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I
DATSUN
I
0
o
1980
DATSUN
200
SX
rl1
SERVI CE
MANUAL
A
J
i
I
I
h
t
fi
t
i
t
i
CI o
I I V
I NI 55ANI
HlUM lOco
QUI CK
REFERENCE
I NDEX
GENERAl
I NFORMATI ON
GI
DATSUN
200SX
MAI NTENANCE
M
ENGI NE
MECHANI CAL
E
Model
S J JOSeri es
ENGI NE LUBRI CATI ON
COOLI NG
SYSTEMS LC
ENGI NE FUEL
i F
FOREWORD
EMI SSI ON
CONTROL
SYSTEM
E
Thi s servi ce manualhas been
prepared pri
mari ly
forthe
purpose
of
assi sti ng
servi ce
personnel
i n
provi di ng
effecti ve servi ce and
mai ntenance
ofthe
1980DATSUN
200SX
ENGI NE
REMOVAL I NSTALLATI ON
E
ENGI NE
CONTROl
FUEL
EXHAUST SYSTEMS
F
Thi s manuali ncludes
procedures
formai n
tenance
adjustments
removaland i nstalla
ti on
di sassembly
and
assembly
of com
ponents
and trouble
shooti ng
Alli nformati on i llustrati ons
and
speci fi ca
ti ons
contai ned
i n thi s
manualare based on
the latest
product
i nformati on avai lable
at
the ti me
of
publi cati on
I f
your
DATSUN
model
di ffers
from the
speci fi cati ons
con
tai nedi nthi smanualconsult
your
NI SSANI
DATSUN dealerfori nformati on
CLUTCH
C
MANUAL TRANSMI SSI ON
M
AUTOMATI C
TRANSMI SSI ON
A
PROPELLER SHAFT DI FFERENTI AL
CARRI ER P
FRONT AXlE
FRONT SUSPENSI ON F
The
ri ght
i s reserved to
make
changes
i n
speci fi cati ons
andmethods
at
any
ti me
wi th
out noti ce
REAR AXLE
REAR SUSPENSI ON
R
BRAKE
SYSTEM
B
STEERI NG SYSTEM
S
NI SSAN MOTOR CO
LTD
BODY
B
HEATER AI R CONDI TI ONER
H
@
t
979
NI SSAN
MOTOR CO
LTD
Pri nted
i n
Japan
Not
tobe
reproduced
i n
whole ori n
part
wi thout
the
pri or
wri tten permi ssi on
of Ni ssan Motor
Com
pany
Ltd TokyoJapan
ELECTRI CAL SYSTEM
E
v
w
I
HOW
TO
USE
THI S MANUAL
Thi sServi ceManuali s
desi gned
as a
gui de
for
servi ci ng
cars
Thi s manuali s di vi dedi nto
19secti ons The fi rst half
of
themanual
presents
secti onswhi ch
concern
the
engi ne
andthesecond
half
presents
secti onswhi chdeal
wi th
thechassi s and
body
A QUI CK REFERENCE
I NDEX i s
provi ded
on
the fi rst
page
Refertothi si ndex
along
wi th
the
i ndexof the
parti cular
secti on
you
wi shto
consult
Thefi rst
page
of each
secti on li sts thecontentsand
gi ves
the
page
numbers forthe
respecti vetopi cs
SE
RVI Cr
DATA ANDSPECI FI CATI ONS arecontai ned
i n eachsecti on
TROUBLE DI AGNOSES
AND
CpRRECTI ONS
are alsoi ncluded i n eachsecti on Thi s
featureofthe
manual
li sts
the
li kely
causesof troubleand recommends the
appropri ate
correcti veacti ons
to
be
taken
A
li st of
SPECI ALSERVI CE TOOLS i si ncluded
i n
eachsecti on
The
speci al
servi ce
tools
are
desi gned
to
assi st
you
i n
performi ng repai r
safely
accurlltely
and
qui ckly
For
i nformati on
concerni ng
howto
obtai n
speci al
servi cetools wri tetothe
followi ng
address
Kent Moore
Corporati on
Kent Moore of
Canada Ltd
29784Li ttle ack 2395
Cawthra
ROevi lle
Mi chi gan
48066
Mi ssi ssauga
Ontari o
Canada L5A 3P2
Themeasurements
gi ven
i n thi smanual
are
pri mari ly expressed
wi th
the
Sluni t I nternati onal
System
of
Uni t
and
alternately
expressed
i n
themetri c
system
andi n the
yardpound
system
The
back
coverof
themanual
provi des
mai ntenancedatafor
qui ck
reference
I n thetext the
followi ng
abbrevi ati ons
are
used
sos Servi ceData nd
Speci fi cati ons LH
R
H
left
Hand Ri ght Hand
fJ
Ti ghteni ng TorQue MOrrAi T Manual
Transmi ssi on Automati cTransmi ssi on
The
capti ons
CAUTI ON and
WARNI NG
warn
you
of
steps
that must
befollowedto
prevent
personal
i njury
and
or
damage
to
somepart
of the
car
N
I MPORTANT
SAFETY NOTI CE
I
The
properperformance
of
servi ce
i s
essenti alforboththe
safetY
of themechani candtheeffi ci ent
functi oni ng
ofthecar
The servi ce methodsi n thi s
Servi ce
Manual
are
descri bed
i n
such
a
manner
that theservi ce
may
be
per
formed
safely
and
accurately
Speci al
servi ce tools have been
desi gned
to
permi t
safe and
properperformance
of
servi ce
Be
sureto
usethem
Servi ce
vari es
wi th
the
procedures
used the
ski lls of
themechani cand
the
toolsand
parts
avai lable
Accordi ngly anyoneusi ng
servi ceprocedures
toolsor
parts
whi ch
are
not
speci fi cally
recommended
by
NI SSAN
must fi rst
completely
sati sfy
hi mself that
nei ther
hi s
safety
nor
thecars
safety
wi ll
be
jeopardi zed
by
the
servi cemethod
selected
DATSUN 200SX
ModelSI lO
Seri es
SECTI ONGI
GI
GENERAL
I NFORMATI ON
CONTENTS
GENERALVI EWS
MODELVARI ATI ON
I DENTI FI CATI ON
NUMBER
LI FTI NG
POI NTS AND
TOWI NG
PANTOGRAPH
JACK
GARAGE
JACKAND
SAFETY
STAND
GI 2
GI 3
GI 4
GI
5
GI 5
GI 5
TI E DOWN
TOWI NG
SPECI AL SERVI CE TOOLS
TI GHTENI NG TORQUE
OF
STANDARD
BOLT
GI 5
GI 5
GI 6
GI 6
Genetal
Vi ews
GENERAL
I NFORMATI ON
Hardtop
l
I
r
I O
I I
JI 1
Po
dI
V
Ll34S S30
1
680
661
ll
r
lU
I
11
hF
oi
11
LI
345 53O
J
1 680661
Uni t
mm
i n
Hatchback
t
c
i q
L1 345 530
1
68066
1
Uni t
mmi n
GI 2
GENERAL VI EWS
J
c
f
1
11
I
I
r
L
1
m
41
f 1
1
g
t
I
ll
t
X
990390
2 40094
5
1
090429
480 176 4
SGI OO2
fT
d
r
I i
r
bt
I
I
J
I
t
i L
L
J J
I
I
J
J
r
1
t
uJJ
I l
I Y
1
T
2 400
945 t 090429
4480t 76 4
990390
5GI 003
GENERAL I NFORMATI ON
Model
Vari ati on
MODEL VARI ATI ON
Desti
Di fferenti al
Road
wheel
nati on
Class
Model Engi ne Transmi ssi on
carri er
Si ze
Offset
Ti resi ze
mm
i n
PI SI I OFEV
FS5W71B
Hardtop
PLSI I OAEV
I
3N71B
Cali forni a
KPLSI lOFEV
I
5J
14
25
185
FS5W71B
Hatchback
0
98
70
SR
14
KPLSllOAEV
I
3N71B
U
S A
PLSI l
OFEU
I
FS5W71B
Hardtop
I
I
PLSllOAJ i U
3N71B
5 1 2JJ
14
25 185
Z20E HI 65B
KPLSllOFEU
I
FS5W71B
098
70
SR14
Hatchback
Non
I
KPLSI I OAEU
I
3N71B
Cali forni a
I
PLSllOFEN
I
FS5W71B
Hard
top
I I
2
PLSllOAEN
3N71B
4Tx
16
35
T135
Canada
I
KPLSllOFEN
I
FS5W7I B
138 70D16 2
Hatchback
I
KPLSllOAEN
I
3N71B
Prefi xandsuffi x
desi gnati ons
K
o
P
L
Hatchback
I
Hardtop
J
Z20
engi ne
Left handdri ve
K P
L
SI lO J
I
0
PST
LT
0
means no
i ndi cati on
I
Alumi numwheel
Opti on
2
Spare
ti re
Sunroof Glass
Sport Luxury
model
Power
steeri ng
Sun
roof Steel
Rearwi ndow
wi per
Ai r
condi ti oner
Non Cali forni a model
for
U
S
A
V Cali forni amodel
N Canada
model
E E Fl
F Manualtransmi ssi on
S
P
R
L
C
U
A
Automati c
transmi ssi on
GI 3
I denti fi cati onNi Jmber
GENERAL I NFORMATI ON
CAR SERI AL NUMBER
PLATE
CAR SERI AL
NUMBER
Hatchback
Z20
engi ne
Model
ENGI NE
SERI AL
NUMBER
The
engi ne
seri a numberi s
stamp
ed on
the
left si de of the
cyli nder
block
I
Q
SGI OO6
GI 4
I DENTI FI CATI ON NUMBER
EMI SSI ON CONTROL
I NFORMATI ON LABEL
K
P
SlI D
r
x X X X X X
I
MANUAL TRANSMI SSI ON
NUMBER
The
transmi ssi on
seri a number
i s
stamped
on
thefront
upper
faceofthe
transmi ssi on case
TM235
SGI 004
Carseri alnumber
AUTOMATI C
TRANSMI SSI ON
NUMBER
The
transmi ssi on seri al number
plate
i s
attachedon
the
ri ght
handsi de
of
the
transmi ssi on
case
AT344
GENERAL
I NFORMATI ON
Ufti ngPoi ntsand
Towi ng
LI FTI NG
POI NTS
AND TOWI NG
Towi ng
hook
UL
I W I
@
A
@
Ii l
Towi ng
hook
Jack up poi nt
for
pantographjack
Jack
up poi nt
for
garage
jack
Supportablepoi nt
for
safety
stand
PANTOGRAPHJACK
WARNI NG
a Never
get
underthecar
whi lei t
i s
supported only by
the
jack
Always
use
safety
stands to
support
framewhen
you
haveto
get
underthe
car
b Place
wheelchocks at bothfront
andback of thewheel
di agonally
opposi te
the
jack posi ti on
Apply
the
pantograph jack
fur
ni shed
wi ththe
car
tothe
posi ti on
i ndi cated
below i n a safe manner
t
GARAGE JACK
AND
SAFETY
STAND
WARNI NG
a
When
carryi ng
out
operati ons
wi ththe
garage jack
be sureto
support
the carwi th
safety
stands
b
When
jacki ng
up
therearfront
of
the car
place
thechocks at
the
front rearof the
front
rear
wheels toholdthem
CAUTI ON
Always
place
a
wood block between
safety
stand
and car
body
when
supporti ng body
wi th
safety
stand
Apply
the
garage jack
and
safety
stand tothe
posi ti on
i ndi catedbelow
i n
a safe manner
TI E DOWN
FRONT SI DE
Use
front
towi ng
hooks
forti e
down
REAR
SI DE
Userear
towi ng
hooks
for
ti edown
TOWI NG
CAUTI ON
a
I t i s
necessary
touse
proper
towi ng
equi pment
to
avoi d
possi ble
dam
age
to
the car
duri ng
a
towi ng
operati on
Towi ng
i s i n accordancewi thTow
i ng
ProcedureManualat dealersi de
Towi ng
hook
7
r
J
@
I I
1I
6
Towi ng
hook
SG
1007
b All
appli cable
State orProvi nci al
i n
Canada laws
and locallaws
regardi ng
the
towi ng
operati on
must be
obeyed
c Before
towi ng
make
sure
that the
transmi ssi on
axles
steeri ng system
and
power
trai n are i n
good
order
I f
any
uni t i s
damaged
a
dolley
must
beused
d
I f
the
transmi ssi on i s
i noperati ve
tow
thecarwi ththerearwheels
off
the
ground
orwi ththe
propeller
shaft removed
e When thecar
i s towedwi thi ts front
wheels
on the
ground
secure the
steeri ng
wheeli n a
strai ght
ahead
posi ti on
wi th the
i gni ti on
key
turnedi n
OFF
posi ti on
f When
towi ng
an automati c
trans
mi ssi on modelon i ts rear
wheels
donot exceed 30
km h20
MPH
anda
di stanceof
30
km 20mi les
g
Release the
parki ng
brake and
set
the
gearshi ft
leveri n
Neutral
posi ti on
before
starti ng
totowthe
car
GI
5
Speci a Servi ce
Too
s
Ti ghteni ng
TO 1ueofStandardBolt
GENERAL
I NFORMATI ON
SPECI ALSERVI CE TOOLS
Speci al
Tools
play very i mportant
role i n
the
mai ntenance
ofcars These
are essenti alto
thesafe
accurate
and
speedy servi ci ng
The
worki ng
ti mes
li sted
i n the
column under
FLAT RATE TI ME i n
FLAT RATE
SCHEDULE
are com
puted
based on the
use of
Speci al
Tools
The
i denti fi cati on
code of
mai nte
nancetools
i s
made
up
of2
alphabeli
calletteI Sand 8di gi tal
fi gures
The
headi ng
twoletters
roughly
classi fy
toolsor
equi pment
as
STOOOOOOOO
Speci al
Tool
KVOOOOOOOO
Speci al
Tool
EMOOOOOOOO
Engi ne
Overhaul
i ng
Machi ne
General
Gauge
Garage
Tool
HandTool
GGOOOOOOOO
LMOOOOOOOO
HTOOOOOOOO
TI GHTENI NG TORQUE OF
STANDARD
BOLT
Grade Bolt ornut si ze
M6
M8
4T
MI O
MI 2
MI 4
M6
M8
7T
MI O
MI 2
MI 4
M6
M8
9T
MI O
MI 2
MI 4
1
Speci alpamare
excluded
2
Thi s
standardi s
appli cable
tobolu
havi ng
the
followi ng
marksembossed
onthebolt head
Grade
Mark
4T
7T
9T
GI
6
Bolt
ornut di am
eter
mm
Pi tchmm
60
1
0
125
1
0
15
125
175
125
15
1
0
125
1
0
15
125
175
125
15
10
125
10
15
125
175
125
15
80
10
0
12
0
140
6
0
8
0
10
0
12
0
140
60
80
100
120
140
Nomi naldi ameter
4
7
9
M6
TT
Ti ghteni ng torque
N m
kg
m
ft
I b
29 3
9 030
4 2 2 2 9
78 108 08 Ll5 8 8
0
7
8
10
8 08 Ll5 8 80
16 22 16 2 2 12 16
16 22
1
6
2 2 12 16
26
36 27
3 7
20
27
30403
1 41
22 30
46 62 4
7 63
34 46
5
9 69
0
6
0
7
43
51
I
14 18
1
4 1
8 1013
I
14
18 14
18
1013
I
25
35 2
6
3 6
19 26
I
26 36
2 7
3
7
20
27
I
45 61
4
6
6
2 33
45
I
5068 51
69 37
50
L
76
103
7 7
10
5
56 76
I
78
10
8 O 115 8 8
0
I
19
25 1
9 25 14 18
I
20
27 20
2
8
14 20
I
36 5037
51
27
37
I
39
51 4
052 29 38
I
65 88 66
90
48 65
I
72 97
73
9
9
53 72
I
109
147
11 1
15
0
80108
Nomi naldi ameterofbolt threads Uni t
mm
Metri cscrewthreads
DATSUN
200SX
Model
SJ
J 0Seri es
I I
MAI NTENANCE
CONTENTS
MAI NTENANCE SCHEDULE
MA
2
MANUAL TRANSMI SSI ON
MA
23
LUBRI CATI ON CHART
MA
4
AUTOMATI C
TRANSMI SSI ON MA 24
RECOMMENDED
FUEL AND
PROPELLER SHAFT
AND
LUBRI CANTS
MA 5
DI FFERENTI AL
CARRI ER
MA 24
FUEL
MA 5
FRONT AXLE AND
LUBRI CANTS
MA 5
FRONT SUSPENSI ON
MA 24
SAE
VI SCOSI TY
NUMBER
MA 5
REAR AXLE
AND
APPROXI MATE
REFI LL
REAR SUSPENSI ON
MA 27
CAPACI TI ES
MA
5
BRAKE
SYSTEM
MA 28
ENGI NE
MAI NTENANCE
MA
6
WHEEL AND TI RE
fVlA 29
BASI C MECHANI CAL
SYSTEM
MA
6
STEERI NG
SYSTEM MA 33
I GNI TI ON
AND FUEL SYSTEM
MA 9
BODY
MA
35
EMI SSI ON CONTROL
SYSTEM
MA 14 HEATER
AND AI R
CONDI TI ONER
MA 36
MI NOR TROUBLE
DI AGNOSES SERVI CE
DATA
AND
AND
CORRECTI ONS
MA 15
SPECI FI CATI ONS
MA39
CHASSI S
AND
BODY
ENGI NE
MAI NTENANCE
MA
39
MAI NTENANCE
MA 23
CHASSI S
AND
BODY
ENGI NE
CONTROlFUEL MAI NTENANCE
MA 39
AND EXHAUST
SYSTEMS MA 23
SPECI AL
SERVI CE TOOL
MA 40
CLUTCH
MA 23
Mai ntenanceSchedule
MAI NTENANCE
MAI NTENANCE
SCHEDULE
The
followi ng
tabels li st
the
peri odi c
mai ntenance
servi ci ng requi red
toensure
good
emi ssi oncontrol
performance good
engi ne performance
and
good
mechani calcondi ti on i nDATSUN
Thefi nt 1 600km
11 000mi les servi cei soneof themost
i mportant
servi ces
ui red
to
nsurw the
maxi mum mi ssi oncontrol
perfonnlnce
and
opti mui nengi ne
con I i ti on
MAI NTENANCE
OPERATI ON
MAI NTENANCE
I NTERVAL
Peri odi cmai ntenanceshouldbe
performed
Ki lometers
x
1000 16 t2
24 36 48 60 72
at numberof ki lometers mi lesormonths
Ref
rence
whi chever
comes
fi rst
Mi lesx1
0001
1 7
51 t51 225 301 375
451
page
Months 6
t2 t8 24 3D 36
I ntake exhaust valveclearance
Dri ve
belts
En ui ne
oi l oi l
fi lter
Engi necoolant
I dle
rpm
Fuelfi lter
Fuel
li nes hoses
pi pi ng
connecti ons etc
Ai rcleanerfi lter
Spark plugs
EMI SSI ON
CONTROL MAI NTENANCE
@
CALI FORNI A
@ @
j
A
So NOTE 111 R RO R R R
RO
@
So NOTE
131
I
SooNOTE
121
@
@
I gni ti onwi ri ng
Ai ri nducti on v8lvfi lter
Vapor
li nes
NOTE
I I I
121
131
41
So NOTE 121 R
@
MA 6
MA
6
MA 7
MA 8
MA 12
MA 13
MA 13
MA 14
MA 9
MA 9
MA t4
MA t4
RO
Abbrevi ati ons A
Adjust A
Replace
I I
nspect correct replace
i f
necessary
I f
nhi clai s undersevercondi ti ons
short
di stance
dri vi ng
extensi ve
i dli ng
or
dri vi ng
i ndusty
condi ti ons
change
engi ne
oi l
every
5 000km
3000mi les
or3
months whi chever
comes
fi rst
More
frequent
mai ntenance
i s
requi red
und
dusty dri vi ng
condi ti ons
I fthevehi clei s
operated
underextremeadverseweathercondi ti ons or
i n
ars
whereambi ent
temperaturas
are
ei ther
extremely
low
or
extremely hi gh
thefi lter
mi ght
become
clogged
I nsuchan
event replace
the fi lt
i mmmi atefy
D @
an
@
arethemai ntenancei ntervals
requi red
by
Cali forni a
Regulati ons @
li mi tsthewarranty
COYI I tothesere
placement
I nterYals andR the ui redmai nUNI ncei ntervals
Othermai ntenancei temsandi ntervalsarerecommended
by
NI SSAN
MOTOR COLTO
EMI SSI ON CONTROL MAI NTENANCE
NON CALlFORNI A
1
A A
I
R R
R
A
I ntake
exhaust valveclearance
Drjvebel
s
Engi ne
oi l oi lfi lter
Engi ne
coolant
I dle
rpm
mi xture
rati o
Fuel
fi lter
Fuelli nes hoses
pi pi ng
connecti ons
etc J
Ai rcleanerfi lter
I gni ti on ti mi ng
Spark plugS
So NOTE
151
R
R R
I dle
rpm
A A
Mi xturerati o
Soo
NOTE 7
So NOTE
161 R
A
R
I
R
A
I gni ti onwi ri ng
Ai ri nducti on valvefi lter
except
Canada
Vapor
li nes
MA
2
SooNOTE
61
A MA 6
MA
6
MA 7
MA 8
MA
l0
MA l0
MA 13
MA 13
MA t4
MA l0
MA 9
MA 9
MA 14
MA 14
R
A
A
51
161
171
81
Abbrevi ati ons
A
Adjust
R
Replace
I
I nspect
correct replace
i f
necessary
I fvehi clei s
operated
undersenre
condi ti ons short di stance
dri vi ng
extensi ve
i dli ng ordri vi ng
i n
dusty
condi ti ons
chenge
engi ne
oi l
every 5000
km 3
000mi les
or
3months whi chner
comes
fi tst
Mor
frequent
mai ntenancei s
requi red
undar
dusty
dri vi ng
condi ti ons
I fthevehi clei s
opemed
underextreme
adverseweathercondi ti onsori n
areas
whereambi ent
temperatures
areei ther
extremely
lowor
extremely hi gh
the
fi lter
mi ght
become
dow l
I n suchI I n event
replacethefi lter
i mmeduty
Mai ntenancei temswi th
are
recommended
by
NI SSANMOTOR COLTO
Other
mai ntenancei temsI fll
requi red
MAI NTENANCE
Mai ntenance
Schedule
Peri odi c
mai ntenance
shouldbeperformed
at numberof ki lometers
mi les
or
months
whi chevercomes
fi rst
MAI NTENANCE I NTERVAL
Ki lometers
x1 000 16 t2 24
36 48 60 72
Reference
Mi les
x1
000 I I I
17 5 I t51 122 51 130 137 51
451
page
Months
6 t2 t8 24 30 36
MAI NTENANCE OPERATI ON
UNDERHDOD
MAI NTENANCE
Brakeflui d
Brakebooster
vacuumhoses
connecti ons check valve
Ai r
condi ti oni ng system
hoses
connecti ons
refri gerant
leaks
Power
steeri ng
flui d
li nes
R
MA 23 24
28 33
R R MA 28
MA 28
MA J7
I
I
MA
33
Brake clutchsteeri ng
gear
automati c
transmi ssi on flui dor
ci llevel
leaks
UNDER
VEHI CLE
MAI NTENANCE
Brake
clutch fuel exhaust
systems
for
proper
attachment leaks cracks
chafi ng
abrasi on deteri orati on
etc
MA 2328
Manualtransmi ssi on
di fferenti al
gear
oi l
SeeNOTE
19
MA 23
24
MA
2427
34
Steeri ng gear
box li nkage suspensi on parts propeller
588 NOTE 10
shaft
for
damaged
loose
mi ssi ng parts
Underbody
flush
and
clean
every
12 months
OUTSI DE
AND I NSI DE MAI NTENANCE
Rotatewheel
posi ti on
nspect
wheelbalance
wheel
ali gnment
MA2630
32
yJ
Di scbrakepads
other
brake
components
for
wear
deteri orati on leaks
SeeNOTE
111
MA 28
Front wheel
beari ng
MA25
Locks
hi nges
hood
latch
Seat betts buckles
retractors anchors
adjuster
Foot
brake
parki ng
brake
clutchforstroke free
play operati on
SeeNOTE 11 L
L L MA 35
MA35
MA
23 28
Abbrevi ati ons
R
I
Replace
L
Lubri cate
I nspect
correct replace
i f
necessary
NOTE 91 When
towi ng
atrai ler
change
oi li ndi fferenti al
gearevery
48000km 30
000mi les or24months
whi chevercomesfi rst
10
Steeri ng li nkage
front
suspensi on
ball
joi nt i nspecti on
shouldbe
performedevery
96000km 60000mi les
or4
years
whi chever
comes
fi rst
111
I fvehi clei s
operated
i n
areas
usi ng
road salt
or
othercorrosi vemateri als
i nspect every
5 000km 3000mi lesl
or3
months
whi chevercomesfi rst
The
abovechartsshow
thenormalmai ntenanceschedule
Dependi ng upon
weatherand
atmospheri c
condi ti ons
varyi ng
roadsurfaces
i ndi vi dual
dri vi ng
habi ts andvehi cleusage
addi ti onal
orore
frequent
mai ntenancemay
be
requi red
MA
3
3
0j
f
li Sl
CHANGE
ll
CHECK
LUBRI CATE
QI Q
GREASE
UP
ENGI NE ANTI FREEZE
COOLANT
n
FRONT
WHEEL
BEARI NGn
CLUTCH
FLUI O
BRAKE
FLUI O
6
STEERI NG
GEAR
OI L
LOCKS
HI NGES
81
@
HOOD
LATCH
DI FFERENTI AL
GEAR
OI L@
@
I f
vehi cle
i s
operated
i n
ereai
u
i ng
road
salt
or
other
corrosi ve
materi al
i nspect
every
6
000
km
3
000
mi le
or
3
month
whi chever
cornel
fi l lt
km
mi la
Month
EVERY
411
000130
000
@
EVERY
24
000
115
000
@
1
L
@
When
towi ng
lI
trai ler
change
011
i n
di fferenti al
gear
every
48
000
km
30
000
mi les
or
24
onth
whi chever
cornel
fll lt
@
I f
the
vehi cle
i
operated
under
extreme
adverse
wheather
condi ton
or
i n
erel l
where
ambi ent
temperature
lI re
ei ther
extremely
low
or
extreme
I V
hi gh
the
fi lter
mi ght
become
cloggltd
I n
such
an
event
replI Ce
the
fi lter
I mmedi atelv
BATTERY
ELECTROLYTE
WI NDSHI ELD
AND
REAR
WI NDOW
WASHER
FLUI D
@
FUEL
FI LTER
POWER
STEERI NG
GEAR
OI L
@OI LFI LTER
@ENGI NEOI L
MANUAL
TRANSMI SSI ON
AUTOMATI C
TRANSMI SSI ON
@
I f
vehi cle
i
operated
under
sevare
condi ti ons
short
dluance
dri vi ng
extensi ve
i dli ng
or
dri Vi ng
dusty
condi ti ons
change
engi ne
oi l
every
6
000
km
3
000
mi les
or
3
months
whi chever
comes
1111t
I cmJJ obo 5
Z
ctg
I
3 ZlmZ znm
2JJ
Recommended
Fuel
andLubri csnts
MAI NTENANCE Approxi mate
Refi ll
Capaci ti es
RECOMMENDED FUEL
AND LUBRI CANTS
FUEL
Usean unleaded
gasoli ne
only
ofat least 91 research
octanenumber
Anti
knock
i ndex87
Underno
ci rcumstances should
a leadedfuelbe
used i nce thi swi ll
damage
thecatalyti c
converter
LUBRI CANTS
SAE VI SCOSI TY
NUMBER
Lubri cant Speci fi cati ons
Remarks
Gearoi l
Transmi ssi on
and
steeri ng
API
GL4
Further
detai ls refer
to
recommendedSAE
vi scosi ty
chart
ENCEOI L
I
I I I I
0
I
I CM
211
JGI I f4l
I
t
l
1 lo
r
Gasoli ne
engi ne
oi l
API SE
Anti freeze Ethylene
glycol
base
I I
I
or
vrJ
dri
I
I
II
l
I
IrIII1
I1II
I
III
r
1
I
I
40
I
I
I
I I
1 1 TI
c
nI I OlI l ll4OlllC11lllllll101 11 F
T Jl
Nut
OCh
Di fferenti al API GL
5
Automati c
T Mand
power
steeri ng
flui d
Type
DEXRON
Multi
purposegrease
NLGI
No
2 li thi um
soap
base
Brakeandclutch
flui d DOT
3
US FMVSS
No116
APPROXI MATE
REFI LL
CAPACI TI ES
li ter usmeasure
I mp
measure
Fueltank
Hardtop
53
14gal
I I 5
8
gal
Hatchback 60
15 7
8
gal
13 1 4
gal
Coolant Wi thheater 9
5
I Oqt
83
8qt
Wi thout heater
88 9
1
4qt
7 3 4
ql
Engi ne
Wi thoi lfi lter
41 43 8
qt
3
5
8qt
Wi thout
oi lfi lter
3 9 41
8
qt
3
3 8
ql
Transmi ssi on
MT
20
41 4
pt
3 1
2
pt
A
T 55
5 7 8
qt
47 8
qt
Di fferenti alcarri er 11
2 3 8
pi
2
pt
Power
steeri ng
system
1
2
11
4ql
I 1 8
ql
Steeri ng
gear
028
5 8
pt
1 2
pt
Wi ndshi eldwasher
tank
20 21
8
ql
13
4qt
Rear
wi ndowwasher
tank
10
1 1 8
qt
7
8
qt
Ai r
condi ti oni ng
system Compressor
oi l 027 91fOZ
9
0
oz 95f
OZ
90oz
Refri gerant
09
11
kg
2024lb 202
41b
MA 5
Engi ne
Mai ntenance
MAI NTENANCE
BASI C
MECHANi CAL
SYSTEM
ADJUSTI NG I NTAKE
AND
EXHAUST
VALVE
a
EARANCE
Adjustment
should be made whi le
engi ne
i shot
I
Start
engi ne
and warm
up engi ne
unti lwater
temperature
i ndi cator
poi nts
to
themi ddle of
gauge
then
stop engi ne
Valve clearance
adjustment
cannot
be made whi le
engi ne
i s i n
operati on
2
Remove
valverockercover
3
Set so
that
hi gh
poi nt
of NoI
camlobe
poi nts
down
No1 earn lobe
SMA005
When
turni ng
crankshaft
wi th
starter
remove
hi gh
tensi on
cable
from
i gni ti on
coi lthenturn
i t
Adjust
clearance of half of
the
valves
Adjust
only
CD @ @
and
j
valves
CD 4
Front
o
1lJf
Dt
DFJ
000
SMA049
MAS
ENGI NE
MAI NTENANCE
Valveclearance
Hod
I ntake
CD
@
030mm
0012i n
Exhaust
@ j
030mm
10
012i
n
I Usi ng
feeler
gauge
measureclear
ance between valve stem end
and
rockerarmscrew
Feeler
gauge
should move wi th
a
very sli ght drag
8M
AQSO
2
I fthe
clearance
i s
not wi thi n
spec
i fi edvalue loosen
rocker
armnut and
turnrocker
ann screw
to
provi depro
per
clearance
3 Hold rockerarm screw and
ti ghten
rockerarm
nut
SMA051
dl
Rocker
arm
nut
16 22N m
1 6
2
2
kg
m
12
16
ft b
4
Recheck
clearance
4
Turn
crankshaft and set sothat
hi ghpoi nt
of
No I
camlobe
poi nts
above
0
No1
earn lobe
SMA001
Adjust
I D
I D
@
and
@
valves
usi ng
same
procedureas
for
Step
3
@ @
Front
kG D
tDf
OO I D
SMA052
Valveclearance
Hod
I ntake
@ @
030
mm
0012i n
Exhaust
I D I D
030
mm
0
012i n
5 I nstallvalverocker
cover
CHECKI NG AND
ADJUSTI NG DRI VE BELTS
I
Vi sually i nspect
for
cracks or
damage
Th belts should
not touchthe
bottom
of the
pulley groove
2 Checkbelltensi on
by
pushi ng
The belts shoulddeflect
by
the
spe
ci fi ed
amount
Dri ve
belt
deflecti on
8 12
mm
0
31
047
i n
Appli ed
preni ng
forc
98
N 10
kg
22lb
A
Loosen to
adjust
I
t
fJr
Checki ng
poi nt
of dri ve
belt
deflecti on
3
Adjust
belt tensi onas follows
Fan and alternatorbelt
I
Loosenthe
upper
andloweralter
nator
securi ng
boltsunti l
thealterna
torcan bemoved
sli ghtly
2 Move
the alternator
wi th
a
pryi ng
bar
unti l
the
belt tensi on i swi thi nthe
speci fi ed
range
Then
ti ghten
thebolts
securely
Ai rcondi ti oner
compressor
andpower
steeri ng
011
pump
belts
Loosen
the i dler
pulley
lock nut
2
Adjust
the
adjusti ng
bolt unti lthe
belt tensi on i s wi thi n the
speci fi ed
amount
3
Ti ghten
the
i dler
puUey
lock nut
securely
MAI NTENANCE Engi ne
Mai ntenance
Alternator
t
i lJ
J
I dler
puUey
LoCk nut
Adjust
Loosen
Compressor
pulley
Crank
pulley
I dler
pulley
Adjusti ng
bolt
Adjust
8MA053
CHANGI NG ENGI NE OI L
AND OI L FI LTER
1 Start
engi ne
and warm
up engi ne
unti l water
temperature
i ndi cator
poi nts
tothe mi ddle of
gauge
then
stop
engi ne
2 Remove
oi l
pan
drai n
plug
and oi l
fi Uer
cap
andallowoi ltodrai n
A
mi lky
oi li ndi cates the
presence
of
cooli ng
waterI solatethe
cause
andtakecorrecti ve
measure
An oi lwi th
extremely
low
vi scosi ty
i ndi catesdi luti on wi th
gasoli ne
3 Clean and i nstall
oi l
pan
drai n
plug
wi th
washer
WARNI NG
Be carefulnot toburn
yourself
as
the
engi ne
oi l
may
behot
I i J
Oi l
pan
drai n
plug
2029N m
2030
kg
m
14 22ft lb
4
Usi ng
Toolremove
oi lfI lter
1
1
01
I
1
E0036 SLC028
MA 7
Engi ne
Mai ntenance MAI NTENANCE
5
Wi pe
oi l
fI lter
mounti ng
surface
wi tha clean
rag
6 Smear
a
li ttle
engi ne
oi lon
rubber
gasket
ofnewfI lter
SMA010
7
I nstall new
oi l fI lter
Hand
ti ghten
ONLY DONOT
usea wrench
to
ti ghten
thefi lter
8
Refi ll
engi ne
wi thnew recom
mended
engi ne
oi l
referri ng
to
RE
COMMENDEDLUBRI CANTS
Checkoi llevelwi th
di psti ck
Oi l
Capaci ty
Wi thoi lfi lter
4
1
li te
4
3
8US
qt
358I mp
qt
Wi thout oi lfi lter
39
li te
4 18US
qt
338
I mp qt
E0038
9 Start
engi ne
Check area around
drai n
plug
and oi lfI lterfor
any
si gn
of
oi l
leakage
I f
any
leakage
i s evi dent these
parts
havenot been
properly
i nstalled
10
Run
engi ne
unti li t reaches
oper
ati ng temperature
Then turn
i t
off
and
wai t several
mi nutes
Check oi l
levelI f
necessary
add
engi ne
oi l
MA 8
When
checki ng
on level
park
the
earona
levelsurface
v
SMA163
CHANGI NG ENGI NE
COOLANT
WARNI NG
To BVoi d the
danger
of
bei ng
scalded never
attempt
to
change
thecoolant
whenthe
engi ne
i s hot
When
changi ng
engi ne
coolant
on
heater
equi pped
model
set heater
TEMP control
leverat
fully
HOT
posi ti on
I
Open
drai n
cock
at bottom of
radi ator
and
removeradi ator
cap
r l
i ld
1xrC
rl
1
rli
I
v
t
I I I
1
4
i l
I
I
ll
LOOSEN
CS015
2 Remove
cyli nderblock drai n
plug
located
at left rearof
cyli nder
block
W
F
O
3
Drai n coolant
completely
Then
flush
cooli ng system
4
Closedrai n
cock and
plug
5
Fi llradi atorwi th
coolant
up
to
fI ller
openi ng
observi ng
i nstructi ons
attached toanti freeze
contai nerfor
mi xi ng
rati oof
anti
freeze
towater
Cooli ng
water
capaci ty
95
li te
10US
qt
83
8I mp
qtl
6 Run
engi ne
fora few
mi nutes I f
necessary
add
coolant
7
Fi ll
reservoi rtank
wi thcoolant
up
to MAX level
I
t
CS021
8 I nstall
radi ator
cap
Check
drai nvalve and
plug
for
any
si gn
ofleakage
CHECKI NG
Di GI NE
COMPRESSI ON
PRESSURE
I Warm
up
engi ne
unti lwatertem
perature
i ndi cator
poi nts
tothemi ddle
of
gauge
2 Remove
au
spark plugs
on
one
si deforCali forni a
models
3
Di sconnect
allharness
connectors
at
i njector
4
Properly
attach
a
compressi on
testerto
spark plug
hole i n
cyli nder
bei ng
tested
8MA042
S
Depress
accelerator
pedal
to
open
throttlevalve
fully
6 Crank
engi ne
andread
gauge
i ndi
cati on
Run
engi ne
at about
350
rpm
Engi ne
compressi on
measurement
shouldbe made as
qui ckly
as
possi
ble
Compressi on pressure
kPa
kg
em
psat
rpm
Standard
1 177 120171 350
Mi ni mum
883
901281
350
7
Cyli ndercompressi on
i n
cyli nders
should not be
less than
80
of
the
hi ghest readi ng
I f
cyli nder
compressi on
i n
one or
more
cyli nders
i s low
pour
a
small
quanti ty
of
engi ne
oi l
i nto
cyli nders
through
the
sparkplug
holesand
retest
compressi on
I f
addi ng
oi l
helps
the
compres
si on
pressure
chances
are
that
pi ston
ri ngs
are
wornor
damaged
I f
pressure
stays
low valve
may
be
sti cki ng orseati ng i mproperly
I f
cyli nder
compressi on
i n
any
two
adjacent
cyli nders
i low
and i f
addi ng
oi ldoe not
help
the com
pressi on
there
i s
leakage past
the
gasketed
surface
Oi landwater
i n combusti oncham
bers
can result fromthi s
problem
I GNI TI ON AND
FUELSYSTEM
REPLACI NG
SPARK
PLUGS
I Di sconnect
spark
plug
wi re at
boot Do
not
pull
o
thewi res
O
K
N
G
SMAO
1 7
2
Remove
spark plugs
wi th
spark
plug
wrench
3
Usi ng
feeler
gauge
check new
spark plug gap
I f
i t i s
not
wi thi n
speci fi ed
range
set
gap by bendi ng
si de
ele
trode
Si deelectrode
i f
Gap
08 09mm
1003t
0035 1
SMA019
MAI NTENANCE Engi ne
Mai ntenance
SPARK
PLUG
Re
si stor
Standard bui lt
i Jl
type
Standard
BP6ES BPR6ES
type
Hot
type
BPSES
BPRSES
Cold
type
BP7
ES BPR7ES
4 I nstallnew
spark
plugs
and re
connect
hi gh
tensi on
cables
All
cable aremarked to
i denti fy
thei r
ori gi nal
locati ons
i YJ
Spark plug
15 20N
m
1 5
2 0
kg
m
11 14ft
I bl
CHECKI NG I GNI TI ON
WI RI NG
I
Vi sually
check
wi ri ng
for
cracks
damaged
andburned
termi nals
2
Usi ng
an
ohmmeter
measure
the
resi stance between
cable
tenni nal
on
the
spark plug
si de and
correspondi ng
electrode
i nsi decap
Resi stance
Lessthan30000ohms
SMA166
Shake
thewi rewhi le measuri ng
re
si stanee to check
fori ntermi ttent
brake
3
I f
the
resi stance
i s morethan
the
li mi t remove
cable from
cap
and
check thecable
resi stance
only
I f
resi stance i s sti llmore
than the
li mi t
replace
cable
assembly
MA 9
Engi neMai ntenance MAI NTENANCE
ADJUSTlNGI DLERPM
ADJUSTI NG
I GNI TI ON
TI MI NG AND
CHECKI NG
MI XTURE RATI O
NonCali forni a models
Preparati on
1 Makosure
thauhofollowi ng
parts
arei n
good
order
Battery
I gni ti onsystem
Mai ntenance
procaclure
MA
l0
Efl
i lrness
cOi ri ecti ri
Vacuum
hoses
Ai r
i ntako
system
Oi lfi ller
cap
oi l
level
gauge
etc
2
Connect
engi ne
tacho
terand
ti mi ng li ght
i ndi ei r
properpOsi ti ons
3 On
ai rcondi ti oner
equi pped
modes
checks should be carri ed out
whi lo
thooi condi ti oneri s OFF
4 On automati ctransmi ui on equi p
peel
modols checksshouldbe carri ed
out whi les
i ft leveri s i n O
posi ti on
START
Start
engi ne
andwann
up engi ne
unti l
water
temperature
i ndi cator
poi nts
to
the
mi ddle
I
of
gauge
Open engi ne
hood
Run
engi ne
at about 2 000
rpm
forabou
2 undet
no
load
WARNI NG
a WI len selector
leveri s
shi fted
to
0
posi ti on apply
parki ng
brakeand block
bothfront and
reanvheels
wi thchocks
b When
raci ng engi ne
on
auto
mati c transmi ssi on
equi pped
modelsi make
sure that shi ft
leveri s i n N or
P
posi ti on
and
depress
brake
pedal
to
pre
vent
forward
SUI 8
ofcar
c Aftertha
adjustment
has been
made
shi ft thelever
tothe
N
or
P
posi ti on
and remove
wheelchocks
E
1
Run
engi ne
at i dle
speed
ForCanada ForU S A
I
Di nnect hose fromai ri nducti on pi pe
andamtall
propercap
on
ai ri nducti on pi pe
t
Race
engi ne
two
orthreeti mes
underno
load
Thenrun
engi ne
foronemi nute
at i dle
speed
Check i dlespeed
Mnuai lransmi Ri on
7oo t 100
tpm
Autom w
i c
Transmi ssi on
700
100rpmi n
D
posi ti on
OK
j
N
G
I
Adjust
i dle
SPeedby turni ng
i dle
opeed
adjusti ng screw
j
bthi s
mai ntenanceoperati on
at
1
600km
I
1
000mi les servi ceor
rechecki ng
i dle
CO
I NO
@
YES
I
I
b
g @
r
Note
a When
measuri ng
CO i ni ert
probe I
i nto
tai lpi pe
morethan 04
m
16
i n
J
b
Use COmeteralter
engi ne
i s
fully
warmed
up
e
When
adjusti ng
i dle CO at
hi gh
alti tude adjust
toobtai n
followi ng
valua
Alti tude
Uni t m ft
fdte
00
2
7
600t
200
2 0004000
1
200
1
800
4
0006000
Above
1 800
6000
38
5 0
L J
N
G
I
Adjust i gni ti on
ti mi ng by
turn
g
di tri
ut
r
1
after
looseni ng
bolts
whi ch
securedi stri butor
i
of
Check
i gni ti on
ti
i ng
wi th
i r ni ng
t
8
f 20
B T DC
O
K
I
Race
eri gi ne
two
or
threeti mes
under00
I
load thenrun
engi ne
at
i dlespeed
Check
CO
wi th
COmeter
1 3t 1
O
K
I
Turn
off
engi ne
andconnect ai ri nducti on
rhose
toai ri nducti on
pi pe
i
Start
engi ne
Race
engi ne
twoorthreeti mesunder
no
load then
run
engi ne
at i dle
speed
I
Check i dle
speed
Mnu 1
Transmi ssi on
700 t 100
rpm
Automati cTrnsmi ssi on
7 1 100
rpm
i n 0
posi ti on
OK
I
NG
END
MAI NTENANCE
Engi ne
Mai ntenance
@@
f
SMA059
I f
SMA061
Adjust
CO by turni ng
ai r
by pass
screw
onai rflowmeter
When
adjusti ng
CO remove
bli nd
plug
fromai r
by pass
screw
After
adjustment
i nstallthe
plug
on ai r
flowmeter
r
r
SMA263
I
Adjust
i dle
speedby
turni ng
i dle
speed
ad
justi ng
screw
L
l
MA ll
i ntI i ne
M
i ti t ance
MAI NTENANCE
ADJUSTI NG
I DLE
RPM
Cali forni a models
Preparati on
1
On ai rcondi ti oner
equi PPed
mod
els checks should be carri ed
out
whi letheai rcondi ti oneri s OFF
2
On automati ctransmi ssi on
equi p
ped
models
checks should becarri ed
out whi le
shi ft leveri s i n Ou
posi ti on
I ntenai lce
procedure
MA
12
WARNI NG
a When selectorleveri s
shi ftedto
0
posi ti on apply parki ng
brake and block both
front
and
fearwheels wi thchocks
b Whe
raci ng engi ne
on auto
mati c transmi ssi on
equi pped
models make
sure that shi ft
leveri s
i n N orP
posi ti on
and
depress
brake
pedal
to
pre
vent forward
surge
ofcar
c After
the
adjlUtrDent
has been
made shi ft thelevertothe N
or
P
posi ti on
and remove
wheel
chockS
START
1
Start
engi ne
andwarm
up
engi ne
unti lwater
temperature
i ndi catQf poi nts
to
themi ddle
of
gauge
j
Open engi ne
hood
Run
engi ne
about 2 000
rpmforabout
2 mi nutes undeJ
no load
1
Run
eDsi ne
at
I dle
speed
1
Check
i dle
speed
Ma
alTl Bnsmi ai on
700
100
rpm
Automati cTransmi ssi on
700f 1
rpm
Un D
posi ti on
f
O
K
tG
8
SMA020
SMA022
SMA263
I
dj
sti dle
speedby
turni ng
i dle
speed
ad
I
JustJ I Jg
screw
1
END
CHECKI NG
FUELLI NES
Hoses
pi pi ng
connecti ons etc
I Check
fuel
li ne
for
leaks
parti cu
larly
around connecti on of fuel
pi pe
andfuelhose
2
Reti ghten
loose
connecti ons
and
replace
any
damaged
ordefonned
parts
SMA034
CAUTI ON
a 00
not
reuse
fuelhose
clamp
after
looseni ng
b
Ti ghten hi ghpressure
rubber
hose
clamp
sothat
clamp
end
i s
3mm
012 i n from hose
end
or
screw
posi ti on
wi der
than
other
porti ons
of
clamp
i s
flushWi thhoseend
Ti ghteni ng
torque speci fi cati ons
are
the
Same
forallrubberhose
clamps
When
ti ghteni ng
ose
clamp
8n ure
that screwdoes not comei nto
con
tact wi th
adjacent
parts
REPLACI NG
FUEL
FI LTER
The
fuelfI lteri s
desi gned
especi ally
for
use
wi ththeEFI
systerri
I t
should
be
replacedas
an
assembly
I Follow
the
procedure
below
tore
duce fuel
pressure
tozero
CAUTI ON
Before
di sconnecti ng
fuel
hose release
fuel
pressure
from fuelli ne to
eli mi
nate
danger
I Start
theengi ne
MAI NTENANCE Engi ne
Mai ntenance
Fuelreturn
pi pe
l
To
fueltan
rbm
f
eltank
rFue
pi pe
Fuel
damper
t
Fuel
pump
r
Fuel
pi pe
l
tr
btor
J
J
Jf
1j
I njector
W W
W
J
Fuelhose
clamps
1 01 5N
m
1010015
kg m
07
1 1 ft
I bl
E
F976
2
Di sconnect fuel
pump
relay
2har
ness
connectorwi th
engi ne
runni n
Relay
bracket
SEF131
SMA062
1
3mmlo12i nl
fl
f
I
E
F336A
3
After
engi ne
stall
crank
the
engi ne
twi ce
or
three
ti mes
4
Turn i gni ti on
swi tch
offand
con
nect fuel
pump
relay
2hamess connec
tor
2 Unfasten
clamps
securi ng
fuel
hoses to
the
outlet andi nlet si des
of
fuelfI lteranddi sconnect
fuelhoses
Be carefulnot to
spi ll
fuelover
engi ne
comP lrtment
Place
a
rag
toab
so
b fuel
MA
13
Engi neMai ntenanpe
MAI NTENANCE
3
Removefuelmter
I
V
tJl
SMA264
4 To
i nstaI lfuel
mterreverse the
orderofremoval
REPLACI NG AI R
CLEANER
FI LTER
The vi scous
papertype
ai rcleaner
fi lterdoes not
requi re any deani ng
operati on
betweenrenewal
Di sengage
ai rduct
I
1
SMA063
2
Di sengage
EAt Exhaust
Ai r
I nducti on
System
hose from
ai r
i n
ducti on
pi pe
r
J
MA
14
3
Remove ai r
cleanercoverand
remove
ai rcleanerftI ter
SMA065
4
I nstaI lai rcleaner
mterwi thUP
mark
faci ng upward
SMA039
EMI SSI ON
CONTROL
S
YSTEM
REPLACI NG
AI R
I NDUCTI ON
VALVE
FI LTER
SMA036
1 Ai r
i nducti on
valve case
2 Ai ri nducti on
valve
3 Ai r
i nducti onvalverdter
4
Ai r
cleaner
Remove
ai r
i nducti on
valve case
from ai r
cleanerandtake
out
ai ri n
ducti on
valve fI lterTheni nstaI l
new
ai r
i nducti on valvefi lter
When
replaci ng pay
stri ct
attenti on
towhi ch
di recti on the valve i
faci ng
sothat
exhaust
gas
wi llnot
flowback
ward
J
1
CHECKI NG
VAPOR
LI NES
Check allhoses
and
fuel
tank fi ller
cap
for
leaks
I
Dsi connect the
vapor
vent
li ne
connecti ng
carbon cani sterto
fuel
tank
2
Connect a 3
way
connector
a
manometerand
a cock oran
equi va
lent 3
way
carge
cock
to
the
end
of
thevent li ne
3
Supply pressure
i nto
the
vapor
vent li ne
tI uough
the
cock
li ttle
by
li ttle unti l
pressure becomes tothe
below
Leakage
test
pressure
3923
kPa
400
mmll20
15
75
i n
H20
4
Shut the
cock
completely
and
leavei t unattended
5 After25
mi nutes measure the
hei ght
of the
li qui d
i n
manometer
Pressurevari ati on
Lessthen
0245
kPe
25
mmH20
098
i nH201
MAI NTENANCE
Mi norTrouble
Di agnoses
andCorrecti ons
I Y
When
fi ller
cap
does not close
completely
the
hei ght
should
drop
to
zero
i n
a
short ti me
2
I f the
hei ght
does
not
drop
to
zero
i n
a short
ti me when i ller
cap
i s
removed
i t i s the cause of
a
staCfy
hose
AI I
@
I n
case
the vent li nei s
stuffy
the
breathi ng
i n fueltank i snot
thorough
ly
made thus
causi ng
i nsuffi ci ent
deli very
of fuelto
engi ne
or
vapor
lock
I t must therefore
be
repai red
or
replaced
Carboncani ster
3923kPI I
400
mmH20
15 75
i nH20
Manometer
Check
valve
Fuel
fi ller
cap
1
EC091A
MI NOR
TROUBLE
DI AGNOSES
AND
CORRECTI ONS
Condi ti on Probablecause
CANNOT CRANK
ENGI NE OR SLOW
CRANKI NG
I mpropergrade
oi l
Parti ally
di schargedbattery
Malfuncti oni ng battery
Loose
fanbelt
Trouble
i n
chargi ng system
Wi ri ng
connecti on
trouble
i n
starti ng
ci rcui t
Malfuncti oni ng i gni ti on
swi tch
Malfuncti oni ng starti ng
motor
Correcti ve
acti on
Replace
wi th
propergrade
oi l
Charge
battery
Replace
Adjust
I nspect
Correct
Repai r
or
replace
Repai r
or
replace
Troubleshooti ng procedure
on
starti ng
ci rcui t
Swi tchonthe
starti ng
motorwi thhead
li ghts
ON
When head
li ghts go
off
ordi m
consi derably
a Check
battery
b Check
connecti on
andcable
c Check
starti ng
motor
Whenhead
li ghts
stay bri ght
a Check
wi ri ng
connecti onbetween
battery
and
starti ng
motor
b Check
i gni ti on
swi tch
c Check
starti ng
motor
MA 15
Mi nor
TrrJUbleDi agnoses
end
Correcti ops
MAI NTENANCE
Condi ti on
ENGI NE WI LL CRANK
NORMALLY BUT WI LL NOT
START
Probablecause
Correcti veacti on
I n thi s
case the
followi ng
troublecauses
may
exi st but i n
many
cases
i gni ti onsystem
orfuel
system
i 1
i n trouble
I gni ti onsystem
i n
trouble
Fuel
system
i n
troubk
Valve
mecluzni smdoesnot work
properly
Low
compressi on
Trouble shooti ng
procedure
Check
spark
plug fI rstly
by followi ng procedure
Di sconnect
hi ghtensi on
cable
from one
spark
plug
and
hold i t
about
10
mm 039 i n from
the
engi ne
metal
part
and
crank the
engi ne
ENGI NE CRANKS
NORMALLY BUT
WI L OT
5
ART
I gni ti on
system
i n
trouble
Fuel
system
malfuncti on
MA
16
Good
spark
occurs
a Check
spark plug
b Check
i gni ti on ti mi ng
c Check fuel
system
d Check
revoluti on
tri ggersi gnal
e
Check
cyli ndercompressi on
Very hi gh
current Checkthe
current flow
i n
pri mary
ci rcui t
I nspect pri mary
ci rcui t forshort
Checkdi stri butor
pi ck
up
coi l
operati on
CheckI C
i gni ti on system
No
spark
occurs
Low
or
nocunenL
Malfuncti oni ng
di stri butor
pi ck
up
coi l
I mproper
ai r
gap
Leak
at rotor
cap
androtor
Malfuncti flni ng spark plug
I mproper
i gni ti onti mi ng
Malfuncti oni ng
i gni ti on
coi l
Di sconnecti on
of
hi gh
tensi on cable
Loose
connecti on
ordi sconnecti on
41
pri mary
ci rcui t
I rregnlar
revoluti on
tri gger
pulse
Malfuncti oni ng
I C
i gni ti on
uni t
Lackof
fuel
Damaged
electroni cfuel
i njecti on
harnessor
relay
Malfuncti oni ng
fuel
pump Usten
to
opera
ti ng
sound
Damaged
control
uni t
Sei zed
i njector
Usten to
operati ng
sound
Malfuncti oni ng
ai rflow
meter
Damaged
water
temp
sensor
Check for
loose
termi nalordi sconnecti oni n
pri mary
ci rcui t
Checkforburned
poi nts
Replace
Adjust
Clean
or
replace
Clean
adjust plug
gap
or
replace
Adjust
Replace
Replace
Repai ror
replace
Replace
I C
i gni ti on
uni t
Replace
Supply
Replace
Replace
Replace
Replace
Replace
Repl
ce
For
i nspecti onprocedures
for
electroni cfuel
i njecti on sys
tern
components
referto
Engi ne
Fuelsecti on
Condi ti on
Fuel
system
malfuncti on
Lowco
prelli on
UNSTABLE
ENGI NE I DLI NG
I gni ti onsystem
i ntrouble
Engi ne
mechani cal
system
i ntrouble
Fuel
system
malfuncti on
MAI NTENANCE
Mi norTrouble
Di agnoses
and
Correcti ons
Probablecause
Malfuncti oni ng pressure regulator
Di rty
fuel
f1lter
Di rty orclogged
fuel
pi pe
Clogged
fueltank
breather
pi pe
I ncorrect
spark plug ti ghteni ng
or
damaged
gasket
I mpropergrade engi ne
oi l
or
low
vi scosi ty
I ncorrect valveclearance
Compressi on
leakfromvalveseat
Sti cky
valve
stem
Weak
or
damaged
valve
spri ngs
Compressi on
leak
at
cyli nder
head
gasket
Sti cki ng
ordefecti ve
pi ston ri ng
Worn
pi stonri ng
or
cyli nder
Trouble
shooti ng procedure
Pour
the
engi ne
oi lfrom
plug
hole and then measure
cyli nder
compressi on
Compressi on
i ncreases
Compressi on
doesnot
change
Malfuncti oni ng i gni ti on system spark
plug
hi gh
tensi on cable di stri butorI C
i gni ti on
uni t
i gni ti on
coi letc
I ncorrect
basi c
i gni ti onti mi ng
Loose
mani fold
and
cyli nder
headbolts
I ncorrect
valve
clearance
Clogged
ai r
cleaner
f1lter
I ncorrect
i dle
adjustme
nt
Damaged
mani fold
gaskets
I ntakeai r
leakage
at
followi ng poi nts
Di psti ck
Oi l
fi ller
cap
Blowby
hoses
I ntake
ai r
duct
ai r
flowmetertothrottle
chamberetc
Correcti veacti on
Replace
Replace
Clean
Repai r
andclean
Ti ghtefl
tonormal
torque
or
replacegasket
Replace
wi th
propergrade
oi l
Adjust
Lap
valves
Correct or
replace
valve
and
valve
gui de
Replace
valve
spri ngs
Replacegasket
Replace
pi ston ri ngs
Overhaul
engi ne
Trouble
i n
cyli nder
or
pi stonri ng
Compressi on
leaks fromvalve
cyli nder
head
or
head
gasket
Replace
Adjust
Reti ghten
bolts
Adjust
Replace
f1lte
Adjust
Replacegasket
Repai r
or
replace
MA 17
Mi nor
Trouble
Di agnolJt
sand
Correcti om
MAI NTE ANCE
Condi ti on
Fuel
system
malfuncti on
Low
compressi on
Others
HI GH ENGI NE
I DLE SPEED
Fuel
system
malfuncti on
Others
ENGI NE
POWER
BELOWNORMAL
Low
compressi on
I gni ti onsystem
i n
trouble
Fuel
system
malfuncti on
MA
18
Probablecause
Damagedelectroni cfuel
i njecti on
harness
Sei zed
i njector
Usten to
operati ng
sound
Malfuncti oni ng
ai r
regulatorDuri ng
warm
up
dri vi ng
only
Damaged
controluni t
Damaged
water
and
ai r
temp
sensor
Malfuncti oni ng
throttlevalveswi tch
I rregular
fuel
pressure
Malfuncti oni ng
P C V valve
Malfuncti oni ng
EG R
control
system
I ncorrect
adjustment
ofi dle
speed
adjusti ng
screw
Malfuncti oni ng
ai r
regulator
Throttlevalvei s
opened
excessi vely
at
i dle
Malfuncti oni ng
FI
CD
Dragged
accelerator
li nkage
Malfuncti oni ng
Vacuum ControlValve
V
C
V
I ncorrect
i gni ti on ti mi ng
Malfuncti oni ng spark plugs
Malfuncti oni ng
di stri butor
pi ck up
coi l
Throttlevalvedoesnot
open
fully
Damaged
electroni cfuel
i njecti on
harness
Sei zed
i njector
Usten
to
operati ng
sound
Malfuncti oni ng
ai rflowmeter
Malfuncti oni ng
throttlevalveswi tch
I rregular
fuel
pressure
Clogged
fuel
pi pe
Di rty orclogged
fuelftI ter
Fuel
pwnp
wi llnot
work
properly
Correcti ve
acti on
Replace
Replace
Replace
For
i nspecti on
procedures
for
electroni cfuel
i njecti on sys
tern
compo
nents referto
Engi ne Fuel
Secti on
Replace
Replace
Repai r
or
replace
Replace pressure
regulator
Previ ously menti oned
Check or
replace
COrrect or
replace
Correct
Replace
For
i nspecti on procedures
for
ai r
regulator
referto
Engi ne
Fuelsecti on
Replace
throttlechamber
Replace
Check
andcorrect accelerator
li nkage
Checkor
replace
i f
necessary
Previ ously
menti oned
Adjust
Clean
adjust
or
replace
plugs
Replace
Adjust
Replace
Replace
Replace
Repai r
or
replace
Replace pressureregulator
i f
necessary
Replace
i f
necessary
Replace
Replace
For
i nspecti on
proce
dures forelectroni c
fuel
i njecti on
system
components
referto
Engi ne
FuelSecti on
Condi ti on
Ai ri ntake
system
malfuncti on
Overheati ng
Othe
NOI SY ENGI NE
Car
knocki ng
Mechani cal
knocki ng
Crankshaft
beari ng
knocki ng
MAI NTENANCE
Mi norTrouble
Di agnosessnd
Correcti ons
Probablecause
Clogged
ai rcleanerfi lter
Ai r
leaki ng
frommani fold
gasket
I ntakeai r
leakage
at
followi ng poi nts
Di psti ck
Oi lftller
cap
Blow
by
hoses
I ntake ai r
duct
ai rflowmeter
tothrottle
chamber
etc
I nsuffi ci ent coolant
Loosefari belt
Worn or
damaged
fan belt
Malfuncti oni ng
thermostat
Malfuncti oni ng
water
pump
Clogged
or
leaky
radi ator
Malfuncti oni ng
radi ator
ftller
cap
Ai ri n
cooli ng
system
I mproper
engi ne
oi l
grade
I ncorrect
i gni ti onti mi ng
Malfuncti oni ng
thermostat
I mproper
octane fuel
I mproper
ti re
pressure
Draggi ng
brake
Clutch
sli ppi ng
Malfuncti oni ng
E
G R
control
system
Overloaded
engi ne
Carbon
knocki ng
Ti mi ng
knocki ng
Fuel
knocki ng
Prei gni ti on mi susi ng
of
spark
plug
Thi s strong
dull
noi se i ncreases when
engi ne
i s accelerated
To
locate
the
place
cause a
mi sfi re on
each
cyli nder
I f
thenoi se
stops
by
the mi sfi re
thi s
cyli ndergenerates
the
noi se
Correcti ve
acti on
Replace
fi lter
Replacegasket
Repai r
or
replace
Repleni sh
Adjust
fan belt
Replace
Replace
Replace
Flush
repai r
or
replace
Replace
Reti ghten
each
part
of
cooli ng
system
Replace
wi th
propergrade
oi l
Adjust
Replace
Replace
wi th
speci fi ed
octane fuel
I nflateto
speci fi edpressure
Adjust
Adjust
Correct
or
replace
Use
ri ght
gear
i n
dri vi ng
Di sassemble
cyli nder
head and clean car
bon
Adjust i gni ti on ti mi ng
Use
speci fi ed
octane fuel
Use
speci fi edspark plug
Thi s
i s caused
by
wornor
damaged
beari ngs
or
unevenly
worD
crankshaft
Renew bear
i ngs
and
adjust
or
change
crankshaft
Check
lubri cati on
system
MA
19
Mi nor
Trouble
Di agnoseund
Correcti ons
MAI NTENANCE
Condi ti on
Connecti ng
rod
beari ng knocki ng
Pi ston
and
cyli nder
noi se
Pi ston
pi n
noi se
Water
pump
noi se
Others
Others
ABNORMAL
COMBUSTI ON
backfi re
after
fi re
run on etc
I gni ti onsystem
i ntrouble
Fuel
system
malfuncti on
MA20
Probablecause
Thi s
i s
a li ttle
hi gherpi tched
noi se
than the
crankshaft
knocki ng
and
also
i ncreases
when
engi ne
i s
accelerated
Cause a mi sfue
on
each
cyli nder
and i f the
noi se
di mi ni shes
almost
completely
thi s crankshaft
beari ng
generates
thenoi se
When
you
hearan
overlappi ng
metalli c
noi se
whi ch
i ncreases i ts
magni tude wi ththe
revoluti on of
engi ne
andwhi ch
decreases
engi ne
i s
wanned
up
thi snoi sei s
caused
by
pi ston lUI d
cyli nger
Tolocate
the
place
causea mi sfueon
each
cyli nder
Thi s noi se i s
heard at each
hi ghest
and
lowest
dead end of
pi ston
Tolocatethe
place
causea mi sfi reoneach
cyli nder
Thi s noi se
may
be caused
by worn or
damaged beari ngs
or
by
theuneven surface
of
sli di ng
parts
An
i mproper
adjustment
of
valveclearance
Noi seofti nri ngchmn
Anexcessi ve
end
play
oncrankshaft
Wearonclutch
pi lot
bushi ng
Thi s
noi se wi llbe heard when
clutchi s
di sengaged
I mproperi gni ti onti nri ng
I mproper
heat
range
of
spark plugs
I ntake
ai r
leakage
at
followi ng
poi nts
Di psti ck
Oi lf1l1er
cap
Blow by hoses
I ntake
ai r
duct
ai r
flowmetertothrottle
chamber
etc
Damaged
electroni cfuel
i njecti on
harness
Damaged
control
uni t
Malfuncti oni ng
ai r
flowmeter
Damaged
water
temp
sensor
Correcti ve
acti on
Sameas thecase
ofcrankshaft
beari ngs
Thi s
may
cause an abnonnal
weari ng
of
cyli nderand lower
compressi on
whi ch
i n
turn wi ll
cause a
lower
out
put powerand
excessi ve
consumpti on
ofoi l
Overhaul
engi ne
Thi s
may
cause a wear
on
pi ston pi n
or
pi ston pi n
hole
Renew
pi ston
and
pi ston pi n
assembly
Replace
water
pump
wi th
a newone
Adjust
Adjust
thetensi onof
chmn
Di sassemble
engi ne
andrenewmai n
beari ng
Renew
bushi ng
and
adjust
dri veshaft
Adjust
i gni ti on ti mi ng
Use
speci fi ed
spark plugs
Repai r
or
replace
Replace
Replace
Replace
Replace
J
For
i nspecti on
procedures
for
electroni c
fuel
i njecti on
sys
tern
components
referto
Engi ne
FuelSecti on
Condi ti on
Defecti ve
cyli nder
head
etc
Others
EXCESSI VE OI L
CONSUMPTI ON
Oi l
leakage
Others
POOR FUEL
ECONOMY
Engi ne
power
belownormal
Fuel
system
malfuncti on
MAI NTENANCE Mi norTrouble
Di agnoses
and
Correcti ons
Probablecause
I mproperly
adjusted
valveclearance
Excesscarbon i ncombusti onchamber
Damaged
v
alve
spri ng
backfi re
afterfi re
Malfuncti oni ng
E
G
R control
system
Loose
oi ldrai n
plug
Looseor
damaged
oi l
pangasket
Loose
or
damaged
chai n
covergasket
Damaged
oi lseal i n front and rearof
crankshaft
Lo
eor
damaged
rockercover
gasket
I mproperti ghteni ng
of oi l
fI lter
Loose
or
damaged
oi l
pressure
swi tch
I
I
Cyli nder
and
pi ston
wear
I mproper
locati on of
pi stonri ng
or
reversely
assembled
pi stonri ng
Damagedpi ston ri ngs
Worn
pi ston ri ng groove
and
ri ng
Fati gue
ofvalve oi lseal
li p
Worn
valvestem
I nadequate
quali ty
of
engi ne
oi l
Engi ne
overheat
Exceedi ng i dli ng
revoluti on
Fuel
leakage
from
fuel
li ne
Damaged
electroni cfuel
i njecti on
harness
Damaged
control
uni t
Malfuncti oni ng
ai rflow
meter
Damaged
ai r
temperature
sensor
Malfuncti oni ng
throttle
valve
swi tch
I rregular
fuel
pressure
Correcti ve
acti on
Adjust
Removeheadand
get
ri dofcarbon
Replace
i t
wi tha newone
Correct
or
replace
Ti ghten
i t
Renew
gasket
or
ti ghten
i t
Renew
gaskei
or
ti ghten
i t
Renewoi lseal
Renew
gasket
or
ti ghten
i t
but not too
much
Renew
gasket
and
ti ghten
i t
wi ththe
proper
torque
Renewoi l
pressure
swi tchor
ti ghten
i t
Overhaul
cyli nder
andrenew
pi ston
Remount
pi ston ri ngs
Renew
ri ngs
Repai r
r
renew
pi ston
and
cyli nder
Renew
pi ston
and
pi stonri ng
Replace
seal
li p
wi th
a newone
Renewvalveor
gui de
Usethe
desi gnated
oi l
Previ ously
menti oned
Previ ously
menti oned
Adjust
i t
tothe
desi gnatedrpm
Repai r
replace
or
ti ghten
theconnecti on
of
fuel
pi pes
Replace
Replace
Replace
Replace
Replace
Replace
pressureregulator
i f
necessary
For
i nspecti on procedures
for
electroni c fuel
i njecti on
sys
tern
components
referto
Engi ne
FuelSecti on
MA
21
Mi norTrouble
Di agnoses
and
Correcti om
MAI NTENANCE
Condi ti on
TROUBLE I N OTHER
FUNCTI ONS
Decreased oi l
pressure
Excessi ve
wearon
the
sli di ng parts
Scuffi ng
of
sli di ng
parts
MA22
Probablecause
I nadequate
oi l
quali ty
Overheat
Malfuncti oni ng
oi l
pump regulator
valve
Functi onaldeteri orati onofoi l
pump
Blockedoi lf1lter
I ncreasedclearance
i nvari ous
sli di ng parts
Blockedoi lstrai ner
Malfuncti oni ng
o
gauge pressure
swi tch
Oi l
pressure
decreases
Damagedquali ty
orcontami nati onofoi l
Ai r
leakage
from
ai ri ntake
duct
Damaged
ai r
cleaner
Overheat
or
overcoat
I mproper
fuelmi xture
Decreaseofoi l
pressure
I nsuffi ci ent clearances
Overheat
I mproper
fuelmi xture
Correcti veacti on
Usethe
desi gnated
oi l
Previ ously
menti oned
Di sassemble
oi l
pump
and
repai r
orrenew
i t
Repai r
or
replace
i t
wi thanew ne
Renew
i t
Di sassemble and
replace
the
worn
parts
wi th
newones
Clean
i t
Replace
i t
wi th
anewone
Previ ously
menti oned
Exchange
the oi lwi th
proper
one and
change
element
Repai r
or
replace
Change
element
Previ ously
menti oned
Checkthefuel
system
Previ ously
menti oned
Readjust
tolI i e
desi gnated
clearances
Previ ously
menti oned
Check thefuel
system
MAI NTENANCE
Chassi sand
Body
Mai nwnance
CHASSI S
AND
BODY
MAI NTENANCE
ENGI NE CONTROL
FUEL AND EXHAUST
SYSTEMS
CHECKI NG FUEL AND
EXHAUST SYSTEM
Check
fuelandexhaust
systems
for
condi ti on connecti ons and
leaks
Fuel
system
SMA034
Exhaust system
@
SMA
147
CLUTCH
CHECKI NG
CLUTCHFLUI D
LEVELAND
LEAKS
Addto MAX
level
SMA1QO
CHECKI NG
CLUTCH
SYSTEM
Check clutch
system
for
proper
at
tachment
leaks
chafi ng
abrasi on
de
teri orati on etc
@j
J@
SMA101
CHECKI NG
CLUTCH
PEDAL
HEI GHT AND FREE
PLAY
Check
clutch
pedalhei ght
andfree
play
Adjust
i f
necessary
Master
cyli nde push
rod
Pedal
stopper
r1
w
lotf
51
8
8
71
i Ll
111
h
I nSU1ator
FI Oor j
H
Lock nut
fl7
8 11
8
10
8 1 2
5 8
8
71
A
fl
N
m
kg
m
ft lb
SMA102
Pedal
hei ght
H
168
174
mm
661 6
85 i n
Padalfree
play
A
J 5 mm 0
04 020
i n
I
Adjust
pedal
hei ght
wi th
pedal
stopper
Then
ti ghten
locknut
2
Adjust
pedal
free
play
wi thmaster
cyli nderpush
rod Then
ti ghten
lock
nut
8 Pedalfree
play
means the
followi ng
total
measured at
posi ti on
of
pedal
pad
Play
due
to
clevi s
pi n
and
clevi s
pi n
holei n
pedal
lever
Play
due to
pi ston
and
pi ston
rod
b
Depress
nd release clutch
pedal
over
i ts enti restroketo
ensure
that
theclutch
li nkageoperates
smooth
ly
wi thout
squeak
noi se i nter
ferenceand
bi ndi ng
MANUAL
TRANSMI SSI ON
CHECKI NG MANUAL
TRANSMI SSI ON
OI L
LEVEL
Neyerstart
engi ne
whi le
checki ng
oi lleyel
ff
4f
i tner
plug
S
25
35
kg
m Fi ll
to
thi s
level
18
25 ft
I bl
SMA
1
03
CHANGI NG MANUAL
TRANSMI SSI ON
OI L
I
Drai n
oi l
completely
SMA104
MA 23
Chassi s
and
Body Mai ntenance MAI NTENANCE
2
Refi ll
transmi ssi on and check
oi l
level
25ft lb
Oi l
capaci ty
2
0li ten 41 4
USJi t
31
2
I mp pt
AUTOMATI C
TRANSMI SSI QN
CHECKI NG AUTOMATI C
TRANSMI SSI ON FLUI D
LEVEL
I Checkunder
followi ng
condi ti ons
i
Place selector
lever
i n P
pARK
posi ti on
andi dle
engi ne
2 Mai ntai n flui d
temperature
at 50
to80DC 122to176DF
2 Addoi li f
necessary
Use
only
automati c transmi ssi on
flui d
havi ng
OEXRON
i denti fi ca
ti ons
i n 3N71B automati c
trans
i Sli on
Q
J
Addto
H level
Donot overfi ll
SMA106
MA 24
CHECKI NGAUTOMAnC
TRANSMI SSI ON
FLUI D
CONDI TI ON
Check flui d forcontami nati on
to
determi ne condi ti on
of automati c
transmi ssi on
I f flui d i s
very
dark or
smells burned
the
fri cti onalmateri al
clutches
band
etc
may
need reo
placemen
t
Oleck flui d
forcontami nati on
I
Check
flui d forsmell
SMA107
PROPELI
ER SHAFT
AND
DI FFERENTI AL
CAR I ER
CHECKI NG
PROPELLER
SHAFT
Check
propeller
shaft
replace
i f
necessary
Oteek tube
surfaces
fOJ denu
orcracks
SMA231
Oleck
ti ghteni ng torque
CHECKI NG DI FFEREN11AL
CARRI ER
OI LLEVEL
Fi lltothi s
level
S
MA10B
CHANGI NG
DI FFERENTI AL
CARRI ER
OI L
I
Drai n
oi l
completely
CV
59
98N m
610kg m
72ft
blL
W
SMA109
2 Refi ll di fferenti al
carri erand
check oi l
level
cv
59 98Nm
6
101qj
m
43
72ft lb
SMA11Q
Oi l
capaci ty
1
1li ten
2
38
US
pt
2
I mp pt
FRONT
AXLE AND
FRONT SUSPENSI ON
CHECKI NG FRONT
AXLE
AND SUSPENSI ON
PARTS
I
Block rearwheelswi thchock
and
rai se
front of car
andthen
support
i t
wi th
safety
stand Referto
li fti ng
Poi nts
and
Towi ng
Secti on
GI
2 Shakeeachfront wheel
by
hold
i ng
upper
andlowersurfaces
of
ti resas
shown
SMA111
Check
suspensi on parts
forloose
ness
wearor
damage
Reti ghten
all
loose
nuts
and bolts
tothe
speci fi ed
torque
RefertoSec
ti onFA for
ti ghteni ng torque
Replace
all
worn
parts
as
descri bed
underFront
Suspensi on
Secti on
FA
o
Strut
upper
end
3
Check strut Shock
absorberfor
oi l
leakage
or
damage
J
MAI NTENANCE
Chsssi s
and
Body
Mai ntensnce
4
Check
suspensi on
ball
joi nt
for
grease
leakage
andball
joi nt
dust cover
for
damage
5
Removewheelandti re
assembly
6
Check front
axle
parts
for
crack
or
damage
Replaceworn
parts
Refer
toFront Axle Secti onFA
7 Removebrake
pads
Refertosecti on BR
8
Checkwheel
beari ng
I fthere
i s
any
axi al
end
play
or
i f
wheel
beari ng
does not
smoothly
turn
adjust
beari ng
to
speci fi cati ons
Replacewornor
damagedbeari ngs
Referto
Front Axle Secti on FA
SMAllS
ADjUSTI NG WHEEL
BEARI NG
PRELOAD
Afterwheel
beari ng
has been reo
placed
or
front
axle has been reo
assembled be sure to
adjust wheel
beari ng
preloadas
descri bed
below
I Before
adjustment
thoroughly
clean all
parts
to
prevent
possi ble
en
try
of di rt
2
Apply recommended multi
pur
pose
grease spari ngly
tothe
followi ng
parts
Threaded
porti on
of
spi ndle
Contact
surface
between wheel
beari ng
washerand outerwheel
beari ng
Hub hub
cap
and
O
ri ng
Greaseseal
li p
dl
nng
SMAl16
Multi
purpose
grease
poi nt
3
Ti ghten
wheel
beari ng nut
iJ 25 29N
m
12
5
30
kg
m
18
22ft lbl
SMAT17
4 Turn wheelhub
severalti mes i n
bothdi recti ons
to
seat wheel
beari ng
correctly
SMAllS
5
Agai nti ghten
wheel
beari ng
nut
MA
25
Chassi undBodyMai nl11nance MAI NTENANCE
6 Turn
back
wheel
beari ng
nut wi th
i n600
Tumbac
kA
Wi thi n600
SMA119
7
Fi t
adjusti ng
cap
and
new
cotter
pi n
8
Measure wheel
beari ng preload
andaxi al
play
900
Axi al
play
0mm
0i n
Wh
1 b
ri ng
prelo
Asmeasuredat wh
1 hub bolt
Wi thnew
parts
6
9
147 N
10
7 1 5
kg 1 5 331bl
Wi th
US8
t
parts
207B N
10 2
08
kg
04 1 8I b
SMA121
Repeat
above
procedures
unti lcor
rect
starti ng
torque
i s obtai ned
MA 26
9
Spread
otterpi n
F
A265
10
I nstallhub
cap
wi thnewO
ri ng
CHECKI NG WHEEL
ALI GN MENT
Before
checki ng
front
wheel
ali gn
ment be
sure tomake
a
preli mi nary
i nspecti on
of
allfront end
parts
Ti re
pressure
Wheel
beari ng
axi al
play
Suspensi on
ball
joi nt
Steeri ng
gearhousi ng looseness
at
frame
Steeri ng
li nkage
and
connecti ons
Shock
absorber
oparati on
Ti ghten
each
front
axle
and
suspen
si on
pam
Measure car
hei ght when
not
loaded
Repai r
or
replace
the
d
amagedpor
ti onor
parts
Camber
casterand
ki ngopln
i ncli nati on
Camber
casterand
ki ng
pi n
i ncli na
ti on
are
preset
at the
factory
andcan
not be
adjusted
I f
cambercaster
or
ki ng pi n
i n
cli nati on
ali gnment
i s not wi thi n
speci
fi cati ons
check
perti nent parts
Repai r
or
replace
as
necessary
Camber
4050
Caster
1045 3
15
Ki ngpi n
i ncli nati on
7025 SOSS
Toe I n
Measure
toei n
andmake
necessary
adjustments Use the
followi ng pro
cedure
when
maki ng adjustments
I Rai se
front of
car
andmark
a base
li neacross
the
tread
of left and
ri ght
wheels
Base
li ne
SMA123
2
Set wheels i n a
strai ght
ahead
posi ti on
and
then lowerfront
ofcar
3
Measure
toe
i n
and
make neces
sary
adjustments
li nes
parallel
to
center
li neof
body
Toei n Unladen
o2 mm O OOS
i nl
012
On
both
si des
Si d
sli p
Reference
datal
Out 1 mm n 1
mmlm
Out
0012
i n
I n 0
012i n ftl
Toei n
can be
adjusted by varyi ng
the
length
of
steeri ng
si derods
SMA265
Unladen
Fueltank radi atorand
engi ne
oi l
tank allfull
Spare
ti re
jack
handtools
mats
i n
posi ti on
All
ti res i nflated to
speci fi ed
pres
sure
Allaccumulati on of
mud di rt
and
road
deposi ts
removed fromchassi s
and
underbody
I fsi derodshave
been
di sassembled
set thedi stance between
lock
nuts to
the
speci fi ed
value
A
pri or
to
reo
assembli ng
JJ
Si d red
length
An
710mm12795 i n
ssn05
a Lock si de rodbar
lock nut sothat
ball
joi nt
on outersocket i s 770
wi th
respect
to that on i nner
socket
b Make
sure
that
adjusti ng
bari s
screwed i n eam
socket at least 25
mm098i n
4 Aftercorrect toe
i n
has been ob
tai ned
ti ghten
si derodbarlock
nuts
I i l
78 98N
m
80100
kg
m
58 72ft lb
Front wheel
turni ng engle
I Set wheels i n
strai ght
ahead
posi
ti on and
then move carfoward
unti l
front wheels rest on turn
ng
radi us
gaugeproperly
MAI NTENANCE
Chassi s
and
Body
Mai ntenance
2 Remove
stopperpi n
of
turni ng
radi us
gauge
and
then
fully
rotate
steeri ng
wheelto
the
ri ght
and
left
measure
turni ng
angle
on
i nner
wheel
and
make
necessary adjustments
FA632
Front
wheel
turni ng angle
Toe
ut turns
When i nnerwheel
200
Outer
wheel1870
Fullturns On
power
steeri ng
mo
dels wheelturni ng
force at
ci r
cumference
of
steeri ng
wheellof
98
147
N 1015
kg
22
33I b wi th
engi ne
at i dle
I nner
wheel330350
Outerwheel270290
Turni ng
angle
of outerwheelwi ll
automati cally
be set
by
adjusti ng
turn
i ng angle
of i nner
wheelto
speci fi ed
values
3 After
adjustment
lock
adjusti ng
lock
nut
REAR AXLE AND
REAR
SUSPENSI ON
CHECKI NG
REAR AXLE
AND SUSPENSI ON
PARTS
Check
rear
axle and
suspensi on
parts
for
looseness wearor
damage
Reti ghten
allloose nuts
and bolts
to
the
speci fi ed
torque
Refer
to
Sec
ti onRA for
ti ghteni ng torque
Replace
aU worn
parts
as
i nstructed
under
Rear
Suspensi on
Secti on
RA
Check
ti ghteni ng torque
SMA129
MA 27
OI l1Sfi sand
Body
Mai ntenance
MAI NTENANCE
BRAKE SYSTEM
CHECKI NG
BRAKE FLUI D
LEVELAND
LEAKS
Addto MAX level
SMA130
I f flui d level i
extremely
low
checkbrake
system
for
leaks
CHANGI NG
BRAKE FLUI D
I
Change
brakeflui d
Use
same
procedure
I S i n ai rbleed
i ng
to
change
brake flui d i n
ystem
Thi
operati on
should
bedone
for
one
wheelat
a
ti me Refer
toSecti on BR
CAUTI ON
Never
reuse brake
flui d
because i ts
characteri sti c i s
chang2d by
oxi di za
ti on as wellas contai ns the
forei gn
materi alanddi rt
Ai rbleed
valve
3
l6
9 88N
m
O7 O
9kg
5 1 6
5ft
lb
SMA131
Refi llunti lnewflui d
appears
MA 28
2
CI i eck brake
flui dleve
3 Checkforleaks
CHECKI NG BRAKE
BOOSTER
VACUUMHOSES
coNNECTI ONS
AND
CHECKVALVE
1
Check condi ti on of
vacuum
hoses
andconnecti ons
2 Check vacuum hoses
and
check
valvefor
ai r
ti ghtness
SMA
125
CHECKI NG BRAKE SYSTEM
I
Check brake
system
f
r
proper
attachment leaks
chafmg
abrasi on
deteri orati on etc
SMA
133
CHECKI NG
DI SC
BRAKE
I Check
condi ti on
of
di sc brake
components
beck
pads
forwear
SMA134
Oteck cali per
operati on
and
X
i nspect
for
leaks
Padwearli ni i t
1
ll
A
I
TT
PI I d
war
li mi t
tAt
N22 2mm008i n
AN12H 2mm008i n
SMA266
RefertoSecti on
BR for
pad
re
placement
Rotor
repai r
li mi t
ROtor
repai r
li mi t B
N22 105
mm10413i n
AN12H 86mm 0339i n
SMA267
CHECKI NG
FOOT BRAKE
1
Check brake
pedal
free
hei ght
and
free
play
Adjust
i f
necessary
Brake b
t
0
hl
P
i
1
Ck
nut
j
l12
15
11 2 1 5
9
11
Lock
nut
1
16 22
1
I
16
2212
16
I
I nsulator
Floor h
SMA140 lNm
kg
m Ct tb
Pedalfree
hei ght
h
155
161
mm610
634i n
Pedal
free
play
a
1 5
mm
004 020i n
1
Adjust pedal
free
hei ght
wi th
brake
lamp
swi tch
Then
ti ghten
lock
nut
Adjust pedal
free
