aFl

MODEL I -SiEFIIES
 O U I C KR E F E R E N CI N
EDEX

NI55AN
McItrIEL S1E SEFTIES

e lgb{ \ISSA\ }IOTOR CO., LTD. Printed in Japan

Not to be reproduced in whole or in part without the prior written permission of Nissan Motor Company Ltd., Tokyo, Jr
 B||DY

SECTIOilBF

G|lI{TEI{TS
G E N E R ASLE R V I C I N , .G
.. ... ,,. .
B o D YE N DA N o D 0 0 A . . . . . . . . .
]NSTFUMEN , ,T. ,. .. . . . . . . . . . . . .
S E A .T. . . . . . . .. . . , . , , . . . ., , . ..
T R I \ I A N D M O L D I N ,G. , , . . . . . , .
I I I N O S H I E LADN D W I N D O W .S. . .
MANUALsUN BOoF (Hatchback) ,
ELECTRICAL SUN FOOF lcoups).
v t R R o. .B. .. . ., . .. . ., . .. . , , . .
R E A RA R s P o l L E a( H t s b h b a c. .k )
] O D YA L L G N I \ , I E. .N, .T. . . . . . . .
 GENERAL
SERVICING
Precautions-
. ltF Emovinsor lnnallinsvariouspans,placea cloth or paddlnsonto the vehicebodv io pr.v.m

. Handl.rim, molding,inntumens,qrile, etc.carelullY orin{allalion B.6rclulnotb

durinqremoving

. Applylea ingcompound whoranecessrywhileintrallinqpafrs.

. whenapplyinsseains compound, do6 not prctruderiom parh
becarefuihat the*alinqcompound
r whenrepladingany meblp.it {tor examplebodyouterptnel,membe6,eid.),besureio rakeruspe

Clio and Fastener-

. Clips.ndLnensGin BF3.crlonconespond to ihefolowinqnumbeuandsymbos.
. F e p l a c e a n y c l i p s a n d / o r f a s t e n e B w h i c h a r e d a m a q e dodrui nr idnasbr er im
o no.v a

=L

t
@)

I.
BF.2
 GENERAL
SERVICING
Clip and Fastener(Cont'd)

!@

.@

=:

BF-3
 SERVICING
GENERAL
CliPand Fastener(Cont'dl

fY'

@
-fsF_".:_

BF.4
 BODYENDAND DOOR

when rcmovinqand insb jnq hood, iunk tid or &ck d@r, pa a cLori or other pad.ring
on hoad,
iruoklidorbackdoorconehtoavoidectchinqvehictebodv.
when removinsc ip o. fasbner,fete.to cLtp & FASTENEn.
Apprysealinqcompoundwhee neery wien intutLinqp&E

Noodadiunhent:Adju*at hinq.ponion.
Hood ock adjuslment:Afteradjuninq,checkhoodtockconiorop€€rion.Arpty a @r
hood ockseng.gingmachanhm.
b.nd cabteforcibv. Doinssoincrcas effod requiEdro
Bumperldscia:k is dade of ptastic,so do not useex@$iw force

I rt.*,

@
q I

=_: -,,..,,,.",",,,
 BODYENDAND DOOR
Rear End

Backdoorrdjlsment(Hatchb€ckl: Adju*arhinqetor properb€ckdoorrit

TrunkLidadju*m€ni (coupelr pdjust lid podionfor properttunklid fir'
ar hinqe.trunk
Backdoor ock systemadiushenr(Hatchback): Adju.t lock & sirikersothat th€Yarc in fte cenE-
Aheradiunment, .hdk backdoorlsk operailon.
Tfunk lid lock sv{em adjustment(Coupel:Adjustsriker sorhat it is in lhe cantr of the lock AfE
adju*ment, chel rdnl lid locloperalion.
Bumperfdscia:hkmadeorplastic,sodonotuseexc*sivefor@andtakecaretokeepoi awavlrom iL

a. Be 6.erul not to sarch back door nlv wh€n installinqback door' A !@tch.d ttav mv duE

b. Th. 6nt€nt of th. brck door dav arc underprc$! r. Do not ltke apan,prncture,aPtlv h6t or.l

lFJ

Pll
7/

' t
-gir-
 BODYENDAND DOOR
R e a rE n d{ C o n t d )

-'#'
EI

'-11' a

---l-
'G,

_.,/,

rver i---

@
,e?

rut-
!c@

BF-7
 BODYENDANDDOOR
Trunk Lid/BackDoor and Fu€lFillerLid Opener
. Ooenercable: 0o notan:enpttobendeb. usinsexce$iveforce.
. makesurcthattuiklidlbackdoortndfu€lfillerlld open3moothLv
Afierinsbllarion,

--1\\\ i r
-1ffi>
\.6lll

BF-8
 BODYENDAND DOOR

. Whenadjuninsdooror doof ock,checkdoorlockopererion.

I e

t\

BF.9
 BODYENDAND DOOR
Front Door {Cont'd)

le zI f;T
:
!
t ' :ii:
t ;
:. f ' . I1 .t
i
r : if.
.-; q;;]:* l€l:, | , I
r 3 : L l I !6 :
t; . - .t t +
- . I I I"ET
6 ! L'; lE
: lF- rla:- i , .rr l l . T
',f]
ol
Y ! 9L-.'l L l
E E
3-=;F"-.----
=3!Ff l l : l=r
g
.
; r . E Tl::-T_:;-
. r ( +
-T T:Tl 13 !e
I
? s
i E g F-q s
LJ
E E :
: a €
; : i 3 :
9 : 9 Ei
3 : ! ! : ;

i*iiir

""09
L"rl
:::: ed gs 2- I
5|
q
:i
s

BF.1O
 BODYENDANDDOOR
F r o n l D o o r { C o n td )

Powerwlndowsynemfor R,H,drivemodelk d*sned ro luly openor croserhe driver'swindowauto

maticallyby onetouch(auro)opeGtionof driver'sdoorwindowswlrch.Sloppinslhe windowatthafu y
openorcrosed pcirronh doneby powr windowAMP.

Fi

BF-11
 INSTRUMENT

ln6e p.d tre mad. o'pl$"c. so do rot Ls6.t..siva lorcedlo be carclu -oL rodamagsrfam.

3
E

\$
E

8F.12
 SEAT I
inna ingthesairimi caieruyhande irro keeodid ourandavoiddamaqe.
whenremovinsor

Front Seat
. Besureairhoseknotgushed,
. Whendlsonneclinq an ho*,itk b4ter to dieonn€t it d chmpponion,
. ll hoseconn@ilonis d *onn*tad ar ealanrponion,apply*. anrio hosconner on to prcEntanair

. Sesureairpump kfrcefr6m dirt.forciqnsubslances,

etd.
. nddllstfay vavein itsp@perdir€tion.
. S@rllfrinsdeviceis a$embedwnhcushion frame.Thellrtinsdevlcecannorbereplac.dindependently.
Whenreplacingit, rapacecushionlrameasemby.
@

g G r EtrdF6E '

."."^'.-*s i-l

@l

BF-13
 SEAT
Se6t {Cont'd}

AIR DIAGRAM - PowerS€d

)-4 0
I o @ o ii
/1
I Gr o I

@
o o €.)

@ 6 1 a

B F -1 4
 SEAT
ont Seat lCont'd
WIBING DIAGFA[' POWET
S'At

E
i! E
: :
:c e
:t:55
d
.

EH
I
I
L l

+T
a

;4!_-!t ;

BF-15
 SEAT

$
'i

9r n

)rFz
#:
"_j{-S/
 TRIMAND MOLDING

Whenremovnqdtipor Janener,
relerio cLtp & FASTcNER.
whenhandlinqrimoffroldins,donoruseexcesiveforceandbk

ide Trim
SIDE, LUGGAGE,TFUNK
BOOMAND FLOOFTRIM

E :9
/-1
\ /

rP1
fl,
o
i
I t @ '

,ry,
@
i
I

I
:
w
6
ln

8F.17
 TRIMAND MOLDING
Inside Trim {Cont'd)

. Frontponionol pa$enserroom
t.im h theede asrhd ot Harchback

<>
-g
6

-i
\---

8F.18
 TRIMAND MOLDING
side Trim (Cont d)

. ' / /

8F.19
 TRIMAND MOLDING
Weatherstrioand Extsrior
. Applv seailhgcompoundwheren68sary whileinsbLlingFars
. whenappyinqsealingompound,becareluliharthesetslinqdomFounddoesnorpfolruderrom

7.1

BF.2O
 TRIMANDMOLDING
Weathersiripand ExreriorlCont'd)
'!)
Windshield
!ppe moldinq O @ Windshiold
low.fmoldinsandHoodsealinq

1L

1l

!a a5l

- Cutoft sealant at sla$end

: C e a n t h e s i d ew
o nh i c h p a nwea s m o u n r e d .

@
nnall moldlnsby arisninsthe moldinsmark
Gbd oncenrerwiih vehiclecenter.

8F.21
 TRIMAND MOLDING
weath€rstriDand Erterior (Cont'd)
ad

ar-t,B Sidewindowlowerou$idemoldinq
inlidesal
O O Dooroucid.mordinqand

f, Sidewindow upDer& sidefroldinqi

k's sameas door ssh moldins.So rcler6
Doorlashmo dinq'and"SideWindow".
n airoudd sille (colpel

\\"

&@

8F.22
 TRIMAND MOLDING
Exieriorlcont d)
'iir
G Sidewindos lowermoldinsand @r dip a0 tt sun mor lid wErhffiip

--' - :-=.--
< -""".,".".", l'*"f-"
<- \
'!-\*-
t
\

v -F -r

rl Sid.windowfrontmoldinq{H.tch6a.kl
Thk moldingk a$dmbledwith windowsla$.So @ sun'ool wearhs4rip(coupe)
ahenraplacin9,
replace
as. sel.
'j sidewindoww@th€Etrip
(Harchback)

_t-:i:::t
l
.J"' ,

a Sunroofwe.th66&ip(Harchba.kl
 TRIMANDMOLDING
Exiorior(Cont'd)
@ B.dkwindosupler& nde ,i Bac*doorwErh.n$ip lH*hbsck)

<@
:i7
@
Sid. quad moldingon fendertid. ie!fiir.i
Lndo. panel wirh dolblefsd adh€riv.
and on door sid. it k affixsd to door
withclipanddouble.fa.ei tdheivebpe.

t'

Bshov€it only il it ir .eNry to do 5.

13 Trunklid we.th.rdrip{coup.l portionto 30 to 4(rc

1 . t-teatmoLdinq

'rt
2 . Raileend of moldingand, whil6cu
bonding
ag.nt,detachmoldins.

Femovaall tmcesol bondinq.qenlf1a

A Hde. rindow moldins(H8tchbadk) pan6l.Thencleanconbcrlae ol body.
thi noEE t se ascoupebaokwindowupper 2, Heatbody paneland moldngro 3) r.
& dib rE|fq Rds to " O 8.ck window upper (36 ro lol"F) with a hst qun.Tha

8F.24
 ANDWINDOWS
WINDSHIELD
-Windshield, Re.r window {Coups) and Back Door Wiodow {Haichback)-

,%'
/ g
F9

(Nathb&kr
l lcoloe)
IJ
! 1
o . 6 ) o

BF-25
 ANDWINDOWS
WINDSHIELD
-Windshi€ld, Rear Window (Coupe)and Back Door Window (Hatchback)-
(cont d)
@ e o
I
o
1 I
8rk doorwhdow (Hdchbekl
I

,tfr-'

;,v

BF-26
 rSHtlE1
WIND LD ANDWINDOWS
-Windshield, Rear c
(i ) a n d B a c k D o o rW i n d o w
{c
? !
i
Be(dodrsddowrturhb3ck) G$!de
1
I

B&kdoqw ndow lHdch6eo

--L_r
ts"lppdmodhs. I

II
l
 ANDWINDOWS
WINDSHIELD
-wind6hiold, Rearwindow (Coupe)and Back Door Window lHatchback)-
{coni'd)

$o!ld nor b. dfta

J"J""'i;ci;r-i

,A*

BF-24
 ANDWINDOWS
WINDSHIELD

/ \
^rn
-SYt
'frl l

8F.29
 MANUALSUNROOF(Hatchback)

Hande sla$ lld wnh careso not to &maqe it.

BF.30
 SUNROOF(Coupe)
ELECTRICAL

. Do not moveor remove limirswitchun es ir is nessrv.

. arieranyadjustmenr, checks
. F l a n d l e rsi h
n e r p l . i e a ngda s L i dw i t h @ r e e n o rt o d a h a qiet .

-S
:*n:Y \

? F'; E
^r' ' @

.i.,."".,-r? eZ

Y4.:..=
.1
.1i
:$
\
 SUNROOF(Coupe)
ELECTRICAL
ElectricalCircuit

d6;;
 SUNROOF(Coupe)
ELECTRICAL
ElectricalCircuit {Cont d)

E
a E
tl
anl F/F]I
I qjE YI
B
E
5ii

:;

tisi
li I
F trd

iE,

!!t

| :t @
l; i L-i
- t " 5?i
i:3

-
9rl
I
L 6 I:

BF-33
 SUNROOF(Coupe)
ELECTRICAL
DrainHose& ElectricalUnit

ElectricalUnit Inspection

B F -3 4
 SUNROOF(Coupe)
ELECTRICAL
Eloctical Unt Inspeciion {Cont'd)

. Do not movaor rehovelimirswirh unl6 it isne6ery.

o
o

BF-35
 MIRROR
Door Mirror

CONTBOLDOORMIRROR/ WIRINGOIAGRAM
ELECTRICALBEIVIOTE

_r-
,?t*
EE)
Hi HIB*]irffTq

BF-36
 REARAIRSPOILEB(Hatchback)

Wheninstalins,ftk. sur.tharthe'earenosap!or mG at endsor rcarairspoiter.

8F.37
 BODYALIGNMENT

ALIdimension. indicatedih fisu16areactual one.

Whena tam sackinsqauqeh !s.d, sdrun both pointaftro equallensthandchek rhe poinie6and
s.useitsellto m.kesurerhere is no rreep aV.
Whena mesuringiape is used,checkto besurethercis noe onqation, iwktingor bendlng
MeasurcmedsrhouLd beiakenatlhecenter oJ the holes
mounrins
An anerhk{')lollowinsthevalued the maasurlns poinrindic.res polnron theolhF
rharthe metrurinq
sideis symmeticallyrhesamevalue.

The coodinat6 of the m€asurement lrom the respedive

poinEareihe dktnces measurcd dimensim
llnasinthedirectionsol "r", "y"and "z .
Dimension llns: "x" -
line c€nrerllneorvehicle
"y" ine centerlineof front axle(Anv measurcmenr pointln froniorthedim*
sion inerefersroa minus "- v3lus)
"z'line DatumI na (Any neasu.emenipoinrunderthe dimensonlinerefe6roa
minus "-" value.l
. <[@ : LB.S,model
@: LinklYPar€tr suspension model

EngineCompartment

,l

"F--
I.
BF-38
 BODYALIGNMENT
EngineCompartment (Cont'd)
MEASUREMENTPOINTS

=:s"';; :;;
-:
--
t_;
@ l,:-o'-1 :
;'- :rll-

@@

oo -_.:
)

,;, o

o@

BF-39
 BODYALIGNMENT
(Cont dl-
Engin€CompErrment

o@

@o

GJ@
/

@o

(t

BF-4O
 BODYAUGNMENT

:
j

I
6
L a
&) tt

gEr

{!
;;

I '?>.1
:
t€'<!

a
!
I

o-

BF-41
 BODYALIGNMENT
Underbody {Cont'd}
POINTS
MEASUREMENT
o
-e
e'
f+
'il
5

5
e

o
r'€9
:1
@ o @

o .Jle

@1. .:@
€

8F.42
 BODYALIGNMENT
U n d e r b o d y{ C o n r ' d )

@ 6

@@

@o

@o

oo
oo

@!

OO
@

@ @

BF-43
 BODYALIGNMENT
Underbodv {Cont'dl-

@o
G)

oo

@
@@ o<-l @rlffi;
"'f
o@

oo H
3 q

I
-/l-J.-@---
'" - (-(-.r.-"-rb*'"
Ba

BF-44
 BODYALIGNMENT
U n d 6 r b o d y( C o n l ' d )

oo

oo

BF-45
 SEGTIO-CL

itlNTENTS
Y D R A U L I CC L U T C HC O N T R O L cL- 2
L U TC HuNl r " cL- 7
: R V I C ED A T AA N D S P E C I F I C A T I O. N
. .S
. CL-10
'EC I ALS ER V T CTEO O L S .. CL- 12

:
'. i,. ," tr r' l r
|{t:
'rlll1,
,1t,t,
 HYDRAULIC
CLUTCHCONTROL

C l u t c h m a s t e rc y l i n d e r
fa

E - r i n gJ
f I
Releasebearing

Operating
cylinder

3.
p : N.m{ks-m,fr-tb) 4.

scL r 80 5.
Precautions
6.
o Recommended fluid is brakefluid ,,DOT3,,.
a Do not reusedrainedbrakefluid.
o Be carefulnot to splashbrakefluid
on painted
areas.
When removingand installingclutch tube,
use
Tool GG94310000.
To clean or wash all parts of master
cylinder,
operatingcylinder and clutch damper.
clean
brakefluid mu$t be used.
Never use mineral oils such as gasoline
or
kerosene.lt will ruin the rubber parts
of the
hydraulicsystem.

cL-2
L
 CLUTCHCONTROL
HYDRAULIC
Procedure Adjusting Ctutch Pedal
--Bleeding
Pushrod
mastercylinder
)arefutlymonitor fluid levelat
luringbleedingoPeration'
brake
,-op up reservoirwith recommended
luid. Lock nut
)onnecta transparent VinYltube to air bleeder lOl r Pedal stoPPot
f
iG -22
ralveof operatingcYlinder' 1 1. 6 ' 2 . 2 ,
12 - 161
. Clutch 3witch
Lock nut 12-15
lt ot l 8 - 1 2 1 1 . 2' 1 5 ,
(08'12, 9 - rll
53 - 8.71
A

Floor carper
Melt sheet
Dash insulator

floor Panel
-Dash
pl : N'm (ks-m'ft-lb)
Fully depress times'
clutch pedalseveral ,
,t'
J,.l

With clutchpedaldepressed, open bleedervalve s c L lA r

'li
' t l li

air.
to release 1l,i
Close bleeder valve.
clear
Repeatsteps 3 through 5 aboveuntil Pedalheight"H"
brakefluid comesout of air bleedervalve' 193 - 203 mm (7.60- 7'99 in)
"A"
PedalfreePlaY
1 - 1 . 5m m ( 0 . 0 3 9 ' 0 . 0 5 9i n )

l . Adiust pedal height with

pedal stopper
clutch slrritch.
2. Adiust pedalfree play with pushrod'

cL-3
 HYDRAULIC
CLUTCHCONTROL
Clutch Master Cylinder

rPiston assembly

Return spring
\

Lock nut p ) a .r r
t 0 . 8 -1 . 1 , 5 . 8 - 8 . 0 1

Supplyvalvestopper-
-\ A
' ' 2.s-3.e
lol ----g lt
lo.2s 0.4, 1.8- 2.g1
-
Remove this stopper,
when removing piston,
spring seat and return
spring.

" Do not reuse it

after removal.

pl ru"" (ks-m,
ft-tbl
scLl 63

INSPECTION
o Check parts for wear. or damage. Replace if
any of aboveconditions are observed.

cL-4
 HYDRAULICCLUTCHCONTROL

.h rod

\""'.;;.,.i3]0,,,.,n,
G\.bB

Pistonspring

Pistoncup I rtl't (kg-m,ft'lbl

,)o not reusepiston cup and dust cover after

'emoval.

' r ,h,
tl!''

ttf

cL-5
 HYDRAULIC
CLUTCHCONTROL
ReleaseBearing
REMOVAL AND INSTALLATION
LUBRICATTON
. Apply recommendedgreaseto contact
surface
and slidingsurface.
. A small amount of recommendedgrease
should
be applied.

cLr45 th is recess

Press

+ f,'a
scLl 67

f,'E3,
W
Cl,
af'
scLl 66 air

scLl 68

cL-6
 CLUTCHUNIT
Clutch

Slight burn or discoloration of contact surface

with clutch disc can be f ixed by polishing with
emery paper-

Flywheel'1

"m
. Do not clean in solvent.
. When installing, be careful that greaseapplied to
main drive shaft does not adhere to clutch disc.

Clutch cover'1

scLl 58 ,;lli1
,ilj,
.{{,

INING:
n awayclutch disc dust usinga dust collector
' cleaningwith a cloth. Do not usecompressed

cL-7
 CLUTCHUNIT
nspecting Clutch Cover_
Checkclutchdiscfor runout,etc.
Check height and unevenness of diaphragm o l l
springaftersettingTool.
cl
Runout limit of facino Diaphragm springheight,,A,,:
Iat 115 mm (4.53 inlirom rhe hub cenrerl
1 . 0 m m 1 O . 0 3 9i n l
: 33 - 35 mm (1.30- 1.38in)
Unevenness:
Lessthan0.5 mm (0.020in)

sT20050100

scLl 53

Checkclutchdiscfor wear.
Adjust unevenness
of diaphragm spring with
Tool.

Maasure the depth of rivst head.

More than 0.3 mm {0.O12 inl
scLl 69

o Check thrust rings for wear or damage

by
shaking cover assemblyup and down
to listen
for chattering noise, or lightty hammering
on
rivets for a slightly crackednoise.

cL-8
 CLUTCHUNIT
- Installing Clutch Gover

lrt Tool into clutch disc hub when

:chcoveranddisc.

KV30100100

$G
i,l:
' i',ii[,
,Ili,
.llli

cL-9
 SERVICEDATAAND SPECIFICATIONS
General Specifications Inspection and Adjustment
CLUTCH CONTROL SYSTEM CLUTCHPEDAL
Unit: mm (inl
Type of clutch control Hydraulic
Pedal height' r 93 - 203 (7.60- 7.991

CLUTCH MASTER CYLINDER Pedal free play 1 - 1.5 (O.O39

- O.O59t
'Measured from floor panel
Inner diameter mm {inl 15.87{5/8} to pedal pad.

CLUTCH DISC
C L U T C H O P E R A T I N GC Y L I N D E R
Unit: mm (inl

Inner diameter mm (inl 1 7 . 4 6( 1 1 / 1 6 )

225TBL

Wear limir of facing surface

CLUTCH DISC to rivet head 0.3 (0.0121

Model 22sTaL 2.tt Cx & L Runout limit 1.0(0.0391

Facingsize Distance of runout checkpoint
Outer dia. x inner dia- x
225x150x3.5 (from the hub center) 107.5(4.231
( 8 . 8 6 x 5 . 9 1x 0 . 1 3 8 )
thickness mm (inl
M a x i m u m b a c k l a s ho f s p l i n e
Thickness of disc assembly (at outer edge of discl 1.0(0.0391
Free mm (inl 8.3 - 9.0 (0.327- 0.3541

With load 3,923 N

(40Okg,882 lbl 7.6 - 8.0 {0.299- 0.315}
mm (inl CLUTCH COVER
Unit: mm (inl
Number of torsion springs
Model c225S
CLUTCHCOVER Diaphragm spring height 33 - 35 (1.30- 1.38)

c225S Unevennessof diaphragm

spring toe height Lessthan0.5 (0.0201
Full load N {ks, lb}
CA2OE engine 3,923 (400,882)

C A 1 8 E T , F J 2 O Ee n g i n e s 4,413(450,9921

cL-10
 SERVICEDATAAND SPECIFICATIONS
Tightening Torque

kg-m fr-lb

Pedal stopper lock nut 16 -22 1 . 6- 2 . 2 12- 16

Cfutch switch lock nut 12 - 15 1.2-1.5 9-r1
Master cylinder push rod 8 - 11 0 . 8- 1 . 1 5.8- 8.O
lock nut
Supply valvestopper 2.5 - 3.9 0.25 - 0.4 r.8 - 2.9
Mastercylinder 8-11 0 . 8- 1 . 1 5 . 8. 8 . O
securingnut
Clutch tube flare nut 15-18 r.5-1.8 1t-13
Bleederscrew 2 . 5- 3 . 9 0.25 - 0.4 1.A- 2.9
Operatingcylinder 30-40 3..1- 4.1 22 - 30
securingnut
Cfutch hose to operating 17 -20 1 . 7- 2 . O 1 2- 1 4
cylinder securing nut

Cfutch cover securing bolt 22 - 29 2-2 - 3.O 16 - 22

cL-11
 EMlSSlolr
G0ltTRot
SYSTEM

sEcTroilEC

oilTEilTS
C A A N K C AESMEI S S I O CO NNTRO SL Y S T E- C
T A E n g i n. .e. . . . . . . . . . . . . . . . , . . . E C 2-
aAANKCASE EMISSION CONTFOL SYSTEM FJ20Ensine ,,. ,,. ,,. ,, ,., ,,, ,.. . EC 3
€ ( H a u s TE M t s s t oCNo N T R osLY s T E M ,,. ,,. ,,... ,,. ...,,.,,.,, ,,..,,.... Ec-
-
E H A U S TE M I S S I OCNO N T F OSLY S T E I IF o r A u s t 6 a l , l o d e.l. - . . . . . . . . . . . . . . EC 5
E V A ' O F A T I VEEl \ r l S S l O
CN -
O N T R OSLY S T E MF o rA u n r . l iMr o d e. .l . . . . - . . . . . . Ec
B V I C ED A T A A N D S O E C I I C A T I O N
. . S. . E C .1I
CRANKCASE
EMISSION SYSTEM- FJ2OEngine
CONTROL

u
t

<lr
rvnem is desiqnad
to reiurnblowby qasto
m.nifolda^d to brinq freshan inro $e
@. A positivecra^kca*ventilationlP.C.V.)

|-

ll ml

EC-3
 SERVICEDATAAND SPECIFICATIONS

Unit N.m ft-lb

E.G.R. control valve 18-23 1 . 8- 2 . 3 1 3- l 7

E . G . R . t u b e s e c u r i n gn u t 34-44 3.5 - 4.5 25 - 33

Thermal vacuum valve 15-22 1 . 5- 2 - 2 1 1- 1 6

B . P . T . v a l v em o u n t i n g 3.7 - 5.0 0.38 - 0.51 2.7 - 3.7

screw
Water temperature sensor 15-20 1.5-2.O 11-14

Throttle valve switch 2.O- 2.4 o.20 - o.24 1.4 - 1.7

Detonation sensor 25 -34 2.5 - 3.5 l8 - 25

Air regulator 5-6 0.5 - 0.6 3.6 - 4.3

Iniector 2.s-3-Z o.25 - 0.33 1.8 - 2.4

Throttle chamber securing 18-22 1.8-2.2 1 3- 1 6

screw
T u r b o c h a r g e ro u t l e t t o 22'E 2.2-3.O 1 6- 2 2
housing

Fuel hose clamP r . 0- t . 5 o . 1 0 - 0 . 1 5 0 . 7- 1 . 1

Fuel hoss clamPihg Position

3 mm (0.12inl

EF336A

EF.76
 P R E C A U T I O NFSO R E . F . I . E N G I N E

FORE.F.I.ENGINE
PRECAUTIONS
.2
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SE F053C

EF.77
 '' ' :::':i;

..,&.&s
<:.
-:.
j-
.!
;i:'
,

ffi
lli
PARTS LOCATION
E.F.I. COMPONENT

PARTSLOCATION
E.F,I.COMPONENT
I FJ2OEI

iii
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sEFostc

EF-78
 E.F.I. CONTROLSYSTEMDIAGRAM

E.F.I.CONTROLSYSTEMDIAGRAM

-------
Fuel line
ffi Vacuum line Fuel pump
(with damper
t7 Inputsignal
- Output signal

Pressureregulator

P.C.V. valve

Water temperatu
sensor

Fuel pump relay Ignition switch

SE F055C

EF.79
 E.F.I. SYSTEMDESCRIPTION

E.F.I.SYSTEMDESCRIPTION
F U E L I N J E C T I O NC O N T R O L CONTROL UNIT the control unit generatesa pulse
whose duration (injector open-valve
The fuel injectors are electrically con- time period) is controlled to provide
nected,in parallel, in the control unit. an optimum quantity of fuel according
All injectors receive the injection sig- to the enginecharacteristics.
nal from the control unit at the same
The control unit consists mainly of
time. Therefore, injection is made
three ini.egratedcircuits formed on the
independently of the engine stroke
printed circuit board. This construc-
cycle (intake, combustion, and ex-
tion provides superior control unit
haust). In the four-cycle engine, injec-
reliability.
tion is made once every revolution of
the engine, triggered by the ignition
coil.
Fuel in this E.F.l. system is not in-
jected directly into the cylinder, but is SIGNALSFOR CONTROL
injected into the intake port. There- UNIT
The control unit is connectedto the
fore, the air-fuel mixture is drawn into
E.F.I. hamessby means of a multi- An electricalsignalfrom eachsensoris
the cylinder when the intake valve
connector, and the E.F.I. harnessis introduced into the control unit for
opensto start the intake stroke.
connectedto other sensors. computation. The open-valve time
The essentialrole of the control unit period of the injector is controlled by
is to generate a pulse. Upon receiving the duration of the pulse computedin
an electrical signal from each sensor, the control unit.

Temperature
of intake air

IGNITION COIL IGNITION SWITCH

NEGATIVE "START" position
TERMINAL

Quantity of
intake air

EF.80
 E.F.I. SYSTEMDESCRIPTION

FUEL SYSTEM
Outlet
FUEL PUMP
The fuel pump is a wet type pump
where the vane rollers are directly
coupledto a motor which is filled with
fuel.

FUEL DAMPEB
A relief valve in the pump is desigred
The fuel damper acts like a shock
to open when the pressurein the fuel Changein the pump dischargepres
absorberin fuel flow dischargedfrom sure is monitored by the diaphragm
line rises over 422 to 490 l<Pa(4.22 to
the fuel pump. There are not adjust- and spring, which vary the volume of
4 . 9 0 b a r , 4 . 3 t o 5 . 0 k g l c m z ,6 l t o 7 l
mentson this damper. the fuel chamber.
psi) due to malfunction in the pressure
system.
The check valvepreventsabrupt drop FUEL PUMPCIRCUIT AND OPERATION
of pressure in the fuel pipe when
stoppingthe engine.
F U E L P U M PR E L A Y

CONTROL
Operation UNIT

lgnition switch F u e lp u m p Fuel pump

Engine speed
position relay state operation

ON ON for a Operatesfor
Stops
few seconds a few seconds
START Cranking speed ON Operates
Below 50 rpm OFF Stops
ON
Above 50 rpm ON Operates

SEF

EF-81
 E.F.t.SYSTEMDESCRIPT|ON I FJ20EI
FUEL FILTER INJECTOR
kPa Oar, kglcm2, psi)
196 The injector receives the pulse sig"
Fuel outlet
nal from the control unit, and injects
the fuel toward the intake vahe in the
250.1kPa (2.501bar,
2.55kg/cm'. 36.3 psi) cylinderhead.
& 14)
i o
-98 J Full
(-0.98, l d l i n g throttle Manifol
_1.0, Yacuum
-14)
EF258A

Electricterminal
The fuel lilter is placedbetweenthe
fuel damper and the injector, and is
usedto removeforeignmatter in the
fuel. Water in the fuel is collectedat
the bottomof the filter casing.

