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 INDEX
QUICK REFERENCE
I I

DATSUN

SERVICE
MANUAL
MOOEl
ES
610 SER
1

A
LN

CO tD
N SSAN MOtOR
lOIC
JAPAN
YO
 FOREWORD

This service manual has been prepared for the purpose of ass1stmg servIce
personnel of

authonzed NISSAN DATSUN dealers In provldmg effective servIce and maintenance of the

Datsun 180B

Smce proper maintenance and service are absolutely essential m

satisfYing the Datsun

owners this manual should be kept In a handy place for ready reference and should be

carefully studied

ThIS manual includes procedures for maintenance adjustments minor service operations
removal and installation and for dIsassembly and assembly of components

Some of these service operations require the use of Specml Tools especmlly designed for
effective performance of servIce operations

As you read through the mamtenance procedures In thiS service manual you will

occaSIOnally come acro

paragraphs headed NOTE or CAUTION A NOTE IS upplemental
CAUTION of steps that must
informatIOn that IS important to a
particular procedure warns

be followed to prevent personal mJury and or damage to some part of your DATSUN

The Reference Index the first page enables the user to quickly locate the
Quick on

deSIred sectIOn At the of each indIVidual section IS a table of contents which

beglnmng
the page number whIch each major subject begins An index IS placed at the
gives on

beginning of each major subject WIthin the section

All information illustratIOns and specificatIOns contallled in this manual are based on the

latest product information available at the time of pubhcatlOn approval If your DATSUN

model differs from the specificatIOns contained m tlus manual consult your NISSAN

DATSUN dealer for informatIOn

Rights for alteration at any time of speCifications and methods are reserved

Lmblhty for any personal injury or property damage occasioned by the use of thiS service

manual m
effectmg mamtenance or repair of your Datsun is in no way assumed by N1ssan
Motor Co Ltd

service procedure tool which is not specifically

Accordingly anyone uSing a or

recommended Nissan must first completely satisfy himself that neither his safety nor the
by
car s safety will be jeopardIzed by the service method selected

NISSAN MOTOR CO LTD

TOKYO JAPAN

@ 1976 NlSSAN MOTOR CO LID Pnnted In

Japan
 r
General Information

APPROXIMATE REFILL CAPACITY

Liter US
t
measure
Imp measure
SECTION GI
Fuel tank

Sedan and Hardtop 55 14 igal 12 gal

Station Wagon 52 13 U gal II igal I
Engine cooling system I 65 6 U qt 5 U qt
GENERAL
Engine crank case 2 43 4 iqt 3 Y qt t
Manual transmiSSIOn DATSUN INFORMATION
4 speed 20 4 Y pt 3 ipt
f MODEL 610 SERIES
5 speed 17 3 U pt 2 U pt

Automatic transmISSIOn case 3 55 5 U qt 4 U qt

r

Fmal dnve case

hOUSing
Sedan and Hardtop 08 I U pt 1 pt
Station Wagon 1 3 2 Y pt 2 Y pt

Steenng gear box 028 U pt ipt

1 Includes 0 5 liter US qt Imp qt for heater

2 Includes 05 liter US qt Imp qt for 011 filter
3 Includes 4 0 liters 4 US qt 3 Imp qt for torque converter

RECOMMENDED FUEL
I
Use a proper grade gasoline of above 88 octane ratmg
I
I

RECOMMENDED LUBRICANTS I
RECOMMENDED SAE VISCOSITY NUMBER
GASOLINE ENGINE OIL
I
VISCOSlty
Mul1l
MODEL VARIATION GI 2
I
JO
lOW 40 lOW 50
100 40 20W 50
200

5W 30 5W O lOW 30 co
lOW

5W 20 5W JO 40
5W
IDENTIFICATION NUMBERS GI 3
Smgle VISCOSIty
SAE 5W 20 Oils are not
recommended for sustamed
30
4050

I APPROXIMATE REFILL
CAPACITY GI 4
2OW 2r1N 20
ugh speed dnvmg

75W
lOW

1 RECOMMENDED FUEL GI 4

RECOMMENDED LUBRICANTS GI 4
IIDW

B5W r LIFTING POINTS AND

GI 6
I NISSAN I TOWING
90

I
140

i5 29 t8 7 4 15 27 38
30 201 0 20

Temperature Range Antlclpa1ed Before Next 011 Change Oc OF

40 1601 80 tOOl
NISSAN MOTOR CO LTD

GI 4
I TOKYO JAPAN
r d
f
General InformatIon General Information

MODEL VARIATION IDENTIFICATION NUMBERS

Ii

Model The umt and car numbers are

Engme model TransmiSSion model
at the Car Engine model ChaSSIS number
stamped and regIstered factory
KP6I0GFM The engIne and car IdentificatIOn
LIS FS5W63A 5 speed Sedan
Hardtop numbers are used on legal documents
KP6I OGATM LIS Hardtop LIS P6IO xxxxxx
3N71B 3 speed These numbers are used for factory
Station Wagon
commumcatIon such as Technical
P6lOTM LIS F4W63L 4 speed Warranty Clal1ll Service
Sedan Report
P6I0ATM LIS 3N7IB 3 Journal and other mformatIon
speed
ENGINE SERIAL NUMBER
WP6I0TM LIS F4W63L 4 speed
Station Wagon The engme serIal number IS stamp
CAR IDENTIFICATION
WP6I0ATM LIS 3N71B 3 speed ed on the rIght hand Side of the
PLATE
cylInder block The number IS broken
The car IdentIficatIon plate IS lo down shown
as m the followmg chart
cated at the center of the cowl top to the
accordmg type of the engme
The plate contams the car type engme

The meamng of prefix and suffIX capacity maxl1llum horse power

wheelbase and engme serIal and chaSSIS
Engme model Engme number
W K P 610 G T F A M numbers
LIS LIS xxxxxx SP066

For AustralIa FIg 01 3 Engme serial number

locatIOn
Automatic transmission

5 speed manual transmiSSion and floor sluft

COLOR CODE NUMBER
Floor slnft
1111I1111Ji The color code number label IS

Deluxe specifications
1 I
IIII
stuck
radiator
on the rIght hand Side of the
core
support as shown m the

LIS engine
1
followmg figure
1 I

I
llllllllllliU
Hardtop SP064

Station Wagon FW 01 1 IdentificatIOn plate locatIOn

I CHASSIS NUMBER
FIg 01 4 Color code number label

I The chaSSIS number

the left Side of the cowl

broken down as shown

IS

m
stamped
top and
the follow
on

IS
location

I mg chart accordmg to the type of the

car

1
1
I
I FW 01 2 ChassIS number locatIon
SP065

GI 2 f GI 3
 SECTION GI

GENERAL
DATSUN INFORMATION
MODEL 610 SERIES

pt

MODEL VARIATION GI 2

IDENTIFICATION NUMBERS GI 3

APPROXIMATE REFILL
GI 4
CAPACITY

RECOMMENDED FUEL 61 4

RECOMMENDED LUBRICANTS 61 4

LIFTING POINTS AND

GI 6
I NISSAN I TOWING

NISSAN MOTOR CO LTD

TOKYO JAPAN
 I
J

General Information

MODEL VARIATION

Model Engme model TransnuSSlon model

FSSW63A S
KP6 lOG FM LIS speed
Hardtop
3N71B 3
KP6I OGATM LIS speed

F4W63L 4
P6IOTM LIS speed
Sedan
3N71B 3
P610ATM LIS speed

LIS F4W63L 4speed

WP610TM
Station Wagon
WP610ATM LIS 3N71 B 3 speed

The meanmg of prefix and suffIX

W K P 610 G T F A M

For Austraha

Automatic transmisSion

S speed manual transmission and floor sluft

Floor sluft

Deluxe peclficatlOns

LIS engme

Hardtop
Station Wagon

GI 2
 l

General Information

IDENTIFICATION NUMBERS

The umt and car numbers are

Car EnglOe model ChasSIS number

stamped and regIstered at the factory
The englOe and car 1denl1ficatlOn
Sedan
numbers are used on legal documents
Hardtop LIS P610 xxxxxx
These numbers are used for factory
Stal10n Wagon
commumcatlOn such as Technical
Claim ServJce
Report Warranty
Journal and other lOformatlOn

ENGINE SERIAL NUMBER

The englOe senal number IS stamp

CAR IDENTIFICATION
ed on the fight hand Side of the
PLATE
cyhnder block The number IS broken
down as shownthe follOYlOg chart
10

accord 109 to the type of the engme

Engme model EnglOe number

LIS LIS xxxxxx SP066

r

Fig GI 3 Engme senal number

locatron
t
j

H I

COLOR CODE NUMBER

1

111111 stuck
The color code
the
number label

hand Side of the

1S

on
nght
I
I
radiator core
support as shown ill the
followlOg figure
I
JI IIDI
SP064

Fig GI l Identbeaton plate locatIOn

CHASSIS NUMBER
Fig GI 4 Color code number label
The chassIs number IS
stamped on
loealron
the left side of the cowl top and IS

broken down as shown 10 the follow

the
109 chart accordlOg to the type of
car

SP065

Frg GI2 ChassIS number locatIOn

GI 3

l
 General Information

APPROXIMATE REFILL CAPACITY

LJter us measure
Imp measure

Fuel tank

Sedan and Hardtop 55 14 M gal 12 M gal

Stal10n Wagon 52 13 Y gal II M
gal
Engine cooling system 1 65 6 Ji qt 5 Y qt

Engine crank case 2 43 4 M qt 3 Y qt

Manual transmiSSIOn
4 20
speed 4 Y pt 3 M t

5 speed 17 3
pt 2 U pt

Automatic transmiSSIOn case 3 55 5 Ji qt 4 U qt r

FInal dnve case hOUSIng

Sedan and Hardtop 0 8 1 Y pt I pt
Stal10n Wagon 1 3 2 Y pt 2 Y pt

Steenng gear box 028 pt Mpt

1 Includes 0 5 liter US qt Imp qt for heater

2 Includes 05 liter US qt Imp qt for 011 filter
3 Includes 4 0 liters 4 US qt 3 Imp qt for torque converter

RECOMMENDED FUEL
Use a
proper grade gasoline of above 88 octane ratIng

RECOMMENDED LUBRICANTS

RECOMMENDED SAE VISCOSITY NUMBER

GASOLINE ENGINE OIL
MultI VISCOSIty
30
100 ow O
lOW 2DW40 2QW 50

30
5W 40
5W 1 aN 30 40
lOW

5W20 5WJO 5W

Single VIscosIty 4050

SAE 5W 20 OIls are not

30
recommended for sus1amed
ugh speed dnVlng 20N 20W 20

lOW

75W

BOW

BSW

90

140

35 J8
30 20l 0 120 40 60 SO OlIO
Temperature Range AntiCipated Before Nex1 Od Change oC OF

GI 4
 1
General Information

II
RECOMMENDED LUBRICANTS

Item SpecIfIcatIons Remarks

c
SAE ClasSIfication SD or
biJ Gasohne
Ii c
0
SE MIL L 2104B

Refer to Recommended
TransmiSSion and
API 4 MIL L 2105
GL SAE V ISCOSlty Chart
0 Steenng

Dlfferenllal API GL 5 MIL L 2105B

Automallc TIM Type DEXRON

MultI purpose grease NLGI 2 LIthIUm soap base

DOT 3 FMVSS Federal Motor

Brake and Clutch flUId
F M V S S No 116 Vehtcle Safety Standard

Permanent antifreeze
Antifreeze
Etylene glycol ba

GI 5
 General Information

LIFTING POINTS AND TOWING

4l
PANTOGRAPH JACK
Place the pantograph Jack furnIShed
with the car under the position mdi
cated below In a safe manner

Notes
a Never get under the car while It IS

supported only by the jack

Always use safety stands to support
fmme when you have to get under WH097

the car FIJ1 GI 13 Front supportable pomfs

Fig GIll Lowenng spare tITe
b Block the wheels diagonally by Station Wagon

wheel chocks REAR SIDE

1 When j3ckmg up the rear of the

L II the chocks at the front SIde
GARAGE JACK car place
I of the front wheels to hold them
Note When carrymg out operations 2 Apply the garage Jack under the

with the gamge Jack be sure to differentIal carner all models the

support the car with safety stands suspensIOn ann A Sedan or suspen

sion member B Sedan

3 Jack up the car gently Just high
enough to place the safety stands
Detail Detail FRONT SIDE under the rear suspensIOn member or
WH130
body Sedan or under the rear axle
1 When Jacking up the front of the
FIGI B Jack up pomts case StatIOn Wagon
the chocks behmd the rear
car place the stands at the pOSItIons
Place
wheels to hold them
indicated below
2 the garage Jack under the
Apply 4 Release the J3ck slowly
front suspension member Be sure not
to 11ft up the engine otl pan located

Just behmd the suspensIOn member

3 Jack up the car gently Just Iugh
the
enough to place safety stands
under both the Side members Place
the stands at the posItion md1cated In

Figure GI 12
4 Release the Jack slowly
Fig GI 9 Wheel chocks and nck
Sedan and Hardtop

FIGI 14 Rear Jack up pomts

Sedan and Hardtop

Rear supportable pomts

FIGI 15
10 Jack StatIOn Wagon Sedan and Hardtop
FIGI FIg GI 12 Fronf ock up pomt

GI 6
 General InformatIon

2 Car must be towed for a long

distance over 10 km 6 miles
3 TransmissIOn IS not operatmg
properly

GI072
f
i on
It car IS towed on ItS front wheels

should
the

straight
be
ground
secured
ahead posItIon
the steenng wheel
to mamtam a

WH169

FJg GI I6 Rear supportable pomts FIg GI IB Front towmg hook

StaflOn Wagon Station Wagon

TIE DOWN
The front tIe down hook IS located
as shown m
Figure GI 21

WH193

TOWING FIg GI 19 Rear towmg hook

Sedan and Hardtop
MANUAL TRANSMISSION
MODEL

When the car IS towed forward

connect the rope securely to the hook
G1269
shown m
Figures GI 17 and GI 18
FJg GI 21 Front tie down hook
To tow another car connect a rope
the hook shown GI 19
to m
Figures
and GI 20 There are two rear he down hooks

A towmg rope should not be con on Sedan and Hardtop Each hook IS

nected to any pos1hons than those located as shown m Figure GI 22

descnbed above
FIg GI 20 Rear fow ng hook
Note Do not use the rear hooks as a
Note Do not load Sfatlon Wagon
attempt to apply
towmg hook
to a
rope suddenly to prevent
damage
AUTOMATIC TRANSMISSION
MODEL

The car may be towed safely on ItS

rear wheels on the ground with the
select lever m N Neutral posItIon
of at of less than 30 km h 19
speeds
However the shaft
MPH propeller
must be disconnected or the car must
be towed on ItS front wheels on the
under the condi
ground followmg
WHl68 tIOns GI077

1 Tow speed of more than 30 km h FIg GI 22 Rear tie down hook

FIg GI 17 Front towmg hook
Sedan and Hardtop 19 MPH Sedan and Hardtop

GI 7
 SECTION ET

ENGINE
DATSUN TUNE UP
MODEL 610 SERIES

ENGINE TUNE UP ET 2

SERVICE DATA AND

ET 11
SPECIFICATIONS
TROUBLE DIAGNOSES AND
ET 12
CORRECTIONS

I NISSAN I EMISSION TROUBLE SHOOTING ET 19

NISSAN MOTOR CO LTD

TOKYO JAPAN
r
Engine Tune up

ENGINE TUNE UP

CONTENTS

DESCRIPTION ET 2 CHECKING FUEL LINES

EMISSION CONTROL SYSTEM Hoses piping connections etc ET 6

COMPONENTS ET 2 ADJUSTING CHOKE MECHANISM

BASIC MECHANICAL SYSTEM ET 4 Choke and ET 6
plate linkage
RETIGHTENING CYLINDER HEAD ADJUSTING CARBURETOR IDLE RPM

BOLTS MANIFOLD NUTS AND AND MIXTURE RATIO ET 6

CARBURETOR SECURING NUTS ET 4 LUBRICANT AND COOLING SYSTEMS ET 7

ADJUSTING INTAKE AND EXHAUST REPLACING OIL FILTER ET 7

VALVE CLEARANCES ET 4 CHANGING ENGINE OIL ET 7

CHECKING AND ADJUSTING CHANGING ENGINE COOLANT

DRIVE BELT ET 4 Permanent anti freeze coolant ET 7

IGNITION AND FUEL SYSTEM ET 4 CHECKING FOR COOLANT OIL AND

CHECKING AND REPLACING FUEL LEAKS ET 8

SPARK PLUGS ET 4 EMISSION CONTROL SYSTEM ET 8

CHECKING IGNITION WIRING ET 4 CHECKING AND REPLACING PCV

REPLACING DISTRIBUTOR BREAKER VALVE ET 8

POI NTS ET 5 CHECKING VENTILATION HOSES ET 8

CHECKING VACUUM FITTINGS CHECKING ELECTRIC ADVANCE

HOSES AND CONNECTIONS ET 5 CONTROL SYSTEM ET 8

CHECKING DISTRIBUTOR CAP ROTOR INSPECTING BOOST CONTROLLED

AND CONDENSER ET 5 DECELERATION DEVICE B COD ET 9

CHECKING AND ADJUSTING CHECKING VAPOR LINES

IGNITION TIMING ET 5 Hoses connections etc AND FUEL

REPLACING AIR CLEANER VAPOR CONTROL VALVE ET 9

FILTER V scous type ET 6 CHECKING FUEL TANK VACUUM

REPLACING FUEL FILTER ET 6 RELIEF VALVE ET 10

DESCRIPTION This sectIon descnbes proper mamte SlStS of a spark advance control sys
nance procedures tem a BCD D Boost Controlled
To the engme In top runmng
keep
Deceleration DeVice an
Evaporative
condItIon at all tImes proper mamte
EmiSSIon Control system and a PC V
nance tune up IS More
necessary
PosItive Crankcase VentilatIOn
the engIne be
over It IS Important that EMISSION CONTROL These deVices reduce HC CO and
tuned up In accordance With the
mamtenance schedule
SYSTEM NOx emiSSIOns suffiCiently to meet
The results of
Australia
proper engine mamtenance are among COMPONENTS exhaust emISSion regulations

others rrummum exhaust emissions The emiSSIOn control system con

ET 2
 Engine Tune up

GI287

I Water temperature sWItch

2 hoke heater
Auto

3 Throttle SWItch
4 Flow gUIde valve
5 BC DD
6 PCV valve
7 2 pomt dIstributor

6f
c

I hoke relay
Auto
2 Voltage regnla tor
3 2 pomt relay
4 Horn relay
5 LIght relay

@ Connector for ehoke

auto relay
Connector for voltage regulator
@

l ET 1 Locahol1 of emlSSlOn control components

Fl

ET 3
r
 Tune up
Engine

3 Remove valve rocker cover

BASIC MECHANICAL
Loosen PIvOt lockmg nut and
SYSTEM
turn pivOt screw untIl speCified clear
RETIGHTENING CYLINDER ance IS obtamed whtle engme IS cold
HEAD BOLTS MANIFOLD Usmg semce tool tIghten PIvot
NUTS AND CARBURETOR lockmg nut securely after adjustment
SECURING NUTS and recheck clearance

I Exhaust valve of No I cylmder

2 Intake valve of No I cyhnder
Refer to folloWIng lIghtenmg
the
3 Intake valve of No 2 cylInder
torque speCIficatIOns
5 Exhaust valve of No 3 cylInder

Tightening torque 4 Agam rotate crankshaft one turn tensIOn

FIg ET 4 Drwe belt
so that No 4 pIston IS at top dead
Cylinder head bolts center of Its compreSSIOn stroke Ad
7 0 to 8 5 kg m Just the followmg valves IGNITION AND FUEL
Mamfold nuts
4 Exhaust valve of No 2 cylinder
I 2 to I 6 kg m SYSTEM
6 Intake valve of No 3 cylinder
Carburetor nuts
7 Intake valve ofNo 4 cylinder CHECKING AND REPLACING
o 5 to I 0 kg m
8 Exhaust valve of No 4 cylmder SPARK PLUGS

Notes Remove and clean plugs m a sand

Adjustment should be made whIle
When engme is cold bolts should blast cleaner Inspect eachspark plug
a
engme IS hot
be three steps Make sure that they are of the spec1fi
lightened m two or

m the sequence shown In Figure ed heat range Inspect msulator for

ET 2 cracks or chips Check both center and

starting from center and
electrodes If
workmg out toward ends ground they are exces

b Retighten cyhnder head bolts after Sively worn replace With new
spark
engme has warmed up plugs File center electrode flat

Tlghtemng torque
Spark plug
STl 064000 1 ET009 2 0 to 3 0 kg m

clearance
Fig ET 3 AdJustmg valve

Valve clearance
Umt mm

Intake 020

Cold
Exhaust 025
FIg ET 2 Retwhtenmg cylmder
head bolt
Intake 025
Wann
Fig ET 5 Checkmg spark plug pomt
Exhaust 030
gap

ADJUSTING INTAKE AND

EXHAUST VALVE Spark plug speCifIcatIOns
CLEARANCES CHECKING AND ADJUSTING Heat range BP6ES L4SPW

DRIVE BELT Plug gap 0 8 to 0 9 mm

Valve clearance adjustment cannot

be made whIle engIne IS m operalion I Check for cracks or

damage Re
To adjust proceed as follows place If necessary CHECKING IGNITION
I Start engIne and run It unlll It 2 Adjust dnve belt tension It IS WIRING
reaches operatmg temperature or correct If deflectIOn IS as md1cated m

engIne 011 temperature IS more than chart when thumb pressure of 10 kg IS Distributor breaker points
800C then stop engme apphed mIdway between fan pulley
2 Rotate crankshaft to bnng No I Make sure
they are properly aligned
and alternator pulley
dead center of ItS and that pomt dwell and gap are
cylinder to top
Slackness 8 to 12 mm correct
compressIOn stroke

4
ET
 Engine Tune up

Ignition wiring I Loosen lead wife settmg screws CHECKING DISTRIBUTOR

and remove lead wife from contact CAP ROTOR AND
Use an ohmmeter to check resist
pomt set CONDENSER
ance of secondary cables Disconnect
2 Remove two setscrews on each
cables from spark plugs
pomt set Pomt then be
assembly can
Note This operatIOn should be per
Remove distrIbutor cap and second taken out formed whde checking dIstrIbutor
cables Do not
ary as an assembly 3 Install new contact pomt the
m
pomts Inspect dIstributor cap for
remove cables from cap reverse
sequence of removal cracks and flashover
Check resistance of one cable at a

tIme Connect ohmmeter between Notes External surfaces of all parts jf

spark plug sIde and correspondmg elec Coat heel WIth
a carn a lIght coating secondary system must be cleaned to
trode mSlde cap If reSIStance IS more of grease reduce POSSlblhty of voltage loss All
than 30 000 ohms remove cable from b AdJllSt contact point gap properly wires should be removed from dlstnb
cap and check cable resIstance only If by measunng point gap WIth a utor
cap and cod so that termmals can
resistance IS stIli more than 30 000 feeler galge before setscrews are be and cleaned Burned
ohms mspected or
replace cable assembly hghtened securely corroded termmals mdlcate that WIres
not
are
fully seated whIch causes

Distnbutor pomt gap arcmg between end of WIre and ter

045 to 0 55 mm mmal When replacmg wires m ter
Distnbutor dwell angle mmal make sure that
they are
fully
49 to 55 degrees seated before pushmg rubber mpple
down
rotor for
over tower Check dIStrIbutor
t
damage and dIstrIbutor cap
t
for cracks

6 Spark plug Condenser

Fig f
E wire

I Clean ou tlet of condenser lead

REPLACING DISTRIBUTOR Wife and check for loose setscrew
BREAKER POINTS RetIghten If necessary

2 Check condenser With a con

Check dlstnbutor breaker pomts
denser tester Refer to DistrIbutor m
Re
for abnormal plttmg and wear

service manual for engme

place pomts penodlcally After
re

placmg pomts make sure they are m Frg ET B AdJustmg pomt gap
correct ahgnment for full contact and

that pomt dwell and gap are correct

CHECKING AND ADJUSTING
pean nd apply dtstnbutor grease
to

lobes IGNITION TIMING

cam
CHECKING VACUUM
Note Do not apply excess amount of I Check spark
FITTINGS HOSES AND plugs and distrIbutor
I
grease breaker pomts for conditIon
CONNECTIONS
2 Thoroughly remove dlft and dust
The distrIbutor has two contact CheLk fittmgs and hose for loose from tImmg mark on crank
pulley and
pomts Each ppmt can be replaced onnectlOns RetIghten as necessary tImmg mdlcator on front cover
mdependently Both pomts however replace any faulty parts 3 Warm up engme suffiCiently
are usually replaced at the same tIme
4 Install No
a
tImmg hght on I
and mstall
cylinder spark plug
I Wife a

tachometer
II I

5 Set to the
I IdlIng speed follOWIng
speCificatIOns
6 WIth tImmg I1ght check that
a

19mtIOn tImmg IS at the speCified

value

I Note There are two 19mhon timmgs

Retard and Advance The igm
ET270
hon should be
tmung adjustment
Fig ET 9 Connectmg vacuum passnge
lmes earned out on the Retard side

ET 5
r
 Engine Tune up

IndIca tor element at recommended 2 Before

IlIng
Tl
Replace startmg
engme depress
mtervals or more often under dusty the accelerator pedal to see If choke
dnvmg condtlions valve closes automatically
If It fails to close probable cause IS
Top dead center mark that lmk movement IS unsmooth or
REPLACING FUEL
that b1 metal IS out of order Refer to
Fig ET 10 Checking Ignition trmlng FILTER Automatic choke m Seclion EF

Check for a con tam mated element

IgmtlOn tUllIng and water depOSIt

All engmes use a fuel
cartndge type
M T A T f11ter replaceable ADJUSTING CARBURETOR
as an
assembly
The IDLE RPM AND MIXTURE
fuel f11ter IS located m the
60 800 RATIO
Tlmmg engIne compartment
BTDC rpm
700
60 N POSI
tion Idle adjustment IS made by throttle

adJusling screw and Idle adJustmg

IgmtlOn tlmmg IS on Retard side after engme warmed up
screw IS See
Figure ET 13
If necessary follows
adjust It as

I Loosen setscrew until d1stnbutor

be moved hand See
can
by Figure
ET 11

2 Adjust Igml10n tlmmg to the

followmg specificatIOns
3 Lock dlstnbutor setscrew and
make sure that tlmmg IS correct

ETOll 1

FIIf ET 12 Fuel filter ET274 1 Idle adjusting screw

2 Throttle adjustIng screw

Fl ET 13 Throttle and die

l
adjusting screws
CHECKING FUEL LINES
Hoses piping
With CO meter
connections etc
CO meter IS very useful tool for Idle
Inspect fuel hnes for loose connec
mIXture When prepanng
tlOns cracks and detenoratlOn Re adjustment
to adjust HIIe mIxture It IS essentIal
tighten loose connections and replace
that meter be thoroughly warmed and
any damaged or deformed parts
cahbrated
I Warm up engme and
suffiCiently
I
ET356 apply wheel chocks
ADJUSTING CHOKE 2 Contmue engme opera lion for
Frg ET 11 Adjusting IIfnltlOn tIming
MECHANISM one mmute at Idling speed
Choke plate and linkage 3 Adjust throttle adJustmg screw so
REPLACING AIR CLEANER
that engIne speed IS at the speCIfied
FILTER Viscous type Check choke valve and mechamsm
value hsted below
for free operation and clean or replace
AIr cleaner wet paper
employs a
If necessary Bmdmg can result from
type cleaner element VISCOUS type
petroleum gum formation on choke TransmiSSion AdJustmg value
As this element has been specially
shaft or from damage model rpm
treated at factory It need not be
cleaned before ultimate replacement I Check b1 metal cover settmg In
M T 700
Even If cleaner element should look dex mark on bl metal cover IS usually
set at center ofscale
dIrty do not attempt to clean It AfT 800 In N pOSllion
Cleamng performance IS constantly
mamtamed even though It looks con Note When somewhat over choked
tammated Care must be taken not to turn b1 metal cover clockWISe slight 4 Check JgmtlOn and If necessary

damage cleaner element ly adjust t to specIficatIOns

ET 6
 Engine Tune up

5 Adjust Idle adJustmg screw so

jushng screw down completely b 011 With extremely low viscosity
that CO
percentage IS at the specifi Domg so could cause damage to hp mdtcates dilutIon With gasohne
ed value check with CO meter whtch m turn Will tend to cause c Make sure that car is on a level
malfunctions surface wbile engme is bemg dram
Note On automahc transmission e
b On automatic transmiSSIOn models ed filled and checked

models make sure that

qUipped adjustment should be made 10 N
made With selector 2 Check 011 level If below
adjustment IS
posItIon speCIfied
level up to H level
N raise It
lever m posItion
TABLE II FINAL ENGINE
IDLING SPEED
CO 2 0 iO 5 Engine oil capacity
011 filter 4 9 hters
M T A T Includmg
6 Repeat procedures descnbed m

3 and 5 until CO 800

Items above
Idle speed rpm 700 N
percentage and engine speed are both In
at the value posItIOn
specified CHANGING ENGINE
COOLANT
Do not
Note attempt to screw down LUBRICANT AND
I Idle adJustmg screw completely
COOLING SYSTEMS
Permanent anti freeze
coolant
nus may cause damage to tip
which m turn Will tend to cause Permanent antI freeze coolant IS an
REPLACING OIL FILTER
malfunchons ethylene glycolbase product contam
The 011 filter and
IS a
cartndge type
mg chenllcal mhlbltors to protect the
can be removed WIth Oil Filter Wrench
coohng system from rustIng and cor
STl9320000
Without CO meter roslOn The an 11 freeze does not con
I Check for 011 leaks gasket
past
tam any glycenne ethyl or
methyl
Warm up engme completely flange If leakage JS found
retIghten alcohol It Will not evaporate or bod
Check to be that float level
stop leakage If re
sure
Just enough to
away and can be used With ellher hIgh
and correct while
IgmtlOn hmmg are
tlghterung IS no longer effectIve re low
or tempera ture thermostat It
at Idle speed
engme IS
place filter as an assembly flows transfers heat
2 When mstalhng 011 filter tIghten
freely effiCiently
2 Turn out throttle
adjustIng screw and Will not clog the passages m the
by hand
gently untll speCified engme speed IS The anti freeze must
coohng system
approximately obtamed be mixed With other
Notes not products
od filter od Tins coolant be used throughout
a Do not overtighten or can

TABLE I leak may occur the seasons of the year

SPECIFIED ENGINE
b When assembhng oil Whenever coolant IS
IDLING SPEED hghtly apply changed the

to seal nng coohng system should be flushed and

M T 750 refilled wIth a new coolant Check the

d
c
level See the mslruclJons attached to
A T N
850 In poslhon the anlJ freeze as to the ratIo of an

antI freeze and waler

3 Turn Idle adjustIng screw m or

out until engme runs smoothly at the

Oc
Inghest speed
4 Turn out throttle STl9320000 o
adJustmg screw
until speCified engme speed table I IS EL015 10
obtamed
5 Readjust Idle adJust 109 screw FIg ET 14 RemOVing 011 liter
20 I
untll engine runs smoothly at the I

I
With the Inghest vacu 30
highest speed CHANGING ENGINE OIL I

um readmg
I
40
6 Repeat steps 4 and 5 until engme Check If od
I
IS diluted With water I
speed does not nse 10 spite of adjust 50
or gasohne Dram and refill 011 If
109 Idle adJustmg screw 30 40 50
necessary
7 Fmally turn Idle adJustmg screw EGOOl

10 unhl the final specmed engme speed

Notes Fill ET 15 Protection concentratIon
table II IS attamed
a MlIky oil mdicates presence of

Notes coobng water Isolate cause and Water refill capacity

a Do not attempt to screw idle ad take corrective measure With heater 68 hters

ET7
i
l
 Engine Tune up

BollIng pomt

Percent concentratIOn Freeze protection

09 kg cm2
Sea level coolmg
system pressure

30 1060C l240C 15OC

50 1090C l270C 35OC

CHECKING FOR COOLANT CHECKING VENTILATION

OIL AND FUEL LEAKS HOSES

Check coolant hoses and fittIngs for I Check hoses and hose connec
Fig ET 18 DlSconnectmg water
loose connectIOn or detenoratlOn lions for leaks temperature lead wire

Relighten or
replace If necessary 2 Disconnect all hoses and clean
Check cylInder head front cham With compressed air

over 011 pan rocker cover 011 filter I f any hose cannot be freed of 3 After engme warms up discon
gasket etc for SignS of leaks past their obstructIOns replace nect a paIr of throttle SWitch lead
surfaces Ifnecessary replace Be sure that flame arrester
gasketed IS pro WIres located beside carburetor Check
gaskets or faulty parts After mamte perly Inserted hose between
Igmtlon timIng change when harness
In aIr

has been done check cleaner and rocker

nance
replaced cover SIde termInals for throttle SWitch are

parts to see If any leaks occur connected to each other

Check carburetor fuel pump fuel It IS correct If Igmtlon timIng ad
filterand fuel lInes for leaks loose vances about 6 degrees
conneclions cracks or detenoratlOn

Relighten loose connections and re

place any damaged or deformed parts

EMISSION CONTROL
SYSTEM

CHECKING AND REPLACING

P C V VALVE

Check PC V valve as follows

With engine runmng at Idle remove

ventilator hose from PC V valve If

valve IS workmg properly a
InSSIng Fig ET 19 Throttle SWItch lead
nOise wIll be heard as aIr passes wire

through It and a strong vacuum should E T277

be felt Immediately when a finger IS
FIjf ET 17 Cleanmg ventllahon hose
placed over valve Inlet
4 If any malfunction IS found by
the check mentIOned above any of the

followmg may be the cause

CHECKING ELECTRIC
Loose connectIOn broken har
ADVANCE CONTROL SYSTEM 1 or

ness

I Start and check Igmtlon 2 throttle SWitch

engine Malfunctlomng
limmg change WIth a timIng scope 3 Malfunctlomng water tempera
before engme warms up ture SWitch
2 Disconnect lead of water 4
WIre
MalfunctionIng water tempera
temperature SWItch at connector ture relay
It If Igmtlon timIng ad 5
correct 2 pOlnt type dls
IS
MalfunctIOnIng
ET330 vances about 6 degrees Then recon tnbutor
FIg ET 16 CheckIng P C V valve nect lead wire to Its ongInal pOSItion Refer to EmISSIOn Control Seclion

8
ET
 Engine Tune up

mamfold In this case the must be

INSPECTING BOOST At thIS time vacuum pres engine
labored I road test
CONTROLLED sure wIll mcrease abruptly to 600 by or 2

mmHg aprox or above and then chassis dynamometer acceleratmg

DECELERATION DEVICE
decrease to level set at Idling the car to 60 to 80 km h m top
B C D D gradually
manual transmission
In decreasmg the mamfold vacuum gear or m

Check BCD 0 operatmg pressure WIll mamtam a constant pressure for a D position automatic transmis
If not correct and then
adjust It whIle That ISthe operating pressure sion releasing the ac
To properly set the BCD Doper 6 Check that the BCD Doper celerator pedal and
letting the car
atmg pressure proceed as follows atmg pressure IS the speCified value decelerate After doing this check
I Connect vacuum gauge to mtake whether the BCD D operating
mamfold A plug IS mstalled on BCD 0 set pressure pressure IS at the predetermined
servIce

mtake mamfold so remove plug and 560 llO

mmHg mmHg value or not
mstall adapter for vacuum gauge

Charactenstlc curve IS same as that

for throttle opener
Note A qUIck response boost gauge
such as Bourdon s tube is recom 7 If IthIgher than the set
IS level

mended Do not use manometer turn adJustmg screw clockwise until

correct adjustment IS made

If It IS lower than the set level turn

adJustmg screw counterclockwise 1 Road test

C
L

ET285

FIf ET 22 Road test

ET286

CHECKING VAPOR LINES

Hoses Connections etc

AND FUEL VAPOR

CONTROL VALVE

Checking fuel tank

Frg ET 20 Connecting vacuum gauge
fuel liquid separator and
1 AdJu5ung crew S CD
2 Cover c vapor vent line
2 Start engme and contmue
ET037
warmmg up until engIne reaches Its
I Check all hoses and fuel tank
normal operating temperature Fig ET 21 Adjusting set
fIller cap
preBBure
3 Check IgmtlOn tlmmg and Idling 2 Disconnect the vapor vent line
speed connectmg flow gUide valve to fuel
8 Race engIne and check that ad
liqUid separator
Justment IS correct
3 way
3 Connect a connector a
M T NT
manometer and a cock or an
Engme Idling eqUIv
rpm Ummg 800 UN Note alent 3 way change cock to the end of
7oo 60 When the operating pressure
BTDC the vent lme
posltlon 60 can not be observed clearly It is
necessary to reduce the negative
4 Supply fresh au mto the vapor

vent lme through the cock little by

4 Place gearshift lever m Neutral idling pressure of the mamfold to
lower than the set pressure of the little until the pressure becomes 400
for manual transmisSIOn and m N
BCD D The engine speed will not mmAq
or P posItion for automatIc trans
when the 5 Shut the cock completely and
mJSSlOn drop idling
to speed
leave It that way
5 Run engIne under no load In negative idling pressure is higher
than the set of the 6 After 2 5 mmutes measure the
creaseengIne rpm to 3 000 to 3 500 pressure
B C D D height of the liqUId m the manometer
rpm then qUickly close throttle valve

ET 9
 Engine Tune up

should remam hose

7 VanatlOn 10 height Irolll
dJr LIt lIlt r

wltlun 25 mmAq
Note In case the vent line IS stuffy
8 When the filler cap does not close
I full
should drop to the breathing in fUll tank IS not rom t JIll
completely the height
thus causmg 10
zero 10 a short lime thoroughly made
If the does not drop to sufficient delivery of fuel to engIne
9 heIght
zero 10 a short lime when the filler cap or vapor lock It must therefore be
10
mf
IS removed It IS the cause of the stuffy repaued or replaced u cast

400 mmAq EC030

Frg ET 24 Flow gUide valve

I uelhqUld CHECKING FUEL TANK

separator
VACUUM RELIEF VALVE

Remove fuel filler cap and see It

funcllons properly as follows

I Wipe clean valve housmg and have
It 10 your mouth
2 Inhale A reSIStance ac
au
shght
compamed by valve mdlcates that
ET341

control system valve IS 10 good mechamcal condItIOn

Fig ET 23 Checkmg evaporatIVe emISSIon

Note also that by further mhalmg au

the resistance should be disappeared
With valve chcks

3 If valve seems to be clogged or If

no resistance IS felt replace cap as an
assembled umt

Checking flow guide valve case side It should never flow to the
other two vent hnes
I Disconnect all hoses connected to
3 While the mto the
the flow gUide valve
an IS pressed
2 While lower pressure flow gUide valve from the carburetor
an IS pressed
the flow valve from the
au cleaner side It flows to the fuel
mto gUide
ends of vent hne of fuel tank side the tank side and or crankcase side
the valve and 4 ThJS valve opens when the lOner
au should go through
IS 10 mmHg In case of
flow to crankcase side If the au does pressure EF 132
Pressure rehef vdlve
not flow the valve should be replaced Improper operatIOns or
breakage re

But when the au IS blown from crank place It Fig ET 25 Fuel fIller cap

ET 10
 Engine Tune up

SERVICE DATA AND SPECIFICATIONS

Basic mechanical system

Valve clearance

Cold Intake mm 020

Exhaust mm 025

Hot Intake mm 025

Exhaust mm 030

8 to 12
Dnve belt tensIOn mm

Tigh temng torque

bolts 7 0 to 8 5
CylInder head kg m
12 to I 6
Mamfold nuts kg m

Carburetor nuts kg m 05 to I 0

2 0 to 3 0
Spark plugs kg m
011
Engme capacity
Maximum lIters 44
H
Mlmmum L hters 34

system capacity with heater hters 68

Coolmg

Engme compressIOn pressure at rpm

Standard kg cm2 rpm 12 0 350

Mmunum kg cm2jrpm 9 0 350

Ignition and fuel system

IgmtlOn and Idle adjustment degree rpm

T 60 B TD C 700 Retard side

M
A T 60 B T DC 800 Retard side
Retard side N posJtIon

Dlstnbutor

Pomt gap mm 045 to 0 55

Dwell 49 to 55
angle degree
Condenser capacIty lF
J o 05 Retard sIde

o 22 Advance Side

Condenser insulation resistance Mn 5

mm o 8 to 0 9
Spark plug gap
CO percentage at Idle speed rpm

M T 2 0 700
5

A T 2 0 5 800 In N positIOn

ofBCD D mmHg 550 to 570

Operating pressure

ET 11
 Engine Tune up

TROUBLE DIAGNOSES AND CORRECTIONS

CondItIon Probable cause Corrective action

CANNOT CRANK Improper grade 011 Replace with proper grade 011
ENGINE OR SLOW
DIscharged battery Charge
CRANKING
Faulty battery Replace
Malfunction m charge system Inspect
Wmng connectIOn loose In
startIng CirCUIt Correct

Faulty Igml10n sWItch Repair or replace

Faulty starter motor Repair or replace

Trouble shootIng procedure on startIng CirCUIt

SWItch on startmg motor wIth hghts ON

When hghts go off or dIm consIderably

a Check battery
b Check connection and cable
c Check starter motor

When hghts stay bnght

a Check wmng connection between battery and starter
motor
b Check Igmtlon sWItch
c Check starter motor

ENGINE WILL CRANK NORMALLY BUT WILL NOT START

In thIS case the folloWIng may be the source of the problem In most cases the trouble hes In
19mtlon system or fuel
system

Trouble In Ignlllon system

Trouble In fuel system
Valve mechanism does not work properly

Low compressIOn

Trouble shoo ling procedure

FIrSt check spark plug as follows

DIsconnect ugh tensIOn cable from one
spark plug and hold It
about 10 mm from engIne metal part and crank engine

Good spark occurs

a Check spark plug

b Check Igmtlon timIng
c Check fuel system
d Check cyhnder compressIOn
No spark occurs Check current flow In pnmary CirCUit

Very ugh current Inspect pnmary CirCUit for short

Check breaker pOInt operation

ET 12
 Engine Tune up

CondItIon Probable cause Corrective action

Low or no current Check for loose terminal or dISconnectIOn 10

pnmary CUCUlt
Check for burned pOints

Ignition system out of Burned d1stnbutor pomt Repau or replace

order
Improper pomt gap Adjust
Faulty condenser Replace
Leak at rotor cap and rotor Clean or replace
Faulty spark plug Clean adjust plug gap or replace
Improper 19mtIon timmg Adjust
Faulty 19mtlOn coil Replace
Disconnection of ugh tension cable Replace
Loose connectIOn or disconnectIOn 10 Repau or replace
pnmary CUCUlt

Fuel system out of Lack of fuel Supply

order
Duty fuel strainer Replace
Duty or clogged fuel pipe Clean

Fuel pump will not work properly Repau or replace

Carburetor choke will not work properly Check and adjust
Improper adjustment offloat level Correct

Improper Idling Adjust

Duty or clogged carburetor Disassemble and clean

Clogged fuel tank breather pipe Repau and clean

Malfunctlomng antI dleseltng solenOId valve Check for loose term mal or wue harness

Low compreSSIon Incorrect spark plug tIghtemng or faulty to normal

Tighten torque or
replace gasket
gasket
Improper grade or low VISCOSIty engme oil Replace With proper grade oil

Incorrect valve clearance Adjust

CompressIOn leak from valve seat Remove cylinder head and lap valves

StIcky valve stem Correct or replace valve and valve guide

Weak or damaged valve spnngs Replace
CompressIOn leak at cyltnder head gasket Replace gasket
Stlckmg or
damaged pISton nng Replace
Worn piston nng or cyltnder Overhaul engine

Trouble shooting proced ure

Pour engine oil mto plug hole and then measure cyltnder
compressIOn
CompressIon mcreases MalfunctIomng cylinder or piston nng
CompressIOn does not change CompressIOn leaks from valve cyhnder head
or head
gasket

ET 13
 Engine Tune up

Cond111on Probable cause Correcl1ve action

IMPROPER ENGINE
IDLING

Fuel system out of Clogged or damaged carburetor Jets Clean or replace

order Incorrect Idle adjustment Adjust
Clogged aIr cleaner f1lter Replace element

Damaged mamfold gaskets or carburetor Replace gasket or Ulsulator

msulator

Improper float level adjustment Adjust

Loose air hoses or carburetor air fuel mIX Check for loose connectIOns
ture hoses

Malfunctlomng carburetor choke Check and adjust

Low compressIon PreVIously mentIoned

Others Incorrect valve clearance Adjust

Extremely low rpm Adjust
MalfunctIon m
IgmtlOn system spark plug Replace
high tensIOn cable breaker pomt IgmtIon
cOli etc

Incorrect baSIC IgmtIon tlmmg Adjust

MalfunctIon m choke valve or linkage Adjust
Incorrect Idle adjustment Idle
Adjust speed
Clogged aIr cleaner fIlter Replace
Loose mamfold and head bolts
cylinder Retighten

High engine Idle Dragged accelerator linkage Check and correct accelerator linkage

speed Incorrect Idle adjustment Adjust Idle speed

MalfunctIon of BCD D system or throttle Check for loose vacuum hose and harness
connectIons
opener
Adjust or replace If necessary

ET 14
 Engine Tune up

Cond1IIon Probable cause Corrective action

ENGINE POWER NOT

UP TO NORMAL

Low compression PreVIOusly menlIoned

Igmtlon system out of Incorrect IgmtIon tImmg Adjust

order
Damaged spark plugs Clean adjust or replace plugs
Worn d1stnbutor pomts Dress or replace pomts Also check con

denser

MalfunctIOn 10 eJectnc advance control Check and correct

system

Fuel system out of MalfunctIOn m choke system Adjust

order
Clogged fuel pIpe or
Iloatmg valve Clean

Duty or
clogged fuel stramer Replace
Fuel pump WIll not work properly Repau or replace
Clogged carburetor Jets Disassemble and clean

AU mtake cleaner element

system out Clogged au Replace
oforder mamfold
Au suckmg around gasket or car Replace gasket
buretor gasket

Overheatmg Insufficient coolant Refill

Worn or oiled fan belt Replace

InoperalIve thermostat Replace
Worn water pump Replace
Clogged or leaky radIator Flush repau or replace

Worn radIator fIller cap Replace

Air system RelIghten each part of coolmg system
m
coolIng
Incorrect IgmlIon tImmg Adjust
carburetor lean Overhaul carburetor
Clogged mixture

Overcooling Inoperative thermostat Replace

With specified octane fuel

Others Improper octane fuel Replace
lIre pressure Inllate to specIfied pressure
Improper
Draggmg brake Adjust
Clutch slIppmg Adjust

ET 15
 Engine Tune up

Probable cause Correchve action

Condlhon

NOISY ENGINE

Car knodung Overloaded engme Use proper gear m dnvmg

Carbon knockIng Disassemble cylinder head and remove

carbon

TImIng knockIng Adjust 19mhon tImUlg

Fuel Use speCIfied octane fuel
knockIng
PreIgmtIon mIsuse of spark plug Use speCIfied spark plug

Mecharucal knockIng Crankshaft beanng

Crankshaft bearIng This strong dull nOIse Increases when engme ThiS IS caused
by worn or damaged beanngs
knockIng IS accelerated To locate the place cause a or an unevenly worn crankshaft Replace
mlSfrre on each cylInder
stops as a If nOIse beanngs and adjust or change crankshaft
result of the misfire thIS cyhnder generates Check lubncatlon system
the nOIse

ConnectIng rod ThIS IS a httle hIgher pItched nOIse than the Same as m the case of crankshaft bearmgs
beanng knockIng crankshaft knock 109 and also Increases

when engme IS accelerated Cause a mIsfire

on each cyhnder and If the nOIse dlm1mshes
almost completely thIS crankshaft beanng

generates the nOIse

Piston and When you hear an overlappmg metalhc nOise Tlus may cause abnormal weanng of cyl
cyhnder
nOIse wluch Increases m magmtude With engme mder and lower compreSSIOn which m turn

rpm and which decreases as engine IS Will cause lower output power and excessive

warmed up thIS nOIse IS caused by pIston 011 consumptIOn

and To locate the
cyhnder place cause a
mlSfue on each cylinder Overhaul engme

IS heard at top and bottom dead ThIS may or

PIston pIn nOIse ThIS nOIse cause wear on pISton pm piston
ends of piston To locate the place cause a pm hole
mIsfire on each cyhnder Replace pIston and pIston pm assembly

Water pump nOIse This nOIse may be caused by worn or Replace water pump

damaged beanngs or
by the uneven surface
of slidmg parts

Others Improper adjustment of valve clearance Adjust

tensIOn ofcham
NOIse from tImmg cham Adjust
bear
ExceSSive end play on crankshaft Disassemble engme and replace maIn

mg

Note ThIS nOIse wIll be heared when clutch

is dIsengaged

and dnve shaft

Wear on dut h pIlot bushmg Replace bushmg adjust

Note TIus noise WIll be heard when clutch

is disengaged

ET16
 Engine Tune up

CondlllOn Probable cause Corrective action

ABNORMAL
COMBUSTION
backfife afterfire
run on etc

Improper Jgmtlon Improper IgmtlOn lImmg Adjust IgmtlOn lImmg

tlmmg
Improper heat range of spark plugs Use s pec1fied spark plugs

Fuel out of
system Damaged carburetor or mamfold gasket Replace them wIth new parts
order BackfIre afterflfe
Clogged carburetor Jet Disassemble carburetor and check It

Malfuncllonmg float
Adjust lever and check needle valve
Uneven Idling Run on
Adjust
MalfunctIOn of anll d1esehng solenOId valve Check or replace
MalfunctIOn of automallc choke
Adjust

Faulty cylinder head Improperly adjusted valve clearance

Adjust
Excess carbon m combustIOn chamber Remove head and get nd of carbon
valve spnng
Damaged Backfire afterfire Replace

EXCESSIVE OIL
CONSUMPTION

011 leakage Loose 011 dram plug Tighten It

I

Loose or
damaged 011 pan gasket Replace gasket or tighten It

Loose or
damaged cham cover gasket Replace gasket or
Ighten It
r t l J

Worn OIl seal m front and rear of crankshaft Replace 011 seal

Loo or
damaged rocker cover
gasket Replace gasket or tighten It but not too
much

of 011 fIlter
Improper lIghtemng Replace gasket and lighten It to proper
I

torque
Loose or damaged 011 pressure SWItch Replace 011 pressure SWItch or
tighten It

ET 17
 Engine Tune up

Condll1on Probable cause Corrective action

E cesslve ot Cyhnder and piston wear Overhaul cyhnder and replace piston
consumption Remount
Improper location of piston rmg gap or piston nngs
reversely assembled piston nng
Damaged pIston nngs Replace nngs

RepaIr or replace piston and cylmder

Worn pIston nng groove and nng Replace piston and piston nng

Fal1gue ofvalve 011 seal IIp Replace seal IIp

Worn valve stem valve
Replace or
gUIde

Others Inadequate engine 011 qualIty Use deslgna ted 011

overheats mentIOned
Engine PrevIOusly

POOR FUEL
ECONOMY

See explanation for

power loss

Others Too lugh IdlIng rpm AdJust It to deSIgnated rpm

Inoperal1ve acceleratIOn recovery Adjust It

Fuel leakage RepaIr or tighten fuel pIpe connections

PROBLEM IN
OTHER AREAS

Reduced ot pressure Inadequate OIl qualIty Use deSIgnated 011

OverheatIng PrevIOusly mentioned

Worn 011 pump regulator valve Disassemble 011 pump and repaIr or replace
It

Funcl10nal detenoratlOn of 011 pump RepaIr or replace

Blocked 011 fil ter Replace It

Increased clearance DIsassemble and WIth

In vanous
slIdIng parts replace worn parts
new ones

Blocked 011 straIner Clean It

Inoperal1ve 011 gauge pressure sWItch Replace

Excessive wear on 011 pressure decreases PrevIOusly mentIOned

slIdmg parts Improper qualIty or contamInation of 011 Exchange 011 for proper one and change
element

Damaged aIr cleaner Change element

OverheatIng or overcoolIng PreVIously mentioned

Improper fuel mIxture Check fuel system

Scuffing of shdmg Reduced 011 pressure PrevIOusly men tlOned

parts InsuffiCient clearances clearances

Readjust to deSignated
OverheatIng PrevIOusly mentioned

Improper fuel mIXture Check fuel system

ET 18
 Engine Tune up

EMISSION TROUBLE SHOOTING

EXCESS HC OR CO EMISSION IN EXHAUST GASES

On recelvmg malfunctionIng car check exhaust gas Note Each time a

problem is located make the
concentration and engme runnIng condition and necessary repaIrS orreplacement and then check
record resul ts the CO and HC concentration When the con

centration is down to the prescribed level and the

the work
engme IS stili runmng in good condition
can be considered as being completed
Check air cleaner for cloggmg
Check float level
Check carburetor for cloggmg

Adjust IgnItion tlmmg and Idle CO

Check IgnItion spark

Check dlstnbutor pomt

Good No good Check IgnItIOn coil
Check spark plug wires

Check spark plugs

Check emiSSIOn control system
BCDD
Electnc advance control system

Good No good
Refer to EmiSSion Control System SectIOn

Check mtake manIfold for leakage

Good No good
RepaIr

Others
Is clutch slippmg
Any overcooling
Any overheatmg
Is runnIng resIstance excessive

Is tire pressure proper

Is proper gasoline used
Is CO and HC measured by correct methods

ET 19
 Engine Tune up

MAIN CAUSES FOR EXCESS CO HC AND NOx IN EXHAUST GASES

Clogged P C V valve
Au cleaner
Improper au fuel
Carburetor
mixture
Fuel filter clogged
Intake mamfold leakage

Spark plug
Spark plug Wire
Trouble m IgIlIlIon Dls1nbutor
system Igmtlon COli
Wmng harness

Spark plug leakage

Valve clearance
InsufficIent com
Blown cylinder head gaske t
pressIon PISton ring
Engme and other parts Cyhnder

Overcooled Thermostat

Radiator
Fan belt
Engme 011
Radiator hose
Insufficient coohng
Thermostat
Fan
Water pump
Cyhnder head and gasket

Excess CO or HC Brakes
ExcesSIve runnIng
emiSSIon
reSIstance Load

BCD D se t pressure
Troublc 10 BCD D
Vacuum control solenOid valve
system
Speed SWItch MIT
InhIbItor SWItch A IT

Trouble 1n automatic
Check proper functIOn
choke system

EmISSIon control sys tern rcv lIne

OIl filler cap
Cylmder head cover

011 pan
VentIlation hose

Water temperature swItch

Trouble In electriC Relay
advance control system DIStributor WIrIng and pIpIng
Emission control system

Throttle SWitch

NOx
Exce
emISSIon

Improper IgmtlOn D1stnbutor

EngIne Igmllon system
tlm10g Breaker pomt gap

ET 20
 SECTION EM

ENGINE
DATSUN MECHANICAL
MODEL 610 SERIES

GENERAL DESCRIPTION EM 2

ENGINE DISASSEMBLY EM 4

INSPECTION AND REPAIR EM 7

ENGINE ASSEMBLY EM 2o

SERVICE DATA AND

EM 26
SPECIFICATIONS

TROUBLE DIAGNOSES AND

EM 33
I NISSAN I CORRECTIONS

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Engine Mechanical

GENERAL DESCRIPTION

CONTENTS

MODEL L1S ENGINE EM 2 CAMSHAFT EM 3

CYLINDER BLOCK EM 3 VALVE MECHANISM EM 3

CRANKSHAFT EM 3 CAMSHAFT DRIVE EM 3

PISTON AND CONNECTING ROD EM 3 MANIFOLDS EM 3

CYLINDER HEAD EM 3

MODEL LI8 balanced 5 beanng crankshaft to turn CYLINDER BLOCK

out smooth dependable power
ENGINE The cylinder block a monoblock
The cylinder block IS cast as a smgle

The LI8 engine features 0 H C UnIt and features deep skutIng Tlus specIal castIng employs a
structure

valves combuslion five beanng support system for qUiet

wedge shaped engme IS eqUipped wIth a sIngle 2
chamber ness and hIgher durability
a1ummum head and a
fully barrel downdraft carburetor
The cylinder bores are surrounded
by cooling Jackets and machIned di
rectly In the block The 011 ways m the
block are arranged so that the full flow
011 filter JS duectly attached to the

nght hand Side of the block

FIg EM 2 Cylmder block

EM595

FlfJ EM 1 Cross sectIOnal vIew

Main specifications

LI8

DIsplacement cc cu In 1 770 108 CRANKSHAFT

The crankshaft IS a specIal steel
85 78
Bore x stroke mm In
x
forgIng Fully balanced It turns out
3 35 x 3 07 smooth dependable power at high

speed
CompressIOn raho 85 The LI8 engme uses eight balance

weights
MaIn beanngs are lubncated by 011
M T 6 700
pumped through the mam 011 gallery
IgnItIon hmIng
and the 011 holes which run m parallel
Degree B T DC rpm 6 800
A T WIth cylinder bores There are Ollways
N
m posllion dnlled m the crankshaft for the lubn

caling 011 The center mam beanng IS

MT Manual TransmissIOn AfT Automahc TransmissIOn
eqUipped WIth thrust washers to take
Igmlion limmg IS on Retard Side up end thrust of the crankshaft

EM 2
 Engine Mechanical

CAMSHAFT CAMSHAFT DRIVE

The camshaft made of
IS a
special The camshaft IS drIvenby a double
cast lion and IS located mS1de the roller chaIn dnven
row
by the crank
rocker cover Four alummum alloy shaft The tensIOn of the cham IS
brackets support It Camshaft beanngs controlled by a cham tenslOner whIch
are lubrIcated from 011 holes which IS operated by
spnng and 011 pressure
lead to the 011 of the
mam
gallery The rubber shoe type tenslOner damps
Fzg EM 3 Crankshaft cylInder head VibratIOn of the cham and controls ItS
Concentnc passages are drIlled m tension
the front and rear
parts of the cam

shaft
011 each lobe
to cam IS supplIed
PISTON AND 011 hole drIlled the base
through an m

CONNECTING ROD CIrcle of each lobe LubrIcant IS

sup
plIed to the front 011 gallery from the
The pistons are of a speCial alumi
2nd camshaft and to the
num
casting and have stru ts to control bearIng rear

thermal expanSion two compressIOn 011 gallery from the 3rd camshaft

rIngs and one combmed 011 rIng The bearIng These holes on the base cude
of the lobe supply lubncant to the
piston heads are slightly dIshed The
piston pms are a special hollow steel
cam
pad surface ofthe rocker arm and
to the valve end The cams feature
shaft They are full floatIng fit to the tip
and press fit to the a overlap
long profile to reduce NOx
piston connectmg
emiSSIOn
rods

The rods of a
connecting are
special
steel 011 the
forged IS sprayed to
rod small ends
connectmg through EM537
drIlled passages m the large ends of
FIg EM B Chain drIVing system
rod 011 holes m the connectmg rods
are located so as to msure optimum
lubrIcatIOn under heavy load EMOB2

FIg EM 6 Camshaft

@Dm
O
tt
@ VALVE MECHANISM MANIFOLDS
EMOBO
o The valve system has the pivot type The mtake mamfold
EM 4 P ston and connecting rod IS of an alumI
FIg rocker arms that are actIvated duectIy num cast alloy
by the cam mecharusm thiS has made
ItS The exhaust mamfold IS of a dual
movmg parts conSiderably lIghter
and proVides deSIgn The exhaust pIpe IS connected
Ideallugh speed perform
ance to the flanged surface of the exhaust

CYLINDER HEAD Dual type valve spnngs are m

mamfold

The head of stalled

cylInder IS made a

lIght strong alummum alloy With good

coolIng effiCiency It con tams
wedge
type combustIOn chambers
i G f

iii
Exhaust
f
Intake EM084
EMOB6

FIg EM 9 Intake and exhaust

FIg EM 5 Cylinder head FIg EM 7 Valve mechanIsm manIfolds

EM 3
 Engine Mechanical

ENGINE DISASSEMBLY

CONTENTS

PISTONS Ar m CONNECTING RODS EM 6

PRELIMINARY CLEANING AND
HEAD EM 6
4
EM CYLINDER
INSPECTION
DISASSEMBL Y 4
EM

PRELIMINARY
CLEANING AND 3 Remove 011 filter usmg specIal 9 Remove rocker cover

INSPECTION tool OIl Filter Wrench STI 9320000 10 Remove carburetor

II Remove 1I1take and exhaust

4 Rcmovc OIl pressure SWitch
Before dl a sembhng engme
5 Install engme attachment to mamfolds
observe the followmg Items
block bolt holcs
I Fuel 011 or wa ter may leak past cyhndcr usmg

and block PrIor to secunng alternator bracket and water

cyhnder head
dram
dIsassembling check cylmder head plug
Set engme on the stand
front cham cover 011 pan and OIl filt r 6Y
and crankshaft and water
gaskets Engme Attachment ST05260001
seals for sIgn of leak past theu
pump Ellgme Stand ST0501S000
gasketed surfaces
2 Check carburetor and fuel pump
for condition fuel hoses for detenora
tIon cracks or otherWIse leakage of
f
fuel past theu JOInted or connected
surfaces FIg EM 15 RemOVing manifolds
3 Remove aIr deaner altcl nator
dIstrIbutor and starter and ping up

carburetor au horn and dtstnbutor

12 Remove engme mount1l1g L H
hole to prevent enlry of foreIgn 13 Remove crank pulley
matter
14 Remove water pump
4 WIpe dust and mud off engIne ST05 26000 I 15 Remove fuel pump
EM088
5 Inspect block rocker cover front
16 Remove fuel pump dnve cam
cham cover 011 pan and all other outer FIg EM 13 Engine on engme stand
17 Remove camshaft sprocket
parts for VIsual defects and broken or

mlssmg parts such as bolts and nuts

4 Remove 011 level gauge
6 Test all ptPIngs and electncal
broken
5 Remove clutch assembly
CIrCUItS for dIscontInUity or or

6 Remove high tensIOn cable

damaged msulatlon
7 Remove spark plugs
8 Remove thermostat hous1l1g

DISASSEMBLY
To remove engme from vehIcle
refer to relative toptc under Engme
Removal and InstallatIon m ChaSSIS EM091

and Body ServIce Manual SectIOn ER FIg EM 16 RemOVing camshaft

sprocket
I Remove transmtSSlOn from

engme
2 Thoroughly dram engme otl and
18 cyhnder head assembly
Remove
coolant by removmg draIn pings
the Use speCIal Cyhnder H ad Bolt
tool
3 Place engIne assembly on
Wrench STI0120000 to remove cyl
engme stand
mder head bolts Loosen bolts from
I Remove fan and fan pulley FIg EM 14 RemOVing thennostaf
CD to @ 3S shown m Figure EM IS
2 Remove engme mountmg R H hOUSing

EM 4
 Engine Mechanical

26 Remove and
19 Invert engme pIston connectmg
Extract
20 Remove ot pan and 011 stramer rod assembly connectmg rod
them order
beanngs keepmg 10

Fig EM IS Cylmder head bolt

loosenmg sequence

EM094

Fig EM 20 Removmg 011 stramer

FIg EM 23 Removmg pIston and
and 0 1 pump
connectmg rod assembly
Notes When hean
removing cyhnder
from engme mstalled on car follow
the instruchons below 27
21 Remove 011 pump and Its dnve
Remove flywheel and rear pia te
Be careful not to
Turn crankshaft unt1l No 1 pl5ton See Figure EM 20 drop them
a
spmdle
IS at TD C on Its compressIon 22 Remove front cover

stro ke 23 Remove cham tensloner and

b Remove rocker cover and fuel cham slack Side guIde
pump
To fact itate
c
assembling operation
scnbe mark cham and
a on hmmg
camshaft wllh be
sprocket pamt
fore removal

d Loosen camshaft bolt and remove

fuel pump dnve cam

e
Support hmmg cham by uttlZIng
Chain Stopper STl7420001 bet Fig EM 24 Removmg flywheel
ween uming chains as shown m

Ftgure EM 19
ThIS operation ehmmates the prob
lem of reahgmng timing marks on 28 Remove malO beanng caps
EM095

timuJg chain and crankshaft Use Crankshaft MalO Beanng Cap

sprocket Fig EM 2I Removmg cham tenslOner Puller STI 651 SOOO to remove cen ter
and tlmmg cham
and rear malO beanng caps Keep them
10 order

24 Remove tlmmg cham See

EM 21
Figure
25 Remove ot thrower crankshaft
worm gear and cham dnve sprocket STl651 SOOO

EM539

FIg EM 25 Removmg rear mam

EM538
bearmg cap
FIg EM 19 Suppomng tlmmg cham

29 Remove two SIde seals from rear

f Remove camshaft sprocket
g Loosen cyhnder head bolts and FIg EM 22 Removmg cham drive
malO
beanng cap

sprocket 30 Remove rear 011 seal

remove cylinder head

EM 5
 Engine Mechanical
Note Be careful not to damage cam

shaft beanngs and earn lobes

3 Remove valves usmg Valve Lifter

STl2070000

EM103

EM417 Fig EM 29 Remoumgplstonpm

011 seal
Fig EM 26 Remoumg rear

3 Keep disassembled parts m order

31 Remove crankshaft

32 Remove baffle plate and cyl

mder block net

CYLINDER HEAD
Fig EM 32 Remoulng ualues
1 Remove valve rocker spnngs
Loosen valve rocker PIvot lock nut and
remove rocker arm by pressmg valve

spnng down
Notes

a Take care not to lose valve spnng

seat 011 seal valve collet and valve
rocker guide
b Be sure to keep camshaft bearIngs
intact or the beanng center IS table

FIg EM 27 Remoumg baffle plate and to come out of alignment

net

PISTONS AND
IS
CONNECTING RODS

i i
nngs with a
Remove piston nng
Fig EM 3D RemOVing rocker arms
remover

2 Remove locate plate and remove

t f
camshaft

EM107
Exhaust Intake

Fig EM 33 Value components

Fig EM 28 Removing piston rings

EM105
2 Press piston pm out with Piston

Fig EM 31 Remoumg camshaft

Pm Press Stand STl303000 I

6
EM
 Engine Mechanical

INSPECTION AND REPAIR

CONTENTS

PREPARATION FOR INSPECTION EM 7 PISTONS PISTON PINS AND

CYLINDER HEAD AND VALVE EM 7 PISTON RINGS EM 14
CHECKING CYLINDER HEAD MATING CONNECTING ROD EM 15
FACE EM 7 CRANKSHAFT EM 15
VALVE ASSEMBLY EM 7 BUSHING AND BEARING EM 16
VALVE SPRING EM 8 MEASUREMENT OF MAIN BEARING
ROCKER ARM AND VALVE ROCKER CLEARANCE EM 16
PIVOT EM 9 MEASUREMENT OF CONNECTING ROD
VALVE GUIDE EM 9 BEARING CLEARANCE EM 17
VALVE SEAT INSERTS EM 10 FITTING BEARINGS EM 17
CAMSHAFT AND CAMSHAFT BEARING EM 11 MISCELLANEOUS COMPONENTS EM 18
CAMSHAFT BEARING CLEARANCE EM 11 CRANKSHAFT AND CAMSHAFT
VALVE TIMING EM 11 SPROCKETS EM 18
CAMSHAFT ALIGNMENT EM 12 CHAIN TENSIONER AND CHAIN GUIDE EM 19

CYLINDER BLOCK EM 12 FLYWHEEL EM 19

HOW TO MEASURE CYLINDER BORE EM 12 FRONT COVER AND REAR OIL SEAL EM 19

CYLINDER BORING EM 13

PREPARATION FOR Head surface flatness

Note Never remove camshaft bear
INSPECTION ings unless you have a sUItable
I Before clean 109 check for signs machme for bonng camshaft bear
of water and 011 leaks 10
cyhnder block Ing in Ime If you once remove Standard MaXImum
and head camshaft beatings beanng centers
2 Clean 011 carbon depOSIts and wIll come out of ahgnment re less than 0 05 Olmm
sealant from all parts Remove gasket
condltionmg IS very dIfficult wIth mm 0 0020 10 00039 m
3 Clean all 011 holes with solvent out center bonngs
and dry wIth compressed all Make
I Make ViSUal check for cracks
sure that they are not restncted a

and flaws
2 Measure the surface of cyhnder VALVE ASSEMBLY
head block sIde for
on
cyhnder I Check each mtake and exhaust
warpage If It JS found to be
beyond valve for worn damaged or deformed
the hmlt deSignated below regnnd the
valve caps or stems Correct or replace
affected surface With a surface
gnnder any valve that IS faulty
CYLINDER HEAD 2 Valve face or valve stem end
AND VALVE surface should be refaced WIth a valve
gnnder
CHECKING CYLINDER
HEAD MATING FACE

EM109
EM407
FIg EM 36 Intake and exhaust valve
FIg EM 35 Checkmg cylmder head
FIg EM 34 Cylrnder head surface d menslons

EM 7
 Engine Mechanical

VALVE SPRING
In 42 Ot042 2 654to 1661
Valve head dIameter I
H Check valve sprIng for squareness
mm ln
Ex 35 0 to 35 2 I 378 to I 386 uSing a steel
square and surface plate
If spnng IS out of square S more
In 1149 to 1152 4 524 to 4 535
Valve length than 1 6 mm 0 063 In replace
L
2 Measure the free and ten
mm In
Ex 1157 to 1160 4 555 to 4 567 length
sion of each sprIng If the measured
In 7965 to 7 980 0 3136 to 0 3142 value exceeds specified hm1t replace
Valve stem diameter
D
mm In sprIng
Ex 7945 to 7 960 0 3128 to 0 3134

Valve seat
In 45030
a angle
Intake and Exhaust
Ex 45030

EM296

FIg EM 39 Measuring spring squareness

EMll0

FIg EM 37 Checking valve stem

EMIlI
dIameter
f EM 38
FI Regrinding valve face

Note When valve head has been worn

down to 05 mm 00197 m In

thIckness replace the valve

Grinding allowance for valve stern EMl13

end surface IS OS mm 00197 In

or less FIg EM 40 Measuring spnng tensIOn

Spring specifications

Valve sprIng free length mm In

Intake and exhaust

Outer 4998 I 968

Inner 4485 I 766

Valve sprIng pressured length

valve open mm kg In lb

Intake and exhaust

Outer 29 5 49 0 I 161 108

Inner 245 25 5 0965 562

Valve sprIng assembled height

valve close mm
kg In lb

Intake and exhaust

Outer 400 21 3 I 575 470

Inner 350 123 378 27 I

EM B
 Engine Mechanical

ROCKER ARM AND Replacement of valve guide

VALVE ROCKER PIVOT 8 3 to 8 5 dla I To old
Exhaust
0 327 to 0 335
remove
gUIdes use a drIft
Check pivot head and cam contact and a press under a 2 ton pressure or

and pivot contact surfaces of rocker

I a hammer
arm
damage or wear If damage IS
for
found replace them A faulty PIvot
must be replaced together with ItS
3 0121 12 223 to 12 234
DrIve them out from combustIOn
chamber
Heated
SIde
cyhnder
toward rocker cover

head Will facIlltate the

Intake 150 04812 to 0 4817
correspondmg rocker arm dId
operatIon
2 Ream cyhnder head Side guIde
hole at room temperature
VALVE GUIDE 76 to 7 8
0 299 to 0 307 d a

Measure clearance between valve

10 8 0 425 I
and valve stem If clearance Urnt mm m
gUide 590 2 323
lImIt
exceeds deSIgnated replace worn EM572

both valve and valve In

parts or gUIde
thiS case tt IS essentIal to determIne If Fig EM 41 Service valve gUide

such a clearance has been caused by a

worn or bent valve stem or by a worn

valve gUide

In take valve Exhaust valve

Stem to gUIde clearance 0020 to 0 053 o 040 to 0 073

mm m 00008 to 0 0021 00016 to 0 0029

MaXimum hmlt of above

o I 0 0039 EM116
clearance mm m Urnt mm m

Fig EM 43 Valve guide hole

As an
emergency expedIent a valve
can be pushed Into valve gUide and
and left fIts up III
moved to the rIght For factory standard II 985 to II 996
deflects about 0 2 mm 0 0079 In or

valve gUide 04718 to 0 4723

more It IndIcates that the clearance GUide hole Inner

between stem and gUide exceeds the dIameter a mm In

For service valve 12185 to 12 196
maximum hmlt of 0 I mm 0 0039

In guide 04797 to 04802

Note Valve should be moved paral

In
3 Carefully press new valve guIde ReamIng bore
lel wIth rocker arm Generally a Into valve so that It WIll fit
amount of wear occurs m thts
smoothly 8000 to 8 018 mm
large after head to 150 to
duectIon
heatIng cyhnder 03150 to 03157 In

2000C 302 to 3920F

Valve of 0 2
Max allowable deflectIon gUIde mm 00079 In
o 2 0 0079 dIameter
mm m oversize IS avaIlable for ser
r VJce as mdlcated above
30 mm 1181 m

Interference fit of valve

to hole
gUIde gUIde
0027 to 0 049 mm

00011 to 0 00 9 In

EM115
4 Ream bore With valve
Fig EM 42 Measurmgclearance gUide press
ed In USIng Valve GUIde Reamer Set EM419
between valve stem
and valve gUide STlI03S000 EM 44 Reaming valve guule
FIIJ

EM 9
 Engine Mechanical

5 Correct valve seat surface WIth Replacing valve seat insert

new valve gUide as the aXIs 1 Old Insert be removed
can by
bOrIng It out unliI It collapses The

VALVE SEAT INSERTS machme depth stop should be set so

that bonng cannot contmue beyond

Check valve seat mserts for any
the bottom face of the msert recess m

eVidence of p1ttmg at valve contact

cyhnder head
surface and reseat or replace If worn 2 Select a suitable valve seat msert
excesslve y and check ItS outSIde dIameter
Valve seat msert of 0 5 mm 0 0 97 3 Machme cyhnder head recess to
m oversize IS available for service as Fig EM 45 Correctmg valve seat
the cucles valve
concentrIC m
gUide
shown below
center so that msert wil have the
correct fit
4 Heat head to
cylInder a tempera
ture of 150 to 2000C 302 to 3920 F
5 Fit msert ensurIng that It beds on
the bottom face of ItS recess and
Intake caulk more than 4 pomts
37 9 10 38 I 6 Newly fitted valve seats should be
I492 to I dla
QO

C
0

N
I
45597 to 45 613
150 cut orground at the speCified dunen
SlOns as shown m Figure EM47
I 795 to I 796 dla
VOlt mm m 7
EM573 Apply small amount of fine grInd
mg compound to valve contactmg face
and put alve mto gUIde Lap valve
326 I2835 dla agamst ItS seat unlil proper valve seat
mg IS obtamed Remove valve and then

7
clean valve and valve seat
5 0295
Exhaust

37580 to 37 596 I4795 to I 4802 dla

VOII mm m

Fig EM 46 Service valve seat dimenSions

Cylinder head recess diameter

Umt mm m

For standard
factory 45000 to 45016 17717 to 1 7723
msert

Intake
For servIce msert 45500 to 45516 17913 to 1 7920

For factory standard

37000 to 37 016 14567 to 1 4573
msert
Exhaust

For service msert 37500 to 37516 14764 to 14770

Intake 0081 to 0113 00032 to 0 0044

Interference
fit mm m
Exhaust o 064 to 0 096 0 0025 to 0 0038

EM l0
 Engine Mechanical

Intake

38 I4961 dla
396 I5591ldla
418 16457 a
d

45 1 7717

Unit mm 10

900
Exhaust

I 00512

o 11811 dla
2 6 I 2835 dla

34 6 1 3622 dla
l37 14567 dla

EM121

UnIt mm 10

F g EM 47 Standard valve seat dImensIOns

CAMSHAfT AND VALVE TIMING

CAMSHAfT BEARING ThiS dtagram dpphes to all cy

mders If any vdlve IS found out of

CAMSHAFT BEARING
specificatIOns one p SSlblhty IS that
CLEARANCE ThIS
cam lobe I worn ur damaged
dldlneter of calls tur tepldcement of camshaft
Medsure mSlde cam

shdftbedflng wtth1I1slde dial gauge

an

and outside dIameter of camshaft JOur

ndl With d micrometer If wear IS

EM119
lound mS1de of bracket replace cyl
mder hedd dssembly Fig EM 48 Checking camshaft beurl1lg

Camshaft journal to bearing clearance

Standdrd Wear IlImt

o 038 tu 0 067
011 c1earam e rnm m o 1 00039
00015 to 0 0026
B DC

Inner dIameter of ldm 48000 tu 480 6 EM421

shaft beallng mm m 8898 to I 8904 EM 49 v alve tllnlng dlUglum

Fig

EM
 Engine Mechanrcal
3 Usmg a bore gauge measure cyl
Standard Bend lun1t mder bore for of
out round or taper If
of
out round or taper IS exceSSive re

Camshaft bend bore walls with

o 02 0 0008 o 05 0 0020 cylInder a
bonng
mm m machme Measurement should be
taken along bores for taper and around
bores for of
out round See Figure
CAMSHAn ALIGNMENT EM 52
I Check camshaft camshaft Journal
and earn surface for bend wear or

damage If damage IS beyond lunltS Out ofround X y

replace affected parts Taper A B

2 A bend value IS one half of the

obtamed when camshaft IS
readmg
turned one full revolutIon with a dllll

gauge apphed to 2nd and 3rd Journals

FIg EM 50 CheckIng camshaft bend

I

FIg EM 52 MeasurIng cylmder bore

dIameter

Intake
Standard 40 30 to 40 35
heIght 4 When wear taper or out of round
of earn mm m I 5866 to I 5886
Exhaust IS mmor and w1thm limits remove step
at topmost portion of cylmder usmg
Wear lunlt of earn height mm m 025 00098 a
ndge reamer or other sunllar tool

Allowable difference m dIameter

between max worn and mm mm m 005 00020
worn
parts of camshaft Journal

MaXimum tolerance m Journal

mm m o I 0 0039
diameter
HOW TO MEASURE
CYLINDER BORE
Camshaft end play mm m 008 to 0 38 0 0031 to 0 0150
A bore gauge IS used Measure
cylinder bore at top middle and bot
tom pOSJtlOns toward A and B duec

lIons as shown m Figure EM 53 and

Standard Maximum tolerance record the measured values

Surface flatness less than

010 0 0039
mm m 005 00020

CYLINDER BLOCK
I Visually check cylinder block for
cracks or flaws
of block
2 Measure top cylInder
cyhnder head matmg face for warp Umt mm 10
EM422
age If warpage exceeds IImtts correct
It EM540

FII EM 51 CheckIng cylInder block FIg EM 53 Cylmder bore measurmg

IJUrface pOSItIOns

EM 12
 Engine MechanIcal

Standard Wear 11Imt

85 000 to 85 050
Inner diameter o 2 0 0079
3 3465 to 3 3484

Cylmder bore
nun m Out of round 0015 00006

0015 00006
Taper
Difference In cylInder bore 005 00020 o 2 0 0079
mm m

CYLINDER BORING
I When any needs 2 Determme piston overSize ac
cylInder bonng
all other also be bored cordmg to amount of wear of cylInder
cylInders must
at the same tIme

Oversize pistons specifications

FIg EM 55 Measuring pIston sklTt

Piston dIameter mm m diameter

84985 to 85 035 Rebored Size calculatIOn

ServIce standard
3 3459 to 3 3478
D A B C A 0 005 to

0025 mm 00002 to 00010 In

050 00197 85465 to 85515

Overs12e 3 3648 to 3 3667 where
D Honed diameter
A SkITt d13meter as measured
1 00 0 0394 85 965 to 86 0 5
B P1ston to wall clearance
overS12e 3 3844 to 3864
3
C Machining allowan e 0 02 mm

00008 In

3 The size to which cylInders must

be honed determmed Standard clearance mm In 0025 to 0 045 00010 to 0 0018
IS by addmg
clearance the
plston to cylInder to
skrrt Feeler gauge mm In 004 0 0016
largest piston d13meter at pIston
In thrust drrectIon

ExtractIng force kg lb 02to 15 044t0331

Notes 5 Measurement of a Just macluned

a To prevent stram due to cuttIng cylInder bore requITes utmost care
heat bore the cylinders In the order SInce It IS expanded by cuttIng heat
of 24 1 3 6 As a final step cylInders should
b Before be honed to SIZe
bonng any cylInder install
mam bearing caps m place and 7 Measure the fimshed cylInder
tighten to the specificatIon so that bore for of
out round or tapered part
the crankshaft bearing bores will 8 Measure plston to cylInder clear
not become distorted from the bor ance

mg operatIon ThIS clearance can be checked

easily by uSIng a feeler gauge and a

4 Do not cut too much out of spnng balance hooked on feeler gauge

cylmder bore at a tIme Cut only 0 05 measunng the amount of force re

mm 0 0020 m or so m dIameter at a qUIred to pull gauge out from between
and
FIg EM 54 Measuring pIston dIameter tIme pJston cylInder
EM 13
 Engine Mechanical
Notes
PISTONS
a When measurmg clearance slowly
PISTON PINS AND
pull feeler gauge straIght upward
b It IS recommended that pISton and PISTON RINGS
cylmder be heated to 200C 680F I Remove carbon from pIston and

nng grooves wIth a carbon scraper and

a curved steel
wue Clean out 011 slots

m bottom land of 011

nng groove
2 Check for damage scratches and
wear
Replace If necessary
3 Measure sIde c1earan e of nngs m
EM542
nng grooves as each nng IS Installed
FIg EM 58 Mensurmg rmg gap
SIde clearance should be as follows

Notes

a When piston ring only is to be

replaced Without cylmder bore
bemg corrected measure gap at
bottom of cyhnder where wear is
minor
b Oversize pISton rmgs are available
EM541 for semce

FIg EM 56 Measurmg pIston flf OversIZe

m cylmder EM423
05 mm 0 0197 m and
FIg EM 57 Measurmg pIston
rmg 10 mm 0 0394 m
sIde clearance
5 Measure piston pm hole m rela
tion to outer diameter of pm If wear
Side clearance exceeds Iumt replace each pIston pm
Umt mm m WIth the pIston
together on winch It IS

mstalled
6 Determme the fittmg of piston
Standard WearluTUt
pm mto piston pm hole to such an
extent that It can be finger
pressed at
o 040 to 0 073
Top nng
room
temperature ThiS piston pm
00016 to 0 0029 must be a tight press fit mto connect
o I 00039
109 rod
o 030 to 0 070
Second nng
00012 to 0 0028

Oil nng

4 Push nng mto cyhnder WIth PIS feeler gauge

ton so as to place It squarely m Rmg should be placed to dIameter

cyhnder measure nng gap with a at upper or lower hm1t of nng travel

Ring gap Umt mm m FIg EM 59 P ston pm

fIttmg

Standard Wear IUTUt

o 25 to 0 40
Top nng
00098 to 0 0157

o 30 to 0 50
Second nng 1 0 0 0394
00118 to 0 0197

o 30 to 0 90
01lnng EM 60
00118 to O 0354 FIg Measurmg pISton pm
dIameter

EM 14
 Engine Mechanical
Umt mm m
CRANKSHAFT
I Whenever crankshaft IS removed
Piston pm outside diameter 20993 to 20 998 08265 to 0 8267
from engme It should be cleaned

thoroughly m a sUJtable solvent After

Piston pm hole diameter 21001 t021 008 08268 to08271
cleanmg check crankshaft Journal and
crank pm for score bias wear or

Piston pm to piston clearance 0003 to 0 015 00001 to 00006

cracks Repalf or
replace as required
If damage IS mmor dress with fme
Interference fit of piston 00006 to 00014
0015 to 0 035 crocus cloth
pm to connectmg rod 2 Check Journals and crank pms for

taper and out ofround with a micro

meter Measurement should be taken

along Journals ior taper and around

Journals for out ofround See FIgure
CONNECTING ROD EM 63 for detailed mformal1on
2 Check connectlfig rod for bend or
I If connectlfig rod has any flaw
a IfJournals crank pms are
or tapered
on either side of the thrust face or the torsIOnusmg connectmg rod ahgner
a or Qf
out round beyond hm1ts replace
end correct replace It If bend or torsIOn exceeds the limn With shaft
large or a new

correct or replace

EM 61 rod alignment
ffi
Fig Checking

Standard MaXImum Out ofround X Y

Taper AB

rod bend
Connectmg VOlt mOl m

or torsIOn per 100 mm 195 0768

or 3 94 m
length
003 00012 005 0 0020 1 30 tit27
l 063
11 181
mm m

3 When replacmg connectmg rod

select rod so that weight dIfference
between new and old ones IS wIthm 7

gr 0 25 oz All malO Journal

59 942 to 59 955
4 Install connectmg rods with bear
2 3599 to 2 3604
mgs on to correspondmg crank pms
EM424
and measure thrust clearance If meas
Fig EM 63 Crankshaft and Journal
ured value exceeds hmIt replace dimenSIOns

end play
Fig EM 62 Checking big

Standard Maximum
v

o 2 to 0 3
end play mm m 06 0 0236
Big 00079 to 0 0118

EM 15
 Engine Mechanical

Standard Ma omum

ST166 10001

Taper and out of round

less than
ofjournal and crank pIn 0025 0 0010
001 00004
mm m

3 Crankshaft bend can be checked

V blocks and USIng

by placmg It on a
EM425
dIal gauge with ItS Indica ling finger Fig EM 66 Pulling outpIlot
restmg on center journal bushIng

2 Before mstallmg a new buslung

thoroughly clean
bushing hole Press
fit buslung so that ItS height above

flange end IS 4 5 to 5 0 mm 0 177 to

o 197 m Do not oIl buslung

FIg EM 64 Checking crankshaft bend

4StoSOmm
0177 to 0 197 m

Standard Maximum

less than
Crankshaft bend mm In o 10 0 0039
o 05 0 0020

EM418

Note When measunng bend use a Fig EM 67 Press flttmg new pIlot
bush Ing
dl3l gauge Bend value IS half of the

readmg obtamed when crankshaft IS

turned one full revolution with a

dl3l gauge attached to ItS center

journal
BUSHING AND
4 After regnndIng crankshaft fimsh BEARING
tt to the necessary size Indicated on

page EM 18 by USIng an
adequate MEASUREMENT OF
undeTSlze the
beanng accordmg to MAIN BEARING CLEARANCE
extent of reqUired repalT
1 Thoroughly clean allbeanngs and
5 Install crankshaft m cylInder check for scratches meltmg score or
block and measure crankshaft free end
Fig EM 65 Checking crankshaft end wear
play play Replace beanngs If any fault IS

detected
2 Crankshaft journals and beanngs
should be clean and free from dust and
Standard Wearlumt dirt before or clearance IS measured

3 Set mam beanng on cap block

Crankshaft free end 005toOl8
03 00118 4 Cut a plasl1gage to Width of bear
play mm In 00020 to O 0071 With crank
1ng and place It m parallel
pIn gettmg clear of the oIl hole Install
cap on the assembly and tighten them
6 At the rear end of crankshaft To replace crankshaft rear pdot
together to the speCified torque
check crankshaft
pIlot bushing for bushIng proceed as follows
wear or damage Replace It If any fault 1 Pull out bushmg usmg Pdot Tlghtemng torque
detected 4 5 to 5 5 kg m 33 to 40 ft lb
JS Bushmg Puller ST166 1000 1
EM 16
 Engine Mechanical

Bearing oil clearance

Standard Wear lImit

Mam beanng clearance 0020 to 0 062

o 12 0 004 7
mm m 00008 to 0 0024

Connectmg rod beanng 0025 to 0 055

012 00047
clearance mm m 0 to 0 0022
000
Fl EM 68 PlastIgage
J

2 If clearance exceeds specIfIed 3 Then crush H

measure beanng
Note Do not turn crankshaft while value with an under wIth feeler gauge See Figure EM 70
replace beanng a

is 1I1serted
plastJgage be1l1g SIze
beanng and gnnd crankshaft Jour The standard beanng crush value IS
nal adequately IIsled below
5 Remove cap and compare width
of the plastJgage at Its wIdest part with FITTING BEARINGS
the scale pnnted 111
plashgage enve

manufactured with
lope Beanngs are

crush to make beanng snug down mto

Weight
ItS bore To measure thiS proceed as
H
follows

I Set beanng m mam beanng

mam

cap recess cylInder block beanng

or

recess correctly

2 Lock one SIde of beanng and

press other SIde untIl beanng back
surface touches the recess Flf EM 70 Checkmg bearing crush

Bearing crush

Frg EM 69 Measunng bearing All mam

beanngs mm m Oto003 0 to 00012
clearance

All rod 0015 to 0 045 00006 to 0 0018

connectIng beanngs mm m

MEASUREMENT OF 4 Handle connectIng rod beanng m the same manner as above

CONNECTING ROD BEARING

CLEARANCE

I Measure connectulg rod beanng

clearance 111 the same manner as ahove Main bearing underslze
Umt mm m

TIghtemng torque
4 5 to 5 5 kg m 33 to 40 ft Ib Beanng top thIckness Crank Journal diameter

I 827 to I 835 59942 to 59 955

STD
2 3599 to 2 3604
00719 to 00722

025 00098 1 952 to I 960 59 692 to 59 705

UnderSize 0 0769 to 0 0772 2 350 I to 2 3506

050 0 0197 2 077 to 2 085 59442 to 59 455

UnderSIze 00818 to 0 0821 2 3402 to 2 3407

075 00295 2202to22

O 59192 to 59 205
UndersIze 00867 to 0 0870 2 3304 to 2 3309

EM 17 I
 Engine Mechanical

Connecting rod bearing undersize Umt mm m

Beanng top thIckness Crank pIn diameter

I 493 to I 506 49961 to 49 974

SID
00588 to 0 0593 I 9670 to I 9675

1618 to I 631 49711 to 49724

025 00098 UndersIZe
00637 to 0 0642 1 9571 to I 9576

I 743 to I 756 49461 to 49 474

o 50 0 0197 UndefSlze
00686 to 0 0691 1 9473 to I 9478

I 868 to I 881 49211 to 49224

075 00295 UndersIZe
00735 to 00741 I 9374 to I 9379

3 Check chaIn for damage exces

MISCELLANEOUS
Sive wear or stretch at roller lmks
COMPONENTS If faulty
Replace
CRANKSHAn AND 4 To properly adjust cham tension
CAMSHAn SPROCKETS or valve hmIng camshaft sprocket
has a earn locatIng plate and three
I Check tooth surface for flaws or

locatIOn holes Nos 1 2 and 3

wear Replace sprocket If fa ult IS

found
Camshaft sprocket is preset at
EM144
No I the factory
hole at If cham
2 Install camshaft sprocket In
POSI
FIf EM 72 Checkmg camshaft end becomes loose adjust It by settIng
tIon and check for rounout If It
play camshaft sprocket at No 2 hole If
exceeds 0 I mm 00039 In total
chaIn IS too loose adjust It by settIng
Indicator readIng replace camshaft
camshaft sprocket at No 3 hole
sprocket Also check for end play

Camshaft end play

o 08 to 0 38 mm
00032 to 00150 In

Q ID
to f

1 to 3

Locallon match

Before adJu tment After adJu lment

FIf EM 71 Checking camshnft EM311

sprock f ll ut FIf EM 73 AdJustmg camshlJft sprocket location

EM 18
 Engine Mechanical

1 Turn engine untIl No I pJston IS CHAIN TENSIONER AND

at T D C on Its compression stroke CHAIN GUIDE
Determine whether camshaft sprocket and breakage Re
Check for wear

locatIOn notch comes off the left end

If necessary
place
of the oblong groove on camshaft
locating plate If the locatIOn notch IS
off the left end of the oblong groove
cham stretch IS beyond lImits

EM426

FIg EM 76 Checkmg flywheel

deViatIOn

40 ISO 3 Check tooth surfaces of nng gear

u
for flaws or wear

Replace If necessary

Ci D FRONT COVER AND

REAR OIL SEAL

i FIrSt check front

seal for

or
worn or

011 leakage If necessary

cover

folded over
and rear

seahng hp
Install
011

a
EM147
EM146 new seal When installIng a new seal
FIg EM 75 Camshnft drIVe mechanISm
pay attentIOn to mounting directIOn
FIf EM 74 Camshaft locatmg plate
Note It to replace ad
IS
good practtce
seal whenever engine is overhauled

2 Tilrn engine untIl No 1 piston IS

r
at T DC on Its compressIOn stroke

setting camshaft on No 2 locatIon

hole m camshaft sprocket Tlus No 2
Front
notch should then be the end FLYWHEEL
on nght
of the oblong groove When No 2 hole I Check clutch diSC contact surface I
I

IS used No 2 tImmg mark must also wIth flywheel fur damage or wear

be used The amount of the modifIca

Repair or replace If necessary Front

tIon IS a 40 rotatIon of crankshaft 2 Measure mnout of clutch diSC Rear

3 When modificatIOn becomes Im contact surface wIth a dIal gauge IfIt EM150

possible even by transfernng camshaft exceeds 0 15 mm 00059 m total

locatIOn hole replace cham assembly FIg EM 77 Oil seals of crankshaft

md1ca tor readmg replace It

1
X
1

EM 19
 Engine Mechanical

ENGINE ASSEMBLY

CONTENTS

PRECAUTIONS EM 20 PISTON AND CONNECTING ROD EM 21

CYLINDER HEAD EM 20 ENGINE ASSEMBLY EM 21

PRECAUTIONS Cylmder block Rear mam beaTIng cap

Use cleaned
I thoroughly parts
make sure that 011 holes 20 to 25
Especially are mm

clear of foreign matter

2 When mstalhng shdmg parts such

as beanngs be sure to apply engme 011

to them

3 Use and Oil seals

new
packmgs Pomts to be apphed sealant EM151
4 Do not reuse lock washers
Fig EM 79 Applymg sealant
5 Keep tools and work benches Mam bearmg cap and Fig 81
EM InstallIng valves
clean
cylmder block
6 and tools Notes
Keep necessary parts
near at hand a Ensure that valve face IS free from
3 Cyhnder block Step portIons at matter
7 Be sure to follow specified tIght foreign
four matmg surfacescylmder block to b The LI8 double type
emng torque and order engine uses
front cham cover and cyhnder block valve
8 Applymg sealant springs
Use sealant to ehmmate water and to rear mam beanng cap See Figure
EM 80 2 Valve rocker piVOt assembly
011 leaks Parts requITIng sealant are
Screw valve rocker pivots Jomed
I Front cover and corners of cyl Note Do not apply too much sealant WIth lock nuts mto pivot bushmg
mder block See FIgure EM 78
3 Camshaft assembly
Setlocatmg plate and carefully
mstall camshaft m
cyhnder head Do
not damage the beanng mS1de Oblong

groove of locatmg plate must be

directed toward front sIde of engIne

Camshaft bracket tIghtemng

torque
18 to 2 0 kg m 13 to 15 ft lb

4 Install camshaft sprocket on cam

Apply alant at these pomts shaft and tIghten It together With fuel
EM152 pump dnve cam to speCified torque
FIg EM 80 Applymg sealnnt Tlghtemng torque
EM153 Cylmder block
12 tol6 kg m 87 to 116 ft lb
FIg EM 78 Applymg sealant
Front and
B cover
At thIS tIme check camshaft end
cylmder block
play

CYLINDER HEAD
Valve assembly and valve spnng

Usmg Valve Lifter STl2070000 set

valve spnng seat m
pOSItIOn and fit
valve gUide With 011 seal
2 Ma I beal g cap and cylmder Assemble valve m the order shown
block Each side of rear mam beanng below valve mner and outer valve
EM154
cap and each corner of cylmder block spnngs spnng retamer valve collet
Fig 82
EM InstallIng camshaft
See EM 79 and valve rocker gUide
FIgure sprocket
EM 20
 Engine Mechanical

5 Install rocker arms by pressmg b Arrange so that 011 Jet of connect 3 Install baffle plate mcludmg cyl
valve spnngs down with a screwdnver 1ng rod big end is duected toward mder block net
6 Install valve rocker spnngs nght Side of cyhnder block
Notes
7 After assembling cylinder head c Be sure to mstall pISton in cyhnders a Only center bearIng No 3 is a

turn camshaft until No I piston IS at with notch mark of piston head

T D C on Jts compressIOn stroke
flanged type
toward front of engme
b All beanngs
mter No 2 and No 4

are the same

2 Install piston nngs type
Install c Front bearIng No 1 is also the
top and second nngs m nght 5
position with marked Side up same type as rear bearing No
The dIfference IS that an 011 hole is
Notes
proVided m the front bearing
a
Top nng IS chromIUm plated on
d All upper and lower bearIngs are

Imer contactmg face mterchangeable

b Second rIng has larger taper surface
4 engme all to beanng
than top ring Apply mam

EM155 In the combmed 011 upper rail surfaces on both SIdes of cylinder
c
ristg
IS the same as lower one block and cap and then mstall crank
FIg EM 83 Assembling cylinder head
shaft
5 Install mam beanng cap and tight
en bolts to speCified torque
Tlghterung torque
PISTON AND
CONNECTING ROD 1 0 Notes
4 5 to 5 5 kg m 33 to 40 ft Ib

Assemble pistons pISton pms and a Apply sealant to each Side of rear
connectmg rods on the deSIgnated EM158 main bearing cap and each corner

cyhnder of cyhnder block as shown in

Fig 86
EM Instal mc plsfon nngs
Figure EM 79
3 FIX b Arrange parts so arrow mark on
beanngs on
connectmg rod
and connectmg rod cap bearIng cap faces toward front of
engme
Note Clean back SIde ofbearing care
PrIor to
c tightening bearing cap
fully bolts place bearing cap m proper
posttIon by shifting crankshaft m
the aX181 direction

d Tighten bearing cap bolts gradually

m two to three stages outwardly
EM156
ENGINE ASSEMBLY from center beanng m the sequence
Fig EM 84 Instal lng pISton pin as shown Figurem 88
EM
The first step m engme assembly
e After securing bearIng cap bolts
IS to bolt Engme Attachment ascertain that crankshaft turns
ST05260001 to right hand SIde of
block smoothly
cyhnder Next mstall block on
another Stand ST050lS000
Engme
WJth engme bottom up

2 Set mam at the proper

beanngs
portion of cyhnder block

EM157 Rear Front

Fig EM 85 Assembling pISton and

connecting rod m Ii L
III fi
Notes

a Piston is pressed into connecting

DDDDD
rod wrth fittmg force of0 5 to 1 5
tons

When
aid of PISton

Stand ST 1303000 lis necessary

pressing piston pm
Pin

mto
Press

con
waa
65 N4 63 62 61
@ @ @ @EM543
nectmg rod apply engIne oil to pm EM159
FIg EM 88 Torque sequence off
and small end of connectmg rod FIg EM 87 Mam bearmgs cap bolts

EM 21
 Engine Mechanical

6 Make that Note When

sure crankshaft has installing 011 seal gIVe

proper end play coatmg of engme 011 to matIng

1 shaft to prevent scratches and fold
Crankshaft end play
005 toO 18 mm
ed IIp Also gIVe coating of ad to
of ad seal
00020 to 0 0071 m penphery
9 Install end
plate
rear EM166

IO Install
flywheel securely and EM 94
Fig Installmg connectmg rod
tighten bolts to specIfied torque cap

Tlghtemng torque
14 to 16 kg m Note Install connecting rods and con
OI to 116 ft Ib
necting rod caps so that their as
II Insert pistons m
corresponding signed nwnbers are positIoned on
cyhnder usmg PIston Rmg cOmpressor the same SIde and in the same
EM03470000 drrection WIth respect to cyhnders
13 Make sure that connectmg rod
end has proper end
EM03470000 big play
Fig EM 89 Checkmg crankshaft
end play

7 Install sIde 011 seals mto rear mam

beanng cap Pnor to mstallIng apply

sealant to seals

FIg EM 92 Installmg pISton rod

assembly
FIg EM 95 Checkmg big end play

Notes

a Apply engine 011 to shdtng parts end

Big play
b Arrange so that notch mark on
o 2 to 0 3 mm

pISton head faces to front Of en

0008toOOI2m
gme
14 Install head
c Install pIston lingS at 1800 to each cylInder assembly
other avoidmg thell fit m the
thrust and pISton pm directions

8 Install rear 011 seal usmg Crank c

Top rmg

shaft Rear 011 Seal Dnft STl5310000 B Otlnng

lf
Ptston pm CltoJ FIg EM 96 Tlghtenmg sequence of
cyllndefhead bolts

EM165

FIg EM 93 PIston ring directIOn I clean

Thoroughly cyhnder block
and he d surface
12 Install rod caps
connectmg Do not apply sealant to any other
head sur
EM163
Tlghtemng torque part of cylInder block and
Fig EM 91 Installmg rear 011 seal 4 5 to 5 5 kg m 33 to 40 ft Ib face

d 1

EM 22
 Engine Mechanical

Turn crankshaft until No I PIS Install cham slack side b Install front cover wtth head gasket
2 17 gUide to

ton IS at T DC on ItS compressIOn cyhnder block m

place
Check dIfference between
stroke 18 Install cham tensloner
c
heIght
cyltnder block upper face and front
3 Make sure that camshaft sprock Note Adjust protrusion of cham ten cover upper face Difference must
et location notch and plate oblong
at thelf correct
Slonerspindle to 0 mm 0 m be less than 0 IS mm 000S9 m
groove are
ahgned
d Note that different types of bolts
posItions
are used
4 head
When mstalhng cyhnder
Before front
make sure that all valves are apart
e
tnstalllng cover on

from heads of pIstons cylinder block apply coating of

5 Do not rotate crankshaft and engme od to sealing lip of oil seal
camshaft separately or valves willlut
J heads of pistons
6 Temporanly tighten two bolts
shown Figure EM 96
ill @ m

Tlghtenmg torque
2 kg m 14 ft Ib
and FIg EM 98 Installmg cham tensloner
15 Install crankshaft sprocket
011 dnve and fIt 011
pump gear
thrower
19 Press new oil seal m front cover

that Fig EM IOO Front bolts

matIng marks of cover
Note Make sure

crankshaft face to front Notes

sprocket
a Front cover oil seal should be re Tightenmg torque
Size M8 0 315
16 Install tImmg cham when front cover is disas m
placed
I 0 to I 3 7 2 to 9 4 ft Ib
sembled kg m
Notes
b Before pressmg oil seal mto front SIZe M6 0 236 m
a Make sure that crankshaft and cam
cover give coatmg of engine oil to 04 to 06 2 9 to 4 3 ft Ib
shaft keys pomt upwards kg m

penphery of od seal
21 Install crankshaft pulley and
c TIus oil seal IS a threaded seal type
water pump assembly then set No
which has Improved seahng charac
tenshcs Do not apply grease to pISton at T D C on ItS compressIOn
stroke
sealing lip
Crankshaft nut
pulley
20 Install front cover wIth gasket m
Fuel
pump dnve tIghtemng torque
cam place 12 to 16 kg m 87 to 116 ft lll
2 Chain gUide
3 Chain tenslOner
4 Crank sprockel
5 Cam sprocket
6 Chain gUide

EM439

Its
b Set tImmg cham by allgmng
marks wJth those of crank
matmg 1 Ttmmg mark

shaft sprocket and camshaft sprock 2 Tunmg mark EM545 Fig EM IOI In tallmg crankshaft
et at the nght hand stde There are
Fig EM 99 Installmg rant cover pulley and
water
forty four cham links between two pump

matmg marks of tImmg chain

22 Fmally tIghten head bolts to
c No 2 hole IS factory adjusted
the speCified torque m three steps
When chain stretches exceSSively
Notes
accordmg to the lightemng sequence
adjust camshaft sprocket at No 3
a Apply sealant to front cover and shown m FIgure EM 96
hole
d Use a of tImmg marks
set and comers of upper sectIon of cylinder Note that two types of Bolts are

locatIon hole numbers block as shown in Figure EM 78 used

1
h
i j

EM i

1 231rII
 t

I
lt fll
Engine Mechanical
ti
tool He ad Bolt TIghtemng torque
Special Cyhnder
Wrench STl 0 120000 011 stramer bolts
08 to I I kg m 58 to 8 0 ft Ib
Tlghtenmg torque
011 pan bolts
1st turn
06 to 0 9 kg m 43 to 6 5 ft Ib
40 kg m 29 ft Ib
2nd turn
60 kg m 43 ft lb Notes
3rd turn sealant to the
a
Apply step portio lIS
7 0 to 8 5 kg m at four mating surfaces as shown in
51 to 61 ft Ib EM 80
Figure
b 011 should be
pan tightened in
cnss
ross pattern to a final torque
B a0 A of0 6 to 0 9 rn
kg 4 3 to 6 S ft Ib
0

A 26
B o
0 0
Adjust valve clearance to the

B
specified dimenSIOns
0 0
B w
o

Spec131 tool
O 0 A PiVOt Adjuster STI0640001
B

B O O JO A TIghtemng torque
5 0 to 6 0 kg m 36 to 43 ft Ib

EM176
Notes

Fig EM I02 Cylmder head bolts a Fust set clearance to the cold
Fig EM 104 Installmg 011 pump specI
ficatiollS

Notes Y
24 Install fuel pump water mlet
Be sure to two small bolts elbow and front engme
a
tighten shnger In their
b After engine has been operated for poslhons
several minutes retighten if neces Fuel pump tlghtenmg torque
sary I 2 to I 8 kg m

23 87 to I3 0 ft lb
Install 011 pump and dlstnbutor
t

1 dnvmg spmdle In front cover Note Do not

A forget to install fuel EM 105
Fig AdJustmg oolue clearance
TIghtemng torque pump spacer and pac1ung between
I I to I 5 spacer and block spacer and fuel
kg m

80 to 108 ft Ib pump b After engine has been assembled

it for at least
seVlral
run mmutes
25 Install od stramer 011 pan gasket and finally adjust clearance to the
c
and 011 pan
wann specifications

Notes
Intake o 20 0 0079
a Assemble od pump and drive spin Cold
dle abgnmg dnvmg spindle face
Exhaust o 25 0 0098
wIth oil pump hole Valve clearance
mm 10
b Install oil pump together with drive
Intake o 25 0 0098
spmdle so that the projection on its Warm
top is located at the 11 2S a m Exhaust 030 00118
posItion At this point the smaller
bow shape will be faCing toward the
front 27 IlIStall cooler compressor
Do not to install TIghtemng torque
c
forget gasket bracket to cylInder block If so I 5 to 2 0 kg m
eqUIpped II to 14 ft Ib

28 Install rear engme shnger ex

haust mamfold and mtake m amfold

EM 24 I 1 t
I
tfjm
 Engine Mechanical
34 Install spark plugs 39 Install alternator bracket ad
35 Connect dlstnbutor to plug hIgh Justmg bar alternator fan pulley fan
tensIOn lead WIre and fan belt m tlus order Then check

36 Install left engIne mount to be sure that deflectIon of fan belt IS

bracket held w1tlun 8 to 12 mm 0315 to

37 Install clutch assembly on o 472 m when thumb pressure IS

between A
flywheel with Clutch Ahgmng Bar apphed midway pulleys
about 10
ST20660000 pressed force IS kg 22 0

Ib

Tlghtemng torque
I 06 I 2 to 2 2 kg m
Fig EM
87 to 159 ft Ib

29 Install dlstnbutor assembly

30 Install carburetor assembly and
carburetor msulator with stamp facmg

upward

Tightemng torque
o 5 to I 0 kg m

ET007
36 to 7 2 ft lb
Fig EM lOB Fan belt tensIon

3I Install fuel pIpes and vacuum

hose 40 Install nght engIne mount brack

All and should et 011 fIlter 011 pressure SWitch 011
pIpes hoses be
clamped securely bemg careful not to ST20660000 I EMl77 level gauge and water dram plug When
allow them to mterfere wIth adjacent Fig EM I07 Installmg clutch assembly mstallmg an 011 filter fasten It on
cyhnder block by hand
or
surroundmg parts
32 Install thermostat hOIlSmg Note Do not overtighten filter or 011
thermostat and water outlet theIr 38 overhead hOIst and
m Usmg an
occur
mstall
leakage may
posItIons Do not forget to hftmg cable hOist engme up a way
from engme stand and then down onto 41 Power engIne 011 up to
gasket specIfied
33 Install rocker cover
engme carner level

EM 25
I

Engine Mechanical

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS

Engine model Ll8

CylInder arrangement 4 in lIne

DIsplacement cc cu In I 770 108 0

Bore and stroke mm In 85 78 3 35

x x 3 07

Valve arrangement OHC

Fmng order 1 3 4 2

Idle
Engine rpm

Manual transmiSSIOn 700

Automatic transmiSSIOn In N posItion 800

CompressIOn ratio 85

Od pressure Warm at 2 000 rpm

kgcm2 pSI 3 5 to 4 0 50 to 57

SPECIFICATIONS
8 Valve mechamsm

Valve clearance Warm mm In

Intake
o 25 00098
Exhaust
030 00118
Valve clearance Cold mm In

Intake
020 0 0079
Exhaust
025 00098
Valve head dl8meter mm In

Intake 420 to 42 2 I 654 to I 661

Exhaust 35 0 to 35 2 1 378 to 1 386
Valve stem dl8meter mm In

Intake 7965 to 7 980 03136 to 0 3142

Exhaust 7945 to 7 960 03128 to 0 3I 4
Valve length mm In

Intake 1149 to 1152 4 524 to 4 535

Exhaust 1157 to 1160 4 555 to 4567
Valve 11ft mm In

Intake
10 0 0 394
Exhaust
10 5 0413

Valve spnng out of square mm In less than I 6 0 063

Valve spnng free length mm In

Intake and exhaust Outer 49 98 968

1
Inner 44 85 1 766

EM 26
 Engine Mechanfcal

Valve spnng pressured length

valve open lb
mm kg m

Intake and exhaust

1

Outer 295 1161

490 108
Inner 24 5 25 5 0 965 56 2
1
Valve spnng assembled height
valve close mm kg lIl lb
Intake and exhaust

Outer 400 2 3 1 575 470

Inner 1 378 27 1
123
350
Valve gUide length mm m

Intake and exhaust 59 0 2 323

Valve gUide height from head surface mm m 106 0417

Valve gUide mner diameter mm m

Intake and exhaust 8000 to 8 018 0 3150 to 0 3 57

Valve gUide outer diameter

servIce mm m
parts
Intake and exhaust 12223 to 12234
0 4812 to 0 4817

Valve gUide to stem clearance mm m

Intake 0020 to 0 053 0 0008 to 0 0021

Exhaust o 040 to 0073

00016 to 0 0029

Valve seat width mm m

Intake 1 4 0 0551

Exhaust 13 00512

Valve seat angle

Intake and exhaust 450

Valve seat mterference fit mm m

Intake 0081 to 0113 0 0032 to 0 0044

Exhaust 0064 to 0 096 0 0025 to 0 0038

Valve gUide mterference fit mm m 0027 to 0 049 0 0011 to 0 0019

b Camshaft and timing chain

Camshaft end play mm m 008 to 038 0 0032 to 00150

Camshaft lobe lift mm lIl

I
Intake and exhaust 0 0 276

Camshaft Journa l diameter mm m

1st 2nd 3rd and 4th 47949 to 47 962

1 8877 to 1 8883

Camshaft bend mm m 002 0 0008

Camshaft Journa to beanng clearance nun m 0038 to 0 067 0 0015 to 00026

Camshaft beanng Hiller diameter mm m

p
1st 2nd 3rd and 4th 48 000 to 48 016

1 8898 to 1 8904

EM 27
 Engine Mechanical

c ConnectIng rod

Center distance mm m 13035 5 1319

I 493 to I 506 0 0588 to 0 0593

BearIng thickness Standard mm m

Big end play mm m 020to030 0008toOOI2

Connectmg rod bearIng clearance mm m 0025 to 0 055 0 0010 to 0 0022

ConnectIng rod bend or torsIOn per 100 mm or 2 937 m

mm m less than 003 00012

d Crankshaft and mam bearing

Journal diameter mm m 59 942 to 59 955 2 3599 to 2 3604

Journal taper of
out round mm m lebs than 0 01 00004

Crankshaft free end play mm m 005 toO 18 00020 to 00071

Wear hm1t ofdIttoed play mm m 03 0 0118

49961 to 49974 I 9670 to I 9675

Crank pm diameter mm In

Crank pm taper out of round mm m less than 001 00004

Mam bearIng thickness Standard mm m I 827 to I 835 00719 to 00722

Mam beanng clearance mm In 0020 to 0 062 00008 to 0 0024

Wear hmlt of dittoed clearance mm m 012 00047

Crankshaft bend mm m o 05 00020

run out at clutch diSC contact face

Flywheel
mm Ill less than 0 15 00059

e Piston

PIston dIameter Semce standard mm m 84 985 to 85 035

3 3459 to 3 3478

o 50 0 0197 OversIze mm m 85465 to 85515

3 3648 to 3 3667

I 00 0 0394 Oversize mm m 85965 to 86 015

3 3844 to 3 3864

Rlllg groove WIdth mm m

2030 to 2 050 0 0799 to 0 0807

Top
Second 2020 to 2 040 0 0795 to 0 0803
ad 4015 to 4040 0 1581 toO 1591

Piston to bore clearance mm Ill 0025 to 0045 00010 to 0 0018

Piston pm hole set

off mm Ill 095 to I 05 00374 to 3
004

Piston pm hole diameter mm Ill 21 001 to 21 008 08268 to 0 8271

f PIston pin

Pm d13meter mm m 20 993 to 20 998

08265 to 0 8267

Pin length mm m 72 25 to 73 00
28445 to 2 8740

PIston pm to piston clearance mm m 0003 to 0 015 0 0001 to 00006

Interference fit of piston pm to connectmg rod buslung

mm m 0015 to 0035 00006 to 0 0014

EM 28
 Engine Mechanical
Piston
g ring

Rmg heIght mm m

1 977 to 1 990 0 0778 to 0 0783

Top and second

SIde clearance mm m

Top 0040 to 0 073 0 0016 to 0 0029

Second 0 030 to 0 070 0 0012 to 00Q28
Rmg gap mm m

Top 025 to 0 40 0 0098 to 0 0157

Second 030 to 0 50 0 0118 to 0 0197
Od 030 to 0 90 0 0118 to 00354

h Cyhnder block

Cyhnder bore mner dIameter mm m 85 000 to 85 050

33465 to 33484

Wear hrmt of dittoed mner dIameter mm m o 2 0 0079

Cyhnder bore taper ld

3 out of round mm m 0 015 0 0006

DIfference m cyhnder bore mm m o 05 0 0020

Surface fl tness mm m less than 0 05 0 0020

i Cylinder head

Surface flatness mm m less than 0 05 0 0020

J

TIGHTENING TORQUE
Cyhnder head bolts kg m ft Ib 7 Ot08 5 51 t061

Connectmg rod bIg end nuts kg m ft Ib 4 5 to 5 5 33 to 40

Flywheel fixmg bolts kg m ft Ib 14 to 16 101 to 116

tt
Mam beanng cap bolts kg m ft Ib 45 to 5 5 33 to 40

Camshaft brack et bolts kg m ft Ib I 8 to 2 0 13 to 15

Camshaft sprocket bolt kg m ft lb 12 to 16 87 to 116

Oil pan bolts kg m ft Ib 06 to 0 9 4 3 to 6 5

Oil pump bolts kg m ft Ib lito 1 5 8 0 to 10 8

011 stramer bol ts kg m ft Ib 08 to I I 5 8 to 8 0

Oil pan dram plug kg m ft Ib 20 to 3 0 14 to 22

Rocker pivot lock nuts kg m ft lb 5 0 to 6 0 36 to 43

Camshaft locatmg plate bolts kg m ft Ib 06 to 09 4 3 to 6 5

Carburetor nuts kg m ft Ib o 5 to I 0 3 6 to 7 2

Mamfold bolts kg m ft Ib I 5 to 2 0 11 to 14

Fuel pump nuts kg m ft Ib 1 2 to 1 8 8 7 to 13 0

Crank pulley bolt kg m ft lb 12 to 16 87 to 116

Water pump bolts ft Ib 2 9 to 3 6

kg m o 4 to 0 5

Front cover bolts kg m ft Ib 8 mm 0 315 m dla I 0 to 1 3 7 2 to 9 4

6 mm 0 236 m d1a 04 to 0 6 2 9 to 4 3

EM 29
 Engine Mechanical

TROUBLE DIAGNOSES AND CORRECTIONS

ConditIon Probable cause CorrectIve actIOn

I Noisy engine
Loose beanng Replace
Knockmg of crankshaft malO

and beanng SeIzed beanng Replace

Bent crankshaft RepaIr or replace
Uneven wear of Journal Correct

Excessive crankshaft end play Replace center beanng

Loose
Knockmg of piston beanng Replace
and connectmg rod
SeIzed beanng Replace
Loose piston pm Replace pm or
buslung
Loose pIston 10
cylinder RecondItIon cylinder
Broken pJston nng Replace
connect 109 rod alignment RealIgn
Improper