play
wi th
brake
booster
i nput
rod
Then
ti ghten
lock
nut
Pedalfree
play
mean
the
followi ng
totalmeasured
at
posi ti on
of
pedal
pad
Play
duetoclevi s pi n
andclevi s
pi n
holei n
pedal
lever
Play
dueto
pi ston
and
pi ston
rod
2
Check
brake
pedal
depressed
hei ght
I
I
d
v
DeprltSSllKlhei ght
Mor
thi ln 60mm2
36i n
SMA141
I f
depressed hei ght
i below
the
speci fi ed
value check brake
system
for
leaks accumulati on
of a ror
any
ab
normali ty
regardi ng
component parb
master
cyli nderadju
i er
etcI and
makethe
necessary repai n
CHECKI NG PARKI NG
BRAKE
I Pullleverwi th
speci fi ed
amount
offorce
MAI NTENANCE
Chassi s
and
Body
Mai ntenance
Measure
leverstroke
i n a
strai ght
li neat centerof
gri p
Pulli ng
force
196N
120kg
44I b
I
l
n
1
I
L
I
Leverstroke
90100mm
0
0
354 394
nl
Numberof notches 7 8 SMA
142
2
Use
adjuster
to
adjust
leverstroke
I
Lock
fi U
t
SMA143
3 Bend
parki ng
brake
warni ng
lamp
swi tch
plate
down sothat brakewarn
i ng
li ght comes
on when
ratchet
at
parki ng
brakelever
i s
moved
back
one
notchand
goes
out when
returned to
i ts
ori gi nal posi ti on
WHEEL
AND TI RE
CHECKI NG
TI RE
CONDI TI ON
Ti re
condi ti on
1 Ti res
are
provi ded
wi th
tread
weari ndi cator
at si x
places
around
ti re ci rcumference
i ndi cati ng
16mm
1
16
i n
tread
depth
When ti reswear
and then marks
appearreplace
them
wi th
new
ones
Tread
wear
i ndi cator Ti retread
t
WH024
2 Remove
pebbles
glass
or
any
otherforei gn
materi al
embedded
i n
ti re treads
3
Check
tread and si de
walls for
cracks
holes
separati on
ordamage
4 Check
ti re
valves
for
ai r
leakage
Ti re I nflati on
I
Check
ti re
pressure
I f
necessary
adjust
i t
to
the
speci fi ed
value
i ndi
cated
i n
the
labelattached tothecar
also
found
i n Owners Manualor
S D S
Ti re
pressure
should be easured
when ti rei s cold
I
J
ri rei nflati on
pressure
label
l
I
SMA268
2 After
i nflati ng
ti res
valves should
be checked
for
leakage
Wheneverti re
pressure
i s checked besureto
ti ghten
valve
caps
fi rmly by
hand
tokeep
dust
and
water
out
MA
29
ChaS3i s
and
BodyMai nrenanaJ
MAI NTENANCE
Abnormalti rewear
Correct
abnormal
ti re
wear
ac
cordi ng
tothe
chart shownbelow
Condi ti on
i
1
1
1
J
1111
allll j ll
Shoulderwear
I f
I
i i i i
I
t
I i
Centerwear
Feathered
edge
j
l
I i
I
1
I i
I I
1
1
t
1i
I
I
II
l
I
r
i
I I I
Toe i n
or
toe out wear
I j
I i j
j
H
l
m
I
i l
I
1
fI ll
11
I
I
I
f1 1
1
ll
ll
o
I i
Uneven wear
Probablecause
Underi nflati on
both
si des ar
I ncorrect wheel
camber
one
si de
wear
Hard
corneri ng
Lack ofrotati on
Overi nflati on
lackof
rotati on
I ncorrect
toe
lncorrect
camber
or
caster
Malfuncti oni ng suspen
si on
Unbalancedwheel
Out lf
roundbrake
drum
Other
mechani calcondi
dons
Lack
ofrotati on
TI RE
ROTATI ON
1
Ti res tend to
wear
unevenly
and
become
unbalanced aftera certai n
runni ng
di stance
Uneven
ti re
wear
often results
i n
ti re
noi se whi chi s
attri buted torearaxle
gears
beari ng
MA 30
Correcti ve
acti on
Measureand
adjust
plessure
Repai r
or
replace
axleand
suspensi on
parts
Reduce
speed
Rotateti res
Measure
and
adjust
pressure
Rotate
ti res
Adjust
toe
i n
Repai r
or
replace
axle
and
suspensi on
parts
Repai rreplace
or
i f
necessary
rei nstall
Balanceor
replace
Correct
or
replace
Correct or
replace
Rotate
ti res
SMA068
etc Front
ti res alsotend
to
wear
un
evenly
because of
i mproperly
ali gned
front wheels
2 Accordi ngly
to
equali Ze
ti rewear
i t i s
necessary
torot8te
ti res
peri odh
cally
Radi alti res
Ri ght
front
Ri ght
rear
ccl
@
clcl
Left front Left
rear
4WHEELS
SMA126
TI RE REPLACEMENT
CAUTI ON
Di fferent
types
of ti res Ri ch
es bi as
bi as
belted
and radi al
ti rl S murt not
be
mi xed under
any
ci n
umstances
Mi nd use
of di fferent
types
of ti i es
can
adversely
affect car
handli ng
and
may
causedri vertolose
control
i
a When
replaci ng
wornor
damaged
ti re use a replacement
ti reof the
same si zeand
load
carryi ng
capaci
ty
as that wi thwhi ch
the
carWI S
aqui pped
when
manufactUred
The
use
of
di fferent
si ze andorload
capaci ty ti
wi ll
not
only
horten
ti reservi ce li febut
may
alsoresuh
i n
a seri ousacci dent
b Do
not
use
ti res and wheels other
than
those recommeooed
and do
not mi xti re of di fferent brandt or
tread
patterns
The
use of
ti re andwheels other
than
those recommended
orthe
mi xed
use
of ti res of di ffarent
brands or
1
ead patterns
can
ad
versely affect
the ri de
braki ng
handli ng ground
clearance
body
toti re clearance and
sp
et tom8ter
cali brati on
c
I t i t recommended
that newti res
be
i nstalled i n
pai n on
the
same
axle
When
replaci ng
only
one
ti re i t
should
be
pai red
wi ththe most
tread
to
equali zebraki ng
tracti on
d When
replaci ng
ori gi nal
ti res
wi th
those
ti res of
8n
opti onal
recom
mended si zeand
of di fferent di am
ator
tha
speedometermust
ba
ra
cali brated
1 To
replace
a ti rewi th
a
jack
i n
a
safe
mannerrefe
to
li fti ng
Poi nts
Secti on
GI
for
jacki ng
up
WARNI NG
Never
get
undercar
whi lei t i s
sup
portedonly by
jack
Always
use
safety
stands
to
support
si de member
of
body
constructi on
when
you
must
get
beneath
car
2 To
i nstall
wheel
ti ghten
wheel
nuts
i n cri sscross
fashi on
SMA069
Alumi num
whee
Toi nstall
an
alumi num
wheel
pro
ceed
as
followS
I
Snugly
ti ghten
four
nuts
after
the
wheeli s
posi ti oned
SMA070
2
Sli ghtly pull
the
wheel
back
to
properly ali gn
thenuts
wi th
bolt holes
i n thewheeland
ti ghten
the nuts as
much
as
possi ble
wi th
your
fi ngers
MAI NTENANCE
Chassi sandBodyMai ntenance
Ali gn
nuts
wi thbolt
holesi n
wheel
and
evenly ti ghten
nuts
eachone a
li ttle
at a
ti me
SMA071
3
Ti ghten
wheelnuts
evenly
wi th
a
wheel
wrench
i n cri sscross
fashi on
Be
sure
to
check
the
wheelnuts for
ti ghtness
afterthe
alumi num wheel
has been Nn for
the fi rst 1 000km
600mi leslalso
i n
cases
of
repai ri ng
flat ti re
ti rerotati on
etc
Reti ghten
i f
necessary
Wheel
nut
CAUTI ON
Two
types
of wheelnuts areused
one
i s
desi gned
foruse
wi thsteelwheel
and the otherforuse
wi thalumi num
wheel00not
mi xdi fferent
types
of
wheel
nuts
Foralumi num
wheels
only
Forsteel
wheels
only
r
C
tJ
78 98N
m
18
0
100
kg
m
58
72
ft
I bl
SMA234
Be
careful
not
to
smear
thread
ed
porti on
of bolt and
nut and seat
of
nut wi thoi l
orgrease
T TYPE SPARE
TI RE
Si ze
T135 70D16
The T
type
spare
ti rei s
desi gned
for
emergency
use
only
The
spare
ti re
can
be
used
repeatedly
for
emergency
si tuati ons
Precauti ons whenuslng
T
type
spa
ti re
Pe
i odi cally
checkti re
i nflati on
pres
sure
and always
keep
i t at 60
psi
412
kPa
Do
not dri ve
car
at
speed
faster
than80kmh
50MPH
The T
type spare
ti re i s
desi gned
only
fpr
temporary
use
as
a
spare
Di smount
i t and
keep
i t
as a
spare
as
soon
as thestandard
ti re
repai r
has
been
completed
Donot
enteri ntoan automati c
car
wash
wi ththe Ttype
spare
ti re
fi tted
Do
not attacha ti rechai n
Donot
use
theTtype
spare
ti reon
othercars
Donot make
a
sharp
turn or
apply
thebrakesuddenly
whi le
dri vi ng
As
soonas thetreadweari ndi cator
becorri es
vi si ble
replace
the ti re
wi tha
new
one
Mounti ng
and di smounti ng
toand
from theroad wheelcan
becarri ed
out i nthesame
manner
as
any
ordi
nary
ti n
Useof
wheelbalancei s unneces
ary
CAUTI ON
I f thecar
i s
equi pped
wi th
alumi num
wheels be suretouse the
wheelnuts
forsteelwheelonthe
rtyp spare
ti re
wheelNeverus the
wheelnuts for
alumi num wheelon
the
spare
ti re
wheel
The
spare
ti re
wheel
may
comeoffthe
axle and cause
personali njury
i f the
wheel
nuts foralumi num wheels
are
used onthe
spare
ti rewheel
TI RE REPAI R
I nspect
ti re
followi ng
the
proce
dureshown
below I f
any
defect
i s
pre
sent
repai r
orreplace
as
necessary
1
Apply soapy
soluti on or
submerge
ti re and wheelortube
i n waterafter
i nflati ng
i t
tospeci fi ed
pressure
2
I nspect
forleaks
3
Speci ally i nspect
forleaks around
valve
or
wheelri mand
along
tread
4 Note
bead
andri m
whereleakage
occurs
Wi pe
water
away
from
any
area
whi chleaks
ai rbubbles
andthen
markplace
wi th
chalk
S
Remove
object
whi ch caused
p
unctureandsealthe
poi nt
MA 31
Chassi s
and
Body
Mai ntenance
MAI NTENANCE
a When
repai ri ng B
puncture use 8
ti re
repai r
ki t furni shed
by any
ti re
dealer
followi ng
i nstructi ons
pro
vi dedwi thki t
b
I f 8
puncture
i stoo
large
or
therei s
lome
damage
toti refabri c
repai r
shouldbecarri edout
by authori zed
ti re
ller
6 Di scardwhen
any
ofthe
followi ng
problems
occurs
Broken
ordamaged
beadwi re
Ply
ortread
separati on
Worn fabri c
damage
on tubeless
ti re
Crackedor
damaged
si dewall
Ti res wi th
tread
weari ndi cator
showi ng
etc
CAUTI ON
When
replaci ng
ti re take extra care
n t to
damage
ti re bead ri m
flange
andbeadseat
Donot U58 ti re i ronstoforcebeads
away
from wheel ri m flange
that
i s
always use
ti re
replacement
devi ce
wheneverti rei rmoved
7
I nstall
ti re
noti ng
the
followi ng
i tems
a
I nstallvalve
core
aOd
i nflate to
properpressure
CheC
the
loceti ng
ri ngs
of the ti re tobe
sure
they
show
around the ri m
flanges
on
bothsi des
b Check valves
10rleakage
efteri n
flati ng
ti res
c Be
I Ufe
to
ti ghten
valve
capsfi rmly
by
hand
MA
32
WARNI NG
When whi le ti re
i s
bei ng
i nflated
bead
sni pS
over
safety hump
i t
mi ght
break
Thus
to
avoi dseri ous
personali njury
neverstli nll
over
ti rewhen
i nflati ng
i t Neveri nflate
toa
pressure greater
than 40
psi
275kPa
I f
beads
fai ltoseat
I t that
presRlre
deflate the ti re
lubri cate i t
agai n
and then
rei nflate i t I ftheti ra i s
overi nflated
thebead
mi ght
break
possi bly
resulti ng
i n seri ous
pl
r
sunal
i njury
WHEEL
I NSPEcnON
I nspect
wheel
taki ng
care of
the
followi ng poi nts
i n
ordertoensure
sati sfactory steeri ng
condi ti on as well
as
maxi mumti re
li feI f
any
defect i s
present repai r
or
replace
as
necess uy
I
Check wheelri m
especi ally
ri m
flangeand bead seat forrust di stor
ti on cracks
orotherfaults whi ch
mi ght
cause
ai r
leaks Functi on of
tubeless ti re
depends
on a
good
seal
between
ti re
beadand
wheel
ri m
2
Thoroughly
remove rust dust
oxi di zed rubber
orsand from
wheel
ri m
Ri m
bead seets
should be ct aned
wi th
the
followi ng
Steelwheel
Wi rebrush
coarsesteelwooletc
Alumi numwheel
Neutral
detergent
cloth
ole
3
Exami ne wheel
ri m
forlateraland
radi al
runout
usi ng
di al
gauge
B B
A A
SMA074
LaterI I I runout A and i ll
rvnout B
S I wheel
Leathi n
10mm
10
039i n
Lea
than
05mm
10
020i n
Di ff
ence
between
ri ght
and
left la btrel
runout
S
Alumi num
wheel
Alumi num I
Leathen
05mm
O
02Oi n
Leathan
02mm
OllOB
I n
4
Replace
wheelwhen
any
of the
followi ng
problems
occurs
Bent dentedor
heavi ly
rusted
Elongated
bolt holes
Excessi velateralorradi alrunout
Ai rleaks
through
welds
Wheelnuts wi llnot
stay
ti ght
Wheelbalance
I nspect
wheeland ti re
forwheel
balance and correct i t i f
unbalance
i s
present
taki ng
the
followi ng poi nts
i nto
consi derati on
I Correct
unbalance when the
symptom
of
unbalance
appears
as
wheel
tramps
andwheel
shi mmy
2
Balance wheel
and
ti re
both
stati cally
end
dynami cally
I aneln wheels
WARNI NG
When
balanci ng
wheeland
ti re on
the carbe SlI re to observe
the
equi pment
manufacturers i nstruc
ti ons
carefully
Cause
Wheelstati c
unbalance
Symptom
of
unbalance
Wheel
tramp
Wheel
shi mmy
Correcti ve
acti on
Balance
stati cally
Place
balance
wei ghts
here
Wheel
tramp
o
leavy
Locati on
Maxi mum
allowableunbalanClat
ri m
flange
10
g
035
oz
Baln
wei ght
10
6Og
O35 2
120z
at
10
D
10
35 odi nterval
SMA076
MAI NTENANCE Chassi sand
Body
Mai ntenance
Wheel
dynami cunbalance
Wheel
shi mmy
Balance
dynami cally
Wheel
shi mmy
o
Placebalance
wei ghts
here
Wheel
shi mmy
SMA075
a Be
sur
to
place
correct balance
wei ghtsoni nner
edge
of ri m
b Donot
put
more
than two
wei ghts
on
eachsi de
c
Two
type
6f balance
wei ght
are
used
onei s
desi gned
foruse wi th
steelwheel
and tha
other
for
u
e
wi thalumi num
wheel
Do
not mi x
di fferent
types
of balance
wei ghts
d
Properly
rebalance the wheel
and
ti ewhenever
puncture
i s
repai red
STEERI NG
SYSTEM
CHECKI NG
STEERI NG GEAR
OI L LEVELAND
LEAKS
Check flui d reaks
o
Addflui d
SMA604
CHECKI NG POWER
ST
EERI NG FLUI D
AND LI NES
I Mter
stoppi ng
the
engi ne
check
oi 11evel
i n
reservoi r
Check
di psti ck on
HOT
i de at
normal
operati ng
temperature
or
COLD i dewhen
oi li
cold
Addrecommendedoi li f
necessarY
CAUTI ON
00
not overfi ll
I
c
1
UI llI fI I
Oi l
levelshould
be
mai ntai ned
A
wi thi n
thi s
range
SMA12
MA33
Chassi s
and
Body
Mai nte UJJlce
MAI NTENANCE
2
I nspect
li necondi ti on
and
check
forleaks
Check for
flui d leaks
CHECKI NG STEERI NG
GEAR
BOX AND LI NKAGE
Steerlna
aeer
box
Check
parts
forlooseness wearor
damage
Reti ghten
i f
neccessary
RefertoSecti on ST
for
ti ghteni ng
torque
Steerlna I lnkeae
Check
parts
for
looseness
wearor
damag
Reti ghten
i f
necessary
RefertoSecti on ST
for
ti ghteni ng
torque
Check ball
joi nts
andi dlerarm
for
grease
leakage
Check for
any
mi ssi ng parts
cotter
pi ns
washeretc
SMA190
Q
Ch
ck
grease
leakage
Check
ti ghteni ng torque
MA 34
SMA
145
MAI NTENANCE
Chassi sand
Body
Mai ntenance
BODY
LUBRI CATI NG
LOCKS
HI NGES
AND HOOD LATCH
Lubri cati on
poi nts
TlI
i
c
SMA191
CHECKI NG
SEAT BELTS
BUCKLES
RETRACTORS
ANCHORS AND
ADJUSTER
O1eck
retractors
forsmooth
operati on
SMA232
MA
35
Cha i s
and
Body
Mai ntenance MAI NTENANCE
HEATER
AND
AlI I
CONDI TI ONER
CHECKI NG
REFRI GERANT
LEVEL
L
Open
doors
fully
2 Start the
engi ne
3
Set ai r
condi ti onerswi tch
to
ON
posi ti on
Amount
of
refri gerant
Almost
no
refri gerant
Check i tem
4 Set
temperature
leverto
maxi
mumcold
posi ti on
5
Set blower
tomaxi mum
speed
6
Checlc
si ght glass
afterthe
lapse
of
Temperature
of
hi ghpressure
andlow
pressure
li nes
Almost
nodi fference
between
hi gh
pressure
and
low
pressure
si de
temperature
Bubbles flow
conti nu
ously
Bubbles
wi ll
di sappear
amsom
thi ng
li kemi st wi ll
flowwhen
lI f
i glrant
i s
nearly gone
Statei n
si ght glass
nl
AC256
Pressureof
system
Hi gh
pressure
si de
i s
abnormally
low
top compnssor
i m
medi ately
andcon
duct
an overall
ch
k
Repai r
a The
bubbl
seen
through
the
si ght
glass
are
i nfluencedby
tha
ambi ant
temperature
Si nce
the
bubbl
ere
hard tohow
up
i n
comparati vely
low
temperature
below
20De
68d
Fh
i t i
possi ble
that a
li ghtly
larger
amount of
refri getant
would
be fi lled i f
uppli edaCCOrdi ng to
the
i ght glass
Be u to chock
MA 36
I nsuffi ci ent
Hi ghpressure
si de
i s
warmand
low
pressure
si dei s fai rly cold
Thebubbles
areseen
at i ntervalsof
1 2
seconds
n
r
I
AC257
Bothpress
reon
hi gh
and
tow
pressure
si des
are
sli ghtly
low
Check
fot
gas leakage
repai I
a
lequi ted
re
pleni sh
and
charge
system
the
amount when i t exceeds
2DoC
68DF I n hi gher
temperatura
the
bubble
ara
easy
to
show
up
b When the screen
i n the recei ver
dri eri
clogged
tha bubble wi ll
appear
en
i f theemount of refri g
erant i s
normal
I n
thi s case the
outlet si de
pi pe
of
tha
racei verdri er
bacome
consi derebly
cold
about fi vemi nutes
Judge
accordi ng
to
the
followi ng
table
Sui table Too
much
refri genmt
Hi ghpressure
si de
i s
hot and
low
pressure
si de i s
cold
Hi gh
pressure
si de i s
abnormally
hot
Almost
transparent
Bubbles
may
appear
when
engi nespeed
i s
rai sed
and
lowered
No
bubbles
canbeseen
Nocleardi fferencrexi stsbetwen
thMetwo
condi ti ons
n
AC258
Both
pressures
on
hi gh
andlow
pressure
si des
are
nonnal
Both
pres
ureson
hi gh
andlow
pressure
si des
are
abnormally
hi gh
Di scharge
refri gerant
fromserVi ce
val
eof
lowpressure
si de
CHECKI NG COMPRESSOR
DRI VE
BELT
Refer
to
Engi ne
Mai ntenance for
i nspecti on
and
adjustment
CHECKI NG
HOSES AND
PI PES
Check
heater
and ai r
condi ti oner
for
damaged
hoses or
pi pes
due to
i n
terference
orfri cti on
wi th
adjoi ni ng
parts
I f
damage
i s mi nor
repai r
thoseaffected
hose or
pi pes
I f
damage
i s
major
and
i f
therei s
the
possi bi li ty
of
encounteri ng
holes replace
the
affected
parts
Carefully
check hoses
and
pi pes
especi ally
thOle
locatedCI OM
to
moy
i ng parts
Or
sharp edge
of
panel
CHECKI NG
REFRI GERANT
LEAKS
Conduct
a leak
test
wi th
hali de
or
electri cleak detector
whenever
leakage
of
refri gerant
i s
suspected
and
when
conducti ng
servi ce
operati ons
whi ch
are
accompani ed
by di sassembly
or
looseni ng
ofconnecti on
fi tti ngs
MoI Jor
check
poi nt
I
Compressor
Compressor
shaft sealrotate the
compressor
by
hand
Flexi ble
hose
connecti ons
Front andrear
head
gaskets
Servi cevalve
2 Condenser
Condenser
pi pefi tti ng
Condenser
i nlet
and
outlet
pi pe
connecti ons
3
Refri gerant
li nes
Flared
secti on of
hi gh
pressure
and
low
pressure
flexi blehoses
li ne
connecti ons
4
Evaporatorhousi ng
I nlet andoutlet li ne
connecti ons
Expansi on
valve
Sucti on
throttlevalve
111
1
I I lI
Flame
adjusti ng
li nes
MAI NTENANCE Chassi s
and
Body
Mai ntenance
Engi ne
co
ressor
a
o
I
L
Condenser
I
SMA233
Sampli ng
tube
The followi ng
i nformati on and
cauti ons
shouldbe
kept
i n
mi nd when
checki ng
for
leakage
SMA150
MA 37
Chassi send
Body
Mai nt mance
MAI NTENANCE
I f
a
hali de
leak detector
i s used de
termi ne
whether
ornot
there
i s
gas
leaki ng
by
thecolorof theflame as
i ndi catedi nthechart below
Propane
type
Butane
type
NOLEAK
Greeni sh
blue
Pale
blue
SMALL
LEAK Yellow
Bri ght
blue
LARGE
LEAK
Purple Vi vi d
green
WARNI NG
a
Neveri nhalethe
fumes
produced
by
combusti onof J
nt
gas
si nce
they
aretoxi c
b Neveruse
hali detorchi na
place
where combusti ble
or
explosi ve
gas
i s
present
MA 38
Si nce
refri gerant gas
i s
heavi erthan
ai mallleaks canbe
easi ly
detect
ed
by
placi ng sampli ng
tubedi rect
ly
belowthecheck
poi nt
I f
eny
trace
of oi li noted at and
around connecti on
fi tti ngs
i t
i s
a
sure
i ndi cati on that
refri gerant
i s
le
ki ng
I fa
gas
leak
i s
detectei l
proceed
as
follows
I
Check
torque
on
the
connecti on
fi tti ng
and i ftooloose
ti ghten
tothe
proper
torque
Oi eck for
gas leakage
wi th
a leakdetector
2
I f
leakage
conti nues even
after
the
fi tti ng
has been
reti ghtened
di s
chargerefri gerant
from
system
di scon
nect
the
fi tti ngs
andcheck i t
eati ng
face for
damage Always
replace
even
i f
damage
i s
sli ght
3
Che
k
compressor
oi landaddoi l
i f
requi red
4
Oi arge refri gerant
and
recheck for
gas
leaks I fnoleaksarefound evacu
ateand
charge
system
OFF
SEASON MAl
ANCE
Even i n
the offseason turn
the
compressor
for10mi nutes at least
once
a month
by
runni ng
the
engi ne
at
i dli ng rpm
MAI NTENANCE Servi ce
Dataand
Speci fi cati ons
SERVI CE DATA AND SPECI ACATI ONS
ENGI NE
MAI NTENANCE
I NSPECTI ON
AND ADJUSTMENT
Basi c
mecl
anlcalsystem
Valveclearance
mmi n Hot
Cold
I ntake
03010Ot 2 02t 10
008
023
100091 Exhaust
0
30OOt 2
Dri vebelt defleti on
Fan
AlternatorAi rcondi
ti oner
compressor
and
Power
steeri ng
oi l
pump
mm
i n
8
t210
3t 047
Appli ed pressed
force
N
kg
lb
98110221
Compressi on pressure
kPa
kg cm2 psi lrpm
Standard
t
t77lt2
0
17t1
350
883 90t 281350
Mi ni mum
At
ambi ent
temperature
200C 680F
Afterchecki ng
valve
clearancewhi le
engi ne
i s
cold I socheck i t whenengi ne
i shot
to
i f i t remai ns
wi thi nthe
Jpeci fi
value I fi t does
not
rudjuni t
I
ni ti on andfuel
system
Spark plug
Type
Plug gap
mm i n
Hot
type
Cold
type Standard
I StBnd
U S A
ard
I
Opti
on
8P7ES 8P5ES 8P6ES
08 0
9
003t
0035
8PR6ES 8PR5ES
8PR7ES
ResUor
bui lt
i n
type
I I
ohm
I
Lessthan 30
000
Canada
Hi gh
tensi on cableresi stance
I gni ti on
ti mi ng
i dle
speed
andi dle CO
1
on cali forni a
Cali fronhi models
1
models
I
ManuOl
tran
mi ssi on
8t 20B T D C
60B T D C
I
700 l100
700l
100
I
Automati ctran
mi ssi on 8l20B T D
C
60
B T OC
I
li n
0
posi ti onI
700tOO 700
tOO
1
3i
t
I dlemi xturescrew
CO
at
i dli ng speed
i spreset
and
No
ai r
sealedat factory
Emi ssi on
control
system
Uni t kPa
mmH20
i nH201
Vapor
li ne
leakage
es
Suppli edpressure
3923 40015 751
Pressure vari ati on Lessthan0245 25 0981
TI GHTENI NG TORQUE
Uni t
N
m
kg m
ft
I b
Rockerarm
nut 16 22 t 6 22 12 t6
Oi l
pan
drai n
plug
2029 2030 t4 22
I
Spark plug
t5 20 15 20 tt
t4
Fuelhose
clamp
10t 5
O
tO 0t5
0
7
11
h
3mm012 i n
l
@
Fuelhoseclampi ng posi ti on
EF335A
CHASSI S AND
BODY
MAI NTENANCE
I NSPECTI ON
AND ADJUSTMENT
Clutch
Uni t
mm
i nl
Pedal
hei ght
H
t68 1741661
6851
5
10
04 020
Pedal
free
play
AU
Front
axleand
front
suspensi on
Axi al
play
mm i nl
0
01
Wheel
beari ng
Pl
eload
As
measured
at
wheelhub bolt
Wi thnBWpBrts N
I kg
lbl
69
t4
710
7 15 15
3
3
Wi thusedpart N
I kg
I bl
2
078 020
8
04 t81
Wheel
ali gnment
Camber degree
40
SO
Carter degree
1045 3015
Ki ngpi n
i ncli nati on
degree
7025
8055
Toei n Unladenl
o
2 mm
10008i nl
0
12 On
both
si des
Si de
sli p
Reference
data
Out
1 mm I n1
mmm
Out
0012i n I n0
012i n
ftl
MA 39
Speci alSi
rvi ceTool MAI NT NANCE
Standard
i derod
length
A
mmli nl 71012 80
Front wheel
turni ng angle
Toe out
turnsI Wheni nner
wheeli
200
I
degree
Outerwheel 1870
Fullturn degree
I nnerwheel
33350
270
29
Outerwheel
On
powersteeri ng
models wheel
turni ng
force lat ci rcumference
of
steeri ng
wheelof 98 147 N110 15
kg
22
33I b wi then
gi ne
at i dle
Brake s stem
Uni t
mm
li n
N22 210 081
2
10001
105
104131
8610339
155 16116
106
341
5
10 04 0201
Padwearli mi t
AN12H
N22
Rotor
repai r
li mi t
AN12H
Pedal
hei ght
h
Pede
fre8
play
a
Pedaldepressedhei ght Morethan60f2
36
Parki ng
brake
Leverstroke 8t
pulli ri g
00t96N120
kg
44lbll
901001354 3941
Number
of
notches 7 8
Wheelandti re
Recommended I dti re
i nflati on
pressure
t85 7OSR14 26psi 1177 kPaI
Ti resi ze
00not
use
i n
excess
of
80
kmlh150MPHI
Spare
ti re
T135 70DI 6
60
psi 1412
kPa
Ti re
prlSlure
shouldbecheckedwhenti resareCOLD
Wheelri mlateraland radi al
mm i n
runout
LeCsthan1 00039
05 1002002
Di fferencebetween
ri ght
endleft lateralrunout
Less than 05
0
020
1
02
10
008 2
mm i n
Wheelbalance
Maxi mumallowable
unbelanceat i m
flange
grozl
to
1035
Ti re
balanci ng
wei ght
10
601035
2
121
Spacng
to10
351
gr
loz
1 Steet wheel
2
Alumi num
wheel
TI GHTENI NG TORQUE
Uni t N
m
kg
ft fb
Clutch
Pedal
stopper
lock nut 78
11 8
08
12 5 8 8
7
Mastercyli nder
push
78 118 08 t2 588
7
rodlocknut
Manual
transmi ssi on
Drai nand
fi ller
plugs
25 34 25 35 18 25
Propeller
shaft and
di f
ferenti alcarri er
Di fferenti alcarri er
59 98
6
10 43 72
drai nand
fi ller
plugs
Front axleand
front
suspensi on
Si derodlock
nut
78 98 80toO 58 72
Brake
system
Ai rbleedvatve
69 8
8 07
O
51 65
Brake
lamp
swi tch
12
15 12 1 5 9
11
locknut
Brake
booster
i nput
16
22 1622 12 16
rod
k
nut
Wheel
and ti re
Wheelnut
78
98 80toO
58
72
SPECI AL
SERVI CE
TOOL
Tool
number
Kent
Moore
No
Toolname
ST19320000
125664
Oi lfI lterwrench
MA 40
SJ
DATSUN 200SX
ModelS 0
Seri es
ENGI NE
MECHANI CAL
CONTENTS
ENGI NE
COMPONENTS
Outerparts
ENGI NE COMPONENTS
Body parts
ENGI NE
DI SASSEMBLY
PRECAUTI ON
DI SASSEMBLI NG
ENGI NE
OVERALL
DI SASSEMBLI NG
PI STON
AND
CONNECTI NG ROD
DI SASSEMBLI NG CYLI NDER HEAD
DI SASSEMBLI NG
I NTAKE
MANI FOLD
I NSPECTI ON AND
REPAI R
CYLI NDER
HEAD
VALVE
VALVE SPRI NG
ROCKER
ARMAND ROCKER SHAFT
GAMSHAFT AND CAMSHAFT BEARI N
CYLI NDER BLOCK
PI STON PI STON PI N AND
PI STON
RI NG
EM 2
EM 3
EM
4
EM 4
EM 4
EM 6
EM 6
EM 6
EM
7
EM 7
EM 8
EM
8
EM
8
EM 8
EM
9
EMlO
CONNECTI NG ROD
CRANKSHAFT
MAI N BEARI NG
AND
CONNECTI NG
ROD
BEARI NG
MI SCELLANEOUS COMPONENTS
ENGI NE
ASSEMBLY
PRECAUTI ONS
ASSEMBLI NG
CYLI NDER
HEAD
ASSEMBLI NG PI STON AND
CONNECTI NG
ROD
ASSEMBLI NG I NTAKE MANI FOLD
ASSEMBLI NG
ENGI NE OVERALL
SERVI CE
DATA AND
SPECI FI CATI ONS
I NSPECTI ON
AND ADJUSTMENT
TI GHTENI NG TORGUE
TROUBLE
DI AGNOSES
AND
CORRECTI ONS
SPECI AL SERVI CE
TOOLS
EMll
EMl1
EM 12
EM12
EM14
EM14
EM14
EM15
EM16
EM
16
EM20
EM20
EM24
EM
25
EM
27
Engi neComponenrs
Outer
parts
ENGI NE
MECHANI CAL
ENGI NE
COMPONENTS
Outer
parts
I I i gb
temi on coble
1
l
I ntake
mani foldst
y
Il
34
44
35
4
5 25 33
EA tube
E
G
R
ValVe
Exhaust mani fold
1l16
21
i ti 6
2
t
Starter
motor
1l16
21
16 2 1
t2 t5
I ntakemani fold
157 12
16 87 116
Alternatoradjusti ng
bar
Fanbelt
J 29 39
30
4
022
P
C
V valve
Oi lpump
J
Nm
tg
m
ft lb
15
8 11
SEM136
EM
2
ENGI NE
MECHANI CAL Engi ne
Components
Body
parts
ENGI NE
COMPONENTS
Body
parts
Front
cove l
Valverockercover
I f 16
22
16
22
2
Valve
rocker
and
shaft assem
bly
@ Exhaust
tntake
9
Vatvecotter
eam
shaft
Spri ng
retai ner
Rubber
e
1
Oi lseal
plug Spri ng
seat
j
snap
ri ng
Valve
gUi de
Cyli nder
head
bolt
I f
69
18
Valve at
1
0
80
51 58
Cyli nder
head
Camshalt
sprocket
Cyli nder
li ner
Only for
servi ce
Cyli nder
block
t51
t6
116
Dri ve
plate
151
16
116
Oi ldrai n
plug
I f
2029
2
0 3014
22
I f
N
m
kg
m ft lb
EM137
EM
3
Eqgi neDi sassemb y
ENGI NE
MECHANI CAL
PRECAUTI ON
Arrange
the di sassembled
parts
on
the
parts
stand i n
accordance wi th
thei rassembled locati ons
sequence
etc sothat the
parts
wi llbe
reas
sembled to thei r
ori gi nal
locati ons
Place
mati ng
marks on the
parts
i f
necessary
DI SASSEMBLI NG
ENGI NE OVERALL
MOUNTI NG
ENGI NE
ON
WOi tK
STAND
I Remove
followi ng
parts
located
at rear
and
ri ght
si deof
engi ne
Starterotor
Transmi ssi on
Clut
h
cover
assembly usi ng
Tool
KV30100100
or
torque
convertor
I ntakemani fold
stays
Alternatorandi ts
bracket
Engi ne mounti ng
bracket
2 I nstall
engi ne
attachment to
cyli nderblock Then mount the
engi ne
ontheworkstand
SEMl38
3
Drai n out
engi ne
oi l
and
coolant
REMOVI NG OUTER PARTS
4
Remove
engi ne
front si de
parts
Fan
Dri vebelts
Belt
tensi oner
for
powI
steeri ng
i f
equi pped
Alternator
adjusti ng
bar
Water
pump
Vacuumtube
assembly
for
di stri bu
tot
andcani ster
EM4
ENGI NE
DI SASSEMBLY
Crankshaft
pulley
Usesui tabletool
on
ai r
condi ti oner
equi pped
model
SEMl39
5
Remove
engi ne
left si de
parts
Di stri butor
cap
and
hi gh
tensi on
cables
Di stri butor
Exhaust mani fold
wi th ai r
i n
ducti on tubes after
removi ng
E G
R
tube
SEM140
Compressor
brac ret
i f
equi pped
Oi llevel
gauge
Engi ne
mounti ng
bracket
Spark
plugs
6
Remove
engi ne
ri ght
si de
parts
I
Cyli nder
block to PC
V
valve
hose
2 Power
steeri ng
pump
bracket and
throttlechamber
stay
i f
equi pped
3
I ntake mani fold
mbly
i nclud
i ng
wateri nlet water
pi pes
waterout
let
vacuumtubes
E
G R valve throt
ti e chamberand
EFI
parts
lnjecturs
fuel
pi pes
ai r
regulator
etc
SEM142
4 And
follpwi ng
parts
Oi lf1I ter
usi ng
Tool
STl932ci OOO
Oi l
pressure
swi tch
Spark
plugs
7 Remove
engi ne
bottomsi de
parts
Oi l
pump
and
oi l
pump
dri ve
spi ndle
Gussets
REMOVI NG BODY PARTS
8 Removeoi l
pan
and
oi l
strai ner
9 Removevalve
rockercover
10Remove
cyli nder
head
assembly
1
Remove camshaft
sprocket
and
slowly
lower
ti mi ng
chai n
2
Loosen
cyli nder
head boltsi n
the
sequence
shown
SEM144
3
Remove
bolts
securi ng
cyli nder
headto
front cover
4 Remove
cyli nder
head
When
removi ng cyli nder
headfrom
engi ne
i nstalled
on carfollow
the
i nstructi onsbelow
8 Turn crankshaft
unti lNo1
pi ston
i s
at TD C on i ts
compressi on
stroke
b Tofaci li tate
assembli ng operati on
scri be a mark on
ti mi ng
chai and
camshaft sprocket
wi th
pai nt
before
removal
c
Support
ti mi ng
chai n
by uti li zi ng
Toolbetween
ti mi ng
chai ns
I I Removefront si de
parts
I Front cover
2 Chai n
tensi onerandchai n
gui de
3
Ti mi ng
chai n
4 Oi lthroweroi l
pump
dri ve gear
andcrankshaft
spr
ocket
ENGI NE MECHANI CAL Engi ne
Di sassembly
1 Chai ntensi oner
2
Slack
si dechai n
gui de
3 Tensi on
si dechai n
gui de
40
i lthrower
5 Oi l
PUJlP
dri vegear
6
Crankshaft
sprocket
I f
i t i s
hard to
extract
crankshaft
sprocket
use
a sui table
puller
EM286
12
Remove
pi ston
and
connecti ng
rod
assembly
I Remove
connecti ng
rod
beari ng
cap
wi th
beari ng
2
Pushout
pi ston
wi th
connecti ng
rod toward
cyli nder
headsi de
J1c l
J
C
j
I
r
G 0
I I
O
EJ S7
8 Pi ston can
be
easi ly
removed by
scraJi i ng
carbon off top
face of
cyli nder
wi tha
scraper
b Numbers are
stamped
on connect
i ng
rod
and
cap correspondi ng
to
each
cyli nder
Care should
betaken
to
avoi d
wrong
combi nati on
i nclud
i ng
beari ng
13
Remove
flywheel
andend
plate
WARNI NG
When
removi ng
flywheel
be
careful
not to
drop
i t
14
Removecrankshaft
1
Remove mai n
beari ng caps
wi th
beari ngs
8
When
looseni ng
mai n beari ng
cap
bolts loosen from
outsi de i n se
quence
b Use
Toolto
remoye
centerand
rear
mai n beari ng
caps
Keep
them i n
order
KVI OI 041S0
EM608
f
Remove
rear
oi lseal
T
@rb EM1QO
EM5
Engi neOi sa Sl fTlbly ENGI NE
MECHANI CAL
3 Removecrankshaft
4 Remove mai n
beari ngs
at
block
si de
15 Remove
baffle
plate
and steelnet
from
cyli nder
block
DI SASSEMBLI NG
PI STON AND
CONNECTI NG
ROD
1 Remove
pi ston ri ngs
wi tha
ri ng
remOver
2
Press
pi ston pi n
out
usi ng press
and
Too
ST13030001
EM156
Keep
the
di sassembled
parts
i n
order
EM 6
DI SASSEMBLI NG
CYLI NDER
HEAD
1
Remove
rocker
shaft
assembly
together
wi th
securi ng
bolts
a
Donot removebolu at
No1
and
No5 brackeU si nce rockershaft
bracket
and
rockerwi ll
spri ng
out
b When
looseni ng
bolts
evenly
loosen
from
outsi dei n
sequence
SEM145
2 Removecamshaft
3 Remove
valves
valve
spri ngs
and
relati ng partsusi ng
Too
ST12070000
Keep
the di sassembled
parts
i n
order
DI SASSEMBLI NG
I NTAKE
MANI FOLD
1
Remove followi ng
fuel
system
parts
referri ng
toSecti on EF
I
Throttlechamber
2
Ai r
regulator
3 Fuel
andvacuumtube
assembly
4 Fuel
pressure
regulator
5
I njectors
6 Throttle
controlcablebracket
2
Remove
cooli ng
system
parts
1
Water
outlet
2
Thermostat
3
Water
gallery
4 Wateroutlet
5 Semol
housi ng
6
Water
pi pe
3 Remove
followi ng
emi ssi on con
trol
system
parts
referri ng
toSecti on
EC
E
G
R controlvalve
ThermalvacuumvalveS
Nota
i nstalled
di recti onof
i nlet and
outletfor
reassembly
Vacuumcontrolvalve
Posi ti vecrankcaseventi lati on
valve
4
Remove followi ng
mi scellaneous
parts
Fast i dlecontroldevi ce
i f
equi p
ped
Plugs
Vacuumconnectors
Note
i nstalled di recti on
of outl
t
forr
mbly
Water
temperature
sensors
5
Di sassemble i ntake
mani fold
body
CYLI NDER HEAD
CYLI NDER HEAD MATI NG
FACE
I
Makea vi sualcheck for
cracks and
flaws
2
Measure the surface of
cyli nder
head
on cyli nderblock si de for
warpage
I f
beyond
the
speci fi ed
li mi t
correct
wi th
a
surface
gri nder
Warpage
of surface
li mi t 01 mm 0004i nt
I t
Ci l
SEM14g
Surface
gri ndi ng
li i t
The
gri ndi ng
li mi t of
cyli nderhead
i s
determi ned
by
the
cyli nder
block
gri ndi ng
i nan
engi ne
Depth
of
cyli nder
head
gri ndi ng
i s
A
Depth
of
cyli nder
block
gri ndi ng
i s
8
li mi t
A B 02 mm10
008
i n
VALVE GUI DE
Measure the clearance between
valve
gui de
and
valve stem I fthe
clearance exceeds the
speci fi ed
li mi t
replace
the worn
parts
orbothvalve
and valve
gui de
I n
thi s case i t i s
essenti alto
detenni ne
i f sucha clear
ance has been caused
by a
worn Or
bent valve stem or
by
a
worn valve
gui de
Determi ni ng
clearance
Preci se
method
I
Measure the di ameterof valve
ENGI NE MECHANI CAL
lnspecti onandRepai r
I NSPECTI ON AND REPAI R
stem wi th
a
mi crometeri n
three
places
top
centerand
bottom
2
Measure valve
gui de
horeat center
usi ng telescope
hole
gauge
F
A
T
Mr
h
oP
10
1
L j1
@
I
C
d
SEM150
3
Subtract the
hi ghest
readi ng
of
valve stem di ameterfrom
valve
gui de
bore toobtai n thestemto
gui de
clear
ance
Stemto
gui de
clearance
li mi t 01 mm10004i n
2
Expedi ent
method
Pry
valve
i n lateraldi recti on and
measure deflecti on at stem endwi th
di al
gauge
Stemend
deflecti on
li mi t
0
2
mm
0
008
i n
Valve
shouldbe moved i n
parallel
wi throcker
arm
Generally
a
large
amount
of
wear
occurs
i n thi s
di reC
ti on
SEM151
Replacement
of valve
gui de
1 Toremove
old
gui des
use Tool
S111033000
and a
press
undera
2
ton
pressure or
a hammer
Dri ve them out toward rocker
coverHeated
cyli nderhead wi ll
faci li tatethe
operati on
2 Ream
cyli nder
head
valve
gui de
hole
usi ng
Tool
at
room
temperature
Reami ng
bore
12185 12
196
mm
0
4797
0
4802
i n
SEM152
3 Fi t
snap ri ng
on
newvalve
gui de
and
press
the
gui de
i nto
head unti l
snap
ri ng
comes i n
contact wi th
cyli nder
head surface
after
heati ng
cyli nder
headto
150
to2000C 302
to
3920F
Valve
gui de
of
0
2 mm 0008 i n
oversi ze
di ameter
i s
avai lable for
servi ce
RefertoS
D
S
4
Ream the
bore
usi ng
1001
STl1032000
Reami ng
bore
80008018
mm
0
3150
0
3157
i n
5
Correct valve seat
surace wi th
newvalve
gUi de
as theaxi s
VALVE SEAT I NSERTS
Check valve seat
i nserts for
any
evi dence
of
pi tti ng
at valve contact
surface andreseat or
replace
i f
worn
out
excessi vely
Correct valveseat surfacewi thTool
and
gri nd
wi tha
gri ndi ng
compound
EM
I nspecti on
and
Repai r
ENGI NE MECHANI CAL
Valve seat i nsert
of
05 mi n 0020
i n oversi ze i s avai lableforservi ce
Referto
S O
S
J
a
When
repa nng
valve
seat
check
valve
gui de
for
wear
beforehand I f
worn replace
i t Then
correct
valve
seat
b The
Toolshould
beused wi th
both
handsforuni form
cutti ng
Replacement
valveseat
i nsert
I Old i nsert can be removed
by
bori ng
out unti li t
collapses
The
machi ne
deplh
stop
should
be
set
so
that
bori ng
cannot
conti nue
beyond
thebottomface of
the
i nsert recess
i n
cyli nder
head
2
Select a sui table valve seat i nsert
andcheck
i tsoutsi de
di ameter
3 Machi ne
cyli nder
head recess to
the concentri c
ci rcles tovalve
gui de
center
4 Reamthe
cyli nder
head recessat
room
temperature
RefertoS
O
S
5 Heat
cyli nder
head 10a
temper
atureof 150to
2000C
302to
3920F
6
Fi t
i nserl
ensuri ng
that i t
beds on
the bottom face of
i ts
recess
and
caulk morethan 4
poi nts
7
Valveseats
newly
fi ttedshould
be
cut or
ground
usi ng
ToolST1l65000l
at the
speci fi ed
di mensi ons
as
shown
i nS OS
8
Apply
small
amount of fi ne
gri ndi ng
compound
tovalve
contacti ng
face and
put
valve
i nto
gui de Lap
valve
agai nst
i ts seat unti l
proper
valve
seati ng
i s
obtai ned Remove
valve and
then
cleanvalveandvalveseat
EM 8
VALVE
I Check
each
of
the i ntake and
exhaust valve forworn damaged
or
defonned
valve
head
or
stem
Correct
or
replace
thevalvethat i s
faulty
Refer
to
Sos
2 Valve faceorvalvestem end
sur
faceshouldbetefaced
byusi ng
avalve
gri nder
Valve
head
margi n
Li mi t
0
5
mm10
020i nl
Gri ndi ng
of valve stemend
Li mi t
05
mm
10
020i n
EM111
vALVE SPRI NG
1
Check valve
spri ng
for
squareness
usi ng
a steel
square
andsurface
plate
I f
spri ng
i s out
of
square
S
more
than
speci fi ed
li mi t
replace
wi thnew
ones
Out
of
square
S
Outer
Li mi t
1 6mm
0
063
i n
I nner
Li mi t 1
6
mm10063
i nl
J
0
i BEM29s
2
Measure the
free
length
andthe
tensi on ofeach
spri ng
I fthe
I lleasured
value exceeds
the
speci fi ed
li mi
I
re
place
spri ng
RefertoS
Os
EM113
ROCKER ARMAND
ROCKER
SHAFT
1 Check rockerannsand
shafts for
si gn
of wearordamage
andi f worn
excessi vely replace
rockerarmandor
shaft
2
Check
oi l clearance between
rockerarm
androckershaft
Rocker
arm
toshaft
clearance
0
007
0049mm
100003
00019i nl
CAMSHAn AND
CAMSHAn
BEARI NG
CAMSHAFT BEARI NG
CLEARANCE
Measurethei nsi de
di ameterofcam
shaft
beari ng
wi than i nsi de
di al
gauge
and theoutsi de di ameter
of camshaft
journal
wi th
a mi crometer
I f
any
malfuncti on
i s
found
replace
camshaft
or
cyli nder
head
assembly
Camshaft
beari ng
clearance
li mi t
01
mm
10
004
i nl
SEM154
CAMSHAFT
ALI GNMENT
I Check
camshaft camshaft
journal
and cam
surface forbend wearor
damage
I f
beyond
the
speci fi ed
li mi ts
replace
the
parts
2
A bend value
i s one
half of the
total
i ndi catorreadi ng
obtai nedwhen
camshaft
i s turnedone full
revoluti on
wi th
a
di al
gauge
at
center
journal
Camshaft
bend
Totali ndi catorreadi ngl
li mi t 010
mm
10
0039
i n
SEM156
3 Measure
camshaft
cam
hei ght
I f
beyond
the
speci fi ed
li mi t
replace
camshaft
Wear
li mi t
ofcom
hei ght
0
25
mm10
0098i n
4
Measure camshaft end
play
I f
beyond
the
speci fi ed
li mi t
replace
camshaft or
cyli nder
headassembly
Camshaft end
play
li mi t
02
mm
0008
i n
CYUNDER BLOCK
1
Vi sually
check
cyli nder
block for
cracksorflaws
2 Measure the
top
of
cyli nder
block
cyli nder
head
mati ng
face for
warpage
I f
i t
exceeds
the
speci fi ed
li mi t correct
wi tha
gri nder
Warpage
ofsurfaC8
li mi t
0
1
mm 0004
i n
ENGI NE MECHANI CAL I tJSPecti onand
Repai r
EM540
Surface
gri ndi ng
li mi t
The
gri ndi ng
li mi t of
cyli nder
block i s
determi ned
by
the
cyli nder
head
gri nd
i ng
i n
an
engi ne
Depth
of
cyli nder
head
gri ndi ng
i s
A
Depth
of
cyli nder
block
gri ndi ng
i s
8
li mi t
A B
02
mm
0008i n
3
Usi ng
a
bore
gauge
measure
cyli n
derbore
for
wear
out ofround or
taper
I f those
are excessi ve rebore
the
cyli nder
walls
by
means
of
a
bori ng
machi ne Measurement
should
be
taken
along
bores
for
taper
and
aroundbores forout
of round
RefertoS OS
Out of
round Xy
Taper
A B
FA
J
1zU
0791
I
I i I L
60
12
361
I I I
I
fli t
17
X
I
Uni t
mm
i n
EM422
L
I
EM124
4
When wear
taper
or
out ofround
i s mi norand wi thi ntheli mi t
remove
the
step
at the
topmost
porti on
of
cyli nderusi ng
a
ri dge
reamerorother
si mi lartool
I f
cyl
i nderbore
has
worn
beyond
thewear
li mi t
use cyli nder
li ner
Undersi ze
cyli nder
li ners
areavai l
ablefor
servi ce
RefertoS D S
I ntarferenC8
fi t of
cyli nder
li ner
0
08
to
0
09mm
0
0031
to
0
0035
i n
CYLI NDER
BORI NG
When any cyli nder
needs
bori ng
all
other
cyli nders
must alsobe
boredat
thesameti me
Determi ni ng
bore
si ze
1 Determi ne
pi ston
oversi zeaccord
i ng
toamount
ofwearof
cyli nder
Oveni ze pi stons
are avai lable
for
servi ce
Refer
to
S D S
2
The si ze
to
whi ch
cyli nders
must
be
honed i s determi ned
by addi ng
pi ston
to cyli nder clearance to
the
pi ston
ski rt
di ameter
A
T
tI
A
SEM714
EM126
Di men i on
di stancefrom
center
of
pi nl
Approxi mately
20
mm 0
79
i n
EM
9
I n5Pecti onandRepai r
ENGI NE MECHANI CAL
Rebored
si ze
calculati on
D A B
C A 0005 to
0025 mm
0
0002to00010i n
where
D
A
B
C
Honeddi ameter
Ski rt
di ameteras measured
Pi ston
to
wallclearance
Machi ni ng
allowance
002mm 0
0008i n
Bori n
g
CAUTI ON
a To
prevenl
strai n due
to
cuni ng
heat borethe
cyli nders
i n theorder
of 241 3
b Before
bori ng
any
cyli nder
i nstall
mai n
beari ng
caps
i n
place
and
ti ghten
tothe
speci fi cati on
sothat
the
crankshaft
beari ng
bores
wi ll
not
become di storted from
the
bori ng operati on
3
Do
not cut toomuchout of
cyli n
derbore
at a
ti me
Cut
only
005 rnm
0
0020
i n
orso
i n
di ameterat a ti me
4 As a fi nal
step
cyli nders should
behoned
to
si ze
5
Measure
the
fmi shed
cyli nderbore
for
out
f
roundor
taperedpart
Referto
SDS
Measurement
of a
just
machi ned
cyli nderbore
requi res
utmost
care
si nce i t i s
expanded
by cutti ng
heat
Measuri ng pi ston
to cyllnder
clearance
6
Thi s clearance
can
be checked
easi ly by
usi ng
a feeler
gauge
anda
spri ng
balance
hookedonfeeler
gauge
measuri ng
the
amount of force
re
qui red
to
pull
gauge
oUt frombetween
pi ston
and
cyli nder
Feeler
gauge
used
0
04
mm
0
0016i n
Extracti ng
force
2
014
7 N
02 1 5
kg
04 33
I bl
a
When
measuri ng
cl
slOWly
pull
feeler
gaugestrai ght
upward
b I t i s
recommendedthat
pi ston and
cyli nder
be
heated
to200C
680F
EM10
I
l
t
Jl
l
EM641
PI STON
PI STON
PI N
AND PI STON
RI NG
PI STON
I
Scrape carbon off
pi ston
and
ri ng
grooves wi th
a
carbon
scraper
and
a
curved steel
wi re
The
wi re
wi llbe
usefuli n
cleani ng
bottomland of
ri ng
groove
Oean
out
oi l
slots
i n
bottom
land ofoi l
ri ng groove
2
Check for
damage
scratches
and
wear
Replace
i f
sucha
fault i s
de
tected
PI STON
RI NG
I Measurethesi declearanceof
ri ngs
i n
ri ng grooves
as each
ri ng
i s
i nstalled
I fsi de clearance exceeds the
speci
fi edli mi t
replace
pi ston
together
wi th
pi stonri ng
Si de
clearance
Li mi t 01 mm0004i nl
EM129
2
Measure
ri ng
gap
wi tha feeler
gauge placi ng
ri ng squarely
i n
cyli nder
usi ng pi ston
Ri ng
should be
placed
todi i lmeter
at
upper
orlowerli mi t of
ri ng
travel
I f
ri ng gap
exceeds the
speci fi ed
li mi t
replaceri ng
Ri ng gap
Li mi t 1 0mm 0039i n
8
When
pi ston
ri ng only
i s
to
be
replaced
wi thout
cyli nder
bore
bei ng
corrected
measure
the
gap
at
the bottom of
cyli nder
where the
weari smi nor
b
Oversi ze
pi ston
ri ngs
are
avai lable
for
servi ce
05 mm
0
020
i nl1 0
mm
0039
i n oversi ze
PI STON PI N
1
Check the
fi tti ng
of
pi ston
pi n
i n
to
pi stonpi n
holeto
be
suchan
extent
that i t
can be
pressed
smoothly by
fmger
at room
temperature
Thi s
pi s
ton
pi n
must be
a
ti ght
press
fi t
i nto
connecti ng
rod
2
Measureoi lclearancebetween
pi s
ton
pi n
and
pi ston
I fi t
i s
excessi ve
replace pi ston pi n together
wi th
pi s
ton
Pi ston
pi n
to
pi ston
dearance
0006 0013mm
00002 00005 i n
CONNECTI NG ROD
I
I f
a
connecti ng
rod has
any
flaw
on both
si des
of the thrust face and
the
large
endcorrect or
replace
i t
2 Check
connecti ng
rod forbendor
torsi on
usi ng
a
connecti ng
rod
ali gner
I f
bend or
torsi on exceeds theli mi t
correct or
replace
Bend andtorsi on
per
100mm
3
94i n
length
li mi t 005
mm
100020i n
EM133
3
I nstall
connecti ng
rods
wi thbear
i ngs
on
to
correspondi ng
crank
pi ns
and
measure the thrust
clearance I f
the
measured value
exceeds the
li mi t
replace
such
connecti ng
rod
Bi g
end
play
Li mi t
06
mm
00024i n
When
replaci ng
conneCti ng
rod
select sothat
wei ght
di fference be
tween each
cyli nder
i s
wi thi n
7
g
025
ozl
i n the
condi ti on
of
pi ston
and
connecti ng
rod
assembly
ENGI NE MECHANI CAL
I nspecti onsndRepai r
CRANKSHA
CRANKJOURNAL
AND PI N
I
Repai r
or
replace
as
requi red
I f
faults
are
mi norcorrect wi thfme
crocuscloth
2 Check wi tha
mi crometer
journals
and crank
pi ns
fortaper
and out of
round Measurement
shouldbe taken
along
journals
for
taper
andaround
journals
for
out of
round
I fout of roundor
taper
exceeds the
speci fi ed
li mi t
replace
or
repai r
Out of round
X
Y
li mi t 0
03
mm
00012i n
Taper
A BI
Li mi t 003mm
00012i n
I
A
B
EP
EM767
3
After
regri ndi ng
crankshaft fi ni sh
i t
tothe
necessary
si zei ndi cated
i n
the
chart under
SD S
by usi ng
an
adequate
undersi ze
beari ng accordi ng
totheextent
of
requi redrepai r
BEND AND END PLAY
I Crankshaft
can
be checked for
bend
by placi ng
i t on V blocks and
usi ng
a
di al
gauge
wi thi ts
i ndi cati ng
fi ngerresti ng
oncenter
journal
Bend value
i s half of thetotali ndi
cator
readi ng
obtai ned
when
crank
shaft
i s turned
one
fullrevoluti on
I fbendexceeds the
speci fi ed
li mi t
replace
or
repai r
Bond
Totali ndi cator
readi ng
li mi t 010mm 00039i n
2 I nstall crankshaft i n
cyli nder
block
andmeasurecrankshaft freeend
play
at
centerbeari ng
End
play
li mi t
03
mm10
012i nl
REPLACI NG
PI LOT BUSHI NG
To
replace
crankshaft rear
pi lot
bushi ng
proceed
as follows
I
Pullout
bushi ng usi ng
Tool
2
Before
i nstalli ng
a
new bushi ng
thoroughly
clean
bushi ng
hole
EM11
r
I nspecti on8ndRepai r
ENGI NE MECHANI CAL
3
I nsert
pi lot
bushi ng
unti ldi stance
between
flange
endand
pi lot bushi ng
i s the
speci fi ed
di stance
A
Di stance A
Approxi mately
40mm0157 i n
EM719
When
i nstalli ng
pi lot
bushi ng
be
carefulnot to
damage edge
of
pi lot
bushi ng
and not toi nsert
exceui Yely
MAI N BEARI NG
AND
CONNECTI NG
ROO
BEARI N
MAI N BEARI NG
I
Thoroughly
cleanall
beari ngs
and
check forscratches melt score or
wear
Replace beari ngs
i f
any
fault i s
detected
2 Measure
beari ng
clearan as
follows
I
Cut
a
plasti gage
tothe wi dthof
beari ng
and
place
i t i n
parallel
wi th
crank
journal
axi s
getti ng
clearofthe
oi lhole
Sale
Plasti gage
EM141
EM12
2 I nstall
heari ng
and
beari ng
cap
wi ththe
bolts
ti ghtened
tothe
speci
fi ed
torque
rJJ
Mai n
beari ng
cap
bolt
44
54N m
145 55
kg m
33
40ft lb
Do
not turn
crankshaft
whi le the
plasti gage
i s
bei ng
i nserted
3
Remove
beari ng
and
cap
Com
pare
wi dthof
plasti gage
at i ts wi dest
part
wi ththe scale
pri nted
i n
plasti
gageenvelope
Mai n
beari ng
clearance
Li mi t
0
12 00047i n
3 I f
clearance exceeds the
speci fi ed
value
replace beari ng
wi th
an
under
si ze
beari ng
and
gri nd
crankshaft
journal
adequately
Refer
to SD S
CONNECTI NG
ROD BEARI NG
I Measure
connecti ng
rod
beari ng
clearance
i nthe
samemanneras above
rJJ Connecti ng
rod
beari ng cap
nut
44 54N
m
14
5 5 5
kg
m
33 40ft lb
Connecti ng
rod
beari ng
dearance
Li mi t 012
mm
00047i n
2 I f
clearance exceeds the
speci fi ed
value
repl
ce
beari ng
wi than under
si ze
beari ng
and
gri nd
the
crankpi n
adequately
RefertoS
D
S
MI SCELLANEOUS
COMPONENTS
CAMSHA SPROCKET
I
Check toothsurface forflaws
or
wear
Replace
sprocket
i f
any
fault i s
found
2
I nstall
sprocket
on camshaft and
check for
runout
I f
runout exceeds the
speci fi ed
li mi t
replace
camshaft
sprocket
Runout
Totali ndi cator
readi ng
Li mi t 01 mm 0
004i nl
SEM157
CHAI N
Check chai n for
damage
excessi ve
wearat rollerli nks
Replace
i f
faulty
CHAI N
TENSI ONER
AND CHAI N
GUI DE
Check forwear
and
breakage
Re
place
i f
necessary
FLYWHEEL
I
Check the clutch
di sc contact
surface on
flywheelfor
damage
or
wear
Repai r
or
replace
i f
necessary
2 Measure runout of
theclutchdi sc
contact surface
wi tha di al
gauge
I fi t
exceeds the
speci fi ed
li mi t
replace
i t
Runout
Total
i ndi cator
readi ng
Li mi t
015
mm
10
0059i n
ENGI NE
MECHANI CAL I nspecti on
and
Repai r
3
Check
toothsurfaces of
ri ng gear
forflawsorwear
Replace
i f
necessary
ReplaC8 ri ng gear
at about
180to
2200C 356
to4280F
FRONT AND
REAR
OI L SEAL
Check front and rearoi lseals for
wornorfolded over
seali ng li p
or
oi l
leakage
I f
necessary replace
wi tha
new seal
When
i nstalli ng
a newseal
pay
attenti on
to
i ts
mounti ng
di rec
ti on
I t i s
good practi ce
to
renew
oi lseal
whenever
engi ne
i soverhauled
Front
l
F
1
Front
L
EM150
Rear
EM
13
Engi neAS3embly
ENGI NE MECHANI CAL
PRECAUTI ONS
I
When
i nstalli ng
sli di ng part
such
as
beari ngs
be
sureto
apply
engi ne
oi l
on
the
sli di ng urfaces
2
Usenew
packi ngs
andoi lseals
3
Be sure to follow
speci fi ed
ti ghteni ng
torque
and
order
4
Apply
sealant to the
followi ng
poi nts
Do
not
apply
sealant toomuch
1
Front si deof
cyli nder
lock
Mati ng
surfacewi thfront
coverand
top
offront cover
2 Rear
si deof
cyli nder
block
Each
si de
of rearmai n
beari ng cap
andeachcornerof
cyli nder
block
Cyli nderblock
Rear
mai n
beari ng cap
10
79 O
gSI
4i R
i
Poi ntstobe
appli ed
wi th
sealant
Uni t mm
i n
N
EM151
3
Bottom
si de
of
cyli nderblock
Step
porti ons at
four
mati ng
sur
faces
cyli nder
block
tofront chai n
cover
and
cyli nderblock torearmai n
beari ng
cap
EM14
ENGI NE
ASSEMBLY
c
d
Apply
sealant
at
these
poi nts EM152
4
Front
and
rearsi deof
cyli nder
head
Mati ng
surfaceswi th
rubber
plug
Apply
sealant
SEMl58
ASSEMBUNG
CYLI NDER
HEAD
I
I nstall
valve
andvalve
spri ng
I
Set valve
spri ng
i nnerand
outer
seat andvalveoi lseal
2
I nstallvalve valve
spri ng
i nner
andouter
J
valve
spri ng
retai ner
Com
pressspri ngs
and
fi t
valve
spri ng
collets
by usi ng
Tool
Oi lseal
I nner
spri ng
tor
0
t
1
@
I nstallabove
order
SEM160
a When i n
taI li ng
valve
apply engi ne
oi lon the valva stem and
li p
of
valveoi lseal
b Check whetherthevalvefacei free
from
forei gn
matter
c
I nnerand outervalve
spri ngs
are
of
an
uneven
pi td1 type
I nstallvalve
spri ng
wi thi ts
narrow pi tch
si de
pai nted
at
cyli nder
head
i d
Pai ntedsi d
111
c
Narrow
pi tchw
Wlde
Pltch
SEM202
2 Make
up
valve rockershaft
as
sembly
I nstallrockershaft bracket
valve
rocker
and
spri ng
on valve
rocker
shaft
observi ng
the
followi ng
Wf SEM161
1
Rockerbracket
2 Rockershaft
3 Bolt
4
Spri ng
5 Rockerarm
I
I ntake
rockershaft has i denti fi
cati on
mark
sli t onfront surface
but
exhaust rockershaft does not
2 Bothrockershafts should
be as
sembled so that
punched
marks
on
front surfaces come
to
upsi de
Marks
are usedtoi denti fy
oi lholedi recti on
Sli ts
I ntake
Front
0
Exhaust
SEM162
3
Valve
rockeri s same fori ntake
and
exhaust andalso
No1
and
No 3
cyli nder
and
provi des
i denti fi cati on
mark
I
Si mi larly
theone
for
No
2
and
No4
cyli nder
provi des
mark 2
4
Be
carefulnot to
mi ss
ori gi nal
locati on of rocker
shaft brackets For
thi s
purpose
i denti fi cati on marks are
provi ded
oneach
bracket and
cyli nder
head
A Z
Marked
on
cyli nder
head
v
Markedonbrackets SEM163
To
prevent
rockershaft brackeu
from
sli ppi ng
out of rocker
shafts
i nsert bracket bolts
any
bolt wi ll
dol
i ntobolt
holes
of
No
1
and No5
rockershaft bracket
3
Mount camshaft onto
cyli nder
head
placi ng dowellpi n
at front end
to
top
posi ti on
ENGI NE
MECHANI CAL
Engi ne
Assembly
Plae e
upsi de
SEM164
4 Mount valverocker
shaft
assembly
on cyli nder
head by accommodati ng
toknock
pi n
ofthehead Then
ti ght
en
to
the
speci fi ed
torque
li l
Rockershaft bracket
bolt
15 25 N
m
1 5
2 5
kg m
11 18ft lb
a
Ti ghten
bolts
gradually
i n twoto
three
stages
outwardly
from center
bracket
b
When
ti ghteni ng
bolts make
space
under
cyli nder
head
si nce
some
valves wi ll
open
andi nterfered
t
Z
5 After
assembli ng
Ll1I U rhead
turn
camshaft unti lNo
1
pi ston
i s
at
T
D
C
on
i ts
compressi on
stroke
ASSEMBLI NG
PI STON AND
CONNECTI NG ROD
I
Assemble
pi stons pi ston pi ns
and
connecti ng
rods of the
desi gnated
cyl
i nder
a Pi ston
pi n
i s
pressed
i nto
connect
i ng
rod and
fi tti ng
force i s
from
49to147 kN 05 to1 5
t 06to
1 7
US ton
049to1 48
I mp
tonl
andtheai dof
Tooli s
necessary
When
pressi ng
pi ston
pi n
i n con
necti ng
rod
apply engi ne
oi l
to
pi n
andsmall
endof
connecti ng
rod
ST13030001
SEM156
b
Arrange
so
that oi l
jet
of connect
i ng
rod
bi g
end i s di rectedtoward
the
ri ght
si de of
cyli nder
block
EM151
c
Connecti ng
rods
are
markedat si de
of
bi g
end
for
i denti fyi ng
the de
si gnatedcyli nder
2 I nstall
pi ston
ri ngs
I nstall
so that
stamped
mark on
ri ng
faces
upward
a
Top
ri ng
i s
chromi um
plated
on
li ner
contacti ng
face
b
Second
ri ng
has
largertaper
surface
than
top ri ng
c
I n thecombi ned
oi l
ri ng
upper
rai l
i sthe
same
as
lower
one
Marked
si de
1
101
r
EM158
EM15
Engi neAssembly
ENGI NE MECHANI CAL
ASSEMBLI NG
I NTAKE MANI FOLD
Assemhle
i n
the reve
order
of
di sassembly
and
wi ththe
speci fi ed
torque
i f
desi gnated
Referto
Di sassembli ng
I ntake
Mani fold
a
When
i nstalli ng
thermostat
and i ts
housi ng
refer
tJ
Secti on
LC
b When
i nstalli ng
emi ssi on control
system parts
andfuel
system
parts
refertoSecti ons EC and
E F
respec
ti vely
ASSEMBLI NG
ENGI NE OVERALL
I NSTALLI NG BODY PARTS
1 I n
thefi rst
place
mount
cyli nder
block on
work stand referto
engi ne
overall
di Sassembly
2 I nstallbaffle
plate
and steelnet
i nto
crankcase
3 I nstallcrankshaft
1
Set
upper
mai n
beari ngs
at the
properporti on
of
cyli nder
block
a
Only
center
beari ng
No3
i s a
flangedtype
b All i nter beari ngs
No
2and
No
4
are
thesame
type
c
Front
beari ng
No
11
i s also
the
same type as rear
beari ng
No
5
d
Upper
and
lOwerbeari ngs
ara not
i nterchangeable
Upper
ones have
oi l
groove
Rear
Front
I I I
I I I
i ll
Upper
I T
I T I a
wwer
ga
HS
14
H3
N2 HI
SEM168
2
Apply engi ne
oi ltomai n
beari ng
surfaces on bothsi des
of
cyli nder
block and
cap
3 I nstallcrankshaft
EM
16
4
I nstalllowermai n
beari ngs
and
caps
and
ti ghten
bolts to
speci fi ed
torque
Cl
Mai n
beari ng
cap
bolt
4454N m
45 55
kg
m
33 40ft lb
a
Apply
sealant to
eachsi de of rear
mai n
beari ng
caP
and each
corner
of
cyli nder
block Referto
Pre
cauti ons
b
Arrange
the
parts
sothat tha
arrow
mark
on
beari ng
cap
faces toward
thefront
of
engi ne
c
Pri or
to
ti ghteni ng
beari ng cap
bolts
placo
beari ng cap
i n
proper
posi ti on
by shi fti ng
crankshaft i n
the
axi al
di recti on
d
Ti ghtenbeari ng cap
bolts
gradually
i n
separati ng
two
to
three
stages
and
outwardly
from center
beari ng
i n
sequence
@ CD @
J
I
i ll
@
L I
V @
e After
securi ng beari ng
cap
bolts
ascertai n that
crankshaft turn
smoothly
p
Make
surethat there
exi sts
proper
end
play
of
crankshaft
at centerbear
i ng
Crankshaft end
play
Li mi t
03
mm
0012 i n
4
Apply
sealanltosi de oi l
seals
Theni nstallthosei ntorearmai nbear
i ng cap
n
J
I
I
f5 S
EM724
5 I nstall
rearoi l
seal
usi ng
Tool
SEM166
a When
i nstalli ng
oi lseal
gi vecoati ng
of
engi ne
oi l
to
seali ng li p
and
mati ng
shaft to
prevent
scratches
and
folded
li p
Also
apply
coati ng
of oi l
to
peri pherY
of
oi lseal
b I nstalloi lseal
wi thi ts dust
sealli p
at
outsi de
6 I nstallrearend
plate
and
fly
wheel
ClFlywheelfi xi ng
bolt
137
157
N m
14 16
kg
m
101 116ft lb
EM327
When
i nstalli ng
flywheel
wi pe
oi l
or
forei gn
matter
away
from
fi tti ng
surfaces
7
I nstall
pi stons
wi th
connecti ng
rod
1
I nstallthem
i nto
correspondi ng
cyli nderusi ng
Tool
J
EM544
a
Apply
engi ne
oi lto
sli di ng
parts
b
Arrange
so
that thefront mark
on
pi ston
head faces to
the front of
engi ne
c
I nstall
pi ston ri ng
as shown below
c
Top
ri ng
fi Oi l
ri ng
J0
upper
rai l
ll
Oi lri ng
expander
Pi ston
pi n
di recti on
fJ
secon
Oi l
ri ng
lowerai l EM725
2 I nstall
connecti ng
rod
beari ng
caps
CfJ
Connecti ng
rod
beari ng ClI p
nut
44
54
N
m
14
5
5
5
kg
m
33 40
ft
lb
EM329
ENGI NE MECHANI CAL
Engi neAssembly
Arrange
connecti ng
rods
and
con
necti ng
rod
caps
so
that
the
cyli nder
numbers
face
i nthe
samedi recti on
I
SEM167
3
Make surethat thereexi sts
proper
end
play
at
connecti ng
rod
bi g
end
Referto
I nspecti on
and
Repai r
8 I nstall
cyli nder
head
assembly
through gasket by accommodati ng
knock
pi n
of
cyli nder
block as
follows
1
Thoroughly
clean
cyli nder
block
and
head
surface
po
not
apply
sealant to
mati ng
sur
faceof
cyli nder
block andhead
2
Turn crankshaft
unti l
No1
pi ston
i s
at
TD
C on
i ts
compressi on
stroke
3
When
i nstalli ng cyli nder
head
make
SUre that
allvalves are
apart
from head of
pi stons
I f
necessary
loosen
adjusti ng
screws of
rockerann
to
drawvalves
i n
4
Temporari ly
ti ghten
two
center
bolt
CfJ
Cyli nder
headbolt
I Temporary
20N m
2
kg
m 14ft lbl
a
Fi nal
ti ghteni ng
should
be
carri ed
out
after
i nstalli ng
chai n andfront
cover
b
Donot
rotate
crankshaft
and
cam
shaft
separately
because
valyes wi ll
hi t
head
of
pi stons
c
Always use new
cyli nder
head
gasket
9
I nstallfront si de
parts
4
SEM169
1
Chai n
tensi oner
2
Slack si de
chai n
gui de
3
Temi on si dechai n
gui de
4 Oi l
thrower
5
Oi l
pump
dri ve
gear
6
Crankshaft
sprocket
7
Ti mi ng
chai n
1
I nstall crankshaft
sprocket
oi l
pump
dri ve
gear
and
oi l
thrower
a Make
sure
that
the
mati ng
marks of
crankshaft
sprocket
faces tothe
front
b
I nstall
oi l
pump
dri ve
gear
so
that
large
chamfered
i nnersi de
faces
rearward
2
I nstallchai n
gui de
to
cyli nder
block
3
Set chai n
on camshaft
sprocket
and crankshaft
sprocket by ali gni ng
each
mati ng
mark Then i nstallcam
shaft
sprocket
to
camshaft
CfJ
Camshaft sprocket
bolt
118 157 N
m
12 16
kg
m
87 116ft lb
SEM170
EM
17
Engi neA
mbly
ENGI NE
MECHANI CAL
a
Set
ti mi ng
chai n
by ali gni ng
i ts mat
i ng
marks wi ththoseof crankshaft
sprocket
and cemshaft
sprocket on
the
ri ght
handsi de
b
Camshaft
sProcket
should be i n
stalled
by
accommodati ng
i ts No2
holeto
knock
pi n
of camshaft
No2 hole
4 I nstallchai n
gui de
and chai n ten
si oner
fl
Chai n
gui de
andtensi onerbolt
5 9 9
8
N
06 1 0
kg m
43 7 2ft b
Adjust
the
protrusi on
of chai n
tensi onerspi ndleto
0
mm
0i n
wi th
slacksi de
chai n
gui de
5
I nstall
front cover
wi th
gaskets
observi ng
the
followi ng
a
Before
i nstalli ng
front
cover
press
new
oi l
seali n
thecover
wi th
dust
seal
li p
at
outsi de
b
Apply
alant tothe
seali ng
por
ti ons
desi gnated
Refer
to
Precau
ti ons
c
Apply li thi um
grease
to
seali ng li p
of oi lseal
d Check the
hei ght di fference be
tween
cyli nder
block
upper
face
and front
cover
upper
face
I ts
di f
ference must be
less
than
015
mm
0
0059i nl
EM
18
e Notethat di fferent
length
ofbolts
areused
Ci J
Front cover
bolt
Si ze
M8
1016N m
1 01 6
kg
m
7 12ft
bl
Si zeM6
39 98N
m
04 1 0
kg m
29 7 2ft bl
6
I nstallcrankshaft
pulley
fl
Crankshaft
pulley
bolt
118 157 N m
112 16
kg
m
87
116
ft lbl
10
Ti ghtencyli nder
head
boltstothe
speci fi ed
torque
i n
several
steps
and
i n
the
sequence
shownbelow
SEM172
fl
Cyli nder
headbolt
69 78N m
7 080
kg m
51 58ft lb
a
Be
sure
to
ti ghten
bolts
securi ng
cyli nder
head
to
front
cover
b
After
engi ne
has
been
operated
for
severalmi nutes
reti ghten
i f
neces
sary
I I
Adjust
valve
clearance tocold
speci fi cati ons
referri ng
to Secti on
MA
Valveclearance
Cold
I ntake 021
mm
0
008i n
Exhaust 023
mm
0
009i nl
At
ambi ent
temperature
200C
680F
After
engi ne
has
been
assembled
fi nally adjust
clearance to
hot
speci
fi cati ons
12 I nstall
valve rocker
cover
wi th
gasket
fl
Valverocker
cover
bolt
7 8 98N
m
08 1 0
kg m
5 8 7 2ft
lbl
a
Rockercoverbolts should
be
ti ghtened
i n
cri ss cross
fathi an
b
Always
use
new rockercover
saskat
13
I nstalloi lstrai ner
and
oi l
pan
wi th
gasket
fl
Oi l
strai ner
bolt
1016N m
11 01 6
kg m
7 12ft lbl
Oi l
pan
bolt
5 9 98N m
06 1 0
kg
m
43 72ft
lbl
a
Apply
sealant tothe
desi gnated
porti ons
Refer
toPrecauti ons
b Oi l
pan
shouldbe
ti ghtened
i n
cri ss
cross
pattern
c
Always
use
newoi l
pan gasket
I NSTALLI NG
OUTER
PARTS
14 I nstall
followi ng parts
i n
thereo
verse orderof
di sassembly
and
wi th
the
speci fi edtorque
i f
desi gnated
Referto
Di sassembli ng
OuterParts
and
S O
S for
ti ghteni ng
torque
I
Engi ne
bottomsi de
parts
When
i nstalli ng
oi l
pump
anddi s
tri butor
dri vi ng
spi ndle
i n
front
cover
refertoSecti on
LC
2
Engi neri ght
si de
parts
a Whe
i nstalli ng
i ntakemani fold
to
faci li tate work
previ ously
set the
securi ng
bolts and nut wi th
wash
ersat lower
and centersi de
as i l
lustrated
Temporari ly
set
oltsandnut
SEM173
b
When
connecti ng
vacuum
pi pes
re
fertoSecti on EC
c When
i nstalli ng
oi lfi lterreferto
Secti on
LC
3
Engi ne
left si de
parts
a
When i nstalli ng di stri butortern
porari lvti ghten i gni ti on ti mi ng
ad
just screws
at
center
of
adjusti ng
holes
b
When
i nstalli ng hi gh
tensi on cable
clamp
those
as i I I ustrat d
4
Engi ne
front si de
parts
ENGI NE
MECHANI CAL
Engi neAssembly
DI SMOUNTI NG
ENGI NE
FROMWORKSTAND
15
Di smount
engi ne
i n the
reverse
orderof
mounti ng
and i nstall
engi ne
ri ght
si de and
rear
si de
parts
remai ned
wi th
the
speci fi ed
torque
i f
desi gnated
Referto
Mounti ng Engi neonWork
Stand and
S
Ds for
ti ghteni ng
tor
que
When
i nstalli ng
clutch
assembly
use
Tool
KV30100100
16 Fi ll
engi ne
oi l
and
coolant to
the
speci fi ed
level
after
engi ne
has been
i nstalledon
car
Refer
toSecti on
MA
ENGI NE
TUNE UP
17
Referri ng toSecti on MA
fi nally
adjust followi ng
i tems
1 Dri vebeltsdeflecti on
2
Valveclearance
Warm
up engi ne
unti l
watertem
perature
i ndi cator
poi nts
tomi ddleof
gauge
then
adjust
clearance to hot
speci fi cati ons
Valveclearance
I Hotl
I ntake
0
30mm
0
012i n
Exhaust
0
30mm 0012
i n
3
I gni ti onti mi ng
4 I dle
rpm
EM
19
Setvi ce
Dataand
Spec
fi cati on ENGI NE MECHANI CAL
SERVI CE
DATA AND SPECI FI CATI ONS
I NSPECTI ON
AND ADJUSTMENT
CYLI NDER
HEAD
Cyli nder
head
Head
surface
flatness
Valve
guI de
EXHAUST
I NTAKE
Li mi t
rnmli n
01
100041
Uni t mmOn
838
510
327 03551
di a
310
2
r
Snap ri ng groove
10
UtO7 11010421 0433
SEM175
i ntake
Exhaust
10 4106
I l
104106 I
h
10409
04
11
O
409
0
417
Fi r
i l
V
I
P
f i J
J
I J
1 1
c
I NTAKE
EXHAUST
EM116
Valve
gui de
Outerdi ameter
0
Valve
gui de
I nner
di ameter
d
Fi ni shed
si ze
Cyhnder
headvalve
gui de
holedi ameter
8
I nterferencefi tof valve
gui de
I ln
Stem
togui de
clearance
I
Ex
Stem
end
deflecti on
EM20
St8ndari i
Servi ce
12
023 1203412
223 12
234
0
4733
047381 10
4812
048171
8
0008
018103150
0
31571
11
985 11
996
1
2
85
12
196
10
4718
04723 10
4797 0
4802
0027 004900011
00019
Standard
Li mi t
0020
0053
10
0008
0OO21
0
1
0004
0
040
0
073
00016
0
0029
02
10
OOSI
Valve seat
Seali nsert
di mensi ons
I ntake
xL
Q
I
I
I
o
Contacti ng
face
angle
rt
Contacti ng
wi dth
W
Stendard
Standard
Outerdi ameter0
Servi ce
Exhaust
C
mtactlng
face
angle
cr
Contacti ng
wi dth
W
StaruWd
Standard
Outer
di ameter0
Servi ce
Cyli nder
headseat mess
di ameter
I
For
standard
nsen
I n
Forservi ce
i nsert
For
standardi nsert
EX
I
For
servi ce
i nsert
Uni t
mm
i n
l
SEM177
45
12
18
0
047 00711
45 097