PRESSURE
REGULATOR
sE FO98

Air chamber
Diaphragm The injector operateson the sole- DROPPINGRESISTOR
noid valveprinciple.Whenan electric
Fuel inlet The dropping resistoris used to lower
signalis appliedto the coil built into ..tl
the source voltage to a level suitable
the injector,the plungeris pulled into
for the injector. :li-J

Fuel chamber the solenoid, thereby opening the

The dropping resistor is connectedin
needle valve for fuel injection. The
serieswith the injector.It reducesthe
quantity of injectedfuel is in propor_
voltage to approximately ll4 of the
tion to the duration of the pulse ap-
SEF6ISA sourcevoltage.
plied from the control unit.
These resistors protect the injectors
from alternator voltagesurgesand the
effects of other components in the :.-
The pressure regulator controls the ,Po^
'@d^f
.1::
vehicle'selectricalsystem. 'ir,
pressureof fuel so that a prOsuredif- 1 / Y o t
i'iI'-'
ferenceof 25b.1 kpa (2.501bar, 2.55
kglcm2, 36.3 psi) can be maintained
betweenthe fuel pressureand intake ? ryW

4*
manifold vacuum.Thepressureregula- "{(
tor is divided into the air chamberand

N
fuel chamberby the diaphragm.Intake
manifold vacuum is introduced into sEFO99
the air chamber,thereby keepingdif-
I Injector lower rubber insulator
ferential pressure constant causing
2 Injector lower holder
excessivefuel to return to the fuel 3 Injector upper rubber insulator
tank throughthe retum sideport. This 4 Injector upper holder sEF187C
!.
constantdifferentialpressureprovides 5 Injector ,..+
optimum fuel injectionin everymode ::.'
ofengineoperation.
rsL'
@
,rE+
affi.
i^&
ffi
;.?8:
EF-82
tlj*&"
 E.F.I. SYSTEMDESCRIPTION

THROTTLE CHAMBER
i'ltutt sHUr'oFF 3,000
I ,Fu.l shutoff is accomplished during
' 2,s00
decelerationwhen the engine does not
2,000
sequirefuel-

/&
E

The graph on the right shows the fuel

o I,500
shut'off range. o l,000

a\
4
500
',t
0
Perat ure
Cylinder head^tem
i' sEF76a at 80"C (176"F)

SEF6l 9A

"A" Fuel is strutoff; and fuel is injected The throttle chamber,located between
Decelerationfrom zone "C".
againin zone the air flow meter and the intake
manifold, is equipped with a valve.
"B"
Decelerationfrom zone This valve controls the intake air flow
Fuel is not shut off.
'C" in responseto acceleratorpedal move-
Decelerationfrom zone
ment. The rotary shaft of this valve is
connectedto the throttle valveswitch.

AIR REGULATOR
!
amount of intake air is extremelY
lArR FLOWSYSTEM small, the air flows parallel with the
The air regulatorby-passesthe throttle
valve to control the quantity ofair for
lein rr-owMErER flap tfuough the by-pass port so that increasing the engine idling speed
ifn. "it flow metermeasures the quan- the specified intake air flow can be when starting the engine at a bimetal
1.._
Itity of intake air, andsendsa signalto
t -
provided correctly. temperatureofbelow 80"C (176"F).
the control unit so that the basepulse An air temperature sensor is installed
width can be determinedfor correct in the air passage. Air outlet
fuel injectionby the injector.The air The by-pass port has the air by-pass t '

flow meter is providedwith a flap in screw which regulatesthe idle mixture

,the air p:rssage.As the air flows ratio. r-i'.'

.tluough the pasage, the flap rotates Adjusting the idle mixture should be
andits angleof rotationelectronically performed only when it is necessary.
si.gnalsthe controlunit.
Refer to SestionMA for adjustingthe
During idling operation when the
idle mixture.

Case Damper chamber SEF356A

Ro
Helicalspring Damper plate
Rr
To intake manifold
I
Potentiometer A bimetal and a heater are built into
R9
the air regulator. When the ignition
"START'posi-
switch is turned to the
Rro tion or engjne running, electric current
flows through the heater, and the bi
Air temperature
sensor metal, as it is heated by the heater,
begins to move and closes the air pas-
Terminal number sagein a few minutes. The air passage
By-passport remains closed until the engine is stop
ped and the bimetal temperature drops
Air temperrture sensor
to below 8o"c (176"F).
Potentiometer
To EFI harness
SEF667

EF.83
 E.F.I. SYSTEMDESCRIPTION

THROTTLE VALVE SWITCH

COLD WATER TEMPERATTJRE
SENSOR
The throttle valveswitch is attachedto
CHARACTERISTICCURVE
the throttle chamber and actuatesin
30 responseto accelerator pedal move-
20 ment. This switch has two setsof con-
ko ar -looc (l4oF)
l0 tact points. One set monitors the idle
- 8 position and the other set monitors
! s
E 4 2 . 1t o 2 . 9k o a t 2 0 o C
full throttle position.
!r
. 3 r
o 0.68 to I
I
0.8
0.6
0.4
0.3
0.2
0.1
0.08
0.05
-30 -20 0 20 40 60 80
(-22)(-4)(321 (68) (104)(140)(l 76)
I Bimetal oc
Tempcrature (oF)
2 Shutter
J Heater EF334A
EF 2 5 3 4

A I R T E M P E R A T U R ES E N S O R Full throttle
contact
The air temperaturesensot,built into
ELECTRICAL SIGNAL
the air flow meter, monitors changein SEF621A
WATER TEMPERATURE SENSOR the intake air temperatureand trans-
The water temperature sensor, built mits a signalfor the fuel enrichment to
into the thermostat housing, monitors changethe pulse duration. ldle contact
change in water temPerature and The temperaturesensingunit employs
The idle contact closes when the
transmits a signal to increasethe pulse a thermistor which is very sensitivein
throttle valve is positioned at idle and
duration during the warm'uP period. the low temperaturerange.
openswhen it is at any other position.
The temperature sensingunit employs The electrical resistanceof the ther'
The idle contact compensatesfor after
a thermistor which is very sensitivein mistor decreasesin responseto air
idle enrichment, and sends the fuel
the low temperaturerange. temperaturerise.
shut-off signal.
The electrical resistanceof the ther-
mistor decreasesin response to the Air tempereturesensor
temperaturerise. Y<---.=5> -/\ Full throttle contact

5-3sr:t-Y
'-\-\-\*-SZ
\' .._\ ? The full throttle contact closesonly
when the throttle valve is positioned at

l' ll full throttle (more than 35 degree

opening of the throttle valve). The
contact is open while the throttle valve
is at any other position.
The full contact comPensatesfor en-
richment in full throttle.

EF-84
 DIAGNOSTICPROCEDUREFOR PROBLEMS

FORPROBLEMS
DIAGNOSTICPROCEDURE
DIAGNOSIS ment will be indicated and the pro-
CAUTION:
I N T E R M I T T E N TP R O B L E M blems may remain. Therefore,
When connecting or disconnecting
DIAGNOSIS OF INTERMITTENT
DIAGNOSTIC CHARTS CANNOT E.F.l. harnessconnector to or from
PROBLEMSSHOULD START WITH
BE USED TO DIAGNOSE INTER. any E.F.l. unit, ensurethat the igni-
A VISUAL AND PHYSICAL IN.
MITTENT FAILURES.This is because tion switch is in the "OFF" position
SPECTION OF THE CONNECTORS
many intermittent problems are and that the negativebattery terminal
involvedin the circuit, especiallycon-
causedat electricalconnections,and if is disconnected. Removingand install-
trol unit, air flow meter. and water
intermittentproblemsare not correct- ing theseconnectorswith the ignition
temperaturesensor.
ed, unnecessarycomponent replace- switch left in the "ON" position will
damagecontrol unit.

DIAGNOSTICPROCEDURE
DRIVEABILITY

l. Inspectengineand E.F.l. systemfor air leaks,etc. l.ocateak leakand repair.

2. Checkigrition spark. Conect, repairor replacecomponentsas follows:

o Distributor cap
o.K.
o Rotor
o Primaryand secondarywires
o Spark plugF
o lSrrition coil

3. Checkignition timing, idle RPMand throttle valve

svitch.

Adjust to specifications.

4. Check idle mixture ratio. Adjust to specifications.

5. Performdriveabilitytest.

EF-85
 .:il

FOR PROBLEMS
DIAGNOSTICP R O C E D U R E

Injection test' Repairor replacecomponentsas necessary'

7. PerforrncompleteElectric Fuel

RPM' Adjust to sPecifications.

8. Checkidle mixture ratio and idle

9. Perform driveabilitYtest'

I M P R O P E RI D L I N G

leaks' lrcate air leak and rePatr'

1. InspectengineandE-F.I'systemfor air

Repair or replacecomPonentsas follows:

2. CheckigrritionsPark. o Distributor caP
. Rotor
o Primaryand secondarY wires
o Spark Plugs

test' Repairor replacecomponentsas necessary'

3. PerformcompleteElectricFuelInjection

valve N.G. Adjust to sPecifications.

4. Check ignition timing, idle RPM and throttle

N.G. Adjust to sPecifications'

5. Check idle mixture ratio-
Not adjustable

EF-86
 PROCEDURE
DIAGNOSTIC FOR PROBLEMS

E N G I N ES T A R T A B I L I T Y

l. Inspectengineand E.F.l. systemfor air leaks,etc. locate air leak and repair.

2. Checkbattery and chargingsystemfor battery. Correct,repairor replacecomponentsas applicable.

3. Checkstartingsystem. Repairor replaceparts and circuits as necessary.

Supply fuel or changeto the recommendedfuel.

5. Check ignition spark. Corrector replacethe following parts asapplicable.

o Distributor cap
. Rotor
o PrimaU and secondarywires
o Sparkplugs
o lgnition coil

6. Performcomplete Electric Fuel Injection test. Repair or replacecomponents as necessary.

o.K.

7. Perform startability test. 8. Checkidle mixture ratio andadjustit if necessary.

o.K.

EF.87
S;,,r.

DIAGNOSTICPROCEDUREFOR PROBLEMS

ENGINE STALL

l. InspectengineandE.F.I. systemfor air leaks,etc. l,ocateair leakand rePair.

2. PerformcornpleteElectricFuelInjectiontest. Repairor replacecomponentsas necessary.

4. Checkfuel shut-offsystem. asnecessary.

Repairor replacecomPonents

EF.88
 'Fl?:t

DIAGNOSTICPROCEDUREFOR PROBLEMS

DIAGNOSTICSTEPS (2) Hold high tensioncableand crank Adjust as necessary.

FOR DRIVEABILITY engine.Check for igrition spark.
l. Inspectengineand E.F.l. system
for leaks.
(l) Check clamps at all air intake
components.
(2) Checkvacuumhosesfor leakage.
(3) Check air cleaner filter for clog-
gn8.
(4) Visually inspect for leaks at the
following:
o Engineoil dipstick
o Intake manifold gasket
o Valverocker cover
r Ol filler cap (3) If weak spark or no spark,check f. Connectdistributor vacuumhose.
o Air intake hosesand duct igrition systemand repairor replace. c. Rev the engine to 4,000 rpm two
o P.C.V. valve 3. Check igrition timing, idle rpnt or three times under no-load, then
o Idle speedadjusting screw unit and throttle valveswitch. allow it to run at idle speed for
(5) Checkair regulatoroperation. (l) Checking and adjusting igrition one minute.
a. Starting engine, and pinch rubber timing and idle speed. h. Verify that idle speedand ignition
hosebetweenthrottle chamberand timing are in the specifiedrange.
Ctecks and adjustments are made
air regulator. ldle speed:
with the air conditioning compressor
"OFF". 900t50 rpm
lgnitiontiming:
a. Verify that engine is at operating
2ool5" B.T.D.c.:
temperature.
Except for Europe and
b. Dsconnect distributor vacuumhose
Hong Kong
from distributor vacuumcontroller,
12"!4" B.T.D.c.:
and plug hosewith proper plug.
Y / - c. Rev the engine to 4,000 rpm two or
For Europeand Hong Kong

\^\ three times under no-load. then (2) Check throttle valve switch.
ler block -\ allow it to run at idle speedfor one

nir r"gutlo, \ H minute.

d. Check idle speed.
A) ldle contact
Useohmmeter.

(: 900150 rpm a. Dsconnect throttle valve switch

o Enginespeeddecreasesduring harness connector from throttle
If necessary, adjust to the specified
c',warm-up .... O.K. switch body.
rpm by turning the idle speedadjust-
o Englnespeedremainsunchanged b. Connect an ohmmeter betweenter-
ing screw.
. afterwarm-up ..... O.K. minals @ and @, make sure con-
-b. Dsconnect electric connector of tinuity exists.
fo air regulator, and check continuity.
I Continuity should exist. If not, air
i . regulatoris faulty.

SEF376A
e. Check ignition timing with a timing
light.
4"11" B.T.D.c.: c. Increase engine speed. The ohm-
i -
Except for Europeand meter should show continuity until
Hong Kong about 1,100 rpm, and at that point
IZs:Checkigrition spark.
(l) Disconnect Sotlo B.T.D.C.: the circuit should break and cause
hightensioncable.
For Europeand Hong Kong the ohmmeter to ind.icatean open

EF-89
 'l::
li.,.

FOR PROBLEMS
D I A G N O S T I CP R O C E D U R E

circuit. If incorrect, adjust as fol-

lows.

d. Depressacceleratorpedal to floor.
If continuity exists between ter'
minals @ and @, fu[ throttle con' (9) Stop engine,remove the lead wire
tact is functioning properlY. and reconnectthe throttle valveswitch
4. Checkidle mixture ratio. harness to the throttle valve switch.
d. Hold engine speed at about I,100 (l) Verify that engine is at opera- (10) Check the idle speed. Readjust
rpm by manually opening the ting temperature. to the specifiedspeed.
throttle. (2) With the hood open, run engine 5. Performdriveability test.
lmportant: Do not use the idle sPeed at 2,000 rpm for 2 minutes at no' (l) Evaluate effectivenessof adjust-
screw. load, to stabilizeits condition. mentsby drivingvehicle.
e. l,oosen the tfuottle switch mount' (3) Reset idle speed to the specified (2) If unsatisfactory, proceed to
ing screwsand turn the switch bodY speed. step6.
until the ohmmeter shows a closed (4) Turn the ignition switch to the 6. Cleaninjecton.
circuit. "OFF" position. 7. Perform complete Electric Fuel
f. Slowly rotate the switch counter- (5) Disconnect the throttle valve Injection test.
cloclcrviseuntil the ohmmeter indi- switch hamessconnector. (l) Use E.F.I. harness checker and
ri cates an open circuit; at that exact (6) Connect a lead wire, as shownbe' adapteror circuit tester.Refer to Elec'
point, tighten the mounting screws. tween terminals No. 24 and No. 30 of trical SystemInspection.
ti
ii!
the throttle valve switch harnesscon- (2) Check injector.
nector. a. Disconnect ground cable from
h
ti.
battery.
b. Disconnect electric connectors
from injectors.
c. Check continuity between the two
terminals. Continuity should exist'
Ifnot, injector(s)are faultY.

il,
t,
ii

f.),"\\ f.)"o",
g. Recheck the adjustment. (7) Rev the engine to 4,000 rpm
h. Resetidle speedif necessary.

B) Full throttle contact

2 or 3 times under no-load, finally,
allow it to run at idle speed for one
minute.
7
F63OA

(8) Adjust mixture ratio with engine

a. Disconnect ground cable from
speedset at maximum by tuming air
battery-
by-passscrew.
b. Remove throttle valve switch con-
nector. When adjusting mixture ratio, remove
c. Connect ohmmeter between ter- blind plug from air flow meter. After d. Connectinspectionlamp to inlec-
minals @ and @, and make sure adjustment,install the plug on air flow tion hamessconnector and start
continuity doesnot exist. meter" engine.CheckinsPectionlamP to

EF-90
)
 D I A G N O S T I CP R O C E D U R EF O R P R O B L E M S

see if it flashesat regular intervals. o @and@(No. lcylinder) respectively, and release accelerator
If so, it is normal. . @ and@ (No.2 cytinder) pedal. Check inspection lamp illu-
o @ and@ (No.3 cylinder) mination.
o @and@(No.4cylinder) Check inspection lamp with engine
The resistanceshouldbe approximate- speedin each zone, as shown in chart
ly 6 ohms[at 20"C (68"F)] . . . O.K. below.
, t,Vn\
(4) Checkfuel shut off system. While inspection lamp is off, fuel shut-
lW,
',r\l(. Increaseengine speedto each zone, off is operational.

* Enginerpm "A" .(B" ..c"

Decelerationfrom Above
OFF ON
zone "A" 1,900
OFF

Decelerationfrom
- 1,900
1,300 ON ON
e. Connect injector harness, start zone"8"
"clicking"
engine and listen for the
Decelerationfrom Below
sound which confirms the injector ON
zone "C" 1,300
is operating. The interval between
clicks shortenswhen enginespeed *: Enginerpm at water temperature g0"C (176'F).
of ON: Lamp ON
is increased.
OFF: hmp OFF
(3) Checkdroppingresistorcircuit.
a. Continuity

Injector harnessconnector

(5) Checkair flow meter. a. Fully open the flap by hand to

check that it opens smoothly with-

N',)/ out binding. If it doesn't,it is out

. @__J. A
\-4
Dropping resistor \\
of order.

harnessconnector SEF188C

o No. I cylinder connector and @

o No. 2 cylinder connector and @
o No. 3 cylinder connector and @
o No.4 rylinder connectorand @

b. Resistance
EF3lAA

sEF 189C

EF-91
 DIAGNOSTICPROCEDUREFOR PROBLEMS

b. Measure the resistancebetween D I A G N O S T I CS T E P S F O R

terminals@ and @ .nt" standard I M P R O P E RI D L I N G
is 100to 400 ohms.
resistance
l. Inspect engineand E.F.l. system
for leaks.
2. Checkignitionspark.
3. Perform complete Electric Fuel
Injection test.
4. Check ignition timing, idle rpm
and throttle va.lveswitch.
5. Checkidle mixture ratio.
6. Cleaninjectors.
Refer to DIAGNOSTIC STEPS FOR
DRMABILITY on the inspection
SE F587A
procedureof eachitem.
f. Checkair temperaturesensor.
o Measurethe outside air tempera-
ture.
c. Measure the resistancebetween . Measureresistancebetweentermi-
terminals@ and @ . ttr. standard nals @ and @ of the air flow
resistance
is 200to 500 ohms. meterconnector.

ENGINESTARTABILITY
l. Inspectengineand E.F.I. system
for leaks.
RefeTto DIAGNOSTICSTEPSFOR
DRTVEABILIry.
2. Check battery and chargingsys-
tem for battery.
(l) Checkbatteryvoltage.
(2) lt poor battery voltage, check
chargingsystemfor battery.
o Altemator
r Voltageregulator
d. While sliding flap, measureresist- o Others
ance between terminals @ and Referto EL section-
r Checkinsulationresistance
between 3. Checkstartingsystem.
@ . If resistanceis at any value terminal @ and air flow meter
other than 0 and - ohm, air flow (l) Checkstarteroperation.
body. (2) lf it doesnot operate,checkthe
meteris normal.
following:
o Starter
o Ignitionrelay
o Ignition switch
o Others
Referto EL section"
4. Checkfuel.
(l) Checkfuel level.
If low or empty,add fuel.
(2) Checkfuel octanerating.
If not proper, changeto the recorn-
EF319A mendedgasoline.
5. Checkignitionspark.
Refer to DIAGNosTIc sTEPs FoR
e. Checkinzulationresistance between 8. Check idle mixture ratio and idle DRIVEABILITY.
the air flow meter body and any rpm. Follow the procedure in step 4, 6. Perform complete Electric Fuel
one of the terminals @, @, @ operations(l) through (5). lnjectiontest.
and @ . If continuityexists,the air 9. Perform driveability test. Refer to DIAGNosTIc srEPs FoR
flow meteris out of order. Re-evaluatevehicleperformance. DRIVEABILIry.

EF-92
 DIAGNOSTICPROCEDUREFOR PROBLEMS

7. PerformstartabilitYtest. 4. Check fuel shut-off system.

(l) Start enginewith the recommend' (l) Check fuel shut-off system. WATER TEMPERATURE SENSOR
CHARACTERISTICCURVE
ed staringprocedure. Follow the procedurein step7, opera-
(2) If engi4edoesnot start, proceed tion (4), in DIAGNOSTIC STEPS 30
to step8. FOR DRIVEABILITY. 20
7 . 0r o l l . 4 k o a t - l o o c ( l { o F )
8. Check and adjust idle mixture (2) If unsatisfactory, check as fol- l0
ratio. lows: F 8
i 6
Follow the procedurein step4, opera- a. Check enginespeedsignd. (ignition 3 4 2.1rb 2.9ka ar 20oC
tions(l) through(5) in EIAGNOSTIC coil-trigger input transmitted to !r
'a2
STEPSFOR DRTVEABILITY. E.F.I. control unit from ignition o l.
&
coil)
I c
b. Checkwater temperaturesensor. 0.8
0.6
o Check componentasfollows: 0.4
ENGINESTALL
0.3
l. Inspectengineand E.F.I. system 0.2
for leaks.
0.1
Refer to DIAGNOSTICSTEPSFOR 0.08
DRTVEABILITY.
-30 -20 0 20 40 60 80
2. Perform completeElectric Fuel ( - 2 2 ) ( - 4 ) ( 3 2 )( 6 8 )0 0 4 X 1 4 0 ) ( 1 7 6 )
Injectiontest. oc (oF)
Tcmpcraturc
Refer to DIAGNOSTICSTEPSFOR
DRIVEABILITY. EF3344
3. Checkidle rpm.
Oreckidle rpm. Follow the procedure
in step3, operations(l)-a throueh(l)-
lL in DIAGNOSTIC STEPS FOR € F3 2 9 A
DRIVEABILITY. 5. Cleaninjecton.

. 1

;'I -
i,!
:.r,,\

iut.
:;.1
i3.
i:
itn,.
.if-- -

E F -9 3
 %
ELECTRICALSYSTEMINSPECTION I FJroEl
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SYSTEMINSPECTION
ELECTRICAL
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EF.94
 j.i; ,
.i i : ':
:irr

ELECTRICALSYSTEM INSPECTION

WITH E.F.I. HARNESS Connectingchecker Inspection with igrrition switch in

"START" position
CHECKER l. Securely connect E.F.L hamess
connector to checker Connector via l. Set O-V selectorin "V".
adapter. 2. Securely connect battery ground
cable.
3. Tumbler switch remains in "B"
position.
4. Set ignition switch in "START"
and measurevoltage by pushing check
button of rotary switch "2".
5. Tum ignition switch "OFF".
6. Connect lead wire to "S" terminal
SEF371 A of startermotor.
7. Set ignition switch to "ON" and
I Checkbutton 6 Tumblerswitch watch deflection of meter pointer by
2 O-SET knob 7 35Ain connector pushing check button in position "4"
3 Rotary svitch 8 Groundclip
of rotary switch.
4 V-SET screw 9 Adapter CAUTION:
5 o-V selector
When insertingconnector into control
unit. insert slowly, securely and
straight, being careful not to bend or
break the pin terminak.
FOR
PREPARATIONS
Inspection with igrition switch in
INSPECTION 2. Securely clamp ground clip on a "ON" position
l. Turn ignition switch to "OFF" metal portion of vehicle.
position. l. Turn ignition switch "ON" and
Body earth should be made by con-
measurevoltage by pushing check but-
necting with unpainted metal such as
ton in each position of rotary switch
CAUTION: bolt. *Irr.
Before disconnectingand connecting
2. Set tumbler switch on "A".
glectrical connectors, ensurethat igni-
tion switch is in the position. INSPECTION 3. Turn ignition switch "ON" and I
measurevoltage by pushing check but-
For items to be checked, refer to ton in position "l" of rotary switch.
2. Disconnectbattery groundcable. InspectionProcedureTable.
3. Disconnect lead wire from "S" 4- Measure voltage by pushing check
terminal of starter motor. Resistancemeasurement button
4, Remove air cleaner cover and "S)". 5. Turn ignition switch "OFF".
l. Set O-V selectorin
filter so that air flow meter flap can be "A". . 6. Disconnect pin connector from
2. Set tumbler switch in
moved by hand. E.F.l. hamessconnector.
3. Measure resistance by pushing
t. DisconnectE.F.I. harnessconnec- check button at each position of
CAUTION:
!9r from control unit. rotary switch from "2" to "l2".
Be extremely careful not to break or
4. Set tumbler switch on "8".
CAUTION: bend the pin terminals when discon-
5. Measure resistance by pustring
d. Before disconnrting E.F.l. harness necting.
check button at position of rotary
I connector, ensrrre that ignition switch "3".
"OFF,, position. 7. Connect E.F.l. harness connec-
i- switch is in the
b. Be extremely careful not to break tor to control unit.
Voltage measurement
t or bend pins when disconnecting Inspection with ignition switch in
I terminal. "OFF" position CAUTION:
a. Before connecting E.F.l. harness
i
I l. S€t O-V selectorin "V". connector, ensrrre that ignition
I 2. Securely connect battery ground switch is in the "OFF" pocition.
phecker preparations cable. b. When insertingconnector into con-
;I.-- Set Sl-V selector on
"V", and 3. Tumbler switch remains irl ..8'r trol unit, insert slowly, securely
,Ldjust voltmeter to zero, using "V- position. and straight, being careful not to
SET': ss1srv. 4- Turn ignition switch "OFF" and bend or break the pin terminals.
"Q.SET",
?. Set e-V selectoron measure voltage by pustring check but-
fnd adjustohmmererto zero, using ton in each position of the rotary 8. Bring air flow meter back to its
LQ-SET- knob. switch from "5" to "8"- originalcondition.

EF-95
 : :rk1,
i
.- ,::;l
_._.,}-

ELECTRICALSYSTEMINSPECTION

INSPECTIONPROCEDURETABLE to measurementsto be made with located,againcheck measurementsin'

E.F.I. HarnessChecker. volved in that circuit. In this case.
How to usg
2. After measuring, compare meas' check ignition switch, f,l-V selector,
l. Inspection procedure table is de' ured valueswith standardvaluesto de' tumbler switch, rotary switch, ground
signed so that items to inspect are ar' termine whether circuits/partsare mal- clip, etc. to be certain they are set at
rangedin a sequentialorder according functioning or not. properpositions.
3. When a malfunctioning circuit is

Inspectionprocedureuble (With E.F.l. harnesscheckerl

"OFF"
Noto: Bofor. dirconnecring and connecting otoctricd connoctor and tsrminalr, ensure that ignition twitch i3 in Pcition.
. Although voltrge may drop below brttory volttgp, this is not an indication of abnormality.

lnspectioncircuit
Ignition o-v Tumbler Rotary Auxiliary operation or condition Standard value
Step
switchselector switch switch
"S" termind and E.F.I. hamessconnector from control unit.
l. Disconnectbattery negativeterminal, starter motor
2. Connectcheckerconnector to E.F.t. hamessconnector and clamp ground clip.
3. Arrangeso that air'flow meter llap can be pushed from air cleanerside.
Air flow meter (potentiometer) Any value except
I 2 Pushair flow meter flap.
0and-o
diding resistor and cfucuit
2 J

3 Ground circuit 4 0a
4 5
Throttle valveswitch idle contact Fully depressed €o
5
and circuit Accelerator Released 0()
pedal Fully depressed 0r,
Throttle valve switch full throttle
6 8
contact and circuit Released 6 a

OFF a A 20"c (68"F)or Below 2.9 ka

Watertemperaturesensorand Water
7 9 above
circuit temPerature
Below20'c (68"F) 2.1 ko or above
20'c (68"F) or
Intake air Below 2.9 ka
I Air temperature sensorand circuit t0 above
tempemture
Below20"C (58"F) 2.1 ko or above
9 Air flow meter (pgtentiometer) ll 100to 400 r,
10 risistor and circuit t2 200to 500 f,)
Circuit betweenair regulator and
11 B 3 Below300 a
fuel pump
Connect battery negative terminal.
t2 lnjector I 5
Battery,E.F.I.
t3 relay, dropping Injector 2 6
ON
14 resistorand Injector 3 7
injector circuits v B Battery voltage
15 lnjector 4 8
*Circuit betweenignition switch
16 START 2
and control unit power source
"s"
Connect starter motor terminal. CAUTION: Excrcise care in performing stop lT a3 it involvas turning enginc.
17 funition coil triggercircuit START B 4 Pointer deflects

Battery,E.F.I. relayand control v BatterY

18 ON A I
unit power sourcecircuits voltage
Disconnect checker connector from E.F. hamess connector and connect E.F.I. harness connector to control unit.

EF.96
 ELECTRICALSYSTEM INSPECTION

2. Disconnectbattery ground cable. switch is in the "OFF" position.

WITH CIRCUIT TESTER "S"
3. Disconnect lead wire from b. Be extremely careful not to break
PREPARATIONS FOR or bend pins when ditconnecting
terminalof startermotor.
INSPECTION terminal.
4. Anange so that air flow meter
"OFF" Do not touch the circuit tester
l. Turn ignition switch to flap can be pushed by hand from air
position. probe to any unneoessarypin on
cleanerside.
the connector. Doing so could
5. DisconnectE.F.I. harnessconnec-
CAUTION: tor from control unit. causedamageto the circlit tester.
Before disconnectingand connecting c. After inspectionor replacement,se-
electrical connoctors,onsursthat igni' CAUTION: curely connect E.F.l. harnesscon-
"OFF" position. nector with control unit, and then
tion switch is in the E.F.l. harness
a. Beforedisconnecting
connsctor, ensuro that ignition test it to make sure.

EF-97
ii;'. ..

ELECTRICALSYSTEMINSPECTION

THROTTLE VALVE SWITCHTESTS

lf test it O.K., go to Test No. 2.

TestNo. I ldle contacts
lf test is not O.K., go to Throttle
Tcrtrr L.rdt to Pint Notrr Sherld Rcad Valve Switch Adlustment.

(+) (-)
Throttle released. Continuity
Ohmmeter
29 30 Throttle depressed No continuity

sEF68t

lf test is O.K., So to Test No. 3.

TestNo.2 Full throttle contacts
lf test is not O.K., go to Full Throt-
Trrtrr Lrrdr to Pinr Notcr Shanld Rcad tle ContactCheck.

(+) (-)
Throttle released No continuity
Ohmmeter
24 30 Full throttle Continuity

sE F682

lf test is O.K., go to Throttle Valve

Test No. 3 Insulationtest
Switch Adlustment
Testcr Lredr to Pins N otes Shanld Rcad lf test is not O.K., go to Compo
nent Check.
(+) (-)
Ohmmeter 24 eO
Body
29 ground
30

sEF6a3

EF.98
 ELECTRICALSYSTEM INSPECTION

AIR FLOW METER TESTS

lf test is O.K., go to Test No. 2.

TestNo. I Air flow meterresistance lf test is not O.K., perform component
T!rict Lreds to Pins N otrs Shonld Read check.

(+) (-)
Ohmmeter 100 to 400f,l
33- 34

llg

sEF689

lf test is O.K.,go to Test No. 3.

TestNo.2 Air llow meterresistance lf test is not O.K., perform component
Tcstcr Lcads to Pinr Notes Shqrld Rcad check.

(+) (-)
Ohmmeter 200to 500n
34 35

EF-99
 -r'X.
:

ELECTRICALSYSTEMINSPECTION

lf test is O.K.,go to Test No.4.

Test No. 3 Air IIow meter resistance lf test is not O.K., perform component
check.
Trcicr Lrrdr to Pinr Notcr Shqrld Rcrd

(+) (-)
Ohmmeter Except 0 and eO
l2 34

s€F691

lf test is not O.K., perform component

TestNri.4 Insulationresbtance check"
Tostrr Lradr to Pins Notcr Shqrld Rrd

(+) (-)
Ohmmeter
37 ofl
33 Body.
34 ground
35

sEF692

E F -1 0 0
 ELECTRICALSYSTEM INSPECTION

AIR TEMPERATURESENSORTESTS

lf test is O.K., go to test No. 2.

TestNo. I Air Temperature
Sensor
lf te* is not O.K., perform component
Tstrr Lrrdr ro Pinr Notlr Shold Rrd check.

(+) (-) lntake air temPeralure

Ohmmeter 2ooc (68oF) or abovc Below 2.9 kfl

25- 34
Below2ooc(68oF) 2.1 kO or above

lf test is O.K., air temperaturesenior

TestNo. 2 InsulationResistance is O.K.
Trtrr Lrrdr to Pinr Not.i Shold Rord
lf test is not O.K., perform component
check.
(+) (-)
Ohmmeter 6o
25 Body
ground

WATER TEMPERATURESENSORTEST
lf tert is O.K., te* is complete.
Watertemperaturesensortest lf ten b not O.K., perform compo.
Tcrtrr Lrrds to Pins Notes Rcrd
nent dreck.
Shold

(+) (-)
20oc (68oF) or above Below 2.9 ko
Ohmmeter
Body
t4 ground Belo\r 20oC (58oF) 2.1 kft or above

sEF693

E F -1 0 1
 ELECTRICALSYSTEMINSPECTION

C O N T R O LU N I T G R O U N DC I R C U I TT E S T S
lf tests are O.K., ground circuits are
o.K.
Trstol Leads to Pins Notot Should Rcad
lf test are not O.K., check wiring
diagramand harness.
(+) (-)
Ohmmetet l5 Continuity
Body
l9
ground
20

I
i'
I
i i

SEF6344

A I R R E G U L A T O RC I R C U I TT E S T S

lf test is O.K., go to Test No. 2.

