steerins

0 45 2 5

eel oolw

panel
S eerillj oolumn

tiJ

13

18

3
1

18

To instrument

Cnuplinj Plat

9

bly

13

panel

Steerillj oolumn
aaembly

16

Column band

j

fJ

39
To

49

4 0

5

0 29

36

Z32

worm shaft

38 3 3 3 9
To stub shaft

@

N

m

rn
kj

ft Jb

24

28

Pl S 56L only
Model

SST125

REMOVAL

4

I

Disconnect

2

Remove bolt securing stub shaft

or worm

rubber

battery ground

cable

shaft and universal joint

or

Remove

steering

column

shell

covers

5

Remove

6

Remove

panel
combination switch

heater duct

from

dash

side

as

sembly

coupling

al
SST078
SST076

3

Remove steering wheel
Steering Wheel

4
ST

Refer to

I

STEERI NG SYSTEM
7

Remove jacket tube bracket from

2

Set

wheels

in

a

straight

ahead

position

dash panel

3
to

Fit

stub shaft

Carefully
at

or

on

shaft

worm

install so that punch mark

top ond

of

column

haft

J

Tighten stub shaft or
securing bolts temporarily
upper side

of

steering

worm

to

column

shaft

upport
assem

bly
5

8

mounting

column

Remove

steering wheel can not be
smoothly check the steering
column for the following matters and
replace faulty parts
I

Check column bearings for darn
lubricate with

age or unevenness If so

4

SST079

When

rotated

fece

upward

recommended multi purpose grease

if damaged

or

it

2

the

bracket
3 4

4 4 N

I

3 3 ft Ibl

2 5

3

Check column spring and replace
When

weakened
car

comes

check the

into

following

light
parts

and replace if necessary

0 45 kg m

0 35

sary

collision

m

or

replace with a new one as steering
column assembly
2
Check jacket tube for deforma
tion or breakage and replace if neces

Tighten column mounting bracket
temporarily
6
After sliding jacket tube bracket
to dash panel tighten nuts to retain

Iil

and Column

INSPECTION
I

steering column assembly

Steering Wheel

Jacket tube
Measure dimension L
When

7

Tighten stub shaft or worm shaft
securing bolts and then tighten column
mounting bracket securing bolts

p
j I

JJ

Worm shaft to

Draw out
room

or

39

49 N

40

SST1 39

steering column

is

crushed

is reduced

coupling

L1
t

m

5 0 kg

m

Column

Modell P S 56Ll

assem

32

side

38 N

3 3
24

3 9

length

13

J

L

Model VRB47L
179

m

mm

7 05 in

ModoII P S 56L
m

kg

180

mm

7 09 in
SSTOBO

28 ft Ibl

Column

mounting bracket

18 N

1 3
9

F
LL

36 ft Ibl

Stub shaft to universal joint

9

L

Model VRB4711

29

bly from

tube

jacket

dimension

m

1 8 kg

m

13 ft Ibl

INSTALLATION
Install

steering column

in reverse

CAUTION
I

order of removal

Mike
not

I

Remove

install

column band and then

centering band
equipped model only

lS
P

2

that Iny undue strea is
Ipplied to rubber coupling
Rife

b To Ivoid

56L

tions
worm

dlmlging

bolt

coupling

Remove centering band and then
install
column band
PS
l
56L

@

10

8
SST126

Centering band

mounting

Standard

B

dimension is 0 mm

0

in

When

jacket

is crushed

dimension

jg

model only

Install

Steering

column

B is increased

9

equipped

sure

bracket touches block

or serrl

groove in stub shaft or
shaft with bolt hole in rubber

align

Column mounting bracket
Make

steering wheel

Refer

to

Wheel

After installation

steering wheel

turns

make sure that

smoothly

ST835

ST 5

m

STEERING SYSTEM

Steering Gear Model VRB47L

STEERING GEAR

Model

VRB47L

Lock nut

cp

29

J

3913 0

4

15

25

15

11

18

0

29

22

F

l1
d1erpl

25

SeetorsIWlCOV

to

v

0

Lo

Goskel

J
rt

5

Adjustm shim
Refer to S O S

Sector shar adjusting
When adjustirj

Oil

25

32

181

231

I

Removed oil seal must not be used agJ l1L

0
saew
h use
backla

314

it

Adjustins Pilla
When

adjust
preload use

wonn

bearing

it

Sector maft
BaD nut and

worm

assembly

Be a rcful not to allow ball nut to
down to either end of worm

run

The end ofba1l guides will be
lamag
if nut is rotated until it stops at the em

Steering gear housing

of

wonn

Do not detach

ball nut from

worm

shaft

assembly
If necessary replace ball nut and
assembly with sector shaft

worm

147
15 94

J
I

108

N

m

q m ft Ib
SST081

REMOVAL AND INSTALLATION

Worm shaft to rubber couplin

J
I

39

49 4 0

5 0 29

36

the

groove in worm shaft with
the bolt hole in rubber coupling
flange

Align

yoke and

prcssooupling bolt through

the undercut section of wonn shaft

Undercut section

1
Sector shaft to idler arm
J 127 147 13 15 94
I
Remove gear

108

arm

Sf29020001

Install gear

Align

four

arm

grooves of gear arm
four projections

serrations with

of sector shaft serrations and
install and tighten lock washer
and nut

ST 6

Gear housing to frame
625 3 6 3 38
J52
1

J
I

N

46

m

m ft Ib
q
SST082

STEERING SYSTEM

Steering Gear

Model VR847L

DISASSEMBLY
CAUTION
Before

disassembling

by

hand
a

make sure external is clean and free
from

dust

drain

gear

and dirt
fluid

7fY

and

thoroughly
by removing filler

worm

gear in

a

worm

guides will be damaged

Ends of ball

until it stops It end

if nut is

of worm

1
Place steering gear in a vice using
Tool KV48100301 in place
Set

down to either end of

run

0

plug

2

Be careful not to allow ball nut to

b Do not detach ball nut from

worm

shaft assembly

straight
ahead

replace

If necessary

position

en

SST083
c

If
Remove

from

necessary

housing

sector shaft cover from

as

Do not remove sector shaft needle

bearings
5

entire unit

assembly

IS an

steering gear housing
replace entire gear
asSembly

sector shaft
Remove

6

sector

shaft oil seal

if

necessary

ST725

3

Remove sector shaft cover

fixing

bolts
SST086

SST084

KV48100301

9

Remove

plug using

4f

7

L

Loosen adjusting

using

plug lock

oil

seal from

adjusting

Tool

nut

Tool

ST35322000
4

Remove sector shaft with sector

shaft

cover

CAUTION
a

When

careful

SST087

pulling
not to

sector shaft out

damage

oil seal

be
or

SST085

associated parts
b 00 not remove sector shaft needle

bearings from steering
If necessary replace
assembly

gear
gear

housing
housing

8

Draw out

bearing

worm

gear with

worm

ASSEMBLY

AND
ADJUSTMENT
Before
hand
and

Fill

assembling
meke

ure

lubricate

and

with

paee between

new

ctor

oil

1

adjusting by

each pert i

h ft and

geer

elean
fluid

Iing lip of
adju ting plug

with rlICOmmendad multi

purpose grease

ST7

Steering

STEERING SYSTEM

VR847U

Gear fModel

Worm bearins preload
1

Fit

worm

assembly

gear

worm

lock

Tighten

5

Tooh

using

nut

2

Install sector

oil

cover

adjusting

screw with sector shaft

with
KV48101500

bearing in gear housing

Adjusting

screw

KV48101400

SST091
SST094
SST088

6

After tightening lock

nut

bearing preload
within specification

make

to

worm

it is

2

Install adjusting

plug using

check
sure

Adjust
using Tools

Set

4

Insert

preload

bearing

gear

Sector shaft end play

adjusting shim and
play between sector shaft

Select suitable
CAUTION

adjust

Always adjust worm bearing preload
by turning adjusting plug in tighten

and

end

adjusting

a

straight ahead

shaft

sector

with

and sector

gasket

into

housing

Carefully insert sector shaft in
place using care not to scratch oil seal

screw

Sector shaft

direction

gear in

assembly

cover
worm

worm

position

Tool

KV48101400
3

3

adjusting

screw

shims

Refer to S O S
Rotate

worm

shaft

a

few turns in

bearing

and measure

Upper

preload

sector

I

cover

side
Worm

bearing preload with oil sean

0 39
40

059 N
6 0 kg

him

Adjusting

both directions to settle down worm

m

em

35

52

lb

Sector shaft end
O Ol

0 03

10 0004

play

mm

0 0012

n

Tighten
housing

sector

5

Steering
I

Press

gear

oil

housing using
Before
4

Apply

suitable

liquid

sealant

contacting

seal

to

steering

gear

pressing
face of

oil
oil

seal
seal

coat

seal

with gear

f

25 N

11 5

sealant

6

m

5 kg
2

m

11

Pour recommended gear oil into
through flller hole and

assembly

install ftller plug
Adj usting plug

SST090

8
ST

Specified

refill

capaeity

Approximetely 0 28 liter

Lock nut

gear

Tool

1iJ15
Apply

to

preload

fluid

around lock nut inner surface

cover

5 8 US pt 112

Imp pt

STEERING SYSTEM
Tighten adjusting screw so that
preload is within specification
7

gear

Check

pitting
damage

CAUTION

Always adjust steering gear preload by
turning adjusting screw in tighten
direction

2

Sector shaft

2

tooth

gear

burrs

cracks

and

replace

surface

or

if

for

necessary

its serration

on

Also

and

check

replace if neces
housing for

gear

gear

fsw turn

stroke

Be careful

guide

not to

damage ball

tuba whi Ie check is

being

nut

made

CAUTION
Be caraful not to allow ball nut to

deformation
a

entire

Check sector shaft for distortion

sary

Rotate worm

move freely
replace assembly

If ball nut does not

over

other

any

Steering Gear Model VR841Li

in

run

down to either end of worm

both directions to settle down steering
gear

and then measure

preload in

steering gear

position

streight
lhead

a

Steering

worm

assembl

Inspect ball nut gear tooth sur
face
and teplace if pitting burrs
I

wear

any other

or

is found

damage

Ball nut must rotate smoothly

2

gear If found too tight
should be replaced

J

LScrewdriver
Steerinlllilear
with oil
1

total

Less than 1 23 N

Check

m

12 5

06 N
6

praia

I

of

ball

to

either

nut

as

SST097

worm

Beulng
Inspect worm bearing for wear
pitting or any other damage Replace
I

Move ball nut

worm

m

3 5 5 2 in Ib
kll
cm
higher than at worm bearing
4

rotation

follows
kg m
c

10 9 in I b
04

bly

preload

on

assem

worm

gear

and

end of

gradually

stand

as

shaft and ball nut assembly until

ball nut

moves

downward

gear under its own

weight

on

requried
When

worm

replace it

If found to be outside of above

Oil

Downward

all

the disassembled

parts in solvent and check for condi
tion

set

worm

of

bearing

bearing and

are

damaged replace as an as
sembly of gear housing and bearings

INSPECTION
clean

8

If sector shaft needle bearings

worn

steering gear preload specifications
readjust adjusting screw until correct
steering gear preload is obtained

Wash

as

outer race

2
8

replacing

own

SST098

weight

J

or

eal

Discard any oil seal which has once
removed
Replace oil seal if

been

sealing lip

is

deformed

Also discard oil

or

cracked

seal if spring is fa

tigued or dislocated

ST 9

Power Steering lear Model I P S 56L andOil

STEERING SYSTEM

PUTflP

POWER STEERING GEAR

Model

IP S

56L

AND OIL PUMP

DESCRIPTION
Po

r

steering

s

The integral power steering unit is a
gear housing into which a control valve

stem

2 pool valve type

The power steering gear is licensed
I1Y ZF company in West Germany

der

are

and power

built compactly

components

are as

folloW

Oil pump
Reservoir tank

cylin

Power

The major

steering

gear

Oil piping

Reservoir tank

cfl

2 9

4

9

0 3

0 5 2 2

cfl

3 6

cfl
cfl

49

69 5 0 7 0 36
To each hoses
52

6i

5 3

32

38

3 3

Gear assembly

6 3 38

3 9 24

To stub shaft

51

46

To body frame

High pressure hose
and piping

cfl

2 9
To

N

cfl

m

4 9 0 3

In

SST12T

The integral power steering gear is
accurate oil pressure mechanism

disassembling

dust

it

be careful to

CAUTION
a
The parts which
bled

keep

out ofthe gear

assembly

ST10

must

be

housing

replaced

as an

J

d

in the manual

Ied

instead of
b

are

also

Disassembly of integral power steer
ing gear should be performed in a
place l
5 dean as p ssible although
a dust preventing device is not reo
quired

disassembly
steering gear

of

integral

remain

un

finished for any reason indicate it
as
Half Disassembled and COVllr

and

replace the assembly
bling those parts

Should
power

be disassem

strongly

are

indicated

gear

can

disassemble other parts than
the specified ones If parts not

Only the sealing parts of the gear
assembly can be replaced The remain
ing parts

Co

never

iron powder and other foreign

particles

3 6

kgm ft tb

Power steering gear

an

0 5 22

suspension aossmember

parts with

a

clean cover

d Hands should be cleaned immedi

ately
e

before disassembly

Do not

use

a

rag

Be sure to use

nylon
paper cloth
f Be sure to follow procedures and
cautions indicated in the Service
Manual
or

STEERING SYSTEM

PowerSteeringGear

I P S 56L

Model

andOilPump

ring
O
Breather

Breather

l6
i

9

I
cf

cap

screw

8 8

0 7

lock nut

l28
i

34

2 9

3

5

21

25

Copper washer

@

J
@

l26
i

V

2

32
7

3 3 20

24

fill

rins
O
Sector shaft

Between sector

adjusting

cover

screw

to gear

housing

Sector shaft

Worm end nlve

mbly With
interm i te
t
cov
l

o

o

Special washer Small
OUseal

0

ru
2

7

20

rear cover

ospring washer

24

Nut

tY
I
N

m

sea1

3 3

Once removed must not be used again

l
i

DUst

apring

0il1e3 1
In

Special washer La
IJle

Icg

m

011 pump and

Malfunctioning

l127
i

147 13 15 94 108
To gear arm and sector shaft

ft lb
SST033

r

volr tank

Replace

as

an

oil

pump assembly
STll

Power Steering Gear Model I P S 56L and Oil Pump

STEERING SYSTEM

REMOVAL
clean exterion of gear housing and oil pump with steam and

Before removing

Steering

dry

with compressed air

gear

51

Joint to stub shaft
J 32 38 3 3 3 9
t

Sector sIWI to sou

J 127
t

24

28
of gear housing and
securely locate hose connectors

Plug openings

ann

15 94

147 13

108

at

a

and

i
Install gear

Align fOUI

cover

than

entry of foreign matter into
hoses through connectou

j1

arm

serrations with four projections
of sector shaft serrations and

J
t

N

m

R

install and tighten lock washer

and
1
2

m
kg

g

and nut

Oil pump

oil pump

with rag

Be extremely cucful to prevent

arm

grooves of gear

position higher

fHb

points

SST128

resevoir tank

each hose

Remove air duct at air cleaner
Loosen oil pump pulley lock nut
Turn

belt

adjusting

bolt counter

clockwise

5
tank

Remove

oil

pump

and reservoir
6
7

Disconnect hoses from oil pump
Remove oil pump brackets and

other brackets from

8

Unfasten hose

engine

clamps

and remove

hoses from suspension crossrnember

INSTAUATION AND
ADJUSTMENT
3
4

Remove oil pump belt
not
Loosen
remove

pump

ST 12

hoses

at

In tall

steering

order of removal

gear

in the reverse

STEERING SYSTEM
2

Fluid level
I

fluid level

Check

pump

assembly with dipstick whether fluid
level is on HOT side at normal operat
ing temperature

or

side

COLD

on

steering wheel

right

to

Steering Gear

Model I P S 56LJ and Oil Pump

to

Pressure gauge
calibrate

left several times

oil

in

Turn

Power

when oil is cold

3

Hold steering wheel at each lock
position for five seconds and carefully
check the following points for fluid
leakage
Oil seal

at rear cover

9 807 kP

100

kg em2

1 422

To oil pump
outlet

psi

To control

valve

Y

Intermediate cover

Adjusting

1

Sector

IOK

cover

Shut off valve

O ring

SST036

Oil pressure line connectors

Q

4

fSTi7091000

Sector shaft oil seal

lllm

Add

lock nut

screw

t

e

OK

Oil pump and reservoir tank

CAUTION

steering wheel

Do not hold

position
SST133

for

more

at lock

thin fifteen seconds

It I time

Hydreulic system check
Do not overfill with fluid

to

8o C

1760F
running engine

When

To

operating temperature i 60

Nanna

140 to

make

pump ere

Ie than 2

mm

0 08 in

Recommended
Transmission

fluid

Fluid

Oexron

Type

capacity

pressu
I

must

be

Open

inflated to normal

Check

fluid level and fluid leak

age adding oil if necessary

6

Check fluid level

Run

7

8
with oil pump

adding

fluid if

engine

idle for

at

3 to

5

and check fluid level

Stop engine

adding fluid if necessary

engine and check fluid level
again adding oil if necessary
10 Turn steering wheel fully in left
or right until fluid reaches operating
9

1 1 4 US qt

1 118 Imp qt

Run

temperature
Be

Pump belt edJustment

sure

that

all

connections

are

tight

oil pump belt tension

Expel

any air from system

I I Slowly close shut off valve with
steering wheel fully turned in left or
right and lightly touch wheel stopper

Pump belt adjusting bolt
Thumb pressure
911Nj10kg 221b
I

Lock nut

71

CAUTION
Do not close shut off valve for
thin
2

G

Run

IJ

I Oil pump belt
8

12

mm

OA7 in

SST134

Check fluid leekege
Run

engine

at idle

speed

or

1 000

fifteen

seconds

more

this would

as

abnormally

increase

lubricant

tem

perature and

cause

undue pump

weir

fully

closed pump pres

Make sure temperature of fluid in
rises to 60 to 800 C 140 to

deflection

10 31

engine

pump

1760 F with a tamperature indicator

rpm

Tool

seconds

Approximately

I

at

necessary

steering gear assembly

Adjust

valve

off
shut

ST27091000

reservoir tank each hose and

1 2

5

reo

Recom

mended Lubricant
Fluid

check belt tension and

condition of driving pulley
Tires

is Automatic

Refer to Seetion MA for

carefully

measure

hydraulic system

Before conducting
test

Check fluid level and leakage

2

oil pump

steering gear or
operating pressure

sure

fluid level variations in opening oil

determine whether problem is

in

Wilh valve
sure

3

Stop engine

4

Set Tool

Gauge

must

should be at maximum

Normal preuure
be

between

valve and oil pump

fl
shut

About 5 394 kPa
782 psi

at

55

kg cm2

idling
ST 13

STEERING SYSTEM

Power Steering Gear Model IP S 56LJ and Oil Pump
If pressure increases beyond upper

12

limit

pressure relief valve in oil pump

is not

functioning properly Replace

oil pump assembly
13 If with shut offvalve

drops
Replace as
assembly

pressure

the

pump

oil

pump

After

3
que

as

turned 3600 from straight ahead posi
tion

fully closed

Steering wheel turning force

problem is in
pump assembly

29 4

at

as necessary then complete
bleed air out of system

I

making
wi

stem

10

I

in

2

I

Make

lure

temperature of fluid in

pUmp rises to 60 to BOO C 140

to

176

o

F

with

B

temperature indicator

Check fluid level

nece

adding fluid

if

sary

be

perfonned

in specified limit

1

steps

this

until

operation

air

is completed

through

9

completely

proceed

as

SST13B

fol

lows
With

engine runing

1 000 to

at

INSPECTION AND

1 500 rpm repeat step 9
2

Turn steering wheel to

left

from

times

3

7 7 Ib

that fluid level is kept

If air cannot be bled

Raise front end of car until wheels
clear ground
Run engine

should

sure

Repeat
bleeding
s

6 6

kg

circumference of steering wheel

SST137

Operation

h draullc

3 5

I

checking hydraulic system

Bleeding

34 3 N

3 0

add fluid

ly

Check steering wheel turning tor
when steering wheel has been

lock to

Carefully

right

lock five

check

fluid

to

and

ADJUSTMENT

ten

leakage

Wash

dean

bled parts
and ch
k
solyent
cleaning

with steering wheel held at each lock

in suitable

position for five seconds

thejr condition

all

d

Check Sealing portion

CAUTION

Adjusting

00 not

hold

position

for

steering

more

wheel at lock

than fifteen seconds

at a time

screw

nut O

Sector shaft cover O

Sector
Rear

sl1aft

ring
ring

oil seals

housing oil seal

Intermediate cover Q rings
Discard

any

which have

once

Replace

oil

Steering

O

ring

oil seal and O ring if sealing

surface is deformed

Steering wheel turning
torque check

seal and

been removed

gear

or

cracked

turning torque

measurement

dry surface
and set parking b rake firmly
2
Bring power steering fluid up to
I

4

Run

engine for 3 to 5 seconds
Stop engine adding fluid if

5

nes

Quickly
to

way

lightly
7

turn

right

steering wheel

all the

and left ten times end

touch whee stoppen

Check fluid level

adding fluid

Start engine at idle
Repeat steps 4 through 8 until air

will be bled from pump

9

With
left

steering wheel fully turned

open bleeder screw to expel
air and then tighten bleeder screw
to

ST 14

proximately
1760FII

60

It is easy to
if

necessary

8

a

car on

level

adequate operating temperature

sary

6

Park

to

bring

80 C

power

140

Ap

I
Measure turning torque at 3600
position
I Install steering gear on Tool

to

steering

fluid up to

adequate operating tern
perature by idling engine and at the
time turning steering wheel
same
from left to right for about two
minutes
Alternatively drive car
several miles

Tires

must

pressure

be

inflated to normal
SST040

STEE
2

Turn stub shaft all

the way

right and left several times
3
Measure turning torque
position from
using

straight

ING SYSTEM

Power

Steering Gear Model
Straight

to

I P S 56LJ and Oil Pump

ahead

is

position

8

position

where stub shaft is turned two turns

3600

at

ahead position

by 450 from lock position
3
Disconnect sector shaft

cover

Do not loosen adjusting

screw

Tool

I

Do not turn lock nut unless neces
sary

otherwise it will

resulting
l 28
i

34 N

12 9

within

in

an

damage

O ring

oil leak

m

35

Measure
not

lock

nut

4

m

bolt

21

kg

25 h Ibl

SST043

turning torque If they are
specifications replace gear

assembly

J
DISASSEMBLY
Stub shaft can be turned

ping vinyl
of

area

wrap

around serration

tape
stub

by

shaft

and

fitting

Before disassembly

it

is

must be

If

beyond specification gear
replaced as an assembly

turn

4

they

tions

Draw

out sector

Knock

ing torque

wrench lOcket
If

measure

are

within

not

replace steering

specifica

out

shaft

end

approximately 20

of

mm

sector

shaft

0 79 in

gear assembly
20mm

CAUTION
2

Measure

turning

torque

at

Set worm gear in a

0 79

oil

sealing

dust

parts

washers and snap ring
removed must not be used again

special

straight ahead position
I

Each

nl

seal
once

straight ahead

position
Straight
ahead
where stub shaft

position

by 450

position

2

from lock

Measure

is 8 position

AdJusting

is turned two turns

turning

Remove

lock nut

screw

adjusting

screw

se

1

lock nut
SST046

and replace a ring

torque

using

Tool

5

Connect

a

roll of plastic fIlm

to

sector shaft
Turning torque at streight
d position
h

l0
i

10

1

0 39 N

4

higher

cm
kg
than

Plastic film
Thickness 0 1 mm

m

09
t

3 5 in lb

3600
O

LJJ

mg

Length

x

width

200

x

200

mm

0 004 in

7 87

x

7 87 in

Lock nut

Copper washer
SST044

1 Plastic film
Sector sh ft 011
I

Install

se

steering

1

gear

on

Tool

KV48l00301
5

After

tighten

adjustment

lock nut

is

completed

2

Set stub shaft in

a

straight

ahead
SST065

position
ST 15

STEERING SYSTEM

Power Steering Gear Model I P S 56LJ end Oil Pump

6

Attach plartie film to two bearings
located inside gear housing while
simuttaneously pulling
so

that

bearings

out sector

shaft

drop

into

will

not

seal

Rear housing

PuiI out sector shaft by harid

Install gear

on

Tool KV48l00301

in a vise

2

Loosen

not

remove

CAUTION
When worm assembly is removed
piston may turn and come off

a

rear cover

under iU

bolts

own

weight

housing

clearance exceeds 45
Remove snap ring

7

Hold

prevent it from turning
If
piston to intermediate

piston

to

by looseninll

mm

cover

1 77 in

ball will

ulating
recin

be out of groove of worm do not
reinstall piston but replace the en
tire

assembly

b Take care not to
at

fs

piston

damage

tellon

ring

end wilen removing

ST697

8

Remove rear

sembly upside

cover

down

turn worm as

and

lightly tap

stub shaft end on top of workbench

SSTQ47

3

Turn sector shaft clockwise slight

ly to raise intermediate
piston

through

cpver

CAUTION
Do not strike shaft with

a

hammer

or

pry it with a screwdriver
8
ers

Remove

dust

seal

special wash

and oil seal

Apply blade of screwdriver to oil
seal I ightly so that it will not damage
inner side of gear housing

Special

d
0ru

washer A

Oil

n
L4i

Q
g

I

Smail

I
t

sea
SST050

Special
B

lL

ST701

4
Dustseal

I J

w

Turn stub shaft counterclockwise

and place piston

worm

gear

in its

straight ahead position

snapring
SST048

S

Remove sector shaft
Refer to Seetor Shalt Seal for disas

sembly

9

Remove a

ring

Remove rear cover bolts

7

Pull out

cover

SST049

ST 16

6

with

rear cover

worm

intermediate

9

Remove

gear assembly

ST700

ST702

rear

housing

oil seal

STEERING
10

Remove O ring

intermediate

both sides of

on

2

SYSTEM

Install

O rings

intermediate

cover

cover

on

with

Power

both sides

CAUTION
a

Apply
new C rings prior

to

vaseline

their installa

b

O

careful

rings

as

not

to

some

install

Be careful that teflon

ring at piston
damaged during insertion
of gear housing
When worm assembly is halfway
inserted teflon ring is deflected
Insert remaining part of worm as
sembly paying particular attention
Take care nol to damage teflon ring
end is not

to

tion
Be

wrong

of them resemble

in size

on corner

Be
Intermediate

Pump

of

new ones

thin coat of

a

Model I P S 56LI and Oil

Steering Gear

sure

of sector hole

that teflon

cover

correct

ring

settles in its

position

SST051

tJ

ASSEMBLY

AdJusting
Insert
screw

screw

lock nut
into

a ring

new

se

1

SST054

adjusting

lock nut

Before

inserting apply
ring
C ring to make

a

thin coat

of vaseline to O
Inort

sure

it

fits

into groove

3

oring

r

Fit

cover

onto intermediate

rear cover

with worm gear

assembly

CAUTION
a

Do not tilt ball

bearing
rings
truding or extruding

b Make

L Adjusting

housing

r

I

Install

rear

se

that O

are

not pro

screw

lock nut

Re

sure

SST052

1

housing

oil seal using

Tool

Before

installing

oil

seal

apply

recommended multi purpose greM

5

to

Gradually

bolts in

lips

a

tighten

rear

housing

criss cross fashion

ST705

4

Insert

worm

gear

assembly with

rear cover and intermediate cover into
cross
Criss

SST053

gear

fashion

SST055

housing
ST 17

Power

Sreering Gear

Model I P S

56LJ

and Oil

Pump

2

Install

CAUTION
If bolts

L

are

while

tightened

STEERING SYSTEM
a

new

ring

snap

into gear

housing
wonn

assembly is tilted inner seals will
be dam8llld Tighten bolts while
assembly is level
If wonn assembly is tilted stub
shaft s turning torque will be in

a

Turn soap
into groove

b

Always
rounded

creased

G

Q

CAUTION

ring

to make sure it fits

inslllll snap

with its

ring

oil seal

edges facing

b Check O
do not

6

rings to ensure lhat they
protrude or extrude

ST696

Install sector shaft into gear hous

ing
R

Refer to Sector Shaft

face
Imide snap ring

Oil Seal for

assembly

of sector shaft

The reason
vents

Inspection and

Refer to

Wrap vinyl tape around

area

Outside

Check turning torque

7

5

Adjust

I

talling

snap

ring

SST058

ment

I

Press

using

new

se

1

oil

oil seal and dust cover

tape pre

being damaged

Gradually insert sector shaft into
being careful not to dam

When

irstalling

seal

dust

be lure to

use new

and

special

cover

installing apply

of vueline to

new

a

insening seetor shaft into
housing remove plastic film 8e
careful not to drop bearings into gear
housing

gear
3

Fit

new

O ring into sector shaft

cover

washen
Before

from

gear housing
age oil seal

Toot

When

is that vinyl

lip

during insertion
6

Sector shaft 00

oil seal

serration

thin coat

Before installing

oil seal and dust

apply a thin coat
ring
that O ring is installed

7

Tighten sector

cover

bolts

of vaseline to O

seal

Make certain

properly and
Special washer

not

damaged by

IIi

sec

24ft lb

tor shaft

Small

00

SST056

ST695

8

Check steering gear turning torque
Refer to

Inspeetion

and

Adjust

ment

4

Set piston

worm

gear

at

straight

al1ead position
Turn piston rllck about 100 to 150
toward

youself

with your

finger

This is for smooth insertion of lec
tor gear

ST 18

If

there

tween

is

great difference be

8

values

of

fore and after

turning torque be
disassembly it must

be assumed that some new problem
has occurred

It will be

replace the entire assembly

nece
ary to

Steering Linkage

STEERING SYSTEM

STEERING LINKAGE

BaD joints

IiJ

I

31

42

3 23 31
To body frame

cover

29

69

3 0
Side rod adjusting bar

inthe tightening

To

direction

7 0

22

51

Be

rod

cros

Inner ball joint

98
8 0 10 0
58 72
78

specified

torque and align the cotter

pin hole

IiJ

IiJ

nut to the

Tighten

@
Outer ball joint

careful not to damage dust

Be

4

3 2

sure

pin and

Gear

to insert

new

bend it

ecurely

cotter

ann

J
CroSlrod

Cotter
Front

PinV
Side rod assembly
Model vRB47L

Side rod adjusting bar

IiJ

29

69

3 0

To knuckle

@
IiJ

Multil urpose greasing points
Nm

54

ft Ib

m
ks

7 0
arm

22

and

P S 56L
Modell
55
10 0

98

To knuckle

arm

51
cross

rod

L

and

cross

rear wheels

3

Remove

gear

mm

OJ more

in

the

order ofremoval

Gear arm to seetor shaft

J
G

127

with chocks

147 N

13

tool

15

94

kg

m

m

108lt lb

Idler arm to body frame
42 N m
31

Gear housing

3 2
23

arm

5

Remove

ann

using

side rod

from

4 3 kg m
31lt lbl

Side rod to knuckle
Model VRB47L

SST010

Gear

it

steering linkage

Install

reverse

using

use

SST099

6

arm

toe in

that side rod bar

rod

Jack up front of car and support
safety stands
Block

sure

0 98 in

72

n the

2

adjusting

Make

is crewed in socket 25
40

REMOVAL AND
INSTALLATION

it

When

knuckle

29

69 N

13 0

7 0 kg m
51lt lb

22

Tool

arm

m

Modell P S 56L

n

54
5 5
40

98 N m
10 0 kg

m

72 ft Ib

SST0100

7

After installing

check wheel
sary

Remove idler

ann

assembly

STa8l

and if

neces

adjust

Refer to Seetion
4

steering linkage

alignment

MA

for

adjust

ment

ST 19

STEERING SYSTEM

Steering Linkage
DISASSEMBLY

INSPECTION AND REPAIR

Side rod
I

@@

w

Remove both side rods from

I

rod using Tool HT72520000
2

Separate

and

outer

joints from side

rod

I

ball

inner

2
J

I

When

dust

deformed

J

i

joint

When ball stud is

worn

play exists replace
joint with a new one

adjusting bar

Z
Inner ball

Ball joint

cross

be

to

axial

rod

is

broken

cover

sure

or

side

ball

or

replace with

a

new one

Initial turning torque

SST104

Ball joint
0 5
2

Press bushing into idler body and

insert

shaft

J
t

54
5 5

SST102

idler

until

catefully
Lock nut

of

40

bracket

arm

bushing

5

protrudes

m

7 0

kg

Remove

nut

and

separate

each

part

cm
kg

21 7 in b

Swivel pin
25

2 5 N

m

22 in b

arm

essembly

cm
kg

m

51 ft b

Check rubber bushing of idler
for

When side rod ball join ts and side
rod adjusting bar are separated adjust
I

assembly

m

Le than

69 N

Cross rod and side rod
arm

25

4 3

Idler

Idler

2 5 N

side rod length correctly
Adjustment should be

breakage wear
necessary replace

arm

and

play

or

if

Initial turning torque
Less than

done

be

7 8 N m 80

cm
kg

69 in bl

tween lock nuts

e
Nut

Apply
StandardJength
71

o

mm

at

A

grease to idler

assembly

12 80 in

Cross rod and side rod

BU5hing

Check side rod and
Idler

arm

recommended intervals

breakage bend

t

ann

or

cross

rod for

and

replace

crack

with a new one if
necessary

Flxlns location
SST013

Unit

mm

Check

in

SST105

cotter

breakage
found
2

ASSEMBLY
Assemble
order

reverse

the

following

Tighten side

steering linkage in the
of disassembly observing

l
r

78

To

assembly

assemble idler

arm

proceed

Apply coat
grease to bushing

ST20

b

of

10 0

kg

m

72 ft b

Lock side

on

as

multi purpose

rod

that

so

adjusting
joint

ball

bar lock
outer

on

to

that

inner socket

Make

sure

sa ewed
mm

When looseness

check

for

or

wear on
arm

play

and
or

play is
tapered
of idler

When reassembling each ball joint

m

socket is 770 with respeet

follows
I

98 N

58

nuts

looseness

arm

18 0

instructions

location

for

portion of ball stud gear

use new

nut
erm

adjusting

bar

lock nut

a

Idler

rod

fixing

pins

that

in each

0 98 inl

adjusting

bar

is

socket at least 25

cotter

pi

s

STEERING SYSTEM

Service Data and Specifications

SERVICE DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS

Adjusting shim thickness
Thickness

Steering column
Standard column
VRB47L

IP S

length

L

I
I

56L equipped model

steering

1600

10 0620

1 525

1550

10 0600

0 0610

48215 801 00

1500

1 525

10 0591

0

48216 80100

1475

1500

0 0581

0 0591

48217

80100

1450

1 475

0 0571

0

48218

80100

pad y

I

0610

06201

06001

0581

L

VR847L

IP S

56L

01

Model

IUS p

Imp p

0 26

Approx

15 8 1 2

I P 5 56L

car

3 5

18 0

8

3 1

Oil pump belt deflection

20 5

17 0

inl
mm

INSPECTION AND ADJUSTMENT
IP S

VR847L

56L

turning angle

Inner wheel

degree

33

350

33

Outer wheel

degr

270

290

270

350

I
I

turning radius

5 7

mlttl

Steering wheel axial play

mm

in

Steering wheel play

mm

inl

18

1210 31
98 N

I

Normal

Fluid

7

71

kg Ib

5 394

operating temperature at fluid
Oc 10FI

capacity

34 3

13 0 3 5 6 6

kg cm2 psi

kPa

47
0

110 kg 22 Ib

4
29

steering wheel

Oil pump maximum pressure

USqt lmpqt

I

60

80

IAPprox

55

782

140

1 2

1761

1 1 4 1 1 8

Steering gear turning torque
N

e

at

Steering wheel turning force
N

wall

48214 60100

7 09

0

At circumference of

to

0

180

h

Steering gear ratio

Wall

48213 80100

1575

Lock lock

Minimum

0 0630

1550

I
wheelan the

1575
7 05

LL

Steering gear model

Front wheel full

Part No

179

SST080

Turns of

in

in

mm

equipped model

I

I

mm

Collapsible column

290

m

Ib

cm
kg

3600 position from
position

straight
ehead

Less than 1 2 12

101

71
position As com
Straight
ahead
pared with steering wheel turned
3600

01
0
Less than 35

1

0 10
0 9

0 3911
35

4

higher

381

steering models
Wheel turning force at circumference of steering wheel
of 98 147 N 10 15kg 22 231b with engine at idle
On power