45
113
11 7755
1776
45
597 45
613
11 1952
1 1958
Uni t
mmi n
I
SEM118
45
1 5 1 90059
O07S
40
080
40
096
115779
1 57861
40597
40613
1
5983
t 59891
Uni t mm
i n
45 000
45
016
11
7717 1
77231
45
50045 516
111913
1 79201
40
000
40016
11
5748 1 5754
40500
40
516
11
5945
1
59511
I nterferencefi t ofseat i nsert
I n
Ex
Machi ni ng
di mensi ons
ofseat
I ntake
I
I
i
I
Y
90
L41
641
8J
11
638 1
646
di a
SEM179
VALVE
T
H
J
M
I
I
I
I n
I
I
Ex
I
i ln
Valve
length
L
I
Ex
I
I n
I
Valvehead
di ameterH
Valve
stem
di ameter0
ValvefBee
angle
C
Valvehead
margi nI
I n
M
I
Gri ndi ng
of
valve
stem
end
Standard
Servi ce
Standard
Servi ce
ENGI NE MECHANI CAL Servi ceDara
and
Speci fi csti ons
Uni t mm
i n
0081 0113
100032
0
00441
0
064 0
096
0
0025 0
00381
0
081
0113
00032 000441
Uni t
mm i n
Exhaust
I
r
o
l
L
1
374 37 61
11
472 1
4801
di a
SEM180
Uni t mm
On
j
D
1
L
SEM181
Standard Li mi t
420422
11 654 1
66tl
38
0382
1
496
1
504
122
8 123
1
4
835
4
846
1236
123
9
14866
4
8781
4530
05
10
020
0
5 0020
0
5 10020
VALVE
SPRI NG
Followi ng
data
ere
commonto
bothi ntakeandexhaust
Uni t
mm
i n
I
Standard
Free I
Outer 4977119594
hei ght
I
I nner
44
1011 7362
mmN
400
226
2301
Assem
Outer
kg
1575
50
7
bled
li n
lb
hei ght
mm
N
tensi on
I nner
I kg
35 0108111 0
li nllbl
1
3783
24
31
Cut 0
Outer
square
I nner
li mi t
40
0189119 31
1 575 4261
35 08718
91
11 3783 19 61
2
2 0
0871
19
10075
ROCKER ARMAND
ROCKER SHA
Uni t mmi n
1
I
I I
Rocker
arm
to
shaft
clearance
0
007
0
049 00003 00019
Standard
Camshaft
CAMSHA
AND CAMSHAFT BEARI NG
Outerdi ameterof cam
shaft
journal
Cami haft bendat
center
journal
Total
i ndi cator
readi n91
I
Cami haft
nd
pl
Cam
hei ght
A
Camshaft
beari ng
I nnerdi ameter
Cemshaft
journal
to
beari ng
clearance
Oi l
clearance
Standard
32935 32955
112967 1 29741
11
lt
I n
38477 38527
11
5148
1 51681
Ex
Standard
3300033025
11
2992
1
3002
0
045 0090
10
0018
0
0028
Uni t mm
I i
Li mi t
I
Oto0
00391
0
2
10008
EM871
025 000981
Uni t mmti n
Li mi t
01
10004
EM21
Servi ceDatasnd
Speci fi cati ons
ENGI NE MECHANI CAL
CYLI NDER BLOCK
Cyli nder
block
A 1J
120
10791
1111
6012
1111
I
0
i
P
Front
X
V
Surface
flatness
I nner
di ameter
Cyli nder
bore
Out of
round
I X VI
Taper
A
B
Di fferene i ni nnerdi a
meterbetween
cyli nders
Pi stonto
cyli nder
clearance
Feeler
gauge
ex
tracti ng
force N
wi th
gauge kg
thi ckness004 I b
mrn0
0016
i n
Cyli nder
li nerfor
s
Outsi de
di ameter
I nterference
fi tof
cyli nder
li ner
EM22
Standard
85
00085
050
13
3465 334841
Less than
00151000061
Less
than
0
0151000061
Less then
005
000201
0
025
0045
10
00100
00181
2014
710
2
1
5
04 331
40
10
1571
Undersi ze
4
5
01711
Undersi ze
5 0101971
Undersi ze
Uni t
f11m i o
EM422
li mi t
0
110
004
0200081
02
100081
Wear
li mi t
PI STON
PI STON RI NG
AND PI STON PI N
Pi ston
Uni t rnmi n
f
I
A
cr
a About
2010791
EM714
Standard
84 985
85
035
133459
334781
Pi stondi ameter
A
0
501001971 85
465
85
515
Oversi ze
133648
336671
1 00
1003941 85
965 86015
O
ersi ze 33844
3
38641
Si de clearance
of
pi ston ri ng
Uni t mmUnl
Standard
Li mi t
I
Top ri ng
I
Second
ri ng
I
Oi lri ng
00400
073
100016
0
00291
01 00041
0
030
0063
00012
0
00251
Ri ng gap
1
Standard
I
Top
ri ng
025 040
100098 001571
Second
ri ng
015 030
10
0059
001181
Oi l
ri ng
0
30
090
10
0118
003541
Uni t mmi n
Li mi t
1 0
100391
Pi ston
pi n
Uni t mmli n
Uni t mmi n
89
00
89
05
Standard
135039 3 5059
I
Pi ston
pi n
outsi de
di
meter
20993 2099808265 0
82671
89
50
89
55
135236 3 6256
Pi stonpi n
holedi ameter
21
001 21008
10
8268
082711
90
00
9005
I
Pi stonpi n
to
pi ston
135433 3
54531
clea
ance
0006 0013100002
0
00051
008 009
I
I nterferencefi t of
pi ston
0
0031 00035
pi n to
c
onnecti ng rod
0
015
0035 100006 0oot41
ENGI NE
MECHANI CAL
Servi ceOataandSpeci fi cati ons
CONNECTI NG
ROD BEARI NG
Uni t
mm i n
Beari ng
clearence
1
Uni t mm
i n
Standard
Li mi t
I
Standard Li mi t
Connecti ng
rodbend
or
torsi on
per
100mrn 003 0
00121 005 1000201
I
Mai n
beari ng clearance
00200
062
0
121000471
3
94
i nllength
00008 00024
I
Bi d
end
plev
02 03
I
Connecti ng
rod
beeti ng
0
025
0055
0008 0
0121
0
600241
clearance
000100
00221
0
12 000471
CRANKSHAFT
Uni t mmli n
a
t1b
S
I
I
Journaldi ameterA
I
Pi n
di ameter
B
I
S
Out of
round X
V
Taper
AB
A
8
54
942
54955 21631 2
16361
EM790
49961 49
974
1
9670
1
96751
42
97 4303116917 169411
A
o
I
Taper
of
journal
and
pi n
A S
I Out
of roundof
Journal
and
pi n
XY
I
Crankshaft bendTotal
i ndi catorreedi ng
I
Crenksheft
freeend
plav
I
Pi lot
bushi ng
i nserti ng
di stance
Standard
Lessthan
OOf
000041
less
than
001 000041
Lessthan
0
05
0
00201
005 OlB
100020
0
00711
8
EM715
Li mi t
003 0
00121
J
I
0031000121
I
0
10
0
00391
I
03
100121
400
1571
Mai n
beari ng
undersi ze
Uni t mmi n
T
EM738
Beari ng
top Crank
jou
rnal
thi ckness T
di ameter
I
STD
1
822 1835 54942
54955
10
0717 00722
12
1631 21636
I
025
1000981
Undersi ze
1 947 1
960
54692 54705
00767 0
07721
2
1532
2
15371
I
050001971
Undersi ze
I
2
072
2
085
54
442
54 455
00816 0
08211
2
1434
2
14391
I
075 0
02951
Undersi ze
I
2197 2210 54
192
54205
00865 0
08701 121335
2
13411
1
0000394
Undersi ze
I
2322 2
335
53
942 53955
00914 0
09191
2
1237
2
12421
Connecti ng
rod
beari ng
undersi ze
Uni t rnmOnl
I
Beari ng top
Crankpi n
thi ckness
T ci i ameter
I
STD
1493 1 506 49961 49
974
00588
005931 09670
1
9675
I
025
000981Undersi ze
1
618
1
631 49711
49
724
100637 006421 1 9571
1 95761
I
050
001971 Undersi ze
1 743 1
756
49461
49 474
0
0686 006911 t
9473 1
94791
I
0751002951 UDdersi ze
1868 1881 49
211
49
224
00735
0
07411 1 9374
1
93791
EM
23
Servi ce
DatallndSpeci fi cati ons
ENGI NE MECHANI CAL
Camshaft
sprocket
MI SCELLANEOUSCOMPONENH
I
Runaut Totali ndf
mm
i n
cator
readi ngl
Flywheel
I
Runout frotsli odi
mmi n
cator
readi ng
ENGI NE
TUNE UP
Valveclearance
1
I
I ntake
I
Exhaust
03010
012
03010
012
Li mi t
Q
1
0
004
Li mi t 015
100059
Hot
Uni t
mmi n
Cald
021 0008
023 0
009
At ambi ent
temperature
200C 168
F
Whenevervalve clearances are
adjusted
tocold
speci fi c
ti ons
check
thdtheclearances
sati sfy
hot
speci fi cati ons
andedjust agai n
i f
necessary
Engi ne
front
si de
TI GHTENI NG
TORQUE
Uni t
Front coverbolt
M8
M6
I
Chai n
gui de
bolt
I
Chai n tensi onetr
bolt
Water
pump
bolt
M6
M8
Crankshaft
pulley
bolt
Engi neri ght
si de
I
Water
i nlet bolt
I
Wateroutlet bolt
I
I ntakemani foldbolt and
nut
I
Alternatorbracket
bolt
I
Alternator
to
adjusti ng
barbolt
I
Engi nemounti ng bracket
bo1t Samefot left si de
EM
24
N
m
1016
3
9
98
5 9 98
5
9
9
8
39 98
10
16
118 157
10
16
1016
16 21
39
59
2029
29 39
kg m
1 01 6
04 1 0
06 1 0
0
6
1 0
04 10
1 016
12 16
1 016
1 016
1 621
4060
2030
304
0
ft lb
7
12
29 7 2
43 72
43 7
29 7 2
7 12
87 116
7
12
7
12
12 15
29 43
14
22
22
29
Engi ne
left si de
Uni t
I
Di stri butor
support
bolt
I
Exhaust mani foldbolt
andnut
I
E
G
R tubenut
I
E A I tubenut
I
Ai rcondi ti onercern
pressor
bracket bolt
N m
39 78
16 21
34 44
34 44
44 54
Engi netop
si de
I
Cyli nder
headbolt 69
78
I
Cyli nder
head
to
front
COYerbolt
39 78
I
Rocker
shaft bracket bott 15 25
I
Camshaftsprocket
bolt 118 157
I
Rocker
coverbolt 7 8
9
8
I
Sparkplug
15
20
I
Rockerarmnut
16 22
Engi ne
bottomsi de
I
M
i n
beari ng
cap
bolt
I
Connecti ng
rod
bi g
end
nut
t
Oi l
strai nerbolt
Oi l
pan
bolt
Oi l
pan
drai n
plug
Oi l
pump
bolt
Gusset to
cyli nder
block
bolt
Engi ne
rearsi de
I
Flywheel
bolt
MTI
I
Dri ve
plate
bolt
Arr
1
Clutchcoverbolt MT
Torqueconverterbolt
AfT
Startermotorbolt
Transmi ssi on tocyli nder
block
bolt
I T
ransmi ssi onto
gU
et
bolt
44 54
4454
1016
59 98
2029
11 15
43
58
kQ m
04
08
1 6 21
35 45
35 45
45 55
7
080
0408
1 5 25
12 16
0
8 1 0
1 5 20
1
6 22
45
5 5
45 5
5
1
0
1 6
061 0
2030
11
1
5
4
4 5
9
ft lb
2 9
5 8
12 15
25 33
25 33
33 40
51 58
29
5
8
11 18
87 116
5 8 72
11 14
12 16
33
40
33
40
7 12
43 72
14 22
8 11
32 43
137 157 14
0t60
101
116
137 157 14
0160101 116
16
21
1
6
2
1 12 15
39 49
405 0 29 36
29 39
3
0
40
22 29
43 58 4
45
9
32 43
43 58 4
4
59 32
43
ENGI NE MECHANI CAL
Trouble
Di agnoses
andCorrecti ons
TROUBLE
DI AGNOSES
AND CORRECTI ONS
Condi ti on
I
Noi sy engi ne
Pi stonand
connecti ng
rod
knocki ng
Knocki ng
of crank
shaft
and
heari ng
Ti mi ng
chai nnoi se
Camshaft
andvalve
mechani sm
knocki ng
Camshaft
knocki ng
Water
pump knocki ng
Probablecause
Sei zed
pi stonpi n
Sei zed
pi ston
i n
cyli nder
Broken
pi stonri ng
I mproperconnecti ng
rod
ali gnment
Sei zedorloose
connecti ng
rod
beari ng
Sei zedorloosemai n
beari ng
Bent
crankshaft
Uneven
wear
of
journal
Excessi vecrankshaft
end
play
I mproper
chai n
tensi on
Worn and
or
damaged
chai n
Worn
sprocket
Worn and
orbroken chai n
gui de
andor
tensi on
adjusti ng
mechani sm
I mproper
valve clearance
Worn
rocker
beari ng
Worn rockerface
Loosevalvestemi n
gui de
Weakenedvalve
spri ng
Sei zedvalve
Excessi ve
camshaft
beari ng
clearance
Excessi veaxi al
play
Womearn
gear
I mproper
shaft
endplay
Broken
i mpeller
Stuck
valve
I I Other
mechani caltroubles
I mproper
valveclearance
I nsuffi ci ent
clearance
between valve stem
and
gui de
Weakenedorbroken
valve
spri ng
Sei zed
or
damaged
valvestem
Poor
quali ty
fuel
Correcti veacti on
Replace
pi ston
wi th
pi n
Recondi ti on
cyli nder
and replace
pi ston
wi th
pi n
Replace
ri ng
and
or
recondi ti on
cyli nder
Reali gn
rodor
replace
rod
Replace
Replace
Repai r
or
replace
Correct
Replace
center
beari ng
Adjust
Replace
Replace
Replace
Adjust
Replace
Replace
Replacegui de
Replace
Replace
Replace
Replace
thrust
plate
Replace
Replace
water
pump
assembly
Replacewater
pump
assembly
Adjust
Clean stemorream
gui de
Replace
Replace
orclean
Use
good
fuel
EM
25
TroubleDi agnosessndCorrecti ons
ENGI NE MECHANI CAL
Condi ti on
Sei zed
valve
seat
Excessi vely
worn
cyli nder
and
pi ston
Faulty connecti ng
rod
Faulty
crankshaft
beari ng
EM
26
Probablecause
I mproper
valveclearance
Weakened
valve
spri ng
Thi nvalve
head
edge
Narrowvalve
seat
Overheati ng
Over
speedi ng
Stuck valve
gui de
Shortage
of
engi ne
oi l
Di rty
engi ne
oi l
Poor
quali ty
ofoi l
Overheati ng
Wrong
assembly
of
pi ston
wi th
connecti ng
rod
I mproperpi ston
ri ng
clearance
Broken
pi ston
ri ng
Di rty
ai r
cleaner
Mi xture
toori ch
Engi ne
overrun
Stuck
chokevalve
Overchoki ng
Shortage
of
engi ne
oi l
lowoi l
pressure
Poor
quali ty
engi ne
oi l
Rough
surface
of
crankshaft
Clogged
oi l
passage
Beari ng
worn
oreccentri c
Beari ng i mproperly
assembled
loose
beari ng
I ncorrect
connecti ng
rod
ali gnment
Shortage
of
engi ne
oi l
lowoi l
pressure
Poor
quali ty
engi ne
oi l
Crankshaft
journal
wornor out of
round
Clogged
oi l
pasSage
i ncrankshaft
Beari ng
wornoreccentri c
Beari ng i mproperly
assembled
Eccentri
crankshaft or
beari ng
Correcti ve
acti on
Adjust
Replace
Replace
valve
Reface
Repai r
or
replace
Dri ve
at
properspeed
Repai r
Addorreplace
oi l
Clean
crankcase
replace
oi l
and oi lfi lter
element
Use
proper
oi l
Repai r
or
replace
Repai r
or
replace
Adjust
Replace
Clean
Adjust
Dri veat
proper
speeds
Cleanand
adjust
Start correct
way
Addoi l
Correct
Use
proper
oi l
Gri ndand
replacebeari ng
Clean
Replace
Correct
Replace
Repai r
or
replace
Addor
replace
Correct
Use
speci fi ed
oi l
Repai r
Clean
Replace
Correct
Replace
Toolnumber
Kent
Moore No
KV30100
100
KVlO105001
ST050lS000
126023
CD
ST050l1000
126023
2
CVST05012000
126023 1
ENGI NE MECHANI CAL
Speci al
Servi ceTools
SPECI AL
SERVI CE TOOLS
Toolname
Clutch
ali gni ng
bar
Engi ne
attachment
Engi ne
stand
assembly
Engi ne
stand
Base
Speci alServi ce
Tools ENGI NE
MECHANI CAL
Toolnumber
Kent
MooreNo
KVI OlO39SO
125618
D
STlI 08l000
1256183
@
STlI 032000
125618
2
@ STl1320000
125618
1
STl165000
I
STl6610001
123907
KVlOI 05500
125640 01
EM03470000
EM28
Toolname
Valve
gui de
reamerset
Reamer
12
2
mm 0480i n di a
Reamer
80mm 0315
i n di a
Dri ft
Valveseat
cutter
set
Pi lot
bushi ng
puller
Crankshaft
rear
oi l
seal
dri ft
Pi ston
ri ng compressor
D
@
@
M
DATSUN
200SX
Model
S
J J
0
Seri es
SECTI ON
LC
ENGI NE
LUBRI CATI ON
COOLI NG
SYSTEMS
CONTENTS
ENGI NE
LUBRI CATI ON
SYSTEM
LUBRI CATI ON
CI RCUI T
01L PUMP
OI L PRESSURE REGULATOR
VALVE
OI L
FI LTER
OI L
PRESSURE
RELI EF VALVE
COOLI NG
SYSTEM
COOLI NG
CI RCUI T
RADI ATOR
THERMOSTAT
WATER
PUMP
LC 2
LC 2
LC 3
LC 4
LC 4
LC 4
LC 5
LC 5
LC
6
LC 6
LC 7
TEM
COUPLlNG
SERVI CE
DATA
AND
SPECI FI CATI ONS
GENERAL
SPECI FI CATI ONS
I NSPECTI ON
AND ADJUSTMENT
TI GHTENI NG TORQUE
TROUBLE
DI AGNOSES
AND
CORRECTI ONS
LUBRI CATI ON SYSTEM
COOLI NG
SYSTEM
SPECI AL SERVI CE TOOL
LC 7
LC 8
LC 8
LC 8
LC 8
LC 9
LC 9
LC
9
LC 10
Engi ne
Lubri Csti on
System ENGI NE
LUBRI CATI ON
COOLI NG
SYSTEMS
ENGI NE
LUBRI CATI ON
SYSTEM
LUBRI CATI ON
CI RCUI T
SLC021
j
Oi l
pan
I
Oi l
gallery
i n
cyli nder
block
Oi lstrai ner
I
I
By
passpassage
I
Regulator
valve
I
Oi l
pump
I ntermi ttently
j
Pump
dri ve
gear
r
oi li ng porti on
Oi lpassage Oi lfi lter
I
Reli ef
valve
I
l
Mai n
ari ng
f
I
Con
ecti ng
rod
I I
Oi l
J
et
I I
Chai n tensi oner
I
beari ng
I
Connecti ng
rod
I I
Ti mi ng
chai n
I
I
I
l
Pi ston
Pi n pi s
I
tonand
cyli nder
I
A
Rocker
arm
t
j
I
Camshaft beari ng
I
Camsurface
LC 2
I
Cyli nder
head
I
oi l
gallery
I
Center
earn
bracket
I
Rockershaft
Cambracket
t
I
Ti mi ng
chai n
I
and front
cover
S LC022
ENGI NE
LUBRI CATI ON COOLI NG SYSTEMS Engi ne
Lubri cati on
System
OI L PUMP
REMOVAL
1 Remove
di stri butor
cap
2 Turn crankshaft so that No 1
pi ston
i s
at
T
D C on
i ts
compressi on
stroke
by ascertai ni ng
the
posi ti on
of
di stri butorhead
rotorand
ti mi ng
mark
on
crank
pulley
Remember
posi ti on
of he rotor
underabove
condi ti on
Cali forni amodels
Front
SLC074
Non Cali fomi a models
Front
3 Remove
oHpump
body
wi thdri ve
spi ndleassembly
I NSTALLATI ON
I
Make
sure that di stri butorhead
rotor
i s i n
the
same
posi ti on
as i t was
beforeremoval
ofoi l
pump
2
Fi ll
pump housi ng
wi th
engi ne
oi l
then
ali gn punch
mark
of
dri ve
spi ndle
wi thhole
i n
oi l
pump
41
Punchmark
Oi l
hole
E
L009
3
Usi ng
a new gasket
i nstalloi l
pump
anddri vespi ndle assembly
4
Make sure
that the
ti p
ofthe
dri ve
spi ndle
fi ts di stri butorfi tti ng
hole
securely
5
Ti ghten
bolts
securi ng
oi l
pump
to
front cover
lfJ
Oi l
pump mounti ng
bolts
11 15 N m
111
1 5
kg
m
8 11
ft lb
6 I nstall
di stri butorcap
DI SASSEMBLY
AND
ASSEMBLY
@
1
@1
EL032
I
1 Oi l
pump
body
2 Outerrotor
3
I nnerrotor
and
shaft
4 Gasket
5 Oi l
pump
cover
6
Regulator
valve
7
Regulator
spri ng
8
Regulator
cap
lfJ
Oi lpump
cover
bolt
69 98N m
07 1 0
kg
m
5 1 7 2 ft lb
a
Always replace
wi th
a
new
gasket
b Outerrotorshouldbeassembled so
that
the chamferedsi de
faces
to
oi l
pump body
J
i i 9
SLC025
I NSPECTI ON
1
I nspect
the
followi ng
forwearor
damage
Pump body
andcover
Pump rotors
androtorshaft
2
Usi ng
a feeler
gauge
check the
follo Yi ng
Clearances
Wearli mi t
Rotor
ti p
clearance
CD
020mm 00079i n
Outerrotor
to
body
clearance
V
050mm 0020i n
o
LC026
3
Usi ng
a feeler
gauge
anda
strai ght
edge
check the
followi ng
gap
@
or
@
wi thout
gasket
LC
3
Engi neLubri cati onSystem
ENGI NE LUBRI CATI ON
COOLI NG SYS1EMS
Rotorto
strai ght
edge @
Lessthan
006
mm
00024
i n
Oi
pump body
to
strai ght edge @
Less
than
003
mm
00012
i n
Then
rotorsi declearance rotorto
bottoni
coverclearance wi th
gasket
should
sati sfy
the
followi ng speci fi ca
ti on
Wearli mi t
Rotorsi de
clearance
020
mm
0
0079
i n
SLC027
Pump
rotors
and
body
are not
servi ced
separately
I f
pump
rotors or
body
are
damaged
or
worn
replace
pump
rotorset
or
enti reoi l
pump
as
sembly
LC4
OI L PRESSURE
REGULATOR VALVE
I NSPECTI ON
Check valve
sli di ng
surface
and
valve
spri ng
and
replace
enti re valve
assembly
i f
necessary
E L076
N
OI L FI LTER
REMOVAL AND
I NSTALLATI ON
When
removi ng
oi lf1lter
use
Tool
When
i nstalli ng
i t
li ghtly
coat oi lon
oi lsealand
fasten i t
by
hand
Do
not
overti ghten
fi lter
or
oi l
leakagemay
occur
S lC028
OI L PRESSURE
RELI EF
VALVE
I NSPECTI ON
Wi thoi lf1lter
rellloved
check valve
uni t for
operati on I nspect
for
a
cracked orbroken
valve
I f
replace
I l
ent
i s
necessary remove
valve
by
pryi ng
i t
out wi thascrewdri verI nstaI I
a
newvalve
i n
place
by
tappi ng
i t
a
5LC029
ENGI NE LUBRI CATI ON COOLI NG SYSTEMS
Cooli ng
System
COOLI NG
SYSTEM
COOLI NG
CI RCUI T
Radi atorto
waterpump
oWater
pump
to
cyli nder
block
andheatercore
Cyli nderblock to
cyli nder
head
1
Cyli nder
headto
i ntakemani fold
Thermostat toradi ator
Radi ator
to
reservoi r
tank
5LC030
L
Water
pump
A
WARNI NG
Toavoi d
seri ous
peRonali njury
never
remove
II di ator
cap qui ckly
when
engi ne
i s
hot
Sudden release
of
cooli ng system pressure
i s
very
dal1llerous
I fi t i s
necessary
to
remove
I adi ator
cap
when
I adi atori s hot
turn
cap
slowly
counterclockwi seto
thefi llt
stop
Afterall
pressure
i n
the
coo
i ng
system
i s
released turn
cap
passi ng
the
stop
andremovei t
Radi atorcap
F
Reservoi r
tank
t
Radi ator
Thermostat
Cyli nder
block
H
Heater
I J
Thermostat
housi ng
t
f
Cyli nder
head
l
I ntakemani fold
SLC031
LC5
Cooli ng System
ENGI NE
LUBRI CATI ON
COOLI NG SYSTEMS
RADI ATOR
REMOVAL
AND
I NSTALLATI ON
I Drai n coolant
i ntoa
clean con
tai ner
2
Remove
ai r
cleaneri nlet
pi pe
3
Remove
ai rduct
wi thbracket
after
looseni ng
clamps
and
screws
at
porti on
i llustrated
4
Di sconnect
radi ator
upper
and
lowerhoses and
reservoi rtank hose
5
Remove radi ator
shroud attach
i ng
screws and
place
radi atorshroud
close to
engi ne
Radi atorshroud
can
be removed after
removi ng
radi ator
6
On
a
carwi th
automati ctransmi s
si an
di sconnect cooleri nlet andoutlet
li nes
fromradi ator
7
Removeradi ator
8 I nstallradi ator
i n
the reverse se
quence
of
removal
and refi ll
cooli ng
system
wi thcoolant to
speci fi ed
level
RefertoSecti on MA
I NSPECTI ON
I nspect
radi ator
cap
and
water
leakageusi ng
cap
tester
LC 6
I nspecti on
ofradi ator
cap
Fi rst check rubbersealon
cap
for
tears
cracks
or
deteri orati on after
cleani ng
i t
Then i nstall
radi ator
cap
ona testerI f
cap
doesnot
holdor
wi ll
not
release at
the
speci fi ed pres
sure
replacecap
Cap
reli ef
pressure
88kPa
09
kg
cm2 13
psi
ET012
2
I nspecti on
ofwater
leakage
Wi th
radi ator
cap
removed
apply
test
pressure
toradi atorona car
I f
leakage
i s detected
repai r
or
replace
radi ator
Leakage
test
pressure
157 kPa 16
kg
cm2
23psi l
I
y
SLC037
THERMOSTAT
REMOVAL
AND
I NSTALLATI ON
1
When
removi ng
drai n
coolant
parti ally
anddi sconnect
upper
radi ator
hose
at wateroutlet
2
I nstallthennostat and
waterout
let as
i llustrated
1
Ji ggle
valve
2
Thermostat
SLC033
3 Gasket
4
Wateroutlet
I NSPECTI ON
I nspect
thennostat for
thefollow
i ng
and
replace
i f
necesS3l
I
Valve
seati ng
condi ti on at ordi
nary
temperature
I t should
seat
ti ghtly
2
Valve
openi ng
temperature
and
maxi mumvalveli ft Refer
toSDS
VJj
i
SLC034
3 Then check i f valvecloses at SOC
90F below
valve
openi ng tempera
ture
I t i s
necessary
to
check
a new
ther
mostat
before
i nstalli ng
i t i n
engi ne
WATER
PUMP
DI SASSEMBLY
Water
pump
i s made of alumi num
and i ts
beari ng
outerrace
i s
of
a
press
fi t
type
Forthi sreason water
pump
should
not
be
di sassembled
I NSPECTI ON
I nspect pump
assembly
forthe
followi ng
condi ti ons
and
replace
i f
necessary
I
Badly
rusted
or
corroded
body
assembly
and
vane
2
Excessi ve
end
play
or
roughness
of
beari ngs
i n
operati on
I f excessi ve mechani cal
seal
squeak
occurs when
engi ne
i s
runni ng
use
sui table
water
pump
seallubri cant to
prevent squeak
TEMCOUPLlNG
DI SASSEMBLY
The
coupli ng
i s so
desi gned
that i t
cannot bedi sassembled
I NSPECTI ON
I nspect
the
coupli ng
foroi l
leakage
orbend of
bi metalI f
necessary
reo
place
as a
pump assemhly
ENGI NE
LUBRI CATI ON
COOLI NG
SYSTEMS
Cooli ng
System
cf
N m
kg
ln ft I b
Belt dcllccti on
mm
i n
fN
kg
I b
@
M6 39 9
810
4 1 029
7
21
M8 1016 10167 121
a
1210
31 047
98 1022
Pump gasket
Always replace
Water
pump
wi th
fan
coupli ng
Fan belt
SLC035
t
C0077
1 Bi metalthermostat
2
Sli devalve
3 ReseI Vechamber
for
QFF
4 Beari ng
5
Dri vi ng
chamberforON
6 Coupli ng part Labyri nth
Le
r
Servi ceDataandSpeci fi cati ons
ENGI NE
LUBRI CATI ON COOLI NG SYSTEMS
SERVI CE
DATA AND
SPECI FI CATI ONS
GENERAL
SPECI FI CATI ONS
I
Oi l
pump
I
Oi l
fi lter
Oi l
pressure
reli ef valve
Valve
openi ng
pressure
kPa
kg
cm2
psH
I
Redi etor
I
Thermostat
I
Water
pump
Tem coupli ng
Fen
speed
at water
pump
speed
4000
rpm
rp
oC OF
Trochoi dtype
Fullflowand
cartri dgetype
59 813
6
060075 85
10
7
Down
flow
corrugated
fi n
andtube
type
Wax
type
Centri fugaltype
2 150
601401
Less
than
1
650lbelow
50
122
I NSPECTI ON
AND
ADJUSTMENT
OI L PUMP
1
Rotor
ti p
clearance
Outer
rotor
to body
clearance
I
Rotor
si declearance
rotortobottomcover
Uni t mm i n
Standard
Wearli mi t
Lessthen
012
000471
020100079
015
0
21
I
00
0
10
0059
0llO831
5 197
004
008
I
01
0
0016 000311
2000079
OI L
PRESSURE
REGULATOR
VALVE
Free
length
mm jn
Re
ulator
valve
spri ng
I nstalled
lengthl
loed
mm i n N
I kg
lbl
Regulator
valve
openi ng
pressure
kPa
kg cm2
psi rpm
LC 8
525 2
0671
34 81 3701 77
5 85 3
7
9
87 174
1921
343
412
13
5 42 50
601
3
000
RADI ATOR
CaP
reli ef
pressure
kPa
kg cm2 psi 88 0913
157
11
6
231
Leakage test
pressure
kPa
I kg
cm2
psi
THERMOSTAT
1
Standard
Fri gi dtype
Tropi caltype
I
Valve
openi ng
tom
82 1801 8811901
76
170
perature
oC OF
I
Max valveli ft
895 8
100
8
90
mmoC Un oF
I 10
31
203
10
31 212
O3t 194
WATER PUMP
I
Fanbelt
deflecti on
mm
li n
N
I kg
I bl
I
8 12 10
31
0
471 9810221
TI GHTENI NG TORQUE
Uni t
N m
kg m
ft
lb
Oi l
pump mounti ng bolu
11 15 11
15 8 11
I
Oi lpump coverbolts 69
98
0
7 1 0 5 1 72
Regulatorvalve
cap 39 49 45
29 36
Water
pump securi ng
bolt
M6
39
98 04 1 0 29
72
Me
10
16 1
0
16 7
12
ENGI NE LUBRI CATI ON COOLI NG
SYSTEMS
Trouble
Di agnoses
andCorrecti ons
TROUBLE
DI AGNOSES
AND CORRECTI ONS
LUBRI CATI ON
SYSTEM
Condi ti on
Probablecause
Oi l
leakage
Damaged
orcracked
pump
body
cover
Oi l
leakage
from
gasket
andoi lseal
Oi l
leakage
from
regulator
valve
Oi l
leakage
from
bli nd
plug
Decreasedoi l
pressure
Lack
ofoi li n
engi ne
oi l
pan
Di rty
oi lstrai ner
Damaged
or
worn
pump
rotors
Malfuncti oni ng regulator
Use
of
poor
quali ty
engi ne
oi l
Warni ng li ght
remai ns on
engi ne runni ng
Decreasedoi l
pressure
Oi l
pressure
swi tch
unservi ceable
Electri calfault
Noi se
Excessi vebacklashi n
pump
rotors
COOLI NG SYSTEM
Condi ti on
Probablecause
Water
leakage
Damaged
radi atorseams
Leaks from
heaterconnecti ons
or
plugs
Leak from
water
pump
shaft
seal
Leak
fromwater
temperature
gauge
Leaksfrom
gaskets
or
small
cracks
Loose
joi nts
Damagedcyli nder
head
gasket
Waterleakage Cracked
cyli nder
block
Cracked
cyli nder
head
Loose
cyli nder
headbolts
Correcti veacti on
Replace
Replace
Ti ghten
or
replace
Replace
G
orrect
Clean
or
replace
Replace
Replace
Replace
Previ ously
menti oned
Replace
Check
ci rcui t
Replace
Correcti veacti on
Repai r
Repai r
Replace
as
pump assembly
Ti ghten
Ti ghten
oruse
Ni ssan
Cooli ng System
Sealer
or
equi valent
Ti ghten
Replace
Check
engi ne
oi lforcontami nati onandrefi ll
as
necessary
Replace
Check
engi ne
oi l
i n
crankcase fonni xi ng
wi thwater
by
pulli ng
oi llevel
gauge
Replace
Ti ghten
LC 9
Speci al
Servi ceTool
ENGI NE LUBRI CATI ON
COOLI NG
SYSTEMS
Condi ti on
Poorci rculati on
Corrosi on
Overheati ng
Overcooli ng
Noi se
Tool
number
Kent
Moore
No
STl9320oo0
125664
LC l0
Probablecause
Restri cti on
i n
system
I nsuffi ci ent
coolant
I noperati vewater
pump
Loose fanbelt
I noperati ve
thennostat
Excessi ve
i mpuri ty
i n
water
I nfrequent
flushi ng
and
drai ni ng
of
system
Malfuncti oni ng
thennostat
radi ator
cap
and
fan
coupli ng
Radi atorfm
chokedwi th
mud
chaff etc
I ncorrect
i gni ti on
andvalve
ti mi ng
Di rty
oi l
and
sludge
i n
engi ne
I noperati ve
water
pump
Loosefanbelt
Restri ctedradi ator
I naccurate
temperaturegauge
I mpuri ty
i n
water
Malfuncti oni ng
thennostat
I naccurate
temperaturegauge
Squeak
at water
pump
mechani calseal
Damaged
orworn
water
pump beari ng
C
arrecti veacti on
Check hosesfor
cri mps
andclearthe
system
ofrust and
sludge
by
flushi ng
radi ator
Repleni sh
Replace
Adjust
Replace
Use soft clean
water
rai n
wateri s
sati s
factory
Cooli ng
system
should
be drai nedand
flush
ed
thoroughly
at least twi ce
a
year
Perma
nent anti freeze
Ethylene glycolbase can
beused
throughout
theseasonsof
a
year
Replace
Clean out
ai r
passage
thoroughly
by
usi ng
ai r
pressure
from
engi ne
si deofradi ator
Adjust
Refi ll
Replace
Adjust
Flush
radi ator
Replace
Usesoft clean
water
Replace
Replace
Use sui table water
pump
seallubri cant or
replace
as
pump
assembly
Replace
as
pump
aSsembly
SPECI AL
SERVI CE TOOL
Tool
name
Oi lfi lterwrench
00
DATSUN
200SX
ModelS J J 0Seri es
SECTI ONEF
ENGI NE
FUEL
CONTENTS
DESCRI PTI ON
EFI
SYSTEM
FEATURES
EFI SYSTEM
OPERATI ON
FUEL
FLOW
SYSTEM
AI R
FLOW SYSTEM
ELECTRI CAL
FLOW
SYSTEM
FUEL
I NJEC
TI ON CONTROL
FUEL
I NJECTI ON
TI MI NG
FUEL I NJECTI ON QUANTI TY
EFI SYSTEMCOMPONENT
PARTS
CONSTRUCTI ON AND FUNCTI ON
FUEL FLOW SYSTEM
AI R
FLOW
SYSTEM
ELECTRI CAL SI GNAL SYSTEM
PRECAUTI ONS
FOR AN EFI
ENGI NE
REMOVAL
AND
I NSTALLATI ON
I NJECTOR
AND FUEL PI PE
PRESSURE REGULATOR
AI R REGULATOR
WATER
TEMPERATURE
SENSOR
THROTTLE
VALVE SWI TCH
THROTTLE
CHAMBER
DASH
POT
VACUUM
SWI TCH
ALTI TUDE SENSOR
DROPPI NG
RESI STOR
CONTROL
UNI T
RELAY
AI R CLEANER
AI R FLOW METER
AI R TEMPERATURE
SENSOR
FUEL FI LTER
FUEL
PUMP AND
FUEL DAMPER
FUEL
HOSE
ELECTRI CAL
SYSTEMI NSPECTI ON
EF 2
EF 4
EF 4
EF 4
EF 4
EF 5
EF 5
EF 7
EF 7
EF 7
EF11
EF11
EF13
EF15
EF
18
EF19
EF19
EF
20
EF20
EF20
EF20
EF20
EF21
EF21
EF
21
EF21
EF21
EF22
EF
22
EF
22
EF22
EF
22
EF
23
F2
3
EF
24
DESCRI PTI ON
PREPARATI ONS
FOR
I NSPECTI ON
I NSPECTI ON
I NSPECTI ON PROCEDURE
TABLE
EFI
CI RCUI T DI AGRAM
COMPONENT
PARTS I NSPECTI ON
FUEL
PRESSURE
CHECK
FUE L
PUMP
FUEL DAMPER
FUEL FI LTER
I NJECTOR
PRESSURE REGULATOR
AI R FLOW METER
AI R
TEMPERATURE
SENSOR
AI R REGULATOR
THROTTLE CHAMBER
DASHPOT
WATER TEMPERATURE SENSOR
THROTTLE VALVE SWI TCH
VACUUMSWI TCH
ALTI TUDE
SENSOR
DROPPI NG RESI STOR
RELAY
CONTROL UNI T
CHECKI NG
AI R LEAKAGE
I N
AI R I NTAKE SYSTEM
CHECKI NG
FUEL
HOSES
SERVI CE
DATA AND
SPECI FI CATI ONS
GENERAL
SPECI FI CATI ONS
I NSPECTI ON
AND ADJUSTMENT
TI GHTENI NG TORQUE
TROUBLE
DI AGNOSES
AND
CORRECTI ONS
TROUBLE SHOOTI NG
CHART
CHECKI NG
AND
ADJUSTI NG
I DLE RPM
I GNI TI ON
TI MI NG AND
MI XTURE
RATI O
EF24
EF24
EF24
EF25
EF28
EF29
EF29
EF29
EF29
EF29
EF29
EF30
EF30
EF30
EF31
EF31
EF31
EF32
EF32
EF33
EF33
EF
33
EF
34
EF
34
EF
35
EF
35
EF
36
EF
36
EF36
EF
36
EF
37
EF37
EF
43
Descri pti on
ENGI NE FUEL
DESCRI PTI ON
SYSTEM
DI AGRAM
fUELUNE
VACUUM
LI NE
I NPUT SI GNAL
OUTPUT SI GNAL
r
t
essure
regulatm
h
f
Fuel
tank
i
I
i li J
Fuelmter
Fuel
pump
L
cu
wi tchCali forni amodelA
Swi tchi ng
module
I dle
speed adjus i ng
screw
i
Ji
t
0
r
Ai r
pi pe
EAtube
Oi l
pressure
swi tch
1
lli ru
Cali forni amodels
I
a
I
CJ
I
8j 8
I
ON
1ST
U
0
I h
Fuel
pump relay I gni ti on
coi l
I gni ti on
swi tch
q
EF
2
Ai r
i nducti ln
valve
Ai rcleaner
Ai r
nwmei
dlJ
fj
1r
L
b
I Ai r
temperature
ypall
semOl
ew
I I cI
J
s
lt1
Control
uni t
SEF081
Watet
tem Perature
sensot
Vacuum
wltch
IA
ltCl
i forni l
models
f
A
11
i
0
i
0
I I
i
yuel
pump
fue
d
aI n
pex
Alti tude
5en oor
Cali forni a
model
C
i
T
C
I
S
i
contro
uni t
Droppi ng
tes1
tot
MI
ternpetaW
re
n
or
EFI SystemOpenlti on
ENGI NE
FUEL
EFI SYSTEM
operati ng
condi ti ons
i nto
electroni c
si gnals
These
si gnals
are sent
tothe
controluni t
where
the
opti mum
i n
jector
open
valve
ti me
peri od
i s com
puted accordi ng
to the i nfonnati on
stored i n
the memorY
forcontrolof
fuel
i njecti onquanti ty
The
Electroni cFuel
I njecti on
EFI
system
i s used tocontrolfuel
supply
electri cally
i n
place
of the
conven
ti onalcarburetor
system
The EFl
system
employs
vari ous
types
of sensors to
convert
the
engi ne
Vari oussensors
I
Fordetecti ng engi ne operati on
1
Electri cal
si gnal
Control
uni t
I
For
calculati ng opti mum
fuel
i njecti
on
Electri cal
si gnal
I njector
I
For
i njecti ng
fuel
EFI SYSTEM
OPERATI ON
FUELFLOWSYSTEM
Fueli s sucked from the fueltank
i nto
the
fuel
pump
from whi ch
i t i s
di scharged
under
pressure
As
i t
flows
through
the
mechani cal
fuel
damper
pulsati on
i n
thefuelflow
i s
damped
Then the
fueli s fi ltered
i n the
fuel
fi lter
goes
through
thefuelli neand
i s
i njected
i nto
thei ntake
mani fold
cyl
i nder
branch
fromthe
i njector
Surplus
fueli s led
through
the
pres
sure
regulator
and
i s returnedtothe
fuel
tank
The
pressure
regulator
con
troi s the
i njecti on pressure
i n
such
a
manner
that
the
pressure
di fference
between the
fuel
pressure
andthe
i n
take
mani fold vacuum
i s
always
250
kPa 255
kg
cm 36 3
psi
J
D
EF 4
FEATURES
The EFl
system
uti li zes
electroni c
elements such
as
i ntegrated
ci rcui ts
I Cs resi stors thenni stors
etc for
electri cally controlli ng
the
amount of
fuel
i njected
correspondi ng
to
changes
i n
engi ne operati ons
Because of thi s
use of
electroni c
components
thi s
system
i s able to
provi de
a
qui ck
response
to
changes
i n
operati ng
con
di ti ons
and serves to
i mprove
the
engi ne perfonnance
and
to
reduce
fuel
consumpti on
andhannful
gases
un
J
r n
L
SEFQ83
AI R FLOWSYSTEM
I ntake
ai r
from
the ai rcleaneri s
metered at
the ai rflowmeterflows
through
the
throttlechamberand
i n
to
the
i ntake mani fold and
then flows
through
eachi ntake
mani foldbranch
i ntothe
cyli nder
Ai r
flow
duri ng
dri vi ng
i s
controlled
by
the
throttle
valvelocated
i n
the
throttlechamber
Duri ng
i dli ng
operati on
the throttle
valve i s i n thealmost closed
posi ti on
and
the
ai r
i s
led
through
the
by pass
li ne
between
ai r
pi pe
and throttle
chamber
I n thi scase
the
quanti ty
of
sucti on ai ri s
adjusted
by
means of
the
i dle
speed
adjusti ng
screw
Duri ng
warmi ng up
operati on
the
ai rflowi s
bypassed through
the
ai r
regulator
to
i ncrease
engi ne rpm
ELECTRI CALFLOW
SYSTEM
The sucti on ai rflowvari es
wi ththe
movement of the ai rflow
meter
and
the
quanti ty
of fuelto
be
i njected
shouldbe controlled
correctly
i ncor
I njector
11 R
A
respondence
wi th the
present
ai r
flow I n theEFI
system
the
i njecti on
pressure
i s held
constant
at 250kPa
255
kg
cm2 36 3
psi
and
the area
of the
i njector
noulehole
i s
alsocon
stant Therefore the fuel
i njecti on
quanti ty
can be
determi ned
by
the
l
11
I
ENGI NE
FUEL
EFI SystemOperati on
I dle
speed
adjusti ng
Ai r
cleaner
screw
0
Ai rflOwmter
f
LA S
uni t
i
I Throttle
chamber
L
Ai r
pi pe LAi rby
pass
screw
SEF084
i njectoropen
valve
ti me
peri od
The
controluni t of
theEFI
system
deter
mi nes thi s
pulse
wi dthdurati on ac
cordi ng
toi nformati on
electri cal
si g
nals from vari ous
types
of sensors
thereby
controlli ng
the fuel
i njecti on
quanti ty
L Vacuumswi tchCali forni amodels
Swi tchi ng
module
Ai rflOW
o
Ai r
by
pass
screw
I
Ai r
temperature
sensor
f
s
Control
uni t
SEF085
EF5
EFI SystemOperati on
ENGI NE
FUEL
SI GNALS
FOR
CONTROl
UNI T
An electri cal
si gnal
from
each
sen
sor
i s
i ntroduced
i nto
the
controluni t
I
Openi ng
of
L
throttlevalve
I
Engmerpm
H
Quanti ty
of
i ntake
ai r
H
TI lROI TLE
VLA
VE
SWI TCH
I GNmONCOI L
NEGATI VE
TERMI NAL
AI R
FLOW
METER
I NDEPENDENT
SI GNALS OF
CONTRDLUNI T
Fuelpump
operati on
I GNrI lON SWI TCH
START
I GNI TI ON SWI TCH
I G
ENGI NE REVOLUTI ON
I
ALTERNATOR
I I
lTERMI NAL
FUELpU lp ULA
Y
FUEL PlJlI P RELAY
fUELPUMP
EF
6
I
OI L rRf5SURE
I
SWI TCH
r
I
I EF37
1
for
computati on
The
open
vaI ve
ti JUe
peri od
of the
i njector
i s
controlled
by
I
Temperature
of
cooli ng
water
I
WATER
TEMPERA11JRE
I
SENSOR
I NJECTOR
When
starti ng
the
engi ne
thefuel
pump
i s
operated
by
the current
suppli ed through
fuel
pump
relays
2 and 1Afterthe
engi ne
starts
the
fuel
pump
conti nuesto
operate
usi ng
current
suppli ed
from
fuel
pump
relay
2
moni tori ng
the en
gi ne
revoluti on
and fuel
pump
reo
lay
1
I fthe
engi ne
stalls
forsomereason
fuel
pump
relay
2recei ves
the en
gi ne
stall
si gnal
and
stops feedi ng
current
thereby stoppi ng
the
opera
ti on
ofthefuel
pump
thedurati on of the
pulse
computed
i n
thecontroluni t
AI R TEMPERATURE
HTempctalUI el
SENSOR
of mtake
ai r
I GNI TI ON
SWI TCHH
START posi ti on
Starti ng
operati on
VACUUMSWI TCH
HI
take
mani fOldl
vacuum
Cali forni a
models
ALTI TUDE SENSOR
H
Cali forni a
modet
Atmospheri c
I
preuure
SEF169
Rotati on of
the
engi ne
i s detected
by moni tori ng
both
the
generati on
of thealternator
andthe
engi ne
oi l
pressure
Because
ofthi sdual
moni
tori ng system
fuel
pump
operati on
can be
assured
duri ng
engi ne
rota
ti on
even
i f one of these moni tor
uni tsshouldfai l
I f
theengi ne
stalls
completely
due
toa
malfuncti on
the
supply
offuel
i s
stopped
at once thi s
system
i JU
proves
safety
i ncaseof
engi ne
mal
functi on
FUELI NJECTI ON TI MI NG
FUEL
I NJECTI ON CONTROL
Crank angle
Cyli nder
o
1200
2400 3600 4800 6000
7
200
10
I
v
I
f
1k
I
l
1
4
I
I
m
71 ii
c
Start
of
i njecti on
fJ
I gni ti onpoi nt
The
engi ne
has
a
repeti ti ve
four
stroke
cycle
sucti on
compressi on
4
combusti on
exhaust Fuel
i njecti on
i s
made
just pri or
10
the
begi nni ng
of
the sucti on stroke
i n each
cyli nder
However
thi s
si tuati on i s
not the
sameforthe
EFI
system
The
fuel
i njectors
are electri cally
connected
i n
parallel
i n the control
uni t All
i njectors
recei vethe
i njecti on
si gnal
from the control
uni t si mul
taneously
Therefore
i njecti on
i s
made
i ndependently
of the
engi ne
stroke
cycle
sucti on
compressi on
combus
ti on
and exhaust I n the four cyli n
der
engi ne
i njeCti on
i s made once
after
recei vi ng
the
i gni ti on si gnal
from
the
i gni ti on
coi ltwoti mes
The
requi red
fuel
quanti ty
i s at
tai ned after
fuel
i njecti on
i s
made
twi ce
duri ng
one
stroke
cycle
sucti on
compressi on
combusti on
exhaust I n
other
words
one
i njecti on
of fuel
provi des
only
half the fuel
quanti ty
necessary
for
operati on
of
onestroke
cycle
ofthe
engi ne
Fueli n thi s EFI
system
i s not i n
jected
di rectly
i ntothe
cyli nder
but
i s
i njected
i ntotheoutsi de
porti on
of
the i ntake Valve Therefore the ai r
fuel
mi xture
i s
sucked
i nto
the
cyli n
derwhen the i ntake valve
opens
to
start the sucti on stroke I n other
strokes
the
ai r
fuelmi xture i s
kept
outsi dethei ntakevalve
8400
I ntake
valve
opens
SEF086
FUEL
I NJECTI ON
QUANTI TY
The
fuel
i njecti on
quanti ty
i s
the
sum
of the basi c
i njecti on
quanti ty
whi chi s
the basi s
of the
i njecti on
quanti ty
and the
enri chment
I hat
i s
used to correct
the basi c
i njecti on
quanti ty
i n
correspondence
wi ththe
vari ouscondi ti ons
Fuel
i njecti on
quanti ty
Basi c
i njecti on
quanti ty
Enri ch
ment
BASI C
I NJECTI ON
QUANTI TY
The
engi ne rpm
i nfonnati on
and load state i nformati on are
created
by
two
si gnals
whi ch
pro
vi de forthe
rolati on
of
the
engi ne
One of these two
si gnals
i s
sent out
fromthe
i gni ti on
coi lthat detects
the
engi ne rpms
The
otherone i s
the
si gnal
sent
from the ai rflowmeter
whi chmoni tors the sucti on ai r
quan
ti ty
The
i njecti on quanti ty
deter
mi ned
by
these
si gnals
i s caI led
the
basi c
i njecti onquanti ty
ENRI CHMENT
The basi c
i njecti on quanti ty
i s
used
ENGI NE FUEL Fuel
I njecti on
Control
as the basi s for
provi di ng engi ne
rota
ti on but the
i njector
i s
not controlled
by
thi sfactoralone
For
example
the
fuelshouldbeenri ched
when
starti ng
the
engi ne
or
i n
the
full
throttle
posi
ti on
For
provi di ng
thi s enri chment
the
control
uni t
computes
the
quan
ti ty
of fuel
to
be
added tothebasi c
i njecti on quanti ty
by usi ng
si gnals
sent from eachsensor
I t
causes
the
total
quanti ty
offueltobe
i njected
Warm
up
enri chment
Fueli s i ncreased accordi ng to
the
cooli ng
water
temperature
moni tored
by
the
water
temperature
sensor
Thi s
enri chment i s zero
when
the cooli ng
watertemperature
i sabove
40to
600C
104
tol400F
Enri chment
rati o i s
changed by
ON
or
OFF of
i dle
contact
I ntake ai r
temperature
enri chment
Fuel
i njecti on
i s
i ncreased accord
i ng
tothe
i ntake
ai r
temperature
moni
tored
by
the ai r
temperature
sensor
Thi s enri chmen
I
i s zero
when the
i ntake ai r
temperature
i s
above 400C
104OF
Cold start enri chment
Cold start
enri chment
provi dedes
i mproved starti ng abi li ty
i n
cold
weather
wi ththe
i gni ti on
swi tchon
START
duri ng
the
cranki ng opera
ti on and
when
thewater
temperature
i s
lowerthan
400C 1040F
The
elapsed
ti me
and
amount of
thi s en
ri chment
i s
detenni ned
by
the water
temperature
and
cranki ng speed
Stsrt enri chment
When the
i gni ti on
swi tchi s
i n
the
START
posi ti on
duri ng cranki ng
operati on
a
constant amount of fuel
i s
i ncreased
i rrespecti ve
of the
cooli ng
water
temperature
When Cold start
enri chment
reaches zerothi s
START
enri ch
ment wi llthenoccur
EF7
FUtJllnjecti on
Control
ENGI NE
FUEL
EXAMPLE OFFUEL I NJECTI ON
QUANTI TY
Cold start
I ntakeai r
temperature
I t
DoC
320F
constant and water
temperature
ri ses fromDoC
320
F
I gni ti on
swi tch
Throttle
VlI lve
tI I ltch
Wi tertemperalure
sen Ol
I
Ai rtempcratureleDSOl
Ai r
fi o
metcr
I ni ti on oi l
Vcbi decoodi ti oll
Jani ti on
I Wjlcb
Threl
eVlI lveswi tch
Vacuumswi tch
Cali forni amodels
Water
temperature
I ntake
lemper
i I turc
COlD
START
nri dunent
AFTER
START
ehmenl
llni tlon
ch
1
Waler
empcr lllurcsensor
FTER
I DLE enri chrne at
Thrbllle i
lwswi tch
I ertemperaluresenlor
I DLE chmenl
FULL nri ehmen
r
Throltle
aheswi tch
I
vacuumswi tcb
QOLI NG WATER
TEMPERAnJRE
ori chm
I
TA
KE I R
P R RE
Bots i c luel
njecti on
quanti ty
OOe
nor
200C
6110FI 40C l04on 600C 140oF
8
oC
11760F
lI o0e
17601
ConSlant
OnCali forni a models the Full
enri chment cti nted
when
the
vacuumswi tch ON whenthe
Fullthrottlecontact i s ON
oGC 32oF Const
nt
restart
I ntake
ai r
temperature
at I soe
S90F
constant andwater
temperature
ri ses
from
600e
I 400F
AFTER START
ehment
1F
ni li On ch
Wtr
emperalure
I lensm
Hot
I jl
ni li on i lch
W
telh
mpcl lI Ull
sensor
TluoltlevlI lYeswi lCh
Ai r
1 lemar
Ai r
no
meter
I
ni li on I I
Vehi cle
condi ti on
I gni li onswi tch
Thronlev
oI he si tch
Vaeuum
i lch
Cali forni a
1odeb
WOI tet
empc
nlure
I n J
ke emper llure
On
Cali forni a
models
the
Fun enri chment
cti nted benthevacuumswi tchi s
ON
whenthe
FuU throttle ntut
i s ON
SEF344
EF 8
i
ri cbmcnt
w
I
I NTAKE AI R TEMPERAltlRE
enri chment
FULL enri chment Throttle
nlveswi tdl
vacuum
swi tch
si e fuel
i njecli on
qUlrnli ty
nki nr I dli nl
Vehi cle
starli ng
ConstanHpecddri vi na
START
ON
I DLE cI ON OFF
FULL
THROTTLE
rontac10N
OFF
OFF ON
OFF
600 140l
F 800e 176l F 800C
117b
01
I Const ntJ
I SoC S90F Constant
Afterstart
enri chment
When
the
i gni ti on
swi tchi s turned
from
the
START
to ON
posi ti on
after
cranki ng
operati on
the start
orcold start
enri chment becomes
zeroThe afterstart enri chment
i s
provi ded
to
compensate
forthi s
sudden decrease
i n
fuel
quanti ty
The
afterstart enri chment
decreases
gradually
as
ti me
passes
fi nally
be
comi ng
zero
and i s detenni ned
by
cooli ng
water
temperature
I dle
enri chment
When the
engi ne
i s
i dli ng
that
i s
when
the accelerator
pedal
i s
not
depressed
the throttle valve
swi tch
i dle contact i s
ON
to
provi de
ad
di ti onalfuel
i njecti on
AfterI dle enri chment
The after
i dle enri chment
pro
vi dessmooth
accelerati on
when the
ac
celerator
pedal
i s
depressedtostart
the
vehi cle
The
after
i dle enri chment de
creases
gradually
as ti me
passes fi nally
becomi ng
zeroand i s detenni ned
by
cooli ng
water
temperature
ENGI NE
FUEL
Fuellnjecti on
Control
Full enri chment
The
smooth
ance
full
enri chment
provi des
full
throttle
dri vi ng
perfonn
Cali forni amodels
The fullenri chment i s
acti vated
when the i ntake mani foldvacuum i s
below 21 3
kPa
160mmHg
630
i nHg
or
when the
throttle
valve
open
i ng
i s
morethan 450
Non Cali forni a
models
The fullenri chment i s acti vated
when
the
throttle valve
openi ng
i s
more
than450
ENRI CHMENT SI GNAL
AND
SI GNAL SOURCE
CHART
Throttle
valveswi tch
I Vacuum
I gni ti on
Water Ai r
I gni ti on
Full
wi tch
swi tch
coi l
Remarks
tempera tempera
I dle
Cali forni a
negati ve
Fuel
ture
sensorturesensor
throttle
START
enri chment
contact
contact
models
termi nal
Coldstart
0 0 0
Start
0
Afterstart
0 0
1
1
I gni ti on
swi tch
START ON
I dle 0
After
i dle
0
0
2
2
I dle
contact
ON OFF
Full
0 0
Warm
up
0
0
I ntake
ai r
0
temperature
EF 9
FuelI njecti on
Control ENGI NE
FUEL
FUEL SHUT
OFf
Fuel shut off
i s
accompli shed
dur
i ng
decelerati on when the
engi ne
does
Automati ctransmi ssi on
models
3 000
I
S
2600
e
1
2
200
1
S
I
9
1
800
1
400
1
I
oooi
Decelerati onfrom
zone A
Decelerati onfrom
rone B
Decelerati on
fromzone e
Engi ne
rpm
i ncreased i n
order
of e S and
A
I dleswi tchON downhi ll
dri vi ng
etc
SEF095
not
requi re
fuel
@
@
@
Cooli ng
watertemperature
at 80C 1I 6
F
Fueli sshut off andfuel
i s
i njectedagai n
i ntoneCi
Fueli s shut off andfuel
i s
i njected agai n
i nzone e
Fueli snot shut
off
Fueli snot
shut
ofT i nzones
C and B
i nzone
A
fuel
i s
shut
off
ALTI TUDE COMPENSATI ON
Cali forni a models
The
densi ty
of
ai l
becomes thi n
i n
proporti on
tothe alti tude sothat
the ai r
fuel
rati o
becomes ri che
t
hi gh
alti tude
The alti tude
compensator
i s a
devi ce tocorrect
ai rfuelmi xture
to
an
opti mum
rati o
automati cally
EFl0
The
graph
below
shows the
fuel
shut off
tange
Manual n
models
3 OC
2
600
s
e
2 200
0
0
I l
0
1 800
1 400
1
000
Decelerati onfrom
zone
A
Decelerati on
fromzone B 1
D
from
zone
B2
Deceltrati on
fromzone e
Engi nerpm
i ncreased i norder
orue S2
Bland
A
I dleswi tchON
downhi ll
dri vi ng
etc
@
@
@
@
Cooli ng
water
temperature
at 80
C 1I 6
F
Fuel
i sshut off and
fuel
i s
i njectedagai n
i n
zone C
Fudi sshut off and
fueli s
i njected agai n
i n
zone
en
Fuel
i sDot shut off
Fueli snot shut
off
Fueli snot shut
off
i n
zones
en
B2
and Bl
i n
z one A fuel
i s
shut
off
ENG I NE FU
EL EFI
System
Component
Parts Constructi on
andFuncti on
EFI
SYSTEM
COMPONENT PARTS
CONSTRUCTI ON
AND
FUNCTI ON
FUEL FLOW
SYSTEM
FUEL
PUMP
Normalflow
Reli ef valve
actuated
due tocloggeddi scharge
li ne
I nl
The fuel
pump
employs
a
wet
type
constructi on
whe
e a
vane
pump
wi th
roller
i s
di rectly
coupled
to
a
motor
fI lledwi th
fuel
Thi sconstructi on
pro
vi des
superi or
coupli ng
characteri sti cs
between
the
pump
and motor
and
greater
safety
i ncaseoffi re
RoUer
Outlet
E F252A
Outlet
Fuel
pump relay Fuel
pump
Battery
El
Pi
1
s
1
I
Oi lpres
ureswi tch
I I
I gni ti on
I
swi tch
I G
Fuel
pump relay
2
Alternator
Normal
swi tchposi ti on
I GN SW
posi ti on
I n
the
vane
pump
the
rolleri s
pushed
outward
by centri fugal
force
when
the
pump
rotates andi s
pressed
agai nst
the
outer
wallThi s
rotary
porti on
and surroundi ng
wallare not
coaxi al and
pumpi ng
i s
perfonned
by
the
change
i n clearance between
the
wallandthe
rotary
porti on
Thus
when
the clearance
i s
large
fuel
i s
sucked
i n when i t decreases
fueli s
di scharged
The reli ef valve
i n the
pump
i s
desi gned
to
open
when
the
pressure
i n
thefuelli ne
ri ses
over
294to
44I
kPa
3
0to
45
kg
cm2
43
to64
psi
due
to
malfuncti on i nthe
pressure system
The check
valve
prevents
abrupt
drop
of
pressure
i n
the
fuel
pi pe
when
stoppi ng
the
engi ne
Operati on
When
the
i gni ti on
swi tch
i s
turned
Nhene i ne When
nli ne
opped opErati on
Allenulor
L
rmi lUll
OLlprclSurt
wi tch
ON 011
START
No No
ON
generate
pressure
ON Gentrate Normal
ON
ON
Fai lure NOllTUI 1 ON
ON Gencr atc
Fai lure ON
ON l ai lure
Fwure OFF
OFF
No
No
OFF
SEF096
teneralt prcuure
Alternator
Oi l
Fuel
pump
relay
I
1
pump
Fuel
pump
relay
2
prellure
I I Actuate
Actuak
Actuate
Actuate
No
actuate
No
actuate
to
the START
posi ti on
for
cranki ng
operati on
the fuel
pump
i s
actuated
i rrespecti ve
of
the
condi ti ons
of
the
alternatorand
the
engi ne
oi l
pressure
swjtch
After
starti ng
the
engi ri e
the
i gni
ti on swi tch
i s
ON
the
alternator
operates
and
the
engi ne
oi l
pressure
swi tch
i s
open
through
rotati on
of
the
engi ne
th
reby
actuati ng
the fuel
pump
I fthe alternator
stops
andtheen
gi ne
oi l
pressure
decreases
forsomere
ason thefuel
pump relay
2contact i s
turned to I I and
the fuel
pump
relay
li s
turned OFF
Thenthefuel
pump
i s
stopped through
the
i gni ti on
swi tchremai ns i n the
ON
posi ti on
I nthi s mannerfuel
supply
i s cut off
for
safety
purposes
when the
engi ne
acci dentally stops
duri ng
dri vi ng
EFl1
FUEL DAMPER
EFI 1
Component PartsConstrocti onand
Functi on
ENGI NE FUEL
Fuel
outlet
SEF097
The fuel
damper
i s
provi ded
to
suppress
pulsati on
i n fuelflow
di s
charged
from thefuel
pump
Noad
justment
i s
allowed
on
thi s
damper
Change
i n
the
pump
di schargepres
sure
i s moni tored
by
the
di aphragm
and
spri ng
whi ch
vary
thevolumeof
the fuel
chamberfor
suppressi ng pul
sati on
FUEL
FI LTER
I l
R
Fueloutlet
j
Fueli nlet
EF256A
The fuelf1lter
i s
placed
between
the fuel
damper
and the
i njector
and
i s
used
toremove
forei gn
matteri nthe
fuelWater
i n thefuel
i s
collectedat
the
bottomof
thef1lter
casi ng
I NJECTOR
The
i njector
recei ves the
pulse
si gnal
from
the control
uni t
andi n
jects
the fueltoward thei ntakevalve
i n
the
cyli nderhead
The
i njector
operates
on
the
EF12
solenoi d valve
pri nci ple
When
i I
dri vi ng pulse
i s
appli ed
to
thecoi lbui lt
i ntothe
i njector
the
plunger
i s
pulled
i ntothesolenoi d
thereby
openi ng
the
needle valve forfuel
i njecti on
The
quanti ty
of
i njected
fueli s i n
propor
ti on
to
the
durati on of
the
pulse
ppli ed
fromthecontroluni t
SEF099
1
I njector
lower
rubberi nsulator
2 I njectorlowerholder
3
I njector
upperrubberi nsula or
4
I njector
upper
holder
5
I njector
ole
FJectri ctermi nal
li
11 I
f
Fi lter
PRESSURE
REGULATOR
Toi ntake
mani fold
t
Ai rchamber
Di aphragm
Fueli nlet
SEF100
The
pressure regulator
controls the
pressure
of fuel
sothat
a
pressure
di fference of 250kPa 255
kgjcm
36 3
psi can
be
mai ntai nedbetween
thefuel
pressure
and
i ntake
mani fold
vacuum
The
pressure regulator
i s
di vi ded i ntotheai r
chamberand fuel
SEF098
chani ber
by the
di aphragm
I ntake
mani fold
vacuum
i s
i ntroduced i nto
the
ai r
chamber
thereby keepi ng
di fferenti al
pressure
constant
causi ng
excessi ve fuelto
return tothe
fuel
tank
through
the return si de
port
Thi s constant di fferenti al
pressure
provi des opti mum
fuel
i njecti on
i n
every
mode
of
engi ne
operati on
kPa
kg
em
psi
196
t
2 0
Fuel
pressure
u 28
98 250kPa
2 55
kg
em
e
10
366
si
14
I
tmospheri c
0
D CSSW e
Ttme
98
Foi l
Mani Cotd
1
0
I dli ng
throttle
vacuum
14
E F258A
AI R FLOWSYSTEM
AI R FLOW METER
Heli cal
spri ng
Fromai rcleaner
ENGI N
E FUE L EFI
SystemComponent
Parts
Constructi on
andFuncti on
Damperplate
To
i ntake
mani fold
By pass port
Ai rtemperature
sensor
The ai r
flowmetermeasures the
quanti ty
of
i ntake ai r
and sends
a
si gnal
to
the
control
uni t
so
that the
base
pulse
wi dth
can
be detenni ned
for
correct fuel
i njecti on
by
the
i njec
torThe ai rflow
meteri s
provi ded
wi tha
flap
i n the
ai r
passage
As
the
ai rflows
through
the
passage
the
flap
rotates and i ts
angle
of rotati on
i s
electroni cally
moni tored tocount
the
ai r
flowrate
More
speci fi cally
the
angle
of
rota
ti on of the
flap
i s
moni tored
by
a
potenti ometer
provi ded
i nsi de as a
potenti al
di fferenceV When
the
flap
deflects
along
wi tha
change
i n the
i ntake
ai r
flowrate the termi nal@
mounted to
the
flap
shaft
sli des
on
thevari able resi stor
R
fromRI
toR9
causi ng
the
voltage
across
tenni nals
@
and@tochange
A constant
voltage VB
battery
voltage
i s
appli ed
across termi nals
@
and
@
Then the
ai r
flowrate
i s
convertedi ntothe
voltage
rati o
si gnal
V
VB
whi ch
i n
turn
i s
sent tothe
Potenti ometer
To
EFI harness
controluni t for
computati on
The
flap
i s
able torotate toan
angle
where an
equi li bri um
between
the
ai r
flow
pressure
and
the return
torque
of lhe
coi l
spri ng
can
be mai n
tai ned The
damper
chamber
and
damperplate
are
provi ded
as a
damper
forthe
flap
sothat
the
flap
wi llnot be
di sturbed
by pulsati on
i n
mani fold
vacuum
duri ng
operati on
The
damperplate
i s
i nterli nked
wi th
the
flap
and
as the
flap
rotates
the
compensati ng
plate
rotates
i n
the
damper
chamber
keepi ng
a
very
small
clearancebetweenthechamberwall
Duri ng i dli ng
operati on
when the
amount of
i ntake ai ri s
extremely
smallthe
ai r
flows
parallel
wi ththe
flap through
the
by pass
port
sothat
the
speci fi ed
i ntake
ai r
flowcan
be
provi dedcorrectly
Theai r
passage
i s
provi ded
wi ththe
ai r
temperature
sensor
andthe
by
pass
port
has the
ai r
by
pass
screw
whi ch
regulates
the
i dle
mi xture
rati o
U
35
Ro
33
R
Potenti ometer
32
R
I B
RJO
34
Ai r
temperature
sensor
25
Termi nalnumber
fi
EF441A
AI R
REGULATOR
Electri c
termi nal
Shutter
Sleeve
Ai routlet
r
Heater
SEF101
The
ai r
regulatorbypasses
the
throttle valve tocontrolthe
quanti ty
EF13
EFI
ystBrn
Component
PansConstructi on
and
Functi on
EN
GI N
E FUEL
of ai rfor
i ncreaSi ng
the
engi ne
i dli ng
speed
when
starti ng
the
engi ne
at a bi
Characteri 5ti cs curve
COLD
40
metal
temperature
of
below
800C
I 412
176OF
3
30
32
1
30
c
A
bi metalanda heater
arebui lt
i n
1059
to
theai r
regulator
When the
i gni ti on
e
20 21
5 759
2
swi tchi s turned
to
the
START
posi l
706
on
or
engi nerunni ng
electri c
current
10
16
5
583
flows
through
theheater
and thebi
a
353
2
5 88
Ai r
i nlet
metal as
i t
i s
heated
by
theheater
0
0
hegi ns
to
moveand closes
the
ai r
pas 20 0 20 40 60
80
sage
i n
a
fewmi nutes
Theai r
passage
g
4
32 68 104 140
176
remai ns
cloSedunti lthe
engi ne
i s
stop
Tempetature
oe
FJ
ped
andthe
bi metal
temperature
drops
to
below
800C 176OF
0
I ni ti albi metal
temperature
200e
68
HOT
I A UNI T
I dle
speed
adjusti ng
screwuni t
Throttlevalve
remai ns closed dur
i ng engi ne i dli ng
andthe
ai r
requi red
fori dli ng
passes through
by pass
li ne
between
ai r
pi pe
andthrottlechamber
I dle
adjustment
i s made
by
the i dle
speed
adjusti ng
screw at the 1
A
S
uni t
AI R PI PE
Theai r
pi pe
located
ontheli nebe
tween the
ai r
flow
meterand
the
throttle
chamber
prevents
the
pulsat
i ng
ofthe
i ntakeai r
THROTTLE
CHAMBER
The
throttle chamber
located
be
tween
theai rflowmeterand the
i n
take
mani fold
i s
equi pped
wi th
a
valves
Thi s valve controls thei ntake
ai r
flow
i n
response
toaccelerator
pedal
movement
The ai r
passage
i s
a
twobarrel
type
whi chconsi sts
of a
pri mary
si deanda
secondary
si de A venturi
i s
provi ded
onthe
pri mary
si de
When the
openi ng
angle
of the
pri mary
throttlevalvereaches350the
secondary
throttle valve wi llbe
opened
by
a
li nkage
whi ch
i s
connect
ed
to
the
pri mary
throttlevalve
The
rotary
shaft of the
pri mary
throttle valve i s
connected tothe
throttlevalveswi tch
EF14
30
e
1
059
s
20
10
ri
o
177
25 88
I
g
2
4
6 8 10
Thne mmwU
I ntake
mani fold
Ai rduc
dr
ThI ottle
valve wi tch
1
Bi metal
2
Shutter
3
Heater
SEF102
j
di cr
L
c
JFj
pi
IAS uni t
Ai r
flowmeter
SEF106
Pri maty
throttlevalve
I
Secondary
throttlevalve
I H
J
SEF104
DASH
POT
Automati c
transmi ssi on
models
The dash
pot
i s attached
tothe
throttle chamberThe dash
pot pre
vents the throttle valve from
closi ng
abruptly
and thus stalls the
engi ne
The
throttle valve wi ll
gradually
reo
turn
to
the i dle
openi ng posi ti on
duri ng
decelerati on
ELECTRI CALSI GNAL
SYSTEM
WATER
TEMPERATURE
SENSOR
Thewater
temperature
sensor
bui lt
i nto
the
thermostat
housi ng moni tors
change
i n
cooli ng
water
temperature
and transmi ts a
si gnal
for
the
fuel
enri chment
to
change
the
pulse
dura
ti on
duri ng
the
wann
up peri od
I
The
temperature sensi ng
uni t
em
ploys
a thermi storwhi chi s
very
sensi
ti ve
i nthelow
temperature
range
The electri calresi stanceof
thether
mi stordecreases
i n
response
tothe
water
temperature
ri se
AI R
TEMPERATURE
SENSOR
The ai r
temperature
sensorbuHt
i ntothe ai r
flow meter
moni tors
change
i n
the i ntake ai r
temperature
and transmi ts a
si gnalforthe fuel
enri chment to
change
the
pulse
dura
ti on
The
temperature sensi ng
uni t
em
ploys
a thermi storwhi chi s
very
sensi
ti ve
i nthelow
temperaturerange
The electri cal
resi stance
ofthether
i stor
decreases i n
response
totheai r
temperature
ri se
THROTTLE
VALVE SWI TCH
The throttlevalve
swi tch
i s
attach
ed tothe throttle
chamber
and ac
tuates i n
response
toaccelerator
pedal
movement Thi s swi tchhas twosets
of
contact
poi nts
One set
moni tors
the i dle
posi ti on
and the other
set
moni torsfullthrottle
posi ti on
EN
GI N
E
FU
EL
EFI SystemComponent
Parts
Constructi on
and
Functi on
WATER TEMPERATURE
SENSOR
q
AI R
TEMPERATURE
SENSOR
Ai r
temperature
sensor
SEF101
I dl
contact
The
i dle contact
closes when the
throttlevalvei s
posi ti onedat i dleand
opens
wheni t i s at
any
other
posi ti on
The i dle
contact
compensates
for
i dle wann
up
and after
i dle
en
ri chment and sends the fuelshut
off
si gnal
Fullthrottle
contact
The fullthrottle
contact closes
only
whenthethrottlevalvei s
posi ti oned
at
fullthrottle more
than
45
degree
openi ng
of the throttle
valve The
contact i s
open
whi lethe
throttlevalve
i s
at
any
other
posi ti on
The fullcontact
compensates
for
fullenri chment
Dash
pot
Ai r
Throttle
passage
lever
Throttle
h
L
valve
J
SEF105
CHARACTERI STI CS
CURVE
I
I
11
4
knat I OoC
l40F
30
I
20
7 0
10
8
6
4
I
21
2 9Jen at 200C
c
3
680F
I
J
8
2
068
1
00
kn I
0
I
t SOOC
1220
1
I
06
I
1 0
06
L
30 200
20
4060 80
22 432
68
104
140
176
Temperature
OcOF
04
0
31
02
Fullthrottle
contact
SEF108
EF15
EFI
System
Component
PartsConstructi onandFuncti on
ENGI NE FUEL
VACUUM
SWI TCH
Cali forni a
models
The vacuum swi tch
compensates
forthe full
enri chment
by controll
i ng
the
i ntakemani foldvacuum
Thi s
swi tch
consi stsofa vacuum
di aphragm
and
ami croswi tch
When
the
i ntakemani fold
vacuum
lowers
duri ng
accelerati on the
tensi on
of
the
spri ng
wi ll
push
the
di aphragm
back
and
open
the
contact of
the
mi croswi tch
Thi s wi ll
cause the
swi tchi ng
moduletotransmi t
an ON
si gnal
tothecontroluni t
ALTI TUDE
SENSOR
cali forni a models
Thi s alti tude sensori s a
devi ce
to
obtai n theelectri c
si gnal
i n
proporti on
toalti tude for
the
electroni ccontrol
uni t
Thi s alti tudesensor
i s
composed
of
thebellows the
magnet
and
the
mag
neto
resi stance
element
At
hi gh
alti
tude thebellows
extends
and
changes
the
posi ti on
of
the
magnet
i nstalled
at the
ti p
of bellows The
magneto
resi stance
element
senses
the
posi ti on
of the
magnet
andtransfonns tothe
electri c
si gnal
The electri c
si gnal
fromthealti tude
sensor
i s
transmi tted
to
the
elecroni c
control
uni t andi he
i njecti on
durati on
of the
i njectors
i s
detenni ned toob
tai n the
opti mum
ai r
fue
rati o
by
the
electroni c
control
uni t
CONTROL
UNI T
The
controluni t i s
connected to
the EFI harness
by
means ofa multi
connector
and the EFI harness i s
connectedtoothersensoI S
The
essenti alrole of the
control
uni t i s to
generate
a
pulse
Upon
recei vi ng
an electri cal
si gnal
from
each
sensorthe controluni t
generates
a
pulse
whose durati on
i njector
open
EF16
Battery
j
@
Tocontrol
uni t
@
r
@
Swi tchi ng
mo j
ule
Bellows
i f
m
J
To
control
uni t
Magnet
j
Magneto
resi stance element
SEF113
valve ti me
peri od
i s
controlled to
provi de
an
opti mum quanti ty
of fuel
accordi ng
to
the
engi ne
characteri sti cs
Thecontrol
uni t consi sts
mai nly
of
three
i ntegrated
ci rcui ts
fonned
onthe
pri nted
ci rcui t board Thi s construe
ti on
provi des
superi or
control
uni t
reli abi li ty
Swi tchi ng charact8ri sti cs
Termi nal
@ @
ON
hn
j
OFFj
21 3
kPa
160
mmHg
6
30
i nHg
Vacuum
Vacuum
i ncrease decrease
I ntake
mani fold
uum
l
O1aracteri sti cs curve
6
m
U
nn
u
s
0
2 6
c
o
Alti tude
m ft
500
1
641
Atmospheri c
pressure
kPa
mmHg
i nHgJl
95
4
716
282
SEF217
1 800
5 906
814
611
24
1
SEF275
EF323A
DROPPI NG RESI STOR
The
droppi ng
resi stori s used to
lower
the source
voltage
to
a
level
sui tablefor
the
i njector
The
droppi ng
resi stori s
connected
i n seri es wi ththe
i njector
I t reduces
the source
voltage
to
approxi mately
1 4
ofthesource
voltage
These
resi s
tors
protect
the
i njectors
froma1terna
tor
voltagesurges
and
fromtheeffects
of other
components
i n the
vehi cle
s
electri cal
system
RELAY
EFI
relay
The
EFI
relay
servestoacti vatethe
electroni c fuel
i njecti on
system
through
the
i gni ti on
swi tch
Fuel
pump relay
1 and
2
The fuel
pump
relay
serves toac
ti vate thefuel
pump
For
9perati on
of
thefuel
pwnp
refertoFuel
Pump
EFI
HARNESS
One
wi ri ng
harness
i s
used
to
con
nect
li nes
between the
controluni t
and
the
related
major
uni ts
The
35
pi n
connector
of the EFI
harness i s
connected
to the control
uni t and runstothe
engi ne compart
ment The harness runs
to
vari ous
uni ts the
ai rflow meterthrottle
valve swi tchvacuum
swi tch
ai r
regu
latoralti tude sensor
water
tempera
ture sensor
droppi ng
resi storandi n
jector
etc
Battery suppli es power
to
i njector
andcontrol
uni t
through
fusi ble li nk
desi gnedespeci ally
forEFl
EN
G
I N
E FUEL
EFI
System
Component
Parts
Constructi on
andFuncti on
Electri c
Resi stor
tenni nal
tL
L
1
I
I I
r
SEF114
Battery
l
I
81
Fusi ble
li nk
o
5 I
I G
I gni ti on
swi tch
Droppi ng
resi stor
I
I
I
I
I
I njector
1
Control
uni t
SEF115
1
i
Droppi ng
resi stor
I
I
I I I
Ai r
flowmeter
7
SEF116
EF
17
Alwll
1I
UJe
12
olt
batteti c
as
power
Qurce
Do
not
attempt
to
di sconnect
batter
cable
i
whUe
engi ne
i s
operati ng
I f
a
recei ver4ranltnlttet
i s
i nstalled
route
antenna
fceder
cable
along
opposi te
si de
ftom
Efl
hatnes
and
control
uni t
Make
i ure
that
there
i s
no
i nterferen e
whUe
engi ne
i s
i dli ng
Do
not
applY
bnttery
pOWe
di rectly
to
i nlectan
i
a
l
j
I
rn
c
p1
PRECAUTI ONS
FOR
AN
EFl
ENGI NE
PaY
clo
ttentlon
to
the
followi ng
poi nt
when
i ll5pecti ng
or
cvi ci ng
en
EfI
car
Securely
connect
EFI
harne
55
connector
A
poor
connecti on
can
cause
an
extreme
ly
hi gh
surge
voltll
e
to
develop
i n
coi l
and
condenser
thus
rerulti ng
i n
damage
tolCci rcui t
Keep
EFt
h
rne
t
e
t
10
em
1
91n
away
from
adjacent
hlU llesses
to
prevent
an
EFl
syltetn
malfuncti on
due
to
recepti on
of
external
noi se
degraded
operati on
of
I e
ci rcui t
etc
Keep
EFt
parts
end
h
rne
dI Y
BefotO
removi ng
pl1I ta
turn
off
i gni ti on
swi tch
and
then
duccnnect
batter
ground
cable
00
not
operate
fuel
pump
when
there
i s
nO
ruel
i n
i MJ
00
not
use
antHrceze
agents
i
n
fuel
Do
not
reule
fuel
hose
cla mp1l
Ti ghten
fuel
hose
clamp
suffi ci entlY
Randle
ai r
floW
meter
carefullY
to
avoi d
dalTlage There
should
not
occur
even
a
ti ght
leak
i n
ai r
i nt
ke
i
tero
v
Do
not
depteSS
aCCClen
tot
pedal
when
I tarUPi
I mrnt dtatelY
afte1
starti ng
do
not
rev
up
engi ne
unneceuarUY
i j
ENGI NE
FUEL Removalsnd
I nstallsti on
REMOVAL
AND I NSTALLATI ON
I NJECTOR
AND
FUEL PI PE
1
Follow
the
procedure
below to
reducefuel
pressure
to
zero
CAUTI ON
Before
di sconnecti ng
fuelhose release
fuel
pressure
from
fuelli ne
toeli mi
nate
danger
I
Start
the
engi ne
2
Di sconnect
the harness
connector
of fuel
pump
relay
2
whi le
the
engi ne
i s
runni ng
Rei
bracket
SEF131
3 Afterthe
engi ne
stalls crank the
engi ne
two
orthree
ti mes
4
Turnthe
i gni ti on
swi tch
OFF
5
Reconnect the
harness
connector
offuel
pump relay
2
I f the
engi ne
w
1 not start remove
fuel
pump
relay
2
Ia rness
connector
and crank the
engi ne
forbout 5 sec
conds
Then turn the
gni ti on
swi tch
OFF
2
Remove
or
di sconnect
thefollow
i ng parts
andconnectors
Accelerator
wi re
I njector
harness
connector
VC valve hose
and ai r
regulator
hoses
Ai r
regulator
and
i ts harness con
nectar
Vacuum
hose
at the
fuel
pi pe
con
necti onend
3
Di sconnect
fuel
feed
hose
and
fuelreturnhosefrom
fuel
pi pe
Place
a
rag
underfuel
pi pe
to
pre
vent
splashi ng
of fuel
4
Removevacuum
hose
connecti ng
8 Unfasten hose
clamp
on fuel
i n
jector
and remove
fuel
i njector
from
fuel
pi pe