TestNo. I Air regulatorresistance
lf test is not O.K., check air regulator.
Tcstcr Lrad: to Pinr Noia5 Shold Read

(+) (-)
Ohmmeter 25 to 90rl
Body
2l
916und

sEF598

Test No. 2 Air regulator and fuel 2. Tum ignition switch to "ON". pump relay.
pump power circuit 3 - Usten for fuel pump operating If fuel pump operates,check air regu'
l. Connect E.F.I. harnessconnector soundfor a few seconds- lator.
to E.F.L control unit. 4. If no sound is heard, check fuel

E F -1 0 2
 ELECTRICALSYSTEMINSPECTION

I G N I T I O NC O I L T R I G G E R I N P U T T E S T
lf tert ir O.K., trigger input to con'
tgnitioncoil triggerinPut test trol unit ir O.K.
lf ten ir not O.K., check ignition
Tartaa Lcadr to Pins Notc: Shqrld Rred
coil and wire harner.
(+) (-) Connect starter motor
l.
"S" terminal and batterY
Voltmetet Pointer deflects.
BodY ground cable.
l8 ground "ON".
2. Ignition

sEF705

I N J E C T O RC I R C U I TT E S T S
lf test is O.K., go to Test No. 2.
Test No. I Cylinder No. I lf test is not O.K., go to comPonent
check.
Tartct Lrcdr to Pins Notlg Shqrtd Rrrd

(+) (-)
Voltmeter Connect batterY ground cable. BatterY voltage
Body
2 ground

sEF706

tf test is O.K., go to TestNo.3-

TestNo. 2 CylinderNo. 2 lf test is not O.K., perform component
Shqrld Rcd
check.
Tcstcr Lcads to Pinr N otat

(+) (-)
Voltmeter Battery voltage
Body
6 ground

sE F707
--;...1i

EF-103
giri,,
tI

;l
il ELECTRICALSYSTEM INSPECTION
ill l
tl lf test i3 O.K., go to Test No.4.
ll l l TestNo. 3 CylinderNo. 3 lf test is not O.K., go to comPonent
ll
check.
Lrrdr lo Pinr N otcr Should Rcad
Tr:tlr

(+) (-)
Voltmeter BatterY voltage
BodY
5 ground

sEF708

lf test is O.K., all iniectorsare O'K'

TestNo. 4 CYlinderNo.4 lf test is not O.K., go to component
Shold Read check.
Tcatat L..di to Pint Nota3

(+) (-)
BatterY voltage
Voltmeter BodY
7 ground

sEF709

E F -1 0 4
 ELECTRICALSYSTEMINSPECTION

R E L A Y A N D F U E L P U M PR E L A Y T E S T S
lf test is O.K., E.F.l. relay is O.K., go
TestNo. I E.F.I. relay test (Controlunit powerinput circuit test) to Test No. 2.
Should Rcrd
lf test is not O.K., checkE.F.l. relay.
Tr3tat Lcrdr to Pinr Notct

(+) (-)
l. connect battery Sround
Voltmeter cable. Batlery voltage
Body "ON".
77 ground 2. Ignition

sEF7l3

Test No. 2 Fuel pumP relaY lf no sound is heard, 90 to test No. 3.

"ON".
l. Ignition
2- Listen to fuel PumP oPerating
sound for a few secondsafter turning
"oN".
igrition switch to

lf test No. 3 is O.K., checkfuel PumP

TestNo.3 FuelpumPrelaYtest and circuit.
lf fuel pumP is O.K., check compo-
Tcstrr Lredr to Pinr Notcr Should Rcad
nent check.
(+) (-) tf test No. 3 is not O.K.' go to compo-
'Ohmmeter Except 0 and of,l
nent check.
BodY
13 ground

SE F3434

:
:it

'':
:'-iSI+.
. -fi;

''.-..'':
E F -1 0 5
 ELECTRICALSYSTEMINSPECTION

Check fuel pump relay. CheckE.F.l. relay

Behindair flow meter Behindthebattr

t-\+
I \ -

1 2V direct current
12V direct current
is applied be-
is applied be-
tween terminals
tween terminals
Oand@
@and@

No continuity

lf E.F.l. relayand fuel pump relayareO.K., checkharness.

lf fuel pump and harnessare O.K., replacecontrol unit

IGNITION START SIGNAL TEST

lf test is O"K", ignhion ttart 3i9n€l
Igrition start signa[test is O.K.
Lodr to Pinr Should Rcad lf ten i3 not O.K., inrPect ignition
Trct r Notcs
coil and harness.
(+) (-) l. Disconnectstartermotor
"S" terminal.
Voltmeter 2. Connect battery ground Battery voltage
Body
26 ground cable.
3. lgnition "START".

sEF715

E F -1 0 6
 FUEL SYSTEMINSPECTION

FUELSYSTEMINSPECTION
RELEASING FUEL PRESSURE Vacuum Fuelpressure
l. Remove relaYbracket.
2. Startengine.
3. Disconnectthe harnessconnector
of fuel pump relay while the engineis
With 0 kPa l0 mber,0 mmHg,
running.
0 inHgl Yrcuum fucl prerrr
drould bc 248.1 - 255.0 kPr
Tool box (Rearright-handside) 12.81 - 2.550 brr,2.53 - 2.60
kg/cm2. 36.0 - 37.0 pdl

s€ F675

Vacuum Fuel pressurc

6fl.n
Kiv
SMA931 A With 16.9 kPa (169 mbrr,
127 mmHg,5.q) inHgl
v.cuum fuel pretrc rtngc
is227.5 - 241.3 kP! 12.2'15'
Tighten clampssecurely
2.413 bar, 2.912- 2.6 kd""ttt .
preventfuel leaks.
SEF635A 33.O- 35.0 nril sEF676

Vacuum Fuel pressure

4. After the enginestalls, crank the

engineseveraltimes.
5. Tum the ignition switch
"OFF".
fT.h
Y-Y
6. Reconnectthe harnessconnector Wath iXl.g kPr (SI) mbrr,254
mmHg, 1O.fi} inHgl e.cuum
of fuel pumprelay. fucl prerrc renge b 2138 -
3. Start engine and read fuel pressure 22O-7k?a (2.138 - 2.2O7 blrr,
gau8e. 2.1a - 2-26 kg/cmt, 31.O-
32.0 psi)
At idling: sEF677
Approximately206 kPa(2.06bar,
2 . 1 k g l c m 2 , 3 0p s i )
Vacuum Fuel pressure
The moment acceleratorpedalis
fully depressed:
Approximately255 kPa(2.55bar,
2 . 6 k g l c m 2 , 3 7p s i )
f;'"T.h
\{9
With 5O.8 kPr (5{B mbrr,
4. lf fuel pressureis not asspecified, 381 mmHg, 15.0OinHgl
replace pressureregulator, and repeat vacuum fuel prrratrr nqo b
fuel pressurecheck. 200.1 - 206.9 kPr l2.OOl .
2.06!l ber, 2.U -2.17 kglanf ,
FUEL PRESSURECHECK If below the specifiedvalue,checkfor 29.0 - 3t.O pcil sEF67a
clogged or deformed fuel lines, and if
$lhen reconnecting the tines, always
necessary,replace fuel pump as an as-
ite new clampr and be sure to position sembly or check valve. Vacuum Fuelpressurc
ihem correstly.

l.
a torque driver to tighten clamps.
.Uro
Releasefuel pressure in fuel line.
5. Connect variable vacuum source,a
handy vacuum gaugeor its equivalent,
to fuel regulator. Disconnect fuel
f;fr
k_y
kef.'t; il;;g' Fu;ie,",,u,.. pressure regulator vacuum hose from
- intake manifold and attach hose to Wath67.7 kP! (677 mbr,508
Install Pressure Gauge between
mmHg, 20.fl1 inHgl vrcuum
filter hoseandmetalpipe at point variablevacuumsource. fuel pracruro rango b 1795 -
For convenience
in later tests, 6. Start engineat idle speed. 1932 kPa (1.795 - 1.932 b.r,
iion gauge so that it can be read 7. Obsgrve fuel pressurereadingsas 1-83 - 1.97 kgr/crnt, 26.0 -
28.Opril sEF67e
driver's seat. vacuumis changed.

E F -1 0 7
 FUEL SYSTEMINSPECTION

Fuelpressure mustdecreage ai vacuum Place a rag under iniector when dis-

increases.lf resultsare unsatisfactory, connectingfuel pipe to preventsplash-
replacepressure regulator. ing of fuel.

%
8. Releasefuel pressureuntil it is
about49 kPa(0.49bar,0.5 kglcmz,7
psi).
"OFF".
9. Turn key to
10. Disco0nect variable vacuum
sourceand connectfuel pressureregu-
lator vacuumhoseto intakemanifold.

sE FO99

I lnjector lower rubberinsulator

2 Injector lower holder
5. Remove bolts securing fuel in- 3 Injector uPPerrubber insulator
jectors. 4 Injector upperholder
5 Injector

9. To install injector and fuel pipe,

reversethe order of removal.
a. When installing iniector, checkthar
there are no scratchesor abrasional
lower rubber insulator,and securely
install it, making sure it is air-tight.
b. For installation of fuel hose, refer
to Fuel Hose.

6. Remove fuel pipe and injector as

REMOVALAND an assembly. Injectorrubberhose
INSTALLATION
If necessary,replace injector rubber
Before removing or replacingthe fuel hose,proceedasfollows:
syitem line, releasefuel pressurefrom
fuel line for safety reasons.

I N J E C T O RA N D F U E L P I P E
l. Releasefuel pressurein fuel line.
Refer to ReleasingFuel Pressure. Removal
2. Remove or disconnect the follow-
ing parts and connectors.
o Injector harnes connector. SEF6404
o High tension cable.
. Vacuum hose connecting pressure
regulator to intake manifold.
3- Disconnect fuel feed hose and fuel
return hose from fuel pipe.
Place a rag under fuel pipe to prevent 7. Unfastenhose clamp on fuel in' 20 mm (0.79in)
splashingof fuel. jecfor and removefuel injectorfrom
4. Removebolts securingfuel pipe. fuel pipe.

E F -1 0 8
 FUEL SYSTEM INSPECTION

l. On injector rubber hose, measure P R E S S U R ER E G U L A T O R CAUTION:

outlet
off a point approx. 20 mm (0.79 in) l. Disconnect ftrcl inL't lrrd a. Do not reur fuel hoseclampsafter
. from socket end. hosesand vacuunrhosc'' loosening
2. Heat solderingiron (150 watt) for b. Cleandust rd dirt from parts with
15 minutes. Cut hose into braided comp.ess€d ar when assembling.
reinforcement from mark to socket c. Tighten hilnr pressurerubber hose
end. clamp so tiet clamp end is 3 mm
(0.12 in) fr:rn hose end or screw
Do not feed soldering iron until it
touche3iniectoi tail piecc. position (wiur than other portions
of clampl b nlrh with hoseend.
CAUTION: Tightening ?.rque 3p€c'ficationsare
a. Ba careful not to damage socket, the samefor al rubber hore clampr.
plartic connector, etc. with solder-
ing iron. O : Fuet hore =arnps
1 . 0- 1 5 t . m
b. Never place injector in a vise when
( 0 . 1 0 - ! . 1 5k g - m ,
disconneaingrubber hose.
2. RemovePressure,..*u1.1o1from 0.7 - 1.1ft.tb)

3. Then pull rubber hose out with intakemanifold.

hand.

Installation
l. Clean exterior of injector tail
.,, Piece.
1, 2. Wet inside of new rubber hose
', with fuel.
,!\\-_seFoagr .
i 3. Pushendof rubberhosewith hose EF976

: socketonto injectortail pieceby hand

t-{ asfar asthey will go. - -
-4.--' 3. To install pressureregulator' re- 3 mrn (0.12 inl
.5ti. Clamp is not necsssaryat this con- versethe order of removrl'
:i.t': negtion.
For installation of fuel hose, refer to
GAUTION: Fuel Hose.
'Afbr
properlyconnectingfuel hoseto
.iniestor, chock connection for fuel
EF3364
:ft..
FUEL HOSE
ii,, Make sure that all low pressurefuel
Fi. s,:,' hosesare fully insertedrnd are free d. When tightrrirg hoseclamp, ensure
49",. r;
.*i:jl
from unduestrainbeforeclamping' that screw orea not come into con-
Whenremovingor installinghighpres' tast with a4a€entparB.
surefuel hose,observethe following'

E F -1 0 9
 FUEL SYSTEM INSPECTION

FUEL PIPING

Fressureregula

Fuel pipe assembly

fype @ : Insert rubber hoseuntil its Type @ : Push end of rubber hose Type @ : Push end of rubber hose
end contactsunit onto fuel pipe until it is 28 mm with hose socket onto unit by hand as
Type @ : Push end of rubber hose (1.10 in) from end of pipe. far as they will go. ClamP is not
onto fuel pipe until it contacts inner necessaryat this connection.
bulge.

SEFO59C

E F - 11 0
 SERVICEDATA AND SPECIFICATIONS

SERVICEDATAAND SPECIFICATIONS
AND ADJUSTMENT
INSPECTION T I G H T E N I N GT O R O U E

FUEL PRESSURE Unit Ntn kg{n tr-lb

lMeasuring point: between fuel
filter and fuel pipe) Throttl€ charnber
16-21 1 . 6- 2 . 1 12-15
kPa (bar' Approximately 206 securing screw
At idtino
kg/cmt. psil 12.06,2.1, 30)
Fuel hoseclrnp r . 0- 1 . 5 o.ro- 0.15 o . 7- t . l
Tle momenll.
kPa(bar, Approximately 255
celerator pedal is Fucl horc clarnping position
ks/cmr,psir (2.55,2.6,371
;;;;;;,;;'

AIR FLOW METER

Potentiorneter resistance
betrveen terminals ^
t00 - 400
@ano@
between terminals ^
r! 200 - 500
@ ana@

benrreen terminals ^
Except 0 and -
@ano@
AIR TEMPERATURESENSOR
Thermistorresistance
ar-10'c (14"F1 kO 7 . O- 1 1 . 4

at 2o"c l58"Fl ko 2 - 1- 2 . 9

at so"c 1122"Ft ka 0.68- r.o

THROTTLEVALVE SWITCH
Enginespeedwhen
idle switch is
tPm
changedfrorn
'.oN" to "oFF"
'..,4: About l,lOO

WATERTEMPERATUR E SENSOR
lr
Thermistorresistance
ar-lo"c (14'Fl ka 7.0 - I t_4

:::'t' 2 . 1- 2 . 9
-1r. i

0.68- r.o

li,tlr
, it:;-
....,1
|

EF-1 1 1
 ETECTRICAT
SYSTEM

SECTIOilEL

c01{TEilTS
I ] O WT O B E A DD A G R A M S .. ..
S T A N D A R D I ZBEEDL A Y . .. .. ., . EL. 4
P O W ESRU P P LR YO U T I N G . . . . . . .
8 A T T E 8. Y
. . . . , .. . .. . .. . .. . .. . E L 9
STARTINGSYSTEM
STARTINGSYSIEM- Sbrtgr . .. EL 13
C N A F G | NSGY S T E M . . ., . . . . . , . . . . EL 22
CI-IAFGlNG SYSTEM Alternaror-
rGNITON SYSTEM{Noniudocharser -;;;,;
GNrTON SYSTEMlNoniurbocharqer EL 36
c o r M B l N A T st owNt T c H
.. .. .. .. . E1.44
H E A D L A T. ,\ .4. P
, . , . . .. . . . . . . . . EL 47
EXTEFIOR LAMP
NTERTO 1AR] V 1 P . . . . . . . , . , . . . . . . .
METEF A N D G A U G E. S . ... . E L -3 3
I 1 ' A RNNG L A M P A S N D C I .M ] E. . , . , , , . . , . . . . . . EL 87
i M E C O N T R OS LYSTEN] EL.S3
. V I PRE A N D W A S HFE
N O R NC, I G A B E T TLEI G H T E R C ,L O C K. . . . . . , . EL.103
R E A RW I N D O W O E F O G G.E, .F.
{ U D I OA N OP O W E A RN T E N N .A. , . . . . . . , . . . E1.113
A U T O I 4 ACT S P E E D C O N T R OD L E V I C E( A . S . C , D . ) F L1 T 6
: O C A T I OO NF E L E C T F C AULN I T S , , .. . . . . . . . EL.r23
] A R N E S SL A Y O U T E L] 2 3
JUNCTTO ( SN. M . J, .. ). . . . . . .
 HOW TO READDIAGRAMS

POWERSUPPLYROUTING is commonwith the metertsndgauges.Therelde

mu$lie
rhecaus ol lhis speclllcproblem 0.n rlr
Thk diasEmis helpfulinid€ntifying sp* fic prob
pow.r podion of the eecnical fuse,suchasin the wiring,rcarwindowdefoqF,
lemsin the supply
cncuils.For€xampLo, let's$y a vahiclehasan in.
operativerear windowdetogser. A quick ch*k
prov6 rhar meterand qaug* in rh6 vehiclearc
op.raiive.The powersupplyd Thk diasGmidenrifies rypesandnumberol
iherc cannotbe a problembelweentha b.t.ry, n41oa,eletlcal temint po.itionsin thecon
isnition relay. iqnitionswtch or tus sincathe tor, color codlngof wires,and conneclorc
po@r supplyclrcuitlor the rearwindowdefosser Relerto thefo Lowlhgextmp6.

.l-l
A R
q
T L..-

I' "fl
._J
e
@

o
I o
rr @

EL.2
 HOW TO READDIAGRAMS

POWERSUPPLYROUTING is commonwith the metertsndgauges.Therelde

mu$lie
rhecaus ol lhis speclllcproblem 0.n rlr
Thk diasEmis helpfulinid€ntifying sp* fic prob
pow.r podion of the eecnical fuse,suchasin the wiring,rcarwindowdefoqF,
lemsin the supply
cncuils.For€xampLo, let's$y a vahiclehasan in.
operativerear windowdetogser. A quick ch*k
prov6 rhar meterand qaug* in rh6 vehiclearc
op.raiive.The powersupplyd Thk diasGmidenrifies rypesandnumberol
iherc cannotbe a problembelweentha b.t.ry, n41oa,eletlcal temint po.itionsin thecon
isnition relay. iqnitionswtch or tus sincathe tor, color codlngof wires,and conneclorc
po@r supplyclrcuitlor the rearwindowdefosser Relerto thefo Lowlhgextmp6.

.l-l
A R
q
T L..-

I' "fl
._J
e
@

o
I o
rr @

EL.2
 I
HOWTO READDIAGRAMS

SUPERIVIULTIPLE JUNCTION{S,IVI,J,I
. The "S.tvl.J."
indic.bd in wirtnsdiasEmsrelere
ro rhesupernuk ptejunction,andisdrawnin asimpt.
riedrorm.Thelocation6f connectof terminahshouldihereloreb€retercdro in rhefordouraltheend

Thefoldoutshoud bespread,
asshownn rheexampte
b€tow,in orderioreadtheenrnewirinq
dhgmm.

"A -"--- EE:16

t6 +3
-
+h t!€o^
F -" +-1""-.e
6 r ; 17 1
L ?

r(.:1-"'.
I
(+

EL-3
 RELAY
STANDARDIZED

"f

d 6
o ldf
7 9
@

?;t
a
 POWERSUPPLYROUTING
I
Diasram{For EuropeL.H. drive model}

!
i ! t!
i ! i I F i
!:;:i l=A : =! " :
I: :! !_:! iii
i ii :Fi;+! i.4 : a-
iii!E*::id i!3
1

3€
+ ii
s;
ffidFr:1

lm#1ffi
,f+r cl,

EL-5
 POWERSUPPLYROUTING
Wirins Diasram{For EuroP8R.H. drive model)

- e
a .
- g :
: . ; :! :

.ii ' : ! i : l:
iii :=i; !; I !;e i :: :
, i i i ii , i ! i l ;
, 1 i.!i! c riii
i5 i i i : i ; i i : s !; i
;;ii;ii;i!; : : : i;;ii;i:iii!

ffirffim
':;e:hmlffio
6r
?ID

i/l
q-n
 POWERSUPPLYROUTING
Wirins Diagram(Exceptfor Europemodel)

a
:
i -. i , i i
.
.
e 6
. !,r3!
i
Ll
!
: , E !l i i ... :
: : t3:F ,z :i;:!!it
s':iii:::i
A ;t
J i i
;i :; :! :, :a ! €

-r
i_ ! ;::i: i;Ei ! i i i e : i ; ; " i :;, : ::

i i i i i : F E i:i: ii5!5i !i !3E3:::i :r J:o !1 :5

;; EEa ; ; : . :i a. ;
1?i ;;
; !
i ; t j . 1 E : " i 3 F! i d 08 9 9 8Eo. . : C : 3 ; E l i ; : ;: r ; :

L:j41

B6)I
iE
t-; e6
\.1-".
HI,

ru

EL-7
 POWERSUPPLYROUTING
Chsck FusibleLink
A metad fosiblaLinkcan be derecred eiiherby
visualnspection
or by feeinsw
condtionis que{ionable,usecircunie$erof rd

lf tuF k blown,be iurc to el,minate cau5eol

problembefor€inttallinqnewfue,
LJsefu* ol specifiedBtins, Ndverule fuseof
mDrethanspeiriedBtins,
Do not initalltu!e in obliquedtection;.lways a, lf tu6iblelink shouldmelt, it h po$ible
insedh rntolls holdd pbpedy, critjcalcncuit {pow.r lopply or larc. d
@iryingcn.uit) h shorted.In lucha die.
lollv .h*k and.liminateeuseor problem-
b. Neverwmp ps'phery ol futibl€link w'th vi
bpe. €rieme €re lhould be rak€n with rl
hnk ro.nrurc that ir do6 nor comeinto
tact with any orhr wnins harne* or viryl

EL-8
 BATTERY

a. lr h b*ome. rh. ensine whh .nd jume6 dbta, ue a

r 2rorr b@d& banery.
b. Ahe. connetinqbanely cabt8,eneurethat rhey areiishrly clampedto ban.ry teminatrror nood

c, Nneradddiiilled war.r$mush thehoteusd

C H E C K I NS
GP E C I F IG
CB A V I T Y 2. Convefr
iniospeiricqmviiyai 20'C {63'F).
1. Fead hydromeierand rherha!gatrssindi@
. iemperaturcs 3s"C (95.F)
when erectroryte
and speitic giaviry of etecloyte is 1.230,
convertedspefic sravilyd 2CrC(63"F1k

. when eectrolytetemp€Gture k 0"c (32"F)

rffi'\ and speclic qhvity ol etectiolyteis 1.210,

l \ILlll cdnvertedspecilcgEvity at 20.C (6a"F) h

1.1S6.

EL.9
 BATTERY
Check(Cont d)
3 . D.i€nine oharsingondhionorbattery. AATTERYCAPACIJYTEST
sravitv6nwh.d at 20 C l6trF) is
lf specific
smarrerrh.n vslu6 shoM below, $ltery

o ,@' ,o

Wnh banerv conn*red to tester s shoq.

tum load knob unll a dr ol 3lim6
bahory rdinq is shown.{Example:B
rarlng60AHTurn oadto lA0Adraw.l
2. HordihG drdw ror 15 *condi rhenloo&
vohaqe. f vo tase remtinsal 9.6 volB
above,THE SATTEFYlS GOOo,ll m
dropsbelow9.6 vohs,then Prededro

CHARGETEST
THREE.MINUTE
1_
2. Turndharserto a lasirarenorover40A.
3 . Aiier rh'ee minulss, (hRl vb tm.rer I
ll ir is der 16.5 vob bdtery shouldb.

EL-10
 I

BATTERY
Charsins
CHARGING R A T EA N O S P E C I F IG
CR A V I T Y
OF BATTEFYELECTBOLYTE a, Kep baftry away fiom open rtame whit.
The 'erationshipberweenrha charsedcondrion
ot rhe bdtery andthe specifca.aviryol bdtery b. When @nnding charser, conn*t Jsad!
eectoyre dirlere,3s shown n tsurcs beow, rn6t, ih6n torn on charsar.
i5 discharsinsaid when i s darq.rfid,.s thism.y 6u$ a ipaa.
c, Do not 3llow defrotyb Emp€Etureto go

CHARGING CUBFENT ANDTIME

REOI]IBEDFOB CHARGING
Charsethe batiervat 1/l0lhe cuftenrol bareiy

lB(nol moE rhsi 1tunpd?)

Do not $e moE thrn l(}amp€E cur.ntllow ro

chrrs. rh. bftry quickry,a6this wirr.hon€n rh.

-Ssrvic€ Data and Spocifications-

As canbe seenlrcm lhesetigures,

rhe barery has

. The specirc qrdiiy or bdiery etecrotyle

incre6esverydowtywh e rhebarerykbei^s

. The smatterthe chaiqingcuneni rhe.ower

the speific sreviryolthedecrotyr .cra*es,

EL.11
 STARTINGSYSTEM
Wning Diagram

i : : '
:E < F 9 !
\22
-'EE;- -.- ;lEl
9 PEI;iE-;si
@E 5555;i:3i
@E

ftn l@
E; !:E

[-:lf"-tl
-n
l-Tf-,Tf
firlll

w
; ; :s

A
\rt
*Dt]J
F m
qlf
@
"rro1,
E m
H
E
HJ
€)6 @

I
;=d
E

EL.12
 SYSTEM-Starter-
STARTING
I
5114320 (Non{ddudiontyps)

@ e

!
9---....-;s

t[

EL.13
 STARTINGSYSTEM-Starter-
Construciion(Cont'd)
tvp.) [HlTAcHlmare]
s1t4.322{Reduclion
d_ q^ 3
ii+ :E:

3
s A.

T E
:

E s
6
I
t

i
i

@ 6 i

EL-14
 STARTINGSYSTEM-Slarter-
Construction(Cont dl
MZT5a,32{Rodudilntyp.) IMITSIBISHImakol

! 1rn
:
3 5
!...
l - e

3; o r
6
E

r;i E i
5
€
g

.i a 3

E
i !Jr'
l\b Ea !

5e6
d
 STARTINGSYSTEM-Starter-
Magnstic Switch Check Pinion/Clutch Check
10check,dkconnect
Seforestartins batbry 1, Check10 se if piniona$emby lsl14320l/
c r u r c ha s e m by ( s 1 1 4 3 2 2 ) / p i n os nh a f t . s
. Disonnect"M" termlnalof siadermotor. semby 1M2T52032)o.ks in one direciion
"S" terminar and androbtessmoorhly in theopposite dlrcction.
I , continuiiy b$ (between
. f h doasnot ock {or lockslin either
. No conilnuiry... Repla@. dkeciionor unuEual resistance s evidanr

2. Continuhyien (beeean "S'

s114322
. N o c o n t i n u i i yR
..e
. place.
 STARTINGSYSTEM-Starter-
- Pinion/Clutch ChecklCont dI - BrushCheck
2. Check pinion movemenr.(Sedudiontype)

. . .s 1 1 4 . 3 2S01, 1 4 3 2 2

3.

Spin ouler raceol ball bearing

ro ensure
rhat
y
tturnssmooth withourbinding.

. Repke pinionir eerh afa worn or dam.

ase.l.lAlso checkconditionof .inq qear

nspectrcdudionqearteerh.(Reduction
lype)
. Fepacereducrion q6mifieeth arewornor
damased. lAko check@ndirionol .rna

EL-'t7
 STARTINGSYSTEM-Starter-
Bru3hCheck(Conr'd) FieldCoil Check
SRUSHHOIDER 1 . Conrinuiryre* (beeeen fierd coir positive
1. Pertorminslarionte* berweenbrushholder i.rminalandposniwb.ushet.
side)andhshrse(neq3tivesidel.
{positiva
s114.320

s t 1 43 2 2
. N oc o n t i n u i -r .y. . R e p k c e l i ecl d
oil.
Insuhrioni.* lberweentield coil posiri-

. Codlinuhyexins. . . . Beplace.
2. Ch-k brushlo seeiJ il movessmoolhly.
. ll brur\ ho der h benl,replace
itj ifsliding

EL-18
 SYSTEM-Starter-
STARTING

4. Check.liamdte/ ol commurator.
commutaror ninimumdiam4or:
29 mm (1.14in) .. , S114.322, M2T52032
3 9d h ( 1 . 5 4
i n )- . . 5 1 1 43 2 0
. Le$thanspeclfied valm. . . Beptace.

. N o c o n r i n u i t y ,.. R e p a c e
InsuLationlest lbslweeneachcommutator bar

5. Checkdeptholinsuarl.s m calrohcommub.

:a)
. Le$ than 0.2 mm 10.003in) ... Undercui
i o 0 , 5 0 , 8 m m( 0 . 0 2 00 . 0 3 1t n )

N
.o.

. C o n t i ntuy e : k r . . . R e p t a c e .
Checkcommutator surtace.
. B o u q h .S. a n dl s h r y w i i h N o .5 0 0 6 0 0

EL-19
 SYSTEM-Starter-
STARTING

Carcf!llyobseruethe
fo lowingin$rucrions, s i+322, M2f52042
compare movement't' in helqhlot pnion
with maqndic sn.h en
. Bearcovefmeral(s114.320 only) andwhan t is pullenout by handunt'l tt
. c€rcasemera (sl14320and M2T520321
. Cenierbradketmeral {N12T52042)
. Frictionalsurf.ceof pinion 0.3-1.5 mm {0.o12' 0.059inl
(S113 4 2 0a n dS l l 4 3 2 2 )
. Movinsportlonof shifr ever
. Plungerofmasnellc switch
. Reduciion sear (S114.322 andN12T52082)

PINIONPROTRUSION
LENGTHADJUSTMENT

Wth pinlondrivanout by maqneicswnch,push

plnionbackto remove
s ackand
"! " betueenthe Jroni edseof the pin on and

0.3- 2.5dm (0.012.0.093inl

Not in rhe speclledvalue... AdjE
d!ncovnlAdjuninqplate),

Nor in tha speciled value..A

. djui by
dun coverladjuningpraie).

EL.2O
 l

STARTINGSYSTEMStarter

PINIONSHAFTTI{RUSI GAP
ADJUSTMENT lM2T52o32 onlyl

0- - "'"
Checkrhru* gap with a sap saugeby pulllns
pinion shalt in tho axialdlrectionwith a {rcw

Maximum
ofrhrustgap:

a
Service Data 6nd Specifications

EL-21
 CHARGINGSYSTEM
Wirins Diagram

k
=
@

FMFN t@

(t lE, qel
E e :!
: E +i ; - @@
-.ii--

(0$ie
ffiffi
! ltffi ffi*I

EL.22
 CHARGING
SYSTEM

B e l o rcco n d u c l i n
aqna r e r n d o tre * , m a k e s u r eh a tr h eb d r e r ys r u l y c h ' q . d A 3 0 V o r v o h { e r a n d
sutbe ie* Drab.s3€ necesarvtor llre ien. The alerndor c

o
T;s;.:t
--t----q;;1

t"----*I
;;;;l
- |;;----l

--G;;,mr
LT4ii l

Fil;-l
; l ' l

. -Lta

EL-23
 SYSTEM-Alternator-
CHARGING

Rer cos nay beh.rd to romovebe@u.e6 ring G usedro lock oute. 6d ol retr betrinq.B. @rtlul hot -
loselhisins doinqramowl,

tr) Llil s

t,,
"S*+m
e-oo I

EL.24
 Alternator-
CHARGINGSYSTEM I
Fotor SlipBins Check-

Roa covsrmaybs hardb removebecrusa rins

k usd lo lockout r raE of r..r bsaring.
Tolacili
be rcfroval of 6ar 6ver, hd ju{ b6ins box
*ction win' a 200{adsolderinsiron.
Do not us a heal $n, as it candama9s diods

ffiffiF . Nocontinuiiy...Beplaceroror.