Camshaft knockmg Loose beanng Replace

ExceSSive aXial play Replace beanng thrust plate
Rough gear teeth RepalI
Broken cam gear Replace

Tmung cham nOise Improper cham tensIOn Adjust

Worn and or damaged cham Replace
Worn sprocket Replace
Worn and or broken tensIOn adJustmg Replace
mechamsm

ExceSSIve camshaft and bearmg clearance Replace

Camshaft and valve Improper valve clearance Adjust

mechamsm knockmg Worn adJustmg screw Replace
Worn rocker face Replace
Loose valve stem 10 gUide Replace gUide
Weakened valve sprmg Replace
Seized valve Repalf or replace

Water pump knocking Improper shaft end play Replace

Broken Impeller Replace

II Other mechanical troubles

Stuck valve Improper valve clearance Adjust

InsuffiCIent clearance between valve stem Clean stem or ream gUide
and gUIde
Weakened or broken valve sprIng Replace
B1tmg or
damage ofvalve stem Replafe jlr clelln
Poor Quality offuel Use good fuel

30
EM
 Engine Mechanical

CondItion Probable cause Corrective actIOn

Seized valve seat Improper valve clearance Adjust

Weakened valve spnng Replace
Thm valve head valve
edge Replace
Narrow valve seat Reface

Overheatmg RepaIr or
replace
Over speedmg Dnve at proper speeds
Stuck valve Re paIr
gUIde

Excessively worn Shortage of engme 011 Add or

replace 011

cylInder and piston Oil Clean crankcase replace Oil and Oil filter
Duty engme
element

Poor of Oil Use nght od

qualIty
Overheatmg RepaIr or
replace
Wrong assembly of piston WIth connectmg RepaIr or
replace
rod

Improper piston rmg clearance Adjust

Broken pIston rmg Replace
DIrty aIr cleaner Clean

MIXture too nch Adjust

Engme Dnve at proper
over run
speeds
Stuck choke valve Clean and adjust
Overchokmg Start correct way

Faulty connectmg Shortage of engme 011 Add od

rod Low Oil pressure Correct

Poor of engme 011 Use proper od

qualIty
Rough surface of crankshaft Gnnd and replace beanng
Clogged Oil passage Clean

Beanng worn or eccentnc Replace

Beanng unproperly assembled Correct

Loose beanng Replace

Connectmg rod alIgnment mcorrect RepaIr or replace

Faulty crankshaft Shortage of engme od Add or

replace
beanng Low od pressure Correct

Poor qualIty of engme Oil Use proper od

Cr3nkshaft Journal worn or of

out round RepaIr
011 pass ge m crankshaft Clean
Clogged
Beanng worn or eccentnc Replace
Beanng Improperly assembled Correct

Eccentnc crankshaft or beanng Replace

EM 31
 Engine Mechanical

SPECIAL SERVICE TOOL

Tool number For Reference

No DescnptIon use or
page
tool name
on
Umt mm m Figure No

STOSOISOOO TIus engme stand assembly used for

IS dIsassembling or All Fig EM 13
assembling engme block or d1fferenl1al carner throughout models Page EM 2I
Engme stand 3600 m all directIons
assembly

tSTOSOIIOOO
Engme

STOSOl2000
Base
stand

SE184

2 ST05260001 This engme attachment IS mstalled to engme stand LIS Fig EM 13

ST050ISOOO m disassembling or assembling engme
attachment Page EM 2I
Engme

SE185

3 STI 0 120000 Special hollow set bolts used

are m tIghtenmg cylmder heads All FIg EM IS
m senes
L engmes This wrench IS used to torque cylmder L senes Page EM 24
Cylinder head bolt
head bolts and Its head can be mserted mto the
wrench torque
wrench

SE186

4 STI 064000 I This toolIS used together with a torque wrench m All FIg EM IOS
tlghtenmg pivot lock nut for valve clearance adjustment senes
L
PIvot adjuster

SE187

EM 32
 Engine Mechanical

Tool number For Reference

No Descnptlon use page or

tool name UnIt mm m on FIgure No

5 STl103S000

Valve gUIde reamer ThIS gUIde IS used for All FIg 44

EM
set L senes
Pressing used gUIde out of place
Dnvmg a new gUide mto place
STlI031000
FlnIslung the bore of new gUide
Reamer
122 mm dla

STlI032000

Reamer
8 0 mm dla

STlI033000
l
Dnft
l

SE192

6 STll650001

V dIve seat cutter set ThiS valve seat cutter set IS used to or refinIsh a valve seat All Fig EM 45

L senes

SE193

7 STl2070000

Valve hfter 11l1s tool IS used to compress valve spnng by the combmed All Fig EM 32

action of ItS and lever the removal models FIg 81

EM
cam
thereby faclhtatmg
or mstallatlOn of valve collet for general use

SE194

EM 33
 Engine Mechanical

Tool number For Reference

No Descnpl10n use or
page
tool name on No
Umt rnrn m Figure

8 STI3030001 TIus tool IS used with a press to dnve pm mto or out of All EM 29
Fig
connecl1ng rod L senes Fig 84
EM
Piston pm press stand

SE188

9 STI53 10000 ThiS tool used to push a IIp type rear od seal for L senes EM 91
IS All Fig
engme mto place by glVlng hammer blows L senes
Crankshaft rear od
seal dnft

SEl89

10 STI651S000 ThiS 001 IS used to remove the cap from All EM 25

mam
bearmg Fig
When usmg thiS tool turn Its adapter mto the threaded hole L senes
Crankshaft mam
m mam beanng cap
beanng cap puller

STI 65 11000

Body

STI6512001

Adapter

SE190

11 STI6610001 ThiS tool IS used to pull pdot bushmg out of place Ll8 Fig EM 66

Pdot bushmg puller

SE19l

EM J4
rd
 Engine Mechanical

Tool number For Reference

No Descnptlon use page or

tool name
Umt rom In
on
Figure No

12 ST17420001 ThIS tool used to prevent chainS from fallmg out of place All EM 19
IS FIg
In removing cyhnder heads or cam gears and shafts L senes
Chain stopper

A 157
40

JJ SE196

13 ST19320000 ThIS tool IS used to take Oil f1lter out of place In All
tightening Page EM 4
the filter do not tlus tool to prevent
011 filter wrench
use excess
tIghtening models

120 4 7

SE197

14 ST20660000 ThiS tool IS used to Install clutch assembly to engme L20B Fig EM 107

Clutch ahgmng bar

SEOOl

15 EM03470000 TIus tool IS used to compress piston nngs while piston IS All Fig EM 92

beIng Inserted Into cylInder models

Piston nng

compressor

SE199

35
EM
 SECTION EL

ENGINE
DATSUN LUBRICATION
MODEL 610 SERIES SYS TEM

ENGINE LUBRICATION SYSTEM EL 2

SERVICE DATA AND EL 5

SPECIFICATIONS

TROUBLE DIAGNOSES AND

EL 5
I NISSAN I CORRECTIONS

NISSAN MOTOR CO LTD

TOKYO JAPAN
 ENGINE LUBRICATION SYSTEM

ENGINE LUBRICATION SYSTEM

CONTENTS
LUBRICATION CIRCUIT EL 2 Inspection EL 3
01 L PUMP EL 2 01 L PRESSURE REGULATOR VALVE EL 4
Removal EL 2 OIL FILTER El 4
Installation EL 2 RELIEF VALVE EL 4
Disassembly and assembly EL 3

From thIS gallery 011 holes go

directly to all camshaft
beanngs
through carn brackets
011 supplied through the No 2 and
No 3 camshaft beanngs IS then fed

to the rocker arm valve and carn

lobe through the 011 gallery m the

camshaft and the small channel at the
base circle portIon of each carn

OIL PUMP
The 011 pump IS located In the
bottom of the front cover by four
bolts and dnven the 011 pump
by
dnve spIndle assembly whIch IS dnven
by the helical gear on the crankshaft
The 011 pump assembly consists of
an 011 pressurtO regulator valve and
E L007
outer and Inner rotors
f EL l
Fl Lubncatmg CirCUit
The spnng loaded 011 pressure re

gulator valve houts the 011 pressure to

LUBRICATION a maxnnum of 6 kg cm2 80 pSI
CIRCUIT
The pressure lubncatlon of the cylinder head to provide lubncatIon
engine IS
accomphshed by a tro of the valve mechamsm and tImmg
chOid type 011 pump TIus pump
Removal
chain as shown In Figure EL 2
draws the 011 through the od strainer I Remove dlstnbutor
Into pump and then forces It 2 Dram engIne 011
hOUSing
through the full flow type 011 filter 3 Remove front stabilizer
Into the main 011 gallery Part of the 4 Remove shIeld board
splash
011 IS
supplied to all crankshaft 5 Remove 011 pump body With
bearings chain tenslOner aml tUnIng dnve spIndle assembly
chain 011 supplied to crankshaft

beanngs IS fed to connectIng rod

beanngs through the dnlled passages

In the crankshaft 011 Injected l1
fro

Jet holes on
connectIng rods lubn Installation
cates the cylinder walls and pISton I Before Installing 011 pump m
pInS The other part of the 011 IS
ELOOB engIne turn crankshaft so that No
brought to the 011 gallery In the Fig EL 2 Lubrlcatmg cylrnder head pIston IS at T D C

EL 2
 ENGINE LUBRICATION SYSTEM

2 Fill pump housmg with engme of distrIbutor or excessIVe wear

spmdle through fittmg
011 then align punch mark of spmdle hole 3 Check mner rotor shaft for
with hole m 011 pump as shown m 4 bolts secunng 011 pump looseness m body
pump
Tighten
Figure EL3 to front cover 4 Inspect regulator valve for wear

or scormg
5 Check regulator sprIng to see

that It IS not worn on ItS Side or

Disassembly collapsed
6 Usmg a feeler gauge check tip
and assembly and
Punch mark clearance outer rotor to body
1 Remove cover clearances shown EL 7
pump attachmg m Figure
bolts pump cover and cover gasket
and slide out pump rotors I SIde clearance
2 Remove regulator cap regulator 2 Tip clearance
valve and spnng 3 Outer rotor to

3 body clearance
E L009 Install pressure regulator valve
4 Rotor to bottom
FJg EL 3 AIJgnlng punch mark and related parts cover clearance
and 011 hole 4 Install outer rotor mner rotor
and shaft m pump body and do not
3
Usmg a new gasket mstall 011
and
turn cover gasket up
pump dnve spmdle assembly so
I Oil pump body
that the projectIOn on Its top IS 2 Inner rotor and shaft
located m 11 25 am pOSItion at 3 Outer rotOl
tins tune the smaller bow shape will 4 Otl pump cover

5
D
be placed toward the front as shown Regula tor valve
6 S
4
EL Regulator
m Figure 7 Washer v
spnng EL013

8
@
Regula tor cap EL 7 Checking rotor clearances
FIg
9 Cover gasket

7 Place a straight edge across the

Front
face
of pump as shown m Figure
EL 7 Check Side clearance outer to
mner rotor and gap between body
Inspection and straight edge
Wash all parts m c1eanmg solvent The gap should be 0 03 to 0 06
and dry WIth compressed au mm 00012 to 00024 m then
1 and rotor to bottom cover clearance With
Inspect pump body cover

for cracks or excessive wear

gasket should satIsfy the specifi
2 Inspect pump rotors for damage catIons

Standard Wear hmlt

Rotor Side clearance 004to008

mm m o 20 0 0079
outer to mner rotor 00016 to 0 0031

Less than
Rotor tip clearance mm m
0 0047
020 0 0079
o 12
EL011

Fig EL 5 Installing 011 pump Ou ter rotor to body 015 to 0 21

mm m 050 0 0197
clearance 00059 to 00083

Rotor to bottom cover o 03 to 0 13

Ascertam whether the engagement mm m o 20 0 0079
clearance 00012 to 0 0051
IS m order or not by checkmg the top

EL 3
 ENGINE LUBRICATION SYSTEM

Note Pump rotors and body are not OIL PRESSURE

servicedseparately If pump rotors REGULATOR VALVE
or body are damaged or worn
replacement of the entire 011 pump
assembly is necessary The 011 pressure regulator valve IS

not adjustable At the released

plSltlOn the valve permits the 011 to

by pass through the passage m the

pump cover to the mlet Side of the
EL014
pump Check regulator valve sprmg to
ensure that spnng tensIOn IS correct f EL8
F Regulator ualue

TIghtemng torque
011 pump mountmg bolts ft b J I to I 5
kg m 8 to II

011 pump cover bolts kg m ft Ib 07 to I 0 5 to 7

Regulator valve cap nut kg m ft lb 4 to 5 29 to 36

SpecificatIOns
011 pressure at 1dhng kg cm2 pSI o 8 to 2 8 II to 40

Regulator valve spnng

Free length mm m 52 5 2 067

Pressured length mm m 348 I 370

Regulator valve operung pressure kg cm2 pSI 3 5 to 4 2 50 to 60

01 L FI LTER RELIEF VALVE With 011 filter removed check

val e umt for operatIOn Inspect for a
The 011 filter IS of a cartndge type The rehef valve located at the
cracked or broken valve If replace
The 011 filter element should be re center portIOn secunng 011 filter m
ment IS necessary remove valve by
placed penodlcally With the use of 011 the cyhnder block the 011
by passes
It out With a screwdnver
Filter Wrench ST19320000 mto the prymg
mam gallery when the 011
Install a new valve m place by
When mstalhng an 011 filter fasten filter element IS
excessIVely clogged
tappmg It
It on cyhnder block by hand

Note Do not overtighten filter or

oil leakage may occur

STl9320000

EL016
EL015

F EL 9
f RemoulIll1 011 fdter 1 EL IO
FI Relief ualue

4
EL
 ENGINE LUBRICATION SYSTEM

SERVICE DATA AND SPECIFICATIONS

Ou pump

Standard Wear hlTut

Rotor side clearance o 04 to 0 0 020

mm In
outer to Inner rotor 00016 to 0 0031 0 0079

Rotor tip clearance mm m less than 0 12 0 0047 o 20 0 0079

015 to 0 21 050
Outer rotor to body clearance mm In
00059 to 0 0083 00197

o 03 to 0 13 020
Rotor to bottom cover clearance mm m
00012 to 00051 0 0079

Ou pressure regulator valve

cm 2
Ou pressure at Idhng kg PSI 08 to 2 8 11 to 40

Regulator valve spnng

52 5 2 067
Free length mm m

Pressured length mm In 348 1 370

Regulator valve opemng pressure kg cm2 pSI 3 5 to 4 2 50 to 60

T1ghtemng torque
l p mp mounting bol
C s kg m ft Ib I I to 1 5 8 to 11

Ou pump cover bolts kg m ft lb 07 to 1 0 5 to 7

valve cap nut ft Ib 4 tn 5 29 to 36

Regulator kg m

TROUBLE DIAGNOSES AND CORRECTIONS

CondItion Probable cause Corrective acbon

OU leakage Damaged or cracked body cover Replace

011 leakage from gasket Replace
011 leakage from regulator valve TIghten or replace
011 leakage from bhnd plug Replace

Decreased 011 Leak of Oil In engine 011 pan Correct

pressure 011 straIner Clean or

replace
DIrty
Damaged or worn pump rotors Replace
MalfunctIomng regulator Replace
Use of poor quality engine 011 Replace

Decreased 011 pressure Previously mentioned

Warmng hght
on
remams 011 pressure SWitch unservIceable Replace
engine runmng
Electncal fault Check CIrCUit

NOise ExceSSive backlash In pump rotors Replace

EL 5
 SECTION CO

COOLING
DATSUN SYSTEM call
MODEL 610 SERIES

COOLING SYSTEM CO 2

SERVICE DATA AND

CO 5
SPECIFICATIONS

TROUBLE DIAGNOSES
CO 6
I NISSAN I AND CORRECTIONS

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Cooling System

COOLING SYSTEM

CONTENTS

DESCRIPTION CO 2 Fan belt adjustment CO 3

Coolant level CO 2 THERMOSTAT CO 3
Draining and flushing the cooling system CO 2 Removal and installation CO 3
WATER PUMP CO 2 Inspection CO 3
Removal CO 3 RADIATOR CO 4
Disassembly CO 3 Removal and installation CO 4
Inspection CO 3 Inspection CO 4
Installation CO 3

OEseRI PTION CAUTION

The coolmg system IS of the To avoid
coolant and mcreases the coolmg serIOus personal injury
conventional pressure type A centn of the radIator never radiator cap quickly
efficiency remove

fugal pump built the front cover When the thermostat IS closed the when the engine is hot Sudden
serves to clfculate the coolant release of
coolant remams m the cyhnder head coolmg system pressure
The pressure type radiator filler and block for sWift warnung up of IS very dangerous
mstalled on the radiator operates
clF
the coolmg system at higher than
the engme Mter reached normal
If It IS necessary to remove the
operatmg temperature the coolant
The radiator cap when the radiator IS hot
atmosphenc pressure higher clfculates through the radiator
turn the cap slowly counterclockwise
pressure nses the bollmg pomt of the
to first stop After all pressure 1D
coohng system IS released then turn
the cap past the stop and remove It

Draining and flushing

the cooling system
To dram the coohng system re

move the
radiator cap release the
dram cock at the bottom of the
radiator and a dram plug on the nght
Side of the cylmder block If the
heater system IS Installed set the
heater temperature control valve at

open posItion
Mter the coolant IS drained com

pletely close the dram cock and plug

and refill the system With clean
water

FI COol Coolmg system

WATER PUMP
Coolant level neck when the engme IS cold The ex The water pump IS of a centrifugal
The radiator coolant level should
panslOn and contraction ofthe coolant type which IS mounted on the engme
be checked and mamtamed 254 mm
will cause the level to drop by over front cover The fan and pulley are
1 m below the bottom of the filler flow bolted at the pulley hub

00 2
 Cooling System

The pump shaft IS supported by a function of thermostat IS to control

Inspection the flow of coolant
double row ball beanng press fit m the
facilitatmg fast
aluffilnum die cast body Inspect pump assembly for warm up and regulating
an pump engme
The permanently lubn follOWing conditions and replace It If
coolant temperature The thermostats
beanngs are
necessary
cated and sealed to prevent loss of are deSigned to open and close at
I Badly rusted or corroded body
lubncant entry of dirt predeternuned temperatures and If
assembly and vane
The pump contams an lffipeller end
not operating properly should be
steel shaft which
2 ExceSSIve play or roughness
that turns on a removed and tested as listed below
of beanngs In operation
rotates In the ball beanngs and the
volute chamber IS built In the front
The mlet of the
cover assembly Removal and
pump IS connected to the radiator
lower tank by a hose
installation
Installation I Drain coolant partially
I Make sure to clean the gasket 2 DISconnect upper radllltor hose
and front at water outlet
surfaces on pump cover

Always use new gasket when Instal 3 Loosen two securmg nuts and

Img pump assembly sure to remove water outlet gasket and

Be
tighten bolts umformly thermostat from thermostat hOUSing
2 Fill cooling system and check 4 After checking thermostat satIS

for leaks at pump factorily remstall

replacing With a

3 Install fan pull y and fan blade new hOUSIng gasket

cooos and tighten fiXing bolts securely 5 Remstall water outlet and
F CO 2 Water pump and Install belt and adjust for proper tighten secunng nuts
front cover
tensIOn 6 coolant and check for
Replemsh
leaks

Removal
I Dram coolant mto a clean con

tainer
Fan belt adjustment
2 Loosen four bolts retaining fan The fan belt should be properly
shroud to radiator and remove adjusted at all time A tight belt
shroud serves wear of alternator and water

3 Loosen belt then remove fan pump bearIngs A loose belt cause

blade and pulley from hub Improper cooling fan water pump

4 Remoye five bolts pump and alternator operation

COOlO
and from front Check the belt slack between
assembly gasket
alternator apd fan pulley FIg CO 4 RemOVIng thermostaf
cover by pressIng
a force of 10
kg 22 Ib
Slackness of fan belt
8 to 12 min I

031 to 47
0 In

If
adjustment IS necessary loosen
bolt retaining alternator adjusting bar Inspection
to alternator Move alternator toward stlclong thennostat will prevent
A

or away from engine until the correct the cooling system from functlomng
tensIOn IS obtained properly If the thennostat stiCks m
the open pOSItion the engine will
C0006
warm up very slowly If thermostat
FIg CO 3 Removmg water pump sticks In the closed pOSItion over

heating Will result Therefore the

thennostat should be Inspected so as

Disassembly to make sure that It IS In good

The water IS made of

THERMOSTAT condition
pump
A thermostat IS I Submerge thermostat In hot
alununum and ItS bearing outer race wax pellet type
SoC 90F above the tem
mounted m the thermostat housmg at water
ISpress fIt For thIS reason the body
the water outlet speCified In the follOWing
shaft beanng should not be disas cylmder head perature
adjacent to the mlet mamfold The table
sembled

CO 3
 Cooling System

Standard For cold areas For tropIcal areas

75 to 78
Valve operung temperature 80 5 to 83 5 86 5 to 89 5
177 to 183 to 193 167 to 172
oCoF 187

above 8 95 above 8 100 above 8 90

MaXlmum valve hft
OF 0315 203 0315 212 0315 194
mmrC m

Note It is necessary to check a new thennostat before mstalling it m the engine

2 Measure the bft height of valve RADIATOR Removal and

by inserting a screwdnver marked at The radIator IS a conventIOnal installation
8 0315
the pomt about mm In down flow type havmg the top and I Dram coolant mto a clean con
from Its lip bottom tanks to dlstnbute the
tamer
3 Remove thermostat and place In
coolant flow umformly through the
2 Remove front grille
water 50C 90F below temperature vertical tube of the radiator core
3 Disconnect radIator upper and
stamped on the frame The radiator ftIler cap IS deSIgned velucle WIth
lower hoses On a

4 Under the above conditIon valve to mamtam a pre set pressure 09

automatic tranSln1SSl0n disconnect
should be closed completely In tlus kg cm2 13 pSI above atmosphenc cooler 1ruet and outlet bnes from
conSisted of
case agitate water thorougWy pressure The rehef valve radiator
a blow off valve and a vacuum valve
4 Remove bolts retam1ng radIator
helps to prevent coolant loss from from radiator SIde supports and
boiling for by ralSlng the pressure on remove radiator upwards
the coolant On the contrary as the
5 Install radiator m reverse

pressure IS reduced below atmos

sequense of removal
phenc pressure the vacuum valve

allows air to enter

re the radiator

preventmg the formation of vacuum

m the coohng system

The bottom tank on cars equIpped

With the automalic transmiSSion m

011 cooler for the

corporates an
Inspection
transmISSion flUId
Radiator cap should be checked
for pressure at regular tune up
CO 5 Inspecting thermostot check rubber seal
FIB mtervals FIrSt on

cap for tears cracks or detenoratIon

after c1earung It Then mstall radiator

cap on a tester If cap does not hold

pressure or will not release at the

proper pressure replace cap

Also mspect radiator for water

leakage usmg the cap tester under

If thennostat does not operate at
the above It C0012 applymg a pressure of I 6 kg cm2
speCified temperatures
22 8 pSI If such fault detected
must be replaced because It can not Fl CO 6 Radiator for manual
l IS

trnnsm18SIOn radiator
be repaIred repair or replace

4
CO
 Cooling System

SERVICE DATA AND SPECIFICATIONS

Thermostat
For cold For tropical
Standard areas areas

Valve openIng temperature oC eF 80 5 to 83 5 86 5 to 89 5 75 to 78

177 to 183 187 to 193 I 67 to 172

MaxImum valve hft mm oC In uF 8 95 8 100 8 90

0 31 203 031 212 031 194

RadIator

Type
Manual transmIssIon
Corrugated fIn type
Automatic transmISSion
Corrugated fin type equIpped WIth 011 cooler

Cap relief pressure kg cm 2 pSI o 9 13

Coohng system

Leakage testIng pressure kg cm2 pSI I 6 22 8

Capacity
With heater hters US qt Imp qt 65 6 5
Without heater hters US qt Imp qt 60 6 5X

Fan

Number ofblades x outer dIameter

mm In 4 x 350 14

CO 5
 Cooling System

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

I
J
Loss of water Damaged radIator seams RepaIr
Leaks at heater connectIOns or plugs RepaIr
Leak at water temperature gauge Tighten
Loose Jomts TIghten
Damaged cylInder head gasket Replace
Check engme 011 for con tam mati on and refill
as necessary
1
Cracked cylInder block Replace
Check engme 011 m crankcase for mlXmg
WIth water by pullIng 011 level gauge

Cracked cylInder head Replace

Loose head bolts
cylInder TIghten

Poor CIrculation RestnctIon m system Check hoses for cnmps and clear the system
of rust and sludge by flushmg radIator

InsuffiCIent coolant Replemsh

Inoperative water pump Replace
Loose fan belt Adjust
Inoperative thermostat Replace

CorrosIOn Excessive Impunty m water Use soft clean water Ram water IS satis

factory
Infrequent flushmg and drammg of system CoolIng system should be dramed and
flushed Permanent anti freeze
penodlcally
Ethylene glycol base can be used through
aut the seasons of the year and change

penodlcally at mtervals recommended

Overheatmg Inoperative thermostat Replace

Radiator fin choked wIth mud chaff etc Clean out aIr passage thoroughly by usmg au

pressure from engme SIde of radiator

Incorrect 19mtIbn and valve tlmmg Adjust

DIrty 011 and sludge m engme Refill

Inoperative water pump Replace

Loose fan belt Adjust
Restncted radiator Flush radiator

Inaccurate temperature gauge Replace

Impunty m water Use soft clean water

OvercoolIng Inoperative thermostat Replace

Inaccurate temperature gauge Replace

CQ 6
 SECTION EF
p

ENGINE FUEL
DATSUN
MODEL 610 SERIES

FUEL STRAINER EF 2

FUEL PUMP EF 2

TWO BARREL CARBURETOR EF 4

lNI NI
NISSAN MOTOR CO LTD
TOKYO JAPAN
 Engine Fuel

FUEL STRAINER

DESCRIPTION REMOVAL
Disconnect mlet and outlet fuel
The fuel stramer IS of a cartndge hnes from fuel stramer and remove

type It uses a paper element wluch fuel strainer

can be checked for condition from the

outside Tlus stramer should be re

placed penodically
Note Before dlsconnectmg fuel lines
I Body
2 use a con tamer to receive the
Paper element
lines
3 Cover EF005 remammg fuel m

Fig EF 1 SectIonal view ofcartridge

fype fuel stramer

FUEL PUMP

CONTENTS

DESCRIPTION EF 2 REMOVAL AND DISASSEMBLY EF 3

FUEL PUMP TESTING EF 2 INSPECTION EF 4

Static pressure test EF3 ASSEMBLY EF 4

EF 3
Capacity test

the at all pump IS stIll mounted on the engme

DESCRIPTION engine s
requirements
speeds Pressure and capacIty must be Be sure there IS fuel m the tank when
The fuel pump transfers fuel from
determmed while the carrYing out the tests
by two tests
the tank to the carburetor m suf
ficlent quantIty to meet the engme

reqUirements at any speed or load

Thefuel pump IS of a pulsatmg

type deSIgned for easy mamtenance

It consists of a body rocker arm

assembly fuel diaphragm fuel dIa

phragm spnng seal mlet and outlet

valve FIgure EF 2 shows a cross

sectIonal view of the pump

The fuel diaphragm conSISts of
treated rubber which IS not
specially
affected by gasoline and held m place
by two metal diSCS and a
pull rod
This type of fuel pump IS used m

the Ll4 Ll6 and LIS engmes

FUEL PUMP I Outlet valve

2 Diaphragm
TESTING 3 DIaphragm spnng
A fuel pump IS operatmg properly 4 Inlet valve
when wltlun 5 Rocker arm EF006
1Is pressure IS specifi
catIons and ItS IS equal to FIfJ EF 2 Sc e atIc view offuel pump
capacity

EF 2
 Engine Fuel

Static pressure test working part It also indIcates ruptur REMOVAL AND
The test should be ed diaphragm worn warped dirty or
static pressure
weak DISASSEMBLY
gumming valves and seats or a
conducted as follows
Pressure Remove fuel
I DIsconnect fuel line between d13phragm returnspnng pump assembly by
carburetor and fuel pump above the upper lImit indicates an unscrewing two mounting nuts and
excessively strong tensIOn of dia disassemble In the follOWing order
2 Connect a rubber hose to each
I and lower
open end of a T connector and phragm return spnng or a
diaphragm Separate upper body
that IS too lIght Both of these body by unscrewing body set screws
connect tlus connector hose assembly
between carburetor and fuel pump condllIons requIre the removal of 2 Take off cap and cap gasket by
pump assembly for replacement or removing ca p screws
3 Unscrew elbow and connector
repair
Note Locate thIS Tconnector as
4 Take off valve retainer by un
close to carburetor as possible
screwing two valve retainer screws

and two valves are

3 Connect a sUitable pressure eaSily removed
5 To
gauge to the opening of T connector
remove diaphragm press

and fasten the hose between car down ItS center against sprIng force
WIth diaphragm pressed down lIlt It
buretor and T connector with a
chp
untIl the end of
securely pull rod touches the
4 Start and run the engine at Capacity test Inner wall of body Then release the
The capacIty test IS conducted dtaphragm to unhook push rod Use
varYing speeds
only when stalIc pressure IS Within care
dUrIng thiS operation not to
5 The pressure gauge indicates
the specIfication To conduct thiS damage diaphragm or otl seal
static fuel pressure In the hne The
test proceed as follows
gauge reading should be wIthin the
following range I Disconnect pressu re gauge from
018 to 0 24 kg cm2 T connector and In ItS vacant place
2 6 to 3 4 pSI Install a sUitable container as a fuel
sump
Note If the fuel In the carburetor
2 Start and run at 1 000
float chamber has run out and engine
has rpm
engine stopped remove chp
3 The pump should delIver 1 000
and pour fuel into carburetor
2 II U S of fuel In
Fasten dip securely and repeat
cc pts one

nunute or less EF007

static pressure test
If lIttle or no fuel flows from the 1 EF 3 Removmg
FI pull rod
Pressure below the lower lImit indIcation
open end of pIpe It IS an

indicates extreme that fuel hne 6 DrIve out ro ker bv

wear on one part IS clogged or pump IS arm pin
or a small amount of wear on each malfunctioning lIsmg a
press or hammer

EF 3
 Engine Fuel

INSPECTION
I Check and lower
upper body
body for cracks
i
lIil 2 Check valve for
assembly wear

on valve and valve spnng Blow valve

assembly wIth breath to examme Its
functIOn
3 Check for small holes
dIaphragm
cracks or wear

4 Check rocker arm for wear at

the portIOn m contact with camshaft
5 Check rocker arm pm for wear

A pm may cause 011

worn
leakage
6 Check all other components for
any abnormalItIes and replace wIth
new parts If necessary

ASSEMBLY
I Fuel pump cap Rever e the order of dIsassembly
2 Cap gasket the
Closely observe followmg ill
3 Valve packmg assembly structlOns
4 Fuel pump valve assembly
I Use new
5 Valve retamer gaskets
2 Lubncate rocker rocker
6 Diaphragm assembly arm arm

7 DIaphragm spring link and rocker arm pm before

8 Pull rod mstallatlOn
9 Lower body seal washer 3 To test the funcllon proceed as
10 Lower body seal
follows
11 Inlet connector
12 Ou t1et connector Pos1l1on fuel pump assembly about
13 Rocker arm sprIng I meter 33ft above fuel level of
14 Rocker arm fuel stramer and connect a pIpe from
IS Rocker arm
Side pm stramer to fuel pump
16 Fuel pump packing
rocker arm
17 Spacer fuel pump to Operate by hand If
EF008 fuel IS drawn up soon after rocker
q Imder block
arm IS released fuel pump IS fun
Fig EF 4 Structure offuel pump cl10mng properly

TWO BARREL CARBURETOR

CONTENTS

DESCRI PTION EF 5 TROUBLE DIAGNOSES AND

STRUCTURE AND OPERATION EF 5 CORRECTIONS EF 10
Pflmary system EF 6 SPECIFICATIONS AND SERVICE DATA EF 11
Secondary syslem EF 7 AUTOMATIC CHOKE EF 12
Float system EF 8 Descflptlon EF 12
ADJUSTMENT EF 8 Inspection EF 13
fuel level adJus ment EF 8 Trouble diagnoses and corrections EF13
Dash pot adjustment AfT only EF 8 choke
Auto heater EF 13
MAJOR SERVICE OPERATION EF 9 Auto choke EF 14
relay and wIfing
Removal EF 9 Adjustment EF 14
Disassembly EF 9 IDLE COMPENSATOR EF 16
CleanI ng and I nspectl on EF 9 Descflptlon EF 16
Assembly and installation EF 10 Inspection EF 16
JETS EF 10 Replacement EF 16

EF 4
 Engine Fuel

DESCRIPTION These carburetors are almost SimIlar

above
m appearance as explamed
Carburetor type Applied engme except the dash pot for the automal1c
transnnsslOn models
21A304 03 L 18 wIth manual transmiSSIOn The dIfferences In petfOlmanle are
21 04
A304 LI8 wIth automatIc transmIssIon explamed Itl the follOWIng speclfi
ca hons table

As almost all the mechamsm of 2 The power valve mechJmsm

these carburetors are

qUite similar the so called vacuum pIston type affords
wIth all high speed performance STRUCTURE AND
general explanation apphes
except for some vanatlOns 3 AcceleratIng pump gives excellent OPERATION
These are downdraft type and are acceleratIOn These carburetors consist of the
4 The carburetor for automJ hc
desIgned to Increase power and fuel pnmary system for normal runnmg
transmISSIOn IS
eqUipped wIth so called and the for full load
economy secondary system
dash pot that It makes smooth
These present several
carburetors IS
runnIng
dlstmct features of Importance to the deceleratIOn without engme stall at The float system whIch IS com

condlllOn
car owners any operatIng monly used by pnwary and secondary
A of features as 5 Installed order to the secondary sWltchover
summary IS BCD D IS In systems
follows decelera mechamsm the startmg mechamsm
reduce HC enllSSlon dunng
Secondary throttle valve mechJmsm also
I IS
lion acceleratmg etc are

the whIch IS attached

operated by diaphragm 6 An automahc choke system IS

the that the

actuated by vacuum so
adoped On these carburetors both pnmary
hIgher power and better accelerahon 7 Ant1 d1eselmg solenOid IS also add and secondary maIn systems adopt
are achIeved as compared wIth the ed Stromberg type nozzle
mechamcal throttle valve type

I Coastmg an bleed 1st

2 Coastmg air bleed 2nd
3 Coastmg jet
4 S small ven tun
5 S throttle Ive

6 P small ven 1wI

7 Choke valve
8 Slow air bleed
9 Idle nozzle
10 By pass hole
II P throttle valve

EF644

EF 5
 Engine Fuel

Secondary Pnmary

t
12 S mam nozzle 17 S maIn Jet

13 Air vent 18 P
pIpe mam nozzle
14 S mam au bleed 19 P maIn aIr bleed

15 S emulsIOn tube 20 P emulslOn tu be

16 Float 21 P mam Jet

EF644

Fig EF 5 SectIOnal ulew of two barrel carburetor

Primary system
I of the with fuel m the emulsIOn hole
Pnmary mam system AdoptIOn submerged type of
The pnmary mam system IS of slow jet ehrrunates such heSItation as ThIs mixture IS further rruxed and

Stromberg type Fuel flows through occurs on sudd n deceleration of the atorruzed With arr commg from the
the slow bleed The atonuzed nuxture
mam jetmlXmg with air wruch car au

comes m from the mam au bleed and Slow econonuzer system IS useful to IS supphed to the engme from the Idle

passes through the emulsIOn tube obtam smooth deceleration at rugh hole and bypass hole via the slow
and IS pulled out mto the ventun speed Models 21A304 03 and 04 are system passage

through the mam nozzle See FIgUre equIpped With the Idle nozzle as 3 Acceleratmg mechamsm
EF 5 shown m Figure EF 5 Through this The carburetor IS equipped With the
2 Idlmg and slow system nozzle 1dlmg rruxture IS further atom piston type accelerating mechamsm
Dunng low engine speed as shown 1zed by au stream below throttle valve hnked to the throttle valve When the
m FIgure EF 5 fuel flows through the and ensures the stable 1dlmg pnmary throttle valve IS closed the
slow let located m the rear left Side of Small openmg of the throttle valve piston goes up and fuel flows from
the mam jet rruxmg with au corrung m 1dhng load create the float chamber through the mlet
or
partial a large
from the slow air bleed and passes m the mtake valve mto the space under the piston
negative pressure mam

through the slow econorruzer let rrux fold When the throttle valve IS opened the
mg With au corrung from the slow au By thiS negative pressure fuel IS pISton goes down openmg the outlet
bleed and then IS pulled out mto the measured yalv and lJells forced
through the slow let located out through
engine through the Idle hole and by berund the mam jet And au corrung the mjector See Figure EF 6
pass hole from the econorruzer bleed IS ffilxed

EF 6
v
 Engine Fuel

5 Dash pot deVIce

The dash pot deVice IS

provided
for model 21 04
A304 carburetor
only
for an automatic transmiSSion
A dash pot IS Interlocked With the

prunary throttle valve through a

link mechamsm The dash pot which
IS exclUSively Installed on cars equIpp
ed With automatic transmisSion IS

Intended to prevent engine stall that

I Pump Injector would result from qUick applicatIOn
2 WeIght of the brakeunmed13tely after driVing
3 Ou tle t valve
the car or from the
qUick release of
4 Pl ton
5 the accelerator pedal after treadmg
Damper spnng
6 Piston return spnng It slightly
7 ClIp When the pnmary throttle valve IS
8 Strainer closed at 110 pOint from
fully closed
9 Inlet valve
posll1on a throttle lever stnkps against
EF645
thedash pot stem and makes the
FIg EF 6 AccelerotlOn mechanISm
pnmary throttle valve gradually close
thus keeping the engine runmng
4 Power valve mechamsm
The power valve mechamsm so

called vacuum piston type ul1hzes the

vacuum below the throttle valve

When the throttle valve

Secondary system
IS
shghtly
1
opened dunng hght load runmng a Secondary main system
The
secondary mam system IS of
the Intake
high vacuum IS created In
mamfold This vacuum pulls the Stromberg type
Fuel air nnxture the
vacuum pIS Ion upward against the produced by
functIOns of the main Jet mam atr
spnng leaVing the power valve closed
bleed and emulSion tube m the same
When the vacuum below the throttle
manner as m the pnmary system IS
valve tS lowered dunng full load or

accelerating runnmg the spnng pushes pulled out through the mam nozzle
mto the mall venlun
the vacuum pIston downward openmg
The structure IS Ilmost the same as
the power valve to furmsh fuel
I Vacuum pIston the pnmary tltbe
SIde bul emulSIOn
2 Power Je t
EF646 and ventun are dltTerenl Take Lare

FIg EF 7 Power valve mechanISm not to assemble Improperly

I Prtrnary vacuum port

2 Secondary vacuum
port
3 DIaphragm chamber
cover
I Pump IDJector
4 DIaphragm spnng
2 WeIght 5 Draphragm
3 Outlet valve
6 Secondary throttle
4 PIston
valve
5 Dam per spnng
7 Pnmary throttle
6 PIston return spnng
valve
7 Inlet valve
ET023 ET025

Fig 8
EF Full throttle at low speed Fig EF 9 Full throttle at high speed

EF 7
 Engine Fuel

2 Step system fuel consumptIOn will not be m

The constructIOn of this system fluenced by some dirt accumulated m

to the and slow the all cleaner

may correspond IdlIng
system of the pnmary system The needle valve mcludes specIal
Tlus system alms at the proper hard steel ball and will not wear for all

fillIng up of the gap when fuel supply ItS considerably long use BeSides the
IS transferred from the pnmary system mserhon of a spnng will prevent the
to the secondary one The step port IS floodmg at rough road runfitng

located near the

secondary throttle
valve edge m ItS fully closed state ADJUSTMENT
3 sWltchover mech EF017
Secondary
afit m Fig EF 10 Adjustmg loat seat
Fuel level adjustment
The secondary throllle valve IS

linked the which A constant fuel level IS mamtamed

to diaphragm IS

actuated by the vacuum created m the by float level and ball valve

ventun A vacuum Jet IS

provided at If the fuel level IS m accord WJth
each of the and
pnmary secondary level gauge Ime float level IS
properly
ventunes and Ihe composite vacuum set If float level IS not correct adjust
of these Jets actuates the diaphragm It by bendmg float seat as shown m
As the linkage shown Figure
m
Figure EF lO
EF 8 the throttle
causes
secondary ApproXimately H mm IS reqUired
valve not to open until the pnmary for effective stroke of needle valve So
throttle valve opefitng reaches approxI
adjust gap between valve stem and
mately 500 fuel consumption dunng float seat to H mm wIth float fully
normal operatIOn not excesSive
by bendmg float stopper
IS EF018
lifted up
Dunng lugh peed runnmg as H 10 mm 0039 m FIg EF 11 Adjustmg float stopper
shown m
Figure EF 9 as the vacuum

at thc ventun IS mcreased the

the dta
diaphragm pulled agamst
IS

and then
phragm spnng force
throttle valve
secondary IS
opened
The other side dunng low speed
as the pnmary throttle valve
runmng

opelllng does not reach 500 the

secondary throttle valve IS locked to

close the
completely by lockmg arm

which IS Interlocked with pnmary

throllle arm by hnkage
the
When pnmary throttle valve 1 Ball valve
opemng reaches wIder pOSItion than 2 Valve seat
500 the secondary throllle valve IS 3 Float

because the 4 Floa t arm

ready to open lockIng
5 Float stopper
arm revolves and leaves from the EF016

secondary Ihrottle arm

Fig EF 12 Adjustmg fuelleuel

D sh pot djustment
Float system
AfT only
There float chamber
IS
only one

while two carburelor systems pnmary Proper contact between throttle

and secondary are provided lever and dash pot proVides
stern

hel fed from the fuel pump flows normal dash pot performance AdJust
through the filter and needle valve Into ment of the proper contact can be
the float chamber A constant fuel made by dash pot setscrew
level I maIntamed by the float and If normal set can not be obtamed
needle valve between dash pot stem and throttle
Because of the mner vent arm rotate dash pot to the proper
aIr type
of the float chamber ventdatlon the pos1hon FIlf EF 13 Dash pot adjustment

EF 8
 Engine Fuel
I It Auto choke heater
IS
necessary that the Idhng 2 hOUSing can be It IS preferable to leave throttle

speed of engine and mIXture have been removed by loosemng three set screws valve Intact unless otherWIse reqUIred
well tuned up and engine IS suffiCient If throttle valve must be dIsas
ly warm sembled to remedy a defect secondary
2 Turn throttle valve by hand and throttle valve must be Installed to be
read etengu speed when dash pot Just gap free
touches the stopper lever OtherWise stable and slow
IdlIng
3 the pOSItIon of dash pot
Adjust speed performance Will not be

by turmng nut untIl engine speed IS In obtained

the range
of 1 650 to 1 850 rpm
4 Then f sten loos ned lock nut
1 Choke chamber ET038
5 Make that the engine
sure speed IS 2 Thermostat cover

smoo hly reduced from 2 000 to 3 Pu1 P lever

4 Throttle return pnng

1 000 rpm
In about three seconds rod
5 Pump

FIg EF 14 RemOVing auto choke

heater hOUSing
MAJOR SERVICE
OPERATION
I 3 Prunary and secondary emulSIOn Choke
fk
The perfect carburetor delivers the
tubes can be disassembled for a check unloader
for all speeds
proper fuel and arr rabos bleed tongue
by removing main an on
of the partIcular engine for whIch It
respectlve Sides EC526
was deSIgned By completely dISas
4 To check accelerator pump FIg
sembling at regular Intervals which
arm can be removed
pump
will allow cleamng of all l1i
P and 6 To check float float chamber
be re
passages the carburetor can
cover can be removed as Instructed In
turned to ItS onglnal cond1bon and It

m
Will then dehver the proper rabos It a separate paragraph
as
o
oo o e JP
lJIIill I

did when new 00 0

To maintain the accurate carbure

tlOn of passages and

must
dIscharge
be
holes

taken In
s
06
@e
extreme care

cleaning EF027
only carburetor solvent and
Use
l
o
0

e
compressed arr to clean all passages Fig EF 15 RemOVing accelerator
and discharge holes Never use WIre or pumPI
other pOinted Instrument to clean as
cahbratlOn of carburetor will be
EF030

affected FIg EF 18 DISassembling float

chamber

Removal 7 Diaphragm can be disassembled

1 Remove aIr Cleaner by removing three set screws that hold
2 Disconnect fuel line vacuum line diaphragm chamber and other three
set that hold
and electncal wires from carburetor screws diaphragm
3 Remove throttle lever chamber cover In reassemblIng It take

4 Remove four nuts and washers care so that edge of diaphragm WIll not

retaining carburetor to mamfold @ be turned up

off mamfold 8 In disassemblIng and reassemblIng
5 Lift carburetor 1 VentuJ 4
6 Remove and discard the gasket 2 MalO au bleed 5 interlocking hnks take care so that
used between carburetor and mam 3 EmulSIon tube each hnkage has a smooth actlon and

fold It 1f necessary that It IS not fItted In any forced

Replace EF 16 Removing emulsIOn tubes
Fig
posltlon

Disassembly 5 Throttle chamber be

can etach
d
Cleaning and
I Main Jets and slow Jets on both ed from float chamber by removing

pnmary and secondary Sides are rod hnkIng diaphragm With the secon inspection
acceSSible from outSide carburetor for dary throttle valve and loosening Dirt gum water or carbon con

disassembly three set screws that hold tt taminatIOn In or on extenor movIng

EF 9
 EngIne Fuel
often check conditIon of fuelmJectlOn from Replacement of deSIgnated Jets to
parts of a carburetor are

nozzle meet the servIce condition of the

responsIble for unsatIsfactory per the accelerating
effIcIent rod of dla vehIcle must be carned out keeping In
formance For this reason 7 Push connectIng
mmd the above directions To cite a
carburetIon depends upon carelul phragmchamber and block passage of
practical example when It becomes
c1eamng and inspectIon whtle servlc vacuum by finger And when con
to econonuze fuel at a
mg neLtIng rod becomes free check for necessary
and hmlted sacnf1ce of output to meet
1 Blow
passages all castings leakage of air and damage of dia
wIth compressed air and blow off all phragm frequent hght load operatIon use

smaller mam Jets or slow Jets or larger

parts untIl dry
mam au bleeds or slow au bleeds than
Note Do not pass dolls or wues Assembly and
regularly speCIfied ThiS should meet
calIbrated Jets or passages
through installation the purpose Inversely when Increase
as thIS may enlarge orifice and
removal m output IS deSIred at the hnuted
Follow disassembly and
affect carburetor calIbra
seriously sacnfice of fuelconsumptIOn use
tion procedures m
reverse

larger main Jets or slow Jets or smaller

Replace gaskets If necessary
mam air bleeds or slow au bleeds and
In disassemblIng and reassemblIng
2 Check all parts for wear If wear
mterlock link and related components
that should bnng a satIsfactory result
IS noted defectIve parts must be
be careful not to bend Carburetor secondary Jets such as
the follow
or deform any
replaced Note especially
of components secondary mam Jet secondary malll air
Ing bleed step Jet and step au bleed could
Careful reassembly wIll restore
1 Check float needle and seat for Interlock be dlstmgUlshed by theu white color
smooth operatIon of all
wear If wear IS noted assembly must pallltlllg from Jets or au bleed of
parts
be replaced pnmary system
2 Check throttle and choke shaft
bores In throttle chamber and choke TROUBLE
chamber for wear or out ofroundness
JETS
The carburetor
DIAGNOSES AND
3 Inspect Idle adjusting needle for performance
burrs Such a condition depends on Jets and aIr bleeds That IS CORRECTIONS
or
ndges
requIres replacement why these components must be In the followlllg table the

If fabncated WIth utmost care To clean symptoms and causes of carburetor

3 Inspect gaskets 10 see they
them c1eamng solvent and blow troubles and remedies for them are
appear hard or bnttle or If edges are
use

torn or distorted If any such con air on them Larger mner numbers ISted to faCIlitate qUickrepaIrS
the Jets mdlcate larger There vanous causes of engllle
dItIonIS noted they must be replaced stamped on are

Check filter screen for dlTt or lInt diameters mam alld slow troubles It sometImes happens that
4 Accordingly
ncher the carburetor which has defect
Clean and If It IS distorted or remains Jets With larger numbers prOVide no

plugged replace nuxture and the smaller numbers 1he seems apparently to have some

5 Check lInkage for opera tlng con leaner mixture Inversely the mam 1roubles when electnc system IS

and slow air bleeds which are for air defective Therefore whenever the
dItIOn
troubles electriC system
6 Inspect operalton of accelerating to pass through make the fuel leaner engme has
must be checked first before taklllg to
pump Pour fuel mto float chamber If they bear larger numbers and 1he
And smaller numbers the ncher fuel carburetor adjustment
and make throttle lever operate

ConditIon Probable caUse CorrectIve actIOn

Overflow Out accumulated on needle valve Clean needle valve

Fuel pump pressure too high Repau pump

Needle valve seat Improper Lap or

replace

ExceSSIve fuel Fuel overflow See above Item

consumption Each malll Jet slow Jet too large Replace

Each mam air bleed clogged Clean

Choke valve does not fully open Adjust

Outlet valve seat of accelerator pump Lap
Imprpper

L mked opemng of secondary throttle valve Adjust

too early

EF 10
 Engine Fuel

Con dJ tlOn Probable cause CorrectIve actIOn

Power Each mam Jet clogged Clean

shortage
Each throttle valve does not fully open Adjust
IdlIng adjustment mcorrect Repair
Fuel stramer clogged Clean

Vacuum Jet clogged Clean

AIr cleaner Clean

clogged
DIaphragm damaged Replace
Power valve operated Improperly Adjust

Slow Jet Clean

Improper IdlIng clogged
Each throttle valve does rot close Adjust
Overhaul and clean
Secondary thr9ttle valve operaled Impro
perly
Each throttle valve shaft worn Replace
Packmg between mamfold carburetor defec Replace packmg
tIve

Mamfold carburetor tIghtemng Improper Correct tlghtemng

Fuel overflow See the fust Item

Mam slow Jet clogged Clean

Engme heSitation Jet or

By pass hole Idle passage clogged Clean tube

Clean
EmulSIOn tube clogged
IdlIng aJdustment mcorrect Correct adjustment

throttle valve operated Overhaul and clean

Secondary Impro

perly

does not Fuel overflows See the fIrSt Item

Engme
start No fuel Check pump fuel pIpe and needle valve

IdlIng adjustment mcorrect Adjust

Fast Idle adjustment mcorrect Adjust

SPECIFICATIONS AND SERVICE DATA

Carburetor type 21A304 03
21A304 04

Applied engme LI8

Pnmary Secondary
Outlet diameter mm 30 34

Ventun diameter mm 23 30
16 x 8 18 x 9

Mam 102 165

Jet

Mam au bleed 60 60

Slow jet 48 80

EF ll
 Engine Fuel

Slow au bleed 160 100

Slow economizer mm 18

Slow econom12er bleed 100

Power Jet 41

Float level mm 22

Fuel pressure kg cm2 024

Main nozzle mm 26 25

AUTOMATIC CHOKE the auto choke

When the engme IS cold the choke Consequently
closes heater actuates only wlule the engine
DESCRIPTION plate fully
The cholte
auto heater IS located In
IS runnmg
The automatIc choke serves to the thermostat cover and electnc cur The bl metal m the thermostat
open
the choke plate automatIcally under rent flows Into the heater through the cover IS heated by the heater and
varYing engine conditIons auto choke relay opens the choke plate In proportIon to
11us system conSists of an auto The auto choke located ItS own temperature
relay IS In

choke heater an unloader mechamsm the relay bracket of the engine com The choke unloader mechamsm
and some electrical wmng as Illus partment and IS actuated by the alter slightly opens the choke plate at Wide
trated In the follOWing figure nator N terminal voltage open throttle

BATTERY

AUTO
TIC CHOKE
HEATER

EC431

I BCDD
2 Throttle SWItch
3 AntI hesehng solenOId

4 Throttle shaft lever

5 Throttle shaft nut

AutomatI choke
a Thermostat cover

heater WIth blmetal

b Choke pIston lever
c Choke pIston rod
d Choke plate
e Choke connectIng rod
f Fa t Idlmg earn

EC51S

Fig EF 19 AutomatIc choke

EF 12
 Engine Fuel

linkage about 200C

INSPECTION
3 Check to be sure that thermostat If Illsn t
replace thermostat cover

I Before startlOg englOe fully de cover IS set to meet score marks on the

press accelerator pedal to ensure that thermostat houslOg and cover Note Remove au cleaner to facihtate
choke pia te closes properly tlus operatIon
2 Push choke plate WIth a flOger
and check for
blOdlOg 10 choke plate

Thermostdt cover
EC519
BI metdl
ehdmber
FIg EF 21 Measurrng resIstance
2 Thermostat hOUSIng
3 Groove of auto choke heater
ETOJ4 Br metat settmg

4 Check auto choke heater source warms up

wifing for secure fittmg If It doesn t there IS a problem 10

5 Start engme and check that choke the choke

auto mecharusm So pro Replacement
as
plate progressIvely opens engme ceed With trouble diagnoses The auto choke heater IS lOstalled

10 the thermostat cover The cover IS

secured to the thermostat houslOg

TROUBLE DIAGNOSES AND CORRECTIONS WIth three screws

I Remove three screws retamlOg

thermostat cover The cover can then

Trouble 10 Choke mechamsm be taken out easIly

Note Each screw has a small retamer

Be careful not to lose them
Check auto choke heater

Good No good
Replace
thermostat
cover

Check wifing and relay

Good No good
Replace EC520
auto choke
t
relay FIg EF 22 Removmg thumostaf cover

Check and adjust choke and carburetor linkage

2 Install cover WIth three

new

In bl metal
screws lOstalhng cover

choke heater WIth low ohm must be set

AUTO CHOKE a readmg
meter 3 Set thermostat cover score mark
HEATER
Ensure that reStstance between to the score mark on thermostat hous
Inspection
auto choke heater termmal and 109 Refer to
FIgure EF 20
Measure the of thermostat 8 60 i 0 3 at 4 Secure the three screws
resistance auto housmg IS

EF 13
 Engine Fuel
AUTO CHOKE
From Replacement
RELAY AND WIRING
alternator
The auto choke Installed
relay IS

belund the bracket the engIne

Inspection relay In
Earth
compartment RH
I Turn Igmtlon sWItch ON and I Remove screws retaining relay
check the voltage of harness side ter bracket to dash SIde panel RH
mlnal of auto choke heater WIth a low
reading voltmeter No voltage should
Note Three screws are at upper end
eXIst If voltage eXists auto choke
of bracket and other two at bot
nilay IS out oforder Thus check relay tom

Note The harness for auto choke

2 Remove
heater is blue L
screw retaining auto
choke relay bracket Relay
relay to

can then be taken out

3 Install new relay In the reverse

EC522
sequence ofremoval
4

Flff EF 25 Auto choke relay

ET2BO

Fig EF 23 Auto choke heater

connector

6
2 Start engine and check the volt e
age of harness sIde terminal of auto

choke heater with a low volt

l
reading
meter as I
In step 0
If a
voltage of 12V eXIsts the relay
IS In
good conditIOn
If It doesn t check auto choke re

lay

I 2 pomt relay
2 Voltage regulator
3 choke
Auto relay
4
Light relay
5 Horn
EC602

Fig EF 26 RemOVing auto choke relay

n EC521

Fig EF 24 Checking auto choke relay

3 DIsconnect connector for auto ADJUSTMENT

choke and check the contInUity
relay
choke In the 3
through auto relay Vacuum break adjustment Gnp vacuum break rod with

normal condItion contInuity should phers and pull stralght fully

I close choke valve
not eXIst between CD and @ Completely 4 Under tlus condItion adjust the
When 6V direct current IS 2 Hold choke valve close
apphed by stretch gap between choke valve and carbure
between @ and @ continUity be Ing a rubber band between choke tor body to I 5 mm by bendIng
and should exist
tween CD @ If It pIston lever and stationary part of vacuum break rod See FIgures EF 27
doesn t replace auto choke relay carburetor and EF 28

EF 14
 Engine Fuel

Note Make sure that throttle valve

mounted
opens when carburetor IS

on the car

If throttle valve fads to open un

loader becomes inoperative result

Ing In
poor acceleration after engine
I
IS started
LL
I

lJ
J
View from the bottom
EC527
of carbure tor

J
I Choke pISton rod E T033 Flff EF 30 Measuring throttle valve
2 DIaphragm clearance
3 Choke pISton lever
4 Choke valve
5 Choke connecttng rod
EC525 Fast
Idling cam steps

E C528

Fig EF 27 Vacuum break adjustment

Fig EF 31 Fast Idling cam

EC526

Fig EF 29 Adjusting choke unloader

2 The clearance should be specified
value In the follOWing table

Fast idling adJustment

Carburetor removed

If a new or reconditioned carbure MT o 76 mm

tor IS
being Installed tune as follows
I With carburetor assembly re A T o 98 mm

moved from engine measure throttle

EC524 valve clearance A In FIgure EF 30

Fig EF 28 Justlng
Ad vacuum break rod WIth a WIre gauge plaCing the upper
SIde of fast the second If It
Idhng screw on Isn t adJust the clearance by
step of the fast Idling cam fast Idhng screw

Choke unloader adJustment

I Close choke valve

completely
2 Hold choke valve close Engine
by stretch Throttle Clearance revolu tlon rp m
Ing a rubber band between choke A
opening
pIston lever and statIonary part of Ll8
degree mm

carburetor
3 Open throttle lever all the way Manual
II i 0 5 076 i 005 2 OOOi 100
Under tlus condItIon
adJust the TransmissIOn
clearance between choke
plate and
carburetor body to 2 5 mm by bend Automatic
13i 0 5 o 98 0 05 2 400i 100
Ing unloader tongue See
Figure TransmissIOn
EF29

EF 15
 Engine Fuel

I DLE COMPENSATOR

DESCRIPTION

The Idle compensator IS baSIcally a

thennostatlc valve wluch functions to

Introduce the air directly from the au

cleaner to the Intake mamfold to

compensate for abnormal ennchment

of ffilxture In Iugh Idle temperature

cv The bl metal attached to the Idle Flff EF 34 Checking Idle

compensator detects the temperature compensator

of Intake air and opens or closes the for operation

ET033
valve
The Idle compensator operates In Notes
I Fast Idhng cam
response to the underhood air temper is not stabilized
2 Nut
a Engtne operation
ature shown below
3
as
due to wann air flow before idle
Faslldbng screw

4 Choke valve compensator reaches SO to 650C

5 Choke connectIng rod As idle reaches its
compensator
6 Throttle valve
operating temperature secondary
Intake au BI metal
air is introduced into intake maw
Fig EF 32 Justlng
Ad the clearance of temperature function
fold and engine operation becomes
throttle valve
stabilized
Below 500C close
Fully b Locate stick temperature gauge as
close to as possible so that
sensor
500C to 650C Close to open
3 Install carburetor on engine wann au from dryer is directed to

Start engtne and ensure that fast these parts evenly

Above 650C Fully open
Idling screw IS on the second step
4 After warrmng up measure en 4 Idle compensator IS In good order

gine rpm It should be at the specified If a lusslng sound IS heard when ItS
value A d temperature reaches 50 to 650C
5 To fast Idle rpm turn fast Ifnot replace Idle compensator
adJust
clockwIse to Increase
Idhng screw

and counterclockwise to decrease

REPLACEMENT

I Remove au cleaner

2 DIsconnect hose from Idle com

pensator
3 Remove two setscrews from back
To tnlake
Fast Idling adJustment of air cleaner lower cover
mamfold
EF004
Carburetor Installed Idle compensator can then be taken
out easily
If fast Fig EF 33 Construction of Idle
Idhng speed IS too Iugh or
compensator
too low adJust fast Idhng

J
I Warm up engine thoroughly
2 Stop engtne and adJust fast Idhng
screw

Turn fast Idhng screw clockwISe to

Increase or counterclockwISe to de i
crease engtne speed See FIgure INSPECTION r A
EF 32 I
3 Start engtne and place upper SIde Warm up engtne completely
2
of fast Idhng screw on second step of Open engtne hood and remove air EC618

fast See cleaner cover EF 35 RemOVing Idle

Idhng cam Figure EF 31 Flff
Ensure that engtne 3 DIrect warm air to Idle compe nsJL compensator
speed IS Wltlun
tor WIth a heat gun L24 and L26 enlflnes
the specIfied range
If not And measure
repeat above operatIOn to operating temperature 4 InstallatJon IS In the reverse se
obtain correct engtne of Idle compensator
speed quence of removal

EF 16
 SECTION EC

EMISSION
DATSUN CONTROL
MODEL 610 SERIES SYSTEM

GENERAL DESCRIPTION EC 2
CRANKCASE EMISSION
CONTROL SYSTEM EC 2

EXHAUST EMISSION
EC 3
CONTROL SYSTEM

EVAPORATIVE EMISSION
EC 11
I NISSAN I CONTROL SYSTEM

NI55AN MOTOR CO LTD

TOKYO JAPAN
 Emission Control System

GENERAL DESCRIPTION

There are three types of control system

They are

I Crankcase emiSSion control system

2 Exhaust emiSSioncontrol system
3 emiSSion control system
EvaporatIve

CRANKCASE EMISSION CONTROL SYSTEM

CONTENTS

DESCRIPTION EC 2 Ventilation hose EC2

INSPECTION EC 2 REPLACEMENT EC 3

P C V valve EC 2

The
DESCRIPTION venlllatlng air IS then drawn INSPECTION
from the clean side of the carburetor
ThiS system returns blow by gas to air cleaner through the tube connect P C V valve
both the mtake mamfold and carbure the carburetor air cleaner to the
Ing
tor air cleaner rocker cover Into the crankcase Check PC V valve In accordance
The poslllve crankcase ventllallon Under full throttle condlllon the With the follOWing method
P C V valve IS provided to conduct mamfold vacuum IS insuffiCient to With engine running at Idle remove
crankcase blow by gas to the Intake draw the blow by flow through the venlllallon hose from PC V valve If
mamfold valve and Its flow goes through the valve IS working properly a hiSSing
of
DUring partIal throttle operatIOn tube connectIOn In the reverse dlrec nOIse will be heard as air passes
the engine the Intake mamfold sucks It and should
lion through a strong vacuum

the blow by gas th rough the P V On with be felt Immed18tely when a finger IS
cars an
excessively high
valve blow by some of the flow will go placed over valve Inlet Replace P C V
the of the valve
Normally capacity through the tube connecllon to the valve In accordance With the Mam
IS suffiCient to handle any blow by and carburetor air cleaner under all condl tenance Schedule
a small amount of ventilatIng air lions

c ventila
Crankca
tion control valve

2 011 separator
3 Sealed filler cap
ET330
4 Baffle plate
5 011 level gauge Fig EC 2 Checking P C V valve

6 0 Ring

Ventilation hose

I Check hoses and hose connec

lions for leaks

EC031
2 Disconnect all hoses and clean
With compressed If any hose can
air

Flff EC l Crankcase emiSSIOn control system not be freed of obstructIOns replace

EC2
 EmiSSion Control System

ET277
EC598
Flff EC 3 Checking ventilation hose
Fig EC 4 Checking flame arrester FIg EC 5 RemOVing P C V valve

3 To mstall reverse the removal

procedure
Notes

a After Instalhng P C V alve on in

take marufold ensure that there IS

REPLACEMENT no allleakage
I Disconnect ventilatIOn hose from Tightening torque
3 Ensure that flame arrester IS PC V valve 3 0 to 4 0 kg m
se

Inserted hose between 2 Remove PC V valve from Intake

curely In air b If ventilatIOn hose clamp IS
fatigu
cleaner and rocker mamfold See Figure EC 5 ed
cover
replace

EXHAUST EMISSION CONTROL SYSTEM

CONTENTS

SPARK ADVANCE CONTROL SYSTEM EC 3 DISTRIBUTOR 2 potnt type EC 8

DESCRIPTION EC 3 BOOST CONTROLLED DECELERATION
INSPECTION EC 4 DEVICE B CD D EC 8
TROUBLE DIAGNOSES AND
DESCRIPTION EC 8
CORRECTIONS EC 5 INSPECTION EC 9
WATER TEMPERATURE SWITCH EC 5 ADJUSTMENT EC 9
2 POINT RELAY EC 5 REPLACEMENT EC 10
THROTTLE SWITCH EC 7

ThIS system consIsts of a throttle When the car IS In wIde

runmng
SPARK ADVANCE switch a two pOint dlstnbutor and open throttle the advance liming op
CONTROL SYSTEM some electncal wmng and sensors as lImum one IS used In order to Im
Illustrated In the followmg figure The fuel consumptIOn
prove Conversely
DESCRIPTION main component of thiS system IS the the retard liming IS used when the car
dlstnbutor wluch has two breaker IS
runnIng In urban areas The throttle
The spark advance control system pOints One IS for advance
opllmum SWItch detects such runmng condlllons
serves to changeIgmllon timing under IgnItIOn lImmg and the other for reo by momtonng the throttle valve open
varying car cunmng condlllons so as to tard delayed by 60 from optimum Ing
reduce HC and NOx emiSSIOns
liming

EC 3
 Emission Control System

The advance and retard I1mlngs are engine IS cold the optImum tIming IS

with the aid of the

changed by a relay which mom tors always obtamed
whether the throttle opens more than water temperature sWitch

400 or less than 400 But when the

ID
o EC482

FIg EC 8 Ignition timing mark

CD @ ADVANCE
SIDE POINT f

CD WATER TEMPERATURE
5 If not
SWITCH
proceed with trouble dIag
IGNITION @ THROTTLE SWITCH noses
RELAY
COIL C3 2 POINT
If the system IS conditIOn
In good
proceed as follows
6 After stopping engine check con

f tinUIty between two lead wues of

1 throttle sWitch wIth an ohmmeter or

test lamp
When accelerator pedal IS depressed
more than half Its stroke
I
I
contI

nUIty should eXIst

I I
when accelerator
Conversely re
I I
IS

U I Advance pOlO I leased continUIty should not eXist

2 Retard poml

If above test does not

Fig EC 6 Throttle control system produce
proper results replace or
adJust throt
tie sWItch
INSPECTION 3 Start engtne and
keep It at Idhng
speed
I Warm up engine and
completely Check IgmtlOn tIming wlule re
then turn It off
peatedly connecting and disconnecting
2 Disconnect pair of wues from the two harness side lead WIres wluch Accelerator pedal ContinUity
throttle sWItch mstalled besIde car
were connected to throttle SWItch
buretor
4 If the results are as below the Depressed Yes

N ate To facilitate system IS In

good conditIon
dlSconnectmg Released No
these wues remove aU cleaner Connect two harness WIres

Advance tIming
DIsconnect two harness WIres

Retard tIming

Note Difference between Advance

and Retard IS about 60

EC483
Fig EC 7 Dlconnectmg throttle
sWItch wire Fig EC 9 Checking throttle sWitch
I

4
EC
 EmiSSion Control System

TROUBLE DIAGNOSES AND CORRECTIONS

Trouble In
Spark advance control system

Check continUIty of water temperature sWItch

Good No good
Replace water temperature SWitch

Check operallon of 2 polnt

relay

Good No good
Replace 2 pOlnt relay

Check 2 polnt dlStnbutor wlflng

Good No good
Repair or replace breaker pOint

Others
I IgmtlOn liming adJustment
2 Pomt gap adJustment

2 Check between Note Some coolant will flow out

WATER TEMPERATURE contlOUlty the

terminal and when switch is removed so have a

SWITCH engine body wIth an

ohmmeter or test lamp rag handy

The water temperature switch There should be no
wIth continUIty
eqUipped a parr of lead Wires IS
3 Install water
when engine IS suffiCIently warmed up
new temperature
mstalled on the thermostat hOUSing SWItch
coolant temperature IS above 500C
One lead wue IS connected to the
If cont ulty eXIsts replace water tem torque
harness wire and the other IS for body TIghtening
perature sWItch 2 0 to 3 0
earth When the engine IS warmed up kg m

coolant IS above 500C there IS no

After engine has cooled down
Note Note Pnor
continUity Conversely when the to Instalbng SWItch to
ensure that there is in
continuity thermostat houslOg be sure to
engine IS cold coolant IS below 500C the SWItch thread of
apply sealer to new
then IS contlOUlty between the two
SWItch
termmals

2 POINT RELAY

The 2 pOlnt relay IS Installed on the

the
relay bracket and IS connected
I
to

harness
engine compartment
ThiS relay changes the Igmllon
Fig EC ll Checking continuity of
tlffilng by breaking or not breaking the
EC484 water temperature SWitch
retard Side pOint CirCUIt
In the normal condltlon the retard
FIg EC ID Water temperature sWitch
SIde pOInt C1CCUlt IS ahve When the
Replacement engine IS warmed up and the throttle

I DIsconnect pair of lead WIres valve IS opened WIde thiS 2 polnt relay
Inspection from water breaks the retard SIde polOt CirCUIt
temperature SWitch
I Disconnect water temperature 2 Remove water temperature Then the IgnItlon tlmlng IS changed to
sWItch leag WIres from harness wire swItch from thermostat hOUSing the advance SIde opllmum tlmlng

EC 5
 EmiSSion Control System

e 2
ic 4
i
I t 3
5 II Useless
6 t
PJ 2 To advance pOint
3 Useless
4 To retard
pOint
5 Power source

6 To water temperature sWitch

throttle SWIlch
EC487

Fig EC 12 2 pomt relay

Inspection Replacement The 2 polnt Installed behmd

relay IS

the
Turn IgmtlOn sWitch on relay bracket In the engine com

partment
1 DIsconnect
Note It IS to start battery ground cable
unnecessary
and relay connector
engine
2 Remove screws retaining relay
bracket and
2 Disconnect pair of dlstnbutor pull bracket out a httle
lead wrres at connector

Note Three screws are at upper side

of bracket and other two are at the
bottom

I Auto choke relay

2 Voltage regulator

k 3
4

5
2 potnt relay
Horn relay
LIght relay

Fig EC 13 DISconnecting dlstrlbutor

@ Connector for autochoke relay
lead wire
@ Conneclor for voltage regulator

3 Check continUIty between har

ness sIde terminals In the connector
disconnected In step 2
When engme IS warm enough contJ

nUlty should eXist If not

replace
2 pomt relay

Note When engine is cold dIsconnect

water temperature swItch tenninal

I 2 poln I relay
2 Voltage regulator
4 Then accelerator
depress pedal 3 Automatic choke
more than half ItS stroke and check 4 LIght relay
continuIty as In step 3 5 Horn

ltlnulty
tfS9 d s not eXist 2 po nt

relay IS In
good condltJon EC601

If It does replace 2 polnt relay Fig EC 15 2 polnt relay replacement

EC 6
 EmiSSion Control System

3 After removIDg 2 polnt relay AdJustment

Retalmng screw

retaining
taken out
screw relay can easily be
f1
I
I
The throttle SWitch should operate

4 Install new the I at the throttle valve opemng of about

relay In reverse
400
sequence of removal

Consequently touch pOint adJust

ment of the throttle swlIch IS neces

sary
THROTTLE SWITCH I Disconnect accelerator torsIOn
shaft from carburetor TorsIOn shaft
Inspection can be disconnected
EC491 by pulling pin
I Check continUity between two securing stopper
L 2 Install bolt
lead WIres of throttle switch with an a With opemng
ohmmeler test onto throttle shaft of
or
lamp gauge nut
o When accelerator pedal IS depressed carburetor as ID the follOWing figure
more than half Its stroke contI

nUlty should eXist Notes

When accelerator released contI
o IS a
Opemng gauge can be made With a
nUity should not eXist conventional M8 bolt and paper
On the paper mark the 400 point

b Indicator IS also necessary

EC492
Indicator should be Installed on

Fig EC 17 Throttle SWitch statIc part of carburetor

Opemng gduge

FIg EC 16 Checking continuIty of

throttle SWItch

2 If above conditions are not met

replace throttle SWItch

or
adJust

EC493
Replacement
FIg EC 18 Installing throttle opening gauge
The throttle SWitch IS Installed on

the rear sIde of the carburetor

Whenever the throttle SWitch IS

removed from the carburetor the 3 Then throttle lever shaft by

pull
throttle switch touch must be
pOint hand and confIrm that touch pOint IS
readJusted at 400 opemng of throttle valve If
touch
Remove
not adJust pOint by adJusting
air cleaner housing
throttle SWItch adJusting screw
2 Disconnect two throttle SWItch
lead WIres

3 Remove two Notes

screws retaining
throttle SWItch to carburetor a Touch pOint can be detected With
Throttle swlIch can then be taken ohmmeter or test lamp EC494

out b The throttle SWitch also clicks at

touch
4 InstallatIon can be carned out In point
the reverse
sequence of removal

Note In relnstalhng throttle switch

some
adJustment is necessary Refer
the followIDg section
to AdJust FIg EC I9 AdJustmg touch pomt
ment of throttle SWitch

EC 7
 EmISSion Control System

DISTRIBUTOR 2 point type When pomt surface IS rough re Vacuum advance mechanIsm
wIth fine sandpaper mechanIcal parts
move
nregulantles
The 2 polnt type dlstnbutor has of 500 or 600 or with 011 stone
If vacuum advance mechamsm falls
two breaker and condensers When wear on contact pOInts IS
pOints
to operate properly check for the
located opposite to each other with a nOllceable replace pOInts together
follOWing Items and correct the
phase difference of 60 with contact arm

malfunction as requned
Other than the dual pOint mecha
I Check vacuum Inlet for signs of
msm the construcllon of the dlstnb
leakage at lis connectIOn If necessary
utor follows the conventIOnal desIgn
retIghten or replace
2 Check vacuum diaphragm for an

leak
If leak IS found
replace vacuum

controller assembly
3 Inspect breaker plate for smooth

movement
If plate does not move smoothly
tlus condlllon could be due to sllcky
steel balls or grease to
piVOt Apply
steel balls or If necessary replace
Breaker
breaker plate as an
assembly
Flff EC 20

Condenser

Satisfactory performance of con

denser depends on capaclly and degree
Inspection of insulatIOn Thus ensure that ter

mmals are clean and setscrews are

CAP AND ROTOR HEAD light

Condenser should be checked wllh
The cap and rotor head must be a condenser tester
Inspected at regular Intervals In addl
lion pOint replacement and pOint gap ET268

adJustment also should be carrIed out Fig EC 22 Jushng

Ad POint gap
at regular Intervals
I Remove and clean all dust
cap BOOST CONTROLLED
and carbon depOSllS from cap and
DECELERATION
rotor

If cap IS cracked or leaking replace DEVICE B C D D

It

2
Contact point replacement DESCRIPTION
Check Insulator of Po In t lead
wnes
The BCD D serves to reduce HC
If msulator IS cracked or detenorat Fnst turn out setscrews I to I 5 emIssIonsdunng coastIng
ed replace It and
turns at contact arm
pnmary lead The high mamfold vacuum dunng
wire connectIOn Just far enough to pull coasting prevents the complete com
out pnmary lead termInal busllon of the mIXture gas due to the
21
Refernng to FIgure EC unscrew reduced amount of mIXture gas avaIl
two contact set fiXing screws and able
Contact
pOint adJustment remove lead amount ofHC
wIre As a result an excess

Contact pOint should be replaced In Holding contact arm with fingers emllted mto the
IS atmosphere
accordance with the Maintenance pull contact set out toward you by When mamfold vacuum exceeds the
Schedule ralSlng 11 shghtly Contact pOInt and value thIS BCD D
5l t operates to
Standard pOint gap IS 045 to 055 arm can then be removed together supply addlllonal mixture gas of
mm If size IS off the standard Install contact pOInt and
adJust new arm
opllmum mixture rallo
ment can be made by loosemng pOint assembly In reverse sequence of re Complete combusllon of fuel IS

moval Apply a
screws Gap gauge IS reqUired for hght coating of grease aSSisted by thiS addlllonal mIXture
adJustment tocam and HC emISSions are thereby reduced

EC S
 EmiSSion Control System

I Au passage
2 Mixture control valve

3 Dlaphragm ll
4 Vacuum control valve

EC514

Fig EC 23 Boost controlled deceleration deVice

It will BCD D and

suddenly up to about inoperatIve
a remains
INSPECTION nse

600 mmHg decreases with no

negatIve pressure
I Conned vacuum gauge to Intake b It will decrease gradually to 560 sustained
plateaus wlule It IS falhng
mamfold In such a case
mmHg and stay there for a while See dIagram A adJust
It will to Idle boost operating pressure as follows
c drop pulse

a MaXimum negative pressure

Ncgal1ve A
b Operalmg pressure Pressure
c
Idling pressure

Negal1ve
pressure

Set
pressure Sel
Pressure
ET285
Idling
pressure Idling
Flff EC 24 Connecting vacuum gauge Negative
Pressure
1 line
TIme
Note A servIce plug IS Installed on Chdractensltc curve of BCD D
Intake marufold Remove thIS plug EC502
Negative B
Pressure
and Install an attachment whIch IS
Flff EC 25 CharacterIStic curve of
equIpped wIth a vacuum gauge
BCDD

2 Start engine and observe vacuum 4 If It does not react as descnbed

gauge whIle floonng and releasing ac abo e set pressure must be adJusted Set
celerator pedal abruptly In such a case refer to AdJustment Pressure

Note ThIs sImulates Idling

operation the
Negal1ve
engine coastll1g condItIon ADJUSTMENT Pressure
Time

3 If BCD D IS m
good condItion EC503
High operating pressure
vacuum gauge will indicate the follow Fig EC 26 Characteristic curve
too
Ing phenomena When operating pressure IS
high hlffh operating pressure

EC 9
 EmiSSion Control System

Low 2 New BCD D

operating pressure assembly can be
Installed In the reverse sequence of
When operating pressure IS too low engme rpm will not fall to Idle speed removal

NCgJtlVL Negative
Prc urc
Tlghtenmg torque
Prc urc
o 2 to 0 4 kg m

Note After securing three secunng

screws rescrew other three
S l Scl BCD D
Prc
assembly screws 111 order
ucc Prc url
to avoid warping BCD D
body
Idling Idling
NCgJtlvl NCgJtlvL
Prc ur
Pre surc

TlOlt
TmlC
EC504

Fig EC 27 Characteristic curve low operating pressure

I Remove rubber cap at bottom of Notes

BCDD a
Turning adJust1l1g screw one
quarter
will
2 Turn adJusl1ng screw slIghtly rotahon cause a change 111

Then race and confirm that operahon pressure of about 20

engine

opera ling pressure IS at the speCified mmHg

b Do not fit tip of screwdriver
value tightly
into screw slot

After has been com

3 adJustment
pleted Install rubber hose and service
BCD D set pressure
560 i 10 pi ug In their onglnal posttlOn
mmHg

REPLACEMENT

I Remove three BCD D secunng

screws BCD D assembly can then be

taken out from carburetor

Note There are SIX screws at the

bottom of BCD D Three of them
I AdJu tmg
ULV
are BCD D securing screws and
2 Cover
ET037
others are BCD D assembly
screws

Fig EC 28 AdJusting control valve

I
SCLurmg suews

2 Assembly rews
ET286

Fig EC 29 AdJusting setscrew Fig EC 30 RemOVing BCD D

EC l0
 Emission Control System

EVAPORATIVE EMISSION CONTROL SYSTEM

CONTENTS

DESCRIPTION EC 11 Checking fuel tank vacuum relIef valve

INSPECTION EC 13 operation EC 13
Checking fuel tank fuel liquid separator REPLACEMENT EC 13
and vapor vent line EC 13 Flow valve
gUide EC 13

Checking flow gUIde valve EC 13 Fuel Sedan and

liqUid separator Hardtop EC 14
Fuel Station
lIquid separator Wagon EC 14

DESCRIPTION 2 Fuel hqUld separator valve and IS led to the crankcase Once

3 Vapor vent hne the engine starts the gas evaporatIng

This system IS adopted to prevent
4 Flow gUide valve In the crankcase IS sucked Into the
fuel vapor from evaporating Into the
The flow gUide valve prevents mamfold for combustIOn When the
atmosphere Thefuel vapor from the
blow gas from Into the fuel pressure of the sealed type fuel tank
sealed fuel tank IS led Into the crank
by floWIng
tank and fresh Into It
case of engine
gUIdes air fuel hqUld separator and vapor vent

preventing gasohne vapor from escap line becomes negatlve by decreaSing

ThIS system consists of four basIc
Ing Into the carburetor au cleaner the fuel the flow gUide valve opens to
elements indicated below
WhIle the the from the carburetor
I Fuel tank wIth engIne IS stopped send fresh air au
posltlve sealIng
evaporatlve gas opens the flow guIde cleaner to the fuel tank
filler cap

EC 11
 EmiSSion Control System

From all cleaner

From fuel lank

To crankcase

Sedan and Hard top

I I low gUide valve

2 I uel
pIpe
3 Venl hne
4 I uellank
S ruel liqUid epdrdlor
6 I uelldnk Wllh pO l1ve

sedllng filler Cdp

StdllOn Wagon

EF609

Fig EC 31 EvaporatIVe emISSion control system

EC 12
 EmiSSion Control System

INSPECTION 3 Connect a 3 way connector a

manometer and a
clamp or an eqUlv
Checking fuel tank dlent 3 way change cock to end of
fuel liquid separator and
vent lIne
vapor vent line 4 fresh
Supply au Into vapor vent
line through cock lIttle by lIttle untll
I Check all hoses and fuel tank
pressure becomes about 400 mm
Aq
filler cap
Water Then leave and
height clamp
2 DIsconnect the lIne
vapor vent cock closed for 2 5 minutes
connecting flow valve to fuel
gUide 5 After 2 5 minutes measure height
lIqUid separator of lIqUid In manometer
EF640
VarIatIOn should
In
height remain

wlllun 25 Aq Water
mm
height Fig EC 35 Flow gUide valve
If height should drop to zero In a

short lime some pIpIng may be dam

aged
6 If height does not drop to zero In
Chel king fuel tank vacuum
short lime when filler cap IS removed
relief valve operation
hose IS stuffy
Remove fuel filler cap and see It
Note In case vent bne IS
stuffy functIOns properly
breathing In fuel tank IS not I clean valve
Wipe hOUSing and have
thoroughly made thus causing in It In your mouth
suffiCIent dehvery of fuel to engine
2 Inhale A
EF610
It must
air
slIght reSIStance ac
or vapor lock therefore be
Fig EC 32 Disconnecting vapor companied by valve indIcates that
vent line repaued or
replaced valve condlllOn
IS In good mechamcal
Note also thaI further
by inhalIng air
3 WdY lonncctor resistance should be disappeared With
valve clIcks

3 If valve IS clogged or If no reSISt

Mdnomctu uelltquld separJtol felt
ance IS
replace cap as an assem

bled umt

I low gUide vJlve

EC029
Ventilation hole

Fig EC 33 Checking evaporatIVe emiSSIOn control system

1
I DIsconnect all hoses connected to

Checking flow guide valve the flow gUide valve

2 Whlle lower pressure au IS pressed

Tlus valve IS mounted Inthe engine
mto the flow gUide valve from the
Marks A F and Care
compartment ends of vent lIne of fuel tank Side F PIe surc reliefVJlvl
engraved In the body of the valve to
the should go the valve and
au
through
indicate the connectIOn of the vapor ET072
flow to crankcase Side C If the au
vent line Fig EC 36 Fuel Iller cap
does not flow the valve should be

replaced But when the air IS blown

from crankcase Side C 11 should

the other two venl lInes REPLACEMENT

never flow to

the
3 While the au IS pressed Into
Flow guide valve
I rom
flow gUIde valve from the carburetor
81r cleaner Side A It flows to the fuel The flow valve secured to
cdrburctor gUide IS

lIT dCJnu tank Side F and or crankcase SIde the bracket In the engine compart
C ment
4 ThiS valve opens when the Inner Remove flow gUide
bolt seCUrIng
E T042 10 l r c
mklJo

pressure IS 10 mmHg In case of valve to bracket Valve can then be

Flff EC 34 Checking flow gUIde Improper operatIOns or

breakage re taken out eaSily InstallatIOn IS In the
valve place 11 reverse sequence of removal

EC 13
 Emission Control System

3 Fuel lIqUid separator can then be 2 Loosen three screws retaining fuel
taken out In the trunk room
lIqUid separator
4 Installal10n IS In the reverse se 3 Taking out fuel bqUld separator
quence of removal dIsconnect fuel vapor hoses Fuel

lIqUId separator can then be taken out

eaSIly
4 Installation IS In the reverse se

quence of removal

EF611

FIg EC 37 Removing flow gUide

valve f

I
Fuel liquid separator
Sedan Hardtop

On the Sedan or Hardtop model

Flff EC 38 RemOVing fuel liquid

separator Sedan
EF612

l
the fuel bqUld separator IS onlocated
the lower sIde of the
parcel shelf Fuel liquid separator
I Remove rear parcel shelf fjmsher
Station Wason
by removing nvets EF613
Remove R H Side
2 Remove four bolts securing fuel body trim by Flff EC 39 RemOVing fuel liqUid

lIqUid separator to parcel shelf panel removing nvets separator StatIon Wagon

EC 14
 SECTION EE

ENGINE
DATSUN ELECTRICAL
MODEL 610 SERIES SYSTEM

BATTERY EE 2

STARTING MOTOR EE 3

CHARGING CIRCUIT EEll

ALTERNATOR EE 13

REGULATOR EE 19

IGNITION CIRCUIT EE 25

DISTRIBUTOR EE 26

IGNITION COIL EE 31

I NISSAN I SPARK PLUG EE 32

NISSAN MOTOR CO LTD

TOKYO JAPAN
 ENGINE ELECTRICAL SYSTEM

BATTERY

CONTENTS

REMOVAL EE 2 Battery freezing EE 3

CHECKING ELECTROLYTE LEVEL EE 2 CHARGING EE 3

CHECKING SPECIFIC GRAVITY EE 2 INSTALLATION EE 3

REMOVAL
I Disconnect negal1ve and pOSll1ve
terffilnals
2 Remove nuts from battery
clamps take out clamps
3 Remove battery

I Thermal gauge
EEOOl
2 Hydromeler

Fig EE l Checking specific gravity

St 00007 t 20
CHECKING Where Converted speCific gravIty 520
ELECTROLYTE LEVEL
St SpeCific gravity of electrolyte
Remove SIX filler plugs and check
at tOC
the electrolyte level In each filler If
S20 SpeCIfic gravity of electrolyte
necessary add only dlsl1lled water to
corrected at 200C 680F 0
the level to the indIcator e
bnng In each
Electrolyte temperature a
filler operung Do not overfill
For A 8 24
example hydrometer e

readlOg of I 260 at 300C 860F

would be I 267 corrected to 200C
680F e
IOdlcatlng fully charged 1j
battery On the other hand a hydro il

meter reading of 1220 at lOoC

I40F would be I 199 corrected to
CHECKING 200C 680F indIcating a parl1ally
SPECIFIC GRAVITY charged battery U
12
SpeCific graVIty of battery electro The state of charge of battery can

lyte IS tested by a hydrometer If the be deterffilnedby the follow 109 table 10

state of charge of battery IS 60 full If the

speCific graVIty of electrolyte IS IJ

below known Before checking check to be

or speCific graVity reading IS

I 20 as corrected at 200C 680F sure that cells are filled to correct

recharged or battery
must be level EE003
battery
electrolyte concentration adJusted Flff EE 3 SpecifIC gravity at
Add or subtract gravlly pOints electroly te temperature

accordmg to whether the electrolyte

temperature IS above
680F standard
The

00007 for every l C l8 E tem

or

gravity of electrolyte changes

bellow 200C

n
8
en
1M
0 10 JO

CharJln
I

cO SO 60

condltt6n
10
I
80 JO 100

perature A correcl1on can then be EE002

made by usmg the followlOg formula Fig EE 2 Charglng conditIOn

EE 2
 ENGINE ELECTRICAL SYSTEM

battery falls below I I the Indlcal10n nunals should be cleaned With brush
Battery freezing a

that the and baklllg soda solutIOn In

IS battery
completelyIS common
Temperatures at which battery
freezes wIth aCid discharged and will freeze readily addition the
follOWing Items should
electrolyte vary
when temperatures fall below freezlllg be observed dunng recharging battery
concentral1on or Its spe lfic gravity A
I Be sure that electrolyte level IS
battery WIth a insuffiCIent state of Note Use extreme caution to aVOId
above top ofeach plate
wIll freeze lower tem freeZing It will
charge at battery since
2
of Keep removed plugs In a safe
peratures If specIfic gravIty a
generally ruin the battery
10cal1on
3 Do not allow electrolyte tempera
0 ture to go over 450C 1 130 F

After be
4 rechargtng check to
10 certaIn that speCific gravIty does not
o
G
exceed 1 260 at 200C 680F
20
Correcl1on can be made by adding
E distilled water Into cells as necessary
30
5 from
Keep battery away open
40 flame while It IS being recharged
5l
6 After all have been
0
vent plugs
50 clean all spraYing ofelectro
lightened
lyte off upper face of battery
60
0

I
e
70 I
7
80

1 00 I 04 I 08 I 12 I 16 1 20 I 24 I 28 I 32 EE004

SpecIfIc gravIly of eleclrolYle

Flff EE 4 FreeZing pOint of electrolyte

INSTAllATION
I Install and lighten clamps secure

CHARGING Iy
be bnng It up to full charge 2 After clamps have been tightened
Bat ery must recharged when charged to
cable termInals and
electrolyte gravity reading falls below the operation should be carned out clean battery
i 20 With electrolyte level belllg With negal1ve terminal removed apply grease to retard formalion of

If battery IS
qUick Pnor to charging corroded ter corrosIOn
satisfactory

STARTING MOTOR

CONTENTS

EE 8
SPECIFICATIONS EE 4 Over runnll1g clutch assembly
Brush holder test for EE 8
DESCRI PTION EE 4 ground
metal EE 8
OPERATION EE 4 P llion case beanng
SWitch assembly EE 8
CONSTRUCTION EE 5 Magnetic
ASSEMBLY EE 8
REMOVAL EE 5
TEST EE 8
DISASSEMBLY EE 5
Performance test EE 8
CLEANING AND INSPECTION EE 6
EE 9
Terminal EE 6 DiagnOSIs of test
test EE 9
Field COli EE 6 Magnetic SWitch assembly
EE 10
Brushes and brush lead wire EE 7 SERVICE DATA

Brush spnng tension EE 7 TROUBLE DIAGNOSES AND

EE 10
Armature assembly EE 7 CORRECTIONS

EE 3
 ENGINE ELECTRICAL SYSTEM

SPECIFICATIONS

HITACHI S114 103P

Type
12 volts
Voltage
10KW
OutpLlI
Less than 480 amps 6 volts
Startmg current voltage
Less than 60 amps 12 volts
No load current voltage
More than 7 000 rpm
No load starter revolutIon
Magnetic shift
Shift type of pinIOn gedr
9
Number of teeth on
pUllon gear
120
Number ofteeth on
nng gear
5 1 11
Weight kg lb

DESCRIPTION pOMtIon
This breaks the solenOId CirCUit so
the solenOid complete the CirCUit to
The function of the starting system the
that reverse current flows through
the starting motor and then
wnslstmg of the battery Igmtlon operAte
senes coil and the magnetIc field
out the adual
SWltlh startIng motor and solenOid IS the motor cdrnes
bUilds LIP In the direction In which the
The eledncal the engme
to crank the eng1l1e crallkl11g of
plunger moves balk As tlllS happens
IS supplied from the bdttery
energy the resultant force of the magnetIc
fields 1ll the shunt coil and the senes
COIl becomes zero The return spnng
then actuates the shift lever to pull the

plunger whIch allows toopen the

solenOId swltch contacts Con

sequently the starting motor stops

I ShIft lever
2 Over runmng c1ulch
3 PInion
4 PinIOn stopper
5 Armature
6 Yoke
7 Brush
8 MagnetIc SWItch Ass y

9 Plunger

Flff EE 5 Sectional view of starting motor

OPERATION
When the Igmtlon SWitch IS turned nng gear
fully clockWIse to the START POSI ClOSing of the solenoid SWitch
tIon battery current flows through contacts causes the motor to crank the EE006
senes and shunt COils of the engine and also cut out the senes
I 8
SlallOnary conlact ShIft lever
solenOId magnetIZIng the solenOId COIL of the solenOid the magnetic pull 2 Senes COIl 9 Dnve pinIOn
The Into the solenOId of the shunt cod being suffiCient to 3 Igmllon SWllch 10 Ring gear
plunger IS pulled
4 SolenOid II PinIOn sleeve spnng
so that It operates the shift lever to hold the pinIOn In mesh after the
5 Shunl cod 12 Armalure
move the dnve pinIOn Into the shifting has been performed
6 Plunger 13 Movable conlaclor
flywheel nng gear Then the solenOId After the engtne starts runmng the 14 Battery
7 Return sprmg
SWitch contacts close after the drive driverreleases the IgmtIon key and It
Fig EE 6 Startmg motor Circuit
plmon IS partially engaged WIth the automatically returns to the ON

EE 4
 ENGINE ELECTRICAL SYSTEM

More meshing and the the armature shaft from the motor armature to the nng
posll1ve pinIOn along
demeslung of the pinIOn and the nng Into or out of mesh wllh the nng gear gear but permit the plnlOll to over run
the
gear teeth of the
are secured by means teeth The over runmng clutch IS armature after the engine has

runmng clutch The over transmit dnvlng torque started

over runmng designed to
clutch employs a shift lever to shde

CONSTRUCTION

@ @ @ j @

t
@ j @
O
0

elf 1 @

1 Shlfllever ptn 13 PinIOn stopper

2 Gear Lase 14 PinIOn
3 Dust cover 15 Over funmng clutch
4 ShIft lever 16 Field cod
5 Dust cover 17 Yoke
6 Magnetic SWitch Ass y 18 Brush
7 Armature 19 Brush
8 Thrust washer 20 Brush spnng
9 Melal 21 Brush holder Ass y @ @@@ @ @
10 Thrust washer 22 Metal
EEOO7
11 Stopper washer 23 Rear cover

12 Slopper chpe 24 Through bolt

ofstartmg motor
FIg EE 7 Exploded vIew

REMOVAL magnetIc sWitch and remove magnetIc 2 Remove two through bolts and
sWitch assembly brush cover assembly
Disconnect cable
battery ground
Disconnect black WIre with yellow
tracer from magnetIc SWitch terminal
and black battery cable from battery Il
Iml
Jm
Ill
ten111nal of magnetIc SWitch
2 Remove two bolts secunng start
Ing motor to gear case Pull starter

forward and
Q
assembly remove starting
motor

@
@
DI
DISASSEMBLY
I Loose nut
secunng connecting EEOOB
EEooe

plate to magnetIc SWitch M ter

Flff EE 8 Removmg magnetlc SWitch
mlnal Remove three screws secunng assembly Fig EE 9 Removmg brush cover

EE 5
 ENGINE ELECTRICAL SYSTEM

3 Remove yoke assembly by hitting 6 Unsolder brushes uSing

1
a

lIghtly with a wooden hammer soldenng Iron and remove each brush

EE014

Fig EE 14 RemOVing brush holder

EE013
EE010

Flff EE I0 RemOVIng yoke assembly Fig EE 13 RemOVIng brush

Withdraw armature and

4 assembly
shift lever

IJIPo
o i
H o l
@

@l @

m
EEOll m

Flff EE ll RemOVing armature

aJ
@0l
EE015
assembly and shift lever

5 Remove pinion stop nng located Flff EE 15 DISassembly

at the end of armature shaft To

remove stop nng first push stop nng CLEANING AND Field coil
to clutch side and then after removing
INSPECTION Check field coil for insulation If
snap nng remove stop nng With
the insulation of cod
over clutch Withdraw over
Clean all disassembled parts but do IS damaged or

wnmng
worn It should be
clutch from
not use grease dissolVing solvents for replaced
runmng assembly
armature shaft c1eamng over running clutch armature
Testi g field coIl for continuity
assembly magnetic SWitch assembly
and field cOlis since such a solvent Connect the of
probe a CIrCUit
would dissolve grease packed In c1u tch tester or an ohmmeter to field coil
mechamsm and would damage coils or ternunal and
posItive posItive brush
other Insulators holder
Check them for excessIVe damage If tester shows no conduction field
or wear and they should be replaced If CIrCUIt or coil IS open
necessary

no @ @
EE012
Terminal
Check terminal for and
Fig EE 12 RemOVing over
running damage
clutch and If necessary
assembly wear replace

EE 6
 ENGINE ELECTRICAL SYSTEM

Brush spring tension

Check brush spnng tension by a Replace spnng If tensIOn IS lower than
I 4 kg 3 I Ib
spnng scale as shown In FIgure EE IS
The should be I 6 kg 3 5 Ib
readmg

EE016
I
Flff EE 16 Testing field coli
for continUity

Testing field coIl for grQund

Place one probe of CU U1t tester

onto yoke and the other onto field

cod lead posll1ve terffilnal
@
If very lIttle resIstance IS read field
cod IS grounded EE018

Flff EE 18 Inspecting brush spring tensIOn

Armature assembly from commutator surface Com

armature should be turned
Check ext rnb appearance of
mutator
m a lathe so that the out ofround IS
armature and cO imnuftort
less than 0 05 mm 0 0020 In
1 Measure armature shaft for bend
Insulating mica should also be under
dIal
EE017 by a gauge Replace armature
cut so that the depth of It IS from 0 5
shaft If the bend exceeds 0 08 mm

Fig EE 17 Testing field COIl to 0 8 mm 0 0197 to 00315 In

00031 1n
for ground The wear lImit of commutator

diameter IS 2 mm 0 079 In If com

Field coIl tester for short

Unsolder the connecting portion of

mutator IS beyond repau replace
each cOli and proceed to the same Note It IS recommended to replace
mentJoned above commutator as an assembly If worn

If a defecttve cod IS found It or damaged

should be replaced

to

Brushes ana
brush lead wire
Check the surface condltJon of
brush contact and wear of brush If a EE019
less than 6 0 mm 0 236 In replace Flff EE I9 Inspecting armature
be rep laced shaft for bend
If brush IS worn and ItS heIght IS
less than 6 0 mm 0 236 In replace
Check the connectton of lead clIp 2 Inspect commutator If the sur

and lead wue face of commutator IS rough It must

Check rush holders and spnng be sanded lIghtly wIth a No 500

clIp
to see If they are not defonned or emery paper Commutator must be
bent and wdl hold brushes checked also for out of round If the
properly
out of round than 02
against the commutator IS more mm
EE020

If brushes or brush holders are 0 0079 In or the depth of insulating

duty they should be cleaned ffilca IS less than 02 mm 00079 In Fig EE 20 Inspechng commutator

EE 7
 ENGINE ELECTRICAL SYSTEM

tester shows conductIon brush holder

IS shorted to ground Replace dn

Insulator or brush holde r

Round
S 05 to 0 8 mm Commutator

roiWi
o

Correct Incorrect

EE021
EE025

Fig EE 21 Undercutting insulating mica Fig EE 25 Testing brush for

ground
3 soldered conneclion of
Inspect 6 Check armature for continUity by
armature lead and commutator If of
placing probes tester on two Pinion case
loose connectIOn found solder It sIde
segments side by If tester shows
IS

uSing rosin flux no conductIon the CirCUit IS

bearing metal
open
4 Armature test for ground Inspect bearillg metal for wear or

side play If the clearance between

USing a cIrcuIt tester place one test
beanng metal and armature shaft IS
probe onto armature shaft and other

onto each commutator bar

more than 0 2 mm 0 0079 tn replace
If tester shows conductIve arma Over running metal Press In a new bearing and

adJust the clearance 003 to 0 10 mill

ture IS grounded and must be replaced clutch assembly
00012 to 00039 In Beanng metal
Inspect pinIOn assembly and screw should be that the end of
so pressed In

sleeve Screw sleeve must slIde freely the beanng metal would be equal to

along armature shaft splInes If

gear case end plane
damages are found or resistance would

be felt when
slIding It must be
repaired Inspect pillIOn teeth If
excesSive rubbing would be found on Magnetic
teeth It should be replaced Flywheel switch assembly
ring gear also must be Inspected Inspect fI1agnel1c sWitch contacts If
be found the
Flff EE 22 Testing ormature for
a
rough welding on

contact It should be repaired

ground

5 Check for short

armature by ASSEMBLY
placing on armature tester glora and

00
Reassemble motor
starting In re
with
core
a pIece
rotate
of
armature
Iron over

If the
armature

plate ij @ @ verse

When
sequence of disassembly
assembhng make sure to
vibrates armature IS shorted
EE024
apply grease to gear case and rear

Fig EE 24 Over running clu tch cover beanng metal and apply 011 to
assembly pinIon shghtly

TEST

Performance test
Brush holder test
Starter motor should be subJected
ID for ground to a no load test whenever It has

EE023 USing a circuit tester place one test been overhauled to ensure that ItS

Fig EE 23 Testing armature for probe onto negatIve side brush holder performance will be sal1sfactory when
short and another onto positive side If Installed to engll1e Starter motor

EE 8
 ENGINE ELECTRICAL SYSTEM

should also be subJected to the test No load test Magnetic switch

of abnormal operatIOn
when the cause Connect starting motor In senes
assembly test
IS to be detennlned A bnef outline of With speCified 12 volts battery and

the test IS given below an ammeter capable of indicating

IgnitIon SWItch
1 000 amperes

SpeCified current draw and revolu

lion In these test are shown ill

speclficalion

SWItch
Ba ttery Starter motor
EE027
Starter motor
Fig EE 27 CirCUit ofmagnetic SWitch
5
assembly test

If the starting motor check IS

OK check magnetJc SWitch as

Connect cables between

sembly
negatJve ry
batte terminal and start
Voltmeter Ammeter M terrmnal
Ing motor posltJve
battery terrmnal and starting motor
EE026 terrmnal
S connecting IgmtJon
SWitch shown
In series as In FIgure
EE 27
Flff EE 26 No load testlng
With IgmtlOn SWitch on measure

e between pinIOn front

Diagnosis of test the gap
dge and pinIOn stopper
I Low speed with no load and high follOWing Items

from the I A field coIl

current draw may result grounded or open o 3 10 I 5 mm
following causes Inspect the conneclion and trace 001181000591
bearings CirCUIt by CUCUlt tester
I Tight duty or worn a

7 Bent armature shaft or loosened 2 Armature COli does not operate

field probe Inspect commutator for excessive

3 Shorted armature burning In this case arc

may occur on

Check armature further defeclive commutator when motor IS

4 A ground armature or field operated With no load

3 Burned out commutator bar
a Remove Input tennlnal
Raise two negalive Side brushes Weak brush spnng tensIOn broken
b
from commutator brush spnng rubber bush thrust out EE028

c USing a CUCUlt tester place one of mica In commu tator or a loose

Fig EE 28 Measuring gap l
contact
Input terminal and the between brush and com
probe onto

other onto yoke mutator would cause to burn com

a If tester indIcates conduclion mutator bar

raise the other two brushes and check 3 Low current draw and low
field and armature separately to no load speed would cause high
determine whether field or armature IS Internal resistance due to loose con

grounded neclions defective leads duty com

2 Failure to operate WIth high mu tator and causes listed on Item

current draw may result from the 2 3

EE 9
 ENGINE ELECTRICAL SYSTEM

SERVICE DA
A
SI14 103P

Armature shaft diameter plmon side mm In 10950 to 10968 04311 to 0 4318

Armature shaft dIameter rear end mm In II 450 to II 468 0 4508 to 0 4515
Amendment limIt of shaft dIameter mm In o I 0 0039
Amendment 11Imt ofshaft bent mm In o OS 0 0031

Clearance between shaft and bush mm In 003 to 0 I 00012 to 0 0039

Amendment lrrmt of dittoed clearance mm In 02 0 0079

Outer diameter of commutator I 378
mm In 350
Wear lrrmt of commutator diameter mm In 2 0 0 079

Brush length mm In 18 5 0 72S

Wear hmlt of dittoed
length mm In 60 0 236
remaining brush should be more than mm In 12 5 0492
Brush spnng tensIOn
kg Ib o S I 8

Front bracket metal Inner diameter mm In II 000 to II 018 0 4331 to o 433S

Rear cover metal Inner dldmeter mm In II 500 to II 521 04528 to 0 4536

TROUBLE DIAGNOSES AND CORRECTIONS

Condlllon Probable cause Correcllve acllon

Startl11g motor wIll Discharged battery Charge or

replace battery
not operate Defective solenOId SWItch RepaIr or replace solenoid sWlt h

Loosen connectIOns of terminal Clean and lighten terminal

Defecllve brushes Replace brushes

Defecllve starting motor Remove starting motor and make test

NOISY starling motor Loose securIng bolt TIghten bolt

Worn pinIon gear Replace pinIOn gear

Poor lubncatlon FIll In 011

I

Worn commutator DIsassemble motor

Worn brushes Replace brushes

Starting motor DIscharged battery Charge or

replace battery
cranks slowly
Loose connect of tenmnal Clean and terminal
IOn
lighten
Worn brushes brushes
Replace
Locked brushes
Inspect brush spnng tenslon or repair brush
holder

EE l0
 ENGINE ELECTRICAL SYSTEM

CondItIOn Probable cause Correcllve actIOn

Clean and repair

Starting motor Duty or worn
Fommutator
cranks slowly Armature rubs field cOli Replace assembly
De fec lIve solenOId sWitch Repair or replace sWitch

Starting motor Worn pinIOn I Replace pinion

operdtes but does J Locked pinIOn gUide Repau pmlOn gUide

not crank engine
Worn nng gear Replace nng gear

solenold sWitch Repau or replace solenOId sWitch

Starting motor wdl Defecllye
not disengage even Replace defecllve gear
Defecllve gear teeth
IgmtlOn sWitch IS
turncd off

CHARGING CIRCUIT

Then the warmng P2 from the

The charging CirCUit consists of the lamp lIghts IS separated pnmary
When the alternator beginS to Side contact PI by the
battery alternator regulator and magnel1c
three force of COli VC2 Therefore
necessary Wifing to connect these operate phase alternating cur
rent Induced the armature ThiS reglstor RI IS apphed mto tbc field
parts The purpose of thiS IS In
system IS to

convert mcchamcal energy from the alCernatlng current IS recl1fied by the CirCUit and output voltage IS decrcased
I

engine Into electncal energy which IS poslllve and neg lIve SIlIcon diodes As the output voltage IS decreased the
P2 and
used to opcrate all electncally operat The recllfied direct current output movabljl contact pOint

ed umts and to keep J e battery fully reaches the alternator A and E pnmary Side contdct PI comes Into
ternuIlals contact once again and the dlternator
charged
On the other hand the neutral voltage Increases Thus the rapid
When the IgnitIOn SWItch tq
IS set

ON current flows from the battery pOint voltage feaches N and E VIbratIOn of the movable contact pOint
terrmnals nearly half of the output P2 maintains an alternator output
ground through the Ignlllon sWItch
a
to

voltage regulator IG terminal prunary voltage and current flows from voltage constant

Side contact PI movable voltage regulator N termlnal to E When the alternator speed IS further
pOint
OntaLt pOint P2 voltage regulator terrmnal or ground through the cod Increased or the voltage starts to nse
VCI shown EE 30 by excessively tbe movable contact
F terminal alternator F ternunal as In
Figure pOint
field COIl and alternator E terrmnal the dotted hne arrpw marks Then the P2 comes Into contact with

shown EE 29 full line cod VC I IS eXCited and the secondary Side contact pOint P3
as m Figure by
arrow marks Then the rotor In the movable contact pOint P5 comes Tlien the field current IS shut off and

alternator IS eXCIted On the other Into contact wIth voltage wmdlng Side alternator output voltage IS decreased

hand current flows from the contact pOint P6 ThIS acl10n causes Immedl8tcly ThiS actIOn causes to
battery
off the and
to ground through the Igml10n SWl tch to turn warning lamp separate movable contaLt P2 from

thc voltage Winding CUCUlt Thus the

warmng lamp voltage regulator L complete secondary Ontact P3
terrmnal as shown by the full line arrow marks rapid vlbral10n ofthe movablc contact
lamp Side contact pOint
P4 movable contact pOint P5 When the alternator speed IS in pOint P2 or
breaking and complet
the field CirCUit mamtalns an
and voltage regulator E terrmnal as creased or the voltage starts to nse Ing

shown by dotted lIne arrow marks excessIvely the movable contact pOint alternator output voltagc constant

EE ll
 ENGINE ELECTRICAL SYSTEM

n
u
r r
I I
IgnitIon swItch
I IG
I

I Co

Ol j1
oe
0
e 0
t 0 u
T Battery
e I

I
2 I

0
I
III e
I Ol
I

r
e 0
I
I I
I I
I I
I I
I
I
I I
I I
I

I I I I
l J L J

Alternator Voltage regulator

EE029

Flff EE 29 Charging CirCUit 1

r 1

I
I

Battery
T
I

I e

C
III

I
I
I
I I
III

GO
e

Cl
0

r
J L

Ln
Alternator Voltage regulator

EE030

Fig EE 30 Chargmg CircUit II

EE 12
 ENGINE ELECTRICAL SYSTEM

ALTERNATOR

CONTENTS

DESCRIPTION EE 13 I nspectlon of brush EE 16

REMOVAL EE 14 Spnng pressure test EE 17

EE 14 REASSEMBLY
DISASSEMBL Y EE 17
EE 15 ALTERNATOR TEST
INSPECTION AND REPAI R EE 17

Rotor inspection EE 15 SPECIFICATIONS AND SERVICE DATA EE 18

EE 15
I nspectlon of stator Specifications EE 18

of diode EE 15 Service data EE 18

Inspection

reverse current IS shut out In tlus

DESCRIPTION alternator SIX dIOdes three negatJve
and three posll1ve are Installed In

In the alternator a
magnetic field IS generated In the armature COlIs located
posll1ve and negatJve plates as an

produced by the rotor whIch consIsts In the stator The stator has three assembly
of alternator shaft field cod pole Windings and generates three phase Pack type silicon dIodes are used
pieces and shp rings The
slIp nngs alternating current Slllcon dIodes act In thiS alternator These dIOdes are
the shaft conduct only a lIke a one way valve for electnclty so direct soldered their and
pressed In at tipS
small field current Output current IS that charging current passes easlly but constructed With poslllve and
negative
conJunctJon They are mounted on the
two plates whIch combine the
functIOn of heat dIssipating plate and
and
posll1ve negatlve terrmnals are

and easy to service

lIght In
weIght

@l
I Pulley assembly
2 Front Qver
3 Fronl beanng
4 Rotor
5 Rear bearing
6 Stator
7 Rear cover

8 Brush assembly
9 Diode set plate assembly
J

y 10 Diode cover
II bolt
Through
@ EEC31

Flff EE 31 Exploded view of alternator

EE 13
 ENGINE ELECTRICAL SYSTEM

n
g I

CI

EE035

Flff EE 35 Separating front cover

with rotor from rear cover

4 Remove three set screws from

beanng retainer and eparate rotor

from front cover

EE032

I FronI heanng 4 Pulley

Q OD
2 Rolor 5 Front cover

3 Stator 6 Encased dIOde

Flff EE 32 SectIOnal view of alternator

REMOVAL 2 Remove brush holder ftxlng

screws and remove brush holder
I Disconnect negdl1ve battery ter
cover Remove brush holder forward
rmnal EE036
and brushes
2
remove together wIth
DIsconnect two lead wrres and Flff EE 36 RemOVing rotor
brush holder
connector from alternator
3 Loosen bolt 5 Pull out rear be mng from rotor
adJusting
4 Remove alternator dnve belt assembly WIth a
press or
beanng
5 Remove parts assoCla ted WIth puller
Note Do not dIsconnect N terrmnal
alternator from engtne
6 Remove alterna tor from velucle from stator cod 1 3d WIre

DISASSEMBLY
I Remove pulley nut pulley nm

fan and spacer EE037

FIEE 37 Pulling out of

rear

1 N terminal bearing 1
2 Brush holder
3 BlUsh holder cover
EE034

Flff EE 34 RemovlIlff brush

@ @ 3

bolts
Loosen

Separate
and

front
remove

cover
through
WIth rotor
fQm re c9ver With stator by hghtly EE038
@@@ EE033
tapping front bracket WIth a wooden Pung out of rear
Fig EE 38
Flff EE 33 RemOVing pulley and fan mallet bearing II

EE 14
 ENGINE ELECTRICAL SYSTEM

6 Remove dIOde cover fIXing screw

Rotor inspection
and remove diode cover DIsconnect
I ConductIOn test of rotor coil
three stator cod lead wires from diode
tester between
terrmnal WIth
Apply slIp nngs of
a soldenng Iron
rotor as shown
7 Remove A terrmnal nut and dIOde
In
FIgure EE 41 If
there IS no conductIOn dIscontinUIty
InstalJal10n nut and remove dIode
of fIeld cod may eXist When resIstance
assembly normal
IS
approxImately 44n at
ambIent temperature condll1on IS

CD sal1sfactory
EE043

L Fig 43 Testing stator for

conduction

o
o@
cf oO

I DIode assembly @o
2 DIode cover 2 Ground test
EE039
If each lead wire of arma ture coil
Flff EE 39 Removing diode assembly including neutral wue IS not con

ductIve wlth stator core condll1on IS

Note Use care in handlIng dIode
If there conduction
undue stress
EE041 sal1sfactory IS

assembly to prevent an
stator cod IS
grounded
on it
Flff EE 41 Conduction test of
rotor COIl

INSPECTION AND
REPAIR 2 Ground test of rotor coil
Check conducl1on between
Remove alternator from velucle and slIp nng
and rotor core If conducl1on eXIsts
between lead F
apply tester wue
field
wlute WIth black tracer and lead wue
replace rotor assembly because
coil or slIp nng may be grounded
E black color

When the resIstance IS approxI

mately 5n the condll1on ofbrush and

field coil IS
satISfactory When no
EE044
conductIOn eXISts In brush or field
Fig EE 44 Testing stator for
coil or when res stance dIffers
ground
remarkably between those parts diSas
semble and Inspect

Inspection of diode
Perform a conductIOn test on

dIOdes In both dlreCl1ons uSing an

EE042 ohmmeter A total of SIX dIOdes are

used three are mounted on the

Fgl EE 42 Testing rotor COIl for
posll1ve fl plate and other three are
ground
on the negal1ve 8 plate The
conducl1on test should be performed
on each dIOde between the terrmnal

of stator
and plate
Inspection
I ConductIOn test
Stator IS norma when there IS

conductIOn between indIvidual stator

EJ cod terminals When there IS no con
Q
duction between indIVIdual tennlnals
EE040
cable IS broken