Place a
rag
under
i njector
when
di s
J
connecti ng
fuel
pi pe
to
prevent
splash
i ng
of fuel
pressure
regulator
to
i ntake mani
fold
5
Remove
boi ts
securi ng
fuel
pi pe
and
pressureregulator
SEF119
6
Removescrews
securi ng
fuel
i njce
tors
7 Remove
fuel
pi pe assembly by
pulli ng
out fuel
pi pe
i njector
and
pressureregulator
as an
assembly
SEF099
1
I njector
lowerrubberi nsulator
2
I njector
lowerholder
3
I njector
upper
rubberi nsulator
4
I njectorupper
holder
i 5
I njector
9 Toi nstall
i njector
and fuel
pi pe
reverse
theorderofremoval
a
When
i nstalli ng
i njector
checkthat
there
are
no
scratches
or
abrasi on at
lowerruti beri nsulator
and
securely
i nstalli t
maki ng sure
i t i sai r
ti ght
b Fori nstallati on of fuel
hose refer
toFuel
Hose
I NJECTOR
RUBBER HOSE
I f
necessary
replacei njector
rubber
hose
proceed
as follows
Removal
Socket
Y
20
mm
0
79i n
EF551
EF
19
Remoli alandI nstBllati oh ENGI NE
FUEL
1
On
i njector
rubberhose
measure
off a
poi nt
approx
20
mm 079i n
fromsocket
end
2
Heat
solderi ng
i ron 150watt for
15 mi nutes
Cut hose i ntobrai ded
rei nforcement from
mark tosocket
end
Donot
feed
solderi ng
i ron unti li t
touches
i njector
tai l
pi ece
CAUTI ON
a Be carefulnot to
damage
socket
plasti c
connec1oretc
wi thsolder
i ng
i ron
b Never
pi ecei njector
i n a vi sewhen
di sconnecti ng
rubberhose
3
Then
pull
rubberhose
out wi th
hand
I nstallati on
1 Clean exteri orof
i njector
tai l
pi ece
2
Wet
i nsi de
of new rubberhose
Wi thfUel
3 Push
end of rubberhose wi th
hose socket onto
i njector
tai l
pi eceby
hand
as faras
they
wi ll
go
Clamp
i s not
necessary
at thi scon
necti on
CAUTI ON
After
properly
connecti ng
fuelhose
to
i njector
check connec1i on forfuel
leakage
PRESSURE
REGULATOR
Fuel
pi peassembly
SEF122
I Remove
the
fuel
i njector
fuel
pi pe
and
pressure regulator
as an as
sembly
from thei ntakemani fold
Re
ferto
I njector
and Fuel
Pi pe
forreo
moval
EF20
2 Remove
pressure regulator
from
fuel
pi peassembly
3
Toi nstall
pressure
regulator
reo
versetheorder
ofremoval
Fori nstallati on
of fuelhose
refer
toFuel
Hose
AI R
REGULATOR
I
Di sconnect
ground
cable from
battery
2 Unfasten
clamp
on eachsi de of
hose and
di sconnect hose
3 Remove
setscrews
and remove
ai r
regulator
4
Di sconnect
electri c
connector
fromai r
regulator
S
To i nstallai r
regulatorreverse
the
orderof
removal
WATER
TEMPERATURE
SENSOR
I
Di sconnect
battery ground
cable
2 Remove
radi ator
cap
Drai n
coolant
by openi ng
drai n
plug
CAUTI ON
The
coolant should not
be
drai ned
unti li t
has cooled
off
completely
Otherwi se
burns
may
be
i ncuned
3 Remove ai r
pi pe
tofaci li tatereo
movalof
water
temperature
sensor
4
Di sconnect water
temperature
sensorharness
connectorandthen re
move water
temperatur
sensor
by
turni ng
i t
counterclockwi se
5
Toi nstallwater
t
Ult
ture sen
r
reversethe
Ordi
f of
removal
Be
sure
to i nstall
copper
washer
when
i nstalli ng
watar
temperature
sensor
THROTTLE
VALVE
SWI TCH
1 Di sconnect
battery ground
cable
2 Di sconnect throttle
valve
swi tch
harnessco ector
3 Remove screws
securi ng
throttle
valveswi tchtothrottlechamber
4
Slowly
pull
throttle valve
wi tch
toward
you
5
To
i nstallthrottle valve
wi tch
reversetheorderofremoval
6 After
i nstallati on
adjust posi ti on
ofthrottle
valvesWi tch
Referto
Throttle Valve Swi tch
underthe
headi ng Component
Parts
I nspecti on
THROTTLE
CHAMBER
1 Di sconnect
battery
ground
cable
2
Remove
hoses
tubeand
ai r
duct
fromthrottlechamber
3 Di sconnect throttle valve swi tch
harness connector
4 Remove acceleratorwi re from
throttlelever
5 Remove bolts
securi ng
throttle
chamber
to i ntake
mani fold The
throttle
chambercan beremoved
6
To
i nstall
throttle chamherreo
verse
the
order
ofremoval
Gasket should
be
replaced by
new
one
eachti me
the
throt tle
chamberi s
removed
Throttle
chamber
iJ
Nm
lkg m
ft
lbl
18 22 18
2213 161
SEF126
Donot
adjust
throttle
valve
stopper
screw as i t i s
properly adjusted
at
factory
DASHPOT
Dash
pot
0
11
Throttle
chamber
I J
SEF142
Removethrottlechamber
Referto
throttle chamberforreo
moval
ENGI NE
FUEL Remova and
I nstallati on
2 Remove dash
pot
from throttle
chamber
3 To
i nstalldash
pot
reverse
the
order
of removal
4 After
i nstallati on
adjust
dash
pot
touch
speed
Refer
toDash
Pot
under
the
headi ng
of
Component
Parts
I nspecti on
VACUUMSWI TCH
SEF141
I Di sconnect
battery ground
cable
2 Di sconnect
vacuumhose
and har
ness connector
fromvacuumswi tch
3 Remove
vacuum
swi tch from
bracket
4
Toi nstallvacuumswi tch
reverse
theorder
of
removal
ALTI TUDE SENSOR
Left si de
dI Sh
panel
SEF323
1 Di sconnect
ground
cable from
battery
2
Removecontroluni t
RefertoControl
Uni t
forremoval
3 Remove
alti tude sensor
attachi ng
bolts
4 Di sconnect harness connector
fromalti tudesensor
5
Toi nstallalti tude sensorreverse
the
orderof removal
DROPPI NG
RESI STOR
SEF128
1 Di sconnect
ground
cable
from
battery
2
Remove ai r
cleaner
and ai r
flow
meter
as an
assembly
Referto
Ai r
Cleanerfor
removal
3 Di sconnect
harness connector
from
droppi ng
resi stor
4 Remove
droppi ng
resi storattach
i ng
screw
5 To
i nstall
droppi ng
resi storre
verse
the
orderof removal
CONTROL UNI T
The controluni t i smountedonthe
left si de
dash
panel
I Turn
i gni ti on
swi tch
OFF and
then di sconnect
ground
cable from
battery
EF21
Remoraland
I nstal
sti on ENGI NE
FUEL
CAUTI ON
Before
di sconnecti ng
EFI
harness at
3511i n
connectorbe sure to
turn
i gni ti on
swi tch 0FF
andthan di s
connect
ground
cable
from
battery
to
prevent
control
uni t from
bei ng
dam
aged
2
Remove
LHdash
si de fi ni sher
3 Pulllock leverback
and di scon
nect
3S
pi n
connector
from control
uni t
4 Remove bolt
whi chsecures con
troluni t to
LR dashsi de
panel
and
remove
controluni t
5 To
i nstallcontrol
uni t reversethe
orderof
removal
CAUTI ON
When i nserti ng 35 pi n
connector
i nto
control
uni t be carefulnol
to
bendat
break termi nals
RELAY
The
relays
are
i nstalledonthe
relay
bracket
I nsi de
relay
brKket
Fuel
pump
telay
l
SEF130
Relay bncket
SEF131
EF
22
I
Oi sconnect
battery ground
cable
andremove
relay
bracket
2 Di sconnect
harnessconnector
3
Removerelay
from
relay
bracket
4
Toi nstall
relay
reverse the
order
of
removal
AI R
CLEANER
SEF132
I
Di sconnect ground
cable from
battery
2 Di sconnect
ai rducts and hoses
connecti ng
rcleaner
and rflow
meter
3 Remove I As
uni t
from
ai r
cleaner
4
Remove bolts
securi ng
ai r
cleaner
toai rcleanerbracket and detach
ai r
cleanerwi thai rflowmeteras
an
as
sembly
5
Di sconnect
ai rflowmeterharness
connector
6 Remove ai rflow meter
from
ai r
cleaner
RefertoAi rFlowMeterfor
removal
7 Toi nstallai rcleanerreverse
the
orderof
removal
AI R FLOWMETER
I
I
l
I
Di SConnect
battery ground
cable
2 Di sconnect ai rducts and
hoses
connecti ng
ai r
cleaner
and ai rflow
meter
3
Remove
ai rcleaner
cover
4
Remove bolts
securi ng
ai rfi ow
meter
S Di sconnect
ham
cOnnector
andremove
ai rflowmeter
6 To
i nstallai rflowmeterreverse
the
orderof
removal
AI R TEMPERATURE
SENSOR
The
ai r
temperature
sensori s bui lt
i nto
the
ai rflowmeterand
cannot be
removedas
a
si ngle
uni t When
replace
ment of ai rt
mper
ture 8eDSOI
i s
necessary
the enti re
ai rflowmeter
assembly
shouldbe
rep
d
FUEL
FI LTER
I
Reduce
fuelli ne
pressure
tozero
Refer
to
i tem
I
underthe
headi ng
I njector
andFuel
Pi pe
2
Unfasten
clamps
securi ng
fuel
hoses to
the outlet and
i nlet si des of
fuelfI lter
and
di sengage
fuelhoses
Becarefulnot
to
spi ll
fuel
overen
gi ne
compartment
Place
a
rag
toab
sorb fuel
3
RemovefuelfI lter
4
To
i nstallfuelfdter
reverse
the
orderofremoval
S Fori nstallati on
of fuelhose
refer
toFuelHose
FUEL PUMP AND
FUEL DAMPER
1
Di sconnect
ground
cable from
battery
2
Reduce
fuelli ne
pressure
to
zero
Refertoi tem
1 underthe
headi ng
I n
jector
and Fuel
Pi pe
3
Rai se therear
porti on
ofcarwi th
a
jack
and
block wheels
4
Temporari ly
clamp
hose between
fueltank andfuel
pump
S
Unfasten
clamps
and the sucti on
si de
of fuel
pump
and outlet si de of
fuel
damper
and di sconnect fuel
hoses
Be
sure
torecei ve fueli ntoB sui t
ablecontai ner
6
Di sconnect fuel
pump
harness
connector
7 Remove bolts whi chsecure fuel
plmp
bracket to
body
and remove
fuel
pump
and
fuel
damper
as an
as
sembly
frombracket
8 Fuel
pump
andfuel
damper
can
beremoved
9
To
i nstallfuel
pump
and fuel
damperreversetheorderofremoval
10For
i nstallati on of fuelhose refer
toFuel
Hose
FUELHOSE
Make surethat alllow
pressure
fuel
hoses are
fully
i nserted and are free
from
unduestrai n
before
clampi ng
When
removi ng
or
i nstalli ng
hi gh
pressure
fuelhose observe thefollow
i ng
CAUTI ON
a
Donot reusefuelhose
clamps
after
looseni ng
b
Clean dull
and di rt from
parts
wi th
compreS 8d
ai rwhen
assembli ng
c
Ti ghten hi gh
pressure
rubberhose
clamp
so
thi lt
clamp
end i s 3mm
012 i n from hose end orscrew
posi ti on
wi derthan other
porti ons
of
clamp
i s flushwi thhoseend
Ti ghteni ng torque
speci fi cati ons
are
thesame
forallrubberhose
clamps
SEF138
I f Clamps
1
01 5Nm
0
10015
kg m
07 1 1f
lbl
@
Pre
ure
regulator
l
3
mm
1012i n
li
I I @
EF336A
L
Fuelftlter
J
fJ
ENGI NE
FUEL
RemovalBnd
I nstallati on
d When
ti ghteni ng
hose
clamp
ensure
that
screw does not come i nto
contact
wi th
adjacenlparts
I nsert
hi gh
pressure
fuelhoses
i nto
thei r
proper
posi ti ons
as i nstructed
helow
Type
@
I nsert rubberhose unti li ts
endcontactsuni t
Type@
Pushend
of
rubberhose
ontofuel
pi pe
unti li t contacts i nner
bulge
Type
@
Pushend
of
i njector
rubber
hose
onto
fuel
pi pe
unti li t i s 28
mm
1 10i n
fromendof
pi pe
Type
@
Pushend of rubberhose
wi thhose socket ontouni t
by
hand
as far
as
they
wi ll
go
Clamp
i s not
necessary
at thi sconnecti on
Tofueltank Fromfueltank
n
n
Fuel
damper
Fuel
pi pe
mblY
I
@
SEF139
EF
23
Electri cal
SystemI nspecti on ENGI NE
FUEL
ELECTRI CAL
SYSTEM
I NSPECTI ON
DESCRI PTI ON
Electri cal
system i nspecti on can
be
perfonned
by usi ng
the
EFI ANA
LYZER J
25400
CAUTI ON
When
checki ng
the electri cal
system
wi thEFI
ANAL
VZER
be
sure
to
use
the
proper
adapter
harness
I fthe
analyzer
i s not
avai lable use
the
followi ng
procedures
PREPARATI ONS FOR
I NSPECTI ON
VEHI CLE PREPARATI ONS
1
Turn
i gni ti on
swi tchto OFF
posi ti on
CAUTI ON
Before
di sconnecti ng
and
connecti ng
electri calconnectors ensure
that
i gni
ti on
SWi lchi s i nthe 0FF
posi ti on
2
Di sconnect
battery ground
cable
3
Di sconnect lead wi re from
S
tenni nalof
startermotor
4
Di scQnnect
va
uum
sw i t
hharness
connector
Cali forni amodels
5
Arrange sothat
ai r
flow meter
flap
can be
pushed
manually
fromai r
cleanersi de
6 Di sconnect 35
pi n
EFI
harness
connectorfrom
controluni t
CAUTI ON
a Before
di sconnecti ng
EFI harness
at
35
pi n
connectorensure that
i gni
ti on
swi lchi s i n the OFF
posi
ti on
b Be
extremely
carefulnot tobreak
or
bend 35
pi n
when
di sconnecti ng
termi nal
EF24
I NSPECTI ON
To
i nspect
theelectri cal
system
use
a ci rcui t
tester
Conti nui ty
test
can be
perfonnedeasi ly
by
measuri ng
resi st
ance
and
voltage
between termi nals of
35
pi n
EFI harnessconnectori nstalled
oncar
CAUTI ON
Do
not touchtheci rcui t tester
probe
to
any
unnecessary pi n
onthe
35
pi n
connector
Doi ng
socouldcause dam
age
to
theci rcui t
tester
For
i tems tobe
checked referto
I nspecti on
Procedure
Table
RESI STANCE
MEASUREMENT
I
Set
ci rcui t
testeri n
theOhm R
range
2
Check
conti nui ty
between ter
mi nals
@
and
@
shown
i n
the
I nspecti on
Proceduretable
Body ground
should
be mad
by
connecti ng unpai nted
metal
such
81
bolt
Fl
Resi stancemeasurement
1
r
1
B
I
r
l
L i
i
l8
I I
jj
I
1
U
3
After
steps
I
through
11
above
have all
been
completed
proceed
to
step
12
only
forCali forni amodels
I
Connect the vacuum swi tch
har
ness connectorand di sconnect
the
hose i n
theli nebetween the
vacuum
swi tch
andthei ntakemani fold
2
Di sconnect
the throttle valve
swi tchand
alti tudesensorharness
con
nectar
3 Check
conti nui ty
when no
pres
sure
i s
appli ed
tovacuumswi tch
4
Apply
a
pressure
below 21 3kPa
160
mmHg
630
i nHg
tovacuum
swi tch
by
orally sucki ng port
back and
check
conti nui ty
5
Bri ng
back vacuum swi tcha1ti
tude sensor
andthrottlevalveswi tch
tothei r
ori gi nal
condi ti on
VOLTAGE
MEASUREMENT
1
Set ci rcui t
testeri n theDC
Volt
DC
V
range
2
Securely
connect
battery ground
cable
3
Connect
negati veprobe
of ci rcui t
Fl
2
I
2
6
26
9
27
0
1811
1l1
L13
U i4
1
I
I T
ENGI NE FUEL Electri cal
System
I nspecti on
testerto
body
metal
Body
earth
shouldbemade
by con
necti ng
wi th
unpai nted
metalsuch
as
bolt
4
Contact
posi ti ve
probe
of
ci rcui t
testertotenni nal
@
shown
i n
the
I nspecti on
Procedure
table
S
I nspecti on
wi th
i gni ti on
swi tch
i n
START
posi ti on
1
Set
i gni ti on
swi tchon START
and
measure
voltage
i n each
step
of
I nspecti on
ProcedureTablefrom13to
14
2 Turn
i gni ti on
swi tchOFF
3 Connect lead
wi re to
S ter
mi nalof
starter
roptor
4 Set
i gni ti on
swi tch
on
START
and
measurevoltage
i n
step
1 S
6
I nspecti on
wi th
i gi I i ti on
swi tchi n
ON
posi ti on
I
101
g
O
L
1
fJU
EF452A
I
Turn
i gni ti on
swi tch ON and
measure
voltage
i neach
step
of
nspec
ti onProcedureTable
from
16
to
22
2 Turn
i gni ti on
swi tch
OFF
3
Di sconnect
oi l
pressure
swi tch
harness
connector
4 Turn
i gni ti on
swi tch ON and
measure
voltage
i n
step
23
S Turn
i gni ti on
swi tch OFF
6
Connect oi l
pressure
swi tchhar
ness connector
7
Di sconnect alternator
2
pi n
con
nector
L and S
termi nals
8
Turn
i gni ti on
swi tch ON
and
measure
voltage
i n
step
24
7 Turn
i gni ti on
swi tch OFF
8
Connect
EFI harness connector
tocontroluni t
9
Connect
2
pi n
alternatorcon
nectar
10
Bri ng
ai rflow
meter
back
to
i ts
ori gi nal
condi ti on
I NSPECTI ON
PROCEDURE TABLE
HOW
TOUSE
1 After
measuri ng compare
meas
ured values
wi th
standard values to
determi ne
whetherci rcui ts
parts
are
malfuncti oni ng
or
not
2
When
a
malfuncti oni ng
ci rcui t
i s
located
agai n
check measurements i n
volved i n that ci rcui t I n
thi s
case
check
i gni ti on
swi tch
ci rcui t
tester
range
probe
etc tobe
certai n
they
areset at
properposi ti ons
CAUTI ON
a Before
connecti ng
EFI harness at
35
pi n
connectorensure that
i gni
ti on swi tchi s i n the 0FF
posi
ti on
b
When
i nserti ng
35
pi n
connector
i nto controluni t i nsert
slowly
securely
and
strai ght bei ng
careful
not tobend orbreak
35
pi n
termi
nals
EF
25
I NSPECTI ON
PROCEDURE
TABLE
m
T1 N
Ci rcui t tester range
Checktermi nala
A
8J
I
Be
I gni ti on
swi tch
Step
I nspecti on
ci rcui t
Auxi li ary
op
rati on
or
condi t
on
J
2
Di sconnect
vacuum
swi tch
harness
connector
Judgment
1
Di sconnect
battery
negati ve
termi nal
starter
motor
US
termi nal
35
pi n
EFI
harness
connector
from
oontrol
uni t
Cali forni a
models
3
Arrange
so
that
ai r
flow
meter
flap
can
be
pushed
from
ai r
clenner
si de
Ai r
now
meter
potenti ometer
sli di ng
resi stor
and
ci rcui t
32
34
Push
ai rflow
meter
flap
Fully
deprcs5ed
Releai ed
ully
depressed
Released 2p
OC
680P
or
above
B
elow
200C
680F
I
lOae
680P
or
above
I
Below
200C
680F
Standard
value
Measured
value
I
f
o
I
mZ
ClZm
C
mr
I
Except
Qand
n
on
wn
on on
n
Below
2
9kn
2
1kO
or
above
Below
2
9kn
2
1kn
or
above
100
to
400
n
200
to
500
n
2St090n
30
24
Canfornla
model
1
Connect
vacuum
swi tch
harness
connector
and
dbconnect
hose
vacuum
swi tch
t6
i tttake
mani fold
at
i ntake
mani fold
si de
2
Di sconnect
tnrottle
valve
swi tch
and
alti tude
sensor
harnels
connector
Ci rcui t
betweon
i gni ti on
swi tch
Bnd
control
uni t
power
source
Ci rcui t
between
i gni ti on
swi tch
fuel
pump
relay
and
ai r
regulator
Note
a
Before
di sconnecti ng
and
connecti ri a
electri cal
connecton
and
termi nab
enlUfO
that
i gni o
n
I Wi tch
i s
i n
OFF
podti on
b
E
Body
Earth
Althoush
volllp
may
drop
dfshti y
below
battery
volllp
thi s
I s
not
an
i ndi cati on
of
abnormali ty
I S I S
No
preuure
i s
appli ed
to
vacuum
swi tch
12
Vacuum
swi tch
and
ci rcui t
OFF
n
Apply
a
pressure
below
21
3
kPa
160
mi nHg
6
30
i nHg
to
vacuum
swi tch
by
ori lly
sucki ng
port
bac
k
Cali forni
models
Bri ng
back
vacuum
swi lch
throttle
vavel
swi tch
and
alti tude
sensor
to
thei r
ori gi nal
condi ti on
I S
27
Connect
battery
negati ve
termi nal
131
14
I
26
START
v
E
21
Ho
to
300
kn
SO
to
300
kn
I wn
400
to
600
n
Battery
vottaa
Step
I nspecti on
ci rCu
t
Connect
starter
motor
S
teri ni n
al
15
I gni ti on
coi l
tri gger
ci rcui t
16 17 16 19
I njector
1
attery
droppi ng
resi stor
and
i njce
tor
ci rcui ts
20
I njector
2
I njector
3
I njector
4
Battery
EFI
relay
and
control
unjt
POWC
f
source
ci rcui ts
Alti tude
senI Or
and
ci rcui t
Cali forni a
models
Ci rcui t
between
battery
i gni ti on
swi tch
fuel
pump
relay
2
a1ter
22
nator
and
oi l
pressure
swi tch
Check
alternator
and
oi l
pressure
swi tch
t
for
operatI on
21 Di sconnect
oi l
pressure
swi tch
hames
connector
Battery
i gni ti on
swi tch
fuel
pump
relay
2
and
ai r
regulator
ci rcui tl
Check
fuel
pump
relay
2
for
operati on
23 24
I gni ti on swi tch
Ci rcui t
tester range
Check
termi nals
Aj
I
Be
Auxi li ary
operati on
or
condi ti on
1
Connect
dtemator
2pi n
connector
uL
and
S
termi nals
START
CAUTI ON
Exerci
care
i n
performi ng
step
1
lI S
i t
i nvolve
turni ng
engi ne
r
ON ON ON
18
265 7
27
v
E
Standard
value
Poi nter
deflects
Battery
voltage
Above
O
SY
ov
Battery
voltage
Battery
voltage
Note
a
Before
di sconnecti ng
and
connecti ng
electri cal
connectors
and
termi nab
ensure
that
i gni ti on
swi tch
i
i n
uOFF
posi ti on
b
E
Body
Earth
Although
voltage
may
drop
sli ghtly
below
battery
voltage
thi s
i s
not
an
i ndi cati on
or
abnormali ty
I
1
Connect
oi l
pressure
swi tch
harness
connector
2
Di sconnect
alternator
2
pi n
connector
UL
and
S
termi nals
Battery
i gni ti on
swi tch
fuel
pump
relay
2
and
ai r
regulator
ci rcui ts
Check
fuel
pump
relay
2
for
operati on
m
N
28 21
v
I
21
E
v
21
E
2
Bri ng
ai r
flow
meter
back
to
i ts
ori gi nal
condi ti on
L
Measured value
Judgment
J
mZ
G
Zm T1Cmr
I
l
g
m
n ex
EFI
CI RCUI T
DI AGRAM
FUSI BLE LI NK
oc
FUS
BLE
LI NK
c
EFI
RELAY
F
t
A
I
Ei
PUMP
REI
AV
1
e
FUSE
I
I
I
FUEL
PUMP
RELAY
2
I GNI TI ON
SW
TCH
OFf
ON
5TA
RT
B
0
0
I G
0
0
S0J
I G
1
0
cp
B
I GNI TI ON
AL
TEANATOR
SWI TCH
L
FUSI BLE
OI L
LI NK
PRESSURE
J
SWI TCH
When
engi ne
i l
t
nopped
BATTERY
t
Ai ternetor
Ltermi nal
ON
Oi l
prullure
swi tch
DROPPI NG RESI STOR
43
3738
404
cp
FUEL PUMP
Whln
anai na
I s
i n
operati on
I NJECTOA
CYLI NOER
NO
WATER
TEMP
111
121
131
14
oo
j
11
l
N
0
l
J
I GNI TI ON
eQ
L
2
l
7
r
14
15 18
19l21 242526278
9
10
32
33
34
t
c
f
i t
GROUND
Jjln
R
Jre
11l
1O
I
I
DLE
FULL
U
THROTTLE
L
T
ALTI TUDE
VALVE
SW
SENSOR
AlA
FLOW
Cellfornle
METER
models
A
R
TEMP
SENSOR
I
I
I
I
VACUUM SWI TCH
Cllllfornlll
modol
OFF
SEF183
s
i 1
0
I
m
Z Zm
T1C
m
r
ENGI NE FUEL
Component
Parts
I nspecti on
COMPONENT
PARTS I NSPECTI ON
FUEL
PRESSURE
CHECK
1
Follow the
procedure
below
to
reducefuel
pressure
tozero
CAUTI ON
Before
di sconnecti ng
fuelhose release
fuel
pressure
fromfuelli netoeli mi
nate
danger
I
Start
the
engi ne
2 Di sconnect theharness
connector
of fuel
pump
relay
2 whi le
the
engi ne
i s
runni ng
Rel v
brcket
SEF131
3 Afterthe
engi ne
stalls
crank
the
engi ne
twoor
threeti mes
4 Turn
the
i gni ti on
swi tch OFF
5 Reconnect the
harness connector
ofthefuel
pump
relay
2
2
Connect a fuel
pressure
gauge
between fuel
pi pe
and
fuelhoseoffuel
ftI ter
3
Start
engi ne
and read fuel
pres
sure
gauge
At
i dli ng
Approxi mately
206kPa
12
1
kg
cm2 30
psi
The moment accelerator
pedal
i s
fully
depressed
Approxi mately
255 kPa
2
6
kg
em2
37
psi
4
I ffuel
pressure
i s
not as
speci fi ed
replace pressure regulator
and
repeat
fuel
pressure
check
I f
below
the
speci fi ed
value check
for
clogged
ordefonnedfuelli nes
and
i f
necessary replace
fuel
pump
as an
assembly
orcheck valve
FUEL PUMP
FUNCTI ONAL TEST
After
di sconnecti ng
alternator
L
termi nal
or
oi l
pressure
swi tch
connec
torset
i gni ti on
swi tch
at ON
posi
ti on Then make sure
that
fuel
pump
operati ng
soundi s
heard I f
not
check
allfuel
pump
ci rcui ts I fall
ci rcui tsare
checkedout OK
eplace
fuel
pump
FUEL DAMPER
I f
noi se
from fuel
pump
i s
abnor
mally
loud
replace
fuel
damper
and
recheck
for
noi se
FUELFI LTER
I fthecar
i s
operated
underextreme
adverseweathercondi ti ons
ori n
areas
where ambi ent
temperature
i s ei ther
extremely
low
or
extremely hi gh
the
fuelftI ter
mi ght
become
clogged
I n
suchan event
replace
thefuelftI ter
i mmedi ately
I NJECTOR
CONTI NUI TY CHECK
1 Di sconnect
ground
cable from
battery
2 Di sconnect electri c connectors
from
i njectors
3
Check
conti nui ty
between the
two termi nals
Conti nui ty
sho
ld
exi st
I fnot
i njectorCs
are
faulty
i t
P
LJ
Tf
r
SEF144
OPERATI NG SOUND CHECK
Engi necan run
1 Start
the
engi ne
and
run
i t at i dle
Attach
the
ti p
of
a screwdri ver
to
each
i njector
toensure
that i t sounds whi le
operati ng
2 All
i njectors
are
functi oni ng
prop
erly
i f cli ck soundi sheardat
regular
i ntervals Note
however
that as en
gi ne speed
i ncreases
cli ck
i ntervals
shorten
J
1J
1I l
Engi necannot
run
1
Crank
the
engi ne
and check that
i njectors produceoperati ng
sounds to
i ndi cate
operati on
EF29
ComponentParttlnspecti on
ENGI NE FUEL
2
I fadi fferent sound
i s
produced
from
any
parti cular
i njector
that
i njector
i s
faulty
3 I f nosound
i s
heard
from all
i njectors
check
harnesses
referri ng
to
Electri cal
SystemI nspecti on
4
I f harnesses
are nonnal
check
operathm
ofcontroluni t
PRESSURE
REGULATOR
Refer
toFuelPressure Check for
i nspecti on
AI R FLOWMETER
CHECKI NG
TlOMETER
Potenti ometer
@
@
RO
t
RI
i JJ
R
i
I
LJ
R
SEF146
@
@
I Measure
the
resi stance between
termi nals
@ and@
The standard
resi stancei s
100
to
400ohms
EF482A
EF 30
2 Measure the resi sta nce between
tenni nals
@
and
@
The
standard
resi stance
i s
200to
500ohms
EF483A
3 Whi le
sli di ng flap
measure
resi st
ancebetween
tenni nals
@
and
@
I f
resi stance i s at
any
valueother
t1aJl
0
and
0Cl
ohm
ai rflowmeter
i s nonnaJ
UlI
EF319A
CHECKI NG I NSULATI ON
RESI STANCE
Check
i nsulati on
resi stancebetween
the
ai r
flow
meter
body
and
anyone
ofthetenni n s@ @ @and@
I f
conti nui ty
exi sts
theai rflow
meteri s
out oforder
EF327A
CHECKI NG
RAP
Fully open
the
flap by
hand
to
check that i t
opens
smoothly
wi thout
bi ndi ng
I fi t
doesn
t i t i s out oforder
EF318A
AI R TEMPERATURE
SENSOR
CHECKI NG I NUI TY
I
Measure
the
outsi deai r
tempera
ture
2
Measure resi stance between
ter
mi nals
@
and
@
of the
ai rflow
meter
connector
3
The
relati onshi p
between
the
out
si de
ai r
temperature
and
resi stance i s
shown
i n
the
followi ng graph
WATER
nMPERATURE
SENSOR AND
AI R TEMPERATURE
SENSOR
CHARACTERI STI C
CURVE
30
r
TC iEJ
r1
ri
0
4
21
to2 9
k at 20oe
3
I
6tF
8
2
O6SI o
00knl
at50oC l220Fl
I
g
J
04 l
03
0
2
I
0
1
O
OS
0
06
30
20
0 20 4060 SO
22
432 6S
104
140176
Temperature
Oc OF
EF334A
I f
test
results
arefarfrom
the
range
i ndi cate i n the
graph
the
ai r
tern
perature
sensor
i s
out
of
order
Theai r
temperature
sensorshould e
replaced
as an
ai r
flowmeterassembly
CHECKI NG I NSULATI ON
RESI STANCE
Check i nsulati onresi stance
between
termi nal
@
ana ai rflowmeter
body
I f
conti nui ty
exi sts
the
ai r
tempera
ture
sensor
i s out of orderThe
ai r
terpperature sc
nsorandai rflowmeter
shouldbe
replaced
as an
assembly
ENG I N
E FUEL
Component
Parts
I nspecti on
AI R REGULATOR
I
Starti ng engi ne
and
pi nch
rubber
hose between i ntakemani fold
and ai r
regulator
Engi ne speed
decreases
warm
up
Engi ne speed
remai ns
afterwarm
up
duri ng
OK
unchanged
OK
Ai r
regulator
Shutteri s
opened duri ng engi ne
warm
up
thereby
i ncreasi ng quanti ty
of i ntake
ai rcausi
ng engi ne
speed
to
i ncrease
Engi ne speed
decreases when
passage
i s
narrowed
by
pi nchi ng
hose
duri ng
warm
up
Afterwarm
up
shuttercloses Therefore
engi ne
speed
remai ns
unchanged
when
passage
i s
narrowed
by
pi nchi ng
hose
after
warm up
2 Di sconnect
electri cconnector
of
ai r
regulator
and
check
conti nui ty
Conti nui ty
should exi st I f not
ai r
regulator
i s
faulty
3 Di sconnect hoses from
bothends
of ai r
regulator
and
vi sually
check to
seei fai r
regulator
shutter
opens
The
shutter
openi ng
at a
tempera
ture
of
200C 680F i s
as shown
i n
followi ng
fi gure
Ai r
flow
rea
at
approxi mately
200C 6SoF
EF328A
Di recti oll
of hi metal
movement wi th
i ncreasi ng temperature
4
Pry
ai r
regulator
shutterto
open
wi tha
flat
b1ade
screwdri verthen
close I f shutter
opens
and
closes
smoothly
i t i s
operati ng properly
I f
not
replace
THROTTLE
CHAMBER
1
Make sure that throttle valve
moves
smoothly
when throttleleveri s
mani pulated
2
Make surethat
by pass
port
i s free
fromobstacles
and
i s clean
Donot
adjust
throttlevalve
stopper
screwas
i t i s
factory adjusted
Throttlelever
F127
DASHPOT
1 Set
engi ne speed
to
1 500
rpm
under
noload
2 Check thedash
pot
tomake sure
that the rod end comes
i n
contact
wi tli the
adjusti ng
screwwhentherod
i s
fully
extended orwhen noback
pressure
i s
presentat
the
di aphragm
Adjusti ng
screw
I
SEF149
3 I f
necessary
adjust
the
adjusti ng
screw sothat therodendcomes
i nto
contact wi ththe
adjusti ng
screw
EF 31
CompOfJentParu I nspecti on
ENGI NE
F1JEL
WATER
TEMPERATURE
SENSOR
CHECKI NG I NSULATI ON
RESI STANCE
1
Check
conti nui ty
between the
sensor
body
and
eachof
the
tenni
nalsat sensor
2
I f
conti nui ty
exi sts
thesensor
i s
out of
order
CHECKI NG
CONTI NUI TY
1
Di p
the
sensori nto
watermai n
tai ned at a
temperature
of
200C
680F
800C 1760F
etc and
read
i ts
resi stance
r
rr
EF329A
2
I f thesensor
resi stance wi th
re
spect
to
thecoolant
temperature
i s not
held wi thi n
the
range
speci fi ed
i n
the
graph
the water
temperature
sensor
may
be
o
t of order
EF
32
WATER
TEMPERATURE
SENSOR
AND
AI R
TEMPERA11JRE SENSOR
CHARACTERI STI C CURVE
g
T
U I j I
I
7
010114
kn
al lOoC
1401
10L
j
8
j
6
4
i
2
1
to
29
knat
lOoe
3
I I
6tF
g
21 068to100knI
I I
I
aI SOoC 1220FI
Ht i
0
3
I
0
2r
0
u
gggL
1
30200 204060
80
1
22
432 68 104 140
176
Temperature
DC
COF
EF334A
THROTTLE VALVE
SWI TCH
ADJUSTI NG
SWI TCH
POSI TI ON
Di sconnect
throttle valve swi tch
connector
2 Connect ohmmeterbetween ter
mi nals @ and
@
and
make sure
conti nui ty
eXi sts
3
Adjust
throttlevalve swi tch
posi
ti on
wi th
retai ni ng
screw sothat
i dle
swi tch
may be
changed
from ON to
OFF
when
engi nespeed
i s
speci fi ed
i dle
rpm
70
rpm M
T
Neutral
A T
N
posi ti on
underno
load
To
adjust
posi ti on
of throttlevalve
swi tch wi th
engi ne
off
proceed
as
follows
When
clearance
A
between throt
tle valve
stopper
screw andthrottle
valve shaft lever
i s 03
mm 0
012
i n
adjust
throttlevalveswi tch
posi ti on
so
that i dleswi tchi s
changed
from
ON
toOFF
I f clearance between throttlevalvo
stopper
screw
andthrottlevalve shaft
leveri s 03mm 0
012
i n
engi ne
speed
wi llbecome
speci fi edrpm
Shi m
Changi ng i dle swi tchfrom
ON
to OFF
correspond to
change
from0
to i nfi ni te
ohms i n
resi st
ance
between
termi nals
@and@
CHECKI NG
fULLTHROTTLE
cONTAcT
1 Connect
ohmmeterbetween
ter
mi nals
@
and
@
and
make sure
conti nui ty
does not exi st
o
i
SEF153
2
Depress
accelerator
pedal
tofloor
I f
conti nui ty
exi sts
between
tenni nals
@
and fullthrottle
contact i s
functi oni ng
properly
CHECKI NG
I NSULATI ON
RESI STANCE
1
o
SEFl54
Connect
ohmmeterbetween
engi ne
and tenni nals
@
@
and
@
Ohm
meter
readi ng
mould be
i nfI ni te
VACUUM
SWI TCH
1 Removevacuum
swi tch
2 Connect the test lead
wi re
as
follows
3
Measurethe
output
voltage
Condi ti ons
Output voltage
No
pressure
i s
ap
pli ed
to
vacuum
swi tch
Approxi mately
battery
voltage
Apply
a
pressure
below
21 3
kPa
160
mmHg
630
i nHg
to
OV
vacuumswi tch
by
orally ucki ng
port
back
4 I f the test results are not the
speci fi cati ons
the vacuum
swi tchi s
malfuncti oni ng
ENG I NE
FUEL
Component
Parts
I nspecti on
Vacuum
gauge
11
Resi stance
lkn
Voltmeter
I I
EB
ova
o0
Regstan
30kn
Battery
12V
o
SEF324
ALTI TUDE SENSOR
I
Connect
the
test lead
wi res
as
follows
i
Battery
Jf
12V
I I I
Voltmeter
0
4
SEF166
2
Measurethe
output
voltage
MorethOri O5V
O
K
3
I f the
test results are not the
speCi fi cati on
the alti tude sensor
i s
malfuncti oni ng
43and38
No
2
cyli nder
43
and37
No
1
cyli nder
The
resi stance should be
mately
6ohms
approxi
OK
DROPPI NG
RESI STOR
Conduct resi tance checks on
drop
pi ng
resi storbetween the
followi ng
poi nts
43and41 No
4
cyli nder
43
and40No
3
cyli nder
l
SEF155
EF33
Cpmpopentp
ral 5Per
Von
N I NE FUEL
RELAY
I
Di sconnect
battery ground
cable
2 Remove
relay
from
car
3
Test
conti nui ty
through relay
wi th
an ohmmeter
i n
accordance
wi th
EFI
relay
andfuel
pump relay
I
rp
Chccktermi nals
d
1
nu
j @
1
@ @
@ @
Fuel
pump relay
2
the
followi ng
chart
Normalcondi ti on
112V
di rect
current
i I
ppUed
I
bet t uololls
CDond@
Tellresultl
Coati Dui ty
f
Yea
No
Yes
Ya
No
Yes
Cori ti i lufty
shouldex i I t
No
Conti nui ty I hoti I dnot
abt
I ZVI li Nct
aI I fI W
I
2
J
l
T
D
t
I
NDnI aI
@
@
7
nau
0tndI aI I lt
y y
No
No
No y
No y
y
CONTROLUNI T
CHECKI NG
ELECTRI C
I GNAL TO
I NJECTORS
I
I nspecti on
lamp
as shown
i n
fi gure
b
low i s
requi red
forthi S
test
E F353
Make
i nspecti onlamp as follows
1
Prepare
12V
3W
lamp
2
Preparesocket and set
lamp
i n
i t
EF 34
ac
kll llllli lod l
CD
00
@@
j
@
j
@
3 Useflat
plate
tenni nals3
mm
012
i n wi de 08
mm
0031 i n
thi ck
as
male termi nals
Place
flat
plate
termi nals
parallel
wi theachother
and
keep
di stance
between
i nsi de
faces
2 mm
008i n
The
n secUre
termi nals
by
wrappi ng
i nsulati on
tape
orwi th
sui tabletermi nal
body
2
Di sconnect
i njector
harness
con
nector
3 Connect
i nspecti on
lamp
to
i njec
torharness
connector
YQC
cUI I
CO
1i nulll
nolalA
cct
ao
c I rI
SEFl56
4
Starti ng
engi ne or
cranki ng
en
gi ne
check
i i tspecti on lamp
to
seei f
i t
flashes at
regular
i nterval I f
soelec
tti c
si gnals
are
bei ng properly
trans
mi tted
to
i njectors
a
The
engi ne
shouldbe
cranked at
a
speed
of
more
tJ I ari SO
rpm
b
The
control
uni t
may
fai l
to
gener
ate a correct
pulse si gnal
at
an
excessi wely
low
battery
voltage
I t i s
recomm nded
therefore
that a
battery voltage
of
more
than9volts
be
appli ed duri ng
the
cranki ng
operati on
CHECKI NG
FUEL SHUT OFF
FUNCTI ON
1
Wann
up engi ne
suffi ci ently
2 Connect
i nspecti on lamp
to
i njec
torharness connector
Automati c
transmi ssi on models
3000
2 600
e
e
0
2 200
51
5
t
800
t 400
1 000
ENGI NE FU
EL
Component
Parts
I nspecti on
3
I ncrease
engi ne speed
to
each
zone
respecti vely
and release acce
lerator
pedal
Check
i nspecti on lamp
i llumi nati on
Check
i nspecti on lamp
wi th
engi ne
speed
i lleach
zone as
shown i nchart
below
Whi le
i nspecti on
lamp
i s off fuel
shut off i s
operati onal
Manual
transmi ssi on m els
3
000
I
2 600 1
@
e
e
2 200
0
51
1
800
c
1400
1
000
@
@
Cooli ng
water
temperature
at
80C 1760F
CECKI NG
AI R
LEAKAGE I N AI R
I NTAKE SYSTEM
Make sure even a
sli ght
ai rleak
doesnot occur
When
i nspecti ng
theelectroni cfuel
i njecti on system pay parti cular
atten
ti on tohose
connecti ons
di psti ck
oi l
fi ller
cap
etc for
any
i ndi cati onof
ai r
leaks
Si nce the ai rflow
meterused i n
the electroni c fuel
i njecti on system
di rectly
measures the
quanti ty
of i n
take ai rto
permi t
the
supply
of the
opti mum
fuel
quanti ty
foreach
cyli n
der
CHECKI NG FUEL
HOSES
Check fuelhoses for
leakage
loose
@
@
@
@
Cooli ng
watertemperature
at
800C
1760F
connecti ons
cracks
ordeteri orati on
Reti ghten
loose connecti ons and
replace
any
damaged
ordefonned
parts Replace any
fuelhose whose
i nner
surfacei s deformed scratchedor
chafed
For
replacement
of
hi gh
pressure
fuelhose
referto
FuelHoseunderthe
headi ng
Removaland
I nstaUati on
EF35
Servi ceOatasndSpeci fi cati om
ENGI NE FUEL
SERVI CE
DATA
AND SPECI FI CATI ONS
GENERAL
SPECI FI CATI ONS
I
Desi gnvoltage V
12
fuel
I
Cut off
di kPat cm2
294
44113
045
pump charge
pressure psi
43 641
Desi gncurrent
A
5 1
Pressure
Regulated
kpa
kg
em
2SO
1255 3631
regulatorpressure psi
I
Ai rflow
Desi gn voltage
V 12
I
meter
Desi gnvoltage
V 12
I
Ai r
regulator
Ai rflow
quanti tY
m cuft hr
190
611l
I
I At
200C
I 68
FlJ
i
votteee
V 12
I
Control
Consumpti on
wattage
I
uni t At
i dli ng
W 15
At fullthrottle W 140
J
I NSPECTI ON
AND
ADJUSTMENT
fuel
pressul B
A dr
measure
t
1n9
i og
poi nt
between
Themoment
acce
kPa I
2
fuel
eretorpedal
i s
kg
em
Approx 255
2637
fi lter
and fullydepre1sed
PSI
fuel
pi
kPa
kg
em
Appro
206121 301
PI I
Fuel
Coi lresi stance
i njector
n
2
35
Ai rflow
@
@
n 100
400
metar
Potenti a
@ @
fl
200SOO
meter
@
@ resi stance
fl Except
0
and
Ai rtem
peratu
re
At
tOOC t4OFI
kfl 1
0114
sensor
water
tempera
At 200C 168OF kfl
2
1 29
lUre
sensor
therml
tor
re At5OC t22F
kfl 068
10
si stance
Ai r Heater
coi l
25 90
reQulstor
resi stance
n
Engi nespeed
Speci fi ed
i dlerpm
Throttle
wh dl ch
70
i n Neutn
I
enll SWlt
va
i s
changed
from
rpm
MfT
i n N
pasi
SWi tch
ON toOFF
ti on
AfT
EF36
I
Dashpot
T ou hspeed rpm Approx
1 500
Vacuum
Mani fold
vacuumwhenvacuum
Approx
21
3kPa
swi tch
swi tch
i s
changed
from
OFF
160
mmHg
to
ON
6
30
i
Hi l
I
Alti tude
Output voltage
V
Above05
leos
or
I Dr
i ng
Resi stance
fl
Approx
6
resi stor
Perresi stor
TI GHTENI NG TORQUE
I
Uni t
N
m
ft lb
I
Throttlechamber
I
A
I
hOSl
clBn lp
Futtl
hose
clBr11pi ng
posi ti on
18 22 1 8 22
13
16
1015
0
1 015
01 11
3mmI O
l2i n
Q
EF336A
ENGI N
E FUEL Trouble
Di agnoses
andCorrecti ons
TROUBLE
DI AGNOSES
AND CORRECTI ONS
TROUBLE
SHOOTI NG CHART
The
EFl
system
can be checked i n
accordance
wi ththe trouble shooti ng
chart
I f
any abnonnaI i ty
i s foundi n
any
i nspecti on
i tem refer
to
the
I nspec
ti on
secti on and
carry
out further
i nspecti on followi ng
the
procedures
descri bed
therei n
Note
that
any component part
excepti ng
some of the EFI
system
must
be
replaced
as an
assembly
i f
i t i s
foundtobe
faulty
si nce
no
repai ri ng
i s allowed
Checke
before
i nspecti on
Before
attempti ng any
test check
the
followi ng
i tems toensure that
nothi ng
hasbeen overlooked
I The
greatest
problem
source wi th
a
system
of thi s
type
li es
i n
the
connecti ons
between
components
Condi ti on
Save ti me by perfonni ng
a
qui ck
check
i f allharness
connecton
espe
ci ally
the
35
pi n
connectorand
ai r
flowmeterconnector
are
securely
i n
place
Connector
termi nals are free
fromcorrosi on
anddeformati on
Pullall
connecton off andrecon
nect
after
i nspecti ng
termi nals
2
Si nce theEFI
system
accurately
meters
thei ntake
ai r
flowthrough
an
ai rflowmetereven a
sli ght
ai rleak
wi llcause an
i mproper
ai rfuelrati o
resulti ng
i n
faulty
engi ne
operati on
duetoexcessi ve
ai r
For
thi sreason a thorough
i nspec
ti on forleaks
shouldbe made at the
oi lftller
cap
di psti ck
blow
by
hoses
ai r
flow
metertothrottlechamber
ai r
duct etc
3 Make surethe
i gni ti on
and
start
i ng systems
are sati sfactory
and the
battery
i si n
good
condi ti on
Probablecause
Engi ne
wi llnot start
or
hardto
start
I mproper
i gni ti on system
I ntake
ai r
leakage
at
followi ng poi nts
P
C V valve V C valve
di psti ck
sealoi l
ftller
cap
blow
by
hoses
Ai rflowmeterhoses
and
clamps
Mani fold
gaskets
etc
Fuel
pump
does
not work
I mproperi gni ti onsi gnali nput
I nspecti on
I nstructlone
Beforechecki ng
theEFI
system
be
sureto
observe
thei nstructi onsbelow
Fai luretodo
socouldresult i n
damage
tothe
control
uni t or
cause fuel
li ne
leakage
CAUTI ON
When
connecti ng
or
di sconnecti ng
EFI
harness connectortoortom
any
EFI
uni t enlUrethat
the
i gni ti on
swi tchi s
i n the OFF
posi ti on
and that the
I battery
termi nali s di scon
nected
Removi ng
and
i ns18l1i ng the
connectors
wi th
the
i gni ti on
swi tch
left i n the ON
posi ti on
wi ll
damage
controluni t
Replace
fuelhoses i f
they
are de
fonned scratched orchafed Do
not
reuse fuel
hose
clamps
afterremoval
Check andcorrecti ve
acti on
Di sconnect
hi gh
tensi on cable from one
spark plug
andcheck
forhot
spark
Check
fori ntake ai rleaks and
repai r
or
replace
i f
necessary
Di sconnect startermotorS temti nal
and
i gni ti on
swi tch
i n START
posi ti on
li sten for
fuel
pump
and
pressure
regulator
operati ng
sound
I fnosound
i s heard check fuel
pump
con
trol
ci rcui t
Then
proceed
tothe
followi ng
checks
Fuel
pump
Alternator
L termi nal
Oi l
pressure
swi tch
Fuel
pump
relays
I and
2
Check
i gni ti on
si gnal
i nput
EF
37
Trouble
Di agnoses
and
ComJCti on ENGI NE FUEL
Condi ti on
Engi ne
starts then
stalls
EF 38
Probablecause
Malfuncti oni ng
EFI
relay orcontrol
uni t
or
i njector
Problemi n
the
followi ng
ci rcui ts
Vater
temperature
sensor
Ai r
flowmeter
potenti oni etef
Start
si gnal
ci rcui t
Poorly chaI ged
battery
I mproper
i gni ti on si gnali nput
Malfuncti oni ng
EFI
relay or
controluni t
or
i njector
Fuel
pump
doesnot work
Check
and
correcti veacti on
Connect
a
leadwi re
to
i gni ti on
coi l
negati ve
termi nalWi th
i gni ti on
swi tch
ON attach
otherendofleadwi re to
engi ne body
for
a
short
peri od
and
repeat
i t
rapi dly
li sten to
each
i njector
soundwi tha
screw
dri ver
Results
a
I njectors
cli ck
every
secondbreak
check
the
followi ng
ci rcui ts
eWater
temperature
sensor
Ai r
0lJleterpotent ete r
Start
si gnal
ci relli t
Ai r
regulator
b
I njectors
donot cli ck check
thefollow
i ng
ci rcui ts
Controluni t
power
i nput
ci rcui t
I gni ti on
coi l
tri gger
i nput
ci rcui t
Controluni t
groundci rcui t
e
I njector
ci rcui t
Check each
ci rcui t Then
proceed
to
Com
ponent
checks
Check
charge
ci rcui t
Recharge
battery
i f
necessary
Check
i gni ti onsi gnal
i nput
Connect
a
leadwi reto
i gni ti on
coi l
negati ve
termi nalWi th
i gni ti on
swi tch ON
attach
otherendoflead wi reto
engi nebody
for
a
short
peri od
and
repeat
i t
rapi dly
li sten toeach
i njector
soundwi th
ascrew
dri ver
Results
a
I njectors
cli ck
every
second break check
fuel
pump
ci rcui t
b
I njectors
donot cli ck check thefollow
i ng
ci rcui ts
Start
si gnal
ci rcui t
Control
uni t
power
i nput
ci rcui t
I gni ti on
coi l
tri ggeri nput
ci rcui t
Control
uni t
ground
ci rcui t
I njector
ci rcui t
Wi th
i gni ti on
swi tch
i n
ON
posi ti on
di s
connect oi l
pressure
swi tchharness connec
toralternator
L
tenni nal
Li sten forfuel
pump
and
pressure
regulator
operati ng
sound
I fnosoundi s heard check fuel
pump
con
trol
ci rcui t
Condi ti on
Engi ne
i dles
toofast
cannot
be
adjust
edwi thi dle
speed
adjusti ng
screw
oren
gi ne
i dlei s
unstable
Engi ne
mi sfI res
ENGI NE
EUEL Trouble
Di a9nosessnd
Correcti ons
Probablecause
I mproper
wate
temperature
sensor
ci rcui t
i I
Malfuncti oni ng
ai r
regulator
I mproper
i ntaJ
e
an
exhaust valveclearance
Malfuncti oni ng
throttlevalve
Malfuncti oni ng
ai r
regulator
rJ
r
l
I mproperi gni ti on
ci rcui t
I mproper
EFI harness
connectors
I mproper
fuelli ne
Checkand
correcti veacti on
Then
proceed
to
the
followi ng
checks
Fuel
pump
Alternator
L
tenni nal
Oi l
pressure
swi tch
Fuel
pump relays
I
and 2
Check ci rcui t
Checkai r
regulatorand
replace
i f
necessary
Note I fthesetestsare
sati sfactory prOceed
to
Engi ne
wi llnot start
Adjust
valveclearance
Check that
plate
i s
closi ng
when throttlei s
releasedand
replace
i f
necessary
To
check
ai r
regulatorproceed
tothe
followi ng steps
Start
engi ne
Pi nchoffhoseto
ai r
regulator
Results
al
I fi dle
speeddrops
perfonn
ci rcui t
test
I fnofault i s found
replace
ai r
regulator
b I f i dle
speed
remai ns
hi gh
orunstable
perfonn
the
followi ng
checks
Check
formani foldvacuumleaks i nclud
i ng
at
P
CV valve
V
C valve
di psti ck
ndoi lf1ller
cap
seals
I fno
problem
i s found
perfonn
the
fol
lowi ng
ci rcui t tests
Throttle valve swi tch i dle
contact and
fullthrottlecontact
Va
9u
urp
swi tch
Ai r
temperature
sensor
Water
temperature
sensor
Control
Jti t
ground
ci rcui t
Ai rflowmeter
potenti ometer
Ai r
regwator
andfuel
pump
ci rcui t
I gni ti on
coi l
tri ggeri nput
ci rcui t
Control
uni t
poweri nput
ci rcui t
1
I nj
ctor
ci rcui t
Then
proceed
to
Component
checks
Check
i gni ti on
ci rcui t
PullEFI harness
connectors
apart
and
check
forlooseness and
corrosi on
i ncludi ng
groi md
ci rcui ts
Do
not
forget i gni ti on
i n
put
lead
Check fuelli ne
for
blockage
Tank
strai ner
Fuelfi lter
I njectors
Fuel
pi pes
EF 39
Trouble
Oi sgnosesandCorrecti ons ENGI NE
FUEL
Condi ti on
Engi ne
wi llnot
re
volve lack of
power
Hesi tati on stumble
onaccelerati on
EF 40
Probable
cause
Malfuncti oni ng
controluni t
I mproper
fuel
pressure
i mproper
EFI ci rcui t
Lor
t
f
i gni ti on system
Malfuncti oni ng
throttlevalve
Malfuncti oni ng
ai rflow
meter
I mproper
fuel
li ne
I mproper
fuel
pressure
Problem
i n
the
followi I lg
ci rcui ts
I gni ti on
coi l
tri gger
i nput
ci rcui t
Controluni t
poweri nput
ci rcui t
I njector
ci rcui t
Ai rflowmeter
potenti ometer
Throttle valve swi tchi dle
contact and
fullthrottlecontact
Vacuumswi tch
Ai r
temperature
sensor
Water
temperature
sensor
Alti tudesensor
Ai r
re atorandfuel
pump
ci rcui t
I mproper
i gni ti onsystem
Malfuncti oni ng
ai r
flowmeter
I ntakeai r
leakage
at
followi ng
poi nts
P C V
valve
V
C valve
Di psti ck
andoi lfi ller
cap
seals
Mani fold
gaskets
Ai rflowmeterhoses etc
I mproper
fuel
pressure
I mproper
i dle CO ll
adjustment
I mproper
EFI
ci rcui t
Checkandcorrecti veacti on
Tap
control
uni t
whi le
dri vi ng
tosee i f thi s
aggravates
oraI levi ates
the
problem
I fso
try
another
control
uni t
Perfonnfuel
pressure
test
Perfonn allci rcui t tests
Then
perfonn Component
checks
Check
I C
i gni ti on
uni t
pi ck up
coi land
i gni
ti on
coi l
Make sure throttle
plate
i s
openi ng fully
when
accelerator
i s
fuI 1ydepressed
Check ai r
flowmetermechani calmovement
Usi ng
a fi nger
pushflap open
checki ng
that
i t
opens smoothly
and
fully
Checkfuelli nefor
blockage
Tank
strai ner
Fuelfdter
Fuel
pi pes
Perfonn fuel
pressure
test
Checkeachci rcui t
Thi n
perfonn Component
checks
Check
i gni ti onsystem
Check
ai r
flowmetermechani calmovement
Usi ng
a
fi nger
check forsmooth
flap move
ment
Checkfor
i ntake
ai r
leaks
Perfonn fuel
pressure
test
Check
i dle CO lli f
necessary adjust
i t
Perfonn
complete
ci rcui t
test
Then
perfonn
Components
checks
Condi ti on
Poor
gas mi leage
or
CO
readi ng
too
hi gh
Surge
Backf
ui ng
ENGI NE
FUEL Trouble
Di agnoses
and
Correcti ons
Probablecause
I mproper
i gni ti onti mi ng
or
i gni ti on
system
I mproper
ai r
cleanerf1lter
I mproper
fuel
pressure
Problemi n
the
followi ng
ci rcui ts
Water
temperature
sensor
Ai r
temperature
sensor
Throttle valve swi tchi dle
contact
and
fullthrottlecontact
Vacuum
swi tch
Ai r
flowmeter
potenti ometer
Ai r
regulator
andfuel
pump
ci rcui t
I njector
ci relli
ts
Malfuncti oni ng
ai rflowmeter
I ntake
ai r
leakage
at the
followi ng poi nts
P
Cvvalve
Di psti ck
and
oi lftller
cap
seals
Mani fold
gaskets
Ai rflow
meterhoses
etc
I mproper
fuel
pressure
I mproper
i dle CO
adjustment
Problemi nthe
followi ri g
ci rcui ts
Throttle valve
swi tch
i dle contact and
fullthrottlecontact
Vacuumswi tch
Ai rflowmeter
potenti ometer
Controluni t
ground
ci rcui t
Ai r
temperature
sensor
Water
temperature
sensor
Alti tudesensor
Ai r
regulator
andfuel
pump
ci rcui t
I gni ti on
coi l
tri ggeri nput
ci rcui t
Controluni t
poweri nput
ci rcui t
I njector
ci rcui t
I ntakeai r
leakage
at
the
followi ng
poi nts
P
C V valve
V
C valve
Di psti ck
andoi lftller
cap
seals
Mani fold
gaskets
Ai r
flowmeterhoses etc
I mproper
fuel
pressure
I mproper
i dleCO
adjustment
Check
andcorrecti veacti on
Check
i gni ti on ti mi ng
Check
i gni ti on
system
for
hot
spark
Check ai rcleaner
f1lterand
replace
i f
necessary
Perfonnfuel
pressure
test
Checkeach
ci rcui t
Then
proceed
to
Component
checks
Check
ai r
flowmetermechani calmovement
Usi ng
a
fmger
check
flap
movement for
smooth
operati on
Check fori ntake
ai rleaks
Perfonnfuel
pressure
test
Check i dle CO i f
necessary adjust
i t
Checkeach
ci rcui t
Then
proceed
toComponent
checks
Check fori ntake
ai r
leaks
Perf
nnfuel
pressure
test
Checki dleCO i f
necessary
adjust
i t
EF 41
Trouble
Di agnoses
and
Correcti ons ENGI NE FUEL
Condi ti on
Probablecause
Problemi nthe
folloWi ng
ci rcui ts
e
Throttle valve swi tch i dlecontact
and
fulllhrottlecontact
Vacuum
swi tch
eAi dlowmeter
potenti ometer
Ai r
temperature
sensor
eWater
temperature
sensor
Alti tudesensor
e
I gni ti on
coi l
tri gger
i nput
ci rcui t
e
Controluni t
power
i nput
ci rcui t
e
I njector
ci rcui t
Afterfi re
or
a
g
Problem
i n
the
followi ng
ci rcui ts
Throttle valve swi tch i dlecontact
and
fulllhrottle
contact
Vacuum
swi tch
e
Ai rflowmeter
potenti ometer
Ai r
temperature
sensor
Water
temperature
sensor
I njecti on
ci rcui t
e START
si gnali nput
Checkand
correcti veacti on
Check
each
ci rcui t
Then
proceed
tothe
Component
checks
Check
each
ci rcui t
Then
proceed
to
Component
checks
COMPONENT
CHECKS
To
be
performed
only
afterci rcui t tests
are
completed
Control
Ai r
flowmeter
Fuel
system
Problem
I njector
Ai r uni t
Flap
Relay Resi st
sound
regulator
replace
Fuel
pres I njector
opera
ance
leakage
ment
sure
test
ti on means
Engi ne
wi ll
not start
X
X
I
X
X
X
X X X
I dletoo
hi gh
ortoo
rougli
X
X
I
X
X
Engi ne
mi sfi res X
I
X
X X
X
Lack of
powerengi ne
X
X
X X X
wi llnot rev
Hesi tati on
stumble
X X X X
Poor
gas
mi leage
or
X X X X
X
COtoo
hi gh
Engi ne
surgAs
I I
X X X X
X
Backfi ri ng
I
I
X X X X
Afterbumi ng
I
I
X
X
X X
X
EF 42
CHECKI NG
AND
ADJUSTI NG I DLE
RPM I GNI TI ON
TI MI NG AND
MI XTURE
RATI O
PRECAUTI ON
a
To
di scourage tlI mperi ng
wi ththe
i dle mi xtu
adjus1
i ng screw
on
Cali forni a model i t i ssealed wi thH
steel
bli nd
plug
attar
adjustment
of
i dle mi xture at
factory
So the
bli nd
plug
shouldnot be removed
duri ng
routi nemai ntenance
except
that case as di rectedby
offi ci ali n
specti on
tolowerexhaust emi s
si on
b
Adjusti ng
mi xture
uli ng
otherthan
the method below
may
vi olate
federalandorCali forni a orother
tate
and
provi nci al
laws
I nspecti on procedure
ENGI NE FUEL Trouble
Di agnoses
andCorrecti ons
Preparati on
1 Make
surethat the
followi ng parts
are
i n
good
order
Battery
e
gni ti onsystem
E FI harnessconnectors
Vacuum
hoses
Ai
i ntake
system
Oi lfi ller
cap
oi llevel
gauge
etc
2
C
onnect
engi ne
tachometerand
ti mi ng
li ght
i n thei r
proper
posi ti ons
3 When
measuri ng
CO i nsert
probe
i nt tai l
pi pe
morethan 04m
16i nl
4 Use CO meter
afteri t i s
fully
warm
d
up
5 On ai r
condi ti oner
equi pped
models checks
should be carri ed out
whi letheai rcondi ti oneri
OFF
START
Start
engi ne
andwarm
up engi ne
unti lwaL
temperature
i ndi catorpoi nts
to
he
mi ddle
of
gauge
Open
engi ne
hood
Run
engi ne
at
about
2 000
rpm
forabout
2mi nutesunderno
load
SMA021
1
Run
engi ne
at
i dli ng speed
ForCanada
I
uS
A
For
Di sconnect
hose
from
ai i i ndUcti on
pi pe
andi nstall
propercap
on ai ri nducti on
pi pe
t
Race
engi ne
twoorthree
ti mesunderno
load
Then
rune efor
onemi nute at i dle
speed
Check
i dle
speed
MfT
700
z
tOO
rpm
AfT
700
t100
rpm
Un
0
posi ti on
OK
NG
6 On automati ctransmi ssi on equi p
pad
models
checks
shouldbe
carri ed
out whi le
shi ft leveri si n 0
posi ti on
WARNI NG
a When
selectorleveri s shi ftedto
0
posi ti on apply parki ng
brake andblock
bothfront
and
rearwheels
wi thchocks
b When
raci ng
engi ne
on auto
mati c
transmi ssi on
equi pped
models
make Ri fe that shi ft
leveri s i n N orP
posi ti on
and
depress
brake
pedal
to
pre
vent
forwardRI
rge
of car
c After
the
adjuS1ment
has been
made shi ft thelevertothe N
or
P
posi ti on
and remove
wheel
shocks
S
M
f
SMA263
Adjust
i dle
speed
by turni ng
i dle
spee4
ad
justi ng
screw
I
@
@
@
EF 43
Trouble
Di agno
eund
Cof1l Cti ons ENGI NE fUEL
I
Does
engi ne
run
smoothly
YES
r
I
Note Alter
dri lli ng
be
ure
to I
remove
dlavi Dgs
and
dUll
L
1
EF 44
@U
ji J
@
@@
OI eck
i gni ti on ti mi ng wi th
ti mi ng Ught
Nol1 Clli fomi a
Cali forni l
a
zoaT
DC 6ZOB T DC
OK
J
N G
I
Adjust i gni ti onti mi ng
by turni ng
di stri butor
I
aftedooseni ng
bolts
whi chsecuredi stri butor
I
Race
engi ne
twoorthreeti mesundern
load
then
run
engi ne
at i dle
I pced
r
OK
I
N
G
I
f
0I eclri dle CO
wi th
CO
meter
OK Non C li forni C
li forni a
t 311
0 less
than
4
I N G
OI eckthe
followi ng
Followi ng
hosesfor
proper
connecti ons
VaCWlm
hoses
Blow
by
hoses
Ai r
regulatOJ
hOle
Ai r
duct hoses
Cani ster
purge
hoses
Ai rleaks
at throttlechamber
mounti ng
andi ntakemani fold
Removebli nd
plug
fromai r
by PUl
SCI tW
on
ai rflowmeter
Cali forni
models
Steel
plug
Non cali fomi a models
Rubberplug
Noi i canrorni a
models
Race
engi ne
two
ortluee ti mesunder
noload
then
run
engi ne
at
i dli ng speed
@
SMA059
Correct or
replace
malfuncti oni ng parts
Cali forni a
models
I
Turnoff
engme
andremove
ai rflowmeterfromcu
t
Dri ll
a
hoJi
i n
steel
plug
wbi ch
seab ai r
by pass
screwand
remove
steel
plug
r
I mta11ai rflowmeteroncar
Start
engi ne
and
warm
up
engi neunti l
ter
temperature
i ndi cator
pOi nts
to e
mi ddle
of
gauge
@
Only
for non owrOtni a
models
When
adjUlti na
i dle CO at
hi gh
alti tude
adjust
to
obtai n
foUowi ng
val
Uni t m
ft
I
Alti tude I dleCO
I
6001 200
2
7
2 0004000
I
1
2001 800
3
8
4000
6000
i
I
Above 1 800
5
0
6000
ForCanada
n
ENGI NE FUEL
Trouble
Di sgnosesand
Correcri ons
n
cp
Adjust
CO
by turni ng
ai r
by pass
screwon
ai rflow
meter
I dle CO 13 10lI
I N
G
Not
adjustable
i n
thi s
case
Comct
or
replace
ai rflowmeteror
other
malfuncti oned
parts
of fuel
i njecti onSYstem
Non ali forni a
models
Ai rby
pass
screw SEF
348
For
U
S A
ForCanada
I
For
U SA
Turn off
engi ne
andconnect ai ri nducti on
hosetoai ri nducti on
pi pe
I
Start
engi ne
t
Race
engi ne
twoor
threeti mesunderno
J
load
thenrun
engi ne
at i dle
L
Oleck i dle
speed
MfT 7OO
100rpm
AfT 700 1100
rpmi n 0
posi ti on
O
K
I N G
END
I
OK
@
SMA061
I nstallbli nd
plug
on
ai r
flowmeter
I
Cali forni a
Non Cali tom e
HI M
steel
plug
Ori gi nal
rubber
plug
Cali forni a
models
Turnoff
engi ne
and
removeai r
flowmeter
from
Cat
I
I nsert newsteel
plug
fumi hed
as a servi ce
part
wi th
i ts
convexai de
up
i ntoai r
by pass
screw
Tap
steel
plug
wi thsui tablebar
thereby i nltalli ng
steel
plug
on
ai rflow
meter
I
I nstall
ai rflowmeteronCat
Start
engi ne
and
warm
up
engi ne
unti l
water
temperature
i ndi cator
poi nts
to
the
mi ddle
of
gauge
L
r
Adjust
i dle
speedby
turni ng
i dle
speed
ad
justi ng
screw
EF 45
DATSUN 200SX
ModelS
rr
0
Seri es
SECTI ONEC
EMi SSi ON
CONTROL
SYSTEM
CONTENTS
EMI SSI ON
CONTROL DEVI CES
GENERAL DESCRI PTI ON
CRANKCASE EMI SSI ON CONTROL
SYSTEM
DESCRI PTI ON
I NSPECTI ON
EXHAUST
EMI SSI ON
CONTROL
SYSTEM
DESCRI PTI ON
AI R I NDUCTI ON SYSTEM A I S l
EXHAUST GAS RECI RCULATI ON E G R l
CONTROL SYSTEM
EC 2
EC 3
EC 5
EC 5
EC 5
EC 6
EC 6
EC 6
EC 9
SPARK
TI MI NG
CONTROL SYSTEM
DECELERATI ON CONTROL SYSTEM
Ilntake
mani foldvacuumcontrol
type
CATALYTI C CONVERTER
EVAPORATI VE EMI SSI ON
CONTROL
SYSTEM
DESCRI PTI ON
OPERATI ON
I NSPECTI ON
SERVI CE DATA AND
SPECI FI CATI ONS
TI GHTENI NG TORQUE
EC 15
EC1
EC 17
EC19
EC19
EC 20
EC 21
EC 23
EC
23
Pl
EMI SSI ON
CONTROL
DEVI CES
i o
Engi ne
model
Z20E
SI lO
Car
model
a
Non
Cali forni a
models
Cali forni a
models
Canada
models
li
for
Us
A
a
I tem
M
T
A
T
M
T
A
T
M
T
A
T
I
Ai r
i nlet
Fresh
ai r
duct
X
X
X
X
X
X
m
system
Ai r
pi pe
X
X
X
X
X
X
Ci i
Ai r
flow
meter
X
X
X
X
X
X
Cl
Throttle
chamber
2
barrel
X
X
X
X
X
X
5Z
Ai r
temperature
sensor
X
X
X
X
X
X
C
Ai r
Fuel
Throttle
valve
swi tch
X
X
X
X
X
X
0
Z
system
Vacuum
swi tch
X
X
I 0
Ai r
regulator
X
X
X
X
X
X
0
r
Water
temperature
sensor
X
X
X
X
X
X
Cl
Alti tude
sensor
X
X
Cl
I C
i gni tor
for
I
plug
X
X
X
X
I
I gni ti on
m
system
I C
i gni tor
for
2
plugs
X
X
3
Water
temperature
control
X
X
I
X
X
Exhaust
ai r
i nducti on
system
Type
A
X
X
A
I
S
Exhaust
ai r
i nducti on
system
Type
B
X
X
E
G
R
system
wi th
V
V
T
valve
Type
1
X
X
E
G
R
E
G
R
system
wi th
V
V
T
valve
Type
2
X
X
system
E
G
R
system
wi th
B
P
T
valve
Type
3
X
X
Catalyzer
Catalyti c
converter
X
X
X
X
X
X
Evaporator
system
Cani ster
X
X
X
X
X
X
Crankcase
venti lati on
Posi ti ve
crankcase
venti lati on
P
C
V
valve
X
X
X
X
X
X
system
EMI SSI ON
CONTROL SYSTEM GeneralDeScri pti on
ENERAL DESCRI PTI ON
There
are three
types
of
control
systems
whi ch
areas follows
1
Closed
type
crankcase
emi ssi on
control
system
2
Exhaust emi ssi on control
system
3
Evaporati ve
emi ssi on control
system
Peri odi c
i nspecti ons
and
necessary
servi ci ng
of these
systems
should
be
perfonned
to
keep
hannful
emi ssi ons
toami ni mum
CALI FORNI A
MODELS
Vacuum
control
valve
Throttlechamber
lntakemani fold
Ai rregulator
01I L
I T
11
1
en
II
Ai rpi pe
i
I
T
n
f
i
rr
J
u
c
j
tP
Catalyti c
convert
r
j
i
f
o
C
r
I
I i
I f
1
I dle
adjust
aewumt
lj
r
Di stri butor
i
f
A
I
tube
Cani ster
l
L
Ai ri nducti on
valve
J Ai l
cleaner
Thermalvacuum valve
Portedvacuum Di stri butor
Portedvacuum EG R
Ai r
Venturi
vacuum
Mani foldvacuum
Q
0
Cani ster
purge
Secondary
ai r
Carbonmonoxi de hydrocarbon
Carbon
di oxi de
gas
water
Fuel
tank
vaporvent li ne
BEeoo
EC 3
General De Cri pti on
EMI SSI ON
CONTROL SYSTEM
NoN CALI FORNI A
MODELS
For
U
S A
Vacuumcontrol
valve
I ntau
Thenn2
ftOUum
valve
Throttlechamber
mmi fOI d
G Rntve
Ai rregulator
r
ta
H
BP tube
ell I
n
i l
b
i
1
I I
VV
T
Valve
Ai r
pi pe
0
f
I
I
raL
I 1
I
no
l
T
v
1J
J
E G
R tube
I
J
I
J
t
J
l
u
1
b
J
S
I I
t C2Wyti c
cooverler
I I
C
MalfI Or
t
ldI eadjusls
uni t
f
f
J
Di stri butor r
t
EAI
lube
Omi ster
y
f
dL
Ai r
mducti
valve
1
J
Ai r
cleaner
Fuel
tank
vapor
vent
li ne
CANADA
MODELS
I ntake
mani f
ld
acuum
con
t
vacuum
vaI ve
Throttlechamber
E
GR
val
n
i
i i
M
pi pe
1
kL
Ji
1
J
BP
T
val
J
I I
I
I I
I
E
GR
tube
7
1
gr
21
r
r
ta
yti ccon
rter
Y
JA
J
Muffi er
I dle
adjust
saew t
I I
t
1t 1 J
F
Di stri butor
Cani ster
Fueltank
vaporvent li ne
EC 4
1
Portedvacuum
Di stri butor
Porled vacuum
E
G
R
Venturi
vacuum
Ai r
Cani ster
purge
Q
Q
Secondary
ai r
Oi rbon monoXi de
hydrocarbon
Carbondi oxi de
gas
water
SECOO2
Portedvacuum Di stri butor
Portedvacuum
E
G
R
Ai r
Cani ster
purge
Q
9
Exces sai r
Carbonmonoxi de
hydrocarbon
Cubondi oxi de
gas
water
SECOO3
EM
I SSI ON
CONTRO
L
SYSTEM
Crankcase
Emi ssi onControlSystem
CRANKCASE EMI SSI ON CONTROL
SYSTEM
DESCRI PTI ON
Ti lls
system
returns blowby gas
to
boththei ntake
mani foldand
ai r
pi pe
The
posi ti ve
crankcase venti lati on
P
C
V
valve
i s
provi ded
toconduct
crankcase
blow
by gas
tothe
i ntake
mani fold
Duri ng parti al
throttle
operati on
of
the
engi ne
the i ntake
mani foldsucks
the blow
by
gas
through
the
P
C
V
valve
Nonnally
the
capaci ty
ofthevalve
i ssuffi ci ent to
handle
any
blow
by
and
a
smallamount
of
venti lati ng
ai r
Sealtype
oi llevel
gauge
The
venti lati ng
ai ri s then drawn
through
the
tube
connecti ng
ai r
pi pe
to
rockercover
i ntothecrankcase
Underfull
throttle condi ti on
the
mani fold
vacuwn
i s
i nsuffi ci ent
to
draw
the blow
by
flowthrough
the
valve and
i ts
flow
goes
through
the
tube
connecti on i n the reverse di I ee
li on
On cars wi than
excessi vei y
hi gh
blow
by
some
of
the flow wi ll
go
through
the tube
connecti on
to
ai r
pi pe
under
all
condi ti ons
Flamearrester
i C
I ntakemani fold
J
v
l
T
r
J
Ai r
L
pi pe
R
Throttle
chamber
P C
V valve
Steel
net
Freshai r
Blow
by
gas
SECOO4
I NSPECTI ON
pC V VALVE AND FI LTER
Wi th
engi ne runni ng
at i dle
remove
the venti latorhosefrom
P
C
V
valve
i f the valve i s
worki ng
a
hi ssi ng
noi se
wi llbe
heardas
ai r
passes through
the
valve and a
strong
vacuumshould
be
felt
i mmedi ately
when a
fi nger
i s
placed
over
valvei nlet
VENTI LATI ON HOSE
1
Check hosesandhose
connecti ons
forleaks
2
Di sconnect
allhoses and dean
wi th
compressed
ai r
I f
any
hose cannot be free of
obstructi ons
replace
Ensure that
flame arresteri s
surely
i nserted
i n
hose between
ai r
pi pe
and
rockercover
ET277
EC 5
ExhaurtEmi ssi on Control
System
EM
I SSI ON
CONTROL
SYSTEM
EXHAUST
EMI SSI ON
CONTROL
SYSTEM
DESCRI PTI ON
Theexhaust emi ssi on
control
system
i s
made
up
of
followi ng
Emi ssi on control
system
Cali forni amodels
Ai r
i nducti on
system
Type
A
Ai ri nducti on valve
EA tube
Type
2
E
G R valve
Thermalvacuum
valve
3
port
type
TYpe
A2 A3
VV
Tvalve
Thermalvacuumvalve
3
port
type
Type
A2 A3
Catalyti c
converter
E
G
R
system
Sparkti mi ng
control
system
Catalyst
AI R I NDUCTI ON
SYSTEM A I S
NonCali forni amodels
for
U S A
Type
B
Ai r
i nducti onvalve
E A
tube
Type1
EG
R
valve
Thennalvacuumvalve
3
port type
TYpe
A
I A3
VV T
valve
Thennalvacuumvalve
3
port type
Type
A
I A3
Catalyti c
converter
exhaust
mani fold
The exhaust
pressure
i nthe
exhaust
mani fold
usually pulsates
i n
response
tothe
openi ng
and
closi ng
of
the
exhaust valve and i t decreases below
atmospheri cpressureperi odi cally
I f a
secondary
ai ri ntak
pi pe
i s
opened
to the
atmosphere
under
DESCRI PTI ON
The
ai r
i nducti on
system
A IS i s
desi gned to
send
seco
dary
ai rtothe
exhaust mani fold
uti li zi ng
a
vacuum
caused
by
exhaust
pulsati on
i n the
I
Type
A
Canadamodels
Type
3
E G R valve
Thennalvacuumvalve
2
port type
BP T valve
Catalyti c
converter
vacuum
condi ti ons
secondary
ai rcan
be drawn
i nto
theexhaust
mani fold
i n
proporti on
tothe
vacuum
Therefore theai r
i nducti on
system
A I
S reduces COand
HC emi ssi ons
i n
exhaust
gases
The
system
consi sts
of
twoai ri nducti on
valves a fi lter
andhoses
Ai rcleaner
cy
I njector
Wf
E
Altube
EC
6
n
I I
SECOO6
EM
I SSI ON
CONTROL SYSTEM
Exhaust Emi ssi on
Control
System
Type
B
Ai ri nducti on valve
Ai r
cleaner
Fi lter
Exhaust
mani fold
E
A
tube
SECOC
Ai r
i nducti on valve
Two
reed valves arei nstalled
i nthe
ai r
cleaner
When theexlui ust
pressure
i s below
atmospheri c pressure
nega
ti ve
pressure
secondary
ai ri s
sent to
theexhaust
mani fold
When
theexhaust
pressure
i s
above
atmospheri c
pressure
the
reed
valves
prevent
secondary
ai rfrom
bei ng
sent
back tothe
ai r
cleaner
Ai r
i nducti on valve
case I
The
ai r
i nducti on
valvecase whi ch
consi sts oftworeed
valves a valvecase
and
a
fI lter
i s attached tothe
ai r
cleaner
There
are two
types
of
ai r
i nduc
ti on
valve cases
The
type
A
i s
equi p
ped
wi thtwo
hose
connectors and
i s
i nstalled
onCali forni amodels and
the
type
B i s
equi pped
wi th
one
connector
and
i s
i nstalled
on all non Cali fornla
models
except
Canada
EC921
Type
A
Toexhaust mani fold
1
Ai r
I nducti on
pi pe
The
secondary
ai rfedfromthe
ai r
i nducti on valve goes
through
the
EA tube tothe
exhaust mani fold
SEC009
n
MO
Dlkwrtd i i llQl
Ai rfi lter
SEC059
Type
A
rEAl
pi pe
Z
Fromai r
i nducti on
valve
Type
B
Toexhaust mani fold
Ai ri nducti on
valve
S
al e
mg
rubber
1
LAi rfi er
SEC060
Ai ri nducti on valve
fi lter
The
ai ri nducti on valve fI lter
i s i n
stalled
at the dust
si de
of the
ai r
cleanerI t
puri fi es
secondary
ai r
tobe
sent
totheexhaust mani fold
EC
7
Exhaust Emi ssi onControl
System
EM
I SSI ON CONTROL SYSTEM
Type
B
E
A I
pi pe
REMOVAL
AND
I NSTALLATI ON
Ai rI nducti on valve andfi lter
Remove thevalve and fI lteron the
ai rcleaner
The
ai r
i nducti onvalveand
valvefI lter
can
thenbe taken out easi
ly
I nstallati on i s i n
the
reserve se
quence
ofremoval
SECQ12
Ai r
I nducti on
pi pe
Remove nut
securi ng
the
pi pe
to
the exhaust mani fold At the
same
ti me
removethescrews
securi ng
the
bracket andrubberhose
clamp
EC 8
The
ai r
i nducti on
pi pe
can thenbe
taken
out I nstallati on i si n
the
reverse
sequence
ofremoval
Type
B
I NSPECTI ON
Preli mi nary I nspecti on
Check hose forlooseness
flatti ng
damage
or
faulty
connecti ons and
each
part
for
proper
i nstallati on
I f
nere
ry replare
AI ri nducti on valve and fDter
I
Di sconnect
ai r
i nducti on hose
at
ai r
i nducti on
pi pe
si de Suck orblow
hose tomake surethat
ai r
flows
only
on
the
ai r
i nducti on
pi pe
si de
SEC016
2 Check ai r
i nducti on valve for
bi ndi ng
or
damage
At
thesame
ti me
check fI lterfor
damageor
pluggi ng
I f
necessary replace
Fi lter