. Continuiiyexists.,. Replace.oior.
3. Checks Drinsrorwear.
Sliprinsminmumouterdiamerer:
3 0 . 0m m{ 1 , 1 3 i1n ) [ 1 F 1 6 0 . 9 3 ]
2 1 , 6m m( 0 . 3 5 i0n l [ 1 R 1 7 0 706]
3 0 . 6f r m 1 1 . 2 0i 5n l t 1 R 1 7 0 . 1 0 1

EL.25
 S YSTEM-Alternator
CHARGING
BrushCheck Stator Check

CheckrmoorhmoEmentoJbrush. To t€sl rhe *ator or diode, you mln s.pr@

. Not smooth... Checktush holderand thm by un5olderinsthecoinedinswnes

2,
Ue only.s muchhar asrsqunedlo meheldr.
wiUbe&m.q.d by .xGdB hoat,
Diodes

. Aepace brushir it k worn dowi to rhe

3, Ch*k brushpiqbil for damage.

ch*k brushsprlnspre$ure.
Measurebrushspriiqprasur. with brushpro.
jecredapproximately2 mm 10.08inl lrom

2,501-3.333N (256'345q,
a,Sg.12,17oz) lLR16G93,!R17G101
1.471.3,531N (150-360s,
5.29' 12J0oz) ILR170.7061 continuiiy...Bepl6ce
slator.

Not nlhe !pe.iliedvalue...R.ph.e.

Conlinuiiyex ds . Repacenator.

EL-26
 SYSTEM-Alternator-
CHARGING
Diode Check

conditionof diodesasindicaredin chat be ow

nor elisjacrory,rep acediodeasembv.

. albch ohmmeEr's probeio

ro checklor conrlnuny.
. J, aiter reverclns
ohmmeter probes,
conrinuily
nil ,"xist, of nilldoesnor erist,subdodeis
iauhyanddiodeasemblymus berepsced

'l
'.i
l

EL.27
 SYSTEM-Alternator-
GHARGING

carefurryobserverhefoowinsin*ructions.
l. when slderins eachsator coil eadwire ro
diodea$emby re.minal,cairv out the op.ra.
l on 6 iasiasp6sible,
2. when blderinq tush leadwire, obserrerha

{1) Posiiionbrushso rhd !r exlendstt mm {0.43

3 . Fit rin9inlo gfooveid rearbearlnq

sotharn6
d thepositionol minimumprotuslon.

t2l Coil ead wne r.5 timas .rouid ierminal

qroove.
Solderoulsideof terminal,

EL.28
 CHARGINGSYSTEMAlternator
(Cont'd)
Reassembly ServiceDataand Sp€cifications-
B-"rorein*a ns tronr covs wiih pu ey aid
.oror wirh rear cover,plsh brushup wrh
linss6andrerainbrush,by inseiinqbrushlllt
nlo brushlifr hoe irom oua de.
AiterinsELins,rsmovewnelorbrushlili

Do not pull brulh lilt by pushi

or .over asii will damasedip rins didins su.face

EL-29
 SYSTEM(Non-turbocharger
IGNITION model)
WirinsDiasram
CA2OEENGINEIMOOELFOR AUSTRALIA

Ffffit
Ef*t-n
i9 ETTTN"
A-.P

CF

H?l a
#is 911

d :
] E @
9
e 9E

ref.rio EF *ction.
For isnitionsystemfofturbocharqerhodel,
 IGNITION (Non-turbocharger
SYSTEM model)
Wiring DiagramlCont'd)
CA2OEENGINEIMODEIEXCEPT

!t
1.o*; ;,
I
I
'.

5a
E

FJ2OENGINEMODEL

tH'f-

! :

F o ' q n t r i o lnv n e ml o l r l - e r u r o o r l d s eT o d e t , ' . , a o F E s R r i o l .

EL.31
 SYSTEM(Non"turbocharger
IGNITION model)
lC lgnition S ystem-Trouble-shootin9

&261:

iidN=t
\S
bu.hwi6brehandhightn.ion

dlhco!|dds6trdehtho.|c

EL-32
 IGNITION ger model)
SYSTEMINon-turbochar
lC lgnition Syst€m Trouble.shooting( C o n t ' d )
TESTTAALE

EL-33
 (Non-turbocharger
lcNlTlONSYSTEM model)
(Cont'dl
lC lgnhionSystem-Troubls-shooring

.E

EL-34
IGNITION (Non.turbocharger
SYSTEM model)
lC lgnition System-Trouble-shootins {Cont dJ

dN

N
o

EL-35
 model) -Distributor-
SYSTEM(Non-turbocharger
IGNITION

-'"-.-ffio

\e:, -,/
e€i'
o
Wi{ \l::,:
Ea 6r : H!h Feotre sa* @nr
 model)-Distributor
SYSTEM(Non-turbocharger
IGNITION
construclion (Cont'd)

@./
,5
l;

B'L>"'""""" @
A @

[@e""".'".,
=*Y
"r@)
-'6€ Ei
'Vr,
I
6@
st€
,A-€--R
\OZ-
E/6e
je!_
wr

E@, ko{nF4rurdasE6i

EL.37
 model)-Distributor-
SYSTEM(Non.turbocharger
IGNITION
Construclion{Cont dl

e
e

E@

u-.llll--!c ^
E/l"n H E
'-..-*s)€s
/\€(----:

" l-l -EG)

@
@

'#:r^""1

w* )
-t-']

-_

@0 Es'EhFclio&!rcd

EL-38
 SYSTEM(Non-turbocharger
IGNITION model) Distributor*
Cap and Boto. He6dCheck vacuumAdvanceCheck
Checkdp and dor headlor d!d, srbon Connecrvacuumpump ro the vacuumcon
draw a vacuumwhile
Measurcinsulation waichinqbreakerphre movemenr.Checktor
todeson lgnilioncoilandtideol sp.rkplug. smoothoperalion
wih noevidenceolbindin9.

2, Turn breakerplale rishtdndlen io check,or

3.
o4N83.22 lr leak is found, replace$cuum controLler.
Ll breakerplaiedoesnot move.moothy,thG
condilon could be due to slcky neel b?k
or pivor appy greaseto *eer bars or, I
necessry, rcpraebreakerprat-a
a$embry

GovsrnorAdvanceCheck
Turn the cam assnbly (Pointtypd) or ihe
rcluclor lBuih.in lC tvpel counterclockwke,
h andcheckrMr rhecamasemby or
release
rhereuctorretunsslishty clockwise,
2. checkthat the cama$embly(Pointrype) h

L a s i h a ne p . . i f i . dv a l u a . .F. e p a ( e .

EL-39
 IGNITION model)-Distributor-
(Non-turbocharger
SYSTEM

To ssemble,reveEeorder

. Fricrionasudaceot sovernorweishi
. Fricrional pLate
surlae ol breaker

I N S I A L L A T I OONF P I N I O N
Arisn a isiinq maikr on pinionand housins,and
drveFinon nrothesha{t.
After drivinqpi^id^ nio place,drivea newroll

INSTALLATION OF BR€A(EF PLATE

Ensurethar aligninqmalkson brcakerplaieand
linedup p.openy.
housinqaro

EL-40
 IGNITION (Non-iurbocharger
SYSTEM modet)_Distributor_

r. In'talbrionol qov€morlptinq! orrol plnasshownbdlow.

Arech the smallefdiametersprinsro rhe hanqer

pim of shaftandqorernor
weishrfid; theninda I
the krserdiameter
sprinq.

CONNECTINGHARNESS
Ensurethal rrarne$ro lc qnirion unir h tishrty

b. Inn.,larionol bior sh.lt {Buitr.intc type)or

can asMbty {Poinrrwel

Poshionculout diredtionol roror shafr(Buirt.tn

lC typel/cama$emblv(Pointtvpe) wiih cutour
dnecrionof shaft as shownbelow;rhen insratl

c, U$ 3 nes ioll pinwhanihtuttinscdpling.

d. Inlt ll.tionof br@ksrpt.re
Ensure that alignment ma*s on breakerprateand
h o u s i n g aifnee d u p p r o p e r y .

EL.41
 model)-Distributor-
IGNITIONSYSTEM(Non-turbocharger

Loosen poimsetscrew
breaker andadiusr
oap

P o i n i q a p0:. 4 5 . 0 , 5 5 m m ( 0 . 0 1 3 . 0 , 0 2 2 i n )

2.
Tak6off any irregulariiiss with fineltndpaper
(No,50o 0 r 6 0 0 l o . w i t ho i l n o n e .

Air Gap

ber@enle|!ful.nddator.
lercrew andadjustgrp wnh a

0.5mm{0.012.0.020inl

e $-"**

EL.42
 IGNITION modet)-Distributor-
(Non-lurbocharger
SYSTEM
Servic€ Data and Specificarions

IGNITION
COII

EL-43
 SWITCH
COMBINATION
C h e c k{ 1 . H . d r i v e m o d e l )

,
*S)

I
,;-
t
er
I
& ol:{ilma m I

"\

t]Em

EL.44
 COMBINATION
SWITCH
check{F.H.drivemodel)

I KT
7tu[4<F I
t )qr]'- h ('))
*-+ +!
t )
I
I
F:F{kFr
\

t L !

o
L:7"ff
"^:;v
Efu

EL-45
 COMBINATION
SWITCH

Liqhringsitchi wip.r & washerviich, A,S.CD-

swirchand harardvitch can be rcplaced with
out €movingcombinaionsitch base,

+ **-*
f(l I

To Em6ve combination3whchb3e, rcmoE base

afiachinq$rew .nd ruh altd pushingonii.

E1.46
 HEADLAMP
Sch€maiic{1.H. drivs model except for Europe)

5d

P
=
rb

t;

3;

EL.47
 HEADLAMP
Wiring Diagram(1.H. driv€ modelexceptlor Europe)

E:

,j 0
E}:

I ;;*E#t
riii
1 4 1Epr
IE
f ffi
; LEB
!i
;l##'ili;
:: ilffi
!E :': *s ii
diltsldtJl
\-
E:
!,6
iFcs"

&3@so
ig s iiF Ei
il - : 'i
|E
ilH E
!ri:
; :
lt
t ! :
i t
?
0 !:

EL-44
 HEADLAMP
Schematic(For Europernodel)

c:
: !

E2i,
?e,

a
,,t
a

I
{
P:

EL-49
 HEADLAMP
Wirins Di.sram lFor Europemod€l)

i
i!
I
i! I .6E

!Effi
ryl rffil
!i!a3
ii
I
: ! Lii !lr o
otsJ 5i

@!ft

q
q9
:-
lq#lT i:

t+E/lIE!
t

9i

-i,,0@ :3

!€ElEtr* i.i!gElEtS

'$ Ei
+.iFi
u c
4t
ii
:r
EL-5O
 HEADLAMP
SchematiclB.H. drive mod€l except for Europe)

i:

3;

is
i!i

5E:
7l 99

iE
ir
EL.51
 HEADLAMP
Whing DiagramlR.H.drivsmod€l

Eg
i9

EIm
s+€;t+l
. :

ii
:i

i;
ii E;tt :
!

Ei
"#r
te!s
ji
ri
iii
::
:;
t !.
;i
6

EL,52
HEADLAMP

EL,53
 HEADLAMP
Description(L.H. drive modeloxceptlor Europel

. Thefo lowingchad depicts

the operationalmodes mororcin rclationrorhe posi
of relavsandheadlamp
rionsol the lightinqsieh andrerdctswi1ch.

o4 i iir'--t i . ,

roMdo)

EL.54
 HEADLAMP
Descriprion{1.H. drive modelexceprfor Europe){Cont'd)

lAi Wh€nlightinqsiich k fbn "1ST'' "zND

A-1:Whilehsadlamp moiorisopor.tinghaadlanps
lo rheop.n posiiion

*' [&]
H--1, ilWj
-- -' -- I'iif,
Ti".
11'!""":::
I
thehe.dlamp
motorraachBful,Vopenporhion

EL-55
 HEADLAMP
Description(1.H. driv€ modelexcept for Eu.ope) {Cont'd)

IBI Whenliqhrinq3whchkswi.hed fron "2ND"- "1ST

{Hsadlampnolor holdsopenpositiont

"tST '-
lcl when liqhlinqsjich k Niichad lrom
(Whil. haadlamp molor k opaEr,ngheadl.nps

EL.56
 HEADLAMP
Dscription {1.H. drive model excapi lor Europe){Confd}

lol Whonlishransswithk.whchedio "PASSING"

D l;Whil.h€rdl.mpmolorisopedrinshgadtamprtorheopenpGirion
{Themomentlighting3wiichistuhed to PASS|NG
position)

-""1'

O.2: Whilehe.dl.mp mobr is opeEiinqh€idtampsb $e openposilron

{Wh.n lightinqswirchis ele.sedl.om PASSINGposirionl

EL.57
 HEADLAMP
Description(L,H. drive modeloxceptfor EuroPel{Cont'd}
heailampmoror4ehe ,ully op.n position

IEI Wh.n Errafur ewitchi5 tuned ON

lwhilehoadldpmott i5opoEring hsdlamplto rh. op.n pGirion,

iiifi,,

,/ i *-"I

EL.5A
 HEADLAMP
Description(For Europemodsl)

i The followinSchrrt depictsthe operaiional mod.k of rel.ysand headhmpmorotstn rekrionro the

posirionsof the lishtinsewitchrnd rera.t swhch,

EL-59
 HEADLAMP
Descriprion{For Europemodoll (Cont'd)

circuitop..aiionror tAl, lBl, lci andIEI is $ei.me asihos for L.fi. drivemodelexceptfor
Europe
Wheh lightinqsrit h i $iich6d to 'PAsstNG"
[D]
Dl: Whilehe.dlrmpmotorir opeBriisheadlanps to rheopenposirion
{The momanr lishtins3oith is turnedto PASSING pdiiion)

iiiii,,

D 2: Whileheadlamp notor k opeErinsh€adlamplb rheopenpcnion

(Whenlighiinq3witchis al@ed lrofr PASSINGpchionl

EL-6O
 HEADLAMP
D€scription{For Europemodel)lCont'dl
D3:Afierrheheadlampmorornachesfullvopenpcirion
(whenrishtinqswnDh
h kep!in PAsstNGposiijon)
 HEADLAMP
DescripiionlR.H. drive modelsxc€ptfor Europe)

. The lollowingchartdBpict rhe opeBtionalmodekor relavsand headlamp

motou in rclationio th.
position.oltne ishtinssitoh andretraotsitch.

o"d@)

ord@r

"'--'iiiii
L.l*- +-1.] Fi

EL-62
 HEADLAMP
Dascriprion{R.H.drive modslexcepl lor Europs){Conr'd)

lAl whenlishtinssn h k $itched lrom -lsT- + -2ND-

A 1r Whileheadlampmobr i! oporarin0headtanps
io rheopehposition

A-2iAfi€r rfieheadlamp
motorE h6slullyop.npGhion

EL-63
 HEADLAMP
Description{R.H.drive mod€lsxcaPrfor Europe}(Cont'd)
"1sT"
lBl whenliqhtinssoitchh ewith.d from 2ND"'
{Headlampmotorhol&op6nposationl

EL.64
 HEADLAMP
D€scriprion(R.H-driv€ modelexc€prfor Europe){Conr.dl
h sitchedto ,,PAsstNc,,
lDl whonlishrins.witch
D.l, Whjlehordl.hpnotorisop.rdinsheadtamF
to rheope.posirion
{Th€momentliqhting
siidr islun€dto PASSTNGposhion)

o-2i Whil. h€.dl.mpmotorG op.rctingh@drampsb rh. op6npGirion

IWho lishrinsrwibhit eleasd trcm eAsstNGp6ition)

EL-65
 HEADLAMP
DescriprionlL.H. drive mod€l€xceptfor Europel(Conl'd)
headlrmpmoior erchss tullv op.n pdition

[E] WhenrctEcto. switch k tum€d ON

{whileheadlampmoto.Gopsratins to the oponposirion)
hsadlampl

EL-66
 HEADLAMP

EUROPEMODEI AND L.H. OBIVE I ODEL EXCEPTFOR EUROPE

L.H.drivemod.lexc.prlor EuJop€only
 HEADLAMP

R.H. DRIVE MODELEXCEPTFOR EUNOPE

lch(k DoWNcodeipohr)

EL-68
 HEADLAMP

@__

EL-69
 HEADLAMP
Installationand Adjustment-
mororto "closE"poshion.
sorrhoheadlamp ln$all headlampblackeito bodytempodit
Connedhfina* io headlamp molor and sei rnd ch.ckri9hrrafi.ri9nnenr.
reiaci sitch to "cLosE". H.adhmpmotor cover headlampbracketwith d and trn
en now be 3et to -DoWN" with relracl motormanuaknobroc o$ hftd amp.
B€loredoingthis,bs sur€ro dk6nn*t h*
2, A$emblr haadlampmotor ro rhe headanp

Asemblethe link A to the headlamp

moror 21 oaremindhedrampbrackdtberion onb.dt
so rharrighlleftalignmenr
berween
lld, ho.d,
aid fenderk asshownbelow.

A
\!
llr
As*dble lihk B to link A and the h*dlamp
3l After adjusins risht olr rlisnmenr,re'le
LJthe l@k nur oi link B hasb€n oo*ned, lid and t9hren headlamp bracketscurctvb
confim that link B is rhelenqthshowi
below,
thenljghlenlocknurfirm y.

1l Loosanlocknuton stopper.
2l Turn motor manuaL knob ro openhsdtanp

/P,S

. rd--i-,;.1 \l
0'//E
+'\/z\

EL.7O
 HEADLAMP
Inslallaiionand Adjustment AimingAdiustmsnt-
(cont'd,
whenpedormins headlamp aiminsadjuimenr,u*
anaidingmdchin.,.imingwall$r.sn or h.rdl.mp
. Adiust lid, hood an'l lender ror a snmeni tenef. For operatinsinstructioNof anytimer,il
while openiis and closins headLamp wnh shouldbe in qoodrepak,elibraiedand u*d ac.
@rdlns1o respective operarionnaiuah suppiied
Use motor dnud knob to openand close
headlamp, rranyaime.is nol avriable,aiminqrdju$mantcan
andadjurtalisnmentwhile checkins
rhd lld k nd int.rf€ringwith pror.tur.
Before na.finq adjustm€nt,be $re that bar For d6taik,r6fsrro rhe BsulatioNin your own
l.ry qround6bl€ isdk@nn.ded.

a. K*p all tire!inll.radto cond prc$urcs.

b. Pla@vehicleandre*er on one.nd ,.mt !l.t

n no bad inwhidle{cooltnt.en-
up to codrt loveland iull fuel
rhrn rh€ driv€r lor €quiv.l.nt

Adjuslheadlampi s rh4 mainaris.l listt is

p.6llel to cenftr line ot body and is rlign.d
with p.int P showninillunrdion.
Abovefiqlre lhowsh6d!.mp riming palt.rn
for d vanqon rightsideof @d;for divingon
left sideol road.riminsp6tem nrev6F.d.
Dotted lines an illu.tBtion show enter of

EL.11
 HEADLAMP
H€adlampMolor Check
Disonned batefY sroundcabre
Fully open rhe headlampwith moror manua

3 . Removeheadlamplin$er and froni combina

suppod headlamp brtckei

bLockol wood lrom be ow
Remove Erinq, an'l ink B
.'...
ai (L)

A.H.driremodel€^captfor Eu'opa

6. Use dn ohmme&r ro check lor conlinuity in

For Europeand
L,H,drivenodelexceptfor

o rt
a Itj
o
a3) n
1) a
it
aa-
o Q]

EL.12
 HEADLAMP
HeadlampMotor Check(Cont'd)

il.tFq
F{/q
L

4I

Delecring$hchpolation:

EL-73
 EXTERIORLAMP
Lic€nse,Teil and Stop LamPs/WirinsDiagism
Clearance,

za ,
!r
\2* H; 53S
-
g5
tti .Ltm m l ]@l l i H m lE{tE
LL:r I
i'ls I
[[1 r+l
l"It lJlI
l: T l*6r tdr
lI

E @@'
lior A
@
@ -t-,-..+
;
!r/ 6€)e
i

o ;:

-.?

@@
6;
FS o€)

Ed AA
at@ -
9,

EL-74
 EXTERIORLAMP
claarairce,License,Tailand Stop Lamps/wirinsDiagralnlCont d)
EXCEPTFON EUBOPEI\'IODEL

5 E
r,ii! 'it! ir-! liti
l-
q:i i3i;Eii!
]Gtht
4 d tl,E ry
t".

JT :J F
;?

0@g
.F "\*
g: :

6
i3i €

@ @

@ 6a
Fi 66
w

a
ZF
I L
sii
EL-75
 LAMP
EXTERIOR
Back-upLamp/wirins Di.gram

@@
gE::
,i5 llaF

@6 A@

RsarFos Lamp/WirinsDiasram

* - El,l€:[
- L:l
o,
o,

EL-76
 LAMP
EXTERIOR
Turn Sisnaland HazardWarningLamps/Warans
Diaqram

ai
'9 f=

ir
Fi F
:r
:d t1 rdl
ei
?:
!;@ Ii
T T

(i) 0@a
tt
.:! l
6

@6 ::!.;;
..:;lii

e
s;
EA
,d
LT
'E:

EL.77
 EXTERIORLAMP
-stop and TailLamp Sensor Check CombinationFlasherUnit Ch4k-
enurerhal bulbsmeer3p*i Seroecheckins.
ensure
lhat b!lb6meeisp..;

connect a baltery and test amp to rie m

binationJlashefunn, asshownb€lou C.mt;
nationllashefunit is properlyfunctioninq
itn
b inkswhen pNaf ksuppliedro rhecncun.

+ FETNF]iH

-
Bulb sp€citications

+ $Hl tfil

EL.7A
 INTERIOR
LAMP
lllumination/Wiring Diagram

t;-;r
i!
,ft | m*
. @ - - ffii 4 E i1

l i B f f i
I t: Hl
I FE MI :7'
! = l
erek H E
Fft
I
t<
6
!
3a
#E 3i1
F
H A
9
@
q5

@
g
a e a: RrsI- .:
:5
i1 LU_I I
F5

EL-79
 INTERIOR
LAMP
llluminalion/wirinsDiasram{Cont'd}

6! F1
r€rr F]
.f@i: Bl :1
L'€- |
Ta.i;;
I trel H
ZEtfol! HLEE-s " ! t| --19] 5
-l
L ""o*-gl gii

*,-r
t]l z6

E
- t - t E1
! 6)
=i
#E
F 6 .,- f=-
;:
ii ffi @ l @
:1

€
"{
t a..
6 , ii ; i
3

c
r@
MIITIM # ffi
ts
!e Y1
:
i<
1i tst:'

EL,8O
 INTERIORLAMP
Inierior, tugg8ge, Foot, Slsp and Spot Lamps/Wiring Diagram

t
3, 16i E trgl
- 6 F 5! t+ LCil ii ; tl
:=d ;;m
;ir€€; a,i
-- @ € @
i;ii;! ie
I
. os€tA a3
, ,c c
@
E
e
eE € i i
I
ffiffi'E

,@F E

o
l:I:Elrfrnr-- :!
FE
ffiffi 3e It 1 I
::
Lql

EL-81
 INTERIORLAMP
-lnterior, Luggage,Foot, Step and Spot Lamps/WiringDiagram(Cont'dl

16l
lf
40
ai
F 6:
i r!
--
= i E! e0 e, B
It l
@

@s:#Sr: g BilBfl!ffi:+E€
I

6 :

t f l 3
t: =
E E::
@ * i ! i E !
9
dn
la -Tf
w
_!_
l@J
5 @E

EL-82
 METERANDGAUGES
Combination Meter

7:.fuL?iz'
,sr )i;6 dU/,;6

t
e
I
E@ S
ee
T I t

. "-1^/\-." G\- "

:r+_/ \ _/--,,

EL-83
 METERAND GAUGES
-Tacho, T€mp.,Oil,Fusl,Volt and Boost Gausss/Wirin!Diagram

l_!

/@l r\r\ryE;:
66r :g
l-:
ffi g
E ff E i E I
k F IFH
E lq" *i !:!;::-l@;iq
EEI :I :i:::;5i5:Fi:
u p o " p Qooe -@ Q .
I !J!44|

ffffi^-s@"
9",
0
i= trw@
.:!
@
€@ 5?
r 36
6G)

s
: l?9 E
P ii e
uA 6 s
AE
E
Az

EL-84
 METERANDGAUGES
FuelTank GaugeUnir Check Speed Ssnso. Signal Check-
(Coupefor Allstralia model)
Fo emovat,
rererto FEs(i on.
. speedsensorsbuitrinrorhespeed
omerer.
. Turn lp€"domeiefslowlv 6iis sma $rew.
dnver,3nd checkconrinuityot speedsensor

Conrinuity
exi!$rworimeslor4ch torn...O.K.

"l T@#=-
I Y[\n .-- \
---\

Spe€dometerCable
Removaland Installation
Combinaiion meterandlpeedomerer €bte €n
b€ jolned togerhorsimplv by in*trinq the

EL-85
 METERAND GAUGES
aoost SensorCheck

D sco.nect harne$
sensorand connKt bat@ryand vo rmeteras

{0 mbar,0mnHs,0 inHq)

appror.1,3Vat 53.3kPa
( 533mbar,-400mnHg,-15,75inHq)

-Oil Presure Sending Unit Check-

t-i

EL-86
 WARNINGLAMPSAND CHIME
arning Lamps/Schematic

@r

E
E iiiiE
€; A

EL-87
-

WARNINGLAMPSAND CHIME
WarninsLamps/Wirins
Diasram

BF"

tr13
si
€e

.Tffi"H ;:;

u :i
eE: Eyl:

6 LEtUj ti;
fH iit t!:

F]IFF s.
1:

€)
.],*i.3
@
6S"
ffi€
Ef ffi0
I

5
Lr/,Qr

:ie i-
ffi
L+
F
E3 :}F

EL.A8
 I

WARNINGLAMPSAND CHIME
W.rning hmps/Wiring DiasramlCont d)

E ts', -
!
.: !
:? I
f=:l
i ; :i : i : '4,Jr:i,
.09€ !:

i: Eit
0 6 f.e-Jrs'E
1L t;
E !!ErL d l ;

e-- EE+

5
i E
i+ efAl::
f FI
! & r l Etr-
' " : 'iniFl-!.
E ;!

EL-89
 WARNINGLAMPSAND CHIME
warninsChime/Wiring
Diasram
'"fer ro "TltUECO\TFOLSYSIEM
Cl ,rs ! d.! qnedasro givaa ligfr wdlinq. ro' roub e rhoorinq.

ei
6
!
{3i
E f;
\
3;;

g! d]' E;i
?:i
,F-hg;:=frgSU F F E
! i 6 @ 'rffil ffi.:
!t
lm EE
;F
6; i E::iili!s= ."*-ffi t!+ 9:
9 3;;:5:;::iIi
,
6"
'@eeeoo @(9
i
'@€)a

I
ffi L#
6
E
I
e
n++fH#

EL-90
 WARNINGLAMPSAND CHIME
Diods Ch6ck

COMBINATION WABNINGLAIMP
. Dodaslor w.hins tampsa.e toGtedon the
panewhercMhinq butb.aretocaten.

COIMBINATION METER
. Diodo!ldr wamingtanpsare buit! into rhe
combination
mebrpriniedcircuir.

E
@
k'", @
@

EL-91
 WARNINGLAMPSAND CHIME
ChimeCheck- Seat Bolt
(For Australia Harchbackmodel)

,"6,,,
J

EL-92
 TIMECONTROL
SYSTEM

Nevertouchihe temina s ol time rcntbtunit with b.rc handr.

= !

:3;

R
ffi
AE is ffi
at
[ffi

EL-93
 SYSTEM
TIMECONTROL
Whing Diagra

EI r-il I
F -?+ I
5'
lrl ::

tJi
l-i I
B
I
$ E
E

H
nnrni
@0 i.sc6g*
.s+B
*' Effiti
f l4t#ie
Br€ l:e I
l! "trEjiiii;
ffi
:-
ESE$! e5r:r
.i6
!. I
E5(i
B ; . ; a: 3
rl liL
T E :Eg;
6 l9at[-| ! 3 EI
IITTITtrI
i:

ffi
EL-94
 TIMECONTROL
SYSTEM
Whing Diagram{Cont'd}

i
;:
t \ l t !!
p
E $ ; llil
FI
I
E
:i
i!
F
t1.l
!l e6
KN gB IL
I
{lJ ;1 tr tu+ !
i
rmg
id llf+ffiFo
mPt
,+
' 1 4a,lEPrl'lEE
HH:d

3
i--
{Ft

@
E
@
i i iiL ii
;

@
E9 ?F
LT ffi i€ t
FI
l
IH
1llTlrFl
p

E6lTfn
F

EL.95
 S YSTEM
TIMECONTROL

. T n e c o n i o u n r h a s t h e f oo w l n sl u n c t o n s

wips n op'ded ncotrl!rcton {d sshd rwich

EL.96
 TIME.CONTROL
SYSTEM
D€€cripiionlCont'd)
oPERAilo coNDlrioNs'

O @-@ o {1 @ @ @-@ @
@

rll
@

EL-97
 TIMECONTROL
SYSTEM
- Preparationfor Trouble-shooting Troubls-shooting
1. RemoveR.H,dashsidedowr.
2, Femovatime @ntlol

@@r

PowerSupply CircuitChsck- T , C , UO, U T P UFTO R W I P EBRE L A Y

L Tumwipersitchb"lNT.
2. Turniqniiionsitch to "acc".
3. Masurevoltaqeacos@ and€).

@ o

WIPEBSWITCHCIRCUITCHECK
1. Iurnwipar$lthto "lNl ,
2. Iuro isnilionsith to "OFF',
3, Checkcontinu (, andO,
ity between

EL-98
 TIMECONTROL
S YSTEM
{Cont'dl

whPf md w4he.ei,*k hd, du, rYb,, rci;

l- Tum ignitionsitch to ,,OFF,,. 1, Turnisnitionswilchro ,OFF,,.

2. Msura reskene betwsn 6 and @ 2. Turhwasher.wilch !o,,ON,_
whileiuhing internittentwipervotum6. 3, Checkconiinuitybelw*n @ and@

N
o@o

E1.99
 S YSTEM
TIMECONTROL
{Cont d)

L I G H TSWITCHCIRCUITCHECK

CIRCUITCHECK
ILLUIMINATION
I.C.U.OUTPUTFORINTEBIORLAMP

1, Turnisnitionsith ro "OFF".
2. M@sruvolbseacrc$@ andO,

IL!UMINATIONCONTROLCIRCIJIT
CHECK

t2l o
@ \'

EL-100
 TIMECONTROL
S YSTEM
{confd)

I.C,U. OU'IPUTFOF AELT M/ABNING

. Mea.urevohaseacro$ It and !r_.wh

qnnionswirchis,,oN"

ffi
="\_\
T . C . UO
. UTPUF
T O RC H I I V C
l EI R C U I T
i":$it%sliJTil"ll:it'i::"ftrJ
1 . T u r ni s n t i o n s w i t c h"t O
o FF .
2. Measr. vohaseacfo$ O and O whei
driver'sdoor isopened a^dclo*d.

EL-lO1
 TIMECONTROL
SYSTEM
Trouble.shooting(Cont'dl

T.C.U.OUTPUTFOR CLOC(

BEAB DEFOGGEA CIRCIJITCHECK

L Turn iqnitionsltchto "ON .
2. MeasurcvoLtaseacrc$ [} and O while N
opeEtlnsetr d.fogssrviich , iMEu
CLOCRCIFCUITCHECK

2. Dhdonnect
harne$conn6dor for ctock
3, Checkbrminal voltasear ifttument
harnesconnodorror c ock.

SWr'lCflClRCUtl
DOFOGGER

E]lTmImmlT

o
o o
G)

EL-102
 WIPERANDWASHER
WindshioldWipsr and Washsr/WiringDiasram
I
o
o
@

-3t1p-FdR 2
@
r;i.l=
,.9i9+ffi
q-l

.,94E\

ltE

G
g i q t 6 : :
t ; j - a ! ;

q
;

EL.103
t)
 WIPERANDWASHER
Rear Wiper and Washe./Wiring Diagram

.L*,

@ L-i;iJ
a@

dqrnl:

o
(D
6E

'+,= I6

Wiper RelayCheck

Nlake
connectlons
asshownbelow. A checkvave is providedln the wtrher fluid

termnal O and batery sround,w per relay washertube in the wronsdtsciion.