Flff EE 40 Inspecting alternator Replace WIth stator assembly

EE 15
 ENGINE ELECTRICAL I1
SYSTEI

If current flows toward both

posll1ve and negal1ve directions dIode

IS short circUIted If current flows ill
Conductive directIOn the same dlrecl10n only dIode IS ill

good condlhon These diodes are

unserviceable If there IS a defective

dIode replace all dIOdes SIX dIOdes as

an
assembly See below table

I
plate
2 plate
3 DIOde
EE045

Fig EE 45 ConductIVe directIOn of dIOde

Diode Installed on EB plate IS a

Test of a CirCUit tester

posll1ve dIOde wluch allows current probe
from terrmnal ConductIOn
flowing to EB plate
only In other words current does not 8 G
flow from EB plate to terminal
terminal EB pia te X

EB plate tennlnal

terminal e plate

e plate terminal X

e plate G1 plate X

EB plate e plate
I plate
EE046
2 Tetmtnal

Fig EE 48 Inspecting dIOdes

Fig EE 46 Inspecting positIVe dIOde Inspection of brush
Check movement of brush and If down to less than the speCifIed lImIt
DIOde Installed on 8 plate IS a
movement IS unsmooth check brush brush
replace assembly
negal1ve dIOde wluch allows current
holder and clean It Check brush pig tall and If found
flowing from 8 plate to terrmnal
Check brush for wear If It IS worn defechve replace
only In other words current does not
flow from terminal to 8 plate

Brush Wlar
hnutmg line

I plate
EE047 EE04B
2 Tenmnal

Flff EE 47 Inspecting negatllle diode Flff EE 49 Brush wear limit

EE 16
 ENGINE ELECTRICAL SYSTEM

nut with
Spring pressure test REASSEMBLY 3 Tighten pulley lighten
With brush Reassemble alternator In the reverse Ing torque of 350 to 400 kg 303 cm
proJected approximate
to 347 lb When
2 mm 0 079 from brush holder sequence of disassembly noting follow
In
pulley tighten
IS

ly In
ed make sure that deflectIOn of V
measure brush spnng pressure by th Ing matters
groove IS less than 0 3 mm 0 OilS In
use of a spnng balance Nonnally the
10
rated pressure of a new brush spnng IS I When soldenng edch stator coli
255 to 345 g 9 0 to 122 oz lead wire to dIOdeassembly terrmnal
Moreover when brush IS out the fast
worn carry operation as as

pressure decreases approximately 20 g possible

07 oz per I mm 0 039 In wear 2 installing diode A terrmnal
When

Installinsulating bush and insulating

tube correctly

2 mm 0 079 In

EE051

FIg EE 52 Tlffhtenlng pulley nut

ALTERNATOR TEST
EE049

Before alternator
conduGtlng an

Fig EE 50 Measuring spring pressure

test make sure that the battery IS fully
charged
To conduct a test It IS necessary to
use a 30 volt voltmeter and sUitable
test probes
Set up a test CIrCUit as shown In

EE 53 and test alternator In the

Figure
manner indicated In the flow chart
below

Insulatmg bush

Rear cover

DIOde assembly
Ins JaUng tube

A termmal bolr
DIode cover

EE050
FIg EE 51 Sectional vIew of dIode
and A terminal

I DIsconnect connectors at alternator

2 Connect one test probe from voltmeter posItive termmal to N terminal
or BAT termlOal Connect the other

test probe to ground Make sure that voltmeter registers battery voltage
and sWitch to Main Beam
3 Turn on
headlIghts
4 Start engine

5 Increase engme speed gradually until It IS approx I 100 rpm and take the voltmeter reading

I I
Measured value Below 12 5 volts Measured value Over 12 5 volts

Alternator IS In trouble remove and check It Alternator IS In

good condItion

for condition

EE 17
 ENGINE ELECTRICAL SYSTEM

Notes

a Do not run engine at the speed of

more than 1 100 cpm whde test IS

being conducted on alternator

b Do not race engtne

f
Battery

EE052

Fig EE 53 Testing alternator

SPECI FI CATIONS
AND SERVICE DATA

Specifications

LTl50
05B

Applicable to 610 all models

Maker H TACHI

Nominal rating 12V 50A

Ground polanty Negative

Revolution 1 000 to 13 500 rpm

Mlmmum revolutIOn under no load Less than 1 000 rpm

Output current 37 SA 14V 2 500 rpm

Pulley ra 110 225

Service da ta

Stator COli

ReSistance per a phase n 017 at 200C 680 F

Rotor coli

ReSistance n 4
at
4J 200C 680F

Brush

Brush length mm 111 145 0571

Wear limit 111111 111 7 0 276

Spnng pressure kg Ib o 25 to 0 35 0 55 to 0 77

EE 18
 ENGINE ELECTRICAL SYSTEM

SlIp ring

Ou ter dla 31 22
mm In
1
ReductIOn lumt mm ll I 0039

RepaIr accuracy mm In 005 00020

REGULATOR

CONTENTS

DESCRIPTION EE 19 Charging relay EE 22

MEASUREMENT OF REGULATOR SPECIFICATIONS AND SERVICE

VOLTAGE EE 20 DATA EE 23

ADJUSTMENT EE 22 TROUBLE DIAGNOSES AND

Voltage regulator EE 22 CORRECTIONS Including alternator EE 24

OESCRI PTION

B
field CIrCUIt dIrect to and the
The
regulator consIsts basICally of a ground
voltage regulator and a charge relay upper contacts when closed complete
The voltage regulator has two sets of the field CIrCUit to ground through a
contact pOInts lower set and upper
a reSIStance field cod and produces
set to control alternator voltage An alternator output
The
armature plate placed between the two charge relay IS sunllar 111
of contacts construchon to the voltage regulator
sets moves upward or

downward vibrates The lower When the upper closed

or contEicts are
EE053
contacts when closed complete the IgmtlOn warning lamp goes on

Flff EE 54 View of removIng cover

As for the construchon the voltage

the
regulator IS very Similar to charge
55
relay as shown In Figure EE

EE054

I POInt gap 10 I POIn I gap 10 Lock nul

Adjust spnng
2 II AdJusl spnng
2 Lower contact II Cod Charge relay conlact
3 Armature 12 3 mm 0 118 In dla 3 Connecting 12 Cou
spnng
4 4 Alma ture 13 3 mln 0 118 m dla
Core gap serey

5 Yoke gap 13 4 mm 0 157 m dta 5 Core gap screw

6 screw 6 Yoke gap 14 4 mm 0 157 m dta

Connecting spnng
7 Yoke 14 Contact set 7 Yoke screw

8 AdJuSl1ng screw 15 Upper contacl 8 Adjusting screw 15 Con lact sel

9 Lock nul 9 Voltage regulalor conlacl

a Construction of voltage regulator b Construction ofcharge relay

Fig EE 55 Structural vieW

EE 19
 ENGINE ELECTRICAL SYSTEM
r

MEASUREMENT
OF REGULATOR
VOLTAGE
Regulator voltage IS measured with
regulator assembled with alternator
When measunng voltage With regula tor
mounted on vehicle It IS necessary to
rotate engine at lugh speed
Connect DC voltmeter 15 30V

DC ammeter 15 30A battery and

resistor 025 ohms With cables as

shown
I Check to be sure tha t all
electncal loads such as
lamps air

conditIOner radIO etc are dlscon

nected

2 Before slartmg engme be sure to

make short CirCUit With a cable
EE055
between fuse side ternllnal of resistor
0 25n and negal1ve side ternllnal of Fig EE 56 Measuring regulator voltage With regulator on vehicle

ammeter Fadure to follow thiS

caul10n causes needle of ammetel to
sWing Violently and reversely resultlllg 3 Refer to the follOWing chart to parts are In good conditIOn
In a
damaged ammeter deternllne If regulator and relative

EE 20
 ENGINE ELECTRICAL SYSTEM

I Start engine
2 Rotate engine at 2 500 rpm for several minutes

Mter racing for several minutes ammeter readlng After racing for several minutes ammeter
below SA 5A
reading over

Fully charged battery avaIlable Fully charged battery not avaIlable

I Replace with fully charged battery I Connect a 0 25 ohm resistor In senes
2 Check to see If current falls below SA

I
I I

Current falls below SA Current does not fall below SA

Recharge battery and see If current falls below

SA

I
I

Reduce engine speed to Idhng and then ralse It to 2 500 rpm whIle observing needle of voltmeter

r
I I
Needle of voltmeter held within hmlts shown In the below Needle of voltmeter out of limits shown In

table the chart

follOWing
Regulator functlomng properly Regulator out of order Have It repaired at

authonzed shop

Regulator model TLIZ 58B HITACHI

speed
V
c
Voltage may be approx 03
Temperature Oc OF Voltage V
higher than the rated for two to

three minutes after engine IS

10 14 1475 to 15 25 started or more

specIfically when
becomes self heated
o 32 1460tol51O regulator
Measurements should then be made
10 50 1445 to 1495
WIthin minute after
one starting
20 68 1430to 1480
engine or when regulator IS cold
30 86 14 15 to 1465 d The regulator IS of a temperature

40 104 1400 to 1450 compensating type Before measur

Ing voltage be sure to measure

surrounding temperature and cor
rect measurements according to the

table in the left hand Side

Notes cold
regulator IS
Do not measure Immediate
a
voltage b To measure voltage raise engine
ly after driVing Do thIS while speed gradually from IdlIng to rated

EE 21
 ENGINE ELECTRICAL SYSTEM

4
ADJUSTMENT AdJusting pOint gap
Loosen screw 3 mm 0 118 In

Voltage regulator diameter used to secure

upper
contact and move upper contact
As the result of above measure

ment when regulating voltage IS upward or downward adequately See

deviated from rdted value adJust Figure EE 58

c0rdance with the
regulator In a

EE400
lollOWIng instructIOns
1 surface and If
Inspect contact I Wrench
wIth fine
rough hghtly polIsh surface 2 Crosshead screwdrIver
500 or 600 3 AdJusllng screw
emery paper
4 Lock nut
2 Measure each gap and adJust If

necessary AdJust core gap and pOint Fig EE 59 AdJusting regulating voltage
that order No
gap In
adJustment IS

required for yoke gap

EE399
3 AdJusting core gap I Thickness gauge
Loosen 4 0 157 2 3 mm 0 118 In
screw mm In
d
Charging relay
diameter whIch IS used to secure screw

3 Crosshead screwdnver Normal relay operating voltage IS 8

contact set on yoke and move contact
4 Upper contacl to 10V as measured at alternator A
See
upward or downward properly
terrmnal Relay Itself however
FIgure EE 57 Fig EE 58 AdJusting pOint gap
operates at 4 to 5 V

Use a DC voltmeter and set up a

shown EE 60
CirCUit as In Figure

5 AdJustJng voltage
AdJust regulating voltage as

follows
Loosen lock nut secunng
I Conlacl sel
E E398 adJusting
screw Turn thiS screw clockwise to
2 Thickness gauge
3 4 mm 0157 In d a screw Increase or counterclockwise to
4 Crosshead screwdnver decrease See
regulating voltage
Figure EE 59

Flff EE 57 Adjusting core gap

Connect
1 posItIve terminal of voltmeter to regulator lead connector N terminal with negatJve termInal
grounded
2 Start engine and keep It Idle
3 Take voltmeter reading

I I

o Volt Below 5 2 Volt Over 5 2 Volt

I Check for continUIty be Pilot lamp remains hi pIlot lamp remains lIt
tween N terminals of re I Check fan belt tension Pdot lamp relay cod or contact

gulator and alternator 2 If correct remove regulator pOints out oforder

2 Alternator CirCUit defectIve and adJust as necessary Replace regula tor
If continUIty eXists

Over 5 2 Volt

pilot lamp does not lIt

Pilot lamp relay assembly IS In good condItIOn

EE 22
 ENGINE ELECTRICAL SYSTEM

IG W B

F W B
Regulator
E B

Voltmeter

EE059

Flff EE 60 Testing charging relay

SPECIFICATIONS AND SERVICE DATA

oltage regulator
Model
TLlZ 58B
Regulating voltage WIth fully charged battery V 143 to 15 3 at 200C 680F
Voltage cod resistance n 10 5 at 200C 680F
Rotor cod resIstance
inserting n 10

Voltage coll senes resistance n 31

Smoothing resistance n 40
Core gap mm In
06 to I 0 0 0236 to 0 0394
POint gap
mm In 035 to045 0014toOOI8

Charge relay

Release voltage 4 2 to 5 2 at N
V terrmnal
Voltage coll resistance n 378 at 200C 680F J
Core gap mm In o 8 to I 0 0 0315 to 00394
POint gap mm In 04 to 0 6 00157 to 0 0236

Standard temperature gradient 0015V oC

EE 23
 ENGINE ELECTRICAL SYSTEM

TROUBLE DIAGNOSES AND CORRECTIONS Including alternator

ConditIon Probable cause Correcllve acllon

No brushes Correct
output StIcking or replace brushes and brush spnngs

DIrty brushes and shp nngs Clean

Loose connectIOns or broken leads RetIghten or solder connectIOns

Replace leads Ifnecessary
Open stator WindIng RepaIr or
replace stator

Open rotor Winding Replace rotor

Open diodes Replace dIOdes

Shorted rotor
Replace rotor

Shorted stator RepaIr or replace stator

Grounded BAT termInal Insulator
Replace
Broken fan belt belt
Replace

Excessive Broken neutral wire color of wire wlute

output IS
Replace wue

Defecllve voltage regulator Check regulator operatIOn and repaIr or

replace requIred
as

Poor grounding of alternator and voltage Rellghten term mal connecllon

E termInal
regula tor

Broken ground wire color of wire IS black Replace WIre

Low Loose fan belt belt

output or worn
Rellghten or
replace
Slicking brushes Correct or
replace brushes and spnngs If
necessary

Low brush spnng tensIOn brush spnngs

Replace
Defecllve voltage regula tor Check regulator operatIOn and repair or

replace reqlllred
as

Duty sh p nngs Clean

PartIal short ground or open In stator Replace stator

wlIldlng
Partially shorted or grounded rotor Winding Replace rotor

Open or defective dIOde Replace diode

NOIsy alternator Loose mountmg Retighten mountIng bolts

Loose dnve pulley RetIghten pulley correctly

Defective ball beanng Replace bearIng
seated brushes Seat brushes
Improperly correctly

EE 24
 ENGINE ELECTRICAL SYSTEM

IGNITION CIRCUIT

The Igmhon CirCUit consists of the Tlus system consIsts of a throttle The high voltage current flows
sWItch coli dlstnbutor to the
19mtlon SWitch a two pOint dlstnbutor and through the high tension cable
then the rotor distrIb
wIrIng spark plugs and battery some electncal wIrIng and sensors as distrIbutor cap
The cncUlt IS eqUipped with a Illustrated the The utes the current to one of the spark
In
follOWing figure
reSIStor Dunng cranking electncal main
component of thIS system IS the plug terminals In the distrIbutor cap

current bypasses the resistor thereby dlstnbutor whIch has breaker Then the obtainS while the
two spark
connecting the IgmtlOn cod dnectly to pOints One IS for advance optimum high voltage current Jumps the gap
battery ThIS proVides full battery Igmtron trmlng and the other for between the Insulated electrode and
voltage available at cod and keeps retard delayed by 60 from optrmum the ground SIde electrode of the spark
IgmtlOn voltage as high as possible tumng plug ThiS process IS repeated for each
The low voltage current IS supplied When the car IS cunmng In WIde power stroke of the engine
by the battery or alternator and flows open throttle the
trmlng advance The distrIbutor contact
pOints and

through the prImary CirCUit It consists optrmum one IS used In order to Im spark plugs requne perIodiC service

of the Igmhon sWItch resistor prove fuel consumption Conversely That the breaker
pOints should be
IS

the retard tUnIng IS used when the

pnmary Winding of the Igmtlon cod car
Inspected cleaned and regapped at

dlstnbutor contact pOints condenser IS cunmng In urban areas The throttle If necessary
tune up or
replaced In
and all connecting low tension wmng SWItch detects such cunmng condItions additIOn lubrIcate distrIbutor shaft
The by momtonng the throttle valve open
high voltage current IS pro and cam heel every suitable main te

duced by the IgmtlOn cOil and flows Ing nance penod Spark plugs should be
through the secondary cncUlt result The advance and retard tmungs are removed Inspected and maintained to

Ing In hIgh voltage spark between the changed by a relay wluch momtors obtain good firIng
electrodes of the spark plugs In engine whether the throttle opens more than The remainder of the Igmtlon
cylInders ThiS cncUlt contalr s the 400 or less than 400 But when the should be
component parts Inspected
secondary Winding of the Igmtlon cod engine IS cold the optimum timing IS
for only then operation tightness of
coli to dlstnbutor obtained with the aid of the
high tension cables always electrIcal terminals and wmng con

dlstnbutor rotor and cap water temperature SWItch ditIOn

When the IgmtlOn sWitch IS turned The IgmtlOn CirCUit IS shown below
on and the distrIbutor contact POints
IGNITION
are closed the prImary current flows SWITCH

the pnmary Winding of the

through
coli andthrough the contact pOIn ts to
ground ThiS flOWing produces a
ID
magnetic field around the coli wmdlng
and then electrIcal energy In the coli B

When the contact CD @ ADVANCE

pOints opened are
SIDE POINT f
by the revolVing dlstnbutor cam the
l
magnetic field bUilt up In the prImary
Winding of the coli through
moves the

secondary Winding ofthe cot indUCing CD WATER TEMPERATURE

SWITCH
J
high voltage The high voltage IS IGNITION @ TH ROTTlE SWITCH

produced every hme the contact

COil @ 2 POINT RELAY
EE461

pOints open F g EE 61 IgnitIOn system CirCUIt diagram

EE 25
 ENGINE ELECTRICAL SYSTEM

DISTRIBUTOR
CONTENTS

CONSTRUCTION EE 26 Advance mechanism EE 28

CHECKING AND ADJUSTMENT EE 26 DISASSEM8L Y AND ASSEMBLY EE 2B

Cap and rotor head EE 26 Disassembly EE 28

Pomt EE 26 Assembly EE 29

Replacmg distributor breaker pOints EE 27 SPECIFICATIONS AND SERVICE

DATA EE 30
Checkmg and adJustmg Ignition timing EE 27

Condenser EE 28

The dlstnbutor follows the conven umt dnve shaft and

CONSTRUCTION amsm vacuum

for dual EE 63 shows sectIOnal

tIOnal design except the rotor Figure a

pOints breaker plate with

I e contact VIew of the umt
Dlstnbutor model ApplIed engine
pOints centnfugal advance mech

D4B4 02 LIS

The dlstnbutor for the Ll8 engine

has two breaker pOints located

opposite each other wIth a

phase
dIfference
The difference be
In phase can

adJusted by turmng the adJusting

screw

A phase difference of 60 crank

adopted Two breaker pOints
angles IS

whIch consIst of advance and retard

breakers are
placed In
parallel with
each other In the prImary IgmtlOn
CircUit

The retard breaker pomt works

EE463
when the relay ISswitched ON and
the advance breaker works when 1 Center carbon 4 Condenser 7 Governor weight
pOint
2 Rotor head 5 Shaft 8 Cap
the sWitched OFF
relay IS
3 Breaker plate Conlact SIde plug
6 HOUSIng 9
The relay switches OFF when water
turned Flff EE 63 ConstructIOn
temperature switch IS on If the
engine IS cold or when throttle
sWItch IS placed In the ON poslllon CHECKING AND Point
when the throttle valve IS open more

than 40
ADJUSTMENT Standard gap of retarded pOints IS
degrees 045 to 0 55 mm and standard gap of

Cap and rotor head

t Cap and head
advanced pOints IS 0 40 to 0 60 mm
If the gap IS off the standard adJust
q Inspected at
rotor

regular
must

Intervals
be

In
ment should be made by loosemng
I additIOn
pOlOt screws Gap gauge IS reqUIred for
I remove cap and clean all dust
adJustment
and carbon depOSits from cap and
III rotor from lime to lime If cap IS
POint gaps
lime to lime
must be checked from

I
J
cracked With
or IS leaking replace a

I II1J POint gap

W
J 1 new one

045 to 055 mm Retard SIde

I Advanced breaker pOInt
2 Retarded breaker pOInt 040 to 0 50 mm Advance SIde
EE462

FIg EE 62 External view of Dwell angle

dual pOints 490 to 550

EE 26
 ENGINE ELECTRICAL SYSTEM

amount of No 1
Note Do not apply excess 4 Install a tIming Itght on

grease cylInder spark plug wire and Install a

tachometer
The dlstnbutor has Set to the
two contact 5 IdlIng speed follOWing
pomts Each pOint can be replaced speCIfIcatIons
Independently Both pOints however 6 With a liming lIght check that
are usually replaced at the same tIme IgmtlOn tIming IS at the speCified
value

Note There are two 19t1ition tlnungs

EE464 Retard and Advance The

igmtIon tIming adjustment should

Flff EE 64 Measuring pOint gap
be camed out on the Retard
Side
If pOint gap IS
adJusted by ex

amlnlng dwell angle Install dlstnbutor

J
on engine and proceed as follows
I Disconnect wiring harness of ET270

dlstnbutor from engine harness

Top dead center mark
2 USing a lead wire connect B
EE465
black of engme harness and L blue Fig EE 65 Breaker pOint
Flff EE 66 Checking lffmtlOn timing
of dlstnbutor harness advance Side
3 dwell angle of advance
AdJust
I Loosen lead wire
setting screws
Side by loosemng pOint screw
and remove lead wire from contact
4 Disconnect lead wire from B MT A T
pOint set
black of dlstnbutor harness and then
2 Remove two set screws on each
connect It to G green of dlstnbutor 60 800
POint then be TIming
Retard side pOint set assembly can
700
60 N POSI
BTDC rpm
5 dwell angle of retard Side taken out
AdJust tlOn
3 Install contact the
by loosening pomt screw
new pOint In

lgmtlOn tIming IS on Retard Side

After disconnect lead reverse sequence of removal
6 adJustment
wire then connect engine harness and If necessary follows
adJust It as

dlstnbutor harness securely Notes

I Loosen set screw until dlstnbu
When take a Coat earn heel WIth a light coatmg
pOint surface IS rough tor can be moved by hand
off any with fine sand of grease
IrregulantIes 2 AdJust IgmtIon liming to the
b
paper of No 500 or 600 with od AdjUst contact pOint gap properly
or
follOWing specificatIOns See FIgure
SlOne by measurelng pOint gap with a EE67
At thiS tIme feeler gauge before set screws are
grease must be sup 3 Lock dlstnbutor set screw and

phed to camshaft and cam heel tIghtened securely make sure that tIming IS correct
When wear on breaker pOints IS Dlstnbutor pOint gap
nol1ceabJe replace pOints together 045 to 0 55 mm
WI th contact set
Retard side
o 40 to 0 50 mm

Advance side
Dlstnbutor dwell angle

Replacing distributor 49 to 55 degrees

breaker points
Checking and adjusting
Check dlstnbutor breaker pOints
Re
ignition timing
for abnormal pitting and wear

place pomts penodlcally After re I Check spark plugs and dlstnbutor

plaCing pOints make sure they are In breaker pOints for condItIon
correct alignment for full contact and 2 Thoroughly remove dirt and dust
that pOint dwell and gap are correct from trrmng mark on crank pulley and
Clean and apply dlstnbutor grease to
tIming indIcator on front cover
cam lobes 3 Warm up engine suffiCIently Fig EE 67 AdJusting IgnitIOn timing

EE 27
 ENGINE ELECTRICAL SYSTEM

and adjustment of 2 USing a notchadJuster plate as trouble as

reqUired
Inspection In

hold turn I Check Inlet for signs of

phase difference a adJuster plate as reqUired vacuum

connecllon I fnecessary
untd correct phase difference IS ob leakage a titS

To check difference Install With

phase tained retighten or
replace a new one

dlstnbutor on engIne and proceed as 2 Check vacuum

d18phragm for all

follows ledk
I Disconnect harness of If leak found
wIrIng IS replace vacuum

dlstnbutor from engine harness control assembly With a new one

2 USing lead connect B 3 Inspect breaker plate for

a wile smooth
black of engine harness and G moving
green of dlstnbutor harness Retard If plate does not move smoothly
SIde Refer to Figure EE 68 thiS condll1on could be due to sl1cky
steel balls or piVOt Apply grease to
steel balls If
or
necessary replace
breaker plate as an
assembly

Centnfugal advance
3 Tighten adJuster plate set screws mechamcal parts
to secure the adJustment
4 Make that the
sure Igml10n
I Green retard SIde of engine
tuning of retard SIde IS at the When cause trouble IS
2 Blue advance Side specIfied
value traced to centnfugal advance
EE466
5 After lead mechanical part use dlstnbutor tester
adjustment remove

Flff EE 68 Connecllng wire wire and connect wIrIng harness of to check ItS charactenstlc

dlstnbutor When nothing With ItS

engine harness IS
to securely wrong

3 charactensl1c conceivable causes are

With engine
Idhng adJust IgmtlOn
dlstnbutor to defectiveness or abnormal weanng out
lImlng by rotating
2
1
60
Condenser of dnvlng part or others
speclflcallons 700 rpm M T
60 800 rpm A T retard SIde Satisfactory performance of con So do not disassemble It In case of

from G denser characteflSl1c take off

4 DIsconnect lead wife depends on capacity and degree Improper
green ofdlstnbutor harness and then of Insula lion requmng at tenlion to be SWitch on off part and check closely
of dlstnbutor sure that termInals are clean and set shaft
connect It to L blue cam
assembly governor weight
harness Ad vance sIde screws light
are and governor spnng etc
In advance
5 With engine sllll Idling check to Checking of condenser IS made by a case centnfugal
determine that 6 degrees capacity tester ThiS can also be made mechamcal part IS reassembled be
phase delay IS sure

to check advance charactensl1c

In terms of crank shaft angular diS by a CIlCUlt tester With ItS range set to by
placement high resistance reading When needle dlstnbutor tester
further of tester
To correct proceed as sWings Violently and then
follows moves back to Infimte gradually 11 IS

I Referring FIgure to 69
EE turn an indica lion that condenser IS In
good
out adJuster plate set screw 1 2 to 2 condll1on
If needle shows any steady
turns AdJuster plate IS located on readIng
ad vance SIde or If It registers
zero the hkelIhood IS

thdt transformer IS out of order

DISASSEMBLY
calhng for replacement AND ASSEMBLY

Disassembly
Advance mechanism To disassemble follow the below

procedure
I Take off cap and disconnect rotor
Vacuum advance mechamsm
head
mechamcal parts
2 Remove contact set
If vacuum advance mechamsm fads Refer to Figure 65
EE when
EE467 check for con tact set IS removed
to operate properly the
Fig EE 69 AdJuster plate set screws
follOWIng Items and correct the 3 Remove vacuum controller

EE 28
 ENGINE ELECTRICAL SYSTEM

8 When governor and spnng

weight
are disconnected be careful not to
stretch or deform governor sprIng
After dlsassembhng apply grease to

governor weights

Flff EE 75 RemOVing rotatIOn parts

EE469

Fig EE 71 Jssembllng
DlS vacuum

controller
Assembly
7 When cam IS to be removed first be made
4 Remove tennlnal Assembly can In rever e
assembly shaft head
remove set screw SInce IS
of dIsassembly Refer to
5 Unscrew two contact breaker set sequence
fastened by the screw to hold cam
screws and remove contact breaker Figure EE 77 for
repJact ment and
down Put match mark across Cdm and
reassembly of and
governor sprIng
assembly shaft that comblnalion
so
OrIginal can
cam

be restored at
assembly When assemblIng shaft and cam set
the dnven slIt offset dlreclion and

rotor head posltlOmng lip should be as

shown In Figure EE 77 The governor

spring clfcular hook must be attached

to the SIde of the rotor head pOSItIOn
Ing lip at the CdIl1

Then weight pin for govt rnor spong

A With Circular hook comes In long
E E470 rectangular hole
Fig EE 72 Unscrewing breaker set After assembly check operatJon of
screws EE075
governor bt fore installIng It on engine

IgmtlOn timing should be tested

Fig EE 76 Removlngcam With umt mounted on engine

Fig EE 73 RemOVing contact breaker 2

6 Pull knock pin out and discon

nect collar to remove the entue

rotating parts 1 Governot weIgh t

2 Clearance for slart and
end of advancmg angle
3 Reclangular hook
4 Governor spring B

5 Cam plate
6 Welghl pm
7 Cllwlar hook
8 Governot spring A
EE077 9 Rotor pOSUtonmg lip

EE073

Fig EE 74 knock pin

RemOVing Fig EE 77 Setting governor spring and cam

EE 29
 ENGINE ELECTRICAL SYSTEM

SPECIFICATIONS AND SERVICE DATA

DIstnbutor type 02
D4B4

Make HITACHI

ApplIed engtne
Ll8 610
car

order 42
13
Fmng

Rotatmg duechon CounterclockwIse

IgmtlOn trrnmg degree 60 B T DC

Retard SIde
Phase difference 60 at crank angle
degree

Idhng adJustment
M T 60 700 rpm
A T 60 800 rpm
In N posItion

Dwell angle degree 490 to 550

Condenser capacity pF

Advance SIde o 2 to 0 24

Retard SIde 005i 15

EE 30
 ENGINE ELECTRICAL SYSTEM

IGNITION COIL

The Igmlton coil IS of an OlI ftIled from starting to engine high revolutIOn COli and dlstnbutor contact pOints
The filled the reSIStor which used the
type Igml10n cot case IS by IS In Thus It protects the contact pOints
wIth od which has good insulating and IgnItIOn cod CIrCUit The Internal
dUring slow speed opera lion when
heatrad18tlng characterIStics resistor hrmts to a maximum safe flow
they are closed for long Intervals
HIgh sparking voltage IS produced of the pnmary current through the

I Pnmary lermmal
2 Secondary lermmal
3 Cap
4 Spnng
5 SIde core

6 Pnmary cot
7 Secondary COIl
8 Insula lor ot
9 Cen tee core
10 Segmenl
11 Case
EE078

FIg EE 78 Constructlon

SPECIFICATIONS

Make and HITACHI C6R 206

type

Primary voltage V 12

Spark gap mm In More than 7 0 2756

Primary resistance at 200 680F n I 5 to I 7

Secondary resIstance at 200 680F Kn 95 to J 16

Resistor n 16

EE 31
 ENGINE ELECTRICAL SYSTEM

SPARK PLUG

CONTENTS

DESCRI PTION EE 32 SPECIFICATIONS AND SERVICE DATA EE 33

INSPECTION EE 32 TROUBLE DIAGNOSES AND
CLEANING AND REGAP EE 32 CORRECTIONS EE 33

DESCRIPTION
The spark plugs are of the resIster Overheating WhIte or hght low fuel pump pres
gray 10
spark plugs
type haVIng 14 mm threads and 0 8 to sulator wllh black or gray brown sure wrong selectIOn of fuel a
o 9 mm gap The
inspectIOn and clean spots and bluish burnt electrodes hotter plug etc
should be made indicate engine More It adVisable to
Ing penodlca1Jy as overheating IS
replace with plugs
speCIfied In the Maintenance over the appearance results from haVing colder heat range

Schedule Incorrect Igmhon liming loose

Note All spark plugs Installed on an

engine must be of the same brand

and number ofheat range

INSPECTION
I Remove Normal
spark plug WIre by Carbon fould

pulhng on boot not on WIre Itself

2 Remove spark plugs
3 Check electrodes and Inner and

outer porcelainS of plugs noting the

type of depOSits and the degree of
electrode erosIOn Refer to Figure
EE 79

Normal Brown de
to graYish tan

pOSitS and shght electrode wear

Indicate correct spark plug heat

range
Carbon fouled Ovcrhcdlmg Life
Dry fluffy carbon EE079

depOSits on the Insula tor and Fig EE 79 Spark plug

electrode were mostly caused by
slow speed driVIng In city weak 4 After dress
cleamng electrodes type cleaner AVOId excessive blasting
Igmhon too rich fuel nuxture with a small flOe file to flatten the Clean and remove carbon or oXide
dirty air cleaner etc surfaces of both and Side
center depOSits but do not wear away
It IS advisable to with
replace plugs electrodes In
parallel Set spark plug porcelain If depOSits are too stubborn
haVing hotter heat range gap to speCificatIOn discard plugs
Oil fouled Wet black depOSits show 5 Install spark plugs and torque After cleamng spark plugs renew
011 entlance mto
excessIVe com each plug to I 5 to 20 kg m II to 14 firing surface of electrodes wllh file
bushon chamber through worn ft Ib menhoned above Then gap spark
rings and pistons or excessive 6 Connect spark plug WIres
plugs to 08 to 09 ffim 00315 to
cledrance between valve gUlde and o 0354 In
uSing a round wire feeler
stems If the same condItion CLEANING
gauge All park plugs new or used
remainS after rapalr use a hotter AND REGAP should have iile gap checked and reset
plug Clean spark plugs In a sand blast by bendIng ground electrode

EE 32
 ENGINE ELECTRICAL SYSTEM

SERVICE DATA AND SPECIFICATIONS

Make NGK

Model BP 6ES

Ll8 wIth
ApplIed engine
single carb

Size screw dla x reach 14 x 19

EEOBO
mID

Fig EE 80 Settmg spark plug

gap o 8 to 0 9
Plug gap mm

2 0 to 3 0
TIghtening torque
kg m

TROUBLE
DIAGNOSES AND
CORRECTIONS
When engine does not start high tensIOn cable from high tension cable and spark plug
spark plug
If there IS no trouble In fuel system starting engme and observing con terminal After checkmg thiS repau as

Igml10n ystem should be checked ditIOn of spark that occurs between necessary
This be done
can easily by detaching a

Spark length LocatIOn Probable cause Correchve achon

No sparks at all Dlstnbutor Defecl1ve Insulal10n of condenser Replace

Breakage oflead wlre on low tensIOn side Repair
Defective Insulahon of cap and rotor head Replace
POint does not open or close Repair

coil Wire short CircUit of COIl

Igmtlon breakage or
Replace with new one

tensIOn cable WIre coming off

HIgh Re paIr

DefeCl1ve insulatIOn Replace

1 to 2 mm 0 0394 Dlstnbutor Pomt gap too Wide Correct

to 0 0787 In or
Oil Clean
sticking on pOint
Irregular
POint burnt too much Replace

Less than 6 mm
Spark plugs Electrode gap too Wide Correct or replace
0 2362 In
Too much carbon Clean or replace
Broken neck of Insulator
Replace
ExpIrY of plug lIfe Replace

EE 33
 ENGINE ELECTRICAL SYSTEM

2 When engine rotates but does not from the IgmtIon system and
resulting inspectIon of IgmtIon system should
run
smoothly other engine condlllons not related to be carned out
In thIs case there are Therefore first complete
many causes IgmtlOn

ConditIon LocatIon Probable cause Correcbve action

Engine misses Dlstnbutor Dirty pOint Clean

Improper pOint gap Correct

Leak of electnclty of cap and rotor head Rep8lr or replace

DefectIve insulatIon of condenser
Replace
DefectIVe arm ad shaft

DefectIVe spnng of arm Replace assembly

Breakage of lead wrre Replace
Worn out or shaky breaker plate Replace assembly
Worn out dlstnbutor shaft
or shaky Replace assembly

IgmtlOn cod Layer short CirCUit or use of Infenor quahty Replace with good one

High tension code DetenoratIon of insulatIOn and leak of Replace

electnclty

Spark plugs Dirty Clean

Leak of electnclty at upper porcelain Repair or replace

Insula ter

Engine causes Dlstnbutor Improper and advance liming Correct the fitting
knocking very off
Cormng or
breakage of governor spnng Correct or replace
often
A pin hole of governor portIon
or a worn
Replace
out

Burnt too much

Spark plugs Replace

Engine does not Dlstnbutor Improper and retarded liming Correct the fitting
give enough
DefectIve funcllon of governor Replace assembly
power
Dirty pOint Clean

POint gap too narrow Correct

Spark plugs Dirty Clean

EE 34
 SECTION ER

ENGINE
DATSUN REMOVAL
MODEL 610 SERIES INSTALLATION

ENGINE REMOVAL AND IR 2

I NISSAN I INSTALLATION

Nt SSAN MOTOR CO LTD

TOKYO JAPAN
 Engine Removal Installation

ENGINE REMOVAL AND INSTAllATION

CONTENTS

ER 2 ENGINE MOUNTING INSULATOR 4

ER
REMOVAL
4
ER FRONT INSULATOR 4
ER
INSTALLATION
REAR INSULATOR ERA

Notes On automahc transmISSIon 9 DIsconnect

REMOVAL Fuel hose at fuel pump
equipped cars I
It IS much easier to remove engme a Remove splash board 2 Accelerator hnkage
and transmiSSIon as a Single umt than b DIsconnect 011 cooler hoses at oil
to remove only engtne from the engme cooler Installed at the lower end of 10 Remove Iugh tensIon cable from
removal the
compartment After raa18tor See Figure ER 2
IgmtJon cod
can be separated from the
engIne II DIsconnect wIring harnesses for
transmiSSIOn assembly 011
starter alternator back up lamp
Notes pressure SWItch and thennal transmIt

a Be sure to hOist engine and Jack up ter at two connector plugs of engine

transmiSSIon In a safe manner compartment main harness

b Fender covers should be used to 12 DIsconnect vacuum hose of

body Master Vac at mtake manifold If so

prevent damagmg car

c Place wheel chocks lfi front offront eqUIpped

13 DIsconnect heater Inlet and out
wheels and m rear of rear wheels
let hoses If so eqUIpped See FIgure
ER121
cable ERA
I DIsconnect battery ground
from battery terminal Flff ER 2 RemOVing 011 cooler hoses
2 Remove hood as follows

Mark hood locatIOns on

I hinge
c Dlscon
1ect vacuum hose
hood to faCIlItate proper reInstallahon
d Disconnect WIre connections at In
2 Support hood with hand and
bolts securmg It to hood hibltor sWItch and at downshtft
remove hmge
not to let hood when solenOid
taking care shp
bolts are removed See Figure ER I
6 Remove four bolts secunng radIa

tor to body and detach radiator and

ER340
radiator shroud If so eqUipped
7 DIsconnect engine ground cable Flff 4
ER RemOVing heater Inlet and
outlet hoses
at the body connectIOn end See

Figure ER 3

14 Remove clutch operating cyl

mder from clutch hOUSing See Figure
ER5

Fig ER 1 RemOVing hood seCUring

bolts

3 Remove hood from hood hmge

ER176
with the help of an aSsistant
3 Dram engtne coolant and engtne Fig ER 3 Disconnecting engine
ground cable
011
4 Remove radiator grdle
8 DIsconnect hose s from an clean
5 DIsconnect upper and lower hoses Flff ER 5 RemOVing clutch operating
from radiator er and remove au cleaner cylinder

ER 2
 Engine Removal Installation

15 DIsconnect cab Ie Note Put match marks on both the

speedometer
from rear extensIon houSIng shaft and compamon flange so that
16 DIsconnect parking brake cable shaft can be reinstalled in the origI
at cable adJuster nal position
17 Remove transmISSIon control
20 For cars equIpped WIth 3 Jomt
Imkage
propeller shaft remove center beanng
I For cars eqUipped WIth manual
transrmsslon remove gear sluft control
bracket attaclung bolts and remove

center beanng support from floor

lever See FIgure ER 6
panel See FIgure ER 9
ER125

I Rear engine mounting nut

2 Rear engine mounting
member securing boll
3 Rear engine mounting
menber
4 Rear engine mounltng
Insulator
5 Rear engine mounllng
msulator to transmiSSIon
securing bolt

TM415 Tlghlemng torque T of

ER 6 RemOVing gear shift bolts or nuts kg m ft Ib
Flff
09 to I 2 7 to 9
control ever @ T
T I
@ 9 10 2 6 14 to 19
2 For WIth auto
cars eqUIpped Flff ER 9 Remove center bearing
malic transmissiOn dIsconnect selector Flff ER 10 RemOVing rear engine
support
range lever from manual shaft See mounting member

Figure ER 7 21 Withdraw sleeve yoke from rear 25 Connect SUitable WIres to engme
extenSIon hOUSing Plug up rear end of and
slmgers engine to take
ralse
weIght
rear extensIOn hOUSing to prevent 011 off front mountlDg Insulators
leakage
26 Remove bolts securing engIDe
22 Support transmiSSion With Jack
support front mounting Insulators
to
23 Remove two rear engtne mount
27 Raise engtne and transmissIOn
109 nuts CD as shown In FIgure ER 10 and remove from car as a single umt
24 Remove four rear engme mount
See FIgure ER II
Ing member secunng bolts @ as

shown In Figure ER 10 and detach Note Be careful not to allow the umt
ER124 mountlDg member to hit agaInst any adjacent parts
Flff ER 7 Disconnecting selector
range lever

18 DIsconnect exhaust front tube b

from exhaust mamfold
Loosen rear tube connector and
remove front tube assembly

fu
I Front lube
ER1BO 2 Rear tu be

f
Fl 8 DISconnecting exhaust front
ER
tube from rear tube

shaft ER126
19 OlSconnect propeller at

compamon flange of gear carner Lifting the engine

ER 3
 Engine Removal Installation

Front Insulator
INS TALLATION ENGINE MOUNTING can be adJusted
SIdeways After mounting the engme
Install In the reverse order of reo INSULATOR on front msulators make sure that the
moval obserVIng the following Instruc engine IS
properly alIgned
lions Three Insulators are used to mount
Note When front insula
I When Instalhng fIrSt secure rear the engIne and transmIssIOn two lo connecting
tor to
cated at left and nght front ends of engine mounting bracket
engine mounting member to body
block and on alIgn the proJectIon on front InsUla
2 Refer toapphcable section when cylinder e at transmISSIOn
tor with the notch in en e mount
installing and adJusting any parts
rear extensIOn housing
mg bracket
3 When installing hood followmg Replace msuJator If It shows sIgns
that It IS of separatIOn or detenoratlon
engme Installallon be sure
Be sure to
properly centered and that hood lock keep Insulator free from REAR INSULATOR

operates securely Refer to SectIOn 011 or grease See FIgure ER 12 Front

BF for AdJustment

Fronl mounl1ng

Rear mountmg

Front
ER128

Fig ER 14 Rear Insulator

Removal

I the transmISSIon With

Support a

A Jack
2 Remove nuts securing rear
Umt mm m 1 9 to 2 6 14 to 19 engine
Tlghtemng lorque T of @ T
bolts or nuts kg m ft lb @ T 09 to I 2 7 to 9 mounting msulator to mounting mem
ER127
ber
Fig ER 12 Structure view of engine mounting
3 Remove bolts connecting rear

FRONT INSULATOR
engme mounting Insulator to transmis
2 xe
Remo nuts securmg front sIOn rear extensIOn hOUSing
RIght and left front 1ClSulators are engine mounting Insulator to front 4 Raise transmISSion slIghtly and
Identical and are
Interchangeable See suspensIOn member remove Insulator
FIgure ER I3 Reniove bolts secunng engine

mountthg IAsulator to engine mount

Front Ing brack t
ProjectIon ProJecl1on
3 alse engine
shghtIy and remove Inspection
msulators
If there IS damage detenoratlOn or

separatIOn of bounded surface re

place
Inspection I

If there IS damage detenoratlOn or

separa lion of ounded surfa e re

Installation
ER079 place
Install rear engine mounting insula
Flff ER 11 Front Insulator
tor m the reverse order of removal
Installation
observmg the follOWing instructIOns
Removal InstaIJ front msulator In the reverse InstaIJ msulator In plac ylth the
order of removal observing the fol dIrectIOn of mounted msulator the
Support engine Wltl a Jack lOWing mstructlOns same as that In
Figure ER 14

ERA
 Engine Removal Installation

SERVICE DATA AND SPECIFICATIONS

kg m ft Ib
Tlghtenmg torque
Rear mounting member to 19t026 14toI9
body
09 to I 2 7 to 9
Rear Insulator to rear mounting member
o 9 to I 2 7 to 9
TransmIssIOn to rear Insulator

09 to I 2 7 to 9
Front Insulator to front suspensIOn member

Front Insulator to engine support bracket 19t026 14toI9

19 to 2 6 14 to 19
Engme to engtne support bracket
block gusset to automatic transmISsIOn 2 7 to 3 3 20 to 24
Cyhnder

ER 5
 SECTION CL

CLUTCH
DATSUN
MODEL 610 SERIES

CLUTCH CL 2

CLUTCH CONTROL CL 5

SERVICE DATA AND

CL 9
SPECIFICATION

TROUBLE DIAGNOSES AND

CL10
CORRECTIONS

I NISSAN I SPECIAL SERVICE TOOLS CL 12

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Clutch

CLUTCH

CONTENTS

DESCRIPTION CL 2 INSPECTION AND ADJUSTMENT CL 3

REMOVAL CL 2 ASSEMBL Y CLA

DISASSEMBL Y CL 2 INSTALLATION CLA

DESCRIPTION
The clutch C2ODS Type IS a single It conSIsts of the clutch dISC pres clutch cover and clutch release
nngs
dry disc type uSing a dIaphragm spnng sure plate diaphragm thrust
spnng beanng

I Clulch dISC assembly

2 Clutch cover assembly
3 Release bearmg
4 Releasesleeve
5 WIthdrawal lever
6 WIthdrawal lever ball ptn

CL149

Fig CL l Exploded view of clutch assembly

Be sure to them out

REMOVAL turn In a cnss b Be careful not to drop clutch disc
cross fashIon clutch
I Remove transmiSSIOn from en
or cover assembly
3 Remove clutch diSC and cover
gtne Refer to Section TM for Removal
assembly
Procedure
2 Loosen bolts attaching clutch Notes DISASSEMBLY
cover to flywheel one turn at a time a Be careful not to allow grease or ad I Clutch cover assembly cannot be
each untIl spring pressure IS released to get on clutch lInmgs dISassembled since dlaphragtn spnng IS
CL 2
 Clutch

securely nveted to c1u tch cover and 3 Check dISC plate for runout when
c1u tch cover assembly IS balanced ever the old dIsc or a new one IS

If necessary replace clutch cover Installed

If runout exceeds 0 5 0 020
assembly as a complete umt 4 mm

2 Remove clutch release mechanism Ul at the outer crrcumference of

as follows faCing 95 mm 374 In from the
center replace or repaIC dIsc assembly

Flff CL 4 Pulling outpilot bushIng

INSPECTION AND
ADJUSTMENT I

Wash all the CL009

dIsassembled parts
except release beanng and dISC assem

Flff CL 6 MeaSUring dISC runout

I Release beanng bly In SUitable cleamng solvent to
2 Release beanng drrt and grease before
remove making
sleeve 5
Inspechon and adJustment Check the fit of dISC hub on
3 Holder spnng
CL213 transmiSSion dnve
4 Dust cover
main
gear splInes
for smooth slIdUlg IfsplInes are worn
5 WIthdrawal lever
Retamer spnng that IS backlash exceeds 04 mm
6
Flywheel and pressure plate 0016 In at the outer edge of clutch
Fig CL 2 Exploded view of clutch
release mechanism dISC clutch diSC or m8ln dnve gear
Check fnctlon surface of flywheel
and for should be replaced
pressure plate sconng or

I Remove dust cover from clutch

roughness Shght roughness may be
housing smoothed by uSing fine emery cloth If
2 USing a flat head screwdnver Clutch cover assembly
surface IS deeply scored or grooved
remove
retaining spnng from ball pin I Check the end surface of dIa
the part should be replaced
m front cover of transmIssIon
phragm spnng for wear If excessive
3 Remove withdrawal lever to
wear IS found replace clutch cover as
gether with clutch release beanng and Clutch disc assembly an
assembly
holder spnng 2 Measure the of dIaphragm
Inspect clutch dISC for worn or oily heIght
4 Remove holder spnng from
faCings loose nvets and broken or spring as outlIned below
withdrawal lever and detach clutch
loose torsion spnngs I Place Distance Piece
release bean gJr
Jm wlthdrawallever
ST20050100 on Base Plate
I If faCings the dISC should
At thIS lime remove retainer spnng are OIly
ST20500010 and then hghten clutch
be In thiS case
from wIthdrawal lever replaced Inspect trans
the
cover assembly on base plate by
rmsslon front cover od seal pIlot
3 Remove clutch release beanng uSing Set Bolts ST20050051 See
buslung engme rear 011 seals and other
from beanng sleeve uSing a umversal FIgure CL 7
pOints for oIl leakage
puller See FIgure CL 3 2 The diSC should also be
S n0050 1U0
replaced ST200500 10 S 120050051
when facmgs are worn
locally or worn

d
down to less than 03 mm 0012 In
A
at nvets

CL151

Flff CL 7 MeasUring the height of

diaphragm spring

2 Measure the A
height at sever

al pOints WIth a vermer calIper depth

Flff CL 3 DlSassemblmg release bearmg gauge See Figure CL 7
If the
height A of spnng end IS
4 Remove pilot buslung In crank beyond the speCIfied value adJust the
shaft uSing a Pilot Bushing Puller spnng height WIth DIaphragm Spnng
CLOB9
STI 661000 I If necessary See Figure Adjusting Wrench ST20050240 See
CL4 Fig CL 5 Measuring clutch lining Figure CL 8
CL 3
 Clutch

4 Contact surface of transmissIOn

A
Height ASSEMBLY
310 to 33 0 mm
main dnve gear sphnes grease

I 220 to I 229 In Release bearing and sleeve including Molybdenum Dlsulphlde

When release beanng on Note A very small amount of grease
I installIng
sleeve and seat should be applied to the above
use a press beanng
securely on sleeve pOints If too much lubncant is

apphed It WIll run out on the

Note Do not press ou race See
If necessary
replace clutch cover as CL 9
fncllon plates when hot resulting
Figure
an
assembly Also unevenness of dla
In
damage to clutch disc faCings
phragm spring toe heIgh t should be 3 After connect With
less than 05
lubncatlng
mm 0 020 In on 62 mm
drawal lever to holder spnng and
2 44 In diameter of d13phragm release beanng and beanng sleeve as

spring holder
sembly to spring After in
stalling them on clutch hOUSing Install
dust cover

Pilot bushing
Before
installing a new bushing
CL215 thoroughly clean bushing hole Install
Fig CL 9 Installing release bearing bushing In crankshaft uSing a soft
hammer

Bushing need not be OIled See

2 Before or
dunng assembly Figure CL 12
lubncate the
CL152
follOWing pOints WIth a
lIght coat of mulll purpose grease
Flff CL 8 Adjusting spring height
1 Inner groove of release beanng
sleeve
3 thrust rings for
Inspect wear or

damage
As these parts are InvlSlble from

outsIde shake cover assembly up and

down to hsten for clattenng nOIse or

hammer nvets and lIsten for

lIghtly on

CL217
a slIghtly cracked nOIse Any of these
nOises indicates necesslly for Fig CL 12 Installing pilot bushing
replace
ment as a
complete assembly
INSTALLATION
Release bearing and sleeve I Apply a lIght coat of grease
I Check for abnormal wear on con including Molybdenum Dlsulphlde to
tact surface of wIthdrawal lever ball transmissIOn main dnve gear splInes

Shde clutch diSC on main dnve gear

pin and bearing sleeve Fig CL IO Lubricating recess of
Hold beanng Inner race and rotate bearing sleeve several limes
outer race while Remove clutch dISC and wIpe off
applYing pressure to
2 Contact surfaces of Withdrawal excess lubncant pushed off by diSC
It
If the lever lever ball pin and beanng sleeve hub
beanng rotallon IS
rough or

3 Contact surfaces of transmiSSion

nOIsy replace bearing Note Take spectal care to prevent
front cover See FIgure CL II
grease or oil from getting on clutch
Pilot bushing faclng
Check the fit of pIlot bushing In the
2 Reinstall clutch dISC and clutch
bore of crankshaft
Check pIlot bushing In crankshaft
coverassembly
for wear
roughness or bell mouthed Support clu tch hsc and cover as
condlllon sembly WIth Clutch Aligmng Bar
If necessary STI0660000 See Figure CL 13
replace It When bush
Ing IS not SUitable for further use be Note Be sure to dISC
Fig CL ll Lubricating pOints of keep faCings
sure to check transmIssion main dnve and pressure
Withdrawal lever and flywheel plate clean
gear at the same lime and dry
front cover

4
Cl
 Clutch

3 Install bolts to
securely tlgh ten 4 Remove Clutch Aligning Bar
c1u tch assembly to flywheel
cover 5 Install transmIssIon In
engUle
ST20660000 Each bolt should be tightened one turn 6 Install clutch
operatmg cylInder
at a lime In a cross
cnss fasluon to the to clutch houslng

specIfied torque 1 6 to 2 I 12
kg m
to 15 ft Ib

Note Dowels are used to properly

locate clutch cover on
flywheel
CL 153

Flff CL 13 Installing clutch cover

assembly

CLUTCH CONTROL

CONTENTS

DESCRIPTION CL 5 ASSEMBL Y CL 7
CLUTCH PEDAL CL 6 INSTALLATION CL 7
REMOVAL CL 6 OPERATING CYLINDER
CL B
INSPECTION CL 6 REMOVAL CL B
INSTALLATION CL 6 DISASSEMBL Y CL B
ADJUSTMENT CL 6 INSPECTION CL B
CLUTCH MASTER CYLINDER CL 7 ASSEMBL Y CL 8
REMOVAL CLl INSTALLATION CL 8
DISASSEMBL Y CL 7 BLEEDING CLUTCH SYSTEM CL 8
INSPECTION CL7

DESCRIPTION
The hydraulIc clutch control When the clutch
con
pedal IS
depressed of the operating cylInder piston IS
SISts of pendent pedal a master
a the pISton of the master cylUlder transmitted to the withdrawal lever
cylmder an operating cylinder and a forces clutch flUId to the operating through the push rod thus disengaging
withdrawal lever cylInder Via a pIpe hne The movement the clutch

I GUlch pedal
2 Clulch master cylInder
3 Clulch plpmg
4
Operalmg cylinder
5 Withdrawal lever
6 Release bearing
1 Clutch cover

8 Clutch dISC
9 Return spnng
10 Push rod

CL097

Flff CL 14 Clutch operating system

CL 5
 Clutch

Stroke 30 mm 1 18 m

I l

I
I ClevIS pm
2 Cotter pm
3 Return sprmg
4 Pedal boss
5 Pedal assembly
6 Bush
7 Sleeve
8 Push rod
9 Fulcrum pm

CL098 CL099

FI8 CL 16 Exploded view of clutch pedal

Flff CL 15 adJustable
Non operating cylinder

The operating cyhnder IS a non INSTALLATION

return
adJustable type that uses no
To Install reverse the order of
spnng In thIS umt the wlthdrawal to removal mulll purpose grease
Apply
push rod play adJustment IS not neces to the fncllon surfaces of the diSas
sary since the S as shown m
Figure sembled parts as shown In FIgure
CL IS serves to automatically com
CL 19
pensate for clutch dISC wear

Note Refer to FJgUre CIA7 for the

correct directIon of return spring

CLUTCH PEDAL Fig CL 18 Bending clevIS pm

REMOVAL
Notes
I Pry off cotter pin and take out
a Exercise care in adjusting the play
clevIS pin dIsconnect push rod from
so as not to block the port on
pedal assembly
A blocked port
2 Unhook return spring Back off master cylinder
may result if there is too small a
fulcrum pm and remove pedal as

play at clevIS pin

sembly
b Bend l pin
c1evicompletely

Flff CL 17 Hooking return Spring

Tightenmg torque
Pedal installation bolt
Note Before removmg clutch pedal
Fulcrum pin
note toe board clearance at pedal
306 to 14
4 m
kg
pad 22 to 30 ft Ib
ADJUSTMENT
Lock nut A 8
I AdJust pedal heIght to 175 mm o 79 to I07 kg m

INSPECTION 6 89 In by adJusting pedal stopper 6 to 8 ft Ib

Clean the follOWing parts In clean and lighten lock nut A to speCified
Ing solvent and check for wear dam torque
age or other abnormal condlllon
2 Turn In or out push rod adJusting
Replace faulty parts screw unlll a play of I to 5 mm

I Return spnng 004 to 020 m at cleVIS pin IS

obtained Then lock nut B

2 Pedal sleeve lighten
3 Pedal boss etc to speCIfied torque
6
Cl
 Clutch

DISASSEMBLY

I Remove dust cover and take off

stopper nng from body

2 Remove push rod and pIston as

sembly
Remove
3 spnng seat from pIston
and take off piston cup If necessary
See Figure CL 20

Note Discard pISton cup If It IS re

moved from pISton assembly

I Lock nut A

2 Lock nut 8 INSPECTION

Pedal height a
Note To clean or wash aD parts of
175 mm 689 to
master cybnder clean brake fluid
Pedal full stroke b
135 mm 531 to must be used Never use mineral
oils such as
gasobne and kerosene
@ Multi purpose grease
CLl02 It wdl ruin the rubber parts of the
hydraulIc system
Fig CL 19 AdJusting pedal height
I Check cyhnder and piston for
uneven wear or damage and replace If
Note Depress and release clutch CLUTCH MASTER necessary
2 Renew piston cup when dIsas
pedal over its entire stroke to en
sure that the clutch linkage oper
CYLINDER sembled It must also be replaced when

ates smoothly without squeaking REMOVAL wear or deformallon due to fallgue or

noise interference or bIRding damage IS found

I Pry off snap nng on cleVIS pin od reservon
3 dust cover
Damaged
2 Remove cleVIS pin at rod
push or cap should be replaced Return
3 DIsconnect clutch tube from mas also be
spnng and valve spring must
ter cylInder and drain brake flUid when are broken or
replaced they
4 Remove nuts securing master cyl weak
Inder to dash and disconnect
panel
rr
master cylInder
ASSEMBLY

Assemble cylinder In
clutch master
the reverse procedures of
disassembly
obserVing closely the follOWing Instruc
lions

I DIp pIston cup In brake flUid

before installIng Make sure that It IS

correctly faced In posltlon

2 Apply a coating of brake flUid to
cylInder and piston when assembbng

INSTALLATION
Install clutch master cylInder In the
reverse procedures of removal observ

I ReservoII cap 6 Return 11 Pnmocy cup 16

Ing closely the follOWing instructIOns
prmg Stopper rmg
2 Reservorr 7 Sprmg seat 12 Piston 17 Du t cover IAdJust the pedal heIght by chang
3 ReservoII band 8 Valve 13 Pu h rod 18 Lock nu t
4
prmg
length of push rod referring to
Ing the
Cybnder body 9 Supply valve rod 14 Secondary cup InstallatIOn and AdJustment
5 Supply valve stopper 10 Supply valve 15 Slopper
CL265 2 Bleed an out of hydraulIc system

Fig CL 20 Exploded view of clutch master cylinder referring to Bleeding Clutch System

CL 7
 Clutch

Tlghtemng torque b Do not install return spnng or

Master cylInder to dash panel clutch will not dIsengage properly

trT
secunng nut
Tightening torque
o 79 to I 07 kg m Opera ting cylInder
6t08ft Ib
securing bolt
Clutch tube connector 2 5 to 3 0 kg m
I 5 to I 8 kg m
CLl07 18 to 22 ft Ib
II to 13 ft Ib
Bleeder screw

Note When o 7 to 0 9 m
kg
installing clutch tube use

Flare Nut 5 to 7 ft Ib
Torque Wrench
I Push rod 4 PlSlon
GG943 I 0000 2 Duslcovel 5 Operdllng cylinder
3 PISton spnng 6 Bleeder sClew

Fig CL 22 Exploded view of BLEEDING CLUTCH

OPERATING operating cylinder
SYSTEM
CYLINDER To bleed clutch system use the

INSPECTION
same procedure as descnbed UI Brake
System
Visually Inspect all disassembled I Fill 011 reservOIr of operating
parts replaCing those worn or dam
cyl
Inder WIth brake flUId
aged beyond speclfical10ns 2 Detach cap from bleeder screw on

operatUlg cylInder and In Its place

connect a Vinyl tube
ASSEMBLY 3 Pour a small amount of brake
flUId Into a clean contamer and Insert
Assemble In the reverse order of
the open end of the VInyl tube Into It
observe the fol
dIsassembly Closely 4 Have worker
a co
depress clutch
10wUlg instructIOns
pedal two or three tunes With clutch
I Pnor to
FIg CL 21 Removing operatlng assembly dIp piston cup
pedal depressed fully loosen bleeder
cylinder In clean brake flUId screw to bleed air out of clutch sys
When U1stalllng cup pay parllcular tem
atten lion to ItS dlrecllon 5
REMOVAL TIghten bleeder screw and release
2 Dip cylInder and piston In clean the
I Detach
pedal
clutch hose from oper brake flUid before assembly 6 Repeat above steps untIl no au

atlng cylInder
Note Be sure to Install pISton as bubbles appear In Vinyl tube
2 Remove two bolts secunng oper
sembly With pISton spring m
place
atlng cyhnder to clutch housing Notes
a Always keep brake flwd In ad
reservou so that it flows continu

INSTALLATION ously into the line

b Use care not to allowbrake flwd to
DISASSEMBLY Install In the reverse order of re
come Into contact with painted
Remove rod with dust
moval Closely observe the follOWing
push inS trucl10ns
surfaces
cover c Make sure that no leak occurs at
2 Remove pIston assembly and Notes connections
pIS ton spnng a Bleed au thoroughly from clutch d Pour brake fluid mto oil reservoir
3 Remove bleeder hydrauhc system up to the specified level
screw

CL 8
 Clutch

SERVICE DATA AND SPECIFICATIONS

Clutch cover

spnng to flywheel distance mm In 31 0 to 33 0 1 220 to I 229

Diaphragm
Unevenness of diaphragm sprIng toe
height mm In less than 0 5 0 020

Full pressure Ib 450 992

kg
Outer of flatness of pressure plate mm In o 05 0 0020

Allowable refaclng lumt mm In I 0 0 039

Clutch disc

Facing SIze

Outer dla x inside dla

x thickness mm In 200 x 130 x 3 5

7 87 x 5 12 x 0 138
Total fnctlon area cm2 sq In
362 56 I
Thickness of disc assembly
Free mm In 8 5 to 9 2 0 335 to 0 362

Compressed mm In 7 6 to 8 0 0 299 to 0 315

Number of torsIOn spnngs 6

Allowable mlmmum depth of rivet

head from surface mm In 03 0012
Allowable facing runout mm In o 5 0 020
Allowable free play of splIne
at the outer edge of dIsc mm ln 04 0016

Clutch pedal

Pedal 689
height mm In 175

Play at cleVIs pin mm In I to 5 0 04 to 0 20

Full stroke mm ln 135 5 31

Pr sslng full stroke

strength at kg Ib 10 4 22 9

Master cylInder c1utch

DIameter of master cyhnder mm In 1587

Allowable maxImum clearance between

cylInder and piston mm In 015 00059

Clutch operating cylInder

Diameter of operating cylInder mm In 19 05 Y

Tlghtemng torque
Clutch mounting bolt kg m ft Ib l6t022
12to 16

CLog
 Clutch

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause and testing Correcl1ve acllon

Shpplng clutch SlIpping of the clutch IS obvIOus when any of the following symptoms IS encountered dunng
opera lion

I Car wlIl not respond to

engine speed dunng acceleratIOn

2 Insufficlen t car
speed
3 Lack of power dunng uphdl dnvlng

Some of the above condll1ons expenenced when engine problem occurnng FIrSt
are also

determine whether engine clutch

or causing the problem
IS

If slIpping clutch IS left unheeded wear and or overheating will occur on clutch faCing untdlt IS
no
longer serviceable
TO TEST THE CLUTCH FOR SLIPPING follows
proceed as

h 25 to
Dunng upgrade travelhng open throttle untd engine IS runmng at about 40 to 50 km
30 MPH WIth gear shift lever In 3rd speed positIOn Now shift mto top gear and at the same

lime rev up engine If clutch IS slIpping car wlll not respond soon to the operallon of

accelerator pedal

Clutch faCing worn excessIvely Replace

011 or grease on clutch faCing Replace
Warped clutch cover or pressure plate Repalf or
replace

IS parllcularly obVIOUS when shIfting gears especIally Into gear low

Dragging clutch Grabbing clutch
TO TEST THE CLUTCH FOR DRAGGING OR GRABBING proceed as follows

1 Start up engine Disengage clutch Shift Into reverse gear and then Into Neutral Under tlus
conditIOn gradually Increase engine speed and again shIft Into reverse gear If clutch IS

dragging gear grallng IS heard when shifting from Neutral Into Reverse

2 Stop engtne and shIft gears Conduct thIS test at each gear posll1on

3 In step 2 gears are shIfted smoothly except I st speed posItIOn at Idhng

a If dragging IS encountered at the end of sluftmg check condlllon of transmiSSIOn

synchromechamsm
the beginning of shifting 4 below
b If dragging IS encountered at proceed to step

to check for free play

4 Push change lever toward Reverse sIde depress pedal
a If the pedal can be depressed further check clutch condll1on
b If the pedal cannot be depressed further proceed to step 5 below

5 Check clutch control pedal height free play etc If no abnormal condlllon eXIsts and If

pedal cannot be depressed further check clutch condlllon

Clutch dISC runout or warped Repalf or replace

Wear or rust on hub splInes In clutch dISC Clean and lubncate WIth grease or
replace

DIaphragm spnng toe height out of ad AdJust or replace

Justment or toe lip worn

Worn or Improperly Installed parts Repalf or

replace

CL 10
 Clutch

Condll1on Probable cause and testing Correcl1ve actIOn

Pulsating clutch Pulsating clutch pedal IS

usually nol1ceable when car
Just starts off and clu tch IS parl1ally
engaged

Weakened or broken clutch diSC torsIOn Replace

spnng

011 or grease on clutch faCing Replace

Clutch faCing out of proper contact or Replace
clutch diSC runout

Loose nvets Replace

Warped pre ssure plate or clutch cover Repair or replace
surface

Unevenness of dIaphragm spnng toe AdJust or

replace
height
Loose detenora ted
engtne mounting or
Rel1ghten or
replace
rubber

NOISY clutch A nOise heard after clutch

IS IS
disengaged

Damaged release beanng Repla e

A nOise IS heard when clutch IS

disengaged
InsuffIcient grease the surface
on
shdlng Apply grease
of beanng sleeve

Clutch cover and beanng are not mstalle9 AdJust

I
correctly

A nOise IS heard when the started off With clutch

I car IS
suddenly partJally engaged

Faulty pilot bushing

I Replace

ab lIt hopptng flutch When rabbit hopping of clu tch occurs car WIll not s art off smoothly from a s
tandlng start o

clutch IS engaged before clutch pedal IS fully depressed

011 or grease on clutch faCing Replace

Clutch faCing worn or loose nvets Replace
Wear or rust on
splInes In dnve shaft and Clean or
replace
clutch dISC

Warped flywheel or pressure plate Repair or

replace
Loose mountings for engine or power
Rel1ghten
train umts

CL 11
 Clutch

SPECIAL SERVICE TOOLS

Tool number For Reference
No Descnphon use pdge or

No
tool name Umt mm In on FIgure
710 CL 7
f ST20050010 Fig
610
pldte

cue
Base 510
CliO
CI30
2 ST20050051 @
230
SE002 D
l
Set bolt C30

3 ST20050100 O

Distance piece

@J
7 8 mm 0 307 In

SE003

710
4 ST20050240 Fig 8
CL
610
150 591
DIaphragm spnng 510
adJusting wrench CliO
CI30
SE032 230
32 0 126
C30

ThIs tool IS used to conduct disc

5 ST20660000 centenng by inserting the tool Into Page 4
CL

Clutch alIgning pdot buslung In

flywheel when Instalhng clutch assembly to flywheel FIg CL 13

bar

1
c
SEOOl

6 ST16610001 G20 Fig CL 4

GI8
PIlotbushing L24
puller Ll8
Ll6
Ll4
SE191

7 CL 8
GG943 10000 Tlus tool IS used to tIghten and loosen clutch tube flare nut All Page
models
Flare nut torque
wrench

SE227

CL12
 SECTION TM

TRANSMISSION
DATSUN
MODEL 610 SERIES

4 SPEED TRANSMISSION
TM 2
TYPE F4W63U
5 SPEED TRANSMISSION
TYPE FS5W63A TM 1D

SERVICE DATA AND

TM 22
SPECIFICATIONS

TROUBLE DIAGNOSES AND

TM 24
CORRECTlllNS

I NI AN I SPECIAL SERVICE TOOLS TM 25

NISSAN MOTOR CO LTD

TOKYO JAPAN
 TransmiSSIon

4 SPEED TRANSMISSION TYPE F4W63L

CONTENTS

DESCRIPTION TM 2 BAULK RINGS 6

TM
REMOVAL TM 3 Oil SEAL TM 6
DISASSEMBL Y TM 3 ASSEMBL Y TM 6
GEAR DISASSEMBLY 4
TM FRONT COVER 6
TM
MAINSHAFT DISASSEMBLY 4
TM REAR EXTENSION HOUSING TM 7
MAIN DRIVE SHAFT DISASSEMBLY TM 5 GEAR ASSEMBLY TM 7
SYNCHROMESH DISASSEMBLY TM 6 MAIN DRIVE GEAR ASSEMBLY B
TM

INSPECTION TM E REVERSE IDLER GEAR ASSEMBLY TM 8

TRANSMISSION CASE AND COUNTER GEAR ASSEMBLY B

TM
REAR EXTENSION HOUSING 6
TM TRANSMISSION ASSEMBLY TM 9
BEAR INGS TM 6 INSTALLATION TM 9
GEARS AND SHAFTS TM 6

DESCRIPTION beanng thus rotating freely on the Warner type On Warner type the
The transmIssIon IS a
fully synchro mamshaft When the transmissIOn IS baulk nngs synchromze the couplIng
mzed 4 speed type that uses hehcal shIfted the actIOn causes the
couphng sleeve wIth the mamshaft gear PlacIng
gears The reverse gear IS a shdlng mesh sleeve to slIde on the synchromzer the speed control lever In the reverse
type uSing spur gears In construction hub This engages ItS Inner teeth with
positIon throws the malnshaft reverse
the mam drive gear IS meshed wIth the the outer teeth fonned on the maln
gear Into engagement wIth the reverse
counter dnve gear The forward shaft gear
speed Idler gear the tranSlfilSSlon IS reversed
gears proVIded on the countershaft are The synchromzer hub IS fitted to The transmIssIon consists of two maJor
m constant mesh with the mam gears the malnshaft by splme so they turn elements a complete transrmsslOn case
I
Each of the main gears ndes on the together as a umt as the malnshaft IS and a rear extensIOn The contams
case
malnshaft through the needle roller rotated The transmissIon IS of a all gears and gear shafts

I Fron t cover 13 I speed gear mamshaft

2 Main dnve shaft 14 Counlershaft

3 mlSSlon case
Trano 15 Matnshafl beanng
4 Counler gear 16 Reverse hub
5 Baulk nng 7 Reverse gear
6 Coupling sleeve 18 Mamshaft lock nul
7 Shifting Ino
ert
19 Reverse Idler gear
8 Synchronizer hub 20 Reverse dler shaft
9 3rd speed gear mamshaft 21 Mamshaft

10 2nd speed gear mam haft 22 Rear ilOn

ten housmg
TMB21 Needle beanng
1 il Speedome ler dnve gear
12 Reverse Idler gear

Flff TM l SectIOnal view of F4W63L transmISSIOn

TM 2
 TransmiSSion

REMOVAL 8 Disengage propeller shaft Refer 15 Remove bolts secunng transmis

to the section Shaft sIOn to and

To dismount the transmissIOn from Propeller engine move transmiSSIon

backward and away from the car

the car proceed as follows Note the
Plug up openlRg In rear

011 Note Take care m dismounting the

DIsconnect battery ground cable extensIOn housIRg to prevent
from flOWing out transmission not to strike any ad
2 Jack up the car and support ItS
Make Jacent parts and main dnve shift
weight on safety stands sure
9 the engine
Support by locating a

that safety IS Insured

Jack under 011 pan With a wooden
3 Loosen off control lever secunng block used between 011 pan and Jack DISASSEMBLY
nut and remove lever See Figure 10 Support the transmISSion by I
TM 2 Thoroughly wipe clean dirt and
means of a
Jack grease from each component parts of
II Remove two bolts secunng transmission Drain out 011 In transmls
transmiSSion to rear engine mounting slOn case Place the transmiSSIOn on
Insulator and remove four cross
the SUitable stand securely
member mounting bolts See FIgure 2 Detach dust cover from transmis
TM 5
sion case Remove Withdrawal lever
and release Remove five bolts
beanng
secunng front cover to transmission
case and detach front cover See
TM 7
Figure
TM415

FIg TM 2 Removing control lever

4 DIsconnect front exhaust tube

5 DIsconnect wires from reverse

lamp SWItch back up lamp SWitch at

connectIOns
6 Remove clutch operatmg cyhnder TM984

from transmission case See Figure Flff 5 RemOVing crossmember

TM
TM3 TM241

FIg TM 7 RemOVing front cover

12 Lower that transmISSion
Jack so

can be dismounted from the car easIly 3 from trans

Detach bottom cover
13 Remove starter motor from
mISSIOn case
transmission case
4 Remove reverse lamp SWitch and
14 Remove four bolts secunng
speedometer gear assembly from rear

engine to gussets extension

Remove three bolts secunng gussets
5 Move gear to Neutral poslllon
to engtne rear plat and transmiSSIOn
6 Pull out
and separate gussets from engine
stnklng rod pin CD See
case

See
Figure 8
TM
TM416 ck
bl and transmiSSIOn case
Flff TM 3 Removing clutch TM 6
Figure
operating cylmder

7 Disconnect speedometer cable

from rear extensIOn housing See

Figure TM4

TM243

FIg TM 8 DIsassembling rear

extensIOn

7 Remove SIX bolts secunng rear

extension to transmiSSIon case Detach

Note These gussets are not used In rear extension hOUSing by hghtly tap

FIg TM 4 DIsconnecting wires and the Stahon Wagon equipped with a ping It With a soft hammer as shown m
cables 3 Joint propeller shaft Figure TM 9
TM 3
 Transmission

4 Mesh gear at two places Remove 8 Take out ptlot bearing located
lock nut from mamshaft and take out between malnshaft and mam dnve
reverse gear and reverse gear hub
gear
5 Countershaft GUIde
USing 9Dnve out main dnve gear as
ST23100000 push out countershaft shown usmg the wooden handle of a
from the transmiSSIon case as shown m hammer See FIgure TM 15
TM 12 Take
Figure care not to drop
needle beanngs mto case
TM 9 Removing extensIOn
Flff rear Remove counter gear together WIth
housing needle and washers from
beanngs
transmissIon case
8 Draw out stnkmg rod @ See
8
TM Note Make sure that washers used
Figure
between counter gear and transmis
sion case are removed
GEAR DISASSEMBLY
I Back off check ball plugs and
remove three locking spnngs and
TM249
check balls Take care not to lose these
Flff TM 15 RemOVing main drIVe
JO
parts See FIgure TM gear assembly

Rev rod 3rd 4th rod

1st 2nd rod
MAINSHAFT DISASSEMBLY
Flff TM 12 Pushlngoutcountershaft
IPry off snap ring on the front end
6 Pry off snap nng retaining reverse of malnshaft and remove 3rd 4th
Idler gear In place Withdraw Idler gear synchromesh assembly and 3rd gear
shaft from the rear of transmissIon See Figure TM 16
case See Figure TM I3

Note Do not remove needle

I bearmg
2
3

Flff TM I0 Layout of check balu

and Interlock plungers

2 Usmg Fork Rod Pin Punch

ST23540000 dnve out retalnml oms
TM418
from fork rod See Figure TM II TM 16
Flff RemOVing snap ring
Take care not to lose two plungers
when draWing out fork rods
2 Pry off snap rmgs and remove

speedometer dnve gear

3 Remove lock nut from malnshaft
and take out reverse gear reverse gear
hub
4 Attach a SUitable tool to the front
SIde of I st gear and press out I st gear
together WIth ball beanng and retainer
See FIgure TM 17

Notes
a Do not attach this tool to 2nd
gear
Flff TM ll RemOVing retaining This may damage 1st gear mam
pins shaft buslung
b Be careful not to remove needle
3 Remove snap rmg and speed bearmg together Wlth
bearing1st
ometer dnve gear Take care not to otherwise needle
bearing may
lose steel ball retarmng speedometer Interfere with steel ball 1
Flff TM 14 RemOVing malnshaft P
sulting in
dnve gear
assembly damaged bearing
4
TM
 TransmiSSion

cp

I Beanng retamer

2 Beanng
3 Needle roller

beanng
4 1st gear

5 Pulle stand I PIlot beanng 13 Couphng sleeve

2 3rd 4th synchromesh 14 Bush 1st gear
6 2nd gear
7 assembly 15 1st speed gear malnshaft
Bushing
8 Sleel ball 3 SnJp rmg 16 Thrust washe malnshaft
TM251
4 Baulk nng 17 Malnshaft bearing
Flff TM 17 DraWing out malnshaft Needle beanng
5 18 Snap rtng malnshaft
bearing 6 3rd speed gear mamshaft beanng
7 MamshJft 19 Steel ball
8 2nd speed gear mamshaft 20 Reverse gear
5 Then attach aproper puIler stand 9 1st 2nd synchromesh 21 Reverse hub
to the front side of 2nd gear ill the assembly 22 Speedomeler dnve gear

out 23 Lock plate

same manner as step 3 and press 10 Shifting Insert
24 Nut
together with 1st 11 Spread spnng
I st gear buslung
12 SynchronIzer hub TMB29
2nd synchromesh assembly and 2nd
gear

Note Before conductingthIS opera

F4W63L transmISSIOn
tion be sure to remove steel ball FIg TM 18 Exploded VIew of malnshaft assembly

MAIN DRIVE SHA DISASSEMBLY

Pry off snap nng and remove spacer See FIgure TM 19

I Snap nng
2 Space
3 Main dnve beanng wtth snap ling
4 MaIO dnve gear

of main drIVe shaft

Flff TM 19 Exploded view

TM 5
 Transmission

2 Press out dnve shaft Ings and dry these parts With com
main beanng
wIth the use of an ordinary beanng pressed aIr

puller and a sUitable press See Figure 2 Check balls outer race and Inner

TM 20 race for wear burr or damage Also

check for smooth opera lion If nec

See TM 22
essary replace Figure

Fig TM 24 backlash
Measuring gear
TM349

TM067
I Main dnve beanng
Flff TM 22 CheckIng ball bearing
2 Main dnve gear BAULK RINGS
TM 20 DrIVIng out main drIVe
FIg GEARS AND SHAFTS I Replace any baulk nng which IS
shaft bearing
deformed or cracked
I Check for wear crack or
gears
2 Posll1on baulk nng In
place on
SYNCHROMESH damage and If necessary replace
DISASSEMBLY gear cone and measure the baulk
2 Check shafts for wear crack or

nng gear
to clearance With baulk nng
I Removespread spnngs CD and bending If necessary re place
pushed toward gear See Figure
take out shifting Inserts @ 3 Check gears for end play See
TM 25
2 Figure TM 23
Sepdfate couplIng sleeve @ from
synchro hub @ See Figure TM 21 Standard end play
1st gear

0 32 to 0 42 mm

00126 to 0 0165 In

2nd gear

o 22 to 0 32 mm

00087 to 0 0126 In

3rd gear
o OS to 0 15 mm

00020 to 0 0059 In
TM258

Reverse Idler gear

I FIg TM 25 Baulk ring to cone gap
Spread pnng 4 Synchro hub o 10 to 0 30 mm
2 Shifting tn crt 5 Baulk nng
00039 to 0 0118 In
3 Coupling keve OIL SEAL
TM255

Fig TM 21 Exploded view of It IS adVIsable not to reuse 011 seals

synchromesh assembly that have been removed Always Install
new od seals

Replace OIl seal If sealIng lip IS

INSPECTION deformed or cracked Also discard od

Wash clean all parts seal If spnng IS out of posll1on Check

In an approved
solvent and check for the 011 seal IIp contacting face on
wear or damage
shaft If necessary replace the seal and

TRANSMISSION CASE AND the shaft as a set

REAR EXTENSION HOUSING TM419

Wash clean WIth an

approved Flff TM 23 Measuring gear end play ASSEMBLY
solvent and check for any crack which To assemble reverse the order of
may be the cause of 011 leak 4 Measure backlash In gears disassembly
If rear extensIOn bush IS worn or
Standard backlash
cracked replace It as an
assembly of
005 to 0 20 mm
FRONT COVER
bush and rear extensIOn housing 00020 to 0 0079 In I Make sure that seal mating sur

If the backlash exceeds the spec1fi face IS clean

BEARINGS dnve seal Into
ed value replace dnve and dnven gears USing a press new

WIpe clean 011 or grease on bear as a set See Figure TM 24 place on front cover

TM 6
 TransmiSSion

4 U sing TransmissIOn
2 Lubncate seal lip and main drIve Adapter
shaft with gear 011 when Instalhng 011 ST23800000 as shown In
Figure
seal See TM 26 TM 31 Install main shaft beanng to
Figure
gether With reverse hub to main shaft

Front

CD
t

TM071
FIg TM 28 Installing spread Spring

TM354
3 Install the following parts to
malnshaft In the order lIsted 2nd gear
FIf TM 26 LocatIOn offron t cover
needle roller 2nd gear 2nd
011 seal beanng
gear baulk nng 1st 2nd speed @
synchromesh assembly Then fit 1st
REAR EXTENSION HOUSING gear bushing onto mamshaft by usmg a @
proper brass dnft And Install I st gear
I Clean rear extension housing and
I st gear
baulk nng needle beanng
press 011 seal Into posll1on Apply a
steel ball and thrust washer See
coating of gear 011 to sealing IIp when
Figures TM 29 and TM 30
Ulstalllng lll seal See Figure TM 27 TransmiSSion adapter
ST23800000
Bushlllg
2 e gear hub
Reve
3 Beanng retamer
4 Beanng
5 Needle roller bearlllg
Front 6 lslgear
7 2nd gear

8 S leel ball
9 Bushlllg

TM078 TM534

Fig TM 29 nstalllnfl thrust washer

TM 31
Fig Installing malnshaft
TM260 bearing
Ist gear de
Flff TM 27 LocatIOn of rear 2nd gear de
extensIon housing 011 seal
5 Install 3rd gear needle roller bear
h2 hI
2 Install stnklng rod In place on
lng 3rd baulk nng 3rd 4th speed
rear extensIOn housing synchromesh assembly to malnshaft
Front
6 Fit SUitable snap nng
hi h2 a In place so

that there eXists a minimum clearance

GEAR ASSEMBLY between the end face of hub and nng
groove See Figure TM 32
I W lsh clean all parts and dry With
TM 262 Refer the following chart
to as a
compressed air

2 Assemble synchromesh assembly Fig TM 30 Installing synchro hub gUide In selecting a SUitable snap nng

1 Place hro hub Into couphng

syn
sleeve Available synchro hub snap nng
Fit three
2 shifting Inserts In

grooves In synchronizer hub

the No Thickness mm In
3 Locate one spread spnng on

lower side of shifting Inserts to secure

I 140 to 145 00551 to 00571
them to the Inner side of couphng
sleeve 2 145 to 150 00571 to 00591

Install other spnng on the

the
3 150 to 155 0 0591 to 00610
opposite Side of couphng sleeve pro
4 I 55 to 160 0 0610 to o 0630
perly Make sure that they are Installed
each other See
opposite to Figure 5 160 to 165 00630 to o 0650
TM 28

TM 7
 TransmiSSion

Mamshaft beanng retainer Standard reverse Idler gear

Tlghtemng torque end play

o 8 to I 0 kg m o 10 to 0 30 mm

6 to 7 ft Ib 00039 to 0 0118 m

AvaIlable snap rmg

Front

4th gear sIde 3 rd gear SIde No ThIckness mm In

MAIN DRIVE GEAR
ASSEMBLY
TM264 I 15 to I 25

Fig TM 32 Installing synchro hub I 00453 to 00492

USing Malnshaft Beanng Dnft
snap ring ST22452000 press main dnve beanng 2 I 35 to I 45
onto main dnve shaft 00531 to 00571
2 Install a set ofsUitable spacer 3l1d
3 I 25 to I 35
snap ring Into groove so that there
eXIsts a minImum clearance between 00492 to 00531
7 Insert mamshaft assembly Into the groove and end face of spacer See 4 I 45 to I 55
pOSItIon from the rear SIde of trans Figure TM 33 Be sure to Install pIlot 00571 to 00610
mIssIon case and secure to transmIS beanng In place when Istalhng main
sIon wIth mamshaft dnve gear assembly to transmissIon 5 I 05 to I 15
case
bearing
retainer mounting bolts case 00413 to 00453

Chart Snap nng thIckness

No Thickness mm In
@H I
I 149 to 155 00587 to 00610

2 156 to 162 00614 to 00638

@@
3 162 to 168 00638 to 00661 j TM265

4 168 to 174 00661 to 00685 Idler

Flff TM 35 Assembling reverse

5 174 gear assembly

to 180 0 0685 to 00709

6 180 to 186 0 0709 to 00732 Note Install thrust washers @ and

CID so that grooved sides are facing

7 186 to 192 0 0732 to 00756
toward gears

Fr COUNTER GEAR ASSEMBLY

m
BE3ffi
IdenuflcallOn mark
@
To
washer
Install needle

@ and
roller beanng
Countershaft
GUIde ST23100000 Into counter gear

TM249 proceed as follows See FIgure

TM 36
FlTM 34 Installing reverse Idler
haft IApply grease to all needle roller

beanngs
2 Refernng to FJ gure TM 35 as 2 Install washer @ to counter
semble thrust washer CID and reverse gear then assemble needle beanngs
Idler gear @ hencal gear Seat snap coated WIth grease In counter gear

TM085 nng f In groove In

top of reverse
Notes
Flff TM 33 Installing snap ring Idler shaft
a Be careful not to damage needle
3 Insert a 0 I mm 0 004 In
roller beanngs
thickness gauge between hencal gear
b Use 42 needle roller beanngs 21
REVERSE IDLER GEAR @ and thrust washer CID
on each side
ASSEMBLY CD pushed fully toward
WIth shaft
c Mter attaclung needle roller bear
I Insert reverse Idler shaft CD mto rear @ and spur
Install thrust washer
in
place apply grease thIckly
ings
place In transmISSion case from rear gear @ then fit snap rlng @ of so that bearings will not come off
with IdenuficatlOn mark faCing toward proper thickness so that spec1fled end
fear See Figure TM 34 play IS obtamed for reverse Idler gear 3 Install washer@
8
TM
 TransmiSSIon

GUide
Plug tightening torque
I 7 to 2 I kg m
ST22520000 12 to 15 ft Ib

See TM40
Figure

CID@
TMB31

@
Flff TM 37 Tlffhtenlng nsha nut
malt
TM266

Flff TM 36 Exploded view of

counter gear assembly @
TM421

2 Install these parts together with

Flff TM 40 Interlock mechanism
washers @ and CID to transmission
7
case and Insert countershaft 00 Into Apply gear 011 to all slIding parts
counter gear through the hole of case and make sure that gears are meshed
and retaining pm j Into ItS hole on smoothly therr pOSlltons
In

the front side of countershaft 8 Make sure that gears are placed
3 Select and Install rear thrust Into Neutral pOSitIOns and Install ex

washer CID of the sUitable thickness TMB32 tensIOnhousmg to transmISSIOn case

Flff TM 38 Staking malnshaft nut
With
unlll proper counter gear end play IS by properly alIgning stnklng lever
obtained shift rod brackets
5 AlIgn 1st 2nd shIft fork CD and 9 Install front cover on transmls

Standard counter gear 3rd 4th shift fork @ With the slon case

end play grooves on

couplIng sleeves respec Install release beanng WIthdrawal

005 toO 15 mm lively lever and dust cover In theu poslltons

00020 to 0 0059 Insert 1st 2nd shift rod and Then apply grease including molybde
In
@
dnve In pin @ securely num dlsulplude as shown In Figure
Rear thrust washer WIth 1st 2nd shIft rod In Neutral TM41

No ThIckness mm In
pOSItIOn Install Interlock plunger @
and Insert 3 rd 4th shift rod CID Into
235 to 2 40
poslllon and dnve In pin @ securely
0 0925 to 00945
3 Place 3rd 4th shift rod CID Into
2 40 to 2 45 Neutral pOSitIOn and Install Interlock
2
0 0945 to 0 0965
plunger @ Install reverse shift rod @
2 45 to 2 50
3 through reverse sluft fork j and
0 0965 to 0 0984
secure WIth retaining pin @ See
2 50 to 2 55
TM 39
4 FIgure
00984 to 01004
2 55 to 2 60
5 Flff TM 41 ApplYing grease
0 1004 to 0 1024

10 Install bottom cover to transmIS

TRANSMISSION ASSEMBLY SIon case

II Make sure that main dnve shaft

I Install
@
reverse gear hub reverse
rotates smoothly at a force of 120
gear and new malnshaft nut and light cm
kg 100 In lb With transmIssion m

en temporaruy Neutral
2 WIth gears meshed at two POSI
lions malnshaft nut to
tIghten a

to II 0 58 to 80
TM420
INSTALLATION
torque of 80 kg m
Flff TM 39 Installmg shift rod
ft Ib uSing Wrench ST22520000 See To Install reverse the order of
shift fork
Figure TM 37 removal
3 Stake mamshaft and countershaft 6 Install check balls and Remove filler plug at the Inspecl10n
locking
nuts to groove of mamshaft with a
spnngs at three places In the transmis hole and fill the transmiSSIon case

punch See Figure TM 38 SIOn case and

lIghten With plugs With gear 011 to the level of the filler
4 Install speedometer dnve gear and Before tightening these plugs apply hole ApproXimately I 7 IJters 3
sealant to plugs US pt 3
snap nngs Imp pt
TM 9
 TransmISSion

S SPEED TRANSMISSION TYPE FSSW63Al

CONTENTS

DESCRIPTION TM 10 GEARS AND SHAFTS TM 16

REMOVAL TM 11 BAULK RINGS TM 16

DISASSEMBL Y TM 11 OIL SEALS TM 16

TRANSMISSION CASE DISASSEMBLY TM 11 ASSEMBL Y TM 16

DISASSEMBLY OF GEAR ASSEMBLY TM 12 FRONT COVER ASSEMBLY TM 16
REAR EXTENSION DISASSEMBLY TM 15 REAR EXTENSION ASSEMBLY TM 17
ADAPTER PLATE DISASSEMBLY TM 16 ADAPTER PLATE ASSEMBLY TM 17

INSPECTION TM 16 ASSEMBLY OF GEAR

TRANSMISSION CASE AND ASSEMBLY TM 17
REAR EXTENSION HOUSING TM 16 TRANSMISSION ASSEMBLY TM 21

BEAR ING TM 16 INSTALLATION TM 22

DESCRIPTION beanngs couphng sleeve moves to mesh With

When the transmiSSion IS shifted the reverse Idler gear the transmission

The transmissIOn IS a 5 speed for the acl10n causes the couplIng sleeve IS reversed
ward with overdnve 4 OD speed to slIde on the synchromzer hub Tlus The transmiSSIOn assembly consists

fully synchromzed constan tmesh type engages ItS Inner teeth with the other of three main parts a transmIssIon

that uses helIcal gears teeth formed on the malnshaft gear case WIth clutch hOUSing an
adapter
The reverse shdlng mesh The hub fitted to the plate to wluch all gears and shafts are
gear IS a
synchromzer IS

type uSing spur gear provided on the malnshaft by sphnes so they turn Installed and a rear extensIOn

outer Side of 1st Reverse coupling together as a umt as the malnshaft IS The cast ICon adapter plate supports
sleeve rotated The transmISSIOn IS a Warner the malnshaft countershaft reverse

In construcl1on the main dnve gear On Warner the baulk nngs Idler shaft and three fork rods and IS
type types
IS meshed with the counter dnve gear synchromze the couplIng sleeve with bolted at the front to the transmIssIOn
The forward speed gears provided on the main shaft gear When the trans case and at the rear to the rear

the countershaft are In constant mesh miSSIOn IS shifted Into reverse

pOSll1on extension by means of through bolts
with the main gears which nde on the the malnshaft reverse gear proVIded on By removing these through bolts ail
malnshaft the needle the outer SIde of 1 st Reverse
freely through gears and shafts are strIpped

I MaIO drive gear

2 Front cover

3 Baulk ring
4 CouplIng sleeve
5 Shlftmg mserl
6 SynchronIzer hub
75th gear matnshaft
8 3rd gear mamshaft
9 Adapter plale
10 2nd gear mamshaft
II Bearing retamer

12 Isl gear mamshaft

13 Reverse gear mamshaft
14 Slrlkmg lever
15 Slrlkmg rod
16 Rear extensIOn

17 haft
Mam

18 Speedomeler drive gear

19 Reverse Idler shaft

20 Reverse Idler gear
21 I sl coun ter gear
22 Counter gear
23 Counter gear beanng shim
24 TransmiSSion case

torque T of bolts and nut kg m ft lb

Tlghlemh
T 14 to
@ 17 101 to 123 @ T 25 to 3 5 18 to 25
ThIS nul should lightened by @ T 1 3 to I 8 9 to 13
TM544
refernng 10 page TM 27
Flff TM 42 Sectional view of FS5W63A transmISsion
TM 10
 Transmission

8 Remove reverse select return

REMOVAL
plug reverse select return spnng and
To dismount transmissIon from the

follows plunger from rear extensIOn See

car
proceed as

Figure TM46
Disconnect cable
I battery ground
from terminal
2 Disengage torsIOn shaft from ac

celera tor lInkage

3 Place transmiSSIOn control lever In

neutral position TM546

4 Remove E nng and control lever Flff TM 44 Bottom view of car

pIn from transmiSSion stnklng rod
14 Remove starter motor
gUide and remove control lever See
15 Remove bolts securing transmis
Figure TM43
sIOn to engine

After removing these bolts support

TM547
the engine and transnllSSlOn With Jacks
and then slIde transmiSSIOn rearward Fig TM 46 RemOVing reverse select
return plug
away from engtne and remove from
the car
9 Remove rear extensIOn secunng
bolts Extract rear extensIOn backward
Take trans
Note care In
dismounting uSing a stand ard puller See FIgure
mIssIon not to strike any adj8cent TM47
parts or main dnve shaft

Flff TM 43 RemOVing control lever

DISASSEMBLY

TRANSMISSION CAS
DISASSEMBLY
5 Jack up the car and support ItS transmis
I Pnor to dlsassembhng
weight on
safety stands Use a hydrau Sion thoroughly wipe off dirt and
lIc hOIst or open pit IfaVallable grease from It
Confirm that safety IS Insured
2 Dram ou thoroughly
6 Disconnect front exhaust tube from
3 Remove dust cover trans
7 Disconnect WIres from reverse
miSSion case
See Figure TM44 TM548
lamp SWitch CD Remove release beanng and With
8 Remove clutch operating cylInder drawallever
Flff TM 47 RemOVing rear extensIOn

@ from transmiSSion case See FIgure 4 Remove reverse lamp SWitch

TM44 10 Separate transmissIOn case from
5 Remove speedometer pinion and
9 Disconnect speedometer cable @ adapter plate With a soft hammer See
pInIOn sleeve by taking off lock plate
fro rear ex tensIOn hOUSing See Figure TM48
6 Remove front cover secunng
Figure TM44
bolts and remove front cover
10 Remove propeller shaft
Detach countershaft front beanng
Refer to Sechon PD page PD 3
shIm
for Removal
7 Remove main dnve beanng snap

nng See Figure TM45

Note Plug up the opemng In the rear

extension hOUSIng to prevent 011

from flowlDg out

TM549
II Support engtne by locating a

Jack under 011 pan With a wooden Flff TM 48 RemOVing transmISSion

case
block between 011 pan and Jack
placed
Plate
12 Support transmission With J II Set up Setting Adapter
transmISSion ST22490000 on adapter plate
jack
13 Remove redr engIne mount se With countershaft Side up place the
wrmg bolts @ Jnd uossmember Fig TM 45 RemOVing main drIVe
above assembly In a vise See FIgure
mountlllg bolt 1 See Figure TM44 bearing snap ring TM49

TM l1
 Transmission

Gear assembly
I Remove reverse Idler gear to
gether WIth shaft See FIgure TM 52

TM550 TM556

Flff TM 49 Attaching gear assembly Fig TM 55 RemOVing reverse and

to special tool 1st gears

5 Remove snap nng and thrust

DISASSEMBLY OF GEAR washer from rear end of 1st counter

ASSEMBLY TM553 gear

Flff TM 52 RemOVing reverse Draw out 1st counter gear uSing
Shift forks and fork rods Idler gear Gear Puller ST22480000 See Figure
TM 56
I Dnve out from 2 Remove snap
retalmng pinS nng of malnshaft
each fork rod With Fork Rod Pin end beanng Draw out beanng uStng
Punch ST23540000 See Figure Bearing Puller KV32I013IO Remove
TM 50 other snap nng of malnshaft end bear
tng See FIgure TM 53

TM557

Fig TM 56 RemOVing 1st counter gear

6 Draw out matnshaft gear as

TM551
sembly USIng Malnshaft Puller

Flff TM 50 DrIVe out retaining pins KV32101320

Remove main dnve gear and count
2 Remove three 3 check ball TM554
plugs er gear then draw out malnshaft about
and dnve out fork rods from adapter Flff TM 53 RemOVing malnshaft
end bearing 10 mm 039 In See Figures TM 57
pia te by lIghtly tappIng on the front
and TM 58
end 3 I st and 2nd gears
With doubly
Be careful not to lose the three 3 engaged release caulking on mamshaft
check balls and two 2 Interlock nut and loose It See FIgure TM 54

plungers See FIgure TM 51

Note Each gear and shaft can be

detached from adapter plate with
out remoVIng each fork rod

1st Reverse TM558

fork rod
Flff TM 57 RemOVing malnshaft gear
Interlock

2nd 3rd plunger TM555

fork rod Flff TM 54 Xeleaslng caulking on

malnshaft nut
I 4 Remove malnshaft nut and take
4th 5th
fork rod out dnve gear
speedometer synchro
hub With reverse gear and I st gear
together WIth needle beanng Remove
thrust washer Be careful not to lose

TM552
steel ball retaining speedometer dnve TM559

Fig TM 51 gear and thrust washer See Figure Flff TM 58 RemOVing

Layout of check ball main drIVe
and Interlock plunger TM 55 gear and counter gear

TM 12
 Transmission

Note Be careful not to drop off Note When pressing out bushing 3 Pry off snap nng on the front end
hold mainshaft by hand so as not to of mamshaft and remove 4th 5th
gears
drop it speed synchromzer and 5 th gear See
FIgure TM 60

Malnshaft

I Remove thrust washer steel baIl

2nd gear and needle beanng Be care
ful not to lose steel baIl retammg
thrust washer
2 Press out 2nd malnshaft
gear
bushIng together WIth 3rd gear and
2nd 3rd speed synchroruzer uSing TM560
TM561

Beanng Puller ST30031000 See Flff TM 59 Removing 2nd gear Flff TM 60 RemOVing snap ring
malnshaft bushlrlff
FIgure TM 59

I Snap nng II Shul1ng msert

2 BauIk rtng 12 2nd speed gear mamshaft
3 Couphng sleeve 13 Bushing
4 14 Thrust washer
Synchromzer hub
5 51h speed gear matnshaft IS Mamshafl beartng

6 Needle beanng 16 1st speed gear matnshaft

7 Mamshaft 17 Reverse gear mamshaft

8 Steel baU 18 Speedometer dnve gear
9 3rd speed gear matnshaft 19 Nut
10 Spread sprmg 20 Matnshaft end bearmg

TM562

Flff TM 61 Exploded view of malnshaft assembly

Main drive gear

Pry off snap nng and remove

spacer
2 Press out main dnve beanng uSing
Beanng Puller ST30031000 See

FIgure TM 62

I MaIn dnve beanng

TM349 2 MaIn dnve gear
Note When pressing out bearing hold
gear by hand so as not to drop gear Fig TM 62 RemOVing main drIVe

onto floor bearing

TM 13
 Transmission

TM564

Flff TM 64 Removing counter gear

front bearing

2 Press out counter gear rear bear

Ing uSing Beanng Puller ST22730000

See Figure TM 65
I Snap nng
2 Spacer Note Be careful not to drop off
3 Maw dnve bearing with counter gear
snap ring
4 Maw dnve gear
5 PIlot bearing

TM563

Flff TM 63 Exploded view of main drwe gear assembly

Counter gear

I Press out counter gear front bear Note When pressing out bearing hold
Ing uSing Beanng Puller ST22730000 gear by hand so as not todrop gear TM565

and Adapter ST22471040 See FIgure onto floor Fig TM 65 RemOVing counter gear
TM 64 rear
bearing

CD

I ShIm
2 Bearmg
3 Counler gear
4 1st counler gear
5 Spacer
6 Snap nng

TM566

Flff TM 66 Exploded View of counter gear assembly

TM 14
 TransmiSSion

Reverse Idler gear REAR EXTENSION

DISASSEMBLY
DIsassemble reverse Idler gear as

See TM 67
sembly FIgure I Remove screw and stopper pin
from rear extensIOn See Figure
TM 69

Flff TM 69 RemOVing stopper pin

I Reverse washer
2 Relatntng pm 2 Remove lock pin from stnklng
3 Reverse Idler gear lever and remove
stnklng rod See
4 Needle bearmg spacer TM 70
FIgure
5 Reverse Idler shaft
6 Needle beallng
TM567

Flff TM 67 Exploded View of reverse Idler gear assembly

Synchronizer

I 2nd 3rd 4th 5th

speed
synchromzcr
Remove spread spnngs @ and take

out shIfting Inserts @ Separate

couphng sleeve CD from synchromzer
hub @ See Figure TM 68
21st reverse synchromzer
I Coupling sleeve 5 Rever
gear
Separate reverse main gear CID from 2 Spread sprmg 6 Synchro spnng
TM569

synchromzer hub @ Take out shIft 3 Shifting Inserl 7 Slopper rmg

Flff TM 70 RemOVing lock pin
Ing Inserts @ and synchro springs @ 4 Synchro hub
Note Do not disassemble rear ex

Pry off stopper nng j See FIgure Flff TM 68 Exploded view of

tensIOn bush from rear extension
TM 68 synchronizer assembly

h
e
I Stnkmg lever
2 Stnkmg rod
3 SlOp per pm
4 Controllever
5 StrIkmg rod gUIde
6 Reverse select plunger
7 Reverse select plug
TM570

Fig TM 71 Exploded view ofshlfhng mechanism

TM 15
 TransmISSion

ADAPTER PLATE 4 Check for

BEARING stnpped or damaged
DISASSEMBLY speedometer puuon gear If necessary
I Thoroughly clean bearmg and dry
replace
I Remove four retainer at with
beanng compressed au

taclung screws wIth an unpact dnver 2 When race and ball surfaces are

and remove beanng retainer from when balls

worn or rough or are out
adapter plate See Figure TM 72 of round BAULK RINGS
or rough replace beanng
with a new one See Figure TM 73 I Replace any baulk nng whIch IS
defonned or cracked
2 POSItion baulk nng In place on

gear cone and measure the bauIk

nng gear
to clearance WIth baulk rmg

pushed toward gear See FIgure

TM 75

TM571

Flff TM 72 Removing screws

TM372

Flff TM 73 Inspecting ball bearing

2 Remove malnshaft from

beanng
3 needle
the rear extenSIon SIde Replace beanng and taper
3 To remove outer race of counter roller bearing If worn or damaged

gear rear beanng apply a bras dnft to

TM258
race Side surface and withdraw It by
Flff TM 75 Baulk ring to cone gap
the of dnft With
tapping top a

hammer

GEARS AND SHAFTS

I Check all gears for excessive wear

chIps or cracks replace requrred

as OIL SEALS
2 Check shaft for
INSPECTION bending craclss
It IS adVIsable not to reuse 011 seals
wear or worn
splIne If necessary
Wash all parts In a sUitable cleamng
replace
that have been removed Always Install
solvent and check for wear damage or Measure gear end new 011 seals
3 play See FIgure
other faulty condItIOns TM 74 Replace oil seal If sealing IIp IS

defonned or cracked Also dIscard seal

Notes Standard end paly If spnng IS out of posItIon Check the
a Be careful not to damage any parts I st gear
oil seal hp contacting face on shaft If
with scraper 032 to 0 42 mm
necessary replace seal and shaft as a
b Do not clean wash or soak 011 seals 00126 to 0 0165 In
set
in solvent 2nd gear
o 22 to 0 32 mm

00087 to 0 0126 In

3rd and 5 th gear

TRANSMISSION CASE AND
REAR EXTENSION HOUSING
005 toO 15 mm ASSEMBLY
00020 to 0 0059 m
To assemble reverse the order of
I Clean WIth
thoroughly solvent
disassembly Observe the
and check
follOWing
for cracks wluch mIght Instruchons
cause oil leak or other faulty condi
tions

2 Check mating surface of case to

engine or adapter plate for small mcks

FRONT COVER ASSEMBLY
proJectIOn or sealant
Remove all nIcks proJection I clean seal front
or WIpe seat In

sealant with a fine stone then press fit oil seal

cover m place
3 If rear extensIOn bush IS worn or Coat Illr seal WIth gear oil to
cracked replace It as an assembly of TM572 prOVIde Imtlal lubncatlon See FIgure
bush and rear extensIOn Flff TM 74 MeaSUring end play TM 76
hOUSing

TM 16
 Transmission

ADAPTER PLATE 2 FIt

s1uftmg Inserts In three
ASSEMBLY grooves synchromzer hub
In

3 Locate one spread spnng on the

I Install outer race of counter gear
lower SIde of s1uftlng mserts to secure
Fronl rear beanng by lIghtly tapping around
It WIth a brass dnft and a hanuner them to the lnner SIde of couplmg
2 Install malnshaft sleeve Properly Install the other sprmg
beanng by hght
around WIth soft on the oppoSIte SIde of couplmg
Iy tapping It a

hammer sleeve Make sure that they are in

3 Install stalled opposIte to each other See
beanng retamer In
adapter
TM354 plate FIgure TM 79

TM 76 Front oil 8eal Torque screws to 0 8 to I 3 kg m

Flff cover

6 to 9 ft Ib and stake each screw at

2 Apply sealant to withdrawal lever
two pOints WIth a
punch See FIgure
ball pin screw Install wIthdrawal lever
TM 78
ball pin to front cover and tIghten
3 0 to 5 0 22 to 36
screw to kg m
ft lb torque

TM077

Flff TM 79 In8talllng 8pread Spring

REAR EXTENSION
TM573
ASSEMBLY 2 1st reversesynchromzer
Flff TM 78 Staking screw I PosItIon
I WIpe clean seal seat In rear ex shifting Insert spnngs
and shIfting Inserts In three 3 slots In
tensIOn housmg press fit 011 seal In

place synchromzer hub

2 Put coupling sleeve
Coat 011 seal and buslung WIth gear on synchro
ASSEMBLY OF GEAR mzer hub
011 for 1fi1t1al lubncatlOn See FIgure
ASSEMBLY
TM 77

Clean all parts In solvent and dry Malnshaft

WIth compressed au
I PosItion 5 th gear needle beanng
maInshaft 5th gear baulk nng and 4th
Front Synchronizers
5th speed synchroruzer on the front
I 2nd 3rd 4th 5th of malnshaft
speed
synchromzers 2 FIt snap ring of proper tluckness
I Place synchro hub Into couplmg so that It will fit the groove m maln
sleeve shaft See FIgure TM 80

TM355

Flff TM 77 Rear extensIon oil seal

AvaIlable snap nng

No T1uckness mm In

2 Apply multi purpose grease to

O nng and plunger grooves In stnklng I 140 to I 45 00551 to 0 0571

rod 145 to I SO 0 0571 to 0 0591
2
stnkmg rod WIth stnklng rod
Insert
I 50 to I 55 0 0591 to 0 0610
3
guIde through rear extenSIon
4 I 55 to I 60 0 0610 to 0 0630
3 Install stnklng lever on front end
of stnklng rod Install lock pin and 5 I 60 to I 65 00630 to 0 0650
torque screw to 0 9 to I 2 kg m 7 to
9 ft lb

TM 17
 Transmission

2 Place drIVe
main beanng spacer
on mall dnve beanng and secure mall

dnve beanng With a new tlucker snap

rllg that WIll elumnate end play

TM574 TM577

Flff TM 80 InstallIng snap ring Flff TM 83 Installing main dnve

bearing
3 Install the follOWing parts on

malnshaft In the order lIsted 3rd gear

Available snap ring
needle roller 3rd gear 3rd
beanng
gear baulk nng 2nd 3rd speed No ThIckness mm 10
synchromzer Then fit 2nd gear bush

Ing onto malnshaft uSing Base I I 49 to I 55 00587 to 0 0610

ST30901000 and malnshaft beanng
2 I 56 to I 62 0 0614 to 0 0638
thrust washer See FIgure TM 81
And Install 2nd gear baulk nng needle 3 162 to I 68 0 0638 to 0 0661
beanng 2nd gear steel ball and thin 4 1 68 to I 74 0 0661 to 0 0685
thrust washer
5 I 74 to I 80 0 0685 to 00709

Note Assemble 2nd 3rd speed 6 I 80 to I 86 00709 to 0 0732

Synchronizer paYing attentIon to 7 I 86 to I 92 00732 to 00756

its direction See Figure TM 82

Counter gear Gear assembly

Press counter gear front bearing J Attach Setting Plate Adapter

onto counter gear uSing Dnft ST22490000 to adapter plate and
ST22360002 place It In a VIse

2 Press 2 Place
counter gear rear
bearing malnshaft assembly Into
onto counter gear uSing Dnft adapter plate assembly Place main
TM575
ST22360002 and Adapter shaft nut onto mallshaft
Flff TM 81 Installing 2nd gear
KV32101330 See FIgure 84
TM 3 Pull malnshaft
bushing assembly Into

adapter plate usmg Malnshaft Puller

3rd gear SIde
KV32101310 Beanng Puller
hI ST22360002
KV32101320 and Adapter
KV32101330 until the thrust washer
tobeanng clearance reaches approxI

Front mately 10 mm 039 In See FIgures

TM 85 and TM 86

TM578

TM576 Flff TM 84 Installing counter gear

Flff TM 82 Installing 2nd 3rd speed rear bearing
synchrOnizer
Reverse Idler gear

Main drive gear Assemble reverse Idler gear as

sembly
I Press dnve onto the
main
beanng
shaft of main dnve gear uSing Base Note When posltionmg thrust wash
ST30901000 Make sure that snap nng ers on shaft make sure that the
groove on shaft clears bearIng See brown surfaces are facing toward TM579

Figure 83
TM gears Flff 85
TM Setting speCial tools

TM 18
 Transmission

Stake main shaft nut to groove of

malnshaft wIth a punch See FIgures

TM 90 and TM 91

ST22360002

KV3210133

TMS80
TM5B3

Flff 86
TM Installing malnshaft FIg TM 89 Installing 1st counter gear

assembly
7 Place spacer on the rear end of
1st counter gear and secure It with a
4 Posllion baulk ring on cone new snap nng TMS84
surface of main dnve gear Apply gear 8 Install the to the
follOWing parts Flff TM 90 Tlffhtemng malnshaft nut
od to malnshaft pLlot bearing and rear of malnshaft In the order hsted
Install It on malnshaft Steel ball thIck thrust washer I st gear
Assemble main dnve gear assembly bushing needle 1st gear 1st
beanng
on the front end ofmalnshaft gear baulk nng 1st synchromzer to
Assemble counter gear assembly on
gether With reverse mam gear steel
malnshaft and main dnve gear See ball speedometer dnve gear and maln
TM 87
Figure shaft nut

Tighten malnshaft nut temporanly

9 WIth I st and 2nd gears doubly
engaged lighten malnshaft nut to the
converted torque C See FIgure TMS85

TM 92 uSing Wrench ST22520000 l TM 91

FI Staking malnshaft nut

S if
TMS81 16
Flff 87
TM Installing dnve gear
main
limit hoe
Upper
and counter gear
llO
15
5 Pull malnshaft assembly Into

adapter plate together with main dnve

C
gear and counter gear 14
100
When installing malnshaft hold
s
gears carefully by hand and do not 0
Converted torque
13
drop gears on floor See Figure B

TM 88 5
90
c
o

11
s

80

70

9
02 03 04 05 06 07 08 m
Flff TM 88 Installing malnshaft
assembly I5 20 2 5 ft
I0
6 Press I st counter gear onto count
L Effecl1ve length of lorque wrench
er shaft uSing Dnft ST22360002 and

TMS86
Adapter KV32101330 See Figure
89
TM Flff TM 92 Converted torque

TM 19
 TransmIssion

tlghtenmg check
Explanation of converted AvaIlable snap nng ball plug apply
sealant to check baJJ plug
torque
Ahgn center notch In 1st reverse
Mamshaft nut should be lightened No ThIckness mm In fork rod WIth check baJJ
14 to 17 101 to 123 ft lb
to kg m
torque WIth the aJd of Wrench
I 1 0 043 Note Ball plug for 1st reverse fork
ST22520000 When dOing so the
rod is lODger than those for 2nd
amount of torque to be read on 2 I 2 0 047
3rd fork rod and 4th 5th fork
wrench needle should be modIfied 13 0051
3 rod See TM Sl
to the fonnula Figure
according following
4 I 4 0 055

4 InstaJJ Interlock
Ckg m 14 x 1 to plunger on a

L OI
dapter plate See FIgure TM 51

5 InstaJJ 2nd 3rd fork rod

17 x
L LO I through adapter plate
fork and 4th
2nd
5th s1uft fork
3rd shIft
and

or
secure WIth new
retamlng pin
6 Install check baJJ and check ball

C ft lb 101 x to spnng
L 33
Apply sealant to check ball plug
and mstalllt In place
L
123 x
center notch
L 0 33 TMS88 AlIgn In 2nd 3rd
Flff TM 94 Installing malnshaft end fork rod WIth check ball
Where bearing 7 Install Interlock plunger on a

C Value read on the torque 13 Install reverse Idler gear as dapter plate
8 Install 4th 5th fork rod
wrench kg m ft lb sembly
through adapter plate and 4th 5th
L Effecllve length of torque
s1uft fork and secure WIth new re
wrench m ft Shift forks and fork rods
talnmg pin
I Place three 3 s1uft forks In 9 InstaJJ check ball and check baJJ

groove In each couphng sleeve Be spnng

ST22520000 careful not to
C drop off sluft forks Apply sealant to check ball plug
ill n
2 InstaJJ 1st reverse fork rod and Install It In place
each check ball
through 1st reverse shIft fork and 10 Torque plug to

adapter plate 16 to 2 2 kg m 12 to 16 ft lb

U o 1m
Lm ft Secure
s1uft fork WIth
1st reverse fork rod to II Apply gear od to all slIding
surfaces and check to see that shIft
new retalfung pin
033 ft 3 Install check ball check ball rods and
operate correctly gears
spnng and check baJJ plug Pnor to engage smoothly
TM587

Flff TM 93 Setting wrench

Example
When a 0 4 m
long torque wrench IS
used the C In
Figure TM 92
wIll be 112 to 13 6kg m SI to 98
ft lb

10 Measure gear end play

Make sure that they are held wltlun
the specIfied values
For detaIls refer to Page TM 24 for