should be
replaced peri odi cally
i n
accordance
wi thMai ntenanceSchedule
SEC016
EM
I SSI ON
CO
NTROL SYSTEM
Exhaust Emi ssi on Control
System
EXHAUST
GAS
RECI RCULATI ON
E
G R
CONTROL SYSTEM
DESCRI PTI ON
I
I n the
exhaust
gas
reci rculati on
system
a
part
ftheexhaust
gas
i s
returned to
thecombusti on chamber
tolowerthe
spark
flai ne
temperature
Type
2
EG R valve
Type
I L
l
E G R valve
duri ng
combusti on Thi s results
i n a
reducti on of the
ni trogen
oxi de
NOx
content
i nthe
exhaust
gas
When
the
E
G
R
controlvalve
i s
open
some
of the
exhaust
gas
i s led
from the exhaust mani fold to the
E G R chamberThe exhaust
gas
i s
then controlled i n
quanti ty by
the
E G
R valve
and i s
i ntroduced
i nto
thei ntake
mani fold
JJ
From
ai r
pi pe
JT
I I
1
All
n
o
Throttle
I
chamber
venturi
I I
1
Throttle
valve
E
G
R
vacuum
port
rEngi ne
coolant
Advance
oontrolli nel
v
L
J
t
Exhaust
gas
fromexhaust mani fold
Thermal
vacuum
valve
Type
A2
L
Thermal
vacuum
valve
Type
A3
SEC017
D
romai r
pi pe
I
Ai r
0
Throt
e
chamber
venturi
I
I
Throttle
t
valve
E G
R
vacuum
port
I I
11
Ad
ancecontrolli ne
Engi ne
coolant
T
0
r
I f
L J
I
L
Thermalvacuumvalve
Type
AI
Thermal
vacuum vuve
Type
A3
Exhaust gas
fromexhaust mani fold
SEC018
EC 9
Exhaust
Emi ssi on
Control
System
EM
I SSI ON CONTROL SYSTEM
Type
3
I
Ai r
I
I
lL ro
ILJ
Vacuum
port
I
r
Engi ne
coolant
L
Exhaust
gu
fromexhaust mani fold
SEC309
OPERATI ON
The
operati on
ofthe
system
i sas follows
Type
2
Water
temperature
I
Thermal
vacuum
valve
VVT valve
E G R
Oc
oF
Type
A2
Type
A3
Venturi vacuum Exhaust
gas pressure Operati on
control
system
Hi gh
Low
I Hi gh
Hi gh
Closed
Below
15
59
Open
Closed Not actuated
I
Low
Hi gh
Low Low
Open
Hi gh
Low
15 60
J
Hi gh
Hi gh
Closed
Sli ghtly
Leak Closed
59 140 I
Low
Hi gh
actuated
Low Low
Open
Not actuated
Hi gh
Low
Hi gh
Hi gh
Closed
6095
Closed Closed Actuated
140
203
Low
Hi gh
Low
Low
Open
Not
actuated
Hi gh
Low
Hi gh
Hi gh
Closed
Above95
Closed
Open
Not actuated
203
Low
Hi gh
Low Low
Open
EC I O
EM
I SSI ON CONTROLSYSTEM
Exhaust
Emi ssi onControl
System
Type
I
Water
temperature
Thermalvacuum
valve
V V T
valve
E
G R
Oc
eF
Type
Al
Type
A3
Venturi vacuum
Exhaust
gas pressure
Operati on
control
system
Hi gh
Low
Hi gh
Hi gh
Closed
Below
60
140
Open
Closed
Not
actuated
Low
Hi gh
Low Low
Open
Hi gh
Low
Hi gh
Hi gh
I
Closed
Actuated
6095 Closed
Closed
Hi gh
140203
Low
Low
Low
Open
Not actuated
Hi gh
Low
I
Hi gh Hi gh Closed
Not actuated
Above95
Closed
Open
I
203
Low Hi gh
1
Low
Low
Open
TYpe
3
1
B
P
T valve
Water
temperature
Exhaust
gas pressure
E
G
R
Thermalvacuumvalve Operati on
control
system
Oc
em
kPa
mmHzOi nHzO
Below0206 0324
21 33 082 i30
Open
Below
50 122
Closed
Not
actuated
Above
0
206
0324 21 33
0
82
130 Closed
Below
0206
0324
21
33
082
130
Open
Not actuated
Above50122
Open
Above
0
206 0324
21
33
082
130
Closed Actuated
Wi ththe
engi ne
at i dle
or
at
full
throttletheE G R controlvalvedoses
todeacti vatetheE G R
systemregard
less
of water
temperature operati on
of
thethermalvacuum valve and
V
I t
T
valveorB P T valve
E
G R controlvalve
The EG R
controlvalve controls
the
quanti ty
of
exhaust
gas
tobe led
to
thei ntakemani fold
through
verti cal
movement
of the
taper
valveconnect
ed
to
the
di aphragm
towhi chvacuum
i s
appli ed
i n
response
tothe
openi ng
ofthethrottlevalve
E
G
R control
valve constructi on
and
type
vary
wi thtransmi ssi on
type
andcardesti nati ol
Fori denti fi cati on
purposes
the
part
number
i s
stamped
on
the recessed
porti on
at the
top
of
thevalve
G
d
I
I
I D
ur
I
SEC019
1
Di aphragm
spri ng
2
Di aphragm
3
Valveshaft
4 Valve
5 Valveseat
6 Valvechamber
Thermal
vacuum valve
3
port type
Two
thermal
vacuum
valves are
i nstalled
oneon the
upper
si deofthe
i ntake
mani fold and
the
other
on
the
lowersi de These thennalvacuum
valves detect
the
temperature
of the
engi necooli ng
waterThevalveshaft i s
pushed
up
ordown
by
the thennal
expansi on
force
ofwaxwhi ch
depends
on the
temperature
Thi s acti on
opens
and closes thevalve whi chcauses the
E G
R
controlvacuum li ne tobe
opened
orclosed tothe
atmosphere
When
the
valve
opens
ai r
from the
throttlechambervacuum
si gnal
li nei s
i ntroduced and whi le
the venturi
vacuumtransducer
V
V T
valvecon
trolori fi ceandEG R
valve
di aphragm
are
exposed
tothe
atmosphere
the
EG R
operati on
wi llnot functi on
EC
Exhaust
Emi ssi on
ControlSystem
EMI SSI ON
CONTROL SYSTEM
Type
A2
To
E G
R
controlli ne
JQ
r
From
ai rcleaner
JQ
Ori fi ce
Q
Type
AI
1
1
n
I
O
j
1
Type
AJ
Spri ng
1
I i
Vatve
I
T
Wax
EC
12
Todi stri butor
advance
controlli ne
Wax
SEC020
From
I
r
ai r
cleaner
Q
ToEG R
controlli ne
I Q
Todi stri butor
advance
controlli ne
Wax
SEC021
From
ai rc1eanCi
C
E
G R
controlli ne
Spark
advance
control
vacuum
li ne
SEC022
Thermalvacuum
valve
2port type
The 2
port type
thennalvacuum
valve i s mounted on the
engi ne
thennostat housi ng
I t detects
engi ne
coolant
temperature
by means
of a
bui lt i n bi metaland
opens
orcloses
the
vacuum
pa ge
i n
the thermal
vacuum
valve
When thevacuum
passage
i s
open
the throttlechambervacuum
si gnal
i s
appli ed
to the
di aphragm
of the
E G
R
controlvalve toactuate the
per
valve connected
tothe di a
phragm
Bi metal
Spi i ng
8P T valve
The
BP T valve moni tors exhaust
pressure
to
acti vate the
di aphragm
controlli ng
throttle chambervacuum
appli ed
totheEG R controlvalve
I n
otherwords the amount of
reci rcu
tated exhaust
gas
vari es
wi th
the
posi
ti on oftheEG R valve
regulatedby
the
operati ng
condi ti on of the
engi ne
ToE G
R
ubberClI p
control1i ne
Ai r
f
Exhaust
pressure
SEC20a
SEC023
REMOVAL
AND
I NSTALLATI ON
Venturi vacuumtransducer
V V T valve
The vVT valve moni tors the
pressure
of
the
exhaust
gas
whi ch
actuates the
di aphragm @
and the
venturi
vacuumwhi ch
i n
turnacti vate
the
di aphragm
1@
Thi svalvecon
trols thethrottlevacuum i n
orderto
cti vate
theEG R controlvalve
I n otherwords theamount of reo
ci rculated exhaust
gas
vari es wi ththe
posi ti on
oftheE G R valve
regulated
by
the
operati ng
condi ti on of the
engi ne
Control
ori fi ce
Ai rbleed
1
E G R
control
ported
vacuum
Ai r
pi pe
Exhaust
gas
t
pressu SEC024
1
Di aphragm
2
Di aphragm
3
Di aphragm
E G
I i
controi valve
and E G R tube
1
Remove nuts whi ch secure
E G R tubeand BP tube toEG
R
valve anddi sconnect tubesfromvalve
2 Di sconnect vacuum hose and
remove nuts
securi ng
E G R control
valve toI ntake Mani fold The E GR
controlvalvecan thenbe taken out
J
CAUTI ON
Pay
attenti on not 10
gi ve damage
to
packi ng
of E
6R
controlvalve
3
I nstallati on
i s i n
the
reverse
sequence
ofremoval
a When
i nstalli ng
a newE G R valve
veri fy
i t
i s of
thesame
type
model
number
and
i denti fi cati on mark
etc
las
that whi ch
was previ o
slY
i nstalled
b
Always
i nstalla
new
gasket
Thermalvacuum
valve
The thennalvacuum
valve
i s
made
of
plasti c Consequently
care
should
be taken toavoi d
damagi ng
i t
On
U
S A
models twovalves are located
on the i ntakemani fold Onei s
located
on the front si de of the
i ntake
mani
fold The other
i s
located
underthe
rearend of
the i ntake
mani fold On
Canada models the
valve
i s
located
on
the
i ntake
mani fold
I
Drai n
engi ne
coolant
about one
li ter
2 Di sconnect vacuum hoses and
unscrew
the
thermalvacuum valve
Then thevalvecan beremoved
3
I nstallati on i s i n
the
reverse
sequence
of
removal
a
Besurato
apply
sealertothreads
of
the
valve
pri or
to
i nstalli ng
a
new
valve
b When
i nstalli ng a new thermal
vacuum valve be
sure
that
color
and
shape
are
correct
Type
A2
J
SEC026
SEe027
EM
I SSI ONCONTROL SYSTEM Exhaust Emi ssi on
ControlSystem
Type
A3
SEC029
V V
T
valve
1
Di sconnect vacuum
tubes
on
the
V V
T
valve
2 Di sconnect screws whi chsecure
V VT valve tobracket
3 Di sconnect back
pressure
tube
from
V V T
valve
TheV V
T
valve
can thenbetaken
out
SEC029
4 I nstallati on i s
i n
the reverse
sequence
ofremoval
When
replaci ng
the
V V T valve
wi th
a newone veri fy
that the
type
number
onthe
noYi
part
i s the
same
as
that ontheformerone
iJ
V V T valve
mounti ng
crew
i
3
7 5 0
N m
038 051
kg
m
27
3
7
ft lb
8P T
valve
1
Remove vacuum tube on the
B P T valve
2
Remove screws
securi ng
B P
T
valveto
thebracket
3 Di sconnect
back
pressure
tube
fromB
P
T
valve
TheB
P
T
valvecan thenbe taken
out
SEC030
4
I nstallati on i s i n
the reverse
sequence
ofremoval
When
replaci ng
the B P T valve
wi th
new
co
frm
that the
type
number
on
newpart i s the same as
that on
former
one
iJ
B P T valve
mounti ng
screw
37 5 0N m
Q
38
051
kg
m
27 37 ft lb
I NSPECTI ON
Enti re
system
l
Make
a
thorough
vi sualcheck of
EG R control
system
I f
necessary
wi pe
away
oi ltofaci li tate
i nspecti on
I f
any
hoses are cracked orbroken
replace
2
Wi th
engi ne stopped
i nspect
EG R controlvalvefor
any
i ndi cati on
of
bi ndi ng
or
sti cki ng by
movi ng
di a
phragn
Of c ntrolvalve
up
ds wi th
a
fmger
J
3 Wi th
engi ne runni ng
i nspect
EG R controlvalve and thennal
vacuumvalvefornonn 1
operati on
Place
your
fi nger
on
di aphragm
of
EG R
controlvalvetoensurethat the
valve
functi ons as descri bedbelow
r
f
SEC031
EC
13
Exhau
Emi ssi on Co
1
System
I
MI SSI ON CONTROL
SYSTEM
SECOO2
1
When
temperature
of the
engi ne
coolant
i s
low
Below
I SoC S90F
Cali forni amodels
Below
600
1400F
Non
Cali forni amodals
BelowSOOC
1220F
Canada models
Make
sure that
EG
R
control
valve
does not
operate
when
engi ne speed
i s
i ncreasedfrom
i dleto
20002500
rpm
2
When
temperature
of the
engi ne
coolant
i s
hi gh
AboveI SoC
S90F
Cali forni a
models
Above
600C
1400F
Non Cali forni amodels
Above
SOOC
1220F
Canada
models
1 Make sure that E G R control
valve
operates
when
engi ne speed
i s
i ncreased fromi dleto
2
000
2 SOO
rpm
2
I fEG R controlvalve does not
operate properly
check
i t
as follows
Di sconnect oneend
KG
R
control
valve
si de
of
vacuumh
whi ch
connects
3
way
connecter to
EG R controlvalve
I ncreaseengi ne
speed
fromi dleto
2
0002SOO
rpm
Make sure
that thennalvacuum
valve
i s
closed
and that throttle
EC 14
vacuui n
i s
present
at the end
E
GR control valve si de
of
vacuumhose
Type
Al
Type
A2
Canada
Ai rregulatort
f
TV VJ C035
I fvacuum
pressure
i s
ei therweak or
nonexi stent
replace
thermal
vacuumvalve
I fvacuum
Pse
ss
lJ
e
i s
detected
replace
EG R
valve
I f
any
di ffi culty
i s encounteredi n
judgi ng
the condi ti on
of
any
com
ponent duri ng
above
i nspecti on
check
the
questi onable
component
i nde
pendently
as follows
E GR cori t
ol
valve
Di smount E
G R control valve
from
engi ne
1
Apply
vacuumtoEG
R
control
valve
referri ng
tothe
followi ng fi gure
I f
the
valvemovesto
full
posi ti on
i t i s
nonnal
EG
R controlvalve wi llremai n
open
formore than 30seconds after
vacuumhas cut off
seC018
I I
ucsl
2
Vi sually
check E G R
control
valvefor
damage
wri nkleordeforms
li on
Thermal
vacuum
valve
Di smount thennal
vacuum valve
fromengi ne
Before
di smounti ng
drai n
engi ne
coolant
from
engi ne
Apply
vacuumto
thennal
vacuum
valve
and check to
be sure that
ther
malvacuum valve
opens
orcloses i n
c to
engi ne
coolant
tempera
ture
as
speci fi ed
Thennalvacuum
valveshould
open
orclose at
a
temperature
speci fi ed
below
completi ng
the vacuum
pa5Sage
EMI SSI ON CONTROL
SYSTEM
Exhaust Emi ssi on Control
System
Thermal
vacuum
valve
operati ng temperature
Oc OF
Close
Type
Operati ng temperature
Leak
Open
60
95 Below60
140
NonCali forni a
140
203 Above
95 203
for
U
S
A
15 60 6095
Below15
Cali forni a
59
140
140203
59
I
Above95
I
Below95
Apply pressure
203 203
U S A
above
0
785 kPa
Above
50
1
Below50
80 mmH aO
122
122
Canada 315
i nH OI
SEC038
Wax
Type
AI
Wax
Type
A2
Wax
Type
A3
Bi
metal
Appli ed
model
Canada
CAUTI ON
Donot
allowwaterto
gel
i nsi de the
thermal
Vllcuum valve
UsA
1OC1
EC242
SEC036
V V
T valve
1
Apply
a
pressure
above 1961kPa
200
mmH20
7
87
i nH20
to
V V T
valveandcheck i t
for
leakage
as shown
below I fa leak i snoted
replace
vai ve
SEC037
Apply
vacuum
above
t
1
961kP
200mmH207
87
i nH
OJ
2
Apply
vacuum
pressure
above
0
785 kPa 80
mmH20
315
i nH20
toV
V
T valveand
check for
leakage
as shown below
I fa
leaki s
di scover
ed
replace
valve
B P
T
valve
1
Di sconnect
two cuumhoses on
B
P
T valve
2
Plug
one of two
ports
of B P
T
valve
Apply
a
pressure
above
0
490kPa
50
mmH20
197
i nH20
to
B P T
valve
and
orally
suck
back other
port
of
B
P
T
valve as shown below to
check
for
leakage
I fa leak i s
noted
replace
valve
t
Apply pressure
above
0
490
kPI I
50
mmH20
1 97
i nH201
EC381
A
SPARK
TI MI NG
CONTROL
SYSTEM
DESCRI PTI ON
The
spark ti mi ng
control
system
i s
desi gned
tocontrolthe di stri butor
vacuumadvance
under
varyi ng
dri vi ng
condi ti ons
so as to reduce HC and
NOx
emi ssi ons
EC 15
ExhsustEmi ssi onControlSystem EMI SSI ON
CONTROL
SYSTE
OPERATI ON
The
operati on
of the
system
i s
as
follows
Water
temperature
Thennalvacuumvalve
Spark ti mi ng
Oc
OF
Type
AI
A2
Type
A3
control
system
Below15 59 Closed Closed Actuated
15 6059
140
Open
Closed
Not actuated
6095 140
203 Closed Closed Actuated
Above95 203 Closed
Open
Not actuated
Thi s
system
does
no1
operate
wi th
tha
engi ne
at i ale
Thermalvacuumvalve
3port type
Type
Ai
Two thennalvacuum valves are
I
i nstalled one on the
upper
si deofthe
i ntakemani fold andtheotheron the
I
I
lowersi de These thennal
vacuum
1
valves detect the
temperature
of the
engi ne
coo
li ng
waterThe valve shaft i s
pushed up
or
down
by
the thennal
I
expansi on
forceofwaxwhi ch
depends
onthe
temperature
Thi s
acti on
opens
and closes thevalve whi chcausesthe
I
di stnbutorvacuum li netobe
opened
l
orclosedtothe
atmosphere
When the valve
opens
thevacuum
I
si gnal
li ne wi ll
open
to
the
atmos
phere
stoppi ng
thedi stri butor
vacuum
from
advanci ng
Type
A2
ToE G
R
controlli ne
e
C
From
I
ai rcleaner
TYpe
A3
Spri ng
t1
i i
Valve
i
i 1i
I
e
Todi stri butor
advance
controlli ne
Wax
Wax
SEC020
EC
16
I
Ensure that vacuum hoses
are
properly
connected to
thei r
con
I
Q
19
controllme
2 Make
sure
that di stri butor
vacuum
controllerfuncti ons
properly
3 Set
ti mi ng
li ght
4
Check thennalvacuum valve
begi nni ng
wi tha cold
engi ne
1 Usi ng
a
ti mi ng li ght
check the
spark
ti mi ng
whi le
temperaturegauge
i s i ntheC
posi ti on
A
From
J
r
ai rcleaner
i Q
Todi stri butor
a4vance
coI i trolli ne
Wax
SEC021
From
ai rcleaner
n
lQ
i i CE
G R
controlli ne
Q
Q
ce
control
vacuum
li ne
SEC022
REMOVAL
AND I NSTALLATI ON
Thermalvacuum
valve
The thermal
vacuumvalve
desi gns
are
exactly
thesame as those used
i n
the E G R control
system
Refer
to
the i nstructi ons under
the
headi ri g
EG R control
system forremoval
andi nstallati on
procedures
I NSPECTI ON
Enti re
system
SEC039
2
Usi ng
a
ti mi ng li ght
ensure that
the
spark ti mi ng
retards from
i ts
pre
vi ous
posi ti on
when
temperaturegauge
changes
from the C
posi ti on
tothe
mi ddle
posi ti on
3 Wann
up
the
engi ne
unti l
coolant
temperature
gauge
poi ntermoves to
mi ddle
posi ti on
of scale Ensure that
the
spark ti mi ng
advances from i ts
previ ousposi ti on
SEC040
I f
spark ti mi ng
does not
change
reo
place
thennal
vacuumvalve
Thermal
vacuum
valve
operati ng
temperature
Type
EMI SSI ON CONTROL SYSTEM
Exhaust Emi ssi on
ControJ
System
To
check for
operati on
of thermal
valve
proceed
as
follows
Thermalvacuum
valve
Removethermalvacuum
valve
from
engi ne
I nhale
ai r
from
port
of
spark
ti mi ng
control
system
and check tobe
sure that thermal
vacuumvalve
opens
or
closes
i n
response
to
i ts
tempera
ture
Operati ng
temperature
Oc
F
Open
Close
Below15
59
Above
60
140
Wax
Type
Al
A2 15 60
59
140
Wax
Type
A3
Above95
203
Below95
203
CAUTI ON
00
not allowwater10enterthether
mal
vacuumvalve
SECQ36
DECELERATI ON
CONTROLSYSTEM
I ntake
mani fold
vacuumcontrol
type
DESCRI PTI ON
The
decelerati on control
system
i s
desi gned
tocontrol
the
i ntake
mani
fold
vacuum
under
decelerati ng dri vi ng
condi ti on
59
as
to
reduce
the
oi l
con
sumpti on
OPERATI ON
Thi s
system
i s used toforce
ai r
di rectly
i ntothei ntakemani fold
wen
the
preset
vacuum
levelhas
been
at
tai ned thus
preventi ng
excessi ve
i n
creases
i n
thei ntake
mani foldvacuum
duri ng
decelerati on
Ai ri s
di rected
fromthe
3
way
connector
through
the
ai r
hose
andvacuumcontrol
valve To
keep
oi l
consumpti on
low
as
the
ai r
enters the i ntake
mani fold vacum
wi llbe mai ntai ned at less than
the
speci fi ed
level
Vacuum
controlvalve VC
V
Tocheck
for
operati ng proceed
as
follows
I
Di sconnect one
end Ai r
regulator
si de
of
ai r
hose connecti ng
3
way
connectortoV C
V
2 Make sure
that vacuum control
valve
operates
when
engi ne
speed
i s
decreased
from3 500
4
000to
i dle
Place
fi nger
on the hose end
to
check forvalveoperati on
3
I fthei ntakemani fold vacuum
i s
not
present
at
the
end
of ai rhose
replace
vacuumcontrolvalve
CATALYTI C
CONVERTER
DESCRI PTI ON
The
catalyti c
converteraccelerates
thechemi cal
reacti onof
hydrocarbons
HC and carbon
monoxi de CO
i n
the
exhaust
gas
and
changes
themi nto
non
hannful carbon di oxi de
CO
and water
H
O
Thi s chemi cal
reacti on
process
requi res
the
proper
amount of
ai rwhi chi s i nduced
y
the
ai ri nducti on valve
Refer
t
the i tem
A
IS
Thi s ai ri scalled
secondary
ai r
EC 7
Exhaust Emi ssi on ContrQl
System EM
I SSI ON CONTROL
SYSTEM
Catalyti c
converter
OPERATI ON
Exhaust
gas
emi tted from
the
engi ne
contai ns
some hannfulsub
stances dueto
i ncomplete
combusti on
i n the
combusti on chamberThe ai r
i nducti on
system
i s
desi gned
toreduce
the
content of suchsubstances i n the
exhaust
gas
I n
thi s
system
the
secondary ai ci sJed
from the ai ri n
ducti on valve and
i njected
i nto
the
exhaust mani fold
Wi ththi s
i njecti on
of the
secondary
ai r
hydrocarbons
HC and
carbon monoxi de CO
i n
theexhaust
gas
are
gradually
oxi di zed
wi th
oxygen
0
i n
the
secondary
ai r
and
converted
i nto non hannful
carbon
di oxi de CO and
water
H
O
The
catalyti c
converter
further
cleans
engi ne
exhaust
gas
Through
catalyti c
acti on
i t
changes
resi dual
hydrocarbons
and
carbon
monoxi de
contai ned
i n
exhaust
gas
i ntocarbon
di oxi de andwaterbefore
exhaust
gas
i s
di scharged
tothe
atmosphere
REMOVAL
AND
I NSTALLATI ON
I Jack
up
thecar
Apply parki ng
brake and
place
wheel
chocks
2
Remove screws
securi ng
lower
shelterof
catalyti c
converter
Loosen
flange
bolts
connecti ng
catalyti cconvertertofront and
rear
exhaust tubes
Catalyti c
converter
assembly can
thenbe
taken out
EC
18
I
Vi sually
check
catalyti c
converter
for
damage
or
cracks
2
Adjust
engi ne
i dle
speed
Refer
to
Mjus g
I dle
RPMfor
adjustment
SEC044
3
Race
engi ne
1500 to
2000
rpm
two
or
threeti mes under
no
load
4 I f i dle
speed
i ncreases
readjust
i t to
speci fi ed speed
wi ththrottle
adjusti ng
screw
SWann
up
engi ne
forabout four
mi nutes
at 2
000
rpm
undernoload
6 Measure CO
percentage
at i dle
speed
After
step
S has been
com
pleted
wai t forone mi nute before
maki ng
CO
percentage
measurement
7 I fCO
percentage
measured
i n
step
6
i s
less than03
thecatalyti c
con
verter
i s
nonnal
8 I fCO
percentage
measured
i n
step
6
i s
over
03
recheck
Al
S ari d
replace
ai r
i nducti on valve Then
per
form
i nspecti on
steps
S
and6
9 i f CO
percentage
i s
sti llover03
i n
step
8
catalyti c
converteri s mal
functi oni ng Replace catalyti c con
verter
ft
L
MufI I er
SEC043
SEe04S
3 I nstallati on i s i n the reverse
sequence
ofremoval
CAUTI ON
a Be careful
not to
damage
catalyti c
converter
when
handli ng
b Newrwet
catalyzer
wi th
wa1eroi l
etc
fJ
Lowershelterbolt
63
8
3N
m
064 085
kg m
46 61 ft lb
Catalyti c
converterbolt
31
42N m
3
2 4
3
kg m
23 31
ft bl
I NSPECTI ON
Preli mi nary
I nspecti on
Vi sually
check condi ti on
of all
component parts
i ncludi ng
hoses
tubes
and
wi res
replace
i f
necessary
Refer
to
Ai r
I nducti on
System
for
i nspecti on
Ci
converter
Whether
catalyti c converter
i s
normal
or
not
can
be checked
by
observi ng
vari ati on i n CO
percentage
The
checki ng
procedure
i s
as follows
Apply parki ng
brake Shi ft
gears
i nto Neutral formanualtrans
mi ssi on
and
N
orP forauto
mati ctransmi ssi on
posi ti on
Cali forni a
models
Non Cali fomi a
models
I
Vi suaI ly
check
catalyti c
converter
for
damage
orcrack
2
Adjust
engi ne
i dle
speed
andCO
percentage
Referto
Adjusti ng
I dle
RPM
and Mi xture Rati ofor
adjust
ment
EMI SSI ON CONTROL
SYSTEM Evaporati ve
Emi ssi on
Control
System
3
Race
engi ne 1500
to
2
000
rpm
twoOrthree
ti mes
underno
load
and
make
sure that
speci fi ed CO
per
centage
i s
obtai ned
4
Remove
cap
and
connect
ai r
hose
toai r
i nducti on
va1ve
I f
i dle
speed
i ncreases
readjust
i t
to
speci fi ed
speed
wi th
throttle
adjust
i ng
screw
5 Wann
up
engi ne
for
about
four
mi nutes at
2
000
rpm
underno
lmi d
6 Measure
CO
percentage
at i dle
speed
After
step
4
has been
com
pleted
wai t
for
one mi nute
before
maki ng
CO
percentage
measurement
7
I fCO
percentage
measuredi n
step
5
i s less
than
03
the
catalyti c
con
verteri s normal
8
I fCO
percentage
measured
i n
step
S
i s
over03 recheck AJ S
and
replace
ai r
i nducti on valve Tli en
per
fonn
i nspecti on
steps
4and 5
9
I fCO
percentage
i s
sti llover03
i n
step
7
catalyti cconverter
i s
mal
functi oni ng Replace catalyti c con
verter
EVAPORATI VE
EMI SSI ON CONTROL
SYSTEM
DESCRI PTI ON
Thi s
system
i s
made
up
of the
followi ng
1
Fuel
tank wi th
posi ti veseali ng
fi ller
cap
2
Fuelcheck
valve
3
Vapor
vent li ne
4
Carboncani ster
S
Vacuum
si gnal
li ne
6 Cani ster
purge
li ne
7
Vaporli qui dseparatorHatchback
models
Removal
and
i nstallati on of above
components are descri bed i n Secti on
FE
The
evaporati ve
emi ssi on control
system
i s
used
to
reduce
hydrocarbons
emi tted
to
the
atmosphere
fromthe
fuel
system
Thi s reducti on
of
hydro
carbons
i s
accompli shed by
acti vated
charcoalsi nthe
carbon
cani ster
FuelHller
cap
Vacuum
reli et
Pressure
regulator
j
Vapor
li qui dseparator
HATCHBACK
model
OnlY
Fuelcheck
valve
I
Fueltank
c
I
Fuelf1lter
Fuel
return
li ne
Z
Fuelreedli ne
1
Fuel
mjector
Fueltank
vapor
vent
li ne
81
Fuel
danlper
J
sendi ng
uni t
Electri cal
fuel
pump
f
Vaporstorage
cani ster
I ntakemani fold
Cani ster
purge
li ne
SEC046
EC 19
Etlaporati ve
Emi ssi on
ContlOlSystrm EMI SSI ON
CONTROL
SYSTEM
rr
OPERATI ON
Fuel
vapors
from
the sealed fuel
tank are
di rectedtothe carbon
cani s
ter
whi ch
i s
fi lled
wi thacti vated
char
coals andstoredthere
when
the
engi ne
i snot
nmni ng
HARDTOP models
ILJ
ri
POsi ti ve
Sea lli 1g gas
cap
wi thaCllumreli ef valve
Vacu1 J111
lli ne7
jFUel
vapor
I
vent li ne
r
n
Fuel
che
L
Freshai r
Fuet
vapor
t
j
L
Fuel
tank
I ntakeffi llI li fOldJ
i j ffJ
SEC041
HATCHBACK
m
odeb
Yaporjli qui d
separator
L J
Vacuumsi gnal
li ne
7
Purge
controli alve
G
tr
I
ILJ
r
Fuel
vapor
vent
li ne
Fuel
check
Fi xedori fi ce
I
Con tant
purge i
li ce
Si
S
i ji i ji
J
si ti ve
seali ng gas
cap
wi th
vacuum
reli ef valve
1
LFUetank
I ntake mani fold J
Fresh
ai r
Fuel
vapor
SEC048
EC20
The
cani ster
retai ns the
vapor
unti l
i t i s
purgedby
the
ai rdrawn
through
the
purge
li ne
towards
the
i ntake
mani foldwhi le
the
engi ne
i s
operai i ng
When
the
engi ne
runsat i dle the
purge
control
valVe i s closed
Only
a
small
amount of
purge
ai rflows i nto
the
i ntakemani fold
through
theconstant
purge
ori fi ce As the
engi ne speed
i n
creases and the
ported
vacuum
ri ses
hi gher
the
purge
controlvalve
opens
and the
vapor
i s drawn i ntothei ntake
mani fold
through
boththe fi xed
ori fi ce
and
the
constant
purge
ori fi ce
I Engi ne
does
not
operate
From
fuel
tank
Fuel
vapor
i
I
umuu 11
l
N
fl
SEC049
1
Di aphragm
2 Purge
control
valve
3 Fi xedori fi ce
4
Constant fi xed
ori fi ce
5 Acti vatedcarbon
Engi ne
operates
at i dle
Freshai r
Fuel
vapor
SEC050
4
Constant fi xed
ori fi ce
5
Acti vatedcarbon
6 Fi lter
1
Di aphragm
2
Purge
control
valve
3 Fi xedori fi ce
EMI SSI ON
CONTROL SYSTEM
Evaporati ve
Emi ssi on Control
System
3
Engi ne
speed
i ncreases
Tocarburetor
CJ
Portedvacuum
Toi ntake
mani fold
@
Freshai r
Fel
vapor
1
Di aphragm
4
Constant
fi xed
2
Pltrge
control
ori fi ce
valve
5
Acti vatedcarbon
3 Fi xedori fi ce 6 Fi lter
I NSPECTI ON
FUEL
TANK
AND VAPOR
VEfo
T LI NE
Check allhosesand
fuel tank I Dler
cap
2 Di sconnect
the
vapor
vent li ne
COnnecti ng
carbon
cani sterto fuel
i ank
3 Connect a
3
way
connectora
manometerand
a cock
or
an
equi va
lent
3
way
charge
cock
totheend of
thevent li ne
4
Supply
freshai r
i ntothe
vapor
vent li ne
through
t
e
cock li ttle
by
li ttleunti l
pressure
becomes
3923kPa
400
mmH20
15
75
i nH20
3way
connector
75 H0
Cock
3kPo400
mmH20
15 i n
2
Ai r
Manometer Check
valve
@
Carboncani ster
5
Shut the cock
completely
and
leave
i t
unattended
6
After25
mi nutes
measure the
hei ght
of the
li qui d
i n
the
manometer
7 Vari ati oni n
hei ght
shouldremai n
wi th 0245 kPa 25
mmH20
098
i nH20
8
When fi ller
cap
does
not close
completely
the
hei ght
should
drop
to
zeroi n
a short
ti me
9
I fthe
hei ght
does not
drop
to
zeroi n
a
short
ti me whenfi ller
cap
i s
removed i t i s the
cause of a
stuffy
hose
I n
case
the vent li nei s
stuffy
the
breathi ng
i nfuel
tank
i s not
thorough
Fuel
fi llercap
EC091A
I y
made thus
causi ng
i nsuffi ci ent
de
li very
of
fuelto
engi ne
or
vapor
lock
I t
must
therefore
be
repai red
or
replaced
CARBON CANI STER PURGE
CONTROL VALVE
Check forfuel
vapor
leakage
i nthe
di stri butor
vacuum li neat
di aphragm
of carbon cani ster
purge
controlvalve
To
check
for
leakage proceed
as
follows
EC
21
Evaporati veEmi on
Control
smem
EMI SSI ON
CONTROL SYSTEM
I
Di sconnect rubbernose
i n
he
li ne
between
T
connectorand carbon
cani ster
at T onnector
2
I nhale ai ri nto
the
openi ng
of
rubber
h
se
runni ng
tovacuumholei n
carbon cani sterand
ensure that there
i s
no
leak
EF199
I
Di sconnect
thblub berllooe
onthe
li ne between the steel
pi pe
of the
engi ne
andcani ster
2
Force ai ri ntothe
openi ng
of the
rubberhosewhi chruns to
ti Je
carbon
canI sterand
ensure that there are
leaks
SEC052
3 I f
there
i s a
leak remove
top
3
I f there are
no
leaks
remove
coverfrom
purge
control
valve
and
purge
controlvalve and check the
check fordi slocated
orcracked di a
constant
purge
ori fi ce forleak I f
phragm
I f
necessary
replace
di a
necessary
clean
the
constant
purge
phragm
ki t whi chi s made
up
oLa
ori fi r
retai ner
di aphragm
and
spri ng
Cover
Di aphragm
Retai ner
t
Di aphragmspri ng
EF200
CARBON
CANI STER
CONSTANT
PURGE ORI FI CE
Check
the constant
purge
flowi n
the
i ntake mani fold
vacuum li ne at
the constant
purge
ori fi ce
of carbon
cani ster
Tocheck the
purge
flow
proceed
as follows
EC
22
SEC053
CARBON
CANI STER FLTER
Check
fora
contami natedelement
Element
can be
removed at the
bottom of
cani ster
i nstalled on
car
body
FUn
TANK
VACUUM
RnlEFVALVE
Remove
fuelfi ller
cap
and see
i t
functi ons
properly
I
Wi pe
clean valve
housi ng
andhave
i t i n
your
mouth
2
I nhale ai rA
sli ght resi stance ac
cornpani edby
valve i ndi cates
that
valve i s i n
good
mechani cal
condi ti on
Notealso
that
by
further
i nhali ng
ai r
the
resi stanceshouldbe
di sappeared
as
valvecli cks
3 I fvalve
i s clogged
ori f no
resi st
ance
i s felt
replace cap
as an assem
bleduni t
r
ET500
FUEL CHECK VALVE
1 Blow ai r
through
connector
on
fueltank
si de
A
consi derableresi stanceshouldbe
felt
at
themouth
and a
porti on
of ai r
flowbedi rected
towardthe
engi ne
2
Blow ai r
through
connector
on
engi ne
si de
Ai rflowshould
be
smoothly
di rect
edtowardfuel
tank
3 I ffuelcheck valvei s
suspected
of
not
bei ng
properly
functi oni ng
i n
steps
I
and2
above
replace
tm
r
ltank
1
e
l
Q
Evaporati ve
fuelflow
Freshai rflow
EC090A
EM
I SSI ON CONTROL SYSTEM
Servi ce Dataand
Speci fi cati ons
SERVI CE
DATA AND SPECI FI CATI ONS
TI GHTENI NG TORQUE
Uni t Nm
kg m
ft lb
Uni t
N m
kg
m ft I b
E G R tube
securi ng
nut
34 44 35 45 25
33
I
V VT valve
mounti ng
37 5 00
38
051
2
7 37
E A I tube
securi ng
nut
44 45
25 33
screw
34 35
Lessthan Lessthan Lessthan
18
P
T valvo
mounti ng
37 5 0038 051 27 37
Thermalvacuum valve
22 22 1 6
screw
I
Catalyti cconverter
bolt 31 42 32 43 23 31
EC
23
DATSUN
200SX Mod
1
S
I I 0
Seri es
SECTI ONER
ENGI NE
REMOVAL
I NSTAllATI ON
CONTENTS
ENGI NE REMOVAL
AND
I NSTALLATI ON
CONSTRUCTI ON
REMOVAL
ER 2
ER 2
ER 2
I NSTALLATI ON
SERVI CE
DATA AND
SPECI FI CATI ONS
TI GHTENI NG
TORQUE
ER
5g
ER
5
ER 5
Engi ne
Removaland
I nstallati on
ENGI NEREMOVAL
I NSTALLATI ON
ENGI NE
REMOVAL AND
I NSTALLATI ON
CONSTRUCTI ON
I i i 3040
3
1 41
22
I i i
44 54
4
5
5 5 33 0
1
I i i N m
I tg m
ft
b
REMOVAL
I t
i s mucheasi er
toremove
engi ne
andtransmi ssi on
as a
si ngle
uni t than
toremove them
separately
After
reo
moval
engi ne
can be
separated
from
transmi ssi on
assembly
WARNI NG
a
Place wheel
chocks
i n
front
of
front
wheels
andi nrearof
rear
wheel
b Be
suretohoi st
engi ne
and
jack
up
transmi ssi on
i n
a safe man
nero
C
You
should
not
remove
the
engi ne
unti lthe
exhaust
system
has
completely
cooledoff
Otherwi se
you
may
burn
your
self
and
or
fi re
may
break out
i n
fuelli ne
I
FoUow the
procedure
below to
reducefuel
pressure
tozero
ER
2
CAUTI ON
Before
di sconnecti ng
fuelhose
release
fuel
pressure
fromfuelli neto
eli mi
nate
danger
I
Start the
engi ne
2 Di sconnect the
harness connector
of fuel
pump
relay
2 whi le
theen
gi ne
i s
runni ng
Relay
bracket
SEF131
3 After
the
engi ne
staUs
crank the
engi ne
twoorthree
ti mes
87
8 7
19
I i i 3040
3 1 4
1 22 30
31 42
3
2
43
23
31
SERD01
4 Turn
the
i gni ti on
swi tchOFF
5
Reconnect tJi e harness connector
offuel
pump
rel
y
2
Fnd r
co shCll
ld b
uBI to
protect
car
body
2
Di sconnect
the
negati ve
battery
cable
On ai r
condi ti on
r
aqui pped
modls
desti ned for
Cali forni a remon tho
battery
to
faci li
thi s
operati on
3 Drai n
engi ne
coolant
4 Removehood
Mark tholocati on
of
hood
hi nges
on
hood to
faci li tot correct rei nsta
loti on
CAUTI ON
Have
an
assi stant
help you
soas to
PI I
vent
damage
to
body
5
RemoveaU wi res
and
hoses
where
i ndi cated
by
the
arrows
i n
the
fi gure
below
ENGI NE
REMOVAL
I NSTALLATI ON Engi ne
Removs andI n tallati on
1
u
Ai rcondi ti onerequi pped
models
Remove
compressorfoUowi ng
the
procedures
below
I
Remove
compressor
dri vebelt
To
remove thi s belt loosen
both
i dler
puUey nut
and
adjusti ng
bolt
P
fi
qa
9
5
ey
nut
a
1
n
djUS
i ng
I
11
l
I
AOO
Yr
p
t
1
J
0
2
Remove
compressor
Place
removed
compressor
as
shown
below
Neerd
i lCherge
gas from
compres
sor
whi leservi ce
repai r
work i s
bei ng
performed
I I I
r
I
o
o
SER003
Power
steeri ng
equi pped
models
Remove
powersteeri ng
oi l
pump
foUowi ng
the
procedures
below
I
Remove
oi l
pump
dri vebelt
To
remove
thi s
belt
loosen both
i dler
puUey
nut and
adjusti ng
bolt
ER 3
Engi ne
Removaland
I nstallati on ENG I NE REMOVAL I NSTALLATI ON
2
Removeoi l
pump
Place removed oi l
pump
as shown
below
Neverdrai noi l
from
oi l
pump
whi le
sorvi ce
repai r
rki
bei ng perfonnod
6
Remove transmi ssi on
controlli nk
age
as foUows
1
Manual
transmi ssi on
E 33 i W
2 Automati c
transmi ssi on
7 Remove
radi atorand radi ator
shroud
On
ai rcondi ti oner
equi pped mo
dels remove
oi l
coolerho
ER
4
SER010
I
g
Di sconnect
speedometer
cable
9
Di sconnect down shi ft solenoi d
wi reand i nhi bi torswi tchwi re
AfT
only
10Di sconnect vacuum hose
AfT
only
I I Removeclutch
operati ng
cyli nder
front exhaust tubeand
propeUer
shaft
Place
marks
on
propeller
haft be
fora
remo
altofaci li tate
rei nstall
ti on
Mk 1 ar
mgp
SER024
Plug open
holes i n
rear
extensi on
housi ng
as
hown
12 Attachsui table
wi res
to
engi ne
sI i ngers
andrai se
engi ne
usi ng
ahoi st
to
take the
wei ght
off front
and
rear
mount i nsulators
WARNI NG
BeforB
rai si ng engi ne try looseni ng
wi res twoorthree
ti mes
tomake
surei t i s safetodoso
I 3 Remove
rear
engi ne mounti ng
support
to body
aUachi ng
bolts
ENGI NE
REMOVAL I NSTALLATI ON
Servi ceDataandSpeci fi cati ons
14 Remove front
engi ne mounti ng
bolts
15 Rai se
engi ne
andtransmi ssi on
and
removethemfromcaras
a
si ngle
uni t
WARNI NG
When
rai si ng engi ne
be
especi ally
careful
not
toknock i t
agai nst
ad
jacent parts
16 Set engi ne
and transmi ssi on
onan
engi ne
stand
I NSTALLATI ON
I nstaU
i n
the reverse orderof reo
moval
observi ng
the
foUowi ng
When
i nstalli ng
be luretocheck
that electri cal
heme
are
correcdy
connected
I
When
i nstalli ng
fi rst secure rear
engi nesupport
bracket torearmount
i ng
i nsulator
2 Referto
perti nent
secti on when
i nstalli ng
and
adjusti ng any parts
Adjust
accelerator
control
system
Referto
Engi ne
Control
System
Secti on FE for
adjustment
I nstaU
ai r
condi ti oner
compressor
and
adjust
belt
Referto
Engi ne
Mai ntenance See
ti on MA for
checki ng
and
adjust
i ng
dri ve
belts
I nstaU
power
steeri ng
oi l
pump
and
adjust
belt
Refer
to
Pump
Belt
Adjustment
Secti on
ST
for
adjustment
3 When
i nstalli ng
exhaust front tube
on
exhaust mani fold be
sure
toi nstaU
a new
gasket
4
When
rei nstalli ng
thehoodfoUw
i ng engi ne
i nstaUati on be
surethat
i t
i s
properly
centered
and that
hood
lock
operates securely
RefertoHood
Secti on BF
for
adjuslment
5 Add
the
correct amount of
engi ne
coolant
6 Forautomati ctransmi ssi on
mod
els
add
thesameamount ofautomati c
transmi ssi on
flui d
as
wasdrai ned
SERVI CE
DATA AND SPECI FI CATI ONS
TI GHTENI NG
TORQUE
Uni t
N
m
kg m
ft I b
Front
engi ne
support
bracket
tocyli nder
block 30
40 31 41
22 30
Front
engi nesupport
bracket to
mounti ng
i nsulator
31 42
3
2
43 23 31
Front
mounti ng
i nsulatorto
body
31 42
32 43
23 31
Compressor
tobracket
44 54
45 5 5
33 40
Steeri ng
oi l
pump
tobracket
19 25 19 26
14
19
Rear
mounti ng
i nsulator
totransmi ssi on 88
118 09 12
6
5
8
7
Rear
mounti ng
i nsulatorto
mounti ng
member
88 11 8
09 12
65
8
7
Mounti ng
memberto
body
2042 2 43
14 31
Exhaust mani floldtoexhaust tube
2025 2
0
2
6
14 19
Clutch
operati ng cyli nder
to
engi ne
3040 31 41
22
30
ER
S
DATSUN
200SX
Mode S110
Seri es
SECTI ONFE
ENGI NE
CONTROL
FUEL
EXHAUST
SYSTEMS
CONTENTS
ENGI NE
CONTROL
SYSTEM
ADJUSTMENT
REMOVAL
I NSPECTI ON
I NST
ALLATI ON
FUEL
SYSTEM
REMOVAL
FE 2
FE 2
FE 3
FE 3
FE
3
FE 4
FE
5
I NSPECTI ON
I NSTALLATI ON
EXHAUST
SYSTEM
REMOVAL
I NSPECTI ON
I NSTALLATI ON
FE
6
FE 7
FE S
GI I
FE 9
FE 9
FE 9
EngjneControI Syltem
ENGI NE
CONTROL FUEL EXHAUST SYSTEMS
ENGI NE CONTROL SYSTEM
Adjusti ng
bet nut
Ptdal
free
play
o 2
mm 0
0
08i n
frPedaI
arm
I i i
2 9 39
03 0
4
2
2 29
Pedalarm
brlcket
t
j
aI
t
etum
PlUI ll
I i i
N
m
kg
m
ft
lb
SFEQ01
ADJUSTMENT
ACC RATOR
WI llE
Adjust
accelerator
pedal
free
play
to
speci fI Cati on usi ng
a
djusti ng
nuts
a
Depress
accelerator
pedal
to
make
I ura
i ts
li nkage
moves
lI DootI tly
wi thout
jammi ng
or
draggi ng
re
lease
pedal
tomake
lure
i t
returns
toi ts
ori gi nalposi ti on smoothly
b Check
tosee
i f throttlevalve
fully
open
when
accelerator
pedal
i
completely
depressed
and i f i t
returns to i dle when releasad
c Pedal
hei ght adjustment
i not
necessary
si nce i ts
hei ght
i s deter
mi ned
by stopper
SFEOO3
FE
2
ENGI NE
CONTROL
FUEL EXHAUST SYSTEMS Engi ne
Control
System
REMOVAL
ACCELERATOR
WI RE
I Loosen
adjusti ng
lock nuts and
di sconnect accelerator
wi refrom car
buretor
2 Remove
nylon
coUar
by pushi ng
i t
toward
wi re end and di sconnect
accelerator
wi re from
pedal
ann
SFE154
3
Remove
pedal
stopper
bracket
and
extract accelerator
wi re toward
passenger
compartment
SFE155
ACCELERATOR
PEDAL
Remove
nylon
collarand di scon
nect accelerator
wi refrom
ti p
of
pedal
arm
Then
remove
pedal
arm
assembly
by removi ng
pedal
armbracket
retai n
r
i ng
01t
EF156
I NSPECTI ON
I Check
pedal
return
spri ng
forrust
fati gue
or
damage
Replace
i f neces
sary
2
Check
acceleratorwi re cases
socket andfasteni ng
locati ons for
rust
damage
orlooseness
Repai r
or
replace
i fnecessai y
I NSTALLATI ON
To
i nstaU reverse the order
of
removal
a
Check
accelerator
contror
parts
for
i mproper
contact wi th
any
ad
jacent parts
b When connecti ng
acceleratorwi re
becarefulnot totwi lt or
scratch
i ts
i nner
wi re
c On automati ctransmi ssi onmodels
depress
accelerator
pedal
tomake
su
that ki ckdown
swi tchturn
on
when
throtti e
alve i s
fully open
and
t t
push
rod
mo
properly
FE
3
m
J
Hatchback
Fuel
check
vol
Fuel
fi ller
hose
10
k
I
c
pate
uel
tankaauge
uni t
O
i ng
Hardtop
Fuel
fi ller
cap
Fuel
fi ller
tube
Venti lati on
ho
Fuel
fi ller
hole
Fuel
outlet
hoae
Fuel
fetum
hOle
o
Fuel
outlet
tube
Fuel
return
tube
Enporati on
tulx
I I mQQom
Fuel
tank
I i i
14
18N
m
1
4
1
8
I tg
m
10
13
fHb
I i i
N
m
kg
m
fHb
mren enI
mi
r
l
I
mZ
G
Zm no
zl0
o
r
T1Cm
r
ll
mXJI c
Cl
lCl
Cll
m
s
Cl
REMOVAL
WARNI NG
When
replaci ng
fuelli ne
parts
be
sure to
observe the
followi ng
a
put
a CAUTI ON
I NFLAM
MABLE
si gn
i n
workshop
b Be
sure
tofurni sh
workshop
wi th
an
asphyxi ator
c Be sure todi sconnect
battery
ground
cablebefore
conducti ng
operati ons
d Put drai ned
fuel
i n an
explosi on
proof
contai nerand
put
on
li d
secu
rely
FUELTANK
1 Remove
battery
ground
cable
2 Drai n fuel
fro
fueltank
3 Remove
protector
from luggage
compartment
and then
remove the
foUowi ng
parts
Harness
connectorfor
fueltank
gauge
uni t
Venti lati onhose
Evaporati on
hoses
Fuelfi llerhose
Hatchback
Hardtop
Harness
connector
Venti lati on
hose
HatchbackrHai nei S
nnector
A
Venti lati on
hose
b1J
o
o
o
SFE010
4
Remove the
foUowi ng parts
from
undersi deoffloor
Fueloutlet hose
Fuelreturnhose
ENGI NE
CONTROL
FUEL EXHAUST
SYSTEMS
Fuel
System
Evaporati on
hose
Fuelfi llerhose Hardtop
5 Remove
bolts
whi chsecure fuel
tank i n
place
and
di smount fueltank
SFE012 1 4
18N m
3ft lb
RESERVOI R
TANK
Hatchback
I Remove
battery ground
cable
2 Remove
protector
from
luggage
compartment
Also remove
R
H
speaker
and si de lowerflni sher
l
SFE013
3
Remove
evaporati on
hoses and
thenremovereservoi rtank
FUEL
TANK
GAUGE UNI T
I Di sconnect
battery ground
cable
2
Remove
protector
from
luggage
compartment
and di sconnect
harness
forfuel
tank
gauge
uni t
Alsoremove
rubber
grommet
3
Turn
lock
plate
counterclockwi se
andextract fuellank
gauge
uni t
FUEL FI LLER
TUBE AND
HOSE
I
Di sconnect battery
ground
cable
2
Drai n fueli f fuel
overfloWs when
di sconnecti ng
bothfuelfi ller
tubeand
hose
3
Open
fuelfi llerli d remove
fuel
fi ller
cap
and
remove fuelfI ller
attachi ng
bolt
G
i i
I
j
1
2
uelfi llerp
SFE016
FE
S
Fuel
System ENGI NE CONTROL FUEL
EXHAUST
SYSTEMS
4 Remove
fuelfi llertube
andhose
as
follows
Hardtop
1
Di sconnect fuel
fi llerhose from
fuel
al k
undersi deof
floor
2 Remove
protectors
from
luggage
compartment
and
di sconnect
venti la
ti onhose
Remove fuelcheck valve bracket
andthen extract bothfuelfi llertube
andhose
Hatchback
Remove
protectors
from
luggage
compartment
Also
removerear
speak
er
and si de lowerfmi sherfrom
ri ght
si de of
luggage compartment
Di s
ccmnect
evaporati on
hoses venti lati on
hose and fuelfi llerhose from fuel
tank andthen
remove
fuelfi llertube
ari dhose
1
Fuelfi ller
t
be
1fi ller
110
I
SFE018
FUELCHECK
VALVE
Remove fuel
check valve as fol
lows
Remove
protectors from
luggage
compartment
Di sconnect fuel
check
valvefrom
evaporati on
hose
FE 6
Hardtop
D
9
cl1eckvalve
SFEO
FUELTUBE
Fueltubes areservi cedas anassem
bly How
erdonot di sconnect
any
fuel
li ne
unless
absolltely
necessary
I Di sconnect
batlery
ground
cable
2 Drai n fuelfromfuel
tank
3
Loosen fuelhose
clamps
and
di sconnect fuel
tube
at each end
Plug
hose and tube
openi
ng
to
prevent entry
of dust
or
di rt whi le
removi ng
4 Removefuel
tube
clamps
andfuel
pump
bracket
from
underbody Re
move
fueltubes andfuel
pump
as an
assembly
Leave brake
tubeonunder
body
FUEL
PUMP
DAMPER
AND FI LTER
Referto
Secti onEF
I NSPECTI ON
FUEL TANK
Check
fueltank
forcracks
or
defor
mauon I fo
ecessary replacl
FUEL TANKGAUGE
UNI T
Refer
toFuelTank
Gauge
Uni t Jor
i nspecti on
Secti on EL
FUEL
FI LLER TUBE
AND
HOSE
I nspect
aU hoses and tubes for
cracks
fati gue sweati ng
ordeteri ora
ti on
Replace any
hose ortube that
i s
damaged
FUEL CHECK VALVE
Referto FuelCheck Valve for
i nspecti on
Secti on
EC
FUEL TUBE
Replact
any
fueltube
1hat
i s
crack
ed rusted
coUapsed
ordeformed
FUEL PUMP
FUEL DAMPER
AND
FUEL
FI LTER
RefertoFuel
Pump
Fuel
Damper
and
FuelFi lterfor
component
parts
i nspecti on
Secti on EF
ENGI NE
CONi fROL
FUEt
EXHAUST
SYSTEMS FueI Sysll1
I NSTALLATI ON
I nstaU any
parts
of
the
fuelsystem
i n the reverse
orderof removal
Observe
the
foUowi ng
notes andrefer
to Fuel Fi lter
Fuel
Pump
Fuel
Darnper
aod Fuel
Hose forremoval
aod
i nstaUati on Secti on
EF
GJ
Fuel
tan
k
retai ni ng
bolt
14 18N m
1 4 1 8
kg
m
10
13ft lb
a
I nstall
hoe
clamp ecurely
Donot
ti ghten
excessi vely
toavoi d
damag
i ng
hose
b Fasten fueltube
clamp
onund r
body ecurely
Fai lure to
follow
thi s cauti on could
result i n
damage
tothe
urf
e
of fueltube
c Donot ki nk
ortwi st
ole
andtube
when
they
are
routed
d
Run
the
engi ne
andcheck
forleak
at
connecti on
e Fuel
tank
I nstall
fuel
fi llerhose
etterfuel
tank has been
mounted i n
place
Fai lure tofollow thi s
rule could
result i n lea
ge
from around
hose
connecti ons Donot twi st orsmash
venti lati on and
evaporati on
hoses
when
they
are
routed
Be sure
to
retai n them
wi th
cli ps securely
f
Fueltank
gauge
uni t
When
i nstalli ng
fuel
tank
gauge
uni t
ali gn
tlle
projecti on
of
fuel
tank
gauge
uni t
wi ththe notchi n
fuel
tank and
ti ghten
i t
ecurely
Be
sure to
i nstallfueltank
gauge
uni t
wi th
Q
ri ng
i n
place
FE 7
fflermo
ti r18
Upper
mu
raCket
8
I i i
7
8
11
58
8
7
0
81
2
gg
I
Lower
mumer
1i
mountlos
1
bncket
@
1
7
@
8
7
m
Co
I i i
7
8
11
8
0
8
1
2
5
8
LI i i
2
9
4
9
0
3
0
5
Front
exhaua
tube
2
2
3
6
I i i
2
9
4
9
0
3
0
5
2
2
3
6
Front
ePaust
tube
lower
heat
i ni ulatOJ
m0
I I Umer
bond
opper
I i i
7
8
H
8
0
8
12
5
8
j
ounli ll8
Ri I l8
rUbJer
fj
7
8
H
8l
0
8
12
5
8
8
7
I
Exhaust
murtler
Catalyti c
converter
4
23
31l
8
7
Rear
mutner
mounti ng
l
I i i
7
8
1l
8
0
8
1
2
5
8
8
7
1fJ7
8
H
8
0
8
12
5
8
8
7
I i i
N
m
kg
m
ft
b
m J
I i cf
f f m
3
lI
11 m
ZcZ
m
oZlDo
rCm
r
I i
mX
I C J
J
lm J
ENGI NE CONTROL FUEL
EXHAUST
SYSTEMS ExhBustSystem
REMOVAL
FRONT TUBE
1
Remove
catalyti c
converter
lower
shelter
2 Remove bolts
ornuts
attachi ng
front exhaust tube toexhaust
mani
foldandfront tube
mounti ng
bracket
Front tubecan then
beremoved
SFE025
CATALYTI C CONVERTER
Remove
catalyti c
converterlower
shelterand
remove
catalyti cconverter
CAUTI ON
a Be
carefulnot
to
damage
catalyti c
converterwhen
handli ng
b
Neverwet
catalyti c
converterwi th
wateroi lm
SF
E026
EXHAUST
MUFFLER
L li ft
up
car
wi th
a
framehoi st
2 Remove
catalyti c
converterlower
shelter
3 Remove bolts
attachi ng
exhaust
mufflerto
catalyti c
converterremove
rear
muffler
mounti ng
nut
andrubber
ri ngs
Di smount
exhaust
muffler
throughunderbody
and
rear
axlecase
I
Exhaust
muffler
1
U
SFE027
I NSPECTI ON
I Check mufflerand tubes for
cmcks
damageor
corrosi on
Replace
any
parts
that i s
damaged
beyond
li mi ts
2
Replace
bracket and
hanger
rub
ber
parts
that arecracked
fati gued
or
sweated
I NSTALLATI ON
I nstaU theexhaust
system parts
i n
the
reverseorder
ofremoval
i fl
Exhaust mani foldtofront
tubenuts
26 31 N m
2 7 32
kg
m
2023
ft lb
Front tube
mounti ng
bracket
nuts
7 8 11 8
N
m
0
8
1 2
kg
m
5
8
87 ft lb
Catalyti c
converter
attchi ng
bolts
31 42
N
m
32 43
kg
m
23
31 ft lb
Rearmuffler
mounti ng
i nsulator
nut
7 8 11 8N m
08 1 2
kg
m
5 8 87 ft lb
Mufflerband
stopper
attachi ng
bolts
7 8 11 8N
m
08 1 2
kg m
5 8 8i ft lb
Muffler
mounti ng
bracket B
7 8 11
8
N m
08 1 2
kg
m
5 8 87 ft lb
Heet hi ei i l
plate ecuri ng
bolt
29 49N
m
0
3 05
kg
m
2 2 36
ft lb
a
Keep
suffi ci ent clearance
between
exhaust
system components
and
underbody adjacent parts
b
Replace
ga
ket
for
catalyti c
con
verter
andforfront tubewi thnew
one
when
removed
c After
i nStallati on check that
mounti ng
brackets and
mounti ng
rubbers arefree
from
unduestress
I f
any
of the above
part
i
not
i nstalled
properly
excessi ve
noi se
orvi brati ons
may
betransmi ttedto
the
car
body
d Wi th
engi nerunni ng
check
alltube
connecti on
forexhaust
gas
leaks
and enti re
system
for
unusual
noi ses
FE
9
NG
N
CON
ROL
fU
L
E1
AUS
S
S
e
f
j
q
o
E
1
1
j
j
I I
I I
a
P
A
Q
9
1
a
Q
oJ
a
j
6
jO
e
SFI
DATSUN
200SX
Mode S
I I 0Seri es
SECTI ONCL
HYDRAULI C CLUTCHCONTROL
CLUTCHPEDAL
CLUTCH
MASTER
CYLI NDER
OPERATI NG
CYLI NDER
CLUTCH
LI NE
BLEEDI NG CLUTCHSYSTEM
CLUTCHUNI T
CLUTCH
DI SC AND COVER
RELEASE
BEARI NG
CLUTCH
CONTENTS
CL 2
l
Ci 2
CL 2
CL 4
t
5
CL
5
C
7
CL 7
CL 9
PI LOT BUSHI NG
SERVI CE
DATA AND
SPECI FI CATI ONS
GENERAL SPECI FI CATI ONS
I NSPECTI ON
AND
ADJUSTMENT
TI GHTENi NG TORQUE
TROUBLE
DI AGNOSES AND
CORRECTI ONS
SPECI AL SERVI CE TOOLS
CL
9
CL11
clli
CL11
CL11
CL12
CL14
RefertoSecti on
MA Clutchfor
CHECKI NG
CLUTCH
PEDAL HEI GHT
AND FREE
PLAY
Hydrauli c
CutJ h
Conrrol
CLUTCH
HYDRAULI C CLUTCH
CONTROL
CLUTCH
PEDAL
REMOVAL
1
Remove
i nstrument lowercover
2
Pry
off
snap pi n
and
take
out clev
i s
pi n
0
o
3
SCLOOl
1
li ri ng
1 Return
spri ng
3 Oevi
pi n
4
Stopper
bolt
5
Outchpedal
3 Remove
stopper
bolt
4
Remove E
ri ng
on fulcrum
pi n
then remove clutch
pedal
andreturn
spri ng
I NSPECTI oN
I nspect
the
foUowi ng
parts
I f
ab
nonnali ti esarefound
repai r
or
replace
the
affected
parts
I
Clutch
pedalbushi ng
D
at
boss
fulcrum
pi n
V
and E
ri ng
@
for
weardeformati onor
damage
Bushi ng
i J
p fi tted
I f
i t
shows
si gn
of
abnonnali ty replaca
pedal
as
sembly
2 Clevi s
pi n
@
forwearor
damage
and
snap pi n@
for
any
deformati on
3
Pedal
@ pedalpad
j
and
pedal
stopper
@
orclutchswi tch forde
formati on or
damage
4
Return
spri ng
@
for
fati gue
or
damage
Cl
2
rD
G
SC
l002
l
I NSTAllATI ON
I I nstallclutch
pedal
i n
reverse
or
derofremoval
ObservefoUowi ng
a
Apply
grea
toboss of
clutch
ped
alreturn
spri ng
and
fi i h
rum
pi n
SCL003
b
Fi rmly
attach
E
ri ng
to
fulcrum
pi n
SCL0Q4
Q
Co
I nstallclevi s
pi n
on tha left of
clutch
pedal
and attach
snap pi n
sa
curaly
d I nstallreturn
spri ng
as
shown i n
Fi gure
on
thi s
page
2
After
assembly
adjust
clutch
ped
aI
hei ght
andfree
play
Referto
Checki ng
ClutchPedal
Hei ght
andFree
Play
Secti on
MA
tV
Pedal
rtoppar
locknut
7B
11 8N
m
10
8
12
kg
m
5 8 87ft lbl
CLUTCHMASTER
CYLI NDER
REMOVAL
I
Remove
snap pi n
fromclevi s
pi n
2 Pull
out clevi s
pi n
3 Di sconnect clutch
tube
4 Remove
master
cyli nder
When
di sconnecti ng
clutchtube
be
sure
to
recei drai ni ng
clutchflui d
i ntoa contai nerUse
of
rags
i s also
suggestad
to
keep adjacent parts
and
area dean
CAUTI ON
When
di sconnecti ng
dutchtube use
sui tableflarenut wrench
Neveruse an
open
end wrenchor
adjustable
wrench
DI SASSEMBLY
CLUTCH Hydni uli c
ClutchControl
I
Remove
dust
cover
and take
off
stopperri ng
t1
SCLOO6
2
Then the
push
rod and
stopper
can betakenout
3
Loosen
stopper
bolt and take
i t
out
4
The
pi ston spri ng
seat and
return
spri ng
can be
taken
out
Di scardpi ston
cup
and ust
cover
i r
Reservoi rband
1
I i i 78
11
8 08
Stoppetbol
Return
spri ng
12
5
8 8 7
CAUTI ON
Neverdetachreservoi r
I f
i t i sremoved
for
any
reason
di scard i t andi nstall
newone
I NSPECTI ON
CAUTI ON
Toclean orwash
all
parts
of master
cyli nder
clean brake flui d must be
used Never
use mi neraloi ls suchas
gasoli ne
andkerosene I t wi ll
rui nthe
rubber
parts
of the
hydrauli c
system
1 Check
cyli nder
bore
and
pi ston
forscore orrust andi f
fond
replace
2
Check
cyli nder
bore
and
pi ston
Lock
nut
li i 7
8
11
8
08
12
5
8 8
7
I i i
Nm
kg m
fHb
SCL005
for
wear
I f the
clearance between
cyli nder
bore
and
pi ston
exceeds
speci fi ed
value
replace pi ston
as
sembly
ormaster
cyli nder
assembly
Cearancebetweencyli nder
boreand
pi ston
Le than
015 mm
0
0059i n
3
Check
condi ti on of
pi ston cup
and dust cover
Always replace
them
after
di sassembly
4 Check aU recesses
openi ngs
and
i nternal
passages
toensure
that
they
are
clean andfree from
forei gn
matter
ASSEMBLY
I
Apply grease
to
cyli nder
body
sli di ng part
and
pi ston
cup
CL3
Hydrauli cC1u
th
Control
CLUTCH
2
I nstall
pi ston assembly
to
cyli nder
body
Be
careful
not to
damage pi ston
cup
4 Make
sure
that
master
cyli nder
operates
normally
5
Make
sure thai
pi ston
can move
maxi mumsi roke
smoothly
Stopper
bolt
1
5
2
9
N m
015 03
k9
m
1 1 22 ft lb
I NSTALLATI ON
I nstaU clutchmaster
cyli nder
i n
reverse orderof removalObserve
foUowi ng
I Bleedai r
out
of
hydrauli csystem
Referto
Bleedi ng
Clutch
System
2
Adjust pedalhei ght
and
pedRl
free
play
Referto
Checki ng
ClutchPedal
Hei Rht and
Free
Play
Secti on
MA
Master
cyli nder
to
dash
panel
HCUri ng
nut
7 8 118N m
08 12
kg m
58 87 ft
bl
Clutchtubeflarenut
15 18N m
1 5 1 8
kg m
11 13ft b
Pushrodlock nut
7
8 11
8N
m
0
8 1 2
kg m
5
8 8
7
ft bl
CAUTI ON
When
connecti ng
dutchtube useTool
GG94310000
I
J
When
ti ghteni ng
flare nut
hold
pi
by
handto
prevent
i t from
twi st
i n9
OPERATI NG
CYUNDER
REMOVAL
L
lo9sen
clutch
tl
be
flare nut
at
thebracket
on
si demember
Cl 4
I
fTI
scL001
CAUTI ON
When
di sconnecti ng
clutchtube use
sui tableflare
nut
wrench
Neveruse an
open
end
wrench
or
adjustable
wrench
2 Remove
lock
spri ng
then di s
engage
hosefrombracket
3 Remove clutchhose from
oj er
ati ng
cyli nder
4
Remove
operati ng
cyli nder
DI SASSEMBLY
I
Removedust coverand
push
rod
2
Remove
pi ston
and
pi ston cup
as
an
assembly
Di scard
pi ston
cup
and dun
cover
3
Removebleederscrew
CL222
1 Pushrod
2 Dwt
cover
3 Pi ston
spri ng
4 Pi ston
5 Pi ston
cup
6
Operati ng cyli nder
7 Bleederscrew
I NSPECTI ON
Vi sually
i nspect
alldi sassembled
parts
and
replaceparts
whi chareworn
or
damage
CAUTI ON
Toclean orwashall
parts
of
operati ng
cyli nder
clean brake
flui d
must be
used
NeverUSe mi neral
oi ls suchi s
gasoli ne
andkerosene
I t
wi ll
rui n therubber
parts
of the
hydrauli c
system
I Check
cyli nderbore and
pi ston
forscoreor
rust and
i ffound
replace
2 Check
cyli nder
bore and
pi ston
for
wear
I f
clearancebetween
cyli nder
bore and
pi ston
i s
more than
the
speci fi edvalue
replace
pi ston
or
oper
ati ng cyli nderassembly
Cearancebetween
cyli nder
bore
and
pi ston
lessthan015 mm
00059i n
3 Check
condi ti on of
pi ston
cup
and
dust cover
Always replace
them
after
di sassembly
heck
bleederholnobesurnhat
i t i s
clean
ASSEMBLY
Assemble
operati ng cyli nder
i n
reverse
order
of
di sassembly
Observe
followi ng
I
Pri orto
assembly di p
a new
pi s10n cup
i n
clean brake flui d To
i nstall
pi ston
cup
on
pi ston pay
parti cular
attenti on
toi ts di reci on
2
Di p cyli ndernd
pi s10n
i n
clean
brake
flui dbefore
assembly
I NSTALLATI ON
I nstall
operati ng cyli nder
i n
reverse
orderof removalObserve
foUowi ng
Bleed ai r
thoroughly
from clutch
hydrauli c system
Referto
Bleedi ng
Clutch
System
8 When
operati ng
cyli nder
i srmoved
from
or
i nstalled
on
elutchhou
i ng
wi thout
di sconnecti ng
clutch
hose from
operati ng cyli nder
loos
en
bleeder
scrow sothat
push
rod
moves
li ghtly
b Exerci se care not
to
warp
ortwi st
clutch hose
Be
sure to
i nstall
clutch
hose
away
from exhaust
tube
c
When
ti ghteni ng
flare
nut hold
pi pe
by
hand to
prevent
i t
from
twi sti ng
CAUTI ON
When
connecti ng
clutchtube useTool
GG94310000
li
Bleederscrew
69
88
N
m
0
7 09
kg
m
5 1
65 ft lb
Operati ng cyli nd
r
10
clutch
housi ng securi ng
bolts
3040N
m
3 1 41
kg
m
22
30
ft
lb
Clutch
hose to
operati ng cyli nder
17 21 N m
1 7 2
1
kg
m
12
15 ft lb
CLUTCH
UNE
I NSPECTI ON
Check clutchli nes tubeand
hose
forevi denceof cracks deteri orati onor
other
damage Replace
i fnecessary
I f
leakage
occurs
at
or
around
joi nts reti ghten
and
i f
necessary
re
placedamagedparts
REMOVAL
CAUTI ON
When
di sconnecti ng
clutchtube use
sui table
flare
nut wrench
Neveruse
an
open
end
wrench
or
adjustable
wrench
I Di sconnect clutch
tube
from
clutch
hose at bracket on si de memo
ber
2 Remove lock
spri ng
then di sen
gage
hose
frombracket
3 Remove
clutch
hose from
oper
ati ng
cyli nder
4
Di sconnect clutchtubefrom
mas
ter
cyli nder
5
Remove
clamp
fi xi ng
clutch
tube
to
dash
panel
I NSTALLATI ON
Wi pe
the
openi ng
ends
of
hydrauli c
li ne
to
remove
any forei gn
matter
before
maki ng
connecti ons
I I nstallclutch
tube
I
Connect
clutchtube tomaster
cyli nder
wi thflarenut
2 Fi x clutchtube to
dash
panel
wi th
clamp
3 Then
ti ghten
flarenut
li
Clutchhose tomaster
cyli nder
15
18N m
1 5 1 8
kg
m
t1
13ft lb
2 I nstallclutch
hose on
operati ng
cyli nder
wi th
a gasket
i n
place
Usenew
gasket
li
Clutchhose to
operati ng
cyli nder
17 21 N m
1 7
2 1
kg
m
12 15 ft lb
3
Engage opposi te
end
of
hose
wi th
bracket I nstall
lock
spri ng
fi xi ng
hose
tobracket
a When
ti ghteni ng
flare nut
hold
pi pe by
hand to
prevent
i t from
twi sti ng
b Exerci se carenot
to
warp
or
twi st
clutch
hose
4
Connect
clutch
tube
to
hose wi th
flare
nut
and
ti ghten
i t
li
Flarenut
15 18N m
1 5 1 8
kg
m
11
13
ft lb
5 Check di stance
between clutch
li ne
and
adjacent
parts
especi ally
be
tween
hoseand
exhaust tube
6 Bleed
ai r
out of
hydrauli c
sys1em
Referto
Bleedi ng
Clutch
System
for
adjustment
CLUTCH
Hydrauli c
ClutchControl
CAUTI ON
When
ti ghteni ng
flare nut use Tool
GG94310000
BLEEDI NG
CLUTCH
SYSTEM
The
hydrauli c
clutch
system
must
be
bled
wheneverclutch
li ne
has
been
di sconnectedor
ai r
has
enteredi t
I Remove
cap
of
reservoi r
and
top
up
wi threcommendedbrake
flui d
I
o
SCLoDe
2
Thoroughly
clean
mud and
dust
from
bleederscrew
of
operati ng
cyli nder
so
that outlet hole
i s
free
from
any forei gn
materi alI nstall
bleeder
hose
vi nyl
hose
on
bleeder
screw
Place
the
other
end
of
i t i n a
con
tai nerfi lled
wi thbrakeflui d
J
SCL009
CL5
Hydrauli cClutchControl CLUTCH
3 Have a coworker
depress
clutch
pedal
twoorthreeti mes
Wi thclutch
pedal
depressed fully
loosen bleeder
screw
to
bleed ai rout of clutch
system
CD
Depress pedal
twoorthreeti mes
dlll
y
I
Ii lr
j
CJy
@
SCL010
CL 6
4
Close bleeder
screw
qui ckly
as
clutch
pedal
i s
ondown
stroke
S
Allowclutch
pedal
10return
slow
ly
wi thbleeder
screwclosed
6
Repeat
steps
3
through
5 unti lno
ai r
bubbleshowsi n
the
vi nyl
hose
Gl
Bleeder
screw
69 88N
m
07 09
kg m
5 1 65 fHbl
7
Depress and release dutch
pedal
severalti m
s then check
for
external
hydrauli c
leaksat connecti ons
a Brake flui d
contai ni ng
ai ri whi te
andhasvi si bleai rbubbles
b Brake
flui d
contai ni ng
noai rruns
out
of
bleederscrew
i n
a
soli d
stream
wi thout ai r
bubbles
c
Pay
close attenti on toclutch
flui d
leve i n
reservoi r
duri ng
bleedi ng
operati on
d Add brake
flui d to
reservoi r
only
up
to
h
f
tl
leyel
qo
not
overfi ll
CAUTI ON
a Donot
re use
brake
flui d drai ned
duri ng bleedi ng
operati on
b
Exerci se
care
not to
splash
brake
flui d on exteri orfi ni sh
as i t wi ll
damage
the
pai nt
cWhen
ti ghteni ng
flare
nut useTool
GGg4310000
CLUTCHUNI T
CLUTCHDI SC
AND COVER
CLUTCH Clutch
Uni t
REMOVAL
Be
sure
toturn
them
out
i na
cri sscross
fashi on
I Remove transmi ssi on
from
engi ne
RefertoRemovalSecti on
MT
2
I nsert
Tool
i ntoclutchdi sc
hub
@
4
Remove clutchdi sc and cover
assembly
3 Loosen bolts
attachi ng
clutch
coverto
I lywheel
one turn eachat a
ti me unti l
spri ng pressure
i s
released
I NSPECTI ON
Washall
di sassembled
parts except
di sc
assembly
i n sui table
cleani ng
SCLOll
solvent
to remove
di rt and
grease
before
maki ng
i nspecti on
and
adjust
ment
Flywheel
endpressure
plate
Check
fri cti on surface of
I lywheel
and
pressure plate
for
scori ng
or
roughness Sli ght
roughness
may
be
smoothed
by usi ng
fi ne
emery
clothI f
surface i s
deeply
scored
or
grooved
the
part should
be
replaced
Clutchdi scassembly
I nspect
clutchdi scforwornor
oi ly
faci ngs
loose
ri vets
and
broken or
loosetorsi onal
spri ngs
I
I f
faci ngs
are
oi ly
di scshouldbe
replaced
I n thi s case
i nspect
trans
mi ssi on
front
coveroi lseal
pi lot
bushi ng engi ne
rear
oi lsealsandother
poi nts
foroi l
leakage
CL7
C1Ul1h
Uni t
CLUTCH
2
The di scshouldalsobe
replaced
when
faci ngs
are
worn
locally
orworn
down
tothe
speci fi ed
li mi t
Wearli mi t of
faci ng
A
Lessthan03mm
10
012i nl
I I
I
ri l
Q
l
l
c
F
l
I
I
A
CL336
3 Check
di sc
plate
for
runout when
everthe old
di sc
ora new
one
i s
i nstalled
4 I f
runout exceeds
the
speci fi ed
value at outerci rcumferenceof
faci ng
place
or
repai r
di sc
Runout
li mi t
totali ndi cator
readi ng
Less
than05
mm
0020i n
R fromhub
center
95
mm
374i n
Backlash
Less
than
04mm
10
016
i nl
Clutchcover
assembl
1
Check
end
surface of
di aphragm
spri ng
forwear
I f
excessi ve
wear
i s
found
replace
clutchcover
assembly
2 Measure
hei ght
of
di aphragm
spri ngs
as outli ned
below
I
Place ToolST20050100on
Tool
ST20050010and then
ti ghten
clutch
cover
assembly
on
base
plateby usi ng
ToolST20050051
ST20050010
ST20050051
jST20050100
1
@
CAUTI ON
When
repai ri ng
di sc
plate
neverhold i t
forci bly
wi th
pli ers
orbend i t exces
si veI y
otherwi se
faci ng
wi llbe dam
aged
CL 12
5 Check fi t of
di schub ontransmi s
si on
mai ndri ve
gear
spli nes
forsmooth
sli di ng
I f
spli nes
are
worn clutchdi sc
ormai n dri ve
gear
shouldbe
replaced
that
backlash
exceeds the
speci fi ed
valueat outer
edge
ofclutchdi sc
CL 8
CL151
2 Measure
hei ght
A
at several
poi nts
wi tha
verni er
cali per
depth
gauge
Oi aphragnt
spri ng hei ght
A
31
6 33
6
mm
11
244 1
323i nl
l
SCL014
I f
hei ght
A
of
spri ng
end
beyond
speci fi ed
value
dju
t
spri lll
hei ght
wi th
Tool ST20050240
1
necessary replace
clutch
coveras
sembly
SCL018
Also unevenness of
di aphragm
spri ng
toe
hei ght
should bewi lhi n
the
speci fi ed
li mi t
Unevenness of
di aphragm
spri ng
toe
hei ght
Lessthan05 mm 0020
i n
A
I f
unevenness
of
di aphragm
spri ng
toe
hei ght
beyond speci fi ed
value
adjust
spri ng hei ght
wi th Tool
ST20050240
3
I nspect thrust
ri ngs
forwear
or
damage As these
parts
are i nvi si ble
from outsi de shake
cover
assembly
up
and
down to
li sten for
chatteri ng
noi se or
li ghtly
hammeronri vets for
a
sli ghi ly
cracked noi se
Any
of
1hese
noi sesi ndi cates need
of
replacement as
a
complete
assembly
I NSTALLATI ON
I
Apply
a
li ght coat
of
grease
i n
c1udi ng molybdenum
di sulphi de
10
transmi ssi on
mai n
dri ve
gear
spli nes
Sli de clutch
di sc
on mai n
dri ve
gear
several
ti mes Removeclutchdi scand
wi pe
off excess
lubri cant pushed
off
by
di schub
Take
speci alcare
to
prevent grease
or
oi lfrom
getti ng
oncluteh
faei ng
2 Rei ns1a11
clutchdi sc and clutch
cover
assembly
Support
clutch
di sc
and coverassembli es wi th
Tool
KV30100100
Be
ure to
keep
di sc
faei ngs
fly
wheel
and
pressure
plate clean and
dry
KV30100100
CL340
3 I nstall clutch cover
assembly
Eachbolt
should
be
ti ghtened
one
turn at a ti me i n a
cri sscross fashi on
ti l
Clutch
cover
bolt
16 21N
m
1 6 21
kg
m
12
15lt lb
4 Remove clutch
ali gni ng
bar
5 Rei nstall
transmi ssi on Refer
to
I nstallati on Secti on
MT
RELEASE BEARI NG
REMOVAL
1
Remove transmi ssi on from
engi ne
RefertoRemovalSecti on
MT
2
Di sconnect
holder
spri ng
from
beari ng
sleeve
3 Remove release
beari ng
andsleeve
as
an assembly
from transmi ssi on
case
front cover
4
Take
clutchrelease
beari ng
out
from
beari ng
sleeve
usi ng
a uni versal
puller
anda sui table
adapter
CLt45
I NSPECTI ON
Check forabnormalwearon con
tact
surface of wi thdrawalleverball
pi n
and
beari ng
sleeve
Hold
beari ng
i nnerraceand
rotate
outerrace
whi le
applyi ng pressure
to
i t
I f the
beari ng
rotati on i s
rough
or
noi sy
replace beari ng
I NSTALLATI ON
I
Assemble
release
beari ng
on
sleeve
usi ng
a
press
l
j
l
I
u
SCL015
Donot
depress
outer
race
2 Before
or
duri ng assembly
lubri
cate the
followi ng poi nts
wi tha
li ght
coat of
multi
purposegrease
1
I nner
groove
of release
beari ng
sleeve
L
SCL016
2
Contact surfaces of wi thdrawal
lever
lever
ball
pi n
and
beari ng
sleeve
3
Beari ng
sleeve
sli di ng
surface
of
transmi ssi oncasefront cover
SMT016
CLUTCH
ClutchUni t
4
Transmi ssi on
mai n dri ve
gear
spli nes
Use
greasei ncludi ng molybde
numdi sulphi de
A
mallmount of
gre
houldbe
coatad totho bov
poi nts
I f too
muchlu ri cant
i s
appli ed
i t
wi lt run
out on
thefri cti on
plltes
when hot
re
lulti ng
i n
damaged
clutchdi sc
faci ng
