Nissan 1980 200Sx Repair Manual Service Datsun

v

I

DATSUN

I

0

o

1980

DATSUN

200

SX

rl1

SERVICE

MANUAL

A

J

i

I

h

t

fi

t

i

t

i

CI

o

IIV

INI55ANI

HlUM

lOco

QUICK

REFERENCE

INDEX

GENERAl

INFORMATION

GI

DATSUN

200SX

MAINTENANCE

M

ENGINE

MECHANICAL

E

Model

S

J

JO

Series

ENGINE

LUBRICATION

COOLING

SYSTEMS

LC

ENGINE

FUEL

iF

FOREWORD

EMISSION

CONTROL

SYSTEM

E

This

service

manual

has

been

prepared

pri

marily

for

the

purpose

of

assisting

service

personnel

in

providing

effective

service and

maintenance

ofthe

1980

DATSUN

200SX

ENGINE

REMOVAL

INSTALLATION

E

ENGINE

CONTROl

FUEL

EXHAUST

SYSTEMS

F

This

manual

includes

procedures

for

main

tenance

adjustments

removal

and

installa

tion

disassembly

and

assembly

of

com

ponents

and

trouble

shooting

All

information

illustrations

and

specifica

tions

contained

in

this

manual

are

based

on

the

latest

product

information

available

at

the

time

of

publication

If

your

DATSUN

model

differs

from

the

specifications

con

tained

in

this

manual

consult

your

NISSANI

DATSUN

dealer

for

information

CLUTCH

C

MANUAL

TRANSMISSION

M

AUTOMATIC

TRANSMISSION

A

PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

P

FRONT

AXlE

FRONT

SUSPENSION

F

The

right is

reserved

to

make

changes

in

specifications

and

methods

at

any

time

with

out

notice

REAR

AXLE

REAR

SUSPENSION

R

BRAKE

SYSTEM

B

STEERI

NG

SYSTEM

S

NISSAN MOTOR

CO

LTD

BODY

B

HEATER

AIR

CONDITIONER

H

@

t

979

NISSAN

MOTOR

CO

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

ELECTRICAL SYSTEM

E

v

w

I

HOW

TO

USE

THIS

MANUAL

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

concern

the

engine

and

the

second

half

presents

sections

which

deal

with

the

chassis

and

body

A

QUICK

REFERENCE

INDEX

is

provided

on

the

first

page

Refer

to

this

index

along

with

the

index of

the

particular

section you

wish

to

consult

The

first

page

of

each

section

lists

the

contents

and

gives

the

page

numbers

for

the

respective

topics

SE

RVICr

DATA

AND

SPECIFICATIONS

are

contained

in

each

section

TROUBLE

DIAGNOSES

AND

CpRRECTIONS

are

also

included

in

each

section

This

feature

of

the

manual

lists

the

likely

causes

of

trouble

and

recommends

the

appropriate

corrective

actions

to

be

taken

A

list

of

SPECIAL

SERVICE

TOOLS

is

included

in

each

section

The

special

service

tools

are

designed

to

assist

you

in

performing

repair safely

accurlltely

and

quickly

For

information

concerning

how

to

obtain

special

service

tools

write

to

the

following

address

Kent

Moore

Corporation

Kent

Moore

of

Canada

Ltd

29784

Little

ack

2395

Cawthra

RO

eville

Michigan

48066

Mississauga

Ontario

Canada

L5A

3P2

The

measurements

given

in this

manual

are

primarily

expressed

with

the

Sl

unit

International

System

of

Unit

and

alternately

expressed

in

the

metric

system

and

in

the

yard

pound

system

The

back

cover

of

the

manual

provides

maintenance

data

for

quick

reference

In

the

text

the

following

abbreviations

are

used

s

o

s Service Data

nd

Specifications

L

HR

H

left

Hand

Right

Hand

f

J

Tightening

TorQue

MOrr

AiT

Manual

Transmission

Automatic

Transmission

The

captions

CAUTION

and

WARNING

warn

you

of

steps

that

must

be

followed

to

prevent

personal

injury

and

or

damage

to

some

part

of

the

car

N

IMPORTANT

SAFETY

NOTICE

I

The

proper

performance

of

service is

essential

for

both

the

safetY

of

the

mechanic

and

the

efficient

functioning

of

the

car

The

service

methods

in

this

Service

Manual

are

described

in

such

a

manner

that

the

service

may

be

per

formed

safely

and

accurately

Special

service

tools

have

been

designed

to

permit

safe

and

proper

performance

of

service

Be

sure

to

use

them

Service

varies

with

the

procedures

used

the

skills

of

the

mechanic

and

the

tools

and

parts

available

Accordingly

anyone

using

service

procedures

tools

or

parts

which

are

not

specifically

recommended

by

NISSAN

must

first

completely

satisfy

himself

that

neither

his

safety

nor

the

car

s

safety

will

be

jeopardized

by

the

service

method

selected

DATSUN

200SX

Model

SIlO

Series

SECTIONGI

GI

GENERAL

INFORMATION

CONTENTS

GENERAL

VIE

WS

MODEL

VARIATION

IDENTIFICATION

NUMBER

LIFTING

POINTS

AND

TOWING

PANTOGRAPH

JACK

GARAGE

JACK

AND

SAFETY

STAND

GI 2

GI 3

GI

4

GI 5

GI

5

TIE

DOWN

TOWING

SPECIAL

SERVICE

TOOLS

TIGHTENING

TORQUE

OF

STANDARD

BOLT

GI 5

GI 6

Genetal

Views

GENERAL

INFORMATION

Hardtop

l

I

r

I

O

II

JI1

Po

dI

V

Ll

34S

S3 0

1

680

66

1

ll

r

lU

I11

hF

oi

11

LI

345

53

O

J

1

680

66

1

Unit

mm

in

Hatchback

t

c

iq

L

1

345

53

0

1

680

66

1

Unit

mm

in

GI

2

GENERAL

VIEWS

J

c

f

1

11

I

r

L

1

m

41

f

1

g

t

I

ll

t

X

990

39

0

2

400

94

5

1

090

42

9

480

176

4

SGIOO2

fT

d

r

Ii

r

b

t

I

J

I

t

iL

L

J

I

J

r

1

t

uJJ

Il

IY

1

T

2

400

94

5

t

090

42

9

4

480

t

76

4

990

39

0

5GI003

GENERAL

INFORMATION

Model

Variation

MODEL

VARIATION

Desti

Differential

Road

wheel

nation

Class

Model

Engine

Transmission

carrier

Size

Offset

Tire

size

mm

in

PI

SIIOFEV

FS5W71B

Hardtop

PLSIIOAEV

I

3N71B

California

KPLSIlOFEV

I

5J

14

25

185

FS5W71B

Hatchback

0

98

70

SR

14

KPLSllOAEV

I

3N71B

U

S

A

PLSIl

OFEU

I

FS5W71B

Hardtop

I

PLSllOAJ

iU

3N71B

5

1

2JJ

14

25

185

Z20E

HI65B

KPLSllOFEU

I

FS5W71B

0

98

70

SR14

Hatchback

Non

I

KPLSIIOAEU

I

3N71B

California

I

PLSllOFEN

I

FS5W71B

Hard

top

II

2

PLSllOAEN

3N71B

4

T

x

16

35

T135

Canada

I

KPLSllOFEN

I

FS5W7IB

1

38

70D16

2

Hatchback

I

KPLSllOAEN

I

3N71B

Prefix

and

suffix

designations

K

o

P

L

Hatchback

I

Hardtop

J

Z20

engine

Left

hand drive

K

P

L

SIlO

J

I

0

PST

LT

0

means

no

indication

I

Aluminum

wheel

Option

2

Spare

tire

Sun

roof

Glass

Sport

Luxury

model

Power

steering

Sun

roof

Steel

Rear window

wiper

Air

conditioner

Non

California

model

for

U

S

A

V

California

model

N

Canada

model

E E

F

l

F

Manual

transmission

S

P

R

L

C

U

A

Automatic

transmission

GI

3

IdentificationNiJmber

GENERAL

INFORMATION

CAR

SERIAL

NUMBER

PLATE

CAR

SERIAL

NUMBER

Hatchback

Z20

engine

Model

ENGINE

SERIAL

NUMBER

The

engine

seria

number

is

stamp

ed

on

the

left

side

of

the

cylinder

block

I

Q

SGIOO6

GI

4

IDENTIFICATION

NUMBER

EMISSION

CONTROL

INFORMATION

LABEL

K

P

SlID

r

x

XXXXX

I

MANUAL

TRANSMISSION

NUMBER

The

transmission

seria

number

is

stamped

on

the

front

upper

face

of

the

transmission

case

TM235

SGI004

Car

serial

number

AUTOMATIC

TRANSMISSION

NUMBER

The

transmission

serial

number

plate

is

attached

on

the

right

hand

side

of

the

transmission

case

A

T344

GENERAL

INFORMATION

UftingPointsand

Towing

LIFTING

POINTS

AND TOWING

Towing

hook

UL

IW

I

@

A

@

I

il

Towing

hook

Jack

up

point

for

pantograph

jack

Jack

up

point

for

garage

jack

Supportable point

for

safety

stand

PANTOGRAPH

JACK

WARNING

a

Never

get

under

the

car

while

it

is

supported

only

by

the

jack

Always

use

safety

stands

to

support

frame

when

you

have

to

get

under

the

car

b

Place

wheel

chocks

at

both

front

and

back

of

the

wheel

diagonally

opposite

the

jack

position

Apply

the

pantograph

jack

fur

nished

with

the

car

to

the

position

indicated

below

in

a

safe

manner

t

GARAGE

JACK

AND

SAFETY

STAND

WARNING

a

When

carrying

out

operations

with

the

garage

jack

be

sure

to

support

the

car

with

safety

stands

b

When

jacking

up

the

rear

front

of

the

car

place

the

chocks

at

the

front

rear

of

the

front

rear

wheels

to

hold

them

CAUTION

Always

place

a

wood

block

between

safety

stand

and

car

body

when

supporting body

with

safety

stand

Apply

the

garage

jack

and

safety

stand

to

the

position

indicated

below

in

a

safe

manner

TIE

DOWN

FRONT

SIDE

Use

front

towing

hooks

for

tie

down

REAR

SIDE

Use

rear

towing

hooks

for

tie down

TOWING

CAUTION

a

It

is

necessary

to

use

proper

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

Towing hook

7

r

J

@

II

1I

6

Towing

hook

SG

1007

b

All

applicable

State

or

Provincial

in

Canada

laws

and

local

laws

regarding

the

towing operation

must

be

obeyed

c

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

used

d

If

the

transmission

is

inoperative

tow

the

car

with

the

rear

wheels

off

the

ground

or

with

the

propeller

shaft

removed

e

When

the

car

is

towed

with

its

front

wheels

on

the

ground

secure

the

steering

wheel

in

a

straight

ahead

position

with

the

ignition

key

turned

in

OFF

position

f

When

towing

an

automatic

trans

mission

model

on

its

rear

wheels

do

not

exceed

30

km

h

20

MPH

and

a

distance

of

30

km

20

miles

g

Release

the

parking

brake

and

set

the

gearshift

lever in

Neutral

position

before

starting

to

tow

the

car

GI 5

Specia

Service

T

oo

s

Tightening

TO

1ueofStandardBolt

GENERAL

INFORMATION

SPECIAL

SERVICE

TOOLS

Special

Tools

play

very

important

role

in

the

maintenance

of

cars

These

are

essential

to

the

safe

accurate

and

speedy

servicing

The

working

times

listed

in

the

column

under

FLAT

RATE

TIME

in

FLAT

RATE

SCHEDULE

are

com

puted

based

on

the

use

of

Special

Tools

The

identification

code

of

mainte

nance

tools

is

made

up

of

2

alphabeli

calletteIS

and

8

digital

figures

The

heading

two

letters

roughly

classify

tools

or

equipment

as

STOOOOOOOO

Special

Tool

KVOOOOOOOO

Special

Tool

EMOOOOOOOO

Engine

Overhaul

ing

Machine

General

Gauge

Garage

Tool

Hand

Tool

GGOOOOOOOO

LMOOOOOOOO

HTOOOOOOOO

TIGHTENING

TORQUE

OF

STANDARD

BOLT

Grade

Bolt

or

nut

size

M6

M8

4T

MIO

MI2

MI4

M6

M8

7T

MIO

MI2

MI4

M6

M8

9T

MIO

MI2

MI4

1

Special

pam

are

excluded

2

This

standard

is

applicable

to

bolu

having

the

following

marks

embossed

on

the

bolt

head

Grade

Mark

4T

7T

9T

GI 6

Bolt

or

nut

diam

eter

mm

Pitch

mm

6 0

1

0

1

25

1

0

1

5

1

25

175

1

25

15

1

0

1

25

1

0

15

1

25

175

1

25

15

1

0

1

25

1

0

1

5

1

25

1

75

1

25

1

5

8 0

10

0

12

0

14

0

60

8

0

10 0

12

0

14

0

6 0

8 0

10

0

12

0

14

0

Nominal

diameter

4

7

9

M6

TT

Tightening

torque

N

m

kg

m

ft

Ib

2939

03

0

4 2 2 2 9

7 8

10

8

0

8

Ll

5

880

7810 8 0 8

Ll

5

8 8 0

16

22

1

6

2

12 16

16

22

1

62 2 12 16

26 36

2 7

3

7

20

27

30

40

3

1

41

22

30

46 62

4

7

63

34 46

5

9 6 9

0

607

43

51

I

14

18

1

4

1

8

10 13

I

14

1814

1

8

10 13

I

25

35

26

3

6

19

26

I

26 36

2 7 37

20

27

I

45

61

46

62

33

45

I

50 68

51

6 9

37

50

L

76

103

7 7

10

5

56 76

I

7 8 10 8

O

11

5 8 8

0

I

19

25

1

9

25

14 18

I

20

27

2

0

2814

20

I

36 50

37

51

27

37

I

39

51

4

0

52

29

38

I

65 88

6 6 9

0

48

65

I

72

97

73

99

53 72

I

109

147

11

1

15

0

80

108

Nominal

diameter

of

bolt

threads

Unit

mm

Metric

screw

threads

DATSUN

200SX

Model

S

JJ

0

Series

II

MAINTENANCE

CONTENTS

MAINTENANCE

SCHEDULE

MA

2

MANUAL

TRANSMISSION

MA

23

LUBRICATION

CHART

MA

4

AUTOMATIC

TRANSMISSION

MA

24

RECOMMENDED

FUEL

AND

PROPELLER

SHAFT

AND

LUBRICANTS

MA

5

DIFFERENTIAL

CARRIER

MA

24

FUEL

MA

5

FRONT

AXLE

AND

LUBRICANTS

MA

5

FRONT

SUSPENSION

MA

24

SAE

VISCOSITY

NUMBER

MA

5

REAR

AXLE

AND

APPROXIMATE

REFILL

REAR

SUSPENSION

MA

27

CAPACITIES

MA

5

BRAKE

SYSTEM

MA

28

ENGINE

MAINTENANCE

MA

6

WHEEL

AND

TIRE

fVlA

29

BASIC

MECHANICAL

SYSTEM

MA

6

STEERING

SYSTEM

MA

33

IGNITION

AND

FUEL

SYSTEM

MA

9

BODY

MA

35

EMISSION

CONTROL

SYSTEM

MA

14

HEATER

AND

AIR

CONDITIONER

MA

36

MINOR

TROUBLE

DIAGNOSES

SERVICE

DATA

AND

CORRECTIONS

MA

15

SPECIFICATIONS

MA

39

CHASSIS

AND

BODY

ENGINE

MAINTENANCE

MA

39

MAINTENANCE

MA

23

CHASSIS

AND

BODY

ENGINE

CONTROl

FUEL

MAINTENANCE

MA

39

AND

EXHAUST

SYSTEMS

MA

23

SPECIAL

SERVICE

TOOL

MA

40

CLUTCH

MA

23

Maintenance

Schedule

MAINTENANCE

SCHEDULE

The

following tabels

list

the

periodic

maintenance

servicing

required

to

ensure

good

emission

control

performance

good

engine

performance

and

good

mechanical

condition

in

DATSUN

The

fint

1

600

km

11

000

miles

service

is

one

of

the

most

important

services

uired

to

nsurw

the

maximum

mission

control

perfonnlnce

and

optimuin

engine

con

Iition

MAINTENANCE

OPERATION

MAINTENANCE

INTERVAL

Periodic

maintenance

should

be

performed

Kilometers

x

1

000

1

6

t2

24 36 48 60

72

at

number

of

kilometers

miles

or

months

Ref

rence

whichever

comes

first

Miles

x

1

0001

1

7

51

t51

22

5

301

37

5

451

page

Months

6

t2 t8

24

3D

36

Intake

exhaust

valve

clearance

Drive

belts

En

uine

oil oil

filter

Engine

coolant

Idle

rpm

Fuel

filter

Fuel

lines

hoses

piping

connections

etc

Air

cleaner

filter

Spark

plugs

EMISSION

CONTROL

MAINTENANCE

@

CALIFORNIA

@ @

j

A

So

NOTE

111

R

RO

R R

R

RO

@

So

NOTE

131

I

Soo

NOTE

121

@

Ignition

wiring

Air

induction

v8lv

filter

Vapor

lines

NOTE

III

121

131

41

So

NOTE

121

R

@

MA

6

MA

6

MA

7

MA

8

MA

12

MA

13

MA

13

MA

14

MA

9

MA

9

MA

t4

MA

t4

RO

Abbreviations

A

Adjust

A

Replace

I I

nspect

correct

replace

if

necessary

If

nhicla

is

under

sever

conditions

short

distance

driving

extensive

idling

or

driving

in

dusty

conditions

change

engine

oil

every

5

000

km

3

000

miles

or

3

months

whichever

comes

first

More

frequent

maintenance

is

required

und

dusty driving

conditions

If

the

vehic

le

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

filt

immmiatefy

D

@

an

@

are

the

maintenance

intervals

required

by

California

Regulations

@

limits

the

warranty

COYII

to

these

re

placement

InterYals

and

R

the

uired

mainUNInce

intervals

Other

maintenance

items

and

intervals

are

recommended

by

NISSAN MOTOR

CO

L

TO

EMISSION

CONTROL

MAINTENANCE

NON

CALlFORNIA

1

A A

I

R R

R

A

Intake

exhaust

valve

clearance

Drjve

bel

s

Engine

oil oil

filter

Engine

coolant

Idle

rpm mixture

ratio

Fuel

filter

Fuel

lines

hoses

piping

connections

etc

J

Air

cleaner

filter

Ignition

timing

Spark

plugS

So

NOTE

151

R

R R

Idle

rpm

A A

Mixture

ratio

Soo

NOTE

7

So

NOTE

161

R

A

R

I

R

A

Ignition

wiring

Air

induction

valve

filter

except

Canada

Vapor

lines

MA

2

Soo

NOTE

61

A

MA

6

MA

6

MA

7

MA

8

MA

l0

MA

l0

MA

13

MA

13

MA

t4

MA

l0

MA

9

MA

9

MA

14

MA

14

R

A

51

161

171

81

Abbreviations

A

Adjust

R

Replace

I

Inspect

correct

replace

if

necessary

If

vehicle

is

operated

under

senre

conditions

short

distance

driving

extensive

idling

or

driving

in

dusty

conditions

chenge

engine

oil

every

5

000

km

3

000

miles

or

3

months

whichner

comes

fitst

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

low

or

extremely

high

the

filter

might

become

dow

l

In such

IIn

event

replace

the

filter

immeduty

Maintenance

items

with

are

recommended

by

NISSAN

MOTOR

CO

L

TO

Other

maintenance

items

Ifll

required

MAINTENANCE

Maintenance

Schedule

Periodic

maintenance

should

be

performed

at

number

of

kilometers

miles

or

months

whichever

comes

first

MAINTENANCE

INTERVAL

Kilometers

x

1

000

1

6

t2

24 36 48 60

72

Reference

Miles

x

1

000

III

17

5

It51

122 51 130 137 51 451

page

Months

6

t2 t8

24 30

36

MAINTENANCE

OPERATION

UNDERHDOD

MAINTENANCE

Brake

fluid

Brake

booster

vacuum

hoses

connections

check

valve

Air

conditioning

system

hoses

connections

refrigerant

leaks

Power

steering

fluid

lines

R

MA

23

24

28 33

R R

MA

28

MA

28

MA

J7

I

MA

33

Brake

clutch

steering

gear

automatic

transmission

fluid

or

cillevel

leaks

UNDER

VEHICLE

MAINTENANCE

Brake

clutch

fuel

exhaust

systems

for

proper

attachment

leaks

cracks

chafing

abrasion

deterioration

etc

MA

23 28

Manual transmission

differential

gear

oil

See

NOTE

19

MA

23 24

MA

24

27

34

Steering

gear

box

linkage

suspension

parts

propeller

588

NOTE

10

shaft

for

damaged

loose

missing

parts

Underbody

flush

and

clean

every

12

months

OUTSIDE

AND

INSIDE

MAINTENANCE

Rotate

wheel

position

nspect

wheel

balance

wheel

alignment

MA

26 30

32

yJ

Disc

brake

pads

other

brake

components

for

wear

deterioration

leaks

See

NOTE

111

MA

28

Front

wheel

bearing

MA

25

Locks

hinges

hood

latch

Seat

betts

buckles

retractors

anchors

adjuster

Foot

brake

parking

brake

clutch

for

stroke

free

play

operation

See

NOTE

11

L

MA

35

MA

35

MA

23

28

Abbreviations

R

I

Replace

L

Lubricate

Inspect

correct

replace

if

necessary

NOTE

91

When

towing

a

trailer

change

oil

in

differential

gear

every

48

000

km

30

000

miles

or

24

months

whichever

comes

first

10

Steering

linkage

front

suspension

ball

joint

inspection

should

be

performed

every

96

000

km

60

000

miles

or

4

years

whichever

comes

first

111

If

vehicle

is

operated

in

areas

using

road

salt

or

other

corrosive materials

inspect

every 5

000

km

3 000

milesl

or

3

months

whichever

comes

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

30

j

f

liSl

CHANGE

ll

CHECK

LUBRICATE

QIQ

GREASE

UP

ENGINE

ANTIFREEZE

COOLANT

n

FRONT

WHEEL

BEARINGn

CLUTCH

FLUIO

BRAKE

FLUIO

6

STEERING

GEAR

OIL

LOCKS

HINGES

81

@

HOOD

LATCH

DIFFERENTIAL

GEAR

OIL@

@

If

vehicle

is

operated

in

ereai

u

ing

road

salt

or

other

corrosive

material

inspect

every

6

000

km

3

000

mile

or

3

month

whichever

cornel

fil

lt

km

mila

Month

EVERY

411

000130

000

@

EVERY

24

000

115

000

@

1

L

@

When

towing

l

I

trailer

change

011

in

differential

gear

every

48

000

km

30

000

miles

or

24

onth

whichever

cornel

fll

lt

@

If

the

vehicle

i

operated

under

extremeadverse

wheather

conditon

or

in

erel

l

where

ambient

temperature

lIre

either

extremely

low

or

extreme

IV

high

the

filter

might

become

cloggltd

In

such

an

event

replICe

the

filter

Immediatelv

BATTERY

ELECTROLYTE WINDSHIELD

AND

REAR

WINDOW WASHER

FLUID

@

FUEL

FILTER

POWER

STEERING

GEAR

OIL

@OILFILTER @ENGINEOIL

MANUAL

TRANSMISSION AUTOMATICTRANSMISSION

@

If

vehicle

i

operated

under

sevare

conditions

short

dluance

driving

extensive

idling

or

driVing

dusty

conditions

change

engine

oil

every

6

000

km

3

000

miles

or

3

months

whichever

comes

1111t

I

c

m

JJ

o

bo

5

Z

ct

g

I

3

Z

l

m

Z zn

m

2

JJ

Recommended

Fuel

and

Lubricsnts

MAINTENANCE

Approximate

Refill

Capacities

RECOMMENDED

FUEL

AND

LUBRICANTS

FUEL

Use

an

unleaded

gasoline

only

of

at

least

91 research

octane

number

Anti

knock

index

87

Under

no

circumstances

should

a

leaded

fuel

be

used

ince

this

will

damage

the

catalytic

converter

LUBRICANTS

SAE

VISCOSITY

NUMBER

Lubricant

Specifications

Remarks

Gear

oil

Transmission

and

steering

API

GL4

Further

details

refer

to

recommended

SAE

viscosity

chart

ENC

EOIL

I

III

0

I

ICM

211

JGIIf4l

I

t

l

1

lo

r

Gasoline

engine

oil

APISE

Anti

freeze

Ethylene

glycol

base

II

I

or

v

rJ

dri

I

l

I

r

I

1

I

1

I

r

1

I

40

I

II

1

TI

c

nII

OlIl

ll4OlllC11lllllll101

11 F

T

Jl

Nut

O

Ch

Differential

API

GL

5

Automatic

T

M

and

power

steering

fluid

Type

DEXRON

Multi

purpose

grease

NLGI

No

2

lithium

soap

base

Brake

and

clutch

fluid

DOT

3

US

FMVSS

No

116

APPROXIMATE

REFILL

CAPACITIES

liter

us

measure

Imp

measure

Fuel

tank

Hardtop

53

14gal

II

5

8

gal

Hatchback

60

15

78

gal

13

1

4

gal

Coolant

With

heater

9

5

IOqt

8

38

qt

Without

heater

8 8 9

1

4qt

7

3

4

ql

Engine

With

oil

filter

4

1

4

3

8

qt

3

5

8qt

Without

oil

filter

3

9

4

1

8

qt

3

38

ql

Transmission

M

T

2 0

4

1

4

pt

3

1

2

pt

A

T

55

5

7 8

qt

4 7 8

qt

Differential

carrier

11

2

3

8

pi

2

pt

Power

steering

system

1

2

11

4ql

I

1

8

ql

Steering

gear

0

28

5

8

pt

1

2

pt

Windshield

washer

tank

2 0

21

8

ql

13

4qt

Rear

window

washer

tank

1

0

1 1

8

qt

78

qt

Air

conditioning

system

Compressor

oil

0

27

91

f

OZ 9

0

oz 95

f

OZ 9 0

oz

Refrigerant

0

9

11

kg

2 0

2

4lb

2 0 2

41b

MA

5

Engine

Maintenance

MAINTENANC

E

BASIC

MECHANiCAL

SYSTEM

ADJUSTING INTAKE

AND

EXHAUST

VALVE

a

EARANCE

Adjustment

should

be made

while

engine

is

hot

I

Start

engine

and

warm

up

engine

until

water

temperature

indicator

points

to

the

middle

of

gauge

then

stop

engine

Valve

clearance

adjustment

cannot

be made

while

engine

is

in

operation

2

Remove

valve

rocker

cover

3

Set

so

that

high

point

of

No

I

cam

lobe

points

down

No

1

earn

lobe

SMA005

When

turning

crankshaft

with

starter

remove

high

tension

cable

from

ignition

coil

then

turn

it

Adjust

clearance

of

half

of

the

valves

Adjust

only

CD

@ @

and

j

valves

CD

4

Front

o

1lJf

Dt

DFJ

000

SMA049

MAS

ENGINE

MAINTENANCE

Valve

clearance

Hod

Intake

CD

@

0

30

mm

0

012

in

Exhaust

@

j

0

30

mm

10

012

i

n

I

Using

feeler

gauge

measure

clear

ance

between

valve

stem

end

and

rocker

arm

screw

Feeler

gauge

should

move

with

a

very

slight

drag

8M

AQSO

2

If

the

clearance

is

not

within

spec

ified

value loosen

rocker

arm

nut

and

turn

rocker

ann

screw

to

provide

pro

per

clearance

3

Hold

rocker

arm

screw

and

tighten

rocker

arm

nut

SMA051

dl

Rocker

arm

nut

16

22

N

m

1

6

22

kg

m

12

16

ft

b

4

Recheck

clearance

4

Turn

crankshaft

and

set

so

that

high

point

of

No

I

cam

lobe

points

above

0No

1

earn

lobe

SMA001

Adjust

ID ID @

and

@

valves

using

same

procedure

as

for

Step

3

@ @

Front

kG

D

tDf

OO

ID

SMA052

Valve

clearance

Hod

Intake

@ @

0

30

mm

0

012 in

Exhaust

ID ID

0

30

mm

0

012 in

5

Install

valve

rocker

cover

CHECKING

AND

ADJUSTING

DRIVE

BELTS

I

Visually

inspect

for

cracks

or

damage

Th

belts

should

not

touch

the

bottom

of

the

pulley

groove

2

Check

bell

tension

by

pushing

The

belts

should

deflect

by

the

spe

cified

amount

Drive

belt

deflection

8

12

mm

0

31

0

47

in

Applied prening

forc

98

N

10

kg

22lb

A

Loosen

to

adjust

I

t

f

J

r

Checking

point

of

drive

belt

deflection

3

Adjust

belt

tension

as

follows

Fan

and

alternator

belt

I

Loosen

the

upper

and

lower

alter

nator

securing

bolts

until

the

alterna

tor

can

be

moved

slightly

2

Move

the

alternator

with

a

prying

bar

until

the

belt

tension

is

within

the

specified

range

Then

tighten

the

bolts

securely

Air

conditioner

compressor

and

power

steering

011

pump

belts

Loosen

the

idler

pulley

lock

nut

2

Adjust

the

adjusting

bolt

until

the

belt tension

is

within

the

specified

amount

3

Tighten

the

idler

puUey

lock

nut

securely

MAINTENANCE

Engine

Maintenance

Alternator

t

ilJ

J

Idler

puUey

LoCk

nut

Adjust

Loosen

Compressor

pulley

Crank

pulley

Idler

pulley

Adjusting

bolt

Adjust

8M

A053

CHANGING

ENGINE

OIL

AND

OIL

FILTER

1

Start

engine

and

warm

up

engine

until

water

temperature

indicator

points

to

the

middle

of

gauge

then

stop

engine

2

Remove

oil

pan

drain

plug

and

oil

fiUer

cap

and

allow

oil

to

drain

A

milky

oil

indicates

the

presence

of

cooling

water

Isolate

the

cause

and

take

corrective

measure

An

oil

with

extremely

low

viscosity

indicates

dilution

with

gasoline

3

Clean

and

install

oil

pan

drain

plug

with

washer

WARNING

Be

careful

not

to

burn

yourself

as

the

engine

oil

may

be

hot

IiJ

Oil

pan

drain

plug

20

29

N

m

2 0 3 0

kg

m

14 22

ft

lb

4

Using

Tool

remove

oil

fIlter

1

01

I

1

E0036

SLC028

MA

7

Engine

Maintenance

MAINTENANCE

5

Wipe

oil

fIlter

mounting

surface

with

a

clean

rag

6

Smear

a

little

engine

oil

on

rubber

gasket

of

new

fIlter

SMA010

7Install

new

oil

fIlter

Hand

tighten

ONLY

DO

NOT

use a

wrench

to

tighten

the

filter

8

Refill

engine

with

new

recom

mended

engine

oil

referring

to

RE

COMMENDED

LUBRICANTS

Check

oil

level

with

dipstick

Oil

Capacity

With oil

filter

4

1

lite

4

3

8

US

qt

35

8

Imp

qt

Without

oil

filter

3 9

lite

4

18

US

qt

33

8

Imp

qt

E0038

9

Start

engine

Check

area

around

drain

plug

and

oil

fIlter

for

any

sign

of

oil

leakage

If

any

leakage is

evident

these

parts

have

not

been

properly

installed

10 Run

engine

until

it

reaches

oper

ating

temperature

Then

turn

it

off

and

wait

several

minutes

Check

oil

level

If

necessary

add

engine

oil

MA

8

When

checking

on

level

park

the

ear

on

a

level

surface

v

SMA163

CHANGING

ENGINE

COOLANT

WARNING

To BVoid

the

danger

of

being

scalded

never

attempt

to

change

the

coolant when

the

engine

is

hot

When

changing

engine

coolant

on

heater

equipped

model

set

heater

TEMP

control

lever

at

fully

HOT

position

I

Open

drain

cock

at

bottom

of

radiator

and

remove

radiator

cap

r

l

ild

1xrC

rl

1

rli I

v

t

III

1

4

il

I

ll

LOOSEN

CS015

2

Remove

cylinder

block

drain

plug

located

at

left

rear

of

cylinder

block

W

F

O

3

Drain

coolant

completely

Then

flush

cooling

system

4

Close

drain

cock

and

plug

5

Fill

radiator

with

coolant

up

to

fIller

opening

observing

instructions

attached

to

anti

freeze

container

for

mixing

ratio

of

anti

freeze

to

water

Cooling

water

capacity

9 5

lite

10

US

qt

83

8

Imp

qtl

6

Run

engine

for

a

few

minutes

If

necessary

add

coolant

7

Fill

reservoir

tank

with

coolant

up

to

MAX

level

I

t

CS021

8

Install

radiator

cap

Check

drain

valve

and

plug

for

any

sign ofleakage

CHECKING

DiGINE

COMPRESSION

PRESSURE

I

Warm

up

engine

until water

tem

perature

indicator

points

to

the

middle

of

gauge

2

Remove

au

spark

plugs

on

one

side

for

California

models

3

Disconnect

all

harness

connectors

at

injector

4

Properly

attach

a

compression

tester to

spark

plug

hole

in

cylinder

being

tested

8M

A042

S

Depress

accelerator

pedal

to

open

throttle

valve

fully

6

Crank

engine

and

read

gauge

indi

cation

Run

engine

at

about

350

rpm

Engine

compression

measurement

should

be

made

as

quickly

as

possi

ble

Compression

pressure

kPa

kg

em

ps

at

rpm

Standard

1

177

12

0

171

350

Minimum

883

9 0

1281

350

7

Cylinder

compression

in

cylinders

should

not

be

less

than

80

of

the

highest

reading

If

cylinder

compression

in

one

or

more

cylinders

is

low

pour

a

small

quantity

of

engine

oil

into

cylinders

through

the

spark

plug

holes

and

retest

compression

If

adding

oil

helps

the

compres

sion

pressure

chances

are

that

piston

rings

are

worn

or

damaged

If

pressure

stays

low

valve

may

be

sticking

or

seating

improperly

If

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

Oil

and

water in

combustion

cham

bers

can

result

from

this

problem

IGNITION

AND

FUEL

SYSTEM

REPLACING

SPARK

PLUGS

I

Disconnect

spark

plug

wire

at

boot

Do

not

pull

o

the

wires

O

K

N

G

SMAO

1

7

2

Remove

spark plugs

with

spark

plug

wrench

3

Using

feeler

gauge

check

new

spark

plug

gap

If

it

is

not

within

specified

range

set

gap

by

bending

side

ele

trode

Side

electrode

if

Gap

08 0 9mm

10

03t

0

035

1

SMA019

MAINTENANCE

Engine

Maintenance

SPARK

PLUG

Re

sistor

Standard

built

iJl

type

Standard

BP6ES

BPR6ES

type

Hot

type BPSES

BPRSES

Cold

type

BP7

ES

BPR7ES

4Install

new

spark

plugs

and

re

connect

high

tension

cables

All

cable

are

marked

to

identify

their

original

locations

iYJ

Spark

plug

15 20

N

m

1

52 0

kg

m

11

14

ft

Ibl

CHECKING

IGNITION

WIRING

I

Visually

check

wiring

for

cracks

damaged

and

burned

terminals

2

Using

an

ohmmeter

measure

the

resistance

between

cable

tenninal

on

the

spark

plug

side

and

corresponding

electrode

inside

cap

Resistance

Less

than

30

000

ohms

SMA

166

Shake

the

wire

while

measuring

re

sistanee

to

check

for

intermittent

brake

3

If

the

resistance

is

more

than

the

limit

remove

cable

from

cap

and

check

the

cable

resistance

only

If

resistance

is

still

more

than

the

limit

replace

cable

assembly

MA

9

Engine

Maintenance

MAINTENANCE

ADJUSTlNGIDLERPM

ADJUSTING

IGNITION

TIMING

AND

CHECKING

MIXTURE

RATIO

Non

California

models

Preparation

1

Mako

sure

thauhofollowing

parts

are

in

good

order

Battery

Ignition

system

Maintenance

procaclure

MA

l0

Efl

ilrness

cOi

riecti

ri

Vacuum

hoses

Air

intako

system

Oil

filler

cap

oil

level

gauge

etc

2

Connect

engine

tacho

ter

and

timing

light

in

dieir

proper

pOsitions

3

On

air

conditioner

equipped

mode

s

checks

should

be

carried

out

whilo

tho oi

conditioner

is

OFF

4

On

automatic

transmiuion

equip

peel

modols

checks

should

be

carried

out

while

s

ift

lever

is

in

O

position

START

Start

engine

and

wann

up

engine

until

water

temperature

indicator

points

to

the

middle

I

of

gauge

Open

engine

hood

Run

engine

at

about

2

000

rpm

for

abou

2

undet

no

load

WARNING

a

WIlen

selector

lever

is

shifted

to

0

position

apply

parking

brake

and

block

both

front

and

reanvheels

with

chocks

b

When

racing

engine

on

auto

matic

transmission

equipped

modelsimake

sure

that

shift

lever is in

N

or

P

position

and

depress

brake

pedal

to

pre

vent

forward

SUI

8

of

car

cAfter

tha

adjustment

has

been

made

shift thelever

to

the

N

or

P

position

and

remove

wheel

chocks

E

1

Run

engine

at

idle

speed

For

Canada

For

U

S

A

I

Di

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

M

nuai

lransmiRion

7oo

t

100

tpm

Autom

w

ic

Transmission

700

100

rpm

in

D

position

O K

j

N

G

I

Adjust

idle

SPeed

by

turning

idle

opeed

adjusting

screw

j

b

this

maintenance

operation

at

1

600

km

I

1

000

miles

service

or

rechecking

idle

CO

INO

@

YES

I

bg

@

r

Note

a

When

measuring

CO

iniert

probe

I

into

tail

pipe

more

than

04m

16

in

J

b

Use

CO

meter

alter

engine

is fully

warmed

up

e

When

adjusting

idle CO

at

high

altitude

adjust

to

obtain

following

valua

Altitude

Unit

m

ft

fdte

00

2

7

600

t

200

2

000

4

000

1

200

1

800

4

000

6

000

Above

1

800

6

000

3 8

5

0

L

J

N

G

I

Adjust

ignition

timin

g

by

turn

g

di

tri ut

r

1

after

loosening

bolts

which

secure

distributor

i

of

Check

ignition

ti

ing

with

ir

ning

t

8

f

20 B

T DC

O

K

I

Race

erigine

two

or

three

times

under

00

I

load

then

run

engine

at

idle

speed

Check

CO

with

CO

meter

1

3

t

1

OK

I

Turn

off

engine

and

connect

air

induction

rhose

to

air

induction

pipe

i

Start

engine

Race

engine

two

or

three

times

under

no

load

then

run

engine

at

idle

speed

I

Check

idle

speed

M

nu

1

Transmission

700

t

100

rpm

Automatic

Tr

nsmission

71100

rpm

in

0

position

O K

I

N G

END

MAINTENANCE

Engine

Maintenance

@@

f

SMA059

If

SMA061

Adjust

CO

by

turning

air

by

pass

screw

on

air

flow

meter

When

adjusting

CO

remove

blind

plug

from air

by

pass

screw

After

adjustment

install

the

plug

on

air

flow

meter

r

SMA263

I

Adjust

idle

speed

by turning

idle

speed

ad

justing

screw

L

l

MA

ll

i

ntIine

M

itit

ance

MAINTENANCE

ADJUSTING

IDLE

RPM

California

models

Preparation

1

On

air

conditioner

equiPPed

mod

els

checks

should

be

carried

out

while

the

air

conditioner

is

OFF

2

On

automatic

transmission

equip

ped

models

checks

should

be

carried

out

while

shift

lever

is

in

Ou

position

Intenailce

procedure

MA

12

WARNING

a

When

selector

lever

is

shifted

to

0

position apply

parking

brake

and

block

both

front

and

fear

wheels

with

chocks

b

Whe

racing

engine

on

auto

matic

transmission

equipped

models

make

sure

that

shift

lever

is

in

N

or

Pposition

and

depress

brake

pedal

to pre

vent

forward

surge

of

car

c

After

the

adjlUtrDent

has

been

made

shift

the

lever

to

the

N

or

Pposition

and

remove

wheel

chockS

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

rpm

for

about

2

minutes

undeJ

no

load

1

Run

eDsine

at

Idle

speed

1

Check

idle

speed

Ma

al

Tl

Bnsmiaion

700

100

rpm

Automatic

Transmission

700

f

1

rpm

Un

D

position

f

O

K

tG

8

SMA020

SMA022

SMA263

I

dj

st

idle

speed

by

turning

idle

speed

ad

I

JustJ

IJg

screw

1

END

CHECKING

FUEL

LINES

Hoses

piping

connections

etc

I

Check

fuel

line

for

leaks

particu

larly

around

connection

of

fuel

pipe

and

fuel

hose

2

Retighten

loose

connections

and

replace

any

damaged

or

defonned

parts

SMA034

CAUTION

a

00

not

reuse

fuel

hose

clamp

after

loosening

b

Tighten

high

pressure

rubber

hose

clamp

so

that

clamp

end

is

3

mm

0

12

in

from

hose

end

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

When

tightening

ose

clamp

8n

ure

that

screw

does

not

come

into

con

tact

with

adjacent

parts

REPLACING

FUEL

FILTER

The

fuel

fIlter

is

designed

especially

for

use

with

the

EFI

systerri

It

should

be

replaced

as

an

assembly

I

Follow

the

procedure

below

to

re

duce

fuel

pressure

to

zero

CAUTION

Before

disconnecting

fuel

hose release

fuel

pressure

from

fuel

line

to

elimi

nate

danger

I

Start

the

engine

MAINTENANCE

Engine

Maintenance

Fuel

return

pipe

l

To

fuel

tan

rbm

f

el

tank

rFue

pipe

Fuel

damper

t

Fuel

pump

r

Fuel

pipe

l

tr

btor

J

Jf

1j

Injector

W W W

J

Fuel

hose

clamps

1

0

1

5N

m

10

0

15

kg

m

07

1 1

ft

Ibl

E

F976

2

Disconnect

fuel

pump

relay

2

har

ness connector

with

engine

runnin

Relay

bracket

SEF131

SMA062

1

3mmlo

12inl

fl

f

I

E

F336A

3

After

engine

stall

crank

the

engine

twice

or

three

times

4

Turn

ignition

switch

off

and

con

nect

fuel

pump

relay

2

hamess

connec

tor

2

Unfasten

clamps

securing

fuel

hoses

to

the

outlet

and

inlet

sides

of

fuel

fIlter

and

disconnect fuel

hoses

Be

careful

not

to

spill

fuel

over

engine

comP

lrtment

Place

a

rag

to

ab

so

b

fuel

MA

13

Engine

Maintenanpe

MAINTENANCE

3

Remove

fuel

mter

I

V

tJl

SMA264

4

To

instaIl fuel

mter

reverse

the

order

of

removal

REPLACING

AIR

CLEANER

FILTER

The

viscous

paper

type

air

cleaner

filter

does

not

require

any

deaning

operation

between

renewal

Disengage

air

duct

I

1

SMA063

2

Disengage

EAt

Exhaust

Air

Induction

System

hose

from air

in

duction

pipe

r

J

MA

14

3

Remove

air

cleaner

cover

and

remove

air

cleaner

ftIter

SMA065

4

InstaIl

air

cleaner

mter

with

UP

mark

facing

upward

SMA039

EMISSION

CONTROL

S

YSTEM

REPLACING

AIR

INDUCTION

VALVE

FILTER

SMA036

1

Air

induction

valve

case

2

Air

induction

valve

3

Air

induction

valve

rdter

4

Air

cleaner

Remove

air

induction

valve

case

from

air

cleaner

and

take

out

air

in

duction

valve

fIlter

Then

instaIl

new

air

induction

valve

filter

When

replacing

pay

strict

attention

to

which

direction

the

valve

i

facing

so

that

exhaust

gas

will

not

flow back

ward

J

1

CHECKING

VAPOR

LINES

Check

all

hoses

and fuel

tank

filler

cap

for

leaks

I

Dsiconnect

the

vapor

vent

line

connecting

carbon

canister

to

fuel

tank

2

Connect

a

3

way

connector

a

manometer

and

a

cock

or

an

equiva

lent

3

way

carge

cock

to

the

end

of

the

vent

line

3

Supply

pressure

into

the

vapor

vent

line

tIuough

the

cock

little

by

little until

pressure

becomes

to

the

below

Leakage

test

pressure

3

923

kPa

400

mmll20

15

75

in

H20

4

Shut

the

cock

completely

and

leave

it

unattended

5

After

25

minutes

measure

the

height

of

the

liquid

in

manometer

Pressure

variation

Less

then

0245

kPe

25

mmH20

0 98

inH201

MAINTENANCE

Minor

Trouble

Diagnoses

and Corrections

I

Y

When

filler

cap

does

not

close

completely

the

height

should

drop

to

zero

in

a

short

time

2

If

the

height

does

not

drop

to

zero

in

a

short

time

when iller

cap

is

removed

it

is

the

cause

of

a

staCfy

hose

AII

@

In

case the

vent

line

is

stuffy

the

breathing

in

fuel

tank

is

not

thorough

ly

made

thus

causing

insufficient

delivery

of

fuel

to

engine

or

vapor

lock

It

must

therefore

be

repaired

or

replaced

Carbon

canister

3

923

kPII

400

mmH20

15 75

inH20

Manometer

Check

valve

Fuel

filler

cap

1

EC091A

MINOR

TROUBLE

DIAGNOSES

AND

CORRECTIONS

Condition

Probable

cause

CANNOT

CRANK

ENGINE

OR

SLOW

CRANKING

Improper

grade

oil

Partially

discharged

battery

Malfunctioning

battery

Loose

fan

belt

Trouble

in

charging

system

Wiring

connection

trouble

in

starting

circuit

Malfunctioning

ignition

switch

Malfunctioning

starting

motor

Corrective

action

Replace

with

proper

grade

oil

Charge

battery

Replace

Adjust

Inspect

Correct

Repair

or

replace

Repair

or

replace

Trouble

shooting

procedure

on

starting

circuit

Switch

on

the

starting

motor

with

head

lights

ON

When

head

lights

go

off

or

dim

considerably

a

Check

battery

b

Check

connection

and

cable

c

Check

starting

motor

Whenhead

lights

stay

bright

a

Check

wiring

connection

between

battery

and

starting

motor

b

Check

ignition

switch

c

Check

starting

motor

MA

15

Minor

TrrJUbleDiagnoses

end

Correctiops

MAINTENANCE

Condition

ENGINE

WILL

CRANK

NORMALLY

BUT

WILL

NOT

START

Probable

cause

Corrective

action

In this

case

the

following

trouble

causes

may

exist

but

in

many

cases

ignition

system

or

fuel

system

i1

in

trouble

Ignition

system

in

trouble

Fuel

system

in

troubk

Valve

mecluznism

does

not

work

properly

Low

compression

Trouble

shooting

procedure

Check

spark

plug

fIrstly

by

following

procedure

Disconnect

high

tension

cable

from

one

spark

plug

and

hold

it

about

10

mm

0

39

in

from

the

engine

metal

part

and

crank

the

engine

ENGINE

CRANKS

NORMALLY

BUT

WI

L

OT

5

ART

Ignition

system

in

trouble

Fuel

system

malfunction

MA

16

Good

spark

occurs

a

Check

spark

plug

b

Check

ignition

timing

c

Check

fuel

system

d

Check

revolution

trigger

signal

e

Check

cylinder

compression

Very

high

current

Check

the

current

flow

in

primary

circuit

Inspect

primary

circuit

for

short

Check

distributor

pick

up

coil

operation

Check

IC

ignition

system

No

spark

occurs

Low

or

no

cunenL

Malfunctioning

distributor

pick

up

coil

Improper

air

gap

Leak

at

rotor

cap and

rotor

Malfunctiflning spark

plug

Improper

ignition

timing

Malfunctioning

ignition

coil

Disconnection

of

high

tension

cable

Loose

connection

or

disconnection

41

primary

circuit

Irregnlar

revolution

trigger

pulse

Malfunctioning

IC

ignition

unit

Lack

of

fuel

Damaged

electronic

fuel

injection

harness

or

relay

Malfunctioning

fuel

pump

Usten

to

opera

ting

sound

Damaged

control

unit

Seized

injector

Usten

to

operating

sound

Malfunctioning

air

flow

meter

Damaged

water

temp

sensor

Check

for

loose

terminal

or

disconnection

in

primary

circuit

Check

for

burned

points

Replace

Adjust

Clean

or

replace

Clean

adjust

plug

gap

or

replace

Adjust

Replace

Repair

or

replace

Replace

IC

ignition

unit

Replace

Supply

Replace

Repl

ce

For

inspection

procedures

for

electronic

fuel

injection

sys

tern

components

refer

to

Engine

Fuel

section

Condition

Fuel

system

malfunction

Low

co

prellion

UNSTABLE

ENGINE

IDLING

Ignition

system

in

trouble

Engine

mechanical

system

in

trouble

Fuel

system

malfunction

MAINTENANCE

Minor

Trouble

Diagnoses

and

Corrections

Probable

cause

Malfunctioning

pressure

regulator

Dirty

fuel

f1lter

Dirty

or

clogged

fuel

pipe

Clogged

fuel

tank

breather

pipe

Incorrect

spark

plug

tightening

or

damaged

gasket

Improper grade

engine

oil

or

low

viscosity

Incorrect

valve

clearance

Compression

leak

from

valve

seat

Sticky

valve

stem

Weak

or

damaged

valve

springs

Compression

leak

at

cylinder

head

gasket

Sticking

or

defective

piston

ring

Worn

piston

ring

or

cylinder

Trouble

shooting

procedure

Pour

the

engine

oil from

plug

hole

and

then

measure

cylinder

compression

Compression

increases

Compression

does

not

change

Malfunctioning

ignition

system

spark

plug

high

tension

cable

distributor

IC

ignition

unit

ignition

coil

etc

Incorrect

basic

ignition

timing

Loose

manifold

and

cylinder

head

bolts

Incorrect

valve

clearance

Clogged

air

cleaner

f1lter

Incorrect

idle

adjustme

nt

Damaged

manifold

gaskets

Intake

air

leakage

at

following

points

Dipstick

Oil

filler

cap

Blow

by

hoses

Intake

air

duct

air

flow

meter

to

throttle

chamber

etc

Corrective

action

Replace

Clean

Repair

and

clean

Tightefl

to

normal

torque

or

replace

gasket

Replace

with

proper

grade

oil

Adjust

Lap

valves

Correct

or

replace

valve

and

valve

guide

Replace

valve

springs

Replace

gasket

Replace

piston

rings

Overhaul

engine

Trouble

in

cylinder

or

piston

ring

Compression

leaks

from

valve cylinder

head

or

head

gasket

Replace

Adjust

Retighten

bolts

Adjust

Replace

f1lte

Adjust

Replace

gasket

Repair

or

replace

MA

17

Minor

Trouble

DiagnolJt

s

and

Correctiom

MAINTE

ANCE

Condition

Fuel

system

malfunction

Low

compression

Others

HIGH

ENGINE

IDLE

SPEED

Fuel

system

malfunction

Others

ENGINE

POWER

BELOW

NORMAL

Low

compression

Ignition

system

in

trouble

Fuel

system

malfunction

MA

18

Probable

cause

Damaged

electronic

fuel

injection

harness

Seized

injector

Usten

to

operating

sound

Malfunctioning

air

regulator

During

warm

up

driving

only

Damaged

control

unit

Damaged

water

and

air

temp

sensor

Malfunctioning

throttle

valve

switch

Irregular

fuel

pressure

Malfunctioning

P

C

V

valve

Malfunctioning

E

G R

control

system

Incorrect

adjustment

of

idle

speed

adjusting

screw

Malfunctioning

air

regulator

Throttle

valve

is

opened

excessively

at

idle

Malfunctioning

F

I

C

D

Dragged

accelerator

linkage

Malfunctioning

Vacuum

Control

Valve

V

C

V

Incorrect

ignition

timing

Malfunctioning

spark

plugs

Malfunctioning

distributor

pick

up

coil

Throttle

valve

does

not

open

fully

Damaged

electronic

fuel

injection

harness

Seized

injector

Usten

to

operating

sound

Malfunctioning

air

flow

meter

Malfunctioning

throttle

valve

switch

Irregular

fuel

pressure

Clogged

fuel

pipe

Dirty

or

clogged

fuel

ftIter

Fuel

pwnp

will

not

work

properly

Corrective

action

Replace

For

inspection

procedures

for

electronic

fuel

injection

sys

tern

compo

nents

refer

to

Engine

Fuel

Section

Replace

Repair

or

replace

Replace

pressure

regulator

Previously

mentioned

Check

or

replace

COrrect

or

replace

Correct

Replace

For

inspection

procedures

for

air

regulator

refer

to

Engine

Fuel

section

Replace

throttle

chamber

Replace

Check

and

correct

accelerator

linkage

Check

or

replace

if

necessary

Previously

mentioned

Adjust

Clean

adjust

or

replace

plugs

Replace

Adjust

Replace

Repair

or

replace

Replace

pressure

regulator

if

necessary

Replace

if

necessary

Replace

For

inspection

proce

dures

for

electronic

fuel

injection

system

components

refer

to

Engine

Fuel

Section

Condition

Air

intake

system

malfunction

Overheating

Othe

NOISY

ENGINE

Car

knocking

Mechanical

knocking

Crankshaft

bearing

knocking

MAINTENANCE

Minor

Trouble

Diagnosessnd

Corrections

Probable

cause

Clogged

air

cleaner

filter

Air

leaking

from

manifold

gasket

Intake

air

leakage

at

following

points

Dipstick

Oil

ftller

cap

Blow

by hoses

Intake air

duct

air

flow

meter

to

throttle

chamber

etc

Insufficient

coolant

Loose

fari

belt

Worn

or

damaged

fan

belt

Malfunctioning

thermostat

Malfunctioning

water

pump

Clogged

or

leaky

radiator

Malfunctioning

radiator

ftller

cap

Air

in

cooling

system

Improper

engine

oil

grade

Incorrect

ignition

timing

Malfunctioning

thermostat

Improper

octane

fuel

Improper

tire

pressure

Dragging

brake

Clutch

slipping

Malfunctioning

E

G

R

control

system

Overloaded

engine

Carbon

knocking

Timing

knocking

Fuel

knocking

Preignition

misusing

of

spark

plug

This

strong

dull

noise

increases

when

engine

is

accelerated

To

locate

the

place

cause

a

misfire

on

each

cylinder

If

the

noise stops

by

the

misfire

this

cylinder

generates

the

noise

Corrective

action

Replace

filter

Replace

gasket

Repair

or

replace

Replenish

Adjust

fan

belt

Replace

Flush

repair

or

replace

Replace

Retighten

each

part

of

cooling

system

Replace

with

proper

grade

oil

Adjust

Replace

with

specified

octane

fuel

Inflate

to

specified

pressure

Adjust

Correct

or

replace

Use

right

gear

in

driving

Disassemble

cylinder

head

and

clean

car

bon

Adjust

ignition

timing

Use

specified

octane

fuel

Use

specified

spark

plug

This

is

caused

by

worn

or

damaged

bearings

or

unevenly

worD

crankshaft

Renew

bear

ings

and

adjust

or

change

crankshaft

Check

lubrication

system

MA

19

Minor

Trouble

Diagnoseund

Corrections

MAINTENANCE

Condition

Connecting

rod

bearing

knocking

Piston

and

cylinder

noise

Piston

noise

Water

pump

noise

Others

ABNORMAL

COMBUSTION

backfire

after

fire

run

on

etc

Ignition

system

in

trouble

Fuel

system

malfunction

MA

20

Probable

cause

This

is

alittle

higher

pitched

noise

than

the

crankshaft

knocking

and

also

increases

when

engine

is

accelerated

Cause

a

misfue

on

each

cylinder and

if

the

noise

diminishes

almost

completely

this

crankshaft

bearing

generates

the

noise

When

you

hear

an

overlapping

metallic

noise

which

increases

its

magnitude

with

the

revolution

of

engine

and

which

decreases

engine

is wanned

up

this

noise

is

caused

by

piston

lUId

cylinger

To

locate

the

place

cause

a

misfue

on

each

cylinder

This

noise

is

heard

at

each

highest

and

lowest

dead

end

of

piston

To

locate

the

place

cause

a

misfire

on

each

cylinder

This

noise

may

be

caused

by

worn

or

damaged

bearings

or

by

the

uneven

surface

of

sliding

parts

An

improper

adjustment

of

valve

clearance

Noiseoftinringchmn

An

excessive

end

play

on

crankshaft

Wear

on

clutch

pilot

bushing

This

noise

will

be

heard

when

clutch

is

disengaged

Improper

ignition

tinring

Improper

heat

range

of

spark

plugs

Intake

air

leakage

at

following

points

Dipstick

Oil

f1l1er

cap

Blow

by

hoses

Intake

air

duct

air

flow

meter

to

throttle

chamber

etc

Damaged

electronic

fuel

injection

harness

Damaged

control

unit

Malfunctioning

air

flow

meter

Damaged

water

temp

sensor

Corrective

action

Same

as

the

case

of

crankshaft

bearings

This

may

cause

an

abnonnal

wearing

of

cylinder and

lower

compression

which

in

turn

will

cause

a

lower

out

put

power

and

excessive

consumption

of

oil

Overhaul

engine

This

may

cause

a

wear on

piston

or

piston

hole

Renew

piston

and

piston

assembly

Replace

water

pump

with

a

new

one

Adjust

the

tension

of

chmn

Disassemble

engine

and

renew

main

bearing

Renew

bushing

and

adjust

drive shaft

Adjust

ignition

timing

Use

specified

spark plugs

Repair

or

replace

Replace

J

For

inspection

procedures

for

electronic

fuel

injection

sys

tern

components

refer

to

Engine

Fuel

Section

Condition

Defective

cylinder

head

etc

Others

EXCESSIVE

OIL

CONSUMPTION

Oil

leakage

Others

POOR

FUEL

ECONOMY

Engine

power

below

normal

Fuel

system

malfunction

MAINTENANC

E

Minor

Trouble

Diagnoses

and

Corrections

Probable

cause

Improperly

adjusted

valve

clearance

Excess

carbon

in

combustion

chamber

Damaged

v

alve

spring backfire

after

fire

Malfunctioning

E

G

R

control

system

Loose

oil

drain

plug

Loose

or

damaged

oil

pan

gasket

Loose

or

damaged

chain

cover

gasket

Damaged

oil

seal

in

front

and

rear

of

crankshaft

Lo

e

or

damaged

rocker

cover

gasket

Improper

tightening

of

oil

fIlter

Loose

or

damaged

oil

pressure

switch

I

Cylinder

and

piston

wear

Improper

location

of

piston

ring

or

reversely

assembled

piston

ring

Damaged

piston

rings

Worn

piston

ring

groove

and

ring

Fatigue

of

valve

oil

seal

lip

Worn

valve

stem

Inadequate

quality

of

engine

oil

Engine

overheat

Exceeding

idling

revolution

Fuel

leakage

from

fuel

line

Damaged

electronic

fuel

injection

harness

Damaged

control

unit

Malfunctioning

air

flow

meter

Damaged

air

temperature

sensor

Malfunctioning

throttle

valve

switch

Irregular

fuel

pressure

Corrective

action

Adjust

Remove

head

and

get

rid

of

carbon

Replace

it

with

a

new

one

Correct

or

replace

Tighten

it

Renew

gasket

or

tighten

it

Renew

gaskei

or

tighten

it

Renew

oil

seal

Renew

gasket

or

tighten

it

but

not too

much

Renew

gasket

and

tighten

it

with

the

proper

torque

Renew

oil

pressure

switch

or

tighten

it

Overhaul

cylinder and

renew

piston

Remount

piston

rings

Renew

rings

Repair

r

renew

piston

and

cylinder

Renew

piston

and

piston

ring

Replace

seal

lip

with

a

new

one

Renew

valve

or

guide

Use

the

designated

oil

Previously

mentioned

Previously

mentioned

Adjust

it

to

the

designated

rpm

Repair

replace

or

tighten

the

connection

of

fuel

pipes

Replace

pressure

regulator

if

necessary

For

inspection

procedures

for

electronic

fuel

injection

sys

tern

components

refer

to

Engine

Fuel

Section

MA

21

Minor

Trouble

Diagnoses

and

Correctiom

MAINTENANCE

Condition

TROUBLE

IN

OTHER

FUNCTIONS

Decreased

oil

pressure

Excessive

wear on

the

sliding

parts

Scuffing

of

sliding

parts

MA

22

Probable

cause

Inadequate

oil

quality

Overheat

Malfunctioning

oil

pump

regulator

valve

Functional

deterioration

of

oil

pump

Blocked

oil

f1lter

Increased

clearance

in

various

sliding

parts

Blocked

oil

strainer

Malfunctioning

o

gauge

pressure

switch

Oil

pressure

decreases

Damaged

quality

or

contamination

of

oil

Air

leakage

from

air

intake

duct

Damaged

air

cleaner

Overheat

or

overcoat

Improper

fuel

mixture

Decrease

of

oil

pressure

Insufficient

clearances

Overheat

Improper

fuel

mixture

Corrective

action

Use

the

designated

oil

Previously

mentioned

Disassemble

oil

pump

and

repair

or

renew

it

Repair

or

replace

it

with

a

new

ne

Renew

it

Disassemble

and

replace

the

worn

parts

with

new

ones

Clean

it

Replace

it

with

a

new

one

Previously

mentioned

Exchange

the

oil

with

proper

one

and

change

element

Repair

or

replace

Change

element

Previously

mentioned

Check

the

fuel

system

Previously

mentioned

Readjust

to

lIie

designated

clearances

Previously

mentioned

Check

the

fuel

system

MAINTENANCE

Chassis

and

Body

Mainwnance

CHASSIS

AND

BODY

MAINTENANCE

ENGINE

CONTROL

FUEL

AND

EXHAUST

SYSTEMS

CHECKING FUEL

AND

EXHAUST

SYSTEM

Check

fuel

and

exhaust

systems

for

condition

connections and

leaks

Fuel

system

SMA034

Exhaust

system

@

SMA

147

CLUTCH

CHECKING

CLUTCH

FLUID

LEVEL

AND

LEAKS

Add

to

MAX

level

SMA1QO

CHECKING

CLUTCH

SYSTEM

Check

clutch

system

for

proper

at

tachment

leaks

chafing

abrasion

de

terioration

etc

@j

J

@

SMA101

CHECKING

CLUTCH

PEDAL

HEIGHT

AND

FREE

PLAY

Check

clutch

pedal

height

and

free

play

Adjust

if

necessary

Master

cylinde

push

rod

Pedal

stopper

r1

w

lotf

51

8

71

iLl

111

h

InSU1ator

FIOor

j

H

Lock

nut

fl7

8

11

8

10

8

1

2

5 8 8

71

A

fl

N

m

kg

m

ft

lb

SMA102

Pedal

height

H

168 174

mm

6 61 6

85

in

Padal

free

play

A

J

5

mm

0

04

020

in

I

Adjust

pedal

height

with

pedal

stopper

Then

tighten

lock

nut

2

Adjust

pedal

free

play

with

master

cylinder

push

rod

Then

tighten

lock

nut

8

Pedal

free

play

means

the

following

total

measured

at

position

of

pedal

pad

Play

due

to

clevis

and

clevis

hole

in

pedal

lever

Play

due

to

piston

and

piston

rod

b

Depress

nd

release

clutch

pedal

over

its

entire

stroke

to

ensure

that

the

clutch

linkage

operates

smooth

ly

without

squeak

noise

inter

ference and

binding

MANUAL

TRANSMISSION

CHECKING

MANUAL

TRANSMISSION

OIL

LEVE

L

Neyer

start

engine

while

checking

oilleyel

ff

4f

itner

plug

S

2 5

3

5

kg

m

Fill

to

this

level

18

25

ft

Ibl

SMA

1

03

CHANGING

MANUAL

TRANSMISSION

OIL

I

Drain

oil

completely

SMA104

MA

23

Chassis

and

Body

Maintenance

MAINTENANCE

2Refill

transmission

and

check

oil

level

25ft lb

Oil

capacity

2

0

liten

4

1

4

USJit

3

1

2

Imp

pt

AUTOMATIC

TRANSMISSIQN

CHECKING

AUTOMATIC

TRANSMISSION

FLUID

LEVEL

I

Check

under

following

conditions

i

Place

selector

lever

in

P

pARK

position

and

idle

engine

2

Maintain

fluid

temperature

at

50

to80DC

122

to

176DF

2 Add

oil

if

necessary

Use

only

automatic

transmission

fluid

having

OEXRON

identifica

tions

in

3N71B

automatic

trans

iSlion

Q

J

Add

to

H

level

Do

not

overfill

SMA106

MA

24

CHECKINGAUTOMAnC

TRANSMISSION

FLUID

CONDITION

Check

fluid

for

contamination

to

determine

condition

of

automatic

transmission

If

fluid

is

very

dark

or

smells

burned

the

frictional

material

clutches

band

etc

may

need

reo

placemen

t

Oleck

fluid

for

contamination

I

Check

fluid

for

smell

SMA107

PROPELI

ER SHAFT

AND

DIFFERENTIAL

CAR

IER

CHECKING

PROPELLER

SHAFT

Check

propeller

shaft

replace

if

necessary

Oteek

tube

surfaces

fOJ

denu

or

cracks

SMA231

Oleck

tightening

torque

CHECKING

DIFFEREN11AL

CARRIER

OIL

LEVEL

Fill

to

thislevel

S

MA10B

CHANGING

DIFFERENTIAL

CARRIER

OIL

I

Drain

oil

completely

CV

59 98

N

m

6

10

kg

m72ft

blL

W

SMA109

2

Refill

differential

carrier

and

check

oil

level

cv

59 98

N

m

6

101qj

m

43

72ft

lb

SMA11Q

Oil

capacity

1

1liten

2

38

US

pt

2

Imp

pt

FRONT

AXLE

AND

FRONT

SUSPENSION

CHECKING FRONT

AXLE

AND

SUSPENSION

PARTS

I

Block

rear

wheels

with

chock

and

raise

front

of

car

and

then

support

it

with

safety

stand

Refer

to

lifting

Points

and

Towing

Section

GI

2

Shake

each

front

wheel

by

hold

ing

upper

and

lower

surfaces

of

tires

as

shown

SMA111

Check

suspension

parts

for

loose

ness

wear

or

damage

Retighten

all

loose

nuts

and

bolts

to

the

specified

torque

Refer

to

Sec

tion

FA

for

tightening

torque

Replace

all

worn

parts

as

described

under

Front

Suspension

Section

FA

o

Strut

upper

end

3

Check

strut

Shock

absorber

for

oil

leakage

or

damage

J

MAINTENANCE

Chsssis

and

Body

Maintensnce

4

Check

suspension

ball

joint

for

grease

leakage

and

ball

joint

dust

cover

for

damage

5

Remove

wheel

and

tire

assembly

6

Check

front

axle

parts

for

crack

or

damage

Replace

worn

parts

Refer

to

Front

Axle

Section

FA

7

Remove

brake

pads

Refer

to

section

BR

8

Check

wheel

bearing

If

there

is

any

axial

end

play

or

if

wheel

bearing

does

not

smoothly

turn

adjust

bearing

to

specifications

Replace

worn

or

damaged

bearings

Refer

to

Front

Axle

Section

FA

SMAllS

ADjUSTING

WHEEL

BEARING

PRELOAD

After

wheel

bearing

has

been

reo

placed

or

front

axle

has

been

reo

assembled

be

sure

to

adjust

wheel

bearing

preload

as

described

below

I

Before

adjustment

thoroughly

clean

all

parts

to

prevent

possible

en

try

of

dirt

2

Apply

recommended

multi

pur

pose

grease

sparingly

to

the

following

parts

Threaded

portion

of

spindle

Contact

surface

between

wheel

bearing

washer and

outer

wheel

bearing

Hub

hub

cap

and

O

ring

Grease

seal

lip

dl

nng

SMAl16

Multi

purpose

grease

point

3

Tighten

wheel

bearing

nut

i

J

25

29N

m

12

5

3

0

kg

m

18

22ft

lbl

SMAT17

4

Turn

wheel

hub

several

times

in

both

directions

to

seat

wheel

bearing

correctly

SMAllS

5

Again

tighten

wheel

bearing

nut

MA

25

ChassiundBodyMainl11nance

MAINTENANCE

6

Turn

back

wheel

bearing

nut

with

in

600

Tumbac

kA

Within600

SMA119

7

Fit

adjusting

cap

and

new

cotter

8

Measure

wheel

bearing

preload

and

axial

play

900

Axial

play

0

mm

0in

Wh

1

b

ring prelo

As

measured

at

wh

1

hub

bolt

With

new

parts

69

14

7

N

10

7

1

5

kg

1

5 3

31bl

With

US8

t

parts

2

0

7B N

10

208

kg

04

1

8

Ib

SMA121

Repeat

above

procedures

until

cor

rect

starting

torque

is

obtained

MA

26

9

Spread

otterpin

F

A265

10

Install

hub

cap

with

new

O

ring

CHECKING

WHEEL

ALIGN

MENT

Before

checking

front

wheel

align

ment

be

sure

to

make

a

preliminary

inspection

of

all

front

end

parts

Tire

pressure

Wheel

bearing

axial

play

Suspension

ball

joint

Steering

gear

housing

looseness

at

frame

Steering

linkage

and

connections

Shock

absorber

oparation

Tighten

each

front

axle

and

suspen

sion

pam

Measure

car

height

when

not

loaded

Repair

or

replace

the

d

amaged

por

tion

or

parts

Camber

caster

and

kingopln

inclination

Camber

caster

and

king

inclina

tion

are

preset

at

the

factory

and

can

not

be

adjusted

If

camber

caster

or

king

in

clination

alignment

is

not

within

speci

fications

check

pertinent

parts

Repair

or

replace

as

necessary

Camber

40

50

Caster

1045

3

15

Kingpin

inclination

7025

SOSS

Toe

In

Measure

toe

in

and

make

necessary

adjustments

Use

the

following

pro

cedure

when

making

adjustments

I

Raise

front

of

car

and

mark

a

base

line

across

the

tread

of

left

and

right

wheels

Base

line

SMA123

2

Set

wheels

in

a

straight

ahead

position

and

then

lower

front

of

car

3

Measure

toe in

and

make

neces

sary

adjustments

lines

parallel

to

center

line

of

body

Toe

in

Unladen

o

2

mm

O O OS

inl

0

12

On

both

sides

Sid

slip

Reference

datal

Out

1

mm

n

1

mmlm

Out

0

012 in

In

0

012

in

ftl

Toe

in

can

be

adjusted

by

varying

the

length

of

steering

side

rods

SMA265

Unladen

Fuel

tank

radiator

and

engine

oil

tank

all

full

Spare

tire

jack

hand

tools

mats

in

position

All

tires

inflated

to

specified

pres

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

specified

value

A

prior

to

reo

assembling

JJ

Sid

red

length

An

71

0

mm

12

795

in

ssn05

a

Lock

side

rod bar lock

nut

so

that

ball

joint

on

outer

socket

is

770

with

respect

to

that

on

inner

socket

b

Make

sure

that

adjusting

bar

is

screwed

in

eam

socket

at

least

25

mm

0

98 in

4

After

correct toe

in

has

been

ob

tained

tighten

side

rod bar

lock

nuts

Iil

78

98

N

m

8 0

10

0

kg

m

58 72

ft

lb

Front

wheel

turning

engle

I

Set

wheels

in

straight

ahead

posi

tion

and

then

move

car

foward

until

front

wheels

rest

on

turn

ng

radius

gauge

properly

MAINTENANCE

Chassis

and

Body

Maintenance

2

Remove

stopper

of

turning

radius

gauge

and

then

fully

rotate

steering

wheel

to

the

right

and

left

measure

turning

angle

on

inner

wheel

and

make

necessary

adjustments

FA632

Front

wheel

turning

angle

Toe

ut

turns

When

inner wheel

200

Outer

wheel

18

70

Full

turns

On

power

steering

mo

dels

wheel

turning

force

at

cir

cumference

of

steering

wheell

of

98

147

N

10

15

kg

22 33

Ib

with

engine

at

idle

Inner

wheel 330 350

Outer

wheel 270 290

Turning

angle

of

outer

wheel

will

automatically

be

set

by

adjusting

turn

ing

angle

of

inner wheel

to

specified

values

3

After

adjustment

lock

adjusting

lock

nut

REAR

AXLE

AND

REAR

SUSPENSION

CHECKING

REAR

AXLE

AND

SUSPENSION

PARTS

Check

rear

axle

and

suspension

parts

for

looseness

wear

or

damage

Retighten

all

loose

nuts

and

bolts

to

the

specified

torque

Refer

to

Sec

tion

RA

for

tightening

torque

Replace

aU

worn

parts

as

instructed

under

Rear

Suspension

Section

RA

Check

tightening

torque

SMA129

MA

27

OIl1Sfisand

Body

Maintenance

MAINTENANCE

BRAKE

SYSTEM

CHECKING

BRAKE FLUID

LEVEL

AND

LEAKS

Add

to

MAX

level

SMA

130

If

fluid

level

i

extremely

low

check

brake

system

for

leaks

CHANGING

BRAKE

FLUID

I

Change

brake

fluid

Use

same

procedure

IS

in air

bleed

ing

to

change

brake

fluid

in

ystem

Thi

operation

should

be

done

for

one

wheel

at

a

time

Refer

to

Section

BR

CAUTION

Never

reuse

brake

fluid

because

its

characteristic

is

chang2d

by

oxidiza

tion

as

well

as

contains

the

foreign

material

and

dirt

Air

bleed

valve

3

l6

9

88

N

m

O

7

O

9kg

5

1

65ft

lb

SMA131

Refill

until

new

fluid

appears

MA

28

2

CIieck

brake

fluidleve

3

Check

for

leaks

CHECKING

BRAKE

BOOSTER

VACUUM

HOSES

coNNECTIONS

AND

CHECK

VALVE

1

Check

condition

of

vacuum

hoses

and

connections

2

Check

vacuum

hoses

and

check

valve

for

air

tightness

SMA

125

CHECKING

BRAKE

SYSTEM

I

Check

brake

system

f

r

proper

attachment

leaks

chafmg

abrasion

deterioration

etc

SMA

133

CHECKING

DISC

BRAKE

I

Check

condition

of

disc

brake

components

beck

pads

for

wear

SMA134

Oteck

caliper

operation

and

X

inspect

for

leaks

Pad

wear

liniit

1

ll

A

I

TT

PIId

war

limit

tAt

N22

2

mm

0

08

in

AN12H

2

mm

0

08

in

SMA266

Refer

to

Section

BR

for

pad

re

placement

Rotor

repair

limit

ROtor

repair

limit

B

N22

10

5mm

10

413

in

AN12H

86

mm

0

339

in

SMA267

CHECKING

FOOT

BRAKE

1

Check

brake

pedal

free

height

and

free

play

Adjust

if

necessary

Brake

b

t

0

hl

P

i

1

Ck

nut

j

l12

15

11

2

1

5

9

11

Lock

nut

1

16

22

1

I

16

22

12

16

I

Insulator

Floor

h

SMA140

l

N

m

kg

m

Ct

tb

Pedal

free

height

h

155

161

mm

6 10

6 34

in

Pedal

free

play

a

1

5

mm

0

04

0

20

in

1

Adjust

pedal

free

height

with

brake

lamp

switch Then

tighten

lock

nut

Adjust

pedal

free

play

with

brake

booster

input

rod

Then

tighten

lock

nut

Pedal

free

play

mean

the

following

total

measured

at

position

of

pedal

pad

Play

due

to

clevis

and

clevis pin

hole

in

pedal

lever

Play

due

to

piston

and

piston

rod

2

Check

brake

pedal

depressed

height

I

d

v

DeprltSSllKl

height

Mor

thi

ln

60

mm

2

36

in

SMA141

If

depressed

height

i

below

the

specified

value

check

brake

system

for

leaks

accumulation

of

a

ror

any

ab

normality

regarding

component

parb

master

cylinder

adju

ier

etc

I

and

make

the

necessary

repain

CHECKING PARKING

BRAKE

I

Pull

lever

with

specified

amount

of

force

MAINTENANCE

Chassis

and

Body

Maintenance

Measure

lever

stroke

in

a

straight

line at

center

of

grip

Pulling

force

196N

120

kg

44

Ib

I

l

n

1

I

L

I

Lever

stroke

90

100

mm

0

3

54

3

94

nl

Number

of

notches

7

8

SMA

142

2

Use

adjuster

to

adjust

lever

stroke

I

Lock

fiU

t

SMA143

3

Bend

parking

brake

warning

lamp

switch

plate

down

so

that

brake

warn

ing

light

comes

on

when

ratchet

at

parking

brake

lever

is

moved

back

one

notch

and

goes

out

when

returned

to

its

original

positi

on

WHEEL

AND

TIRE

CHECKING

TIRE

CONDITION

Tire

condition

1

Tires

are

provided

with

tread

wear

indicator

at

six

places

around

tire

circumference

indicating

1

6

mm

1

16

in

tread

depth

When

tires

wear

and

then

marks

appear

replace

them

with

new

ones

Tread

wear

indicator

Tire

tread

t

WH024

2

Remove

pebbles

glass

or

any

other

foreign

material

embedded

in

tire

treads

3

Check tread

and

side

walls

for

cracks

holes

separation

or

damage

4

Check

tire

valves

for

air

leakage

Tire

Inflation

I

Check

tire

pressure

If

necessary

adjust

it

to

the

specified

value

indi

cated

in

the

label

attached

to

the

car

also

found

in

Owner

s

Manual

or

S

D

S

Tire

pressure

should

be

easured

when

tire

is

cold

I

J

rireinflation

pressure

label

l

I

SMA268

2

After

inflating

tires

valves

should

be

checked

for

leakage

Whenever

tire

pressure

is

checked

be

sure

to

tighten

valve

caps

firmly

by

hand

to

keep

dust

and

water

out

MA

29

ChaS3is

and

Body

MainrenanaJ

MAINTENANCE

Abnormal

tire

wear

Correct

abnormal

tire

wear

ac

cording

to

the

chart

shown

below

Condition

i

1

J

1111

allll

j

ll

Shoulder

wear

If

I

ii

I

t

Ii

Center

wear

Feathered

edge

j

l

Ii

I

1

Ii

II

11

t

1i

I

l

I

r

i

II

I

Toe

in

or

toeout

wear

Ij

Iij

j

H

l

m

I

il

I

1

fIll

11

I

f

1 1

1

ll

o

Ii

Uneven

wear

Probable

cause

Underinflation

both

sides

ar

Incorrect

wheel

camber

one

side

wear

Hard

cornering

Lack

of

rotation

Overinflation

lack

of

rotation

Incorrect

toe

lncorrect

camber

or

caster

Malfunctioning

suspen

sion

Unbalanced

wheel

Out

lf

round

brake

drum

Other

mechanical

condi

dons

Lack

of

rotation

TIRE

ROTATION

1

Tires

tend

to

wear

unevenly

and

become

unbalanced

after

a

certain

running

distance

Uneven

tire

wear

often

results

in

tire

noise which

is

attributed

to

rear

axle

gears

bearing

MA

30

Corrective

action

Measure

and

adjust

plessure

Repair

or

replace

axle

and

suspension

parts

Reduce

speed

Rotate

tires

Measure

and

adjust

pressure

Rotate

tires

Adjust

toe

in

Repair

or

replace

axle

and

suspension

parts

Repair

replace

or if

necessary

reinstall

Balance

or

replace

Correct

or

replace

Correct

or

replace

Rotate

tires

SMA068

etc

Front

tires

also

tend

to

wear

un

evenly

because

of

improperly

aligned

front

wheels

2

Accordingly

to

equaliZe

tire

wear

it

is

necessary

to

rot8te

tires

periodh

cally

Radial

tires

Right

front

Right

rear

c

l

@

c

l

c

l

Left

front

Left

rear

4

WHEELS

SMA126

TIRE

REPLACEMENT

CAUTION

Different

types

of

tires

Rich

es

bias

belted

and

radial

tirl

S

murt

not

be

mixed

under

any

cin

umstances

Mind

use

of

different

types

of

tiies

can

adversely

affect

car

handling

and

may

cause

driver

to

lose

control

i

a

When

replacing

worn or

damaged

tire

use a

replacement

tire

of

the

same

size

and

load

carrying

capaci

ty

as

that

with

which

the

car

WIS

aquipped

when

manufactUred

The

use

of

different

size

and

or

load

capacity

ti

will

not

only

horten

tire

service

life

but

may

also

resuh

in a

serious

accident

b

Do

not

use

tires

and

wheels

other

than

those

recommeooed

and

do

not

mix

tire

of

different

brandt

or

tread

patterns

The use

of

tire

and

wheels

other

than

those

recommended

or

the

mixed

use

of

tires

of

diffarent

brands

or

1

ead

patterns

can

ad

versely

affect

the

ride

braking

handling

ground

clearance

body

to

tire

clearance

and

sp

et

tom8ter

calibration

c

It it

recommended

that

new

tires

be

installed

in

pain

on

the

same

axle

When

replacing

only

one

tire

it

should

be

paired

with

the

most

tread

to

equalize

braking

traction

d

When

replacing

original

tires

with

those

tires

of

8n

optional

recom

mended

size

and

of

different diam

ator

tha

speedometer

must

ba ra

calibrated

1

To

replace

atire

with

a

jack

in a

safe

manner

refe

to

lifting

Points

Section

GI

for

jacking

up

WARNING

Never

get

under

car

while

it

is

sup

ported only by

jack

Always

use

safety

stands

to

support

side

member

of

body

construction

when

you

must

get

beneath

car

2

To

install

wheel

tighten

wheel

nuts

in

criss

cross

fashion

SMA069

Aluminum

whee

To

install

an

aluminum

wheel

pro

ceed

as

followS

I

Snugly

tighten

four

nuts

after

the

wheel

is

positioned

SMA070

2

Slightly

pull

the

wheel

back

to

properly

align

the

nuts

with

bolt

holes

in

the

wheel

and

tighten

the

nuts

as

much

as

possible

with

your

fingers

MAINTENANCE

Chassis

and

Body

Maintenance

Align

nuts

with

bolt

holes

in

wheel

and

evenly

tighten

nuts

each

one

a

little

at

a

time

SMA071

3

Tighten

wheel

nuts

evenly

with

a

wheel

wrench

in

criss

cross

fashion

Be

sure

to

check

the

wheel

nuts

for

tightness

after the aluminum

wheel

has

been

Nn

for

the

first

1

000

km

600

milesl

also

in

cases

of

repairing

flat tire tire

rotation

etc

Retighten

if

necessary

Wheel

nut

CAUTION

Two

types

of

wheel

nuts

are

used

one

is

designed

for

use

with

steel

wheel

and

the other

for

use

with

aluminum

wheel

00

not mix

different

types

of

wheel

nuts

For

aluminum

wheels

only

For

steel

wheels

only

r

C

t

J

78

98

N

m

18

0

10

0

kg

m

58

72

ft

Ibl

SMA234

Be

careful

not

to

smear

thread

ed

portion

of

bolt

and

nut

and

seat

of

nut

with

oil

or

grease

T

TYPE

SPARE

TIRE

Size

T135

70D16

The

T

type

spare

tire

is

designed

for

emergency

use

only

The

spare

tire can

be

used

repeatedly

for

emergency

situations

Precautions

whenuslng

T

type

spa

tire

Pe

iodically

check

tire

inflation

pres

sure

and

always

keep

it

at

60

psi

412 kPa

Do

not

drive

car

at

speed

faster

than

80

km

h

50

MPH

The

T

type

spare

tire

is

designed

only

fpr

tempora

ry

use

as

a

spare

Dismount

it

and

keep

it

as

a

spare

as

soon

as

the

standard

tire

repair

has

been

completed

Do

not

enter

into

an

automatic

car

wash

with

the

T

type

spare

tire

fitted

Do

not

attach

a

tire

chain

Do

not

use

the

T

type

spare

tire

on

other

cars

Do

not

make

a

sharp

turn

or

apply

the

brake

suddenly

while

driving

As

soon

as

the

tread

wear

indicator

becorries

visible

replace

the

tire

with

a

new

one

Mounting

and

dismounting

to

and

from the

road

wheel

can

be

carried

out

in the

same

manner

as

any

ordi

nary

tin

Use

of

wheel

balance

is

unneces

ary

CAUTION

If

the

car

is

equipped

with

aluminum

wheels

be

sure

to

use

the

wheel

nuts

for

steel

wheel

on

the

r

typ

spare

tire

wheel

Never

us

the

wheel

nuts

for

aluminum

wheel

on

the

spare

tire

wheel

The

spare

tire

wheel

may

come

off

the

axle

and

cause

personal

injury

if

the

wheel

nuts

for

aluminum

wheels

are

used

on

the

spare

tire

wheel

TIRE

REPAIR

Inspect

tire

following

the

proce

dure

shown

below

If

any

defect

is

pre

sent

repair

or

replace

as

necessary

1

Apply

soapy

solution

or

submerge

tire

and

wheel

or

tube

in

water

after

inflating

it

to

specified

pressure

2

Inspect

for

leaks

3

Specially

inspect

for

leaks

around

valve

or

wheel

rim

and

along

tread

4

Note

bead

and

rim

where

leakage

occurs

Wipe

water

away

from

any

area

which

leaks

air

bubbles

and

then

mark

place

with

chalk

S

Remove

object

which

caused

p

uncture

and

seal

the

point

MA

31

Chassis

and

Body

Maintenance

MAINTENANCE

a

When

repairing

B

puncture

use 8

tire

repair

kit

furnished

by

any

tire

dealer

following

instructions

pro

vided

with

kit

b

If

8

puncture

is

too

large

or

there

is

lome

damage

to

tire

fabric

repair

should

be

carried

out

by

authorized

tire

ller

6

Discard

when

any

of

the

following

problems

occurs

Broken

or

damaged

bead

wire

Ply

or

tread

separation

Worn

fabric

damage

on

tubeless

tire

Cracked

or

damaged

side

wall

Tires

with

tread

wear

indicator

showing

etc

CAUTION

When

replacing

tire

take

extra

care

n

t

to

damage

tire

bead

rim

flange

and

bead

seat

Do

not

U58

tire

irons

to

force

beads

away

from

wheel

rim

flange

that

is

always

use

tire

replacement

device

whenever

tirei r

moved

7

Install

tire

noting

the

following

items

a

Install

valve

core

aOd

inflate

to

proper

pressure

CheC

the

loceting

rings

of

the tire

to

be

sure

they

show

around the rim

flanges

on

both

sides

b

Check

valves

10rleakage

efter

in

flating

tires

c

Be

IUfe

to

tighten

valve

caps

firmly

by

hand

MA

32

WARNING

When

while

tire

is

being

inflated

bead

snipS

over

safety

hump

it

might

break

Thus

to

avoid

serious

personal

injury

never

stlinll

over

tire

when

inflating

it

Never

inflate

to

a

pressure

greater

than

40

psi

275kPa

If

beads

fail

to

seat

It

that

presRlre

deflate

the

tire

lubricate

it

again

and

then

reinflate

it

If

the

tira

is

overinflated

the

bead

might

break

possibly

resulting

in

serious

pl

r

sunal

injury

WHEEL

INSPEcnON

Inspect

wheel

taking

care

of

the

following

points

in

order

to

ensure

satisfactory

steering

condition

as

well

as

maximum

tire

life

If

any

defect

is

present

repair

or

replace

as

necess

uy

I

Check

wheel

rim

especially

rim

flange

and

bead

seat

for

rust

distor

tion

cracks

or

other

faults

which

might

cause

air

leaks

Function

of

tubeless

tire

depends

on

a

good

seal

between

tire

bead

and

wheel

rim

2

Thoroughly

remove

rust

dust

oxidized

rubber

or

sand

from

wheel

rim

Rim

bead

seets

should

be

ct

aned

with

the

following

Steel wheel

Wire

brush

coarse

steel

wool

etc

Aluminum

wheel

Neutral

detergent

cloth

ole

3

Examine wheel

rim

for

lateral

and

radial

runout

using

dial

gauge

B B

A A

SMA074

LaterIII

runout

A

and

ill

rvnout

B

S

I

wheel

Lea

thin

10mm

10

039

in

Lea

than

05mm

10

020

in

Diff

ence

between

right

and left

la

btrel

runout

S

Aluminum

wheel

Aluminum

I

Lea

then

05

mm

O

02O

in

Lea

than

02mm

O

llOB

In

4

Replace

wheel

when

any

of

the

following

problems

occurs

Bent

dented

or

heavily

rusted

Elongated

bolt

holes

Excessive

lateral

or

radial

runout

Air

leaks

through

welds

Wheel

nuts

will

not

stay

tight

Wheel

balance

Inspect

wheel

and

tire

for

wheel

balance

and

correct

it

if

unbalance

is

present

taking

the

following

points

into

consideration

I

Correct

unbalance

when

the

symptom

of

unbalance

appears

as

wheel

tramps

and

wheel

shimmy

2

Balance

wheel

and

tire

both

statically

end

dynamically

Ianeln

wheels

WARNING

When

balancing

wheel

and

tire

on

the

car

be

SlIre

to

observe

the

equipment

manufacturers

instruc

tions

carefully

Cause

Wheel

static

unbalance

Symptom

of

unbalance

Wheel

tramp

Wheel

shimmy

Corrective

action

Balance

statically

Place

balance

weights

here

Wheel

tramp

o

leavy

Location

Maximum

allowable

unbalanCl

at

rim

flange

10

g

0

35

oz

Bal

n

weight

10

6Og

O

35

2

120z

at

10

D10

35

od

interval

SMA076

MAINTENANCE

Chassis

and

Body

Maintenance

Wheel

dynamic

unbalance

Wheel

shimmy

Balance

dynamically

Wheel

shimmy

o

Place

balance

weights

here

Wheel

shimmy

SMA075

a

Be

sur

to

place

correct

balance

weights

on

inner

edge

of

rim

b

Do

not

put

more

than

two

weights

on

each

side

c

Two

type

6f

balance

weight

are

used

one

is

designed

for

use

with

steel

wheel

and

tha

other

for

u

e

with

aluminum

wheel

Do

not

mix

different

types

of

balance

weights

d

Properly

rebalance

the

wheel

and

ti

e

whenever

puncture

is

repaired

STEERING

SYSTEM

CHECKING

STEERING

GEAR

OIL

LEVEL

AND

LEAKS

Check

fluid

reaks

o

Add

fluid

SMA604

CHECKING

POWER

ST

EERING

FLUID

AND

LINES

I

Mter

stopping

the

engine

check

oi11evel

in

reservoir

Check

dipstick

on

HOT

ide

at

normal

operating

temperature

or

COLD

ide

when

oil

i

cold

Add

recommended

oil

if

necessarY

CAUTION

00

not

overfill

I

c

1

UIllIfII

Oil

level

should

be

maintained

A

within

this

range

SMA12

MA

33

Chassis

and

Body

MainteUJJlce

MAINTENANCE

2

Inspect

line

condition

and

check

for

leaks

Check

for

fluid

leaks

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

wear

or

damag

Retighten

if

necessary

Refer

to

Section

ST for

tightening

torque

Check

ball

joints

and

idler

arm

for

grease

leakage

Check

for

any

missing

parts

cotter

pins

washer

etc

SMA190

Q

Ch

ck

grease

leakage

Check

tightening

torque

MA

34

SMA

145

MAINTENANCE

Chassis

and

Body

Maintenance

BODY

LUBRICATING

LOCKS

HINGES

AND

HOOD

LATCH

Lubrication

points

TlI

i

c

SMA191

CHECKING

SEAT

BELTS

BUCKLES

RETRACTORS

ANCHORS

AND

ADJUSTER

O1eck

retractors

for

smooth

operation

SMA232

MA

35

Cha

is

and

Body

Maintenance

MAINTENANCE

HEATER

AND

AlII

CONDITIONER

CHECKING

REFRIGERANT

LEVEL

L

Open

doors

fully

2

Start

the

engine

3

Set

air

conditioner

switch

to

ON

position

Amount

of

refrigerant

Almost

no

refrigerant

Check

item

4

Set

temperature

lever

to

maxi

mum

cold

position

5

Set

blower

to

maximum

speed

6

Checlc

sight

glass

after

the

lapse

of

Temperature

of

high

pressure

and

low

pressure

lines

Almost

no

difference

between

high

pressure

and

low

pressure

side

temperature

Bubbles

flow

continu

ously

Bubbles

will

disappear

am

som

thing

like

mist

will

flow

when

lIf

iglrant

is

nearly

gone

State

in

sight

glass

nl

AC256

Pressure

of

system

High

pressure

side

is

abnormally

low

top

compnssor

im

mediately

and

con

duct

an

overall

ch

k

Repair

a

The

bubbl

seen

through

the

sight

glass

are

influenced

by

tha

ambiant

temperature

Since

the

bubbl

ere

hard

to

how

up

in

comparatively

low

temperature

below

20De

68d

Fh

it

i

possible

that

a

lightly

larger

amount

of

refrigetant

would

be

filled

if

upplied

aCCOrding

to

the

ight

glass

Be

uto

chock

MA

36

Insufficient

High

pressure

side

is

warm

and

low

pressure

side

is

fairly

cold

The

bubbles

are

seen

at

intervals

of

1

2

seconds

n

r

I

AC257

Both press

reon

high

and

tow

pressure

sides

are

slightly

low

Check

fot

gas

leakage

repaiI

a

lequited

re

plenish

and

charge

system

the

amount

when

it

exceeds

2DoC

68DF

In

higher

temperatura

the

bubble

ara

easy

to

show

up

b

When

the

screen

in the

receiver

drier

i

clogged

tha

bubble

will

appear

en

if

the

emount

of

refrig

erant

is

normal

In

this

case the

outlet

side

pipe

of

tha

raceiver

drier

bacome

considerebly

cold

about

five

minutes

Judge

according

to

the

following

table

Suitable

Too

much

refrigenmt

High

pressure

side

is

hot

and

low

pressure

side

is

cold

High

pressure

side

is

abnormally

hot

Almost

transparent

Bubbles

may

appear

when

engine

speed

is

raised

and

lowered

No

bubbles

can

be

seen

No clear

differencr

exists

betwen

thMe

two

conditions

n

AC258

Both

pressures

on

high

and

low

pressure

sides

are

nonnal

Both

pres

ureson

high

and

low

pressure

sides

are

abnormally

high

Discharge

refrigerant

from

serVice

val

e

of

low

pressure

side

CHECKING

COMPRESSOR

DRIVE

BELT

Refer

to

Engine

Maintenance

for

inspection

and

adjustment

CHECKING

HOSES

AND

PIPES

Check

heater

and

air

conditioner

for

damaged

hoses

or

pipes

due

to

in

terference

or

friction

with

adjoining

parts

If

damage

is

minor

repair

those

affected

hose

or

pipes

If

damage

is

major

and

if

there

is

the

possibility

of

encountering

holes

replace

the

affected

parts

Carefully

check

hoses

and

pipes

especially

thOle

located

CIOM

to

moy

ing

parts

Or

sharp

edge

of

panel

CHECKING

REFRIGERANT

LEAKS

Conduct

a

leak

test

with

halide

or

electric

leak

detector

whenever

leakage

of

refrigerant

is

suspected

and

when

conducting

service

operations

which

are

accompanied

by

disassembly

or

loosening

of

connection

fittings

MoIJor

check

point

I

Compressor

shaft

seal

rotate

the

compressor

by

hand

Flexible

hose

connections

Front

and

rear

head

gaskets

Service

valve

2

Condenser

pipe

fitting

Condenser

inlet

and

outlet

pipe

connections

3

Refrigerant

lines

Flared

section

of

high

pressure

and

low

pressure

flexible

hoses

line

connections

4

Evaporator

housing

Inlet

and

outlet

line

connections

Expansion

valve

Suction

throttle

valve

111

1

I I

l

I

Flame

adjusting

lines

MAINTENANCE

Chassis

and

Body

Maintenance

Engine

co

ressor

a

o

I

L

Condenser

I

SMA233

Sampling

tube

The

following

information

and

cautions

should

be

kept

in

mind

when

checking

for

leakage

SMA150

MA

37

Chassis

end

Body

Maint

mance

MAINTENANCE

If

a

halide

leak

detector

is

used

de

termine

whether

or

not

there

is

gas

leaking by

the

color

of

the

flame

as

indicated

in

the

chart below

Propane

type

Butane

type

NO

LEAK

Greenish

blue

Pale

blue

SMALL

LEAK

Yellow

Bright

blue

LARGE

LEAK

Purple

Vivid

green

WARNING

a

Never

inhale

the

fumes

produced

by

combustion

of

J

nt

gas

since

they

are

toxic

b

Never

use

halide

torch

in

a

place

where

combustible

or

explosive

gas is

present

MA

38

Since

refrigerant

gas

is

heavier

than

ai mall

leaks

can

be

easily

detect

ed

by

placing

sampling

tube

direct

ly

below

the

check

point

If

eny

trace

of

oil

i

noted

at

and

around

connection

fittings

it

is

a

sure

indication

that

refrigerant

is

le

king

If

a

gas

leak

is

detecteil

proceed

as

follows

I

Check

torque

on

the

connection

fitting

and

if

too

loose

tighten

to

the

proper

torque

Oieck

for

gas

leakage

with

a

leak

detector

2

If

leakage

continues

even

after

the

fitting

has

been

retightened

dis

charge

refrigerant

from

system

discon

nect

the

fittings

and

check

it

eating

face

for

damage

Always

replace

even

if

damage

is

slight

3

Che

k

compressor

oil

and add

oil

if

required

4

Oiarge

refrigerant

and

recheck

for

gas

leaks

If

no

leaks

are

found

evacu

ate

and

charge

system

OFF

SEASON

MAl

ANCE

Even

in

the

off

season

turn

the

compressor

for

10

minutes

at

least

once

a

month

by

running

the

engine

at

idling

rpm

MAINTENANCE

Service

Data

and

Specifications

SERVICE

DATA

AND

SPECIACATIONS

ENGINE

MAINTENANCE

INSPECTION

AND ADJUSTMENT

Basic

mecl

anlcal

system

Valve

clearance

mm

in

Hot

Cold

Intake

0

30

10

Ot

2 0

2t

10

008

0

23

10

0091

Exhaust 0

30

O

Ot

2

Drive

belt

defle

tion

Fan

Alternator Air

condi

tioner

compressor

and

Power

steering

oil

pump

mm

in

8

t210

3t

0

47

Applied

pressed

force

N

kg

lb

98110

221

Compression

pressure

kPa

kg

cm2

psil

rpm

Standard

t

t77lt2

0

17t1

350

883 9

0 t

281

350

Minimum

At

ambient

temperature

200C

680F

After

checking

valve

clearance

while

engine

is

cold

Iso

check

it

when

engine

is

hot

to

if it

remains

within the

Jpecifi

value

If

it

does

not

rudjunit

I

nition

and

fuel

system

Spark

plug

Type

Plug

gap

mm

in

Hot

type

Cold

type

Standard

IStBnd

U

S

A

ard

I

Opti

on

8P7ES

8P5ES8P6ES

0

8 0

9

0

03t

0

035

8PR6ES 8PR5ES 8PR7ES

ResUor

built

in

type

II

ohm

I

Less

than

30

000

Canada

High

tension

cable resistance

Ignition

timing

idle

speed

and

idle

CO

1

on

california

Califronhi

models

1

models

I

ManuOl

tran

mission

8

t

20 B T

D C

60 B

T D

C

I

700

l

100

700

l

100

I

Automatic

tran

mission

8

l

20

B

T

D

C60 B

T O

C

I

lin

0

position

I

700

tOO

700

tOO

1

3i

t

Idle

mixture

screw

CO

at

idling

speed

is

preset

and

No

air

sealed

at

factory

Emission

control

system

Unit

kPa

mmH20

inH201

Vapor

line

leakage

es

Supplied

pressure

3 923 400

15

751

Pressure

variation

Less

than

0

245

25

0

981

TIGHTENING

TORQUE

Unit

N

m

kg

m

ft

Ib

Rocker

arm

nut

16

22

t

6 2 2

12

t6

Oil pan

drain

plug

20 29

2 0 3

0

t4

22

I

Spark

plug

t5

20

1

5 2

0

tt

t4

Fuel

hose

clamp

1

0 t

5

O

tO

0

t5

0

7

11

h

3

mm

0

12

in

l

@

Fuel

hose

clamping

position

EF335A

CHASSIS

AND

BODY

MAINTENANCE

INSPECTION

AND ADJUSTMENT

Clutch

Unit

mm

inl

Pedal

height

H

t68

17416

61

6

851

5

10

04

0

20

Pedal

free

play

AU

Front

axle

and

front

suspension

Axial

play

mm

inl

0

01

Wheel

bearing Pl

eload

As

measured

at

wheel

hub

bolt

With

nBW

pBrts

N

Ikg

lbl

69

t4

710

7

1

5

1

5

3

With

used

part

N

Ikg

Ibl

20

78 02

0

8

04

t

81

Wheel

alignment

Camber

degree

40

SO

Carter

degree

1045

3015

Kingpin

inclination

degree

7025

8055

Toe

in

Unladenl

o

2

mm

10

0

08 inl

0

12

On

both sides

Side

slip

Reference

data

Out

1

mm

In

1

mm

m

Out

0

012

in

In

0

012

in

ftl

MA

39

SpecialSi

rvice

Tool

MAINT

NANCE

Standard

ide

rod

length

A

mmlinl

71

0

1280

Front

wheel

turning

angle

Toe

out

turns

IWhen

inner

wheel

i

200

I

degree

Outer

wheel

18

70

Full

turn

degree

Inner

wheel

33

350

270

29

Outer

wheel

On

power

steering

models

wheel

turning

force

lat

circumference

of

steering

wheel

of

98

147

N

110

15

kg

22 33

Ib

with

en

gine

at

idle

Brake

s

stem

Unit

mm

lin

N22

210081

2

10001

10

5

10

4131

86

10

339

155

16116

10

6

341

5

1004

0

201

Pad

wear

limit

AN12H

N22

Rotor

repair

limit

AN12H

Pedal

height

h

Pede

fre8

play

a

Pedal

depressed

height

More

than

60

f2

36

Parking

brake

Lever

stroke

8t

pullirig

0

t96N

120

kg

44lbll

90

100

13

54

3

941

Number

of

notches

7

8

Wheel

and

tire

Recommended

Id

tire

inflation

pressure

t85

7OSR14

26

psi

1177

kPaI

Tire

size

00

not

use in

excess of

80

kmlh

150

MPHI

Spare

tire

T135

70DI6

60

psi

1412

kPa

Tire

prlSlure

should

be

checked

when

tires

are

COLD

Wheel

rim

lateral

and

radial

mm

in

runout

LeCs

than

1

0 0

039

0

5

10

020

02

Difference

between

right

end

left

lateral

runout

Less

than

0

5

0

020

1

0

2

10

008

2

mm

in

Wheel

balance

Maximum

allowable

unbelance

at

im

flange

gr

ozl

to

10

35

Tire

balancing

weight

10

60

10

35

2

121

Spac

ng

to

10

351

gr

loz

1

Steet

wheel

2

Aluminum

wheel

TIGHTENING

TORQUE

Unit

N

m

kg

ft

fb

Clutch

Pedal

stopper

lock

nut

78

11

8

08

12

5 8 8

7

Master

cylinder

push

78 11

8

08

t

2

58

8

7

rod

lock

nut

Manual

transmission

Drain

and

filler

plugs

25 34

25 3

5

18 25

Propeller

shaft

and

dif

ferential

carrier

Differential

carrier

59 98

6

10

43 72

drain

and

filler

plugs

Front

axle

and

front

suspension

Side

rod

lock

nut

78

98

80

to

O58

72

Brake

system

Air

bleed

vatve

6 9 8

8 0

7

O

5

1

6

5

Brake

lamp

switch

12

15

1

2

1

5

9

11

lock

nut

Brake

booster

input

16

22

16

2 2

12

16

rod

k

nut

Wheel

and

tire

Wheel

nut

78

98

80

to

O58

72

SPECIAL

SERVICE

TOOL

Tool

number

Kent

Moore

No

Tool

name

ST19320000

125664

Oil

fIlter

wrench

MA

40

SJ

DATSUN

200SX

Model

S

0

Series

ENGINE

MECHANICAL

CONTENTS

ENGINE

COMPONENTS

Outer

parts

ENGINE

COMPONENTS

Body

parts

ENGINE

DISASSEMBLY

PRECAUTION

DISASSEMBLING

ENGINE

OVERALL

DISASSEMBLING

PISTON

AND

CONNECTING

ROD

DISASSEMBLING

CYLINDER HEAD

DISASSEMBLING

INTAKE

MANIFOLD

INSPECTION

AND

REPAIR

CYLINDER

HEAD

VALVE

SPRING

ROCKER

ARM

AND

ROCKER

SHAFT

GAMSHAFT

AND

CAMSHAFT

BEARIN

CYLINDER

BLOCK

PISTON PISTON

AND

PISTON RING

EM

2

EM 3

EM

4

EM

4

EM

4

EM

6

EM 6

EM

7

EM 7

EM

8

EM

8

EM 8

EM

8

EM

9

EM lO

CONNECTING

ROD

CRANKSHAFT

MAIN

BEARING

AND

CONNECTING

ROD

BEARING

MISCELLANEOUS

COMPONENTS

ENGINE

ASSEMBLY

PRECAUTIONS

ASSEMBLING

CYLINDER

HEAD

ASSEMBLING

PISTON

AND

CONNECTING

ROD

ASSEMBLING

INTAKE

MANIFOLD

ASSEMBLING

ENGINE

OVERALL

SERVICE

DATA

AND

SPECIFICATIONS

INSPECTION

AND

ADJUSTMENT

TIGHTENING

TORGUE

TROUBLE

DIAGNOSES

AND

CORRECTIONS

SPECIAL

SERVICE

TOOLS

EM

ll

EM

l1

EM

12

EM 12

EM 14

EM 15

EM 16

EM

16

EM

20

EM

20

EM

24

EM

25

EM

27

EngineComponenrs

Outer

parts

ENGINE

MECHANICAL

ENGINE

COMPONENTS

Outer

parts

IIigb

temion

coble

1

l

Intake

manifold

st

y

I

l

34

44

35

4

5

25 33

EA

tube

E

G

R

ValVe

Exhaust

manifold

1

l16

21

iti6

2

t

Starter

motor

1

l16

21

1

6 2 1

t2 t5

Intake

manifold

157

12

16 87

116

Alternator

adjusting

bar

Fan

belt

J

29 39

3 0

4

0

22

P

C

V

valve

Oil

pump

J

N

m

tg

m

ft

lb

15

8

11

SEM136

EM

2

ENGINE

MECHANICAL

Engine

Components

Body

parts

ENGINE

COMPONENTS

Body

parts

Front

cove

l

Valve

rocker

cover

If

16 22

1

6

2 2

2

Valve

rocker

and

shaft

assem

bly

@

Exhaust

tntake

9

Vatve

cotter

eam

shaft

Spring

retainer

Rubber

e

1

Oil

seal

plug

Spring

seat

j

snap

ring

Valve

gUide

Cylinder

head

bolt

If

69

18

Valve

at

1

0

8 0

51

58

Cylinder

head

Camshalt

sprocket

Cylinder

liner

Only

for

service

Cylinder

block

t51

t6

116

Drive

plate

151

16

116

Oil

drain

plug

If

20 29

2

0 3

0

14

22

If

N

m

kg

m

ft

lb

EM137

EM

3

EqgineDisassemb

y

ENGINE

MECHANICAL

PRECAUTION

Arrange

the

disassembled

parts

on

the

parts

stand

in

accordance

with

their

assembled

locations

sequence

etc

so

that

the

parts

will

be

reas

sembled

to

their

original

locations

Place

mating

marks

on

the

parts

if

necessary

DISASSEMBLING

ENGINE

OVERALL

MOUNTING

ENGINE

ON

WOi

tK

STAND

I

Remove

following

parts

located

at

rear

and

right

side

of

engine

Starter

otor

Transmission

Clut

h

cover

assembly

using

Tool

KV30100100

or

torque

convertor

Intake

manifold

stays

Alternator

and

its

bracket

Engine

mounting

bracket

2 Install

engine

attachment

to

cylinder

block

Then

mount

the

engine

on

the

work

stand

SEMl38

3

Drain

out

engine

oil

and

coolant

REMOVING

OUTER

PARTS

4

Remove

engine

front

side

parts

Fan

Drive

belts

Belt

tensioner

for

powI

steering

if

equipped

Alternator

adjusting

bar

Water

pump

Vacuum

tube

assembly

for

distribu

tot

and

canister

EM4

ENGINE

DISASSEMBLY

Crankshaft

pulley

Use

suitable

tool

on

air

conditioner

equipped

model

SEMl39

5

Remove

engine

left

side

parts

Distributor

cap

and

high

tension

cables

Distributor

Exhaust

manifold

with

air

in

duction

tubes

after

removing

E

G

R

tube

SEM140

Compressor

brac

ret

if

equipped

Oil

level

gauge

Engine

mounting

bracket

Spark

plugs

6

Remove

engine

right

side

parts

I

Cylinder

block

to

P

C

V

valve

hose

2

Power

steering

pump

bracket

and

throttle

chamber

stay

if

equipped

3

Intake

manifold

mbly

includ

ing

water

inlet

water

pipes

water out

let

vacuum

tubes

E

G R

valve

throt

tie

chamber

and

EFI

parts

lnjecturs

fuel

pipes

air

regulator

etc

SEM

142

4

And

follpwing

parts

Oil

f1Iter

using

Tool

STl932ciOOO

Oil

pressure

switch

Spark

plugs

7

Remove engine

bottom

side

parts

Oil

pump

and

oil

pump

drive

spindle

Gussets

REMOVING

BODY

PARTS

8

Remove

oil

pan and

oil

strainer

9

Remove

valve

rocker

cover

10

Remove

cylinder

head

assembly

1

Remove

camshaft

sprocket

and

slowly

lower

timing

chain

2

Loosen

cylinder

head

bolts

in the

sequence

shown

SEM144

3

Remove

bolts

securing

cylinder

head

to

front

cover

4

Remove

cylinder

head

When

removing

cylinder

head

from

engine

installed

on

car

follow

the

instructions below

8

Turn

crankshaft

until

No

1

piston

is

at

T

D C

on

its

compression

stroke

b

To

facilitate

assembling

operation

scribe

a

mark

on

timing

chai

and

camshaft

sprocket

with

paint

before

removal

c

Support

timing

chain

by

utilizing

Tool

between

timing

chains

II

Remove

front

side

parts

I

Front

cover

2

Chain

tensioner

and

chain

guide

3

Timing

chain

4

Oil

thrower

oil

pump

drive

gear

and

crankshaft

spr

ocket

ENGINE

MECHANICAL

Engine

Disassembly

1

Chain

tensioner

2

Slack

side

chain

guide

3

Tension

side

chain

guide

4

0

il

thrower

5

Oil

PUJl

P

drive

gear

6

Crankshaft

sprocket

If

it

is

hard

to

extract

crankshaft

sprocket

use asuitable

puller

EM286

12

Remove

piston

and

connecting

rod

assembly

I

Remove

connecting

rod

bearing

cap

with

bearing

2

Push

out

piston

with

connecting

rod

toward

cylinder

head

side

J1c

l

J

C

j

I

r

G

0

II

O

EJ

S7

8Piston can

be

easily

removed

by

scraJiing

carbon

off

top

face

of

cylinder

with

a

scraper

b

Numbers

are

stamped

on

connect

ing

rod

and

cap

corresponding

to

each

cylinder

Care

should

betaken

to

avoid

wrong

combination

includ

ing

bearing

13

Remove

flywheel

and end

plate

WARNING

When

removing

flywheel

be

careful

not

to

drop

it

14

Remove

crankshaft

1

Remove

main

bearing

caps

with

bearings

8

When

loosening

main

bearing

cap

bolts

loosen

from

outside

in

se

quence

b

Use

Tool

to

remoye

center

and

rear

main

bearing

caps

Keep

them

in

order

KVIOI041S0

EM608

f

Remove

rear

oil

seal

T

@rb

EM1QO

EM

5

EngineOisa

Sl

fTlbly

ENGINE

MECHANICAL

3

Remove

crankshaft

4

Remove

main

bearings

at

block

side

15

Remove

baffle

plate

and

steel

net

from

cylinder

block

DISASSEMBLING

PISTON

AND

CONNECTING

ROD

1

Remove

piston

rings

with

a

ring

remOver

2

Press

piston

out

using

press

and

Too

ST13030001

EM156

Keep

the

disassembled

parts

in

order

EM

6

DISASSEMBLING

CYLINDER

HEAD

1

Remove

rocker

shaft

assembly

together

with

securing

bolts

a

Do

not

remove

bolu

at

No

1

and

No

5

brackeU

since

rocker shaft

bracket

and

rocker

will

spring

out

b

When

loosening

bolts

evenly

loosen

from

outside

in

sequence

SEM145

2

Remove

camshaft

3

Remove

valves

valve

springs

and

relating parts

using

Too

ST12070000

Keep

the

disassembled

parts

in

order

DISASSEMBLING

INTAKE MANIFOLD

1

Remove

following

fuel

system

parts

referring

to

Section

EF

I

Throttle

chamber

2

Air

regulator

3

Fuel

and

vacuum

tube

assembly

4

Fuel

pressure

regulator

5

Injectors

6

Throttle

control

cable

bracket

2

Remove

cooling

system

parts

1

Water

outlet

2

Thermostat

3

Water

gallery

4

Water

outlet

5

Semol

housing

6

Water

pipe

3

Remove

following

emission

con

trol

system

parts

referring

to

Section

EC

E

G

R

control

valve

Thermal

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

Vacuum

connectors

Note installed

direction

of

outl

t

for

r

mbly

Water

temperature

sensors

5

Disassemble

intake

manifold

body

CYLINDER

HEAD

CYLINDER

HEAD

MATING

FACE

I

Make

a

visual

check

for

cracks

and

flaws

2

Measure

the

surface

of

cylinder

head

on

cylinder

block

side

for

warpage

If

beyond

the

specified

limit

correct

with

a

surface

grinder

Warpage

of

surface

limit

0

1

mm

0

004

int

It

Cil

SEM14g

Surface

grinding

li

it

The

grinding

limit

of

cylinder

head

is determined

by

the

cylinder

block

grinding

in

an

engine

Depth

of

cylinder

head

grinding

is

A

Depth

of

cylinder

block

grinding

is

8

limit

A

B

0 2

mm

10

008

in

VALVE GUIDE

Measure

the

clearance

between

valve

guide

and

valve

stem

If

the

clearance

exceeds

the

specified

limit

replace

the

worn

parts

or

both

valve

and valve

guide

In this

case

it

is

essential

to

detennine

if

such

a

clear

ance

has

been caused

by

a

worn

Or

bent

valve

stem

or

by

a

worn

valve

guide

Determining

clearance

Precise

method

I

Measure

the

diameter

of

valve

ENGINE

MECHANICAL

lnspectionandRepair

INSPECTION AND

REPAIR

stem

with a

micrometer

in

three

places

top

center

and

bottom

2

Measure valve

guide

hore

at

center

using

telescope

hole

gauge

F

A

T

Mr

h

oP

10

1

L

j1

@

I

C

d

SEM150

3

Subtract

the

highest

reading

of

valve

stem

diameter

from

valve

guide

bore

to

obtain

the

stem

to

guide

clear

ance

Stem

to

guide

clearance

limit

0

1

mm

10

004 in

2

Expedient

method

Pry

valve

in

lateral

direction

and

measure

deflection

at

stem

end

with

dial

gauge

Stem

end

deflection

limit

02

mm

0

008 in

Valve

should

be

moved

in

parallel

with

rocker

arm

Generally

a

large

amount

of

wear

occurs

in

this

direC

tion

SEM151

Replacement

of

valve

guide

1

To

remove

old

guides

use

Tool

S111033000

and

a

press

under

a

2

ton

pressure

or

a

hammer

Drive

them

out

toward

rocker

cover

Heated cylinder

head

will

facilitate

the

operation

2

Ream

cylinder

head

valve

guide

hole

using

Tool

at

room

temperature

Reaming

bore

12

185

12

196

mm

04797

0

4802

in

SEM152

3

Fit

snap

ring

on

new

valve

guide

and

press

the

guide

into

head

until

snap

ring

comes

in

contact

with

cylinder

head

surface

after

heating

cylinder

head

to

150

to

2000C

302 to

3920F

Valve

guide

of

02

mm

0

008

in

oversize

diameter is

available

for

service

Refer

to

S

D

S

4

Ream

the

bore

using

1001

STl1032000

Reaming

bore

8

000

8

018

mm

0

3150

0

3157

in

5

Correct

valve

seat

sur

ace

with

new

valve

gUide

as

the

axis

VALVE

SEAT

INSERTS

Check

valve

seat

inserts

for

any

evidence

of

pitting

at

valve

contact

surface

and

reseat

or

replace

ifworn

out

excessively

Correct

valve

seat

surface

with

Tool

and

grind

with

a

grinding

compound

EM

Inspection

and

Repair

ENGINE

MECHANICAL

Valve

seat

insert

of

05

min

0

020

in

oversize

is

available

for

service

Refer

to

S

O

S

J

a

When

repa

nng

valve

seat

check

valve

guide

for

wear

beforehand

If

worn

replace

it

Then

correct

valve

seat

b

The

Tool

should

be

used

with

both

hands

for

uniform

cutting

Replacement

valve

seat

insert

I

Old

insert

can

be

removed

by

boring

out

until

it

collapses

The

machine

deplh

stop

should

be

set

so

that

boring

cannot

continue

beyond

the

bottom

face

of

the

insert

recess

in

cylinder

head

2

Select

a

suitable

valve

seat

insert

and check

its

outside

diameter

3

Machine

cylinder

head

recess

to

the

concentric

circles

to

valve

guide

center

4

Ream the

cylinder

head

recess

at

room

temperature

Refer

to

S

O

S

5

Heat

cylinder

head

10

a

temper

ature

of

150

to

2000C

302

to

3920

F

6

Fit

inserl

ensuring

that

it

beds

on

the

bottom

face

of

its

recess

and

caulk

more

than

4

points

7

Valve

seats

newly

fitted

should

be

cut

or

ground

using

Tool

ST1l65000l

at

the

specified

dimensions

as

shown

in

S

O

S

8

Apply

small

amount

of

fine

grinding compound

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

EM

8

VALVE

I

Check

each

of

the

intake

and

exhaust

valve

for

worn

damaged

or

defonned

valve

head

or

stem

Correct

or

replace

the

valve

that

is

faulty

Refer

to

S

o

s

2

Valve

face

or

valve

stem

end

sur

face

should

betefaced

by

using

a

valve

grinder

Valve

head

margin

Limit

05

mm

10

020

inl

Grinding

of

valve

stem

end

Limit

0 5

mm

10

020 in

EM111

vALVE

SPRING

1

Check

valve

spring

for

squareness

using

a

steel

square

and

surface

plate

If

spring

is

out

of

square

S

more

than

specified

limit

replace

with

new

ones

Out

of

square

S

Outer

Limit

1

6

mm

0

063

in

Inner

Limit

1

6

mm

10

063

inl

J

0

iBEM29s

2

Measure

the

free

length

and

the

tension

of

each

spring

If

the

Illeasured

value

exceeds

the

specified

limi

I

re

place

spring

Refer

to

S

O

s

EM113

ROCKER

ARM

AND

ROCKER

SHAFT

1

Check

rocker

anns

and

shafts

for

sign

of

wear

or

damage

and

if worn

excessively

replace

rocker

arm

and

or

shaft

2

Check

oil

clearance

between

rocker

arm

and

rocker shaft

Rocker

arm

to

shaft

clearance

0

007

0

049

mm

10

0003

0

0019

inl

CAMSHAn

AND

CAMSHAn

BEARING

CAMSHAFT

BEARING

CLEARANCE

Measure

the

inside

diameter

of

cam

shaft

bearing

with

an

inside

dial

gauge

and

the

outside

diameter

of

camshaft

journal

with

a

micrometer

If

any

malfunction

is

found

replace

camshaft

or

cylinder

head

assembly

Camshaft

bearing

clearance

limit

0

1

mm

10

004

inl

SEM154

CAMSHAFT

ALIGNMENT

I

Check

camshaft camshaft

journal

and

cam

surface

for

bend

wear

or

damage

If

beyond

the

specified

limits

replace

the

parts

2

A

bend

value is

one

half

of

the

total

indicator

reading

obtained

when

camshaft is

turned

one full

revolution

with

a

dial

gauge

at

center

journal

Camshaft

bend

Total

indicator

readingl

limit

0

10

mm

10

0039

in

SEM156

3

Measure

camshaft

cam

height

If

beyond

the

specified

limit

replace

camshaft

Wear

limit

of

com

height

025

mm

10

0098

in

4

Measure

camshaft

end

play

If

beyond

the

specified

limit

replace

camshaft

or

cylinder

head

assembly

Camshaft

end

play

limit

0 2

mm

0

008

in

CYUNDER

BLOCK

1

Visually

check

cylinder

block

for

cracks

or

flaws

2

Measure

the

top

of

cylinder

block

cylinder

head

mating

face

for

warpage

If

it

exceeds

the

specified

limit correct

with

a

grinder

Warpage

of

surfaC8

limit

0

1

mm

0

004

in

ENGINE

MECHANICAL

ItJSPectionand

Repair

EM540

Surface

grinding

limit

The

grinding

limit

of

cylinder

block

is

determined

by

the

cylinder

head

grind

ing

in

an

engine

Depth

of

cylinder

head

grinding

is

A

Depth

of

cylinder

block

grinding

is

8

limit

A

B

0 2

mm

0

008

in

3

Using

a

bore

gauge

measure

cylin

der

bore

for

wear

out

of

round

or

taper

If

those

are

excessive

rebore

the

cylinder

walls

by

means of

a

boring

machine Measurement

should

be

taken

along

bores

for

taper

and

around

bores

for

out

of

round

Refer

to

S

O

S

Out

of

round

X

y

Taper

A

B

FA

J1

zU

0

791

I

IiIL

60

12

361

III

I

flit

17

X

I

Unit

mm

in

EM422

L

I

EM124

4

When

wear

taper

or

out

of

round

is

minor

and

within

the

limit

remove

the

step

at

the

topmost

portion

of

cylinder

using

a

ridge

reamer

or

other

similar

tool

If

cyl

inder

bore

has

worn

beyond

the

wear

limit

use

cylinder

liner

Undersize

cylinder

liners

are

avail

able

for

service

Refer

to

S

D

S

IntarferenC8

fit

of

cylinder

liner

0

08

to

0

09

mm

0

0031

to

0

0035

in

CYLINDER

BORING

When

any

cylinder

needs

boring

all

other

cylinders

must

also

be

bored

at

the

same

time

Determining

bore

size

1

Determine

piston

oversize

accord

ing

to

amount

of

wear

of

cylinder

Ovenize

pistons

are

available

for

service

Refer

to

S

D

S

2

The

size

to

which

cylinders

must

be

honed

is

determined

by

adding

piston

to

cylinder

clearance

to

the

piston

skirt

diameter

A

T

tI

A

SEM714

EM126

Dimen

ion

distance

from

center

of

pinl

Approximately

20

mm

0

79

in

EM

9

In5PectionandRepair

ENGINE

MECHANICAL

Rebored

size

calculation

D A

B

C

A

0

005

to

0

025

mm

0

0002

to

0

0010

in

where

D

A

B

C

Honed diameter

Skirt

diameter

as

measured

Piston

to

wall

clearance

Machining

allowance

0

02

mm

0

0008

in

Borin

g

CAUTION

a

To

prevenl

strain

due

to

cuning

heat

bore

the

cylinders

in

the

order

of

24

1

3

b

Before

boring

any

cylinder

install

main

bearing

caps

in

place

and

tighten

to

the

specification

so

that

the

crankshaft

bearing

bores

will

not

become

distorted

from

the

boring

operation

3

Do

not

cut too

much

out

of

cylin

der

bore

at

a

time

Cut

only

0

05

rnm

0

0020

in

or

so

in

diameter

at

a

time

4

As

a

final

step

cylinders

should

be

honed

to size

5

Measure

the

fmished

cylinder

bore

for

out

f

round

or

tapered

part

Refer

to

S

D

S

Measurement

of

a

just

machined

cylinder

bore

requires

utmost

care

since

it

is

expanded

by

cutting

heat

Measuring

piston

to

cyllnder

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

14

7

N

0

2

1

5

kg

0 4

3

Ibl

a

When

measuring

cl

slOWly

pull feeler

gauge straight upward

b

It

is

recommended

that

piston

and

cylinder

be

heated

to

200C 680F

EM

10

I

l

t

J

l

EM641

PISTON

AND

PISTON

RING

PISTON

I

Scrape

carbon

off

piston

and

ring

grooves

with

a

carbon

scraper

and

a

curved

steel

wire

The

wire

will

be

useful

in

cleaning

bottom

land

of

ring

groove

Oean

out oil

slots

in

bottom

land

of

oil

ring

groove

2

Check

for

damage

scratches

and

wear

Replace

if

such

a

fault

is

de

tected

PISTON

RING

I

Measure

the

side

clearance

of

rings

in

ring

grooves

as

each

ring

is

installed

If

side clearance

exceeds

the

speci

fied

limit

replace

piston

together

with

piston

ring

Side

clearance

Limit

0

1

mm

0

004

inl

EM129

2

Measure

ring

gap

with

a

feeler

gauge

placing

ring

squarely

in

cylinder