EL.104
 WIPERAND WASHER
Bemovaland Installation

. when removing
wip€rarm, lilt up wper rm, Wipsr .rms of ditr€@nt lenslh are used for iha
pu outarmretainer.
andhold.rmsteadv. driver'r sid€ rnd pa$enser ddo, They hav€ rn
ideniiiyinsmark6nd6r. mus be$ken ro instatl

"o"
h h o ral m ) . . . . . . . .
"A"(lo.sarm).,,,.....

Priorto wiperarn installation,

serwipefehch
to ,LOWii to operabwipermororandthei
turn it "0FF" lAurostop).
2, Adjusrwiperbladeswilhin.tsrdnce,,C,, rnd
righrenwipe.am an.chingnut ro rhe speci

3 . Eiectwashdrnuid, Setwipe/sitch ro,,LOW"

to operete wiper froro. and then turn ir

Ensure
th.twiper badesltop wirhincte*a^ca

IB s

EL-105
 WIPERAND WASHER
H€adlampWipsr and Washet/WiringDiagram

<!fjlttr*
--l
@d d@
odde
@i;;+@ 3?B:""
t"lt",SL,

(R'L
Do norr€md. h..dlampwipd mobrai a.inol€unir'Alw.vsremd€ it.t6h@dl'np 'smblv

EL-106
 WIPERAND WASHER
{Conr'd)

3. Checkfor properopehtionofwjpersynem.

-Headramp Wiper Motor Check_

Whenwip€rmorori! lock€d,a prctodivecircun

buih inro wip€r moto. ad,vrtcr to nop wip€r
motor.lr wipernotor witt nor reabrr ovsn.nd
crus of problems hasb..n eliminarod, ru'n iqni.
tion rrh.h OFF and t..w ir ofi for spprox. i tu 3
nui andsdjui the tensthof ink

Belorc innalinq hedl.mp wiper arm, *i

t )
hoadrdmp wipermoior to the auro4topposi. o o
o o
2. Posilionwipn arm$ rhatwiperbade lishty o o
o t

EL-107
 HORN.CIGARETTE
LIGHTER.
CLOCK
Wking Diasram

. ! ; g 3 , : ;!
:0
Iii$: ;;5
-

f;:i;sii.;j
@ @ 89 B so
(rF,
@
@€ r ; H '?
9
^flnl
ffi 3,
BGI"
a{
/t:r.t a
e
Eqr a
€t/i e
-",r n .G:ll, ;

@
9

EE
5;3 E E

t l
gr'; ej"E

EL-108
 REARWINDOWDEFOGGER

3E

m
flt

iTt
_
U1 t]-t
5r
5

{3t4
@6

@ @

e@
@@
o
;E
! !

EL-10S
 REARWINDOWDEFOGGER
Wiring Diagram{Cont'd}
EXCEPTFOR EUROPEMODEL
a;
6i
-o Tr'1
9* ! l
t 3 tL!< l
.a * l
5 P-f
E tr
F F
:s@
I
E

I
5
E
a -'- €\
3 -F W, t m\9
l:'
2@
u;
!t
o .h
a c/4

e6 EI

-3, :!
zi

63
ss
"!
i:
iEEPI ! E a :
-E-] 9 ! i i :
lffil t=ii:;
L I
@
o@\rJo@

E L - 11 0
 REABWINDOWDEFOGGER
FilamentChock
At$ch prob. circuiten r (in @tt 3. To lo€te burnedoul point,moveprobeto left
niddl€ponid^ol @chfilament. lilamentto derermine
poin!
wh.re t6ter neede swins abrupdy.

lf a filament is burn€dout, cncuh teter

FilamsntFeFir -

1. Conduciikril@rcompdirion
{oupontNo.4317or eq!ivaleni)
2 , B u r e r , 3 0 c (m1 1 . 8i n ) l o n g

FEPAIAINGPROCEOURE
1. W p6 brokenhslwiEand iil siioundingarea
cl€n withaclothdamp.n€d in alcohol.
2. Appy a $all amountof condudi@3ilver
comP6jtionto tip ofdrawinqp€n.
Sh!k. silv.r conpolition .o.triner beforcure,

E L - 11 1
 REARWINDOWDEFOGGER
Filamen'tRepair{Cont d)

3 . Paceru er on sla$ alonsbrokenline.Deposit 5 applv a con{ant$reamor h

on breakwth $e repaifed 20 minuics
areafor approximately
co^ductvesiver composirion
drawinspen.Slqhiyoverlap etkrinsheatwne wiih a hed sun.A min mumdisbnceol3 cm
5 mfr {020 in)l ol be keptberwee^
{r.2 ln) shouLd reparedarea
on borh sideslpreferablv
andhotair ounet.ll a heatsunisnoi avaiL.ble.
letrhercpanedareadry lor 24 houre'
i3

4. Alrer repairhas becn completed, chek re

pairedwirelo. co^rinuhv.This checkshoud
be cdnducted 10 minuiesaflErslvercomposi'

areawhilsrodi5beinqcon'
Do not touchrepaned

EL-112
 -l
AUDIOAND POWERANTENNA
s Diagram

: * :l 9

LL _,dd
"_
TGrj ,! ;
lt lil

'r.
t t:

c!@r

"80
+€'
l
E*",.H ,i!i)-
@ .,

fi I 55

'l
E
l;
B]
It
l ;ii
"r€

EL-113
 AUDIOAND POWERANTENNA
SpaceDiversilySystem

(Fod aotinron res i€nd€iL.H,l

I
I

I
I
I

I
I

ThL sy*m h* tuo iyp$ or

EL-114
 AUDIOAND POWERANTENNA
ll
afr& ir h$ beenrcmoeedand

-Antenna TrimmerAdjustment-
Theanlennatimmershouldbeadjusted
in ihe fol
dto b€rcnoved,
. Fadlnqand weaklVlW(AM)reception.
2. W thdraw anren.a rod whlle hisins ir by r Aiter inia laion ol newanrnna,leder cabe

Bsfor€sdjunihs.be i!rc to dreck hrrne* and

antennafsodorable connectohtd prop€rcon.

1. Exrend.nienna complerey.
2. Turn mdioon, andtun volumeconrol ro in-
creasespeakervoluhe,
3. Tunein rheweake${atlon(b.rely.udible)on
dlalatrherangearound14 ll,40OkNzl.
4. Turn a.tennrtimmer ro lefr or rishrslowly,
and ser ii in rhe positionwheraruceprons

2. Insertsearsectionof
wirh it lacingtoward

3. As soonI anieniaropek woundon anrenna

molor,sop antennamotor.In*fr.ntennar.d
lorerond inroantenftmdor plpe
Aevactantennarod compeley bV opectins

5 . Ln{alanlennanurandbase. oE d'an one har

EL-115
AUTOMATIC DEVICE(A.S.C.D.)
SPEEDCONTROL

: '
!5 €:
e€
:5
i2 : 3
i:; :;

E6

:E; -

>5
l

t .
i

;:
:'E

6E
6;
i- !:i

EL-116
 AUTOMATTC
SPEEDCONTROL (A.S.C.D.)
DEVTCE
g Diagram

i a
! 6
! :!
6
Gl i=er i l
\a
r;*ffim@ :,:!! I
: l
gi:
t;;tll :i?$ FE I
!
| 3r:6:e"
Eil 6 t
1."",-l ,ti.-+ E'
l"".Et-=fl/
l-s-l !s
f-l l rg
e! _iEAH&" l

?a

ai#
i
t
! iEt
;li=l

ii

ltt/FE E,

EL-117
 DEVICE(A.S.C.
SPEEDCONTROL
AUTOMATIC D.)
ng.

.onlror unt wnh harnes Asco(4hlutdrct&5{orcFY

to mlk€ rureidiubr lroard abowcombhdbn

POWERSUPPLYCIRCUITCHECK
L Releaebtukeand cutch pedak.
2 . T u i ni s n h i o n s w i r c h r o ' o N " .
3, IurnA.S.C.D.mainswilchto '0N".
4. checkvoltase beeeenrE dndO.

N
"o.
SET SWITCTi CIRCUITCHECK
1. Turnignitionswhdhto'oFF".
2. Pu.hA.S.C.0.serswltch,
batween
3. checkcontinuiry O and'B

EL-118
 AUTOMATTC
SPEEDCONTROL (A.S.C.D.)
DEVTCE 1
o u b l e . s h o o t i n{gC o n t ' d ) I

"METEFAND GAUGES"
{FO] T6 )

1 . T u mi q n i t i ow
ni l c h t o " o F F " .
2. Di*onned speedomarr cabief.omrdns

3. Conhectan ohdmererb.tw*n @ and

@.
4. Turnignitionswitchto "ON".
5, Slowlyturo speedomerer cablepinlonby
hand ro make sure ohmmatr pointer

Ohmmelorpointar dellectstuice per

l.a.I

EL-119
AUTOMATTC
SPEEDCONTROL (A.S.C.D.)
DEVTCE
Trouble-shooting(Cont'd)

RESIJME SWITCHCIRCUITCHECK
1. Turniqniiionshch ro "OFF".
2. Tlrn resumeswiichb "ON".
3. Checkcominuity b.iw*n O andir.

ACCELERATE SWITCHCIRCUITCHECK
r. Turniqnirionswitchto "oFF".
2, Turnaeelerate*itch to "ON".
3. Chedkcontinuhyberwenagrand il

N
.@.

EL-120
 l r
AUTOMATTC
SPEEDCONTROL (A.S.C.D.)
DEVTCE .

I
Trouble-shootins
{Cont'd) A . S . C . D .A c t u a t o rC h e c k
1. Check coniinuily beiweenrerminal O and
r a , m i n (a4k, I t a n da a .

.--e
,ped trnnotb€ ruhFhldJ

Do not atempi to renovevalv6from

2, Connectbattery {apprcx.l2Vl

Torn ignhion$itch to "ON". ll diaphragm smoothy,acruabrisO.K.

moves
Tuh 0.o.can@l$itch to "OFF
ch4kvoree o.o andG o. when checkins aduatorbv applyinsvacuun,do
not applyongin.vacuuB diiectlyasit hbo stons
lo chek actualorprop€ y.

EL-121
 DEVICE(A.S.C.D.)
SPEEDCONTROL
AUTOMATTC
A.S.c.D.wne Adjustms

-\1-\ \ .!€r-\\1
t /

switch and c uich sw tch

. Be €rerul not to tuist wirew
. Do nol r.nse wn. exce$ivelydurinssdju*'

After conlnmlnsthat acceerato

adiu{ed,adjos the lensionol ASc D. w re ln

(l) T shlenA.S.CD wirc with adjuninsnul unt!

portionA ol throh e levercofresintoconuct
1 2 )r h - A nb,a c k o f f a d l u n innust1 / 2 r or r u r n .
(3) Securelyiishien ock iut to hold ad!!$Lnq

EL-122
 LOCATION
OF ELECTRICAL
UNITS

g i c-!.
i
' : !iEE
!ie"
ii /'

{E
:

,i
!
s.
: B I
e : ;e I
E

il :ee+ ;
i \//
-,s
,tp>!t
a
1 i!

!i I r9
€ ;
i!

EL-123
 LOCATIONOF ELECTRICAL
UNITS

:i!: E

!gEi

E : O

l E :
ii : E
bE a!
9 :! d!

_ , .a : iH H=!
ii fa : Ei
aq

EL-'t24
LOCATIONOF ELECTRICAL
UNITS

lJ')

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;5
! i

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;!
.

EL-125
 UNITS
OF ELECTRICAL
LOCATION

! H :!

:; !:

't
il;

;! .e
I
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;nd)
3

7
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>\E:*
I-i1;:
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Et-t26
LOCATION
OF ELECTRICAL
UNITS

@,\

EL-127
 LAYOUT
HARNESS
O u l l i n e{ 1 . H .

EL-128
NESSLAYOUT
m o d e l ){ c o n t ' d )

EL-l29
 HARNESSLAYOUT
MainHarness{1.H. drivs model}
ENGINECOMPARTMENT

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EL-130
 HARNESSLAYOUT
Main Harness{1.H. drivo mode (Confdl
PASSENGEBCOIVPAFIMENT

€rq
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EL-131
 HARNESSLAYOUT
Main Harne3s(L.H. drive modol){Contrd)

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EL-134
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EL-140
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EL-l42
 SUPERMULTIPLE (S.M.J.)
JUNCTION
Disconnscting
and Conn€cting

S.M.J.k lo€td on the riqhi Eidaol the

To di5connecl
the S.M..1..oosn the lixing

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wlakeswe the specifledtishteninqrofqueh

EL-143
 SUPERMULTIPLE (S.M.J.}
JUNCTION
TerminalArsngement
'.e. Bl". 00", erc, are 'dent

l J l s ll 3
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EL-144
 (OuterParts)
ENGINE COMPONENTS

(OuterParts)
ENGINECOMPONENTS

Distributor covei
e zo - 2s Q.o - 3.o,14- 221

Water pump

e uo,
6.3 - 8.3
(0.64 - 0.85,
4 . 6- 6 . 1 )
M8:
16-21
(1.6-2.1,
12- 151

V
t - / / v
\ o ./,/

I / 'J.
6.3- 8.3

b
( 0 . 6 4- 0 . 8 s ,
4 . 6- 6 . 1 1

Fuel filter - '--\-

e +s-se ) -- z i :p;l- 196 {1s.0 - 20.0, 108' 1451
14.4- s.9, l:> --7\ ./
| \
\ ,^>.Y/b\1
32- 431 \6((5gV /.) \ \ -'-
,/AY ;.{ (d // Oil pressuresuitclr
: \ \ y t \ - ) / .

:r 1 6 - 2 ' f ( 1 . 6- 2 . 1 , 1 2 ' 1 5 1

45 - 60 (4.6- 6.1, 33 - 441

i| : N.m (kg-m,ft-lb)

EM-46
 ENGINE COMPONENTS(Outer Parts) lFJrotl

3.7 - 5.O
(o.38- O.51,
2.7-3.71
o

Intake manifold
supporr

O go-co
(3.1 - 4.1,
22 -301

Intake manifold

Throttle valve ---7

switch
/
/N
3.7.s.0 s\s
(0.38-0.51,
37 -42
13.2- 4.3,
\| h 23- 311
2.7-3.71 --{i
e re-zt /
( 1 . 6- 2 . 1 , gauge
", rever
1 2- r 5 l Throttle chamber

@ ro-zr
( 1 . 6- 2 . 1 . 1 2 - 1 5 )

Exha ust manifold

16-21
(1.6- 2.r, 12 - 151

t-4.
WaterpiPe
\s

U J : N.m (kg-m, ft-lb)

SEM632A

EM-47
 '.:
' t .:' .'ji .
'' 'ttt t'
' - 't
, , : . . . - ' j . . y . . * . - - : : . . . : . . i * ' . r ; - - i j $ j . r r * . : ' : - ' : - : , - ; ' iti ] i .:. l#-,

C Y L I N D E RH E A D

HEAD
CYLINDER

Valve rocker cover

Cylinder head bolt

i, 9 . 1 - 1 1 . 8 ( O . 9 3- 1 . 2 , 6 . 7 - 8 . 7 ' l - r3.o,87 - e4l
1i r re - 127112.0
; Camshaft (lntake)
\
\

O t a - t s { r . 4-
't.81
, 0- 1 3 1 S lCamshaft
(Exhaust)

Chain guide A Valve Ifter

Chain Gasket1
tensionerA -, I
O e.s- s.s
(0.64 - 0.85,4.5 - 6.1) -.
Valve seat

d"QQ
@ : N'm (kg-m, ft-lb)
@ r o - . z r( 1 . 6 -2 . 1 ,1 2 - 1 s l SEM6334

C Y L I N D E RH E A D 5. Removechain tensionerA cover

DISASSEMBLY and chaintensionerA.

CAUTION:
a. Do not rotate crankshaft and cam-
shaft separately, because valves will
hit piston heads.
b. Always use new cylinder head
gasket.

CYLINDER HEAD BEMOVAL

SEM81 O
l. Remove outer parts attachedto
cylinder head.
2. Turn crankshaftuntil No. I piston Be careful not to drop chain tensioner
is at top dead center on its compres- sleeveand spring.
sion stroke.
3. Scribe marks on timing chain and
camshaft sprocketsu'ith paint before
removal.
4. Loosencamshaftsprocketbolts.

EM.48
 C Y L I N D E RH E A D

6. Removecamshaftsprockets. 8. Removecamshafts. (2) Remove valves and springsusing

9. Removechain guideC upperbolt. Tool.

KV101089S0

SEMAl3

Support timing chain with a Proper

wire so it does not fall, however the 10. Loosencylinderheadboltsin two Pay particularattention not to damage
supporter is located on the front or threestages. valvelifter guide hole.
oover.
(3) Removevalve oil sealsusins Tool.

\
Chain c € , . C I o , o
supporler o o o o o

,o a o@ o( } o @ o o

sEM814
SEM634A

7. Remove camshaft brackets and I l. Removecylinderhead.

(4) Removevalvespringseats.
chainguide A in the sequencebelow. 12. Disassemblecylinderhead.
Keepthe removedbracketsin order. partsin order.
Keepthe disassembled
(l) Removevalvelifters and caps.

o @

' ' i : Il

I
:1
'i
Valve lifter can be removed easier by
using magnet or suctlon rubber.

EM.49
 ' ! ' l
'''l' ' '"t" "ti
,-,€sr4 ".Jr
:..::3:
. ,,i^* ".,; -. ,. ^ : t .; i!:,

C Y L I N D E RH E A D

CYLINDER HEAD DISTORTION 2. Measure the diameter of valve

Warpageof surface: stem with a micrometer in three
places;top, centerand bottom.
Lessthan 0.1 mm (0.004in)

@
-r=Jt
ll
A
SEM638A

3. Measurevalve guide bore using

insidedial gauge.

W: Refer to S.D.S. sEM635A

SEM636A

CAMSHAFTAND CAMSHAFT
If beyond the specifiedlimit, correct BEARING
with a surfacegrinder. CAMSHAFTBEARING
Surfacegrindinglimit: CLEARANCE
4. Subtract the highest reading of
The grinding limit of cylinderhead is l. Clean camshaft journal and bear-
valve stem diameter from valve guide
determined by the cylinder block ing-
grinding. bore to obtain the stem to suide
clearance. 2. Placeplastigageacrossjournal.
Depth of cylinderheadgrindingis "A" 3. Install capsand tighten.
Depth of cylinderblockgrindingis"B" Stem to guideclearance:
The limit is asfollows: I ntake @ : la- 18N-m
( 1 . 4- 1 . 8 k s - m ,
A + B = 0.2 mm (0.008in) 0.025 - 0.055 mm
(0.0010- 0.0022in) 10 - 13 ft-tb)
VALVE GUIDE Exhaust
0.040 - 0.077 mm 4. Remove caps and measurePlasti-
VALVE GUIDE CLEARANCE gage.
(0.0016- 0.0030inl
l. Checkvalvedeflection. Max. toleranceof camshaftbearing
Valvedeflection: clearance:
Limit VALVE SEAT INSERTS 0.1 mm (0.004 in)
0.2 mm (0.008in) Check valve seat inserts for any
evidence of pitting at valve contact
H : 1 5 m m ( 0 . 5 9i n l surface,and reseatif worn out exces-
sively.
Correct valve seat surface with Tool
and grind with a grindingcompound.
. When repairing valve seat, check
valve and valve guide for wear
beforehand. Then correct valve
seat.
o The cutting should be done with
SEM637A
both handsfor uniform cutting.

EM-50
 C Y L I N D E RH E A D

5. Measurecamshaftjournal diame- CAMSHAFT END PLAY 2. Measure the free length and the
ter and cylinderheadcamshaftjournal tensionof eachspring.
End play:
Referto S.D.S.
diameter. Limit 0.3 mm (0.012 in)

VALVE LIFTER
l. Measureoutsidediameterof valve
lifter and insidediameterof valvelifter
guidehole.
Valvelifter clearance:
0.025 - 0.075 mm
(0.0010- O.0030in)

VALVE

w
SEM639
o When valve head has been worn
down to 0.5 mm (0.020' in) in'
margin-thickness, replace the valve.

SEMA27

CAMSHAFT BEND
Camshaft bend: nil
Limit 0.05 mm (0.002O in)
il
-*11*
C Y L I N D E RH E A D A S S E M B L Y
l. Installvalveand va.lve spring.
Limit (l) Install valve spring seat and valve
oil sealusingTool.
Limit
SEM641 A
K V I 0 l 0 7 5 0I
and
+ KVlolo88oo
. Stem worn down: Limit 0.2 mm
(0.008in)

VALVE SPRING
l. Checkvalvespringfor squareness
usinga steelsquareandsurfaceplate.
IVIZ\T
1 8 . O- 1 8 . 6 m m ) \
C A M S H A F TC A M H E I G H T (0.709 - 0.732 inl / \
Out of square ("S"): --*/\fl,ser.aaze
Camheight:
Outer
42.835 - 42.865 mm
( 1 . 6 8 6 4- 1 . 6 8 7 6i n ) Limit 2.0 mm (0.079in)
I nner (2) Install valve, valve spring inner
Wearlimit:
Limit 1.8mm (0.O71in) and outer, valve spring retainer,using
0 . 1 m m ( 0 . 0 0 4i n l
Tool.
a. When installingvalve,apply engine
r++ or oil on valvestemand lip of valveoil
seal.
N.G. b. Check whether valve face is free
from foreign matter.
(3) Install valvecap and valvelifter.
a. Pay particrrlar attention not to.
damagevalvelifter guidehole.
sEM333

EM-51
I C Y L I N D E RH E A D
I

3rd (Retightenafter loosening Valve clearancesshould ultimately

b. Apply engine oil on valve caP and
to 1st torque) be adjustedto the hot values.
outer wall of valve lifter.
1 1 8- 1 2 7N . m 7. Set timing chain on camshaft
( 1 2 . 0- 1 3 . 0k s - m ,
Valve lifter
sprockets bY aligning each mark
87 - 94 ft-lb) scribedbefore removal.Then, install
Valvecap
4. TightenchainguideC upperbolt. camshaftsprocketsto camshafts.
Valve collet
Valve spring 5. Installcamshaftsand tighien cam- @ : Camshaftsprocketbolt
retainer shati bracketnuts with chain guide A 127'177 N'm
Outer spring
in the reverseorder of removal in two ( 1 3 . 0 ' 1 8 . 0k g ' m ,
lnner spring
or threestages. 94 - 130 ft-lb)
Gutter sPring
Valve oil seal @ : Camshaftbracketnut
spring seat 1 4 - 1 8N . m 8. Installchain tensionerA-
( 1 . 4 ' ' 1 . 8k s - m ,
@ : ChaintensionerA bolt
10 - 13 ft-lb) 6.3'8.3 N'm
(0.64'0.85 ks-m,
(4) Check valve lifter for smooth Chain guide A 4.6 - 6.1 ft-lb)
rotation.
a-.-@_o-@
Beforeinstallation,fill chaintensioner

il il#
I
A with engineoil.

Fill engine oil

't
o-g-o-@- SEM544A
%^il
a. Install camshafts so that No. 1
\dd\ - q \\
camsare at toP deadcenter.
l\t'
sEMa31
2. Install cylinder headonto cylinder
block.
Always use new gasket.
9. Install chain tensionercover.
3. Tighten cylinder head bolts in the 10. Install rubber plug with sealant.
reverseorder of removal. I l. Installvalverocker cover.
@ : Cylinder headbolt @ : Valve rocker coverbolt and nut
lst 9 . 1 ' 1 1 . 8N ' m
49 - 59 N'm (0'93 - 1.2 ks'm,
(5.0 - 6.0 kg-m,
. 6.7 - 8.7 ft-lb)
36 - 43 ft-]b)
2nd b. Appty engineoil on cam, camshaft a. Rocker cover bolts should be
1 1 8- 1 2 7N ' m journal, camshaftbearingand valve
fashion.
tightenedin criss-cross
112.0'13.0 ks-m, lifter upper surface. b. Always use new rocker cover
87 - 94 ft-lb) 6. Adjust intake and exhaust valve gasket.
clearance-Refer to Adjusting Intake
12. Install outer Parts.
And Exhaust Valve Clearance in

ffi1,
sectionMA.
Valve clearance[Cold] :
at 20"G (68'Fl
I ntake
0.20 - 0.26 mm
(0.0079- 0.0102 in)
Exhaust
0 . 2 8' 0 . 3 4 m m
SEM643A ( 0 . 0 1 1 0' 0 . 0 1 3 4 i n l

EM-52
 CAMSHAFTAND JACK SHAFT DRIVE

CAMSHAFTAND JACK SHAFT DRIVE

- Camshaft (Intake;

Camshaft (Exhaust)
Chain guide A -

e r o e -1 3 7( r 1 . o -1 4 . o8, o ' 1 o 1 )
Chain guide B 6 . 3 - 8 . 3( 0 . 5 4- 0 . 8 5 , 4 . 6- 6 . r 1

Iack shaft
e '&
b- Locatinsplate
- Camshaft sprocket (Exhaust)

B
*^-chain guide C

\,.r, 16-21 (1.6 -2.1.12- lsl

-/
Jack shaft sProcket a , Timing chain B
{ ' \- Crankshaftsprocket e : N.m (ks-m,ftlb)
* Chain tensionerB
- o.gs,4.6
ii. 6.3- 8.3(o.Bo - 6.11\ SEM645A

VALVE TIMING CHAINTENSIONER

ChaintensionerA

/"m%r(>
SEM681 A

Chain tensioner B
rhin W
.i.

@_&d"
'-r
.iI

)':
N{K25 -'V' rhi"k
\\fr(-nts
\ uvz-,

Rotating
direction
SEM833 'EM646A
-j;
;.,i

EM-53
 i .. .i rL.:i,=L-;.-ii .:l

ENGINEREMOVAL
FJ2OE

10004-R2001

10005-R2000

: \

L
orl p zs-zt
@ 12.3-2.8,
- o Engine 17 -201 par-sz
U gusset

Yi":;:;..30.38,
p) n-zt
12.3- 2.A,
17-

pl zs- ss
(3.O- 4.O,
22 - 291

,-P a r- s z
6 14.2-5.3, I so-cz
\ 30-38) 13.7-4.a,27 -351

-*..
14.2-5,3,30-38)
\p! ar- az
13.2-4.3,23-311

6- ---p
ar - sz
14.2- 5.3,
30 - 38)

pl : ru.m(ks-m.ft-lbl
SER322

EM.54
 CYLINDER BLOCK. CRANKSHAFTAND PISTON

AND PISTON
BLOCK,CRANKSHAFT
CYLINDER
o When installingsliding parts such as on the sliding surfaces. . Be careful not to damageoil seal.
bearings,be sureto apply engineoil o Usenew packingsand oil seals.

I c-s
(o.4- o.5,2.9- 3.6)
Oil jet

O s.z- s.o{o

Rear oil seal

:-O Me, 16-2r {

' M6: 6.3- 8.3

I0\z/,
'?qll
,
O o.g- a.s /],/X'.€ $ rsz-rsz
10.64-0.85,4.6-6.1) (14.0- 16.0,101 -

Mff-W\R
\ , . ,

v-j Piston ring o 3.7 - 5.O

wN''uffi
(0.38 - O.sl,

{.4 Piston

dw w' Connecting
rod
oil p u m p m n e r g e a r r -
I \ t^b
Oil pumpoutergearJ \ ny
Oil pump"o"., \
N'
Rear plate
o 5e- 64(6.0- 6.s,43- 47t-+w

R a

s
Oil strainer
@rs-zr..6-2.r,
12-1sl$

#-u 7 -ao.7-o.B.s.r
-5.8t

@: N.m(kg-m,fi-lb) O ss - 47 {3.6- 4.8,26 - 351

SEM834

EM-55
 i
. - . . y

'..,'..'.;..,;'.''..,-;.'..i','.:,::i-;:;.*'.;:+i,;.iogi!.d;.,*':"-:j,:l'ol5...ii;.ff+j*':

CYLINDER BLOCK, CRANKSHAFTAND PISTON

E N G I N EA T T A C H M E N T o Set piston ringsas shownbelow.

KV l 0106500
?1.:WE
fr
il;
l =
l e
l l

q l t-:
F
-
i'il'
il;
P t r l o np r n d r r e c l r o n

\ / /) o,t,i"g
EMT (\ (lower rail)
r
,//
Second ring
KV10108700 sEM747

Measurering gap with a feelergauge.

placing ring squarely in cylinder using
P I S T O NA N D C O N N E C T I N G piston at upper or lower part of cylin- P I S T O N ,P I S T O NP I N A N D
ROD der. C O N N E C T I N GR O D
o Piston can be easily removed by Max. toleranceof ring gap: l. Check for sntooth nlovenlent,
scraping carbon off top face of 1.0 mm {O.O39in) pushingpiston pin with a finger at
cylinder with a scraper. room tenlperalure.
o Numbers are stamped on the
connecting rod and cap correspond-
ing to each cylinder. Care should be
taken to avoid a wrong combina-
tion including bearing.
. Arrange so that the front mark on
piston head faces to the front of
engine.
o Arrange so that oil hole of connect-
ing rod big end is directed toward
the right side of cylinder block.

Front mark
Grade No.
Install piston rings so that stamped
-ov
mark on ring facesupward. 2. Measure inside diameter of con-

Oil jet

Matching
mark
}K necting rod small end bearing and
outerdiameterof pistonpin.
Connectingrod smallend bearing
clearance:
0.004- 0.017 mm
{0.0002 - 0.0007 in} at
2o"c (68oF)

3. Measureinner diameter of piston

P I S T O NR I N G pin hole and outer diameterof piston
pin.
Measurethe side clearanceof rings in sEM566
ring groovesas eachring is installed.
Pistonpin to piston pin hole
Max. toleranceof sideclearance: ctearance:
0.1 mm {0.004in} -0.005 - 0.004 mm
(-0.0002 - 0.0002in) at
zo"c(68"F)

EM.56
 CYLINDER BLOCK,CRANKSHAFTAND PISTON

4. Measure the extracting force by CRANKSHAFT

pullirrgfeelergaugestraight upward. CRANK JOURNAL AND PIN
l. Check crankshaft journals and
pins for score,bias. wear or cracks.If
faults are minor, correct with fine
crocus cloth-
2. Check journals and crank pins
with a micrometerfor taper and out-
of-round. Measurement should be
taken along journals for taper and

'i'(-ffi= aroundjournalsfor out-of-round.

lf out-of-round or taper exceedsthe
CAUTION: specifiedlimit, replace
or repair.
Connecting rod with same weight Out-of-round (X-Y) and
Feelergaugethickness:
tolerance is available only as a set Taper (A-Bl:
0.04 mm (0.O016inl
of four. Lessthan 0.01 mm (0.0004in)
Extractingforce:
2.0 - 14.7 N
{ 0 . 2- 1 . 5 k g , 0 . 4 - 3 . 3 l b }
CONNECTING
ROD BEARING
5. Measurecylinder bore diameter Ivleasure
connectingrod bearingclear-
and piston skirt diameter. anceusingplastigage.
l. Removeconnectingrod caps.
Pistonto cylinder wall clearance:
l. Clean crankshaft journal and
0.050 - 0.070 mm
bearing.
{0.0020 - 0.0028 in}
3. Placeplastigageacrossjournal.
4. Installcapsand tighten.
6. Check connecting rod for bend or EM757
torsion using a connecting rod aligner. l! : Connectingrod bearingcap
If bend or torsion exceedsthe limit, 59 - 64 N.m
corrector replace. {6.0 - 6.5 kg-m, CRANKSHAFT RUNOUT
Bend and torsion 43 - 47 ft-tb)
Check crankshaftrunout.
[per 10Omm (3.94 in] lengthl:
Lessthan 0.05 mm (0.0020in) 5. Removecap and measureplasti-
gage.
Max. toleranceof connecting
rod bearingclearance:
0.10 mm {0.0039in)

CAUTION:
Do not turn crankshaftor connecting
rod while the plastigage is being {Total indicator readingl :
inserted. Los than O.0Smm (O,(xt2{linf' EM7r6

eM133

MAIN BEABING
7. Measure the thrust clearance.If Measuremain bearing clearanceusing
the measuredvalue exceedsthe limit, plastigage.
replacesuch connecting rod.
@ : Main bearingcap
83 - 98 N.m
(8.5 - 10.0 ks-m,
61 - 72 ft-tb)
Max. toleranceof main bearing
clearance:
0 . 1 Om m ( 0 . 0 0 3 9i n )

EM-57
 CYLINDER BLOCK, CRANKSHAFTAND PISTON

Crankshaftfree end PlaYlimit: R E P L A C I N GJ A C K S H A F T

C R A N K S H A F T.I N S T A L L A T I O N
0 . 3 0 m m ( 0 . 0 1 1 8i n ) BUSHING
l. Set upper main bearings in the
o Align cylinder block oil hole and
properpositionon cylinderblock-
bushingoil hole.
o Only center bearins (No. 3) is a o Checkbushingclearance.
flangetyPe. o Install welch Plug into cYlinder
o Front bearing (No. 1) is also the block,apPlYingsealant.
sirmetype as rqar bearins(No. 5).
I Other inter bearings,except center
bearing,are the sametYPe.