3 After
lubri cati ng i nstallwi th
drawalleverrelease
beari ng
andsleeve
assembly
i n
posi ti on
Connect them
wi thholder
spri ng
SMT010
4
Rei nstall
transmi ssi on
Referto
I nstallati on Secti onMT
PI LOT
BUSHI NG
REMOVAL
I Removetransmi ssi on from
engi ne
RefertoRemovalSecti onMT
2
Remove
clutchdi sc and
cover
assembly
Refer
to
Clutch
Di sc
and
Coverforremoval
3
Remove
pi lot bushi ng
i n crank
shaft wi th
TooL
CLOSS
CL 9
OutdWni t CLUTCH
I NSPECTI ON
Check
pi lot
bushi ng
forfi t i n bore
of
crank5haft
Check i nnersurface of
pi lot
bushi ng
for
wear
roughness
orbell
mouthed condi ti on
I f
pi lot bushi ng
i s
worn or
damaged replace
When
bushi ng
i s
damaged
be sure
tocheck
transmi ssi on mai n
dri ve
gear
at the
same
ti me
I NSTALLATI ON
1 Before
i nstalli ng
a new
bushi ng
thoroughly
clean
bushi ng
hole
2
I nser1
pi lo1
bushi ng
unti l
di stance
A
between
flange
end and
pi lot
bushi ng
i s
speci fi ed
di stance
CL10
Di stance A
40mm 0157
i nl
Do
not oi l
bushi ng
When
i nserti ng pi lot
bushi ng
be
careful
not tod
amage edge
of
pi lot
bushi ng
A
Pi lot
bushi ng
EM719
3
I nstaU clutch di sc and
clutch
cover
assembly
RefertoClutch
Di sc
and
Coverfori nstallati on
4
I nstalltransmi ssi on Referto
I n
staUa1i on Secti on MT
CLUTCH
Servi ce
Dataand
Speci fi cati ons
SERVI CE DATA
AND SPECI FI CATI ONS
GENERALSPECI FI CATI ONS
a
UTCH
CONTROL
SYSTEM
I
Type
of clutchcontrol
aUTCH
MASTER CYLI NDER
I lnnar
di ameter mmOn
Hydrauli c
15 88 15 81
TV
aUTCH
OPERATI NG
CYLI NDER
Non adjustable
I nnerdi ameter
mm jn
a
UTCHDI SC
I
Type
Faci ng
si ze
Outerdi exI nnerdi e
x
Thi ckness
mm
i nl
Thi cknessof di sc
assembly
Free
mm
i n
I nstalled mmUnl
Numberof torsi on
spri ngs
a
UTCH
COVER
Type
Full
load N
I kg
lb
1746111
161
200CB L
20
130
x
35
17 87
x5 12
x
01381
850
9
20
103346 036221
7680
10299 0315
6
C200S
39231400882
I NSPECTI ON
AND
ADJUSTMENT
aUTCH
PEDAL
I
Pedal
hei ght
H
l
Pedal
free
play
AU
mm i n
mm i n
a
UTCHMASTER
CYLI NDER
I
Clearance
between
cyli nder
bore
and
pi lton
mmUnl
168 17416
61 6
85
5 1004
0
201
I
Lossthan015
10
0059
j
aUTCHOPERATI NG
CYLI NDER
I
Clearance
between
cyli nder
bore
and
pi ston
mrni n
I
Lessthan
015
1000591
J
aUTCH
DI SC
Uni t
mm
I n
I
Model
200CBL
I
Wearli mi t
offaci ng
surfacetori vet
03
100121
I
hood
Runout li mi t
05
100201
I
Di stanceof nout
checki ng poi nt
9513741
fromthehub center
I
Maxi mum
backlash
of
spli ne
0
410
016
at outer
edge
of di sci
aUTCHCOVER
Uni t
mm
li n
I
Model C200S
I
Di oph
ag
m
spri ng
ho
ght
316336
11
244 1
3231
I
Unevenness
of
di ophragmspri ng
toe
Less
than05 0020
hei ght
PI LOT BUSHI NG
I
I nserteddi stanceof
pi lot bushi ng
40
10
1571
mrni n
TI GHTENI NG
TORQUE
Uni t
Nm
kg
m ft I b
I
Pedal
stopper
bolt
lock
78 11 8
08 12 5 8 87
nut
I
Manercyli nderpush
cd
7 8
118 08 12
5 8 87
locknut
Master
cyli nder
stopper
1
5 29 015 03
1122
bolt
Master
cyli nder
securi ng
78 118
08 1 2
5 8 87
nut
Clutch
fube
flarenut 15 18
15 18
11 13
I
Pushrodlocknut
78 118 0
8 12 5 8 87
I
Dporati ng
cyli ndor
69
88 07
09 5 1 65
bleederscrew
Operati ng cyli nder
30
40 31 41
22 30
lecuri ng
bolt
Clutch
hoseto
operati ng
17 21
1721
12 15
cyli ndersecuri ng
nut
I
Clutch
coversecuri ng
16 21 1 6 21
12 15
bolt
CL
11
I
TroUble
Di agnosesBnd
Correcti ons
CLUTCH
TROUBLE DI AGNOSES
AND CORRECTI ONS
a
UTCHSLI P
Sli ppi ng
of
clutch
may
be
noti ceable
when
any
of
the
followi ng
symptoms
i sencountered
duri ng
operati on
I
Carwi ll
not
respond
to
engi ne
speedduri ng
accelerati on
2
I nsuffi ci ent
car
speed
I Lack
of
powerduri ng uphi lldri vi ng
4
I ncreasi ng
of fuel
consumpti on
Some
of the
above
condi ti ons
may
alsobe
attri butable
to
engi ne problem
Fi rst determi ne
whether
engi ne
or
clutchi s caus
i ng
the
problem
I f
sli ppi ng
clutch
i s
left unheeded wear
and
or
overheati ng
wi ll
occur
onclutch
faci ng
tosuch
an exten1that
i t i sno
longer
servi ceable
TOTEST
FOR SLI PPI NG CLurCH
proceed
as
follows
I nspecti on
I nsure that
parki ng
brake i s
engaged
Di sengage
clutch
and shi ft
transmi ssi on
gears
i nto
TOP
Gradually
i ncrease
engi ne
speed
whi le
si multaneously engagi ng
clutchI f
engi ne stops
whi leclutch
i s
bei ng engaged
clutchi s
functi oni ng
properly
I f
cardoesnot moveandthe
engi ne
does not
slop
clutch
i s
sli ppi ng
Probable cause
Correcti veacti on
Clutch
faci ng
hardenedorwet
wi th
oi l
Clutch
faci ng excessi vely
worn
Di aphragmspri ng
weak
or
damaged
Flywheelor
pressureplatewarped
Parti cles
i nreturn
port
ofmaster
cyli nder
Pi stonfai ls
toreturn
toi ts
ori gi nal
posi 1i on
Clutchtubedeformed
orcrushed
Repai r
or
replace
Replace Replace
i Lengi ne
transmi i on
oi lseali s
faulty
Replace
Repai r
or
replace
Clean
or
replace faulty
pari s
Replace
a
UTCH
DRAGS
Draggi ng clutcl
i s
parti culr1y
noti ceable
when
shi fti ng
gears especi ally
i ntolow
gear
TOTESTFOR DRAGGI NG
CLUTCH
proceed
to
i nspecti on
I nspecti on
Di sengage
clutch
and
shi ft
gears
i ntoReverse
Shi ft
gears
i nto
Neutral
gradually i ncreasi ng
engi nespeed
Aftera
short i nter
mi ssi on
shi ft
gears
i nto
Reverse I f
noi sei s
heardwhi le
gears
are
bei ng
shi fted clutch
i s
draggi ng
CL
12
CLUTCH
Trouble
Di agnoses
and
Correcti ons
Probablecause
Correcti veacti on
Clutchdi schub
spli nes worn
orrusted
Replace
orremove
rust
and
coat wi th
grease
Replace faulty
parts
Bleedai r
Adjust
Replace
Replace
04
Replace
Coat wi th
grease
Replace
Replace
i f
engi ne
transmi ssi on oi lseali s
faulty
Oi l
leakage
at
master
cyli nder
operati ng cyli nder
tubeor
hose
Ai r
i n
hydrauli c
system
I nsuffi ci ent
pedal
stroke
Clutchdi sc
runout
or
warped
Di aphragm
spri ng
fati gued
Pi ston
cup
deformed
or
damaged
Lack of
grease
on
pi lot
bushi ng
Clutch
faci ng
wet
wi th
oi l
CLUTCHCHATTERS
Clutch
chatteri ng
i s
usually
noti ceable
whencari s
just
rolledoff
wi th
clutch
parti ally engaged
Probablecause
Correcti ve
acti on
Oi lonclutch
faci ng
Di aphragmspri ng
fati gued
Clutch
faci ng
hardened
Clutch
faci ng
warped
Pressure
plate
worn
or
warped
Engi nemounti ng
looseorrubberdeteri orated
Clutch
faci ng
ri vets loose
Replace
Replace
Replace
Repai r
or
replace
Replace
Ti ghten
or
replace
Replace
NOI SY CLUTCH
Probable
cause
Correcti veacti on
Release
beari ng
sleeve
damaged
or
i mproperly
lubri cated
Pi lot
bushi ng
worn
jammed
or
damaged
Clutch
faci ng
ri vets
loose
Di sc
plate
cracked
Clutch
di sc
torsi on
spri ngs
fati gued
Replace
Replace
Replace
Replace
Replace
RABBI T HOPPI NG CLUTCH
When rabbi t
hoppi ng
ofclutchoccurs
carwi llnot rol1
off
smoothly
from
a
standi ng
star1 orclutchwi ll
be
engaged
be
foreclutch
pedal
i s
fully depressed
Probable
cause
Correcti ve
acti on
Oi lOn clutch
faci ng
Clutch
faci ng
wornorri vetsloose
Flywheelpressure
platewarped
orworn
Mounti ng
boltson
engi ne
or
power
trai n
loose
Di aphragm
spri ng fati gued
Replace
Replace
Replace
Ti ghten
Replace
CL
13
Speci alServi ce
Tools CLUTCH
SPECI AL
SERVI CE
TOOLS
Toolnumber
Toolname
Kent
MooreNo
KV30100100
Clutch
ali gni ng
bar
CLJI
2
1
ST20050100
Di stance
pi ece
@
ST20050010
Base
plate
@
39
ST20050051
Set bolt
ST200S0240
Di aphragmspri ng
adjusti ng
wrench
STI 661000
I
123907
Pi lot
bushi ng puUer
n
o
GG94310000 Flarenut
torque
wrench
I I I I lI I lI I 1A
CL14
DATSUN
200SX Mode
S
I I
0
Seri es
MANUAL
TRANSMI SSI ON
REMOVAL AND I NSTALLATI ON
REMOVAL
I NSTALLATI ON
5 SPEED TRANSMI SSI ON
Model
FSsW71B
REAR EXTENSI ON
TRANSMI SSI ON
CASE
FORKS
AND
FORK RODS
GEARS
AND SHAFTS
REPLACEMENT
OF OI LSEALS
CONTENTS
MT 2
MT 2
MT 2
MT
3
MT 6
MT
7
MT 8
MT 9
MT14
REPLACEMENT
OF BEARI NGS
SERVI CE
DATA AND
SPECI FI CATI ONS
GENERAL SPECI FI CATI ONS
I NSPECTI ON
AND ADJUSTMENT
TI GHTENI NG
TORQUE
TROUBLE
DI AGNOSES
AND
CORRECTI ONS
SPECI ALSERVI CE TOOLS
MT14
MT16
MT16
MT16
MT17
MT18
MT2 2
Removaland
I nrtallati on
MANUAL
TRANSMI SSI ON
REMOVALAND
I NSTALLATI ON
REMOVAL
I
Di sconnect
battery ground
cable
2
Removeaccelerator
li nkage
J
Jack
up
car
anI
support
i ts
wei ght
on
safety stands
Usea
hydrauli c
hoi st
or
openpi t
i f
avai lable
Make surethat
safety
i s
i nsured
4
Di sconnect front exhaust
tube
5
Di sconnect
wi res
from reverse
back
up lamp Top
and
O
D
gear
i f
so
equi pped
swi tches
6
Di sconnect
speedometer
cable
7
Remove
propeUer
shaft
Referto
Propeller
Shaft Secti on
POforremoval
Plug up openi ng
i n
rear
extensi on
to
prevent
oi lfrom
flowi ng
out
8 Removeclutch
operati ng cyli nder
9
Support
engi ne by
placi ng
a
jack
underoi l
pan
wi tha
wooden
block
usedbetweenoi l
pan
and
jack
CAUTI ON
00
not
placejack
underoi l
pan
drai n
plug
10
Support
transmi ssi onwi 1h
a
trans
mi ssi on
jack
H
I
Remove
console box Referto
ConsoleBox Secti on
BFfor
removal
2
Place
transmi ssi on controlleveri n
neutral
posi ti on andremoveE
ri ng
and
controllever
MT
2
TM335
12 Loosen
rear
engi ne
mount secur
i ng
nuts
CD tempobi ri ly
and remove
crossmember
mounti ng
nuts
00
I 3 Removestartermotor
14 Remove
bolts
securi ng
1ransmi s
si an
to
engi ne
Then
support
the
engi ne
andtrans
mi ssi on
wi th
jacks
and
sli de transmi s
si on rearward
away
ffom
engi ne
and
removefromthecar
CAUTI ON
Take
care
i n
di smounti ng
transmi ssi on
not tostri ke
any
adjacent parts
and
mai n
dri ve
gear
I NSTALLATI ON
I nstall
the transmi ssi on i n
reverse
orderof
removal
payi ng
attenti on to
the
foUowi ng poi nts
I Before
i nstalli ng
clean
mati ng
surfaces
of
engi ne
rear
plate
andtrans
mi ssi on
case
2 Before
i nstaUi ng
li ghtly apply
grease
to
spli ne parts
of clutchdi sc
and
mai n dri ve
gear
Andalso
apply
grease
to
movi ng
surfaces of control
leverand
stri ki ng
rod
3
When
i nstalli ng
control
leverbe
sureto
apply
multi
purpose
grease
to
sli di ng parts
as
shownbelow
Bushi ng
Grease
coati ng
Control
lever
Grease
coati ng
SMT142 Stri ki ng
gui de
4
Remove
fi ller
plug
and fi ll
1rans
mi ssi onwi threcommended
gear
oi I o
the
levelof
1he
plug
hole
Oi l
capaci ty
2 0li ten
41
lJ P1
2I mp Ill
5
Apply
sealant
to
threads of fi ller
plug
andi nstaU fi ller
plug
totransmi s
si onc
i J
Fi ller
plug
25 34
N m
25 35
kg m
18 25
ft lb
6
Ti ghten
bolts
securi ng
transmi s
ti on
to
engi ne
i J @
43 58
N m
4
4 59
kg
32
43ft bl
@
25 35N
m
2
6 3
81qj
m
19 28ft
lb
A
7 Lubri cate oi lseal
li p
and
bushi ng
onrearextensi onwi th
gear
oi lfori ni
ti allubri cati on
3
Neutral
swi tch
I i i
20
29
2
0
3
0
14
22
Oi l
leal
Apply
gear
oi l
to
oi l
seal
on
I i i
20
29
2
0
3
0
14
22
I i i
20
rTOP
gear
wi tch
iJ
20
29
2
0
Revet
lampowS
29
2
0
3
0
14
22
23
1
6
2
3
12
17
f
Beari ng
3
0
14
2
Adapter
plate
Front
cover
Fi ller
plll8
I i i
25
34
2
5
3
5
18
25
Apply
sealant
to
thread
of
bolts
Drai n
plug
I i i
25
34
2
5
3
5
18
25
E
21
1
6
21
12
15
I i i
N
m
kg
m
ft lb
C1I en
m
mC f0Z
en
3
enen
5
z
3ZC rI Z
CJl
3
enCJlo
Z
I
i a
3
oQ1 JJC1I
e OJ
I i i i g Cl
I t
ll
5
speed Trafl lTli ssi of1
ModeI FS5W71BJ
MANUALTRANSMI SSI ON
3rdmai n
gear
SnaPri nB
Mai n
dri ve
gear
ball
beari ng
Washer
Snap ri nB
Apply gear
oi l
toneedle
bearq
3rd11 4th
synchroni zet
hub
preadspri ng
Pay
attenti on toi tsdi recti on
Shi fti ng
i mert
r
G
1st
a
2nd
synchroni zer
hub
2ndmai n
gear
123
CounterJbaCt lock
nut
i fJ
98 127
10013012 94
counter
geu
Apply
gear
oi l
to
needle beari ng
Counterfront
beari ng
Snap
ri ng
Woodruff
key
Reverse
i dlet
searbeari ng
Reversei dler
throt washer
Reversei dlershaft
Shi m
Refertotransmi ssi on casefor
assembly
I i i
N m
kg
m
ft
b
SMT040
MT 4
MANUAL TRANSM
I SSI ON
5
speed
Transmi ssi on
Model
FS5W71BJ
Stri ki ng gui de
25 19
25 14
18
Check pri ns
Check
ball
E
ri nB
r
J
O
r
StoPper
gui depi c
fRetum
spri plUS
J
Applylocki ng
sealer
j
tothread
of
bolt
t
Retrun
pri I i i 7 8 9
8
O
g 10Check
pri ns
1
plunger
5 8 7
2
Return
checki ng
Check
ball
pl1lll
SPri Dl Apply locki ng
sealer
to
thread
of bolt
qeontrollever
@
bushi ng
0
J
Lock
pi n
Apply gear
oi lto
O
ControlleYer
5
Controlleverb
ahUw
Retai ni ns Pi n
I nterlock
baD
3m
4th
Cork rod
Reverse OD
shi ft Cork
3m 4th
shi ft Cork
I i i
19 25
19 2 5 14
18
I oterlock
baD
I i i
l
m
k8
m Ct lb
SMT150
MT
5
54peed
TT8I l fTJi ssi on ModeJ FS5W71B
MANUALTRANSMI SSI ON
REAR
EXTENSI ON
DI SASSEMBLY
I
Wi pe
offdi rt and
grease
2
Drai noi l
3
Remove 00
gear
swi tch
i f
so
equi pped
4
Remove E
ri ng
and
stoppergui de
pi n
SMT006
I NSPECTI ON
@NEur
4
1
W
@
I n
SMT007
5 I nstaU
plunger
return
spri ng
and
return
spri ng
plug
I Clean wi thsolvent
andcheck for
cracks
or
cavi ti es
by
means of
dyei ng
test
TM337
2 Check
mati ng
surface of
rearex
tensi on
forsmall
ni cks
projecti on
or
sealant
I f
fesrextensi on
bushi ng
i swornor
5
Remove
return
spri ng
plug
retum
pla
i t as
an assembly
of
spri ng
and
plunger
from rearexten bushi ng
and rearextensi on
housi ng
si on
SMT003
6
Removerearextensi on
SMTOOS
7
Removelock
pi n
andthen
remove
stri ki ng
rod
MT 6
ASSEMBLY
I
Stand
transmi ssi on
case
assembly
on
wooden
plates
ofmorethan20rom
0
79i n
thi ck
2 Clean
mati ng
surfaces of
adapter
plate
andrearextensi on
3
Apply
sealant to
mati ng
surface
of
adapter
plate
4
I nstaU rearextensi on as foUows
I
Se
gears
at Neutral
2 Turn
stri ki ng gui de
counterclock
wi se
3
Set
stri ki ng gui de
at Neutral
4
Ali gh
end of
stri ki ng
leverwi th
cutout
porti on
of
forkrod
SMT041
1
PlUJl8O
2 Return
spri ng
3
Return
spri ng plug
6
Apply
sealant to
stoppergui de
pi n
then i nstaU
stopper
gui de
pi n
and
E
ri ng
7 I nstaU 0
0
gear
swi tch i f so
equi pped
8 Make sure that
gears
operate
smoothly
9
I nstalldrai n
plug
I i l
25 34N m
25
35
kg fD
18
25
ft lbl
TRANSMI SSI ON
CASE
DI SASSEMBLY
1
Remove rearextensi on Referto
RearExtensi on for
di sassembly
2
Remove dust coverrelease
bear
i ng
and
wi thdrawallever
3 Remove front coverand
gasket
Detach countershaft front
beari ng
shi m
4
Remove mai n
dri ve
beari ng snap
ri ng
5
Separate
transmi ssi on case from
adapter
plate
TM153
MANUAL TRANSMI SSI ON
5speed
Transmi ssi on
ModelFS5W71B
I NSPECTI ON
1
Clean wi thsolvent
andcheck for
cracks
or
pi ts
by
means
of
dyei ng
test
2
Check
mati ng
surface
of transmi s
si on
caseforsmall
ni cks
projecti on
or
sealant
ASSEMBLY
1
clean mati ng
surfaces of
adapter
plate
andtransmi ssi oncase
2
Stand transmi ssi on
case
onwood
en
plates
of
more
than20mm
O79i n
thi ck
3
Apply
sealant
to
mati ng
surfaceof
transmi ssi on
case
4 Sli de
gearassembly
onto
adapter
plate by li ghtly tappi ng
wi th
a
soft
hammer
5 Make certai n that mai nshaft roo
tates
freely
SMT014
6
Fi t
mai n dri ve
beari ng
snap
ri ng
7
Select countershaft front
beari ng
shi mas foUows
1
Measure
hei ght
A
I
TM371
1
Tranlmi ssi on case
2
Counter
gear
front
beari ng
3
Counter
gear
2 Select a
shi m
of thi ckness
A
measured
Counter
geer
front
beari ng
hi m
Refer
to
S OS
8
Clean
mati ng
surfaces of front
coverand
transmi ssi oncase
9
Apply grease
toshi m
selected to
rtai ni t onfront
cover
10Lubri cate
seal
li p
and mai n
dri ve
shaft wi th
gear
oi lthen
i nstaU new
gasket
andfront cover
I I
Apply
sealant
to
threads of
through
bolts and
ti ghten
them to
transmi ssi on
case
I i i
111
21N m
11 621
kg
m
12 151t lbl
rmrl
SMT015
12
Apply
a
li ght
coat of multi
pur
posegrease
MT 7
XpeerI
Transmi ssi on
Mode
FS5W71BJ MANUAL
TRANSMI SSI ON
rC
SMT016
13 I nstaU dust coverrelease
beari ng
andwi thdrawallever
14 Assemble RearExtensi on Refer
toRearExtensi on
for
assembly
FORKS
AND FORK
RODS
DI SASSEMBLY
1
Remove
rear
extensi on Refer
to
Rear
Extensi onfor
di sassembly
2
Remove
transmi ssi on case Refer
toTransmi ssi on
Case for
di sassembly
3
Set
up
Tool
on
adapter
plate
4
Placeabove
assembly
i na vi se
TM754
5
Remove
check baU
plugs and
check
spri ngs
MT
B
Fork rod
1st l2nd
Fl
Chect baD
@
ED
I nterlock
ball
TM198A
6
Dri ve
out
retai ni ng pi ns
7 Dri ve out
fork rods andremove
i nterlock
baUsandcheckbaUs
Be
carefulnot tolose
three 3
check balls and four
4 i nterlock
balls
I NSPECTI ON
Clean
wi thsolvent
and
check for
wear
scratches
projecti on
damage
or
other
faulty condi ti ons
Replace
any
part
whi ch
i s wornor
darnaged
one
6
SMT137
ASSEMBLY
I I nstaU 1st 2nd
3rd
4thand
Q
D Rev
shi ft forks and1st 2nd
fork rod
then secure wi th
retai ni ng
pi n
2
I nstaU two
2
i nterlock baUs
3
I nstaU 3rd
4th
fork rod then
secure wi th
retai ni ng pi n
SMT019
4 I nstaU two
2 i nterlock baUs
5
I nstaU OD Rev
shi ft fork
and
fork
rod
then secure
wi th
retai ni ng
pi n
6 I nstaU check
baI ls and check
spri ngs
7
Apply
locki ng
sealerto
check
ball
plugs
andi nstallthem
dl
19 25 N m
1 9 2 5
kg
m
14
18
ft lb
a Check ball
plug
for1st 2ndfork
rod i s
longer
than that
for
Rey
shi ft fork
rod and
3rd 4thfork
rod
b Toi nsure that i nterlock
plunger
i s
i nstalled
properly
sli de 3rd 4th
fork rod
and
operata
the
otherfork
rod Make
lure
that the
gearexcept
3rdor4th
gear
does
not m sh
8
Apply
gear
oi l
toall
sli di ng
sur
faces and
check
tosee
1hat
shi ft rods
operate
correctly
and
gears
are en
gaged smoothly
9
I nstall
transmi ssi o
case
Referto
Transmi ssi onCase forassembly
10
I nstallrear
extensi on Refer
to
Rear
Extensi on
for
assembly
GEARS AND SHAFTS
DI SASSEMBLY
Mei n dri ve
endcounter
dri ve geer
1
Remove
rear
xtensi on
Referto
Rear
Extensi on
for
di sassembly
2 Remove
transmi ssi on
case Refer
toTransmi ssi on Case for
di sassembly
3
Remove
forks and fork rods
Refer10Forks and Fork rods fordi s
assembly
4 Measure
g
rend
play
Referto
Gears andShaftsfor
i nspecti on
S Mesh2nd and reverse
gear
then
draw
out
counter
front
beari ng
MANUAL TRANSMI SSI ON
5
speed
Transmi ssi on
ModelFS5W71B
TM398
6
Remove
counter
dri ve
gearsnap
ri ng
7 Draw
out counterdri ve
gear
wi th
mai ndri ve
gear
When
drawi ng
out
mai n dri ve
gear
mbly
b carful
not to
drop
pi lot
n
edle
beari ng
and
baulk
ri ng
3rd meln geer
I Remove
snap
ri ng
and thrust
washer
2 Drawout 3rd 4th
synchroni zer
and3rd
gear
o
D
geer
end
reverse
geer
1
Remove mai n dri ve
and
counter
dri ve
gears
Refer
toGears
and
Shafts
for
di sassembly
2
Remove 3rd mai n
gear
Refer
to
Gears
and
Shafts
for
di sassembly
3
Measure 00
ge
r
end
play
Refer
toGears and
Shaftsfor
i nspecti on
4 Mesh2nd
and reverse
gears
Re
lease
staki ng
on counter
gear
nut and
mai nshaft
nut and
loosen these
nuts
Remove
counter
gear
nut
Removednuts should
bedi scarded
nd
should
not bereused
TM757
S Dri ve
out
counter
0
0
gear
and
beari ng
6
Remove
revene counter
gear
and
spacer
Remove
snap ri ng
from
reverse
i dlershaft and remove reverse i dler
gear
7 Remove
snap
ri ngs
steelball
speedometer
gear
and
beari ng
f
I
KV32101330
TM760
8
Remove
mai nshaft nut thrust
washer
reverse
mai n
gear
0
0
synchroni zer
and
OD
gear
1st
end2nd mei n
geer
end
countereer
I Draw out mai nshaft
assembly
together
wi thcounter
gear
by
tappi ng
rear
end of mai nshaft and
counter
gear
MT
9
5si Jeed
Trantmi i si on
ModelFS5W71B MANUAL
l
RANSMI SSI ON
Hold
front
of mai nshaft
assembly
by
hand
bei ng
careful
not to
drop
counter
gear
TM W1
I
J
4
I
rT
2
Remove thrust washersteel
baU
1st
gear
and
needle
beari ng
Be
careful
not to
lose teelball
retai ni ng
thlUlt washer
Synchroni zer0D
I
Remove
ci rcli p
wi i h
snap
ri ng
pli er
2 Remove
syncbro ri ng
band
brakes anchorblock
and
thrust block
I NSPECTI ON
Beari ng
I
Thoroughly
clean
beari ng
anddry
wi th
compressed
ai r
CAUTI ON
Donot allowthe
beari ngs
to
spi n
Because i t wi ll
damage
the
race
and
balls
Turnthem
slowly by
hand
3
Press ou1
1st
gear
rnai nshaft bush
i ng together
wi th2nd
gear
and
1st
2nd
synchroni zer
Wlli i n pri i si ng
oi i rli i i
li i ng
holi f
mai nshaft
by
hand
081not
to
drop
i t
H
r
ST30031000
TM049A
Synchroni zer
lat a2nd and3rd a4th
Di sassemble
synchroni zer
G
Q
sleeve
Shi fti ng i nsert
SMT02A
MT10
TM372
2 When raceand baU surfaces are
worn or
rough
orwhen
balls are
out of roundor
rough
replacebeari ng
wi th
a
newone
3
Replace
needle
beari ng
i fwornor
damaged
Gears snd
ahafts
I Check
all
gears
forexcessi ve
wear
chi ps
orcracks
replace
as
requi red
2 Check
shaft for
bendi ng
crack
wear
d worn
spli ne
i f
necessary
replace
3
Measure
gear
end
play
I t
i s
necessary
tomeasure
end
play
before
di sassembli ng
mai nshaft and
after
reassembli ng
mai nshaft
Ti ghten
mai nshaft lock
nut
to
speci fi ed
li mi t
and
tneasure end
play
to i nsure
thai
i t i s wi thi n
speci fi ed
li mi t
I fend
play
i s
not
wi thi n
speci fi ed
li mi t
di sassemble and
check
parts
for
condi ti on
Replace any part
whi chi s wornor
damaged
i EndPmY
Mai nshaft
o
bushi ng
CI JE
SMT025
Standardend
play
1st
lI 88r
q2
03
tD lm
00106 00134
i nl
2nd
gear
012 019mm
00047
00075
i n
3rd
gar
013
037
mm
100051
00146
i n
0
0
5thl
gear
010011mm
00039 00061
i n
Reverse
i dlar
gear
005
0
50mm
0
0020
00197 i nl
Baulk
ri ng
I
Replace
baulk
ri ng
i ffoundtobe
deformed
cracked orotherwi se
dam
aged
excessi vely
SMT026
2
Place
baulk
ri ng
i n
posi ti on
on
gear
cone
Whi le
holdi ng
baulk
ri ng agai nst
gear
as
faras
i t wi ll
go
measure
gap
between
baulk
ri ng
and outer
gear
I f the clearance
i s
smaUer
than
wearli mi t
di scardbaulk
ri ng
B8Ulk
ri ng
to
glar
clearance
Standard
1 20
1 60
mm
00472
00630i n
Wearli mi t
La
than08mm
0031i n
SMT140
ShlftlnB
I nsert
Replace
i f worn
excessi vely
worn
unevenly
deformed
ordamaged
L
J
SMT064
Oi lseals
1 Replace
oi lseal
i f
seali ng li p
i s
deformed orcracked Alsodi scard
oi l
seali f
spri ng
i s
out
of
posi ti on
Refer
to
Replacement
of
Oi lSeals
2 Check the oi l
seal
li p contacti ng
wi thshaft i f
necessary replace
oi lseal
andshaft as
a
set
MANUAL
TRANSMI SSI ON 5speed
Transmi ssi on
ModelFS5W71B
ASSEMBLY
Adapterplate
I
Place
new
dowel
pi n
mai nshaft
beari ng
on
adapterplate
and
tap
them
Adapterplate
Dowel
pi n
2
places
Mai nshaft
beari ng7
1fU11
Uni t
mmi n
SMT027
2 I nsert reverse
i dlershaft
3
I nstaU
beari ng
retai ner
4
Ti ghten
eachscrew then
stake
i t
at two
poi nts
I
I
r
A
5 I nstaU counter
rear
beari ng
wi th
a
soft
hammer
Synchroni zer
1st 2ndand3rd
4th
I
Assemble
coupli ng
sleeve
and
hub
2
Posi ti on
spread
spri ngs
andshi ft
i ng
i nserts i n three slots i n syncli ro
ni zer
hub
put coupli ng
sleeve on
synchroni zer
hub
Synchroni zer
G D
Posi ti on
synchroni zer
ri ng
band
brake
thrust block
andanchorblock
on
overdri ve
clutch
gear
i nstall
ci rcli p
JH
D
rjeU
Bandbrake
Anchor
block
TM449
Thrust block
1st and2nd
mai n
Bear
I Assemble
2nd
gear
needle
beari ng
2nd
gear
baulk
ri ng
1st 2nd
syn
chroni zerassembly
I st
gear
baulk
ri ng
I
st
gear
bushi ng
needle
beari ng
1st
gear
steelbaU andthrust washer
on
mai nshaft
MTll
5PeedTrsn
i ssi on
ModelFS5W71B MANUAL
TRANSMI SSI ON
Before
i nstalli ng
Sle8I bolland
thrut washer
apply
gr
atotham
TM358
2 Set Tooland
place
adapterplate
assembly
oni t
For
counter
gear
and
Formai nshaft and
rever i deshaft
rever
i dler
shaft
I oU
J
I D
lJ f31100401
koles
for
reveri ei dler
shaft
2
Press
counter
gear
i nto
adapter
plate
KV31100401
TM O
3
Posi ti on needle
beari ng
3rd
mai n
gear
baulk
ri ng
and
3rd 4th
synchroni zerassembly
onthefront
of
mai nshaft
Assemble
3rd4th
synchroni zer
hub
payi ng
attenti on toi ts
di recti on
TM438
Front
3
Press
mai nshaft
assembly
to
adapter
plate
KV3H00401
TM439
3rdmai n andcounter
8ear
I
Tap
newwoodruff
keys
unti l
they
are
seated
securely
MT12
Vl
SMT031
4 I nstall
thrust
washer
onmai nshaft
and
secure
i t wi th
snap ri ng
of
proper
1hi ckness that
wi llmi ni mi ze
clearance
of
groove
i n
mai nshafl
Mai nshaft front
snspri ng
RefertoS OS
TM441
cHOJ
L
Mai n dri ve andcounter
dri ve 8ear
1
I nstallbaulk
ri ng
on
synchroni zer
Be
RU
to
ali gn
of baulk
ri ng
wi th
i nserts
2
Apply gear
oi l
tomai nshaft
pi lot
beari ng
andi nstall
i t on
mai nshafl
3 I nstaU
mai n dri ve
gear
wi th
counter
dri ve
gear
Assembfecounterdri y
gear
payi ng
attenti on toi ts di recti on
Front
SMT065
4
Press
counterdri ve
gear
onto
counter
gear
ST23860000
KV31100400
n
TM442
Mai n dri ve
gear
and counter
dri ve
gear
shouldbe handled as a matched
set When
replaci ng
mai n
dri va gear
or
counterdri ve
gear
be sure
to
replace
8S 8set ofmai n dri ve
gear
and
nter
dri va
gear
Counter
dri vege
ar
snap ri ng
RafertoS OS
5
Secure counter
dri ve
gear
wi th
snap
ri ng
that
wi llmi ni mi zeclearance
of
groove
i ncountershaft
o
TM366
6
Press counter
gear
front
beari ng
onto
counter
gear
ST22360002
KV31100400
n
TM443
ASSEMBLY
OD
gear
and
reverae
gear
I Afterfront
si dei s assembled as
semble
reverse
counterspacersnap
ri ng
spacer
needl
beari ng
reverse
i dler
gear
spacer
and
snap ri ng
Fr
I
LJ
I
TM451
2
Assemble O
D reverse
synchro
ni zer
hub reverse
gear
aD gear
bushi ng
needle
beari ng
OD
gear
assembly
steelbaU and
thrust
washer
on
mai nshaft rearsi de Beforei nstaU
i ng
a
steelbaU
apply grease
to
i t
MANUAL
TRANSMI SSI ON
5
speed
Transmi ssi on
Mode FS5W71S
a Assemble
OO
reverse
synchro
ni zer
hub
payi ng
attenti on to
i ts di rec
ti on
Front
TM297A
b
Mai n 00
gear
and countor
00
goor
shouldbe handled as a
motch
ed
set
When
replaci ng
mai n
00
gear
and
counter00
gear
be
sure
tore
place as
a set
of
mai n 00and
counter00
gears
3
Assemble reverse counter
gear
overdri vecounter
gear
4 Assemble
new
mai nshaft nut and
ti ghten
i t
temporari ly
5 I nstaU
beari ng
6 Mesh2nd and reverse
gear
and
ti ghten
mai nshaft lock nut andcount
er
gear
lock nut
w
ST22520000
I i i
137 167 Nm
114
017 0
kg
m
101 123ft lbl
SMT044
i J
Counter
gear
lock
nut
98 127 N m
100
130
kg
m
72
94
ft
lbl
Conversi on
of
torque
Mai nshaft nut should
be
ti ghtened
to
speci fi ed torque
wi th
ToolWhen
doi ng
so
the amount of
torque
tobe
read on
wrenchneedle should
be
modi fi ed
accordi ng
to
the
foUowi ng
chart
I f
137
167 N m
14 17
kg
m
101 123ft lb
ST22520000
C
f1
0
Lm
f
rr
OlOm
033 ft
e
S z
u
c
u
u
1O
C
s
u
00
c
o
0
e
Vi
1
Upp
rli mi tll
ne7 J
147
135 1
0
i t
uun
o
i i
11
04
05
66 07 08
m
90
u
80
15
2
0
2
5
ft
SMT034
7
Stake
mai nshaft lock
nut and
counter
gear
lock nut
wi th
a
punch
8
Measure
gear
end play
Referto
Gears
andShaftsfor
i nspecti on
MT13
5speed
Transmi ssi on Model
FS5W77BJ
MANUALTRANSMI SSI ON
I I Assemble
soap ri ngs
steelbaUand
speedometer
dri ve
gear
12 I nstaU forks andfork
rods Refer
toForks andFork
Rodsfor
assembly
13 I nstaU transmi ssi on case Referto
Transmi ssi onCase
for assembly
14
I nstaU
rear
extensi on
Referto
RearExtensi on
for
assembly
9 FI t
soap ri ng
thenassemblemai n
shaft rear
beari ng
ST223500i
TM068A
10
Fi t thi ck
snap
ri ng
tomai nshaft
rear
beapng
toeli mi nateend
play
Mai nshaft rear
beari ng snap ri ng
RefertoS OS
REPLACEMENT
OF
OI L SEALS
FRONT COVER OI LSEAL
I t i s
necessary
toremovetransmi s
si on uni t fromcar
Replace
oi lsealas
follows
Remove
transmi ssi on
Referto
RemovaL
2
Wi pe
offdi rt and
grease
3 Drai n
oi l
4
Remove dust
cover
release
bear
i ng
andwi thdrawallever
MT14
MAI N DRI VE AND
7
COUNTER FRONT
1
Remove
mai n
dri ve and
counter
dri ve
gear
Refertb Gears
and Shafts
for
di sassembly
2
Remove mai n
dri ve
gearsnap
ri ng
and
spacer
3 Removemai n
dri ve
beari ng
5 Removefront CO I er
6
Removeoi lseal
7
Apply
coat
of
gear
oi l0oi l
seal
surface thendri venewseali nto
place
ST23800000
PreS
ZY
o
J
oV
80
SMT036
8 Lubri cate seal
li p
and mai n
dri ve
shaft wi th
gear
oi l
9 I nstallfront coveri n
reverseorder
ofremoval
REAR
EXTENSI ON OI L
SEAL
Rearextensi on oi lseal
can be
replaced
wi thout
removi ng
transmi s
si on
Replace
oi l
sealas follows
I Remove
propeller
shaft Referto
PropeUer
Shaft Secti on PD forreo
movaL
2 Removeoi lseal
SMT037
3
Apply
coat of
gear
oi ltooi lseal
surface then dri ve
newseal
i nto
place
4
I nstaU
propeller
shaft Referto
PropeUer
Shaft Secti on
PD fori nstal
lati on
REPLACEMENT
OF
BEARI NGS
TM349
4 Press
new
mai n dri ve
beari ng
Press
SMT038
5
Place mai n dri ve
beari ng spacer
on mai n dri ve
beari ng
and
secure
mai n
dri ve
beari ng
wi ththi cker
snap
ri ng
that wi D eli mi nate
end
play
Mai ndri ve
gearsnap ri ng
Refer
toS OS
6
Mesh
2nd
and reverse
gear
then
drawout counter
front
beari ng
TM398
7
Press counter
gear
front
beari ng
ontocounter
gear
ST23860000
KV31100400
n
TM442
8 I nstaU
mai n
dri ve
and counter
dri ve
gear
Refer
toGears and
Shafts
forassembly
MAI NSHAFT
AND
COUNTER
REAR
1
Remove rear
extensi on Referto
RearExtensi on
for
di sassembly
2 Remove transmi ssi on case
Refer
toTransmi ssi on Case
for
di sassembly
3
Set
up
Tool
on
adapter
plate
4
Placeabove assembly
i n
a vi se
MANUAL TRANSMI SSI ON
5
speed
Transmi fi 1i i on
Model
FS5W71B
TM754
5 Remove mai n
dri ve and counter
dri ve
gear
Referto
Gears and Shafts
for
di sassembly
6 Remove reverse
mai n
gear
Refer
toGears andShafts
for
di sassembly
7 Draw
out
mai nshaft
assembly
together
wi th
countergearby tappi ng
rearend
of mai nshaft and
counter
gear
Hold front of
mei nshaft
essembly
by
hand
bei ng
carefulnot
to
drop
counter
gesr
TP 347
8 Remove
beari ng
retai ner
SMT039
9 Replace
mai nshaft
beari ng by
new
one
10
Press out
countershaft rear
bear
i ng
CAUTI ON
When
pressi ng
out
beari ng
gear
hold
shaft
by
hand
so
as not
to
drop
i t
I I I
Countenhaft
rear
beari ng
I
I
11
TM351
11 Press counterrear
beari ng
onto
adapterplate
12
I nstaU mai nshaft
beari ng
onto
adapterplate
13 I nstaU
beari ng
retai nerand
ali gn
beari ng
retai nerwi threversei dler
shaft
at thecut out
porti on
of
the
shafl
14
Ti gh1en
and stake
eachscrew at
two
poi nts
15 I nstall
mai n dri ve
and counter
dri ve
gear
RefertoGears
and
Shafts
for
assembly
16 I nstaU reverse
mai n
gear
Referto
Gears andShaftsfor
assembly
17
I nstaU transmi ssi on case
Refer
to
Transmi ssi onCase for
assembly
18 I nstaU rear
extensi on
Refe to
Rear
Extensi on
for
assembly
MAI NSHAFT REAR
AND
COUNTER
REAR END
RefertoGears
andShaftsfordi sas
sembly
andassembly
MT15
Servi ceData
sndSpeci fi cati om
MANUAL
TRANSM
I SSI ON
SERVI CE DATA AND
SPECI FI CATI ONS
GENERAL
SPECI FI CATI ONS
Transmi ssi on
model
Noof
speed
Synchromesh
type
Shi ft type
Gear
rati o
Numberof teeth
Speedometer
gearrati o
Mai nshett
Counter
shaft
Revi dlershaft
Oi l
capaci ty
I I US
pt
I mp
pt
MT16
1st
2nd
3rd
4th
5th
Rev
Dri ve
1st
2nd
3rd
5th
Rev
Dri ve
1st
2nd
3rd
5th
Rev
FS5W71B
5
1 to4thWarner
5thServo
3 5
L
r
2
4 R
3321
2077
1308
1 000
0
864
3382
22
33
28
26
19
36
31
1
19
28
31
15
23
lB 6
12
04
1
4
3 121
I NSPECTI ON
AND ADJUSTMENT
GEAR
END PLAY
1
st mai n
gear
2nd
mai n
gear
3rdmai n
gear
5thmai n
gear
Revi dler
gasr
Uni t mm
i n
FS5W718
027 0
34
0
0106 0
0134
012 019 00047
00075
013 0
37100051 001461
0100
17 00039 000671
005 0500002000197
a
EARANCE
BETWEEN
BAULKRI NG AND
GEAR
I
Standard
I
Wear
li mi t
Uni t rnm i n
Allmodels
1201
6010
0472 0
06301
0
8100311
Mai n drlv
s
er
b
erlns
AVAI LABLE SNAP RI NG
Thi ckness
mm
i n
1 73 0
06811
180
10
0709
1
87
0
0736
1 94 007641
2
01 007911
2
08100819
Malnsheft front
Thi ckness
mm
i n
140
055
15
100591
1
6
0
063
Part
number
3220478005
32204
78000
32204
78001
32204
78002
32204 78003
32204
78004
Part number
32263
E9000
32263
E9001
32263 E9002
MANUAL
TRANSM
I SSI ON
Servi ce
Dataand
Speci fi cati ons
Maln haft
rearend
besrlna
Thi ckness mmli n
Part number
110
043
1 2
00471
1 3 00511
1400551
32228
20100
32228
20101
32228
20102
32228
20103
Counterdri ve aear
Thi ckness mm
li n
Part number
1 4 0055
1 5 0059
160
0631
32215
E9000
32215
E9oo1
32215 E9oo2
AVAI LABLE SHI M
Counter
front bearlna
Uni t
mm
i n
D
A
@
I
j
TM371
1 Transmi ssi on case
2 Counter
gear
front
beari ng
3 Counter
gear
4Shi m
A
Thi ckness of shi m Part number
342 351
01 00041 32218 E9000
01346
0
13821
3
32 341
02 100081 32218
E9001
0
1307
013431
3
22 3
31
03 0012 32218
E9002
0
1268
01303
312 321
040016 32218
E9003
01228 01264
3
02
311
05 00201 32218
E9004
01189 012241
2
92 3
01
060024 32218
E9005
0
1150011851
TI GHTENI NG TORQUE
1
Uni t
Nm
kg m
ft b
I
Transmi ssi on
i nstallati on
I
Clutch
operati ng
cyli nder
3040 31 41 22
30
I
Transmi ssi on
toengi ne
43 58 44
5 9 32
43
I
Gusset totransmi ssi on
25
35 2636 19 26
transmi ssi on
I
Crossmember
to
body
31 42
32 4
3
23 31
I
Rearmounti ng
i nsulator
31 42
32 43 23 31
to
crossmember
I
Rear
mounti ng
i nsulator
31
42
32 43 23 31
toreaf extensi on
I
Transmi ssi on caseto
16 21 162
1
12
15
rear
extensi on
I
Startermotor
to
29 39 3
040 22
29
transmi ssi on
I
Gear
assembly
I
Beari ng
retai nerto
16 23 16
23 12 17
adapterplate
Mai nshaft
locknut 137 167
14017 0101
123
Counter
gear
lock nut
98 127 100130
72 94
Rearextensi on to
16 21 1621
12 15
transmi ssi on case
Front coverto
16 21
1621 12 15
transmi ssi on case
Fi ller
plug
25
34 25 35 18
25
Drai n
plug
25 34 25
3
5
18 25
Ball
pi n
2034 2035
14
25
Stri ki ng
lever
locknut
88 11 8 0
9
1 2
65 87
Check
ball
plug
19
25 19 2
5 14
18
Speedometer
sleeve
39 49 04
05 29 36
i nstallati on
Back up lamp
swi tch
2029 20
3
0
14 22
Return
spri ng plug
7
8
98
08 1 0 5 8 72
MT17
TroubleDi agnosesa
Correcti ofl
MANUAL
TRANSMI SSI ON
TROUBLE
DI AGNOSES AND
CORRECTI ONS
Levelcolor
N
G
Noi se
Check leveland color
ofoi l
I
L
Add
replace
oi l
I f
oi l
leaks
repai r
cause
Check
noi se
I
NOi se
does not
stop Noi se
stops
O
K
LevelandcolorOK
Shi ft
gears
and locote
whi ch
0
gearposi ti on
makes noi se
I
Noi sei n
Neutral
I
Di sengage
clutchto
see
i fnoi se
stops
I
Noi se
does
not
stop
Noi seoutsi de
transmi ssi on
Check
engi ne
anddutch
etc
Noi seoccurs
i n
a
speci fi c
gearposi ti on
and
peaks
at
speci fi cengi nerpm
and
stops
wi th
gears
i nTOP
posi ti on
1
Noi se
appears
tooccur
i n
transmi ssi on
Di sassemble
and
check
gear
i n
whi ch
l
noi se
occursfor
meshi ng
surface
nd
beari ngs
1
Replace
gear
and
or
beari ng
MI lS
Noi se
i n
posi ti on
otherthan
Neutral
Noi se
stops
Noi sei ntransmi ssi on Noi se
may
becaused
by
vari ati ons
i n
engi ne
torque
Adjust engi ne
i dle
speed
Hi gh
roari ng
noi se
occurs
i n
all
posi ti ons
and
peaks
8t
speci fi c
engi ne
rpm
I
Noi se
occurs
i n
all
posi ti ons
except
Neutral
and
peaks
at
a
speci fi c
car
speed
1
Noi se
source
appears
tobe
locatedi ndi fferenti al
carri erCheckdi fferenti al
carri erandeli mi nate
cause
ofnoi se
Noi se
occurs
whi le
shi fti ng
gears
Referto1hesecti on
Faulty
Synchromesh
Mechani sm
L
Gears
grate
whi le
synchro
ni zi ng
L
Noi seoccurswhen
stroki ng
further
after
shi fti ng
gears
Movi ng parts
coupli ngs
gears
etc of
transmi ssi on
i nterferi ng
wi thother
parts
MANUAL TRANSMI SSI ON
Trouble Di sgnoseundCoi rr
cti ons
Gear
jumpi ng
out of
mesh
L
Loc i lte posi ti on
where
gearsjump
out of
mesh
Checkfor
free
play
i n
control
lever
Shi fti ng
i s
accompli shed
wi thout
problems
Check
i nterferenceof control
leverwi th
console and
check
rubber
boot
of
control
lever
for
fati gue
N G
Adjust
or
replace
OK
I
Check
for
fati gue play
etc
on
front
and
rear
engi ne
mounts
I
N G OK
Problem
may
bei nsi detransmi ssi on
Di sassemble
andcheck transmi ssi on
Adjust
or
replace
Replace
Checkend
play
of
jump
out
gear
I
End
play
O
K
Check
for
engagi ng damage
orwear
on
coupli ng
sleeve
synchroni zer
hub andclutch
gear
of mai n
gear
I
End
play
excessi ve
Damage
or
wear
OK
Check
forwearor
damage
on
check ball
and
fati gue
or
breaks
oncheck
spri ng
I
Replace
Damage
or
wear
Replace
O
K
Check
for
wear
ordeformati on
of fork
rod
ball
groove
Wearordeformati on OK
Check
for
wearor
play
of
jump out
synchro
ni zerandmai nshaft
spli nes
I
Replace
Wear
or
play
No
wearor
play
Replace
Checkforwearor
damage
on
beari ngs
of
mai n
shaft
andcountershaft
Replace
i f
worn
MT19
Trouble
Di sgnoseund
CDrrecti ons
MANUAL
TRANSMI SSI ON
N
G
Repai r
or
replace
Clearance
N G
Replace
baulk
ri ng
Chamferedarea worn
1
Replace
I mpropercontact
l
Replace
baulk
ri ng
Spread
spri ng
broken bent
1
Replace
MT 20
Faulty
synchromesh
mechani sm
Noi se
occurswhi le
shi fti ng gears
Locate
posi ti on
where
i mpropersynchro
meshi ng
occurs
L
Check
di sengagi ng
of
clutch Refer
to
Clutch
Drags
Secti on CL
for
trouble
di agnoses
and
correcti ons
I
OK
Problem
may
be
i nsi de
transmi si on
Di sassembleandcheck transmi ssi on
1
Measurebaulk
ri ng to gear
clearance
Refer
to
Baulk
Ri ng
for
i nspecti on
Clearance OK
l
Check forw
aron chamfered
area
of
baulk
ri ng
I
Chamferedarea not worn
1
Check contact
pattern
ofbaulk
ri ng
and
tapered cone
ofclutch
gear
Propercontact
l
Check
spreadspri ng
for
any
break or
bendi ng
I
Spread
spri ng
not broken bent
1
Check forweardeformati on
ofi nsert
Referto
Shi fti ng
I nset
for
i nspecti on
N
G
Repai r
or
replace
N G
L
Replace
MANUAL TRANSMI SSI ON
TroubleDi agnoseund
Correcti on
Di ffi cult
gearmeshi ng
shi fti ng
Shi ft
gears
up
and
downwhi le
operati ng
car
to
seei f
gears
shi ft smoothly
Shi ft
gears
whi le
engi ne
i s
OFF
I
Problem
may
be
i nsi de
transmi ssi on Remove
trans
mi ssi on fromcar
di sassemblei t and check
i t
forsource
ofdi ffi cult
meshi ng
shi fti ng of
gears
L
Check
operati on
of
stri ki ng
rod
I
N G
Check for
proper
i nstalla
ti onof
controllever
O
c
N G
Repai r
or
replace
OK
Check
gear
endfaces and
gear
bores
for
any si gn
of
sti cki ng
jammi ng
I fdetected
replace
faulty
parts
OK
N G
Check
engi ne
i dle
speed
I
Adjust
O
K
I
Check
for
i mproper
di s
engagi ng
of
clutch
Check
for
i mproperoper
ati on of
clutch
operati ng
cyli nder
master
cyli nder
I
Operati on
N G
Operati on
OK
I
Check
lubri cati on
oi llevel
and
color
I
Repai r
clutch
N G
Add
replace
oi l
I
OK
Check
for
smooth
shi fti ng
whi le
cari s
operati ng
N G O
K
I nstructscustomers
i n
correct
shi fti ng
method
Ox
Check
operati on
offork
rod
1
Check for
possi ble
bent fork
rodorscratchedcase
Scratched
bent
I
Replace
Check
engagi ng
ofhub cou
pli ng
sleeve clutch
gear
etc
I
MT 21
Speci al
Servi ceTools
MANUAL TRANSMI SSI ON
Toolnumber
Kent
MooreNo
ST2381000l
125693
KV31100300
ST30031000
125733
1
KV311004n
ST23860000
ST22360002
125679
ST22520000
ST23800000
125691
KV32101330
ST22350000
125678
MT 22
SPECI AL SERVI CE TOOLS
Tool
name
Adaptersetti ng plate
Fork rod
pi n
punch
Beari ng puUer
Transmi ssi on
press
stand
Counter
gear
dri ft
Beari ng
dri ft
Wrench
Transmi ssi on dri ft
Beari ng puUer
Mai nshaft
beari ng
dri ft
9
Lo
rQ
OJ
rUoLh
i fi
Tool
number
Kent Moore
No
ST33400001
126082
MANUAL
TRANSMI SSI ON
Speci al
Servi ceTools
Toolname
OU sealdri ft
MT23
DATSUN
200SX Mode S 110
Seri es
SECTI ON
AT
AUTOMATI C TRANSMI SSI ON
CONTENTS
DESCRI PTI ON
HYDRAULI C CONTROL UNI T AND
VALVES
HYDRAULI C
CONTR
LCI RCUI TS
MI NOR ADJUSTMENTS
REMOVAL AND I NSTALLATI ON
TRANSMI SSI ON
ASSEMBLY
MAJOR OVERHAULOPERATI ONS
SERVI CE
NOTES
FOR
DI SASSEMBLY
DI SASSEMBLY
COMPONENT PARTS
AT 2
AT 3
AT 5
AT 25
AT28
AT
28
AT30
AT31
AT31
AT 34
FI NAL ASSEMBLY
TROUBLE SHOOTI NG AND
DI AGNOSES
PRELI MI NARY CHECKS
Pri or
toroad
testi ng
DI AGNOSTI C ROAD TEST
PRESSURE TESTI NG
STALL TESTI NG
SERVI CE DATA AND
SPECI FI CATI ONS
SPECI AL
SERVI CE
TOOLS
AT 44
AT51
AT 51
AT 52
AT54
AT55
AT 52
AT
53
1
Descri pti on AUTOMATI C TRANSMI SSI ON
The 3N7lB transmi ssi on i s
a
fully
automati cuni t
consi sti ng pri mari ly
of
a 3
element
hydrauli c
torque
converter
and
two
planetary gear
sets
Two
i nulti ple di sc
clutches a
multi ple di sc
brake brakeband andone
way
clutch
provi de
thefri cti onelements
necessary
toobtai n thedesi redfuncti on of
the
two
planetary gear
sets
A
hydrauli c
control
system
i s
used
to
operate
the
fri cti on
elements
and
automati cshi ft controls
TORQUE CONVERTER
The
torque
converteri s attachedto
thecrankshaft
through
a flexi ble
dri ve
plate
Heat
generated
i n the
torque
converteri s
di ssi pated by ci rculati ng
thetransmi ssi on flui d
through
an on
towater
type
cooler
i n the
radi ator
lowertank
The welded
constructi on
ofthe
tor
que
converter
prohi bi tsdi sassembly
or
servi ce unless
hi ghly
speci ali zedequi p
ment i savai lable
@ i f
1
Transmi ssi on
case
2
Oi lpump
3
Frori t clutch
4 Band
brake
5 Rear
clutch
6 Front
planetary gear
7 Rear
planetary
gear
DEScRI PTI ON
FLUI D
RECOMMENDATI ON
Use DEXRON
type
automati c
transmi ssi on flui d
only
I DENTI FI CATI ON
NUMBER
Stamped
posi ti on
The
plate
i s
attached tothe
ri ght
handsi deoftransmi ssi on
case
AT344
8 One
way
clutch
9 Low Reverse
brake
10Oi ldi stri butor
11 JQvemor
12
Outputshaft
13
Rear
extensi on
G
14 Oi l
pan
I S Controlvalve
16
1npot
shaft
17
Torque
oonverter
18 Converter
housi ng
19
Driplate
AT2
I denti fi cati on of number
arrangementa
I APO
AUTOI lATle
TllAI I SI I I SSlOllCO lTO
MODEL
X
01 23
NO 7601234
Number
desi gnati on
7601234
L
Seri al
producti on
mber
forthemonth
Monthof
producti on
1 Jan
2 Fob no
X Oct Y
N01
Z Dec
Lat
fi gu
denoti ng
tho
year
A DJ
Ti ghteni ng torqueTof
bolts
andnuts N m
kg m
fHb
@ T 39 49 4
5
29 36
@ T 137 157
14
16 101
116
@ T 44 54 4 5 5 5 33 40
@
T 5 9 7 8
06 08 4 3 5 8
@ T 49 69 05
0
736
5 1
T
2025 2 02
5
14
18
@T 13 l8 LJ 18 9 13
@
T 54 7 4 055 075 4054
CD
T 2 5 34 025 035 182
5
AT312
AUTOMATI C
TRANSMI SSI ON
Hydi auli c
ControlUni t andValves
HYDRAULI C
CONTROL
UNI T
AND
VALVES
The
hydrauli c
orautomati c
control
system
i s
compri sed
of four
4
basi c
groups
the
pressure
supply
system
the
pressure
regulati ng
system
the
flowcontrol
valves and the
fri cti on
elements
PRESSURE SUPPLY
SYSTEM
The
pressure
supply system
consi sts
of a
geartype
oi l
pump
dri ven
by
the
engi ne
through
the
torque
converter
The
pump
provi des pressure
for
aU
hydrauli c
and
lubri cati on needs
PRESSURE REGULATOR
VALVES
The
pressure regulati ng
valvescon
trolthe
output pressure
of the
oi l
pump
Pressure regulator
valve
The
pressure regulator
valve con
trols mai nli ne
pressure
based on
throttle
openi ng
for
the
operati on
of
theband clutchesandbrake
Governor
valve
The
governor
valve tranSffi ts
re
gulated
pressure
based on
car
speed
tothe
shi fi
valves tocontrol
upshi fts
anddownshi fts
Vacuum
throttlevalve
Thevacuumthrottlevalve
transmi ts
regulated
pressure
based on
engi ne
load vacuum Thi s
pressure
controls
the
pressure
regulator
valve Alsothi s
pressure
i s
appli ed
toone
end
of the
shi ft valves
i n
opposi ti on
to
governor
pressure
whi chacts on theother
end
of theshi ft valves
controlli ng upshi ft
anddownshi ft
speeds
FLOW CONTROL
VALVES
Manualvalve
The manual
valve i smoved
manual
ly by
the
car
operator
to
select the
di fferent
dri ve
ranges
12
Shi ft valve
The
1 2 shi ft valve
automati caUy
shi fts
the transmi ssi on from fi rst to
second orfromsecondto
fi rst
depend
i ng upon
governor
and throttlepres
sure
along
wi th
accelerator
posi ti on
solenoi d
downshi ft valve See
Hy
drauli cControl
Ci rcui ts
Dri ve2
2
3Shi ft
valve
The 2
3 shi ft valve automati cally
shi fts the
transmi ssi on
from
second
to
top
gear
orfrom
top
to
second de
pendi ng
up governor
and
throttle
pressure
oraccelerator
posi ti on
sole
noi d
downshi ft
valve
See Hydrauli c
ControlCi rcui ts
Dri ve
3
Range
2
3
Ti mi ng
valve
For23shi fts a
restri cti ve
ori fi ce
slows
the
appli cati on
flui dto
the
front
clutch
whi le theslower
reacti ng
band
i s
allowed
torelease
Thi s
prevents
a
hard 2
3
or
3 2
shi ft Under
heavy
load however
the
engi ne
wi ll
tend
to
run
away
duri ng
the
2 3 or3 2 shi ft
pause
therefore
a 2 3
ti mi ng
valve
usi ng
throttle
and
governor
pressure
i s
used to
bypass
the restri cti veori fi ce
duri ng
such
heavy
load
condi ti ons
Solenoi d
downshi ft valve
The solenoi d
downshi ft
valve i s
acti vated electri cally
when
the
ac
celerator
i s floored
causi ng
a forced
downshi ft from
top
tosecond
top
to
fi st
or
secondtofi rst
geardependi ng
upon
car
speed
governor
pressure
Pressure modi fi edvalve
The
pressure
modi fi er
valve
assi sts
the
mai nli ne
pressure
regulator
valve
i n
loweri ng
mai nli ne
pressure
duri ng hi gh
speed li ght
load
condi ti ons such
as
steady speed
crui se
Governor
pres
sure
worki ng agai nst
a
spri ng
opens
thevalvewhi chaUowsmodi fi edthrot
tle
pressure
towork
agai nst
the
pres
sure regulator
valve
spri ng loweri ng
mai nli ne pressure
Lower
operati ng
pressure
under
li ght load reduces oi l
temperature
and
i ncreases transmi s
si Oli li fe
Throttleback
up valve
The throttle back
up
valve
assi sts
the
vacuumthrottle valve to
i ncrease
li ne
pressure
whenthemanualvalvei s
shi fted
ei therto 2 orI
range
Secondlock valve
The
second lock
valve
i s
used to
bypass
the
1
2shi ft valveto
mai ntai n
the band
apply pressure
i n 2
posi
ti on
The valve
i s
alsoused as an oi l
pass ge
forthe
1 2
shi ft valve band
apply pressure
i n D D
and
I
Range
CLUTCHES AND BAND
SERVOS
The servo
pi stons
of
the
clutches
lowreversebrake andbandaremoved
hydrauli caUy
to
engage
the
clutches
brake and
apply
theband Theclutch
and
prake
pi stons
are
released
by
spri T 1g
tensi on
and band
pi ston
i s
released
by spri ng
tensi on
and
hy
drauli c
pressure
AT3
Hydl7lUli c
ControlUni t andValves
AUTOMATI C TRANSMI SSI ON
ControlvalVe
rTi l
SV
J
AT094
1
Pressure
regulati ng
valve
2 Manualvalve
3 lst 2ndshi ft valve
4 lnd
3rdshi ft valve
5 Pressuremodi fi er
valve
6 Vacuumthrottlevalve
7 Throttle back up valve
8 Solenoi ddownshi ft valve
9
Second
lockv8I ve
102 3
ti mi ng
valve
AT 4
AUTOMATI C TRANSMI SSI ON
Hydrauli c
ControlUni tsnd
Valves
OI L CHANNEL
I DENTI FI CATI ON
Oi lChannels
i nCase Front Face
The ci rcui t numbers shown
i neach
Hydrauli c
ControlCi rcui t
areclassi fi ed
as follows
accordi ng
to
the
functi on
Auxi li ary
li ne
pressure
13
Torque
converter
pressure
14
Governor
pre
ure 15
Throttle
system pressure
1617 18
19
Pressure
source
of theli ne 7
Operati ng
li ne
pressure
for
fri cti onelements
12
3 45 6 8 9 10
1112
AT106
Oi lChannels
i n
Oi l
Pump
Oi l
Channelsi nCase
Face
0
r
o90
Oi l
pump di scharge
hole 7 Governor
pressure
15
i
j J
Torque
converter
0
0 f
i
pressure
l4 0
Servo
release
Rearclutch
pressure10
Governor
feed
pressure
1
pressure
1
Servoti ghteni ng
o
0
pressure
9
11
lnl
Front clutch
rr
I
I
Low reversebrake
pressure12f
pressure
11
U
0
0
Jj
J
o
P
sucti
e
Oi l
pump di scharge
hole 7
Torque
converter
pressure
14
q
Rear
clutch
pressure
1
Front clutch
pressure
11
LOi i J
unm
P
sucti on
hole
a
AT10S
AT107
MECHANI CALOPERATI ON
I n
the
3N71B
automati c
transmi ssi on each
part
operates
as shown
i nthe
foUowi ri g
tableat each
gear
select
posi ti on
Gutch Low Band servo
One
Range
Gear Parki ng
rati o
reverse
way
pawl
Front
Rear brake Operati on
Release
clutch
Park
on
on
Reverse 2
182
on on
on
Neutral
Dl Low 2458 on
on
Dri ve
D2 Second 1458
on
on
D3
Top
1000 on on on
on
2
Second 1458
on on
12
Second
1458
on
on
I Low 2458 on
on
The
low reverse brakei s
appli ed
i n 1
range
to
prevent
free
wheeli ng
when
coasti ng
andallows
engi nebraki ng
AT5
Hydrauli c
Control
Ci rtui rs
AUTOMATI C
TRANSMI SSI ON
HYDRAULI C CONTROL CI RCUI TS
P RANGE PARK
Iarki ng
Mechani sm
Powerflow
I n P
range
the shi fl
li nkage
actuated
parki ng pawl
meshes
i n
a
gear
spli ned
tothe
output
shaft
preventi ng
movement of the
carWhen the
engi ne
i s
runni ng
thelowandreversebrake
i s
appli ed
by pressure
from
the
manual
vUve passi ng
through
the 1 2 shi ft
valye
F
Locr
11
AT086
Flui dflow
ManualValve 4
Downshi ft Valve 13 2nd
3rdShi ft valve
1st 2ndShi ft Valve
ThrottleBack
up
Valve
5 I st
2ndShi ft
Valve
12
I
1h
ottleBack
up
Va
ve
y
Low
ReverseBrake
I
AT 6
AUTOMATI C
TRANSM
I SSI ON
Hydrauli c
Control
Ci rcui ts
Oi l
Pressure
Ci rcui t
Di agram
P
rangepark
r
nh r
c
h
11
rI f
0
I
h
gm
j E
J
I
rl
j
@1
9
10
I Y
t
r
r
l
l
I
olu
l
volv
I I
oI ll
I
I
I
I I
oL
LLl
fi r
x
lL
I
r
16 13
TorQu
conv t
Oi
I
cooler
TI C Oi l
r
Slllt
ro
O
j
01
Rnt lubri cati on
o
Drai n
14
01
Front
lubri cati
0
0
1
1
J
1
x
J
l
I
6
I I CD
P
ur
otor
JJI
1
p
1
1
Throttl
drai n
1
I
C
1
SI I JL
J
2Z
I I
x
1J
I E
2no3d
I i
mi no
vol
1
I
I I
I
@
I ck
I I
r3
I
I
15
J
ji
t2
Sh I
j
I
ru
I
I I
Monuol
YOI
I
I
xn
llrrI tr
Not Mork
d X ort droi n
Secondory
Qovunar lOlv
Li n
prulUr
lGoy rnorfud
pt
r
Pri mo
OO
l I Or olv
Go
rnor
prUI 1 l11l
I
Torqu
con t
t r
pr
r
Th
rolI
pr
r
AT455
AT7
Hydrauli c
ContrrJI
Ci rcvi ts AUTOMATI C TRANSMI SSI ON
R RANGE
REVERSE
Power
flow
Wi th the
selectorlever
i n R
range
the front clutchi s
appli ed
to
transmi t clockwi se
engi ne torque
through
the
connecti ng
shellto
the
Sun
gear
Theclockwi se
rotati on
ofthe
sun
gear
causes
the
planet gears
to
rotate counterclockwi se
Wi ththelow
and reverse brake
holdi ng the rear
planet
carri er
the reari nternal
gear
spli ned
tothe
output
shaft turns
counterclockwi se i n a reducti on
rati o
of
approxi mately
2
18to
I
Flui d flow
ManualValve 4
Mechai ti cal
Operati on
duri ng
R
Range
Front
gear
set
Front clutch ON
Rear
gear
set
Output
I nput through
front
clutch
Held
by
low reverse
brake
A
T329
Low
reversebrake ON
N
Front clutch
Rearclutch
Lowandreversebrake
Brak
bandservo
One way
clutch
Downshi ft
Valve I 3
5
Throttle
Back
up
Valve
6
I st
2ndShi ft Valve 12
L
Pressure
Regulator
Valve
2nd3rdShi ft
Valve
10
AT 8
ON
OFF
ON
OFF
Pressure
release
Overrunni ng
AT085
2nd3rdShi ft Valve
L
I st 2ndShi ft
Valve
I
ThrottleBack
up
Valve
y
Low Reverse Brake
BandServoRelease
Si de
I I
1
Front Clutch
AUTOMATI C
TRANSMI SSI O
N
Hydrauli c
Control
Ci rcui ts
Front RlOr
I
h
l
h
0
I
I
trJI
ki ll
TI C Oi l
cr
l
r
reOlollalni l
volu
1
1
1
l
T
I
JUI
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U
Oral 01
I L
J
i
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11 LL
l
h
fi
ThMI I
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drai n
val
I
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xjJ l
uff
I
n
ui
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M
O k
I I
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1
L J
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lr
1
vci
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l
l
1
x
No
Markld
X
dfoi n
lrto
Li n preuur
Go
rnor
udpr
ur
Oi lPressure
Ci rcui t
Di agram
R
range
Reverse
Torque
ton l
rt r
broi l
Brok
band
J
12
Oi lcool
x
jJ
G9
2nd3rd
li mi ng
olv
x
CD
p
Jr
ator
L
r
G
avrnor
prn ure
fm
Torqu COMut r
prl
ll
Thronlpr
un
I D
24
Ool
lr
rl
6
I
Secondory
go
rnOI
lGlv
Pri mor
go
i tlr
01
1
AT456
AT
9
Hydrauli c
Control
Ci rwi u AUTOMATI C
TRANSMI SSI ON
N RANGE
NEUTRAL
Powerflow
I n
ange
nofri cti on
elements
are i n use thus nopower
i s trans
mi ttedto
the
output
shaft
AT10
AUTOMATI C
TRANSMI SSI O
N
Hydrauli c
ControlCi rcui ts
Oi lPressure Ci rcui t
Di agram
N
range
Neutral
flL
4
1t
T11 r1I
11 I
Ori fi ce
18
chlcll
fol
a
L
I
6
Torql ll
convrt r Front
lI tCh
Oi l
1
i
I
Oi
I
cooler
RI O
I
i
eali a
Drai n
I
101
Front
lubri caf t
Drai n
01
1
t
x
Xl
I I
CD
P
otor
Bond
YO
I
1
Throttle
drai n
101 11
10
c
o
Z2
I I
t1J
x
21
6
I V
i lL@
dlock
frO 6
I I
r
OI
@
Not
Worked
on
drai n
li nt
prUSUft
Go
rnorudpr
nur
G
o no prlssure
nItI
Torqu
conyut
pnn
r
ft
Th
rottl
p
ur
I
12
x
@
Vacuum
I hrottl
oh
Throtllt
bacllup
wolv
IJI
Fe
X
own
i 1t OI Y
rI 5
I
jULj
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I I
I I
fLx
5
l
r
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t
2
dl
Shi flI llGI Y
I
I
I
I
Slcondar
OOv
nor
01
Pri mory
00
rnor
vol
A
T457
AT11
Hydrauli cCentrolCi rcui ts AUTOMATI C
TRANSMI SSI ON
D RANGE
LOW GEAR
Powerflow
Wi ththeshi ft
selector
i n D
low
gear
engi ne
torque
i s transmi tted
through
the
appli edrearclutchto
the
i n1ernal
gear
of the
fron1
gear
set The
clockwi se rotati on
of the front
i nter
nal
gearcauses
the front
planet gears
torotate clockwi se
dri vi ng
thecom
pound
sun
gear
counterclockwi se
The
front
planetary
carri er
i s
spli ned
10the
output
shaft Thi s causes
the
planet
gears
todri ve the
sun
gear
i nsteadof
walki ng
around
the sun
gear
Thi s
counterclockwi se rotati on
of the sun
gear
causes
the
rear
planet
gears
to
rotate
clockwi se Wi ththe one
way
clutch
holdi ng therear
planet
carri er
the
rearplanetary
gears
turn therear
i nternal
gearand
outpu1
shaft
clock
wi se i n
a reducti on rati o
of
approxi
mately
246 toI
Flui d flow
ManualValve
Mechani cal
Operati on
duri ng 61 Range
Front
gear
set
Rear
gear
set
Output
shaft
Held
by
oneway
clutch
I nput
fromfront
gear
set
Output
toreai
gear
set
A
T330
Front clutch
Rearclutch
Lo andreversebrake
Brakebandservo
One
way
clutch
OFF
ON
OFF
OFF
HOLDI NG
AT081
GovernorValve 15
PressureModi fi erValve
2nd3rdShi ft Valve
I st 2ndShi ft
Valve
I st
2ndShi ft Valve
2nd3rd
Ti mi ng
Valve
J
Rear
Clutch
2
3
SecondLockValve
Second
Lock Valve
L
Ori fi ceCheck
Valve 2nd3rdShi ft
Valve
AT12
AUTOMATI C
TRANSMI SSI O
N
Hydrauli c
ControlCi rcui ts
Oi lPressureCi rcui t
Di agram D1 range
Low
gear
1
Torqu
ean
rlr
Oi I
pump
t
1
Pres ur
rlQulo1
or
valv
L
Front
cluleh
t
I
6
2
J
1
t
Rlar
clutch
Brake
bond
Low Q
nd
r
v
1 brake
3 Shi ll OI
o
t
Bond
I b
7
ervo
I
1
Torque
conyerter
pressure
Throttle
prlssure
I t
ll
1
Throttle
pr
sur
t
@
I
Governor
pressure
li nt
pr
s ur
Governor
pre
sure
AT446
AT13
Hydrauli c
ControlCi rcui m
AUTOMATI C
TRANSMI SSI ON
D
RANGE 2ND
GEAR
Mechari i caI
Operati ondti ri ng D2 Range
Power
flow
I o
D
range
the brake band
i s
appli ed
tohold the
connecti ng
sheU
and sun
gearstati onary Engi ne
torque through
the
appli ed
rearclutch
i s
deli vered
to
thei nternal
gear
of the
front
gear
set
i n
a clockwi se
rotati on
Clockwi se
rotati on
ofthei nternal
gear
causes the
planet gears
to walk
around the
stati onary
sun
gear
i n a
clockwi se di recti on
Thi s
causes
the
output
shafl
whi ch
i s
spli ned
to
the
front
planet
carri er
toturn
i n
a
clock
wi se di recti on wi tha reducti on rati o
ofabout 146toI
Front
gear
set Rear
gear
set
AT331
Front clutch OFF
Rearclutch ON
LOwand
revelSe
bi ake OFF
llr I ke band
servo
ON
One
way
clutch OFF
AT079
Flui dflow
Ascar
speed
and
governorpressure
i ncrease the
governor
pressure acti ng
on
the end of
the
1
2 shi ft valve
overcomes the force of
the
1
2
shi ft
valve
spri ng
and li ne
pressure
Thi s
aUows the
1 2
shi ft valve tomove to
the
upshi ft
posi ti on
whi chdi rectsli ne
pressure
through
the
2nd
lock valve
and
on
tothebrakeband
ManualValve Governor
Valve 15 Pressure Modi fi erValve
2nd3rd
Ti mi ng
Valve
2nd3rd
Shi ft Valve
I st 2ri dShi ft Valve
I st 2ndShi ft
Valve 8 SecondLock Valve 9
BandServo
Apply
Si de
4
Rear
Clutch
I
2 SecondLock Valve
3
I
SecondLock Valve
L
Ori fi ceCheck Valve
2nd3rdShi ft Valve
AT 14
AUTOMATI C TRANSM
I SSI ON
Hydrauli c
ControlCi rcui ts
Oi l
Pressure Ci rcui t
Di agram D2
range
2nd
gear
F
Oi l
pump
t
fJ
Tor
q
ua
conYerter
Pressure
r
oulator
valve
Li ne
pressure
Gover
or
pressure
Front
clutch
Brake
band
Low
and
revers broke
Reor
clutch
I
tl
t
2 hjf
llvOI V
t
r
t
u
l
1I trrr1ltrrr1I trrr
Throttl
e
I t
pressure
j
@
P RND21
Govern
or
pressure
Torque
converterpressure
Throlll
prellur
AT448
AT15
t
Hydrauli cControlCi rcui ts
AUTOMATI C
TRANSM
I SS10N
D RANGE 3RD GEAR
Powerflow
I n on
range
engi ne torque
i s
transmi tted
through
bothclutches
The
front clutch
turns the
i nternal
gear
oftheforward
gear
set
clockwi se
The rearclutchturnsthesun
gears
i n
a
clockwi se
di recti onalsoWi thboththe
i nternal
gear
andthe sun
gear
of the
forward
gear
set
turni ng
i n
the same
di recti on
at
the
same
speed
the
planet
gears
are
locked i n
posi ti on
andturn
as a uni t
The
output
shaft
spli ned
to
the
forward
planet
carri er
turns at
a
rati oof I I
Flui d flow
Governor
pressure
i ncreases tothe
poi nt
that
i t
can overcomethe com
bi ned forces
of
spri ng
and
throttle
pressure and move the
2nd
3rd shi ft
Manual
Valve
Mechani cal
Ojlei ati onduri ng
D3
Range
Front
gearset
Rear
gearset
I nput through
front
andrear
clutches
Output
shaft
A
T332
Front
clutch ON
Rearclutch
ON
I l
N
Front clutch
Rear
clutch
Lowandreverse brake
Brakeband servo
One
way
clutch
valve When the
2nd
3rd
shi ft valve
opens
pressure
passes
through
the
valvelands
tothe
2 3
ti mi ng
valve
and
on to
apply
the front
clutchand
GovernorValve
15
ON
ON
OFF
OFF Presswerelease
OFF
AT083
release the
brakeband Thecar
i s
now
i n
D ordi rect dri ve the
rearclutch
was
already
appli ed
Pressure
Modi fi erValve
2nd3rdShi ft Valve
2nd3rd
Ti mi ng
Valve
I st
2ndShi ft
Valve 8
lst
2nd
Shi ft Valve
i
I
Band
Servo
i s
released
t
SecondLock
Valve
I
LOri fi Ce
Check Valve
2nd3rdShi ft Valve
10
TI Band
ServoRelea Si de
I
42nd3rd
Ti mi ng
Valve I I
I
Front Clutch
1
J
RearClutch
I
2
SecondLock
Valve
3
AT16
Second
LockValve 9
I i
Band
Servo
Apply
Si de
AUTOMATI C
TRANSM
I SSI O
N
Hydrauli c
Control
Ci rrui t3
Oi lPressure
Ci rcui t
Di agram D3
range
3rd
gear
1
t
Oi
I
pump
Torq
ue
canYlrter
r
l
Pressure
re
QU
lator
valve
L
i n
pressure
Governorpressure
Fronf
clutch
Low and
rever brake
Rear
clutch
Brake
bond
0
t
Bond
JJ
JI 1
y Wr
t
It
sY
i f
t
tr
I l
PRN021
t
t
@
Throttle
pressure
Ya I v
Governor
pressure
i
t
lo
I I DJWq
Torque
eonvrter
pr
ur
I i jp
I
Throlll
preuur
AT449
AT 17
Hydrauli c
ControlCi rcui ts
AUTOMATI C
TRANSMI SSI ON
D
RANGE
KI CKDOWN
Toachi eve a forced
downshi ft from
3rd
to2nd the
car
speed
must be
under
approxi mately
100kmh60
MPH from
2nd to
1st i t
must
be
under
approxi mately
50
km h30
MPH
FuUy
depressi ng
the
accelerator
pedalenergi zes
the downshi ft sole
noi d
whi ch
opens
the
solenoi d down
shi ft
valve Oi l
pressure
i s then
exerted
agai nst
the shi ft valves Between 50
and 100
km h30and 60
MPH
thi s
pressure
wi D close the 2nd
3rd shi ft
valve
agai nst governor
pressure
andthe
car
downshi fts When
the
car
speed
i s
below50
km h30
MPH
the
I
st 2nd
shi ft valvewi ll
beclosed
and
the1rans
mi ssi on
wi llbe i n 1
st
gear
As car
speed
and
governor
pressure
i ncrease
theshi ft valves
automati caUy
reopen
AT I S
AUTOMATI C
TRANSMI SSI ON
Hydrauli c
ControlCi rcui ts
Oi lPressureCi rcui t
Di agram
D
range
ki ckdown
shi ft valvesi n
2nd
gearposi ti on
Torqulconv
rlr
Front Rlor
I utch
ClutCh
Oi l
J1
r
I
TI C on
p
V
ro
I
O
rog
o
1
0
I t
i
i
N
all
COOler
RI hlbri cot
i on
8
Oraln
14
vohl
I
Front
lubri CQti f
W
11
X
J
j
D
1
I
t
1
Qto
j
oz
n
l
I
I
m
I
lI D
Vacuum
throttl
01
i
d
Yol
23
Ol
yoll
@
PRND2 I
f
S
D
o
t
y
d
I
3r
J
lu
i
I
own
i 1
01
lI
S
U
I
I
8
18
16
@Z l
3n I
Shi ft
Yol
Hmu u
Jr
5
r
r
1 pul B
2 d
I
i i
lJlu
r
I
N
Tr
Throttle
drai n
101
I
C
JI J
Z2
g
2nd
3rd
li mi ne
avI
X
J
L
1
I
Hot
Worbdl
ore
Oroln
I I o U
Li n pr
r
Govlrnor
fudp
uunl
L
GOY
flU
pr
u
Tor4 lt
c
on I r
pr
sure
v
Th
r011l
pr
ur
Pri mor
90
rrroryoY
A
T458
AT19
Hydrauli c
Control
Ci lCui l
AUTOMATI C
TRANSMI SSI O
N
2
RANGE
2ND
GEAR
Flui d flow
openi ng
the valve and
aUowi ng
pres
sure to
pass
i ntothe li ne of the
throttle valve thus
assuri ng adequate
throttle
pressure
even
duri ng
decelera
ti on
The downshi ft solenoi d valve
i s
used as a
passage
for
li ne
pressure
to
lock
the1 2
and
2 3
shi ft valves
Powerflow
Powerflow
i n
2 range
i s thesame
as
i n
D1 range
Li ne
pressure
from the
manual
yalve
opens
the second lock valve
agai nst
spri ng
pressure
As thi s
valve
opens pressure
then
passes
to
apply
the band servo Li ne
pressure
also
flows to the
throttle back
up
valve
The
range
2
posi ti on
i s used to
lock he
cari n 2nd
gear
preventi ng
upshi fts
or
downshi fts
under
any
con
di ti ons
ManualValve Governor
Valve
15 Pressure Modi fi erValve
2nd3rd
Ti mi ng
Valve
L
2nd
3rd
Shi ft Valve
I s1
2ndShi ft
Valve
lst 2ndShi ft Valve
Rear
Clutch
I
2
BandServo
Apply
Si de
I
Solenoi dDownshi ft Valve 13
t2nd
3rdShi ft
Valve
1st 2ndShi ft Valve
SecondLock Valve 9
4
ThrottleBack
up
Valve
17
VacuumThrottleValve
16
Pressure Modi fi erValve
2nd3rd Shi ft Valve
2nd3rd
Ti mi ng
Valve
Throttle
Drai nValve
Pressure
Regulator
Valve
AT
20
AUTOMATI C TRANSM
I SSI O
N
Hydrauli c
Control
Ci rcui ts
Oi lPressure
Ci rcui t
Di agram
2
range
2nd
gear
Torqvt
convr1
r
Oi lcooler
Drai n
olv
Drai nvolv
Front
lubri cati t
WI
x
x
1
J
Q
Pr
or
I auotor
01 1
Rlor
r
r
rl
vi t
I
9 10
ll
14
12
bock
up
downall
ft
volv
yolv
t
6
ff
I I
I
l
r
13
@
Vacuum
I hrottlt
01
Throttl
drai n
01
11
l
1
1
i
22
@2nr3rd
Shi ft
01
I n
I I
21
6
6
I I
Manual
I
@
P
R
f
No
worktd
X or
droln
li nt pr
ur
l
ornor
t
dpr
urel
Pri mory
QO
nor
volvl
1i
lS
Ga
tnor
p
U Ur l
JA
Torque
con
pt
r
Throttl
pt
fI
AT459
AT21
Hydrauli c
ControlCi rcui u
AUTOMATI C TRANSMI SSI ON
1 RANGE
LOW AND
2ND GEAR
The
range
I
posi ti on
i s used to
lock the
cari n 1
st
gearpreventi ng any
upshi fts
I ftheselectorJever
i smoved
to
the 1
posi ti on
whi le
the
cari s
movi ng
at
hi ghspeeds
the transmi s
si onwi llnot shi ft
i nto
fI rst