STEERING GEAR
Model VRB47L
Worm

bearing preload With oil seal
N

m

Ibl

cm
lkg

Steering gear preload With oil seall
N

Backlash

at

gear

In neutral

arm

m

cm
kg

in Ib

STEERING LINKAGE

06

4
0

6 3 5

14

5

21
Initial

turning torque
N

Less than
1

23112 5

9
10

Ball

Swivel

top end

o
mm

01

0

play

Between
screw

sector

shaft and adjusting
mm

cm
kg

in Ib
05

2 5

15

25

Less than 2 5

pin

43

25

7
21

221

0004

lin
Idler

End

m

joint

tinl

01
0

0 03

0 0004

0 00121

Lessthan 7 8 80 69

arm

Standard side rod

length
jnl
mm

71 0

795
12

ST 21

Service Data and Specifications

STEERING SYSTEM

TIGHTENING TORQUE

Model I P S 56L

STEERING COLUMN

Unit

Unit

I Steering

I
I
I

m
N

wheel

37

ut

Jacket tube blacket
dush

to

3 4

Jacket tube

13

mounting

bracket

Coupling fixing

8
3

I

0

5 2

5

0

mount

bracket

I

18

34

451
I
451

18

3
11

44

0 35

22

1 5

0

27

38

25

9

3 3

13

shaft

to

Stee

I

Sector shaft to gear

I

Rea

ing
ge housing
bOOy frame

cove

3 3

cove

22

11

to

goa

housing

16

screw

only

I

0

I

Hose

I

to

to

bracket

oil pump
oi tank

se

to

to

Hose

I

Worm shaft

to

coupling

Steering gear housing

suspension

I

Sect
screw

ST 22

shaft

4

52

52

5 3

5

gear

c

oss

gear

arm

lock nut

cover

bolt

adjusting

lock nut

housing

35

38

46

Unit
53

127

147

13

15

94

245

314

25

32

181

15

2 5

11

15

29

25

39

30

40

62

53

63

13

15

147

26

32

2 7

3 3

26

32

27

33

28

34

2

9

3 5

26

36

27

37

29

49

30

50

29

49

03

05

l

29

49

03

05

49

69

50

70

I
I

I
I
I

28

38

46

94

108

20

24

20

24

21

25

I

20

27

I

22

36

I

2 2

36

I

22

36

I

36

51

STEERING LINKAGE

29

Idler arm
to

Adjusting plug
Sector shaft

49

52

24

lb
ft

m
kg

39

to

to

body frame
Sector shaft

m

9
3

en

STEERING GEAR

N

33

glne compartment
Hose

Unit

I

adjusting

member

Model VRB47L

38

lock nut

pump

Oii

32

127

to gea

Sector shaft
15

arm

ft lb

kg m

m

to

housing
Secto shaft

2 5

joint

I

nut

VRB47L equipped
mod 1

44

panel

Stee ing column

iog

51

Stub

ft Ib

m
kg

N

22

108

231
18

29

to

body frame

8all stud end swiVIII

I

I

Idler

arm

nut

Side rod bar lock nut

I P S

N

pin

m

31

42

32

43

23

31

29

59

30

7 0

22

51

54

69

5 5

70

40

51

78

98

10 0

58

72

80

56L equipped model only
assembly 54 69 N m 15 5 7 0 kg

Side rod

lb
ft

n
kg

m

40

511t b

Trouble Oiagnoses and Corrections

STEERI NG SYSTEM

TROUBLE DIAGNOSES AND CORRECTIONS
following probalbe causes and corrective actions refer to
and
Corrections in Front Axle and Front Suspension section
Trouble Diagnoses
Except

for the

Probable

Condi1ion
Excessive wheel

play

Insufficiently
stalled

tightened or improperly
steering gear housing

Damaged steering linkage
Incorrect

Vibration

shock

or

adjustment

or

or

Insufficiently tightened

shimmying of steering
wheel

Wear of steering

Damaged
Worn

idler

column

or

wheel

improperly

in

Retighten
Replace faulty parts

Replace

bearing

column

Replace

suspension

Replace

weakened

or

retighten

loose clamp

Deformed steering linkage and

or

link

left

Stiff or heavy

Adjust

linkage

or

Retighten
Replace faulty parts

ball joint

arm

bearing spring

right

in

of steering gear

stalled steering gear housing

Car pulls to

Corrective action

cause

steering

Insufficient lubricants
in

steering linkage

or

or mixing impurities
excessively worn steer

Replenish grease

or

replace

the part

ing linkage
Worn

or

damaged steering gear

and bearing

Replace

Incorrectly adjusted steering gear

Adjust

Deformed steering linkage

Replace

Interference of steering column with turn

Adjust

signal

switch

ST 23

r

STEERING SYSTEM

DiagnO and Corrections
tJS

Trouble

POWER STEERING

Condition
Oil pressure does

Probable
not

build up

Steering

wheel

moves

heavily

Pump drive

belt

Corrective action

cause

slipping on pulley

Readjust belt

Pump malfunctioning

Replace

Oil leaking through hose joints

Replace

Oil

Replace sealing parts at steering

leaking through power steering

Refill

Air

Bleed air

present in oil

See

Wheel alignment out of specifications
pressure in tires

Steering

column out of alignment

or

Idler

Steering effort is
the

same

in both

directions

Unstable running

not

arm

or

air

improperly engaged

damaged

Re

retighten copper washer

Hydraulic system

a1ign

or

gear

check

inflate tires to correct pressure

low

gears

and steering

to

too

Steering

Worn

return

or

Lack of oil in oil pump

Oil pressure too low

Steering wheel fails

tension

ball

joint

at

Replace
Repair
suspension

gear

assembly

replace

or

Replace

linkage

dragging

Repair

Refer to items marked

or

above

Front wheel caster improperly adjusted

Readjust

Internal gears dragged

Replace

or

gouged

Oil leakage in steering gear

gear

Stuffy

Replace

Wheel

bearing

Readjust

Stuck

or

properly adjusted

damaged

control valve in steering

assembly

Replace sealing parts

oil passage in steering gear

not

replace

Replace

gear

gear

assembly

assembly

gear

Noisy pump

Front wheel alignment not properly

Readjust

Excessive steering gear play

Readjust backlash

Play

Replace

at

suspension and linkage ball joint

Lack of oil in oil pump

Refill

Hoses

or

Clean

Loose

pulley

oil filter clogged

Belt noisy

or

Readjust

Replace

replace

gear

if necessary replace

Repair
slapping

Broken pump part

ST 24

or

or

tension

assembly

STEERING SYSTEM

Special

Service Tools

SPECIAL SERVICE TOOLS
Unit
Tool number
Kent Moore No

ST27l80001

Tool

name

Model VRB47L

1i
steering gear box

KV48 100301

Strut

125729

attachment

ST3127S000

Preload gauge

CD GG91030000
See 125765

P S 56L
Modell

Steering wheel puller

125726

See 125765

application

Torque wrench
Socket adapter
Socket adapter

x

x

X

X

X

X

i
CD

@ HT62940000
@

@HT62900000

ST29020001

Steering gear

arm

puller

J25725

HT72520000

Ball joint

KV48 101 500

Lock nut wrench

remover

X

KV48 101 400

Adjusting plug

wrench
X

ST27091000

Pressure gauge
X

Shut

ff valve

ST 25

Special

Service Tools

STEERING SYSTEM

I

Tool number
Moore
Kent

KV48I 009S0

No

Tool

name

I

Unit application
Model VRB47L

Model IP S 56L

Oil seal drift set

126367

CD KV48lO091O

Drift

@ KV48100920

Adapter

@

Adapter

KV48100930

CDsT35322000

Front wheel

@ST35325000

Drift bar

ST 26

x

bearing

drift
x

Model S II 0 Series

DATSUN 200SX

SECTIONBF
BODY

CONTENTS
BF

2

REAR WINDOW

Hardtop

BF 22

BF

2

BACK WINDOW

Hatchback

BF 24

BF

3

FRONT APRON

BF

3

ROOM

FRONT SIGHT SHIELD

BF

3

BODY

FRONT FENDER

BF

3

REAR PARCEL

HOOD

BF

4

BF

6

INSTRUMENT

BF 29

BF

7

CONSOLE

BF 31

BODY FRONT

END

FRONT BUMPER
RADIATOR

Shock absorber type

GRILLE

DOOR
DOOR

TRIM AND MOLDING

BF 11

SEAT

REAR BUMPER

BF 11

SEAT

TRUNK LID
BACK DOOR

BF 12

Hardtop

BF13

Hatchback

WINDSHIELD AND WINDOWS
WINDSHIELD

BF 16

SIDE

BF 26
TRIM AND MOLDING

SUN RDOF
REMOVAL AND INSTAllATION
BODY ALIGNMENT

COMPARTMENT

REAR OUARTER

WINDOW

Hardtop

BF 19

ENGINE

REAR QUARTER

WINDOW

Hatchback

BF 21

UNDERBODY

Hardtop

BF 22

OPERA

WINDOW

Hatchback

BF 22

BF 27
BF 28
BF 29

BF 31
BELT

DESCRIPTION

WINDOW

Hardtop

BOX

BF 16

OPERA

SHELF

INSTRUMENT AND SEAT

BODY REAR END
Shock absorber type

BF 26

TRIM

SPECIAL SERVICE TDOLS

BF 32
BF 34
BF 34
BF

35

BF 35
BF 35
BF 36
BF 37

a

BODY

Body FronrEnd

BODY FRONT END
FRONT BUMPER

Shock absorber type

Front bumper
Shock absorber

31

42

3 2

59
6 0

4

3

31

23

78
8

0 43

58

wq

B
bucket

OYerrider

N

m

rn
Icg

ftlb

SBF126

I

Disconnect

2

Disconnect

lamp
3

from

distance

REMOVAL AND
INSTAUATION

meets the

top edges
specifications

to

ground

battery ground cable
front

combination

connectOIs

Remove

bolts

securing
bumper assem
front bumper assem

special

shock absorber to front

bly then
bly

remove

Remove shock absorber from car

4

body
CAUTION
The shock absorber is filled with

pressure gas and should not be

high

disassembled
an

5

p p

a

drilled

or

exposed

t

to

open flame
Installation is in

reverse

order of
Unit

removal

111m

in

Section A A

SBF121

ADJUSTMENT
flat

surface under

weight conditions

Tires must be

Place

Bumper height
I

Adjust

BF 2

bumper

curb

height

so

that

car

OB

II

inflated to rated pressure

After

adjustment
and nuts securely

2

tighten

bolts

BO DY

RADIATOR GRILLE

FRONT APRON

REMOVAL AND
INSTALLATION

REMOVAL AND
INSTALLATION

1

Open engine hood

1

2

Remove radiator

Refer to Front

grille

2

FRONT SIGHT
SHIELD
REMOVAL AND

Remove front bumper assembly

Bumper

INSTALLATION

for removal

Remove front apron

1

Remove

reverse

fmisher and

2

Remove radiator grille

3

Remove front

4

Remove front sight shield

bumper assembly

Jf

Q

SBF129

Installadon is in

headJamp

headlamp

1

3

Body Front End

1

order of

removal
SBF130

CAUTION
a

3

Radiator grille is made of plastic
so

do not

use

b Take Clre to
radiator

excessive force

keep

oil away from

grille

Installation is in

reverse

order of

removal
When
to sea

installing front apron be sure
mating surface of front fender

and front apron

5

Installation is in

reverse

order of

removal

FRONT FENDER

Section A A

Seal completely to mating surface of
fender and hoodJedse

IR

ff

i
J

a

J1
A

b

SBF131

BF 3

Body Front

End

BO DY

REMOVAL AND
Fender
I

Disconnect

2

Remove front

Refer to

5

CAUTION

INSTALLATIoN
battery ground

cable

bumper assembly
Front Bumper Assembly for

and

panel

hoodledge are
removing

When

installing front fender apply
mating surface of front
lender and hoodledge

secured with sealant Before

front fender be

sure

Installation is in reverse order of

removal

sealant

to remove seal

ent

to

removal and installation
3
Remove fender protector sight
shield front apron and fender stay
4
Remove bolts attaching front
fender and then

remove

front fender

HOOD

Hood

Striker

Hood louver
Torsion bar

Hood hinv

Cowl grille

Hood lock

Hood

rear

molding

Hood control
cable
SBF132

REMOVAL AND
INSTALLATION

3

I

Installation is in

removal

reverse

order of

Adjust hood Refer

to Ad

justment
Hood
I

Open

hood and

remove

washer
Torsion bar

tube
2

Support

hood and

bolts

I

Open hood

remove

2

Support

remove

attaching hood hinge and then
hood

7

lIB
11 6

BF 4

21 N
21

bar

torsion

bar from hood

m

m
kg

12

15fHb

S8F133

hood and

torsion

remove

each

by disengaging end of

suitable screwdriver

hinge

Use

a

Body

BODY
Disconnect lock control wire from

2

lock

hood

then

and

remove

hood

2

Loosen bolts attaching hood lock

and

move

hood up

optimum posi
opened and closed

tion when

SBF134

Installation is in

reverse

down and side

or

to side until it is set in

lock

3

F ontEnd

JLlI

order of

t

SBF136

removal

SBF138

Lubricate

sliding surface

of

tor

sion bar
hood

After

3

4

engine hood
2
Remove wiper arm and then
move windshield lower grille
3

Remove

Remove

remove

torsion

bar

and

re

then

hood hinge

Refer

to

clearance

fenders is

nearly equal

at

and

hood

all

points

and then draw cable out through pas
senger
5

compartment

Installation is in

reverse

order of

fj

bumpers until hood

Raise two hood

is flush with fenders

Hood lock attaching bolU
16

after torsion bar

hinge onlv

Bumper rubber

removal Adjust hood Refer to Hood

1 6

has been removed

12

21 N

Fende r

m

alaI

2 1 kg m

HO d

Check hood lock control

0101

7

15 ft lb

J

I

1
operation

@

I

I

Unit

mm

Hood and lock
I

Loosen

hinge

and

bolts
move

attaching

Installation is in

reverse

order of

2

Adjust bolt
Bumper rubber

3

Lock nut

4

Weld nut

hood

hood

forward

or

backward and side to side until it is
set in

SBF139

1

2

SBF135

@

in

ADJUSTMENT

t7

4

ensure

adjustment
between

Remove hood lock control knob

Adjustment

CAUTION
Remove

Lower

that

Cover for removal

Hood hinge
I

Instrument

left

Remove

cover

instrument

lower

optimum position

Ensure
in

contact

that rubber bumpers
with mating

come

panels

removal

fj

Hinge attaching
39

4 9 N

0 4
2 9

0 5 kg m
3 6 ft lbl

Hood lock and
I

bolt

m

Remove

bolts

lock control

attaching

hood
SBF137

lock
BF 5

Door

BODY

DOOR

Door

gtus

Door outside moulding

II
i1

Doot stabilizer

Outside haodle

Front

guide

rail

liar
npper
It

i

@

t
lnad

J

screen

hand1e

Ann

Door fmisher

SBf140

BF 6

BODY

DOOR

4

Remove bolts

Door

door win

attaching

dow to guide channel

REMOVAL AND
INSTAlLATION
Door aasembly

Support
Place
or

2

a

door with

a

stand

or

jack

rag between door and stand

jack

O
SBF142

Remove door from

c

hinges

SSF144

I

I

5

When

W

00

Remove sealing

careful

screen

removing sealing

taet with

be

screen

to allow it to come in

not

con

S

adjacent parts

Remove door glass by pulling it
upwards and away from door
7
Remove regulator attaching bolts

r

0

JL

6

C

Installation is in

To

prevent

water

removal

Adjust

reverse

Door

order

b

of

pins

Refer to Ad

Door

hinge securing

16

22 N

1 6
12

of

entering
affix seal

with adhesive tape

door window closed

use set

install regulator handle

to

shown in

justment

l
t

With

from

compartment

passenger

ing SCreen firmly
or bonding
agent
Installation is in

order

reverse

removal
8

SBF141

3

Remove door stabilizer

6

Figure

as

below

bolts

m

2 2 kg m
SBF145

16 ft lb
Front

300

r

Front door trim
1

Lower door

2

Remove

8

glass fully

ann

rest and door inside

handle escutcheon
3

BF879B

Remove

through
panel

regulator

large

access

hole

assembly
in

door

Remove regulator handle by pry

ing out

set

pin

r

Door glass and regulator

Front
o

t

I

Remove door trim

2

Remove door outer

3

Remove

both

molding

front

and

rear

upper stoppers

SBF146

SF879B

IY hf
J
Rear uppe
4

Remove

able tool

door fmisher with suit

and pry door fmisher clip

off door inner

panel

I

9

Installation is in

removal Door

opper

to

Front upper stopper
SBF143

reverse

order of

glass adjustment

Refer

Adjustment

Apply grease to sliding surfaces
regulator and guide channel

of

BF 7

BODY

Door

Door lock and lock control

Inside lock knob

Door outside handle

J

I

Jb

t
Door

s

Key cylinder

l

Imide handle

Imide handle escutcheoD

lock

SBF147

Remove door trim
2

Remove door

glass

ADJUSTMENT
Refer to Door
Door assembly

Glass for removal
3

Jlemove door inside handle at
taching screws door lock assembly
crank
bell
attach
attaching screws and
ing screw
4
Disconnect key rod from key
cylinder and then remove door lock
and lock control
5

Remove door outside handle

6

Installation is in

reverse

j
Il

order of

rcptoval
Apply
leven and

grease to

sliding

4

surfaces of

springs

i

d

SBF148

I
to

Loosen bolts

body

and

side

forward

attaching door hinge

Move door up
or

or

down

backward until it is

correctly positioned
Using
BF B

an

offset wrendl

bolts

attaching hinge

2

Loosen bolts

to door side
remove

to rear

of front

lender

attaching

door

hinge

Move door from side to

side until it is set in optimum position

BODY
Door glas
Before

adjusting

door window

check body side weatherstrip to
that it is properly positioned

glass

ensurl
as

proper positioning may
dust leaks

im

@1f

Adjust

window glass

cause

water or

follows

as

Ooor

Tilt

adjustment Upper side of glass

I

Loosen

front

and

rear

upper

stopper securing bolts and front and
rear guide rail securing nuts
2
Adjust door regulator so that
upper side of glass is parallel with
body side weatherstrip

@

1

ln ut

adjustment

at waist
2

3

4

area

adjustment
upper side ofgalss
Tilt adjustment
upper side of glass
Gut
In

Regulator

SBF153

Glass upper stop

adjustment
5

Glass fore and
aft adjustment

3

After

adjustment

tighten guide

rail securing nuts and guide channel

securing bolts
SBF149

In out
1

At waist area

adjustment

Loosen nuts

of both front and

11 2

mm

0 441 in

securing upper ends
rear guide rails
Glass upper stop

rfjV

ll

I

I l

t

idi

Jr
j

J

I

Adjust

changing

II

rear

upper

adjustment
height of glass by
stopper position

rear

Side

roof rail

SBF151

C

Front

adjustment Upper side of glass

out
In
SBF 150

1

Loosen nuts securing lower end of

guide rail and turn adjusting bolts
until glass is set in position as
n
showni
below
Figure

Door glass
SBF154

Side roof rail

2

Raise window

3

Turn upper

direction

or

completely
adjusting bolts

in one

the other until distance

between glass and rubber seal for door
waist
as

molding

is 112

mm

shown in Figure below

441
0

in

14

17

10 55

crt

mmLn

0 67

g

inlrOoorgla

SBF152

BF 9

BODY

Door

2

Adjust front height of glass by
changing upper front stopper position

@

Door lock and lock control
I

Move

rank front and rear
bell
until free play of lock knob is mini

BF l0

nut until clearance

Tighten lock knob attaching

11i

nut

screws

U

I

UI

0

SBF158

0

1mm
inl

0 04

P

completing adjus1ment en
adjustment is within

that each
limit

Adjust

with each other when lock is engaged

J

specified

adjusting

Check lock knob and inside
handle to insure that they are flush

il
After

Turn

between outside handle rod and door
lock lever is 0 to I mm 0 to 0 04 in

mum

ri

sure

2

Mter adjustment
SBF157

check to deter

mine if door lock operates

correctly

BODY

Body

Rear End

BODY REAR END
Shock absorber type

REAR BUMPER

i31
J

42

3 2

4

3 23

31
umper

ll
mounti
Rear

bracket

bumper

Shock absorber
mder
O

S
i
Bumper face

if
13 7

J 59
i

78

6

8

43

9

t

58

side

J
i

N

m

kg

molding

m

fHb

SBF159

REMOVAL AND

INSTALLATION
battery ground cable
lamp harness
Remove
3
special bolts securing
shock absorber to bumper assembly
and detach bumper assembly
I

Disconnect

2

Disconnect reverse

4

Remove shock absorber from car

M

600 23 62

body
CAUTION
The shock absorber is filled with

512
a

544

20 16

21 42

pressure gas and should not be
disassembled drilled or exposed to

high
an

5

t

open flame
Installation is in

M

reverse

600

23

621

t

order of

removal

Unit

ADJUSTMENT

mm

in

Section A A

SBF160

Bumper height
I

Adjust bumper height so that
top edges to ground
meets the specifications
distance from

Place
curb

car on

weight

a

flat

conditions

surface
Tires

under
must

2

After

and nuts

adjustment
securely

tighten

bolts

be inflated to rated pressure
BF ll

Body

Rear End

BQDY
3

TRUNK LID

Installation is in

reverse

order of

removal

Hardtop

I

REMOVAL AND
INSTAUATION

Trunk lid

Open

I

trunk

lid

trunk opener cable
2
Support trunk
bolts
then

attaching
remove

and

lid

and
lid

trunk

remove

I

Remove trunk

2

Remove trunk lid

remo

to

hinge

and then

trunk lid

3

remove

remove

fmisher

rear

SBF163

attaching bolts

striker

Remove lock

then

i

l

Trunk lid lock end striker

attaching bolts

and

lock

4

Installation is in

reverse

order of

removal

Trunk lid opener

III

3

Installation is in

reverse

order of

removal
trunk lid

AdjUst

Refer to Adjust

ment

i
G

Trunk lid

39
0 4
2 9

securing

4 9 N
0 5

bolts

m

kg m

3 6 ft lb

SBF164

Torsion bar

1

I

Open

seat back

2

Support

trunk lid
trunk

each torsion bar by
of to

ion bar from

suitable screwdriver

lid

and

remove

disengaging
trunk lid

end

Use a

2

Remove

Remove

rear

seat cushion and rear

ADJUSTMENT
T un

kicking plate

3

I

Il

an

Loosen bolts

Remove trunk lid lock attaching
bolts and then remove trunk lid lock

hinges

4

backward and side

Trun up floor carpet
lid opener handle
S

Remoye trunk lid

near

trunk

set in

Move

oc k

attaching trunk lid

trunk lid

forward

or

to side until it is

optimum position

opener handle

6

Remove trunk lid opener cable

7

Installation is in

reverse

order of

v

removal
Fasten trunk opener cable

securely

with adhesive tape

L

SBF166

BF 12

BODY
Loosen bolts attaching trunk lid

2

lock Move trunk lid lock forward

BACK DOOR

or

correctly positioned when opened and
closed

a

Be careful not to scralch back door

staV when installing A scralched
staV mav cause gas leakage
b Back door staV contents are under
pressure 00 not take apart punc

REMOVAL AND
INSTALLATION

I

Rear End

CAUTION

Hatchback

backward and side to side until it is

Body

Back door

ture

applv heat

or

fire

Back door lock end lock

cylinder

J3

9

49N

10 4

05

2 9

m

kg

m

I

Open

2

Remove

3

Remove back door lock from

SBF166

3 6 f1
lbl

back door

luggage

rear

fmisher
rear

panel
SBF168

Trunk lid opener

Adjust trunk lid

opener until clear

ance between trunk lid

end and control

control cable

lever is within 1

mm

0 04 in when trunk lock is engaged

2

Open back door
Mark hinge locations

1

mm

Less than

0 04 in

AdjusUble

1

dow

i

0

0

Remove
rear

rear

Q

roof rail trim and

defogger

harness

wiper

SBF

and rear win

connector

169

and

hose

Locking lever

A

bolts

disconnect

Lock

body for

back door to back door stay

remove

Clearance

on

proper reinstallation
3
Support back door by hand and

Support back door by hand and
back door to back door hinge
attaching bolts Then remove back
door
This operation requires two
5 mm 1
10

20

inl

Remove

combination lamp

4

4

remove

and then remove lock

rear

cylin4er

men

SBF167

CAUTION
Place

rags

between roof and upper end
to avoid damaging paint

of back door
ed surfaces
5

Installation is in

reverse

order of

removal

l
t

Back door stay retaining bolt
16
1 6
12

21 N

m

2 1

kg

15 ft lb

5
m

r

Installation

mova

is in reverse order of

Adjust back door

to Back Door for

referring

adjustment

BF 13

8OdyRearEnd
Back door

BODY

opener

Back door lock cable

SBF171

I

Open

2

Remove

luggage

3

Remove

back

rear

panel

back door

2
rear finisher

door

lock

To make side

move

from

toide

back door

required

to

to obtain

an

left

Remove

rear

seat back

3

5

Remove

move

6

Turn up floor carpet riear back

rear

cushion

seat

and

kicking plate

door opener handle

rear

right

as

clearance
fender on

both sides

tion

To make

and
fore

back door in

required

aft

adjustment

and
fore

to obtain

5

Turn

and
8

back door opener handle
Remove back door opener cable

9

Insta1Iation is in

luggage

room

To obtain

door and

snug fit between back
weatherstrip loosen down
a

stopper securing screw Loosen back
door lock attaching bolts enough to
move lock working lock up or down
and from side to side

as

required

aft direc
an

equal

clearance between back door and roof

7

up

or

equal

between back door and

4

adjustment

h

carpet

7

remove

reverse

1f

order of

removal
Fastan

back door

P

opener control

cable securely with adhesive tape

0

U

y

P
l4
SBF172

ADJUSTMENT
BF6848

Back door end striker
Back door

can

be

adjusted

with

bolts attaching back door to back door

hinge
I

and back door lock

Loosen bolts attaching back door

to back door

BF 14

hinge

6
4

After alignment is

tighten bolts securely

properly

made

After

tained

desired

tighten

adjustment

is

ob

back door lock attach

ing bolts securely

BODY

7

Adjust down stopper

hollow

of back

down stopper

door

securing

to set with

then tighten

screws

Body

Rear End

door opener

Back door lock

Balik

Adjust back door lock and key
rod until they are correctly positioned

Adjust clearance between rear door
opener cable end and locking plate

shown

when door is locked until it is within

when door lock is
in

engaged

as

range indicated in

Figure below

Figure below

v
r

C
J
BF6868

0
0

Key

rOd

Adjust

o

II

0

0

o

c

mm

004

inl

Locking

lever

nut
SBF173

SBF174

BF 15

BODY

Winrhhieldand Windows

WINDSHIELD
REMOVAL

WINDSHIELD
to
pre mixed one part sealant
cement windshield glass to windshield

I

Protect hood

A

opening

is available

After using this sealant it is highly
recommended that the car should reo
main
so

stationary for about 24 hours

that the sealant can

cure

welL

molding is in
continuous plastic mold

windshield

Upper

stalled with

a

AND WINDOWS

ing fastener

front

tpanelandftoot

strum

in

fenders

th

ns

covers

2

ndshield

Remove

pillar gamishes
Refer to

front

pers

and windshield

Roof Trimming

garnish
for

re

moval
3

Remove front

4

With

off

a

pillar moldings
sharp cutting knife

caulking

ma1erial

BF331 B

to

gttached

upper and lower moldings
move

cut

Then

reo

moldings

1

Adhesive caulking material

2

Glass

3

Knife cur

Cut here

7

Cut off

caulking material

entire perimeter of glass

Using

I

a

as

cut

knife

around

follows

through part

of caulking material
2

Secure
05

re

BF330B

Windshield glass
Windshield molding

Using long nose pliers insert other
re through caukling material
edge of glass then secure that end

Body

end of

4

Double faced adhesive tape

at

5

Molding falteDU

6

Sealant

7

of

Dam

Reaching

from

inside

strip

car

dam rubber from around windshield

glass

can serve as a

handle

3

5

in diameter

0 020 in

piece of wood that

to a
I
2

of steel music

end

one

mm

3

re

to another wood handle

With

the

of

aid

assistant

an

re through caulk
carefully cut puJi
ing material around entire perimeter of
ndow using a sawing motion

CAUTION
a

Use

Genuine

Nissan

Sealant Kit
or equivalent Seal
ant kit consists of Piimer A Primer
E dam caution label and sealant
which is made from silicone Using
72891 U7425

this kit

proceed

to

operations

I
Ye I

de

scribed in removal and installation
b Do not use sealant if it is more than
six months old
c
Open cartridge only at the time of

1

Bf288B
BF35 B

use

S

d Keep Primen and sealant in a cool
dry place ldeally sealant should be
stored in

a

push glass up
opening
or sharp
razor blade

From inside

Using

9

refrigerator

scraper

a

edge

opening leaving
WARNING
IS

heat

Primen

BF 16

or open

are

flames away

flammable

6
off

sharp cutting knife cut
caulking material along edge of

With

mm

caulking

remove

entire

along

Keep

car

and out ofwindow

it

of

material

windshield

about 10 to 2 0

0 039 to 0079 in thick

a

entire window opening

If
move

millual

sealant i

all traces of it

ilicon

re

Windshield and Windows

BO DY
5

CAUTION
a

When

Molding

be

scra1Ched

surface

painted

body

sure

to

repair

fastener

is

With

furnished

sponge

Primer A

apply

a

light

with

coat of Primer

to cleaned area of glass

with

paint
b

of

Identificetion
material

be

can

used

adhesive

accomplished

as

follows

piece of gxcess
glass or windshield
opening flange
Stick small piece of sealant on

1

Cut

smell

e

sealant from
2

IlIMERA

the end of knife or the like and
hold it over flame from match or

Iighler until

it

Polysulfide
flamg and

3

Apply glass

sealant beside mold
BF376B

ing fastener

igniles
burns with

a

clear

very small amount
of white smoke or no smoke and
a

CAUTION

is very objectionable
sulfur dioxide

its

odor

00 not

apply
ing flanges

heavy
Polyurethane burns with a
dirty flame and emit black
smoke and very little odor
Silicone glows with little
no

With

6

or

Primer E

flame and emits white smoke
Sealant

and very little odor
Burnt residue is white ash

8 F

3338

Primer A to

glass

furnished

sponge
a

glass surface where the
sealant will be applied and dam with
non

lead

Residual sealant

gasoline

About

20

ij
IMERE

mm

0 79 in

WJ
BF377B

INSTALLATION
Clean

with

non

Cleaning

contacting face of body

lead

with

light coat of Primer
to original caulking material left on
glass opening flange

apply

Clean

3

L

open

area

gasoline

BF531

CAUTION
grease or waler
clean surfaces from dirty

00 not allow oil
to

get
hands or tools
on

4

Install dam

windshield

excess

windshield opening
1

Heat molding

as

on

follows

fastener and

con

and press
more than 490 kPa
kg em 71 psi using a suitable roller
Make certain that
t

shown

come

in ide
31
0

of
in

off

If residual
move

it

not

to

mm

amount at its ends

hADam

is

silicone

r8

CAUTION

dry for 10 to 15
proceeding to the next

Allow Primers to

GlaSS

step

5

7

as

Insert

cartridge

in

Gun ST08810000 and

fastener

molding
from body

Dam

sealant

all traces of it

minutes before

Attach molding fastener to body

does

8

upper

tacting face of body up to about 400C
I040 F using a heat giltl
2

rubber

inboard from edge of glass and cut off

Install molding fastener

2

glass

Unit

mm

8F955

in

continuous

bead

0 43 in above

on

glass

Caulking Hand

place
glass

smooth
11

mm

surfaces
BF 17

BODY

WincMield and Windows

After
to

installing

attach caution label

glass surface

d

CAUTION
LEAVE ONE WINDOW
OPEN SLlGtlTlT
FOR THREE

OATS

This is to protett f04 ew wfndshield
ure lnduC8d
nstallation from
pre
Iuks before the
ubb 1 has com
pletely ulconizecl

BF335B

BF6988

Dam

10

Apply

glass

on

pressure

10

aid

in

seating on plate
Wipe excess caulking material
off molding fasteners edges of glass
II

mm

nl

o

Section A

and body
12 Remove

A

13
BF782B

protective

Water test

Be lure that

is

covers

immediately using

a

opened

dosed
be

cold water spray

it does

not

obstruct

visibility The label noting the faet
that sealing will be impaired if door
osed

or

with

window

before sealant has dried

furnished

will

with the kit

direct stream of water at

Do not

fresh adhesive material Allow water to

spill
Cut off nozzle end of cartridge as
shown below

over

edges

of glass

If leaks

are

encountered

use Caulking Hand Gun
in
additional
to work
caulking material

at leak

point

Install

14

all

previously

removed

CAUTION
AdviSB the

of the fact that car
rough roads

user

should not be driven on
or

surfaces until sealant has properly

wlcanized

parts

h

Reference

required

Period

for sealant to dry to desired hardness

Unit

days

1

70
Relative

0 311

humidity
50

90
Unit

mm

BF957

in

Temperature oC

F
25 77

15

5
2

6

10 50

3

3
5

10

10

sealing film with needle
cartridge on hand gun

Pierce
install

CAUTION
Sealant starts to harden 15 minules
after

it

shield

is

should

glass

windshield

opening

installed in

be

body

in

wi1hin

15 minutes of applying sealant

Leaks

Support

windshield

glass

can

I To stop leaks lint
with

2

area

remove

17

Apply

repaired without
reinstalling glass in
be

moving and
following manner

ings in
8

10

14

REPAIRING LEAKS

wind

1herefore

applied

25

reo

pushing

ofleak

Mark location of leak

on

to

leak

area

while

glass

Mark extent of leak point

the

mold

water

34

Apply Primer and then sealant to
leak points
following procedures
3

shown below

SuckerST08800000
9

Install

windshield

opening flange
tween

windshield

about 7 mm

BF 18

so

28
0

glass

on

that clearances be

glass
in

and body

are

If water is leaking between caUlking
matarial and
Kfy or between glass
b
and
tent

ex
caulking material cietermine
of leak by pushing glass outward

CAUTION
Do not

sealant

apply

Primar to old sil

one

BODY

Windshield and Windows

TrUn

1

PrUner E

PDIYlulphide

4
Silicone

or

polyureth

ne

sulant

l

81lant

Work into joints

BF498B

REAR QUARTER WINDOW

Hardtop

REMOVAL AND INSTALLATION

I

J
Rear upper

I
stopper

0

Front upper stopper

I

Rear

quarter window glaM

Jt f

V
D

Guide plate

Ann rest

Regulator handle

SBF175

BF 19

BODY

Winchhield and Windows

L

Remove

rear seat

seat

rear

cushion

Remove regulator handle and
side finisher

rear

Remove air outlet grille and seaI

ing screen
4

Installation is in reverse order of

8

removal

2

3

and

back

Glass

refer to

adjustment

Adjustment
of

reguI

to

guide plate attaching

tor

t

adJu

nt
g

lde of

Upper
Adjust

Apply grease to sliding surfaces
regulator and guide channel

Remove upper stoppers and nuts

attaching glass

ciut
In

rear

quarter window glass

shown in Figure below
position
using adjusting bolt located on lower
end of guide plate
as

Remove
roof
rai

Side

nuts

ADJUSTMENT

I

In out adJu tment
wa
t erea

At

14

Close

quarter window com
pletely Adjust position of adjusting
bolt securing upper end of guide
plate until distance between glass
and rear quarter waist molding rubber
rear

seal is I 1 2

5

Remove

glass and

both

guide

quarter

mm

0 441 in

as

2 mm
11

window

17

0 55

mmLn gr

061

inlV

Door glass
SBFl52

shown

441
0
in

plate tIuough top

opening
Angle adJu tment
Close door
window

that tear

glasses

ed with door
SBF161

side

Rear quarter
win ow glass

SBFl77

Narrow

and

rear

glass completely to
quarter window glass

glasses
weatherstripping

quarter
ensure

is

align

and fits body

Wide

I

I

6

Remove bolts attaching

L

regulator

Glass adjusted too far to forward

ID

L Door
sI adjusted too far to
Gla

window

glass

rear

em
Glass inclined

liD
7

UD

Draw out regulator tIuough lower

opening
BF 20

SBF179

BODY
G1

ss

upper

Adjust

glass

and

two

stop

4

dJustment
stoppers until

upper

side roof rails

set

are

at

dimensions

raised

glass fully

indi

Remove

Windshield and

regulator attaching bolts

and detach regulator

cated in Figure below

f

Side roof rail

0

00

0

glass

Q

y

SBF154

0

06

III

5l

Door

Windows

SBF18

SBF180

5

Remove air outlet

grille and

rear

fender molding

REAR QUARTER WINDOW

Hatchback

REMOVAL AND INSTALLATION

SBF184

6

rwindow
Quarte

Remove rear body side retainer

b

regulator

SBF185
SBF181

7

Remove quarter window attaching
then remove quarter window

screws

1

Remove

cushion

and

regulator

handle

rear

and

luggage

side

rear

seat

I

seal back
2

side

Remove

fmisher

finisher and
3

Remove

top

sealing screen
bolts attaching glass

remove

to

regulator

f

SBFl

2

BF 21

Windlilield and Windows

8

Installation is in

BO DY

reverse

OPERA WINDOW

order of

removal
To

Hatchback

leakage through
door
fasten sealing screen securely
using adhesive tape or bonding agent
prevent

water

Rubber

Glass

REMOVAL AND
INSTALLAnON
1

Remove

back

seat

rear

rear side

cushion

seat

finisher and luggage

side upper fInisher

2

Remove air outlet

3

Remove opera window

nuts

then

remove

1

y

grille

SBF189

attaching

window
4

Installation is in

reverse

order of

removal

OPERA WINDOW
Hardtop

REAR WINDOW

Hardtop

REMOVAL AND
INSTALLATION
1

Remove

back and
2

rear

rear side

Remove assist

seat

cushion

seat

fmisher

grip and rear corner

fmisher

Sedan

CD

SB

3

Remove opera window

then

nuts

remove

187

attaching

window

1
2

Weatherstrip
Window glass
3 Molding set
4 Roof panel
5

@

Outer panel
SBF361

REMOVAL
SBF188

Place protective
door and rear fenders
2

ve
Rem

garnishes
4

Installation is in

removal

BF 22

reverse

order of

ness

L

parsel

after

covers

shelf lUId

removing

cushion and back from
disconnect

rear

window

back

on

rear side

panel

3

Remove

rear

prying

seat

4
to

body
defogger

har

coMectors

r on rear

Then

rear

at

co

out

Place protective

window

molding by

molding

Attach two Suckers ST08800000

glass beforehand for convenience in
lifting out rear window glass

BO
5

From

inside passenger compart
ment apply hand pressure to edges of
rear window

and

glass

weather

remove

strip lip from body flange starting
from top to sides Use a conventional
covered

screwdriver

cloth

with

or

other suitable tool and carefully put

weatherstrip

body flange

over

With

3

and

rear

glass supported

window
in

centered

body
check relationship between glass and
opening around entire perimeter of
glass

1

Entire

opening

in

inside

surface

glass

of

should be in contact with opening
2
Curvature of glass should

con

form to that of opening
3

Mark any section of

be reformed

opening
J

4

Remove

opening to
glass and reform

required

as

Install

rear

window

glass

as

1
to

With

Install rear window

weatherstrip

glass

in

opening

rear

free from

of

a

in

helper
rear

carefully

window

body supporting

glass

it with

Sucker ST08800000
4

When glass and weatherstrip

are

opening slowly
pull ends of cord with another person
pushing glass from outside starting
from lower center of rear window glass
to seal lip of weatherstrip on opening
flange
Cord should be pulled first across
bottom of glass then up each side and

properly positioned

in

across top
Carefully tap around rear window
glass to assist in seating weatherstrip

5

flange
Never

t

tap

or

hammer

at

glass

to

position

8F229B

After

aid

position and center

on

6

Windshield and Windows

fmally

follows

rO

3

V
O

window weatherstrip is

body flange

helper carefully

with aid

remove rear

of

a

window

with Suckers ST08800000

glass

BF647

INSTALLATION
important that rear window
body be checked throughly
opening
It

is

in

before

of

installation

rear

window

2

Insert

Insert

glass
Procedure below includes checking

BF650

strong cord in groove of
weatherstrip where opening flange fits
a

Cord

so

that ib ends

are

at

bottom center of glass

of rear window opening in body
L

Check re

f

window weatherstrip
opening in body for

and rear window
any

irregularities

2

Stick

rear

window

person

opening

ST08800000

Suckers

glass

carefully
in body

position

CAUTION
Care should be exercised

Certain glass

on

With aid ofanother

does

not

metal during installation
can lead to future breaks

BF649

glass in

to

make

BF648

strike

body
Edge chips

1

Windshield glass

2

cord
Draw

3

Weatherstrip

5

Install

all

previously

removed

parts

BF 23

Windshield and Windows

BODY

BACK WINDOW

Hatchback

REMOVAL

Back wbldow gWs

lumm
S8F19Q

l

de

Remove both

corner

molding and

molding

glass retainers
Disconnect rear defogger harness
3
if so equipped
4 Remove welt from inside pas

2

Remove four

senger compartment
S
Remove butyl tape with
knife

then

remove

back

a

Wipe

1

glass and
gasoline

any trace of

door

butyl tape off

panel using

non

leaded

3

Using

1dowil

Jr

B

6

of glass

mm

B

SBF191

INSTALLATION

BF 24

points

SBF193

t
butyl tape starting
point A figure bon and ending
at point A and overlap some length of
tape at point A
Use care to a oidtouching adhesive