Inspecllon
II FIt I I mm 0043 In thIck
snap nng to the front SIde of maln
shaft end beanng
12 Install maJnshaft end beanng
uSlng Beanng Dnft ST22350000
FIt
tluck snap nng to the rear SIde of TM589

beanng to eltmlnate end play Flff TM 95 Installing shift forks and fork rods

TM 20
TRANSMISSION ASSEMBLY Front cover assembly

Rear extension assembly

I Select countershaft front bearing
ST22500000
it
slum as follows
G
1 Clean mating surfaces of adapter I Support transmiSSion assembly
pia and rear extensIOn
te WIth ItS front SIde up
Apply sealant to mating surfaces of Place Counter
2 Beanng SettIng
adapter plate and rear extensIOn Gauge ST22500000 on countershaft
2 With fork rods their 5th POSI front
In
beanng and turn main dnve
TM591
tIons gradually shde rear extensIOn shaft untu beanng IS settled yn
do Flff TM 98 Measuring clearance
onto adapter plate 3 Measure the clearance B be
tween the setting gauge and the front
Notes end of transmiSSIon case uSIng tluck 4 The
a
depth H can be obtained
a Use care when instaUing not to ness gauge See Figures TM 97 and from the follOWing fonnuJa
come shift arm off strikmg lever TM 98
H A B
pin
b Install shift ann onto 4th 5th Where
fork rod and then fit striking lever H Depth from front end of
pin into other fork rods
transmIssIon case to count
A
ershaft front beanng
3 Check to see that shIft rods oper
mm In
ate correctly H A FIgure marked on the

setting gauge mm 111

B Measured value uSing

thickness gauge mm In

Counter gear
TM590

5 Select a shIm of tluckness H

Transmission case assembly Flff TM 97 AdJusting countershaft
front bearing shim measured
I Clean mating surfaces of adapter

plate and transmission case

AvaIlable slum
Apply sealant to mating surfaces of
adapter plate and transmIssIOn case
2 SlIde transmissIon case onto a Thickness ofcountershaft
No H mm In
dapter plate by lIghtly tapping WIth a front bearing shim mm 111

soft hammer untIl case presses against

I I 200 to I 225 00472 to 0 0482 1350 00531
adapter plate
Carefully Install main dnve bearIng 2 1 225 to I 250 0 0482 to 00492 1375 00541
and countershaft front beanng I 250 to I 275 0 0492 to 0 0502 1400 00551
3
Make certain that malnshaft rotates
4 1275 to I 300 0 0502 to 0 0512 1425 00561
freely
3 Install washers and through bolts 5 1300 to 1 325 00512 to 0 0522 1450 00571
and torque to 1 3 to I 8 kg m 9 to 6 1325 to I 350 0 0522 to 0 0531 1475 00581
13ft lb
4 7 1350 to I 375 00531 to 0 0541 1500 00591
FIt main dnve beanng snap nng
to groove In main dnve beanng See 8 1375 to 1400 0 0541 to 0 0551 I 525 0 0600

FIgure TM 96 9 1400 to I 425 00551 to 0 0561 I 550 00610

10 1425 to 1450 00561 to 0 0571 1 575 0 0620

II 1450 to 1475 00571 to 00581 I 600 0 0630

12 1475 to I 500 0 0581 to 00591 I 625 0 0640

13 I 500 to I 525 00591 to 0 0600 I 650 0 0650

14 1525 to I 550 00600 to 0 0610 I 675 00659

15 1 550 to I 575 00610 to 0 0620 I 700 0 0669

16 I 575 to I 600 0 0620 to 0 0630 I 725 00679

o 17 I 600 to I 625 0 0630 to 00640 I 750 00689

TM340

Flff TM 96 Fitting main drwe 18 I 625 to I 650 0 0640 to 0 0650 I 775 00699
bearing snap ring

TM 21
 TransmISSion

Example return Install It

plunger m rear ex 7 Install control lever
temporanly
A I 75 mm B 0 22 mm tensIOn and sluft con trol lever through all
H A B Install reverse select return spnngs gears to make sure that gears operate
and Install reverse select return plug
I 75 0 22 smoothly
I 23 mm With sealant In placeand torque to 0 8
to I 0 6 to 7 ft lb
kg m
The correct shim IS 1 375 mm 4 Install speedometer pinIOn as INSTALLATION
thick After
sembly on rear extensIOn
2 Clean Install the transmiSSIon In the re
mating surfaces of front making sure that lock
plate IS lined up
verse order of removal paYing allen
cover and transmISSIOn case WIth groove In speedometer pinIOn
lion to the following pOints
Apply grease to shIm selected to sleeve Install through bolts and
torque
retam It on countershaft front I Before
bearIng to 0 3 to 0 4 kg m 2 to 3 ft Ib installing clean mating
Install front cover to transmiSSion case surfaces of engine and trans
5 Install back up lamp SWitch and rear plate
Apply sealant to both surfaces of front to 20 to 3 0 14 to 22 miSSion case
torque kg m
cover and transmiSSIon case before 2 Before
ft Ib installing lightly apply
installatIOn 6 grease to splIne parts of clutch dISC
Apply a lIght coat of multi
Install through bolts with washers purpose grease to Withdrawal lever and main drIve gear

under them and lighten to I 3 to I 8 release and 3 Remove filler

beanng beanng sleeve in plug and fill trans
kg m 9 to 13 ft Ib torque stall them on clutch
hOUSing miSSIOn WIth recommended gear 011 to
Apply sealant to threads of After connecting them With holder the level of the plug hole
ApproXI
through bolts before installatIOn spnng Install dust cover on clutch mately I 7 hters 3 U US pt 3 Imp
3 Apply grease to reverse select hOUSing pt

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS

Stallon
Hardtop Sedan
Item Wagon

TransmIssIOn model FS5W63A 63L

F4W

No of speeds 5 4

Synchromesh type Warner Warner

Floor Floor

R 2 4 I 3
Shift type

I
HI 3 5
h
I2 4 R

1st 3382 3382

2nd 2013 2013

3rd I 312 1312

Gear ral10
4th 1000 1000

5th 0854

Rev 3570 3364

011 capacIty hter US pt lmp pt I 7 3 3

TM 22
 TransmiSSion

TIGHTENING TORQUE
Umt kg m ft Ib

TransmISSIon type
FS5W63A F4W63L
t

Item

Engine to transmIssIon InstallatJon bolt 3 7 to 5 0 27 to 36 40 to 4 8 29 to 35

Clutch operating cyhnder installatIOn bolt 2 5 to 3 0 18 to 22 2 5 to 3 0 18 to 22

Propeller shaft to dlfferentJal companIOn flange nut 24 to 3 3 17 to 24 24 to 3 3 17 to 24

Center bracket installation bolt 3 6 to 4 8 26 to 35

Rear mounting Insulator to transmiSSIon InstallatJon bolt 09 to I 2 7 to 9 o 9 to I 2 7 to 9

Crossmember mounting bolt 19 to 2 6 14 to 19 I 9 to 2 6 14 to 19

Malnshaft retainer to transrmsslOn case 08 to I 3 6 to 9 o 8 to I 0 6 to 7

Malnshaft nut 14 to 17 101 to 123 8 0 to II 0 58 to 80

Check ball plug 16 to 2 2 12 to 16 1 7 to 2 I 12 to 15

Rear extensIOn installation bolt I 3 to I 8 9 to 13 1 4 to I 8 10 to 13

Front cover installation bolt 1 3 to I 8 9 to 13 o 8 to I 0 6 to 7

Bottom cover InstallatJon bolt o 8 to I 0 6 to 7

Reverse select return plug o 8 to I 0 6 to 7

SPECIFICATIONS

FS5W63A F4W63L
Item

1st o 05 to 0 20 0 0020 to 0 0079 005 to 0 20 0 0020 to 0 0079

2nd o 05 to 020 0 0020 to 00079 o 05 to 0 20 0 0020 to 0 0079

Gear backlash 3rd o 05 to 0 20 0 0020 to 0 0079 o 05 to 020 0 0020 to 0 0079

mm In
5th o 05 to 0 20 0 0020 to 0 0079

Rev o 05 to 0 20 0 0020 to 0 0079 o 05 to 0 20 0 0020 to 0 0079

Dnve o 05 to 0 20 0 0020 to 0 0079 o 05 to 0 20 0 0020 to 0 0079

1st 032 to 042 0 0126 to 0 0165 032 to 0 42 0 0126 to 0 0165

2nd 022 to 0 32 0 0087 to 0 0126 022 to 0 32 0 0087 to 0 0126

3rd 005 to 0 15 00020 to 0 0059 005 to 015 0 0020 to 0 0059

Gear end play
5th 005 to 0 15 00020 to 0 0059
mm In

Rev Idler 015 to 040 0 0059 to 0 0157 o 10 to 0 30 0 0039 to 0 0118

Counter gear 005 to 015 00020 to 0 0059

Clearance between standard I 2 to I 6 0 047 to 0 063 I 2 to I 6 0 047 to 0 063

baulk nng and gear

mm In lImit o 5 0 020 o5 0 020

Counter bearIng slum I 350 to I 775 0 0531 to 0 0699

adJusting
mm tn Every 0025 0 0010

TM 23
 TransmiSSIon

TROUBLE DIAGNOSES AND CORRECTIONS

Condllton Probable cause CorrectIve actIOn

DIfficult to mtennesh gears

Causes for difficult gear shIfting are classI Worn gears shaft and or beanng Replace
fied to troubles concerning control system
Insufficient operating stroke due to worn
and transmission When gear shIft lever IS
or
Repair or replace
loose shdlng part
heavy and It IS difficult to shIft gears clutch
Worn or damaged synchromzer Replace
disengagement may also be unsmooth First
make sure that clutch operates correctly
and Inspect transmission

Gear shps out of mesh

In most cases this trouble when Worn Interlock

occurs plunger Replace
Interlock ball check ball and or spnng IS Worn check ball and or weakened or broken Replace
worn or weakened or when control system
spring
IS faulty In tlus case the trouble cannot
be corrected and there Worn fork rod ball groove Replace
by replaCing gears
fore trouble shooting must be carried out Worn or damaged beanng Replace
carefully It should also be noted that gear Worn or damaged gear Replace
slIps out of mesh due to vlbrallon generated
by weakened front and rear engine mounts

NoISe

When nOIse occurs With engine IdlIng and Insufficient or Improper lubncant Add 011 or
replace
ceases when clutch dIsengaged or when With
IS
deslgttated 011
nOise occurs whlle shifting gears It IS an 0tI leakmg due to damaged od seal or Clean or replace
indication that the nOIse IS from transmis
sealant clogged breather etc
Sion
Worn beanng HIgh humming occurs at a
Replace
ITransmIssion may rattle dunng engine
Iugh speed
IdlIng
Check aIr fuel mIXture and Igmlton Damaged beanng Cychc knocking sound Replace
occurs also at a low speed
liming
After above procedure readJust engine Worn sphne Replace
I
IdlIng
Worn bushing Replace as a rear

extensIon hOUSing
assembly

TM 24
 Transmission

SPECIAL SERVICE TOOlS

Tool number For Reference

No DescnptJon use page or

tool name on
FIgure No
Umt mm m

ST23 100000 For prevehtJon of needle beanng from fa1hng offwhen countershaft 63L FIg TM 12
removed from mserted mto the transrmsslOn case 6SL
IS or
Page TM 8
Countershaft
F60A Page TM 9
gwd TM

153 602

0 17 0 67 dill

2 ST23540000 For removal and assembly of fork rod retalnmg pm 63A FIg TM ll
1
63L FIg TM SO
Fork rod pin
71 B
punch T M
150 591

4 0 16 dta
10 0 39 dill

SEOB2

3 ST30031000 For replacing bearmg 63A FIg TM 20

65L FIg TM 59
rmg
Bea puller 63L FIg TM 62
7IB

TIM

80 3 15
50 1 97

SE041

4 ST224900001 For setting 63A

adapter plate In a VIse
FIg 49
TM
TIM Page TM 18
Adapter setting
plate

220 8 66

SE311

TM 25
 TransmiSSIon

Tool number For Reference

No Descnptlon use page or

tool name on FIgure No

Umt mm In

5 KV321013S0 Forassembly ofm81nshaft assembly 63A FIg TM 8S

Puller se t Tlus set does not Include screw shaft for ST22460001 Bearmg Puller T M FIg TM 86

KV32 1013 10 For removal of m81nshaft end bearmg counter overdnve gear and 63A FIg TM 53

bearing FS5W7IB FIg TM 85

Beanng puller TIM FIg TM 86

SE308

KV32101320 For removal ofmalnshaft assembly 63A TM 57

FIg
TIM FIg TM 58
M81nshaft
FIg TM 84
puller TM 85
FIg
FIg TM 86

FIg TM 89

KV32 10 1330
a Adapter ST22471040
Adapter SE309

6 ST22480000 For removal of 1st counter gear 63A FIg TM S6

TM
Gear puller

SE310

7 ST22730000 For removal of counter gear beanng 63A FIg TM 64

TM 65
TIM FIg
Beanng puller

Outer dta 82 3 23
Inner dta 30 1 18

SE041

TM 26
 Transmission

Tool number For Reference

No Descnpbon use page or

tool name
Umt mm m
on Figure No

8 ST22360002 For of counter gear and 1st counter gear 63A TM 84

assembly beanng FIg
71B FIg TM 89
Bearmg dnft
T M

SE307

9 ST3090 I 000 For assembly of maJn dnve beanng and 2nd gear rnamshaft bushing 63A FIg TM 81
TIM FIg TM 83
Base

SE041

10 ST22520000 For removal and assembly ofmamshaft nut 63L FIg TM 37

63A TM 90
FIg
Wrench
T M FIg TM 93
38 mm 150 In

SE313

II ST22S00000 T1us tool IS used to adJust counter beanng 63A FIg TM 97

TIM FIg TM 98
Counter beanng

setting tool

SE312

TM 27
 Transmission

For Reference
Tool number
use page or
No Descnptlon
on Figure No
tool name Umt mm In

12 ST22350000 For assembly ofmalnshaft end bearing I S6A FIg TM 94

60
Malnshaft bearing 71B
dnft TIM

Outer dill 34 1 34
Inner dill 28 1 10

SE037

of main bearIng 63L Page TM 8

13 ST2 452000 For assembly

Malnshaft beanng
dnft

Outer dla 45 1 77
Inner dla 36 1 42

SE429

TM 28
 SECTION AT

AUTOMATIC
DATSUN TRANSMISSION
MODEL 610 SERIES

DESCRIPTION AT 2

CONSTRUCTION AND OPERATION AT 3

HYDRAULIC CONTROL SYSTEM AT 10

REMOVAL AND INSTALLATION AT 39

MAJOR REPAIR OPERATION AT 44

TROUBLE DIAGNOSES AND

AT 58
ADJUSTMENT

SERVICE DATA AND

AT 70
SPECIFICATIONS

AT 73
INI NI SPECIAL SERVICE TOOLS

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Automatic Transmission

DESCRIPTION

The model 3N71B automahc trans 2 2 range provides perfor

mIssIon fully automahc umt con
IS a mance for dnvlng on slippery surfaces
SIsting pnmanly of 3 element hydrau 2 range can also be used for engine
hc torque converter and two planetary braking
2 be selected at any
gear sets Two mulhple dlsc clutches a range can

multIple disc brake a band brake and vehIcle speed and prevents the trans
a one way sprag clutch provIde the mISSIon from shifting out of second
fnchon elements requued to obtain gear

the deSIred funchon of the two plan AT057

I range can be selected at
etary gear sets Flff AT 1 lIcdatenhlOn number
any vehIcle speed and the transmiSSIOn
The two planetary gear sets gIve wtI1 shIft to second gear and remain In
three forward rahos and one reverse
second until vehIcle reduced
speed IS

Changing of the gear rahos IS fully to approXImately 40 to 50 km h 25

automahc In relatIOn to vehicle speed Identification of number
to 31 MPH
and engine torque Input Velucle speed I range pOSitIon prevents the arrangements
and engine mamfold vacuum SignalS transmISsIon from shifting out of low Untt number
are
constantly fed to the transmIssion gear This IS parhcularly benefiCIal for Model code
to proVIde the proper gear raho for
maintaining maxImum engine braking
maxunum efficIency and performance
when continuous low gear operahon IS

at all throttle opemngs

desuable
The model 3N71 B has SIX selector The torque converter assembly IS of
P R N D 2 I
poslhons welded constructIOn and can not be
Senal producUon
disassembled for servIce number for the month
P Park poslhon locks
poslhvely Month of producUon
the output shaft to the transmIssIon
X Oct Y Nov Z Doc
case by means of a locking pawl to
Last figure denottng
prevent the vehIcle from rolling In the year A D

eIther direchon
This FLUID RECOMMENDATION
posItIOn should be selected
whenever the dIlver leaves the vehIcle
Use automatIc transmiSSion flUid
The engine may be started In Park
having DEXRON IdentifIcatIOns
posItIon
only In the 3N71 B automahc trans
mISSion
R Reverse range enables the
velucle to be operated In a reverse

drrechon

N Neutral enables the

poslhon
engine to be started and run Without
IDENTIFICATION NUMBER
dnvlng the vehIcle

D used
Stamped position
Dnve range IS for all
nonnal dnvlng condlhons The plate IS attached to the nght
Dnve range has three gear rahos hand Side of transmISsIOn case as

from the starting raho to dIrect dnve shown In Figure AT I

AT2
 Automatic Transmission

CONSTRUCTION AND OPERATION

CONTENTS

TORQUE CONVERTER AT 4 BAND BRAKE AT B

AT 6 lOW AND REVERSE BRAKE AT 9
TRANSMISSION
Oil PUMP AT 7 PLANETARY GEAR AT 9
ONE WAY CLUTCH AT 9
FRONT CLUTCH AT 7

REAR CLUTCH AT B

I Turbme runner 13 Low reverse brake

2 One way clulch 14 OIl dlStnbulor
3 Slator 15 Governor
4 Pump Impeller 16 Output shaft
5 TransmISSIon case 17 Rear extenSIon

6 011 pump 18 Dnve plate

7 Front clutch 19 Converter housmg
8 Band brake 20 Torque converter
9 Rear clutch 21 Inpul shaft
10 Front planelary gear 22 Control valve
II Rear planelary gear 23 011 pan For B210 models
12 One way clutch

AT304

Flff AT 2 Cross sectional view of 3N71B automatic transmlSSlan

AT3
 Automatic Transmission

TORQUE CONVERTER one unpeller connected to the engIne to the tranSffilSSlon case through a

crankshaft through the drIve plate one one way clutch The converter assem

turbIne splmed to the transmISSIOn bly IS welded together and cannot be

The torque converter consIsts of mput shaft and one stator connected dIsassembled for servIce

1 Dnve plate
2 Crankshaft
3 Turbme
4 Torque converter

S Ot pump
6 Input shaft
7 One way clutch
8 Stator
9 Impeller

AT316 AT063

Fig AT 3 Torque converter

The operatIon of a torque converter converted mto the torque that tends and the torque T exerted by
peller 3
IS characterIZed by the fact that be to rotate the turbme runner Itself the ou m the stator act m the same
sides merely rotatmg the turbme 3 The dIrectIOn of the flow of od dIrectIon Thus there eXIsts the
runner by the actIon of the pump winch has been dIscharged from the followmg relatIon between these
unpeller It mcreases the engIne torque back SIde of the turbIne runner IS torques and the torque T 2 exerted by
and transmIts It to the transmISsIOn changed by the stator blades and the the od m the turbIne runner
ThIs torque multIplymg functIon IS the 011 enters the pump
agam unpeller
most The 011 thus CIrculates through a
outstandmg feature of a torque TI T3 T2
converter and for that reason It IS closed CIrCUIt whIch IS constItuted by

distIngUIshed from an ordmary flUId the pump unpeller turbme runner

couplIng mechamsm The torque and stator In thIS closed mCIDt the
multIplYIng actIOn IS effected by the sum of actIon and reactIon becomes For thiS reason the torque exerted
presence of a stator located 10 the zero on the turbme runner IS mcreased
by
converter FIgures AT 5 and AT 6 FIgure AT 7 analytIcally shows the the amount of the torque wluch IS
show the dIrectIon of the 011 flow actIon of 011 and the dIrectIOn of exerted on the stator ThiS IS why
takmg place 10 a
torque converter rotatIon of each blade by parallely torque IS
multIplIed m a
torque con
I The oLl whIch has been Intro the blades It wdl be noted
placmg verter
duced at the center of pump unpeller from the dIagram that the flow of od When the revolutIon of the
speed
IS thrown outward
by the centrIfugal winch has passed through the pump turbme runner mcreases and ap
force of the unpeller It rotates unpeller and turbIne will exert
as runner proaches near that of the pump 1fO
The directIon of oLl flow force to rotate the stator But
IS so a
by peller the dIrectIon of ou winch has
regulated by the blades of pump un the actIon of a one way clutch whIch left the pump unpeller IS changed and
peller that It wLlI properly strIke the IS
eqUipped m the stator the stator IS begms to strike the opposIte Side of
blades of turbme runner allowed the stator blade
only to rotate In the opposite glvmg the stator a

The od first strikes the surface of dIrectIon and wul not rotate m the free rotatIon 10 the dIrectIon which IS

turbIne runner and then flows dIrectIOn of force exerted by the 011 not locked the one way clutch The
by
through the runner towards ItS back The OIl wluch has left the stator enters waste of engIne power IS thus aVOIded
SIde the pump unpeller and flows ThIS relatIon shown AT 8
through a IS 10 Figure
2 The blades of turbIne runner are cIrculatmg CIrCUIt and dUrIng thIS and the characterIstIc curve of the
so
shaped to obstruct the flow of of OIl the T
as
lIlatIon torqu 1 torgu converter IS shown 10 Figure
od Therefore the force of od flow exerted
IS by the ou 10 the pump Im AT4

AT 4
 Automatic TransmissIon

The torque ratIo speed ratIo and The state of oLl cIrculatIOn 10 whIch mum value and thIS torque ratIo IS
the efficIency are
expressed as follows the stator IS locked by the flow of oLl called the stall torque ratIo
IS called the converter range
whereas the state 10 wluclI the rotor IS
Couphng
turned by the ou flow IS called the
Output torque range
Torque ratIo couplIng range
Input torque In the couplIng range the stator
g
only makes Idle rotatIOn presentlOg a u
c

state sundar to that of a flUId cou l

Output speed plIng wIth IE

Speed ratIo
no mcrease m
torque The C

Input speed pomt where the speed ratIo becomes 05

zero that the state winch

IS m
only
the pump shaft engme SIde rotates
Output horsepower and the turblOe shaft IS held
statIOnary
EffiCIency The vehIcle
Inpu t horsepower bemg stand stdl IS called 05 10

the stall Under thIS condItIon the Speed ratio AT067

torque ratIo between the turbme shaft A T 4 Characteristic

Fig curve of

and the pump shaft attaInS a maXI torque converter

T The force exerted by the oil of Otlflow

I pump
T The force exerted by the 011 of turbme Duectlon of rotation
2
T The force exerted by the 011 of stator Duectlon of force
3

Free wheel

TurbIne runner Stator Pump Impeller TurbIne runner Stator Pump Impeller
AT317 AT318

Fig AT 5 Torque converter 011 flow Fig AT 6 Torque converter 011 flow
Converter range Couplmg range

J Tpump Impeller
i Pump Impeller

J
LTurbme runner

r TurbIne runner

1
OOQ tator vT3 0 Stator
Locked Free wheel

AT319 AT320

Fig AT 7 011 flow berween each Fig AT 8 Od flow between each

blade Converter range blade Coupling range

AT 5
 Automatic Transmission

TRANSMISSION brakes band brake and one way the front clutch drum by the clutch
clutch plates On the other hand when the
The transmIssion IS a mechanIsm B Planetary gear rear clutch IS coupled together the
whIch changes the speed of IOput shaft
front mternal gear IS rotated whIch IS
that IS transmItted from the englOe hub
connected to the rear clutch
the and
through torque converter The transmItted the
power IS m
through a splme
then transmits the power to the pro
followmg manner When the servo pIston of the band
peller shaft The torque of turblOe whIch has brake operates the rotatIOn of front
In the transmISSIOn mechanIsm a
been converted by the torque con clutch drum IS stopped and the sun
planetary gear IS employed In the verter IS first transmItted to the gear winch IS connected to It by the
mput
planetary gear a wtde range of speed shaft through the splIne clutch and shell IS held statIOnary
connectlOg
changes IS performed by rotatmg or thIS torque then transmItted
gear IS ThIS sun gear IS
always kept 10 mesh
lockmg ItS mternal gear pInIon carrIer to the rear clutch drum 10 the trans With the front and rear planetary
or sun gear In model 3N7IB auto
mISSIon gears
matIc transmiSSIon automatIc speed
As the clutch plate of the front The rear planetary gear carner IS
change IS obtalOed by comblOmg two clutch IS connected to the front SIde of connected to the connectmg drum on
slfOple type planetary gears 10 the ar the rear clutch drum by a splIne It ItS perIphery and thts perIphery at the
rangement of the Sympson gear tralO rotates at the same speed as the rear same tlfOe serves as the hub of the low
The Sympson gear tram IS a kmd of
clutch drum See paragraph under and reverse brake
planetary gear arrangement IOvented Clutch When oLl pressure IS The engme power IS thus trans
by Howard Sympson an AmerIcan exerted the front clutch pISton the
on mItted from the output shaft to the
engmeer clutch plates drIve plate and drIven propeller shaft after ItS speed has been
The transmiSSIon comprISes the
plate are forced to couple together changed by the planetary gear 10 the
the ele
followmg parts as prlOclpal Therefore the rotatIon of the IOput transmissIon and thIS output shaft IS
ments for power transmiSSIon
shaft IS transmItted to the sun gear splIned to the planetary gear carner at
A Clutches and bands front clutch through both the rear clutch and the the front end and to the mternal drIve
rear clutch low and reverse connectlOg shell whIch IS coupled to flange at the rear end

AT069

I Engme crankshaft 8 Oil pump IS Planetary pmlon

2 Dnve plate 9 Brake band 16 Rear planetary carner
3 Pump IDIpeller 10 Front clutch 17 Low and reverse brake
4 Turbme runner 1 I Rear clutch lR Parkmg pawl
S Stator 12 Front planetary 19 OIl dlstnbu tor
carner

6 One way clu tch 13 In ternal gear 20 Governors

7 Input shaft 14 Sun gear 21 Output shaft

Fig A T 9 Schematic draWing shOWing concept of automatic transmISSIOn

AT 6
 Automatic Transmission

In the 3N71B automatIc transmIs

Clutch low l ban servo One
Gear Parking
SIon each
part operates as shown 10 reverse way
Range rallo
Front Rear Release pawl
the followmg table at each gear select brake Operation clutch

posItIon Park on on

Reverse 2 182 on on on

OIL PUMP
Neutral
The 011 pump IS an IOternally mesh
ed mvolute gear pump and ItS lOner 01 low 2458 on on

rotated at the as the

gear IS same
speed Drive 02 Second I 458 on on

englOe by the drIve sleeve whIch forms

a portIon of the pump Impeller of the 03 Top 1000 on on on on

torque converter 2 Second I 458 on on

The 011 pump serves to supply the

oLl for the operatIOn of torque con 12 Second I 458 on on

verter to lubrIcate every mechanIsm I

II low 2458 on on

and to proVIde ou for the operatIon of

all frIctIon elements clutches and
bands and the control system

AT071
I Housmg 4 Inner gear
2 Cover S Crescent
3 Ou tcr gcar

Fig AT 10 O lpump Front clutch drum 6 DrIVC plate

Dutch pISton 7 Retalnmg platc
SprIng retainer 8 Snap rmg
Snap nng 9 Rcturn spnng
Olshed plate 10 Dnvcn platc
AP21
FRONT CLUTCH
Fig AT 11 Components offront clutch
IllustratIon A m
Figure AT 11
shows the state when 011 pressure IS
exerted on the pIston Under thiS

condItIon clutch plates come mto

rIgId contact wIth each other and the

rotatIon of the hub IS transmItted to

the clutch drum

When the 011 pressure IS released as

shown at B the return sprIngs move
the to the released
piston posItIon and
the clutch plates are released
When 011 pressure works on the

front clutch pISton and the clutch

plates engage the sun gear IS rotated

the connectlOg shell winch
1 Piston L
through IS 2 Clutch drum
connected to the front clutch drum A clutch ON 3 Clutch hub B clutch OFF

The front 4 011 pump covcr

clutch IS used only In

Reverse and 10 3rd forward gear AT322

pOSItIons Fig AT 12 Operation of clutch

AT7
 Automatic Transmission

REAR CLUTCH

The rear clutch drum IS drIven by

the mput shaft through the splIne
connectIon The rotatIon of thIS rear

clutch drum drIves the steel drIve

plates m the real tch and the lIned
drIve plates In the front clutch
When the rear clutch pIston IS

applIed by 011 pressure the movement

of the pISton agaInst the return sprmgs
locks the steel and lIned clutch plates

together to drIve the rear clutch hub

and the front mternal gear

When the oil pressure IS released
1 Rear clu Ich drum 7 Rc taInIng plate
the return sprIngs the pIston to
move
2 Clutch piston 8 Snap nng
the released posItIon and the steel and 3 Spring retaIncr 9 Needle bcanng
hoed clutch plates are released 4 Snap rIng 10 BearIng race
S Dished plate II Return spnng
ThIS stops the rotation of the rear
6 Dnve plate 12 Dnve plate AT323
clutch hub and the front Internal gear
F g AT 13 Components of rear clutch
The rear clutch IS
applIed In all for
ward drIve gear ranges

BAND BRAKE

One end of the band brake IS

locked to the transmISSion case by the

anchor end pm
When oIl pressure IS dIrected to the
apply SIde of the servo piston the
pIston moves agamst the
return spnng
to tIghten the brake band around the
front clutch drum connectmg shell
and sungear
To release the servo pIston the oIl
pressure IS dIrected to the release SIde I Nut
of the servo pISton The release pres 2 PISton stem
sure assIsted the 3 Band servo pISton
IS by compressed
4 Rcturn spnng
return sprIng to move the servo pIston S Brake band
and brake band to the released POSI
6 Washer
tIon 7 Servo rctaIncr
The band brake IS
applIed only In 8 Band stru t
AT324
the 2nd forward speed range
Fig AT 14 Components of band brake

AT 8
 Automatic Transmission

LOW AND REVERSE BRAKE

The steel drIven of low and

plates
reverse brake are locked to the trans
mISSIOn case the
through splIne con

nection
When 011 pressure IS dIrected to the

low and reverse brake the

piston
pIston moves agaInst the return sprIng
disC sprIng
The piston movement locks the
steel and lIned plates together Then
the lIned lock the connectIng 7
plates
shell and gearsun
5 Thrusl spnng nng
When the 011 pressure IS released
6 PIston return sprIng
the return sprlOg movcs back the
7 Thrust washer
pIston to the relased The
pOSItion 8 One way clutch lOner race
steel and lIned plates are now released I Dnve plate 9 Dlshcd plate
The low and reverse brake IS ap 2 Transmission case 10 Dnven plate

plIed 10 the 1st forward of 1 3 Low rcvcrsc brake pIston 11 RetaInIng plate
speed
4 Hcx slotted bolt 12 Snap nng AT325
range and R range
F g AT 15 Components ofow and reverse brake

Front planetary gear Rcar planetary gcar

Internal gear 72 teeth

PLANETARY GEAR

The I PInion carner

planetary gear IS of nonas
Cl
sembly type and
C2
IS combIned three V
1

ffo J t

planet pmlOns Ll
1 oi
r

Sun gear 33 tecth

PInIOn I9 teeth

AT326 AT327

F g AT 16 Components ofplanetary gear

ONE WAY CLUTCH

Lock
The clutch the
one way adopts
In this mechamsm the
sprag type
rotatIon m one directIOn alone IS

allowed and that In the opposIte dIrec

tlon prohIbited by
IS the dIfference 10
the dIagonal length of a roller as

shown In FIgure AT 17
AT137 AT075

FIAT 17 One way clutch

AT 9
 Automatic Transmission

HYDRAULIC CONTROL SYSTEM

CONTENTS

FUNCTIONS OF HYDRAULIC CONTROL P RANGE PARK AT 20

UNIT AND VALVES AT10 R RANGE REVERSE AT 22

Oil PUMP AT10 N RANGE NEUTRAL AT24
MANUAL LINKAGE AT10 0 RANGE LOW GEAR AT 26
VACUUM DIAPHRAGM AT 11 RANGE 2ND GEAR AT 28
02
DOWNSHIFT SOLENOID AT 11 RANGE TOP GEAR AT 30
03
GOVERNOR VALVE AT 11 0 RANGE KICK DOWN AT 32
CONTRO l VALVE ASSEMBLY AT12 2 RANGE 2ND GEAR AT 34
HYDRAULIC SYSTEM AND 1 RANGE lOW GEAR AT 36
MECHANICAL OPERATION AT18 RANGE 2ND GEAR AT 38
12

tams an 011 pump for

packmg up 011 nOld These parts work m
conjunctIon
FUNCTIONS OF
from the 011 through the 011
pan wIth valves m the valve body assembly
HYDRAULIC CONTROL straIner A slnft control IS proVIded by located m the base of the transmISSIOn
UNIT AND VALVES two centrIfugally operated hydraulIc The valves regulate 011 pressure and
governors the output shaft vacuum
on dIrect It to approprIate transmIssIon

The control system control dIaphragm and downshift sole components

hydraulIc con

I I
011 pump Con rol valve Torque converter
I I

Manual lInkage Front clutch

Rear clutch
Vacuum diaphragm
Low and reverse brake
Downshift solenOid Band brake

Governor valve
LubrIcatIOn

OIL PUMP houslOg delIvery port TransmIssIOn MANUAL LINKAGE

case delIvery Lower body delIv
port
The 011 pump IS the source of
ery port Control valve lIne pressure The hand lever motion the hand
control medIUm I e 011 for the lever IS located 10 the drIver s
CirCUIt compart
control system ment mechamcally transmItted from
As shown AT 18 the 011
m
Figure the remote control lInkage IS further
enters at the suction sIde and collects transmitted to the lOner manual lever
m the space at A and then the
by m the transmISSIOn case from the range
rotation of the mner and outer gears
selector lever m the rtght center por
IS earned and discharged from the tlOn of the transmISSIOn case
through
B
portion the manual shaft The lOner manual
The 011 flows through the followlOg lever IS thereby turned
route A pm lOSt ailed on the bottom of
011 pan 011 stralOer bottom of the
the lOner manual lever shdes the
control valve Control valve lower manual valve
spool ofthe control valve
body suctIon port Transmission case
thu posltIQnIng h spool opposIte the
sucton port Pump hOUSIng suction AT328
approprIate select posItion
port Pump gear space Pump Fig AT 18 Operation of 011 pump The rod plO held the
parklOg IS m

AT10
 Automatic Transmission

groove on the top of the lOner manual towards atmospherIc pressure and the

plate The parkmg rod pm operates the vacuum reaction mcreases smce the Ih
of mSlde the 1
rod at P range and operates the flow velOCity mIXture
KICkdown
mechalllcallock system mtake manIfold IS slow Contrarily
Down shIft solenOid SWl tch
The above descrIbed manual shaft IS when the engme speed mcreases and
further wIth mhlbltor
equipped an the flow velOCIty of the mIxture 10

sWItch A rotor mSlde the mhlbltor creases or when the carburetor IS

AT089
sWItch rotates 10 response to each closed the malllfold negatIvc pressure
When the range IS selected at tends towards vacuum Fig AT 21 Downshift solenOid
range mcreases I e

P or N thc rotor closes the and the vacuum reactIon IS reduced

starter magnet CirCUIt so that the GOVERNOR VALVE
Thus a
sIgnal to generate hydraulIc
can be started When the range
engme sUIted to the engIne
pressure perfectly
selected at R the rotor closes the
The prlfOary and secondary gover
IS
loadmg at the control valve IS trans
nor valves are lOSt ailed separately on
back up lamp CIrCUIt and the back up mItted from the vacuum
diaphragm the back of the 011 dIStrIbutor on the
lamp lIghts and the most SUItable
tlfOmg for speed
transmiSSIOn output shaft They oper
change and lIne pressure IS obtamed so
ate at the same
speed as that of the
that the most proper torque capacIty
output shaft That IS
they operate at
IS obtamed agamst the transmlttmg a
speed 10 proportion to the vehicle
torque
speed The lIne pressure IS
applIed to
those the
valves as
mput from the
control valve through the transmISSIOn
OU
case rear flange and distrIbutor
The governor pressure 10 proportion
to the output shaft speed vehIcle
led to the shift valve of the
speed IS

valve the
AT087 control through opposIte
3 route of the output In thIS manner
1 Manual plate Parkmg rod A TOBB

2 Inhlbllor sWitch 4 Manual shaft speed change and hne pressure are

Fig AT 20 Vacuum diaphragm controlled

Fig AT 19 Manua mkage

DOWNSHIFT SOLENOID

The downshift solenOid IS of a of secondary

VACUUM DIAPHRAGM Operation
magnetIc type lOStailed on the left rear
governor valve
lOStailed
The vacuum
diaphragm IS portIOn of the transmission ase When

of the The secondary valve IS a control

on the left center portIon a driver reqUIres acceleratmg power
The mternal and the accelerator valve winch receives hne pressure 1
transmiSSion case con
depresses pedal
structIon of the vacuum down the kick down and controls the governor pressure
dIaphragm IS to stopper a

as follows SWitch located 10 the middle of the When the manual valve IS selected
A rubber dIaphragm forms a
partI accelerator lInk IS
depressed by a push at D 2 or 1 range lIne pressure

tIon 10 the center The engme mtake rod the klckdown SWItch closes cur IS applIed to the rIng shaped area of
led thIS valve from CirCUit 1 and thIS
malllfold negatIve pressure IS rent flows to the solenOid the sole
valve toward the center
through a vacuum tube and sprIng nOid push rod IS depressed the down IS depressed
force to the front surface of shift valve of the control valve mSlde Movement of thiS valve to a certam
applIed
IS

the rubber dIaphragm whIle atmos the transmISSIOn

depressed and
case IS pOSItIOn closes the CirCUIt from 1 to
pherIC pressure IS applIed to the back the speed IS changed forcedly from 15 whIle
slfOultaneously makmg a
surface The difference between pres 3rd to 2nd wlthm a certam space from 15 to the center dram
and
sure
applIed to the front and back vehicle speed lImit port pressure 10 the CirCUit 15 IS
surfaces causes a vacuum reactIon lowered
whIch actIvates the throttle valve of Note Smce the klckdown SWItch When the vehicle IS stoppcd and the
the control valve mSlde the transmIS closes when the accelerator pedal IS centrIfugal force of thiS valve IS zero

sIon case depressed from 7 8 to 15 16 of the the valve balanced At thiS pomt a
IS

When accelerator pedalfully de

IS whole stroke the accelerator pedal governor pressure which IS balanced

pressed and the carburetor IS fully should be correctly adjusted so as With the sprIng force occurs on 15

opened but the engme speed IS not to atrord a complete stroke When the vehicle IS started and the

sufficIently mcreased the malllfold The arrangement of the SWItch centrifugal force mcreases thiS valve
lowers I e tends model to the outSide and as
negative pressure vanes accordmg to moves slIghtly

AT 11
 Automatic Transmission

the space from I to 15 Increases To control valve

space from 15 to the dram port Governor

pressure I5
slfOultaneously decreases As a result
governor pressure of 15 Increases

and the governor pressure IS balanced

AT091
wIth the sum of centrIfugal force and
FlAT 23 Output shaft WIth oil
sprlOg force The governor pressure
dIStributor and governor
thus changes In response to the vclncle

speed change centnfugal force

AT090

Operation of primary I Primary governor 4 Oil dlstnbutor

governor valve 2 Secondary governor S Output shaft
3 Governor valve body
The valve IS an ON OFF valve AT092
whIch closes the governor pressure FlAT 22 Cross sectIOnal view of 1 011 distributor

governor 2 Governor valve body

IS regulated by the secondary gover 3 Pnmary govcrnor valve
nor valve when the vehIcle reaches the
4 Secondary governor valve
minImum speed and when the vehIcle

speed exceeds a certaIn level the f AT 24 Exploded

Fl v ew ofgovernor
governor opens and forwards the gov
15 to the control CONTROL VALVE
ernor pressure ASSEMBLY
valve
When the vehIcle IS stopped the Flow chart of control valve system
governor pressure IS zero However
when the vehicle IS runnIng slowly
thiS valve the center
IS
depressed to
011 from pUnIp
and the groove to 15 IS closed SInce

the governor pressure applIed to the

r
Regulator vJlve I
rIngshaped area IS
hIgher than the
I
centrIfugal force of thiS valvc When I

I
the governor speed exceeds a certaIn I

revolutIon the AUXIlIary valve I

governor pressure In

the CIrCUIt 15 also mcreases How I

I
the force
ever as
centrIfugal Increases I
Lmc pressure
I
and exceeds the governor pressure thIS
I
valve moves toward the outsIde and I
1 Govcrnor
the governor pressure IS transmitted to valve
the CIrCUIt IS
Two dIfferent valves are employed
In the governor so that It Will IOde
pendently control the speed at high
and low speeds That IS wlthlll the low

speed range the governor pressure IS The control valve assembly receIves dIrectIOn changeover valves mcludmg
not generated because of the prImary oLl from the ON OFF valve and
pump and IndIVidual regulator valves IS
valve wherea at the
high speed range SIgnals from the vacuum dIaphragm newly reformed to a throttle system
above the breakIng and transmIts the mdlvldual lIne pres
pOInt governor ou pressure and opera tes other valves
pressure IS regula ted by the secondary to the transmISSion frIctIon ele
sures FInally the lIne pressure IS translll1tted
valve ment converter CirCUIt and to the clutch
torque reqUIred or brake servo

lubncatlOg system CirCUIt as outputs pISton UnIt 10 response to the IndIVId

The breakIng pOInt IS the pOInt at More speCIfically the 011 from the oIl ual
runnmg condItIons after recelvlOg
whIch the functIOn of of the
pump IS regulated by the regulator
one
SIgnals from the vacuum dIaphragm
governor IS red to the other
ansfe valve as llll e pr sure QuIlds up The downshift soleno
9 governor valve
the
as
speed changes from the Ime prcssure IS fed out from the and or manual lInkage
low the high speed rangc
speed to control valve asscmbly through vanous

AT12
 Automatic Transmission

The control valve assembly consIsts the lIne pressure 6 and the throttle
18
of the followmg valves See FIgure pressure 16 IS equal to

AT 35

1 Pressure PRV
regulator valve
2 Manual valve MNV Manual valve MNY
31st 2nd shIft valve FSV
The manual lever turmng motIon IS
4 2nd 3rd shut valve SSY
5 Pressure modifier valve PMY converted to reclprocatmg motIon of

6 Vacuum throttle valve VTY the manual valve through a pm and

7 Throttle back up valve TBY the MNV IS

pOSItioned so that the 110e
pressure 7 IS dIstrIbuted to the mdl
8 SolenOId downshIft valve SOY
9 VIdual lIne pressure CIrcuits at each
Second lock valve SLV
P R N D 2 or I range
10 2nd 3rd tImmg valve TMV
as shown below

P range
7 4 SOV and TBV
Pressure regulator valve 5 FSV 12 TBV and

PRY Low reverse brake

R range
The valve
pressure regulator re

7 4 same as above
ceives valve sprIng force force from
5 same as above
the plug created by the throttle pres
6 PRY and SSV F C
sure 16 and lIne pressure 7 and
and band rclease
force of the throttle pressure 18
With the mte actIon of those forces N range 7 None

the PRY regulates the lIne pressure 7 0 range

to that most SUItable for mdlVldual AT095 7 I Govcrnor valve fSV

drIvmg condItIOns c1ukh

j
and rear
Fig AT 25 Pressure regulator valve
The ou from the 011 pump IS ap 2 SLY
plIed to the rIng shaped area through 3 SLY and SSV
OrIfice 20 As a result the PRY IS When the range IS selected at R
2 range
Reverse the lIne pressure 6
depressed downward and moves from IS

7 I Same as abovc
that the to the plug manner Iden
up to such m a
port 7 extent applIed
2 SL V 9 Band
space to the next dram port marked tIcal to the throttle pressure 16 and
With X ill FIgure AT 25 opens IS added to the sprIng force Con applIed
7
4 SOV and TBV
lIne pressure 7 IS the lIne pressure further
slIghtly Thus the sequently
balanced With the sprIng force there mcreases I range
vehIcle and above
by balanclOg the PRY In thIS opera When speed mcreases 7 I Same as

tIon the space from port 7 to the the governor pressure nses the throt 4 Samc as above

subsequent converter 011 pressure 14 tle pressure 18 IS applIed to the port 5 FSV
CirCUit has also been opened As a on top of the PRY and pressure IS
the

result the converter IS fuled With applIed contrarily agamst the sprmg Moreover I 2 3 4 5 and

pressurIZed ou m CIrCUIt 14 and thiS force As result the lIne pressure 7

a 6 are always dramed at a
pOSItIon
oLl IS further used for lubrIcatIon of decreases Moreover at mdlvldual con where the IInp pressure IS not dIStrIb

the rear umt Moreover part of the 011 dItIons the line pressure 7 IS equal to uted from 7

IS branched and used for lubrIcatIon of

the front UnIt for the front and rear
23
clutchcs

pressed
When the accelerator
the throttle pressure
pedal IS

16
de

10
xLA
creases as deSCrIbed m the precedmg
paragraph oIl pressure IS
applIed to
the plug through OrIfice 21 and thIS
r I
pressure added to the sprmg force
IS
p R N D 2
As a result the PRY IS contrarIly
forced upward space to the dram port
AT096
IS reduced and the lIne pressure 7
mcreases
FIfJ AT 26 Manual valve

AT13
 Automatic Transmission

1st 2nd shift valve FSV governor pressure 15 IS

conSIderably released the front clutch IS engaged
hIgh the valve IS forced completely and speed IS shifted to 3rd
The FSV IS a transfer valve whIch toward the and the When the accelerator
nght FSV IS
pedal IS de
shifts gears from low to second When returned to the Low pOSItIon ThiS pressed both the Ime pressure 3 and
the vehicle IS stopped the FSV IS caUed Klckdown shIft the throttle pressure 19 are hIgh and
operatIOn IS

depressed to the rIght sIde by force of the SSV IS thus retaIned 10 2nd
a spnng located on the left sIde unless the governor pressure 15 ex
puttmg the FSV IS m the Low ceeds the lme pressure 3 and the
pOSItIOn throttle pressure 19
When vehIcle speed mcreases the In the 3rd pOSItIOn force depres
15
governor pressure IS applIed to
SIng the SSV toward the right IS
the nght side of the FSV and the FSV
retamed the throttle pressure
13 only by
IS forced toward the left Contrdllly 16 and the throttle pressure 16 IS
the lIne pressure 1 together wIth the slIghtly lower than that toward the
sprIng force forces the FSV toward the
nght whIch IS applIed whIle shlftmg
rIght opposmg the governor pressure from 2nd to 3rd
15
Consequently the SSV IS returned
When the vehicle speed exceeds a
to the 2nd posItIon slIghtly
at a

certam level the governor pressure lower

15
speed ShiftIng from 3rd to
exceeds the sum of the throttle 2nd occurs at a speed slIghtly lower
pressure and the spnng force and the than that for 2nd to 3rd shlftmg
FSV IS forced toward the left
When kicked down at 3rd lIne
When the FSV IS
depressed to a
pressure 13 IS led from the SDV and
certam pOSItIon the lIne pressure I IS
the SSV IS forced toward rIght the
closed and only the spnng deprcsses AT097 the governor pressure
Although IS con

the FSV toward the nght and It IS

Fig AT 27 1st 2nd sh ft valve Siderably Ingh the valve IS forced

depressed to the end for a moment As
complctely toward the rIgh t and the
a result the lIne pressure 1 IS for SSV 2nd
2nd 3rd shift valve
IS thus returned to POSI
warded 8 SSV
to the band servo IS
tion Tins operatIon IS called KIck
engaged through the SL V and the The SSV IS a transfer valve which down shift
speed IS shIfted to 2nd With the shIftS gears from 2nd to 3rd When the shift lever IS shIfted to
accelerdtor pedal depressed the FSV When the vehicle 2
IS
stopped the SSV or 1 range at the 3rd speed
the Low posItion unless
remams m
IS forced toward the rIght by the the lIne pressure 3 IS dramed at the
the governor pressure 15 mcreases to
sprmg and IS 10 the 2nd pOSItIon It MNV Consequently the front clutch
a
high level correspondmg to the lIne IS so
deSIgned however that the FSV and band servo releaSIng Oils are dram

pressure 1 smce the lIne pressure 1 can deCIde to shift either to Low or ed As a resul t the transmISSion IS
wh thp lp r
ppcbl11i
Increases n I p r
t
2nd shifted to 2nd or Ul Jl eed
depressed When the velncle the SSV the 3rd
IS runnIng the although IS m

Contranly when vehIcle speed 15 to

governor pressure IS
applIed posItIon
decreases the governor pressure 15 the end surface and the SSV When the shIfted to the
rIght IS speed IS

decreases However the gear IS not forced toward the left ContrarLly the 3rd a one way OrIfice 24 on the
shifted to Low unless the governor
sprIng force
lIne pressure 3 and top of the SSV relIeves oIl transmlttlOg
pressure 15 becomes zero SInce the
throttle pressure 19 force the SSV velOCIty from the lIne pressure 3 to
force depreSSIng the FSV toward the
toward the lIne pressure 10 and reduces the
rIght
nght IS beIng delIvered only by the
shock from the
When vehIcle speed exceeds a generated shiftIng
sprmg the lever
certaIn level
the governor pressure ContrarIly when IS shIfted
Low range 1InIS led to the
2 I range and the
surpasses the sum of the spnng force to or
speed IS
low and reverse clutch from lIne pres
Ime pressure and throttle pressure shIfted from 3rd to the 2nd the
5
sure
through lIne pressure 12
and the velave IS forced toward the OrIfice checkIng valve sprIng 24 IS
and IS SImultaneously led to the left becomes mef
left The lIne pressure 3
IS then depressed the throttle
end sprmg UnIt Consequently closed Consequently the forces bemg fectIve the lIne pressure 10 IS dram
although the governor pressure In
unbalanced the force ed qUickly and delay shlftmg
rapIdly depres In

creases the valve IS stIli forced toward

SIng the SSV toward the nght de speeds s thus elImmated
the nght and the SFV IS fixed In the creases and thus the SSV IS depressed The throttle of lIne pressure 6
Low posItIon When kicked down to to the left end for a moment WIth the transmits the 011 transmIttIng velOCIty
the 2nd speed the SDV operates
SSV toward the left end the 6
depressed frol1JJIne pressure to 1
Il pr ssure

and the hne pressure 13 forces the lIne pressure 3 IS connected WIth the 10 when the lever IS shifted to the
FSV toward the rIght Although the R
110e pressure 10 the band servo IS range and transmits dram velocl

AT 14
 Automatic Transmission

from Ime 10 to lIne pressure loss to thIs space IS Contranly when the vehIcle speed
ty pressure eqUIvalent
6 when shiftIng from 3rd genera ted the pressure loss IS added to decreases and the governor pr ssure
pressure
at D Thus the the sprIng force and the plug IS thus 15 decreases the force toward the
to 2nd range
throttle of lIne pressure 6 reduces forced back from the nght to the left nght exceeds the governor pressure

the shock generated from shlftlOg When thIS pressure 19 Increases ex the valve IS forced back toward the
A plug In the SSV left end readjusts cessIVely the plug IS further depressed nght and the throttle pressure 18 IS
the throttle pressure 16 which varIes toward the left space from the throt draIned to the spnng UOlt
the engIne throttle con tie pressure 19 to the dram CIrCUIt The valve IS swItched when the
dependIng on

ditIon to a throttle pressure 19 13 Increases and the throttle pres throttle pressure and tl1e governor
SUIted to the
speed change control sure 19 decreases Thus the plug IS pressure are high or when they are
Moreover the plug IS a valve which balanced and the throttle pressure both low
lIeu of the
applIes 110e pressure 13 In
19 IS reduced to a certam value
throttle pressure to the SSV and the agaInst the throttle pressure 16
FSV when klckdown IS perfonned When performmg thektckdown
When the throttle pressure 16 IS SDV moves a hIgh Ime pressure IS led

to the left SIde of thIs plug to the CIrCUIt 19 from the lIne
applIed
and the toward the pressure CIrCUIt 13 whIch had been
plug depressed
IS

rIght slIght space IS formed

a from the dralOed the plug IS forced toward the
throttle pressure 16 to 19 A throt left and CIICUlt 19 becomes equal to

tle pressure 19 whIch IS lower by the the Ime pressure 13

15
AT099

Fig AT 29 Pressure modlf er valve

Vacuum throttle valve VTV

The vacuum throttle valve JS a

regulator valve winch uses the lIne

7 for the pressure source
pressure
and regulates the throttle pressure 16
whIch IS proportIoned to the force of
the vacuum illaphragm The vacuum

the
dIaphragm vanes dependIng on

englOe throttle conditIon negatIve

pressure 10 the Intake lIne
AT098
When the Ime pressure 7 IS ap

plIed to the bottom through the valve

FIg AT 28 2nd 3rd sh ft valve
hole and the valve IS forced upward
the
space from the 110e pressure 7 to
throttle pressure 16 IS closed and
Pressure modifier valve PMV
the PMV IS low the valve IS forced the space from the throttle pressure
to the toward the rIght by the throttle pres 16 to the draIn CIrCUIt 17 IS about
Compared operatIng pressure

required m startIng the vehicle the sure 16 applIed to the area dlf to open In thIS operatIon the throttle
of the and the sprIng
of the valve 16 becomes lower than the
power transmlttlOg capacIty rence pressure
force and the CIrCUIt from CIrCUIt 16 lIne pressure 7 the pressure eqUiv
clutch that IS reqUIred operatIng pres by
sure may be lower when the velncle IS to CIrCUIt 18 IS closed However alent of the loss of space and the

started When the IlOe pressure IS and the the rod of the vacuum
once when vehIcle speed Increases force depreSSIng
retamed at a htgh level up to a hIgh governor pressure IS exceeds a cer
dIaphragm IS balanced with the throt
shock from to the
vehIcle speed generated taIn the governor pressure to
level tie pressure 16 applIed upward
the shift109 mcreases and the 011 ward the left whIch IS applIed to the bottom

pump loss also mcreases In order to nght sIde exceeds the sprIng force and When the engIne torque IS hIgh the

prevent thIS the throttle pressure must the throttle pressure 16 toward the negatIve pressure In the Intake lIne
be changed over WIth the operatIOn of nght the valve IS depressed toward the rISes tendmg toward atmosphenc
the governor pressure 15 to reduce left and the throttle pressure IS led
pressure and the force of the rod to
the lIne pressure The PMV IS used for from CirCUIt 16 to CirCUIt 18 This the valve Increases As a result
depress
thIS purpose throttle pressure 18 IS applIed to the the valve IS depressed downward the
15
When the governor pressure top of the PRY and the force of the space from the throttle pressure 16
whIch IS applIed to the rIght SIde of lIne pressure source 7 IS reduced to the dralO 17 decreases and the

AT 15
 Automatic Transmission

space from the lIne pressure 7 to the pressure loss due to the space from
throttle pressure 16 Increases cIrcuIt 4 to CirCUit 17 IS balanced

Consequently the throttle pressure WIth the sprlOg force

16 Increases and the valve IS bal Further when gear IS slnfted from
anced Contraruy when the engIne 2nd to Low at the range 1 lIne
torque lowers and the negative pres pressure IS led from CirCUit 12 and
sure In the Intake lIne lowers tendIng the lIne pressure IS applIed
upward to
toward vacuum the force of the rod the bottom of the valve through the
the valve decreases and the
depreSSIng Valve hole Consequently the valve IS
throttle pressure 16 also decreases forced upward and locked As a re
When pressure the throt sult the space from the ltne pressure
regulated by
tle back up r alve descnbed In the 4 to the back up pressure 17 IS
subsequent paragraph IS led to CirCUit closed completely and the back up
17 dramed
17 a
hIgh pressure IS
applIed through pressure IS upward
the space from the CIrCUIt 17 to the 7
throttle pressure 16 Consequently
the VTV IS unbalanced the throttle
becomes the ATl02
pressure 16 cqual to
back up pressure and the valve Fig AT 32 SolenoId downshift valve
17 IS

locked upward
Second lock valve SLV

ThIS valve IS a transfer valvc which

assists the shift valve 10
determmmg
the fixed 2nd speed at the 2

range
4
In the 0 range the sum of the

spnng force and lIne pressure 3

exceeds the lIne pres
applIed upward
2 which
sure IS
applIed to the valve
area difference as a downward force
ATlOl As a result the valve IS locked upward
and the CIrCUit from hne pressure 8

F g AT 31 Throttle bach up valve to lIne pressure 9 IS opened

the FSV becomes
Consequently
the 2nd condlllon
speed and lIne

pressure IS led to the band servo

Solenoid downshift valve pressure I IS released to hne pressure

8
SDV
ATlOO In the 2 the
range upward force
ThIS valve IS a transfer valve whIch retamed the spnng and the
IS
only on
leads the lIne pressure 7 to 13 and downward lIne 2 exceeds
Fig AT 30 Vacuum throttle valve pressure
transmits the to the FSV and the
same upward force
SSV when a kIck down SIgnal IS re As a result the valve IS locked
ceived from the downsluft solenOid downward hne pressure 2
Throttle back up valve THV IS relcased
Usually the solenOid push rod and to 9 regardless of the operatmg
Usually thIS valve IS
depressed valve locked upward by the spnng
are condition of the FSV and the band
downward by the sprIng force 10 the lower end and the CIrCUIt from servo IS
engaged
As soon the lever shifted either lIne pressure 4 to lIne pressure
as IS
13 IS

to 2 or 1 lIne pressure IS opened

range
led from CIrCUit 4 the lIne pressure IS When klckdown IS
performed the 2
the area difference of the
applIed to push rod operates the valve IS dcpres

valve the valve IS forced upward the sed downward and the CIrCUIt from
space from CIrCUIt 4 to Circuit 17 IS lIne pressure 7 to hne pressure 13
closed and With the space from CirCUIt Lme pressure 8
opens 13 opposes the
17 to the upper dram about to open govern9 pres ure 15 at the SSY and
the back up pressure 17 whIch IS FSV thus
accomplIshmg the down ATl03 3
lower than the lIne pressure 4 by the shift operatIOn
FIg AT 33 Second loch valve

AT16
 Automatic Transmission

the upward force exceeds the down

2nd 3rd timing valve TMV
ward force the valve IS locked upward
This valve IS a transfer valve whIch and passage from CIrCUIt 10 2nd

sWItches the bypass circuit of the from the Top to CIrCUIt 11 IS

IO
onfice 22 the front clutch pres closed
In Consequently the lIne pressure

sure CIrcUIt 11 In response to vehicle 10 IS led to the front clutch CIrCUIt CII
speed and throttle condition A force II through the OrIfice 22 and the 22
created when the governor pressure ou pressure IS thus transmitted slowly
to the bottom of the However under normal shlftmg the
15 IS applIed
TMV constItutes the upward force throttle pressure 16 has a pressure
x
and a force created when the spnng exceedmg a certam level and the
force and the throttle are downward force exceeds the
pressure upward
applIed to the top of the TMV con force As a result the valve IS locked
ATl04
stitutes the downward force downward the passage from CIrCUIt
When the throttl pressure 16 IS 10 to CIrCUIt 11 IS opened and the

lower than the governor pressure 15 onfice 22 IS bypassed Fig AT 34 2nd 3rd tlmmg valve

I Pressure regulatIng valve PRV 6 Vacuum throttlc valve VTV

2 Manual valvc MNV 7 Throttle back up valvc TBV A T094

31st 2nd sluft valve FSV 8 SolenOId down shtft valvc SDV
4 2nd 3rd sluft valvc SSV 9 Second lock valve SL V
S Prcssure modIfier valve PMV 10 2 3 llmIng valve TMV

FIg AT 35 Control valve

AT 17
 Automatic Transmission

HYDRAULIC SYSTEM
AND MECHANICAL
OPERATION
The operatmg system of oLl pres
sure m each range IS descrIbed below

The oLl pressure m each CIrCUIt

shown 10 the LllustratIon IS clasSIfied as

follows accordmg to the functIon
The numerals show the CIfCUlt

numbers

Pressure source of the lIne 7 AT106

Opefatmg lIne pressure Fig A T 37 Identlf catlOn of 011 channels m case front face
for frIction elements

1 2 3 4 5 6 7 8 9 10 11 12

AUXIlIary Ime pressure 13

Governor pressure IS
Throttle system pressure

16 17 18 19

Governor feed prcssure I

Others 14 15

011 pump dIscharge hole 7

ATl07

Fig A T 38 Identlf catlon of 011 channels In case face

ATlOS

Fig AT 36 Identlf catlOn of 011 channels m 011 pump

AT18
 Automatic Transmission

Hydraulic control system

Low a Rev r

erak
arak
a

II
14

Front
Lubrication Orlflc
Cheek
Dr V 0
111
Vah

Throttl
Drain
Valva

CD Pranura
R ul to Valva

Zl Manua
V
l

Nota Marked X Drain

Pnma
Secondarv
or V Gov rnor Valva
Gor I

Fig AT 39 Hydraul c control system

AT 19
 Automatic Transmission

P RANGE PARK

The operation ofclutches and band

the same as Neu
are functIonally m

tral
In parkmg however when the

parklOg pawl meshes m a gear whIch IS

splIned to the output shaft the output
shaft IS mechanIcally locked from

rotatlOg Frec lock

The oLl dIscharged from the 011

pump IS fed to each part m a SlmLlar

to that of the
manner N range The
011 havmg the lIne pressure 7 whIch

has been mtroduced IOto the manual

1 st 2nd
valve @ reaches the shIft AT086

valve I through the lIne pressure

CIrCUIt 5 As the 1st 2nd shIft Fig AT 40 Parkmg mechanism
valve IS forced to the nght hand SIde
by the sprmg the lIne pressure 5 and

12 actuates the low and reverse

brake through the groove Also the

parklOg pawl engages With the outer

teeth of the ou distrIbutor by means
of the manual lever mechanIcally
10cklOg the output shaft

AT 20
 Automatic Transmission

P range Park

1ft Valv

011Cooler
except A12

Front

Lubrialtl

Throttl
Drain

Not Marked X Or ln

Line prelSUf Governor feed preaur

Secondary plmort
GOY nor Vatv Governor Valve
Governor preuur

Torque rtel pressure

Throttle pr

Fig AT 41 011 pressure ClrcU t dlllifram P range Park

AT21
 Automatic Transmission

R RANGE REVERSE
R

In R range the front clutch and

the low and reverse brake are
applIed
The power flow IS through the mput
shaft front clutch and connectlllg
shell to the sun gear Clockwise
rotatIOn of the sun gear causes

counterclockwISe rotatIon of the rear

planetarygears With the connectlllg

drum held statIonary by the low and
reverse brake the rear planetary gears
rotate the rear mternal gear and drIve

the flange counterclockwise The rear

drIve flange splmed to the output shaft
rotates the output shaft counter
Fig AT 42 Power transmISSIOn dUring R range
clockWISe at a reduced speed With an

mcrease III torque for reverse gear

Front clutch ON O

When the manual valve @ IS pOSI 7

tIoned at R range the od haVIng the
lIne pressure 7 IS dIrected to lIne

pressure CIrCUItS 5 and 6 The

10 the CIrCUIt 5 actuates the
pressure
low and reverse brake after bemg
Illtroduced Illto Ime pressure CIrCUIt
12 through the 1st 2nd shIft valve
The pressure m the CIrCUit oper
ID AT085
ates the release SIde of the band servo

and the front clutch after AT 43 Operation of each mechanISm R

bemg led to Fig during range
lIne pressure CIrCUIt 10 through the
2nd 3rd shIft valve @ The throttle
16 pd thp Imp lIlp Ii
pressure prp

whIch vary WIth the degree of accelera

tor pedal depreSSIOn both act on the Front planetary gear Rcar planetary gear
pressure regulator valve CD and press
agalllst ItS valve CD mcreaslllg IlOe

pressure 7 In Rrange the gover

absent maklllg all such Held
nor pressure IS

valves as the 1 st 2nd ID

shift valve
2nd 3rd shift valve@ and pressure
modifier valve @ 1ll0peratIve

AT329

A T 44 Operation ofplanetary gears dUring R range

Fig

AT 22
 Automatic Transmission

R range Reverse

ftVe

011
Cooler
lexcept A12

Front
Lubdut n

Drain Vaive

Throttl

Drain
V tv

j Pr Jr

Regulator Velve

Note M t rk X Drain

Linepressure rnor fMCI

IOo pre lUr second ry Pnmery
Governor Ve
e I GO norVal
Gornor pr

J
c Tl rque converter prHCur

Throttle p r

AT 45 Oil pressure CircUit lram

dlll R range Reverse
Fig

AT 23
 Automatic Transmission

N RANGE NEUTRAL

In N range none of the clutches

and band applIed thus no power
are IS

transmItted to the output shaft

The pressure of 011 discharged from

the 011 pump IS regulated by the

pressure regulator valve D to mam

tam the lIne pressure 7 and the oIl IS

led to the manual valve @ vacuum

and solenOid down

throttle valve @
slnft valve @ The oIl IS further
mtroduced mto the
torque converter

at Itsoperatmg pressure 14 and a

portIon of thIS 011 IS dIstrIbuted to
each part as the front lubncant The
oLl which has been from the
discharged
torque converter IS also dlS tnbuted to
each part as the rear lubrIcant
As the 011 pump rotates at the same

speed as the englOe the oLl pump

discharge IOcreases wIth engme speed
But the surplus OU IS returned to the
oLl pan by the pressure regulator valve

AT 24
 Automatic Transmission

N range Neutral

011 Cooler
OlCcept A12
Throttle
Back up
Velve
ijl ID Solo

Dow
l1ft Volve

Menue
v Valva

Note

tiiiiiiiiiiiiii
Marked

Llna preuur

Go
rnor
X Drain

Governor

prer
feed pressure
Secondary
nor Valva
Gow
m Primary
nor
Gov Verve

Torque converter prouur

Throttle pror

Fig AT 46 011 pressure CirCUit dwgram N range Neutral

AT 25
 Automatic Transmission

D RANGE LOW GEAR

The low gear m D range IS

somewhat dIfferent from that m

11
range
The clutch
rear IS
applIed as m

I range but the one way clutch

I
holds the connecting drum The power
flow IS the same as m
II range That
IS the power flow takes place through
the shaft and IOtO the rear
mput
clutch The Input shaft IS splIned to C
the rear clutch drum and dnves It

Rotation of the rear clutch drIves the

rear clutch hub and front mternal gear Fig AT 47 Power transmISSion dUring D range
The front mternal gear rotates the
front planetary gears clockWise to Rear clu tch ON Onc way clutch LOCKED
cause the sun gear to rotate counter
clockwlSc CounterclockwIse rotation
ofthe sun gear turns the rear planetary
clockWIse WIth the
gears plane
rear

tary carner held statIOnary by the

one way clutch the clockWIse rotatIOn
of the rear planetary gears rotates the
IOternal gear and drIves the
rear
flange
clockWISe The IOternal drIve flange IS II

splIned to the output shaft and rotates ATOBl

the output shaft clockWIse Fig A T 48 Operation of each mechanism D

dUring range

When the manual valve IS POSI

Front planctary gear Rcar planetary gear
tIoned at D the Ime pressure 7

mtroduced mto the manual valve IS led

to the Ime pressure CIrCUItS I 2

and 3 The m the CirCUit I Held

pressure

nor and at the same time operates the

1st 2nd sluft valve @ to change the

speed The CIrCUIt 2 leads to the

second lock valve The CIrCUIt 3
@
actuates the 2nd 3rd shIft valve @
for the 2nd 3rd and
speed change
at the same time locks the second
AT330
lock valve @
The throttle pressure 16 whIch Fig AT 49 OperatIOn ofplanetary gears durmg D range

changes With the degree of accelerator

pedal depreSSIOn presses the pressure the sprmg and the throttle pressure IS the throttle pressure 19 lIne pressure
regulator valve D and Increases the led to the throttle pressure 18 ThiS 1 and the sprmg whIch are exertmg
lIne pressure 7 When the speed of pressure acts agamst the force of the agamst the governor pressure There
the vehicle has Increased the governor sprIng of the pressure regulator valve fore when the governor pressure ex

pressure 15 Introduced from the Ime and also agalOst the throttle pres ceeds thIS pressure the speed IS shifted
D
CIrCUIt I actuates the 16 thus the llOe pres from the 1st gear to the 2nd g ar
pressure sure 10wer1Og
1st 2nd shut valve @ 2nd 3rd sure 7 The further the accelerator pedal IS

shIft valve @ and pressure modIfier The governor pressure also mcreases depressed the Ingher becomes the
valve ID When the governor pressure WIth the speed of the vehicle exertlOg throttle pressure 19 mcreaSIng the
IS hIgh the pressure modifier valve ID a
pressure on one SIde of the governor pressure and shiftIng the
acts m such a dIrection as to compress 1st 2nd slnft valve and counteracts the hIgher Side
speed change pOInt to

AT 26
 Automatic Transmission

D range Low gear

Low I Rev

Brate
Srak
S nd
Torque Cony teI Downstuft
SolenOid

ID Vocu
Thro
9 10 a
Valv
Or Cooler
except A12
eool

Throttl
Or ln
Valve

r
Llna pr Governor f pr Primary
soco
O nor Vatwo
nor VaW
Gov
Goy rnor pr

J
c Torque blT pr
conV

Throttl pr

Fig AT 50 011 pressure CircUit dllJgram D range Low gear

AT 27
 Automatic Transmission

0 RANGE 2ND GEAR

In thIS case the rear clutch IS

applIed and the band brake holds the

front clutch drum the connectlOg
shell and the sun gear from rotatIng
The power flow takes place through
the Input shaft Into the rear clutch and
the front mternal gear WIth the sun
gear held statIonary the front plane

tary gears rotate around the sun gear

carryIng the front planet carner wIth

them The front planet carner beIng
A T078

splIned the output shaft causes

to
clockwISe rotatIon of the output shaft Fig AT 51 Power transmlSs on durmg D range

at a reduced speed compared wIth the

speed of the Input shaft wIth an

Increase In
torque As the low and Rear clutch ON
reverse brake IS not applIed the clock
wise rotatIon of the output shaft
causes clockwISe rotatIon of rear Inter
nal gear and the rear planet carner also
rotates around the sun gear In a

clockwIse dIrectIon The one way

clutch wul act to allow the clockWise
rotatIon of connectIng drum

AT079

When the car while

speed mcreases FIg AT 52 Operatron of each mechanISm dUring D range
D 1st gear the
runnmg at 1 range
1st 2nd shIft valve @ moves allow

mg the lIne pressure 1 to be Intro Rear

Front planetary gear planctary gear
duced Into the lIne 8
pressure
through Itself The Ime pressure 8 IS

further led to the Ime pressure 9

by lockIng the band servo obtalOs the

2nd gear conditIOn

AT33l

Fig AT 53 OperatIOn ofplanetary gears dUring D range

AT 28
 Automatic Transmission

Dl range 2nd gear

011 Cooler
Ie copt A12
8 Sol
IDow
l
l
1ft Valve

nol

n
Fn
Lubrlcd n Orifice
Check
Vatva

Throm
Drain
V

j p

R ulator Valve

Note Marked X O aln

Line p Governor fMd pressure prlm y

3eConaary
nor Valve Qovernor VaM
Gov
Governor p

J Torque
c converter pressure

Throttle
pr

Fig AT 54 0 1 pressure CirCUIt drogram D range 2nd gear

AT 29
 Automatic TransmIssion

D RANGE TOP GEAR

In 3rd gear posItIon the front and

rear clutches are engaged The power
flow takes place through the Input
shaft IOtO rear clutch drum The rear

clutch drum rotates the steel drIve

plates of the rear clutch and the Imed

drIve plates of the rear clutch and the
Imed drIve plates of the front clutch
The rear clutch dIrects the power flow

through the rear clutch hub and front

A T082
Internal gear to the front planet ear

Fig AT 55 Power transmISSion

ner dUring D range

The front clutch dIrects the power

flow through the connectmg shell to
the sun gear With the sun gear and the
rear clutch hub drIven at the same

the Front clutch ON

speed front planet assembly IS

forced to rotate the output shaft at

the same speed In the dIrectIon to

provide the top gear

When the further

ear speed In

while runnIng at
creases
D2 range
2nd gear and the governor pressure
15 exceeds the combIned force of AT083

the sprmg of the 2nd 3rd shift valve

Fig AT 56 OperatIOn ofeach mechanism D range
@ and the throttle pressure 19 the I

2nd 3rd shIft valve @ moves and

the lIne pressure 8 acts to release the
front clutch and band servo through Front planetary gear Rear planetary gear

the lIne pressure 10

AT332

D
FW AT 57 Operation ofplanetary gears during range

AT 30
 Automatic Transmission

D range Top gear

r
Low R

Brata
Braka
Front B nd
Torque Con Clutch

1ft Vatva

011 CooIllr

except A12

Front
n
Lubrlcat

Drain Va

Throttle
Drain
Valva

Nota Marked X Drain

Llna pr r Go nor
feed pr r
teCondary Prima
nor
Goy Vat
G no Valve
Gov rnor pt

J Torque
c converter pr

Throttle pr

D Top gear
Fig AT 58 011 pressure CircUit dUlgram range

AT 31
 Automatic Transmission

D RANGE KICK DOWN

While operatlOg at speeds below

approxImately 80 to 90 km h 50 to
56 MPH a kIck 3rd 2nd downshift
can be accomplIshed by fully depres
SlOg the accelerator
A lack 3rd 1 st or 2nd 1 st
downshIft can also be accomplIshed
below 40 to 50 km h
approximately
25 to 31 MPH

When klckdown IS the

performed
push rod operates by the solenOId the
valve IS downward and the
depressed
CIrCUit from the lIne pressure 7 to
1

the lIne pressure 13 opens The lIne

13 3 the force of the
pressure plus
2nd 3rd shIft valve sprlOg oppose
the governor pressure IS at the

2nd 3rd shIft valve @ and thus

perform 3rd 2nd downshIft opera

lion

Moreover the lIne pressure 13

plus the force of the 1st 2nd slnft

valve sprIng oppose the governor pres
sure 15 at the 1st 2nd shIft valve
CID and thus perform 3rd 2nd or

2nd l st downshIft operatIon

AT 32
 Automatic Transmission

D range kickdown Shift valves in 2nd gear position

all Cooler
l
od

IftV I

except A12
1

ill P r

Regulator Valve

Nota Marked X Dr ln

Governor i f praaura 8ry

Prltn
Llna pranur Secondary
Governor V eve Governor Valvi
Gov rnor p

Torque n p

Throttle praau

n shift valves 2nd gear pasltlOn

Fig AT 59 Oil pressure CircUit diagram range klckdow
n m

AT 33
 Automatic Transmission

2 RANGE 2ND GEAR

In 2 range the gear ratIo IS locked

10 the 2nd forward speed In tins case
the rear clutch IS engaged and the band
brake holds the front clutch drum the

connectIng shell and sun gear from

rotatmg
The power flow takes place through
the mput shaft mto the rear clutch and
the front mternal gear With the sun

gear held statIonary the front plane

tary gears rotate around the sun gear
AT078
carrymg the front planet carner WIth
The front Fig AT 60 Power transmISSIOn dumlg 2 range
them planet carner bemg
splmed the output shaft causes
to

clockWISe rotation of the output shaft

at a reduced speed compared to the

speed of the mput shaft WIth an Rcar clutch ON

mcrease m torque As the low and

brake not the clock
reverse IS
engaged
wIse rotatIon of the output shaft
causes clockWISe rotatIon of rear mter
nal gear and the rear planet carner also
rotates around the sun gear m a

clockwISe dIrectIon The one way

clutch wu1 act to allow clockWIse
rotatIon of connectmg drum
A T079

When the manual valve @ IS POSI Fig AT 61 operation of each mechanism dUring 2 range
tioned at 2 the Ime pressure 7 IS
mtroduced IOto the Ime pressure CIr

CUltS I 2 and 4 The lIne pressure Front planctary gear

Rcar planetary gear
I IS led to the governor rear clutch
and 1st 2nd slnft valve @ as 10 the
case of D range The lIne pressure Outpul
2 locks the second lock valve @ and
IS led to the tIghtenIng sIde of the
band servo

The 2nd gear IS therefore fixed

regardless of vehIcle speed When

3rd shIfted to 2
D3 gear IS

the lIne pressure 4 enters the

range
throttle Ek
bl up valve J and pro
duces a
high pressure m the CIrCUIt
17 mcreasmg the throttle pressure
AT33l
16 The Ime pressure 7 IS there
fore mcreased and Fig AT 62 Operation of planetary gears durmg 2 range
qUIckly tightens
the ba nd

2 position causing the lme pres decrease from 3rd gear to 2nd
sure circuit 3 to be drained gear In this casethe speed change

Note range 3rd gear to 2 Therefore the hne pressure circuit quickly takes place because the line
D3
range 10 which is Situated 8t the release pressure 7 and other pressure are
If
D3 range 3rd gear IS shifted Side of the front clutch and servo is heightened by the action ofthe line
to 2
range during operatIon the also drained through the 2nd3rd pressure 4 m the same manner as
shift valve the speed to described under 2 range
manual valve @ is also slufted to @ forcing

AT 34
 Automatic Transmission

2 range 2nd gear

Front
Torque Conv rter
Clutch

011 Cooler
except A12
enol

Front

Lubtlcat n

Drain V I

Throttle

Drain
Vatva

t
@ 2nd 3Td Timing
Valva

@ Manu

Valva

PR

Nota Marked X r Drain

Lu pr Governor f
d pr P ny
Second
Governor Vatv
Governor VaIvtI
I Governor pressure

l Torque converter
c preDJr

Throttle pr

Fig AT 63 011 pressure ClrcU t diagram 2 range 2nd gear

AT 35
 Automatic Transmission

1 RANGE LOW GEAR

When 1 the
startmg m range

drIvmg gear IS locked to the low gear

ratio

In 1 range the rear clutch IS

engaged and the low and reverse brake

holds the connectmg drum and rear

from rotatmg The

planet carner

power flow takes place through the

mput shaft and mto the rear clutch
RotatIon of the rear clutch drIves the
clutch hub and front mternal gear
rear
AT076
The front mternal gear rotates the

front planetary gears clockwIse to

Fig AT 64 Power transmlS8 on durmg 1 range
cause the sun gear to rota te counter

clockwIse
CounterclockWISe rotatIon of the
Rear clutch ON
sun gear turns the rear planetary gear
clockwIse
The rear planet carner spllOed to

the connectmg drum IS held from

rotatmg by the low and reverse brake

The clockwISe rotation of the rear

planetary gears therefore rotates the

rear mternal gear and Internal drIve

flange The IOternal drIve flange IS

splIned to the output shaft and rotates

the output shaft clockWISe However ATOn

the output shaft rotates at a lower

Fig AT 65 Operation of each mechanism dUring 1 range
speed compared to that of the mput
shaft Tins IS caused by the fact that

the front planet carner rotates at the

Rcar
same speed as the output shaft m the Front planctary gear planetary gcar
same dIrection SInce the carner IS

to the output shaft The front

splIned
IOternal gear and planetary gear assem

Hcld
bly are rotatmg m the same dIrection
but the planet carner IS rotatmg at a

speed slower than the rmg gear So the

gear ratIo of tins speed range IS a

comblOatIon of the ratios prOVIded by

the front and rear
planetary gear as
semblIes

AT330

Fig AT 66 Operation of planetary gears dUring 1 range

When the manual valve @ IS POSI

110ned at I the lIne pressure 7 IS the rear clutch and governor The lIne the IOcrease of car speed The governor

applIed mto the lIne pressure CIrCUItS pressure 4 acts m the same manner as pressure 15 whIch acts on the
I 4 and 5 The oIl pressure m 5 2 1st 2nd sluft valve does not mcrease
III range
actuates the low and reverse brake SImilar to that of the 0 range until It overcomes the comb med force
after
bemg Illtroduced Illto the CirCUit the lIne pressure IOcreases WIth the of the lIne pressure 12 and the

12 through the 1st 2nd slnft valve degree of accelerator pedal depreSSIon sprlOg causmg no I st 2nd speed
@ and the 110e pressure 1 acts on and the lIne pressure decreases With change

AT 36
 Automatic Transmission

I range Low gear

ftVel
9 10
OtlCooler
except A12
1

Front

Lubrlcat n

elv

No

Line pressure IGovernor feed

r pressure
SKondary
Governor Valve
G rnor pr s Jre

Torque convert
pr Ial

Throttle prauu

Fig A T 67 0 1 pressure Clrcu t diagram 1 range Low gear

AT 37
 Automatic TransmIssion

I range 2nd gear

011 Cooler

except A12

no

Rn Lu Icatlon

Drain
I V
l
Front
n
Lubr t
Otlflce
Check
Ora nValv
Vatv

Throttle
Drain
Val

Q pr r

Regy ator Val a

@ Manua
Vatva

Nota Markm X Drain

X
Ir Go nor eMf prnaur
Li pr ond ry IIry
Prln
nor Vatva
Governor VaM Gov
G rnor p

Torque rUt pter

Thron pressur

Fig A T 68 011 pressure cm U1t dlllifram 1 range 2nd gear

AT 38
 Automatic Transmission

REMOVAL AND INSTAllATION

CONTENTS

TRANSMISSION ASSEMBLY AT 39 TRANSMISSION CONTROL LINKAGE 41

AT

REMOVAL AT 39 ADJUSTMENT AT41

INSTALLATION AT 39 Oil COOLER LINES AT42

TR NSMISSION 11 DIsconnect 011 cooler mlet and INSTALLATION

ASSEMBLY outlet tubes at transmISSIon case
For lflStallatIon of automatIc trans
12 Support engme by placmg a Jack
When the automatic
removlOg WIth miSSIon reverse the order of removal
under oIl pan a wooden block
transmISSIon from a vehIcle pay atten However observe the follow 109 Ill
between 011 pan and Jack
tion to the followmg pOlOtS stallatIon notes
1 Before removlOg the transmission
Support transmiSSIon by means of a
1 DrIve
transmiSSion Jack plate runout

mspect It WIth the aId of the Trouble 13

Turn crankshaft one full turn and
Detach englOe rear plate rubber
Shoot 109 Chart and remove only measure drIve runout WIth Indl
plug Remove bolts securmg torque plate
when consIdered to be absolutely catlllg finger of a dial gauge restlllg
converter to drIve plate See Figure
necessary
AT 69 agamst plate See Figure AT 70
2 Remove the transmiSSIOn WIth If III excess of
Replace drIve plate
utmost careand when mountlOg ob 05 mm 0 020 10

serve the tightenIng torque tables Do

MaxlfOum allowable runout
not exert excessive force
03mm 00121O
TotallOdlcator readlOg

REMOVAL

In removmg automatic transmiSSIon

from ehlcle proceed as follows

1 Disconnect battery ground cable
from termmal
2 shaft from
Disengage torsIon ac
A T287
celerator lInkage
3 Fig AT 69 RemOVIng torque converter
Jack up vehicle anq support ItS
attaching bolts
weIght on safety stands A hydraulIc
AT288
hOist or an open pit should be utilIzed Fig AT 70 Measurlng drIVe plate
If avaLlable runout

Ensure that safety precautions are

Note Before
removmg torque con
observed verter SCribe match marks on two 2 InstallatIon of torque converter
4 Remove shaft
propeller parts so that
they may be replaced Lme up notch 10 torque converter
in their onginal positions With that m I ll pump Be extremely
Note Plug up the opening III the rear
careful not to cause undue stresses m
extensIOn to prevent 011 from leak 14 Remove rear engme mount se
parts while mstallIng torque converter
tog out cunng bolts and crossmember mount See Figure AT 71
mg bolts
5 DIsconnect front exhaust tube Remove starter motor
15
6 Disconnect selector range lever 16 Remove bolts securIng transmis
from manual shaft SIon to engme After removmg these
7 Disconnect WIre connections at bolts support engme and transmiSSIon
mhlbltor SWitch WIth Jack and lower the Jack gradually
8 DIsconnect vacuum tube from untLl transmISSIon can be removed
vacuum dIaphragm and wire connec from under the car

tIons at downshIft solenoid

9 DISconnect speedometer cable Note Plug up any openmgs such as AT116

from rear extensIOn oil charging pipe 011 cooler tubes F g AT 71 Torque converter
10 DIsconnect 011 chargmg pIpe etc aligning cut

AT 39
 Automatic Transmission

A Notes
DIstance
More than 5
21 mm 0 846 10 a Refer to page AT S9 for Checking
and Adjusting InhIbitor SWItch
b Inspect and adjust switch as detail
ed above whenever it has to be
removed for semce

9 Check mhlbltor SWItch for opera

tIon

Starter should be mto op

brought
eration only when selector lever IS m

P and N It should not

posItIons
be started when lever IS 10 0 2

I and R pOSItIOns
Back up lamp should also lIght
when selector lever R
ATll7
IS
placed 10

posItion
10 Check level of 011 m transmIS

For detailed
Fig AT 73 Installmg torque converter sIon procedure see page
AT 58 for Checklllg OLl Level
11 Move selector lever through all
4 Bolt converter to drIve plate posItions to be sure that transmIssIon

operates correctly
Note Align chalk marks painted WIth hand brake engaged rotate
across both parts during disassem engIne at IdlIng speed WIthout dls
turbmg the above settmg move selec
bly process
tor lever N to 0 to 2
through
5 Mter converter IS mstalled rotate to I and to R A slight shock

crankshaft several turns and check to should be felt each time transmiSSIon
IS shifted
be sure that transmISSIon rotates freely
WIthout blOdlOg
Note See page AT S9 for Checking
6 Pour recommended automatic

transmISSion flUid up to correct level Engine Idling

through oIl charge pIpe
3 When connectmg torque con 7 Connect selector range lever to 12 Check to ensure that lIne pres
verter to transmIssIon dIs manual shaft correct To do thIS refer to
measure
OperatIon should be sure IS

tance A to ensure that they are camed out WIth manual and selector page AT 63 for Testmg Lme Pressure

correctly assembled See Figure levers 10 N 13 Perform stall test as descnbed 10

AT 73 8 Connect mhlbltor SWitch WIres page AT 60 for Stall Test

AT 40
 Automatic Transmission

TRANSMISSION
CONTROL LINKAGE

ADJUSTMENT

The of IS as
adjustment lInkage
of oLl level
IfOportant as InspectIon
for the automatic transmISSIOn
Thercfore great care should be
exercised because defectIve adjustment N
wu1 result m the breakdown of the
transmISSIOn

I PrIor control knob

to IOstallIng
set the dimenSion A to II to 12 mm

0433 to 0 472 m
D
2 Install control knob on lever At
l
the same time check the dImenSIOn
T
B and It to 0 1 to 1 1 mm
adjust
0 0039 to 00433 m by turnIng
pusher CD
3 Set
Loosen adjust nuts V con

trollever and selector lever CID at N

pOSItIon moreover set the clearance r r

C to I mID 0039 m by turnIng m

or out adJustmg nuts at trunnIon @
whIch connects selector rod @
AT 292

FIg AT 74 Controllmkage

AT 41
 Automatic Transmission

OIL COOLER LINES

d
rl
I
j I
I
ill
t b
i I r
1

1
L

LJ
Insert rubber hose until It butts
agamst second bead Tlgh temng torque
i
3 to S kg m 22 to 36 ft Ib AT333

Fig AT 76 011 cooler Imes

AT 42
 Automatic Transmission

MAJOR REPAIR OPERATION

CONTENTS

SERVICE NOTICE FOR DISASSEMBLY FRONT CLUTCH AT 50

AND ASSEMBLY AT 46 REAR CLUTCH AT 51

TORQUE CONVERTER AT 46 LOW REVERSE BRAKE AT 52

INSPECTION AT 46 SERVO PISTON AT 52

TRANSMISSION AT 46 GOVERNOR AT 53
DISASSEMBLY AT 46 OIL PUMP AT 53

INSPECTION AT 48 PLANETARY CARRIER AT 54

ASSEMBL Y AT 48 CONTROL VALVE AT 54

COMPONENT PARTS AT 50

AT3l2

TIghtemng torque ro of
bolts and nuts kg m ft Ib

@T 4 to S 29 to 36

@T 14 to 16 101 to 106
6S t07 S 47 toS4
for AI2 cngInc
4 S to S S H to 40
@T
06 to 0 8 4 3 to S 8
36tOStoSl07
ctJT 2 0 to 2 5 14 to 18
@T I 3 to I 8 9 4 to 13
t8JT o 5S to 0 7S 4 0 to S 4

jT o 2S to 0 3S I8 to 2 S

QJT I S to 4 0 11 to 29

@T 1 2 to 1 S 87 to 108
3 to 4 22 to 29
IT
AT290

Turn back two turns after 1gb temng Fig AT 79 Trghtenlng torque of bolts and nuts

AT 44
 Automatic Transmission

Brake band
Converter hOUSIng

Input shaft

Torque converter

One way clutch

ConnectIng drum
ear planetary gear

ConncctIng shell

Front planetary gear

Needle bearIng
Needle beanng
Bearmg race
Needlc bearIng

Beanng race

Governor ass y

011 dIstrIbutor

l
r t l

BcarIng
J
l
race

Oil chargIng pIpe Nccdle bearIng

ne w
y clutch

L
ParkIng
Inncr race

mechanIsm
I

1
10 Downshift solenOid

Vacuum
J
I
dIaphragm
L

1 r Spccdomcter ptnIon
I lIb tJ

Rcar extensIOn

iJ
CbItoOC

ofm

L
ParkIng mechanIsm

AT337

Fig AT 80 Components of automatic transmISSIOn

AT 45
 Automatic Transmission

SERVICE NOTICE 3 Blow aIr mto torque converter 5 Remove bolts whIch hold valve
and flush and dralO out gasolIne body to transmISSIOn case See
FOR DISASSEMBLY Figure
4 FIll converter WIth AT 83
torque
AND ASSEMBLY 011
torque converter approxImately
1 It IS advIsable that rcpaIr opera
05 lIter 1US pt UImp pt
i
tions be carned out m a dust proof 5 Agam blow aIr IOtO torque con

room
verter and dralO torque converter 011
2 Due to the differences of the
engme capaclltes the speClflcaltons of
for each model s
componcnt parts
transmISSIOn may be dIfferent They
do however have common
adjust
ment and repair
TRANSMISSION
procedures as well as
cleanIng and mspectlOn procedures DISASSEMBLY
outlmed heremafter

3 refer to
DUrIng repaIr operatIOns Dram 011 from the end of rear
ServIce Data and
6 Loosen lock nut @ on
pIston
SpecIficatIons sec
extensIOn Mount transmISSIon on

for the
stem CD as shown In
FIgure AT 84
tlOn correct parts for each TransmIssIOn Case Stand ST07870000
model Then tighten pIston stem m order to
or ST07860000 Remove 011 pan See
4 Before removmg any of subassem prevent front clutch drum from fall109
FIgure AT 82
when 011 pump IS Withdrawn
blIes thoroughly clean the outside of
the transmiSSIOn to prevent dIrt from
the mechanIcal
entenng parts
5 Do not use a waste rag Use a

nylon paper cloth

or

6 After disassemblIng wash all dIS

assembled parts and examme them to

see If there are
any worn damaged or
defective parts and how they are

affected Refer to Servtce Data for ATl18

the extent of that Fig AT 81 Remov ng 011 pan
damage Justifies
replacement
7 As rule seals and AT12l
a
packmgs
SImIlar parts once disassembled should Fig AT 84 Loosenmg band servo

be With
replaced new ones 2 Remove bolts seCUrIng converter

housmg to transmIssion case Remove 7 Pull out Input shaft

torque converter 8 WIthdraw oIl pump usmg SlIdIng

3 Remove Hammer ST25850000 Do not allow
speedometer pInIon

TORQUE CONVERTER sleeve bolt WIthdraw pInIon front clutch to come out of posItIon
4 Remove downshIft solenOId and and floor See
The converter IS a welded drop onto Figure
torque Do not leave dIa
vacuum dta phragm AT 85
construction and can not be disassem

bled
phragm rod at thiS stage of dIsassem
bly Rod IS assembled In top of vacu
um
dIaphragm See FIgure AT 82
INSPECTION

1 Check torque converter for any

sign of damage bendmg 011 leak or

deformation If necessary replace
2 Remove from and
rust pIlots
bosses completely
If torque converter 011 IS fouled or
contammated due to burnt clutch
flush the converter follows A T 85 Remov ng 011 pump
torque as Fig
1 Dram ou m torque converter
2 Pour lead
non gasolIne or

kerosene mto torque converter ap 9 Remove band strut Tins can be

ATl19
lIter
proxlfOately 05 iU S
1 done by loosenIng pIston stem further
Fig A T 82 Downsh ft solenOid and
pt U1mp pt vacuum dllJphragm See Figure AT 86

AT 46
 Automatic Transmission

I
AT123 I AT126

AT129
Fig AT 89 RemOVIng connectIng
Fig AT 86 RemovIng band strut drum Fig A T 92 RemOVIng drIVe and
drIVen plates

14 Remove snap rIngs and then

18 back SIde of
remove rear
planetary carner Internal ReachIng through
drum transmiSSIOn hex head
way clutch
one case remove
10 Remove brake band front gear connectmg
outer race and one way clutch that slotted bolts as shown In
FIgure
clutch and rear clutch as an assembled m

AT 93 To do thiS Hex head Ex

UnIt order use

11 Remove shell 15 Remove rear extensIon by tension ST25570001 ST25570000

connectIng rear

One way cluch thrust

secunng bolts lOner race
clutch hub and front planetary carner loosenIng See FIgure
A T 87 AT 90 washer piston return sprmg and thrust
as a umt See FIgure
spnng rmg can now be removed

AT127

AT124 FIg AT 90 RemOVIng rear extensIOn

AT130
Fig AT 87 Remov ng connecting shell
Fig AT 93 Removmg hex head slotted
bolt
16 Pull out output shaft remove 011

12 WIth the aId of Snap RIng Rc dIstrIbutor @ together WIth governor

See AT 91
mover HT69860000 pry snap nng off
valve CD Figure 19 Blowout low and reverse brake
See FIgure A T 88
output shaft pISton by directIng a Jet of air Into
hole In cylInder See FIgure AT 94

AT125 AT128

Fig AT 88 RemOVIng snap ring Fig AT 91 Removmg governor and

011 dIStributor
AT13l

Fig AT 94 Remov ng pIston

17 Pry off snap nng USIng a pm of
13 Remove drum and
connectmg plIers Remove retaInmg plate drIve
mner
gear of rear planetary carner as
plate drIven plate and dIsh plate In 20 Remove band servo by loosenIng
an assembly See Figure AT 89 that order See FIgure A T n attachnlg bolts

AT 47
 Automatic Transmission

Note If dIfficulty IS encountered in Gaskets and Oring

removmg retamer dIrect a Jet of aIr

I when the
toward release SIde as shown in Always use new
gaskets ST2S57000I
UnIts are to be dIsassembled
AT 95
FIgure ST2S490000
2 Check O rlOgs for burrs or crack
GG930IOOOO
mg If necessary replace WIth new

rlOgs

011 distributor

I Check for signs of wear on seal

AT135
nng and rmg groove replacmg WIth
new ones If found worn beyond use Fig AT 98 Installing one way clutch
Inner race
2 Check that clearance between seal
rmg and nng groove IS correct If out
ofspeCIfication replace wlnchever IS 2 After low and reverse brake has
Fig AT 95 RemOVing band servo worn beyond lImits Correct clearance been assembled measure the clearance
IS from 004 to 016 mm 00016 to between snap rIng D and retammg
00063 See AT 97
m Figure plate V Select proper thickness of
21 Pry snap rmgs D from both retammg plate to gIve correct nng to
ends of parkIng brake lever V and plate clearance See Figure A T 99
remove the lever Back off manual
Low and reverse brake
shaft lock nut @ and remove manual Clearance
clearance
See
plate @ and parkIng rod @ o 8 to 1 05 mm
Figure AT 96
0031 to 0 041 m

AT133

Fig AT 96 Remov ng manual plate

AT134

Fig AT 97 MeaSUring seal ring to

22 Remove mhlbltor sWitch and
rmg groove clearance
manual shaft by loosenIng two se AT136

cunng bolts Fig A T 99 MeasUring rmg to plate

clearance

ASSEMBLY

INSPECTION Assembly IS m reverse order of AvaIlable retammg plate

disassembly However observe the
See page AT 71 for SpeCifIcations
Torque converter housing followmg assembly notes
I After mstallIng pISton of low and and Adjustment
transmission case and
reverse brake assemble thrust spnng
rear extension
nng return sprIng thrust washer and
I Check for damage or crackmg If one way clutch Inner race Torque For mspechon procedure for low
necessary replace hex head slotted bolt to 1 3 to 1 8 and reverse brake see page AT 52 for
2 Check for dents marks
or score
kg m 9 4 to 13 ft Ib usmg Hex head Assembly
on matmg surfaces RepaIr as neces ExtenSion ST255710001 3 Install one way clutch so that the
sary ST25570000 Torque Wrench arrow mark IS toward front of
3 Check for marks
score or sIgns of GG93010000 and Socket ExtenSIon velucle It should be free to rotate

burnIng on extensIOn bushmg If neces ST25490000 ST2551200 I See only m clockWISe dIrectIon See FIgure
sary replace FIgure AT 98 AT 100

AT 48
 Automatic Transmission

Adjustment of total end play

Select 011 pump coverbearmg race

the
by calculatlOg followmg formula
T A B W
T

where

TT ReqUIred thickness of ou pump

AT137
cover beanng race mm m

Fig AT 100 One way clutch A Measured dIstance A mm 10

B Measured dIstance B mm 10

4 W Tlnckness of bearIng
mstallIng rear extensIOn
After race tempo
torque attaclnng bolts to 2 0 to 2 5 rarily mserted mm m

kg m 14 to 18 ft Ib Place manual Available 011 pump cover beanng

lever m P range and check to be sure
race
Front clutch 5 TransmissIOn
that rear output shaft IS
securely case

thrust washcr 6 011 pump gaskct

blocked Thickness mm 10
2 011 pump cover 7 011 pump cover
5 TIghten servo retamer temporan 3 Fron t clutch bearing race
1 2 0047
Iy at this stage of assembly 4 Rcar clutch
6 Place clutch wIth
rear
assembly I 4 0055
F g AT 103 End play
needle bearmg on front assembly 6 0063
7 Install rear clutch hub and front
1 Measure the dIstances A I 8 0 071
planetary carner as shown m Figure and
AT 101 C by shown
vernIer
calIpers as 10 2 0 0 079
AT 104
FIgure 22 0 087

Spectfied total end play

025 to 0 50 mm

0010 to 002010

Adjustment of front end play

Select front clutch thrust washer by

clutch
calculatIng the folloWlOg formula
Needle bcanng
AT142
T C D 0 2 mm

Fig AT 101 Installing planetary

BearIng race
I AT139
F

carner where
Fig AT 104 Measurmg the dIStances
A and fe T ReqUIred thIckness of front
8 Assemble shell and F
connectIng clutch thrust washer mm m
other parts up to front clutch 10
C Measured dIstance C mm 10
reverse order of disassembly
D Measured dIstance D mm 10
2 Measure the dIstances B and
D of 011 pump cover as shown 10
AvaIlable front clutch thrust
FIgure AT 105
washer

Thickness mm m

1 5 0059

1 7 0 067

I 9 0075

AT143
2 1 0083

Fig AT 102 Install ng connecting 2 3 0 091

shell
2 5 0098

9 2 7
Adjust total end play and front
Fig AT 1 05 Measurlng the d stances 0 106
end playas follows B and D

AT 49
 Automatic Transmission

Avatlable dtaphragIll rod

SpecIfied front end play
o 5 to 0 8 mm

0020 to 0 03110
DIstance measured L mm m
DIaphragm rod length mm 10

Under 25 55 I 006 1142

290
Notes
Correct tluckness of 2565 to 2605 I 010 to 1 026
a bearing race 1161
295
and thrust washer is always the one 26 15 to 26 55 1 030 to I 045 300 1 181
which IS nearest the calculated one
2665 to 27 05 1 049 to 1 065
b Installed thickness of oIl 1
305 201
pump
gasket is 4 mm 0 016
0 Ill Over 27 15 I 069 31 0 I 220

FRONT CLUTCH
10 Check to be sure that brake
servo pIston moves freely For detaIled
procedure refer to page AT 52 for Disassembly
Servo PIston Use care to prevent
pISton from commg placeout of
durUlg testlOg slOce servo retalOer IS
not tIghtened at thIS polOt of assem

bly
11 Make sure that brake band strut
IS
correctly mstalled Torque pIston
I 2 to 1 5
stem to kg m 8 7 to 11
ft Ib back off two full turns and
secure wIth lock nut Lock nut

tIghterung torque IS I 5 to 4 0 kg m
11 to 29 ft Ib

12 After lOhlbltor SWItch IS 10

stalled check to be that It oper

sure

ates each range For detaLl

properly 10
edprocedure refer to page AT 59 for
Checkmg and Adjusting Inhibitor
AT146
SWltch
I P ston 6 RetalRmg plate
13 Check the L between
length 2 CoIl spnng 7 Snap nng
case end to rod end of vacuum throttle 3 Front clutch drum 8 Dnvc plate
4 Dlshcd plate 9 re tamer
valve fully pushed m Then select Spnng
S Dnven platc
adequate dlllphragm rod of cor

respond 109 measured length See

Fig AT 108 Sectional v ew of
FIgure AT 106 front clutch

Pry off snap rIng CD with a

SUItable screwdrIver or a paIr of plIers

COMPONENT PARTS Remove a
retammg plate @ drIve
The transmISSion consIsts of many plate CID plate @
drIven and dIshed
small parts that are qUite alike 10 plate @ 10 the order hsted as shown
construction yet machmed to very m Figure AT 108

close tolerances When disassemblIng 2 Compress clutch sprIngs usmg

parts be sure to place them 10 order 10 Clutch Spong Compressor
AT145
part rack so they can be restored 10 ST25420001 or ST25420000 Re
the UOlt theIr proper pOSItIOns It IS from
m move snap rlOg @ spnng re

Fig AT 106 MeasUring the dlSdance also very Important to perform func tamer Remover
usmg Snap Rmg
L tlonal test whenever It ST25320001 See Figure AT 109
IS deSIgnated

AT 50
 Automatic Transmission

AT147 AT152

AT150
Fig AT 109 Removing snap Fig AT 113 front clutch
f Fig AT 111 Inserting clutch plate
Testmj
3 Take out sprmg retalller f and REAR CLUTCH
3 After clutch assembled make
sprIng @ See Figure AT 108
IS

4 Blowout pISton by dIrectlllg a Jet sure that clearance between snap nng
DI sembly
of aIr IOto hole III clutch drum See CD and retallllllg plate @ IS held
AT 110 wltlnn specIfied lunlts If necessary
Figure
try WIth other plates haVing different
thIckness until correct clearance IS

obtallled See Figure AT 112

SpeCifIed clearance
1 6 to I 8 mm

0063 to 0 071 m

AvaIlable retaInlllg plate

AT149
thIckness mm Ill
Fig AT 110 Blow ng out pISton

AT3l3

106 0 417 I Rear c1u tch drum Snap nng

Inspection 2 PISton Spnng retaIncr
108 0425
3 Dlshcd plate Dnve plate
Check for SIgnS of wear or dam 11 0 0 433 4 COli spong Dnven plate
age to clutch drIve plate faCIng If 5 Rc taInIng plate
112 0441
found worn or damaged excesSIvely
discard See ServIce Data for lImits II 4 0 449 Fig AT 114 Sectional v ew of
2 Check for rear clutch
wear on snap rIng and II 6 0 457
for weakened or broken coLl sprIng
If necessary replace wIth new ones
I Take out snap rlllg
SprIng retaIner should also be Ill @ retalllIng
dnve
plate CID plate @ drIven plate
spected for warpage
@ and dIshed plate 00 Same tech
nIque can be applIed as III dlsassem
Assembly
blmg front clutch See FIgure AT 114
I Assembly IS III reverse the order 2 Remove snap rIng from coIl
of dIsassembly Dip all parts m clean spnng retaIner See Figure AT 115
automatIc transmISsIOn flUId before

InstallIng
2 Lllle drIven
up plates so that
stnpped arcs are properly alIgned
paYlllg particular attentIOn to the loca
tion of 011 holes m clutch drum See Fig AT 112 MeaSUring rmg to plate
AT III clearance
FIgure

Note The number of drive and dnven 4 Testlllg front clutch

plates vanes With the type of With front clutch assembled on 011
vehicle For detailed InformatIon dIrect
pump cover a
Jet of air Into
see Semce Data Specifica hole m clutch drum See Figure
tIOns AT 113 Fig AT 115 RemOVIng snap rmg

AT 51
 Automatic Transmission

3 Blowout piston by dtrectmg a Jet 3 WIthout chsturbmg the above set

of aIr mto hole m clutch drum See ting check to be sure that clearance

Figure AT 116 between snap rIng and retammg plate

IS wlthm specIfIed lImIts If necessary

use other plates of dIfferent thIckness

until correct clearance IS obtalOed

SpeCIfied clearance
o 80 to I 05 mm

0031 to 0 041 m

AT157 4 Blow compressed au mto 011 hole

Fig AT 118 Testing rear clutch m low reverse brake to test for
AT155
definIte brake operation as shown 10

FIgure AT 119
Fig AT 116 Blow ng outpISton

Inspection LOW REVERSE BRAKE

Refer to page AT 51 for Inspection Disassembly

of Front Clutch
1 Follow steps as deSCrIbed 10 page
Assembly AT 46 for TransmiSSIon DIsassembly
2 Blowout piston by dtrectmg a Jet
Assemble 10 reverse the order of
of aIr IOtO 011 hole 10 clutch pIston
disassembly Dip all parts 10 clean
automatic transmISsIon flUId before
Inspection
assemblmg Note that the number of AT158
drIve and drIven plates vanes with type 1 Check drIve plate facmg for wear Fig AT 119 Testing low reverse

of velncle For details refer to brake

or
damage If necessary replace Refer
ServIce D ata Speclficatlons to Service Data SpeCifications for
1 After rear clutch IS assembled tolerances
2 SERVO PISTON
check to be sure that clearance be Test pIston sprIng for
return
weakness Discard Ifweakened beyond
tween snap rlOg D and retammg plate
use Disassembly
00 IS held wltlun prescnbed toler
3 With
ances See FIgure AT 117 Replace faulty parts new
1 Blowout pIston by dIrectmg a Jet
ones
of aIr mto hole m release side of
SpecIfIed clearance
1 0 to I 5 mm piston
Assembly 2 Remove return
0 039 to 0059 10 servo piston
1 Mter low SprIng
reverse pIston IS

mstalled assemble thrust sprIng nng

return sprIng thrust washer and one Inspection

way clutch mner race Usmg Hex head

Check pIston for wear damage or

ExtenSIon ST25570001
other faults winch mterfere With
might
ST25570000 torque hex head
proper brake operation
slotted bolt to 1 3 to 1 8 kg m 9 4 to
I Ht Ib

2 Insert dIshed drIven

plate plate
drIve and
AT156
plate retammg plate mto
transmIssIon case 10 that order Install
8 AT 117
F MeasUring ring to
snap rIng to secure the mstallatlon
plate clearance

2 TestlOg rear clutch

Install rear clutch on 011 pump

cover
Note The number of drive and driven
Blow compressed air mto 011 hole WIth type of vehIcle
plates vanes
to test for defmlte clutch operatIon as For detaIled mfonnatIon refer to AT159
shown 10
FIgure AT 118 ServIce Data SpeCIfications Fig AT 120 Remov ng pISton

AT 52
 Automatic Transmission

3 If pnmary governor IS to be disas

sembled for any purpose remove

sprmg seat pnmary governor valve

sprmg and sprlOg seat

Inspection

I Check valve for

I Anchor cnd pm faulty condItIon
2 Band strut Replace sprlOg If found weakened
3 Apply beyond use Faulty piston should also
4 Release
be replaced WIth a new one
S Return spnng
2 Examme to see If prImary gover
6 Band servo piston stem
7 Band servo pIston nor slIdes freely WIthout blOdmg
8 Servo retamer 3 To determlOe If secondary gover
9 Brakc band assembly nor IS 10 good condition blow aIr
10 TransmissIOn case
under lIght pressure mto hole at A

Fig AT 121 Sect onal v ew of servo pISton and lIsten for nOIse like that of a

model plane
Assembly
Assembly
I PrIor to assembly dip
all parts m
clean automatic transmIssIon flUId Reverse dIsassembly procedure to

Reverse assemble governor

dIsassembly procedure to
assemble brake
Note Do not confuse
2 Use extreme care to aVOId damag primary gover
mg rubber rmg when nor th secondary governor After
IOstallIng seal w

lace tnstallation check that spring IS not

3 Blow compressed from deflected
aIr
apply
SIde of piston to test for definIte
Fig AT 123
piston operation as shown 10 FIgure
AT 122

GOVERNOR
OIL PUMP
Disassembly

1 Disassembly
Separate governor from oIl dls
tnbutor by unscrewmg attachmg bolts I Free cover from
pump pump
2 To disassemble secondary gover
housmg by removmg attaclung bolts
nor remove sprIng seat sprmg and 2 Take out lOner and outer gears
secondary governor valve from valve from pump housmg
body m that order as shown 10 FIgure
AT 124
Inspection
To control valve

AT160 Governor Inspect for wear or

damage to

AT 122 Testing p ston pressurc IS gear teeth Replace rubber rmg If

Fig
U
Apply s de fround damaged beyond use
2 USlOg a straight edge and feelers
measure pump and gear clearances as

follows

Clearance between mner or outer

gear and pump cover See FIgure

AT 125

From control valve

4 WIth apply sIde of pIston plugged Standard tclceaera
Lme pressure I AT090
With thumb blow compressed aIr IOto o 02 to 0 04 l
mn
1 Pnmary govcrnor 4 011 dlstnbutor
cylmder from release side as shown 10 00008 to 0001610
2 5 Output shaft
Secondary govcrnor
FIgure AT 123 If retalOer IS raIsed a
3 Governor valve body
lIttle It IS an mdlcatlon that attachmg Replace If over 008 mm 00031
Fig AT 124 Testing secondary
bolts loose for
are
callmg retightenIng governor m

AT 53
 Automatic Transmission

Replace If over 080 mm 0031

m

CONTROL VALVE

The control valve assembly consIsts

of many precIsIon parts and requires
extreme care when It has to be re

moved and servIced It IS good practice

to part rack that
AT264 place parts 10 a so

AT162 they can bc reassembled 10 valve body

Fig AT 128 MeaSUring runou t
F g AT 125 Measuring clearance m theIr proper posItIons Added care

5 should also be exercised to prevent

Tighten pump securIng bolts to
Clearance between seal rmg and specifIed torque 0 6 to 0 8 kg m 4 3 sprmgs and other small parts from
See AT 126
rIng groove FIgure to 5 8 ft Ib bemg scattered and lost
Standard clearance Before assembly dIp all parts 10

004 to 016 mm Note Be sure td alIgn converter clean automatIc transmISSIOn flUid and
00016 to 0006310 housmg seCUring boIt holes check to be certam that they are free
of lInt and other mmute partIcles If
6 Agam check the runout of 011 clutch or band IS burnt or If 011
pump cover becomes fouled the control valve as

sembly should be dIsassembled and

Note When former 011 Pump Assem flushed
bling Gauge i L to be used make a

screw hole in side of it Disassembly

c
o Jldt
I Remove bolts and nuts wluch
Bolts may be

pL
retam 011 stramer re

r
PLANETARY CARRIER moved WIth a screwdrIver but It IS

recommended that Hexagon Wrench

AT165 The planetary carner cannot be
AT 126 HT61000800 and Spmner Handle
Fig MeaSUring clearance diVided mto Its IOdlVldual components
HT62350000 be used See FIgure
If any part of component IS faulty
AT 130
Assembly replace the carner as a UnIt

I Set up pump housmg with mner

Inspection
and outer pump gears on It
2 Check clearance between pInIon
Usmg 011 Pump Assemblmg
washer and planetary carner WIth a
Gauge ST25580000 mstall pump
cover to pump housmg as shown m feeler See Figure AT 129
Figure AT 127 Standard clearance
o 20 to 0 70 mm

0008 to 0028 10

Clearance

AT168

Frg AT 130 D sassemblmg valve

body

2 Remove attaclnng bolts WIth

bolts removed lower valve body sepa
AT166 rate plate and upper valve body are

free for removal See FIgure AT 131

F g AT 127 011 pump
Centermg

3 Temporanly tighten pump se

CUrIng bolts Note Do not allow onfice check

AT167 valve and valve spnng 10 lower valve
4 Set the runout of 011 pump cover

wlthm 007 mm 00028 10 total Fig AT 129 MeasUring pmlOn body to be scattered and lost when
mdlcator readmg See Figure AT 128 washer to carrier clearance remOVIng separate plate

AT 54
 Automatic TransmissIon

Note Do not work It off WIth sC rew

drIvers To avoid damagmg machine

screws do not work It off with
screwdrIver

AT169
Fig AT 132 Removmg manual
valve
Fig AT 131 Remov ng separate
plate
5 Remove SIde plate pull out pres
valve second lock valve
sure regulator
regulator plug and two valve
pressure
spnngs
3 Pull out manual valve as shown m 6 Remove slde plate With SIde

FIgure AT 132 plate removed solenOId downshift

4 Remove sIde plate Take out valve throttle back up valve vacuum
1st 2nd sluft valve 2nd 3rd shift throttle valve 2nd 3rd tlfOlOg valve
valve pressure modIfier valve and HT61000800 AT17l and three valve sprmgs are free for
thrce valve spnngs See AT 133
FIgure F g AT 133 Removing s de plate removal

Spring seat

V @
Prcssurc regulator valve

Pressure regulator sleeve

Pressure regulator plug
1
Sccond lock valve

valve body
Upper

Lower valve body

Manual valve

011 straIRcr

ST338

Fig AT 134 Component parts of control valve

Inspection

I Check valves for sign of tension If necessary 5 Check oIl passages 10 valve body
burnIng replace
and If necessary for sIgn of damage and other condI
replace 4 Examme for any sign of damage
2 Check to be certam that 011 marks If which Interfere WIth
or score on separate plate tions might
stramer IS m
good condition If found left unl1eeded ou Will bypass correct proper valve operatIOn
damaged In any manner discard ou passages causlOg many types of 6 Check bolts for strIpped threads
3 Test valve spnngs for weakened abnormalIties 10 the system Replace as
requIred

AT 55
 Automatic Transmission

Valve spring chart

Installed
Mean coLl
Wire dla No of Free
Valve sprIng dIa
length
mm 10 actIve coli mm 10 Length Load
mm 10
mm 10 kg lb

Manual detent 13 00512 60 150

0 2362 324 1 276 26 5 1 043 5 5 12

Pressure I 2 0 0472 10 5 04134 130 43 0

regulator 1 693 23 5 0 925 28 6 2

Pressure modIfIer 04 0 0157 80 0 3150 50 185 0728 90 0 3543 o I 0 2

1 st 2nd shIft o 6 0 0236 6 0 0 2362 160 320 1 260 160 0 630 0625 4
1

2nd 3rd shIft 07 0 0276 62 0 2441 180 410 1614 17 0 0 669 1 40 3 1

2nd 3rd tlmmg o 7 0 0276 5 5 02165 150 1

325 280 270 I 063 o 55 I 2

Throttle back up 08 0 0315 6 5 0 2559 140 360 1417 188 0 740 I 92 4 2

SolenoId downshift 055 00217 50 01969 120 22 0 0 866 12 5 0492 060 1 3

Second lock 055 00217 50 01969 160 335 1319 210 0 827 060 1 3

Throttle reltef 09 0 0354 5 6 0 2205 140 268 1 055 190 0748 219 48

Onflce check o 2 0 0079 48 0 1890 150 215 0 846 II 5 0453 001 002

PrlfOary governor 045 00177 8 3 0 3268 50 21 8 0 858 7 5 02953 0215 05

Secondary governor o 7 0 0276 8 5 0 3346 55 25 I 0 988 105 0413 110 24

2 Install Side Install onfice check valve valve

plates usmg Torque 3
Dnver ST25160000 and Hexagon spnng throttle relIef valve spnng and
Wrench HT61000800 See Figure steel ball 10 valve body
AT 136

TightenIng torque
Note spring so
Install check valve and
that they properly
are posItioned in
ATl72 025 to 0 35 kg m
valve body See Figure AT 138
Fig AT 135 Valve sprmg 19 to 2 5 ft lb