No.5

JACK SHAFT AND JACK

SHAFT BUSHING
J A C K S H A F T F R E EE N D P L A Y SEMA38

Measurejack shaft free end PlaY'

sEM835 Freeend PlaY:
0 . 0 4 5 ' 0 . 1 0 5m m C Y L I N D E RB L O C K
( 0 . 0 0 1 8 ' 0 . 0 0 4 1i n )
CYLINDER BLOCK DISTORTION
2. Install main bearing caP and AND WEAR
tighten bolts to specifiedtorque-
Warpageof surface:
Lessthan 0.1 mm (0.004 in)

o-@- SEM683A

SEM649A JACK SHAFT BUSHING

CLEARANCE
Journal diameters should be checked
with a micrometer,and bushingswith
Arrange the parts so that the figure
an inside dial gauge. Measurements
on bearing cap faces toward the
should then be comparedto determine
water pump.
whetherbushingsareworn'
Prior to taghtening bearing caP
bolts, placc bearing caP in ProPer Max. toleranceof iack shaft
position by shifting crankshaft in bushingclearance:
the axial direction. 0 . 1 5 m m ( 0 . 0 0 5 9i n )
Tighten bearingcap bolts gradually
in separatingtwo to three stages
and in sequenceoutwardlY from
centerbearing.
. After securing bearing cap bolts,
ascertain that crankshaft turns
smoothlybY hand.

3. Measurecrankshaft free end play

at the centerbearing:
sEM837

EM.58
 CYLINDER BLOCK, CRANKSHAFTAND PISTON

If beyond the specifiedlimit, correct Determiningbore size APPLYING SEALANT

with surfacegrinder. l. Determinepistonoversizeaccord- Use sealantto eliminate water and oil
Surfacegrindinglimit: ing to amountof cylinderwear. leaks.Do not apply too much sealant.
The grindinglimit of cylinder block is Referto S.D.S. Part requiringsealantis:
determinedby the cylinderheadgrind' 2. The size to which cylinder must
ing. be honed is determined by adding
Depthof cylinderheadgrindingis A piston-to-cylinderclearance to the
Depthof cylinderblock grindingis B Distonskirt diameter.
The limit is asf<illows:
A + B = 0.2 mm (0.008in)

Using a bore gauge,measurecylinder

bore for wear,out-of-roundor taper.
Referto S.D.S.
Out-of-round X-Y sLc391
Taper . A-B

FLYWHEEL
Measure runout of the clulch disc
contact surfacewith a dial gauge.
Reboredsizecalculation:
Runout
D=A+B-C (Total indicator reading):
= A + [0.030to 0.050mm
(0.0012to 0.0020inll Lessthan 0.1 mm (0.004in)
where,
D : Honed diameter
Unit: mm tin) \ | -,2 sEMs4B A : Skartdiameteras
measured
B : Piston-to-wallclearance
C : Honingallowance
0.02 mm (0.0008 in)

Boring
l. Install main bearingcapsin place,
and tighten to the specifiedtorque to
prevent distortion of the cylinder
boresin final assembly.
2. Hone the cylindersto the required Check tooth surfacesof ring gear for
sizereferringto S.D.S. flawsor wear.
Install ring gear on flywheel, heating
ring gear to about 180 to 220"C
When wear, taper or out-of-round is (355 to 428"F').
F R O N TC O V E R
minor and within the limit, removethe
step at the topmost portion of cylin- Be[ore installing front cover, align
der using a ridge reamer or other locatingnotches.
similartool.

C Y L I N D E RB O R I N G
When any cylinder needs boring, all
other cylindersmust also be bored at
the sametime.
Crankshaft

sLc392

EM-59
 CYLINDER BLOCK, CRANKSHAFTAND PISTON
DISTRIBUTOR
OIL SEAL
l. Make sure No. I piston is at toP
o lt is good practice to renewoil seal
dead center.
wheneverengineis overhauled' 2. Align distributor gear with the
Check front, and rear oil seals for
worn or folded over sealinglip and oil tl mark on the shaft.

leakage.Wheninstallinga new front or

rearseal,pay attentionto its mounting
tt-'
tjll
Front

r\I
direction.
SEM651 A
Rear oil seal

Kffi
When installing oil seal retainer,
give coating of engine oil to mating
Enginerear Engine front shaft to prevent scratches and
folded lip. Also aPPIY coating of
oil to periphery of oil seal.
lnstall oil seal in the direction that
dust seal lip faces to the outside of 3. Install distributor and tighten
SEM839 crankcase. fixing plate bolt.

EM-60
 SERVICEDATA AND SPECIFICATIONS

SERVICEDATAAND SPECIFICATIONS
G E N E R A LS P E CFI I C A T I O N S VALVE
Unit: mm linl
Except for
Europe&
HongKong

1 . 9 9 0( 1 2 r . 4 3 ) r , 9 9 1( 1 2 1 . 4 9 1

Bore and stroke mm (inl 89 x 80 (3.5Ox 3.151

sEM841

Intake 34.5 (1.358)

Number of rrrain bearings Valve head
"D"
diameter
Exhaust 3 0 . o( 1 . 1 8 r )

I ntake t2s.o1 - 125.5114.922-4.9411

"L"
Valve length
Exhaust 124.96- 125.4614.920-4.939)

Intake 6.960 - 6.975 (0.2740- 0.27461

Varve stem
INSPECTIONAND ADJUSTMENT "dr "
diameter
Exhaust 6.988 - 6.960 {0.2731- 0.27401
CYLINDER HEAD
Unit: mm (in) I ntake
Valve stem end
"d" " 6a 5.572 - 5.590 (0.2194- 0.22011
Standard Limit diameter - Exhaust

Less than "o"

Head surface flatness 0.1 (0.0041 Valve seat angle 45" 1s' - 45045'
o.os{0.0020)
Intake o.30 (0.0121
Valve clearance
{Hot}
Exhausr o.35 (O.O14)

I ntake o20 -0-26 (0.008- 0.0101

Valve clearance
{Cold)' Exhaust o2a-o34(0-0r1-o.ol3l
*Cold: Used as approximate values during engine assembly,
clearancesshould ultimately be adiusted to the above hot
values; refer to section MA for procedure.

Valve lifter
Unit: mm {in)

Standard Limit

Valve lifter 3.950 - 33.97s

outer diameter (1.g}66 - 1.33761

Cylinder head valve -34.025

34.OOO
lifter guide hole
{1.386 - 1.3396}
inner diameter

Valve litter guide

o.o25- o.o75
hole clearance (o.oo10- o.oo30)
[Oil clearancel

EM-61
 t'i :
,i.
i
-,1
'..
. ' '
P
II
*...-:;,;it; .r-:'.i.: ;i.i;!;';{*';*l. i:,r::il*-=rdG.;i:'* :*:r' ::i :::'!

II SERVICEDATA AND SPECIFICATIONS

I
I
,l
I Valve seat
I Valvespring Unit: mm (inl
iI
45.0711.77441
4 1 . 6 6( r . 6 4 0 2 )

Pressureheight
mm/N (mm/kg. inilb)
Outer 28.71324.6 128.7 1.130/73.0)
133.' t,
25.2| 17i.6 125.2
I 17.6,O.99a3a.al

Assemblyheight
mm/N (mm/kg. in/lbl
s€M445
Outer 37.21155.9131.2115.9,I .465/35.1)
(33.7/8.s3,
1.327n8.A1| '?" 450
33.7/83.65 Contacting face angle

lntake 1.63(O.oal2l
contacting width
2.0 (0.0791 '1n/"
Exhaust t.s5 (0.06lo)
1 . 8( 0 . o 7 1 )
33.9 - 34.1
Intake ( 1 . 3 3 s- 1 . 3 4 3 )
tnrsheo
29.4 - 29.6
Exhaust ( 1 . 1 5 -7 1 . 1 6 5 )
Valveguide
Unit: mm (inl
36.780- 36.796
I n take
{1.4480- 1.44871
"D"
Outer diameter
33.080 - 33.@6
Exhaust (1.3024- 1.3030)
16.7- 17.3
(0.657- 0.681) 36.700- 36.716
Intake
il
11.4449- 1.44551
it Cylinder head seat
recessdiameter 33.OO0- 33.O16
Exhaust
tl .2992- 1-2998)

0.064 - 0.096
Hll l n t e r f e r e n c ef i t o f s e a t i n s e r t (o.oo25- 0.0038)
ul

ill 12.033- 12.U4

SEM843

Valve guide
Outer diameter 10.4737- 0.47421

Valve guide 7.000- 7.O15

l n n e r d i a m e t e r { F i n i s h e ds i z e } 10.2756- 0.27621

Cylinder head valve guide hole 1 1 . 9 7 0- 1 1 . 9 8 8

(0.4713- 0.47201

illi diameter

lnterference fit of valve guide

o.o45- 0.074
(0.0018- O.OO29)

lili Intake
0.025 - O.O55
(0.0o10- 0.0022)

lili Stem to $ride

clearance
Exhaust
0.040- 0.077
(0.0016- 0.0030)

itli
EM-62
 SERVICE DATA AND SPECIFICATIONS

CAMSHAFT AND CAMSHAFT BEARTNG JACK SHAFT AND JACK S H A F T B U S H I N G

Unit: mm (in)
Unit: mm (inl
Standard Max. tolerance

Carnshaft lournal to o.o25- o.o85

bearing clearance {o.oo10- o.oo33l o.1 (o.oo4l Jack shaft
journal to o.1s(0.00591
lnner diameter of 32.OOO- 32.021 bushing
o.o20- o.o74
camshaft bearing_ 0o.2598- 1.26071 clearance
(0.0008- o.oo29l 0.15 (O.OOsgt
Outer diameter ol 3 1 . 9 3 6- 3 1 . 9 7 5
34.025 - 34.064
camshaft iournal f .2573- 1.2589) Inner diameter ( 1 . 3 3 9 6- 1 . 3 4 f i 1
of jack shaft
Carnshaft bend
Lessthan O.O5(O.OO2O, bushing
ITotal indicator reading]

Carnshaft end play Lessthan O.3 (0.O12)

Front
33.975 - 34.OOO
outer diameter
{1.3376- 1,3386}
of jack *raft
lou rnal 28.979- 29.000
{ 1 . 1 4 0 91- . 1 4 1 7 }
Jrck shaft end play 0.o4s- o.10s {0.0018- O.OOIll

C Y L I N D E RB L O C K
EM67I Unit: mm (in)

carn height ,,A,' cz.ms - 42.A65(1.6864_ 1.68761

I
Wear limit of cam heighr O.t (O.OO4|
I

Valve timing

EM!2('
l o c
Surface flatness Less than
Unit: degree o.os(0.0020)

a b Cylinder bore
c ct e
89.OOO- 89.050
Inner diameter
256" 256" 2 3 " l s s ' l r r " l o s . (3.so39- 3.so59)

Out-of-round (X-y) Lessthan O.O15(0.0006I

Lessthan O.015(0.0006)

EM-63
 ' - d

1: -:
,-..,*t
-.'t,J.ii:3:.,..!.ii!,r:'.ii..i+;:r i' :-- ;lu--ii.:li}'-:' -; :.-:,,..i
i :r':J!'-.i:l'

&4g.. .- .-: .'. +;)agaii*.*'* *" t";t-

SERVICE DATA AND SPECIFICATIONS

Connectingrod
PISTON, PISTON R I N G A N D P I S T O N P I N
Unit: mm (in)
Piston
Unit: mm (in)
Center distance
1 4 0 . O( 5 . s 1 !

8end.torsion
lper lOO(3.94!l
Standard 0.02s{o.oo10)

Umit o.o5(0.00201

Piston pin bushing diameter 22.O@- 22.013 10.8661- 0.8667)

Big end PlaY - o.oo71)

Standard o.o5- o.r8 (O.OO20

Limit 0 . 3{ o . o 1 2 }

"A''
Piston skirt diameter CRANKSHAFT
Standard 88.940 - 88.990 (3.so16- 3.5035) Unit: mm {in}

Oversize for service '3.52321 54.942- 9.955 (2.1631- 2.1636)

89.440 - 89.490 (3.5213
I0.5{0.020}l 49.961- 49.974 (1.9670- l -9675)
"a" dimension 11.O(0.4331

(O.86s8- 0.8661)
21.991 - 22.OOO
Piston pin hole diameter
Out-of-round (X-Yl and
Piston clearance to 0.050- o.o?oto.@20- o.fi)281 taper {A-B)
Less than O.Ol (O.OOO4I
cylinder block Limit

Pistonring Lessthan O.O5(0.O02O)

Unit: mm (inl

-____ Standard Limit - o-oo71,

o.o5- o.18(O.OO20
Side clearance
Less than O.3 (O.O12)
o.o3- O.O7 o.1 (0.004)
Top (0.0012- 0.00281

0.03- 0.07 o.1 {0.0011

2nd {0.0012- 0.00281

oil

Ring gaP
0.3- o.4 1.0 (0.G391
Top 2 - 0.ol6l
(0.o1

o.3- 0.5 1.0(0.039)

2nd (o.o12- O.O20l
X-Y
Out-of -tound
A'B
o.2- 0.6 1.O(O.O39l
Taget
Oil (rail ring) {0.008- 0.0241

Pistonpin

Piston pin outer diameter

Piston pin to piston

clearance
(0.8658- 0.8661)
21.991 - 22.OOO

-o.oo5- o.oo4t-o.ooo2'0.0002)
at 20"c [68"F]
Unit: mm (inl
@ff EM7r5

Piston pin to connecting 0.004- 0.017(0.0002'0.0007)

rod clearance at 2o"c [68"F]

EM.64
 SERVICEDATA AND SPECIFICATIONS

BEARING Engineinternalparts

Bearingclearance Unit N-m k9-m

Unit: mm (in)
Camshaft bracket nut 14-18 1.4-1.8 10-13
Standard Limit
Camshaft sprocket bolt 108-137 1 1 . O - t 4 . O8 0 - r 0 1
0.035- 0.075 Cylinder head
Main bearing clearance (o.oo14- 0.oo301 o.1 (0.0041 '|
st 49-59 5.O-6.0 36-43
2nd 118 - 127 12.O- l3-O 87 - 94
Connecting rod o.o35- o.075
(0.oor4- 0.oo30) o.1 (o.oo4) 3rd (After loosening 118- 127 12.O- 13.O 87 -94
bearing clearance
to I st torquel

Main bearing cap bolt 83-98 8.5 - 10.0 61 - 72

Main bearing undersize
Unit: mm {in) Connecting rod nut 59-64 6.0-65 43-47

"Dm"
Jack shaft locating 6.3 - 8.3 0.64 - O.85 4.6 - 6.1
Crank main iournal diameter plate bolt

Standard Jack shaft sprocket bolt 76 - 98 7.8 - tO.O A6 - 72

Chain guidebolt 16 - 2t 1 . 6- 2 . r 1 2- 1 5
Undersize
*.692 - *.705 12.1532- 2.15371 C h a i n t e n s i o n e rb o l t 6.3 - 8.3 o.il - 0.85 4.6 - 6.1
0.25 (0.00981
Front coverbolt
M6 63 - 8.3 0.64 - O-85 4.6 - 6.1
MISCELLANEOUSCOMPONENTS 't6 - 21 r.6- 2.1
M8 1 2- 1 5
Unit: mm (inl
Rear oil seal retainer bolt 3.7 - 5.0 o.38 - O.51 2.7 - 3.7
Camshaft pulley Oil strainer bolt 1 6- 2 1 1 . 6- 2 . 1 1 2- 1 5
Runout fTotal indicator reading] o.o8{0.00311
Oil pan bolt 7- 8 o.7 - 0.8 5.r - 5.8
Flywheel Oil pan drain plug 35-47 3.6 - 4.8 26 - 3s
Runout [Total indicator reading] o.1 {o.oo4}
Flywheel bolt 1 3 7- 1 5 7 1 4 - O- 1 6 0 tol - 116

T I G H T E N I N GT O R O U E
Engineouter parts

Unit N.m kg-m ft-lb

Alternator bracket bolt

Cylinder block 43-58 4.4 - 5.9 32 - 43
Front cover 30-40 3.r -4.1 22-30
' t . 6-
Alternator to adiusting 16-21 2.1 12- 15
bar bolt

Cfutch cover fixing bolt 16 - 21 1 . 6- 2 . 1 1 2- 1 5

Engine mounting 30 - 40 3 . 1- 4 . 1 22-30
brackd to rylinder block
Intaka manifold nur 31 - 42 3.2 - 4.3 23 - 31
Intake manifold 30 - 40 3 . 1- 4 . 1 22-30
suppon bolt

Exhaust manifold nut 16 - 21 1 . 6- 2 . 1 1 2- 1 5

Throttle chamber bolt 16 - 21 1 . 6- 2 . 1 1 2- 1 5
Water pump bolt
M6 6.3 - 8.3 o.il - o.85 4.6 - 6.1
M8 16 -21 1 - 6- 2 . 1 1 2- 1 5
Cooling fan bolt 6.3 - 8.3 0.64 - O.85 4.6 - 6.1
SFerk plug 20 -29 2.O- 3.O 14 - 22
Oompressor bracket bolt 30 - 40 3 . 1- 4 . 1 22-N
Compressor to bracket 43 - 58 4.4 - 5.9 32 - 43
.r47 - 196
Gank puiley bort 15.O- 20.O 108 - 145
Distributor support bolt 6.3 - 8.3 0.64 - O.8s 4.6 - 6.1
Water outlet bolt 9.,| - I 1.8 0.93 - 1.2 6-7 - 4.7

EM-65
 --.r -*b.ra--.,.

ENGINECONTROLSYSTEM
Accelerator Control System

a. Checkto seeif throttlevalvefully openswhenaccelerator pedalis fully depressed and if it returnsto idle
when released. ,
b. Adjust acceleratorpedalfreeplay by turningadjustingnut.
c. On automatictransmission models,makesurekickdownswitch rod is fully pushedin whenaccelerator
pedalis depressedcompletely.
d. Checkacceleratorcontrol partsfor impropercontactwith any adjacentparts.
e. Whenconnectingaccelerator wire,be carefulnot to twist or scratchits innerwire.
t. Apply a light coat of recommended multi-purpose greaseto all slidingor frictionsurfaces. Do not apply
greaseto wire.

Adiustingnut
pl a - to to.8- t.o,s.8-7.21
Remove cable by gripping both
pawls f rom compartment side.

Push

pl a - tz (0.8- 1.2,s.8- 8.71

Freo play at pedal pad center:

I - 3 mm (0.04- 0.12 inl

pl : N'm (ks-m,ft-lbl
sFE793

FE-2
&r&*;
 FUELSYSTEM

fo1
t t
s.r - a.g Fuel outlet hose
(0.32-0.44,
2.3 - 3.21
- - - 1.91
q. 9p t.o z.s lo.2o 0.26,1.4

Fuel pump assembly

, ' Jl i'
rllr
rtl

- - -
$$Ize 36 12.7 3l,2o 271
) \
- o.44,2.3' s.zl
t., - 4.s to.t2
4r Fuel tank Protector

side

l \(to r Ir l
F u e l return tube

$0

Fuel outlet tube {//

Evaporative tui:-\

FE.3
 FUELSYSTEM

WARNING:
Whenreplacing fuel line parts,be sureto observethe following:
a. Put a "CAUTION:INFLAMMABLE"signin workshop.
b. Be sureto furnishthe workshopwith a co2 fire extinguisher.
c. Be sureto disconnectbatterygroundcablebeforeconductingoperations.
d. Put drainedfuel in an explosion-proof containerand put lid on securely.
CAUTION:
Beforedisconnecting fuel hose,releasefuel pressurefrom fuel line.Referto the "ReleasingFuetpressure,,
in
EF & ECsection.
a. Do not disconnectany fuel line unlessabsolutelynecessary.
b. Plughoseandpipeopenings to prevententry of dustor dirt.
c. AlwaysreplaceO-ringand clampswith new ones.
d. Do not kink or twist hoseand tube when they are installed.
e. Do not tighten hoseclampsexcessively to avoid damaginghoses.
f . when installingfuel checkvalve,be carefulof its designated direction(Referto sectionEC).
g. Run the engineand checkfor leaksat connectaons.

Installation of Fuel Tank Band Removal of Electric Fuel Pump-

lnserttop of the band into the hole in the rear Remove electric fuel pump from the hole in the
crossmember(A). Then turn the band 90 trunk floor.
degrees (B)"
Installband accordingto identificationmarks
indicatingleft and right.

<w

sFE772

FE-4
 EXHAUSTSYSTEM

\
00

r4
@
C'l
! e

: o
t r o

i+A
2 co
c,
ict
o ct
t\
E o.
g
x
o i
q
(E c,
o
N
st
3
,9
o \qt tr \ (vt
00 Fr
u? ra lJ:
a0 (o ro
d
{.!

o!
@ N

6!
,l-

o
N
o
o!
o ,,ii,;
(t)
N
n| ,!fi,
gr
(tt il,ti
tir tr
Yr Yt I:' ^

ac
: F

' ; ( ' ,
t ;
- " N
. " t '
{
\ (.!
.\ \ ( "
\l \ l N
, / /1 .' -i
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. / F
a ct,
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,e\ Yt -v,
v/<r-t\ _=< |
2
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c('

() s FE796

FE.5
 EXHAUSTSYSTEM

CAUTION:
o On non-turbochargermodels,when removingheat shieldplatesfrom front tube, removethe entirefront
tube assembly.
o After installation,check that mountingbracketsand mounting insulatorare free from unduestress.lf
any of abovepara is not installedproperly,excessive
noisesor vibrationsmay be transmittedto vehicle
body.
o Whenconnectingcentertubeandmufflerassembly, usethe GenuineNissanSealant"ExhaustSealantKit
2072o-N2225"or an equivalentto eliminategasreakage at the joint.
o Check all tube connectionsfor exhaustgasleaks,and entire systemfor unusualnoises,with
engine
running.

Removing -Main Muffler Assembly

(Rigid rear axle models)

Whenremovingmain muffler assembly on rigid rearaxle models,disconnectrearshockabsorberlowerend

on eachside and releaseparkingbrakeleverand left sideupperlink on axlecaseside,then lift vehiclebody
(or lower rearaxle),to makeclearance
betweenrearaxleand body to extractthe mufflerassembly.

Have muffler tube out-

side the side member
when disconnecting it.

sF E797

Takecarenot to damagebrakehose,parkingbrakecabreor earthcabte.

FE.6
 GEiIERAI
IIIF|IRMATI|III

SEGTMilGI

G01{ftt{Is
PRECAIJT|O . . .N. 5. . . . . . . , , ..Gr2
-
H O WT O U S ET H | SM A N U A L . ...... ... ... .. ..Gt 5
lDENTIFicAIIOL NN F O B M A T I O , .N. , . . . . . . . .G r 8
B E C O M M E N DF EU DE LA N D I U B F I C A N T S . . .Gr12
LIFTING,TOWINGAND TIE.OOWNPOINIS..
TIGHTENING TOROUEOF STANDAFOBOLT. G .17
 PRECAUTIONS

oberuethe lollowinsprcc.ulio 3. when removinsa heavycomponenisuchasthe

sib.d in ach indilidualsectionto enrurc$re enqineor tansaxlethn.m $ion, iake caie nor
rnd pioperefliF op€ratrons. 10 oseVour ba anceand drop il or causento
hit asain* adjacenrpaib,especalyaqalnnlhe
1. Do nor operatethe ensinelor an exrended
bGks paiis such as take rube and mdtdr
perlodor r mew thourproperexhaunve.ta-
Beforedan ns repairswhich do not aqu re
Keeprhework are.we lvenr lareda^dlreeof
banery powr, always tum oft rhe isnilion
any inlammablemaleflas.Specialcarcsho! d
switch,then disconnedrhe groundcabletrom
be rakenwhen handLins anv intlammable or
iha baneryto prcventaccidentashodc rcu t
suchas 93soline, refuiqe-
Enr sas,eic. t you are workinq in a pit or
orher.ncload area,ba.ura to pmpedyveni'
latebelorcworkinqwhh hazardour mdei,ars
e h i e w o r k i nognr h e v e h i c a .
O on o l . m o k w

5.
hot melal pdt such as ihe raddor, exhaud
2. Belore jackinq up the vehlcle,apply wheeL manllod, h PlPeandfrufliet
chocksor other rire bocks ro ihe wheeh to Oo noi rcmove
prevenrihe vehcle lrom movin9.AtrerFckins
u p r h ev a h c l es, u p p o di h a v e h c e r e s h t w t r h
risid rackr at rhe point desis^dedior proper
ilrinq and towlnq before wo*ins on the

Thee operalionsrhould be doneon a eveLsuf

,

To prevenrsBtchs and soilins,proreciien

de6, uphokleryandcarpetinqwiih appropri.
cove6before*ad ns s.rvic'ns.
Takecaotlonthal keys,buckes or bu(ons.n

Gt-2
 PRECAUTIONS
Precautionsfor a Caralyn

rue i.r:
ll a argeahountof unbumed -:: ::

rv hish. To preventthn, fo ovr th: o_:..: -

ony. Lesded,:;:: -:
qasoline
1. Us unleaded

tor
2. Whenchecklns
ensinecompre$on,

3 Do not run ensinewiih low fuel in ni. '!:

enk, orheRisecnsine

Do not 0..e vehicleon infknmarrlehi.riz

K e e pn f l a m m a bnea t e r a o l f e x h a u r pp e
7 Cledna dha$embed p:rt in rhe desqnded
q u d o r 5 0 v e n rp r o r i o

qilket, packnss orinss,

o.kin9 w3$e6, co(ei pins,sef ockins nut,
ek. * in*rucled and disc:id usd on*.
TapeEd ,o er bedinss and neede ber nqs
shoud be replacedas a sei ol inier and outer

l0 Aftanse rhe dis4smbled pans i accordan.e

wiihihend$embed
l l D o n o l r o u c hl h e e r m i n a so r e l e c t c a c o m

units. Sralc eectical

vacuumhoseor a r hos,
12. Aft{ disconneclins
dtrh rag whlch nd cdes rhe properconnec

13. Usdonlylhe ubricant specfied in theapp ca-

"Fecom
be sction or rho* indicatedunder

r4 use soprovedbondinsaqenr
equlvalenswhen requned.
15 The useof the propertooh a
esenia iook shoud be usedwhtre specired
lor proper,sle and efl cientsedicerepans
16 whei effe.t ns repa6 on rhe fue, oil, warer,
make ce(a n ro
che.k a aflectedlineslor kaks.
'7 Dnposeol dra ned o or rhe so venr usedlor
 PRECAUTIONS
P r e c a u t i o nlso r E . F . l o r Prscautionsfor Turbochargsr-
E . C . C . S .E n g i n e
The turbochdqersy{em usesensineoi rar lubr
cariona^d coo ins ol irs roiarinscomponent The
Beloreconnectinq or dlsonneciinqE F l. or iurbochrser turbine turns ar 6 s
E c.cs. lrdrnesconnetor to or lrom anv 100,000rpm d rull thrdtle an
unir, be surcio turn the
E.F.l. or E.C.C.S, can reach a70rc 11,600'F). li k e$ential io
"oFF" positionand
siition swith ro the mainbin a cl.a. sUPPLY ol o
disconneci bdrervlermLnd
ilrenesarive lurbocharsersy*en. Therefore, asuddenintenup
orherwse,thsrd may be damasero contro lion ol o supplymay causea ma funcron in rhe

tuelllnelrom
2. Beroredisonnecllngprc$urlzed For proper optration ol rhe sysiam,follow the
lud pump10 injectoE,besureio rele6eluel
pre$urero eLinnde danggr' 1. A ways use the reconmendedo Fo ow rhe
Be carefulnoi to jar componencsucn as lnnructlom for proper I me to chanqehe o
co.ro unnandan fow meter
2. Avod accelerarlnsensine 10 a hsh rpm
arter*ad ns
immedlarely

_.<j>-

Lf ensinehadbeei operarinsd hiqhrpm to' an

exrendedpdriod ol 1ime, ei ii idle Jor a iew
mlnutesprior ra shutt ns ir oft

Gt-4
I HOWTO USETHISMANUAL

a o u . r c KB L F E a E N CTLN D E Xd b a , . r d b r o "".",."..,
"c.r <" rionb, nr(t- .9 r .o r11,+(rion.
oLrr ko
2 . THECONTENTSaTg ned onrhef rerpaqe6t eachsecrion.
THETIrLE k indicdadonthauppefponionot eachpaseand
showsrhe paitor sy$em.
rHE PAGENUMBEBor eachsedionm6 ns of rwo eite6,which
desisnarethepadicuar$crion,:r.
5. THE FTFSTLABGE |LIUSTFAT|ONof eachsedrionis .n exptoded
view and donrainrliqh!.nine
r o ' q - { . L b '( c n o' p o i - B d n o

AXLE- WheetHubandKnuckte
FBONT

/ / ,".'-.,,""'^-*.*a
2
s!.'b"'.4btr@',8

Gt-5
 HOWTO USETHIS MANUAL

6. THE FOTIOWINGSIIIALLILLUSTFATION
shos tho imporlantsiepssuchasinrp€clon
ue olsp*ialiools knacks ol wo 'ndhidden
or ricklv {eps whichare nol sh@n in tie . Rsmo€wh€elbtains olrer i'c*
or
prwiousklgdillusr.uon. when repLaclnswh.el bsa is ruplaceds a 3er
A$embly,inspectionand adiu*menr
proce ourerandinnn th61 be.rin!6$smbrv
rne
dureslor lhs complic.redunitssuchm
rrc
auloflaic t.n$xle or tdnsml$ion elc
presentadin a siepbvstep fo'mat whsrenecee

areused:
tollowins.SYMBOLSAND ABBREVIATIONS
s,D,s.: S.d ic€DalaandSpecitic&ons
wLthorease.
shouldbelubrlcared
6t lndlcaeduse
Man!alTnnsaxle/ThnsmEeon
UnLe$orhaeGe AuiomaticTGnexle/Tnnsm6eon
r4ommended mukiPurpose sre'se

n wnhoi
shouldbeLubricared
c
o unitl
qiven rhc arc
manuaL primarilv
expres*d withrheslUNlT (lnrenation'lsvltemol
a. TheuNlT in
svtbm
andin rhevsrd/pound
dxpreM rnrnemedc avstem
3ndalrernaiely

s 9 . 7 3N m ( 6 0 3 0 k s m 4 3 5 3 l t l b t

Gt-6
 HOWTO USETHISMANUAL

wlRlNG DIAGFAMareshownbetow.