I

at

alent when

to

shown in Figures below

0 24 in

Be sure to affix

equi

as

r
J

or

IS80F

tyltape

Cross section B

side
of 8 mm

heat adhesive

700C

C

1

r5

butyl tape

tape

to

putty

glass

Use

heat gun

Apply bonding agent

4

2
Affix butyl tape to entire surface
of glass as shown in Figure below

a

side of butyl

0 31 in

replacing glass

of butyl tape with fingen

finger
adhesi

prints
e

or

stains

force of tape

may

as

reduce

2OO
4

mm

points

I

7 41 in

O

SBF194

BODY
5

Support

rear

window

glass

with

glass

Sucker ST08800000
6

With

the

with

help of

panel

at all

haJ11ffier

points

as

until

shown

to

molding

mine
5mm

0 16

G

o 20in

II

Check rear window
all

side

lower side
are

glass

dearances

left side

and

upper side
right side

equal

Temporarily tighten four reo
tainers
and lightly tap around glass
8

one

shocks

after

Direct water

periphery of glass
is

or

hour

to

deter

water leak inside

Remove excess

or

protruded butyl

tape

Butyltape

to ensure

vibration

passenger compartment

S

dow
c

apply

for at least

if there

securely

molding

has been installed

toward

4

all four retainers

corner

Do not

glass

glass

7

that

Tighten

10
Be careful notto scratch

defogger harness

Carefully position rear window
glass on opening flange of rear win

9

and attach

assistant

an

window glass close to open
bring
ing flange of rear window and connect
rear

rear window

rubber faced

a

fits

Windshield and WindOM

J
ml
Backdoor

panel

SBF195

1

BF 25

Trimand

Molding

BODY

TRIM AND MOLDiNG
ROOM TRIM
Hardtop

AssistgriP

HeadIinins

Rear

L

upper

garnish
Room lamp

hieJd
Wirul

mbly

upper prnish

Sun riser
SBF196

REMOVAL AND

9

INSTALLATlqN

nish

I

Remove front

Remove

rear

window upper gar

pillar garnish

I
r

if ii

1

tl

SBF198

r
SBF199

BF197

5

Remove

rear

seat

cushion and

back
6

2

Remove sun visor and holder

3

Remove

4

Remove roof side

BF 26

room

lamp assembly

garnish

Remove assist grip

Hardtop

coat

hanger Hatchback

7

Remove rear side finisher

8

Remove

Hardtop

rear
or

corner

luggage

finisher Hatchback

or

finisher

10

Remove head

side

II

Installation is in

upper

removal

lining
reverse

order of

BO DY

Trim and Molding

BODY SIDE TRIM AND MOLDING
HARDTOP

Rear sid

finisher

Kicking plate

SBF200

HATCHBACK

Rear

body side retainer

Rear

side finisher

SBF201

BF 27

Trim and Molding

BO DY

REAR PARCEL SHELF

Hardtop

SBF202

BF 28

dSeat

IrislflJ

ent an

600

NS1 RUtAEN1

AND

S EA1

ftEtlT

STRU

II

ia

1u

ll

g
II

i
5g

J

u

II

8

a

0

lit

l
e

g
c
u

s

BODY

Instrument and Seat

REMOVAL AND INSTALLATION
Instrument panel

SBF204

battery ground cable
steering wheel Refer to

Disconnect
2

Remove

Steering

Wheel

ST section

for

8

Remove heater control attaching

screws

and floor attaching bolts

re

moval
3

Remove

shell

cover

and

com

bination switch
4

Remove instrument

lower

j

cover

and side ventilator duct
S

Remove

cluster

lid

D

Remove

console box
6

Disconnect

wlOng

connectors

from junction block
7
Disconnect
speedometer

cable

harness connectors and antenna cable

BF 30

SBF205

9

Remove defroster

10

Remove instrument securing bolts

and then

remove

by pulling

it out

11

instrument

Installation is in

removal

grille

reverse

assembly
order of

BODY

lnStromentBndSeat

CONSOLE BOX

SBF206

REMOVAL AND
INSTALLATION
I

Remove

screws

SEAT
attaching

console

FRONT SEAT

box and slide console box rearward
2

Remove parking brake

and lift

out console box

I
1

S6 F207

ifi16
11 6

3

Installation is in

removal

reverse

22N
22

m

m 12
kg

order of
SBF208

BF 31

Instrumenund Seat

BO DY

REAR SEAT

SEAT BELT

Hardtop

FRONT

SEAT BELT

SBF211

SBF209

itJ

Seat belt
24
2 4

Hatchback

17

l

iiiJ
rJ

SBF210

BF 32

anchorage

31 N m

2k
3
23 ft Ib

bolt

BODY
REAR SEA r

Instrument and Seat

r
BEL

HARDTOP

HATCHBACK

J2434N
1

m

12 4 32 k m
g
17 23ft lbl

J
I

24
24
17

34N

m

32kg
23 ft

m

lbl

SBF212

I

BF 33

Sun Roof

BODY

SUN ROOF

Bndet

EICutcheon

Sun roof handle

Safety catch

Sun roof rmi5her

SBF213

DRAIN HOSES

REMOVAL AND
INSTALLATION
SUN ROOF
1

To unlock

safety

safety

catch slide the

catch knob all the way to the

left
2

and

Depress sun
push handle

roof handle knob
up to disengage it

from link

o

SBF215

SBF214
I
trim

3

Remove sun roof

4

Installation is in

removal

34
BF

Remove
rear

roof trim

pillar

front

trim and then remove drain hoses
reverse

order of

2

Installation is in

removal

reverse

After installing drain

pillar

trim and da side
order of

1hat watar is
car

with

no

compartment

h

s

emure

property drained outside
seepage

into

passenger

BODY

BodyAlignment

BODY ALIGNMENT
2

MEASUREMENT

DESCRIPTION

OPERATIONS
DIMENSION LINES
All

When

drawings illustrations
design values

are

the standard

Black dimension line

I

distance from

body

car

to

a

a

in the

indicated

dimensions

Indicates

to

uring tape
2
an

or

tram

Thin line
actual

tracking

Indicates

distance

or

a

length

An asterisk

I

When

between

a

tram

tracking

adjust pointe
lengths

as

A

gauge is used

and B to equal

Check the pointe
sure

sure

tion

twisting

If

part

a

interferes

measure

shown in the figure be

itself to make

measuring tape
be

or

is used

there is no

elonga

bending

or

parts of the

with

car

and gauge

the distance or

body
when

measurement

using the measuring tape you

following points

Measurement method

low
or

cannot

length

accu

rately
2

Measurement point
should be taken at

Measurements

the center of mounting holes

there is no free

play

gauge

following the value

at the measuring point indicates that

the measuring point
is

1

to

and can be measured with a

points
measuring tape or tram tracking

two

to the

meas

direct

thick

given
a

a

check
are

careful consideration should be

gauge
a

measurements

line

be measured

and cannot be measured with

body

taken in accordance with the

phantom line of the

point

car

When

symmetrically

on

the

the other side
same

value

I
A

I
B

f

ENGINE COMPARTMENT

Unit

mm

in

SBF216

BF 35

Ij

t
i

cz

tD o o
I

IIIaIIo
6
0
I

i 166
I

51
u

13

19

r

95
2
75

IS
2

Lcp

r

t

RCLUIe centrli

r
i

1
Eq

4J

0l
I

tO

c

7
9

I

o

1

I

17

1

7i

Oalumin

8

69

9

40

J

7

86

EO
df
t
If

4S9

f
I

I

t
il

111
9118

9

85

C

0
7

SctlonC

21

1

0

945

24

0

n

21

0

1

0

575
6

db

97tO
1

0

1

PIXNG VIEW

008

02

1
31

ntf

6 10 STG SIDE
93tO 3
2

FOa

m

n
S5

1

1

c

if

0

SetionB

11

0

008l

95l

I

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sOtO

14

91tO

J0

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H

76

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Se lion
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LG

611

line

tum

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L

Unit

Fm
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6

U

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Cu

39

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91

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11
l

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3
J

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IJ5

695

0

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87
31

36
17

c

1

51N

0i

8

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L
I

0

Front flo r

lfv
J

i

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400

I

I

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Il

37 L

L

D

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u

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IJ

L

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ALOWNCE

R

oJ L

mHo

5
s

H

I

n

8

9

lde
1
3

H

B

l

69

917
lide
70

I

l

008

BODY

Special

Service Tools

SPECIAL SERVICE TOOLS
Tool number

Tool

name

Kent Moore No
ST08800000

Sucker

8W
ST08810000

Caulking

hand gun

BF 37

Model S 11 0 Series

DATSUN 200SX

SECTIONHA
AIR CONDITIONER

HEATER

CONTENTS
I

SERVICE PROCEDURE

HEATER I

PRECAUTIONS FOR

DESCRIPTION
HEATER
HEATER

SYSTEM

COMPONENTS

FLOW

AIR

SERVICE PROCEDURES
HEATER
HEATER

CONTROL

ASSEMBLY

HA

2

HA

2

HA

2

HA

3

HA

4

HA

4

UNIT

HA

5

BLOWER UNIT

HA

6

RESISTOR

HA

6

HEATER

HA

7

DUCT

REAR HEATER DUCT

HA

7

DEFROSTER NOZZLE

HA

7

VENTI LATOR

ELECTRICAL

DUCT

HA

7

CIRCUIT

HA

B

SCHEMATIC

HA

8

WIRING

HA

8

HA

9

I AIR

CONDITIONER

HA 25

IDLER PULLEY

COMPRESSOR

HA 25

COMPRESSOR

HA 26

CONDENSER
RECEIVER
FAST

HA 26

DRIER

IDLE

ILlOUID TANK

HA 26

ACTUATOR

HA 27

COOLER RELAY

HA 27

COOLING UNIT

HA 27

AMBIENT

SWITCH

HA 27

EXPANSION VALVE

AND

SUCTION THROTTLE

VALVE
AIR

HA 28

CONDITIONER

CONTROL

ASSEMBLY

HA 28

RESISTOR

HA 28

REFRIGERATION CYCLE

HA l0
HA ll

CONDITIONING

COMPONENTS

LOCATION OF ELECTRICAL

AND

HA 29
HA 30

COMPRESSOR CLUTCH

HA 30

SHAFT SEAL

HA 32

COVER

HA 33

COVER AND

REAR

CYLINDER

HA
FLOW

12

HA 12

GENERAL SERVICE

HA 13

PRECAUTIONS

HA 13

MANIFOLD GAUGE

HANDLING REFRIGERANT

HA 13

SERVICE CAN

TAP

HA 14
REFRIGERANT
AND

CHARGING

HA 14

REFRIGERANT
HA 14

SYSTEM
COMPRESSOR OIL

LEVEL CHECK

PERFORMANCE TEST
PERFORMANCE CHART
PERFORMANCE TEST DIAGNOSES

HA 34

REPLACEMENT

ELECTRICAL

OF CYLINDER

HA 35

CIRCUIT

HA 37

SCHEMATIC

HA 37

WIRING

HA 38

VACUUM

UNIT

DISCHARGING

HA 2B

SWP167

COMPRESSOR
PRECAUTIONS

HEAD
HA l0

HA 16
HA 17
HA 17
HA 20

HA 28

BLOWER UNIT

REAR END

AIR

EVACUATING

HA 24

REFRIGERANT LINES

SIDE

I

DESCRIPTION

INSTALLING

INSTALLATION

MAGNET VALVE

DIAGRAM

TROUBLE DIAGNOSES
AND CORRECTIONS

AIR

HA 24

REMOVAL AND

DIAGRAM

TROUBLE DIAGNOSES
AND CORRECTIONS
AIR CONDITIONER DIAGNOSES

HA 39
39
HA

BLOWER MOTOR DIAGNOSES
COMPRESSOR CLUTCH DIAGNOSES

4l
HA

COMPRESSOR

45
HA

FAST IDLE

43
HA

DIAGNOSES

CONTROL DEVICE DIAGNOSES

SERVICE DATA
AND SPECIFICATIONS

47
HA

48
HA

GENERAL SPECIFICATIONS

48
HA

INSPECTION ANO ADJUSTMENT

48
HA

TIGHTENING TOROUE

48
HA

SPECIAL SERVICE TOOLS

4
HA

Ref

to Section MA Heater and Air Conditioner for
CHECKING REFRIGERANT LEVEL
CHECKING

Reflr

to

REFRIGERANT LEAKS

Section MA

CHECKING AND

Basic MechaniClI
ADJUSTING

Systam for

DRIVE

BELTS

r

Desrription

HEATER

DESCRIPTION
HEATER SYSTEM

To defroster

To ventilator

nozzle

duct

To Yentilator
duct
o

c

t

Fresh air

Intakedoor

Floor

L

door

To

S

J

JUlT
hJ

1b

J

nn

Jr

e

5L lLJU

j

L

ear

I

er

To floor

To floor
Side view

To rear
heater
duct

L

Air mix

door
To floor

Heater

J

i

I

eciJculatiOD
au

1I11

r

Blower motor

core

SHA113

HEATIE R COMPONENTS

Side defroster
QDterddroster

Side defrolter
noule

Heater

core

oo

f

IIJrffi5

Blower motor
oClfj
I

Water coet
Heater duct

Heater

control

assembly

0

fritch
C

Side ventilatnr
duct

AirSUide
Air uide

eonaol

tiniaher

J
SHA114

HA 2

HEATER

Description

AIR FLOW
VENT

position

Fresh air
FRESH

VE

t

po

r

positio7n

n

tjJ

o

o

5
if
to
the desired

BIL

BI

Ievel

br

position

the desired

Il

l

1I
111111111111 rlrl

Jc

roster

TOVentil torduc

1

17
i

jfd
l
ij

o

l

L

O
pos
To floor

DEF

1

H

Side view

ll

L

Move the lever

1
li
C

position

o

r

j
I

position
FRESH

DEF POsition

positixJD1

3

1ky

o

E
Move thelever
the desired
position

To rear
heater duct

To floor

r
l

HEAT position
To defroster

FRESH POsit

nozzle

7
tb1

HEAT POsitioo

J
o

4

II

L
Move the lever

V

daired POI

REC

To floor

To

position

To floor

rear

heater

duct

ition

REC7

TpoIition

r

o

o

0

J

Move the Ie
the desired

Ji

oo

r

If sL

tjfT
Il
Tf
r
l
LTCi t
I

Recirculation

jJ
J
lllllll
J

Y
io
SHA116

J
HA

f
ServkeProcedut

HEATER

SERVICE PROCEDURE
HEATER CONTROL

ASSEMBLY
REMOVAL AND

Always conduct

INSTAUATION
I

I
lower

Remove instrument

Tenn

covers

Disconnect

cab les from

control

I

@

r

and cluster lids
2

DIQ
I

Wuntinatioo

lamp

heater unit and blower unit
DiscOnnect

3

and

ground

harness

connectors

wire terminal

SHA116

@
IDumination
4

Remove

lamp

pivot pin

I Terminal

L

OFF

II

I

@

I
I

@

I

@

I

QD

I

I

@

Iv

16

5

Remove heater control
Installation is in the

Alter
ref

I
0

i1

I
I

I
I
SHA118

assembly

reverse

order

ADJUSnNG HEATER
REC position

CONTROL

of removal

by

I

3

I
I

SHA117

6

2

installing adjust control cable
ring to Adjusting Heater Con

Inbke door control
I

trol

Set air intake lever at

cable
REC

I
posi

tion

2

INSPECTION

Connect control cable to air in

take door lever while

pushing

lever to

its Closed

Fan switch
Test
with

3

continuity

a test

lamp

through

or ohnuneter

switch

position
Securely clamp the cable while

pushing

cable outer

case

in direction

of arrow

SHA119

4
HA

H EATER
Air mix door control cable
Set

I

temperature
position

COLD
2

lever

at

Water cock control linkage

max

I

Set air mix door
COW

Connect control cable to air mix

2

full open position

closed position
the

7

Securely clamp

pushing

Stay ofinstrument panel

control rod while

water cock

lever to its full

I

while

ble
ca

case

max

Radio sound balancer and stereo

cassette deck

position

door lever while pushing lever to its
3
Securely clamp
pushing cable outer

lever at

6

Service Procedures

in direction

of arrow
c

1

a

I4f
c

M

Max COLD position
M

Adjusting

saew

r

Max COLD position

8

Rear heater duct

l
SHA18Q

SHA122

A1rcontrol ceble
I

Set

air control

lever at

DEF

position
2

Connect

linkage

while

control

cable

pushing

the

to

side

linkage

in

direction of arrow
3

Securely clamp
pushing cable outer
of

HEATER UNIT
REMOVAL AND
INSTALLATION
I

the cable while
case

in direction

SHA 125

Set TEMP lever to

HOT

max

19

Center ventilator duct

position and drain engine coolant
2

Disconnect

heater

hoses

from

heater unit

arrow

DEF position

I
I

3

Remove

I

Front seats

foUowing Wis

2

Console box

3

Floor carpet

4

Instrument

lower

covers

and

cluster lids
5

Side

ventilator duct

1
I

on

the left

hand side
SHA126

SHA121

SHA123

HA 5

Service Procedures
Air

10

guides at

HEATER

lower outlets

r

core

Il

Clean fms and check for water leak
age

BLOWER UNIT
REMOVAL AND

INSTAlLATION

r
SHA1 29

I

Remove instrument

and cluster lid

on

lower

oover

tIie right hand

2

Disconnect
control
cable and
harness connector from blower unit

Right

side guide

Remove air control linkage

2

secur

3

Remove blower unit

ing screws

1
SHA127

SHA132
I

Disoonnect

4

wire harness

connec

SHA130

tions
5

4

Remove heater

with heater

J1it
1

Installation is in the

reverse

order

of removal

lntrohssembly

5eparate

heater unit

by

case

re

moving clips
4

Assemble heater unit in the

verse

Adju
referring

1

to

rcorrtrolcablebi
Adjusting Heater Control

reo

order of disassembly

DISASSEMBLY

After

installing heater core and
water cock lKljust water cock co
trol linkage by referring to Adjust
ing Heater Control
When assembling air control link
age set it as illustrated

a

b

I

Remove blower D otor

2

Separate

SHA128

Remove heater control assembly

6

Refer to the item

o

Heater Control

Assembly
Installation is in the

7

reverse

order

of removal
After

installing heater unit lKljust
control coble by referring to Adjusting

SHA131

blower unit

case

by

reo

moving clips

Heater Control

RESISTOR
INSPECTION
DISASSEMBLY AND
ASSEMBLY
I

Remove heater

cock
6
HA

core

witli water

REMOVAL AND
Ce

INSTALLAnON

e

If it is cracked

place

or

deformed

re

I

Remove instrument cluster lid

2

Remove resistor from heater unit

HEATER

REAR HEATER D

CT

Service Procedures

VENTILATOR DUCT

REMOVAL AND

REMOVAL AND

INSTALLATION

INSTALLATION

Refer to the item on Heater Unit
Center ventilator duct
Refer to

the

item on Heater Unit

Side ventilator duct

DEFROSTER NOZZLE

Temperature

ide
to

the item

on

Heater Unit

REMOVAL AND
IN

RighUide

TALLATION

Proceed after removing instrument

Front window defroster
nozzle
Resistorw

SHA134

Proceed after

reJlK

ving

assembly

instrument

3

assembly
3

Left

Refer

fuse

F

Install resistor so that temperature

fuse locates at upper side

J
INSPECTION
Test continuity using

test

lamp

c

or

ohmmeter

SHA139

T

jf

SHA137

@

Foot ventilator duct

I

Side window defroster nozzle

I
J

Proceed after removing instrument
lower covers and cluster lids

uCD

o@

Left side

HEATER DUCT
SHA 140

REMOVAL

AND

INSTALLATION
Proceed after removing instrument
cover and cluster lid on the right

lower

hand side

Right side

SHA136

HA 7

Electrical Cirwir

HEATER

ELECTRICAL CIRCUIT
SCHEMATIC
TO

AI R CONOlTlONER SWITCH

I

RESISTOR

BLOWER

FUSE

MOToR

O

1M

I

WIPER

ISA

u

TO

1

c

W
I
n

Jl
FAN

r

u

LAM

IGNITION
RELAY

1
15

I

L

SWITCH

J

c

r

ILLUMINATION

CONTROL SWITCH
BATTERY

B

IGNITION
SWITCH

I

Q
FUSIBLE LINK

SHA141

WIRING DIAGRAM
RESISTOR

4J

BLOWER
MOTOR

j

LHJ
3
J

TO

WI

fR
P
G

ow

It

f j

LIGHTING
SWITCH
4
00

e

FUSE

2

tl
1

GN

T

ON

JI

TO AIR
CONDITIONER
SWITCH

FAN

SWt reH

IUUIIIINATION
L
P

RELAY

I

G IITION
SWITCH

ILlUMlNATIONC J

CONTROL
SWI reH

FUSIBLE LINK

i
f BATTERY
SHA 14

S
HA

HEATER

Trouble

Diagnoses and Corrections

TROUBLE DIAGNOSES AND CORRECTIONS
Probab Ie

Condition

Corrective

cause

ction

Insufficient heating

performance
No heated air

Cooling

water

temperature

Check thermostat

too low

Replace

discharged

plugged

Clean

Insufficient cOoling water level

Refill

Heater

core

necessary

control cable

Malfunctioning

air mix door

Adjust

Malfunctioning

water cock

Adjust control

Replace
Insufficient air flow

as

as

cable

Check water cock

necessary

Check motor terminal voltage

Blower motor speed too low

Repair poor connection and discontinuity
Replace motor if necessary

to floor

Adjust control cable

Malfunctioning floor door

Insufficient defrosting

performance
No heated air

Cold air discharged

Refer to

Insufficient air flow

Malfunctioning floor door

to defroster

Defroster nozzle plugged

Clean

Leak at defroster duct to nozzle connection

Correct

Water cock

Adjust control cable
Replace as necessary

Heated air discharged

not

discharged

or

faulty

Adjust control cable

seal

operating properly

with lever in VENT
Mode door

not

operating properly

or

seal

Adjust

Check water cock

control cable

damaged

Blower motor does

Refer to Trouble Diagnoses and Corrections
Air conditioner

not operate

Control lever drags

Inner wire rubbing against outer

case

end

Correct

Control cable bent excessively

Malfunctioning doorn door levers
Outside air

comes

in

with AIR control

Air intake door not operating
Control cable out of

Adjust control cable

etc

properly

adjustment

Check and correct

Repair

or

Adjust

control cable

rep

ce

lever REC

Noise from blower

Loose bolt in blower motor

Check and tighten loose bolts

motor

HA 9

Description

AIR CONDITIONER

DESCRIPTION
REFRIGERATION CYCLE

Compressor
The low pressure refrig
is

erant
to

a

h

compressed
pJeC and
SU1

high

Jle

High pressure

Low pressure

gas

liquid

N

i

l High presswe
liquid

t

1

1
0

Low pre

sure

gas

V

Is

l

I
Outside air

r
l

Recirculation air

u
Condenser
The

lPIl

Iv
xyyv

heated and

V

Evaporator
The

pressed refrigerant gas

refrigerant liquid
evaporates and cools

from

the air

com

the

compressor
condenses to aliquid

I

I

o
w

w

R
erant

and

v

particles
erant

i

t e

removes

w

fL
w

and

moisture

as

J

q

drier

Stores the liquid refrig

JJ

b

foreign
the refrig

Blower motor

circulates within

the system

tmfJ

Controls the enporat
ins pressure and pi
vents
e fomation
of
the frost

Expansion

i
High pressure

valve

Low pmmue switch

Discluuges

Tums OFF at pressures

to

below 196 IcPa

refrigerant
atmosphere at pres

lfes

38

above 3 727 IcPa

kgfem2

540 psi

valve

DeliVers sprayed refrig
erant to the eVaporator

em 2

28

psi

compressOI

2 81

cutting
power

to

facilitate refrigerant
h

hl

and

con

trols the amount of

frigerant

possing

re

the

orifke

supply

SHA 142
HA l0

AIR CON DITION ER

Description

AIR CONDITIONING COMPONENTS

a
o

I
1I
5

l

2

s
a
o

5

e

l
L

e

8

j

j

u

8

SH

143

HA ll

ription
Desr

AIR CONDITIONER

LOCATION OF ELECTRICAL AND VAcuuM UNIT

L

SHA1

AIR FLOW
Air

flow at any position
B L HEAT
DEF and REC

VENT
is the

Ventilator door

1
1Mi

r

that of HEATER except that

same as

aU air

discharged with blower

ventilator

nozzlll

duct

T

To

rear

heater
duct

unit

ide air

n

7u

ilJ
t

To f1oor

1

To delio tor now

1 i
To floor
Side view

through cooling

O

To

To
defroster

1t

passes

unit

7

ll

iIllJlL

lr
Qjr

mower motor

To floor

Heater

core

SMA 146

HA 12

J

J

AIR CONDITIONER
i

General Service

i

GENERAL

SERVICE

r

INSTALLING MANIFOLD GAUGE

PRECAUTIONS
WARNING
1

Since direct conlllct of the

valve

with your skin will
always be careful

refrigerant

pressure valve suction valve and high pressure valve discharge
should be connected securely to high and low respectively on the manifold

Hoses for the low

liquid

Refer

to

identification marks

on

muse frostbite

compressor

handling the refrigerant
Always wear goggles to protect
your eyes when working around
when

the system
2 The

refrigerant service conllliner
safe strength However if
handled incorrectly it will ex
plode Therefore always follow
has

a

the instructions

on

particular

store it in a hot

never

the label

above S20C

location

Low pressure

High pressure

gauge

gauge

In
Manifold
gauge

1260F

drop it from a high height
refrigerant gas is odorless
and colorless and breath ing may
or

Before connecting
hoses close valves

3 The

completely

become difficult due to the lack
of oxygen Since the refrigerant
gas is heavier than air and will

lay close to
cially careful

the floor
when

be espe
handling it in

Q

small confined spaces
refrigerant itseit is nonflam

4 The

mable

1fT

toxic gas
a
gas is produced when
it conlllCb fire and special care is

However

phosgene

therefore

ing

required

when check

for leaks in the system

with

o

R 12
en

Vacuum
pump

Refrigerant

a

SH A045

can

halide torch
5 Do not steam clean on the sys
tem especially condenser since

high pressure will
build up in the system resulting
in explosion of the system
excessively

Connection to service

v

lve

Funy close both valves of mani
fold gauge Connect high and low
I

pressure

charging

hoses

to

Disconnection from

r

service valve
I

manifold

gauge
2
Remove caps from service valves
Connect high and low pressure charg
ing hoses to service valves in system

Close

Fully close both valves of

S

2

Quickly

charging

caps on service valves

I

Cap

4

Packing

CAUTIDN

Service valve

5

Check valve

Do

3

Cha

hose

disconnect two

hoses from service valves and install

2

rging

mani

fold gauge

not over

tighten

valve cap

HA 13

AIR CONDITION ER

General Service

HANDLING

EVACUATING AND

REFRIGERANT

CHARGING
REFRIGERANT
SYSTEM

SERVICE CAN TAP
The foUowing
conventional
For

can

correct

manufacturer

s

procedures apply

I

to

taps
usage

refer

to

the

EVACUATING

instructions

SYSn W

Purging air
Connect

I

charging hose between

manifold gauge and
2

FuUy

turn in

can

turning

can

until

Make

turning

a

can

hole in

refrigerant

pressure

reaches

on

system

from system

atmospheric

pressure
Fl

refrigerant can
tap handle fuUy

12
SHA04S

WARNING

counterclockwise
4

InstaU manifold gauge

and discharge

Add

close valve stem of

manifold gauge
3
Attach can tap to

by

I

W

tap

REFRIGERANT

refrigerant

can

Securely

by

charge

tap handle clockwise

manifold gauge with a hose also
low pressure suction
service valve to that of manifold

DISCHARGING
REFRIGERANT

n
Car tap handle

connect

approaching atmospheric
refrigerant

pressure

pressure prior to evacuating
inside the system

Close

I

r
Refrigerant
an

gauge

The pressurized refrigerant gas in
side the system must be discharged at
a

Needle

and

high

connect high pressure dis
service valve to that of

2

Connect center

charging

hose to

vacuum

low pressure

pump
Close both

3

valves

of manifold

valves of manifold gauge fuUy
2
Connect two charging hoses of

gauge fuUy Then start vacuum pump
4
lve
and SlIck
Open low pressure av

manifold

old refrigerant from system

gauge

to

their

respective

service vavles
SHA046

WARNING

5

TUrn

the

handle

fully

counter

clockwise to raise the needle

Refriger

ant

Securely

connect

charge

service

high pressure dis
valve to that of

manifold gauge with a hose also
cOnnect
low pressure
suction
service valve to that of manifol
gauge

gas will flow up to the manifold

p

gauge

3
and

n

Open both manifold gauge valves
discharge refrigerant from system

Open

Oose

40

U0

LO

rJ

SHA041

SHA060

High

1
Slowly

Slowly
5

6

air from

Purge
loosening charging
fold gauge
HA 14

charging

hose

by

hose nut at mani

When low pressure gauge reading
approximately 66 7 kPS

has reached to
40

500

SHA949

mrnHg
high pressure

19 69
valve

inHg slowly open

AIR CONDITION ER
MA section
3

When

Discharge

and

refrigerant again

slow

refrigerant charging

to

0

Low

SYSTEM

lligh

Close

from
3

manifold

Purge

charging

hose

b A

charging

re

be wanned in water

blow torch

or

be used to

never

center

can

a temperature of
520C 1260F

vacuum

pump
air from

about

short time

heated to
valves

gauge

and disconnect

securely

lOpen

W

Evacuate refrigerant system

2

a

WARNING
a
Under no circumstances the

frigerant
I

of

temperature

a

400c I1Q4OFl for

CHARGING REFRIGERANT

i

peed

immerse refrigerant can in water

heated

then evacuate system

GeneralSefYice

over

stove must
up the

warm

can

hose

00

I
SHA051

Connect center charging hose to

refrigerant
2

through

can

Break seal of

top

can

refrigerant

can

and

purge air

6

When

dropped

has
pressure inside system
710 mmHg
to 94 6 kPa

27 95 inHg

fully close both valves of

about

gauge and stop vacuum
Let it stand for 5 to 10 minutes
pump
in this state and confIrm that the
manifold

reading
B

r

300

Perform

1

itl elevation

evacuation

according

to

R

Vacuum of system

ft

Purging

2

air

Open high
fold

gauge

frigerant

12

600 2 000

0 660 25 98
88

900 3 000

84 6 635 25 00

Valuesshow

reading

Charge refrigerant into system
I
I n case of charging re igerant gas
Open high and low pressure valves
of manifold gauge and charge refriger
4

The rate of ascension

into

system with

can

reo

upside

charging liquefied refrigerant

into the system with the can turned
upside down to reduce charging tima

charge

it

only through high

discharge

service valve

pressure
After com

of charging the compressor
always be turned several times
manually

pletion

ant into system

ofthe

should

low pressure gauge
b

pressure valve of mani

and charge liquefied

CAUTION
When

3 685 26 97
91

re

SHA048

94 6 710 27 95

I 000

charging liquefied

down

kPa mmHg inHg

0 0

ln case of

frigerant

k

the following table

Elevation

short

AC184A

1 000

m

a

time

does not rise

per

300

400C
1040F
for

I

The low pressure gauge reads lower
by 3 3 kPa 25 mmHg 0 98 inHg

m

Immerse
zl in water
i
heated to

12

A

of

the low

pressure gauge should be leIS than
3 3 kPa

25

mmHg

0 98 inHg

in

five minutes

If the pressure rises

negative pressure
there is

a

ean

or

the

specified

leak in the system In this
as described in the

repair the leak
following
ease

Low

not be obtained

I Charge system with a can of
refrigerant about 0 4 kg 0 9 Ib
Refer to Charging Refrigerant
2 Check for refrigerant leakage with
a leak detector
Repair any leakages
found Refer to Checking for Leaks

lt

lt
O

W

o

9ft Open

n

t
Close

Open

r
t

SHA052

10

SHAOS

HA 15

General SefVice

AIR CONDITION ER

When refrigerant

5

charginiJ sPeed

Refrigerant capacity
0 9 1 1 kg 2 0 2

while running
the compressor for ease of charging
slows

charge

down

it

doors of
low

After having taken the steps up to 3
above proceed with cahrging in the

pressor oil to compressor

off high pressure valve of

Measure the a
mount or

charged refriger
ant with

a scale
Make a note of
the amount
charged from

Set mode

dial temperature dial
and fan lever at maximum 0001 and

1

11

Charge refrigerant while oon
trolling low pressure gauge reading at
275 kPa
8 kg em2 40 psi or less
2
by turning in or out low pressure valve

glass

of manifold gauge

whgther

should

only

is

be used

small

high

pressure side discharge side
of systerri since this will fon
e nt
back into

refrigerant

Level

Section

2

charged refriger
ant can be correctly judged by means
of discharge pressure

can

8

Close manifold gauge valves Then
detach charging hoses from service

explode

SHA376

The amount of

MAl

valves of system

Be

sure

SPEED

Refer to

not

or

MAX FAN

COLD

sight
for checking
charged r

the amount of

Checking Refrigerant

wrge mrigerant through

MAX

The state of the bubbles in

frigerant
WARNING

and can may

i

AC252

4

frigerant

ON

can

speed respectively

l
NgVl

with controls set for maximum

to 30 minutes in order to return com

manifold gauge
2
Run the engine at idling speeds
below 1
500
rpm
3

compressor at

1 000 rpm or be

cooling and high blower speed for 20

order

following
I Shut

Opernte

car

engine idling speed

4Ib

to install

Stop the engine

and

discharge

frigerant of system and then
oompressor from the car

re

remove

3
Remove oompressor drain plug
Drain compressor oil from oompressor
oil siunp and measure the amount

valve cap on service valve
9

ConIum that there

system by checking

Run at

are no

with

a

leaks in

leak detec

tor

idling

Refer

1

to

Checking

for Leaks

MA

section

Conducting a performance test
prior to removing manifold gauge is 8
good service operation Refer to Per

w

formance Test
aose

SHA056

t

T

COMPRESSOR OIL

Q

The oil

SHA054

used

pressor circulate
the

ail

sump

When

fully

refrigerant

can

is

empty

close both valves of manifold

gauge and

replace refrigerant

can

with

a new one

Before
new can

purge air from inside

ftom

charg

oil

Charge the specified amount of
refrigerant into system by weighing
charged refrigerant with scale Owr
lg will cause discharge pressure
chargi
to rise

HA 16

to

correctly

When
pressor

of

refrigerant

gas occurs

of compressor oil

checking
oil

ent

following

is also

or

the level of

when

replacing

part ofthe system

service

oom

procedure

use

This

any
the

helps

to return oil to oompressor

I

Imp

OZ

fl ozl

If the amount is below the above

values

refrigerant

replace faulty parts

leakage

r

4

6 4 US
6 7

If a considerable amount

considered

w

5 6

m

Conduct leak tests

leakage

tha

5 4

lubricate the com

into the system from
while compressor i

l
oille

190

compressor oil the amount of
flowing in the system must be

considered

ing hose
7

160

measure

of

charging refrigerant

to

Therefore

operating
6

Residual

LEVEL CHECK

Fully

open

all

windows

all

on

leaked

connections of

each system and if necessary repair
5
oil

or

Check the purity of the oil If the
contains chips or other foreign

material clean oil sump with new oil
6
Discard the used oil and fill with
the sanie amount of

new

oil

as was

drained when removing compressor If
the residual oil level is below the
minimum level

or

may have

add additional oil to

reach the minimum level

AIR CONDITIONER

Performance Te t

PERFORMANCE TEST
PERFORMANCE CHART
TEST CONDITION

Testing

must be

performed

as

follows
in the shade

outside wind velocity Less than 2

Car location

Indoors

Doors

Closed

Door window

Open

Hood

Open

MODE dial

Max COLD position

TEMP dial

Max COLD position

FAN lever

4

Engine speed

1 500 rpm

Manifold gauge

Connect manifold gauge to

Measurement of discharge air

temperature

or

m

7 ft

sec

positions
constant

high discharge

and low

suction

service valves

Center outlet grille

Measurement ofinside air relative

humidity and temperature

Blower assembly inlet

Measurement of ambient air relative

humidity and temperature

A

point

1 m

3 ft in front of condenser

0

HA 17

Performance Test

AIR CONDITIONER

TEST READING

Inside air

Recirculating air
assembly inlet

at blower

Air temperature

Relative humidity

Discharge

air

temperature at
oCoF

center ventilator

Oc OF

40

15 59

4 5

5 2

40 41

20 68

65

75

44 46

25 77

8 7

9 8

48

50

50

30 86

8
10

2
12

51

54

35 95

12 9

14 5

55

58

40 104

15 0

17 0

59

63

5 2

5 8

41

42

20 68

5
7

5
8

46

47

25 77

8
9

110 50

52

30 86

12 2

5
13

54

56

35 95

5
14

16 2

58

61

17 0

18 9

63

66

59

5 8

6 5

42 44

20 68

5
8

94

47 49

15

50

59

60

40 104
15

25

77

60 70

15

2

56

59

35 95

16 2

18 2

61

65

18 9

1
21

66 70

40

104

15

59

5
6

1
7

44

45

20 68

94

3
10

49

51

77

12 3

13 7

54

57

30 86

15 2

17 0

59

63

35 95

18 2

2 65
20

68

1
21

23 5

70

74

59

1
7

7 9

45

46

I

25 68

3
10

51

53

I
I

30 77

13 7

0
15

57

59

35 86

17 0

18 6

63

65

r

40 95

20 2 22 2

68

72

I

45

26 0 74

79

40 104
15

HA 18

54

J3 5

80

80 90

52

30 86

25
70

11 0 12 3

104

23 5

n5

AIR CONDITIONER

Performance Test

Ambient air
Pressure high
Relative humidity

15

40

65

1 079

30 86

110
1 245

35 95

7
12
104

15

59

1 393

14

105

121

1 010

94

2

l22

3 134
10
1 196

I

173

1 373
14 0

6 7

I 40

199

1

45

225

19 9

1 60 20 6

22 8

5
176

105

25 6

1
196
2 00 25 6

180

li2

1
98

74 95

17 8

5
176

15 8 202

16 4

1 80 22 8

60

1 550

14 9

156 9

156 9

181

14 2

3
137

1i

142 2

12 2 156

5
13

112 8
15
1

125

146

726

657

100

103 0

5 109
8

922

77

1
98

0 95

95

834

755

68

40

kPa kg em2 psi

93 2

6 7 73

7 7
25

Pressure low Suction side

657

500

59

1
5

20

Discharge side

kPa kg cm2 psi

Temperature
oCF

100

15
01

4
28

8

i6

14 2

4

1

834

20 68

94 121

1 010

65

25

77

30

86

35

95

3
10

40

The

pressure

following

will

manner

change in the
manges in

with

cond itions

speed is low dis
charge pressure will drop
When the relative humidity of in
take air is low discharge pressure
When