4 1 nstall upper and lower valves

See AT 137
Assembly Ftgure
Tlghtemng torque
Assemble 10 reverse order of disas
o 25 to 0 35 kg m

sembly However observe the follow I 8 to 2 5 ft lb

109 assembly notes Refer to Valve
Reamer bolt tlghtemng torque
Spnng Chart and Illustration 10 as o 5 to 0 7 kg m
semblIng valve spnngs Dip all parts 10 36 to 5 I ft lb
clean automatIc transmISSion flUId be
fore assembly Tighten parts to
speCIfi
cations when deSignated
1 SlIde valve mto valve body and be
particularly careful that they are not AT173

forced 10 any way Fig AT 136 Installing Side plate

AT 56
 Automatic TransmiSSion

5 Install 011 stramer

TightenIng torque
o 25 to 0 35 kg m

1 8 to 2 5 ft Ib

F g AT 137 Installing valve body

Throttle rehcf valvc

AT342

F g AT 138 PosItIOn of check valve and prlng

AT 57
 Automatic Transmission

TROUBLE DIAGNOSIS AND ADJUSTMENT

CONTENTS

INSPECTION AND ADJUSTMENT ROAD TEST AT 51

BEFORE TROUBLE DIAGNOSIS AT 58 CHECKING SPEED CHANGING
TESTING INSTRUMENT FOR CONDITION AT 51
INSPECTION AT 58 CAR SPEED AT GEAR SHIFT AT 51
CHECKING OIL LEVEL AT 58 CHECKING ITEMS DURING SPEED
INSPECTION AND REPAIR OF CHANGE AT 52
OIL LEAKAGE AT 59 SHIFT SCHEDULE AT 52
CHECKING ENGINE IDLING LINE PRESSURE TEST AT 53
REVOLUTION AT 59 LINE PRESSURE governor feed pressure AT 54
CHECKING AND ADJUSTING KICKDOWN JUDGEMENT IN MEASURING LINE
SWITCH AND DOWNSHIFT SOLENOID AT 59 PRESSURE AT 54
INSPECTION AND ADJUSTMENT OF TROUBLE SHOOTING CHART AT 54
MANUAL LINKAGE AT 59 INSPECTING ITEMS AT 54
CHECKING AND ADJUSTING INHIBITOR TROUBLE SHOOTING CHART FOR 3N71B
SWITCH AT 59 AUTOMATIC TRANSMISSION AT 55
STALL TEST AT 50 TROUBLE SHOOTING GUIDE FOR 3N71B
STALL TEST PROCEDURES AT 50 AUTOMATIC TRANSMISSION AT 58
JUDGEMENT AT 50

SlOce most automaltc transmIssIon 3 011 pressure gauge englOe and run It unltl normal operat

troubles be It
can
repaIred by sImple IS convenIent to IOstall these 109 temperatures otl temperature 50
adjustment do not dIsassemble 1fO mstruments m a way that allows to 800C 122 to 1760F ApproXI
mediately measurements to be made from the mately ten mmute of operatIon wLlI
FlfStly IOspect and adjust the auto dnver s seat raise the temperature to thIS range
matIc transmiSSIon 10 place uttllZmg and engme IdlIng condItIons are stabi
the Trouble ShOOtlOg Chart CHECKING OIL LEVEL lIZed Then apply the brakes and
If the trouble can not be solved by move the transmISsIOn shIft lever
In check 109 the automatIc transmIs
thIS procedure and dIsas all dnve poslltons and place It
remove

sion the 011 level and the condllton of

through
semble the automaltc transmission It P
10
park posItIon In thIS IOspec
otl around the otllevel gauge should be
IS adVISable to check overhaul and the must be level
5 000 km
lton car
placed on a
exammed every 3 000
repaIr each part m the order lIsted 10 surface
the Trouble mues ThIS IS an easy and effecltve
ShootlOg Chart The amount of the otl vanes WIth
I In the Trouble ShOOtlOg Chart trouble shOOtlOg procedure SlOce some
the As rule the 011 level
temperature a

the dIagnOSIs Items are

arranged ac changes m 011 condItIOn are often
must be measured after ItS tempera
lInked WIth developed troubles
cordlOg to dIfficulty from easy to ture becomes suffiCiently high
dIfficult therefore please follow these I Ftll the 011 to the lIne H The
Items The transmISSion should not be For mstance dIfference of capaclltes between both
removed unless necessary L
Lack of otl causes
H and IS
approxunately 0 4
2 Tests and adjustments should be faulty operalton lIter UU S and
pt YcImp pt
made on the baSIS of standard values by maklOg the clutches and brakes therefore do not fill the lIne
beyond
and the data should be recorded slIp resultlOg 10 severe wear H
ThIS because the otl pump sucks
IS
2 When tOpplOg and
Up changlOg
aIr
causmg otl foamlOg thus rapIdly oLl should be taken to prevent
care

INSPECTION AND deterIOratlOg the otl qualIty and pro

mlXlOg the 011 With dust and water
dUClOg sludge and varnIsh
ADJUSTMENT ExceSSIve 011 IS also bad because of
BEFORE 011 foammg causedby the gears sltrnng Inspection oil condition

TROUBLE DIAGNOSIS up the 011 DUflng high speed drIVlOg

the transmIssIon often The condllton of 011 SltCklOg to the
excesSive ou m

level gauge mdlcates whether to over

TESTING INSTRUMENT FOR blows out from the breather
haul and repaIr the transmiSSIon or
INSPECTION
oil level look for the faulty part
1
Measuring
Engme tachometer If the 011 has deterIorated to a
2 Vacuum gauge To check the flUid level start the varnIsh lIke qualIty It causes the con

AT 58
 Automatic Transmission

trol valve to stick Blackened 011 mdl red wme so It IS easily dlstm Note Watch for od leakage from

cates a burned clutch brake band etc gUlshed from engme 011 or gear 011 transmISSion case

dust
In these cases the transmIssIon must Wipe off the leakmg oLl and
be and detect the spot of oLl leakage INSPECTION AND
replaced
Use nonflammable organIc solvent ADJ USTMENT OF MANUAL
such as carbon tetrachlonde for LINKAGE
Notes
wlplOg
a In checkmg 011 level use special The adjustment of manual lInkage
Raise the oLl remperature by oper
paper cloth to handle the level IS
equally IfOportant as InspectIon of
gauge and be careful not to let the atmg the engme and sluft the lever 011 Level for the automatic transmIs
to 0 to Increase the 011 pressure
scraps of paper and cloth stick to sion Therefore great care should be
the gauge The spot of 011 leakage will then be exerCIsed because Incorrect adjustment
r
b Insert the gauge found more easily
fully and take It wLlI result In the breakdown of the
out qUickly before splaslung od transmiSSIon

adheres to the gauge Then observe Note As odleakage from the breath
the level er does not takeplace except when Inspection
c Use automatic tr nsmisslOn flUid running at high speed It IS unpos

SIble to locate thIS leakage WIth Pull the selector lever toward you
having DEXRON Identifications
and turn It as far as P to 1 range
the 3N71 B automatic trans vehIcle stationary
only in
where clIcks wLlI be felt hand ThiS
mISSIOn by
IS the detent of manual valve the
d Pay attention because the od to be CHECKING ENGINE IDLING 10

valve and mdlcates the correct

used differs from that used 10 the REVOLUTION body
of the lever
NIssan Full AutomatIc TransmIS posItion
The engme revolution should
IdlIng
sIon 3N71A Never mixthe oils Inspect whether the pOInter of
be properly adjusted
selector dial corresponds to thISpOInt
I If the engme revolution IS too low
and also whether the lever comes 10
INSPECTION AND REPAIR the engme does not operate smoothly
OF OIL LEAKAGE alIgnment With the steppIng of POSI
and If too high a strong shock or
tIon plate when It IS released
when
When 011 ieakage takes place the creep develops changIng over

the covered from N to 0 or R

portIOn near
leakage IS Adjustment
with 011 detec
presentlOg difficulty 10

the Therefore the CHECKING AND ADJUSTING ThIS procedure can be accomplIsh
tIng spot places
ed
where oLl seals and gaskets are KICKDOWN SWITCH AND by referrmg to page AT 40 for
enumerated below DOWNSHIFT SOLENOID Removal and InstallatIon
eqUIpped are

I Converter housmg When the kIck down operatIon IS

Rubber nng of 011 pump housmg CHECKING AND ADJUSTING
not made properly or the speed chang
011 seal of oLl pump housmg INHIBITOR SWITCH
Ing pOInt IS too high check the kIck
OLl seal of engme crankshaft
down SWitch downshIft solenOId and the
Bolts of converter housmg to case
The mhlbltor SWItch lIghts re

wlflng between them When the Ignt verse lamp 10 the range R of the
2 TransmISSIon and rear extensIon
tlOn key IS pOSItioned at the 1st stage transmIssIon operatIon and also rotates
Junction of transmISSion and rear
and the accelerator pedal IS
depressed the starter motor In the ranges N
extensIon
the SWItch contact should be
OLl cooler tube or 011 tube con
deeply and P

closed and the solenOId should clIck If CD

nectors
It does not clIck It IOdlcates a fault
011 pan
Then check each WIth the
Ou pressure mspectIon holes Refer part testmg
mstruments See FIgure AT 139 cv
toFIgure AT 144
Mountmg por lOn of vacuum dIa
phragm and downshift solenOId
Breather and 011 chargIng pIpe

Speedometer plOlOn sleeve

011 seal of rear extension CID ATl09

I Inhtbltor SWItch 6 Nut

Toexactly locate the place of 011 2 Manual shaft 7 Washer
3 Washer 8 Inhlbtlor SWItch
leakage proceed as follows
4 Nut 9 Range select lever
Place the vehIcle pit and by
m a

S Manual platc
the leaked 011 determme
samplIng
If It the torque converter 011 The
IS ATlOS
Fig AT 140 Construction of mh b tor
torque converter 011 has a color like Fig AT 139 Downsh ft solenOId sw tch

AT 59
 Automatic Transmission

2 Secure the front and rear wheels

Check whether the reverse lamp
and the starter motor operate normal WIth chocks and apply the hand brake

ly 10 these ranges If there IS any

Be sure to depress the brake pedal
problem first check the lInkage If no fIrmly WIth the left foot before depres
fault IS found 10 the lInkage check the smg the accelerator pedal

mhlbltor sWItch 3 Throw the selector lever mto the

the manual lever from the range D

Separate
4
remote control selector rod and turn Slowly depress the accelerator
the range select lever to N pedal untLl the throttle valve IS fully
opened QUIckly read and record the
revolutIon when the
Note In the posItion N the slot of engme engme

the manual shaft IS vertIcal begms to steadIly

rotate and then
release the accelerator pedal
5 ShIft the selector lever to N
Usmg a tester check the two
and the at
black yellow BY wIres from the 10 operate engme approxI
1 200 rpm for more than one
hlbltor sWItch the ranges
10 N and mately
mmute to cool down the
P and the two red black RB WIres torque con

R Turn verter oLl and coolant

m the range for contmUlty
select lever 10 both dIrectIons
6 Make slmLlar stall tests m ranges
range
2 1 and R
from each lever set posItIon and check
each contmUlty range It IS normal If
the Note The stall test operation as
electrICity IS on wlnle the lever IS

wlthm an angle of about 30 on both speCIfied in Item 4 should be

Sides from each lever set lIne How STALL TEST made Within fIVe seconds If It takes

ever If ItS contmUlty range IS obvIOUS too long the ot detenorates and
The purpose of thIS test IS to check the clutches brake and band
ly unequal on both SIdes adjustment IS are
the transmISSIon and for affected SuffiCIent
requIred engme adversely
trouble
If any malfunctIon IS found un by measunng the maxImum
coolIng time should be gIven be
numbers of revolutions of the engme tween each test for the four ranges
screw the fastenlOg nut of the range
whJ e vehIcle IS held 10 a stalled condi D 2 I and R
selector lever and two fastenIng bolts
tIon The carburetor IS m full throttle
of the SWItch body and then remove
the selector
the machme screw under the SWItch operation WIth lever m

0 2 and I JUDGEMENT
body Adjust the manual shaft correct
ranges respectively
Compare the Measured results WIth the
ly to the pOSItIon N by means of the 1 High stall revolutIon more than
standard values
selector lever When the slot of the standard revolution
shaft becomes vertIcal the detent If the engme revolution m stall
works to Components to be te ted and
posItIon the shaft correctly condItion IS
htgher than the standard
test Items
With a clIckmg sound values It mdlcates that one or more

Move the SWItch aSIde

shghtly so 1 Clutches brake and band m trans clutches 10 the transmISSion are slIp
that the screw hole wul be alIgned for pmg and therefore no further test IS
mIssIon shppmg
WIth the pm hole of the mternal rotor 2 for proper func reqUIred
Torque converter
combmed WIth the manual shaft and For the abnormalItIes
tlonmg followmg
check theIr alIgnment by msertIng a 3 for overall the respectIve causes are presumed
Engme properly
1 5 00591 dIameter pm mto Low lIne
HIgh rpm 10 all ranges
mm 10

the holes If the alIgnment IS correct

STALL TEST PROCEDURES pressure
fastenthe SWItch body With the bolts 0 2 and I and
High rpm 10
Before test 109 check the engme 011
pull out the pm tIghten up the screw normal rpm m R Rear clutch
10 the hole and fasten the selector and torque converter oJ warm up the
slIppmg
lever as beforeCheck the contmUlty engme coolIng water to SUItable tem
High rpm m 0 and 2 and
agam With the tester If the malfunc perature by runnIng at 1 200 rpm With I
normal rpm m One way
tIon stIll remalOS replace the IOhlbltor the selector lever m the range P for clutch slIppmg
SWitch several mmutes Warm up the torque HIgh rpm 10 R only Front
converter ou to SUItable temperature clutch or low and reverse brake
60 to 1000C 140 to 2120F slIppmg
1 Mount the engme tachometer at a
location that allows good vlSlbulty To determme wluch IS slIppmg
from the dnver s seat and put a mark front clutch or low and reverse brake
on specIfIed revolutions on the meter a road test IS needed

AT 60
 AutomatIc Transmission

If wlnle coastIng after startIng CHECKING SPEED

ROAD TEST
wIth the lever 10 1 engIne range CHANGING CONDITIOlll
brakIng does not work properly the An accurate knowledge of the auto
low and brake mattc transmiSSIon IS reqUIred for an
The feelIng durlOg gear
drIver s
reverse IS slIppIng
exact diagnOSIs changes also be checked at
should
OtherwISe the front clutch IS slIppIng
Shppmg of the band brake IS dlf It IS recommended that a dIagnOSIs tentIvely
I A sharp shock or unsmoothness IS
ficult to ascertaIn However If It gUIde chart WIth the standard velncle
felt dUrIng a gear change
occurs WIth the lever 10 2 range speeds for each stage of the up and
2 A gear cha ge IS made WIth a long
englOe revolutIon IOcreases up to the downshIftmgs be prepared Measured
vehIcle speeds are to be ruled m the and draggIng feelIng
same level as 10 1 st range It IS
to check It 10 the stall test adJomlOg column after each testIng These mdlcate that the throttle
IfOposslble
Also It IS adVIsable to mount a pressure IS too low or some valve

2 Standard stall revolutIon stopper for posItionIng the throttle connected to the throttle IS faulty
If the engme revolutIon In stall openIng
condition IS wlthlO the standard
values the control elements are nor

the 0
1
mally operatIng In ranges
2 1 and R CAR SPEED AT GEAR SHIFT
Also the engIne and one way
clutch of the torque converter are

normal 10
performance and operatIon
Propeller shaft
The one way clutch of the torque revolutIOn
Throttle openUlJ
converter however sometlfOes stIcks Gear shut
mmHI pm
ThIS IS determlOed 10 the road test

1 840 10 340
2
OJ D2
3 Lower stall revolutIon than stand KJckdown 3 340 to 3 840
O2 to
OJ
0 3 460 to 2 960
ard revolution OJ O2
O2 DJ 1 790 to I 290
If the engIne revolutIOn In stall
condItion 330 to 830
IS lower than the standard DI O2
0 1 to 2
O2 120 220
values It mdlcates that the engme IS In Half throttle
or
200 OJ O2 1 350 to 850
to
abnormal condItIon or the torque con OJ DI
700 Max
O2 01
verter s one way clutch IS slIppIng
FuU throtlle
1 860 to I 360
0 12 II
4 Others
If the MlOunum throttle
1 acceleratIng performance 12 I 1 860 10 1 360
450
poor until
IS vehIcle speed of approXI

mately 50 km h 30 MPH IS attaIned Reduce the speed by sluftmg to J range from 0 range output shaft 2 000 rpm

and then normal that

beyond speed It
can be Judged that the torque con

verter s one way clutch IS slIppIng Note Car speed can be calculated by the following formula
2 If the torque converter s one

way clutch sticks vehIcle speed can

2xlrxrxN x60
not exceed approximately 80 km h P
V
50 MPH In the road test In such a

RF x 1 000
case the torque converter oIl tempera
ture rISes abnormally and so speCIal

care IS
reqUIred where V Carspeed h
km
3 If the transmISSion does not N Propeller shaft revoh tlon rpm
opera te properly at all vehIcle speeds RPF Final gear ratIo
It IndIcates poor engme performance r Tire effectIve radius 10

lr The ratio of CIrcumference of a CIrcle to ItS diameter 314

AT 51
 Automatic Transmission

CHECKING ITEMS DURING SHIFT SCHEDULE

SPEED CHANGE

1 In 0 range gear changes 01 o

3 2 3
effected In R Klckdown range 2
02 03 are
Full throttle 1 2 I 2

range the speed does not mcrease 12 2

100
2 V
2 The klckdown operates properly I
1
I
3 By movmg the lever from 0 to g
i L3
2 I
I
I
I 2 200
gear changes 03 12 11 I
effected In the ranges and e
are
12 I
the engllle braklllg works pro S I
11 300
I
Z S
perly 1 L11
4 In the does not mmHg I
speed m
oo I
crease
I
5 Should be ftxed at 2 3SA
qUIckly I

range 5000 500 1000 1500 2000 2500 3000 3500 ooo

6 In P vehicle be
can parked Output shaft speed rpm AT1l0
properly
Ifany malfunctIOn occurs III second

gear dunng the road test that IS If

vehicle shakes drags or
slIngs whLle
shlftmg up from 0 dIrectly to
I

03 or m
up from 01
shlftlOg to

the brake band should be ad

02
Justed If these problems remalll after
the brake band IS adjusted check the
servo piston seal for otlleakage

AT 62
 Automatic Transmission

Car speed propeller shaft revolution chart Approximate figures

4 000

II

610 SSS

610
3 000

Ii
E
E

c 2 000
0

0
e
f
I

j
l

g
1 000
t7
j

o
o 20 40 60 80 100 120 140 h
km

o 10 20 30 40 so 60 70 80 MPH

Car speed

AT343

Fig AT 143 Car speed Propeller shaft revolut on chart

LINE PRESSURE case See Figure AT 144

The lIne pressure measurement IS
TEST
begun at IdlIng and taken step by step
When any slIppmg occurs m clutch by enlargIng the throttle openIng
or brake or the feelIng dunng a speed I A sharp shock U1 upshlftmg or
too ugh changlOg speeds are caused
change IS not correct the lIne pressure
must be checked mostly by too htgh throttle pressure
Measunng IlOe pressure done 2 SlIppmg or mcapabllIty of opera
IS
by a
I LIRC
tIon IS mostly due to 011 pressure prcssurc
pressure gauge attached to two pres
2 Governor feed
sure measurIng holes after removmg leakage wlthm the gear trams or spool 3 Servo rclease pressure ATl13
blmd plugs located at transmiSSIon valve
Fig AT 144 MeaSUring Ime pressure

AT 63
 Automatic Transmission

LINE PRESSURE governor feed pressure

At cut back pomt After cut back

under 15 km h
Throttle openIng approxImately over approxImately 35 km h
Range UnIt 9 MPH 22 MPH
mmHg
UnIt kg cm2 PSI UnIt kg cm2 pSI

Full throttle 0 9 4 to 11 0 134 to 156 5 5 to 6 5 78 to 92

D
MmlfOum throttle 450 3 0 to 4 0 43 to 57 3 0 to 4 0 43 to 57

Full thro ttle 0 100 to 120 142 to 171 5 5 to 7 0 78 to 100

2
Mmlmum throttle 450 6 0 to 12 0 85 to 171 5 5 to 7 0 78 to 100

Full throttle 0 140 to 160 199 to 228 140 to 160 199 to 228
R
MmlfOum throttle 450 3 0 to 5 5 43 to 78 3 0 to 5 5 43 to 78

Notes a The lIne pressure durlOg Idlmg corresponds to the oil pressure before cut down at mmlfOum throttle
b The oIl pressure After cut back means that after the pressure modifier valve has operated

JUDGEMENT IN MEASURING Vacuum leakage IS checked by A 011 level

the negatIve pres B
LINE PRESSURE dIrectly measurIng Range select lInkage
sure after removmg the vacuum pIpe C InhIbitor SWItch and wlrlOg
Low IdlIng lIne pressure 10 the A puncture of the vacuum dIa o Vacuum dIaphragm and pip 109

D 2 1 R and P be E DownshIft
ranges phragm can easily ascertamed be solenOid klckdown
ThIS can be attrIbuted to trouble 10 the
cause
torque converter 011 IS ab SWitch and wlflng
the pressure supply system or too low sorbed mto the engme and the exhaust F EngIne IdlIng rpm
output of power caused by pIpe emIts wlnte smoke G 011 pressure throttle
1 A worn oIl pump 4 Items to be checked when the H Engme stall rpm
2 An 011 pressure leak m the oIl lIne pressure IS mcreasmg I Rear lubrIcatIon
pump valve
body or case In thIS check the lIne J Control valve manual
pressure
3 regulator valve
A stIck 109 should be measured With vacuums of K Governor valve
2 Low IdlIng lIne 450
prcssure 10
mmHg and 0 mmHg 10 accordance L Band servo
certam ranges only WIth the stall test M TransmISSIon aIr check
procedure
ThiS IS presumably caused by an 011 I If the lIne pressure do not 10 N 011 quantIty
leak 10 the deVIces or CirCUIts connect crease
despIte the vacuum decrease o IgmtIon SWItch and starter motor
ed to the relevant ranges check whether the P
vacuum rod IS Engme adjustment and brake 10
I When there IS an 011 leak 10 the
mcorporated spectIon
rear clutch and governor the lIne 2 If the lIne pressure do not meet
pressure m 0 2 and I are low the standard It IS caused mostly by a 2 after mspectmg auto
but the pressure IS normal 10 R
InspectIon
stIckmg pressure regulatmg valve pres matIc transmiSSIon on vehIcle
2 When OU leak the
an occurs m sure
regulatmg valve plug or amplIfier
low and m Rear clutch
reverse brake CIrCUIt the lIne
10 R and P are low but n Front clutch
pressure
0 2 q Band brake
the pressure IS normal 10 and
I r Low and reverse brake

TROUBLE s OIl pump

3 HIgh IdlIng Ime pressure SHOOTING
ThIS IS presumably caused by LeakageofoIl passage
an
CHART
mcreased vacuum throttle u One way clutch of torque converter
pressure
to a leak the tube v One way clutch of transmIssIon
owmg m vacuum or INSPECTING ITEMS
mcreased lIne VI Front clutch check ball
dIaphragm or by an

pressure due to a stIckmg regulator I InspectIon With automatIc trans X Parkmg Imkage
valve mission on vehicle y Planetary gear

AT 54
 Automatic Transmission

TROUBLE SHOOTING CHART FOR 3N71B AUTOMATIC TRANSMISSION

The number shown below mdlcates the sequence m whIch the checks should be taken up

Trouble ABC D EFGHI J K L MNOP mnq r s t u v w x y

Engme does not start m N P

2 3 1
ranges

other range than

Engme starts m N
I 2
and P

Sharp shock m
shlftmg from N to
2 I 3 4
D @
range

VehIcle wIll not run m D range but I 2 3

runs In 2 I and R
ranges

VehIcle wIll not run m D I 2

ranges but runs m

rangeR I 2 4 5 6 3 7 @ @
Clutch Very poor acceleration
slipS

VehIcle wIll not run m R range but

runs In D 2 and I ranges 1 2 3 5 6 4 9 8 j @ @
Clutch slIps Very poor acceleration

Vehicle will not run m any range 1 2 3 5 6 4 j@ @

Clutches brakes somewhat

or
slIp m
1 2 6 3 5 7 4 @@
startmg

VehIcle runs m N range I 3 2

Maxrrnum speed not attamed

I 2 4 5 7 6 3 8 @ j@@ @
AcceleratIon poor

Vehicle braked by throwmg lever mto

3 2 1 @ @
R range

ExceSSIve creep I

No crecp at all 1 2 3 5 4 @@ j
@

FaIlure to change gear from 2nd

1 2 3 5 6 8 7 4 @
to 3rd

Failure to from 1st

change gear @ @
2nd
I 2 3 5 6 8 7 4 @
to

Too from
high a gear change pomt
1st to 2nd from 2nd to I 2 3 5 6 4 j
3rd

Gear change directly from 1st to

2 4 3 I @ @
3rd occurs

AT 65
 Automatic Transmission

Trouble ABCD EFGHI J KL MNOP mnq r s t u v w x Y

Too sharp a shock m change from

1 2 4 5 3 @
1st to 2nd

Too sharp a shock m change from

1 2 3 3 5 4 @
2nd to 3rd

Almost no shock or clutches

slIppmg m
change from 1st to 1 2 3 4 6 875 @ @
2nd

Ahnost no shock or shppmg 10

change from 2nd to 3rd 1 2 3 4 6 8 7 5 @ @ @

Engme races extremely

VehIcle braked by gear change from

2 1 @ @ ID
1st to 2nd

Vehicle braked by gear change from

3 2 I @
2nd to 3rd

FaIlure to change gear from

1 3 4 6 5 2 CV@ @
3rd to 2nd

Failure to change gear from 2nd

1st 1st
1 3 4 6 5 2 CV @
to or fronI 3rd to

Gear change shock felt dUrIng

deceleratIon by releaslOg 1 2 3 4 5 6 CV
accelerator pedal

Too hIgh a change pomt from

3rd to 2nd from 2nd to 1 2 3 4 5 6 CV
1st

Klckdown does not operate when

depresslOg pedal m 3rd wlthm 2 1 4 5 3 @ CV

klckdown vehIcle speed

Klckdown operates or engme over

runs when depresslOg
pedal m 3rd 1 2 3 5 6 7 4 @ @
beyond klckdown vehIcle speed lunlt

Races extremely or slIps 10 changmg

from 3rd to 2nd when I 2 4 6 5 3 CV@ @ @
depresslOg pedal

change from 3rd

Failure to to 2nd
1 2 4 5 3 @ CV
when changmg lever mto 2 range

Gear from 2nd 1st

change to
1 2 3
or from 2nd to 3rd m 2 range

AT 66
 Automatic Transmission

Trouble ABCD EFGHI J KL MNOP n r s t u v w x y

m q

No shock at from I 2
change to
@
1 2 3 4 I 6 7 5 @
range or
engme races extremely

Failure to change from 3rd to 2nd

1 2 4 5 7 6 3 @@ @
when shlftlOg lever IOto 1 range

Engme brake does not operate m

I
I 2 4 5 3 @ j
range
I

Gear from 1st 2nd

change to
3rd 1
I 2 ID
or from 2nd to m range

Does not change from 2nd

1st 1
I 2 456 7 3 @ @
to m range

Large shock changlllg from 2nd

to 1st m 1
I 2 4 3 @
range

VehIcle moves when changlllg

Illto P does
range or
parklllg gear 1 @
not dIsengage when shIfted ou t of
I
P range

TransmIssion overheats 1 3 4 2 6 8 7 5 @@@ @@@ @

011 shoots out dUrIng operatIon

WhIte smoke emItted from exhaust 1 3 5 6 2 7 8 4 @@@ @@@ @
pipe dUrIng operatIon

OffenSIve smell at 011 charglllg pIpe 1 2 ID@@@ j@@ @

TransmIssIon nOIse III P and N

1 2 ID
ranges

TransmIssIon nOIse In D 2 1
I 2 ID @ @ @
and R ranges

AT 67
 Automatic Transmission

TROUBLE SHOOTING GUIDE FOR 3N71B AUTOMATIC TRANSMISSION

Order Test Item Procedure

Checkmg 1 Oulevel gauge Check gauge for oLl level and leakage before and after each
test

2 DownshIft solenOId Check for sound of operatmg solenoId when depresSlllg

accelerator wIth ON
pedal fully IgnItIOn key
3 Manual lInkage Check by shlftmg mto P R N 0 2 and 1

ranges wIth selector lever

4 InhIbItor SWItch Check whether starter operates 10 N and P ranges only

and whether reverse lamp operates m R range only
5 Check whether
Engme IdlIng rpm IdlIng rpm meets standard

6 Vacuum pressure of vacuum Check whether vacuum pressure IS more than 450 mmHg 10

pIpe IdlIng and whether It decreases wIth mcreaslOg rpm

7 each range
OperatIon 10 Check whether transmIssIon engages posItIvely by shtftmg
N D N 2 N t and N R range
while IdlIng with brake applIed
8 Creep ofvehicle Check whether there IS any creep m 0 2 I and
R ranges

Stall test 1 011 pressure before testmg Measure lIne pressures 10 0 2 1 and R range
whIle IdlIng
2 Stall test Measure engme rpm and lIne pressure 10 0 2 1 and
R full throttle operation
ranges dUrIng

Notes

a Temperature of torque converter oil used 10 test should

be from 60 to 1000C 140 to 2120F ie sufficiently

warmed up but not overheated
b To cool oil between each stall test for D 2 1
and R idle rpm at about 1 200
ranges engine I e

rpm for more than 1 mmute III P range Measurement

tIme must not be more than 5 seconds

3 011 pressure after testmg Same as Item I

Road test I Slow acceleratIon Check vehicle speeds and engme rpm III shtftmg up 1st

1 st 42nd 2nd range and 2nd 3rd range wlnle runnIng with lever III
0 range and engme vacuum pressure of about 200
43rd
2nd

mmHg
2 QUIck acceleratIon Same as Item I above except WIth engllle vacuum pressure
1st 2nd of0 mmHg posItion Just before klckdown
I e 10

43rd
2nd

3 Klckdown operatIon Check whether the klckdown operates and measure the
3rd 2nd or 2nd 1st tIme delays while runnIng at 30 40 50 60 70 km h 19
25 31 38 44 MPH III
03 range

AT 68
 Automatic TransmissIon

Order Test Item Procedure

4 ShIft down Check vehIcle speeds and engIne rpm In shIftmg down from

3rd sequenttally
2ndlst while coastIng With ac

D3 D2 D1 celerator pedal released In range and engine

D3 vacuum

pressure of about 450 mmHg

and and
D3 12 and engine brakIng after
5 Shift down Check for shIfting down
further for shIfting down 12 engine brakIng
D3 12 l1 II
shIftIng the lever Into I range WIth the accelerator pedal
released and the engine vacuum pressure of 0 mmHg wlule

drIVing at about 50 km h 31 MPH 10 range D3

6 ShIft down Check for qUIck shIfting down D3 2 and engine braking
2 after shlftmg the lever Into 2 range wlule drIVing at about
D3
50 km h 31 MPH In
D3 range
Further locking of the
check for transmISSion In 2nd gear

ratIo regardless of vehIcle speed

7 ShIft up Check for faLlure of the transmISSIon to shift up durlOg
acceleration when starting In I range
11 12
8 ShIft up or down when starting Check the transmiSSIon for not shlftmg up or down durmg
In 2 range acceleratIon or deceleratIon when startIng In 2 range

9 ParkIng ConfIrm that vehIcle will not move on grade when shlftlOg
to P range

Others Abnormal shock ouleakage Enter IOto record condItions observed durIng these tests
such as gear nOIse abnormal clutch nOIse and acceleratIon

performance

AT 59
 Automatic Transmission

SERVICE DATA AND SPECIFICATIONS

General specifications

Torque converter

3 element I
Type SymmetrIcal stage 2 phase torque converter
Stall torque ratIo 20 1

TransmisSIon

Type 3 speed forward and one speed reverse wIth planetary gear tram

Control elements

dIsc clutch 2
MultIple
Band brake 1

brake I
dlMulstIpcle
One way clutch 1

Gear ratIo

1st 2458

2nd 1458

3rd 1000

Reverse 2182

Selector posItIons

P park TransmISSIon IS placed III neutral

Output shaft IS fIXed

Engllle can be started

R Reverse Backward runnIng

N Transmission IS III neutral

Neutral
Engme can be started

D DrIve Up or downshtfts automatIcally to and from 1st 2nd and top

2 2nd lock FIXed at 2nd

1 Lock up FIXed at low or downshtfts from 2nd

011 pump

Type Internally llltermeshmg lllvolute gear pump

Number of pumps

011 AutomatIc transmISSion flUId DEXRON type

CapacIty 5 5 lIters SJi U S qt 4Ji Imp qt except B2l0

50IIters 5Y US qt 4XImp qt onB21O

ApproxlfOately 2 7 lIters 2JiU S qt 2 XImp qt m

B21O
torque converter 25 lIters 2XU S qt 2Y Imp qt on

HydraulIc control system Controlled by measurIng the negative pressure ofllltake

manIfold and the revolutIon of output shaft

lubrIcation system Forced lubrIcatIon by an 011 pump

CoolIng system Water cooled by a Circulation type auxilIary cooler located

at the radIator

AT 70
 Automatic Transmission

Specifications and adjustment

AIT model code number X240I

car model 710 610

ApplIed
model Ll6 Ll8
EngIne
Torque converter assembly
mark the TIC 16 B
Stamped on

Front clutch

Number ofdrIve plates 3

Number of drIven 3
plates
16 to I 8 0063 to 0 071
Clearance mm m

T1uckenss of retammg plate mm 10 106 0 417

10 8 0425

11 0 0 433

11 2 0441

11 4 0 449

11 6 0 457

Rear clutch

4
Number of drIve plates
4
N umber ofdrIven plates
I 0 to 1 5 0 039 to 0 059
Clearance mm Ill

Tlnckness of retammg plate mm m 48 0 189

Low reverse brake

Number ofdrIve 4
plates
4
Number of dnven plates
Clearance mm m 080 to 1 05 0 031 to 0041

Tlnckness of retanung plate mm m 11 8 0465

120 0 472

122 0480

124 0 488

126 0 496

128 0 504

Brake band

PIston size mm m

64 2 52
Blgdla
Small dla 40 1 58

Control valve assembly

E
Stamped mark on stramer

Governor assembly
mark 35
Stamped on
governor body

AT71
 Automatic Transmission

Engine stall revolution

LI6 engIne Smgle carb 1 800 to 2 000 rpm

LI8 engIne Smgle carb 1 950 to 2 150rpm

LI8 engIne Twill carb 1 900 to 2 150 rpm

rlghtenlng torque
kg m ft Ib

DrIve crankshaft
plate to 140 to 160 101 to 116
65 to 7 5 47 to 54 for B210

DrIve plate to torque converter 4 0 to 5 0 29 to 36

Converter houSlOg to engme 4 0 to 5 0 29 to 36

TransmiSSIon case to converter housmg 4 5 to 5 5 33 to 40

TransmISSIon case to rear extension 20 to 2 5 14 to 18

Otl pan to transmission case 05to07 36t05 I

Servo pIston retainer to transmIssion case 05to07 36t05 I

Piston stem When adjustIng band brake 1 2 to 1 5 8 7 to 108

PIston stem lock nut I 5 to 4 0 11 to 29

One way clutch mner race to transmiSSIon case 1 3 to 1 8 9 4 to 13

Control valve body to transmisSIon case 055 to 0 75 40 to 5 4

Lower valve body to upper valve body 025 to 0 35 1 8 to 2 5

Side plate to control valve body o 25 to 0 35 1 8 to 2 5

Nut for control valve reamer bolt o 5 to 0 7 3 6 to 5 1

011 stralller to lower valve body o 25 to 0 35 1 8 to 2 5

Governor valve body to 011 dIstrIbutor o 5 to 0 7 3 6 to 5 1

011 pump houslllg to oLl pump cover 06 to 0 8 4 3 to 5 8

InhIbItor SWitch to transmissIon case o 5 to 0 7 3 6 to 5 I

Manual shaft lock nut 3 0 to 4 0 22 to 29

011 cooler pipe or 011 pIpe to transmIssion case 3 0 to 5 0 22 to 36

Test plug oLl pressure mspectIon hole I 4t02l IOto 15

Support actuator parklllg rod msertlOg

o 8 to I 1 5 8 to 8 0
posItion to rear extensIon

011 charging pIpe to case 055 to 0 75 4 0 to 5 4

Dust cover to converter housmg 055 to 0 75 4 0 to 5 4

Selector range lever to manual shaft 3 0 to 4 0 22 to 29

Turn back two turns after tightenIng

AT 72
 Automatic Transmission

SPECIAL SERVICE TOOLS

Tool number For Reference

No DeSCrIption use or
page
tool name on figure No

ST2505S001 Use for checklOg hydraulIc 3N71B

pressure FIg AT i44
and
3N71A
OIl pressure gauge
AfT
set

2 ST07870000 Use for settlOg transmIssIon

0 SEl19

3N71B Page AT 46
AfT
TransffilsslOn
case stand

SE120

3 ST2585 0000 Use for removlOg 011 pump 3N71B FIg AT 85

and
SlIdlOg hammers 3N71A

AIT
adCJ
II
DI

SE121

4 ST25420001 Use for assemblIng or dIsassemblIng front and rear clutch 3N71B Page AT 50
and FIg AT 109
3N71A FIg AT 115
Clutch sprmg
AIT
compressor

SEI22

5 GG93010000 Use for tIghtemng correct torque 3N71 B FIg AT 98

Max torque 4 6 kg m 0 33 ft Ib and
Torque wrench
DlIve angle 3 8 square 3N71A

AIT

SE123

AT 73
 Automatic Transmission

Tool number For Reference

No DescrIptIon use
page or

tool name on
figure No

6 ST25490000 Socket extensIOn to connect torque wrench GG930l0000 with 3N71B FIg AT 98

square socket wrench AfT

Socket extension

SE124

7 ST25 160000 Use for tIghtemng correct torque 3N71B FIg AT 136
Max torque 1 04 kg m 90 ft Ib AfT FIg AT 137
Torque dnver
and
3N71A

SE125

8 HT69860000 Use for remOVIng and replacIng snap nng 3N71B FIg AT 88
and
Snap rIng remover 3N71A

AfT

SE126

9 ST25320001 Use for removlOg and replacmg snap nng 3N71B Page AT 50
and FIg AT 109
Snap rIng remover
3N71A FIg AT 115
AfT

SE30S

10 ST25570001 Use for removIng and mstallIng one way clutch mner race with 3N71B FIg AT 93
torque wrench AfT FIg AT 98
DrIve angle square and 6 mm across flat width Page AT 52
Hex head
ex tensIon

SE128

AT 74
 Automatic Transmission

Tool number For Reference

No
DescnptIon use page or
tool name on figure No

II HT62350000 Use and control valve

dIsassemblIng assemblIng 3N71B Fig AT 130
and Fig AT 133
Spmner handle
3N71A

AfT

SE129

12 HT6 I000800 Use for disassemblIng and assemblIng control valve 3N71B FIg AT 130
and AT 133
FIg
Hexagon wrench
3N71A AT 136
FIg
AfT AT 137
FIg

SE130

13 ST25580000 Use for centenng 011 pump 3N71B Fig AT 127

and AT 128
011 pump
FIg
3N71A
assemlbmg gauge
AfT

SE13l

AT 75
 SECTION PD

PROPELLER
DATSUN SHAFT
MODEL 610 SERIES
DIFFERENTIAL
CARRIER

PROPELLER SHAFT AND PO 2

CENTER BEARING

DIFFERENTIAL CARRIER
TYPE R160 FOR SEDAN po 1
AND HARDTOP I R SJ

DIFFERENTIAl CARRIER
TYPE H165B FOR po 18
STATION WAGON RIGID AXLE

TROUBLE DIAGNOSES AND

po 21
CORRECTIONS

SERVICE DATA AND

PD 29
SPECIFICATIONS

I NISSAN I SPECIAL SERVICE TOOLS po 32

NI55AN MOTOR CO LTD

TOKYO JAPAN
 Propeller Shaft Differential Carner

PROPELLER SHAFT AND CENTER BEARING

CONTENTS

DESCRIPTION 3
PD INSTALLATION PD4

REMOVAL PD 3 CHECKING AND CORRECTING

DISASSEMBLY PD 3 UNBALANCED PROPELLER SHAFT PD 5

CENTER BEARING DISASSEMBLY PD 3 PROPELLER SHAFT VIBRATION PD 5

INSPECTION PD 3 SERVICE DATA PD 5

ASSEMBLY PD 3 TROUBLE DIAGNOSES AND

CENTER BEARING ASSEMBLY PD4 CORRECTIONS PD 6

2 Sedan
joint type

1 000 39 37 3S
138
I Slceve yokc assembly 5 Propeller shafl tube
7 Beallng sembly
racc a asse mb ly

3 Journal a embly 6 Flange yoke

UOlt mm 10
4 Snap ling
P0226

FIg PD l Cross sectional v ew ofpropeller shaft for Sedan

3 and Station Wagon

jomt type Hardtop L mm m Car model

720 28 3S Stal10n Wagon

5S0 21 6S Hardtop

440 17 32 L
1485 S 846
1 38

I Sleeve yokc a cmbly S Washer 9 Flangc yokc TlghtcOlng torque T of bolts

2 Cenler bearing 6 CompaOlon flange 10 Bcarmg race and nut kg m ft Ib
3 Center bcallng IIlsulalor 7 Plam washer assembly @ T 20 to 24 145 to 174
4 Cu lllon rubber 8 Lockmg nut 11 Snap nng @ T 24 to 3 307 to 24
P027B UOlt mOl 10

Fig PD 2 Cross sectIOnal vIew ofpropeller shaft for Hardtop and StatIOn Wagon

PD 2
 Propeller Shaft Differential Carner

3 Draw out propeller shJft sleeve

DESCRIPTION
yoke from transmiSSion by movmg
The shaft used to trans
propeller IS shaft I eJrward passmg It under reJr
fer the the
engme power through axle
transmiSSion to the dIfferentIal and
Watch for 011 leakage from trans
the rear axle which transmIts It to the mISSIon end
rear wheels The propeller shaft has
Nole Remove
two or three unIversal jomts center propeller shaft care
beanng except 2jomt type and a fully so as nol todamage the splIne
sleeve and rear 011 seal ST3lS00000
sleeve yoke The splInes 10 the sleeve yoke
PDl72
yoke and on the transmISSIOn mam

shaft output shaft pernut tlIe propel FIg PD 5 Remov ng lock nut
ler shalt to move forward and rear

ward
DISASSEMBLY
INSPECTION
propeller shaft and unIversal
The PnnIanly do not dlsJssemble pro
I CheLk for dent
jomt assembly IS carefully balanced peller shaft because It IS balanced as an Journal pm or

bnnell mark yoke dnd hole for sign

dunng ongmal assembly that IS the assembly Check movement of propel
of wear or dalllJge
dynamIC unbalance IS under 35 gr cm ler shJft With Journal and If Journal

049 m oz at 4 000 rpm for Sedan does not move smoothly disassemble Snap ring beJrlng and seal rmg
should also be mspected to see If these
and 3S gr m 049 oz
m as 5 800 I Mark propeller shJft and Journal
rpm for Hardtop and StatIOn Wagon so thJt the ongmal comblllatlon can
are
damaged worn or deformed Re
be rcstorcd at assembly place If nccessary
If the propeller shaft has to be
2 CheLk center bcanng by rotatmg
2 Removc snJp rIng With a standard
dIsassembled It must be made careful
Olscdrd If
lImit not sLrewdnver bearing race It IS
rough
ly so that the above IS
3 nOIsy or CraLked bearing
damaged
exceeded Therefore when the car IS Lightly tap base of yoke WIth a

msulator Lannot be tolerated here

hammer and Withdraw beanng race
to be undercoated cover the propeller Check shaft tube sur
See Figure PD4 3 propeller
shaft and unIversal jomts to prevent for crack
face dent or Change If
of the undercoatmg
applIcatIon ma
necessary
tenal

ASSEMBLY
To assemble the
reverse
forego 109
proceoure usmg reference marks pre
SCrIbed on page PO 3 for Removal and

REMOVAL Disassembly
New bedflng necd not be lubrlLated
I RaIse car on hOist Put match PD005
smce It IS lubricated for lIfe Fill Jomt
marks both on propeller shaft and
Fig PD 4 RemOVing bearmg WIth recommended multi purpose
companIon flange so that shJft can be
grease whenever propeller shaft IS over

relllstalled m the ongmal pOSItion Note When removmg Journal from hauled
2 Remove bolts connect 109 shaft 10
be careful not to damage
yoke Two opposlle snap rIngs should be
companIon flange Remove bolts CD Journal and yoke hole
thickness Be that
equal 10 sure play IS
retammg center beanng support 10
below 0 02 mOl 0 0008 10

case of the 3 jomt type See Figure

PD 3 CENTER BEARING
AvaIlable snap nng
DISASSEMBLY

When disassemblIng and repJlrmg ThIckness Color

center beanng are reqUired the fol mm 10 Iden tlficatlOn
lowlllg procedures are applIed
I Put
matdl marks on flange and 2 00 00787 White
front propeller shaft Remove bolts 202 00795 Yellow

conncctmg flange yoke to compalllon 2 04 0 0803 Red

flange 206 00811 Green

2 Release caulklllg on 10Lkmg nut 208 00819 Blue
2 10 00827
3 Applymg DrIve PmlOn Flange Light brown
212 00835
Wrench ST315 30000 loosen off lock Unpamted
2 14 00843 Pmk
FIg PD 3 109 nut and remove center bearing See
PO 5
Figure
PD 3
 Propeller Shaft Differential Carner

Install and dssemble components Note Apply lIthIUm base grease m center
support on
bearIng and tIghten
correctly that JOInt moves under
so
e1udmg dlSUlphlde Molybdenum to bolts CD to specIfied torque See
frIctIon resistance of less than 15 both faces of bearing washer when 6 and PD 7
FIgures PD
cm
kg 13 In Ib mstalhng
When the above steps are complete
TlghteOlng torque
place the shaft m a balancmg machme 3 Install
washer and lock nut on I 9 to 2 6 kg m
and adjust unbalance less than 35 front shaft and
tighten nut usmg DrIve 14 to 19 ft Ib
gr cm 049 oz
m at 4 000 rpm for PInIOn Flange Wrench ST3l530000 to
Sedan or less than 35 gr cm 049 speCIfied torque Note When mstallmg center beanng
oz
m at 5 800 rpm for Hardtop and bracket and support be sure to set
Tlghtenmg torque
StatIOn the longer portIOn on support end
Wagon 20 to 24 kg m
to right See FIgures 6 and
PD
145 to 174 ft Ib
PD 7
4 the upper
USIng punch collapse
CENTER BEARING
part of lock nut mto the groove of
ASSEMBLY
shaft
Center beanng assemblIng pro 5 JOin wmpanIon flange of front
cedures are as follows shaft With flange yoke of rear shaft
1 Install center beanng to enter
and tighten wnnecllllg bolts to spe l

Insulator fled torque

bearIng
2 Install center bearlOg assembly Tlghtemng torque
washer and comparuon flange on front 2 4 to 3 3 kg m
shaft USIng reference marks put m to 24 ft Ib
17
dISassembly procedure and press It by
a specified load of 400 to 1 500 kg
Frg PD 6 Installing center bearing
882 to 3 307Ib 6 Install center bearIng bracket and bracket and support

I Ccnter bcarlng support

2 Center bcanng brackct
3 CushIOn rubber
4 Center beanng

TightenIng torque T of
bolts and nuts kg m ftIb
@ T 3 6 to 4 8 26 to 3S
I 9 to 2 6 14 to 19
@ T
PD280

Fig PD 7 Cross sectional vIew of center bearing

INSTALLATION TIghtenIng torque TightenIng torque

To the 2 4 to 3 3 kg m 3 6 to 4 8 kg m
Install rcverse foregomg
17 to 24 ft Ib 26 to 35 ft Ib
removal pro edure

Align propellcr shaft With com Insert bolts through the holes of
panion flange usmg refcrence ma rks center bearIng support and plaIn wash
presLrlbed In Removal procedure ers and torque bolts to retaIn center
and lIghten them with bolts See
bearIng on body Figure PD 3

PD 4
 Propeller Shaft Differential Carner

CHECKING AND 1 Remove undercoatmg and other

CORRECTING foreIgn materIal whIch could upset

shaft balance and check shaft VIbra
UNBALANCED tIon by road test

PROPELLER SHAFT 2 If shaft VIbratIOn IS noted dunng

road test dIsconnect propeller shaft at
PROPELLER SHAFT dIfferential companIon flange
carner

VIBRATION rotate comparuon flange 180 degrees

and relOstall propeller shaft
To check and correct unbal 3
an
AlIgn check shaft VIbration If
anced propeller shaft proceed as fol VIbration stIll perSIsts replace propel
lows ler shaft assembly

SERVICE DATA

Type
Item

2 3 Jomt type
Jomt type

PermISSIble dynamIC unbalance cm

gr oz
m 35 0 49 at 4 000 rpm 35 0 49 at 5 800 rpm

AxIal play of spIder Journal mrn 10 less than 0 02 00008

Iournal swmgIng Ib less than 15 13 0

torque kg cm m

Propeller shaft front and rear

less than 0 6 0 024
out ofround mrn 10

Tlghterung torque kg m ft Ib

Shaft to comparuon flange

24 to 3 3 17 to 24
gear carner bolts

CompanIon flange fIxmg nut front shaft 20 to 24 145 to 174

Flange yoke rear shaft to companIon flange 2 4 to 3 3 17 to 24

front shaft bolts

Center bearmg bracket f1xmg nuts 19 to 2 14to

6 19

Center to
bearmg bracket body bolts 3 6 to 4 8 26 to 35

PD 5
 Propeller Shaft Differential Carner

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective actIon

Worn damaged UnIversal jOlOt needle Replace

VibratIOn dUrIng at or

medIUm or high speed beanng

Unbalance due to bent or dented propeller Replace
sha ft

Loose propeller shaft IOstallatlOn RetIghten

Worn transmiSSion rear extensIOn bushlOg Replace
Damaged center bearIng or IOsulator Replace
mud on the shaft causlOg Clean up shaft
UndercoatlOg or

unbalance

TIre unbalance Balance wheel and tire assembly

Balance weIghts mlsslOg Replace

KnocklOg sound dUrIng Worn damaged UnIversal jOlOt Replace

starting or nOise Worn sleeve and malOshaft splIne Replace
yoke
dunng coastlOg on
Loose propeller shaft IOstallatIon Retighten
propeller shaft
Loose jOlOt IOstallatIon Adjust snap nng

Damaged center bearIng or IOsulator Replace

Loose or mlssmg bolts at center beanng Replace or tighten bolts

bracket to body

StraIghten out dust cover to remove IOter

ScraplOg nOise Dust cover on sleeve yoke rubblOg on

transmiSSion rear extensIon Dust cover on ference

companIon flange rubblOg on differential

carner

WhlOe or whIstle Damaged center bearlOg Replace

PD 6
 Propeller Shaft Differential Carner

DIFFERENTIAL CARRIER TYPE R160

I
FOR SEDAN AND HARDTOP IR S

CONTENTS

DESCRIPTION PD 7 ADJUSTMENT OF DRIVE PINION

REMOVAL PD 9 PRELOAD PD ll
PRE DISASSEMBl Y INSPECTION PD 9 ADJUSrMENT OF DRIVE PINION
DISASSEMBl Y PD 9 HEIGHT PD 12
DISASSEMBl Y OF DIFFERENTIAL ADJUSTMENT OF SIDE
r
RETAINER
CASE PD lO SHIMS PD 13
INSPECTION PD lO INSTAllATION PD 15
ASSEMBl Y AND ADJUSTMENT PD 10 REPLACEMENT OF FRONT Oil SE Al PD 16
PRECAUTIONS IN REASSEMBLY PD 10 SIDE 01 l SEAL PD 17
ASSEMBl Y OF DIFFERENTIAL GEAR
CASE PD lO

DESCRIPTION

pOSItioned for proper rmg

The differential gear carner as pInIon beanng adJustlOg spacer and assembly IS

sembly on the 610 senes IS avaIlable m washer dunng assembly gear to nve pInIon backlash by vary

two dIfferent The dnve pInIon IS posItioned by a 109 these shims The nng gear IS bolted
types
One type used on Sedan and Hard washer located between a shoulder of to the differential case The case

top has a dnve pInIon and

hypOld type the dnve pInIon and the rear
beanng houses two SIde gears 10 mesh wIth

rtng gear set with three dIfferent gear The dIfferentIal supported 10 two mounted
case IS on a
pmlons pmlon

IOdlcated the the carner by two tapered roller Side shaft The plOlon shaft IS anchored 10
ratIos as 10 followmg
table bearmgs These are preloaded by 10 the case by lock plO The plOlOns and
The dnve pInIon IS mounted wIth sertIng shuns between the carner and SIde gears are backed by thrust
ball and two roller the Side retamers The dIfferential case washers
one beanng tapered
beanngs wluch are pre loaded by

Type of gear carner

R160 H165B
assembly

Gear ratIo 3700 4111 3889

model Ll8 Ll8 Ll8

Engme
StatIon
Car model Sedan Hardtop
Wagon

PD 7
 Propeller Shaft Differential Carrier

TYPE R160

I Compamon flange
2 011 seal
Supply multI purpose grease
to oil seal hp when

assemblmg
3 Front ptlot bearing

4 Front pilot beanng spacer

5 Drive pinion
6 PinIOn front beanng
7 PmlOn bcanng adjusting washer
Adjust pinIOn bcarlng prcload
by selecting CD and @
8 Pinion bearing adjusting spaccr
9 Plnton rcar beanng
10 Pinion heIght adjUsting washer
II Side rctalncr adjusting shim
Adjust Side beanng preload
and rIng gear dnve
to pinIon
backlash by selcctlng @
12 O rmg

13 011 seal
Supply purpose
multl grease
to oil seal hp when assembhng
14 Sldc retalncr
IS Side beanng
16 DlffercnlIal case
17 Plnton matc shaft
18 Rcar cover

19 DlffercnlIal mounting mcmbcr

20 Brcathcr

21 Ring gear
22 Thrust washcr
23 Plnton mate
24 Thrust washer
thc
Adjust pinion mate to sldc
gear backlash or the clearance
between thc rear face of sldc
gear and thrust washer to

o I to 0 2 mm 0 0039 to
o 0079 In by @
2S Stde gcar
26 Lock pm
27 Lock strap

Tlghtcnl1lg torque T of
bolts and nuts kg m ft lb

@ T 17 to 20 l23 to 14S
@ T 0 9 to I 2 6 5 to 8 7
@ T 6 to 8 43 to S8
@ T 7 to 8 SI to 58

PD317

Fig PD 8 sectional
Cross view of d fferentlal carrier for Sedan and Hardtop 1 R S

8
PD
 Propeller Shaft Differential Carner

After carner assembly IS removed Carner Sldc Retalller Attachment

REMOVAL
support suspension member on a stand ST337lO000 and sUItable puller See

I to prevent ItS Illsulators beIng tWisted Figure PD 13

Jack up rear of car and support
on safety stands
or
damaged
2 DIsconnect propeller shaft at the center of Notes
Note Do not place
com panlon Mark and left Side
flange suspenSIon member on the stand
a
nght retamers
3 DIsconnect dnve shafts CD on the
before removal operation Other before removal
wheel sIde See FIgure PD 9 WIse It WIll be difficult to extract b Be careful not to confuse nght and
Remove sIde yoke fixmg bolts and the gear left hand Side retamers and shims
carrier assembly
extract sIde yokes together wIth drIve for proper reassembly

shafts See FIgure PD lO

ST337IOOOO

Note Be careful sIde PRE DISASSEMBLY

not to damage
yoke and 011 seal when removmg INSPECTION
Dlfferenllal carner should be 10

speLled before any parts are rcmoved

from It
These mspectlOns are helpful 10

findmg the cause of the trouble and 10

detcrnunmg the correlllons needed PDl77

I Mount carner on Gear Carner

F g PD 13 RemOVing Side retainer
Attaclunent KV38lO0800 See Figure
2 Extract differentIal case from
PD 12 Remove mountmg member and
PD318
carner
Fig PD 9 Under view rear cover

3 When Side beanng ex

replaCIng
tract beanng outer race from stde
retamer usmg Gear Carner 011 Seal
Puller ST33290001 Sce FIgure PD 14

PD320

F g PD 12 Holding differential carrier

Fig PD I0 RemOVing s de yoke fIXing
bolt 2 Visually Inspect parts for wear or

damage I
4 With differential carner Jacked 3 Rotate gears to see that the e IS

up remove nuts @ on both ends of any roughness whtch would mdlcate Fig PD 14 RemOVing Side bearing
differential member See FIgure damaged beanngs or chipped gears
I
outer race

PD 9 Check the gcar teeth for sconng or

4 Loosen drIve pinion nut holdIng
5 Loosen off four fittmg bolts @ signs of abnormal wear Measure pre
that hold differential carner onto sus load ofdrIve pmlon
companion flange wllh Dnve PmlOn
PD 9 Flange Wrench ST31530000 and pull
pensIOn member See FIgure 4 Set up a dial mdlcator and check
off compaOlon flange usmg a SUItable
6 Pull off carner backward together the backlash at several pomts around
wIth Jack See Balklash should be wlthm
puller See FIgure PD 15
Figure PD ll rIng gear
o I to 0 2 mm 00039 to 00079 10

5 C helk the gear tooth contact

wllh a mixture of powdered red lead

and 011 apply spanngly to all nng gear
teeth
For the tooth contact pattern see

page PD 15 for Contact Pattern

PD178
DISASSEMBLY
PD3l9 F g PD 15 Removing drIVe pinIOn
Fig PD ll RemOVing differential carrier Remove sldc retamers usmg Gcar nut

PD 9
 Propeller Shaft Differential Carner

5 Extract drIve pmlOn from carner Notes 3 Inspect all bearIng races and roll
The puller should be handled With ers for sconng cluppmg or eVidence
usmg a press Take out drIve pmlon a

together with rear beanng cone bear

care 10
catchmg the edge of beanng of excessive wear They should be 10

109 spacer and adJustmg washers lOner race tIptop condition such as not worn and
6 Remove 011 seal b Be careful not to confuse the left With lIke surfaces If
mIrror
Replace
and nght ha nd part there IS a shadow of doubt on their
Note 011 s al must not be reused
2
effiCiency as an mcorrect beanng op
RenIove rmg by unfoldIng
gear era tIon may result 10 nOises and gear
7 Remove pIlot bearIng together lock strap and loosenmg nng gear
WIth pIlot beanng spacer and front seIzure
bolts
If need the mformatIon
beanng cone usmg Puot Beaflng Dnft you on

Visual Standard for

ST30650001 Note Loosen bolt diagonally ServiceabilIty
8 Hold rear bearing lOner race With Taper Roller Bcarmg rcfer to SectIOn

Dnve Pm IOn Rear Inner Race 3 Punch off plOlon mate shaft lock FA for
Beanng InspectIOn
Puller ST30031000 and extract from pm from rIng gcar Side usmg SolId 4 Inspect thrust washer faces Small
dnve pm IOn With See Punch KV311 00300 faults be corrected WIth sand
a press Figure can

PD 16 paper If plOlon ma tc to slde gcar

Note Lock pm IS caulked at pm hole
backlash or thc dearance between
mouth on dlfferenllal case Do not
Side gear and thrust washer exceeds
punch It off forCibly Without
lImits 0 I to 0 2 mm 00039 to
check 109 how It IS caulked
0007910 replace thrust washers

4 Draw out pmlOn mate shaft and 5 and differentIal

Inspect Lamcr
remove
plOlon mJte gears Side gears case for Lracks or distortIon If either
and thrust wdshers condItIon eVIdent
replace
IS

As
ST30031000 Note Put marks
6 general rule 011 seal
a should
gear and thrust
on
be replaced at each dIsassembly
washer so that they can be remstal
led in theIr ongmal posItIons from
which they were removed

PO 179

F g PD 16 RemOVIng pmlOn rear

bearing mner race

ASSEMBLY AND
9 To remove front and rear
bearIng ADJUSTMENT
outer races put a dnft to race surface
Assembly can bc done 10 the re

and Withdraw them by tappmg the top

verse order of disassembly The follow
of dnft With a hammer INSPECTION
109 dneLllOns for adjustment and

Thoroughly clean all dIsassembled usage of speCIal tools enable to obtalll

parts and examme them to see that a perfect dlffcrenllal operatIOn

they are worn or damaged and how

DISASSEMBLY OF
they are affected Repau or replace all
DIFFERENTIAL CASE
faulty parts wluchever IS necessary PRECAUTIONS IN
IExtract bearIng usmg DifferentIal REASSEMBLY
I Check gear teeth for scorIng
SIde Bearing Puller ST3306S001 set I
cracklllg or Chlpplllg and make sure Arrange slums washers and the
of ST3305l001 and ST3306l000 lIke to mstall them
that tooth contact pattern mdlcates correctly
See PD 17
Figure 2 Thoroughly clean the surfaces on
correct meshmg depth If any fault IS

eVlden t which shims washers bearings and

replace parts as requued
bearing retalllers are lOSt ailed
Note DrIve pmlon and drIve gear are 3 011 when
Apply gear mstallIng
supplIed for replacement as a set bearings
therefore should either part be 4 Pack recommended multi purpose
1replace as a set
damagl grease Lavlty hctwccn lips whcn fill 109
011 seal
2 Check plOlon gear shaft and

pmlOn gear for scores and signs of

ASSEMBLY OF
wear and replaLe as requlrcd
DIFFERENTIAL GEAR CASE
Follow the Sdmc
proLcdure for Side
POOBl
gear dnd thclr seals on differential I Assemble pmlon mates Side gears
and thrust washers 10 differentIal case
Fig PD 17 RemOVIng s de bearing case

PO 10
 Propeller Shaft Differential Carner

2 FIt 10 Set new 011 seal on Side retaIner

pInIon shaft to dIfferentIal
case so that It meets lock pIn holes USIng OIl Seal DrIft Sn3270000
recommended
3 Adjust SIde gear to pInlOn mate Apply multI purpose

backlash or
adjust the clearance be grease cavIty between seal lIps
tween the rear face of SIde gear and
thrust washer See PD 18
Figure
If above procedure IS not effectIve
with wIth
eXistIng washer try other
PD124
washers avaIlable for the purpose ADJUSTMENT OF
Normal backlash or clearance Fig PD 19 Tapping bolt head
DRIVE PINION PRELOAD
0 1 to 0 2 mm

00039 to 0 0079 of drIve pm IOn WIth

In
Adjust preload
spacer and washer between front and
7 When SIde
replaCIng beanng rear
bearIng cones regardless of thIck
measure beanng WIdth USIng Master washer
ness of pmlOn heIght adJustmg
Gauge KV38101900 and Weight Block ThiS adjustment must be carned
ST32501000 pnor to InstallatIOn See out WIthout 011 seal Inserted
FIgure PD 20
Press fit front and rear bearIng
Standard beanng WIdth
outer races Into gear carrIer usmg
2000 mm
Dnve PInIOn Outer Race Dnft Set
ST30611000 ST30701000 and
ST30613000

Front Sn061100 and

F g PD 18 Measuring clearance ST307QlO00

Rear Sn0611000 and
S 30613000
Beanng

Side gear thrust washer 2 Insert pInIon heIght adjustIng

washer use 3 09 thickness and rear

bearlOg cone Into Dummy Shaft

Thickness 111m In ST3l212000 to make convenIent to

adjust pInion heIght See FIgure

Fig PD 20 MeaSUring bearing WIdth
o 75 to 0 80 0 0295 to 0 0315 PD 24

080to085 00315 to00335

8 Press fit Side beanng cone on
Note Reuse the old washer If they
085 to 0 90 0 0335 to 0 0354 differential case usmg Gear Carner have normal tooth contact pattern
Side Beanng Dnft Sn3230000 and In a disas embly
pre check
Adapter Sn3061000 See Figure
PD 21 3 Fit drIve pInIon beanng spacer
4 Lock pInIOn shaft lock pIn USlOg a washer front cone Dnve Pm
beanng
punch after It IS secured 10 to place Ion Dummy Collar Snl214000 and

5 Apply oIl to gear tooth surfaces companIon flange In on thiS order

and thrust surfaces and check If they dummy shaft and tIghten dnve pmlOn
turn properly nut to the speCified torque usmg
6 Place rIng gear on dIfferentIal case Snl213000 See Figure
Stopper
and mstall bolts and lock washers
PD 22

TIghtenIng torque
7 to 8 k m

51 to 58 ft lb

PD244 sn 3061 000

Fig PD 21 Installzng SIde bearing

Notes cone

a Use only genuIne rmg gear bolts

and new lock washers 9 Press fll Side bearmg outer race

PD184
b Tighten bolts in ross fashIOn
criss mto Side retall1er lIsmg Dnve PlOlOn

lightly tappIng around bolt heads Outer R lle Dnft Set Sn061 1000 and
nut
WIth a hammer See PD 19 sn062 1000 Fig PD 22 TIghtening drIVe pinIOn
FIgure
PO 11
 Propeller Shaft Differential Carner

Measure pInIon beanng preload PmlOn bcanng adJustmg wash r

usmg Preload Gauge Sn127S000 and

select washer and spacer that wIll ThICkness mm 10

See Figure
proVIde required preload
PO 23 230 to 232 0 0906 to 0 0913

232 to 234 0 0913 to 0 0921

234 to 236 0 0921 to 0 0929

2 36 to 2 38 00929 to 0 0937
Pm beanng preload
IOn P009l
2 38 to 2 40 0 0937 to 0 0945
WIthout 011 seal 240 to 242 00945 to 0 0953
7 to I 0 kg m F g PD 23 AdJustmg pmlOn height
242 t02 44 00953 to00961
6 I to 8 7 m Ib
244 to 246 0 0961 to 0 0969
At companIon flange bolt hole 3 The thIckness of dnve pmlon
2 0 to 9 kg 246 to 2 48 00969 to 0 0976
height adJustmg washer can be ob
44 to 6 41b 2 48 to 2 50 0 0976 to 0 0984 tamed from the followmg formula
TIghtenIng torque of pInIon nut 2 50 to 2 52 0 0984 to 0 0992
17 to 20 kg m
252 to 254 0 0992 to 01000
123 to 145 ft Ib T W N H 0 S x 001
254 to 2 56 0 1000 to 0 1008
02
256 to 258 0 1008 to 01016
258 to 260 0 1016 to 0 1024
Where
Notes
a Replace bearmg washer and spacer T ReqUIred thIckness of rear bear
WIth thicker ones If pmlOn cannot
Ing adJustmg washers mm
be turned by hand whIle It IS
bemg W
I
ThIckness of washers temporan
tIghtened ADJUSTMENT OF ly mserted mm
b Preload of used beanng IS the same N Measured value With thickness
value as that of a new bearmg DRIVE PINION HEIGHT gauge mm

H marked the dnve pm

Adjust pInIon heIght with washer Figure on

Ion head See FIgure PO 26

proVIded between rear bearIng cone

and back of pmlon gear 0 Figure marked on the dummy

shaft
1 InstaU HeIght Gauge Snl211 000 S Figure marked on the height
on carner with dummy shaft mounted gauge
See Figure PO 25

2 Measure the clearance be for H 0 and S are

N FIgures
tween the tip end of height gauge and dImensIOnal vanatIons m a UnIt of
the end surface of dummy shaft usmg 1 100 mm agamst each standard meas

ST3I 27S000 thIckness gauge See PO 24 urement

a
Figure
P0245

F g PD 23 MeaSUring pmlOn preload

Pmlon beanng adJustmg spacer

Length 10m 10

5620 22126

5640 2 2205

5660 2 2283
r

5680 2 2362
Helllhl gauge
5700 22441 ST3l211 000
IP018S
57 20 2 2520

FIg PD 25 Measurmg the clearance

PD 12
 Propeller Shaft Differential Carner

3 09 0 45 0 0 2 5 Lubncate pinIon front and rear

334mm Install dnve pmlon

bearIngs In
gear
Hcad
3 33 carner mto w1l1ch dnve pinion bearmg
The correct washer IS mm
numbl r
and washer front
H thick spacer bearlOg cone
and front bearIng pilot spacer more
Note If values sIgnifying H D and S
over
pilot bearIng and 011 seal are
P0186
fitted Fit 011 seal usmg 011 Seal DrIft
are not gIven regard them as zero
Fig PD 26 VariatIOn number on STJ0720000
and compute After assembly
drIVe pinIOn 6 FIt dnve
check to see that tooth contact IS compaOlon flange on

plOlon and secure It In

pOSItIon by
ofcalculatIon correct If not readjUst
Examples
For the tooth contact tIghtenIng nut to speCIfied torque con
Exl pattern see

page PO IS for Contact Pattern

firmIng preload
W 309mm
N 0 33 mm
washer TightenIng torque
H 2 0 1 S 0
PIOIon height adjustIng 17 to 20 kg m

T W N H 0 S 0 Thickness mm In 123 to 145 ft Ib

x 01 Preload wIth 011 seal
02
8 to 11
kgm
309 033 2 1 309 01217 69 t09 5 m Ib
O xOOI 02 01228
3 12 At compaOlon flange bolt hole
3 09 0 33 2 I 0
315 01240 2 3 to 3 2
xOOI 02 kg
3 18 0 1252 5 I to 7 1 Ib
3 09 0 33 3 x 001 0 2
3 09 0 33 3 21 0 1264
0 03 0 2
Note If drive pmlon lock nut IS worn
319 mm 324 01276
replace It
The correct washer IS 3 18 mm 327 0 1287
thIck 330 0 1299

333 01311 ADJUSTMENT OF SIDE

336 01323 RETAINER SHIMS
Ex 2
339 01335 1 If the hypOld gear set carner
W 309mm
342 0 1346 differential Side
beanng or Side
case
N 028mm
345 0 1358 beanng retamer has been
replaced With
H 2 0 1 S 1
348 0 1370
new part
adjust the Side bearIng pre
T load With adJustmg shim The reqUIred
W N H O S x001 3 51 0 1382
02 thicknesses of the left and nght re
354 0 1394
309 028 2 1 tamer shims can be obtamed from the
357 0 1406
I xOOI 02 follow 109 formulas

3 09 0 28 2 I I 360 01417
TI A C GI D xOOI
363 0 1429
x 001 0 2
0 76 E
3 09 0 28 2 x 001 3 66 0 1441
T2 B D G2 xOOI
02
0 76 F
309 028 002 02
Where
319 mm 4 Fit determIned pInion height ad
TI ReqUIred tluckness 01 lelt Side
The correct washer IS 3 18 mm Justmg washer In dnve pInIOn and
retJmer hlnI 10m
thIck press fit rear
bearIng LOne In It usmg
T2 ReqUIred thickness of nght Side
Base STJ0032000 See Figure PO 27
retamer slum 10m

A B Flgurc marked on the gear

Ex 3
carner See Figure PD 29
W 309mm C D Figure marked on the dIffer
N 045mm entIal caseSee Figure PO 30
H 0 0 0 S 0 E F These are dIfferences m WIdth
of left or nght Side beanng agamst
T W N H 0 S x 001
the standard WIdth 2000 mm
02
rom
3 09 045 0 0 0
IfbearlOg Width IS 19 89 the differ
x 0 01 02
ence win be as follows
309 045 OxOOI P0092

02 Fig PD 27 Pressing rear bearing cone 2000 19 89 011

PD 13
 Propeller Shaft Differential Carner

0 07
GI G2 Figure marked on the left Examples of calculatIon The correct slums are plus
Side See o 50 thIck
or
nght retamer Figure Ex 1 mm

PD 3I
A 5 B 5 C 3 D 3

4 I E 011
Figures for A B C D GI and G2 GI G2 O1m

dimensional vandtlons 10 a UOlt of F 015 mm

are

each standard SIde

1 100 mm
agamst eas
Left SIde
RIght
urement B 0 01
T2 D G2 x
A C C D xOOI
To measure Width of Side beanng TI 0 76 F
0 76 E
see differential case assembly pro 3 3 3 0 76
5
x 001
ced me 3 4 3 x 001
0 11 017
0 76
9 x 001 0 76 017
9 x 001 0 76 0 11
0 09 0 76 0 17
0 09 0 76 0 11
068mm
GI G2 074mm

The correct shIms are as follows

The correct shlfOS are as follows

thIckness QuantIty
007 2 014 Thickness
x
Quantity
010 x I 10
0 007 x 4 028
T2 050 x I 0 50 020 x 2 040
P0093

Fig PD 28 Th ckness of left and Total thickness 0 74 mm Total tlnckness 0680101

right shIms

RIght SIde
B D xOOI 076
T2 G2
F
Note If values slgI1 fymg A B C D
5 3 I x 001 0 76
Gl and G2 are not given regard
015
them as zero and compute
9 x 001 0 76 0 IS After assembly check to see that
009 0 76 015
Fig PD 29 A B figure preload and backlash are correct If

10
0 70 mm
not readjust

The correct shuns are 0 20 plus

050 mm thick Side retamer adJustmg shim

ThKkness mm 10

005 00020

007 0 0028
P0188
Ex 2
o 10 0 0039
Fig PD 30 C D fgure
A 2 B 3 C 0 D 3
o 20 00079
2 3 E 0 20 mm
GI G2
050 00197
F 0 17 O1m

Left SIde
2 In tall differential case
assembly
TI A IC C D xOOI ngearcarner n reverseoriferto
0 76 E which It IS dlsassembletl I

2 0 2 3 x 001 3 Fit gIVen slums and O nng 10 both

0 76 0 20 Side retamers and mstall retamers m

Re
1 x 001 0 76 0 20 carner usmg Gear Carner Side
P0189 0 01 0 76 0 20 tamer GUide ST33720000 See Figure
Fig PD 31 01 02 fgure 057 mm PD 32 and the arrow mark on retam

PD 14
 Propeller Shaft Differential Carrier

er positIOned as shown 10 Figure If

preload IS not aLcordlng to tlus c Flank contact
PD 33 speCifiCatIOn adjust It With Side retain Adjust In the same manner as In b
er slums See
Note When installIng retainers take FIgure PD 37
InCidentally decrease or Increase In
care that Side bearIng outer races
tluckness of slums causes change of
are not damaged by roller
ring gear to plnlOn backlash
Thus check If they have proper
backlash
6 Check and adjust the tooth con

tact pattern of rmg gear and drIve Vt

pinIon PD195
1 Thoroughly clean nng and drIve Fig PD 37 Flank contact
pinion gear teeth
2 Pamt nng gear teeth lIghtly and
d Face contact
evenly wlIh a mixture of powdered red

lead and 011 of a SUItable consistency Adjust In the same manner as In a

See FIgure PD 38
to produce a contact pattern
3 Rotate pinIOn through several
Fig PD 32 Installing s de retainer
revolutIons In the forward and reverse

dIrection untIl a definIte contact pat

tern IS developed on rIng gear
4 When contact pattern IS mcor
rect readjust tluckness of adjust shim
Be sure to wIpe off red lead com

pletely upon completIOn of adjust

PD196
ment
5 Fig PD 38 Face contact
Incorrect contact pattern of
teeth be the
can adjusted In follOWIng
manner e Correct tooth contact
PD1 2

Fig PD 33 The arrow mark on

Contact pattern
rftalner
a Heel contact

4 Measure rIng gear to dnve pinion To correct mcrease thIckness of

order
backlash by usmg a dIal indIcator and pmlOn heIght adjustIng washer m

adjust It to 0 1 to 0 2 mm 0 0039 to to bnng dnve pmlon close to rmg gear

0007910 See FIgure PD 34 See FIgure PD 35
PD197
If It IS below the speCified value
move shim from nght to left If It IS
Fig PD 39 Correct contact
over It move It mversely
Note Change In thick
1ess of ad

Justing washer IS accompanIed by

change In backlash Check It when

Installing gear
PD193

Fig PD 35 Heel contact

7 Install rear cover

b Toe contact 8 FIt dIfferential mountIng mem

ber and
tIghten nuts to speCIfIed
To correct reduce thIckness of
torque of 6 to 8 kg m 43 to 58 ft Ib
pmlon heIght adJustmg washer In order
PD32l to make drIve pmlOn go away from

Fig PD 34 Measurlng the backlash of nng gear See FIgure PD 36 INSTALLATION

rlng gear and pinIOn

Install In the reverse order of re

5 At the same time check Side moval

bearing preload Bearing preload I Poslllon gear carner assembly

should be 9 to 17 cm
kg 78 to 148 onto member and
Vf
rear suspensIOn
m Ibof rotatmg torque at compaOlon It WIth four bolts
temporarily IIghtcn
flange 26 to 49 kg 5 7 to 1081b PD194 together With dIfferential mountIng
at companIon flange bolt hole Fig PD 36 Toe contact spacer See FIgure PD40
PO 15
 Propeller Shaft Differential Carner

5 Extract compaOlon flange usmg al

standard puller See Figure PD43

P0324

Fig PD 41 Tightening Side yoke

xing bolt
Fig 43
PD RemOVing companIOn
PD242
5 Jom dnve shafts wIth companIOn flange
Nut 6 Remove 011 seal Gear
T
flanges of rear axle shafts and tIghten usmg
S to 7 kg m 36 to S I fI Ib
Carner 011 Seal Puller ST33290001
2 Suspcn lOn member connectmg bolts to speCIfied torque
See PDM
3 Spdccr Figure
Tlghtenmg torque
4 Dlff carner assembly ST33290001
5 to 6 kg m

36 to 43 ft Ib
Fig PD 40 Layout of spacer
6 Install other parts 10 the manner

reverse ofremoval
DIfferentIal mountmg spacer 7 FIll correct gear 011

ThIckness mm 10 Note 011 quantity 0 8 lIter

Ji U S qt Y Imp qt
PD265
A 4 5 0 177
Fig PD 44 RemOVing 0 1 seal
B I 0 0 039
REPLACEMENT OF
7
FRONT OIL SEAL Set new 011 seal 10
pOSitIon usmg
Gear Carner OU Scal Dnft
2 Fit differential mountmg member Replacement of front 011 seal With
STJ0720000 Apply grease cavity
to flttmg bolts by pushmg It forwards differential gear carner assembly 10
between seal lIps
and torque nuts to 7 to 10 kg m 51 to stalled on the car
8 FIt compaOlon flange on dnve
72 ft Ib Procedures are as follows
pmlOn and secure them 10 pOSItIon by
3 Sewre gear carner assembly onto
Dram gear 011 tIghtenlOg nut tospeCified torque con
rear suspensIOn member wIth four 2 RaIse the rear end of car and firm109 the followmg preload USing
bolts
support It Withsafety stands DrIve Pmlon Flange Wrench

Tlghtenmg torque 3 Detalh

propeller shaft from com STJI530000
5 to 7 pamon flange of carner
kg m
Ttghtenmg torque of
36 to 51 ft Ib 4 Remove dnve pmlon nut holdmg
pmlOn nut
companIon flange With Dnve PI111011 17 to 20 kg m

Flange Wrench Snl530000 Sce 123 to 145 ft Ib

4 Install sIde yokes together wIth Figure PD42
Pm IOn
dnve shafts to dIfferentIal gear carrIer beanng preload
and Side WIth 011 seal
assembly tIghten yoke fixmg
bolts to 8 to 11 cm
kg
specIfied torque USlllg torque
wrench 7 0 to 9 6 m Ib
See FIgure PD4l

Tlghtenmg torque At companIon flange bolt hole

3 2 to 4 3 kg m 23 to 3 2 kg 5 1 to 7 lIb

23 to 31 ft Ib

Note Be careful not to SIde

damage
yoke and oil seal when installIng

9 Remstall propeller shaft by re

PD322
versmg the forego 109 removal pro
Fig PD 42 RemOVing drIVe pm on

nut cedure And fill up gear oIl

PD 16
 Propeller Shaft Differential Carner

SIDE OIL SEAL

SIde 011 seal IS

replaced by usmg the Note Apply grease to caVIty between 6 10m dnve shaft WIth companIon
followmg procedures oil seal
lips flange of rear axle shaft and
tighten
1 Disconnect dnve shaft on the connectlOg bolt to speCified torque
5 Install SIde yoke together With
wheel SIde
dnve shaft to dIfferential gear carrIer
2 Remove SIde yoke ftxlOg bolt Ttghtenmg torque
assembly tighten Side yoke fixmg bolt
and extract SIde yoke together With 5 to 6 kg m
to speclfted torque uslOg torque
dnve shaft See FIgure PD 1O 36 to 43 ft Ib
wrench See Figure PD41

Note Be careful not to damage SIde

yoke and oil seal when removmg TlghtenlOg torque Note Check ring
O of side yoke fIX
3 2 to 4 3 kg m 109 bolt If necessary remove urn
Remove oLl seal
3 uSIng OIl Seal 23 to 31 ft Ib versal JOlOt spIder located at the
Puller ST33290001 SIde yoke side and replace Oi
lng
4 Set 10 new 011 seal USing 011 Seal Note Be careful not to
damage side Refer to Section RA for Disassem
Drift ST33270000 yoke and oLl seal when instaUing bly and Assembly

PD 17
 Propeller Shaft Differential Carner

DIFFERENTIAL CARRIER TYPE H165B

FOR STATION WAGON RIGID AXLE

CONTENTS

DESCRIPTION PD 18 ASSEMBLY OF DIFFERENTIAL

REMOVAL PD 20 GEAR CASE PD 21

PRE DISASSEMBLY INSPECTION PD 20 ADJUSTMENT OF DRIVE PINION

HEIGHT PD 22
DISASSEMBL Y PD 20

DISASSEMBLY OF DIFFERENTIAL ADJUSTMENT OF DRIVE PINION

CASE PD 20 PRELOAD PD 23

PD 2l ADJUSTMENT OF SIDE BEARING

INSPECTION
ASSEMB L Y AND ADJUSTMENT PD 2l SHIMS PD 23

PRECAUTIONS IN REASSEMBLY PD 2l INSTALLATION PD 25

REPLACEMENT OF FRONT OIL SEAL PD 26

DESCRIPTION
The dIfferentIal gear carner assem The dnve pinIon IS
posItioned by a case houses two SIde gears m mesh

bly for StatIon Wagon IS available m washer located between a shoulder of With two pInIons mounted on a pm Ion
type Hl65B as mdlcated 10 the follow the dnve pInIon and the beanngrear shaft The pmlon shaft anchored 10 the
The dIfferential The pmlons and Side
Ing table supported 10
case IS case by lock pm
The dIfferentIal gear carner assem the carner by two tapered roller Side gears are backed by thrust washers

bly has hYPold type dnve pmlOn and beanngs These are preloaded by m The carner IS ofmalleable cast Iron

rIng gear set WIth a gear ratIo of 3 889 sertmg shlfOs between the bearmgs and
The dnve pInIon IS mounted 10 two thc differentIal case The differential Note Replacement of front od seal

roller which case assembly IS for proper

pOSItioned With differential gear carner assem
tapered beanngs are pre
loaded by a collapsIble spacer dUrIng nng gear to
drIve pmlon backlash by bly mstalled on the car must not be
varymg these shuns The nng gear IS allowed due to used collapsible
assembly
bolted to the dIfferentIal case The spacer on ItS model

Type ofgear carner

RI60 HI65B
assembly

Gear ratIo 3700 4 III 3889

model Ll8 Ll8 Ll8

Engme

StatIon
Car model Sedan Hardtop
yagon

PO 18
 Propeller Shaft Differential Carrier

TYPE H16SB

I Compamon flange
2 011 seal
Supply grcase to otl seal hp
when assembhng
3 PInion front bearIng

4 Collapsible spaccr
Adjust plmon beanng preload
by thIS spacer Proccdurc can
be accomphshcd by referrmg to

Adjustment of dnve plmon

preload
S Dnve plnton
6 PInIOn rear bcanng
7 PInIOn hClght adJustmg washcr
8 Lock pm
9 SIde beanng
10 SIde bearIng adjustIng shlDl
Adjust Side beanng preload and
nng gcar t
Hlrlve
pmlon backlash
by selectmg @
11 SIde gear
I2 Thrust washer
Adjust pmlon mate to slde gear
backlash the clearance be twecn
or

the rcar face of sldc

gcar and
thrust washcr 0 I to 0 2 mm

O 0039 to 0 0079 10 by @
13 Thrust washer

14 PInIon mate
IS DlffercntIal pmlon shaft
16 RIng gear

Ring gear dnvc

to pUllon
backlash 0 10 to 0 15 mm

O 0039 to 0 00S9 10
17 Dlffercntlal gear case
18 Lock strap

TIghtemng torquc f of
bolts and nut kg m ft Ib

@ T Morc than 14 101

ThtS nut should tIghtencd

by refcrnng to Adjustment
of dnve pinIOn preload

@ T S to 6 36 to 43
7 to 8 51 to S8
@ T

L 17323 to 173 29 mm
6 8201 to 6 8224 10

PD3l6

Fig PD 68 SectlO
1ll vIew ofdlfferentlal carrier for Statlon Wagon

PD 19
 Propeller Shaft Differential Carrier

REMOVAL For the tooth contact pattern see Note 011 seal must not be reused
page PD 25 for Contact Pattern
Jack up rear of car and support It 5 Hold rCdr
beanng Inner race With
safety stand under rear DrIve PInIOn Rear Beanng Inner Rdce
by plaCIng a

axle case Dram gear oLl Puller ST30031000 and extract from

2 Remove shaft and dnve pInion With a press See Figure

propeller rear

axle shafts These works can be done

DISASSEMBLY PD 72

as descnbed In SectIOn RA for Re I Put match marks on SIde bearIng

moval and and
caps carner remove Side
3 Loosen off nuts securmg differ
beanng caps and take out dlfferenllal
enllal carner to rear axle case and case
assembly See FIgure PD 70
take out differentIal gear carner assem

bly ST30031000

PRE DISASSEMBLY
INSPECTION
Differential PD205
case or carner should
be Inspected before any parts are Fig PD 72 RemOVing pln on rear
removed from It bearing Inner race
These InspectIOns are
helpful m PD266
6 To remove outer races of both
findIng the cause of the problem and
Fig PD 70 RemOVing differential front and rear beanng apply a brass
In
determInIng the correctIons needed
case assembly dnft to race Side surface and WIth
I Mount carner on Gear Carner
draw them the top
by hghtly tappIng
Attachment ST0636000l See FIgure of drIft With a hammer See Figure
PD 69
Note Care should be taken PD 73
not to
confuse the left and right hand
beanng caps andheanng outer races
so that reassembly will be easily
earned out WIth the same parts 10

the origmal position

2 Remove dnve pInion nut USIng
Dnve PInIOn Flange Wrench
ST31530000 and pull off compaOlon
flange USIng a suitable puller See
ST0636000l P0268
PD71
Figure
PD20l
Fig PD 73 RemOVing pinIOn front and
rear bearing ou ter races

Fig PD 69 Holding differential carrier

DISASSEMBLY OF
DIFFERENTIAL CASE
2 Visually Inspect parts for wear or
I When replacmg SIdebeanng use
damage
3 Rotate gears to see that there IS Gear Carner Sldc Beanng Puller
ST3305S001 set of ST33051001 and
any roughness which would Indicate
ST33052000 See Figure PD 74
damaged beanngs or chipped gears
Check the gear teeth for SCOrIng or Fig PD 71 RemOVing tjnve pinIOn
nut
signs of abnormal wear Measure pre
load ofdnve pinIon
4 Set up dIal Indicator dnd check 3 Extract drive lIRlOn
d
assembly to

the backlash dt several pOInts around the realWards by tappIng the front end

nng gear Backlash should be 0 10 to With a soft hammer Dnve pInIOn an

015 mm 0 0039 to 00059 be taken out
In together wllh rear bear
5 Check the tooth contact and
gear 109 lOner race bearIng spacer
With a mIXture of powdered red lead
and 011 applIed spanngly to all nng 4 Remove 011 seal and take out P0081

gear teeth front bearing Inner race Fig PD 74 Remov ng side bearing

PD 20
 Propeller Shaft Differential Carrier

Notes Note DrIve plmon and rmg gear are ASSEMBLY OF

a Pullcr should be handled WIt h care supplied for replacement as a set
DIFFERENTIAL GEAR CASE
therefore should eIther part be
of
In catching the edge bearIng
lOner race damaged replace as a set 1 Assemble pInIon mates Side gears
b Be careful not to confuse left and and thrust washers In differentIal case
2 Check pInion gear shaft and pin
fight hand parts 2 Fit pmlon shaft to differentIal
Ion gear for scores and sIgns of wear
case so that It meets lock pm holes
2
and replace as requued
Remove nng gear by spread 109 Follow the same procedure for Side 3 Adjust pinion mate to slde gear
out lock strap and loosemng nng gear backlash
gear and their seats on differential or the clearance between the
bolts 10 diagonally face
case rear of SIde gear and thrust
3 Punch off pInIOn mate shaft lock
3 Inspect all bearing races and roll washer to 01 to 02 mm 00039 to
pm from rIng gear Side usmg SolId select 109 SIde gear thrust
ers for sconng chIppIng or eVidence of 00079 10
by
Punch KV31100300 See FIgure excessive wear They should be In washer
PD 75
tiptop condItIon such as not worn and
With mirror like surfaces Replace If
there IS a shadow of doubt on their Side gear thrust washer
effiCiency as an Incorrect beanng op
eratIon may result 10 nOises and gear Thickness mm 10

seIzure If you need the infOrmatIOn

on Vlsual SefVlceabllIty Standard for o 785 0 0309

Taper Roller BearIng refer to Section 0835 00329

FA for InspectIon
o 885 00348
4 thrust washer faces Small
Inspect
faults can be corrected WIth sand I 035 0 0407

paper If pInion mate to side gear I 185 0 0467

backlash or the clearance between
Fig PD 75 RemOVing lock pm Side gear and thrust washer exceeds
lImits 0 I to 0 2 mm 0 0039 to
00079 In
replace thrust washers 4 Lock pmlOn shaft lock pm USing a
5 Inspect carner and differential
Note Lock pIn IS caulked at pIn hole punch after It IS secured IOtO place
case for cracks or distortion If either
mouth on dIfferential case Do not 5 Apply 011 to gear tooth surfaces
condItion IS eVIdent replace faulty
off without and thrust surfaces and check If they
punch It forcibly
parts
checkIng how It IS caulked turn properly
6 As a general rule 011 seal should
6 Place nng gear on differentIal case
be
4 Draw out pmlon mate shaft and replaced at each dIsassembly and Install bolts and lock washers
remove pmlon mate gears SIde gears and
Torque bolts to speCificatIon
and thrust washers bend up lock washers
ASSEMBLY AND
Note Put marks on gear and thrust ADJUSTMENT Tightening torque
washer so that they can be re 7 to 8 kg m
Assembly can be done In the re
mstalled 10 their orlgmal positions 51 to 58 ft Ib
verse order of disassembly The follow
from which they were removed
Ing directions for adjustment and
Notes
usage of speCial tools enable to obtam
a Use only genuIne drIve gear bolts
a perfect differential operatIon
and new lock washers
b Tighten bolts m cross
cllSs fashIon
INSPECTION
PRECAUTIONS IN lightly tapping around bolt heads
WIth a hammer
Thoroughly clean all dIsassembled REASSEMBLY
parts and examme them to see that I Arrange slums washers and the
they are damaged
worn or otherWISe lIke to Install them correctly
faulty and how they are affected 2 clean the surfaces on
Thoroughly
RepaIr or replace all faulty parts
7 When replacmg SIde beanng
which shims washers beanngs and
whIchever IS necessary
measure beanng Width usmg Master
beanng caps are Installed
Gauge ST33741000 and a WeIght
3 011 when mstallIng
I Check gear leet h for scormg Apply gear
Block ST32501000 pnor to IOstalla
U JLkmg or
chlppmg and make sure beanngs tlOn See FIgure PD 76
thJt tooth tOntJct pattern indicates 4 Pack recommendcd multI purpose
Standard beanng WIdth
correct meshing depth If any fault IS grease cavIty between hps when flttmg
eVIdent ou seal 185 mOl 0 7283 In
replace parts as reqUIred

PD 21
 Propeller Shaft Differential Carner

Head
number
H

P0186

Fig PD 80 Variation number on drIVe

pinion
P02l0

w dth
Fig PD 76 Measuring bearing Fig PD 78 Adjusting pm on he ght

3 Measure the clearance N be

8 P ress fit Side beanng cone mto
tween the tIp end of height gauge and
dlfferenl1al case usmg Gear Carner
the end surface of dummy shaft usmg Examples of calculatIon
SIde BearIng DrIft KV38102l00 and a tluckness gauge See Figure PD 79 Ex I
Adapter ST33052000 See FIgure
PD 77 N 042mm H 2 D I

S I

T N H 0 S x 0 01
2 98

0 42 2 I 1

xOOI 298
0 42 2 1 1 x 001
298
0 42 2 x 001 2 98

042 002 2 98
3 38 mm

4 The thickness of dnve pmlOn The correct washer IS 3 39 mm

P0244

heIght adJustmg washer can be ob thIck

Fig PD 77 Installing s de bearing tamed from the followmg formula
cone

ADJUSTMENT OF DRIVE Ex 2
T N H D S x 0 01
PINION HEIGHT
298 N 0 35 mm H 3 D I

Adjust the pinIon heIght with wash S 2

er provIded between rear beanng lOner

T N H 0 S x 001
race and the back of pmlOn gear
2 98
Press fIt front and rear beanng 0 35 3 1 2
Where
outer races mto gear carner USlOg xOOl 298
Dnve PmlOn Outer Race Dnft Set
T I 2 xOOI
ReqUired thickness of rear bear 035 3
ST30611000 ST30701000 and
109 adJustmg washer mm 298
STJ0613000 N 035
Measured value with thIckness 2x001 298
Front STJ0611000 and mm 0 35 0 02 2 98
gauge
STJ0701000 H marked the dnve pm 3 35 mm
Figure on

Ion head See Figure 80

PD The correct washer IS 3 36 mm
Rear STJ0611000 and
D marked the
STJ0613000 Figure on
dummy thIck

I shaft
2 FIt bearIng on carner and
rear S Figure marked on the hctght
mstall Dummy Shaft on rear beanng gauge

and place Height Gauge on carner See

FIgure PD 78 Figures for H 0 and S are dimen

SiB 1 141000 Height gauge sIOnal va natIons 10 a UnIt of 1 100 10m

STJI942000 Dummy shaft agamst each standard measurement

PD 22
 Propeller Shaft Differential Carner

Ex 3 5 FIt determmed pmlOn heIght Whcn the dnve pmlon end play IS
washer dnve and elImmated the
N 051 mm H O D O adJustmg 10 pmlon speCified preload IS
S O press fit rear beanng mner race m It bemg approached Replace collapsIble
usmg Base ST30032000 spacer If thIS speCification IS exceeded
T N H D S x001
2 98 Note Do not decrease preload by
051 0 0 0 x001
100senIDg pInIOn nut ThIS will re

2 98
move compressIOn between pmlOn
O I Ox001 298 ADJUSTMENT OF DRIVE
front and rear bearmg cones and
0 51 0 2 98 PINION PRELOAD
collapsible spacer and may permIt
0 51 2 98
of drIve pm On
Adjust the
preload front bearIng cone to turn on dnve
3 49 mm
with collapsIble spacer pmlOn moreover nut becomes
The correct washer IS 3 48 10m ThiS proced ure has nothmg to do loose

tlnck wIth thIckness of pmlOn heIght adjust

7 Turn dnve plOlon 10 both dtrec
mg washer
tlOns several times to set beanng
of a
Note Reuse collapsible spacer rollers And
adjust beanng preload to
If values H D and S
Note slgmfYlng must not be allowed
speCIfIcations usmg Prcload Gauge
are not gIven regard them as zero
ST3127S000 See Figure PD 81
1 After
and compute After assembly adJustmg pm Ion height
lubncate front beanng WIth gear 011
check to see that tooth contact IS
c
and It of pInIon nut
correct If not readjust place 10 carner
Tlghtenlllg torque
2 Install a new 011 seal 10 carner l4to 17kg m
For the tooth lcO
tact pattern see

uSIng 011 Seal Dnft ST33400001 101 to 123 ft Ib

25 for Contact Pattern
page PQ
LubrIcate cavity between seal lIps WIth Preload WIth 011 seal

recommended multi purpose greasc 8 to II kg cm

when 69 to 9 5 Ib
mstallIng m

3 Place a new
collapsIble spacer on At companIon flange bolt hole
dnve 20 to 29 kg 44 to 641b
pmlOn and lubncate pmlon rear

bearIng WIth gear ou

4 Insert companIon flange mto otl Note Preload of used beanng IS the
washer seal and hold It firmly agamst
PlOlOn heIght adJustmg pmlOn same value as that of a new bearIng

front From the of

bcanng cone rear

the carrIer msert dnve pInIon mto

ThIckness mn m companIon flange

5 Ascertam that threaded portion
309 01217 of drIve pmlon and a new
pInIon nut ST3l27S000

0 1228 are free from 011 or

grease
3 12
6
315 01240 Holdmg flange WIth
companIon
DrIve PmlOnFlange Wrench
318 01252
ST31530000 and then
tighten nut
321 01264 dnve plmon IS pulled mto front bear

324 01276 Ing cone and mto flange

3 27 0 1287 As dnve pmlon IS pulled mto front

3 30 0 1299 beanng cone dnve pm IOn end play IS

PD270
reduced WhIle there IS sttll end play m
333 01311
drIve plmon Fig PD 81 Measuring pinIOn preload
companIon flange and
3 36 0 1323
cone wIll be felt to bottom Tins
3 39 0 1335 mdlcates that beanng cone and com

3 42 0 1346 pamon flange have bottomed on col

345 01358 lapSIble spacer ADJUSTMENT OF SIDE
348 01370 thIS pomt a much greater
From
BEARING SHIMS
torque must be applIed to turn pmlOn
3 51 0 1382
I If hYPOld gear set carner dIffer
nut smce spacer must be collapsed
354 01394 entIal case or Side bearIng have been
From thIS pomt nut should also be
357 0 1406 replaced With new ones adjust the SIde
tightened very slowly and dnve pm On
360 01417 end play chccked often so that pmlOn beanng preload WIth adJusttng shlfO
The reqUIred thickness of adJustmg
363 0 1429 beanng preload does not exceed the
lImits shIm can bc calculated by the follow
366 01441
109 formulas

PD 23
 Propeller Shaft Differential Carner

TI A C 0 H x 0 01 Examples of calculatIOn RIght SIde

0 200 E Ex I B
T2 0 H x 0 01
T2 B 0 H x 001 0090 0090 F
A 1 B 2 C 2 0 3
F E 015 3 0 2 x 001
0 II mm F mm

H 2 0090 017
Where 3 0 2 x 0 01
Left SIde 0090 017
TI ReqUired thickness of left Side
A C 0 H 001 5x001 0090 017
bearIng adJustmg shlfO mm TI x

0 05 0 090 0 17
T2 ReqUired thIckness of rIght SIde 0 200 E
I 2 3 2 0 31 mm
beanng adjustIng shim mm
0 01 0 200 0 II
A Figure marked on the left SIde x The correct slums are as follows
beanng housmg of gear carner 1 2 3 2 x 0 01
B FIgure marked on the rIght Side 0 200 0 II ThIckness QuantIty
beanng of gear carner 4 x 0 01 0200 0 II 007 x 3 0 21

C 0 FIgure marked on the differ 0 04 0 200 0 II 010 x I 010

enltal case 0 35 mm
Total tluckness 0 31 mm
E F These are dIfferences m Width
The correct shlfOs are 0 05 plus
of left or nght Side beanng agamst
o 10 0 20 mm thick
the standard Width
plus
18 50 mm
mm

Note If values slgmfYIng A B C D

If Width 1839 the dIffer
bearIng IS

and H are not given regard them as

ence Will be as follows
RIght SIde zero and compute
1850 18 39 011
T2 B 0 H x 0 01 After assembly check to see that
H marked the rlOg gear
FIgure on
0090 F preload and backlash are correct
See Figures PO 82 and 83
P0 If not readjUst
2 3 2 x 001
0 090 0 15
FIgures for A B C 0 and H are
2 3 2 x 0 01
dmlenslOnal vanatIons 10 a UnIt of
0090 015 SId e bearIng adJ uStlOg shun
100
1 mm agaInst each standard meas
3 x 0 01 0 090 0 15
urement
003 0 090 015 ThIckness mm In

021mm

The correct shlfOs are three pIeces o 05 0 0020

of0 07 mm thick
o 07 0 0028

010 00039

o 20 00079

050 00197

Ex 2

A 0 B 3 I 0 0 2 FIt determIned SIde bearIng ad

C
E 020mm F O 17mm JUStlOg shlfO on dIfferentIal case and

press fit left and ngh t SIde bearIng

H 2
Inner races on It USIng SIde BearlOg
PD2l4
Left sldc Dnft KY38I02100 and Adapter
Fig PD 82 ThIckness of sh m on left TI A 0 H ST33052000 See FIgure PD 77
C x 0 01
and rlgh t SIdes
0 200 E 3 Install differentIal case assembly
1 2 0 01 IOto gear carner tappIng WIth a soft
0 0 x

0 200 0 20 hammer

0 1 0 2 x 001 4 AlIgn mark on bearIng cap With

0 200 0 20 that on gear carner and mstall beanng

3 0 01 0 200 cap on carner And tIghten bolts to

x 0 20
0 03 0 200 0 20 speCifIed torque
PD190 0 37 mm
TIghtenIng torque
5 to 6 kg m
Fig PD 83 VariatIOn number on The correct slums are 0 07 plus
36 to 43 ft Ib
ring gear o 10 plus 0 20 mm thIck

PD 24
 Propeller Shaft Differential Carner

5 Measure L dImensIon 3 Rotate several

between pmlon through
left and rIght beanng cap edges by a revolutions 10 the forward and reverse

nucrometer See FIgures PD 68 and dIrectIon untIl a defInIte contact pat

84
PD tern IS
developed on rIng gear
4 When contact pattern IS 10 cor
L dunenslOn
rect readjust tlnckness of adjust shlfO
17323 to 17329 mm

Be sure to wIpe off red lead com

68201 to 6822410 Fig PD 88 Flank contact
pletely upon completion of adjust
ment
d Face contact
5 Incorrect contact of
pattern
teeth be the Adjust 10 the same manner as 10
can adjusted 10 follOWIng a

See 89
PD
manner FIgure

PD39l PD196
t
Contact pattern
F g PD 89 Face contact
Fig PD 84 Measunng L dimensIOn
a Heel contact
e Correct tooth contact
To correct mcrease thIckness of
6 Measure rIng gear dnve
to pmlon
backlash See 85
PD
pInIon heIght adjusting washer m order
Figure
If backlash IS too small decrease
to bnng dnve pmlOn close to rmg gear
See FIgure 86
PD
thIckness of left shlfO and mcrease

tluckness of nght shlfO by the same

amount
If backlash IS too great reverse the

above procedure
Backlash Fig PD 90 Correct contact

010 to 015 mm

00039 to 0 0059 10
Note in thIckness of ad
Change
PD193 JustIng washer is accompanied by
Fig PD 86 Heel contact change 10 backlash Check It when
Installing gear

b Toe contact

To correct reduce thIckness of

washer order
pInIon heIght adJustmg m

to make drIve pIllion go away from

rmg gear See FIgure PD 87

INSTALLATION
InstallIng can be done 10 the reverse

order of removal
F g PD 85 Measuring backlash

Tlghterung torque
Gear carner to rear axle case
7 Check and the tooth
adjust con
2 0 to 2 5
tact kg m
pattern of rlOg gear and dnve
14 to 18 ft Ib
PD194
pmlOn FIfI PD 87 Toe contact DralO and filler plug
1 Thoroughly clean rIng and drIve
42 to 6 9 kg m
pmlon gear teeth
30 to 50 ft Ib
2 Pamt rmg gear teeth lIghtly and
c Flank contact
evenly With a mIXture of powdered red Gear oLl quantIty
lead and 011 of a SUItable conSIstency Adjust 10 the same manner as m b 1 3 lIters

to produce a contact pattern See Figure 88

PD 1 iUS qt I Ji Imp qt
PD 25
 Propeller Shaft Differential Carner

REPLACEMENT OF Lubncate cavity between seal lIps wIth These works can be done by re
recommended multI purpose grease ferrlOg to Adjustment of SIde Beanng
FRONT OIL SEAL
when IOstallIng Slums procedure
When replacmg front 011 seal do as 4 Place a new collapsible spacer on 7 Remstall dIfferentIal gear carner

follows drIve pInIon and lubrIcate pillIon rear

assembly rear axle shafts and propel
Remove dIfferentIal gear carner beanng WIth gear 011 ler shaft FIll up dIfferentIal carner

5 Insert companIon flange mto 011 WIth correct gear 011

assembly and mount It on Gear Carner
seal Insert drIve pillIon llltO com
Attachment ST0636000l
from the of the
Tlus work can be done by referrmg
panIon flange rear

Notes
carner and secure them pOSItIOn by
III
to Removal procedure
the gIven torque a Replacement of front ot seal WIth
2 Remove sIde beanng caps and tightenIng nut to
confirmlllg speCified preload differential gear carrier assemb Iy
take out dIfferentIal case assembly the car must not be
These works be done Installed on
Remove dnve pillIon nut and extract
can by re

of Dnve PInIon allowed due to used collapsible

dnve pInIon assembly Remove 011 fernng to Adjustment
Preload procedure spacer on its model
seal
6 Install dIfferential b Whenever front ot seal is replaced
These works can be done
by re case assembly
Illto gear carner Measure L dimen collapsible spacer must be replaced
fernng to DIsassembly procedure
backlash WIth
3 Install a new 011 seal III carner
SIOn speCIficatIon
them WIth SIde
uSlllg Ot Seal Dnft ST3340000I adjust beanng slums

PD 26
 r

Propeller Shaft Differential Carrier

TROUBLE DIAGNOSES AND CORRECTIONS

of surface exhaust unIversal JOInt pro be corrccted by adjustment or replace

When a gear carner IS
suspected
shaft wheel bearIngs ment of parts 10 the rear axle as
beIng nOIsy It IS advISable to make a peller engme

thorough test to whether

deterf ilr
te transmission or gear carner NOIse sembly
the nOISe ongInates In the tIres road whIch orIgInates In other places cannot

CondItIon Probable cause CorrectIve actIon

NOIse on dnve Shortage of 011 Supply gear 011 RebUIld gear carner If
coast and float necessary

Incorrect tooth contact between nng gear tooth contact the

Adjust or
replace hypold
and drIve pinIon gear set

Incorrect backlash between nng gear and backlash the

Adjust or
replacc hypOld gear
dnve plOlon set If necessary

SeIzed up nng gear and drIve the

or
damaged Replace hypOld gear set

pInIon

SeIzed up damaged or broken drIve pInion Replace the pIruon beanng and faulty parts

bearlOg
Seized up damaged or broken Side bearing Replace the SIde bearIng and faulty parts
and
Loosen bolts or nuts fiXIng nng gear Side Clamp them to speCIfied torque replace
retaIners beanng cap etc faulty parts

NOIse on turn SeIZed up damaged or broken Side and Replace faulty parts
plOlon gear

SeIZed up damaged or broken Side gear and Replace faulty parts

pInion thrust washer
their shaft
Pillion gears too tIght on Replace faulty parts
Interference between Side yoke and dIffer RepaIr the part responsIble for Interference
entIal case for IRS model or replace the Side yoke and dIfferentIal
case

Knock1Og sound dunng ExceSSIve backlash

starting or gear sluftIng Incorrect backlash rmg gear to drIve Adjust backlash

pmlon backlash or slde to pInIOn gear

Worn gears or case Replace worn parts

Worn SIde yoke or rear axle shaft and Replace worn parts
SIde gear splIne
Pillion bearIng under preload Adjust preload
Loosened drIve pInIon nut RepaIr or replace
Loosen bolts or nuts foong nng gear SIde Clamp them or replace If necessary
etc
retamers beanng cap

PD 27
 Propeller Shaft Differential Carner

ConditIon Probable cause CorrectIve actIOn

Seizure of breakage Shortage of 011 or use of unsUitable 011 Replace faulty parts
Excessively small backlash Adjust backlash and replace as reqUired
Incorrect adjustment of beanngs or gears Replace faulty parts
Severe service due to an excessive loadmg Replace faulty parts
Improper use of clutch

Loose bolts and nuts such as rIng gear bolts Replace faulty parts

Ouleakage Worn out damaged or Improperly dnven Replace faulty 011 seal RepaIr the affected
front 011 seal or bruised dented or abnor flange WIth sandpaper or replace If nec
mally worn slIde face of companIon flange essary

Worn driven Side Treat as above

damaged or Improperly
oLl seal or bruISed dented or abnormally
worn slIde face of SIde yoke
Loose bolts such SIde SIde retamer the bolts to
as
yoke Tighten speCIfied torque
or gear carrIer

Faulty gasket or O nng Replace faulty parts WIth new ones

Loose filler dram the

or plug Tighten plug
Clogged or damaged breather RepaIr or replace

PD 28
 Propeller Shaft Differential Carner

SERVICE DATA AND SPECIFICATIONS

Sedan and Hardtop

StatIOn Wagon
IRS

Type RI60 H165B

Gear carner matenal Malleable cast uon

Gear ratIo
Sedan 3700
4 III 3889
Hardtop

Dnve pmlOn Slum

preload adjusted by Collapsible spacer

Dnve pmlOn

Preload kg cm m Ib
without Oil 7 to 10 61 t08 7
seal
with 011 8 to 11 6 9 to 9 5 7to10 61 t087
seal
At companion flange bolt
hole kg lb
without Oil seal 20 to 2 9 44 to 6 4

with Oil seal 2 3 to 3 2 5 1 to 7 I 20 to 2 9 4 4 to 6 4

Thickness of pmlOn height adJustmg 309 01217 309 01217

washer mm m 3 12 0 1228 312 01228
3 15 0 1240 315 01240
3 18 0 1252 318 01252
321 0 1264 321 0 1264
324 01276 324 01276
327 01287 327 01287
330 01299 330 01299
333 01311 333 01311
336 01323 336 01323
339 0 1335 339 01335
342 01346 342 01346
345 01358 345 0 1358

3 48 0 1370 348 01370

351 0 1382 351 0 1382
354 01394 354 01394
357 0 1406 3 57 0 1406
360 01417 360 01417
363 0 1429 363 0 1429
366 01441 366 01441

Length of puuon beanng adJustmg 562 2 2126

spacer mm m 56 4 2 2205
56 6 2 2283
Non adjustable
56 8 2 2362
collapsible spacer

570 22441
57 2 2 2520

PD 29
 Propeller Shaft Differential Carner

R160 H165B

Thickness of pmlOn beanng 2 30 to 2 32 00906 to 0 0913

washer rom m 232 to 2 34 00913 to 0 0921

adJustmg
234 to 2 36 00921 to 0 0929

2 36 to 2 38 00929 to 0 0937

2 38 to 2 40 0 0937 to 0 0945

240 to 242 00945 to 0 0953

242 to 2 44 0 0953 to 0 0961

Non adJustable
244 to 2 46 0 0961 to 0 0969
collapSible spacer
246 to 2 48 0 0969 to 0 0976

248 to 2 50 0 0976 to 0 0984

250 to 2 52 00984 to 0 0992

2 52 to 2 54 00992 to 0 1000

254 to 2 56 0 1000 to 0 1008

256 to 2 58 0 1008 to 0 1016

258 to 260 0 1016 to 0 1024

Side gear and pullon mate

Thickness ofSide gear thrust 075 to 0 80 0 0295 to 0 0315 o 785 00309

washer mm m 080 to 085 00315 to 0 0335 o 835 00329

o 85 to 0 90 0 0335 to 0 0354 o 885 0 0348

1 035 00407

1 185 0 0467

PinIOn mate to slde gear backlash o 1 to 0 2 0 0039 to 0 0079 o 1 to 0 2

or clearance between Side gear 0 0039 to 0 0079

and thrust washer rom m

Ring gear
Ring gear to dnve pinIOn backlash o 1 to 0 2 0 0039 to 0 0079 o 10toO 15

mm m 0 0039 to 0 0059

Thickness of Side retamer o 05 0 0020

adJustmg slum rom m o 07 0 0028

010 0 0039
o 20 0 0079
050 0 0197

Thickness of Side beanng adJustmg o 05 0 0020

slum mm m o 07 0 0028
o 10 0 0039
o 20 0 0079
050 0 0197

Side beanng standard Width

200 07874
rom m 185 0 7283

L dImenSIOn rom In 173 23 to 173 29

6 8201 to 6 8224

PD 30
 Propeller Shaft Differential Carner

RI60 Hl65B

lighterung torque kg m lb
ft
Drive pmlOn nut 17 to 20 123 to 145 More than 14 101
7 to 8 51 to 58
Ring gear bolt
Side 5 to 6 36 to 46
bearing cap bolt
DifferentIal carner to ax1e case 20t025 14 to 18

Side retainer bolt o 9 to 1 2 6 5 to 8 7

Side yoke fIxmg bolt 3 2 to 4 3 23 to 31

Rear cover fIxmg bolt 1 9 to 2 6 14 to 19

Rear cover to mountmg member 6 to 8 43 to 58

Differential carner to suspensIOn

member 5 to 7 36 to 51
Drive shaft to rear axle shaft fIxmg 5 to 6 36 to 43

bolt

Differential mounting member self

lock nut 7 to 10 51 to 72
2 4 to 3 3
CompanIOn flange to propeller shaft 17 to 24

4 to 6 29 to 43 4 2 to 6 9 30 to 50
011 dram and fIller plug

011 capacity about o 8 hter 1 3 I1ters

H U S qt Yo Imp qt 1 X U S qt IX

Imp qt

Adjusting methods
mm xOOl
Variable numbers expressed by

Dummy shaft Use

formula T W N H D N D
Dnve pinion adJusting T H
S x 0 01 0 2 S xOOI 298

formula TI A C Gl D TI A C D
Side bearing adJustmg
x 001 0 76 E H x 0 01
020 E
T2 B D G2 X001

0 76 F T2 B D H
x 0 01 0 09

PD 31
 Propeller Shaft Differential Carner

SPECIAL SERVICE TOOLS

Tool number For Reference

No DescriptIOn use page or

tool name on Figure No

Urut mm In

KV381 00800 T1us attachment IS used with engine stand ST0501S000 71O SSS Fig PD 12
Strut and steering gear box mountmg holes are proVIded With 610
Gear carner
engraved IdentIficatIOn marks HGCI10
attachment
D for gear carner KC130
RI60
S for strut S30
G for steering gear box 510

2 ST06360001 Same as above W610 Fig 69

PD

Dlff 1710 Page PD 26

attachment HC110

HI65B B120

SE206

3 ST3121S000 These tools are used to adJust the pmlOn height 610 Fig PD 22
Dnve pinIOn
S30 Fig PD 24
HGCIlO Fig PD 25
settmg gauge
KHCI30 Page PD ll
assembly RI60

ST3121l000

Height gauge
155 6 I
ST31212000

Dummy shaft

ST31213000

Stopper
ST31214000
Collar

34 l34 d
J
a 151 62
J
PD 32
 Propeller Shaft Differential Carner

Tool number For Reference

No Descnptlon use page or

No
tool name
Unit mm In
on
Figure

4 ST3114S000 These tools are used to adJust the pmlOn height W610 Fig PD 78
1710
Dnve pmlOn Fig PD 79
CIlO
setting gauge
B120
assembly HI65