.n
L
n
A
i L

: A T

] T A O U B L ED I A G N O S E S
A N D C O R A E C T I O NM
Sg i N C U d E d
N secronsde, ns wirh conc
- sERvlCE
D A T AA N D S p E C t F t c A T t O N
aSn da r * o r S P E C I ASLE F v t C E
T o O L Sr : . : - : :
2 I h e c a p r o nw
s A R N t N Ga n dC A U T i O N
w a r ny o uof {eps rhar mui be folow.d r
nrrrystrd/ordafrase to.omepa of rhevdhice.
 DENNFICANONINFORMANON

a
i

Frcfirand{fiir dBignati.n5:

TI
tr andarnbria)
lExeprEurcpe

lt ' =

Gt-a
l
t IDENTIFICANON
INFORMANON
ldentification Number

t\

vEHICLE lD€NTIFICATION (Ch6sknumb€r)

NUaT|BEB
Prelix andeullix dEisnations

Gt-9
 I'EffIIFIG'ATIOII INFQRMATION
ldenrificationNumbar{Cont'd)
IDENTIFICATION
PLAIE ENGINESERIAL NUMBER

IlISSANMOTOR
CO,LID,JllPAII

A
::>1
A
A
A

I1ISSAN CO.,LTD.JAPAIT
MOTOR

o l;;ffiH!, ^a o

15 ;t;
EEHAF*;I?IT;.A

NUMBEA
IVIANUALTRANSMISSION
 INFORMATION
IDENTIFICATION
-ldentitication Number{Cont'd)
AUTOMATICTRANSMISSION
NUMBEH

1;-

Gt-ll
 FUELAND LUBRICANTS
RECOMMENDED

For HonsKonsmodehwirhFJ20Eensineand

Becommend.d qasoline:
Above97octane{RoN)
For FJ20Eengine
modelsexceptlo.Europ€aid

g!soline:
Recomnendod
Above91octdn.(BoN)

R.commendedsasoline:
Abov.92odano(RoNl
Erceptfor iheabovemodek
Bocommended
sasoli.e:
Ab.ve8eoct.ne(RoNl

- ApproximatoB€fillCapaciti€s
-
SAEViscosityNumber-

Gr-12
 LIFTING,
TOWINGANDTIE-DOWN
POTNTS

a. Neverg.t ondertha vehicte

whiteir is sppon.d onty jack. Alway. us6 salery dandr b {ppd:
iiamewh.hyouhd€tu qetlnder thevehicte.
b Phcewh*l Dhocks at bothfrcnrandbackoJrhewheel is diasoiallyopporirefle t*k pGirion.

GaraseJack and Safety Srand

. Pltre a woodonor rubberblockbdtween*faty dand andvehictehody whonih. lupporiiig body isfld.

F-=:
i l lIl
E

Gl-13
 TOWINGANDTIE-DOWNPOINTS
LIFTING,
carageJack snd Sal€tv stand{Cont'd

Gt-14
 LIFTING,
TOWINGANDTIE.DOWN
POINTS
z-poini Lift

whenrirttnsrheyehicte,
openrheams a. wide m pGsibleand ensuEthar th.frcnr and retr or fie y4f :

Wlrenser nsmm,becarelutnorb .[ow r h e r m b , n r e d e r w

e n hr h eb s k e p i p e
a n dt u e t pp e .
 LIFTING,
TOWNGANDTIE.DOWN
POINTS

u$ pEp& ;rowin! aq!,pne.r to mid po$6lo d6mq. b rhe vehictsdurinq. iowlng

T@inq i. in r@rda@ wirh Towinop@rdure t .nuat .r d*tor !d4

b. Befo6 rolving, m*e lurc rin th. iEnsi*ion, dt6, nsing 3wt€mandpow€rr6in or€ in ooodord*.
It anyu.it i! d!m.ged,a dottynultbou.€d.
c, lf dre tanni$ion k inop€Etiv€,iow the vohrto wilh th. rc.r whak oft rho sbund, or wirh rhe pro,

Wh.n the vehicl€ii towed wnh hr frotr whek on the qound, scur. th. rt4rlno whel in. ftighi
ah€d politlonwn r$e igniionk.vtuhd In,,OFF,losnior
when towins 6 .ubh'tic tE|wisaion nod€t, try to |kicr towins .p.€d b.low 30 kn/h 120tdPH)
.nd bsins dirt ne le$ than30 km (20hit€t,
Whh monu.l ir nsi!5ion mod.l, r.y to r.5tricl towlng ipe€daOkm/h (50 MpH)ad towing d inrnce t6.

It th. lpeed o. dirrane nun neoEr y be s.ere, rcmovethe popel6 $!tt Mo@hand ro Dra€n
drn.so to rh. r.nh i$ion.
L Rd{€ rl|e pa*ing br.ke ard si ihe odtshin tad ir,,Neub.t, Foitbn bdor€ n.hing to row th.

Do noi rFptyfore b thetowinghook'n r t.tdat dirdion.

K..p rhorowropoor dmilardwic. irElqhrahsd, in tinetr.ththevshict€.

{ifi tlE hook dsiqn€d sxclu.iv.ly for li.dom.

Gt-16
 TOROUEOF STANDARD
TIGHTENING BOLT

Gt-17
 ENGINE LUBRICATIONSYSTEM

SYSTEM
ENGINELUBRICATION
L U B R I C A T I O NC I R C U I T
Camshaft (lntake)

Chain tensioner A
C a m s h a f t( E x h a u s t )

Jack shaft
Oil pressure
switch

Oil jet
Oil filter
Oil pressurerelief valve

Oil pressureregulator valve

Chain tensioner B Oil i€t installarion

Oil ja should be
installsd so that
the nozzle in-
Oil pumP clines bY 8
engins
, degree to
vertical line'
I

a u r t t l
t?E t I

lY
., l
Y >s"
I
Oil fitter relief valve
I e - s N'm (o.4 - 0.5 kg-m,2.9 - 3.6 ft-lb)

I
L

(f : Oil passage

{3 : Oil gallerY in cylinder block

---- : Bypass Passage

s Lc663

LC-14
 E N G I N E L U B R I C A T I O NS Y S T E M

OIL PUMP
DISASSEMBLYAND ASSEMBLY
(?l:3.7-5.o
lo.:tlt - o.51,
YI lo.3s u-5r, Front cover
\ 2.7 - 3.71
7-O-ting

\,6) O, Always rePlace

)

"""",W@
oilpump
lnner gear
Outer gear-

Pressweregulatorvalve O I L P R E S S U R ER E G U L A T O R
h--
VALVE
F--sprine
Check valve sliding surface and valve
\springretainer
\Snap ring
spring.Replaceentire valveassemblyif
necessary.

*L
16-21
( 1 . 6- 2 . 1 ' -1 2 - 1 5 I
Oil strainer

@ : N.m (kg-m,ft-lb)

a. Before removing front cover, re- INSPECTION

moveoil pan and oil strainer. l. Measureclearance.
b. Do not damage rylinder head
gasket. Body to outer gearclearance@:
c. Always use new gaskets,snap ring, 0 . 1 1 - 0 . 2 0m m
(0.0043 - 0.0079 in)
O-ringand oil seal.
d. When installing front cover, apply Inner gearto ctesoentclearance@:
Sealant. 0.12 - 0.23 mm
(0.0047 - 0.0091 in)
outer gear to crescent
clearance @: OIL FILTER
0.21 - 0.32 mm
(0.0083- 0.0126in) O I L P R E S S U R ER E L I E F V A L V E
Checkfor a crackedor broken valve.If
replacementis necessary,removevalve
by prying it out with a screwdriver.
Then, install a new valve in place by
tappingit.

e. Before installing front cover, align

locating notches.
7/- o
o \-/

2 , Measureoil pump gearend play.

Housingto gparclearance:
0 . 0 6- 0 . 1 2m m
sLc392 (0.0024 - 0.0047 in)

LC-15
 COOLING SYSTEM

COOLINGSYSTEM
C O O L I N GC I R C U I T

I l:t
l i
it.
r i

sLc664
o Always usenew gaskets.
WARNING: o After installation, run enginefor a
To avoid seriousperconaliniury, never few minutes,and checkfor leaks.
remove radiator caP quickly when
engine is hot. Sudden release of
cooling rystem pressure is very
dangerous.
lf it is necessaryto remove radiator
cap when radiator is hot, turn cap
slowly counterclockwise to the first
stop. After all pressure in the cool-
ing system is released,turn cap passing
the stop and removeit.

LC-16
 COOLING SYSTEM

RADIATOR

INSPECTION
Refer to MA section for checking
cooling system.

.€:_:{r.

.l:,::

4-.a
.':
'-'1 .
, Feti LC-17
.l::
;-,1-:
St+"
 COOLING SYSTEM

E L E C T R I CC O O L I N GF A N
OPERATION

IGNITION RELAY

-FAN MOTOR AN MOTOR

r@r OFF * ON e0(re4)

t l
?J- OFF-+ON e5(203)
a
5o

THERMO
SWITCH
NO. l
INSPECTION

:$Ffi Check thernro switch for

operation.
proper

BATTERY "€rm
:i Ji
I t - r l
THERMO
SWITCH
NO.2 OFF* ON
Toheater I l--ili
l t r !
unit I -tr*;-l I
RADIATOR FAN
RELAY NO.2
RADIATOR FAN
RELAYNO.1
sLc667

sLC463

OIL COOLER

INSPECTION
Check oil cooler for oil and water
leakage.

Connector pipe

To cylinder
block

pl,r-3eN.m
(3.0 - 4.0 kg-m, 22 - 29 ft-tbl
 r, ai.lr.i&erde*rre.**,..

COOLINGSYSTEM

WATERPUMP vane for rust or corrosion.

2. Inspect water pump bearing for
INSPECTION excessiveend play or rough operation.
o The water PumP cannot bo dis' . After installation,adjust drive belt
assembledand should be replaced deflection. Refer to SectionMA for
as a unit. drivebelt deflection"
l. Inspect water PumP bodY and

- -
@ ue : G.3- 8.3 (0.64 o.8s,4.6 6.11
Waterpump

@ tvts:c-s
(o.4-0.s,2.9-3.61

O Ma,ts-zt
{1.6 - 2.1, 12 - 15}

Fan pulley

Fan belt

@ : N.m (kg-m, ft-lb)

THERMOSTAT
INSPECTION
l. Check valve seating condition at
ordinary temperatures- It should seat
tightly.
2. Check valve opening temperature
and maximurn valve lift.
3. Check valve closing temperature'
Valve closes at 5"C (9"F) below valve
opening temPerature.
o lt is neoetsary to c*reck the new
thermostat.

Frigid type
(Standardtype
Standardtype Tropical type
for Europe&
Hong Kong)
Valve openingtemperature
'c ('F) 88(le0) 8 2( 1 8 0 ) 76.s(170)

Max. valvelift 8/100 sles 8/eo

mmf"C (in/"F) (o.3rl2r2) (0.3r1203) (0.31/le4)
 SERVICEDATA AND SPECIFICATIONS

SERVICEDATAAND SPECIFICATIONS
E N G I N ELUBRICATIONSYSTEM INSPECTIONAND ADJUSTMENT

G E N E R A L SPECIFICATIONS Waterpump
Adjust deflec- Set deflection
Lubrication method Pressedfeed flow Drive belt deflection tion of used belt of new belt

Oil pump type Inner gear type

8 . 5- 1 2 . 5 8 . O- 1 0 . 5
Alternator m m ( i n l ( 0 . 3 3 5- 0 . 4 9 2 1 ( 0 . 3 1 5- 0 . 4 1 3 )
Oil filter type Full flow and cartridge type

Air conditionercompressor 7 - 10-5 7 '8

mm (inl ( O . 2 8- O . 4 1 3 1 (0.28 -O.311

INSPECTION AND ADJUSTMENT

Power oilpumpmm(in) ,..11-3k,
steerins ,ol? . l]u,
Oil pump
Unit: mm (inl
A p p l i e d p u s h i n gf o r c e N (k9, lbl 98 (10,22)
Body to outer g€ar clearance 0.11 - 0.20(0.0043- 0.00791

lnner gear to crescent clearance o.12 - O.23(0.OO47- 0.0091)

Outer gear to crescent clearance o.21 - O.32(0.0083- o.o126l Thermostat

Frigid type
Housing to gear clearance 0.06- o.12(0.0024- o.oo47l (Standard
Standard Tropical
tvoe tor
tYPe type
Europe&
Hong Kongl
TIGHTENING TOROUE
Valve opening tem- 7 6 . 5( 1 7 0 }
"c ("F) 88 (190) 82 {1801
Unit N-m kgfi ft-lb perature

Oil pump cover screw 3.7 - 5.O 0.38 - O.51 2.7-3.7 Max. valve lift 8/1OO 8/95 8/9O
mmf c (inf Fl 1o.31t2121 (0.31/203) {0.31/194}
Eront cover bolt (4Tl 9.1 1 1 8 0.93 - 1.2 6.7 -8.7

(7T) 16-21 1 . 6- 2 . 1 12-15

Crankshaft pulley bolt 1 4 7- 1 9 6 15.0 - 20.O r08 - 145

Radiator
Alternator bracket bolt
30-40 3 . 1- 4 . 1 22 -30 Unit: kPa (bar, kg/cm2, Psil
to front cover

zl4 - 59 4.5- 6.0 33 -43 Caprelief pressure 88 (0.88,0.91

. 31
to block

Leakage test pressure t 4 7 1 1. 4 7 , 1 . 5 , 2 1 1

Alternator adiusting 12-'15
16-21 1 . 6- 2 . 1
bar bolt

Oil strainer bolt t6 -21 1 . 6- 2 . 1 12-t 5

Oil pan bolt 5-7 o.5- o.7 3.6- 5.r

T I G H T E N I N GT O R O U E

N.m kg*n ft-rb

Waterpump bolt
E N G I N EC O O L I N GS Y S T E M M6 6.3 - 8.3 0-64 - O.85 4.6 - 6.1
MB 16 -21 1 . 6- 2 . 1 12 -' ts
GENERAL SPECIFICATIONS
Water outlet bolt 9 . 1 - 1 1 . 8 . O . 9 3- 1 . 2 6.7 -4.7
Cooling method Water cooling, forced circulation

Water pump type Centrifugal

Thermostat type Waxgellet

Radiator type Corrugated fin and tube

LC-20
 ENGINEMAINTENANCE
- Retightening Cylinder Head Bolts, Manifolds,
Exhaust Tube
Retighteningshould be performedwhite engine
is tightento a torqueof 74 to g3 N.m (7.5 g.5
cold [approximately
20"C (6g"F)J. to
kg-m, 54 to 61 ft-lb).

CYLINDER HEAD BOLTS Retightening should be made in

the seguence
shown"
1. Removerocker
cover.

CA20E engine

o FJZOengine

SMA3434

@ @ o o @
o o o o o
o o o o o
@ @ @ @ @

SMA3444
2. Retightening procedure
Cylinderheadbolt
o CA engine
1 1 8- 1 2 7N . m
Looseneach cylinderheadbolt slightly,
then (12.O- 13.0ks-m,87 - 94 ft-tb)

MA-6
 ENGINEMAINTENANCE
Retightening Cytinder Head Bolts, Manifolds & Exhaust Tube

MANTFOLD NUTS AND BOLTS

o CA engine
Intake9l:
2 0 ' 2 5 N ' m( 2 .0 '2 .6kg -m,1 4- 1 9ft-l b l
Exhaust 9l:
20 -29N.m(2.0'3.0kg-m'14- 22tt'lbl
o FJZOengine
I n t a k e9 :
-
31 '42N'm (3.2- 4.3 kg-m,23 31 ft'lb)
Exhaust[9l:
M8 1 6 ' 2 1N ' m
(1.6- 2.1 kg-m,12 - 15 ft'lb)
M10 20'25 N'm
l2.O- 2.6 kg-m, 14 - 19 ft-lbl

EXHAUSTTUBE NUTS
p : 26 - 36 N'm (2.7' 3.7 kg-m,20 '27 ft'lbl

MA.7
^a
 ENGINEMAINTENANCE
Adjusting Intake and Exhaust Valve Clearance
Adjustmentshould be madewhile engineis warm
FJ2OENGINE
but not running.
1. Set No. 1 piston at top dead center on its com_
pressionstroke.
CA ENGINE
1. Set No. ! cylinder in top dead centeron its
compressionstroke, and adjust valve clear_
ance@,@,@and@.
2. Set No. 4 cylinder in top dead centeron its
compressionstroke, and adjust valve clear_
a n c e@ , @ , @ a n d@ .

Adjustingscrewlock nuts t
pl : 18 - 22 N.m (t.g - 2.2kg-m,13-
16 ft_tbl

SMA345A

Measurevalveclearance
and write it down.
Valveclearance(Hot)
lntake 0.30mm (0.012inl
Exhaust 0.35mm (0.014inl

SMASOTA

Valve cfearance(Hot) ?+^ ^++

lntake & exhaust 0.30 mm (0.012
in)

SMA347A

MA-8
 ENGINEMAINTENANCE
Adjusting tntake and Exhaust Valve Clearance{Cont'd
on its com-
2 . Set No. 4 pistonat top deadcenter
pressionstroke.
Measure andwrite it down'
valveclearance

l+^ ^l+
sEMA10

(5) RemovecamshaftsProckets'
SMA34AA

adiustvalveclearance'
3. lf out of specification,
(1) ResetNo. 1 piston at top deadcenteron its
compression stroke.
{2) Scribe marks on timing chain and camshaft
sprocketswith Paint-
(3) Loosencamshaftsprocketbolts'

SEMAl 1

Supporttiming chain by a properwire to ensureit

does not drop, even if there is chain supporteron
ttre front cover.
(6) Removecamshaftbracketsand chainguideA
below.
in the sequence

@ @
(4) Removechain tensionercover and chain ten-
sionerA. E
Be careful not to drop chain tensionersleeve guide A

andsPring.

I
@ @
s E M 8 12

MA.9
 ENGINEMAINTENANCE
Adjusting Intake and Exhaust Valve clearance (cont'dl

Keepremovedbracketsin order. (11) Pick out proper valve cap from the list of
(7) Removecamshafts. valvecap thicknessesin S.D.S.
(8) Removevatvelifter andcap.
Before installation, it is necessaryto check thick-
nessof new valve cap.
(12) lnstallvalvecap and valvelifter.
a. Apply engine oil on valvecap and outer wall of
valve lifter.
b. Pay particular attention not to damage valve
lifter guide hole.
c. Check valve lifter for smooth rotation.
Valve lifter

o Valve lifter can be removedeasily by using

magnetor suction rubber.
o Keepvalvelifter and cap in order.
(9) Measurethicknessof removedvalvecap using
surfaceplateand dial gauge,andwrite it down.

(13) Installcamshafts and tightencamshaft

bracket nuts with chain guideA in the reverse
order of removalin two or threestages.
pl : Camshaftbracketnut
14- 18N.m
(1.4- t.B kg-m,10 - t3 ft-tb)
a. Installcamshaftsso that No. 1 camsareat top
deadcenter.

SMA349A

(10) g6lqrlateoptimumthicknessof valvecap.

Intake:
t = t| * Tl - 0.30 (mml
Exhaust:
t = tE + TE - 0.35 (mm)
t1, tg : Measuredvalvecapthickness(mm)
Ts,T6 : Measured valveclearance
(mml

SEMA3O

MA.1O
 ENGINEMAINTENANCE
Valve Clearance(Cont'd)
Adjusting Intake and Exhaust
camshaftiournal'
b. Apply engine oil on cam'
surface'
camshaftbearingand valvelifter upper
by
(14) Set timing chain on camshaftsprockets
removal'
aligning each mark scribed before
camshafts'
Then,installcamshaftsprocketsto
p : CamshaftsProcketbolt
1 0 8 ' 1 3 7N ' m
(11.0- 14.0kg-m,80- 101 ft-lb)
(15) lnstallchaintensioner A'
p! : ChaintensionerA bolt
6.3 - 8'3 N'm
(0.64- 0.85ks-m,4'6'6'1 ft-lb)
in chain ten-
Before installation,fill engineoil
sionerA.

F i l l e n g i n eo i l ,.J

%"$
';
{,

SEM831

( 1 6 )lnstallchaintensionercover' i

( 1 7 )lnstallrubberPlugwith sealant'
( 1 8 )lnstallvalverockercover'
g : Valverockercoverbolt and nut
9 . 1- 1 1 . 8N ' m
(0.93- 1.2ks-m,6'7'8'7 ft'lb)
tightenedin criss-
Rockercoverbolts shouldbe
crossfashion.
gasket'
b. Alwaysusenew rockercover
water tem-
(19) Start engineand warm it up until
middle of
perature indicator points to the
gauge,thenstopengine'
valve
(2Oi nemovevalverockercoverand recheck
clearance.

MA-l1
 ENGINEMAINTENANCE
Checking and Adjusting Drive
Belts
1. Inspectfor cracks,fraying,
wear of oil adhe_ Belt deflection:FJ20ENGINE
sion.Replaceif necessary.
The belts should not touch the Adjust deflec-
bottom of the Drive belt deflection
pulleygroove. tion of used Set deflection
of new belt
b€lt
2. Check driv_ebelt deflections pushing -
by mid_
way betweenpulfeys. Alternator@ mm (in) 8.5- 12.5 8.0- 10.5
(0.335- 0.4921(0.315- 0.413)
Adjust if belt deflectionsexceedthe
timit. Air conditioner 7 - 10.5 7_8
compressor@mm (in) (0.28-
0.413) (0.28 - 0.31)
Beltdeffection:CA ENGINE
Powersteeringoil -21
Unit: mm (in) 17 13-17
P U m P@ mm (in) (0.67- 0.t]:t) (0.5r - 0.67)
Used belt deflection -
Set deflection Applied pushingforce
Limir Adjusr of new belt
N (ks. lb) 98(1o,22)
Alternator r 3 (0.s1) 7-10 5-8
@
(o.28 - o.39' 10.24- 0.311
-
A/C compressor Adjusting bolt -
7 (0.28!, 3-5 3-5 power steering
oir pump
@ 10.12- O.20t @.12- o.20l

ffi-@
P/S oil pump -
t4 (o.ss) 8-tl 6-9
@ (0.31 - 0.43) to.24- O-35t
Applied pushing force: 9g N (1O
kg, 22 tb)
L- Lock nut
Air conditioner
compresior - Adiusting
'a *t'

Oil pump puiley

,,"i;,>tffiU .

Alternator
a.
ta Lock nut

MA9664

Alternator
J
Loosen

Crank pulley

ldler pulley

Lock nut

! : Checking point Adjusting bott

SMA927A

MA-I2
t-
 ENGINEMAINTENANCE
,3::
Changing Engine Oil and Oil Filter +l
a5*

ii

1. Warm up engine,then stop it, and checkfor 5. Wipeoil filter mountingsurface.

:r:
from enginecomponents.
oil leakage 6. Smear a little engineoil on rubber gasketof ,
oil filter.
l r t

2. Removeoil fillercapanddrainoil.
WARNING:
Be carefulnot to burn yourself,as the engineoil ,$
may be hot. .T
1
Oil fil16r cap ;+.
:.
It lt l ':

L
.ii
.t.

eut
Loosen I f
"J.
:'*
;.i
*
:l
-z--/ J

SMAOl0

7. Installoil filter.
Hand-tightenonly. Do not usea wrenchto tighten
the filter.
8. Add recommended engineoil.

3. Clean and install oil pan drain plug with Oilcapacity:

washer. Unit: liter (lmp qt)
pt : Drainplug
CA engine:
29 - 39 N.m
(3.0- 4.0 kg-m,22'29 ft-lb)
FJ20engine:
35 - 47 N.m
(3.6- 4.8 ks-m,26- 35 ft-lb)
4. Removeoil filter.

SMA935A

MA.13
 ENGINEMAINTENANCE

tffi5il+,t{tfl
#ir ilit:,
l1,g
:ll:
CAUTTON:
a. fdle mixture ratio is adjusted 3. Turn o,ffair conditionerand
at factory and headlamps.
requiresno further adjustment. 4. Make ihe check after the radiator
lf it becomes coolingf
necess:rry
to adjust it, proceedwith the hasstopped.
follow- 5. Before disconnectingand
ing steps. connectingE.F.l
b. To prevent possibte E.C.C.S.componentparts harness
damageto the adjusting connector
ensure that ignition switch
screwwhife performingthe
CO%check,do not is in ,,oFF
exceedthe depth of ,,T,,when position.
driflingthe seal 6. Use "CO,,-meterafter it is fuily
plug. warmedu l
and insert ,,CO,,-meter
cA20E engine probe into tail ip
CAI8ET engine more than 0.4 m (1.3 ft).
- Aluminumplug Aluminumplug Measure"CO,,o/owith air cleanerinstalled.
\ , D , ^ When adjustingidle ',CO,'yo,prepare
a resistor.

T : 5 rnm (O.20in)
D : 12.6 mm (O.496inl T: 1,2 mm (0.047inl
D: tO mm (0.39int
D,: 7 mm (0.2gin)
s E F 19 0 c
SEF191C

The adjustingscrewof CAISET

air ffow meter
turns only 360 degrees.

Preparation sMA21 1

1. Makesure that the folfowing

partsare in good
order.
o Battery Maketeadwire asfoilows:
r lgnition system 1) Useflat pfate terminafs
3 mm (0.12 in) wide,
o Engineoil and coolant 0.8 mm (0.031 in) thick as
tevels male terminals.
o Fuses Place frat pfate terminars parafrer
with each
o E.F.f. harness other and keep distancebetween
connectors inside faces
o Vacuumhoses 2 mm (0.08in).
o Air intake system 2l Solderteadwire to terminals.
{oif filler cap,oif fevetgauge, 3) Solder resistor to side opposite
etc.) to terminaf
. clearance,engine"ornprurrion and wrap insulation tape around
Yu]r" soldered
portion.
vatveoperation(For Arr.r"li.
Io 5:G.R. modet)
Throttle valve and throttle
valve switch oper_
ation
,?,,
Resistance
2" Set shift leverin ,,Neutrat,,
"P" position position(i1 ,,1\f
,,
s1-
for the automatictransmission).
Engageparkingbrake
and lock boJ f.ont .nd
rearwheefswith wheel
chocks.

MA.l6
 ENGINEMAINTENANCE

andadjustingidle rpm and ignitiontiming

Checking

S t a r t e n g i n ea n d w a r m u p e n g i n e u n t i l w a t e r
temperature indicator points to the middle
of gauge.

To harness
E ensineflJflf
lFJ20ensine
connector of
Stop engine and attach adapter harness
ignitioncoil
between ignition coil primary winding
terminals and harnessconnector. Then set
tachometer to adapter harness (CAl 8ET
\ and FJ20l.
To ignition coil terminals
SMAT9OA

Disconnect distributor vacuum hose from

distributor vacuum controller, and plug hose
with proper plug. (Except CAl8ET enginel

,..'.1'f ' frr.

Run engine at about 2,OOOrpm for r-- \ --7
about 2 minutes under no-load.
o;-'Q -8
SMAOTlA
Race engine two or three times under no-
load, then run engine for one minute at
idle sp€ed.

ldle speed: rpm

Below l,O(X) rpm

CA18ET engine

Adjust idte speed by turning idle speed

adiusting screw.

MA-17
 checkignition.i.inglffi

ffi
timinsc B.T.D.C. desree
ls:1.:"_.
CA20E: 4t I Excspt for Austrstaa
_ Orl For Australia
CAISET: l5rl
FJ2O: 4t1 Except for Hong
Kong & Europe
----- Blackpaint
gtl For Europe SrnreOOee
& Horrg X-ong

Connect distributor *"r.rrn

hoa". Adjust ignition timing by turning
(Except CA18ET,
distributor.

Raceengine(2,OOO.-3,0OOrpml 2 or 3
trmesunderno-load.and then
run engine

Adjust idle speedby turning idle

speed
adjustingscrew.
ldle geed: rpm
CA M/T: TfrOrlOO

:ljrT' ssoiloo in ..N,,pos,tion

FJA} g(xrrso

Conf i rm i gn it ion ti m i n g; t-idle

speed.

!T:"" timing: B.T.D.Clesree

CA20E: l2r5 Excaptfor Australia
8t5 For Austrafia
CA18ET:tstl
FJ2&. 20tS Excopt for Hong Kong
& Europe
12t4 Fot Hong fong & Europe

Checkdistributorand E.F.,./E.C.C.S.
"o-ponents (Refer to EF section).
 ENGINEMAINTENANCE

Checkingand adjustingmixtureratio
"CO"-meter]
lwith

Raceengine(2.000- 3,000 rpm) 2 or 3

timesunderno-load,then run engineat
idle speed.
SMAO1 1 B
"CO" with "CO"-meter 18ET engine
Check

ldle "CO"%
CA engine
Except Europe: 1.0!0.5
Europe: Bolow 2.0
FJ engine:
CA2OE Below 1.O
CA18ET

Turn off engine and remove blind plug

on air f low meter.
WatertemPerature

Disconnect water ternperature sensot

harnessconnector, and connect a
resistor between terminals of harness
connector.

Start engine and warm up until water

temperature indicator reads normal
operating temPerature.

Race engine two or three times under

no-load, then run engine at idle speed.

"CO"% by turning variable resistor

Adjust
or air by-passscrew on air flow meter-

Resistor
I t*to enrichmentl
Below8
CAl8ET engine
2.5 kO I engines/

16rLeanerl
'')r.'\'\
Turn off engine.

SMAOlOB
connect water temperature sensor
harnessconnector.

MA.l9
 @
I
I
+
Race engine two or three times
uncrer
no-load, then run engine at idle
speed.

ldle speed: rpm

CA M/T: 7S0rtO0
Aff : 8S0! tOO in ,,N,, position
FJ20: 9OOTSO

Adjusr idte speed by turning idle

sDeed
a d j u s t i n gs c r e w .

MA-20
 ENGINEMAINTENANCE

"CO"-meter]
[Without

Raceengine(2,000- 3,000rPml 2 or 3
timesunderno-load,then run engineat
idlespeed.

Water temperature
connect a resistor, as shown between
t e r m i n a l so f t h e w a t e r t e m p e r a t u r e
s e n s o rh a r n e s sc o n n e c l o r .

Start engine and race engine two or three

times under no'load, then run engineat
idte.

18ET engine- & A d i u s t m i x t u r e r a t i o w i t h e n g i n es p e e d

set at maximum bY turning variable
Leaner resistor or air by'pass screw on air flow
meter.

SMAOl OB
Stop engine, remove the resistor and
reconnect the water temperature sensor
harnessto the water temperature sensor'

Race engine two or three times under

n o - l o a d .t h e n r u n e n g i n ea t i d l e .

ldle speed: rpm

CA M/T: 750i10O
"N"
Aff : S5OrlOO in Position
FJ2O: 9O0r50

CAl8ET engine
Faster
=-A'

SMAOOTBI

MA.21
 ENGINEMAINTENANCE
Checking Fuel System_
The.firter is designedespeciafty
for use with the
E.F.f. system.Because Checkfuel tinesand tank for
of the fuel pressurein fuel proper.attachmen
fineis hisher
than196tpa (r.g;-ui'i"r.oks/cm2, leaks.cracks,damage,loose
connections,chafinr
28 psi). and deterioration. '
Before disconnectingfuel
hose, releasefuef pres-
surefrom fuel fineto eliminat"
A"ng"r.--
Reducefuel pressure
to zero,
(1) Startengine.
(2) Disconnectthe
harnessconnector of
pump. fuet

Tool box (Rear right_hand

sidel

SMAAO3A

(3) After enginestalt,

crank the enginetwice
threetimes. or
(4) Turn the ignition
switch,,OFF,,.
(5) Reconnect the
harness connector of fuel
pump.
Be carefut not to spitt fuel
over engine compart_
ment.Placea ragto absorb
fuef.

SMA932A

tvtA-22
 ENGINEMAINTENANCE
Checking Fuel System (Cont'd

FuelPumP CAUTION:
Do not reusefuel clamp after loosening.Tighten
high pressurerubber hoseclamp so that clamp end
is 3 mm (0.12 in) from hose end. Ensurethat
screw does not come into contact with adjacent
parts.

enZOe engineFuelinlet I Iniectorandfilter

CAl8ET engine Fuel inlet and outlet

t t Fuet- hoseclamr
f0'l

/W
r.o r.5 N.m
(0.1O- O.15kg-m,
0.7 - 1.1 ft-rbl

Injector and filter SMAA04A

FJ20 engine -. Iniectorand inlet and outlet

Fuel inlet, outlet

SMAOl 2B

MA-23
 ENGINEMAINTENANCE
-Replacing Air Cleaner Filter Changing and Reptacing_
Spark plugs
The viscouspaper type air cleanerfilter doesnot
requireany cleaningoperationbetweenrenewal. 1. Disconnectspark plug wire at boot. Do not
pull on thewire.
I n s t a l l a i r c l e a n e rf i l t e r w i t h , , U p , ,
m.ark facing upward.

SMAO3TA

SMA928A
2. Removesparkplugswith sparkplugwrench.