using

piston

Ring

should

be

placed

to

diilmeter

at

upper

or

lower

limit

of

ring

travel

If

ring

gap

exceeds

the

specified

limit

replace

ring

Ring

gap

Limit

1

0

mm

0

039 in

8

When

piston

ring

only

is

to

be

replaced

without

cylinder

bore

being

corrected

measure

the

gap

at

the

bottom

of

cylinder

where

the

wear

is

minor

b

Oversize

piston

rings

are

available

for

service

0

5

mm

0

020

inl

1

0

mm

0

039

in

oversize

PISTON

1

Check

the

fitting

of

piston

in

to

piston

hole

to

be

such

an

extent

that

it

can

be

pressed smoothly

by

fmger

at

room

temperature

This

pis

ton

must

be

a

tight

press

fit

into

connecting

rod

2

Measure

oil

clearance

between

pis

ton

and

piston

If

it

is

excessive

replace

piston

together

with

pis

ton

Piston

to

piston

dearance

0

006

0

013

mm

0

0002

0

0005

in

CONNECTING

ROD

I

If

a

connecting

rod

has

any

flaw

on

both

sides

of

the

thrust

face

and

the

large

end

correct

or

replace

it

2

Check

connecting

rod

for

bend

or

torsion

using

a

connecting

rod

aligner

If

bend

or

torsion

exceeds

the

limit

correct

or

replace

Bend

and

torsion

per

100

mm

394

in

length

limit

0

05

mm

10

0020

in

EM133

3

Install

connecting

rods

with

bear

ings

on

to

corresponding

crank

pins

and

measure

the

thrust

clearance

If

the

measured

value

exceeds

the

limit

replace

such

connecting

rod

Big

end

play

Limit

0

6

mm

0

0024

in

When

replacing

conneCting

rod

select

so

that

weight

difference

be

tween

each

cylinder

is

within

7

g

0

25

ozl

in the

condition

of

piston

and

connecting

rod

assembly

ENGINE

MECHANICAL

Inspectionsnd

Repair

CRANKSHA

CRANK

JOURNAL

AND

I

Repair

or

replace

as

required

If

faults

are

minor

correct

with

fme

crocus

cloth

2

Check

with

a

micrometer

journals

and

crank

pins

for

taper

and

out

of

round

Measurement

should

be

taken

along

journals

for

taper

and

around

journals

for

out

of

round

If

out

of

round

or

taper

exceeds

the

specified

limit

replace

or

repair

Out

of

round

XY

limit

0

03

mm

0

0012

in

Taper

A

BI

Limit

0

03

mm

0

0012

in

I

A

B

EP

EM767

3

After

regrinding

crankshaft

finish

it

to

the

necessary

size

indicated

in

the

chart

under

S

D

S

by

using

an

adequate

undersize

bearing according

to

the

extent

of

required

repair

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

specified

limit

replace

or

repair

Bond

Total

indicator

reading

limit

0

10

mm

0

0039

in

2

Install

crankshaft

in

cylinder

block

and

measure

crankshaft

free

end

play

at

center

bearing

End

play

limit

0 3

mm

10

012

inl

REPLACING

PILOT

BUSHING

To

replace

crankshaft

rear

pilot

bushing

proceed

as

follows

I

Pull

out

bushing

using

Tool

2

Before

installing

a

new

bushing

thoroughly

clean

bushing

hole

EM

11

r

Inspection8ndRepair

ENGINE

MECHANICAL

3

Insert

pilot

bushing

until

distance

between

flange

end and

pilot

bushing

is

the

specified

distance

A

Distance

A

Approximately

4

0

mm

0

157

in

EM719

When

installing

pilot

bushing

be

careful

not

to

damage

edge

of

pilot

bushing

and

not

to

insert

exceuiYely

MAIN

BEARING

AND

CONNECTING

ROO

BEARIN

MAIN

BEARING

I

Thoroughly

clean

all

bearings

and

check

for

scratches

melt

score

or

wear

Replace

bearings

if

any

fault

is

detected

2

Measure

bearing

clearan

as

follows

I

Cut

a

plastigage

to

the

width

of

bearing

and

place

it

in

parallel

with

crank

journal

axis

getting

clear

of

the

oil

hole

Sale

Plastigage

EM141

EM 12

2

Install

hearing

and

bearing

cap

with

the

bolts

tightened

to

the

speci

fied

torque

rJJ

Main

bearing

cap

bolt

44

54

N

m

14

5

55

kg

m

33

40

ft

lb

Do

not turn

crankshaft

while

the

plastigage

is

being

inserted

3

Remove

bearing

and

cap

Com

pare

width

of

plastigage

at

its

widest

part

with the

scale

printed

in

plasti

gage

envelope

Main

bearing

clearance

Limit

0

12

0

0047

in

3

If

clearance

exceeds

the

specified

value

replace

bearing

with

an

under

size

bearing

and

grind

crankshaft

journal

adequately

Refer

to

S

D

S

CONNECTING

ROD

BEARING

I

Measure

connecting

rod

bearing

clearance

in

the

same

manner

as

above

rJJ

Connecting

rod

bearing

cap

nut

44 54

N

m

14

5 5 5

kg

m

33

40

ft

lb

Connecting

rod

bearing

dearance

Limit 0

12

mm

0

0047

in

2

If

clearance

exceeds

the

specified

value

repl

ce

bearing

with

an

under

size

bearing

and

grind

the

crankpin

adequately

Refer

to

S

D

S

MISCELLANEOUS

COMPONENTS

CAMSHA

SPROCKET

I

Check

tooth

surface

for

flaws

or

wear

Replace

sprocket

if

any

fault

is

found

2

Install

sprocket

on

camshaft

and

check

for

runout

If

runout

exceeds

the

specified

limit

replace

camshaft

sprocket

Runout

Total

indicator

reading

Limit

0

1

mm

0

004

inl

SEM157

CHAIN

Check

chain

for

damage

excessive

wear

at

roller

links

Replace

if

faulty

CHAIN

TENSIONER

AND

CHAIN

GUIDE

Check

for

wear

and

breakage

Re

place

if

necessary

FLYWHEEL

I

Check

the clutch

disc

contact

surface

on

flywheel

for

damage

or

wear

Repair

or

replace

if

necessary

2

Measure

runout

of

the clutch

disc

contact

surface

with

a

dial

gauge

If

it

exceeds

the

specified

limit

replace

it

Runout

Total

indicator

reading

Limit

0

15

mm

10

0059

in

ENGINE

MECHANICAL

Inspection

and

Repair

3

Check

tooth

surfaces

of

ring

gear

for

flaws

or

wear

Replace

if

necessary

ReplaC8

ring

gear

at

about

180

to

2200C

356

to

4280F

FRONT

AND

REAR

OIL

SEAL

Check

front

and

rear

oil

seals

for

worn or

folded

over

sealing

lip

or

oil

leakage

If

necessary

replace

with

a

new

seal

When

installing

a

new

seal

pay

attention

to

its

mounting

direc

tion

It

is

good

practice

to

renew

oil

seal

whenever

engine

is

overhauled

Front

lF

1

Front

L

EM150

Rear

EM

13

EngineAS3embly

ENGINE

MECHANICAL

PRECAUTIONS

I

When

installing

sliding

part

such

as

bearings

be

sure

to

apply

engine

oil

on

the

sliding

urfaces

2

Use

new

packings

and

oil

seals

3

Be

sure

to

follow

specified

tightening

torque

and

order

4

Apply

sealant

to

the

following

points

Do

not

apply

sealant

too

much

1

Front

side

of

cylinder

lock

Mating

surface

with

front

cover

and

top

of

front

cover

2

Rear

side

of

cylinder

block

Each

side

of

rear

main

bearing

cap

and

each

corner

of

cylinder

block

Cylinder

block

Rear

main

bearing

cap

10

79

O

gSI

4iR

i

Points

to

be

applied

with

sealant

Unit

mm

in

N

EM151

3

Bottom

side

of

cylinder

block

Step

portions

at

four

mating

sur

faces cylinder

block

to

front

chain

cover

and

cylinder

block

to

rear

main

bearing

cap

EM 14

ENGINE

ASSEMBLY

c

d

Apply

sealant

at

these

points

EM152

4

Front

and

rear

side

of

cylinder

head

Mating

surfaces

with

rubber

plug

Apply

sealant

SEMl58

ASSEMBUNG

CYLINDER HEAD

I

Install

valve

and

valve

spring

I

Set

valve

spring

inner

and

outer

seat

and valve

oil

seal

2

Install

valve valve

spring

inner

and

outer

J

valve

spring

retainer

Com

press

springs

and

fit

valve

spring

collets

by

using

Tool

Oil

seal

Inner

spring

tor

0

t

1

@

Install

above

order

SEM160

a

When

in

taIling

valve

apply

engine

oil

on

the

valva

stem

and

lip

of

valve

oil

seal

b

Check

whether

the

valve

face

i

free

from

foreign

matter

c

Inner

and

outer

valve

springs

are

of

an

uneven

pitd1

type

I

nstall

valve

spring

with

its

narrow

pitch

side

painted

at

cylinder

head

id

Painted

sid

111

c

Narrow

pitchw

Wlde

Pltch

SEM202

2

Make

up

valve

rocker

shaft

as

sembly

Install

rocker

shaft

bracket

valve

rocker

and

spring

on

valve

rocker

shaft

observing

the

following

Wf

SEM161

1

Rocker

bracket

2

Rocker

shaft

3

Bolt

4

Spring

5

Rocker

arm

I

Intake

rocker

shaft

has

identifi

cation

mark

slit

on

front

surface

but

exhaust

rocker

shaft

does

not

2

Both

rocker

shafts

should

be

as

sembled

so

that

punched

marks

on

front

surfaces

come

to

upside

Marks

are

used

to

identify

oil

hole

direction

Slits

Intake

Front

0

Exhaust

SEM162

3

Valve

rocker

is

same

for

intake

and

exhaust

and

also

No

1

and

No

3

cylinder

and

provides

identification

mark

I

Similarly

the

one

for

No

2

and

No

4

cylinder

provides

mark 2

4

Be

careful

not

to

miss

original

location

of

rocker

shaft brackets

For

this

purpose

identification

marks

are

provided

on

each

bracket

and cylinder

head

A

Z

Marked

on

cylinder

head

v

Marked

on

brackets

SEM163

To

prevent

rocker

shaft

brackeu

from

slipping

out

of

rocker

shafts

insert

bracket

bolts

any

bolt

will

dol

into bolt

holes

of

No

1

and

No

5

rocker

shaft

bracket

3

Mount

camshaft

onto

cylinder

head

placing

dowellpin

at

front

end

to

top

position

ENGINE

MECHANICAL

Engine

Assembly

Plae

e

upside

SEM164

4

Mount

valve

rocker

shaft

assembly

on

cylinder

head

by accommodating

to

knock

of

the

head

Then

tight

en

to

the

specified

torque

lil

Rocker

shaft

bracket

bolt

15

25

N

m

1

52 5

kg

m

11

18

ft

lb

a

Tighten

bolts

gradually

in

two

to

three

stages

outwardly

from

center

bracket

b

When

tightening

bolts

make

space

under

cylinder

head

since

some

valves

will

open

and

interfered

t

Z

5

After

assembling

Ll1IU r

head

turn

camshaft

until

No

1

piston

is

at

T

D

C

on

its

compression

stroke

ASSEMBLING

PISTON

AND

CONNECTING

ROD

I

Assemble

pistons

piston pins

and

connecting

rods

of

the

designated

cyl

inder

aPiston

is

pressed

into

connect

ing

rod

and

fitting

force

is

from

4

9

to

14

7

kN

0

5

to

1

5

t

0 6

to

1

7

US

ton

0

49

to

1

48

Imp

tonl

and

the

aid

of

Tool

is

necessary

When

pressing

piston

in

con

necting

rod

apply

engine

oil

to

and

small

end

of

connecting

rod

ST13030001

SEM156

b

Arrange

so

that oil

jet

of

connect

ing

rod

big

end

is

directed

toward

the

right

side

of

cylinder

block

EM151

c

Connecting

rods

are

marked

at

side

of

big

end

for

identifying

the

de

signated

cylinder

2

Install

piston

rings

Install

so

that

stamped

mark

on

ring

faces

upward

a

Top

ring

is

chromium

plated

on

liner

contacting

face

b

Second

ring

has

larger

taper

surface

than

top

ring

c

In

the

combined

oil

ring

upper

rail

is

the

same

as

lower

one

Marked

side

1

101

r

EM158

EM

15

Engine

Assembly

ENGINE

MECHANICAL

ASSEMBLING

INTAKE

MANIFOLD

Assemhle

in

the

reve

order

of

disassembly

and

with

the

specified

torque

if

designated

Refer

to

Disassembling

Intake

Manifold

a

When

installing

thermostat

and

its

housing

refer

t

J

Section

LC

b

When

installing

emission

control

system

parts

and

fuel

system

parts

refer

to

Sections

EC

and

E

Frespec

tively

ASSEMBLING

ENGINE

OVERALL

INSTALLING

BODY

PARTS

1

In

the

first

place

mount

cylinder

block

on

work

stand

refer

to

engine

overall

diSassembly

2 Install

baffle

plate

and

steel

net

into

crankcase

3 Install

crankshaft

1

Set

upper

main

bearings

at

the

proper

portion

of

cylinder

block

a

Only

center

bearing

No

3

is

a

flanged

type

b

All

inter

bearings

No

2

and

No

4

are

the

same

type

c

Front

bearing

No

11

is

also

the

same

type

as

rear

bearing

No

5

d

Upper

and

lOwer

bearings

ara

not

interchangeable

Upper

ones

have

oil

groove

Rear

Front

III III

ill

Upper

IT IT

I

a

wwer

ga

HS

14

H3

N2 HI

SEM168

2

Apply

engine

oil

to

main

bearing

surfaces

on

both

sides

of

cylinder

block

and

cap

3 Install

crankshaft

EM

16

4

Install

lower

main

bearings

and

caps

and

tighten

bolts

to

specified

torque

C

l

Main

bearing

cap

bolt

4454

N

m

4

5

55

kg

m

33 40

ft

lb

a

Apply

sealant

to

each

side

of

rear

main

bearing

caP

and

each

corner

of

cylinder

block Refer

to

Pre

cautions

b

Arrange

the

parts

so

that

tha

arrow

mark

on

bearing

cap

faces

toward

the

front

of

engine

c

Prior

to

tightening

bearing

cap

bolts

placo

bearing

cap

in

proper

position

by

shifting

crankshaft

in

the

axial

direction

d

Tighten

bearing

cap

bolts

gradually

in

separating

two

to

three

stages

and

outwardly

from

center

bearing

in

sequence

@

CD

@

J

I

ill

@

L

I

V

@

eAfter

securing

bearing

cap

bolts

ascertain

that

crankshaft

turn

smoothly

p

Make

sure

that

there

exists

proper

end

play

of

crankshaft

at

center

bear

ing

Crankshaft

end

play

Limit

0 3

mm

0

012 in

4

Apply

sealanl

to

side

oil

seals

Then

install

those

into

rear

main

bear

ing

cap

n

J

I

f5

S

EM724

5

Install

rear

oil

seal

using

Tool

SEM166

a

When

installing

oil

seal

give

coating

of

engine

oil

to

sealing

lip

and

mating

shaft

to

prevent

scratches

and

folded

lip

Also

apply

coating

of

oil

to

peripherY

of

oil

seal

b

Install

oil

seal

with

its

dust

seal

lip

at

outside

6 Install

rear

end

plate

and

fly

wheel

C

l

Flywheel

fixing

bolt

137

157

N

m

14 16

kg

m

101

116

ft

lb

EM327

When

installing

flywheel

wipe oil

or

foreign

matter

away

from

fitting

surfaces

7Install

pistons

with

connecting

rod

1

Install them

into

corresponding

cylinder

using

Tool

J

EM544

a

Apply

engine

oil

to

sliding

parts

b

Arrange

so

that

the

front

mark

on

piston

head

faces

to

the

front

of

engine

c

Install

piston

ring

as

shown

below

c

Top

ring

fi

Oil

ring

J

0

upper

rail

ll

Oilring

expander

Piston

direction

fJ

secon

Oil

ring

lower

ail

EM725

2 Install

connecting

rod

bearing

caps

CfJ

Connecting

rod

bearing

ClIp

nut

44

54

N

m

14

555

kg

m

33 40

ft

lb

EM329

ENGINE

MECHANICAL

EngineAssembly

Arrange

connecting

rods

and

con

necting

rod

caps

so that

the cylinder

numbers

face

in the

same

direction

I

SEM167

3

Make

sure

that

there

exists

proper

end

play

at

connecting

rod

big

end

Refer

to

Inspection

and

Repair

8

Install

cylinder

head

assembly

through

gasket

by

accommodating

knock

of

cylinder

block

as

follows

1

Thoroughly

clean cylinder

block

and

head

surface

po

not

apply

sealant

to

mating

sur

face

of

cylinder

block

and

head

2

Turn

crankshaft

until

No

1

piston

is

at

T

D

C

on

its

compression

stroke

3

When

installing

cylinder

head

make

SUre that

all

valves

are

apart

from

head

of

pistons

If

necessary

loosen

adjusting

screws

of

rocker

ann

to

draw

valves

in

4

Temporarily

tighten

two

center

bolt

CfJ

Cylinder

head

bolt

ITemporary

20

N

m

2

kg

m

14

ft

lbl

a

Final

tightening

should

be

carried

out after

installing

chain

and

front

cover

b

Do

not

rotate

crankshaft

and

cam

shaft

separately

because

valyes

will

hit

head

of

pistons

c

Always

use

new

cylinder

head

gasket

9Install

front

side

parts

4

SEM169

1

Chain

tensioner

2

Slack

side

chain

guide

3

Temion

side

chain

guide

4

Oil

thrower

5

Oil

pump

drive

gear

6

Crankshaft

sprocket

7

Timing

chain

1

Install

crankshaft

sprocket

oil

pump

drive

gear

and

oil

thrower

a

Make

sure

that

the

mating

marks

of

crankshaft

sprocket

faces

to

the

front

b

Install

oil

pump drive

gear

so

that

large

chamfered inner

side

faces

rearward

2Install

chain

guide

to

cylinder

block

3

Set

chain

on

camshaft

sprocket

and

crankshaft

sprocket

by

aligning

each

mating

mark Then

install

cam

shaft

sprocket

to

camshaft

CfJ

Camshaft

sprocket

bolt

118

157

N

m

12 16

kg

m

87

116ft

lb

SEM170

EM 17

EngineA

mbly

ENGINE

MECHANICAL

a

Set

timing

chain

by

aligning

its

mat

ing

marks

with

those

of

crankshaft

sprocket

and

cemshaft

sprocket

on

the

right

hand

side

b

Camshaft

sProcket

should

be

in

stalled

by

accommodating

its

No

2

hole

to

knock

of

camshaft

No

2

hole

4 Install

chain

guide

and

chain

ten

sioner

fl

Chain

guide

and

tensioner

bolt

5

998

N

0

6

1

0

kg

m

4 3

7

2

ft

b

Adjust

the

protrusion

of

chain

tensioner

spindle

to

0

mm

0

in

with

slack

side

chain

guide

5Install

front

cover

with

gaskets

observing

the

following

a

Before

installing

front

cover

press

new

oil

seal

in

the

cover

with

dust

seal

lip

at

outside

b

Apply

alant

to

the

sealing

por

tions

designated

Refer

to

Precau

tions

c

Apply

lithium

grease

to

sealing

lip

of

oil

seal

d

Check

the

height

difference

be

tween

cylinder

block

upper

face

and

front

cover

upper

face

Its

dif

ference

must

be

less

than

0

15

mm

0

0059

inl

EM

18

e

Note

that

different

length

of

bolts

are

used

CiJ

Front

cover

bolt

Size

M8

10 16 N

m

1

0

1

6

kg

m

7

12

ft

bl

Size

M6

39

9

8

N

m

0 4

1

0

kg

m

2

9

7 2

ft

bl

6Install

crankshaft

pulley

fl

Crankshaft

pulley

bolt

118 157

N

m

112

16

kg

m

87

116

ft

lbl

10

Tighten

cylinder

head

bolts

to

the

specified

torque

in

several

steps

and

in

the

sequence

shown

below

SEM172

fl

Cylinder head

bolt

69

78

N

m

7

0 8 0

kg

m

51

58

ft

lb

a

Be

sure

to

tighten

bolts

securing

cylinder

head

to

front cover

b

After

engine

has

been

operated

for

several

minutes

retighten

if

neces

sary

I

Adjust

valve

clearance

to

cold

specifications

referring

to

Section

MA

Valve

clearance

Cold

Intake

0

21

mm

0

008

in

Exhaust

0

23

mm

0

009

inl

At

ambient

temperature

200C

680F

After

engine

has

been

assembled

finally

adjust

clearance

to

hot

speci

fications

12 Install

valve

rocker

cover

with

gasket

fl

Valve

rocker

cover

bolt

7 8 9 8

N

m

08

1

0

kg

m

5 8 7 2

ft

lbl

a

Rocker

cover

bolts

should

be

tightened

in

criss

cross

fathian

b

Always

use

new

rocker

cover

saskat

13

Install

oil

strainer

and

oil

pan

with

gasket

fl

Oil

strainer bolt

10

16

N

m

11

0

1

6

kg

m

7

12

ft

lbl

Oil

pan

bolt

5 9 9 8

N

m

0 6

1

0

kg

m

4

3

72 ft

lbl

a

Apply

sealant

to

the

designated

portions

Refer

to

Precautions

b

Oil

pan

should

be

tightened

in

criss

cross

pattern

c

Always

use

new

oil

pan

gasket

INSTALLING

OUTER

PARTS

14

Install

following

parts

in

the

reo

verse

order

of

disassembly

and

with

the

specified

torque

if

designated

Refer

to

Disassembling

Outer

Parts

and

S

O

S

for

tightening

torque

I

Engine

bottom

side

parts

When

installing

oil

pump

and

dis

tributor

driving

spindle

in

front

cover

refer

to

Section

LC

2

Engine

right

side

parts

a

Whe

installing

intake

manifold

to

facilitate

work

previously

set

the

securing

bolts

and

nut

with

wash

ers

at

lower

and

center

side

as

il

lustrated

Temporarily

set

olts

and

nut

SEM173

b

When

connecting

vacuum

pipes

re

fer

to

Section

EC

c

When

installing

oil

filter

refer

to

Section

LC

3

Engine

left

side

parts

a

When

installing

distributor

tern

porarilv

tighten

ignition

timing

ad

just

screws

at

center

of

adjusting

holes

b

When

installing

high

tension

cable

clamp

those

as

iIIustrat

d

4

Engine

front

side

parts

ENGINE

MECHANICAL

EngineAssembly

DISMOUNTING

ENGINE

FROM

WORK

STAND

15

Dismount

engine

in

the

reverse

order

of

mounting and

install

engine

right

side

and

rear

side

parts

remained

with

the

specified

torque

if

designated

Refer

to

Mounting

Engine

on

Work

Stand

and

S

D

s

for

tightening

tor

que

When

installing

clutch

assembly

use

Tool

KV30100100

16

Fill

engine

oil

and

coolant

to

the

specified

level

after

engine

has

been

installed

on

car

Refer

to

Section

MA

ENGINE

TUNE

UP

17

Referring

to

Section

MA

finally

adjust

following

items

1

Drive

belts

deflection

2

Valve

clearance

Warm

up

engine

until

water

tem

perature

indicator

points

to

middle

of

gauge

then

adjust

clearance

to

hot

specifications

Valve

clearance

IHotl

Intake

0

30

mm

0

012

in

Exhaust

0

30

mm

0

012

in

3

Ignition

timing

4

Idle

rpm

EM

19

Setvice

Data

and

Spec

fication

ENGINE

MECHANICAL

SERVICE

DATA

AND

SPECIFICATIONS

INSPECTION

AND

ADJUSTMENT

CYLINDER

HEAD

Cylinder

head

Head

surface

flatness

Valve

guIde

EXHAUST

INTAKE

Limit

rnm

lin

0

110

0041

Unit

mm

On

83

8

510

327

0

3551

dia

310

2

r

Snap

ring

groove

10

UtO

7

11

010

421

0

433

SEM175

intake

Exhaust

10

4

10

6

I

l

10

4

10

6

I

h

10

409

04

11

O

409

0

417

Fir

il

V

I

P

f

iJ

J

IJ

11

c

INTAKE

EXHAUST

EM116

Valve

guide

Outer

diameter

0

Valve

guide

Inner

diameter

d

Finished

size

Cyhnder

head

valve

guide

hole

diameter

8

Interference

fit

of

valve

guide

Iln

Stem

to

guide

clearance

I

Ex

Stem

end

deflection

EM

20

St8ndari

i

Service

12

023

12

03412

223

12

234

0

4733

0

47381

10

4812

0

48171

8000

8

01810

3150

0

31571

11

985

11

996

1

2

85

12

196

10

4718

0

4723

10

4797

0

4802

0

027

0

049

0

0011

0

0019

Standard

Limit

0

020

0

053

10

0008

0

OO21

0

1

0

004

0

040

0

073

0

0016

0

0029

02

10 OOSI

Valve

seat

Seal

insert

dimensions

Intake

xL

Q

I

o

Contacting

face

angle

rt

Contacting

width

W

Stendard

Standard

Outer

diameter

0

Service

Exhaust

C

mtactlng

face

angle

cr

Contacting

width

W

StaruWd

Standard

Outer

diameter

0

Service

Cylinder

head

seat

m

ess

diameter

I

For

standard

nsen

In

For

service

insert

For

standard

insert

EX

I

For

service

insert

Unit

mm

in

l

SEM177

45

1

2

1

80

047

0

0711

45

097

45

113

11

7755

1

776

45

597

45

613

11

1952

1

1958

Unit

mm in

I

SEM118

45

1

5

1

9

0

059

O

07S

40

080

40

096

11

5779

1

57861

40

597

40

613

1

5983

t

59891

Unit

mm in

45

000

45

016

11

7717

1

77231

45

500

45

516

11

1913

1

79201

40

000

40

016

11

5748

1

5754

40

500

40

516

11

5945

1

59511

Interference

fit

of

seat

insert

In

Ex

Machining

dimensions

of

seat

Intake

I

i

I

Y

90

L41

6

41

8J

11

638

1

646

dia

SEM179

VALVE

T

H

J

M

II

I

In

I

Ex

I

iln

Valve

length

L

I

Ex

I

In

I

Valve

head

diameter

H

Valve

stem

diameter

0

Valve

fBee

angle

C

Valve

head

margin

I

In

M

I

Grinding

of

valve

stem

end

Standard

Service

Standard

Service

ENGINE

MECHANICAL

Service

Dara

and

Specificstions

Unit

mm

in

0

081

0

113

10

0032

0

00441

0

064 0

096

0

0025

0

00381

0

081

0

113

0

0032

0

00441

Unit

mm

in

Exhaust

I

r

o

l

L

1

374

37

61

11

472

1

4801

dia

SEM180

Unit

mm

On

j

D

1

L

SEM181

Standard

Limit

42

0

42

2

11

654

1

66tl

38

0

38

2

1

496

1

504

122

8

123

1

4

835

4

846

123

6

123

9

14

866

4

8781

45

30

0

5

10

020

05

0

020

0

5

10

020

VALVE

SPRING

Following

data

ere common

to

both

intake

and

exhaust

Unit

mm

in

I

Standard

Free

I

Outer

49

7711

9594

height

I

Inner

44

1011

7362

mm

N

40

0

226

23

01

Assem

Outer

kg

1

575

50

7

bled

lin

lb

height

mm

N

tension

Inner

Ikg

35

0

108111

0

linllbl

1

3783

24

31

Cut

0

Outer

square

Inner

limit

40

0

189119

31

1

575

42

61

35

0

87

18 91

11

3783

19 61

2

0

0871

1

9

10

075

ROCKER

ARM

AND

ROCKER

SHA

Unit

mm in

1

I

II

Rocker

arm

to

shaft

clearance

0

007

0

049

0

0003

0

0019

Standard

Camshaft

CAMSHA

AND

CAMSHAFT

BEARING

Outer

diameter

of

cam

shaft

journal

Camihaft

bend

at

center

journal

Total

indicator

readi

n91

I

Camihaft

nd

pl

Cam

height

A

Camshaft

bearing

Inner

diameter

Cemshaft

journal

to

bearing

clearance

Oil

clearance

Standard

32

935

32

955

11

2967

1

29741

11

l

t

In 38

477

38

527

11

5148

1

51681

Ex

Standard

33

000

33

025

11

2992

1

3002

0

045

0

090

10

0018

0

0028

Unit

mm

Ii

Limit

I

O

to

0

00391

0

2

10

008

EM871

0

25

0

00981

Unit

mm

tin

Limit

0

110

004

EM

21

Service

Datasnd

Specifications

ENGINE

MECHANICAL

CYLINDER

BLOCK

Cylinder

block

A

1J

120

10

791

1111

6012

1111

I

0

i

P

Front

XV

Surface

flatness

Inner

diameter

Cylinder

bore

Out

of

round

IX

VI

Taper

A

B

Differene

in

inner

dia

meter

between

cylinders

Piston

to

cylinder

clearance

Feeler

gauge

ex

tracting

force

N

with

gauge

kg

thickness

0

04

Ib

mrn 0

0016

in

Cylinder

liner

for

s

Outside

diameter

Interference

fit

of

cylinder

liner

EM

22

Standard

85

000

85

050

13

3465

3

34841

Less

than

0

01510

00061

Less

than

0

01510

00061

Less

then

0

05

0

00201

0

025

0

045

10

0010

0

00181

2 0

14

710

2

1

5

04

3

31

40

10

1571

Undersize

4

5

0

1711

Undersize

5

010

1971

Undersize

Unit

f11m

io

EM422

limit

0

110

004

0

2

0

0081

0

2

10

0081

Wear

limit

PISTON

RING

AND

PISTON

Piston

Unit

rnm in

f

I

A

cr

a

About

20

10 791

EM714

Standard

84

985

85

035

13

3459

3

34781

Piston

diameter

A

0

50

10

01971

85

465

85

515

Oversize

13

3648

3

36671

1

00

10

03941

85

965

86

015

O

ersize

3

3844

3

38641

Side

clearance

of

piston

ring

Unit

mm

Unl

Standard

Limit

I

Top

ring

I

Second

ring

I

Oil

ring

0

040

0

073

10

0016

0

00291

0

1

0

0041

0

030

0

063

0

0012

0

00251

Ring

gap

1

Standard

I

Top

ring

0

25

0

40

10

0098

0

01571

Second

ring

0

15

0

30

10

0059

0

01181

Oil

ring

0

30

0

90

10

0118

0

03541

Unit

mm

in

Limit

1

0

10

0391

Piston

Unit

mmlin

Unit

mm in

89

00

89

05

Standard

13

5039

3

5059

I

Piston pin

outside

di

meter

20

993

20

998

0

8265

0

82671

89

50

89

55

13

5236

3

6256

Piston

hole

diameter

21

001

21

008

10

8268

0

82711

90

00

90 05

I

Piston

to

piston

13

5433

3

54531

clea

ance

0

006

0

01310

0002

0

00051

0

08

0 09

I

Interference

fit

of

piston

0

0031

0

0035

to

c

onnecting

rod

0

015

0

035

10

0006

0

oot41

ENGINE

MECHANICAL

ServiceOataandSpecifications

CONNECTING

ROD

BEARING

Unit

mm

in

Bearing

clearence

1

Unit

mm

in

Standard

Limit

I

Standard

Limit

Connecting

rod

bend

or

torsion

per

100

mrn

0

03

0

00121

0

05

10

00201

I

Main

bearing

clearance

0

020

0

062

0

1210

00471

3

94

inllength

0

0008

0

0024

I

Bid

end

plev

0

2

0

3

I

Connecting

rod

beeting

0

025

0

055

0

008

0

0121

06 0

0241

clearance

0

001

0

00221

0

12

0

00471

CRANKSHAFT

Unit

mm

lin

a

t1b

S

I

Journal

diameter

A

I

diameter

B

I

S

Out

of

round

X

V

Taper

AB

A

8

54

942

54

955

2

1631

2

16361

EM790

49

961

49

974

1

9670

1

96751

42

97

43

0311

6917

1

69411

A

o

I

Taper

of

journal

and

A

S

IOut

of

round

of

Journal

and

X Y

I

Crankshaft

bend

Total

indicator

reeding

I

Crenksheft

free end

plav

I

Pilot

bushing

inserting

distance

Standard

Less

than

O

Of

0

00041

less

than

0

01

0

00041

Less

than

0

05

0

00201

0

05

O

lB

10

0020

0

00711

8

EM715

Limit

0

03

0

00121

J

I

0

03

10

00121

I

0

10

0

00391

I

0

3

10

0121

40 0

1571

Main

bearing

undersize

Unit

mm in

T

EM738

Bearing

top

Crank

jou

rnal

thickness

T

diameter

I

STD

1

822

1

835

54

942

54

955

10

0717

0

0722

12

1631

2

1636

I

0

25

10

00981

Undersize

1

947

1

960

54

692

54

705

0

0767

0

07721

2

1532

2

15371

I

0

50

0

01971

Undersize

I

2

072

2

085

54

442

54

455

0

0816

0

08211

2

1434

2

14391

I

0

75

0

02951

Undersize

I

2 197 2

210

54

192

54

205

0

0865

0

08701

12

1335

2

13411

1

00

0

0394

Undersize

I

2

322 2

335

53

942

53

955

0

0914

0

09191

2

1237

2

12421

Connecting

rod

bearing

undersize

Unit

rnm

Onl

I

Bearing

top

Crankpin

thickness

T

ciiameter

I

STD

1

493

1

506

49

961

49

974

0

0588

0

05931

0

9670

1

9675

I

0

25

0

00981

Undersize

1

618

1

631

49

711

49

724

10

0637

0

06421

1

9571

1

95761

I

0

50

0

01971

Undersize

1

743

1

756

49

461 49

474

0

0686

0

06911

t

9473

1

94791

I

0

7510

02951

UDdersize

1

868

1

881

49

211

49

224

0

0735

0

07411

1

9374

1

93791

EM

23

Service

DatallndSpecifications

ENGINE

MECHANICAL

Camshaft

sprocket

MISCELLANEOUSCOMPONENH

I

Runaut

Total

indf

mm

in

cator

readingl

Flywheel

I

Runout

frotsl

iodi

mm

in

cator

reading

ENGINE

TUNE

UP

Valve

clearance

1

I

Intake

I

Exhaust

0

3010

012

0

30

10

012

Limit

Q1

0

004

Limit

0

15

10

0059

Hot

Unit

mm in

Cald

0

21

0

008

0

23

0

009

At

ambient

temperature

200C

168

F

Whenever

valve

clearances

are

adjusted

to

cold

specific

tions

check

thd

the

clearances

satisfy

hot

specifications

and

edjust

again

if

necessary

Engine

front

side

TIGHTENING

TORQUE

Unit

Front

cover

bolt

M8

M6

I

Chain

guide

bolt

I

Chain

tensionetr

bolt

Water

pump

bolt

M6

M8

Crankshaft

pulley

bolt

Engine

right

side

I

Water

inlet

bolt

I

Water

outlet

bolt

I

Intake

manifold

bolt

and

nut

I

Alternator

bracket

bolt

I

Alternator

to

adjusting

bar

bolt

I

Engine

mounting

bracket

bo1t

Same

fot

left

side

EM

24

N

m

10 16

3

9

8

5

9 98

5

9

8

3 9

98

10

16

118 157

10

16

10 16

16 21

39

59

20 29

29 39

kg

m

1

0

1

6

04

1

0

6

1

0

6

1

0

04

1

0

1

01

6

12

16

1

0

1

6

1

0

1

6

1

6

2

1

4

0

6

0

20

3

0

3 0

4

0

ft

lb

7

12

2

9

7 2

4

3

7

2

4

3 7

2

9

7 2

7

12

87

116

7

12

7

12

12 15

29 43

14

22

29

Engine

left

side

Unit

I

Distributor

support

bolt

I

Exhaust

manifold

bolt

and

nut

I

E

GR tube

nut

I

E

A

I

tube

nut

I

Air

conditioner

cern

pressor

bracket

bolt

N

m

3 9 7

8

16 21

34 44

44 54

Engine

top

side

I

Cylinder

head

bolt

69 78

I

Cylinder

head

to

front

COYer

bolt

3 9 7 8

I

Rocker

shaft

bracket

bott

15

25

I

Camshaftsprocket

bolt

118 157

I

Rocker

cover

bolt

7

89

8

I

Spark

plug

15

20

I

Rocker

arm

nut

16

22

Engine

bottom side

I

M

in

bearing

cap

bolt

I

Connecting

rod

big

end

nut

t

Oil

strainer

bolt

Oil

pan

bolt

Oil

pan

drain

plug

Oil

pump

bolt

Gusset

to

cylinder

block

bolt

Engine

rear

side

I

Flywheel

bolt

M

TI

I

Drive

plate

bolt

Arr

1

Clutch

cover

bolt

M

T

Torque

converter

bolt

AfT

Starter

motor

bolt

Transmission

to

cylinder

block

bolt

IT

ransmission

to

gU

et

bolt

44 54

4454

10 16

59 9 8

20 29

11

15

43 58

kQ

m

04 0

8

1

6 2

1

3

5

4

5

3 5

4

5

4

5

7

0

8

0

04

08

1

5 2

5

12

16

0

8

1

0

1

5 2

0

1

6 2 2

45

5 5

45

5

1

0

1

6

06

1

0

20

3

0

11

15

44

5

9

ft

lb

2 9

5

8

12 15

25

33

25 33

33

40

51

58

29

5

8

11

18

87

116

5

8

7 2

11

14

12 16

33

40

33

40

7

12

4

3 7

2

14

22

8

11

32 43

137 157

14

0

t6

0

101

116

137 157

14

0

16

0

101

116

16 21

1

6

21

12

15

39

49

40

5

0

29 36

29

39

3

0

4

0

22 29

43

58

44

5

9

32 43

43 58

445

9 32

43

ENGINE

MECHANICAL

Trouble

Diagnoses

and

Corrections

TROUBLE

DIAGNOSES

AND

CORRECTIONS

Condition

I

Noisy

engine

Piston

and

connecting

rod

knocking

Knocking

of

crank

shaft

and

hearing

Timing

chain

noise

Camshaft

and

valve

mechanism

knocking

Camshaft

knocking

Water

pump

knocking

Probable

cause

Seized piston

in

cylinder

Broken

piston

ring

Improper

connecting

rod alignment

Seized

or

loose

connecting

rod

bearing

Seized

or

loose

main

bearing

Bent

crankshaft

Uneven

wear

of

journal

Excessive

crankshaft

end

play

Improper

chain

tension

Worn

and

or

damaged

chain

Worn

sprocket

Worn

and

or

broken

chain

guide

and

or

tension

adjusting

mechanism

Improper

valve

clearance

Worn

rocker

bearing

Worn

rocker

face

Loose

valve

stem

in

guide

Weakened

valve

spring

Seized

valve

Excessive

camshaft

bearing

clea

rance

Excessive

axial

play

Wom

earn

gear

Improper

shaft

end

play

Broken

impeller

Stuck

valve

II

Other

mechanical

troubles

Improper

valve

clearance

Insufficient

clearance

between

valve

stem

and

guide

Weakened

or

broken

valve

spring

Seized

or

damaged

valve

stem

Poor

quality

fuel

Corrective

action

Replace

piston

with

Recondition

cylinder

and

replace

piston

with

Replace

ring

and

or

recondition

cylinder

Realign

rod

or

replace

rod

Replace

Repair

or

replace

Correct

Replace

center

bearing

Adjust

Replace

Adjust

Replace

guide

Replace

thrust

plate

Replace

water

pump

assembly

Replace

water

pump

assembly

Adjust

Clean

stem

or

ream

guide

Replace

or

clean

Use

good

fuel

EM

25

TroubleDiagnosessndCorrections

ENGINE

MECHANICAL

Condition

Seized

valve

seat

Excessively

worn

cylinder

and

piston

Faulty

connecting

rod

Faulty

crankshaft

bearing

EM

26

Probable

cause

Improper

valve

clearance

Weakened

valve

spring

Thin

valve

head

edge

Narrow

valve

seat

Overheating

Over

speeding

Stuck

valve

guide

Shortage

of

engine

oil

Dirty

engine

oil

Poor

quality

of

oil

Overheating

Wrong

assembly

of

piston

with

connecting

rod

Improper

piston

ring

clearance

Broken

piston

ring

Dirty

air

cleaner

Mixture

too

rich

Engine

over

run

Stuck

choke

valve

Overchoking

Shortage

of

engine

oil

low

oil

pressure

Poor

quality

engine

oil

Rough

surface

of

crankshaft

Clogged

oil

passage

Bearing

worn or

eccentric

Bearing

improperly

assembled

loose

bearing

Incorrect

connecting

rod

alignment

Shortage

of

engine

oil

low

oil

pressure

Poor

quality

engine

oil

Crankshaft

journal

worn

or

out

of

round

Clogged

oil

pasSage

in

crankshaft

Bearing

wornor

eccentric

Bearing

improperly

assembled

Eccentri

crankshaft

or

bearing

Corrective

action

Adjust

Replace

valve

Reface

Repair

or

replace

Drive

at

proper

speed

Repair

Add

or

replace

oil

Clean

crankcase

replace

oil

and

oil

filter

element

Use

proper

oil

Repair

or

replace

Repair

or

replace

Adjust

Replace

Clean

Adjust

Drive

at

proper

speeds

Clean

and

adjust

Start

correct way

Add

oil

Correct

Use

proper

oil

Grind

and

replace

bearing

Clean

Replace

Correct

Replace

Repair

or

replace

Add

or

replace

Correct

Use

specified

oil

Repair

Clean

Replace

Correct

Replace

Tool

number

Kent

Moore

No

KV30

100

KVlO105001

ST050lS000

126023

CD

ST050l1000

126023

2

CVST05012000

126023

1

ENGINE

MECHANICAL

Special

Service

Tools

SPECIAL

SERVICE

TOOLS

Tool

name

Clutch

aligning

bar

Engine

attachment

Engine

stand

assembly

Engine

stand

Base

Special

Service

Tools

ENGINE

MECHANICAL

Tool

number

Kent

Moore

No

KVIOlO39SO

125618

D

STlI08l000

125618

3

@

STlI032000

125618

2

@

STl1320000

125618

1

STl165000

I

STl6610001

123907

KVlOI05500

125640

01

EM03470000

EM

28

Tool

name

Valve

guide

reamer

set

Reamer

12

2

mm

0

480

in

dia

Reamer

8

0

mm

0

315

in

dia

Drift

Valve

seat

cutter

set

Pilot

bushing

puller

Crankshaft

rear

oil

seal

drift

Piston

ring

compressor

D

@

M

DATSUN

200SX

Model

S

J J

0

Series

SECTION

L

C

ENGINE

LUBRICATION

COOLING

SYSTEMS

CONTENTS

ENGINE

LUBRICATION

SYSTEM

LUBRICATION

CIRCUIT

01 L

PUMP

OIL

PRESSURE

REGULATOR

VALVE

OIL

FILTER

OIL

PRESSURE

RELIEF

VALVE

COOLING

SYSTEM

COOLING

CIRCUIT

RADIATOR

THERMOSTAT

WATER

PUMP

LC

2

LC

2

LC

3

LC

4

LC

4

LC

4

LC

5

LC

5

LC

6

LC

6

LC

7

TEM

COUPLlNG

SERVICE

DATA

AND

SPECIFICATIONS

GENERAL

SPECIFICATIONS

INSPECTION

AND

ADJUSTMENT

TIGHTENING

TORQUE

TROUBLE

DIAGNOSES

AND

CORRECTIONS

LUBRICATION

SYSTEM

COOLING

SYSTEM

SPECIAL

SERVICE

TOOL

LC

7

LC

8

LC

8

LC

8

LC

8

LC

9

LC

9

LC

9

LC

10

Engine

LubriCstion

System

ENGINE

LUBRICATION

COOLING

SYSTEMS

ENGINE

LUBRICATION

SYSTEM

LUBRICATION

CIRCUIT

SLC021

j

Oil

pan

I

Oil

gallery

in

cylinder

block Oil

strainer

I

By pass

passage

I

Regulator

valve

I

Oil

pump

Intermittently

j

Pump

drive

gear

r

oiling

portion

Oil

passage

Oil

filter

I

Relief

valve

I

l

Main

aring

f

I

Con

ecting

rod

II

Oil

J

et

II

Chain

tensioner

I

bearing

I

Connecting

rod

II

Timing

chain

I

l

Piston

pis

I

ton

and

cylinder

I

A

Rocker

arm

t

j

I

Camshaft

bearing

I

Cam

surface

LC

2

I

Cylinder

head

I

oil

gallery

I

Center

earn

bracket

I

Rocker

shaft

Cam

bracket

t

I

Timing

chain

I

and

front

cover

S

LC022

ENGINE

LUBRICATION

COOLING

SYSTEMS

Engine

Lubrication

System

OIL

PUMP

REMOVAL

1

Remove distributor

cap

2

Turn

crankshaft

so

that

No

1

piston

is

at

T

D

C

on

its

compression

stroke

by

ascertaining

the

position

of

distributor

head

rotor

and

timing

mark

on

crank

pulley

Remember

position

of

he

rotor

under

above

condition

California

models

Front

SLC074

Non

Califomia

models

Front

3

Remove

oHpump

body

with

drive

spindle

assembly

INSTALLATION

I

Make

sure

that

distributor

head

rotor

is

in

the

same

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

41

Punch

mark

Oil

hole

E

L009

3

Using

a

new

gasket

install

oil

pump

and

drive

spindle

assembly

4

Make

sure

that the

tip

of

the

drive

spindle

fits

distributor

fitting

hole

securely

5

Tighten

bolts

securing

oil

pump

to

front

cover

lfJ

Oil

pump

mounting

bolts

11

15

N

m

111

1

5

kg

m

8 11

ft

lb

6Install

distributor

cap

DISASSEMBLY

AND

ASSEMBLY

@

1

@1

EL032

I

1

Oil

pump

body

2

Outer

rotor

3

Inner

rotor

and

shaft

4

Gasket

5

Oil

pump

cover

6

Regulator

valve

7

Regulator

spring

8

Regulator

cap

lfJ

Oil

pump

cover

bolt

6 9 9 8

N

m

0 7

1

0

kg

m

5

1

7 2

ft

lb

a

Always

replace

with

a

new

gasket

b

Outer

rotor

should

be

assembled

so

th

at

the

chamfered

side

faces

to

oil

pump

body

J

ii9

SLC025

INSPECTION

1

Inspect

the

following

for

wear

or

damage

Pump

body

and

cover

Pump

rotors

and

rotor

shaft

2

Using

a

feeler

gauge

check

the

follo

Ying

Clearances

Wear

limit

Rotor

tip

clearance

CD

0

20

mm

0

0079

in

Outer

rotor

to

body

clearance

V

0

50

mm

0

020 in

o

LC026

3

Using

a

feeler

gauge

and

a

straight

edge

check

the

following

gap

@

or

@

without

gasket

LC

3

EngineLubricationSystem

ENGINE

LUBRICATION COOLING

SYS1

EMS

Rotor

to

straight

edge @

Less

than

0

06

mm

0

0024

in

Oi

pump

body

to

straight

edge

@

Less

than

0

03

mm

0

0012

in

Then

rotor

side

clearance

rotor

to

bottoni

cover

clearance

with

gasket

should

satisfy

the

following

specifica

tion

Wear

limit

Rotor

side

clearance

0 20

mm

0

0079

in

S

LC027

Pump

rotors

and

body

are

not

serviced

separately

If

pump

rotors

or

body

are

damaged

or

worn

replace

pump

rotor set

or

entire

oil

pump

as

sembly

LC4

OIL

PRESSURE

REGULATOR

VALVE

INSPECTION

Check

valve

sliding

surface

and

valve

spring

and

replace

entire

valve

assembly

if

necessary

E

L076

N

OIL

FILTER

REMOVAL

AND

INSTALLATION

When

removing

oil

f1lter

use

Tool

When

installing

it

lightly

coat

oil

on

oil

seal

and

fasten

it

by

hand

Do

not

overtighten

filter

or

oil

leakage

may

occur

S

lC028

OIL

PRESSURE

RELIEF

VALVE

INSPECTION

With oil

f1lter

rellloved

check

valve

unit

for

operation

Inspect

for

a

cracked

or

broken

valve

If

replace

Il

ent

is

necessary

remove

valve

by

prying

it

out

with

a

screwdriver

InstaII

a

new

valve

in

place

by

tapping

it

a

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

L

Water

pump

A

WARNING

To avoid

serious

peRonal

injury

never

remove

I

Idiator

cap

quickly

when

engine

is

hot

Sudden

release

of

cooling

system

pressure

is

very

dal1llerous

If

it

is

necessary

to

remove

Iadiator

cap

when

Iadiator

is

hot

turn

cap

slowly

counterclockwise

to

the

fillt

stop

After

all

pressure

in

the

coo

ing

system

is released

turn

cap

passing

the

stop

and

remove

it

Radiator

cap

F

Reservoir

tank

t

Radiator

Thermostat

Cylinder

block

H

Heater

I

J

Thermostat

housing

t

f

Cylinder

head

l

Intake

manifold

SLC031

LC

5

Cooling

System

ENGINE

LUBRICATION

COOLING

SYSTEMS

RADIATOR

REMOVAL

AND

INSTALLATION

I

Drain coolant

into

a

clean

con

tainer

2

Remove

air

cleaner

inlet

pipe

3

Remove

air

duct

with

bracket

after

loosening

clamps

and

screws

at

portion

illustrated

4

Disconnect

radiator

upper

and

lower

hoses

and

reservoir

tank

hose

5

Remove

radiator

shroud

attach

ing

screws

and

place

radiator

shroud

close

to

engine

Radiator

shroud

can

be

removed

after

removing

radiator

6

On

a

car

with

automatic

transmis

sian

disconnect

cooler

inlet

and

outlet

lines

from

radiator

7

Remove

radiator

8 Install

radiator

in

the

reverse

se

quence

of

removal

and

refill

cooling

system

with

coolant

to

specified

level

Refer

to

Section

MA

INSPECTION

Inspect

radiator

cap

and

water

leakage

using

cap

tester

LC

6

Inspection

of

radiator

cap

First

check

rubber

seal

on

cap

for

tears

cracks

or

deterioration

after

cleaning

it

Then

install

radiator

cap

on

a

tester

If

cap

does

not

hold

or

will

not

release

at

the

specified

pres

sure

replace

cap

Cap

relief

pressure

88

kPa

0 9

kg

cm2

13

psi

ET012

2

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

pressure

157

kPa

1

6

kg

cm2

23psil

I

y

SLC037

THERMOSTAT

REMOVAL

AND

INSTALLATION

1

When

removing

drain

coolant

partially

and

disconnect

upper

radiator

hose

at

water

outlet

2

Install

thennostat

and

water out

let

as

illustrated

1

Jiggle

valve

2

Thermostat

SLC033

3

Gasket

4

Water

outlet

INSPECTION

Inspect

thennostat

for

the

follow

ing

and

replace

if

necesS3l

I

Valve

seating

condition

at

ordi

nary

temperature

It

should

seat

tightly

2

Valve

opening

temperature

and

maximum

valve

lift

Refer

to

SDS

VJj

i

SLC034

3 Then

check

if

valve

closes

at

SOC

90F

below

valve

opening

tempera

ture

It

is

necessary

to

check

a

new

ther

mostat

before

installing

it

in

engine

WATER

PUMP

DISASSEMBLY

Water

pump

is

made

of

aluminum

and

its

bearing

outer

race

is

of

a

press

fit

type

For

this

reason

water

pump

should

not

be

disassembled

INSPECTION

Inspect

pump

assembly

for the

following

conditions

and

replace

if

necessary

I

Badly

rusted

or

corroded

body

assembly

and

vane

2

Excessive

end

play

or

roughness

of

bearings

in

operation

If

excessive

mechanical

seal squeak

occurs

when

engine

is

running

use

suitable

water

pump

seal

lubricant

to

prevent

squeak

TEM

COUPLlNG

DISASSEMBLY

The

coupling

is

so

designed

that

it

cannot

be

disassembled

INSPECTION

Inspect

the

coupling

for

oil

leakage

or

bend

of

bimetal

If

necessary

reo

place

as

a

pump

assemhly

ENGINE

LUBRICATION

COOLING

SYSTEMS

Cooling

System

cf

N

m

kg

ln ft

Ib

Belt

dcllcction

mm

in

fN

kg

Ib

@

M6

3 9

9

810

4

1

0

2 9 7

21

M8

10

16

1

0

1

6

7

121

a

1210

31

0

47

98 10

22

Pump

gasket

Always

replace

Water

pump

with

fan

coupling

Fan

belt

SLC035

t

C0077

1

Bi

metal

thermostat

2

Slide

valve

3

ReseIVe

chamber

for

QFF

4

Bearing

5

Driving

chamber

for

ON

6

Coupling

part

Labyrinth

Le

r

ServiceDataandSpecifications

ENGINE

LUBRICATION

COOLING

SYSTEMS

SERVICE

DATA

AND

SPECIFICATIONS

GENERAL

SPECIFICATIONS

I

Oil

pump

I

Oil

filter

Oil

pressure

relief

valve

Valve

opening

pressure

kPa

kg

cm2

psH

I

Redietor

I

Thermostat

I

Water

pump

Tem

coupling

Fen

speed

at

water

pump

speed

4

000 rpm

rp

oC

OF

Trochoid

type

Full

flow

and

cartridge

type

59

8

13

6

0

60

0

75

8

5

10

7

Down

flow

corrugated

fin

and

tube type

Wax

type

Centrifugal

type

2 150

60

1401

Less

than

1

650lbelow

50

122

INSPECTION

AND

ADJUSTMENT

OIL

PUMP

1

Rotor

tip

clearance

Outer

rotor

to

body

clearance

I

Rotor

side

clearance

rotor

to

bottom

cover

Unit

mm

in

Standard

Wear

limit

Less

then

0

12

0

00471

0

20

10

0079

0

15

0

21

I

0 0

0

10

0059

0

llO831

5

197

0

04

0

08

I

0

1

0

0016

0

00311

20

0

0079

OIL

PRESSURE

REGULATOR VALVE

Free

length

mm

jn

Re

ulator

valve

spring

Installed

lengthl

loed

mm in

N

Ikg

lbl

Regulator

valve

opening

pressure

kPa

kg

cm2

psi

rpm

LC

8

52

5 2

0671

34

8 1

3701

77

5

85

3

7

9

8

7

174

19

21

343

412

13

5

4

2

50

601

3000

RADIATOR

CaP

relief

pressure

kPa

kg

cm2

psi

88

09

13

157

11

6

231

Leakage

test

pressure

kPa

Ikg

cm2

psi

THERMOSTAT

1

Standard

Frigid

type

Tropical

type

I

Valve

opening

tom

82

1801

8811901

76

170

perature

oC

OF

I

Max

valve

lift

8

95

8

100

8

90

mm

oC Un oF

I 10

31

203

10

31

212

O

3t

194

WATER

PUMP

I

Fan belt

deflection

mm

lin N

Ikg

Ibl

I

8

12

10

31

0

471

98

10

221

TIGHTENING

TORQUE

Unit

N

m

kg

m

ft

lb

Oil

pump

mounting

bolu

11

15

11

15

8

11

I

Oil

pump

cover

bolts

69

98

07

1

0

5

1

7 2

Regulator

valve

cap

39 49

4 5

29 36

Water

pump

securing

bolt

M6

3 9

98

0 4

1

0

2 9 7 2

Me

10

16

1

0

1

6

7

12

ENGINE

LUBRICATION

COOLING

SYSTEMS

Trouble

Diagnoses

and

Corrections

TROUBLE DIAGNOSES

AND

CORRECTIONS

LUBRICATION

SYSTEM

Condition

Probable

cause

Oil

leakage

Damaged

or

cracked

pump

body

cover

Oil

leakage

from

gasket

and

oil

seal

Oil

leakage

from

regulator valve

Oil

leakage

from

blind

plug

Decreased

oil

pressure

Lack

of

oil

in

engine

oil

pan

Dirty

oil

strainer

Damaged

or

worn

pump

rotors

Malfunctioning

regulator

Use

of

poor

quality

engine

oil

Warning

light

remains

on

engine

running

Decreased

oil

pressure

Oil

pressure

switch

unserviceable

Electrical

fault

Noise

Excessive

backlash

in

pump

rotors

COOLING

SYSTEM

Condition

Probable

cause

Water

leakage

Damaged

radiator

seams

Leaks

from

heater

connections

or

plugs

Leak

from

water

pump

shaft

seal

Leak

from

water

temperature

gauge

Leaks

from

gaskets

or

small

cracks

Loose

joints

Damaged

cylinder

head

gasket

Water

leakage

Cracked

cylinder

block

Cracked

cylinder

head

Loose

cylinder

head

bolts

Corrective

action

Replace

Tighten

or

replace

Replace

G

orrect

Clean

or

replace

Replace

Previously

mentioned

Replace

Check

circuit

Replace

Corrective

action

Repair

Replace

as

pump

assembly

Tighten

or

use

Nissan

Cooling

System

Sealer

or

equivalent

Tighten

Replace

Check

engine

oil

for

contamination

and

refill

as

necessary

Replace

Check

engine

oil

in

crankcase

fonnixing

with

water

by

pulling

oil

level

gauge

Replace

Tighten

LC

9

Special

Service

Tool

ENGINE

LUBRICATION

COOLING

SYSTEMS

Condition

Poor

circulation

Corrosion

Overheating

Overcooling

Noise

Tool

number

Kent

Moore

No

STl9320oo0

125664

LC

l0

Probable

cause

Restriction

in

system

Insufficient

coolant

Inoperative

water

pump

Loose

fan

belt

Inoperative

thennostat

Excessive

impurity

in

water

Infrequent

flushing

and

draining

of

system

Malfunctioning

thennostat

radiator

cap and

fan

coupling

Radiator

fm

choked

with

mud

chaff

etc

Incorrect

ignition

and valve

timing

Dirty

oil

and

sludge

in

engine

Inoperative

water

pump

Loose

fan

belt

Restricted

radiator

Inaccurate

temperature

gauge

Impurity

in

water

Malfunctioning

thennostat

Inaccurate

temperature

gauge

Squeak

at

water

pump

mechanical

seal

Damaged

or worn

water

pump

bearing

C

arrective

action

Check

hoses

for

crimps

and

clear

the

system

of

rust

and

sludge

by

flushing

radiator

Replenish

Replace

Adjust

Replace

Use

soft

clean

water rain water

is

satis

factory

Cooling

system

should

be

drained

and

flush

ed

thoroughly

at

least

twice

a

year

Perma

nent

antifreeze

Ethylene

glycol

base

can

be

used

throughout

the

seasons

of

a

year

Replace

Clean

out

air

passage

thoroughly

by

using

air

pressure

from

engine

side

of

radiator

Adjust

Refill

Replace

Adjust

Flush

radiator

Replace

Use

soft

clean

water

Replace

Use

suitable

water

pump

seal

lubricant

or

replace

as

pump

assembly

Replace

as

pump

aSsembly

SPECIAL

SERVICE

TOOL

Tool

name

Oil

filter

wrench

00

DATSUN

200SX

Model

S

J J

0

Series

SECTIONEF

ENGINE

FUEL

CONTENTS

DESCRIPTION

EFI

SYSTEM

FEATURES

EFI

SYSTEM

OPERATION

FUEL

FLOW

SYSTEM

AIR

FLOW

SYSTEM

ELECTRICAL

FLOW

SYSTEM

FUEL

INJEC

TION

CONTROL

FUEL

INJECTION

TIMING

FUEL

INJECTION

QUANTITY

EFI SYSTEM

COMPONENT

PARTS

CONSTRUCTION

AND

FUNCTION

FUEL

FLOW

SYSTEM

AIR

FLOW

SYSTEM

ELECTRICAL

SIGNAL

SYSTEM

PRECAUTIONS

FOR

AN

EFI

ENGINE

REMOVAL

AND

INSTALLATION

INJECTOR

AND

FUEL

PIPE

PRESSURE

REGULATOR

AIR

REGULATOR

WATER

TEMPERATURE

SENSOR

THROTTLE

VALVE

SWITCH

THROTTLE

CHAMBER

DASH

POT

VACUUM

SWITCH

ALTITUDE

SENSOR

DROPPING

RESISTOR

CONTROL

UNIT

RELAY

AIR

CLEANER

AIR

FLOW

METER

AIR

TEMPERATURE

SENSOR

FUEL FILTER

FUEL

PUMP

AND

FUEL

DAMPER

FUEL

HOSE

ELECTRICAL

SYSTEM

INSPECTION

EF

2

EF

4

EF

4

EF

4

EF

4

EF

5

EF

5

EF

7

EF

7

EF

7

EF

11

EF

11

EF

13

EF

15

EF

18

EF

19

EF

19

EF

20

EF

20

EF

20

EF

20

EF

20

EF

21

EF

21

EF

21

EF

21

EF

21

EF

22

EF

22

EF

22

EF

22

EF

22

EF

23

F

2

3

EF

24

DESCRIPTION

PREPARATIONS

FOR

INSPECTION

PROCEDURE

TABLE

EFI

CIRCUIT

DIAGRAM

COMPONENT

PARTS

INSPECTION

FUEL

PRESSURE

CHECK

FUE L

PUMP

FUEL

DAMPER

FUEL

FILTER

INJECTOR

PRESSURE

REGULATOR

AIR

FLOW

METER

AIR

TEMPERATURE

SENSOR

AIR

REGULATOR

THROTTLE

CHAMBER

DASH

POT

WATER

TEMPERATURE

SENSOR

THROTTLE

VALVE

SWITCH

VACUUM

SWITCH

ALTITUDE

SENSOR

DROPPING

RESISTOR

RELAY

CONTROL

UNIT

CHECKING

AIR

LEAKAGE

IN

AIR

INTAKE

SYSTEM

CHECKING

FUEL

HOSES

SERVICE

DATA

AND

SPECIFICATIONS

GENERAL

SPECIFICATIONS

INSPECTION

AND

ADJUSTMENT

TIGHTENING

TORQUE

TROUBLE

DIAGNOSES

AND

CORRECTIONS

TROUBLE

SHOOTING

CHART

CHECKING

AND

ADJUSTING

IDLE

RPM

IGNITION

TIMING

AND MIXTURE

RATIO

EF

24

EF

24

EF

24

EF

25

EF

28

EF

29

EF

29

EF

29

EF

29

EF

29

EF

29

EF

30

EF

30

EF

30

EF

31

EF

31

EF

31

EF

32

EF

32

EF

33

EF

33

EF

33

EF

34

EF

34

EF

35

EF

35

EF

36

EF

36

EF

36

EF 36

EF

37

EF

37

EF

43

Description

ENGINE

FUEL

DESCRIPTION

SYSTEM

DIAGRAM

fUEL

UNE

VACUUM

LINE

INPUT

SIGNAL

OUTPUT

SIGNAL

r

t

essure

regulatm

h

f

Fueltank

i

I

ili

J

Fuelmter

Fuel

pump

L

cu

witch

California

modelA

Switching

module

Idle

speed

adjus

ing

screw

i

Ji

t

0

r

Air

pipe

EA

tube

Oil

pressure

switch

1

lliru

California

models

I

a

I

C

J

I

8j

8

I

ON

1ST

U

0

Ih

Fuel

pump

relay

Ignition

coil

Ignition

switch

q

EF

2

Air

inducti

ln

valve

Air

cleaner

Ai

r

nwmei

dlJ

fj

1r

L

bI

Air

temperature

y

pall

semOl

ew

II

c

I

J

s

lt1

Control

unit

SEF081

Watet

tem

Perature

sensot

Vacuum

wltch

I

A

ltCl

iforni

l

models

f

A

11

i

0

i

0II

i

yuel

pump

fue

d

aIn

pex

Altitude

5en

oor

California

model

C

i

T

C

I

S

i

contro

unit

Dropping

tes1

tot

MI

ternpetaW

re

n

or

EFI

System

Openltion

ENGINE

FUEL

EFI

SYSTEM

operating

conditions

into

electronic

signals

These

signals

are

sent

to

the

control

unit

where

the

optimum

in

jector

open

valve

time

period

is

com

puted

according

to

the

infonnation

stored

in

the

memorY

for

control

of

fuel

injection quantity

The

Electronic

Fuel

Injection

EFI

system

is

used

to

control

fuel

supply

electrically

in

place

of

the

conven

tional

carburetor

system

The

EFl

system

employs

various

types

of

sensors

to

convert

the

engine

Various

sensors

I

For

detecting

engine

operation

1

Electrical

signal

Control

unit

I

For

calculating

optimum

fuel

injecti

on

Electrical

signal

Injector

I

For

injecting

fuel

EFISYSTEM

OPERATION

FUEL

FLOW

SYSTEM

Fuel

is

sucked

from

the

fuel

tank

into

the

fuel

pump

from

which

it

is

discharged

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

injector

Surplus

fuel

is

led

through

the

pres

sure

regulator

and

is

returned

to

the

fuel

tank

The

pressure

regulator

con

trois

the

injection

pressure

in

such

a

manner

that

the

pressure

difference

between

the

fuel

pressure

and

the

in

take

manifold

vacuum

is

always

250

kPa

2

55

kg

cm

36

3

psi

J

D

EF

4

FEATURES

The

EFl

system

utilizes

electronic

elements such

as

integrated

circuits

ICs

resistors

thennistors

etc for

electrically

controlling

the

amount

of

fuel

injected

corresponding

to

changes

in

engine

operations

Because

of

this

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

un

J

r

n

L

SEFQ83

AI

R

FLOW

SYSTEM

Intake

air

from

the

air

cleaner

is

metered

at

the

air

flow

meter

flows

through

the

throttle

chamber

and

in

to

the

intake

manifold

and

then

flows

through

each

intake

manifold

branch

into

the

cylinder

Air

flow

during

driving

is

controlled

by

the

throttle

valve

located

in

the

throttle

chamber

During

idling

operation

the

throttle

valve

is

in

the

almost

closed

position

and

the

air

is

led

through

the

by

pass

line

between

air

pipe

and

throttle

chamber

In

this

case

the

quantity

of

suction

air

is

adjusted

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

ELECTRICAL

FLOW

SYSTEM

The

suction

air

flow

varies

with

the

movement

of

the

air

flow

meter

and

the

quantity

of

fuel

to

be injected

should

be

controlled

correctly

in

cor

Injector

11

R

A

respondence

with

the

present

air

flow

In

the

EFI

system

the

injection

pressure

is

held

constant

at

250

kPa

2

55 kg cm2 36

3

psi

and

the

area

of

the

injector

noule

hole

is

also

con

stant

Therefore

the

fuel

injection

quantity

can

be

determined

by

the

l

11

I

ENGINE

FUEL

EFISystemOperation

Idle

speed

adjusting

Air

cleaner

screw

0

AirflOwm

ter

f

LA

S

unit

i

I

Throttle

chamber

L

Air

pipe

LAir

by

pass

screw

SEF084

injector

open

valve

time

period

The

control

unit

of

the

EFI

system

deter

mines

this

pulse

width

duration

ac

cording

to

information

electrical

sig

nals

from

various

types

of

sensors

thereby

controlling

the

fuel

injection

quantity

L

Vacuum

switch

California

models

Switching

module

Air

flOW

o

Air

by

pass

screw

I

Air

temperature

sensor

f

s

Control

unit

SEF085

EF

5

EFI

SystemOperation

ENGINE

FUEL

SIGNALS

FOR

CONTROl

UNIT

An

electrical

signal

from

each

sen

sor

is

introduced

into

the

control

unit

I

Opening

of

L

throttle

valve

I

Engme

rpm

H

Quantity

of

in

take

air

H

TIlROITLE

VLA

VE

SWITCH

IGNmON

COIL

NEGATIVE

TERMINAL

AIR

FLOW

METER

INDEPENDENT

SIGNALS

OF

CONTRDL

UNIT

Fuel

pump

operation

IGNrIlON

SWITCH

START

IGNITION

SWITCH

IG

ENGINE REVOLUTION

I

ALTERNATOR

II

l

TERMINAL

FUEL

pU

lp

ULA

Y

FUEL

PlJlIP

RELAY

fUEL

PUMP

EF

6

I

OIL

rRf5SURE

I

SWITCH

r

I

EF37

1

for

computation The

open

vaIve

tiJUe

period

of

the

injector

is

controlled

by

I

Temperature

of

cooling

water

I

WATER

TEMPERA11JRE

I

SENSOR

INJECTOR

When

starting

the

engine

the

fuel

pump

is

operated

by

the

current

supplied

through

fuel

pump

relays

2

and

1

After

the

engine

starts

the

fuel

pump

continues

to

operate

using

current

supplied

from

fuel

pump

relay

2

monitoring

the

en

gine

revolution

and

fuel

pump

reo

lay

1

If

the

engine

stalls

for

some reason

fuel

pump

relay

2

receives

the

en

gine

stall

signal

and

stops

feeding

current

thereby

stopping

the

opera

tion

of

the

fuel

pump

the

duration

of

the

pulse computed

in

the control

unit

AIR

TEMPERATURE

H

TempctalUIel

SENSOR

of

mtake

air

IGNITION

SWITCHH

START

position

Starting

operation

VACUUM

SWITCH

HI

take

manifOldl

vacuum

California

models

ALTITUDE

SENSOR

H

California

modet

Atmospheric

I

preuure

SEF169

Rotation

of

the

engine

is

detected

by

monitoring

both

the

generation

of

the

alternator

and

the

engine

oil

pressure

Because

of

this

dual

moni

toring

system

fuel

pump

operation

can

be

assured

during

engine

rota

tion

even

if

one

of

these

monitor

units

should

fail

If

the

engine

stalls

completely

due

to

a

malfunction

the

supply

offuel

is

stopped

at

once

this

system

iJU

proves

safety

in

case

of

engine

mal

function

FUEL INJECTION

TIMING

FUEL

INJECTION

CONTROL

Crank

angle

Cylinder

o

1200

2400 3600

4800

6000

7

200

10

I

v

I

f

1k

I

l

1

4

I

m

71

ii

c

Start

of

injection

fJ

Ignition

point

The

engine

has

a

repetitive

four

stroke

cycle

suction

compression

4

combustion

exhaust

Fuel

injection

is

made

just

prior

10

the

beginning

of

the

suction

stroke

in

each

cylinder

However

this

situation

is

not

the

same

for

the

EFI

system

The

fuel

injectors

are

electrically

connected

in

parallel

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

tion

and

exhaust

In

the

four

cylin

der

engine

injeCtion

is

made

once

after

receiving

the

ignition

signal

from

the

ignition

coil

two

times

The

required

fuel

quantity

is

at

tained

after

fuel

injection

is

made

twice

during

one

stroke

cycle

suction

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

Fuel

in

this

EFI

system

is

not

in

jected

directly

into

the

cylinder

but

is

injected

into

the

outside

portion

of

the intake

Valve

Therefore

the air

fuel

mixture

is

sucked

into

the

cylin

der

when

the

in

take

valve

opens

to

start

the

suction

stroke

In

other

strokes

the

air

fuel

mixture

is

kept

outside

the

intake

valve

8400

Intake

valve

opens

SEF086

FUEL

INJECTION

QUANTITY

The

fuel

injection

quantity

is

the

sum

of

the

basic

injection quantity

which

is

the

basis

of

the

injection

quantity

and

the

enrichment

Ihat

is

used

to

correct the

basic

injection

quantity

in

correspondence

with

the

various

conditions

Fuel

injection

quantity

Basic

injection

quantity

Enrich

ment

BASIC

INJECTION

QUANTITY

The

engine

rpm

infonnation

and

load

state

information

are

created

by

two

signals

which

pro

vide

for the

rolation

of

the

engine

One

of

these

two

signals

is

sent

out

from

the

ignition

coil

that

detects

the

engine

rpms

The

other

one

is

the

signal

sent

from

the

air

flow

meter

which

monitors

the

suction

air

quan

tity

The

injection quantity

deter

mined

by

these

signals

is

caIled

the

basic

injection quantity

ENRICHMENT

The

basic

injection quantity

is

used

ENGINE

FUEL

Fuel

Injection

Control

as

the

basis

for

providing

engine

rota

tion

but the

injector

is

not

controlled

by

this

factor

alone

For

example

the

fuel

should

be

enriched

when

starting

the

engine

or in

the

full

throttle

posi

tion

For

providing

this

enrichment

the

control

unit

computes

the

quan

tity

of

fuel

to

be

added

to

the

basic

injection quantity

by

using

signals

sent

from

each

sensor

It

causes

the

total

quantity

of

fuel

to

be

injected

Warm

up

enrichment

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

600C

104

to

l400F

Enrichment

ratio

is

changed

by

ON

or

OFF

of

idle

contact

Intake

air

temperature

enrichment

Fuel

injection

is

increased

accord

ing

to

the

intake

air

temperature

moni

tored

by

the

air

temperature

sensor

This

enrichmen

I

is

zero

when

the

intake air

temperature

is

above

400C

104OF

Cold

start

enrichment

Cold

start

enrichment

providedes

improved

starting

ability

in

cold

weather

with

the

ignition

switch

on

START

during

the

cranking

opera

tion

and

when

the

water

temperature

is

lower

than

400C

1040F

The

elapsed

time

and

amount

of

this

en

richment

is

detennined

by

the

water

temperature

and

cranking

speed

Stsrt

enrichment

When

the

ignition

switch

is

in

the

START

position

during cranking

operation

aconstant amount

of

fuel

is

increased

irrespective

of

the

cooling

water

temperature

When

Cold

start

enrichment

reaches

zero

this

START

enrich

ment

will

then

occur

EF

7

FUtJllnjection

Control

ENGINE

FUEL

EXAMPLE

OF

FUEL

INJECTION

QUANTITY

Cold

start

Intake

air

temperature

It

DoC

320F

constant

and

water

temperature

rises

from

DoC 320 F

Ignition

switch

Throttle

VlIlve

tIIltch

Witertemperalure

sen

Ol

I

AirtempcratureleDSOl

Air

fio

metcr

I

nition

oil

Vcbide

cooditioll

Janition

IWjlcb

Threl

e

VlIlve

switch

Vacuum

switch

California

models

Water

temperature

Intake

lemper

iIturc

COlD

START

nridunent

AFTER

START

ehmenl

llnitlon

ch

1

Waler

empcr

lllurcsensor

FTER

IDLE

enrichrne

at

Thrbllle

i

lw

switch

Iertemperaluresenlor

IDLE

chmenl

FULL

nriehmen

r

Throltle

ahe

switch

I

vacuumswitcb

QOLING

WATER

TEMPERAnJRE

orichm

I

TA

KE

IR

P

R

RE

Bots

ic

luel

njection

quantity

OOe

nor

200C

6110FI

40

C

l04on

600C 140oF 8oC 11760F lIo0e

17601

ConSlant

On

California

models

the

Full

enrichment

ctinted

when

the

vacuum

switch

ON

when

the

Full

throttle

contact

is

ON

oGC

32oF

Const

nt

restart

Intake

air

temperature

at

Isoe

S90F

constant

and

water

temperature

rises

from

600e

I400F

AFTER START

ehment

1F

niliOn

ch

W

t

r

emperalure

Ilensm

Hot

Ijl

nilion

ilch

W

telh

mpcl

lIUll

sensor

TluoltlevlIlYeswilCh

Air

1

lemar

Air no

meter

I

nilion

II

Vehicle

condition

Ignilionswitch

Thronlev

oIhe

s

itch

Vaeuum

ilch

California

1odeb

WOItet

empc

nlure

In

J

ke

emper

llure

On

California

models

the

Fun

enrichment

ctinted

ben

the

vacuum

switch

is

ON

when

the

FuU

throttle

ntut

is

ON

SEF344

EF

8

i

ricbmcnt

w

I

INTAKE

AIR

TEMPERAltlRE

enrichment

FULL

enrichment

Throttle

nlve

switdl

vacuum

switch

sie

fuel

injeclion

qUlrnlity

nkinr

Idlinl

Vehicle

starling

ConstanHpecd drivina

START

ON

IDLE

cION

OFF

FULL

THROTTLE

rontac10N

OFF

ON

OFF

600

140l

F

800e

176l

F

800C

117b

01

IConst

ntJ

ISoC

S90F

Constant

After

start

enrichment

When

the

ignition

switch

is

turned

from

the

START

to

ON

position

after

cranking

operation

the

start

or

cold

start

enrichment

becomes

zero

The

after

start

enrichment

is

provided

to

compensate

for

this

sudden

decrease

in

fuel

quantity

The

after

start

enrichment

decreases

gradually

as

time

passes

finally

be

coming

zero

and

is

detennined

by

cooling

water

temperature

Idle

enrichment

When

the

engine

is

idling

that

is

when

the

accelerator

pedal

is

not

depressed

the

throttle

valve

switch

idle

contact

is

ON

to

provide

ad

ditional

fuel

injection

After

Idle

enrichment

The

after

idle

enrichment

pro

vides

smooth

acceleration

when

the

ac

celerator

pedal

is

depressed

to

start

the

vehicle

The

after

idle

enrichment

de

creases

gradually

as

time

passes

finally

becoming

zero

and

is

detennined

by

cooling

water

temperature

ENGINE

FUEL

Fuellnjection

Control

Full

enrichment

The

smooth

ance

full

enrichment

provides

full

throttle

driving

perfonn

California

models

The

full

enrichment

is

activated

when

the

intake

manifold

vacuum

is

below

21

3

kPa

160

mmHg

6

30

inHg

or

when

the

throttle

valve

open

ing

is

more

than

450

Non

California

models

The

full

enrichment

is

activated

when

the

throttle

valve

opening

is

more

than

450

ENRICHMENT

SIGNAL

AND

SIGNAL

SOURCE

CHART

Throttle valve

switch

I

Vacuum

Ignition

Water

Air

Ignition

Full

witch

switch

coil

Remarks

tempera tempera

Idle

California

negative

Fuel

ture

sensor ture

sensor

throttle

START

enrichment

contact contact

models

terminal

Cold

start

0 0 0

Start

0

After

start

00

11

Ignition

switch

START

ON

Idle

0

After

idle

0

22

Idle

contact

ON

OFF

Full

0 0

Warm

up

00

Intake

air

0

temperature

EF

9

Fuel

Injection

Control

ENGINE

FUEL

SHUT

OFf

Fuel

shut

off

is

accomplished

dur

ing

deceleration

when

the

engine

does

Automatic

transmission

models

3

000

I

S

2

600

e

12

200

1

S

I

9

1

800

1

400

1

I

oooi

Deceleration

from

zone

A

Deceleration

from

rone

B

Deceleration from

zone

e

Engine

rpm

increased

in

order

of

e

S

and

A

Idle

switch

ON

downhill

driving

etc

SEF095

not

require

fuel

@

Cooling

water

temperature

at

80

C

1I6

F

Fuel

is

shut

off

and

fuel

is

injected

again

in

tone

Ci

Fuel

is

shut

off

and

fuel

is

injected

again

in

zone

e

Fuel

is

not

shut

off

Fuel

is

not

shut

ofT

in

zones

C

and

B

inzone

A

fuel

is

shut

off

ALTITUDE

COMPENSATION

California

models

The

density

of

ail

becomes

thin

in

proportion

to

the

altitude

so

that

the

air

fuel

ratio

becomes

riche

t

high

altitude

The

altitude

compensator

is

a

device

to

correct

air

fuel

mixture

to

an

optimum

ratio

automatically

EF

l0

The

graph

below

shows

the

fuel

shut

off

tange

Manual

n

models

3

OC

2

600

s

e

2

200

0

Il

0

1

800

1

400

1

000

Deceleration

from

zone

A

Deceleration

from

zone

B

1

D

from

zone

B2

Deceltration

from

zone

e

Engine

rpm

increased

in

order

orue

S2

Bl

and

A

Idle

switch

ON

downhill

driving

etc

@

Cooling

water

temperature

at

80

C

1I6

F

Fuel

is

shut

off

and

fuel

is

injected

again

in

zone

C

Fud

is

shut

off

and

fuel

is

injected

again

in

zone

en

Fuel

is

Dot

shut

off

Fuel

is

not

shut

off

Fuel

is

not

shut

off

in

zones

en

B2

and

Bl

in

z

one A

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

Normal

flow

Relief

valve

actuated

due

to

clogged

discharge

line

Inl

The

fuel

pump

employs

a

wet

type

construction

whe

e a

vane

pump

with

roller

is

directly

coupled

to

a

motor

fIlled

with

fuel

This

construction

pro

vides

superior

coupling

characteristics

between

the

pump

and

motor

and

greater

safety

in

case

of

fire

RoUer

Outlet

E

F252A

Outlet

Fuel

pump

relay

Fuel

pump

Battery

El

P

i

1

s

1

I

Oilpres

ureswitch

II

Ignition

I

switch

IG

Fuel

pump

relay

2

Alternator

Normal

switch

position

IGN

SW

position

In

the

vane

pump

the roller

is

pushed

outward

by

centrifugal

force

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

relief

valve

in

the

pump

is

designed

to

open

when

the

pressure

in

the

fuel

line

rises

over

294

to

44

I

kPa

3

0

to

45

kg

cm2

43

to

64

psi

due

to

malfunction

in

the

pressure

system

The

check

valve

prevents

abrupt

drop

of

pressure

in

the

fuel

pipe

when

stopping

the

engine

Operation

When

the

ignition

switch

is

turned

Nhene

ine

When nline

opped

opEration

Allenulor

L

rmilUll

OLlprclSurt

witch

ON

01

1

START

No

ON

generate

pressure

ON

Gentrate

Normal

ON

Failure

NOllTUI1

ON

Gencr

atc

Failure

ON

l

a

ilure

Fwure

OFF

No No

OFF

SEF096

teneralt

prcuure

Alternator

Oil

Fuel

pump

relay

I

1

pump

Fuel

pump

relay

2

prellure

II

Actuate

Actuak

Actuate

No

actuate

No

actuate

to

the

START

position

for

cranking

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

tion

switch

is

ON

the

alternator

operates

and

the

engine

oil

pressure

switch

is

open

through

rotation

of

the

engine

th

reby

actuating

the

fuel

pump

If

the

alternator

stops

and

the

en

gine

oil

pressure

decreases

for

some

re

ason

the

fuel

pump

relay

2

contact

is

turned

to

II

and

the

fuel

pump

relay

l

is

turned

OFF

Then

the

fuel

pump

is

stopped

through

the

ignition

switch

remains

in

the

ON

position

In

this

manner

fuel

supply

is

cut

off

for

safety

purposes

when

the

engine

accidentally

stops

during

driving

EF

l1

FUEL

DAMPER

EFI

1

Component

Parts

Constroction

and

Function

ENGINE

FUEL

Fuel

outlet

SEF097

The

fuel

damper

is

provided

to

suppress

pulsation

in

fuel

flow

dis

charged

from

the

fuel

pump

No

ad

justment

is

allowed

on

this

damper

Change

in

the

pump

discharge

pres

sure

is

monitored

by

the

diaphragm

and

spring

which

vary

the

volume

of

the

fuel

chamber

for

suppressing

pul

sation

FUEL

FILTER

Il

R

Fuel

outlet

j

Fuel

inlet

EF256A

The

fuel

f1lter

is

placed

between

the

fuel

damper

and

the

injector

and

is

used

to

remove

foreign

matter

in

the

fuel

Water

in

the

fuel

is

collected

at

the

bottom

of

the

f1lter

casing

INJECTOR

The

injector

receives

the

pulse

signal

from

the

control

unit

and

in

jects

the

fuel

toward

the

intake

valve

in

the

cylinder

head

The

injector

operates

on

the

EF

12

solenoid

valve

principle

When

iI

driving

pulse

is

applied

to

the

coil

built

into

the

injector

the

plunger

is

pulled

into

the

solenoid

thereby

opening

the

needle

valve

for

fuel

injection

The

quantity

of

injected

fuel

is

in

propor

tion

to

the

duration

of

the

pulse

pplied

from

the

control

unit

SEF099

1

Injector

lower

rubber

insulator

2

Injector

lower

holder

3

Injector

upper

rubber

insula

or

4

Injector

upper

holder

5

Injector

o

le

FJectric

terminal

li

1

I

f

Filter

PRESSURE

REGULATOR

To

intake

manifold

t

Air

chamber

Diaphragm

Fuel inlet

SEF100

The

pressure

regulator

controls the

pressure

of

fuel

so

that

a

pressure

difference

of

250

kPa

2

55

kgjcm

36

3

psi

can

be

maintained

between

the

fuel

pressure

and

intake

manifold

vacuum

The

pressure

regulator

is

divided

into

the

air

chamber

and

fuel

SEF098

chaniber

by

the

diaphragm

Intake

manifold

vacuum

is

introduced

into

the

air

chamber

thereby keeping

differential

pressure

constant

causing

excessive

fuel

to

return

to

the

fuel

tank

through

the

return

side

port

This

constant

differential

pressure

provides

optimum

fuel

injection

in

every

mode

of

engine

operation

kPa

kg

em

psi

196

t

2 0

Fuel

pressure

u

28

98

250 kPa

2

55

kg

em

e

1

0

36

6

si

14

I

tmospheric

0

D

CSSW

e

Ttme

98

Foil

ManiCotd

1

0

Idling

throttle

vacuum

14

E

F258A

AIR

FLOW

SYSTEM

AIR

FLOW

METER

Helical

spring

From

air

cleaner

EN

GIN

E

FU

E

LE

F

I

System

Component

Parts

Construction

and

Function

Damper

plate

To

intake

manifold

By

pass

port

Air

temperature

sensor

The

air

flow

meter

measures

the

quantity

of

intake air

and

sends

a

signal

to

the

control

unit

so

that the

base

pulse

width

can

be

detennined

for

correct

fuel

injection

by

the

injec

tor

The

air

flow

meter

is

provided

with

a

flap

in

the

air

passage

As

the

air

flows

through

the

passage

the

flap

rotates

and

its

angle

of

rotation

is

electronically

monitored

to

count

the

air

flow

rate

More

specifically

the

angle

of

rota

tion

of

the

flap

is

monitored

by

a

potentiometer

provided

inside

as

a

potential

difference

V

When

the

flap

deflects

along

with

a

change

in

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

VB

battery

voltage

is

applied

across

terminals

@

and

@

Then

the

air

flow

rate

is

converted

into

the

voltage

ratio

signal

V

VB

which

in

turn

is

sent

to

the

Potentiometer

To

EFI

harness

control

unit

for

computation

The

flap

is

able

to

rotate

to

an

angle

where

an

equilibrium

between

the

air

flow

pressure

and

the

return

torque

of

lhe

coil

spring

can

be

main

tained

The

damper

chamber

and

damper

plate

are

provided

as

a

damper

for

the

flap

so

that

the

flap

will

not

be

disturbed

by

pulsation

in

manifold

vacuum

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

clearance

between

the

chamber

wall

During

idling

operation

when

the

amount

of

intake air

is

extremely

small

the

air

flows

parallel

with

the

flap through

the

by

pass

port

so

that

the

specified

intake

air

flow

can

be

provided

correctly

The

air

passage

is

provided

with

the

air

temperature

sensor

and

the

by

pass

port

has

the

air

by

pass

screw

which

regulates

the

idle mixture

ratio

U

35

Ro

33

R

Potentiometer

32

R

IB

RJO

34

Air

temperature

sensor

25

Terminal

number

fi

EF441A

AIR

REGULATOR

Electric

terminal

Shutter

Sleeve

Air outlet

r

Heater

SEF101

The

air

regulator

bypasses

the

throttle

valve

to

control

the

quantity

EF

13

E

FI

ystBrn

Component

Pans

Construction

and

Function

EN

GIN

E

FU

EL

of

air

for

increaSing

the

engine

idling

speed

when

starting

the

engine

at

a

bi

Characteri5tics

curve

COLD

40

metal

temperature

of

below

800C

I

412

176OF

3

30 32

1

30

c

A

bimetal

and

a

heater

are

built

in

1

059

to

the

air

regulator

When

the

ignition

e20

21

5

759

2

switch

is

turned

to

the

START

posi

l

706

on

or

engine

running

electric

current

10 16

5

583

flows

through

the

heater

and

the

bi

a

353

2

5

88

Air

inlet

metal

as

it

is

heated

by

the

heater

0

hegins

to

move

and

closes

the

air

pas 20

0

20 40 60 80

sage

in

a

few

minutes

The

air

passage

g

4

32

68

104

140

176

remains

cloSed

until

the

engine

is

stop

Tempetature oe

FJ

ped

and

the

bimetal

temperature

drops

to

below

800C

176OF

0

Initial

bimetal

temperature

200e

68 HOT

I

A

UNIT

Idle

speed

adjusting

screw

unit

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

1

A

S

unit

AIR

PIPE

The

air

pipe

located

on

the

line

be

tween

the

air

flow

meter

and

the

throttle

chamber

prevents

the

pulsat

ing

of

the intake

air

THROTTLE CHAMBER

The

throttle

chamber

located

be

tween

the

air

flow

meter

and

the

in

take

manifold

is

equipped

with

a

valves

This

valve

controls the intake

air

flow

in

response

to

accelerator

pedal

movement

The

air

passage

is

a

two

barrel

type

which

consists

of

a

primary

side

and

a

secondary

side

A

venturi

is

provided

on

the

primary

side

When

the

opening

angle

of

the

primary

throttle

valve

reaches

350

the

secondary

throttle

valve

will

be

opened

by

a

linkage

which

is

connect

ed

to

the

primary

throttle

valve

The

rotary

shaft

of

the

primary

throttle

valve

is

connected

to

the

throttle

valve

switch

EF

14

30

e

1

059

s

20

10

ri

o

177

2

5 8 8

I

g

2

4

6 8

10

Thne

mmwU

Intake

manifold

Airduc

dr

ThIottle

valve

witch

1

Bimetal

2

Shutter

3

Heater

SEF102

j

dicr

L

c

JFj

pi

I

A

S

unit

Air

flow

meter

SEF106

Primaty

throttle

valve

I

Secondary

throttle

valve

IH

J

SEF104

DASH

POT Automatic

transmission

models

The

dash

pot

is

attached

to

the

throttle

chamber

The

dash

pot

pre

vents

the

throttle

valve

from

closing

abruptly

and

thus

stalls

the

engine

The

throttle

valve

will

gradually

reo

turn

to

the

idle

opening

position

during

deceleration

ELECTRICAL

SIGNAL

SYSTEM

WATER

TEMPERATURE

SENSOR

The

water

temperature

sensor

built

into

the

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

ploys

a

thermistor

which

is

very

sensi

tive

in

the

low

temperature

range

The

electrical

resistance

of

the

ther

mistor

decreases

in

response

to

the

water

temperature

rise

AIR

TEMPERATURE

SENSOR

The

air

temperature

sensor

buHt

into

the

air

flow

meter

monitors

change

in

the

intake

air

temperature

and

transmits

a

signal

for

the

fuel

enrichment

to

change

the

pulse

dura

tion

The

temperature

sensing

unit

em

ploys

a

thermistor

which

is

very

sensi

tive

in

the

low

temperature

range

The

electrical

resistance

of

the ther

istor

decreases

in

response

to

the air

temperature

rise

THROTTLE

VALVE

SWITCH

The

throttle

valve

switch

is

attach

ed

to

the

throttle

chamber

and

ac

tuates

in

response

to

accelerator

pedal

movement

This

switch

has

two

sets

of

contact

points

One

set

monitors

the

idle

position

and

the

other

set

monitors

full

throttle

position

EN

GIN

E

FU

EL

EFI

System

Component

Parts

Construction

and

Function

WATER TEMPERATURE

SENSOR

q

AIR

TEMPERATURE

SENSOR

Air

temperature

sensor

SEF101

Idl

contact

The

idle

contact

closes

when

the

throttle

valve

is

positioned

at

idle

and

opens

when

it

is

at

any

other

position

The

idle

contact

compensates

for

idle

wann

up

and

after

idle

en

richment

and

sends

the

fuel

shut

off

signal

Full

throttle

contact

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

Dash

pot

Air

Throttle

passage

lever

Throttle

h

L

valve

J

SEF105

CHARACTERISTICS

CURVE

I

114

kn

at

IOoC

l40F

30

I

20

7 0

10

8

6

4

I

2

12 9

Jen

at

200C

c

3

680F

IJ

8

2

0 68

1

00

kn

I

0

I

t

SOOC

1220

1

I

0

6

I

1

0

06

L

30 20

0

20

40 60 80

22

4

32

68

104 140 176

Temperature

Oc

OF

04

0

31

0 2

Full throttle

contact

SEF108

EF

15

EFI

System

Component

Parts

Construction

and

Function

ENGINE

FUEL

VACUUM

SWITCH

California

models

The

vacuum

switch

compensates

for

the

full

enrichment

by

controll

ing

the

intake

manifold

vacuum

This

switch

consists

of

a

vacuum

diaphragm

and

a

microswitch

When

the intake

manifold

vacuum

lowers

during

acceleration

the

tension

of

the

spring

will

push

the

diaphragm

back

and

open

the

contact

of

the

microswitch

This

will

cause

the

switching

module

to

transmit

an

ON

signal

to

the control

unit

ALTITUDE

SENSOR

california

models

This

altitude

sensor

is

a

device

to

obtain

the

electric

signal

in

proportion

to

altitude

for

the

electronic

control

unit

This

altitude

sensor

is

composed

of

the

bellows

the

magnet

and

the

mag

neto

resistance element

At

high

alti

tude

the

bellows

extends

and

changes

the

position

of

the

magnet

installed

at

the

tip

of

bellows

The

magneto

resistance

element

senses

the

position

of

the

magnet

and

transfonns

to

the

electric

signal

The

electric

signal

from

the

altitude

sensor

is

transmitted

to

the

elec

ronic

control

unit

and

ihe

injection

duration

of

the

injectors

is

detennined

to

ob

tain

the

optimum

air

fue

ratio

by

the

electronic

control

unit

CONTROL

UNIT

The

control

unit

is connected

to

the

EFI

harness

by

means

of

amulti

connector

and

the

EFI

harness is

connected

to

other

sensoIS

The

essential

role

of

the control

unit

is

to

generate

a

pulse

Upon

receiving

an

electrical

signal

from

each

sensor

the control

unit

generates

a

pulse

whose

duration

injector

open

EF

16

Battery

j

@

To

control

unit

@

r

@

Switching

mo

j

ule

Bellows

if

m

J

To

control

unit

Magnet

j

Magneto

resistance

element

SEF113

valve

time

period

is

controlled

to

provide

an

optimum

quantity

of

fuel

according

to

the

engine

characteristics

The

control

unit

consists

mainly

of

three

integrated

circuits fonned

on

the

printed

circuit

board

This

construe

tion

provides

superior

control

unit

reliability

Switching

charact8ristics

Terminal

@ @

ON

hn

j

OFFj

21

3

kPa

160

mmHg

6

30

inHg

Vacuum Vacuum

increase

decrease

Intake

manifold

uum

l

O1aracteristics

curve

6

m

U

nn

u

s

0

2 6

c

o

Altitude

m

ft

500

1

641

Atmospheric

pressure

kPa

mmHg

inHgJl

95

4

716

28

2

SEF217

1

800

5

906

81

4

611

24

1

SEF275

EF323A

DROPPING RESISTOR

The

dropping

resistor

is

used

to

lower

the

source

voltage

to

a

level

suitable

for the

injector

The

dropping

resistor

is connected

in

series

with

the

injector

It

reduces

the

source

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

electrical

system

RELAY

EFI

relay

The

EFI

relay

serves

to

activate

the

electronic

fuel

injection

system

through

the

ignition

switch

Fuel

pump

relay

1

and

2

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

nect

lines

between

the

control

unit

and

the

units

The

35

connector

of

the

EFI

harness

is

connected

to

the control

unit

and

runs

to

the

engine

compart

ment

The harness

runs

to

various

units

the

air

flow

meter

throttle

valve

switch

vacuum

switch

air

regu

lator

altitude

sensor

water

tempera

ture

sensor

dropping

resistor

and

in

jector

etc

Battery

supplies

power

to

injector

and

control

unit

through

fusible

link

designed

especially

for

EFl

EN

G

IN

E

FU

EL

EFI

System

Component

Parts

Construction

and

Function

Electric

Resistor

tenninal

tL

L

1

I

r

SEF114

Battery

l

I

81

Fusible

link

o

5

I

IG

Ignition

switch

Dropping

resistor

I

II

Injector

1

Control

unit

SEF115

1

i

Dropping

resistor

I

II

I

Air

flow

meter

7

SEF116

EF

17

Alwll

1I

UJe

12

olt

battetic

as

power

Qurce

Do

not

attempt

to

disconnect

batter

cable

i

whUe

engine

is

operating

If

a

receiver4ranltnlttet

is

installed

route

antenna

fceder

cable

along

opposite

side

ftom

Efl

hatnes

and

control

unit

Make

iure

that

there

is

no

interferen

e

whUe

engine

is

idling

Do

not

applY

bnttery

pOWe

directly

to

inlectan

i

a

l

j

I

rn

c

p1

PRECAUTIONS

FOR

AN

EFl

ENGINE

PaY

clo

ttentlon

to

the

following

point

when

ill5pecting

or

cvicing

en

EfI

car

Securely

connect

EFI

harne

55

connector

A

poor

connection

can

cause

an

extreme

ly

high

surge

voltll

e

to

develop

in

coil

and

condenser

thus

rerulting

in

damage

tolCcircuit

Keep

EFt

h

rne

t

e

t

10

em

1

91n

away

from

adjacent

hlU

llesses

to

prevent

an

EFl

syltetn

malfunction

due

to

reception

of

external

noise

degraded

operation

of

Ie

circuit

etc

Keep

EFt

parts

end

h

rne

dIY

BefotO

removing

pl1Ita

turn

off

ignition

switch

and

then

duccnnect

batter

ground

cable

00

not

operate

fuel

pump

when

there

is

nO

ruel

in

iMJ

00

not

use

antHrceze

agents

i

n

fuel

Do

not

reule

fuel

hose

cla

mp1l

Tighten

fuel

hose

clamp

sufficientlY

Randle

air

floW

meter

carefullY

to

avoid

dalTlage

There

should

not

occur

even

a

tight

leak

in

air

int

ke

i

tero

v

Do

not

depteSS

aCCClen

tot

pedal

when

ItarUPi

Imrnt

dtatelY

afte1

starting

do

not

rev

up

engine

unneceuarUY

ij

ENGINE

FUEL

Removalsnd

Installstion

REMOVAL

AND

INSTALLATION

INJECTOR AND

FUEL

PIPE

1

Follow

the

procedure

below

to

reduce

fuel

pressure

to

zero

CAUTION

Before

disconnecting

fuel

hose release

fuel

pressure

from

fuel

line to

elimi

nate

danger

I

Start

the

engine

2

Disconnect

the

harness

connector

of

fuel

pump

relay

2while

the

engine

is

running

Rei

bracket

SEF131

3

After

the

engine

stalls

crank

the

engine

two

or

three

times

4

Turn

the

ignition

switch

OFF

5

Reconnect

the

harness

connector

of

fuel

pump

relay

2

If

the

engine

w

1

not

start

remove

fuel

pump

relay

2

I

a

rness

connector

and

crank the

engine

for

bout

5

sec

conds

Then

turn

the

gnition

switch

OFF

2

Remove

or

disconnect

the

follow

ing

parts

and

connectors

Accelerator

wire

Injector

harness

connector

V

C

valve

hose

and

air

regulator

hoses

Air

regulator

and

its

harness

con

nectar

Vacuum

hose

at

the

fuel

pipe

con

nection

end

3

Disconnect

fuel

feed

hose

and

fuel

return

hose

from

fuel

pipe

Place

a

rag

under

fuel

pipe

to

pre

vent

splashing

of

fuel

4

Remove

vacuum

hose connecting

8

Unfasten

hose

clamp

on

fuel

in

jector

and

remove

fuel

injector

from

fuel

pipe

Place

a

rag

under

injector

when dis

J

connecting

fuel

pipe

to

prevent

splash

ing

of

fuel

pressure

regulator

to

intake

mani

fold

5

Remove

boits

securing

fuel

pipe

and

pressure

regulator

SEF119

6

Remove

screws

securing

fuel

injce

tors

7

Remove

fuel

pipe assembly

by

pulling

out

fuel

pipe

injector

and

pressure

regulator

as

an

assembly

SEF099

1

Injector

lower

rubber

insulator

2

Injector

lower

holder

3

Injector

upper

rubber

insulator

4

Injector

upper

holder

i5

Injector

9

To

install

injector

and

fuel

pipe

reverse

the

order

of

removal

a

When

installing

injector

check

that

there

are

no

scratches

or

abrasion

at

lower

rutiber

insulator

and

securely

install

it

making

sure it

is

air

tight

b

For

installation

of

fuel

hose

refer

to

Fuel

Hose

INJECTOR

RUBBER

HOSE

If

necessary

replace

injector

rubber

hose

proceed

as

follows

Removal

Socket

Y

20

mm

0

79

in

EF551

EF

19

Remolialand

InstBllatioh ENGINE

FUEL

1

On

injector

rubber

hose

measure

off

a

point

approx

20

mm

0

79

in

from

socket

end

2

Heat

soldering

iron

150

watt

for

15

minutes

Cut

hose

into

braided

reinforcement

from

mark

to

socket

end

Do

not

feed

soldering

iron

until

it

touches

injector

tail

piece

CAUTION

a

Be

careful

not

to

damage

socket

plastic

connec1or

etc

with

solder

ing

iron

b

Never

piece

injector

in

a

vise

when

disconnecting

rubber

hose

3

Then

pull

rubber

hose

out

with

hand

Installation

1

Clean

exterior

of

injector

tail

piece

2

Wet

inside

of

new

rubber

hose

With

fUel

3

Push

end

of

rubber

hose

with

hose

socket

onto

injector

tail

piece

by

hand

as

far

as

they

will

go

Clamp is

not

necessary

at

this

con

nection

CAUTION

After

properly

connecting

fuel

hose

to

injector

check connec1ion

for

fuel

leakage

PRESSURE

REGULATOR

Fuel

pipe

assembly

SEF122

I

Remove

the

fuel

injector

fuel

pipe

and

pressure

regulator

as

an

as

sembly

from

the

intake

manifold

Re

fer

to

Injector

and

Fuel

Pipe

for

reo

moval

EF

20

2

Remove

pressure

regulator

from

fuel

pipe assembly

3

To

install

pressure

regulator

reo

verse

the

order

of

removal

For

installation

of

fuel

hose

refer

to

Fuel

Hose

AIR

REGULATOR

I

Disconnect

ground

cable

from

battery

2

Unfasten

clamp

on

each

side

of

hose

and

disconnect

hose

3

Remove

setscrews

and

remove

air

regulator

4

Disconnect

electric

connector

from

air

regulator

S

To

install

air

regulator

reverse

the

order

of

removal

WATER

TEMPERATURE

SENSOR

I

Disconnect

battery

ground

cable

2

Remove

radiator

cap

Drain

coolant

by

opening

drain

plug

CAUTION

The

coolant

should

not

be

drained

until

it

has

cooled

off

completely

Otherwise

burns

may

be incuned

3

Remove

air

pipe

to

facilitate

reo

moval

of

water

temperature

sensor

4

Disconnect

water

temperature

sensor

harness

connector

and

then

re

move

water

temperatur

sensor

by

turning

it

counterclockwise

5

To

install

water

t

Ult

ture

sen

r

reverse

the

Ordi

f

of

removal

Be

sure

to

install

copper

washer

when

installing

watar

temperature

sensor

THROTTLE

VALVE

SWITCH

1

Disconnect

battery ground

cable

2

Disconnect

throttle

valve

switch

harness

co

ector

3

Remove

screws

securing

throttle

valve

switch

to

throttle

chamber

4

Slowly

pull

throttle

valve

witch

toward

you

5

To

install

throttle

valve

witch

reverse

the

order

of

removal

6

After

installation

adjust

position

of

throttle

valve

sWitch

Refer

to

Throttle

Valve

Switch

under

the

heading

Component

Parts

Inspection

THROTTLE

CHAMBER

1

Disconnect

battery

ground

cable

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

bolts

securing

throttle

chamber

to

intake

manifold

The

throttle

chamber

can

be

removed

6

To

install

throttle

chamher

reo

verse

the

order

of

removal

Gasket

should

be

replaced

by

new

one

each

time

the

throt

tle

chamber

is

removed

Throttle

chamber

i

J

Nm

lkg

m

ft

lbl

18 22

18

2

13

161

SEF126

Do

not

adjust

throttle

valve

stopper

screw

as

it

is

properly

adjusted

at

factory

DASH

POT

Dash

pot

0

11

Throttle

chamber

IJ

SEF142

Remove

throttle

chamber

Refer

to

throttle

chamber

for

reo

moval

ENGINE

FUEL Remova

and

Installation

2

Remove

dash

pot

from

throttle

chamber

3

To

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

Inspection

VACUUM

SWITCH

SEF141

I

Disconnect

battery

ground

cable

2

Disconnect

vacuum

hose

and

har

ness

connector

from

vacuum

switch

3

Remove

vacuum

switch

from

bracket

4

To

install

vacuum

switch

reverse

the

order

of

removal

ALTITUDE

SENSOR

Left

side

dISh

panel

SEF323

1

Disconnect

ground

cable

from

battery

2

Remove

control

unit

Refer

to

Control

Unit

for removal

3

Remove

altitude

sensor

attaching

bolts

4

Disconnect

harness

connector

from

altitude

sensor

5

To

install

altitude

sensor

reverse

the

order

of

removal

DROPPING

RESISTOR

SEF128

1

Disconnect

ground

cable from

battery

2

Remove

air

cleaner

and

air

flow

meter

as

an

assembly

Refer

to

Air

Cleaner

for removal

3

Disconnect

harness

connector

from

dropping

resistor

4

Remove

dropping

resistor

attach

ing

screw

5

To

install

dropping

resistor

re

verse

the

order

of

removal

CONTROL

UNIT

The

control

unit

is

mounted

on

the

left

side

dash

panel

I

Turn

ignition

switch

OFF

and

then

disconnect

ground

cable

from

battery

EF

21

Remoraland

Instal

stion

ENGINE

FUEL

CAUTION

Before

disconnecting

EF

I

harness

at

3511in

connector

be

sure

to turn

ignition

switch

0

FF

and

than

dis

connect

ground

cable

from

battery

to

prevent

control

unit

from

being

dam

aged

2

Remove

L

H

dash

side

finisher

3

Pull

lock

lever

back

and

discon

nect

3S

connector

from

control

unit

4

Remove

bolt

which

secures

con

trol

unit

to

L

R

dash

side

panel

and

remove

control

unit

5

To

install

control

unit

reverse

the

order

of

removal

CAUTION

When

inserting

35

connector

into

control

unit

be

careful

nol

to

bend

at

break

terminals

RELAY

The

relays

are

installed

on

the

relay

bracket

Inside

relay

brKket

Fuel

pump

telay

l

SEF130

Relay

bncket

SEF131

EF 22

I

Oisconnect

battery

ground

cable

and

remove

relay

bracket

2

Disconnect

harness

connector

3

Remove

relay

from

relay

bracket

4

To

install

relay

reverse

the

order

of

removal

AIR

CLEANER

SEF132

I

Disconnect

ground

cable

from

battery

2

Disconnect

air

ducts

and

hoses

connecting

r

cleaner

and

r

flow

meter

3

Remove

I

A

s

unit

from

air

cleaner

4

Remove

bolts

securing

air

cleaner

to

air

cleaner

bracket

and

detach

air

cleaner

with

air

flow

meter

as

an

as

sembly

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

order

of

removal

AIR

FLOW

METER

I

l

I

DiSConnect battery

ground

cable

2

Disconnect

air

ducts

and

hoses

connecting

air

cleaner

and

air

flow

meter

3

Remove

air

cleaner

cover

4

Remove

bolts

securing

air

fiow

meter

S

Disconnect

ham

cOnnector

and

remove

air

flow

meter

6

To

install

air

flow

meter

reverse

the

order

of

removal

AIR

TEMPERATURE

SENSOR

The

air

temperature

sensor

is

built

into

the

air

flow

meter

and

cannot

be

removed

as

a

single

unit

When

replace

ment

of

air

t

mper

ture

8eDSOI

is

necessary

the

entire

air

flow

meter

assembly

should

be

rep

d

FUEL

FILTER

I

Reduce

fuel

line

pressure

to

zero

Refer

to

item

I

under

the

heading

Injector

and

Fuel

Pipe

2

Unfasten

clamps

securing

fuel

hoses

to

the

outlet

and

inlet

sides

of

fuel

fIlter

and

disengage

fuel

hoses

Be

careful

not

to

spill

fuel

over

en

gine

compartment

Place

a

rag

to

ab

sorb

fuel

3

Remove

fuel

fIlter

4

To

install

fuel

fdter

reverse

the

order

of

removal

S

For

installation

of

fuel

hose

refer

to

Fuel

Hose

FUEL

PUMP

AND

FUEL

DAMPER

1

Disconnect

ground

cable

from

battery

2

Reduce

fuel

line

pressure

to

zero

Refer

to

item

1

under

the

heading

In

jector

and

Fuel

Pipe

3

Raise

the

rear

portion

of

car

with

a

jack

and

block

wheels

4

Temporarily

clamp

hose

between

fuel

tank

and fuel

pump

S

Unfasten

clamps

and

the

suction

side

of

fuel

pump

and

outlet

side

of

fuel

damper

and

disconnect

fuel

hoses

Be

sure

to

receive

fuel

into

B

suit

able

container

6

Disconnect

fuel

pump

harness

connector

7

Remove

bolts which

secure

fuel

p

lmp

bracket

to

body

and

remove

fuel

pump

and

fuel

damper

as

an

as

sembly

from

bracket

8

Fuel

pump

and fuel

damper

can

be

removed

9

To

install

fuel

pump and

fuel

damper

reverse

the

order

of

removal

10

For

installation

of

fuel

hose

refer

to

Fuel

Hose

FUEL

HOSE

Make

sure

that

all

low

pressure

fuel

hoses

are

fully

inserted

and

are

free

from

undue

strain

before

clamping

When

removing

or

installing

high

pressure

fuel

hose

observe

the

follow

ing

CAUTION

a

Do

not

reuse

fuel

hose

clamps

after

loosening

b

Clean

dull

and

dirt

from

parts

with

compreS

8d air

when

assembling

c

Tighten

high

pressure

rubber

hose

clamp

so

thilt

clamp

end

is

3

mm

0

12

in

from

hose

end

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

SEF138

If

Clamps

1

0

1

5N

m

0

10

0

15 kg

m

0

7

1 1

f

lbl

@

Pre

ure

regulator

l

3

mm

10

12

in

li

II@

EF336A

L

Fuel

ftlter

J

fJ

ENGINE

FUEL

RemovalBnd

Installation

d

When

tightening

hose

clamp

ensure

that

screw

does

not

come

into

contact

with

adjacenl

parts

Insert

high

pressure

fuel

hoses

into

their

proper

positions

as

instructed

helow

Type

@

Insert

rubber

hose

until

its

end

contacts

unit

Type

@

Push

end

of

rubber

hose

onto

fuel

pipe

until

it

contacts

inner

bulge

Type

@

Push

end

of

injector

rubber

hose

onto

fuel

pipe

until

it

is

28

mm

1

10 in

from

end

of

pipe

Type

@

Push end

of

rubber

hose

with

hose

socket

onto

unit

by

hand

as

far

as

they

will

go

Clamp is

not

necessary

at

this

connection

To

fuel

tank

From

fuel

tank

n

Fuel

damper

Fuel

pipe

mblY

I

@

SEF139

EF 23

Electrical

System

Inspection

ENGINE

FUEL

ELECTRICAL

SYSTEM

INSPECTION

DESCRIPTION

Electrical

system

inspection

can

be

perfonned

by

using

the

EFI

ANA

L

YZER

J

25400

CAUTION

When

checking

the

electrical

system

with

EFI

ANAL

VZER be

sure

to

use

the

proper

adapter harness

If

the

analyzer

is

not

available

use

the

following

procedures

PREPARATIONS

FOR

INSPECTION

VEHICLE

PREPARATIONS

1

Turn

ignition

switch

to

OFF

position

CAUTION

Before

disconnecting

and

connecting

electrical

connectors

ensure

that

igni

tion

SWilch

is

in

the

0

FF

position

2

Disconnect

battery

ground

cable

3

Disconnect

lead

wire

from

S

tenninal

of

starter

motor

4

DiscQnnect

va

uum

sw

it

h

harness

connector

California

models

5

Arrange

so

that

air

flow

meter

flap

can

be

pushed

manually

from

air

cleaner

side

6

Disconnect

35

EFI

harness

connector

from

control

unit

CAUTION

a

Before

disconnecting

EFI

harness

at

35

connector

ensure

that

igni

tion

swilch

is

in

the

OFF

posi

tion

b

Be

extremely

careful

not

to

break

or

bend

35

when

disconnecting

terminal

EF

24

INSPECTION

To

inspect

the

electrical

system

use

a

circuit

tester

Continuity

test

can

be

perfonnedeasily

by

measuring

resist

ance

and

voltage

between

terminals

of

35

EFI

harness

connector

installed

on

car

CAUTION

Do

not

touch

the

circuit

tester

probe

to

any

unnecessary

on

the

35

connector

Doing

so

could

cause

dam

age

to

the circuit

tester

For

items

to

be

checked

refer

to

Inspection

Procedure

Table

RESISTANCE

MEASUREMENT

I

Set

circuit

tester

in

the

Ohm

R

range

2

Check

continuity

between

ter

minals

@

and

@

shown

in

the

Inspection

Procedure

table

Body

ground

should

be

mad

by

connecting

unpainted

metal

such

81

bolt

Fl

Resistance

measurement

1

r

1

B

I

r

l

L

i

l8

II

jj

I

1

U

3

After

steps

I

through

11

above

have

all

been

completed

proceed

to

step

12 only

for

California

models

I

Connect

the

vacuum

switch

har

ness connector

and

disconnect

the

hose

in

the

line

between

the

vacuum

switch

and

the

intake

manifold

2

Disconnect

the

throttle

valve

switch

and

altitude

sensor

harness

con

nectar

3

Check

continuity

when

no

pres

sure

is

applied

to

vacuum

switch

4

Apply

a

pressure

below

21

3

kPa

160

mmHg

6

30

inHg

to

vacuum

switch

by

orally

sucking

port

back

and

check

continuity

5Bring

back

vacuum

switch

a1ti

tude

sensor

and

throttle

valve

switch

to

their

original

condition

VOLTAGE

MEASUREMENT

1

Set

circuit

tester

in

the

DC

Volt

DC

V

range

2

Securely

connect

battery

ground

cable

3

Connect

negative

probe

of

circuit

Fl

2

I

26

9

27

0

1811

1

l1

L13

U

i

4

1

I

IT

ENGINE

FUEL

Electrical

System

Inspection

tester to

body

metal

Body

earth

should

be made

by

con

necting

with

unpainted

metal

such

as

bolt

4

Contact

positive

probe

of circuit

tester to

tenninal

@

shown

in

the

Inspection

Procedure

table

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

14

2

Turn

ignition

switch

OFF

3

Connect

lead

wire

to

S

ter

minal

of

starter

roptor

4

Set ignition

switch

on

START

and

measure

voltage

in

step

1

S

6

Inspection

with

igiIition

switch

in

ON

position

I

101

g

O

L

1

fJU

EF452A

I

Turn

ignition

switch

ON

and

measure

voltage

in

each

step

of

nspec

tion

Procedure

Table

from

16

to

22

2

Turn

ignition

switch

OFF

3

Disconnect

oil

pressure

switch

harness

connector

4

Turn

ignition

switch

ON

and

measure

voltage

in

step

23

S

Turn

ignition

switch

OFF

6

Connect

oil

pressure

switch

har

ness connector

7

Disconnect

alternator

2

con

nector

L

and

S

terminals

8

Turn

ignition

switch

ON

and

measure

voltage

in

step

24

7

Turn

ignition

switch

OFF

8

Connect

EFI

harness

connector

to

control

unit

9

Connect

2

alternator

con

nectar

10

Bring

air

flow

meter

back

to

its

original

condition

INSPECTION

PROCEDURE

TABLE

HOW

TO

USE

1

After

measuring

compare

meas

ured

values

with

standard

values

to

determine

whether

circuits

parts

are

malfunctioning

or

not

2

When

a

malfunctioning

circuit

is

located

again

check

measurements

in

volved

in

that

circuit

In

this

case

check

ignition

switch

circuit

tester

range

probe

etc

to

be

certain

they

are

set

at

proper

positions

CAUTION

a

Before

connecting

EFI

harness

at

35

connector

ensure

that

igni

tion

switch

is

in

the

0

FF

posi

tion

b

When

inserting

35

connector

into

control

unit

insert

slowly

securely

and

straight

being

careful

not

to

bend

or

break

35

termi

nals

EF 25

INSPECTIONPROCEDURE

TABLE

m

T1

N

Circuit

tester range

Checkterminala

A

8J

I

Be

Ignition

switch

Step

Inspection

circuit

Auxiliary

op

ration

or

condit

on

J

2

Disconnect

vacuum

switch

harness

connector

Judgment

1

Disconnect

battery

negative

terminal

starter

motor

US

terminal

35

EFI

harness

connector

from

oontrol

unit

California

models

3

Arrange

so

that

air

flow

meter

flap

can

be

pushed

from

air

clenner

side

Air

now

meter

potentiometer

sliding

resistor

and

circuit

32

34

Push

airflow

meter

flap

Fully

deprcs5ed

Releaied

ully

depressed

Released

2p

OC

680P

or

above

B

elow

200C

680F

I

lOae

680P

or

above

I

Below

200C

680F

Standard

value

Measured

value

I

f

o

I

m

Z

Cl

Z

m

C

m

r

I

Except

Qand

n

on

wn

on on

n

Below

2

9kn

2

1kO

or

above

Below

2

9kn

2

1kn

or

above

100

to

400

n

200

to

500

n

2St090n

30

24

Canfornla

model

1

Connect

vacuum

switch

harness

connector

and

dbconnect

hose

vacuum

switch

t6

itttake

manifold

at

intake

manifold

side

2

Disconnect

tnrottle

valve

switch

and

altitude

sensor

harnels

connector

Circuit

betweon

ignition

switch

Bnd

control

unit

power

source

Circuit

between

ignition

switch

fuel

pump

relay

and

air

regulator

Note

a

Before

disconnecting

and

connectiria

electrical

connecton

and

terminab

enlUfO

that

igni

o

n

IWitch

is

in

OFF

podtion

b

E

Body

Earth

Althoush

volllp

may

drop

dfshtiy

below

battery

volllp

this

Is

not

an

indication

of

abnormality

IS

No

preuure

is

applied

to

vacuum

switch

12

Vacuum

switch

and

circuit

OFF

n

Apply

a

pressure

below

21

3

kPa

160

minHg

6

30

inHg

to

vacuum

switch

by

orilly

sucking

port

bac

k

Californi

models

Bring

back

vacuum

swilch

throttle

vavel

switch

and

altitude

sensor

to

their

original

condition

IS

27

Connect

battery

negative

terminal

131

14

I

26

START

v

E

21

Ho

to

300

kn

SO

to

300

kn

Iwn

400

to

600

n

Battery

vottaa

Step

Inspection

cirCu

t

Connect

starter

motor

S

terinin

al

15

Ignition

coil

trigger

circuit

16 17 16 19

Injector

1

attery

dropping

resistor

and

injce

tor

circuits

20

Injector

2

Injector

3

Injector

4

Battery

EFI

relay

and

control

unjt

POWC

f

source

circuits

Altitude

senIOr

and

circuit

California

models

Circuit

between

battery

ignition

switch

fuel

pump

relay

2

a1ter

22

nator

and

oil

pressure

switch

Check

alternator

and

oil

pressure

switch

t

for

operatIon

21

Disconnect

oil

pressure

switch

hames

connector

Battery

ignition

switch

fuel

pump

relay

2

and

air

regulator

circuitl

Check

fuel

pump

relay

2

for

operation

23

24

Ignition

switch

Circuit

tester range

Check

terminals

A

j

I

Be

Auxiliary

operation

or

condition

1

Connect

dtemator

2

connector

uL

and

S

terminals

START

CAUTION

Exerci

care

in

performing

step

1

lIS

it

involve

turning

engine

r

ON ON ON

18

2 6

5 7

27

v

E

Standard

value

Pointer

deflects

Battery

voltage

Above

O

SY

ov

Battery

voltage

Battery

voltage

Note

a

Before

disconnecting

and

connecting

electrical

connectors

and

terminab

ensure

that

ignition

switch

i

in

uOFF

position

b

E

Body

Earth

Although

voltage

may

drop

slightly

below

battery

voltage

this

is

not

an

indication

or

abnormality

I

1

Connect

oil

pressure

switch

harness

connector

2

Disconnect

alternator

2

connector

UL

and

S

terminals

Battery

ignition

switch

fuel

pump

relay

2

and

air

regulator

circuits

Check

fuel

pump

relay

2

for

operation

m

N

28

21

v

I

21

E

v

21

E

2

Bring

air

flow

meter

back

to

its

original

condition

L

Measured

value

Judgment

J

m

Z

G

Z

m

T1

C

m

r

I

l

g

m

n

ex

EFI

CIRCUIT

DIAGRAM

FUSIBLE

LINK

o

c

FUS

BLE

LINK

c

EFI

RELAY

F

t

A

I

Ei

PUMP

REI

AV

1

e

FUSE

I

FUEL

PUMP

RELAY

2

IGNITION

SW

TCH

OFf

ON

5TA

RT

B

0

IG

0

S

0J

IG

1

0

cp

B

IGNITION

AL

TEANATOR

SWITCH

L

FUSIBLE

OIL

LINK

PRESSURE

J

SWITCH

When

engine

il

t

nopped

BATTERY

t

Aiternetor Lterminal

ON

Oil

prullure

switch

DROPPING RESISTOR

43

37 3840

4

cp

FUEL

PUMP

Whln

anaina

Is

in

operation

INJECTOACYLINOER

NO

WATER

TEMP

111

121

131

14

oo

j

11

l

N

0

l

J

IGNITION

eQ

L

2

l

7

r

14

15 18

19

l

21

24 252627

8

9

10

3233 34

t

c

f

it

GROUND

Jjln

R

Jre

11l

1O

I

DLE

FULL

U

THROTTLE

L

T

ALTITUDE

VALVE

SW

SENSOR

AlA

FLOW

Cellfornle

METER

models

A

R

TEMP

SENSOR

I

VACUUM

SWITCH

Cllllfornlll

modol

OFF

SEF183

s

i

1

0

I

m

Z

m

T1

C

m

r

ENGINE

FUEL

Component

Parts

Inspection

COMPONENT

PARTS

INSPECTION

FUEL

PRESSURE

CHECK

1

Follow

the

procedure

below

to

reduce

fuel

pressure

to

zero

CAUTION

Before

disconnecting

fuel

hose

release

fuel

pressure

from

fuel

line

to

elimi

nate

danger

I

Start

the

engine

2

Disconnect

the

harness

connector

of

fuel

pump

relay

2while

the

engine

is

running

Rel

v

br

cket

SEF131

3

After

the

engine

stalls

crank

the

engine

two

or

three

times

4

Turn

the

ignition

switch

OFF

5

Reconnect

the

harness

connector

of

the

fuel

pump

relay

2

Connect

a

fuel

pressure

gauge

between

fuel

pipe

and fuel

hose

of

fuel

ftIter

3

Start

engine

and

read

fuel

pres

sure

gauge

At

idling

Approximately

206

kPa

12

1

kg

cm2

30

psi

The

moment

accelerator

pedal

is

fully

depressed

Approximately

255

kPa

26

kg

em2

37

psi

4

If

fuel

pressure

is

not

as

specified

replace

pressure

regulator

and

repeat

fuel

pressure

check

If

below

the

specified

value

check

for

clogged

or

defonned fuel

lines

and

if

necessary

replace

fuel

pump

as

an

assembly

or

check

valve

FUEL

PUMP

FUNCTIONAL

TEST

After

disconnecting

alternator

L

terminal

or

oil

pressure

switch

connec

tor

set

ignition

switch

at

ON

posi

tion

Then

make

sure

that

fuel

pump

operating

sound

is

heard

If

not

check

all

fuel

pump

circuits

If

all

circuits

are

checked

out

OK

eplace

fuel

pump

FUEL

DAMPER

If

noise

from

fuel

pump

is

abnor

mally

loud

replace

fuel

damper

and

recheck

for

noise

FUEL

FILTER

If

the

car

is

operated

under

extreme

adverse

weather

conditions

or

in

areas

where

ambient

temperature

is

either

extremely

low

or

extremely

high

the

fuel

ftIter

might

become

clogged