gear
unti l
car
speed
slows to
approxi mately
50
kmh
30
MPH I nsteadi 1wi llshi ft to
Manual alYe
second
I
as
governor
pressUrepre
vents the 1
2shi ft valvefrom
closi ng
Power
flow
The
power
flowi n I
di ffers
sli ght
I y
fromD i n
that
thelow
andreverse
band i s
appli ed
to
hold
the
rear
gear
set
planet
carri er
provi di ng engi ne
braki ng
Powerflowi n I i s 1he
same
as
i n
D
1
Governor
Valve
15
Pressure Modi fi erValve
Flui d
flow Low
gear
Manual
pressure passi ng
through
the
1 2
shi ft valvei s
usedtoclose the
1 2
shi ft
valve
preventi ng
a 1 2
up
shi ft
Manual
pressurepassi ng through
the
downshi ft
valvelocksthe2 3shi ft
valve
closed
along
wi th
applyi ng addi
ti onal
c1
si ng
pre
ssuretothe1 2
shi ft
valve
2nd lnl
Tuni ng
Valve
tolst
2nd Shi ft Valve
lst 2nd
Shi ft Valve
2nd lrdShi ft Valve
j
RearClutch
I
4
Solenoi dDownshi ft Valve 13
t2nd
lrdShi ft Valve
I st 2ndShi ft Valve
ThrottleBack up Valve
5 I st 2nd Shi ft
Valve 12
FluI dflow 2n l
gear
ManualValve
lbrottleBack
up Valve
I
Low
I i ReverseBrake
I
1 GovernorValve 15
Pressure
Modi fi erValve
2ndlnlShi ft Valve
2nd3rd
Ti mi ng
Valve
1st
2nd Shi ft
Valve
8
1st
2nd
Shi ft
Val
Second
Lock
Valve
91
Band
Servo
I
Apply
Si de
j
Rear
Clutch
I
4 Solenoi dDownshi ft Valve
13
t2nd
lrdShi ft Valve
1st
2nd
Shi t
t Valve
Throttle Back up
Valve
17
1
2ndlrdShi ft
Valve
Pressure
Modi fi erValve
2nd
3rd
Ti mi ng Valve
ThrottleDrai nValve
5 bt 2ndShi ftValve
Pressure
Regulator
Valve
AT
22
AUTOMATI C
TRANSMI SSI ON
Hydrauli c
Control
Ci rcui ts
Oi lPressureCi rcui t
Di agram
I I range
Low
gear
La and
b
r
Rlor
Srok
Ccllutth
bond
J
p
I
j
I JI
I I
Ji r
I u
r
I
o
i
1@
112
1 1 XI I
CI
Vacuum
Throttl OI UOld
t9 10
throttl
back
up
downlhlft lol
1
I
01 1
vol ll
1
I
I I
r
1
I
i
i
f
c
1
J
I
I
j
l
wr
X
I e 16
1
@2nct
3rdShi ft
val
D
ft
m
I
I I
1
lr
11
I
f
n
j
J
i j
jl
N dX d ooo
X
Secondory
Qov
rnor
01
Torqul
con
r
I
11 cooler
Rlorlubri cali on
I
Drai n
yo
Oroln Yol
Front
lubri CG ltc
tu
I
x
rl
u
CD
P
UI
otor
C
m
con o
Et
oPhrogm
ThroW
drai n
vol
I I
Li n
prusur
Goy
rnortudpr
un
Pri mory
90
I er
nor 101 1
G ov
rnor
pr
ul t
A03
Torqul
converler
pre
ure
AT460
Th
oltl
preure
AT 23
Hydrauli c
ControlCi rcui ts
AUTOMATI C
TRANSMI SSI ON
1
L
@2n
3tdSlli ft
10
101
S
I
r
i
@2nd
3rdli mi nv
vol
I t
I i i
tJJ
r
I
II
r
jjPressure Ci rcui t
Di agram
1
2
range
2nd
gear
La and
broi l
Torqu can
rt r
Front
clufeh
R
or
tuteh
Oi lcool
TI C Oi lpt u
re9U
Olloro
J
I
oB
0
l
I
oro
l
JI
Rlorlubri cati on
n
4
I i i
I I
11
Orai n
0
01
FrOnt
lub i coti c
Throttl
drai n
101 1
Orai n
1
01
1
f
I
D
Pr
uro
nouotor
vol
uum oot ol
hro
m
2
I
I I
17
1t
6
b
J J
I I I
11i
Th t1
I I tI Ol1
g
bocll
up
downahi
tyol
101
I
3
ldI
I
zo
1
r
Sh
l
u
L
6
I
w
Manual
2
PRND2
I f1
n
Not Mork dX ondrai n
Lute pruGov
rnor d
pt
urt
Goy
rnOt
prlS
U
U
T
T
rquI
COn
pr
lur
Thotll
p
nut
AT
24
S
condor
90 t
ftOI
YQlv
Pti mOI
Q
0Vllnololv
AT461
KI CKDOWN
SWI TCH
ADJUSTMENT
The ki ckdown
swi tch
i s located
at
the
upperpost
of the accelerator
pedal
i nsi de
the
car
When
thepedal
i s
fuUy
depressed
a
cli ck can
be heard
just
before the
pedal
bottoms
out I f
the
cli ck
i s
not
heard loosen thelocknut and
extend
theswi tchunti lthe
pedal
lever
makes
contact wi ththeswi tch
and
the
swi tch
cli cks
Wi ri ng
Di agram
AUTOMATI C
TRANSMI SSI ON
Mi nor
Adjustments
MI NOR
ADJUSTMENTS
Ki ck downswi tch
7
SATOO1
Do
not
allow
the swi tchto
make
contact toosoon
Thi s
would
cause
re
t
1
mO
R
o
BATTERY FUSI BLE
LI NK
ST ON
t
CC OFF
J
D
rI l
J
6
r
I BW
8
r
WR
I GNI TI ON SWI TCH
MAI N HARNESS
WB
Q
O
O O O O O
D
lI l0000Ul 0Ul
OJ
00UI 0
o
q
o
0
0
0000
lD
O
Q
O
D
FUSE BLOCK
G
I
I
J
rOl
E S
G1 No2 0
DOWNSHI FT
8
SOLENOI D
J
i O
I
I
the transmi ssi on to
downshi ft on
part
throttle
DI AGNOSI S
Swi tch
can
be heard
cli cki ng
and the
transmi ssi onsti lldoes
not
ki ckdown
Check the
conti nui ty
of the swi tch
usi ng
a
conti nui ty
tester
Also
check
for
avai lablecurrent
The car
upshi fts
at
approxi mately 65
and110kmh 40and
70
MPH
only
The
ki ckdown
swi tch
may
bei nternal
ly
shorted When theswi tchi s short
ed
there
i s
conti nui ty
through
the
swi tch
i n
any
posi ti on
Wi Df
WB
BW
I GNI TI ON
ANO
1J
ACCESSORY
RE
rJ
K1CKDOWN
SWI TCH
SEL490
AT
25
Mi nor
Adjustmentt
AUTOMATI C
TRANSMI SSI O
N
I NHI BI TOR SWI TCH
ADJUSTMENT
current to
pass
from the
starteronly
when theleveri s
placed
i n the
p
or
N
range
A
conti nui ty
tester
may
be
usedto
check
the
i nhi bi torswi tchfor
proper
operati on
The twoblack and
yeUow
B
Y
wi res
should
have
con1i nui ty
whenthe
lever
i s i n
the
P
and
Nfl
posi ti ons
Red and
black R
B
wi res should
have
conti nui ty
when
the
shi ft
lever
i s
moved
to
R
range
Thei nhi bi torswi tchhas
two
major
functi ons
I t
allows the
back
up
li ghts
to
i llumi nate when the shi ft
lever
i s
placed
i n
the
reverse
range
I t
alsoacts
as a neutraJ
safety swi tch
allowi ng
Wi ri ng DI agram
00
00
BACKUP LAMP RH
gg
i i i i
RB RB
00
B
8
o
BODY HARNESS
BO
BACKUP LAMP LH
R
O
W
B TTE
a
E
WR
5T ON ACC
Off
1
g g
J
J
I 11LBw
J
6
0
rr
w
I GNI TI ON SWI TCH
WW
we
c2
BW
I GNI TI ON
AND
lJ
ACCESSORY
R
i i
W
O U i i
i i i i
o
N
000
0 0
0000
0
r
o
o
I
o 0
Q
0
Q
o
o
L
FUSE
BLOCK
w
r
I
I
m
a
I I I
co
I i
flfj@
q
Js
l
DlC
BR
l
G
Do
on
ENGI NE
HARNESS
RB oo oU
No2
wecJCJO
M
LW
J
STARTER MOTOR
MAI N
HARNESS
r
BY
B
BR
LW
t
I NHI BI TOR RELAY
I NHI BI TOR
SWI TCH
SEL491
AT
26
I
Place the
manualvalve
i n
Neutral
verti cal
posi ti on
2
Removethe
screw
as
i llustrated
3 Loosenthe
attachi ng
bolts
4
Usi ng
an
ali gni ng
pi n
move the
swi tch
unti lthe
pi n
falls i ntothehole
i n
the
rotor
5
Ti ghten
the
attachi ng
bolts
6 Recheck for
conti nui ty
I f
faulty
replace
theswi tch
MANUAL LI NKAGE
ADJUSTMENT
The
adjustment
of the manual
li nkage
i s
an
i mportant adjustment
of
the auto ti ctransmi ssi on
Move
the
shi ft leverfrom
the P
range
to
Range
I
you
should beableto
feel
thedetents
i n
each
range
I fthedetents cannot be
felt orthe
poi nter
i ndi cati ng
the
range
i s
i m
properly ali gned
the
li nkage
needs
adjustment
AUTOMATI C
TRANSMI SSI O
N
Mi nor
Adjustments
F
R
N
D
I
I
1
Grommets
r
J
c
I
nJ4I
Front
Lock nuts
SAT099
Placeshi ft lever
i n D
range
2
Loosen
locknuts
and
move
shi ft
leverunti l
D i s
properly ali gned
and
cari si n D
range
3
Ti ghten
locknut
Recheck
P and
Range
1
posi
ti ons As
a
safety
measure besure
you
can
feelfull
detent when
shi ft lever
i s
placed
i n
P
I f
you
are unable to
make an
adjustment grommets may
be
badly
wornor
damaged
and
should
be
replaced
Vacuum
di aphragm
rodselecti on
Measured
depth
L
mm i n
Under 25 55 1
0059
25
65
2605
10098 10256
26
15
26
55 10295
1
0453
2665 27
05 10492
1
0650
Over 27 15
1
0689
BRAKE BAND ADJUSTMENT
Proper
brake band
adjustment
results i n smooth
shi fti ng
between 1st
2nd and 2nd 3rd
Although
the
adjustment
i s
very
si mple
i t i s i m
portant
to use an accurate
torque
wrench
I
Loosenlocknut
2
Torque
bandservo
pi ston
stemto
12
to I 5 N
m
12
to15
kg m
9to
I I
ft lb
VACUUM
DI APHRAGM
ROD
ADJUSTMENT
The vacuum
di aphragm
and
the
length
of i ts
di aphragm
rod
help
deter
mi netheshi ft
patterns
ofthetransmi s
si on
I t i s essen1i althat the correct
length
rodbe i nstalled
1 Di sconnect vacuum
hose
at
vacuum
di aphragm
and remove
di a
phragm
from
transmi ssi on
case
2
Usi ng
a
dep1h
gauge
measure
depth
L
Be
sure vacuum throttle
valve
i s
pushed
i nto
valve
body
as
far
as
possi ble
3 Check
L
depth
wi th
chart
below
and select
proper
length
rod
L
Depth
SAT002
1 Noteseated
valve
body
2 Transmi ssi on
case
wall
3
Di aphragm
rod
4 Valve
body
si de
plate
5
Vacuumthrottlevalve
Rod
length
mmi n Part number
29
01142
295 1161
30
0
1181
30 5
1
201
31
0
1220
31932 XOI 03
31932
XOlO4
31932
XOI OO
31932 XOlO2
31932 XOI OI
3
Back
off band servo
pi ston
stem
two
complete
turns
CAUTI ON
00not back off EXCESSI VElY on
adjusti ng
stem as anchor
block
may
fallout of
place
4
Ti gh1en
locknut
to
approxi mately
20
N m 2
kg
m 14ft lb whi lehold
i ng
bandservo
pi ston
stem
stati onary
AT27
Removaland
I nstallati on
AUTOMATI C TRANSMI SSI ON
REMOVAL AND I NSTALLATI ON
TRANSMI SSI ON
ASSEMBLY
When
di smounti ng
the
automati c
tran on from
a
car
pay
attenti on
to
the
foUowi ng
poi nts
I
Before
di smounti ng
the transmi s
si on
ri gi dly
i nspect
i t
by usi ng
the
Trouble shooti ng Chart
and di s
mount
i t
only
when
i t i s
necessary
2
Di smount
the transmi ssi on wi th
utmost care and when
mounti ng
ob
servi ng
the
ti ghteni ng torque
i ndi cated
on
anothertable do
Dot exert exces
si ve
force
REMOVAL
I n
di smounti ng
the automati c
transmi ssi on
from
a car
proceed
as
foUows
I
Di sconnect
battery
ground
cable
fromtermi nal
2
Jack
up
car
and
support
i t on
safety
stands
We
recommend a
hydrauli c
hoi st or
open
pi t
beuti li zed
i favai lable
Observe all
safety regulati ons
3
Remove
propeUer
shaft
Plug
up
the
openi ng
i n the
rearex
tensi on
to
prevent
oi lfrom
flowi ng
out
4
Di sconnect front exhaust tube
5
Di sconnect selector
range
lever
frommanualshaft
6
Di sconnect wi re connecti ons at
i nhi bi torswi tch
7
Di sconnect
vacuum tube from
vacuum
di aphragm
andwi re
connee
ti ons
at downshi ft solenoi d
8
Di sconnect
speedometer
cable
fromrear
extensi on
9 Di sconnect oi l
chargi ng pi pe
10Di sconnect oi lcooleri nlet
and
outlet tubes at transmi ssi oncase
I I
Support engi neby
locati ng
a
jack
underoi l
pan
wi thawodenblock
used
between oi l
pan
and
jack Support
transmi ssi on
by
means of a transmi s
si on
jack
AT 28
CAUTI ON
Do
not
place
the
jack
underthe oi l
pan
drai n
plug
12 Detach converter
housi ng
dust
coverRemove bolts
securi ng
torque
convertertodri ve
plate
QOOOO
Before
removi ng torque
converter
i nscri bechalk mari a on two
parts
so
that
they
may
be
replaced
i n thei r
ori gi nalposi ti ons
at
assembly
13 Remove
rear
engi ne
mount
se
curi ng
bolts and
crossmember
mount
i ngbolts
14 Remove
startermotor
15 Remove
bolts
securi ng
transmi s
si on to
engi ne
After
removi ng
these
bolts
support engi ne
and
transmi ssi on
wi th
jack
andlowerthe
jack graduaUy
unti ltransmi ssi on
can
be removedand
takeout transmi ssi onunderthe
car
Plug up openi ngs
such
as
oi l
charg
i ng
pi pe
oi l
co
lertubes
etc
CAUTi ON
Take
care
when
di smounti ng
transmi s
si on
not to
stri ke
any
adjacent
parts
I NSTALLATI ON
I nstaUati on of automati c
transmi s
si on
on car
i s i n
reverse orderof re
movalHowever
observethe
foUowi ng
i nstallati onnotes
Dri ve
plate
tUnout
Turn crankshaft
one
fuU
turn and
measure dri ve
plate runout
wi th
i ndi
eati ng fI nger
of a di al
gauge
rested
agai nst
plate
Maxi mumallowablerunout
05 mm 0020i n
A
T268
2
I nstaUati onof
torque
converter
li ne
up
notch
i n
torque
converter
wi ththat
i n
oi l
pump
Be extremely
carefulnot to
put
undue
stress
on
parts
when
i nstalli ng
torque
converter
ATl16
3
When
conneCti ng
torque
converter
to
transmi ssi on measuredi stance A
tobe
certai n that
they
are
correctly
assembled
Di stance A
More
than21 5
mm
0846i n
A
ATl17
4
Bolt converter
to
dri ve
plate
Ali gn
chalk
marks
pai nted
across
both
parts
duri ng di sassembli ng
pro
cesses
5
After
converteri s i nstalled rotate
crankshaft severalturns andcheck
to
be surethat
transmi ssi on
rotates freely
wi thout bi ndi ng
6 Pourrecommended
automati c
transmi ssi on flui d
up
tocorrect level
ough
oi l
chargepi pe
7
Connect
manuallevertoshi ft rod
Operati on
should be carri ed out wi th
manual
andselectorlevers
i n N
8 Connect
i nhi bi torswi tch
wi res
a Referto
pages
AT 26and 27 for
I nhi bi tor
Swi tch
Adjustment
b
I nspect
and
adjust
swi tchas above
wheneveri t has tobe removed
for
servi ce
AUTOMATI C
TRANSMI SSI ON
Removal
andI nstallati on
9
Check i nhi bi tor
swi tchfor
oper
ati on
Startershould
be
brought
i nto
operati on only
when selector
leveri s
i n P and N
posi ti ons
i t should
not be started
when
leveri s i n D
2 I and R
posi ti ons
Back
up lamp
should also
li ght
when selectorlever
i s
placed
i n
R
posi ti on
I O
Check
flui d level
i n transmi ssi on
Fordetai led
procedure
see
page
AT
51
11 Move
selector
lever
through
aU
posi ti ons
to
be surethat
transmi ssi on
operates
correctly
Wi thhand
brake
appli ed
rotate
engi ne
at
i dli ng
Wi thout
di sturbi ng
the
above
setti ng
move selectorlever
through
N
to
D
to
2
to
I
and to
R
A
sli ght
shock
should be
felt
by
hand
gri ppi ng
selectoreach
ti metransmi ssi on
i s
shi fted
See
page
AT52
for
Checki ng
En
gi ne
I dle
12
Checkto
be
sure
that
li ne
pressure
i s
correct
Todo
thi s
refer
to
page
AT 54
forLi nePressureTest
13
PerformstaU test
as
descri bedi n
page
AT 55
AT 29
Major
OlllHhaul
Operati ons
AUTOMATI C
TRANSMI SSI ON
MAJOR OVERHAUL OPERATI ONS
Torque
converter
I nput
shaft
Needleb
reftTsebraJce
Beari ng
race
Needle
beari ns
L
Needlebeari ng
Output
abaft
Oi l
chaI Ji ng pi pe
c
i I
Speedometerpi ni on
Valve
body
otI l
L
et
L
Parki ng
mechani sm
SAn01
AT 30
SERVI CE NOTES
FOR DI SASSEMBLY
Before
proceedi ng
wi th di s
assembly
thoroughly
clean
the
outsi de
of thetransmi ssi on
I t
i s
i mportant
to
prevent
thei nternal
parts
ofthetrans
mi ssi on
from
becomi ng
contami nated
by
di rt
orotherforei gn
matter
Di sassembly
should be
d
ne i n
a
clean
work area
Use
a
nylon
cloth
or
paper
towel
for
wi pi ng
parts
clean
Common
shop
rags
can leave li nt
that
mi ght
i nterfere
wi ththetransmi ssi on
s
operati on
DI SASSEMBLY
1
Remove
torque
converterdrai n
transmi ssi on flui d
through
end of rear
extensi on and
place
transmi ssi on
on
TooL
SAnoa
2
Removeconverter
housi ng
SAT003
3 Unscrew and remove downshi ft
solenoi d
anda
ri ng
AUTOMATI C TRANSMI SSI ON Major
Overhaul
Operati ons
4
Unscrew
and removevacuumdi a
phragm
di aphragm
rod
anda
ri ng
SA
T006
5 Remove
speedometer
lock
plate
retai ni ng
bolt
Remove
speedometer
pi ni on
SAT102
6
Remove oi l
pan
and
i nspect
i ts
contents
An
analysi s
of
any forei gn
mattercan i ndi cate the types
of
prob
lems tolook for
I f
the
flui di s
very
dark smells burned or
contai ns for
ei gn parti cles
the
fri cti onalmateri al
clutches band
may
need
replace
men A
tacky
fi lm
that wi llnot
wi pe
clean
i ndi cates
varni shbui ld
up
whi ch
can causevalves servoandclutchesto
sti ck and
may
i nhi bi t
pump
pressure
7 Removecontrolvalve
body
Bolts
of 3
di fferent
lengths
are
used
Care must be taken to
i denti fy
i ndi vi dualbolt
lengths
andlocati ons
Remove
manualvalve
from
valve
body
as a
precauti on
to
prevent
valve
from
droppi ng
out
acci dentaUy
8 Loosen band servo
pi ston
steI l
locknut
and
ti ghten pi ston
stem to
prevent
front clutch
drumfrom
drop
pi ng
out
when
removi ng
front
pump
SATOOB
9 Remove
i nput
shaft from
pump
AttachToolto
pump
andremove
pump
Do
not aUow front Clutchto
AT31
Major
Olll1rhaulOperati ons
AUTOMATI C TRANSMI SSI O
N
come
out of
posi ti on
and
drop
onto
floor
Take
care
that shaft i s not i nserted
backward
duri ng reassembly
10Remove front clutch thrust
washerand
beari ng
race
SAT010
I I
Back off band servo
pi ston
stem
toreleaseband
SAT011
12 Remove
brake band strut Brake
band front and
rearclutchassembli es
may
be
removed
together
AT 32
SAT012
To
prevent brake
I i n
i nus
from
cracki ng
or
peeli ng
donot stretch
the
flexi ble
band
unnecessari ly Before
re
movi ng
the brakeband
elwaYI secure
i t wi th
a cli p as
showni nthe
fi gure
be
low
Leave the
cli p
i
i ti on
fterra
movi ng
thebrakeband
Flexi ble
type
bendInk
Uni t mm i n
SAT106
oW 157
ApprOXi mately
2 008 di a wi re
cli p
13 Remove
pump
thrust
beari ng
and
rearclutchthrust washer
SAT013
14 Remove
rear
clutchhub front
planetary
carri erand
connecti ng
sheU
rearclutchthrust
beari ng
front
plane
tary
carri erthrust washer
and thrust
beari ng
I
AT124
15 Back out about haI f
way
band
servo
ajtachi ng
bolt
Usi ng
an ai r
gun
carefuUy
apply pressure
to loosen
bandservoRemoveband
servo
retai n
i ng
bolts
and
puu
band
servo
16 Remove rear
planetary
carri er
snap
ri ng
and
rear
planetary
carri er
17
Remove
output
shaft s
ap ri ng
18
Remove rear
connecti ng
drum
wi th
i nternalannulus
gear
SATon
19
Pry
off one
end
of
snap ri ng
wi th
a
screwdri ver
Remove
snap ri ng
from
lowand reverse brake
assembly
whi le
applyi ng pli er
force i n
di recti on
of
arrow
20Ti lt
extensi on
housi ng upward
and
remove
low and reverse brake
clutch
assembly
21
Remove
rear
extensi on
AUTOMATI C TRANSM
I SSI ON
Major
Overhaul
Operati ons
22
Be
careful
not
tolose
parki ng
pawlspri ng
andretai nerwasher
01
23
Remove
outpu1
shaft wi th
gover
nor
24 Remove
governor
thrust washer
andneedle beari ng
Remove
one
way
clutch
i nnerrace
attachi ng
hexhead slotted
bolts
usi ng
Tool
SAT020
25
Remove one
way
clutch
i nner
race return
thrust
washer
low
and
reverse
return
spri ng
and
spri ng
thrust
ri ng
o
LI
C
Ei L J 0Jl
O
0
C
J
r 11
AT021
26
Usi ng
an
ai r
gun
wi tha
tapered
rubber
ti p
carefuUy apply
ai r
pressure
to remove
low and reverse
brake
pi ston
SAT022
27
Pry
off
snap ri ngs CD
fromboth
ends
of
parki ng
brake
lever
@
and
remove
the leverBack
off manual
shaft lock nut
@
and remove
manual
plate
@
and
parki ng
rod
I D
AT33
MsjorOverhaulOpsrsti ons AUTOMATI C
TRANSMI SSI ON
AT133
28 Remove i nhi bi torswi tch
and
manualshaft
by
looseni ng
two
se
cmi ng
bolts
COMPONENT PARTS
The transmi ssi on consi sts
of
many
small
parts
that
are
qui te
ali ke
i n
constructi on
yet
machi ned
to
very
c1 e
oI erances
When
di sassembli ng
parts
besureto
place
themi norderi D
part
rack
sothey can
be
put
back i n
theuni t i n thei r
proper
posi ti ons
AU
parts
shouldbe
carefuUy
cleaned
wi th
a
generalpurpose
nonflanunablesol
vent before
i nspecti on
or
reassembly
Gaskets
seals
andsi mi lar
parts
should
be
replaced
I t
i s
also
very i mportant
to
perform
functi onaltests
whenever
i t
i s
desi gnated
OI L PUMP
I
Remove front
pump
gasket
and
O
ri ng I nspect pump body
pump
shaft and
ri ng groove
areasforwear
w
SAT023
2 Remove
pump
coverfrom
pump
housi ng
AT34
1
u
SAT024
3
I nspect gears
and aU i nternalsur
faces forfaultsandvi si blewear
4
Measure clearance between outer
gear
and
crescent
Standard
dearanc e
014 021
mm
00055 00083i n
Replace
i f
the
clearance exceeds
025
mm
00098i n
SAT025
5
Measure clearance between outer
gear
and
pump housi ng
Standarddearance
005 020mm
0002000079
i n
Replace
i f
the
clearance exceeds
025 mm
00098i n
SA
T026
6
Usi ng
a
feeler
gauge
and
strai ghf
edge
measureclearance between
gears
and
pump
cover
Standardclearance
002 004
mm
00008 00016i n
Replace
i f the clearance exceeds
008
mm00031 i n
7
Measure clearance between
seal
ri ng
and
ri ng groove
Standard
clearanca
004 016
mm
0
0016
0
0063i n
Replace
i f
the clearance exceeds
016mm 00063i n
Of
course
i t
i s
goodpracti ce
to
reo
place
aU seal
ri ngs
duri ng
an overhaul
l
1earance
J
Sealri ng
w
yw
11
4 I
AT1 5
8 Mount
pump housi ng
i n
ToolSet
up pump housi ng
wi thi nnerandouter
pump
gears
on i t
and i nstaU
pump
cover
to
pump housi ng Temporari ly
assembleoi l
pump
AUTOMATI C TRANSMJ
SJON
Major
Overhaul
Operati ons
Totari ndi cator
readi ng
Less than007
mm
00028
i n
9 Set
run out of thecover
towi thi n
speci fi edtotali ndi cator
readi ng
0
ST25580001
10
Ti ghten
pump securi ng
bolts to
speci fi edtorque
b
Oi l
pump housi ng
tooi l
pump
cover
5 9 7 8N m
06 08
kg
m
43 5 8
ft
lb
1t
t
AT166
Recheck
run out
Replace
Q
ri ng
and
gasket
AT264
FRONT CLUTCH
Ori ng
Spri ng
retai ner
Di sh
plate
Dri ven
plate
steel
plate
Dri ve
plate
ri cti on
plate
Snap
ri ng
SAT086
AT 35
Major
Overhaul
Opersti ons
AUTOMATlG TRANSMI SSI ON
1
Usi ng
a screwdri verremove
large
clutch
retai ni ng
platesnap
ri ng
2 Remove
clutch
plateassembly
AT1S0
3
Compress
clutch
spri ngs
and
remove
snap ri ng
from
spri ng
retai ner
When Tooli s to b used cut
toe
ti ps
of
thlegs
wi th
gri ndi ng
wheel
AT36
L
C
1
J
20
079
Cut
offhatched
porti on
Uni t
mm i n
ATl48
4
Remove
spri ng
retai ner
and
spri ngs
SA
T029
5 For
easy
removalof
pi ston
from
drum
mount
clutch
on
pump
Use an
ai r
gun
wi th
a
tapered
rubber
ti p
to
carefully
apply
ai r
pressure
to
loosen
pi ston
fromdrum
SAT030
6 Checkclutchdri ve
plate
faci ng
for
wearor
darnage
Dri ve
plate
thi ckness
must no1 beless than1 4
mm
0055
i n
Standard
dri
plate
thi ckness
1501 65
mm
00591 0
0650
i n
J
7 Check for
wearon
snapri ng
weak
or
broken coi l
spri ngs
and
warped
spri ng
retai ner
S Lubri cate clutchdrum hub and
seals and i nstaU i nnersealand
pi ston
sealas i llustrated Be
careful
not
to
stretchseals
duri ng
i nstallati on
Neyer
a
mblclutch
dry I ways
lubri
to
i ts
componentsthoroughly
SAT031
9
Assemble
pi ston
bei ng
carefulnot
to aUow seal
toki nk orbecome
damaged duri ng
i nstaUati on After
i n
stalli ng
turn
pi ston
by
hand
toensure
that therei s
no
bi ndi ng
10Reassemble
spri ng
and retai ner
Rei nstaU
soap
ri ng
Besure
snap ri ng
i s
properly
seated
I I
I nstalldi sh
plate
wi thdi sh
faci ng
outward
SA
T033
12
Now i nstalldri ven plate
steel
plate
then
a
dri ve
plate
fri cti on
plate
and
repeat
i n
thi s
orderunti l
correct number
of
plates
has
been
i nstaUed check
Servi ce Data and
Speci fi cati ons
for
properquanti 1y
of
plates
Nowi nstallretai ner
plate
and
snap ri ng
1
Snap ri ng
2 Retai ner
plate
3 Dri ve
plate
Fri cti on
plate
4 Dri ve
plate
Steel
plate
5
Di sh
plate
AUTOMATI C
TRANSMI SSI ON
Major
Overhaul
Operati ons
13 Measure
clearance
between re
tai ner
plate
and
snap ri ng
Speci fi ed
clearance
1 6 2 0
mm
0063 0
079
i n
I f
necessary try
other
retai ni ng
plates
havi ng
di fferent
thi cknesses
un
ti l
correct clearance
i s obtai ned
Avai lable
retai ni ng plate
Thi ckness
mm
i n
Part number
106
0
417
108 0425
110
0433
112 0
441
I I
4
0
449
116
0
457
31537 XOI OO
31537 XOI OI
31537
X0102
31537 XOI 03
31537 XOI 04
31537
X0105
SA
T034
14
Testi ng
front clutch
Wi th
front
clutch
assembled on
oi l
pump
cover
di rect a
jet
of ai r
i nto
hole i nclutchdrumfor
defi ni teclutch
operati on
AT152
REAR CLUTCH
AT153
1 Rear
clutch
drum 6
Snap ri ng
2 Pi ston 7
Spri ng
retai ner
3 Di shed
plate
8
Snap ri ng
4 Coi l
spri ng
9 Dri ve
plate
5
Retai ni ng plate
10
Dri ven
plate
Servi ce
procedures
forrearclutch
are
essenti ally
the same
as those for
front
clutch wi th
the
foUowi ng
ex
cepti on
Speci fi ed
clearancebetWeen
retai nerplate
and
snap ri ng
08 1 6mm
0031 0063i n
SA
T035
Test rearclutch
I I I
AT157
AT37
Mai or
OverhaulOperati ons AUTOMATI C
TRANSMI SSI O
N
LOW REVERSE
BRAKE
Spri ng
thrust ri ng
Low
andreversereturn
spri ng
Return tluust
washer
Pi ston
Di shplatc
Dri venplate
Steel
plate
Dri vc
platc
Fri cti on
plate
Retai nerplate
Snap ri ng
SA
T094
Exami ne
low
and
reverse
brake for
damaged
clutchdri ve
plate
faci ng
and
worn
soap
ri ng
Check dri ve
plate
faci ng
forwearor
damage
i f
necessary replace
Dri Y
4l
plate
thi ckness
Standard
1 902
05
mm
100748
0
0807
i n
Allowabl
li mi t
1
8
mm10071
i n
Test
pi ston
return
spri ng
forweak
ness
Di scardi f
i t i s
too
weak
BRAKE
BAND
AND BAND SERVO
AT38
I nspect
band fri cti on
materi alfor
wear
I fcracked chi pped
or
burnt
spots
are
apparent replace
the
band
SAT036
Check
band servo
components
for
wear
and
scori ng Rep
ace
pi ston
a
ri ngs
andaU
other
components
as
necessary
GOVERNOR
To
controlvalve
11
3
I Go
rnot
prc
15
z
1 Anchorend
pi n
2 Bandstrut
3
Apply
4
Release
4
5 Return
spri ng
Fromcontrolvalve
6 Bandservo
pi ston
stem
Li nc
prcssur
I
J
7 Band servo
pi ston
8 Servoretai nes
ATQ90
9 Brakeband
assembly
10Trammi ssi on
case
1
Pri mary governor
4 Oi ldi stri butor
2 Secondary
governor
5 Output
shaft
AT290
3 Governorvalve body
Di sassemble
governor
and
check
valves for
i ndi cati on of
burni ng
or
scratches
I nspect
spri ngs
for
weak
ness orburni ng Replace parts
as
necessary
and
reassemble
Donot i nterchange
components
of
pri mary
and secondary governor
valves
D
aOlri MI
I I lI 1
SAT038
AUTOMATI C TRANSMI SSI O
N Major
Overhaul
Operati ons
Governorvalve
sprI ng
chart
Free
length
I
Asi nstalled I
Lm
m
0
Wi re
di a
SA
T039
Assemble
governor
on
oi l
di stri bu
tor
tl
Governor
valve
body
tooi l
di stri butor
Outer
Noof
Free
I nstaUed
Valve
spri ng
Wi re
di a
coi ldi a
acti ve
length Length
Load
mm
i n
mm i n
coi l
mm
i n mm i n
N
kg
lb
Pri mary governor
045 8
75
5 0 21
8 7 5 2
109
00177
03445
0
858
0295 0215
0474
Secondary governor
070 920
5 5 25 1
10
5 10788
0
0276 03622
0988 0413
11
00
2426
PLANETARY
CARRI ER
The
planetary
carri ercannot be
di vi dedi ntoi ts i ndi vi dual
components
I f
any
part
of
the
component
i s
faulty
replace
the
carri eras a
uni t
Check clearance between
pi ni on
washerand
planetary
carri er
wi th
a
feeler
Standardclearance
020070mm
00079
00276
i n
Replace
i f the
clearance
exceeds
080mm
00315
i n
Clearance
that have
been
damaged by
over
heati ng
wi D have a blue
di scolora
ti on
1
rI
J
I n
AT167
1
Check
planetary
gear
sets for
darnaged
orworn
gears
Gearsets
SAT040
AT
39
MajorOverlJaulOperati ons AUTOMATI C
TRANSMI SSI ON
CONTROL
VALVE BODY
The valve
body
contai ns
many pre
ci si on
parts and
requi res
extremecare
when
parts
are
removed and
servi ced
Place removed
parts
on
a
parts
rack so
they
canbe
put
back i nthevalve
body
i n
the
same
posi ti ons
and
sequences
Carewi llalso
prevent spri ngs
andsmaU
parts
from
becomi ng
scatteredorlo
t
L
Remove oi l
strai ner
aod
i ts
attach
i ng
screws nuts andbolts
SAT041
2 Di sassemble valve
body
and i t
remai ni ng attachi ng
bolts andnuts to
carefully separate
lower
body
separa
tor
plate
and
upp
r
body
HT61000800
AT168
9
9
J
Q
J I OI i
c
I
9
I
19uDdI
i o
J ui i L
I 1 I
ll
AT1 9
3
Duri ng
valve
body separati on
do
not scatterorloseori fi ce
check
valve
servoori fi ce check
valve
and
thro11le
AT 40
reli ef
check valve
baU
and
related
spri ngs
4
Remove si de
plate
A
pressure
regulator
valve
spri ng spri ng
seat
sleeve aod
plug
and
secondlock valve
aod
spri ng
Placeeachloose
part
on
a
rack
toretai n correct
sequence
of as
sembly
Spri ng
seal
Spri ng
I I
L
Si de
plate
A
SAT042
5
Remove i de
plate
B
2nd3rd
ti mi ng
valve
and
spri ng
vacuumthrot
tle
valve
thro1tle back
up
valve and
spri ng
aod
the
ki ckdown valve and
spri ng
Place
eachloose
part
ona rack
to
retai n
sequence
of
assembly
2nd
3rd
ti mi ng
valve
Spri ng
a
a
Throttle
back
up
valve
Ki ck down
vai ve
Si de
plate
B
SAT043
6
Remove si de
plate
C
pressure
modi fi ervalve
and
spri ng
2nd3rd
shi ft valve
spri ng
and
plug
and
I
st
2nd
shi ft valve
and
spri ng
Place eachloose
part ona
rack
to
retai n
sequence
of
assembly
AUTOMATI C
TRANSMI SSI ON
Major
Overhaul
Operati ons
Manualvalve
was
removed when
valve
body
was removed from
trans
mi ssi on I nclude valve i n
subsequent
i nspecti on
andservi ce
sequence
d@4tt
h1fu
I
1 ni b
t
fkq T
AJ
2M
J
L
35t1t
i
w
ml
k
w
Mw
l
I
i 1
Wi p
j1
11
i i JU
1
jt
PbEH1 ltwmJ
j
111
1 I I
Jt
I
@n
vun
Lowervalve
bOdY
Spri ng
Spri ng
C
Plug
1
2
d
shi f
11
Pressure modi fi ervalve
i t n t valve
Spnng
nd
3rdshi ft valve
I
g
I
Slde
plate e
A A
I
Precauti onfor
i nspecti on
A
newly
manufacturedvalve
body
represents
preci si on
manufactured
valvesassembledwi thclosetolerances
i nto
preci si on
bores ofthevalve
body
I f
i nspecti on
reveals excessi ve
clear
ances 003mm 00012 i n ormore
between the
valves and thevalve
body
bores
replace
the en1i re
valve
body
ratherthan
attempt
rework
I fone ormore
valves are
sti cki ng
from
varni sh
deposi ts
or
burns
resulJ
i ng
from deteri orated oi l
or
overhea1
i ng you may
be able to clean the
valves and valve
bodi es
Always
use
croeus clothwhi chi s a
very
fme
type
of
cutti ng
materi alNever
use
emery
cloth as
i t
i s
toocoarse and can
scratch the valves
or
valve
bores
Scratches can lead tofuture
deposi ts
ofvarni shor
forei gn
matter
SAT044
Duri ng cleani ng
do
not removethe
sharp
edges
of thevalve When
edges
are
rounded
orscratched
entry
i s
pro
vi ded for
di rt
or
forei gn
matterto
work i ntothe si des
of
thevalves and
hi ndervalvemovement
The valves
may
be cleaned
usi ng
alcohol
or
lacquer
thi nnerThe valve
bodi es
can be
di p
cleaned
wi tha
good
carburetorcleaneror
lacquer
thi nner
Donot
leave valve
bodi es
SUbmerged
i n carburetor
cleaner
longer
thanfi ve
mi nutes Ri nse
parts thoroughly
and
dry
Lubri cate
all
parts
i n clean auto
mati c
transmi ssi on flui d
before reas
sembly
7
Checkvalvesfor
si gns
of
burni ng
Replace
i f
beyondclean
up
8 Check oi lstrai nerfor
general
con
di ti on
Replace
i f
necessary
9
Check
separator plate
for
scratchesor
damage Replace
i fneces
sary
Scratches
or
score
marks
can
cause oi lto
bypass
correct oi l
passages
and result
i n
system
malfuncti on
Co
nDllD o
o
o
o
0
b
nnn
0
0
0
10
0
oo
0
SA
T046
10Check oi l
passages
i n
upper
and
lowervalve
bodi es forvarni sh
deposi ts
scratches Orotber
damagethat would
i mpai r
valvemovement Check
thread
ed holes andrelated bolts
and screws
for
stri pped
threads
replaceas
needed
I I Test valve
spri ngs
for
weakened
load
condi ti on Refer
to
Valve
Body
Spri ng
Chart for
spri ng speci fi cati ons
Valvebody
spri ng
chart
i 5
l
O
Free
length
I
As
i nstalled
I
ri j
0
Wi redi a
SAT039
AT 41
Major
Overflaul
Operati ons
AUTOMATI C
TRANSMI SSI O
N
I nstaUed
Wi re
di a
Outercoi l
No
of
Free
length
Valve
spri ng
mm
i n
di a
acti ve
coi l
mm i n
Length
Load
mm i n
mm i n N
kg
lb
Manual
detent 13
73 15
32 4
26
5
53
9
0
051 0287 1276
1
043
55
12 1
Pressure
regulator
valve 12 11 7
13
43
0
23 5
27 5
0047 0461
1
693 0925
28 6
2
Pressure modi fi er
valve 0
4
84
5 185 9
0
10
0016
0331
0
728 0354 01 02
1st 2ndshi ft
valve 0
6 66
16
320
16
0 6129
0
024 0260 1260
0630 0625 1378
2nd
3rd
shi ft
valve
0
7 6
9
18 410 17 0 13
73
0028
0272
1
614 0669
I
40309
2nd
3rd
ti mi ng
valve 07
6
2
15 32 5 27
0
539
0
028
0244
1280 1063
0
55
121
Throttle
back
up
valve 08
73 14
36
0 18
8
1883
0
031 0287 1
417 0740 1
92
423
Solenoi d
downshi ft valve
055
5
55
12
220
12 5
5 88
00217
0
2185
0866
0492
060
132
Secondlock valve
055 555
16 335 210 5
88
00217 0
2185 1319 0
827 060132
Throttlereli ef
check valve 0
9 65 14
268 190
2148
0
035
0256
1055 0748
2
19 4
83
Ori fi cecheck
valve
0
23
5
0
12
15 5
11 5
0
10
0
0091 0
197
0610 0453
001
0
02
Servoori fi ce
check valve
AT 42
AUTOMATI C TRANSM
I SSI O
N
Major
DverhsulOperati ons
12
Assemble si de
plate
A
group
of
parts
i nto
lowervalve
body
Rei ns1aU
si de
plateand
fmgerti ghten
screws
Assemble si de
pla1e
B
group
and
Si d
Pi a
talA
Cl
Spri ng
seat
UJ@
Pressure
regl llat
r
sleevei
Pressure
regulatorplug
Second
lock
valve
Upper
valvebody
Manualvalve
13
Ti ghten
screws
cD
Si deplatetovalve
body
2 5
34
N
m
025
035
kg
m
1 8 25
ft lb
14
I nstallori fi ce check
valve valve
spri ng
1hrottle reli ef
valve
spri ng
and
steelballi n
valve
body
AT173
Ori fi cecheck
valve
AT430
si de
plate
C
group
i n
same
manneras
A
group
SAT095
15 I nstall
upper
and
lower
valves
cD Upper
snd
lower
VBlves
2 5 34N m
025 035
kg
m
1
8 25
ft lb
Reamerbolt
49 69N m
05 07
kg
m
36 5 1 fNb
ST25160000
16
I nstalloi lstrai ner
cD
Oi l
strsi ner
to
valve
body
25 34N
m
fO
25 0
35
kg
m
1
8
25
ft
lb
The
manualvalve i s
i nserted
i nto
the valvB
body
when
the latteri s i n
stalled
i n
the
transmi ssi on
AT 43
Majo
OverhaulOperati ons
AUTOMATI C
TRANSMI SSI ON
FI NAL
ASSEMBLY
When
i nstalli ng
assembli ng
needle
beari ng beari ng
race snap ri ng
and
i Uustrati on as a
gui de
toi nstaUati on
O
ri ng
seal
ri ng
use
the
foUowi ng
procedures
and locati ons
@
Co
Q
gE
do 0
a
0
c2
Q
Q
0
c
u
5
Coe
QO
C
Q
QC
S
oU
e
ll
30
C
e
oS
F
8
i
d
8
Co
ci i
a8
Q
a
5
H
Q
u
e
@
r
1
ll
Ji
Q
Q
U
U
e
e
C
S
d
a
j
@Q
1
5
zj
Q
U
e
I
8
f
l
i l
d
e
C
C
Co
ci i
Q
U
e
S
a
5
Q
a
zs
8
S
Co
f
t
e
I S
SA
T099
AT 44
I
Before
proceedi ng
wi ththefmal
assembly
of all
components
i t i s i m
portant
toveri fy
that
thecase
housi ng
and
parts
are cleanand
free
from
dust
di rt and
forei gn
matter
use ai r
gun
Have
a
tray
avai lablewi thclean trans
mi ssi on flui dfor
lubri cati ng
parts
Petroleum
jeUy
can
be
used to
secure washers
duri ng
i nstallati on
All
new
seals
and
ri ngs
should
have been
i nstalled before
begi nni ng
fi nal
as
semb
ly
SAT047
2
Lubri cate
and i nstaU
low
and
reverse
pi ston
i ntothecase
3 I nstaU
thrust
ri ng pi ston
return
spri ng
thrust washer
and
one
way
clutch
i nner
race
JGOC
Oe
c
o
j
cl
GOo I I U
o
0
o v
1
c
Co 0
l
f
9
rJP
o o
s
r
I I I S
TOZl
AUTOMATI C
TRANSMI SSI ON Major
OverhaulOperati ons
4
Ali gn
and start
hexhead slotted
bolts
i ntoi nnerracefrom
rearofcase
WARNI NG
Checkthat return
spri ng
i s centered
on race
before
ti ghteni ng
Ti ghten
the
bolts
GJ
One
way
clutchi nner
race
to
transmi ssi on case
13 18N m
1
3
1 8
kg
m
9 13ft lb
I
I
i
i
7l
i
ST25570001
lfi u
ST25490000
GG91060000
5 I nstallsteeldi shed
pla1e
fi rst
then
steel
and fri cti on
plates
and
fmaUy
retai ni ng
plate
and
snap ri ng
6 Afterlowand reverse brake has
been
completely
assembled measure
clearance between
snapri ng
and re
tai ner
plate
I fmeasurement exceeds
speci fi cati ons
i t
can be
adjusted
by
replaci ng
retai ner
plate
wi thone of a
di fferent thi ckness
Low
and
reverse
brakeclearance
0801 25 mm
00315 0
0492i nl
7
Usi ng
an ai r
gun
wi th
a
tapered
rubber
ti p
check low
and
reverse
brake
operati on
8
I nstaU
governor
thrust washer
and
needle
beari ng
9
Sli de
governor
di stri butoras
sembly
on
output
shaft from
fron1 of
shaft I nstallshaft and
governor
di s
tri butor
i nto
case
usi ng
care
not to
damage
di stri butor
ri ngs
AT 45
Major
Overhaul
Operati ons AUTOMATI C TRANSMI SSI ON
10I nstaU one
way sprag
i nto
one
way
clutch
outer
race attached to
connecti ng
drum
Arrowon
sprag
must
facefront of
transmi ssi on
I I I nstaU
connecti ng
drum wi th
sprag by
rotati ng
drumclockwi se
usi ng
a
sli ght
pressure
and
wobbli ng
to
aI i gn
plates
wi thhub and
sprag assembly
Connecti ng
drumshould
now
be free
torotate clockwi se
only
Thi s check
wi ll
veri fy
that
sprag
i s
correctly
i n
stalledand
operati ve
12
I nstaU reari n1ernal
gear
AT 46
c
D
CO
V
j a
13 I nstall
mapri ng
onshaft
14 Secure thrust
beari ng
and
thrust
washerwi th
petroleum
jeUy
and
i nstaU
rear
planetary
carri er
SATOSS
15
I nstall
rear
planetary
carri er
snap
ri ng
Thi s
snap ri ng
i s
thi nner
than 8
clutchdrum
snap
ri ng
so
ba
sure
you
are
usi ng
correct
si ze I f
you have
i n
suffi ci ent
spaco
to
i nstall
snap ri ng
i nt
drum
groove
pullconnecti ng
drum forward a faras
possi ble
Thi s
wi ll
gi ve you
suffi ci ent
groove
clear
ancotoi nstalldrum
nap ri ng
16
Adjust
front
end
playas
foUows
Front end
p1aY
1
JL
v
r
l
J
CC
j
SAT091
Front clutch
thrust
washer
2
Oi l
pump
cover
3 Front clutch
4 Rearclutch
5 Transmi ssi on case
6 Oi l
pump ga5Ket
7
Oi l
pump
cover
beari ng
race
I
Assemblefront andrearclutches
front i nternal
gear
front
planetary
carri erand
connecti ng
sheU Secure
thrust
beari ngs
wi th
petroleum
jeUy
I
4
SATOS7
2
I nstall
assembly
i nto
transmi ssi on
caSe
Check
that
parts
are
properly
seated
before
proceedi ng
wi th
measurements
SAT05S
3
lsi ng
a di al
gauge
orcali per
wi tha
seven i nchbase
measure
from
rear
hub
thrust
beari ng
race
to
case
di men
si on A
3
cI D
@
SAT059
1
Di al
gauge
2
Front
clutch
drum
3 Transmi ssi on
case
4
Beari ng
race
5
Thrust
beari ng
6 Rear
clutchdrum
4
Assemble front and rearclutch
drumassembli es
together
and
lay
them
l1at
on
benchBe surerear
hub
thrust
beari ng
i s
properly
seated Measure
AUTOMATI C TRANSM
15510N
Major
OverhaulOperati ons
from face of clutch
drum
to
top
of
thrust
beari ng
race
di lli ensi on
B
@ SAT061
1
Depthgauge
2 Front
clutch
drum
3
Rearclu
tch
drum
4 Thrust
beari ng
5
Measure
from top
of oi l
pump
shaft
to
gasket
i nstalled di mensi on
C
1
c
I
G k
I
ty
oi lPump
SAT063
fU 0
I I I
SAT064
6 I nstall
thrust washer
Measure
from
top
of oi l
pump
shaft tothrust
washer
di mensi onD
I
L
fffi
llV
Oi l
pumpU
SAT096
7
Di fferencebetweendi mensi on
A
01
mm
0004 i n
B
and
C D i s
front
end
play
and must be
wi thi n
speci fi ed
value
Speci fi ed
front end
play
05 08mm
0020
0031
i nl
Front end
play
can be
adjusted
wi thfront clutchthrust washers of
di fferent thi ckness
Avai lable
front clutchthrust washer
Thi ckness
mm
i n
Part number
IS 0059 31528 XOlO6
17 0067 31528
XOl05
1
9 0075
31528 XOI OO
21 0083 31528
XOI OI
23
0091
31528 XOI 02
25 0
098 31528 XOlO3
2 7 0106 31528 XOI 04
17
Adjust
totalend
playas
follows
Thi s
adjustment
i s seldom
requi red
because
thi s
type
ofthrust
beari ng
and
AT 47
Major
Overhaul
Operati ons
AUTOMATI C TRANSMI SSI ON
race
wi ll
normally show very li ttle
wear
We
also
have
a standard taler
ance
of 025 to050
mm
00098 to
00197 i n Howeverwe are
present
i ng
correct
checki ng
procedure
j
i
C1l
i
E
r
Tott
Jf
play
SA
T092
Front clutch
thrust
washer
2
Oi l
pump
cover
3 Front clutch
4 Rear
clutch
5
Transmi ssi on
case
6 Oi l
pump ga5ket
7 Oi lpump
cover
be
ari ng
race
1
Meamre di mensi on A
usi ng
i n
structi ons i n
steps 1
2 and 3
underNo16above
2 Measure di mensi on
C
usi ng
i n
structi ons i n
step
5 under
N
16
above
3
Di fference between di mensi on
AQ
I
mm 0004
i n
andC
i s
total
end
play
and i t must bewi thi n
speci
fi edvalue
Speci fi ed
totalend
play
0
25
0
50mm
0009800197
i nl
I f di fference
Jletween
AQ
2
mm
0008 i n
andC
i s
not wi thi ntaler
ance select
proper
si ze
oi l
pump
cover
beari ng race
Avai lableoi l
pump
cover
beari ng
race
Thi ckness mmi n
Part number
12
0047
31556XOlOO
14
0055
31556XOI OI
1
6 0063
31556XOI 02
1
8 0071
31556XOI 03
2
0
0079
31556XOI 04
2
2 0087 31556
XOl05
AT 48
18 I nstallbrake band bandstrut and
band servo Lubri cate servoO
ri ngs
before
i nstalli ng
Care
shouldbetaken
toavoi d
damagi ng
O
ri ngs
when
re
mbli ng
19 I nstall
and
torque
the retai ner
bolts Loosen
pi ston
stem
rfl
Servo
pi ston
retai nerbolt
49 69N m
05 07
kg m
36 5 1 ft b
20
Fi ngerti ghten
brake band servo
pi ston
stem
enough
to
prevent
brake
band and strut from
falli ng
out Do
not
adjust
bnlke
bandat
thi s
ti me
21 Mount oi l
pump
gasket
on oi l
pump
wi th
petroleum
jelly
Ali gn
pump
totransmi ssi on
caseand i nstall
n
SAT069
22
Adjust
band Makesurethat
brake
band
strut i s
correctly
i nstalled
Torquepi ston
tern
to
speci fi ed
vJue
Back off twofull
turns and secure
wi thlock nut
rfl
Pi stonstem
12 15 N m
1 2 1 5
kg m
9 11
ft bl
Pi ston stem
locknut
15
39N
15 40
kg m
11 29ft lb
GG91060000
ST25490000
SAT070
23 Before
proceedi ng
wi thi nstalla
ti on
ofvalve
body
assembly
perform
a
fmal
ai r
check of allassembled
com
ponenjs
Thi s wi ll
ensure
that you
havenot overlooked
ti ghteni ng
of
any
bolts
or
damaged any
seals
duri ng
as
sembly
Ai rcheck
poi nt
1
Band
servo
apply
9
2 Rear
clutch
1
Front
clutch
11
3
Band
servo
release 10
4
Governorfeed1
5 Low
reversebrake 12
4
Usi ng
an
ai r
gun
wi th
a
tapered
rubber
ti p perform
ai rchecks
25 Check that
parki ng pawl pi n
spri ng
and washer
are assembled
correctly
6
c
l
0
o
0
1
o
2
o
SAT073
26
I nstall
rear
extensi on
AUTOMATI C TRANSMI SSI O
N
Major
Overhaul
Operati ons
Q
Rear
extensi ontotransmi ssi on
case
20
25 N
m
2 025
kg
m
14 18ft I b
n
SAT014
27 I nstallcontrolvalvebody
Be
sure
manual
valve i s i n
ali gnment
wi th
selector
pi n
u
o
tK
oo1
o
28
Ti ghten
controlvalve
body
attach
i ng
bolts
dl
5 4 74N
m
055 075
kg
m
405 4ft I bl
Controlvalve
body
attachi ng
bolts
vary
i n
length
Care must be takento
ensure
that eachbolt
i s returned to
correct hole
29
Check
pump
to
transmi ssi onali gn
I 11ent
andi nstallconverter
housi ng
dl
44 54N m
45 5 5
kg
m
33 40ft I bl
30Before
i nstalli ng
vacuum
di a
phragm
valve measure
depth
of hole
i n whi ch
i t i s
i nserted Thi s measure
ment
determi nes
correct
rod
length
to
ensure
properperformance
SAT078
1
Noteseatedvalve
body
2 Transmi ssi oncase
wall
3
Vacuwn
di aphrngm
4
Di aphragm
rod
5 Valve
body
si de
plate
6
Vacuum
throttlevalve
AT 49
Major
Overhsul
Operati ons
AUTOMATI C TRANSM15510N
Throttlemodulatorvalve rodselecti oo
Measured
depth
L
mm i n Rod
length
mm
i n
Under 25 55
25 65
26
05
26 15 26 55
26
65 27 05
Over
27
15
J 0059
1
0098 10256
1
0295
1 0453
10492 1
0650
1
0689
29
0
1142
29 5 1161
30
0ll81
30 5
1201
310
1
22 0
31
I nstall
vacuum
di aphragm
32 Before
i nstalli ng
down shi ft sole
noi d check
to
veri fy
that i t i s
oper
ati ng
properly
Use
a hot
lead
and
ground
tocheck solenoi d
A
33 I nstalldownshi ft solenoi d
L
@J
E
F
SATOS1
AT 50
34 I nstalli nhi bi torswi tchCheck for
properoperati on
i n
each
rangeusi ng
a
ci rcui t
testerReferto
Mi nor
Adjust
ment
SAT082
35
Before
i nstalli ng
oi l
pan
check
ali gnment
and
operati on
of control
lever
and
parki ng pawl
engagement
Blow
mechani sm wi th
ai r
toclean
Make
fmalcheck tobe sureallbolts
are
i nstalledi n
valve
body
36
I nstall
oi l
pan
wi th
new
gasket
tfl
Oi l
pan
to
transmi ssi on
ease
49 69N m
05 07
kg
m
3
6
5 1 ft I bl
Part number
31932 XOI 03
31932
XOI 04
31932 XOlOO
31932 XOI 02
31932 XOI OI
37
Carefully i nspect
torque
converter
for
damage
Check converterhub
for
grooves
caused
by
hardened
seals Also
check
bushi ng
contact area
38
Lubri cate oi l
pump li p
sealand
converterneck before
i nstalli ng
con
verter
I nstallconverter
bei ng
sure that
converteri s
properly
meshedwi thoi l
pump
dri ve
gear
AUTOMATI C TRANSMI SSI ON
Trouble
shooti ngsndDi agnoses
TROUBLE
SHOOTI NG
AND DI AGNOSES
PRELI MI NARY
CHECKS Pri orto
road
testi ng
Veri fy
customercomplai nt
The customershould supply
as
muchi nformati on as
possi ble
i nclud
i ng any
unusualcharacteri sti cs
that
accompany
the
comp lai nt
Flui d level
To
properly
check l1ui d
level
1
Placecar
ona
level
surface
2 Put wheelchocks
i n
place
and
apply
parki ng
brake
securely
3 Warm
up engi ne
on
fast
i dle
4 Return
engi ne
tocurb
i dli ng
speed
5
Slowly
move the
gear
selector
through
tli e enti re shi ft
pattern
and
return i t to
park
6
Remove the
di psti ck
clean i t
and
replace
i t
fully
i nthe
fi llertube
7
Qui ckly
remove i t
agai n
and
read
thelevel
The
L
mark
onthe
di psti ck
i ndi
cates the
transmi ssi on i s
approxi mate
ly
0
4
li ter
7
8 US
pt
3 4
I mp pt
low
Add
only
clean Dexron
transmi s
si on
l1ui d
or
equi valent
Flui d
leakage
Todetect a l1ui d
leak
I Rai se
car
2 Clean
area
suspected
of
leaki ng
3 Start
engi ne
apply
foot brake
place
gear
selectori n dri ve
and
wai t a fewmi nutes
4
Stop engi ne
5 Check forfresh
leakage
I fthe transmi ssi on breather
i s
8US
pected
I Rai secar
2 Clean
the
area around
the
breather
3 Runthecarat hi ghway
speeds
4 Check thebreatherforfreshleak
age
Toai d
i n
locati ng
leaks use
the
followi ng
li st ofsealsand
gaskets
1Converter
housi ng
Rubber
O
ri ng
ofoi l
pump
housi ng
Oi l
pump housi ng
oi lseal
transmi s
si an front
seal
Crankshaft oi lseal
Bolts
of
converterhousi ng tocase
f
CD
I I
1 I I
8
1
I L
I
I I
I
I
I
I f
O
fi lse
i f o
2 Transmi ssi on
and
rearextensi on
Juncti on
of
transmi ssi on and rear
extensi on
Oi l
coolertube connectors
Oi l
pr
ssure
i nspecti on ports
Vacuum
di aphragm
and downshi ft
solenoi d
Speedometerpi ni on
sleeve
Rearextensi onoi lseal
I
SAT104
AT51
TroublfHhooti ngand
Di lJgnoses AUTOMATI C TRANSM
15510
N
Flui d condi ti on
Transmi ssi on flui d
color
and tex
ture can ai d
greatly
i n transmi ssi on
trouble
shooti ng
When
checki ng
l1ui d
level
exami ne
the
transmi ssi on l1ui d
and note
i ts
color
texture
andodor
Some
common
fonns of contami
nati on areli stedbelow
I DarkorBlack Flui d
Wi th
a
burnedodor
Wornfri cti onmateri al
Wi thout an odor
Sli ght
engi ne
coolant leak
i nradi ator
2
Mi lky
Pi nk Flui d WaterContami
nati on
Coolant leak
Road water
enteri ng
through
fi llertubeorbreath
er
3 Varni shed Flui d
li ght
to dark
brownand
tacky
Oxi dati on
Overor
Underfi lli ng
Overheati ng
Engi ne
I dle
Check and
adjust
i dle
to
speci fi ca
ti ons
I dli ng
speed
700i 100
rpm
at 0
range
Engi ne
011
andcoolant levels
Pri ortoroad
testi ng
check
engi ne
oi land coolant levels andfi llas neces
sary
Shi ft
li nkage
Start i n
park
posi ti on
depress
detent button and
slowly
move the
gear
selector
through
all
ranges
The
detent
cli cks should
correspond
wi ththe
range
i ndi cator
AT 52
pI AGN
STI C ROAD
TEST
Pri or
to
road
testi ng perform
the
preli mi nary i nspecti ons
outli ned
earli erI fthecari s not
equi pped
wi th
a tachometeri nstalla
portable
tacho
tneter
i n
the carAnd alsoi nstalla
sui table vacuum
gauge
and
pressure
gauge
I f
the customerhas a
speci fi c
complai nt
select road condi ti ons
si mi lartothose descri bed
eg steep
hi lls
freeways
etc
Follow the test
sequence
as out
li ned
i n
thi s
secti on
and mark
the
results on the
Symptom
Chart
on
page
AT 59 I t
may
be
necessary
to
repeat
secti ons
of the test underdi fferent
throttlecondi ti ons e
g
li ght
medi um
orfullthrottle After
completi ng
the
road test
compare
thetest results to
lI I e
Trouble
shooti ng
Chart on
page
AT
56
ROAD
TESTI NG
L Park
Range
Place the
gear
selectori n P
range
andstart the
engi ne Stop
the
engi ne
and
repeat
the
procedure
i n allother
ranges
and
neutralI n
park
the car
shouldbelocked
i n
posi ti on
unableto
rollor
move
Mark allresults on
the
Symptom
Chart
2 Reverse
Manually
shi ft the
gear
selector
from
P
to R and
note
shi ft
quali
ty
Dri ve the cari n reverse
long
enough
to detect
sli ppage
orother
abnormali ti es Noteresults
3 Neutral
Manually
shi ft the
gear
selector
from P to N and note
quali ty
I n
neutralno
clutches
or
bands
are
ap
pli ed
and there shouldbe
nomove
ment Noteresults
4
Dri ve
Range
Manually
shi ft the
gear
selectorto
ran
e
0and note
shi ft
quali ty
Dri ve
the car
through
all
automati c
shi fts and
i n
all
gear
ranges
Noteshi ft
quali ty
and
ti mi ng
kmh
MPH
check
for
sli ppage
noi se
orother
abnormal condi ti onS I f
necessary
dri vethe
test
sequence
underdi fferent
throttle
openi ngs
e
g
li ght
medi um
or
fullthrottle
5
Range
2
Manually
shi ft the
gear
selectorto
range
2 Check for
sli ppage
hesi ta
ti on orabnormalcondi ti on The
trans
mi ssi on should remai n i n 2nd
gear
regardless
of car
speed
or
engi ne
re
voluti ons Note relts
6
Range
I
Manually
shi ft the
gear
selectorto
range
I
Note shi ft
quali ty
I t
should however downshi ft i m
medi ately
to2nd
gear
anddownshi ft
agai n
to 1st
gear
as
road
speed
de
creases Accelerate and decelerate i n
1st
gear
todetermi ne
engi ne
braki ng
Noteresults
The transmi ssi on should
not
shi ft
i nto1st
gear
from 0
range
i f tha
car
road speed
i s
above
approxi mately
50
kmh30MPHI
7 Recordli ne
pressure
and
governor
pressure
at each
range
and at each
throttle vacuum i n
accordance wi th
the
pressure testi ng
descri bed below
AUTOMATI C
TRANSM15510N
Trouble shooti ng and
Di agnoses
Car
speed
andli ne
pressure
when
shi fti ng gears
I ntake
mani fold
vacuum
Gearshi ft
Car
speed Propeller
shaft
Li ne
pressure
kPa
mmHg i nHg kmhMPH
revoluti ons
rpm
kPa
kg
em
2
psi
0
O2
6068 38 42
1 9702
220
0
0
0
107
115
66
71
3
4803730
530
686
Ki ekdown
0
0 105 97 65 60
3 4103
160 5 4
7 077
100
0 0
53
45
33 28
17201470
0
O2
23 31
14
19
7501 000
13 3100
3
94
O2 0 63
70
39
44
2
0402290
441 598
0
0
4032 25
20 1
3001
050
45 61
64 87
O2
0
I I
18 7 I I
350600
oFullthrottle I I
54 46 33
29
1750
1 500
549
706
5 6 7
2
80102
400
3001181 I I 54
46 33 29 1
750
1500 549 706
5
6 7
2
80
102
Car
speedcan
becalculated
by
the
followi ng
formula
v
where V
Np
RF
r
v
where V
Np
RF
r
0
0307x
Np 1
2
x x
rx
Np
x60
RF
x1 000
Car
speed
kmh
Propeller
shaft revoluti on
rpml
Fi nal
gear
rati o13700
Ti re
effecti ve
radi us
m 185nOSR14 0
301
m
The
rati o
of
ci rcumference
of a ci rcle
to
i ts di ameter3141
0
01905xNp
2xll
xrxNPx60
RF
x
63 360
Car
speed
MPH
Propeller
shaft
revoluti on
rpm
Fi nal
gear
rati o
3
700
Ti reeffecti ve radi us
i n
18SnO
SR14 11 85 i n
The
rati oof ci rcum
of a
ci rcle
toi ts
di ameter
314
AT 53
Trouble shooti ng 8m
i agnoses
AUTOMATI C
TRANSMI SSI ON
Shi ft schedule
Fullthrottle
Ki ckdown
range
1 2
1t2
2
t
t3
133
1
2
2Y3
3
0003
94
I
E
267
I
f 200787
I
lc
I
0
I
I
3r
400
1 1
12
S
e
I
E
300
1181
I
E
I
I
d
I
53 3
5
0
I
I
OO 15 75 I
I
I
667
I
500
1969 c
0 500
1
000
1
500
2
000
2500 3000
3 500
4000
Propeller
shaft
revoluti on
rpm
kmfh
0
Carspeed
I
MPH
10
PRESSURE TESTI NG
The 3N71
B
transmi ssi on i s
pro
vi ded wi ththree
pressure
test
ports
Only
twoare usefulfor
transmi ssi on
trouble
shooti ng li ne Pressure and
GovernorPressure
ST2505S001
AT454
1 Li ne
pressure
2 Governor
pressure
3 Servo
releasepressure
LI NE
PRESSURE
I
I nstall
pressure
gauge
toli ne
pres
sure
port
When
shi ft
lever
i s i n 0
2
or 1
range
i nstall
pressure
gauge
to
port
CD
and when
i n
R
range i nstall
pressure
gauge
to
port
@
shown above
Locate the
gauge
so
i t
can be seen
by
dri verMeasure li ne
pressureat
i dli ng
andat stalltest
2
Road
test carand note
pressure
underdi fferent
throttlecondi ti ons
AT 54
20 90 100 130 140 30 40 50
30
60
70
120
70
80
10
20
80
40
50 60
SAT105
At
i dli ng
Range
Li ne
pressure
kPa
kg
cm2
psi
412
549 42 5
66080
314 373
3
2 3 8
46
54
588 1
147 6
0117
85 166
314 373 3
2 3
8
46 54
R
D
2
At
tall
test
Range
Li ne
pressur
kPa
kg
cm2
psi
R
1402
1589
14 3
162
203
230
D 971 1 089 99 11 1141 158
2
1
000
1 147
10
2 117 145 166
971
1
089 99
11 1141
158
Key poi nts
of
pressure
testi ng
are
alPressure at i dle Look fora
teady
ri se i n
pressure
as
carspeed
i n
cre under
li ght
load
bl
Pr
ur
drop
b tween hi ft
poi nt
hould not
exceed 98
kPa 1 0
kg
cm2 15
p
n
Ex
i
pressure
drop
may i ndi catean
i nternal
leakat a
servo
or
clutchseal
Cut back
poi nt
The cut back
poi nt
i ndi cates
a
poi nt
where
li ne
pressure
changes
from
hi gh
tolow
value
a
output
shaft
AUTOMATI C TRANSMI SSI ON
Trouble
shooti ngandOi agnoses
rotati on
i s gradually
i ncreased
from
stall
poi nt
The
car
speed
and
out
put
shaft rotati on at that cut back
poi nt
are
as
i ndi cated
i nchart below
I ntakemani foldvacuum
Car
speed
Propeller
shaft
revoluti ons
kPa
mmHg i nHg
kmhMPH
rpm
o0
0
40
48
25
30 1 310
1 560
13 3 100
3
94
20
2813
17
660910
GOVERNOR PRESSURE
I I nstall
pressuregauge
to
governor
pressure
port
Locate the
ga
ge
so
i t
can
be
seen
by
dri ver
2
Road
test carandnote
pressure
at
di fferent road
speeds
Gov
mor
pres
sure
i ncreases
di rectly
wi throad speed
and should
always
be
less
than
li ne
pressure
STALL TESTI NG
The
stalltest
i s an
effecti ve
method
of
testi ng
clutchand
band
holdi ng
abi li ty
to
rque
converterone
way
clutch
operati on
and
engi ne
perform
ance
A stall
test should
only
be
per
formed
as a last
resort because
of the
hi gh
l1ui d
temperature
i t
generates
and
the
excessi ve load i t
places
on
the
engi ne
andtransmi ssi on
1
CAUTI ON
a Transmi ssi on
and
engi ne
flui d
levels
should
alwavs
becheckedand
flui d
added
as
needed
b Run
engi ne
at 1 200
rpm
toattai n
proper
warm
up
c
Duri ng
test neverhold throttle
wi de
open
formorethan5 seconds
d DoNot test more than two
gear
ranges
wi thout
dri vi ng
cartocool
off
engi ne
andtransmi ssi on
STALL
TEST PROCEDURE
1 I nstalla tachometerwhere
i t can
beseen
by
dri ver
duri ng
test
2 Set
hand
brake andblock
wheels
3
Start
engi ne
and
place
shi ft
lever
i n D
range
4
Apply
foot brake
and accelerate
to
wi de
open
throttle
Donot hold
throttle
open
longer
than
fi veseconds
5
Qui ckly
note the
engi ne
stall
speed
and i mmedi ately
release throt
tle
Stallrevoluti on
1 6501 950
rpm
6
Place
shi ft lever
i n
R
range
and
repeat
above
test same as
i n D
range
I f stalltest i ndi cates
proper
stallre
voluti on i n D
range
nofurthertost
i ng
i s
necessary
STALL
TEST
ANALYSI S
I
Sati sfactory
results i n
0
range
i ndi cates rear
clutch
one
way
clutch
of
transmi ssi on
apd sprag
flutch
of
torque
converter
are
functi oni ng
pro
perly
2 Stallrevoluti on i n 0
range
1st
gear
i s above
carspeci fi ed
The
rear
clutchi s
faulty
3 Stallrevoluti on i n R
range
i s
above
speci fi ed
revoluti on for0
range
Lowand
Reverse Brakes are
faulty
4 Stall
revoluti on i n
0
range
1St
gear
i sbelow
speci fi ed
revoluti on
Converter
sprag
clutch
i s
faulty
sli ppi ng
or
engi ne
i s
not
performi ng
properly
I f
converter
sprag
clutchi s frozen
car
wi llhave
poor
hi ghspeed
perfor
mance
I f converter
sprag
clutchi s
sli ppi ng
carwi llbe
sluggi shup
to50
or60kmh30or
40
MPHl
AT
55
Troubleshooti ng
BndDi agnoses
AUTOMATI C
TRANSM
I S I ON
TROUBLE
SHOOTI NG
CHART
Numbers
arearranged
i norderof
probabi li ty
Perform
i nspecti ons
starti ng
wi thnumberoneandwork
i ng up
Ci rclednumbers
i ndi cate
that
thetransmi ssi on must be
removedfromthecar
Engi ne
does not start i n Nn
P
ranges
Engi ne
starts
i n
range
otherthan
N
and p
Transmi
si onnoi sei n P and
N
ranges
Car
moves
when
changi ng
i nto
P
range
or
parki ng
gear
does
not
di s
engage
when shi fted
out
of
P
range
Carrunsi n
N
range
Carwi llnot run
i n
R
range
but
runs
i n 0
2
and
I
ranges
Clutch
sli ps Very poor
accelerati on
Carbraked
when
shi fti ng
i nto
R
range
Sharp
shock
i n
shi fti ng
from N to
D
range
Carwi llnot run
i n 0
range
but
runs
i n
2
and R
ranges
Carwi llnot run
i n D I 2
ranges
but ri ms
i n R
range
Clutch
sli ps Very
poor
accelerati on
Clutches
or
brakes
sli p
somewhat
i n
tarti ng
Excessi ve
creep
No
creep
at all
Fai lureto
change
gear
from
I st
to
2nd
Fai lureto
change
gear
from 2nd
to 3rd
Too
hi gh
a
gear
change poi nt
from
1st to 2nd from
lnd to3rdu
Gear
changedi rectly
from
1st
to
3rd occurs
AT56
J
S
s
0
2
s
Cf7
CO
E
13
Ei b
o
e
4
ti
e
fe
aOClO
co
Sf
a
fe
0
i i
EEo
tag o
r
i
Ur J
Q
d
oS
J5
2 3
2
I
I
2
2
I 2
I
2
6
2
I
3
I
2
3
2
3
I 2
ONCAR
c
E
i t
c
fi
e
L
a
u c
M O
tIf
C
0
S
c
c
0
J
R
f
t
S
0
t CI
Ci r
EJsou
I
t0
OI l c
i 8
cSg jl
t
2
3 2
3
64
5
321
3 4
2
3
4 6
3
5
3
7
4
5
5 4
56874
56874
3
5 6
4
2
4
3 I
I N CAR
l
0
tl
fj
t
fi
f
GJ
l
0
111
J
f
e
CI I
o cfJB
i
CO
g
Ct
0c
cE 3C5C5
@
@
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CI D
@
7
@
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@
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@D
@
@
CI D
OFFCAR
OFFCAR
s
J
0
5fJ
s
E
00
ra
11
E
0
S
M C
I t
I
V
@
@
@
@
@
@
D
@
Numbersare
arranged
i norderof
probabi li ty
Perform
i nspect
ons
starti ng
wi thnumberone
andwork
i ng up
Ci rcled
numbers
i ndi cate
that thetransmi ssi on
must be
removedfrom
thecar
Too
sharp
a
shock
i n
change
from
1st
to 2nd
Too
sharp
a shock
i n
change
from
2nd
to 3rd
Almost noshockorclutches
sli ppi ng
i n
change
from
1st to
2nd
Almost
noshock or
sli ppi ng
i n
change
from
2nd to 3rd
Engi ne
races
extremely
Carbraked
by gearchange
from
lst to 2nd
Car
braked
by gearchange
from
2nd
to
3rd
Maxi mum
speed
not attai ned
Accelerati on
poor
Fai lureto
change
gear
from
3rd to
2nd
Fai lureto
changegear
from
2nd
to 1st or
from 3rd to
lst
Gear
change
shock
felt
duri ng
decelerati on
by releasi ng
accelerator
pedal
Too
hi gh
a
changepoi nt
from
3rd
I
to 2nd from 2nd to 1st
Ki ckdown
does
not
operate
when
depressi ng pedal
i n
3rd wi thi n
ki ckdown
car
speed
Ki ckdown
operates
or
engi ne
over
runswhen
depressi ng pedal
i n
3rd
beyond
ki ckdown
car
speed
li mi t
Races
extremely
or
sli ps
i n
changi ng
from 3rd
to
2nd
when
depress
i ng pedal
AUTOMATI C TRANSM
15510
N
Trouble
shooti ng
and
Di agnoses
s
J
e
or
UJg
0
E
f1
6
I 2 3
123
I 2
I 2
I 2
I 2
r
I
I
2
f
i
ff
i
0
Ei
0
e
t
tJ
o
o
s
Jt
rJJ
2 3
4
4
4 5
3
4
3
4
3
2
ON
CAR
l
a
c
o
u
0
t
a
E
g
g
C5tE
2 4
3
6
6
2
3
2
7
6
346
346152
5 6
5 6
4
5
5 6
4
ON CAR
I f
i i
N
E
g
3
1
0
i 5
Ei
o
c
0
v
c
o
5 3
5 4
8 7 5
8 7 5
3 8
5 2
3
7 4
6
5 3
o
tf
S
e
0
or
fj
E
3
0
0
d ct i J
@
@
OFFCAR
fi
5
rJ
o
i t
0
5fj
c
or
e
B
fJ E
u
S
00
S
r
388 s
@
@
@
@
j
@
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CI D
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j
CD@
@
@
CD@
I
CD
@
CD
CD
@
CD
@
@ @
OFFCAR
AT57
Trl
ble
shooti ng
and
Oi agnOSJ S
AUTOMATI C TRANSMI S I O
N
Numbers are
arranged
i n
orderof
probabi li ty
Perform
i nspecti ons
starti ng
wi thnumber
oneandwork
i ng up
Ci rclednumbers i ndi cate
that the
transmi ssi on must
be
removedfrom
thecar
Carwi llnot
run
i n
any range
Transmi ssi on
noi sei n D 2
I and R
ranges
Fai lure
to
change
from 3rd to
2nd when
changi ng
leveri nto
2
range
Gear
change
from 2nd
to
1st
or
from 2nd to
3rd
i n 2
range
No
shock at
change
from I to
2
range
or
engi ne
races
extremely
Fai lureto
change
from 3rd
to
2nd
when
shi fti ng
leveri nto
I
range
Engi ne
brakedoesnot
operate
i n 1
range
Gear
change
from
1st to
2nd
orfrom 2nd
to
3rd i n
I
range
Does
not
change
from
2nd
to
1st i n 1
range
large
shock
changi ng
from
2nd to
st
i n
range
Transmi ssi on overheats
n
n
0
f
a
0g
0
i i S
oo
f
l
601
2 3
123
I
2
Oi lshoots out
duri ng operati on
Whi tesmoke
emi ttedfrom 3
exhaust
pi pe
duri ng
operati on
Offensi vesmell
at oi l
chargi ng
pi pe
AT58
ON CAR
E
e
J E
IlO fi
e
5
2
a
Q
tl
I V G
1i O e ti C
Ji tSJi
g
e
c
g
0
0
0
C
E
c
c
5
2
2
4
2 3
4 5 7
OFF
CAR
fi
o
9
t
G
E
0
0
rS
rl
6
1
2
r
e
0
fi
Q
v
I V
I V
c
CJ t
0
c
I V
eo
8
gag
u
tl
i o
o
J 65
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CVI D
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f
0
0
c
0
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rt
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e
I I
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641
I @
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5
@
3
8 6
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2 4 5
763
@@
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2 4
531 I @
I
2
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4
5
6
7 3
I I
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4 3
I I
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I
3 4
I
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6 8
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I @@I @@@I @
I
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5
6 2 7
8 4
@@ @@@
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2
I @@@
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ON CAR
OFFCAY
AUTOMATI C TRANSM15510
N
Trouble
shooti ng
and
Di agnoses
ROAD TEST
SYMPTOM
CHART
I
Z
SHI FT
QUALI TY
S2
I
t
l
g
l
8
0
t
z
e
e
I
1
I
l
i f
x
I
I
i s
g
x
f
t
t
0
o
r0
5
t
t
Z
u
COMMENTS
PARK I
ENG START
I I I I
I
I
I
I I
L
RANGE
HOWI NG
I I I
I
I I I
R
Man
shi ft
P
R
I I
I I I
I I I
I I
RANGE
REVERSE
I
I I
I I
I
Man
shi ft
R
N
I I
I I
I I I
I I I
N
I
ENG
START
I I I I I
I I I
I I
RANGE
I N
I I I
I
I
I
I I I
I
I
Man shi ft N D
I I I I
I I I I I
I
lI st
I I I I I
I I
I
I
Auto
shi ft
2
I I
I I
I I
I
2nd
I
I I
I
I I I
D
I
Autoshi ft 23
I
I I I I
I I I I
RANGE
I
3rd
I I
I I
I I I
Decel 3
2
I
I I
I
I I
I
Ki ckdown
32
j
I
I I I
I
I
Decel 2
1
I I
I
I
I
I
Ki ckdown
2 1
I I I
I I
I
2
I
Man shi ft 02
I I
I
I
RANGE
I
2nd
I I
I I
I I I I
I
Man
shi ft 2 1
I
I
I
I
Man shi ft 01
I
I I
I
Accelerati on
I
I I
RANGE
I
Engi ne
I I
I
I
I
Braki ng
I I I
I
I
i
AT
59
TroublNhoovng
and
Di agnoses AUTOMATI C
TRANSM
15510
N
TROUBLE SHOOnNG GUI DE FOR
3N71B
AUTOMATI C
TRANSMI SSI ON
Order
Test i tem
Checki ng
Oi llevel
gauge
2
Downshi ft solenoi d
3
Manual
li nkage
4
I nhi bi tor
swi tch
5
Engi ne
i dli ng rpm
6
Vacuum
pressure
of vacuum
pi pe
7
Operati on
i neach
range
8
Creep
of
car
Stalltest I Oi l
pressure
before
testi ng
2 Stall
test
3
Oi lpressure
after
testi ng
Road
test 1 Slow
accelerati on
I st
2nd
2nd 3rd
2
Qui ck
accelerati on
1st
2nd
2nd 3rd
3
Ki ck down
operati on
3rd 2ndor2nd 1st
AT 60
Procedure
Check
gauge
foroi lleveland
leakage
before
and aftereach
test
Check forsound of
operati ng
solenoi d when
dep ressi ng
accelerator
pedalfully
wi th
i gni ti on
key
ON
Check
by
shi fti ng
i nto P
R D 2 and I
ranges
wi th
selectorlever
Check whether
starter
operates
i n
N and P
ranges only
andwhether
reverre
lamp operates
i n
R
rangeonly
Checkwhether
i dli ng
rpm
meet
standard
Check whethervacuum
pressure
i s
more than
600
kPa 450
mmHg
17 72
i nHg
i n
i dli ng
andwhether
i t
decreases wi th
i ncreasi ng rpm
Check whethertransmi ssi on
engages
posi ti vely by
shi fti ng
N D 2
N and N R
range
whi le
i dli ng
wi thbrake
appli ed
Checkwhethertherei s
any creep
i n
D
I
and R
ranges
Measureli ne
pressures
i n D
2
I
and OR
range
whi le
i dli ng
Measure
engi ne rpm
and li ne
pressure
i n D 2
and
R
ranges
duri ng
fullthrottle
operati on
Temperature
of
torque
converter
oi lused i n
test shouldbe