134

15
1

140

162

1 196

1 314

12 2

4
13

blower

14

0

1 550

104

15 8

will
b

173

1 60

176 5

1 510
154

199

219

1 80

249

2 00

1
196

1 716
5 225
17

drop

16 4

2
19

152 0
55
1

156 9
191

132 4

35
1

3
137

1 118
II 4 146

90

1 372

a

112 8

922

5
8

22 0

19 9

171 6
75
1

22 8

24 9

1
196
4
28

2 00 25 6

220 7
2 25 28 4

32 0

If the test reveals that there is any
in system pressure isolate

The temperature will change in the
following manner with changes in

abnormality

conditions

formance Test Diagnoses

the

cause

and repair

Refer to Per

When the 8rrmient air temperature
is low

the outlet air temperature

will becomg low

HA 19

Perfonnance

AIR CONDITIONER

t
Te

NCE

PERFOR

As to the method of

TEST DIAGNOSES
Characteristics
manifold

gauge

conditioning
following

revealed

are

a

range baSed

tion that the air

Test

in

the

on

good

order

on the lissump
conditioning system is

This range is described

in PERFORMANCE CHART
In the

shown in the

following table

smeared with ink

on

Condition

I

indicateS

performance

for the air

rcading

system

a

refer to the item of Performance

test

the portion

sam gauge scale

Probable

Corrective action

cause

INSUFFICIENT REFRIGERANT CHARGE

Insufficient

1

Bubbles

appear

in

sight

Refrigerant is
leaking a little

small

or

I

Leak test

2

Repair leak
Charge system

3

glass

00
@

cooling

EVKUatB
and

as

necessary

recharge system

@
AC352A

ALMOST NO REFRIGERANT

I

Stop
ately
No cooling action

refrigerant

leak

In sight glass appear a lot
of bubbles or something

00
@

Serious

compressor immedi

1

Leak test

2

Discharge

system

3 Repair leak
4

like mist

s

Replace receiver drier if

neCessary
5

Check oil level

6 Evacuate and

recharge

system

@
AC353A

I

FAULTY

EXPANSION VALVE

I
Sight cooling
frosted expan
sion valve inlet

Sweating

0
@

or

Expansion
refrigerant

valve

If valve inlet reveals sweat
or

Expansion valve

is

clog

ged

frost

IDischarge system

2

Expansion valve

is in

Remove valve and clean
it

operative

Replace

sary
3

Evacuate system

Thermal

4

Charge system

bulb

has

If valve does not operate
IDischarge system
2

Replace

valve

3 Evacuate
AC354A

HA 20

it if neces

Valve stuck closed

lost charge

@

restricts

flow

system

and

charge

AIR CONDITION ER

Probable

Condition
Insufficient cooling

010
@
fg

Sweated suction line

CorreCtive action

cause

Expansion valve allows too
much refrigerant through

Check valve for operation
If suction side does not

evaporator

show

a

pressure decrease

replace valve

@
f

fi

AC355A

Faulty expansion valve

No cooling

Sweating

or

frosted

L

Discharge

2

Replace

3

Evacuate

sue

tion line

system

valve
and

replace

system

0
@

Performance rest

@
AC356A

I

FAULTV SUCTION
THROTTLE VALVE

Insufficient cooling
Frosted evaporator

Suction

throttle valve

is

inoperative

I
2

Discharge system
Replace valve

3

Evacuate

and

charge

system

C0
@

@
AC357A

Insufficient cooling

Suction
restricts

throttle

valve

refrigerant flow

I
2

Discharge system
Replace valve

3

Evacuate

and

charge

system

0
@

@
AC358A

HA 21

Perfonnance Test

AIR CON DITION ER

Condition

I

AIR

IN

SYSTEM

Probable

Corrective action

cause

I
Insufficient cooling

r

Sight glass shows

Air mixed with

occasion

refrigerant

in system

I

Discharge system
Replace receiver drier
3 Evacuate
and charge
2

al bubbles

010
@

system

@
AC359A

I MOISTURE IN

SYSTEM

I
After
side

010
@

air

on

vacuum

reading

During
discharge

condition
will be

warning

a

suction

show

may

pressure

this

for

operation

while pressure

As

warm

of this

shows 39 kPa

is

Drier

saturated

moisture
zen

at

with

Moisture has fro

expansion

Refrigerant

I

Discharge system

2

Replace

valve

flow is restrict

receiver

drier

twice if necessary
3

ed

Evacuate system

pletely
minute

a

reading

Repeat

com

30

evacuating three

times
4

0 4 kg cm2

Recharge system

6 psi vibration

@
AC360A

I FAULTY

CONDENSER

I
No cooling action

engine

may overheat

Bubbles

appear

Usually

a

Check

malfunctioning

condenser
in

sight

@

e

Check

condenser

dirt accumulation

Suction line i very hot

Check

If pressure remains
in

spite

of all

tions taken

inspect

@

A

and
for

engine cooling
system for overheat
Check for refrigerant
overcharge
high

above ac

remOW8

and

the condenser for

possible oil dogging

AC361

HA 22

belt

glass of drier

t

00

fan

fluid coupling

AIR CONDITIONER

Probable

Condition

I

HIGH PRESSURE LINE BLOCKED

Corrective action

cause

I

Insufficient cooling
Frosted

6

SelViceProceduref

liquid

high

Drier

clogged

tion in
pressure

high

or

restrie

pressure line

I

Discharge system

2 Remove
or

line

receiver
and

strainer

drier

replace

it

3 Evacuate

and

charge

system

@

@

AC362A

I FAULTY

COMPRESSOR

I
Insufficient cooling

Internal problem in
pressor

or

com

damaged gasket

I

and valve

and

check

compressor

00
@

Discharge system

2 Remove
3 Repair

or

replace

com

pressor
4

Check oil level

5

Replace

6 Evacuate

@

receiver drier

and

charge

system

AC363A

TOO

MUCH OIL IN

SYSTEM

Insufficient cooling

Excessivel

Too

much oil

with

refrigerant

circulates

causing
the cooling capacity of the

Refer to Oil Level Check
for correcting oil level

system to be reduced

r

0
@

@
AC364A

HA 23

AIR CONDITIONER
s
ServiceProcedu

SERVICE
4

PRECAUTIONS FOR

After

openings

REMOVAL AND

PROCEDURE

disconnectinll tubes plug
immediately

to

all

prevent

entrance of dirt and moisture

INSTALLATION
When

replacing refrigerant cycle

components observe the following
1

Discormect battery ground cable

2

Before starting
discharge system

work

be

sure

to

I uamnr
s

SHA059

WARNING

Gradually loosen discharge
hOse fitting and remove it
remaining

pressure

has

side

Plug

after

been

re

SH A058

IlIIsed
3

When disconnecting

tubes be sure to use

or

connecting

wrenches

on

both tubes
7

Check tightening torque of

con

nedions to

lpecification
sure
refrigerant
clamped securely

8

Make

Check
5

SHA057

HA 24

Compressed air must never be
usad to dean dirty line Clean with
refrigerant gas
When connecting tubes
install
6
new a ring
never reuse used one into
connection and be sure to apply com
pressor oil to seating surface and 0
ring

they

are

all

componenb

neither damaged

t

nor

line

is

insure

interfere

with

9

adjacent parts
Conduet leak test and make

sure

that there is no leak from connections
10

Determine quantity of oil to be
charged into compressor by referring
to Compressor Oil Level Check in
General SerYi

AIR CONDITIONER

ServiceProcedure

REFRIGERANT LINES

Insull

Oing into each connection

new

of tubes

OloUng unit
10 8 0 8

J
i

N m kg

m

J15
i

ft lb

J125
i

29

20 1
5
5
2

3

2 0 11

0 18

8 0

1 5 8

14
SHA148

22

COMPRESSOR IDLER PULLEY
REMOVAL AND
Loosen

INSTAlLATION
1

Rem

2

Loosen idler

fully

e

loosen

under

cover

pulley lock
adjusting bolt

3

Remove drive belt

4

Remove idle

5

Installation is in the

nut and

pulley assembly
reverse

order

ofremoval
Refer to Section MA for

adjusting

drive belt

Adjusting bolt

SHA149

HA 25

AIR

ServiceProcedures

CONDITIONER

CONDENSER

COMPRESSOR

REMOVAL AND
INSTALLATION
I

Remove radiator grille

2

Remove

for

stay

hood

locI

upport
401

Disconnect

3

refrigerant

lines from

condenser
4

Remove condenser

5

Installation is in the

of

order

reverse

l
l

INSPECTION
Inspect joints of inlet

and outlet

for cracks and scratches

pipes
rmding

any

problem

leak

to

gas
denser

repair

Condenser fIns
5414 5

Q

N

m

ged

ft lb

m
kg

SHA150

with dirt

denser In such

or

3

MOVAL AND
INSTALLATION

Remove

compressor

with

it

effIciency

tioner controls set for maximum cool

ing and high blowerspeed for 10
minutes with

all

windows

to IS

open to

return oil into compressor

2

Remove compressor drive beh
Refer to the item on Compressor

Idler
3
low

Pulley

Disconnect

uction

and

high discharge

fleXible hose from

com

con
or a

ed air
compr

to

use

cold

water or

compressed

air

CAUTION
attempt to leave the com
pressor on its side or upside down for
more than 10 minutes IS 1IIe com
pressor oil will enter the low pressure
chambers If under that condition
compressor should be operated sud
denly interllll damage would result
To expel oil from chambers hand
Do

of

clean fms

CAUTION
sure

Operate compressor if possible at
engine idling peed with air condi

con

Do not clean condenser with steIIm Be

clutch facing up

I

replace

cause

air passage clog
or leaves will

a case

passages with

R

or

insect

cooling

reduce

Upon

which may

not

RECEIVER DillER

Liquid tank

crank compressor several times in its
installed condition

pressor
4

DiScOnnect

clutch

compressor

Installation is in the

harness

6

5

of removal

1

Remove compressor
DiSconnect air induction pipe

When

flexible
new

O

conneeting
hoses to

ring

order

reverse

high

and

compressor

low

install
SHA152

into connectiQn

REMOVAL AND

INSTALLATION
I

Disconnect

refrigerant

line from

receiver drier

J

CAUTION

5HA317

Plug

all

openings

drier
2

Remove

HA 26

ignition

coils

e
enttem

to

of din and moistUre

into

l1lC iver

AIR CONDITIONER
Disconnect refrigerant lines from

2

Disconnect harness for low pres

2

Sure

switch

cooling

3

Remove receiver drier

3

4

Installation is in the reverse order

tube

unit

ServiceProcedures

in the reverse order of

3

Assembly is
disassembly

Remove cooling unit with drain

of removal
INSPECTION

INSPECTION

V

Check receiver drier

damage

If necessary

for leaks

c

or

Check

replace

for

cracked

or

deformed

case

Ev por tor

FAST IDLE

I

ACTUATOR

If fins are corroded

sion
Drain tu

mbly

Clean fms and check for

corro

replace

SHA155

From

Q

F IC D magnet valve

CAUTION
Do not clean evaporator with steam
4

Installation is in the

reverse

order

2

FrOmair

regulator

sure

pressed

of removal

tube

to

use

cold

IIIIIter or com

lir

Check

valve

and

for gas leaks at expansion
suction throttle valve If

there are leaks retighten

SHA 153

Intake manifold

Be

defective part with

a

new

replace the
assembly

or

DISASSEMBLY AND
ASSEMBLY
INSPECTION
Refer to

Trouble

Diagnoses and

Expansion valve

Corrections

AMBIENT SWITCH
REMOVAL AND
INSTALLATION

COOLER RELAY

f

6
r

SHA157

SHA154

Thermo bulb

SHA378

COOLING UNIT

I

Remove instrument

lower

cover

and cluster lid

REMOVAL AND
INSTAlLATION
I

Remove instrument

and cluster lid

2
I
lower

cover

Remove

lower
2

clips fIxing

upper

case

assembly

Disconnect harness connector and

remove

3

case

Withdraw evaporator

to

ambient switch

Installation is in the

reverse

order

of removal
HA 27

ServiceProcedvres

AIR

CONDITIONER

INSPECTION

AIR CONDITIONER

RESISTOR

CONTROL ASSEMBLY

Refer

to

Resistor in Heater

REMOVAL AND
INSTALLATION

r

Refer to Heater Control Assembly

1101

MAGNET VALVE
INSPECTION

INSPECTION

Ambient

Continuity

temperatwe

F an switch
Refer to Fan Switch in Heater

2 SoC
410F

00

Above

36

Ves

Air conditioner switch
Below

0

30C

O

@

No

370F
Air passing
SHA158

EXPANSION VALVE
AND SUCTION
THROTTLE VALVE

Thermo bulb

Clamp and

Electrical conductivity

wrap

Ch

CD

2 3 @ CID

c

ON

0

0
0

OFF
lnle

IUwnination lamp is located between
anCl

I

CD

IlJ

I

00

outle

Suction throttle valve

L Service valve

SHA169

Do
sary

not

disassemble

replace

HA 28

as

Iy

val

neces

Applied
voltage

I

OV

I

12V

CDOO@
0

0
1

I
SHA162

with heat insulator

I

I

BLOWER UNIT
Refer to Blower Unit in Heater

SHAle1

0Z
II l

8

I

l

C

en t

f

rnff0

5 z rn II

10 j

14

4b
f

m

k8

gas

N

1

ling

fiXing

spring cover cavet

s

@
14

Shaft Shaft

Compreso

a

D

Silencer Silencer Silencer Gasket Side Side

36 37 38
33 34 3S
29 30 31 32

13
0

22

bOlt

and hell
lnd
seat
piece piece
seal seal plinug

til

25

ket

ring
O

m

2

5
3

8
1

@

0

20

3

34

til18

til29

bearing

nut

ji1
tl

2

asemblY Gasket Front mouCointi g l Felt Retainer

asembly

23 24 2S 26 21

20 21 22

0

@JJ

ring

end

LOCK LOCK PuloY Coil

5

iJJ

washet and

cover

screw

2

2

v

35

@

0

28
0

bolt

4

j

3
iling

1

head

til2

as5fmb1y cover cover

cylinder

pipe

Oll Rear

pump end end

8her
w9

nut nut

hub

Qutch
Gear Rear Rear nd Shan Hub S18paoet 19
a

14 15
11 12 13

16 11

8
2

20

21

5

25 2 18

3

12

til

asemblY

6
I

L1
1

11

til16

cylinder

head plate

6

ring
O

covet roing

end pipe
cylinder valVe
Gasket Front suction Gaslo Key Compreso Gasket Rear on
pm

et

nock
j

1

2

34

89
7
56

10

1

21

2

15

8
1

til18

13

t

l

Compressor

AIR

SWP167J

2

3

o

CONDHIONER

l
C

r
Y

i1lfJl

II
I

tf

Key

5
6

Shaft seal seat
Shaft seal
Front end cover
Front cylinder head
Suction valve plate

10

Silencer spring
Silencer piece

11
12

Thrust bearing
Side cover

13

J

11

Clutch hub

4

9

r

4

Hub nut

3

8

iMt l
YJt
t

Shaft nut

2

7
i

A

I

1

15

Rear cylinder head
Compressor shaft

16

Rear end

17

Oilp ump

18

Rear

14

c
l

cover

cylinder
Oilpipe
20 Swash plate

4

19

1

@l

21

Shoe disc

22

Front

cylinder

23

Drive

ball

24

Shell

2S

Needle bearing
26 Clutchcoil
27

Pulley and bearing assembly

SHAl64

PRECAUTIONS
I

Plug all openings in compressor to
prevent from entering of moisture and

low pressure side and purge air at the
high pressure side

3

Make

sure

that terminal voltage at

magnetic coil is above 105V

foreign matter
00 nc
tleave

2

its side

the compressor on

oruplide down for

10 minutes

as

enter the low

under

that

should be

from

more

lubricating

operated

Before

new

I

compressor
suddenly internal

result

chambe

To

expel oil

crank
hand

installed

COMPRESSOR

from

The
clutch
are

in the old compressor

I

When

replacing

eal with
5

new

When

sure

to fill it

with

vent

rusting

Add

HA 30

parts or oil
Oing and oil

ones

storing

a

compressor

refrigerant
refrigerant

wrench

remove

Then

With

suitable

hold
socket

shaft nut from shaft

using Tool

remove

clutch

hub nut Remove spacers

CWTCH

compressor and fill with an

always replace gaskets

Tool KV99412302

hub

new

emount of oil equaling that remaining
4

Using

clutch

2

com

replacing with the
complately drain oil

compressor
the

REMOVAL

If

condition

pressor several times in its
condition
3

than

oil will

pressure chambers

would

damage

the

be

to pre
at the

most

common

Service

slippage

listed below Exercise

care

Clearance between clutch hub and

pulley

should be 0 5 to 0 8 mm 0D20

to ODJI in at all

2

Make

dirt

on

sure

or

peripheral points

that there is

no

oil

or

friction surfaces of clutch disc

clutch hub
oil

problem is
procedures

and

dirt with

a

pulley
dry rag

Remove any
AC024A

AIR CONDITION ER

ifJ

3
Using Tool remove clutch hub
Thread tool into the bore of clutch

hub

Coil

mounting

2 7

3A

0 28

hold tool with wrench and then

screw

m
N

0 35

2 0

thread in center bolt

Compressor SWPI67J

kg

m

5 ft lb
2

AC028A

7
ACQ25A

Using

an

impact tool loosen

six

coil mounting screws Use of the im
pact tool is advisable as screws have

AC029

been calked
2
4

With an ordinary
flatten lock washer tab

Using a plastic mallet drive pulley
and bearing assembly onto the neck of

screwdriver

the installed coil assembly Turn the

pulley making

sure that there is

noise and that

rotation is

make
3

sure

that there is

no

free

no

Also

pulley play

Position lock washer and lock nut

place Using Tool KV994123IO
tighten lock nut firmly With lock
in

tab

washer
matched
AC680

and

lock

nut

Proceed

driver

carefully
bearing cage damage

ifJ
AC026A

8

Remove coil mounting

screws

25

27 N

2 5

1

18

Using

Tool loosen lock nut Re

shaft

INSPECTION

lock nut and lock washer
I

Check the friction surfaces of the

clutch for damage due to

excessive

grooving due to
If
necessary
replace coil
slippage
and
and
assembly
bearing
pulley
heat

dutch
2

excessive

o

hub

Oil

should

or

as a

solvent and
3

n

dry

with

a

suitable

13

5

or

opened

ifJ

tighten
6

2 1

Remove pulley and bearing as
sembly When the assembly can not be
removed by hand use a puller Tooi

in an

KV994123I3 and Tool KV99412312

ing

Phillips

with locking

Shaft nut
17 N m
1

m
7kg

12 3lt lb

screwdriver

coil assembly mounting

alternating pattern After
one

nut

place

in

11 6

have been frrmly tightened
each at

m
kg

Tighten shaft

1 6

INSTALLATION

spacer

the

which

15lt lb

16

a

adjusting

to

21 N m

1 8

agent

rag

Check coil for shorted

Using

clutch hub

Hub nut

A

I

m

and clutch hub

18

binding leads
AC027

kg

the friction surfaces

cleaned
a

m

20 It lb

Select

pulley

set

dirt

be

avoid

the correct clearance between the

gives

ifJ

8

Fit key and

4

5

to

Lock nut

and

separate coil assembly

move

cutouts

bend the tab with the screw

screws
screws

puncWock

location to prevent loosen

6

Using

a

thickness gauge

the clutch hub to
Hub to
5
0
020
0

pulley

measure

pulley clearance
clearance

0 8 mm
0 031 in

HA 31

If the
obtained

AIR

SWPI67

lSOr
Comprt

CQN OITlON ER

specified clearance is
replace adjusting spacer

not

and

rcadjust

2

Cormect

hose

charging

to

re

Install

Tool

KV994CI552 to other end of

charging

frigerant

can

hose and insert it into hole in middle
of blind

cover

at low pressure side

5
Wrap shaft end with ra8 Apply
refrigerant pressure of 196 to 490 kPa
28 to 71 psi thrnugh
2 to 5 kg em

low pressure line of compressor until
shaft seal seat is received at rag

INSPECTION
AC029A

I

CAUTION
a

When
a

replacing
do

embly

operation
and

not

br k in

forget

moisture dust

Break in

the clutch some

llll
ins

thirty

raises

operation

Check the carbon seal surface of

shaft seal for

damage

ete

b If shaft slllll seat is not

accomplished by engaging

disengaging

times

compressor dutch

Do not use air to prevent entry of

it

again

and

plucked out
apply refrigerant

Carbon seal

pressure

Contact surCace

the

level of transmitted torque
KV994C1552
KV994C4531
KV994C4533

SHAFT SEAL

KV994C4559

REMOVAL
I

AC035

Remove drain plug

thereby

drain

ing the oil
2

Remove clutch hub

pulley

2

and

bearing assembly and coil assembly
Proceed
according to information
under Compressor Clutch
3
Using snap ring pliers compress
and

remove

retainer

Check Q ring and the carbon seal

contact surface of shaft seal seat for

damage Make
surface at

sure

front

that O ring contact
end cover is not

damaged
SHA165

ring

6

Insert Tool

of front

end

through

cover

the open end

Depress the carbon

seal and hook the tool at the

case

Contact
surface

pro

jection of shaft seal Slowly pull out
the tool thereby removing shaft seal
ACS05

INSTALlATION
Do not re use shaft seal
4

To

as

follows

I

Plug

remove

suction

high

shaft seal seat proceed

discharge

and

pressure openings of

low
com

pressor using Tool KV994C4548 or
blind cover and gasket which are in
stalled
HA 32

on

service compressor

KV994U32

seat

and

shaft seal

CAUTION
In placing a new seal on the IIIIIrk
belich mllke sure that the contact
surface faces upwerd Take necessary
steps to avoid damage

AIR CONDITIONER
Make

I

sure

that the shaft seal

tact surface is free of dirt and

amply

lubricated with compressor oil
2

Cap Tool KV994l2322

3

con

to the

top

aligned
Apply force

case

insert

shaft seal seats

Conduct

leak

remove

a

leak test If there is

silencer springs

pieces

a

and then install again

and shaft
KV994C4531

properly

Remove

4

process Discard used O rings

to turn the seal some

right

charge

loosening blind cap

cutout

what to the left and

top

and O rings Do not damage O ring
surface of silencer piece during this

4

Using Tool KV9941232l

shaft seal with shaft seal

can

SWPI67

refrigerant from low pressure side and
purge air from high pressure side by

end of compressor shaft

3

of

Open valve

Compressor

KV994C1552

9

KV994C4534

Insure that

KV994C4559

in the shaft
O ring

cutout

Piece
Silencer
pnng
AC207

INSPECTION
I

Make

that side

sure

surface and shell

gasket

cover

surface

gasket
are

not

damaged
AC037

Make

2

t

that silencer pieces and

sure

shell contact surfaces in contact with
O
4

scats
5

lbiJ

Apply

ample

an

that seat easily slides
front end

on

t so

a

thin coat of grease

cover

SIDE COVER

until it bottoms up to

I

6

2

Loosen

2

not

and

remove

eight

side

the

cover

will force up side

cover

shell

tap

aligned

are

rings
3

Coat O ring and the

shell hole with
compressor
KV99412328

4
with

Coat the

installed

on

5

service

Connect

charging

hose

to

low

lfJ

of manifold

gauge
pressure gauge
Install Tool KV994C1552 to other

end of

charging

cover

referlgerant

can

cover

AC687

1 8
13

position

cover

in

eight

place by

hand

mounting bolts
in an alter

bolt

20 N m
2 0

m
kg

14lt lb

at low

pressure side
Connect center hose of manifold
gauge to

Side

18

hose and insert it into

hole in middle of blind

Hold side

and

cover

Tighten these boIts evenly
nating pattern

compressor
2

oil

compressor

and thread in

and

surface of shell

gasket

KV994C4548

are

around

install O ring into the

gasket and side

gasket which

area

ample amount of
oil
Tool
Using
an

Then install silencer piece

Plug high and low pressure joints
Tool
into
Using
compressor
I

cover

compressor

with Tool KV99412327

leakage as follows

blind

the

on

that holes of cylinder
and install O

sure

shell hole

pressor shaft and turn shaft 5 to 6
turns clockwise Then check for gas

or

gasket and O

upward

Make

and

cover mounting bolts in an alternate
pattern Note that two silencer springs

inside
com

old

Place the mounting swface of side

cover

land

groove
Install Tool KV99412329 to
7

I

REMOVAL
Drain oil

Using snap ring pliers compress
retainer ring and fit it into front end
cover
Seat retainer ring firmly in the

damaged

shalt

or

oil to shaft Push shaft seal seat iilto
front end

Do

inner side of

cover

Also apply

not

INSTALLATION

of oil to

coat

are

Do not reuse

rings

SHA166

properly

contact surface and shaft seal

ring

3

Fit O ring to the outside groove of
shaft seal seat making sure that it

6
3

Remove side

gasket

cover

and side

Discard the gasket

cover

Fill with compressor oil

7

Upon completion of the above
operations cOnduct a gas leak test by
HA 33

AIR CONDITION ER

Compressor SWP167
the

referring

to

under the

topic Shaft

item

Installation

INSTALLATION

Seal

Do not reuse old

I

Using

gasket

suitable

and

blocks

ring
O

position

compressor with the front face down
ward and the rear upward

AR
Np
AND REAR

2

CQV

Insert

3

CYLINDER HEAD

AC042

Coat both

Drain oil
Remove

five

end

rear

lop

the

rear

surfaces

of

of cylinder

that

the

three

plate making
S properly
valV

align with cylinders and gasket
cover

mounting bolts with Tool Starting
the

in

Install suction valve

slife

L

pins

head gasket with compressor oil and
align gaaket with cylinder
4

REMOVAL

2

two

cylinder

cut

outs

at

5

loosen all bolts one turn in an

Remove O ring

pins Discard the

alternating pattern Then remove bolts

6

in turn

Remove

gasket and two
and gasket
head
cylinder

ring
O

rear

suction valve

plate and gasket Discard
Carefully remove suction

the gasket
valve

plate avoiding defonnation

7

When removal proves difficult use
Tool Insert this tool into hole in cyl
inder head With the nut in frrm con
tact

with the back side of

head

tighten

cylinder

the bolt slowly to break
AC224

loose the head

AC6 8

5

Install cylinder head

gasket and

in the order listed

q at gasket

ring
O
and

ring
O

beforehand with

an

ample

amount of compressor oil
3

Grasp

separate

rear end cover

and

it from compressor

flange lightly
quired with

a

carefully
Tap the

and

alternately
plastic mallei

Do not reuse old

gasket

and

as

reo
AC210

ring
O

AC045

INSPECTION
I

Make

sure

that the gasket contact

surface is free of damage
2
AC689

If

replacement

connector and
sary

of

rear

end

check valve is

replace rear end

cover

with

cover
neces
anew

one

3

Check

suction

valve

plate

and

cylinder head for broken valves
4

Remove pump gear Do not allow
pump gear to damage the surface
HA 34

4

Check pump

damage

gear

for

wear

and

Compressor SWP167

AIR CONDITION ER
6

Fit pump gear to rear end cover
Carefully fit rear end cover to the

7

rear of

6

Using long

suitable tool

carefully

compressor

as

nose

pull out

pliers

other

or

oil pipe Proceed

oil pipe is easily bent

Unless oil

pipe

attemp t the

hIS been removed

Remove

10

gasket
plate and
gasket When removing two pins
proceed carefully to amid cylinder
head damage Do not deform suction
valve plate in removing suction valve
plate Discard oil gasket
cylinder head

CAUTION
not

Remove shaft seal from the shaft

9

do

following steps

pins

two

suction valve

CAUTION
Do

deform

not

when

removing

R1ction valve

plate

it

INSTALLATION

AC211

suitable
blocks
face
Using
Insert
two
assembly
upward
cylinder
pins Position gasket and suction valve
plate in the order listed while making
I

Using Tool KV99412330 tighten
alternating pattern
starting at the top Do not f9rget lock
8

up five bolts in an

AC212

fl

3 0
22

7

34N m

29

3 5

the front

facing

downward

Using a
support compressor
the
rear
mallet
at
end of
plastic
tap
the shell flange driving shell straight

kg

25 It lb

conduct a leak test

operation
ferring to the

With

shell

Fill with compressor oil
Upon completion of the above

10

aligned with the cylinder and
Coat gasket with com
oil
to assembly Gaskets
prior
pressor
and suction valve plates are the same

plate

by

under

topic

are

gasket

Rear end cover bolt

9

that three valves of suction valve

sure

washers

downward

Discard front

end

cover

gasket

cutouts

for front and

The

rear

cylinder

head

with the smaller numbers of holes goes
to

the

rear

front

Do not mix front

an

parts

re

Shaft

Seal

REPLACEMENT OF
CYLINDER

bBJ

REMOVAL

1 ACOS1
l

AC213

I

Drain oil

2

Remove compressor clutch assem
bly Refer to Compressor Clutch
3

Using

ring pliers
shaft seal retainer ring Then
snap

shaft seal seat Refer to

remove

mallet

Shaft Seal

frain
cover

front

end

cover

from

Using a plastic
drive end cover upward Re

assembly

from

excessive

force

to

avoid

damage

It may be removed when

cylinder assembly
front end

Detach

cylinder

Removal of shaft seal is not absolutely
necessary

8

remove

cover

i

removed

from

tj

In fact this approach

facilitates work
4

Remove side cover Refer to

1

Side

AC052

Cover
5

Remove rear end cover Refer to
Rear End Cover and Rear Cylinder

Head

Remove O ring

gasket

pins

cylinder

plate

and gasket in the order listed

This exposes the

head

rear

suction

2

two

valve

part of cylinder

shaft

Align

cutaway

Firmly

shaft land

seal with the

shaft

seat shaft seal at the

Attempt

to turn shaft seal

right confirming that it
properly

to the left and
AC050

is seated

HA 35

AIR CONDITION ER

SWP767
r
Compre

Place gasket on cylinder head and
end cover Coat gasket

3
with

oil

compressor

Make

sure

used

lation of

beforehand

Gasket differs for the front and

Installation
and Rear

rear

that the correct gasket is

After

completing

this

8

work

Rear End Cover

under

Cylinder

Head

Continue with work up to instal
of side cover
according to

lation

protruding from front end
cylinder head should be
adjusted by hand

Installation

gasket

and

cover

Continue with work up to instal
rear end cover according to

7

install front

9

instructions

Side Cover

under

Install shaft seal

s

t

according

Installation

in

to

under

Shaft Seal
AC690

10

Install

clutch

and

acoording

Installation
5

Turnover the asSembled shell and
that the

front

may face downward

D

t

so

OJ

SIlencer hole

6

ring
O
with an
Coat oil pipe and
amount of oil Insert oil pipe at

ample

J

the rear of the
AC053

sure

in

step

4

are

matched

compressor

instructions

under

Fill with

in

Compressor

oompressor

tighten oil plug with

copper

oil

and

gasket

in

place

til

Oil plug
18

cylinder After making

that the hole lines

specified

to

Clutch
II

cylinder assembly

adjust

8
1

as

13

continue with

20

rn
N

2 0

rn
kg

14 ft lb

stepp 6 work
12
4

Fit gasket

to

front

end

Then bring the shell into place
the

cylinder assembly

make

sure

and

cover

matched
will

no

to the

cover
over

At this tin1e

that the two holes of side

cylinder holes

the

are

Note that later adjustment

longer

be

possible

as

inside

and outside diameters of these are not

perfectly
shen

round Note that moving the
down may cause the

up and

gasket

HA 36

to

slip out

of place

AC226

Conduct

a

leak st
te by referring
Shaft Seal

topic under

AIR CONDITIONER

ElectricaICirr
uit

ELECTRICAL CIRCUIT
SCHEMATIC
OFF

position

BLOWER
RESISTOR

FUSE

MOTOR

20A

M
5A

OFF

AMBIENT
SWITCH

0
D

O

RELAY

PRESSURE
SWITCH

IGNITION
SWITCH

tJ

ft

I

01
Ie
COOLER
1 1

RELAY

BATTERY
COMPR ESSQR

F IC O

MAGNET

MAGNET

B L

o

L
R

FUSIBLE
LINK

VALVE

CLUTCH

VENT

IGNITION

LOW

7

D

AIC
SWITCH

DEF and RECIRC position

HEAT

BLOWER
MOTOR

RESISTOR

FUSE
20A

M

AMBI ENT
OFF

O
D

OFF

G 8
fl
0
S

n

SWITCH

FAN
SWITCH

LOW

PRESSURE
SWITCH

2
fP

IGNITION
SWITCH

D
BATTERY

R

COMPRESSOR

F IC O

FUSIBLE

MAGNET

MAGNET

LINK

CLUTCH

VALVE

BLOWE R

AC positIon

MOTOR

RESISTOR

M

ON

GJ

r
DDonO

n

a

A

I

IGNITION
SWITCH
G

BATTERY

COMPRESSOR
MAGNET

CLUTCH

F IC O

MAGNET
VALVE

G

R
FUSIBLE
LINK
SHA 146

HA 37

Co z o

5z

l1
C
i

JJ

9

II

ER E

COloPRESOR

O

l

oO

I
GIleUCI

C

IoI

1
11
l

Ilo

GIle

lll

c

IoI

J
t

I

Gf lla

II11CI
S

PRES URE

aJJ

1
0

It
I

Il11CI
S

1I01l
IIl

UI

tkMP

ll

ON
f
l
0

J
Ul

lOIlER

I

COlOl1

II11CI
S

1I01l

RESI 10R

I
lCI

IlI
IR S
f

I

lEI IROUI MP
t

1
1
5C

Gll

ll

I
t
I

Il11CI
S

fUSIl

E

M010R

IGl 10 l

4IER

Il

all

N
a

COl RO

I

I

I

IIIIlG
IGI

1I01l
Iu

UI

1l

II11CI
S

JI
Ill1CI
S

AIR CONDITIONER

TROUBLE DIAGNOSES AND

TroubleOiagnosesandCorrecrionr

CQRRECTIONS

AIR CONDITIONER DIAGNOSES

Insufficient cooling

Bubbles

in

sight glass

No bubbles in sight glass

Check refrigeration line for gas leaks and repair leaks if any

frigerant
charge

to correct level

In

case

the system evacuate and

Charge

reo

of too many leaks stop compressor dig
the system

recharge

As necessary

replace

receiver drier

Air in system may

cause

bubbles in sight glass

air

System pressure and temperature of discharge
Performance Test Diagnoses for detail

are

abnormal

Refer

to

With manifold gauge

check system

pressures

Measure temperature of discharge air
Refer to Performance Test

Temperature of discharge

air is ab

normal but system pressure is

normal

Suction pressure
is

Discharge

pressure is

Suction pressure

high

high while
discharge pres

is

high

sure

Overcharge of refrigerant
Discharge some refrigerant
Expansion valve

to correct level

is open exces

Air is mixed in

sively

Replace

tern
expan

sian valve

and

Discharge

replace

Valve

sys

Check air flow system

is low

or

gasket

of compressor is

drier

Evacuate and recharge system
Condenser s fin is dented or

damaged
Repair or replace

clogged with dust

compressor

Check grommets on car s dash panel
for air leaks check other seals of
car

Clean exterior surface with
water

Suction pressure is low

Pipe

at receiver drier outlet has

low temperature Receiver drier
is restricted Replace receiver

Fin and tllbe of evaporator have
some

dents

Replace

or

repair evaporator

Expansion valve is close excessively
or gas leakage from thermo bulb
Replace expansion valve

drier

HA 39

Trouble

AIR CON DITION ER

Diagnoseund Conectiom

Noisy

Compressor

OFF

Compressor ON

I

r

Bearings of compres

Blower motor makes

sor clutch

noise

pulley
Repair

or

idler

make noise

Repair

Belt is loose

Adjust
or

Compressor itself

When engine rpm Is

makes noise

changed there are

Repair

resonant sounds

belt

replace

blower motor

or

replace

compressor

Retighten

compres

sor bracket

Blower motor does not

Compressor

rotate

run

Refer to

Blower Motor

Diagnosesu

F IC D does not operate

Refer to

Fast Idle

Control Device Diagnoses

40
HA

Refer to

does not

Compressor Clutch
Diagnoses and Compressor DiagnoseS

bolts

AIR CON DITION ER

Trouble Diagnosesand Corrections

BLOWER MOTOR DIAGNOSES

II

II

Condition

Check

Test conditions

Probable

Battery

OK

Fusible link Red and green

OK

Ignition switch
Ignition relay

OK

Fuse 20A

Quick check

OK

Position of ignition switch

ACC

Position of fan sWitch

ON

I

Check that wiper and washer operate
Ifthey do not operate check fuse l5A in fuse
block

O K

in fuse block

cause

at

first

I

Blower motor does not run

Remove instrument lower cover and

cluster lid

I
Connect test light
wire

leading

to

blue white

to blower motor

I
Ught ON

Ugh OFF

Ground

SHA168

Ground blue black wire leading to
blower motor

I

I

Motor runs

Motor does not

I

fun

Faulty blower motor without

problem

SHA169

in lead wire connection

t
Replace

@

@

41
HA

AIR

TroubieDiagnosesandCorrections

CONDITIONER

Broken lead wire

Check fan switch for

between ignition

ductivity

relay and blower

Refer

to

con

Fan Switch

motor

I

t

Motor

Repair

Faulty fan switch without problem
in lead wire connection

t

I
Motor does not

runs

I

I

run

Check resistor for conductivity
Refer to Resistor

I

Replace

ot

N G

I
Faulty
lead

resistor without
e

problem

Check other lead wire and connection

connection

Replace

I

Speed ofblower motor does

not

J1

change

Remove instrument lower

cover

and

cluster lid

Check resistor on heater unit
Refer to Resistor

Faulty

resistor without

in lead wire connection

l

Replace

42
HA

problem

N G

O K

I

I
t

Check other lead wire and connection

AI R CO N 0 ITIO N ER

COMPRESSOR CLUTCH DIAGNOSES
Test conditions

Battery

OK

Fusible link Red and green
Ignition switch

OK

Ignition relay

OK

Fuse I SA

in

Position of ignition switch

ACC

Position of fan switch

ON

Position of air conditioner switch

ON

Compressor clutch

is not

Connect two wires leading

I

I

Check

I

I

Probable

Condition

cause

to

engaged

I

low pressure switch

I

I
Clutch is

J

Corrections

OK

fuse block

I

I

Diagnosesand

Check that wiper and washer operate

Quick check

OK

Trouble

Clutch is not engaged

engaged

AC371 A

1

Check refrigerant level

I

I

N G

OK

L
Faulty low pressure switch

problem lead

without

yire connection

light to blue black wire
magnet clutch

Connect test

leading to

I

I

Replace

AC373A

light OFF

light ON

Insufficient

o

re

frigerant

t
Add

Ground earth terminals leading to

Connect wire between two termi

magnet clutch

Clutch is
not

engaged

0

1

Clutch is

Clutch is

engaged

engaged

00 re

Clutch i
not

engaged

I

I

@

@

@j
@

SHA17G

HA43

Trouble Diagnore end Correction

@

AIR CON DiTtON ER

Ii

Faulty magnet clutch

@

Remove

without pro

instrument

blem in lead wire connection

lower cover
and

t

rlid
clust

Repair

Broken

ground

wire of magnet

clutch

t
Repair

Faulty cooler relay without problem
to ambient

leading

in lead wire connection

temperature

switch
SHA 174

I
Clutch is

engaged

Replace

I
Clutch is
not

engaged

I
Faulty ambient temperature
switch without

problem

in lead

wire connection

Connect wire between green and
blue wire leading to air conditioner
switch
I

Replace

Clutch is

ClutCh1is

engaged

engaged

no

J

U
SHA

Faulty air conditioner switch
without problem in lead wire
connection

Replace

HA44

Check other lead wire
and connection

175

AIR CONDITIONER

Trouble

Diagnosesand

Corrections

COMPRESSOR DIAGNOSES

Compressor clutch

is

compressor does not run

engaged but

I

I I

Clutch slipping

Check and
Clean oil

readjust

or

dust

gap of clutch

on

contact sur

If

Check belt tension and
If belt is worn out or

replace

face ofclutch

slipping continues replace

II

Belt slipping

adjust

Seizured compressor

Internal problem in compressor cyl

it

inder

damaged

Check system

it

Repair

com

or

replace if necessary

pressor clutch

High torque

Overcharge

1

of refrigerant

sure
sure

OK if

discharge

pres

Discharge pressure
reduced

is not

refrigeration system

Discharge system from service valve
Evacuate and recharge the system

Discharge refrigerant gas to an extent that sight glass
of receiver drier has only a few bubbles
Engine speed 1 500 rpm