In

such

an

event

replace

the

fuel

ftIter

immediately

INJECTOR

CONTINUITY

CHECK

1

Disconnect

ground

cable

from

battery

2

Disconnect

electric

connectors

from

injectors

3

Check

continuity

between

the

two

terminals

Continuity

sho

ld

exist

If

not

injectorCs

are

faulty

it

P

LJ

Tf

r

SEF144

OPERATING

SOUND

CHECK

Engine

can

run

1

Start

the

engine

and

run

it

at

idle

Attach

the

tip

of

a

screwdriver

to

each

injector

to

ensure

that

it

sounds

while

operating

2

All

injectors

are

functioning

prop

erly

if

click

sound

is

heard

at

regular

intervals

Note

however

that

as

en

gine

speed

increases

click

intervals

shorten

J

1J

1I

l

Engine

cannot

run

1

Crank

the

engine

and

check

that

injectors

produce

operating

sounds

to

indicate

operation

EF

29

ComponentParttlnspection

ENGINE

FUEL

2

If

a

different

sound

is

produced

from

any

particular

injector

that

injector

is

faulty

3

If

no

sound

is

heard

from

all

injectors

check

harnesses

referring

to

Electrical

System

Inspection

4

I

f

harnesses

are

nonnal

check

operathm

of

control

unit

PRESSURE

REGULATOR

Refer

to

Fuel

Pressure

Check

for

inspection

AIR

FLOW

METER

CHECKING

TlOMETER

Potentiometer

@

RO

t

RI

iJJ

R

iI

LJ

R

SEF146

@

I

Measure

the

resistance

between

terminals

@

and@

The

standard

resistance

is

100

to

400

ohms

EF482A

EF

30

2

Measure

the

resista

nce

between

tenninals

@

and

@

The

standard

resistance

is

200

to

500

ohms

EF483A

3

While

sliding

flap

measure

resist

ance

between

tenninals

@

and

@

If

resistance

is

at

any

value

other

t

1aJl

0

and

0Cl

ohm

air

flow

meter

is

nonnaJ

UlI

EF319A

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

out

of

order

EF327A

CHECKING

RAP

Fully

open

the

flap

by

hand

to

check

that

it

opens

smoothly

without

binding

If

it

doesn

t

it

is

out

of

order

EF318A

AIR

TEMPERATURE

SENSOR

CHECKING

INUITY

I

Measure

the

outside

air

tempera

ture

2

Measure

resistance

between

ter

minals

@

and

@

of

the

air

flow

meter

connector

3

The

relationship

between

the

out

side

air

temperature

and

resistance

is

shown

in

the

following

graph

WATER

n

MPERATURE

SENSOR

AND

AIR

TEMPERATURE

SENSOR

CHARACTERISTIC

CURVE

30

r

TC

i

EJ

r

1

r

i

0

42

1

to

2 9

k

at

20oe

3

I

6tF

8

2

O

6SIo

00

knl

at50oC

l220Fl

I

g

J

04

l

0 3

02

I

0

1

O

OS

0

06

30

20

0

20

40

60

SO

22

4

32

6S

104 140 176

Temperature

Oc

OF

EF334A

If

test

results

are

far

from

the

range

indicate

in

the

graph

the

air

tern

perature

sensor

is

out

of

order

The air

temperature

sensor

should

e

replaced

as

an

air

flow

meter

assembly

CHECKING

INSULATION

RESISTANCE

Check

insulation

resistance

between

terminal

@

ana

air

flow

meter

body

If

continuity

exists

the air

tempera

ture

sensor

is

out

of

order

The

air

terpperature

sc

nsor

and

air

flow

meter

should

be

replaced

as

an

assembly

EN

G

IN

E

FU

EL

Component

Parts Inspection

AIR

REGULATOR

I

Starting

engine

and

pinch

rubber

hose

between

intake

manifold

and

air

regulator

Engine

speed

decreases

warm

up

Engine

speed

remains

after

warm

up

during

OK

unchanged

OK

Air

regulator

Shutter

is

opened

during

engine

warm

up

thereby

increasing

quantity

of

intake

air

causi

ng

engine

speed

to

increase

Engine

speed

decreases

when

passage

is

narrowed

by

pinching

hose

during

warm

up After

warm

up

shutter

closes

Therefore

engine

speed

remains

unchanged

when

passage

is

narrowed

by

pinching

hose

after

warm

up

2

Disconnect

electric

connector

of

air

regulator

and

check

continuity

Continuity

should

exist

If

not

air

regulator

is

faulty

3

Disconnect

hoses

from

both

ends

of

air

regulator

and

visually

check

to

see

if

air

regulator

shutter

opens

The

shutter

opening

at

a

tempera

ture

of

200C

680F

is

as

shown

in

following

figure

Air

flow

rea

at

approximately

200C

6SoF

E

F328A

Directioll

of

hi

metal

movement

with

increasing

temperature

4

Pry

air

regulator

shutter

to

open

with

aflat

b1ade

screwdriver

then

close

If

shutter

opens

and

closes

smoothly

it

is

operating

properly

If

not

replace

THROTTLE

CHAMBER

1

Make

sure

that

throttle

valve

moves

smoothly

when

throttle

lever

is

manipulated

2

Make

sure

that

by

pass

port

is

free

from

obstacles

and

is

clean

Do

not

adjust

throttle

valve

stopper

screw

as

it

is

factory

adjusted

Throttle

lever

F127

DASH

POT

1

Set

engine speed

to

1

500

rpm

under

no

load

2

Check

the

dash

pot

to

make

sure

that

the

rod

end

comes

in

contact

witli

the

adjusting

screw

when

the

rod

is

fully

extended

or

when

no

back

pressure

is

presentat

the

diaphragm

Adjusting

screw

I

SEF149

3

If

necessary

adjust

the

adjusting

screw

so

that

the

rod

end

comes

into

contact

with

the

adjusting

screw

EF

31

CompOfJentParu

Inspection

ENGINE

F1JEL

WATER

TEMPERATURE

SENSOR

CHECKING

INSULATION

RESISTANCE

1

Check

continuity

between

the

sensor

body

and

each

of

the

tenni

nals

at

sensor

2

If

continuity

exists

the

sensor

is

out

of

order

CHECKING

CONTINUITY

1

Dip

the

sensor

into

water

main

tained

at

a

temperature

of

200C

680F

800C

1760F

etc

and

read

its

resistance

r

rr

EF329A

2

If

the

sensor

resistance

with

re

spect

to

the

coolant

temperature is

not

held

within

the

range

specified

in

the

graph

the

water

temperature

sensor

may

be

ot

of

order

EF

32

WATER TEMPERATURE

SENSOR

AND

AIR

TEMPERA11JRE

SENSOR

CHARACTERISTIC

CURVE

g

T

U

I

j

I

7

010114

kn al

lOoC

1401

10L

j

8

j

6

4

i

2

1

to 2 9

kn

at

lOoe

3

I I

6tF

g

21

0

68

to

1

00

kn

I

II

I

aISOoC

1220FI

Ht

i

0

3I

0

2r

0

u

gggL

1

30

20

0

20

40 60

80

1

22

4

32

68

104

140

176

Temperature

DC

COF

EF334A

THROTTLE

VALVE

SWITCH

ADJUSTING

SWITCH

POSITION

Disconnect

throttle

valve

switch

connector

2

Connect

ohmmeter

between

ter

minals

@

and

@

and

make

sure

continuity

eXists

3

Adjust

throttle

valve

switch

posi

tion

with

retaining

screw

so

that

idle

switch

may

be

changed

from

ON

to

OFF

when

engine

speed

is

specified

idle

rpm

70

rpm

M

T

Neutral

A

T

N

position

under

no

load

To

adjust

position

of

throttle

valve

switch

with

engine

off

proceed

as

follows

When clearance

A

between

throt

tle

valve

stopper

screw

and

throttle

valve

shaft

lever

is

03

mm

0

012

in

adjust

throttle

valve

switch

position

so

that

idle

switch is

changed

from

ON

to

OFF

If

clearance

between

throttle

valvo

stopper

screw

and

throttle

valve

shaft

lever

is

03

mm

0

012

in

engine

speed

will

become

specified

rpm

Shim

Changing

idle

switch

from

ON

to

OFF

correspond

to

change

from

0

to

infinite

ohms

in

resist

ance

between

terminals

@and@

CHECKING

fULL

THROTTLE

cONTAcT

1

Connect

ohmmeter

between

ter

minals

@

and

@

and

make

sure

continuity

does

not

exist

o

i

SEF153

2

Depress

accelerator

pedal

to

floor

If

continuity

exists

between

tenninals

@

and

full

throttle

contact

is

functioning

properly

CHECKING

INSULATION

RESISTANCE

1

o

SEFl54

Connect

ohmmeter

between

engine

and

tenninals

@

and

@

Ohm

meter

reading

mould

be

infInite

VACUUM

SWITCH

1

Remove

vacuum

switch

2

Connect

the

test

lead

wire

as

follows

3

Measure

the

output

voltage

Conditions

Output

voltage

No

pressure

is

ap

plied

to

vacuum

switch

Approximately

battery

voltage

Apply

a

pressure

below

21

3

kPa

160

mmHg

6

30

inHg

to

OV

vacuum

switch

by

orally

ucking

port

back

4

If

the

test

results

are

not

the

specifications

the

vacuum

switch

is

malfunctioning

ENG

INE

FU

EL

Component

Parts

Inspection

Vacuum

gauge

11

Resistance

lkn

Voltmeter

I I

EB

ova

o

0

Regstan

30kn

Battery

12V

o

SEF324

ALTITUDE

SENSOR

I

Connect

the

test

lead

wires

as

follows

i

Battery

Jf

12V

III

Voltmeter

0

4

SEF166

2

Measure

the

output

voltage

More

thOriO

5V

O

K

3

If

the

test

results

are

not

the

speCification

the

altitude

sensor

is

malfunctioning

43

and

38

No

2

cylinder

43

and

37

No

1

cylinder

The

resistance

should

be

mately

6

ohms

approxi

O

K

DROPPING

RESISTOR

Conduct

resitance

checks

on

drop

ping

resistor

between

the

following

points

43

and

41

No

4

cylinder

43

and

40

No

3

cylinder

l

SEF155

EF

33

Cpmpopentp

ral

5Per

Von

N

INE

FUEL

RELAY

I

Disconnect

battery

ground

cable

2

Remove

relay

from

car

3

Test

continuity

through

relay

with

an

ohmmeter

in

accordance

with

EFI

relay

and

fuel

pump

relay

I

rp

Chcck

terminals

d

1

nu

j

@

1

@

Fuel

pump

relay

2

the

following

chart

Normal

condition

112V

direct

current

iI

ppUed

I

bet

t

uololls

CDond@

Tell

resultl

CoatiDuity

f

Yea

No

Yes

Ya

No

Yes

Coritiilufty

should

ex

iIt

No

Continuity

IhotiId

not

abt

IZVIliNct

aIIfIW

I

2

J

l

T

D

t

I

NDnIaI

@@

7

nau

0tndIaIIlt

y

No

No No

y

No

y

CONTROL

UNIT

CHECKING ELECTRIC

IGNAL

TO

INJECTORS

I

Inspection lamp

as

shown

in

figure

b

low

is

required

for

thiS

test

E

F353

Make

inspection lamp

as

follows

1

Prepare

12V 3W

lamp

2

Prepare

socket

and

set

lamp

in

it

EF

34

ac

kll

l

llllilod

l

CD

00

@@

j

@

j

@

3

Use

flat

plate

tenninals

3

mm

0

12

in

wide

0 8

mm

0

031

in

thick

as

male

terminals

Place

flat

plate

terminals

parallel

with

each

other

and

keep

distance between

inside

faces

2

mm

0

08

in

The

n

secUre

terminals

by

wrapping

insulation

tape

or

with

suitable

terminal

body

2

Disconnect

injector

harness

con

nector

3

Connect

inspection

lamp

to

injec

tor

harness

connector

YQ

C

cUII

CO

1inulll

nol

alA

c

ct

ao

c

Ir

I

SEFl56

4

Starting

engine

or

cranking

en

gine

check

iitspection

lamp

to

see

if

it

flashes

at

regular

interval

If

so

elec

ttic

signals

are

being

properly

trans

mitted

to

injectors

aThe

engine

should

be

cranked

at

a

speed

of

more

tJ

IariSO

rpm

b

The

control

unit

may

fail

to

gener

ate

a

correct

pulse signal

at

an

excessiwely

low

battery

voltage

It

is

recomm

nded

therefore

that

a

battery

voltage

of

more

than

9

volts

be

applied

during

the

cranking

operation

CHECKING

FUEL

SHUT

OFF

FUNCTION

1

Wann

up

engine

sufficiently

2

Connect

inspection

lamp

to

injec

tor

harness

connector

Automatic

transmission

models

3

000

2

600

e

0

2

200

51

5

t

800

t

400

1

000

EN

GIN

E

FU

EL

Component

Parts

Inspection

3

Increase

engine

speed

to

each

zone

respectively

and

release

acce

lerator

pedal

Check

inspection lamp

illumination

Check

inspection

lamp

with

engine

speed

ill

each

zone

as

shown

in

chart

below

While

inspection

lamp

is

off

fuel

shut

off

is

operational

Manual

transmission

m

els

3

000

I

2

600

1

@

e

2

200

0

51

1

800

c

1

400

1

000

@

Cooling

water

temperature

at

80

C

1760F

C

ECKING

AIR

LEAKAGE

IN

AIR

INTAKE

SYSTEM

Make

sure

even

a

slight

air

leak

does

not

occur

When

inspecting

the

electronic

fuel

injection

system

pay

particular

atten

tion

to

hose

connections

dipstick

oil

filler

cap

etc for

any

indication

of

air

leaks

Since

the air

flow

meter

used

in

the

electronic

fuel

injection

system

directly

measures

the

quantity

of

in

take

air

to

permit

the

supply

of

the

optimum

fuel

quantity

for

each

cylin

der

CHECKING

FUEL

HOSES

Check

fuel

hoses

for

leakage

loose

@

Cooling

water

temperature

at

800C

1760F

connections

cracks

or

deterioration

Retighten

loose

connections

and

replace

any

damaged

or

defonned

parts

Replace

any

fuel

hose

whose

inner

surface

is

deformed

scratched

or

chafed

For

replacement

of

high

pressure

fuel

hose

refer

to

Fuel

Hose

under

the

heading

Removal

and

InstaUation

EF

35

Service

OatasndSpecificatiom

ENGINE

FUEL

SERVICE DATA

AND

SPECIFICATIONS

GENERAL

SPECIFICATIONS

I

Design

voltage

V

12

fuel

I

Cut

off

di

kPa

t

cm2

294

44113

0

4

5

pump

charge

pressure

psi

43

641

Design

current A

5

1

Pressure

Regulated

kpa

kg

em

2SO 12

55 36

31

regulator

pressure

psi

I

Airflow

Design

voltage

V

12

I

meter

Design

voltage

V

12

I

Air

regulator

Air

flow

quantitY

mcuft

hr

19

0

611l

I

IAt

200C

I68

FlJ

i

votteee

V

12

I

Control

Consumption

wattage

I

unit

At

idling

W

15

At

full

throttle

W

140

J

INSPECTION

AND

ADJUSTMENT

fuel

pressul

B

A

dr

measure

t

1n9

iog

point

between

The

moment

acce

kPa

I2

fuel

eretor

pedal

is

kg

em

Approx

255

2

6

37

filter

and

fully

depre1sed

PSI

fuel

pi

kPa

kg

em

Appro

206

12

1

301

PII

Fuel

Coil

resistance

injector

n

2

35

Airflow

@@

n

100

400

metar

Potentia

@ @

fl

200

SOO

meter

@@

resistance

fl

Except

0

and

Air

tem

peratu

re At

tOOC

t4OFI

kfl

1

0

114

sensor

water

tempera

At

200C

168OF

kfl

2

1

29

lUre

sensor

therml

tor

re

At5O

C

t22

F

kfl

0 68

1

0

sistance

Air

Heater

coil

25

90

reQulstor

resistance

n

Engine

speed

Specified

idle

rpm

Throttle

wh

dl

ch

70

in

Neutn

I

enl

l

SWlt

va

is

changed

from

rpm

MfT

in

N

pasi

SWitch

ON

to

OFF

tion

AfT

EF

36

I

Dash

pot

T

ou

h

speed

rpm

Approx

1

500

Vacuum

Manifold

vacuum

when

vacuum

Approx

21

3 kPa

switch switch

is

changed

from

OFF

160

mmHg

to

ON

6

30

i

Hil

I

Altitude

Output

voltage

V

Above

05

leos

or

IDr

ing

Resistance

fl

Approx

6

resistor

Per

resistor

TIGHTENING

TORQUE

I

Unit

N

m

ft

lb

I

Throttle

chamber

I

A

IhOSl

clBn

lp

Futtl

hose

clBr11ping

position

18 22

1

8 2

2

13

16

1

0

1

5

0

1

0 15

0

1

11

3mmIO

l2in

Q

EF336A

EN

GIN

E

FU

EL

Trouble

Diagnoses

and

Corrections

TROUBLE

DIAGNOSES

AND

CORRECTIONS

TROUBLE

SHOOTING

CHART

The EFl

system

can

be

checked

in

accordance

with

the

trouble

shooting

chart

If

any

abnonnaIity

is

found

in

any

inspection

item

refer

to

the

Inspec

tion

section

and

carry

out

further

inspection

following

the

procedures

described

therein

Note

that

any

component

part

excepting

some

of

the

EFI

system

must

be

replaced

as

an

assembly

if

it

is

found

to

be

faulty

since

no

repairing

is

allowed

Checke

before

inspection

Before

attempting

any

test

check

the

following

items

to ensure

that

nothing

has

been

overlooked

I

The

greatest problem

source

with

a

system

of

this

type

lies

in

the

connections

between

components

Condition

Save

time

by

perfonning

a

quick

check

if

all

harness

connecton

espe

cially

the

35

connector

and

air

flow

meter

connector

are

securely

in

place

Connector

terminals

are

free

from

corrosion

and

deformation

Pull

all

connecton

off

and

recon

nect

after

inspecting

terminals

2Since the

EFI

system

accurately

meters

the

intake

air

flow

through

an

air

flow

meter

even

a

slight

air

leak

will

cause

an

improper

air

fuel

ratio

resulting

in

faulty

engine

operation

due

to

excessive

air

For

this

reason

a

thorough

inspec

tion

for

leaks

should

be

made

at

the

oil

ftller

cap

dipstick

blow

by

hoses

air

flow

meter

to

throttle

chamber

air

duct

etc

3

Make

sure

the

ignition

and

start

ing

systems

are

satisfactory

and

the

battery

is

in

good

condition

Probable

cause

Engine

will

not

start

or

hard

to

start

Improper

ignition

system

Intake

air

leakage

at

following

points

P

C

V

valve

V

C

valve

dipstick

seal

oil

ftller

cap

blow

by

hoses

Air

flow

meter

hoses

and

clamps

Manifold

gaskets

etc

Fuel

pump

does

not

work

Improper

ignition

signal

input

Inspection

Instructlone

Before

checking

the

EFI

system

be

sure

to

observe

the

instructions

below

Failure

to

do

so

could

result

in

damage

to

the control

unit

or

cause

fuel

line

leakage

CAUTION

When

connecting

or

disconnecting

EFI

harness

connector

to

or

tom

any

EFI

unit

enlUre

that

the

ignition

switch

is

in

the

OFF

position

and

that

the

I

battery

terminal

is

discon

nected

Removing

and

ins18l1ing

the

connectors

with

the

ignition

switch

left

in

the

ON

position

will

damage

control

unit

Replace

fuel

hoses

if

they

are

de

fonned

scratched

or

chafed

Do

not

reuse

fuel

hose

clamps

after

removal

Check

and

corrective

action

Disconnect

high

tension

cable

from

one

spark

plug

and

check

for

hot

spark

Check

for

intake

air

leaks

and

repair

or

replace

if

necessary

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

Check

ignition

signal

input

EF

37

Trouble

Diagnoses

and

ComJCtion

ENGINE

FUEL

Condition

Engine

starts

then

stalls

EF

38

Probable

cause

Malfunctioning

EFI

relay

or

control

unit

or

injector

Problem

in

the

following

circuits

Vater

temperature

sensor

Air

flow

meter

potentionietef

Start

signal

circuit

Poorly

chaIged

battery

Improper

ignition

signal

input

Malfunctioning

EFI

relay

or

control

unit

or

injector

Fuel

pump

does

not

work

Check

and

corrective

action

Connect

a

lead

wire to

ignition

coil

negative

terminal

With

ignition

switch

ON

attach

other

end

of

leadwire

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

break

check

the

following

circuits

e

Water

temperature

sensor

Air 0

lJleter

po

tent

ete

r

Start

signal

cirelli

t

Air

regulator

b

Injectors

do

not

click

check

the

follow

ing

circuits

Control

unit

power

input

circuit

Ignition

coil

trigger

input

circuit

Control

unit

ground

circuit

e

Injector

circuit

Check

each

circuit

Then

proceed

to

Com

ponent

checks

Check

charge

circuit

Recharge

battery

if

necessary

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

a

short

period

and

repeat

it

rapidly

listen

to

each

injector

sound

with

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

circuit

With

ignition

switch

in

ON

position

dis

connect

oil

pressure

switch

harness

connec

tor

alternator

L

tenninal

Listen

for

fuel

pump

and

pressure

regulator

operating

sound

If

no

sound

is

heard

check fuel

pump

con

trol

circuit

Condition

Engine

idles

too

fast

cannot

be

adjust

ed

with

idle

speed

adjusting

screw

or

en

gine

idle

is

unstable

Engine

misfIres

ENGINE

EUEL

Trouble

Dia9nosessnd

Corrections

Probable

cause

Improper

wate

temperature

sensor

circuit

iI

Malfunctioning

air

regulator

Improper

intaJ

e

an

exhaust

valve

clearance

Malfunctioning

throttle

valve

Malfunctioning

air

regulator

rJ

r

l

Improper

ignition

circuit

Improper

EFI

harness

connectors

Improper

fuel

line

Check

and

corrective

action

Then

proceed

to

the

following

checks

Fuel

pump

Alternator

L

tenninal

Oil

pressure

switch

Fuel

pump

relays

I

and

2

Check

circuit

Check

air

regulator

and

replace

if

necessary

Note

If

these

tests

are

satisfactory

prOceed

to

Engine

will

not

start

Adjust

valve

clearance

Check

that

plate

is

closing

when

throttle

is

released

and

replace

if

necessary

To

check

air

regulator

proceed

to

the

following

steps

Start

engine

Pinch

off

hose

to

air

regulator

Results

al

If

idle

speed

drops

perfonn

circuit

test

If

no

fault

is

found

replace

air

regulator

b

If

idle

speed

remains

high

or

unstable

perfonn

the

following

checks

Check

for

manifold

vacuum

leaks

includ

ing

at

P

CV

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

temperature

sensor

Water

temperature

sensor

Control

Jtit

ground

circuit

Air

flow

meter

potentiometer

Air

regwator

and fuel

pump

circuit

Ignition

coil

trigger

input

circuit

Control

unit

power

input

circuit

1

Inj

ctor

circuit

Then

proceed

to

Component

checks

Check

ignition

circuit

Pull

EFI

harness

connectors

apart

and

check

for

looseness

and

corrosion

including

groimd

circuits

Do

not

forget

ignition

in

put

lead

Check

fuel

line

for

blockage

Tank

strainer

Fuel

filter

Injectors

Fuel

pipes

EF

39

Trouble

Oisgnosesand

Corrections

ENGINE

FUEL

Condition

Engine

will

not

re

volve

lack

of

power

Hesitation stumble

on

acceleration

EF

40

Probable

cause

Malfunctioning

control

unit

Improper

fuel

pressure

improper

EFI

circuit

Lor

t

f

ignition

system

Malfunctioning

throttle

valve

Malfunctioning

air

flow

meter

Improper

fuel

line

Improper

fuel

pressure

Problem

in

the

followiIlg

circuits

Ignition

coil

trigger

input

circuit

Control unit

power

input

circuit

Injector

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

ator

and fuel

pump

circuit

Improper

ignition

system

Malfunctioning

air

flow

meter

Intake

air

leakage

at

following

points

P

C

V

valve

V

C

valve

Dipstick

and

oil

filler

cap

seals

Manifold

gaskets

Air

flow

meter

hoses

etc

Improper

fuel

pressure

Improper

idle

CO

ll

adjustment

Improper

EFI

circuit

Check

and

corrective

action

Tap

control

unit

while

driving

to

see

if

this

aggravates

or

aIleviates

the

problem

If

so

try

another

control

unit

Perfonn

fuel

pressure

test

Perfonn

all

circuit

tests

Then

perfonn Component

checks

Check

IC

ignition

unit

pick

up

coil

and

igni

tion

coil

Make

sure

throttle

plate

is

opening

fully

when

accelerator

is

fuI1ydepressed

Check

air

flow

meter

mechanical

movement

Using

a

finger

push

flap

open

checking

that

it

opens

smoothly

and

fully

Check

fuel

line

for

blockage

Tank

strainer

Fuel

fdter

Fuel

pipes

Perfonn

fuel

pressure

test

Check

each

circuit

Thin

perfonn

Component

checks

Check

ignition

system

Check

air

flow

meter

mechanical

movement

Using

a

finger

check

for

smooth

flap

move

ment

Check

for

intake

air

leaks

Perfonn

fuel

pressure

test

Check

idle

CO

ll if

necessary

adjust

it

Perfonn

complete

circuit

test

Then

perfonn

Components

checks

Condition

Poor

gas

mileage

or

CO

reading

too

high

Surge

Backf

uing

ENGINE

FUEL

Trouble

Diagnoses

and

Corrections

Probable

cause

Improper

ignition

timing

or

ignition

system

Improper

air

cleaner

f1lter

Improper

fuel

pressure

Problem

in

the

following

circuits

Water

temperature

sensor

Air

temperature

sensor

Throttle

valve

switch

idle

contact

and

full

throttle

contact

Vacuum

switch

Air

flow

meter

potentiometer

Air

regulator

and fuel

pump

circuit

Injector

cirelli

ts

Malfunctioning

air

flow

meter

Intake

air

leakage

at

the

following

points

P

C

v

valve

Dipstick

and

oil

ftller

cap

seals

Manifold

gaskets

Air

flow

meter

hoses

etc

Improper

fuel

pressure

Improper

idle

CO

adjustment

Problem

in

the

followirig

circuits

Throttle

valve

switch

idle

contact

and

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

Intake air

leakage

at

the

following

points

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

Check

and

corrective

action

Check

ignition

timing

Check

ignition

system

for

hot

spark

Check

air

cleaner

f1lter

and

replace

if

necessary

Perfonn

fuel

pressure

test

Check

each

circuit

Then

proceed

to

Component

checks

Check

air

flow

meter

mechanical

movement

Using

a

fmger

check

flap

movement

for

smooth

operation

Check

for

intake

air

leaks

Perfonn

fuel

pressure

test

Check

idle

CO

if

necessary

adjust

it

Check

each

circuit

Then

proceed

to

Component

checks

Check

for

intake

air

leaks

Perf

nn

fuel

pressure

test

Check

idle

CO

if

necessary

adjust

it

EF

41

Trouble

Diagnoses

and

Corrections

ENGINE

FUEL

Condition

Probable

cause

Problem

in

the

folloWing

circuits

e

Throttle

valve

switch

idle

contact

and

fulllhrottle

contact

Vacuum

switch

e

Aidlow

meter

potentiometer

Air

temperature

sensor

e

Water

temperature

sensor

Altitude

sensor

e

Ignition

coil

trigger

input

circuit

e

Control

unit

power

input

circuit

e

Injector

circuit

Afterfire

or

a

g

Problem

in

the

following

circuits

Throttle

valve

switch

idle

contact

and

fulllhrottle

contact

Vacuum

switch

e

Air

flow

meter

potentiometer

Air

temperature

sensor

Water

temperature

sensor

Injection

circuit

e

START

signal

input

Check

and

corrective

action

Check

each

circuit

Then

proceed

to

the

Component

checks

Check

each

circuit

Then

proceed

to

Component

checks

COMPONENT

CHECKS

To

be

performed

only

after

circuit

tests

are

completed

Control

Air

flow

meter

Fuel

system

Problem

Injector

Air

unit

Flap

Relay

Resist

sound

regulator

replace

Fuel

pres

Injector

opera

ance

leakage

ment

sure

test

tion

means

Engine

will

not

start

XX

I

X

XX

X X X

Idle

too

high

or

too

rougli

XX

I

XX

Engine

misfires

X

I

XX X X

Lack

of

power

engine

XXX X X

will

not

rev

Hesitation

stumble

XXXX

Poor

gas

mileage

or

X

X X

X

CO

too

high

Engine

surgAs

I I

XXXXX

Backfiring

II

XXXX

Afterbuming

II

X

XX

X

EF

42

CHECKING

AND

ADJUSTING

IDLE

RPM

IGNITION

TIMING

AND

MIXTURE

RATIO

PRECAUTION

a

To

discourage

tlImpering

with

the

idle

mixtu

adjus1

ing

screw

on

California

model

it

is

sealed

withH

steel

blind

plug

attar

adjustment

of

idle

mixture

at

factory

So

the

blind

plug

should

not

be

removed

during

routine

maintenance

except

that

case

as

directed

by

official

in

spection

to

lower

exhaust

emis

sion

b

Adjusting

mixture

uling

other

than

the

method

below

may

violate

federal

and

or

California

or

other

tate

and

provincial

laws

Inspection

procedure

EN

GIN

E

FU

EL

Trouble

Diagnoses

and Corrections

Preparation

1

Make

sure

that the

following

parts

are

in

good

order

Battery

e

gnition

system

E

F

I

harness

connectors

Vacuum

hoses

Ai

intake

system

Oil

filler

cap

oil

level

gauge

etc

2C

onnect

engine

tachometer

and

timing

light

in

their

proper

positions

3

When

measuring

CO

insert

probe

int

tail

pipe

more

than

0 4

m

16

inl

4

Use

CO

meter

after

it

is

fully

warm

d

up

5

On

air

conditioner

equipped

models

checks

should

be

carried

out

while

the air

conditioner

i

OFF

START

Start

engine

and

warm

up

engine

until

waL

temperature

indicator

points

to

he

middle

of

gauge

Open

engine

hood

Run

engine

at

about

2

000

rpm

for

about

2

minutes under

no

load

SMA021

1

Run

engine

at

idling

speed

For

Canada

I

u

S

A

For

Disconnect

hose

from aii

indUction

pipe

and

install

proper

cap

on

air

induction

pipe

t

Race

engine

two

or

three

times

under

no

load

Then

run

e e

for

one

minute

at

idle

speed

Check

idle

speed

MfT

700

z

tOO

rpm

AfT

700

t

100

rpm

Un

0

position

O K

N G

6

On

automatic

transmission

equip

pad

models

checks

should

be

carried

out

while

shift

lever

is

in

0

position

WARNING

a

When

selector

lever

is

shifted

to

0

position apply parking

brake

and

block

both

front

and

rear

wheels

with

chocks

b

When

racing

engine

on

auto

matic

transmission

equipped

models

make

Rife

that

shift

lever

is

in

N

or

Pposition

and

depress

brake

pedal

to pre

vent

forward

RI

rge

of

car

c

After

the

adjuS1ment

has

been

made

shift

the

lever

to

the

N

or

P

position

and

remove

wheel

shocks

S

M

f

SMA263

Adjust

idle

speed

by turning

idle

spee4

ad

justing

screw

I

@

EF

43

Trouble

Diagno

eund

Cof1l

Ctions

ENGINE

fUEL

I

Does

engine

run

smoothly

YES

r

I

Note

Alter

drilling

be

ure

to

I

remove

dlaviDgs

and

dUll

L

1

EF

44

@U

jiJ

@

@@

OIeck

ignition

timing

with

timing

Ught

Nol1

Cllifomia

Californil

a

zo

a

T

D C

6

ZO

B

T D C

O K

J

N

G

I

Adjust

ignition

timing

by turning

distributor

I

aftedoosening

bolts

which

secure

distributor

I

Race

engine

two

or

three

times

under

n

load

then

run

engine

at

idle

Ipced

r

O K

I

N

G

I

f

0Ieclr

idle

CO

with

CO

meter

O K

Non

C

liforni

C

lifornia

t

31

1

0

less

than

4

I

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

Remove

blind

plug

from air

by

PUl

SCItW

on

air

flow

meter

Californi

models

Steel

plug

Non

califomia

models

Rubber

plug

Noii

canrornia

models

Race

engine

two

or

tluee

times

under

no

load then

run

engine

at

idling

speed

@

SMA059

Correct

or

replace

malfunctioning

parts

California

models

I

Turn

off

engme

and

remove

air

flow

meter

from

cu

t

Drill

a

hoJi

in steel

plug

wbich

seab

air

by

pass

screw

and

remove

steel

plug

r

Imta11

air

flow

meter

on car

Start

engine

and

warm

up

engine

until

ter

temperature

indicator

pOints

to e

middle

of

gauge

@

Only

for

non

owrOtnia

models

When

adjUltina

idle

CO

at

high

altitude

adjust

to

obtain

foUowing

val

Unit

m

ft

I

Altitude

Idle

CO

I

600

1

200

2

7

2

000

4

000

I

1

200

1

800

38

4

000

6

000

iI

Above

1

800

5

0

6

000

For

Canada

n

ENGINE

FUEL

Trouble

Disgnosesand

Correcrions

n

cp

Adjust

CO

by turning

air by

pass

screw

on ai

r

flow

meter

Idle

CO

1

3

1

0lI

IN

G

Not

adjustable

in

this

case

Comct

or

replace

air

flow

meter

or

other

malfunctioned

parts

of

fuel

injection

SYstem

Non

alifornia

models

Air

by

pass

screw

SE

F348

For

U

S

A

For

Canada

I

For

U

SA

Turn

off

engine

and

connect

air

induction

hose

to

air

induction

pipe

I

Start

engine

t

Race

engine

two

or

three

times

under

no

J

load

then

run

engine

at

idle

L

Oleck

idle

speed

MfT

7OO

100rpm

AfT

700

1

100

rpm

in

0

position

O

K

I

N G

END

I

O

K

@

SMA061

Install

blind

plug

on

air

flow

meter

I

California

Non

Calitom

e

HIM

steel

plug

Original

rubber

plug

California

models

Turn

off

engine

and

remove

air

flow

meter

from

Cat

I

Insert

new

steel

plug

fumi

hed

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

I

Install

air

flow

meter

on

Cat

Start

engine

and

warm

up

engine

until

water

temperature

indicator

points

to

the

middle

of

gauge

L

r

Adjust

idle

speed

by turning

idle

speed

ad

justing

screw

EF

45

DATSUN

200SX

Model

S

r r

0

Series

SECTIONEC

EMiSSiON

CONTROL

SYSTEM

CONTENTS

EMISSION

CONTROL

DEVICES

GENERAL

DESCRIPTION

CRANKCASE

EMISSION

CONTROL

SYSTEM

DESCRIPTION

INSPECTION

EXHAUST

EMISSION

CONTROL

SYSTEM

DESCRIPTION

AIR

INDUCTION

SYSTEM

A

I

Sl

EXHAUST

GAS

RECIRCULATION

E

G

R

l

CONTROL

SYSTEM

EC

2

EC

3

EC

5

EC

5

EC

5

EC

6

EC

6

EC

6

EC

9

SPARK

TIMING

CONTROL

SYSTEM

DECELERATION

CONTROL

SYSTEM

I

lntake

manifold

vacuum

control

type

CATALYTIC

CONVERTER

EVAPORATIVE

EMISSION

CONTROL

SYSTEM

DESCRIPTION

OPERATION

INSPECTION

SERVICE

DATA

AND

SPECIFICATIONS

TIGHTENING

TORQUE

EC

15

EC1

EC

17

EC19

EC

20

EC

21

EC

23

EC

23

Pl

EMISSION

CONTROL

DEVICES

i

o

Engine

model

Z20E

SIlO

Car

model

a

Non

California

models

California

models

Canada

models

li

for

U

s

A

a

Item

M

T

A

T

M

T

A

T

M

T

A

T

I

Air

inlet

Fresh

air

duct

X

m

system

Air

pipe

X

Cii

Air

flow

meter

X

C

l

Throttle

chamber

2

barrel

X

5

Z

Air

temperature

sensor

X

C

Air

Fuel

Throttle

valve

switch

X

0

Z

system

Vacuum

switch

X

I

0

Air

regulator

X

0

r

Water

temperature

sensor

X

C

l

Altitude

sensor

X

C

l

IC

ignitor

for

I

plug

X

I

Ignition

m

system

IC

ignitor

for

2

plugs

X

3

Water

temperature

control

X

I

X

Exhaust

air

induction

system

Type

A

X

A

I

S

Exhaust

air

induction

system

Type

B

X

E

G

R

system

with

V

T

valve

Type

1

X

E

G

R

E

G

R

system

with

V

T

valve

Type

2

X

system

E

G

R

system

with

B

P

T

valve

Type

3

X

Catalyzer

Catalytic

converter

X

Evaporator

system

Canister

X

Crankcase ventilation

Positive

crankcase

ventilation

P

C

V

valve

X

system

EMISSION CONTROL SYSTEM

General

DeScription

ENERAL

DESCRIPTION

There

are

three

types

of

control

systems

which

are

as

follows

1

Closed

type

crankcase

emission

control

system

2

Exhaust

emission

control

system

3

Evaporative

emission

control

system

Periodic

inspections

and

necessary

servicing

of

these

systems

should

be

perfonned

to

keep

hannful

emissions

to

a

minimum

CALIFORNIA

MODELS

Vacuum

control

valve

Throttle

chamber

lntake

manifold

Airregulator

01IL

IT

11

1

en

I

Airpipe

i

I

T

n

f

i

rr

J

u

c

j

tP

Catalytic

convert

r

j

i

f

o

C

r

I

Ii If

1

Idle

adjust

a

ew

umt

lj

r

Distributor

i

f

A

I

tube

Canister

l

L

Air

induction

valve

J

Ail

cleaner

Thermal

vacuum

valve

Ported

vacuum

Distributor

Ported

vacuum

EG

R

Air

Venturi

vacuum

Manifold

vacuum

Q

0

Canister

purge

Secondary

air

Carbon

monoxide

hydrocarbon

Carbon

dioxide

gas

water

Fuel

tank

vapor

vent

line

BEeoo

EC

3

General

De

Cription

EMISSION

CONTROL SYSTEM

NoN

CALIFORNIA

MODELS

For

U

S

A

Vacuum

control

valve

Intau

Thenn2

ftOUum

valve

Throttlechamber

mmifOId

G

R

ntve

Airregulator

r

ta

H

BP

tube

ell

I

n

il

b

i

1

II

VV

T

Valve

Air

pipe

0

f

I

raL

I

1

I

no

l

Tv

1J

J

E

G

R

tube

I

JI

J

t

J

l

u

1

b

J

S

II

t

C2Wytic

cooverler

II

C

MalfIOr

t

ldIeadjusls

unit

f

J

Distributor

r

t

EA

I

lube

Omister

y

f

dL

Air

mducti

valve

1

J

Air

cleaner

Fuel

tank

vapor

vent

line

CANADA MODELS

Intake

manif

ld

acuum

con

t

vacuum

vaIve

Throttle

chamber

E

GR

val

n

i

ii

M

pipe

1

kL

Ji

1

J

BP

T

val

J

II

I

II

I

E

GR

tube

7

1

gr

21

r

ta

yticcon

rter

Y

JA

J

Muffier

Idle

adjust

saew t

II

t

1t

1

J

F

Distributor

Canister

Fuel

tank

vapor

vent

line

EC

4

1

Ported

vacuum

Distributor

Porled

vacuum

E

G

R

Venturi

vacuum

Air

Canister

purge

Q

Secondary

air

Oirbon

monoXide

hydrocarbon

Carbon

dioxide

gas

water

SECOO2

Ported

vacuum

Distributor

Ported

vacuum

E

G

R

Air

Canister

purge

Q

9

Exces

sair

Carbon

monoxide

hydrocarbon

Cubon

dioxide

gas

water

SECOO3

EM

ISSION

CONTRO

L

SYSTEM

Crankcase

Emission

Control

System

CRANKCASE

EMISSION

CONTROL

SYSTEM

DESCRIPTION

Tills

system

returns

blow

by

gas

to

both

the intake

manifold

and

air

pipe

The

positive

crankcase

ventilation

P

C

V

valve

is

provided

to

conduct

crankcase

blow

by

gas

to

the

intake

manifold

During

partial

throttle

operation

of

the

engine

the

intake

manifold

sucks

the

blow

by

gas through

the

P

C

V

valve

Nonnally

the

capacity

of

the

valve

is

sufficient

to

handle

any

blow

by

and

a

small

amount

of

ventilating

air

Seal

type

oil

level

gauge

The

ventilating

air

is

then

drawn

through

the

tube

connecting

air

pipe

to

rocker

cover into

the

crankcase

Under

full

throttle

condition

the

manifold

vacuwn

is

insufficient

to

draw

the blow

by

flow

through

the

valve and

its flow

goes

through

the

tube

connection

in

the

reverse

diIee

lion

On

cars

with

an

excessiveiy

high

blow

by

some

of

the

flow

will

go

through

the

tube

connection

to

air

pipe

under

all

conditions

Flame

arrester

iC

Intake

manifold

J

v

l

T

r

J

Air

L

pipe

R

Throttle

chamber

P

C

V

valve

Steel

net

Fresh

air

Blow

by

gas

SECOO4

INSPECTION

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

should

be

felt

immediately

when

a

finger

is

placed

over

valve

inlet

VENTILATION

HOSE

1

Check

hoses

and

hose

connections

for

leaks

2

Disconnect

all

hoses

and

dean

with

compressed

air

If

any

hose

cannot

be

free

of

obstructions

replace

Ensure

that

flame

arrester

is

surely

inserted

in

hose

between

air

pipe

and

rocker

cover

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

California

models

Air

induction

system

Type

A

Air

induction

valve

EA

tube

Type

2

E

G

R

valve

Thermal

vacuum

valve

3

port

type

TYpe

A2 A3

VV

Tvalve

Thermal

vacuum

valve

3port

type

Type

A2

A3

Catalytic

converter

E

G

R

system

Spark

timing

control

system

Catalyst

AIR

INDUCTION

SYSTEM

A I

S

Non

California

models

for

U

S

A

Type

B

Air

induction

valve

E

A

tube

Type

1

E

G

R

valve

Thennal

vacuum

valve

3

port

type

TYpe

A

I

A3

VV

T

valve

Thennal

vacuum

valve

3

port

type

Type

A

I

A3

Catalytic

converter

exhaust

manifold

The

exhaust

pressure

in

the

exhaust

manifold

usually

pulsates

in

response

to

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

DESCRIPTION

The

air

induction

system

A

I

S

is

designed

to

send

seco

dary

air

to

the

exhaust

manifold

utilizing

a

vacuum

caused

by

exhaust

pulsation

in

the

I

Type

A

Canada

models

Type

3

E

G R

valve

Thennal

vacuum

valve

2

port

type

BP

T

valve

Catalytic

converter

vacuum

conditions

secondary

air

can

be

drawn

into

the

exhaust

manifold

in

proportion

to

the

vacuum

Therefore

the

air

induction

system

A

I

S

reduces CO

and

HC

emissions

in

exhaust

gases

The

system

consists

of

two

air

induction

valves

a

filter

and

hoses

Aircleaner

cy

Injector

Wf

E

A

l

tube

EC

6

n

II

SECOO6

EM

ISSION

CO

NTROL

SYSTEM

Exhaust

Emission

Control

System

Type

B

Air

induction

valve

Air

cleaner

Filter

Exhaust

manifold

E

A

tube

SECOC

Air

induction

valve

Two

reed

valves

are

installed

in

the

air

cleaner

When the

exluiust

pressure

is

below

atmospheric

pressure

nega

tive

pressure

secondary

air

is

sent

to

the

exhaust

manifold

When

the

exhaust

pressure

is

above

atmospheric

pressure

the

reed

valves

prevent

secondary

air

from

being

sent

back

to

the

air

cleaner

Air

induction

valve

case

I

The

air

induction

valve

case

which

consists

of

two

reed

valves

a

valve

case

and

a

fIlter

is

attached

to

the

air

cleaner

There

are

two

types

of

air

induc

tion

valve

cases

The

type

A

is

equip

ped

with

two

hose

connectors

and

is

installed

on

California

models and

the

type

B is

equipped

with

one

connector

and

is

installed

on

all

non

Californla

models

except

Canada

EC921

Type

A

To

exhaust

manifold

1

Air

Induction

pipe

The

secondary

air

fed

from

the

air

induction

valve

goes

through

the

EA

tube

to

the

exhaust

manifold

SEC009

n

MO

Dlkwrtd

iillQl

Air

filter

SEC059

Type

A

rEAl

pipe

Z

From

air

induction

valve

Type

B

To

exhaust

manifold

Airinduction

valve

S

al

e

mg

rubber

1

LAirfi

er

SEC060

Air

induction

valve

filter

The

air

induction

valve

fIlter

is

in

stalled

at

the

dust

side

of

the

air

cleaner

It

purifies

secondary

air

to

be

sent

to

the

exhaust

manifold

EC

7

Exhaust

Emission

Control

System

EM

ISSION

CO

NTROL

SYSTEM

Type

B

E

A

I

pipe

REMOVAL

AND

INSTALLATION

Air

Induction

valve

and

filter

Remove

the

valve

and

fIlter

on

the

air

cleaner

The

air

induction

valve

and

valve

fIlter

can

then

be

taken

out

easi

ly

Installation

is

in

the

reserve

se

quence

of

removal

SECQ12

Air

Induction

pipe

Remove

nut

securing

the

pipe

to

the

exhaust

manifold

At

the

same

time

remove

the

screws

securing

the

bracket

and

rubber

hose

clamp

EC

8

The

air

induction

pipe

can

then

be

taken out

Installation

is

in

the

reverse

sequence

of

removal

Type

B

INSPECTION

Preliminary

Inspection

Check

hose

for

looseness

flatting

damage

or

faulty

connections

and

each

part

for

proper

installation

If

nere

ry

replare

AIr

induction

valve

and

fDter

I

Disconnect

air

induction

hose

at

air

induction

pipe

side

Suck

or

blow

hose

to

make

sure

that

air

flows

only

on

the

air

induction

pipe

side

SEC016

2

Check

air

induction

valve

for

binding

or

damage

At

the

same

time

check

fIlter

for

damage

or

plugging

If

necessary

replace

Filter

should

be

replaced

periodically

in

accordance

with

Maintenance

Schedule

SEC016

EM

ISSION

CO

NTROL

SYSTEM

Exhaust

Emission

Control

System

EXHAUST

GAS

RECIRCULATION E

G

R

CONTROL

SYSTEM

DESCRIPTION

I

In

the

exhaust

gas

recirculation

system

a

part

fthe

exhaust

gas

is

returned

to

the

combustion

chamber

to

lower

the

spark

flaine

temperature

Type

2

E G R

valve

Type

IL

l

E

G R

valve

during

combustion

This

results

in a

reduction

of

the

nitrogen

oxide

NOx

content

in the

exhaust

gas

When

the

E

G

R

control

valve

is

open

some

of

the

exhaust

gas

is

led

from

the

exhaust

manifold

to

the

E

G

R

chamber

The exhaust

gas

is

then

controlled

in

quantity

by

the

E

G

R

valve

and

is

introduced

into

the

intake

manifold

JJ

From

air

pipe

JT

II

1

All

n

o

Throttle

I

chamber

venturi

II

1

Throttle

valve

E

G

R

vacuum

port

r

Engine

coolant

Advance

oontrollinel

v

L

J

t

Exhaust

gas

from

exhaust

manifold

Thermal

vacuum

valve

Type

A2

L

Thermal

vacuum

valve

Type

A3

SEC017

D

rom

air

pipe

I

Air

0

Throt

e

chamber

venturi

I

Throttle

t

valv

e

E

G

R

vacuum

port

II

11

Ad

ance

controlline

Engine

coolant

T

0

r

If

L

J

I

L

Thermal

vacuum

valve

Type

AI

Thermal

vacuum

v

uve

Type

A3

Exhaust

gas

from

exhaust

manifold

SEC018

EC

9

Exhaust

Emission

Control

System

EM

ISSION

CONTROL SYSTEM

Type

3

I

Air

I

lL

ro

I

LJ

Vacuum

port

I

r

Engine

coolant

L

Exhaust

gu

from

exhaust

manifold

SEC309

OPERATION

The

operation

of

the

system

is

as

follows

Type

2

Water

temperature

I

Thermal

vacuum

valve

V

T

valve

E

G R

Oc

oF

Type

A2

Type

A3

Venturi

vacuum

Exhaust

gas

pressure

Operation

control

system

High

Low

I

High

Closed

Below

15

59

Open

Closed

Not

actuated

I

Low

High

Low Low

Open

High

Low

15

60

J

High High

Closed

Slightly

Leak

Closed

59

140

I

Low

High

actua

ted

Low

Open

Not

actuated

High

Low

High

Closed

60

95

Closed

Actuated

140

203

Low

High

Low Low

Open

Not

actuated

High

Low

High

Closed

Above

95

Closed

Open

Not

actuated

203

Low

High

Low Low

Open

EC

IO

EM

ISSION

CONTROL

SYSTEM

Exhaust

Emission

Control

System

Type

I

Water

temperature

Thermal

vacuum

valve

V V

T

valve

E

G

R

Oc

eF

Type

Al

Type

A3

Venturi

vacuum

Exhaust

gas

pressure

Operation

control

system

High

Low

High

Closed

Below

60

140

Open

Closed

Not

actuated

Low

High

Low

Open

High

Low

High

I

Closed

Actuated

60 95

Closed Closed

High

140

203

Low

Open

Not

actuated

High

Low

I

High High

Closed

Not

actuated

Above

95

Closed

Open

I

203

Low

High

1

Low

Open

TYpe

3

1

BPT

valve

Water

temperature

Exhaust

gas

pressure

E

G

R

Thermal

vacuum

valve

Operation

control

system

Oc

em

kPa

mmHzO

inHzO

Below

0

206

0

324

21

33

0

82

i

30

Open

Below

50

122

Closed

Not

actuated

Above

0

206

0

324

21

33

0

82

1

30

Closed

Below

0

206

0

324

21

33

0

82

1

30

Open

Not

actuated

Above

50

122

Open

Above

0

206

0

324

21

33

0

82

1

30

Closed

Actuated

With the

engine

at

idle

or at

full

throttle

the

E

G

R

control

valve

doses

to

deactivate

the

E

G R

system

regard

less

of

water

temperature

operation

of

the

thermal

vacuum

valve

and

V

It

T

valve

or

B

P

T

valve

E

G R

control

valve

The E

G R

control

valve

controls

the

quantity

of

exhaust

gas

to

be

led

to

the intake

manifold

through

vertical

movement

of

the

taper

valve

connect

ed

to

the

diaphragm

to

which

vacuum

is

applied

in

response

to

the

opening

of

the

throttle

valve

E

G

R

control

valve

construction

and

type

vary

with

transmission

type

and

car

destinatiol

For

identification

purposes

the

part

number

is

stamped

on

the

recessed

portion

at

the

top

of

the

valve

G

d

I

ID

ur

I

SEC019

1

Diaphragm spring

2

Diaphragm

3

Valve

shaft

4

Valve

5

Valve

seat

6

Valve chamber

Thermal

vacuum

valve

3

port

type

Two

thermal

vacuum

valves

are

installed

one

on

the

upper

side

of

the

intake

manifold

and

the

other

on

the

lower

side

These

thennal

vacuum

valves

detect

the

temperature

of

the

engine

cooling

water

The

valve

shaft

is

pushed

up

or

down

by

the

thennal

expansion

force

of

wax

which

depends

on

the

temperature

This

action

opens

and

closes

the

valve

which

causes

the

E

G

R

control

vacuum

line to

be

opened

or

closed

to

the

atmosphere

When

the

valve

opens

air

from

the

throttle

chamber

vacuum

signal

line

is

introduced

and

while the

venturi

vacuum

transducer

V

T

valve

con

trolorifice

and

E

G R

valve

diaphragm

are

exposed

to

the

atmosphere

the

E

G R

operation

will

not

function

EC

Exhaust

Emission

Control

System

EMISSION

CONTROL

SYSTEM

Type

A2

To

E

G

R

control

line

JQ

r

From

air

cleaner

JQ

Orifice

Q

Type

AI

1

n

I

O

j

1

Type

AJ

Spring

1

Ii

Vatve

I

T

Wax

EC

12

To

distributor

advance

control

line

Wax

SEC020

From

I

r

air

cleaner

Q

To

E

G R

control

line

IQ

To

distributor

advance

control

line

Wax

SEC021

From

air

c1eanCi

C

E

G R

control

line

Spark

advance

control

vacuum

line

SEC022

Thermal

vacuum

valve

2

port

type

The

2

port

type

thennal

vacuum

valve

is mounted

on

the

engine

thennostat

housing

It

detects

engine

coolant

temperature

by

means of

a

built

in

bi

metal

and

opens

or

closes

the

vacuum

pa

ge

in

the

thermal

vacuum

valve

When

the

vacuum

passage

is

open

the

throttle

chamber

vacuum

signal

is

applied

to

the

diaphragm

of

the

E

G

R

control

valve

to

actuate

the

per

valve

connected

to

the

dia

phragm

Bi

metal

Spiing

8

P T

valve

The

BP

T

valve

monitors

exhaust

pressure

to

activate

the

diaphragm

controlling

throttle

chamber

vacuum

applied

to

the

E

G

R

control

valve

In

other

words

the

amount

of

recircu

tated exhaust

gas

varies

with

the

posi

tion

of

the

E

G R

valve

regulated

by

the

operating

condition

of

the

engine

To

E

G

R

ubber

ClIp

control1ine

Air

f

Exhaust

pressure

SEC20a

SEC023

REMOVAL

AND

INSTALLATION

Venturi

vacuum

transducer

V V T valve

The

v

V

T

valve

monitors

the

pressure

of

the

exhaust

gas

which

actuates

the

diaphragm

@

and

the

venturi

vacuum

which

in

turn

activate

the

diaphragm

1

@

This

valve

con

trols

the

throttle vacuum

in

order

to

ctivate

the

E

G R

control

valve

In other

words

the

amount

of

reo

circulated

exhaust

gas

varies

with

the

position

of

the

E

G R

valve

regulated

by

the

operating

condition

of

the

engine

Control

orifice

Air

bleed

1

E

G R

control

ported

vacuum

Air

pipe

Exhaust

gas

t

pressu

SEC024

1

Diaphragm

2

Diaphragm

3

Diaphragm

E

GIi

controi

valve

and

E

G R

tube

1

Remove

nuts

which

secure

E

G R

tube

and

BP

tube

to

E

G

R

valve

and disconnect

tubes

from

valve

2

Disconnect

vacuum

hose

and

remove

nuts

securing

E

G

R

control

valve

to

Intake

Manifold

The E

GR

control

valve

can

then

be

taken

out

J

CAUTION

Pay

attention

not

10

give

damage

to

packing

of

E

6

R

control

valve

3Installation

is

in

the

reverse

sequence

of

removal

a

When

installing

a

new

E

G R

valve

verify

it

is

of

the

same

type

model

number and

identification

mark

etc l

as

that

which

was

previo

slY

installed

b

Always

install

a

new

gasket

Thermal

vacuum

valve

The

thennal

vacuum

valve

is

made

of

plastic

Consequently

care

should

be

taken

to

avoid damaging

it

On

U

S

A

models

two

valves

are

located

on

the

intake

manifold

One

is

located

on

the

front

side

of

the

intake

mani

fold

The

other

is

located

under

the

rear

end

of

the

intake

manifold

On

Canada

models

the

valve

is

located

on

the

intake

manifold

I

Drain

engine

coolant

about

one

liter

2

Disconnect

vacuum

hoses

and

unscrew

the

thermal

vacuum

valve

Then

the

valve

can

be

removed

3Installation

is

in

the

reverse

sequence

of

removal

a

Be

sura

to

apply

sealer

to

threads

of

the

valve prior

to

installing

a

new

valve

b

When

installing

a

new

thermal

vacuum

valve

be

sure

that

color

and

shape

are

correct

Type

A2

J

SEC026

SEe027

EM

ISSIONCONTROL

SYSTEM

Exhaust

Emission

Control

System

Type

A3

SEC029

V

T

valve

1

Disconnect

vacuum

tubes

on

the

V V

T

valve

2

Disconnect

screws

which

secure

V V

T

valve

to

bracket

3

Disconnect

back

pressure

tube

from

V V

T

valve

The V V

T

valve

can

then

be

taken

out

SEC029

4 Installation

is

in

the

reverse

sequence

of

removal

When

replacing

the V V

T

valve

with

a

new

one

verify

that

the

type

number

on

the

noYi

part

is

the same

as

that

on

the

former

one

i

J

V V

T

valve mounting

crew

i

37 5 0

N

m

0

38

0

51

kg

m

2

737

ft

lb

8

P

T

valve

1

Remove

vacuum

tube

on

the

BP

T

valve

2

Remove

screws

securing

B P

T

valve

to

the

bracket

3

Disconnect

back

pressure

tube

from

B

P

T

valve

The B P

T

valve

can

then

be

taken

out

SEC030

4

Installation

is

in

the

reverse

sequence

of

removal

When

replacing

the

B

P

T

valve

with

new

co

f

rm

that

the

type

number

on

new

part

is

the

same

as

that

on

former

one

i

J

B

P

T

valve

mounting

screw

3 7 5 0

N

m

Q

38

0 51

kg

m

2

7 3 7

ft

lb

INSPECTION

Entire

system

l

Make

a

thorough

visual

check

of

E

G R

control

system

If

necessary

wipe

away

oil

to

facilitate

inspection

If

any

hoses

are

cracked

or

broken

replace

2

With

engine

stopped

inspect

E

G R

control

valve

for

any

indication

of

binding

or

sticking

by moving

dia

phragn

Of

c

ntrol

valve

up

ds

with

a

fmger

J

3

With

engine

running

inspect

E

G R

control

valve and

thennal

vacuum

valve

for

nonn

1

operation

Place

your

finger

on

diaphragm

of

E

G

R

control

valve

to

ensure

that

the

valve

functions

as

described

below

r

f

SEC031

EC

13

Exhau

Emission Co

1

System

I

M

ISSION

CONTROL

SYSTEM

SECOO2

1

When

temperature

of

the

engine

coolant

is

low

Below

ISoC

S90F

California

models

Below

600

1400F

Non

California

modals

Below

SOOC

1220F

Canada

models

Make

sure

that

E

G

R

control

valve

does

not

operate

when

engine

speed

is

increased

from

idle to

2

000

2

500

rpm

2

When

temperature

of

the

engine

coolant

is

high

Above

ISoC

S90F

California

models

Above

600C

1400F

Non

California

models

Above

SOOC

1220F

Canada

models

1

Make

sure

that

E

G R

control

valve

operates

when

engine

speed

is

increased

from

idle to

2

000

2

SOO

rpm

2

If

E

G

R

control

valve

does

not

operate

properly

check

it

as

follows

Disconnect

one

end

KG R

control

valve

side

of

vacuum

h

which

connects

3

way

connecter

to

E

G R

control

valve

Increase

engine

speed

from

idle

to

2

000

2

SOO

rpm

Make

sure

that

thennal

vacuum

valve

is

closed

and

that

throttle

EC

14

vacuuin is

present

at

the

end

E

GR

control

valve

side

of

vacuum

hose

Type

Al

Type

A2

Canada

Airregulatort

f

T

V

J

C035

If

vacuum

pressure

is

either

weak

or

nonexistent

replace

thermal

vacuum

valve

If

vacuum

Pse

ss

lJ

e

is

detected

replace

E

G R

valve

If

any

difficulty

is

encountered

in

judging

the

condition

of

any

com

ponent

during

above

inspection

check

the

questionable

component

inde

pendently

as

follows

E

GR

corit

ol

valve

Dismount

E

G

R

control

valve

from

engine

1

Apply

vacuum

to

E

G

R

control

valve

referring

to

the

following

figure

If

the

valve

moves

to

full

position

it

is

nonnal

E

G

R

control

valve

will

remain

open

for

more

than

30

seconds

after

vacuum

has

cut

off

seC018

I I

ucsl

2

Visually

check

E

G R

control

valve

for

damage

wrinkle

or

deforms

lion

Thermal

vacuum

valve

Dismount

thennal

vacuum

valve

from

engine

Before

dismounting

drain

engine

coolant

from

engine

Apply

vacuum

to

thennal

vacuum

valve

and

check

to

be

sure

that

ther

mal

vacuum

valve

opens

or

closes

in

c

to

engine

coolant

tempera

ture

as

specified

Thennal

vacuum

valve

should

open

or

close

at

a

temperature

specified

below

completing

the

vacuum

pa5Sage

EMISSION CONTROL SYSTEM

Exhaust

Emission

Control

System

Thermal

vacuum

valve

operating

temperature

Oc

OF

Close

Type

Operating

temperature

Leak

Open

60

95

Below

60

140

Non

California

140

203

Above

95

203

for

U

S

A

15

60 60

95

Below

15

California

59

140

140 203

59

I

Above

95

I

Below

95

Apply

pressure

203 203

U

S

A

above

0785 kPa

Above

50

1

Below

50

80

mmH

aO

122 122

Canada

3

15

inH

OI

SEC038

Wax

Type

AI

Wax

Type

A2

Wax

Type

A3

Bi

metal

Applied

model

Canada

CAUTION

Do

not

allow

water

to

gel

inside

the

thermal

Vllcuum

valve

U

s

A

1OC1

EC242

SEC036 VVT valve

1

Apply

a

pressure

above

1

961

kPa

200

mmH20

7

87

inH20

to

V V

T

valve and

check

it

for

leakage

as

shown

below

If

a

leak is

noted

replace

vaive

SEC037

Apply

vacuum

above

t

1

961

kP

200

mmH20

7

87

inH

OJ

2

Apply

vacuum

pressure

above

0

785

kPa

80

mmH20

3

15

inH20

to

VV

T

valve

and

check

for

leakage

as

shown

below

If

a

leak

is

discover

ed

replace

valve

B

P

T

valve

1

Disconnect

two

cuum

hoses

on

BPT

valve

2

Plug

one

of

two

ports

of

BPT

valve

Apply

a

pressure

above

0

490

kPa

50

mmH20

1

97

inH20

to

B P

T

valve

and

orally

suck

back

other

port

of

BP

T

valve

as

shown

below

to

check

for

leakage

If

a

leak is

noted

replace

valve

t

Apply

pressure

above

0

490 kPII

50

mmH20

1

97

inH201

EC381

A

SPARK

TIMING

CONTROL

SYSTEM

DESCRIPTION

The

spark

timing

control

system

is

designed

to

control

the

distributor

vacuum

advance

under

varying

driving

conditions

so as to

reduce

HC

and

NOx

emissions

EC

15

ExhsustEmissionControlSystem

EMISSION

CONTROL

SYSTE

OPERATION

The

operation

of

the

system

is

as

follows

Water temperature

Thennal

vacuum

valve

Spark

timing

Oc

OF

Type

AI

A2

Type

A3

control

system

Below

15

59

Closed Closed

Actuated

15

60

59

140

Open

Closed

Not

actuated

60 95

140

203

Closed Closed

Actuated

Above

95

203

Closed

Open

Not

actuated

This

system

does no1

operate

with

tha

engine

at

iale

Thermal

vacuum

valve

3

port

type

Type

Ai

Two

thennal

vacuum

valves

are

I

installed

one

on

the

upper

side

of

the

intake

manifold

and

the other

on

the

I

lower

side

These

thennal

vacuum

1

valves

detect

the

temperature

of

the

engine

coo

ling

wa

ter

Th

e

valve

shaft

is

pushed

up

or

down

by

the

thennal

I

expansion

force

of

wax

which

depends

on

the

temperature

This

action

opens

and

closes

the

valve

which

causes

the

I

distnbutor

vacuum

line to

be

opened

l

or

closed

to

the

atmosphere

When the

valve

opens

the

vacuum

I

signal

line

will

open

to

the

atmos

phere

stopping

the

distributor

vacuum

from

advancing

Type

A2

To

E

G

R

control line

e

C

From

I

air

cleaner

TYpe

A3

Spring

t1

ii

Valve

i

i1i

I

e

To

distributor

advance

control line

Wax

SEC020

EC

16

I

Ensure

that

vacuum

hoses

are

properly

connected

to

their

con

I

Q

19

controllme

2

Make

sure

that

distributor

vacuum

controller

functions

properly

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

A

From

J

r

air

cleaner

iQ

To

distributor

a4vance

coIitrolline

Wax

SEC021

From

airclea

ner

n

lQ

iiCE

G

R

control line

Q

ce

control

vacuum

line

SEC022

REMOVAL

AND

INSTALLATION

Thermal

vacuum

valve

The

thermal

vacuum

valve

designs

are

exactly

the

same

as

those

used

in

the

E

G

R

control

system

Refer

to

the

instructions

under

the

headirig

E

G R

control

system

for removal

and

installation

procedures

INSPECTION

Entire

system

SEC039

2

Using

a

timing

light

ensure

that

the

spark

timing

retards

from

its pre

vious

position

when

temperature

gauge

changes

from

the

C

position

to

the

middle

position

3

Wann

up

the

engine

until

coolant

temperature

gauge

pointer

moves

to

middle

position

of

scale

Ensure

that

the

spark

timing

advances

from

its

SEC040

If

spark

timing

does

not

change

reo

place

thennal

vacuum

valve

Thermal

vacuum

valve

operating

temperature

Type

EMISSION CONTROL SYSTEM

Exhaust

Emission ControJ

System

To

check

for

operation

of

thermal

valve

proceed

as

follows

Thermal

vacuum

valve

Remove

thermal

vacuum

valve from

engine

Inhale

air

from

port

of

spark

timing

control

system

and

check

to

be

sure

that

thermal

vacuum

valve

opens

or

closes

in

response

to

its

tempera

ture

Operating

temperature

Oc

F

Open

Close

Below

15

59

Above

60

140

Wax

Type

Al

A2

15

60

59

140

Wax

Type

A3

Above

95

203

Below

95

203

CAUTION

00

not

allow

water

10

enter

the

ther

mal

vacuum

valve

SECQ36

DECELERATION

CONTROL

SYSTEM

Intake

manifold

vacuum

control

type

DESCRIPTION

The

deceleration

control

system

is

designed

to

control

the

intake

mani

fold

vacuum

under

decelerating

driving

condition

59

as

to

reduce

the

oil

con

sumption

OPERATION

This

system

is

used

to

force

air

directly

into

the

intake

manifold

w

en

the

preset

vacuum

level

has

been

at

tained

thus

preventing

excessive

in

creases

in

the

intake

manifold

vacuum

during

deceleration

Air

is

directed

from

the 3

way connector

through

the

air

hose

and

vacuum

control

valve

To

keep

oil

consumption

low as

the

air

enters

the intake

manifold

vacum

will

be

maintained

at

less

than

the

specified

level

Vacuum

control

valve

V

C

V

To

check

for

operating

proceed

as

follows

I

Disconnect

one

end

Air

regulator

side

of

air

hose connecting

3

way

connector

to

V

C

V

2

Make

sure

that

vacuum

control

valve

operates

when

engine

speed

is

decreased

from

3

500

4

000

to idle

Place

finger

on

the

hose

end

to

check

for

valve

operation

3

If

the intake

manifold

vacuum

is

not

present

at

the

end

of

air

hose

replace

vacuum

control

valve

CATALYTIC

CONVERTER

DESCRIPTION

The

catalytic

converter

accelerates

the

chemical

reaction

of

hydrocarbons

HC

and

carbon

monoxide

CO

in

the

exhaust

gas

and

changes

them

into

non

hannful

carbon

dioxide

CO

and

water H

O

This

chemical

reaction

process

requires

the

proper

amount

of

air

which

is induced

ythe

air

induction

valve

Refer

t

the

item

A

I

S

This

air

is

called

secondary

air

EC

7

Exhaust

Emission ContrQl

System

EM

ISSION

CONTROL

SYSTEM

Catalytic

converter

OPERATION

Exhaust

gas

emitted

from

the

engine

contains

some

hannful

sub

stances

due

to

incomplete

combustion

in

the

combustion

chamber

The

air

induction

system

is

designed

to

reduce

the

content

of

such

substances

in

the

exhaust

gas

In this

system

the

secondary

aicisJed

from

the

air

in

duction

valve and

injected

into

the

exhaust

manifold

With

this

injection

of the

secondary

air

hydrocarbons

HC

and

carbon

monoxide

CO

in

the

exhaust

gas

are

gradually

oxidized

with

oxygen

0

in

the

secondary

air

and

converted

into

non

hannful

carbon

dioxide

CO

and

water

H

O

The

catalytic

converter

further

cleans

engine

exhaust

gas

Through

catalytic

action

it

changes

residual

hydrocarbons

and

carbon

monoxide

contained

in

exhaust

gas

into

carbon

dioxide

and

water

before

exhaust

gas

is

discharged

to

the

atmosphere

REMOVAL

AND

INSTALLATION

I

Jack

up

the

car

Apply

parking

brake

and

place

wheel

chocks

2

Remove

screws

securing

lower

shelter

of

catalytic

converter

Loosen

flange

bolts

connecting

catalytic

converter

to

front

and

rear

exhaust

tubes

Catalytic

converter

assembly

can

then

be

taken

out

EC

18

I

Visually

check

catalytic

converter

for

damage

or

cracks

2

Adjust

engine

idle

speed

Refer

to

Mjus

g

Idle

RPM

for

adjustment

SEC044

3

Race

engine

1

500

to

2

000

rpm

two

or

three

times

under

no

load

4

If

idle

speed

increases

readjust

it

to

specified

speed

with

throttle

adjusting

screw

SWann

up

engine

for

about

four

minutes

at

2

000 rpm

under

no

load

6

Measure

CO

percentage

at idle

speed

After

step

S

has

been

com

pleted

wait

for

one

minute

before

making

CO

percentage

measurement

7

If

CO

percentage

measured

in

step

6

is

less

than

03

the

catalytic

con

verter

is

nonnal

8

If

CO

percentage

measured

in

step

6

is

over

03

recheck

Al

S

arid

replace

air

induction

valve

Then

per

form

inspection

steps

S

and

6

9

if

CO

percentage

is

still

over

03

in

step

8

catalytic

converter

is

mal

functioning

Replace

catalytic

con

verter

ft

L

MufIIer

SEC043

SEe04S

3 Installation

is

in

the

reverse

sequence

of

removal

CAUTION

a

Be

careful

not

to

damage

catalytic

converter

when

handling

b

Newr

wet

catalyzer

with

wa1er

oil

etc

fJ

Lower

shelter

bolt

6

38

3

N

m

0

64

0

85 kg

m

4 6 6

1

ft

lb

Catalytic

converter

bolt

31

42

N

m

32

43

kg

m

23

31

ft

bl

INSPECTION

Preliminary

Inspection

Visually

check

condition

of

all

component

parts

including

hoses

tubes

and

wires

replace

if

necessary

Refer

to

Air

Induction

System

for

inspection

Ci

converter

Whether

catalytic

converter

is

normal

or

not

can

be

checked

by

observing

variation

in

CO

percentage

The

checking

procedure

is

as

follows

Apply

parking

brake

Shift

gears

into

Neutral

for

manual

trans

mission

and

N

or

P

for

auto

matic

transmission

position

California

models

Non

Califomia

models

I

VisuaIly

check

catalytic

converter

for

damage

or

crack

2

Adjust engine

idle

speed

and

CO

percentage

Refer

to

Adjusting

Idle

RPM

and

Mixture

Ratio

for

adjust

ment

EMISSION

CONTROL

SYSTEM Evaporative

Emission

Control

System

3

Race

engine

1

500

to

2

000

rpm

two

Or

three

times

under

no

load

and

make

sure

that

specified

CO

per

centage

is

obtained

4

Remove

cap

and

connect

air

hose

to

air

induction

v

a1ve

If

idle

speed

increases

readjust

it

to

specified

speed

with

throttle

adjust

ing

screw

5

Wann

up

engine

for

about

four

minutes

at

2

000

rpm

under

no

lmid

6

Measure

CO percentage

at

idle

speed

After

step

4

has

been

com

pleted

wait

for

one

minute

before

making

CO

percentage

measurement

7

If

CO

percentage

measured

in

step

5

is

less

than

03

the

catalytic

con

verter

is

normal

8

If

CO percentage

measured

in

step

S

is

over

03

recheck

AJ

S

and

replace

air

induction

valve

Tlien

per

fonn

inspection

steps

4

and

5

9

If

CO

percentage

is

still

over

03

in

step

7

catalytic

converter

is

mal

functioning

Replace

catalytic

con

verter

EVAPORATIVE

EMISSION CONTROL

SYSTEM

DESCRIPTION

This

system

is

made

up

of

the

following

1

Fuel

tank

with

positive

sealing

filler

cap

2

Fuel

check

valve

3Vapor

vent

line

4

Carbon

canister

S

Vacuum

signal

line

6

Canister purge

line

7Vapor

liquid

separator

Hatchback

models

Removal

and

installation

of

above

components

are

described

in

Section

FE

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

charcoals

in

the

carbon

canister

Fuel

Hller

cap

Vacuum

reliet

Pressure

regulator

j

Vapor

liquid

separator

HATCHBACK

model

OnlY

Fuel

check

valve

I

Fuel tank

c

I

Fuelf1lter

Fuel

return

line

Z

Fuel

reed

line

1

Fuel

mjector

Fuel tank

vapor

vent

line

81

Fuel

danlper

J

sending

unit

Electrical

fuel

pump

f

Vapor

storage

canister

Intake

manifold

Canister

purge

line

SEC046

EC

19

Etlaporative

Emission

ContlOlSystrm

EMISSION

CONTROL

SYSTEM

rr

OPERATION

Fuel

vapors

from

the

sealed

fuel

tank

are

directed

to

the

carbon

canis

ter

which

is

filled

with

activated

char

coals

and

stored there

when

the

engine

is

not

nmning

HARDTOP

models

I

LJ

ri

POsitive

Sealli1g

gas

cap

with

aCllum

relief

valve

Vacu1

J111

lline7

jFUel

vapor

I

vent

line

r

n

Fuel

che

L

Freshair

Fuet

vapor

t

j

L

Fuel

tank

Intake

ffillIlifOldJ

ij

f

fJ

SEC041

HATCHBACK

m

odeb

Yaporjliquid

separator

L

J

Vacuum

signal

line

7

Purge

control

ialve

G

tr

I

LJ

r

Fuel

vapor

vent

line

Fuel

check

Fixed

orifice

I

Con

tant

purge

i

lice

Si

S

iji

i

ji

J

sitive

sealing

gas

cap

with

vacuum

relief

valve

1

LFUe

tank

Intake

manifold

J

Fresh

air

Fuel

vapor

SEC048

EC

20

The canister

retains

the

vapor

until

it

is

purged

by

the

air

drawn

through

the

purge line

towards

the

intake

manifold

while

the

engine

is

operaiing

When

the

engine

runs

at

idle

the

purge

control

valVe

is

closed

Only

a

small

amount

of

purge

air

flows

into

the

intake

manifold

through

the

constant

purge

orifice

As

the

engine

speed

in

creases

and

the

ported

vacuum

rises

higher

the

purge

control

valve

opens

and

the

vapor

is

drawn

into

the

intake

manifold

through

both

the

fixed

orifice

and

the constant

purge

orifice

I

Engine

does

not

operate

From

fuel

tank

Fuel

vapor

i

I

umuu

11

l

N

fl

SEC049

1

Diaphragm

2

Purge

control

valve

3

Fixed

orifice

4

Constant

fixed

orifice

5

Activated

carbon

Engine

operates

at

idle

Fresh

air

Fuel

vapor

SEC050

4

Constant

fixed

orifice

5

Activated

carbon

6

Filter

1

Diaphragm

2

Purge

control

valve

3

Fixed

orifice

EM

ISSION

CONTROL SYSTEM

Evaporative

Emission

Control

System

3

Engine

speed

increases

To

carburetor

C

J

Ported

vacuum

To

intake

manifold

@

Fresh

air

F el

vapor

1

Diaphragm

4

Constant

fixed

2

Pltrge

control

orifice

valve

5

Activated

carbon

3

Fixed

orifice

6

Filter

INSPECTION

FUEL

TANK

AND

VAPOR

VEfo

T

LINE

Check

all

hoses

and

fuel

tank

IDler

cap

2

Disconnect

the

vapor

vent

line

C

Onnecting

carbon

canister

to

fuel

iank

3

Connect

a

3

way

connector a

manometer

and

a

cock

or

an

equiva

lent

3

way

charge

cock

to

the

end

of

the

vent

line

4

Supply

fresh

air

into

the

vapor

vent

line

through

t

e

cock

little

by

little

until

pressure

becomes

3

923

kPa

400

mmH20

15

75

inH20

3

way

connector

75

H

0

Cock

3 kPo

400

mmH20

15

in

2

Air

Manometer

Check

valve

@

Carbon

canister

5

Shut

the

cock

completely

and

leave

it

unattended

6

After

25

minutes

measure

the

height

of

the

liquid

in

the

manometer

7

Variation

in

height

should

remain

with

0

245

kPa

25

mmH20

0

98

inH20

8

When

filler

cap

does

not

close

completely

the

height

should

drop

to

zero

in

a

short

time

9

If

the

height

does

not

drop

to

zero

in a

short

time

when

filler

cap

is

removed

it

is

the

cause

of

a

stuffy

hose

In

case the

vent

line

is

stuffy

the

breathing

in

fuel

tank

is

not

thorough

Fuel

filler

cap

EC091A

Iy

made

thus

causing

insufficient

de

livery

of

fuel

to

engine

or

vapor

lock

It

must

therefore be

repaired

or

replaced

CARBON

CANISTER

PURGE

CONTROL

VALVE

Check

for

fuel

vapor

leakage

in

the

distributor

vacuum

line at

diaphragm

of

carbon

canister

purge

control

valve

To

check

for

leakage

proceed

as

follows

EC

21

Evaporative

Emi

on

Control

smem

EMISSION

CONTROL SYSTEM

I

Disconnect

rubber

nose

in

he

line

between

T

connector

and

carbon

canister

at

T

onnector

2

Inhale

air

into

the

opening

of

rubber

h

se

running

to

vacuum

hole

in

carbon

canister

and

ensure

that

there

is

no

leak

EF199

I

Disconnect

thb

l

ub

ber

llooe

on

the

line

between

the

steel

pipe

of

the

engine

and

canister

2

Force

air into

the

opening

of

the

rubber

hose

which

runs

to

tiJe

carbon

canIster

and

ensure

that

there

are

leaks

SEC052

3

If

there

is

a

leak

remove

top

3

If

there

are

no

leaks

remove

cover

from

purge

control

valve

and

purge

control

valve

and

check

the

check

for

dislocated

or

cracked

dia

constant

purge

orifice

for leak

If

phragm

If

necessary

replace

dia

necessary

clean

the constant

purge

phragm

kit

which

is

made

up

oLa

orifir

retainer

diaphragm

and

spring

Cover

Diaphragm

Retainer

t

Diaphragm

spring

EF200

CARBON

CANISTER

CONSTANT

PURGE

ORIFICE

Check

the

constant

purge

flow

in

the

intake

manifold

vacuum

line

at

the

constant

purge

orifice

of

carbon

canister

To

check

the

purge

flow

proceed

as

follows

EC

22

SEC053

CARBON

CANISTER

FLTER

Check

for

a

contaminated

element

Element

can

be

removed

at

the

bottom

of

canister

installed

on

car

body

FUn

TANK

VACUUM

RnlEF

VALVE

Remove

fuel

filler

cap

and

see

it

functions

properly

I

Wipe

clean valve

housing

and

have

it

in

your

mouth

2

Inhale

air

A

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

ance

is

felt

replace

cap

as

an

assem

bled

unit

r

ET500

FUEL

CHECK

VALVE

1

Blow

air

through

connector

on

fuel

tank

side

A

considerable

resistance

should

be

felt

at

the

mouth

and

a

portion

of

air

flow

be

directed

toward

the

engine

2

Blow

air

through

connector

on

engine

side

Air

flow

should

be

smoothly

direct

ed

toward

fuel

tank

3

If

fuel

check

valve

is

suspected

of

not

being

properly

functioning

in

steps

I

and

2

above

replace

tm

r

ltank

1

e

l

Q

Evaporative

fuel

flow

Fresh

air

flow

EC090A

EM

ISSION

CONTROL

SYSTEM

Service

Data

and

Specifications

SERVICE

DATA

AND

SPECIFICATIONS

TIGHTENING

TORQUE

Unit

N

m

kg

m

ft

lb

Unit

N

m

kg

m

ft

Ib

E

G

R

tube

securing

nut

34

44

3 5

45

25

33

I

V V T

valve

mounting

3 7 5

0 0

38

0

51

2

7 3 7

E

A

I

tube

securing

nut

44

4

5

25 33

screw

34

3 5

Less

than

Less

than

Less

than

18

P

T

valvo

mounting

3 7 5

0 0

38

0

51

2

7 3 7

Thermal

vacuum

valve

22

2 2

1

6

screw

I

Catalytic

converter

bolt

31

42

3 2

4

3

23 31

EC

23

DATSUN

200SX

Mod

1

S

II

0

Series

SECTIONER

ENGINE

REMOVAL

INSTAllATION

CONTENTS

ENGINE

REMOVAL

AND

INSTALLATION

CONSTRUCTION

REMOVAL

ER

2

ER

2

ER

2

INSTALLATION

SERVICE

DATA

AND

SPECIFICATIONS

TIGHTENING

TORQUE

ER

5g

ER

5

ER

5

Engine

Removal

and

Installation

ENGINEREMOVAL

INSTALLATION

ENGINE

REMOVAL

AND

INSTALLATION

CONSTRUCTION

Iii

30

40

31

4 1

22

Iii 44 54

4

5

5 5

33

0

1

Iii

N

m

Itg

m

ft

b

REMOVAL

It

is

much

easier

to

remove

engine

and

transmission

as

a

single

unit

than

to

remove

them

separately

After reo

moval

engine

can

be

separated

from

transmission

assembly

WARNING

a

Place

wheel

chocks

in

front

of

front

wheels

and

in

rear

of

rear

wheel

b

Be

sure

to

hoist

engine

and

jack

up

transmission

in

a

safe

man

nero

C

You

should

not

remove

the

engine

until

the

exhaust

system

has

completely

cooled

off

Otherwise

you

may

burn

your

self

and

or

fire

may break

out

in

fuel

line

I

FoUow

the

procedure

below

to

reduce

fuel

pressure

to

zero

ER

2

CAUTION

Before

disconnecting

fuel

hose release

fuel

pressure

from

fuel

line

to

elimi

nate

danger

I

Start

the

engine

2

Disconnect

the

harness

connector

of

fuel

pump

relay

2

while

the

en

gine

is

running

Relay

bracket

SEF131

3

After

the

engine

staUs

crank

the

engine

two

or

three

times

8

7

8 7

19

Iii

30 40

31

4

1

22 30

31

42

3

2

4

3

23

31

SERD01

4

Turn

the

ignition

switch

OFF

5

Reconnect

tJie

harness

connector

of

fuel

pump

rel

y2

F

nd

r

co

shCll

ld

b

uBI

to

protect

car

body

2

Disconnect

the

negative battery

cable

On

air

condition

r

aquipped

mod

ls

destined

for

California

remon

tho

battery

to

facili

this

operation

3

Drain

engine

coolant

4

Remove

hood

Mark

tho

location

of

hood

hinges

on

hood

to

facilitot

correct

reinsta

lotion

CAUTION

Have

an

assistant

help

you

so as

to

PII

vent

damage

to

body

5

Remove

aU

wires

and

hoses

where

indicated

by

the

arrows

in

the

figure

below

ENGINE

REMOVAL

INSTALLATION

Engine

Removs

and

In

tallation

1

u

Air

conditioner

equipped

models

Remove

compressor

foUowing

the

procedures

below

I

Remove

compressor

drive

belt

To

remove

this

belt

loosen

both

idler

puUey

nut

and

adjusting

bolt

P

fi

qa

9

5

ey

nut

a

1

n

djUS

ing

I

11

l

I

AOO

Yr

p

t

1

J

0

2

Remove

compressor

Place

removed

compressor

as

shown

below

Ne

er

d

ilCherge

gas

from

compres

sor

while

service

repair

work

is

being

performed

III

r

I

o

SER003

Power

steering

equipped

models

Remove

power

steering

oil

pump

foUowing

the

procedures

below

I

Remove

oil

pump

drive

belt

To

remove

this

belt

loosen

both

idler

puUey

nut

and

adjusting

bolt

ER

3

Engine

Removal

and

Installation

ENG

INE

REMOVAL

INSTALLATION

2

Remove

oil

pump

Place

removed

oil

pump

as

shown

below

Never

drain

oil

from

oil

pump

while

sorvice

repair

rk

i

being

perfonnod

6

Remove

transmission

control

link

age

as

foUows

1

Manual

transmission

E

33

iW

2

Automatic

transmission

7

Remove

radiator

and

radiator

shroud

On

air

conditioner

equipped

mo

dels

remove

oil cooler

ho

ER

4

SER010

I

g

Disconnect

speedometer

cable

9

Disconnect

down

shift

solenoid

wire

and

inhibitor

switch

wire

AfT

only

10

Disconnect

vacuum

hose

AfT

only

II

Remove

clutch

operating

cylinder

front

exhaust

tube

and

propeUer

shaft

Place

marks

on

propeller

haft be

fora

remo

al

to

facilitate

reinstall

tion

Mk

1

ar

mgp

SER024

Plug

open

holes

in

rear

extension

housing

as

hown

12

Attach

suitable

wires

to

engine

sIingers

and

raise

engine

using

a

hoist

to

take

the

weight

off

front

and

rear

mount

insulators

WARNING

BeforB

raising

engine

try

loosening

wires

two

or

three

times

to

make

sure it

is

safe

to

do

so

I3

Remove

rear

engine

mounting

support

to

body

aUaching

bolts

ENGINE

REMOVAL

INSTALLATION ServiceDataandSpecifications

14

Remove

front

engine

mounting

bolts

15

Raise

engine

and

transmission

and

remove

them

from

car

as

a

single

unit

WARNING

When

raising

engine

be

especially

careful

not

to

knock

it

against

ad

jacent

parts

16

Set

engine

and

transmission

on

an

engine

stand

INSTALLATION

InstaU

in

the

reverse

order

of

reo

moval

observing

the

foUowing

When

installing

be

lure to

check

that

electrical

heme

are

correcdy

connected

I

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

InstaU

air

conditioner

compressor

and

adjust

belt

Refer

to

Engine

Maintenance

See

tion

MA

for

checking

and

adjust

ing

drive

belts

InstaU

power

steering

oil

pump

and

adjust

belt

Refer

to

Pump

Belt

Adjustment

Section ST

for

adjustment

3

When

installing

exhaust

front

tube

on

exhaust

manifold

be

sure

to

instaU

a

new

gasket

4

When

reinstalling

the hood foUw

ing

engine

instaUation

be

sure

that

it

is

properly

centered

and

that

hood

lock

operates

securely

Refer

to

Hood

Section

BF

for

adjuslment

5

Add the

correct

amount

of

engine

coolant

6

For

automatic

transmission

mod

els

add

the

same

amount

of

automatic

transmission

fluid

as was

drained

SERVICE

DATA

AND

SPECIFICATIONS

TIGHTENING

TORQUE

Unit

N

m

kg

m

ft

Ib

Front

engine

support

bracket

to

cylinder

block

30

40

3

1

4

1

22 30

Front

engine

support

bracket

to

mounting

insulator

31

42

32

4

3

23

31

Front

mounting

insulator

to

body

31

42

3 2

4

3

23

31

Compressor

to

bracket

44 54

4

5 5 5

33 40

Steering

oil

pump

to

bracket

19

25

1

9

2

6

14 19

Rear

mounting

insulator

to

transmission

88

11

8

09

1

2

658

7

Rear

mounting

insulator

to

mounting

member

88

11

8

0

9

1

2

6

5

8

7

Mounting

member

to

body

20 42

2 4 3

14

31

Exhaust

maniflold

to

exhaust

tube

20 25

2

0

2

6

14

19

Clutch

operating

cylinder

to

engine

30 40

3

1

4

1

22 30

ER

S

DATSUN

200SX

Mode

S

110

Series

SECTIONFE

ENGINE

CONTROL

FUEL

EXHAUST

SYSTEMS

CONTENTS

ENGINE

CONTROL

SYSTEM

ADJUSTMENT

REMOVAL

INSPECTION

INST

ALLATION

FUEL

SYSTEM

REMOVAL

FE

2

FE

2

FE

3

FE

3

FE

3

FE

4

FE

5

INSPECTION

INSTALLATION

EXHAUST

SYSTEM

REMOVAL

INSPECTION

INSTALLATION

FE

6

FE

7

FE

S

GII

FE

9

FE

9

FE

9

EngjneControISyltem

ENGINE

CONTROL

FUEL

EXHAUST

SYSTEMS

ENGINE

CONTROL

SYSTEM

Adjusting

bet

nut

Ptdal

free

play

o

2

mm

0008

in

frPedaI

arm

Iii

2 9 3 9

0

3 0

4

2

2 2

9

Pedal

arm

brlcket

t

j

aI

t

etum

PlUIll

Iii

N

m

kg

m

ft

lb

SFEQ01

ADJUSTMENT

ACC

RATOR

WIllE

Adjust

accelerator

pedal

free

play

to

specifICation

using

a

djusting

nuts

a

Depress

accelerator

pedal

to

make

Iura

its

linkage

moves

lIDootItly

without

jamming

or

dragging

re

lease

pedal

to

make

lure

it

returns

to

its

original

position

smoothly

b

Check

to

see

if throttle

valve

fully

open

when

accelerator

pedal

i

completely

depressed

and

if it

returns

to

idle

when

releasad

c

Pedal

height

adjustment

i

not

necessary

since

its

height

is

deter

mined

by

stopper

SFEOO3

FE

2

ENGINE

CONTROL

FUEL

EXHAUST

SYSTEMS

Engine

Control

System

REMOVAL

ACCELERATOR

WIRE

I

Loosen

adjusting

lock

nuts

and

disconnect

accelerator

wire

from

car

buretor

2

Remove

nylon

coUar

by

pushing

it

toward

wire

end

and

disconnect

accelerator

wire

from

pedal

ann

SFE154

3

Remove

pedal

stopper

bracket

and

extract

accelerator

wire

toward

passenger compartment

SFE155

ACCELERATOR

PEDAL

Remove

nylon

collar

and

discon

nect

accelerator

wire

from

tip

of

pedal

arm

Then

remove

pedal

arm

assembly

by

removing

pedal

arm

bracket

retain

r

ing

01t

EF156

INSPECTION

I

Check

pedal

return

spring

for

rust

fatigue

or

damage

Replace

if

neces

sary

2

Check accelerator

wire

cases

socket

and

fastening

locations

for

rust

damage

or

looseness

Repair

or

replace

if

necessaiy

INSTALLATION

To

in

staU

reverse

the

order

of

removal

a

Check accelerator

contror

parts

for

improper

contact

with

any

ad

jacent

parts

b

When

connecting

accelerator

wire

be

careful

not to

twilt

or

scratch

its

inner

wire

c

On

automatic

transmission

models

depress

accelerator

pedal

to

make

su

that

kickdown

switch

turn

on

when

throttie

alve

is

fully

open

and

t t

push

rod

mo

properly

FE

3

m

J

Hatchback

Fuel

check

vol

Fuel

filler

hose

10

k

I

c

pate

uel

tankaauge

unit

O

ing

Hardtop

Fuel

filler

cap

Fuel

filler

tube

Ventilation

ho

Fuel

filler

hole

Fuel

outlet

hoae

Fuel

fetum

hOle

o

Fuel

outlet

tube

Fuel

return

tube

Enporation

tulx

II

m

Q

om

Fuel

tank

Iii

14

18N

m

1

4

1

8

Itg

m

10

13

fHb

Iii

N

m

kg

m

fHb

m

r

en en

I

m

i

r

l

I

m

Z

G

Z

m

n o

z

l

0

o

r

T1

C

m

r

ll

m

X

J

I

c

C

l

C

l

C

l

m

s

C

l

REMOVAL

WARNING

When

replacing

fuel

line

parts

be

sure

to

observe

the

following

a

put

a

CAUTION

INFLAM

MABLE

sign

in

workshop

b

Be

sure

to

furnish

workshop

with

an

asphyxiator

c

Be

sure

to

disconnect

battery

ground

cable

before

conducting

operations

d

Put

drained

fuel

in

an

explosion

proof

container

and

put

on

lid

secu

rely

FUEL

TANK

1

Remove

battery

ground

cable

2

Drain

fuel

fro

fuel

tank

3

Remove protector

from

luggage

compartment

and

then

remove

the

foUowing

parts

Harness

connector

for

fuel

tank

gauge

unit

Ventilation

hose

Evaporation

hoses

Fuel

filler

hose

Hatchback

Hardtop

Harness

connector

Ventilation

hose

HatchbackrHaineiS

nnector

A

Ventilation

hose

b1J

o

SFE010

4

Remove

the

foUowing

parts

from

underside

of

floor

Fuel

outlet

hose

Fuel

return

hose

ENGINE

CONTROL

FUEL

EXHAUST

SYSTEMS

Fuel

System

Evaporation

hose

Fuel

filler

hose

Hardtop

5

Remove

bolts which

secure

fuel

tank

in

place

and

dismount

fuel

tank

SFE012

1

4

18N

m

3ft

lb

RESERVOIR

TANK

Hatchback

I

Remove

battery

ground

cable

2

Remove

protector

from

luggage

compartment

Also

remove

RH

speaker

and

side

lower

flnisher

l

SFE013

3

Remove

evaporation

hoses

and

then

remove

reservoir

tank

FUEL

TANK

GAUGE

UNIT

I

Disconnect

battery

ground

cable

2

Remove

protector

from

luggage

compartment

and

disconnect

harness

for

fuel

tank

gauge

unit

Also

remove

rubber

grommet

3

Turn

lock

plate

counterclockwise

and

extract

fuel

lank

gauge

unit

FUEL

FILLER

TUBE

AND

HOSE

I

Disconnect

battery

ground

cable

2

Drain

fuel

if

fuel

overfloWs

when

disconnecting

both

fuel

filler

tube

and

hose

3

Open

fuel

filler

lid

remove

fuel

filler

cap and

remove

fuel

fIller

attaching

bolt

G

ii

I

j

1

2

uel

filler

p

SFE016

FE

S

Fuel

System

ENGINE

CONTROL

FUEL

EXHAUST

SYSTEMS

4

Remove

fuel

filler

tube

and

hose

as

follows

Hardtop

1

Disconnect

fuel

filler

hose

from

fuel

al

k

underside

of

floor

2

Remove

protectors

from

luggage

compartment and

disconnect

ventila

tion

hose

Remove

fuel check

valve

bracket

and

then

extract

both

fuel

filler

tube

and

hose

Hatchback

Remove

protectors

from

luggage

compartment

Also

remove rear

speak

er

and

side

lower

fmisher

from

right

side

of

luggage

compartment

Dis

cc

mnect

evaporation

hoses

ventilation

hose

and

fuel

filler

hose

from

fuel

tank

and

then

remove

fuel

filler

tube

arid

hose

1

Fuel

filler

t

be

1

filler

110

I

SFE018

FUEL

CHECK

VALVE

Remove

fuel

check

valve

as

fol

lows

Remove

protectors

from

luggage

compartment

Disconnect

fuel

check

valve

from

evaporation

hose

FE

6

Hardtop

D

9

cl1eckvalve

SFEO

FUEL

TUBE

Fuel

tubes

are

serviced

as

an

assem

bly

How

er

do

not

disconnect any

fuel

line

unless

absolltely

necessary

I

Disconnect

batlery

ground

cable

2

Drain

fuel

from

fuel

tank

3

Loosen fuel

hose

clamps

and

disconnect fuel

tube

at

each

end

Plug

hose

and

tube

openi

ng

to

prevent

entry

of

dust

or

dirt

while

removing

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

DAMPER

AND

FILTER

Refer

to

Section

EF

INSPECTION

FUEL

TANK

Check

fuel

tank

for

cracks

or

defor

mauon

If

o

ecessaryreplacl

FUEL

TANK

GAUGE

UNIT

Refer

to

Fuel

Tank

Gauge

Unit

Jor

inspection

Section

EL

FUEL

FILLER

TUBE

AND

HOSE

Inspect

aU

hoses

and

tubes

for

cracks

fatigue

sweating

or

deteriora

tion

Replace

any

hose

or

tube

that

is

damaged

FUEL

CHECK

VALVE

Refer

to

Fuel

Check

Valve

for

inspection

Section

EC

FUEL

TUBE

Replact

any

fuel

tube

1hat

is

crack

ed

rusted

coUapsed

or

deformed

FUEL

PUMP

FUEL

DAMPER

AND

FUEL

FILTER

Refer

to

Fuel

Pump

Fuel

Damper

and

Fuel

Filter

for

component

parts

inspection

Section

EF

ENGINE

CONifROL

FUEt

EXHAUST

SYSTEMS

FueISysll1

INSTALLATION

InstaU

any

parts

of

the

fuel

system

in

the

reverse

order

of

removal

Observe

the

foUowing

notes

and

refer

to

Fuel

Filter

Fuel

Pump

Fuel

Darnper

aod

Fuel

Hose

for

removal

aod

instaUation

Section

EF

GJ

Fuel

tan

k

retaining

bolt

14 18

N

m

1

4

1

8

kg

m

10

13ft

lb

a

Install

ho e

clamp ecurely

Do

not

tighten

excessively

to

avoid

damag

ing

hose

b

Fasten

fuel

tube

clamp

on

und

r

body

ecurely

Failure

to

follow

this

caution

could result in

damage

to

the

urf

e

of

fuel

tube

c

Do

not

kink

or

twist

ole

and

tube

when

they

are

routed

d

Run

the

engine

and

check

for

leak

at

connection

e

Fuel

tank

Install

fuel

filler

hose

etter

fuel

tank

has

been

mounted

in

place

Failure

to

follow

this

rule

could

result in

lea

ge

from

around

hose

connections

Do

not

twist

or

smash

ventilation

and evaporation

hoses

when

they

are

routed

Be

sure

to

retain them

with

clips

securely

f

Fuel

tank

gauge

unit

When

installing

fuel

tank

gauge

unit

align

tlle

projection

of

fuel

tank

gauge

unit

with

the

notch

in

fuel

tank

and

tighten

it

ecurely

Be

sure

to

install

fuel

tank

gauge

unit

with

Q

ring

in

place

FE

7

fflermo

tir18

Upper

mu

raCket

8

Iii

7

8

11

58

8

7

0

81

2

gg

I

Lower

mumer

1i

mountlos

1

bncket

@

1

7

@

8

7

m

Co

Iii

7

8

11

8

0

8

1

2

5

8

LIii

2

9

4

9

0

3

0

5

Front

exhaua

tube

2

3

6

Iii

2

9

4

9

0

3

0

5

2

3

6

Front

ePaust

tube

lower

heat

iniulatOJ

m

0

IIUmer

bond

opper

Iii

7

8

H

8

0

8

12

5

8

j

ounlill8

RiIl8

rUbJer

fj

7

8

H

8l

0

8

12

5

8

7

I

Exhaust

murtler

Catalytic

converter

4

23

31l

8

7

Rear

mutner

mounting

l

Iii

7

8

1l

8

0

8

1

2

5

8

7

1fJ7

8

H

8

0

8

12

5

8

7

Iii

N

m

kg

m

ft

b

m

J

Ii

c

ff f

m

3

l

I

11

m

Zc

Z

m

oZ

l

D

o

r

C

m

r

Ii

m

X

I

C

J

l

m

J

ENGINE

CONTROL

FUEL

EXHAUST

SYSTEMS

ExhBustSystem

REMOVAL

FRONT

TUBE

1

Remove

catalytic

converter

lower

shelter

2

Remove

bolts

or

nuts

attaching

front

exhaust

tube

to

exhaust

mani

fold

and

front

tube

mounting

bracket

Front

tube

can

then

be

removed

SFE025

CATALYTIC

CONVERTER

Remove

catalytic

converter

lower

shelter

and

remove

catalytic

converter

CAUTION

a

Be

careful

not

to

damage

catalytic

converter

when

handling

b

Never

wet

catalytic

converter

with

water

oil

m

SF

E026

EXHAUST

MUFFLER

L

lift

up

car

with

a

frame

hoist

2

Remove

catalytic

converter

lower

shelter

3

Remove

bolts

attaching

exhaust

muffler

to

catalytic

converter

remove

rear

muffler

mounting

nut

and

rubber

rings

Dismount

exhaust

muffler

through

underbody

and

rear

axle

case

I

Exhaust

muffler

1

U

SF

E027

INSPECTION

I

Check

muffler

and

tubes

for

cmcks

damage

or

corrosion

Replace

any

parts

that

is

damaged

beyond

limits

2

Replace

bracket

and

hanger

rub

ber

parts

that

are

cracked

fatigued

or

sweated

INSTALLATION

InstaU

the

exhaust

system

parts

in

the

reverse

order

of

removal

ifl

Exhaust

manifold

to

front

tube

nuts

26

31

N

m

2 7 3 2

kg

m

20 23

ft

lb

Front

tube

mounting

bracket

nuts

7 8

11

8

N

m

08

1

2

kg

m

588 7

ft

lb

Catalytic

converter

attching

bolts

31

42

N

m

3 2 4 3

kg

m

23

31

ft

lb

Rear

muffler

mounting

insulator

nut

7 8 11 8

N

m

0 8

1

2

kg

m

5 8 8 7

ft

lb

Muffler

band

stopper

attaching

bolts

7 8

11

8N

m

0 8

1

2

kg

m

5 8 8

i

ft

lb

Muffler

mounting

bracket

B

7 8 11 8

N

m

0 8

1

2

kg

m

5 8 8 7

ft

lb

Heet

hieiil

plate

ecuring

bolt

2

9 4

9

N

m

03 0 5

kg

m

2 2

3 6

ft

lb

a

Keep

sufficient

clearance

between

exhaust

system

components

and

underbody

adjacent

parts

b

Replace

ga

ket

for

catalytic

con

verter

and

for

front

tube

with

new

one

when

removed

c

After

inStallation

check

that

mounting

brackets

and

mounting

rubbers

are

free

from

undue

stress

If

any

of

the

above

part

i

not

installed

properly

excessive

noise

or

vibrations

may

be

transmitted

to

the

car

body

d

With

engine

running

check

all

tube

connection

for

exhaust

gas

leaks

and

entire

system

for

unusual

noises

FE

9

NG

N

CON

ROL

fU

L

E1

AUS

S

e

f

j

q

o

E

11

jj

II

a

P

A

Q

9

1

a

Q

oJ

a

j

6

j

O

e

SFI

DATSUN

200SX

Mode

S

II

0

Series

SECTIONCL

HYDRAULIC

CLUTCH

CONTROL

CLUTCH

PEDAL

CLUTCH

MASTER

CYLINDER

OPERATING

CYLINDER

CLUTCH

LINE

BLEEDING

CLUTCH

SYSTEM

CLUTCH

UNIT

CLUTCH

DISC

AND

COVER

RELEASE

BEARING

CLUTCH

CONTENTS

CL

2

l

Ci

2

CL

2

CL

4

t

5

CL

5

C

7

CL

7

CL

9

PILOT

BUSHING

SERVICE

DATA

AND

SPECIFICATIONS

GENERAL

SPECIFICATIONS

INSPECTION

AND

ADJUSTMENT

TIGHTENiNG

TORQUE

TROUBLE

DIAGNOSES

AND

CORRECTIONS

SPECIAL

SERVICE

TOOLS

CL

9

CL

11

clli

CL

11

CL11

CL12

CL14

Refer

to

Section

MA

Clutch

for

CHECKING

CLUTCH

PEDAL

HEIGHT

AND

FREE

PLAY

Hydraulic

C

utJ

h

Conrrol

CLUTCH

HYDRAULIC

CLUTCH

CONTROL

CLUTCH

PEDAL

REMOVAL

1

Remove

instrument

lower

cover

2

Pry

off

snap

and

take

out

clev

is

0

o

3

SCLOOl

1

li

ring

1

Return

spring

3

Oevi

4

Stopper

bolt

5

Outchpedal

3

Remove

stopper

bolt

4

Remove

E

ring

on

fulcrum

then

remove

clutch

pedal

and

return

spring

INSPECTIoN

Inspect

the

foUowing

parts

If

ab

nonnalities

are

found

repair

or

replace

the

affected

parts

I

Clutch

pedal

bushing

D

at

boss

fulcrum

V

and

E

ring

@

for

wear

deformation

or

damage

Bushing

iJ

p

fitted

If

it

shows

sign

of

abnonnality

replaca

pedal

as

sembly

2

Clevis

@

for

wear

or

damage

and

snap

@

for

any

deformation

3

Pedal

@

pedal

pad

j

and

pedal

stopper

@

or

clutch

switch

for

de

formation

or

damage

4

Return

spring

@

for

fatigue

or

damage

Cl

2

r

D

G

SC

l002

l

INSTAllATION

I

Install

clutch

pedal

in

reverse

or

der

of

removal

Observe

foUowing

a

Apply

grea

to

boss

ofclutch

ped

al

return

spring

and

fiih

rum

SCL003

b

Firmly

attach

E

ring

to

fulcrum

SCL0Q4

Q

Co

I

nstall

clevis pin

on

tha

left

of

clutch

pedal

and

attach

snap

sa

curaly

d

I

nstall

return

spring

as

shown

in

Figure

on

this

page

2

After

assembly

adjust

clutch

ped

aI

height

and

free

play

Refer

to

Checking

Clutch

Pedal

Height

and

Free

Play

Section

MA

tV

Pedal

rtoppar

lock

nut

7

B

11

8N

m

10

8

12

kg

m

5 8 87

ft

lbl

CLUTCH

MASTER

CYLINDER

REMOVAL

I

Remove

snap

from

clevis

2

Pull

out

clevis

3

Disconnect

clutch

tube

4

Remove

master

cylinder

When

disconnecting

clutch

tube

be

sure

to

recei

draining

clutch

fluid

into

a

container

Use

of

rags

is

also

suggestad

to

keep

adjacent

parts

and

area

dean

CAUTION

When

disconnecting

dutch

tube

use

suitable

flare

nut

wrench

Never

use

an

open

end wrench

or

adjustable

wrench

DISASSEMBLY

CLUTCH

Hydniulic

Clutch

Control

I

Remove

dust

cover

and

take

off

stopper

ring

t1

SCLOO6

2

Then

the

push

rod

and

stopper

can

be

taken

out

3

Loosen

stopper

bolt

and

take

it

out

4

The

piston

spring

seat

and

return

spring can

be

taken

out

Discard

piston

cup

and

ust

cover

ir

Reservoir

band

1

Iii

78

11

8 0 8

Stoppetbol

Return

spring

1

2

58 8

7

CAUTION

Never

detach

reservoir

If it

is

removed

for

any

reason

discard

it

and

install

new

one

INSPECTION

CAUTION

To

clean

or

wash

all

parts

of

master

cylinder

clean

brake

fluid

must

be

used

Never

use

mineral

oils

such

as

gasoline

and

kerosene

It

will

ruin

the

rubber

parts

of

the

hydraulic

system

1

Check

cylinder

bore

and

piston

for

score

or

rust

and

if

fo

nd

replace

2

Check

cylinder

bore

and

piston

Lock

nut

lii7

8

11

8

0

8

1

2

58 8

7

Iii

N

m

kg

mfHb

SCL005

for

wear

If

the

clearance

between

cylinder

bore

and

piston

exceeds

specified

value

replace

piston

as

sembly

or

master

cylinder

assembly

Cearance

between

cylinder

bore

and

piston

Le

than

0

15

mm

0

0059

in

3

Check

condition

of

piston

cup

and

dust

cover

Always

replace

them

after

disassembly

4

Check

aU

recesses

openings

and

internal

passages

to

ensure

that

they

are

clean and

free

from

foreign

matter

ASSEMBLY

I

Apply

grease

to

cylinder

body

sliding

part

and

piston

cup

CL3

Hydraulic

C1u

t

h

Control

CLUTCH

2Install

piston

assembly

to

cylinder

body

Be

careful

not to

damage

piston

cup

4

Make

sure

that

master

cylinder

operates

normally

5

Make

sure

thai

piston

can

move

maximum

siroke

smoothly

Stopper

bolt

1

529

N

m

0

15

0 3

k9

m

1 1

22

ft

lb

INSTALLATION

InstaU

clutch

master

cylinder

in

reverse

order

of

removal

Observe

foUowing

I

Bleed

air

out

of

hydraulic

system

Refer

to

Bleeding

Clutch

System

2

Adjust

pedal

height

and

pedRl

free

play

Refer

to

Checking

Clutch

Pedal

HeiRht

and

Free

Play

Section

MA

Master

cylinder

to

dash

panel

HCUring

nut

7

8

11 8

N

m

0

8

12

kg

m

58

8

7

ft

bl

Clutch

tube flare

nut

15 18 N

m

1

5

1

8

kg

m

11

13ft

b

Push

rod

lock

nut

7

8

11

8N

m

0

8

1

2

kg

m

58

87

ft

bl

CAUTION

When

connecting

dutch

tube

use

Tool

GG94310000

I

J

When

tightening

flare

nut

hold

pi

by

hand

to

prevent

it

from twist

in9

OPERATING

CYUNDER

REMOVAL

L

lo9sen

clutch

tl

be

flare

nut

at

the

bracket

on

side

member

Cl

4

I

fTI

sc

L001

CAUTION

When

disconnecting

clutch

tube

use

suitable

flare

nut

wrench

Never

use

an

open

end

wrench

or

adjustable

wrench

2

Remove

lock

spring

then

dis

engage

hose

from

bracket

3

Remove

clutch

hose

from

oj

er

ating

cylinder

4

Remove

operating

cylinder

DISASSEMBLY

I

Remove

dust

cover

and

push

rod

2

Remove

piston

and

piston

cup

as

an

assembly

Discard

piston

cup

and

dun

cover

3

Remove

bleeder

screw

CL222

1

Push

rod

2

Dwt

cover

3

Piston

spring

4

Piston

5

Piston

cup

6

Operating

cylinder

7

Bleeder

screw

INSPECTION

Visually

inspect

all

disassembled

parts

and

replace

parts

which

are

worn

or

damage

CAUTION

To

clean

or

wash

all

parts

of

operating

cylinder

clean

brake

fluid

must

be

used

Never

USe

mineral

oils

such

is

gasoline

and

kerosene

It

will

ruin

the

rubber

parts

of

the

hydraulic

system

I

Check

cylinder

bore

and

piston

for

score

or

rust

and

if

found

replace

2

Check

cylinder

bore

and

piston

for

wear

If

clearance

between

cylinder

bore

and

piston

is

more

than

the

specified

value

replace

piston

or

oper

ating

cylinder

assembly

Cearance

between

cylinder

bore

and

piston

less

than

0

15

mm

0

0059

in

3

Check

condition

of

piston

cup

and

dust

cover

Always

replace

them

after

disassembly

heck

bleeder

holno

be

surnhat

it

is

clean

ASSEMBLY

Assemble

operating

cylinder

in

reverse

order

of

disassembly

Observe

following

I

Prior

to

assembly

dip

a

new

pis10n

cup

in

clean

brake

fluid

To

install

piston

cup

on

piston

pay

particular

attention

to

its

direc

ion

2Dip

cylinder

nd

pis10n

in

clean

brake

fluid

before

assembly

INSTALLATION

Install

operating

cylinder

in

reverse

order

of

removal

Observe

foUowing

Bleed

air

thoroughly

from

clutch

hydraulic

system

Refer

to

Bleeding

Clutch

System

8

When

operating

cylinder

is

r

moved

from

or

installed

on

elutch hou

ing

without

disconnecting

clutch

hose

from

operating

cylinder

loos

en

bleeder

scrow

so

that

push

rod

moves

lightly

b

Exercise

care

not to

warp

or

twist

clutch

hose

Be

sure

to

install

clutch

hose

away

from

exhaust

tube

c

When

tightening

flare

nut

hold

pipe

by

hand

to

prevent

it

from

twisting

CAUTION

When

connecting

clutch

tube

use

Tool

GG94310000

li

Bleeder

screw

6 9 8 8

N

m

07 0 9

kg

m

5

1

6 5

ft

lb

Operating

cylind

r

10

clutch

housing

securing

bolts

30

40

N

m

3

1

41

kg

m

22 30

ft

lb

Clutch

hose

to

operating

cylinder

17

21

N

m

1

7 2

1kg

m

12 15

ft

lb

CLUTCH

UNE

INSPECTION

Check

clutch

lines

tube

and

hose

for

evidence

of

cracks

deterioration

or

other

damage Replace

if

necessary

If

leakage

occurs

at

or

around

joints

retighten

and

if

necessary

re

place

damaged

parts

REMOVAL

CAUTION

When

disconnecting

clutch

tube

use

suitable

flare

nut

wrench

Never

use

an

open

end

wrench

or

adjustable

wrench

I

Disconnect

clutch

tube

from

clutch

hose

at

bracket

on

side

memo

ber

2

Remove

lock

spring

then

disen

gage

hose

from

bracket

3

Remove

clutch

hose

from

oper

ating

cylinder

4

Disconnect

clutch

tube

from

mas

ter

cylinder

5

Remove

clamp

fixing

clutch

tube

to

dash

panel

INSTALLATION

Wipe

the

opening

ends

of

hydraulic

line

to

remove

any

foreign

matter

before

making

connections

I

Install

clutch

tube

I

Connect

clutch

tube

to

master

cylinder

with

flare

nut

2

Fix

clutch

tube

to

dash

panel

with

clamp

3

Then

tighten

flare

nut

li

Clutch

hose

to

master

cylinder

15 18

N

m

1

5

1

8

kg

m

t

1

13

ft

lb

2

Install

clutch

hose

on

operating

cylinder

with

a

gasket

in

place

Use

new

gasket

li

Clutch

hose

to

operating

cylinder

17

21

N

m

1

72

1kg

m

12 15

ft

lb

3

Engage

opposite

end

of

hose

with

bracket

Install

lock

spring

fixing

hose

to

bracket

a

When

tightening

flare

nut

hold

pipe

by

hand

to

prevent

it

from

twisting

b

Exercise

care

not

to

warp

or

twist

clutch

hose

4

Connect

clutch

tube

to

hose

with

flare

nut

and

tighten

it

li

Flare

nut

15 18

N

m

1

5

1

8

kg

m

11

13

ft

lb

5

Check

distance

between

clutch

line and

adjacent

parts

especially

be

tween

hose

and

exhaust

tube

6

Bleed

air out

of

hydraulic

sys1em

Refer

to

Bleeding

Clutch

System

for

adjustment

CLUTCH

Hydraulic

Clutch

Control

CAUTION

When

tightening

flare

nut use

Tool

GG94310000

BLEEDING

CLUTCH

SYSTEM

The

hydraulic

clutch

system

must

be

bled

whenever

clutch

line

has

been

disconnected

or

air

has

entered

it

I

Remove

cap

of

reservoir

and

top

up

with

recommended

brake

fluid

I

o

SC

LoDe

2

Thoroughly

clean

mud

and

dust

from

bleeder

screw

of

operating

cylinder

so

that

outlet

hole

is

free

from

any

foreign

material

Install

bleeder

hose

vinyl

hose

on

bleeder

screw

Place

the

other

end

of

it

in a

con

tainer

filled

with

brake

fluid

J

SCL009

CL

5

Hydraulic

Clutch

Control

CLUTCH

3

Have

a

co

worker

depress

clutch

pedal

two or

three

times

With

clutch

pedal

depressed

fully

loosen

bleeder

screw

to

bleed

air out

of

clutch

system

CD

Depress

pedal

two

or

three

times

dlll

y

I

ilr

j

CJy

@

SCL010

CL

6

4

Close

bleeder

screw

quickly

as

clutch

pedal

is

on

down

stroke

S

Allow

clutch

pedal

10

return

slow

ly

with

bleeder

screw

closed

6

Repeat

steps

3

through

5

until

no

air

bubble

shows

in

the

vinyl

hose

G

l

Bleeder

screw

69

88

N

m

0 7 0 9

kg

m

5

1

6

5

fHbl

7

Depress

and

release

dutch

pedal

several

tim

s

then

check

for

external

hydraulic

leaks

at

connections

a

Brake

fluid

containing

air

i

white

and

has

visible

air

bubbles

b

Brake

fluid

containing

no

air

runs

out

of

bleeder

screw

in

asolid

stream

without

air

bubbles

c

Pay

close

attention

to

clutch

fluid

leve

in

reservoir

during

bleeding

operation

d

Add

brake

fluid

to

reservoir

only

up

to

h

f

tl

le

yel

qo

not

overfill

CAUTION

a

Do

not

re

use

brake

fluid

drained

during

bleeding

operation

b

Exercise

care

not

to

splash

brake

fluid

on

exterior

finish

as

it

will

damage

the

paint

c

When

tightening

flare

nut use

Tool

GGg4310000

CLUTCH

UNIT

CLUTCH

DISC

AND

COVER

CLUTCH

Clutch

Unit

REMOVAL

Be

sure

to

turn

them

out

in

a

crisscross

fashion

I

Remove

transmission

from

engine

Refer

to

Removal

Section

MT

2

Insert

Tool

into

clutch

disc

hub

@

4

Remove

clutch

disc

and

cover

assembly

3

Loosen

bolts

attaching

clutch

cover

to

Ilywheel

one

turn

each

at

a

time

until

spring

pressure

is

released

INSPECTION

Wash

all

disassembled

parts

except

disc

assembly

in

suitable

cleaning

SCLOll

solvent

to

remove

dirt

and

grease

before

making

inspection

and

adjust

ment

Flywheel

end

pressure

plate

Check

friction

surface

of

Ilywheel

and

pressure

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

Clutch

disc

assembly

Inspect

clutch

disc

for

worn

or

oily

facings

loose

rivets

and

broken

or

loose

torsional

springs

IIf

facings

are

oily

disc should

be

replaced

In

this

case

inspect

trans

mission

front

cover

oil

seal

pilot

bushing

engine

rear

oil

seals

and

other

points

for

oil

leakage

CL

7

C1Ul1

h

Unit

CLUTCH

2

The

disc

should

also

be

replaced

when

facings

are

worn

locally

or worn

down

to

the

specified

limit

Wear

limit

of

facing

A

Less

than

03

mm

10

012

inl

II

I

ril

Q

l

c

F

l

I

A

CL336

3

Check

disc

plate

for

runout

when

ever

the

old

disc

or

a

new

one

is

installed

4

If

runout

exceeds

the

specified

value

at

outer

circumference

of

facing

place

or

repair

disc

Runout

limit

total

indicator

reading

Less

than

05

mm

0

020 in

R

from

hub

center

95

mm

3

74

in

Backlash

Less

than

0

4

mm

10

016

inl

Clutch

cover

assembl

1

Check

end

surface

of

diaphragm

spring

for

wear

If

excessive

wear

is

found

replace

clutch

cover

assembly

2

Measure

height

of

diaphragm

springs

as

outlined

below

I

Place

Tool

ST20050100

on

Tool

ST200500

10

and

then

tighten

clutch

cover

assembly

on

base

plate

by

using

Tool

ST20050051

ST20050010

ST20050051

jST20050100

1

@

CAUTION

When

repairing

disc

plate

never

hold

it

forcibly

with

pliers

or

bend

it

exces

siveIy

otherwise

facing

will

be

dam

aged

CL

12

5

Check

fit

of

disc

hub

ontransmis

sion

main drive

gear

splines

for

smooth

sliding

If

splines

are

worn

clutch

disc

or

main

drive

gear

should

be

replaced

that

backlash

exceeds

the

specified

value

at

outer

edge

of

clutch

disc

CL

8

CL

151

2

Measure

height

A

at

several

points

with

a

vernier

caliper

depth

gauge

Oiaphragnt

spring

height

A

31 6

33

6

mm

11

244

1

323inl

l

SCL014

If

height

A

of

spring

end

beyond

specified

value

dju

t

spri

lll

height

with

Tool

ST20050240

1

necessary

replace

clutch

cover

as

sembly

SCL018

Also

unevenness

of

diaphragm

spring

toe

height

should

be

wilhin

the

specified

limit

Unevenness

of

diaphragm

spring

toe

height

Less

than

0 5

mm

0

020

in

A

If

unevenness

of

diaphragm

spring

toe

height

beyond

specified

value

adjust spring

height

with

Tool

ST20050240

3

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

INSTALLATION

I

Apply

a

light

coat

of

grease

in

c1uding

molybdenum

disulphide

10

transmission

main

drive

gear

splines

Slide

clutch

disc

on

main

drive

gear

several

times

Remove

clutch

disc

and

wipe

off

excess

lubricant

pushed

off

by

disc

hub

Take

special

care

to

prevent

grease

or

oil

from

getting

on

cluteh

faeing

2

Reins1a11

clutch

disc

and

clutch

cover

assembly

Support

clutch

disc

and

cover

assemblies

with

Tool

KV30100100

Be

ure

to

keep

disc

faeings

fly

wheel

and

pressure

plate

clean

and

dry

KV30100100

CL340

3

Install

clutch

cover

assembly

Each

bolt

should

be

tightened

one

turn

at

a

time

in a

crisscross

fashion

til

Clutch

cover

bolt

16

21

N

m

1

6 2

1

kg

m

12

15lt

lb

4

Remove

clutch

aligning

bar

5

Reinstall

transmission

Refer

to

Installation

Section

MT

RELEASE

BEARING

REMOVAL

1

Remove

transmission

from

engine

Refer

to

Removal

Section

MT

2

Disconnect

holder

spring

from

bearing

sleeve

3

Remove

release

bearing

and

sleeve

as

an

assembly

from

transmission

case

front

cover

4

Take

clutch

release

bearing

out

from

bearing

sleeve

using

a

universal

puller

and

a

suitable

adapter

CLt45

INSPECTION

Check

for

abnormal

wear on

con

tact

surface

of

withdrawal

lever

ball

and

bearing

sleeve

Hold

bearing

inner

race

and

rotate

outer

race

while

applying

pressure

to

it

If

the

bearing

rotation

is

rough

or

noisy

replace

bearing

INSTALLATION

I

Assemble

release

bearing

on

sleeve

using

a

press

l

j

l

I

u

SCL015

Do

not

depress

outer

race

2

Before

or

during

assembly

lubri

cate

the

following

points

with

a

light

coat

of

multi

purpose

grease

1

Inner

groove

of

release

bearing

sleeve

L

SCL016

2

Contact

surfaces

of

withdrawal

lever

ball

and

bearing

sleeve

3

Bearing

sleeve

sliding

surface

of

transmission

case

front

cover

SMT016

CLUTCH

Clutch

Unit

4

Transmission

main drive

gear

splines

Use

grease

including

molybde

num

disulphide

Amall

mount

of

gre

hould

be

coatad

to

tho

bov

points

If

too

much lu

ricant

is

applied

it

wilt

run

out

on

the

friction

plltes

when hot

re

lulting

in

damaged

clutch

disc

facing

3

After

lubricating

install

with

drawal

lever release

bearing

and

sleeve

assembly

in

position

Connect them

with

holder

spring

SMT010

4

Reinstall

transmission

Refer

to

Installation

Section

MT

PILOT

BUSHING

REMOVAL

I

Remove

transmission

from

engine

Refer

to

Removal

Section

MT

2

Remove

clutch

disc

and

cover

assembly

Refer

to

Clutch

Disc

and

Cover

for removal

3

Remove

pilot

bushing

in crank

shaft

with

TooL

CLOSS

CL

9

OutdWnit

CLUTCH

INSPECTION

Check

pilot

bushing

for

fit

in

bore

of

crank5haft

Check

inner

surface

of

pilot

bushing

for

wear

roughness