Use a sJitable
CA engines"

Wrench with a magnet

to hold spark plug

k
l \ . / l
)
t l
16 mm
{0.63 in}

SEM294A

MA-24
 ENGINEMAINTENANCE
Checking lgnition Wires-
Checking and RePlacing
S P a r k P l u g s( C o n t ' d ) Check the high tension wires
for cracks'
damage, burnedterminalsand properfit'
CleanPlugsin sandblastcleaner' Measurethe resistanceof the high'
tension
chips' gasket
inrp"", insulator for cracks or wires,by stakingit and checkingfor
intermit-
electrodefor
for damageor deteriorationand tent brakes.
worn'
wearand burning.l-fthey areexcessively
replacewith newsparkPlugs'
; . ChecksParkPluggaP'

- in)
Gap: 1.0- 1.1mm (0'039 0'043

Side electrode

H SMAOl5A
'-
,i
.f,

SparkPlug:
Destination

Engine Type Except for EuroPe For Hong Kong

& Hong Kong & EuroPe

1'
BCP6ES-1
Standard
CA2OE 1*
Cold BCP7ES.1

Standard BCP6ES-11* | aceRse$tt'

CA18ET 'l'
BCP7E911' BCPRTES-l
Cold

BP6ES-11 BPR6ES.l 1
Standard
FJzO
Cold BP7E911 BPR7ES.l1

*Distance between two opposing sides of spark plug hexagonal base:

16 mm (O.63in)
high tension
6. Install spark plugs' Reconnect
cablesaccording to Nos' indicatedon them'
p! : SparkPlug
Used: 20 - 29 N'm
(2'0 - 3'0 kg-m' 14 - 22ft-lbl
New: Turn 112or 314of a turn after
gasketis seated'

MA.25
 ENGINEMAINTENANCE
hecking and Replacing Distributor
contact point
VISUAL CHECK
2. lf dwell angleis not within the
1. Inspectpointsfor excessive specifiedvalue,
burningor pitting. turn off engineandadjustpoint gap.
2. Use a point file to cleancontactareaand 3. lf dwell angleis not within the specified
re_ value
movescafefrom points. when point gap is correct,cam lobe
is worn.
Replacecam.
CHECKINGPOINT GAP
Set contact point on the noseof cam,
and check REPLACINGDISTRIBUTOR
point gapwith oiflessthickness
gauge. CONTACTPOINT

Projected pin
Mounting screw
for adjustment

lt t rl
I l-r,
l . /

V Disrributor
point gap:
'0.45- 0.55
mm
fO.Of8 - O.O22inl
Contact point set Greasinspoint
@:
SMA5124 SMA515A

lf out of specification,
loosencontactpoint pfate fnstall new contact point set and adjust
point
attaching screw and adjust point gap gapand dwellangfe.
by pivoting
projectedpin. 2. Apply the specifiedgreaseto cam
and cam
head.
C H E C K T N GD W E L L A N G L E
1. Run engineat idle speedand
measuredwell
anglewith a dwell meter.
Dweltangle: 49' - Sbo

Wide point gap

Ttre wider point gap,

The narrower point gap,
the smaller dwell angle.
the larger dwell angle.
SMAs144

MA-26
 ENGINEMAINTENANCE
Checking Positive Crankcase Ventilation (P.C.V.) System

CHECKINGP.C.V.VALVE FJ20 engine

Disconnecthoseand check P.C.V.valve to seeit

is operatingProPerlY.

sMAO48

CHECKINGVENTILATIONHOSES
Check ventilation hosesfor proper connection,

CA2OEengine

I
I
I
I

SMAOl 3B
 CHASSISAND BODY MAINTENANCE
Body
L U B R I C A T I N GL O C K S ,H I N G E SA N D H O O D LATCHES
Coupe
E
c
v

;
t\
Hatchback

Trunk lid lock

P
c

Trunk tid P
9

Eil t
E i
Aa
SMA925A

CHECKING SEAT BELTS. BUCKLES, RETRACTORS,ANCHORSAND ADJUSTERS

CAUTION:
1. lf the vehicleis collidedor overturned,
replace the entire belt assembly,
regardlessof nature of accident Check anchors for loose mounting.
2. lf the condition of any co.mponent Check belts for damage.
of a seat b€lt is questionable,do not Check function of
have seat bett repaired, but replaced b u c k l e sa n d t o n g u e s
as a belt assembly. when buckled and
released.
3. lf webbing is cut, frayed,
or damaged,
replacebelt assembly.
4. Do not spilt drinks,
oil, etc. on inner
lap buckle.
-belt Never oil tongue and
buckle.
5. Use a NTSSAN
genuine seat belt
assembly.
pAnchor bolt
24 - 31 N.m
(2-4 - 3.2 kg*n, lZ - Rearseatbelt
23 f.bl
Front seat belt
SMAOO2B

MA.48
 SERVICEDATAAND SPECIFICATIONS
Engine Maintenance it
. rt - -

AND ADJUSTMENT Valvecap(FJ20engine) rjt

SPECTION .,+'
Part number Thickness mm (in)
system
sicmechanical ,:i.
13229-A0200 1.25(0.0492) :i
,208& CAl8ET engine 1 . 3 0( 0 . o 5 1 2 1
i'
r 3229-AO201
s
hm (in) 13229-AO202 1 . 3 s( 0 . 0 5 3 1
l ',f
,. "1s616n6e(Hotl :'t
t8ke
0.30 (0.0121 r 3229-A0203 1.40 (0.0551I ;r',L.
l"t
o.30(0.o12l 13229-AO204 1 . 4 5( 0 . 0 5 7 I1
10fi,
13229-A020s 1.so (0.0591| t;
,e belt deflection
(1 0 kg.22 lbl ,n6 {in} 13229-A0206 1.55 (0.0610l
:n applying pushing force of 98 N
13229-AO207 1.60 (0.0630)
Used belt Set deflection
13229-A0208 1.65 (0.06501
of new belt
Limit Adiust
13229-AO209 1.70 (0.06691
7- 10 6-8 0
13229-4021 1.75 (0.0689)
grnator r3 (0.511 (0.28- 0.391 ( 0 . 2 4- 0 . 3 1 1
13229-A0211 1.80 (O.O709)
3-5 3-5 13229-AO212 1 . 8 s( 0 . 0 7 2 8 1
7 (0.28) ( 0 . 1 2- O . 2 0 )
npressor {0.12- 0.20)
13229-AO213 1.90 (0.07481
:oil 8-11 6-9 13229-A0214 1.95 (0.0768)
14 t0.55) (0.24- 0.351
np {0.31- O.431
13229-AO215 2.00 (0.07871
13229-AO216 2.05 {0,08071
13229-A0217 2.10 lo.o827l
20 engine
13229-AO2r8 2.15 (0.0846)
13229-A0219 2.20 (0.08661
o.30(0.012)
13229-AO220 2.2s (0.08861
o.35 (0.O14)

ve belt deflection mm (inl Emissioncontrol system(Australiamodel)

Unit: kPa (mbar, mmHrO, inHrO)
8 . 5- 1 2 . 5 8.O- 10.5
{0.335 - 0.4921 ( 0 . 3 1 5 -O . 4 1 3 )
Vapor line leakagetest
Supplied pressure 3.923 (39.23.400. 15.75)
7 - 10.5
{o.28- 0.413) Pressurevariation/
Lessthan 0.245 12.45,25,0.98)
2 - 1 1 2m i n u t e s
17 -21
(0.67- 0.831

98 110,221

MA-49
 SERVICEDATAAND SPECIFICATIONS
Engine Maintenance (Cont,d

Coolingand lubricationsystem lgnitiontiming

"B.T.D.C.
Unir:

E n g i n em o d e l With
Radiator cap relief pressure vacuum advance
kPa (bar, kg/cm!, psil 8 8 ( 0 . 8 8 , 0 . 91, 3 1
12t5
Cooling system leakage testing
pressure kPa (bar, kg/cm2, psi) 1 5 7( 1 . s 7 , 1 . 6 , 2 3 1
815
Coolant capacity
MIT
liter {lmp qtl
CAl8ET
With heater 8.6 {7-518) AIT
Oil capacity
4!1: 20t5:
titer (lmp qt)
Except for Hong Except for Hong
With oil filter
Kong & Europe Kong & Europe
FJ2O
8!1: 12!4:
Without oil filter 3.s {3-1l81
For Hong Kong & For Hong Kong &
Europe Europe

T I G H T E N I N GT O R O U E
BCP6ES-1
I
BCPR6E911'
For CA engine
BP6ES-1
1 BPTES-I1
Item N.m kg-tn ft-lb
BPR6E911' BPRTES-I 1'
Alternator adjuster lock 14-17 1 . 4- 1 . 7 1 0- 1 2
bolt
o.8- o.9 (o.o31- 0.03s)
Cylinder head bolt 74-83 7.5-8.5 il-61
CAl8ET & FJ2O 1.0 - 1.1 (0.039- 0.043)
Exhaust manifold nut 20 -29 2.O- 3.0 14 - 22
Intaka manifold nut 20 -25 2 . O- 2 . 6 1 4- 1 9
Oil pan drain plug 29 - 3!) 3.0 - 4.0 22 -29
tResistor
built-in type for Europe & Hong Kong Rocker cover screw 1-3 0.1 - o.3 0.7 - 2.2
Valve rocker adjusting nut 1a-22 1.8-2.2 13-16

For FJ engine
Itsm N.m kg+n ftjb

850t10O (in "N" positionl Camshaft bracket nut 14-18 1 . 4- r . 81 0- 1 3

Camshaft sprocket bolt r08 - 137 -
11.O 14.O 80 - 101
Chain tensioner A bolt 6.3 - 8.3 0.64 - o.85 4.6 - 6.1
Cylinder head bolt 1 1 4- 1 2 7 12.0- 13.O a7 - 94
Exhaust manifold nut
M8 16-21 1 . 6- 2 . 1 1 2- 1 5
En(lrno modol
Europe
M10 20 -25 2 . O- 2 . 6 14- 19
CA20E Intake manifold nut 31-42 3-2 - 4.3 23 - 31
cAl 8Er 2.0 or lower Oil pan drain plug 35-47 3.6 - 4.8 26 - 35
FJ2O Valve rocker cover bolt 9 . 1- 1 1 . 8 o.93 - 1.2 6.7 - 8.7
1.0 or lower
& nut

MA-5O
 SERVICEDATAAND SPECIFICATIONS
Engine Maintenance (Cont'd

:or CA & FJ engine

ftJb

'xhaust tub€ nut 26-36 2.7 - 3.7 20 - 27

:uel hose clamP 1 . 0- 1 . 5 0 . l o - 0 . 15 0.7-1.1
'patk
Plug' zo -zg 2.0 - 3.0 14 - 22

Whenusinga nerar sparkplug,tightenby turning it 112or 314

of a turn after gasketis seated.

MA-51
GONTENTS
FEMOVAL AND INSTALLATION. . - MT- 2
C X - V E H I C LSEE R V I C E .... MT-3
Y A J O RO V E R H A U.L. . . , . M T .4
D I S A S S E M B L YF- S 5 W 7 1 B . MT- 7
f l E P A I RF O R C O M P O N E NPTA R T S - F S 5 W 7 1 B .,..... MT.9
ASSEMBLY-FSsW7IB .... MT.19
S E R V I CDE A T AA N D S P E C I F I C A T I O
. .N
. .S. . ....... MT-21
S P E C I ASLE R V I C T
EO O L S . ........ MT.23
 REMOVALAND INSTALLATION
Removal lnstallation

o Removepropellershaft. . Tightenboltssecuring to engine.

transmission
Referto PD section. Thesebolts havedifferent lengths.
Insert plug into rear oil seal after removing pro- Transmission to engine:
pellershatt. 39 49 N.m (4.0 - 5.0 ks-m,29 ' 36 ft'lb)
-
. Supportengineby placinga lack underoil pan. Gussetto transmission:
29 - 39 N.m (3.0 '4.0 kg-m,22' 29 ft'lbl
CAUTION:
o Be careful not to damagespline, sleeveyoke o gearoil.
with recommended
Fill transmission
and rear oil seal, when removing propeller
shaft.
. Do not placejack underthe oil pandrainplug.

. Removeshift lever.

WARNING:
while removingit.
Srpport ManualTransmission,

MT-2
 SERVICE
ON-VEHICLE
Rear ExtensionOil Seal

MT-3
 : : , : i

MAJOROVERHAUL

Adapter plate

I :.g. s.g
(0.4-0.6.2.9-4.31
Fleverse
lamp switch p r e .z o
11.6- 2.O,
12 - 14'l
Top gearswitch &
{- fDi 1 9 - 2 5
(1.9- 2.s,
B e a r i n gr e r a i n e r
1 4- 1 8 1
'b-
rir", prusEl
gl 2s- 34(2.s.3.s.1s- 251

Transmissioncase

Drainplugp
pl zs. sc{z.s. a.s,ro- zsl
20 - 34 l2.O - 3.5. 14 - 25t

plq ro - zt 11.6- 2.1,12- 151

A thread of bolti Pl : N.m(ks-m,frlb)

sMT358

MT-4
 MAJOROVERHAUL

3rd main gear Needle bearing

fl Gearoit
P,lor bearingfl Gearoit

Snapring

Main drive geer ball bearing

1
,)
Snap ring t

g-spread spring
a--shilring insert

,4.
)
Mainshaft ball boaring
Thrust
@

Mainsh6tt

driv€ gear
lsr & 2nd synchronlzerhub Overdrive
mainshatt I
2nd main gsar 6 bearing
E gearoil ring
ring*
Mainahaft lock nut'
p r s r - r o zt r l . o . 1 7 . or,o t - 1 2 3 1
washer Without soecialtool .1"'

Baulk
rine fl Count€rshett
lock nut'
gea. bushing
Shiftinsinsert-\)a fc|l .
' ' 98 127
.D. (sthl main gear
tro.o- ra.o,zz - gll
Spre6d .pring Reve6e counter gear

Countershattrear end
( bearing
- '
^a Flov6rssmain gpar Overdrivecounter gear

^.",1r-9
O.D. lSth) synchronizer
hubt
Counter rear
tearing

Reverse idler gear

gear spacer

Snap ring

Reverseidler thrust

Reverse idler gear bearing

Roverse idler thrust washer

' Alwavs reolace.
Heverse roler snart
drive gear t * ser€r; with orooer thrckness.
* Pay attention to its direcrion.
Snapring*
N.m lkg-m, f t ' l b l
sM TO!)OA

MT-5
 MAJOROVERHAUL

Striking rod plug p

1.
Expansion
Oilseal

Striking guide

E-ring

O.ring
Stopperguidepin
n
I
lU,- Comrot rever

Return sprihgplug
D Thread of bolr
IJ
I io.rtlr.o.
u.r.,.r,
Lock pin ----\
searoil to o{ing
\ 9
R€turn springI Checkspring-\
n \
plunger g
\
ReturncheckingJ
Strikinglever
E-ring 2.
Conlrol lever
bushing

Controlleverbushing
--F} Control leverpin

Checksp.ing
Check ball
Check plug
El Threadof boh.
p) i9 - 2s (r.9 - 2.5,14- 181

pin
Retaining

lst & 2nd shift rod

lnterlock ball
lst & 2nd shi{t fork

lnterlockplunger pin
Retainin9

3.
R e t a i n i n gp i n

3rd & 4rh shift rod

Check ball
O.D. & teverse
shift fork
3rd & 4th shift fork
Check ball

O-O. & reversefork rod

gl : N.m (ks-m,ft-lbl

SMTO9lA

MT.6
 DISASSEMBLY_FS5W71B

RemoveE-ringandstopperguidepin. Removefront cover,gasket,countershaftfront

bearingshim,and maindrivebearingsnapring.

SMTOl l
Removereturn springplug, return spring,and
plungerfrom rearextension.

5. Separatetransmissioncasefrom adapterplate.

,,iii;.
!tL
1H,

Removerearextensionby lightly tappingit.

6. Set up Tool on adaPterPlate.
i,

MT-7
 DISASSEMBLY-FS5W71B

7. Remove check ball plugs, check springs,and

checkballs.
8. Drive out retaining pins. Then drive out fork
rods and removeinterlockballs.

MT.8
, L
 REPAIRFOR COMPONENTPARTS-FSsW7lB
,-Forks and Fork Rod Gears and Shafts

INSPECTION DISASSEMBLY
r Checkfor wear, scratches,projectionor dam- 1. Eefore disassembly,measureeach gear end
age. play.
o lf end play is not within the specifiedlimit, dis-
assembleand checkthe parts.
o Replace any part which is worn or damaged.

sMTr37

sMT025

End play mm (in)

., '.:1
0.31- 0.37 (0.0r22- 0.0146) ,dl

0.31- 0.37{O.0122 - 0.0146) 1tl.

o . 1 1- 0 . 1 7( 0 . 0 0 4-30 . 0 0 6 7 )
0.32- 0.35 (0.0126- O.O138)
0.05- 0.50 (0.0020- 0.0197)

Mesh 2nd and reverse gear, then draw out

counterfront bearing.

MT-9
li

REPAIRFORCOMPONENTPARTS-FSsW7lB
Gears and Shafts (Cont'd)

J. Removesnapring and draw out counterdrive 7 . Drawout reversecountergearand spacer.

gearwith maindrivegear. U . Removesnapring from reverse
idlershaft,and
draw out reverseidler gear.
gear
Removesnaprings,steelball,speedometer
and bearing.

sMTO23

4 . Remove snap ring and draw out 3rd & 4th

synchronizerand 3rd gear.
TM76O
Releasestakingon countergearnut and main-
shaftnut and loosenthesenuts.
10. Remove mainshaft nut, thrust washer, steel
ball, steelroller,needlebearing,O.D. gearand
baulkring.
11. RemoveO.D. gearbushing,insertretainerand
O.D.synchronizer.

\'M757
Main*f aft nut Left-hand thrmd

b. Pull out counter O.D. gearwith bearing.

MT-1O
\
 REPAIRFORCOMPONENTPARTS-FSsW71B
Gears and Shafts (Cont'd)

Baulkrings
Q. Draw out mainshaftasembly togetherwith
countergear,by tappingrearend of mainshaft o lf found to be deformed,crackedor otherwise
andcountergear. damaged replacebaulk ring-
excessively,

Place baulk ring in position on gear cone.

Whileholdingbaulk ring againstgearasfar asit
will go, measuregap betweenbaulk ring and
gear.
is smallerthan the wear limit,
lf the clearance
13.Removethrustwasher,steelball,and lst gear. replacebaulkring.
Becarefulnot to losesteelball. Baulkring to gearclearance:
14.Pressout lst gearmainshaftbushingtogether Standard
with 2nd gear. lst & 2nd gear
1.00- 1.40mm
(0.0394'0.0551inl
rli
3rd & maindrivegear
. 1.2O- 1.60mm
(0.0472'0.0630in)
O.D. gear
1.00 - 1.40mm
(0.0394-0.0551in)
Wearlimit
lst & 2nd gear
0.5 mm (0.024in)
sr3003r000
3rd & main drive gear
0.8 mm (0.031inl
O.D. gear
0.6 mm (0.024in)
Baulk ring to
gear clearance

INSPECTION
. wear, chips and
Checkall gearsfor excessive
cracks;replaceasrequired.
r Checkshaft for bending,cracksand wear; if
necessary,replace.

MT-11
 REPAIRFORCOMPONENTPARTS-FSsW71B
Gears and Shafts (Cont'd

Shifting insertsand springs o 3rd & 4th

lf worn excessively,
worn unevenly,deformed,or
damaged, replace.

o
ltt
MID q/
t l

o o.D.

Spreedspring

ASSEMBLY
Note:
Apply gearoil to eachpart.
r Needlebearings
o BaulkringF €w
o Shafts
o Gears E?
r Oil seals
O.D. {5th)synchronizer
1. Placeinserts. nuD
. lst & 2nd SMTO9SA

Assemble2nd gearand lst & 2nd synchronizer

then press-1stgearbushingon main-
assembly,
shaft.

MT-12
I
 REPAIRFORCOMPONENTPARTS-FSsW7lB
Gears and Shafts {Cont'd}

3. Assemblelst gear.steelball.and thrust washer 7. Install3rd maingear,and3rd & 4th synchroni-

on mainshaft. zerassembly.
Bsfo.einstallingsteel ball and thrust washerapply Payattention to directionof rynchronizer.
to them.
grease

.-*f

sMTO3r
TM358

4. Installcounterrearbearingto adapterplate. 8. Installthrust washeron mainshaftand secure

5. Pressmainshaftassembly to adapterplateusing it with mainshaftfront snapring-
Tool. Select proper snap ring $at will minimize clear-
anceof groovein mainshaft,

1ll

KV31100401

6. Presscountergearinto adapterplate.

Mainshaftfront snapring:

KV31100401
Apply gearoil to mainshaftpilot bearingand
installit on mainshaft.

MT.13
 REPAIRFORCOMPONENT
PARTS-FSsW71B
Gears and Shafts (Cont'd)

10. Pres counter drive gearwith main drive gear Counterdrive gearsnapring:
usingTool,
Payattention to direstion of counter front gear.

12. Presscountergearfront bearingonto counter

ar"*
f
13. Installidlergearto reverse
idlershaft"

11, Securecounter drive gearwith snapnng.

'Select proper snap ring fiat will minimizeclear-
anceof groovein countershaft.

MT-14
 REPAIRFORCOMPONENTPARTS-FSsW71B
Gears and Shafts (Cont'd

4. tnstall insert retainerand O.D. synchronizer

to mainshaft.
'ay attention to direction of synchronizer.
- Spreadspring
/-
Shiftinqinserr-

bJ&
/

?w
sMTO43
E?
Front

O.D. {sth) sYnchronizer 19. Mesh2nd and reversegearsand tightenmain-

hub SMTO95A shaft lock nut.
o With specialtool
5. lnsull O.D. gearbushingto mainshaft.

ltl,

sMT531

16.InstallO.D. main gear,steelroller and thrust

washerto mainshaft.
17.Install spacer, reversecounter gear and O.D.
countergearto countershaft.
ilain O,D. gear and counter O.D. gear should be
Endledasa matchedset.
rearend bearing.
18.lnstallcountershaft

MT.15
 REPAIRFORCOMPONENTPARTS-FSsW7lB
Gears and Shafts (Cont'd)-
Usingthe followingchart 20.Tightencountergearlocknut.
(Length of torque wrench vs. setting or reading F
p| : 98 -.127N.m
torque)
(10.0- 13.0kg-m,72- 94 ft-tbl
21.Stakemainshaftlocknut andcountergearlock
nutwith a punch.

N.m
(ft-lbl lkq-ml
157
( 161

(r10)
147
(15t . Always usenew lock nuts.

137 22. Measuregear end play. For the description,

1100) ( 1 4 1
refer to Disassembly
of Gearsand Shafts.
127
fi3l

118
112l

108
(1r16: 0.5 0.6 0.7 0.8
rtr

{1.5} {2.01 (2-51{fl}

L: Length of lorque wrench

SMTOO4A

Withoutsoecialtool
gl r37- 167N.m
114.0- 17.O
ks-m,101- 123ft-lb)

MT-16
 REPAIRFORCOMPONENTPARTS-FSsW7lB
Oil Seals Plate

ONT COVER OIL SEAL

o When replacingadapter plate parts, use the
followingprocedures.

DOWELPIN

/^\-
/lr(>
'/ld
q.__-/ (
t
\ o \

unir: mm lin)
Becarefulnot to damagelip of oil seal.

OIL GUTTER
lnstall oit gutter on adapter plate and expand on
rearside.
,,,,rii
!tir
$tl
{,1,

MT-17
--
 REPAIRFORCOMPONENT
PARTS-FSsW71B
-Adapter Plate(Cont'd)
EEARINGRETAINER
1, Insert reverseshaft, then install bearing re-
tainer.

SMTO2A

2. Tighten eachscrew,then stake it at two points.

MT.18
 ASSEMBLY-FSsW71B

lnstall shift rods, interlock balls and check

balls.

Fo.k rod
(1rt & 2nd)

Fork rod
{3rd & 4th}
lnterlock
plun9er

lnterlock
ball

Fo.k rod 2. Apply sealantto matingsurfaceof transmission

{O-D-& R€v.} case.

Slide gear assemblyonto adapter plate

lightlytappingwith a soft hammer.

MT-19
 t,-.4; :; -.
!i,' !:'' i!1.;:1":;

ASSEMBLY-FS5W71B

4. Apply sealantto mating $rface of adaoter Unit: mm (in)

plate.
T h i c k n e s so f s h i m

3.52 - 3.'t1
(o.r386 - O.146r)

3.42,3.51
10.1346- O.13821
0.r {0.0(X1 32218-V5000

3 . 3 2- 3 . 4 1
{ o . 1 3 0 7- O . r 3 4 3 }
0.2 t0.008) 32218-V500
|

3 . 2 2- 3 . 3 1
0.3{0.0r21 322r&V5002
{ o . 1 2 6-80 . r 3 0 3 1

3 . 1 2- 3 . 2 1
0.4 {0.0t6) 322r8-V5003
lo.122a- o.t264l

3.O2- 3.1'l
to.1189 - O.r224)
0.5(0.o?o) 32218-V5004 (
2.92 -3.O1
{ o . r1 5 0 - 0 . 1 1 8 5 1
0.6t0.024) 322r8.v5005

5. Installrearextension.

;
8. Installgasketandfront cover.
9. Installplunger,returnspring,and returnspring
plug.

(9l re - zr lt.-
{1.6 - 2.1 kg-n,
12 - 15 rt-rb)

sMT36a

6. Fit maindrivebearingsnapring.
7. Selectcountershaft
front bearinoshim.

1 Plunger
Return spr;ng
sMT366
3 R e t u r n s p r i n gp l u g

A : D i s t a n c ef r o m b e a r i n g
surface 1s 116n5nr;551aa 10. Apply sealantto stopperguidepin, then install
stopperguidepin and E.ring.

1 Transmission case
2 C o u n t e r g e a rf r o n t b e a r i n g
3 Countergear

TM371

MT-20
i
\..-r.
 SERVICEDATAAND SPECIFICATIONS
General Specifications Inspection and Adiustment

FS5W718
GEAREND PLAY
Instnisiion model
mm (inl
CA18ET, FJ20E
,in. CA20E lst maingear 0.31- 0.3710.0122 - o.0r46l
znd main gear o.31- 0.3710.0122 -o.or46)
h pattern 3rd main gear o.l I - 0.17to.oo43- 0.0067l/
O.D. gear o.32- 0.35(0.0r26- 0.0138)
R€veraeidler gear 0.0s- 0.5010.00m- 0.01971

CLEARANCEBETWEENBAULK RING
AND GEAR
mm (in)
rchromeshtYPe
Standard
lst & 2nd gear 1.00- 1.40(o.o394- 0.05511
lst 3.592 3.321 3rd & main drive gear I.20 - 1.50{0.0472- 0.0591)
2nd 2.O57 1.902 O.D.gear L00 - r.40 (0.0394 - 0.os51)
3rd r-361 1.308
4th 1.000 1.000 Wearlimit
oD 0.9r3 0.833 lst & 2nd 0.6 (0.024)
Reverse 3.657 3.382 3rd & main drive gea. o.8 (0.0311
O.O.gear 0.6 (0.024)
mber of teeth
tvGindrive gear 2l 22
MaingEar lst 33 33
2nd riil
3rd 26 Availablesnapring i{!ll
o.D. 24 {,t,
Revelse Main drive gearbearing

32 31 Thickn6i mm linl Pan number

Counterdriva gear
'lst 14 14
Countergear 32204- 78005
20 m r.73 (0.0681)
r.80 (0.0709) 32204- 78000
3rd 2a 2A
1.S7{0.0736) 32204- 78001
o.D. 45 44
't5 r .94{0.07641 32204- 7aOO2
heverce
2.01t0.0791t 32204- 79003
Reverseidler gear 21 21
2.08(0.o8r9) 32204- 78004
capacity liter llmp ptl 2.1 13-3141

Mainshaftfront

Thicknessmm {in) Partnumbea

r.4 (0.o55) 32263- E9000

1.5(0.059) 32263- E9001
1.6(0.063' 32263- E9002

Mainshaftrear end bearing

Thicknessmm{in} Part number

1.1(0.0431 32224 - 20100

r.2 {0.047} 32228 - 20101
r.3 l0.os1) 32228 - 20102
1.4(0.05s) 32228 - 20103

MT.21
 SERVICEDAtrAAND SPECIFICATIONS
-lnspection and Adjustment TighteningTorque-
(Cont'd)
TRANSMISSION
INSTALLATION
Counter drive gear
Unit N.m xg{n
Thickness mm (in)
Clutch operatingcytioder 30-40 3.f - 4.t 22 -30
1.4{O.055) 32215- 89000 Transmissionto eogine
r.5 10.0691 39.49 4.0 - 5.0 29 - 36
3 2 2 1 5E
- 9001
r.6 (0.0631 Guss6tto transmi3sion 29 -39 3.0 .4.o
32215- E9002 22.29
Crossrnember to body 3 1- 4 2 3.2 - 4.3 23 - 31
Rearmountinginsulator 3l -42 3 . 2. 4 . 3 23- 31
Availableshim to cro$member

Counter front bearing

Rearlnounting insulator 3 1- 4 2 3.2 - 4.3 23 - 3l
lo reaaexlension
Unit: mm (inl
Transmissio^caseto 1 6- 2 1 1 . 6. 2 . 1 1 2- 1 5
tear extenSton
L,4 Starteamotoa to 29-39 3.0 - 4.0 22 - 29

ffiffi
L
fl
.'
A: Distancefrom bearing
surfaceto transmission
transmitsion

ffiir-
Edirffi
1 Transrnission
case GEARASSEMBLY
qflffi 2 Countergearfront bearing
3 Countergear kg-m ft-tb
Q==- TM37l
Eerring retainerto 19-25 1.9-2.5 14-18
adaprorptale
Part number
Mainshaftlock nut 't37 -
167 14.0. t7.O lol - 123
3.52- 3.71{0.t396- o.t46t) Not necessary Countergearlock nut 98 - t27 10.0- 13.0 72 - 94
3.42 - 3.51 (0.1346- 0.1382) Rearext€nsionto 1 . 6- 2 . 0
0.1 (0.004) 32218- V50oo 16.20 12-14
3.32 - 3.41 (O.1307- O.1343' o.2 (0.008) transmisdoncase
322r8- V5001
3-22- 3.31 (O.t268- 0.13031 o.3 (0.012t 3221A- V50,O2 16.21 1 . 6- 2 . 1 1 2- 1 5
3.12 - 3.21 lO-122A- 0.1264' 0.4 (0.0r61 322tA- V5003 transmissioncase
3.O2. 3.11 (0.1189- O.12241 0.5 (0.020) 32218- VfiO4 Fillerplug 25-34 2.5- 3.5 1a -25
2 . 9 2- 3 . 0 r ( 0 . 1 1 5 0 - 0 . | 1 8 5 1 0.6 (0.0241 32218.V5005
Drain plug 25-34 2.5- 3.5 18- 25
Ball pin 20 -34 2.0.3.5 1 4- 2 5
Striking lever lock nut 9-12 0.9- 1.2 6.5- 8.7
Checkball plug 19- 25. 1 . 9- 2 . 5 1 4- 1 8
Speedometsrsleeve 4-5 0.4 - 0.5 2.9- 3.6
installation
Back-uplamp srwitch 20-29 2.0- 3.0 t4 -22
Return springplug 8- r0 0.8- 1.O 5.8-7.2

MT-22
 SPECIALSERVICETOOLS

': Specialtool or a commercialequivalent

Tool number

sT23810001 Adapter setting plate

KV31100300' Fork rod pin punch

KV32101330 gearingpuller

sT30031000' Bearingpuller

KV311qr401 Transmissionpressstand o
,lrii,"
o ulli.
.!fi,

sT23860000' Counter gear drift

sT22360002'

sr22520000

sT22350000' Main*raft bearingdrift

sT23800000' Transmissionadapter

MT-23
SPECIALSERVICETOOLS

MT-24
 !.
!r I Bi

tt
UJ
IJJ
o
N =

ot
J ('
u,l
tt 5 i
::
= ii :
E :t
zf F

.A o
q G,
zo
;
ai I
i:
ai I

E
:!d

@
 E !:
t
g
i?i

I
i
t. 6

+u,."dfl
;
!!

3 E
:e
#E
g E.
E!
:;
E:

!i ii
i E ::
i ;
-
! I I E
3 5 ii I 3-
!;
-*,*^,--^..J

li.
trt

ti
l!E
li"
 t-"
!ii

::
:i

il.
r.tf l:!:E

ltla
li.
 -r@

i
q

I ;! i! 3
;;

: ?q
:"1
;!:'.

:"^,.^,.^r;
",

i :

t :2 6 3i
g: 1\ i\
EE