Check for discharge pres

Air in

I

When torque is still

great repair

or

on

discharge

replace

side

compressor

is reduced

45
HA

I

AIR CONDITION ER

Trouble Diagnoseund Corrections

Compressor oil leaking

Air blow

on

Compressor

spot where oillcak evidence is found
refrigerant leaks using leak detecror

Then check for

I

Refrigerant leaking

No refrigerant leaking

Noisy only when clutch
is engaged

is

noisy

Noisy when clutch
not

Check for loose compres
sor mounting bolts

Remove compressor belt

Retighten bolts

sor clutch

Turn pulley of compres

by

hand and

check for noise
is heard

Repair

or

replace

compressor

Wipe

clean oil with rag

Compressor drive belt
is loose

Adjust

belt

tension

Ifcompressor is still

noisy repair
compressor

46
HA

is

engaged

or

replace

sor

repair

clutch

Ifnoise
compres

AIR

FAST IDLE CONTROL DEVICE

CONDITIONER

OK

Fusible link Red and green

OK

Ignition switch
Ignition relay

OX

IS

Fuse

II

q

Condition

I

I

Check

I

I

Probable

Quick check

cause

Check that wiper and washer operate

OK

in fuse block

OX

Position of ignition switch

ACC

Position offan switch

ON

Position of air conditioner switch

ON

F LC D is not

II

operated

Check operation of compressor clutch

I

Check electric circuit of clutch

j

I

Clutch is not engaged

ferring

Diagnoses and Corrections

DIAGNOSES

Test condition

Battery

Trouble

D

Outch is engaged

Run

reo

to compressor clutch dia

at idle speed

engine

Disconnect

LC
F

vacuum

SHA177

D magnet

valve to F LC D device hose at

gnoses

F LC D magnet valve and check
vacuum

I

I
Vacuum O K

Vacuum N G
I

Faulty

lC D magnet valve
F

Disconnect

vacuum
l C D magnet
F
valve lo F LC D device hose at

l C D device and check
F

vacuum

I

I

Vacuum O K

Replace

Vacuum N G

j
Faulty

l C D device
F

J I

Broken

1
vacuum

hose

J
Replace

Check
vacuum

Repair

7

Fl C D
device
SHA17S

47
HA

AIR CONDITIONER

Setvice Data and Specifications

SERVICE DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS

TIGHTENING

COMPRESSOR

TORQUE

Unit

Model

N

Compressor bracket

SWP167

m

to

44

54

45

55

33

40

44

54

45

5

33

40

Low pressure line

25

29

25

3 0

18

22

High pressure line

15

20

5
11

20

11

14

1 1

58

0

1

2 0

2 5

cylinder block
TVpe

Swash

plate
Compressor

I

cm3

Displacement

I

Cylinder bore

x

stroke

I

Direction of fotation

I

Type of driving belt

inl

cu

167110 191

rev

compressor

2 25 7

37

in
mm

to

bracket

Refrigerant line connec

11 465x 1 0121

tion

ClOckwise
A type

flexible hose to
corilpreuor

LUBRICATING OIL

I

Capacity

US fl

ml

OZ

Imp fI

02

270

19 1

9

mounting screw

Type

R 12

Capacity

3 4

kg UbI

09

1

411
2

INSPECTION AND ADJUSTMENT
ENGINE IDLING SPEED

Unit

Transmission

When

rpm

Ale is ON

About 900

Manual

cidjustablel
Non
At

N

About

rangsl

1000

adjustable
Nori

BELT TENSION
Fan belt Applied
mm

UnlN

kg Ibl

pressure

18

1210 31 0 4711
98 110 221

COMPRESSOR
Clutch hub to

pulley

in
mm

5 0 8
10 020 0 0311

0

I

0 28

035

27

12

5

2 8

I

18

20

Hub nut

18

21

11

8

2 1

I

13

15

Shaft nut

16

17

6
11

1 7

111 6

18

20

11

8

20

I

13

14

29

34

13

0

35

I

22

25

18

20

11

8

20

I

13

14

Side

12 0

lOB

25

nut

cover

Reaf end

Oil

48
HA

2 7

51

REFRIGERANT

clearance

10 8

SUNISO 5GS
Lock

Automatic

8
7

Compressor
Coil

I

Type

ft lb

k

plug

bolt

coyer

bolt

12 3

AIR CONDITIONER

SpecialService Tools

SPECIAL SERVICE TOOLS
Tool nwnber
Kent Moore No

KV99412302

Tool

name

Clutch hub wrench

J94878 1

KV99412305

Hub nut socket

124878 2

KV99412306

124878

Clutch hub

puller

3

KV99412310

Lock nut socket

1248784

KV99412313

QD
Puller adapter

126066

KV99412312

Puller

pilot

125472

KV994C1552

Charge nozzle

KV994C4548

Blind

CD

KV994C453I

cover

Blind

cover

@KV994C4532

Gasket

@

Gasket

KV994C4533

set

Useless

3

@

c

@

KV994C4534

Gasket
0 39

@KV994C4559

1
0 39

11
0 61

1

0 51

Bolt

Unit

rom

in

@
HA49

Special Service Tools

Tool number
Kent Moore

KV9941232I
126067

KV99412322

No

AIR CONDITION ER

Tool

name

Shaft seal

remover

and

installer

Shaft seal pilot

125473

o
KV99412329

Shaft handle socket

126072

KV99412327

Silencer piece installer

KV99412328

O ring insta11er

KV99412330

Allen socket

KV99412315

Cylinder head remover

HA 50

DATSUN 200SX

Model S J J 0 Series

SECTIONE L
ELECTRICAL SYSTEM

CONTENTS
SERVICE DATA AND SPECIFICATIONS

EL

37

EL

38

SPECIFICATIONS

EL

38

3

COMBINATION SWITCH

EL

38

EL

3

HEAD LAMP

EL

40

EL

3

EXTERIOR

LAMPS

EL

43

EL

4

INTERIOR

LUGGAGE COMPARTMENT
LAMPS

EL

51

EL

54

EL

2

SCHEMATICIPOWER SUPPLY ROUTING

EL

2

FUSE

EL

3

BULB

EL

POWER SUPPLY ROUTING

FUSIBLE

LINK

IGNITION SWITCH
IGNITION AND ACCESSORY

RELAY

BATTERY

LIGHTING SYSTEMS

EL

4

AND STEP

CHECKING SPECIFIC GRAVITY

EL

4

INSTRUMENT PANEL ILLUMINATION

CHARGING

EL

5

METERS

BATTERY FREEZING

EL

5

WARNING SYSTEMS

EL

56

BATTERY TESTING

EL

5

COMBINATION METER

EL

56

SERVICE DATA AND SPECIFICATIONS

EL

7

WARNING DISPLAY

EL

65

EL

8

WARNING CHIME

EL

70

EL

B

EL

73

EL

8

EL

73

EL

79

ELECTRICAL ACCESSORIES

EL

81

EL

81

EL

83

CHECKING

ELECTROLYTE

LEVEL

STARTING SYSTEM
SCHEMATIC
WIRING

DIAGRAM

STARTING SYSTEM
9

GAUGES AND

WIPER AND WASHER
WINDSHIELD WIPER AND WASHER
REAR WINDOW WIPER AND WASHER

TROUBLESHOOTING

EL

STARTER

ELla

REAR WINDOW DEFOGGER

EL 16

REMOTE CONTROL DOOR

EL 17

CLOCK

EL

85

87

MOTOR

SERVICE DATA AND SPECIFICATIONS

CHARGING SYSTEM

MIRROR

DESCRIPTION

EL 17

HORN

EL

SCHEMATIC

EL 18

AUDIO

EL

89

EL

94

EL

94

EL

95

EL

99

WIRING

DIAGRAM

EL 18

AUTOMATIC SPEED CONTROL
DEVICE

CHARGING SYSTEM

A S C D

TROUBLESHOOTING

EL 19

DESCRIPTION

ALTERNATOR

EL20

TROUBLE

EL 23

COMPONENT

IC

VOLTAGE

REGULATOR

SERVICE DATA

AND SPECIFICATIONS

IGNITION SYSTEM
IC

DISTRIBUTOR
IC

IC type

IGNITION UNIT

PARTS

EL25

ELECTRICAL UNIT LOCATION

EL 104

EL 26

WI RING

EL 106

IGNITION SYSTEM

TROUBLESHOOTING

DIAGNOSES

EL28
EL31

EL35

HARNESS

CABLE COLORS

EL 106

HARNESS

EL 106

LAYOUT

Power

ELECTRICAL SYSTEM

Supply Routing

POWER SUPPLY ROUTING
Before

CAUTION

starting to worll

J system disconnect

on any

battery ground cable

SCHEMATIC POWER SUPPLY ROUTING

Q

f T

8

1

BATTERY

ci

C

CD

FUSIBLE

LINK

t
J

I

sr

occ
l
Or

BOg

A I
16 Q

0
0

IGNITION SWITCH

I

I

S5
I

E1

a

o
IGNITION AND
z
a

ACCESSORY

w

RELAY
J

f

l l

in

ir

1

I

I

o

FUSE BLOCK

L

HEADLAMP

STOP LAMP
i

HAZARD FLASHER

HORN
V

CIGARETTE LIGHTER CLOCK
w

LAMP MONITOR

VOLT GAUGE

z

0

t
t

w

i

z

INTERIOR LAMP STEP LAMP LUGGAGE COM
KEWARNING
PERTMENT LAMPS

u

w

TAIL

CLEARANCE SIDE MARKER AND LICENSE PLATE

LAMPS METER ILLUMINATION
7HEATER OR AIR CONDITIONER BLOWER MOTOR

1

7 AIR CONDITIONER

WIPER

AND WASHER WINDSHIELD AND REARl

RAOIO POWER ANTENNA
w

a

REAR WlNDOW
TURN

SIGNAL

TACHOMETER

EL 2

DEFOGGER

UP LAMPS WARNING LAMPS
GAUGES SEAT BELT WARNING WARNING DISPLAY
BACK

SEL365

ELECTRICAL SYSTEM

FUSIBLE UNK

FUSE

Power Supply

Routing

IGNITION AND
ACCESSORY RELAY

LOCAnON

LOCATION
The
are

ignition and accessory relay
on the right side of the

located

dash panel

Refer

page

EL 104

at case

attaching

to

INSPECTION
Ground is made
bolt and tenninal

rJ

SEL277
SEL275

INSPECTION

CAUTION
a

c

that critical circuit

possible
supply

l

l

link should melt

If fusible

or

circuit

large

is shorted

power

carrying

current

In such

carefully
of problem

SE L276

SE

a case

check and eliminate

CI
c

it is

L279

I

cause

b Never wrap periphery of fusible
link with vinyl tape Extreme care
should be taken with this link to
ensure thet it does not come into

8

If fuse is blown
nate

cause

installing
b

Never

sure

to

Do

not

fuse of more than

vinyl

wiring

har

rubber parts

or

A melted fusible link can be detect

speci

by visual inspection or by
feeling with fmger tip If its condition
ed either

install

fuse

direction
holder

ness or

fuse

fied rating
c

contact with any other

elimi

of the problem before

new

use

be

always
properly

in

oblique

snap it into fUle

is

questionable

test

use

circuit tester

n

or

lamp

IGNITION SWITCH
S

B

1G

A

t

T

sr

c

s
k

U

01
o
5

g

Q

5

B

From battery

A

To accessOIY system

IG

To

s

tionsystem

To starting

system

Key warning switch

IN OUT

I

g
SEL369

EL3

ELECTRICAL SYSTEM

Battery

BATTERY

CHECK

WARNING
Naver touch

positive

termill8ls at the
bare hands This

and

same

could

negative

injury

O

SPECIFIC GRAVITY
J

hydrometer

Read

and

thermal

S20

t

Thermal gauge

If the

battery cables are discon
they should be tighdy
clamped to the battery terminals to

good contact

Electrolyte temperature

1
When electrolyte temperature is
350C 950F and specific gravity of
electrolyte is L2 O specific gravity
corrected at 20 C 680F is 1243
2
When electrolyte temperature is
O c 320F and specific gravity of

and other electric

nected

secure a

tOC

Examples

components will be damaged
b

at

Specific gravity of
electrolyte corrected
at 20C 680F

fuei

injection system

20

Specific gravity of
electrolyte

Reed top level with leale

r

t

Where

gauge indications at eye level

CAUTION
a
If it becomes necessary to start the
engine with a booster battery end
jumper cables the booster battery
12 volts
voltage must not ex
or the control
unit of the

0 0007

St

St

time with
result in

G

SE L045

2

Correct specific gravity

et

200C

electrolyte

1680 Fl

is

210
1

specific gravity

corrected at 200C 680F is 1
196

j specific gravity 50

1

130

CHECKING
ELECTROLYTE
LEVEL

@

128

E
u
Co

Check for electrolyte level in each
cell

E
B
u

g

o
u

Overflow

Correct

Shomse
o

t j

t 1t

114
Co

121
1
10
1

EE358

I

I
10
14

If the level is low fUI with distilled
water

EL 4

I
o
32

I

10
SO

r
40

104

I

SO
122

Electrolyte temperature oC OF
SEL096

ELECTRICAL SYSTEM
Determine charging state

3

of bat

Battery

BATTERY FREEZING

tery

1 1

CAUTION
Usa extreme caution to avoid

Examples
Charging

state

whose

of battery

freezing

Ie

battery

JI

J

4@ Qo

0

I

is 1
26

charging specific gravity
specific gravity corrected
200C 680F is 1 243 is 92
max

and whose

at
0

m

charging
battery whose
1
28
state
is
charging
specific gravity
is 82
at a corrected specific gravity
of 200C 680F
For

1

14
10

U
o

20

4

22

40

0

Specific plvity
680F

20oC

60

76

70

94

80

o
O

55

SO

1I2

EE004

80

90

I

1 08
1 04

70

I

I
L

I to

Charsin

SE L047

00

0

16
1
20
1

SpecifIC

32
1

24
1

12
1

28
1

oreleclrolyte
Iflvil

1

Set

2

Touch negative lead of voltmeter

low

to

range

negative battery post
Touch positive lead of voltmeter
to top of battery and move it around
If reading goes over 0 5 volts then
clean off top of battery and retest
to

3

3

100

voltmeter

BATTERY CAPACIlY TEST

nditian l

SE L097

BATTERY TESTING
Recharge battery if its rate drops
below 7m of full charge
4

PRELIMINARY CHECKS

I

Visual

Inspection

Clogged

I

vents

lfil fil W
Corrosion
Cracks

I

Y

Warped

A M

SEL046

CAUTION

Carry

a

rating

I

case

CHARGING

Check

8

r

SEL048

Dirt

out

charging

with

negative

electrolyte tempera
over 450C 1130 Fl
1

Clean

corroded

terminal

common

with

e

solu

soda
baking

2

3

away from open
flame while it is being charged

Keep battery

b When
nect

connecting

charger

leads first then turn

cherger
first

as

Check for cracks and warpage of
case

Make

cables

sure

are

00 not turn
this may

on

charger
spark

on

cause a

con

mains

at

9 6 volts

clean and

above

or

BATTERY IS GOOD

THE

You need not

any further tests If voltage
drops below 9 6 volts then proceed to

perform

next test
4

tight

WARNING
a

Check battery rating against that

of original factory equipment
the

tion

of 3 times the battery rating is shown
Example Battery rating 60 AH Turn
2 Hold this draw for 15 seconds
thim look at voltage If voltage re

b Do not allow

brush and

With battery connected to tester
shown turn load knob until a draw

load to 180 A draw

cab Ie removed

ture to go

1
as

THREE

CHARGE

performed only

TEST

5

Make

sure

6

Make

sure

battery has failed Capacity Test in step
nwnber 3

2

BATTERY

Check to make

discharging
posts

clogged

top of battery is clean
LEAKAGE
sure

across

top

battery

Connect

be

if

Check acid level
vents are not

To

MINUTE

4

good quality battery

TEST

1

is

Remove cell caps

not

between two

2

a

Tum charger to

a

fast

charge rate

not over 40 A

EL 5

ELECTRICAL SYSTEM

Battery

5

I

probe
reading

0Jol

o

Now

put positive probe in ceU
positive post Put negative

nearest the
in

next

cell

down

Record

7
When you get to point where
positive probe is in last cell of battery

touch negative probe to negative post
Record this reading

nnlol

J

ee
9

SE L049

After three minutes

3

meter

reading If it

check

volt

is over 15 5 volts

SEL051

SE L053

16 for Maintenance Free Batteries
5
battery should be replaced If it is
below

5 volts
15

then proceed to step
8

nwnber 5
CELL TEST UNPER CHARGE
Connect tester and battery charger as

readings

5

in step number 4
rate

35

40 A

I

Turn

to

2

Attach

Set to fast charge

low

range

special

cell

6

Continue

on

down

recording reading each

the battery

Touch positive probe to
terminal
positive
Stick black probe in

varies

the

WRITE

DOWN

batteiy

positive

voltmeter

to

more

2 6
2 6

post

reading
SE L052

24

2 6

02

2 6

26

26
02

6
EL

seven

two

than this amount from any
battery is bad and must be

2 4

cell

SEL050

have

volt of each other If one cell

other then

battery

battery

now

reading to
will give you six readings

replaced

3

nearest

the last this
tenths

voltmeter leads

4

should

Now add the fIrSt

They should aU be within 0 2

time

voltmeter

probes

You

f

c

i
V
J

S

li Y t C
t

lh

lE

1 rA

AND

SPE I

r H rT

r1iICAL

STEM

Battriry

C

l

9

BAr E l
t
w

g

N50Z

NS70

r
c
pacify

U S A

AH

12 60

iliffAf

F
g

iI

n s

f

iliYJa

Jth65
f

1

A

1
ficI26f
i 28

c

6

nada

r

tf

i

i

f

ffliiodel

N

1

r

Ii
A

j

0

i
r

F

1

t

t

a

4

i
J
t

f

1

I
1

r

fT

i

l

t

j

Ii

t

c

V

S

tM
f

l

t

C

j

f

c

i

Jii

1Iit

p

135

t

7r

1

rl
j

rJf

l

w
GI

It X9

I

J
L

4
o

Jt

j

t
I

ti

f
tYt

rt

7

6

i
rt
4
o

O

yj
t

a

lI

r

L

i Il
7

f

l

i

i

fi

I

ht

te

t

j

V
1i el
f
Co

tt
I

f
c

t

i

jt

1

j

ltii

H

J
7

tt
it

AAi

L

j
H

i

y

3

1

EIi 7

b

ttjj

t

1

ELECTRICAL SYSTEM

Starting System

STARTING SYSTEM
SCHEMATIC

OFF

Ace ON

C
l

1

ST

g

FUSIBLE
LINK

Ie

5

sr

IGNITION

SW

I

0

C

o

I
c

FUSIBLE

1

LINK

1

FUSE

IGNITION AND

@

1

INHIBITOR SW

ACCESSORY RELAY

BATTERY

STARTER

1

MOTOR

o

@INHIBITOR

0
RELAY

SEL098

WIRING DIAGRAM

re

FUSIBLE LINK

BATTERY

o

Cf

R

@ll

@

WB

ON Ace Off

sr

BW

g

6

J

DD
Ie

5

s

IEI

r
r

ID1
w

BW
ey

IGNITION AND
ACCESSORY RELAY

WR

@

IGNITION SW

oJ

It

@

0

r
O

Q

tJl

0

0

0

o

0

0

0

0

0

ij

O

ij

ij

ij

0 COO
000000
0
00

o

o

FUSEBL

0

0

CK

Ji

We

@

@ri
@

@
@INHIBITORRELAY

g@

t1
a
al

E

e@

m

3
lD

g

o

g
@

@
ao
@WB
LW

STARTER MOTOR

EL 8

ao

@ INHIBITOR

I
SEL099
SW

m rm0 II1 n

batery

stare

engine

O

Stare

and

Bad

J
than

than
Less

Stare fast 60A draws 60A
than
key
S
t
a
r
e
more
t
h
at
hold

normal

in

back but

Spe d

wire

so

Plug Start over

than

V
I

STARING
I

coil

draw

from

curent

from Not

2

Less

stare
Click

4

3

IV

coil

engine
Crank

scale posit ve cable

in

low

drops

ISOA
I

4

than slow
Less Spe d

l

to

to

to

lead
lead Not

terminal stare

to

batery terminal

distrbuo

of

uM

voltage cir uit voltme r positve batery negative switch conetd wire ground engine
to

out

Testing positve Turn Touch post Con ect magnetic Terminal
for

of

2

I

3

oc
N

1

igniton switch

it

coil and
Pull cap
4

Ustart Yelow Con ect negative somen
Black betw en Have
Pull

off test and

I

key

terminal turn

light
No

positve bayonet
to

to

low lead

lead

drops

this

igniton Usualy stare light batery

scale

in

lead

at

Turn

turns

than

stare

wire cap read

wire
I

I

I

does

r

Light

k

to

Check

not

to

than

turns

start
key

conetrs

Open relay

5
0

5V
I

than

than
Less

Less

Crank

betwen

s

the

wire and

switch

jumper terminal
Conect positve magnetic

on

5

t

r

the

No

Automaic

to

I

3

Click Stare

I

cir uit

tinhbitor ransmio

f

t

batery

Igniton

switch

to

4

2

I

Fully

switch Overhaul

click

IV

of

at

SYTEM

and

of

out
s
t
a
r
e
ting Discon e t Con ect betw en terminal Pull distrbuo

charged

O

to

stare

positve 50 A and
curent bateiy am etr cthabISle
tarter
or

s

Stare turn

More SV

to

stop

range stare

drew

TROUBLE

Bad

stare

More IV

cable

Te

Overhaul

J1

itch and

in

in

More l50A

SHOTING

Open

magnetic

ill g
I

B

not

to

in

staring scale negative stare
c
o
n
e
C
t
i
switch
low lead
drops
lead good
e
n
g
i
n
e
lead
magnetic conetd Crank voltage cir uit voltme r negative batery positve Make engine
negative
Turn Con ect terminal Hold housing Crank
Move terminal Terminal bat ery Testing ground

start
engine docs

coil

than
Less

rn Im s

stare

bolts

than

0

than

More

tground erminal ground

bad

J

turns less

magnetic

and

and

Magnetic Remove replace switch Bad batery cable coneti s stare

in

rt

150A

switch

c
o
n
e
t
i
m
a
g
n
e
t
i
c
Tight Mechani l problem Short Overhaul
betwen switch

K

Check

r rn

than

B

Yelow Leave

magnetic positve batery negative Black switch wire
engine
Stare voltme r
c
o
n
e
t
d
Testing Iwitch cir uit Turn Con ect terminal Con ect conetr magnetic wire Ground Crank
to

voltage
1

at Y

More lSV

coil

of

for

I

2

3

4

5

m reO

ElECTRICAL SYSTEM

StBrtingSystem

STARTER MOTOR
Reductlon
Non

ear

type

J 74
l

9 8 0 75

100

5 4

7 2

Mqnetic lWitcl asoembly
Q

Ocarance

between

Pinion front edge and pinion stopper
0 3 2 5 0 012 0 098
Dust

00

Adjust

Adjllllin8
clearance

er

2

Washer thickness
0 5 0 020
0 8
0
0
31

Dust

cover

ring
E

Brush
Brush min

length

12 0 47
Brush spring
Tension
14
Ileu

13 7

18

kg 3

17 7N
1

4

0 Ib

00

metal

Through

bo

J3
l

7

0 38

Commutator min

39

Depth of insulating mica
0 5 0 8 0 020 0 031

s
Les

J
l
Unit

N

m

mm

27

dia

154

Armature

5 0
0 51

shaft bend

Center bracket
5114 180F only
Pinion assembly
Pinion stopper

than 0 08 0 0031

lcg m ft4b
in

SE L007

EL10

ELECTRICAL SYSTEM
Reduction

r

Starting System

typo

Dust

cover

Adjusting washer

Adjust clearance
washer thickness
0 5 0 020

Through bolt

0 8

0 031

co
f

v

ring
Q

Drush
Brush min
11

length

0 43
Center bearing
Brush holder
Brush spring
Tension
15 1

19 6 N

16

2 0 k8

3 5

4

41b

Field coil
3 1

Commutator min
29 1
14

Depth

of

dia

insulating mica

i6
C

3

8

0 64

3
0 85 4 6

0 5

0 8
0 020 0 031
ring
O

Pinion gear

i
C
Unit

N

m

kg

mm

m

in

fHb

Difference

in

height of pinion
0 3

Packing

5
1

0 012

0 059

Gear

ca

SE LOOS

ELll

r

Starting System

ELECTRICAL SYSTEM
RedueUon

DISASSEMBLY

I

Non

ucUon

r

tJP

magnetic switch assemb

ly

Remove magnetic switch

1

Remove

rtJpe

2

Remove torsion

3

Remove through bolts and

spring
rear

cover

CAUTION
Ba careful not

to

ring
O

damage

SEL011

Remove

4

holder

as

yoke armature and brush
assembly from center

an

housing
5

Remove

yoke

CAUTiON
Be careful not to knock brush
mutator or coil

against

Iny

com

edjacent

plrt

2
1

Remove

rear cover

Remove dust

thrust

washer

cover

E ring and

s

2

Remove brush holder setscrews

3

Remove through bolts

6

Withdraw

armature

and

shift

lever
EE61 6

SE LOtO

5

Remove center housing

6

Remove pinion gear

7

Lift up brush springs

8

Remove

I

brushes

from

brush

holder
SE L019

3

Lift

p brush springs
7

Remove overrunning clutch
Remove pinion stopper clip push
ing pinion stopper toward clutch
side

EE616

EEt50

4

Remove brush holder

EL12

EE277

Pinion stopper clip

9

Remove brush holder

10

Remove yoke

ELECTRICAL SYSTEM

Starring System

INSPECTION

t

Field coD

Continuity test between field
coil positive terminal and positive
I

J
0 5

0 8

mm

brushes

i

Correct
SE L030

f l

1

Commutator
SEL107

Bru h

prlnll

1T1in

Check brush spring tension
No

continuity

Spring

Replace field coil

tension

Incorrect

Non reduction gear type

14

between field coil
positive terminal and yoke
Ground test

EE021

17 7 N

13 7

2

1 8

3 1

kg
Check diameter of commutator

3

4 0Ib

Commutator minimum diameter

Reduction gear type
15 7
19 6 N
2 0

1 6

Positive
terminal

i

3 5

Non reduction gear

kg

32

4 4 Ib

mm

tYpe

11 26 in

Reduction geor type
29mm 11 14inl

Not in the
or

specified

value

Repair

Less

replace

than

specified

value

Replace

Sprin

scale

SEL 1 oS

Conlinuity

Replace

exists

field

coil

WI
SEL 109
SEL031

4

Bru h
Check

the

surface condition

brush contact

Replace

Loose contact

Check wear ofbrush
Minimwn

between each com

length

of
Arm ture
I

of brush

mm

2

0 47 in

Reduction goor typo
1 mm

Check

wear

Replace

mica

from commutator surface
Less than 0 2

0 43 in

surface

Sand lightly with No 500

sandpaper
Check depth of insulating

Undercut
Excessive

mbl

commutator

Rough

Non reduction goor typo

12

Ground test

mutator bar and shaft

0 031 in

to

0 5

mm

0 008

0 8 mm

in

0 020
EE022

EL 13

ELECTRICAL SYST M

Scarting System

Short

growler

test with
and

annature

piece of

a

PInIOn caN burin

Replace

Continuity exists
5

ndilctlon
Non

tester

iron

over

armature core

ear

Check clearance
metal and

armature

Iearingmetl l
I

to

Iii8taoI
type

Reduction gear type
Compare difference

of pinion when it u pushed out with
magnetic switch energized and when it

Irmatuinhaft

u

pulled

Less thin 0 2

by hand until it touches

specified

than

H

0 008 in

mm

Difference 1
03

value

1 5 mm
0 059

0 012

Replace

Ball b rln
Reduction

tyP

ar

inl

Pushoutwitb
electric

PoD out by
hand until

current

pinion stops

Holding outer race with fmger
bearing
Any play or bind
Replace

EEQ23

out

stopper

dearance

More

en in height

between bearing
shaft

rotate

Plate vibrates

1

r

0

Replace

6

Continuity test between
segments side by side
No continuity
Replace

two

r

Me

n

tIc switch

mbly

L

Difference

I

Con1inuity

between

test

e

sn

SEL016

terminal and switch body
No continuity
2

Continuity

naIs
r runnln

1

clutch

No

mbly

Not in the

tenni

continuity

Replace

Adjusting washer
0 6 mm 10 020 in

Repair

Apply

thielmo

e to gear case and rear
gre

bearing metal ond Ipply oil
to pinion slightly

Replace

cover

TESnNG
Perform nc
load
No

gear also must be in

duction
Non
With the
back to
the

tut

test

8type
Il

switch

remove

on

push pinion

all slack ond

clearance

en

between

p

me
ure

pinion

front edge and pinion stopper
Brush hold

Adjust

ASSEMBLY

CAUTION

Flywbeel ring
spected

value

08 mm 0 031 in

Inspect pinion teeth
Excessive rubbing

specified

by adjusting washers

M

Inspect smooth sliding of pinion

gear
Abnormal resistance
2

S and

Replace
between

test

r

J
t
b

Clearince 2

Ground test between negative side
of brush holder and another positive
side

3
0

25 mm

0 012

0 098 in
Voltmeter

Ammeter

Capacity 300A
SE LOSS

I

r

J

Specifications
Refer to

s
sn

L
Dlqnos
e
SEL015
EE025

Not in the

Continuity
EL14

exists

Replace

value

specified
by adjusting washer s

Adjust

I

Low

of test

speed

with

lold
no

and high

current draw

I

Tight

2

Bent annature shaft

field probe

dirty

or

worn
or

bearings
loosened

ELECTRICAL SYSTEM
3

Shorted armature coil

4

A

2

grounded armature offield coil

Disconnect lead wire which con
nects terminal M of magnetic switch
1

cur

rent draw

I

A

2

grounded

Burned

or

out

jrJ

open field coil

commutator

bar

Weak brush spring tension

1

Loose contact between brush and
commutator

3

I

and low

Low current draw

e

CI

SEL012

no

Dirty

3

Burned out

S rle

commutator

commutator bar

I

coil

Connect terminal

M

of magne

tic switch and negative e terminal of
battery with a jumper lead wire
2

Connect terminal

S

of magnetic

switch and positive tJ terminal of bat

I

r

wttch

netlc

Disconnect lea

Connect terminal

M

and posi

terminal of battery with

jumper lead

tery with
3

a

With

been made

of magnetic iwitch

M

2

tJ

bllltr

wire from termi

nal
tive

rn

a

jumper wire

in its

Connect terminal

2

3

connections

2

nect a

tery with

speed
Loo

and starting motor teoninal and

con

place
S

of magnetic

switch and positive tJ terminal ofbat

Thrust out of mica in commutator

load

co

Shunt

Failure to operate with high

Sysrem

ing
Sta

force

jumper
these

jumper

wire

negative

e terminal of

battery and starting motor body with
ajumper wire Plunger should be pull
ed in by force
4
Disconnect jumper wire from ter
minal

M

5

plunger

If

in with

jumper

terminal

M

continues

to

be pulled

wire disconnected from

shunt coil is
oJ

properly

functioning

wire
connections

having

i

if plunger is pulled in by

series coil i

a

Connect

properly function

ing

wire

3

Connect starter motor body and
negative e terminal of battery with a
jumper lead wire
4

Pull

pinion

gear all

with your hands
5
Release your hand

the way

CI

SEL014

from pinion

gear
6

1

out

If pinion gear returns to its origi
magnetic switch is pro

t

nal position

perly functioning

SE L013

EL15

ELECTRICAL SYSTEM

Starting System

SERVICE DATA AND SPEciFICATIONS
STARTER MOTOR

S114 l80F

Type

I

S114 229E

S114 255A

Non reduction gear type

Applied

UA
s

Terminal
No load

Outer diamet

Minimum

voltage

U SA

MfT

Canada A T

MfT

12

115

11

Current

A

Less than 60

Less than 100

Revolution

rpm

r

of commutator

mm

in

1

mm

in

mm

in

mm

in

in

height

of pinion

More than 39 1
54

I

Clearance between bearing metal
and armature shaft
between pinion

th

in

N kg lb

front edge and pinion stopper

IMore

mm

Brush spring tension

Difference

I

V

length of brush

Clearance

A T

V

System voltage

EL16

ction gear type
Red

model

6

ooolMore

12

13 7
14

than 7 000

More than 3 900

More than 29

047

11

17 7

18 3 1

043

15 7
4 0

16

14
1

2 0

19 6
5
3

Less than 0 2 0 008

03

5 0 012
2

0 098

3
0
0 012

5
1
0 059

4

ELECTRICAL SYSTEM

Charging System

CHARGING SYSTEM
When the voltage at terminal

DESCRIPTION
charging

The

higher than battery voltage

produced

circuit consists of a

nal

connects ihese
I

circuit between transistor
IC

voltage regulator

and

is

warning lamp
warning lamp
words

through

turn

rotor

over

by

current

produced

begins to oper
three phase alternating current is
produced in the stator coil This alter

S

negative silicon diodes

through

allows
the

specified

current

rotor

value

to

increasing

flow
the

generating voltage
In this manner output voltage from
the alternator does not rise above the

and

specified

value by the ON OFF opera
rotor coil through the IC

tion of the

monitors

The
voltage regulator
generating voltage to be applied to the
battery at terminal S When current

by the posi

flows

ground nor to the
reducing the voltage
to

is reduced to the

through

at the stator

IC

then
ZD

at the stator

transistor

is then closed

Tr 1

it

When voltage generated at terminal

Accordingly

F

Tr

thereby

generated

off In other

L

current neither

transistor

current does not flow from the

The circuit between terminal

When ihe alternator

tive and

point

current flow through the rotor is taken

L to excite the rotor

current is rectified

to

battery to terminal

ate

nating

equal

value

flows through
closing the circuit consisting of transis
tor
At this
TrJ and resistor R1

to that of terminal

which causes the charge

ground

on

is

specified

the zener diode

re

of the

flows along ihe route shown by the
arrow in Figure turning on the charge
terminal

L

the

exceeds

B

the

closed Current from the battery then

warning lamp and flowing

flows to

stator

At this point there is no voltage
differential on either side of the charge

in ON

Tr I

the

is

charge the battery While the battery is
charged
being re
the voltage at termi

battery an alternator incorporating an
IC voltage regulator and wiring that
parts
With the ignition switch

at

B

current

voltage regulator

IB

0

I

1

RJ

D3

is
CHARGE LAMP

011

J

0
a

0
a

7

L

R
T

t

STATOR COIL

D4

IGN ITION

t010

0

Q
T

R
A

Di
F

@

R2

Wv
R

SW1TC1 67

BATTERY

ld

e
zo
T

AI

T

E

ALTE RNATOR

itT

IC VOLTAGE

REGULATOR
SE LOSS

EL 17

ELECTRICAL SYSTEM

Chargmg System

SCHEMATIC
OFF

ACC ON

g

FUSIBLE
LINK

sr

g

Sf

I

IGNITION 1m
t

FUSIBLE

B

LINK

1

r
FUSE

CHARGE

IGNITION AND

WARNING

ACCESSORY RELAY

LAMP

5

L

I

BATTERY

E
ALTERNATOR
SEl100

WIRING DIAGRAM

t

f8

R

l

BATTE RY

m
L1NK@

fUSIBLE

iAgCOFF

Bj

BW

1 6

lffLBW

IG

6

if
r

s

J

IGNITION

WR

t

AND

ACCESSORY RELAY

l
@

IGNITION SW

1

R@

f@t

WB

I

a

0

c

0 0 0 0

s
0

0
0

0
0

0
0

0
0

0
0

JCJ
O

u

FUSE BmCK
c

G

I
B

@
If
fii
l
CJ
L

I

l
i
I

WhIte

@

CONDENSER

E

W

v

a

J
L

S
I

rt

B

ALTERNATOR

fil WR
W

fil

WR
W

@

I

II

i
S

d

COMBINATION METER
C

1
G

J

@
For radio noise

RGE

@

prewntion
SEL10

ELlS

III

ELECTRICAL SYSTEM

Charging System

CHARGING SYSTEM TROUBLE SHOOTING
conducting

Before

an

tlie battery

test make sure that

A

alternator
i

fully

test

30 Volt voltmeter and suitable
are necessary for the test

probes

can

be checked eaSi

to the

Inspection Table

The alternator

ly by referring

charged

With alternator side L terminal
grounded internal short occurs
when
diode is short circuited

@

out
Bumed

bulb Replace
and Proceed

Light

Disconnect

L 11 ht

Ignition

connector 5
L and g ound

OFf

L lead

switch ON
Check light
for operation

to

OFF

wue

Lag ht

Checl light
for operation

light ON

I

ON

Connect con
nec or S
l

I

F
or
und
term mal
Che ck light
for operalion

J

Lioht
e

ON

Ligh t OFF

rs

t

J

Faulty IC RG

1

FauI ty A

G
C

I

I

Faulty A C G

l

I

Faulty

Rep I ace

1

ON

Light

lead

Contact

Engine idling
Measure

1
Engine speed
500 rpm

I

ofvoltmcter
B
positive
terminal and negative lead
to L terminal

I

OFF

Light

1

I

and

Dim light

Engine idling
Check light
for operation

A

voltage
8

on

More

thanO
5

A

C G

I

1

the

across

and

L

thanO SV

I

OK

Mure than IS SV

I

Faulty 1C RG
Replace

Less

terminals
Dim

light

Ligh ting
switch ON
Check light
for operation

Light

J

OFF

Engine speed
1

500 rpm

Measure 8
teoninal volt

13

to

15V

age

11 Uao fully
21

AC G

Ar

Il
RG

IC

correct
4

porta

F
I

car

or

M od
Contlct

end

e
I

of

tip of

S

t

IC

ngulo

is in good condition
IOft 1118r
ren
tty AC G
nble
da
inspect and

eultv parts

nding F 18rmiMI
r with brush and

L

SAT

sure

tenninal is
nected

S
con

correctly

Engine idlins
Lighting
switch ON
Check light
for operation

Light ON

I Faulty

A

eG

I

ttKh

body

to

T

Make

ngulOtor

ICI

WMn
natoI from

61

be

ming lith

O K
3

clio

Light

Light

OFF

I

OK

E

on rear cover of

El19

111

Charging System

ELECTRICAL SYSTEM

ALTERNATOR
LRl60

Slip ingdia

more
at

listancc
Re

than 316

lOoe 680f I

0 244
3 8 n Rear bearing

Resistance per phuc
n
la 200C 680 I 0 051

Rotor

Front bearing

6 0 lcg

m

33

43 ft lb
Rear

cover

Ie ro1use rtBulator

Brushassembly
Unit

mm

Diode SOl plate

in

a

mbly

DISASSEMBLY
I

Remove

through

bolts

2

Separate

front

cover

Min brush length

Spring

7

5

0 295

255

2 501 3 383 N
345 I 8 99 12 17 oz

5

Pull rear bearing off rotor

pressure

SEL060

assem

bly
from

rear

cover

fA
1

UD

SE L062

l

J
4

Separate

rotor front cover

Remove setscrews from
SELOSl

3
I

Remove
Place

pulley

SEL064

bearing

re

tainer

and fan

rear cover

side of rotor in

SE L06S
a

vice

2

Remove

EL 20

pulley nut

SEL083

ELECTRICAL SYSTEM
6

Disconnect stator coil lead wires

2

Charging System

Diode

Ground test

from diode terminals

Perform

a

continuity test on diodes
using an ohmmeter

in both directions

Circuit tester terminal
Conduction
Positive

plate
Holder plate
Diode
SE L069

plate
Rear

Continuity
7

exists

Replace

cover

rotor
Diode
terminal

Remove brush assembly with IC

I

I

terminal

EE623

Negative

I

I

Diode

Yes

terminal

plate
plate

Holder

Diode

No

terminal

plate
Rear

Nn

Yes

cover

regulator
8

Remove diode holder

CAUTION
Ind insullton in order
peckin
10 thlt they cen be placad back in
their originll p
or locations from
which they were removed

Po ltlve dlod

Pllce

Stator
I

Continuity

test

t
e

j

0

ca

l I

EE536
0

1

Diode holder plate

2

Positive diode

SEL070

Conduction test is N G
EE624

diode
No

continuity

Replace

stator

Me

INSPECTION
Rotor

Continuity

2

Replace

assembly

tlve diode

Ground test

test

@
EE537

SEL071

cover

3

Rear

4

Nega live diode

SEL068

Conduction test is N G
No continuity

Replace

rotor

Continuity

exists

Replace

stator

Replace

diode assembly
EL21

ELECTRICAL SYSTEM

ChargingSY tWn
dlode
Sub

Check brush

3

pig

tail fur

damage

Replace
Check brush spring pressure
Measure brush spring pressure with
Damaged

Direction of current

4

brush

2

projected approximately

mm

4

Before

installing front and rear
push brush up with

sides of alternator

and retain brush

fmgers
brush

into brush

lift

lift

by inserting
hole from

outside

0 08 in from brush holder
Bru

Spring
2 501

255
8 99

3 383 N

o

345 g
12 17 0
pressure de

When brush is worn

epproximatoly

crease

0 196 N

0 710 1 per lmm O 04 in
Conduction test is N G
diode
sub

1
00

pressure

i

20 g
r

Replace
2

CAUTION

mm

10 08 in

If it

iliode
sub
isneceSSlry to remove
lead
wire
with
8
diode
pinch
pair of
to
heat
transfer
from
plien
prevent
solde ing iron to dil de when unsolder
ing connection

nT

I

eeOEf

EE541

Not in the

Brush
I

Check

smooth

movement

specified

value

Re

place

of

5

brush
Not smooth

ASSEMBLY

and clean
2

Check brush for
Min

brush

7 5 mm

wear

pushing

Assemble alternator in the

length

order

0 295 in

follo

of

disassembly

lead

the

noting

wire

l
C

Through

When

as

fast

A
installing diode
insulating bushing

install

rectly
Tighten pulley

as

ter
cor

nut and make sure

that deflection of V groove is proper

Pulley
44
5

Less than the

place

EL 22

specified value

Re

lift

the operation

3 4

33

and

brush lift

cover

Tighten through bolt

3

l
C

of

6

possible
2

pull brush

outside

soldering each stator coil
assembly terminal

to diode

carry out

minal

toward

pull

nut

59 NofII
6 0 kg
m
43

lb
ft

Vllroove deflection
0 3 mm 0 012 in

rear

by

toward center

Do not

reverse

front

installing

by pushing
as

damage slip ring sliding urface

ng
When

1

EE651

After

sides of alternator

Check brush holder

bolts

39 N m

0 35 0 40 kg
2 5

2 9 ft Ib

m

it

will

ELECTRICAL SYSTEM

IC VOLTAGE

1

Resistor R 1

REGULATOR
2

Rv

circuits

incorporating tran
interrupt and

3

Batteries

4

DC voltmeter

admit current flow to the alternator
thus

rotor coil

voltage

at a constant value Unlike in a

relay

an

ransistors

are

2

electron

or

compact sealed case The
relay is soldered to the
brush assembly inside the alternator
Should any problem with the relay
arise it should be replaced together
with the brush assembly
On the
circuit
a
diode is
charge warning lamp
generating voltage
when

the

x2

VI

10 to 13 volts
Ifthere is such

1

x

V

voltage
10

are

a

Regulator is functioning properly

battery

at

I

13

to

volts

1

Ie

Regulator

Re

is out of order

L

JI

regulator
L

L

J1

r

l

I

crT

I
6

Hold

3

Measure
Below

voltage

2 0

variable resistor Rv at the

voltage

VI 10
Measure voltage V4

same

V2

volts

Regulator

as

13

volts

is

Ic

L

1

egulato

IC

n

cr

EFLSB
SE LOB6

e

t

l r
SE LOBB

Voltage

4

INSPECTION

same

time

as

outlined in

assemb4t and Assembly
the heading Alternator
CAUTION
When performing

test

Dis

accessories are

within 20 to

charge

or

test

required

SEL091

Figure

replace

Re

26 volts

either

or

both

batteries

continuously

1

Ie

regu tor
la
L

generate

following

J

section under

heat If it
becomes high temperature stop test
ing for a while to avoid burning
may