or

bell

mouthed

condition

If

pilot

bushing

is

worn

or

damaged

replace

When

bushing

is

damaged

be

sure

to

check

transmission

main

drive

gear

at

the

same

time

INSTALLATION

1

Before

installing

a

new

bushing

thoroughly

clean

bushing

hole

2

Inser1

pilo1

bushing

until

distance

A

between

flange

end and

pilot

bushing

is

specified

distance

CL10

Distance

A

4 0

mm

0

157

inl

Do

not

oil

bushing

When

inserting

pilot

bushing

be

careful

not

to

damage

edge

of

pilot

bushing

A

Pilot

bushing

EM719

3

InstaU

clutch

disc

and

clutch

cover

assembly

Refer

to

Clutch

Disc

and

Cover

for

installation

4

Install

transmission

Refer

to

In

staUa1ion

Section

MT

CLUTCH

Service

Data and

Specifications

SERVICE

DATA

AND

SPECIFICATIONS

GENERAL

SPECIFICATIONS

a

UTCH

CONTROL

SYSTEM

I

Type

of

clutch

control

a

UTCH

MASTER

CYLINDER

Ilnnar

diameter

mmOn

Hydraulic

15

88

1581

TV

a

UTCH

OPERATING

CYLINDER

Non

adjustable

Inner

diameter

mm

jn

a

UTCH

DISC

I

Type

Facing

size

Outer

die

x

Inner

die

x

Thickness

mm

inl

Thickness

of

disc

assembly

Free

mm

in

Installed

mmUnl

Number

of

torsion

springs

a

UTCH

COVER

Type

Full

load

N

Ikg

lb

1746

111

161

200CB

L

20

130

x

3 5

1787

x

5

12

x

0

1381

8

50

9

20

10

3346

0

36221

7

6 8

0

10

299

0

315

6

C200S

3

923

1400

882

INSPECTION

AND

ADJUSTMENT

a

UTCH

PEDAL

I

Pedal

height

H

l

Pedal

free

play

AU

mm

in

mm

in

a

UTCH

MASTER

CYLI

NDER

I

Clearance

between

cylinder

bore

and

pilton

mm

Unl

168 174

16

61

6

85

5

10

04

0

201

I

Loss

than

0

15

10

0059

j

a

UTCH

OPERATING

CYLINDER

I

Clearance

between

cylinder

bore

and

piston

mrn in

I

Lessthan

0

15

10

00591

J

a

UTCH DISC

Unit

mm

In

I

Model

200CBL

I

Wear

limit

offacing

surface

to

rivet

0

3

10

0121

I

hood

Runout

limit

0 5

10

0201

I

Distance

of

nout

checking

point

9513

741

from

the

hub

center

I

Maximum

backlash

of

spline

04

10

016

at outer

edge

of

disci

a

UTCH

COVER

Unit

mm

lin

I

Model

C200S

I

Dioph

ag

m

spring

ho

ght

31

6

33

6

11

244

1

3231

I

Unevenness

of

diophragm spring

toe

Less

than

0

5

0

020

height

PILOT

BUSHING

I

Inserted

distance

of

pilot

bushing

4

0

10

1571

mrn in

TIGHTENING

TORQUE

Unit

N

m

kg

m

ft

Ib

I

Pedal

stopper

bolt

lock

7

8

11

8

08

1

2 5

8

8 7

nut

I

Maner

cylinder

push

cd

7

8

11

8 0

8

1

25 8

8

7

lock

nut

Master

cylinder

stopper

1

5 2

9 0

15

0 3

11

2 2

bolt

Master

cylinder

securing

7 8

11

8

0

8

1

25

8

8 7

nut

Clutch

fube flare

nut

15

18

1

5

18

11

13

I

Push

rod

lock

nut

7

8 11

8

08

1

2 5 8

8

7

I

Dporating

cylindor

6 9

88

0 7

09

5

1

6

5

bleeder

screw

Operating

cylinder

30

40

3

1

4

1

22 30

lecuring

bolt

Clutch

hose

to

operating

17 21

17

2

1

12 15

cylinder

securing

nut

I

Clutch

cover

securing

16 21

1

6 2

1

12 15

bolt

CL

11

I

TroUble

DiagnosesBnd

Corrections

CLUTCH

TROUBLE

DIAGNOSES

AND

CORRECTIONS

a

UTCH

SLIP

Slipping

of

clutch

may

be

noticeable

when

any

of

the

following

symptoms is

encountered

during

operation

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

engine

problem

First

determine

whether

engine

or

clutch

is

caus

ing

the

problem

If

slipping

clutch

is

left

unheeded

wear

and

or

overheating

will

occur

on

clutch

facing

to

such

an

exten1that

it

is

no

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

slipping

Probable

cause

Corrective

action

Clutch

facing

hardened

or

wet

with

oil

Clutch

facing

excessively

worn

Diaphragm

spring

weak

or

damaged

Flywheel

or

pressure

plate

warped

Particles

in

return

port

of

master

cylinder

Piston

fails

to

return

to

its

original

posi1ion

Clutch

tube

deformed

or

crushed

Repair

or

replace

Replace Replace

iLengine

transmi

ion

oil

seal

is

faulty

Replace

Repair

or

replace

Clean

or

replace

faulty

paris

Replace

a

UTCH

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

speed

Aftera

short

inter

mission

shift

gears

into

Reverse

If

noise

is

heard

while

gears

are

being

shifted

clutch

is

dragging

CL

12

CLUTCH

Trouble

Diagnoses

and

Corrections

Probable

cause

Corrective

action

Clutch

disc

hub

splines

worn

or

rusted

Replace

or remove

rust

and

coat

with

grease

Replace

faulty

parts

Bleed

air

Adjust

Replace

04

Replace

Coat

with

grease

Replace Replace

if

engine

transmission

oil

seal

is

faulty

Oil

leakage

at

master

cylinder

operating

cylinder

tube

or

hose

Air

in

hydraulic

system

Insufficient

pedal

stroke

Clutch

disc

runout

or

warped

Diaphragm

spring

fatigued

Piston

cup

deformed

or

damaged

Lack

of

grease

on

pilot

bushing

Clutch

facing

wet

with

oil

CLUTCH

CHATTERS

Clutch

chattering

is

usually

noticeable

when

car

is just

rolled

off

with

clutch

partially

engaged

Probable

cause

Corrective

action

Oil

on

clutch

facing

Diaphragm

spring

fatigued

Clutch

facing

hardened

Clutch

facing

warped

Pressure

plate

worn

or

warped

Engine

mounting

loose

or

rubber

deteriorated

Clutch

facing

rivets

loose

Replace

Repair

or

replace

Replace

Tighten

or

replace

Replace

NOISY

CLUTCH

Probable

cause

Corrective

action

Release

bearing

sleeve

damaged

or

improperly

lubricated

Pilot

bushing

worn

jammed

or

damaged

Clutch

facing

rivets

loose

Disc

plate

cracked

Clutch

disc

torsion

springs

fatigued

Replace

RABBIT

HOPPING

CLUTCH

When

rabbit

hopping

of

clutch

occurs

car

will

not

rol1

off

smoothly

from

a

standing

star1

or

clutch

will

be

engaged

be

fore

clutch

pedal

is

fully

depressed

Probable

cause

Corrective

action

Oil

On

clutch

facing

Clutch

facing

worn

or

rivets

loose

Flywheel

pressure

plate

warped

or

worn

Mounting

bolts

on

engine

or

power

train

loose

Diaphragm

spring

fatigued

Replace

Tighten

Replace

CL

13

Special

Service

Tools

CLUTCH

SPECIAL

SERVICE

TOOLS

Tool

number

Tool

name

Kent

Moore

No

KV30100100

Clutch

aligning

bar

CLJI

2

1

ST20050100

Distance

piece

@

ST200500

10

Base

plate

@

39

ST20050051

Set

bolt

ST200S0240

Diaphragm

spring

adjusting

wrench

STI

661

000

I

123907

Pilot

bushing

puUer

n

o

GG94310000

Flare

nut

torque

wrench

IIIIlII

lII1A

CL14

DATSUN

200SX Mode

S

II

0

Series

MANUAL

TRANSMISSION

REMOVAL

AND

INSTALLATION

REMOVAL

INSTALLATION

5

SPEED

TRANSMISSION

Model

FSsW71B

REAR EXTENSION

TRANSMISSION

CASE

FORKS

AND

FORK

RODS

GEARS

AND

SHAFTS

REPLACEMENT

OF

OIL

SEALS

CONTENTS

MT

2

MT

2

MT

2

MT

3

MT

6

MT

7

MT

8

MT

9

MT14

REPLACEMENT

OF

BEARINGS

SERVICE

DATA

AND

SPECIFICATIONS

GENERAL

SPECIFICATIONS

INSPECTION

AND

ADJUSTMENT

TIGHTENING

TORQUE

TROUBLE

DIAGNOSES

AND

CORRECTIONS

SPECIAL

SERVICE

TOOLS

MT14

MT16

MT17

MT18

MT2

2

Removal

and

Inrtallation

MANUAL

TRANSMISSION

REMOVAL

AND

INSTALLATION

REMOVAL

I

Disconnect

battery

ground

cable

2

Remove

accelerator

linkage

J

Jack

up

car

anI

support

its

weight

on

safety

stands

Use

a

hydraulic

hoist

or

open

pit

if

available

Make

sure

that

safety

is

insured

4

Disconnect

front

exhaust

tube

5

Disconnect

wires

from

reverse

back

up

lamp

Top

and

O

D

gear

if

so

equipped

switches

6

Disconnect

speedometer

cable

7

Remove

propeUer

shaft

Refer

to

Propeller

Shaft

Section

PO

for

removal

Plug

up

opening

in

rear

extension

to

prevent

oil

from

flowing

out

8

Remove

clutch

operating

cylinder

9

Support

engine

by

placing

a

jack

under

oil

pan

with

a

wooden

block

used

between

oil

pan

and

jack

CAUTION

00

not

place

jack

under

oil

pan

drain

plug

10

Support

transmission

wi1h

a

trans

mission

jack

H

I

Remove

console

box

Refer

to

Console

Box

Section

BF for

removal

2

Place

transmission

control

lever

in

neutral

position

and

remove

E

ring

and

control lever

MT

2

TM335

12

Loosen

rear

engine

mount

secur

ing

nuts

CD

tempobirily

and

remove

crossmember

mounting

nuts

00

I3

Remove

starter

motor

14

Remove

bolts

securing

1ransmis

sian

to

engine

Then support

the

engine

and

trans

mission

with

jacks

and

slide

transmis

sion

rearward

away

ffom

engine

and

remove

from

the

car

CAUTION

Take

care

in

dismounting

transmission

not

to

strike

any

adjacent

parts

and

main

drive

gear

INSTALLATION

Install

the

transmission

in

reverse

order

of

removal

paying

attention

to

the

foUowing

points

I

Before

installing

clean

mating

surfaces

of

engine

rear

plate

and

trans

mission

case

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

lever

and

striking

rod

3

When

installing

control

lever

be

sure

to

apply

multi purpose

grease

to

sliding

parts

as

shown

below

Bushing

Grease

coating

Control

lever

Grease

coating

SMT142

Striking

guide

4

Remove

filler

plug

and

fill

1rans

mission

with

recommended

gear

oiI

o

the

level

of

1he

plug

hole

Oil

capacity

2

0

liten

4

1

lJ

P1

2Imp

I

ll

5

Apply

sealant

to

threads

of

filler

plug

and

instaU

filler

plug

to

transmis

sionc

iJ

Filler

plug

25 34

N

m

25 35

kg

m

18

25

ft

lb

6

Tighten

bolts

securing

transmis

tion

to

engine

iJ

@

43

58

N

m

4

59

kg

32

43

ft

bl

@

25

35N

m

2

6 3

81qj

m

19

28ft

lb

A

7

Lubricate

oil

seal

lip

and

bushing

on

rear

extension

with

gear

oil

for

ini

tial

lubrication

3

Neutral

switch

Iii

20

29

2

0

3

0

14

22

Oil

leal

Apply

gear

oil

to

oil

seal

on

Iii

20

29

2

0

3

0

14

22

Iii

20

rTOP

gear

witch

i

J

20

29

2

0

Revet

lampowS

29

2

0

3

0

14

22

23

1

6

2

3

12

17

f

Bearing

3

0

14

2

Adapter

plate

Front

cover

Filler

plll8

Iii

25

34

2

5

3

5

18

25

Apply

sealant

to

thread

of

bolts

Drain

plug

Iii

25

34

2

5

3

5

18

25

E

21

1

6

21

12

15

Iii

N

m

kg

m

ft

lb

C1I

en

mm

C

f

0 Z

en

3

en

5

z

3

Z

C

r

I

Z

CJl

3

en

CJl

o

Z

I

i

a

3

o

Q

1

JJ

C1I

e

OJ

I

iii

g

Cl

It

l

5

speed

Trafl

lTlissiof1

ModeIFS5W71BJ

MANUAL

TRANSMISSION

3rd

main

gear

SnaPrinB

Main

drive

gear

ball

bearing

Washer

Snap

rinB

Apply

gear

oil

to

needle

bearq

3rd

11

4th

synchronizet

hub

pread

spring

Pay

attention

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 94

counter

geu

Apply

gear

oil

to

needle

bearing

Counter

front

bearing

Snap

ring

Woodruff

key

Reverse

idlet

sear

bearing

Reverse

idler

thro

t

washer

Reverse

idler

shaft

Shim

Refer

to

transmission

case

for

assembly

Iii

N

m

kg

m

ft

b

SMT040

MT

4

MANUAL

TRANSM

ISSION

5

speed

Transmission

Model

FS5W71BJ

Striking

guide

25

1

9

2 5

14

18

Check

prins

Check

ball

ErinB

r

J

O

r

StoPper

guide

pic

fRetum

spri

plUS

J

Apply

locking

sealer

j

to

thread

of

bolt

t

Retrun

pri

Iii

7

8 9

8

O

g

1

0

Check

prins

1

plunger

5 8 7

2

Return

checking

Check

ball

pl1lll

SPriDl

Apply

locking

sealer

to thread

of

bolt

qeontrollever

@

bushing

0

J

Lock

Apply

gear

oil

to

O

ControlleYer

5

Controlleverb

ahUw

Retainins

Interlock

baD

3m

4th

Cork

rod

Reverse

OD

shift

Cork

3m

4th

shift

Cork

Iii

19 25

1

9 2

5

14

18

Ioterlock

baD

Iii

l

m

k8

m

Ct

lb

SMT150

MT

5

54peed

TT8Il

fTJission

ModeJ

FS5W71B

MANUAL

TRANSM

ISSION

REAR

EXTENSION

DISASSEMBLY

I

Wipe

off

dirt

and

grease

2

Drain

oil

3

Remove

00

gear

switch

if

so

equipped

4

Remove

E

ring

and

stopper

guide

SMT006

INSPECTION

@NEur

4

1

W

@

In

SMT007

5

InstaU

plunger

return

spring

and

return

spring

plug

I

Clean

with

solvent

and

check

for

cracks

or

cavities

by

means of

dyeing

test

TM337

2

Check

mating

surface

of

rear

ex

tension

for

small

nicks

projection

or

sealant

If

fesr

extension

bushing

is

worn

or

5

Remove

return

spring

plug

retum

pla

it

as

an

a

ssembly

of

spring

and

plunger

from

rear

exten

bushing

and

rear

extension

housing

sion

SMT003

6

Remove

rear

extension

SMTOOS

7

Remove

lock

and

then

remove

striking

rod

MT

6

ASSEMBLY

I

Stand

transmission

case

assembly

on

wooden

plates

of

more

than

20

rom

0

79 in

thick

2

Clean

mating

surfaces

of

adapter

plate

and

rear

extension

3

Apply

sealant

to

mating

surface

of

adapter

plate

4

InstaU

rear

extension

as

foUows

I

Se

gears

at

Neutral

2

Turn

striking

guide

counterclock

wise

3

Set

striking

guide

at

Neutral

4

Aligh

end

of

striking

lever

with

cutout

portion

of

fork

rod

SMT041

1

PlUJl8O

2

Return

spring

3

Return

spring

plug

6

Apply

sealant

to

stopper

guide

then

instaU

stopper

guide

and

E

ring

7

InstaU

00

gear

switch

if

so

equipped

8

Make

sure

that

gears

operate

smoothly

9

Install

drain

plug

Iil

25 34 N

m

2

53

5kgfD

18

25

ft

lbl

TRANSMISSION

CASE

DISASSEMBLY

1

Remove

rear

extension

Refer

to

Rear

Extension

for

disassembly

2

Remove

dust

cover

release

bear

ing

and

withdrawal

lever

3

Remove

front

cover

and

gasket

Detach

countershaft

front

bearing

shim

4

Remove

main

drive

bearing

snap

ring

5

Separate

transmission

case

from

adapter

plate

TM153

MANUAL

TRANSMISSION

5

speed

Transmission

Model

FS5W71B

INSPECTION

1

Clean

with

solvent

and

check

for

cracks

or

pits

by

means of

dyeing

test

2

Check

mating

surface

of

transmis

sion

case

for

small

nicks

projection

or

sealant

ASSEMBLY

1

clean

mating

surfaces

of

adapter

plate

and

transmission

case

2

Stand

transmission

case

on

wood

en

plates

of

more

than

20

mm

O

79

in

thick

3

Apply

sealant

to

mating

surface

of

transmission

case

4

Slide

gear

assembly

onto

adapter

plate

by

lightly

tapping

with

a

soft

hammer

5

Make

certain

that

mainshaft

roo

tates

freely

SMT014

6

Fit

main drive

bearing

snap

ring

7

Select

countershaft

front

bearing

shim

as

foUows

1

Measure

height

A

I

TM371

1

Tranlmission

case

2

Counter

gear

front

bearing

3

Counter

gear

2

Select

ashim

of

thickness

A

measured

Counter

geer

front

bearing

him

Refer

to

S

O

S

8

Clean

mating

surfaces

of

front

cover

and

transmission

case

9

Apply

grease

to

shim

selected

to

r

tain

it

on

front

cover

10

Lubricate

seal

lip

and

main

drive

shaft

with

gear

oil

then

instaU

new

gasket

and

front

cover

II

Apply

sealant

to

threads

of

through

bolts

and

tighten

them

to

transmission

case

Iii

111

21

N

m

11

6

2

1

kg

m

12

151t

lbl

rmrl

SMT015

12

Apply

a

light

coat

of

multi

pur

pose

grease

MT

7

XpeerI

Transmission

Mode

FS5W71BJ

MANUAL

TRANSMISSION

rC

SMT016

13

InstaU

dust

cover

release

bearing

and

withdrawal

lever

14

Assemble

Rear

Extension

Refer

to

Rear

Extension

for

assembly

FORKS

AND

FORK

RODS

DISASSEMBLY

1

Remove

rear

extension

Refer

to

Rear Extension

for

disassembly

2

Remove

transmission

case

Refer

to

Transmission

Case

for

disassembly

3

Set

up

Tool

on

adapter

plate

4

Place

above

assembly

in

a

vise

TM754

5

Remove

check

baU

plugs

and

check

springs

MT

B

Fork

rod

1st

l

2nd

Fl

Chect

baD

@

ED

Interlock

ball

TM198A

6

Drive

out

retaining

pins

7

Drive

out

fork

rods

and

remove

interlock

baUs

and check

baUs

Be

careful

not

to

lose

three

3

check

balls

and

four

4

interlock

balls

INSPECTION

Clean

with

solvent

and

check

for

wear

scratches projection

damage

or

other

faulty

conditions

Replace

any

part

which

is

wornor

darnaged

one

6

SMT137

ASSEMBLY

I

InstaU

1st

2nd

3rd

4th

and

Q

D

Rev

shift

forks

and

1st

2nd

fork

rod

then

secure

with

retaining

2

InstaU

two

2

interlock

baUs

3

InstaU 3rd

4th

fork

rod

then

secure

with

retaining

SMT019

4

InstaU

two

2

interlock

baUs

5

InstaU O

D

Rev

shift

fork

and

fork

rod

then

secure

with

retaining

6

InstaU

check

baIls

and

check

springs

7

Apply

locking

sealer

to

check

ball

plugs

and

install

them

dl

19 25

N

m

1

9

2 5

kg

m

14

18

ft

lb

a

Check

ball

plug

for

1st

2nd

fork

rod

is

longer

than

that

for

Rey

shift

fork

rod

and

3rd

4th

fork

rod

b

To

insure

that

interlock

plunger

is

installed

properly

slide

3rd 4th

fork

rod

and

operata

the

other

fork

rod

Make

lure

that the

gear except

3rd

or

4th

gear

does

not

m

sh

8

Apply

gear

oil

to

all

sliding

sur

faces

and

check

to

see

1hat

shift

rods

operate

correctly

and

gears

are

en

gaged

smoothly

9Install

transmissio

case

Refer

to

Transmission

Case

for

assembly

10

Install

rear

extension

Refer

to

Rear

Extension

for

assembly

GEARS AND

SHAFTS

DISASSEMBLY

Mein

drive

end

counter

drive

geer

1

Remove

rear

xtension

Refer

to

Rear

Extension

for

disassembly

2

Remove

transmission

case

Refer

to

Transmission

Case

for

disassembly

3

Remove

forks

and

fork

rods

Refer

10

Forks

and

Fork

rods

for

dis

assembly

4

Measure

g

r

end

play

Refer

to

Gears

and

Shafts

for

inspection

S

Mesh

2nd

and

reverse

gear

then

draw

out

counter

front

bearing

MANUAL

TRANSMISSION

5

speed

Transmission

Model

FS5W71B

TM398

6

Remove

counter

drive

gear

snap

ring

7

Draw

out

counter

drive

gear

with

main

drive

gear

When

drawing

out

main drive

gear

mbly

b

car

ful

not

to

drop pilot

n

edle

bearing

and

baulk

ring

3rd

meln

geer

I

Remove

snap

ring

and

thrust

washer

2

Draw

out

3rd

4th

synchronizer

and

3rd

gear

o

D

geer

end

reverse

geer

1

Remove

main

drive

and

counter

drive

gears

Refer

to

Gears

and

Shafts

for

disassembly

2

Remove

3rd

main

gear

Refer

to

Gears

and

Shafts

for

disassembly

3

Measure

0

ge

r

end

play

Refer

to

Gears

and

Shafts

for

inspection

4

Mesh

2nd

and

reverse

gears

Re

lease

staking

on

counter

gear

nut

and

mainshaft

nut

and

loosen

these

nuts

Remove

counter

gear

nut

Removed

nuts

should

be

discarded

nd

should

not

be

reused

TM757

S

Drive

out

counter

00

gear

and

bearing

6

Remove

revene

counter

gear

and

spacer

Remove

snap

ring

from

reverse

idler

shaft

and

remove

reverse

idler

gear

7

Remove

snap

rings

steel

ball

speedometer

gear

and

bearing

f

I

KV32101330

TM760

8

Remove

mainshaft

nut

thrust

washer

reverse

main

gear

00

synchronizer

and

OD

gear

1st

end

2nd

mein

geer

end

counter

eer

I

Draw

out

mainshaft

assembly

together

with

counter

gear

by

tapping

rear

end

of

mainshaft

and

counter

gear

MT

9

5

siJeed

Trantmiision

Model

FS5W71B MANUAL

l

RANSMISSION

Hold

front

of

mainshaft

assembly

by

hand

being

careful

not to

drop

counter

gear

TMW1

I

J

4

I

rT

2

Remove

thrust

washer

steel

baU

1

st

gear

and

needle

bearing

Be

careful

not

to

lose

teel

ball

retaining

thlUlt

washer

Synchronizer

0

D

I

Remove

circlip

wiih

snap

ring

plier

2

Remove

syncbro

ring

band

brakes

anchor

block

and

thrust

block

INSPECTION

Bearing

I

Thoroughly

clean

bearing

and dry

with

compressed

air

CAUTION

Do

not

allow

the

bearings

to

spin

Because

it

will

damage

the

race

and

balls

Turn

them

slowly by

hand

3

Press

ou1

1st gear

rnainshaft

bush

ing together

with

2nd

gear

and

1st

2nd

synchronizer

Wlliin

priising

oiirliii

liing

holif

mainshaft

by

hand

081

not

to

drop

it

H

r

ST30031000

TM049A

Synchronizer

lat

a

2nd

and

3rd

a

4th

Disassemble

synchronizer

G

Q

sleeve

Shifting

insert

SMT02A

MT10

TM372

2

When

race

and

baU

surfaces

are

worn

or

rough

or

when

balls

are

out

of

round

or

rough

replace

bearing

with

a

new

one

3

Replace

needle

bearing

ifworn or

damaged

Gears

snd

ahafts

I

Check

all

gears

for

excessive

wear

chips

or

cracks

replace

as

required

2

Check shaft

for

bending

crack

wear

d

worn

spline

if

necessary

replace

3

Measure

gear

end

play

It

is

necessary

to

measure

end

play

before

disassembling

mainshaft

and

after

reassembling

mainshaft

Tighten

mainshaft

lock

nut

to

specified

limit

and

tneasure

end

play

to

insure

thai

it

is

within

specified

limit

If

end

play

is

not

within

specified

limit

disassemble

and

check

parts

for

condition

Replace

any

part

which

is

worn

or

damaged

iEndPmY

Mainshaft

o

bushing

CIJE

SMT025

Standard

end

play

1st

lI88r

q2

03

tDlm

0

0106

0

0134

inl

2nd

gear

0

12

0

19

mm

0

0047

0

0075

in

3rd

gar

0

13

037

mm

10

0051

0

0146

in

0

5thl

gear

0

10

0

11

mm

00039 0

0061

in

Reverse

idlar

gear

0

05

0

50

mm

00020

0

0197

inl

Baulk

ring

I

Replace

baulk

ring

if

found

to

be

deformed

cracked

or

otherwise

dam

aged

excessively

SMT026

2

Place

baulk

ring

in

position

on

gear

cone

While

holding

baulk

ring

against

gear

as

far

as

it

will

go

measure

gap

between

baulk

ring

and

outer

gear

If

the

clearance

is

smaUer

than

wear

limit

discard

baulk

ring

B8Ulk

ring

to

glar

clearance

Standard

1

20

1

60

mm

0

0472

0

0630

in

Wear

limit

La

than

0 8

mm

0

031

in

SMT140

ShlftlnB

Insert

Replace

if

worn

excessively

worn

unevenly

deformed

or

damaged

L

J

SMT064

Oil seals

1

Replace

oil

seal

if

sealing

lip

is

deformed

or

cracked

Also

discard

oil

seal

if

spring

is

out

of

position

Refer

to

Replacement

of

Oil

Seals

2

Check

the

oil

seal

lip

contacting

with

shaft

if

necessary

replace

oil

seal

and

shaft

as

aset

MANUAL

TRANSMISSION

5

speed

Transmission

Model

FS5W71B

ASSEMBLY

Adapter

plate

I

Place

new

dowel

mainshaft

bearing

on

adapter

plate

and

tap

them

Adapter

plate

Dowel

2

places

Mainshaft

bearing7

1fU11

Unit

mm

in

SMT027

2

Insert

reverse

idler

shaft

3

InstaU

bearing

retainer

4

Tighten

each

screw

then

stake

it

at

two

points

I

r

A

5

InstaU

counter

rear

bearing

with

a

soft

hammer

Synchronizer

1st

2nd

and

3rd

4th

I

Assemble

coupling

sleeve

and

hub

2Position

spread

springs

and

shift

ing

inserts

in

three

slots

in

syncliro

nizer

hub

put

coupling

sleeve

on

synchronizer

hub

Synchronizer

G D

Position

synchronizer

ring

band

brake

thrust

block

and

anchor

block

on

overdrive

clutch

gear

install

circlip

JH

D

rjeU

Band

brake

Anchor

block

TM449

Thrust block

1st

and

2nd

main

Bear

I

Assemble

2nd

gear

needle

bearing

2nd

gear

baulk

ring

1st

2nd

syn

chronizer

assembly

I

st

gear

baulk

ring

I

st gear

bushing

needle

bearing

1st

gear

steel

baU

and

thrust

washer

on

mainshaft

MTll

5

PeedTrsn

ission

Model

FS5W71B

MANUAL

TRANSMISSION

Before

installing

Sle8I

boll

and

thru

t

washer

apply

gr

ato

tham

TM358

2

Set

Tool

and

place

adapter

plate

assembly

on

it

For

counter

gear

and

For

mainshaft

and

rever

id

e

shaft

rever

idler

shaft

IoU

J

ID

lJ

f31100401

koles

for

reverie

idler

shaft

2

Press

counter

gear

into

adapter

plate

KV31100401

TM

O

3

Position

needle

bearing

3rd

main

gear

baulk

ring

and

3rd

4th

synchronizer

assembly

on

the

front

of

mainshaft

Assemble

3rd

4th

synchronizer

hub

paying

attention

to

its

direction

TM438

Front

3

Press

mainshaft

assembly

to

adapter

plate

KV3H00401

TM439

3rd

main

and

counter

8ear

I

Tap

new

woodruff

keys

until

they

are

seated

securely

MT12

Vl

SMT031

4

Install

thrust

washer

on

mainshaft

and

secure

it

with

snap

ring

of

proper

1hickness

that

will

minimize

clearance

of

groove

in

mainshafl

Mainshaft

front

snspring

Refer

to

S

O

S

TM441

cHOJ

L

Main

drive

and

counter

drive

8ear

1

Install

baulk

ring

on

synchronizer

Be

RU

to

align

of

baulk

ring

with

inserts

2

Apply

gear

oil

to

mainshaft

pilot

bearing

and

install

it

on

mainshafl

3

InstaU

main

drive

gear

with

counter

drive

gear

Assembfe

counter

driy

gear

paying

attention

to

its

direction

Front

SMT065

4

Press

counter

drive

gear

onto

counter

gear

ST23860000

KV31100400

n

TM442

Main drive

gear

and

counter

drive

gear

should

be

handled

as

a

matched

set

When

replacing

main

driva

gear

or

counter

drive

gear

be

sure

to

replace

8S

8

set

of

main

drive

gear

and

n

ter

driva

gear

Counter

drivege

ar

snap

ring

Rafer

to

S

O

S

5

Secure

counter

drive

gear with

snap

ring

that

will

minimize

clearance

of

groove

in

countershaft

o

TM366

6Press

counter

gear

front

bearing

onto

counter

gear

ST22360002

KV31100400

n

TM443

ASSEMBLY

O

D

gear

and

reverae

gear

I

After

front

side is

assembled

as

semble

reverse

counter

spacer

snap

ring

spacer

needl

bearing

reverse

idler

gear

spacer

and

snap

ring

Fr

I

LJ

I

TM451

2

Assemble

O

D

reverse

synchro

nizer

hub

reverse

gear

a

D

gear

bushing

needle

bearing

O D

gear

assembly

steel

baU

and

thrust

washer

on

mainshaft

rear

side

Before

instaU

ing

a

steel

baU

apply

grease

to

it

MANUAL

TRANSM

ISSION

5

speed

Transmission

Mode

FS5W71S

a

Assemble

O O

reverse

synchro

nizer

hub

paying

attention

to

its

direc

tion

Front

TM297A

b

Main

0 0

gear

and

countor

0

goor

should

be

handled

as

a

motch

ed

set

When

replacing

main

0

gear

and

counter

0 0

gear

be

sure

to

re

place

as

a

set

of

main

0

and

counter

0 0

gears

3

Assemble

reverse

counter

gear

overdrive

counter

gear

4

Assemble

new

mainshaft

nut

and

tighten

it

temporarily

5

InstaU

bearing

6

Mesh

2nd

and

reverse

gear

and

tighten

mainshaft

lock

nut

and

count

er

gear

lock

nut

w

ST22520000

Iii

137 167

N

m

114

0

17

0

kg

m

101

123ft

lbl

SMT044

iJ

Counter

gear

lock

nut

98

127

N

m

10

0

13

0

kg

m

72

94

ft

lbl

Conversion

of

torque

Mainshaft

nut

should

be

tightened

to

specified

torque

with

Tool

When

doing

so

the

amount

of

torque

to

be

read

on

wrench

needle

should

be

modified

according

to

the

foUowing

chart

If

137 167

N

m

14

17

kg

m

101

123

ft

lb

ST22520000

C

f1

0

Lm

f

rr

O

lOm

0

33

ft

e

S

z

u

c

u

1O

C

s

u

00

c

o

0

e

Vi

1

Upp

r

limitll

ne7

J

147

135

1

0

it

uun

o

ii

11

0

4

0 5

6

0

70 8

m

90

u

80

15

2

0

2

5

ft

SMT034

7

Stake

mainshaft

lock

nut

and

counter

gear

lock

nut

with

a

punch

8

Measure

gear

end

play

Refer

to

Gears

and

Shafts

for

inspection

MT13

5

speed

Transmission

Model

FS5W77BJ

MANUAL

TRANSMISSION

II

Assemble

soap

rings

steel

baU

and

speedometer

drive

gear

12

InstaU

forks

and

fork

rods Refer

to

Forks

and

Fork

Rods

for

assembly

13

InstaU

transmission

case

Refer

to

Transmission

Case

for

assembly

14

InstaU

rear

extension

Refer

to

Rear

Extension

for

assembly

9

FIt

soap

ring

then

assemble

main

shaft

rear

bearing

ST223500i

TM068A

10

Fit

thick

snap

ring

to

mainshaft

rear

beapng

to

eliminate

end

play

Mainshaft

rear

bearing

snap

ring

Refer

to

S

O

S

REPLACEMENT

OF

OIL

SEALS

FRONT

COVER

OIL

SEAL

It

is

necessary

to

remove

transmis

sion

unit

from

car

Replace

oil

seal

as

follows

Remove

transmission

Refer

to

RemovaL

2

Wipe

off

dirt

and

grease

3

Drain

oil

4

Remove dust

cover

release

bear

ing

and

withdrawal

lever

MT14

MAIN

DRIVE AND

7

COUNTER

FRONT

1

Remove

main

drive

and

counter

drive

gear

Refer

tb

Gears

and

Shafts

for

disassembly

2

Remove

main

drive

gear

snap

ring

and

spacer

3

Remove

main

drive

bearing

5

Remove

front

CO

Ier

6

Remove

oil

seal

7

Apply

coat

of

gear

oil

0

oil

seal

surface

then

drive

new

seal

into

place

ST23800000

PreS

Z

Y

o

J

oV

80

SMT036

8

Lubricate

seal

lip

and

main

drive

shaft

with

gear

oil

9 Install

front

cover

in

reverse

order

of

removal

REAR

EXTENSION

OIL

SEAL

Rear

extension

oil

seal

can

be

replaced

without

removing

transmis

sion

Replace

oil

seal

as

follows

I

Remove

propeller

shaft

Refer

to

PropeUer

Shaft

Section

PD

for

reo

movaL

2

Remove

oil

seal

SMT037

3

Apply

coat

of

gear

oil

to

oil

seal

surface

then

drive

new

seal

into

place

4

InstaU

propeller

shaft

Refer

to

PropeUer

Shaft

Section

PD

for

instal

lation

REPLACEMENT

OF

BEARINGS

TM349

4

Press

new

main

drive

bearing

Press

SMT038

5

Place

main

drive

bearing

spacer

on

main

drive

bearing

and

secure

main

drive

bearing

with

thicker

snap

ring

that

wiD

eliminate

end

play

Main drive

gear

snap

ring

Refer

to

S

O

S

6

Mesh

2nd

and

reverse

gear

then

draw

out

counter

front

bearing

TM398

7

Press

counter

gear

front

bearing

onto

counter

gear

ST23860000

KV31100400

n

TM442

8

InstaU

main

drive

and

counter

drive

gear

Refer

to

Gears

and

Shafts

for

assembly

MAINSHAFT

AND

COUNTER

REAR

1

Remove

rear

extension

Refer

to

Rear

Extension

for

disassembly

2

Remove

transmission

case

Refer

to

Transmission

Case

for

disassembly

3

Set

up

Tool

on

adapter

plate

4

Place

above

assembly

in

a

vise

MANUAL

TRANSMISSION

5

speed

Transmifi1iion

Model

FS5W71B

TM754

5

Remove

main drive

and

counter

drive

gear

Refer

to

Gears

and

Shafts

for

disassembly

6

Remove

reverse

main

gear

Refer

to

Gears

and

Shafts

for

disassembly

7

Draw

out

mainshaft

assembly

together

with

counter

gear

by

tapping

rear

end

of

main

shaft

and

counter

gear

Hold

front

of

meinshaft

essembly

by

hand

being

careful

not

to

drop

counter

gesr

TP

347

8

Remove

bearing

retainer

SMT039

9

Replace

mainshaft

bearing

by

new

one

10

Press

out

countershaft

rear

bear

ing

CAUTION

When

pressing

out

bearing

gear

hold

shaft

by

hand

so

as

not

to

drop

it

III

Countenhaft

rear

bearing

I

11

TM351

11

Press

counter

rear

bearing

onto

adapter

plate

12

InstaU

mainshaft

bearing

onto

adapter

plate

13

I

nstaU

bearing

retainer

and

align

bearing

retainer

with

reverse

idler

shaft

at

the

cut

out

portion

of

the

shafl

14

Tigh1en

and

stake

each

screw

at

two

points

15

Install

main drive

and

counter

drive

gear

Refer

to

Gears

and

Shafts

for

assembly

16 InstaU

reverse

main

gear

Refer

to

Gears

and

Shafts

for

assembly

17 InstaU

transmission

case

Refer

to

Transmission

Case

for

assembly

18

InstaU

rear

extension

Refe

to

Rear Extension

for

assembly

MAINSHAFT

REAR

AND

COUNTER

REAR

END

Refer

to

Gears

and

Shafts

for

disas

sembly

and

assembly

MT15

Service

Data

sndSpecificatiom

MA

N

UAL

TRANSM

ISSION

SERVICE

DATA

AND

SPECIFICATIONS

GENERAL

SPECIFICATIONS

Transmission

model

No

of

speed

Synchromesh

type

Shift

type

Gear ratio

Number

of

teeth

Speedometer

gear

ratio

Mainshett

Counter

shaft

Rev

idler

shaft

Oil

capacity

II US

pt

Imp

pt

MT

16

1st

2nd

3rd

4th

5th

Rev

Drive

1st

2nd

3rd

5th

Rev

Drive

1st

2nd

3rd

5th

Rev

FS5W71

B

5

1

to

4th

Warner

5th

Servo

3

5

L

r

24

R

3

321

2

077

1

308

1

000

0

864

3 382

22

33

28

26

19

36

31

1

19

28

31

15

23

lB

6

12

0 414

3

1

21

INSPECTION

AND

ADJUSTMENT

GEAR

END

PLAY

1

st

main

gear

2nd

main

gear

3rd

main

gear

5th

main

gear

Rev

idler

gasr

Unit

mm

in

FS5W718

0

27

0

34

0

0106

0

0134

0

12

0

19

0

0047

0

0075

0

13

0

3710

0051

0

01461

0

10

0

17

0

0039

0

00671

0

05

0

50

0

0020

0

0197

a

EARANCE

BETWEEN

BAULK

RING

AND

GEAR

I

Standard

I

Wear

limit

Unit

rnm

in

All

models

1

20

1

60

10

0472

0

06301

0

810

0311

Main

drlv

s

er

b

erlns

AVAILABLE

SNAP

RING

Thickness

mm

in

1

73

0

06811

1

80

10

0709

1

87

0

0736

1

94

0

07641

2

01

0

07911

2

0810

0819

Malnsheft

front

Thickness

mm

in

1

4 0

055

1

5

10

0591

1

6

0

063

Part

number

32204 78005

32204

78000

32204

78001

32204

78002

32204

78003

32204

78004

Part

number

32263

E9000

32263

E9001

32263

E9002

MANUAL

TRANSM

ISSION

Service

Data

and

Specifications

Maln

haft

rear

end

besrlna

Thickness

mm

lin

Part

number

11

0

043

1

20

0471

1

3 0

0511

1

4

0

0551

32228

20100

32228

20101

32228

20102

32228

20103

Counter

drive

aear

Thickness

mm

lin

Part

number

1

4

0

055

1

5

0

059

1

6

0

0631

32215

E9000

32215

E9oo1

32215

E9oo2

AVAILABLE

SHIM

Counter

front

bearlna

Unit

mm

in

D

A

@

I

j

TM371

1

Transmission

case

2

Counter

gear

front

bearing

3

Counter

gear

4

Shim

A

Thickness of shim

Part

number

3

42

3

51

0

1

0

0041

32218

E9000

0

1346

0

13821

3

32

3

41

0

2

10

0081

32218

E9001

0

1307

0

13431

3

22

3

31

0 3

0

012

32218

E9002

0

1268

0

1303

3

12

3

21

0

4 0

016

32218

E9003

0

1228

0

1264

3

02

3

11

0

5 0

0201

32218

E9004

0

1189

0

12241

2

92

3

01

06

0 024

32218

E9005

0

1150

0

11851

TIGHTENING

TORQUE

1

Unit

N

m

kg

m

ft

b

I

Transmission

installation

I

Clutch

operating

cylinder

30 40

3

1

4

1

22 30

I

Transmission

to

engine

43 58

44

5

9

32

43

I

Gusset

to

transmission

25 35

2

6

3

6

19

26

transmission

I

Crossmember

to

body

31

42

3

2 4

3

23

31

I

Rear

mounting

insulator

31

42

3 2

4

3

23

31

to

crossmember

I

Rear

mounting

insulator

31

42

3

2 4

3

23

31

to

reaf

extension

I

Transmission

case

to

16

21

1

6

2

1

12

15

rear

extension

I

Starter

motor

to

29 39

3

0 40

22

29

transmission

I

Gear

assembly

I

Bearing

retainer

to

16

23

1

6

2 3

12

17

adapter

plate

Mainshaft

lock

nut

137

167

14

0

17

0

101

123

Counter

gear

lock

nut

98

127

10

0

13

0

72 94

Rear

extension

to

16 21

1

6

2

1

12 15

transmission

case

Front

cover to

16 21

1

6

2

1

12

15

transmission

case

Filler

plug

25 34

2

5

3 5

18

25

Drain

plug

25 34

2 5

3

5

18 25

Ball

20 34

2

0

3 5

14

25

Striking

lever

lock

nut 88

11

8

0

91

26 5 8 7

Check

ball

plug

19

25

1

9

25

14

18

Speedometer

sleeve

3 9

49 04 0

5 2 9 3 6

installation

Back

up

lamp

switch

20 29

2

0

3

0

14

22

Return

spring

plug

7

8

98 0

8

1

0 5 8 7 2

MT17

TroubleDiagnosesa

Correctiofl

MANUAL

TRANSMISSION

TROUBLE

DIAGNOSES

AND

CORRECTIONS

Level

color

N

G

Noise

Check

level

and

color

of

oil

I

L

Add

replace

oil

If

oil

leaks

repair

cause

Check

noise

I

NOise

does

not

stop

Noise

stops

OK

Level

and

color

OK

Shift

gears

and

loco

te

which

0

gear

position

makes

noise

I

Noise

in

Neutral

I

Disengage

clutch

to

see

if

noise

stops

I

Noise

does

not

stop

Noise

outside

transmission

Check

engine

and

dutch

etc

Noise

occurs

in a

specific

gear

position

and

peaks

at

specific

engine

rpm

and

stops

with

gears

in

TOP

position

1

Noise

appears

to

occur

in

transmission

Disassemble

and

check

gear

in

which

l

noise

occurs

for

meshing

surface

nd

bearings

1

Replace

gear

and

or

bearing

MIlS

Noise

in

position

other

than

Neutral

Noise

stops

Noise

in

transmission

Noise

may

be

caused

by

variations

in

engine

torque

Adjust

engine

idle

speed

High

roaring

noise

occurs

in

all

positions

and

peaks

8t

specific

engine

rpm

I

Noise

occurs

in

all

positions

except

Neutral

and

peaks

at

a

specific

car

speed

1

Noise

source

appears

to

be

located

in

differential

carrier

Check

differential

carrier

and

eliminate

cause

of

noise

Noise

occurs

while

shifting

gears

Refer

to

1he

section

Faulty

Synchromesh

Mechanism

L

Gears

grate

while

synchro

nizing

L

Noise

occurs

when

stroking

further

after

shifting

gears

Moving

parts

couplings

gears

etc

of

transmission

interfering

with

other

parts

MANUAL

TRANSMISSION

Trouble

DisgnoseundCoirr

ctions

Gear

jumping

out

of

mesh

L

Loc

ilte

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

N G

Adjust

or

replace

O

K

I

Check

for

fatigue

play

etc

on

front

and

rear

engine

mounts

I

N

G

O K

Problem may

be

inside

transmission

Disassemble

and

check

transmission

Adjust

or

replace

Replace

Check

end

play

of

jump

out

gear

I

End

play

OK

Check

for

engaging damage

or

wear on

coupling

sleeve

synchronizer

hub

and

clutch

gear

of

main

gear

I

End

play

excessive

Damage

or

wear

OK

Check

for

wear

or

damage

on

check

ball

and

fatigue

or

breaks

on

check

spring

I

Replace

Damage

or

wear

Replace

O

K

Check

for

wear

or

deformation

of fork

rod

ball

groove

Wear

or

deformation

O

K

Check

for

wear

or

play

of

jump

out

synchro

nizer

and

mainshaft

splines

I

Replace

Wear

or

play

No

wear

or

play

Replace

Check

for

wear

or

damage

on

bearings

of

main

shaft

and

countershaft

Replace

if

worn

MT19

Trouble

Disgnoseund

CDrrections

MANUAL

TRANSMISSION

N

G

Repair

or

replace

Clearance

N

G

Replace

baulk

ring

Chamfered

area

worn

1

Replace

Improper

contact

l

Replace

baulk

ring

Spread

spring

broken

bent

1

Replace

MT

20

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

O

K

Problem

may

be

inside

transmision

Disassemble

and

check

transmission

1

Measure

baulk

ring

to

gear

clearance

Refer

to

Baulk

Ring

for

inspection

Clearance

O

K

l

Check

for

w

ar

on

chamfered

area

of

baulk

ring

I

Chamfered

area

not

worn

1

Check

contact

pattern

of

baulk

ring

and

tapered

cone

of

clutch

gear

Proper

contact

l

Check

spread

spring

for

any

break

or

bending

I

Spread

spring

not

broken

bent

1

Check

for

wear

deformation

of

insert

Refer

to

Shifting

Inset

for

inspection

NG

Repair

or

replace

N G

L

Replace

MANUAL

TRANSMISSION

Trouble

Diagnoseund

Correction

Difficult

gear

meshing

shifting

Shift

gears

up

and

down

while

operating

car

to

see

if

gears

shift

smoothly

Shift

gears

while

engine

is

OFF

I

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

I

N

G

Check

for

proper

installa

tion

of

control

lever

O

c

N G

Repair

or

replace

O

K

Check

gear

end

faces

and

gear

bores

for

any

sign

of

sticking

jamming

If

detected

replace

faulty

parts

O K

N G

Check

engine

idle

speed

I

Adjust

O

K

I

Check

for

improper

dis

engaging

of

clutch

Check

for

improper

oper

ation

of

clutch

operating

cylinder

master

cylinder

I

Operation

N G

Operation

O K

I

Check

lubrication

oil

level

and

color

I

Repair

clutch

N G

Add

replace

oil

I

O K

Check

for

smooth

shifting

while

car

is

operating

N G

O

K

Instructs

customers

in

correct

shifting

method

Ox

Check

operation

of

fork

rod

1

Check

for

possible

bent

fork

rod

or

scratched

case

Scratched

bent

I

Replace

Check

engaging

of

hub

cou

pling

sleeve

clutch

gear

etc

I

MT

21

Special

Service

Tools

MANUAL

TRANSMISSION

Tool

number

Kent

Moore

No

ST2381000l

125693

KV311

00300

ST30031000

125733

1

KV311

004

n

ST23860000

ST22360002

125679

ST22520000

ST23800000

125691

KV32

101330

ST22350000

125678

MT

22

SPECIAL

SERVICE

TOOLS

Tool

name

Adapter

setting

plate

Fork

rod pin

punch

Bearing

puUer

Transmission

press

stand

Counter

gear

drift

Bearing

drift

Wrench

Transmission

drift

Bearing

puUer

Mainshaft

bearing

drift

9

Lo

rQ

OJ

rUoLh

ifi

Tool

number

Kent

Moore

No

ST33400001

126082

MANUAL

TRANSMISSION

Special

Service

Tools

Tool

name

OU

seal

drift

MT23

DATSUN

200SX Mode

S

110

Series

SECTION

A

T

AUTOMATIC

TRANSMISSION

CONTENTS

DESCRIPTION

HYDRAULIC

CONTROL

UNIT

AND

VALVES

HYDRAULIC

CONTR

L

CIRCUITS

MINOR

ADJUSTMENTS

REMOVAL

AND

INSTA

LLATION

TRANSMISSION

ASSEMBLY

MAJOR

OVERHAUL

OPERATIONS

SERVICE

NOTES

FOR

DISASSEMBL

Y

DISASSEMBLY

COMPONENT

PARTS

AT

2

AT

3

AT

5

AT

25

AT

28

AT

28

AT30

AT31

AT

34

FINAL

ASSEMBLY

TROUBLE

SHOOTING

AND

DIAGNOSES

PRELIMINARY

CHECKS

Prior

to

road

testing

DIAGNOSTIC

ROAD

TEST

PRESSURE

TESTING

STALL

TESTING

SERVICE

DATA

AND

SPECIFICATIONS

SPECIAL

SERVICE

TOOLS

AT

44

AT51

AT

51

AT

52

AT

54

AT

55

AT

52

AT

53

1

Description

AUTOMATIC

TRANSMISSION

The

3N7l

B

transmission

is

a

fully

automatic

unit

consisting

primarily

of

a

3

element

hydraulic

torque

converter

and

two

planetary

gear

sets

Two

inultiple

disc

clutches

a

multiple

disc

brake brake

band

and

one

way

clutch

provide

the

friction

elements

necessary

to

obtain

the

desired

function

of

the

two

planetary

gear

sets

A

hydraulic

control

system

is

used

to

operate

the

friction

elements

and

automatic

shift

controls

TORQUE

CONVERTER

The

torque

converter

is

attached

to

the

crankshaft

through

a

flexible

drive

plate

Heat

generated

in

the

torque

converter

is

dissipated

by

circulating

the

transmission

fluid

through

an

on

to

water

type

cooler

in

the

radiator

lower

tank

The

welded

construction

of

the

tor

que

converter

prohibits

disassembly

or

service

unless

highly

specialized

equip

ment

is

available

@

if

1

Transmission

case

2

Oilpump

3

Frorit

clutch

4

Band

brake

5

Rear

clutch

6

Front

planetary

gear

7

Rear

planetary

gear

DEScRIPTION

FLUID

RECOMMENDATION

Use

DEXRON

type

automatic

transmission

fluid

only

IDENTIFICATION

NUMBER

Stamped

position

The

plate

is

attached

to

the

right

hand

side

of

transmission

case

AT344

8

One

way

clutch

9

Low

Reverse

brake

10

Oil distributor

11

JQvemor

12

Outputshaft

13

Rear

extension

G

14

Oil

pan

IS

Control

valve

16

1npot

shaft

17

Torque

oonverter

18

Converter

housing

19

Dri

plate

AT

2

Identification

of

number

arrangementa

IAPO

AUTOIlATle

TllAIISIIISSlOll

CO

lTO

MODEL

X

01

2

3

NO

7601234

Number

designation

7601234

L

Serial

production

mber

for

the

month

Month

of

production

1

Jan

2

Fob

no

X

Oct

Y

N01

Z

Dec

Lat

figu

denoting

tho

year

A

DJ

Tightening

torque

T

of

bolts

and

nuts

N

m

kg

mfHb

@

T

39 49

4

5

29

36

@

T

137 157

14

16

101

116

@

T

44 54

4 5 5 5

33 40

@

T

5 9 7 8 0 6

0

8 4 3 5 8

@

T

4 9

6 9

0

5

0

73

65

1

T

20

25

20 25

14

18

@T

13

l8

LJ 1

8 9

13

@

T

54

7 4

0 55 0

75

4

05

4

CD

T

2 5 3 4

0

25

0 35

18

2

5

AT312

AUTOMATIC

TRANSM

ISSIO

N

Hydiaulic

Control

Unit

and

Valves

HYDRAULIC

CONTROL

UNIT

AND

VALVES

The

hydraulic

or

automatic

control

system

is

comprised

of

four 4

basic

groups

the

pressure

supply

system

the

pressure

regulating

system

the

flow

control

valves

and

the

friction

elements

PRESSURE

SUPPLY

SYSTEM

The

pressure

supply

system

consists

of

a

gear

type

oil

pump

driven

by

the

engine

through

the

torque

converter

The

pump

provides

pressure

for

aU

hydraulic

and

lubrication

needs

PRESSURE

REGULATOR

VALVES

The

pressure

regulating

valves

con

trol

the

output

pressure

of

the

oil

pump

Pressure

regulator

valve

The

pressure

regulator

valve

con

trols

mainline

pressure

based

on

throttle

opening

for

the

operation

of

the

band

clutches

and

brake

Governor

valve

The

governor

valve

tranSffi

ts

re

gulated

pressure

based

on

car

speed

to

the

shifi

valves

to

control

upshifts

and

downshifts

Vacuum

throttle

valve

The

vacuum

throttle

valve

transmits

regulated

pressure

based

on

engine

load

vacuum

This

pressure

controls

the

pressure

regulator

valve

Also this

pressure

is

applied

to

one

end

of

the

shift

valves

in

opposition

to

governor

pressure

which

acts

on

the

other

end

of

the shift

valves

controlling

upshift

and

downshift

speeds

FLOW CONTROL

VALVES

Manual

valve

The

manual

valve

is

moved

manual

ly

by

the

car

operator

to

select

the

different

drive

ranges

1

2

Shift

valve

The

1

2shift

valve

automaticaUy

shifts

the

transmission

from

first

to

second

or

from

second

to

first

depend

ing

upon

governor

and

throttle

pres

sure

along

with

accelerator

position

solenoid

downshift

valve

See

Hy

draulic

Control

Circuits

Drive

2

23

Shift

valve

The

2

3

shift

valve

automatically

shifts

the

transmission

from

second

to

top

gear

or

from

top

to

second

de

pending

up

governor

and

throttle

pressure

or

accelerator

position

sole

noid

downshift

valve

See

Hydraulic

Control

Circuits

Drive

3

Range

23

Timing

valve

For

23

shifts

a

restrictive

orifice

slows

the

application

fluid

to

the

front

clutch

while

the

slower

reacting

band

is

allowed

to

release

This

prevents

a

hard

2

3

or

3

2

shift

Under

heavy

load

however

the

engine

will

tend

to

run

away

during

the

2

3

or

3

2

shift

pause

therefore

a

2

3

timing

valve

using

throttle

and

governor

pressure

is

used

to

bypass

the

restrictive

orifice

during

such

heavy

load

conditions

Solenoid

downshift

valve

The

solenoid

downshift

valve

is

activated

electrically

when

the

ac

celerator is

floored

causing

a

forced

downshift

from

top

to

second

top

to

fi

st

or

second

to

first

gear

depending

upon

car

speed

governor

pressure

Pressure

modified

valve

The

pressure

modifier

valve

assists

the

mainline

pressure

regulator

valve

in

lowering

mainline

pressure

during

high

speed

light

load

conditions

such

as

steady

speed

cruise

Governor

pres

sure

working

against

a

spring

opens

the

valve

which

aUows

modified

throt

tle

pressure

to

work

against

the

pres

sure

regulator

valve

spring

lowering

mainline

pressure

Lower

operating

pressure

under

light

load

reduces

oil

temperature

and

increases

transmis

siOli

life

Throttle

back

up

valve

The

throttle

back

up

valve

assists

the

vacuum

throttle

valve

to

increase

line

pressure

when

the

manual

valve

is

shifted

either

to

2

or I

range

Second

lock

valve

The

second

lock

valve

is

used

to

bypass

the

1

2

shift

valve

to

maintain

the

band

apply

pressure

in

2

posi

tion

The

valve

is

also

used

as

an

oil

pass

ge

for

the

1

2

shift

valve

band

apply

pressure

in

D D

and

I

Range

CLUTCHES

AND BAND

SERVOS

The

servo

pistons

of

the

clutches

low

reverse

brake

and

band

are

moved

hydraulicaUy

to

engage

the

clutches

brake

and

apply

the

band

The

clutch

and

prake

pistons

are

released

by

spriT

1g

tension

and

band

piston

is

released

by

spring

tension

and

hy

draulic

pressure

AT3

Hydl7lUlic

Control

Unit

and

Valves

AUTOMATIC

TRANSM

ISSIO

N

Control

valVe

rTil

SV

J

AT094

1

Pressure

regulating

valve

2

Manual

valve

3

lst

2nd

shift

valve

4

lnd

3rd

shift

valve

5

Pressure

modifier

valve

6

Vacuum

throttle

valve

7

Throttle

back

up

valve

8

Solenoid

down

shift

valve

9

Second

lock

v8Ive

10

2 3

timing

valve

AT

4

AUTOMATIC

TRANSMISSION

Hydraulic

Control

Unitsnd

Valves

OIL CHANNEL

IDENTIFICATION

Oil

Channels

in

Case

Front

Face

The

circuit

numbers shown

in

each

Hydraulic

Control Circuit

are

classified

as

follows

according

to

the

function

Auxiliary

line

pressure

13

Torque

converter

pressure

14

Governor

pre

ure

15

Throttle

system

pressure

16

17

18

19

Pressure

source

of

the

line

7

Operating

line

pressure

for

friction

elements

12

3

4 5

689

10

1112

AT106

Oil

Channels

in

Oil

Pump

Oil

Channels

in

Case

Face

0

r

o

90

Oil

pump

discharge

hole

7

Governor

pressure

15

i

j

J

Torque

converter

00f

i

pressure

l4

0

Servo

release

Rear

clutch

pressure

10

Governor

feed

pressure

1

pressure

1

Servo

tightening

o0

pressure

9

11

lnl

Front

clutch

rr

I

Low

reverse

brake

pressure

12f

pressure

11

U

0

Jj

J

o

P

sucti

e

Oil

pump

discharge

hole

7

Torque

converter

pressure

14

q

Rear

clutch

pressure

1

Front

clutch

pressure

11

L

OiiJ

u

nm

P

suction

hole

a

AT10S

AT107

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

Range

Gear

Parking

ratio

reverse

way

pawl

Front

Rear

brake

Operation

Release

clutch

Park

on

Reverse

2

182

on on

on

Neutral

Dl

Low

2

458

on

Drive

D2

Second

1458

on

D3

Top

1

000

on on

2

Second

1458

on on

12

Second

1458

on on

I

Low

2

458

on on

The

low

reverse

brake

is

applied

in

1

range

to

prevent

free

wheeling

when

coasting

and

allows

engine

braking

AT

5

Hydraulic

Control

Cirtuirs

AUTOMATIC

TRANSMISSION

HYDRAULIC

CONTROL

CIRCUITS

P

RANGE

PARK

I

arking

Mechanism

Power

flow

In

P

range

the

shifl

linkage

actuated

parking

pawl

meshes

in a

gear

splined

to

the

output

shaft

preventing

movement

of

the

car

When

the

engine

is

running

the

low

and

reverse

brake

is

applied

by

pressure

from

the

manual

v

Uve

passing

through

the

1

2

shift

valye

F

Locr

11

A

T086

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

1h

ottle

Back

up

Va

ve

y

Low

Reverse

Brake

I

AT

6

AUTOMATIC

TRANSM

ISSION

Hydraulic

Control

Circuits

Oil

Pressure

Circuit

Diagram

P

range

park

r

nh

r

c

h

11

rIf

0

Ih

gm

j

E

J

I

rl

j

@1

9

10

IY

tr

r

l

lI

olu

l

volv

II

oIll

I

II

oL

LLl

fir

x

lL

I

r

16

13

TorQu

conv

t

Oi

I

cooler

TIC

Oil

r

Slllt

ro

O

j

01

Rnt

lubrication

o

Drain

14

01

Front

lubricati

0

1

J

1

x

J

l

I

6

IICD

P

ur

otor

JJI

1

p

1

Throttl

drain

1

I

C

1

SII

JL

J

2Z

II

x

1J

IE

2no 3 d Ii

mino

vol

1

I

II

I

@

I

ck

II

r3

II

15

J

ji

t

2

Sh

I

j

I

ru

I

II

Monuol

YOI

I

xn

llrr

Itr

Not

Mork

d

X

ort

droin

Secondory

Qovunar

lOlv

Lin

prulUr

lGoy

rnor

fud

pt

r

Primo

OO

l

IOr

olv

Go

rnor

prUI1

l11l

I

Torqu

con

t

r

pr

r

Th

ro

lI pr

r

AT455

AT

7

Hydraulic

ContrrJI

Circvits

AUTOMATIC

TRANSMISSION

R

RANGE

REVERSE

Power

flow

With

the

selector

lever

in

R

range

the

front

clutch

is

applied

to

transmit

clockwise

engine

torque

through

the

connecting

shell

to

the

Sun

gear

The

clockwise

rotation

of

the

sun

gear

causes

the

planet

gears

to

rotate

counterclockwise With

the

low

and

reverse

brake

holding

the

rear

planet

carrier

the

rear

internal

gear

splined

to

the

output

shaft

turns

counterclockwise

in

a

reduction

ratio

of

approximately

2

18

to

I

Fluid

flow

Manual

Valve

4

Mechaitical

Operation during

R

Range

Front

gear

set

Front

clutch

ON

Rear

gear

set

Output

Input

through

front

clutch

Held

by

low

reverse

brake

A

T329

Low

reverse

brake

ON

N

Front

clutch

Rear

clutch

Low

and

reverse

brake

Brak

band

servo

Oneway

clutch

Downshift

Valve

I3

5

Throttle

Back

up

Valve

6

Ist

2nd

Shift

Valve

12

L

Pressure

Regulator

Valve

2nd

3rd

Shift

Valve

10

AT

8

ON

OFF

ON

OFF

Pressure

release

Overrunning

AT085

2nd

3rd

Shift

Valve

L

Ist

2nd

Shift

Valve

I

Throttle

Back

up

Valve

y

Low

Reverse

Brake

Band

Servo

Release

Side

II

1

Front

Clutch

AUTOMATIC

TRANSM

ISSIO N

Hydraulic

Control

Circuits

Front

RlOr

I

h

l

h

0

I

trJI

kill

TIC

Oil

cr

l

r

reOlollalnil

volu

1

l

T

I

JUI

T

U

Oral

01

IL

J

i

I

11

L

lh

fi

ThMII

l

drain

val

I

II

xjJ

l

uff

I

n

ui

i

@

M

O

k

II

r

1

L

J

U

lr

1

vci

I

u

r

l

1

x

No

Markld

Xdfoin

lrto

Lin

preuur

Go

rnor

ud pr

ur

Oil

Pressure

Circuit

Diagram

R

range

Reverse

Torque

ton

l

rt

r

broil

Brok

band

J

12

Oil cool

x

jJ

G9

2nd

3rd

liming

olv

x

CD

p

Jr

ator

L

r

G

av

rnor prn

ure

f

m

Torqu

COMut

r

prl

ll

Th

ronl

pr

un

ID

24

Ool

l

r

rl

6

I

Secondory

go

rnOI

lGlv

Primor

go

itlr

01

1

AT456

AT

9

Hydraulic

Control

Cirwiu

AUTOMATIC

TRANSM

ISSION

N

RANGE

NEUTRAL

Power

flow

In

ange

no

friction

elements

are

in

use

thus

no

power

is

trans

mitted

to

the

output

shaft

AT10

AUTOMATIC

TRANSM

ISSIO N

Hydraulic

Control

Circuits

Oil

Pressure

Circuit

Diagram

N

range

Neutral

flL

4

1t

T11

r1I

11

I

Orifice

18

chlcll

fol

a

L

I

6

Torql

ll

conv

rt

r

Front

lItCh

Oil

1

i

I

Oi

I

cooler

RIO

I

i

ealia

Drain

I

101

Front

lubricaf

t

Drain

01

1

t

x

Xl

II

CD

P

otor

Bond

YO

I

1

Throttle

drain

101

11

10

c

o

Z2

II

t1J

x

21

6

IV

ilL

@

d

lock

frO

6

II

rOI

@

Not

Worked

on

drain

lint

prUSUft

Go

rnor

ud

pr

nur

G

o

no

prlssure

nI

tI

Torqu

conyut

pnn

r

ft

Th rottl

p

ur

I

12

x

@

Vacuum

Ihrottl

oh

Throtllt

bacll

up

wolv

I

JI

F e

X

own

i1t

OIY

rI5

I

jULj

I

II

fLx

5

l

r

J

t

2

dl

ShiflIllGIY

I

Slcondar

OOv

nor

01

Primory

00

rnor

vol

A

T457

AT11

Hydraulic

Centrol

Circuits

AUTOMATIC

TRANSM

ISSIO

N

D

RANGE

LOW

GEAR

Power

flow

With

the

shift

selector

in

D

low

gear

engine

torque

is

transmitted

through

the

applied

rear

clutch

to

the

in1ernal

gear

of

the

fron1

gear

set

The

clockwise

rotation

of

the

front

inter

nal

gear

causes

the

fron

t

planet

gears

to

rotate

clockwise

driving

the

com

pound

sun

gear

counterclockwise

The

front

planetary

carrier

is

splined

10

the

output

shaft

This

causes

the

planet

gears

to

drive

the

sun

gear

instead

of

walking

around

the

sun

gear

This

counterclockwise

rotation

of

the

sun

gear

causes

the

rear

planet

gears

to

rotate

clockwise

With

the

one

way

clutch

holding

the

rear

planet

carrier

the

rear

planetary

gears

turn

the

rear

internal

gear

and

outpu1

shaft

clock

wise

in

a

reduction

ratio

of

approxi

mately

2

46

to

I

Fluid

flow

Manual

Valve

Mechanical

Operation

during

61

Range

Front

gear

set

Rear

gear

set

Output

shaft

Held

by

one

way

clutch

Input

from

front

gear

set

Output

to

reai

gear

set

A

T330

Front

clutch

Rear

clutch

Lo

and

reverse

brake

Brake

band

servo

One

way

clutch

OFF

ON

OFF

HOLDING

AT081

Governor

Valve

15

Pressure

Modifier

Valve

2nd

3rd

Shift

Valve

Ist

2nd

Shift

Valve

Ist

2nd

Shift

Valve

2nd

3rd

Timing

Valve

J

Rear

Clutch

2

3

Second

Lock

Valve

Second

Lock

Valve

L

Orifice

Check

Valve

2nd

3rd

Shift

Valve

AT12

AUTOMATIC

TRANSM

ISSIO

N

Hydraulic

Control

Circuits

Oil

Pressure

Circuit

Diagram

D1

range

Low

gear

1

Torqu

ean

rl

r

Oi

I

pump

t

1

Pres

ur

rlQulo1

or

valv

L

Front

cluleh

t

I

62

J

1

t

Rlar

cl

utch

Brake

bond

Low

Q

nd

r

v1

brake

3

Shill

OI

o

t

Bond

I

b

7

ervo

I

1

Torque

conyerter

pressure

Throttle

prlssure

It

ll

1

Throttle

pr

sur

t

@

I

Governor

pressure

lint

pr

s

ur

Governor

pre

sure

AT446

AT13

Hydraulic

Control

Circuim

AUTOMATIC

TRANSMISSION

D

RANGE

2ND

GEAR

MechariicaI

Operation

dtiring

D2

Range

Power

flow

Io

D

range

the

brake

band

is

applied

to

hold

the

connecting

sheU

and

sun

gear

stationary

Engine

torque

through

the

applied

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

planet

gears

to

walk

around

the

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

wise

direction

with

a

reduction

ratio

of

about

1

46

to

I

Front

gear

set

Rear

gear

set

AT331

Front

clutch

OFF

Rear

clutch

ON

LOw

and

revelSe

biake

OFF

llr

Ike

band

servo

ON

One

way

clutch

OFF

A

T079

Fluid

flow

As

car

speed

and

governor

pressure

increase

the

governor

pressure

acting

on

the

end

of

the

1

2 shift

valve

overcomes

the

force

of

the

1

2

shift

valve

spring

and

line

pressure

This

aUows

the

1

2

shift

valve

to

move

to

the

upshift

position

which

directs

line

pressure

through

the

2nd

lock

valve

and

on

to

the

brake

band

Manual

Valve

Governor

Valve

15

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

Side

4

Rear

Clutch

I

2

Second

Lock

Valve

3

I

Second

Lock

Valve

L

Orifice

Check

Valve

2nd

3rd

Shift

Valve

AT

14

AUTOMATIC

TRANSM

ISSIO

N

Hydraulic

Control

Circuits

Oil

Pressure

Circuit

Diagram

D2

range

2nd

gear

F

Oil

pump

t

f

J

Tor

q

ua

conYerter

Pressure

r

oulator

valve

Line

pressure

Gover

or

pressure

Front

clutch

Brake

ba nd

Low

and

revers

broke

Reor

clutch

I

tl

t

2

hjf

llvOIV

t

r

t

u

l

1Itrrr 1ltrrr 1Itrrr

Throttl

e

It

pressure

j

@

P

RND21

Govern

or

pressure

Torque

converter

pressure

Throlll

prellur

AT448

AT15

t

Hydraulic

Control

Circuits

AUTOMATIC

TRANSM

ISS10

N

D

RANGE

3RD

GEAR

Power

flow

In

on range

engine

torque

is

transmitted

through

both

clutches

The

front

clutch

turns

the

internal

gear

of

the

forward

gear

set

clockwise

The

rear

clutch

turns

the

sun

gears

in

a

clockwise

direction

also

With

both

the

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

position

and

turn

as

a

unit

The

output

shaft

splined

to

the

forward

planet

carrier

turns

at

a

ratio

of

I I

Fluid

flow

Governor

pressure

increases

to

the

point

that

it

can

overcome

the

com

bined

forces

of

spring

and

throttle

pressure

and

move

the

2nd

3rd

shift

Manual

Valve

Mechanical

Ojleiation

during

D3

Range

Front

gear

set

Rear

gear

set

Input

through

front

and

rear

clutches

Output

shaft

A

T332

Front

clutch

ON

Rear

clutch

ON

Il

N

Front

clutch

Rear

clutch

Low

and

reverse

brake

Brake

band

servo

One

way

clutch

valve

When

the

2nd

3rd

shift

valve

opens

pressure

passes

through

the

valve

lands

to

the 2 3

timing

valve

and

on

to

apply

the

front

clutch

and

Governor

Valve

15

ON

OFF

Presswe

release

OFF

AT083

release

the

brake

band

The

car

is

now

in

D

or

direct

drive

the

rear

clu

tch

was

already

applied

Pressure

Modifier

Valve

2nd

3rd

Shift

Valve

2nd

3rd

Timing

Valve

Ist

2nd

Shift

Valve

8

lst

2nd

Shift

Valve

i

I

Band

Servo

is

released

t

Second

Lock

Valve

I

LOrifiCe

Check

Valve

2nd

3rd

Shift

Valve

10

TIBand

Servo Relea

Side

I

42nd

3rd

Timing

Valve

II

I

Front

Clutch

1

J

Rear

Clutch

I

2

Second

Lock

Valve

3

AT16

Second

Lock

Valve

9

Ii

Band

Servo

Apply

Side

AUTOMATIC

TRANSM

ISSIO

N

Hydraulic

Control

Cirr

uit3

Oil

Pressure

Circuit

Diagram

D3

range

3rd

gear

1

t

Oi

I

pump

To

rq ue

c

anYlrter

r

l

Pressure

re

QU

lator

valve

L

in

pressure

Governor

pressure

Fronf

clutch

Low

and

rever

brake

Rear

clutch

Brake

bond

0

t

Bond

JJ

JI

1

y

W

r

t

It

sY

if

t

tr

Il

PRN021

tt

@

Throttle

pressure

Ya

Iv

Governor

pressure

i

t

lo

IIDJWq

Torque

eonv

rter

pr

ur

Iijp

I

Throlll

preuur

AT449

AT

17

Hydraulic

Control Circuits

AUTOMATIC

TRANSM

ISSION

D

RANGE

KICKDOWN

To

achieve

a

forced

downshift

from

3rd

to

2nd

the

car

speed

must

be

under

approximately

100

km

h

60

MPH

from

2nd

to

1st

it

must

be

under

approximately

50

km

h

30

MPH

FuUy

depressing

the

accelerator

pedal

energizes

the

downshift

sole

noid

which

opens

the

solenoid

down

shift

valve

Oil

pressure

is

then

exerted

against

the

shift

valves

Between

50

and

100

km

h

30

and

60

MPH

this

pressure

wiD

close

the

2nd

3rd

shift

valve

against

governor

pressure

and

the

car

downshifts

When

the

car

speed

is

below

50

km

h

30

MPH

the

I

st

2nd

shift

valve

will

be

closed

and

the

1rans

mission

will

be

in

1

st

gear

As

car

speed

and

governor

pressure

increase

the

shift

valves

automaticaUy

reopen

AT

IS

AUTOMATIC

TRANSM

ISSIO

N

Hydraulic

Control Circuits

Oil

Pressure

Circuit

Diagram

D

range

kickdown

shift

valves

in 2nd

gear

position

Torqul

conv

rl

r

Front

Rlor

Iutch

ClutCh

Oil

J1

r

I

TIC

on

p

V

ro

I

O

rog

o

1

0

It

i

N

all

COOler

RI

hlbri

cot

ion

8

Oraln

14

vohl

I

Front

lubriCQtif

W

11

X

J

j

D

1

I

t

1

Qto

j

oz

n

l

I

m

I

lID

Vacuum

throttl

01

i

d

Yol

23

Ol

yol

l

@

PRND2

I

f

S

D

o

t

y

d

I

3r

J

lu

i

I

own

i1

01

lI

S

U

I

8

18 16

@Z

l

3n

I

Shift

Yol

Hmu

u

Jr

5

r

1pul

B

2 d

I

ii

lJlu

r

I

N

Tr

Throttle

drain

10

1

I

C

JI

J

Z2

g

2nd

3rd

limine

a

vI

X

J

L

1

I

Hot

Worbd

l

ore

Oroln

IIo

U

Lin

pr

r

Govlrnor

fud

p

uunl

L

GOY

flU

pr u

Tor4

lt

con

I

r

pr

sure

v

Th

r011l

pr

ur

Primor

90

rrror

yo

Y

A

T458

AT19

Hydraulic

Control

CilCuil

AUTOMATIC

TRANSMISSIO

N

2

RANGE

2ND

GEAR

Fluid

flow

opening

the

valve

and

aUowing

pres

sure

to

pass

into

the

line

of

the

throttle

valve

thus

assuring

adequate

throttle

pressure

even

during

decelera

tion

The

downshift

solenoid

valve

is

used

as

a

passage

for

line

pressure

to

lock

the

1

2

and

2

3

shift

valves

Power

flow

Power

flow

in

2range

is

the

same

as

in

D1

range

Line

pressure

from

the

manual

yalve

opens

the

second

lock

valve

against

spring

pressure

As

this

valve

opens

pressure

then

passes

to

apply

the

band

servo

Line

pressure

also

flows

to

the

throttle

back

up

valve

The

range

2

position

is

used

to

lock

he

car

in

2nd

gear

preventing

upshifts

or

downshifts

under

any

con

ditions

Manual

Valve

Governor

Valve

15

Pressure

Modifier

Valve

2nd

3rd

Timing

Valve

L

2nd

3rd

Shift

Valve

Is1

2nd

Shift

Valve

lst

2nd

Shift

Valve

Rear

Clutch

I

2

Band

Servo

Apply

Side

I

Solenoid

Downshift

Valve

13

t2nd

3rd

Shift

Valve

1st

2nd

Shift

Valve

Second

Lock

Valve

9

4

Throttle

Back

up

Valve

17

Vacuum

Throttle

Valve

16

Pressure

Modifier

Valve

2nd

3rd

Shift

Valve

2nd

3rd

Timing

Valve

Throttle

Drain

Valve

Pressure

Regulator

Valve

AT20

AUTOMATIC

TRANSM

ISSIO

N

Hydraulic

Control

Circuits

Oil

Pressure

Circuit

Diagram

2range

2nd

gear

Torqvt

conv

r1

r

Oil

cooler

Drain

olv

Drain

volv

Front

lubricatit

WI

x

1

J

Q

Pr

or

Iau

otor

01

1

Rlor

r

l

v

it

I

9

10

ll

14

12

boc

k

up

downall

ft

volv

yolv

t

6

ff

I I

I

l

r

13

@

Vacuum

Ihrottlt

01

Throttl

drain

01

11

l

1

i

22

@2nr3rd

Shift

01

In

II

21

6

II

Manual

I

@

P

R

f

No

worktd

X

or

droln

lint

pr

ur lo

rnor

t

d

pr

urel

Primory

QO

nor

volvl

1

i

l S

Ga

tnor

p

U

Ur

l

JA

Torque

con

pt

r

Th

rottl

pt

fI

AT459

AT

21

Hydraulic

Control

Circuiu

AUTOMATIC

TRANSMISSION

1

RANGE

LOW

AND

2ND

GEAR

The

range

I

position

is

used

to

lock

the

car

in

1

st

gear

preventing

any

upshifts

If

the

selectorJever

is

moved

to

the

1

position

while

the

car

is

moving

at

high

speeds

the

transmis

sion

will

not

shift

into

fIrst

gear

until

car

speed

slows

to

approximately

50

km h

30

MPH

Instead

i1

will

shift

to

Manual

alYe

second

I

as

governor

pressUre

pre

vents

the

1

2

shift

valve

from

closing

Power

flow

The

power

flow

in

I

differs

slight

Iy

from

D

in

that

the

low

and

reverse

band

is

applied

to

hold

the

rear

gear

set

planet

carrier

providing

engine

braking

Power

flow

in

I

is

1he

same

as

in

D

1

Governor

Valve

15

Pressure

Modifier

Valve

Fluid

flow

Low

gear

Manual

pressure

passing through

the

1

2shift

valve

is

used

to

close

the

1

2

shift

valve

preventing

a

1

2

up

shift

Manual

pressure

passing

through

the

downshift

valve

locks

the

2 3

shift

valve

closed

along

with

applying

addi

tional

c1

sing

pre

ssure

to

the

1

2

shift

valve

2nd

lnl

Tuning

Valve

to

lst

2nd

Shift

Valve

lst

2nd

Shift

Valve

2nd

lrd

Shift

Valve

j

Rear

Clutch

I

4

Solenoid

Downshift

Valve

13

t2nd

lrd

Shift

Valve

Ist

2nd

Shift

Valve

Throttle

Back

up

Valve

5

Ist

2nd

Shift

Valve

12

FluId

flow

2n

l

gear

Manual Valve

lbrottle

Back

up

Valve

I

Low Ii

Reverse

Brake

I

1

Governor

Valve

15

Pressure

Modifier

Valve

2nd

lnl

Shift

Valve

2nd

3rd

Timing

Valve

1st

2nd

Shift

Valve

8

1st

2nd

Shift

Val

Second

Lock

Valve

91

Band

Servo

I

Apply

Side

j

Rear

Clutch

I

4

Solenoid

Downshift

Valve

13

t2nd

lrd

Shift

Valve

1st

2nd

Shit

t

Valve

Throttle

Back

up

Valve

17

1

2nd

lrd

Shift

Valve

Pressure

Modifier

Valve

2nd

3rd

Timing

Valve

Throttle

Drain

Valve

5

bt

2ndShiftValve

Pressure

Regulator

Valve

AT

22

AUTOMATIC

TRANSM

ISSIO N

Hydraulic

Control

Circuits

Oil

Pressure

Circuit

Diagram

II

range

Low

gear

La

and

b

r

Rlor

Srok

C

cllutth

bond

J

p

I

j

IJI

II

Jir

I

u

r

I

o

i

1@

112

1 1

XII

CI

Vacuum

Throttl

OIUOld

t

9

10

throttl

back

up

downlhlft

lol

1

I

01

1

vol

ll

1

I

II

r

1I

i

f

c

1

J

I

j

l

wr

XIe

16

1

@2nct

3rd

Shift

val

D

ft

m

I

II

1

lr

11

I

f

n

j

J

ij

jl

N

dX

d

ooo

X

Secondory

Qov

rnor

01

Torqul

con

r

I

11

cooler

Rlor

lubricalion

I

Drain

yo

Oroln

Yol

Front

lubriCG

ltc

tu

I

x

rl

u

CD

P

UI

otor

C

m

con

o

Et

oPhrogm

ThroW

drain

vol

II

Lin

prusur

Goy

rnor

tud

pr

un

Primory

90

Ie

r

nor

101

1

G

ov

rnor

pr

ul

t

A

03

Torqul

converler

pre

ure

AT460

Th

oltl

pre

ure

AT

23

Hydraulic

Control

Circuits

AUTOMATIC

TRANSM

ISSIO

N

1

L

@2n

3tdSllift

10

101

S

I

r

i

@2nd

3rdliminv

vol

It

I

ii

tJJ

r

I

r

jj

Pressure

Circuit

Diagram

12

range

2nd

gear

La

and

broil

Torqu

c

an

rt

r

Front

clufeh

R

or

tuteh

Oil cool

TIC

Oil

pt

u

re9U

Olloro

J

I

oB

0

l

I

oro

l

JI

Rlor

lubrication

n

4

Iii

II

11

Orain

0

01

FrOnt

lub

icotic

Throttl

drain

101

1

Or

ain

1

01

1

f

I

D

Pr

uro

nou

otor

vol

uum

oot

ol

hro

m

2

I

II

17

1

t

6

b

J

III

11i

Th

t1

IItIOl1

g

bocll

up

downahi

tyol

101

I

3

ldI

I

zo

1

r

Sh

l

u

L

6

I

w

Manual

2

PRND2

I

f1

n

Not

Mork

dX

on

drain

Lute

pru

Gov

rnor

dpt

urt

Goy

rnOt

prlS

U

T

rquI

COn

pr

lur

Th

otll

p

nut

AT

24

S

condor

90

t

ftOI

YQlv

PtimOI

Q

0

Vllnol

olv

AT461

KICKDOWN

SWITCH

ADJUSTMENT

The

kickdown

switch

is

located

at

the

upper

post

of

the

accelerator

pedal

inside

the

car

When

the

pedal

is

fuUy

depressed

a

click

can

be

heard

just

before

the

pedal

bottoms

out

If

the

click

is

not

heard

loosen

the

locknut

and

extend

the

switch

until

the

pedal

lever makes

contact

with

the

switch

and

the

switch

clicks

Wiring

Diagram

AUTOMATIC

TRANSM

ISSION

Minor

Adjustments

MINOR

ADJUSTMENTS

Kick

down

switch

7

SA

TOO

1

Do

not

allow

the

switch

to

make

contact

too

soon

This

would

cause

re

t

1

mO

R

o

BATTERY

FUSIBLE

LINK

ST

ON

t

CC

OFF

J

D

rIl

J

6

r

I

BW

8

r

WR

IGNITION

SWITCH

MAIN

HARNESS

WB

Q

OO O O O O

D

l

Il

0 0 0 0 U

l

0Ul

O

J

0 0

UI

0

o

q

o0

0

0000

l

D

O

Q

O

D

FUSE

BLOCK

G

I

J

rOl

E S

G1

No

2

0

DOWNSHIFT

8

SOLENOID

J

iO

II

the

transmission

to

downshift

on

part

throttle

DIAGNOSIS

Switch

can

be

heard

clicking

and

the

transmission

still

does

not

kickdown

Check

the

continuity

of

the

switch

using

a

continuity

tester

Also

check

for

available

current

The

car

upshifts

at

approximately

65

and

110

km

h

40

and

70

MPH

only

The

kickdown

switch

may

be

internal

ly

shorted

When

the

switch

is

short

ed

there

is

continuity

through

the

switch in

any

position

W

iDf

WB

BW

IGNITION

ANO

1J

ACCESSORY

RE

r

J

K1CKDOWN

SWITCH

SEL490

AT25

Minor

Adjustmentt

AUTOMATIC

TRANSM

ISSIO

N

INHIBITOR

SWITCH

ADJUSTMENT

current

to

pass

from

the

starter

only

when

the

lever

is

placed

in

the

p

or

N

range

A

continuity

tester

may

be

used

to

check

the

inhibitor

switch

for

proper

operation

The

two

black

and

yeUow

B

Y

wires

should

have

con1inuity

when

the

lever

is

in

the

P

and

Nfl

positions

Red

and

black

R

Bwires should

have

continuity

when

the

shift

lever

is

moved

to

R

range

The

inhibitor

switch

has

two

major

functions

It

allows

the

back up

lights

to

illuminate

when

the shift

lever

is

placed

in

the

reverse

range

It

also

acts

as

a

neutraJ

safety

switch

allowing

Wiring

DIagram

00

BACK

UP

LAMP

R

H

gg

iiii

RB RB

00

B

8

o

BODY

HARNESS

BO

BACK

UP

LAMP

L

H

R

O

W

B

TTE

a

E

WR

5T

ON

ACC

Off

1

g g

J

I11LBw

J

6

0

rr

w

IGNITION

SWITCH

WW

we

c2

BW

IGNITION

AND

lJ

ACCESSORY

R

ii

W

O U

ii ii ii

o

N

0

000

0

0 0

0

00

r

oo

I

o 0

Q

0

Q

o

L

FUSE

BLOCK

w

r

II

ma

III

co

Ii

flfj@

q

Js

l

Dl

C

BR

l

G

Do

on

ENGINE

HARNESS

RB

oo

oU

No

2

we

cJ

CJO

M

LW

J

STARTER

MOTOR

MAIN

HARNESS

r

BY

B

BR

LW

t

INHIBITOR

RELAY

INHIBITOR

SWITCH

SEL491

AT

26

I

Place

the

manual

valve

in

Neutral

vertical

position

2

Remove

the

screw

as

illustrated

3

Loosen

the

attaching

bolts

4

Using

an

aligning

move

the

switch

until

the

falls

into

the

hole

in

the

rotor

5

Tighten

the

attaching

bolts

6

Recheck

for

continuity

If

faulty

replace

the

switch

MANUAL

LINKAGE

ADJUSTMENT

The

adjustment

of

the

manual

linkage

is

an

important

adjustment

of

the

auto

tic

transmission

Move

the

shift

lever

from

the

P

range

to

Range

I

you

should

be

able

to

feel

the

detents

in

each

range

If

the

detents

cannot

be

felt

or

the

pointer

indicating

the range

is

im

properly

aligned

the

linkage

needs

adjustment

AUTOMATIC

TRANSM

ISSIO N

Minor

Adjustments

F

R

ND

I

1

Grommets

r

J

c

I

nJ4I

Front

Lock

nuts

SA

T099

Place

shift

lever

in

D

range

2

Loosen

locknuts

and

move

shift

lever

until

D

is

properly

aligned

and

car

is

in

D

range

3

Tighten

locknut

Recheck

P

and

Range

1

posi

tions

As

a

safety

measure

be

sure

you

can

feel

full detent

when

shift

lever

is

placed

in

P

If

you

are

unable

to

make

an

adjustment

grommets

may

be

badly

worn

or

damaged

and

should

be

replaced

Vacuum

diaphragm

rod

selection

Measured

depth

L

mm

in

Under

2555

1

0059

25

65

26

05

1

0098

1

0256

26

15

26

55

1

0295

1

0453

26

65

27

05

1

0492

1

0650

Over

2715

1

0689

BRAKE

BAND

ADJUSTMENT

Proper

brake

band

adjustment

results

in

smooth

shifting

between

1st

2nd

and

2nd

3rd

Although

the

adjustment

is

very

simple

it

is

im

portant

to

use

an

accurate

torque

wrench

I

Loosen

locknut

2

Torque

band

servo

piston

stem

to

12

toI5

N

m

12

to

1

5

kg

m

9

to

II

ft

lb

VACUUM

DIAPHRAGM

ROD

ADJUSTMENT

The

vacuum

diaphragm

and

the

length

of

its

diaphragm

rod

help

deter

mine

the

shift

patterns

of

the

transmis

sion

It

is

essen1ial

that

the correct

length

rod

be

installed

1

Disconnect

vacuum

hose

at

vacuum

diaphragm

and

remove

dia

phragm

from

transmission

case

2

Using

a

dep1h

gauge

measure

depth

L

Be

sure

vacuum

throttle

valve

is

pushed

into

valve

body

as

far

as

possible

3

Check

L

depth

with

chart

below

and

select

proper

length

rod

L

Depth

SAT002

1

Note

seated

valve

body

2

Transmission

case

wall

3

Diaphragm

rod

4

Valve

body

side

plate

5

Vacuum

throttle

valve

Rod

length

mm

in

Part

number

29

0

1

142

29

5

1

161

30

0

1

181

30

5

1

201

31

0

1

220

31932

XOI03

31932

XOlO4

31932

XOIOO

31932

XOlO2

31932

XOIOI

3

Back

off

band

servo

piston

stem

two

complete

turns

CAUTION

00

not

back

off

EXCESSIVElY

on

adjusting

stem

as

anchor

block

may

fall

out

of

place

4

Tigh1en

locknut

to

approximately

20

N

m

2

kg

m

14

ft

lb while

hold

ing

band

servo

piston

stem

stationary

AT

27

Removal

and

Installation

AUTOMATIC

TRANSMISSION

REMOVAL

AND

INSTALLATION

TRANSMISSION

ASSEMBLY

When

dismounting

the

automatic

tran

on

from

a

car

pay

attention

to

the

foUowing

points

I

Before

dismounting

the

transmis

sion

rigidly

inspect

it

by

using

the

Trouble

shooting

Chart

and

dis

mount

it

only

when

it

is

necessary

2

Dismount

the

transmission

with

utmost

care

and

when

mounting

ob

serving

the

tightening

torque

indicated

on

another

table

do

Dot

exert

exces

sive

force

REMOVAL

In

dismounting

the

automatic

transmission

from

a

car

proceed

as

foUows

I

Disconnect

battery

ground

cable

from

terminal

2

Jack

up

car

and

support

it

on

safety

stands

We

recommend

a

hydraulic

hoist

or

open

pit

be

utilized

if

available

Observe

all

safety

regulations

3

Remove

propeUer

shaft

Plug

up the

opening

in the

rear

ex

tension

to

prevent

oil

from

flowing

out

4

Disconnect

front

exhaust

tube

5

Disconnect

selector

range

lever

from

manual

shaft

6

Disconnect

wire

connections

at

inhibitor

switch

7

Disconnect

vacuum

tube

from

vacuum

diaphragm

and

wire

connee

tions

at

downshift

solenoid

8

Disconnect

speedometer

cable

from

rear

extension

9

Disconnect

oil

charging

pipe

10

Disconnect

oil

cooler

inlet

and

outlet

tubes

at

transmission

case

II

Support

engine

by

locating

a

jack

under

oil

pan

with

a

woden

block

used

between

oil

pan and

jack Support

transmission

by

means of

atransmis

sion

jack

AT

28

CAUTION

Do

not

place

the

jack

under

the

oil

pan

drain

plug

12

Detach

converter

housing

dust

cover

Remove

bolts

securing

torque

converter

to

drive

plate

QOOOO

Before

removing

torque

converter

inscribe chalk

maria

on

two

parts

so

that

they

may

be

replaced

in

their

original

positions

at

assembly

13

Remove

rear

engine

mount

se

curing

bolts

and

crossmember

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

be

removed

and

take

out

transmission

under

the

car

Plug

up

openings

such

as

oil

charg

ing

pipe

oil

co

ler

tubes

etc

CAUTiON

Take

care

when

dismounting

transmis

sion

not

to

strike

any

adjacent

parts

INSTALLATION

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

one

fuU

turn

and

measure

drive

plate

runout

with

indi

eating

fInger

of

a

dial

gauge

rested

against

plate

Maximum

allowable

runout

0

5

mm

0

020 in

A

T268

2

InstaUation

of

torque

converter

line

up

notch

in

torque

converter

with

that

in

oil

pump

Be

extremely

careful

not

to

put

undue

stress

on

parts

when

installing

torque

converter

ATl16

3

When

conneCting

torque

converter

to

transmission

measure

distance

A

to

be

certain

that

they

are

correctly

assembled

Distance

A

More

than

21

5

mm

0

846

in

A

ATl17

4Bolt

converter

to

drive

plate

Align

chalk

marks

painted

across

both

parts during

disassembling

pro

cesses

5

After

converter

is

installed

rotate

crankshaft

several

turns

and

check

to

be

sure

that

transmission

rotates

freely

without

binding

6

Pour

recommended

automatic

transmission

fluid

up

to

correct

level

ough

oil

charge

pipe

7

Connect

manual

lever

to

shift

rod

Operation

should

be

carried

out

with

manual and

selector

levers

in

N

8

Connect

inhibitor

switch

wires

aRefer

to

pages

AT

26

and

27

for

Inhibitor

Switch

Adjustment

b

Inspect

and

adjust

switch

as

above

whenever

it

has

to

be

removed

for

service

AUTOMATIC

TRANSM

ISSION

Removal

and

Installation

9

Check

inhibitor

switch

for

oper

ation

Starter

should

be

brought

into

operation

only

when

selector

lever

is

in

P

and

N

positions

it

should

not

be

started

when

lever

is

in

D

2

I

and

R

positions

Back

up

lamp

should also

light

when

selector

lever

is

placed

in

R

position

I

O

Check

fluid

level

in

transmission

For

detailed

procedure

see

page

AT

51

11

Move

selector

lever

through

aU

positions

to

be

sure

that

transmission

operates

correctly

With

hand

brake

applied

rotate

engine

at

idling

Without

disturbing

the

above

setting

move

selector

lever

through

N

to

D

to

2

to

I

and

to

RA

slight

shock

should

be

felt

by

hand

gripping

selector

each

time

transmission

is

shifted

See

page

AT

52 for

Checking

En

gine

Idle

12

Check

to

be

sure

that

line

pressure

is

correct

To

do

this

refer

to

page

AT

54

for

Line

Pressure

Test

13

Perform

staU

test

as

described

in

page

AT

55

AT

29

Major

OlllHhaul

Operations

AUTOMATIC

TRANSMISSIO

N

MAJOR

OVERHAUL

OPERATIONS

Torque

converter

Input

shaft

Needleb

reftTsebraJce

Bearing

race

Needle

bearins

L

Needle

bearing

Output

abaft

Oil

chaIJing pipe

c

iI

Speedometer

pinion

Valve

body

otIl

L

et

L

Parking

mechanism

SAn01

AT

30

SERVICE

NOTES

FOR

DISASSEMBLY

Before

proceeding

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

d

ne

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

DISASSEMBLY

1

Remove

torque

converter

drain

transmission

fluid

through

end

of

rear

extension

and

place

transmission

on

TooL

SAnoa

2

Remove

converter

housing

SAT003

3

Unscrew

and

remove

downshift

solenoid

and

a

ring

AUTOMATIC

TRANSMISSIO

N

Major

Overhaul

Operations

4

Unscrew

and

remove

vacuum

dia

phragm

diaphragm

rod

and

a

ring

SA

T006

5

Remove

speedometer

lock

plate

retaining

bolt

Remove

speedometer

pinion

SAT102

6

Remove

oil

pan

and

inspect

its

contents

An

analysis

of

any

foreign

matter

can

indicate

the

types

of

prob

lems

to

look

for

If

the

fluid

is

very

dark

smells

burned

or

contains

for

eign particles

the

frictional

material

clutches

band

may

need

replace

men

A

tacky

film that

will

not

wipe

clean

indicates

varnish

build

up

which

can

cause

valves

servo

and

clutches

to

stick

and

may

inhibit

pump

pressure

7

Remove

control

valve

body

Bolts

of

3

different

lengths

are

used

Care

must

be

taken

to

identify

individual

bolt

lengths

and

locations

Remove

manual

valve

from

valve

body

as

a

precaution

to

prevent

valve

from

dropping

out

accidentaUy

8

Loosen

band

servo

piston

steIl

locknut

and

tighten

piston

stem

to

prevent

front

clutch

drum

from

drop

ping

out when

removing

front

pump

SATOOB

9

Remove

input

shaft

from

pump

Attach

Tool

to

pump

and

remove

pump

Do

not

aUow

front

Clutch

to

AT31

Major

Olll1rhaul

Operations

AUTOMATIC

TRANSMISSIO

N

come

out

of

position

and

drop

onto

floor

Take

care

that

shaft

is

not

inserted

backward

during

reassembly

10

Remove

front

clutch

thrust

washer

and

bearing

race

SAT010

II

Back

off

band

servo

piston

stem

to

release

band

SAT011

12

Remove

brake

band

strut

Brake

band

front

and

rear

clutch

assemblies

may

be

removed

together

AT

32

SAT012

To

prevent

brake

Iin

inus

from

cracking

or

peeling

do

not

stretch

the

flexible

band

unnecessarily

Before

re

moving

the

brake

band

elwaYI

secure

it

with

a

clip as

shown

in the

figure

be

low

Leave

the

clip

i

ition

fter

ra

moving

the

brake

band

Flexible

type

bend

I

nk

Unit

mm in

SAT106

oW

1

57

ApprOXimately

2

0

08

dia

wire

clip

13

Remove

pump

thrust

bearing

and

rear

clutch

thrust

washer

SAT013

14

Remove

rear

clutch

hub

front

planetary

carrier

and

connecting

sheU

rear

clutch

thrust

bearing

front

plane

tary

carrier

thrust

washer

and

thrust

bearing

I

AT124

15

Back

out

about

haIf

way

band

servo

ajtaching

bolt

Using

an

air

gun

carefuUy

apply

pressure

to

loosen

band

servo

Remove

band

servo

retain

ing

bolts

and

puu

band

servo

16

Remove

rear

planetary

carrier

snap

ring

and

rear

planetary

carrier

17

Remove

output

shaft

s

ap

ring

18

Remove

rear

connecting

drum

with

internal

annulus

gear

SATon

19

Pry

off

one

end

of

snap

ring

with

a

screwdriver

Remove

snap

ring

from

low

and

reverse

brake

assembly

while

applying plier

force

in

direction

of

arrow

20

Tilt

extension

housing

upward

and

remove low

and

reverse

brake

clutch

assembly

21

Remove

rear

extension

AUTOMATIC

TRANSM

ISSIO

N

Major

Overhaul

Operations

22 Be

careful

not

to

lose

parking

pawl

spring

and

retainer

washer

01

23

Remove

outpu1

shaft

with

gover

nor

24

Remove

governor

thrust

washer

and

needle

bearing

Remove

one

way

clutch

inner

race

attaching

hex

head

slotted

bolts

using

Tool

SA

T020

25

Remove

one

way

clutch

inner

race

return

thrust

washer

low

and

reverse

return

spring

and

spring

thrust

ring

o

L

I

C

EiL

J

0J

l

O

0

C

J

r

11

AT021

26

Using

an

air

gun

with

a

tapered

rubber

tip

carefuUy

apply

air

pressure

to

remove

low

and

reverse

brake

piston

SAT022

27

Pry

off

snap

rings

CD

from

both

ends

of

parking

brake

lever

@

and

remove

the

lever

Back

off

manual

shaft

lock

nut

@

and

remove

manual

plate

@

and

parking

rod

ID

AT

33

MsjorOverhaulOpsrstions

AUTOMATIC

TRANSMISSION

AT133

28

Remove

inhibitor

switch

and

manual

shaft

by

loosening

two

se

cming

bolts

COMPONENT

PARTS

The

transmission

consists

of

many

small

parts

that

are

quite

alike

in

construction

yet

machined

to

very

c1

e

oIerances

When

disassembling

parts

be

sure

to

place

them

in

order

iD

part

rack

so

they

can

be

put

back

in

the

unit

in

their

proper

positions

AU

parts

should

be

carefuUy

cleaned

with

a

general

purpose

non

flanunable

sol

vent

before

inspection

or

reassembly

Gaskets

seals

and

similar

parts

should

be

replaced

It

is also

very

important

to

perform

functional

tests

whenever

it

is

designated

OIL

PUMP

I

Remove

front

pump

gasket

and

O

ring

Inspect

pump

body

pump

shaft

and

ring

groove

areas

for

wear

w

SAT023

2

Remove

pump

cover

from

pump

housing

AT34

1

u

SA

T024

3

Inspect

gears

and

aU

internal

sur

faces

for

faults

and

visible

wear

4

Measure

clearance

between

outer

gear

and

crescent

Standard

dearanc

e

0

14

0

21

mm

0

0055

0

0083

in

Replace

if

the

clearance

exceeds

0

25

mm

0

0098

in

SA

T025

5

Measure

clearance

between

outer

gear

and

pump

housing

Standard

dearance

0

05

0

20

mm

0

0020

0

0079

in

Replace

if

the

clearance

exceeds

0

25

mm

0

0098

in

SA

T026

6

Using

a

feeler

gauge

and

straighf

edge

measure

clearance

between

gears

and

pump

cover

Standard

clearance

002 0 04

mm

0

0008

0

0016

in

Replace

if

the

clearance

exceeds

0

08

mm

0

0031

in

7

Measure

clearance

between

seal

ring

and

ring

groove

Standard

clearanca

0

04

0

16

mm

0

0016

0

0063

in

Replace

if

the

clearance

exceeds

0

16

mm

0

0063

in

Of

course

it

is

good

practice

to

reo

place aU

seal

rings

during

an

overhaul

l

1earance

J

Sealring

w

yw

11

4

I

AT1

5

8

Mount

pump

housing

in

Tool

Set

up

pump

housing

with

inner

and

outer

pump

gears

on

it

and

instaU

pump

cover

to

pump

housing

Temporarily

assemble

oil

pump

AUTOMATIC

TRANSM

J

SJON

Major

Overhaul

Operations

Totar

indicator

reading

Less

than

0

07

mm

0

0028

in

9Set

run

out

of

the

cover

to

within

specified

total

indicator

reading

0

ST25580001

10

Tighten

pump

securing

bolts

to

specified

torque

b

Oil

pump

housing

to

oil

pump

cover

5 9 7 8

N

m

0 6

08

kg

m

4

3 5 8

ft

lb

1

t

AT166

Recheck

run

out

Replace

Q

ring

and

gasket

A

T264

FRONT

CLUTCH

O

ring

Spring

retainer

Dish

plate

Driven

plate

steel

plate

Drive

plate

riction

plate

Snap ring

SAT086

AT

35

Major

Overhaul

Operstions

AUTOMATlG TRANSMISSIO

N

1

Using

a

screwdriver

remove

large

clutch

retaining

plate

snap

ring

2

Remove

clutch

plate

assembly

AT1S0

3

Compress

clutch

springs

and

remove

snap

ring

from

spring

retainer

When

Tool

is

to

b

used

cut

toe

tips

of th

legs

with

grinding

wheel

AT

36

L

C

1

J

20

0

79

Cut

off

hatched

portion

Unit

mm in

ATl48

4

Remove

spring

retainer

and

springs

SA

T029

5

For

easy

removal

of

piston

from

drum

mount

clutch

on

pump

Use

an

air

gun

with

a

tapered

rubber

tip

to

carefully

apply

air

pressure

to

loosen

piston

from

drum

SA

T030

6

Check

clutch

drive

plate

facing

for

wear

or

darnage

Drive

plate

thickness

must

no1

be

less

than

1

4

mm

0

055

in

Standard

dri

plate

thickness

1

50

1

65

mm

0

0591

00650

in

J

7

Check

for

wear on

snapring

weak

or

broken

coil

springs

and

warped

spring

retainer

S

Lubricate

clutch drum

hub

and

seals

and

instaU

inner

seal

and

piston

seal

as

illustrated

Be

careful

not

to

stretch

seals

during

installation

Neyer

a

mbl

clutch

dry

Iways

lubri

to

its

components

thoroughly

SAT031

9

Assemble

piston

being

careful

not

to

aUow

seal

to

kink

or

become

damaged

during

instaUation

After

in

stalling

turn

piston

by

hand

to

ensure

that

there

is

no

binding

10

Reassemble

spring

and

retainer

ReinstaU

soap

ring

Be

sure

snap

ring

is

properly

seated

II

Install

dish

plate

with

dish

facing

outward

SA

T033

12

Now

install

driven

plate

steel

plate

then

a

drive

plate

friction

plate

and

repeat

in

this

order

until

correct

number

of

plates

has

been

instaUed

check

Service

Data

and

Specifications

for

proper

quanti1y

of

plates

Now

install

retainer

plate

and

snap

ring

1Snap

ring

2

Retainer

plate

3

Drive

plate

Friction

plate

4

Drive

plate

Steel

plate

5

Dish

plate

AUTOMATIC

TRANSMISSION

Major

Overhaul

Operations

13

Measure

clearance

between

re

tainer

plate

and

snap

ring

Specified

clearance

1

6 2

0

mm

0

063

0

079

in

If

necessary

try

other

retaining

plates

having

different

thicknesses

un

til

correct

clearance

is

obtained

Available

retaining

plate

Thickness

mm

in

Part

number

10 6 0

417

10

8

0

425

11

0

433

11

20

441

II

4

0

449

11

60

457

31537

XOIOO

31537

XOIOI

31537

X0102

31537

XOI03

31537

XOI04

31537

X0105

SA

T034

14

Testing

front

clutch

With

front

clutch

assembled

on

oil

pump

cover

direct

a

jet

of

air

into

hole

in

clutch drum

for

definite

clutch

operation

AT152

REAR

CLUTCH

AT153

1

Rear

clutch

drum

6Snap

ring

2

Piston

7

Spring

retainer

3

Dished

plate

8Snap

ring

4

Coil

spring

9

Drive

plate

5

Retaining

plate

10

Driven

plate

Service

procedures

for

rear

clutch

are

essentially

the

same as

those

for

front

clutch

with

the

foUowing

ex

ception

Specified

clearance

betWeen

retainer

plate

and

snap

ring

0 8

1

6

mm

0

031

0

063 in

SA

T035

Test

rear

clutch

III

AT157

AT37

Maior

Overhaul

Operations

AUTOMATIC

T

RANSMISSIO

N

LOW

REVERSE

BRAKE

Spring

thrust

ring

Low

and

reverse

return

spring

Return

tluust

washer

Piston

Dishplatc

Driven

plate

Steel

plate

Drivc

platc

Friction

plate

Retainer

plate

Snap

ring

SA

T094

Examine

low and

reverse

brake

for

damaged

clutch

drive

plate

facing

and

worn

soap

ring

Check

drive

plate

facing

for

wear

or

damage

if

necessary

replace

DriY

4l

plate

thickness

Standard

1

90

2

05

mm

10

0748

0

0807

in

Allowabl

limit

1

8

mm

10

071

in

Test

piston

return

spring

for

weak

ness

Discard

if

it

is

too

weak

BRAKE

BAND

AND

BAND

SERVO

AT

38

Inspect

band

friction

material

for

wear

If

cracked

chipped

or

burnt

spots

are

apparent

replace

the

band

SAT036

Check

band

servo

components

for

wear

and

scoring

Rep

ace

piston

a

rings

and

aU

other

components

as

necessary

GOVERNOR

To

control

valve

11

3

I

Go

rnot

prc 15

z

1

Anchor

end

2

Band

strut

3

Apply

4

Release

4

5

Return

spring

From control

valve

6

Band

servo

piston

stem

Linc

prcssur

I

J

7

Band

servo

piston

8

Servo

retaines

A

TQ90

9

Brake

band

assembly

10

Trammission

case

1

Primary

governor

4

Oil

distributor

2

Secondary

governor

5

Output

shaft

AT290

3

Governor

valve

body

Disassemble

governor

and check

valves

for

indication

of

burning

or

scratches

Inspect

springs

for

weak

ness

or

burning

Replace

parts

as

necessary

and

reassemble

Do

not

interchange

components

of

primary

and

secondary

governor

valves

D

aOlriMI

IIlI1

SA

T038

AUTOMATIC

TRANSM

ISSIO N

Major

Overhaul

Operations

Governor

valve

sprIng

chart

Free

length

I

As

installed

I

Lm

m

0

Wire

dia

SA

T039

Assemble

governor

on

oil

distribu

tor

tl

Governor

valve

body

to

oil

distributor

Outer

No

of

Free

InstaUed

Valve

spring

Wire

dia

coil

dia

active

length

Length

Load

mm

in

mm

in

coil

mm in

mm

in

N

kg

lb

Primary

governor

0

45

8

75

5

0

21

8

7 5

2

109

0

0177

0

3445

0

858

0

295

0

215

0

474

Secondary

governor

0

70

9

20

5 5

25

1

10

5

10

788

0

0276

0

3622

0

988

0

413

11

00

2

426

PLANETARY

CARRIER

The

planetary

carrier

cannot

be

divided

into

its

individual

components

If

any

part

of

the

component

is

faulty

replace

the carrier

as

a

unit

Check

clearance

between

pinion

washer

and

planetary

carrier

with a

feeler

Standard

clearance

0

20

0

70

mm

0

0079

0

0276

in

Replace

if

the

clearance

exceeds

0

80

mm

0

0315

in

Clearance

that

have

been

damaged

by

over

heating

wiD

have

a

blue

discolora

tion

1

r

I

J

In

AT167

1

Check

planetary

gear

sets

for

darnaged

or

worn

gears

Gear

sets

SA

T040

AT

39

MajorOverlJaulOperations

AUTOMATIC TRANSMISSION

CONTROL

VALVE

BODY

The

valve

body

contains

many

pre

cision

parts

and

requires

extreme

care

when

parts

are

removed

and

serviced

Place

removed

parts

on

a

parts

rack

so

they

can

be put

back

in

the

valve

body

in

the

same

positions

and

sequences

Care

will

also

prevent

springs

and

smaU

parts

from

becoming

scattered

or

lo

t

L

Remove

oil

strainer

aod

its

attach

ing

screws

nuts

and

bolts

SAT041

2

Disassemble

valve

body

and

it

remaining

attaching

bolts

and

nuts

to

carefully

separate

lower

body

separa

tor

plate

and

upp

r

body

HT61000800

AT168

9

J

Q

J

IOIi

c

I

9

I

19uDdI

io

J

uii

L

I

1

I

l

AT1

9

3

During

valve

body

separation

do

not

scatter

or

lose

orifice

check

valve

servo

orifice

check

valve

and

thro11le

AT

40

relief

check

valve

baU

and

4

Remove

side

plate

A

pressure

regulator

valve

spring

seat

sleeve

aod

plug

and

second

lock

valve

aod

spring

Place

each

loose part

on

a

rack

to

retain

correct

sequence

of

as

sembly

Spring

seal

Spring

II

L

Side

plate

A

SA

T042

5

Remove

ide

plate

B

2nd

3rd

timing

valve and

spring

vacuum

throt

tle

valve

thro1tle

back

up

valve

and

spring

aod

the

kickdown

valve and

spring

Place

each

loose

part

on

a

rack

to

retain

sequence

of

assembly

2nd

3rd

timing

valve

Spring

a

Throttle

back

up

valve

Kick

down

vaive

Side

plate

B

SAT043

6

Remove

side

plate C

pressure

modifier

valve

and

spring

2nd

3rd

shift

valve

spring

and

plug

and

I

st

2nd

shift

valve

and

spring

Place

each

loose part

on

a

rack

to

retain

sequence

of

assembly

AUTOMATIC

TRANSM

ISSIO

N

Major

Overhaul

Operations

Manual

valve

was

removed

when

valve

body

was

removed

from

trans

mission

Include

valve

in

subsequent

inspection

and

service

sequence

d@4tt

h

1fu

I1

nib

t

fkq

T

AJ

2M

J

L

35t1t

i

w

ml

k

w

Mw

l

I

i1

Wip

j1

11

iiJU

1

jt

PbEH1

ltwmJ

j

111

1

II

Jt

I

@n

vun

Lower

valve

bOdY

Spring

C

Plug

12

d

shif

11

Pressure

modifier

valve

it

nt

valve

Spnng

nd

3rd

shift

valve

I

g

I

Slde

plate

e

A

I

Precaution

for

inspection

A

newly

manufactured

valve

body

represents

precision

manufactured

valves

assembled

with

close

tolerances

into

precision

bores

of

the

valve

body

If

inspection

reveals

excessive

clear

ances

0

03mm

0

0012

in

or

more

between

the

valves

and

the

valve

body

bores

replace

the

en1ire

valve

body

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

Always

use

croeus cloth

which

is

a

very

fme

type

of

cutting

material

Never

use

emery

cloth

as

it

is

too

coarse

and

can

scratch the

valves

or

valve

bores

Scratches

can

lead

to

future

deposits

of

varnish

or

foreign

matter

SA

T044

During

cleaning

do

not

remove

the

sharp

edges

of

the

valve

When

edges

are

rounded

or

scratched

entry

is

pro

vided

for

dirt

or

foreign

matter

to

work

into

the

sides

of

the

valves

and

hinder

valve

movement

The

valves

may

be

cleaned

using

alcohol

or

lacquer

thinner

The

valve

bodies

can

be

dip cleaned

with

a

good

carburetor

cleaner

or

lacquer

thinner

Do

not

leave valve

bodies

SUbmerged

in

carburetor

cleaner

longer

than

five

minutes

Rinse

parts

thoroughly

and

dry

Lubricate

all

parts

in

clean

auto

matic

transmission

fluid

before

reas

sembly

7

Check

valves

for

signs

of

burning

Replace

if

beyond

clean

up

8

Check

oil

strainer

for

general

con

dition

Replace

if

necessary

9

Check

separator

plate

for

scratches

or

damage Replace

if

neces

sary

Scratches

or

score

marks

can

cause

oil

to

bypass

correct

oil

passages

and

result

in

system

malfunction

Co

nDllD

o

0

b

nnn

0

10

0

oo

0

SA

T046

10

Check

oil

passages

in

upper

and

lower

valve

bodies

for

varnish

deposits

scratches

Or

otber

damage

that

would

impair

valve

movement

Check thread

ed

holes

and

screws

for

stripped

threads

replace

as

needed

II

Test

valve

springs

for

weakened

load

condition

Refer

to

Valve

Body

Spring

Chart

for

spring

specifications

Valve

body

spring

chart

i5

l

O

Free

length

I

As

installed

I

r

ij

0

Wire

dia

SAT039

AT

41

Major

Overflaul

Operations

AUTOMATIC

TRANSM

ISSIO

N

InstaUed

Wire

dia

Outer

coil

No

of

Free length

Valve

spring

mm in

dia

active

coil

mm in

Length

Load

mm

in

mm

in

N

kg

lb

Manual

detent

13

73

15

32

4

26

5

53 9

0

051

0

287

1

276

1

043

55

12

1

Pressure

regulator

valve

1

2

11

7

13

43

0

23

5

27

5

0

047

0

461

1

693

0

925

28 62

Pressure

modifier

valve

04

84

5

18

5

90

1

0

016

0

331

0

728

0

354

01 0

2

1st

2nd

shift

valve

0

6 6 6

16

32

0

16 0 6

129

0

024

0

260

1

260

0

630

0

625

1

378

2nd

3rd

shift

valve

0

7

69

18

41

017

0

13

73

0

028

0

272

1

614

0

669

I

40

3

09

2nd

3rd

timing

valve

0

7

62

15

32

5

27

0

5

39

0

028

0

244

1

280

1

063

0

55

1

21

Throttle

back

up

valve

0

8

73

14

36

0

18 8

18

83

0

031

0

287

1

417

0

740

1

92

4

23

Solenoid

downshift

valve

0

55 5

55

12 22

0

12

5

88

0

0217

0

2185

0

866

0

492

0

60

1

32

Second

lock

valve

0

55

5

55

16

33

5

21

0

5

88

0

0217

0

2185

1

319

0

827

0

60

1

32

Throttle

relief

check

valve

0

9

65

14

26

8

19

0

2148

0

035

0

256

1

055

0

748

219

4

83

Orifice

check

valve

0

23

5

0

12

15

5

11

5

010

0

0091

0

197

0

610

0

453

0

01

0

02

Servo

orifice

check

valve

AT

42

AUTOMATIC

TRANSM

ISSIO

N

Major

Dverhsul

Operations

12

Assemble

side

plate

A

group

of

parts

into

lower

valve

body

Reins1aU

side

plate

and

fmger

tighten

screws

Assemble

side

pla1e

B

group

and

Sid

Pia

talA

Cl

Spring

seat

U

J@

Pressure

regl

llat

r

sleevei

Pressure

regulator

plug

Second

lock

valve

Upper

valve

body

Manual

valve

13

Tighten

screws

cD

Side

plate

to

valve

body

2 5 3

4

N

m

0

25

0

35

kg

m

1

8 2 5

ft

lb

14

Install

orifice

check

valve

spring

1hrottle

relief

valve

spring

and

steel

ball

in

valve

body

AT173

Orifice

check

valve

AT430

side

plate

Cgroup

in

same

manner

as

A

group

SAT095

15

Install

upper

and

lower

valves

cD

Upper

snd

lower

VBlves

2 5 3 4

N

m

0

25

0

35

kg

m

1

8 2 5

ft

lb

Reamer

bolt

4

9 6 9

N

m

0

5

0

7

kg

m

3 6 5

1

fNb

ST25160000

16 Install

oil

strainer

cD

Oil

strsiner

to

valve

body

2 5 3

4

Nm

fO

25 0

35

kg

m

1

82 5

ft

lb

The

manual

valve

is inserted

into

the

valvB

body

when

the latter

is

in

stalled

in

the

transmission

AT

43

Majo

OverhaulOperations

AUTOMATIC

TRANSMISSION

FINAL

ASSEMBLY

When

installing

assembling

needle

bearing bearing

race

snap

ring

and

iUustration

as

a

guide

to

instaUation

O

ring

seal

ring

use

the

foUowing

procedures

and

locations

@

Co

Q

gE

do

0

a

0

c

2

Q

0

c

u

5

Co

e

QO

CQ

QC

S

oU

e

ll

30

C

e

oS

F

8

i

d

8

Co

cii

a8

Q

a

5

H

Q

u

e

@

r

1

ll

Ji

QQ

UU

ee

C

S

d

a

j

@Q

1

5

zj

Q

U

e

I

8

f

l

il

d

e

C

Co

cii

Q

U

e

S

a

5

Q

a

zs 8

S

Co

f

t

e

IS

SA

T099

AT

44

I

Before

proceeding

with

the

fmal

assembly

of

all

components

it

is

im

portant

to

verify

that

the

case

housing

and

parts

are

clean

and

free

from

dust

dirt

and

foreign

matter

use

air

gun

Have

a

tray

available

with

clean

trans

mission

fluid

for

lubricating

parts

Petroleum

jeUy

can

be

used

to

secure

washers

during

installation

All

new

seals

and

rings

should

have

been

installed

before

beginning

final

as

semb

ly

SAT047

2

Lubricate

and

instaU

low

and

reverse

piston

into

the

case

3

InstaU

thrust

ring

piston

return

spring

thrust

washer

and

one

way

clutch

inner

race

JGOC

Oe

c

o

j

cl

GOo

IIU

o

0

o v

1

c

Co

0

l

f

9

r

JP

o o

s

r

II

IS

TOZl

AUTOMATIC

TRANSMISSION

Major

Overhaul

Operations

4

Align

and

start

hex

head slotted

bolts

into

inner

race

from

rear

of

case

WARNING

Check

that

return

spring

is

centered

on

race

before

tightening

Tighten

the

bolts

G

J

One

way

clutch

inner

race

to

transmission

case

13

18

N

m

1

3

1

8

kg

m

9 13

ft

lb

I

ii

7

l

i

ST25570001

lfiu

ST25490000

GG91060000

5

Install

steel

dished

pla1e

first

then

steel

and

friction

plates

and

fmaUy

retaining

plate

and snap

ring

6

After

low

and

reverse

brake

has

been

completely

assembled

measure

clearance

between

snapring

and

re

tainer

plate

If

measurement

exceeds

specifications

it

can

be

adjusted

by

replacing

retainer

plate

with

one

of

a

different

thickness

Low

and

reverse

brake

clearance

0

80

1

25

mm

0

0315

0

0492

inl

7

Using

an

air

gun

with

a

tapered

rubber tip

check

low

and

reverse

brake

operation

8

InstaU

governor

thrust

washer

and

needle

bearing

9

Slide

governor

distributor as

sembly

on

output

shaft

from

fron1

of

shaft

Install

shaft

and

governor dis

tributor

into

case

using

care

not

to

damage

distributor

rings

AT

45

Major

Overhaul

Operations

AUTOMATIC TRANSMISSION

10 InstaU

one

way

sprag

into

one

way

clutch

outer

race

attached

to

connecting

drum

Arrow

on

sprag

must

face

front

of

transmission

II

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

stalled

and

operative

12

InstaU

rear

in1ernal

gear

AT

46

c

D

CO

V

j

a

13 Install

map

ring

on

shaft

14

Secure

thrust

bearing

and

thrust

washer

with

petroleum

jeUy

and

instaU

rear

planetary

carrier

SA

TOSS

15

Install

rear

planetary

carrier

snap

ring

This

snap

ring

is

thinner

than

8

clutch

drum

snap

ring

so

ba

sure

you

are

using

correct

size

If

you

have

in

sufficient

spaco

to

install

snap

ring

int

drum

groove

pull

connecting

drum

forward

a

far

as

possible

This

will

give

you

sufficient

groove clear

anco

to

install

drum

nap

ring

16

Adjust

front

end

playas

foUows

Front

end

p1aY

1

JL

v

r

l

J

CC

j

SAT091

Front

clutch

thrust

washer

2

Oil

pump

cover

3

Front

clutch

4

Rear

clutch

5

Transmission

case

6

Oil

pump

ga5Ket

7

Oil

pump

cover

bearing

race

I

Assemble

front

and

rear

clutches

front

internal

gear

front

planetary

carrier

and

connecting

sheU

Secure

thrust

bearings

with

petroleum

jeUy

I

4

SATOS7

2Install

assembly

into

transmission

caSe

Check

that

parts

are

properly

seated

before

proceeding

with

measurements

SA

T05S

3

l

sing

a

dial

gauge

or

caliper

with

a

seven

inch

base

measure

from

rear

hub

thrust

bearing

race

to

case

dimen

sion

A

3

cID

@

SAT059

1

Dial

gauge

2

Front

clutch

drum

3

Transmission

case

4

Bearing

race

5

Thrust

bearing

6

Rear

clutch

drum

4

Assemble

front

and

rear

clutch

drum

assemblies

together

and

lay

them

l1at

on

bench

Be

sure

rear

hub

thrust

bearing

is

properly

seated Measure

AUTOMATIC

TRANSM

15510

N

Major

Overhaul

Operations

from

face

of

clutch

drum

to

top

of

thrust

bearing

race

dilliension

B

@

SAT061

1

Depth

gauge

2

Front

clutch

drum

3

Rear clu

tch

drum

4

Thrust

bearing

5

Measure

from

top

of

oil

pump

shaft

to

gasket

installed

dimension

C

1

c

I

G

k

I

ty

oilPump

SAT063

fU

0

III

SAT064

6 Install

thrust

washer

Measure

from

top

of

oil

pump

shaft

to

thrust

washer

dimension

D

I

L

fffi

llV

Oil

pumpU

SAT096

7

Difference

between

dimension

A

0

1

mm

0

004

in

B

and

C

D

is

front

end

play

and

must

be

within

specified

value

Specified

front

end

play

0

5

0 8

mm

0

020

0

031

inl

Front

end

play

can

be

adjusted

with

front

clutch

thrust

washers

of

different

thickness

Available

front

clutch

thrust

washer

Thickness

mm

in

Part

number

I

S

0

059

31528

XOlO6

17

0

067

31528

XOl05

1

9

0

075

31528

XOIOO

2

1

0

083

31528

XOIOI

23

0

091

31528

XOI02

25

0

098

31528

XOlO3

2

7

0

106

31528

XOI04

17

Adjust

total

end

playas

follows

This

adjustment

is

seldom

required

because

this

type

of

thrust

bearing

and

AT

47

Major

Overhaul

Operations

AUTOMATIC

TRANSM

ISSION

race

will

normally

show

very

little

wear

We

also

have

a

standard

taler

ance

of

0

25

to

0

50

mm

0

0098

to

0

0197

in

However

we

are

present

ing

correct

checking

procedure

j

i

C1l

i

E

r

Tott

Jf

play

SA

T092

Front

clutch

thrust

washer

2

Oil

pump

cover

3

Front

clutch

4 Rear

clutch

5

Transmission

case

6

Oil

pump

ga5ket

7

Oil

pump

cover

be

aring

race

1

Meamre

dimension

A

using

in

structions

in

steps

1

2

and

3

under

No

16

above

2

Measure

dimension

C

using

in

structions

in

step 5

under

N

16

above

3

Difference

between

dimension

A

Q

I

mm

0

004

in

and

C

is

total

end

play

and

it

must

be

within

speci

fied

value

Specified

total

end

play

0

25

0

50

mm

0

00980

0197

inl

If

difference

J

letween

A

Q

2

mm

0

008

in

and

C

is

not

within

taler

ance

select

proper size

oil

pump

cover

bearing

race

Available

oil

pump

cover

bearing

race

Thickness

mm

in

Part

number

1

20

047

31556

XOlOO

14

0

055

31556 XOIOI

1

6 0

063

31556

XOI02

1

8

0

071

31556

XOI03

2

00

079

31556 XOI04

22 0

087

31556

XOl05

AT

48

18

Install

brake

band

strut

and

band

servo

Lubricate

servo

O

rings

before

installing

Care

should

be

taken

to

avoid

damaging

O

rings

when

re

mbling

19

Install

and

torque

the

retainer

bolts

Loosen

piston

stem

rfl

Servo

piston

retainer

bolt

49

6

9N

m

05

0

7

kg

m

3 6 5

1

ft

b

20

Finger

tighten

brake

band

servo

piston

stem

enough

to

prevent

brake

band

and

strut

from

falling

out

Do

not

adjust

bnlke

band

at

this

time

21

Mount

oil

pump

gasket

on

oil

pump

with

petroleum

jelly

Align

pump

to

transmission

case

and

install

n

SA

T069

22

Adjust

band

Make

sure

that

brake

band

strut

is

correctly

installed

Torque

piston

tern to

specified

v

Jue

Back

off

two

full

turns

and

secure

with

lock

nut

rfl

Piston

stem

12 15

N

m

1

2

1

5

kg

m

9

11

ft

bl

Piston

stem

lock

nut

15

39N

1 5

4 0

kg

m

11

29

ft

lb

GG91060000

ST25490000

SAT070

23

Before

proceeding

with

installa

tion

of

valve

body

assembly

perform

a

fmal

air

check

of

all

assembled

com

ponenjs

This

will

ensure

that

you

have

not

overlooked

tightening

of

any

bolts

or

damaged

any

seals

during

as

sembly

Air

check

point

1

Band

servo

apply

9

2

Rear

clutch

1

Front

clutch

11

3

Band

servo

release

10

4

Governor

feed

1

5

Low

reverse

brake

12

4

Using

an

air

gun

with

a

tapered

rubber

tip

perform

air

checks

25

Check

that

parking

pawl

spring

and

washer

are

assembled

correctly

6

c

l

0

o

0

1

o

2

o

SA

T073

26

Install

rear

extension

AUTOMATIC TRANSMISSIO

N

Major

Overhaul

Operations

Q

Rear

extension

to

transmission

case

20 25

N

m

2 0 2 5

kg

m

14

18

ft

Ib

n

SA

T014

27

Install

control

valve

body

Be

sure

manual

valve

is

in

alignment

with

selector

u

o

tK

oo1

o

28

Tighten

control

valve

body

attach

ing

bolts

dl

5 4

74N

m

0

55

0

75

kg

m

4

0 5

4

ft

Ibl

Control

valve

body

attaching

bolts

vary

in

length

Care

must

be

taken

to

ensure

that

each

bolt

is

returned

to

correct

hole

29

Check

pump

to

transmission

align

I11ent

and

install

converter

housing

dl

44

54

N

m

4

5 5 5

kg

m

33

40

ft

Ibl

30

Before

installing

vacuum

dia

phragm

valve

measure

depth

of

hole

in

which

it

is inserted

This

measure

ment

determines

correct rod

length

to

ensure

proper

performance

SA

T078

1

Note

seated

valve

body

2

Transmission

case wall

3

Vacuwn

diaphrngm

4

Diaphragm

rod

5

Valve

body

side

plate

6

Vacuum

throttle

valve

AT

49

Major

Overhsul

Operations

AUTOMATIC

TRANSM

15510

N

Throttle

modulator

valve

rod

selectioo

Measured

depth

L

mm

in

Rod

length

mm

in

Under

2555

25 65

26

05

2615

2655

26

65

27 05

Over

27

15