ST31942000

30 1 18 dla
Dummy shaft
1

ST31141000 l I SE209
35 45 1 40
Height gauge

SE210

5 STJ061l000 These tools are used when press fItting beanng outer race 710 Page PD Il

B210 Page PD 22
Beanng dnft bar 610
CIlO
C130
330
138
350 S30

b II WlJItJ w lt tf N
25 093 dJa B120
620
F20
E20
C240
T40
SE405 140

PD 33
 Propeller Shaft Differential earner

Tool number For Reference

No DescnptlOn use page or
tool name on No
Umt rom m Figure

6 ST30701000 For dnve plfUon front beanng outer race Front PD Il

Page
710 PD 22
Dnft
Page
8210
HI50
610
W610
HCllO
KHC130
8120
620
615 242 dla
Rear
8210
HI45A
8210
SE406 HI50

7 ST30613000 For dnve plfUon Rear

rear bearing outer race Page PD Il
10
610 Page PD 22
Dnft
CliO
8120
620
Front
VCIIO
HC130
330
830
R200
72 2 83 dla F20
E20
C240
T40
140
SE407

8 STJ0621000 For Side bearing outer rac Slde PD Il

Page
10
Dnft 610
GCllO
KC130

rJ
VCllO
C130
330
830 AlI
7 9 3 11 dill F20 AlI
E20 AlI

SE408

9 STJ003S000 T1us assembly clamps rear bearing Inner race and pulls It out by a 610 Fig PD 16
Dnve plmon rear hydraul1c press All Fig PD 27
Before inSertIOn place another dnft faCing Inner race and then press fIt 710
mner bearing Fig PD 72
All Page PD 23
puller assembly
510
ST30031 000 38 1 50 dla B210

Puller 31 1 22 dla 620

HC110
ST30032000 B120

Base

SE041

PD 34
 Propeller Shaft Differential Carrier

Tool number For Reference

No DescnptlOn use page or

tool name No
Umt mm m
on Figure

10 ST30650001 For use when pulling out front pilot bearing After dnve plfUon has bee 610 Page PD 10

pulled Insert tills tool from belund the gear carner case and apply It RI60
Pilot beanng onto plfUon front beanng Inner race and then press out pinIOn front 710
dnft
beanng mner race front pilot bearing spacer and pilot bearing RI60
510

HGC 11 0
430 16 93

1 KHC130

24 8 0 976 lJ
J

11 ST30720000 Tlus tool IS used to drive m front 011 seal Without 610 PD 13
damagmg It Page
RI60 Page PD 16
Gear carn r
710
front 011 seal
RI60
drift
510
W510
1 HGCIlO
I
i KHC 130
v
5
55 2 185 dJa
SE208

12 ST33400001 Same above W610 POO23

as
Page
B210 Page PD 26
Front 011 seal
All
dnft 1710
HC110
B120

SE410

PD 35
 Propeller Shaft Differential Carner

Tool number For Reference

No Description use page or
tool name
Unit mm
on
Figure No
m

13 ST33290001 Tlus tool used to out 011 seal from gear

IS pull carn r All Fig PD 14
Gear This tool also enables to remove Side bearmg outer race from models Fig 44
PD
carner 011
retamer without damagmg
seal puller Page PD 17

160 6 30

14 ST31530000 This tool used to hold the

IS flange to ease the operatIOn of 610 Fig PD 5
tightening and loosening dnve pmlOn nut 710
Drive pmOn Fig PD 15
flange wrench 510 Fig 42
PD
W510 Fig PD 71
620 Page PD 23
330

S30
E20
CIlO
CI30
E20
B120

15 ST3127S000 ThiS tool IS used to measure the preload of pillion beanng 610 PD 23
Fig
B210
Preload gauge Fig 81
PD
710
GG91030000 CIlO
TlJrque wrench CD C130
I 330
2 HT62940000 S30
Socket adapter J
t B120
620
3 HT62900000
Socket adapter
1 4 x 3 8 i@ 3 8 x 1 2 8
F20
E20
C240
T40
140
60

16 ST33051001 These tools are used to pull out Side beanng 610 Fig PD 17
B210 Fig PD 74
Side beanng 710
puller CIlO
C130
330
S30
B120
620
F20
E20

SE420

PD 36
 Propeller Shaft Differential Carner

For Reference
Tool number
use page or
No Descnptlon
on
Figure No
tool name Umt mm In

V610 Fig PD 74
17 ST33052000
W610 Fig PD 77

Adapter B210 Fig PD 24

All
22 0 866 dill
1710
ClIO
VCIlO
620
28 110 dill

SE421

KP710 Fig PD 17
18 ST33061000
610 Fig PD 21

Adapter RI60
HGC110
285 110 dla
VCIlO
C130
S30
KSE20

38 1 SO dla

SE422

610 Fig PD 21
19 ST33230000 Use of tlus tool makes It posSIble to dnve In beanng Without damaging
510
It
Dlff Side bearing W510
drift KSE20
620
F20
VHC 11 0
C130

1710 Fig PD 77
20 KV38102100 Use oftills tool makes It pOSSIble to dnve In bearing Without damaging
W610 Page PD 24
It
Dlfr Side bearing V610

dnft CIlO
VCIIO
B120
620

SE217

PD 37
 Propeller Shaft Differential Carner

Tool number For Reference

No DescnptlOn use page or

tool name Umt mm m on Figure No

21 ST337 10000 This tool IS used to hold the puller dnve shaft when removmg 610 Fig PD 13
Side retamer by the puller RI60
Gear carrier Side
510
retamer
710
attaclunent
RI60
HGC 11 0

eJ
KHC130

89 3 50

22 ST33720000 This gUide bolt IS used when attaclung retamer to gear carner 610 Fig PD 32
Use of thiS tool prevents damagmg O ring and helps smooth the RI60 Page PD 14
Gear carner Side
operation 510
retamer gUide
710

RI60
HGCI10
8 031 dla KHC130

40 I 57

23 ST33270000 This tool IS used when drlvmg m 011 seal USing tlus drift completely 610 Page PD Il
el1mmates the POSSlblhty of damaging 011 seal RI60
Gear carner 011 rage PD 17
510
seal drift
S30
710
R160
HGC 11 0
KHC130

Tlus tool used to drive out lock pm of pinion mate shaft 710 AlI
24 KV31l00300 IS
Fig PD 75
610 AlI
CliO Page PD IO
Sol1d punch All
C130
All
330
S30 AlI
8120
620
F20 AlI
nO AlI
E20 AlI
C240
T40
140

PD 38
 Propeller Shaft Differential Carner

For Reference
Tool number
use page or
No DescnptlOn
No
tool name Umt mm m
on Figure

difference Width ofSide beanng 710 Fig PD 20

25 ST32501000 These tools are used to measure m

B210 Fig PD 76
agamst standard Width
Weight block 610 Page PD 21
CliO
70 2 76
C130

V 330

11
S30
B120
333 620

j5 F20
KSE20

SE417

26 ST33741000
J710 Fig PD 76
W610 Page PO 2l
Master gauge ClIO
18 5 mm B120
20 0 79
0728 In

I
8 185 0728

SE418

710 Fig PO 20
27 KV38101900
610
Master gauge V610
20 0 mm VClIO

07910 HI90
20 0 79
HGCllO
C130

I
8
330
530
RI80
620
F20
SE419 KSE20

PD 39
 SERVICE
SECTION FA
MANUA L
4 C t

fi
A t I
J t

FRONT AXLE
DATSUN FRONT
MODEL 610 SERIES
SUSPENSION

GIll

DESCRIPTION FA 2

INSPECTION AND ADJUSTMENT FA 3

FRONT AXLE FA 5

FRONT SUSPENSION FA 7

SERVICE DATA AND

FA 13
SPECIFICATIONS

TROUBLE DIAGNOSES AND

FA 15
CORRECTIONS

I NISSAN I SPECIAL SERVICE TOOLS FA 18

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Front Axle Front Suspension

DESCRIPTION

All the
models employ a strut type to aVOid metal to metal contact mg at top The transverse hnk
frof t suspenSion In which the shock The shock absorber IS baslcany a tensIOn rod and rubber bushing take
absorber and spllldle are assembled double actmg hydrauhc ram conslstmg thrusts from front and rear

mto a smgle Unit It IS supported by a mainly of an outer casmg an mner

The stablhzer uses a tOrsion bar It
coli spring at the top and by the casmg a piston and
piston rod
a

The gland packing and piston gUide takes thrusts from either Side of the
transverse hnk at the bottom
car Thus the enllre suspensIOn
The spmdle and outer casmg are of keep the rod m place as well as prevent
handles thrusts from any angle Ie
an Integral design The ban Jomt leakage
The COil spnng IS the thuse from front and rear by the
located at the outer end of the trans placed on

tensIOn rod those m vertical duec

piston rod wIth ItS seat the bottom a
pivot for the
verse hnk serves as a on

movement of the The sea t IS welded to the outer lion With the strut and those from
spindle
These mounted the either Side of the car
by means of the
These are assembled on the suspen casmg are on

chassIs frame the thrust bear transverse link

sion member through a rubber bushmg through

@ I Strut mounting In ul tor

2 Bound bumper rubber
3 Du t cover

4 COIl pnng
5 Strut embly
6 nre
7 Wheel be rIng
8 Wheel hub

9 Road wheel
10 Suspcntlon b n JOint
II St b lozer bar
12 TenSIon rod
13 Tr nwerse lonk
14 SIde member
15 Knuckle arm

Tlghtemng torque of bolts

and nuts kg m ft lb

@ 4 5 to 5 5 33 to 40

@ 49 to 6 3 35 to 46

@ 19t025
14to 18

@ 2 5 to 3 5 18 to 25

C 601075 431054
@ CD J 8 to 9 58 to 65
3 9 to 5 3 28 to 38
@
5 5 to 7 6 40 to 55
F A524
QJJ
9 0 to 10 0 65 to 72
D
Frg FA 1 Front axle and suspensIOn lembly
as

FA 2
 Front Axle Front Suspension

INSPECTION AND ADJUSTMENT

CONTENTS

FA 3 WHEEL BEARING FA 3
INSPECTION
FA 3 WHEEL ALIGNMENT FA 4
SUSPENSION PARTS
FA3 CAR LEVEL 4
FA
ADJUSTMENT

INSPECTIO I Jack up and support car on the

stands at the Side member m a safe
Periodically Inspect In accordance manner and remove wheel hub cap
with a
regular mamtenance schedule cotter pm and brake pads Refer to
Secllon BR for Pad Replacement
2 Tighten spmdle nut to speclfIca
SUSPENSION PARTS lions usmg a SUitable torque wrench

1 Jack up the front of car until

rront wheels clear the floor Tlghtemng torque
25 to 3 0 kg m 18 to 22 ft lb
2 Shakmg each front wheel by
FIg FA 3 MeaSUring bearing
grasping the upper and lower surfaces preload
of the tlfe check suspension parts for
until
looseness wear or damage Tighten all Repedt dbove pro edures wr

rect preload IS obtaIned

loose bolts and nuts to the specified
torque Repla e all worn parts as Notes

described under Front

Suspension a To measure beanng preload attach
3 Check wheel bearings If any aXial a sprmg balance to hub bolt and
end play IS present adJust bearings to pull right angle to a hne drawn
It at

speclflcal10ns Replace worn or dam F A263

through center of bearing and hub
nut
aged bearings as described un er FIFA 2 TIghtening spindle bolt to which It IS attached
haft be
Front Axle 3 Rotate wheel hub a few turns m b The shghtest play cannot

4 Check the shock absorbers as tolerated here

both dlrecllons to seat wheel beanng
sembled mto stru t If these are not m Then
correctly retighten spIndle nut
6 Insert a new cotter pill With he
wheel
good condlhon car posture and to the above torque
legs through adJuslIl g Lap and spindle
ahgnment may be affected 4 Loosen spmdle nut 60 degrees
sprcad legs away lrolll cadl other
Install adJusl1ng cap and loosen
against Sides of adJustlllg Ldp to secure
wltlun 15 degrees until grooves are
thc lIlstallallon See Figure FA4

aligned With hole In spindle

5 AgaIn spm wheel hub several
In both directions to If It
ADJUSTMENT turns see

rotates freely Then measure bearIng

preload USIng a spring balance as fol
WHEEL BEARING
lows
Improper adJustment ofwheel bear

mgs causes abnormal wear and score Rotdllon startIng torque

on the bearings and knuckle spindle of wheel bearmg
To obtain proper wheel
preload on
New parts
bearings proceed as follows less
85 kg cm 74 m Ib or

Note In order to a sure correct bear As measured at wheel hub bolt FA265
15
mg preload and to extend servIce kg 3 31b orless FA 4 lnstallltlg cotter pIn
FIg
hfe of wheel bearmgs be sure to AdJustment With old parts
and 45 kg em 39 m Ib
prevent dirt foreign particles
from gettmg m bearings grease o eal As measured at wheel hub bolt
08 18Ib 7 Imtall hub cap
and spmdle nut kg
FA 3
 Front Axle Front Suspension

WHEEL ALIGNMENT 1 Turn steermg wheel so that front 2 Turn adJusting bolts indicated by
wheels are pOinted straight ahead arrow m or out as reqUired until
Correct front wheel alignment as
Then check that steering gear correct
IS In turnmg angle IS obtamed See
sures proper vehicle handl1ng charac stralgh t ahead poslhon Figure FA 6
tensl1cs and mmlmum steering effort 3 Put
2 The length of Side adJusting rod nylon cap on
adJustmg bolt
With the least amount of tire wear
marked With an should be
arrow

Before adJustmg front wheel ahgn adJusted to speclfIcahon by turnmg

ment be sure to carry out a
prelumna both Side adJustmg rods See Figure
ry mspecl10n of the front end parts as FA5
follows

I Tire pressure
2 Wheel beanngs and spmd1e nuts

3 Steenng gear play

4 Steering gear housmg loose at

frame
5 and
Steering 1nlkage connecl1ons

6 Shock absorber acl10n

When USing the eqUipment for front

wheel ahgnment mspechon follow the
mstrucl10ns furmshed With the eqUip

ment Moreover the mspechon should

Frg FA 6 AdJustmg steering angle
be made With the car set level and at

curb weight Frg FA 5 AdJustmg toe m

Camber and caster Note Both Sides of the Side rod ball Steenng angle
JOint center to center distances Inner wheel
Camber and 370 to 380
caster are preset at
should be balanced first Outer wheel 30042 to 32042
factory and cannot be adJusted
Car requires only toe m and levehng
adJustments

Toe In Steerlna anale CAR LEVEL

Measure toe and Check steerlf1g angle usmg the fol

m
adJust If neces AdJustment can be made by select
For lOWing procedures If necessary
sary adJustment proceed as fol mg spring which Will keep car m a
lows Place front wheels on turn table normal level pOSll1on

I
I
I

FA 4
 Front Axle Front Suspension

FRONT AXLE

CONTENTS

FRONT AXLE FA 5 INSPECTION FA 5

REMOVAL FA 5 INSTAllATION FA 6

FRONT AXLE 4 Work off hub cap from end of

epmdle usmg two screwdnvers or any

other sUitable tool as shown m Fl8ure
REMOVAL FA 9 If necessary tap around It With
a soft hammer whtle remoVIng cap
1 Jack up car until wheel drops to
full down position remove wheel
2 Remove flare nut connecting
brake hose to brake tube at the
bracket on front strut take out brake
hose lock sprmg and plug up brake
hose opening See Figure FA 7
F FA II Remoumg wheel bearIng
1
outer race

9 Loosen four bolts seCUring brake

FA038 dISC In posll1on remove diSC brake

rotor from wheel hub
F FA 9
assembly
Remoumg hub cap

Note Dunng this operation use cau

tion to 8void damagmg ring

O

S off cotter pm take out ad

Pry
Justmg cap and wheel bearing lock nut
6 Remove wheel hub from spmdle
With bearing mstalled

FA521 7 Wheel hub may be removed to

F Jo A 7 Remoumg brake hose gether with diSC rotor

F FA 12 RemoumgdlSC brake
rotor
3 Remove bolts retalmng brake call

per and take out cahper assembly 10 Loosen screws secunng baffle
See Figure FA 8
plate m position take out baffle plate

INSPECTION
F FA 10 Remoumg wheel hub

Wheel hub

8 Ul1hzmg two grooves mSlde hub Check hub for cracks by means of a
F FA 8 Remoumg brake calIper drive out wheel bearing outer race magnel1c exploral1on ordyemg test
mstallat on bolts from hub with a brass dnft and replace If cracked

FA 5
 Front Axle Front Suspension

Grease seal 2 Install diSC brake rotor to wheel

hub lighten to 3 9 to 5 3 kg m 28 to
If grease leakage IS detected dunng 38 ft Ib
removal replace seal

Replace grease seal every disassem

3 Installbeanng outer race by tap
If It appears pmg ItS outer perIphery with a mallet
bly even
good
or usmg Front Wheel Bearing Drift
ST35300000 until It IS bottomed m

hub

Wheel bearing 4 Pack the mSlde of hub and hub

FIg FA 14 Flllrng bearing cone WIth
cap With recommended multi purpose
Thoroughly clean grease and dlft grease
grease to the deSCribed level See
from wheel bearing with cleaning sol
FA 13 6
vent and
dry with compressed air free Figure Put mner beanng cone In hub and
of mOisture Check wheel bearing to mstall a new grease seal Be sure to

see that It rolls freely and IS free from

lubncate seahng hps of the grease seal

crack or wear Also before mstallatlOn

nOise plttmg
7 Put hub
check condlllon of outer race Re assembly on spmdle and
moval of outer race from hub IS not then mstall outer
bearing cone
8 Apply sparingly grease to washer
necessary
and threaded parts of spmdle and

spmdle nut Then mstall washer and

spmdle nut AdJust the mstallatlOn as

outhned under Wheel Bearing Ad

Justment

Note In order to assure correct bear

mg preload and to extend service

FIg FA 13 Lubrlcatrng pornts of

hfe of wheel beanngs be to
sure
INSTALLATION wheel hub
aVOid dirt and foreign particles get
Install front axle In the reverse
tmg m bearulgs grease seal washer
order of removal and spmdle nut
notmg the fol
lowmg
I Install baffie plate to knuckle 5 Pack caVllles ofeach bearing cone 9 After lowering car to the ground
spindle With grease lighten wheel nut bleed brake

FA 6
 Front Axle A ont Suspension
f

FRONT SUSPENSION

CONTENTS
r

FA 7 INSTAllATION FA 11
SPRING AND STRUT ASSEMBLY
DESCRIPTION FA 7 TRANSVERSE LINK AND
FA 7 BAll JOINT FA ll
REMOVAL lOWER
FA 8 R EMOVAl FA 11
DISASSEMBl Y
FA 8 INSPECTION FA 11
INSPECTION
FA 9 FA 12
ASSEMBl Y INSTAllATION
FA lO FA 12
INSTAllATION SUSPENSION CROSSMEMBER
FA 10 FA 12
TENSION ROD AND STABILIZER BAR REMOVAL
FA 10 FA 12
REMOVAL INSPECTION
FA 10 FA 12
INSPECTION INSTAllATION

The pIston rod piston rod gUide REMOVAL

SPRING AND STRUT
cyhnder and bottom valve should be
ASSEMBLY
handled as a matched set I Jack up car and support It With
If any of these parts becomes
DESCRIPTION safety stands Remove wheel
faulty all the parts must be replaced 2 Loosen flare nut connectmg
The front umt
suspensIOn employs as a
brake hose to brake tube at the
struts right and left Each strut con When a spring requires replacement bracket on front strut See Figure
SIStS of an outer casmg a
piston a use the one
havmg the same color FA 7 Take out brake hose lockmg
pIston rod and an Inner
cyhnder Identification If thiS IS not done the
spring Separate brake hose from brake
The cyhnder mcorporates a piston car may not settle m a normal level
tube
rod gUide at the top and a check valve posture j Loosen flare nut securing brake
at the bottom and then
tube to cyhnder separate
from brake cyhnder
1 Gland paekmg assembly 12 PIston ring 4 Loosen bolts retamlng cahper m

2 011 seal 13 Valve plate

place take out cahper as an assembled
3 O nng 14 Piston body
4 PISton rod gUIde 15 Nut Unit

assembly 16 Bolt 5 Remove bolts connecting strut to

5 Cy hnder 17 DIstance collar FA 16
knuckle arm See Figure
6 Rebound stopper 18 Spring retamer

7 outer
Strut caSIng 19 Check valve spnng

8 PISton rod 20 Bottom valve body

9 Check valve spnng 21 Check valve plate
retainer 22 Valve plate
10 Check valve spnng 23 Nut
11 Check valve plate 24 Bottom plate

Shock absorber operatIon

Operatmg valve
FIg FA 16 RemOVing bolts
connecting knuckle arm

CompreSSIon 6 Detach knuckle arm from bottom

ExpanSIon
of strut ThiS can be done by forcmg
FA268
transverse hnk down WIth a sUitable

FIg FA 15 Seelloruzl vIew of strut assembly bar as shown In Figure FA 17

FA 7
 Front Axle Front Suspension

F A275

Fig FA 21 Remolllng plBton rod

and cyllTlder

Note Under no CIrcumstances should

FA205
piston and pISton rod guide be
FA273
Fig FA 17 RemolllTlgknuckleann removed from cylinder since these
are adjusted to each other to pro
FIfl FA 19 Installing strut ITIl1lBe
vide precision mating surfaces and
7 Place Jack under strut to receive should be handled as a matched set
Its weight when nuts are removed
8 Lift engine hood to gam access to 9 Drain flUId thoroughly from Inner

nuts holding strut m place on car cylinder Use a SUitable container to

4 Take out strut Insulator strut
body See Figure FA 18 receive flUId dramed
beanng oIl seal upper spnng seat and
10Wash all metalliC parts m clean
bound bumper rubber In the order
mg solvent
I1sted
11 Drain flUid which collects inSide
5 Remove spnng from strut With
outer caSing
Spring Compressor ST3565S001 left thoroughly
onspring Note This operation IS very impor
6 Retract pISton rod by pus1nng It tant since performance of strut
down untll It bottoms Without dls varies with amount offluid mitislly
turbmg the above settIng remove filled
gland packing With Gland Packing
Wrench ST35500001 See Figure
FA 20 INSPECTION

FA451

Fig FA 18 RemolllTlg stru t TIg

hold

nuts

9 With springs attached lower Jack

slowly wlule holding strut by hand

take out strut

DISASSEMBLY

When disassembling a strut caul10n

wlrm
should be exerCISed to prevent dut and
1 Strut mountmg Insulator
dust from gettmg InSide strut ThIS dut
2 Beanng
and dust IS extremely abraSive and If
3 Spring upper seat and du t cover

permitted to enter strut causes mter F A274 4 Damper rubber

nal leaks and premature wear of 5 CoIl prmg
lf FA 20 RemolllTlg
F gland packing 6 Strut a sembly
mOVIng parts
FA337
1 Install Gear
Strut Steering
Attaclunent KV48100300 FIfl FA 22 Exploded lIlew of spnng
HOUSing on
and strut y
OBBemb
bottom of strut secure above assem

bly In Jaws of a SUitable VISe See Note Clean gland packlllg of mud
1 Replace gland packlf1g O nng and
flUid With fresh oil when
Figure F A 20 and other accumulated foreign par
new ones or

2 strut IS dISassembled
Pry S11ap ring off dust cover tIcles ever

3 Set up Spnng Compressor 2 Wash aU parts except for non

ST3565S001 on Spring 7 Remove O ring from top of PIS metal1c parts With solvent and
Compress dry
ton rod gwde
spnng Just far enough to permtt turn With compressed alf
Ing of strut InSulator by hand Remove 8 LIft out pISton rod together With 3 Blow dlft and dust off of non

self Iockmg nut See Figure FA 19 cylinder See FigUre F 21 metahc parts uslf1g compressed au

FA S
 Front Axle Front Suspension

rod Install gland packing

I Outer casmg usmg G13nd Figure F A 24 With recommended
Check outer caSIng for eVIdence of Packing GUide ST35530000 mulh purpose grease

deformal1on other dam Lubncate seahng hp dstensked m

cracking or
KYBmake
age If necessary replace AMPCO make
2 Spindle
Check spmdle for hau cracks on
base and damaged threads Replace
strut If any of above conditions exceed

I1mltS
3 Strut mountmg Insulator
Replace If rubber and metal JOints
are melted or cracked Rubber parts
should be replaced If deteriorated

4 Strut mountmg beanng FA221

FA222
Replace If inspection reveals abnor
mal nOIse or excessive rattle m aXIal Frg FA 24 SectIOnal vIew of gland packIng
dIrection
5 to 7 to 13
Tighten gland packing Gland packmg wrench Torque C
51 94 ft Ib See
kg m to torque

ItL
FA 25
ASSEMBLY Figure

assembhng strut be careful

When
not to drop or scratch parts since they o 1 m 0 3 ft
ST35500001
are precisely macillned to very close F A278

tolerances Before assembly clean

FIg FA 26 Gland packing wrench
away all dut to prevent any possible

entry of dut Into strut

6 After the above steps have been
At
1 Set Steermg Gear HOUSing completed au should be removed
tachment KV48100300 m place on KV48100300 from shock absorber system In the fol
bottom of strut and place attachment lOWing manner

m
Jaws of a SUitable Vise r 1 Hold strut by hand With ItS
2 Install piston rod and cyhnder FA274 I spindle end facmg down Without dIS
mto place m outer casmg turbing the above setting pull out
Fig FA 25 Trghtenrng gland packIng
3 Pour correct amount of flUid Into pISton rod completely Then turn
outer casmg See FA 23
Figure strut upSide down so that spindle end
Notes up Under tills condition
IS now facmg
a When tightening gland packing it is retract pISton rod all the way See
important that pISton rod be ex Figure FA 27
tended approXimately 120 mm 2 Repeat the above procedure
4 72 in from end of outer cssmg several times so that au will be com

to expel most of au out of strut pletely bled from strut

3 If dunng the above step an
b Gland packing should be tightened
to 7 0 to 13 0 kg m 51 to 94 ft Ib equal pressure IS felt through the hand
FA330
torque With the aid of Gland Pack gnpplng piston rod on both strokes It
FA 23 outer casrng an indication that an has been
Fig Flllmg ing Wrench ST3SS0000 I When
IS

wIth fluid
doing so the amount of torque to completely expelled from strut

be read beneath wrench needle

Note It that correct
IS Important should be modified according to
amount of flUid be poured mto the follOWing formula
strut to assure correct dampmg
t
force of shock absorber C kg m 7 x or
t 1
0
Amount ofoil t
C ft Ib 5 I x
325 cc 19 83 cu in for AMPCO t 0 33
ATSUGI make
Where
332 cc 20 26 CD in for K Y B
C Value read on the torque wrench
KAYABA make
kg m lb
ft
t Effective length of torque
wrench ft
4 Place rod gUide on top of pIston m

FA 9
 Front Axle Front Suspension

Notes d When Installmg steering knuckle

a Use care to aVOid
damagmg pISton ann to the bottom of strut as

rod during d1Sllssembly and assem sembly apply the sUitable sealing
bly Do not use phers or the hke to matenal to the portion mdicated In

FA 31 so as to
extract piston rod Figure prevent ball
b Install mounting beanng so that it stud from rust

points m correct duechon See

Figure FA 28

11 Tighten pISton rod self lockIng

FA279
nut to 60 to 7 5 kg m 43 to 54 ft Ib EngIne
SIde
torque
12 After sprmg m pOSitIon
placmg
Figure FA 29 between upper and
lower spring seats release compressor

gradually
F A520

Fig FA 30 MountmgdlrectlOn of
strut Insulator

Fig FA 27 Bleedmg air from strut

F A282
7 Place Strut Steering Gear Hous

Ing Attachment KV48100300 In Jaws FIg FA 29 Installing front sprrng

of a vise

8 Before proceedmg any further

13 Raise bound bumper rubber to FA525

pull piston rod all the way out to the upper spring seat
hmlt of Its stroke mstall bound bum Fig FA 31 Applymg sealmg materral

per rubber to prevent pIston rod from

failIng by Its own weight

9 Place front spring on lower sprmg
INSTAllATION
sea t and compress spring WIth Spring
Install the strut and sprmg assembly
Compressor ST3565S001
m the reverse order of removal notmg
Install dust cover upper spring seat
the followmg
mountmg bearing and msulator m the TENSION ROD AND
order hsted STABILIZER BAR
10 Lubricate parts mdlcated by
FA 28 With recom TIghtening torque
arrow m Figure REMOVAL
mended mull1 purpose grease Strut to
body nuts
25 to 3 5 kg m 18 to 25 ft Ib I Jack up car and support It With

safety stands remove wheel

Steering knuckle arm to strut
2 Remove splash board
70 to 100 kg m 51 to 72 ft Ib
3 Back off nut CD securing tensIOn
rod to bracket and remove bolts @
Notes which secure tensIOn rod to transverse

a When mstalhng strut and spring lInk TenSIOn rod can then be taken
assembly to body make sure that out
the pamted mark on strut msulator 4 Remove nut stabl
@ connectmg
faces the engtne Side See Figure hzer connecl1ng rod to transverse Imk
FA 30 5 Take out bolts @ securing stabl
b self Iockmg nuts whenever hzer bracket m posll1on Loosen four
Replace
strut IS disassembled
FA211 tensIOn rod bracket bolts ID In ad
c Make sure brake hose IS secure and vance Remove stabthzer from
Fig FA 28 Greasmg mountmg car
not twisted frame See FA 32
bearrng and 011 seal Figure
FA 10
 Front Axle Front Suspension

Tightening torque
Stablltzer bar to frame bolt
1 4 to 1 8 kg m

10 to 13 ft Ib
Stablhzer connectmg rod nut
1 2 to 1 7
kg m

9 to 12 ft Ib

TensIOn rod bracket bolt

5 1 to 6 9 kg m

37 to 50 ft lb
FA338 TensIOn rod mstallallon nut
FIg FA 32 Removing stabilIZer and 45 to 5 5 kg m FIg FA 34 RemOVing transverse link
tensIOn rod 33 to 40 ft Ib
TensIOn rod to transverse 7 Place transverse ltnk m a VIse

Imk bolt loosen bolt securing ball Jomt to trans

INSPECTION
4 9 to 6 3 verse link and remove ball
kg m Jomt from
I Check tensIOn rod and stabilizer 35 to 46 ft Ib transverse I1nk With Ball JOint Re
for eVidence of deformation and crack mover HT72520000
mg If necessary replace 8 WIthdraw transvers hnk bushmg
2 Check rubber parts such as ten
from transverse ltnk usmg Front Trans
sIon rod and stabilizer bushmgs to be
verse LInk Bushing Replacer Set
sure they are not deteriorated or TRANSVERSE LINK ST36700000 and a
press
cracked AND LOWER
BALL JOINT
INSTALlATION The transverse hnk IS connected to

Instdll tensIOn rod and stabilizer bar the suspensIon member through a

m the reverse order of removal rubber bushmg and to the strut

notmg
through a ball Jomt
the followmg
The lower ball IS assembled at
Jomt
1 Emure that stabilizer IS
correctly the factory and cannot be disas
mstalled to the porllon of th left and sembled Lubricate ball Jomts with
FA214
right sides recommended multi purpose grease
2 Check to be sure that tensIOn rod FIFA 35 RemOVing transverse link
recommended mamtenance
every bushIng
centered
bushmg IS
properly m ItS seat mterval
3 Examme If clearance between
rod and stablhzer bar INSPECTION
tensIOn IS equal REMOVAL
on both SIdes See Figure FA 33
1 Jack up car and support It With Transverse link
safety stands remove wheel
2 Remove splash board 1 Check for signs of cracks dlstor
3 Pry cotter pm off slde rod socket lion or other damage Replace If any
ball Jomt Remove castle nut and of above condlllons are beyond repair

separate Side rod socket from knuckle 2 If rubber bushmg shows eVidence
arm With Ball Jomt Remover of crackmg replace WIth a new one
HT72520000
4 Loosen bolts holdmg knuckle arm Ball Joint
m
place Separate knuckle arm from I Ball Jomt IS assembled at factory
bottom end of strut For details refer
and cannot be disassembled Measure
to and Strut
Spring Assembly force reqUired keep Jomt turning If
to
FIg FA 33 AdJusting clearance 5 Remove tensIOn rod and stablllzer
found to be more or less than speCIfI
between tensIOn rod
bar
and stabIlizer bar catIOns discard
For detail refer to Spring and
Strut Assembly
4 Be 6 Remove pm
sure that bolt attaching ten assembly connectmg Turnmg torque
SIon bracket IS correctly tIghtened transverse hnk to
suspensIOn cross New parts
5 Do not lighten transverse hnk member after loosenmg front and rear 75 to 125 kg cm
Side bolt of tensIOn rod wIthout fIrst nuts 65 to 109 m lb
bolt securing tension rod to Remove hnk WIth
tightening transverse sus U sed parts
tensIon rod bracket pensIOn ball Jomt and knuckle arm More than 50 kg cm 43 m 1b

FA ll
 Front Axle Front SuspensIon

Tlghtenmg torque 6 USIng floor Jack beneath center of

suspenSion crossmember raISe car
Ball Jomt bolt
until wheel falls to full down poSition
Socket bolt
I 9 to 2 5 Remove bolt indicated by arrow and
kg m
14 to 18 ft Ib separate suspensIOn crosS111ember from
Tension rod fastening bolt
car body
49 to 6 3 kg m
35 to 46 ft 1b

Ball Jomt castle nut

FA526 5 5 to 7 6 kg m
40 to 55 ft lb
FlFA 36 Sectronallllew of
lower ball JOmt Transverse I1nk to suspension
crossmember
2 Check condll1onal dust cover If
90 to 100 kg m
found 10 be cracked excessively be
65 to 72 ft Ib
yond use replace ball JOInt wIth a new

one

3 Lubncate ball JOint wIth recom

mended multI purpose grease regu SUSPENSION
larly CROSSMEMBER Fig FA 38 Removmg su pell lOn

lubricate and crossmember

To remove plug
mstall greasenipple 111 ItS place
REMOVAL
Pump grease slowly until old grease
IS completely forced out After greas 1 Jack up car and support It With
mg remstall plug safety stands remove wheels
2 Remove
Note When a high
pressure grease gun
splash board
3 Remove transverse hnk For de INSPECTION
is used operate the grease glDl
tails refer to Transverse Lmk and
carefully so that grease is injected 1 Check suspensIOn crossmember
Lower Ball JOint
slowly and new grease does not for eVidence of deformation and crack
4 With an overhead hOist and hftlfig
come out from the c1smp portion mg If necessary replace
cable support weight of efigme to
remove load from mountings

5 Remove engme mounting bolts

and nuts indicated by arrows m the

sketch below Separete suspensIOn
crossmember from engine

INSTALLATION
INSTALLATION
Install transverse I1nk and lower ball

Jomt In reverse order of removal In Install strut and Spring assembly m

rebushlng hnk use Front Transverse the reverse order of removal notmg
Lmk Replacer Set ST36700000 the follOWing
Rebusillng should also be In the
manner that outer end of bushmg IS

flush With end of hnk

To Install fIrst tighten transverse Tightemng torque
hnk mountmg bolts temporarily Final SuspensIOn member to frame
40 to 5 0 kg m
tlghtenmg should be camed out With
vehicle under normal load Fig FA 37 Front mountmg mSlllator 29 to 36 ft Ib

FA 12
 Front Axle Front Suspension

SERVICE DATA AND SPECIFICATIONS

SuspenSion type Independent strut

Shock absorber type Double acting hydraulIC

Wheel alignment Unladen

All models

Caster 55 to 2025
degree

Camber degree 50 to 2020

4 to 6 2
mm m
016to024
Toe In

degree 1 22 to 33

Klngpm 6040 to 8010

mchnatlon
degree

1 On both sides
2 Radial tlfe 3 to 5 mm 0 12 to 020 m

Front wheel turnmg angle

Inner wheel 370 to 380

Outer wheel 30042 to 32042

Coli spring

Station
Sedan Hardtop Wagon

hand Left hand Right hand Left hand Right hand Left hand
Right
spring spnng spnng
spring spring spnng

12 047 13 051 12 047 12 047

Wire dImater mm m

Cotdiameter rom m 130 512 130 512 130 5 12 130 5 12

371 5 63
Free length rom m 3865 15 22 330 1299 3865 15 22 14

Effective turn 65 625 65 65

Installed load 200 270 185 270

height 200 270 7 87 595 200 270 7 87 595
787 595 7 28 595
mm kg In lb

I 45 81 2 208 116 5 I 45 81 2 1 45 81 2
Spring constant kg mm lb m

FA 13
 Front Axle Front Suspension

Strut assembly

Sedan and
Hardtop
StatIOn Wagon

Piston rod diameter 22 0 87

m In 22 0 87

Damplf1g force
ExpansIOn 0 3 m sec kg lb 32 to 48 71 to 106 64t096 141 t0212

0 3
CompressIOn m sec
kg lb 20 to 30 44 to 66 32 to 48 71 to 106

Stroke mm In 178 7 01 178 701

Wheel bearing
RotatIOn startmg torque
In case of new parts kg cm m Ib 8 5 74 or less
At wheel hub bolt kg lb 1 5 3 3 or less
In Ib
case
ofrcadJustment kg m In 4 5 3 9 or less
At wheel hub bolt kg lb o 8I8 or less

Spmdle nut returning angle degree 60

Tlghtenmg torque

SuspensIOn member to body kg m ft Ib 4 0 to 50 29 to 36

Stablllzer bar to connectmg rod nut kg m ft Ib 1 2 to 1 7 9 to 12

Drum brake back bolt m ft Ib

plate fiXing kg 8 to 4 0 20 to 29
2

TenSion rod nut kg m ft Ib 45 to 55 33 to 40

TenSion rod to transverse hnk kg m ft 1b 49 to 63 35 to 46

TenSion rod bracket bolt kg ft Ib

m 5 1 to 6 9 37 to 50

Strut assembly upper support nut kg m ft Ib 25 to 3 5 18 to 25

Transverse I1nk to suspension crosstnember m ft Ib

kg 90to 100 65 to 72

Knuckle arm to strut assembly kg m ft Ib 70to 100 51 to 72

Ball JOint to transverse lmk kg m ft Ib 19t02 5 14to 18

Ball JOint to transverse I1nk With tensIOn

rod kg m ft Ib 49 to 6 3 35 to 46

Ball JOint to knuckle arm kg m ft Ib 5 to 76 40 to 55

Engine mountmg bracket bolt kg m ft Ib o 9 to 12 7 to 9

Gland packing m ft 1b
kg 7 0 to 13 0 51 to 94

Wheel beanng nut kg m ft Ib 5 to 3 0

2 18 to 22
TIghten to thIS torque then adJUst to specIfIed preload

FA 14
 Front Axle Front Suspension

TROUBLE DIAGNOSES AND CORRECTIONS

CondlllOn Probable cause Corrective action

Vibration shock and shIm mymg of steenng Improper tire pressure AdJust
wheel
Imbalance and deforma tlon of road wheel Correct the Inlbalance
or
replace
Unevenly worn tire or insuffiCient Replace or tighten
Vibration Loose connectIOn of the serration

parts and wedr of each part of hnkage ause hghtenlng

VibratIOn of front wheels which m turn IS Improperly adJusted or worn front wheel AdJust or
tighten
transmllted to the steering wheel ThiS IS bearing
very noticeable when travelhng over rough
Faulty wheel ahgnment AdJust
roads
Worn fittmg transverse lmk bushmgs Replace
Insufficiently tightened steering gear Retighten
Shock When the front wheels are
travelhng housmg
over bumpy roads the play of the steering Wear of steenng hnkage Replace defective
hnkage IS transmitted to the steering wheel parts
ThiS IS espeCially noticeable when lravelhng
Worn suspension ball Jomt Replace
on rough roads

ExceSSive backlash due to Improper adJust AdJust correctly

ment of the retamer parts
Shlmmymg Abnormal VIbration of the front
Damaged Idler arm Replace
suspensIOn group and the whole steering
Worn column bearing weakened column Replace or retighten
hnkage which occur when a specific speed IS
attamed bearing spring or loose clamp
Malfunction of shock absorber mslde the Replace or retighten
strut or loose mstallatlOn bolts

Correct the un balance

Imbalance ofvehicle level

Vehicle pulls to right or left Improper tIre pressure or msufflclent AdJust or tighten
When hands off the steering tlghtenmg ofwheel nuts
drlvmg With
wheel over a flat road the car gently swerves
Difference m height of right and left tire Replace tires

to rlgh t or left treads

Incorrect adJustment or abraSIOn of front AdJust or replace

wheel bearing
Note A faulty rear suspensIOn may also be Collapsed or tWisted front spring Replace
the of thIS problem
cause therefore see
Incorrect wheel ahgnment AdJust
also the chapter deahng with the rear
Incorrect brake adjustment bmdmg AdJust
suspension
hnk and
Worn rubber bushmgs for transverse Replace
tensIOn rod

Deformed steering lmkage and suspension Replace

hnk

Imbalance of car level Correct the Imbalame

FA 15
 Front Axle Front Suspension

Condition Probable cause Correcl1ve acl10n

Instability of car
Improper lire pressure AdJust
Worn rubber bushings for transverse link and Re pIa ce

tensIOn rod

Incorrect wheel ahgnment AdJust

Worn or deformed steering linkage and Replace
suspensIOn hnk

Incorrect adJustment of steenng gear AdJust

Deformed or Imbalanced wheel Correct or replace

SlIff steenng wheel Improper lire pressure AdJust

check up procedure Insufficient lubricants or mixing Impunlles Replenish grease or

m
steering hnkage or excessIVely worn
replace the part
steering hnkage
Jack up front wheels detach the steering Stiff or damaged suspensIOn ball Jomt or
Replace
gear and operate the steenng wheel and lack of grease

Worn or mcorrectly adJusted wheel beanng Replace or

adJust
If It check steenng and Worn damaged steenng gear and
IS light hnkage bearing Replace
suspensIOn groups
Incorrectly adJusted steenng geal AdJust
If It IS
heavy check steering gear and
Deformed steering linkage Replace
steering column groups
Incorrect wheel ahgnment AdJust
Damaged strut upper end bearing Replace
Damaged or stiff piston or shock absorber Replace
rod m the strut

Interference of steenng column with turn AdJust

Signal SWitch

Excessive steering wheel play Incorrectly adJusted steering gear housmg AdJust
Worn steering hnkage Replace
Improperly fitted gear box Retighten
Incorrectly adJusted wheel bearing AdJust
Worn transverse hnk and tensIOn rod fittmg Replace
buslungs

Noises Improper tire pressure AdJust

InsuffiCient lubricating 011 and grease for Replenish lubrlcatmg
suspension ball Jomt and steering hnkage or 011 and grease or

their breakage replace

Loose steering gear bolts hnkage and sus Retighten
pension groups

Damaged shock absorber inSide the strut Replace

Damaged wheel bearmg Replace
Worn steering I1nkage and steenng gear Replace
Worn transverse hnk and tension rod fIttmg Replace
buslungs

FA 16
 Front Axle Fro Suspension

Condll1on Probable cause CorreCl1ve acl10n

Noises Broken or collapsed cOil spring Replace

Loose strut mounting msulator tightening Retighten
nuts

Loose stabilIZer bolt Retighten

Gratmg hre noise Improper tIre pressure AdJust

Incorrect wheel alignment AdJust
Deformed knuckle spmdle and suspensIOn Replace
hnkage

Jumping of disc wheel Improper tire pressure AdJust

Imbalance wheels AdJust

Damaged shock absorber Replace

Damaged lire Replace

Deformed wheel rim Replace

Excessively or partially worn tire Improper tire pressure AdJust

Incorrect wheel ahgnment AdJust
Worn wheel bearing Replace
Incorrect brake adJustment AdJust

Improper tire sluftmg rotatIOn AdJust

Rough and Improper drlvmg manner Drive more gently

FA 17
 Front Axle Front Suspension

SPECIAL SERVICE TOOLS

For Reference
Tool number
use page or
No DeSCription
on FigUre No
tool name UnIt mm m

used atiachment to strut or steering gear box when 610 Fig FA 20

KV481OO300 ThiS tool IS as an
All Fig FA 25
wo k IS perfonned In a Vise
Strut and 710
S mark indicates hole for strut
steering gear All
G mark mdlcates hole for sleerlng gear box
hOUSing CllO
L mark mdlcates hole for L H steenng gear box All
attachment
C130
All
330
All

5E400

B210 Page FA 6
2 ST3530000 This loolls used to attach outer race for front wheel beanng
For
Front wheel
Europe
bearmg drift 710

T 610
S30

59 2 32 dJa HGCllO
45 1 1 776 dla
C130

B210 FA 20
3 ST35500001 This tool IS used to remove or mstall gland packing at the top end of Fig
For Fig FA 25
strut
Gland packmg Europe
wrench 710
610
CllO
C130

WIdth across flats 55 2 17

5E 220

B210 Fig FA 19
4 ST3565S001 This tool IS used to compress COli spring m dlsassembhng or

For
assembling strut assembly
Coli spnng Europe
compressor 710
610
ST3565 1001
CllO
Body C130
S30
ST35652001
B120
Clamp

5E221

FA 18
 Front Axle Front Suspension

Tool number For Reference

No Description use page or

tool name on Figure No

Umt mm m

5 ST36700000 This tool IS used to replace transverse hnk buslung In ItS apphcatIon B210 Fig FA 35
ahgn the tool with the bushmg center by usmg For
Transverse hnk
a prs Page FA 12
Europe
bushmg replacer 710
610
S30

SE222

FA 9
6 ST35530000 This tool IS used as a guide m mstallmg gland packmg by covenng B210 Page
shock absorber shaft to prevent 011 seal from marnng m packmg 710

Gland packmg 610

guide CliO
C130

5E093

Tlus tool used to ball stud from knuckle arm All Page FA II
7 HT72520000 IS remove
models
Ball JOint
remover

SE399

FA 19
 SECTION RA

REAR AXLE
DATSUN REAR
MODEL 610 SERIES
SUSPENSION

REAR AXLE AND REAR

SUSPENSION RA 2
RIGID AXLE

REAR AXLE AND REAR

SUSPENSION INDEPENDENT RA 8
REAR SUSPENSION

SERVICE DATA AND

RA 16
SPECIFICATIONS

TROUBLE DIAGNOSES AND

RA 19
CORRECTIONS

I NISSAN I SPECIAL SERVICE TOOLS RA 20

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Rear Axle Rear Suspension

REAR AXLE AND REAR SUSPENSION RIGID AXLE

CONTENTS

DESCRIPTION RA 2 INSPECTION RA 6

REAR AXLE ASSEMBLY RA 4 INSTALLATION RA 6

REMOVAL RA 4 REAR SPRING RA 6
INSTALLATION RA 4 REMOVAL RA 6

REAR AXLE SHAFT AND INSPECTION RA 6

WHEEL BEARING RA 4 INSTALLATION RA 6
REMOVAL RA 4 SHOCK ABSORBER RA 7

INSPECTION RA 5 REMOVAL RA 7

INSTALLATION RA 5 INSPECTION RA 7

REAR AXLE CASE RA 6 INSTALLATION RA 7

REMOVAL RA 6

DESCRIPTION
The rear suspension IS
mtegrated
with the rear axle assembly
The rear axle assembly IS of the
seml floatmg type m which the car
weight IS carned on the axle shafts
through the bearings In the outer end
of the rear axle case The axle case IS a

BanJo type
The rear axle assembly IS attached
to the frame through elhptIc
semt leaf

springs and shock absorbers

Rubber bus1nngs at each end of the
leaf sprmgs and shock absorbers

spring pad at sprmg seats smgly or m

combinatIOn effecl1vely absorb Vibra

tIOn and nOIse

The rear axle shafts are floatIng

fItted to the differentIal Side gears

through splmes The outer ends are

supported at the ends of rear axle case
by a smgle set of sealed ball beanngs
The bearings are lubricated with
recommended multI purpose grease

1 Rear axle case end slum The axle shaft 011 seals are located
2 Od CDtter mboard of the The beanngs
bearings
3 Beanng aresecured agamst shaft shoulders by
4 Od seal
means of collars
5 Beanng colLu

6 Rear axle case housmg

7 Brake dIsk
8 Rear axle shaft
9 Beanng spacer

TlghteDlng torque T
of nut

@ T 8 to 9 kg m 58 to 65 ft Ib

@ T 2 2 to 2 7 kg m
16 to 20 ft Ib

FI RA 1
f Cross sechonalu ew of rear axle

RA 2
 5J
310p onlW
J
l
C c 00
Ql
0 W 00
P 35 p
0 0 Ql
bolts 41
to to
9
to W
of
lft
ue tU 43 l1
1 l 16 S

totl 65 4

to
S
to to
uts 60 09 36

fIShteu1 l

alId @ @@

W plate RA
as etUbpInlY bUsh absotbel tub et ocatlOn as tUblY bUsh sptl seat ateste
c
ns pad S

t
seat
lSI pad
S

S h
nS nS
a c k l e R u b e t Leaf Sptl fotque
et bo
t nS
t t
Spt
ftOnt Rub el Shock
1 3
45
61
l
Bu
U t U l
SI SI
90
1 3

ll
 Rear Axle Rear Suspension

REAR AXLE 8 Place a Jack under the center of

ASSEMBLY axle case Pass axle Cdse through space

above spring and take It out to the
REMOVAL Side See Figure 4
RA

It IS not necessary to remove the

rear axle assembly for mlllor
repairs
However If the axle case IS dam

aged the rear axle assembly may be

removed as follows

1 Raise rear of car

high enough to
peflTIlt workmg under It Place a Jack
FIg RA 5 RemOVIng brake parts
under the center of axle case so It Just
starts to raise rear axle assembly FIg 4
RA axle
RemOVIng rear
Place stands under body member 4 Remove brake drum
assem bly
on both SIdes Remove rear wheels 5 Remove nuts retammg brake diSC
2 Mark
propeller shaft flange and to axle case RA 6
See Figure
compal1lon flange of differential
carncr so that the
orlgmal cOnlbma
lion can be restored at
assembly
3 Withdraw propeller shaft sleeve INSTALLATION
yoke from transnllSSlOn by movmg the Install the axle the
shaft rearward It under rear
case assembly m
passmg
reverse order of removal nohng the
axle Watch for 011 from trans
leakage
followmg mstrucl10ns
miSSion end

Tightening torque
Note Remove propeller shaft care RA 6
U bolt Spnng chp FIg Remuvlng nuts

fully so as not to damage splme 6 0 to 6 5 kg m

sleeve yoke and rear oil seal 43 to 47 ft Ib 6 Pull out axle shaft assembly to

getherWith brake diSC usmg Rear Axle

Shock absorber lower end nut
3 6 to 4 8 Stand KV40101000 and Shdmg Ham
kg m

mer ST36230000 See Figure RA 7

26 to 35 ft Ib
4 Disconnect hand brake cable by
removlllg clCVIS pm CD See hgure Propeller shaft tocompamon

RA 3 flange connectmg bolt

5 Dlsconncct rcar brake hose 2 4 to 3 3 kg m
at

body SIde @ Cover brake hose and 17 to 24 ft 1b

pipe openmgs to prevcnt entrance of

dirt Sce RA 3
Figure
6 Disconnect shock absorbers at

lower end @ and push shock ab RA351

sorbers up out of the way See figure FIg RA 7 RemOVing rear axle shaft

RA 3 assembly
REAR AXLE SHAFT
7 Remove 011 seal axle
7 Lower under axle Re AND WHEEL m case If
jack case

necessary and mstall new scal Insure

move V bolts spring chps @ to BEARING agamst damdgmg the seal lip
separa te axle ca e from spring See
8 Cut bearing collar With cold
RA 3
Figure chisel See Figure RA 8
REMOVAL

I Raise rear of car and place tand

under axle case on both Sides Remove

rear wheels

2 Pull off spring CD and disconnect

cross rod from lever by removmg cleVIS
pm @ See Figure RA 5
3 Disconnect brake tube at rear

brake diSC See Flgurc RA 5

RA155
RA194 Cover brake hose and pipe operungs

RA 3 Under entrance of dirt FIg RA 8 Cutting bearing collar

FIg llew to
prevent
RA 4
 Rear Axle Rear Suspension

011 seal
Note Take care not to damage axle
4 Use care not to ddmdge
when 1I1stdlhng
shaft with cold chisel during opera
5 When IIlsell1ng dxle Shdft 1I1to
tion
dxle La e use ReM Axle Shaft GUide

not he seal
ST37840000 10 ddmdge
mg hps of 011 sedl
ST38210000
To msert axle shaft mto Jxle ca e

proceed as follows
Instdll Rear Axle Shaft GUIde
RA157
ST37840000 on dxle case

when the dls

Fig RA 10 Installmg wheel bearing
Remove the gUide
between the axle and
tanLe A flange
70 to 90 2 76 to 3 54
bearing IS mm
2 Install 011 seal usmg 011 Seal Drift m See FJgure RA II
RA156
KV40 1 00300
3 PaLk Lavlly between seal hps with Note mulh purpo e grease to
Apply
IF g RA 9 Removing wheel beamlg
recommended multi purpose grease the outer periphery of the rear axle
when 1I1stJlhng shdft bearing collar

9 Remove wheel beanng dnd wllar

uSlIlg Redr Axle Sluft Beanng Puller
HT72480000 Then take out brdke

dl L See Figure RA 9
62 mm 2 44 m dla

1 Redr axle hJtt

72111m

2 83 m dla 2 Rear axle Shdft gUIde

3 Rear 3 le case

INSPECTION 4 OJ seal

Inspect the followmg parts for fauIl RA205

and replace as necessary

Fig RA 11 Installing rear axle shaft
I Check axle Shdft for bendmg
cracks dnd dl tortlOn
ddmage wear

2 Check the hp of oil seal for

C
the between
6 AdJust gap
ddmage deformdtlon and wear
wheel beanng and brake dISC to wlth1l1
3 Check for and
beanng wear
o I mm 0004 m by use of shim See
damdge RA 12
FIgure
Rear axle cdse end shim

tluckness
0075 mm 0 0030 m
INSTALLATION
Install m the reverse or del of re

nloval
Fig RA 13 Measurlllg end play
I Install beanng spaLer bearing and
new beanng COlldl onto axle shaft lIld
press bearing collar by specified IOdd
more than 3 tons uS1l1g Rear Axle
Collar Inserter
Shaft Lock
ST382 I 0000 See Figure RA 1O Tlghtemng tOlquc

Brdke dISC ftxmg nut

2 2 to 2 7 kg m
Notes RA196
16 to 20 ft lb
a A new collar mu t be used Before
FIg RA 12 Gap C Brake tnbe
mstalhng clean collar and axle
I 5 to I 8 kg m
shaft
II to 13 ft Ib
b Clean and pack with re 7 Measure play of axle
aXial end
bearlllg
sh lfI with dial mdlcdtor It shonld be Wheelnnl
commended multi purpose grease
8 10 9
c Insert wheel bearmg with seal SIde o 10 to 045 mm 0 0039 to 0 0177 kg m
See RA 13 58 to 65 ft Ib
toward wheel m
Figure
RA 5
 Rear Axle Rear Suspension

INSPECTION
REAR AXLE CASE
Clean all rust and dirt from spnng
REMOVAL leaves usmg a wife brush If necessary

I Examme spring leaves for frac

Rear axle case IS removed and
tures or cracks
mstalled as follows
2 Check front brack t and pm
I Raise of and stands
rear car
place shackle U bolts and spring seat for
under body member on both sides
wear cracks bendmg and damaged
2 Remove rear axle assembly Refer
threads If defectIve parts are found
to Removal of Rear Axle Assembly RA197
with neV ones
3 Remove rear axle shaft on both replace
Fig RA 14 RemOVing shock absorber 3 Inspect all rubber parts for wear
Sides Refer to Removal of Rear Axle lower end and U bolts
Shaft and Wheel
damage selara tlOn and deformatIon
Beanng
4 Remove differential gear carner
Replace them Ifnecessary

assembly
3 PositIOn Jack under rear axle case

An alternate procedure can be fol Raise Jack and float axle case from
lowed as hsted below spring
4 Disconnect spnng shackle
I Raise of and stands
rear
by
rear car
place
removmg nuts See Figure RA 15
under body member on both Sides
INSTALLATION
2 Remove rear axle shaft on both
Use the followmg procedure when
Sides
3 Remove dlfferenhal gear carner
tIghtening U bolts spnng chps
I
assembly Apply soapy water to each Side of
4 Remove rear axle case spring pad
2 Torque U bolts to the specified
settmg exen lSlng care not to tIlt
U bolts Sideways

8
INSPECTION RA198

Check axle case for deformatIOn or

Fig RA 15 RemOVing spring shackle
cracks and replace If necessary

5 Disconnect spnng front pin by

INSTALLATION Fill RA 17 U bolt
nuts Installing
remoVIng Dlsconnectmg spnng
InstallatIon can be accomphshed from See
body Figure RA 16
the reverse order of removal
followmg 3 Install four nuts place by
m

Tlghtemng torque makmg them snug tight evenly untIl

Differential carner to
the same number of threads IS en

axle ca fix nut gaged before

tIghtemng WIth a box

20 to 2 5 wrenchsecurely
kg m

to 18 ft lb 4 When tlghtenmg nuts With a box

14
Oil dram and filler wrench alternately turn them one full
plug
rotahon at a hme untIl the proJectIOn
42 to 69 kg m
of each bolt head IS wltlun 3 mm
30 to 50 ft lb
0 12 In above the nut Check again
that the four nuts are
torqued evenly
REAR SPRING Notes
a Close adherence to the above tn
Fill RA 16 RemOVing spring pin
REMOVAL struchons will add much to m

I Raise rear of car and place stands creased service hfe of U bolts
under body member on both Sides b After installahon make sure that
2 Disconnect shock absorber 10cal1on and spnng seat close
at plate
lower end U bolts
CD and remove 6 Remove rubber bush m
spring If ly come into contact With each

Spring chps CV See Figure RA 14 necessary and mstall new bush other

RA 6
 Rear Axle Rear SuspenSion

2 Check for oil

Closely observe the foIlowl
ng mstruc SHOCK ABSORBER leakage and cracks
lions Also check shaft for bendIng
c Do not remove any particular U REMOVAL 3 Inspect rubber bushIngs for dam
bolt alone Be sure to remove ad age cracks and deformatIOn Replace
Raise rear of car and stands
I place parts Ifnecessary
Jacent U bolts too under axle case on both Sides

Use a hOist or
open pit If available
2 Disconnect lower end of shock
absorber by removmg bolt CD or nut

CD at spnng seat See Figure RA 18

3 Disconnect upper end of shock
absorber by removmg riu t @ or bolts
@ at frame See Figure RA 18
To mstall the part other than U
bolts reverse the order of removal

closely observmg the followmg INSTALLATION

Coat rubber bushes With soapy
water pnor to assembly Install shock absorber In the reverse
Car weight must be on rear wheels order of removal notIng the followmg
when lIghtenmg front pm shackle and
Note Car
shock absorber lower end bolt m order weight must be on rear
wheels when lIghtenmg shock ab
to clamp rubber bu hes In an unloaded
sorber upper and lower ends In

posll1on order to clamp rubber bushings m

an unloaded posltJon
Tightening torque
Spnng front pm nut RA311

6 0 to 6 5 FIg RA 18 Removmg shock absorber

kg m

Shock absorber upper end bolt

43 to 47 ft Ib
09 to 1 2 kg m

Spnng shackle nut 7 to 9 ft Ib

6 p to 6 5 kg m
Shock absorber lower end nut
43 to 47 ft 1b
3 6 to 4 8 kg m
U b6lt INSPECTION
26 to 35 ft Ib
0 t 6 5 kg m
43 to 47 ft Ib I Test shock absorber and compare
I
I
With Service Cauhon Do not or heat gas
Shock absorber lower end bolt speclfIcal10ns given m open

Data and SpecificatIOns If filled type shock absorbers which

3 6 to 4 8 kg m Replace
are equipped on some models
26 to 35 ft Ib teces ary
r

RA 7
 Rear Axle Rear Suspension

REAR AXLE AND REAR SUSPENSION

INDEPENDENT REAR SUSPENSION

CONTENTS

ARM RA 12
RA lO REAR SUSPENSION
DESCRIPTION
REMOVAL RA 12
REAR AXLE SUSPENSION
RA 13
RA lO INSPECTION
ASSEMBl Y
INSTAllATION RA 13
RA lO
REMOVAL
RA REAR AXLE SHAFT WHEEL BEARINGS
INSPECTION AND REPAIR
RA ll AND SEALS RA 13
INSTAllATION
RA 11 REMOVAL AND DISASSEMBLY RA 13
SUSPENSION MEMBER
RA 13
REMOVAL RA 11 INSPECTION
RA 13
INSTAllATION RA 11 ASSEMBLY AND INSTAllATION
WHEEL BEARING ADJUSTMENT RA 14
RA 12
SUSPENSION COil SPRING
RA 14
REMOVAL RA 12 DR IVE SHAFT
RA 15
RA 12 REMOVAL
INSPECTION AND REPAIR
RA 15
RA 12 DISASSEMBl Y
INSTAllATION
RA 15
RA 12 INSPECTION
SHOCK ABSORBER
RA 15
REMOVAL RA 12 ASSEMBl Y
RA 15
INSPECTION RA 12 INSTAllATION
RA 12
INSTAllATION

4 s 6

1 Snap nng 15 SuspensIOn arm

2 Sleeve yoke plug Beanng housmg
3 O nng 16 Rear axle shaft I l
4 Dnve shaft snap nng 17 Beanng spacer
5 Dnve shaft stopper 18 BearIng outer I I

6 Dnve shaft ball 19 Tlghtenmg torque T of L1

Apply wheel beanng
7 Ball spacer grease to wheel bearIngs bolts and nuts kg m ft lb
8 Sleeve yoke stopper and the surface of dIS @ T 0 32 to 044 2 to 3
9 Snap nng tance piece @ T 2 7 to 3 7 20 to 27
RA324
10 Rubber boot 20 BearIng dIStance piece @ T 8 to 9 58 to 65
II Rear axle flange 21 Bearmg mncr @ T 5t06 36t043
12 011 seal 22 Plam washcr @ T 13 to 17 94 to 123
13 Brake dISC 23 DrIve shaft assembly
14 Grea e catcher 24 Snap rlOg

RA 19 CroS ecllOnal VIew of rear u1 le

Fig

RA 8
 Rear Axle Rear Suspension

Differential gear carner 10 lOn member

Suo pcno mountmg TightenIng torque of
bolts and nut kg m ft Ib
3
embly mulator
5 to 7 36 to 5I
2 Differential mounting member II penslOn member
Suo mounting
7
3 Differential mountmg ulator
mo upper topper @ to 10 51 to 72
4 mounting lower
Dlfferentl 12 Rear suo
penslOn front rfJ T1ghten under side nu t of

topper double until

nuto they will
mountIng bolt
5 Rubber bu hIng 13 Rear c uo lOn member
pen
no longer go
6 Shock orbcr as embly
lbo 12t@l16to0I226
7 Rubher hu hIng 7 10 51 to 72
14 lOn drrn
Suspeno pm tgJ to

8 lOn Jrm
pcno 3ocmbly
Su 15 ipCnSlOn
SU arm bu h Cf II to 15 80 to 108
9 pc lOn member mountmg 8
Su @ to 10 58 to 72
lower topper 7 51
fi1 5 to 36 to

CD 20 to 30 145 to 217

RA313

FIg RA 20 Rear sUSperl lOn system

RA 9
 Rear Axle Rear Suspension

DESCRIPTION 4 Remove rear exhaust tube and

The rear suspension IS of the

muffler @
5 Mark rear flange of propeller
semltrallmg arm type mdependent
shaft and pmlOn flange of differentIal
suspensIOn
gear carner for proper reassembly
Primarily rear wheel IS supported
disconnect
With the coli sprmg and suspensIOn
t en rear flange from
arm the differentIal gear carrier IS pmu2n flange by removmg four bolts
@ Remove propeller shaft assembly
aligned mdependently dnd separately
6 DIsconnect rear brake hoses CID
from the suspenSIOn and the gear
carner IS mstalled directly on the
at suspension aJms on both Sides
RA102
the Cover brake hoses and pipe openings
body with suspensIOn member
Fig RA 21 Support pomts
to prevent entrance of dlft
and the differentIal mountmg mem
ber through four rubber Insulators
7 Posll1on Jack under suspension
2 Remove rear wheels arm and raise Jack slightly to relieve
Coli springs are mounted between
3 Disconnect hand brake cables tensIOn on shock absorber Discon
the suspensIOn arms and body The by
nect shock absorbers at lower end
upper end of sprIng IS mstalled on removmg adJustmg nut adJuster
at

CID Carefully lower Jack under

the body through rubber cushIOn and CD and return spnng @ See Figure sus

arm
RA 22 pensIon
the suspensIOn arm IS mstalled on

member with rubber

suspension
cushIOn
The rear wheel bearing housmg
and shock absorber lower bracket are

welded the end of the

to tralhng
suspensIOn affi1

Drlvmg power IS tranSlmtted to

the rear axle shaft with the freely
extenSible drIve shaft through flange
yoke on both ends of the dIfferentIal

gear carner The rear axle shaft IS

supported with two ball bearings m

the rear wheel beanng housmg

RA265

REAR AXLE Fig RA 22 Rear suspensIOn removal pomts

SUSPENSION
ASSEMBLY
REMOVAL
8 under center of suspen
It IS not necessary to remove rear Support
sIOn member and differentIal gear
axle and suspensIOn assembly for any
carner With a
Jack
normal repaIrs However If the rear
9 Disconnect suspensIon mjlmber
suspensIOn member IS
damaged the
from removmg two nuts
rear axle and the suspenSion member
body by j
at both ends of member
be removed and
assembly may m

stalled usmg the 10 Disconnect differentIal mount

followmg procedure
mg member by removmg two nuts

Raise the rear of car high enough @ at both ends of member

to permit workmg underneath and 11 Carefully lower Jack With sus

support It on stands Place stands pension assembly and It out from
solidly under body member on both under car Support suspensIOn so that axle and
Fig RA 23 Removmg rear

Sides It does not tilt and fall off Jack suspensIOn assembly

RA lO
 Rear Axle Rear SuspensIon

INSPECTION AND REPAIR INSTALLATION 2 Rubber msu1ators should be cor

rectly hned up as shown m Figure

When the suspensIOn has been
rear Install the rear axle and the
RA 27 and mserted from the under
removed examIne all parts for wear suspensIOn assembly In the reverse
Side of member
or damage Particular attention order of removal notmg the follow
3 Do not use lesser qual1ty or
should be gIVen to bushmg m suspen Ing pomts subsl1tutedeSign parts
slOmarms and bound bumper rubbers 1 Ensure suspension member and
Also check the conditIOn of rubber differential member
4 Tightenmg torque values must be
mountmg are
I
used as speCified dUring reassembly to
msul tors the suspensIon member
m
correctly hned up
the differential
assure proper retentIOn of parts
and mountmg mem
ber

Any of these components If worn T 11 Oto 150kg m

can res lt n lsy and vlbral10n to the l
c

80 to 108 ft Ib
mterlor of car g
c
Replace rubber msulators of the 8
J
c
suspensIOn merl1ber
penii1on Merpber Ilsulator Replacer
usmg Rear Sus 8

u
c
0
c
0

1 Front

ST38290000
1 20mm
1200 mm 0 79 m
4724 m

ST38290000
555 mm

21 85 m T 20 0 to 30 0 kg m
L 145 to 217 ft lb

410 mm

16 14 m

Rear

RA027

Fig RA 24 Removmg msulator from T 7 0 to 10 kg m

suspensIOn member 51 to 72 ft Ib
1
n T Tightening torque
t

rubber msul the RA107

Replace t9rs Rf
tlal
1
fereI rno ntmg rber
mep ISIng 1 RA 27 Insulator
lF

I fferentlal Mountmg nsulator Dpft

ST33300010 for and center of suspension member See
reIJIpvaJ Tightening torque
ST3330020 for mstallatlOn Figure RA 28
SuspensIon member
3 Disconnect
mountmg nut
CD suspension arms by
7 to 10 kg m remOVIng suspensIOn arm
pinS CV
51 to 72 ft Ib

Dlfferenl1al mountmg
member nut
mountmg CV
7 to 10 kg m

51 to 72 ft Ib
Shock absorber lower

end bolt
fiXing
1 RA 25 Removmg mjulator from
lF I 6 to 2 2 kg m RA266

differential mountmg member 12 to 16 ft lb

p j Fl1 RA 28 Removmg suspensIOn
member

SUSPENSION INSTALLATION
MEMBER Install the rear suspensIOn member
REMOVAL m the reverse order of removal

o I Remove rear suspensIOn as

Note weight must be on rear
Car
See Rear Axle
s mbly SuspensIOn wheels whentightenIng suspensIOn
Assembly Removal arm pms m ord r to clamp rubber
RA106

2 DIsconnect dIfferential gear car

l1 RA 26 Tnstallmg msulator
F
to bushmgs m a neutral on unloaded
dlfferenhal mountmg member ner by remOVIng four bolts CD at pOSitIOn

RA ll
 Rear Axle Rear Suspension

Tlghtemng torque
DifferentIal gear drner

filling bolt 5 to 7 kg m

36 to 51 ft Ib

SuspensIOn arm pin

i8 to 10 kg m

58 to 72 ft lb Q 2
RAllO 21tJ

SUSPENSION COIL RA 31 Sprmg and rubbers

FIg J RA 32 InstallatIOn of rear
FI
shock absorber upper end
SPRING

REMOVAL INSPECTION
INSPECTION AND REPAIR
1 Raise the rear of car and support 1 Test shock absorber and com
1 Check coli sprIng for YlCld
It on stands Place stands solIdly under pare With the specificatIOn gIVen m
deformation or cracks
Data
body member on both sides ServIce and SpeCificatIons Re
2 Test spring and compare With
If necessary
2 Remove redr wheels
the Service place
speCifIcations gIVen m
Check for oJ
3 Disconnect hand brake cables by Data and SpecificatIOns
2 leakage and cracks
Also check shaft for straightness
removmg adJustmg nut at adJuster 3 Check all rubber parts for wear

CD and return spring @ See Figure If

3 Inspect rubber bushIngs for
damage and deformation Replace Re
RA29 ne
damage cracks and deformation
essary
4 Remove dnve shaft flange nuts place parts If necessary
@ on the wheel side and bound
rubber flXlng nut @ INSTALLATION
5 Disconnect rear brake hose CID Install COIl spring m reverse the INSTALLATION
dt suspensIOn arm order of removal notmg the follow
6 Position under suspensIOn Installdl10n of sho k absorber IS
jack mg pomts
and relIeve the reverse order of removal
arm raise Jack slIghtly to 1 spnng seat on top of
Install
tensIOn on shock absorber Discon rubber m sprIng
spring and bound Note Car weIght must be on rear
nect shock dbsorbers at lower end and ensure that COIl spring IS cor
wheels when tlghtenmg shock ab
7 Carefully lower Jack to fully flat face of spring
rprtly m
posItion sorber lower end m order to clamp
extend spring after dlsconnectmg IS top rubber bushmgs m a neutral or
shock absorber and remove spnng 2 torque values must
be
TIghtenmg unloaded posll1on
sedt and bound rubber
sprmg used dS follows
Shock absorber lower end
fix mg bolt

6 to 2 2 kg m
12 to 16 ft lb REAR SUSPENSION
Bound rubber nut
ARM
1 6 to 2 2 kg m

The rear axle shaft housmg and

12 to 16 ft lb
shock absorber lower mountmg
Drive shaft flange bolt
bracket are welded suspensIOn arm
5 to 6 kg m 36 to 43 ft Ib

REMOVAL
I Raise the rear of car and support
under body member on stands
wheel and brake
SHOCK ABSORBER 2 Remove rear

drum
REMOVAL 3 DIsconnect dnve shaft from axle

1 the trunk and remove shaft

Open
4 DIsconnect hand brake cable
1k
tru flnl her as
embly
from hed to wheel
2 Remove double nuts which lever atta cyl
shock Inder
fa ten the upper end of rear

5 Disconnect brake hose from

absoher to body
brake tube by removmg lock spnng
3 DI connect shock absorber by
removing bolt at suspension arm
and draw out through connector
FI RA 30 Removmg coli sprmg
J

RA 12
 Rear Axle Rear Suspension

Note Cover brake hose and tube II Drdw out rubbcr from
bushings
of
operung to prevent entrance suspensIOn arm usmg ReJr SuspenSIOn KV40101000
dirt Arm Bush Remover ST38280000

RA351
RA267
I
Fig RA 37 Removmg rear axle
FIg RA 33 Removmg brake hose
Izaft
and tube

6 Remove wheel bearing lock nut Fig RA 36 Removmg rubber bushmg 6 Remove 011 seal and mner
beJrmg
7 Remove axle shaft wheel Rear Axle Shaft
red usmg Beanng Dlllt
bearings and 011 seal ST37750000
8 INSPECTION
Remove rcar br Jke Jssembly
from suspensIOn arm I eXJmlne suspensIOn Jlms to
ensure
they dre not deformed or

rd ked

2 Che k rubber bushmgs for wear

dJmJge and separJtlon ReplJ e If
ne essary

Fig RA 38 Removlllg OIl eal

INSTALLATION and lIlner bem mg

Install 10 the revcrse order of

7 R move grease atcher
removJI
RAl14 notmg the followmg pomts
8 Withdraw outer beanng from
I Car
Fig RA 34 Removmg rearbrake weight must be on rear standard
rear axle shaft usmg a
assem bty wheel when tlghtclllng suspensIOn
beanng puller
arm pms 10 order to dJmp rubbcr
8 After removc bound rubber fiX bush lOgs m a ncutral on unloJded
mg nut posItion p k under sus
Note Do not reuse beanng which
positIOn
pensIOn drm and raise
Jack hghtly to 2 Change self lo has been pulled out
kmg nuts at ea h
rchcve tensIon on sho k absorbcr
ovcrhaul
Dlsconncct sho k absorber Jt lower
end
INSPECTION
9 lower
Carefully Jack to fully
extend spring after dlsconnectmg Inspect the followmg parts Replace
or repair If necessary
sho k absorber Jnd remove spring

spring seat and bound rubber

REAR AXLE SHAFT 1 Check axle shaft for straightness
cracks wear and distortion
10 Dlswlmect suspensIOn arm by WHEEL BEARINGS
2 Check beanng for excessive wear
removmg suspensIOn arm pms secur AND SEALS
and damage Replace If necessary
109 suspensIOn arm to suspensIOn
REMOVAL AND
member
DISASSEMBLY

I Raise the rear of ASSEMBLY AND

car and support
under membcr INSTALLATION
body on stdnds
2 Rcmove redr wheel and brake Install m the reverse order of
drum removal the followmg pomts
noting
3 Disconnect dnve shdft from axle I Clean wheel beanngs 011 seal
shaft and the mSlde of axle shaft housmg
4 Remove wheel lock nut Wheel beanngs are scaled type
bearing 2
5 DrJw out axle shaft that the sealed
assembly When mstalhng ensure

Rear Axle Stand KV4010 I 000 Side of

usmg outer beanng fa es the wheel
and Hammer the sealed SIde of mner
RAl15 Shdmg ST36230000 and that

FIg RA 35 Removmg suspensIOn arm Remove rear axle flange bearing faces the differential

RA 13
 Rear Axle Rear Suspension

of distance 4 wheel
Pack wIth wheel bearmg The length piece IS Replace bearmg grease peri

grease MP2 or MP3 at 005 mm 00020 m shorter than the odically

each overhaul Pack wheel bearings With MP2 or
length of housmg Example When an

axle hOUSing IS coded B select B MP3 grease as shown m Ftgure

coded distance piece RA 39 Apply grease to I1p seal and
wheel bearing
Notes

a Change lock nut and 011 seal at

Beanng housmg mark each overhaul

b Reuse of an 011 seal must not be
allowed Install 011 seal by Rear
1

2
Grease seal
Wheel bearmg mner

FIg RA 39
3 DIStance pIece

SectlOnallllew of
rear axle
RAl16

L
EJ Axle
ST37710000
Grease Seal Drut

AXLE HOUSING DISTANCE PIECE

3 When suspensIOn arm
replacmg RA268
WHEEL BEARING
measure the dimenSIOns L1 and L2
Fig 40
RA DImensIon of dIStance
ADJUSTMENT
See Figure RA40 pIece and hOUSIng
1 After lock
tightenmg nut to

specIfIed torque 25 to 33 kg m 181

Rear wheel distance piece to 239 ft Ib check the axle
Rear axle shaft housmg bearing rear

shaft end It should be 0 to 0 15

mm m mm m play
rom 0 to 00059 m and should have
Mark Mark L2 length a
turnmg torque less than 4 5
Ll length kg cm
39 In Ib or 08 kg I 8 lb at hub

59 05 to 59 15 59 02 to 59 08 bolt
A A
2 3248 to 2 3287 23236 to 23260
2 Lock nut usmg a punch
58 59 to 59 05 58 92 to 58 98
B B
23197 to 2 3220 3 If the correct
2 3067 to 2 3248 end play or

58 85 to 58 95 58 82 to 58 88 turning torque cannot be obtamed

C C dISassemble agam and distance
23169 to 2 3209 23157 to 2 3181 replace
piece

DRIVE SHAn

1 Dnve shaft 9 Sleeve yoke plug

2 Dnve shaft ball 10 SpIder Journal
3 Ball spacer 11 SIde yoke
4 Dnve shaft stopper 12 011 seal
5 Rubber boo I 13 Needle beanng
6 Bool band 14 Snap nng
7 Snap nng 15 SIde yoke flttmg bolt
8 Sleeve yoke RA269

Fig 41
RA DrllJe shaft

RA 14
 Rear Axle Rear Suspension

REMOVAL 2 Check dnve shaft for straightness 3 Apply an adequate quantity of

cracks and distortIOn multi purpose gredse to the ball rolling
I Jack up rear of car and support danlage wear

drive shaft assembly If nec groove and 011 groove approximately

on safety stands Replace
10 g 035 In addition 35 g
2 Disconnect drive shafts CD on the essary oz apply
42
RA 3 Check steel balls and sleeve yoke i23 oz of grease to the area shown
wheel side See Figure
45
RA
for damage wear and distortion Re m
Figure
place drive shaft assembly If faulty
Needle
parts are found beanng
4 If any abnormal condition IS J I

found m umversal Jomts replace Jomt

5 Wash out old grease from sleeve
yoke drive shaft ball rolling groove RA270
UPi
J tIllS
I

Apply grease In area

and 011 groove

RA270
6 Check the play m drive shaft as

shown FIg 45
RA SectIOnal of
m
Figure RAM If the play view

dnve shaft
PD318 exceeds 0 1 rom 0 004 In replace
dnve shaft assembly
42
RA Under view Note of drive shaft
Fl Component parts
Note The measurement should be are not available except as an as
taken with dnve shaft fully com Therefore If any wear or
3 Remove side yoke fittmg bolts sembly
pressed damage eXists In a certam part
and extract Side yokes together with
drive shaft Will have to be
drive shafts See Figure RA43 assembly
replaced

INSTALLATION

I Install Side yoke together WIth

drive shafts to differential gear carner

assembly and tighten Side yoke flttmg

bolts to speCified torque usmg torque
wrench See Figure 46
RA

RA 43 Removing Side yoke

FIg
Ittlng bolt Tightening torque
3 2 to 4 3 kg m
DISASSEMBLY 23 to 31 ft lb
ASSEMBLY
Disassembly should be done only t9
Assemble m the reverse order of
lubricate ball sphne the
disassembly notmg followmg
I Remove universal Jomt spider pomts
located at the differential Side Refer
I Ahgn the yokes and ensure that
to the secl10n covering propeller shaft steel balls and spacers are fItted m the
2 Remove bolt together with 0 correct sequence
ring plam washer and spring washer
2 Use related snap rings of the same
securing drive shaft yoke to the lhffer thickness and be sure that play IS
en tlal
below 0 02 mm 00008 m Snap
3 Remove snap ring which secures
rings are aVdllable m four different
sleeveyoke plug and remove plug
thickness
Compress drive shaft and remove snap FIg 46
RA Tightening Side yoke
nng securing stopper Figure 41
RA lttlng bolt

@ Umversal Jomt snap ring

4 Disconnect boot and split drive
shaft takmg care not to lose balls and Thickness mm m
Note Be careful not todamage Side
yoke and 011 seal when Instalhng
spacers L

I 49 00587 2 Jom drive shafts With compamon

INSPECTION I 52 00598 flanges of rear axle shaft and tighten

I 00610 connecl1ng bolts to speCIfIed torque
Replace boot O nng of sleeve 155

yoke plug and O ring of SIde yoke If I 58 0 0622 Tightening torque

damaged 5 to 6 kg m 36 to 43 ft lb

RA 15
 Rear Axle Rear Suspension

SERVICE DATA AND SPECIFICATIONS

RIGID AXLE Station Wagon

Axle type Seml floatmg banJo

SuspensIOn type ell1pltc
Semt leaf sprmg

Shock absorber type TelescopIc double actmg

Leaf spnng

DimensIOn

Length x Width x Thickness

Number of leaves mm In 1 200 x 60 x 7 2
6 1
12 1

4724 x 2 36 x 0 28 2
024 1

047 1
Free camber rom m 126 4 96
Laden camber 706
59
mm
kg m lb 320
15 0

Shock absorber

Stroke Max 205 510 8 07

x
length mm m x x 2008

Dampmg force at 0 3 m sec

I0 ft sec

ExpanSIOn kg lb 110 243

41 90
CompresSion kg lb

Rear axle shaft

End play rom m 010 to 0 45 00039 to 0 0177

Thickness of rear axle case end shim mm m 0075 00030

Tlghtemng torque kg m ft Ib

Shock absorber upper end bolt o 9 to 1 2 710 9

Shock absorber lower end nut 3 6 to 4 8 26 to 35

Rear spnng U bolt chp 6 0 to 6 5 43 to 47

Spnng front pm bolt and nu 6 0 to 6 5 43 to 47

shackle nut
Spnng 6 0 to 6 5 43 to 47

Leaf sprmg front bracket fIxmg nut 6 0 to 6 5 43 to 47

Brake diSC back plate fIXmg nut 2 2 to 2 7 16 to 20

Dlfferenltal gear carner to axle case nut 2 0 to 2 5 14 to 18

Propeller shaft flange bolt 24 to 3 3 17 to 24

rubber
Bumper fIXing nut o 9 to 1 2 7 to 9

Dram and fIller plug 4 2 to 6 9 30 to 50

Wheel nut 8 to 9 58 to 65

RA 16
 Rear Axle Rear Suspension

INDEPENDENT REAR SUSPENSION Sedan and Hardtop

Axle type Independent
SuspensIOn type Senu trallmg arms cOIl spring

Shock absorber type TelescopIc double actmg

COIl sprmg and shock absrober

Sedan
Hardtop

R H spring L H spnng R H spring L H spring

COIl spring
load 229 602 215 602 229 602 222 602
Installed height
9 1
02 327 327 902 1 327 8 74 1 327
mm
kg m lb 1
846

Spnng constant g mm
lb m 656 367 4 656 367 4 782 437 9 782 437 9

Shock absorber

Stroke Max length 211

x ffim m x 585 8 31 x 23 03

Dampmg force at 0 3 m sec

i0 ft sec
ExpansIOn kg lb 61 135

Compression kg lb 39 86

Apphed models
Sedan Hardtop
Items

Wheel al1gnment Unladen

Toe m mm m 4to 14 016 to 0 55 2 to 12 0 08 to 0 47

Camber Degree lOS to 2035 20 to lOSS

RA 17
 Rear Axle Rear Suspension

Drive shaft snd Journal

Shdlng resIStance kg lb Less than 20 44

Radial play ofball spline rom In leos than 0 1 0004

Axial play of spider Journal rom In Less than 0 02 0 0008

Journal swmglng torque cm

kg m 1b Less than 10 8 7

Rear axle shaft

Turmng torque kg cm In Ib Less than 4 5 3 9

kg lb 08 1 8 at hub bolt

End play rom In Less than 0 15 0 0059

Tightening torque ft Ib
kg m
Rear wheel bearing lock nut 13 to 17 94 to 123

Brake diSC back plate fIxmg bolt 2 7 to 3 7 20 to 27

Shock absorber upper end nut Securely tIghten under

Side nuts of double nuts
untll they Will no longer
go

Shock absorber lower end nut 1 6 to 2 2 I2 to 16

Drive shaft flange bolt 5 to 6 36 to 43

Drive shaft Side yoke bolt 32t043 23t031

1 6 to 2 2 12 to 16
Bumper rubber foong nut
Rear suspension member mountmg nut 8 to 10 58 to 72

Dlfferenl1al mountmg member nut 7 to 10 51 to 72

to suspenslOn member 7 to 10 51 to 72
Suspension arm
fIXIng pm
Dlff to suspensIOn member 5 to 7 36 to 51
foong bolt
Dlff to dlff mountmg member foong nut 6 to 8 43 to 58

Rear suspension mounting bolt front II to 15 80 to 108

Rear suspension mounting bolt rear 20 to 30 145 to 217

Propeller shaft flange bolt 20t027 14t020

Wheel nut 8 to 9 58 to 65

Dnve shaft to differential bolt 32 t043 23 to 31

RA 18
 Rear Axle Rear Suspension

TROUBLE DIAGNOSES AND CORRECTIONS

When rearaxle and suspensIOn are shaft engme transmission umversal rear axle and rear uspenSlon
suspected of bemg noISY It IS advisable Jomt wheel bearings or suspenSion In case ofotlleak fIrst check to see

to make thorough test to determme NOise wluch orlgmates mother If there IS any damage or restrlcl10n m

whether the nOise ongmates m the places cannot be corrected by adJust breather
tires road surface exhaust propeller ment or
replacement of parts m the

Condition Probable cause Correcl1ve action

NOise Loose wheel nuts Tighten wheel nuts

Loose securing bolts Tighten to the s eclfied torque

Lack of lubrlcatmg 011 or grease Lubricate as requued
Damaged shock absorber Replace
Incorrect adJustment of rear axle shaft end AdJust
play
Damaged or worn wheel bearing Replace
Worn sphne portIOn of rear axle shaft Replace If necessary

Broken leaf spnng R place

Loose Journal connections or so on Tighten to the given torque
Imbalance ofwheel and tue Balance wheel and tlTe

Damage to rubber parts such as leaf spnng Replace parts as requITed

bush suspension affi1 bush shock absorber

mountmg bush
Deformed differential mountmg member Replace
Damaged umversal Jomts AdJust or replace
Worn or damaged rear suspension member Replace suspensIOn member mounting in

mountmg msulator sulators on both Sides

Worn or seized shdmg portion ofdrive shaft Replace drive shaft assembly
ball splme

Breakage of coil spring Replace COIl spring

Instablhty m drIVIng Loose wheel nuts Tighten to the given torque

Damaged rear suspensIOn arm rubber bushes Replace the rubber bushes

Worn shock absorber shock absorber

Replace worn

Faulty wheel ahgnment

I Spring wear Replace Spring
2 out
Worn
sphne porl1on of drive shaft Replace drive shaft assembly
ball sphne

Otlleakage Damaged or restricted au breather Clean or replace au breather

Damaged 011 seal on rear axle shaft Replace the damaged Oil seal

011 leakage from the differential carner Replace as requued

Damaged dust cover of dnve shaft Replace dust cover

Damaged grease seal of rear axle shaft Replace grease seal

RA 19
 Rear Axle Rear Suspension

SPECIAL SERVICE TOOLS

Tool number For Reference

No use page or
Descnptlon
No
tool name Unit mm m
on Figure

KV40101000

This stand IS used together with

the shdmg hammer ST36230000

Rear axle
m
tdkmg rear axle shaft out of
All RA 7
place The stand IS also used to Fig
stand RA 37
hold the removed axle shaft models Fig
rear

assembly with the vise In taking

beanng out of the assembly

SE402

2 ST33300000

I Dnft 0 D 39 mm 1 54 m

ST33300010
Dlff To take Insulator out of place 610

mountmg use dnft K610 RA 25

Fig
msulator 2 Dnft 0 D 52 mm 2 05 In K710 RA 26
Fig
drift ST33300020 GC 11 0
To KC130
push Insulator Into place use
thiS dnft together WIth a press
SE223

3 ST36230000

ThiS hammer used

Shdmg
IS
together All RA 7
with axle stand Fig
hammer
rear
dnvmg
m
models
axle shaft out of place Fig RA 37

SE059

HT72480000

Rear axle shaft

leanng
I puller

All
ThiS puller IS
deSigned so as to
rigid
dnve out rear axle shaft bearing axle
Fig RA 9

models

SE265

RA 20
 Rear Axle Rear Suspension

For Reference
Tool number
use or
No DeSCrlpl10n page
tool name Unit mm m
on
Figure No

5 ST377 10000

610

Rear axle grease ThiS drift IS used to set 011 seal m K610
K710 RA 14
seal drift ItS correct posItion without Page
GCIIO
marnng seal
KCI30

SE065

6 KV4olO0300

W610

V610
B210
Rear axle
This drift S used to mstall 011 710 RA 5
011 seal Page
seal mto rear axle tube end ClIO
drift
VCIIO
C130

SE388

7 ST37840000

W610
V610
B210
Rear axle shaft 710 Page RA 5
ThiS tool IS used to msert rear

gUide ClIO Fig RA 11

axle shaft to rear axle case
VCllO
C130

8 ST37750000

610
ThiS dnft IS used to mstall wheel
Rear axle K610
rear axle shaft or to
shaft
bearing onto
K710
Install bearing Fig RA 38
Inner
bearing In
GC110
bearing to take out of the
drift housmg or
KCI30
hOUSing

SE066

RA 21
 Rear Axle Rear Suspension

For Reference
Tool number
use 0r
DeSCription page
No on No
tool name
Umt mm m Figure

9 ST382 10000

W610
V610
Rear axle B210
This tool IS together with a
used
shaft bearing 710 Fig RA 10
m drlvmg bearing
hydraulic press
collar press CIlO
collar new mto place
stand VCIlO
Cl30

SE226

10 ST38280000

610

Rear K610
K710
suspensIOn ThiS tool IS used to remove rear
RA 36
GC110 Fig
arm bush suspensIOn arm bushmg
KCI30
remover

SE067

II ST38290000

7 870
200

10
610
039 dIa
Rear suspemlOn K610
Thl tool IS used to Imtall or re

member K710
move rear
suspen lOn member Fig RA 24
msulator GCIIO
msulator
replacer KC130

5E068

RA 22
 SECTION BR

BRAKE SYSTEM
DATSUN
MODEL 610 SERIES

BRAKES BR 2

FRONT BRAKE BR 10

REAR BRAKE BR 14

MASTER VAC BR 16

SERVICE DATA AND

BR 21
SPECIFICATIONS

TROUBLE DIAGNOSES AND

BR 23
CORRECTIONS

I NISSAN I SPECIAL SERVICE TOOLS BR 24

NISSAN MOTOR CO LTD

TOKYO JAPAN
 BRAKE SYSTEM

BRAKES

CONTENTS

DESCRIPTION BR 2 Inspection BR 7
ADJUSTMENT BR 2 Assembly BR 7
Bra e pedal BR 2 InstallatloP BR 7
Front disc brake BR 3 BRAKE LINE BR 7
Removal BR 8
Rear brake BR 3 Inspection BR 8
Hand brake BR 3 Installation BR 8
Brake warning light PR 4 NP valve BR 8

Bleeding hydraulic system BR 4

BRAKE PEDAL BR 4

Removal BR 4 HAND BRAKE BR 9

Inspection BR 4 Removal BR 9
Installation BR 4 F ront cab Ie BR 9
MASTER CYLINDER BR 5 BR 1O
Inspection
Removal BR 6 Installation BR 10

ssembly
DIS BR 6

DESCRIPTION ADJUSTMENT
The front wheels use the model Brake pedal
Annette type disc brakes with a rotor
of 245 mm 9 65 m In diameter and
the rear wheels use drum brakes of
228 6 mm Inner9 diameter
m

The NP valve and brake fluid warn

mg lamp
equipped
brake flUid warning
are Installed
with the disc brakes

lamp
on

IS
the car

The

operated
rlL lvf
on the amount of the brake flUid m

the reservolf of the master cyhnder

Tandem master used
I
IS
cyl1nder on

all models The diameter of the master

cyl1nder IS 1905 mm Yo m

The Master Vac with

of 1143 mm 4 U In
a

m
diaphragm
diameter 145
u
571 1 Push rod adjusting screw
tDeluxe model
18 and 1524 mm

2 Pedal stopper
6 m m diameter 1 tSSS
8 model IS
1 3 Brah lamp WItch
mstalled the with diSC l
on car eqUipped 4 CleVIS pIn
Unll mm In
brakes
The hand brake IS of a mechanical SR241

type wluch serves to brake the rear

FIg BR I AdJustmg brake pedal
wheels It IS apphed or released

through the stick type lever In the

driver compartment As these brakes

s

are appl1ed the brake wammg lamp

located on the mstrument panel Will
come on to mdlcate that the hand
brake IS m
appl1ed condition

BR 2
 BRAKE SYSTEM

1 brake 4 Turn out httle at

AdJust lamp sWitch bolt cam a a time

Then lighten lock nut securely until brake drum IS free from shoe

grab
Tightening torque
1 6 to 2 2 kg m

12 to 16 ft 1b Hand brake
2 AdJust pedal stopper until pedal
posllloned 185
I AdJust rear brake shoe to drum
pad IS rom 728 m
clearance before adJusting hand brake
above the floor Then lock pedal
With lock nut 2 Take up all slack m rear cable
stopper
lighten lock nut fumly
T1ghtenmg torque Note Any slightest pull on wheel
o 8 to I I kg m
6 to 8 ft Ib
cyhnder lever cannot be tolerated
when adjusted
3 AdJust the length of push rod
unlll a pedal free play of 1 to 5 mm

0 04 to 0 20 m IS obtamed at the

pedal pad Then lighten lock nut

securely

Tightening torque
I 6 to 2 2 kg m

12 to 16 ft Ib Rear brake
Note 1 Make sure that each wheel cyl
Use care not to aUow the push
Inder lever of parkmg brake IS
rod getting mto master cyhnder properly
returned to ItS ongma1 poslllon
4 After adJustmen t IS made depress 2 Depress brake pedal several limes
and release brake pedal several tImes so that brake shoes are settled down 111 FIg BR 5 Rear cable adjuster

to msure that It travels over Ils entire normal pOSlllons

stroke 145 mm 571 m smoothly 3 Rotate adJustmg cam m the same

Without showmg squeak nOise tWiSt duectlOn as car drives forward unlll 3 front cable so that when
AdJust
mg or mterference shoes drag agamst brake drum hand brake control lever IS pulled by a

force of20 kg 44Ib a lever stroke of

90 to 100 rom 3 54 to 3 94 m IS

obtained Then lock nut se

Front disc brake lighten
curely
Adjustment IS not necessary under

normal condlllon
since pad to rotor

clearance automallcally
IS com

pensated by elasllclty of piston seal

BR243

Fig BR 3 Rear brake shoe

adjustIng earn
Sedan and Hardtop

1 AdJuSIlRg nul 3 Center lever

2 4 Cenler lever braekel
Equaltzer
FIg BR 6 Center lever

4 Ascertam that each wheel cylin

SR244
der lever returned
FIg BR 4 Rear brake shoe
IS to ItS ongmal
adJustmg earn poslllon With hand brake control lever
StatIOn Wagon moved back

J
BR
 BRAKE SYSTEM

and With 2 Remove cotter pin from cleVIS

cover top up reservoir
recommended brake flUid pin and separate pedal from Master
2 clean mud Vac push rod
Thoroughly or dust
from bleeder valve so that outlet hole 3 Remove fulcrum pin and pedal
IS free from any foreign material
Note Turn fulcrum pin clockWise to
Install a bleeder hose to bleeder valve
loosen it
Dlr the other end of hose In a

container filled With brake flUid

3 Depress brake pedal two or three Inspection
tImes and keep pedal fully depressed for the follOWIng
4 With brake pedal fully depressed
Check brake pedal
Items serviCIng as necessary
open bleeder valve to exhaust air
F BR 7 AdJusting hand brake

Notes
5 Replace front and rear cables If s Carefully monitor brake fluid level
adJustment IS no longer effective on st master cylinder during bleeding
their threaded ends operation
b Do not reuse brake flwd drained
After adjustment dunng bleeding operation
c Bleed air in the following sequence
1 Make sure that each wheel cyl
mder lever Rear wheel Front wheel
IS returned to ItS onglnal
d Exercise care not to splash brake
pOSItion as hand brake lever IS moved
fluid on painted portions
back Also check to be sure that Inner

cable IS not slackened exceSSIvely 5 Close bleeder valve qUickly as

2 Make sure that ratchet IS apphed brake down stroke
pedal IS on

posItively as hand brake control lever 6 Allow brake pedal to return

IS pulled back ThiS lever should be
slowly With bleeder screw closed SR249
released and automatically return to 7 1 Brake pedal 4 Fulcrum pm
Repeat bleedmg operations until
2 Pedal bushIng 5 Return sprl11g
Its onglnal posll1on when lever IS no au bubbles show In hose
3 Pedal shaft sleeve
rotated 600 It should not show any
eVIdence ofbind or nOise Notes F BR 9 Brake pedal

s Brake fluid containing air is white

I Check
pedal bushing for wear
and contsins sir bubbles
deformation or damage
Brake warmng light b Brake fluid containing no air runs
2 Check pedal shaft sleeve for wear
out of eder
ble valve In s solid
Bend down hand brake warnIng or roughness
stream free ofair bubbles
lamp switch plate so that brake 3 Check for bent brake pedal
8 Repeat above steps on the re
warning hght comes on when ratchet 4 Check for fatigued return spnng
at hand brake control lever IS moved mamlng brake l1ne to expel au

back one notch and goes out when

returned to
BRAKE PEDAL Installation
ongmal pOSItion
Install brake pedal m the
Bleeding hydraulic Removal reverse

sequence of removal paymg attention

system I Remove pedal return sprIng to the follOWing instructions

Hydrauhc brake system must be I Install fulcrum pin from the

bled whenever any line has been nght Side
dISconnected or au has In some
way
entered tlus system 2 Install cleVIS pin from the nght
When pedal feehng was spongy Side
pedal action It IS an indicatIOn that air 3 Install return sprmg With the
has entered In the system hook toward
longer pedal arm

Bleedmg hydrauhc system deserves 4 Apply a coatmg of recom

much attenl10n as It IS an essenttal mended multipurpose grease the mner
factor for regular brake service oper and outer faces of pedal bushing
ation
BR248 cleVIS pm and hooks of return spnng
1 Clean all dirt around master 1 Fulcrum pm 2 Cotter pm
Charge the clearances m buslungs
cyhnder reservou remove cyl1nder F BR 8 Brake pedal mounting With grease

4
BR
 BRAKE SYSTEM

Grease Pedal stopper lock nu t brake system will leave the front brake

0 8 to 1 I kg m system s ill opera live

6 to 8 ft Ib The brake fluid level gauge IS
available as an standard equipment for
model SSS
The brake warning I1ght BRAKE
located on the mstrument panel comes
on to mdlcate that the brake flUid

MASTER CYLI NDER level m the cyl1nder IS lower than the

B R250 mlmmum allowable level

The master cyhnders are of a
Two master
Frg BR 10 Greasl1lg place types of cylinder are
tandem type which actuates on the
used one for dISC brake and the other
front and rear brake I1nes independent
t
for drum brake They differ from each
5 the brake after
AdJust pedal ly other m the reservOir capacity and
mstallal10n Refer to the mstrucl10ns Brakmg force IS
constantly mam
check valve
under AdJustment tamed when failure occurs m either
the front brake system or the rear
Tightening torque
Fulcrum pm brake system Failure m the front
3 6 to 4 2 kg m brake system Will leave the rear brake
26 to 30 ft Ib sl1ll operal1ve or fallure In the rear

DISC brake

ReserVOir 110 cc 6 71 cu In
capacity

Brake warning hght goes on

when remammg flUid m 60 cc 3 66 cu m

reservoir reaches the

amount of

The reservoir IS eqUipped With a

retenl10n To remove tlus cup

cap
proceed as follows
I Turn retentIOn nng fully m the
REMOVE dlrecl10n
2 Pull out retention cap
To Install It proceed as follows
1 Turn retenl10n nng used m the
retenl10n cap fully m the REMOVE
dlrecl10n
2 the proJeCl1on In retenl10n
Align
ring With the sht m the reservOir tank

and
3
push retenl10n cap m the tank

Turn retentIOn nng fully m the

LNfI II 0

TIGHTEN dlredlOn

BR262

Frg BR 11 Cross sectIOnal view of drum brake master cyll1lder

Made by Tokrco

BR 5
 BRAKE SYSTEM

1 Remove reservolf cap and filter

and dram out brake flUid
2 off stopper
Pry ring usmg a

screwdnver
3 Remove stopper screw and take
out stopper piston assembly
prImary

spring and secondary piston assembly

In the order shown

Note Discard cup If it is removed

from piston assembly and use a new
one

4 Unscrew plug to gam acceSSlblhty

of check valve for dlsassembhng
Note Never detach reservoir tank If
it IS removed for any reason
1 Reservoir cap 5 Pnmary pIston return spnng discard It and Install a new one Do
2 ReservOIr tank 6 Pnmary pIston
return spnng
not remove or disassemble brake
3 Secondary pISton 7 Level gauge
4 Secondary pIston fluid level gauge

Fig BR 12 Cross sectIOnal view of disc brake master cylinder with level gauge
Brake fluid level gauge
Made by Nabco

Removal 3 Remove master cyhnder securing

nuts and withdraw master cyl1nder
On the car not eqUipped wtlh the from engine room sldt
Master Vac
Note Before brake
dISConnecting
I Pull out clevIs pin and separate tubt be sure to use a contamer that
brake pedal from master cyhnder push receivesdraining brake fluid Use of
rod a
rag also suggested to keep
IS

2 DIsconnect brake tube from adjacent parts and place clean at all
master cylinder times

Disassembly

Q
0
CD r
0 0 2

rl @
Cf e
I@
L @
B R255

I Lead wife 5 Magnet

2

n
ReSIstor 6 Float
3 Ftlter Reed

J
7 sWItch
4 Case
c

I j
Fig BR 14 Brake flUid level gauge

i
5 Stopper
6 Pnmary pIston assembly
r
m
r
I 1
19
4 7 Pnmary pIston return sprmg
BR254
8 Secondary pISton assembly
1 Reservolf cap 9 Secondary pIston return spnng Opera lion The float lowers as level of
2 FIller 10 Plug brake flUid becomes low
3 Stopper flng II Check valve As the magnet IS close to the reed
4 Stopper screw 12 ReservOIr
SWitch SWitch contacts are closed
Fig BR 13 Master cylinder to hght the brake warmng hght

BR 6
 BRAKE SYSTEM

and 1 Check cyhnder and piston for

Checking method Raise cap IS faulty
ascertam that brake warning hght eVidence of abnormal wear or damage
Note Do not clean rubber parts with
goes on when float comes mto Replace Iffound defective
mmeral od since thIS will be the
2 Check plston ta cyhnder clear
contact With stopper
sure way of detenorating parts Use ance If It IS more than 0 15 mm

b1 ke fluid
l or alcohol When 0 0059 m either piston
replace or

alcohol is used for cleaning these

Inspection cyhnder
parts do not Immerse them In it 3 Check for weakened fal1gued or
Thoroughly clean all parts m a
longer than 30 seconds After parts
damaged spnngs replaCing as neces
sUitable solvent and check for worn or are cleaned dry with compressed sary
damaged parts Replace any part that air

Return spring Side Side

nary
Prn Secondary

Maker Toklco Nabco Toklco Nabco

Free length mm m 55 2 17 545 2 146 505 I 988

I 8 to 2 2 3 6 to 4 4 2 5 to 3 I
Installed load Do not disassemble
kg lb 40t049 7 9 to 9 7 5 5 to 6 8

357 1 406 345 1 358 33 1 1 303

Length rom In

4 When master disas Brake tube connector

cyhnder IS

sembled be sure to dlstard cups and 1 5 to I 8 kg m

valvesReplace any other

parts which II to 13 ft 1b

show eVldente of deforlnatm wear or

otherWise damdge
5 Oil
Replace damaged reservons

and caps

Assembly
Assemble master cyhnder m the BRAKE LINE
reverse sequence of dlsdssembly

paymg parl1cular attentIOn to the

follov lIlg notes

Note

S Replace gaskets and packlllgs With

new ones

b Apply brake flUid or rubber grease

to shding contact surfaces of parts

to facilitate assembly of master

cyhnder

Installation
Install the
master yhnder m

reverse
sequence of removal
Bleed au out of master cyhnder
after 11 IS mstdlled m ItS origmal
posll1on Brake bne pressure
dlfferenllal warnmg
Tightening torque
Brake ma ler cyhndcr lIght SWItch

attachmg nu t
o 8 to 1 I kg m SRS55

6 to 8 ft Ib Fig BR 15 Broke Ime

BR 7
 BRAKE SYSTEM

Removal 8 mm diameter bolt

quently even In
emergency braking
1 08 to I 1 kg m the brakes operate safely and effec
Removing flare nuts on both ends
6 to 8 ft lb
and chps effects the removal of brake tlvely Problem such as brake I1ne
tube and brake hose leakage In either the front or rear
4 Upon completIOn of Installal10n
2 Rear brake hose can be removed brake system Will not affect the nor
of brake I1nes bleed air out of brake
the tube and then mal operatIOn of the unaffected sys
by dlsconnectlf1g Imes
tem
turnmg round the hose CD
Front brake hose
2

Inspection Install1ng the front brake hose re

qUlfes the followmg special cares

Check brake hnes tubes and hoses
1 the
for any eVidence of crack deten Keep car straight ahead
In

and raise the Master

oration or other damage Replace parts posItion nght and left
cyhnder
which are front wheels from ground by placmg a
faulty front Side
If leakage OCCUI s at and around Jack under crossmember

If 2 Connect brake hose to brake tube

Jomts retighten or necessary
at the bracket on front strut and
replace faulty parts
secure With lock spring
100nng
Installation Tlghtemng torque 2 Plunger BR556
1 7 to 2 0 kg m 3 Back up nng
Pay partIcular a ttentlons to the to 14 ft Ib 4 Y seal 7 Spnng
12
follOWing instructions when mstall1ng 5 LIp seal 8 Cup seal
brake lines 3 Install hose to bracket on the 6 Valve body 9 Spnng relamer
body Side and secure With lock spnng
1 Leave a suffiCient space between Fill BR 18 Cross sectlonal Ulew of
Do not tWiSt hose when mstalhng NP ualue
brake I1nes and adJacent parts so that
brake I1nes are completely unparted
from Vibration durmg dnvmg
Operating test
2 ExerCise care not to warp

II
nor
Conduct follOWIng periodic test
twist brake hoses

Extreme should be taken of

1 every scheduled maintenance period
care it
At the test place the car on dry
brake hoses so that they are kept away
concrete road With no more than a
froJ11 tires and suspension system
driver laden and apply a sudden brake
components
at 50 km h 30 nules h
3 USing Flare Nut Torque Wrench
1 NP valve functions
GG94310000 FA453 normally when
tighten each connector
FIg BR 17 Instalmg front broke hose rear wheels lock SImultaneously With
to the specIfIed torque front wheels or when front wheels

Note When hose lock ahead of rear wheels

replacing slways
2 If the rear Instead of front
renew copper gasket
Do not sllow dirt and water to get wheels has locked In advance It may

into brake hose and tube be attnbutable to malfunctIomng of

NP valve Replace NP valve with a new
4 The standard assembly clearance one as an assembly
IS as follow

Body to hose clearance

BR257 Full bound at maXImum

Fill BR 16 turn of steering handle

Tlllhtenml broke tube
25
ApprOXImately mm 098 In

Tightemng torque
Brake tube and hose connector
1 5 to 18 kg m NP valve
11 to 13 ft Ib
The NP valve completely separates
Connector mounting bolt
the front and rear brake
I1nes allOWing
6 mm diameter bolt them to functIOn Independently and
o 5 to 0 7 kg m preventmg the rear brakes from lock
4 to 5 ft lb before the front brakes Conse
Ing

8
BR
 BRAKE SYSTEM

HAND BRAKE Removal

Control stem
1 Disconnect terminal from hand
brake warning sWitch
2 Remove nuts securing control
bracket m place on dash panel
3 Pull out lock pin and cotter pm
and then remove control stem as

sembly

BA261

I Control stem 6 Control yoke 11 Rear cable

adjuster
2 Control ratchet spnng 7 Lever spnng 12 Cable lock plate
3 Control ratchet 8 Control lever 13 Return spnng

4 Control gUide 9 Front cable 14 Rear cable

5 Control bracket 10 Center lever IS QevlS
l BR 21
Fl Control atem

l BR 20 Hand brake
Fl lInkage

Front cable
I Remove return sprlfig and loosen

adjuster lock nut Separate front cable

from control stem
2 Remove nuts secunng cable to
dash panel and remove cable from the

engme compartment side

Flfl BR 22 Front cable attachIng nut

BR 9
 BRAKE SYSTEM

Rear cable Sedan and Hardtop Inspection

I Check control stem and ratchet
for eVIdence of wear other damages
or

Replace parts which are faulty

2 Replace worn or fatigued springs
3 Check wlfes for eVidence of dls

contmUlty or other detenoratlOn Re

place If necessary
4 Replace faulty warnmg hght andf
or SWitch
5 Check parts at each ton
connec
and If found deformed or
damaged
replace

B R264

1 Return spnng 3 Lock plate

2 Cable adjuster 4 Clem pm
Installation
Fig BR 23 Rear cable

I Disconnect cable at 2 Install hand brake assembly In the

rear
adJuster Remove nut secunng cross rod
Unfasten return spring reverse sequence ofremoval by closely
from center balance lever and detach balance lever
lever observmg the follOWing mstructlOns
from rear axle
housing
2 Remove cable lock from 1 When
plates Install1ng apply a coatmg
rear suspensIOn of grease to shdlng contact surfaces
3 Remove clevIs from Make sure that each shdlng part func
wife attach
Ing to rear wheel cyl1nder tons smootWy Without bmd
2 Upon completion of installatIOn
of hand brake assembly adJust the
Rear cable ton
Sta Wagon entire system as per mstructlOns de
and Van
scnbed under tOpiC ADJUSTMENT
I Unfasten pull spring Remove 3 Make sure that each cable IS not
clevIs pin on the balance lever side and mterfered With by any adJacent parts
on the wheel side and detach cross Do not apply an undue stress to
rod FIg BR 24 cables

FRONT BRAKE

CONTENTS

DISC BRAKE BR 10 Removal and installation BR 12

Description BR 10 Disassembly and assembly BR 12
Pad replacement BR 11 Inspection BR 13

DISC BRAKE

Description
The Annette type dISc brake has With the aid of the yoke the pads sary because pad clearance IS automati
two pistons on one Side of the brake clutch the rotor equally from both cally adJusted due to the elalsy
tCl of
rotor Sides Brake adJustment IS not neces the piston seal

BR 10
 BRAKE SYSTEM

8 Notes
a Do not use common brake grease
b Be careful not to get brake grease
on rotor and pads

2 Loosen au bleeder and push

B
ptston outer piston m
cyhnder
until the end surface of piston B
COlnctdes With the end surface of

retammg ring on boot Then mner pad

can be Installed

@
I BIas spnng 5 PIston B 9 Yoke spnng 13 Pad spnng
Boot 10 Bias nng 14 Pad
2 Yoke 6
7 11 PISton A 15 Pm
3 Bleeder RetaInIng nng

4 PISton seal 8 Chp 12 Cyhnder body BR5B6

SR5SS
FIg BR 30 Exploded vIew of Annette type dISC brake
FIg BR 33 Pushing pISton

Cyhnder SIde Note PISton can be easily pushed m

by hand but if pushed too far

groove of piston will go Inside of

pISton seal as shown in Figure

BR 34 At this pomt if piston IS

l pressured or moved piston seal w1l1

CompressIOn Decompression be damaged If piston has been
Movement exceeding the
Returns In elastIc
elastic dIsplace ment IS of the
pushed m too far remove brake
wIth shppmg on
dISplacement
ed
relea
the seal
seal assembly and d1S8ssemble It Then
surface
BR055 push pISton out m the direcl10n
shown by arrow
FIg BR 31 PISton seal automatic adjusting operatlOlI Assemble it agam refemng to fol

lowmg section
Pad depress brake pedal smce piston
replacement w1l1 Jump out

Removal

To remove the brake pads proceed

as follows

I Jack up front of car and support

NOllndl
It with safety stands Remove front
pOSlllon
I
wheels I
L
2 Remove chps and pull out pms
extracting coil spring and pad springs
BR5S7 SR409
by hand Frg BR 32 RemOVing pad

that FIg BR 34 POSltlO1I for pushing plStOIl

Note Check to ensure pad 4 To mstall brake pads proceed as

springs rebound easily follows

I Clean and apply P B C grease on 3 Push piston A mner piston In

3 Detach pads from caltper as

With pl1ers
yoke gUIde groove of cyltnder body cyl1nder by pulhng yoke as shown m

sembly
sl1dmg contact portIOns of yoke and Figure BR 35 The outer pad can then
Note After removmg pads do not end surface of piston be mstalled

BR 11
 BRAKE SYSTEM

2 Remove brake tube from cal1per 2 follows

Tighterung torques are as

assembly DISC rotor secunng bolts

Notes 3 9 to 5 3 kg m

a When removmg brake tube use 28 to 38 ft Ib

sutlable tube wrench Never u e Cahper secunng bolts

open end or adjustable wrench 7 3 to 9 9 kg m

b 53 to 72 ft Ib
Plug up hole In the cal1per so that
brake flUid does not flow out from Brake tube flare nuts
1 5 to I 8
cyl1nder body kg m
BR5B9 11 to 13 ft lb
3 Loosen bolts
FIg BR 35 Pulling In pIston A securing cyhnder
Note
body to knuckle spindle and remove When mstalllng brake tube use

caliper assembly from strut Pipe Torque Wrench GG94310000

5 After mstalling pads depress
After bleed au
brake pedal several times and pads
3 Installmg pad
from system
wdl settle mto proper poslhon

Note When out

worn pads are re

placed With new ones brake flUid

may overflow reservoir While re Disassembly and
placing pads keep loosening bleeder
to release brake flUid
assembly
Disassembly
6 Install wheels and lower car to

ground FA454 1 Dram brake flUid from top hole

FIg BR 36 DetachIng brake caliper
of cylinder body
assembly 2 Remove au bleeder valve
3 Push both pistons A and B Into
Inspection 4 If necessary remove diSC rotor as
cyl1nder Refer to preVIous section
Because clearance between pad and follows
Pad Replacement
rotor IS adJusted automahcally pad Remove hub cap and cotter pm
I 4 Placeyoke In a VIse as sketched
wear should be checked penodlcally 2 Loosen beanng lock nut and
below and tap the top of yoke hghtly
Clean
remove wheel hub With diSC rotor
pads With a hammer The cyhnder Will then
3 Secure wheel hub m a VISe
Note Do not use rmneral od to clean separate from yoke See Figure BR 38
loosen bolts and remove rotor from
pads wheel hub

SOiled
If pads
greasy
are

or
mcompletely
deteriorated
seated
from
Yl
overheatmg replace them
3 If pads are worn to less than 2 0
mm 079 In m tluckness not m

metal
cludlng backing plate replace
all four pads at the same lime

Note full set

Always replace pads In
BR591
of four using genume parts
FIg BR 37 FIg BR 38 Tapping yoke
4 Check rotor to follow
refernng
mg sechon Inspechon

Installation 5 Remove bias nng from piston A

6 Remove retaining rings and boots
1 Install diSC brake
Removal and assembly and at the end ofboth pIStons A and B
diSC rotor In reverse procedure of 7 Push out pistons duechon
installation removal
m one

8 Remove piston seals

Note When
Removal installing wheel hub to Note Be careful not to
knuckle
damage pISton
spindle refer to Sechon and
I Remove pads Refer to Pad Re FA for Wheel Bearing Adjust
cylinder body
placement mentn 9 Remove spring from
yoke yoke
BR 12
 BRAKE SYSTEM