1t

Measure voltage V 3
Not

Remove IC regulator and brushes at

11

umlol

V4 is within specified range

indicated in

The

to

functioning properly

L

I

SEL090

SE LOB7

equal

1

resistor

1

Ie regulator

3

and

circuit

the

variation

replace battery

monitor

monitored

voltage

between

No variation

at the stator so that

voltage
during
reharging the charge warning lamp is
turned
off Accordingly
a
charge
warning relay is not employed in this
charging

V2

enclosed

electronic

to

Rv
voltage

of

300 ohms

Voltage V 2 should increase at a
point to as high as voltage

in a very

attached to the stator coil

measure

resistance

from

certain

30 volts

Measure

charge

I

x

I and 2

Not within

is

transistors

employing

utilized These

to

maintaining its output

mechanical type regulator
ic

o

resistor

terminals E and F

12 volts

sistors These transistors

variable

O to 300

decrease

Gradually

and

ohms 20 watts

The regulator consists essentially of

I

x

Variable resistor

DESCRIPTION

integrated

S

10 ohms 20 watts

Charging System

equipment and

II

i
T
SE L089

EL 23

ELECTRICAL SYSTEM

Charging System

Example
When
is 4O C

7

voltage V4

temperature of regulator case
I04OF regulator is normal if

is within range ofl4to 15

volts

wlftng

as

shown in

and

Fugure
repeat steps 5 and 6
If voltage V 4 is 0 5 to 2 0 wolb
higher than that in step 6 regulator
is functioning properly If it i
not
replace

1

o

o
o
o

Reconnect

j

Ie regulator

u

0
z
o

J

1

IU

I
m

M

cHI

Rc

ul tor

I

case

IIIIM

ll21l

10

IwICIJlICIUICIMl l UlGl

temperature

Oc OF
SE L092

EL 24

r

SEl093

ELECTRICAL SYSTEM

Charging System

SERVICE DATA AND SPECIFICATIONS
ALTERNATOR

Type

Applied

lR16047

model

All
V A

Nominal rating

60
12

Ground polarity

Negative

Minimum revolution under no load

When

Hot

14 volts is

output

Pulley

applied

current

Less than 1 050

rpm

More than

A rpm

ratio

Regulated

output voltage

45

2 500

More than 60 5 000

2 09

v

144

Minimum length of brush

mm

in

Brush spring pressure

N

oz

Slip ring outer diameter

mm

g

in

7 5

501
2

383
3

0 295

255

31 6

15 0

345 8 99

12 17

244
1

EL 25

ELECTRICAL SYSTEM

Ignition System

IGNITION SYSTEM

R

og

1

e

t

t
WB
BW

iP
w

0
0
lJlJ
Jf

@

1

IGNITION AND
ACCESSORY RELA

9@

IGNITION SW
B

@

rw
0

0

i

E

0

0

0

f

0

0

0

0

r

0

o

o

0

0

0

0

0

Q

o

0

0
o

@
@

FUSE BLOCK

California models
Non

California models

f

f

l

ia models

Califomia
INon

Q

models

TERMINAL BLOCK
VB

O

G

a

L

a

@
CIl

DISTRIBUTOR
we
L

e

@

cJ

B

0
n

I

I

I

8 Q

@L

@
J

I

SPAR K PLUGS

@

ff

JiljlJ1J1J

IGNITION COIL

if

J

0
u

@L

SPARK

j

J

@

@

IGNITION COIL

PLUGS

ff

IGNITION COIL

SEL 102

EL 26

ELECTRICAL SYSTEM
CHECKING PROCEDURE
condition

No start

once

Sparking
1

Turn

ignition

indicated

Spark

the problem before continuing If all
tests indicate
OK
replace the Ie

occur

OK

switch to

1C ignition system and
component parts need not be checked
beyond this

OFF

Disconnect EF1 fusible link

No
con

spark

fault is found correct

a

Ignition Unit

In this case

check

position
2

JUDGMENT

1C ignition system

If

Ignition System

occurs

sparks

on

THE

UNIT

HAVB

DO NOT
UNTILL

BEEN

INDICATE

REPLACE

ALL TESTS

COMPLETED

AND

OK

are

intermittent
nector

N G

1C ignition system

CAUTION
enlllre thet

connector

3

OFF

ignition

switch

Disconnect

high

uslna

tension cable from

distributor
4

Keeping high tension cable end

to 5 mrn

0 16 to 0 20 in

engine block

away from

rotate starter motor and

check whether sparks
clearance

4

occur

across the

a

to

sstem

IC lanltlon

position

ronge

Manual testlna of

2

voltmeter

1C Ignition System

let
is best checked

accurately

the

If
it

0 to

run

for

0 to 1 0000 0

oOOn
50

5 to

15 minute

Thi

will

using J 26350 Transistor
Ignition
Analyzer However if an analyzer is

componenu

not available

diagnose intermittent problems

V OM

a

may

transistor

be

used

diagnose

to

ignition malfunctions While

this method requires
nevertheless
Follow

milliammeter

ohm
volt

the

provide
steps

more

time

accurate
in

the

it can
results

sequence

perature
3

and

with

bring all
normal operating tem

closed
to

can

following

tart the vehicles and

possible

hood

following
which

in the

0 to 20V D C

10V A C

the

multitester

a

USI

measure

Before disconnecting EFI fusible link

performing

When

teltS

Proceed with tests below

is in

1

will make it

easier to

It is not necessary to disconnect

the harness connecton when perform

ing

the

tests

which

follow

Simply

insert the meter probes into the back
of appropriate connector cavity

EL27

Ignition SyrnJm

IC

ELECTRICAL SYSTEM

IGNITION

SYSTEM TROUBLE SHOOTING

TEST
1

TEST METHOD

CONDITIONS

Battery Voltage
no

Ignition key in
position

load

Reading
olts

12

2

RESULT

OFF
11 5

Connect voltmeter

12

5volts

Low

J
t

scale

2

Battery
Cranking
VoUage

Highscale

Battery charging

Red

positi

pOlitive

e

Read and record battery

selector

voltage reading

I

Black negative

2

Connect yoltmeter

as

appropriate

volts

Remove coil wire from
distributor cap and

Secondary

1

Wiring

the resistance

high tension

Proceed

K

to

Step 3

Battery charging
or
starting

Voltage reading

system

less

Refer to

applicable

secti9ns

in

than 9 6

volts

Faulty
rvice

Manual to correct
the

situation

D

Conn eel ohmmeter
illustrated and

Battery O

system

Record voltage reading

Battery cranking
voltage

SEU03

3

voltmeter while

cranking engine f9 I ap
proximately 15 seconds
4

Voltage reading
greater than 9 6

scale

Sen ice

the situation

illustrated and set to

Read

Refer to

Manual to correct

D

ground it
3

Below 11 5 yolts

starting

Faulty
applicable

sections in

Battery voltage

I

or

system
3

l

system

scale

Scale

1

Proceed to Step 2

as

ilIusua ted tnd sct to

appropriate

ACTION

as

measure

of each

cable

Resistance

Distiibutor cap and

readings

high tensioo cables

less than 30 000

QK
Proceed to Step 4

ohms
Resistance

Replace high tensiou

readings

cable

greater than
30 000 ohms

distributor cap

California models
7 400
000
11
ohms
Gllifornia
Non
models
8 200 12 400

Ignition coil sec
ondary windittp

s

and

or

as

required

EF125
4

Ignition Coil
Secondary

I

Ignition key
position

2

Coil wire removed from

in

OFF

Circuit
coil
3

Connect ohmmeter

as

OK
Proceed to step 8
for California

ohms

illustrated
Resistance reading
not between
7 400
11 000
ohms
California models
or 8 200
12 400
ohms Non
California models

Terminal

SEU04

S

Power Supply
Circuit

L

Reaeptacle

Connect voltmeter
illustrated and

appropriate

35

set to

115

12 5 yolts

Proceed to

Step 6

scale

Below 11 5 volts
2

Faulty ignition coil
replace

Turn ignition key to
ON position

Check wiring from
ignition switch to
ICunit

catifomia
Non
models only

5EL078
Continued

EL 28

n

xtpage

ELECTRICAL SYSTEM

TEST METHOD

TEST
6

Power

Ground coil output wire
while performing test

Supply

Circuit

Cranking
2

RESULT

Connect voltmeter as
illustrated and set to

Voltage reading

appropriate sCale

below

from

3

Tum

key

START

to

observe

and

7

8

an

Proceed to Step 7

6 volts

Voltage reading
more

cranking voltage

battery

or

ignition switch
wiring from

Check
and

switch to

below

is cranking

and

is

than I volt

voltmeter while engine

canfornia
Non
models only

battery

cranking voltage
t

it

position

is

less than 1 volt

and is greater

distributor cap and

ground

System

ACTION

CONDITIONS

PUU out coil wire

Ignition

Ie unit

is below

8 6 volts

SE L079

Connect voltmeter

Ignition

illustrated and set

Primary
Circuit

5
11

12 5

volts

Proceed to

Step

9

Step

8

scale

appropriate
2

as

to

Ignition key
position

in

ON

Below 1 15 volts

Proceed to

Ignition key
position

in

OFF

California models

Ignition coil primary

california
Non

mode1sonly
8

Ignition

SELOBO

Coil

1 range

Primary
Circuit

2

104

california
Non

Coil wire removed from

0 84
Connect ohmmeter

and

102 ohms

as

Resistance

illustrated

reading

not between
104
127 ohms

California models
or 0 84
1 02 ohms

I Connect voltmeter

Unit

Ground

illustrated

Circuit

appropriate
2

Pull

out

ground
3

coil

0 5 volts

or

less

tifomia
ca
Non

up
Pick

Coil

while

I

cranking

II

0
dD
up
Pick

Coil

Tum

START

key to

0 5

volts

Proceed to Step 10

ground to
battery including
battery cable

and observe

connections

engine

Engine

above

is at

or

Approximately

Proceed to Step 11

400 ohms

in

Ignition key
position

OFF

Ohmmeter reading

Check

op
pick

substantially

and

to it

ceeds

3

Connect ohmmeter

arr

SE L082

Ground coil secondary while cranking

I

te
r

scale

Engine is at or above
normal operating
temperature

2

Connect voltmeter and
set to the low

3

scale

J

Turn

key

position

a

c

to

and

the engine
SE L083

volt

the

wiring

coil

falls below

400 ohms

specifications
Needle

If No

Wavers

condition stiD exists
replace IC

@
Needle steady

Sj

is cranking

ignition unit
Check physical con

Check wiring and

observe the
while

Spark

dition of pick up
coil and reluctor

START

needle movement

california
Non

or

ex

as

illustrated and set to

Output

models only

coil

temperature
2

california
Non

Faulty ignition
replace

chassis
More than

normal operating

l

models only

to

coil and IC unit

is cranking

SELOS1

Ground coil seoondary

ignition switch

Check distributor
ground wiring from

wire from

voltmeter while

Resistance

switch

scale

it

position

10

ignition

wiring from

as

and set to

distributor cap and

models only

K

california
Non
models

EE567

9 JC

winding O
Check

models

coil

3

127 ohms

@
SEL 105

connections between
up
pick

coil and IC

ignition unit
Continued

n

xt

pIIg

EL 29

Ignition System

ELECTRICAL SYSTEM

TEST

TEST METHOD

CONDITIONS
1

12 Power Supply
Circuit

Ie

Connect voltmeter
illustrated

ignition
2

Turn

ON

ACTION

as

and set to

appropriate

uni

RESULT

II S

12 Svolts

scale

ignition key
position

to

Below 11 5 volts

Check wiring from
ignition switch Co
ICunit

California models
only

EL30

SEL084

ELECTRICAL S YSTEM

Ignition System

DISTRIBUTOR le type
California models

Cap aSJembly

Carbon point
Shaft

a

mbly

g
I

Y

Ro

orhead

RoUpin
RelUclor

Cap

setter

S tor

r

Magnet

it
ICignitionunit

j

G

J

ll
Ell

J

Setter

unit

Vacuu m

controller
ow

connecting

I

li@
r

Q
Il
@

Breaker

plate
assembly
Packing

Rotor

1

shaft

sembIY

t
Thru

w

er

GovernorWeight

Cl

@
COllaJ

se

c

Governor

ng

SE lOOl

EL31

ELECTRICAL SYSTEM

Ignition Symm

CaJifomia
Non

models
6

Shart uoembly

J

cap

mbly

Rotor bead usembly

RoUpin
Reluctor

0

Housing

Stator

Magnet assembly
Grommet
up
Pick

coil

usembly

Ie ignition
unit
Vacuum

controller

Breaker plate

mbly

Rotor shaft

usembly

CoUar

Governor Prins
Governor weisht

SE L201

CHECKING AND

Vacuum

ADJUSTMENT

nical parts

steel balls

I

breaker plate

ad

Check

Cap and rotor head

leakages

Check cap and rotor head for dust
carbon deposits and crack

2

at

Check

mechanism mecha

ce

vacuum

inlet for signs of

st el balls or

vacuum

diaphragm

replace

assembly

for air

found

replace

vacuum

Centrifugal

ad
al parts
mechanil

controller assembly
3

Specifications

moving
If plate doe

EL32

as an

grease to

leak

Advance mechanlsma

D

if necessary

its connection

If leak is

Refer to

pivot Apply

or

Inspect breaker plate for smooth

When
i

not move

smoothly

this condition could be due to sticky

cause

traced to

nical

parts

ce

of engine malfunction
advance mecha

centrifugai
use

distributor tester

check its characteristics

to

ELECTRICAL SYSTEM
If nothing is wrong with its charac
teristics conceivable causes are faulty
abnonnal

or

others

So

wear

do

of

not

driving part

or

disassemble

it

10

Ignition System

Mark rotor shaft and drive shaft

Remove

packing from

shaft and

remove

the top of rotor

rotor shaft

improper character
osely rotor shaft assem

In the event of
istics check

c

governor weight and shaft

bly

If any of the above parts

functioning

place

the

mal

are

parts
SE L004

DISASSEMBLY
California models

EE706

7
I

Take off cap

and

remove

rotor

fixing plate
housing and fixing plate

Remove
Mark

head

II

Pry reluctor from shaft

2

Mark

one

of the govemor springs

and its bracket Also mark one of the

weights and its pivot pins
Carefully unhook and remove
governor springs
13 Remove governor weights Apply
governor
12

after dis

grease to governor weights

assembling

SE

LOOS

SEL002

Non California models
8

Remove collar

CAUTION
When

removing

not to

distort or damage tha teeth

Remove IC

3

reluctor

ignition

be careful

1

Take off cap and rotor head

2

Remoye

3

Remove stator and

4

Remove vacuu

unit
ignitio
magnet

IC

controller

unit and unit

setter
4

Remove stator

and magnet

EE104

9

Remove

rotor

shaft

and

EE746

drive

shaft

5

Using
puller pry

SE L003

pry bars

two

or suitable

reluctor from shaft

CAUTION
Remove

5

vacuum

control

When

assem

not

bly
6

to

reluctor

removing
distort

or

damage

be careful
the teeth

Remove braker plate
Before

disassembling

mark housing and

be

fixing plate

sure

to
EE705

6

Remove roll

7

Remove

pin
up
pick

coil

assembly
EL33

Ignition System
8

ELECTRICAL

Remove breaker

piate

VSTEM
S

assembly

EE706
EE703

Mark

12
and
9

Punch knock pin out and

remove

pinion

its

ofthe gov

one

bracket

rnor

Also

spring

mark

one

of the governor weights and its pivot
unhook

Carefully

governor
14

and

remove

Remove

installing pinion

on

shaft

to

pinion gear correcily
position where it was installed
Apply
S to the top of rotor
grei

shaft

as

required

5

springs

ply grease to
disassembling

When

be sure to install

4

pins
13

3

governor weights
governor

Ap
weights after

Check the opera1ion of governor
before installing distributor on engine
6

enter
properly i
tightening

stator and reluc

tor before

Stenderd eir gep
0 3

@W

0 5

0 012

mm

0 020 in

CeIifomia model
EE704

3
10

Remove

rotor

shaft

and

drive

shaft assembly

ASSEMBLY
To

assemble

reverse

the order of

disassembly Carefully observe
lowing instruction

the fol
03

012
10

SEL0ll6

Celifomia
Non

CAUTION
Before

5 mm
0

020
0

in

model

inslallinglC ignition unit make
R1rfaces of IC ignition unit

sure

mati

and

distributor are clean and free from

dust sand and moisture

EE705

Align match marks
are

assembled

to

so

that part

their original posi

tions
11

Mark rotor shaft and drive shaft

2

Ensure that

EE148

reluctor is

Remove packing from the top of rotor

oriented when installing

shaft and

ways drive in new roll

unscrew rotor

Remove rotor shaft

EL34

shaft setscrew

in

Figure

on

pin

properly
shaft Al
as

shown

7

Adjust ignition timing after distri
on engine

butor is installed

ELECTRICAL SYSTEM

IC IGNITION UNIT

conductor

Ie device and is mounted

3

Duty coritrol

in the distributor

DESCRIPTION

The

ignition
lowing circuits

California modals

Spark
In the conventional distributor the

ignition timing

is detected

by the

it

tor

is detected

by the reluctor

on

the shaft and the pick up coil provided
in place of the breaker The amount of
magn

tic

flux

pick

up coil is

tor

rotates

passing through the
changed when the reluc

and

then

the

electrical

generated in the pick up coil
This electric signal i s conducted
into the Ie ignition unit which makes
and breaks the primary current run
ning through the ignition coil and
generates high voltage in the secondary
winding
The centrifugal and vacuum ad
vance mechanisms employ the conven
signal

is

tional mechanical type
The Ie

ignition

unit utilizes

a

semi

timing

unit has the

fol

This

signal

circuit

signal ffi9nitoring

up coil

detects

the

ignition
pick
signal

from the distributor

sent

and

amplifies the

Lock preventing circuit
This circuit cuts off the ignition
coil primary current when the ignition
2

switch is ON and the engine is

sta

periods in one cycle of ignition
operation
This is equivalent to the dwell angle
of the conventional point type dis
tributor In order to provide high
performance spark firing over a wide
range of driving speeds this duty can
be controlled by the source voltage
and the ambient
as

4

tionary
If the ignition coil primary current
is allowed to flow under such condi
tions excessive current will be drawn

temperature
by the engine rpm
Power switching circuit
This

can

result

in

an

abnormal

used

To ensure efficient
Ie

ignition coil
This

is

circuit

to

as

igniti9n

well

make

break directly the primary circuit
rent of the ignition coil

because of low internal resistance of
the

ls the ratio of the
contn

ignition coil primary current ON OFF
time

circuit

cam

and breaker arm while in this distribu

circuit

This circuit

IC

Ignirion System

or

cur

operation of

the

unit these four circuits are

manufactured in

one

assembly

temperature rise in the ignition coil or
discharged battery These malfunc
tions

can

preventing

be

prevented by

this lock

circuit

California models
swih h

Ignition

8

To distributor

To distributor

Ex side

ffi

f

Battery

8

I

In

A
I

I

f

8

1

I

I

Ignition

r
1

Lo

101

I

8

I

I

101

s

01

I

Ignition

coil

side

coil

E

j
Spark timing
signal monitoring
circuit

Lock

ill

Duty
control

ClfCU

prevellting

circuit

SEL085

EL35

Ignition Smem

ELECTRICAL SYSTEM

Non California models
The

Ie

unit

ignition
Ie

conductor
mi

mounted

on

This
utilizes

device

the side

and

a

discharged

is

surface of the

tions

ing
I

has the follow

3

abnormal

Spark timing signal monitoring
detects the

value

prevented by

this lock

flow

circuit

current

time

cycle of ignition

in one

OFF
ON

operation

ary

and the ambient temperature
as by the engine rpm

This is

tions

4

equivalent
In

Power

excessive current will be drawn

This

circuit is

break

the

current of the

Califomia
Non

order

to the dwell

angle
point type dis
to provide high

switching c

because of low internal resistance of

ignition coil

IC

power

witching

operation

manufactured in one

The

of the

these five circuits

unit

ignition

are

perfonnancespark firing over a wide
this duty can
range of driving speeds
be controlled by the source voltage

If the ignition coil primary current

the

trough

assembly
IC is utilized

conductor
semi

for all these circuits except the power

of the conventional
tributor

the current

that excessive current will not

To ensure efficient

ignition coil primary

periods

controls

circuit

so

circuit

ignition
signal sent from the distributor pick
up coil and amplifies the signal
2
Lock preventing circuit
This circuit cuts off the ignition
coil primary current when the ignition
switch is ON and the engine is station

is allowed to flow under such condi

This

malfunc

This circuit controls the ratio of the

circuit

Current limiting circuit

5

ignition coil or

Duty control circuit

circuits

This circuit

an

These

battery
be

can

preventing
ignition unit

in

result

temperature rise in the

distributor
The IC

can

directly

well

to

circuit

circuit The power witching
power transistor and

uses one

the circuit is arranged on the ceramic
substrate together with resistors capa
citors and diodes
Each component part ofthis unit is
highly reliable however should any
part

rcuit

used

the

as

switching

be

found

faulty

the

entire

assembly must be replaced
make

primary

or

circuit

ignition coil

models

Battery

Ige51Ch

CD

i
B
eh

I

I

J

101

101
2P

J
L

rOl II

Ignition coil

connector

rBCl

r

ti ing sig al
monitoring ClICUlt

Spark
G

Duty control
circuit

Power

switching

circuit

R

Pick up coil

Lock

Current

Preventing circuit

circuit

timating

Lu
Distributor

IC ignition unit

SEL094

EL36

ELECTRICAL SYSTEM

Ignition Sysrem

SERVICE DATA AND SPECIFICATIONS
DISTRIBUTOR

I

I

o5
D4N9

Type

pplied

model

04
D4N9

California

I

Califomia
Non

I

Transmission

I

Firing

order

I

134 2

I
I
I

Rotating direction

I

Coun terc10ckwise

Air gap

mm

Cainsulation resistance
Rotor head insulation
resistance

I cap

carbon point length

I

A T

0 5 0 012

3
0

Mn

mm

M T

0 020

More than 50

More than 50

in

I

10

00

39
0

12 0 47
00

3
9

70 2 76
50
3

Vacuum advance

3 50

mmHg inHgH

50
3

12 0

90

3
13

50
2

54
3

100

3 94

3
33

100

3
33

11 0

10

250 9 84

54
3

50
2

14 7

33
4

110

33
4

3
33

100

3
33

250 9 84

700
00

250 9 84

700
00
1 100

50 1 500

12 0

90

2 50 147

3 94

3
9

70 2 76

12 0

90

100

50 1 700

distributor rpm

50
2

54
3

100

50
3

00

3
9

70 2 76

12 0

13 3

00 900

Distributor degree

00

3 50

250 9 84

Centrifugal advance

3
9

70 2 76

90 3 54

Distributor degree distributor
kPa

AT

I

Mn

Canada

M T

1

in

D4K9 1O

09
D4K9

700
00

30 1 000

30 1 000

60 1 600

60 1 600

IGNITION COIL
CIT 38

Type

Applied

model

California
Non

California

Primary voltage

v

Spark gap

mm

12

680 F

More than 7

in

Primary resistance
at 200C

CIT 30

0 28

104

27
1

0 84

74

110

8 2

1 02

n

Secondary resistance
at 200C 680F

4
12

SPARK PLUG

Applied

model

s A
U
Standard

Type

Size Screw dia

Plug gap

x

BP6ES

Hot

BP5ES BP4ES

Cold

BP7ES

reach

Canada

mm

in

mm

in

BPR6ES
BPR5ES

BPR4ES

BPR7ES
14

08

x

19

0 55

0 9 0 031

x

0 75
0 035

Optional

for

sA
U
EL 37

ELECTRICAL SYSTEM

Lighting Systems

LIGHTING SYSTEMS
CAUTION

Before

starting to

work

on

any part of electricel system disconneet battery

BULB SPECIFICATIONS

ground

ceble

COMBINATION

SWITCH
Item

Wattage

SAE
trade number

REMOVAL AND

INSPECTION

Headlamp
Type I High
Type 11 High

Low

Front combination

50

4651

1

40 60

4652

2

Remove steering wheel
Remove steering column

3

Disconnect all combination switch

lamps
27 8

Tum signal Clearance

1157

wires
4

Rear combination lamps

Loosen

move

Stoprrail
Turn signal

27 8

1157

27

1156

Side marker lamp
Front

34

158

Rear

34

158

27

Back up lamp
license plate lamp

5

retaining

screw

and

re

combination switch

To

install

combination

switch

a1ign protrusion on switch body wiih
hole on steering column and tighten
retaining screw

1156

80r 10

Interior lamp

cover

67

10

Spot lamp

8

Step lamp

5

Luggage compartment lamp
Hatchback

5

Hardtop

34

158

4
3

158

Combination meter
Illumination and brake warning
Waming and monitor lamp

lamp

Turn signal and beam indicator

lamp

Cigarette lighter illumination lamp
on control
Air
illumination lamp

Heater

2
34

158

14

panel
4
3

158

lamp

34

158

Cruise control switch lamp

14

Glove box

Selector lever illumination lamp
AT model

EL38

34

158

SE L283

ELECTRICAL SYSTEM

LighringSystems

INSPECTION
Test
with

switch

continuity through
lamp or ohmmeter

a test

1st

OFF

2nd
N

L

ON

OFF

OFFI

JI

o

ON

1r
o

111f UUJUUU I

I

iF

90
TURN

1

I

SIGNAL

WIPER AND WASHER SWITCH

SWITCH

LEVER

1

i NIL I

111
12

1i

If
LIGHTING

1

1

1ST

ABC

2ND

A Be A 8

C

I

tf

IOFF X

HI
l

WITH
TINE

CONTRod

f

I

zuni
0

INT L O

tJ tu rq

SWITCH

OFF

WIPER

1

AAQ SWITCH

I

M UMJ

nON
22

SEL310

EL39

Lighting Systems

ELECTRICAL SYSTEM

HEADLAMP
SCHEMATIC HEADLAMP

FUSIBLE LINK

FUSE

HEAOLAMP A H

udi

c
r

@

LIGHTING SWITCH

C0

l

BATTERY

HEAD LAMP MONITOR

I

c
o

j
l

FUSE

HEADLAMP SENSOR
HEAD LAMP LH

CD
@

t

rI

1

SEL371

TROUBLE DIAGNOSES AND CORRECTIONS
Condition

Probable

Headlamps do not come
either high or low

on

Corrective action

cause

Burnt fusible link

Correct

cause

and replace fusible link

Burnt fuse

Correct

cause

and replace fuse

beams
Loose connection

or

open circuit

Faulty lighting switch
High low beam comes

@

CD

and

@

Check wiring and

or

repair connection

Replace if necessary
on

when

CD

terminals of hamess

and
con

lighting switch are connected with
including lOA fuse

nector to
test lead

Faulty headlamp

Replace if necessary

sensor

No ground

High beam

cannot be

switched to low beam
or

vice versa

Faulty lighting switch
High low beam comes

@

D

and

nector to
test lead

Headlamps dim

Clean and

@

lighting

terminal

Replace if necessary
on

when

CD

terminals of hamess
switch

tighten ground

are

and
con

connected with

including lOA fuse

Partly discharged

or

down
run

battery

Measure

recharge
Inoperative charging system

Measure
If it

specific gravity of electrolyte
replace battery if necessary

voltage

is

at

headlamp

less than

12 8V

system for proper operation
Poor ground

Headlamp lights
only one side

EL40

on

or

loose connection

Clean and

Loose headlamp connection

Repair

Faulty headlamp

Replace

and

or

or

tighten

terminals
check charging

ELECTRICAL SYSTEM
WIRING

Lighting Systems

DIAGRAM HEADLAMP

R

ill
FUSIBLE
LINK

OW

@

o
BATTERY

I

t

r
LIGHTING SWITCH

HEADLAMP R H

I

ir
fi

RY

@

RR

V

@
RW

1
Tr

R

OFF

4

1ST

4

R

D

I

2ND

r

4

I

a

661 t

lL

RY1th

jR
Y RW

II

R r

0

Ll3

gXZ 6 6 g

H

@

II
r

COMBINATION
Green

METER

White
J

g g giJ

QrJ @

l

lQ
g
I

gglrgg

@

I
CI

I

O U

I

@

HEADL

MP

MONITOR

HEADLAMP LH
HEAD LAMP

0@

SENSOR

@

D
RY

DO
DO

RL
RW

@

@l
@

SE L372

EL 41

ELECTRICAL SYSTEM

LIGHTING SWITCH
Refer

to

AIMING ADJUST
To adjust vertical aim

Combination Switch

adjust

to

screw on

CD

The headlamp

is located on

sensor

relay bracket Refer

Turn

adjusting

use

U

side of headlamp

Location

the

Low beam

upper side of headlamp and
horizontal aim use adjusting

screw on

HEADLAMP SENSOR

ENT

headlamp

on

230 48 43

Horizo tal
center line
Ofheadlam p

I

Th

Wf
fP

t

Q2

i

to page EL

i
il
Gwu

105

Inspection
Ught swi1ch

low beam

n

Lighting Systems

7

s

W

R

j

Unit

nun

in

BE298D

on

1
Before
ensure

checking headlamp

that

11

bulb

meet

sensor
SEL291

Adjust headl mps
edge of hot pot is
to heedl mp height

specifi

cations

1

Vertical adjustment

2

Horizontal

adjumnent

b

Dotted

lines

in

SO

that

upper

equ 1 in h

illustration

ight

show

of headl mp

canter

High beam
Bafor

headl mp

king

m

ob rve

djustment

the

Imlng

lamps

instruction
11

Keep

With

following

tires

infl ted to correct

Place

car

same
Bulb removed

flat

tum

to

tester

on

one

and

urf

2 volts
12volu

c

See

th t there is

cool
SEl373

nt

correct

engine
level

and

no

oil

weight pl

load

in car

filled up

to

H

full fuel tank

other than the driver

or

equivalent

ced in driver s position

When performing headlamp aiming
adjustment use an aiming machine
aiming wall screen or headlamp tester
For
aimer

it

should
and

of any
be in good repair
used according to

Unit

8

respective operation manuals supplied
with the unit
If any aimer is not available aiming

adjustment

can

mm

in

BE2990

instructions

operating

calibrated

EL42

outer

lamps

headlamps

U

and

e
All bulbs in good ordllr

II unit

high beam

pressures
b

type

covered

be done as follows

b

Adjust high beams
of light is p rallel
body
Dotted

lines

so

that main axis

to center

line of

in illustration

show

center of headl mp

ELECTRICAL SYSTEM

Lighting Systems

EXTERIOR LAMPS
Do not

CAUTION

wipe

lens surface

using

cloth

dampered

with

gesoline

SCHEMATIC TAIL CLEARANCE SIDE MARKER LICENSE PLATE AND STOP LAMPS
FRONT SIDE

REAR SIDE
oI
2t

MARKER LAMP R H

c
o
FUSE

@I

OFF

1ST

jlmfr

MARKER
LAMP RH

i

STOP

@

j

STOP LAMP SWITCH

TAIL

CLEARANCE

c
o

LICENSE

FUSE
TAIL LAMP

PLATE LAMP

MONITOR

r

@

c
o
FUSE

IFUSIBLE
LINK

@
STOP LAMP

l

MONITOR

TAIL

T
I
BATTERY
L

fJ
CLEARANCE

EJ

Il

I
FRONT

TAl L ANO STOP

r

SIDE

MARKER

LAMP SENSOR

STOP
REAR SIDE
MAR KER
LAMP LH

Q
SE

LAMP LH

L315

SCHEMATIC TURN SIGNAL AND HAZARD WARNING LAMPS
IGNITION

OACC

SWITCH

1

4c

o
r
FUSleLE

Sf

LINK

L

IGNITION AND

C

c
o

g

ACCESSORY RELAY

0
FUSE

FUSIBLE

HAZARD SWITCH

LINK

c
o
T
I

Fl

HAZARD
FLASHER
UNIT
IN

FUSE

BATTERY

L
TURN SIGNAL

I

Fl

FLASHER UNIT

g

f

TURN SIGNAL
SWITCH

TURN

fl
FRONT
COMBINATION
LAMP
TURN

E1

@

PILOT LAMP R H

TURN
RE
R

COMBINATION

l

LAMP

PILOT LAMP LH

TURN

t3

eL37

EL 43

ELECTRICAL SYSTEM

Lighting Systems
WIRING

DIAGRAM TAIL

CLEARANcE SIDE MARKER

PLATE LAMPS

AND UCENSE

W

R

I
FUSIBLE LINK

@

Et
BATTERY

I
J

FRONT SlOE

1

MARKER LAMP

I

R H

n
@89
ll

FRONT

COMBINA

TION LAMP R H

1

GW
8

@
I

GW

jI
Lg
I

OF

1ST

2ND

ABCABCABC

I1

@

00

@

00

3
I
4

G

5
White
LIGHTING

LICENSE PLATE

SWITCH

LAMP

@

il

00

00

1B
V

ill
@

00

ft

f

ill
WL

@o

e

gg
00

@

gg

FRONT COMBINA

O
i5

TION LAMP LH

g

@
Black

WGH

II

@I
LH

CK

I

Y

WG

JtU@
W

l

wARD
I

fB

TAIL AND

Gll

J@

TAIL
M

ry
TOP

@

MARKER LAMP

r
HATC
B

GB

FRONT SIDE

Ij

lI ltJ
i
GW

00
00

r

e

l

GW

I
14

TAIL LA

I
P

LH
a

L@j

@j
STOP

LAMP SENSOR

Gf
I

REAR SIDE MARKER
LAMP

LH

SEL316

ELM

ELECTRICAL SYSTEM

Lighting Systems

STOP LAMP

WIRING DIAGRAM

BATTERY
COMBINATION METER

01
IU
G
I

Au2
U

L
y

CID
FUSIBLE

STOP LAMP
MONITOR

STOP LAMP SWITCH

LINK

II

@

@

J@

ggggllggt

White

Bluel

J

@

II

IF

J

@
HATCHBACK

J

STOP AND
TAIL LAMP
0

@

0

R H

B
l

GY

W

YG

HARDTOP
w

f YG

L

fB

f

I

41

tJ I

@

I
10

L

J

15

10

c
20

LIi

rII

J

White
Iqj

10

B1

Black

10

OOIIOOOO
oo

o

11
0000

@ I

5
1

ooooo

OJ

rO@
I

FUSE BLOCK

STOP LAMP

I

R H

@
Cill

HATCHeACK
STOP AND
TAIL LAMP

@

f I

tf11
@
TAIL AND STOP
LAMP SENSOR

LH

u
l

B
YG

rHARDTOP

@
I
L

@I
STOP LAMP
LH

I

SEli71

EL 45

ELECTRICAL SYSTEM

Lighring Systems

WIRING DiAGRAM TUm

SIGNAL

AND HAZARD

WARNING

LAMPS

IGNITION SWITCH

@i

R

CJT

I

i

ST

U9Q

rn

FUSIBLE

ICJN
t
iI

0

A

0

J
b Q

IG
s

@

LINK

@

IGNITION AND
ACCESSORY

I

G1

W

RELAY

WB

BATTERY

BW

3

FUSE BLOCK

r

B
HAZARD FLASHER UNIT

j
I
BI
fP
l
1
GY
J
t
co

@
r

J

B

HAZARD

GB

FRONT

2

COMBI

NATION LAMP R H

0

3

JG

SWITCH

r
I
HARDTOP

GB1

8

I

l

O

I

D
0

GB

J

B

4

8

S

u

l

GBbTCHBACK
m

@

t

I

I

I
J

L

TURN SIGNAL

REAR COMBINATION

FLASHER UN IT

LAMP R H

L
G

C

B

TURN SIGNAL SWITCH
LN

@
R

@

j

i

1t
f

Y
GB
I

I

II

i

CD

IWhi

een

e

I

00

i

1

aJ

I@
Ilt@

6

a

IG

I@

t@

I

NATION LAMP LH

OOllOO OilfJ

@

00

0000

ill

@

R

@

a

I
I

I
co

fi

COMBINATION

I
111
J
L @2

RH

jJif

PILOT LAMP

l
I

1

B

METER
L H

GR

GR

00

ll
I

c

r
1

oc

COMBINATION

LAMP LH

White

Y

FRONT COMBI

REAR

ro

GRi fll
B

I

l
r1
P
ID J
t
L

i
I

8

SEL379

46
EL

ELECTRICAL SYSTEM

Lighting Systems

SCHEMATIC BACK UP LAMP

FUSIBLE

OACC

LINK

IGN 1TI0N

BACK UP

SWITCH

R H

1

if CON

c
o

@

C
I

BATTERY

L

C
BACK UP
LAMP LH

FUSIBLE
LINK

IGNITION AND

LAMP
SWITCH

BACK UP

ACCESSORY

I

LAMP

@

RELAY

3
1

INHIBITOR SWITCH

@
SEL380

WIRING DIAGRAM BACK UP LAMP

FUSE

1

9

IGNITION AND
ACCESSORY RELAY

BLOCK

@

@@

@
Jl

F

RB

00
00

RB

t
BB
@
@

i

@

T

BACK UP LAMP
R H

White
BW

WR

IGNITION
SWITCH

@

G

o tf

RB

R

@@
B

FUSIBLE
LINK

I

C

INHIBITOR

o
BATTERY

I@

1@

ll

a

C

9 Q@

0 O@

11

11 I@

SWITCH

@

t

ll
a

B

BACK UP

LAMP SWITCH

t
RBB
@
@

UP
BACK

LAMP

L H
SEL381

47
EL

Lighting Systems
TROUBLE

ELECTRICAl

YSTEM

DIAGNOSES AND CORRECTIONS

Clearance side marker lleense plate and tail lamps
Condition
Neither left

Probable

Corrective action

cause

Burnt fuse

nor

right lamp lights

Loose connection

or open circuit

switch

Faulty lighting
Lamps light when

CD

with

test

replace

Check wiring and

or

repair

connection

Replace if necessary
and

@

terminals of

harness connector to combination switch
connected

Correct cause and

lead

are

including

15A

Tail

lamp

fues

Fa1llly

tail

and

stop lamp

sensor

Replace t
li1 and stop hunp

sensor

only

Lamp on only
side lights

Burnt bulb

one

Replace

Loose bulb

Repair lamp socket

Loose connection

or

open circuit

Check wiring and

or

repair

connection

Stop lamps
Condition
Neither left

nor

Probable

right

lamp lights

Corrective action

cause

Burnt fuse

Correct cause and

Faulty stop switch

Conduct continuity test and replace if neces

replace

sary

Faulty
Stop lamps light

tail and stop

lamp

Replace if necessary

sensor

when @ and

@

terminals

of main harness connector to tail and
stop
lamp sensor are connected with test lead
including lOA fuse
Loose connection