J

0059

1

0098

1

0256

1

0295

1

0453

1

0492

1

0650

1

0689

29

0

1

142

29

5

1

161

30

0

l

l81

30

5

1

201

31

0

1

22

0

31

Install

vacuum

diaphragm

32

Before

installing

down

shift

sole

noid

check

to

verify

that

it

is

oper

ating

properly

Use

a

hot

lead

and

ground

to

check

solenoid

A

33

Install

down

shift

solenoid

L

@J

E

F

SATOS1

AT

50

34

Install

inhibitor

switch

Check

for

proper

operation

in

each

range

using

a

circuit

tester

Refer

to

Minor

Adjust

ment

SA

T082

35

Before

installing

oil

pan

check

alignment

and

operation

of

control

lever

and

parking

pawl

engagement

Blow

mechanism

with

air

to

clean

Make

fmal

check

to

be

sure

all

bolts

are

installed

in

valve

body

36

Install

oil

pan

with

new

gasket

tfl

Oil

pan

to

transmission

ease

4 9

6 9

N

m

0

5 0 7

kg

m

36

5

1

ft

Ibl

Part

number

31932

XOI03

31932

XOI04

31932

XOlOO

31932

XOI02

31932

XOIOI

37

Carefully

inspect

torque

converter

for

damage

Check

converter

hub

for

grooves

caused

by

hardened

seals

Also

check

bushing

contact

area

38

Lubricate

oil

pump

lip

seal

and

converter

neck

before

installing

con

verter

Install

converter

being

sure

that

converter

is

properly

meshed

with

oil

pump

drive

gear

AUTOMATIC TRANSMISSION

Trouble

shootingsndDiagnoses

TROUBLE

SHOOTING

AND

DIAGNOSES

PRELIMINARY

CHECKS

Prior

to

road testing

Verify

customer

complaint

The

customer

should

supply

as

much

information

as

possible

includ

ing

any

unusual characteristics

that

accompany

the

comp

laint

Fluid

level

To

properly

check

l1uid level

1

Place

car

on

a

level

surface

2

Put

wheel

chocks

in

place

and

apply

parking

brake

securely

3

Warm

up

engine

on

fast

idle

4

Return

engine

to

curb

idling

speed

5

Slowly

move

the

gear

selector

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

the

level

The

L

mark

on

the

dipstick

indi

cates

the

transmission

is

approximate

ly

0

4

liter

78

US

pt

3

4

Imp

pt

low

Add

only

clean

Dexron

transmis

sion

l1uid

or

equivalent

Fluid

leakage

To

detect

a

l1uid

leak

I

Raise

car

2

Clean

area

suspected

of

leaking

3

Start

engine apply

foot

brake

place

gear

selector

in

drive

and

wait

a

few

minutes

4

Stop

engine

5

Check

for

fresh

leakage

If

the

transmission

breather

is

8US

pected

I

Raise

car

2

Clean

the area

around

the

breather

3

Run

the

car

at

highway

speeds

4

Check

the

breather

for

fresh

leak

age

To

aid

in

locating

leaks

use the

following

list

of

seals

and

gaskets

1

Converter

housing

Rubber

O

ring

of

oil

pump

housing

Oil

pump

housing

oil

seal

transmis

sian

front

seal

Crankshaft

oil

seal

Bolts

of

converter

housing

to

case

f

CD

I I

1

II

8

1

IL

I

II

I

II

If

O

filse

if

o

2

Transmission

and

rear

extension

Junction

of

transmission

and

rear

extension

Oil

cooler

tube

connectors

Oil

pr

ssure

inspection

ports

Vacuum

diaphragm

and

downshift

solenoid

Speedometer

pinion

sleeve

Rear

extension

oil

seal

I

SAT104

AT

51

TroublfHhootingand

DilJgnoses

AUTOMATIC

TRANSM

15510

N

Fluid

condition

Transmission

fluid

color

and

tex

ture can

aid

greatly

in

transmission

trouble

shooting

When

checking

l1uid

level

examine

the

transmission

l1uid

and

note

its

color

texture

and

odor

Some

common

fonns

of

contami

nation

are

listed

below

I

Dark

or

Black

Fluid

With

a

burned odor

Worn

friction

material

Without

an

odor

Slight

engine

coolant

leak

in

radiator

2

Milky

Pink

Fluid

Water

Contami

nation

Coolant

leak

Road

water

entering

through

filler

tube

or

breath

er

3

Varnished

Fluid

light

to

dark

brown

and

tacky

Oxidation

Over

or

Underfilling

Overheating

Engine

Idle

Check

and

adjust

idle to

specifica

tions

Idling

speed

700

i

100

rpm

at

0

range

Engine

011

and

coolant

levels

Prior

to

road

testing

check

engine

oil

and

coolant

levels

and

fill

as

neces

sary

Shift

linkage

Start

in

park

position

depress

detent

button

and

slowly

move

the

gear selector

through all ranges

The

detent

clicks

should

correspond

with

the

range

indicator

AT

52

pIAGN

STIC

ROAD

TEST

Prior

to

road

testing

perform

the

preliminary

inspections

outlined

earlier

If

the

car

is

not

equipped

with

a

tachometer

install

a

portable

tacho

tneter

in

the

car

And

also

install

a

suitable

vacuum

gauge

and

pressure

gauge

If

the

customer

has

a

specific

complaint

select

road

conditions

similar

to

those

described

eg

steep

hills

freeways

etc

Follow

the

test

sequence

as

out

lined

in

this

section

and

mark

the

results

on

the

Symptom

Chart

on

page

AT

59

It

may

be

necessary

to

repeat

sections

of

the

test

under

different

throttle

conditions

e

g

light

medium

or

full

throttle After

completing

the

road

test

compare

the

test

results

to

lIIe

Trouble

shooting

Chart

on

page

AT

56

ROAD

TESTING

L

Park

Range

Place

the gear

selector

in

P

range

and

start

the

engine

Stop

the

engine

and

repeat

the

procedure

in

all

other

ranges

and

neutral

In

park

the

car

should

be

locked

in

position

unable

to

roll

or

move

Mark

all

results

on

the

Symptom

Chart

2

Reverse

Manually

shift

the

gear selector

from

P

to

R

and

note

shift

quali

ty

Drive

the

car

in

reverse

long

enough

to

detect

slippage

or

other

abnormalities

Note

results

3

Neutral

Manually

shift

the

gear

selector

from

P

to

N

and

note

quality

In

neutral

no

clutches

or

bands

are

ap

plied

and

there

should

be

no

move

ment

Note

results

4

Drive

Range

Manually

shift

the

gear

selector

to

ran

e

0

and

note

shift

quality

Drive

the

car

through

all

automatic

shifts

and

in

all

gear

ranges

Note

shift

quality

and

timing

km

h

MPH

check

for

slippage

noise

or

other

abnormal

conditionS

If

necessary

drive

the

test

sequence

under

different

throttle

openings

e

g

light

medium

or

full

throttle

5

Range

2

Manually

shift

the

gear

selector

to

range

2

Check

for

slippage

hesita

tion

or

abnormal

condition

The

trans

mission

should

remain

in

2nd

gear

regardless

of

car

speed

or

engine

re

volutions

Note

re

lts

6

Range

I

Manually

shift

the

gear

selector

to

range

I

Note

shift

quality

It

should

however

downshift

im

mediately

to

2nd

gear

and

downshift

again

to

1st

gear

as

road

speed

de

creases

Accelerate

and

decelerate

in

1st

gear

to

determine

engine

braking

Note

results

The

transmission

should

not

shift

into

1st

gear

from

0

range

if

tha

car

road

speed

is

above

approximately

50

km

h

30

MPHI

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

Trouble

shooting

and

Diagnoses

Car

speed

and

line

pressure

when

shifting

gears

Intake

manifold

vacuum

Gearshift

Car

speed

Propeller

shaft

Line

pressure

kPa

mmHg

inHg

km

h

MPH

revolutions

rpm

kPa

kg

em

2

psi

0

O2

60 68

38

42

1

970

2

220

0

00

107 115

66

71

3

480

3730

530

686

Kiekdown

00

105

97

65

60

3

410

3

160

5

4

70

77

100

0 0

53

45

33

28

1720

1470

0

O2

23

31

14

19

750

1

000

13

3

100

3

94

O2

0

63

70

39

44

2

040

2

290

441

598

00

40 32

25

20

1

300

1

050

4

5

6

1

64

87

O2

0

II

18 7

II

350 600

o

Full

throttle

I I

54 46 33

29

1750

1

500

549 706

5

6 7 2

80

102

40

0

300

11

81

I I

54

46

33 29

1

750

1

500

549 706

5672

80

102

Car

speed

can

be

calculated

by

the

following

formula

v

where

V

Np

RF

r

v

where

V

Np

RF

r

00307

x

Np

1

2

x

r

x

Np

x

60

RF

x

1

000

Car

speed

km

h

Propeller

shaft

revolution

rpml

Final

gear

ratio

13

700

Tire

effective

radius

m

185nO

SR14

0

301

m

The

ratio

of

circumference

of

a

circle

to

its

diameter

3

141

0

01905xNp

2xll

xrxNPx60

RF

x

63

360

Car

speed

MPH

Propeller

shaft

revolution

rpm

Final

gear

ratio

3

700

Tire effective

radius

in

18SnO

SR14

1185

in

The

ratio

of

circum

of

a

circle

to

its

diameter

3

14

AT

53

Trouble

shooting

8m

iagnoses

AUTOMATIC

TRANSM

ISSION

Shift

schedule

Full

throttle

Kickdown

range

1

2

1t2

2

t

t3

13

3

1

2

2Y3

3

000

3

94

I

E

26

7

I

f

200

7

87

I

l

c

I

0

I

3

r

400

1

12

S

e

I

E

300

11

81

I

EII

d

I

53

3

5

0

I

OO

15 75

I

66

7

I

500

19

69

c

0

500

1

000

1

500

2

000

2

500

3

000

3

500

4

000

Propeller

shaft

revolution

rpm

kmfh

0

Car

speed

I

MPH

10

PRESSURE

TESTING

The

3N71B

transmission

is

pro

vided

with

three

pressure

test

ports

Only

two

are

useful

for

transmission

trouble

shooting

line

Pressure

and

Governor

Pressure

ST2505S001

AT454

1

Line

pressure

2

Governor

pressure

3

Servo

release

pressure

LINE

PRESSURE

I

Install

pressure

gauge

to line

pres

sure

port

When

shift

lever

is

in

0

2

or

1

range

install

pressure

gauge

to

port

CD

and

when

in

R

range

install

pressure

gauge

to

port

@

shown

above

Locate

the

gauge

so

it

can

be

seen

by

driver

Measure

line

pressure

at

idling

and

at

stall

test

2

Road

test

car

and

note

pressure

under

different

throttle

conditions

AT

54

20

90

100 130 140

30

40

50

30

60

70

120

70

80

10

20

80

40

50 60

SAT105

At

idling

Range

Line

pressure

kPa

kg

cm2

psi

412

549

4

2

5

6

60

80

314

373

3

2

3

8

46

54

588

1

147

60

11

7

85

166

314

373

32

3

8

46

54

R

D

2

At

tall

test

Range

Line

pressur

kPa

kg

cm2

psi

R

1402

1

589

14

3

16 2

203

230

D

971

1

089

9 9

11

1

141

158

2

1

000

1

147

10

2

117

145 166

971

1

089

9 9

11

1

141

158

Key

points

of

pressure

testing

are

al

Pressure

at

idle

Look

for

a

teady

rise

in

pressure

as

car

speed

in

cre

under

light

load

bl

Pr

ur

drop

b

tween

hift

point

hould

not

exceed

98

kPa

1

0

kg

cm2

15

p

n

Ex

i

pressure

drop

may

indicate

an

internal

leak

at

a

servo

or

clutch

seal

Cut

back

point

The

cut

back

point

indicates

a

point

where

line

pressure

changes

from

high

to low

value

a

output

shaft

AUTOMATIC TRANSMISSION

Trouble

shootingandOiagnoses

rotation

is

gradually

increased

from

stall

point

The

car

speed

and

out

put

shaft

rotation

at

that

cut

back

point

are

as

indicated

in

chart

below

Intake

manifold

vacuum

Car

speed

Propeller

shaft

revolutions

kPa

mmHg

inHg

km

h

MPH

rpm

o

00

40 48

25

30

1

310

1

560

13

3

100

3

94

20

28

13

17

660 910

GOVERNOR

PRESSURE

I

Install

pressure

gauge

to

governor

pressure

port

Locate

the

ga

ge

so

it

can

be

seen

by

driver

2

Road

test

car

and

note

pressure

at

different

road

speeds

Gov

mor

pres

sure

increases

directly

with

road

speed

and

should

always

be

less

than

line

pressure

STALL

TESTING

The

stall

test

is

an

effective

method

of

testing

clutch

and

band

holding

ability

to

rque

converter

one

way

clutch

operation

and

engine

perform

ance

A stall

test

should

only be

per

formed

as a

last

resort

because

of

the

high

l1uid

temperature

it

generates

and

the

excessive

load

it

places

on

the

engine

and

transmission

1

CAUTION

a

Transmission

and

engine

fluid

levels

should

alwavs

be

checked

and

fluid

added

as

needed

b

Run

engine

at

1

200

rpm

to

attain

proper

warm

up

c

During

test

never

hold

throttle

wide

open

for

more

than

5

seconds

d

Do

Not

test

more

than

two

gear

ranges

without

driving

car

to

cool

off

engine

and

transmission

STALL

TEST

PROCEDURE

1

Install

a

tachometer

where

it

can

be

seen

by

driver

during

test

2

Set

hand

brake

and

block

wheels

3

Start

engine

and

place

shift

lever

in

D

range

4

Apply

foot

brake

and

accelerate

to

wide

open

throttle

Do

not

hold

throttle

open

longer

than five

seconds

5

Quickly

note

the

engine

stall

speed

and

immediately

release

throt

tle

Stall

revolution

1

650

1

950 rpm

6

Place

shift

lever

in

R

range

and

repeat

above

test

same

as

in

D

range

If

stall

test

indicates proper

stall

re

volution

in

D

range

no

further

tost

ing

is

necessary

STALL

TEST

ANALYSIS

I

Satisfactory

results

in

0

range

indicates

rear

clutch

one

way

clutch

of

transmission

apd

sprag

flutch

of

torque

converter

are

functioning

pro

perly

2

Stall

revolution

in

0

range

1st

gear is

above

car

specified

The

rear

clutch

is

faulty

3

Stall

revolution in

R

range

is

above

specified

revolution

for

0

range

Low

and

Reverse

Brakes

are

faulty

4

Stall

revolution in

0

range

1St

gear is

below

specified

revolution

Converter

sprag clutch

is

faulty

slipping

or

engine

is

not

performing

properly

If

converter

sprag

clutch

is

frozen

car

will

have

poor

high

speed

perfor

mance

If

converter

sprag

clutch

is

slipping

car

will

be

sluggish

up

to

50

or

60

km

h

30

or

40

MPHl

AT 55

Trouble

shooting

Bnd

Diagnoses

AUTOMATIC

TRANSM

IS

ION

TROUBLE

SHOOTING

CHART

Numbers

are

arranged

in

order

of

probability

Perform

inspections

starting

with

number

one

and

work

ing

up

Circled

numbers

indicate

that

the

transmission

must

be

removed

from

the

car

Engine

does

not

start

in

Nn

P

ranges

Engine

starts

in

range

other

than

N

and

p

Transmi

sion

noise

in

P

and

N

ranges

Car

moves

when

changing

into

P

range

or

parking

gear

does

not

dis

engage

when

shifted

out

of

P

range

Car

runs

in

N

range

Car

will

not

run

in

R

range

but

runs

in

0

2

and

I

ranges

Clutch

slips

Very

poor

acceleration

Car

braked

when

shifting

into

R

range

Sharp

shock

in

shifting

from

N

to

D

range

Car

will

not

run

in

0

range

but

runs

in

2

and

R

ranges

Car

will

not

run

in

D

I

2

ranges

but

rims

in

R

range

Clutch

slips

Very

poor

acceleration

Clutches

or

brakes

slip

somewhat

in

tarting

Excessive

creep

No

creep

at

all

Failure

to

change

gear

from

I

st

to

2nd

Failure

to

change

gear

from

2nd

to

3rd

Too

high

a

gear

change

point

from

1st

to

2nd

from

lnd

to

3rdu

Gear

change

directly

from

1st

to

3rd

occurs

AT56

J

S

s

0

2

s

Cf7

CO

E

13

Eib

oe

4

ti

e

fe

aOClO

co

Sf

a

f

e

0

ii

EEo

t

ag

o

r

i

Ur

J

Q

d

oS

J5

2 3

2

I

2

I

2

I

26

2

I

3

I

23

I

2

ON

CAR

c

E

it

c

fi

e

L

a

u

c

M

O

t

I

f

C

0

S

c

c0J

R

f

t

S

0

t

CI

Cir

E

Jsou

It

0

OIl

c

i8

cSg

jl

t

2

3 2

3

6 4

5

321

3

4

23

4

63

5

374

5

4

56874

35

64

2

4

3

I

IN

CAR

l

0

tl

fj

t

fi

f

GJ

l

0

111

Jfe

CI

I

o

cfJB

i

CO

g

Ct

0 c

cE

3C5C5

@

@@

J

@

CID

@

7

@

@@

@

@@

@

D

@

CID

OFF

CAR

OFF

CAR

s

J

0

5fJ

s

E

00

ra

11

E

0

S

MC

It

I

V

@

D

@

Numbers

are

arranged

in

order

of

probability

Perform

inspect

ons

starting

with

number

one

and

work

ing

up

Circled

numbers

indicate

that

the

transmission

must

be

removed

from

the

car

Too

sharp

a

shock

in

change

from

1st

to

2nd

Too

sharp

a

shock

in

change

from

2nd

to

3rd

Almost

no

shock

or

clutches

slipping

in

change

from

1st

to

2nd

Almost

no

shock

or

slipping

in

change

from

2nd

to

3rd

Engine

races

extremely

Car

braked

by

gear

change

from

lst

to

2nd

Car

braked

by

gear

change

from

2nd

to

3rd

Maximum

speed

not

attained

Acceleration

poor

Failure

to

change

gear

from

3rd

to

2nd

Failure

to

change

gear

from

2nd

to

1st

or

from

3rd

to

lst

Gear

change

shock

felt

during

deceleration

by

releasing

accelerator

pedal

Too

high

a

change

point

from

3rd

I

to

2nd

from

2nd

to

1st

Kickdown

does

not

operate

when

depressing

pedal

in

3rd

within

kick

down

car

speed

Kickdown

operates

or

engine

over

runs

when

depressing

pedal

in

3rd

beyond

kick

down

car

speed

limit

Races

extremely

or

slips

in

changing

from

3rd

to

2nd

when

depress

ing

pedal

AUTOMATIC

TRANSM

15510

N

Trouble

shooting

and

Diagnoses

s

Je

or

U

Jg

0

E

f1

6

I

2

3

123

I

2

I

2

I

2

I

2

r

I

2

f

i

ff

i

0

Ei

0

e

t

tJ

o

os

Jt

rJJ

2 3

4

5

34

3

2

ON

CAR

l

a

c

o

u

0

t

a

E

g

C5tE

2 4

3

6

2

3

2

76

346

346152

5

6

5

6

4

5

6

4

ON

CAR

If

ii

N

E

g

3

1

0

i5

Ei

o

c

0

v

c

o

5 3

5

4

8

7 5

8

7 5

3

8

5 2

3

7

4

6

5

3

o

tf

S

e

0

or

fj

E

3

0

d

ct

iJ

@

OFF

CAR

fi

5

rJ

o

it

0

5fj

c

or

e

B

fJ

E

u

S

0 0

S

r

388

s

@

@@

@

j

@

I@

CID

@I

@@@I@

j

CD@

@

CD@

I

CD

@

CD

@

CD

@

@ @

OFF

CAR

AT

57

Trl

ble

shooting

and

OiagnOSJ

S

AUTOMATIC

TRANSM

IS

IO

N

Numbers

are

arranged

in

order

of

probability

Perform

inspections

starting

with

number

one

and

work

ing

up

Circled

numbers

indicate

that

the

transmission

must

be

removed

from

the

car

Car

will

not

run

in

any

range

Transmission

noise

in D

2

I

and

R

ranges

Failure

to

change

from

3rd

to

2nd

when

changing

lever

into

2range

Gear

change

from

2nd to

1st

or

from

2nd

to

3rd

in

2

range

No

shock

at

change

from

I

to

2range

or

engine

races

extremely

Failure

to

change

from

3rd

to

2nd

when

shifting

lever

into

I

range

Engine

brake

does

not

operate

in

1

range

Gear

change

from

1st

to

2nd

or

from

2nd

to

3rd

in

I

range

Does

not

change

from

2nd

to

1st

in

1

range

large

shock

changing

from

2nd

to

st in

range

Transmission

overheats

n

0

f

a

0

g

0

ii

S

oo

f

l

601

2 3

123

I

2

Oil shoots

out

during

operation

White

smoke

emitted

from

3

exhaust

pipe

during

operation

Offensive

smell

at

oil

charging

pipe

AT

58

ON

CAR

E

e

J

E

I

lO

fi

e

52

a

Q

tl

IV

G

1iO

e

tiC

JitSJi

ge

c

g

0

C

E

c

5

2

24

2 3

4

5

7

OFF

CAR

fi

o

9

t

G

E

00

r

S

rl 6

1

2

r

e

0

fi

Q

v

IV

IV c

C

J

t

0

c

IV

eo

8

gag

u

tl

io

o

J

6 5

E2

cEo

CV

ID

I

8E

2

f

0

c

0

C

l

I

0

t

rt

gj

e

II

@I

@

641

I@

@@

5@

3

8 6

@ @

2 4

5

763

@@

@

2

4

531

I@

I

2

@

4

5

67 3

I

@

@I

I

24

3

I

@

I

3

4

I

26 8 7

5

I

@@I@@@I@

I

@

5

6

2

78 4

@@

@@@

@@

2

I@@@

@

@I

@

I@

ON

CAR

OFF CAY

AUTOMATIC TRANSM

15510

N

Trouble

shooting

and

Diagnoses

ROAD

TEST

SYMPTOM

CHART

I

Z

SHIFT

QUALITY

S2

I

t

l

g

l

8

0

t

z

e

I

1

Il

if

x

I

is

g

x

ft

t

0

o

r

0

5

t

Z

u

COMMENTS

PARK

I

ENG

START

II

IIIIII I

L

RANGE

HOWING

IIIIII I

R

Man

shift

P

R

II

I III I I II

RANGE

REVERSE

IIII I

I

Man

shift

R

N

IIIII I I I

II

N

I

ENG

START

II I I III I II

RANGE

IN

II

IIIII I I I

I

Man

shift

N D

II

IIIIIII I

lIst

I

I I

I

IIII

I

Auto

shift

2

I I I I II

I

2nd

IIIIIII

D

I

Auto

shift 2

3

II I I III II

RANGE

I

3rd

III I

I

Decel

3

2

I

I I I

II

I

Kickdown

3

2

j

II I I I

I

Decel

2

1

IIIII

I

Kickdown

2

1

I I IIII

2

I

Man

shift

0

2

I

RANGE

I

2nd

II

I

II I

II

I

Man

shift 2

1

III

I

Man

shift

0

1

II

I

Acceleration

II I

RANGE

I

Engine

II

III

Braking

II

III

i

AT

59

TroublNhoovng

and

Diagnoses

AUTOMATIC

TRANSM

15510

N

TROUBLE

SHOOnNG

GUIDE

FOR

3N71B

AUTOMATIC

TRANSMISSION

Order

Test

item

Checking

Oil

level

gauge

2

Downshift

solenoid

3

Manual

linkage

4

Inhibitor

switch

5

Engine

idling

rpm

6

Vacuum

pressure

of

vacuum

pipe

7

Operation

in

each

range

8

Creep

of

car

Stall

test

I

Oil

pressure

before

testing

2

Stall

test

3

Oilpressure

after

testing

Road

test

1

Slow

acceleration

Ist

2nd

3rd

2

Quick

acceleration

1st

2nd

3rd

3

Kick

down

operation

3rd

2nd

or

2nd

1st

AT

60

Procedure

Check

gauge

for

oil

level

and

leakage

before

and

after

each

test

Check

for

sound

of

operating

solenoid

when

dep

ressing

accelerator

pedal

fully

with

ignition

key

ON

Check

by

shifting

into

P

R D

2

and

I

ranges

with

selector

lever

Check

whether

starter

operates

in

N

and

P

ranges

only

and

whether

reverre

lamp

operates

in

R

range

only

Check

whether

idling

rpm

meet

standard

Check

whether

vacuum

pressure

is

more

than

60

0

kPa

450

mmHg

17 72

inHg

in

idling

and

whether

it

decreases

with

increasing

rpm

Check

whether

transmission

engages

positively

by

shifting

N D

2

N

and

N R

range

while

idling

with

brake

applied

Check

whether there

is

any

creep

in

D

I

and

R

ranges

Measure

line

pressures

in

D

2

I

and

OR

range

while

idling

Measure

engine

rpm

and

line

pressure

in

D

2

and

R

ranges

during

full

throttle

operation

Temperature

of

torque

converter

oil

used

in

test

should

be

from

60

to

l000C

140

to

2120Fl

i

e

sufficiently

warmed

up

but not

overheated

CAUTION

To

cool

oil

between

each

stall

test

for

0

2

T

and

R

ranges

idle

engine

i

e

rpm

at

about

1

200

rpm

for

more

than

1

minute

in

P

range

Measuremenl

time

must

not

be

more

than

5

seconds

Same

as

item

I

Check

car

speeds

and

engine

rpm

in

shifting

up

1st

2nd

range

and 2nd

3rd

range

while

running

with

lever

in

0

range

and

engine

vacuum

pressure

of

about

13

3

kPa

100

mmHg

3

94

inHg

Same

as

item

I

above

except

with

engine

vacuum

pressure

of

o

kPa

0

mmHg

0

inHg

i

ein

position

just

before

kickdown

Check

whether

th

kickdown

operates

and

measure

the

time

delays

while

running

at

30 40 50

60 70

km

h

19

25

31

37

43

MPH

in

Os

range

AUTOMATIC

TRANSMISSION

Trouble shooting

and

Diagnoses

Order

Test

item

4

Shift

down

Ds

02

D1

5

Shift

down

D

12

11

6

Shift

down

0

2

7

Shift

up

11

l

12

8

Shift

up

or

down

when

start

ing

in

2range

9

Parking

Others

Abnormal

shock

oil

leakage

Procedure

Check

car

speeds

and

engine

rpm in

shifting

down

from

3rd

2nd

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

for

shifting

down D

I

and

engine

braking

and

further

for

shifting

down

I I

and

engine

braking

after

shifting

the

lever

into

I

range

with

the

accelerator

pedal

released

and

the

engine

vacuum

pressure

of

0

kPa

0

mmHg

o

inHg

while

driving

at

about

50

km

h

30

MPH

in

D3

range

Check

for

quick

shifting

down

0

2

and

engine

braking

after

shifting

the

lever

into

2range while

driving

at

about

50

km

h

30

MPH

in

0

range

Also

check

for

locking

of

the

transmission

in

2nd

gear

ratio

regardless

of

car

speed

Check

for

failure

of

the

transmission

to

shift

up

during

acceleration

when

starting

in

range

Check

the

transmission

for

not

shifting

up

or

down

during

acceleration

or

deceleration

when

starting

in

2range

Confirm

that

vehicle

will

not

move

on

grade

when

shifting

to

P

range

Enter

into

record

conditions

observed

during

these

tests such

as

gear

noise

abnormal

clutch

noise

and

acceleration

per

formance

AT

51

Service

Datund

Specifications

AUTOMATIC

TRANSMISSION

General

specifications

Automatic

transmission

model

Stall

torque

ratio

l

st

Transmission

I

2nd

gear

fatio

I

Top

I

Reverse

Oil

capacity

SERVICE

DATA

AND

SPECIFICATIONS

3N718

I

Number

of

drive

plates

Number

of

driven

plates

2

0 t

Reo

cl

Clearance

mm

in

2 458

1458

Thickness

of

retain

ing

plate

mm

Un

1

000

Number

of

drive

plates

I

Number

of

driven

plates

I

Clearance

mm

lin

2

182

Automatic transmiuion

fluid

Oexron

type

Low

5 5

liters

15

78

US

qt

478

Imp

qtl

Approximately

2 7

liters

12

7

8

US

qt

2

8

Imp

qt

torque

converter

e

verse

brake

Thickness

of

retaining

plate

Specifications

and

adjustment

Automatic

transmission

assembly

Model

code

number

Torque

converter

assembly

Stamped

mark

on

the

TIC

Number

of

drive

plates

I

Number

of

driven

plates

Clearance

mm

in

Front

clutch

Thickness

of

retaining

plate

AT

62

Brake

band

X2305

Piston

size

Big

dia

mmlin

Small

dia

G

Control

valve

assembly

Stamped

mark

on

strainer

3

Governor

assembly

Stamped

mark

on

governor

body

3

1

6

2

0 0

063

0

0791

Thicknesi

mmOnl

Part

number

10

610

4171

10

8

10

4251

110

10

433

t1

210

44t

11

4

10

449

11

6

10

457

31537

X0100

31537

X0101

3t537

X0102

31537

X0103

31537

X0104

31537

X0105

Stall

revolution

I

Stall

revolution

rpm

5

08

1

6 0

031

0

063

5

8

35

10

32871

5

0

80

1

25

10

0315

0

04921

Thickness

mm

in

7

810

3071

8

0

10

315

8

2

10

323

8AI0 33tl

8 6

10

3391

88

10

346

1

650

1

950

Part

number

31667

X0500

31667

X0501

31667

X0502

31667

X0503

31667

X0504

31667

X0505

64

2

52

40 11

57

LRJ

35

AUTOMATIC

TRANSM

15510

N

Specisl

Service

Tools

Tightening

torque

Unit

N

m

kg

m

ft

Ib

Unit

N

m

kg

m

ft

Ib

Drive

plate

to

137 157

14

0

16

0

101

116

Side

plate

to

control

2 5 3 4

0

25

0

35

1

8

2 5

crankshaft

valve

body

Drive

plate

to

torque

39 49

4

0

5 0

29 36

Nut

for

control

valve

4

9

69 0

50 7 3 6 5

t

converter

reamer

bolt

Converter

housing

to

39

49

40

5

0

29 36

Oil

strainer

to

lower

2

9

3

9

0 3 0 4 2 2 2

9

engine

valve

body

Transmission

case

to

44 54

455 5

33 40 Governor

valve

body

to

49

69

0

5

0

7 3

6

5

1

converter

housing

oil

distributor

Transmission

case

to

20 25

2

0

2 5

14

18

Oil

pump

housing

to

5

9

713

0

6 0 8

4

3 5 8

rear

extension

oil

pump

cover

Oil

pen

to

transmission

49

6

90

5

0

7 3

6

5

1

Inhibitor

switch

to 49

6 9

0

5

0

7 3 6 5

t

ca

transmission

case

Servo

piston

retainer

49

6

9

0 5 0 7 3 6 5

1

Manual

shaft

lock

nut

29 39

3

0 4

0

22 29

to

transmission

case

Oil

cooler

pipe

to

29

49

3

0

5

0

22

36

Piston

stem

when

12 15

1

2

1

5

9

11

transmission

case

adjusting

band

brake

Test

plug

oil

pressure

14 21

14

2

1

10 15

Piston

stem

lock

nut

15 39

1

5 4

0

11

29

nspecticn

hole

Oneway

clutch

inner

t3

18

1

3

1

8

9

13

Support

actuator

race

to

transmission

case

parking

rod

nserting

7

8

10

8

0

8

11

513

8

0

positionl

to

rear

Control

valve

body

to

5 4

74

0

55

0

75

40

5

4

extension

transmission

case

I

Lo

v

lv

body

to

Turn back

two

turns

aftar

tightening

2 5 3

4

0

25

0

35

1

8

2 5

upper

valve

body

SPECIAL

SERVICE TOoLs

Tool number

Kent

Moore

No

Tool

name

ST07870000

ST07860000

125607

Transmission

case

stand

ST25850000

125721

Sliding

hammer

GG91060000

GG930

10000

J25703

Torque

wrench

AT

53

Special

Service

Toofs

AUTOMATIC

TRANSM

15510

N

Tool

number

Kent

Moore

No

Tool

name

ST25420001

ST2542000Q

126063

Clutch

spring

compressor

ST25320001

125710

Snap

ring

remover

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

AT

64

DATSUN

200SX

Model

S

rJ

0

Series

SECTIONP

D

PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

CONTENTS

PROPEUER

SHAFT

Model

3S63A

GENERAL

INSPECTION

PROPELLER

SHAFT

VIBRATION

REMOVAL

AND

INSTALLATION

INSPECTION

PROPELLER

SHAFT RUNOUT

FLANGE

YOKE

AND

SLEEVE

YOKE

JOURNAL

AXIAL

PLAY

REPAIR

CENTER

BEARING

DIFFERENTIAL

CARRIER

Final

drive

Model

H165B

PREPARATION

FOR

DISASSEMBLY

REMOVAL

PRE

DISASSEMBLY

INSPECTION

TOOTH

CONTACT

DISASSEMBLY

DIFFERENTIAL

CARRIER

DIFFERENTIAL

CASE

INSPECTION

PD

2

PD

2

PD

2

PD

3

PD

3

PD

3

PD

3

PD

3

PD

3

PD

3

PD

5

PD

6

PD

6

PD

6

PD

6

PD

7

PD

7

PD

B

PD

9

ASSEMBL

Y

DIFFERENTIAL

CASE

DIFFERENTIAL

CARRIER

ADJUSTMENT

SIDE

BEARING

ADJUSTMENT

PINION

HEIGHT

ADJUSTMENT

FINAL

VERIFICATION

SERVICE

DATA

AND

SPECIFICATIONS

PROPELLER

SHAFT

GENERAL

SPECIFICATIONS

SERVICE

DATA

TIGHTENING

TORQUE

DIFFERENTIAL

CARRIER

GENERAL

SPECIFICATIONS

SERVICE

DATA

TIGHTENING

TORQUE

TROUBLE

DIA

GNOSES

AND

CORRECTIONS

PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

SPECIAL

SERVICE

TOOLS

PD

9

PD

9

PD

l0

PD

11

PD

l1

PD

13

PD

15

PD

16

PD

16

PD

16

PD

16

PD

16

PD

16

PD

16

1ft

PD

16

PD

17

PD

17

PD

17

PD

1B

PD

19

1

PropellerSheft

Model

3S63A

PROPELLER

SHAFT

8

DIFFERENTIAL

CARRIER

PROPELLER

SHAFT

Model

3S63A

Companion

flange

Washer

Apply

a

coat

of

muIti

PUIJlOse

lithium

grease

containing molybdenum

disulfide

to

the

end

face

of

the

center

bearing

and

both

sides

of

the

washer

Locking

nut

Flange

nut

type

b245

294

U

25 30

181

217

Nut

and

washer

type

if

196

235

20

24

VI

145 174

Center

bearing

Install

center

bearing

with

F

ffiuk

toward

front

of

car

V

if

32

2

4

3 3

17

24

Propeller

lhaft

1st

tube

fJ

N

m

kg

m

ft

tb

GENERAL

INSPECTION

Inspect propeller

shaft

tube

surface

for

dents

or

cracks

If

damaged

replace

propeller

shaft

assembly

If

center

bearing

is

noisy

or

damaged

replace

center

bearing

If

journal

is

damaged

or

worn

re

place

propeller

shaft

assembly

PD

2

PROPELLER

SHAFT

VIBRATION

To

check and

correct

an

unbalanced

propeller

shaft

proceed

as

follows

I

Remove

undercoating

and

other

foreign

material

which

could

upset

shaft

balance

and

check

shaft vibra

tion

by

road

tesi

2

If

shaft

vibration

is

noted

during

road

test

disconnect

propeUer

shaft

at

differential

carrier

companion

flange

rotate

companion

flange

180

degrlies

and

reconnect

propeller

shaft

Propeller

shaft

2nd

tube

ill

fJ

24

32

24

33

17

24

Center

bearing

support

S

PD11

3

Again

check

shaft

vibration

If

VIbration

still

persists

replace

propel

ler

shaft

assembly

PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

PropellerShaft

Mode

3S63A

REMOVAL

AND

INSTALLATION

I

Put

match

marks

on

l1anges

and

separate propeller

shaft

from

differen

tial

carrier

2

Remove

center

bearing

bracket

I

@

1

ro

S

KO

c

I

J

3

Draw

out

propeller

shaft

from

transmission

and

plug

up

rear

end

of

transmission

rear

extension

housing

o

t

Plug

SPD105

4

To

install

reverse

the

foregoing

procedure

using

reference

marks

in

removal

Install

the center

bearing

on

the

bracket

with

the

contact

surface

of

the

cushion

facing

upward

Connecting

portion

Cushion

c c

r

SPD124

INSPECTION

PROPELLER

SHAn

RUNOUT

Inspect

propeller

shaft

runout

If

ronout

exceeds

specifications

replace

propeller

shaft

assembly

Runout

limit

0 6

mm

0 024

in

itM

SPD106

FLANGE

YOKE

AND

SLEEVE

YOKE

If

l1ange

yoke

and

sleeve

yoke

are

damaged

or

worn

replace

propeller

shaft

assembly

SP0107

JOURNAL

AXIAL

PLAY

Inspect

journal

for

axial

play

if

there

is play

replace

propeller

shaft

assembly

SPD10B

REPAIR

CENTER

BEARING

I

Put

match

marks

on

l1anges

and

separate

2nd

tube

from

1st

tube

SPD109

2Put

match

marks

on

the

l1ange

and

shaft

m

Q

aU

SPD110

3

Remove

locking

nut

with

Tool

PD

3

PropellerShsft

Model

3S63A

PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

4

Remove

companion

l1ange

with

puller

L

5

Remove

center

bearing

with

Tool

and

press

1

iLsP0113

Care

should

be

token when

setting

Tool

in

press

to

make

sure

that

parting

line

of

Tool

is

right

angle

to

support

fixture

of

press

This

is

to

prevent

Tool

from

bending

O K

liC

Ji

N

G

f

Support

fIxture

PD

4

6

Install

new

center

bearing

Be

sure

to

install

center

bearing

with

OF

mark

toward

front

of

car

Apply

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

7

Insert

the

washer

into

the

end

of

the

center

bearing

Align

the mark

on

the

companion

flange

and

install

the

companion

flange

9

center

bearing

Washer

Companion

flange

Locking

nut

I

SPD115

8

Tighten locking

nut

using

Tool

SP0116

C

l

Cent

r

baring

locking

nut

Flange

nut

type

245

294

N

m

25 30

ka

m

181

217

It

lb

Ntit

and

wash

type

196 235

N

m

20 24

ka

m

145

1741t

bl

@

SPD125

9

Stake

the

nut

10

Align

the

mark

and

connect

1st

and

2nd

tubes

Olftere1

tial

case

CD

Villion

ne

llht

e

Iff

ad

UStinS

s

t

et

W

Detetn

inln

b

thick

nesS

Drive

p

wot

ca

inII

I

nllS

er

Rlfl

Ollt

outer

race

Dti

e

inl

t

n

6

ft

J

ir

ill

II

set

l

YI

Bac

K

tn

13

0

18

col1

p

ble

o

005

I

0

00111

S

Jacet

p

waYt

te1

ace

S

de

inll

diP

Lock

tu

MY

a

te

p

ace

J@111911

8

10

511

11

@

49

59

5

6

36

43

L

ftna1

dl

Ie

assern

ty

DJ

taCe

Outct

Side

a

i1

l

adiustifl

sbin

l

oetetrninitW

side

oeatIDS

tnict

t

es

Gas

et

tt

l

HaYt

replace

Ditfelent

cattiet

front

oil

a

A

aY

replace

Corovaniot

ll1

l

y

nWP

mate

hatt

34

15

@

15

35

18

1

5

u

to

1

11

in

on

P

10

O

10

vep

1

43

iI

ON

HI

u

un

I

13

19

1

00

l

of

0

btained

@

1

plte

P

ue

valuen

11

0

ad

to

1

81

10

6

g

Ct

l1

t

M

J

o

I

l

o

J

n

1

l

0

t1

0

Jl

l

t

m

i

J

tJ

n

S

0

a

i

Q

c0

n

oJ

i

0

t

u

st

O

S

Differential

Carrier

Final drive

Model

H165B

PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

PREPARATION

FOR

DISASSEMBLY

REMOVAL

I

Jack

up

rear

of

car

and

support

it

by

placing

safety

stands

under

rear

axle

case

referring

to

section

GI

2

Remove

drain

plug

and

drain

gear

oil

SPD121

3

Remove

propeller

shaft

and

rear

axle

shafts

Refer

to

Section

RA

for

removal

and

plug

up

rear

end

of

tran

mission

rear

extension

housing

SP0105

4

Loosen

bolts

securing

differential

carrier

to

rear

axle

case

and

take

out

differential

carrier

5

Mount

differential

C3rrieron

Tool

PD

6

PRE

DISASSEMBLY

INSPECTION

I

Check

backlash

of

ring

gear

with

a

dial

indicator

at

several

points

If

it

is

not

within

specification

adjust

it

re

ferring

to

SIDE

BEARING

ADJUST

MENT

Backlash

0

13

0

18

mm

10

0051

0

0071

inl

SP

0002

2

Check

runout

of

ring

gear

with

a

dial

indicator

If

it

is

over

specifica

tion

hypoid

gear

set

or

differential

case

should

be

replaced

When

backlash

varies

excessively

in

different

places

the

variance may

have

resulted

from

foreign

matter

caught

between

ring

gear

and

differential

case

I

Runout

limit

0

04

mm

10

0016

in

SPD003

3

Check

tooth

contact

referring

to

TOOTH

CONTACT

4

Check

backlash

of

side

gear

Using

a

thickness

gauge

measure

clearance

between

side

gear

and

differential

case

If

it

is

not

within

specification

adjust

it

by

selecting

side

gear

thrust

washer

Refer

to

S

O

s

Cleal

llnce

0

10

0

20

mm

10

llO39

0

0078

inl

SPD004

TOOTH

CONTACT

Gear

tooth

contact

pattern

check

is

necessary

to

verify

correct

relationship

between

ring

gear

and

drive

pinion

Hypoid

gear

set

which

are

not

posi

tioned

properly

may

be

noisy

or

have

short

life

or

both

With

a

pattern

check

the

most

desirable

contact

for

low

noise

level

and

long

life

can

be

as

sured

Check

I

Thoroughly

clean

ring

gear

and

drive

pinion

teeth

2

Sparingly

apply

a

mixture

of

powdered

ferric

oxide

and

oil

or

equiv

alent

to

3

or

4

teeth

of

ring

gear

drive

side

SPOOD5

3

Hold

companion

flange

steady

by

hand

and

rotate

the

ring

gear

in

both

directions

SPoooa

PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

Oifferent

sl

Carrier

Finsl

drivel

Model

H1658

Adjustment

H

I

contact

F

ce

contact

Toe

contaCt

Flank

cont8ct

To

correct

increase

thickness

of

pinion

height

adjusting

washer

in

order

to

bring

drive

pinion

close

to

ring

gear

To

correct

reduce

thickness

of

pinion

height

adjusting

washer

in

order

to

make

drive

pinion

go

away

from

ring

gear

c

DISASSEMBLY

DIFFERENTIAL

CARRIER

1

Put

match

mark

on

one

side

of

side

bearing

cap

with

paint

or

punch

to

ensure

that

it

is

replaced

in

proper

position

during

reassembly

Bearing

caps

are

line

bored

during

manufacture

and

should

be

put back

in

their

original

place

1

08

Correct

tooth

conae1

2

Remove

side

bearing

caps

SP

0009

1

W

3

Using

apry

bar

remove

differen

tialcase

assembly

Be

careful

to

keep

the

side

bearing

outer

races

together

with

inner

race

don

mix

them

up

V

SPD007

SP0011

PD

7

Differential

Carrier

Final

drive

Model

H165B

PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

4

Remove

drive

pinion

nut

with

TooL

SPD012

5

Remove

companion

l1ange

with

puller

SPD014

1

ij

6

Remove

drive

pinion

with

soft

hammer

Soft

hammer

Remove

oil

seal

by

prying

up

with

a

large

screwdriver

and

remove

front

pinion

bearing

inner

race

Do

this

carefully

so

as

not

to

scratch

seal

bore

with

screwdriver

Cover

end

of

screwdriver

with

a

rag

PD

8

1

S

SPOOl

8

Remove

pmlOn

bearing

outer

race

using

a

brass

drift

SPD017

9

Remove

collapsible

spacer

from

drive

pinion

10

Pull

out

rear

bearing

inner

race

with

a

press

and

Tool

Care

should

be

taken

when

setting

Tool

in

press

to

maka

sura

that

parting

line

of

Tool

is

a

right

angle

to

support

fixture

of

press

This

is

to

prevent

bonding

Tool

SP0018

O K N

G

lie

Support

fIXture

DIFFERENnAL

CASE

I

Remove

side

bearing

inner

race

with

TooL

To

prevent

damage

to

bearing

engage

puller

paws

with

groa

Be

careful

not to

confuse

left

and right

hand parts

ST3305100l

SP0020

ST3305200Q

SPD021

SPD022

2

Remove

ring

gear

by

spreading

out

lock

straps

and

loosening

ring

gear

bolts

in

a

criss

cross

fashion

SPD023

PROPELLER

SHAFT DIFFERENTIAL

CARRIER

Differential

Carrier

Final

drive

Model

H1658

3

Tap ring

gear

off

gear

case

using

a

soft

hammer

Tap

evenly

all

around

to

keep

ring

gear

from

binding

SPD024

4

Drive

out

pinion

mate

shaft

lock

with

Tool

from

ring

gear

side

5

Draw

out

pinion

mate

shaft

and

rota e

pinion

mate

gears

out

of

the

case

and

remove

side

gears

and

thrust

washers

SPD122

Put

marks

on

gears

and

thrust

washer

so

that

they

can

be

reinstalled

in

their

original

positions

from

which

they

were

removed

@

e

@@

@4S

@

SPD026

INSP

CTION

I

Clean

disassembled

parts

com

pletely

Repair

or

replace

any

damaged

or

faulty

parts

When

replacing

drive

pinion

or

ring

gear

replace

with

8

new

hypoid

gear

set

O

II

SP0027

2

The

following

parts

should

be

replaced

by

new

ones

each

time

they

are

removed

CD

Gasket

@Frontoilseal

ID

Collapsible

spacer

@

Lock

strap

@

SP0028

ASSEMBLY

Assembly

should

be

done

in

the

reverse

order

of

disassembly

while

making

any

necessary

inspections

and

adjust

1ents

PRECAUTION

a

Arrange

shims

and

washers

to

in

stall

them

correctly

b

Thoroughly

clean

the

surfaces

on

which

shims

washers

bearings

and

bearing

caps

are

installed

c

Apply

gear

oil

when

installing

bearings

d

Pack

recommended

multi

purpose

grease

inlo

cavity

between

lips

when

fitting

oil

seal

DIFFERENTIAL

CASE

I

Install

pinion

mate

gears

side

gears

and

thrust

washers

into

differen

tia

case

2

Fit

pinion

mate

shaft

3Adjust

clearance

between

rear

face

of

side

gear

and

thrust

washer

by

selecting

side

gear

thrust

washer

Refer

to

S

D

S

Feeler

t

5

B

c

Clurance

0

10

O

20mm

0

0039

0

0079

in

5P0029

4

Insta

l

pinion

mate

shaft

lock

using

a

punch

Make

sure

lock

is

flush

with

case

5P0030

PD

9

Differential

Carrier

fFinaldrive

Model H

65B

PROPEbLER

SHAFT

DIFFERENTIAL

CARRIER

5

Place

ring

gear

on

differential

case

and

install

new

lock

straps

and

bolts

Tighten

bolu

in a

crisl

cross

fa

shion

lightly

tapping

bolt

head

with

a

hammer

Then

bend

up

lock

straps

to

lock

the bolts

in

place

Iii

7S

gSN

m

L

IS

O

10

0

kG

58 72

ft

bl

A

6

Select

side

bearing

adjusting

shims

referring

to

SIDE

BEARING

ADJUSTMENT

7

Install

the

shims

behind

each

bear

ing

and

press

on

the

bearings

using

Tool

SPD033

ST33052000

SPD034

PD

IO

DIFFERENTIAL

CARRiER

I

Press

fit

front

and

rear

bearing

outer

races

using

Tools

SP

0035

1

2

Select

pmlOn

height adjusting

washer

referring

to

PINION

HEIGHT

ADJUSTMENT

3

Install

pinion

height

adjusting

washer

in

drive

pinion

bevel

side

toward

gear

and

press

fit

rear

bearing

inner

race

in

it

using

press

and

Tool

4

Lubricate

front

bearing

with

gear

oil

and

place

it

in

gear

carrier

SPD045

5

Using Tool

carefully

fit

a

new

oil

seal

into

carrier

Make

lure

oil

seal

is

flush

with

end

of

carrier

and

apply

multi

purpose

grease

into

cavity

d

lips

l

SPDQ37

ST33400001

i

I

6

Place

a

new

collapsible

spacer

on

drive

pinion

and

lubricate

rear

bearing

with

gear

oil

and

insert

it

in

gear

carrier

SP003S

7

Install

companion

l1ange

and

hold

it

firmly

Insert

drive

pinion

into

companion

flange

by

tapping

its

head

with

a

soft

hammer

PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

Differential

Carrier

Final

drive

Model

H165B

8

Hold

companion

l1ange

with

Tool

and

temporarily

tighten

pinion

nut

until

there

is

no

axial

play

Ascertain

that

threaded

portion

of

drive

pinion

and

pinion

nut

are

free

from

oil

or

grease

SP

0040

9

Tighten

pinion

nut

by

degrees

to

the

specified

preload

while

checking

the

preload

with

Tools

When

checking

preload

turn

drive

pinion

in

both

directions

several

times

set

bearing

rollers

l

Preload

II

with

oilMan

0

7

1

0

Nom

7

10

kliJ

cm

6

1

8

7in

lb

J

Drive

pinion

nut

137 294

N

m

14 30

kg

m

101

217

ft

Ib

CAUTION

The

preload

is

achieved

by

using

the

permanent

set

of

collapsible

spacer

So

here

if

an

over

preload

results

from

excessive

turning

of the

pinion

nut

the

spacer

should

be

replaced

by

new

one

10 Install

differential

case

assembly

and

side

bearing

miter

races

into

dif

ferential

carrier

and

install

side

bear

ing

cap

Tap

on

the

cap

with

8

soft

ham

mer

to

settle

it

in the

carrier

The

bearing

cap

should

be

installed

with

the

marks

put

8t

disassembly

aligned

IiJ

49 59

N

m

5

0

6 0

kg

m

36

431t

IOI

If

SPD044

ADJUSTMENT

SIDE

BEARING

ADJUSTMENT

Side

bearing

SPD046

Side

bearing

adjulting

shim

When

the

differential

case

side

bearing

or

gear

carrier

is

replaced

or

when

the

ring

gear

backlash

or

side

bearing

preload

is

out

of

specifica

tions

side

bearing

shims

of

proper

thickness

should

be

installed

Required

Tools

D

Weight

Block

ST32501

000

@Master

Gauge

ST33741000

@

Base

Plate

@

Dial

Indicator

@

j@R

tl

I

D

0f

@

SPD048

I

Thickness

of

shim

can

be

calcu

lated

by

following

equation

Left

side

T

A

C

O

H

I

x

0 01 0

20

EI

Right

side

T

2

8 0

H

I

x

0

01 0

09

F

I

L

CAUTION

To avoid

any

confusion

while

calcula

ting

it

is absolutely

necessary

to

stay

with

metric

system

If

you

measure

anything

in inches

the

results should

be

converted

into

the

metric

system

PO

tt

Differential

CarrierfFinal

drivel

Model

H7658

PROPEllER

SHAFT

DIFFERENTIAL

CARRIER

Where

T

Left

side

T2

Right

side

A

B

c

D

2

Measure

values

E

and

F

I

Attach

a

dial

indicator

to

the

base

plate

2

Place

the

outer

race

of

the op

posite

side

bearing

to

be

measured

3

Place

a

weight

block

on

that

outer

race

and

a

master

gauge

on

that

biock

Then

adjust

the

dial

indicator

scale

to

zero

with

its

tip

on

the

master

gauge

ST3

501000

SP0Q49

Oppo

ite

side

outer

race

4

Remove

the

master

gauge

and

weigh

t

block

Place

the

bearing

outer

PD

12

o

H

oo

0

U

o

G

o

l

E

mm

Left

Side

Bearing

Stamped

on

differential

carrier

F

mm

Right

Side

Bearing

Stamped

on

differential

cue

Differences

between

width

of

left

E

or

right

F

side

bearing

and

standard

width

A

B

C

D

and

H

are

dimensional

variations

in

a

unit

ofl

100

mm

against

each

standard

value

race

and

inner

race

to

be

measured

on

the

opposi

e

side

outer

race

and

place

the

weight

block

on

that

bearing

assembly

If

the

bearing

embly

i

placed

on

the

base

plate

the

bearing

width

cannot

be

accurately

determined

due

to

its

cage

being

in

contact

with

the

base

plate

Measured

outer

race

5

Turn

the

bearing

several

limes

to

settle

it

and

then

read

the

indica

tion

of

the

dial

indicator

SPD126

The

indication

should

be

Ear

F

Left

ide

bearing

E

Right

ide

bearing

F

speOS1

3

Substitute

these

values

into

the

equation

to

calculate

the

thickness

of

the

shim

If

value

ignifying

A

BC

0

and

H

are

not

given

regard

them

as

zero

and

calculate

After

as

embly

check

to

ee that

preload

end

backla

h

ere

pecifica

tion

If

not

readjust

PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

Differential

Carrier

Final

drive

Model

H165B

Example

A

I

B

2

C

2

D

3

H

2

E Ol1

F

0

20

Left

side

T

A

C

0

H

xO

OI

0

20

E

1

2 3 2

xO

OI

0

20 0

11

I

A

C

I

2

I

3

2

4

0

H

2 4

x

0 01

0

04

3

0

04

0

20

0

24

4

0

24

0

11

035

E

T

035mm

4

Select

the

proper

shims

Refer

to

S

O

S

If you

cannot

find

the

desired

thickness

of

shims

use

shims

so

that

the

total

thickness

is

the

closest

to

the

calculated

value

Example

Left

side

Calculated

value

T

0

35

mm

Used

shims

Thickness

Quantity

0

20

x

I

0

20

0

10

x

I

0

10

0

05

xI

0

05

Total

thickness

0

35

mm

Right side

T2

B

D H

xO

01

0

09

F

2

3

2

xO

OI

0

09

0

20

I

B

2

D

3

I

H

2

3

2

3

x

001

0

03

3 0

03

0

09

0

06

4

0

06

0

20

0

26

F

T

0

26mm

Right side

Calculated

value

T

2

0

26

mm

Used

shims

Thickness

0

07

x

0

05 x

Quantity

3 0

21

I

0

05

Total

thickness

0

26

mm

PINION

HEIGHT

ADJUSTMENT

I

l

Hiit

SP0056

When

replacing

the

hypoid

gear

set

drive

pinion

bearing

or

gear

carrier

be

sure

to

adjust

the

pinion

height

Adjustment

of

the

pinion

height

can

be made

by

adjusting

the

washer

to

be

installed

between the

rear

bearing

inner

rice

and

the

drive

pinion

head

Pinion

height adjusting

washer

SPD051

Required

Tools

j

Height

Gauge

ST31141

000

CV

Dummy

Shaft

ST31942000

ID

Feeler

Gauge

CV

j

L

r

SPD058

PD

13

Oifferential

Csrrier

Final

drive

Model H165B

PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

I

Thickness

of

washer

can

be

cal

culated

by

following

equation

r

T

N H

0

Sl

x

0

011

I

2

98

I

Where

T

mm

N

mm

H

2

Assemble

Dummy

shaft

on

rear

bearing

inner

race

and

fit

it into

carrier

3

Attach

Height

Gauge

to

carrier

Using

a

feeler

gauge

measure

the

clearance

between

the

height

gauge

tip

and

the

dummy

shaft

face

PO

14

CAUTION

To avoid

any

confusion

while

calculat

ing

it

is

necessary

to

stay

with

the

metric

system

If

you

measure

any

thing

in

inches

the

result

should

be

converted

to

the

metric

system

@

D

s

n

3

H

D

and

S

are

dimensional

variations

in

a

unit

of

1

100

mm

against

each

standard

value

ST31141000

SPD061

SP

0127

4

Substitute

these

values

into

the

equation

to

calculate

the

thickness

of

the

washer

If

value

Sigilifying

H

0

andS

are

not

given

regard

them

8S

zero

and

calculate

After

essembly

check

to

see

that

tooth

contact

is

correct

If

not

readjust

PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

Differential

Carrier

Final

drive

Model

H1658

Example

N

0

35

H

4

D

3

S O

T

N H

0

S

x

0

01

2

98

0

35

4

3

0

x

0

01

2

98

I

H

0

4

3

I

0

I

S

2

I

x

0

01

00

3

N

0

35

0

01

0

36

4

0

36

2

98

3

34

T

3

34

5

Select

the

proper

washer

Refer

to

S

O

S

If

you

cannot

find

the

desired

thickness

of

washer

use

washer

SO

that

thickness

is

the

closest

to

the

calcu

late

value

Example

Calculated

value

T

3

34

mm

Used

washer

T 3

33

mm

FINAL

VERIFICATION

Check

backlash

of

ring

gear

with

a

dial

indicator

If

backlash

is

too

small

decrease

thickness

of

left

shim

and

increase

thickness

of

right

shim

by

the

same

amount

If

backlash

is

too

great

reverse

the

above

procedure

Never

add

or

remove

from

the

total

amount

of

shims

or

bearing preload

will

be

changed

SPD066

2

Check

side

bearing preload

Hook

the

tip

of

a

spring

balancer

on

a

ring

gear

bolt

Check

the

preload

by

mea

uring

the

rotating

resistance

in

a

backlash

Preload

At

ring

gear

bold

14

7

26

5

N

11

5 2

7

kg

33 6

01bl

SPD067

If

prelOad

i

too

great

remove

the

same

amount

of

shims to

each

side

If

preload

i

too

mall

add

the

same

amount

of

shims

to

each

side

Never

add

or

remove

different

amount

of

shims

to

each

side

or

ring

gear

beckla

h

will

be

changed

5P0031

3

Check

runout

of

ring

gear

with

a

dial

indicator

SP

0003

If

backlash

varies

excessively

in

dif

ferent

places

the

variance may

have

resulted

from

foreign

matter

caught

between

the

ring

gear

and

the

differ

entia

case

If

the

backla

h

varies

greatly

when

the

runout

of

the

ring

gear

is

within

a

pecified

range

the

hypoid

gear set

or

differential

case

should

be

replaced

4

Finally

check

for

tooth

contact

pattern

Refer

to

TOOTH

CONTACT

U

ually

the

pettern will

be

correct

if

you

have

calculated

the hims

correctly

and

the

backla

h

i

correct

However

in

extremely

rare

cales

you

will

have

to

use

trial

nd

error

proce

until

you

get

a

good

tooth

contact

pattern

The

tooth

pattem

i

the

best

indieation

of

how

well a

differential

ha

been

et

up

PO

15

ServiceDataandSpecifications

PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

SPDOOS

5

Install

the

differential

carrier

in

the

car

Gasket

should

be

replaced

by

new

one

each

time

the

differential

carrier

is

removed

Then

fill

with

gear

oil

referring

to

Recommended

Lubricants

Section

MA

fl

Differential

carrier

fixing

bolt

25

34

N

m

2 5 3 5

kg

m

18

25

ft

Ibl

Drain

and

filler

plugs

59 98

N

m

6 10

kg

m

43 72

ft

b

Gear

oil

capacity

1 1 I

ita

rs

2

318

US

pt

2

Imp

ptl

SPD123

ngrdler

Oil

level

SERVICE

DATA

AND

SPECIFICATIONS

PROPELLER

SHAn

GENERAL

SPECIFlc

ATIONS

Model

Number

of

joints

Coupling

method

with

transmiSsion

Distance

yokes

Type

of

journal

bearing

Shaft

lenQth

Spider

to

spider

1st

2nd

tst

Shaft

outer

diameter

2nd

SERVICE

DATA

I

Propeller

shaft

runout

limit

TIGHTENING

TORQUE

Unit

I

Flange

yoke

to

com

pani

on

flange

N

m

24 32

Center

b

earing

locking

nut

Flange

nut

tvpct

245

294

Nut

ridwashertvpe

196

235

20 24

I

Center

bearing

support

to

bracket

88

80 9

1

2

I

Center

bearing

bracket

I

to

body

25 39

2

6

4

0

PD

16

Unit

mm

in

3S63A

3

Sleeve

type

63

2

481

Shell

type

Non

Disassemblv

type

3201

2

601

730

28

741

75

0

2

9531

50B

2

0001

Unit

mm

in

06 0

0241

kg

m

fHb

24

3 3

17

24

25 30

8

217

45

74

6

5

8

7

9

29

DIFFERENTIAL

CARRIER

GENERAL

SPECIFICATIONS

I

Model

I

TVpe

I

Ring

gear

pitch

dianleter

mm

Unl

I

Gear

ratio

I

Number

of

teeth

Ring

gear

drive

pinion

I

Oil

cepacity

2

US pt

Imp

pt

SERVICE

DATA

Drive

pinion

bearing

adjusting

mathod

Drive

pinion

preload

with

front

oil

seal

N

m

kg

cm

in

lb

I

Side

bearing

adjusting

method

Drive

pinion

to

ring

gear

mm

jn

Backlash

Side gear

to

pinion

mate

gear

Clearance

side

gear

to

differential

case

mm

in

Ring

gear

nmout

limit

mm

in

H1658

Rigid

axle

suspension

Banjo

typo

t65

6

50

3

700

3710

11

23

8

21

Collapsible

spacer

0

7

0

7

10

6

t

8

71

Shim

0

3 0

8

0

005

0

00711

000

20

10

0039

0

00791

0

04

0

00

61

Side

bearing preload

at

ring

gear

bolt

14

7

26

5

N

kG

lbl

1

5

2

7 3 3 6

01

Side

bearln

adjustin

shim

Thickness

mm

inl

0

05

0

00201

0 07 0

00281

0 0

10

00391

0

20

0

00791

0

50

10

0

971

Part

No

38453 28500

38454

28500

38455

28500

38456 28500

38457 28500

PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

Trouble

Diagnosesand

Corrections

Pinion

height

adjusting

washer

Side

gear

thrust

washer

Thickness

mm

in

Part

No Thickness

mm in

Part

No

3

09

10

12171

38154

U

1500

0

785

10

0309

38424

04101

3

12

10

12281

38154

UI501

0

835

10

03291

8424

08000

3

15

0

12401

38154

Ut502

0

885 10

0348

38424

08001

3

181O

t252

38154

U

1503

1

035

10

04071

38424

08002

3

21

10

12641

38154

U

1504

3

2410

12761

38154

U

1505

1

185

10

04671

38424

08003

3

27

0

12871

38154

U

1506

3

30

0

1299

38154

U1507

TIGHTENING

TORQUE

3

33

10

13111

38

154

l

1508

Unit

N

m

kg

m

ft

Ib

3

36

10

13231

38154

U1509

3

39

0

1335

38154UI510

I

Drive

pinion

nut

137

294

14

30

101

217

3

42

10

1346

38154

U1511

I

Ring

ge

r

bolt

78

98

8

10 58 72

3

4510

13581

38154

Ut612

3

48

10

1370

38154

U1513

I

Side

beari

ng

cap

bolt

49

59

5

6

36 43

3

51

0

13821

38154

U1514

I

Drain

and

filler

plugs

59 1098

6

43 72

3

54

10

t394

38154

U1515

3

57

10

14061

38154

UI516

I

Companion

flange

to

24 32

2

4

33

17

24

3

6010

14171

38154

UI517

propeller

5h8ft

3

63

10

14291

38154

UI518

I

Difforential

co

io

to

3

66

10

14411

38154

U1519

rear

axle

case

25 34

2

5

3 5

18 25

TROUBLE

DIAGNOSES

AND

CORRECTIONS

PROPELLER SHAFT

Condition

Vibration

during

at

medium

or

high

speed

Knocking

sound

during

starting

or

noise

during

coasting

on

propeller

shaft

Scraping

noise

Whine

or

whistle

Probable

cause

Worn

or

damaged journal

beari

n

Unbalance

due

to

bent

or

dented

propeller

shaft

Loose

propeller

shaft

installation

Worn

transmission

rear

extension

bushing

Damaged

center

bearing

U

dercoatiI

g

or

mud

on

he

shaft

ausing

unbalance

Balance

weights ntissing

Worn

or

damaged

journal

Worn

sleeve

yoke

and

mainshaft

spline

Loose

propeller

shaft

installation

Loose

joint

installation

Damaged

center

bearing

or

insulator

Loose

or

ntissing

bolts

at

center

bearing

brac

t

10

body

Dust

cover

on

sleeve

yoke

rubbing

on

transmission

rear

extension

Damaged

center

bearing

Corrective

action

Repla

prol

eller

shaft

assembly

Replace

propeller

shaft

assembly

Retighten

Replac

e

Repl

ace

Clean

up

shaft

j

Replace

propeller

shaft

assembly

Replace

propeller

shaft

assembly

Replace

propeller

shaft

assembly

Retighten

Replace

propellei

shaft

assembly

Repla

center

bear

g

Replace

or

tighten

bolts

Straighten

out

dust

cover

to

remove

inter

ference

Replace

center

bearing

1

0

17

Trouble

Diagnoses

and

Corrections

PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

DIFFERENTIAL

CARRIER

When

a

differential

carrier

is

sus

pected

of

being

noisy

it

is

advisable

to

make

a

thorough

test

to

detennine

whether

the

noise

originates

in

the

Condition

tites

road

surface

exhaust

universal

joint

propeller

shaft

wheel

bearings

engine

transmission

or

differential

carrier

Noise

which

originates

in

other

Noise

on

drive

coast

and

l1oat

Noise

on

turn

Knocking

sound

during

starting

or

gear

shifting

Seizure

or

breakage

Oil

leakage

PD

18

Probable

cause

Shortage

of

oil

Incorrect

tooth

contact

between

ring

gear

and

drive

pinion

Incorrect

backlash

between

ring gear

and

drive

pinion

Seized

up

or

damaged

ring

gear

and

drive

pinion

Seized

up

damaged

or

broken

drive

pinion

bearing

Seized

up

damaged

or

broken

side

bearing

Loose

clamp

bolts

or

nuts

holding

ring

gear

bearing

cap

etc

Seized

up

damaged

or

broken

side

gear

and

pinion

mate

gear

Seized

up

damaged

or

broken

side

gear

and

pinion

mate

gear

thrust

washers

Pinion

mate

gears

too

tight

on

their

shaft

Excessive

backlash

Incorrect

backlash

ring

gear

to

drive

pinion

or

side

gear

to

pinion

mate

gear

Worn

gears

or

case

Worn

rear

axle

shaft

and

side

gear

spline

Pinion

bearing

under

preload

Loose

drive

pinion

miL

Loose

boltS

and

nuts

such

as

ring

gear

bolts

Shortage

of

oil

or

use

of

unsuitable

oil

Excessively

small

backlash

Incorrect

adjustment

of

bearings

or

geats

Severe

ser

vice

due

to

an

excessive

loading

improper

use

of

clutch

Loose

bolts

and

nuts

such

as

ring gear

bolts

Worn

out

damaged

or

improperly

driven

front

oil

seal

or

bruised

dented

or

abnor

mally

worn

slide

face

of

companion

l1ange

Damaged

gasket

Loose

filler

or

drain

plug

Clogged

or

damaged

breather

places

cannot

be

corrected

by

adjust

ment

or

replacement

of

parts

in

dif

ferential

carrier

Corrective

action

Supply

gear

oil

Rebuild

gear

carrier

if

necessary

Adjust

tooth

contact

or

replace

the

hypoid

gear

set

Adjust

backlash

or

replace

the

hypoid

gear

set

if

necessary

Replace

the

hypoid

gear

set

Replace

the

pinion

bearing

and

faulty

parts

Replace

the

side

bearing

and

faulty

parts

Clamp

them

to

specified

torque

and

replal

faulty

parts

Replace

faulty

parts

Replace

faulty

parts

Replace

faulty

parts

Adjust

backlash

Replace

worn

parts

Replace

worn

parts

Adjust

preload

Replace

or

tighten

bolt

ReplaCe

faulty

parts

or

lighten

bolts

Replace

faulty

parts

and

use

recommended

gear

oil

Adjust

backlash

and

replace

as

required

Replace

faulty

parts

Replace

faulty

parts

Replace

faulty

parts

or

tighten

bolts

Replace

damaged

oil

seal

Repair

l1ange

with

sandpaper

or

replace

if

necessary

Replace

Tighten

Repair

or

replace

Tool

number

Kent

Moore

No

ST050

I

SOOO

126023

CD

ST05011

000

126023

2

@ST05012000

126023

1

ST0636000l

ST3003S000

125733

CD

ST30031

000

125733

1

@ST30032000

125733

2

ST30611000

125742

1

ST30613000

1257423

ST30701000

125742

2

ST3114S000

See

125269

01

CD

ST31141000

@ST31942000

PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

Special

Service

Tools

SPECIAL

SERVICE

TOOLS

Tool

name

Engine

stand

Engine

stand

Base

Diff

attachment

Drive

pinion

feaf

bearing

inner

race

puller

set

Puller

Base

Drive

pinion

bearing

outer

race

drift

bar

Drive

pinion

rear

bearing

outer

race

drift

Drive

pinion

front

bearing

Quter

race

drift

6

Drive

pinion

setting

gauge

set

Height

gauge

Dummy

shaft

PD

19

Special

Service

Tools

PROPELLER

SHAFT

DIFFERENTIAL

CARRIER

Tool

number

Kent

Moore

No

Tool

name

ST3127S000

See

125765

CD

GG91030000

CV

lIT62900000

@

lIT62940000

Preload

gauge

Torque

wrench

Socket

adapter

1

2

1

Socket

adapter

3

8

t

o

e

ST31530000

Drive

pinion

l1ange

wrench

125774

ST32501000

Weight

block

125407

3

ST33051001

Diff

side

bearing

puller

ST33052000

Adapter

125797

1

5J

ST33400001

Oil

seal

fitting

tool

126082

ST33741000

Master

gauge

See

125407

1

18

5

mm

0

728

in

8

KY311

00300

Solid

punch

KY38102100

125803

Diff

side

bearing

drift

PD

20

DATSUN

200SX

Model

S

110 Series

SECTION

FA

FRONT

AXLE

FRONT

SUSPENSION

CONTENTS

FRONT

AXLE

AND

FRONT

USPENSION

FRONT

AXLE

FRONT

SUSPENSION

SPRING

AND

STRUT

ASSEMBLY

TENSION

ROD

AND

STABILIZER

BAR

TRANSVERSE

LINK

AND

LOWER

BALL

JOINT

SUSPENSION

CROSSMEMBER

FA

2

FA

3

FA

5

FA

5

FA

9

SERVICE

DATA

AND

SPECIFICATIONS

GENERAL

SPECIFICATIONS

INSPECTION

AND

ADJUSTMENT

TIGHTENING

TORQUE

TROUBLE

DIAGNOSES

AND

CORRECTIONS

SPECIAL

SERVICE

TOOLS

FA

12

FA

12

FA12

FA13

FA10

FA

ll

FA

14

FA

17

Refer

to

Section

MA

Front

Axle

and

Front

Su

pen

ionl

for

ADJUSTING

WHEEL

BEARING

PRELOAD

CHECKING

WHEEL

ALlGNMENT

FrontAxleandFronrSu

lPension

FRONT

XLE

FRONT

SUSPENSION

FRONT

AXLE

AND

FRONT

SUSPENSION

Wheel

alignment

Camber

caster

and

kingpin

are

preset

at

factory

and

cannot

be

adjusted

The

car

requiresonly

toe in

and

car

pouure

adjustment

Toe

in 0

2

mm

0

08

in

00

to

0012

RefeI

to

section

MA

fot

Wheel

Alignment

J

25 34

2 5

3

5

18

25

J

16

21

1

6

21

12

J

62

7S

6 3

7 6

46

Suspension

croumember

Stabilizer

bar

l

Te

llion

rod

TranlVcue

link

J

50 60

5

161

37 44

J

78 98

8

10

58

72

Wheel

bearing

Do

not

overtighten

wheel

bearing

nuts

as

this

can

cawe

wheel

bearing

seizure

Axial

play

0

mm

0

in

Preload

As

measured

at

wheel

bolt

with

used

parts

2

0

7 8

N

0

2

081rg 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

J

59

74

6

0

7

5

43

54

Strut

mounting

insulator

Dust

covet

Coil

SPrinll

Strut

bly

BaUjoint

Tension

rod

bracket

J

31

42

3

2

4 3

23 31

To

body

rame

J

N

m

Irg

m

ft

lb

SFA

9

FRONT

AXLE

FRONT

SUSPENSION

Front

Axle

FRONT

AXLE

We seal

@

Inner

wheel

bearing

Cotter

@

@j

L

LWheelhub

@innerside

Washer

Wheel

bearing

nut

Adjust

wheel

bearing

preload

Hub

cap

Refer

to

Section

MA

for

@g

inner

side

Adjusting

Wheel

Bearing

Preload

Baffle

plate

38

lD

@

N

m

kg

m

ft

lb

Multi

purpose

grease

point

SFA120

REMOVAL

4

Work

off

hub

cap

CAUTION

Be

careful

not

to

drop

wheel

bearing

I

Block

rear

wheels

with

chocks

and

raise

front

of

car

and

then

sup

port

it

with

safety

stands

Refer

to

Section

GI

for

Lifting

Points

and

Towing

2

Remove

wheel

and

tire

assembly

3

Remove

caliper

assembly

Refer

to

Section

BR

for

removal

Screwdriver

7

Separate

outside wheel

bearing

inner

race

and washer

8

Separate

brake

rotor

and hub

O

riJ11

5

Pry

off

cotter

take

out

adjusting

cap

and

wheel

bearing

nut

Cotter

must

not

be

reused

6

Remove

wheel

hub

with

disc

brake

rotor

9

Remove

inside

wheel

bearing

outer

race

grease

seal

and outside

outer

race

CAUTION

Be

careful

not

to

drop

wheel

bearing

CAUTION

Make

sure

brake

hose

is

secured

and

not

twisted

FA258

Grease

seal

mud

not

be

reused

FA

3

FronrAxle

FRONT

AXLE

FRONT

SUSPENSION

INSPECTION

Thoroughly

dean

bearing

and each

part

and

dry

with

compressed

air

Wh

1

bearing

When

race

cage

or

roller

sufaces

make

noise

or

are

cracked

pitted

worn

rough

or

out

f

round

replace

bearing

assembly

Wheel

hub

Check

wheel

hub

for

cracks

by

means

of

magnetic

flaw

detecting

or

dyeing

test

replace

if

necessary

Knuckle

aplndle

Also

check wheel

hub

replace

if

cracked

or

damaged

When

thread

is

damaged replace

strut

assembly

Greaae

aeal

If

grease

leakage

is

detected

during

removal

replace

grease

seal

Replace

grease

seal

at

every

disas

sembly

even

if

it

appears

good

INSTALLATION

Install

front

axle

in

the

reverse

order

of

removal

as

follows

I

Install

bearing

outer

race

with

Tool

until

it

seats

in

hub

FA

4

I I

1

11

1

Y

III

SFA

124

2

Pack

hub

and hub

cap

with

re

commended

multi

purpose

grease

Coat

o

ring

with

recommended

multi

purpose

grease

O

l

q

MuIt

purpo

grease

point

SFA125

3

Coat

each

bearing

with

reCom

mended

multi

purpo

gr

4

Place

inner

bea

J

in

hub

and

install

a

new

grease

seal

coating

seal

ing

lips

with

recommended

multi

pur

PO

gr

@

Multi

purpo

grease

point

SFA126

5

Fix

brake

rotor

to

hub

38

ft

Ib

6

Sparingly

apply

recommended

multi purpose

grease

to

each

part

Threaded

portion

of

spindle

Bearing

washer

to

bearing

contact

ing

face

7

Put

hub

assembly

on

spindle

and

then

install

washer

and

wheel

bearing

nut

8

Adjust

wheel

bearing

preload

Roter

to

Section

MA

for

adjUlt

ment

9 Install

hub

cap

with

a

ring

on

hub

10

Install

brake

caliper

assembly

Roter

to

Section

BR

for

installa

tion

II

Install

wheel

and

tire

cD

78

98

N

m

8

0

10

0

kg

m

58

72

ft

Ibl

FRONT

AXLE

FRONT

SUSPENSION

Front

Suspension

FRONT

SUSPENSION

Croamember

auembly

I

J

59

74

i

or

6 0

7 5

43

54

t

I

J

25 34

f8

2 5

3

5

18

25

I

J

50

60

To

body

J

5

161

3744

I

J

62

75

e

6 3

7

6

t

1

46

55

I

J

60

72

b

t

I

U

t

bIY

tf

J

I

L

5 5

10

0

Ten

n

I

J

t

Transverse

link

1

I

i

oS

I

J

6

2

1

j

br

I

J

g3

9

53

72

XI

J

31

42

12 15

Balljo

nta

sembly

3 2 4

3

I

J

50

60

23 31

51

6

1

37

44

8

e

Stabilizer

bar

1

J4454

4 5

55

33

Z

Tension

rod

bracket

I

J

31

42

3 2

4

3

23

31

I

J

N

m

kg

m

ft

Ib

SFA128

SPRING AND

STRUT

ASSEMBLY

Strut

kit

I

J

59

74

6 0

7 5

Gland

packing

43 54

I

J

25

34

rstruI

packing

kit

C

2 5

3

5

O

nng

3

18 25

I

ton

rud

I

uldebusllIng

Mountingin

u1alor

ShoCk

Lock

nut

Mounting

bearing

b

O

ber

kit

with

dust

seal

I

Washer

sPring

upper

seal

Inner

cylinder

G

Bound

bumper

rubber

DUSI

cover

I

SPring

J

Strut

outer

casing

1

bearing

nut

9

fr

f

r

J

I

J

50

60

V

5

16

1

37

44

SFAl29

Adjusting

cap

Atterpin

I

J

N

m

kg

m

ft

b

Service

parts

SUUt

packing

kit

Shock

absorber

kit

Strut

kit

FA

5

FrontSuspension

FRONT

AXLE

FRONT

SUSPENSION

REMOVAL

AND

INSTAllAnON

Block

rear

wheels

with

chocks

and

raise

front

of

car

and

then

support

it

with

safety

stands

Refer

to

Section

GI

for

Ufting

Points

and

Towing

Remove

wheel

and

tire

assembly

3

Remove

brake

tube

and

caliper

Refer

to

Front

Disc

Brake

Section

BRl

4

Remove

wheel

hub

and

wheel

bearing

if

necessary

5

Separate

knuckle

arm

from

strut

lower

end

r

SFA130

6

Support

strut

assembly

with

a

suitable

stand

7

Remove

strut

upper

end

SFA

31

8

Draw

out

strut

assembly

from

car

9Install

strut

and

spring

assembly

in

reverse

order

of

removal

CAUTION

Make

sure

brake

hose

is

secured

and

not

twisted

When

installing

steering

knuckle

arm

to

the

strut

assembly

apply

suitable

sealing

material

to

portion

indicated

in

figure

FA

6

A

pply

sealing

material

SFA132

GJ

Strut

to

hoodledge

25

34

N

m

2 5 3

5

kg

m

18

25

ft

Ibl

Strut

to

knuckle

arm

72

97

N

m

7 3 9 9

kg

m

53 72

ft

Ibl

DISASSEMBLY

When

disassembling

strut

assambly

extra

caution should

be

exercised

to

prevent

dirt

and

dust

from

entering

strut

Set

up Tools

on

strut

assembly

Compress

spring

just

for

enough

to

permit

turning

of

strut

mounting

in

sulator

by

hand

HT7t730000

ST35652001

SFA133

2

Remove

lock

nut

from

top

of

piston

rod

J

LX

SFA134

Separate

following

parts

Strut

mounting

insulator

Strut

mounting

bearing

Dust

seal

Spring

upper

seat

Bound

bumper

rubber

Coil

spring

Dust

cover

CAUTION

Pay

attention

not

to

damaga

piston

rod

3

Remove

gland

packing

with

Tool

Retract

piston

rod

by

pushing

it

down

until

it

bottoms

J

A

ST35500001

J

FA209

KV48100301

4

Remove

O

ring

from

top

of

outer

casing

and

draw

out

guide

bushing

SFA135

5

Lift

out

piston

rod

together

with

cylinder

Piston

rod

piston

rod

guide

innlr

cylinder

and

bottom

valvl

are

adjusted

to

provide

precilion

mating

surfaces

Ind

should

be

hlndled

IS

I

matched

it

Lift

out

FA275

6

Drain

l1uid

thoroughly

from

inner

cylinder

and

outer

casing

r

Guide

bushing

iJ

Thi

operation

i

very

important

since

performance

of

strut

varies

with

amount

of

fluid

filled

within

strut

INSPECTION

Wash

all

parts

except

for

noome

tallic

parts

clean

with

suitable sol

vent

and

dry

with

compressed

air

Blow

dirt

and

dust

off

of

non

metallic

parts

using

compressed

air

8

Oil

oozing

out

at

and

around

gland

packing

does

not

call

for

strut

maintenance

If

oil

leaks

part

pring

at

check

piston

rod

and

gland

packing

to

correct

the

cause

of

problem

If

oil

leakage

occurs

on

welded

portion

of

outer

strut

casing

replace

strut

assembly

b

If

hock

absorber

itself

is

malfunc

tioning

replace

as

shock

absorber

kit

including

pillion

rod

cylinder

bottom

valve

and

guide

bushing

Gland

packing

O

ring

and

fluid

Replace

with

new

gland

packing

and

O

ring

or

replace

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

shock

absorber

kit

As

for

outer

casing

replace

strut

assembly

FRONT

AXLE

FRONT

SUSPENSION

FrontSuspension

Inner

diameter

Inner

cylinder

30

02

30 10

mm

1

1819

1

1850

in

SFA136

Maximum

runout

Inner

cylinder

Less

than

0 2

mm

0

008

in

t

r

O

cYlinder

SFA137

Piston

rod

Inspect

piston

rod

for

cracks

defoffilation

or

other

damage

Re

place

shock absorber

kit

Inspect

threads

for

cracks

or

ot

her

damage

Replace

shock absorber

kit

Rod

diameter

19

965

19

975

mm

0

7860

0

7864

in

Maximum

runout

Less

than

0

1

mm

0

004

inl

SFA138

Strut

mounting

insulator

Replace

if

cemented

rubber

to

metal

portion

are

melted

or

cracked

Rubber

parts

should

also

be

replaced

if

deteriorated

Strut

mounting bearing

Replace

if

inspection

reveals

ab

normal

noise

or

excessive

rattle

in

axial

direction

ASSEMBLY

Before

assembly

clean

away

all

dirt

to

prevent

any

possible

entry

of

dirt

into

strut

assembly

I

Install

strut

assembly

on

Tool

KV

4810030

I

2

Install

piston

rod

and

inner

cylinder

shock

absorber

kit

Y

Piston

rod

f

M

SFA139

3

Pour

correct

amount

of

fluid

U

e

NISSAN

GENUINE

STRUT

F

LUI

0

or

equivalent

Capacity

325

m2

11

0

US

110z

11

4

Imp

11

ozl

FA

7

Front

Suspension

FRONT

AXLE

FRONT

SUSPENSION

4Place

guide

bushing

Cylinder

Guide

bu

shing

SFA140

5

Lubricate

sealing

lip

of

gland

packing

SFA141

6Install

gland

packing

using

Tool

Be

careful

not

to

damage

sealing

lip

SFA142

FA

8

7

Tighten

gland

packing

ST3SS00001

LJ

fl98

118

N

m

10

12kg

m

4

72

87ft

SFA143

LorIw

1tch

c

f

Lm

ft

O

1m

0

3ftl

108

11

80

o

E

98

10

12

o

88

9

65

B

o

78

8

58

o

0

3

o

u

Converted

torquel

p

59

6

43

N

m

q

ft

lb

0

3

0

4

0

5

06

m

SFA144

1

0

15

2

0

L

Effective

length

of

torque

wrench

ft

8

Remove

trut

from

Tool

KV48100301

9

After

the

above

steps

have

been

completed

air

should

be

removed

from

shock

absorber

syst

m

Repeat

above

procedure

everal

timal

10 that

air

will

ba

bled

out

from

strut

thoroughly

al

hown

FA

279

1

FA280

10

Reinstall

strut

on

Toot

KV48

10030

I

1

L

Compress

coil

spring

u

ing

Tool

HT71730000

SFA14S

12

Set

up

coil

pring

with

Tool

HT71730000

on

spring

lower

seat

of

strut

13

Lubricate

parts

indicated

in

figure

At

SFA1

48

14

Mount

following

part

as

shown

in

figure

G

Lock

nut

Mounting

insulator

c

Bear

ing

With

dust

Seal

spnng

eat

Bound

bumper

rubber

Dust

cover

Hf71730000

LJ

KV48100301

SFA147

Install

bound

bumper

rubber

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

IV

59

74N

m

i6

0

1

5k

43 54

ft

Ibl

Uvd

FA148

16

Remove

Tool

HT71730000

on

strut

assembly

After

placing

spring

in

position

between

upper

and

lower

spring

seatl

release

eompreaor

greduelly

FRONT

AXLE

FRONT

SUSPENSION

Front

Suspension

Coil

spring

mi

I

Sprmg

seat

d

Place

pnng

In

po

ilton

SFA149

Spnng

InstallatIon

TENSION

ROD

AND STABIUZER

BAR

e

Stabilizer

braCketlj

rl1

IV

31

42

3 2 4 3

23

411

IV

50 60

To

tension

rod

bracket

5

1

6

1

IV

44

54

In

cJO

JI

37

44

4 5 5 5

l

33

40

Tension

rod

J

To

tension

rod

t

1

bracket

Transverse

link

A

IV

16

21

1

6 2

1

1215

IV

Nm

kg

m

ft

Ib

SFA150

Remove

under

cover

Set

load

of

car

If

correctly

installed

white

mark

painted

on

stabilizer

bushing

seat

can

be

seen

from

both

sides

of

car

Always

install

the

stabilizer

which

has

the

while

mark

on

it

on

the left

transverse

link

When

installing

a

bushing

do

not

allow

it

to

project

beyond

the

sur

face

area

of

lhe

washer

Do

not

allow the

bushings

and

washers

to

come

in

contact

with

grease

oil

soapy

water

etc

FA

9

Front

Suspension

FRONT AXLE FRONT

SUSPENSION

White

mark

Left

side

only

White

mark

Both

sides

r

SFA152

Stabilizer

position

CD

1

Tluust

washer

2

Tension

lod

bracket

3

Tension

rod

SFAl53

4

Collar

5 Bu

hins

TRANSVERSE

UNK

AND

LOWER

BALL

JOINT

vtJ

9

Front

SFAl54

REMOVAL

AND

INSTAllATION

I

Block

ear

wheels

with

chocks

and

raise

front

of

car

and

then

up

port

it

with

safety

tand

Refer

to

Section

GI

for

Lifting

Points

and

Towing

2

Remove

wheel and

tire

assembly

3

Separate

knuckle

arm

to

side

rod

using

Tool

FA

10

1IT72520000

SFA155

4

Separate

strut

lower

end

to

knuckle

arm

5

Remove

following

parts

from

transverse

link

I

Balljoint

I

Stabilizer

Tension

rod

SFA1511

6

Remove

transverse

link

from

crossmember

SFAl58

7

Separate

following

parts

I

Ball

joint

to

knuckle

arm

using

press

FA712

I

Unk

bushing

to

transverse

link

using

Set

Tool

ST36720000

f

rG

SFA159

8 Install

transverse

link

and

lower

ball

joint

in

the

reverse

order

of

re

moval

noting

the

following

I

Wh

n

instelling

tremver

link

spindle

insert

it

from

rear

lide

of

suspension

crOS3

I

To

instell

transye

link

first

temporerily

tighten

nuts

securing

tren

ve

link

spindl

which

con

neeu

transven

link

to

suspension

cross

member

I

Finel

tightening

hould

be

carried

out lit

curb

weight

with

tire

on

ground

I

Make

ure

mating

urfe

of

bu

h

ing

is

clean

end

free

from

oil

end

gre

I

Install

tren e

link

bushing

u

ing

set

Tool

ST36720000

tfl

Knuckl

erm

to

strut

IISIllmbly

72

97

N

m

17

39

9

kg

ni

53

72

ft

lb

Ball

joint

to

knuckle

arm

97

120

N

m

9 8

122

kg

m

71

88

ft

Ibl

Ball

joint

to

transvene

link

50 60

N

m

5

1

6

1

kg

m

37 44

ft

Ibl

Transverse

link

to

crossmember

62

75

N

m

16

3 7 6

kg

m

46

55

ft

lb

INSPECTION

Transv

rs

link

Check

for

signs

of

cracks

distor

tion

or

other

damage

Replace

if

any

of

above

conditions

are

beyond

repair

If

rubber

bushing

shows

evidence

of

cracking

replace

with

a

new

one

Ball

Joint

BaIl

joint

is

assembled

at

the

factory

and

cannot

be

disassembl

ed

Check

ball

stud

turning

torque

with

nut

in

place

on

ball

stud

If

excessively

higher

or

lower

than

specifications

and

ball

joint

is

pro

perly

lubricated

replace

Turning

torque

New

parts

3

9

8

N

m

40

100

kltcm

35

87 in

Ibl

Used

parts

2

0

7

8N

m

20

80

kg

em

17

69 in

Ibl

2

Check

conditional

dust

cover

If

found

to

be

cracked

excessively

beyond

use

replace

ball

joint

with

a

new

one

3

Lubricate

ball

joint

with

recom

mended

multi

purpose

grease

regular

ly

FRONT

AXLE

FRONT

SUSPENSION

FrontSuspension

To

lubricate

remove

plug

and

install

grease

nipple

in

its

place

Pump

grease

slowly

until

old

grease

is

completely

forced

out

After

greas

ing

reinstall

plug

When

a

high

pressure

grease

gun

is

used

operate

the

grease

gun

carefully

so

that

grease

is

injected

slowly

and

new

grease

does

not

come

out

from

the

clamp

ponion

SUSPENSION

CROSSMEMBER

REMOVAL

AND

INSTALLATION

I

Bl6ck

rear

wheels

with

chocks

and

raise

front

of

car

and

then

sup

port

it

with

safety

stands

Refer

to

Section

GI

for

Lifting

Points

and

Towing

2

Remove

wheel

and

tire

assembly

3

Remove

under

cover

4

Remove

transverse

link

from

crossmember

Refer

to

Tran

vene

Link

and

Lower

Ball

joint

S

Separate suspension

crossmember

from

engine

mounting

insulator

6

Raise

up

engine

Support

weight

of

engine

to

remove

load

from

engine

mounting

7

Remove

suspension

crossmember

from

body

frame

8

Install

suspension

crossmember

in

reverse

order

of

removal

f

Crossmember

to

transverse

link

62 75

N

m

6 3 7 6 kg

m

46 55

ft

Ibl

Engine

mounting

insulator

to

crossmember

31

42

N

m

32

43

kg

m

23

31

ft

Ibl

Crossmember

to

body

frame

Bolt

Center

31

42

N

m

3 2

4

3

kg

m

23

31

ft

Ibl

Nut

Both

sidesl

60

72

N

m

6

1

7 3

kg

m

44

53

ft

Ib

INSPECTION

Check

suspension

crossmember

for

evidence

of

deformation

or

cracking

if

necessary

replace

FA

l1

Service

Os

tBsndSpecifications

FRONT

AXLE

FRONT

SUSPENSION

SERVICE

DATA

AND

SPECIFICATIONS

GENERAL

SPECIFICATIONS

COIL

SPRING

Color

identification

Spring

constant

Dimension

d

DxL

12

2

30

Right

386

ere

m

1

0

480

5

12

White

2

With

power

5

201

steering

12

2

130

1716

N

mm

Lah

392

Pink

1

75

kg

mm

10

480

5

12

Yellow

2

98

0Iblin

5

43

Without

power

steering

2

30

x

3S6

Cream

1

0

480

x

5

12

White

2

5

20

d

x

0

xL

Wire

diameter

mm

lin

x

Coil

diameter

mm in

x

Free

length

mm

in

STRUT

ASSE

MBLY

I

Shock

absorber

type

I

Shock

absorber

fluid

mQ

US

fl

OZ

Imp

fl

ozl

l

Piston

rod diameter

mm

in

linneI

cylinder

inner

diameter

mm

i

n

I

Stroke

mm

in

I

Expansion

Damping

force

N

kg

Ibl

t

0 3

m

11

0

hI

see

I

Compression

N

k9

lb

HYdraulic

325

11

0

114

19

965

19

975

10

7860

0

7864

30

02

30

10

11

1819

1

1850

172

16

77

588

tOO

132

J43

135

77

STABILIZER

BAR

I

Bar

diameter

mm in

t9

10

75

FA

12

INSPECTION

AND

ADJUSTMENT

WHEEL

ALIGNMENT

Unladen

1

Camber

degree

40

50

I

Caster

degree

045

3015

Kingpin

inclination

degree

1025

S055

mm

in 0

2

00

081

Toe

in

degree

2

0

12

Front

wheel Inside

330

350

3

turning

ngle

290

3

Full

turn

degree

Outside

270

Front

wheel Inside

200

Toe

out

turns

degree

Outside

18

70

1

Tankful

of

fuel

radiator

coolant

and

engine

oil

full

Spare

tire

jack

hand

tools

mats

in

designed

position

2

Onboth

sides

3

On

power

steering

models

wheel

turning

force

tat

circumference

of

steering

wheel of

98

147N

10

15 kg

22

33

Ibl

with

engine

at

idle

WHEEL BEARING

Wheel

bearing

axial

play

mm in

N

m

kg

m

Wheel

bearing

nut

ft

lbl

tightening

torque

Return

degree

angle

With

N

m

new

kgan

gre

in

lbl

se

1

With

N

m

used

kg

cm

Wheel gro

bearing

se

l

in

lbl

starting

torque With

new

N

At

grease

Ik9

lbl

wheel

seal

hub

bolt

With

usad

N

grease

Ik9

lb

se

t

0

01

25

29

2 5 3

0

18

22

600

0

39

0

83

14

0

S

5

3

5

741

0

10

0

44

1

0 45 0

9

3

91

6

9

14

7

fO

7

1

5

1

5

33

2

0

7B

10

2 0

8

04

1

8

FRONT

AXLE

FRONT

SUSPENSION

ServiceOataandSpecifications

LOWER

BAlL

JOINT

New

N

m

3 9

98

parts

kg

em

140

100

35

871

in

Ibl

Turning

torque

Used

N

m

2 0 7

8

parts

kg

em

120

80

17

691

Ibl

TIGHTENING

TORQUE

I

Unit

I

N

m

I

kg

mft

Ib

I

Hub

I

Wheel

hub

nut

I

78 98

8

10

I

58 72

I

Disc

brake

I

Rotor

to

hub

I

38 52

I

3953

I

28 38

I

Strut

I

Strut

to

hoodledge

25 34

25 3 5

18

25

I

Piston

rod

sei

Iocklng

59

74

60

7 5

43 54

nut

Gland

packing

9B

118

10

0

12

0

U2

87

Strut

to

knuckle

arm

72

97

7 3 9

9

53 72

Caliper

to

strut

72 97

7 3 9

9

53 72

Knuckle

arm

I

Knuckle

arm

to

side

rod

54

98

5 5

10

0

I

40 72

ball

joint

FA

13

Trou

Jle

Diagnoses

and

Corrections

FRONT

AXLE

FRONT

SUSPENSION

TROUBLE

DIAGNOSES

AND

CORRECTIONS

Condition

Vibration

shock

and

shimmy

of

steering

wheel

Vibration

Loose

connection

of

each

part

and

wear

of

each

part

of

Iini

age

cause

vibra

tion

of

front

wheels

and

steering

wheel

vibration

This

is

very

noticeable

when

trav

elling

on

rough

road

Shock

When

the

front

wheels

are

travelling

on

bumpy

roads

the

play

of

the

steering

linkage

is

transmitted

to

the

steering

wheel

This

is

especially

noticeable

when

travelling

on

rough

road

Shimmy

Abnormal vibration

of

the

front

suspension

system

and

the

whole

steering

linkage

which

occurs

at

specific

speeds

Car pulls

to

right

or

left

When

drivin

with

hands

off

the

steering

wheelan

aflat

road

the

car

gently

swerves

to

right

or

left

A

faulty

rear

lII

ellSion

may

also

b8 the

caUI8

of

this

problem

and

therefore

188

also

Sectinn

RA

FA

14

Probable

cause

Improper

tire

pressure

Imbalance

and

deformation

of

road wheel

Unevenly

wom

tire

or

insufficient

tight

ening

of

wheel

nuts

Improperly

adjusted

or

wom

front

wheel

bearing

Faulty

wheel

alignment

Wom

transverse

link

bushings

Insufficiently

tightened

steering gear

hous

ing

Wear

of

steering

linkage

Wom

suspension

ball

joint

Excessive

backlash

due

to

improper

adjust

ment

of

the

steering

gear

box

Damaged

idler

arm

Worn column

bearing

weakened

column

bearing

spring

or

loose

clamp

Malfunction

of

shock absorber inside

the

strut

or

loose

installation

bolts

Imbalance

of

car

level

Improper

tire

pressure

or

insufficient

tight

ening

of

wheel

nuts

Difference

in

wear

and tear

of

right

and

left

tire

treads

Incorrect

adjustment

or

abrasion

of

front

wheel

bearing

Collapsed

or

twisted

front

spring

Incorrect

wheel

alignment

Incorrect brake

adjustment

binding

Worn

rubber

bushings

for

transverse

link

and

tension

rod

Deformed

steering

linkage

and

transverse

link

and

tension

rod

Imbalance

of

car

level

Corrective

action

Adjust

Correct

the

imbal

ance

or

replace

Replace

or

tighten

Adjust

or

tighten

Adjust

Replace

Retighten

Replace

faulty

parts

Replace

Adjust

correctly

Replace

or

retighten

Replace

or

retighten

Correct

the

imbal

ance

Adjust

or

tighten

Replace

tires

Adjust

or

replace

Replace

Adjust

Replace

Correct

the

imbal

ance

FRONT

AXLE

FRONT

SUSPENSION Trouble

Diagnoses

and

Corrections

Condition

Instability

of

car

Stiff

steering

wheel

Checking

up

procedure

Jack

up

front

wheels

detach

the

steering

gear

arm

and

operate

the

steering

wheel

and

If

it

is

light

check

steering

linkage

and

suspension

parts

If

it

is

heavy

check

steering

gear

and

steer

ing

column

parts

Excessive

steering

wheel

play

Noises

Probable

cause

Improper

tire

pressure

Worn

rubber

bushings

for

transverse

link

and

tension

rod

Incorrect

wheel

alignment

Worn

or

deformed

steering

linkage

and

transverse

link

Incorrect

adjustment

of

steering

gear

Deformed

or

unbalanced

road

wheel

Improper

tire

pressure

Insufficient

lubricants

or

mixing impurities

in

steering

gear

box

or

excessively

worn

steering

linkage

Stiff

or

damaged

suspension

ball

joint

or

lack

of

grease

Worn

or

incorrectly

adjusted

wheel

bearing

Worn

or

damaged

steering

gear

and

bearing

Incorrectly

adjusted

steering

gear

Deformed

steering

linkage

Incorrect

wheel

alignment

Damaged

strut

mounting

bearing

Damaged

or

stiff

piston

or

shock absorber

piston

rod

in

the

strut

Interference

of

steering

column

with

turn

signal

swi

tch

Incorrectly

adjusted

steering

gear

housing

Worn

steering

linkage

Improperly

fitted

gear

housing

Incorrectly

adjusted

wheel

bearing

Worn

transverse

link

and

tension

rod bush

ings

Improper

tire

pressure

Insufficient

lubricating

oil

and

grease

for

suspension

baU

joint

and

steering

linkage

or

their

breakage

Loose

steering

gear

bolts

linkage

and

sus

pension

parts

Faulty

shock absorber

inside

the

strut

Faulty

wheel

bearing

Worn

steering

linkage

and

steering

gear

Worn

transverse

link

and

tension

rod bush

ings

Broken

or

coUapsed

coil

spring

Corrective

action

Adjust

Replace

Adjust

Replace

Adjust

Correct

or

replace

Adjust

Replenish

grease

or

replace

the

part

Replace

or

adjust

Replace

Adjust

Replace

Adjust

Replace

Adjust

Replace

Retighten

Adjust

Replace

Adjust

Replenish

lubrica

ting

oil

and

grease

or

replace

Retighten

Replace

FA

15

Trouble

DiagnmsundCorTfICtions

FRONT

AXLE

FRONT

SUSPENSION

Condition

Probable

cause

Loose

stabilizer

bar

installation

bolts

and

nuts

Loose

strut

to

hoodledge

installation

nuts

Grating

tire

noise

Improper

tire

pressure

Incorrect

wheel

alignment

Deformed knuckle

spindle

and

suspension

linkage

Jumping

of

disc

wheel

Improper

tire

pressure

Imbalanced

road

wheels

Faulty

shock

absorber

Faulty

tire

Deformed

wheel

rim

Excessively

or

partially

worn

tire

Improper

tire

pressure

Incorrect

wheel

alignment

Faulty

wheel

bearing

Incorrect

brake

adjustment

Tires

not

rotated

Rough

and

improper

driving

manner

FA

16

Corrective

action

Retighten

Adjust

Replace

Adjust

Replace

Adjust

Replace

Adjust

Rotate

tires

commended

val

Drive

more

gently

at

re

inter

Tool

number

Kent

Moore

No

KV401021S0

CD

ST35325000

@KV40102110

@KV40102120

@KV40102130

CID

KV

40

102140

@KV40102150

KV48100301

HT71730000

ST35500001

125825

ST35530000

125827

HT72520000

ST36720000

125847

ST35652001

FRONT

AXLE

FRONT

SUSPENSION

Special

Service

Tool

SPECIAL

SERVICE

TOOLS

Tool

name

Bearing

outer

race

drift

set

Drift

bar

Drift

A

Drift

B

Screw

A

Screw

B

Screw

C

Strut

and

steering

gear

housing

attachment

Coil

spring

compressor

G

land

packing

wrench

Gland

packing

guide

Ball

joint

remover

Transverse

link

bushing

replacer

Clamp

V

I

J

tL

t

3

o

FA

17

DATSUN

200SX

Model

SIlO

Series

SECTIONRA

REAR

AXLE

REAR

SUSPENSION

REAR

AXLE

REAR

AXLE

REAR

AXLE

ASSEMBLY

REAR

AXLE

SHAFT

AND

WHEEL

BEARING

REAR

SUSPENSION

REAR

SUSPENSION

STABILIZER

BAR

SHOCK

ABSORBER

COIL

SPRING

UPPER

LINK

AND

LOWER

LINK

CONTENTS

RA

2

RA

2

RA

2

RA

3

RA

5

RA

5

RA

6

RA

6

RA

7

RA

7

SERVICE

DATA

AND

SPECIFICATIONS

GENERAL

SPECIF

ICA

TIONS

INSPECTION

AND

ADJUSTMENT

TIGHTENING

TORGUE

TROUBLE

DIAGNOSES

AND

CORRECTIONS

SPECIAL

SERVICE

TOOLS

RA

8

RA

8

RA

8

RA

8

RA

9

RA

lO

GII

RearAxle

REAR

AXLE

REAR

SUSPENSION

REAR

AXLE

REAR

AXLE

Oil

w

Install

using

oil

seal

drift

KV40100300

Rear

axle

cue

end

shim

BeuiDg

coner

Installed

by

a

p

ing

force

of

29

49

kN

3

5t

3 3 5 5

US

ton

3

0

4

9

Imp

ton

Thickne

0

075

0

0030

0

150

0

0059

0

225

0

0089

0

300

0

0118

I

L

llteatherCOP

l

Breather

72

Filler

PI 1

72

SAA013

C

J22

26

2

2 7

16 20

Rear

axle

cue

end

shim

C

J

78 98

8

10 58

72

BeuiDg

Ax1

I

II

ease

Axle

shafl

Bearingcol1ar

Bearing

spacer

fiJ

Aal

shaft

Beerin8

fIanse

side

ide

1

r

f

Gap

C

0iI

w

W

Gap

C

0

1

0

004

J

C

J

N

m

kg

m

ft

Ib

Unit

rom in

SAA014

RA

2

REAR

AXLE

ASSEMBLY

Removal

and

Inatallatlon

Block

front

wheels

Place

stands

Support

under

differential

carrier

with

garage

jack

I

A

2

Remove

stabilizer

bar

Refer

to

Stabilizer

Bar

for

installation

4

1

I

It

SAA017

3

Disconnect

propeller

shaft

Refer

to

PO

section

for

removal

brake

hydraulic

line

and

parking

brake

cable

CAUTION

When

removing

or

installing

brake

tubes

use

Tool

GG94310000

t

e

c

C

SRA018

4

Disconnect

shock absorber

lower

end

on

each

side

When

removing

shock

absorber

low

er

end

from

bracket

squeeze

shock

absorber

and

lift

it

out

right

above

to

accommodate

embossment

inside

bracket

F

p

c

iI

y

II

I

l

RA485

It

R

A486

5

Lower

jack

and

remove

coil

spring

on

each

side

jf

6Raise

jack

to

Disconnect

upper

link

and

lower

link

at

axle

case

side

REAR

AXLE

REAR

SUSPENSION

Rear

Axle

7

Release

jack

and

pull

it

out

Installation

is

in

reverse

order

of

removal

Refer

to

Upper

Link

and

Lower

Link

for

installation

of

upper

link

and

lower

link

In

p

ction

Check

axle

case

for

yield

deforma

tion

or

cracks

and

replace

if

necessary

REAR

AXLE

SHAFT

AND

WHEEL

BEARING

R

mov

1

nd

dl

mbl

I

Block

front

wheels

Place

stands

Remove

rear

wheel

A

2

Disconnect

parking

brake

cable

and

brake tube

3

Remove

caliper

and

rotor

Re

move

nuts

securing

baffle

plate

4

Draw

out

axle

shaft

Rear

axle

shaft

SAA026

5

Remove

oil

seal

4

SAA027

RA 3

Rear

Axle

REAR

AXLE

REAR

SUSPENSION

6

Cut

collar

with

cold

chisel

Take

care

not to

damage

axle

sheft

SRA028

7

Remove

wheel

bearing

and

collar

L

l

AA492

Inspection

Check

axle

shaft

for

straightness

cracks

damage

wear

or

distortion

Check

lip

of

oil

seal

for

damage

de

formation

or

wear

Check

bearing

for

wear

or

damage

Assembly

and

Installation

I

Install

bearing

spacer

with

cham

fer

ide

facing

axle

haft

flange

Insert

wheel

bearing

with

seal

ido

facing

ollie

haft

flange

CD

SRAQ29

1

Bait

2

Rear

axle

shaft

3

Bame

plate

4

Adapter

plate

5

Bearing

spacer

6

Wheel

bearing

RA

4

2

Press

new

bearing

collar

by

a

load

of

29

to

49

kN

3

to

5

ton

3 3

to

5 5

US

ton

3

0

to

4

9

Imp

Ion

Ions

Baffle

plate

SRA030

3

Install

oil

seal

packing

cavity

be

tween

sealing

lips

with

recommended

multi purpose

grease

KV40100300

SAA031

4

Insert

axle

shaft

into

axle

case

applying

multi purpose

grease

to

the

outer

periphery

of

bearing

collar

Re

move

guide

when

distance

A

be

tween

axle

l1ange

and

bearing

is

70

to

90

mm

2

76

to

3

54 in

CD

1

J

9

AJ

r

A

70

90mm

12

76

3

54

in

RA560

1

Rear

axle

shaft

2

Rear

axle

shaft

gune

ST37840000

3

Rear

axle

case

4

Oil

seal

5Adjust

gap

C

between

wheel

bearing

and

axle

tube

end

by

selecting

shim

Gap

C

less

than

0

1

mm

0

004

in

i

Shim

thickness

d

W

II

IIII

AA559

Rear

axle

case

end

him

Refer

to

S

O

S

6

Measure

end

play

of

axle

shaft

SAA032

Axial

end

play

0

05

0

40

mm

0

0020

0

0157

in

fl

Differential

gear

carrier

fixing

nut

20 25

N

m

2

0

2

5

kg

m

14

18

ft

lbl

Oil

drain

and

filler

plug

59 98

N

m

6

0

10 0

kg

m

43 72

ft

Ibl

Brake

tube flare

nut

15 18 N

m

1

5

1

8

kg

m

11

13

ft

lb

Brake

3

way connector

fixing

bolt

17

20

N

m

1

7

2

0

kg

m

12 14

ft

Ibl

Wheel

nut

78 98

Nm

8 0

10

0

kg

m

58

72

ft

Ibl

REAR

AXLE

REAR

SUSPENSION

Rear

Suspension

REAR

SUSPENSION

REAR

SUSPENSION

dl

@

e

e1

1

15

20

15

2

0

11

14

Coil

Spring

l

D

color

Purple

YeUow

Shock

absorber

Upper

link

bolt

8

0

51

58

dl

3 7

5

0

0 38

0

51

2

7

3 7

Lower

link

bushing

Replaceable

Removed

or

installed

by

a

pressing

force

of

39

69

KN

4

11

4

7 7

US

ton

3

9 6

9

Imp

ton

Differ

in

length

from

upper

link

bolt

78

7

0 8 0

51

58

Differ

in

length

from

upper

link

bolt

dl16

21

1

6 2 1

12

21

12 15

dl

N

m

kg

ft

lb

SAA033

AA

5

Rear

Suspension

REAR

AXLE

REAR

SUSPENSION

STABILIZER

BAR

Remoyal

Remove

stabilizer

bar

P

fI

II

SRA017

Front

IV

16

2111

6

2

1

12

IV

N

m

kg

m

ft

Ib

SHOCK

ABSORBER

Remoyal

and

Installation

I

Disconnect

upper

end

14ft

lbl

1

T

In

trunk

luggage

room

SRA037

2

Disconnect

lower

end

md

remme

shock absorber

Squeeze

shock

absorber

and

lift

it

out

right

above

to

accommodate

em

bossment

inside

bracket

RA

6

Inspection

I

Check

stabilizer

bar

for

evidence

of

deformation

or

cracks

replace

if

necessary

2

Check

rubber

parts

to

be

sure

they

are

not

deteriorated

or

cracked

replace

if

necessary

Installation

a

Install

stabilizer

bar

being

careful

not to

confuse

right

and

left

sides

b

InstJ

U

rubber

bushing

with

metal

fining

on

axle

case

lide

c

Install

bolt

attaching

bushing

so

that

bolt

is

inside

the

car

21

11

6

2

1

SRA035

s

C

fl

ilr

SAA038

L

7 0

80

kg

m

51

58

ft

lbl

c

i

r

I

t

r

RA486

Inspection

Test

shock absorber

and

compare

with

specifications

given

in

S

O

S

Replace

if

necessary

Check

for

oil

leakage

and

cracks

Also

check

shaft

for

bending

Inspect

rubber

bushings

for

dam

age

cracks

and

deformation

Re

place

parts

if

necessary

COIL

SPRING

Remoyal

end

Installation

I

Block

front

wheels

Place

stands

Support

under

differential

carrier

with

garage

jack

L

SRA016

2

Disconnect

shock absorber

lower

end

C

IY

LIV6

78N

ml

SRA038

L

7

0 80

kg

m

51

58

ft

lbl

3

Lower

jack

slowly

and

remove

coil

springs

on

each

side

Inspection

Check

coil

spring

for

yield

defor

mation

or

cracks

Test

spring

and

compare

with

speci

fications

given

in

S

D

S

Check

all

rubber

parts

for

wear

cracks

damage

or

deformation

Re

place

if

necessary

UPPER

LINK

AND

LOWER

LINK

Removal

Remove upper

link

or

lower

link

alone

by

removing

bolt

on

each

end

It

is

possible

to

remove

one

link

assembly

alone

from

car

RA495

LI

g

lr

j

REAR

AXLE

REAR

SUSPENSION

Rear

Suspension

Inspection

Check

for

signs

of

cracks

distor

tion

or

other

damage Replace

if

beyond

repair

Bushing

replacement

For

lower

link

only

If

rubber

bushing

shows

evidence

of

cracks

replace

it

using

Tool

Upper

link

bushing

is

secured

by

adhesion

and

cannot

be

removed

Re

place

as

an

assembly

as

necessary

CAUTION

00

not

tap

end

face

of

bushing

direct

ly

with

a

hammer

as

deformation

may

result

in

loose

bolt

Removed

or

installed

by

a

pressing

force

of

39 69

KN

4

71

44

7 7

US

ton

3

9

6

9

Imp

ton

KV40101420

BUshing

t

KV401O

47

a

ww

SRA039

Installation

a

Securing

bolts

for

use

with

lower

link

differ

in

length

from

those

for

upper

link

If

used

wrong

securing

bolts

cannot

be

tightened

securely

b

When

installing

upper

link

install

one

end

of

upper

link

on

car

body

make

sure

that

link

is

level

and

then

tighten

link

securely

stall the

other

end

of

link

on

axle

side

and

securely

tighten

link

while

tires

are

on

ground

c

When

installing

lower

link

securely

tighten

link

while

tires

are

on

ground

til

Shock

absorber

lower

end

69 78

N

m

7 0 8 0

kg

m

51

58

ft

Ibl

Upper

link

fixing

bolt

and

nut

69 78

N

m

70 8 0

kg

m

51

58

ft

Ibl

Lower

link

fixing

nut

69 78

N

m

7 0 8 0

kg

m

51

58

ft

Ibl

RA 7

ServireDataandSpecifications

REAR

AXLE

REAR

SlJSPENSION

SERVICE

DATA

AND

SPECIFICATIONS

GENERAL

SPECIFICATIONS

SHOCK

ABSORBER

Unit

mm

in

I

Maximum

length

L 525

120

67

I

Stroke

146 5

75

L

C

0

SRA090

COIL

SPRING

I

Wire

diameter

mm

in

I

Coil

diameter

mm

in

I

Free

length

mm

in

I

Effective

turns

I

Spring

constant

N

mm

kg

mm

Ib

inl

10

010

3941

90

13 541

362

14

251

7

75

17

46

1

78 99

71

Identification

color

Yellow

1

PurPle

ll0

5

RA040

INSPECTION

AND

ADJUSTMENT

SHOCK

ABSORBER

I

SHOCK

ABSORBER

DAMPING

FORCE

at

0 3

m

11

0

hIls

I

Expansion

N

kg

lbl

490

686

50 70

110

154

I

Compression

N

kg

Ib

245

402

25

41

55

901

RA

B

REAR

AXLE

End

play

mm

On

0

05

OAO

10

0020

0

01571

Thickness

mm n

Part

umber

Thickness

of

rear

xle

case

end shim

0

075

10

00301

43036

H5000

0

1SO

10

00591

43036

H5oo1

0

225

10

00891

43036

HS002

0

300

10

01181

43036

H5003

TIGHTENING

TORQUE

Unit

N

m

kg

m

ft

Ib

Broke

tube flare

nut

15 18

1

5

18

11

13

Brake

caliper

fixing

bolt

38

52

3

9

5 3

28 38

Baffle

plate

fixing

ut

22 26

2 2 2 7

16 20

Propeller

shaft

to

com

panion

flange

connecting

Refer

to

PO

section

nut

Wheel

nut

78

98

80

10

0

58 72

Drain

and

filler

plugs

59

98

60

10

0

43 72

I

Differential

carrier

to

20

25

2

0

2 5

14

18

axlll

case

nut

I

Shock

absorber

upper

15

20

1

5 2 0

11

14

end

nut

I

Shock

absorber

lower

69 78

7 0 8

0

51

58

end

nut

I

Upper

link

fixing

bolt

69

78

7 0 8 0

51

58

I

Upper

link

fixing

nut

69

78

7

0 8

0

51

58

I

Lower

link

fixing

nut

69 78

7

0 8

0

51

58

REAR

AXLE

REAR

SUSPENSION

Trouble

Diagnoses

and

Corrections

TROUBLE

DIAGNOSES

AND

CORRECTIONS

When

rear

axle

and

suspension

is

suspected

of

being

noisy

it

is

advis

able

to

make

thorough

test

to

deter

mine

whether the

noise

originates

in

the

tires

road

surface

exhaust

pro

Condition

Noise

unusual

sound

Instability

in

driving

This

problem

is also

the

front

suspension

For

trouble

diagnosis

also

refer

to

the

FA

section

Oil

leakage

peller

shaft

engine

transmission

wheel

bearings

or

suspension

Noise

which

originates

in

other

places

cannot

be

corrected

by

adjust

ment

or

replacement

of

parts

in

the

rear

axle

and

rear

suspension

In

case

of

oil

leak

first

check

if

there

is

any

damage

or

restriction

in

breather

Probable

cause

Loose

wheel

nuts

One

or

more

securing

bolts

loose

Lack

oflubricating

oil

or

grease

Faulty

shock absorber

Incorrect

adjustment

of

rear

axle

shaft

end

play

Damaged

or

worn

wheel

bearing

Worn

spline

portion

of

rear

axle

shaft

Loose

journal

connections

etc

Unbalance

of

wheel and

tire

Damage

of

the

rubber

parts

such

as link

bushing

shock

absorber

mounting

bush

ing

Faulty

propeller

shaft

journal

Breakage

of

coil

spring

Loose

wheel

nuts

Damaged

rear

link

rubber

bushings

Worn

shock absorber

Incorrect

wheel

alignment

Spring

wear

Damaged

oil

seal

on

rear

axle

shaft

Oil

leakage

from

the

differential

carrier

Damaged

grease

sea

of

rear

axle

shaft

Corrective

action

Tighten

to

specified

torque

Lubricate

as

required

Replace

Adjust

Replace

if

necessary

Tighten

to

torque

Balance

Replace

damaged

parts

Replace

as

a

propeller

shaft

assembly

Replace

Tighten

to

specified

torque

Replace

Adjust

Replace

parts

as

required

Replace

RA

9

Special

Service

Tools

REAR

AXLE

REAR

SUSPENSION

SPECIAL

SERVICE

TOOLS

Tool

number

knt

Moore

No

GG943

I

0000

Tool

name

Flare

nut

torque

wrench

KV4010I0OO

J

25604

1

Rear

axle

stand

ST36230000

J

25840

Sliding

hammer

lIT72480000

Rear

axle

shaft

bearing

puller

ST38210000

J

25869

1

Wheel

bearing

collar

press

stand

KV40100300

J

25405

Rear

axle

oil

seal

drift

ST37840000

Rear

axle

shaft

guide

@

KV40l0l4S0 Link

rubber

bushing

drift

CD

KV4010141O

Drift

h

V

KV40101420

Drift

@

KV40101430

Base

@

KV40101440

Ring

useless

RA

I0

DATSUN

200SX

Model

S

II

0

Series

SECTIONBR

BRAKE

SYSTEM

CONTENTS

DESCRI

PTION

SERVICE

BRAKE

PEDAL

MASTER

CYLINDER

BRAKE

HYDRAULIC

LINE

BLEEDING

HYDRAULIC

SYSTEM

NP

VALVE

FRONT

DISC

BRAKE

N22

FRONT

DISC

ROTOR

REAR

DISC

BRAKE

AN12H

REAR

DISC

ROTOR

BR

2

BR

3

BR

3

BR

4

BR

5

BR

5

BR

6

BR

6

BR

9

BR

lO

BR

13

BRAKE

BOOSTER

PARKING

BRAKE

PARKING

BRAKE

SERVICE

DATA

AND

SPECIFICATIONS

GENERAL

SPECIFICATIONS

INSPECTION

AND

ADJUSTMENT

TIGHTENING

TORQUE

TROUBLE

DIAGNOSES

AND

CORRECTIONS

SPECIAL

SERVICE

TOOL

BR

14

BR

16

BR

16

BR

1B

BR

18

BR

18

BR

19

BR

20

BR

22

Refe

to

Section

MA

Brake

System

for

CHECKING

FOOT

BRAKE

CHECKING

PARKING

8RAKE

a

CH

ription

BRAKE

SYSTEM

DESCRIPTION

3

way

connector

Pulling

hrake

lever

Brake

hOle

Front

disc

brake

SBR001

The

brake

system

is

a

hydraulically

controlled

dual

line

type

which

operates

independently

on

front

and

rear

wheels

The

brake

booster

is

a

power

assist

device which

utilizes

engine

intake

manifold

vacuum

The

NP

valve

is

a

pressure

control

device

for

the

rear

brakes

The

rear

disc

brake

is

equipped

with

a

mechanically

operated

parking

brake

mechanism

The

pad

clearances

of

the

front

and

rear

brakes

are

automatically

adjusted

BR

2

BRAKE

PEDAL

SERVICE

BRAKE

Input

rod

il

7

8

10

8

Input

rod

lock

nut

0

8

11

t

SnaPrin

5 8

8 0

i

l16

22

1

6

2 2

12

il

7 8

11

8 0

8

12

5

8 8 7

L

HItf

E

ring

il

7

8

10

8

0

8

11

5

8

Be

sure

to

insert

from

L

H

side

il

N

m

kg

m

fHb

REMOVAL

I

Remove

pedal

bracket

assembly

with

brake

pedal

M

T

only

2

Disconnect

clevis

from

brake

pedal

When

removing

clevis

be

careful

not

to

damage

c

ip

of

the

clevi

SBR121

3

Remove

fulcrum

Brake

pedal

can

then

be

taken

out

BRAKE

SYSTEM

Service

Brake

f

R H

il

7

8

10

8 0

8

11

5 8 8 0

10

8

0

8

11

5

8 8 0

Pedal

bracket

ki

l13

Return

spring

18

13

18

9

13

l

t

Brakelamp

witCh

Lock

nut

il

12 15

1

2

1

5

9

11

Pedal

stopper

Lubricating

point

Brake

pedal

o

00

lf

O@

o

I

@II

INSPECTION

Check

brake pedal

for

the

following

items

servicing

as

necessary

SBR120

I

Check

brake

pedal

for

bend

2

Check

return

springs

for

fatigue

3

Check

clevis

for

deformation

and

crack

at

welded

part

SBR122

INSTALLTION

I

Apply

coating

of

recommended

multi purpose

grease

to

sliding

portion

and

return

coil

spring

2

Adjust

brake

pedal

after installa

tion

is

completed

Refer

to

Section

MA

for

adjustment

lil

Fulcrum

fixing

bolt

7

8

10

8

N

m

0

8

1

kg

m

5

8

0

ft

lb

Input

rod

lock

nut

16

22

N

m

1

6 2 2

kg

m

12

16

ft

lb

BR

3

Service

Brake

BRAKE

SYSTEM

MASTER

CYLINDER

Reservoir

cap

Fillet

R

eservoir

teek

Y

alve

88

8 0 9

0 58

65

DISASSEMBLY

The brake

master

cylinder

is

avail

able

only

in

TOKICO

make

There

is

no

interchangeability

of

repair

kits

or

component

part

between

NABCO

and

TOKICO

makes

When

replacing

tha

repair

kit

or

component

part

rtain

tha

brand

of

the

brake

master

cylindar

body

Ba

sure

to

part

of

the

same

make

as

the

former

ones

I

Pry

off

stopper

ring

L

2

Remove

stopper

screw

Primary

and

secondary

piston

assemblies

can

then

be

taken

out

BR

4

H

piston

return

spring

Secondary

pilton

Prim

pilton

Primary

piston

return

spring

88

8

0

90

58 65

tfJ

69 88 0 7

0 9

5

16 5

SBR011

3

Disassemble piston

assembly

Secondary

piston

Primary

piston

assembly

a

uembly

SBR012

4

Remove

piston

cups

and

discard

them

l

J

N

m

ii

m

ft

Ib

SBA009

Secondary

piston

Primary

piston

SBR013

5

Unscrew

plugs

for

disassembling

check

valve

INSPECTION

I

Clean

all

parts

in

a

brake

l1uid

2

Check

the

parts

for

evidence

of

abnoimal

wear

or

damage

3

Check

piston

to

cylinder

clear

ance

Piston

linder

clearance

Less

than

0

15

mm

0

0059

in

ASSEMBLY

a

Replace

piston

cups

and

packing

with

new

ones

b

Apply

braka

fluid

or

rubber

gre

to

Iiding

contact

urface

of

ports

to

focilitata

aaembly

of

master

cyl

inder

i

J

Chock

01

0

plug

78

88

N

m

8

0

9

0

kg

m

58

65

ft

Ibl

BRAKE

HYDRAULIC

LINE

INSPECTION

Check

brake

lines

tubes

and

hoses

for evidence

of

cracks

deterioration

or

other

damage

Replace

any

faulty

parts

If

leakage

occurs

at

end

around

joints

Ie

tighten

or

if

necessary

replace

faulty

parts

REMOVAL

AND

INSTALLATION

To

remove

brake

tube

disconnect

flare

nuts

on

both

ends

and

remove

retainers

and

clips

CAUTION

When

removing

or

installing

brake

tubes

use

Tool

GG94310000

SBROOS

To

remove

brake

hose

first

remove

l1are

nut

securing

brake tube

to

hose

then

withdraw lock

spring

the other

side

Do

not

twist

brake

ho e

Brake

tube

Lock

spring

I

SBA006

a

After

installation

is

completed

bleed

brake

system

Refer

to

Bleeding

Hydraulic

System

BLEEDING

HYDRAULIC

SYSTEM

1

Top

up

reservoir

with

recom

mended

brake

l1uid

a

Do

not

mix

two

different

brand

braka

fluid

b

C

refully

monitor

brake

fluid

le el

at

master

cylinder

during

bleeding

operation

c

Do

not

reuse

drained

brake

fluid

r

BRAKE

SYSTEM

SelYice

Brake

2Install

bleeder

hose

on

bleeder

valve

With

brake

pedal

fully

depress

ed

open

bleeder

valve

to

exhaust

air

Then

close

bleeder

valve

and

allow

brake

pedal

to return

Repeat

bleeding

operation

until

no

air

bubbles

show

in

hose

a

Be

careful

not

to

pla

h

br

ka

fluid

on

painted

areas

b

Brake

fluid

containing

air

is

white

and

contain

air

bubbles

c

Brake

fluid

containing

no

air

runs

out

of

bleeder

valve

in

asolid

stream

free

of

air

bubbles

SBR003

3

Bleed

air

in

the

following

se

quence

Master

cylinder

Rear

wheel

Front

wheel

i

J

Air

bleeder

I

e

6 9 8 8

N

m

0 7 0

9

kg

m

5

1

6

5

ft

Ibl

BR

5

Service

Brake

BRAKE

SYSTEM

NP

VALVE

Do

not

disassemble

NP

val

e

Front

wheel

cylinder

Front

wheel

cylinder

If

Brake

tube

f1ere

nut

15 18

N

m

11

5

1

8

kg

m

11

13

ft

Ibl

NP

waive

to

body

3949

N

m

04

0

5

Irg

m

29

3

6

ft

lbl

SBROO1

FRONT

DISC

BRAKE

N22

Piston

eal

Replace

at

each

disassembly

i

J12

91

1

39

9

53

72

Dustse

a1

Apply

cfuc

bJake

grease

r

Cy1inder

body

aet

ainingring

You

holder

D

Installed

by

pressing

force

196

294N

20 30

leg

44 66

Ib

I

1

rupj

Yoke

II

Minimum

thickness

10

5

0

413

Spring

21

1

6 2 1

12 15

Pad

WeaJ

limit

1

J

i

J

N

m

Ieg

mJtlb

Unit

rom

in

2

0

08

SBA014

BR

6

PAD

REPLACEMENT

I

Remove

clip

Remove

pad

pins

holding

springs

with

finger

SBA015

2

Detach

pads

CAUTION

After

removing

pads

do

not

depress

brake

pedal

or

pistons

will

jump

out

SBRG16

3

Open

bleeder