Notes 9 Install bleeder valve

au on caliper
s When msertlng pIStOns be careful
not to lIIsert too far Refer to Pad

Replacement Inspection
b Install piston A so that the yoke
groove of bias ring of piston A Cahper pad and piston
coincuJes With the yoke groove of
Retaining nng cyl1nder Clean all parts and check for fol
Bool
lOWing
SR412 3 8msnng 4 Install boot and retammg ring

FIg BR 39 Cyhnder body and 5 Install yoke springs on yoke Note Clean rubber pads With alcohol
pISton or brake fluid not with mineral 01

I
Assembly Cyhnder body
1 Check mSlde surface of cyl1nder
1 rubber grease to
Apply cyl1nder for score rust wear
damage and
bore and Install piston seal attached foreign substances If any
2 Insert bias ring Into piston A so surface fault IS detected replace cyl
that the roundish portion of It faces mder body
the bottom of piston A bore See 2 Minor from
damage rust of
40
BR and 41
BR
Figures foreign substances may be el1mlnated

Notes Ou ter face by pol1slung the surface With a fIne

emery cloth If the

damage IS maJor
Be careful not to mistake B
a
piston
for A the cyhnder assembly must be re
piston
b Pistons A snd B are dlstmguished placed
from each other dent at the 2 Check pISton for score rust wear
by a

Inner bottom of pISton A damage and attached foreign sub

stances replace If any fault IS detect

y@@ ed

Note Do not use emery cloth on the

pISton surface because It IS plated

Inner face
BR416 3 Check the shdlng portions of
1 BillS spnng
cv 2 yoke for wear and deformatIOn re
Yoke spnng
place If necessary
Fig 42
BR Yoke WIth yoke sprmg

CD BR414 and bIas sprmg Note As a rule replace pISton seals

1 Roundish portIOn 3 Chamfer dust covers and 8S nng
b each d1S8S
2 PISton A 4 Yoke 6 Install biaS spnng to yoke
7 sembIy
Frg BR 40 Assembly of bIas rmg Apply P B C grease to the yoke
to pISton A shdlng part of cyhnder Then reposI
tion the bias ring so that the groove of Piston seal
bias ring comcldes With yoke
If brake flUid leakage IS found only
8
Leavmg yoke springs mserted on piston seal or
pad does not return
I1ghtly mto cyhnder groove assemble
cylmder body and yoke by tappmg properly e
replapISton seal wllh a

new one m the manner deSCribed In

yoke hghtly See Figure 43
BR
preVIous section DISassembly and As
futon A PlslIon B sembly Keep component parts clean
BR415 wlule dlsassembhng

Frg BR 41 P stons A and B

Rotor
Note Oms
ring must be mstalled on
After diSC brake
assembly has been
the oflgmal position
removed Inspect rotor as follows
3 Apply rubber grease hghtly to the
BR417 Check rotor for score and dam
sl1dlng portions of pistons and msert
Frg BR 43 rlssemblmg yoke and ages If excessive maclune recondl
Into cylinder
cylmder tlOmng will be requued
BR 13
 BRAKE SYSTEM

2 Measure run out of either rotor 3 Measure thickness of rotor uSing

face a micrometer
4 If tillckness of rotor
If It exceeds the hmlted value IS beyond
hmlt 84 0331
machme recondltlonmg or
replace wear mm m replace
rotor
ment reqUired
IS

Llnut of recondlhomng m thickness

IS 84 mm 0 331 In Standard rotor
thickness IS 10 mm 0 39 m

out
Run of rotor should be less
than 012 mm 00047 m at total SR571

indicator readmg FIg BR 44 MeasUring run out of rotor

REAR BRAKE

CONTENTS

DESCRPIPTION BR 14 Brake assembly BR 15

REMOVAL BR 14 Wheel cylinder BR 16

Disassembly of wheel cylinder BR 15 ASSEMBLY AND INSTAllATION BR 16

INSPECTION BR 15 Wheel cylinder BR 16

Brake drum BR 15 Brake drum BR 16

DEseRI PTION REMOVAL

I Jack up the rear of car and
The rear brake IS of a
leadmg be adJusted by turning the end of the
Brake shoe clearance remove tire and brake drum If brake
trallmg type can
adJuster wedge
drum IS hard to remove use bolts 8

mm diameter 1 25 mm pitch to dnve

It out
2 Turn pm 900 and remove antl

4J rattle spnng

3
shoes
Remove return springs and brake

BR2S0
BR279
1 Brake shoe 3 Return sprmg
adjuster
2 Brake shoe assembly 4 Anll raltle pm
1 Brake dISC 8 Return spong cy nder sIde
2 Return spnng adjuster SIde 9 Bleeder FIff BR 46 Remove shoe assembly
3 Brake shoe adjuster 10 Lock plate A
4 Brake shoe assembly fore 11 Lock plate B 4 Remove bolts
5 Anll ratlle pm 12 Lock plate C and D securing adJuster
and detach adJuster
6 Lever I3 Dust cover
5 Disconnect brake tube
7 Rear wheel cy nder 14 Brake shoe assembly after
6 Pull out cleVIS pm to separate
FIg BR 45 Rear brake hand brake cable and lever

BR 14
 BRAKE SYSTEM

7 Remove dust cover adJusl1ng faces of cyhnder and piston and 2 The allowable maximum out

shims and lock plates wheel cyhnder pISton cup of round of brake drum IS 002 mm

then be ved 00008 Re condltlon

can remc easlly m or
replace
8 Remove and remstall the brake brake drum If speCIfIed ltmlt IS

disc as outhned under REAR exceeded

AXLE 3 Measure for brake drum
o
tapered
If speCified hmlt of 0 02 mm 0 0008
Co m IS exceeded as measured at a

where
T@ 6
posll1on
rom i57 In IS
the distance

kept away from mlet

of 40

re condltIon or
replace brake drum
@ @
4 Contact surface With which
I1mngs come Into contact should be
fimshed to such an extent that It IS

No 120
ground by 150 a to

sandpaper
5 Usmg a drum racer fimsh brake
1 Brake tube 1 Snap rmg drum by machmlng If It shows any
4 Lever
2 Dust cover
2 Hand brake cable 5 Dust cover sIgn of score marks partIal or
3 PIston
3 CleVIS pm
4 PIston cup
stepped wear on ItS contact surface
Fllf BR 47 RemolJe wheel cylmder 5 Cylmder Note After brake drum IS com
6 Breeder
7 Hand brake lever
pletely condll1oned
re or replaced
Disassembly of wheel 8 Lock plates check drum and shoes for proper
BR2S2 9 Dust contact pattern
cylinder cover

FIg BR 48 Wheel cylmder

1 The wheel cyl1nder can be disas
sembled m Its mounted conditIon Do Brake assembly
not It unless
remove
replacement of which crack
I Replace hmngs are

the entire master assembly IS neces INSPECTION ed worn or OII stamed

sary
2 Replace hmngs If their thick
2 To disassemble remove snap Brake drum
nesses are worn down to less than I 5
nng dust cover piston and piston
1
m the order enumerated
Replace brake drum whose dia rom 0 059 In

cup
meter IS
beyond the hmlt of I 4 mm 3 Replace shoe return springs
0 055 With the which broken
m respect to are fal1gued or

Note ExercISe care not to give standard mner diameter of 228 6 mm 4 Replace fatIgued antI rattle

scratches to sliding contact sur 9 In springs damaged pms and or retamers

Standard dimensions of shoe springs

Installed
Free Dla of spring o D ofcoli
Item
length No of COils load
mm m mm m mm m
length
mm
kg lb
m

7
1315 t08
Cyhnder Side 1207 4 75 2 0 08 12 047 36 5177 15 to
18

5 to
122 13
4
AdJuster Side 1204 474 2 0 08 10 0 39 325 165 4 819
29 8 to 36 4

7t08
149
AntI rattle 2 008 18 071
20 5 0 807 5 15
0587 to

18

BR 15
 BRAKE SYSTEM

Wheel cylinder
Replace any cyhnder or piston Made by TOKIKO Made by NABCO
which IS scratched scored or worn on

ItSshdmg contact surface A

A
l
2 Replace worn parts If plston to
B
cyhnder clearance IS beyond 0 IS mm
00059 m B

3 Replace piston cup which IS c J

worn or damaged
i1
4 Replace If contactmg face of C J D
Fig BR 50 Pomts requITIng greaatl
cyl1nder and shoe IS worn locally or

BR2S3
m
step
dust
5 Replace damaged cover
Fig BR 49 Lock plate 3 Measurmg wheel cyhnder shdlng
fatIgued piston Spring or damaged resistance usmg a
sprmg scale
threaded parts Standard shdmg resistance
6 Replace tube connector which IS 2 to 7 kg
worn on ItS threaded porl1on 4 to IS lb

AdJuster mountmg nut

ASSEMBLY AND Brake drum tightening torque
I 4 to 1 8 kg m
1 To Install the sequence
INSTAllATION reverse
10 to 13 ft Ib
of removal Note the follOWing m
Wheel cylinder structlons

I To 2 Apply a coatmg of brake grease

assemble reverse the
to the parts mdlcated In Figure
equence of disassembly
BR 50 wheel
2 Apply rubber grease to rubber cyhnder to dlsc shdlng
surfaces cyhnder lever piVOt adJuster
parts to facIlitate the assembly oper
wedge surface and periphery of
al10n
3 To mstall wheel tappet
cyhnder msert
hand brake lever mto diSC and fit Note Apply a thin coating of grease
wheel cyhnder mto
posll1on Then to shoe to
dlSc sliding surfaces 6 BR2S4

drive m the A B C and D

parts m
places exerclSlng care not to wet
Fig BR 51 Me08uTlng wheel cylmder
the order shown usmg a hammer limng With grease SlIdIng resIstance

MASTER VAC

CONTENTS

DESCRIPTION BR 16 F ront shell seal assemb Iy BR 20

I nspectlng vacuum pressure BR 17 INSPECTION BR 20
I nspectmg check valve BR 18 ASSEMBLY AND ADJUSTMENT BR 20

Operation test BR 18 Rear shell seal assembly BR 20

REMOVAL BR 18 Diaphragm plate assembly BR 20
DISASSEMBl Y BR 19 Front shell seal assembly BR 20
Rear shell seal assembly BR 19 Fmal assembly BR 20

Diaphragm plate assembly BR 19 INSTAllATION BR 21

DESCRIPTION
A vacuum
suspended Master Vac IS to retard stop the the engme mtake
or car pressure produced In

mstalled belund the master

cyhnder The Master Vac has a spring loaded manifold
As the brake pedal IS depressed flUid of 1143 M45 type
dlsphragm mm The tandem master cyl1nder IS
IS forced under Iugh 4 and 1524 M60 type 6 m
pressure through In mm
capable of
producmg Iugh pressure
the brake pipes to the wheel cyl1nders m diameter It operates on
negative even If the Master Vac IS faulty

BR 16
 BRAKE SYSTEM

I Plate and seal

2 Push rod
3 DIaphragm
4 Rear shell
5 DIaphragm plate
6 Seal
7 Vacuum valve
8 Poppet assembly
9 Valve body guard
10 Au SIlencer filter
11 Valve operatlOg rod
12 Valve return spring
13 Poppet return spring
14 Exhaust valve
15 Valve plunger
16 Reacllon dISC
BR26S 17 DIaphragm return Spflng
18 Front shell

FIg BR 52 Sectional view of Master Vac

Inspecting vacuum

pressure
1 Connect a vacuum gauge In the Master Vac as shown m Figure 2 Start engme and mcrease engme
Ime between check valve and BR53
speed Stop engme when vacuum

gauge Indicates 500 romHg 1969

mHg

Air tight test

I Fifteen seconds after tS

engme

stopped observe the rate of drop In

air pressure registered by vacuum

gauge If a pressure drop of 25

romHg 098 InHg IS exceeded refer
to the follOWing chart to determine
the cause offailure

BR169

1 Cheekvalve
2 Vacuum gauge

FIg BR 53 AIrtIght test set up

Probable cause Correcl1ve acl10n

1 Au leakage at cleck valve Replace check valve

2 Air leakage at push rod seal Replace seal
3 Au leakage between valve body and Repair or replace faulty
seal
partes
4 Au leakage at valve plunger seat Repair or replace seat
5 Damaged piping or JOints Repair or replace

BR 17
 BRAKE SYSTEM

If Note Determine to whether a mal

2 Fifteen seconds after engme IS a
pressure drop of 25 mmHg 098 as

stopped and brakefully applied InHg IS exceeded refer to the follow function occurs either in Master
the rate of drop In au Vac check valve
observe mg chart to determme the cause of or
Always inspect
pressure registered by vacuum gauge fatlure check valve fl1
St

100 1 420

Probable cause Corrective actIon 90 1 280

80 1 120
1 Air at check valve Replace check valve
leakage 70 1 000
2 Damaged diaphragm Replace
60 850
ME
3 Reaction disc dropped off Remstall and check push 50 710
rod for proper turn i
40 570
ii
4 Au leakage at poppet assembly seat Replace faulty partes
e 30 430
and valve body
l 20 280

10 140

Note When 01 any part

replacement l o 10 20 30 40 50 60
is required be sure to renew
22 4466 88 110 132
Master Vac as an assembly
Pedal operatIng force kg Ib
BR2S5

Fig BR 56 Performance curoe of

Master Vac M45

Inspecting check valve P

TT
1 Remove chp and disconnect
Mamfold de

1
Master Vac de

SR2B9
e m

H
GY
t
Spnng 1
4 I
E
hoses at connectIOns The check v lve 2 Valve k u l
m

be removed
can now
fql I
Fig BR 55 Cross sectIOnal vIew J
J d
of check valve
l
I
Q m IJI P
I
Ip
Operation test c
I
I
XI 40 lllI J l120
1a 140 110 110 2lXl no MO
1 Connect an 011 pressure gauge m 1m 1 lll I 2I1Uall
1tlI lCl1l3l5311 1lI 1 1J4
I1

l o Pedal operatmg force kg Ib

brake line at connection on master BR609

cyhnder Fig BR 57 Performance curoe of

Install Master Vac M60
2 a sprmg scale on brake

pedal
3 Start engme and mcrease engme
REMOVAL
speed until a vacuum pressure of 500
Refernng to Figure BR 58 remove
romHg 1969 mHg IS regIStered on

parts In numerical order enumerated

Fig BR 54 LocatIOn of check valve vacuum pressure gauge With a vacuum
Install these parts the reverse
of 500 mmHg 1969 mHg In
pressure
held measure an 011 pressure With sequence of removal

respect to each pedal operating force 6

between 011
2 Usmg a Master Vac tester apply RelatlOnslup pressure
of 500 and pedal operatmg force IS illustrat
a vacuum pressure mmHg
1969 to the port of check ed BR 56 for M45 and In
InHg m Figure
valve on the Master Vac Side If a
Figure BR 57 for M60 If test results
0 39 InHg
pressure drop of 10 mmHg specified Figure BR 56
In or
are not as

IS exceeded In 15 seconds replace BR 57 check Master Vac for condi

check valve With a new one tIOn m a manner as deSCribed under

3 When pressure IS applied to the Inspection before removal of thIs

BR175
Master Vac Side of check valve and umt

Also check brake I1ne for eVidence Fig BR 58 Removal method of

valve does not open replace check
Vac
Mastel
valve With a new one of flUid leakage

BR 18
 BRAKE SYSTEM

Note After Master Vac IS properly 4 Usmg special tool Master Vac 2 Usmg a screwdriver as shown
Installed on car be sure to conduct Wrench ST08080000 remove rear evenly pry au silencer retamer until It
an air
tight test and operation test assembly and disassemble
shell seal IS detached from diaphragm plate
descnbed previously m this Section diaphragm plate assembly front shell assembly
assembly diaphragm spnng and push Note Never use a hammer to remove
rod assembly
DISASSEMBLY thiS retamer since this will be the
sure way of damaging It
When dlSassemblmg Master Vac
observe the following Instrucllons
a
Thoroughly clean mud or dust from
Master Vac
b Extreme care should be taken not
to allow dut dust water or any
other foreign matter to get Into any

component parts 8 R076

Be sure to select a clean place
before disassembly FIg BR 60 Removrng rear shell
or
dssembly
c Mark matmg Jomts so that they
may be mstalled exactly m theu Rear shell seal
Fig BR 63 RemOVing air SIlencer
orlgmal poslllons assembly re tamer
d Keep all disassembled parts ar off retamer
Pry With use of a

ranged properly so that they may screwdnver as shown and detach

3 Pull out valve plunger stop key
readlly be assembled at any lime beanng and seal
and Withdraw silencer and plunger
e Clean rubber parts and synthe
lIc resin parts m alcohol Note Do not dISassemble seal as assembly
After all disassembled sembly urness absolutely necessary
f parts are Note To remove valve plunger stop
Whenever this IS to be removed
cleaned m an
approved solvent as follows
key properly proceed
use care not to It
place on a clean work bench Use damage With key hole facing down lightly
care not to allow dut and dust
push valve operating rod SImul
to come Into contact With these
taneously w1nle applying vibration
parts to it

1 Install spacer on rear shell spacer

Place Master Vac
temporarlly m a

vISe Use of soft Jaws In

suggested
2 Remove clevIS and lock nut De
tach valve body guard BR078

FIif BR 61 RemOVing retamer

Diaphragm plate
assembly
1 Place diaphragm plate assembly
on a clean work bench Detach
FIif BR 64 Pullmg out stop key
diaphragm from groove m plate as

shown
BR075

1 CleVIS 3 Valve body

2 Lock nul guard
FIif BR 59 Remove rear shell

3 ldenllfy front shell and rear shell

clearly so that they may be reassem
bled m theu orlgmal posItions from
whIch they were Withdrawn Bolts to

be attached on dashboard are not the BR079

FIif BR 65 RemOVing valve operot ng
same In
pitch FIif BR 62 Separotrng dwphragm rod assembly

SR 19
 BRAKE SYSTEM

4 Withdraw reactIOn disc of seal and mstall that seal m rear 2 Install plunger assembly and
shell With the use of special tool SIlencer In diaphragm plate and
Master Vac 011 Seal Retainer Drift I1ghtly push plunger stop key m
ST08060000 place

Note Diaphragm plate is made of

bakel1te Exercise care m
InStalhng
plunger assembly not to damage
dJaphragm plate

BR2S6

FIg BR 66 RemovIng reactIOn dISc

Front shell seal

assembly Frg BR 68 InstallIng 011 seal

1 Detach from front shell

flange
Note Referring to
Figure 69
BR
assembly
IDStalJ seal in
place by properly
sligning the pawl of special tool SR083

wIth seal hole Frg BR 71 Insertllrg stop key

Adjustment IS
correct when specified length at

A IS obtamed

Lenght A 3 Before mstalhng diaphragm mto

6 7 to 70 mm
pOSItIon apply a thm coatmg of
0 264 to 0 276 In mica power to It except outer dia
meter and seatmg portIOn With which

shell comes mto contact

4 Before mstalhng reachon dISC m

place on diaphragm plate apply a

BR2S7
thm coatIng of Master Vac grease
FIg BR 67 RemovIng flange
Front shell seal

2 Withdraw front seal

assembly
assembly Before mstalhng front shell seal
INSPECTION assembly apply a coatmg of Master
Vac grease to the mner wall of seal
1 Check poppet assembly for con and front shell With whl h seal comes
dlhon If It shows eVidence of wear mto contact
or damage replace It and valve Frg BR 69 Length at A

operaung rod assembly

2
Final assembly
Check other component parts for
Diaphragm plate I Apply a thm coatmg of Master
conditIon If any part shows eVidence
of wear or damage replace It With a
assembly Vac grease to the outer edges of
1 thm coatmg of grease to With which and front
new one Apply a diaphragm rear

the shdmg contact portIon on the shells come mto contact before

ASSEMBLY AND periphery of plunger assembly mstalhng diaphragm poslhon m

2 Before mstalhng push rod as

ADJUSTMENT
sembly m place apply a coahng of
Assemble m the reverse sequence Master Vac grease to the shdmg
of disassembly
contact surface of diaphragm plate
3 Ahgn marks SCribed m the rear
Rear shell seal 111 1

shell and front shell Carefully turn

assembly the speCial tool Master Vac Wrench
SR1S6
I Apply a coatmg of Master Vac ST08080000 clockwise until It

grease to the seahng surface and hp Frg BR 70 ReqUIrIng grease place reaches notch m shell retainer

BR 20
 BRAKE SYSTEM

INSTAllATION
Install m the reverse sequence of
removal

Note After Master Vac is properly

Instslled in car conduct an air tIght
snd operatIonal tests as previously
descrtbed
SR290

FW BR 73 Length at B
FIg BR 72 TIghtening rear shell

4 After the
assembly adJust length
of push rod to less than the specIfIed
value mdlcated below Length adJust
ment of push rod IS made at the lip
of push rod
Length B
9 75 to 1000 rom BR2BS

03839 to 0 1937 111 FW BR 74 Ad ushng push rod length

SERVICE DATA AND SPECIFICATIONS

Brake type

Front Model Annette 15AL

14 dISC brake

Rear Leadmg tradmg drum brake

Hand brake Mechamcally operated on
rear wheels

Brake pedal
Free mm In 185 728
height
Full stroke of pedal head mm In 145 5 71

Master cyhnder
19 05 Yo
Inner diameter rom m

Allowable maximum clearance

between cyhnder and piston mm m o 15 0 0059 max

Wheel cyhnder
Inner diameter

Front diSC mm m 51 1 2012

Rear mm In 2222 U

BR 21
 BRAKE SYSTEM

Allowable maximum clearance between

cylmder and piston mm In o 15 0 0059 max

Rear wheel cyhnder shdlng resistance kg Ib 2 to 7 4 to 15

Brake rotor and drum

Rotor diSC outer dlalneter mm m 245 9 65

DlUm brake mner diameter rear mm In 228 6 9

Rotor diSC runout mm m 012 00047 max

r
Drum mSlde out ofround mm m o02 00008 max

Repau I1mlt of rotor m tillckness mm m 84 0 331

RepaIr hmlt ofdrum m diameter

rear mm m 230 9 06

Lmmg
Pad dls Width tlucklless
x x
length rom m 41 2 x 10 x 61 4
I 622 x 0 39 x 2417

Lmmg rear nlln m 40x45x2195

Wid th x tillckness x
length 1 57 x 0 177 x 8 642

Hand brake normal stroke mm In 90 to 100 354 to 3 94

Tightenlllg torque
Brake master cyhnder attaclung nut kg m ft Ib 08 to 1 I 6 to 8

Brake tube connectIOn kg m ft Ib 1 5 to 1 8 11 to 13

Brake hose connecl1on ft Ib 17t020 12toI4

kg m

ft Io o 7 to 0 9 5 to 7
Au bleedel valve kg m
FulclUm pm of brake pedal kg m ft Ib 3 6 to 4 2 26 to 30

Pedal stopper lock nut kg Ill ft Ib 08to11 6t08

Connector mountmg bolt

6 diameter bolt ft Ib o 5 to 0 7 4 to 5
mm
kg m
8 mm diameter bolt kg m ft Ib o 8 to I I 6 to 8

Wheel cyhnder mountmg bolts

Small kg m ft Ib o 5 to 0 7 4 to 5

kg m ft Ib 1 5 to 1 8 11 to 13
Large
Cahper fIxmg bolt kg Ill ft Ib 73 to 9 9 53 to 72

Rotor fIxing bolt kg m ft Ib 3 9 to 5 3 28 to 38

NP va1ve mountmg bolt kg m ft Ib o 3 to 0 4 2 to 3

BR 22
 BRAKE SYSTEM

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause CorreCl1ve acl10n

Spongy pedal Au In brake I1nes Bleed thoroughly

Swollen hose due to detenoral1on or use of Replace hose and bleed system
poor qual1ty hose

Use of brake flUid of which

a
bodmg pOint Change With specified brake fluid and bleed
IS too low system
Reservoir fIller cap vent hole clogged Clean and bleed system
ThIS promotes a vacuum In master cyl
Inder that sucks m au through rear seal

Pedal Yields under Deteriorated check valve Replace check valve and bleed system
slight pressure Ex ternal leaks Check master cyl1nder piping and wheel
cyhnder for leaks and repair

Leakage on master cyhnder Overhaul master cyhnder

ExceSSive pedal Au In system Bleed system

travel
Shoes out of adJustment AdJust shoe to drum clearance

InsuffIcient flUid m master cylinder Fill up With brake flUid and bleed
specIfIed
system
Thermal expansIOn of drums because of Allow drums to cool off
exceSSive overheatmg Check brake shoe hnlngs and drums
Replace damaged parts

All brakes drag InsuffIcient shoe to drum clearance AdJust clearance

Weak shoe return springs

Replace
Brake shoe return no free travel AdJust pedal height
Seized master cyl1nder piston Disassemble master cyhnder and replace
piston Bleed system

One brake drags Loose or

damaged wheel bearings AdJust or
replace as
required
Weak broken or unhooked brake shoe Replace
return spnngs

InsuffIcient clearance between brake shoe Adjust brakes

and drum

Unbalanced brdkes Grease or 011 on hmngs Clean brake mechamsm check cause of
trouble Replace hmngs
Seized piston In wheel cyhnder Service wheel cyhnder and bleed system

Improper tire Inflal1on Inflate to correct pressure

Loose wheel bearings AdJust

Faulty front suspension Check and adJust all front suspensIOn parts

BR 23
 BRAKE SYSTEM

ConditIOn Probable cause Correcllve action

ExcessIVe pedal Grease mud or water on brake shoe Remove drums and clean and dry hnlngs or

pressure requued I1nmgs rep lace

poor brakes Full of contacting drums Replace shoes
area l1n1ngs not

Scored brake drums Reface drums and mstall new hnmgs

Brake chatter Dust on drums or OII stamed hnIngs Remove and clean drums

squeak or
squeal Weak shoe return springs Check and If necessary replace spnngs

Drum out ofround Turn drums on lathe

Worn hnmgs Replace

SPECIAL SERVICE TOOLS

Tool number For Reference

No DeSCription use page or

tool name Unit mm m on Figure No

GG943 10000

ThiS tool IS used to and

lighten
Brake pipe unllghten brake tube flared nut All
Fig BR 16
A bUllt torque hnntmg wrench IS models
torque wrench m

prOVided to assure torque accuracy

5E227

610
2 ST08080000
W610
V610

ThiS tool IS used to remove rear 510

Master Vac 60
BR
shell after ahgnmg rear shell stud 230 Fig
wrench BR 72
bolt With the opening m thiS tool S30 Fig
C30
CIO
GCIO

5E073

3 ST08060000 610
W610
ThiS tool IS used when rear shell
V610
Master Vac seal driven mto
IS poslllon 510
011 seal Note Make sure that thiS tool is Fig BR 68
230
until rear gUide
retamer drift pushed In
S30
of this tool touches rear
C30
shell
CIO
GCIO
sEll 5

BR 24
 SECTION WT

WHEEL AN D TI RE
DATSUN
MODEL 610 SERIES

WHEEL AND TIRE WI 2

TROUBLE DIAGNOSES AND WI 6

CORRECTIONS
INI NI

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Wheel and Tire

WHEEL AND TIRE

CONTENTS

DESCRIPTION WT2 WEAR 4

WT
TIRE USAGE WT2 RADIAL TIRE 4
WT
RECOMMENDED INFLATION PRESSURE WT 3 TIRE ROTATION 4
WT
MAINTENANCE AND SERVICE WT3 INSPECTION WT5
TIRE INFLATION WT3 WHEEL BALANCE WT 5
TIRE REPAIR WT3 WHEEL AND TIRE WT 5

DESCRIPTION
TIRE USAGE

Car model Tire size Wheel size

180B Sedan 645S 4PR

13
4 Jx13 1
180B StatIOn 165SR 13
Wagon
180B 165SR 14 4 J 14
Hardtop x

Remarks 1 Offset 30 rom 1 18 m

WT2
 Wheel and Tire

IS
possible to detect sharp material m
RECOMMENDED INFLATION PRESSURE
the tredd Also the above check aVOids

abnormal wear wluch mVltes serious

Umt pSI problem If tires Indtcate abnormal or

uneven wear the cause of problem

Car speed should be detected and el1mtnated
After mflatmg lIres leakage m valve
Less than More than
should be checked Without valve caps
Tire size 70 MPH 70 MPH
leakage Will occur due to dirt and
II 5 km h lIS km h
watcr resultmg m undennflallon Ac
Front Rear Front Rear
cordmgly whenever tire pressure IS
checked be sure to lighten valve caps
Normal load 24 28 28 32 firmly by hand
645S 13
4PR 28 32 32
MaXimum load 28

Normal load 28 28 28 28
165SR I3
TIRE REPAIR
165SR 14 32 32 32 32
MaXimum load
Tubeless tire

In order to
Inspect a leak apply
Notes a The tire mflallon pressure should be measured when the lire IS cold soapy solutIOn to tire or ubmerge tire
b The tubes deSigned for radIal tire should be used exclusively and wheel m the water after
mflatmg
tire to
specified pressure SpeCial m

spectlon for leaks should be carned

out around the valve wheel rim and
along the tread ExerCise care to bead
and nm where
leakage occurs
Wipe
out water from area which leaks air

bubbles and then mark the With

place
chalk

After rcmovlng the matenals which

caused puncture seal the pomt When

repaIrIng the puncture use the lire

repair kIts whIch are furnished from

lire dealers the mstructlOns

followmg
proVIded With the kits In case that a

puncture becomes large any or there IS

other the tire fabnc repaIr

damage on

must be cdrned out by authonzed lire

dealers

Tubed tire

In order to mspect a leak apply

soapy solullon to lire tube or sub

merge tlfe tube m the water after

mflatmg lire tube SpeCIal mspectlOn

for leaks should be carned out around
the valve Wipe out water from area

where air bubbles eXIst and then mark

the place With chalk
After removing the materials which
caused puncture seal the pomt When
MAINTENANCE AND comfort ThIS also reduces drlvmg repair kIts furnished from lire dealers
sound to
SERVICE
a nUnlmum resultmg m followmg the mstruclIons proVIded
tire life that IS overlnflallun or
longer WIth the kIts When a puncture he
undennfldtlOn promotes wear at cen comes large or there IS any other
TIRE INFLATION
ter tread
or shoulder of tire the tire fabnc
damage on repair must
Correct tire pressure IS very un If all tires are
Inspected frequently be carned out authOrized lire
by an

portant to ease of and ndlng and main tamed correct

steering lire pressure It dealer

WT3
 Wheel and Tire

Wheel repair Shoulder TIRE ROTATION

wheel for bend The wear may be caused fues wedl unevenly and be lIl1e
Inspect rim
flange a
by under
or dent If any of the above deteriora mflatlOn mcorred wheel amber or unbdlan ed acwrdmg to runlllllg dls

tion IS deteded repalf should be made contmuous high speed driVing on t mce Unevell tire wed often resuhs
The tue wlllch dltnbuted to
to secure complete seahng flange curves In general the former two III nOise IS rear

should be cleaned by a wue brush causes are common Underlnflatlon axle gedrs bearlllg etc Meanwhile the
when rust IS found on the flange wear occurs on both Sides of treads front tires tend to
unevenly
wed

Furthermore If and the other hand camber he of

excessive plttmg oc on causes dllse
Inlpropeily Ihgned front
curs 011 the rim ehmmate It with a wear
only on one Side of treads For wheel
file cornering tread wear the driver must Accordmgly to equahze tIre wear

operate car
slowmg down on curves It IS necessary to rotate tlfes periodi
cally as recommended In the PenodIc
WEAR
Maintenance See Figure WT 2

Misalignment
When the front wheels Bias and Bias belted tires
ahgn m

ex esslve toe m or toe out condition All the lIres the spare
I Includmg
tlfes scrape the tread rubber off The Uneven
tue are of the same type
wear of tread appears feathered edge
Uneven wear IS caused by mcorrect
camber Right front Right rear
or cdster malfunctIOning sus
Center
penSIOn unbalan ed wheel out of ll
c
ThiS caused by overlnflatlon round brake drum other mechani
@
wear IS or
Spare
of the tire The mflatIon pressure must cal condlllons To repair thiS abnormal

be kept at the specified value wear correct the above faulty parts C I
Left fronl Left rear WH150

2 The spare tue has a different

brand from 4 lues on the car

Right front Rlght rear

I
I ll
C

@
D Ii
ICI m
I X Spare

c
Toe m or toe ut wear Ovennf11tlOn wear

Left front Left rear WH151

The spare lire should be used In

l
an emergency only

I
Radial ply tires

11m
I I II

1IlW
111
I
tue are
All the tues
of the same type
Includmg the spare

II
1
11111 Right front Right rear
11110

WT004
Undennflal10n wear Uneven wear

FIJ1 WT 1 A bnormal tire wear

rv Spare

J
c l
C
Left front Left rear

RADIAL TIRE mixed With ordl

nry tlfes smce 2 The spare tue has a dIfferent
Tires of radl3l ply oll tructlon will theIr charactemllcs differ from brand from 4 tIres on the car
revolve with less camber thrust force those of ordmary tIres
Right front RJgh t rear
b The brand radial
and with greater cornering power on ame ply lIres
ll
c
turns ThiS tends to cause lo al or should be mstalled on all wheels

rapid
toe m
wear on

ExerCise
the treads with

special care for front

excessive
c The tubes

hould be
deSIgned for radial
used e l
c1uMvely
trre

lC
l
@ Spare

wheel d Snow chain should not be fItted

ahgnment dunng the hfe of Left front Left rear
WH152
l1res bec llIse It damages Side wall
Regardless of tlIe brand the spare tlIe
should be used In an emergency only
Notes

a Rad 11 ply lIres hould not be WT 2 TIre rotation

FIf
4
WT
 Wheel and Tire

The tires provided with tread I Check wheel nm espeCially rIm

are
INSPECTION
wear mdlcator
at SIX places around flange and bead seat for rust dlStor
tue clfcumference mdlcatmg 1 6 mm WHEEL BALANCE lion cracks or other faults wluch
y m tread depth When the tues nught cause air leaks FunctIOn of
The wheel and lire
wear and then the marks appear re assembly should tubeless tue depends on a
good seal

place them with new ones See figure be kept balanced stalically and dynam between tire bead and wheel rIm

WT3 Ically Thoroughly remove rust dust OXI

Proper tire balance IS necessary dized rubber or sand from wheel rIm
when drlvmg the car at high speeds wllh WIre brush emery cloth or paper

Consequently the wheel and tire as Use dial gauge to eXaIlllne wheel nm

Tread wear mdICator Tile tread

sembly should be properly rebalanced for lateral and dlametral runout See
whenever puncture IS repaued 4
WI
Figure
The wheel and tue assembly be Lateral runout hnut
comes out of balance accordmg to Less than I 0 mm 0039 m
uneven tue wear Severe acceleratIOn total mdlcator reading
and brakmg or fast cornering IS the
WH024

cause of wear on tireresultmg m

FIg WT 3 Tread wear mdlcator
unbalance of tire and wheel assembly
The symptom of unbalance appears
as
tramp car shake and steenng
problems
To tue with wheel usmg a
change To correct unbalance use proper
the safe manner observe the
Jack m wheel balancer
follOWing procedures
1 Apply parking brake and block MaXimum allowable unbalance WT005

front wheels when rear wheelIS bemg 177 gr cm 2 46 In oz

Balance weight FIg WT 4 Wheel rlm run out check

changed pomts
2 Remove wheel cover and loosen 10 to 60 gr 0 35 to 2 12 oz

wheel nuts at 10 gr 0 35 oz mterval Note In replacmg tire take extra care

3 Place Jack
Jackmg pomt as
at not to damage tire bead nm flange
Note Be the correct
deSCribed In Section GI for Jack up sure to place and bead seat
and raise car until wheel clears ground balance weights on the mner edge Do not use tire irons to force beads

4 Remove wheel nuts and wheel of TIm as shown m

FIgure WT4 away from wheel nm
flange that is

Do not put more than two weIghts always use lire replacement deVice
from drum
wheel the on each Side whenever lire is removed
5 To mstall reverse

above steps Tighten wheel nuts m

cross
cnss fashIOn to 8 0 to 9 0 kg m 2 DIScard when any of the follow
58 to 65 ft Ib mg problem occurs

Note Never get under the car while It I Broken or

damaged bead WIre

2 tread
IS supported only by the Jack WHEEL AND TIRE
Ply or separatIOn
3 Worn fabriC tubeless
Always stands to support
use
safety damage on

order tue
the Side member of body construc In to ensure satisfactory
lion when you must get beneath steenng condition as well as maximum 4 Cracked or
damaged Side wall
the car tue I1fe proceed as follows etc

WT5
 Wheel and Tire

TROUBLE DIAGNOSES AND CORRECTIONS

Condlllon Probable cause Correcllve acllon

Wheel wobbles Improper tire pressure Measure and adJust

Damaged tue or distorted wheel rim
Repau or
replace
Unbalanced wheel Balance

Loose wheel nuts

Tighten
Worn or damaged wheel bearing or exceSSive Correct play or replace wheel bearing
play of wheel
bearing
Improper front wheel ahgnment Align
Worn or damaged ball Jomt Replace
Excessive steering hnkage play or worn AdJust or replace
steenng linkage
Loose steenng hnkage connecllon Tighten nuts to rated torque or
replace
worn parts If any
Broken suspension spring Replace
Faulty shock absorber Replace

Unevenly or Improper tire rotatIOn Conduct tue rotation periodically

excessively worn Improper lire pressure Measure and adJust
tire
Unbalanced wheel Balance or replace
Improperly adjusted brake AdJust
Improper wheel ahgnment Align
Excessively distorted or
Improperly mstalled Repair replace or If necessary reInstall
suspensIOn hnk

High speed on curves Reduce speed

I

Sudden anc Improper due Follow correct and proper

start speed to drIVIng manner

rapid accelerallon or Improper brake apphca

lion

Tire squeals Improper lire pressure Measure and adJust

Improper front wheel ahgnment AlIgn
Distorted knuckle or suspension hnk Repair or replace

WT 6
 SECTION ST

STEERING
DATSUN SYSTEM
MODEL 610 SERIES

STEERING SYSTEM ST 2

SERVICE DATA AND

ST 12
SPECIFICATIONS

TROUBLE DIAGNOSES AND

ST 13
CORRECTION

I NISSAN I SPECIAL TOOLS ST 13

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Steenng System

STEERING SYSTEM

CONTENTS

ST 2 REMOVAL ST 8
DESCRIPTION
ST 3 DISASSEMBlY ST 8
STEERING WHEEL
ST 3 INSPECTION ST 8
REMOVAL
ST 4 ASSEMBl Y AND ADJUSTMENT ST 9
INSTAllATION
ST 4 INSTAllATION ST 10
STEERING COLUMN
REMOVAL ST 5 STEERING LINKAGE ST 10
ST 5 REMOVAL ST 10
INSPECTION
ST 6 DISASSEMBlY ST 10
INSTAllATION
ST 7 INSPECTION AND REPAIR ST 11
STEERING lOCK
ST 7 ASSEMBLY AND ADJUSTMENT ST 11
REMOVAL
ST 7 INSTAllATION ST 11
INSTAllATION
STEERING GEAR ST 7

DESCRIPTION

The steering IS the type RB47L

IS attached to the Side member located ball type and collapses upon Impact
wluch ISof the reclfculatmg ball type on the opposite Side of the steering Thus If the car should become in
for easy operalion volved collISIon that
designed espeCially gear In a on
head

and Iugh durablhty and has a center The Side rods connect throws the driver forward the steenng
adJustable
distance of 47 mm 1 85 m between the cross rod to the steering knuckle column Will absorb the energy of hiS
the sector shaft and worm shaft arms The rubber coupl1ng located forward movement and greatly reduce
The steering I1nkage IS a
relay de between the steermg column and the the posslbll1ty ofIus being inJured
sign steering gear box prevents road shocks
The gear arm IS connected to one and I1nkage vlbral10ns from Imparting
end of the cross rod to the steermg wheel dunng operalion
The other end of the cross rod IS The collapSible steering column IS

I1nked to the Idler arm whose bracket standard eqUipment which IS a steel

ST 2
 Steering System

CD

1 Steeflng wheel
2 Column clamp
3 Steeflng column
4 Jacket tube flange
5 Rubber couplIng

6 Steeflng gear
7 Gear arm

8 Cros rod
9 SIde rod
10 Idler arm

TIghtenmg torque T of
bolt and nut kg m ft Ib

@ T 3 8 to 5 2 27 to 38
T 1 1
@ 0 8 to 6 to 8
@ T 35 to 45 30 to 39
@ T 4 0 to 5 0 29 to 36
@ T I3 to 15 94 to 108
eEl T 55 to 100 40 to 72
@ T 8 to 10 58 to 72
T 4 0 to 5 0 29 to 36
@
CD T 44 to 6 1 32 to 44

@ MullJ purpose grease

cm
kg m lb
sT492
FIg ST 1 Structural vIew of steering system

4 Remove steering wheel nut

STEERING WHEEL 5 Usmg Steering Wheel Puller

ST27 180001 mstall puller anchor

REMOVAL screws m threaded holes m steering
DISconnect wheel Turn center bolt of the special
I battery ground cable
2 DISconnect horn wumg tool clockwise to remove steering
3 Remove horn pad as follows ac wheel

cordmg to Its type See Figure ST 3

I Two spoke type

Note Do not strike the end of steer
Shdmg horn pad upward pull It
mg column shaft with hammer
a

out See Figure ST 2

2 Three spoke type
Strikmg shsft wdl damage bearing
sT493
or collapsible shaft
Pull1ng up lower spoke fIrst remove

horn pad FIg ST 2 RemOVing horn pad

ST3
 Steering System
INSTALLATION facmg punch mark on the top of upper
column shaft m that direction and
Instdll steenng whcelm the rcverse

order of rClllllvdl Observe the follow tighten steering wheel nut to the specI
fied torque
mg mstrulllllm

I Apply grease to shdmg portIOn of Tlghtenmg torque

3 8 to 5 2
contact plate kg m
27 to 38 ft lb
2 Install steenng wheel on column
shaft m a
straight ahead posItion after

FIg ST 3 Removmg Ieerlllg Il lleel

STEERING COLUMN

1 Upper bearIng 7 Lower jacket tube

2 Upper jacket shaft 8 Lower jacket tube flange
3 Steeflng post clamp 9 Lower bearIng
4 Upper jacket tube 10 Rubber couphng
5 S lee1 ball 11 Column dust cover
6 Lower Jacket shaft
sT1S2

FIg ST 4 SecllOnal vIew ofcollapsible type steermg

4
ST
 Steering System

Instructions for Note When n colhslOn

handhng a
head IS

collapsible steering column encountered inspect steermg sys

tem as follows
Never undue 10
I apply Ill stress

steenng Lolumn 111 d ldl dlreltlon The steermg system IS very Impor
tant umt for dnvmg The
2 Do
apply bendmg
not forLe to collapSI
steenng column when 1I1sldlhng ble type steermg should not be
dISassembled and If necessary re

place It as an assembly
5T476

Fig ST B Signal
RemOVing turn

SWitch assembly
REMOVAL
5 Remove four bolts securing Jacket
I Remove bolt sewrlng worm shdft
tube flange to dash panel
and rubber couphng
See Figure ST 9
See Figure 6
ST
INSPECTION

1 When steenng wheel cannot be

rotated smoothly but steering gear
and suspension system
steenng hnkage
are normal check the steering system
dfld replace damaged parts

i Check column beanngs for dam

age or unsmoothness
sT187 If so lubncate With recommended
steer
multi purpose grease or replace
Flf ST 9 RemOVing Jacket tube
ST474 mg column assembly
flange securing bolts
2 Check Jacket tube for deforma
Fig 6 RemolJmg rubber cuuplmg
ST Remove four bolts securing col
6 tion or breakage and replace If neces
becurmg bult
umn clamp to dash panel sary
See Figure ST 10 3 Check column spnng and re

place If ddl11aged and weakened

2 When the with col

car
eqUipped
2 Remove steering wheel mvolved
lapSible steenng IS m a
hght
Refer to page ST 3 for Removal of front collISIon check the followmg
Steermg Wheel parts and replaLe If necessary
1 L oo n four dnd Jacket tube
SCI ews remove
I
upper and lower steering column shell Measure the dunenslOn A as shown
covers See Figure ST 7 ST 12
m
Figure
Standard mstalled dimenSion IS

1838 mm 724 m

When tube crushed dimen

Flf ST 10 RemOVing column clamp JaLket IS

sIOn A IS red uced

securing bolts
7 Draw out column as
steenng
sembly from the room Side

See Figure ST 11

sT475

Fig ST 7 lIemolJlIlg column shell

covers

sT192
I Jacket tube
2 Column clamp

f ST 12 Standard dimenSIOn
FI
between column clamp and
4 Remove turn slgndl SWltl h dS
f ST 11
FI DraWing steering column the top end of lower
sembly by loosenmg two crews
assembly Jacket tu be
ST 5
 Steering System

2 Column clamp 3 Steenng wheel 4 Sector shaft

Measure dimenSion B as shown m Check steering wheel for aXial pldY When collISIon occurs abnormal

Figure ST 13 When steenng Jacket shaft IS crush to gear arm As

strength IS applIed a

Standard B dimensIOn IS 0 mm 0 ed aXial play eXists result of thiS serra lion of sector shaft
When tube crushed See Figure ST 14
m Jacket IS IS apt to be distorted See Figure
dmlenslon B IS mcreased ST 1 5

Serra lion of
Play
lector shan

l
SteerIng wheel SIde Geu um

@
1 Column clamp 5T399 ST195
2 Block 5T194
3 Jacket tube FIg ST 15 Inspechng the serrollon of
FIg ST 14 Inspectmg steerrng wheel sector maft for
FIg ST 13 Standard dImenSIOn B for aXlat play deformollon

INSTALLATION

Install steering column m the re Observe the follOWing mstrucl10ns

verse order ofremoval See Figure ST 16

I Rubber couplmg
2 Sleerlng column
assembly
3 Worm shaft
4 Dash panel
5 Column shaft

c 6
7
Column clamp
Jacket tube nange

sT197

FIg ST 16 InstallIng steermg column assembly

ST 6
 Steering System

Set the wheelm dhead and then

I a
stratght en four nuts @ tighten bolt
posItion @
2 Fit column
steenng assembly Tightening torque
onto worm shaft serration through 35 to 45 kg cm
dash panel and tighten bolt @ 30 to 39 In Ib
Make sure that punch mark at the
5 After installation make sure that
top end of column shaft IS faced up
steenng wheel turns smoothly
TIghtemng torque
4 0 to 5 0 kg m STEERING LOCK
29 to 36 ft Ib
To sT47S
proVIde tamper proof self shear
Note Do not apply any undue stress type screws are used and their heads FIST 17 Removmg steermg loclr
screws
securIng
to rubber are sheared off when mstalled that
couphng so

the steering lock cannot be removed

3 Install bolts @ to support the eaMly
upper SIde of steering column assem

bly by means ofcolumn clamp REMOVAL INSTALLATION

Tlghtenmg torque I Break two self shear type screws 1 Ahgn steenng lock hole m Jacket
o 8 to 1 I kg m
with a dnll or other proper tool tube WIth the matmg portion of steer
6 to 8 ft Ib 2 Remove two screws and dismount mg lock
tube 2
4 Loosen bolt @ and after shdmg steenng lock from steering Jacket Install self shear type screws nd
tube dash See Figure ST 17 cut off their heads
Jacket flange to
panel tight

STEERING GEAR Type RB47L

Gear ratio 1648 1

1 Woml shaft 11 Lock nut

2 Ball nut 12 AdJustlOg shIm
3 Worm beanng 13 011 seal
4 Rear cover 14 Steenng gear houslOg
15 Sector sh ft cover
5 Beanng shun
6 Onng
Tlghtenmg torque T of
7 011 eal bolts and nuts kg m lb
It
8 Sector shaft
@ T 1 5 to 2 5 11 to 18
9 Sector shaft beanng
@ T 1 7 to 2 5 12 toil8
10 AdJu tlng screw
@ T 1 5 to 2 5 11 to 18 5T479

FIST 18 SectIonal vIew ofsteermg gear

ST 7
 Steenng System

REMOVAL DISASSEMBLY 5 Remove beanng adJustmg

shlm s and steering worm
I Thoroughly dram steering gear 011 assembly
I See ST 25
Remove bolt seCUring worm shaft
by removmg filler plug CD Place Figure
to rubber coupl1ng steering gear m a vise With Steering
See Figure ST 19 Gear Attaclunent KV48100300 m

place
2 Loosen lock nut V and remove
four sector shaft bolts
cover
attachmg
@ After removmg sector shaft With
cover remove cover from sector shaft
by turnmg screw clockWise See Figure
I ST 22

sT4S0 sT4S5

Fig ST 19 RemOVing rubber coupling Frg ST 25 DraWing out steering worm

securing bolt assembly

Notes
a Be careful not to allow ball nut
2 Remove nut and lock washer se
to run down to either end of
cUring gear arm to sector shaft Usmg worm The ends of ball guides will
Gear Arm Puller
Steering be if nut rotated until It
ST2902000 I remove
damaged IS

steering gear
stops at the end of worm
from shaft See
affi1 sector Figure b Do not detach baD nut from worm
ST20
shaft assemb Iy If necessary replace
sT482
assembly
Frg ST 22 Mounting steering gear
c Do not remove sector shaft needle
In a Ui e

bearmgs from steermg gear housing

If necessary replace gear housmg
3 Turn sector shaft s rew
assembly
lstl lg
adJ
a few turns m clo kwlse directIon and
then remove cover and sector shaft
INSPECTION
See ST 23
Figure
Wash clean all the disassembled
m solvent and check for con
parts
dition

Sector shaft
sT254
I Check tooth surfa for
Frg ST 20 RemOVing steering gear arm gear e

burrs cracks other

pittIng or any

3 Remove three bolts securing damage and replace If necessary

Side 2 Check sedor shaft for distortIOn
steering gear housmg to body
member and Withdraw steering gear on ItS serration and If necessary
Frg ST 23 DraWing out sector shaft

housmg from engme compartment replace Also check gear housmg and
See Figure ST 21 steenng worm
assembly for deforma
4 Remove three rear cover securmg
tIon
bolts and detach rear cover See Figure
ST24
Steering worm assembly
I Inspect ball nut gear tooth sur
face and replace If plttmg burrs wear
or any other
damage IS found
2 Ball nut must rotate smoothly on
worm gear If found too tight as

sembly should be replaced

Check rotation of ball nut as fol
lows
sT4S1

Frg ST 21 WIthdraWing steering gear I Move ball nut to either end of

hOllSlng Fig ST 24 Detaching rear cover worm gear and gradually stand worm

ST8
 Steenng System

Adjustment of sector shaft

shaft and ball nut assembly until ball Adjustment of worm
and adjusting screw
nut moves downward on worm gear bearing preload
under Its own weight 4 Place steenng worm assembly In 6 Insert adJustmg screw mto T
2 If ball nut does not freely
move
posll1on gear hOUSing
m With worm shaped groove at sector shaft head
over enUre stroke replace assembly beanngs Install rear cover on gear and adJust the end play between sector
shaft and adJusting screw unl1l It IS
Note Be careful not to damage ball hOUSing With O nng and worm bearing
shims wlthm 001 to 003 mm 00004 to
nut guide tube whde check IS belllg
00012 m by choosmg SUitable ad
made
Tightening torque
I 5 to 2 5 Justmg shuns
kg m

11 to 18 ft lb

Note Be sure to install thicker shims Available sector shaft adJustmg

side shims
to gear housing
Standard shim thickness
No Thickness mm m
1 5 mm 0 059 m

I I 575 to 1 600 00620 to 0 0630

Available WOffi1
bearing shims
2 1 550 to I 575 00610 to 0 0620
5T037
No Thickness mm m 3 1 525 to 1 550 00600 to 0 0610

4 1 500 to 1 525
fST 26 Inspecting wonn shaft
FI 00591 to 0 0600
and ball nut assembly I o 762 0 0300
5 I 450 to 1 475 00571 to 0 0581
2 0254 00100

3 o 127 00050
Bearings
4 o 050 00020
I Replace worm shaft needle bear

mg If plttmg wear or 1Y
a other

damage IS present 5 AdJust the worm beanng preload

SUitable shims so
2 If sector shaft needle beanngs are by selectmg bearing
found worn or damaged replace as an that the Imtlal turnmg torque IS 40 to

assembly of gear hOUSing and beanngs 8 0 kg cm 3 5 to 69 m lb Measure

the Preload
torque uSing Gauge
011 seals ST3127S000 and a SUitable socket

Be sure to use new 011 seals at each With cloth around the top of the shaft f ST 28
FI MeaSUring end play
so that the shaft Will not sl1p See between sector shaft
reassembly and adjustIng screw
Figure ST 27

un111
7 Rotate WOffi1 shaft by hand
ASSEMBLY AND ball nut IS m the center oftravel then
Install sector shaft together With ad
ADJUSTMENT
Assemble steering gear In the re Justmg screw m gear housmg Ijnsure
that center gear of sector shaft engages
verse order of dISassembly
With the center gear of the ball nut
Observe the followmg mstructIons
ST 29
See Figure
Clean all parts
2 Lubncate worm bearings sector sT560 Note Be careful not to damage seal
Ing bps of oil seal durmg operation
shaft bearmgs and gear teeth With f ST 27 MeasurIng Initial turnIng
FI
clean gear 011 torq ue

3 Fill the space between sealing hps

Notes
of new 011 seal With recommended
a Rotate worm shaft a few turns m
mull1 purpose grease and fit It to gear
both dlfections to settle down
housmg and rear cover
worm beanng and measure the pre
Notes load
a To facilitate installatIon coat gear b When readjustment is necessary
oil to seal contacting face of oil mitial tUrfing torque should be 40
seal to 8 0 kg cm 3 5 to 6 9 In Ib

b Press 011 seal into place With Its When worm bearing sT487
c adjusting pre
lettered side towards the outside of load add or remove shuns until

gear housing correct adJustment IS made f ST 29 Instalhng sector shaft

FI

ST 9
 Steering System

8 Install sector shaft cover on gear 14 Fill assembly With recommend I PosItion steering gear and rubber

housmg ed gear 011 of approXImately 0 28 liter couphng m place then mstall and
Be sure to apply sealant to each US pt U Imp pt through fIller lighten bolts secunng steering gear

of sector shaft hole and IDstall fIller housmg body to Side member
Tighten
face cover packing plug
when mstalhng screw additional to 7 to 8kg m 51 to 58 ft lb
cover Tighten adJustmg
By turning adJustmg SLrew counter ly Y to H turn from fully turned Tighten bolt secunng rubber cou
clockwise attach sector shaft cover to pOSItion pl1ng to worm shaft to 4 to 5 kg m 29
then to 36 ft Ib
gear housmg and temporarily Tlghtemng torque
seLure It with fIXIng bolts
RIght hand drive model Notes
9 Pull sector shaft toward cover
2 to 3 kg m 14 to 22 ft lb a Align groove m worm shaft
the
2 3 mm 0 08 to
approximately to
With the bolt hole In rubber cou
Left hand drive model
o 12 m after turning adJustmg screw

Tighten adJustmg screw addi pltng flange yoke and press cou
counterdockwlse and lighten sector
tionally to turn from ful pltng bolt through the undercut
shaft cover fixmg bolts to I 5 to 2 5
turned section of worm shaft
ly posItion
kg m I I to 18 ft lb
b Ahgn four grooves of gear arm
10 Push sector shaft agamst ball nut of
serrations with four projections
gear by gradually turnmg adJusting INSTALLATION
sector shaft serrallons and install
screw clockwise until sector shaft gear Install steering gear the reverse and lock washer and nut to
m tighten
hghtly meshes with ball nut gear and order of removal 94 to
the torque of 13 to IS kg m
then temporanly secure adJustmg Observe the followmg mstructlOns 108 ft Ib
screv with lock nut
1 I Install gear arm on sector shaft

shaft several times

and move sector
STEERING LINKAGE
from the Side of gedr arm to see that It 1

turns
smoothly
j
fi Ill

@ f J
12 AdJust the backlash at the neu
I

tral position of gear arm by tummg L J

out so that the f

t
A T

adJustmg screw m or
f
movement of the gear arm top end IS I
I
less than 0 mm 0 004 m See

Figure ST 30

1 Steermg gear arm

VX
fi

t r v
e

2 Cross rod
C
3 SIde rod
4 SIde rod ouler socket
5 SIde rod Inner socket
6 Idler drm assembly
4

FIg ST 32 Steermg lmkage

5T4SS

ST 30 REMOVAL Note Be careful not to stnke the ball

FIg MeaSUring backlash
stud head the ball socket of Side
I Jack the front of car and
up
13 Turn
adJustmg screw clockWISe rod and Side rod with a hammer
support It on safety stands
approximately 1 8 to 1 6 rotation and
2 Remove cotter pms and nuts 4 Remove ball stud of cross rod
then tighten lock nut to I 7 to 2 5

8 ft Ib after movmg fastenmg Side rod ball studs to knuckle from gear arm and remove Idler arm
kg m 12 to
arms from cross rod m the same manner as
sector shaft several limes See Figure
3 To detach Side rod ball studs deSCribed 3 above
ST31 m step
from knuckle arms msert Steering JlI
B 5 Remove Idler a sembly from Side
Jomt Remover ST72520000 between member off two fiXing bolts
by takmg
them and stnke the top of the tool
With a hammer If thiS operation must
DISASSEMBLY
be done wIthout the tool strike
knuckle arm boSWith a hammer Dlsconnec t both Side rods from

backmg up the oppoSlle Side of It With cross rod follOWIng the procedure for

5T4S9 a large hammer and ball stud IS free removal of Side rod ball Jomts at

FIg ST 31 TIghtening lock nut from knuckle arm knuckle arm SIdes

ST 10
 Steering System
2 Remove Idler arm nut and disas Cross rod and side rod Notes

semble Idler assembly Be sure to bar

Check Side rods and cross rod for
a screw adJustmg In

socket properly
breakage bend crack and If
or
replace b Make sure that adJustmg bar is
INSPECTION AND REPAIR necessary
screwed m socket by 29 9 mm
1 177 in mm
Ball Joint
I When ball stud IS worn and aXial

play IS too exceSSive replace

2
AJual play Tlghtemng torque
o 1 to 0 5 mm Side rod adJustmg bar lock nut
0004 to 0 020 In ASSEMBLY AND
8 to 10 kg m
Swmg torque ADJUSTMENT 58 to 72 ft Ib
05 4 ft lb
kg m Assemble steermg I1nkage m the
order of
2 When dust cover IS broken or reverse disassembly
deformed Observe the follOWing instructIOns
replace

Note To renew
grease replace plug Ball Joints r 313 2 1233

With a grease nipple and apply Before mstalllng a new dust cover tfi n T
recommended multi purpose grease be pack With the recommended r
l
sure to
to ball joints as shown In Figure AdJustmg bar
mull1 purpose grease 1 177 Socket
ST 34 through grease mpple untd Socket assembly assembly
grease IS forced out through dust Tightenmg torque
socket clearance Ball stud
cover to Joint Unit mm m 5T343
5 5 to 10 0 kg m

40 to 72 ft Ib
FIg ST 35 Standard SIde rod length
Notes

a When ball stud be care

tightening
ful not to allow grease to get on Its

tapered section
b
Ball Jomt
Ahgn the cotter pin holes m the
1
2 Du st cover tightenmg directIOns
c Be sure to Insert new cotter
o 1 to 0 5 mm 3 Ball seat pin m

0 004 to 0 020 m 4 Plug place and bend It securely

5 SprIng seat
5T179

FIg ST 33 SectIOnal vIew of ball Idler arm assembly

stud suI e rod

When Idler
assembl1ng assembly
Idler arm assembly observe the follOWing instructIOns
Check nylon bushmg of cross rod Apply soapy water on the outer
and rubber
Jomt bushmg of Idler arm Circumference of buslung INSTAllATION
for breakage wear or
play and If Carefully press buslung mto Idler Install steering hnkage m the re

necessary replace body unl1llt protrudes verse order of removal

Tighten Idler nut to 4 0 to 5 0 kg m Observe the follOWing mstrucl10ns
29 to 36 ft Ib
Tlghtenmg torque
Ball stud
5 5 to 10 0 kg m
Cross rod and side rods 40 to 72 ft lb

1 When Side rod socke ts and Side Idler body to frame bolts
Rad @
rod 4 4 to 6 1 kg m
140 mm 5 51 m adJustmg bar are separated adJust
Side rod length correctly 32 to 44 ft Ib
I Nylon bushIng Tlghtenmg torque
2 Dust cover @ 5 5 to 10 kg m
AdJustment should be made be Note Ahgn the cotter pm holes m the
3 TorSIon rubber 40 to 72 ft lb tween ball stud centers See Figure
tightemng directions
@ 4 0 to 5 0 kg m ST 35
5T1S0 29 to 36 ft lb Standard distance between mner 2 Check wheel ahgnment and If

FIg ST 34 SectIOnal vIew of and outer ball stud centers necessary adJust
Idler assembly 3132 See SectIOn FA
mm 1233 m

ST 11
 Steering System

SERVICE DATA AND SPECIFICATIONS

Steering gear type RecIrculatmg ball type

Steering angle mner wheel degree 370 to 380
outer wheel degree 30040 to 32040

Turns of steermg wheel lock to lock 36

Ball stud aXial play mm m o I to 0 5 0 004 to 0020

swmg torque kg m ft Ib less than 0 5 4

Steering wheel play mm m less than 35 1 38

at outer cIrcumference of steering

wheel

Worm bearing startmg torque

new bearing kg cm m Ib 40 to 8 0 3 5 to 6 9

readJusted bearmg kg cm m Ib 40 to 8 0 3 5 to 6 9

Worm bearing slum

Standard total thickness rom In 1 5 0059

AdJustmg shim No Thickness mm m

1 o 762 00300

2 0254 00100

3 o 127 00050

4 o 050 0 0020

End play between sector shaft and adJustmg screw

mm m 001 to003 0 0004 to 00012

AdJustmg shim No Thickness rom m

I I 575 to 1 600 0 0620 to 0 0630

2 I 550 to I 575 0 0610 to 0 0620

3 I 525 to 1 550 0 0600 to 0 0610

4 I 500 to I 525 00591 to 0 0

06

5 I 450 to 1475 00571 to0058D

Gear backlash at gear arm top end rom In less than 0 1 0004

Tightening torque kg m ft Ib

Steering gear

Gear arm nut 13 to 15 94 to 108

Rear cover bolts I 5 to 2 5 II to 18

Sector shaft cover bolts 1 5 to 2 5 II to 18

Sector shaft I 7 to 25 12 to 18
adJustmg screw lock nut

70 to 8 0 51 to 58
Steering gear hOUSing to body bolts

ST 12
 Steering System

Steering hnkage
Idler arm to frame bolts 44 to 6 1 32 to 44

Ball stud nuts 55 to 10 0 40 to 72

Side rod lock nuts 8 to 10 58 to 72

Column shaft

Steering wheel nut 3 8 to 5 2 27 to 38

Column clamp bolts o 8 to 1 I 61 to 8

Rubber couphng to worm shaft bolt 40 to 5 0 29 to 36

I 5 to 2 2
Rubber couphng securing bolts iI to 16

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause CorrectIVe actIOn

wh el moves Wheel out of speclflLallons Re mflate

Steering heavily ahgnment or
ahgn or lire s to correct
au pressure m tires too low pressure

Re
Steering hnkage out of adJustment adJust and see relative tOpiC under

Front SuspensIOn
Steering column out of ahgnment Repair

Re pair
Steermg wheel returns but Wheels out of alIgnment or air pressure or mflate lIres to correct air

sluggishly m tnes too low pressure

Faulty steering I1nkage Replace and see relative tOpiC under

Front SuspensIOn

Car Side Wheels out of proper Re

pulls to one ahgnment ahgn
Wheel bearing out of adJustment ReadJust
Faulty steering hnkage Replace and see relalive tOpiC under

Front SuspensIOn

SPECIAL SERVICE TOOLS

Tool number For Reference

No DescriptIOn use page or
tool No
name on
Figure

ST27 180001 ThiS tool IS used to drive out steering wheel B210 Fig ST 3

Do not hammer on 610

Caution steenng column shaft
Steering wheel 710
puller

SEl16

ST 13
 Steering System

Tool number For Reference

No Descnpl10n use page or

tool name
Unit mm m
on
Figure No

2 ST29020001 ThiS tool IS used to from steering sector B210

remove steering gear arm
Fig ST 20
shaft 610
Steering gear arm
710
Note Strike the side of the gear arm with double hammer to ease
puller
removal

sEl17

3 KV48100300 ThiS tool IS used to mount steering gear B210

m a vise
Fig ST 22
610
Steering gear
710
attachment

sE42S

4 ST3127S000 ThiS tool used to

IS measure worm
beanng preload All Fig ST 27
models
Preload gauge

GG91030000

Torque wrench CD
2 HT62940000
Socke t 0
adapter
@
3 HT62900000 1 4 J
l x
3 8 J 3 8 J x 1 2
l J
Socket

adapter
SE329

5 ST72520000 ThiS tool IS placed between knuckle arm and steering ball Jomt to B210 Page ST II
faclhtate the disengagement of ball Jomt sectIOn 610
ball
Steering 710
Caution Do not hammer on bolts
Jomt remover

sE399

ST 14
 SECTION FE

ENGINE
DATSUN
CONTROL
MODEL 610 SERIES FUEL
EXHAUST
SYSTEMS

ENGINE CONTROL SYSTEM FE 2

FUEL SYSTEM FE 3

EXHAUST SYSTEM FE 6
NISSAN I

NI SSAN MOTOR CO LTD

TOKYO JAPAN
 Engine Control Fuel Exhaust Systems

ENGINE CONTROL SYSTEM

CONTENTS

FE 2 INSPECTION FE 2
ACCELERATOR SYSTEM
FE 2 ADJUSTMENT FE 2
DESCRIPTION
REMOVAL AND INSTAllATION FE 2

5 Remove two mountmg bolts and ADJUSTMENT

ACCELERATOR
tOrsion shaft support
SYSTEM 6 To Install the order of
reverse Accelerator linkage
removal
DESCRIPTION 1 To adJustment fust
faCll1tate
The accelerator wntrol system IS of adJust according speclfIcanons
to the

a
hnkage type To align the control Bell crank bracket
the JOlnt toJomt length of ball JOint
linkage adJustable rod s are used assembl1es A and B
Remove return spring
Smooth and responsive movement
2 Disconnect two connectmg rods
of the Umt mm m
linkage accompl1shed through
IS

the use of nylon ball Jom ts The ball

two ball Jomt assemblies from bell
Screwed Jomt to jomt
crank
Jomt should be lubncated with multI length length
3 Remove three mountmg nuts
purpose grease at recommended
then remove bell crank bracket as
mamtenance mtervals Balljomt 10 0 394 208 8 19
sembly from dash panel
The tOfSlon shaft assembly A
IS supported by 4 To mstall the order of
reverse
which made from
beanng IS
poly acetal
removal Balljomt 8 0315 652 25 7
resm The resm
beanng and all metal
assembly B
slldmg parts should also be lubncated
Notes
WithmultI purpose grease at recom
a Ball Jomted sections can be sepa 2 AdJust length L to the value
mended mamtenance mtervals
rated from each other by hghtly shown below

pulhng apart
REMOVAL AND b When removmg any parts of accel Length L
INSTALLATION do not disturb ad 87 rom 3 43 In
erator linkage
Justmg screw of ball Jomt assembly
Accelerator pedal
to save control linkage adJustment
pedal arm 3 AdJust the screw at locanon Q to
In case ball JOint assembly should the value shown below
be to page FE 2 3
I Remove two screws and accelera adJusted refer or

for AdJustment
tor pedal Length M
2 DIsconnect ball Jomt at the upper 845 mm 3 33 m

end of pedal arm

3 Remove snap ring then remove

4 at locatIOn D so
AdJust the screw
pedal arm from pedal arm bracket
that the carburetor throttle shaft IS set
4 To mstall reverse the order of
at the IDLE posItion
removal
After the
5 completing adJustment
outhned I
as In steps through 4
agam check to be sure that dImenSion
Torsion shaft torsion
M IS the speCified value If necessary
shaft support
readJust the screw at locatIOn Q
INSPECTION
I Remove return spring 6 Depress the accelerator pedal
2 Disconnect connectmg rod ball I Check accelerator rods to ensure With the carburetor throttle valve fully
Jomt assembly from torsIOn shaft that they are neither tWI ted nor bent opened adJust the height of the stop
3 Remove pm and separate
cotter Also check ball Jomts for cracks or per bolt so that It touches the pedal
torsion shaft from carburetor throttle wear Repair or If necessary replace arm From that pOSition turn the

lever 2 Check return spring for fatigue or stopper bolt one full turn and secure

4 Remove tOfSlon shaft damage Replace Ifnecessary the stopper bolt With a lock nut

FE 2
 Engine Control Fuel Exhaust Systems

I Accelerator pedal 10 Bell crank bracket

2 bolt 11 Ball JOInt assembly B
Stopper
3 Pedal arm 12 Lock nut
4 Pedal arm bracket 13 TorSIon shaft support
5 BallJOlOt assembly A assembly
6 Lock nut 14 TorSion shaft

7 Boot 15 Re turn spIlng

8 Bell crank 16 Klckdown s ltch

9 Nylon bushmg
FE310

FIg FE 2 Engme control system

K1ckdown swHch
arm when pedal IS de
accelerator

pressed fully Always lIghten lock nut

On automatic transmtSSlOn models
securely when proper adJustment IS
It IS also necessary to adJust ktckdown obtained See Figure FE 2
SWitch Ktckdown SWitch adJustment IS
correct If ktckdown sWitch IS actuated
by stopper located on IIp end of pedal

FUEL SYSTEM

CONTENTS

FE 3 FUEL PIPING FE 6
DESCRIPTION
FE 5 FUEL STRAINER FE 6
REMOVAL
FE 5 INSPECTION FE 6
FUEL TANK Sedan and Hardtop
B
FE
FUEL TANK Station Wagon FE 5 INSTAllATION

DESCRIPTION gal 12 i Imp gal In capacity The 13 US gal 11 J

iImp gal T1us urut
tank Unit located to the rear of the located between the front mountmg
types of fuel tank IS IS
There are two

used Sedan and Hard seat back and secured m place with a bracket and the rear crosS111ember and
One type IS on

and the other used Station total of four bolts two on the front secured In place with four bolts
top on

and one on each Side of the tank The fuel strainer IS of a

nylon
Wagon
The fuel tank for the Sedan and The capacity of the fuel tank for cartndge type
Hardtop models IS 55 hters 14 US the StatIOn Wagon model IS 52 I1ters

3
FE
 Engine Control Fuel Exhaust Systems

fJ
cif
c

I Fuel tank
2 Venttlal10n hose
3 Filler hose
4 Filler cap
5 Evapo hose
6 ReseIVon tank
7 Fuel gauge umt
8 Dram plug

F E356

Fill FE 3 Fuel tank Sedan and Hardtop

I Fuel tank
2 Filler hose

3 Venttlal10n rear hose

4 Vapor vent hose
5 Reservon tank
6 Filler cap
7 Venttlal10n front hose
8 Fuel gauge umt

F E357

Fill FE 4 Fuel tank Station Wagon

4
FE
 Engine Control Fuel Exhaust Systems

Sedan and Hardtop

I Fueltank
2 ReservolI tank
3 Fuel pipe
4 Vapor pIpe
5 Flow gUide valve
StatIOn Wagon and Van
6 Fuel stramer

FEl58

Fill FE 5 Fuel pipIng

REMOVAL 6 Detach rear seat cushton and seat FUEL TANK

back Remove four bolts two at the Station Wagon
FUEL TANK front and one on each sIde secunng I Remove battery ground cable
Sedan and Hardtop fuel tank m place and take out fuel
2 Remove from
IDspectJOn cover
tank
I Remove battery ground cable rear floor DISconnect wues from urnt
7 The UnIt gauge IS of a bayonet
2 Remove trunk front ftrnsher gauge
type and can be taken out by turnmg
3 Take out spare ttre Place a sUita
lock plate counterclockwlse wIth a 0
ble contamer under fuel tank dram
screwdnver
plug to receIve the remammg fuel m
8 Reservotr tank removal
tank Remove and then dram
plug plug Unfasten tnm chp and detach rear
to dram fuel mto the contamer
parcel shelf ftnIsh DIsconnect three
breather tubes
Loosen four bolts secunng reservotr

tank and take out the tank

8
FE Removmg mspectlon cover
FI

3 Take out spare tire

4 Loosen dram plug and allow fuel
to dram mto a sUitable con tamer
5 DIsconnect ftller hose ventdatlon
Fill FE 6 DraIning fuel
hose and ou tlet hose tank side
4 DISConnect filler hose ventIlation 6 Remove four bolts from fuel
hose breather hose and outlet hose tank and detach fuel tank
tank sIde 7 Detach bayonet type UnIt gauge
5 DISConnect wtres from fuel tank by turnmg lockplate counterclockwISe
urnt gauge Fig FE 7 Removmg reservoir tank wIth a screwdnver

FE 5
 Engine Control Fuel Exhaust Systems

8 Reservotr tank removal Fuel stramer IS of a cartndge type

I Remove tnm board from the and carmot be cleaned

nght side of rear body Always replace WIth a new one

2 Unfasten three clamps and dIS

connect ven tlla tlon hoses
3 Remove grommet from vapor
hose and dIsconnect hose
4 Remove two screws on the top
face of reserVOlf tank INSTALLATION
5 LIft up reservotr tank and un

fasten latches at lower

Install any parts of fuel system m
flange section FE221
the reverse order of removal Observe
SlJde out reserVOtr tank
FIFE 9 Fuel stramer the follOWIng notes
Notes
Notes
a Use care not to spill fuel over trunk
room floor
a clamps securely Do not
Install hose

b Plug filler openmg to prevent entry tighten excessIvely to aVOId dam

agmg hose
of dust or dirt
b Do not kink or twist hoses and
INSPECTION tubes when they are routed
FUEL PIPING Fuel tank c Install filler hose after fuel tank has
Check fuel tank for cracks or diS been mounted in place Failure to
All fuel hnes can be
easdy dIS
tortIon If necessary replace follow this rule could result in
connected by unfastenmg clamps and
2 Fuel hose Ieakage from around hose connec
Do not dISconnect any fuel lJne
clips tions
Inspect all hoses for cracks fatigue
unless necessary
sweatmg detenoratlon d Fuel gauge tank unit
or
Replace any
Note hose and tube opemngs to
Plug hose that IS faulty When Installing fuel gauge tank
unit
prevent entry of dust or dirt 3 Fuel tube align the projectIon of gauge
any fuel tube that IS crack tank umt with the notch m fuel
Replace
tank and Be sure
ed rusted collapsed or dIStorted tighten It securely
FUEL STRAINER 4 to Install tank umt with
Fuel stramer gauge
I DIsconnect fuel hoses from fuel fuel O ring m
place
Replace stramer at recom

mended mamtenance mtervals If It e Run the engme and check for leak
stramer by removmg clamps or

2 Remove fuel stramer becomes clogged or restncted age at connections

EXHAUST SYSTEM

CONTENTS

DESCRIPTION FE 6 INSTALLATION FE 7

REMOVAL FE 7 SEALING COMPOUND FE 8

INSPECTION FE 7

bly for Station Wagon a mam muf VIbration IS not trans1TI1tted to the
DESCRI PTION
fler assembly mountlftg hangers and body
brackets A protective hea t slueld IS placed
The exhaust system consIsts of a The spnng constant of the mount over the mam muffler to prevent the
fron t tube WIth pre muffler assembly mg Insulator IS low m the vertical trunk floor from bemg heated by the
a rear tube wIth maID muffler assem dtrectlon so that exhaust mam muffler
system
6
FE
 Engine Control Fuel Exhaust Systems

Sedan and Hardtop

I i
StatIon Wagon

lJ
I

EO

I Front lube wllh pre muffler

2 Exhaust rear tube
3 MalO muffler assembly
4 Exhaust rear tube with
malO muffler assembly
F E340

Fill FE 1O Exhaust system

2 Rep lace bracket and hanger rub

REMQ AL ber parts that cracked
are fatigued or
sweated
I Remove bolts and nuts from mam

muffler clamp
2 Break old sealant off the Jomt
whde lightly tappmg around wIth a
hammer and tWist muffler INSTALLATION
3 Usmg a rubber hammer tap the I Wipe clean all the contact por
front end of the muffler whde pullmg tlon allow them to dry thoroughly
It toward rear
2 To mstall reverse the order of
The mam muffler can then be
removal
pulled out Fill FE lI Removmg front tube

4 Remove bolts and nuts from rear Notes

exhaust tube clamp UtdlZmg the same a Make sure that there is a mIDtrnUDl

for the mam muffler clearance of 18 rom 0 71 m be

prooedure as

exhaust tube from front tween body or frame and exhaust

remove rear
INSPECTION
exhaust tube system component parts
5 Remove nuts secunng exhaust I Check muffler and tubes for b Insert each exhaust tube into Its
mamfold to front exhaust tube and cracks damage
or plaoe untd stopper touches matmg
detach front exhaust tube from ex that tube and clamp securely See
Replace any part IS damaged
haust manIfold See FE II FIgure FE I3
Figure beyond l11TI1ts
FE 7
 Engine Control Fuel Exhaust Systems

Tightening torque
kg m ft Ib

Exhaust mamfold to front exhaust tube nuts I 9 to 2 5 14 to 18

U boIt securmg nuts J 4to 16 IOto 12

C c1amp secunng bolts 14to J 6 lOto 12

Mountmg rubber secunng bolts 1 2 to J 4 9 to 10

SEALING COMPOUND
Exhaust Sealant KIt 20nO N2225 6 POSitIOn the nozzle of mJector to
If exhaust tubes are
separated at FE J2 the gUIde and press It there ftrmly
see FIgure or
equIvalent to
connection to muffler
renew
assembly elJmmate gas leakage past the Jomt Inject sealant slowly untll sealant
etc use the Genume Nlssan Sealant Be sure to observe the folloWIng pro begms to flow out of the sht of the
cedure tube
ThIs mdlcates that the bead re

qUires no further sealant ExceSSive

sealant can cause a clogged tube See
Figure FE IS
Sealant lube polyethylene Mter mJectmg wash mJector
thoroughly m clean water to remove

all traces of sealant

FE109

Fill FE 12 Exhaust sealant kit

I clean all the contact por 4

Wipe Torque U bolt secunng nuts and
tlons of tube JOints allow them to
dry exhaust tube mountmg bolts to
thoroughly specificatIOns FE163
2 Temporanly mount m place muf 5 5 to 6 cc Fill FE 15 bvechng sealant
Squeeze 031 to 037
fler assembly and or exhaust tube as
cu m of sealant mto Jector from
11 the
an assembled umt on the car
sealant tube See 7 Start the engme and let It Idle
3 Insert the male tube the
Figure FE 14
Into Be sure to place the cap back to the slowly for ten mmutes 1TI1nrrnum to
female tube fully until the front end
sealant tube smce sealant will harden sealant WIth the heat of ex

of the female tube touches the

dry
stopper haust gas
the male tube See
on
Figure FE 13
8 Check the conditIOn of sealant
before the car
dnvmg
It IS also essential that the car

should not be accelerated sharply for

20 to 30 minutes subsequent to thiS
operation

II Notes
a The sealant should be used within

guaranty term mdlcated on the kit

441010 017310
case
FElll
FEll0 b Exposure of sealant to the skin may
Fig FE 14 Squeezmg sealant to cause a rash Wash sealant off the
Fill FE 13 Exhaust tube connectrons
Injector skin wIth water

8
FE
 Engine Control Fuel Exhaust Systems
Do not 15 to 350C
c
keep the sealant tube m a ture is from 59 to ture of over 400C I040F for a

place where the ambIent tempera 950 F If sealant becomes hardened loftg perIod of time
ture is 400C I040F or above because of low temperatures warm d read the instructIon
Thoroughly
A sealant hardened at 400C the sealant tube WIth lukewann sheet furmshed WIth the kIt before
1040F or above cannot be used water until the sealant is softened usirtg the sealant
The most sUItable Do not warm the tube at a
storage tempera tempera

FE 9
 SECTION SF

BOD Y
DATSUN
MODEL 610 SERIES

GENERAL DESCRIPTION 8F 2

UNDERBODY ALIGNMENT DF 5

BUMPERS DF 9

RADIATOR GRillE AND

DFI0
FRONT APRON
FRONT FENDERS DF tt

ENGINE HOOD AND COWL DF 12

TOP GRILLE

TRUNK LID DF 14
Sedan and Hardtop

TAil GATE
DF 17
Station wagon

DOOR DF 19

SEATS DF 31

WINDSHiElD GLASS
DF 35
AdheSIVe caulked glass

INTERIOR TRIMS BF 39

flOOR MAT AND

DF 41
CENTER CONSOLE

MOULDING DF 44

SPECiAl TOOLS BF 50
I NISSAN I

NISSAN MOTOR CO LTD

TOKYO JAPAN
 BODY

GENERAL DESCRIPTION

The 6J 0 model senes has three member reduces trans1TI1SSl0n of vibra door support roof rat and rear quar
Sedan tion to the floor panel ter are speCially remforced due to a
body types Hardtop and Sta
Under the
tIOn Wagon Each body IS of umtlzed coatmg IS applied to WIder door rnmenslOn
lower surface of the floor Also
construction and IS robust light and as
Body parts for the Sedan Hardtop
safe phalt seats are
placed on the upper and Station Wagon models are to a
The body has a long nose and short surface of the floor to reduce mtenor great extent IDterchangeable For m
deck The engme compartment IS WIde VIbration and nOise stanoe the hood front fender hood

enough to permIt easy accesslbdlty washmg mSlde the floor IS

For ledge front door and dash board for
On Sedan and Hardtop models the proVIded WIth water dram holes the Sedan exactly the same as
are

trunk has a
large capacity because of The front and rear ends of the body those for the Station Wagon
lowered spare tire compartment are constructed so as to absorb Impact Au and water tIghtness IS Improved

Insulation between the floor por energy durmg a crash around the door weatherstnps and
tlon and the shock absorber mountmg On model the front welded panel portions
Hardtop pIllar

BF420A

FIBF 1 Body constructIOn of the Sedan

BF 2
BOO

ef

He
of lhe
lslruchOJ
cOJ l
B 0 dy
Fig BF 2

3
at
BODY

BF422A

Fig BF 3 Body construction of the Station Wagon

8F 4
 BODY

UNDERBODY ALIGNMENT

CONTENTS

UNDERBODY GENERAL SERVICE TRAMMING SEQUENCE BF 5

INFORMATION BF 5 Sedan and Hardtop BF 6

BF 7
ALIGNMENT CHECKING PROCEDURE BF 5 Hardtop
PRINCIPLES OF TRAMMING BF 5 StatIon Wagon BF 8

CAR PREPARATION BF 5

It
UNDERBODY In the event of a colliSIOn IS
CAR PREPARATION
rrnportant that underbody ahgnment
GENERAL SERVICE be throughly checked and If neces Prepanng the car for the underbody
to the drrnen ahgnment check mvolves the follow
INFORMATION sary reahgned speclfted
mg
slons

There are many tools that may be 1 Place the car on a level surface
Smce each underbody component
employed to correct ColliSIon damage 2 The of the should be
duectly affects the overall strength of weight car

the body It IS essential that proper such as stralghtemng maclunes

frame supported at wheel locatIons

weldmg sealmg and rust proofmg

external pullmg eqUipment other 3 A VIsual damage mspectlon
standard body Jacks should be made to elrrnmate unneces
techmques be observed durmg service
To assist m checkmg ahgnment of
operations sary measunng ObVIously damaged
the underbody components repaIrIng or mlsahgned may often be
Whenever the body ISrepaired be areas

the 1TI1nor underbody damage or locatmg located VIsually

sure to proVIde repatred body
replacement parts the followmg
parts With rust proof

rust prooftng cntlcal under underbody dImenSIons and ahgnment

When
checkmg mformatlon are presented TRAMMING
body component It IS essential that a
good quality atr dry pnmer such as SEQUENCE
corrosIOn reSIstant zmc chromate be
The trammmg sequence WIll vary
used PRINCIPLES OF dependmg upon the nature and
Do combmatlOn
not use type TRAMMING locatIOn of the mlsahgned area Pnor
pnmer surfacers 4
BF
figures through BF 6 show to performmg any trammmg oper
reference locations reqUired to deter atIon the accuracy of reference
DUne the extent of 1TI1saIJgnment pre be used be deter
pomts to must
sent m underbody structure the re mmed A measurement that ongmates
ALIGNMENT ference locations are symmetncal from a reference pomt mcluded m a
CHECKI NG about the center line of the car damaged area Will produce untrue

PROCEDURE Trammmg underbody correctly results and confuse the evaluation of

the calls for two measurements the the underbody condition Unhke the
Mlsahgrtrnent m underbody
vertical dimenSIOn from the datum conventional type of frame deSIgn
affects the front fender door trunk
hd and wmdow ahgnments and also hne to the pomts to be measured the urntlzed type of body construc
the tall gate and rear body openIng and the honzontal distance between tlon seldom develops the condition of

a1Jgnments m the case of the Station any two pomts of measurement dIamond m the floor pan area as a

Note that precIsion measurement result of front or rear end collISIOn

Wagon Underbody mlsahgnment
partIcularly affects the suspensIOn can be made only when the trammmg Therefore underbody ahgnment
system thereby cauSIng vanous prob gauge IS parallel to the underbody check g can usually ongmate from
lems that anse from suspensIon mlS If one of the two reference pomts IS the body floor pan area If mspectlon
It IS essential that under the parallel plane mdlcates that these locatIons have
a1Jgnment m 1TI1sallgned area

body components be a1Jgned wltJun between the body and tram gauge may been disturbed and are not SUitable

the speClfted dtrnenslons given m not eXIst mdlcatmg the necessIty of for measunng one of the undamaged
FIgures 4 through BF 6
BF underbody repatr suspensIOn locations should be used

SF 5
 BODY

ponents should be ahgned progres

as an InItial reference pOIDt If a rare reference pOintS reparr operatIOns
body floor pan sIVely from this area
sltuatJon should eXist where all of should begm with the

these locations are not sUitable as area All other underbody com

Sedan and Hardtop

l
2
c

E
E

E
0

o
f o

S 3
c 0 0
c
o 0
c
E
c
c

g
c tl
i

JOlU O XV

tl

B
c
o

li

BF269A
l

Sedan and Hardtop

FIBF 4 Underbody allllnment

BF 6
 BODY

Hardtop
The body surroundmg the door followmg speclftcatlons The body distance between door glass and the
should be repaJred accordmg to the should also be repaJred so that the door surroundmg panels IS equal

No Measurement pOSItion Length mm ID

1 GtoH 1 0460 4118

2 GtoE 1 1372 44 77

3 FtoH 1 0905 4293

4 AtoD 902 2 35 52

5 DloH 9395 36 99

6 H toH 1 3360 52 60

7 B toC 1 5166 59 71

8 EtoE 1 3030 51 30

9 CtoG 1 281 5 5045

10 BtoC 903 2 35 56

11 CtoC 1 1160 43 94
I B
12 DtoD 1 1166 43 96

S 1
oJ
S
13

14

15
A toD

Eto F

FtoH
1

1
5163 59 70

033 0 40 67

1 374 I 54 10
84 3 31 OS
s
1 0
I 0
Tolerance error 1 2 mm 0 08 m

PomtC C D Ii

POlDt E E H H

1
l a

POlDt F G

BF409

FIBF 5 SIde body nment

all

BF 7
 tD o

00 Q Q
991 10
299
6 mm

J 9
face
lower
VOlt

soo panel
go Flo r

me br
floor

mstalhng
for 9843
28 74
Hole 500 74
2
6
122
886
1
1 76
3

dram
water 0685
for
174 2626 1034
Hole

supenIo
fronl
ter

mstalhng
for
cen
y

Bod
I

r
Hole 0

I lll
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lXl71lXl
 BODY

BUMPERS

CONTENTS

FRONT 8UMPER BF 9 REAR BUMPER BF 9

Removal BF 9 Removal BF 9
Installation BF 9 Installation BF 10

FRONT BUMPER Installation

I
Removal Install front bumper m reverse

sequence of removal notmg the

followmg pomt
Adjust bumper for proper ahgn
and
ment tIghten bolts secunng
bumper

REAR BUMPER

Removal
DIsconnect battery ground cable
I t
l
r
2 Dlsconnect WIre connectors of
1

lamp for license number plate It IS not

necessary to dIsconnect them for the

StatJon Wagon
BF423A I Front bumper 5 Fronl bumper stay Remove
3 bolts retammg rear
2 Front bumper side bracket 6 Body Side member
3 Shim
bumper stay to body SIde member and
7 Spnng nul
draw rear bumper out of body
4 Fron t fender 8 down
Tie hook

FIBF 7 Exploded view offront bumper

I DIsconnect battery ground cable 4 Remove bolts retatrUng front

2 DIsconnect front turn SIgnal
lamp bumper stay to body SIde ember and
wue connectors draw front
bumper out of body
3 Remove bolts retammg front
bumper SIde bracket to front fender
lower SIde

BF414 I Rear fender

2 Body Side member

Fig BF 10 RemOVing rear bumper

stay installatIon bolts

I Conneclor 2 1 Front bumper stay For the Sedan and Hardtop

2 Fronl apron It IS not necessary to remove rear
FIBF 8 Removmg front bumper
Side bracket mstallatlon BF 9 Removmg front bumper hcense number plate as It IS mstalled
Fig
bolt stay mstallatlon bolts to body mdependently

BF 9
 BODY

BF415

I License number plate holder

2 Hook
3 Rear bumper
4 LIcense number plate
5 Rear panel

FIBF 11 Exploded vIew of rear license number plate

Installation
Install rear bumper In reverse

sequence of removal

RADIATOR GRILLE AND FRONT APRON

CONTENTS

REMOVAL 8F 10 INSTALLATION SF 11

REMOVAL 2 Remove radiator gnlle attachmg

Remove front bumper screws and remove radiatorgnlle

tf
c1

I Spnng nut 3 Screw

2 Plam washer
BF279A
BF424A
Fill BF 13 Removmg upper attaching
screw and spring nut
FIg BE I2 Removmg screws attachIng radiator grrlle

BF l0
 BODY
3 Remove screws attaclung front
apron to front fender

Q
BF302A
c
Fill BF 16 Removmg screws attaching
front apron to hood lock
1 Spnng washer 3 Screw 1 stay
2 Washer
2
BF2BOA BF301A

Fill BF 14 Removmg lower attaching

INSTALLATION
FIBF 15 Removing attaching
screws
screw washer and
front apron to fender Install radIator grdle and front
spnng nut
apron ill reversesequence of removal
When mstallmg radiator grdle
proceed the followmg manners

I Install lower center attaching

screw first and then mstall other
screws

2 Be careful not to spIll brake

4 Remove screws attachmg front flUid engine 011 and any other

apron to hood lock stay and remove chemical flUIds on radIator grtlle to
front apron prevent from damage

FRONT FENDERS

CONTENTS

REMOVAL SF 11 INSTALLATIOON SF 12

I Spnng nut
2 Front fender I Open engme hood and support It
3 Baffle filler
m open pOSItion wIth a stay
4 Fender rubber
5 Front apron
2 Remove front bumper Side
6 Hood lock stay
7 flasher radIator grdle front apron
Sealing rubber
wmdshleld WIper blades cowl top
grllle and sill mouldings In the order

3 Remove fender attachmg screws

shown In the follOWing 1I1ustratlons

BF2alA

Fig BF 17 Exploded view offront fenders and apron

8F 11
 BODY

I
I
II

I Body sill
2 Front fender

BF423 1 Front fender FIBF 20 Removmg screws attachIng

2 Cowl top panel body sIll to front fender
BF422 lower end
FIBF 19 Removing screw attaching
cowl top panel to front fender
FIBF 18 Removmg screws attaching
hood ledge to front fender INSTALLATION
Instal front fenders m reverse

sequence of removal

ENGINE HOOD AND COWL TOP GRillE

CONTENTS

ENGINE HOOD SF 12 COWL TOP GRILLE AND

Removal SF 12 HOOD HINGE SF 14

Installation SF 12 Removal SF 14

HOOD ALIGNMENT SF 12 Installation SF 14

j
1

ENGINE HOOD Installation

Install hood m reverse sequence of
Removal removal

1 Open engIne hood and protect

body with covers to prevent scratch

to the paInt
HOOD ALIGNMENT
2 Mark hood hmge locations on Hood can be
adjusted by bolts
hood for proper remstallatlOn attachmg hood to hood lunge hood
BF425
3 Support engme hood wIth hand lock mechamsrit and hood bumpers
bolts attachIng
and remove bolts secunng hood hInge FIBF 21 RemOVing Adjust hood for an even fit between
hood
to hood Be careful not to let hood front fenders and for a flush fit WIth
when bolts are removed the front of fenders
slip 4 Remove hoOd from car

SF 12
 BODY

AdJJst hood accordmg to th

followmg procedures
I AdJust hood fore and aft and
from side to sIde by loosenIng bolts

attachmg hood to hmge and re

pOSltIomng hood
@
G @
BF42a

I Lock nut 3 Safety catch I Stopper 3 Hood lock stay

2 Hood lock male 2 Hood lock female part

hood lock male

FIBF 24 Adjushng Fill BF 25 AdJustmg hood lock
female part

Notes When lfISpectmg hood lock

note the follOWing

FIBF 22 AdJustmg bolts attachIng
hood
a OperatIon of safety catch lever
4 Lower engme hood I 0 to 3 0 Check caulkmg portIOn of safety
mm 0039 to 0 118 m from the top catch lever for wear
of front fender by adJustmg hood lock Check spnng for weakness and
male part breakdown If sprmg IS broken
2 Loosen hood bumper lock nuts hood untd
5 Raise two bumpers hood may be unlocked and open
and lower bumpers untIl they do not engme hood IS flush WIth fenders
contact WIth the front of hood when rapIdly dunng dnvmg
6 Tighten hood lock male part lock
hood IS closed b Operation offemale lever
after the proper has
nuts adjustment
Check female lever for smooth and
been obtamed
correct operation
7 Make sure that female lever locks Check spnng for weakness and
hood lock male part securely when breakdown If female lever does not
hood IS closed and also safety catch ve
smoothly engagmg stroke
retams hood properly when hood lock wdl be reduced and It may be
IS released See FIgure BF 26 from hood lock
dISengaged

i
t l i

FIg BF 23 Adjustmg hood bumper

height

BF448A
3 dJust hood lock mechanIsm
after hood has been properly ahgned
Hood lock male be moved fore
can

and aft and from SIde to Side to ahgn

It WIth hood lock female by loosen
I Grommet
mg attachmg bolts
2 Hood lock conlrol cable
Hood lock male can also be moved 3 Cable clamp UOIt mm m

up and down 4 Hood lock female part

Loosen lock nut of hood lock 5 Safety catch
male part and move It up and down by 6 Female body BF2B4A
turmng It clockwISe or counterclock
wISe as
reqUIred Fill BF 26 Exploded vIew of hood lock control

BF13
 BODY

COWL TOP GRILLE 4 Remove engme hood from hood 8 Remove hood lunge clamp pull
AND HOOD HINGE lunge hood lunge pm out of hoodhmge
5 Remove Wlndslueld
WIper blades bracket and remove hood hmge

Removal 6 Remove attaclung screws and

grommets wluch retam cowl top gnlle
Open engme hood
front end
Mark hood locations
2 hmge on
7 Draw cowl top grIlle forwards
hood
Cowl top gnlle can also be removed
3 e
Prot t body wIth covers to without removmg engme hood
prevent scratch to the pamt Installation
Install cowl top grille and hood
lunge m reverse sequence of removal

I Cowl top grille 5 Grommet BF431

2 Engme hood 6 Cowl top panel cap
3 Cowl top seahng rubber 7 Cowl top baffle plate
4 Screw

FIBF 27 Exploded view of cowl top grille

TRUNK LID Sedan and Hardtop

CONTENTS

TRUNK LID 8F 14 Removal and InstallatIon 8F16

Removal and Installation BF 14 TRUNK LID LOCK CYLINDER BF 16
Adjustment BF 15 Removal BF 16
TORSION BAR 8F 15 Installation BF 16
Removal BF 15 TRUNK LID WEATHERSTRIP 8F17
Installation BF 15 Removal and installation BF 17
TRUNK LID HINGE BF 16

TRUNK LID

Removal and
fenders 3 Support trunk Itd by hand and
installation
2 Mark trunk hd lunge locations on remove bolts attachmg trunk Itd to
Open trunk hd and cover rear trunk Itd for proper remstallatlon and remove trunk ltd
lunge

BF 14
 BODY

TORSION BAR

Removal
I Open trunk hd
2 Loosen screws attaclung trunk

room ftnIsher and remove the

fmlSher from the car
3 Support trunk hd m the open

posItion and draw end of left tOrsion

I
bar out ofthe hole drilled at Side panel
by hand
FIBF 28

4 Install trunk hd m reverse

4 Remove torsIOn bar from

sequence of removal
tOrsion bar bracket and hinge
5 Remove nght tOrsion bar m the

same manner above

Installation
Adjustment
I Loosen bolts attachmg trunk lid
to hinge and move trunk lid from
sIde to sIde and fore and aft to ahgn
It wIth stnker located on rear panel

BF436
I
BF433 1
II
Hole
Fill BF 29 AdJustmg trunk lid 1 I for torsIOn b31 end
2 TorSIOn bar bracket

1 3 Left torsIOn bar

4 Left trunk lid hmge
2 To obtam a snug ftt between
torsIOn bar
Fill BF 32 Installing left
trunk hd and weatherstnp move

striker up or down and from sIde to

SIde as requIred trunk hd the open
Support m

positIOn

2 PosItIon the end of nght tOrsIon

bar ftrst to right trunk lid hinge

BF437

BF434 TorSion bar 2 Trunk lid hlDge

Fig BF 30 AdJustrng trunk id Fill BF 33 Posltronmg the end of

lock striker rlllh t torsIon bar to hinge

SF 15
 BODY
3 TWIst torsIon bar backwards and

engage the bar m torsIOn bar bracket

CD @ CID
4 Then msert the end of tOrsion

bar mto the hole at Side panel

Note TensIOn of torsIOn bar can be

adjusted Operly
P by selectmg holes
for torsIOn bar end

BF443
I Lock cylinder 3 Clip
2 lnsulalor
BF440 I TorSIOn bar
2 Trunk lid hmge Fig BF 39 Component parts of
lock cylrnder
FIg BF 36 Removmg trunk lid hmge
clamp

I
BF43B

FIg BF 34 TWlBtrng torsIOn bar Installation

i 1 Assemble lock cyIJnder and
J J
t
msert and push It mtopOSItion untd
@ chp secures lock cyhnder
BF441

I Rear fender 3 Washer

2 Hmge clamp 4 Trunk lid hmge

FIg BF 37 RemOVing trunk id hmge

5 Install hmges m reverse

sequence
of removal
CID
I Right torsIon bar

2 TorSion bar bracket

BF426A
3 Holes for tOISlon bar end BF444
FIg BF 35 Insertmg the end ofright
TRUNK LIP LOCK FIBF 40 Pushmg lock cylmder
torsIon bar rnto the hole
Into posltlon
CYLINDER
5 Install left tOrsIon bar m the
Removal
same manner above
trunk hd
Open
2 Remove trunk hd lock from
trunk lid
3 Loosen screws
retammg cyhnder
and pull cylinder out of trunk lid

TRUNK LID HINGE

Removal and I

installation
I Open trunk hd and protect e
body with covers

2 Remove trunk hd
3 t lnwe tOrsIon bars

4 Pull
hlftge clamps out of nght BF442
and left
lunges and remove washers
Frg BF 38 Removrng cylmder
and hmges from the car attachmg screws

8F 16
 BODY

TRUNK LID WEATHERSTRIP Removal and

installation

I Remove weatherstnp from body

and Wipe remammg adhesIve away
from body with non lead gasohne and
then wash the surface wIth water

2 Coat body side and weatherstnp

with adhesive

3 After coatmg WIth adhesIve leave

It to dry for a h1Ie Install and press
the comers ftrst and then press the

other parts

BF445

I Trunk lid weatherstrip

2 Adhesive

3 Trunk lid
1

41 SectIOnal of trunk lid weatherstrip

FIBF view

TAIL GATE Station Wagon

CONTENTS

REMOVA AND INSTALLATION SF TAIL GATE LOCK AND

17
TAIL GATE ALIGNMENT SF 17 STRIKER 8F 18
TAIL GATE TORSION 8AR SF 18 Removal and tnstallatlon 8F 18
Removal and tnstallatlon 8F 18 Adjustment SF 18
TAIL GATE HINGE SF 18 TAIL GATE LOCK CYLINDER SF 18
Removal and tnstallatlon SF 18 Removal SF 18

Installation SF 18

REMOVAL AND
INSTAllATION
Open tail gate and support It m 3 Install tail gate In reverse

open posItion sequence of removal

2 Remove bolts attachmg tall gate
to tad and remove tall gate
gate hinge
from the lunge
TAil GATE
ALIGNMENT
Tad gate can be moved up and
down and from sIde sIde
to by
loosening bolts attachmg tall gate to BF 43
Fill Adjusting tall gate
up
tail gate Fore and aft adJ ust
lunge and down and from
ment IS obtaIned
by loosenmg bolts sIde to sIde

attaclung tad gate

hinge to body
BF446 I Tail gate Tail gate should be adjusted for an
2 Tail gale hlDge even and parallel ftt WIth the tail gate

Fill BF 42 Removmg tall gate opening

8F 17
 BODY

3 Remove tall
TAil GATE HINGE gate hmge cover

4 Remove head hmng rear portion

Removal and from taIl rall panel
5 Remove tOrsJon bars
installation
6 Loosen bolts and
attaclung hmge
I Open tall gate and support It m remove It
the open posItion 7 Install lunge m reverse sequence
2 Remove tall gate from of removal
hInge

TAil GATE lOCK AND STRIKER

BF 44 AdJushng tail gate
Fig Removal and installation
fore and aft

TAil GATE
TORSION BAR

Removal and l

installation
1 Open tail gate and support It In

open posItion
Loosen screws tail gate
2 attaching
lunge cover and remove It

3 Loosen head I Stnker 6 Shim

screws attachmg
2 Tab tail stnker 7 Down stopper 11 Tad gate striker
end and head
hnIng rear remove
3 FnctlOn plate catcher
BF450 8 Tad gate lock
hnIng rear portion from taIl rad 4 Shim 9 Lock cylmder 12 Sealing screen

panel 5 Bumper rubber 10 Cl1p 13 Tlul gate tnm

4 Support tad gate and remove left
tOrsIon bar paInted yellow fIrSt from
FIBF 46 Exploded view of tOil gate lock and striker
bracket D and c with a SUItable

pipe See 45
BF
Figure
I tad gate and support It Loosen bolts stnker
Open In 4 attaching
the open positIon and remove It
2 Remove screws attachIng taIl 5 Install tall gate lock stnker

gate trIm and remove tum and sealmg catcher and stnker m reverse

screenfrom taIl gate sequence of removal

3 Loosen
bolts attaching taIl gate
lock and remove the lock and stnker Adjustment
catcher from tail gate I Stnker catcher can be adjusted
from Side to Side and stnker can be
@ @
adjusted fore and aft Before adjust
Ing tail gate lock make sure that tad

gate IS properly ahgned

I Lefl torsIOn bar BF449

2 Tad gale hlDge

3 Rlgh t torsIOn bar
4 Pipe for removal and mstallal10n

FIBF 45 RemovIng torsIon bars

5 Remove nght tOrsJon bar m the

BF451 I Lock cylInder
same manner above 2 Tad gate lock
BF452
6 Install torsIOn bars In reverse 3 Stnker catcher
Fill BF 48 Adjusting striker catcher
sequence of removal BF 47 Removmg tail gate lock
FIg from Side to Side

SF 18
 BODY

down
3 Loosen stopper attaching TAl L GATE LOCK
bolts and move down stopper up or
down to ahgn It WIth stopper located CYLINDER
on both SIdes of tail gate
Then bolts
Removal
tighten attachmg
1 tad gate and support It
Open m

open pOSItion
2 Remove tall gate tnm and

seahng screen from tail gate

3 Pull out spring washer which
secures lock cyhnder to tail gate
outer panel Then remove lock cyl
FIBF 49 AdJusting striker fore Inder from tail
and aft gate

Installation
Install lock cyhnder In reverse

sequence of removal
After mstalhng lock cyhnder
contact between stnker make certam that tail gate lock
2 To adjust
and catcher loosen attaclung bolts and mechamsm and lock cyhnder are

move them as requned Fill BF 50 AdJustmg down stopper operated properly

DOOR

CONTENTS

REMOVAL AND INSTALLATION 8F 19 DOOR WINDOW GLASS AND

Front door 8F 19 REGULATORS 8F 22

Rear door SF 20 Front door

DOOR ALIGNMENT SF 20 Sedan and StatIon Wagon SF 22

DOOR TRIMS SF 20 Front door Hardtop SF 24
Removal SF 20 Rear door Sedan and Station SF 27
Wagon
Installation SF 20 REAR SIDE WINDOW GLASS

DOOR LOCK AND STRIKER SF 21 SF 28

Hardtop
Removal and InstallatIOn SF 21 Removal SF 29

Adjustment SF 21 Installation and adjustment SF 29

DOOR LOCK CYLINDER SF 22 SODY SIDE WEATHERSTRIP Hardtop SF 30

Removal and installation SF 22 Removal SF 30

Installation and SF 30
adjustment

REMOVAL AN D I Fronl door

INSTALLATION 2 Supporl

Front door
I Remove front radIator
bumper 3 Open front door and place a

gnlle front apron Wlndslueld Wiper

support under door Use pads be
blades cowl top gnlle and SIll mould tween door and a support to protect
mg m the order door
BF455
2 Remove front fender from the 4 Loosen bolts attachmg door lunge Fill BF 51 Removing bolts attachrrrg
vehIcle to and front door door hlTlge to body
body remove

8F 19
 BODY
5 Install front door m reverse 3 Loosen bolts attaclung arm rest

sequence of removal and remove It from door

Rear door

1 Open front door and keep It

open
2 Open rear door and place a sup

port under door Use pads between

door and support to prevent damage

BF460
3 Loosen bolts attaclung rear door BF457

hmges to center pillar and remove rear

door Fill BF 56 RemOVing bolts attaching

arm rest Hardtop
4 Loosen mSlde
screw attaclung
handle escutcheon and remove door
lock dial and escutcheon

BF456 II

BF45B
I Upper hmge
Fig BF 54 door lock striker
2 Rear door AdJustmg
3 Lower hmge
FIBF 57 Removmg mSlde handle
FIg BF 52 Removmg bolts attachrng Even If front fender IS not removed
escutcheon Hardtop
door hinges to center pIllar front door hmge can be WIth
adJusted 5
Door Remove spnng retammg re
AdJustmg Wrench ST08720000
gulator handle and then remove

regula tor handle and seatmg w sher

4 Install door 6 Remove door
rear m reverse chps retamlng
sequence of removal ftmsher from door mSlde panel and
remove door ftmsher

DOOR ALIGNMENT
Proper door
ahgnment can be BF459 1 Fronl fender
obtamed by adJustmg the posItion of 2 Fronl door
door hmge and door lock stnker 3 ST08720000
Door hmge and stnker can be FIBF 55 AdJusting door hinge
moved Fill BF 58 Removmg door fmlSher
up and down and fore and aft
m enlarged holes by loosenmg 7 Remove wa terhght seal cover
attachmg bolts Door should be DOOR TRIMS
from door panel
adjusted for an even and parallel fit
wIth the door opemng and surround Removal
mg body panels Open door and keep It open
Care should be taken not to 2 RaISe lock knob turn It counter Installation
dIstort or mar door or
surroundmg clockwISe and remove lock knob and Install door tnm m reverse

body panels grommet sequenoe of removal

BF 20
 BODY
WIth door glass up regulator II Install door lock mechamsm m

handle should be mstalled as shown reverse sequence of removal

m FIgure BF 59

Adjustment
Outside door handle
Outside door handle can be ad

Justed by turnmg door handle rod nut

L
L
clockwise or counterclockwIse

BF464 The proper clearance Tn between

Fill BF 61 RemOVing nuts attaching door lock lever and adJustmg nut IS
ousIde door handle below J 0 mm 0039 m See FIgures
BF462
8 Removmg remote control rod BF 66 and BF 68
FIBF 59 Installmg regulator handle from door lock cybnder

DOOR lOCK AND

STRIKER

Removal and
1 Lock sprmg
installation 2 Lock cylinder
BF46a I Door lock cylinder
door and 3 Remole control rod
Open keep It open 2 Adjusting nul

2 Remove door Fill BF 62 RemOVing remote control

arm rest mSlde
rod from door lock cylmder FIBF 65 AdJusting handle
handle escutcheon and regulator free play Front door
handle 9 Loosen screws attaclung door
3 Remove lock knob and lock and remove door lock from
grom
met door CD
4 Remove door ftmsher and water
s1ueld
5 Loosen mSlde
screws attachmg
door handle and
handle
6 Loosen screws
remove

attachmg
mSlde door

remote
fl1@
control and lock knob rod and then BF469

remove them 1 Outside door handle 4 Door loci lever

2 Remote control rod 5 Stopper
3 AdJusllng nul
FIBF 66 Adjusting handle
free play Front door
BF 63
Fill Removmg screws
attachrng
door lock

10 Loosen bolts attaclung door

lock stnker and remove stnker from
body

BF463

Fill BF 60 RemOVing mslde door BF470

handle Hardtop
I Oulslde door handle 2 AdjustIng nul

3 Remote control
7 Loosen nuts attachmg outsIde rod

door handle and remove outside Fig BF 67 Adjustmg handle

handle Fill BF 64 RemOVing door lock strIker free play Rear door

8F 21
 BODY
Do not bend door lock lever
to control rod to
DOOR LOCK
I connecting adJust
CYLINDER

Removal and
installation
BF471
I Remove door finIsher and water
I OutsIde door handle 3 Remote control
tIght seal cover
2 AdJustmg nul rod
2 Disconnect control rod from
FIBF 68 AdJustmg handle door lock
free play Rear door
cyhnder
3 Remove lock spnng secunng door
lock cyhnder to outside door panel
BF463
and then remove door lock
Inside door handle cyhnder
Fill BF 69 AdJustrng mSlde door from door
handle base fore and aft
To insIde door handle free Install lock
adJust 4 door cyhnder m

inside door handle base

play move reverse
sequence of removal
fore and aft m
elongated holes as
Door lock striker
required by loosemng attachmg
screws Door lock stnker can be moved
The free play should be adJusted from side to stde and up and down
below J 0 mm 0 039 m to ahgn with door lock latch

DOOR WINDOW GLASS AND REGULATORS

Front door Sedan and Station Wagon

@
@
@

Door glass 7 GUIde channel A 13 RetamlDg spnng

Ou ISlde door handle 8 14
Regulator assembly SeatlDg wlisher
Lock cylinder 9 Front lower sash 15 Regulator handle
Door lock assembly 10 GUide channel B 16 InSide door handle
Door lock sInker 11 WatertIght seal cover esculcheon
Rear lower sash 12 Door fimsher
BF473 @
FIBF 70 Structural vIew of front door S regulator and door lock mechanISm
a
g

SF 22
 BODY

8 Loosen
Removal and instaIIahon screws attachmg rear

lower sash and remove rear lower

Lower door glass sash
2 Remove arm rest regula tor
handle Inside handle escutcheon
door lock knob door fmlsher and

watertight cover

3 Remove door outside weather

stnp and door lock knob

4 Remove screws attachmg front
lower sash and remove front lower BF477

sash from door glass It IS not Fill BF 74 AdJustIng rear lower sash

necessary to draw front lower sash

out of door before removmg door
3 WIth glass up adJust glass m
glass BF476
5 Support door glass and remove parallel WIth the top rail of door sash
FIfl BF 73 RemOVing rearower sash
screws retammg gUIde channel B to by movmg gUIde channel A up and
glass back plate down The Sideward free play of glass
can be adJusted by movmg front
9 Remove front lower sash
lower sash fore and aft
10 Install door glass and regulator
In reverse sequence of removal

Adjustment
Doorglass ahgnment can be per
BF47B
formed by adJustmg front and rear
BF474 I GUide channel B
Front lower sash
lower sash and guide channel A Fill BF 75 AdJusting front lower sash
2
1 To obtam proper ahgnment of and gUIde channel A
FIg BF 7 I Removmg screws retamlng
guide channel B to glass back
glass temporarlly tIghten front and
plate and front lower sash rear lower sashes
2 WIth the up pOSItion GUide channel A
glass In
adJustments can
6 Draw door glass upwards and adJust rear lower sash from SIde to be performed as follows When door
remove It from door SIde to alIgn With glass and front glass IS as m pIcture 1 of Figure
lower sash RaISe and lower BF 76 move gUide channel A up and
glass to

assure a
good glass fit move It down for the pIcture 2
7 Loosen screwsttaclung gUIde
a

channel A and regulator base remove

regulator assembly and draw It

lower opening of door Q

through the
inSide panel
@

I I Bl B
BF479
I
I
BF475 1 GUIde channel A 1 2 I Door sash
2 base 2 Glass
Regulator

FIBF 72 RemOVing regulator Fill BF 76 AdJusling guide

assembly channel A

SF 23
 BODY

Front door Hardtop

1 Door glass 12 Door lock rod

2 Rear gUide rad 13 Fronl guIde rad
3 Ou ISlde door handle 14 Regula tor assem bly
4 AdJustmg nut 15 Inside door handle
5 Lock sprmg 16 Dust cover

6 Lock cyhnder 17 Waterltght seal cover

7 Door lock assembly 18 Door finIsher
8 Spacer 19 InsIde door handle
9 GUide channel B escutcheon
10 Rod holder 20 Door lock d13l
BF480 II GUIde channel A 21 Retammg spring
22 Regulalor handle

FIBF 77 Structural vIew offront glass regulator and door lock mechanl6m
Removal

I Lower door glass

2 Remove arm rest regulator
handle mSlde door handle escutch
eon door finISher and watertight
cover

3 Remove door outsIde mouldmg

4 Dnve out mner pm of cltp

retammg outsIde fmlsh and then

r I
I
remove retammg chp outside fmISh 8F483
8F482 1 Glass upper stoppers
I Door outSide finish
and outside weatherstnp from door
2 Door outSIde mouldmg Fill BF 80 RemOVing glass upper
3 Glass stoppeNl
4 Door flDlsh