Lamp
lights

on

only

one

side

open circuit

Bumt bulb

Check wiring and

or

repair connection

Replace

Loose bulb
Loose connection

EL48

or

Repair lamp
or

open circuit

socket

Check wiring and

or

repair

connection

ELECTRICAL SYSTEM
Turn

slgnsl

Lighting Systems

and hazard warnIng flasher lamps

Condition

Probable

Turn signals do not

Bumt fuse

operate

Loose connection

or

Hazard waming

lamps operate

Faulty

flasher unit

Faulty

turn

signal

Corrective action

cause

open circuit

Correct cause and

replace

Check wiring and

or

repair

connection

Replace

switch

Conduct continuity test and

replace if neces

sary

Faulty hazard switch
Turn signals operate when

Replace if necessary

CD

terminals

of harness connector

switch

connected with test lead

are

and

to

@

hazard

including

lOA fuse
Hazard warning

lamps

Burnt fuse

do not

Faulty hazard warning flasher

operate
Turn signals

@

and

@

to hazard

lead

signals

unit

and

hazard warning lamps

heard

switch

are

or

too

irregular

is

Replace

if necessary

Loose connection

Reconnect finnly

Burnt bulb

Replace
unit

Replace flasher unit

Bulb

other than

Reconnect finnly

specified wattage

being

Replace with

one

specified

used

Burnt bulbs

Replace

Loose connection

Reconnect

Faulty flasher unit

Replace flasher unit

Burnt bulb

Replace

Loose connection

Repair

fast

Flashing cycle

if necessary

connected with test

Loose connection

not go out

Replace

lOA fuse

hazard switch

Faulty flasher

Flashing cycle is too
slow pilot lamp does

replace

@

do not operate
No flasher click is

and

terminals of harness connector

including

Faulty

cause

Replace

Faulty hazard switch
Left Right side lamps operate when

operate

Turn

Correct

Bulbs

other than specified wattage

being

firmly

Replace with

one

specified

used

Faulty flasher unit

Replace flasher

unit

EL 49

ELECTRICAL SYSTEM

Lighting Symms

LIGHTING

SWrTCH

SIGNAL

TURN

Refer to
STOP

AND
Ct1
SWI1

TURN

SIGNAL FLASHER
UNIT AND HAZARD

Combination Switch

FLASHER UNIT

LAMP SWITCH

Location

Inspection
Test
with

an

continuity

through

switch

ohmmeter
VJ
Bulb in good

ord

Ap
2 volts

Bulb removed

Approx

Steering
column

12wofts
Turn
SEL385

signal flasher
unit

Hazard flasher unit

Z97
SEL
PUSH

NORMAL
POSITION

PLUNGER

CD

Tail

6

@

lamp

light switch

on

BACK

UP LAMP SWITCH

SE L36S

Automatic transmleslon
The

Adjustment

up
back

into the

lamp

switch is built

inhibitor switch

Refer to

AT section

Refer to MA section

Manual transmlealon
The
stalled

back up
on

the

Jamp

switch

IS

ID

manual transmission

case

Bulb in good ord

Approx

r

2 volts
Bulb nmoved

OJ

Approx
12voltl

TAIL AND STOP LAMP

SENSOR

SEL386

Transistor built In

Removal and installation
Before

lamp

tail

removing

sensor

detach

rear

and

HAZARD SWITCH
stop

wheelhouse

Inspection

fInisher See page EL 105
on

Before
senIOr

checking

en ure

tail end

that

aU

top lamp

bulb

meet

specifications

lt

Inspection
145

Stop lamp

OM
OF

Stop lamp

EL 50

switch

on

SEL296

SEL298

ELECT RICAL SYSTEM

Lighting Systems

INTERIOR WGGAGE COMPARTMENT AND STEP LAMPS
CAUTION

00

not wipe lens surface

SCHEMATIC INTERIOR

using cloth dampered

with

gasoline

LUGGAGE COMPARTMENT AND STEP LAMPS

Hatchback model with Interior lamp timer

INTERIOR LAMPS
WITH SPOT LAMPI

6

6 6

011
STEP LAMP RH

ij

INTERIOR
LAMP
TIMER

o
DOOR SWITCH RH

1

FUSE

j

C
o

DOOR SWITCH LH

FUSIBLE LINK

o

LUGGAGE
COMPARTMENT

LAMP

0

1

BATTERY

III

STEP LAMP LH

L

1

n

SEL3a7

EL 51

ELECTRICAL SYSTEM

Lighting Systems

DIAGRAM INTERIOR LAMP

WIRI NG

AND

STEP LAMP

LUGGAGE COMPARTMENT LAMP

FUSE

81

i

u I

11
US BL

BATTERY

@

LINK

0

0

0

BLOCK

0

lG

l

IWITH INTERIOR LAMP TIMER

@

INTERIOR LAMPS

i

STEP LAMP A H

00

lR

6 b 6

INTERIOR
LAMP TIMER

lG

BR

ro

@

1f

Wl@
U

Black

4

CC

I@ fY

Hgg

RG

RB

I

CD
a

CD

H

CH

4

TRUNK ROOM LAMP
HARDTOP

1

W

CD

nO

DOOR

fB@

rif31
a

eR

O

II

I

HATCHBACK

RG

@

@

11

RG

@
Rr

@

Whi

10
000

a

DOOR

I

l

@

iR

SWITCH LH

BR

W

@I
@ 6

h iB
o
tSiB
V
R

on

tt

l

White

19b

iY
I
7I

21

STEP LAMP LH
00

B

ER

J
c
BR

B

ib

A

@@

LUGGAGE COMPART
MENT LAMP

I

J
c
RG

J
c
RG

@

@

@
WITHOUT INTERIOR LAMP TIMER

IrO

k9
1

II

CD

a
co

CD

a

I
@

White

r9l@
I

jl

I

I i
t

J
BR

LUGGAGE COMPART
MENT LAMP IHA TCHBACK

a

W
a

INTERIOR LAMP

@

@
@

h
o
DOOR
SWITCH R H

RG
B D

i@
0

@

0

J
Q

TRUNK ROOM LAMP

HARDTOP

00

@

RG

@

o
t
@
ao

DOOR SWITCH LH

L

0 0
J 00 0
lR

@

2

@
SEL388

EL 52

ELECTRICAL SYSTEM
INTER I OR LAMP

INTERIOR LAMP TI MER

Ic
Bulb

Lighting Systems

built In

replacement
Location

Without spot

lamp

The interior lamp timer is attached

lens by inserting a f1at
blade screwdriver into switch hole To
Remove

avoid

lens

blade

damage

should be covered with

a

to the upper side of instrument frame
Refer to page EL 104

portion

cloth before

insertion

Inspection

DOOR

SWITCH

Inspection
Door switch LR

@
SEl393

Circuit tester indication
As

door is closed

tester

indication

should linearly increase from 0 to ap
proximately 10 volts after 10 seconds
SEL391

With spot
1

lamp

Open

cover

screwdriver
cover

portion

with

inserted

To avoid
should

cover

be

a

into

f1at blade
front

of

damage blade

covered with

a

cloth before insertion

attaching bolts and de
tach interior lamp assembly
2

Remove

I

I

DOOR

CLOSE

FOR USE

OPEN

I
0
126

g I

KEY AND
LIGHT

WARNING
INTERIOR
LAMP

EL 53

ELECTRICAL SYSTEM

Lighting Systems

INSTRUMENT

PANEL

ILLUMINATION

SCHEMATIC INSTRUMENT PANEL IUUMINATION AND CIGARETTE LlGHlER

LIGHTING

SWITCH
FUSE

FUSE

I

Off

1ST

ABC ABC

2ND

c

ABC

3

I

CIGARETTE
LIGHTER LAMP

I

COMBINATION
METER

OPTICAL FIBER

o
i

13

r
KEY

FUSI

LE

ASH TRAY LAMP

ILLUMINATION

bLINK

ILLUMINATION
CONTROL

3

RHEOSTAT

8

GLOVE

TEMPERATURE
CONTROL PANEL
RADIO
AS C D

BOX LAMP

13

ILLUMINATION

MAIN SWITCH

T
BATTERY
I
L

CIGARETTE
LIGHTER

I

LAMP

3
AfT POSITION
INDICATOR LAMP

SEL396

IUUMINATION
RHEOSTAT
I

ROL

Transistor bult ln
8pectlon

J
Battery

EL 54

fe

E
SEL303

rRICAL
ELEC
WIRING DIAGRAM INSTRUMENT

PANEL

IAO

GW

f

T

C A

@

2i

q

@ LJ
a
aa

1ill

C A

I

a

1

Lighting Systems

CIGALETTE LIGHTER

ILLUMINATION AN

Lg

SYSTEM

I

06

6

l

q
0

nun

i

LIGHTING SWITCH

FUSE e LOCK
0

@

0

@

0 fi

t

L9B1

0

GW

00
00

@

I
I

0

@

I

AS C D

GW

MAIN SWITCH

METER
AND KEY

LgS

ILLUMINATION

l

@

I

IllUMINATION
COMBINATION METER

CiD

@r

ij D

G

LgB

r

@

ILLUMINATION
CONTROL RHEOSTAT

CONTROL
PANEL ILLUMINATION
HEATER

@
ll

LY

SleLE
K

Jo
B
GW

@

@

B

flJ Lgg
il I
Lv

GW

B

CIGARETTE LIGHTER

S

LY

D
GW

GW

@GLOVEBOX
I

LAMP

White

@

Eli

LgB

B

BATTERY

f

8

T

I

e
Gw

LgB

@

@

ASH TRA Y LAMP

GW

Bluel

@

II

V
L9

B

a
SIGW
AfT POSITION
INDICATOR LAMP

aa

191
RADIO
ILLUMINATION

@

AS

C D equipped models

SEL396

EL 55

Meters

ELECTRICAL SYSTEM

Gaugesafld Warning Systems

GAUGES AND WARNING SYSTEM

METERS
CAUTION

Before starting

to work on eny

part of electrical system disconnect battery ground cable

COMBINATION METER
R

O

A

ANI

1

tTA

TION

SE L397

EL 56

ELECTRICAL SYSTEM

Meters Gauges andWarning System

INSPECTION

3
0
80
o
JO
@ID

lUTI

r5Tl
S
OUAFlTZ

so
1

o

rei

o

o

w

Beam

ill j
J
J EJ
U

Charge warning
lamp

i

0

b
indicator

lamp

0

mJ

rnm
mill
f1Q m
ITJ m

Optical fiber
Key illwninati9

w
lli ll
m IllJ
Illumination lamp

ReaI defogger
indicator lamp

J

lliumination lamp

G

a e0@8@
A

A

111

Jn8

w

ey

0

0

u

0
0
0

CD

o

11 J

L

n

c
o

J

f
@ c0
i

1

15

I

o
o

ll

u

l l

II
w

1

L

o

w

@

o
1

2
4

Temperature gauge
Seat belt warning lamp
Power

source

5

Right twn indicator lamp

6

Fuel gauge
Beam indicator lamp
Tachometer Signal

7
8
10

Ground

12

20

Clock Power

13

Left turn indicator lamp
Charge WaIning lamp
14 Rear defogger indicator lamp
IS IDumination lamps

21

Oil pressure warning lamp
Clock Illumination

16
17
18
19

Illumination lamps
Tail lamp monitor lamp

22
24
25
28

source

Brake warning lamp
OU presswe gauge
Door warning lamp

Headlamp monitor lamp
Stop lamp monitor lamp
SE L398

EL 57

Merers

ELECTRICAL SYSTEM

Gauges and Warning Systems

SCHEMATIC TACHOMETER

GAUGES AND

WARNiNG

LAMPS

IGNITION

FUSIBLE

SWITCH

LINK

UUUUUJ

Od

FUSIBLE

0

FUSE

C

LINk

RESIS

0

IGNITIO N
COIL

IGNITION AND

ACCESSORY RELAY

T

A

BATTERY

I

I

J

o

VOLT GAUGE

TOR

ALTERNATOR
a

0

1lja
o

CI

C

IDCI
a Z

J

J

g

z

w

4

II

a

0

w

w

Ga

t

115

J

J
C

za

a

Zo

W

0
r

Oa

g

1
f

io
u

y

J

J

J

0

n

tJ 6V

IW
JCJ

z
J

w

U
Cl

z
a

r

ni I

1

Jc
lLCJ

Cl

w

J

CI
Z

Z

WC

1

w

a

w

J

Qi Q

w

a

II

aO

JZ
w

0

J

I

u

w
w
a

u

10

6f
T

41 i

i
0J
a

Ot
O

0

0
o

SE L399

WIRING DIAGRAM TACHOMETER
l

T

I

GD

RG

I

J

FUSIBLE

Et

2

LINK
L

a

BATTERY

a

e

3

0

0

D@

TACtOYETER

0

COMBINATION METER
IGNITION

SWITCH
a

S1

ON ACe OFF

0

i

L9W

@
B

I

IT

00

G

I

II

OOOIIOOri tf7i
l
y

Ih
I

B
White

G

BW

rL9

WR

l

I

I@
t

L9WiL9

IGNITION AND ACCESSORY RELAY

CJ

L9W
t
l

IGNITION

@

WB

@
FUSE BLOCK

EL 58

COIL

G

Bl@

RESISTOR
SEL405

ELECTRICAL SYSTEM

Meters Gauges and Warning Systems

WATER TEMPERATURE

WIRING DIAGRAM OIL PRESSURE GAUGE AND WARNING LAMP
FUEL AND VOLT GAUGE

10

I

FUSIBLE

ACQON

1

CfW

BW

rn
WR
II

6

I

II

O

6t

IGNITION
SWITCH

6

S

LINK

Sf

E9
BATTERY

rn

t

IGNITION AND
ACCESSORY
RELAY

1l

FUSE
BLOCK

I

B

J@
FUEL TANK

I

I

@
@

JU r
f

@
White

GAUGE UNIT

y

i@

0
I

I
@

1
G

COMBINATION METER

B
Jr

@

J

lJg Jlgg

VOLTGAUGE
LY
Y

OIL PRESSURE

VOLTAGE

I

EGULATOR
Green

o

@60@

TEMPERATURE
AUGE

OJ

VOLTAGE
REGULATOR

@

0

@

I
s

GAUGE

co

@

I

6Hv

V

FUEL GAUGE

I

@
@

U@

0
@
OIL PRESSURE

7

LY

WARNING LAMP

RC

362

J
B

1

0

4

5
Y8

1l

u Iu

n
1ll

YW
OIL PRESSURE

THERMAL

SENDING UNIT

TRANSMITTER

@
SEL404

EL 59

Mere17i

Gauges

and

ELECTRICAL SYSTEM

Warning Sysrems

WIRING DIAGRAM

DOOR

CHARGE

AND BRAKE WARNING LAMP

IGNITION SWITCH
Off I
X ON 5T

m

WJ
I

Q

9
6

D

rn
BW

@

FUSIBLE LINK

B

WR

J

I

I

g

o
BATTERY

@

t

1
w
WB
BW

r

I
m

FUSE

BLOCK
IGNITION AND

ACCESSORY

t1
@

RELAY

I

1Wh

@lil

I
BULB CHECK RELAY

i

rr
t

@

00

00
00

C
is

R

B

s

jJ
el
DOOR SWITCH R H

04

J4
BR

Br

@

4

B

I

1

@
@

I

BRAKE FLUID

Green

G
BR

LEVEL SWITCH

L

R
G

@

@
Qtl

YG

OO
r

BJ

@o
PARKING

WR

8

gfgfllg

@l
BR

J

DOOR SWITCH L H

lI 0
e

0

White

WR

JI

BRAKE SWITCH

o
l

@
@

ill

DYG

@

COMBINATION METER

@
w

a

@
L
TERMINAL

@ wr

@

a

J
u

0
0
0

J

a
m

2

BR

G

a
4

G

ALTERNATOR

2
W

W

d
3

@
SEL368

EL 60

ELECTRICAL SYSTEM

Meters

Gauges

and

Warning Systems

TROUBLE DIAGNOSES AND CORRECTIONS
Condition

Probable

Corrective action

cause

Water temperature gauge
does not

Gauge

Faulty

thermal transmitter

or

loose terminal

connection

operate

When

Replace

thermal transmitter

or

correct ter

minal connection

wire to thermal transmitter is

ground

ed gauge pointer fluctuates

Faulty water temperature
Gauge indicates only
maximum temperature

Gauge

does not operate

accurately

Replace

gauge

water

temperature gauge

Faulty thermal transmitter
Gauge pointer returns to original position
when ignition switch is turned off

Replace thermal

Faulty water temperature gauge
Gauge pointer indicates maximum tempera
ture even after ignition switch is turned
off

Replace

water temperature gauge

Faulty water temperature

Replace

water

Loose

or

gauge

transmitter

temperature

gauge

Correct connector terminal contact

poor connection

011 pressure gauge
loose

Oil pressure gauge
does not operate

Faulty

Gauge indicates only

Faulty oil pressure gauge unit
Gauge pointer retums to original position
when ignition switch is tumed off

Replace

Faulty oil pressure

Replace

maximum pressure

oil pressure sending
terminal connection

unit

Replace

oil pressure sending unit

or

correct

terminal connection

gauge

indicates maximtim pressure
tion switch is turned off

or

Gauge pointer
after igni

even

Fuel level gailge
Fuel level gauge
does not operate

Faulty fuel gauge tank

F

only

position

Fuel level gauge does
not

operate accurately

Volt

Replace

fuel gauge tank unit

Pointer deflects when fuel gauge tank unit

yellow

Pointer indicates

unit

wire is

grounded

Faulty fuel level gauge

Replace

Loose connection

Check

or

open circuit

Faulty fuel gauge tank

unit

Faulty fuel level gauge
Faulty fuel gauge tank

wiring and

or

repair

connection

Replace
Replace

unit

Replace

Faulty fuel gauge

Replace fuel level gauge

Poor or loose connection

Correct connector teoninal contact

Faulty gauge voltage regulator

Replace

Faulty volt gauge

Replace

Loose

Check wiring and

gauge

assembly

gauge

Volt gauge does not

operate

or

indicates

abnormally

or

poor connection

or

repair connection

EL 61

Meters

Gauges

and

ELECTRICAL SYSTEM

Warning System

Charge and brake warning lamps
Condition

Lamp

does not

glow

when ignition switch
is turned
out

Probable
Burnt bulb
Loose

or

with

ON

running engffi e

Chellle werning lemp
Lamp does not go out

or loose

Corrective action

cause

bulb

Replace bulb

poor connection

Faulty printed

correct

or

Correct connector terminal contacts

circuit board

Replace

Faulty bulb check relay

Replace

Faulty alternator

Repair

Faulty charging system

Inspect charging system

Faulty parking brake switch When parking
brake lever i released

Replace

Faulty brake fluid level switch When brake

Replace

or

replece

when engine is started
Brake warning lamp
Lamp does not go out

fluid level is nonnal

Oil pre

sure

and door warning

lamps

Condition
Ojl pressure

warning

does not

light

when ignition switch
is set to

ON

Lamp

does not go out

while

engine

is

being

operated

Door warning lamp

Lamp

Faulty

oil

Corrective action

cause

sending

unit or loose

Replace

or

Burnt bulb or looSe bulb

Replace

bulb

Lack of engine oil

Check oil level and add oil

Oil pressure too low

Inspect engine

Faulty oil pressure sending unit

Replace

pressure

r

correct connection

terminal connectio

lamp

Lamp

Probable

does not

glow

with door opened and

When lead wire connected to sending unit
is

grounded warning lamp lights

door switch

Faul1y
Burnt

or

correct

as

required

oil pressure system

Replace

bulb orloose bulb

Replace

bulb

or

correct

engine running

Tachometer

Condition
Tachometer pointer
deflects

Tachometer pointer
will not

EL 62

move

Probable
Loose

or

Corrective action

cause

poor connection

Repair

Faulty

resistor

Replace

Faulty

tachometer

Repair

Loose

Faulty

or

poor connection

tachometer

resistor

or

replace tachometer

Repair
Repair or replace

tachometer

ELECTRICAL SYSTEM

Merers

pe dometer

f

nVi

Probable

Condition
Neither

speedometer

pointer

nor

Loose

odometer

speedometer

Corrective action

cause

union nut

speedometer cable

Broken

ol erates

cable

Meter

Retighten
side

or

cable

Replace speedometer

Transmission side

Damaged

Unstable

Gauges and Warning System

speedometer pinion

Repl

transmission

ce

gear

gear

Faulty speedometer

Replace speedometer

Improperly tightened

speedometer

or

loose

speedometer

speedometer pinion

Retighten

cable union nut

pointer

Unusual sound

transmission

occurs

in

Damaged speedometer cable

Replace speedometer

Faulty speedometer

Replace speedometer

Excessively

bent

or

twisted

speedometer

oflubrication

Replace

or

cable

lubricate

increase in
response to

cable inner wire

driving speed

Faulty speedometer

Replace speedometer

Inaccurate speedometer

Faulty speedometer

Replace speedometer

Faulty speedometer

Replace speedometer

or lack

j

1

indication
Inaccurate odometer

operation

FUEL TANK GAUGE UNIT

Float For fuel gauge

a

Removal and Installation

1

Refer to FE section

E

t

Full

Inapectlon

11

Fuel tank gauge unit has two func
tions

2
e

l

i

II

SEL311
1 4

Empty

d
L

Unit

mm

in

SEL312

EL 63

Maters Gauges and Warning Systems

b

Thermistor

ELECTRICAL SYSTEM

For multiwarning

BULB CHECK RELAY

display
LocaUon

Test lamp

The bulb check relay is attached to
the

s

relay

bracket Refer to pa

EL

105

Inspection

l

f I
I t

Water

i

L

SEL313

Power
sowce

Earth

lll
lI

w

@

SEl406

Test lamp should come on in
proximately t1uee minutes after

ap
re

moval of thermistor from water

DIODE
For charge warning

lamp

SEL314

PARKING BRAKE SWITCH
Location
The diode for

charge warning lamp

is

fastened to harness with tape on
the right side of the dash panel Refer
to page EL 109

RESISTOR
and EFI
DOOR

SWITCH

Plirklng brike

p lIed

ignition coil

n
SEL309

TACHOMETER
Removal

d Installation

BRAKE FLUID LEVEL

1

Remove combination meter

2

Remove

SWITCH

bolts
3

Remove

tachometer

tachometer

attaching
from

com

bination meter lower housing
4

Installation is in the

of removal

Float
Float 1

I

Approx

zson

Approx on
SEL310

EL 64

resistor for tachometer

and EFI system is located

on

Parking bnke released

system

A 2 2 kfl

Refer to page EL 53

FOr tachometer

reverse

order

near

the

ELECTRICAL SYSTEM

Merers

Gauges

and

Warning Systems

SPEEDOMETER
Cable layout

Cable

Speedometor

SEL410

For detailed information

Ipeed

len or

IA S

C D

regarding

refer to page

EL 102

WARNING DISPLAY
DESCRIPTION

Warning lights come

The warning display system con
sists of a warning indicator a warning

display amplifier

and

as

ON

on to

aU items in succession

read

one

at a

time for 2 seconds

sensors

When ignition switch is ON

ing display operates

Ignition switch

J
warn

follows

YES

NO

ight
I

OFF

I

Abnormality

I

Abnormal indication

I

Eliminate abnormality

I
EL 65

Msters

ELECTRICAL SYSTEM

Gauges aM Wa11Iing Systems

Display modes

Identification

I

FUEL

I

BA TTe

Color

fBf I

Item

Red

Indicates that fuel is less than

Fuel level warning

Battery electrolyte

Orange

lllliiD

Warning

WATE

Orange

IWASH

Orange

mately
v

10

liters 2 5 8 US gal 2 1 4 Imp gal

level

Indicates that battery
level

electrolyte

is less than

warning

specified

Coolant level warning

Indicates that engine coolant in radiator reservoir
tank is less than specified level

Washer fluid level

Indicates that windshield washer fluid is less than

warning

specified level

SCHEMATIC WARNING DISPLAY

BATTERY LEVEL SENSOR

1

e

1

RADIATOR

f

lJl

LEVEL SENSOR

iLr

WASHER LEVEL
SENSOR
FUEL LEVEL SENSOR

H

b

Ir

IGNITION SWITCH

OACX

if

CON

I
q

E
WARNING INDICATOR
WARNING

IGNITION AND

ACCESSORY
RELAY

DISPLAY

b

AMPLIFIER

BATT

o
FUSE

SEL411

EL 66

ELECTRICAL

rEM
SYS

Meters

Gauges and Waming Systems

WIRING DIAGRAM WARNING DISPLAY

IGNITION SWITCH

tfW

WR

WR

II

FUSIBLE

@

LINK

BW

1ill
@

EJ
BATTERY

t

J
FUSE eLOCK

fj

IGNITION AND

1

ACCESSORY

ffEU
t

i@

V

n

I

WARNING

jER
WASf

SENSOR

INDICATOR

@
L

0 ClI

LY

JClI

f

Lvi
lB
LR

WARNING

RADIATOR
SENSOR

DISPLAY

BL
RY

@

J

B
BL
LW

1

B

AMPLIFIER

@
o
0
0

LV

J

0

LB
LR

0

L

0

G

i@

YL
BY

FUEL TANK

BATTERY

GAUGE UNIT

SENSOR

n C BY
L
@

@
YL

YL

EYL
00

g
00

I

@ @
@

Black

B

I

@
ill
SEL412

Et 67

ELECTRICAL SYSTEM

MI1te
GaugesandWaming
1
i

TROUBLE DIAGNOSES AND CORRECTIONS

No warning indica1Bd

N G

I

Chec
f11se

fuse
Repla

r

lO K
I

Check forloose connection at

N G

Repan
r

warning indicator and

amplifier

connector

OX

Replace warning display amplifier

When

witch i

ignition

in

one
succeuion

on even

th

ugh

at a

there i

turned to

ON

warning lights come on to read all items
warning lights will not come

time for 2 seconds However

Ibnormality

1
Check

N G

sensor

Repan or rep Iace sensor

lOX
N G

Check for loose connection
or

Repair or replace

open circuit

lOX
Check warning indicator for

N G

Replace warning

burnt bulb

indicator

Replace warning display amplifier

I

Warning light

remain

on even

though th

i

no

IbnormaJity

1
N G

Check sensor

Repan

or

rep Iace

Repair

or

replace

lO K
Check for loose connection

or

open circuit

lOX
Replace warning display

EL 68

amplifier

N G

sensor

ELECTRICAL SYSTEM
MULTI WARNING INDICATOR

FUEL LEVEL SENSOR

Location

InllPectlon

The

multi warning

indicator

Mete
Gauges and

w

Refer to pages EL 63 and 64

is

Warning Systems

located in the combination gauge

InllPectlon
WASHER LEVEL SEN

R

Location
The
on

washer level

sensor

on

Empty

is located

Norm llev t

the bottom of the washer tank

n
SEL415

o

InllPectlon

j

Q

Washer

BATTERY LEVEL SENSOR

Inspection

@@

Before inspection

Radiator

the

make

sure

that

charged and the fluid

is

ftlled up to correct level

Fuel

1
SEl414

eID

battery

is

Battery

Disconnect sensor ha

2

Make sure that

volts

COOLANT LEVEL SENSOR

there is about 8

voltmeter

negative terminals

Location

are

positive

and

connected to

sensor

and battery

respectively
8Y

The coolant level

sensor

is located

the bottom of the radiator reser

MULTI WARNING AMPLIFIER

on

JC

voir tank

bullt ln

when

negative teoninals
battery fluid level

SEL413

ess connec

tor

Location
The multi warning amplifier is at
tached to the instrwnent panel frame
Before

removing

it

remove

lid C Refer to page EL104

cluster

InllPectlon
Coolant level

sensor

is united with

the reservoir tank and cannot be
moved alone

re

BES07D

EL 69

Meters

GaugesandWaming

ELECTRICAL SYSTEM

ms

l

A

WARNING CHIME
SCEMATIC SEAT BELT

KEY

AND LIGHT WARNING

IGNITION
SWITCH

C
ON

c
J

a

L

cON

0srJ

FUSIBLE LINK

L
o

FUSIBLE

FUSE

c

c
o

LIGHTING SWITCH

LINK
OFf

IGNITION AND

FUSE

A

ACCESSORY RELAY

a

c
r

L

BATTERY

2ND

1ST
CAB

C

Ala

c

g8g2@

FUSE

I

SEAT BELT

WARNING TIMER

KEY

WARNING

SWITCH

WARNING CHIME
DIODE

6

SEAT BELT
SW ITCH

o

@

I

SEAT BELT
ING

II

DOOR SWITCH
L H

I I
SEL416

TROUBLE

DIAGNOSES

AND CoRRECTIONS

Condition

Probable

Corrective action

cause

Licht and key

Warning

chime doe

not sound with

in

ignition
switch

Faulty warning
Loose connection

chime
circuit

or open

key ignition
or
lighting switch on

Faulty door

when driver side door

Faulty key warning

is open

sWitch
chime switch

Faulty lighting system
not

Clearance lamp does

Replace
Correct connector terminal contacts

Repair

or

replace

Repair

or

replace

Correct

light

Seat belt
Chime does not sound
and warning lamp does
not

glow with ignition

switch

on

Either chime

or

does not

Faulty

eat belt switch

Repair or replace

Faulty seat belt warning timer

Replace

Loose connection or open circuit

Correct connector terminal contacts

Loose connection

Correct connector terminal contacts

or

open circuit

warning lamp
operate with proper

Burnt bulb

Replace

condition

Faulty chime

Replace

EL 70

ELECTRICAL SYSTEM

Meters Gauges and

Warning Systems

WIRING DIAGRAM SEAT BELT KEY AND LIGHT WARNING

IGNITION SWITCH

I

O

It

WR

R

41

aw

FUSIBLE

41

LINK

@

aa ON S1
Of

I B

iA

g

IG
IS

o

g

@
G
W

BATTERY

n

I

e

a

5

1

aJl
I

WB

aw

5

I

I

Ii

IGNITION AND
ACCESSORY

1
@

@

DOOR SWITCH LH

@
O

REALY

LIGHTING SWITCH

nJ

oo

no

U9 Uo
I

YR

rVR

lVR

GW

JtGW

GW

I

GW

@

1

GW

GW

Lg

White

r

I

OFf

1ST

o

41
41

IillJJ

l
4

oObo
888 g gg

15

@

2ND

ABCABCAB
9
0009

SEAT BELT TIMER

A

KEY WARNING SWITCH

YB

RG

a iO

w

DlJ c

oonU

WARNING CHIME
11
COMBINATION

illY

R

Blue

@

METER

a

@

il

w

SEAT BELT SWITCH

L9Y

GD

2

2

gm

2k

YB
Br

@

e

l@

B
SEAT BELT

rtfJ1J
t

WARNING LAMP

J

l
fi
Whhe

@
SEL417

EL 71

Gauges and Warning
Mete

KEY

Systems

WARNiNG SWITCH

Refer to

ELECTRICAL SYSTEM

SEAi BELT WARNING

Inspeictloil

TIMER

Ignition switch

Location
The

DOOR SWITCH L H

located
Refer

SEAT

to

page

53
El

seat
on

belt

warning

timer

is

the back side of the dash

board on the right side
Refer to page EL 104

BELT SWITCH

Battery

Inspection

l

IElTl
UTl
OUT

I

w

I

I

After about 6 secondl

Battery

SEL418

w

SEL41

SEL420

WARNING CHIME

Uc

built In

DIODE

Location
The warning

EL 72

awltch

Location
chime is located

the back side of the dashboard

right side

For door

on

on

the

The diode for the door switch is
fastened to body hamess with tape
near the injection block

ELECTRICAL SYSTEM

Wiper and Washer

WIPER AND WASHER
CAUTION

Before

starting to

work

on

any part of electrical system disconnect

SCHEMATIC WINDSHIELD WIPER AND WASHER

With

time

battery ground

cable

control

IGNITION

OACC

f

C
J
FUSIBLE LINK

SWITCH

1

CON

OJ
o

c

c
r

FUSIBLE LINK

FUSE
IGN ITlON

AND

ACCESSORY RELAY

WIPER MOTOR

I
SATTERY
L

I

INTERMITTENT
WIPER AMP

AUTO
WIPER SWITCH

11

f

RETURN
DEVICE

WIPER

HI

LO

WASHER MOTOR

INIp

@

o

8

gg

JU

1r

1
SE L422

EL73

Wiperand

ELECTRICAL SYSTEM

Washer

WIRING DIAGRAM WINDSHIELD WIPER AND WASHER

IGNITION
OfF

FUSIBLE
LINK

f
@

R

rl
I

WR1

@

LB

lG

SWITCH

iC i r
0

P

Sf

0

o
B

BATTERY

BL

I

t

4

J

I

@
FUSE BLOCK

IGNITION AND

ld

ACCESSORY

O@

RELAV

J

WIPER MOTOR

o
l

@

I
I

M

I

L

1

Le
G
GL

WIP ER SWITCH
WI

ff INIlO HI

INTERMITTENT
WIPER AMPLI F I ER
LB

@j

L

I

LR

@

It

I

G

ga

I

B

80
00

I
I

LV

LV

LR

LW

ill

W

PER

L

llifl

L

LJ T

gg

og9

5IJO

l

OOO

I

LW
L

@

@

LI

@

WASHER MOTOR
W

U

@

@

With time control

Ji@
SE L423

EL 74

ELECTRICAL SYSTEM

wsher

DIAGNOSES AND CORRECTIONS

TROUBLE

Condition

Probable

Windshield

wiper does

Wiper and

Broken armature

Mqtor

worn

motor brush

or

Replace

motor

seized motor shaft

not

operate

Corrective action

cause

Blown fuse

Power

supply and
cable

Check

circuit
short

side motor

or

and correct
Loose open or broken

I

link

Improper
Foreign

Correct

switch contact

material

interrupts

problem

Correct

wiring

Improper grounding
Switch

bumt component in
part for operation

other

Correct
movement of

Correct

link mechanism

Circuit

Disconnect link rod

Correct

Seized

or

Lubricate

Faulty

circuit breaker

rusted arm shaft

replace

or

arm

shaft

circuit breaker

Replace

breaker
Windshield

Short circuit

Motor

motor brush

wiper operat
ing speed is

Power

too slow

supply

Low source

of motor armature
or

worn

seized motor shaft

Replace motor
engine oiL
Measure

voltage

and

or

lubricate bearing with

check

voltage

other electrical

parts for operation and take corrective
action for power supply if necessary

cable
link

Humming occurs on motor in ann operat
ing cycle due to seized arm shaft

Lubricate or

Switch

Improper switch

Conduct continuity test

contact

replace

and replace if

necessary
Circuit

Faulty

circuit breaker

Replace

circuit breaker

Replace

motor

breaker
dotor

Windshield

wiper speed 9
not be

Motor brush for either low

or

high speed

iswom

n

adjusted

correctly

Stops
c c
0

any
where

v
2

00
9
c

Contaminated auto return relay
or

contact due to

improper

co

foreign

tacts

Remove

mat

clean contacts carefully

auto return

device
so

as

Does

dotor

u

not

cover

and

not to de

form relay plate

ter

e
0

0

Motor

Incomplete
tact is not

auto return operation

Con

interrupted

Remove
correct

auto return device

relay pla

e

Cover

and

bending

stop
Washer motor
does not operate

when

pushing

washer switch

on

Bumt fuse

Corre t c

Faulty switch

Replace

Faulty washer motor
Loose

or

poor

connection contact

use

and

replace

fuse

Replace
at

Repair

motor or switch

Washer motor operates but
washer fluid is not ejected

Clogged

washer nozzle

Clean nozzle

or

replace

EL 75

ELECTRICAL SYSTEM

Wiper and Washer

Intermittent

windshield

The sign for
A

Measure

w1p

action

voltage

termittent

positive

across

B

terminals of in

and negative

amplifier with

a

circuit

C

tester

Check

continuity of all

D

Check continuity of terminals of
wiper motor wiper switch and

E

Probable

Condition

Wipers

do

operate

at Low and

not

operate

intermittently but

High speeds

intermittent

wiper

switch positions

line

voltage

amplifIer

Check continUity in wiper motor
circuit

Altemator or battery is faulty
Corrective action

cause

below 10 volts

A

Replace if

Faulty wiper switch

B

Correct

Faulty wiring

A

Faulty intermittent amplifIer

Replace

necessary

replace
ifneceuary
or
Repair
replace
or

e

if necessary

switch

Faulty wiper
Intermittent speed is too short for proper

wiping

line voltage too

Faulty wiper

Intermittent

speed

is too

long

for proper

wiping

Replace

high

motor

A

Replace

D

Replace if necessary

Faulty intermittent amplifier

Repbce

Faulty wiper switch

Replace

line voltage below 10 volts

A

Faulty wiper switch

B

if necessary

Replace if

necessary

Faulty wiring

Correct or replace
if necessary
A e Repair or replace

Faulty intermittent amplifier

Replace

Faulty wiper switch

Replace

Faulty wiper

D

if necessary

Wipers do

not shut off

Wipers operate intermittently

with

wiper

switch OFF

motor

Replace if

Faulty intermittent amplifier

Replace

Faulty wiper switch

B

necessary

Faulty wiring

Conect or replace
if neCessary
A e Repair or replace

Faulty intermittent amplifier

Replace

Excessive line

E

if necessary

Intermittent speed is erratic

voltage

fluctuation

Faulty wiper switch

B

Faulty wiring

A

Faulty wiper

D

Correct or replace
if necessary
Correct or replace
if necessary

motor

C

Repair

Faulty intermittent amplifIer

Replace

complete wiping stroke only
wiper switch ON but do not
continue operation

line voltage below 10 volts

A

Faulty intermittent amplifier

Replace

Wiper

Poor connections

c

Wipers
one

make

a

time with

motor

is

washer switch is

operation

not interconnected when

depressed

but intermittent

is normal

do not make a complete Wlpmg
stroke when washer switch is fIrst turned on

Wipers
and is

EL 76

quickly

turned off

or

replace

if necessary
Replace if necessary

Replace if necessary

Repair

or

replace

if necessary

Faulty

intermittent

amplifier

Replace

Faulty

intermittent

amplifier

Repbce

ELECTRICAL SYSTEM

Wiper and Washer

WINDSHIELD WIPER
Removal and Installation

OJ

SEL319

CAUTION

Be careful not to bend linkage

during removal

Inspection

uL
urff
M

9

P

B

Motor

should

run

t

low

speed
SEL321

Auto return

deVicez
Stop position

I

Ii

M

E
Motor

should

run at

high speC
SEL322

EL77

Wiper Bnd Washer

ELECTRICAL

SYSTEM
WIPER AND

WASHER

1

SWITCH

OnlY time
control tYP

Combination switch

Refer to

D

I

e
1

i

WIPER

AMPLIFIER

IC

A

JIDECO

IInERMI
SE L323

B

Test lamp

repeatedly

comes

OD

SE

27

bullt ln

Location

Adjustment

The intennittent wiper amplil18r is
attached to the relay bracket Refer to
page EL 105