valve

Push

piston

B

outer

piston

in

until

dust

seal

groove

of

piston

B

coincides

with

end

surface

of

retaining

ring

on

dust

seal

CAUTION

Piston

can

be

easily

pushed

in

by

hand

but

if

pushed

too

far

groove

of

piston

will

go

inside

of

piston

seal

At

this

point

if

piston is

pressur

ed

or

moved

piston

seal

will

be

damaged

If

piston

has

been

pushed

in

too

far

remove

caliper

assembly

and

disassemble

it

Then

push

piston

out

in

direction

shown

by

arrow

Assemble

it

again

referring

to

the

following

Piston

seal

2

Piston

B

Y

Normal

POSitiOn

Do

not

push

too

far

BR780

4

Install

inner

pad

Pull

yoke

to

outer

side

SBA230

5

Install

outer

pad

Coat

the

following

points

with

recommended

pad

grease

Cylinder

body

to

pad

clearance

Pad

to

pad

clearance

Pad

holes

of

cylinder

body

Do

not

grllll8

friction

face

of

pIId

Then

install

pad

ftxing

parts

pre

viously

removed

BRAKE

SYSTEM

Service

Brake

REMOVAL

I

Disconnect

brake

tube

2

Remove

caliper

assembly

BR

7

Service

Bl1lke

BRAKE

SYSTEM

DISASSEMBLY

Remove

pads

Remove

fIXing

bolt

and

separate

yoke and

cylinder

body

0

1

D

BR740

J

BA741

2

Remove

yoke

holder

retaining

rings

and

dust

seals

from

both

pistons

Dust

seal

8R742

3

Push

out

pistons

from

cylinder

SBR019

BR

B

4

Remove

piston

seal

Piston

seal

must

be

replaced

at

each

d

bly

SBR020

INSPECTION

CAUTION

Use

bfllke

fluid

to

clean

Never

use

minefllloil

C

llnder

bod

I

Check

inside

surface

of

cylinder

for

score

rust

wear

damage

or

presence

of

foreign

substance

If

any

surface

fault

i

detected

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

assembly

must

be

replaced

Yoke

Check

for

wear

cracks

or

other

damage

Replace

if

any

fault

i

detect

ed

PIston

Check

piston

for

score

rust

wear

damage

or

presence

of

foreign

sub

stances

Replace

if

any

fault

is

detect

ed

CAUTION

Piston

sliding

surface

is

plated

00

not

polish

with

emery

paper

eveil

if

rust

or

foreign

matter

is

sticked

on

sliding

surface

Gripper

and oke

holder

Check

for

wear

cracks

or

other

damage

Replace

if

any

fault

is

detect

ed

ASSEMBLY

I

Apply

rubber

grease

or

brake

l1uid

to

seal

grooves

and

seals

Install

piston

seals

taking

care

not

to

damage

them

SBR021

2

Apply

rubber

grease

or

brake

l1uid

to

sliding

portions

Insert

pistons

CAUTION

Iniert

piston

A

in

direction

shown

by

arrow

Q1

and

piston

B

in

direction

shown

by

BrroW 02

B

When

inserting

pistons

be

careful

not

to

insert

too

far

Refer

to

Pad

Replacement

for

assembly

b

Instan

piston

A

10

that

its

yoko

groove

coincides

with

yoke

groove

of

cylinder

1

tonA

PistonB

t

I

Q2

3

Install

dust

seal

and

clamp

secure

ly

with

retaining

ring

a

Apply

recommended

disc

brake

grease

to

sealing

surface

of dUlt

1

b

Be

careful

not

to

deform

dust seal

c

Wipe

off

excess

grease

with

alcohol

SBR022

4

Install

yoke

holder

to

piston

A

Install

gripper

to

yoke

Apply

a

coating

of

1

soap

water

to

inner

wall

of

gripper

and

drive

in collar

F

ll

T

L

BR745

5

Install

yoke

to

yoke

holder

and

supporting

end

of

piston

B

press

yoke

into

yoke

holder

by

using

press

or

hands

CAUTION

When

pressing

yoke

inlo

yoke

holder

be

su

re

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

with

a

new

one

Preaing

force

196

294

N

20 30

kg

44 66

Ibl

BR959

6

Install

pads

Refer

to

Pad

Replace

ment

for

installation

FRONT

DISC

ROTOR

REMOVAL

AND

INSTALLATION

Refer

to

section

FA

INSPECTION

I

Sliding

surface

If

there

are

cracks

or

considerable

chips

repair

or

replace

2

Runout

Adjust

wheel

bearing

correctly

Measure

mnout

BRAKE

SYSTEM

Se

Vice

Brake

n

i

I

SBR232

Rotor

repair

limit

Maximum

runout

Total

indicator

reading

at

center

of

rotor

pad

contact

su

rface

0

12

mm

0

0047

in

3

Pariille

lism

SBR233

Rotor

repair

limit

Maximum

parallelism

Circumferential

direction

007

mm

0

0028

in

4

Thickness

Standard

thickness

12

5

mm

0

492

inl

Rotor

repair

limit

Minimum

thickness

10 5

mm

0

413

in

BR

9

o

J

Wear

limit

1

6

0

063

Pad

Rotor

Minimumthickness

8

6

0

339

ke

Retaining

rins

Spring

cover

Shim

Be

sure

to

apply

brake

grease

to

both

sides

when

installing

Anti

lueal

spring

Yoke

Ipring

I

Retainer

r

CyUnder

body

A

Return

Pring

Toggle

lever

Unit

mm

in

SBA037

a

III

IIa a

Itn

m

aII

III

I

IIz

N

Z

I

2

I

C1l

m

en en

l

m

3

PAD

REPLACEMENT

I

Remove

clip

Remove

pad

pins

holding

springs

with

finger

LL

SBR03B

2

Detach

pads

and

shims

CAUTION

After

removing

peds

do

not

dep

ss

breke

pedel

or

pistons

will

jump

out

3

Retract

outer

piston

into

cylinder

body

by

turning

it

clockwise

and

push

ing

it

in

Be

careful

not to

demell8

dust

seal

1

Fllt

blade

screwdriver

BR173A

4

Move

yoke

until

clearances

to

in

stall

pads

are

equal

with

a

lever

placed

between

rotor

and

yoke

5

Install

pads

and

shims

Position

outer

piston

so that

por

tion

of

cutout

is

level

and

install

pad

by

aligning

this

portion

with

protru

sion

at

back

of

pad

Align

Ie

I

J

Ie

1

J

Jrr

rf

BR191A

D

4

7

r

6

1

Coat

the

following points

with

re

commended

pad

grease

Cylinder

body

to

pad

clearance

Y

oke

to

pad

clearance

Pad

to

pad

clearance

Pad

to

bracket

clearance

8

Do

not

grease

friction

face

of

pad

b

Be

sure

to

apply

pad

grease

to

both

sides

of

shims

SBR234

2

Check

that

the

following

points

are

coated

with

silicone

based

grease

BRAKE

SYSTEM

Service

Breke

Nissan

silicone

based

grease

or

equiva

lent

Silicone

based

greasing

points

Friction

surface

of

yoke

and

cyl

inder

body

Cylinder

body

pad

hole

Then

install

pads

fIxing

parts

pre

viously

removed

REMOVAL

I

Disconnect

brake

tube

2

Remove

caliper

assembly

1111

I

SBA041

SBRD42

DISASSEMBLY

I

Separate

cylinder

body

from

yoke

by

pushing

it

2

Remove

retaining

rings

and

dust

seals

BR

II

ServiceBrake

BRAKE

SYSTEM

Replace

dust

seal

at

each

di

m

bly

Piston

SBA043

3

Drive

out

piston

assembly

by

pushing

outer

piston

in

4

Remove

piston

seals

Replace

piston

seal

at

each

di

sembly

SBA044

5

Disengage

piston

assembly

by

turning

inner

and

outer

pistons

BR

12

6

Disassemble

outer

piston

by

re

moving

snap

ring

B

Snap

rilll

SBR045

7

Disassemble

inner

piston

by

re

moving

snap

rings

A

and

C

Snap

ring

remover

SBRD46

8

Remove

hand

brake

toggle

lever

by removing

return

spring

and

nut

Remove

dust

seal

and

cam

tt

Nut

Return

spong

8

Toggle

lever

Caml

LDust

seal

SBR047

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

install

oil

seal

in

specified

direction

BAlBOA

2

Engage

square

hole

in

key

plate

with

push

rod

Also

engage

convex

in

key

plate

in

concave

in

piston

SBR048

3Install

spring

seat

spring spring

cover

and

snap

ring

A

with

suitable

press

and

drift

Drift

SBA235

4

When

installing parking

brake

tog

gle

lever

after

assembling

piston

turn

cam

in

direction

parking

brake opera

tes

Toggle

lever

5

Apply

rubber

grease

or

brake

l1uid

to

seal

grooves

and

seals

6 Install

piston

seals

o

SBA044

7

Apply rubber

grease

or

brake

l1uid

to

sliding

portions

8

Apply

rubber

grease

to

one

hole

Diameter

1

5

mm

0

059

in

of

outer

piston

as

the

figure

shows

Then

insert

piston

assembly

in

direction

of

arrow

1

rl

j

l

out

on

Inne

pi

QI

fJ

Di

m

r

1

5

mm

0

059

in

L

SBR245

9

Install

dust

seals

and

clamp

se

curely

with

retaining

rings

10

Install

yoke

spring

BR181A

II

Coat

the

following

points

with

silicone

based

grease

Frictional

surfaces

of

yoke

and

cyl

inder

body

Cylinder body

pad

hole

fi

l

H

SBR243

I

Silicone

based

greasing

point

1

Yoke

3

Pad

2

Cylinder

body

12

Assemble

yoke

and

cylinder

with

retainer

YOke

Retainer

r

SBR049

13 Install

pads

Refer

to

Pad

Replace

ment

for

installation

INSTAUATION

fl

Coliper

fixing

bolt

38

52

N

m

3

9

5

3

kg

m

28

38

ft

Ib

After

installation

depress

brake

pedal

few

times

to

properly

adjust

brake

pad

to

rotor

clearance

and

check

for

oil

leakage

When

brake

pedal

stroke

is constant

brake

pad

to

rotor

clearance

is

properly

adjusted

It

will

be

automatically

adjusted

by

depressing

brake

pedal

BRAKE

SYSTEM

Service

Brake

REAR

DISC

ROTOR

REMOVAL

AND

INSTAUATION

Remove

caliper

and

rotor

can

be

taken

out

INSPECTION

I

Sliding

surface

If

there

are

cracks

or

considerable

chips

repair

or

replace

2

Runout

Adjust

wheel

bearing

correctly

Measure

runout

at

the

center

of

rotor

pad

contact

surface

Rotor

repair

limit

Maximum

runout

Total

indicotor

reading

at

center

of

rotor

pad

contact

surfacel

0

15

mm

00059

in

3

Parallelism

SBR050

Rotor

repair

limit

Maximum

parallelism

Circumferential

diroctionl

0

07

mm

0

0028

in

4

Thickness

Sblndard

thicknou

9 6

mm

0

378

in

Rotor

repair

limit

Minimum

thickness

8

6

mm

0

339

in

BR

13

Service

Brake

BRAKE

SYSTEM

BRAKE

BOOSTER

D

hngm

Cheek

valve

I

IJp

Pisto

j

Valve

turn

spring

11

0

Fins

rJ

Fulcrum

plate

l

ID

I

Front

meD

SBR059

INSPECTION

2

Start

engine

and

increase

engine

speed

Stop

engine

when

vacuum

is

66

7

kPa

500

mmHg

19

69

inHg

3

If

vacuum

pressure

drops

more

than

the

specified

value

correct

the

cause

in

accordance

with

the

following

chart

Air

tight

test

No

load

1

Connect

a

vacuum

gauge

between

check

valve

and

brake

booster

Maximum

vacuum

leekege

15

seconds

after

engine

is

stopped

3

kPa

25

mmHg

0

98

inHg

J

60

coo

HI

76

J

saRD

D

SBR216

Probable

cause

Corrective

action

Air

leakage

at

check

valve

Air

leakage

at

output

rod

seal

Air

leakage

between

valve

body

and

seal

Air

leakage

at

valve

plunger

seat

Inspect

check

valve

Replace

brake

booster

as

an

assembly

Damaged

piping

or

joints

Repair

or

replace

BR

14

Air

tight

test

Under

loed

Keep

brake

pedal

fully

depressed

Following

procedures

are

same

as

for

no

load

conditions

Probable

cause

Air

leakage

at

check

valve

Damaged

diaphragm

Air

leakage

at

poppet

assembly

seat and

valve

body

Check

velve

Remove

check

valve

M

T

model

With

cooler

SBR061

2

Apply

a

vacuuin

pressure

of

26

7

kPa

200

mmHg

7

87

inHg

to

the

port

of

check

valve

on

the

brake

booster

side

Manifold

side

If

Brake

booster

side

SBR062

3

If

vacuum

pressure

drops

more

than

the

specified

value

in

15

seconds

replace

check

valve

with

a

new

one

Maximum

vacuum

leakage

of

check

01

0

1

3

kPo

10

mmHg

0

39

inHg

Maximum

vacuum

leakage

15

second

after

engine

i

toppedl

3 3

kPa

25

mmHg

0

98

inHg

Corrective

action

Inspecl

check

valve

Replace

brake

booster

as

an

assembly

4

When

pressure

is

applied

to

the

brake

booster

side

of

check

valve

and

valve

does

n

open

replace

check

valve

with

a

new

one

ManVifOI

de

1

c

j

@

L

Brake

booster

side

SBR063

BRAKE

SYSTEM

Service

Brake

Operetlng

test

1

Connect

an

oil

pressure

gauge

to

brake

line

at

connection

on

master

cylinder

2

Install

a

pedal

force

gauge

on

brake

pedal

3

Start

engine

and

increase

engine

speed

until

a

vacuum

pressure

of

66

7

kPa 500

mmHg

19

69

inHg

is

reo

gistered

on

vacuum

pressure

gauge

With a

steady

vacuum

pressure

of

66

7

kPa

500

mmHg

19

69

inHg

measure

oil

pressure

with

respect

to

each

pedal

operating

force

Relationship

between

oil

pressure

and

pedal

operating

force

is

illustrated

in

Fig

If

test

results

are

not

as

speci

fied

check

brake

booster

for

con

dition

in

manner

described

under

Inspection

before

removal

of

this

unit

Also

check brake line

for evidence

of

l1uid

leakage

Determine

whether

source

of

pro

blem

is

in

brake

booster

or

check

valve

Before

you

reach

a

final

conclu

sion

always

inspect

check

valve

fint

M

e

u

ii

S

u

M

0

11

770

120

1

710

10

190 110

1

500

I

II

I

9

810

100

1

420

I

8

830

90

1

280

1

jj

1

850

80

1

140

6

860

10

1

000

I

l

I

5

880

60

850

f

66

jf

4

900

50

710

I

tfl

3

920

40

510

I

2

940

30

430

L

I

J

1

960

20

280

r

J

980

10

140

td

JJ

I I

o

981

1

961

100 221

200 441

Rod

operating

force

N

kg

lb

8

0

6

0

66

Pedal

operating

force

N

kg

Ib

SBR074

BR

15

S8rvicsBrake

BRAKE

SYSTEM

REMOVAL

To

remove

brake

booster

detach

the

following

points

S8A064

ADJUSTMENT

Output

rod

length

PV

seno

cannot

be

adjusted

as

output

rod

thread

portion

is

secured

by

adhesion

Check

length

Langth

AH

9 75

10

00

mm

10

384

0

394

in

u

1

BR109A

2

If

length

is

not

within

specifica

tions

replace

brake

booster

assembly

Input

rod

length

Adjust

length

by

turning

clevis

Length

8

130

mm

5

12

in

PARKING

BRAKE

Front

cable

BR

16

SBA066

r

j

B

BR110A

INSTAllATION

IiJ

M

cylinder

to

brake

booster

7 8

10

8N

m

10

8

1 1

kg

m

5

8 80

ft

Ibl

Brake

booster

to

body

7

8

10

8

N

m

10

8

1

kg

m

58

8

0

fHbl

Input

rod

lock

nut

16

22

N

m

11

6

22

kg

m

12

16

fHb

PARKING

BRAKE

REMOVAL

Control

lever

and

front

cable

Remove

console

box

Disconnect

harness

connector

Re

move

control

lever

SBR067

2

Remove

grommet

rubber

and

lock

plate

Disconnect

cable

adjuster

r

t

IJ

SBA068

3

Pull

front

cable

out

into

driver

s

compartment

SBA069

4

If

necessary

separate

front

cable

from

parking

brake

lever

by

breaking

and

replace

front

cable

CAUTION

Be

careful

not

to

deform

or

damage

control

lever

Front

cable

clevis

and

cotter

are

available

as

Hrvice

parts

Rear

cable

Disconnect

cable

adjuster

Remove

lock

plate

and

strap

or

cable

clamp

SBR071

2

Remove

lock

plate

and

disconnect

rear

cable

from

lever

by

removing

cotter

BRAKE

SYSTEM

Parking

Brake

L

l

SBRQ73

INSPECTION

I

Check

control

lever

for

wear

or

other

damage Replace

if

necessary

2

Replace

worn

or

fatigued

spring

3

Check

wires

for

discontinuity

or

deterioration

Replace

if

necessary

4

Replace

malfunctioning

warning

light

or

switch

5

Check parts

at

each

connection

and

if

found

deformed

or

damaged

replace

INSTALLATION

When

installing

front

cable

to

le

r

u

specified

elevis

end

cotter

I

Apply

a

coat

of

grease

to

sliding

contact

surfaces

2

Adjust

parking

brake

system

after

installation

is

completed

Refer

to

Sec

tion

MA

for

adjustment

BR

17

Service

OataandSpecifications

Bf

lAKE

SYSTEM

SERVICE

DATA

AND

SPECIFICATIONS

GENERAL

SPECIFICATIONS

I

Type

J

Cylinder

inner

die

mm

in

Front

Pad

mm

lin

Width

x

thickness

x

length

I

Rotor

outer

die

mm

in

I

Type

I

Cylinder

inner

die

mm

in

Rear

I

Pad

mm

in

Width

x

thic

ness

xlength

I

Rotor

outer

di

amm

in

IMa

ter

cyljnde

inner

die

mm

in

I

Brak

booster

type

NP

valve

Split

point

kPalkg

cm2

psi

reducing

ratio

Disc

N22

53 98

2

1

8

52

9

x

9

7

x

76

2

083

x

0

382

x

3

0001

253 5

9 98

Disc

AN

12

H

40

4611

5929

I

42

0

x

10

3

x

56

8

1

654

x

0

406

x

2236

269

10

59

22 23

7

8

P75

2

452

25

356

x

04

INSPECTION

AND

ADJUSTMENT

BRAKEPEDAL

I

Pedal

play

8

I

Depressed

height

d

I

Pedal

height

h

PARKING

BRAKE

1

Pulling

force

N

kg

Ibl

I

Number

of

notches

I

Stroke

mm in

MASTER

CYLINDER

I

Allo

N8ble

clearance

between

cylinder

and

piston

BR

18

Unit

mm

in

5

0 04

0

201

More

than

60

2

36

155

t6t

6

10

6

34

196

20

441

7

8

90

100

3

54

3

941

mmOnl

Less

than

I

0

15

0

0059

BRAKE

BOOSTER

Maximum

vacuum

leakage

15

s8cond

after

engine

iutopped

kPa

mmHg

inHg

Output

rod

length

A

mmlin

Input

rod

length

S

mmlin

3 3

25

0

981

9

75 10 00

0

3839

0

39371

130 5

12

r

IW

J

I

r

B

BR109A

8Rll0A

CHECKYALYE

Maximum

vacuum

leakage

15

seconds

after

26

7

kPa

200

mmHg

7

87

inHg

pressure

is

applia

tJ

kPa

mmHg

inHg

DISC

BRAKE

Type

Item

I

Pad

wear

limit

Minimum

thickness

N22

2 0 0

079

Rotor

repair

limit

Maximum

I

unout 0

1210

0047

Maximum

pal

allelism

0

07

0

00281

Minimum

thickness

10

5 0

413

1

3

to

0

391

Unit

mm in

AN12H

1

6

10

0631

0

15 10

0059

8

6

0

339

BRAKE

SYSTEM

Service

Oat1l

and

Specifications

TIGHTENING

TORQUE

Unit

N

m

kg

m

ft

Ib

Brake

tube flare

nut

15 18

1

5

1

8

11

13

I

Brake

hose

connector

17

20

1

72

0

t2

t4

I

Air

bleeder

valw

69 8

8

07

09

5

1

6

5

Fulcrum

fixing

bolt

7 8

10

8

0

8

11

5 8 8

0

Brake

booster

to

body

7B

10

8

OB

11

5 8 8

0

I

nput

rod

lock

nut

16

22

1

62 2

12

16

Flange

to

shell

ver

7

8

10

8 0 8

11

5 8

8

0

I

Mas

cylinder

to

broke

7

8

10

8

0 8

11

5 8 8

0

booster

I

Front

disc

per

IIXI

I

72

97

7399

53

72

bolt

I

Front

disc

rotor

fixing

36 52

3

9

5 3

28

38

bolt

Rear

disc

caliper

fixing

38

52

3 9 53

28

38

bolt

Baffle

plate

fixing

bolt

22

26

22 2 7

18

20

I

Brake

lamp

switch

lock

12 15

1

2

1

5 9

11

nut

I

3

way

connectOr

bol

t

17

20

1

7 2

0

12 14

I

NP

valve

to

body

39 49

04

0

5 2

9

3

6

BR

19

Trouble

Diagnoses

and

Corrections

BRAKE

SYSTEM

TROUBLE

DIAGNOSES

AND

CORRECTIONS

Condition

Probable

cause

Excessive

pedal

travel

Low

brake

l1uid level

or

empty

master

cylinder

reservoir

Leakage

in

master

cylinder

Deteriorated

check

valve

Air

in

system

Faulty

brake

adjustment

Excessive

lateral

play

on

disc

caused

by

loose

or worn

wheel

bearings

or

steering

parts

Spongy

pedal

Low

fluid

level

in

master

cylinder

Air

in

system

Faulty

brake

adjustment

Reservoir

filler

cap

vent

hole

clogged

SwaDen

hose

due

to

deterioration

or

use

of

poor

quality

hose

Distorted

brake

moes

or

excessively

worn

or

cracked

brake

drum

Soft

or

swaDen

caliper

seals

Use

of

a

brake

l1uid

with

too

low

boiling

point

Poor

braking

effect

Fluid

leakage

in

brake

line

Low

brake

fluid

level

or

empty

master

cylinder

reservoir

Air

in

brake

lines

Grease

oil

mud

or

water

on

pads

Deterioration

of

pads

Local

fi

t

of

pads

Pads

excessively

worn

Master

cylinder

Or

caliper

assembly

in

poor

conditions

Frozen

or

seized

caliper

pistons

on

disC

brakes

Binding

mechanical

linkage

at

brake

pedal

BR

20

Corrective

action

Fill

and

bleed

as

necessary

Test

for

source

of

leakage

by

examining

aIllmes

and

connec

tions

Overhaul

master

cYlinder

Replace

check

valve and

bleed

system

Bleed

system

Adjust

pad

to

rotor

clearance

Inspect

auto

adjuster

operation

Replace

or

adjust

faulty

parts

JoP

with fluid

and

inspect

fa

leakage

Correct

as

necessary

Adjust

pad

to

rotor

clearance

Inspect

auto

adjuster

operation

Clean

and

bleed

system

Replace

hose

and

bleed

system

Replace

faulty

parts

Drain

hydraulic

system l1ush

with

alcohol

and

replace

ail

seals

Replace

with

specified

brake

fluid

and

bleed

system

Check

master

cylinder

piping

and

caliper

for

leaks

and

repair

Fill

and

bleed

as

necessary

Bleed

system

Clean

brake

mechani

and check

for

cause

of

problem

Replace

pads

Replace

Shave

or

replace

Replace

Repair

or

replace

Disa

semble

caliper

and

free

up

a

required

Free

up

as

required

Condition

Unbalanced

brakes

Brakes

fade

Brakes

drag

BRAKE

SYSTEM

Trouble

Diagnoses

and

Corrections

Probable

cause

Improper

tire

inflation

Improper

auto

adjustment

of

pad

to

rotor

clearance

Grease

oil

mud

or

water

on

pads

Mud

in

rotor

Deterioration

of

pads

Excessive

wear

of

pads

Caliper

cylinder

in

poor

condition

Looseness

of

caliper

assembly

securing

bolts

Scored

or

out

of

round

rotor

Incorrect

adjustment

of

wheel

bearings

Incorrect

adjustment

of

wheel

alignment

Brake

l1uid

has

too

low

boiling

point

Use

of

improper

pads

Brake

rotor

is

out

of

round

Hydraulic

connections

master

cylinder

and

caliper

cylinders

are

corroded

or

damaged

Bleed

screw

is

open

Pedal

linkage

is

binding

or

output

rod

adjust

ment

is

too

long

Master

cylinder

compensator

part

is

ob

structed

Seized

master

cylinder

piston

Poor

pad

condition

Poor

caliper

cylinder

condition

Deformation

of

piston

cups

Poor

condition

of

caliper

because

of

faulty

piston

seals

Excessive

ronout

of

rotor

Hand

brake

will

not

return

Clogged

master

cylinder

return

port

Clogged

brake

lines

Incorrect

adjustment

of

wheel

bearings

Improper

pad

to

rotor

clearance

No

free

travel

in

brake

pad

return

Corrective

action

Inflate

to

correct

pressure

Readjust

Clean

brake

mechanism

and

check

for

cause

of

problem

Replace

pads

Clean

Replace

Repair

or

replace

Fasten

or

replace

Recondition

or

replace

rotor

as

required

Check

for

improper

pad

contact

with

rotor

and

grind

pad

if

necessary

Adjust

or

replace

Adjust

Drain

and

flll

system

with

approved

l1uid

Replace

Repair

or

replace

as

necessary

Repair

as

necessary

Close

screw

and

bleed

system

Lubricate

linkage

check

pedal

return

spring

for

condition

and

adjust

output

rod

as

neces

sary

Blowout

foreign

matter

with

compressed

air

Disassemble

master

cylinder

and

replace

piston

Bleed

system

Clean

and

repair

Repair

or

replace

Replace

piston

seals

Turn

rotor

on

lathe

or

replace

Check

and

repair

Clean

Check

and clean

Adjust

or

repair

Adjust

pedal

height

BR

21

SpeciafService

Tool

BRAKE

SYSTEM

Condition

Brake

chatters

Brake

squeal

Pedal

pulsates

Rear

lock

under

light

brake

pedal

force

Rear

lock

under

heavy

brake

pedal

force

Tool

number

Kent

Moore

No

GG943

10000

BR

22

Probable

cause

Groove

or

out

of

round

rotor

Loose

or

bent

support

plate

Distorted

pads

Grease

or

brake

fluid

on

pads

Dirty

or

scored

rotor

Bend

support

plate

Glazed

or

contaminated

pad

Lateral

roDout

of

brake

rotor

is

excessive

Excessive

variation

in

thickness

of

brake

rotor

surfaces

Improper

tire

pressures

Excessive

wear

of

tires

Faulty

NP

valve

Improper

tire

pressures

Excessive

wear

of

tires

Poor

front

braking

effect

Grease

oil

mud

or

water

on

pads

Excessive

wear

pads

Local

fit

pads

Master

cylinder

or

caliper

cylinder

in

poor

condition

Corrective

action

Grind

or

replace

as

required

Tighten

support

plate

bolts

to

specified

torque

or

replace

plate

Replace

as

necessary

Replace

pads

Blowout

assembly

with

compressed

air

or

refmish

rotor

Replace

faulty

unit

Grind

pad

to

eliminate

glaze

If

it

doesn

t

replace

pad

Check

with

dial

indicator

turrting disc

by

hand

If

runout

exceeds

specification

repair

or

replace

disc

Measure

around

disc

face

with

micrometer

Replace

disc

as

required

Check

and

adju

t

Check

and

replace

Replace

Check

and

adjust

Check

and

replace

Clean

or

replace

Replace

Shave

or

replace

Repair

or

replace

SPECIAL

SERVICE

TOOL

Tool

name

Flare

nut

torque

wrench

u

I

DATSUN

200SX

Model

SIlO

Series

SECTIONST

STEERING

SYSTEM

STEERING

SYSTEM

STEERING

WHEEL

AND

COLUMN

STEERING

WHEEL

STEERING

LOCK

STEERING

COLUMN

Collapsible

type

STEERING

GEAR

Model

VRB47l

POWER

STEERING

GEAR

Model

I

P S

56l

AIiID

Oil

PUMP

STEERING

LINKAGE

CONTENTS

ST

2

ST

3

ST

3

ST

3

ST

4

ST

6

SERVICE

DATA

AND

SPECIFICATIONS

GENERAL

SPECIFICATIONS

INSPECTION

AND

ADJUSTMENT

TIGHTENING

TORQUE

TROUBLE

DIAGNOSES

AND

CORRECTIONS

SPECIAL

SERVICE

TOOLS

ST

23

ST

25

ST

21

ST

21

ST

21

ST

22

ST

10

ST

19

a

@

s

i1

ll

r

I

t

lon

Steetlng

Vlbeel

1

5

3

8

5

2

21

8

DO

not

sttik

end

of

steerini

column

thaft

W

ith

a

tuu

omer

StIlldt

nO

will

dam

age

needle

bea

IID

or

co

u

U

l

shaft

fie

c

ltefu

not

to

di

m

age

cancel

pole

SId

tOd

em1M

V

1I

54

98

5

0

40

12

1

0

gnuc

de

nt11l

and

eto

s

rod

Ste

S

column

mount

OS

bracl

et

B

18

I

1

8

9

B

2

8

9

24

28

0

3

tub

haft

Steetitll

u

IY

r

S

56L

52

62

503

6

38

46

0

bOdY

tattle

Steeting

eo

umntube

Ne

ef

in

at

case

snou

d

UI

4ue

ttt

S

be

applied

to

stee1

in

co

utJ

ll

n

a

l

a

direction

Wheninsu

lins

do

not

ap

P

bendin5

fotc

e

to

tcet

n8

column

Q

31

jael

et

tube

bt1

c

101

34

44

0

35

0

35

0

45

2

5

3

141

81m

3

42

3

2

4

3

23

0

bOdy

tame

tlU

lbCl

coupUns

39

49

4

0

5

0

29

36

10

wor1

haft

teerl

nllpt

a

ternbW

Vv

l

I1L

52

62

5

3

6

3

8

46

0

bOdY

frame

c

e

r

52

62

5

3

603

38

46

1l

g

l

pte

uto

10

Il

d

pipins

1J

VI

ute

hot

d

pipins

Side

tad

bly

11

J

54

9s

5

10

0

40

12

ol

nuc

d

atm

nd

055

tad

18

98

8

0

58

12

1

0

KnUc

e

arm

and

ClOSS

tod

Side

tad

IY

29

69

3

0

1

0

22

51

to

t

n

1C

a

rm

and

ctOS

fod

00

tad

29

69

3

0

1

0

22

51

To

eaI

aun

and

idle

ann

It

i

Cl

lTI

fft

r

Wi

tj

m

1g

n

I

@

MoIti

Purl

gteaoilll

pO

SST

50

St

tlnS

meel

cOlumn

Il

d

oteerit

S

I

When

temovlng

nd

t

lling

disconnect

l

altetY

gtound

calle

Eacb

dutt

COvel

nnll

and

inatl1

fif4

be

ro

lleJ

STEERING

SYSTEM

Steering

Wheel

and

Column

STEERING

WHEEL

AND

COLUMN

STEERING

WHEEL

REMOVAL

I

Disconnect

battery

ground

cable

2

Remove

horn

pad

and

steering

wheel

nut

SST067

3

Remove

steering

wheel

using

Tool

CAUTION

Do

not

strike

end

of

steering

column

shaft

with

a

hammer

Striking

shaft

will

damage

bearing

or

column

shaft

80001

SST068

INSTALLATION

Inltall

ltaering

wheel

in

the

reverse

order

of

removal

Observe

the

following

instructions

I

Apply

grease

to

sliding

portions

SST069

2

Install

steering

wheel

on

column

shaft

in a

straight

ahead

position

SSTU70

3

Tighten

steering

wheel

nut

l

J

n

51

N

m

13B

52

kg

m

27

38

ft

lb

SST071

4

After

installing

steering

wheel

bJm

it

clockwise

and

counterclock

wise

checking

for

catch

or

drag

Also

check

horn

operation

STEERING

LOCK

REMOVAL

Before

removing

steering

lock

dis

connect

battery

ground

cable

I

Remove

steering

wheel

using

Tool

8T27180001

2

Remove

steering

column

shell

cover

y

1

Upward

Igi

Ii

SST072

3

Break

self

shear

type

screws

with

a

drill

or

other

appropriate

tool

4

Remove

screws

and

disconnect

steering

lock

Self

shear

type

screw

Screw

SST073

INSTALLATION

I

Align

steering

lock

hole

in

steering

column

tube

with

mating

portion

of

steering

10cL

2Install

screws

and

self

shear

type

screws

and

then

cut

off

self

shear

type

screw

heads

V

Self

shear

screw

SST074

ST3

Steering

Wheel

and

Column

STEERING

SYSTEM

STEERING

COLUMN

Collapsible

tYPe

Steering

column

asRmbly

Never

in

any

case

should

undue

stress

be

applied

to

steering

column

in

axial

direction

When

installing

do

not

apply

bending

force

to

steering

column

fJ

37

51

3 8

S

Steerinj

k

Cn

tte

Steerins

eel

oolw

Jacket

tube

bracket

fJ

3

4 4

4

0

35

0

45

2 5

To

dash

panel

Cnuplinj

Plat

j

fJ

39

49

4 0

5

0 29

36

To

worm

shaft

@

N

m

kj

rn

ft

Jb

SST125

REMOVAL

I

Disconnect

battery

ground

cable

2

Remove

bolt

securing

stub

shaft

or

worm

shaft

and

universal

joint

or

rubber

coupling

al

SST076

3

Remove

steering

wheel

Refer

to

Steering

Wheel

ST

4

S

eerillj

oolumn

bly

tiJ

13 18

13

1

8

9

13

To

instrument

panel

16

4

Remove

steering

column

shell

covers

5

Remove

combination

switch

as

sembly

Steerillj

oolumn

aaembly

Column

band

Z32

38

3 3

3

9

24

28

To

stub

shaft

Modell

P

S

56L

only

6

Remove

heater

duct

from

dash

panel

side

SST078

I

7

Remove

jacket

tube

bracket

from

dash

panel

J

SST079

8

Remove

bracket

column

mounting

p

j

I

or

SST1

39

9

Draw

out

steering

column

assem

bly

from

room

side

INSTALLATION

Install

steering

column

in

reverse

order

of

removal

I

Remove

column

band

and

then

install

centering

band

l

P

S

56L

equipped

model

only

@

Centering

band

SST126

STEERI

NG

SYSTEM

Steering

Wheel

and

Column

2

Set

wheels

in

a

straight

ahead

position

3

Fit

steering

column

assembly

on

to

stub

shaft

or

worm

shaft

Carefully

install

so that

punch

mark

at

top

ond

of

column

haft

fece

upward

4

Tighten

stub

shaft

or

worm

shaft

securing

bolts

temporarily

to

upport

upper

side

of

steering

column

assem

bly

5

Tighten

column

mounting

bracket

temporarily

6

After

sliding

jacket

tube

bracket

to

dash

panel

tighten

nuts

to

retain

it

Iil

3

4 4

4

N

m

0

35

0

45

kg

m

2 5 3 3

ft

Ibl

7

Tighten

stub

shaft

or

worm

shaft

securing

bolts

and

then

tighten

column

mounting

bracket

securing

bolts

JJ

Worm

shaft

to

coupling

Model

VRB4711

39 49

N

m

4

0 5 0

kg

m

29

36

ft

Ibl

Stub

shaft

to

universal

joint

Modell

P S

56Ll

32 38

N

m

3 3 3 9

kg

m

24

28

ft

Ibl

Column

mounting

bracket

13

18

N

m

1

3

1

8

kg

m

9

13

ft

Ibl

CAUTION

I

Mike

Rife

that

Iny

undue

strea

is

not

Ipplied

to

rubber

coupling

b

To

Ivoid

dlmlging

bolt

or serrl

tions

align

groove

in

stub

shaft

or

worm

shaft

with

bolt

hole

in

rubber

coupling

9

Remove

centering

band

and

then

install

column

band

l

P

S

56L

equipped

model

only

10

Install

steering

wheel

Refer

to

Steering

Wheel

8

After

installation

make

sure

that

steering

wheel

turns

smoothly

INSPECTION

I

When

steering

wheel

can

not

be

rotated

smoothly

check the

steering

column

for the

following

matters

and

replace

faulty

parts

I

Check

column

bearings

for

darn

age

or

unevenness

If

so

lubricate

with

recommended

multi purpose

grease

or

replace

with

a

new

one

as

steering

column

assembly

2

Check

jacket

tube

for

deforma

tion

or

breakage

and

replace

if

neces

sary

3

Check

column

spring

and

replace

if

damaged

or

weakened

2

When

the

car

comes

into

light

collision

check

the

following

parts

and

replace

if

necessary

I

Jacket

tube

Measure

dimension

L

When

jacket

tube

is crushed

dimension

L

is

reduced

t

L1

LL

F

J

Column

length

L

Model

VRB47L

179

mm

7

05

in

ModoII

P

S

56L

180

mm

7

09

in

SSTOBO

2

Column

mounting

bracket

Make

sure

column

mounting

bracket

touches

block

Standard

B

dimension

is

0

mm

0

in

When

jacket

is crushed

dimension

B is

increased

jg

ST835

ST

5

Steering

Gear

Model

VRB47L

STEERING

SYSTEM

m

STEERING GEAR

Model

VRB47L

Lo

5

314

25 32

181 231

Oil

I

Removed

oil

seal

must

not

be

used

agJ

l1L

Adjustins

Pilla

When

adjust

wonn

bearing

preload

use

it

BaD

nut

and

worm

assembly

Be

a

rcful

not

to

allow

ball

nut

to

run

down

to

either

end

of

worm

The

end

ofba1l

guides

will

be

lamag

if nut

is rotated

until

it

stops

at

the

em

of

wonn

Do

not

detach

ball

nut

from

worm

shaft

assembly

If

necessary

replace

ball

nut

and

worm

assembly

with

sector

shaft

Lock

nut

cp

29

3913

0

4

0 22

29

F

d1erpl

l1

J

15 25

1

5

2 5

11

18

SeetorsIWlCOV

v

to

0

rt

J

Goskel

Adjustm

shim

Refer

to

S

O

S

Sector

shar

adjusting

saew

0

When

adjustirj

backla

h

use

it

Sector

maft

Steering

gear

housing

147

15

94

108

REMOVAL

AND

INSTALLATION

Worm

shaft

to

rubber

couplin

I

J

39

49

4 0

5 0

29

36

Align

the

groove

in

worm

shaft

with

the

bolt

hole

in

rubber

coupling

flange

yoke

and

prcssooupling

bolt

through

the

undercut

section

of

wonn

shaft

Undercut

section

1

Sector shaft

to

idler

arm

I

J

127 147

13

15

94

108

Remove

gear

arm

Sf29020001

Install

gear

arm

Align

four

grooves

of gear

arm

serrations

with

four

projections

of

sector

shaft

serrations

and

install

and

tighten

lock

washer

and

nut

ST

6

I

J

N

m

q

m

ft

Ib

SST081

Gear

housing

to

frame

1

J52

62

5

36 3

38

46

I

J

N

m

q

m

ft

Ib

SST082

DISASSEMBLY

Before

disassembling

by

hand

make

sure

external

is

clean

and free

from

dust

and

dirt

and

thoroughly

drain

gear

fluid

by

removing

filler

plug

1

Place

steering gear

in a

vice

using

Tool

KV48100301

in

place

2

Set

worm

gear

in

a

straight

ahead

position

ST725

3

Remove

sector

shaft

cover

fixing

bolts

KV48100301

4f

L

4

Remove

sector

shaft

with

sector

shaft

cover

CAUTION

a

When

pulling

sector

shaft

out

be

careful

not

to

damage

oil

seal

or

associated

parts

b

00

not

remove

sector

shaft

needle

bearings

from

steering

gear

housing

If

necessary

replace

gear

housing

assembly

STEERING

SYSTEM

Steering

Gear

Model

VR847L

7fY

0

SST083

5

Remove

sector

shaft

cover

from

sector

shaft

6

Remove

sector

shaft

oil

seal

if

necessary

SST084

7

Loosen

adjusting

plug

lock

nut

using

Tool

SST085

8

Draw

out

worm

gear

with

worm

bearing

CAUTION

a

Be

careful

not

to allow

ball

nut

to

run

down

to

either

end

of

worm

Ends

of

ball

guides

will

be

damaged

if

nut

is

until

it

stops

It

end

of

worm

b

Do

not

detach

ball

nut

from

worm

shaft

assembly

If

necessary

replace

entire

unit

as

en

assembly

c

Do

not

remove

sector

shaft

needle

bearings

from

steering

gear

housing

If

necessary

replace

entire

gear

housing

IS

an

asSembly

SST086

9

Remove

oil

seal

from

adjusting

plug

using

Tool

ST35322000

SST087

ASSEMBLY

AND

ADJUSTMENT

Before

assembling

and

adjusting

by

hand

meke

ure

each

pert

i

elean

and

lubricate

with

geer

fluid

Fill

paee

between

Iing

lip

of

new

ctor

h

ft

and

adju

ting

plug

oil

1

with

rlICOmmendad

multi

purpose

grease

ST7

Steering

Gear

fModel

VR847U

STEERING

SYSTEM

Worm

bearins preload

1

Fit

worm

gear

assembly

with

worm

bearing

in

gear

housing

SST088

2 Install

adjusting

plug

using

Tool

KV48101400

3

Adjust

worm

bearing

preload

using

Tools

CAUTION

Always

adjust

worm

bearing preload

by

turning

adjusting

plug

in

tighten

direction

Rotate

worm

shaft

a

few

turns

in

both

directions

to

settle

down

worm

bearing

and

measure

preload

Worm

bearing preload

with

oil

sean

0

39

0

59

N

m

40 60

kg

em

3

5

2

lb

4

Apply suitable

liquid

sealant

around

lock

nut

inner

surface

Apply

sealant

Adj

usting

plug

Lock

nut

SST090

ST

8

5

Tighten

lock

nut

using

Tooh

KV48101500

KV48101400

SST091

6

After

tightening

lock

nut

check

worm

bearing

preload

to

make

sure

it

is

within

specification

Sector

shaft

end

play

Select

suitable

adjusting

shim

and

adjust

end

play

between

sector

shaft

and

adjusting

screw

Sector

shaft

adjusting

screw

shims

Refer

to

S

O

S

Adjusting

him

Upper

I

sector

cover

side

Sector

shaft

end

play

O

Ol

0

03

mm

10

0004

0

0012

n

Steering

gear

preload

I

Press

oil

seal

to

steering

gear

housing

using

Tool

Before

pressing

oil

seal

coat

seal

contacting

face

of

oil

seal

with

gear

fluid

2

Install

sector

cover

oil

adjusting

screw

with

sector

shaft

Adjusting

screw

SST094

3

Set

worm

gear

in a

straight

ahead

position

4

Insert

sector

shaft

and

sector

cover

assembly

with

gasket

into

gear

housing

Carefully

insert

sector

shaft

in

place

using

care

not to

scratch

oil

seal

5

Tighten

sector

cover to

gear

housing

f

1iJ15

25

N

m

11

5

25

kg

m

11

6

Pour

recommended

gear

oil

into

assembly

through

flller

hole

and

install

ftller

plug

Specified

refill

capaeity

Approximetely

0

28

liter

5

8

US

pt

112

Imp

pt

7

Tighten

adjusting

screw

so

that

gear

preload

is

within

specification

CAUTION

Always

adjust

steering

gear

preload

by

turning

adjusting

screw

in

tighten

direction

Rotate

worm

gear

a

fsw

turn

in

both

directions

to

settle

down

steering

gear

and

then

measure

steering

gear

preload

in a

streight

lhead

position

LScrewdriver

J

Steerinlllilear

total

preload

with

oil

1

Less

than

1

23

N

m

12

5

kg

c

m

10

9in

I

b

04

0 6

N

m

4 6

kll

cm

3

5 5

2

in

Ib

higher

than

at

worm

bearing

praia

SST097

8

If

found

to

be

outside

of

above

steering

gear

preload

specifications

readjust

adjusting

screw

until correct

steering

gear

preload

is

obtained

INSPECTION

Wash

clean

all

the

disassembled

parts

in

solvent

and

check

for

condi

tion

STEERING

SYSTEM

Steering

Gear

Model

VR841Li

Sector

shaft

Check

gear

tooth

surface

for

pitting

burrs

cracks

or

any

other

damage

and

replace

if

necessary

2

Check

sector

shaft

for

distortion

on

its

serration

and

replace

if

neces

sary

Also

check

gear housing

for

deformation

Steering

worm

assembl

I

Inspect

ball

nut

gear

tooth

sur

face

and

teplace

if

pitting

burrs

wear

or

any

other

damage

is

found

2

Ball

nut

must

rotate

smoothly

on

worm

gear

If

found

too

tight

assem

bly

should

be

replaced

Check

rotation of

ball

nut

as

follows

I

Move

ball

nut

to

either

end

of

worm

gear

and

gradually

stand

worm

shaft

and

ball

nut

assembly

until

ball

nut

moves

downward

on

worm

gear

under

its

own

weight

Downward

J

own

weight

SST098

2

If

ball

nut

does

not

move

freely

over

entire

stroke

replace assembly

Be

careful

not

to

damage

ball

nut

guide

tuba

whi

Ie

check

is

being

made

CAUTION

Be

caraful

not

to allow

ball

nut

to

run

down

to

either

end

of

worm

Beulng

I

Inspect

worm

bearing

for

wear

pitting

or

any

other

damage Replace

as

requried

When

replacing

worm

bearing

replace

it

as

8

set

of

bearing

and

outer

race

2

If

sector

shaft

needle

bearings

are

worn

or

damaged

replace

as

an

as

sembly

of

gear

housing

and

bearings

Oil

eal

Discard

any

oil

seal

which

has

once

been

removed

Replace

oil

seal

if

sealing

lip

is

deformed

or

cracked

Also

discard

oil

seal

if

spring

is

fa

tigued

or

dislocated

ST

9

Power

Steering

lear

Model

I

P S

56L

andOil

PUTflP

STEERING

SYSTEM

POWER

STEERING

GEAR

Model

I

P

S

56L

AND

OIL

PUMP

DESCRIPTION

Po

r

steering

s

stem

The

power

steering

gear is

licensed

I1Y

ZF

company

in

West

Germany

The

integral

power

steering

unit

is

a

gear

housing

into

which

a

control

valve

2

pool

valve

type and

power

cylin

der

are

built

compactly

The

major

Reservoir

tank

cfl 2 9

4

90 3

0

5 2

2

36

components

are

as

folloW

Oil

pump

Reservoir

tank

Power

steering

gear

Oil

piping

cfl

32 38

3 3 3

9 24

To

stub

shaft

Gear

assembly

cfl

49 69

5 0 7

0

36

51

To

each

hoses

cfl

52

6i

5 3 6 3

38

46

To

body

frame

High

pressure

hose

and

piping

cfl

2 9 4 9 0 3 0

52 2

3 6

To

suspension

aossmember

cfl

N

m

kg

m

ft

tb

Power

steering

gear

The

integral

power

steering gear

is

an

accurate

oil

pressure

mechanism

In

disassembling

it

be

careful

to

keep

dust

iron

powder

and

other

foreign

particles

out

of

the

gear

housing

Only

the

sealing

parts

of

the

gear

assembly

can

be

replaced

The

remain

ing

parts

must

be

replaced

as

an

gear

assembly

ST10

CAUTION

a

The

parts

which

can

be

disassem

bled

are

strongly

J

and

never

disassemble

other

parts

than

the

specified

ones

If

parts

not

indicated

in

the

manual

are

also

d

Ied

replace

the

assembly

instead

of

bling

those

parts

b

Disassembly

of

integral

power

steer

ing

gear

should

be

performed

in

a

place

l

5

dean

as

pssible although

a

dust

preventing

device

is

not

reo

quired

SST12T

Co

Should

disassembly

of

integral

power

steering

gear

remain

un

finished

for

any

reason

indicate

it

as

Half

Disassembled

and

COVllr

parts

with

a

clean

cover

d

Hands

should

be

cleaned

immedi

ately

before

disassembly

e

Do

not use a

rag

Be

sure

to

use

nylon

or

paper

cloth

f

Be

sure

to

follow

procedures

and

cautions

indicated

in

the

Service

Manual

STEERING

SYSTEM

PowerSteeringGear

Model

I

P S

56L

andOilPump

Breather

screw

il

6

9

8 8 0

7

Breather

cap

Sector

shaft

adjusting

screw

Sector

shaft

Worm

end

nlve

mbly

With

interm

t

i

te

cov

l

ru

2

7

3 3

20

24

0il1e3

1

In

rear

cover

Once

removed

must

not

be

used

again

il

N

m

Icg

m

ft

lb

011

pump

and

r

volr

tank

Malfunctioning

Replace

as

an

oil

pump

assembly

I

O

ring

lock

nut

cf

il

28

34

2 9

3

5

21

25

Copper

washer

@

il

26

32

J

V

2

7 3 3

20

fill

@

24

O

rins

Between

sector

cover

to

gear

housing

o

Special

washer

Small

OUseal

0

Special

washer

La

IJle

DUst

sea1

apring

ospring

washer

Nut

I

tY

i

l127

147

13

15

94

108

To

gear

arm

and

sector

shaft

SST033

STll

REMOVAL

Power

Steering

Gear

Model

I

PS

56L

and

Oil

Pump

STEERING

SYSTEM

Before

removing

clean

exterion

of

gear

housing

and

oil

pump

with

steam

and

dry

with

compressed

air

Steering

gear

Joint

to

stub

shaft

t

J

32

38

3 3 3 9

24

28

Sector

sIWI

to

sou

ann

t

J

127

147

13

15

94

108

i

Install

gear

arm

Align

fOUI

grooves

of

gear

arm

serrations

with

four

projections

of

sector

shaft

serrations

and

install

and

tighten

lock

washer

and

nut

Oil

pump

resevoir

tank

and

each hose

1

Remove

air

duct

at

air

cleaner

2

Loosen

oil

pump

pulley

lock

nut

Turn

belt

adjusting

bolt

counter

clockwise

3

Remove

oil

pump

belt

4

Loosen

not

remove

hoses

at

pump

ST

12

5

Remove

oil

pump

and

reservoir

tank

51

j1

Plug

openings

of

gear

housing

and

securely

locate

hose

connectors

at

a

position

higher

than

oil

pump

and

cover

with

rag

Be

extremely

cucful

to

prevent

entry

of

foreign

matter

into

hoses

through

connectou

t

J

N

m

kg

m

fHb

R

g

points

SST128

6

Disconnect

hoses

from

oil

pump

7

Remove

oil

pump

brackets

and

other

brackets

from

engine

8

Unfasten

hose

clamps

and

remove

hoses

from

suspension

crossrnember

INSTAUATION

AND

ADJUSTMENT

In

tall

steering

gear

in

the

reverse

order

of

removal

STEERING

SYSTEM

Power

Steering

Gear

Model

I

PS

56LJ

and

Oil

Pump

Fluid

level

I

Check

fluid

level

in

oil

pump

assembly

with

dipstick

whether

fluid

level

is

on

HOT

side

at

normal

operat

ing

temperature

or

on

COLD

side

when oil

is

cold

1

llllllm

Add

IOK

4

Q

OK

SST133

Do

not

overfill

with

fluid

Nanna

operating temperature

i

60

to

8o

C

140

to

1760F

When

running

engine

make

sure

fluid

level

variations

in

opening

oil

pump

ere

Ie

than

2

mm

0

08

in

2

Check

fluid

level

and

leakage

Recommended

fluid

is

Automatic

Transmission

Fluid

Oexron

Type

Refer

to

Seetion

MA

for

Recom

mended

Lubricant

Fluid

capacity

with

oil

pump

reservoir

tank

each

hose

and

steering

gear

assembly

Approximately

1

2

1

4

US

qt

1

118

Imp

qt

Pump

belt

edJustment

Adjust

oil

pump

belt

tension

Pump

belt

adjusting

bolt

Thumb

pressure

911Nj10kg

221b

71

I

Lock

nut

G

IJ

I

Oil

pump

belt

deflection

8

12

mm

10

31

OA7

in

SST134

Check

fluid

leekege

I

Run

engine

at idle

speed

or

1

000

rpm

2

Turn

steering

wheel

to

right

to

left

several

times

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

Intermediate

cover

Adjusting

screw

lock

nut

Sector

shaft

oil

seal

Sector

cover

O

ring

Oil

pressure

line

connectors

e

Oil

pump

and

reservoir

tank

CAUTION

Do

not

hold

steering

wheel

at

lock

position

for

more

thin

fifteen

seconds

It

I

time

Hydreulic

system

check

To

determine

whether

problem

is

in

steering

gear

or

oil

pump

measure

operating

pressure

Before

conducting

hydraulic

system

test

carefully

check

belt

tension

and

condition

of

driving

pulley

Tires

must

be

inflated

to

normal

pressu

reo

I

Check fluid

level

and

fluid

leak

age

adding

oil

if

necessary

2

Run

engine

Make

sure

temperature

of

flui

d

in

pump

rises

to

60

to

800

C

140

to

1760

F

with

a

tamperature

indicator

3

Stop

engine

4

Set

Tool

Gauge

must

be

between shut

fl

valve

and

oil

pump

Pressure

gauge

calibrate

9 807

kP

100

kg

em2

1

422

psi

To control

t

valve

Y

To

oil

pump

outlet

f

STi7091000

Shut

off

valve

SST036

5

Open

shut

off

valve

at

Tool

ST27091000

6

Check

fluid

level

adding

fluid

if

necessary

7

Run

engine

at

idle

for

3

to

5

seconds

8

Stop

engine

and

check

fluid level

adding

fluid

if

necessary

9

Run

engine

and

check

fluid

level

again

adding

oil

if

necessary

10

Turn

steering

wheel

fully

in

left

or

right

until

fluid

reaches

operating

temperature

Be

sure

that

all

connections

are

tight

Expel

any

air from

system

II

Slowly

close

shut

off

valve

with

steering

wheel

fully

turned

in left

or

right

and

lightly

touch

wheel

stopper

CAUTION

Do

not

close

shut

off

valve

for

more

thin

fifteen

seconds

as this

would

abnormally

increase

lubricant

tem

perature

and

cause

undue

pump

weir

Wilh

valve

fully

closed

pump

pres

sure

should

be

at

maximum

Normal

preuure

About

5

394

kPa

55

kg

cm2

782

psi

at

idling

ST

13

Power

Steering

Gear

Model

I

PS

56LJ

and

Oil

Pump

STEERING

SYSTEM

12

If

pressure

increases

beyond

upper

limit

pressure

relief

valve

in

oil

pump

is

not

functioning

properly

Replace

as

oil

pump

assembly

13

If

with

shut

offvalve

fully

closed

pressure

drops

the

problem

is

in

pump

Replace

as

oil

pump

assembly

pump

assembly

After

checking hydraulic

system

add

fluid

as

necessary

then

complete

ly

bleed

air

out

of

system

Bleeding

h

draullc

s

stem

I

Raise

front

end

of

car

until

wheels

clear

ground

2 Run

engine

Make

lure

temperature

of

fluid

in

pUmp

rises

to

60

to

BOO

C

140

to

176

o

F

with

B

temperature

indicator

3

Check

fluid

level

adding

fluid

if

nece

sary

4

Run

engine

for

3

to

5

seconds

5

Stop

engine

adding

fluid

if

nes

sary

6

Quickly

turn

steering

wheel

all

the

way

to

right

and

left

ten

times

end

lightly

touch

whee

stoppen

7

Check

fluid

level

adding

fluid

if

necessary

8

Start

engine

at

idle

Repeat

steps

4

through

8

until

air

will

be

bled

from

pump

9

With

steering

wheel

fully

turned

to

left

open

bleeder

screw

to

expel

air

and

then

tighten

bleeder

screw

ST

14

I

SST137

Operation

should

be

perfonned

making

sure

that

fluid

level

is

kept

wi

in

specified

li

mit

Repeat

this

operation

until

air

bleeding

is

completed

10

If

air

cannot

be

bled

completely

in

steps

1

through

9

proceed

as

fol

lows

I

With

engine

runing

at

1

000

to

1

500

rpm

repeat

step

9

2

Turn

steering

wheel

to

right

and

left

from

lock

to

lock

five

to

ten

times

Carefully

check

fluid

leakage

with

steering

wheel

held

at

each

lock

position

for

five

seconds

CAUTION

00

not

hold

steering

wheel

at

lock

position

for

more

than

fifteen

seconds

at

a

time

Steering

wheel

turning

torque

check

I

Park

car

on

a

level

dry

surface

and

set

parking

b

rake

firmly

2

Bring

power

steering

fluid

up

to

adequate

operating

temperature

Ap

proximately

60

to

80

C

140

to

1760FII

It

is

easy

to

bring

power

steering

fluid

up

to

adequate

operating

tern

perature

by

idling

engine

and at

the

same

time

turning

steering

wheel

from

left

to

right

for

about

two

minutes

Alternatively

drive

car

several

miles

Tires

must

be

inflated

to

normal

pressure

3

Check

steering

wheel

turning

tor

que

when

steering

wheel

has

been

turned

3600

from

straight

ahead

posi

tion

Steering

wheel

turning

force

29

4

34

3

N

3 0 3 5

kg

66 7 7

Ib

at

circumference

of

steering

wheel

SST13B

INSPECTION

AND

ADJUSTMENT

Wash

dean

all d

bled

parts

in suitable

cleaning

solyent

and

ch k

thejr

condition

Check

Sealing

portion

Adjusting

screw

nut

O

ring

Sector

shaft

cover

O

ring

Sector

sl1aft

oil

seals

Rear

housing

oil

seal

Intermediate

cover

Q

rings

Discard

any

oil

seal

and

O

ring

which

have

once

been

removed

Replace

oil

seal

and

O

ring

if

sealing

surface

is

deformed

or

cracked

Steering

gear

turning

torque

measurement

I

Measure

turning

torque

at

3600

position

I

Install

steering

gear

on

Tool

SST040

2

Turn

stub

shaft

all

the

way

to

right

and

left

several

times

3

Measure

turning

torque

at

3600

position

from

straight

ahead

position

using

Tool

4

m

Stub

shaft

can

be

turned

by

wrap

ping

vinyl

tape

around

serration

area

of

stub

shaft

and

fitting

wrench lOcket

If it

is

beyond specification

gear

must

be

replaced

as

an

assembly

2

Measure

turning

torque

at

straight

ahead

position

I

Set

worm

gear

in a

straight

ahead

position

Straight

ahead

position

is

8

position

where

stub

shaft

is

turned

two

turns

by

450

from

lock

position

2

Measure

turning

torque

using

Tool

Turning

torque

at

streight

hd

position

il

0

10

0

39

N

m

1

4

kg

cm

09

3 5

in

lb

higher

than

t

3600

LJJ

5

After

adjustment

is

completed

tighten

lock

nut

STEE

ING

SYSTEM

Power

Steering

Gear

Model

I

P S

56LJ

and

Oil

Pump

I

il

28 34

N

m

12

9

35

kg

21

25

h

Ibl

SST043

Measure

turning

torque

If

they

are

not

within

specifications

replace

gear

assembly

DISASSEMBLY

Before

disassembly

measure

turn

ing

torque

If

they

are

not

within

specifica

tions

replace

steering

gear

assembly

CAUTION

Each

oil

sealing

parts

dust

seal

special

washers

and

snap

ring

once

removed

must

not

be

used

again

AdJusting

screw

lock

nut se

1

Remove

adjusting

screw

lock

nut

and

replace

a

ring

O

mg

Lock

nut

Copper

washer

SST044

Sector

sh

ft

011

se

1

I

Install

steering

gear

on

Tool

KV48l00301

2

Set

stub

shaft

in

a

straight

ahead

position

Straight

ahead

position

is

8

position

where

stub

shaft

is

turned

two

turns

by

450

from

lock

position

3

Disconnect

sector

shaft

cover

bolt

Do

not

loosen

adjusting

screw

lock

nut

Do

not

turn

lock

nut

unless

neces

sary

otherwise

it

will

damage

O

ring

resulting

in

an

oil

leak

J

4

Draw

out

sector

shaft

Knock

out

end

of

sector

shaft

approximately

20

mm

0

79

in

20mm

0

79

nl

SST046

5

Connect

a

roll

of

plastic

fIlm

to

sector

shaft

Plastic

film

Thickness

0

1

mm

0

004 in

Length

x

width

200 x

200

mm

7

87 x

7

87 in

1

Plastic

film

SST065

ST

15

Power

Steering

Gear

Model

I

P

S

56LJ

end

Oil

Pump

STEERING

SYSTEM

6

PuiI

out

sector

shaft

by

harid

Attach

plartie

film

to two

bearings

locat

ed

inside

gear

housing

while

simuttaneously

pulling

out

sector

shaft

so

that

bearings

will

not

drop

into

housing

7

Remove

snap

ring

fs

SSTQ47

8

Remove dust

seal

special

wash

ers

and

oil

seal

Apply

blade

of

screwdriver

to

oil

seal

I

ightly

so

that

it

will

not

damage

inner

side

of

gear

housing

0

Special

washer

A

Smail

n

Oil

sea

L4i

d

Special

ru

lL

B

Dustseal

w

snapring

SST048

9

Remove

a

ring

SST049

ST

16

Rear

housing

seal

Install

gear

on

Tool

KV48l00301

in a

vise

2

Loosen

not

remove rear cover

bolts

ST697

3

Turn

sector

shaft

clockwise

slight

ly

to

raise

intermediate

cpver

through

piston

Q

g

I

J

t

I

SST050

4

Turn

stub

shaft

counterclockwise

and

place

piston

worm

gear

in

its

straight

ahead

position

S

Remove

sector

shaft

Refer

to

Seetor

Shalt

Seal

for

disas

sembly

6

Remove

rear

cover

bolts

7

Pull

out

rear

cover

intermediate

cover

with

worm

gear

assembly

ST700

CAUTION

a

When

worm

assembly

is

removed

piston

may

turn

and

come

off

under

iU

own

weight

Hold

piston

to

prevent

it

from

turning

If

piston

to

intermediate

cover

clearance

exceeds

45

mm

1

77

in

by

looseninll

recin

ulating

ball

will

be

out

of

groove

of

worm

do

not

reinstall

piston

but

replace

the

en

tire

assembly

b

Take

care

not

to

damage

tellon

ring

at

piston

end

wilen

removing

8

Remove

rear

cover

turn

worm

as

sembly upside

down

and

lightly

tap

stub

shaft

end

on

top

of

workbench

CAUTION

Do

not

strike

shaft

with

a

hammer

or

pry

it

with

a

screwdriver

ST701

9

Remove

rear

housing

oil

seal

ST702

STEERING

SYSTEM

Power

Steering

Gear

Model

I

P S

56LI

and

Oil

Pump

10

Remove

O

ring

on

both

sides

of

intermediate

cover

Intermediate

cover

SST051

ASSEMBLY

AdJusting

screw

lock

nut se

1

Insert

new

a

ring

into

adjusting

screw

lock

nut

Before

inserting apply

a

thin

coat

of

vaseline

to

O

ring

Inort

C

ring

to

make

sure it

fits

into

groove

r

o

ring

L

Adjusting

screw

lock

nut

SST052

Re

r

housing

se

1

I

Install

rear

housing

oil

seal

using

Tool

Before

installing

oil

seal

apply

recommended

multi

purpose

greM

to

lips

SST053

2

Install

O

rings

on

both

sides

of

intermediate

cover

with

new

ones

Apply

a

thin

coat

of

vaseline

to

new

Crings

prior

to

their

installa

tion

Be

careful

not to

install

wrong

O

rings

as

some

of

them

resemble

in

size

t

J

SST054

3

Fit

rear

cover

onto

intermediate

cover

with

worm

gear

assembly

CAUTION

a

Do

not

tilt

ball

bearing

b

Make

sure

that

O

rings

are

not

pro

truding

or

extruding

ST705

4

Insert

worm

gear

assembly

with

rear

cover

and

intermediate

cover into

gear

housing

CAUTION

a

Be

careful

that

teflon

ring

at

piston

end

is

not

damaged

during

insertion

of

gear

housing

b

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

on

corner

of

sector

hole

Be

sure

that

teflon

ring

settles in

its

correct

position

5

Gradually

tighten

rear

housing

bolts

in a

criss

cross

fashion

Crisscross

fashion

SST055

ST

17

Power

Sreering

Gear

Model

I

P

S

56LJ

and Oil

Pump

STEERING

SYSTEM

CAUTION

L

If

bolts

are

tightened

while

wonn

assembly

is

tilted

inner

seals

will

be

dam8lll

d

Tighten

bolts

while

assembly

is

level

If wonn

assembly

is

tilted

stub

shaft

s

turning

torque

will

be

in

creased

b

Check

O

rings

to

ensure

lhat

they

do

not

protrude

or

extrude

6Install

sector

shaft

into

gear

hous

ing

Refer

to

Sector

Shaft

Oil

Seal

for

assembly

7

Check

turning

torque

Refer

to

Inspection

and

Adjust

ment

Sector

shaft

00

se

1

I

Press

new oil

seal

and

dust

cover

using

Toot

When

ir

stalling

be

lure to use

new

oil

seal

dust

cover

and

special

washen

Before

installing

apply

a

thin

coat

of

vueline

to

new

oil

seal

and

dust

seal

Special

washer

Small

00

SST056

ST

18

2 Install

a

new

snap

ring

into

gear

housing

CAUTION

a

Turn

soap

ring

to

make

sure

it

fits

into

groove

b

Always

inslllll

snap

ring

with

its

rounded

edges

facing

oil

seal

R

face

Imide

snap

ring

Outside

I

talling

snap

ring

SST058

3

Fit

new

O

ring

into

sector

shaft

cover

Before

installing

apply

a

thin

coat

of

vaseline

to

O

ring

Make

certain

that

O

ring

is

installed

properly

and

not

damaged

by

sec

tor

shaft

ST695

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

Q

G

ST696

5

Wrap

vinyl

tape

around

serration

area

of

sector

shaft

The

reason

is

that

vinyl

tape

pre

vents

oil

seal

lip

from

being

damaged

during

insertion

6

Gradually

insert

sector

shaft

into

gear

housing

being

careful

not

to

dam

age

oil

seal

When

insening

seetor

shaft

into

gear

housing

remove

plastic

film

8e

careful

not to

drop

bearings

into

gear

housing

7

Tighten

sector

cover

bolts

IIi

24ft lb

8

Check

steering

gear

turning

torque

Refer

to

Inspeetion

and

Adjust

ment

If

there

is

8

great

difference

be

tween

values

of

turning

torque

be

fore

and

after

disassembly

it

must

be assumed

that

some

new

problem

has

occurred

It

will

be

nece

ary

to

replace

the

entire

assembly

Outer

ball joint

IiJ

78 98

80

10

0

58

72

CroSlrod

Front

@

Multil

urpose

greasing

points

IiJ

N

m

ks

m

ft

Ib

REMOVAL

AND

INSTALLATION

L

Jack

up front

of

car

and

support

it

n

the

safety

stands

2

Block

rear

wheels

with

chocks

3

Remove

gear

arm

using

tool

Gear

housing

Gear

arm

n

SST0100

4

Remove

idler

ann

assembly

STEERING

SYSTEM

Steering

Linkage

STEERING

LINKAGE

Side

rod

adjusting

bar

Inner

ball

joint

IiJ

31

42

I

3 2

4

3

23

31

To

body

frame

@

IiJ

29

69

3 0

7 0

22

51

To

cros

rod

Gear

ann

J

Cotter

PinV

Side

rod

assembly

IiJ

Model

vRB47L

29 69

3 0 7 0

22

51

To

knuckle

arm

and

cross

rod

Modell

P

S

56L

54

98

5 5

10

0

40 72

To

knuckle

arm

and

cross

rod

SST010

5

Remove

side

rod

from

knuckle

ann

using

Tool

STa8l

BaD joints

Be

careful

not

to

damage

dust

cover

Tighten

nut

to

the

specified

torque

and

align

the

cotter

hole

in

the

tightening

direction

Be

sure

to insert

new

cotter

and

bend

it

ecurely

Side

rod

adjusting

bar

When

adjusting

toe

in

use

it

Make

sure

that

side

rod bar

is

crewed

in socket

25

mm

0

98

in

OJ

more

SST099

6Install

steering

linkage

in

the

reverse

order

of

removal

G

J

Gear

arm to

seetor

shaft

127 147

N

m

13 15

kg

m

94

108lt

lb

Idler

arm

to

body

frame

31

42

N

m

3 2

4

3

kg

m

23

31lt

lbl

Side

rod

to

knuckle

arm

Model

VRB47L

29

69

N

m

13

0 7 0

kg

m

22

51lt

lb

Modell

P S

56L

54 98

N

m

5 5

10

0

kg

m

40 72

ft

Ib

7

After

installing

steering

linkage

check wheel

alignment

and

if

neces

sary

adjust

Refer

to

Seetion

MA

for

adjust

ment

ST

19

Steering

Linkage

STEERING

SYSTEM

DISASSEMBLY

Side

rod

I

Remove

both

side

rods

from

cross

rod

using

Tool

HT72520000

2

Separate

outer

and

inner

ball

joints

from

side

rod

adjusting

bar

Inner

ball

joint

Lock

nut

SST102

Idler

arm

assembly

Remove

nut

and

separate

each

part

e

Nut

o

BU5hing

Idler

ann

SST013

ASSEMBLY

Assemble

steering

linkage

in the

reverse

order

of

disassembly

observing

the

following

instructions

Idler

erm

assembly

To

assemble

idler

arm

proceed

as

follows

I

Apply

coat

of

multi purpose

grease

to

bushing

ST20

@@

w

I

Z

J

I

J

i

SST104

2

Press

bushing

into

idler

body

and

insert

shaft

of

idler

arm

bracket

catefully

until

bushing

protrudes

t

J

54 69

N

m

5 5 7

0

kg

m

40

51

ft

b

Cross

rod

and

side

rod

I

When side

rod

ball

join

ts

and

side

rod

adjusting

bar

are

separated

adjust

side

rod

length

correctly

Adjustment

should

be

done

be

tween

lock

nuts

StandardJength

A

71

mm

12

80

in

t

SST105 Unit

mm

in

2

Tighten

side

rod

adjusting

bar

lock

nut

r

l

78 98

N

m

18

0

10

0

kg

m

58

72

ft

b

a

Lock

side

rod

adjusting

bar

lock

nut

so

that

ball

joint

on

outer

socket is

770

with

respeet

to

that

on

inner

socket

b

Make

sure

that

adjusting

bar

is

sa

ewed

in

each

socket

at

least

25

mm

0

98 inl

INSPECTION

AND

REPAIR

Ball

joint

I

When

ball

stud

is

worn

or

axial

play

exists

replace

side

rod

ball

joint

with

a

new

one

2

When

dust

cover

is

broken

or

deformed

be

sure

to

replace

with

a

new

one

Initial

turning

torque

Ball

joint

0 5 2 5

N

m

5

25

kg

cm

4 3 21 7

in

b

Swivel

Le

than

2

5

N

m

25

kg

cm

22 in

b

Idler

arm

essembly

Check

rubber

bushing

of

idler

arm

for

breakage

wear

or

play

and

if

necessary

replace

Initial

turning

torque

Less

than

7 8

N

m

80

kg

cm

69 in

bl

Apply

grease

to

idler

arm

assembly

at

recommended

intervals

Cross

rod

and

side

rod

Check

side

rod

and

cross

rod

for

breakage

bend

or

crack

and

replace

with

a

new

one

if

necessary

Flxlns

location

Check

fixing

location

nuts

and

cotter

pins

for

looseness

play

or

breakage

When

looseness

or

play

is

found

check

for

wear

on

tapered

portion

of

ball

stud

gear

arm

of

idler

arm

When

reassembling

each

ball

joint

use

new

cotter

pi

s

STEERING

SYSTEM

Service

Data and

Specifications

SERVICE

DATA

AND

SPECIFICATIONS

GENERAL

SPECIFICATIONS

Steering

column

Standard

column

length

L

mm

in

VRB47L

equipped

model

I

P S

56L

equipped

model

Collapsible

column

179 7

05

180

7

09

I

LL

h L

SST080

I

Steering

gear

model

I

Turns

of

steering

wheelan the

car

Lock

lock

I

Steering

gear

ratio

VR847L

I

P S

56L

3 5 3

1

18

0

20

5

17

0

INSPECTION

AND

ADJUSTMENT

Front

wheel

full

turning

angle

Inner

wheel

degree

Outer

wheel

degr

e

Minimum

turning

radius

Wall

to

wall

mlttl

Steering

wheel

axial

play

mm

in

Steering

wheel

play

mm

inl

VR847L

I

PS

56L

33

350

33

350

270

290

270 290

5 7

18

71

0

01

Less

than

35

1381

On

power

steering

models

Wheel

turning

force

at

circumference

of

steering

wheel

of

98

147

N

10

15kg

22

231b

with

engine

at

idle

STEERING

GEAR

Model

VRB47L

Worm

bearing

preload

With oil

seal

N

m

lkgcm

Ibl

Steering

gear

preload

With oil

seall

N

m

kg

cm

in

Ib

Backlash

at

gear

arm

top

end

In

neutral

mm

lin

End

play

Between

sector

shaft

and

adjusting

screw

mm

tinl

04 06

14

6

3 5 5

21

Less

than

1

23112

5

10

9

o 0

1

0 0

004

0

01

0

03

0

0004

0

00121

Adjusting

shim

thickness

Thickness

mm

in

1

575

1

600

10

0620

0

0630

1

550

1

575 0

0610

0

06201

1

525

1

550

10

0600

0

0610

1

500

1

525

10

0591

0

06001

1475

1

500 0

0581

0

0591

1450

1

475 0

0571

0

0581

I

0

1

pad

y

I

IUS

p

Imp

p

Model

I

P

5

56L

Oil

pump

belt

deflection

mm

inl

Steering

wheel

turning

force

At

circumference

of

steering

wheel

N

kg

Ib

Part

No

48213

80100

48214

60100

48215

801

00

48216

80100

48217

80100

48218

80100

Approx

0

26

15

8

1

2

8

1210

31

0

47

at

98

N

110

kg

22

Ib

29

4

34

3

13

0

356

6

7

71

I

Oil

pump

maximum

pressure

kPa

kg

cm2

psi

5394

55

782

I

Normal

operating

temperature

at

fluid

I

Oc

10FI

60 80

140

1761

I

Fluid

capacity

USqt

lmpqt

IAPprox

1

2

1 1

4

1 1

8

Steering

gear

turning

torque

N

m

kg

cm

Ib

3600

position

from

straight

ehead

position

Straight

ahead

position

As

com

pared

with

steering

wheel

turned

3600

STEERING

LINKAGE

Initial

turning

torque

N

m

kg

cm

in

Ib

Ball

joint

Swivel

Idler

arm

Standard

side

rod

length

mm

jnl

Less

than

1

2

12

101

0

10

0

3911

4

0

9

3

5

higher

0

5 2 5

15

25

4

3

21

7

Less

than

2 5

25

221

Lessthan

7 8

80

69

71

0

12

795

ST

21

Service

Data and

Specifications

STEERING

SYSTEM

TIGHTENING

TORQUE

Model

I

P S

56L

STEERING

COLUMN

Unit

N

m

kg

m

ft

lb

Unit

N

m

kg

m

ft

Ib

Stub

shaft

to

joint

32 38

3 3

39

24 28

I

Steering

wheel

ut

37 51

38

52

27

38

I

Stee

ing

ge

housing

to

52 62

5

3 6

3

I

38

bOOy

frame

46

I

0 5 0

451

I

Jacket

tube blacket

to

3 4

44 2 5

3

I

Sector

shaft

to

gear

arm

I

dush

panel

127 147

13 15 94

108

I

Stee

ing

column

mount

13

18

11

3

1

8

I

9

13

I

Rea

cove

to

gea

26 32

27 3 3

I

20 24

iog

bracket

housing

I

Jacket

tube

mounting

I

3

4 44

0

35

0

451

2 5 3 3 Secto

shaft

cove

to

goa

I

26 32

2 7 3 3

I

20 24

bracket

housing

Coupling

fixing

nut

Sector

shaft

adjusting

28 34

2

9

35

I

21

25

VRB47L

equipped

15

22

1

5

2

11

16

screw

lock

nut

mod

1

only

I

0

pump

to

bracket

2

7

3

7

I

20

2726 36

I

Hose

to

oil

pump

29

49

3 0 5

0

I

22 36

I

Oii

seoi

tank

to

en

2

9 49 03 05

I

2 2

3

6

glne

compartment

Hose

to

suspension

c

oss

l

2

9 4

9

0

3

0

5

I

2

3

6

member

STEERING

GEAR

Model

VRB47L

Hose

to

gear

housing

49 69

5

0

7

0

I

36

51

Unit

N

m

kg

m

ft

lb

I

Worm

shaft

to

coupling

STEERING

LINKAGE

39 49

4

5

29

35

Steering

gear

housing

to

Unit

N

m

kg

n

ft

lb

52 52

5 3

5

3

38 46

body

frame

Idler

arm

to

body

frame

31

42

3 2

4

3

23

31

Sector

shaft

to

gear

arm

127 147

13

15

94

108

8all

stud

end

swiVIII

29 59

30

7

0

22

51

Adjusting

plug

lock

nut

245

314

25 32

181 231

I

Idler

arm

nut

54

69

5 5 7

0

40

51

Sector

shaft

cover

bolt

15

25

1

5 2 5

11

18

I

Side

rod

bar

lock

nut

78 98

8

0

10

0

58 72

I

Sect

shaft

adjusting

29

39

3

0

4

0

22

29

IP

S

56L

equipped

model

only

screw

lock

nut

Side

rod

assembly

54

69

N

m

15

5

7

0

kg

m

40

511t

b

ST

22

STEERI

NG

SYSTEM

Trouble

Oiagnoses

and

Corrections

TROUBLE

DIAGNOSES

AND

CORRECTIONS

Except

for

the

following

probalbe

causes

and

corrective

actions

refer

to

Trouble

Diagnoses

and

Corrections

in

Front

Axle

and

Front

Suspension

section

Condi1ion

Excessive

wheel

play

Vibration

shock

or

shimmying

of

steering

wheel

Car pulls

to

right

or

left

Stiff

or

heavy

steering

wheel

Probable

cause

Insufficiently

tightened

or

improperly

in

stalled

steering gear

housing

Damaged

steering

linkage

or

ball

joint

Incorrect

adjustment

of

steering

gear

Insufficiently

tightened

or

improperly

in

stalled

steering gear housing

Wear

of

steering

linkage

Damaged

idler

arm

Worn column

bearing

weakened

column

bearing

spring

or

loose

clamp

Deformed

steering

linkage

and

or

suspension

link

Insufficient

lubricants

or

mixing

impurities

in

steering

linkage

or

excessively

worn

steer

ing

linkage

Worn

or

damaged

steering

gear

and

bearing

Incorrectly

adjusted

steering

gear

Deformed

steering

linkage

Interference

of

steering

column

with

turn

signal

switch

Corrective

action

Retighten

Replace

faulty

parts

Adjust

Retighten

Replace

faulty

parts

Replace

or

retighten

Replace

Replenish

grease

or

replace

the

part

Replace

Adjust

Replace

Adjust

ST

23

Trouble

DiagnO

tJS

and

Corrections

STEERING

SYSTEM

POWER

STEERING

Condition

Oil

pressure

does

not

build

up

Steering

wheel

moves

heavily

Steering

wheel

fails

to

return

Steering

effort

is

not

the

same

in

both

directions

Unstable

running

Noisy

pump

ST

24

Probable

cause

Pump

drive

belt

slipping

on

pulley

Pump

malfunctioning

Oil

leaking

through

hose

joints

Oil

leaking

through

power

steering

Lack

of

oil

in

oil

pump

Air

present

in

oil

Oil

pressure

too

low

Wheel

alignment

out

of

specifications

or

air

pressure

in

tires

too

low

Steering

gears

improperly

engaged

Steering

column

out

of

alignment

Worn

or

damaged

ball

joint

at

suspension

and

steering

linkage

Idler

arm

dragging

Refer

to

items

marked

above

Front

wheel

caster

improperly

adjusted

Internal

gears

dragged

or

gouged

Oil

leakage

in

steering

gear

Stuffy

oil

passage

in

steering

gear

Wheel

bearing

not

properly

adjusted

Stuck

or

damaged

control

valve

in

steering

gear

Front

wheel

alignment

not

properly

Excessive

steering gear

play

Play

at

suspension

and

linkage

ball

joint

Lack

of

oil

in

oil

pump

Hoses

or

oil

filter

clogged

Loose

pulley

Belt

noisy

or

slapping

Broken

pump

part

r

Corrective

action

Readjust

belt

tension

Replace

or

retighten

copper

washer

Replace

sealing

parts

at

steering

gear

Refill

Bleed

air

See

Hydraulic

system

check

Re

a1ign

or

inflate

tires

to

correct

pressure

Replace

gear

assembly

Repair

or

replace

Replace

Repair

or

replace

Readjust

Replace

gear

assembly

Replace

sealing

parts

Replace

gear

assembly

Readjust

Replace

gear

assembly

Readjust

backlash

or

replace

gear

assembly

Replace

Refill

Clean

or

if

necessary

replace

Repair

Readjust

tension

Replace

STEERING

SYSTEM

Special

Service

Tools

SPECIAL

SERVICE

TOOLS

Unit

application

Tool

number

Kent

Moore

No

Tool

name

Model

VRB47L

Modell

P

S

56L

ST27l80001

125726

Steering

wheel

puller

1i

KV48

100301

125729

Strut

steering

gear

box

attachment

xx

ST3127S000

Preload

gauge

See

125765

Torque

wrench

CD

i

CD

GG91030000

Socket

adapter

See

125765

Socket

adapter

XX

@

HT62940000

@

@HT62900000

ST29020001

Steering

gear

arm

puller

J25725

XX

HT72520000

Ball

joint

remover

KV48

101

500

Lock

nut

wrench

X

KV48

101

400

Adjusting

plug

wrench

X

ST27091000

Pressure

gauge

X

Shut

ff

valve

ST

25

Special

Service

Tools

STEERING

SYSTEM

Tool

number

Tool

name

Kent

Moore

No

KV48I

009S0

Oil

seal

drift

set

126367

CD

KV48lO091O

Drift

@

KV48100920

Adapter

@

KV48100930

Adapter

CDsT35322000

Front

wheel

bearing

drift

@ST35325000

Drift

bar

ST

26

I

Unit

application

I

Model

VRB47L

Model

IP

S

56L

x

DATSUN

200SX

Model

S

II

0

Series

SECTIONBF

BODY

CONTENTS

BODY

FRONT

END

FRONT

BUMPER

Shock absorber

type

RADIATOR

GRILLE

FRONT

APRON

FRONT

SIGHT

SHIELD

FRONT

FENDER

HOOD

DOOR

BODY

REAR

END

REAR

BUMPER

Shock absorber

type

TRUNK

LID

Hardtop

BACK

DOOR

Hatchback

WINDSHIELD

AND

WINDOWS

WINDSHIELD

REAR

OUARTER

WINDOW

Hardtop

REAR

QUARTER

WINDOW Hatchback

OPERA

WINDOW

Hardtop

OPERA

WINDOW

Hatchback

BF

2

BF

2

BF

3

BF

3

BF

3

BF

3

BF

4

BF

6

BF

7

BF

11

BF

11

BF

12

BF13

BF

16

BF

16

BF

19

BF

21

BF

22

BF

22

REAR

WINDOW

Hardtop

BACK

WINDOW Hatchback

TRIM AND

MOLDING

ROOM

TRIM

BODY

SIDE

TRIM

AND

MOLDING

REAR

PARCEL

SHELF

Hardtop

INSTRUMENT

AND

SEAT

INSTRUMENT

CONSOLE

BOX

SEAT

BELT

SUN

RDOF

REMOVAL

AND

INSTAllATION

BODY

ALIGNMENT

DESCRIPTION

ENGINE

COMPARTMENT

UNDERBODY

SPECIAL

SERVICE

TDOLS

BF

22

BF

24

BF

26

BF

26

BF

27

BF

28

BF

29

BF

29

BF

31

BF

31

BF

32

BF

34

BF

34

BF

35

BF

35

BF

35

BF

36

BF

37

a

Body

FronrEnd

BODY

FRONT

END

FRONT

BUMPER

Shock

absorber

type

Front

bumper

REMOVAL

AND

INSTAUATION

I

Disconnect

battery

ground

cable

2

Disconnect

front

combination

lamp

connectOIs

3

Remove

special

bolts

securing

shock

absorber

to

front

bumper

assem

bly

then

remove

front

bumper

assem

bly

4

Remove

shock

absorber

from

car

body

CAUTION

The

shock

absorber

is

filled

with

a

high

pressure

gas

and

should

not

be

disassembled

drilled

or

exposed

to

an

open

flame

5 Installation

is

in

reverse

order

of

removal

ADJUSTMENT

Bumper

height

I

Adjust

bumper

height

so

that

BF

2

Shock

absorber

31 42

32

4

3

23 31

59

78

6 0

8

0

43 58

B

wq

bu

cket

OYerrider

N

m

Icg

rn

ft

lb

SBF126

distance

from

top

edges

to

ground

meets

the

specifications

p p

t

Unit

111m

in

Section

A A

SBF121

Place

car

OB

II flat

surface

under

curb

weight

conditions

Tires

must

be

inflated

to

rated

pressure

2

After

adjustment

tighten

bolts

and

nuts

securely

RADIATOR

GRILLE

REMOVAL

AND

INSTALLATION

1

Open

engine

hood

2

Remove

radiator

grille

3Installadon

is

in

reverse

order

of

removal

CAUTION

a

Radiator

grille

is

made

of

plastic

so

do

not

use

excessive

force

b

Take

Clre

to

keep

oil

away from

radiator

grille

FRONT

FENDER

Section

A A

FRONT

APRON

REMOVAL

AND

INSTALLATION

1

Remove

front

bumper

assembly

Refer

to

Front

Bumper

for

removal

2

Remove

front

apron

1

SBF129

3Installation

is

in

reverse

order

of

removal

When

installing

front

apron

be

sure

to

sea

mating

surface

of

front

fender

and

front

apron

Seal

completely

to

mating

surface

of

fender

and

hoodJedse

BO

DY

Body

Front

End

FRONT

SIGHT

SHIELD

REMOVAL

AND

INSTALLATION

1

Remove

headJamp

fmisher

and

headlamp

2

Remove

radiator

grille

3

Remove

front

bumper

assembly

4

Remove

front

sight

shield

Jf

Q

1

SBF130

5

Installation

is

in

reverse

order

of

removal

I

R

a

ff

J1

J

i

A

b

SBF131

BF

3

Body

Front

End

BO

DY

REMOVAL

AND

INSTALLATIoN

I

Disconnect

battery

ground

cable

2

Remove

front

bumper

assembly

Refer

to

Front

Bumper

Assembly

for

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

REMOVAL

AND

INSTALLATION

Hood

control

cable

Hood

I

Open

hood

and

remove

washer

tube

2

Support

hood

and

remove

bolts

attaching

hood

hinge

and

then

remove

hood

BF

4

CAUTION

Fender

panel

and

hoodledge

are

secured

with

sealant

Before

removing

front

fender

be

sure

to

remove

seal

ent

I

7

lIB

21

N

m

11

6

2

1

kg

m

12

15fHb

S8F133

5

Installation

is

in

reverse

order

of

removal

When

installing

front

fender

apply

sealant

to

mating

surface

of

front

lender

and

hoodledge

Hood

rear

molding

SBF132

3 Installation

is

in

reverse

order

of

removal

Adjust

hood

Refer

to

Ad

justment

Torsion

bar

I

Open

hood

2

Support

hood

and

remove

each

torsion

bar

by

disengaging

end

of

torsion

bar

from

hood

hinge

Use

a

suitable screwdriver

SBF134

3

Installation

is

in

reverse

order

of

removal

Lubricate

sliding

surface

of

tor

sion

bar

Hood

hinge

I

Remove

engine

hood

2

Remove

wiper

arm

and then

re

move

windshield

lower

grille

3

Remove

torsion

bar

and

then

remove

hood

hinge

CAUTION

Remove

hinge

onlv

after torsion

bar

has

been

removed

t7

2

SBF135

4

Installation

is

in

reverse

order

of

removal

fj

Hinge

attaching

bolt

3

9

4

9

N

m

0 4 0 5

kg

m

2 9 3

6

ft

lbl

Hood

lock

and

lock

control

I

Remove

bolts

attaching

hood

lock

2

Disconnect

lock control

wire

from

hood

lock

and

then

remove

hood

lock

SBF136

3

Remove

left

instrument lower

cover

Refer

to

Instrument

Lower

Cover

for removal

4

Remove

hood

lock

control

knob

and

then

draw

cable

out

through

pas

senger

compartment

5

Installation

is

in

reverse

order

of

removal

Adjust

hood

Refer

to

Hood

Adjustment

fj

Hood

lock

attaching

bolU

16

21

N

m

1

6 2

1

kg

m

12 15

ft

lb

Check

hood

lock

control

operation

ADJUSTMENT

Hood

and

lock

I

Loosen

bolts

attaching

hood

hinge

and

move

hood

forward

or

backward

and

side

to

side

until

it

is

set

in

optimum

position

SBF137

BODY

Body

F

ontEnd

2

Loosen

bolts

attaching

hood lock

and

move

hood

up

or

down

and

side

to

side

until

it

is set

in

optimum

posi

tion

when

opened

and

closed

JLlI

t

SBF138

After

hood

adjustment

ensure

that

clearance

between

hood

and

fenders

is

nearly

equal

at

all

points

Bumper

rubber

Raise

two

hood

bumpers

until

hood

is

flush

with

fenders

alaI

1

Fende

r

0101

JJ

I@

I

@

HO

d

7

I

Unit

mm

in SBF139

1

Adjust

bolt

2

Bumper

rubber

3

Lock

nut

4

Weld

nut

Ensure

that

rubber

bumpers

come

in

contact

with

mating

panels

BF

5

Door

BODY

DOOR

Outside

haodle

Door

gtus

Door

outside

moulding

Doot

stabilizer

i1

II

Front

guide

rail

liar

npper

It

i

@

t

lnad

hand1e

J

screen

Ann

Door

f

misher

SBf140

BF

6

DOOR

REMOVAL

AND

INSTAlLATION

Door

aasembly

Support

door

with

a

stand

or

jack

Place

a

rag

between

door

and

stand

or

jack

2

Remove

door

from

hinges

I

00

W

r

JL

0

C

SBF141

3 Installation

is

in

reverse

order

of

removal

Adjust

Door

Refer

to

Ad

justment

tl

Door

hinge

securing

bolts

16 22

N

m

1

62 2

kg

m

12 16

ft

lb

Front

door

trim

1

Lower

door

glass

fully

2

Remove

ann

rest

and

door

inside

handle

escutcheon

3

Remove

regulator

handle

by

pry

ing

out

set

o

Front

t

SF879B

4

Remove

door

fmisher

with

suit

able

tool

and

pry

door

fmisher

clip

off

door

inner

panel

SBF142

5

Remove

sealing

screen

When

removing

sealing

screen

be

careful

not

to

allow

it

to

come

in

con

taet

with

adjacent

parts

6Installation

is

in

reverse

order

of

removal

8

To

prevent

water

from

entering

passenger

compartment

affix

seal

ing

SCreen

firmly

with

adhesive

tape

or

bonding

agent

b

With

door window

closed

use

set

pins

to

install

regulator

handle

as

shown

in

Figure

below

Front

300

r

BF879B

Door

glass

and

regulator

I

Remove

door

trim

2

Remove

door

outer

molding

3

Remove

both

front

and

rear

upper

stoppers

IY

hf

I

J

Rear

uppe

opper

Front

upper

stopper

SBF143

BODY

Door

4

Remove

bolts

attaching

door

win

dow

to

guide

channel

O

c

SSF144

S

Remove

door

stabilizer

6

Remove

door

glass

by

pulling

it

upwards

and away

from

door

7

Remove

regulator attaching

bolts

SBF145

8

Remove

through

large

panel

regulator

assembly

access

hole

in

door

r

SBF146

9 Installation

is

in

reverse

order

of

removal

Door

glass

adjustment

Refer

to

Adjustment

Apply

grease

to

sliding

surfaces

of

regulator

and

guide

channel

BF

7

Door

BODY

Door

lock

and

lock

control

Door

outside

handle

J

I

Jb

Key

cylinder

t

l

Door

lock

Remove

door

trim

2

Remove

door

glass

Refer

to

Door

Glass

for

removal

3

Jl

emove

door

inside

handle

at

taching

screws

door

lock

assembly

attaching

screws

and

bell

crank

attach

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

order

of

rcptoval

Apply

grease

to

sliding

surfaces of

leven

and

springs

BF

B

ADJUSTMENT

Door

assembly

Inside

lock

knob

s

Imide

handle

escutcheoD

j

4

i

d

I

l

I

Loosen

bolts

attaching

door

hinge

to

body

sid

e

Move

door

up

or

down

and

forward

or

backward

until

it

is

correctly

positioned

Using

an

offset wrendl

remove

Imide

handle

SBF147

SBF148

bolts

attaching

hinge

to

rear

of

front

lender

2

Loosen

bolts

attaching

door

hinge

to

door

side

Move

door

from

side

to

side

until

it

is

set

in

optimum

position

Door

glas

Before

adjusting

door

window

glass

check

body

side

weatherstrip

to

ensurl

that

it

is

properly

positioned

as

im

@1f

@

In

out

adjustment

At

waist

area

1

Loosen

nuts

securing

upper

ends

of

both

front

and

rear

guide

rails

rfjV

idi

I

II

I

l

ll

t

J

Jr

j

C

Front

SBF

150

2Raise

window

completely

3

Turn

upper

adjusting

bolts

in one

direction

or

the

other

until

distance

between

glass

and

rubber

seal

for

door

waist

molding

is

11

2

mm

0

441

in

as

shown

in

Figure

below

proper

positioning

may

cause

water

or

dust

leaks

Adjust

window

glass

as

follows

1

ln

ut

adjustment

at

waist

area

2

In

Gut

adjustment

upper

side

ofgalss

3

Tilt

adjustment

upper

side

of

glass

4

Glass

upper

stop

adjustment

5

Glass

fore

and

aft

adjustment

SBF149

11

2

mm

0

441

in

SBF151

In

out

adjustment

Upper

side

of

glass

1

Loosen

nuts

securing

lower

end

of

guide

rail

and

turn

adjusting

bolts

until

glass

is set

in

position

as

showni

n

Figure

below

Side

roof

rail

crt

14

17

mmLn

g

10

55

0

67

inlrOoorgla

SBF152

BODY

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

Regulator

SBF153

3

After

adjustment

tighten

guide

rail

securing

nuts

and

guide

channel

securing

bolts

Glass

upper

stop

adjustment

I

Adjust

rear

height

of

glass

by

changing

upper

rear

stopper

position

Side

roof

rail

Door

glass

SBF154

BF

9

Door

BODY

2

Adjust

front

height

of

glass

by

changing

upper front

stopper

position

@

ri

il

After

completing

adjus1ment

en

sure

that

each

adjustment

is

within

specified

limit

BF

l0

Door

lock

and

lock

control

I

Move

bell

rank

front

and

rear

until

free

play

of

lock

knob

is

mini

mum

Check

lock

knob

and

inside

handle

to

insure

that

they

are

flush

with

each

other

when

lock

is

engaged

Tighten

lock

knob

attaching

screws

11i

U

I

II

J

P

SBF157

2

Turn

adjusting

nut until

clearance

between

outside

handle

rod

and

door

lock

lever

is

0

to

I

mm

0

to

004

in

Adjust

nut

U

0

1mm

0

04

inl

SBF158

Mter

adjustment

check

to

deter

mine

if

door

lock

operates

correctly

BODY

Body

Rear

End

BODY

REAR END

REAR

BUMPER

Shock

absorber

type

if

i

J

31

42

3 2

4

3

23

31

Shock

absorber

umper

mounti

ll

bracket

Rear

bumper

i

S

O

mder

Bumper

face

1

37

9

i

J

59 78

6 8

43 58

t

side

molding

i

J

N

m

kg

m

fHb

SBF159

REMOVAL

AND

INSTALLATION

I

Disconnect

battery

ground

cable

2

Disconnect

reverse

lamp

harness

3

Remove

special

bolts

securing

shock absorber

to

bumper

assembly

and

detach

bumper

assembly

4

Remove

shock absorber

from

car

body

M

600

23

621

M

600

23 62

CAUTION

The

shock

absorber

is

filled

with

a

high

pressure

gas

and

should

not

be

disassembled

drilled

or

exposed

to

an

open

flame

512 544

20

16 21

42

t

5

Installation

is

in

reverse

order

of

removal

ADJUSTMENT

Unit

mm in

Section

A

SBF160

Bumper

height

I

Adjust

bumper height

so

that

distance

from

top

edges

to

ground

meets

the

specifications

Place

car

on

a

flat

surface

under

curb

weight

conditions

Tires

must

be

inflated

to

rated

pressure

2

After

adjustment

tighten

bolts

and

nuts

securely

BF

ll

Body

Rear

End

BQDY

TRUNK

LID

Hardtop

REMOVAL

AND

INSTAUATION

Trunk

lid

I

Open

trunk

lid

and

remove

trunk

opener

cable

2

Support

trunk

lid

and

remo

bolts

attaching

trunk

lid

to

hinge

then

remove

trunk

lid

III

3Installation

is

in

reverse

order

of

removal

AdjUst

trunk

lid

Refer

to

Adjust

ment

G

i

Trunk

lid

securing

bolts

39

4

9

N

m

0 4 0

5

kg

m

2

9

3 6

ft

lb

Torsion

bar

I

Open

trunk

lid

2

Support

trunk

lid

and

remove

each

torsion

bar

by

disengaging

end

of

to

ion

bar

from

trunk

lid

Use

a

suitable screwdriver

L

BF

12

3Installation

is

in

reverse

order

of

removal

Trunk

lid

lock

end

striker

I

Remove trunk

rear

fmisher

2

Remove trunk

lid

attaching

bolts

and

then

remove

striker

3

Remove

lock

attaching

bolts

and

then

remove

lock

Trunk

lid

opener

1

Remove

rear

seat

cushion

and

rear

seat

back

2

Remove

kicking

plate

3

Remove

trunk

lid

lock

attaching

bolts

and

then

remove

trunk

lid

lock

4

Trun

up

floor

carpet

near

trunk

lid

opener

handle

S

Remoye

trunk

lid

opener

handle

6

Remove

trunk

lid

opener

cable

7Installation

is

in

reverse

order

of

removal

Fasten

trunk

opener

cable

securely

with

adhesive

tape

I

l

i

SBF163

4

Installation

is

in

reverse

order

of

removal

SBF164

ADJUSTMENT

T

u

n

I

l

an

oc

k

I

Loosen

bolts

attaching

trunk

lid

hinges

Move

trunk

lid

forward

or

backward

and

side

to

side

until

it

is

set

in

optimum

position

v

SBF166

2

Loosen

bolts

attaching

trunk

lid

lock

Move

trunk

lid

lock

forward

or

backward and

side

to

side

until

it

is

correctly

positioned

when

opened

and

closed

I

J

3 9

4

9

N

m

10

4 0

5

kg

m

2 9

36

f1

lbl

SBF166

Trunk

lid

opener

Adjust

trunk

lid

opener

until

clear

ance

between

trunk

lid

control

cable

end

and

control

lever

is

within

1

mm

0

04

in

when

trunk

lock

is

engaged

Clearance

Less

than

1

mm

0

04

in

Lock

Locking

lever

A

AdjusUble

5

mm

1

10

20

inl

SBF167

BACK

DOOR

Hatchback

REMOVAL

AND

INSTALLATION

Back

door

SBF168

Open

back

door

2

Mark

hinge

locations

on

body

for

proper

reinstallation

3

Support

back

door

by

hand

and

remove

back

door

to

back door

stay

bolts

Remove

rear

roof

rail

trim

and

disconnect

rear

defogger

and

rear

win

dow

wiper

harness

connector

and

hose

4

Support

back door

by

hand

and

remove

back

door

to

back door

hinge

attaching

bolts

Then

remove

back

door

This

operation

requires

two

men

CAUTION

Place

rags

between

roof

and

upper

end

of

back

door

to

avoid

damaging

paint

ed

surfaces

5

Installation

is

in

reverse

order

of

removal

tl

Back

door

stay

retaining

bolt

16 21

N

m

1

62

1kg

m

12

15

ft

lb

BODY

Body

Rear

End

CAUTION

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

ture

applv

heat

or

fire

Back

door

lock

end

lock

cylinder

I

Open

back

door

2

Remove

luggage

rear

fmisher

3

Remove

back

door

lock

from

rear

panel

1

0

i

0

Q

SBF

169

4

Remove

rear

combination

lamp

and then

remove

lock

cylin4er

5

Installation

is

in

reverse

order

of

r

mova

Adjust

back door

referring

to

Back

Door

for

adjustment

BF

13

8OdyRearEnd

BODY

Back

door

opener

I

Open

back door

2

Remove

luggage

rear

finisher

3

Remove

back door

lock

from

rear

panel

4

Remove

rear

seat

cushion

and

rear

seat

back

5

Remove

kicking

plate

6

Turn

up

floor

carpet

riear

back

door

opener

handle

7

Turn

up

luggage

room

carpet

and

remove

back

door

opener handle

8

Remove

back

door

opener

cable

9

Insta1Iation

is

in

reverse

order

of

removal

Fastan

back

door

opener

control

cable

securely

with

adhesive

tape

ADJUSTMENT

Back

door

end

striker

Back

door

can

be

adjusted

with

bolts

attaching

back door

to

back door

hinge

and

back door

lock

I

Loosen

bolts

attaching

back door

to

back door

hinge

BF

14

Back

door

lock

cable

2

To

make

side

to

ide

adjustment

move

back

door

to

left

or

right

as

required

to

obtain

an

equal

clearance

between

back

door

and

rear

fender

on

both

sides

3

To

make

foreand

aft

adjustment

move

back door

in

foreand

aft

direc

tion

required

to

obtain

an

equal

clearance

between

backdoor

and

roof

P

U

BF6848

4

After

alignment

is

properly

made

tighten

bolts

securely

SBF171

5

To

obtain

a

snug

fit

between

back

door

and

weatherstrip

loosen

down

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

h

7

1f

0

y

l4

P

SBF172

6

After

desired

adjustment

is

ob

tained

tighten

back door

lock

attach

ing

bolts

securely

7

Adjust

down

stopper

to

set

with

hollow

of

back

door

then

tighten

down

stopper

securing

screws

BF6868

Back

door

lock

Adjust

back

door

lock

and

key

rod

until

they

are

correctly

positioned

when

door lock

is

engaged

as

shown

in

Figure

below

II

J

C

c

0

mm

0 0

04

inl

Key

rOd

Adjust

nut

SBF173

BODY

Body

Rear

End

Balik

door

opener

Adjust

clearance

between

rear

door

opener

cable

end

and

locking

plate

when

door

is locked

until

it

is

within

range

indicated

in

Figure

below

r

v

o

0

o

Locking

lever

SBF174

BF

15

Winrhhieldand

Windows

BODY

WINDSHIELD

AND

WINDOWS

WINDSHIELD

A

pre

mixed

one

part

sealant

to

cement

windshield

glass

to

windshield

opening

is

available

After

using

this

sealant

it

is

highly

recommended

that

the

car

should

reo

main

stationary

for

about

24

hours

so

that

the

sealant

can

cure

welL

Upper

windshield

molding

is

in

stalled

with

a

continuous

plastic

mold

ing

fastener

I

Windshield

glass

2

Windshield

molding

3

Body

4

Double

faced

adhesive

tape

5

Molding

falteDU

6

Sealant

7

Dam

CAUTION

a

Use

Genuine

Nissan

Sealant

Kit

72891

U7425

or

equivalent

Seal

ant

kit

consists

of

Piimer

A

Primer

E

dam

caution

label

and

sealant

which

is

made

from

silicone

Using

this

kit

proceed

to

operations

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

use

d

Keep

Primen

and

sealant

in

a

cool

dry

place

ldeally

sealant should

be

stored

in

a

refrigerator

WARNING

Keep

heat

or

open

flames

away

IS

Primen

are

flammable

BF

16

REMOVAL

I

Protect

hood

front

fenders

in

strum

tpanelandftoot

ns

th

covers

2

Remove ndshield pers

front

pillar

gamishes

and

windshield

garnish

Refer

to

Roof

Trimming

for

re

moval

3

Remove

front

pillar

moldings

4

With

a

sharp

cutting

knife

cut

off

caulking

ma1erial

gttached

to

upper

and

lower

moldings

Then

reo

move

moldings

Cut

here

BF330B

5

Reaching

from

inside

car

strip

dam

rubber

from

around

windshield

glass

Ye

I

Bf288B

6

With

a

sharp

cutting

knife

cut

off

caulking

material

along

edge

of

entire

window

opening

BF331

B

1

Adhesive

caulking

material

2

Glass

3

Knife

cur

7

Cut

off

caulking

material

around

entire

perimeter

of

glass

as

follows

I

Using

a

knife

cut

through

part

of

caulking

material

2

Secure

one

end

of

steel

music

re

0

5

mm

0

020

in

diameter

to

a

piece

of

wood

that

can

serve

as

a

handle

Using

long

nose

pliers

insert

other

end

of

re

through

caukling

material

at

edge

of

glass

then

secure

that

end

of

re

to

another

wood

handle

3

With

the

aid

of

an

assistant

carefully

cut

puJi

re

through

caulk

ing

material around

entire

perimeter

of

ndow

using

a

sawing

motion

1

BF35

B

S

From

inside

car

push

glass

up

and

out

of

window

opening

9

Using

a

razor

blade

or

sharp

scraper

remove

caulking

material

along

entire

edge

of

windshield

opening

leaving

it

about

1

0

to

2

0

mm

0

039

to

0

079

in

thick

If

millual

sealant

i

ilicon

re

move

all

traces

of

it

CAUTION

a

When

body

painted

surface

is

scra1Ched

be

sure

to

repair

with

paint

b

Identificetion

of

used

adhesive

material

can

be

accomplished

as

follows

1

Cut

e

smell

piece

of gxcess

sealant

from

glass

or

windshield

opening

flange

2

Stick

small

piece

of

sealant

on

the

end

of

knife

or

the

like

and

hold

it

over

flame

from

match

or

Iighler

until

it

igniles

Polysulfide

burns

with

a

clear

flamg

and

a

very

small

amount

of

white

smoke

or

no

smoke

and

its

odor

is

very

objectionable

heavy

sulfur

dioxide

Polyurethane

burns

with

a

dirty

flame

and

emit

black

smoke

and

very

little

odor

Silicone

glows

with little

or

no

flame

and

emits

white

smoke

and

very

little

odor

Burnt

residue

is

white

ash

INSTALLATION

L

Clean

contacting

face

of

body

with

non

lead

gasoline

CAUTION

00

not

allow

oil

grease

or

waler

to

get

on

clean

surfaces

from

dirty

hands

or

tools

2

Install

molding

fastener

on

upper

windshield

opening

as

follows

1

Heat

molding

fastener

and

con

tacting

face

of

body

up

to

about

400C

I

040

F

using

a

heat

giltl

2

Attach

molding

fastener

to

body

and

press

it

more

than

490

kPa

5

kg

em

71

psi

using

a

suitable

roller

Make

certain

that

molding

fastener

does

t

not

come

off

from

body

as

shown

Molding

fastener

3

Apply

glass

sealant

beside

mold

ing

fastener

Sealant

8 F

3338

3

Clean

glass

surface

where

the

sealant

will

be

applied

and

dam

with

non

lead

gasoline

About

20

mm

0

79

in

Cleaning

area

BF531

4

Install

dam

rubber

to

in

ide

of

windshield

glass

8

mm

0

31

in

inboard

from

edge

of

glass

and

cut

off

excess

amount

at

its

ends

hADam

GlaSS

Dam

Unit

mm

in

8F955

BO

DY

Windshield

and

Windows

5

With

sponge

furnished

with

Primer

A

apply

a

light

coat

of

Primer

to

cleaned

area

of

glass

IlIMERA

BF376B

CAUTION

00

not

apply

Primer

A

to

glass

open

ing

flanges

6

With

sponge

furnished

with

Primer

E

apply

a

light

coat

of

Primer

to

original

caulking

material

left

on

glass

opening

flange

Residual

sealant

ij

IMERE

WJ

BF377B

If

residual

sealant

is

silicone

r8

move

all

traces

of

it

CAUTION

Allow

Primers

to

dry

for

10

to

15

minutes

before

proceeding

to

the

7

Insert

cartridge

in

Caulking

Hand

Gun

ST08810000 and

place

smooth

continuous

bead

on

glass

11

mm

0

43

in

above

glass

surfaces

BF

17

WincMield

and

Windows

BODY

d

Dam

mm

o

nl

Section

A A

BF782B

Cut

off

nozzle

end

of

cartridge

as

shown

below

7

0

h

1

0

311

Unit

mm

in

BF957

Pierce

sealing

film

with

needle

install

cartridge

on

hand

gun

CAUTION

Sealan

t

starts

to

harden

15

minules

after

it

is

applied

1herefore

wind

shield

glass

should

be

installed

in

windshield

opening

in

body

wi1hin

15

minutes

of

applying

sealant

8

Support

windshield

glass

with

SuckerST08800000

9

Install

windshield

glass

on

opening

flange

so

that

clearances

be

tween

windshield

glass

and

body

are

about

7

mm

0

28

in

BF

18

BF335B

10

Apply

pressure

on

glass

10

aid

in

seating

on

plate

II

Wipe

excess

caulking

material

off

molding

fasteners

edges

of

glass

and

body

12

Remove

protective

covers

13

Water

test

immediately

using

a

cold

water

spray

Do

not

direct

stream

of

water

at

fresh

adhesive

material

Allow

water

to

spill

over

edges

of

glass

If

leaks

are

encountered

use

Caulking

Hand

Gun

to

work

in

additional

caulking

material

at

leak

point

14 Install

all

previously

removed

parts

After

installing

attach

caution

label

to

glass

surface

CAUTION

LEAVE

ONE

WINDOW

OPEN

SLlGtlTlT

FOR THREE OATS

This

is

to

protett

f04

ew

wfndshield

nstallation

from

pre

ure

lnduC8d

Iuks

before

the ubb

1

has

com

pletely

ulconizecl

BF6988

Be

lure

that

it

does

not

obstruct

visibility

The

label

noting

the

faet

that

sealing

will

be

impaired

if

door

is

opened

or

osed

with

window

dosed

before

sealant

has

dried

will

be

furnished

with

the

kit

CAUTION

AdviSB

the

user

of the

fact

that

car

should

not

be

driven

on

rough

roads

or

surfaces

until

sealant

has

properly

wlcanized

Reference

Period

required

for

sealant

to

dry

to

desired

hardness

Unit

days

Relative

humidity

90

50

25

Temperature

oC F

25

77

1

5

25

6

10

50

3

53

10

14

10 17

34

REPAIRING

LEAKS

Leaks

can

be

repaired

without

reo

moving

and

reinstalling

glass

in

the

following

manner

I

To

stop

leaks

lint

remove

mold

ings

in

area

ofleak

2 Mark location

of

leak

If

water

is

leaking

between

caUlking

matarial

and

b

Kfy

or

between

glass

and

caulking

material

c

ietermine

ex

tent

of

leak

by

pushing

glass

outward

Apply

water

to

leak

area

while

pushing

on

glass

Mark

extent

of

leak

point

3

Apply

Primer

and

then

sealant

to

leak

points

following

procedures

shown

below

CAUTION

Do

not

apply

Primar

to

old

sil

one

sealant

BODY

Windshield

and

Windows

TrUn

1

PrUner

E

PDIYlulphide

or

polyureth

ne

sulant

Work

into

joints

4

l

Silicone

81lant

BF498B

REAR

QUARTER

WINDOW

Hardtop

REMOVAL

AND

INSTALLATION

I

J

I

tJf

J

Rear

upper

stopper

Front

upper

stopper

0

V

D

Guide

plate

Rear

quarter

window

glaM

Ann

rest

Regulator

handle

SBF175

BF

19

Winchhield

and

Windows

BODY

L

Remove

rear

seat

cushion

and

rear

seat

back

2

Remove

regulator

handle

and

rear

side

finisher

3

Remove

air

outlet

grille

and

seaI

ing

screen

4

Remove

upper

stoppers

and

nuts

attaching

glass

to

reguI

tor

Remove

guide

plate

attaching

nuts

5

Remove

both

quarter

window

glass

and

guide

plate

tIuough

top

opening

SBFl77

6

Remove

bolts

attaching

regulator

7

Draw

out

regulator

tIuough

lower

opening

BF 20

8 Installation

is

in

reverse

order

of

removal

Glass

adjustment

refer

to

Adjustment

Apply

grease

to

sliding

surfaces

of

regulator

and

guide

channel

ADJUSTMENT

In

out

adJu

tment

At

wa

t

erea

Close

rear

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

seal

is

I

1

2

mm

0

441

in

as

shown

11

2mm

0

441

in

SBF161

Narrow

I

L

Glass

adjusted

too

far

to

forward

ID

em

Glass

inclined

liD

In

ciut

adJu

t

nt

Upper

lde

of g

Adjust

rear

quarter

window

glass

position

as

shown

in

Figure

below

using

adjusting

bolt

located

on

lower

end

of

guide

plate

Side

roof

rai

I

r

14 17

mmLn

g

0

55

0

61

inlV

Door

glass

SBFl52

Angle

adJu

tment

Close

door

glasses

and

rear

quarter

window

glass

completely

to

ensure

that

tear

quarter

window

glass

is

align

ed

with

door

glasses

and

fits

body

side

weatherstripping

Rear

quarter

win

ow

glass

I

Wide

L

Door

window

glass

Gla

sI

adjusted

too

far

to

rear

UD

SBF179

G1

ss

upper

stop

dJustment

Adjust

two

upper

stoppers

until

glass

and

side

roof

rails

are

set

at

Side

roof

rail

Door

glass

SBF154

dimensions

glass

fully

raised

indi

cated

in

Figure

below

y

Q

SBF180

REAR

QUARTER

WINDOW Hatchback

REMOVAL

AND

INSTALLATION

Quarte

r

window

regulator

1

Remove

rear

seat

cushion

and

seal

back

2

Remove

regulator

handle

rear

side

fmisher

and

top

luggage

side

finisher

and

remove

sealing

screen

3

Remove

bolts

attaching

glass

to

regulator

b

SBF181

I

f

SBFl

2

BODY

Windshield

and

Windows

4

Remove

regulator

attaching

bolts

and

detach

regulator

f

00

0

06

III

5l

SBF18

5

Remove

air

outlet

grille

and

rear

fender

molding

SBF184

6

Remove

rear

body

side

retainer

SBF185

7

Remove

quarter

window

attaching

screws

then

remove

quarter

window

BF

21

Windlilield

and

Windows

BO

DY

8 Installation

is

in

reverse

order

of

removal

To

prevent

water

leakage

through

door

fasten

sealing

screen

securely

using

adhesive

tape

or

bonding

agent

OPERA

WINDOW

Hardtop

REMOVAL

AND

INSTALLATION

1

Remove

rear

seat

cushion

seat

back

and

rear

side

fmisher

2

Remove

assist

grip

and

rear

corner

fmisher

SB

187

3

Remove opera

window

attaching

nuts

then

remove

window

SBF188

4

Installation

is

in

reverse

order

of

removal

BF

22

OPERA

WINDOW

Hatchback

REMOVAL

AND

INSTALLAnON

1

Remove

rear

seat

cushion

seat

back

rear

side

finisher

and

luggage

side

upper

fInisher

2

Remove

air

outlet

grille

3

Remove

opera

window

attaching

nuts

then

remove

window

REAR

WINDOW

Hardtop

Sedan

CD

Rubber

Glass

y

1

SBF189

4

Installation

is

in

reverse

order

of

removal

1

Weatherstrip

2

Window

glass

3

Molding

set

4

Roof

panel

5

Outer

panel

REMOVAL

L

Place

protective

covers

on

back

door

and

rear

fenders

2

Rem

ve

parsel

shelf

lUId

rear

side

garnishes

after

removing

rear

seat

cushion

and

back from

body

Then

disconnect

rear

window

defogger

har

@

SBF361

ness

at

coMectors

Place

protective

co

r

on

rear

panel

3

Remove

rear

window

molding

by

prying

out

molding

4

Attach

two

Suckers

ST08800000

to

glass

beforehand

for

convenience

in

lifting

out

rear

window

glass

5

From

inside

passenger

compart

ment

apply

hand

pressure

to

edges

of

rear

window

glass

and

remove

weather

strip

lip

from

body

flange

starting

from

top

to

sides

Use

a

conventional

screwdriver covered

with

cloth

or

other

suitable

tool

and

carefully

put

weatherstrip

over

body

flange

J

rO

8F229B

6

After

rear

window

weatherstrip

is

free

from

body

flange

with

aid

of

a

helper

carefully

remove

rear

window

glass

with

Suckers

ST08800000

INSTALLATION

It

is

important

that

rear

window

opening

in

body

be

checked

throughly

before

installation

of

rear

window

glass

Procedure

below

includes

checking

of

rear

window

opening

in

body

L

Check

re

f

window

weatherstrip

and

rear

window

opening

in

body

for

any

irregularities

2Stick

Suckers

ST08800000

on

rear

window

glass

With

aid

of

another

person

carefully

position

glass

in

opening

in

body

CAUTION

Care

should

be

exercised

to

make

Certain

glass

does

not

strike

body

metal

during

installation

Edge

chips

can

lead

to

future

breaks

3

With

rear

window

glass

supported

and

centered

in

opening

in

body

check

relationship

between

glass

and

opening

around

entire

perimeter

of

glass

1

Entire

inside surface

of

glass

should

be

in

contact

with

opening

2

Curvature

of

glass

should

con

form

to

that

of

opening

3

Mark

any

section

of

opening

to

be

reformed

Remove

glass

and

reform

opening

as

required

4

Install

rear

window

glass

as

follows

1

Install

rear

window

weatherstrip

to

glass

t

BF647

2

Insert

a

strong

cord

in

groove

of

weatherstrip

where

opening

flange

fits

Insert

Cord

so

that

ib

ends

are

at

bottom

center

of

glass

BF648

1

Windshield

glass

2

Draw

cord

3

Weatherstrip

BO

O

V

Windshield

and

Windows

3

With

aid

of

a

helper

carefully

position

and

center

rear

window

glass

in

opening

in

body

supporting

it

with

Sucker

ST08800000

4

When

glass

and

weatherstrip

are

properly

positioned

in

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

fmally

across

top

5

Carefully

tap

around

rear

window

glass

to

assist

in

seating

weatherstrip

on

flange

Never

tap

or

hammer

at

glass

to

position

BF650

BF649

5

Install

all

previously

removed

parts

BF

23

Windshield

and

Windows

BODY

BACK

WINDOW

Hatchback

REMOVAL

l

Remove

both

de

molding

and

corner

molding

2

Remove

four

glass

retainers

3

Disconnect

rear

defogger

harness

if

so

equipped

4

Remove

welt

from

inside

pas

senger

compartment

S

Remove

butyl

tape

with

a

putty

knife

then

remove

back

wil

1do

glass

r5

J

r

SBF191

INSTALLATION

Use

butyl

tape

of

8

mm

0

31

in

or

equi

alent

when

replacing

glass

BF

24

lumm

1

Wipe

any

trace

of

butyl

tape

off

glass

and

door

panel

using

non

leaded

gasoline

2

Affix

butyl

tape

to

entire

surface

of

glass

as

shown

in

Figure

below

1

C

B

Jr

tyltape

6

mm

0

24

in

Cross

section

BB

Be

sure

to

affix

butyl

tape

starting

at

point

A

figure

bon

and

ending

at

point

A

and

overlap

some

length

of

tape

at

point

A

Use

care

to

a

oidtouching

adhesive

side

of

butyl

tape

with

fingen

as

finger

prints

or

stains

may

reduce

adhesi

e

force

of

tape

Back

wbldow

gWs

S8F19Q

3

Using

a

heat

gun

heat

adhesive

side

of

butyl

tape

to

700C

IS80F

4

Apply

bonding

agent

to

points

of

glass

as

shown

in

Figures

below

SBF193

t

I

2OO

mm

7

41

in

4

points

O

SBF194

5Support

rear

window

glass

with

Sucker

ST08800000

6

With

the

help

of an

assistant

bring

rear

window

glass

close

to

open

ing

flange

of

rear

window

and

connect

rear

window

defogger

harness

7

Carefully

position

rear

window

glass

on

opening

flange

of

rear

win

dow

Check

rear

window

glass

to

ensure

that

all

side

dearances

upper

side

lower

side

left

side

and

right

side

are

equal

8

Temporarily

tighten

four

reo

tainers

and

lightly

tap

around

glass

with

a

rubber

faced

haJ11ffier

until

glass

fits

panel

at

all points

as

shown

Be

careful

not

to

scratch

molding

4

5mm

0

16

o

20in

G

S

c

Butyltape

ml

J

Backdoor

panel

SBF195

BODY

Windshield

and

WindOM

9

Tighten

all four

retainers

securely

and

attach

corner

molding

10

Do

not

apply

vibration

or

shocks

to

glass

for

at

least

one

hour after

glass

has

been

installed

Direct

water

toward

periphery

of

glass

to

deter

mine

if

there

is

water

leak

inside

passenger compartment

II

Remove

excess

or

protruded

butyl

tape

1

BF

25

Trim

and

Molding

BODY

ROOM

TRIM

Sun

riser

REMOVAL

AND

INSTALLATlqN

I

Remove

front

pillar

garnish

r

BF197

2

Remove

sun visor

and

holder

3

Remove

room

lamp

assembly

4

Remove

roof

side

garnish

BF

26

TRIM

AND

MOLDiNG

HeadIinins

Room

lamp

mbly

Wirul

hieJd

upper

prnish

I

if

ii

1

tl

SBF198

5

Remove

rear

seat

cushion

and

back

6

Remove

assist

grip

Hardtop

or

coat

hanger

Hatchback

7

Remove

rear

side

finisher

8

Remove

rear

corner

finisher

Hardtop

or

luggage

upper

side

finisher

Hatchback

Hardtop

AssistgriP

Rear

L

upper

garnish

SBF196

9

Remove

rear

window

upper

gar

nish

r

SBF199

10

Remove

head

lining

II

Installation

is

in

reverse

order

of

removal

BODY

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

ent

an

600

IrislflJ

EA1

AND

S

NS1

RUtAEN1

ft

EtlT

STR

U

i

a

II

1

u

ll

g

II

i

5g

J

u

II

8

e

g

c

u

a

0

lit

l

s

Instrument

and

Seat

BODY

REMOVAL

AND

INSTALLATION

Instrument

panel

Disconnect

battery

ground

cable

2

Remove

steering

wheel

Refer

to

Steering

Wheel

ST

section

for

re

moval

3

Remove

shell

cover

and

com

bination

switch

4

Remove

instrument

lower

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

SBF204

8

Remove

heater

control

attaching

screws

and

floor

attaching

bolts

9

Remove

defroster

grille

10

Remove

instrument

securing

bolts

and

then

remove

instrument

assembly

by

pulling

it

out

11

Installation

is

in

reverse

order

of

removal

j

SBF205

BODY

lnStromentBndSeat

CONSOLE

BOX

SBF206

REMOVAL

AND

INSTALLATION

I

Remove

screws

attaching

console

box and

slide

console

box

rearward

2

Remove

parking

brake

and

lift

out

console

box

SEAT

FRONT

SEAT

I

11

S6

F207

ifi16

22N

m

11

6

22

kg

m

12

3Installation

is

in

reverse

order

of

removal

SBF208

BF

31

Instrumenund

Seat

BO

DY

REAR

SEAT

Hardtop

SBF209

Hatchback

l

iiiJ

rJ

SBF210

BF

32

SEAT

BELT

FRONT

SEAT

BELT

SBF211

itJ

Seat

belt

anchorage

bolt

24

31 Nm

2

4

32

k

17

23

ft

Ib

REAR

SEA

r

BEL

r

HARDTOP

I

1

J2434N

m

12

4 32

k

17

g

m

23ft

lbl

HATCHBACK

BODY

Instrument

and

S

eat

I

J

24

34N

m

2

4

32k

g

m