Fill BF 79 Sectronal VIIW of door

outside and Inside weathers tripS 6 WIth glass m the full down

poSItion support glass

door and
remove screws a ttachmg glass back

plate to gUide channel B

8F481
5 RaIse door unhl glass upper
glass
stoppers appear the upper openIngs
m
Fig BF 78 DrIVing out mner
pm of outside finISh
of mSlde door panel and remove glass

retamlng clIp upper stoppers

BF 24
 BODY

then remove them

regulator base and
tmough the lower openmg of mSlde
door panel

BF4B4

Fill F 81 Removing attaching

screws BF488 Upper adju tmg bolls
glass back plate to gUide 2 Scale
channel B
FIBF 85 Ad ustlng gUide rail
RaISe door and draw upper ad ushng bolts
7 glass It

upwards
8 Loosen bolts BF486 1 GUide channel A
adJustmg front and
2 Regula lor arm base
rearg lIde rail and remove gUIde ralls
3 Regulalor base
from door CD @
Fig BF 83 Removmg regulator
assembly @
Installation and adjustment
85 0 105 10m
I Install regulator assembly gUIde
0 335 100413 10
door
ralls glass and door lock
assembly m reverse sequence of
removal I Door ou tSlde
BF489 panel
2 WIth door glass up temporanly 2 Glass
and lower bolts adJust 3 Door mSlde panel
tighten upper
mg gUide rail m the neutral
BF485 posItion FIBF 86 Proper clearance between
The neutral posItion for upper door outside panel and glass
Fig BF 82 Removing gUide raIl
ad ushng bolts adJustmg bolts means the center of the 4 Install door outside finIsh m

elongated holes For lower adJustmg posItion and make sure that door
bolt tighten It all the way and return
outside weatherstnp properly con
9 Remove screws a ttaclung gUIde DIne turns and secure lock nut at that
tacts WIth door glass when door glass
channel A regulator arm base and posItion IS raised and lowered
5 Raise door
glass to ItS full up
posItion and ahgn door glass With
body weatherstnp to obtam a water
tlgh t seal
Proper glass ahgnment can be
obtained by adJustmg gUIde rails and

gUIde channel A as shown m FIgures

BF 87 through
FIgure BF 91

BF4B7

I Upper adjUSlmg bolls

I
2 Spacer
II 3 Lock nul
4 GUide ra

5 Lower adjustmg boll

FIBF 84 GUide raIl ad ushng mechanISm BF490

Body SIde weather 3 GUIde I4

3 AdJust guide rad upper adJustIng face becomes 85 to IO 5 mm

slnp adjustmg bolls
bolts so that the clearance between 0335 to 0 413 m 2 GUide rail 4 GUide channel A

door outsIde panel and glass outside FIBF 87 Proper glass positIOn

8F 25
 BODY

glass and body sIde weatherstnp IS 0

to 1 0 mffi 0 to 0 039 m

o 10 I 0 mm 0 10 0 039 10

D aD

BF491
BF497 I Weatherstnp retamer

FIBF 88 When moving to front 2 Glass gUIde

3 Door glass

FIBF 94
BF495 Proper clearance between
glass and glass guIde
Fill BF 92 Proper glass clearance
when glass stoppers are secured 10 Raise and lower door glass to
m pOSitIOn
be sure the operation of regulator
handle smooth The operattrtg force
IS

of regulator handle should be per

formed less than 4 kg 9 Ib at the

knob of regulator handle

liD 7 glass up move top edge of
With If proper operating force IS still
glass to
body side weatherstnp to not obtamed adjust regulator
BF492
obtam a tight seal by adJusting gUide mechanism to the followmg
accordmg
FIg BF 89 When movIng to rear
ralllower adJustmg bolts evenly
procedures
Turn lower adJustmg bolts clock I Lubncate gUide rollers gUIde
wISe to release top edge of glass from rails and regula torlinkage
body SIde weatherstnp and counter 2 Perform outSide and mSlde door
clockwISe to tight weatherstnp to door glass adJustment
3 AdJust gUIde rails m parallel
8 Make sure that top edges of glass
mamtam a tight fit evenly at the
POSItiOns shown Figure BF 93
m

BF493

90 When moving front up

FIBF

BF49a

Frg BF 95 Improper Side VIew of

gUIde rails

BF496

FIBF 93 Checking pOSItIOns for

a light It
11 Make certam that the location
ClI of upper glass stoppers IS ahgned
properly If necessaryadjust them
BF494 12 Install outSide door ftmsh and

Fill BF 9I When movmg rear up mouldmg

13 Install watertight seal cover and
9 Make certam that the clearance door fmlsher
between the top of glass and the end 14 Install and
arm rest regulator
6 Raise of glass gUIde IS 0 to 0 5 mm 0 to handle m pOSitIon
glass to Its up posItion
o 020 Just before door glass 15
adjust upper glass stoppers so that m con Install door lock unlocked
of tacts door SIde weatherstnp With dial red mark
the clearance between the top facrng

SF 26
 BODY

Rear door Sedan and Station Wagon

@
@
j

111

q
o

BF499

I Door glass 9 Front lower sash

2 Rear sash 10 Inside handle esculcheon
3 Ou tSlde door handle 11 Walerl1ght seal cover

4 Door lock assembly 12 Door fimsher

5 Door lock stnker I3 RetalOlOg spnng

6 GUide channel A 14 Sea tlOg washer

7 Regulator assembly 15 Regulator handle
8 GUide channel B

Fill BF 96 Structural vIew of front door glass regulator and door lock mechanism

Removal
Lower door glass 6 Remove rear sash and front
2 Remove door lock knob and lower sash from door

grommet
7 Loosen
3 Remove arm rest regulator screws attaclung gUIde
handle mSlde handle escutcheon channel A and regulator base remove
door ftmsh and watertIght seal cover regulator assembly and draw It
from door through the lower opemng of door

4 Remove door outSide weather mSlde panel

stnp and rear sash BF500 I Rear sash

5 Remove screws attachmg gUIde 2 GUIde channel B
channel B to glass back plate and FIBF 97 Removmg screws attachIng
draw door glass out of door sash and channel B
rear gUIde

8F 27
 BODY

Adjustment To
adJust the sIdeward free play of
door glass move rear sash fore and aft
Properglass ahgnment can be
obtained by loosenmg lo er attachmg screw
by adJustmg front lower
Tilt adJustment of glass can be
sash rear sash and gUIde channel A
Front lower sash must be adjusted m performed by movmg gUIde channel
A up and down
parallel wIth rear sash by movIng
from sIde to side

BF501 I GUide channel A

2 Regulator base

FIBF 98 Removmg regulator

assembly attachmg screws

BF503 Rear sash

8 Install regulator assembly and BF502 1 Front lower sash
2 GUide channel A
door glass m reverse
sequence of re 2 A ttachmg screw

Fig BF 100 AdJusting rear sash

moval
Fig BF 99 AdJushng front lower sash and gUIde channel A

REAR SIDE WINDOW GLASS Hardtop

1
1

I
I

BF504

I SIde wmdow glass

2 GUide plate adJuslmg bolts
3 GUide roller
4 Regulalor handle
5 Relammg sprmg
6 Regulator assembly
7 Doollock sInker

Fill BF 101 Structural vIew of SIde Window glass and regulator

SF 28
 BODY

Removal Installation and

1 Remove rear seat cushIOn and watertIght seal cover adjustment
6 Remove finIsher Install wmdow
rear seat back from body draughter I glass and regula
7 Remove belt
2 Remove seat belt
anchorage If seat anchorage If tor assembly m reverse sequence of
equipped and klckmg plate eqUIpped on rear quarter panel removal
Lower sIde wmdow glass Remove 2 WIth
Window glass down tem
3 8 chps retammg rear
4 Remove ftnlsher and
arm rest regulator corner remove rear corner poranly tighten gUIde plate adJusting
handle ftnlsher bolts In the neutral posItion
5 Remove
Remove rear sIde fInisher and 9 Inner seal and bracket The neutral posItion means the
center of the elongated holes
TIghten these adJustmg bolts all
the way and return eight turns and
secure them at that posItIon
3 Adjust gUIde plate upper adJust
Ing bolts to obtain 8 5 to 10 5 mm

0335 to 0413 m clearance from

rear fender to wmdow glass outsIde
face
4 Install rear fender finish In

position and make certam that

wmdow glass properly ahgned wIth

OAf
IS

weatherstnp when wllldow glass

moves up and down
5 Close front door and raIse door
BF505 I Draughler fmlsher 3 Retammg cbps
2 4 Inner glass and Side wmdow glass
Rear corner fJnI er seal
6 AlIgn SIde wmdow glass wIth
FIBF 102
door glass and body SIde weatherstnp
by adJusting gUide plate adJustmg
bolts according to the follOWing
m FIgures BF 104
procedures through
BF I07

BF507 1 Door s
gla
2 Side wmdow glass
3 GUide plate adju tmg bolt
BF506 I
to
FIg BF 104 When movmg front
2
3

10 Raise glass until regulator

bracket appears m the upper openmg
of insIde panel and support glass and
remove attaching regulator arm
nuts
arm
plate
12

panel
Raise wmdow
and remove

senger compartment
13
glass with

them toward pas

gUide JO CID
bracket to Side wmdow back plate Remove regulator base attach
II Loosen lock nuts of gUide plate and draw
Ing screws regulator as

upper and lower adJustmg bolts sembly out through lower openlftg of BF508

Remove adJustmg bolts from gUide trlSlde panel FIBF 105 When moving to rear

BF 29
 BODY

handle
See Door glass adJustment for
detalls
12 Install rear corner fmlsher and

draughter ftnIsher
13 Install seal and
watertight cover

door fmlsher
14 Install arm rest and regula tor
handle BF514

BF509 15 PosItion door outSIde flmsh and I Roof

dnp mould 109 4 Wmdow glass
with and 2 WealherstIlp relamer 5
WealherslIlp
FIg BF 106 When movrng rear up secure It chps
retammg seal retaIner
mstall door outSide mouldmg 3 Body Side weatherslIlp 6 Body SIde welt
16 Install klckmg plate and seat
FIBF III SectIOnal view of body
belt anchorage If eqUIpped

JO
Side weatherstrip retamer seal
17 Install seat back and cusluon and body sIde welt

Installation and
BODY SIDE
WEATHERSTRIP
adjustment
em em 1 Temporanly attach
weatherstnp
Hardtop retamer seal to weatherstnp retamer
with an adheSIve
BF510 Removal 2 PosItion weatherstnp retamer and
Fill BF 107 When movmg rear down I Remove nvets retammg body retamer seal and temporarily tighten
SIde weatherstnp to front pJllar attachmg screws

7 WIth wmdow
glass up adJust 3 Make sure that weatherstnp re

gUIde plate adJustmg bolts so that tamer IS Installed the posItIon as

m
clearance from wmdow glass to sIde
shown m Figure BF I12 and measure
wmdow weatherstnp IS 3 0 to 5 0 mm
the clearance from body SIde flange to
0 118 to 0 197 shown
m as m
Figure weatherstnp retamer at the pomts of
BF 108
shown m
a
through d as
Figure
BF II 3 Proper clearance IS 13 mm
CD Room
05Im

Room
BF512 I RlVel 2 WeatherslIlp

FIBF 109 Removmg body side

weatherstrip retarnlng rIVets

I Weatherslnp weath
2 Remove screws mstalhng
2 Door glass
erstnp retamer to roof Side rall
3 SIde wmdow glass
BF511 DOlt mm 10
BF515

Fig BF 108 Proper clearance from

Wealherslnp 2 Wealherslnp retamer
wmdow gloss to weatherstrip relamer seal 3 Side flange

Fill BF 112 Proper positron of

8 AlIgn wmdow glass wIth body
weatherstrIp retarner
sIde weatherstnp to obtam a tight
seal by adJustmg gUIde plate lower

adJustmg bolt See Door glass adJust

ment for details

9 Install mner seal and bracket

10 Install rear fender ftmsh BF513

J I Install regulator handle and FIBF 110 RemOVing attachrng

raise and lower wmdow glass to be screws ofweatherstrzp retainer

sure operation of the handle IS 3 Remove front pillar garmsh and

BF516
smooth The
operatmg force of the then remove body SIde welts
FIg BF 113 Measuring pomts of
handle should be adjusted less than 3 4 Remove weatherstnp retamer and
weatherstrip retamer to slde
7 Ib at the knob of the handle
kg retamer seal flange clearance

SF 30
 BODY

weatherstnp 6 Install front and

4 Tighten weatherstnp attachmg tered on retamer pillar garrush
5 Install Side bod y SIde welts
screws everily until the tJuckness of body weatherstnp
retamer seal IS I 5 mm 0 059 m Weatherstnp should be mstaIled
Make sure that retainer seal IS cen everily Without stretclung It

SEATS

CONTENTS

BF 32 REAR SEAT Station Wagon BF 32

FRONT SEAT
Removal and installation BF 32 Removal and installation BF 32

REAR SEAT Sedan and Hardtop BF 32 SEAT BELT ANCHORAGES BF 32

Removal and installatIon BF 32 Installation of child restraint 8F 33

anchorages

BF517

1 Reclinmg deVice assembly

2 ASSistant seat assembly
3 Seat slide embly
as

4 Front scat brackel

5 Seat slide release wire

6 Dnver seat assembly

deVice
FIBF 114
Structural view offront seat seat slide and reclmmg

SF 31
 BODY

FRONT SEAT REAR SEAT

Sedan and Hardtop
Removal and
installation Removal and
1 Remove bolts attachmg front installation
seat bracket
I Remove screws attachmg rear seat

front end and remove rear seat

cushIon
2 Remove screws
attachmg rear

seat back and move rear seat back

and then It from
upwards remove
BF521
body
3 Remove screws attachmg head FIg BF lIB RemOVIng rear seat

restramt and remove head restramts hinge attachIng bolts

J
2 Remove rear seat back from
catcher and lunge
3 Remove rear seat back catcher
and hmge bracket from body
4 Install rear seat cushIOn and rear

seat back m reverse sequence of

nuts from removal

2 Remove rear attachmg
beneath the floor

head restramt
FIBF 117 Removmg
attachIng screws

4 Install rear seat cushIOn rear seat

back and head restramts m reverse

sequence ofremoval

SEAT BELT
Fig BF 116 RemovIng attachmg nuts ANCHORAGES
REAR SEAT Station
offront seat bracket
Wagon The seat belt
anclJorages are as
shown FIgures BF 1l9 through
m

3 Rechnmg devIce Removal and BF 122 FIgures BF 121 and BF 122

Removerechnlng deVIce cover and are the mstallatJon
prooedure of the
installation seat belt anchorages for the chdd
remove screws attachmg reclmmg
device to seat and then remove TlIt rear seat cushIOn forwards restramt

rechnmg device and bolts The seat belts should not be

remove attachmg rear seat m
4 Install front seat assembly m
hmge and then remove rear seat stalled on any other posItions except
reverse sequence of removal cushion those deSIgnated

SF 32
 BODY

Sedan and Station Wagon Hardtop

Front side anchorage
Frontside anchorage
Attachmg through anchor
Attaching Ihrough anchor

Retractor

Front floor mner anchorage

BF901A

BF900A
FIBF 119 Front seat belt anchorages

Sedan
Hardtop
Rear floor center Rear floor outer anchorage
anchorage nght

Rear floor lOner anchorage

Rear SIde anchorage

I
Rear floor outer anchorage
Rear floor center anchorage left Rear floor center anchorage left

BF902A

Rear floor tnoel anchorage

BF903A

Station Wagon
Rear SIde anchorage

Rear floor center anchorage

Rear floor outer anchorage

Rear floor lOner anchorage

BF904A

Fig BF 120 Rear seat belt anchorages

SF 33
 BODY

Installation of child restraint anchorages

Rear parcel shelf

Sht
jr 3 shts placed as shown

lJ
Child res traint anchor plate
Forward

5 16 18 UNC bolt

Fmlsher parcel shelf 1 8 mm thick Press down the mSlde of sht cncle
WIth your thumb or screwdIlver

Panel parcel shelf 0 9 mm tluck

Remforce I 6 rum thIck Tighten

5 16 18 UNC boll

Weld nut 5 16 18 UNC 28

t
BF905A

Sedan and Hardtop

Fig BF 121 Child restramt anchorages

8F 34
 BODY

Chlld restraml

Rear seat

Child restramt anchor plale

Forward

5 16 UNC bolt

Rear floor carpet

Rear floor panel

09 mm duck

1st bolster panel

I 2 mm duck

Tighten Weld nut 5 16 18 UNC 2B

BF906A

FIg BF 122 Child restramtanchorages Station Wagon

WINDSHIELD GLASS Adhesive caulked glass

CONTENTS

DESCRIPTION SF 36 INSTALLATION SF 36

REMOVAL SF 36 REPAIRING LEAKS SF 38

SF 35
 BODY
7 From mSlde car push glass up
DESCRI PTION and out ofwmdow openmg

pre mixed one part sealant

A IS 8 USing a ra20r blade or sharp
to cement remove caulkmg matenal
avadable as a servIce part scraper
wmdshleld glass to wmdow opening along entlfe edge of wmdow opernng

After usmg this sealant the car should leaVIng It about I to 2 mm 0 04 to

be allowed to stand Idle for about 24 008 m tluck

hours to allow sealant to cure

BF291A

Fig BF 125 StrIpplllg dam

5 With a sharp cuttmg kmfe cut off INSTALLATION

matenal along edge of entue
caulking 1 Check mouldmg for nussmg re
Window openmg
tamers

2 Clean contacting face of body

WIth noruead gasolme
Note Do not allow oil grease or

water to get on cleaned surfaces by

1 Sealant Silencer
T touching with dirty band or fouled
2 stud Wmdshleld glass
3 Spacer Dam sealant tool
4 Iastener rubber
I Gla
5 Wmdshleld 9 Wel1 3 Install four spacers on wmdow
2 Cut by kmfe
moulding BF450A 3 AdheSive caulkmg matenal opernng
BF479A
FIg BF 123 Sectional offront
view
@
adhesIVe caulked glass FIg BF 126 Cu ttlng off adhesIVe

caulkIng materwl
REMOVAL
6 The may also
J Protect hood front fenders followmg procedure
be used In removmg rear wmdslueld
mstrument panel and front seats WIth
covers 1 Usmg a kmfe cut through part
2 Remove wmdshleld wIpers front of caulkmg matenal

pIllar garnish garnish and

mstrument 2 Secure one end of steel musIc

welt Front wmdshleld glass Remove WIre 05 mm 0 020 m dlllmeter to

rear corner ftnlSher rear parcel shelf a

piece of wood that can serve as a
I Spacer A 180 mm 70910
fmlsh welt Rear wmdow glass handle 2 Body center hoe
3 Usmg a putty knIfe or sl1TI1lar Usmg long nose lplnserlerst other
Fill BF 128 Location of spacers
tool pry mouldmgs out of posItion end of wire through caulkmg matenal Front
startmg at the oenter and workIng at edge of glass then secure that end
toward the ends of wue to another wood handle
3 WIth the aId of an assIstant

carefully pull wife through caulk

cut

Ing matenal around entue penmeter of

WIndow usmg a sawmg motion

r
v
BF290A 140 mm 55110

Fill BF 124 RemoVIng mouldlllg

Spacer A
BF529 2 Body center lUte

BF328 FIf1 BF 129 Location of spacers

4 from mSlde stnp
Reachmg car
Rear
dam from around wmdow glass FIg BF 127 Cuttmg sealant

8F 36
 BODY
7 Install dam tape to mSlde of B SlIlcone glows WIth little or

Wlndslueld glass 8 mm 03J m m no flame and emits wlute smoke

board from of and cut off and very httle odor Burnt reSI
edge glass
excess at ends due is white ash
G
b AiIow primer to dry for 10 to IS
6 0 24 then
mm m
1TI1nutes proceed to the next
A 8 mm 0 31m
Spa er
step

9 Insert cartndge m Caulkmg Hand

BF530
Gun ST088 JOOOO and place smooth
BF 130 Installing g S8 on continuous bead on glass 10 mm 0 39
Fill spacer
m thIck

Notes

Glass a Cut off nozzle end of cartridge as

shown
4 There are two water dram holes BF292A
PIerce sealmg film with a needle
m the bottomedge opemng
of body Frg BF 133 Installmg dam
In applymg caulkmg matenal use care
Install cartridge in hand gun
not to plug these two holes 8 WIth a
apply a hght coat
sponge
5 To set glass m proper pOSl lon m of pnmer to ongtnal calkmg matenal
two pIeces of on wmdow openmg
wmdow opemng paste remaJmng flanges t

maskmg tape at the center top and t

bottom of glass and panel for align
Notes
ment
a It IS not necessary to apply pnmer
7 mm O 28m
to old sealant in replacing glass that 8 mm O 31m
once has been repaired WIth I part
sealant silicone
Identification of old adhesive 1Iia BF293A

teriaI is accomplished as follows

Fill BF 135 Cutting nozzle
1 Cut a small piece of excess ofcartrIdge
sealant from glass or window
opening flanges
2 Stick small piece of sealant on b Sealant starts to harden IS minutes
after It i wmdow
the end of a kmfe or the like IS apphed e glass
BF331 and then hold sealant over flame should be Installed body wlthm
In

of match until it IS minutes after applying sealant

or hghter
Fill BF 131 Allllnmg gloss In WindOW
tgnlles JO wmdslueld WIth
opening Support glass
A Polysulfide burns of while Sucker ST08800000
smoke or no smoke at all and its 11 PosItion wmdshleld glass In
odor IS of whIte smoke or no the
6 Clean surface where the opemng align prevIOusly placed
glass smoke taIl and Its odor very
and dam wIth
a IS
maskmg tape and make sure that glass
sealant IS to be apphed sulfur m
objectionable heavy IS properly set on spacers located at
non lead
gasoline as shown m Figure oxide the glass opening flange
BF 132

ST088 10000
A A
Sec
BF531 BF333

Fill BF 132 Cleaning area ofglass Fill BF 134 Applymg adheSIVe caulkmg

BF 37
 BODY

obstruct A label
not visibilIty
notJrtg the fact that seahng will be CAUTION
impaired If door IS opened or closed
wIth wmdow shut before sealant LEAVE ONE WINDOW
OPEN SLIGHTLY
has dried is furnished WIth the kit
FOR THREE DAYS
b Advise the owner that car should
Thill 0 protiC our n Wlndlhllld
not be dnven on
rough roads for tnstollotlon from pr uur Induc d
I au for the rubb r 1101 hOI com
ST08800000 the tIme belrtg Yukonlud
ple ly
8F334

FIg BF 136 Installmg glass Reference Penod for sealant

reqUIred
to dry to deSIred hardness Fill BF 137 CautIOn label
12 Push to aid
glass m
seatmg on

plate
l3 Umt days
WIpe excesscaulkmg matenal
off T studs edges of glass and body
14 Remove protecttve covers

15 Water test trnmedIately usmg a

90 50 25
cold water spray 0

Do not duect stream of water at

Temperature oC F

fresh adhesIve matenal Allow water to

25 77 I 5 25 6
splll over glass If leaks are
edges of
encountered use Caulkmg Hand Gun
lO 50 3 53 lO
to work m addItIOnal caulkmg matenal

at leak pomt lO 14 lO 17 34
J6 Install all preVIously removed

parts

Notes
REPAIRING LEAKS
a After Installmg attach cautIon label
to glass surface Be sure that It does Leaks can be repaired Without re mOVIng and follows
mstalhng glass as

J
t

Work mlo jomls

8F335

Fill BF 138 AdheSIVe caulked glass leak repair

I To leaks ftrst
stop remove 2 Mark locatton ofIeak pushing the glass outwards
mouJdmgs m area of leak It may be Apply water to leak area while
Note H water is
leakmg between
necessary to remove garnIsh mouldmg pushmg on the glass Mark the
cauIkirtg material and
body or be
or ftnIShmg lace to Isolate cause of the extent ofleak point
tween glass and caulkmg material
problem determme the extent of leak by

BF 38
 BODY

INTERIOR TRIMS

CONTENTS

FRONT PILLAR GARNISH 8F 39 Removal and installation Sedan 40

BF

Removal and installation 40

8F
Removal and installation BF 39 Hardtop
CENTER PILLAR GARNISH 39
BF REAR PARCEL SHELF 40
BF
o

Removal and Installation BF 39 Removal and installation 40

8F

REAR DOOR GARNISH BF 39 HEAD LINING 41

8F

Removal and installation BF 39 Removal 41

8F

REAR CORN R GARNISH 40

8F Installation 41
BF

2 Install front pillar garnish m 3 Install center pillar garnIsh ill

FRONT PILLAR reverse sequence of removal reverse sequence of removal

Removal and
installation
front at
I Remove pillar garnish
tachmg screws ana then remove the

garnISh from front pillar

Be careful not to bend the lower lip
REAR DOOR
of the garnIsh shown ill FIgure
BF l39
GARNISH
Removal and
installation
CENTER PILLAR I Remove screws
attachmg rear

GARNISH door garnISh and remove garnish from

door sash

Removal and
installation 2 Install rear door garrnsh m re

1 Remove body Side welts which verse sequence of removal

BF532 are mstalIed to center pdlar flange
Fill BF 139 Removmg front pIllar
2 Remove center plllar garnish
garnISh from center pillar

@
Secl10n A A

BF533

I Body Side welt

2 Center pillar garmsh

Fill BF 140 Removmg center pIllar

garnISh

SF 39
 BODY

r D

@
I

lu j
4
I
2
3
Rear door garmsh
A ttachmg

Plale spnng
Urethane form
screw

BF534
Secl10n A A

Fill BF 141 Removrng rear door garnISh

REAR CORNER 3 Install rear corner garnish m ter ftnlSh and remove draughter fmlsh
reverse
sequence of removal
GARNISH
2 Remove chps retalnmg rear

corner
garnish and then draw rear

Removal and Removal and corner garnish forwards

installation Sedan installation Hardtop
I Remove screws attachmg draugh
Remove body side welt which IS

Installed to rear corner

flange

2 Remove chps retammg rear

corner garnIsh and then remove rear

corner garnIsh

m
I Draughler fmlsh 4
@
Vmylleather

AJ 2

3
Side wmdow glass
Inner seal
5
6
Urethane form
Hard board
Secl10n A A

BF536

FJ8 BF 143 RemOVIng rear corner

J garnISh

3 Install rear corner garnish m

@ reverse sequence of removal

ID
@
Secl10n A A Secl10n B B

REAR PARCEL C
Rear parcel she f
BF535
SHELF

Of
I Draughter fimsh o 0

2 Welt Removal and

3 Hard board
4 Urethane form installation o

I
5 Vmylleather I Remove rear seat cushion and BF537
6 Retammg cbp
rear seat back Fill BF 144 Removmg rear parcel
7 Rear wmdow glass
2 Remove shelf
chps retammg rear

Fill BF 142 Removing rear corner parcel shelf front end and remove 3 Install rear
parcel shelf In reverse

garnISh rearparcel shelf pulling It forward equence of removal

BF 40
 BODY

HEAD LINING

1 Rear corner garm h assembly

2 Front and rear Windshield welt
3 rronl roof Insulator
4 Redr roof Insulator
5 Rear wmdow welt retaIner
6 Listing wire hook
7 Head IID1ng listing wire

8 Head lining cloth

9 rront Window welt retamer

Fill BF 145 Structural VIew of

head lmmg Hardtop

Removal 6 Remove front pillar garnIShes b Wrinkles can be removed by

7 Remove center plllar garnIShes prylftg Imlng ever
along Immg
I Pull break away type mSlde rear 8 Remove rear corner garnIshes wire
VIew mirror out of bracket and remove
9 Remove the end of head IJnmg
mSlde rearvlew mirror bracket cloth from roof rails 3 Cement the end of head Immg
10 Remove head IInmg IIstmg while
to body flange pullIng It down
WIres from roof ralls and remove at SIdes to remove wrmkles
head hnIng from roof 4 Trtrn the rernammg head l nIng
to proper sIze

Installation Note In trim1TI1ng at front pdlars

I
center pdlars and rear quarter
Apply a tnm adheSIve to body should be taken to
panels care

flange and other body parts before reserve

enough material smce head
mstalhng head hnIng be touched at these
hrnng must
2 Startmg at front and proceedmg
parts
BF134 toward rear or VIce versa mstall hstlftg
wtres 5 Cut hole the head
Fill BF 146 RemOVing mslde back a m IImng
mirror matenal for room lamp and mstall
2 Remove sun vISors Notes room lamp assembly
3 Remove room lamp a All fullness must be removed by 6 Installbody Side welts to body
4 Remove assist straps front and
stretchmg rear listing flang s and other eqUlpments m

5 Remove body sIde welts WIres posItion

FLOOR MAT AND CENTER CONSOLE

CONTENTS

FLOOR MAT 42
8F Removal and installation 42
BF

Removal and installation 42

BF INSTRUMENT PANEL 43
BF
CENTER CONSOLE 42
BF Removal and installatIon 43
BF

8F 41
 BODY

FLOOR MAT

BF539

I Fronl floor mal

2 Center floor mal
@ 3 Rear floor mat
4 Rear seat lower mat

5 Front floor felt

6 Rear floor felt

Fill BF 147 Structural view of

floor mat

2 Remove floor felts from floor

Removal and Removal and
3 After removmg center console
installation installation
remove center floor mats and felts

I Remove floor mats from 4 When mstallmg attach floor felts

hooks and floor to floor WIth adhesive and mstall I Remove transrmsslOn shtft lever
retammg remove a

mats floor mats and center console knob

2 Remove screws attachmg rear

console and remove rear console

3 Remove front console to package
CENTER CONSOLE tray attachmg screws and SIde at

taclung screws and then remove front

console
4 Install front and rear console m

reverse sequence of removal

I Fron I console
2 Rear console
BF295A

Fill BF 148 tructural view of center console and brackets

8F 42
 BODY

INSTRUMENT PANEL

tl

I Instrument garmsh
2 Instrument panel assembly
3 Clus r lId cover BF296A

Fllf BF 149 Structural vIew ofmstrument panel

6 Remove mstrument garmshes

Removal and from mstrument panel
installation
7 Remove cluster lid over

Instrument panel assembly 8 Loosen bolts attachmg Instru

I DIsconnect battery ground cable ment panel and draw mstrument panel
assembly out backwards
2 Remove horn bar steenng wheel
and shell assembly
Connector
Remove control cable 2 Hood lock lever
3 heater
from heater assembly FIg BF 151 DISconnectIng mstrument
clamps
harness connector

Ii
tj
I
1
p

BF542

Fill BF 150 RemOVIng heater control

cable clamps

4 DISconnect speedometer cable

behmd speedometer
BF298A
5 DISconnect body and mstrument
harnesses at a connector Fill BF 152 RemOVing Instrument panel attachIng bolts

8F 43
 BODY

9 Install Instrument panel assembly 2 3 Install cluster hd A m reverse

m reverse sequence of removal sequence of removal

Cluster lid

I Remove steermg column shell

and cluster hd cover It IS not

necessary to remove steenng wheel

2 Remove speedometer cable from Cluster lid B
back sIde of speedometer I Disconnect cable
battery
3 Loosen screws attachmg cluster
2 Remove steenng column shell
IJd and draw cluster IJd out back
assembly cluster hd cover cluster hd
wards
and heater control knobs

3 Remove heater
screws attaclung
control to cluster hd B
assembly
4 Remove screws cluster
S BF299A
attaclung
hd B and remove cluster lid B from
FIBF 154 RemOVing cluster l d A
mstrument
retaIning screws panel

BF545

Fill BF 153 Removmg cluster

I d attaching screws

4 DISconnect related wire harnesses

from back side of meters

5 Install cluster hd m reverse

sequenoe of removal

BF300A

Cluster lid A
I Remove column shell FIBF 155 RemOVIng cluster Id B
steenng attachmg screws
and cluster lid cover 5 Install cluster hd B m reverse sequence of removal

MOULDING

CONTENTS

FRONT WINDSHIELD MOULDING 46

BF Removal and installation 47
BF
Removal and installation 46
BF ROOF DRIP MOULDING 48
BF
REAR WINDSHIELD MOULDING 46
BF DOOR SASH AND CENTER PILLAR
Removal and Installation 46
BF COVERS 49
8F
SILL MOULDING 46
8F REAR PANEL AND TRUNK LID

Removal and installation 47

BF MOULDINGS 49
BF
DOOR MOULDING AND FINISH 47
BF Removal and installation BF 5O

8F 44
 BODY

BF54B

I Front windshield mouldmg

2 Rear wmdshleld mouldmg
3 Roof dIlp mouldmg
4 Sill mouldmg
5 Door outside mouldmg
6 Door outSlde finisher
7 Center pillar cover
8 Door sash cover

FIBF 156 Mouldings of the Sedan

CD

BF549

I Center pillar cover

2 Roof dIlp mouldmg
3 Sill mouldmg
4 Body outsIde mouldmg
5 Body ou tSlde fimsher

FIg BF 157 Mouldrngs of the Stahon Wagon

CD

BF550

I Front wmdshleld mouldmg

2 Rear wmdshleld mouldmg
3 Roof drip mouldmg
4 Sill mouldmg
5 Door and rear fender mouldmg
6 Door and rear fender fmlSher
7 Rear panel mouldmg

Fill BF 158 Mouldmgs of the Hardtop

8F 45
 BODY

FRONT WINDSHIELD REARWINDSHIELD

MOULDING MOULDING

Section B B

1 Wmdshleld glass BF 163 Drrvlng out fastener

Fill
2 Silencer Inner pin
3 Lower mouldmg
SectIOn A A 4 Fastener for lower mouldmg
BF480A
1 Sealant Sllencer Outer
Secl10nal of rear
2 T stud Wmdshleld glass FIBF 161 vIew

wmdshleld moulding
3 Spacer Dam sealant

4 Fastener rubber
5 Wmdshleld 9 Welt

mouldmg BF450A

159 Sectronal vIew of

FIBF
front wmdshleld moulding

1 Fastener BF556

2 Fastener for lower mouldmg BF554 BF 164 Secl10nal

Fill of
vIew

FIBF 162 Rear wmdshleld faste ner

moulding faJ teners 3 Move Side mouldmg down untd
separated corner mouldmg and
from

BF504A Falitcner remove corner mouldmg

Removal and 4 Draw SIde mouldmg upwards
Fig BF 160 Front wmdshleld
installation 5 Draw upper and lower mouldmgs
moulding fasteners Open trunk hd SIdewards
2 Dnve out Inner pm of lower 6 Install rear wmdow mouldmgs m

mouldmg fastener reverse sequence of removal

Removal and
installation
SILL MOULDING
Remove front roof dnp mould

mgs

2 Remove screw attachmg sIde

WIndshIeld mouldmg and remove side
Wlndslueld mouldmgs
3 Move sIde mouldmg down untll
separated from corner
mouldmg and
remove corner 2
mouldmgs
4 Draw stde mouldmgs upwards
5 Draw upper and lower mouldmg BF451A
Sidewards 1 Cbp
2 Sill mouldmg
6 Install wmdshleld mouldmgs m

reverse sequence of remova Fill BF 165 SIll moulding

BF 46
 BODY

Removal and 2 Remove retammg chps from Removal and

body sIde sill
installation installation
I Remove door mouIdmg with a
I Remove screws retammg slll
flat headed dnver Insert be
a
pad
mouIdmg tween dnver and door panel to protect
door pamt

Secl10n B B Cover plasl1cs

Clip plastIcs
BF452A Sill panel
SIll mouldmg

BF558
Fill BF 167 Sechonal vIew of
I Front and rear fenders 3 Spacer retammg clip
2 Sill mouldmg 4 Retammg screw BF562

Fill BF 166 Sechonal VieW of 3 Install sui mouldmg m reverse FIBF 170 RemOVing door mouldIng
retamlng screw and spacer 2 Remove fmlsher
sequenoe of removal door and
watertight seal cover and then dnve
DOOR MOULDING AND FINISH
beadmg chp Inner pms out of chp
and remove chps from outside door
fInish
@
@
@
j
11
CD
I BF560

@ I Outside weatherstnp
2 Fmlsher
3 Mouldmg BF 1 71 DrlVmg out beadIng clip
Fill
4 Clip mner pm
5 Door glass
3 Push door outsIde weatherstnp
6 Wealherstnp clip
toward door glass and remove outsIde
ftnlsh
Fill BF 168 Sectional VIew of door moulding and fmlSher Sedan
4 Remove door outSIde weather

stnp anchor clIps from door outsIde

panel wtth a flat headed dnver and
then remove outside weatherstnp
In the Hardtop outside weatherstnp
can be removed together With outside
door ftnlsh

@ @
CD

1 Fmtsher
2 Mouldmg
3 Clip
8F561 BF564
4 Door glass
FW BF 1 72 RemOVing ou tslde weather
Fill BF 169 Sectional vIew of door mouldIng and finISher Hardtop
strip

8F 47
 BODY

BF565 I Door outSide weatherstrip

2 Anchor chp @ BF566

Anchor clip I OulSlde fmlSb

Fill BF 171
2 Door panel
3 Beadmg chp

5 Install outsIde door ftmsh and

Fig BF 174 Installing door outsIde fInish and moulding
mouldmg as follows Sedan and Statron Wagon

rl BF567

I Oulslde fmlSb
@ 2 Door panel
3 Beading chp
4 Mouldmg

Fill BF 175 InstallIng door outside finISh

and mouldmg Hardtop

ROOF DRIP MOULDING

BF568

I Fronl pillar
2 Front mouldmg
3 Center moulding
4 Roof panel
@ 5 Rear mouldmg

B SectIOn c c
Secl10n A A Secl10n B F BF 176 Roof dnp moulding
Sedan

BF 48
 BODY

DOOR SASH AND

CENTER PILLAR
COVERS
CD
Center pillar cover IS attdched to

center pillar with adhesive tapes as

shown In Figure BF 178

BF569

1 Front pillar
2 Fron t mould 109
3 MalO mouldmg
Secl10n A A Secl10n B B
4 Roof panel

FIBF 177 Roof drip moulding

Hardtop

Q
I
itu Section B B
I
r

i 1 BF570

l 1 Front sash

fL@
cover

2 Rear sash Lover

3 Center pillar cover

@ 4 AdheSIVe
5 Center pillar
Secl10n A A

Fig BF 178 SectIOnal vIew of door

sash and center pillar cover

REAR PANEL AND TRUNK LID MOULDING

fl
@

@
Secl10n A A
I Trunk lid panel
2 Trunk lid mouldmg
3 Beadmg clip
4 Clip
5 Seal rubber
6 Rear fender
7 Rear fender mouldmg
8 Rear panel mould 109
@ 9 9 Retainer for
Secl10n B B rear
panel
mouldmg
j Fill BF 179 SectIOnal VIew of rear
BF571
@ panel and trunk Id mouldmgs

BF 49
 BODY

Removal and installation

I Remove nuts retammg rear panel 2 Remove rear fender mouldmgs 4 Install trunk lid rear fender and

mouldmg and remove rear

panel 3 Remove trunk lid mouldmg from rear panel mo uldmgs m reverse

mouldmg chps sequence of removal

SPECIAL SERVICE TOOLS

Tool number For Reference

No
DescnptlOn use
page or
tool name
on No
UnIt mm m FIgure

ST088 I 0000 For pushmg out the bottom ofwmdshleld sealer

glass cartndge 710 FIg BF 134

CliO
Caulkmg hand gun
50 1 97 Cl30
V 330
S30

SE231

2 ST08800000 ThIs tool used to set and the wmdsJueld the

IS secure
glass panel on All FIg BF J36
spacer models
Sucker It IS also used to assure
satIsfactory adhesIOn of the glass panel to the

body through apphcalIon ofumform pressure after settmg

130 5 12

SE345

3 ST08720000 ThIs specIal wrench IS used to make door adJustments wIthout dlsmount 610 Page BF 20
mg fender FIg BF 55
Door adJustmg
wrench

SE 232

SF 50
 SERVICE
SECTION BE
M A N Ui li
J r

BODY
DATSUN ELECTRICAL
MODEL 610 SERIES
SYSTEM

BODY ELECTRICAL WIRING BE 2

FUSE AND FUSIBLE LINK BE 4

LIGHTING AND SIGNAL

BE 5
SYSTEM

METERS AND GAUGES BE 18

IGNITION SWITCH AND

BE 26
STEERING LOCK

HORN BE 27

WINDSHIELD WIPER AND

BE 29
WASHER

RADIO BE 37

INI NI HEATER BE 40

NI55AN MOTOR CO LTD

TOKYO JAPAN
 t

BODY ELECTRICAL SYSTEM

BODY ELECTRICAL WIRING

CONTENTS

DESCRIPTION BE 2 Inspection BE 2
Colors of cables BE 2 Maintenance instructions BE 2
WI RING HARNESS BE 2

DESCRIPTION supplementary colors to standard

WIRING HARNESS
Cables used for electncal color are estabhshed for cables of
body WIr

mg are low tensIOn cables Their con respeclJve systems such as startmg and
Igmllon system hghtmg system and
ductors are covered With vmyl of
Inspection
vanous colors These va no us colors are sIgnal system By deSignated colors
therefore tell CirCUit Refeumg to wmng dIagrams or
mtended to represent use of respective you can
easlly
CirCUit diagrams mspect enttre e1ec
cables In wiring diagram these colors systems and startmg pomts of respec
tncal wiring and connecllons and
are mdlcated by one or two alpha live cables
msure
behcal letters With different colors
thus used such cables gathered to
Colors of cables I That each electncal component
part or cable IS securely fastened to ItS
gether m wiring harness easlly reveal The
system of colors apphed to the
connector or termmal
their ongms and destmahons BasIc covenng of cable conductors IS as
colors that standard colors and shown the table
2 That each connecllon IS light m
IS m
follOWIng
place and free from rust and dirt
3 That each cable covenng shows
Standard Supplementary Supplementary color no eVldenoe of cracks detenorahon or

CirCUit system
color color to standard color otherWise damage
4 That each termmal IS securely
Startmg and B from any
WY kept away adJaoent metal
IgmtlOn system Black
parts
5 That each cable IS fastened to ItS
W
Chargmg system B R L Y proper connector or ter1TI1nal
White
6 That each groundmg bolt IS plant
R W B G ed tlgh t
Llghtmg system 7 That wJrlng
Red YL securely kept away
IS

from any adJacent sharp edges of parts

G W B R such as
Signal system W Br Brown or parts st pipe havmg
exhau
I
Green Y L
Iugh temperature
8 That wiring IS kept away from
Instrument Y W B G
any rotatmg or workmg parts such as
system Yellow R L
fan pulley fan belts etc
L Y Br 9 That cables between fIXed por
Others W R Y
Blue Lg Light green tlons and reslhently mounted eqUIp
ment are long enough to Withstand
Groundmg B
shocks and Vibratory foroes
system Black

r
Maintenance
To covenng of mdlvldual mam which composed of standard and
IS
instructions
cable of eacn system standard color or supplementary colors Each of such
supplementary color to standard color two tone colors IS mdlcated With com I Before startmg to inspect and
IS generally apphed Colors are repre bmatlOn of two letters hke RW GY
or repair any part of electncal system or
sented respecllvely
by such letters as and first letter of each combmatlon other parts which may lead to a short
G Wand Br Apphed to mmor Item of stands for standard color and second CtrCUlt be sure to disconnect cable at
each CirCUit S termmal IS two tone supplementary color battery terminals

BE 2
 BODY ELECTRI CAL SYSTEM

DIsconnect cables at battery termI ternunal and then the other cable at 3 Never ground an open cJrclUt or
nals In the following manner negatJve e terminal Apply grease to CIrCUItS under no load Use a test lamp
top of these termmals to prevent rust 12 3W or circwt tester as a load
Disconnect cable at negative 8
from them 4 Never disconnect cables
ter1TI1nal and then disconnect the developmg on by pull
2 Never use a screwdnver or service mg them Be sure to loosen termmals
other cable at posItive E termmal
tool to conduct test USE before them
Before connectmg cables at
a contmUlty dlsconnectmg
batteI TEST LEADS TO CONDUCT THIS
ternunals be sure to clean termmals
CHECK
WIth a rag Fasten cable at pOSltJve E

BE 3
 BODY ELECTRICAL SYSTEM

FUSE AND FUSIBLE LINK

CONTENTS

DESCRIPTION 4
8E Fuse 4
BE
MAINTENANCE INSTRUCTIONS 4
BE Fusible link 4
8E

DESCRIPTION MAINTENANCE c Check fuse holders for condItIon If

The fuse and fusible hnk are protec INSTRUCTIONS much rust or dirt IS found thereon
tlve device used In an electnc CircUIt
clean metal parts With gramed
fine
When current mcreases bey nd rated Fuse
sandpaper untll proper metal to
fusible metal meft and In
amperage CIr
nearly all cases visual inspectIOn metal contact IS made Poor contact
CUlt broken and thus cable and reveal
IS can
faulty fuse If condItion of of any fuse holder wdl often lead to
electncal eqUipment are protected fuse IS questIOnable conduct conti voltage drop or heatmg m the cir
from burning Whenever fuse IS melted test With use of CirCUit tester
nUIty or cuit and 10 the worst case may
for one reason or another use system test lamp result m Improper operation of
atic to check and ehmlnate
procedure CirCUIt
cause of trouble before Instalhng new
Notes
fuse m posItion a If fuse IS blown off be sure to

ehmmate the cause before mstalhng Fusible link

1
new fuse In position types of fUSible hnk are In use
Two

b Use fuse of speCified ratmg Do not Each type IS clearly Identlfted by

use fuse of more than speCIfIed colored covenng of wnductors as

ratmg shown below

Max current fuse

Color Size mm2 m ContlOuous current
sq
melts Wlthm 5 sec

Brown o 3 0 0005 IlA Approx 60A

Green o 5 00008 20A Approx 200A
FIBE l
Red 085 0 OOJ 32 26A Approx 250A

Melted fUSible hnk be detected fusible hnk than that specI

can larger
by either Visual inspection or finger tip fied be used

feehng If ItS condition IS questIOnable b Should meltmg of fUSible hnk

use CirCUIt tester or test lamp as occur It IS pOSSIble that crlhcal
required to conduct contmUlty test CirCUIt power supply or
large cur

ThiS continUIty test can be performed rent carrymg CirCUIt IS shorted In

In same manner as for any convention such case
carefully check and eltrn
al fuse mate the cause of trouble

c Never wrap periphery of fUSIble

Notes
link WIth vinyl tape Extreme care
FIBE 2 a FUSible hnk carnes current as
large should be taken of thIS link so that
as 60 or 250 amperes when It melts it does not come mto contact with
m
penod of less than fIve seconds any other harness
wiring or
vinyl
Under no cIrcumstances should any or rubber parts

4
BE
 BODY ELECTRI CAL SYSTEM

LIGHTING AND SIGNAL SYSTEM

CONTENTS
DESCRIPTION BE 5 Bulb replacement BE13
8E 5 BACK UP LAMP
Circuit diagram of lighting system BE14
CircUit diagram of signal lamp system BE 9 TURN SIGNAL AND LIGHTING SWITCH BE14
HEAD LAMP BE 9 Removal BE14
Head beam BE 9 REAR SIDE MARKER LAMP
lamp replacement BE14
BE10
AIming adjustment Lamp assembly replacement BE14
FRONT COMBINATION LAMP BE 11 Bulb replacement 8E14
8ulb replacement BE 11 TR UN K ROOM LAMP 8E14
Lamp assembly replacement BE 11 Trunk room lamp assembly replacement BE14

SIDE FLASHER LAMP BE 11 LIGHTING SWITCH BE14

BE 11 Removal BE14
Lamp assembly replacement
Bulb replacement BE 11 HAZARD WARNING SWITCH BE14
SIDE MARKER LAMP 8E 11 Removal BE14

ROOM LAMP BE 11 STOP LAMP SWITCH BE15

Room lamp BE 11 Removal and Installation BE15

Rear room lamp BE 11 Inspection BE15

REAR COMBINATION LAMP BE12 BULB SPECIFICATIONS BE15

Combination lamp assembly replacement BE12 TROUBLE DIAGNOSES AND CORRECTIONS BE16

Bulb replacement BE12 Head lamp system BE16

LICENSE LAMP BE13 Signal lamp system BE17

License lamp assembly replacement BE13

DESCRIPTION
and left head lamps Independent so
are trouble and of course lit
Circuit diagram of IS normally
that meltmg offuse for
one head lamp BE 3 shows that combIna
FIgure
lighting system causes neither head lamp to go out tion sWitch lever IS m posItion B and
Head lamp system Isolated from hght WIth fuse melted IS dmdy ht by contact ofhghtmg relay IS on one Side
other hghtmg system has Its own dmt ofelectnc current flowmg In from Onoe lever IS sWItched to pOSItIon C as
ClfCUlt Power ClfCUltS of both nght CIrCUit of the other lamp wluch has no shown In FtgUre BE 3 2 contact trans

I 2 3

FROM HEAD LAMP FROM HEAD LAMP FROM HEAD LAMP

TO TO
TO
GROUND FROM GROUND
GROUND
MBINATION
SWITCH

t e l

v
d
B BE239
B
Fill BE 3 Lllfhtrng relay

BE 5
 BODY ELECTRICAL SYSTEM

fers to the other sIde Even when ThIs movement of relay contact IS tlon C electnc current flows to sole
shIfted to posItion C lever automati caused magnet force wluch IS pro
by nOid of relay and produoes magnet
cally retums to pOSItion B See FIgure duced on solenOid of relay When lever turoe whIch transfers contact to the
BE 3 3 of combmalJon sWItch IS set In POSl opposIte Side

BE 6
 BODY ELECTRICAL SYSTEM

IR H 2 HIGH BEAM
INDICATOR LAMP

COMBINATION METER

LIGHTING SWITCH

LIGHTING RELAY

RED

PUSH I
FUSIBLE LINK RING

TURN SIGNAL SWITCH

L Hi

C 8 A

L H1 LEVER POSITION
B E290B

Fill BE 6 CircUIt diagram for llhling system

BE 7
 BODY ELECTRI CAL SYSTEM

FRONT COMBINATION LAMP CR H I REAR COMBINATION LAMP IR H I

CLEARANCE LAMP

LIGHTING SWITCH

TAIL LAMP CR H I

FUSIBLE LINK

LICENCE LAMP
CIGARETTE LIGHTER ILLUMINATION LAMP

KNOB
ILLUMINATION LAMP COMBINA TION METER
CSSS MODEL ONL YI
ILLUMINATION LAMP
CSSS MOOELI

ILLUMINATION

GLOVE BOX LAMP SWITCH CONTROL SWITCH

GLOVE BOX COMBINATION METER

LAMP ILLUMINATION LAMP H
TAIL LAMP IL I
EXCEPT SSS MOOELI

CLEARANCE LAMP REAR COMBINATION LAMP

FRONT L H I
COMBINA TION LAMP IL H I

BE293B

Fill BE 9 CirCuit dIagram for llhtmg system

8
BE
 BODY ELECTRI CAL SYSTEM

Circuit diagram of signal lamp system

Sloe FLASHER LAMP A H I

COMBINATION METER

FRONT TURN SIGNAL

COMBINATION INDICATOR LAMP REAR COMBINATION
lAMP
LAMP IR H IR H I IR H I

TURN SIGNAL

LAMP IR H I
B

HAZARD WARNING
SWITCH

STOP lAMP SWITCH

0
TURN SIGNAL
FLASHER UNIT

o
HAZARD FLASHER UNIT

PUSH

RING

TURN SIGNAL
LAMP l H

REAR COMBINATION LAMP

INHIBITOR SWITCH Il H I
AfT ONL VI

FRONT

COMBINATION
LAMP IL H I

B E294B
H
SlOE FLASHER LAMP Il I

hazard warnrng amp

Fig BE IO CIrcUIt dragram for back up lamp turn lnallamp
sl
and stop lamp system

HEAD LAMP

Head lamp beam 2 Loosen three head lamp retammg 3 Remove retammg rmg by rotatmg
nng screws It may be unnecessary to It clockwise
replacement 4 Remove head beam from
I Remove retauung screws and re
remove screws lamp
mountmg nng and disconnect Wiring
move rad18tor
grille then dIsconnect Note Do not disturb aiming adjust
connector from belund beam
side flasher lamp connector screws
5 head beam and con
Change lamp
nect wJrJng connector to new beam
6 Place head lamp beam m
pOSItion
so that three location tabs behmd
beam ftt m WIth three hollows on

mountmg nng Make sure that stgn

Top of beam lens IS on upper sIde

7 Install head lamp retammg rmg
and tighten screws

head
8 POSItion radiator gnlle or

lamp fmlsher m posItIon and mstall

Aunmg adJustmg screw
Headlamp relammg nng retammg screws

Headlamp beam
BE221A He dlamp moun ling IlDg

Fill BE II Exploded view of head lamp

8E 9
 BODY ELECTRI CAL SYSTEM

To adJust vertIcal atrn use adJustmg c See that there is no load m car
Aiming adjustment I Gasoline radiator and etlgine oil
screw on
upper SIde ofhead lamp and
1 to hOrIZontal atrn use adJustlftg pan filled up to correct levels
1
adJust
screw on SIde ofhead lamp 2 Without passenger

Notes Befomakmg head lamp aun

ing adjustment observe the follow When perfor1TI1ng head lamp aunmg
ing instructions adJustment use an lII1TI1ng machme
a Keep all tJreS inflated to correct lIIrmng wall screen or
headhght tester

pressures For operatmg mstructlons of any

b Place car and tester on one and atrner refer to respective operation
same flat surface manuals supphed WIth the umt

W
1 CenJerlme of vehicle

10 m 328ft
L
I

DRIVING BEAM HIgh Beam

10 m 32 8 fl

L2 BE246
PASSING BEAM Low Beam

Dnvmg beam High beam Passmg beam Low beam

d

HI WI 01 hI I H2 W2 2 h2 L2
0 mm
a
mm mm mm m mm mm mm m
m
Mod l 0 ft 0
m m m m m 0 m ft

610 K610 655 830 128 51 655 1 180 390 17 349

44 2014 20
25 8 32 7 50 167 25 79 46 5 J54 56 13 7

W610 680 830 128 53 680 1 180 390 17 5 349

44 2014 20
26 8 32 7 5 0 174 26 77 465 15 4 57 13 7

Fill BE 13 AimIng adJustment

BEI0
 BODY ELECTRICAL SYSTEM

FRONT Lamp assembly Rear room lamp

COMBINATION replacement
LAMP Side marker lamp IS secured to

RADIATOR GRILLE wIth three

screws

Replace lamp assembly by re

movmg three screws from front oflens

and dlsconnectmg wires from connec
1 1111
tor II

BE222A
Bulb replacement
I Remove two screws securing lens
FIg BE I4 Exploded offront
vieW

combmahon lamp and detach lens

2 Push bulb m turn It counter

ylse
c1ock and remove bulb I
3 Install bulb m the reverse order of

Bulb replacement removal

I Remove two lens

and detach lens

2 Push m on
retalrung

bulb turn It counter

screws
T
clockwISe and remove It from socket

1
3 Insert new bulb mto socket mak
mg certam that lockmg pms m bulb SIDE MARKER LAMP
base are properly posItioned m socket Side marker lamp IS fIxed on fender
Press bulb mward rotate It clockwise WIth two screws Replacement of lamp
and lock bulb In socket BE250
assembly can be done by removlftg
two screws from front of lens and

dlSconnectmg wires from connector I Limp body

Lamp assembly 2 Bulb

3 Lens
replacement
J Remove two lens retalrung screws
ROOM LAMP FIg BE I 7 Rear room lamp
and pull lamp assembly out forStahon Wagon
2 Disconnect lead wtres at connec
Room lamp f

tor I I
To
replace bulb remove lamp body
f and
c change bulb
To remove lamp body pull lamp

body out of roof and disconnect room To replace bulb

l
remove le ns and
I

lamp Wlfes at connector change bulb

SlpE FLASHER LAMP Room lamp IS held by spnng pres To remove lamp body remove two
sure agamst roof retammg screws disconnect lead WIres

from each connector and Withdraw

lamp body
I

BE223A B E224A

Fill BE I5 Exploded view of side Fig BE I6 Exploded view of

flasher lamp room lamp

BE 11
 BODY ELECTRICAL SYSTEM

Sedan and Hardtop

REAR COM BINATION LAMP
Combination lamp assembly replacement DIsconnect trunk harness at con

nector
2 Remove eight flange nuts on lamp
housmg shade m trunk
3 Remove lamp housmg shade

lens and packmg from rear panel to

ward mSlde of trunk WIthdraw lens

nm from car

4 Install new rear combmatlOn

lamp assembly m reverse sequence of

removal

I Bulb 4 Lens
2 Flange nut 5 Packmg
3 Lamp housmg 6 Lens nrn BE251

Fill BE IS Rear combmatlOn lamp

Station Wagon
1 Remove three screws securing

lamp assembly to fender

2 Remove bulb socket from lamp
housmg shade and then remove lamp
assembly
3 Install new assembly m reverse

sequence of removal

Bulb replacement
I Turn bulb socket counterclock
WIse and remove socket from lamp
hr uslOg shade
2 Push m on bulb turn It counter

c10ckwlsc and remove It from socket

3 Insert new bulb mto socket mak

mg oertam that lc kmg pms m base of

bulb IS m position Press bulb mward
rotate It clockWise and lock It m

socket
BE252
4 Insert socket mto lamp housmg
WIth locking tab In proper positIon
Rotate socket clockWIse to lock It m Fill BE I9 Rearcombmahon lamp
Station Wagon
housmg shade

BE12
 BODY ELECTRICAL SYSTEM

License lamp assembly

LICENSE LAMP
replacement
Sedan and Hardtop I Remove three hcense lamp retaln
and remove
mg screws lamp assembly
from bumper
2 Disconnect lead wire at con

nector
3 Install hcense
new lamp assembly
In reverse sequence of removal

Bulb replacement
I Remove two lens cover
retammg
screws

2 Remove lens lens and

cover
pack
mg
3 bulb with one
Replace new

4 Install cover lens and packmg m

reverse sequence of removal

BE253 I Packmg
2 Lens
3 Lens cover

Fill BE 20 LIcense lamp Sedan and Hardtop

Station Wagon

License lamp assembly

replacement
J Remove tailgate tnm
IJ
2 Remove two tailgate handle re CD 9J
8
tammg nuts
3 Disconnect lead wire at con

nector
4 Dismount from
lamp assembly
vehIcle

Bulb replacement
I Remove two lens retammg
screws

2 Remove lens and packing

3 Replace bulb with a new one
4 Install packmg and lens m reverse

sequence of removal

BE254

Fig BE 21 License lamp Statron Wagon

8E 13
 BODY ELECTRICAL SYSTEM

REAR SIDE MARKER LIGHTING SWITCH 1

LAMP
Removal
Lamp assembly I Remove upper and lower shell
J replacement coversfrom steenng column by loos
1 Remove two four
screws secunng lamp emng screws

assembly and lens

body to 2 Loosen two c1uste r hd cover re
2 DIsconnect lamp connector and tammg screws and remove cluster hd
remove lamp assembly cover

3 Remove five screws from front of

cluster A and remove one screw hold

U Ing cluster A to IDstrument panel from

BE22SA r
belund Thus cluster A IS detached
Fill BE 22 Exploded VIew of 4 Remove SWItch knob
I
by de
back up lamp Hardtop
JJ pressIDg It and turmng It counte
Cl
J rclockWIse

Sedan and J hj I
5 Remove hghtlllg SWItch

Station Wa gon SE229A

For
replacement procedure of bulb FIg BE 23 Exploded vIew of rear
and lamp assembly refer to Rear srde marker

Combmatlon Lamp Assembly Replace

ment

Bulb replacement
1 Remove two screws secunng lamp
Hardtop assembly and lens to body and detach
DISconnect wtres at connector lens
2 Remove and left rear combI 2 Push bulb m turn
right It counter

assembhes clockWise and remove bulb

nation lamp Fill BE 25 RemOVIng cluster A
3 Remove four 3 Install bulb m the reverse order of
flange nuts
4 Remove lamp assembly from rear removal

panel
5 Install new assembly m reverse

sequence of removal
TRUNK ROOM LAMP
HAZARD WARNING
Trunk lamp room SWITCH
I

assembly replacement Removal

1 DIsconnect lamp wire 1 Remove cluster hd A follOWing
2 Pull lamp out downward the same
procedures as Removal
TURN SIGNAL AND 3 Lift socket out of pOSitIOn
procedures I through 3 for LIGHT
LIGHTING SWITCH ING SWITCH
2 Remove connector from instru
Removal ment harness
I Remove horn nng 3 Remove SWitch from cluster lid
2 Remove steenng wheel secunng A to wluch SWItch attached
IS by
nut and steenng wheel means of spnng tensIOn From rear of
3 Remove four shell cover retammg cluster hd push SWitch out forward

screws and remove upper and lower

shell covers

4 Disconnect combmatlon switch

B E2 30A
WIres at connectors

5 Loosen two retamlng screws and FIg BE 24 Trunk room lamp

remove combmatlOIi SWItch assembly replacement

BE14
 BODY ELECTRI CAL SYSTEM

STOP LAMP 3 Install m the reverse sequenoe of

oval
SWITCH rem

Removal and
installation
Stop lamp sWitch IS mtegral part of
brake pedal heIght Inspection
Whenever stop lamp sWitch IS re
When plunger IS pressed mto sWItch
moved adJustment IS requued
assembly stop lamp sWitch contacts
1 DIsconnect lead wtres at connec are open Contacts are closed when
BE235A
tors plunger IS proJected FIg BE 26 Stop lamp sWitch
2 Loosen lock nut SWItch assembly Test contmUlty as preViously de
can then be taken out by rotatmg scnbed by test
usmg lamp or ohm
sWItch meter

BULB SPECIFICATIONS

General areas
Item
Wattage

Head lamp Outer 375 50

Inner 375

Front combmatlOn lamp

Turn 2J
SIgnal hght
Parkmg hght 5

SIde flasher lamp 5

Rear combmatlOn lamp

Stop Tall lamp 21 5

Turn 21
signal lamp
Back up lamp 21

License 75
lamp
License 5
lamp Europe
Room lamp
Room lamp lO
Rear lamp
room lO

Trunk room lamp 5

Instrument IllummatJon hght 34

and mdlcator hghts

BE 15
 BODY ELECTRICAL SYSTEM

TROUBLE DIAGNOSES AND CORRECTIONS

Head lamp system

CondItion Probable cause Corrective action

Head lamps both of high beam and FusIble hnk blown off When fused detect and eltrnmate the
low beam do not hght cause and replace WIth new one

NeIther high beam nor low beam IS

ht Faulty hghtmg relay term mal con Check connector for contact and re

I Even when hghtmg sWItch IS set to

nector pair as
required
OFF and hghtmg lever sWitch IS
Inoperative hghtmg relay Conduct continUity test If relay IS

sWItched to operate passmg hght It faulty replace

will not do
Both fuses nght and left Side When fused detect and ehmmate the
beams blown off cause and replace With new ones

Faulty terminal connectors hght Check connectors for contact and re

mg sWitch and lever sWItch pair as

reqUired

InoperatIve sWItch and Conduct continUity test If both

hghtmg
lever sWItch sWItches are faulty replace

2 normal workable sWItch terminal con Check connector for contact and
Passmg hght IS In Faulty hghtmg re

condItion nector pair as required

Inoperative hghtmg sWitch Conduct test If SWItch IS

continUIty
faulty replace

EIther hIgh or low beam IS ht normal Faulty terminal connectors light Check connectors for contact and re

ly HIgh and low beams are not mg relay and or IIghtmg lever pair as
reuqUlred
switched to each other sWItch

Inoperative hghtmg relay and or Conduct continUIty test If any SWItch

hgh tmg lever sWItch IS

faulty replace

Only one head lamp IS ht Either of two fuses for head lamps When fused detect and eltrnmate the
I Head left SIde normal IS mel ted cause and replace WIth a new one
lamp on IS

and that on
rIght SIde IS
only dImly head termmal Check connector for contact and
ht or vice versa
Faulty lamp connec re

tor pair as reqUired

2 Head left Side normal

lamp on IS
Faulty lamp Replace WIth a new one

and that on
nght SIde does not
Faulty head lamp terminal con Check connector for contact and re
hght
nector pair as
reqUIred

Head lamps dim Faulty head lamp CirCUIt Check head lamp CirCUit for cable
about to break faulty
or m or contact

check fuse for faulty contact Repair

or
replace If required

J Head lamps dIm when the engme IS

Battery partly dIscharged Measure speCific gravIty of electrolyte
stopped or Idhng Charge battery IfreqUIred

Faulty battery Replace battery

BE 16
 BODY ELECTRICAL SYSTEM

Condll1on Probable cause CorrectIve action

2 Head stIll dIm wIth engine at head terminals sealed beam UnIts
lamps Voltage lamp IS Replace
runmng faster than IdlIng 12 8 volts or
hIgher
Faulty sealed beam umt

Voltage less than 12 8 volts Check the alternator and

regulator
Faulty chargmg system head lamp CirCUit

Signal lamp system

ConditIOn Probable cause Corrective action

Turn signal lamps When turn sIgnal lever IS moved to left left turn
and off
fad to operate properly signal lamp Will not go on
regularly But
when thiS lever moved to
IS
nght nght turn signal
lamp WIll operate properly
L H turn signal bulb
o
Faulty lamp Replace
o Trouble m L H turn signal CirCUit Check and correct

Both turn SIgnal lamps fail to operate properly

o InoperatJve flasher Unit Replace
Turn slgnalldmps Will Both turn sIgnal lamps fad to hght when turn signal
not be lever IS moved to left and
OIl
nght
I When stop lamp sWitch IS operated stop lamp will
go on
properly
a
Faulty F fuse Replace
b InoperatJve hazard lamp sWitch Replace
c Inoperative flasher UnIt Replace
d Faulty turn signal sWitch Check and correct

2 When stop lamp sWItch IS operated stop lamp will

not go on

a
Discharged battery Re charge
b Trouble In power supply Check and correct

Huard warmng Turn but hazard

lamps Signal lamps will operate properly
will not operdte properly warmng lamp will not hght
I Faulty c fuse Replace
2 Inoperative hazard flasher UnIt Replace
3 Faulty hazard sWitch Replace
but L H hazard
Turn signal lamps operate properly
warning lamp Will not
o Faulty hazard warrnng lamp sWitch contacts left Replace sWitch
Side

Turn signal lamps operate properly but hazard

warmng lamps Will not operate properly Flashmg
cycle IS too low or high
o
Inoperative flasher Unit Replace

8E 17
 BODY ELECTRICAL SYSTEM

METERS AND GAUGES

CONTENTS

CLUSTER LID 8E 20 HAND BRAKE WARNING LAMP 8E 22

Removal TACHOMETER
BE 20 8E22
SPEEDOMETER 8E 20 Installation BE 22
Removal 8E 20 CLOCK BE 22
FUEL MErER AND WATER Installation 8E 22
TEMPERATURE METER 8E 20 TROU8LE DIAGNOSES AND
Replacement 8E 21 CORRECTIONS 8E 23
OIL PRESSURE WARNING LAMP BE 21 Speedometer BE 23
CHARGE WARNING LAMP 8E 21 Water temperature meter and fuel meter BE23
011 pressure and charge warning lamps 8E 25

I Radio Brake
II pedal
2 Side venl1lator 12 Clutch pedal
3 Hood release handle 13 Parkmg brake lever
4 Turn slgnalldimmer passmg sWItch lever 14 Cassete stereo
5 WIper and washer swItch 15 Gear control lever
6 LIght sWItch Healer
16
7 lIlummal10n control rheostat 17 CIgarette lIghter
8 Hazard warnmg sWItch 18 Ash tray
9 Rear wmdow defroster sWItch 19 Glove box
10 Accelerator pedal fO Package tray

IN574

Frg BE 27

8E 18
 BODY ELECTRICAL SYSTEM

3 RemoveSIX attaching screws and maltransmltter IS equipped wIth a

CLUSTER LID
remove pnnted CirCUIt hOUSing to thermIstor element wluch converts
gether with speedometer water tem coohng water temperature vanatIon to
Removal meter and fuel meter a resIstance and thus the thennal
perature
tennmals 4 Loosen two
1 DIsconnect battery speedometer retam transmitter controls current flOWing to

2 Remove shell covers from steenng screws and speedometer

remove the meter
Ing
column by loosemng four screws from pnnted CircUit hOUSing The fuel meter and water tempera
5 Install new speedometer 10 the
3 Remove two cluster hd cover ture meter are proVided wIth a bimetal
retammg screws and remove cluster lid reverse sequence of removal ann and heater coll When the IgmtlOn
cover sWItch IS set to ON current flows to
4 Remove two retammg screws as the heat cod and the heat cod IS

shown m Figures BE 28 and BE 29 c heated WIth tlus heat the btrnetal ann

IS bent and thus the pomter con

nected to the btrnetal ann IS operated

The charactenstIcs of both meters are

the same

A tolerance may occur on the water

temperature meter or fuel meter due

BE260

FIg BE 30 RemOVing speedometer to sourcevoltage fluctuation The volt

age regulator IS used to supply a
constant voltage so that the water
FUEL METER AND temperature meter and fuel meter

WATER opera te correctly

Fig BE 28 Removal of cluster lid TEMPERATURE The operatmg part of the regulator
METER consists of a bImetal arm and a heater

The fuel meter consists of a tank cod When the Igmtlon SWitch IS

UnIt located In the fuel tank and fuel turned on the btrnetal ann IS heated

meter The tank UnIt detects fuel level and bent by the COIl opemng the
with ItS float converts fuel level varia contact Consequently current to the
tIon to a resistance of shde resistor COIl IS Interrupted As the btrnetal
mstalled on the float base and thus cools the contact closes The repeti

controls current 110wmg to the fuel tIon of thIS operatIon produces a

pulsatmg voltage of 8 volts wluch IS

meter
The water temperature meter con applied to the temperature and fuel

BE259 SiStS of a meter and thermaltransmltter gauges

Removal of cluster lid located In the engme block The ther

G
TO WARNING LAMPS
5 Pullmstrument forward
panel FUSE BOX
5
6 From behmd panel
Instrument

dIsconnect connector plug multI pole VR

from pnnted CirCUit housmg wATER TEMPERATURE

VW METER
IGNITION
7 Disconnect speedometer cable SWITCH B

from speedometer head

8 Disconnect other wires at termi L
F METER
v

nals on pnnted CirCUit housing If so

FUSIBLE
LINK
eqUipped GREEN
VW
9 Remove cluster lid assembly from
Instrument panel
FROM
v
o
BTTERY
C

SPEEDOMETER
FUEL TANK

Removal THERMAlTRANSMITTER

Remove cluster lid BE296B

2 Remove odometer knob If so

CI cull dIagram for fuel meter temperature meter and
Fig BE 31
eqUipped voltage regulator

BE 20
 BODY ELECTRICAL SYSTEM

If both the water temperature OIL PRESSURE

meter and fuel meter become faulty the the
WARNING LAMP when engine IS statIOnary
at the same trrne thIS may be attnbut WIth the IgnitIOn SWItch
The engme lubncatmg system m light glows
able to trouble m the voltage regu turned When the engme IS running
corporates an 011 pressure warnmg on

lator and 011 reaches the above

lamp which glows whenever engme 011 pressure
04 to 0 6 kg cm2 the CIrCUIt opens and the light
pressure falls below range

Replacement 6 to 9 pSI Under normal operation goes out

I Remove cluster hd

2 Remove two meter retammg FUSE BOX

SA lR
and TOMETER VOLTAGE REGULATOR
screws remove meter from pnnted
IGl Gl
CirCUit hous1l1g TO OTHER WARNING
G LAMPS
3 Install new meter 111 the reverse
I
sequence of removal

IGN ITION
SWITCH RES URE
WARNING LAMP

t
YB lB

FUSIBLE LINK
0 S GREENl

FROM 1
BAT ER
I

@J BE262
WITHOUT
PRESSURE
BE297B

Fill BE 32 Removing meter

FIlf BE 33 C rcUit ofoil pressure warnmg system

CHARGE
WARNING LAMP
The charge wammg lamp glows c1osed and current flows from the current f10wmg from the warnmg
the current from N termmal
sWItch IgnItion SWItch to the warnmg lamp lamp as
when the IS set to
Igrutlon
ON wIth the engme shut down or and grounds through the regula tor mcreases the solenOid IS more ener

when the alternator fails to cltarge Fig BE 34 1 When the eng1l1e IS glzed and the
lamp relay
warning

WIth the engme operated I

started and the alternator comes mto contacts openell m effect It breaks
are

When the IgmtlOn sWItch IS set to operation the alternator output cur the wammg CirCUit ground connection
rent from N termmal opposes the and the lamp goes out FIg BE 34 2
ON the charge warning CirCUIt IS

FUSIBLE LINK FUSE BOX FUSE BOX

FRON FUSIBLE LINK
A FROM
BATTERY TO METER LTAGE SA TO ETER II
lJAGE
0 REGULATOR BATTERY ere REGULATOR
05 GREEN IGNITION tGI G i O GREEN IGNITION IGl Gl
SWITCH SWITCH
TO BATTER TO 8ATTERY
G
I G

A A

II

CHARGE
WARNING LAMP

WARNING lAMP t
RELA MP
wARNING t
RELA

N
L J
J
ALTERNATOR WLTAGE
ALTERNATOR REGuLATOR
BE29BB

Fig BR 34 1 CIrcUIt ofcharge warning system FIBR 34 2 CirCUit ofcharge warnmg system

BE 21
 r

BODY ELECTRICAL SYSTEM

HAND BRAKE Installation

WARNING LAMP On some velucles tJus lamp IS also I Remove cluster bd
The hand brake warnIng lamp glows used to mdlcate that
as a warDIng lamp 2 Remove mask and mstaIJ tachom
when the hand brake IS apphed there IS a leak m the servIce brake hne eter m place ofmask
When the JgIIltlon switch IS set When a dlfferenoe between 3 Disconnect
pressure blackjwlute blackj
to ON current flows from the Igrn the front and brake Imes reaches laJd
rear green WIre along the lower por
tlon sWItch to the warnIng lamp When the hmlt the SWItch m the brake hne lion of mstrument panel at connector
the hand brake IS apphed hand brake IS actuated by hne pressure and the plug
warmng sWItch IS closed and wammg contacts close As the contacts close 4 Connect tachometer lead wires to
lamp glows the lamp glows disconnected plug ends m senes

5 Connect other lead of ta

wires

chometer to combmatlOn meter

FUSE BOX
TO METER pnnted CIrCUIt ter1TI1nals
5A YR
VOLTAGE 6 Install cluster hd

REGULATOR
G
IGNITION CLOCK
OTHER
SWITCH
WARNING LAMPS

HAND BRAKE
WARNING LAMP
FUSIB LE
LINK YG
05 GREEN

HAND BRAKE SWITCH

YG
01

FROM BATTERY
BRAKE LINE SWITCH
BE267
t HARDTOP MODEL ONLY
o
YG
Fill BE 37 Installing clock

B E299 B

Fig BE 35 CircUIt ram for brake

dUl
warning system

Installation
TACHOMETER I Remove cluster hd

2 Remove mask and mstall clock m

plaoe of mask
3 Connect lead WIre C01TI1ng out
from clock to bluejwlute WIre laId

along the lower portion of mstrument

panel
4 Connect other clock lead wires to

ter1TI1nals on combmallon meter pnnt

ed CirCUit
5 Install cluster hd

BE266

tachometer
FIBE 36 Installing

BE 22
 BODY ELECTRICAL SYSTEM

TROUBLE DIAGNOSES AND CORRECTIONS

Speedometer
Condition Probable cause Corrective action

Speedometer pomter Improperly tightened speedometer cable Retighten

and odometer do not union nut

operate Broken speedometer cable Replace

Damaged speedometer dnve pmlon gear Replace
Inoperative speedometer Replace

Speedometer pOinter RapIdly bent speedometer cable Correct or replaoe

deflects exoesslvely dnve pInIon gear
Damaged speedometer Replace
Inoperative speedometer Replace

Unstable speedometer Improperly tightened speedometer cable Retighten

pomter union nut

Faulty speedometer cable Replace

Inoperative speedometer Replace

Unusual sound occurs ExcessIvely bent or tWisted speedometer Replace or lubncate

m response to cable mner wire or lack of lubncatlOn
mcrease of dnvmg
InoperatIve speedometer Replace
speed

Inaccurate speedometer Inoperative speedometer Replace

mdlcatlOn

Inaccurate odometer Improperly meshed second and tlurd gear Replace speedometer
worm gears
operatIOn

Faulty feeding due to deformed odo Replace speedometer

meter and ptrUon carner

Water temperature meter and fuel meter

CondItion Probable cause Corrective action

Both water temperature Blown off fuse or rrnproper connection Check fuse for fusmg and Improper contact
meter and fuel meter Replace after correctmg cause If fused
do not operate Correct contact

Faulty voltage regulator damaged fused Replace

or open contact

Both water temperature Faulty voltage regulator broken heat In this case meter pOinter fluctuates exces

meter and fuel meter Wire seized contact and or

rrnproper slvely
indIcate maccurately groundmg Replace

Improper cable contact In thIS case meter pomter fluctuates slight

Iy
Check cable for Improper contact and repair
If required

BE 23
 BODY ELECTRICAL SYSTEM

Condlllon Probable cause Corrective acllon

Water temperature meter

Water Faulty thermal transmitter

temperature Replace thermaJtransmltter If pomter de
meter does not flects when thermaltransmltter
operate yellow whIte
cable IS grounded

Faulty water temperature meter Replace meter If pOinter does not deflect
when thermaltransmltter yellow white cable
IS grounded

POinter mdlcates maxI

Faulty thermal transmItter Pomter moves to low hmlt when IgmtlOn
mum
temperature SWItch IS turned off
In this case replace thermaltransmltter

Faulty water temperature meter Pomter indIcates maxImum temperature

even after IgmtIon SWItch IS turned off
In thIs case replace meter

Water temperature meter Faulty water temperature meter Meter IS servIceable when a 40n resistance IS

does not operate apphed between thermaltrans1TI1tler yellowl

accurately whIte cable and ground and meter mdlcates

approximately 800C I760F

Faulty thermaltranslmtter If meter IS normal through the above mspec

lion replace thermaJtransmltter

Improper cable contact If meter indIcates a temperature shghtly

lower than the actual temperature check
cable from meter to thennaltransmltter for
cable belftg about to break poor contact
and and repatr If
faulty grounding neces

sary

Fuel meter

Fuel meter does not Damaged tank umt Replaoe tank UnIt If pomter deflects when
operate tank umt yellow cable IS grounded

Inoperative fuel meter Replace fuel meter WIth a new one If pomter
does not deflect through the above mspec
tlon

Pomter mdlcates F tank urut

Damaged Replaoe tank umt If pOInter lowers below
posItion empty Itrmt when IgmtIon SWItch IS turned
off

Inoperative fuel meter Replaoe fuel meter If pOinter stlll mdlcates

F posItIon through the above mspectJon

Fuel meter funcllons Damaged tank umt tank urnt If pOinter mdlcates a half
Replaoe
Improperly level when a 32n reslstanoe IS apphed
between tank urnt yellow cable and ground

Inoperallve fuel meter Replaoe fuel meter If pOinter does not

mdlcate a half level through the above

mspectJon

BE 24
 BODY ELECTRICAL SYSTEM

CondltJon Probable cause CorrectJve actIon

Improper cable contact If fuel meter mdlcates a level shghtly lower

than actual level check cable from fuel
meter to tank unIt for cable being about to
break poor contact and faulty groundmg
and repair as
neoessary

Oil pressure and charge warning lamps

Condition Probable cause CorrectJve actJon

011 pressure warning

lamp
Lamp does not hght Blown off fuse or faulty contact Check fuse for fusmg and faulty contact
when Ignition sWItch IS
Replace after correctmg cause or repair as
set to ON necessary

Faulty bulb or faulty cable contact If od pressure sWItch yellow black cable IS

grounded and wammg lamp does not hght

check bulb for burnt out ftIament and

replace as neoessary

Damaged od pressure sWItch If warning lamp hghts tIuough the above

trlSpectJon replace 011 pressure SWItch

Lamp does not go out Lack of engme od Check od level and add 011 as required
while engme IS bemg
Od pressure too low Inspect engme 011 pressure system
operated
011 pressure SWitch ContmUlty eXIsts 011 pressure SWitch
Faulty on

when engme IS beIng operated

Replaoe 011 pressure SWItch

Charge Warmng lamp

Lamp does not light Blown offfuse or faulty contact Check fuse for fusmg and faulty contact

when IgrntlOn sWitch Repair or replaoe If necessary

IS set to ON
Faulty bulb or faulty cable contact Pilot lamp does not light when white red
cable voltage regulator wiring connector IS
m

grounded and IgnitIon SWItch IS set to

ON
Check bulb for burnt out ftIament and

replace If necessary

Lamp does not go out Faulty chargmg system Inspect chargmg sysytem
when engme IS started

BE 25
 BODY ELECTRICAL SYSTEM

IGNITION SWITCH AND STEERING LOCK

CONTENTS

IGNITION AND STARTER SWITCH BE 26 Steering lock replacement BE 26

Removal BE 26 Ignition sWitch replacement 8E 27
IGNITION SWITCH WITH STEERING LOCK BE 26

IGNITION AND STARTER SWITCH

Removal
I Remove four screws and remove
OFF ON START ACC
Termmal shell covers

wire color 2 Disconnect lead WIres at con

nector
Battery WR 3 Remove two screws securmg
SWItch assembly to sWitch clamp
Accessory LB
4 Remove sWItch from
assembly
Starter BY SWItch clamp

Ignition BW
ReSistance BG

IGNITION SWITCH WITH STEERING LOCK

Steering lock
replacement
For the purpose of tamper proof
the self shear type screws are used and
posItIon
LOCK OFF ACC ON START their heads are sheared off when m
TermmaI stalled so that the steenng lock system
wire color
carmot be removed easIly Replaoe the

Battery WR I steenng lock m accordance wIth the

followmg mstructJons when reqUired

IgrntJon BW Break two self shear type screws

WIth a drill or other proper tool Now

Starter BY remove the steenng lock from the
Accessory L J J steenng lock clamp
When mstallmg a new steenng lock
ReSIstance BG be two new self shear
sure to tighten
type screws to shear off thetr heads

BE 26
 BODY ELECTRI CAL SYSTEM

Q I Steenng tock clamp

2 Self shear Iype screw
3 Igml10n swllch
4 S leenng lock
BE268

Fig BE 38 Steenng lock mstallatlOn

Ignition switch
replacement
To replace IgrntJon sWItch from

steenng lock deVIce remove shell

covers dIsconnect IgrutJon sWItch
WIres at connector and remove one

retammg screw from back orsteenng

lock devlce Install new sWItch m

reverse sequence ofremoval

BE269

Fill BE 39 IgnItIOn sWitch

HORN

CONTENTS

DESCRIPTION BE 27 TROUBLE DIAGNOSES AND

INSPECTION BE 28 CORRECTIONS BE 28

DESCRIPTION circuit termmal S the current flow IS as a groundmg

The horn CtrCUlt mcludes horn the solenOid and
a
supphed through When the horn button IS pressed
relay Current from the battery flows horn button to the groundmg In the current from the battery energtzes the
through the fUSIble hnk and fuse to other CirCUIt terminal H the current solenoid As the solenoid IS energtzed
the horn relay terminal B where It IS flow IS supphed through the relay the relay contacts close ThIs allows
shunted by the two CirCUItS In one contacts to horn Horn bracket serves the current to flow to the horn

BE 27
 BODY ELECTRI CAL SYSTEM

HORN RELAY INSPECTION

Test system contmulty and each
urnt ohmmeter
G
by usmg test lamp or
BG GY
Refer to BE 40 and 4 J for
Hl Sl B
FIgUres BE
FUSE BOX horn system
20A In
testmg horn relay there must be

contmUlty between CD andCV

I

CID
H
TO STOP LAMP HORN BUTTON
SWITCH

BATT RY

HORN

BE270 FUSIBLE LINK 08S REOl s B

m
CD CV

FIBE 40 CirCUIt diagram for horn system

H B S

BE300B CID CV CD
Fill BE 41 Horn relay

TROUBLE DIAGNOSES AND CORRECTIONS

CondItion Probable cause Corrective action

Horn does not Exoesslvely dIScharged battery Measure of electrolyte

SpeClftC gravIty
operate Charge If reqUIred
Blown offfuse Check fuse for fusmg and rrnproper contact
Replace or repatr If requtred

Improper horn button contact In this case horn sounds when horn relay termmal
5 IS grounded
Check and repair horn button

Inoperative horn relay Horn sounds when horn relay ter1TI1naIs B and
II are clrcUlted
short

Replace horn relay

Faulty horn Horn does not sound though horn relay termmals
B and II are CircuIted
short and hom does not
sound though battery ter1TI1nal IS connected to
horn tenmnal directly
Replace horn

Hom sound Inoperative horn relay Horn does not stop though hom relay S termmal
contmuously IS dISconnected

Replace horn relay

ctrculted
Short horn button and When hom stops through above disconnection
hom relay termmal S check horn button UnIt partIcularly carefully
r

Repau horn relay termmaI 5

Replace horn button

BE 28
 BODY ELECTRICAL SYSTEM

CondItion Probable cause Corrective action

Reduoed volume Improper fuse contact and loose Correct

and or tone qualtty connection

Broken cable Repair or replaoe If required

Improper horn button contact Repair

WINDSHIELD WIPER AND WASHER

CONTENTS

WINDSHIELD WIPER AND WASHER BE 9 Inspection BE 32

DeSCription 8E 29 TROUBLE DIAGNOSES AND

Removal and Insta lIatlon 8E 30 ORRECTIONS BE 35

The mtermlttent The Wlnd

WINDSHIELD WIPER amphfter IS m electncally operated
stalled on the front dash SIde panel slueld washer conSISts ofwashing flUId
AND WASHER tank WIth motor and pump washer
nozzles and vinyl tube used to con
Description nect those components
The Wlndslueld wiper conSIsts of a The wmdshleld washer SWItch IS

WIper motor UDlt a link mecharnsm combmed wIth the wmdslueld WIper
WIper arms blades and an mter
SWItch to a smgle urnt When operatmg
1TI1ttent ampllfter the intermIttent am
the washer tWISt the SWitch knob
plifIer IS Installed on the Hardtop
model only The motor urnt IS made
up of a motor and an auto stop mecha
nISm

The wiper motor UnIt IS located on

B E262A
the ftre wall In the engme com
part
ment and the hnk mechamsm IS lo Fig 42
BE WindOW screen wiper
cated under the cowl top panel amplifier

BE 29
 BODY ELECTRICAL SYSTEM

Removal and installation

1 Pivot L H
2 Wiper arm L H
3 PIvot R H
4 WIper arm R H
5 Wiper molor

BE263A

FIg 43
BE WIper motor and wiper lrnkage

7 Remove two flange nuts attaclurtg

Wiper motor and wiper linkage to cowl top
PIVOt panel and remove
1 DISConnect wIper motor wtre con
link assembly
8 Install wIper linkage and WIper
nector from wIper motor
motor m the reverse sequence of
2 When removing wiper arm from
removal
pIVOt shaftraIse wIper blade from

WIndshIeld and then the Install wIper blade m correct m

glass remove

base of wIper from pIVOt shaft stallatlon angle to obtam correct

arm by
sweeplrtg zones
loosenmg attachmg nut

3 Remove cowl top gnlle by re

movmg set screws

4 Remove three WIper motor at Fill 45
BE RemOVIng lmk 8embly
a

tachmg bolts
5 Remove ball Jomt connecting
motor shaft to wIper hnk

6 Remove wIper motor from cowl

top panel

BE264A BE265A

Fill BE 44 Removrng motor Fill BE 46 Wiper arm rn81allatlon

BE 30
 BODY ELECTRI CAL SYSTEM

Washer nozzle
Remove washer nozzle
I fIxmg 3 Install washer nozzle m the re flUid IS sprayed m proper range as

screw from cowl top panel verse sequence of removal shown m Figure BE 48
2 Remove washer nozzle 4 nozzle dtrectlOn that
AdJust so

I Washer tube
2 Washer nozzle
3 Washer tube
BE276 4 Washer tdnk
5 Washer nozzle R H
6 Washer motor

Fig BE 47 Wmdshleld washer

Bend pIpe With suitable tool

a
Wiper SWItch
I Loosen four screws and remove

and lower shell from

262 upper covers

103 steering column

2 Loosen two cluster hd cover re

r taining screws and remove cluster hd

cover

3 Remove ftve screws from front of

cluster A and remove one screw hold

mg cluster A to Instrument panel from
behmd Thus cluster A IS detached
BE277
VOlt 10m 10 4 Remove sWitch knob by de
It and counter
pressing turmng It
clockWISe
5 Remove wiper and washer sWItch
FIg BE 48 Nozzle adjustment
Ul1hzmg the same procedure as that
for hghtmg sWitch

Note In washer
assembhng motor Never mIX
soap powder or deter
IntermIttent wiper amphfier
and washer tank It IS recommended WIth solution
gent
that soapy water be used to faclll The mtermlttent
2 Do not wIper amphfIer IS
operate wmdshleld washer
tate the operation mstalled on the front dash SIde
continuously more than 30 seconds
WIthout washer flUid I Remove cable
or ThIS often battery ground
Cautions for wmdshleld washer 2
causes Improper wmdshleld washer Remove screw securing mter
operation operatIOn wmdshleld mlttentamphfIer
Normally place m

I Be washer should 3
sure to use
only washmg be operated to Disconnect connector and remove

solution seconds less at See

or one time ampllfter Figure BE 42

8E 31
 ODY ELECTRI CAL SYSTEM

motor turns Ground termmal CD and check to

Inspection Ground eIther termmal CID or
@ to ensure that contmUlty between termI

Hardtop model keep wIper motor m runnmg condi nals CD and CID eXIsts Undo ground
tion Check contmUlty between ter1TI1 utg termmal CD and check that conll

and washer swItch nals CID and V If continuIty eXIsts It nUlty between CD and CID does not
Wiper mwcates that the
I off
on cycle IS re eXISt If test results are as mdlcated
To
perform contmUlty tests prop
peated and that auto stop ClfCUlt IS
wIper motor mter1TI1ttent relay IS func
erly refer
to FIgure 49
BE and
functlonmg properly tlomng properly
as follows
proceed
Note Use of an ohmmeter is suggest
ed to facIlitate contmUlty tests

I Turn wiper sWItch to the OFF

and test
posItion contmUlty between
termmals@andCD f
2 Pull wIper sWItch out to Jst POSl
lion mtermlttent wIper opera lion

a
Test contmUlty between termmaIs @
and CD and between CID and CID

respectively
3 Pull wiper sWItch out to 2nd
posItion low speed wiper operation
Test contmUlty between termmals CID OFF I 2 3 TWIST
I
and @ and between CID and CID
2
respectively
4 Pull SWItch out to 3rd 3 U C C
wiper r

posItion hIgh speed wiper operation

4 0
5 I
Test contmUlty between termmals @
and CID and between @ and CID 6 I C
7 v
respecllvely
5 BE266A 8 1
Push wIper SWitch m all the way
to the OFF posItion and then tWISt It Fill 49
BE Wiper SWItch
With wIper SWItch held III that POSI
tion test contmUlty between termmals

CD and @ and between CID and @

respecllvely
If contmUlty eXIsts III all tests m
steps I through 5 above wIper SWItch
IS III good order

Wiper motor

Refer to
7
FIgure BE50 and perform
contmUlty tests at the followmg termI
nals
@ and @ CD and @
Between
41
@ and@ @ and@ and @ and
CD
Then connect posItive termmal of a
12 volt c
d to termmal
52
power supply
@ and ground termmal @ securely
WIth thIS setup check whether or not 63
wiper motor runs lIdThe motor
sho
run Next ground termmaL@ Do not
II ground termmal @ thIS time W th BE301B

thIS setup check whether or not WIper Fig BE 50 WIper motor

8E 32
 S STE
l
El
800
ECTRICP
u
U

0
ll

0
Cil 3

C0 Z

1 0

t0J
ll l
iil
u

and waShl
of wiper
Cltlt dllllfralll
51 cu
fBE
g

BE 33
 BODY ELECTRICAL SYSTEM

Intermittent amphfier
Set up a test CircuIt as shown m

FIgure BE 52 and check mtermlttent

amphfter for operalJon as follows
Turn sWItch B
on
makmg sure that
ImmedI INSPECTION LAMP
mspectlOn lamp comes on
34w
ately then blmks at 5 to 7 second

mtervals

Next turn on sWItch A InspeclJon

lamp should come on
approxImate
ly 0 7 second after sWItch IS turned
on When sWitch IS turned off 2

seconds after lamp comes on lamp

should remam on for some another
2 5 seconds

If above tests do not come out

posllJve replace mtermlttent amph SWITCH B

fter
BEB94A

Fill BE 52 Intermittent amplIfIer

Sedan and 3

Station Wagon

Wiper and washer sWItch

To perform contmUlty tests prop
erly refer to FIgure BE 53 and pro
ceed as follows

Note Use of an ohmmeter IS

sug
gested to faclhtate contmUlty tests

I Turn wIper sWItch to the OFF

and test between
pOSllJon contmUlty
@ and @
B E303B
2 Pull wIper sWItch out to 1st

posllJon Test contmUlty between FIBE 53 Wiper SWItch Sedan and StatIOn Wagon
termmals @ and @
3
WIper motor
Pull wiper sWItch out to 2nd
Test between
posItion contmUlty
termmals @ and @
4 Push wIper sWItch m all the way
to the OFF pOSItion and then tWiSt
It

With wIper sWitch held m that

pOSItIOn test between
contmUlty
termmals CD and@
If contmUlty eXIsts m all tests 10
WIPER MOTOR
steps through
I 4 above wIper sWItch B E304B

IS m good order
FIBE 54 WIper motor Sedan and StatIOn Wagon

8E 34
 BODY ELECTRICAL SYSTEM

Checking motor termmal CD connected to that voltage 12 volt c

d power supply to ter1TI1nal
undo
Refer to FIgure BE 54 and perform
source groundmg ter1TI1nal@ CD and ground termmal CID WIth thIS
and ground termmal CID setup permit to run wIper motor and
contInUity tests at the followmg termi
WIth each setup check whether or measure voltage at termmal@
nals
not wIper motor runs If It does not If voltmeter pomter deflects from
Between CD and @ and between

CD and CID WIper motor IS faulty 12 volts to 0 volt then back to 12

volts auto stop
Then
CirCUit IS
functlOnmg
connect posItIve ter1TI1nal of
a 12 volt doc power supply to termmal Checking auto stop CIrcuit properly
CD and ground termmal With@ Connect posItive ter1TI1nal of a

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

Wmdslueld wiper does InoperatJve mtermlttent amphfter Replace

not Intermittently wiper and washer sWitch contacts sWitch
Improper Replace
operate
Broken armature of wiper motor Replace wIper motor

Inoperative mtermlttent wiper relay Replace wIper motor

Worn motor brush Replace wiper motor

Motor overheated due seized motor

IS to Replace wIper motor
shaft

Wmdslueld wIper fuse JOA melts due to Replace fuse and wIper motor or repan
short cncult layer short cncUlt or motor faulty part
mSlde component burnt

Wmdshleld wIper does No current flows to motor due to

not operate Broken armature Replace motor

Worn motor brush Replace motor

Motor IS overheated due to seIzed motor Replace motor

shaft

Wmdshleld wiper fuse IDA IS easlly fused Replace motor or repan short cncUlted part
due to short cncUlt layer cncult
short or

motor mSlde component burnt

Blown out fuse due to trouble of other part Check other part for operatIOn and correct
m wmdshleld wiper CirCUit problem
Loose open or broken Wtrmg Check Wtrlng near motor and connector for

connectIOn

Correct If necessary

Erroneous wtrlng Check each wne for color code and correct
If necessary

Improper groundIng Correct

Improper sWitch contact Correct If necessary

Foreign matenals mterrupts the movement Correct

ofhnk mechamsm

Disconnected hnk rod Correct

Seized or rusted arm shaft Lubncate or

replace arm shaft

8E 35
 BODY ELECTRI CAL SYSTEM

CondItion Probable cause CorrectIve actIon

Wmdslueld wIper WIth arm raISed stlll excesSIVe current flows Replace motor

operating speed IS due to leyer CirCUit

short of motor armature
too slow
Wmdshleld wIper stops only by hghtly hold Replace motor

mg WIth hand due to wom motor brush

WIth arm raISed stlll excessive current flows Replace motor or lubncate bearmg WIth
3 to SA due to seIZed motor shaft engine 011

Low source voltage Measure voltage check other electncal parts

for operation and take corrective action for

power supply If necessary

HUffi1TI1Dg occurs on motor m arm operatIng Lubncate or replace

cycle due to seIZed arm shaft
Improper sWItch contact Conduct contmUlty test and replaoe If

necessary

Wmdslucld wIper blade sticks on wmdslueld Raise arm and operate Wlndshteld wIper

glass WIthout applYIDg load

Clean wmdslueld glass and or replace WIper
blade

Wmdslueld wIper speed Motor brush for eIther low or

ugh speed IS Replace motor

cannot be changed worn

correctly

Wmdslueld wIper does

not stop correctly
Contaminated auto stop relay contacts Remove autostop deVIce cover and clean
Stops anywhere or

rrnproper contact due to foreIgn matter contacts carefully so as not to deform relay
plate
Improper connectIon between Ist and 2nd Remove SWItch and make sure that 1st and
swItch steps 2nd steps are not connected at OFF

positIon
Ifconnected replaoe sWItch

Does not stop Contact IS Remove autostop deVIce cover and correct
Incomplete auto stop operation
not mterrupted relay plate bendlftg

8E 36

0
 BODY ELECTRICAL SYSTEM

RADIO

CONTENTS

INSTALLATION BE 37 TROUBLE DIAGNOSES AND

Radio receiver BE37 CORRECTIONS BE 39
Radio antenna BE 38 NOise prevention chart BE 39
ADJUSTING ANTENNA TRIMMER BE38

INSTAllATION

Radio receiver
4 Connect RadIO Antenna tlus
I Remove mstrument panel speaker wtres to mstru gIVen m m

mstrument ment harness at connector

2 PosItion speaker to section

panel and mstall two flange nuts See 5 Connect radIo wtres to trlStru 7 Install mstrument panel
FIgure BE 55 ment harness at connector 8 Connect antenna feeder to radIO
Install radIo to mstru 6 Install aJ tenna Follow cabIe
3 reoelver procedure receIver

ment panel

Fill BE 55 RadiO

BE 37
 BODY ELECTRICAL SYSTEM

2 Install two retamlng and

Radio antenna screws

Install antenna feeder base to front

plllar
3 PosltJon antenna support to front
m positIOn and Install
pdlar retaInmg
screw

4 Install antenna rod assembly

ADJUSTING
ANTENNA TRIMMER
When a new radIo receIver antenna
or antenna feeder IS Installed antenna
trtrnmer should be adJusted
Extend antenna completely
2 Tune m the weakest station be
tween 12 and 16 1 200 to 1 600 KC

on dial
BE279
NOise may be generated but dls
Fill BE 56 Radio antenna regald It

3 Turn antenna trunmer to left and

I Insert antenna feeder mto an and route It dash side right slowly and set It at
through panel to a positIOn
tenna mountmg In front pillar radio receiver where receIVIng sensItivity
openIng IS
highest

CLARION MAKE
BE572

FIBE 57 AdJustrng antenna trImmer

8E 38

1
r

BODY ELECTRICAL SYSTEM

TROUBLE DIAGNOSES AND CORRECTIONS

Noise prevention chart

PosItion vehicle open area away from steel buddmgs run engme extend antenna to ItS maxtrnum
m an length set volume

control to maxImum and set dial at a medIUm pomt Without catchmg broadcastmg wave

CondItion Probable cause Corrective action

Igrntlon system
NOISe occurs when engme IS op High tensIOn cable Install new
high tensIOn cable

era ted

IgmtlOn coil Keep choke wue away from Igrntlon coll

Install 0
51lF capacItor
a to pnmary SIde

termmal of IgnItIOn COli

Note Be careful not to mstall to

capacItor
secondary orprunary breaker Side other
WISe engine becomes Improper

Connect between engme and

wire Igmtlon
cOlllocatmg alea of body
Secure of IgmtlOn coil
grSlUnd
Dtstnbutor Secure contact of carbon electnc pole and
rotor

Ehmmate sharp tip on rotor pole or cap pole

by scrubbmg With a screwdnver
Check stagger between rotor and stator

Chargmg system
Sound of Alternator Install a 0 51lF capacitor to chargmg term 1
alternatmg curren t pre

sents nal A

Note Do not use a

larger apacltor
If capacitor is mstalled to termmal F
alternator coll will be damage

When accelerator Regulator Install a 0 51lF capacitor to A term mal of

pedal IS depressed
or released nOise presents voltage regulator

Supplement equipment
When engme starts nOise presents Operative nOise of water tem Install 0 IIlF capacitor between termmal and
NOIse still presents even after stop perature and fuel meters ground wire

pmg engme Note If a capacitor havmg a larger capacity

IS used mdlcatlon of meter will be
deViated

Install o 51lF capacitor to horn relay

presents when horn blown Horn a
NOise IS

termmal or horn SWitch

when Flasher umt Install a 0 51lF capacitor

NOise presents tu rn
Signal
lamps are operated

Notes b Cut lead wIre as short as pOSSible securely

IN
a Be sure to locate capacItor as close c Ground wire should be attached on e Carefully Identify
as to noISe source and connect m the body completely or OlJf marks

parallel d Make installation and connectIOn

BE 39
 BODY ELECTRI CAL SYSTEM

HEATER

CONTENTS

DESCRIPTION 40
BE Heater core BE 43
Air flow BE41 ADJUSTMENT BE 43
REMOVAL AND INSTALLATION 42
8E Control assembly 43
BE
Heater Unit BE 42 INSPECTION BE 43
Heater control 8E 43 Fan motor power supply BE 43

Air Intake box 8E 43 Fan motor BE 43

Heater motor 8E 43 TROU8LE DIAGNOSES AND CORRECTIONS BE 44

DESCRIPTION
The heater IS controlled by three
levers AIR TEMP and FAN
Heater core

The AIR lever con trois air dIscharge

by means of three doors air mtake
mode and defroster room doors
o The atr mtake door IS used to let
eIther outslde or mSlde alr flow
mto the heater umt The outside au To defroster
nozzle
ISdrawn from the cowl top gnlle
and delivered to the air mtake box
o The mode door serves to supply air

flow to the outlet m the mstrument

panel ThIS door has three detent

posItions open close mIddle

o The defroster room door controls
air flow discharged from heater
umt When the door IS open air IS

dIscharged to the floor area WIth a BE2al

small amount gomg to the defroster

nozzle When It IS closed all air IS BE 58 Sectional
FIg view of heater
dIscharged from the defroster noz

zle
The TEMP lever controls the air

1TI1X door and mixes heated air With air AIR

bypassmg the heater core to obtam the 0 VENT ROOM DEF

deSIred air temperature In tlus man

the temperature of air IS effective
rEMPI
ner

ly controlled OFF 2 3

fJ
The FAN lever controls sWItch that
IS located on the control lever as BE2B2

sembly provldmg three blower speeds Fill BE 59 Contra lever

8EAO
 BODY ELECTRICAL SYSTEM

AiV flow AIR

OFF VENT ROOM

I Heating
TEMP I FAN

TEMP and FAN levers m

any pOSll1on

AIR

Heating and air DFF VENT ROOM DEF

TEMP FAN I
ventilating
AIR lever 10 any poslIlon
belween VENT and ROOM

panel

jument I
AIR

Air ventilating 0
t RD M oEF

Ulifll
TEMP F AN I

TEMP lever 10 OFF

FAN lever 10 any posItion
J l

To defroster nozzle

AIR
I
Defrosting OFF VENT AOOM DEF

IEUP I FAN
I

FAN lever m any posItion

Air conditioning
not in use
AIR
I
OEF

err
OFF vENT ROOM

TEMP I FAN

J
t BE2a3

FIBE 60 Air flow

BE 41
 BODY ELECTRICAL SYSTEM

REMOVAL AND INSTALLATION

I Dem ter nozzle

2 Demlsler hose
3 Intake box
4 Heater duet hose
5 Heater umt

6 Center ventilator
7 Heater conlrol assembly
BE2B4

FIBE 61 Exploded of heater unrt

vIew

Heater unit 8 Remove cable rctdmmg clamps

I DIsconnect for the mix door mode door and
battcry ground cable air

2 Dram engme cooldnt defroster room door Disconnect

3 Remove hose dnd discon cables from door con trollevers

clamps
nect mlet and outlet hoses
4 Perform the followmg operations
m the dnver s compartment side
5 Remove center ventilator and
center console box If so

6 Remove heater duct hose

equlppcd Q
Fill BE 64 Removmg umt securing
bolt

BE286

Fig BE 63 Removmg cable retammg

clamp

9 Disconnect lead wires at two con

nectors

10 Remove three bolts two on

Fill BE 62 Removmg heater duct hose each sld e of heater umt as shown Removmg Unit securing
bolt
Figure BE 64 and one on the top of
7 Remove demlster hose from each thiS unIt as shown Figure BE 65 12 To mstall heater umt reverse
side of heater umt II Remove heater UDlt the sequence ofremoval
o

8E 42

t
 BODY ELECTRI CAL SYSTEM

Heater control ADJUSTMENT INSPECTION

I Remove heater Unit Refer to the Check the followmg Items If fan
Heater Unit Control assembly motor fallS to rotate
2 Pull out fimsher forward Note Whenever a new or re condltloned I Fuse and fUSible hnk

I 3
that fmlsher IS latched m pOSition
Remove two retammg screws and
heater Unit
control
IS

assembly
to be mstalled

as follows
adJust 2

the
To check for burned out fuse
same procedure as that for ordI
use

remove heater control assembly Move AIR lever to OFF nary fuscs With the use of a CIrCUIt
4 To mstall reverse the sequence of posItion
removal
Fit cable to door lever of air mtake tester or test lamp
box and fasten wIth d cable retam 3 Loose wire connectIOn

mg clamp wlule pulhng outer case

Air intake box of cable wIth a force of I to 2 kg

2 to 41b
Remove heater duct hose
2 Move AIR lever to DEF posltJon
2 DISconnect control cable from air
Fit cable to defroster
room door
mtake door
lever and fasten With a cable retam
3 Remove screw air mtake
secunng
mg clamp wlule pulhng outer case
box m place
4 Remove air mtake box
WIth a force of I to 2 kg 2 to 41b Fan motor power
5 To mstall the sequence of FIt cable to mode door lever and
reverse

fasten With a cable retammg clamp

supply
removal I DIsconnect lead wires at con
while pulhng outer case WIth a
nector
force of I to 2 kg 2 to 41b
2 Move Igmtlon sWitch to ACC
Heater motor 3 Move TEMP lever to left stop posltJon
I Remove heater umt FIt cable to air mIX door lever and Connect lead
by referring 3 test lamp wire to

to the Heater Umt fasten With a cable retammg clamp blue wlute wire termmal m connector

2 Remove three whlle pulhng outer case WIth mstrument harness Side and
screws and remove a
plug on

heater motor force of I to 2 kg 2 to 41b the other to the ground

3 To mstall reverse the 4 Make sure that test
sequence of Note Make sure that each control lamp goes on

removal
lever moves smoothly over Its entire
stroke
Fan motor
Heater core
Disconnect lead wires at con

Dram engme coolant nector

2 Remove hose and discon 2 Move sWItch to ACC

clamps IgnitIOn
nect mlet and outlet hose from heater Operatmg force
Control lever posltJon
umt kg Ib 3 Connect test lead to posltJve Side
3 Disconnect two control cables on of fuse block power supply and the
AIR Lever 03 0 7
the Sides of healer umt mID other to blue white wire terminal m

4 Remove chps and remove gnlle TEMP lever o 3 07 mm

connector plug on fan motor Side
4 Make sure that fan motor oper
heater box
FAN lever I 5 3 3 mm
5 Pull ates at each posItion offan lever
out heater core
6 To mstall reverse the sequence of
removal

BE2a9

Fill BE 66 Removing heater core

8E 43
 BODY ELECTRICAL SYSTEM

IGNITION SWITCH
20A
TO RADIO
AC AI
FROM BATTERY
FUSE BOX

FAN LEVER

3 2 OFF
L
B

LR LR RESISTANCE

LB LB

LW LW

FAN SWITCH HEATER UNIT BE290

Fill BE 67 CircUit diagram for heater

TROUBLE DIAGNOSES AND CORRECTIONS

CondItion Probable cause Corrective action

Insufftclent heatmg

performanoe
No heated air
Coohng water temperature too low Check thermostat
dIscharged Replace as necessary

Heater core plugged Clean

Insufftclent coohng water level Refill

Water cock out of proper operation AdJust control cable

Au mIx door out of proper operation AdJust control cable

Insufftclent air Fan motor too low Check for lnotor termmal
speed voltage
flow to floor and discontI
Repair poor connectIon

nUity
Replace motor If necessary

Defroster room door out of proper op AdJust control cable

eratIon

8E 44
 BODY ELECTRI CAL SYSTEM

Condition Probable caus Corrective action

insufficient
defrosting
performance
Cold air
discharged Refer to No heated air discharged
Insufficient air Defroster room door out of proper opera control cable
Adjust
flow to defroster seal
tlOn or damaged
Denuster nozzle plugged Clean

Leak at demlster hose to nozzIe connec Correct

tlOn

Heated aIr discharged Mode door out of proper operation Adjust control cable
with lever In VENT

No heated aIr dlS Mode door ou t of proper operation Adjust control cable Make sure that AIR
charged With lever In lever moves smoothly over Its entire
between VENT and ROOM range

Failure of fan to run Fuse melted

Replace
Motor Wire connector disconnected Correct

SWitch faulty Replace

Motor faulty Check and correct

Control lever drags Inner wire rubbmg against outer case end control cable
Adjust
Control cable bent excessively Correct

Doors door levers etc out of proper Check and correct

operatIOn

Outside air comes Au mtake door out of proper operatIOn Repair or replace
In With fan In OFF
Control cable out of adjustment Adjust control cable

NOise from fan motor Unusual nOise from fan motor Check and loose bolts
tighten

BE 45
BODY ELECTRICAL SYSTEM

f BE 69 Wiring harness
FI

BE 46
 BODY ELECTRI CAL SYSTEM

1 Body harness
2 Room lamp harness No 2
3 Rearroom lamp harness No 1

4 Tallgale harness
5 Body harness rear

BE955A

f BE 70
FI Wiring harness Station Wagon

Voltage regulator

Auto choke relay For Australta

YBlIiRBLB InhibItor relay A T

w

BY
iz RB

00

To engme RW RB RL R Jl

room harness FUSible lInk

WHITE

LYGBYLRYW

RBlf
BL

GREEN
B BR

BE30BB
Llghttng relay Horn relay
f BE 71
FI DetarlA

47
BE
 BODY ELECTRICAL SYSTEM

JUNCTION Block sIde Body harness SIde INSTRUMENT Harness SIde

B BY

l1Yf 1 iWI
G

BiY
t g

illC
G OOGL
RY YL
w
o y R 0 0
I
G

u
8 YW L
LW 18 G
l W R y
GIf
G L WR L
l go RY

YL IN WRL

Black Blue Green Brown White

Brown Green Blue Black

To malO harness Detail C

To malO harness DetaIl A

LW
III

1 To
wiper motor
2 Brake 011 level sWItch @

BE312B

FI BE 72 DetaIl B
f

48
BE
 till o c mr m o fa o r en en fm s

sWItch lamp BE31B Detaz

and
met r lamp lamp sWitch
contrluma
73

Hardtop YB YW
lamp lIghter
box speaker unIt sWitch IlumatOn
only sWitch
pIlot warni g sWItch sWItch earth
BE
Fl
Except
YW RW
YG t glove cigaret radiO radIO heater knob model adJ
To To To To To To SSS To To
combatlOn Earth Cwhaarnrgieg defoger Defoger hazrd Ightmg wiper body
To To To To To
1 2 3456 78 9
10 11 12 13 14 15 16

@
I

VA

R t DETAIL
WHITE
t @

t BLUE
g0

L9
GR GB

YW Y
YG
LW

J YB fM LW
LB
GRE N
LW L

J
0

LR LW ew
YR BROWN

G Tnw LAB
B

BYfJ
LW

WB I

GW

Ol m t0
 till o c mr mofa o r en en fm s

L
BE314B DetaIl
@ 74

@m @k
L

BE
LR LB f
FI
L

BL
R BW
GL
ro BY

BR
GR

RY@RY
@
IJ

BaRB @

@
B
@
RG
@
G
L9

ffi
B @ Hhr
GL
L

block t

UnI
fuse B Unit
use
sWItch harnes
To
relay sWItch flasher sWitch brake
no

s W i t c h sWitch sWitch harnes

block
LY

LY
amplIfier down SIgnal lamp buz er Unit mot r signal Signal sWitch lamp
f l a s h e r
condIt er
wiper defog er kIck turn haz rd stop back parkmg heater heater Igniton turn turn wiper
harnes To To To To To To To To To To To To To To To
au
Ro m
malO 23 45 6789
10 12 13 14 15 16
1
II

To

Ol m c
r o
rc
 WIRING DIAGRAM

WIPER MOTOR oo
LOILffi01 Da
W TH RELAY M T ONLY DYG

HORN RELAY L
LTAGE
3ULATOR
r iH liB LbR LR B

E
L iNK1 I
OWN g B
1O DBL
RY
RL

FUSE BLOCK OORSW R H NOTES

lllffi SNAP TYPE

5
1 W R
R
D
l
EOL
i R MEANS CONNECTOR

GW
MEANS PIN TYPE CONNECTOR
GY EEl
ll@
I@IR
LW
BB 2 COLOR CODE
RG ii L BLUE Br BROWN
INTERIOR
GL
LIGHT B BLACK W WHITE
a
oS R REO Y YELLOW

ll8v
fWl G GRE EN I
J
l LIGHT GREEN

R lW BLUE WITH WHITE STRIPE

6
@eL
DOOR SW L H J
f H m J
3J TERMINAlSSHOUD BE CONNECTED

EACH OTHER WHEN TACHO METER

G
BLG Z IS NOT INSTALLED
0
F U E
C

Ir y r
t

RaY
i tRaG
ITFTI
o JWL m
Jm co tr
eJ
X
f
crmQ Q J
Q Q CD
J
a Q 3
OXt t rrr
aJl

ll MWI tlN
LIGHTING
tU
T
I
L
lW
a
a

W
E
AuroCHCJ
till RELAY

RELAY
IZ I
IW
o 11
1 l @ to @ @ @ SEDAN I
G
H ADAPTER

fJlo
HARNESS

u IB
o
O
i
sG W
c J
J
tlCt mmC lC Q JJ LJID
VaG
n
U Wo

m m B

WIPER SW aa
a

PJl
Ifi B
M TONlYl B
a rlA1TONLy
PARK PLUGS
O
cr
f BR
RY
BBy33J
LLY TAILGATE fh R
J
AT

t fTER
s
o

00 H 0 DO y

LW
SW
P

WURE 8 I
c

tJ5 W a 00 @ GL

IGNITION SW
GRL
d LIGHTING swl B 00
J
c
GW
INOICATOR

tc
fONLY
I

1
STARTER BAOlJP INHIBITOR
0
SW SW KICK DOWN HAHD
MOTOR YG J
n lM TONLYHA TONLYl
LG9
d
SOLENOID E
DIESEUNG
ANT1 SOLENOID HAZAROSW
1
tA TONLY
2E
NA
8 COMBINATION METER

G J T g
AUTO CHOKE KICK DOWN sw 4 2
B c

DJ
J
HEATER A TONLY IM HBEA
YG
J
c
LB

THROTTLE SW
CONTACTS
J
c
GY

CJ
GY
STOP LIGHT SW B
LO
1t9@@crJ
I
@
G
0 0
8
TURHt

TURHtLH
10
H

I TANK UNIT

lFUEL
I

B
GW l A BACK UP
F lD
g rf g SW L S 12

J
u
REAR COMBINATION
II

LSWEB
LIGHT lR HJ
BBw J
c
YG
nLBB ILLUMINATION
LR C

L C
GW B
D
I
un C@B
Lw

JLIC
is
t FANMoroR
1
C tLLUMINATION WR
EI T CLOCK LIGHT
Jl TURN SIGNAL HAZARD oGW p
YR BCD
SEDAN

I
FLASHER QoGW
FLASHER
UN IT
19 BW
J
c
UNIT A
B W lI3 B

11
RES STOR RADIO
TACHO
REAR
v METER

g R
Q COMBINATION

LLR
FOR
L
B
c
J
CJ 9 REAR WINDW
DEFOGGER SW

ILLUMINATlON
LIGHT
L H 1

J
ag
SrnE
AIR CONDITIONER B 113
l CONTROL SW
IGNITION G W J
c I
COIL I
R
B GBW n BJw CIGARETTE
LW r
GLOVE BOX
LIGHTflSW
W
LLW J
c lEU
LIGHTER I
I

I
I
I

L
 t

V
t
t

f
t

t
r

s
t l t w b
j r
7 rol i

1
t
tL
1

j
t
 o
0

0 o o i
O

J O I KQ 1J@ Qoo llli

C o Ij @fuWID o

il 0
6
00
G
0 GO
0 0

o Q
t

0
f
v
o

41

Issued April 1976 011200

p
Prmt d m Japan PublIcation No SM6E 0610AO