3

B

Disconnect lead wire

Test lamp should go out and
back on in a few second

come

Inepectlon
Be careful
20 10 791
20

Unit

mm

to

10 191

not to

connect lead

wir

incorrect te minals

Connect test lead wire

in

SE L324

JIDECO
I

WINDSHIELD WASHER
Wash

r

nozzl

SEL 28

adJus

Only time
11018 69

i

F
100 13 941 dili

i
Unit

EL 78

1

410116 141

11016 69

JIDECO

100 3 94 41

rPr1
1

10116

W
mm

in

BE L326

II

2

Make

sure

that test

lamp

nected

J
F
1 Jf

comes

oil when negative lead wire A is
SEL325

iA
l

control type

con

I

JlDECO

I
SEL329

ELECTRICAL SYSTEM

REAR WINDOW WIPER AND WASHER

Wipe and Washer

r

SCHEMATIC REAR WINDOW WIPER AND WASHER
IGN ITION SWITCH

AUTO RETURN
DEVICE

ACC

o

y

C

ON

Osr

FUSIBLE
LINK

WI

FUSIBLE

REAR
WINDOW

L1N

WIPER

PER

OFF

ON

REAR

I

I

W

WASHER MOTOR

c

FUSE

f

r

@

C
Jo

C

BATTERY

ON

b

MOTOR
I

WASHER

o
REAR WINDOW

IGNITION AND

WIPER AND

ACCESSORY

WASHER

RELAY

SEL434

WIRING DIAGRAM REAR WINDOW WIPER AND WASHER

o

L
Eflf

BATTERY

@

1

E3
IGNITION
AND

Uf

@

FUSIBLE
LINK

Off

o

Age
6

J
D

ci

IG

o

I

S

WR

I

L

BL

o

0

r

B

0
FUSE

o

o

hl@

LB

c
r

BLOC

o

0

Lvi

v

J

I

1

8

REAR WAS iER

@

LB

MOTOR

L

1P1

LB

REAR WINDOW WIPER
ANO WASHER SWITCH

lw

RWIP
Ia
l
t

f N

I

DcQ

to

o

L

U

@

5
CD

LB

W

V

L

@

L 19y

1@

LW

00

Lg

LA

@

u 0
r

1

0

i

i

W

LB

IGNITION SWITCH

ACCESSORY
RELA Y

b

J

L Y

LW
L

REAR WINDOW
WIPER MOTOR

SEL

35

EUll

ELECTRICAL

WtperandWasher

SYSTEM

REAR WlfiiDOW WIPER

I spectlon

Removal and Installation

u

rU

7

t

i

I
I
j

i

0

1

B

t
J

i

i

1

SEL367

I

IO return

device

BXP
S

E

t
Stop position
1

REAR WINDOW

WIPER SWITCH

S

PE

SEL332

AND WASHER SWITCH

Inspection

Washer on
Auto return
Wi

r
I
r

I

Washer
OFF

ON

Wiper

IXI
OFF

ON

I

tl
t
SE L336

EL 80

ELECTRICAL SYSTEM

Electrical Accessories

ELECTRICAL ACCESSORIES
Before

CAUTION

muting

to work on any

part of electrical system disconnect battery ground cable

REAR WINDOW DEFOGGER
SCHEMATIC REAR WINDOW DEFOGGER
Ace

O

c

c
o

IGNITION

L

SWITCH

ON

IGNITION AND

FUSIBLE LINK

ACCESSORY

u
w

Q

c
o

RELAY
REAR WINDOW

C

0

I

DEFOGGER

FUSE

FUSIBLE LINK

@

BATTERY

L

1

MON ITOR LAMP

1
0

DEFOGGER

I

SWITCH

0
SEL436

WIRING DIAGRAM REAR WINDOW DEFOGGER

iJ
FUSIBLE

ig

IGNITION SWITCH

WR

R

LINK

II14

BW

BATTERY

@

0

IGNITION AND

I

ACCESSORY RELAY
FUSE

I

BLOCK

@

Ji

I
I

W
WB
BW
J

@

@
LB

LB

LB

li

@ r

@
@

gg

White

iN

e

iJ @

J@ocr
c

190 I
1

8

2

4

e

rl

8

DEFOGGER
SW ITCH
REAR

WINDOW
DEFOGG ER

o

e

4 LB
t

00

LB

L

L

COMBINATION METER

e

le @
B

@

L

1

White
B

J

00

LB

J
J

d

@

0
co

LB

00

gg@

B

@

2

MONITOR
LAMP

r
D
@
i@

SE L437

EL 81

ELECTRICAL SYSTEM

ElliCtrical Accessories

REAR WINOOW DEFOCCER

2

SWITCH

tester

If a mairieni
registers

is burned oill

Circuit

0 or 12 volts

Repair pI L
I
Wipe broken heat wire and its
surrounding area clean with a cloth
dampened in alcohol

Inspection
H

2

lffl

composition

ing pen
Shake silver

belore
3

V
SEL264

use

on

5

preferably

rTI

reak

1

Lf

IV
aValt

E l265

Unit

Drawing pen

mm

OFF
3

To locate burned out

probe

to left and

to determine

point move
right along filament

point where

tester

needle

swings abruptly

4

This

J

1

repaired
ch ck

minutes

1M
j

Inspection
to middle

tester

is

6

Apply

gun

directly

silver

repaired

m

FUament maintenance

j

Repair equipment
1

I

Conductive silver composition
Dupont No 4817 or equivalent

2 Ruler 30 em 12 in

V
6 Volts

normll

filam

nt

SEL
263

3

Drawing pen

4

Heat gun

5

Alcohol

6 Cloth

Jong

is

rea

to

the repaired

kept

for

area

20 minutes with

should be

area

while

constant stream of hot

a

a

heat

of 3

between

em
re

and hot air outlet Ifa heat

gun is not available

Z

composition

A minimum distance

paired
area

EL B2

being

12 in

filament

r

completed

for continuity

conducted

approximately

portion of each

H

composition

should be conducted 10

after

test

air

SEL266

in

wire

Do not touch

VJ

probe circuit

silver

deposited

0

REAR WINDOW DEFOGGER
FILAMENTS

clean

Wipe

from tip of drawing pen
5
After repair has been
check

volt range

in

eE540
SEL338

Attach

0
2

00
Heat wire

12

I

0

mm

ofthe break

H

l

0 0

com

position on break with drawing pen
Slightly overlap existing heat wire on
in

ON

broken

glass along

Deposit conductive silver

both sides
1 1

container

on

Place ruler

line

12 Volt

of c duc
t
snuillam
to tip of draw

AppJy

tive silver

dry for 24 hours

let the

repaired

M

ELECTRICAL SYST

Electrical Accessories

REMOTE CONTROL DOOR MIRROR
SCHEMATIC REMOTE CONTROL DOOR MIRROR

1

FUSE

SWITCH

I
I

R

DOOR MIRROR

MIRROR

DOOR
FUSIBLE LINK

l

u

SWITCH

LH

R H

I

0

R

l

U

0

I
BATTERY

oOOob

00 00

L

i

0

9

10

0

uO
0

J 00 bo

0

0

i

1
OQ

IQO

r@

r@

DOOR

DOOR MIRROR LH

MIRROR RH

SEL440

DOOR MIRROR

DOOR

Removal and Inatallatlon
Remove door

mirror

MIRROR SWITCH

Inspection

securing bolt

and disconnect harness connector

4

5

a
S

L442

I

1

R

11 9
0
I

15

I
J

L

I

U

1

I

I

I
6

0

0

o

II

I

c
oJ

I

EL444

Ell 8J

Electrical Accessories

WIRING

ELECTRICAL SYSTEM

DIAGRAM

REMOTE CONTROL DOOR

rrR @ o@w

9

1

MIRROR

FUSE BLOCK

BATTERY

DOOR MIRROR

DOOR MIRROR

SWITCH LH

SWITCH R H

RLUD

RLIUD

rU U

tJ

r

a

@
a
CJ

r11

CO

t

5

I

I

I

II

III

CO

a

Clco

@

i
@

@

rTIl

rm

iil

il
R

J

DOOR
R H

III

MIRROR

DOOR MIRROR
LH

SEL441

EL B4

ELECTRICAL SYSTEM

Electrical Accessories

aOCK
SCHEMATIC CLOCK

Digital

IGNITION SWITCH
ACe

C
l

L

FUSE

o

C
FUSIBLE

OST

LINK

a

T

5

I
BATTERY
L

s

rJ
FUSE

FUSIBLE

I

0

LINK

u

In
ILl

II

FROM

1

Day light brightness selection for

LIGHTING SWITCH

II

LI

digital display

SEL438

Turn

DIGITAL CLOCK
Adjustment
SELECT

Push it

Depress the SELECT knob and
will project
HOUR MIN

in that

it

clockwise

and

M1N

SEC

For

in the

the

adjust

HOUR
knob

knob

then

MIN
use

following

the

To
time

with

fust

SELECT

ADJUST

manl er

select

knob

when

to

the

adjusting

the

first set the time be

9 30 and

knob

Then push

10 29

with

simuJt
usly
of 10 00

adjust

MONTH

the

DAY

first

day
with

adjustment
adjust the current

second

select

MIN

minute and

SEC

with the

SELECT

knob

ADJUST

knob to set the time to

and

depress

the

SE

the

AD

then

JUST

knob

counterclockwise

adjustment

or

When the battery cable is detached
and reinstalled

matically

the

return to

display

will auto

12 00

select

knob

tum

the

the

LECT

MONTH

DAY

00 00

example

lcement
annou
To

minute

time

the

set

time for 10 00

the
ADJUST

for

nearest hour

tween

sequencec

to

for

To

adjustment

knob

DAY

for

adjustment

Turn

display

MONTH

counterclockwise

it

hour

for

clockwise

EL 85

Electrical Accessories

ELECTRICAL SYSTEM

WIRING DIAGRAM CLOCK

W

1ll
@I
BATTERY

D

FUSIBLE

WR

LINK

ST

lCCOff
ON

000

J

1

00

b

8

I

B

I

WR

IGNITION SWITCH

LB

I

W
J

J

L

1

@

j
W
I
C

u

w
i

j@

J

J

j

I

IJ

White

Green

iOOOOIIO oooo
l

@

ho

Ii00
1

o

0

@

L

og

01 O@

J

COMBINATION METER

I

H
4

@

@

L
TO

L1GHT

SWITC H

@

G

J
3

e

2

@

EL 86

L

ELECTRICAL

S YSTEM

EIectncal Accessories

HORN
SCHEMATIC HORN
Surge

killer
B

HORN
RELAY

f

1

I

0

FUSIBLE

o

FUSE

C

HOr TN

1

1

LINK

Q

SATTERY

I

HORN

Q
HORN

SEl445

WIRING DIAGRAM HORN

8

r

BATTERY

@

LINK

FUSE BLOCK
HORN
RELAY

D

r

6 Bfl gW

0

G

i

1
a

@

@

J

I

f

HORN R H

I

l

D
l

N

l

BG

D
@l

2

HORN BUTTON
3

I

U

0

I

COMBINATION SWITCH

@G
HORN L H

SEL446

EL 87

Electrical Accessories

ELECTRICAL SYSTEM

TRoUliLE DIAGNOSES AND CORRECTIONS
Condition
Neither high

nor

Probable
low

horn operates

Corrective action

cause

Burnt fuse

Correct

Faulty hom button

contact

CD

Hom sounds when

ment harness conn
switch is grounded

engine harness
with

a

test lead

Low horn

does not operate

Horn does

not

Faulty horn

ctor

combination

to

Replace

@

and

@

terminals of

to horn

relay are connected
including lOA fuse

or

Check wiring and

loose hom terminal

connec

horn

Break in wire to horn

Repair

horn

circuited
Short

button

and

or

hom

or

repair connection

Correct horn terminal connection

tion

stop

to sound

fuse

replace

Repair horn button

Loose connection or open cfrcuit

High

and

terminal of instru

Faulty hom relay
Hom sounds when

cause

Repair horn button

or

its

or

replace

wiring

button lead wire
When ins1rument harness is disconnected
from combination switch horn stops sound

ing
Faulty hom relay
Reduced volume and
or

tone

quality

Loose
Fuse

or

Replace

poor connector contact

relay

horn and

or

Repair

horn button

Faulty homo

HORN

Replace

Inspection

HORN

BUTTON

The horn button is attached to the
combination
EL39

to

HI

SEL340

rJ

@CD@

HORN RELAY

Locstion
The horn relay is located beneath
the

relay

105
EL 88

bracket Refer to page EL
Battery

switch

Refer

to

page

ELECTRICAL

Elecrrical Accessories

SYSTEM

AUDIO
SCHEMATIC AUDIO

IGNITION
SWITCH

y
OST

E
LINK

BATTERY

m

I

L

I

I

6
I

RADIO

DOOR

000000

OeCK

J01
V

REAR SPEAKER R H

SPEAKER R H

t

II

E
DOOR

SPEAKER LH

REAR SPEAKER LH

SEL447

SCHEMATIC POWER ANTENNA

POWER

ANTENNA

SWITCH

IGNITION SWITCH

I

ACC

u

N

0

C
o

CON

1

FUSIBLE LINK

OST

FUSE

0

l
0

BATTERY

u

I
L

f
t
3

POWER ANTENNA

MOTOR

SEL449

EL 89

ELECTRICAL
Accessories

Electrical

WIRING

SYSTEM

DIAGRAM AUDIO

REAR

DWR

ffih
U

BATTE
o

SPEAKER

Y

RH

@

FUSIBLE
LINK

1J

Sf

@

Block

I

J

@

I
I

o

tk@Y

@

J
lgW

I

LW

v

m

illY

LR

4YJ

LB

LyR
I

a

@

I

rT

REAR
SPEAKER
L

i

J

0 01

l@
I

B
DOOR

IBlue

Green

SPEAKER

L
DOOR
SPEAKER

LH

a

m

J

a

I

15i

0000 00

@

0

J

t

II

R H
0000

II

I

YUi U
@

@

@

Irml
9

0
FUSE

RADIO

DECK

SE 1448

EL 90

ELECTRICAL SYSTEM

Elecrrical Accessories

WIRING DIAGRAM POWER ANTENNA

FUSIBLE
LINK

BATTERY

1

D
G

re I

ftWR
@

IGNITION SWITCH
ST

ON

ACC Off

8

@
mtl

I
J

g

1

1

WR

LBi
I

RW
FUSE BLOCK

B W

Whitel@

s

ill

I
I

0

l
Q
L

@

J

White

@ Ifg

Il

s

s

cO

a

n

i
l

@B
0

1

o

1I000ill

lIt

000000

@

II
CD

@

c

@
@

Green

Bluel

s
a

w
I

nht

i

I

lIgg1gitl I

s

I
s

I
POWER

CD

ANTENNA

@L1f3J

SWITCH

I U

N

Ig

D

@r
POWER
ANTENNA
MOTOR

SEL450

EL 91

ELECTRICAL SYSTEM

Electrical Accessories

RADIO

Antenna trimmer adjustment
The

Removal and InataUatlon
Prior
balancer

to

removing

remove

adjusted

antenna
in the

trimmer

following

Fading and weak

radio and sound

Mter installation

cluster lid C

AM

of

should be

cases

reception
n

w

antenna

feeder cable or radio receiver

Inspection

Before

adju ingt

be

sure

to

check

harness and antenna feeder cable con
necton for proper connection
SEL4S3

1

Extend antenna

completely

2

Turn radio

and turn volume

on

control to increase speaker volume
3

Tune in the weakest sta1ion

ly audible
14
4

on

dial at the

range

bare

around

1 400 kHz

CAUTION

Turn antenna trinuner to left

right slowly

and set it in the

or

position

00 not turn antenna trimmer
than

half
one

more

turn

where reception is strongest

POWER ANTENNA
Feeder cable routing

J

t

SEL346

Alway
EL 92

route

feeder cable away from other harne

4

HI

CI

u

OST

s

T

YAX

S

IP I

YEO

5

OIlUl

kQTY

n

3C
l
r

O

Q
l

f

o

O

E

R

SC

T

IP IO

N

r

r

r

c

s

CT
I

DJO

I

f

20081 Combined 1IIlIDtJ81

1

ANY

c

74 654

ITEMS

herein

FROM DATE
were
produced In

Intention

o

26

D271

amply

nd

9

c

ARErIMMED1ATELY

NOT SHIPP

10 DAYS

20082

80

off INVOI
ompllilnce
the

prices

CE
r fo
with

here

all

BACK ORDERED
NO
UNAUTHORIZED RETURNS

provisions of the
comply to

Invoiced do

CLAIMSAI
WED UNLESS
ACCEPTED
ThiS is to

MADE WITHIN
rtity that the 900ds

amended It is
Fair Labor Standards Act of 1938
best of
knowledge with
sting price egulations

tJ1e

SHIPPING

114l

ELECTRICAL SYSTEM
Power antenna motor

Electrical Accessories

NOISE PREVENTION
CAUTION

keep running
fully extended or

PARTS

Do not allow motor to
when antenna rod is

Condenser

retrected

Ignition coil
Alternator

Bonding wire
Body

The

Securely tighten

located

grounding

cover

power
on

switch

antenna

cluster lid C

is

Refer to BF

section

bolts

v

@CD

i

SE L348

DIAGNOSES

TROUBLE

I

engine rocker

Power antenna switch

II
antenna

to

Fading

SEL349

AND CORRECTIONS

and weak radio reception

Noisy radio reception

1
Stop engine and
Check feeder cable connections
O

N G

Kl

I

Check antenna ground
O

N G I

KJ

Adjust

turn off all other

switches
Connect

or

repair

I

1

K
O
secure Iy

l

Fading and
reception

Unchanged

N G

Check noise prevention parts
Condenser

antenna trimmer

Kj

wire

bonding

Replace

I

Kl

O
O

I

weak

Check ignition cables

I
T 1 ghten

Revised

See

Retighten

or

replace

N G

Check spark plugs

Replace radio

OK

Replace
N G

Revised

1

Faulty radio

I
Unchanged

Faulty speaker

Check feeder cable routing
OK
N G

Replace radio
Revised

Faulty radio

I

Repair

I
Faulty speaker

Unchanged
EL 93

ELECTRICAL SYSTEM

D

Automatic Speed Control Device A S C

AUTOMATIC SPEED CONTROL DEVICE
Before

CAUTION

starting to

wort

DESCRIPTION
Device

referred to

subsequently

A SC D

i

a

any part of e1ectricel system disconnect

The construction of this system and
Control

Speed

Automatic

The

on

the location of each

as

combined unit of

electronic circuits with

vacuum

shown

are

The

me

component part

page EL I04 and 105
AS C D controller generates
to the

equivalent

difference between the

ceble

battery ground

and the actual speed

on

electrical signal

an

chanisms

AS C D

preset speed

speed

picked

up by the

sen or

The

rvo

valve converts this

signal

and oper
ates the actuator which adjusts the

into corre

ponding

vacuum

throttle valve opening

SCHEMATIC A S C D

IGNITION SWITCH
FUSIBLE LINK

I

L
Y

L

FUSIBLE LINK

OACC
Y

gr

FUSE

I

FUSE

FUSIBLE LINK

BATTERY

I

C
cY

IGNITION AND
ACCESSORY RELAY

1

l

I

Neutral xmtion
OFF

ON

I

ll

SOLENOID VALVE

TO LIGHTING
SY TE

MAIN SWITCH

I

I

O
Y

r

@
CRUISE

ON

Y
rc

@

L

RELAY

SERVO VALVE

r

EJ
STOP LAMP

SWITCH

SET

I

SWITCH

OPEN

Q

CONTROLLER

I

I

STOP

8
INHIBITOR
SWITCH

o

0

INHIBITOR
RELAY

JATOR
ACl

TO
INTAKE
MANIFOLD

SWITCH

I

CLOSED

t
SPEED
SENSOR

THROTTLE
LEVER

I
SELAOO

EL 94

r

ELECTRICAL SYSTEM

AND

FUNCTION

OPERATION

depressed

lhe switch

cancels the preset
M ln swttch
The main switch has

a

holding type

of circuit
When the main switch is turned ON
wilh lhe ignition switch ON lhe

exciting coil of the relay will be ener
gized and the relay will turn ON lhus
current

supplying

to

lhe

system

Although the main switch automatical
ly retums to its original position the
current is sent

through lhe relay and

fed to the exciting coil via lhe main
switch in this way lhe relay will
When the ignition switch
is tumed off lhe relay will also turn
remain ON

off And

the

operative

until

turned ON

relay will remain

even

lhe

main

if the ignition switch

is set to ON

lhe controller

speed

the switch is released

Speed

R I

y

The

The controller will preset lhe car
speed at which lhe car is running when

ly

release

v

is

ve

lhe safety
atmospheric
line when the

valve wliich shuts off the
passage to lhe

vacuum

system activates

s nsor

Actu tor

Contaln d In speedom t

r

The actuator causes ihe throttle to

The speed sensor is generating two
pulses per revolution of the meter

open and close
lhe servo valve

by

vacuum

through

cable
The output voltage range and lhe
duty cycle must be controlled prop
erly

wttch

Stop

The stop switch is used to release
When the brake pedal is

lhe system
S

ryo y

The

depressed this
power supply to

ly

TransdUc

in

switch is

car

D

Auramatic Speed Control Device A S C

servo

r

valve

causes

the

vacuum

valve and atmospheric valve to open or
close according to the input current
and

adjusts

the

vacuum

from

the

intake manifold

Stop I

off lhe

switch cuts

the A S C D circuil

mp switch

This switch

causes

At the

the stop
time

operate
ating signal of the stop light
same

light

to

the oper
circuit is

sent to lhe controller in order to re

Controll
S t swttch
has

CRUISE

light

OFF
ON

an

switch type of circuil
When the set switch is
lhe

compares the preset
oc
ntrol er
the
actual car speed and
speed with
The

switch

The set

lease the system

r

preset speed by
creasing
decreasing the current
flowing through the servo valve
maintains

depressed

illuminates

Wilh

in

the

or

Inhibitor
The

lliy

relay releases the
system when the selector is

inhibitor

s C D
A
set to

r

N

or

P

position

TROUBLE DIAGNOSES
TEST CONDITIONS

2

If a malfunction is found be
to check lhe
the

system tesl
I
All wiring harness
must be securely connected
ing

sure

following before perform

Indicator

light

A S C D

installed with proper adjustment
3
Vacuum hoses must be properly
attached wilh

connectors

will not glow

cable must be securely

such
or

even

as

no

vacuum

abnorrrial conditions

leakage sharp

if

ON

button of main switch is

WARNING
All following system

tests can be

performed withoutrunning engine
Avoid making test while driving car
or running engine

depressed with ignition switch ON

L

1
Burnt bulb

bends

kinks

DIAGNOSIS

Faulty

main switch

Faulty A S C D relay

EL 95

r

ELECTRICAL SYSTEM

CD i
Automatic Speed Control DBVice A S

Cruise light will not glow
switch ON

Speed

not set

eyen

if let switch is

depressed

and released 81 proper car

speed

with main

in system 1

1
With main switch ON battery
and

V

voltage 12V

is

present between terminals

Set automatic transmission selector lever at any

NW
I

@

of harness connector

position

other than Ip

and

position
YES

to
Open

circuit

I
Faulty

or

unproperly adjuSted

stop switch

When set switch is depressed with main switch ON battery voltage
between terminals @ and V ofhamess connector

12V is

present

YES

1
Faulty

NO

set switch

With main switch ON manually rotate meter cable slowly
Con1inuity between terminals CD and @ofharness connector exists two
times

a

rotation
YES

1

Faulty controller

EL 96

to
Faulty speed

sensor

Faulty inhibitor switch

ELECTRICAL SYSTEM

Cruise light illuminates when speed setting operation i

made but

Automatic Speed Control Device A S C D

peed

is not actually set

A

To servo
valve

When battery voltage

following
1

With

2 With

are

12V is

applied

to the release valve terminal the

possible

A

closed

A

opened

no

suction is

suction is

possible

begun

at

at

tlLL

B

B

YES

to

operates normally

I

B

I
To actuator
LJ
BE089D

Faulty release valve

Servo valve

1

It

Refer to Servo Valve for Inspection

YES

1

NO

Faulty servo valve

Actuator operates smoothly when actuator vacuum port is suctioned

operation

must be

YES

performed

1

Faulty controller

TItis

with A S C D cable released

lNO
Faulty actuator

EL 97

ELECTRICAL SYSTEM

Automatic Speed Control Device A SC D

Other maHunctlon

Condition
Set

Probable

speed is cancelled

Bent meter cable

Corrective act

cause

excessive meter needIe

deflection

Faulty
Pulsation of set speed

play

or

Check and repair meter cable
cable

or renew

Renew

controller

Excessive

on

binding

of A S C D

Adjust

cable

Leakage or clogging

in vacuum hose

Check and repair piping route

or renew

hose

Binding

in actuator

Faulty servo

Renew actuator

valve

Renew

Faulty controller
Excessive setting

error

Excessive

play

or

servo

valve

Renew controller

binding

in

sC D
A

Readjust

cable

Leakage

Speed drops immediately
after setting

or

clogging in vacuum

Faulty

actuator

Faulty

servo

hose

Check and repair
hose

valve

Renew

servo

valve

Renew controller

Faulty speed

Renew

Leakage

sensor

play

or

in A S C D cable

clogging

in vacuum hose

speed sensor

Readjust
Check and repair piping route
hose

Cancel circuit inoperative

EL 98

Faulty

release valve

Faulty

servo

valve

route or renew

Renew actuator

Faulty controller

Excessive

piping

Ren

w

rele

y
Rene

servo

valve
valve

Faulty controller

Renew controller

Faulty controller

Renew controller

or renew

ELECTRICAL SYSTEM

Automatic Speed Control Device A S C D

COMPONENT PARTS
VACUUM ROUTING

Adjusting

nut

Lock nut

Actuator

o

I

f
To vacuum check valVe
Air conditioner

equipped model

ToF I C D

SEL392

EL 99

ntrol Device IA S C D

Automatic Speed

WiltiNG OIAGRAM1A S

ELECTRICAL SYSTEM

CO

IGNITION AND ACCESSORY RElAY
W

f

lJWR

ffi

TT

5T

ON ACC Off

tg

r D

J

@

FUSIBLE
LINK

J

s 1T
l
tf

g

B

I

o

s

@

WR
W

W

IGNITION

TCH

r

we

o

0

VB

QI

0

1

INHIBITOR
5C D
A

t3@

RELAY

FUSE
BLOCK STcp LAMP
SWI

RELEASE

SERVO

v

V

STeP SWITCH

C1
U
L

SET SWITCH
AS

E

f

C D CONTROLLER

II@
jG
J

@
@

@

YL

a

J

I

I
CD

a

J

a

CD

C

a

J

I i

I

@

Ir

1

I

I

I
m

i

1

I

L

BL
m

vn
m
Cl

I
J

l@

lOr

m

@

@
@

Whits

1

iJ
CD

J

W

LgB

C

C

171
Y

m

I
l
I W
XI
Cl

@

III

@1r

J

11 1

I

0
AS

C D
SWITCH

SPEED SENSOR

MAIN

SEL3M

EUOO

ELECTRICAL SYSTEM
A S C D

CABLE

Automatic Speed Control Device AS C D
I

In ectlon
I

Removal and Inatallatlon

Visually check

Normal condition

actuator for dam

age Or deformation
I

Disconnect cable from actuator

2

1

Loosen lock nut at actuator

smoothly without binding when dia
phragm is pushed by hand
3
Apply vacuum to actuator If
diaphragm moves to full position it is

2

Remove rubber boots

Make

that actuator

sure

Check ports

Airflow

CD V
CD @
V @

Yes

moves

normal

Plug hose with
Make

sure

that

remains in full

laJor
act

12V direct current is applied be

2

applied

vacuum

tween terminals

position

2

1

Actuator

3

Cable

2

Rubber boot

4

Lock nut

3

To

Exercise

reverse

the

when

so

as

removing
not

to deform

When
cable

as

checking

by applying
apply engina vacuum

actuator

do not

installing

adjust

RELEASE VALVE
2

Location
Refer to page EL 99

1

0 12 in

This

Measure

the

resistance

cause

throttle

25
2

or

that the valve
air

Disconnect battery ground cable
Disconnect cable from actuator
for

hose

A S C D release valve

bolt attaching actuator

order of removal

Actuator

2

Serio valve side

3

Atmosphere side

side

I
the

performed
car

hose

Disconnect

vacuum

n
ZP

CD
S

E L409

hose

solenoid
at

valve

side

solenoid valve and

connect vacuum gauge

2

Start engine and

until

from

reverse

1

reo

moval

actuator

be

valve connected to system
apply current to servo valve Be

vacuum

i
Battery 12V

body
To install

should

through

Removal and Installation

vacuum

check

to disconnect solenoid valve sida

sure

closes by blowing
port on actuator side

cable

output

servo

do not

30 n

Check to be sure

opens

ACTUATOR

that

CAUTION
With

Circuit tester indication

lever to rotate

Disconnect

sure

between

Do not inc ease tension of cable

A SC D

be

ction

terminals
this may

to

of valve is proper

with the valve installed on

In

0 08
23m

Check

vacuum

play

Remove

between

30n

25

Then tighten lock nut

to

resistance

Circuit tester indication

cable free play is within specified value
at throttle lever

Refer

the

Measure

A S C D

pedal

as

ctlon

terminals

follows

excessively

In
1

directly

Without depressing the accelerator
adjust the adjusting nut until

Free

VALVE

Refer to page EL 99

CAUTION
When

Adjustment

5

No

BE100D

vacuum

to

CD @
V @

and

wire end

4

Yes

Location

care

wire

installing

3

CD V

SOLENOID

install the cable

order of removal

I

Airflow

Loosen lock nut at intake mani

fold bracket

2

Check ports

water

warm up engine
temperature indicator
middle of gauge

points to the
3 Apply
3A
O

direct

current

be

tween tenninals

tor

Using about 20n 5W variable resis
adjust so that a current of 0 3A

will flow

EL 101

Automatic Speed Control Device AoS C O

ELECTRICAL SYSTEM

Variable
resistor

I

I

Ir l

Ammeter
O 3A

0

Battery

e

12V

II

1

Yacuumgauge
73
55

11 3 kP
85

2 17

mmHg

3 35

inHg

Solenoid valve
side

IlL
I
I

I

To intake

l

manifold

Servo valve
BE730D

SPEED SENSOR
Lead switch type

MAIN

SWITCH

Inspection
Location
The speed
speedometer

light with

Test continuity
sensor

through

switch

or

with the

an

ohmmeter in accordance

following

chart

is built into the

f

Inspection

I Off

3
l

I

2Er

must be made with
Inspection
speed sensor installed to speedometer

II

OND

1Il1

lieAulSE

CIN11lfiIl

SE L424

TurDing speedometer SlowlY by
hand

test

continuity of speed

sensor

Switch position

circuit

Continuity existstwo times
a

turn

K
O

nro

A
9JD

ON

OFF

Q

@

No

Yes

No

Q

@

No

Yes

No

@

@

Yes

Yes

No

ID

@

Yes

@

j

Yes

@

j

Yes
Yes
No

EL 102

Normal
Check terminal

Continuity
Continuity

should exist
should not exist

ELECTRICAL SYSTEM

Automatic Speed Control Device AS C D

Inspection

Adjustment

SET SWITCH

Refer to MA section

Inspection
Test
with

an

continuity

through

switch

ohmmeter

A S C D

RELAY

Location

r

a

The A S C D

relay

is

located

1

c

on

@

the relay bracket Refer to page EL
105

@

r NORMAL PUSH
OPSTION SWITCH
1

11

9

12

6

INHIBITOR RELAY
For A S C D
SE L425

0

Location
The

inhibitor relay is located

a

o

t

I
L

on

@

Gr

the relay bracket Refer to page EL
STOP SWITCH

SEL433

105

Inspection
Test

with

an

l2V direct current is

continuity

through

switch

applied between terminals

Normal condition

Check terminals

@and@

ohmmeter

NORMAL
POSITION

PUSH
PLUNGER

@

@

Yes

@

@

Yes

No

CD

@

No

Yes

@

Yes

Continuity should
Continuity should

No

exist
not exist

f
11

9

126
SEL431

lC

Adjustment

CAUTION
Do not touch the circuit

built In

of the

stop switch is

the stop lamp switch
Refer to MA section
same as

The controller is located
dash side

panel

on

the left

to

Inspection

a

as a

single part

Check controller for opera

tion as

system

nosis
Rofer to page

damage

controller
Handle controller carefully to avoid

damage

Controller must not be checked

a

probe

on con

Refer to page EL I04

Inspection
STOP LAMP SWITCH

tester

to eny unnecessery terminal
troller Doing so could cause

Location

Adjustment

the

CONTROLLER

A S C D

referring

to

Diag

b

Keep controller away from electric
noise

source

system from

to

prevent A S C D

malfunctioning and
degraded

Ie

circuit etc from being

sO
El

EL 103

Electrical Unit Location

ELECTRICAL SYSTEM

ELECTRICAL UNIT LOCATION

Ignition arid
accessory

relay

sea tbelt
timer

HI
control
unit

I

SE L432

to

C

v

EL 104
cJ

ELECTRICAL SYSTE M

Air

Magnet

alve

v

Electrlca I Unit Location

conditioner relay

Air con

H

EFI relay
Fuel pump
A

relay l

7

S C D relay

III

Headlamp

@

sensor

I

Inhibitor relay

Intermittent wiper

amplifier

lardtop

Hatchback
I

Tai1 and stop lamp

nso

114
Tail

nd

lamp sensor

EL 105

YStEM

ELECTRICAL

Wiring Harness

WIRING HARNESS
CABLE COLORS
Cable colors

are

generally

used

as

shown in the following table

Circuit system

Base color

Starting and ignition system

Black

B

W

Charging system

White
R

lighting system

Red
G

Signal system

Green
Y

Instrument system

Yellow
L 8r

Others

Blue

Brown

Lg
light green

B

Grounding

system

mack

HARNESS LAYOUT

For easy identification connectors indicated in the system
ness

wiring diagram have

the

same

numbers

as

those used in the har

layout schematic

@
@@

Ii

w

CJ QOYG
YG

@@
Main harness

Wiring diagram
SEL461

EL 106

Instrument harness
SEL

2

ELECTRICAL SYSTEM

WiringHBrn8S

SCHEMATIC

Hatchback

1
2

Main harness

3

EFI harness

4

Body harness

S
6

Door harness

7

Back

8

Fuel pump harness

4

InstTumcnt harness

Console

harness

door

harness

Hardtop

SE L463

EL 107

tJ

CALIS SlE

ELEClf

Is

ttARtlESS
e

CO

e

Il

n

ar

i

I

10

i
g
e

0

0
I

s

6

U

I1i

t

t
o

e

g

11

u

i

u

5 iS

e

9

a
ti

li
a

ts

iJ

g

a

5
n

iio
Z
ll

e

ii
l

a

e II

t

i

t
5

@ @

j
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@
@

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0

d

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ga
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A
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switch

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switch switch
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main switch switch wiper
D

C
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A

Haz rd Igniton Windshel

@ @ @ i@ @@

unit

H

Am panel
lamp harnes harnes
cons le control door
L

Indicator

To

H
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unit

contrle contrle harnes flasher sfilgasnhaelr m5iWriotcrh

D D

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EFI

To

Haz rd Turn Door

@ 1Jjl @ @ @

@

Heater To

S

S

A A

Earth

harnes

relay relay
H

lamp ac es ory ac es ory timer
chime
harnes
and and

Warni g

interio Igniton Igniton belSeatt do r
To

unit

R

To

White Black switch

switch White Gre n Black Blue @l lID brake switch
m
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block
belt

c
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Fuse Heater Thermo

@ @ @ @ @ @@ @

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Air To To To To To To

Parking Seat

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m

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m

mn tIJ n

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rheosta met r met r met r

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muinado combinat combinat combinat

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aenlOr timer indcator switch

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D
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A

lamp

wambtg ante a

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dl

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tray box @ @ 8 @

Interio Multi Audio Power garet Ash Wamlns Glove

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lamp

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lamp

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combinat

Earth

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lamp
up
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Rear

harnes unit

ante a marker omparten speaker switch fupelump tagnkauge earth
Power Side Lug age Rear Door Fuel Body
lamp

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@ @ @ ffi @ @ @ @ ill @

senor senor
White Black

n

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R

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To To

H
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lamp lamp lamp

speaker andstop standop marker

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lamp lamp

lamp
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combinat combinat Licens Licens combinat
lamp lamp lamp

l

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Door To@ To@ Rear Tail Tail Side Rear Rear Back Rear

@ @ @ @ @ @ @ @ @ @ ill ill @ @ ill

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a
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lamp

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up
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Rear Side

@ @ @ @ @l

a

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a
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lamp
a

unit

a

lamp lamtopP lamP lamp tlon lamP gauge
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comb U

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n

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R

R

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ELECTRICAL SYSTEM

Wiring Harness

ENGINE ROOM HARNESS NO 2

@
@
@
@
@

Kickdown rwitch Arr
Inhibitor switch Am

@

Oil pressUIe sending unit
To I@

@
@
@

Inhibitor rwitch Am
Rever
bmp rwitch Mm
Starter motor

To@
To I@

I

f
r
I

0
J

11

1

fr2

fr

II

@

@

J

@
@
@

SEL460

EL 113

i
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f

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CLOSED

INCH TO METRIC CONVERSION TABLE

METRIC TO INCH CONVERSION TABLE

Rounded of for automotivo

Rounded off for automotive

use
inches

mm

inches

use
mm

inches

I

inches
100

2 54

610

49
15

1

0394

51

2 008

I
I

110

2 79

620

15 75

2

079

52

2 047

120

3 05

630

16 00

3

118

53

2 087

I

130

3 30

640

16 26

4

157

54

2 126

I

140

3 56

650

16 51

5

197

55

2 165

150

3 81

660

16 76

6

236

56

2 205

160

4 06

670

17 02

7

276

57

2 244

170

4 32

680

17 27

8

315

58

2 283

180

4 57

690

17 53

9

354

59

323
2

190

4 83

700

17 78

10

394

60

362
2

200

5 08

710

18 03

11

433

61

402
2

210

5 33

720

18 29

12

472

62

441
2

220

5 59

730

18 54

13

512

63

230

5 84

740

18 80

14

551

64

2 520

240

6 10

750

19 05

15

591

65

2 559

250

6 35

760

19 30

16

630

66

2 598

260

6 60

770

19 56

17

669

67

2 638

270

6 86

780

19 81

18

709

68

2 677

280

711

790

20 07

19

748

69

2 717

800

20 32

20

787

70

2 756

21

827

71

2 795

866

72

2 835

906

73

2 874
2 913

290
300
310
320
330

mm

7 37
7 62

mm

480
2

810

20

7 87

820

20 83

22

8 13

830

21 08

23

8 38

840

21 34

24

945

74

21 59

25

984

75

2 953

340

8 64

850

350

8 89

860

21 84

26

1 024

76

2 992

360

9 14

870

22 10

27

1 063

77

3 031

28

1 102

78

3 071

1 142

79

110
3

80

3 150

370

40
9

880

22 35

380

9 65

890

22 61

29

I

390

9 91

900

22 86

30

I

400

10 16

910

23 11

31

1 220

81

920

23 37

32

1 260

82

3 228
3 268

410

I

f
I
I

41
10

181
1

189
3

420

10 67

930

23 62

33

299
1

83

430

10 92

940

23 88

34

1339

84

307
3

440

1118

950

24 11

35

378
1

85

346
3

450

1143

960

24 38

36

1417

86

386
3

460

1168

970

24 64

37

1457

87

470

11 94

980

24 89

38

1496

88

3465

480

12 19

490

45
12

425
3

990

25 15

39

1 535

89

3 504

1000

25 40

40

575
1

90

3 543

500

12 70

2 000

50 80

41

1614

91

3 583

510

12 95

3 000

76 20

42

1 654

92

3 622

520

13 21

4 000

101 60

43

1 693

93

3 661

530

13 46

5 000

127 00

44

1732

94

3 701

540

13 72

6 000

45

772
1

95

3 740

550

13 97

7 000

177 80

46

1 811

96

3 780

560

14 22

8 000

203 20

47

1 850

97

3 819

9 000

228 60

48

1890

98

3 858

570

48
14

40
152

580

14 73

10 000

254 00

49

1929

99

3 898

590

14 99

20 000

508 00

50

1 969

100

3 937

600

15 24

I

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EXPORT SERVICE DEPARTMENT

NISSAN

MOTOR CO

17 1 Ginza 6Chome Chuo ku

LTD
Tokyo

104

Jap
Issued

Printed in Japan

February 1 811 020200
UO
Bll
SMOE

Publication No

I



---

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.2
Linearized                      : No
Page Count                      : 572
Title                           : Service Manual Datsun 200SX 1980
Author                          : Laserfiche Client
Creator                         : Laserfiche
Create Date                     : 2008:09:04 20:35:01

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