17

23

ft

lbl

SBF212

BF 33

Sun

Roof

BODY

REMOVAL

AND

INSTALLATION

SUN

ROOF

1

To

unlock

safety

catch

slide

the

safety

catch

knob

all

the

way to

the

left

2

Depress

sun

roof

handle

knob

and

push

handle

up

to

disengage

it

from

link

3

Remove

sun

roof

4

Installation

is

in

reverse

order

of

removal

BF

34

SUN

ROOF

Bndet

EICutcheon

Sun

roof

handle

Safety

catch

Sun

roof

rmi5her

SBF213

DRAIN

HOSES

o

SBF215

SBF214

I

Remove

roof

trim

front

pillar

trim

rear

pillar

trim

and

da

side

trim

and

then

remove

drain

hoses

2 Installation

is

in

reverse

order

of

removal

After

installing

drain

h

s

emure

1hat

watar

is

property

drained

outside

car

with

no

seepage

into

passenger

compartment

DESCRIPTION

DIMENSION

LINES

All

dimensions

indicated

in

the

drawings

illustrations

are

the

standard

design

values

I

Black

dimension

line

Indicates

a

distance

from a

phantom

line

of

the

car

body

to

a

point

to

be

measured

and

cannot

be

measured

with

a

meas

uring

tape

or

tram

tracking

gauge

2

Thin

line

Indicates

a

direct

or

an

actual

distance

or

length

between

two

points

and

can

be

measured

with

a

measuring

tape

or

tram

tracking

gauge

An

asterisk

following

the

value

at

the

measuring

point

indicates

that

the

measuring

point

on

the

other

side

is

symmetrically

the same

value

ENGINE

COMPARTMENT

BODY

ALIGNMENT

MEASUREMENT

OPERATIONS

When

car

body

measurements

are

taken

in

accordance

with

the

thick

line

careful

consideration

should

be

given

to

the

following

points

1

Measurement

method

I

When

a

tram

tracking

gauge

is

used

adjust

pointe

A

and

B

to

equal

lengths

as

shown

in

the

figure

be

low

Check

the

pointe

and

gauge

itself

to

make

sure

there

is

no

free

play

I

A

f

I

B

BODY

BodyAlignment

2

When

a

measuring

tape

is

used

check

to

be

sure

there

is

no

elonga

tion

twisting

or

bending

If

a

part

or

parts

of

the

car

body

interferes

with

measurement

when

using

the

measuring

tape

you

cannot

measure

the

distance

or

length

accu

rately

2

Measurement

point

Measurements

should

be taken

at

the

center

of

mounting

holes

Unit

mm

in

SBF216

BF

35

c

l

If

n

J

U

i

1

L

o

1

i

I

R

H

n

Fm

I4

g

ig

l

Il

N

if

76

1

i

r

Jlf

1

I

ol

v

l

0

f

N

l

I

y

I

0

51

Cu

Nol

N

I

t

i

m7

1

l

db

no

I

l

o

q

L

H

r

V

I

W

L

0

Ih

I

0

1

i

h

J

II

u

c

il

9

t

O

E

J

c

q

69

I

8

9

0

7

I

l

4J

r

2

t

IS

51

SeetionB

B

ScttlonC

C

9

8

rr

p

Seelion

A

ntf

n

m

24

0

945

Front

floor

Fronlu

1C

ocnIcrlinc

I

RCLUIe

centerline

Oalumlin

en

r

2

4

t

sOtO

2

t

h

1

91tO

008l

0

02

if

rl

J

1

97tO

008

tt

I

0

93tO

2

28

1

l1

l

c

I

11

s5

S5

3

6610

008

o

I

0

ALLOWANCE

FOa

STG

PIXING

I

L

A

I

L

SIDE

VIEW

LG

i

J

D

mHo

j

91

83

61

14

1

0

95l

n

IolJ

0

I

U

11

II

L

IJ

1

11

l

2

0

I

l

L

oJ

L

1

11

3

0

5

L

8

70

917

D

tum

line

695

17

36

R

H

lide

109

68

7

i

70S

8

0

31

19

I

IJ5

3187

37

31

69

161

1

I

L

H

lde

6

39

611

14

45

1

400

9

40

19

13

1

6

0

575

31

1

21

75

2

95

1

cp

L

If

df

t

I

u

7i

17

r

I

1

i

21

7

0

85

EO

7

166

06

I

86

9

f

4S9

9118

111

Unit

rnmlin

c

z

III

aIIo

i

t

I

tD

o

I

j

Tool

number

Kent

Moore

No

ST08800000

ST08810000

SPECIAL

SERVICE

TOOLS

Tool

name

Sucker

8W

Caulking

hand

gun

BODY

Special

Service

Tools

BF

37

DATSUN

200SX

Model

S

11

0

Series

SECTIONHA

HEATER

AIR

CONDITIONER

CONTENTS

I

HEATER

I

DESCRIPTION

HEATER

SYSTEM

HEATER

COMPONENTS

AIR

FLOW

SERVICE

PROCEDURES

HEATER

CONTROL

ASSEMBLY

HEATER

UNIT

BLOWER

UNIT

RESISTOR

HEATER

DUCT

REAR

HEATER

DUCT

DEFROSTER

NOZZLE

VENTI

LA

TOR

DUCT

ELECTRICAL

CIRCUIT

SCHEMATIC

WIRING

DIAGRAM

TROUBLE

DIAGNOSES

AND

CORRECTIONS

I

AIR

CONDITIONER

I

DESCRIPTION

REFRIGERATION

CYCLE

AIR

CONDITIONING

COMPONENTS

LOCATION

OF

ELECTRICAL

AND

VACUUM

UNIT

AIR

FLOW

GENERAL

SERVICE

PRECAUTIONS

INSTALLING

MANIFOLD

GAUGE

HANDLING

REFRIGERANT

SERVICE

CAN

TAP

DISCHARGING

REFRIGERANT

EVACUATING

AND

CHARGING REFRIGERANT

SYSTEM

COMPRESSOR

OIL

LEVEL

CHECK

PERFORMANCE

TEST

PERFORMANCE

CHART

PERFORMANCE

TEST

DIAGNOSES

HA

2

HA

2

HA

2

HA

3

HA

4

HA

4

HA

5

HA

6

HA

6

HA

7

HA

7

HA

7

HA

7

HA

B

HA

8

HA

8

HA

9

HA

l0

HA

l0

HA

ll

HA

12

HA

12

HA

13

HA

13

HA

13

HA

14

HA

14

HA

14

HA

16

HA

17

HA

17

HA

20

SERVICE

PROCEDURE

PRECAUTIONS

FOR

REMOVAL

AND

INSTALLATION

REFRIGERANT

LINES

COMPRESSOR

IDLER

PULLEY

COMPRESSOR

CONDENSER

RECEIVER DRIER

ILlOUID

TANK

FAST

IDLE

ACTUATOR

COOLER

RELAY

COOLING

UNIT

AMBIENT

SWITCH

EXPANSION

VALVE

AND

SUCTION

THROTTLE

VALVE

AIR

CONDITIONER

CONTROL

ASSEMBLY

BLOWER

UNIT

RESISTOR

MAGNET

VALVE

COMPRESSOR

SWP167

PRECAUTIONS

COMPRESSOR

CLUTCH

SHAFT

SEAL

SIDE

COVER

REAR

END

COVER

AND

REAR

CYLINDER

HEAD

REPLACEMENT

OF

CYLINDER

ELECTRICAL

CIRCUIT

SCHEMATIC

WIRING

DIAGRAM

TROUBLE

DIAGNOSES

AND

CORRECTIONS

AIR

CONDITIONER

DIAGNOSES

BLOWER

MOTOR DIAGNOSES

COMPRESSOR

CLUTCH

DIAGNOSES

COMPRESSOR

DIAGNOSES

FAST

IDLE

CONTROL

DEVICE

DIAGNOSES

SERVICE

DATA

AND

SPECIFICATIONS

GENERAL

SPECIFICATIONS

INSPECTION

ANO

ADJUSTMENT

TIGHTENING

TOROUE

SPECIAL

SERVICE

TOOLS

Ref

to

Section

MA

Heater

and

Air

Conditioner

for

CHECKING

REFRIGERANT

LEVEL

CHECKING

REFRIGERANT

LEAKS

Reflr

to

Section

MA

Basic

MechaniClI

Systam

for

CHECKING

AND

ADJUSTING

DRIVE

BELTS

HA

24

HA

24

HA

25

HA

25

HA

26

HA

26

HA

26

HA

27

HA

27

HA

27

HA

27

HA

28

HA

28

HA

28

HA

28

HA

2B

HA

29

HA

30

HA

30

HA

32

HA

33

HA

34

HA

35

HA

37

HA

37

HA

38

HA

39

HA

39

HA

4l

HA

43

HA

45

HA

47

HA

48

HA

48

HA

48

HA

48

HA

4

r

Desr

ription

HEATER

DESCRIPTION

HEATER

SYSTEM

To

defroster

nozzle

To

ventilator

duct

To

Yentilator

duct

Floor

door

To

floor

Fresh

air

c

o

t

Intakedoor

Jr

5L

lLJU

J

e

J

I

eciJculatiOD

L

UlT

nn

J

au

J

j

i

1I11

hJ

L

1b

To

ear

L

Air

mix

r

S

er

I

door

Blower

motor

To

floor

To

floor

To

rear

heater

duct

Heater

core

Side

view

SHA113

HEATIE

R

COMPONENTS

Side

defroster

QDterddroster

oo

Side

defrolter

Heater

core

f

IIJrffi5

noule

Heater

control

assembly

II

oClfj

Blower

motor

Water

coet

Heater

duct

0

fr

itch

Air

uide

AirSUide

C

eonaol

tiniaher

Side

ventilatnr

duct

J

SHA114

HA

2

AIR

FLOW

VENT

position

FRESH

positio7n

VE

po

t

n

r

o

tjJ

if5

to

the

desired

position

BIL

BI

Ievel

position

br

o

ll

r

L

Move

the

lever

the

desired

pos

O

DEF

position

DEF

POsition

FRESH

positixJD1

3

1ky

o

E

Move

thelever

the

desired

position

HEAT

position

FRESH

POsit

7

HEAT

POsitioo

J

tb1

o

II

4

Move

the

lever

daired

POI

V

REC

position

REC7

ition

TpoIition

r

o

J

0

Move

the

Ie

the

desired

Ji

io

Y

I

li

C

Side

view

HEATER

Description

Fresh

air

1

j

1

l

H

111111111111

rlrl

1I

Il

Jc

TOVentil

torduc

roster

17

1

l

jfd

o

l

i

ij

L

To

floor

To

rear

To

floor

heater

duct

l

r

To

defroster

nozzle

L

To

floor

To

rear

To

floor

heater

duct

Recirculation

Tfrl

oo

jJ

Il

tjfT

J

LTCi

t

lllllll

I

J

r

If

sL

SHA116

HA

J

SHA116

@

IDumination

4

Remove

pivot

lamp

I

OFF

II

2

3

I

Terminal

L

I

@

I

@

I I

0

I

@

I

i1

I

QD

I

@

Iv

16

I

ServkeProcedut

f

HEATER

HEATER CONTROL

ASSEMBLY

REMOVAL

AND

INSTAUATION

I

Remove

instrument

lower

covers

and

cluster

lids

2

Disconnect

control

cab

les

from

heater

unit

and

blower

unit

3

DiscOnnect

harness

connectors

and

ground

wire

terminal

SHA117

5

Remove

heater

control

assembly

6 Installation

is

in

the

reverse

order

of

removal

Alter

installing

adjust

control

cable

by

ref

ring

to

Adjusting

Heater

Con

trol

INSPECTION

Fan

switch

Test

continuity

through

switch

with

a

test

lamp

or

ohnuneter

HA

4

SERVICE

PROCEDURE

Always

conduct

I

Tenn

I

DIQ

@

I

r

Wuntinatioo

lamp

SHA118

ADJUSnNG

HEATER

CONTROL

REC

position

I

Inbke

door

control

cable

I

Set

air

intake

lever

at

REC

posi

tion

2

Connect

control

cable

to

air

in

take

door

lever

while

pushing

lever

to

its

Closed

position

3

Securely

clamp

the

cable

while

pushing

cable

outer

case

in

direction

of

arrow

SHA119

Air

mix

door

control

cable

I

Set

temperature

lever

at

max

COLD

position

2

Connect

control

cable

to

air

mix

door

lever

while

pushing

lever

to

its

full

open

position

3

Securely

clamp

the

ca

ble

while

pushing

cable

outer

case

in

direction

of

arrow

M

Max

COLD

position

l

SHA18Q

A1rcontrol

ceble

I

Set

air

control

lever

at

DEF

position

2

Connect

control

cable

to

side

linkage

while

pushing

the

linkage

in

direction

of

arrow

3

Securely

clamp

the

cable

while

pushing

cable

outer

case

in

direction

of

arrow

DEF

position

I

SHA121

Water

cock

control

linkage

I

Set

air mix

door

lever

at

max

COW

position

2

Securely

clamp

control

rod

while

pushing

water

cock

lever

to

its

full

closed

position

1

c

I4f

a

Max

COLD

position

Adjusting

saew

r

SHA122

HEATER

UNIT

REMOVAL

AND

INSTALLATION

I

Set

TEMP

lever

to

max

HOT

position

and

drain

engine

coolant

2

Disconnect heater

hoses

from

heater

unit

3

Remove

foUowing

Wis

I

Front

seats

2

Console

box

3

Floor

carpet

4

Instrument

lower

covers

and

cluster

lids

5

Side

ventilator

duct

on

the left

hand

side

SHA123

H

EATER

Service

Procedures

6

Radio

sound

balancer

and

stereo

cassette

deck

7

Stay

of

instrument

panel

I

8

Rear

heater

duct

SHA

125

19

Center

ventilator

duct

I

1

SHA126

HA

5

Service

Procedures

HEATER

10

Air

guides

at

lower

outlets

Right

side

guide

1

SHA127

4

Disoonnect

wire

harness

connec

tions

5

Remove

heater

1

J1it

with

heater

lntrohssembly

SHA128

6

Remove

heater

control

assembly

Refer

to

the

item

o

Heater

Control

Assembly

7Installation

is

in

the

reverse

order

of

removal

After

installing

heater

unit

lKljust

control

coble by

referring

to

Adjusting

Heater

Control

DISASSEMBLY

AND

ASSEMBLY

I

Remove

heater

core

witli

water

cock

HA

6

r

SHA1

29

2

Remove

air

control

linkage

secur

ing

screws

SHA130

5eparate

heater

unit

case

by

re

moving

clips

4

Assemble

heater

unit

in

the

reo

verse

order

of

disassembly

a

After

installing

heater

core

and

water

cock

lKljust

water

cock

co

trol

linkage

by

referring

to

Adjust

ing

Heater

Control

b

When

assembling

air

control

link

age

set

it

as

illustrated

SHA131

INSPECTION

Ce

e

If

it

is

cracked

or

deformed

re

place

r

Il

core

Clean

fms and

check

for

water

leak

age

BLOWER

UNIT

REMOVAL

AND

INSTAlLATION

I

Remove

instrument lower

oover

and

cluster

lid

on

tIie

right hand

2

Disconnect

control

cable

and

harness

connector

from blower

unit

3

Remove

blower

unit

I

SHA132

4

Installation

is

in

the

reverse

order

of

removal

Adju

1

r

corrtrolcablebi

referring

to

Adjusting

Heater

Control

DISASSEMBLY

I

Remove

blower

D

otor

2

Separate

blower

unit

case

by

reo

moving

clips

RESISTOR

REMOVAL

AND

INSTALLAnON

I

Remove

instrument

cluster

lid

2

Remove

resistor

from

heater

unit

Temperature

fuse

Resistorw

SHA134

3

Install

resistor

so

that

temperature

fuse

locates

at

upper

side

INSPECTION

Test

continuity

using

test

lamp

or

ohmmeter

J

I

T

jf

@

o@

uCD

HEATER

DUCT

REMOVAL

AND

INSTALLATION

Proceed

after

removing

instrument

lower

cover

and

cluster

lid

on

the

right

hand

side

SHA136

REAR

HEATER

D

CT

REMOVAL

AND

INSTALLATION

Refer

to

the

item

on

Heater

Unit

DEFROSTER

NOZZLE

REMOVAL

AND

IN

TALLATION

Front

window

defroster

nozzle

Proceed

after

reJlK

ving

instrument

assembly

SHA137

Side

window

defroster

nozzle

Proceed

after

removing

instrument

lower

covers

and

cluster

lids

Left

side

Right

side

HEATER

Service

Procedures

VENTILATOR

DUCT

REMOVAL

AND

INSTALLATION

Center

ventilator

duct

Refer

to

the

item

on

Heater

Unit

Side

ventilator

duct

Left

ide

Refer

to

the

item

on

Heater

Unit

RighUide

Proceed

after

removing

instrument

assembly

3

F

J

c

SHA139

Foot

ventilator

duct

I

SHA 140

HA 7

Electrical

Cirwir

HEATER

ELECTRICAL

CIRCUIT

SCHEMATIC

RESISTOR

I

FUSE

ISA

MOToR

u

O

c

TO

WIPER

TO

AI

R

CONOlTlONER

SWITCH

BLOWER

I

1M

Jl

n

u

LAM

FAN

SWITCH

L

1

I

W

r

IGNITION

RELAY

I

c

J

15

1

r

ILLUMINATION

CONTROL

SWITCH

BATTERY

IGNITION

SWITCH

B

Q

I

FUSIBLE

LINK

SHA141

WIRING

DIAGRAM

BLOWER

j

MOTOR

RESISTOR

4J

LHJ

TO

WI

P

fR

G

ow

LIGHTING

SWITCH

3

J

JI

TO

AIR

CONDITIONER

SWITCH

00

4 e

FUSE

2

It

f

j

FAN

SWt

reH

ILlUMlNATIONC

J

CONTROL

SWI

reH

t

l

GN

T

ON

RELAY

1

IG

IITION

SWITCH

IUUIIIINATION

L

P

FUSIBLE

LINK

i

f

BATTERY

SHA14

HA

S

HEATER

Trouble

Diagnoses

and

Corrections

TROUBLE DIAGNOSES

AND

CORRECTIONS

Condition

Insufficient

heating

performance

No

heated

air

discharged

Insufficient

air

flow

to

floor

Insufficient

defrosting

performance

Cold

air

discharged

Insufficient

air

flow

to

defroster

Heated

air

discharged

with

lever

in

VENT

Blower

motor

does

not

operate

Control

lever

drags

Outside

air

comes

in

with

AIR

control

lever

REC

Noise

from blower

motor

Probab

Ie

cause

Cooling

water

temperature

too

low

Heater

core

plugged

Insufficient

cOoling

water

level

Malfunctioning

air

mix

door

Malfunctioning

water

cock

Blower

motor

speed

too

low

Malfunctioning

floor

door

Refer

to

No

heated

air

discharged

Malfunctioning

floor

door

or

faulty

seal

Defroster

nozzle

plugged

Leak at

defroster

duct

to

nozzle

connection

Water

cock

not

operating

properly

Mode

door

not

operating

properly

or

seal

damaged

Refer

to

Trouble

Diagnoses

and

Corrections

Air

conditioner

Inner

wire

rubbing

against

outer

case

end

Control

cable

bent

excessively

Malfunctioning

doorn

door

levers

etc

Air

intake

door not

operating

properly

Control

cable

out

of

adjustment

Loose

bolt

in

blower

motor

Corrective

ction

Check

thermostat

Replace

as

necessary

Clean

Refill

Adjust

control

cable

Adjust

control

cable

Check

water

cock

Replace

as

necessary

Check

motor

terminal

voltage

Repair

poor

connection

and

discontinuity

Replace

motor

if

necessary

Adjust

control

cable

Adjust

control

cable

Clean

Correct

Adjust

control

cable

Check

water

cock

Replace

as

necessary

Adjust

control

cable

Adjust

control

cable

Correct

Check

and

correct

Repair

or

rep

ce

Adjust

control

cable

Check

and

tighten

loose

bolts

HA

9

Description

AIR

CONDITIONER

DESCRIPTION

REFRIGERATION

CYCLE

Compressor

The

low

pressure

refrig

erant

is

compressed

to

a

hh

pJe

SU1

C

and

high

Jle

i

N

V

Is

I

l

Outside

air

u

lPIl

I

v

xyyv

I

R

drier

JJ

r

l

Condenser

The

heated

and

com

pressed

refrigerant

gas

from

the compressor

condenses

to

a

liquid

Stores

the liquid

refrig

erant

and

removes

moisture

and

foreign

particles

as

the

refrig

erant

circulates

within

the

system

i

High

pressure valve

Discluuges

refrigerant

to

atmosphere

at

pres

lfes

above

3

727

IcPa

38

kgfem2

540

psi

Low

pmmue

switch

Tums

OFF

at

pressures

below

196

IcPa

2

81

em

2

28

psi

cutting

compressOI

power

supply

HA

l0

w

q

v

i

t

e

w

fL

w

tmfJ

High

pressure

gas

t

l

High

presswe

liquid

Evaporator

The

refrigerant

evaporates

and

the

air

liquid

cools

o

Expansion

valve

DeliVers

sprayed

refrig

erant

to

the

eVaporator

to

facilitate

refrigerant

h

hl

and

con

trols

the

amount

of

re

frigerant

possing

the

orifke

Low

pressure

liquid

1

01

Low

pre

sure

gas

Recirculation

air

V

I

J

b

Blower

motor

Controls

the

enporat

ins

pressure

and

pi

vents

e

fomation

of

the

frost

SHA

142

AIR

CON

DITION

ER

Description

AIR

CONDITIONING

COMPONENTS

a

o

I

1I

5

l

s

a

o

5

2

e

l

L

e

8

jj

u

8

SH 143

HA

ll

Desr

ription

AIR

CONDITIONER

LOCATION

OF

ELECTRICAL

AND VAcuuM

UNIT

L

SHA1

AIR

FLOW

Air

flow

at

any

position

VENT

B

L

HEAT

DEF

and

REC

is

the

same

as

that

of

HEATER

except

that

passes

through

cooling

unit

aU

air

discharged

with

blower

unit

To

O ide

air

defroster

ventilator

n

Ventilator

door

nozzlll

duct

To

delio

tor

now

1

r

1t

t

i

7u

1Mi

T

lJ

7

iIllJlL

1

i

ll

Qjr

lr

mower

motor

To

floor

To

f1oor

To

floor

Side

view

rear

heater

Heater

core

duct

SMA146

J

HA

12

J

PRECAUTIONS

WARNING

1

Since

direct

conlllct

of the

liquid

refrigerant

with

your

skin

will

muse

frostbite

always

be

careful

when

handling

the

refrigerant

Always

wear

goggles

to

protect

your

eyes

when

working

around

the

system

2

The

refrigerant

service

conllliner

has

a

safe

strength

However

if

handled

incorrectly

it

will

ex

plode

Therefore

always

follow

the

instructions

on

the

label

In

particular

never

store

it

in

a

hot

location

above

S20C

1260F

or

drop

it

from

a

high

height

3

The

refrigerant gas is

odorless

and

colorless

and

breath

ing

may

become

difficult

due

to

the

lack

of

oxygen

Since

the

refrigerant

gas is

heavier

than

air

and

will

lay

close

to

the

floor

be

espe

cially

careful

when

handling

it

in

small

confined

spaces

4

The

refrigerant

itseit

is

nonflam

mable

However

a

toxic

gas

phosgene

gas is

produced

when

it

conlllCb

fire

and

special

care

is

therefore

required

when

check

ing

for

leaks

in

the

system

with

a

halide

torch

5

Do

not

steam

clean

on

the

sys

tem

especially

condenser

since

excessively

high

pressure

will

build

up

in

the

system

resulting

in

explosion

of

the

system

Connection

to

service

v

lve

I

Funy

close

both

valves

of

mani

fold

gauge

Connect

high

and

low

pressure

charging

hoses

to

manifold

gauge

2

Remove

caps

from

service

valves

Connect

high

and

low

pressure

charg

ing

hoses

to

service

valves

in

system

i

GENERAL

SERVICE

r

AIR

CONDITIONER

General

Service

INSTALLING

MANIFOLD

GAUGE

Hoses

for

the

low

pressure

valve

suction

valve

and

high

pressure

valve

discharge

valve

should

be

connected

securely

to

high

and

low

respectively

on

the

manifold

Refer

to

identification

marks

on

compressor

Low

pressure

gauge

High

pressure

gauge

Manifold

gauge

Before

connecting

hoses

close

valves

completely

Q

1fT

o

en

R

12

Vacuum

pump

r

S

Close

ICap

2

Service

valve

3

Cha

rging

hose

4

Packing

5

Check

valve

Refrigerant

can

SH

A045

Disconnection

from

service

valve

I

Fully

close

both

valves

of

mani

fold

gauge

2

Quickly

disconnect

two

charging

hoses

from

service

valves

and

install

caps

on

service

valves

CAUTIDN

Do

not

over

tighten

valve

cap

HA

13

General

Service

AIR

CONDITION

ER

HANDLING

REFRIGERANT

SERVICE

CAN

TAP

The

foUowing

procedures

apply

to

conventional

can

taps

For

correct

usage

refer

to

the

manufacturer

s

instructions

I

Connect

charging

hose

between

manifold

gauge

and

can

tap

2

FuUy

turn

in

close

valve

stem

of

manifold

gauge

3

Attach

can

tap

to

refrigerant

can

by

turning

can

tap

handle

fuUy

counterclockwise

4

Make

a

hole

in

refrigerant

can

by

turning

can

tap

handle

clockwise

n

Needle

Car

tap

handle

Refrigerant

an

r

SHA046

5

TUrn

the

handle

fully

counter

clockwise

to

raise

the

needle

Refriger

ant

gas

will

flow

up

to

the

manifold

gauge

n

SHA041

6

Purge

air

from

charging

hose

by

loosening

charging

hose

nut

at

mani

fold

gauge

HA 14

I

Purging

air

W

Add

Fl

12

SHA04S

DISCHARGING

REFRIGERANT

The

pressurized

refrigerant

gas

in

side

the

system

must

be

discharged

at

a

pressure

approaching

atmospheric

pressure prior

to

evacuating

refrigerant

inside

the

system

I

Close

high

and

low

pressure

valves

of

manifold

gauge

fuUy

2

Connect

two

charging

hoses

of

manifold

gauge

to

their

respective

service

vavles

WARNING

Securely

connect

high

pressure

dis

charge

service valve

to

that

of

manifold

gauge

with

a

hose

also

cOnnect

low

pressure

suction

service valve

to

that

of

manifol

gauge

3

Open

both

manifold

gauge

valves

and

discharge

refrigerant

from

system

LO

rJ

High

1

Slowly

40

SHA949

EVACUATING

AND

CHARGING

REFRIGERANT

SYSTEM

EVACUATING

REFRIGERANT

SYSn

W

I

InstaU

manifold

gauge

on

system

and

discharge

refrigerant

from

system

until

pressure

reaches

atmospheric

pressure

WARNING

Securely

connect

high

pressure

dis

charge

service

valve

to

that

of

manifold

gauge

with

a

hose

also

conn

ect

low

pressure

suction

service valve

to

that

of

manifold

gauge

2

Connect

center

charging

hose

to

vacuum

pump

3

Close

both

valves

of

manifold

gauge

fuUy

Then

start

vacuum

pump

4

Open

low

pressure

v

alve

and

SlIck

old

refrigerant

from

system

p

Open

Oose

40

U0

SHA060

5

When

low

pressure

gauge

reading

has

reached

to

approximately

66

7

kPS

500

mrnHg

19

69

inHg

slowly

open

high

pressure valve

Low

0

lligh

W

lOpen

00

SHA051

6

When

pressure

inside system

has

dropped

to

94

6

kPa

710

mmHg

27

95

inHg

fully

close

both

valves

of

manifold

gauge

and

stop

vacuum

pump

Let

it

stand

for

5

to

10

minutes

in

this

state

and

confIrm

that

the

reading

does

not

rise

B

The

low

pressure

gauge

reads

lower

by

3 3

kPa

25

mmHg

0

98

inHg

per

300

m

1

000

itl

elevation

Perform

evacuation

according

to

the

following

table

Elevation

m

ft

0

300

I

000

600

2

000

900

3

000

Vacuum

of

system

kPa

mmHg

inHg

94

6

710

27

95

91

3

685

26

97

88

0

660

25 98

84

6

635

25 00

Valuesshow

reading

ofthe

low

pressure

gauge

b

The

rate

of

ascension

of

the

low

pressure

gauge

should

be

leIS

than

3 3

kPa

25

mmHg

0

98

inHg

in

five

minutes

If

the

pressure

rises

or

the

specified

negative

pressure

ean

not

be

obtained

there

is

a

leak

in

the

system

In this

ease

repair

the

leak

as

described

in

the

following

I

Charge

system

with

a

can

of

refrigerant

about

04

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

MA

section

3

Discharge

refrigerant

again

and

then

evacuate

system

CHARGING

REFRIGERANT

SYSTEM

I

Evacuate

refrigerant

system

2

Close

manifold

gauge

valves

securely

and

disconnect

charging

hose

from

vacuum

pump

3

Purge

air

from

center

charging

hose

I

Connect

center

charging

hose

to

refrigerant

can

through

can

top

2

Break

seal

of

refrigerant

can

and

purge

air

I

1

Purging

air

k

R

12

SHA048

4

Charge

refrigerant

into

system

I

n

case

of

charging

re

igerant

gas

Open

high

and

low

pressure

valves

of

manifold

gauge

and

charge

refriger

ant

into

system

Low

lt lt

o

W

O

n

9ft

Open

t

r

SHA052

AIR

CONDITION

ER

GeneralSefYice

When

refrigerant

charging

peed i

slow

immerse

refrigerant

can

in

water

heated

to

a

temperature

of

about

400c

I1Q4OFl

for

a

short

time

WARNING

a

Under

no

circumstances

the

re

frigerant

can

be

wanned

in

water

heated

to

a

temperature

of

over

520C

1260F

b

A

blow

torch

or

stove

must

never

be

used

to

warm

up

the

can

Immerse

i

zl in

water

heated

to

about

r

400C

1040F

for

a

short

time

A

12

AC184A

2

ln

case

of

charging

liquefied

re

frigerant

Open

high

pressure

valve

of

mani

fold

gauge

and

charge

liquefied

reo

frigerant

into

system

with

can

upside

down

CAUTION

When

charging

liquefied refrigerant

into

the

system

with

the

can

turned

upside

down

to

reduce

charging

tima

charge

it

only

through

high

pressure

discharge

service valve

After

com

pletion

of

charging

the

compressor

should

always

be

turned

several

times

manually

10

Close

Open

t

SHAOS

HA 15

General

SefVice

AIR

CONDITION

ER

5

When

refrigerant

charginiJ

sPeed

slows

down

charge

it

while

running

the

compressor

for

ease

of

charging

After

having

taken

the

steps

up

to

3

above

proceed

with

cahrging

in

the

following

order

I

Shut

off

high

pressure

valve

of

manifold

gauge

2

Run

the

engine

at

idling

speeds

below

1

500

rpm

3

Set

mode

dial

temperature

dial

and

fan

lever

at

maximum

0001

and

speed

respectively

4

Charge

refrigerant

while

oon

trolling

low

pressure

gauge

reading

at

275

kPa

28

kg

em2

40

psi

or

less

by

turning

in

or

out

low

pressure

valve

of

manifold

gauge

WARNING

NgVl

l

wrge

mrigerant

through

high

pressure

side

discharge

side

of

systerri

since

this

will

fon

e

nt

frigerant

back

into

refrigerant

can

and

can

may

explode

Run

at

idling

1

w

aose

T

t

Q

SHA054

6

When

refrigerant

can

is

empty

fully

close

both

valves

of

manifold

gauge

and

replace

refrigerant

can

with

a

new

one

Before

charging

refrigerant

ftom

new

can

purge

air

from

inside

charg

ing

hose

7

Charge

the

specified

amount

of

refrigerant

into

system

by

weighing

charged

refrigerant

with

scale

Owr

chargi

lg

will

cause

discharge

pressure

to

rise

HA

16

Refrigerant

capacity

0 9

1

kg

2 0 2

4Ib

Measure

the

a

mount

or

charged

refriger

ant

with

a

scale

Make

a

note

of

the

amount

charged

from

can

AC252

The

state

of

the

bubbles

in

sight

glass

should

only

be

used

for

checking

whgther

the amount

of

charged

r

frigerant

is

small

or

not

Refer

to

Checking

Refrigerant

Level

Section

MAl

The amount

of

charged

refriger

ant

can

be

correctly

judged

by

means

of

discharge

pressure

8

Close

manifold

gauge

valves

Then

detach

charging

hoses

from

service

valves

of

system

Be

sure

to

install

valve

cap

on

service

valve

9

ConIum

that

there

are

no

leaks

in

system

by

checking

with

a

leak

detec

tor

Refer

to

Checking

for

Leaks

MA

section

Conducting

a

performance

test

prior

to

removing

manifold

gauge

is

8

good

service

operation

Refer

to

Per

formance

Test

COMPRESSOR

OIL

LEVEL

CHECK

The

oil

used

to

lubricate

the

com

pressor

circulate

into

the

system

from

the

ail

sump

while

compressor

i

operating

Therefore

to

correctly

measure

compressor

oil

the

amount

of

oil

flowing

in

the

system

must

be

considered

If

a

considerable

amount

of

leakage

of

refrigerant

gas

occurs

tha

leakage

of

compressor

oil

is

also

considered

When

checking

the

level

of

oom

pressor

oil

or

when

replacing

any

w

r

ent

part

ofthe

system

use

the

following

service

procedure

This

helps

to return

oil

to

oompressor

I

Fully

open

all

windows

or

all

doors

of

car

Opernte

compressor

at

engine

idling

speed

1

000

rpm

or

be

low

with

controls

set

for

maximum

cooling

and

high

blower

speed

for

20

to

30

minutes

in

order

to

return

com

pressor

oil

to

compressor

ON

i

1

11

MAX

COLD

MAX

FAN

SPEED

SHA376

2

Stop

the

engine

and

discharge

re

frigerant

of

system

and

then

remove

oompressor

from

the

car

3

Remove

oompressor

drain

plug

Drain

compressor

oil

from

oompressor

oil

siunp

and

measure

the

amount

SHA056

Residual

oille

l

160

190

m

5

4

6

4

US

OZ

5 6 6 7

Imp

fl

ozl

4

If

the

amount

is

below

the

above

values

refrigerant

may

have

leaked

Conduct

leak

tests

on

connections

of

each

system

and

if

necessary

repair

or

replace

faulty

parts

5

Check

the

purity

of

the

oil

If

the

oil

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

add

additional

oil

to

reach

the

minimum level

PERFORMANCE

CHART

TEST

CONDITION

Testing

must

be

performed

as

follows

Car

location

Doors

Door

window

Hood

MODE

dial

TEMP

dial

FAN

lever

Engine

speed

Manifold

gauge

Measurement

of

discharge

air

temperature

Measurement

of

inside

air

relative

humidity

and

temperature

Measurement

of

ambient

air

relative

humidity

and

temperature

AIR

CONDITIONER

Performance

Te

t

PERFORMANCE

TEST

Indoors

or

in

the

shade

outside

wind

velocity

Less

than

2

m

7

ft

sec

Closed

Open

Max

COLD

position

Max

COLD

position

4

positions

1

500

rpm

constant

Connect

manifold

gauge

to

high

discharge

and

low

suction

service

valves

Center

outlet

grille

Blower

assembly

inlet

A

point

1

m

3

ft

in

front

of

condenser

0

HA

17

Performance

Test

AIR

CONDITIONER

TEST

READING

Inside

air

Recirculating

air

at

blower

assembly

inlet

Discharge

air

temperature

at

center

ventilator

Relative

humidity

Air

temperature

oC

oF

Oc OF

15

59

4

55

2

40

41

20 68

65

75

44

46

25 77

879 8

48

50

40

50

30 86

10

8

12

2

51

54

35 95

12

9

14

5

55

58

40

104

15

0

17

0

59 63

15

59

5258

41

42

20

68

75 85

46

47

25 77

98

11

0

50 52

50

60

30 86

12

2

13

5

54

56

35

95

14

5

16

2

58

61

40

104

17

0

18

9

63 66

15

59

5

8 6

5

42

44

20

68

85

94

47

49

25

77

11

0

12

3

52 54

60

70

15

2

56

30

86

J3

5

59

35 95 16

218 2

61 65

40

104

18

9

21

1

66

70

15

59

65

71 44

45

20 68

94

10

3

49

51

25

77

12

313 7

54

57

70 80 30 86

15

2

17

0

59

63

35

95

18

2

20

2

65 68

40

104

21

1

23

5

70

74

15

59

71

7 9

45

46

I

25

68

10

3

n

5

51

53

I

30 77

13

7

15

0

57

59

80 90

I

35 86

17

0

18

6

63 65

r

40 95 20

2

22

2

68 72

I

45

104

23

5

26

0

74 79

HA

18

AIR

CONDITIONER

Performance

Test

Ambient

air

Pressure

high

Discharge

side

Pressure

low

Suction

side

Relative

humidity

Temperature

kPa

kg

cm2

psi

kPa

kg

em2

psi

oC

F

15

59

500 657

93

2

98

1

51

67

73

95

0

95

1

00

13

5

14 2

20

68

755

834

103

0

112

8

7

85

109

121

1

05

1

15

14

9

16

4

25 77

922

1

010

l22

1i

137

3

40

65

94

10

3

134

146

1

25

I

40

17

819 9

30 86

1

079

1

196

142

2

156

9

11

0

12

2

156

173

I

45

1

60 20

6

22

8

35 95

1

245

1

373

156

9

176

5

12

7

14 0

181

199

1

60

1

80

22

8

25

6

40

104

1

393

1

550

176

5

196

1

14

2

15

8

202 225

1

80

2

00

25

6

28

4

15 59

657

726

98

1

li2

8

67

74

95

105

i6

4

1

00

0115

14

2

1

20

68

834 922

112

8

132

4

85 94

121

134

1

15

1

35

16

4

19

2

25

77

1

010

1

118

137

3

152

0

65

90

10

3

II

4

146

162

140

1

55

19

9

22

0

30

86

1

196

1

314

156

9

171

6

12 2

13

4

173

191

1

60

1

75

22

8

24

9

35

95

1

372

1

510

176

5

196

1

14

0

154

199

219

1

80

2

00

25

6

28

4

40

104

1

550

1

716

196

1

220

7

15 8

17

5

225 249

2

00

2

25

28

4

32

0

aThe

pressure

will

change

in the

following

manner

with

manges

in

cond

itions

When

blower

speed

is

low

dis

charge

pressure

will

drop

When

the

relative

humidity

of

in

take

air

is

low

discharge

pressure

will

drop

b

The

temperature

will

change

in the

following

manner

with

changes

in

conditions

When

the

8rrmient

air

temperature

is

low

the

outlet

air

temperature

will

becomg

low

If

the

test

reveals

that

there

is

any

abnormality

in

system

pressure

isolate

the

cause

and

repair

Refer

to

Per

formance

Test

Diagnoses

HA

19

Perfonnance

Te

t

AIR

CONDITIONER

PERFOR

NCE

TEST

DIAGNOSES

Characteristics

revealed

on

the

manifold

gauge

rcading

for

the

air

conditioning

system

are

shown

in

the

following

Condition

As

to

the

method

of

a

performance

test

refer

to

the

item

of

Performance

Test

indicateS

a

range

baSed

on

the

lissump

tion

that

the

air

conditioning

system

is

in

good

order

This

range

is

described

in

PERFORMANCE

CHART

In

the

following

table

the

portion

smeared

with

ink

on

sam

gauge

scale

I

INSUFFICIENT

REFRIGERANT

CHARGE

1

0

@@

AC352A

ALMOST

NO

REFRIGERANT

I

00

@@

AC353A

I

FAULTY

EXPANSION

VALVE

I

0

@@

AC354A

HA

20

Insufficient

cooling

Bubbles

appear

in

sight

glass

No

cooling

action

In

sight

glass

appear

a

lot

of

bubbles

or

something

like

mist

Sight

cooling

Sweating

or

frosted

expan

sion

valve

inlet

Probable

cause

Refrigerant

is

small

or

leaking

alittle

Serious

refrigerant

leak

Expansion

valve

restricts

refrigerant

flow

Expansion

valve

is

clog

ged

Expansion

valve

is

in

operative

Valve

stuck

closed

Thermal

bulb

has

lost

charge

Corrective

action

I

Leak

test

2

Repair

leak

3Charge

system

EVKUatB

as

necessary

and

recharge

system

Stop

compressor

immedi

ately

1

Leak

test

2

Discharge

system

3

Repair

leak

s

4

Replace

receiver

drier

if

neCessary

5

Check

oil

level

6

Evacuate

and

recharge

system

If

valve

inlet

reveals

sweat

or

frost

I

Discharge

system

2

Remove

valve

and

clean

it

Replace

it

if

neces

sary

3

Evacuate

system

4

Charge

system

If

valve

does

not

operate

I

Discharge

system

2

Replace

valve

3

Evacuate

and

charge

system

Condition

010

@

f

AC355A

@

fg

fi

0

@@

AC356A

I

FAUL

TV

SUCTION

THROTTLE

VALVE

C0

@ @

AC357A

0

@ @

AC358A

Insufficient

cooling

Sweated

suction

line

No

cooling

Sweating

or

frosted

sue

tion

line

Insufficient

cooling

Frosted

evaporator

Insufficient

cooling

AIR

CONDITION

ER

Performance

rest

Probable

cause

Expansion

valve

allows

too

much

refrigerant

through

evaporator

Faulty

expansion

valve

Suction

throttle

valve

is

inoperative

Suction

throttle

valve

restricts

refrigerant

flow

CorreCtive

action

Check

valve

for

operation

If

suction

side

does

not

show

a

pressure

decrease

replace

valve

L

Discharge

system

2

Replace

valve

3

Evacuate

and

replace

system

I

Discharge

system

2

Replace

valve

3

Evacuate

and

charge

system

I

Discharge

system

2

Replace

valve

3

Evacuate

and

charge

system

HA 21

Perfonnance

Test

AIR

CON

DITION

ER

Condition

I

AIR

IN

SYSTEM

I

r

010

@@

AC359A

I

MOISTURE IN

SYSTEM

I

010

@

AC360A

I

FAULTY

CONDENSER

I

t

0

@ @

AC361

A

HA

22

Insufficient

cooling

Sight

glass

shows

occasion

al

bubbles

After

operation

for

a

while

pressure

on

suction

side

may

show

vacuum

pressure

reading

During

this

condition

discharge

air

will

be

warm

As

a

warning

of

this

reading

shows

39

kPa

0

4

kg

cm2

6

psi

vibration

No

cooling

action

engine

may

overheat

Bubbles

appear

in

sight

glass

of

drier

Suction

line

i

very

hot

Probable

cause

Air

mixed

with

refrigerant

in

system

Drier

is

saturated

with

moisture

Moisture

has

fro

zen

at

expansion

valve

Refrigerant

flow

is restrict

ed

Usually

a

malfunctioning

condenser

Corrective

action

I

Discharge

system

2

Replace

receiver

drier

3

Evacuate

and

charge

system

I

Discharge

system

2

Replace

receiver

drier

twice

if

necessary

3

Evacuate

system

com

pletely

Repeat

30

minute

evacuating

three

times

4

Recharge

system

Check

fan

belt

and

fluid

coupling

e

Check

condenser

for

dirt

accumulation

Check

engine

cooling

system

for

overheat

Check

for

refrigerant

overcharge

If

pressure

remains

high

in

spite

of

all

above

ac

tions

taken

remOW8

and

inspect

the

condenser

for

possible

oil

dogging

Condition

I

HIGH

PRESSURE

LINE BLOCKED

I

6

@

AC362A

I

FAULTY

COMPRESSOR

I

0

@@

AC363A

TOO

MUCH

OIL

IN

SYSTEM

Excessivel

r

0

@@

AC364A

Insufficient

cooling

Frosted

high

pressure

liquid

line

Insufficient

cooling

Insufficient

cooling

AIR

CONDITIONER

SelViceProceduref

Probable

cause

Drier

clogged

or

restrie

tion

in

high

pressure

line

Internal

problem

in

com

pressor

or

damaged

gasket

and

valve

Too

much

oil

circulates

with

refrigerant

causing

the

cooling

capacity

of

the

system

to

be

reduced

Corrective

action

I

Discharge

system

2

Remove

receiver

drier

or

strainer

and

replace

it

3

Evacuate

and

charge

system

I

Discharge

system

2

Remove and

check

compressor

3

Repair

or

replace

com

pressor

4

Check

oil

level

5

Replace

receiver drier

6

Evacuate

and

charge

system

Refer

to

Oil

Level

Check

for

correcting

oil level

HA

23

ServiceProcedu

s

AIR

CONDITIONER

PRECAUTIONS

FOR

REMOVAL

AND

INSTALLATION

When

replacing

refrigerant

cycle

components

observe

the

following

1

Discormect

battery

ground

cable

2

Before

starting

work

be

sure

to

discharge

system

WARNING

Gradually

loosen

discharge

side

hOse

fitting

and

remove

it

after

remaining

pressure

has

been

re

IlIIsed

3

When

disconnecting

or

connecting

tubes

be

sure

to

use

wrenches

on

both

tubes

SHA057

HA 24

SERVICE

PROCEDURE

4

After

disconnectinll

tubes

plug

all

openings

immediately

to

prevent

entrance

of

dirt

and

moisture

Plug

SH

A058

5

Compressed

air

must

never

be

usad

to

dean

dirty

line

Clean

with

refrigerant

gas

6

When

connecting

tubes

install

new

a

ring

never reuse

used

one

into

connection

and

be

sure

to

apply

com

pressor

oil

to

seating

surface

and

0

ring

I

uamnr

s

SHA059

7

Check

tightening

torque

of

con

nedions

to

lpecification

8

Make

sure

refrigerant

line

is

clamped securely

Check

all

componenb

t

insure

they

are

neither

damaged

nor

interfere

with

adjacent

parts

9

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

i

J

N

m

kg

m

ft

lb

Insull

new

O

ing

into

each

connection

of tubes

OloUng

unit

10

8

0

8

11

5 8

8 0

i

J15

20

15

20

11 14

i

J125

29

25

3

0

18

22

SHA148

COMPRESSOR

IDLER

PULLEY

Loosen

REMOVAL

AND

INSTAlLATION

1

Rem

e

under

cover

2

Loosen

idler

pulley

lock

nut

and

fully

loosen

adjusting

bolt

3

Remove

drive

belt

4

Remove

idle

pulley

assembly

5

Installation

is

in

the

reverse

order

of

removal

Refer

to

Section

MA

for

adjusting

drive

belt

Adjusting

bolt

SHA149

HA

25

ServiceProcedures

AIR

CONDITIONER

COMPRESSOR

Q

N

m

kg

m

ft

lb

R

MOVAL

AND

INSTALLATION

I

Operate

compressor

if

possible

at

engine

idling

peed

with

air

condi

tioner

controls

set

for

maximum

cool

ing

and

high

blowerspeed

for

10

to

IS

minutes

with

all

windows

open

to

return

oil

into

compressor

2

Remove

compressor

drive

beh

Refer

to

the

item

on

Compressor

Idler

Pulley

3

Disconnect

high

discharge

and

low

uction

fleXible

hose

from

com

pressor

4

DiScOnnect

compressor

clutch

harness

5

Remove

compressor

1

DiSconnect

air

induction

pipe

J

5HA317

2

Remove

ignition

coils

HA

26

401

5414

5

SHA150

3

Remove

compressor

with

it

clutch

facing

up

CAUTION

Do

not

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

crank

compressor

several

times

in

its

installed

condition

6 Installation

is

in

the

reverse

order

of

removal

When

conneeting

high

and low

flexible

hoses

to

compressor

install

new

O

ring

into

connectiQn

CONDENSER

REMOVAL

AND

INSTALLATION

I

Remove

radiator

grille

2

Remove

stay

for

hood

locI

upport

3

Disconnect

refrigerant

lines

from

condenser

4

Remove

condenser

5 Installation

is

in

the

reverse

order

of

l

INSPECTION

Inspect

joints

of

inlet

and

outlet

pipes

for

cracks

and

scratches

Upon

rmding

any

problem

which

may

cause

gas

to

leak

repair

or

replace

con

denser

Condenser

fIns

or

air

passage

clog

ged

with

dirt

insect

or

leaves

will

reduce

cooling

effIciency

of

con

denser

In

such

a case

clean

fms

or

a

passages

with

compr

ed

air

CAUTION

Do

not

clean

condenser

with

steIIm

Be

sure

to

use

cold

water

or

compressed

air

RECEIVER

DillER

Liquid

tank

SHA152

REMOVAL

AND

INSTALLATION

I

Disconnect

refrigerant

line

from

receiver

drier

CAUTION

Plug

all

openings

to

enttem

e

of

din

and

moistUre

into

l1lC

iver

drier

2

Disconnect

harness

for

low

pres

Sure

switch

3

Remove

receiver

drier

4

Installation

is

in

the

reverse

order

of

removal

INSPECTION

Check

receiver

drier

for

leaks

or

damage

If

necessary

replace

FAST

IDLE

ACTUATOR

Q

From

F

I

CD

magnet

valve

FrOmair

regulator

tube

Intake

manifold

SH

A

153

INSPECTION

Refer

to

Trouble

Diagnoses

and

Corrections

COOLER

RELAY

f

6

r

SHA154

COOLING

UNIT

REMOVAL

AND

INSTAlLATION

I

Remove

instrument

lower

cover

and

cluster

lid

AIR

CONDITIONER

ServiceProcedures

2

Disconnect

refrigerant

lines

from

cooling

unit

3

Remove

cooling

unit

with

drain

tube

V

Drain

tu

SHA155

4Installation

is

in

the

reverse

order

of

removal

DISASSEMBLY

AND

ASSEMBLY

Expansion

valve

Thermo

bulb

SHA378

I

Remove

clips

fIxing

upper

case

to

lower

case

2

Withdraw

evaporator

assembly

3

Assembly

is

in

the

reverse

order

of

disassembly

INSPECTION

c

Check

for

cracked

or

deformed

case

Ev

por

tor

mbly

I

Clean

fms and

check

for

corro

sion

If

fins

are

corroded

replace

CAUTION

Do

not

clean

evaporator

with

steam

Be

sure

to

use

cold

IIIIIter

or

com

pressed

lir

2

Check

for

gas

leaks

at

expansion

valve

and

suction

throttle

valve

If

there

are

leaks

retighten

or

replace

the

defective part

with

a

new

assembly

AMBIENT

SWITCH

REMOVAL

AND

INSTALLATION

SHA157

I

Remove

instrument

lower

cover

and

cluster

lid

2

Disconnect

harness

connector

and

remove

ambient

switch

3Installation

is

in

the

reverse

order

of

removal

HA

27

ServiceProcedvres

AIR

CONDITIONER

INSPECTION

r

1101

Ambient

temperatwe

Continuity

Above

2

SoC

36

410F

Ves

Below

O

30C

0

370F

No

SHA158

EXPANSION

VALVE

AND

SUCTION

THROTTLE

VALVE

Thermo

bulb

Clamp

and

wrap

with

heat

insulator

lnle

III

IlJ

outle

Suction

throttle

valve

L

Service

valve

SHA169

Do

not

disassemble

val

neces

sary

replace

as

Iy

HA

28

AIR

CONDITIONER

CONTROL

ASSEMBLY

REMOVAL

AND

INSTALLATION

Refer

to

Heater

Control

Assembly

INSPECTION

F

an

switch

Refer

to

Fan

Switch

in

Heater

Air

conditioner

switch

Electrical

conductivity

Ch

CD

23

@

CID

c

ON

0

OFF

IUwnination

lamp

is

located between

CD

anCl

00

SHAle1

BLOWER

UNIT

Refer

to

Blower

Unit

in

Heater

RESISTOR

Refer

to

Resistor

in

Heater

MAGNET

VALVE

INSPECTION

00

@

Air

passing

I

Applied

voltage

I

OV

I

12V

CDOO@

0

10

I

SHA162

v

@

1

8

rn

ff

0

f

14

II

l

en

0

t

Z

10

j

5

z

rn

II

I

C

l

til18

21

1

8

2

1

13

15

@JJ

tl

ji1

til29

@

34

3

0

35

22

25

@

iJJ

til18

20

1

8

2

0

13

14

j

til

N

m

k8

m

f

4b

1

Gasket

11

Oll

pipe

20

LOCK

nut

29

Shaft

seal

seat

and

O

ring

2

j

nock

pm

12

Rear

cylinder

head

21

LOCK

washet

30

Shaft

seal

3

Front

cylinder

head

13

Gear

pump

as5fmb1y

22

PulloY

and

bearing

31

Compressor

s

hell

4

suction

valVe

plate

14

Rear

end

cover

assembly

32

D

a

in

plug

lnd

gas

ket

5

Gaslo

et

15

Rear

end

cover

i

ling

bolt

23

Coil

assemblY

33

Silencer

piece

ling

6

Key

a

nd

w9

8her

24

Gasket

34

Silencer

piece

7

Compressor

cylinder

assemblY

16

Shan

nut

2S

Front

end

cover

3S

Silencer

spring

l

8

Gasket

11

Hub

nut

26

Coil

mounting

screw

36

Gasket

t

9

Rear

end

covet

O

ring

18

Spaoet

21

Felt

37

Side

cover

10

on

pipe

o

ring

19

Qutch

hub

2

Retainer

ring

38

Side

cavet

fiXing

bOlt

til

25

21

2

5

2

8

18

20

til16

11

1

6

L1

I

6

12

3

til2

1

3

4

0

28

0

35

2

0

2

5

Compressor

SWP167J

AIR

CONDHIONER

2 3

o

C

l

PRECAUTIONS

I

Plug

all

openings

in

compressor

to

prevent

from

entering

of

moisture

and

foreign

matter

2

00

nc

tleave

the

compressor

on

its

side

oruplide

down

for

more

than

10

minutes

as

the

lubricating

oil

will

enter

the

low

pressure

chambers

If

under

that

condition

compressor

should

be

operated

suddenly

internal

damage

would

result

To

expel

oil

from

chambe

hand

crank

com

pressor

several

times

in

its installed

condition

3

Before

replacing

with

the

new

compressor

complately

drain

oil

from

the

new

compressor

and

fill

with

an

emount

of

oil

equaling

that

remaining

in

the old

compressor

4

When

replacing

parts

or

oil

always

replace

gaskets

O

ing

and

oil

eal

with

new

ones

5

When

storing

a

compressor

be

sure

to

fill it

with

refrigerant

to

pre

vent

rusting

Add

refrigerant

at

the

HA

30

Y

r

i1l

f

Jl

i

I

iMt

A

l

r

YJ

t

tf

4

II

11

J

I

l

c

4

1

@l

low

pressure

side

and

purge

air

at

the

high

pressure

side

COMPRESSOR

CWTCH

The

most

common

problem

is

clutch

slippage

Service

procedures

are

listed

below

Exercise

care

I

Clearance

between

clutch

hub and

pulley

should

be

0

5

to

0

8

mm

0

D20

to

ODJI

in

at

all

peripheral

points

2

Make

sure

that

there

is

no

oil

or

dirt

on

friction

surfaces

of

clutch

disc

clutch

hub and

pulley

Remove

any

oil

or

dirt

with

a

dry

rag

1

Shaft

nut

2

Hub

nut

3

Clutch

hub

4

Key

5

Shaft

seal seat

6

Shaft

seal

7

Front

end

cover

8

Front

cylinder

head

9

Suction

valve

plate

10

Silencer

spring

11

Silencer

piece

12

Thrust

bearing

13

Side

cover

14

Rear

cylinder

head

15

Compressor

shaft

16

Rear

end

cover

17

Oilp

ump

18

Rear

cylinder

19

Oilpipe

20

Swash

plate

21

Shoe

disc

22

Front

cylinder

23

Drive

ball

24

Shell

2S

Needle

bearing

26

Clutchcoil

27

Pulley

and

bearing

assembly

SHAl64

3

Make

sure

that

terminal

voltage

at

magnetic

coil

is

above

105V

REMOVAL

I

Using

Tool

KV99412302

hold

clutch

hub

With

suitable socket

wrench

remove

shaft

nut

from

shaft

2Then

using

Tool

remove

clutch

hub

nut

Remove

spacers

AC024A

3

Using

Tool

remove

clutch

hub

Thread

tool

into

the

bore

of

clutch

hub

hold

tool

with

wrench

and

then

thread

in

center

bolt

ACQ25A

4

With

an

ordinary

screwdriver

flatten

lock

washer

tab

AC026A

5

Using

Tool

loosen

lock

nut

Re

move

lock

nut

and

lock

washer

AC027

A

6

Remove

pulley

and

bearing

as

sembly

When

the

assembly

can

not

be

removed

by

hand

use

a

puller

Tooi

KV994123I3

and

Tool

KV99412312

AIR

CONDITION

ER

Compressor

SWPI67J

AC028A

7

Using

an

impact

tool

loosen

six

coil

mounting

screws

Use

of

the

im

pact

tool

is

advisable

as

screws

have

been

calked

AC680

8

Remove

coil

mounting

screws

and

separate

coil

assembly

INSPECTION

I

Check

the

friction

surfaces

of

the

clutch

for

damage

due

to

excessive

heat

o

excessive

grooving

due

to

slippage

If

necessary

replace

coil

pulley

and

bearing

assembly

and

dutch

hub

as

aset

2

Oil

or

dirt

n

the

friction

surfaces

should

be

cleaned

with a

suitable

solvent

and

a

dry

rag

3

Check

coil

for

shorted

or

opened

binding

leads

INSTALLATION

I

Using

a

Phillips

screwdriver

tighten

coil

assembly

mounting

screws

in

an

alternating pattern

After

screws

have

been

frrmly

tightened

puncWock

each

at

one

location

to

prevent

loosen

ing

ifJ

Coil

mounting

screw

2 7

3A

N

m

0

28

0

35

kg

m

2

0

25 ft

lb

AC029

2

Using

a

plastic

mallet

drive

pulley

and

bearing

assembly

onto

the

neck

of

the

installed

coil

assembly

Turn

the

pulley

making

sure

that

there

is

no

noise

and

that

rotation

is

free

Also

make

sure

that

there

is

no

pulley

play

3

Position

lock

washer and

lock

nut

in

place

Using

Tool

KV994123IO

tighten

lock

nut

firmly

With

lock

washer

tab

and

lock

nut

cutouts

matched

bend

the

tab

with

the

screw

driver

Proceed

carefully

to

avoid

bearing

cage

damage

ifJ

Lock

nut

25 27

N

m

2 5

1

8

kg

m

18

20

It

lb

4

Fit

key

and

clutch

hub

to

the

shaft

Select

adjusting

spacer

which

gives

the

correct

clearance

between

the

pulley

and

clutch

hub

ifJ

Hub

nut

18 21

N

m

1

82

1

kg

m

13

15lt

lb

5

Tighten

shaft

nut

with

locking

agent

in

place

ifJ

Shaft

nut

16

17 N m

1

6

1

7kg

m

11 6

12

3lt

lb

6

Using

a

thickness

gauge

measure

the clutch

hub

to

pulley

clearance

Hub

to

pulley

clearance

05

0

8

mm

0

020

0

031

in

HA

31

Comprt

lSOr

SWPI67

AIR

CQN

OITlON

ER

If

the

specified

clearance

is

not

obtained

replace

adjusting

spacer

and

rcadjust

AC029A

When

replacing

compressor

dutch

a

embly

do

not

forget

br

k

in

operation

accomplished

by

engaging

and

disengaging

the

clutch

some

thirty

times

Break

in

operation

raises

the

level

of

transmitted

torque

SHAFT

SEAL

REMOVAL

I

Remove

drain

plug

thereby

drain

ing

the

oil

2

Remove

clutch

hub

pulley

and

bearing

assembly

and

coil

assembly

Proceed

according

to

information

under

Compressor

Clutch

3

Using

snap

ring

pliers

compress

and

remove

retainer

ring

4

To

remove

shaft

seal

seat

proceed

as

follows

I

Plug

high

discharge

and

low

suction

pressure

openings

of

com

pressor

using

Tool

KV994C4548

or

blind

cover

and

gasket

which

are

in

stalled

on

service

compressor

HA

32

2

Cormect

charging

hose

to

re

frigerant

can

Install Tool

KV994CI552

to other

end

of

charging

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

2

to

5

kg

em

28

to

71 psi

thrnugh

low

pressure

line

of

compressor

until

shaft

seal

seat

is

received

at

rag

CAUTION

a

Do

not

use

air

to

prevent

entry

of

moisture

dust

ete

b

If

shaft

slllll

seat

is

not

plucked

out

ins

llll

it

again

and

apply

refrigerant

pressure

KV994C1552

KV994C4531

KV994C4533

KV994C4559

SHA165

6

Insert

Tool

through

the

open

end

of

front

end

cover

Depress

the

carbon

seal

and

hook the

tool

at

the case

pro

jection

of

shaft

seal

Slowly

pull

out

the

tool

thereby

removing

shaft

seal

KV994U32

INSPECTION

I

Check

the

carbon

seal

surface

of

shaft

seal

for

damage

Carbon

seal

Contact

surCace

AC035

2

Check

Q

ring

and

the

carbon

seal

contact

surface

of

shaft

seal

seat

for

damage

Make

sure

that

O

ring

contact

surface

at

front

end

cover

is

not

damaged

Contact

surface

ACS05

INSTALlATION

Do

not

re

use

shaft

seal

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

I

Make

sure

that

the

shaft

seal

con

tact

surface

is

free

of

dirt

and

amply

lubricated

with

compressor

oil

2

Cap

Tool

KV994l2322

to

the

top

end

of

compressor

shaft

3

Using

Tool

KV9941232l

insert

shaft

seal

with

shaft

seal

case

and

shaft

cutout

aligned

Apply

force

to

turn

the

seal

some

what

to

the

left

and

right

Insure

that

shaft

seal

seats

properly

in

the

shaft

cutout

AC037

4

Fit

O

ring

to

the

outside

groove

of

shaft

seal

seat

making

sure

that

it

scats

properly

5

Apply

an

ample

coat

of

oil

to

contact

surface

and

shaft

seal

t

so

that

seat

easily

slides

on

inner

side

of

front

end

cover

Also

apply

a

thin

coat

of

grease

or

oil

to

shaft Push shaft

seal

seat

iilto

front

end

cover

until

it

bottoms

up

to

land

6

Using

snap

ring

pliers

compress

retainer

ring

and

fit

it into

front

end

cover

Seat

retainer

ring

firmly

in

the

groove

7Install

Tool

KV99412329

to

com

pressor

shaft

and

turn

shaft

5

to

6

turns

clockwise

Then

check

for

gas

leakage

as

follows

I

Plug

high

and

low

pressure

joints

into

compressor

Using

Tool

KV994C4548

or

blind

cover

and

gasket

which

are

installed

on

service

compressor

2

Connect

charging

hose

to

low

pressure

gauge

of

manifold

gauge

Install

Tool

KV994C1552

to other

end

of

charging

hose

and

insert

it into

hole

in

middle

of

blind

cover

at

low

pressure

side

Connect

center

hose

of

manifold

gauge

to

referlgerant

can

AIR

CONDITIONER

Compressor

SWPI67

3

Open

valve

of

can

top

charge

refrigerant

from

low

pressure

side

and

purge

air

from

high

pressure

side

by

loosening

blind

cap

4

Conduct

a

leak

test

If

there

is

a

leak

remove

and

then

install

again

KV994C4531 KV994C1552

KV994C4534

KV994C4559

t

lbiJ

SHA166

SIDE

COVER

REMOVAL

I

Drain

oil

2

Loosen

and

remove

eight

side

cover

mounting

bolts

in

an

alternate

pattern

Note

that

two

silencer

springs

inside

the

cover

will

force

up

side

cover

AC687

3

Remove

side

cover

and

side

cover

gasket

Discard

the

gasket

4

Remove

silencer

springs

pieces

and

O

rings

Do

not

damage

O

ring

surface

of

silencer

piece

during

this

process

Discard

used

O

rings

9

O

ring

Piece

Silencer

pnng

AC207

INSPECTION

I

Make

sure

that side

cover

gasket

surface

and

shell

gasket

surface

are

not

damaged

2

Make

sure

that

silencer

pieces

and

shell

contact

surfaces

in

contact

with

O

ring

are

not

damaged

3

Do

not

reuse

old

gasket

and

O

rings

INSTALLATION

Do

not

tap

on

the

compressor

shalt

I

Place

the

mounting

swface

of

side

cover

upward

2

Make

sure

that

holes

of

cylinder

and

shell

are

aligned

and

install

O

rings

3

Coat

O

ring

and

the

area

around

shell

hole

with

an

ample

amount

of

compressor

oil

Using

Tool

KV99412328

install

O

ring

into

the

shell

hole

Then

install

silencer

piece

with

Tool

KV99412327

4

Coat

the

gasket

surface

of

shell

with compressor

oil

and position

gasket

and

side

cover

5

Hold

side

cover

in

place

by

hand

and

thread

in

eight

mounting

bolts

Tighten these

bo

Its

evenly

in

an

alter

nating

pattern

lfJ

Side

cover

bolt

18

20

N

m

1

82 0

kg

m

13

14lt

lb

6

Fill

with compressor

oil

7

Upon

completion

of

the

above

operations

cOnduct

a

gas

leak

test

by

HA

33

Compressor

SWP167

AIR

CONDITION

ER

referring

to

the

item

Installation

under

the

topic Shaft Seal

AR

Np

CQV

AND

REAR

CYLINDER

HEAD

REMOVAL

L

Drain

oil

2

Remove

five

rear

end

cover

mounting

bolts

with

Tool

Starting

at

the

lop

loosen

all

bolts

one

turn

in

an

alternating

pattern Then

remove

bolts

in

turn

AC6

8

3

Grasp

rear

end

cover

and

carefully

separate

it

from

compressor

Tap

the

flange

lightly

and

alternately

as

reo

quired

with

a

plastic

mallei

Do

not

reuse

old

gasket

and

O

ring

AC689

4

Remove

pump

gear

Do

not

allow

pump

gear

to

damage

the

surface

HA

34

AC042

5

Remove

O

ring

gasket

and

two

pins

Discard

the

O

ring

and

gasket

6

Remove

rear

cylinder

head

suction

valve

plate

and

gasket

Discard

the

gasket

Carefully

remove

suction

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

cylinder

head

tighten

the

bolt

slowly

to

break

loose

the

head

AC210

INSPECTION

I

Make

sure

that

the

gasket

contact

surface

is

free

of

damage

2

If

replacement

of

rear

end

cover

connector

and

check

valve

is

neces

sary

replace

rear

end

cover

with

a

new

one

3

Check

suction

valve

plate

and

cylinder

head

for

broken

valves

4

Check

pump

gear

for

wear

and

damage

INSTALLATION

Do

not

reuse

old

gasket

and

O

ring

I

Using

suitable

blocks

position

compressor

with

the

front

face

down

ward

and

the

rear

upward

2

Insert

two

pins

in the

rear

of

cylinder

3

Coat

both

surfaces

of

cylinder

head

gasket

with

compressor

oil

and

align

gaaket

with

cylinder

4

Install

suction

valve

plate

making

slife

that

the

three

valV

S

properly

align

with

cylinders

and

gasket

cut

outs

AC224

5 Install

cylinder

head

gasket

and

O

ring

in

the

order

listed

q

at

gasket

and

O

ring

beforehand

with

an

ample

amount

of

compressor

oil

AC045

6

Fit

pump

gear

to

rear

end

cover

7

Carefully

fit

rear

end

cover

to

the

rear

of

compressor

AC211

8

Using

Tool

KV99412330

tighten

up

five

bolts

in

an

alternating

pattern

starting

at

the

top

Do

not

f9rget

lock

washers

fl

Rear

end

cover

bolt

29

34N

m

3 0 3 5

kg

22 25

It

lb

9

Fill

with

compressor

oil

10

Upon

completion

of

the

above

operation

conduct

a

leak

test

by

re

ferring

to

the

topic

under

Shaft

Seal

REPLACEMENT

OF

CYLINDER

REMOVAL

I

Drain

oil

2

Remove

compressor

clutch

assem

bly

Refer

to

Compressor

Clutch

3

Using

snap

ring

pliers

remove

shaft

seal

retainer

ring

Then

remove

shaft

seal

seat

Refer

to

Shaft

Seal

Removal

of

shaft

seal

is

not

absolutely

necessary

It

may

be

removed

when

cylinder

assembly

i

removed

from

front

end

cover

In

fact

this

approach

facilitates

work

4

Remove

side

cover

Refer

to

Side

Cover

5

Remove

rear

end

cover

Refer

to

Rear

End

Cover

and

Rear

Cylinder

Head

Remove

O

ring

gasket

two

pins

cylinder

head

suction

valve

plate

and

gasket

in

the

order listed

This

exposes

the

rear

part

of

cylinder

AIR

CONDITION

ER

Compressor

SWP167

6

Using

long

nose

pliers

or

other

suitable

tool

pull

out

oil

pipe

Proceed

carefully

as

oil

pipe

is

easily

bent

CAUTION

Unless

oil

pipe

hIS

been

removed

do

not

attemp

t

the

following

steps

AC212

7

With

the

front

facing

downward

support

compressor

shell

Using

a

plastic

mallet

tap

at

the

rear

end

of

the

shell

flange

driving

shell

straight

downward

Discard

front

end

cover

gasket

AC213

8

Detach

front

end

cover

from

cylinder

assembly

Using

a

plastic

mallet

drive

end

cover

upward

Re

frain

from

excessive

force

to

avoid

cover

damage

AC050

9

Remove

shaft

seal

from

the

shaft

10

Remove

two

pins

gasket

cylinder

head

suction

valve

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

CAUTION

Do

not

deform

R1ction

valve

plate

when

removing

it

INSTALLATION

I

Using

suitable

blocks

face

cylinder

assembly

upward

Insert

two

pins

Position

gasket

and

suction

valve

plate

in

the

order

listed

while

making

sure

that

three

valves

of

suction

valve

plate

are

aligned

with

the

cylinder

and

gasket

cutouts

Coat

gasket

with

com

pressor

oil

prior

to

assembly

Gaskets

and

suction

valve

plates

are

the

same

for

front

and

rear

The

cylinder

head

with

the smaller

numbers

of

holes

goes

to

the

front

Do

not

mix

front

an

rear

parts

bBJ

l

1

ACOS1

tj

1

AC052

2

Align

shaft

seal

with

the

shaft

cutaway

Firmly

seat

shaft

seal

at

the

shaft

land

Attempt

to

turn

shaft

seal

to

the

left

and

right

confirming

that

it

is

seated

properly

HA

35

Compre

r

SWP767

AIR

CONDITION

ER

3

Place

gasket

on

cylinder

head

and

install front

end

cover

Coat

gasket

with compressor

oil

beforehand

Gasket

differs

for

the

front

and

rear

Make

sure

that

the

correct

gasket

is

used

After

completing

this

work

gasket

protruding

from

front

end

cover

and

cylinder

head

should

be

adjusted

by

hand

D

t

OJ

SIlencer

hole

J

AC053

4

Fit

gasket

to

front

end

cover

Then

bring

the

shell

into

place

over

the

cylinder

assembly

At

this

tin1e

make

sure

that

the

two

holes

of

side

cover

and

the

cylinder

holes

are

matched

Note

that

later

adjustment

will

no

longer

be

possible

as

inside

and

outside

diameters

of

these

are

not

perfectly

round Note

that

moving

the

shen

up

and

down

may

cause

the

gasket

to

slip

out

of

place

HA

36

AC690

5

Turnover

the

asSembled

shell

and

cylinder

assembly

so

that the

front

may

face

downward

6

Coat

oil

pipe

and

O

ring

with

an

ample

amount

of

oil

Insert

oil

pipe

at

the

rear

of

the

cylinder

After

making

sure

that

the

hole

lines

are

matched

as

specified

in

step

4

continue

with

stepp

6

work

AC226

7

Continue

with

work

up

to

instal

lation

of

rear

end

cover

according

to

Installation

under

Rear

End

Cover

and

Rear

Cylinder

Head

8

Continue

with

work up

to

instal

lation

of

side

cover

according

to

Installation

under

Side

Cover

9 Install

shaft

seal

s

t

according

to

instructions

in

Installation

under

Shaft

Seal

10

Install

and

adjust

compressor

clutch

acoording

to

instructions

in

Installation

under

Compressor

Clutch

II

Fill

with

oompressor

oil

and

tighten

oil

plug

with

copper

gasket

in

place

til

Oil

plug

18 20

N

rn

18

2 0

kg

rn

13

14

ft

lb

12

Conduct

a

leak

test

by

referring

to

the

topic

under

Shaft

Seal

AIR

CONDITIONER

ElectricaICirr

uit

ELECTRICAL

CIRCUIT

SCHEMATIC

OFF

position

OFF

0

D

O

D

7

ft

tJ

VENT

B

L

HEAT

DEF

and

RECIRC

position

OFF

DO

G

0fl8

S

2

n

fP

A

C

positIon

ON

r

GJ

A

I

DDonO a

n

RESISTOR

BLOWER

MOTOR

M

FUSE

20A

5A

AIC

SWITCH

IGNITION

RELAY

COMPR

ESSQR

MAGNET

CLUTCH

RESISTOR

OFF

FAN

SWITCH

COMPRESSOR

MAGNET

CLUTCH

RESISTOR

COMPRESSOR

MAGNET

CLUTCH

AMBIENT

SWITCH

LOW

PRESSURE

SWITCH

I

COOLER

Ie

01

RELAY

1

11

L

BATTERY

R

FUSIBLE

LINK

IGNITION

SWITCH

o

F

I

C O

MAGNET

VALVE

BLOWER

MOTOR

M

FUSE

20A

F

I

C

O

MAGNET

VALVE

AMBI

ENT

SWITCH

LOW

PRESSURE

SWITCH

IGNITION

SWITCH

D

BATTERY

R

FUSIBLE

LINK

BLOWE

R

MOTOR

M

BATTERY

G

IGNITION

SWITCH

G

R

F

I

C

O

MAGNET

VALVE

FUSIBLE

LINK

SHA

146

HA

37

JJ

i

9

II

C

l

1

C

o

zo

5

z

RESIS10R

M010R

Il

4IER

ll

Gll

01

PRESSURE

S

II11CI

I

oO

ERRE

Gf lla

COlolPRESSOR

IoI

GIle

l

C

UCI

I

lll

Il

o

O

c

t

J

IoI

GIle

l

11

1

all

a

N

Ul

J

lEII

1

15

IRO

1I01l

C

UI

I

t

MP

S

II11CI

I

f

ll

UI

IIl

1I01l

lOIlER

tkMP

COllOl1

l

f

ON

IR

lCI

I

0

SIlI

IGI

IIIIlG

S

II11CI

I

aJJ

It

S

Il11CI

I

IGllll101l

S

Il11CI

I

fUSIll

E

I

t

Iu

UI

I

1l

1I01l

COlllRO

S

Ill1CI

I

JI

AIR

CONDITIONER

TroubleOiagnosesandCorrecrionr

TROUBLE

DIAGNOSES

AND

CQRRECTIONS

AIR

CONDITIONER

DIAGNOSES

Insufficient

cooling

Bubbles

in

sight

glass

Check

refrigeration

line

for

gas

leaks

and

repair

leaks

if

any

Charge

reo

frigerant

to

correct

level

In

case

of

too

many

leaks

stop

compressor

dig

charge

the

system

evacuate

and

recharge

the

system

As

necessary

replace

receiver

drier

Air

in

system

may

cause

bubbles

in

sight

glass

System

pressure

and

temperature

of

discharge

air

are

abnormal

Refer

to

Performance

Test

Diagnoses

for

detail

Suction

pressure

is

high

Discharge

pressure

is

high

Expansion

valve

is

open

exces

sively

Replace

expan

sian

valve

Overcharge

of

refrigerant

Discharge

some

refrigerant

to

correct

level

Air

is

mixed

in

Discharge

sys

tern

and

replace

drier

Evacuate

and

recharge

system

Condenser

s

fin

is

dented

or

clogged

with

dust

Clean

exterior

surface

with

water

Suction

pressure

is

low

Suction

pressure

is

high

while

discharge

pres

sure

is

low

Valve

or

gasket

of

compressor

is

damaged

Repair

or

replace

compressor

Pipe

at

receiver

drier

outlet

has

low

temperature

Receiver

drier

is

restricted

Replace

receiver

drier

Fin

and

tllbe

of

evaporator

have

some

dents

Replace

or

repair

evaporator

No

bubbles

in

sight

glass

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

Check

air

flow

system

Check

grommets

on

car

s

dash

panel

for

air

leaks

check

other

seals

of

car

Expansion

valve

is

close

excessively

or

gas leakage

from

thermo

bulb

Replace

expansion

valve

HA

39

Trouble

Diagnoseund

Conectiom

AIR

CON

DITION

ER

Compressor

OFF

Bearings

of

compres

sor

clutch

or

idler

pulley

make

noise

Repair

HA

40

I

Blower

motor

makes

noise

Repair

or

replace

blower

motor

Blower

motor

does

not

rotate

Refer

to

Blower

Motor

Diagnosesu

F

I

C

D

does

not

operate

Refer

to

Fast

Idle

Control

Device

Diagnoses

Noisy

Belt is loose

Adjust

belt

Compressor

ON

r

Compressor

itself

makes

noise

Repair

or

replace

compressor

Compressor

does

not

run

When

engine

rpm

Is

changed

there

are

resonant

sounds

Retighten

compres

sor

bracket

bolts

Refer

to

Compressor

Clutch

Diagnoses

and

Compressor

DiagnoseS

AIR

CON

DITION

ER

Trouble

Diagnosesand

Corrections

BLOWER

MOTOR

DIAGNOSES

Test

conditions

II II

Condition

Check

Battery

Fusible

link

Red

and

green

Ignition

switch

Ignition

relay

Fuse

20A

in

fuse

block

O

K

O

K

O

K

O

K

O K

Probable

cause

Quick

check

Check

that

wiper

and washer

operate

If

they

do

not

operate

check

fuse

l5A

in

fuse

block

at

first

Position

of

ignition

switch

ACC

Position

of

fan

sWitch

ON

II

Blower

motor

does

not

run

II

Remove

instrument

lower

cover

and

cluster

lid

Connect

test

light

to

blue

white

wire

leading

to

blower

motor

I

Ught

ON

Ugh

OFF

Ground

SHA168

Ground

blue

black

wire

leading

to

blower

motor

SHA169

I

Motor

does

not

fun

I

Motor

runs

I

Faulty

blower

motor

without

problem

in

lead

wire

connection

t

Replace

@ @

HA

41

TroubieDiagnosesandCorrections

AIR

CONDITIONER

Broken

lead

wire

between

ignition

relay

and

blower

motor

t

Repair

Faulty

fan

switch

without

problem

I

in

lead

wire

connection

t

Replace

Faulty

resistor

without

problem

lead

e

connection

Replace

Check

fan

switch

for

con

ductivity

Refer

to

Fan

Switch

I

Motor

runs

I

Motor

does

not

run

Check

resistor

for

conductivity

Refer

to

Resistor

I

N

G

I

ot

Check

other

lead

wire

and

connection

I

Speed

of

blower

motor

does

not

change

J1

Remove

instrument

lower

cover

and

cluster

lid

Check

resistor

on

heater

unit

Refer

to

Resistor

Faulty

resistor

without

problem

in

lead

wire

connection

l

Replace

HA

42

N

G

I

O

K

I

t

Check

other

lead

wire

and

connection

AI

R

CO

N

0

ITIO

N

ER

Trouble

Diagnosesand

Corrections

COMPRESSOR CLUTCH

DIAGNOSES

Test

conditions

Battery

Fusible

link

Red

and

green

Ignition

switch

Ignition

relay

Fuse

I

SA

in

fuse

block

Position

of

ignition

switch

ACC

Position

of

fan

switch

ON

Position

of

air

conditioner

switch

ON

OK

O K

O

K

II

J

Condition

I I

Check

I

Probable

cause

Quick

check

Check

that

wiper

and washer

operate

II

AC371

A

I

Compressor

clutch

is

not

engaged

Connect

two

wires

leading

to

low

pressure

switch

I

Clutch

is

engaged

1

Check

refrigerant

level

I I

O

K

N

G

L

Faulty

low

pressure

switch

without

problem

lead

y

ire

connection

Replace

Insufficient

re

frigerant

t

Add

Ground

earth

terminals

leading

to

magnet

clutch

Clutch

is

not

engaged

Clutch

is

engaged

I

Clutch

is

not

engaged

o

Connect

test

light

to

blue

black

wire

leading

to

magnet

clutch

I

light

ON

I

light

OFF

AC373A

Connect

wire

between

two

termi

1

0

00

re

@j

Clutch

is

Clutch

i

@

engaged

not

engaged

I I

@ @

SHA17G

HA43

Trouble

Diagnore

end

Correction

AIR

CON

DiTtON

ER

@

Ii

Faulty

magnet

clutch

without

pro

blem

in

lead

wire

connection

t

Repair

Broken

ground

wire of

magnet

clutch

t

Repair

Faulty

cooler

relay

without

problem

in

lead

wire

connection

Replace

Faulty

ambient

temperature

switch

without

problem

in

lead

wire

connection

Replace

Faulty

air

conditioner

switch

without

problem

in

lead

wire

connection

Replace

HA44

@

Remove

instrument

lower

cover

and

clust

r

lid

leading

to

ambient

temperature

switch

I

Clutch

is

engaged

I

Clutch

is

not

engaged

Connect

wire

between

green

and

blue

wire

leading

to

air

conditioner

switch

I

Clutch

is

engaged

J

ClutCh1is

no

engaged

U

Check

other

lead

wire

and

connection

SHA 174

SHA

175

AIR

CONDITIONER

Trouble

Diagnosesand

Corrections

COMPRESSOR

DIAGNOSES

Compressor

clutch

is

engaged

but

compressor

does

not

run

I

Clutch

slipping

II

Belt

slipping

II

Seizured

compressor

Check

and

readjust

gap

of

clutch

Clean

oil

or

dust

on

contact

sur

face

of

clutch

If

slipping

continues

replace

com

pressor

clutch

Check

belt

tension

and

adjust

it

If

belt

is

worn

out

or

damaged

replace

it

Internal

problem

in

compressor

cyl

inder

Check

system

Repair

or

replace

if

necessary

High

torque

Overcharge

of

refrigerant

11

Air

in

refrigeration

system

Discharge

refrigerant

gas

to

an

extent

that

sight

glass

of

receiver

drier

has

only

a

few

bubbles

Engine

speed

1

500

rpm

Discharge

system

from

service

valve

on

discharge

side

Evacuate

and

recharge

the

system

Check

for

discharge

pres

sure

OK

if

discharge

pres

sure

is

reduced

Discharge

pressure

is

not

reduced

I

When

torque

is

still

great

repair

or

replace

compressor

I

HA

45

Trouble

Diagnoseund

Corrections

AIR

CONDITION

ER

Compressor

oil

leaking

Air

blow

on

spot

where

oillcak

evidence

is

found

Then

check

for

refrigerant

leaks

using

leak

detecror

I

Refrigerant leaking

No

refrigerant

leaking

Repair

or

replace

compressor

Wipe

clean

oil

with

rag

HA

46

Compressor

is

noisy

Noisy

only

when

clutch

is

engaged

Check

for

loose

compres

sor

mounting

bolts

Retighten

bolts

Compressor

drive

belt

is loose

Adjust

belt

tension

If

compressor

is

still

noisy

repair

or

replace

compressor

Noisy

when

clutch

is

not

engaged

Remove

compressor

belt

Turn

pulley

of

compres

sor

clutch

by

hand

and

check

for

noise

If

noise

is

heard

repair

compres

sor

clutch

AIR

CONDITIONER

Trouble

Diagnoses

and

Corrections

FAST

IDLE

CONTROL

DEVICE

DIAGNOSES

Test

condition

Battery

Fusible

link

Red

and

green

Ignition

switch

Ignition

relay

Fuse

IS

in

fuse

block

O

K

OK

OX

OK

OX

Quick

check

Check

that

wiper

and

washer

operate

Position

of

ignition

switch

ACC

Position

of

fan

switch

ON

Position

of

air

conditioner

switch

ON

F

LC

D

is

not

operated

II

Check

operation

of

compressor

clutch

I

Clutch

is

not

engaged

Check

electric

circuit

of

clutch

reo

ferring

to

compressor

clutch

dia

gnoses

Faulty

F

l

C

D

magnet

valve

Replace

Faulty

F

l

C

Ddevice

Replace

II

q

Condition

II

Check

I

Probable

cause

I

Outch

is

engaged

j

D

Run

engine

at idle

speed

Disconnect

vacuum

F

LC

D

magnet

valve

to

F

LC

D

device

hose

at

F

LC

D

magnet

valve

and

check

vacuum

I

Vacuum

N

G

I

Vacuum

O

K

Disconnect

vacuum

F

l

C

D

magnet

valve

lo

F

LC

D device

hose

at

F

l

C

D device

and check

vacuum

I

Vacuum

O

K

j

I

Vacuum

N G

1

J

I

Broken

vacuum

hose

J

Repair

SHA177

7

Check

vacuum

F

l

C

D

device

SHA17S

HA

47

Setvice

Data

and

Specifications

AIR

CONDITIONER

SERVICE

DATA

AND

SPECIFICATIONS

GENERAL

SPECIFICATIONS

TIGHTENING

TORQUE

COMPRESSOR

Unit

N

m

k

ft

lb

Model

SWP167

Compressor

bracket

to

44 54

45 55

33

40

cylinder

block

TVpe

Swash

plate

I

Compressor

to

44 54

4

5

55

33

40

Displacement

cm3

cu

inl

rev

167110

191

compressor

bracket

I

Cylinder

bore

x

stroke

mm

in 37

2

25

7

Refrigerant

line

connec

11

465x

1

0121

tion

I

Low

pressure

line

25 29

2

5

3

0

18

22

Direction

of

fotation

ClOckwise

I

High

pressure

line

15

20

11

5

2

0

11

14

Type

of

driving

belt

A type

flexible hose

to

lOB

corilpreuor

78

10

8

1 1

5

8

0

LUBRICATING

OIL

Compressor

I

0

28

0

35

1

I

Coil

mounting

screw

27

3

4 2

0

2

5

Type

SUNISO

5GS

12

5

I

Lock

nut

25 27

2 8

18

20

Capacity

ml

US

fl

OZ

Imp

fI

02

270

19 1

9

51

Hub

nut

18

21

11

8

2

1

I

13 15

REFRIGERANT

Shaft

nut

16 17

11

6

1

7

111

6

12

3

Type

R

12

Side

cover

bolt

18

20

11

8

2

0

I

13 14

Capacity

kg

UbI

09

11

12

0

2

411

Reaf end

coyer

bolt

29

34

13

0

3

5

I

22

25

Oil

plug

18

20

11

8 20

I

13

14

INSPECTION

AND

ADJUSTMENT

ENGINE

IDLING

SPEED

Unit

rpm

Transmission

When

Ale

is

ON

Manual

About

900

Non

cidjustablel

Automatic

At

N

rangsl

About

1000

Nori

adjustable

BELT

TENSION

Fan

belt

Applied

pressure

mm

UnlN

kg

Ibl

18

1210

31

0

4711

98

110

221

COMPRESSOR

Clutch

hub

to

pulley

clearance

mm

in

0

5

0

8

10

020

0

0311

HA

48

Tool

nwnber

Kent

Moore

No

KV99412302

J94878

1

AIR

CONDITIONER

SpecialService

Tools

SPECIAL

SERVICE

TOOLS

Tool

name

Clutch

hub

wrench

KV99412305

Hub

nut

socket

124878

2

KV99412306

Clutch

hub

puller

124878

3

KV99412310 Lock

nut

socket

QD

1248784

KV99412313

Puller

adapter

126066

KV99412312

125472

KV994C1552

KV994C4548

CD

KV994C453I

@KV994C4532

@

KV994C4533

@

KV994C4534

@KV994C4559

Puller

pilot

Charge

nozzle

Blind

cover

set

Blind

cover

Gasket

Useless

3@

1

c

11

1

039 0

39

0

61

0

51

Gasket

Bolt

@

Unit

rom in

HA49

Special

Service

Tools

AIR

CONDITION

ER

Tool

number

Kent

Moore

No

KV9941232I

126067

KV99412322

125473

KV99412329

126072

KV99412327

KV99412328

KV99412330

KV99412315

HA

50

Tool

name

Shaft

seal

remover

and

installer

Shaft

seal

pilot

Shaft

handle

socket

Silencer

piece

installer

O

ring

insta11er

Allen

socket

Cylinder

head

remover

o

DATSUN

200SX

Model

S

J J

0

Series

SECTIONE

L

ELECTRICAL SYSTEM

CONTENTS

POWER

SUPPLY

ROUTING

EL

2

SERVICE

DATA

AND

SPECIFICATIONS

EL

37

SCHEMATICIPOWER

SUPPLY

ROUTING

EL

2

LIGHTING

SYSTEMS

EL

38

FUSE

EL

3

BULB

SPECIFICATIONS

EL

38

FUSIBLE

LINK

EL

3

COMBINATION

SWITCH

EL

38

IGNITION

SWITCH

EL

3

HEADLAMP

EL

40

IGNITION

AND

ACCESSORY

RELAY

EL

3

EXTERIOR

LAMPS

EL

43

BATTERY

EL

4

INTERIOR

LUGGAGE

COMPARTMENT

CHECKING

ELECTROLYTE

LEVEL

EL

4

AND

STEP

LAMPS

EL

51

CHECKING

SPECIFIC

GRAVITY

EL

4INSTRUMENT

PANEL

ILLUMINATION

EL

54

CHARGING

EL

5

METERS

GAUGES

AND

BATTERY

FREEZING

EL

5

WARNING

SYSTEMS

EL

56

BATTERY

TESTING

EL

5

COMBINATION

METER EL

56

SERVICE

DATA

AND

SPECIFICATIONS

EL

7WARNING

DISPLAY

EL

65

STARTING

SYSTEM

EL

8WARNING

CHIME

EL

70

SCHEMATIC

EL

B

WIPER

AND

WASHER

EL

73

WIRING

DIAGRAM

EL

8

WINDSHIELD

WIPER

AND

WASHER

EL

73

STARTING

SYSTEM

REAR WINDOW

WIPER

AND

WASHER

EL

79

TROUBLESHOOTING

EL

9

ELECTRICAL

ACCESSORIES

EL

81

STARTER

MOTOR

ELla

REAR

WINDOW

DEFOGGER

EL

81

SERVICE

DATA

AND

SPECIFICATIONS

EL

16

REMOTE

CONTROL

DOOR

MIRROR

EL

83

CHARGING

SYSTEM

EL

17

CLOCK

EL

85

DESCRIPTION

EL

17

HORN

EL

87

SCHEMATIC

EL

18

AUDIO

EL

89

WIRING

DIAGRAM

EL

18

AUTOMATIC

SPEED

CONTROL

CHARGING

SYSTEM

DEVICE

A

S

C

D

EL

94

TROUBLESHOOTING

EL

19

DESCRIPTION

EL

94

ALTERNATOR

EL20

TROUBLE

DIAGNOSES

EL 95

IC

VOLTAGE

REGULATOR

EL

23

COMPONENT

PARTS

EL

99

SERVICE

DATA

AND

SPECIFICATIONS

EL25

ELECTRICAL

UNIT

LOCATION

EL

104

IGNITION

SYSTEM

EL

26

WI

RING

HARNESS

EL

106

IC

IGNITION

SYSTEM

CABLE

COLORS

EL

106

TROUBLESHOOTING

EL28

HARNESS

LAYOUT

EL

106

DISTRIBUTOR

IC

type

EL31

IC

IGNITION

UNIT

EL35

Power

Supply

Routing

ELECTRICAL

SYSTEM

POWER

SUPPLY

ROUTING

CAUTION

Before

starting

to

worll

on

any

J

system

disconnect

battery

ground

cable

SCHEMATIC

POWER

SUPPLY ROUTING

1

w

a

EL

2

V

a

o

z

a

w

J

w

t

u

w

f

T

ci

C

CD

FUSIBLE

LINK

t

Q

1

8

BATTERY

J

I

sr

Or

l

occ

E1

BOg

0

IGNITION

SWITCH

AI

0

I

16

Q

S

5

I

IGNITION

AND

ACCESSORY

RELAY

l l

in

ir

1

f

I

FUSE

BLOCK

o

L

HEADLAMP

STOP

LAMP

i

HAZARD

FLASHER

HORN

CIGARETTE

LIGHTER

CLOCK

LAMP

MONITOR

VOLT

GAUGE

z

0

w

t

z

i

INTERIOR

LAMP

STEP

LAMP

LUGGAGE

COM

PERTMENT

LAMPS

KE

WARNING

TAIL

CLEARANCE

SIDE

MARKER

AND

LICENSE

PLATE

LAMPS

METER

ILLUMINATION

7

HEATER

OR

AIR

CONDITIONER

BLOWER

MOTOR

7

AIR

CONDITIONER

WIPER

AND

WASHER

WINDSHIELD

AND

REARl

RAOIO

POWER

ANTENNA

REAR

WlNDOW

DEFOGGER

TURN

SIGNAL

BACK

UP

LAMPS

WARNING

LAMPS

TACHOMETER

GAUGES

SEAT

BELT

WARNING WARNING

DISPLAY

SEL365

FUSE

LOCAnON

SEL275

INSPECTION

c

l

CI

c

SE

L276

8

If

fuse

is

blown

be

sure

to

elimi

nate

cause

of

the

problem

before

installing

new

fuse

b

Never

use

fuse

of

more

than

speci

fied

rating

c

Do

not

install

fuse

in

oblique

direction

always

snap

it into

fUle

holder

properly

IGNITION

SWITCH

S

1G

ELECTRICAL

SYSTEM

Power

Supply

Routing

FUSIBLE

UNK

SEL277

CAUTION

a

If

fusible

link

should

melt

it

is

possible

that

critical

circuit

power

supply

or

large

current

carrying

circuit

is

shorted

In

such

a case

carefully

check

and

eliminate

cause

of

problem

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

contact

with

any

other

wiring

har

ness

or

vinyl

or

rubber

parts

A

melted

fusible

link can

be

detect

ed

either

by

visual

inspection

or

by

feeling

with

fmger

tip

If

its

condition

is

questionable

use

circuit

tester

or

test

lamp

B

A

sr

t

T

01

g

Q

B

From

battery

5

A

To

accessOIY

system

o

IG

To

tionsystem

5s

To

starting

system

c

s

k

U

Key

warning

switch

IN

OUT

I

g

SEL369

IGNITION

AND

ACCESSORY

RELAY

LOCATION

The

ignition

and

accessory

relay

are

located

on

the

right

side

of

the

dash

panel

Refer

to

page

EL

104

INSPECTION

Ground

is

made

at

case

attaching

bolt

and

tenninal

rJ

SE

L279

I

n

EL3

Battery

ELECTRICAL SYSTEM

WARNING

Naver

touch

positive

and

negative

termill8ls

at

the

same

time

with

bare

hands

This

could

result

in

injury

CAUTION

a

If

it

becomes

necessary

to

start

the

engine

with

a

booster

battery

end

jumper

cables

the

booster

battery

voltage

must

not

ex

12

volts

or

the control unit of

the

fuei

injection

system

and

other

electric

components

will

be

damaged

b

If

the

battery

cables

are

discon

nected

they

should

be

tighdy

clamped

to

the

battery

terminals

to

secure

a

good

contact

CHECKING

ELECTROLYTE

LEVEL

Check

for

electrolyte

level

in

each

cell

Overflow

Correct

Shomse

t

j

t

1

t

EE358

If

the

level

is

low

fUI

with

distilled

water

EL

4

BATTERY

CHECK

G

SPECIFIC

GRAVITY

J

Read

hydrometer

and

thermal

gauge

indications

at

eye

level

Reed

top

level

with

leale

r

Thermal

gauge

SE

L045

2

Correct

specific

gravity

et

200C

1680

Fl

O

St

0

0007

t

20

Where

St

S20

Specific

gravity

of

electrolyte

at

tOC

Specific

gravity

of

electrolyte

corrected

at

20

C

680F

Electrolyte

temperature

t

Examples

1

When

electrolyte

temperature

is

350C

950F

and

specific

gravity

of

electrolyte

is

L2

O

specific

gravity

corrected

at 20

C

680F

is

1

243

2

When electrolyte

temperature

is

O

c

320F

and

specific

gravity

of

electrolyte

is

1

210

specific

gravity

corrected

at

200C

680F

is

1

196

1

30

j

specific

gravity

5

0

1

@

1

28

E

u

Co

E

B

u

g

o

u

o

1

14

Co

1

121

1

10

II

10

14

I

o

32

I

10

SO

I

SO

122

r

40

104

Electrolyte

temperature

oC

OF

SEL096

3

Determine

charging

state

of

bat

tery

Examples

Charging

state

of

battery

whose

max

charging

specific

gravity

is

1

26

and

whose

specific

gravity

corrected

at

200C

680F

is

1

243

is

92

For

battery

whose

m

charging

specific

gravity

is

1

28

charging

state

is

82

at

a

corrected

specific

gravity

of

200C

680F

Specific

plvity

20oC

680F

70

80

90 100

Charsin

nditian

l

SE

L097

4

Recharge

battery

if

its

rate

drops

below

7m

of

full

charge

CHARGING

CAUTION

a

Carry

out

charging

with

negative

cab

Ie

removed

b

Do

not

allow

electrolyte

tempera

ture

to

go

over

450C

1130

Fl

Clean

corroded

terminal

with

e

brush

and

common

baking

soda

solu

tion

WARNING

a

Keep

battery

away

from

open

flame

while

it

is

being

charged

b

When

connecting

charger

con

nect

leads

first

then

turn

on

cherger

00

not

turn

on

charger

first

as this

may

cause

a

spark

BATTERY

FREEZING

CAUTION

Usa

extreme

caution

to

avoid

freezing

battery

0

1

U

1014

o

20 4

00

0

22

40

0

o

SO

55 O

I

60

76

70

94

I

80

1I2

L

I

to

1

08

1

16

1

24

1

32

1

04

1

12

1

20

1

28

EE004

SpecifIC

Iflvil

oreleclrolyte

BATTERY

TESTING

I

PRELIMINARY

CHECKS

Visual

Inspection

Clogged

I

Dirt

vents

lfil

fil W

Check

Corrosion

r

8A

M

rating

Cracks

I

Y

I

Warped

case

SEL046

1

Check

battery

rating

against

that

of

original

factory

equipment

2

Check

for

cracks

and

warpage

of

the

case

3

Make

sure

cables

are

clean

and

tight

4

Check

acid

level

5

Make

sure

vents

are

not

clogged

6

Make

sure

top

of

battery

is clean

2

BATTERY

LEAKAGE

TEST

Check

to

make

sure

battery

is

not

discharging

across

top

between

two

posts

ELECTRICAL SYSTEM

Battery

1

JI

J

Ie

0

4@

Qo

I

SE

L047

1

Set

voltmeter

to

low

range

2

Touch

negative

lead

of

voltmeter

to

negative

battery

post

3

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

3

BATTERY

CAPACIlY

TEST

SEL048

1

With

battery

connected

to

tester

as

shown

turn

load

knob

until a

draw

of

3

times

the

battery

rating

is shown

Example

Battery

rating

60

AH

Turn

load

to

180

A

draw

2

Hold

this

draw

for

15

seconds

thim

look

at

voltage

If

voltage

re

mains

at

9 6

volts

or

above

THE

BATTERY

IS

GOOD

You

need

not

perform

any

further

tests

If

voltage

drops

below

9 6

volts

then

proceed

to

4

THREE

MINUTE

CHARGE

TEST

To

be

performed

only

if

battery

has

failed

Capacity

Test

in

step

nwnber

3

1

Connect

a

good

quality

battery

Remove

cell

caps

2

Tum

charger

to

a

fast

charge

rate

not

over

40

A

EL

5

Battery

ELECTRICAL SYSTEM

I

o

0Jol

nnlol

J

SE

L049

3

After

three

minutes

check

volt

meter

reading

If

it

is

over

15

5

volts

16

5

for

Maintenance

Free

Batteries

battery

should

be

replaced

If

it

is

below

15

5

volts

then

proceed

to

step

nwnber

5

CELL

TEST

UNPER

CHARGE

Connect

tester

and

battery

charger

as

in

step

number

4

Set

to

fast

charge

rate

35

40

A

I

Turn

to

low range

voltmeter

2

Attach

special

cell

probes

to

voltmeter

leads

3

Touch

positive

probe

to

battery

positive

terminal

4Stick

black

probe

in

battery

cell

nearest

the

batteiy

positive

post

WRITE

DOWN

voltmeter

reading

SEL050

EL

6

5

Now

put

positive

probe

in

ceU

nearest

the

positive

post

Put

negative

probe

in

down

Record

reading

SEL051

6

Continue

on

down

the

battery

recording

reading

each

time

SE

L052

7

When

you

get

to

point

where

positive

probe

is

in

last cell

of

battery

touch

negative

probe

to

negative

post

Record

this

reading

ee

9

SE

L053

8

You

should

now

have

seven

readings

Now

add

the

fIrSt

reading

to

the

last

this

will

give

you

six

readings

They

should

aU

be

within

0

2

two

tenths

volt

of

each

other

If

one

cell

varies

more

than

this

amount

from

any

other

then

battery

is

bad and

must

be

replaced

2

4

2

6

2 6

2

6

2

6

2

6

0

2

4

0

2

6

i

V

J

lh

t

S

lE

1

rA

AND

SPE

I

r

H

r

T

C

l

BA

r

E

l

t

g

0

w

r

i

N50Z

NS70

Ii

r

A

ffliiodel

U

S

A

tf

r

nada

f

i

c

r

p

acify

AH

12

60

1

f

Jth65

iliff

Af

A

F

iI

f

n

s

c

ficI26f

1

i

28

g

ili

YJa

6

F

1

t

a

4

f

c

l

i

Y

t

C

r1

iICALL

STEM

Battriry

9

j

1

N

i

J

t

r

Il

7

i

r

4

ti

tt

I

f

1

l

1

L

j

yj

t

I

i

fT

tlI

f

r

o

O

t

tYt

f

Ii

1Iit

o

4

Jt

rl

t

e

t

j

1i

el

f

V

6

f

t

i

t

j

V

M

7r

1

rt

l

f

7t

j

C

I

t

w

l

r

Jf

j

GI

It

X9

I

i

c

p

J

l

Ifi

Jii

t

135

L

ht

c

f

c

S

ti

a

i

Co

jt 1

j

ltii

H

J

t

it

AAi

j

i

y

H

3

b

ttj

j

t

1

EIi

7

1

L

7

Starting

System

ELECTRICAL

SYSTEM

STARTING

SYSTEM

SCHEMATIC

OFF

Ace

ON

ST

g

Ie

sr

5

l

C

FUSIBLE

LINK

1

IGNITION

SW

I

o

1

C

0

c

I

FUSE

IGNITION

AND

ACCESSORY

RELAY

1 1

FUSIBLE

LINK

@

INHIBITOR

SW

o

0

STARTER

MOTOR

1

BATTERY

@INHIBITOR

RELAY

SEL098

WIRING

DIAGRAM

re Cf

R

o

BATTERY

FUSIBLE

LINK

@

sr

ON

Ace

Off

g

DD

IEI

BW

J

6

Ie

r

ey

5

s

r

WR

@

@ll

w

ID1

WB

BW

oJ

It

@

IGNITION

AND

ACCESSORY

RELAY

IGNITION

SW

r

0

O

Q

tJl

0 0

0

0 0 0 0

o 0

O

ij ij ij ij

o

0

COO

000000

0

00

0

FUSEBL

CK

Ji

E

@

@ri

g@

@INHIBITORRELAY

@

t1

e@

a

m

al 3lD

g

o

g

@

@WB

ao

LW

ao

I

We

SEL099

STARTER

MOTOR

@

INHIBITOR

SW

EL

8

STARTING

SYSTEMTROUBLE

SHOOTING

I

Check

the

battery

Fully

charged

I

Te

ting

tarter

current

drew

I

Turn

key

to

start

r

Click

or

t

I

Disconnect

batteiy

positive

cable

I

Starter

turns

at

starter

N

I

k

2

Connect

ammeter

500A

range

oc

1

between

thIS

cable

and

starter

terminal

3

Pull

out

coil

wire

from

distributor

cap

Not

from

coil

4

Crank

engine

read

current

draw

Pull

ignition

Ustart

wire

Usually

Black

Yellow

off

at

starter

Connect

test

light

between

this

lead

and

battery

negative

terminal

Have

someone

turn

key

Light

t

I

No

light

1

Testing

for

voltage

drops

in

ignition

Iwitch

Starter

magnetic

switch

circuit

I

Turn

voltmeter

to

low

scale

2

Connect

positive

lead

to

positive

terminal

of

battery

3

Connect

negative

lead

to

bayonet

connector

Black

Yellow

at

magnetic

switch

Leave

B

Y

wire

connected

4

Ground

coil

wire

5

Crank

engine

m

r

eO

More

than

l

SV

More

than

l50A

I

Less

than

ISOA

Speed

slow

l

More

than

4

IV

Testing

for

voltage

drops

in

starter

positive

circuit

I

Turn

voltmeter

to

low

scale

2

Touch

positive

lead

to

positive

post

of

battery

Not

to

cable

3

Connect

negative

lead

to

magnetic

switch

uM

terminal

Terminal

connected

to

starter

4

Pull

coil

wire

out

of

distributor

cap

and

ground

it

5

Crank

engine

Less

than

IV

Less

than

05

Less

than

I

5V

Connect

jumper

wire

between

battery

positive

terminal

and

the

s

terminal

on

magnetic

switch

Less

than

150A

Speed

normal

Plug

coil

wire

back

in

Start

engine

but

hold

key

over

to

start

so

that

starter

docs

not

stop

Starter

turns

r

t

fast

less

than

J

60A

Starter

draws

more

than

60A

More

than

I

V

J

Move

negative

lead

to

B

terminal

of

magnetic

switch

Terminal

connected

to

battery

Crank

engine

Testing

f

r

voltage

drops

in

starting

ground

circuit

I

Turn

voltmeter

to

low

scale

2

Connect

negative

lead

to

negative

terminal

of

battery

3

Hold

positive

lead

to

starter

housing

Make

good

conneCtion

4

Crank

engine

Less

than

IV

More

than

O

SV

No

click

Starter

does

not

turn

Click

starter

turns

0

Starter

O

K

Tight

engine

Mechanical

problem

Short

in

starter

Overhaul

Bad

connection

between

battery

and

magnetic

switch

Magnetic

switch

bad

Remove

and

replace

magnetic

switch

Bad

ground

Check

battery

terminal

cable

ground

connections

and

starter

bolts

J

Open

in

starter

1

Overhaul

Bad

magnetic

switch

and

starter

Overhaul

Open

in

circuit

Ignition

s

itch

connectors

inhibitor

switch

and

relay

Automatic

transmission

m

r

m

0

I

I1

n r

rn rn

I

m

s

I

ill

g

StBrtingSystem

ElECTRICAL

SYSTEM

STARTER MOTOR

Non

Reductlon

ear

type

l

J

74

9 8

0

75

1

00

5

4

7 2

Ileu

00

metal

Through

bo

Brush

min

length

12

0

47

Mqnetic

lWitcl

asoembly

Ocarance

Q

between

Pinion

front

edge

and

pinion

stopper

0 3 2 5

0

012

0

098

Dust

00

Adjllllin8

er

Adjust

clearance

2

Washer

thickness

0

5 0

020

0

8

0

031

Dust

cover

E

ring

Brush

spring

Tension

13

7

17

7N

1

4

1

8kg 31

4

0

Ib

l

J3

7

5

0

38 0

51

2 7

Commutator

min

dia

39

1

54

Center

bracket

5114 180F

only

Pinion

assembly

Pinion

stopper

Depth

of

insulating

mica

0

5

0 8

0

020

0

031

Armature

shaft bend

Les

s

than

0 08 0

0031

l

J

N

m

lcg

m

ft4b

Unit

mm

in

SE

L007

EL10

ELECTRICAL SYSTEM

Starting

System

Reduction

r

typo

Q

ring

Dust

cover

Adjusting

washer

Adjust

clearance

washer

thickness

0

5 0

020

0 8 0

031

v

Through

bolt

f

co

Commutator

min

dia

29

1

14

Depth

of

insulating

mica

0

5

0

8

0

020

0

031

Drush

Brush

min

length

11

0 43

Center

bearing

Brush

holder

Brush

spring

Tension

15

1

19

6

N

1

6

2 0 k8 3 5

4

41b

Field

coil

3 1

C

i

6 3

8

3

064 0

85

4

6

O

ring

C

i

N

m

kg

m

fHb

Unit

mm

in

Pinion

gear

Difference

in

height

of

pinion

Packing

0 3

15

0

012

0

059

Gear

ca

SE

LOOS

ELll

r

Starting

System

ELECTRICAL

SYSTEM

DISASSEMBLY

Non

ucUon

r

tJP

1

Remove

magnetic

switch

2

Remove

rear

cover

1

Remove dust

cover

E

ring

and

thrust

washer

s

2

Remove brush

holder

setscrews

3

Remove

through

bolts

SE

LOtO

I

3

Lift

p

brush

springs

EEt50

4

Remove

brush

holder

EL12

SEL011

5

Remove

yoke

6

Withdraw

armature

and

shift

lever

SE

L019

7

Remove

overrunning

clutch

Remove

pinion

stopper

clip

push

ing

pinion

stopper

toward

clutch

side

EE277

Pinion

stopper

clip

RedueUon

rtJpe

I

Remove

magnetic

switch

assemb

ly

2

Remove

torsion

spring

3

Remove

through

bolts

and

rear

cover

CAUTION

Ba

careful

not

to

damage

O

ring

4

Remove

yoke

armature

and

brush

holder

as

an

assembly

from

center

housing

CAUTiON

Be

careful

not

to

knock

brush

com

mutator

or

coil

against

Iny

edjacent

plrt

EE61

6

5

Remove

center

housing

6

Remove

pinion

gear

7

Lift

up

brush

springs

8

Remove

brushes

from

brush

holder

EE616

9

Remove

brush

holder

10

Remove

yoke

INSPECTION

Field

coD

I

Continuity

test

between

field

coil

positive

terminal

and

positive

brushes

SEL107

No

continuity

Replace

field

coil

2

Ground

test

between

field

coil

positive

terminal

and yoke

Positive

terminal

SEL

1

oS

Conlinuity

exists

coil

Replace

field

Bru

h

Check

the

surface

condition

of

brush

contact

Loose

contact

Replace

Check

wear

of

brush

Minimwn

length

of

brush

Non

reduction

goor

typo

12

mm

0

47 in

Reduction

goor

typo

1

mm

0

43

in

Excessive

wear

Replace

ELECTRICAL

SYSTEM

Starring

System

SE

L030

Bru

h

prlnll

Check

brush

spring

tension

Spring

tension

Non

reduction

gear

type

13

7

17

7

N

14

1

8

kg

3

1

4

0Ib

Reduction

gear

type

15

7

19

6

N

1

6

20

kg

3

5 4 4

Ib

Not

in

the

specified

value

Repair

or

replace

Sprin

scale

WI

SEL

109

Arm

ture

mbl

I

Check

commutator

surface

Rough

Sand

lightly

with

No

500

sandpaper

2

Check

depth

of

insulating

mica

from

commutator

surface

Less

than

0

2

mm

0

008

in

Undercut

to

0

5

0

8

mm

0

020

0

031

in

t

J

0

5

0 8

mm

i

Correct

f

l

1

Commutator

1T1in

i

Incorrect

EE021

3

Check

diameter

of

commutator

Commutator

minimum

diameter

Non

reduction

gear

tYpe

32

mm

11

26

in

Reduction

geor

type

29mm

11

14inl

Less

than

specified

value

Replace

SEL031

4

Ground

test

between

each

com

mutator

bar

and

shaft

EE022

EL

13

Scarting

System

ELECTRICAL

SYST

M

Continuity

exists

Replace

5

Short

test

with

annature

tester

growler

and

a

piece

of

iron

over

armature

core

EEQ23

Plate

vibrates

Replace

6

Continuity

test

between

two

segments

side by

side

No

continuity

Replace

r

runnln

clutch

mbly

1

Inspect

smooth

sliding

of

pinion

gear

Abnormal

resistance

Repair

2

Inspect

pinion

teeth

Excessive

rubbing

Replace

CAUTION

Flywbeel ring

gear

also

must

be

in

spected

Brush hold

r

Ground

test

between

negative

side

of

brush

holder

and

another

positive

side

EE025

Continuity

exists

Replace

EL14

PInIOn

caN

burin

Iii8taoI

Non

ndilctlon

ear

type

Check

clearance

between

bearing

metal

and

armature

shaft

I

Iearingmetlll

to

Irmatuinhaft

dearance

Less

thin

0

2

mm

0

008

in

More

than

specified

value

Replace

Ball

b

rln

Reduction

ar

tyP

Holding

outer

race

with

fmger

rotate

bearing

Any

play

or

bind

Replace

Me

n

tIc

switch

mbly

I

Con1inuity

test

between

sn

terminal

and

switch

body

No

continuity

Replace

2

Continuity

test

between

tenni

naIs

S

and

M

No

continuity

Replace

ASSEMBLY

Apply

gre

e

to

gear

case

and

rear

cover

bearing

metal

ond

Ipply

oil

to

pinion

slightly

Non

duction

Il8

type

With

the

switch

on

push

pinion

back

to

remove

all

slack

ond

me

ure

the

clearance

en

between

pinion

front

edge

and

pinion

stopper

Clearince

2

03

25

mm

0

012

0

098

in

r

I

J

L

e

SEL015

Not in

the

specified

value

Adjust

by

adjusting

washer

s

Reduction

gear

type

Compare

difference

en

in

height

of

pinion

when

it u

pushed

out

with

magnetic

switch

energized

and

when

it

u

pulled

out

by

hand

until

it

touches

stopper

Difference

1

H

03

1

5

mm

0

012

0

059

inl

PoD

out

by

hand

until

pinion

stops

Pushoutwitb

electric

current

1

r

0

r

Difference

L

e

SEL016

Not

in

the

specified

value

Adjust

by

adjusting

washer

s

Adjusting

washer

thielmo

06

mm

10

020

in

08

mm

0

031

in

TESnNG

Perform

nc

tut

No

load

test

p

b

t

J

Voltmeter

Ammeter

Capacity

300A

SE

LOSS

Specifications

Refer

to

sn

s

Dlqnos

of

test

I

Low

speed

with

no

lold

and

high

current

draw

I

Tight

dirty

or worn

bearings

2

Bent

annature

shaft

or

loosened

field

probe

3

Shorted

armature

coil

4

A

grounded

armature

of

field

coil

2 Failure

to

operate

with

high

cur

rent

draw

I

A

grounded

or

open

field

coil

2

Burned

out

commutator

bar

Weak brush

spring

tension

Thrust

out

of

mica

in

commutator

Loose

contact

between brush

and

commutator

3

Low

current

draw

and

low

no

load

speed

I

Loo

e

connections

2

Dirty

commutator

3

Burned

out

commutator

bar

netlc

wttch

r

rn

bllltr

I

Disconnect

lea

wire

from

termi

nal

M

of

magnetic

iwitch

2

Connect

terminal

M

and

posi

tive

tJ

terminal

of

battery

with

a

jumper

lead

wire

3

Connect

starter

motor

body

and

negative

e

terminal

of

battery

with

a

jumper

lead

wire

4

Pull

pinion

gear

all

the

way

out

with

your

hands

5

Release

your

hand

from

pinion

gear

6

If

pinion

gear

returns

to

its

origi

nal

position

magnetic

switch

is

pro

perly

functioning

1

CI

ELECTRICAL

SYSTEM

Sta

ing

Sysrem

jrJ

SEL012

S

rle

coil

I

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

tery

with

a

jumper

wire

3

With

these

connections

having

been

made

if

plunger

is

pulled

in

by

force

series

coil

i

properly

function

ing

t

SE

L013

Shunt

co

1

Disconnect

lead

wire

which

con

nects

terminal

M

of

magnetic

switch

and

starting

motor

teoninal

and

con

nect

a

jumper

wire

in

its

place

2

Connect

terminal

S

of

magnetic

switch

and

positive

tJ

terminal

of

bat

tery

with

a

jumper

wire

3

Connect

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

If

plunger

continues

to

be pulled

in

with

jumper

wire

disconnected

from

terminal

M

shunt

coil

is

properly

functioning

oJ

i

1

CI

SEL014

EL15

Starting

System

ELECTRICAL

SYSTEM

SERVICE

DATA

AND

SPEciFICATIONS

STARTER

MOTOR

Type

S114

l80F

I

S114

229E

S114

255A

Non

reduction

gear

type

Red

ction

gear

type

Applied

model

U

sA

A

T

I

U

S

A

MfT

Canada

A

T

MfT

V

12

System

voltage

Terminal

voltage

V

11

5

11

No

load

Current

A

Less

than

60

IMore

th

6

ooolMore

than

7

000

I

More

than

39

1

54

1

12

0

47

13

7

17

7

1

4

1

8

3

1

40

Less

than

100

Revolution

rpm

More

than

3

900

Outer

diamet

r

of

commutator

mm

in

mm

in

More

than

29

1

14

Minimum

length

of

brush

11

0

43

Brush

spring

tension

N

kg

lb

15

7

19

6

1

6

2 0

35 44

Clearance

between

bearing

metal

and

armature

shaft

mm

in

Less

than

0 2

0

008

Clearance

between

pinion

front

edge

and

pinion

stopper

mm

in

0

3

25

0

012

0

098

Difference

in

height

of

pinion

mm

in

03

15

0

012

0

059

EL16

DESCRIPTION

The

charging

circuit

consists

of

a

battery

an

alternator

incorporating

an

IC

voltage

regulator

and

wiring

that

connects

ihese

parts

I

With

the

ignition

switch

in

ON

the

circuit

between

transistor

Tr

I

of

the

IC

voltage

regulator

and

ground

is

closed

Current

from

the

battery

then

flows

along

ihe

route

shown

by

the

arrow

in

Figure

turning

on

the

charge

warning

lamp

and

flowing

on

through

terminal

L

to

excite

the

rotor

When ihe

alternator

begins

to

oper

ate

three

phase

alternating

current

is

produced

in

the

stator

coil

This

alter

nating

current

is

rectified

by

the

posi

tive

and

negative

silicon

diodes

ELECTRICAL

SYSTEM

Charging

System

CHARGING

SYSTEM

When the

voltage

at

terminal

B is

higher

than

battery

voltage

current

produced

at

the

stator

flows

to

re

charge

the

battery

While

the

battery

is

being

re

charged

the

voltage

at

termi

nal

L

is

equal

to

that

of

terminal

B

At

this

point

there

is

no

voltage

differential

on

either

side

of

the

charge

warning

lamp

which

causes

the

charge

warning

lamp

to

turn

off

In

other

words

current

does

not

flow

from

the

battery

to

terminal

L

Accordingly

current

flow

through

the

rotor

is

taken

over

by

current

produced

at

the

stator

The

circuit

between

terminal

F

and

Tr

1

is

then

closed

The

IC

voltage

regulator

monitors

generating voltage

to

be

applied

to

the

battery

at

terminal

S

When

current

I

0

D3

J

7

t0

0

a

0

a

t010

STATOR

COIL

D4

Di

AL

TE

RNA

TOR

it

T

exceeds

the

specified

value

it

then

flows

through

the

zener

diode

ZD

closing

the

circuit

consisting

of

transis

tor

TrJ

and

resistor

R1

At

this

point

current

neither

flows

through

transistor

Tr

to

ground

nor

to

the

rotor

thereby

reducing

the

voltage

generated

at

the

stator

When

voltage

generated

at

terminal

S

is

reduced

to

the

specified

value

transistor

allows

current

to

flow

through

the

rotor

increasing

the

generating

voltage

In this

manner

output

voltage

from

the

alternator

does

not

rise

above

the

specified

value

by

the

ON

OFF

opera

tion

of

the

rotor

coil

through

the

IC

voltage

regulator

RJ

IB

1

is

011

CHARGE

LAMP

L

R

Q

T

zo

IGN

ITION

Wv

SW1TC1

R

67

BATTERY

e

R

@

R2

A

F

ld

T

IC

VOLTAGE REGULATOR

AI

E

SE

LOSS

EL

17

ELECTRICAL SYSTEM

Chargmg

System

SCHEMATIC

FUSIBLE

LINK

OFF

ACC

ON

sr

g

Sf

IGNITION

1m

1

I

BATTERY

FUSIBLE

LINK

B

E

ALTERNATOR

I

IGNITION

AND

ACCESSORY

RELAY

t

L

5

WIRING

DIAGRAM

f8

t

l

m

R

BATTE

RY

fUSIBLE

L1NK@

iAgCOFF

lffLBW

J

1

6

IG

r

if

WR

6

s

@

l

IGNITION

SW

c

a

s

00000

O

JCJ

0

0 0

0

000000

u

FUSE

BmCK

c

WB

G

B

@

fii

l

CJ

L

CONDENSER

v

E

W

fil

WR

LJ

fil

WR

W

SW

d

B

S

i

I

ALTERNATOR

ELlS

I

If

il

rt

I

WhIte

@

a

I

II

r

FUSE

CHARGE

WARNING

LAMP

SEl100

Bj

1

BW

IGNITION

AND

t

ACCESSORY

RELAY

R@

f@t

I

COMBINATION

METER

@

C

RGE

@

J

1

G

@

For

radio

noise

prewntion

SEL10

III

ELECTRICAL

SYSTEM

Charging

System

CHARGING

SYSTEM

TROUBLE

SHOOTING

Before

conducting

an

alternator

test

make

sure

that

tlie

battery

i

fully

charged

A

30

Volt

voltmeter

and

suitable

test

probes

are necessary for

the

test

The

alternator

can

be

checked

eaSi

ly

by

referring

to

the

Inspection

Table

@

With

alternator

side

L

terminal

grounded

internal

short

occurs

when

diode

is

short

circuited

Disconnect

Light

OFF

L

ht

OFf

connector

5

11

L

and

g

ound

Connect

con

J

Lioht

ON

I

Faulty

IC

RG

I

L

lead

wue L

ht

ON

e

R

I

Checl

light

ag

I

nec

or

S

l

ep

ace

light

ON

for

operation

and

r

ound

F

term

mal

Ligh

OFF

1

F

I

CG

I

Che

ck

light

t

au

ty

A

Dim

light

for

opera

lion

t

rs

1

I

Faulty

A C G

l

J

Light

ON

I

Contact

positive

lead ofvoltmcter

on

B

terminal

and

negative

lead

to

L

terminal

Bumed

out

bulb

Replace

and

Proceed

to

A

Ignition

switch

ON

Check

light

for

operation

Engine

idling

Check

light

for

operation

Dim

light

OFF

J

Mure

than

IS

SV

I

Faulty

1C

RG

1

Engine

speed

Replace

1

500

rpm

Measure

8

teoninal

volt

13

to

15V

age

Engine

idling

Measure

the

voltage

across

8

and

L

terminals

More

thanO

5

I

Faulty

A

C G

I

Light

OFF

1

Engine

speed

1

500

rpm

Ligh

ting

switch

ON

Check

light

for

operation

Less

thanO

SV

I

O K

Light

11

Uao

fully

clio

be

21

Light ming

lith

A

C G

Ar

porta

t

IC

ngulo

Il

RG

IC

ngulOtor

OK

ICI

is

in

good

condition

3

WMn

I

Ftty

A

CG

ren

IOft

1118r

natoI

from

car

end

da

nble

inspect

and

correct

or

I

e

eultv

parts

4

M

od

of

nding

F

18rmiMI

Contlct

tip

of

r

with

brush

and

ttKh

to

body

Make

sure

S

tenninal

is

con

nected

correctly

Engine

idlins

Lighting

switch

ON

Check

light

for

operation

Light

ON

I

Faulty

A

e

G

I

Light

OFF

I

O K

61

T

S

L

SAT

E

on

rear

cover

of

El19

111

Charging

System

ELECTRICAL

SYSTEM

ALTERNATOR

LRl60

Slip

ingdia

more

than

31

6

0

244

Re

listancc

at

lOoe

680f

I3 8

n

Rear

bearing

Rotor

Front

bearing

6

0

lcg

m

33

43

ft

lb

Unit

mm

in

DISASSEMBLY

I

Remove

through

bolts

2

Separate

front

cover

from

rear

UD

1

SELOSl

3

Remove

pulley

and

fan

I

Place

rear

cover

side

of

rotor

in

a

vice

2

Remove

pulley

nut

EL

20

Resistance

per

phuc

la

200C

680

I

0

051

n

Rear

cover

Ie

ro1use

rtBulator

Brushassembly

Min

brush

length

75 0

295

Spring

pressure

2

501

3

383

N

Diode

SOl

plate

a

mbly

255 345

I

8

99

12 17

oz

SEL060

SE

L062

4

Separate

rotor

front

cover

Remove

setscrews

from

bearing

re

tainer

SEL083

5

Pull

rear

bearing

off

rotor

assem

bly

fA

J

l

SEL064

SE

L06S

6

Disconnect

stator

coil

lead

wires

from

diode

terminals

EE623

7

Remove

brush

assembly

with

IC

regulator

8

Remove

diode

holder

CAUTION

Pllce

peckin

Ind

insullton

in

order

10

thlt

they

cen

be

placad

back

in

their

originll

p

or

locations

from

which

they

were

removed

t

e

j

0

I

ca

l0

EE624

ELECTRICAL SYSTEM

Charging

System

2

Ground

test

SE

L069

Continuity

exists

Replace

rotor

Stator

I

Continuity

test

SEL070

No

continuity

Replace

stator

Diode

Perform

a

continuity

test

on

diodes

in

both

directions

using

an

ohmmeter

Circuit

tester

terminal

Conduction

Positive

Negative

plate

I

Diode

Yes

Holder

plate

terminal

Diode

I

plate

Nn

terminal

Holder

plate

I

Diode

No

Rear

cover

terminal

Diode

I

plate

Yes

terminal

Rear

cover

Po

ltlve

dlod

EE536

1

Diode

holder

plate

2

Positive

diode

Conduction

test

is

N

G

diode

assembly

Replace

INSPECTION

Me

tlve

diode

Rotor

Continuity

test

SEL068

No

continuity

Replace

rotor

2

Ground

test

SEL071

Continuity

exists

Replace

stator

@

EE537

3

Rear

cover

4

Nega

live

diode

Conduction

test

is

N G

diode

assembly

Replace

EL21

ChargingSY

tWn

ELECTRICAL

SYSTEM

Sub

dlode

Direction

of

current

Conduction

test

is N

G

sub

diode Replace

CAUTION

If

it

isneceSSlry

to

remove

sub

iliode

pinch

diode lead

wire with

8

pair

of

plien

to

prevent

heat

transfer

from

solde

ing

iron

to

dil

de

when

unsolder

ing

connection

Brush

I

Check

smooth

movement

of

brush

Not

smooth

Check

brush

holder

and

clean

2

Check

brush

for

wear

Min

brush

length

7 5

mm

0

295

in

EE651

Less

than

the

specified

value Re

place

EL

22

3

Check

brush

pig

tail

fur

damage

Damaged

Replace

4

Check

brush

spring

pressure

Measure

brush

spring

pressure

with

brush

projected

approximately

2

mm

0

08

in

from

brush

holder

Spring

pressure

2

501

3

383

N

255

345

g

8

99

12

17

0

When

brush

is

worn

pressure

de

crease

epproximatoly

0

196

N

20

g

0

710

1

per

lmm

O

04

in

r

2

mm

10

08

in

nT

I

eeOEf

Not

in

the

specified

value Re

place

ASSEMBLY

Assemble

alternator

in

the

reverse

order

of

disassembly

noting

the

follo

ng

1

When

soldering

each

stator

coil

lead

wire

to

diode

assembly

terminal

carry

out

the

operation

as

fast

as

possible

2

When

installing

diode

A

ter

minal

install

insulating

bushing

cor

rectly

3

Tighten

pulley

nut

and

make

sure

that

deflection

of

V

groove

is

proper

C

l

Pulley

nut

44

59

NofII

5

60

kg

m

33

43

ft

lb

Vllroove

deflection

03

mm

0

012

in

4

Before

installing

front

and

rear

sides

of

alternator

push

brush

up

with

fmgers

and

retain

brush

by

inserting

brush

lift

into

brush

lift

hole

from

outside

Bru

00

1

o

i

EE541

5

After

installing

front

and

rear

sides

of

alternator

pull

brush

lift

by

pushing

toward

center

Do

not

pull

brush

lift

by

pushing

toward

outside

of

cover

as

it

will

damage

slip

ring

sliding

urface

6

Tighten through

bolt

C

l

Through

bolts

3 4

39

N

m

0

35

0

40

kg

m

2

5 2 9

ft

Ib

IC

VOLTAGE

REGULATOR

DESCRIPTION

The

regulator

consists

essentially

of

integrated

circuits

incorporating

tran

sistors

These

transistors

interrupt

and

admit

current

flow

to

the

alternator

rotor

coil

thus

maintaining

its

output

voltage

at

aconstant

value

Unlike

in

a

mechanical

type

regulator

an

electron

ic

relay

employing

transistors is

utilized

These

ransistors

are

enclosed

in

a

very

compact

sealed

case The

electronic

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

charge

warning

lamp

circuit

a

diode

is

attached

to

the

stator

coil

to

monitor

generating

voltage

at

the

stator

so

that

when

the

monitored

voltage

and

charging

voltage

are

equal

during

re

harging

the

charge

warning

lamp

is

turned

off

Accordingly

a

charge

warning

relay

is

not

employed

in

this

circuit

EFLSB

SE

LOB6

INSPECTION

Remove

IC

regulator

and

brushes

at

the

same

time

as

outlined

in

Dis

assemb4t

and

Assembly

section

under

the

heading

Alternator

CAUTION

When

performing

test

continuously

resistor

may

generate

heat

If

it

becomes

high

temperature

stop

test

ing

for

a

while

to

avoid

burning

I

The

following

test

equipment

and

accessories

are

required

ELECTRICAL

SYSTEM

Charging

System

1

Resistor

R

1

10

ohms

20

watts

x

I

2

Variable

resistor

Rv

O

to

300

ohms

20 watts x

I

3

Batteries

I

and

2

12

volts

x2

4

DC

voltmeter

o

to

30 volts

x

1

2

Measure

voltage

V

I

at

battery

Not

within

10

to

13

volts

Re

charge

or

replace

battery

1

JI

Ie

regulator

L

r

3

I

crT

I

SE

LOB7

3

Measure

voltage

V2

Below

20

volts

Regulator

is

functioning

properly

1

Ic

egulato

1

L

n

cr

l

r

SE

LOBB

4

Measure

voltage

V3

Not

within

20

to

26

volts Re

charge

or

replace

either

or

both

batteries

1

Ie

regu

la

tor

II

L

i

T

SE

L089

S

Gradually

decrease resistance

of

variable

resistor

Rv

from

300

ohms

and

measure

voltage

V2

between

terminals

E

and

F

Voltage

V2

should

increase

at

a

certain

point

to as

high

as

voltage

V

I

10

to

13

volts

If

there

is

such

a

variation

Regulator

is

functioning

properly

No

variation

Regulator

is

out

of

order

L

1

L

l

J1

Ie

regulator

SEL090

6

Hold

variable

resistor

Rv

at

the

same

voltage

as

VI

10

to

13

volts

Measure

voltage

V4

L

IC

e

umlol

11

1

t

J

SEL091

Voltage

V4

is

within

specified

range

indicated

in

Figure

EL

23

Charging

System

ELECTRICAL SYSTEM

Example

When

temperature

of

regulator

case

is

4O

C

I04OF

regulator

is

normal

if

voltage

V4

is

within

range

ofl4to

15

volts

o

0

z

o

u

1

IU

I

m M

10

cHI

I

IIIIM

ll21l

I

wICIJlICIUICIMllllllUlGl

Rc

ul

tor

case

temperature

Oc

OF

SE

L092

EL

24

7

Reconnect

wlftng

as

shown

in

Fugure

and

repeat

steps

5

and

6

If

voltage

V4

is

0

5

to

2 0

wolb

higher

than

that

in

step

6

regulator

is

functioning

properly

If it

i

not

replace

1

j

Ie

regulator

J

r

SEl093

SERVICE

DATA AND

SPECIFICATIONS

ALTERNATOR

Type

Applied

model

Nominal

rating

VA

Ground

polarity

Minimum

revolution

under

no

load

When

14

volts

is

applied

rpm

Hot

output

current

Arpm

Pulley

ratio

Regulated

output

voltage

v

Minimum

length

of

brush

mm

in

Brush

spring

pressure

N

g

oz

Slip

ring

outer

diameter

mm

in

ELECTRICAL

SYSTEM

Charging

System

lR16047

All

1260

Negative

Less

than

1

050

More

than

45

2

500

More

than

60

5

000

2

09

144

15 0

7 5

0

295

2

501

3

383

255 345

8

99

12 17

31

6

1

244

EL

25

Ignition

System

ELECTRICAL

SYSTEM

IGNITION

SYSTEM

e

t

1

o

g

R

B

IGNITION

SW

rw

i

E

o o

Q

o

0 0 0 0

0

0 0 0

0 0 0 0 0 0 0

o

f

r

FUSE

BLOCK

f

l

f

ia

models

Q

CIl

I

@L

I

J

@

ff

IGNITION

COIL

EL

26

8

Q

@

TERMINAL

BLOCK

VB

O

G

a

L

a

@

e

Jilj

lJ

1J1J

@

SPAR

K

PLUGS

IGNITION

COIL

w

iP

t

WB

BW

0

@

lJlJ

Jf

IGNITION

AND

11

ACCESSORY

RELA

9

@

California

models

@

Non

California

models

INon

Califomia

models

DISTRIBUTOR

we

L

@

0

B

cJ

I

n

I

if

0

u

@L

J

j

SPARK

PLUGS

J

@

ff

IGNITION

COIL

SEL

102

CHECKING

PROCEDURE

No

start

condition

Sparking

once

check

1

Turn

ignition

switch

to

OFF

position

2

Disconnect

EF1

fusible

link

con

nector

CAUTION

Before

disconnecting

EFI

fusible

link

connector

enlllre

thet

ignition

switch

is

in

OFF

position

3

Disconnect

high

tension

cable

from

distributor

4

Keeping

high

tension

cable

end

4

to

5

mrn

0

16

to

0

20

in

away

from

engine

block

rotate

starter

motor

and

check

whether

sparks

occur

across

the

clearance

ELECTRICAL

SYSTEM

Ignition

System

JUDGMENT

Spark

occur

1C

ignition

system

O

K

In this

case

1C

ignition

system

and

component

parts

need

not

be

checked

beyond

this

No

spark

occurs

on

sparks

are

intermittent

1C

ignition

system

N

G

Proceed

with tests

below

Manual

testlna

of

IC

lanltlon

s

stem

uslna

a

voltmeter

1C

Ignition

System

is

best

checked

using

J

26350

Transistor

Ignition

Analyzer

However

if

an

analyzer

is

not

available

a

volt

ohm

milliammeter

V

OM may

be

used

to

diagnose

transistor

ignition

malfunctions

While

this

method

requires

more

time

it

can

nevertheless

provide

accurate

results

Follow

the

steps

in

the

sequence

indicated

If

a

fault

is

found

correct

the

problem

before

continuing

If

all

tests

indicate

O K

replace

the

Ie

Ignition

Unit

DO

NOT

REPLACE

THE

UNIT

UNTILL

ALL

TESTS

HA

VB

BEEN

COMPLETED

AND

INDICATE

OK

1

When

performing

the

following

teltS

USI a

multitester

which

can

measure

accurately

in the

following

ronge

0

to

20V

D

C

0

to

1

0000

0

to

10V

A

C

0

to

50

oOOn

2 If

possible

tart

the

vehicles

and

let

it

run

for

5

to

15

minute

with

the

hood

closed

Thi

will

bring

all

componenu

to

normal

operating

tem

perature

and

will

make

it

easier

to

diagnose

intermittent

problems

3

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

ELECTRICAL

SYSTEM

IC

IGNITION

SYSTEM

TROUBLE

SHOOTING

TEST

1

Battery Voltage

no

load

2

Battery

Cranking

V

oUage

3

Secondary

Wiring

4

Ignition

Coil

Secondary

Circuit

S

Power

Supply

Circuit

Non

catifomia

models

only

EL

28

TEST

METHOD

Reading

12

olts

J

Highscale

Low

t

Scale

scale

selector

1

Red

positi

e

Black

negative

pOlitive

l

I

SEU03

Terminal

SEU04

Reaeptacle

5EL078

EF125

CONDITIONS

Ignition

key

in

OFF

position

2

Connect

voltmeter

as

ilIusua

ted

tnd

sct to

appropriate

scale

3

Read

and record

battery

voltage

reading

Battery

voltage

D

I

Connect

yoltmeter

as

illustrated

and

set

to

appropriate

scale

2

Remove coil

wire

from

distributor

cap

and

ground

it

3

Read

voltmeter

while

cranking

engine

f9

I

ap

proximately

15

seconds

4

Record

voltage

reading

Battery

cranking

D

voltage

1

Conn

eel

ohmmeter

as

illustrated

and

measure

the

resistance

of

each

high

tension

cable

I

Ignition

key

in

OFF

position

2

Coil

wire

removed

from

coil

3

Connec

t

ohmmeter

as

illustrated

L

Connect

voltmeter

35

illustrated

and

set

to

appropriate

scale

2

Turn

ignition

key

to

ON

position

RESULT

11

5

12

5volts

Below

11

5

yolts

Voltage reading

greater

than

9

6

volts

Voltage reading

less

than

9 6

volts

Resistance

readings

less

than

30

000

ohms

Resistance

readings

greater

than

30

000

ohms

California

models

7

400

11

000

ohms

Non

Gllifornia

models

8

200

12

400

ohms

Resistance

reading

not

between

7

400

11

000

ohms

California

models

or

8

200

12

400

ohms

Non

California

models

11

5

12

5

yolts

Below

11

5

volts

ACTION

Proceed

to

Step 2

Battery

charging

system

or

starting

system

Faulty

Refer

to

applicable

sections

in

Sen

ice

Manual

to

correct

the

situation

Battery

O

K

Proceed

to

Step

3

Battery

charging

system

or

starting

system

Faulty

Refer

to

applicable

secti9ns

in

rvice

Manual

to

correct

the

situation

Distiibutor

cap

and

high

tensioo

cables

Q

K

Proceed

to

Step

4

Replace

high

tensiou

cable

s

and

or

distributor

cap

as

required

Ignition

coil

sec

ondary

windittp

O

K

Proceed

to

step

8

for

California

Faulty

ignition

coil

replace

Proceed to

Step

6

Check

wiring

from

ignition

switch

to

ICunit

Continued

n

xt

page

ELECTRICAL

SYSTEM

Ignition

System

TEST

METHOD

CONDITIONS

RESULT

ACTION

6

Power

Supply

Ground

coil

output

wire

Connect

voltmeter

as

Voltage

reading

is

Circuit

while

performing

test

illustrated

and

set

to

less

than

1

volt

Cranking

appropriate

sCale

below

battery

Proceed

to

Step

7

2

PUU

out

coil

wire

from

cranking

voltage

distributor

cap

and and

is

greater

ground

it

t

an

8

6

volts

3

Tum

key

to

ST

ART

Voltage

reading

is

Check

ignition

switch

position

and

observe

more

than

I

volt

and

wiring

from

voltmeter

while

engine

below

battery

switch

to

Ie

unit

is

cranking cranking

voltage

Non

canfornia

and

or

is

below

models

only

SE

L079

86

volts

7

Ignition

Connect

voltmeter

as

Primary

illustrated

and

set

to

11

5

12

5

volts

Proceed

to

Step

9

Circuit

appropriate

scale

2

Ignition

key

in

ON

Below

1

5

volts

Proceed

to

Step

8

position

Non

california

mode1sonly

SELOBO

8

Ignition

Coil

1

range

Ignition

key

in

OFF

California

models

Ignition

coil

primary

Primary

position

1

04

1

27

ohms

winding

O K

Circuit

2

Coil

wire

removed

from

Non

california

Check

ignition

switch

coil

models

and

wiring

from

0 84

1

02

ohms

ignition

switch

to

3

Connect

ohmmeter

as

illustrated

Resistance

reading

coil

and

IC

unit

not

between

1

04

1

27

ohms

Faulty

ignition

coil

California

models

replace

or

0

84

1

02

ohms

Non

california

EE567

models

9 J

C

Unit

I

Connect

voltmeter

as

Ground

illustrated

and

set to

0

5

volts

or

less

Proceed

to

Step

10

Circuit

appropriate

scale

2 Pull

out

coil

wire

from

Check

distributor

cap

and

ground

wiring

from

ground

it

More

than

0

5

chassis

ground

to

3

Tum

key

to

START

volts

battery including

position

and

observe

battery

cable

Non

ca

tifomia

voltmeter

while

engine

connections

models

only SELOS1

is

cranking

10

Pick

up

Coil

Ground

coil

seoondary

I

Engine

is

at

or

above

Approximately Proceed

to

Step

11

Resistance

while

cranking

normal

operating

400

ohms

l

temperature

0

2

Ignition

key

in

OFF

Ohmmeter

reading

Check

pick

op

coil

position

substantially

ex

and

wiring

to

it

3

Connect

ohmmeter

as

ceeds

or

falls

below

Non

california

dD

illustrated

and

set

to

the

400

ohms

models

only

arr

r

te

scale

specifications

SE

L082

II

Pick

up

Coil

Ground

coil

secondary

while

cranking

I

Engine

is

at

or

above

Needle

If

No

Spark

Output

normal

operating

Wavers

@

condition

stiD

exists

temperature

replace

IC

2

Connect

voltmeter

and

ignition

unit

set

to

the

low

a

c

volt

Needle

steady

Check

physical

con

scale

J

Sj

dition

of

pick

up

3

Turn

key

to

ST

ART

coil

and

reluctor

position

and

observe

the

@

Check

wiring

and

needle

movement

while

connections

between

Non

california

the

engine

is

cranking

pick

up

coil

and

IC

models

only

SE

L083

SEL

105

ignition

unit

Continued

n

xt

pIIg

EL

29

Ignition

System

ELECTRICAL

SYSTEM

TEST

12

Power

Supply

Circuit

California

models

only

EL30

TEST

METHOD

Ie

ignition

uni

SEL084

CONDITIONS

1

Connect

voltmeter

as

illustrated

and

set

to

appropriate

scale

2

Turn

ignition

key

to

ON

position

RESULT

II

S

12

Svolts

Below

11 5

volts

ACTION

Check

wiring

from

ignition

switch

Co

ICunit

le

type

DISTRIBUTOR

California

models

Shaft

a

mbly

Cap

setter

it

Cl

COllaJ

se

YSTEM

Ignition

System

ELECTRICAL

S

Cap

aSJembly

Carbon

point

g

Y

Ro

orhead

I

RoUpin

RelUclor

S

tor

r

Magnet

ICignitionunit

j

G

J

Setter

unit

Ell

ll

J

m

controller

Vacuu

ow

connecting

Q

Breaker

plate

I

Il

assembly

@

Packing

r

li@

Rotor

shaft

1

sembIY

Thru

t

w

er

GovernorWeight

@

Governor

ng

c

SE

lOOl

EL31

Rotor

bead

usembly

RoUpin

Reluctor

0

Stator

Magnet

assembly

Pick

up

coil

usembly

Vacuum

controller

Breaker

plate

mbly

Rotor

shaft

usembly

Governor

Prins

Governor

weisht

SE

L201

Ignition

Symm

ELECTRICAL

SYSTEM

Non

CaJifomia

models

6

J

Shart

uoembly

Housing

Grommet

Ie

ignition

unit

CoUar

CHECKING

AND

ADJUSTMENT

Vacuum

ad

ce

mechanism

mecha

nical

parts

I

Check

vacuum

inlet

for

signs

of

leakages

at its

connection

2

Check

vacuum

diaphragm

for

air

leak

If

leak

is

found

replace

vacuum

controller

assembly

3

Inspect

breaker

plate

for

smooth

moving

If

plate

doe

not

move

smoothly

this

condition

could

be

due

to

sticky

Cap

and

rotor

head

Check

cap

and

rotor

head

for

dust

carbon

deposits

and

crack

Advance

mechanlsma

Specifications

Refer

to

D

EL32

cap

mbly

st

el

balls

or

pivot

Apply

grease

to

steel balls

or

if

necessary

replace

breaker

plate

as

an

assembly

Centrifugal

ad

ce

mechanil

al

parts

When

cause

of

engine

malfunction

i

traced

to

centrifugai

advance

mecha

nical

parts

use

distributor

tester

to

check

its

characteristics

If

nothing

is

wrong

with

its

charac

teristics

conceivable

causes

are

faulty

or

abnonnal

wear

of

driving

part

or

others

So

do

not

disassemble

it

In

the

event

of

improper

character

istics

check

c

osely

rotor

shaft

assem

bly

governor

weight

and

shaft

If

any

of

the

above

parts

are

mal

functioning

place

the

parts

DISASSEMBLY

California

models

I

Take

off

cap

and

remove

rotor

head

2

Pry

reluctor

from

shaft

SEL002

CAUTION

When

removing

reluctor

be

careful

not

to

distort

or

damage

tha teeth

3

Remove

IC

ignition

unit

and

unit

setter

4

Remove

stator

and

magnet

SE

L003

5

Remove

vacuum

control

assem

bly

6

Remove

braker

plate

Before

disassembling

be

sure

to

mark

housing

and

fixing

plate

ELECTRICAL SYSTEM

Ignition

System

SE

L004

7

Remove

fixing

plate

Mark

housing

and

fixing

plate

SE

LOOS

8

Remove

collar

EE104

9

Remove

rotor

shaft

and

drive

shaft

EE705

10

Mark

rotor

shaft

and

drive

shaft

Remove

packing

from

the

top

of

rotor

shaft

and

remove

rotor

shaft

EE706

II

Mark

one

of

the

govemor

springs

and

its

bracket

Also

mark

one

of

the

governor

weights

and

its

pivot

pins

12

Carefully

unhook

and

remove

governor

springs

13

Remove

governor

weights

Apply

grease

to

governor

weights

after

dis

assembling

Non

California

models

1

Take

off

cap

and

rotor

head

2

Remoye

IC

ignitio

unit

3

Remove

stator

and

magnet

4

Remove

vacuu

controller

EE746

5

Using

two

pry

bars

or

suitable

puller

pry

reluctor

from

shaft

CAUTION

When

removing

reluctor

be

careful

not

to

distort

or

damage

the teeth

6

Remove

roll

7

Remove

pick

up

coil

assembly

EL33

8

Remove

breaker

piate

assembly

Ignition

System

ELECTRICAL

S

VSTEM

EE703

9

Punch

knock

out

and

remove

pinion

@W

EE704

10

Remove

rotor

shaft

and

drive

shaft

assembly

EE705

11

Mark

rotor

shaft

and

drive

shaft

Remove

packing

from

the

top

of

rotor

shaft

and

unscrew

rotor

shaft

setscrew

Remove

rotor

shaft

EL34

EE706

12

Mark

one

of

the

gov

rnor

spring

and

its

bracket

Also

mark

one

of

the

governor

weights

and

its

pivot

pins

13

Carefully

unhook

and

remove

governor

springs

14

Remove

governor

weights

Ap

ply

grease

to

governor

weights

after

disassembling

ASSEMBLY

To

assemble

reverse

the

order

of

disassembly

Carefully

observe

the

fol

lowing

instruction

CAUTION

Before

inslallinglC

ignition

unit

make

sure

mati

R1rfaces

of

IC

ignition

unit

and

distributor

are

clean

and

free

from

dust

sand

and

moisture

Align

match

marks

so

that

part

are

assembled

to

their

original

posi

tions

2

Ensure

that

reluctor

is

properly

oriented

when

installing

on

shaft

Al

ways

drive

in

new

roll

as

shown

in

Figure

3

When

installing

pinion

on

shaft

be

sure

to

install

pinion

gear

correcily

to

position

where

it

was

installed

4

Apply

grei

S

to

the

top

of

rotor

shaft

as

required

5

Check

the

opera1ion

of

governor

before

installing

distributor

on

engine

6

properly

i

enter

stator

and

reluc

tor

before

tightening

Stenderd

eir

gep

0

3

0 5

mm

0

012

0

020

in

CeIifomia

model

3

0 3

05

mm

SEL0ll6

10

012

0

020

in

Non

Celifomia

model

EE148

7

Adjust

ignition

timing

after

distri

butor

is

installed

on

engine

IC

IGNITION

UNIT

DESCRIPTION

California

modals

In

the

conventional

distributor

the

ignition

timing

is

detected

by

the

cam

and

breaker

arm

while

in

this

distribu

tor

it

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

passing

through

the

pick

up

coil

is

changed

when

the

reluc

tor

rotates

and

then

the

electrical

signal

is

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

tional

mechanical

type

The

Ie

ignition

unit

utilizes a

semi

California

models

Ignition

swih h

8

Battery

ffi

8

Spark

timing

signal

monitoring

circuit

Lock

prevellting

circuit

ELECTRICAL

SYSTEM

Ignirion

System

conductor

Ie

device

and

is

mounted

in

the

distributor

The

IC

ignition

unit

has

the

fol

lowing

circuits

Spark

timing

signal

ffi9nitoring

circuit

This

circuit

detects

the

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

sta

tionary

If

the

ignition

coil

primary

current

is

allowed

to

flow

under

such

condi

tions

excessive

current

will

be

drawn

because

of

low

internal

resistance

of

the

ignition

coil

This

can

result

in

an

abnormal

temperature

rise

in

the

ignition

coil

or

discharged

battery

These

malfunc

tions

can

be

prevented

by

this

lock

preventing

circuit

3

Duty

coritrol

circuit

This

circuit

contn

ls

the

ratio

of

the

ignition

coil

primary

current

ON

OFF

time

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

temperature

as

well

as

by

the

engine

rpm

4

Power

switching

circuit

This

circuit

is

used

to

make

or

break

directly

the

primary

circuit

cur

rent

of

the

ignition

coil

To

ensure

efficient

operation

of

the

Ie

igniti9n

unit

these

four

circuits

are

manufactured

in

one

assembly

A

To

distributor

Ex

side

f

8

II

I I

101 101

II

Ignition

coil

s

To

distributor

In

side

f

8

I

r

Lo

1

01

I I

Ignition

coil

E

ill

j

ClfCU

Duty

control

SEL085

EL35

Non

California

models

Ignition

Smem

ELECTRICAL

SYSTEM

The

Ie

ignition

unit

utilizes

a

mi

conductor

Ie

device

and

is

mounted

on

the

side

surface

of

the

distributor

The

IC

ignition

unit

has

the

follow

ing

circuits

I

Spark

timing

signal

monitoring

circuit

This

circuit

detects

the

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

ary

If

the

ignition

coil

primary

current

is

allowed

to

flow

under

such

condi

tions

excessive

current will

be

drawn

because

of

low

internal

resistance

of

the

ignition

coil

Non

Califomia

models

Battery

CD

i

This

can

result

in

an

abnormal

temperature

rise

in the

ignition

coil

or

discharged

battery

These

malfunc

tions

can

be

prevented

by

this

lock

preventing

circuit

3

Duty

control

circuit

This

circuit

controls

the

ratio

of

the

ignition

coil

primary

current

ON

OFF

time

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

perfonnancespark

firing

over

awide

range

of

driving

speeds

this

duty

can

be

controlled

by

the

source

voltage

and

the

ambient

temperature

as

well

as

by

the

engine

rpm

4

Power

switching

c

rcuit

This

circuit

is

used

to

make

or

break

directly

the

primary

circuit

current

of

the

ignition

coil

Ige51Ch

eh

B

I

J

101

LJ

Ignition

coil

r

Pick

up

coil

Lu

Distributor

EL36

Spark

ti

ing

sig

al

G

monitoring

ClICUlt

R

Duty

control

circuit

Lock

Preventing

circuit

IC

ignition

unit

5

Current

limiting

circuit

This

circuit controls the

current

value

so

that

excessive

current will

not

flow

trough

the

power

witching

circuit

To

ensure

efficient

operation

of

the

IC

ignition

unit

these

five

circuits

are

manufactured

in

one

assembly

The

semi

conductor

IC

is

utilized

for

all

these

circuits

except

the

power

switching

circuit

The

power

witching

circuit

uses

one

power

transistor

and

the

circuit

is

arranged

on

the

ceramic

substrate

together

with

resistors

capa

citors

and

diodes

Each

component

part

of

this

unit

is

highly

reliable

however

should

any

part

be

found

faulty

the

entire

assembly

must

be

replaced

2P

rOl

II

connector

rBCl

Power

switching

circuit

Current

timating

circuit

SEL094

ELECTRICAL

SYSTEM

Ignition

Sysrem

SERVICE

DATA AND

SPECIFICATIONS

DISTRIBUTOR

I

Type

I

pplied

model

I

Transmission

I

Firing

order

I

Rotating

direction

I

Air

gap

I

Ca

insulation

resistance

Rotor

head

insulation

resistance

I

mm

in

1

Mn

I

Mn

I

cap

carbon point

length

mm

in

I

Vacuum

advance

Distributor

degree

distributor

kPa

mmHg

inHgH

Centrifugal

advance

Distributor

degree

distributor

rpm

IGNITION

COIL

Type

Applied

model

Primary

voltage

Spark

gap

Primary

resistance

at

200C

680

F

Secondary

resistance

at

200C

680F

SPARK

PLUG

Applied

model

Type

v

mm in

n

Standard

Hot

Cold

Size

Screw

dia

x

reach

mm in

Plug

gap

mm

in

D4N9

o5

D4N9

04

D4K9

1O

D4K9

09

California

Non

Califomia

Canada

A

T

I

A

T

M

T

M

T

134

2

Coun

terc10ckwise

03

0

5 0

012

0

020

More

than

50

More

than

50

10

0

39

12

0

47

00

93

00

93

00

93

00

93

70

2

76 70

2

76 70

2

76 70

2

76

3

50

12

0

3

50

12

0

2

50

12

0

2

50

12

0

90

3

54

90

3

54

90

3

54

90

3

54

3

50

13

3

50 13

3

2

50

147

2

50

14

7

100

3

94

100

3

94

11

0

4

33

110

4

33

100

33

3

100

33

3

10

33

3

100

33

3

250

9

84

250

9

84

250

9

84

250

9

84

00

900

00

700

00

700

00

700

50

1

700

3

50

1

100

30

1

000

30

1

000

50

1

500

60

1

600

60

1

600

CIT

38

CIT

30

California

Non

California

12

More

than

7

0

28

1

04

12

7

0

84

1

02

74

11

0

82

12

4

U

s

A

BP6ES

BP5ES BP4ES

BP7ES

Canada

BPR6ES

BPR5ES BPR4ES

BPR7ES

14

x

19

0

55

x

0

75

0

8 0 90

031

0

035

Optional

for

U

sA

EL

37

Lighting

Systems

ELECTRICAL SYSTEM

LIGHTING

SYSTEMS

CAUTION

Before

starting

to

work

on

any

part

of

electricel

system

disconneet

battery

ground

ceble

BULB

SPECIFICATIONS

Item

Headlamp

Type

I

High

Type

11

High

Low

Front

combination

lamps

Tum

signal

Clearance

Rear

combination

lamps

Stoprrail

Turn

signal

Side

marker

lamp

Front

Rear

Back

up

lamp

license

plate lamp

Interior

lamp

Spot

lamp

Step

lamp

Luggage

compartment

lamp

Hatchback

Hardtop

Combination

meter

Illumination

and

brake

warning

lamp

Waming

and

monitor

lamp

Turn

signal

and

beam

indicator

lamp

Cigarette

lighter

illumination

lamp

Heater

Air

on

control

panel

illumination

lamp

Glove

box

lamp

Cruise

control

switch

lamp

Selector

lever

illumination

lamp

AT

model

EL38

Wattage

50

40

60

27

8

27

8

27

34

27

80r

10

8

5

34

2

34

1

4

34

3

4

14

34

SAE

trade

number

4651

4652

1157

1156

158

1156

67

158

COMBINATION

SWITCH

REMOVAL

AND

INSPECTION

1

Remove

steering

wheel

2

Remove

steering

column

cover

3

Disconnect

all

combination

switch

wires

4

Loosen

retaining

screw

and

re

move

combination

switch

5

To

install

combination

switch

a1ign

protrusion

on

switch

body

wiih

hole

on

steering

column

and

tighten

retaining

screw

SE

L283

INSPECTION

Test

continuity

through

switch

with

a

test

lamp

or

ohmmeter

1st

OFF

2nd

N

L

OFFI

ON

ELECTRICAL SYSTEM

LighringSystems

o

JI

I

1r

111f

UUJUUU

I

TURN

SIGNAL

SWITCH

1

LEVER

I

i

NIL

If

LIGHTING

SWITCH

1

OFF

1ST

2ND

I

ABC

A

Be

A

8 C

zuni

I

0

I

tf

M

UMJ

o

iF

90

ON

OFF

WIPER

AND

WASHER

SWITCH

1

WIPER

IOFF

INT

LO

HI

111

l

12

WITH

1i

X

TINE

CONTRod

f

rq

tJ

tu

AAQ

SWITCH

nON

22

SEL310

EL39

Lighting

Systems

ELECTRICAL SYSTEM

HEADLAMP

SCHEMATIC

HEADLAMP

HEAOLAMP

A H

@

C0

HEAD

LAMP

L

H

CD

@

FUSIBLE

LINK

FUSE

r

c

l

BATTERY

I

oc

FUSE

t

r

I

TROUBLE

DIAGNOSES

AND

CORRECTIONS

Condition

Headlamps

do

not

come

on

either

high

or

low

beams

High

beam

cannot

be

switched

to

low

beam

or

vice

versa

Headlamps

dim

Headlamp lights

on

only

one

side

EL40

Probable

cause

Burnt

fusible

link

Burnt

fuse

Loose

connection

or

open

circuit

Faulty

lighting

switch

High

low

beam

comes

on

when

CD

and

@

CD

and

@

terminals

of

hamess

con

nector

to

lighting

switch

are

connected

with

test

lead

including

lOA

fuse

Faulty

headlamp

sensor

No

ground

Faulty

lighting

switch

High

low

beam

comes

on

when

CD

and

@

D

and

@

terminals

of

hamess

con

nector

to

lighting

switch

are

connected

with

test

lead

including

lOA

fuse

Partly

discharged

or

run

down

battery

Inoperative

charging

system

Poor

ground

or

loose

connection

Loose

headlamp

connection

Faulty

headlamp

udi

LIGHTING

SWITCH

HEAD

LAMP

MONITOR

lj

HEADLAMP

SENSOR

1

SEL371

Corrective

action

Correct

cause

and

replace

fusible

link

Correct

cause

and

replace

fuse

Check

wiring

and

or

repair

connection

Replace

if

necessary

Replace

if

necessary

Clean

and

tighten

ground

terminal

Replace

if

necessary

Measure

specific

gravity

of

electrolyte

and

recharge

or

replace

battery

if

necessary

Measure

voltage

at

headlamp

terminals

If

it

is

less

than

12

8V

check

charging

system

for

proper

operation

Clean

and

or

tighten

Repair

Replace

WIRING

DIAGRAM

HEADLAMP

ill

R

OW

FUSIBLE

@

LINK

ELECTRICAL

SYSTEM

Lighting

Systems

o

BATTERY

t

HEADLAMP

R

H

fi

ir

RY

RR

@

Tr

1

RW

R

@

HEADLAMP

L

H

0

@

RY

RL

RW

@

II

White

QrJ

g g

giJ

@

I

r

@

V

RY1th

j

R

I

Y

RW

LIGHTING

SWITCH

I

OFF

1ST

2ND

4

R

r

4

R

r

4

I

a

lL

661

t

D

L

l3

0

H

gXZ

6 6

g

II

r

Green

J

I

l

lQ

g

gglrgg

CI

I

@

I

COMBINATION

METER

O

U

@

HEADL

MP

MONITOR

HEAD LAMP

SENSOR

@l

D

DO

@

SE

L372

EL

41

Lighting

Systems

ELECTRICAL

SYSTEM

LIGHTING

SWITCH

Refer

to

Combination Switch

HEADLAMP

SENSOR

Location

The

headlamp

sensor

is

located

on

the

relay

bracket

Refer

to

page

EL

105

Inspection

Ught

swi1ch

on

Before

checking

headlamp

sensor

ensure

that

11

bulb

meet

specifi

cations

All

bulbs

in

good

ordllr

Bulb

removed

e

2

volts

12volu

SEl373

EL42

AIMING

ADJUST

ENT

To

adjust

vertical

aim

use

adjusting

screw

on

upper

side

of

headlamp

and

to

adjust

horizontal

aim

use

adjusting

screw

on

side

of

headlamp

CD

Q2

i

il

i

Gwu

1

SEL291

1

Vertical

adjustment

2

Horizontal

adjumnent

Bafor

m

king

headl

mp Imlng

djustment

ob

rve

the

following

instruction

Keep

11

tires

infl

ted

to

correct

pressures

b

Place

car

and

tester

on

one

and

same

flat

urf

c

See

th

t

there

is

no

load

in

car

cool

nt

engine

oil

filled

up

to

correct

level

and

full

fuel

tank

other

than

the

driver

or

equivalent

weight

pl

ced

in

driver

s

position

When

performing

headlamp

aiming

adjustment

use

an

aiming

machine

aiming

wall

screen

or

headlamp

tester

For

operating

instructions

of

any

aimer

it

should

be

in

good

repair

calibrated

and

used

according

to

respective

operation

manuals

supplied

with

the

unit

If

any

aimer

is

not

available

aiming

adjustment

can

be

done

as

follows

Low

beam

Turn

headlamp

low

beam

on

U

Horizo

tal

n

230

48 43

center

line

I

Ofheadlam

p

Wf

Th

fP

t

s

7R

j

W

Unit

nun

in

BE298D

Adjust

headl

mps

SO

that

upper

edge

of

hot

pot

is

equ

1

in

h

ight

to

heedl

mp

height

b

Dotted

lines

in

illustration

show

canter

of

headl

mp

High

beam

With

type

II

unit

lamps

outer

lamps

covered

tum

headlamps

to

high

beam

U

H

Unit

mm in

BE2990

8

Adjust

high

beams

so that

main

axis

of

light

is

p

rallel

to

center

line

of

body

b

Dotted

lines

in

illustration

show

center

of

headl

mp

EXTERIOR

LAMPS

ELECTRICAL

SYSTEM

Lighting

Systems

CAUTION

Do

not

wipe

lens

surface

using

cloth

dampered

with

gesoline

SCHEMATIC

TAIL

CLEARANCE

SIDE

MARKER

LICENSE

PLATE

AND

STOP

LAMPS

FRONT

SIDE

MARKER LAMP

R H

oc

FUSE

@

I

CLEARANCE

r

fJ

CLEARANCE

oc

FUSE

oc

FUSE

IFUSIBLE

LINK

T

I

BATTERY

L

I

EJ

FRONT

SIDE

MARKER LAMP

LH

2toI

1ST

OFF

jlmfr

i

STOP

LAMP

SWITCH

TAIL

LAMP

MONITOR

STOP

LAMP

MONITOR

r

TAl

L

ANO

STOP

LAMP

SENSOR

SCHEMATIC

TURN

SIGNAL

AND HAZARD WARNING

LAMPS

OACC

r

o

4

c

FUSleLE

LINK

Sf

oc

FUSIBLE

LINK

T

I

BATTERY

L

I

TURN

fl

FRONT

COMBINATION

l

LAMP

TURN

E1

oc

FUSE

IGNITION

SWITCH

1

L

IGNITION

AND

ACCESSORY

RELAY

C

00

FUSE

Fl

HAZARD

FLASHER

UNIT

Fl

TURN

SIGNAL

FLASHER

UNIT

PILOT

LAMP

R

H

PILOT

LAMP

LH

REAR

SIDE

MARKER

LAMP

R

H

STOP

j

@

TAIL

LICENSE

PLATE

LAMP

@

l

TAIL

Il

STOP

REAR

SIDE

MAR

KER

Q

LAMP

LH

SE

L315

g

HAZARD

SWITCH

IN

f

g

TURN

SIGNAL

SWITCH

@

TURN

RE

R

COMBINATION

LAMP

TURN

t3

eL37

EL

43

Lighting

Systems

ELECTRICAL

SYSTEM

WIRING

DIAGRAM

TAIL

CLEARANcE

SIDE

MARKER

AND

UCENSE

PLATE

LAMPS

R

I

FUSIBLE

LINK

@

Et

BATTERY

1

FRONT

SlOE

MARKER LAMP

R H

n

@89

ll

FRONT

COMBINA

TION

LAMP

R H

1

GW

8

@

il

FRONT

COMBINA

TION

LAMP

LH

GB

@

@I

FRONT

SIDE

Y

MARKER LAMP

LH

ELM

W

I

J

I

GW

I

OF

1ST

2ND

ABCABCABC

Lg

j

I

00

1

I

00

3

4

5

LIGHTING

SWITCH

GW

00

1B

00

V

00

ft

White

@

I

G

LICENSE

PLATE

LAMP

l

e

r

GW

i

lI

ltJ

ill

@

Ij

f

ill

@o

WL

@

e

gg

@

00

g g

Black

i5O

g

r

TAIL

WGH

HATC

CK

M

B

I

ry

I

wARD

TOP

TAIL

LA

P

WG

LH

I

a

f

B14

Gll

L@j

JJ

@

@j

Gf

REAR

SIDE

MARKER

I

LAMP

LH

II

JtU@

W

l

TAIL

AND

STOP

LAMP

SENSOR

SEL316

WIRING

DIAGRAM

STOP

LAMP

BATTERY

01

IU

G

I

FUSIBLE

LINK

@

0

l

W

w

I

10

15

10

20

10

15

FUSE

BLOCK

STOP

LAMP

SWITCH

ELECTRICAL

SYSTEM

Lighting

Systems

COMBINATION

METER

L

Au2

y

U

CID

II

@

J@

ggggllggt

Bluel

White

@

II

J

IIF

@

J

GY

L

c

LIi

White

OOIIOOOO

Iqj

oo

0000

11

@

I

f

I

tf11

@

TAIL

AND

STOP

LAMP

SENSOR

SEli71

B

YG

STOP

LAMP

MONITOR

HATCHBACK

STOP

AND

TAIL

LAMP

RH

@

f

HARDTOP

f

YG

I

f

B

41

tJ

I

@

L

STOP

LAMP

I

R H

HATCHeACK

STOP

AND

TAIL

LAMP

@

LH

J

r

II

J

Black

o

ooooo

OJ

rO@

I

B1

@

Cill

u

B

l

YG

r

HARDTOP

@I

@

I

STOP

LAMP

L

LH

EL

45

GBbTCHBACK

l

B

m

J

HAZARD

SWITCH

r

l

I

HARDTOP

2

0

8GB1

I

O

I

J

G

3

D

4

0

8tI

I

u

G

B

S I

L

J

REAR

COMBINATION

LAMP

R

H

Lighri

ng

Systems

ELECTRICAL

SYSTEM

WIRING DiAGRAM

TUm

SIGNAL

AND

HAZARD

WARNING

LAMPS

@i

R

FUSIBLE

LINK

i

rn

@

G1

@

W

I

WB

BW

BATTERY

3

FUSE

BLOCK

B

HAZARD

FLASHER

UNIT

@

r

J

B

GB

@

j

I

BI

l

co

fP

1

GY

t

J

FRONT

COMBI

NATION

LAMP

R H

TURN

SIGNAL

FLASHER

UN

IT

L

G C

B

TURN

SIGNAL

SWITCH

@

LN

R

f

1t

i

I

GB

Y

@

j

I

i

II

CD

aJ

I@

IWhi

e

6

Ilt@

00

White

Y

oc

I

00

I

ll

fi

a

IG

een

I

1

i

FRONT

COMBI

NATION

LAMP

L

H

OOllOO

OilfJ I

00

0000

co

ill

@

COMBINATION

METER

L

H

R

H

jJif

GR

PILOT

LAMP

@

R

@

a

I

EL

46

IGNITION

SWITCH

I

CJT

iI

t

ICJN ST

U9Q

A0 0

J

IG

b

Q

s

IGNITION

AND

ACCESSORY

RELAY

r

I@

t@

REAR

COMBINATION

LAMP

L

H

r

cl

111

1

GR

I

1

B

L

@2

J

ro

I

GRi

fll

l

r1

i

B

t

ID

J

P

I

L

8

SEL379

ELECTRICAL

SYSTEM

Lighting

Systems

SCHEMATIC

BACK

UP

LAMP

FUSIBLE

LINK

oc

OACC

if

CON

IGN

1TI0N

SWITCH

1

BACK

UP

LAMP

R H

@

I

BATTERY

L

I

FUSIBLE

LINK

C C

BACK

UP

LAMP

L

H

IGNITION

AND

ACCESSORY

RELAY

BACK

UP

LAMP

@

SWITCH

INHIBITOR

SWITCH

@

13

SEL380

WIRING

DIAGRAM

BACK

UP

LAMP

FUSE

BLOCK

1

IGNITION

AND

9

ACCESSORY

RELAY

Jl

@

@@

RB

00

RB

00

i

White

BACK

UP

LAMP

RH

F

T

IGNITION

SWITCH

@

BW

WR

BB

t

@

o

tf

R

FUSIBLE

LINK

G

@

B

RB

B

@@

I@

1@

o

BATTERY

INHIBITOR

SWITCH

@

I

ll ll

C

aa

C

9

Q@

0

O@

11

t

I@

BACK

UP

LAMP

SWITCH

RBB

t

@

BACK

UP

LAMP

@

L

H

SEL381

EL

47

Lighting

Systems

ELECTRICAl

YSTEM

TROUBLE

DIAGNOSES

AND

CORRECTIONS

Clearance

side

marker

lleense

plate

and

tail

lamps

Condition

Neither

left

nor

right

lamp

lights

Lamp

on

only

one

side

lights

Stop

lamps

Condition

Neither

left

nor

right

lamp lights

Lamp

on

only

one

side

lights

EL48

Probable

cause

Burnt

fuse

Loose

connection

or

open

circuit

Faulty

lighting

switch

Lamps

light

when

CD

and

@

terminals

of

harness

connector

to

combination

switch

are

connected

with

test

lead

including

15A

fues

Fa1llly

tail

an

d

stop

lamp

sensor

Tail

lamp

only

Burnt

bulb

Loose

bulb

Loose

connection

or

open

circuit

Probable

cause

Burnt

fuse

Faulty

stop

switch

Faulty

tail

and

stop

lamp

sensor

Stop

lamps

light

when

@

and

@

terminals

of

main

harness

connector

to

tail

and

stop

lamp

sensor

are

connected

with

test

lead

including

lOA

fuse

Loose

connection

or

open

circuit

Bumt

bulb

Loose

bulb

Loose

connection

or

open

circuit

Corrective

action

Correct

cause

and

replace

Check

wiring

and

or

repair

connection

Replace

if

necessary

Replace

t

li1

and

stop

hunp

sensor

Replace

Repair

lamp

socket

Check

wiring

and

or

repair

connection

Corrective

action

Correct

cause

and

replace

Conduct

continuity

test

and

replace

if

neces

sary

Replace

if

necessary

Check

wiring

and

or

repair

connection

Replace

Repair

lamp

socket

Check

wiring

and

or

repair

connection

Turn

slgnsl

and

hazard

warnIng

flasher

lamps

Condition

Turn

signals

do

not

operate

Hazard

waming

lamps

operate

Hazard

warning

lamps

do not

operate

Turn

signals

operate

Turn

signals

and

hazard

warning

lamps

do

not

operate

No

flasher

click

is

heard

Flashing

cycle

is

too

slow

pilot

lamp

does

not

go

out

or

too

fast

Flashing

cycle

is

irregular

Probable

cause

Bumt

fuse

Loose

connection

or

open

circuit

Faulty

flasher

unit

Faulty

turn

signal

switch

Faulty

hazard

switch

Turn

signals

operate

when

CD

and

@

terminals

of

harness

connector

to

hazard

switch

are

connected

with

test

lead

including

lOA

fuse

Burnt

fuse

Faulty

hazard

warning

flasher

unit

Faulty

hazard

switch

Left

Right side

lamps

operate

when

@

and

@

terminals

of

harness

connector

to

hazard

switch

are

connected

with

test

lead

including

lOA

fuse

Faulty

hazard

switch

Loose

connection

Burnt

bulb

Faulty

flasher

unit

Loose

connection

Bulb

other

than

specified

wattage

being

used

Burnt

bulbs

Loose

connection

Faulty

flasher

unit

Burnt

bulb

Loose

connection

Bulbs

other

than

specified

wattage

being

used

Faulty flasher

unit

ELECTRICAL SYSTEM

Lighting

Systems

Corrective

action

Correct

cause

and

replace

Check

wiring

and

or

repair

connection

Replace

Conduct

continuity

test

and

replace

if

neces

sary

Replace

if

necessary

Correct

cause

and

replace

Replace

if

necessary

Replace

if

necessary

Reconnect

finnly

Replace

flasher

unit

Reconnect

finnly

Replace

with

one

specified

Replace

Reconnect

firmly

Replace

flasher

unit

Replace

Repair

Replace

with

one

specified

Replace

flasher

unit

EL

49

Lighting

Symms

ELECTRICAL SYSTEM

LIGHTING

SWrTCH

AND

TURN

SIGNAL

SWI1

Ct1

Refer

to

Combination Switch

STOP LAMP

SWITCH

Inspection

Test

continuity

through

switch

with

an

ohmmeter

CD

@

NORMAL

POSITION

PUSH

PLUNGER

6

SE

L36S

Adjustment

Refer

to MA

section

TAIL

AND

STOP

LAMP

SENSOR

Transistor

built

In

Removal

and

installation

Before

removing

tail

and

stop

lamp

sensor

detach

rear

wheelhouse

fInisher

See

page

EL

105

Before

checking

tail

end

top

lamp

senIOr en

ure

that

aU

bulb

meet

specifications

Inspection

Stop

lamp

Stop lamp

switch

on

EL

50

VJ

Bulb

in

good

ord

Ap

2

volts

Approx

12wofts

SEL385

Bulb

removed

Tail

lamp

light

switch

on

Bulb

in

good

ord

r

Approx

2

volts

Approx

12voltl

SEL386

Bulb

nmoved

HAZARD

SWITCH

Inspection

lt

145

OM

OF

SEL296

TURN

SIGNAL

FLASHER

UNIT

AND

HAZARD

FLASHER

UNIT

Location

Steering

column

Turn

signal

flasher

Hazard

flasher

unit unit

SEL

Z97

BACK

UP

LAMP

SWITCH

Automatic

transmleslon

The

back

up

lamp

switch

is

built

into

the

inhibitor

switch

Refer

to

AT

section

Manual

transmlealon

The

back

up

Jamp

switch

IS

ID

stalled

on

the

manual

transmission

case

OJ

on

SEL298

ELECT

RICAL

SYSTEM

Lighting

Systems

INTERIOR

WGGAGE

COMPARTMENT

AND

STEP

LAMPS

CAUTION

00

not

wipe

lens

surface

using

cloth

dampered

with

gasoline

SCHEMATIC INTERIOR

LUGGAGE

COMPARTMENT

AND

STEP

LAMPS

Hatchback

model

with

Interior

lamp

timer

INTERIOR

LAMPS

WITH

SPOT

LAMPI

66 6

ij

011

STEP

LAMP

R

H

INTERIOR

LAMP

TIMER

1

o

DOOR

SWITCH

R

H

FUSE

o

C

j

DOOR

SWITCH

L

H

FUSIBLE

LINK

LUGGAGE

COMPARTMENT

LAMP

1

o

0

1

BATTERY

III

L

STEP

LAMP

L

H

n

SEL3a7

EL

51

Lighting

Systems

ELECTRICAL

SYSTEM

WIRI

NG

DIAGRAM

INTERIOR

LAMP

STEP

LAMP

AND

LUGGAGE

COMPARTMENT

LAMP

81

i

BATTERY

11

US BL

u

I

LINK

@

0 0 0 0

FUSE

BLOCK

l

lG

IWITH

INTERIOR

LAMP

TIMER

INTERIOR

LAMPS

INTERIOR

6 b 6

LAMP

TIMER

1f

Wl@

II

rif31

II

W

a

U

Black

CD

4

Hgg

I@

fY

@

CC

CD

aa

RG

RB

l

I

H

@

on

White

19b

21

I

i7I

Y

B

ib

@

1

k9

IrO

jl

a

II

CD

a

co

a

W

White

@

r9l@

0

I

tI

00

a

CD

I

i

LUGGAGE

COMPART

MENT

LAMP

IHA

TCHBACK

RG

B

D

0Q

J

i

@

TRUNK

ROOM

LAMP

HARDTOP

@

RG

ao

@

t

o

L

@

EL

52

@

lR

lG

i

STEP

LAMP

A

H

00

BR

ro

I

A

RG

cJ

LUGGAGE

COMPART

@@

MENT

LAMP

HATCHBACK

eR

@

RG

DOOR

nO

fB@

O

CH

4

@

TRUNK

ROOM

LAMP

HARDTOP

1

@

RG

11

@

Rr

I

Whi

000

1

0

oh

iB

tSiB

V

R

DOOR

SWITCH

LH

BR

W

@I

@

6

l

iR

tt

ER

@

STEP

LAMP

LH

00

BR

cJ

RG

cJ

WITHOUT

INTERIOR

LAMP

TIMER

INTERIOR

LAMP

BR

J

oh

@

DOOR

@

SWITCH

R H

DOOR

SWITCH

LH

0

lR

J

0

2

@

SEL388

INTER

I

OR

LAMP

Bulb

replacement

Without

spot

lamp

Remove

lens

by

inserting

a

f1at

blade

screwdriver

into

switch

hole

To

avoid lens

damage

blade

portion

should

be

covered

with

a

cloth

before

insertion

With

spot

lamp

1

Open

cover

with

a

f1at

blade

screwdriver inserted

into

front

of

cover

To avoid

cover

damage

blade

portion

should

be

covered

with

a

cloth

before

insertion

2

Remove

attaching

bolts

and

de

tach

interior

lamp

assembly

ELECTRICAL

SYSTEM

Lighting

Systems

DOOR

SWITCH

Inspection

Door

switch

L

R

@

SEL391

I

DOOR

I

CLOSE

OPEN

I

0

126

g

I

FOR

USE

KEY

AND

LIGHT

WARNING

INTERIOR

LAMP

INTERIOR

LAMP

TI

MER

Ic

built

In

Location

The

interior

lamp

timer

is

attached

to

the

upper

side

of

instrument

frame

Refer

to

page

EL

104

Inspection

SEl393

Circuit

tester

indication

As

door

is

closed

tester

indication

should

linearly

increase

from

0

to

ap

proximately

10

volts after

10

seconds

EL

53

Lighting

Systems

ELECTRICAL

SYSTEM

INSTRUMENT

PANEL

ILLUMINATION

SCHEMATIC

INSTRUMENT

PANEL

IUUMINATION

AND

CIGARETTE

LlGHlER

FUSE

I

i

FUSI

LE

bLINK

T

I

BATTERY

L

I

LIGHTING

I

Off

1ST

2ND

SWITCH

ABC

IUUMINATION

I

ROL

RHEOSTAT

Transistor

bult

ln

8pectlon

fe

Battery

EL

54

J

E

SEL303

FUSE

c

COMBINATION

METER

OPTICAL

FIBER

r

KEY

ILLUMINATION

o

ILLUMINATION

CONTROL

RHEOSTAT

8

TEMPERATURE

CONTROL

PANEL

A

S

C

D

MAIN

SWITCH

CIGARETTE

LIGHTER LAMP

3

CIGARETTE

LIGHTER

LAMP

13

ASH

TRAY

LAMP

3

GLOVE

BOX

LAMP

13

RADIO

ILLUMINATION

3

AfT

POSITION

INDICATOR

LAMP

SEL396

ELEC

rRICAL

SYSTEM

Lighting

Systems

WIRING

DIAGRAM

INSTRUMENT

PANEL

ILLUMINATION

AN

CIGALETTE

LIGHTER

@

SleLE

K

Eli

8

T

BATTERY

FUSE

e

LOCK

00

l

@

a

B

SI

GW

AfT

POSITION

INDICATOR

LAMP

GW

Lg

1

1ill

@

L9B1

t

GW

0

00

@

A

S

CD

MAIN

SWITCH

ILLUMINATION

@r

r

HEATER

CONTROL

PANEL

ILLUMINATION

@@

B

flJ

Lgg

Lv

i

lI

GW

White

LgB

f

@

Bluel

@

A

S

C

D

equipped

models

@

IAO

f

C

A

T

C

A

2i

aI

q

I

q

a

l

6

06

0

aa

LJ

i

nun

LIGHTING

SWITCH

@

0

fi

@

I

0

I

@

I

GW

METER

I

LgS

AND KEY

IllUMINATION

COMBINATION

METER

CiD

G

ij

D

LgB

ILLUMINATION

CONTROL

RHEOSTAT

@

L

Y

l

B

Jo

GW

B

CIGARETTE

LIGHTER

LY

S

D

GW

@GLOVEBOX

LAMP

GW

I

LgB

B

Gw

e

I

@

ASH

TRA

Y

LAMP

GW

II

aa

L9

V

191

RADIO

ILLUMINATION

SEL396

EL

55

Meters

Gaugesafld

Warning

Systems

ELECTRICAL

SYSTEM

METERS

GAUGES

AND WARNING

SYSTEM

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

@ID

JO

o

rei

0

so

o

l

U

TI S

r

5Tl

OUAFlTZ

1

ReaI

defogger

J

indicator

lamp

lliumination

lamp

w

ill

j

J

U

J

EJ

o

b

m

J

rnm

mill

Beam

indicator

f1Q

m

lamp

ITJ

m

0

i

Optical

fiber

Key illwninati9

w

lli

ll

m

IllJ

Illumination

lamp

Charge

warning

lamp

G

111

w

00

0

u0

ll

o

w

II

w

o

a

e0

@8@

Jn

n

L

ey

8

CD

J

15

o

u

o

11

J

c

o

i

f

c0

@

1

I

L

1

A A

ll

@

1

Temperature

gauge

2

Seat

belt

warning

lamp

4

Power

source

5

Right

twn

indicator

lamp

6

Fuel

gauge

7

Beam

indicator

lamp

8

Tachometer

Signal

10

Ground

12

Left

turn

indicator

lamp

13

Charge

WaIning

lamp

14

Rear

defogger

indicator

lamp

IS

IDumination

lamps

16

Illumination

lamps

17

Tail

lamp

monitor

lamp

18

Headlamp

monitor

lamp

19

Stop

lamp

monitor

lamp

20 Clock

Power

source

21

Oil pressure

warning

lamp

22

Clock

Illumination

24

Brake

warning

lamp

25

OU

presswe

gauge

28

Door

warning

lamp

SE

L398

EL

57

Merers

Gauges

and

Warning

Systems

ELECTRICAL

SYSTEM

SCHEMATIC

TACHOMETER

GAUGES

AND

WARNiNG

LAMPS

T

I

BATTERY

I

1lja

0

oJ

w

a

w

Ga

w

J

a

C

w

tJ

az

w

Ja

FUSIBLE

LINK

FUSIBLE

LINk

0

IGNITION

SWITCH

UUUUUJ

FUSE

0

C

Od

IGNITION

AND

ACCESSORY

RELAY

A

VOLT

GAUGE

o

ALTERNATOR

115

4

CI

J

C

t

II

IDCI

J

aZJJ

WC

z

g

II

io

0Wu

Qi

Q

1

n

6V

I

W

z

JCJ

UJw

Cl

Jc

lLCJ

a

O

JZ

w

0

Z

w

Zo

J

ni

I

r

1

J

0

I

J

u

w

a

u

10

WIRING

DIAGRAM

TACHOMETER

I

Et

e

T

l

R

G

FUSIBLE

LINK

a

D@

BATTERY

0

IGNITION

SWITCH

a

S1

ON

ACe

OFF

@

i

0

B

I

II

BW

IT

WR

IGNITION

AND

ACCESSORY

RELAY

CJ

@

EL

58

@

WB

FUSE

BLOCK

J

6f

T

IGNITIO

N

COIL

RESIS

TOR

a

CI

Z

a

za

0

Oa

r

g

f

1

y

J

41

i

0

o

i

0

J

a

Ot

O

0

SE

L399

GD

L

I

J

2 3

0

TACtOYETER

COMBINATION

METER

I

Ih

OOOIIOOri

l

tf7i

L9W

00

y

B

G

White

rL9

l

I

It

@

L9WiL9

IGNITION

COIL

L9W

t

ll

G

Bl@

RESISTOR

SEL405

ELECTRICAL

SYSTEM

Meters

Gauges

and

Warning Systems

WIRING

DIAGRAM

OIL

PRESSURE

GAUGE

AND

WARNING

LAMP

WATER

TEMPERATURE

FUEL

AND

VOLT

GAUGE

CfW

FUSIBLE

LINK

E9

BATTERY

t

FUSE

BLOCK

I

i@

@

JU

f

r

1

White

G

Jr

B

@

lJg

Jlgg

LY

Y

Green

I

@60@

@

I

@

sco

V

I

@

OJ

1

U@

OIL

PRESSURE

THERMAL

SENDING

UNIT

TRANSMITTER

WR

rn

BW

II

rn

I

10

ACQON

Sf

1

6

O

I

6t

S

6

1l

J@

B

@

y

I

@

IGNITION

SWITCH

IGNITION

AND

ACCESSORY

RELAY

FUEL

TANK

GAUGE

UNIT

J

0

I

COMBINATION

METER

VOLTGAUGE

OIL

PRESSURE

VOLTAGE

GAUGE

EGULATOR

VOLTAGE

REGULATOR

0

I

LY

@

7

R

C

B

0

Y

8

1l

u

Iu

1ll

n

YW

@

362

J

4

5

o

TEMPERATURE

AUGE

@

6Hv

FUEL

GAUGE

@

0

OIL

PRESSURE

WARNING

LAMP

SEL404

EL

59

Mere17i

Gauges

and

Warning

Sysrems

ELECTRICAL SYSTEM

WIRING

DIAGRAM

CHARGE

DOOR

AND

BRAKE

WARNING

LAMP

I

o

t

IGNITION

SWITCH

Off

I

X

ON

5T

m

J

WJ

FUSIBLE

LINK

@

WR

BW

rn

B

9

Q

D

6

I

g

t1

@

BATTERY

@

w

1

WB

BW

I

m

r

FUSE

BLOCK

I

@lil

1Wh

el

jJ

00

isC

BULB

CHECK

RELAY

i

BRAKE

FLUID

LEVEL

SWITCH

rr

t

B

s

4

@

I

R

Br

B

I

R

G

BR

@

L

Qtl

YG

Green

@

r

OO

BJ

@o

WR

gfgfllg

@l

8

White

WR

JI

ill

PARKING

BRAKE

SWITCH

o

D

YG

l

@

ALTERNATOR

L

TERMINAL

EL

60

@

G

@

W

@

wr

@

BR

d

@

G

IGNITION

AND

ACCESSORY

RELAY

DOOR

SWITCH

R

H

BR

J4

04

@

1

@

DOOR

SWITCH

L

H

@

BR

J

elI

0

4

a

J

2

3

COMBINATION

METER

w

2

aW

a

0

J

0

a

u

0

m

SEL368

ELECTRICAL SYSTEM

Meters

Gauges

and

Warning

Systems

TROUBLE

DIAGNOSES

AND

CORRECTIONS

Condition

Probable

cause

Water

temperature

gauge

Gauge

does

not

Faulty

thermal

transmitter

or

loose

terminal

operate

connection

When

wire

to

thermal

transmitter

is

ground

ed

gauge

pointer

fluctuates

Faulty

water

temperature

gauge

Faulty

thermal

transmitter

Gauge

pointer

returns

to

original

position

when

ignition

switch

is

turned

off

Faulty

water

temperature

gauge

Gauge

pointer

indicates

maximum

tempera

ture

even

after

ignition

switch

is

turned

off

Gauge

indicates

only

maximum

temperature

Gauge

does

not

operate

accurately

011

pressure

gauge

Oil

pressure

gauge

does

not

operate

Gauge

indicates

only

maximum

pressure

Fuel

level

gailge

Fuel

level

gauge

does

not

operate

Pointer

indicates

only

F

position

Fuel

level

gauge

does

not

operate

accurately

Volt

gauge

Volt

gauge

does

not

operate

or

abnormally

indicates

Faulty

water

temperature

gauge

Loose

or

poor

connection

Faulty

oil

pressure

sending

unit

or

loose

terminal

connection

Faulty

oil

pressure

gauge

unit

Gauge

pointer

retums

to

original

position

when

ignition

switch

is

tumed

off

Faulty

oil

pressure

gauge

Gauge

pointer

indicates

maximtim

pressure

even

after

igni

tion

switch

is

turned

off

Faulty

fuel

gauge

tank

unit

Pointer

deflects when

fuel

gauge

tank

unit

yellow

wire

is

grounded

Faulty

fuel

level

gauge

Loose

connection

or

open

circuit

Faulty

fuel

gauge

tank

unit

Faulty

fuel

level

gauge

Faulty

fuel

gauge

tank

unit

Faulty

fuel

gauge

Poor

or

loose

connection

Faulty

gauge

voltage

regulator

Faulty

volt

gauge

Loose

or

poor

connection

Corrective

action

Replace

thermal

transmitter

or

correct

ter

minal

connection

Replace

water

temperature

gauge

Replace

thermal

transmitter

Replace

water

temperature

gauge

Replace

water

temperature

gauge

Correct

connector

terminal

contact

Replace

oil

pressure

sending

unit

or

correct

terminal

connection

Replace

fuel

gauge

tank

unit

Replace

Check

wiring

and

or

repair

connection

Replace

fuel

level

gauge

Correct

connector

teoninal

contact

Replace

gauge

assembly

Replace

Check

wiring

and

or

repair

connection

EL

61

Meters

Gauges

and

Warning

System

ELECTRICAL SYSTEM

Charge

and

brake

warning

lamps

Condition

Lamp

does

not

glow

when

ignition

switch

is

turned

ON

with

out

running

engffi

e

Chellle

werning

lemp

Lamp

does

not

go out

when

engine

is

started

Brake

warning

lamp

Lamp

does

not go

out

Probable

cause

Burnt

bulb

or

loose

bulb

Loose

or

poor

connection

Faulty

printed

circuit

board

Faulty

bulb

check

relay

Faulty

alternator

Faulty

charging

system

Faulty

parking

brake

switch

When

parking

brake

lever

i

released

Faulty

brake

fluid

level

switch

When

brake

fluid

level

is

nonnal

Oil

pre

sure

and

door

warning

lamps

Condition

Ojl

pressure

warning

lamp

Lamp

does

not

light

when

ignition

switch

is set

to

ON

Lamp

does

not

go out

while

engine

is

being

operated

Door

warning

lamp

Lamp

does

not

glow

with

door

opened

and

engine

running

Tachometer

Condition

Tachometer

pointer

deflects

Tachometer

pointer

will

not

move

EL

62

Probable

cause

Faulty

oil

pressure

sending

unit

or

loose

terminal

connectio

r

When

lead

wire

connected

to

sending

unit

is

grounded

warning

lamp lights

Burnt

bulb

or

looSe

bulb

Lack

of

engine

oil

Oil

pressure

too

low

Faulty

oil

pressure

sending

unit

Faul1y

door

switch

Burnt

bulb

orloose

bulb

Probable

cause

Loose

or

poor

connection

Faulty

resistor

Faulty

tachometer

Loose

or

poor

connection

Faulty

tachometer

Corrective

action

Replace

bulb

or

correct

Correct

connector

terminal

contacts

Replace

Repair

or

replece

Inspect

charging

system

Replace

Corrective

action

Replace

or

correct

connection

Replace

bulb

or

correct

Check

oil

level

and add

oil

as

required

Inspect

engine

oil

pressure

system

Replace

bulb

or

correct

Corrective

action

Repair

Replace

resistor

Repair

or

replace

tachometer

Repair

or

replace

tachometer

pe

dometer

Condition

Neither

speedometer

pointer

nor

odometer

ol

erates

Unstable

speedometer

pointer

Unusual

sound

occurs

in

response

to

increase

in

driving

speed

Inaccurate

speedometer

indication

Inaccurate

odometer

operation

FUEL

TANK

GAUGE

UNIT

Removal

and

Installation

Refer

to

FE

section

ELECTRICAL SYSTEM

Merers

Gauges

and

Warning

System

1

11

E

t

2

e

l

i

d

Empty

L

Probable

cause

Loose

speedometer

cable

union

nut

Broken

speedometer

cable

Meter

side

or

Transmission

side

Damaged

transmission

speedometer

pinion

gear

Faulty

speedometer

Improperly

tightened

or

loose

speedometer

cable

union

nut

Damaged

speedometer

cable

Faulty

speedometer

Excessively

bent

or

twisted

speedometer

cable

inner

wire

or

lack

oflubrication

Faulty

speedometer

Faulty

speedometer

Faulty

speedometer

a

Float

For

fuel

gauge

Full

Inapectlon

Fuel tank

gauge

unit

has

two

func

tions

II

SEL311

1

4

nVi

f

Corrective

action

Retighten

Replace

speedometer

cable

Repl

ce

transmission

speedometer

pinion

gear

Replace

speedometer

Retighten

Replace

speedometer

cable

Replace

speedometer

Replace

or

lubricate

j

Replace

speedometer

Replace

speedometer

1

Replace

speedometer

Unit

mm

in

SEL312

EL

63

Maters

Gauges

and

Warning

Systems

ELECTRICAL SYSTEM

b

Thermistor

For

multi

warning

display

Test

lamp

s

Water

SEL313

Test

lamp

should

come

on

in

ap

proximately

t1uee

minutes

after

re

moval

of

thermistor

from

water

PARKING

BRAKE

SWITCH

Plirklng

brike

p

lIed

Parking

bnke

released

on

n

SEL309

BRAKE

FLUID

LEVEL

SWITCH

Float

I

Float

1

Approx

zson

Approx

on

SEL310

EL

64

BULB CHECK

RELAY

LocaUon

The

bulb

check

relay

is

attached

to

the

relay

bracket

Refer

to

pa

EL

105

Inspection

l

f

I

t

I

i

lll

L

w

lI

@

SEl406

DIODE

For

charge

warning

lamp

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

DOOR

SWITCH

Refer

to

page

EL

53

TACHOMETER

Removal

d Installation

1

Remove

combination

meter

2

Remove

tachometer

attaching

bolts

3

Remove

tachometer

from

com

bination

meter

lower

housing

4

Installation

is

in

the

reverse

order

of

removal

Power

sowce

Earth

SEL314

RESISTOR

FOr

tachometer

and

EFI

system

A

2 2

kfl

resistor

for tachometer

and

EFI

system

is

located

near

the

ignition

coil

ELECTRICAL SYSTEM

Merers

Gauges

and

Warning

Systems

SPEEDOMETER

Cable

layout

Cable

Speedometor

SEL410

For

detailed

information

regarding

Ipeed

len

or

IA

S

C D

refer

to

page

EL

102

WARNING

DISPLAY

Ignition

switch

ON

DESCRIPTION

Warning

lights

come

on

to

read

aU

items

in

succession

one

at

a

time

for

2

seconds

The

warning

display

system

con

sists

of

a

warning

indicator

a

warning

display

amplifier

and

sensors

When

ignition

switch

is

ON

warn

ing

display

operates

as

follows

J

YES

NO

I

ight

OFF

I

Abnormality

I

Abnormal indication

I

Eliminate

abnormality

I

EL

65

Msters

Gauges

aM

Wa11Iing

Systems

ELECTRICAL SYSTEM

Display

modes

Identification

I

FUEL

fBf

I

TTe

BA

WATE

lllliiD

IWASH

Color

Red

Orange

SCHEMATIC

WARNING

DISPLAY

BATTERY

LEVEL

SENSOR

1

e

1

f

H

IGNITION

SWITCH

OACX

if

CON

q

I

IGNITION

AND

ACCESSORY

RELAY

EL

66

Item

Fuel

level

warning

Battery

electrolyte

level

warning

Coolant

level

warning

Washer

fluid

level

warning

WASHER

LEVEL

SENSOR

Ir

b

o

WARNING

DISPLAY

AMPLIFIER

FUSE

Warning

Indicates

that

fuel

is

less

than

v

mately

10

liters

2

5

8

US

gal

2

1

4

Imp

gal

Indicates

that

battery

electrolyte

is

less

than

specified

level

Indicates

that

engine

coolant

in

radiator

reservoir

tank

is

less

than

specified

level

Indicates

that

windshield

washer

fluid

is

less

than

specified

level

RADIATOR

LEVEL

SENSOR

iLr

lJl

FUEL

LEVEL

SENSOR

b

E

WARNING

INDICATOR

BATT

SEL411

ELECTRICAL

SYS

rEM

Meters

Gauges

and

Waming

Systems

WIRING

DIAGRAM

WARNING

DISPLAY

EJ

BATTERY

t

WASf

jER

SENSOR

0

ClI

JClI

RADIATOR

SENSOR

tfW

WR

II

@

FUSIBLE

LINK

FUSE

eLOCK

BL

J

@

1

B

J

BATTERY

SENSOR

i@

Ln

C

BY

@

YL

@

EYL

00

I

g

Black

00

@

J

fj

i@

IGNITION

SWITCH

WR

BW

1ill

@

1

IGNITION

AND

ACCESSORY

ffEU

V

t

n

I

@

L

LY

Lvi

lB

LR

f

WARNING

INDICATOR

WARNING

DISPLAY

AMPLIFIER

@

RY

B

BL

LW

LV

LR

LB

L

G

YL

BY

o

0

@

YL

B

I

@

ill

FUEL

TANK

GAUGE

UNIT

SEL412

Et

67

i

1

TROUBLE

DIAGNOSES

AND

CORRECTIONS

MI1te

GaugesandWaming

ELECTRICAL

SYSTEM

No

warning

indica1Bd

Chec

f11se

lO

K

Check

forloose

connection

at

I

warning

indicator

and

amplifier

OX

Replace

warning

display

amplifier

I

N G

r

Repla

fuse

N G

Re

ct

r

pan

conne

or

When

ignition

witch

i

turned

to

ON

warning

lights

come

on

to

read

all

items

in

succeuion

one

at

a

time

for

2

seconds

However

warning

lights

will

not

come

on

even

th

ugh

there

i

Ibnormality

1

Check

sensor

lOX

Check

for

loose

connection

or

open

circuit

lOX

Check

warning

indicator

for

burnt

bulb

Replace

warning

display

amplifier

N G

Re

I

pan

or

rep

ace

sensor

N

G

Repair

or

replace

N G

Replace

warning

indicator

I

Warning

light

remain

on

even

though

th

i

no

IbnormaJity

1

Check

sensor

lO

K

Check

for

loose

connection

or

open

circuit

lOX

Replace

warning

display

amplifier

EL

68

N G

I

Repan

or

rep

ace

sensor

N G

Repair

or

replace

MULTI

WARNING

INDICATOR

Location

The

multi

warning

indicator

is

located

in

the

combination

gauge

InllPectlon

o

j

Washer

@

Radiator

Fuel

eID

Battery

SEL413

MULTI

WARNING

AMPLIFIER

JC

bullt

ln

Location

The

multi

warning

amplifier

is

at

tached

to

the

instrwnent

panel

frame

Before

removing

it

remove

cluster

lid

C

Refer

to

page

EL

104

ELECTRICAL

SYSTEM Mete

Gauges

and

Warning

Systems

FUEL

LEVEL

SENSOR

InllPectlon

Refer

to

pages

EL

63

and

64

WASHER

LEVEL

SEN

R

Location

The

washer

level

sensor

is

located

on

the

bottom

of

the

washer

tank

InllPectlon

Q

SEl414

COOLANT

LEVEL

SENSOR

Location

The

coolant

level

sensor

is

located

on

the

bottom

of

the

radiator

reser

voir

tank

InllPectlon

Coolant

level

sensor

is

united

with

the

reservoir

tank and

cannot

be

re

moved

alone

w

Empty

Norm

llev

t

on

n

SEL415

BATTERY

LEVEL

SENSOR

Inspection

Before

inspection

make

sure

that

the

battery

is

charged

and

the

fluid

is

ftlled

up

to

correct

level

1

Disconnect

sensor

ha

ess

connec

tor

2

Make

sure

that

there

is

about

8

volts

when

voltmeter

positive

and

negative

teoninals

are

connected

to

battery

fluid

level

sensor

and

battery

negative

terminals

respectively

8Y

BES07D

EL

69

Meters

GaugesandWaming

ms

ELECTRICAL SYSTEM

WARNING

CHIME

l

SCEMATIC

SEAT

BELT

KEY

AND

LIGHT

WARNING

Jc

FUSIBLE

LINK

FUSIBLE

LINK

L

BATTERY

I

6

SEAT

BELT

SW

ITCH

o

ON

C

a

cON

0srJ

IGNITION

SWITCH

L

o c

FUSE

oc

IGNITION

AND

ACCESSORY

RELAY

FUSE

r

c

FUSE

SEAT

BELT

WARNING

TIMER

WARNING

CHIME

SEAT

BELT

@

ING

I I

TROUBLE

DIAGNOSES

AND CoRRECTIONS

Condition

Licht

and

key

Warning

chime

doe

not

sound

with

ignition

key

in

ignition

switch

or

lighting

switch

on

when

driver

side

door

is

open

Seat

belt

Chime

does

not

sound

and

warning

lamp

does

not

glow

with

ignition

switch

on

Either

chime

or

warning

lamp

does

not

operate

with

proper

condition

EL

70

Probable

cause

Faulty

warning

chime

Loose

connection

or

open

circuit

Faulty

door

sWitch

Faulty

key

warning

chime

switch

Faulty

lighting

system

Clearance

lamp

does

not

light

Faulty

eat

belt

switch

Faulty

seat

belt

warning

timer

Loose

connection

or

open

circuit

Loose

connection

or

open

circuit

Burnt

bulb

Faulty

chime

A

LIGHTING

SWITCH

OFf

1ST

2ND

A

a

CAB

C

Ala

c

g8g2@

KEY

WARNING

SWITCH

DIODE

I

II

DOOR

SWITCH

L

H

SEL416

Corrective

action

Replace

Correct

connector

terminal

contacts

Repair

or

replace

Repair

or

replace

Correct

Repair

or

replace

Replace

Correct

connector

terminal

contacts

Correct

connector

terminal

contacts

Replace

ELECTRICAL

SYSTEM

Meters

Gauges

and

Warning

Systems

WIRING

DIAGRAM

SEAT

BELT

KEY

AND

LIGHT

WARNING

It

O

R

FUSIBLE

LINK

G

BATTERY

n

e

I

1

a

5 5

I

WR

aw

41

@

aJl

W

I

WB

aw

DOOR

SWITCH

L

H

@

rVR

nJ

no

oo

YR

JtGW

U9

Uo

GW

I

@

lVR

GW

SEAT

BELTTIMER

A

YB

WARNING

CHIME

R

a

@

SEAT

BELT

SWITCH

gm

2k

YB

Br

@

White

11

GW

Lg

41

@

illY

Blue

@

il

w

l@

e

rtfJ1

J

t J

fi

l

Whhe

@

1

IillJJ

l

4

15

IGNITION

SWITCH

I

B

iA

IG

IS

Ofaa

ON

S1

g

o

g

IGNITION

AND

ACCESSORY

REALY

Ii

O

@

LIGHTING

SWITCH

I

OFf

r

1ST

I

2ND

ABCABCAB

9

0009

o

oObo

888

g

gg

KEY

WARNING

SWITCH

RG

a

iO

oon

w

DlJ

c

U

COMBINATION

METER

L9Y

GD

2

B

SEAT

BELT

WARNING

LAMP

SEL417

EL

71

Mete

Gauges

and

Warning

Systems

ELECTRICAL SYSTEM

Refer

to

Ignition

switch

KEY

WARNiNG

SWITCH

DOOR

SWITCH

L

H

Refer

to

page

El

53

SEAT

BELT

SWITCH

EL

72

l

UTl

IElTl

OUT

I

SEL418

SEAi

BELT

WARNING

TIMER

Location

The

seat

belt

warning

timer

is

located

on

the

back

side

of

the

dash

board

on

the

right

side

Refer

to

page

EL

104

Inspection

After

about

6

secondl

SEL41

WARNING

CHIME

Uc

built

In

Location

The

warning

chime

is

located

on

the

back

side

of

the

dashboard

on

the

right

side

Inspeictloil

Battery

w

Battery

w

SEL420

DIODE

For

door

awltch

Location

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

battery

ground

cable

SCHEMATIC

WINDSHIELD

WIPER

AND

WASHER

With

time

control

J

C

FUSIBLE

LINK

FUSIBLE

LINK

I

SA

TTERY

L

I

WIPER

SWITCH

11

WIPER

f

HI

LO

INIp

o

gg

8

JU

1r

OACC

f

CON

OJ

IGNITION

SWITCH

1

oc

r

c

FUSE

IGN

ITlON

AND

ACCESSORY

RELAY

INTERMITTENT

WIPER

AMP

WASHER

MOTOR

@

1

WIPER

MOTOR

AUTO

RETURN

DEVICE

SE

L422

EL73

Wiper

and

Washer

ELECTRICAL SYSTEM

WIRING

DIAGRAM

WINDSHIELD

WIPER

AND

WASHER

@

f

R

@

FUSIBLE

LINK

o

BATTERY

t

I

J

I

WR1

LB

B

BL

4

@

FUSE

BLOCK

J

WIPER

MOTOR

l

o

@

M

L

I

Le

1

G

GL

INTERMITTENT

WIPER

AMPLI

F I

ER

@

It

ill

I

G

ga

IB

80

I

LV

00

I

LR

L

I

@

LW

WASHER

MOTOR

U

W

@

Ji@

EL

74

IGNITION

SWITCH

OfF

iC

i

r

rl

lG

0

P

I

Sf 0

IGNITION

AND

ACCESSORY

RELAV

ld

O@

WIP

ER

SWITCH

WI

PER

W

ff

INIlO

HI

I

L

gg

LJ

T

og9

llifl

5IJO

l

OOO

LB

@j

LR

L

LV

LW

L

LI

@

With

time

control

SE

L423

TROUBLE

DIAGNOSES

AND

CORRECTIONS

Condition

Windshield

wiper

does

not

operate

Windshield

wiper

operat

ing

speed

is

too

slow

Mqtor

Power

supply

and

cable

Probable

cause

Broken

armature

worn

motor

brush

or

seized

motor

shaft

Blown

fuse

Loose

open

or

broken

wiring

Improper

grounding

Switch

I

Improper

switch

contact

link

Circuit

breaker

Motor

Power

supply

and

cable

link

Switch

Circuit

breaker

Windshield

dotor

wiper

speed

9

n

not

be

adjusted

correctly

cc

0

v

9

00

2

c

e

0

u

Stops

any

where

Does

not

stop

Washer

motor

does

not

operate

when

pushing

washer

switch

on

Motor

dotor

Washer

motor

operates

but

washer

fluid

is

not

ejected

Foreign

material

interrupts

movement

of

link

mechanism

Disconnect

link

rod

Seized

or

rusted

arm

shaft

Faulty

circuit

breaker

Short

circuit of motor

armature

worn

motor

brush

or

seized

motor

shaft

Low

source

voltage

Humming

occurs

on

motor

in

ann

operat

ing

cycle

due

to

seized

arm

shaft

Improper

switch

contact

Faulty

circuit

breaker

Motor

brush

for

either

low

or

high

speed

iswom

Contaminated

auto

return

relay

co

tacts

or

improper

contact

due

to

foreign

mat

ter

Incomplete

auto

return

operation

Con

tact

is

not

interrupted

Bumt

fuse

Faulty

switch

Faulty

washer

motor

Loose

or

poor

connection

contact

at

motor

or

switch

Clogged

washer

nozzle

ELECTRICAL SYSTEM

Wiper

and

w

sher

Corrective

action

Replace

motor

Check

short

circuit

bumt

component

in

side

motor

or

other

part

for

operation

and

correct

problem

Correct

Lubricate

or

replace

arm

shaft

Replace

circuit

breaker

Replace

motor

or

lubricate

bearing

with

engine

oiL

Measure

voltage

check

other

electrical

parts

for

operation

and

take

corrective

action

for

power

supply

if

necessary

Lubricate

or

replace

Conduct

continuity

test

and

replace

if

necessary

Replace

circuit

breaker

Replace

motor

Remove

auto

return

device

cover

and

clean

contacts

carefully

so as

not

to

de

form

relay

plate

Remove

auto

return

device

Cover

and

correct

relay

pla

e

bending

Corre

t

c

use

and

replace

fuse

Replace

Repair

Clean

nozzle

or

replace

EL

75

Wiper

and

Washer

ELECTRICAL SYSTEM

Intermittent

windshield

w1p

The

sign

for

action

A

Measure

voltage

across

positive

and

negative

terminals

of

in

termittent

amplifier

with

a

circuit

tester

Condition

Wipers

do

not

operate

intermittently

but

operate

at

Low

and

High

speeds

Intermittent

speed

is

too

short

for

proper

wiping

Intermittent

speed

is

too

long

for

proper

wiping

Wipers

do

not

shut

off

Wipers

operate intermittently

with

wiper

switch

OFF

Intermittent

speed

is

erratic

Wipers

make

a

complete

wiping

stroke

only

one

time

with

wiper

switch

ON

but

do

not

continue

operation

Wiper

motor

is

not

interconnected

when

washer

switch

is

depressed

but

intermittent

operation

is

normal

Wipers

do

not

make

a

complete

Wlpmg

stroke

when

washer

switch

is

fIrst

turned

on

and

is

quickly

turned

off

EL

76

B

Check

continuity

of

all

wiper

switch

positions

C

Check

continuity

of

terminals

of

wiper

motor

wiper

switch

and

Probable

cause

line

voltage

below

10 volts

Faulty

wiper

switch

Faulty

wiring

Faulty

intermittent

amplifIer

Faulty

wiper

switch

line

voltage

too

high

Faulty

wiper

motor

Faulty

intermittent

amplifier

Faulty

wiper

switch

line

voltage

below

10

volts

Faulty

wiper

switch

Faulty

wiring

Faulty

intermittent

amplifier

Faulty

wiper

switch

Faulty

wiper

motor

Faulty

intermittent

amplifier

Faulty

wiper

switch

Faulty

wiring

Faulty

intermittent

amplifier

Excessive

line

voltage

fluctuation

Faulty

wiper

switch

Faulty

wiring

Faulty

wiper

motor

Faulty

intermittent

amplifIer

line

voltage

below

10

volts

Faulty

intermittent

amplifier

Poor

connections

Faulty

intermittent

amplifier

Faulty

intermittent

amplifier

intermittent

amplifIer

D

Check

continUity

in

wiper

motor

circuit

E

Altemator

or

battery

is

faulty

Corrective

action

A

Replace

if

necessary

B

Correct

or

replace

ifneceuary

Ae

Repair

or

replace

if

necessary

Replace

A

Replace

if

necessary

D

Replace

if

necessary

Repbce

Replace

A

Replace

if

necessary

B

Correct

or

replace

if

necessary

Ae

Repair

or

replace

if

necessary

Replace

D

Replace

if

necessary

Replace

B

Conect

or

replace

if

neCessary

Ae

Repair

or

replace

if

necessary

Replace

E

Correct

or

replace

if

necessary

B

Correct

or

replace

if

necessary

A

C

Repair

or

replace

if

necessary

D

Replace

if

necessary

Replace

A

Replace

if

necessary

Replace

c

Repair

or

replace

if

necessary

Replace

Repbce

ELECTRICAL SYSTEM

Wiper

and

Washer

WINDSHIELD

WIPER

Removal

and

Installation

OJ

SEL319

CAUTION

Be

careful

not

to

bend

linkage

during

removal

Inspection

9

uL

urff

M

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

SWITCH

SE

L323

Adjustment

20

10

791

20

10

191

Unit

mm

in SE

L324

WINDSHIELD

WASHER

Wash

r

nozzl

adJus

11018

69

i

11016

69

F

100

13

941

dili

100

3

94

41

1

rPr1

II

i

410116

141

1

10116

W

Unit

mm

in

SEL325

EL

78

Refer

to

Combination

switch

IInERMI

AMPLIFIER

IC

bullt

ln

WIPER

Location

The

intennittent

wiper

amplil18r

is

attached

to

the

relay

bracket

Refer

to

page

EL

105

Inepectlon

Be

careful

not

to

connect

lead

wir

to

incorrect

te

minals

Connect

test

lead

wire

JIDECO

BE

L326

2

Make

sure

that

test

lamp

comes

oil

when

negative

lead

wire

Ais

con

nected

1

OnlY

time

control

tYP

D

I

e

1

A

i

B

JIDECO

Test

lamp

repeatedly

comes

OD SE

27

3

Disconnect

lead

wire

B

Test

lamp

should

go

out

and

come

back

on

in

a

few

second

JIDECO

I

SEL

28

J

A

Only

time

li

control

type

1

F

Jf

JlDECO

I

SEL329

REAR

WINDOW

WIPER

AND

WASHER

r

SCHEMATIC

REAR

WINDOW

WIPER

AND

WASHER

FUSIBLE

LINK

IGN

ITION

SWITCH

o

ACC

y

C

ON

Osr

FUSIBLE

L1N

I

BATTERY

W

C

Jo

C

c

FUSE

IGNITION

AND

ACCESSORY

RELAY

ELECTRICAL

SYSTEM

Wipe

and

Washer

REAR

WINDOW

WIPER

MOTOR

REAR

WASHER

MOTOR

@

WIRING

DIAGRAM

REAR

WINDOW

WIPER

AND

WASHER

Eflf

L

o

1

BATTERY

FUSIBLE

@

LINK

Age

Off

J

D

ci

o

6

IG

I

o

S

LB

IGNITION

SWITCH

I

r

c

B

L

o 0

0

o

0

WR

r

o

FUSE

BLOC

J

Lvi

8

REAR

WAS

iER

MOTOR

@

LB

to

o

U

5

L

CD

1P1

LB

REAR

WINDOW

WIPER

ANO

WASHER

SWITCH

lw

RWIP

V

tl

Ia

f

N

I1

i

b

0

J

L

@

L

Y

LW

L

AUTO

RETURN

DEVICE

WI

PER

WASHER

ON

OFF

ON

f

b

r

o

REAR WINDOW

WIPER

AND

WASHER

SEL434

@

E3

Uf

W

LB

L

B

v

1

LB

W

LW

L

19y

00

Lg

r

u

0

REAR

WINDOW

WIPER

MOTOR

IGNITION

AND

ACCESSORY

RELA

Y

i

hl@

I

DcQ

L

@

LA

@

1@

SEL

35

EUll

WtperandWasher

ELECTRICAL

SYSTEM

REAR

WlfiiDOW

WIPER

Removal

and

Installation

r

u

i

U

7

t

1

i

SEL367

I

spectlon

0

I

j

I

i

t

1

J

I

B

IO

return

device

t

Stop

position

BXP

S

E

1

Inspection

REAR

WINDOW

WIPER

SWITCH

AND

WASHER

SWITCH

Washer

on

Auto

return

Wi

r

EL

80

S

PE

SEL332

r

I

Washer

I

Wiper

I

OFF

ON

OFF

I

ON

IX

t

tl

SE

L336

ELECTRICAL

SYSTEM

Electrical

Accessories

ELECTRICAL

ACCESSORIES

CAUTION

Before

muting

to

work

on

any

part

of

electrical

system

disconnect

battery

ground

cable

REAR

WINDOW

DEFOGGER

SCHEMATIC

REAR

WINDOW

DEFOGGER

oc

FUSIBLE

LINK

oc

FUSIBLE

LINK

I

BATTERY

L

I

Ace

c

O

ON

IGNITION

SWITCH

L

IGNITION

AND

ACCESSORY

RELAY

w

u

Q

C

REAR

WINDOW

00

DEFOGGER

FUSE

@

1

MON ITOR

LAMP

DEFOGGER

1

SWITCH

0 0

SEL436

WIRING

DIAGRAM

REAR

WINDOW

DEFOGGER

iJ

i

g

R

FUSIBLE

LINK

BATTERY

0

I

FUSE

BLOCK

IGNITION

SWITCH

WR

BW

II

14

@

IGNITION

AND

ACCESSORY

RELAY

@

I

W

I

WB

BW

Ji

J

LB LB

@

r

li

@

gg

White

8

e

o

00

t

4

LB

e

LB

LL

e

B

le

@

L

White

J

00

B

0

LB

J

co

LB

00

@

d

gg@

LB

@

c

J@ocr

iJ

@

2

4

190

I

1

DEFOGGER

iN

SW

ITCH

e

8rl

REAR

WINDOW

DEFOGG

ER

COMBINATION

METER

@

J1

@

2

MONITOR

LAMP

r

D@

i@

B

SE

L437

EL

81

ElliCtrical

Accessories

ELECTRICAL SYSTEM

REAR

WINOOW

DEFOCCER

SWITCH

Inspection

12

ON

0

OFF

SEL338

REAR

WINDOW

DEFOGGER

FILAMENTS

Inspection

I

Attach

probe

circuit

tester

in

volt

range

to

middle

portion

of

each

filament

H

r

m

j

Z

I

V

6

Volts

normll

filam

nt

SEL

263

EL

B2

2

If

a

mairieni

is

burned

oill

Circuit

tester

registers

0

or

12

volts

H

lffl

V

12

Volt

SEL264

1 1

H

rTI

l

IV

aValt

E

l265

3

To

locate

burned

out

point

move

probe

to

left

and

right

along

filament

to

determine

point

where

tester

needle

swings

abruptly

J

1

1M

0

j

VJ

SEL266

FUament

maintenance

Repair

equipment

1

Conductive silver

composition

Dupont

No

4817

or

equivalent

2

Ruler

30

em

12

in

Jong

3

Drawing

pen

4

Heat

gun

5

Alcohol

6

Cloth

Repair

pI

L

I

Wipe

broken

heat

wire

and

its

surrounding

area

clean

with

a

cloth

dampened

in alcohol

2

AppJy

snuillam

t

of

c

duc

tive

silver

composition

to

tip

of

draw

ing

pen

Shake

silver

on

container

belore

use

3

Place

ruler

on

glass

along

broken

line

Deposit

conductive

silver

com

position

on

break

with

drawing

pen

Slightly

overlap

existing

heat

wire

on

both

sides

preferably

5

mm

0

20

in

of

the

break

00

Heat

wire

reak

1

Lf

Drawing

pen

Unit

mm

in

eE540

4

Wipe

clean silver

composition

from

tip

of

drawing

pen

5

After

repair

has

been

completed

check

repaired

wire

for

continuity

This

ch

ck

should

be

conducted

10

minutes

after

silver

composition

is

deposited

Do

not

touch

repaired

rea

while

test

is

being

conducted

6

Apply

aconstant

stream

of

hot

air

directly

to

the

repaired

area

for

approximately

20

minutes

with

a

heat

gun

A

minimum

distance

of

3

em

1

2

in

should

be

kept

between

re

paired

area

and

hot

air

outlet

If

a

heat

gun

is

not

available

let

the

repaired

area

dry

for

24

hours

REMOTE

CONTROL

DOOR

MIRROR

SCHEMATIC

REMOTE

CONTROL

DOOR

MIRROR

FUSIBLE

LINK

FUSE DOOR

MIRROR

SWITCH

R H

1

I

BATTERY

L

i

DOOR

MIRROR

Removal

and

Inatallatlon

Remove

door

mirror

securing

bolt

and

disconnect

harness

connector

S

L442

I

R

l

I

u 0

00

9

0

uO

10

0

OQ

r@

DOOR

MIRROR

R

H

ELECTRICAL

SYST

M

Electrical

Accessories

1

DOOR

MIRROR

SWITCH

Inspection

4

5

a

1

R

L

U

0

I

11

9

I

01

I

6

c

II

15

J

0

oJ

I

EL444

DOOR

MIRROR

SWITCH

L

H

I

R

l

U

0

oOOob

J

00

bo

0

i

IQO

r@

DOOR

MIRROR

L

H

SEL440

o

Ell

8J

Electrical

Accessories

ELECTRICAL SYSTEM

WIRING

DIAGRAM

REMOTE

CONTROL

DOOR

MIRROR

9

rrR @

o@w

FUSE

BLOCK

1

BATTERY

DOOR

MIRROR

SWITCH

LH

DOOR

MIRROR

SWITCH

R H

RLUD

RLIUD

rU

U

r

tJ

a

@

a

r11

CJ

t

CO

5

I

CO

I

III

@

II

a

Clco

i

@

rm

il

@

rTIl

iil

R

J

III

DOOR

MIRROR

R H

DOOR

MIRROR

LH

SEL441

EL

B4

a

OCK

SCHEMATIC

CLOCK

Digital

L

l

C

FUSIBLE

LINK

T

BATTERY

I

L

I

rJ

FUSIBLE

LINK

ELECTRICAL SYSTEM

Electrical

Accessories

IGNITION

SWITCH

C

ACe

o

OST

FROM

LIGHTING

SWITCH

Day

light

brightness

selection

for

digital

display

DIGITAL

CLOCK

Adjustment

SELECT

knob

Depress

the

SELECT

knob

and

display

will

project

HOUR

MIN

MONTH

DAY

and

M1N

SEC

in

that

sequencec

ADJUST

knob

To

adjust

the

time

fust

select

HOUR

MIN

with

SELECT

knob

then

use

the

ADJUST

knob

in

the

following

manl

er

Turn

it

counterclockwise

for

hour

adjustment

Turn it

clockwise

for

minute

adjustment

Push

it

to

set

the

time

to

the

nearest

hour

For

example

when

adjusting

the

time

for

10

00

first

set

the

time

be

tween

9

30

and

10

29

Then

push

the knob

simuJt

usly

with

the

annou

lcement

of

10

00

To

adjust

the

day

first

select

MONTH

DAY

with

the

SE

LECT

knob

then

tum

the

AD

JUST

knob

counterclockwise

for

MONTH

adjustment

or

clockwise

FUSE

a

5

FUSE

s

0

u

II

In

ILl

II

LI

1

SEL438

for

DAY

adjustment

To

adjust

the

current

minute

and

second

select

MIN

SEC

with

the

SELECT

knob

and

depress

the

ADJUST

knob

to

set

the

time

to

00

When

the

battery

cable

is

detached

and

reinstalled

the

display

will

auto

matically

return

to

12

00

EL

85

Electrical

Accessories

ELECTRICAL SYSTEM

WIRING

DIAGRAM

CLOCK

EL

86

@I

1ll

D

FUSIBLE

LINK

WR

W

BATTERY

I

1

WR

LB

ST

ON

lCCOff

000

B

J

00

8

b

I

IGNITION

SWITCH

I

J

W

u

i

w

C

I

J

1

@

j

J

I

J

L

j@

Green

J

j

White

1

Ii00

0

L

01

O@

L

@

TO

L1GHT

SWITC

H

@

l

iOOOOIIO

ho

o

ooo

o

@

J

I

@

e

@

L

@

o

g

COMBINATION

METER

H

GJ

3

2

4

HORN

SCHEMATIC

HORN

1

f

FUSIBLE

LINK

SA

TTERY

I

WIRING

DIAGRAM

HORN

r

80

BATTERY

HORN

RELAY

D

G

r

@

HORN

R H

@G

HORN

L

H

0

FUSE

ELECTRICAL

S

YSTEM

EI

ectncal

Accessories

Surge

killer

HORN

RELAY

I

o

C

1

HOr

B

TN

1

Q

HORN

Q

HORN

SEl445

6

Bfl

gW

LINK

@

i

@

f

I

l

D

BG

FUSE

BLOCK

1

a

J

I

l

N

D

@l

l

3

I

U

HORN

BUTTON

0

I

COMBINATION

SWITCH

2

SEL446

EL

87

Electrical

Accessories

ELECTRICAL

SYSTEM

TRoUliLE

DIAGNOSES

AND

CORRECTIONS

Condition

Probable

cause

Neither

high

nor

low

horn

operates

Burnt

fuse

Faulty

hom

button

contact

Hom

sounds

when

CD

terminal

of

instru

ment

harness

conn

ctor

to

combination

switch

is

grounded

Faulty

hom

relay

Hom

sounds

when

@

and

@

terminals

of

engine

harness

to

horn

relay

are

connected

with

a

test

lead

including

lOA

fuse

Loose

connection

or

open

cfrcuit

High

Low

horn

does

not

operate

Faulty

horn

or

loose

hom

terminal

connec

tion

Break

in

wire

to

horn

Horn

does

not

stop

to

sound

Short

circuited

horn

button

and

or

hom

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

or

poor

connector

contact

Fuse

relay

horn

and

or

horn

button

Faulty

homo

HORN

Inspection

rJ

@CD@

HI

to

SEL340

HORN

RELAY

Locstion

The

horn

relay

is

located

beneath

the

relay

bracket

Refer

to

page

EL

105

Battery

EL

88

Corrective

action

Correct

cause

and

replace

fuse

Repair

horn

button

Replace

Check

wiring

and

or

repair

connection

Correct

horn

terminal

connection

or

replace

horn

Repair

horn

button

or

its

wiring

Replace

Repair

Replace

HORN

BUTTON

The

horn

button

is

attached

to

the

combination

switch

Refer

to

page

EL39

AUDIO

SCHEMATIC

AUDIO

E

LINK

BATTERY

I

L

DOOR

SPEAKER

R H

DOOR

SPEAKER

L

H

SCHEMATIC

POWER

ANTENNA

1

FUSIBLE

LINK

BATTERY

I

L

RADIO

IGNITION

SWITCH

C

ACC

CON

OST

ELECTRICAL SYSTEM

Elecrrical

Accessories

y

OST

IGNITION

SWITCH

m

I

000000

6

J01

V

t

POWER

ANTENNA

SWITCH

I

u

N

0

o

FUSE

0

u

I

OeCK

REAR

SPEAKER

R H

II

E

REAR

SPEAKER

L

H

SEL447

l

ft

POWER

ANTENNA

3

MOTOR

SEL449

EL

89

Electrical

Accessories

ELECTRICAL

SYSTEM

WIRING

DIAGRAM

AUDIO

ffih

o

BATTE

Y

U

FUSIBLE

LINK

Sf

o

LW

illY

4YJ

LyR

B

I

a

I

J 0

01

IBlue

I

a

m

a

15i

J 0

t

J

DOOR

SPEAKER

L

H

II

I

YUi

U

@@

Irml

9

00

FUSE

RADIO

EL

90

DWR

@

Block

J

lgW

J

I

v

LR

LB

@

i

l@

I

L

Green

0000

00

@

DECK

REAR

SPEAKER

R

H

1J

I

@

I

tk@Y

@

m

rT

REAR

SPEAKER

L

DOOR

SPEAKER

R H

SE

1448

ELECTRICAL SYSTEM

Elecrrical

Accessories

WIRING

DIAGRAM

POWER ANTENNA

1

BATTERY

re

I

IGNITION

SWITCH

ST

ON

ACC

Off

I

8

g

J

I

FUSIBLE

LINK

G

D

ftWR

@

mtl

@

1

WR

LBi

FUSE

BLOCK

s

L

n

@

J

Il

li

White

@

Ifg

lIgg1gitl

Whitel@

ill

I

ss

Q

l

0

a

cO

@B

I

i

nht

0

Bluel

Green

000000

@

1

1I000ill

lIt

o

@

II

I

CD CD

@L1f3J

IU

N

D

Ig

POWER

ANTENNA

SWITCH

I

s

I

s

RW

B

W

s

c

a

w

@

@r

POWER

ANTENNA

MOTOR

SEL450

EL

91

Electrical

Accessories

ELECTRICAL

SYSTEM

RADIO

Removal

and InataUatlon

Prior

to

removing

radio

and

sound

balancer

remove

cluster

lid

C

Inspection

POWER

ANTENNA

Feeder

cable

routing

Antenna

trimmer

adjustment

The

antenna

trimmer

should

be

adjusted

in

the

following

cases

Fading

and

weak

AM

reception

Mter

installation

of

n

w

antenna

feeder

cable

or

radio

receiver

Before

adju

ingt

be

sure

to

check

harness

and

antenna

feeder

cable

con

necton

for

proper

connection

1

Extend

antenna

completely

2

Turn

radio

on

and

turn

volume

control

to increase

speaker

volume

3

Tune

in

the

weakest

sta1ion

bare

ly

audible

on

dial at

the

range

around

14

1

400

kHz

4

Turn

antenna

trinuner

to

left

or

right

slowly

and

set

it

in

the

position

where

reception

is

strongest

Alway

route

feeder

cable away

from

other

harne

EL

92

SEL4S3

CAUTION

00

not

turn

antenna

trimmer

more

than

onehalf

turn

J

t

SEL346

HI

4

r

l

3C

kQTY

OIlUl

I

f

1

c

74

654

CI

OST

YEO

u

s

YAX

T

S

IP

I

5

n

c

O

I

CT

DJO

Q

l

f

O

o

E

SC

R

IP

T

IO N

r

s

20082

20081

Combined

1IIlIDtJ81

80

D271

26

9

c

ANY

ITEMS

NOT

SHIPP

ARErIMMED1ATELY

BACK

ORDERED

NO

CLAIMSAI

WED

UNLESS

MADE

WITHIN

10

DAYS FROM

DATE

off

INVOI

CE

r

fo

UNAUTHORIZED

RETURNS

ACCEPTED

ThiS

is to

rtity

that the

900ds

herein

were

produced

In

ompllilnce

with

all

provisions

of the Fair

Labor

Standards

Act

of

1938

amended

It is

Intention

o

amply

nd

the

prices

here

Invoiced

do

comply

to

tJ1e

best

of

knowledge

with

sting

price egulations

SHIPPING

11

4l

Power

antenna

motor

II

Securely

tighten

antenna

grounding

bolts

SE

L348

ELECTRICAL

SYSTEM

Electrical

Accessories

CAUTION

Do

not

allow

motor

to

keep

running

when

antenna

rod

is

fully

extended

or

retrected

Power

antenna

switch

The

power

antenna

switch

is

located

on

cluster

lid

C

Refer

to

BF

section

v

@CD

i

SEL349

TROUBLE DIAGNOSES

AND

CORRECTIONS

I

Fading

and

weak

radio

reception

Check feeder

cable

connections

O

K

lN

G

I

Connect

or

repair

Noisy

radio

reception

1

Stop

engine

and

turn

off

all

other

I

switches

Revised

1

I

Check

ignition

cables

O

KJ

I

N G

I

T

gh I1

ten

secure

y

O

K

l

Check

antenna

ground

Adjust

antenna

trimmer

O

Kj

Replace

radio

Revised

1

Faulty

radio

Check

noise

prevention

parts

Condenser

bonding

wire

O

K

l

Check

spark

plugs

OK

I

Faulty

speaker

Unchanged

O

K

Check feeder

cable

routing

Replace

radio

Revised

Faulty

radio

I

Unchanged

NOISE

PREVENTION

PARTS

Condenser

Ignition

coil

Alternator

Bonding

wire

Body

to

engine

rocker

cover

See

Fading

and

weak

reception

Unchanged

I

N G

Replace

Retighten

or

replace

N

G

Replace

N G

Repair

N

G

I

Faulty

speaker

EL

93

Automatic

Speed

Control

Device

A

S

CD

ELECTRICAL SYSTEM

AUTOMATIC SPEED

CONTROL

DEVICE

A

S C D

CAUTION

Before

starting

to

wort

on

any

part

of

e1ectricel

system

disconnect

battery

ground

ceble

DESCRIPTION

The

Automatic

Speed

Control

Device

subsequently

referred

to

as

A

S

C

D

i

a

combined

unit

of

electronic

circuits

with

vacuum

me

chanisms

SCHEMATIC

A

S

C

D

The

construction

of

this

system

and

the

location

of

each

component part

are

shown

on

page

EL

I04

and

105

The

AS

C

D

controller

generates

an

electrical

signal

equivalent

to

the

difference

between

the

preset

speed

and

the actual

speed

picked

up

by

the

speed

sen

or

The

rvo

valve

converts

this

signal

into

corre

ponding

vacuum

and

oper

ates

the

actuator

which

adjusts

the

throttle

valve

opening

IGNITION

SWITCH

ON

r

OFF

@

I

ON

rc

Y

FUSIBLE

LINK

Y

L

FUSIBLE

LINK

BATTERY

FUSIBLE

LINK

cY

C

1

I

OACC

I

Y

g

r

L

MAIN

SWITCH

Neutral

xmtion

I

ll

RELAY

EJ

STOP

LAMP

SWITCH

I I

STOP

SWITCH

8

o 0

INHIBITOR

RELAY

INHIBITOR

SWITCH

EL

94

FUSE

II

FUSE

YO

IGNITION

AND

ACCESSORY

RELAY

TO

LIGHTING

I

SY

TE

SOLENOID

VALVE

l

CRUISE

@

L

TO

ACl

JATOR

INTAKE

MANIFOLD

SERVO

VALVE

r

I

SET

SWITCH

I

Q

OPEN

CLOSED

CONTROLLER

t

THROTTLE

LEVER

SPEED

I

SENSOR

SE

LAOO

r

FUNCTION

AND

OPERATION

Mln

swttch

The

main

switch

has

a

holding

type

ofcircuit

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

supplying

current

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

remain

ON

When

the

ignition

switch

is

tumed

off

lhe

relay

will

also

turn

off

And the

relay

will

remain

in

operative

until

lhe

main

switch

is

turned

ON

even

if

the

ignition

switch

is

set

to

ON

S

t

swttch

The set

switch

has

an

ON

OFF

switch

type

of

circuil

When

the

set

switch

is

depressed

lhe

CRUISE

light

illuminates

Wilh

TROUBLE

DIAGNOSES

TEST

CONDITIONS

If

a

malfunction

is

found

be

sure

to

check

lhe

following

before

perform

ing

the

system

tesl

I

All

wiring harness

connectors

must

be

securely

connected

ELECTRICAL

SYSTEM

Auramatic

Speed

Control

Device

A

S

CD

lhe

switch

depressed

lhe

controller

cancels

the

preset

car

speed

The

controller

will

preset

lhe

car

speed

at

which

lhe

car

is

running

when

the

switch

is

released

Speed

s

nsor

Contaln

d

In

speedom

tr

The

speed

sensor

is

generating

two

pulses

per

revolution

of

the

meter

cable

The

output

voltage

range

and

lhe

duty

cycle

must

be

controlled

prop

erly

S

ryo y

ly

TransdUc

r

The

servo

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

Controll

r

The

c

ontroller

compares

the

preset

speed

with

the

actual

car

speed

and

maintains

the

preset

speed

by

in

creasing

or

decreasing

the

current

flowing

through

the

servo

valve

2

A

SC

D

cable

must

be

securely

installed

with

proper

adjustment

3

Vacuum

hoses

must

be

properly

attached

wilh

no

abnorrrial

conditions

such

as

vacuum

leakage sharp

bends

or

kinks

R

I

y

ly

The

release

v

ve

is

lhe

safety

valve

wliich

shuts

off

the

atmospheric

passage

to

lhe

vacuum

line

when

the

system

activates

Actu

tor

The

actuator

causes

ihe

throttle

to

open

and close

by

vacuum

through

lhe

servo

valve

Stop

wttch

The

stop

switch

is

used

to

release

lhe

system

When

the

brake

pedal

is

depressed

this

switch

cuts

off

lhe

power

supply

to

the

A

SC

D

circuil

Stop

I

mp

switch

This

switch

causes

the

stop

light

to

operate

At

the

same

time

the

oper

ating

signal

of

the

stop

light

circuit

is

sent

to

lhe

controller

in

order

to

re

lease

the

system

Inhibitor

r

lliy

The

inhibitor

relay

releases

the

A

s

C

D

system

when

the

selector

is

set

to

N

or

P

position

DIAGNOSIS

WARNING

All

following

system

tests

can

be

performed

withoutrunning

engine

Avoid

making

test

while

driving

car

or

running

engine

Indicator

light

will

not

glow

even

if

ON

button

of

main

switch

is

depressed

with

ignition

switch

ON

1

Burnt

bulb

Faulty

main

switch

L

Faulty

A

S C

D

relay

EL

95

Automatic

Speed

Control

DBVice

A

S

C D

i

ELECTRICAL

SYSTEM

r

Cruise

light

will

not

glow

eyen

if

let

switch

is

depressed

and

released

81

proper

car

speed

with

main

switch

ON

Speed

not

set

in

system

1

With

main

switch

ON

battery

voltage

12V

is

present

between

terminals

@

and

V

of

harness

conn

ector

Set automatic

transmission

selector

lever

at

any

position

other

than

Ip and

I

NW

position

YES

to

Open

circuit

I

Faulty

or

unproperly

adjuSted

stop

switch

When

set

switch

is

depressed

with

main switch

ON

battery

voltage

12V is

present

between

terminals

@

and

V

ofhamess

connector

YES

1

NO

Faulty

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

to

Faulty

controller

Faulty

speed

sensor

EL

96

Faulty

inhibitor

switch

ELECTRICAL

SYSTEM

Automatic

Speed

Control

Device

A

SC

D

Cruise

light

illuminates

when

speed

setting

operation

i

made

but

peed

is

not

actually

set

When battery

voltage

12V is

applied

to

the

release

valve

terminal

the

following

are

possible

1

With

A

closed

no

suction

is

possible

at

B

2

With

A

opened

suction

is

begun

at

B

YES

to

Faulty

release

valve

It

Servo

valve

operates

normally

Refer

to Servo Valve

for

Inspection

YES

1

NO

Faulty

servo

valve

Actuator

operates

smoothly

when

actuator

vacuum

port

is

suctioned

TItis

operation

must

be

performed

with

A

S

C

D

cable

released

YES

1

Faulty

controller

lNO

Faulty

actuator

tl

LL

I

LJ

A

To

servo

valve

1

I

To

actuator

B

BE089D

EL

97

Automatic

Speed

Control

Device

A

S

C

D

ELECTRICAL

SYSTEM

Other

maHunctlon

Condition

Set

speed

is

cancelled

Pulsation

of

set

speed

Excessive

setting

error

Speed

drops

immediately

after

setting

Probable

cause

Bent

meter

cable

excessive

meter

needIe

deflection

Faulty

controller

Excessive

play

or

binding

of

A

S C

D

cable

Leakage

or

clogging

in

vacuum

hose

Binding

in

actuator

Faulty

servo

valve

Faulty

controller

Excessive

play

or

binding

in

A

s

C

D

cable

Leakage

or

clogging

in

vacuum

hose

Faulty

actuator

Faulty

servo

valve

Faulty

controller

Faulty

speed

sensor

Excessive

play

in

A

S C

D

cable

Leakage

or

clogging

in

vacuum

hose

Faulty

release

valve

Faulty

servo

valve

Faulty

controller

Cancel

circuit

inoperative

Faulty

controller

EL

98

Corrective

act

on

Check

and

repair

meter

cable

or

renew

cable

Renew

Adjust

Check

and

repair

piping

route

or

renew

hose

Renew

actuator

Renew

servo

valve

Renew

controller

Readjust

Check

and

repair

piping

route

or

renew

hose

Renew

actuator

Renew

servo

valve

Renew

controller

Renew

speed

sensor

Readjust

Check

and

repair

piping

route

or

renew

hose

Ren

w

rele

valve

Rene

y

servo

valve

Renew

controller

Renew

controller

ELECTRICAL

SYSTEM

Automatic

Speed

Control

Device

A

S

C D

COMPONENT

PARTS

VACUUM

ROUTING

Adjusting

nut

Lock

nut

o

f

I

Actuator

To

vacuum

check

valVe

Air

conditioner

equipped

model

ToF

I

C D

SEL392

EL

99

Automatic

Speed

ntrol

Device

IA

S

C

D

ELECTRICAL

SYSTEM

WiltiNG

OIAGRAM1A

S

C

O

f

TT

ffi

FUSIBLE

LINK

W

IGNITION

AND

ACCESSORY

RElAY

lJWR

r

D

t3@

@

J

1T

B

WR

5T

ON

ACC

Off

J

t

g

I

s

l

o

s

tf

IGNITION

TCH

r

W

we

o

0

QI

FUSE

0

BLOCK

STcp

LAMP

1

SWI

STeP SWITCH

C1

SET

SWITCH

RELEASE

SERVO

L

U

v

V

E

A

S

C

D

CONTROLLER

I

r

I

II@

jG

I

J

aJ

CD

aJ

CD

a

C

a

J

I

i

1

W

@

VB

A

5

C D

f

@

m

I

INHIBITOR

RELAY

@

YL

I

@

I

L

BL

1

i

m

vn

I

lOr

LgB

J

m

l@

@

iJ

1

m

J

CD

C

@

I

@

l

I

W

@

XI

Cl

III

11

1

0

J

A

SC

D

MAIN

SWITCH

EUOO

m

Cl

W

Whits

171

Y

@1r

I

SPEED

SENSOR

SEL3M

A

S

C

D

CABLE

Removal

and

Inatallatlon

I

Disconnect

cable

from

actuator

1

Loosen

lock

nut

at

actuator

2

Remove

rubber

boots

1

Actuator

2

Rubber

boot

3

Cable

4

Lock

nut

2

Loosen

lock

nut

at

intake

mani

fold

bracket

3

To

install

the

cable

reverse

the

order

of

removal

Exercise

care

when

removing

and

installing

wire

so

as

not

to

deform

wire

end

Adjustment

When

installing

adjust

A

S C

D

cable

as

follows

Without

depressing

the

accelerator

pedal

adjust

the

adjusting

nut

until

cable

free

play

is

within

specified

value

at

throttle

lever

Then

tighten

lock

nut

Free

play

23m

0

08

0

12 in

Do

not

inc

ease

tension

of

cable

excessively

as

this

may

cause

throttle

lever

to

rotate

ACTUATOR

Removal

and

Installation

I

Disconnect

battery

ground

cable

2

Disconnect

cable

from

actuator

Refer

to

A

S C

D

cable

for

reo

moval

3

Disconnect

vacuum

hose

from

A

S C

D

release

valve

4

Remove

bolt

attaching

actuator

to

body

5

To

install

actuator

reverse

the

order

of

removal

ELECTRICAL

SYSTEM

Automatic

Speed

Control

Device

AS

C

D

In

ectlon

I

Visually

check

actuator

for

dam

age

Or

deformation

2

Make

sure

that

actuator

moves

smoothly

without

binding

when

dia

phragm

is

pushed

by

hand

3

Apply

vacuum

to

actuator

If

diaphragm

moves

to

full

position

it

is

normal

Plug

hose

with

vacuum

applied

Make

sure

that

act

laJor

remains

in

full

position

BE100D

CAUTION

When

checking

actuator

by

applying

vacuum

do

not

apply

engina

vacuum

directly

RELEASE VALVE

Location

Refer

to

page

EL

99

In

ction

1

Measure

the

resistance

between

terminals

Circuit

tester

indication

25 30

n

2

Check

to

be

sure that

the

valve

opens

or

closes

by

blowing

air

through

port

on

actuator

side

Battery

12V

1

Actuator

side

2

Serio

valve

side

3

Atmosphere

side

I

CD

n

ZP

S

E

L409

I

Normal

condition

Check

ports

Airflow

CD

V

CD

@

Yes

V

@

2

12V

direct

current

is

applied

be

tween

terminals

Check

ports

Airflow

CD

V

Yes

CD

@

No

V

@

SOLENOID

VALVE

Location

Refer

to

page

EL

99

In

ctlon

1

Measure

the resistance

between

terminals

Circuit

tester

indication

25

30n

2

Check

to

be

sure

that

output

vacuum

of

valve

is

proper

This

check

should

be

performed

with

the

valve

installed

on

car

CAUTION

With

servo

valve

connected

to

system

do

not

apply

current

to

servo

valve

Be

sure

to

disconnect

solenoid

valve

sida

vacuum

hose

i

Disconnect

solenoid

valve

side

vacuum

hose

at

solenoid

valve and

connect

vacuum

gauge

2

Start

engine

and

warm

up

engine

until water

temperature

indicator

points

to

the

middle

of

gauge

3

Apply O

3A

direct

current

be

tween

tenninals

Using

about

20n

5W variable

resis

tor

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

Ammeter

O

3A

Ir

l

Battery

12V

SPEED

SENSOR

Lead

switch

type

Location

The

speed

sensor

is

built

into

the

speedometer

Inspection

must

be

made

with

speed

sensor

installed

to

speedometer

TurDing

speedometer

SlowlY

by

hand

test

continuity

of

speed

sensor

circuit

Continuity

existstwo

times

a

turn

O

K

A

nro

9JD

EL

102

0

IlL

I

l

Servo

valve

MAIN

SWITCH

e

Yacuumgauge

1II

7

3

11

3

kP

55 85

mmHg

2

17

3

35

inHg

Solenoid

valve

side

To

intake

manifold

BE730D

Inspection

Test

continuity

through

switch

or

f

2Er

Switch

position

Check

terminal

Q

@

Q

@

@@

ID @

@

j

@

j

light

with

an

ohmmeter

in

accordance

with

the

following

chart

l

3

I

Off

II

lieAulSE

CIN11lfi

Il

OND

1Il1

SE

L424

Normal

ON

OFF

No

Yes

No

Yes

No

Yes Yes

No

Yes

Continuity

should

exist

No

Continuity

should

not

exist

SET

SWITCH

Inspection

Test

continuity

through

switch

with

an

ohmmeter

r

NORMAL

PUSH

1

OPSTION

SWITCH

11

9

12

6

SE

L425

STOP

SWITCH

Inspection

Test

continuity

through

switch

with

an

ohmmeter

NORMAL

POSITION

f

11

9

126

@

PUSH

PLUNGER

SEL431

Adjustment

of

the

stop

switch

is

the

same

as

the

stop

lamp

switch

Refer

to MA

section

STOP

LAMP

SWITCH

Inspection

Rofer

to

page

El

sO

ELECTRICAL

SYSTEM

Automatic

Speed

Control

Device

AS

C

D

Adjustment

Refer

to MA

section

A

S

C

D

RELAY

Location

The

A

SC

D

relay

is

located

on

the

relay

bracket

Refer

to

page

EL

105

INHIBITOR

RELAY

For

A

S

C D

Location

The

inhibitor

relay

is

located

on

the

relay

bracket

Refer

to

page

EL

105

Inspection

a

r

c

1

@@

a

0

o

t

L

I

Gr

@

SEL433

Check

terminals

Normal

condition

l2V

direct

current

is

applied

between

terminals

@and@

@

CD

@

Yes

No

Yes

Continuity

should

exist

No

Continuity

should

not

exist

A

S

C D

CONTROLLER

lC

built

In

Location

The

controller

is

located

on

the

left

dash

side

panel

Refer

to

page

EL

I04

Inspection

Controller

must

not

be

checked

as

a

single

part

Check

controller

for

opera

tion

as

a

system

referring

to

Diag

nosis

CAUTION

Do

not

touch

the

circuit

tester

probe

to

eny

unnecessery

terminal

on

con

troller

Doing

so

could

cause

damage

to

controller

a

Handle

controller

carefully

to

avoid

damage

b

Keep

controller away

from

electric

noise

source

to

prevent

A

S

C D

system

from

malfunctioning

and

Ie

circuit

etc

from

being

degraded

EL

103

Electrical

Unit

Location

ELECTRICAL SYSTEM

ELECTRICAL

UNIT

LOCATION

Ignition

arid

accessory

relay

sea

tbelt

timer

HI

control

unit

I

to

C

v

SE

L432

EL

104

cJ

EFI

relay

l

Fuel

pump

A

S

C

D

relay

III

I

@

Headlamp

sensor

Inhibitor

relay

Intermittent

wiper

amplifier

Hatchback

lamp

nso

I

Tai1

and

stop

I

Unit

Location

M

Electrlca

ELECTRICAL

SYSTE

Air

conditioner

relay

alve

Air

con

Magnet

v

H7

lardtop

114

p

sensor

Tail

nd lam

EL

105

Wiring

Harness

ELECTRICAL

YStEM

WIRING

HARNESS

CABLE

COLORS

Cable

colors

are

generally

used

as

shown

in

the

following

table

Circuit

system

Base

color

Starting

and

ignition

system

B

Black

W

White

R

Red

G

Green

Y

Yellow

Charging

system

lighting

system

Signal

system

Instrument

system

Others

L

8r

Lg

Blue

Brown

light

green

B

mack

Grounding

system

HARNESS

LAYOUT

For

easy

identification

connectors

indicated

in

the

system

wiring

diagram

have

the

same

numbers

as

those

used

in

the

har

ness

layout

schematic

@

@@

I

i

YG

CJ

QO

YG

@@

w

Wiring

diagram

Main

harness

Instrument

harness

SEL461

SEL

2

EL

106

ELECTRICAL SYSTEM

WiringHBrn8S

SCHEMATIC

Hatchback

4

1

Main

harness

2

InstTumcnt

harness

3

EFI

harness

4

Body

harness

S

Door

harness

6

Console

harness

7

Back

door

harness

8

Fuel

pump

harness

SE

L463

Hardtop

EL

107

e

CO

ar

n

Il e

i

I

10

Is

ELEClf

CALS

I

SlE

tJ

ttA

RtlESS

i

g

e

0

I

0

s

e

n5

a

iio

U

6

e

Z

o

t

I1i

ll

tt li

iJ

s

aa

gg

9

e

5

i

S

u

11

l

ii

i

t

u

tia

eII

a

d0

i

5

t

@

@@

j

@@

i

u

Ii

l

s

U

@@

@

et

ooo

g

a

r

ucn

@

@@

g9

l

a

i

Ol

c

dod

U

1l

a

t

A

l

0o

9

a

5e

S6

ji

a

eil

eJ

d

0

a

otIS

i

pp

tt J

@@@

@

i

a

Po

aIIi e

2l

JJ

t

J

8c

4

58

Po

e

ge

q

ss

5

s

ii

s

II

PoPoal

e

i

5

1

l1

nl

gi

1

i

n

SE

@@@@@@@@@

@@@

d

@

Warning

chime

@

To

interior

lamp

harness

Ignition

and

accessory

relay

Earth

@

Ignition

and

accessory

relay

@

Seat

belt

timer

@

To

door

harness

R

H

@

Fuse

block

@

Heater

motor

@

Thermo

switch

Air

conditioner

unit

To

@

White

To

@

Green

@

To

@

Black

@

To

@

Blue

@

To

@

@l

White

@

To

@

lID

Black

@

Parking

brake

switch

8

Seat

belt

switch

Indicator

lamp

Am

To

console

harness

@

Heater

control

panel

1Jjl

To

door

harness

L

H

@

A

S

C

D

controller

@

A

S

C

D

controller

@

To

EFI

harness

Hazard

flasher

unit

Turn

signal

flasher

unit

@

Door

mirror

5Witch

L

H

@@@

i@

@@

Door

mirror

switch

R

H

A

S

C

D

main

switch

A

Hazard

switch

r

Ignition

switch

Windshield

wiper

switch

m

r

m

n

l

0

n r

Ul Ul

l

m

s

I

5

m

if

m

3

0

CO

r

c

@Bl

t

@

2

m

z

III

I

Q

C

I

m m

n

z

t

e

IJ

n

I

m

3

III m

I

III

@

muminadon

control

rheostat

@

To

combination

meter

@

To

combination

meter

@

To

combination

meter

@

A

S

C

D

peed

aenlOr

@

Interior

lamp

timer

@

Multi

wambtg

indicator

ID

Audio

@

Power

antenna

switch

@

garette

Ughter

@

Ash

tray

illumination

@

Wamlns

dl

pby

amplifier

@

Glove

box

lamp

@

To

@

I

Bbck

@

To

@

Blue

@

To

8

Green

@

To

@

White

@

To

8

White

@

To

@

Black

@

Door

switch

R

n

@

To@

@

To@

@

Rear

speaker

R

H

@

Tail

and

stop

lamp

sensor

@

Tail

and

stop

lamp

sensor

@

Side

marker

lamp

R

H

@

Rear

combination

lamp

R

H

ill

Rear

combination

lamp

R

n

ill

License

lamp

R

H

@

Back

up

lamp

R

H

@

License

lamp

L

U

ill

Rear

combination

lamp

L

R

J

Tr

l

m

r

m

r

In

@

Rear

combination

lamp

L

n

@

Back

up

lamp

L

U

@

Power

antenna

ffi

Side

marker

lamp

L

R

@

Luggage

ompartment

lamp

@

Rear

speaker

L

U

@

Door

switch

L

R

@

To

fuel

pump

harness

ill

Fuel

tank

gauge

unit

@

Body

earth

Back

door

hameu

@

To@

@

To@

@

Rear

defogger

@

Rear

wiper

motor

@

Rear

defogger

Earth

f

r

rr

IIo 0

a

z

III

I

m

r

m

n

t

n r

en

CIl

l

m

3

I

S

i

n

@1

Tol@ll

WhitO

@1

To

I@ll

Black

@

Door

switch

R

a

@

Rear

defOSller

@

Rear

speaker

R

a

@

Trunk

room

lamp

awltch

@1

Body

earth

@

Tail

and

top

lamP

aenlOr

@Y

Tail

and

atop

lamP

senIOr

@

ide

marker

lamp

R

a

@1

Rw

combbU

tlon

lamp

R

a

Trunk

room

lamP

@

lear

speaker

L

a

@

Fuel

tank

gauge

unit

@

Licon

lamP

R

a

@

Back

up

lamP

R

a

@

Licen

lampL

a

@

Back

up

lamP

L

a

@

Rear

combination

lamp

L

a

@l

Side

marker

lamp

L

a

@

power

antenna

@

Door

switch

L

a

@

To

fuel

pump

harness

f

i

o

r

1S

m

I

m

0

o

r

ELECTRICAL SYSTEM

Wiring

Harness

ENGINE

ROOM

HARNESS

NO

2

@

Kickdown

rwitch

Arr

@

Inhibitor

switch

Am

@

Inhibitor

rwitch

Am

@

Rever

bmp

rwitch

Mm

@

Starter

motor

@

Oil

pressUIe

sending

unit

@

To

I@

@

To@

@

To

I@

I

r

f

J

0

fr2

fr

@

11

1

II

J

@

SEL460

EL

113

4

i

j

f

11

u

y

1I1NOlllONOO

lilY

OJ

fI1

S

J

H

MS

d

l

d01S

1

11

il

Illffil

II

SOIlYl

H

r

jJ

J

P

cJ

Q

1lO1OW

1

J1I1

01B

c

pn

all

IYH

lUtJ

lDlS

I

os

lHSV

ISOlHII

1I1

llM

1lIlIB

H

l

I

DlS

1I

1

l

11

JIt

11m

J

JlI

Cl

WHO

1H

a

I

DI

II

a

m

NIIYM

5

19

U

All

McJll

ml

3

jl

rb

m

i

j

mr

1IB1

MS

NOU1l

j

1

j

CbM

i

l3

WA

Y1UIl

1

Jt

lllONn

o

H

lIO

S

JS

llOlSl

illl

@

fill

I

f

Hf

f

l

rT

E9J

gjIjiLtLW

I

or

n

A

IIM

J

80

1

0

U

50

IIA

j

11

u

11

2

II

jj

s

EB

J

l

I

Wn

1

fl

lP

J

l

J

llr

k

l

g

Hld

YlOY

H

I

m11111nr

I

r

f

fi

IIIii

i

r

I

IB

66

l

a

EJ

III

II

o

Il

l

Wi

h

Jt

J

1

100

IlOl

fl1

1I1

NlO

l00

oo

J

L

ISIS

lI

1Lw

cP1m

J

1

f1

l

811s

lt

1

tRI

c

a

l

Inl

ii

f

rWU

f

JI

1019

3sn

r

f

o

itri

IT

J

Cl

rno

I

i

E

tEl

9

B

8

I

r

B

n

0

I

uiI

I

o

Q

KIII

lIl

l

J

1

l001

lMl

bIl

l

I

M

ffi

1

I

IM

3

l

300Q

i

J

r

jf

I

H

y

1130

11

1

101

0111

O

A

OS

J

d

lmu

J

lOISHIOlU

1

l

cr

III

II

I

n

i

fill

i

Jl

1

CD

i

Cl

J

S

I

lIllII

l

J

18

l@

ll

tP

ftj

ll

iiJB

II

lmalJlJ

Ui

JndWV

rl

ll

NmSY

l

I

H

M

A

I

UlI

Avll11

l

AY

31

A

f

31

n

1

XSOOZ

NnSJ

va

086L

11

tlOII

M

Blntl

z

Av1

1

I

11n1

dwnd

nn

Ullll

flJ

ASCD

WARNING

A

SC

D

Q

W

11ffll11iiill

err

G

IT

In

rr

iE

1

iiiffll

i11

J

WllHD

I

WITHOUT

SPOT

LA

t

lPl

Il

I

r91

li

I

II

GB GB

ow

GW

R8

B

GGY

cw

i

GW

FIG

R

BR BR

JI

I

t

I

I I

L

I

1

J

l

I

r

t

oio

I

II

t

H

II

lffiJlW

flBl

I

AS

C

O

MAIN

SW

I

UYijj

C5

Iii

2W

fOR

5

i

p

SPEA

ER

t

rR

r

E

NA

lLtH

DOOR

SW

I

WI

I

R

lW

W

If

YL

R8

Jll

i

B

LB

1I1

Cl

Gl

we

i

WB

L8

llll

W

Ji

L

Ii

B

ril

i

@

ll

B

H

l

8

0

B

l

11

u

eo

I

II

L

l

1

I

IP

II

I

1

I

t

I

H

n

Ioo

l

o

AKE

I

T

II

1

I

@

fflllWl

il

I

B

sPEAKEII

Z

B

c

STEP

LAMP

t

I

t

l

I

i I Ii

1

UJlm

m

1l1lmr

J1

I

II

I

lM litni

BLACK

BLUE

Gfl

EEN

WHITE

jIN

I

M1

l

ffiill

llm

fll

Ii

W

if

jft

re

IHEffiHm

I

C

l

1l

l

j

1

liIAI

IW

I

n

11

L

JEl

L

J

W

L

1

I

IlffiM

II

l t

p

ESl

W

B

o

U

i

ll

DECK

NG NG

P

LfGf

m

p

Jre

T

UNIT

INDICATOII

0

l

J

tK

0

r

@

1

@

COMBIN

TlN

llER

RAOIO

J

d

A

REAli

WIPER

SW

U

S

lE

RSPE

ER

i

S

ill

TIIUNK

LUGGAGE

ROOM

fi

C

i

y

I

ffl

i

glJ

I

L

1

mE

Ho

a

sw

AIRCONDITIQNEIl

II

I

i

fB1

fUEL

FUEL

TANK

i

f

PUMP GAUGE

ulm

W

ld

J

REAR

SPEAKEII

1

a

11

G

a

G

BLACK

WHITE

co

GREEN

BLUE

YELLOW

LIGHT

GREEN

BROWN

GREY

IN

THE

CASE

OF

TWO

TONE

COLOR

CABLE

COLOR

IS

INDICATED

BY

BASE

COLOR

ONLY

AND

STRIPE

COLOR

IS

NOT

SHOWN

GREEN

w

t

WHITE

SI

BlU Wl n

GREEN

Sl

p

REAR

WIPER

I

NTfNNA

MOTORlIl

MOTOR

AUTOMATIC

TRANSMISSION

MQDELS

4

MANUAL

TRANSMISSION

MODELS

@

CALIFORNIA

MODELS

@

NON

CALlFORNIA

MODELS

i

A

SeD

EQUIPPED

MODELS

HATCHBACK

l

i

HARDTOP

WITH

TIME CONTROL

INTERMITTENT

WIPER

POSIT

ON

Qlg

IO

lSwmlocK

L

ghl

w

an

per

sw

0000

Io

e

l

C

r

on

n

neut

al

lA

r

110

lever

n

pa

k

l

P

I

krngD

akepullea

O

ver

Io

lal

l

unlocked

n

Y

mot

o

8

z

IIEAIl

SIDE

MARKEll

tAMP

LH

R

AR

SIDE

MARKEll

i

REAR

COMBINATION

M

STOP

iW9G

P

TAil

TAIL AND

STOP

II

AR

COMBINATION

AMP

II

HlJ

hrt

l

ror

lJ

EB

1

ii

l

@

II

M

1

m

ClUTCHm

PFlESSUIIESW

MAGNET

SW

Alii

VALVE

lS

H

j

CABLE

COlORS

mple

GW

0

u

I

a

G

m

e

BACKUP

lAM

GW

LICENSEPlAn

9

cea

LAMPIIH

h

lICENS

wT

PLATE

LAMP

LH

9o

BACIl

UP

Q

LAMPLH

IfI

B

e3

jJ

IIEARCOMBINATlON

q

M

L

STOP

TURN

lJ

y

STOP

we

TURN

REAR

COMBINATION

lAMP

LH

l

MALE NO

CONNECTION

ttBEtE

t

FEMALE

rnHm

CONNECTION

I

CONNECTOR

ttBffiI

J

PLAIN

1

CONNECTOR

ttBtm

NORMALLY

OPEN

0

NORMALLY

CLOSED

INCH

TO

METRIC

CONVERSION

TABLE

METRIC

TO

INCH

CONVERSION

TABLE

Rounded

of

for

automotivo

use

Rounded

off

for

automotive

use

I

inches

mm

inches

mm mm

inches

mm

inches

100

254

610

1549

1

0394

51

2

008

I

110

279

620

15

75

2

079

52

2

047

I

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

2

323

190

4

83

700

17

78

10

394

60

2

362

200

5

08

710

18

03

11

433

61

2

402

210

533

720

18

29

12

472

62

2

441

220

559

730

18

54

13

512

63

2

480

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

290

7 37

800

20 32 20

787

70

2

756

300

7 62

810

20

21

827

71 2

795

310

7

87

820 20 83

22

866

72

2

835

320

8 13

830

21

08

23

906

73

2

874

330

8

38

840

21

34 24

945

74

2

913

340

8

64

850

21

59

25

984

75

2

953

350

8

89

860

21

84 26

1

024

76

2

992

360

914

870

22 10

27

1

063

77

3

031

370

9

40

880

22

35

28

1

102

78

3

071

380

9

65

890

22

61

29

1

142

79

3

110

I

390

9

91

900

22

86

30

1

181

80

3

150

I

400

10 16

910 23

11

31

1

220

81

3

189

410

1041

920 23 37 32

1

260

82

3

228

420

10 67

930

23

62 33

1

299

83

3

268

I

430

10

92

940

23

88 34

1339

84

3

307

f

440

1118

950

24

11

35

1

378

85

3

346

450

1143

960

24 38 36

1417

86

3

386

I

460

11

68 970 24 64 37

1457

87

3

425

I

470

11

94 980 24 89 38

1496

88

3465

480

12 19

990

25 15 39

1

535

89

3

504

490

1245

1

000

25

40 40

1

575

90

3

543

500

12

70

2

000

50 80

41

1

614

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

152

40

45

1

772

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

570

1448

9

000

228

60

48 1

890

98

3

858

580

14

73

10

000

254

00

49

1

929

99

3

898

590

14

99

20

000

508

00

50

1

969

100

3

937

600

15 24

I

f

DUICK

RIHHINCICHJtHI

2DDSlf

ENGINE

TUNE

UP

DATA

CLUTCH

PEDAL

r

FIrinaDnin

IM

T

I

Arr

Cdow

8

T

Dc at

idle

SpIted

CO

ilh

l

lo

topot

ToudllPftd

rpcn

IV

HOd

Jlfttd

Iud

E

tggn

lom

bII

IApplitd

pnMd

fora

mm

1m

98NHO

2tlbn

IfUdiItoraprtlilfpnslUn

kPl

kJfcm2

p

siJ

CooIi

IYIIlM

btt

uSting

p

f

alll

fcm

l

plil

Com ls

kr

lktfcrta

l1l

illrpm

I

Minilmnn

t

H

hMioftc

lb

llrei

I

ill

1

T

L

I

G

p

Innlfrnl

T

C

it

V

AH

f

ull

P

dfil

fY

Dinributor

V

Ilh

Muilllumdlltrit

tllr

lldl

tributDr

IlF

tnlfllHa

lnH

1l

I

l

i

diA

r

bU1of

6iftJIt

tgr

l

JIIl

Ij

AfT

r

dMIp

Of

itod

t

s

fl

lMktr

baIt

MilnifuldbahMldnut

J

BRAKE

0

P

lIlini

lUlIlthi

kn

RotCll

I

W

rlimit

R

jllnl

tircumter

u

l

dncUon

Ml

CIlircitnm

t

I

8IId

dlXD

n

5

J1

sOO

50

1

7OQ

10 15

Tll

1 8

9

11

16

21

Noft

CIIihdII

ForU

s

A

I

forc

adl

Z2llE

34

2

700

1

103

1OO

tl00

lin

D

pclIitionl

11

1

1 0

o

JOIo

012

0

3Ol0

0121

8

12

Cl

Jl

Q

41J

IICO

8

12

151

18

231

1

1nl12

0

171tl35O

11319

0

1281

J50

BPfiU

I

O

o

9IU31

0

Q3SI

12

m

1

21

10

31

1

250

9

o

0

10

0

15

1

0

1

4

21

1

2

S1O

12

65

1

7

5

1

33

3

1250

9

rl1

600

0

7

1

Sl Y

5

8

7

2

11 15

Unit

lIImlilt

R

1AHl1tn

I

2

010

0711

lLeath

lO 2Io

OCM7J

1

Leadl

lO

S

O

OO59I

1

F

tNZ2

m

Q

07

Q

OClZll

10

51D

4111

U

lo

338

EXPORT

SERVICE

DEPARTMENT

NISSAN

MOTOR

CO

LTD

17

1

Ginza

6

Chome

Chuo

ku

Tokyo

104

Jap

Printed

in

Japan

t

J

pq

119BI

1

Unit

lin

161

174

1e

81

e

1SJ

l

S

ta

OiI

a

2D

I

WHEEL

ALlGNMEN

U

Iaden

I

10

S

rlS

Tot

in

IlMPUnJ

0

2

O

o

osl

deQne

rr

lZ

Cet

blMhlidil

ll

Tuming

81

T

twN

umidIl

o

rt

lidlJ

h

m

11

w

1

T

ruIOr

full

adiIT

o

cDatam

qinlail

fuP

SptN

tn

PeSo

tault

INts

In

dn

rillllfpOlh

I

l

J

I

Ti

tnringflXqUl

R

N

mU

ftlb

FRONT

WHEEL BEARING

25

zg12

5

10

18

l21

er1

WHEEL

AND

TIRE

ITireW

nfl

tionp

N

pIlCk

Wh

1

tilillaoin

1arqut

N

mllt

m

tHbl

Ti

prtdIlN

Ihould

tit

dJlckld

wtIm

tlm

COLD

REFilL

CAPACITIES

I

F

tlnk

I

Wid

Mftg

Coobn

IWi

Wlltllllil

jWi1tlou1011fliter

1

EJ9rw

oil

TmMlIlllMott

IDi

Iswring

I

ryrum

I

Windl

lli

tdWllh

1Ift1t

IR

llftlblrtlnk

Aw

candtllllling

I

c

xn

w

rfdam

I

R

lS511OSR14

Tl35J7oo16

IT

1f1III

i

tiN

601412

annl

711 98

1

10

58 72

I

us

1

53

1

71

I

l5

fqt

19

l1qt

4

p

56

7

1qt

1 1

611

12

l

1J4qt

2

1

1q

1

111qt

lflOl

o

lI

1

1tq 2

0

2

4lb

Issued

February

1

811

020200

Publication

No

SMOE

Bll

UO

Nissan 1980 200Sx Repair Manual Service Datsun

Navigation menu

Versions of this User Manual:

Views

Navigation