from60tol000C 140to
2120Fli
e
suffi ci ently
warmed
up
but
not
overheated
CAUTI ON
To
cooloi lbetween eachstall
test for
0 2
T and
R
ranges
i dle
engi ne
i e
rpm
at about
1200
rpm
for
more than 1 mi nute
i n
P
range
Measuremenlti me must
not be
more
than5
seconds
Same
as
i temI
Check car
speeds
and
engi ne rpmi n
shi fti ng up
1st
2nd
range
and
2nd 3rd
range
whi le
runni ng
wi thleveri n 0
range
and
engi ne
vacuum
pressure
of about
13 3
kPa
100
mmHg
3 94
i nHg
Same as
i tem I
above
except
wi th
engi ne
vacuum
pressure
of
okPa 0
mmHg
0
i nHg
i
e
i n
posi ti on
just
before
ki ckdown
Check whetherth
ki ckdown
operates
andmeasuretheti me
delays
whi le
runni ng
at 3040506070
km h19
25 31
37
43
MPH
i n
Os
range
AUTOMATI C TRANSMI SSI ON
Troubleshooti ng
andDi agnoses
Order
Test i tem
4
Shi ft
down
Ds
02 D1
5
Shi ft down
D
12
11
6 Shi ft down
02
7
Shi ft
up
11
l
12
8 Shi ft
up
or
down
whenstart
i ng
i n 2
range
9
Parki ng
Others
Abnormal
shock oi l
leakage
Procedure
Check
car
speeds
and
engi ne rpm
i n
shi fti ng
down from3rd
2nd
1st
sequenti ally
whi le
coasti ng
wi thaccelerater
pedal
released
i n
D3 range
and
engi ne
vacuum
pressure
of
about
600kPa 450
mmHg
1772
i nHg
Check
for
shi fti ng
down D I
and
engi nebraki ng
and
furtherfor
shi fti ng
down I I
and
engi ne
braki ng
after
shi fti ng
the
lever
i nto I
range
wi ththe
accelerator
pedal
releasedand the
engi ne
vacuum
pressure
of 0kPa 0
mmHg
o
i nHg
whi le
dri vi ng
at
about 50
kmh 30
MPH
i n
D3
range
Check
for
qui ck shi fti ng
down 02and
engi nebraki ng
after
shi fti ng
the
leveri nto2
range
whi le
dri vi ng
at about
50km
h30
MPH
i n 0
range
Also
check for
locki ng
of the transmi ssi on
i n
2nd
gear
rati o
regardless
of
car
speed
Check forfai lure of the
transmi ssi on toshi ft
up duri ng
accelerati on when
starti ng
i n
range
Check
the transmi ssi on
for
not
shi fti ng up
or
down
duri ng
accelerati onordecelerati on
when
starti ng
i n 2
range
Confi rmthat vehi clewi llnot moveon
grade
when
shi fti ng
to
P
range
Enter
i ntorecord
condi ti ons observed
duri ng
these tests
such
as
gear
noi se
abnormal
clutchnoi se
and
accelerati on
per
formance
AT
51
Servi ce Datund
Speci fi cati ons
AUTOMATI C TRANSMI SSI ON
Generalspeci fi cati ons
Automati ctransmi ssi on
model
Stall
torque
rati o
l
st
Transmi ssi on
I
2nd
gear
fati o
I
Top
I
Reverse
Oi l
Oi l
capaci ty
SERVI CE DATA
AND
SPECI FI CATI ONS
3N718
I
Numberof dri ve
plates
Numberof
dri ven
plates
20t
Reo
cl
Clearance mm
i n
2458
1458
Thi ckness of retai n
i ng plate
mm
Un
1000 Numberof dri ve
plates
I
Number
of dri ven
plates
I
Clearance mmli n
2182
Automati c
transmi ui on
flui d
Oexron
type
Low
5 5 li ters
15
7
8US
qt
4
7
8
I mp
qtl
Approxi mately
27 li ters
12
7 8US
qt
2 8
I mp qt
torque
converter
e
verse
brake
Thi ckness of
retai ni ng plate
Speci fi cati ons
and
adjustment
Automati ctransmi ssi on
assembly
Model
codenumber
Torque
converter
assembly
Stamped
mark on the
TI C
Numberof
dri ve
plates
I
Numberof dri ven
plates
Clearance
mm
i n
Front
clutch
Thi cknessof
retai ni ng plate
AT 62
Brakeband
X2305
Pi stonsi ze
Bi g
di a
mmli n
Smalldi a
G
Controlvalve
assembly
Stamped
mark
on
strai ner
3
Governor
assembly
Stamped
markon
governor
body
3
1 6200063 0
0791
Thi cknesi
mmOnl
Part number
10
6104171
108
104251
110
10
433
t121044t
11
410
449
116
10457
31537X0100
31537
X0101
3t537X0102
31537 X0103
31537X0104
31537X0105
Stall
revoluti on
I
Stallrevoluti on
rpm
5
08 1 60
031
0
063
5
835
1032871
5
5
080125
10
0315 0
04921
Thi ckness
mm i n
7
8103071
80
10
315
82
10323
8AI 0
33tl
86103391
88
10346
1
650
1
950
Part
number
31667 X0500
31667
X0501
31667 X0502
31667 X0503
31667 X0504
31667 X0505
64
2
52
401157
LRJ
35
AUTOMATI C TRANSM
15510N
Speci sl
Servi ce
Tools
Ti ghteni ng
torque
Uni t
N
m
kg m
ft I b Uni t N
m
kg m
ft I b
Dri ve
plate
to
137 157 140160 101
116
Si de
plate
to
control
25 34
025 035 18 25
crankshaft
valvebody
Dri veplate
to
torque
39 49 4
05 0 29
36
Nut
forcontrolvalve
4
9
69 05
07 36 5 t
converter
reamer
bolt
Converter
housi ng
to
39
49 405 0 29 36
Oi lstrai ner
to
lower
29 39 03
04 22 29
engi ne
valve
body
Transmi ssi oncase
to
44 54
4
5
5 5 33 40
Governorvalvebody
to
49
6
9
05 07 365 1
converter
housi ng
oi ldi stri butor
Transmi ssi oncase
to
2025
2025 14 18
Oi l
pump housi ng
to
5
9
713
06 08 43 5
8
rearextensi on
oi l
pump
cover
Oi l
pen
totransmi ssi on
49 69
05 07 365 1
I nhi bi torswi tch
to
49 69
05
0
7 36 5 t
ca
transmi ssi on
case
Servo
pi ston
retai ner
4969 05 07 36 5
1
Manualshaft locknut 29 39
3040
22 29
to
transmi ssi on
case
Oi lcooler
pi pe
to
29
49
305
0 22 36
Pi ston
stem when
12 15
12 1 5 9
11
transmi ssi oncase
adjusti ng
band brake
Test
plug
oi l
pressure
14 21 1421
1015
Pi stonstem
lock nut
15 39 1 5 40
11 29
nspecti cn
hole
One way
clutchi nner
t3 18 1
3 18 9 13
Support
actuator
raceto
transmi ssi on case parki ng
rod
nserti ng
78 108 08
11 513 80
posi ti onl
torear
Controlvalve
body
to
5 4 74 055 075 4
05 4
extensi on
transmi ssi on
case
I
Lo
v
lvbody
to
Turnback
twoturnsaftar
ti ghteni ng
25 34
025 035 18 25
upper
valvebody
SPECI AL
SERVI CE
TOoLs
Toolnumber
Kent
Moore
No
Toolname
ST07870000
ST07860000
125607
Transmi ssi oncasestand
ST25850000
125721
Sli di ng
hammer
GG91060000
GG93010000
J25703
Torque
wrench
AT
53
Speci al
Servi ceToofs AUTOMATI C
TRANSM15510
N
Toolnumber
Kent Moore
No
Toolname
ST25420001
ST2542000Q
126063
Clutch
spri ng compressor
ST25320001
125710
Snap
ri ng
remover
o
ST2557000
I Hexhead
extensi on
ST2557000Q
J25718
ST25490000 Socket extensi on
ST255 1200
I
125713
HT62350000 Spi nner
handle
ST25160000
Torque
dri ver
ST25580001 Oi l
pump
assembli ng gauge
Q
125719
HT6
I
000800 Hexagon
wrench
j
ST2505S001
Oi l
pressuregauge
set
125695
c
AT 64
DATSUN
200SX
ModelS
rJ
0Seri es
SECTI ONP D
PROPELLER
SHAFT
DI FFERENTI AL
CARRI ER
CONTENTS
PROPEUER
SHAFT
Model 3S63A
GENERAL I NSPECTI ON
PROPELLER
SHAFT VI BRATI ON
REMOVAL
AND I NSTALLATI ON
I NSPECTI ON
PROPELLER
SHAFT RUNOUT
FLANGE YOKE
AND SLEEVE YOKE
JOURNAL AXI AL
PLAY
REPAI R
CENTER
BEARI NG
DI FFERENTI AL
CARRI ER Fi naldri ve
Model H165B
PREPARATI ON
FOR DI SASSEMBLY
REMOVAL
PRE DI SASSEMBLY I NSPECTI ON
TOOTHCONTACT
DI SASSEMBLY
DI FFERENTI AL
CARRI ER
DI FFERENTI AL CASE
I NSPECTI ON
PD 2
PD 2
PD 2
PD 3
PD
3
PD
3
PD 3
PD 3
PD 3
PD 3
PD 5
PD
6
PD
6
PD 6
PD 6
PD 7
PD 7
PD B
PD 9
ASSEMBLY
DI FFERENTI AL CASE
DI FFERENTI AL CARRI ER
ADJUSTMENT
SI DE
BEARI NG
ADJUSTMENT
PI NI ON
HEI GHT ADJUSTMENT
FI NAL VERI FI CATI ON
SERVI CE
DATA AND
SPECI FI CATI ONS
PROPELLER SHAFT
GENERAL SPECI FI CATI ONS
SERVI CE
DATA
TI GHTENI NG TORQUE
DI FFERENTI AL
CARRI ER
GENERAL SPECI FI CATI ONS
SERVI CE
DATA
TI GHTENI NG TORQUE
TROUBLE
DI A
GNOSES AND
CORRECTI ONS
PROPELLER SHAFT
DI FFERENTI AL
CARRI ER
SPECI AL
SERVI CE
TOOLS
PD 9
PD 9
PD l0
PD
11
PD l1
PD 13
PD
15
PD
16
PD 16
PD 16
PD
16
PD
16
PD
16
PD 16
1ft
PD 16
PD 17
PD 17
PD 17
PD
1B
PD
19
1
PropellerSheft Model3S63A
PROPELLER SHAFT 8
DI FFERENTI AL
CARRI ER
PROPELLER SHAFT
Model 3S63A
Compani on
flange
Washer
Apply
a
coat
of
muI ti PUI JlOse li thi um
greasecontai ni ng
molybdenum
di sulfi de
tothe
endface
of thecenter
beari ng
and
both
si desof
thewasher
Locki ng
nut
Flange
nut
type
b245
294
U
25 30
181
217
Nut and washer
type
i f
196
235
2024
VI
145 174
Center
beari ng
I nstallcenter
beari ng
wi th
F
ffi uk
toward
front
of
car
V
i f
32
2
4 33
17
24
Propeller
lhaft
1st tube
fJ
N
m
kg
mft
tb
GENERAL
I NSPECTI ON
I nspect propeller
shaft tubesurface
fordents
or
cracks
I f
damaged
replace
propeller
shaft
assembly
I f center
beari ng
i s
noi sy
or
damaged
replace center
beari ng
I f
journal
i s
damaged
or
worn re
place
propeller
shaft
assembly
PD
2
PROPELLER
SHAFT
VI BRATI ON
To check and
correct an
unbalanced
propeller
shaft
proceed
as
follows
I Remove
undercoati ng
andother
forei gn
materi alwhi chcould
upset
shaft balance andcheck shaft vi bra
ti on
by
road
tesi
2 I f
shaft
vi brati on
i s
noted
duri ng
roadtest di sconnect
propeUer
shaft at
di fferenti alcarri er
compani on
flange
rotate
compani on flange
180
degrli es
andreconnect
propeller
shaft
Propeller
shaft
2ndtube
i ll
fJ
24
32
243
3
17 24
Center
beari ng
support
S
PD11
3
Agai n
check shaft
vi brati on I f
VI brati on sti ll
persi sts replace propel
lershaft
assembly
PROPELLER SHAFT
DI FFERENTI AL CARRI ER
PropellerShaft
Mode 3S63A
REMOVAL
AND
I NSTALLATI ON
I
Put match
marks
on
l1anges
and
separate
propeller
shaft from
di fferen
ti alcarri er
2
Remove center
beari ng
bracket
I
I
@
1
ro
S
KO
c
I
J
3 Draw out
propeller
shaft from
transmi ssi on
and
plug up
rear
end
of
transmi ssi on
rear
extensi on
housi ng
o
t
Plug
SPD105
4 Toi nstallreverse the
foregoi ng
procedure usi ng
reference marks
i n
removal
I nstallthe
center
beari ng
on
the
bracket
wi ththecontact
surfaceof the
cushi on
faci ng upward
Connecti ng
porti on
Cushi on
c cr
SPD124
I NSPECTI ON
PROPELLER SHAn
RUNOUT
I nspect
propeller
shaft runout
I f
ronout exceeds
speci fi cati ons
replace
propeller
shaft
assembly
Runout
li mi t
06mm0024i n
i tM
SPD106
FLANGE
YOKE AND SLEEVE
YOKE
I f
l1ange yoke
and sleeve
yoke
are
damaged
or
worn
replace
propeller
shaft
assembly
SP0107
JOURNAL AXI ALPLAY
I nspect journal
foraxi al
play
i f
there i s
play replace propeller
shaft
assembly
SPD10B
REPAI R
CENTER
BEARI NG
I Put matchmarks on
l1anges
and
separate
2ndtube
from
1st
tube
SPD109
2
Put matchmarks
on
the
l1ange
andshaft
m
Q
aU
SPD110
3 Remove
locki ng
nut wi thTool
PD 3
PropellerShsft
Model3S63A
PROPELLER
SHAFT
DI FFERENTI AL CARRI ER
4 Remove
compani on l1ange
wi th
puller
L
5
Remove
center
beari ng
wi th
Tool
and
press
1
i LsP0113
Care should be token when
setti ng
Tooli n
press
tomakesurethat
parti ng
li ne of Tooli s
ri ght angle
to
support
fi xture of
press
Thi s i s to
prevent
Toolfrom
bendi ng
OK
li C
Ji
N
G
f
Support
fI xture
PD 4
6
I nstall
new
center
beari ng
Besure
to
i nstallcenter
beari ng
wi th OF
mark towardfront of
car
Apply
a coat of multi
purpose
li th
i ui n
greasecontai ni ng molybdenum
di
sulfi de tothe end
faoeof the
cente
beari ng
and both
si des of
the
washer
7
I nsert
thewasher
i nto
theend
of
thecenter
beari ng Ali gn
themark
on
the
compani on flange
and
i nstall
the
compani on
flange
9
centerbeari ng
Washer
Compani on flange
Locki ng
nut
I
SPD115
8
Ti ghten locki ng
nut
usi ng
Tool
SP0116
Cl
Cent
r
bari ng locki ng nut
Flangenut
type
245 294N
m
25 30
ka m
181 217
I t
lb
Nti t
and
wash type
196
235 Nm
2024
ka m
145
1741t
bl
@
SPD125
9
Stakethenut
10
Ali gn
the
mark
and
connect
1st
and2nd
tubes
Olftere1
ti al
case
CD
Vi lli on
ne llht
e
I ff
ad
USti nS
st
et
W
Detetn
i nln b
thi ck
nesS
Dri ve
pwot
ca
i nI I
I
nllS
er
Rlfl
Ollt
outer
race
Dti
e
i nl
t
n
n
6
ft
J
i r
i ll
I I
set
l
YI
Bac K
tn
13
0
18
col1
p
ble
o
005
I
0
00111
SJacet
p
waYt
te1
ace
Sde
i nll
di P
Lock
tu
MY
a
te p
ace
J@111911
8
10
511
11
@
49
59
5
6
36
43
L
ftna1
dl
I e
assern
ty
DJ
taCe
Outct
Si de
a
i 1 l
adi usti fl
sbi n l
oetetrni ni tW
si de
oeatI DS
tni ct
t
es
Gas
et
tt l
HaYt
replace
Di tfelent
catti et
front
oi l
a
A
aY
replace
Corovani ot
ll1 l
ynWP
mate
hatt
34
15
@
15
35
18
1
5
u
to
1
11
i n
on
P
10
O
10
vep
1
43
i I
ON
HI
u
un
I
13
19
1
00
l
of
0
btai ned
@
1
plte
P
ue
valuen
11
0
ad
to
1
81
10
6
g
Ct l1
t
M
J
o
Il
o
J
n
1
l
0
t1
0
0
Jl
l
t
mi
J
tJ
n
S
S
0
a
i
Q
c
0
n
oJ
i
0
t
u
st
O
S
Di fferenti al
Carri erFi naldri ve
Model
H165B
PROPELLER SHAFT
DI FFERENTI AL
CARRI ER
PREPARATI ON FOR
DI SASSEMBLY
REMOVAL
I
Jack
up
rear
of
car
and
support
i t
by
placi ng
safety
stands underrear
axle
case
referri ng
tosecti on GI
2
Remove
drai n
plug
anddrai n
gear
oi l
SPD121
3
Remove
propeller
shaft
andrear
axle shafts
RefertoSecti on RA for
removaland
plug up
rear
endof
tran
mi ssi on
rear
extensi on
housi ng
SP0105
4
Loosen bolts
securi ng
di fferenti al
carri er
torearaxlecase
andtakeout
di fferenti alcarri er
5 Mount
di fferenti alC3rri eronTool
PD 6
PRE DI SASSEMBLY
I NSPECTI ON
I
Check backlashof
ri ng gear
wi th
a di al
i ndi catorat several
poi nts
I f
i t i s
not wi thi n
speci fi cati on
adjust
i t re
ferri ng
to
SI DE BEARI NG
ADJUST
MENT
Backlash
013 018mm
10
0051 00071
i nl
SP 0002
2
Check runout of
ri ng gear
wi tha
di ali ndi catorI fi t
i s over
speci fi ca
ti on
hypoi d
gear
set ordi fferenti al
case
shouldbe
replaced
When backlash
vari es
excessi vely
i n
di fferent
places
the
vari ance
may
have
resulted from
forei gn
matter
caught
between
ri ng
gear
and
di fferenti alcase
I
Runout li mi t
004mm
100016i n
SPD003
3
Check
toothcontact
referri ng
to
TOOTHCONTACT
4
Check
backlashof
si de
gear
Usi ng
a
thi ckness
gauge
measure clearance
betweensi de
gear
anddi fferenti al
case
I f i t i s
not
wi thi n
speci fi cati on
adjust
i t
by
selecti ng
si de
gear
thrust
washerReferto
S Os
Cleal llnce
010020mm
10 llO39
00078
i nl
SPD004
TOOTH
CONTACT
Gear
toothcontact
pattern
check i s
necessary
to
veri fy
correct
relati onshi p
between
ri ng gear
anddri ve
pi ni on
Hypoi d
gearset whi charenot
posi
ti oned
properly may
be
noi sy
orhave
short
li fe orboth
Wi th
a
pattern
check the most desi rable
contact for
lownoi selevel
and
long
li fecan
be
as
sured
Check
I
Thoroughly
clean
ri ng
gear
and
dri ve
pi ni on
teeth
2
Spari ngly apply a
mi xture
of
powdered
ferri c
oxi de
andoi lor
equi v
alent to
3or
4teeth
of
ri ng
gear
dri ve
si de
SPOOD5
3 Hold
compani on flange
steady
by
hand
androtatethe
ri ng
gear
i n
both
di recti ons
SPoooa
PROPELLER SHAFT
DI FFERENTI AL CARRI ER
Oi fferent slCarri er
Fi nsl
dri vel
ModelH1658
Adjustment
H I contact
F cecontact ToecontaCt
Flank
cont8ct
Tocorrect
i ncrease
thi ckness
of
pi ni on
hei ght adjusti ng
washer
i n
orderto
bri ng
dri ve
pi ni on
closeto
ri ng gear
To
correct reducethi cknessof
pi ni on
hei ght adjusti ng
washeri n
order
to
make
dri ve
pi ni ongoaway
from
ri ng gear
c
DI SASSEMBLY
DI FFERENTI AL CARRI ER
1
Put matchmark on
one
si de of
si de
beari ng cap
wi th
pai nt
or
punch
toensure that
i t i s
replaced
i n
proper
posi ti onduri ng reassembly
Beari ng
caps
are li ne bored
duri ng
manufacture
and should be
put
back
i n
thei r
ori gi nal
place
1
08
Correct
toothconae1
2
Remove
si de
beari ng
caps
SP 0009
1W
3
Usi ng
a
pry
bar
removedi fferen
ti al
caseassembly
Be carefulto
keep
the si de
beari ng
outerraces
together
wi thi nnerrace
don mi xthem
up
V
SPD007
SP0011
PD 7
Di fferenti al
Carri erFi nal
dri ve
Model
H165B PROPELLER
SHAFT
DI FFERENTI AL
CARRI ER
4
Remove
dri ve
pi ni on
nut wi th
TooL
SPD012
5 Remove
compani on
l1ange
wi th
puller
SPD014
1 i j
6
Remove
dri ve
pi ni on
wi thsoft
hammer
Soft hammer
Remove oi lseal
by
pryi ng
up
wi th
a
large
screwdri verand
remove
front
pi ni on beari ng
i nner
race
Dothi s
carefully
so
as
not to
scratch
sealbore wi th
screwdri verCoverend
of screwdri verwi th
a
rag
PD 8
1
S
SPOOl
8 Remove
pmlOn beari ng
outer
race
usi ng
a brassdri ft
SPD017
9 Remove
collapsi ble spacer
from
dri ve
pi ni on
10 Pullout rear
beari ng
i nner
race
wi th
a
press
andTool
Care
should be takenwhen
setti ng
Tooli n
press
tomakasurathat
parti ng
li neof Tooli s a
ri ght angle
to
support
fi xture of
press
Thi s i s
to
prevent
bondi ng
Tool
SP0018
OK
N
G
li e
Support
fI Xture
DI FFERENnALCASE
I Remove
si de
beari ng
i nnerrace
wi th
TooL
To
prevent
damage
to
beari ng
engage
puller
paws
wi th
groa
Be
carefulnot
toconfuse left and
ri ght
hand
parts
ST3305100l
SP0020
ST3305200Q
SPD021
SPD022
2
Remove
ri ng
gear
by
spreadi ng
out lock
straps
and
looseni ng
ri ng
gear
bolts
i na
cri ss cross fashi on
SPD023
PROPELLER
SHAFT
DI FFERENTI AL
CARRI ER
Di fferenti al
Carri erFi naldri ve Model
H1658
3
Tap ri ng gear
off
gear
case
usi ng
a
soft hammer
Tap evenly
allaroundto
keep ri ng
gear
from
bi ndi ng
SPD024
4 Dri ve
out
pi ni on
mate
shaft lock
pi n
wi thTool
from
ri ng
gear
si de
5
Draw
out
pi ni on
mate
shaft
and
rota e
pi ni on
mate
gears
out of the
case andremove si de
gears
and
thrust
washers
SPD122
Put marks
on
gears
and thrust
washerso
that
they
can berei nstalled
i n thei rori gi nal
posi ti ons
fromwhi ch
they
wereremoved
@
e
e
@@
@4S
@
SPD026
I NSP
CTI ON
I Clean
di sassembled
parts
com
pletely
Repai r
or
replace
any damaged
or
faulty
parts
When
replaci ng
dri ve
pi ni on
or
ri ng
gear
replace
wi th
8
new hypoi d
gear
set
O
I I
SP0027
2 The followi ng parts
should
be
replaced
by
new
ones each
ti me
they
are removed
CD
Gasket
@Frontoi lseal
I D
Collapsi ble
spacer
@
Lock
strap
@
SP0028
ASSEMBLY
Assembly
should be done
i n
the
reverse orderof
di sassembly
whi le
maki ng any necessary i nspecti ons
and
adjust 1ents
PRECAUTI ON
a
Arrange
shi ms
and washers
to
i n
stallthemcorrectly
b
Thoroughly
clean the surfaces on
whi chshi ms washers
beari ngs
and
beari ng
caps
arei nstalled
c
Apply gear
oi l
when
i nstalli ng
beari ngs
d
Pack recommended multi
purpose
grease
i nlo
cavi ty
between
li ps
when
fi tti ng
oi l
seal
DI FFERENTI AL
CASE
I I nstall
pi ni on
mate
gears
si de
gears
and
thrust
washers
i nto
di fferen
ti acase
2
Fi t
pi ni on
mate
shaft
3
Adjust
clearance between
rear
face of si de
gear
and
thrust
washer
by
selecti ng
si de
gear
thrust washerRefer
toS
D S
Feeler
t
t
5
B
c
Clurance
010O
20mm
00039
00079
i n
5P0029
4 I nstal
pi ni on
mate shaft lock
pi n
usi ng
a
punch
Make sure
lock
pi n
i s flushwi th
case
5P0030
PD 9
Di fferenti alCarri erfFi naldri ve Model H
65B
PROPEbLER SHAFT
DI FFERENTI AL
CARRI ER
5
Place
ri ng gear
ondi fferenti alcase
and
i nstall
new
lock
straps
and
bolts
Ti ghten
bolu i n
a
cri sl
cross
fa
shi on
li ghtly
tappi ng
bolt head wi th
ahammer
Then bend
up
lock
straps
tolock
theboltsi n
place
I i i 7S gSN
m
L
I S
O 100
kG
58 72ft bl
A
6
Select si de
beari ng adjusti ng
shi ms
referri ng
to
SI DE
BEARI NG
ADJUSTMENT
7
I nstallthe
shi msbehi ndeachbear
i ng
and
press
on
the
beari ngs usi ng
Tool
SPD033
ST33052000
SPD034
PD I O
DI FFERENTI AL
CARRi ER
I
Press fi t front and rear
beari ng
outerraces
usi ng
Tools
SP 0035
1
2 Select
pmlOn hei ght adjusti ng
washer
referri ng
to
PI NI ON HEI GHT
ADJUSTMENT
3 I nstall
pi ni on hei ght
adjusti ng
washer
i n
dri ve
pi ni on
bevelsi de
toward
gear
and
press
fi t
rear
beari ng
i nnerrace
i ni t
usi ng press
andTool
4 Lubri cate
front
beari ng
wi th
gear
oi land
place
i t i n
gear
carri er
SPD045
5
Usi ng
Tool
carefully fi t a newoi l
seali nto
carri er
Make
lureoi lseali s
flushwi thend
of carri erand
apply
multi purpose
grease
i nto
cavi ty
d
li ps
l
SPDQ37
ST33400001
i I
6 Place a
new
collapsi ble spacer
on
dri ve
pi ni on
and
lubri cate
rear
beari ng
wi th
gear
oi l
and
i nsert i t i n
gear
carri er
SP003S
7
I nstall
compani on
l1angeandhold
i t
fi rmly
I nsert dri ve
pi ni on
i nto
compani on flangeby
tappi ng
i ts
head
wi th
a
soft hammer
PROPELLER SHAFT
DI FFERENTI AL CARRI ER
Di fferenti al
Carri er
Fi nal
dri ve
Model
H165B
8
Hold
compani on l1ange
wi th
Tool
and
temporari ly
ti ghten pi ni on
nut
unti l
therei sno
axi al
play
Ascertai n
that threaded
porti on
of
dri ve
pi ni on
and
pi ni on
nut
are
free
fromoi lor
grease
SP 0040
9
Ti ghten pi ni on
nut
by degrees
to
the
speci fi ed preload
whi le
checki ng
the
preload
wi thTools
When
checki ng preload
turndri ve
pi ni on
i nbothdi recti onsseveralti mes
set
beari ng
rollers
l
Preload
I I
wi thoi lMan
07 1 0Nom
7 10
kli J cm
61 87i n
lb
J
Dri ve
pi ni on
nut
137 294N m
14 30
kg
m
101 217 ft
I b
CAUTI ON
The
preload
i s
achi eved
by usi ng
the
permanent
set of
collapsi ble
spacer
Sohere i fan over
preload
resultsfrom
excessi ve
turni ng
of
the
pi ni on
nut
the
spacer
should
be
replaced by
new
one
10
I nstalldi fferenti alcase
assembly
and si de
beari ng
mi ter
races
i ntodi f
ferenti alcarri er
and
i nstall
si de bear
i ng cap
Tap
on the
cap
wi th8 soft ham
mer
tosettle i t i nthecarri er
The
beari ng cap
shouldbei nstalled
wi ththe marks
put
8t di sassembly
ali gned
I i J
49 59N
m
5 060
kg
m
36 431t I OI
I f
SPD044
ADJUSTMENT
SI DE
BEARI NG
ADJUSTMENT
Si de
beari ng
SPD046
Si de
beari ng
adjulti ng
shi m
When
the di fferenti alcase si de
beari ng
or
gear
carri eri s
replaced
or
when the
ri ng gear
backlashorsi de
beari ng
preload
i s
out of
speci fi ca
ti ons si de beari ng
shi ms of
proper
thi cknessshouldbei nstalled
Requi red
Tools
DWei ght
Block ST32501
000
@MasterGauge
ST33741000
@
Base Plate
@Di al
I ndi cator
@
j@R
tl
I
D
0f
@ SPD048
I
Thi ckness
of shi m
can
be calcu
lated
by followi ng equati on
Left si de T A C
O H
I
x001
020E
I
Ri ght
si de T
2
8 0H
I x001 009 F
I
L
CAUTI ON
Toavoi d
any
confusi onwhi lecalcula
ti ng
i t i s
absolutely necessary
to
stay
wi thmetri c
system
I f
you
measure
anythi ng
i n i nches the
results should be
converted i ntothe
metri c
system
POtt
Di fferenti al
Carri erfFi nal
dri vel
ModelH7658
PROPEllER SHAFT
DI FFERENTI AL
CARRI ER
Where
T
Left si de
T2
Ri ght
si de
A
B
c
D
2 Measure
values E and
F
I
Attach
a
di al
i ndi catortothebase
plate
2
Place
the outer
race of
the
op
posi te
si de
beari ng
to bemeasured
3
Placea
wei ght
block on
that
outer
race
and
a master
gauge
on
that
bi ock
Then
adjust
the
di ali ndi catorscale
to
zero
wi thi ts
ti p
on the master
gauge
ST3 501000
SP0Q49
Oppo
i te
si de
outer
race
4 Remove
the master
gauge
and
wei gh
t
block
Place
the
beari ng
outer
PD 12
o
H
o
o
0
U
o
G
o
l
E
mm
Left
Si de
Beari ng
Stamped
on
di fferenti al
carri er
F
mm
Ri ght Si de
Beari ng
Stamped
on
di fferenti al
cue
Di fferences
betweenwi dth
of left
E or
ri ght
F
si de
beari ng
andstandard
wi dth
A B
C
Dand
H
are
di mensi onalvari ati ons
i n
a
uni t
ofl
100
mm
agai nst
eachstandardvalue
race
andi nner
race
tobemeasuredon
the
opposi
e si de outerrace and
place
the
wei ght
block on that
beari ng
assembly
I f the
beari ng embly
i
placed
on
the base
plate
the
beari ng
wi dth
cannot be accurately
determi ned due
toi ts
cage bei ng
i n
contact
wi ththe
base
plate
Measured
outerrace
5
Turn the
beari ng
several
li mes
tosettlei t andthen
read thei ndi ca
ti onofthedi ali ndi cator
SPD126
The
i ndi cati on
should
be Ear
F
Left
i de
beari ng
E
Ri ght
i de
beari ng
F
speOS1
3 Substi tute
these
values
i nto
the
equati on
tocalculatethethi ckness
of
theshi m
I f value
i gni fyi ng
A B
C 0and
H are
not
gi ven regard
themas zero
andcalculate
After
as
embly
check to
ee
that
preload
end
backla
h
ere
peci fi ca
ti on I f not
readjust
PROPELLER
SHAFT DI FFERENTI AL CARRI ER Di fferenti al
Carri erFi naldri ve ModelH165B
Example
A
I
B 2
C 2
D
3
H
2
E Ol1
F 020
Left si de
T A
C
0H
xOOI
0
20
E
1
2 3 2
xOOI
0
20
011
I
A
C
I
2
I
3
2
2
4
0
H
2 4
x 001
004
3 004
0
20
0
24
4 024
011
035
E
T
035mm
4 Select
the
proper
shi ms Referto
S
O
S
I f
you
cannot fi nd the desi red
thi ckness of shi ms use shi ms sothat
the totalthi ckness i stheclosest tothe
calculatedvalue
Example
Left si de
Calculatedvalue
T 035 mm
Used
shi ms
Thi ckness
Quanti ty
020
x I
020
0
10
x I 010
005 x
I
005
Totalthi ckness 035
mm
Ri ght
si de
T2
B
D H xO01
009
F
2
3 2 xO
OI
009
020
I B 2
D
3
I
H 2
3
2 3
x 001
003
3 003
009
0
06
4
006
020
0
26
F
T
026mm
Ri ght
si de
Calculatedvalue T
2
026mm
Used
shi ms
Thi ckness
007
x
005 x
Quanti ty
3 0
21
I 005
Totalthi ckness
026mm
PI NI ON HEI GHT
ADJUSTMENT
II
lHi i t
SP0056
When
replaci ng
the
hypoi dgear
set
dri ve
pi ni on beari ng
or
gear
carri er
be sure to
adjust
the
pi ni on hei ght
Adjustment
of the
pi ni on
hei ght
can
be made
by
adjusti ng
thewasher
to be i nstalled
between
the
rear
beari ng
i nner
ri ce
andthedri ve
pi ni on
head
Pi ni on hei ght
adjusti ng
washer
SPD051
Requi red
Tools
jHei ght Gauge
ST31141000
CVDummy
Shaft ST31942000
I D
FeelerGauge
CV
j
L
r
SPD058
PD
13
Oi fferenti al
Csrri er
Fi naldri ve
ModelH165B
PROPELLER
SHAFT DI FFERENTI AL CARRI ER
I
Thi ckness of washercan be cal
culated
by followi ng equati on
r
T N H
0
Sl
x0011
I
298 I
Where
T
mm
N
mm
H
2
Assemble
Dummy
shaft
on rear
beari ng
i nner
race and fi t i t i nto
carri er
3
Attach
Hei ght
Gauge
tocarri er
Usi ng
a feeler
gauge
measure
the
clearance between
the
hei ght gaugeti p
andthe
dummy
shaft face
PO14
CAUTI ON
Toavoi d
any
confusi onwhi lecalculat
i ng
i t i s
necessary
to
stay
wi ththe
metri c
system
I f
you
measure
any
thi ng
i n i nches
the result should be
converted
tothemetri c
system
@
D
s
n
3
H
D
and S aredi mensi onalvari ati ons
i n
a
uni t
of 1
100
mm
agai nst
each
standardvalue
ST31141000
SPD061
SP 0127
4
Substi tute these
values i nto
the
equati on
to
calculate the thi ckness
ofthe
washer
I f value
Si gi li fyi ng
H 0andS
are
not
gi ven
regard
them 8S
zeroand
calculate
After
essembly
check to
see
that
tooth contact
i s
correct
I f not
readjust
PROPELLER
SHAFT
DI FFERENTI AL CARRI ER Di fferenti al
Carri erFi nal
dri ve Model
H1658
Example
N 035
H
4
D
3
S O
T
N H 0S x 0
01
298
035 4
3
0
x
0
01
2
98
I
H
0
4
3
I
0
I
S
2
I
x 001
0
0
3
N 035
001
036
4
036
298
334
T
334
5
Select
the
proper
washerRefer
to
S
OS
I f
you
cannot fi nd
the desi red
thi ckness
of
washer
use washerSOthat
thi ckness i s the closest tothe calcu
latevalue
Example
Calculated
value
T
3 34
mm
Used
washer
T 333
mm
FI NAL
VERI FI CATI ON
Check backlashof
ri ng gear
wi tha
di ali ndi cator
I f
backlashi s too
small decrease
thi ckness
of left shi m and i ncrease
thi ckness of
ri ght
shi m
by
the
same
amount
I f backlashi s
too
great
reverse
the
above
procedure
Neveradd or
remove
fromthetotal
amount
of shi ms or
beari ng preload
wi ll
be
changed
SPD066
2
Check si de
beari ng
preload
Hook
the
ti p
of
a
spri ng
balancer
ona
ri ng gear
bolt
Checkthe
preloadby
mea
uri ng
the
rotati ng
resi stance
i n
a backlash
Preload
At
ri ng gear
bold
147 265
N
11
5 27
kg
336
01bl
SPD067
I f
prelOad
i too
great
remove
the
sameamount
of
shi ms
toeach
si de
I f
preload
i toomalladd the
sameamount ofshi ms
to
each
si de
Neveradd or
remove di fferent
amount of shi ms toeach
si de
or
ri ng
gearbeckla
hwi llbe
changed
5P0031
3 Check
runout of
ri ng
gear
wi tha
di al
i ndi cator
SP0003
I f backlashvari es
excessi vely
i ndi f
ferent
places
the vari ance
may
have
resulted from
forei gn
matter
caught
between
the
ri ng gear
andthe di ffer
enti acase
I f the backla hvari es
greatly
when
therunout
of
the
ri ng gear
i s
wi thi na
peci fi ed range
the
hypoi d
gearset
or
di fferenti alcaseshouldbe
replaced
4
Fi nally
check fortooth
contact
pattern
RefertoTOOTHCONTACT
U
ually
the
pettern
wi llbe
correct
i f
you
have
calculated
the hi ms
correctly
and
the
backla
h
i
correct
Howeveri n
extremely rare cales
you
wi llhave touse tri alnd error
proce
unti l
you get
a
good
tooth
contact
pattern
The
tooth
pattem
i the best
i ndi eati on of how wella
di fferenti al
ha been et
up
PO15
Servi ceDataandSpeci fi cati ons
PROPELLER
SHAFT DI FFERENTI AL
CARRI ER
SPDOOS
5 I nstall
the di fferenti alcarri eri n
the
car
Gasket shouldbe
replaced by
new
one
eachti me
thedi fferenti al
carri eri s
removed
Then
fi ll
wi th
gear
oi l
referri ng
to
Recommended Lubri cants Secti on
MA
fl
Di fferenti alcarri er
fi xi ng
bolt
25 34N m
25 35
kg
m
18 25 ft I bl
Drai n andfi ller
plugs
59 98N m
6 10
kg m
43 72ft b
Gearoi l
capaci ty
1 1 I i tars
2318 US
pt
2
I mp ptl
SPD123
ngrdler
Oi l
level
SERVI CE DATA AND
SPECI FI CATI ONS
PROPELLER
SHAn
GENERAL
SPECI Flc
ATI ONS
Model
Numberof
joi nts
Coupli ng
methodwi th
transmi Ssi on
Di stance
yokes
Type
of
journalbeari ng
Shaft
lenQth
Spi derto
spi der
1st
2nd
tst
Shaft
outerdi ameter
2nd
SERVI CE
DATA
I
Propeller
shaft
runout li mi t
TI GHTENI NG
TORQUE
Uni t
I
Flange
yoke
tocom
pani on
flange
Nm
24 32
Centerb
eari ng
locki ng
nut
Flange
nut
tvpct 245
294
Nut
ri dwashertvpe
196 235 2024
I
Center
beari ng support
to
bracket
88
8
09
12
I
Center
beari ng
bracket
I
to
body
25 39
26
4
0
PD 16
Uni t
mm
i n
3S63A
3
Sleeve
type
63 2481
Shell
type
Non
Di sassemblvtype
3201
2
601
73028
741
75 02
9531
50B 20001
Uni t mm
i n
060
0241
kg m
fHb
24 33 17 24
25 30 8
217
45 74
65
8
7
9
29
DI FFERENTI AL CARRI ER
GENERAL SPECI FI CATI ONS
I
Model
I
TVpe
I
Ri ng gearpi tch
di anleter
mmUnl
I
Gearrati o
I
Numberof
teeth
Ri ng
gear
dri ve
pi ni on
I
Oi l
cepaci ty 2 US
pt I mp
pt
SERVI CE DATA
Dri ve
pi ni on
beari ng
adjusti ng
mathod
Dri ve
pi ni on preload wi thfront oi lseal
Nm
kg cm
i nlb
I
Si de
beari ng
adjusti ng
method
Dri ve
pi ni on
to
ri ng
gear
mm jn
Backlash
Si de
gear
to
pi ni on mate
gear
Clearance
si de
gear
to
di fferenti alcase
mm
i n
Ri ng gear
nmout li mi t mm
i n
H1658
Ri gi daxle
suspensi on
Banjotypo
t65
6
50
3700
37 10
11
238 21
Collapsi ble
spacer
0
7 0
7 10
6
t
871
Shi m
03 08
0005
000711
000
20
10
0039
0
00791
004 000
61
Si de
beari ng preload
at
ri ng
gear
bolt 147 265
N
kG lbl
1 5 27 33 6
01
Si de bearln
adjusti n
shi m
Thi ckness mm
i nl
005 0
00201
007 000281
001000391
0200
00791
050100971
Part No
38453 28500
38454
28500
38455
28500
38456
28500
38457 28500
PROPELLER
SHAFT DI FFERENTI AL
CARRI ER Trouble Di agno sesand
Correcti ons
Pi ni on
hei ght
adjusti ng
washer Si de
gear
thrust
washer
Thi ckness
mmi n
Part No
Thi ckness mm i n
Part
No
3
0910
12171
38154
U1500
0
785
100309
38424
04101
3
12 10
12281
38154UI 501
0
835
1003291
8424 08000
315 012401
38154
Ut502
0885
10
0348 38424 08001
3181Ot252
38154U1503
1 035 1004071
38424 08002
321 1012641
38154
U1504
3241012761
38154
U1505
1
185
1004671
38424
08003
327 0
12871
38154U
1506
33001299
38154U1507
TI GHTENI NG TORQUE
3331013111
38154
l
1508
Uni t N
m
kg m
ft I b
3
361013231
38154U1509
339 01335
38154UI 510
I
Dri ve
pi ni on
nut
137
294 14 30 101 217
3
42
10
1346
38154U1511
I
Ri ng ge
r bolt
78
98 8 10 58 72
3451013581
38154Ut612
348
101370
38154U1513
I
Si debeari
ng cap
bolt
49
59 5 6
36 43
351 0
13821
38154U1514
I
Drai nandfi ller
plugs
59 10 98 6 43 72
3
5410
t394
38154U1515
3
57
1014061
38154UI 516
I
Compani onflange
to
24 32 24
3
3
17 24
3601014171
38154UI 517
propeller
5h8ft
3631014291
38154
UI 518
I
Di fforenti alco i o
to
3 661014411
38154
U1519
rearaxle
case
25 34 25 35 18 25
TROUBLE DI AGNOSES
AND CORRECTI ONS
PROPELLER SHAFT
Condi ti on
Vi brati on
duri ng
at
medi um
or
hi ghspeed
Knocki ng
sound
duri ng
starti ng
ornoi se
duri ng coasti ng
on
propeller
shaft
Scrapi ng
noi se
Whi neorwhi stle
Probablecause
Worn
or
damaged
journal beari n
Unbalance
due
tobent
ordented
propeller
shaft
Loose
propeller
shaft
i nstallati on
Worn transmi ssi on
rearextensi on bushi ng
Damaged
center
beari ng
U
dercoati I
g
ormud on
he shaft
ausi ng
unbalance
Balance
wei ghts nti ssi ng
Wornor
damaged
journal
Worn
sleeve
yoke
andmai nshaft
spli ne
Loose
propeller
shaft i nstallati on
Loose
joi nt
i nstallati on
Damaged
center
beari ng
ori nsulator
Loose
or
nti ssi ng
bolts at centerbeari ng
brac t 10
body
Dust coveron
sleeve
yoke rubbi ng
on
transmi ssi on rearextensi on
Damaged
centerbeari ng
Correcti ve
acti on
Repla prol
eller
shaft
assembly
Replace
propeller
shaft
assembly
Reti ghten
Replac
e
Repl
ace
Clean
up
shaft
j
Replacepropeller
shaft
assembly
Replace
propellershaft
assembly
Replacepropeller
shaft
assembly
Reti ghten
Replacepropellei
shaft assembly
Repla
centerbear
g
Replace
or
ti ghten
bolts
Strai ghten
out dust coverto
remove i nter
ference
Replace
center
beari ng
1
017
Trouble
Di agnoses
and
Correcti ons
PROPELLER SHAFT
DI FFERENTI AL CARRI ER
DI FFERENTI AL
CARRI ER
When a
di fferenti alcarri er
i s
sus
pected
of
bei ng noi sy
i t
i sadvi sableto
make a
thorough
test todetenni ne
whetherthe
noi se
ori gi nates
i n the
Condi ti on
ti tes road
surface exhaust
uni versal
joi nt
propeller
shaft
wheel
beari ngs
engi ne
transmi ssi on or
di fferenti al
carri erNoi sewhi ch
ori gi nates
i nother
Noi seondri ve coast
andl1oat
Noi se
onturn
Knocki ng
sound
duri ng starti ng
or
gear
shi fti ng
Sei zureor
breakage
Oi l
leakage
PD 18
Probable cause
Shortage
of oi l
I ncorrect
toothcontact between
ri ng gear
and
dri ve
pi ni on
I ncorrect backlash
between
ri ng gear
and
dri ve
pi ni on
Sei zed
up
or
damaged ri ng gear
and
dri ve
pi ni on
Sei zed
up damaged
or
broken
dri ve
pi ni on
beari ng
Sei zed
up damaged
or
brokensi de
beari ng
Loose
clamp
boltsornuts
holdi ng ri ng
gear
beari ng
cap
etc
Sei zed
up
damaged
orbroken
si de
gear
and
pi ni on
mate
gear
Sei zed
up
damaged
orbroken
si de
gear
and
pi ni on
mate
gear
thrust
washers
Pi ni on
mate
gears
too
ti ght
onthei rshaft
Excessi ve
backlash
I ncorrect
backlash
ri ng
gear
to dri ve
pi ni on
orsi de
gear
to
pi ni on
mate
gear
Worn
gears
orcase
Wornrear
axleshaft andsi de
gearspli ne
Pi ni on
beari ng
under
preload
Loosedri vepi ni on
mi L
Loose
boltSandnuts
such
as
ri ng gear
bolts
Shortage
ofoi loruse of
unsui tableoi l
Excessi vely
small
backlash
I ncorrect
adjustment
of
beari ngs
or
geats
Severe ser vi ce
duetoan
excessi ve
loadi ng
i mproper
use
ofclutch
Loose
boltsandnuts
suchas
ri ng
gear
bolts
Worn out
damaged
or
i mproperly
dri ven
front oi lsealor
brui sed dented
orabnor
mally
wornsli defaceof
compani onl1ange
Damagedgasket
Loose
fi llerordrai n
plug
Clogged
or
damaged
breather
places
cannot
be
corrected by adjust
ment or
replacement
of
parts
i n
di f
ferenti al
carri er
Correcti ve
acti on
Supply gear
oi lRebui ld
gear
carri eri f
necessary
Adjust
toothcontact or
replace
the
hypoi d
gear
set
Adjust
backlash
or
replace
the
hypoi d gear
set i f
necessary
Replace
the
hypoi d
gear
set
Replace
the
pi ni on
beari ng
and
faulty
parts
Replace
thesi de
beari ng
and
faulty
parts
Clamp
themto
speci fi ed
torque
and
replal
faulty parts
Replace
faulty
parts
Replace
faulty
parts
Replacefaulty parts
Adjust
backlash
Replace
worn
parts
Replace
worn
parts
Adjust preload
Replace
or
ti ghten
bolt
ReplaCe
faulty
parts
or
li ghten
bolts
Replace
faulty
parts
and
use recommended
gear
oi l
Adjust
backlashand
replace
as
requi red
Replacefaulty parts
Replace
faulty parts
Replace
faulty parts
or
ti ghten
bolts
Replace damaged
oi lseal
Repai r
l1ange
wi th
sandpaper
or
replace
i f
necessary
Replace
Ti ghten
Repai r
or
replace
Toolnumber
Kent
Moore
No
ST050
I
SOOO
126023
CD
ST05011000
126023
2
@ST05012000
126023 1
ST0636000l
ST3003S000
125733
CD
ST30031000
125733 1
@ST30032000
125733
2
ST30611000
125742
1
ST30613000
1257423
ST30701000
125742 2
ST3114S000
See 125269
01
CD
ST31141000
@ST31942000
PROPELLER SHAFT
DI FFERENTI AL CARRI ER
Speci al
Servi ce
Tools
SPECI AL
SERVI CE TOOLS
Tool
name
Engi ne
stand
Engi ne
stand
Base
Di ff attachment
Dri ve
pi ni on
feaf
beari ng
i nnerrace
puller
set
Puller
Base
Dri ve
pi ni on beari ng
outerrace
dri ft bar
Dri ve
pi ni on
rear
beari ng
outer
racedri ft
Dri ve
pi ni on
front
beari ng
Quter
race
dri ft
6
Dri ve
pi ni on setti ng gauge
set
Hei ght gauge
Dummy
shaft
PD
19
Speci alServi ce
Tools
PROPELLER SHAFT
DI FFERENTI AL
CARRI ER
Toolnumber
Kent
MooreNo
Toolname
ST3127S000
See125765
CD GG91030000
CV
lI T62900000
@
lI T62940000
Preload
gauge
Torque
wrench
Socket
adapter
1
2
1
Socket
adapter
3 8
t
o
e
ST31530000 Dri ve
pi ni on l1ange
wrench
125774
ST32501000
Wei ght
block
125407
3
ST33051001
Di ff si de
beari ng puller
ST33052000
Adapter
125797
1
5J
ST33400001
Oi lseal
fi tti ng
tool
126082
ST33741000
Master
gauge
See 125407
1
18 5
mm 0728
i n
8
KY311
00300 Soli d
punch
KY38102100
125803
Di ff si de
beari ng
dri ft
PD
20
DATSUN
200SX
ModelS 110Seri es
SECTI ON
FA
FRONT AXLE
FRONT
SUSPENSI ON
CONTENTS
FRONT
AXLE AND
FRONT USPENSI ON
FRONT AXLE
FRONT
SUSPENSI ON
SPRI NG AND
STRUT
ASSEMBLY
TENSI ON ROD
AND STABI LI ZER BAR
TRANSVERSE
LI NK AND
LOWER
BALL JOI NT
SUSPENSI ON
CROSSMEMBER
FA 2
FA 3
FA
5
FA
5
FA 9
SERVI CE
DATA AND
SPECI FI CATI ONS
GENERAL SPECI FI CATI ONS
I NSPECTI ON AND ADJUSTMENT
TI GHTENI NG TORQUE
TROUBLE DI AGNOSES AND
CORRECTI ONS
SPECI ALSERVI CE
TOOLS
FA 12
FA 12
FA12
FA13
FA10
FA ll
FA
14
FA 17
Referto
Secti on
MA
Front
Axleand
Front
Su
pen
i onl
for
ADJUSTI NG WHEEL
BEARI NG
PRELOAD
CHECKI NG WHEELALlGNMENT
FrontAxleandFronrSu lPensi on
FRONT XLE
FRONT SUSPENSI ON
FRONT AXLE AND
FRONT
SUSPENSI ON
Wheel
ali gnment
Cambercaster
and
ki ngpi n
are
preset
at
factory
and
cannot
beadjusted
The
car
requi resonly
toe
i nand car
pouure adjustment
Toe
i n
0
2 mm 0
008
i n
00
to0012
RefeI
to
secti on
MA fot Wheel
Ali gnment
J
25 34
25 35 18 25
J
16
21
1
6
2 1 12
J
62 7S
6 3
76
46
Suspensi on
croumember
Stabi li zerbar
l
Te lli on
rod
Tranl Vcue li nk
J
5060
5
1
6
1
37 44
J 78 98
8
10
58 72
Wheel
beari ng
Donot overti ghten
wheelbeari ng
nuts as thi s
cancawewheelbeari ng
sei zure
Axi al
play
0mm 0i n
Preload As
measuredat wheelbolt
wi thused parts
2 07 8
N 0
2
0
81rg
0
4
18lb
Whenmeasuri ng beari ng
preload
donot
i nclude
draggi ng
resi stance
wi thbrake
pads
Refer
to
Secti on
MA for
Adju li nB
Wheellleari ng
Preload
FA 2
J 59 74
6
07
5 43
54
Strut
mounti ng
i nsulator
Dust
covet
Coi l
SPri nll
Strut
bly
BaUjoi nt
Tensi on
rodbracket
J
31 42
3 2
4 3 23 31
To
body
rame
J
N
m
I rg m
ft lb
SFA
9
FRONT AXLE FRONT
SUSPENSI ON
Front Axle
FRONT
AXLE
We
seal
@
I nner
wheel
beari ng
Cotter
Pi n
@
@j
L
LWheelhub
@i nnersi de
Washer
Wheel
beari ng
nut
Adjust
wheel
beari ng
preload
Hub
cap
RefertoSecti on MA for
@g
i nnersi de Adjusti ng
Wheel
Beari ng
Preload
Baffle
plate
38
lD
@
Nm
kg
m
ft lb
Multi
purpose greasepoi nt
SFA120
REMOVAL
4 Work off
hub
cap
CAUTI ON
Be careful
not to
drop
wheel
beari ng
I
Block rearwheels wi thchocks
and rai se
front of
car
and
then
sup
port
i t wi th
safety
stands
Refer
to
Secti on
GI
for
Li fti ng
Poi nts and
Towi ng
2 Remove wheelandti re
assembly
3
Remove
cali per
assembly
Refer
toSecti on BR forremoval
Screwdri ver
7
Separate
outsi de
wheel
beari ng
i nner
race
andwasher
8
Separatebrake
rotor
andhub
O
ri J11
5
Pry
off
cotter
pi n
take
out
adjusti ng cap
and
wheel
beari ng
nut
Cotter
pi n
must not bereused
6 Remove wheel hub
wi thdi sc
brakerotor
9 Remove i nsi de wheel
beari ng
outerrace
grease
sealand outsi de
outerrace
CAUTI ON
Be careful
not
to
drop
wheel
beari ng
CAUTI ON
Make sure brake hose i s secured
and
not
twi sted
FA258
Grease seal
mud
not be
reused
FA 3
FronrAxle
FRONT
AXLE
FRONT
SUSPENSI ON
I NSPECTI ON
Thoroughly
dean
beari ng
and each
part
and
dry
wi th
compressed
ai r
Wh 1
beari ng
When
race
cage
or
rollersufaces
make noi se orare cracked
pi tted
worn
rough
orout f
round
replace
beari ng assembly
Wheelhub
Check wheelhub forcracks
by
means
of
magneti c
flaw
detecti ng
or
dyei ng
test
replace
i f
necessary
Knuckle
aplndle
Alsocheck wheel
hub
replace
i f
cracked or
damaged
When
thread
i s
damaged replace
strut
assembly
Greaae
aeal
I f
grease leakage
i s
detected
duri ng
removal
replace grease
seal
Replace grease
sealat
every di sas
sembly
eveni fi t
appears
good
I NSTALLATI ON
I nstall
front
axle i n the
reverse
orderofremovalas follows
I I nstall
beari ng
outer
race wi th
Toolunti l
i t seats
i n
hub
FA 4
I I
111 1
Y
I I I
SFA124
2
Pack
hub andhub
cap
wi thre
commended
multi purpose grease
Coat o
ri ng
wi th recommended
multi
purposegrease
Ol
q
MuI t
purpo
greasepoi nt
SFA125
3 Coat each
beari ng
wi threCom
mended
multi purpo
gr
4 Place i nnerbea
Ji n
i n
hub and
i nstalla new
grease
seal
coati ng
seal
i ng li ps
wi th
recommended
multi pur
PO gr
@ Multi purpo
grease
poi nt
SFA126
5 Fi xbrakerotortohub
38ftI b
6
Spari ngly
apply
recommended
multi
purpose
grease
toeach
part
Threaded
porti on
of
spi ndle
Beari ng
washerto
beari ng
contact
i ng
face
7
Put hub
assembly
on
spi ndle
and
then i nstall
washer
and
wheel
beari ng
nut
8
Adjust
wheel
beari ng
preload
Roter
toSecti on MA
for
adjUlt
ment
9 I nstallhub
cap
wi tha
ri ng
on
hub
10I nstall
brake
cali per
assembly
Roterto
Secti on
BR
fori nstalla
ti on
I I
I nstallwheelandti re
cD 78
98
N
m
8
0
10
0
kg
m
58
72ft
I bl
FRONT
AXLE
FRONT
SUSPENSI ON Front
Suspensi on
FRONT
SUSPENSI ON
Croamember
auembly
IJ
59 74
i
or
607 5 43 54
t
IJ
25 34
f8
25
3
5 18
25
IJ
50
60
Tobody
J
5 1 6
1
3744
IJ
62 75 e
63
7
6
t
1
46 55
IJ
60
72
b
t
I
U
t
bI Y
tf
J
I
L
5 5
100
Ten
n
IJ
t
Transverse li nk
1
I
i
oS
I
IJ
6
2
1
j
br
IJ
g3
9
9
53 72
XI J
31 42
12 15
Balljo
nta
sembly
32 4
3 IJ
50
60
23 31
5 1 61
37 44
8
e
Stabi li zer
bar
1J4454
45 55 33
Z
Tensi onrod
bracket
IJ 31
42
3 2
43
23
31
IJ
N
m
kg
m
ft
I b
SFA128
SPRI NG AND STRUT ASSEMBLY
Strut ki t
IJ 59
74
60
7 5
Gland
packi ng
43 54
IJ 25 34
rstruI
packi ng
ki t
C
25
3
5
O
nng
3
18 25
I
ton
rud
I
uldebusllI ng
Mounti ngi n
u1alor
ShoCk
Lock nut
Mounti ng beari ng
bO
ber
ki t
wi thdust seal
I
Washer
sPri ng upper
seal
I nnercyli nder
G
Bound
bumper
rubber
DUSI cover
I
SPri ng
J
Strut outer
casi ng
1
beari ng
nut
9
fr
f
r
J
IJ 50
60
V
5 161
37 44
SFAl29
Adjusti ng
cap
Atterpi n
IJ N
m
kg m
ft
b
Servi ce
parts
SUUt
packi ng
ki t Shock absorber
ki t Strut ki t
FA 5
FrontSuspensi on
FRONT
AXLE
FRONT SUSPENSI ON
REMOVAL
AND
I NSTAllAnON
Block rear
wheels
wi th
chocks and
rai se
front
of
car
and
then
support
i t
wi th
safety
stands RefertoSecti on
GI for
Ufti ng
Poi ntsand
Towi ng
Remove
wheel
and
ti re
assembly
3
Remove brake
tube
and
cali per
Referto
Front
Di sc
Brake Secti on
BRl
4
Remove
wheelhub and wheel
beari ng
i f
necessary
5
Separate
knuckle
arm from strut
lowerend
r
SFA130
6
Support
strut
assembly
wi th
a
sui tablestand
7
Remove
strut
upper
end
SFA 31
8
Drawout strut
assembly
from
car
9
I nstallstrut
and
spri ng assembly
i nreverse
orderofremoval
CAUTI ON
Make sure brake hose i s securedand
not twi sted
When
i nstalli ng steeri ng
knuckle
arm tothe
strut
assembly apply
sui table
seali ng
materi al
to
porti on
i ndi cated
i n
fi gure
FA 6
A
pply seali ng
materi al
SFA132
GJ
Strut to
hoodledge
25
34
N m
25 35
kg m
18 25 ft I bl
Strut toknuckle
arm
72 97 N m
7 3 99
kg
m
53 72ft
I bl
DI SASSEMBLY
When
di sassembli ng
strut
assambly
extra cauti on should be exerci sed
to
prevent
di rt anddust from
enteri ng
strut
Set
up
Tools on strut
assembly
Compress spri ng just
for
enough
to
permi t turni ng
of strut
mounti ng
i n
sulator
by
hand
HT7t730000
ST35652001
SFA133
2
Remove
lock nut from
top
of
pi ston
rod
J
LX
SFA134
Separate
followi ng
parts
Strut
mounti ng
i nsulator
Strut
mounti ng
beari ng
Dust seal
Spri ng upper
seat
Bound
bumper
rubber
Coi l
spri ng
Dust
cover
CAUTI ON
Pay
attenti on
not to
damaga pi ston
rod
3
Remove
gland packi ng
wi th
Tool
Retract
pi ston rod
by
pushi ng
i t
downunti li t bottoms
J
A
ST35500001
J
FA209
KV48100301
4
Remove
Ori ng
from
top
of outer
casi ng
anddrawout
gui de
bushi ng
SFA135
5 Li ft out
pi ston
rod
together
wi th
cyli nder
Pi ston
rod
pi ston
rod
gui de
i nnlr
cyli nder
and
bottom
valvlare
adjusted
to
provi de preci li on mati ng
surfaces
I nd
should be hlndled
I S I matched
i t
Li ft
out
FA275
6
Drai n l1ui d
thoroughly
fromi nner
cyli nder
andouter
casi ng
r
Gui de
bushi ng
i J
Thi
operati on
i
very
i mportant
si nce
performance
of strut vari es wi th
amount of flui dfi lled wi thi nstrut
I NSPECTI ON
Wash
all
parts
except
fornoome
talli c
parts
clean
wi th
sui table
sol
vent
and
dry
wi thcompressed
ai r
Blow di rt and
dust
off of non
metalli c
parts usi ng
compressed
ai r
8
Oi l
oozi ng
out at and
around
gland
packi ng
does not call
forstrut
mai ntenance I foi lleaks part pri ng
at check
pi ston
rod and
gland
packi ng
tocorrect the cause
of
problem
I f oi l
leakage
occurs
on
welded
porti on
of outer
strut
casi ng
replacestrut assembly
b I f hock absorberi tself i s
malfunc
ti oni ng
replace
as
shock absorber
ki t
i ncludi ng pi lli on
rod
cyli nder
bottom valve
and
gui de bushi ng
Gland
packi ng
O
ri ng
and
flui d
Replace
wi thnew
gland packi ng
and O
ri ng
or
replace
wi thfreshl1ui d
whenever
strut
i sdi sassembled
I nnercyli nder
and
outer
casi ng
I nspect
i nner
cyli nder
and outer
casi ng
for
cracks
deformati on
or
other
damage
As for
i nner
cyli n
der
replace
shock
absorberki t
As
forouter
casi ng replace
strut
assembly
FRONT
AXLE
FRONT
SUSPENSI ON
FrontSuspensi on
I nner
di ameter
I nner
cyli nder
3002 3010mm
1 1819 1
1850
i n
SFA136
Maxi mum
runout
I nner
cyli nder
Lessthan
02mm 0008i n
t
r
O
cYli nder
SFA137
Pi ston
rod
I nspect
pi ston
rod for
cracks
defoffi lati on orother
damage
Re
place
shock absorber
ki t
I nspect
threads
for
cracks or
other
damage Replace
shock absorber
ki t
Rod di ameter
19965 19975 mm
0786007864i n
Maxi mum
runout
Lessthan01 mm
0004
i nl
SFA138
Strut
mounti ng
i nsulator
Replace
i f cemented
rubberto
metal
porti on
are melted orcracked
Rubber
parts
shouldalso
be
replaced
i fdeteri orated
Strut
mounti ng beari ng
Replace
i f
i nspecti on
reveals
ab
normal
noi se or
excessi ve
rattle
i n
axi aldi recti on
ASSEMBLY
Before
assembly clean
away
alldi rt
to
prevent
any possi ble entry
of di rt
i nto
strut assembly
I
I nstallstrut
assembly
on Tool
KV4810030
I
2 I nstall
pi ston
rod and
i nner
cyli nder
shock
absorberki t
Y
Pi ston
rod
f
M
SFA139
3 Pour
correct
amount of flui d
U e NI SSAN GENUI NE STRUT
FLUI 0or
equi valent
Capaci ty
325 m2
110US 110z 114
I mp
11
ozl
FA 7
Front
Suspensi on
FRONT AXLE
FRONT SUSPENSI ON
4
Place
gui de
bushi ng
Cyli nder
Gui de
bu shi ng
SFA140
5 Lubri cate seali ng li p
of
gland
packi ng
SFA141
6 I nstall
gland
packi ng
usi ng
Tool
Be
careful
not
todamage
seali ng
li p
SFA142
FA8
7
Ti ghtenglandpacki ng
ST3SS00001
LJ
fl98
118Nm
10
12kg
m
4
72 87ft
SFA143
LorI w
1tch
c
f
Lmft
O1m
0
3ftl
108
11 80
o
E
98 1012
o
88
9
65
B
o
78 8 58
o
0
3
o
u
Converted torquel
p
59
643
Nm
q
ft lb
03 0
4 05
06
m
SFA144
10 15 2 0
LEffecti ve
length
of
torque
wrench ft
8 Remove
trut from
Tool
KV48100301
9
Afterthe above
steps
have
been
completed
ai rshould
be removed
fromshock
absorber
syst
m
Repeat
above procedure
everal
ti mal10
that ai r
wi ll
babled
out from
strut
thoroughly
al
hown
FA 279
1
FA280
10
Rei nstall
strut on
Toot
KV4810030
I
1
L
Compress
coi l
spri ng
u
i ng
Tool
HT71730000
SFA14S
12 Set
up
coi l
pri ng
wi th
Tool
HT71730000
on
spri ng
lower
seat of
strut
13
Lubri cate parts
i ndi cated
i n
fi gure
At
SFA1 48
14 Mount
followi ng
part
as showni n
fi gure
G Lock nut
Mounti ng
i nsulator
c
Bear
i ng Wi th
dust
Seal
spnng
eat
Bound
bumperrubber
Dust cover
Hf71730000
LJ
KV48100301
SFA147
I nstall
bound
bumper
rubber
i n
place
to
prevent
pi ston
rod from
falli ng by
i ts own
wei ght
I nstall
mounti ng beari ng
so
that
i t
poi nts
i ncorrect di recti on
15
Ti ghten
new
pi ston
rodselflock
i n
nut
I V
59 74N m
i 6
01
5k
43 54ft
I bl
Uvd
FA148
16 Remove
Tool
HT71730000
on
strut
assembly
After
placi ng spri ng
i n
posi ti on
between
upper
and lower
spri ng
seatl
release
eompreaorgreduelly
FRONT
AXLE
FRONT SUSPENSI ON
Front
Suspensi on
Coi l
spri ng
mi
I
I
I
Sprmg
seat
d
Place
pnng
I n
poi lton
SFA149 Spnng
I nstallatI on
TENSI ON
ROD AND
STABI UZER BAR
e
Stabi li zer
braCketlj rl1
I V
31
42
32 43
23
411
I V 5060
Totensi onrodbracket 5 1 61
I V
44
54
I n cJO
J
I
37 44
45 5 5
l
33
40
Tensi on rod
J
To
tensi on
rod
t
1
bracket
Transverse
li nk A
I V 16
21
16 2 1
1215
I V
N
m
kg
m ftI b
SFA150
Remove
under
cover
Set
loadofcar
I f
correctly
i nstalled whi te mark
pai nted
on stabi li zer
bushi ng
seat
can
be seenfrom bothsi des ofcar
Always
i nstall
the
stabi li zerwhi ch
has the
whi lemark on
i t
ontheleft
transverse li nk
When
i nstalli ng
a
bushi ng
do
not
allowi t to
project
beyond
the
sur
facearea oflhewasher
Donot allow
the bushi ngs
and
washers to come
i n
contact wi th
grease
oi l
soapy
wateretc
FA
9
Front
Suspensi on
FRONT
AXLE
FRONT
SUSPENSI ON
Whi temark
Left si de
only
Whi te
mark
Bothsi des
r
SFA152
Stabi li zer
posi ti on
CD
1
Tluust washer
2 Tensi on
lodbracket
3
Tensi on
rod
SFAl53
4
Collar
5 Bu
hi ns
TRANSVERSE
UNK
AND LOWER
BALLJOI NT
vtJ
9
Front
SFAl54
REMOVAL AND
I NSTAllATI ON
I Block ear
wheels wi th
chocks
and
rai se
front
of carand then up
port
i t
wi thsafety
tand Referto
Secti on
GI for
Li fti ng
Poi nts and
Towi ng
2
Remove wheeland
ti reassembly
3 Separate
knucklearm
tosi de
rod
usi ng
Tool
FA
10
1I T72520000
SFA155
4
Separate
strut lower
end to
knucklearm
5 Remove followi ng parts
from
transverse
li nk
I
Balljoi nt
I
Stabi li zer
Tensi on
rod
SFA1511
6
Remove
transverse
li nk
from
crossmember
SFAl58
7
Separate
followi ng
parts
I
Ball
joi nt
to
knuckle
arm
usi ng
press
FA712
I Unk
bushi ng
to transverse li nk
usi ng
Set ToolST36720000
frG
SFA159
8 I nstall
transverse li nk and lower
ball
joi nt
i n the reverse orderof re
moval
noti ng
the
followi ng
I
Wh
n
i nstelli ng
tremver li nk
spi ndle
i nsert i t from rearli deof
suspensi on
crOS3
I
To
i nstell
transye
li nk fi rst
temporeri ly ti ghten
nuts
securi ng
tren ve
li nk
spi ndl
whi ch
con
neeu
transven
li nk to
suspensi on
cross
member
I Fi nel
ti ghteni ng
hould becarri ed
out li t curb
wei ght
wi th
ti re on
ground
I
Make ure
mati ng
urfe
of buh
i ng
i s clean endfree from oi lend
gre
I I nstalltren
e
li nk
bushi ng
u
i ng
set
Tool
ST36720000
tfl
Knucklermtostrut
I I SI llmbly
72 97N m
17 3
9
9
kg ni
53
72
ft lb
Ball
joi nt
toknucklearm
97
120N m
98 122
kg
m
71 88ft I bl
Ball
joi nt
totransvene
li nk
5060N
m
5 1 61
kg m
37
44ft
I bl
Transverse
li nk tocrossmember
62 75 N
m
163 7
6
kg
m
46 55 ft lb
I NSPECTI ON
Transv
rs li nk
Check for
si gns
of cracks di stor
ti on or
other
damage Replace
i f
any
ofabovecondi ti ons are
beyond
repai r
I frubber
bushi ng
shows
evi dence
of
cracki ng replace
wi th
a
new one
Ball
Joi nt
BaI l
joi nt
i s assembled at
the
factory
and cannot
be
di sassembl
ed Check
ballstud
turni ng torque
wi thnut i n
place
onballstud
I f
excessi vely hi gher
orlower
than
speci fi cati ons
and
ball
joi nt
i s
pro
perly
lubri cated
replace
Turni ng torque
New
parts
39 98N m
40100
kltcm
35 87 i n
I bl
Used
parts
207 8Nm
20
80
kg
em
17 69i n
I bl
2
Check condi ti onal
dust
cover
I f
found to
be
cracked excessi vely
beyond
use
replace
ball
joi nt
wi th
a
newone
3 Lubri cate
ball
joi nt
wi threcom
mended multi
purpose
grease
regular
ly
FRONT AXLE
FRONT SUSPENSI ON
FrontSuspensi on
To
lubri cate
remove
plug
and
i nstall
grease ni pple
i n i ts
place
Pump grease
slowly
unti lold
grease
i s
completely
forced
out After
greas
i ng
rei nstall
plug
When a
hi gh pressure
grease gun
i s
used
operate
the
greasegun
carefully
so
that
grease
i s
i njected slowly
and
new
grease
does not
comeout from
theclamp poni on
SUSPENSI ON
CROSSMEMBER
REMOVAL
AND
I NSTALLATI ON
I Bl6ck
rear
wheels wi thchocks
and rai se front of carandthen
sup
port
i t wi th
safety
stands
Referto
Secti on GI for
Li fti ng
Poi nts and
Towi ng
2 Remove wheel
and
ti re
assembly
3 Removeundercover
4 Remove transverse
li nk
from
crossmember
Referto Tran vene
Li nkand
LowerBall
joi nt
S
Separate
suspensi on
crossmember
from
engi ne
mounti ng
i nsulator
6 Rai se
up engi ne
Support wei ght
of
engi ne
toremove
loadfrom
engi ne
mounti ng
7 Remove
suspensi on
crossmember
from
body
frame
8
I nstall
suspensi on
crossmember
i n
reverse
orderof
removal
f
Crossmembertotransverseli nk
62 75 N m
63 7 6
kg m
46 55 ft I bl
Engi nemounti ng
i nsulatorto
crossmember
31 42N
m
3
2 4
3
kg
m
2331ft
I bl
Crossmember
to
body
frame
Bolt Center
31 42N m
32 43
kg
m
23 31 ft
I bl
Nut Both
si desl
6072N m
61 7 3
kg
m
44 53ft I b
I NSPECTI ON
Check
suspensi on
crossmemberfor
evi dence
of
deformati onorcracki ng
i f
necessary replace
FA l1
Servi ce
OstBsndSpeci fi cati ons
FRONT
AXLE FRONT SUSPENSI ON
SERVI CE
DATA AND SPECI FI CATI ONS
GENERALSPECI FI CATI ONS
COI L
SPRI NG
Color
i denti fi cati on
Spri ng
constant
Di mensi on
d
DxL
12
2
30
Ri ght
386
ere
m1
0480
5 12
Whi te2
Wi th
power
5 201
steeri ng
122
130
1716
N mm
Lah
392 Pi nk
1
175
kg
mm
10480
5 12 Yellow2
98
0I bli n
5 43
Wi thout
power
steeri ng
2
2
30
x
3S6 Cream
1
0480
x
512
Whi te2
5
20
d
x0
xLWi redi ameter
mm
li n xCoi ldi ameter
mmi n
xFree
length
mm i n
STRUT
ASSE MBLY
I
Shock
absorber
type
I
Shockabsorberflui d
mQ
US
flOZ
I mp
flozl
l
Pi ston
rod
di ameter
mm
i n
li nneI
cyli nder
i nner
di ameter
mm
i
n
I
Stroke
mm
i n
I
Expansi on
Dampi ng force N
kg I bl
t
03
m11
0
hI
see
I
Compressi on
N
k9
lb
HYdrauli c
325
11
0
114
19
965
19
975
107860
0
7864
30
02
3010
11
1819 1
1850
172
16
77
588 tOO132
J43135
77
STABI LI ZER
BAR
I
Bar
di ameter mmi n
t9
10
75
FA 12
I NSPECTI ON
AND ADJUSTMENT
WHEELALI GNMENT
Unladen 1
1
Camber degree
40
50
I
Caster
degree
045 3015
Ki ngpi n
i ncli nati on
degree
1025 S055
mmi n 0
2
0
0
081
Toe i n
degree
2 0
12
Front wheel
I nsi de
330
350
3
turni ng ngle
290
3
Full
turn
degree
Outsi de 270
Front wheel I nsi de 200
Toe out
turns degree Outsi de
1870
1 Tankfulof fuelradi atorcoolant and
engi ne
oi l
full
Spare
ti rejack handtools mats
i n
desi gned posi ti on
2
On
bothsi des
3
On
power
steeri ng models
wheel
turni ng
forcetat ci rcumference
of steeri ng wheelof
98 147N
10
15 kg 22
33I blwi th
engi ne
at
i dle
WHEELBEARI NG
Wheel
beari ng
axi al
play
mm i n
N
m
kg
m
Wheel
beari ng
nut
ft lbl
ti ghteni ng
torque
Return
degree
angle
Wi th
N
m
new
kg an
gre
i n lbl
se 1
Wi th
N
m
used
kg cm
Wheel
gro
beari ng se l
i nlbl
starti ng
torque
Wi th
new N
At
grease
I k9 lbl
wheel
seal
hub
bolt
Wi th
usad N
grease
I k9
lb
se t
001
25 29
25
3018 22
600
0
39
083
140
S
5 3
5
741
0
10
044
1045 0
9
391
6
9 147
fO
7 1 5 1 5 3
3
207B
10
2 0
8
04 18
FRONT
AXLE FRONT SUSPENSI ON Servi ceOataandSpeci fi cati ons
LOWER BAlLJOI NT
New
N m
39 98
parts
kg
em
140
100
35
871
i n
I bl
Turni ng torque
Used
N
m
207 8
parts
kg
em
120
8017
691
I bl
TI GHTENI NG
TORQUE
I
Uni t
I
N
m
I
kg
m ft I b
I
Hub
I
Wheelhub
nut
I
78 98
8 10
I
58 72
I
Di scbrake
I
Rotor
to
hub
I
38 52
I
3
9
5
3
I
28 38
I
Strut
I
Strut
to
hoodledge
25 34 2
5 35 18 25
I
Pi stonrod sei
I ocklng
59 74
6075 43 54
nut
Gland
packi ng
9B 118 10012 0U2 87
Strut toknuckle
arm 72 97 7 3 99 53 72
Cali per
tostrut 72 97 7 3 99
53 72
Knucklearm
I
Knucklearmtosi derod
54 98 5 5 100
I
4072
ball
joi nt
FA 13
Trou Jle
Di agnoses
and
Correcti ons FRONT
AXLE FRONT SUSPENSI ON
TROUBLE
DI AGNOSES
AND CORRECTI ONS
Condi ti on
Vi brati on shock and shi mmy
of
steeri ng
wheel
Vi brati on
Loose connecti on
of eachpart
andwearof each
part
of
I i ni age
cause
vi bra
ti on of front wheels and
steeri ng
wheel
vi brati on Thi s
i s
very
noti ceable
when
trav
elli ng
on
rough
road
Shock When
the
front wheels aretravelli ng
on
bumpy
roads the
play
of
the
steeri ng
li nkage
i s
transmi tted
to
the
steeri ng
wheel
Thi s i s
especi ally
noti ceablewhen travelli ng
on
rough
road
Shi mmy
Abnormalvi brati on of the
front
suspensi on
system
and
the whole
steeri ng
li nkage whi ch
occursat
speci fi cspeeds
Car
pulls
to
ri ght
or
left
When dri vi n wi thhands off
the
steeri ng
wheelan a
flat
road thecar
gently
swerves
to
ri ght
orleft
A
faulty
rear
lI I
ellSi on may
alsob8 the
caUI 8of thi s
problem
and therefore
188
also
Secti nn
RA
FA 14
Probablecause
I mproper
ti re
pressure
I mbalance
anddeformati on
of road
wheel
Unevenly
wom
ti re
or
i nsuffi ci ent
ti ght
eni ng
ofwheelnuts
I mproperly adjusted
orwom front wheel
beari ng
Faulty
wheelali gnment
Womtransverse
li nk
bushi ngs
I nsuffi ci ently ti ghtened
steeri ng gear
hous
i ng
Wear
of
steeri ng
li nkage
Wom
suspensi on
ball
joi nt
Excessi ve
backlash
dueto
i mproperadjust
ment ofthe
steeri ng
gear
box
Damaged
i dler
arm
Worn column
beari ng
weakened column
beari ng spri ng
or
loose
clamp
Malfuncti on
of shock absorberi nsi de
the
strut or
loosei nstallati onbolts
I mbalanceof
car
level
I mproper
ti re
pressure
or
i nsuffi ci ent
ti ght
eni ng
ofwheel
nuts
Di fference
i n
wear
and
tear
of
ri ght
and
left
ti re
treads
I ncorrect
adjustment
orabrasi on
of front
wheel
beari ng
Collapsed
ortwi stedfront
spri ng
I ncorrect wheel
ali gnment
I ncorrect brake
adjustment
bi ndi ng
Wornrubber
bushi ngs
for
transverseli nk and
tensi on
rod
Deformed
steeri ng
li nkage
and transverse
li nk
and tensi onrod
I mbalanceofcarlevel
Correcti veacti on
Adjust
Correct the
i mbal
anceor
replace
Replace
or
ti ghten
Adjust
or
ti ghten
Adjust
Replace
Reti ghten
Replace
faulty parts
Replace
Adjust
correctly
Replace
Replace
or
reti ghten
Replace
or
reti ghten
Correct the i mbal
ance
Adjust
or
ti ghten
Replace
ti res
Adjust
or
replace
Replace
Adjust
Adjust
Replace
Replace
Correct the i mbal
ance
FRONT
AXLE
FRONT SUSPENSI ON Trouble
Di agnoses
and
Correcti ons
Condi ti on
I nstabi li ty
of
car
Sti ff
steeri ng
wheel
Checki ng
up
procedure
Jack
up
front
wheels detach
the
steeri ng
gear
arm
and
operate
the
steeri ng
wheel
and
I f
i t i s
li ght
check
steeri ng li nkage
and
suspensi on
parts
I fi t i s
heavy
check
steeri ng
gear
and steer
i ng
column
parts
Excessi vesteeri ng
wheel
play
Noi ses
Probable
cause
I mproper
ti re
pressure
Worn rubber
bushi ngs
fortransverse
li nk and
tensi on rod
I ncorrect wheel
ali gnment
Worn
or
deformed
steeri ng
li nkage
and
transverse
li nk
I ncorrect
adjustment
of
steeri ng gear
Deformed
or
unbalancedroad
wheel
I mproper
ti re
pressure
I nsuffi ci ent
lubri cants or
mi xi ng i mpuri ti es
i n
steeri ng
gear
box
orexcessi vely
worn
steeri ng
li nkage
Sti ff or
damaged suspensi on
ball
joi nt
or
lack
of
grease
Worn or
i ncorrectly adjusted
wheel
beari ng
Worn
or
damagedsteeri ng gear
and
beari ng
I ncorrectly adjustedsteeri ng
gear
Deformed
steeri ng
li nkage
I ncorrect
wheel
ali gnment
Damaged
strut
mounti ng beari ng
Damaged
or
sti ff
pi ston
or
shock
absorber
pi ston
rod
i nthestrut
I nterference
of
steeri ng
column wi th
turn
si gnal
swi
tch
I ncorrectly adjusted
steeri ng
gear
housi ng
Worn
steeri ng
li nkage
I mproperly
fi tted
gearhousi ng
I ncorrectly adjusted
wheel
beari ng
Worn transverse li nk and
tensi on rod bush
i ngs
I mproper
ti re
pressure
I nsuffi ci ent lubri cati ng
oi l
and
grease
for
suspensi on
baU
joi nt
and
steeri ng
li nkage
or
thei rbreakage
Loose
steeri ng
gear
bolts li nkage
andsus
pensi on
parts
Faulty
shock absorber
i nsi de
the
strut
Faulty
wheel
beari ng
Worn
steeri ng
li nkage
and
steeri ng gear
Worn transverse
li nk
and tensi on
rod bush
i ngs
Broken
or
coUapsed
coi l
spri ng
Correcti veacti on
Adjust
Replace
Adjust
Replace
Adjust
Correct
or
replace
Adjust
Repleni shgrease
or
replace
the
part
Replace
Replace
or
adjust
Replace
Adjust
Replace
Adjust
Replace
Replace
Replace
Adjust
Replace
Reti ghten
Adjust
Replace
Adjust
Repleni sh
lubri ca
ti ng
oi land
grease
or
replace
Reti ghten
Replace
Replace
Replace
Replace
Replace
FA 15
Trouble
Di agnmsundCorTfI Cti ons FRONT
AXLE
FRONT SUSPENSI ON
Condi ti on Probable
cause
Loose
stabi li zerbari nstallati on bolts and
nuts
Loose
strut
to
hoodledge
i nstallati on
nuts
Grati ng
ti renoi se
I mproper
ti re
pressure
I ncorrect wheel
ali gnment
Deformed
knuckle
spi ndle
and
suspensi on
li nkage
Jumpi ng
of di scwheel
I mproper
ti re
pressure
I mbalancedroadwheels
Faulty
shock
absorber
Faulty
ti re
Deformedwheelri m
Excessi vely
or
parti ally worn
ti re
I mproper
ti re
pressure
I ncorrect wheel
ali gnment
Faulty
wheel
beari ng
I ncorrect
brake
adjustment
Ti res
not rotated
Rough
and
i mproper
dri vi ng
manner
FA
16
Correcti veacti on
Reti ghten
Reti ghten
Adjust
Adjust
Replace
Adjust
Adjust
Replace
Replace
Replace
Adjust
Adjust
Replace
Adjust
Rotate
ti res
commended
val
Dri vemore
gently
at
re
i nter
Tool
number
Kent
MooreNo
KV401021S0
CD
ST35325000
@KV40102110
@KV40102120
@KV40102130
CI D
KV
40
102140
@KV40102150
KV48100301
HT71730000
ST35500001
125825
ST35530000
125827
HT72520000
ST36720000
125847
ST35652001
FRONT
AXLE
FRONT
SUSPENSI ON Speci al
Servi ceTool
SPECI AL
SERVI CE
TOOLS
Toolname
Beari ng
outer
racedri ft set
Dri ft bar
Dri ft A
Dri ft
B
Screw
A
Screw
B
Screw C
Strut and
steeri ng gear
housi ng
attachment
Coi l
spri ng
compressor
G
land
packi ng
wrench
Gland
packi ng
gui de
Ball
joi nt
remover
Transverse
li nk
bushi ng
replacer
Clamp
V
V
I
J
tL
t3
o
FA
17
DATSUN 200SX
ModelSI lO
Seri es
SECTI ONRA
REAR
AXLE REAR SUSPENSI ON
REAR AXLE
REAR AXLE
REAR AXLE
ASSEMBLY
REAR AXLE SHAFT AND WHEEL
BEARI NG
REAR
SUSPENSI ON
REAR SUSPENSI ON
STABI LI ZER BAR
SHOCK
ABSORBER
COI L SPRI NG
UPPER LI NK
AND
LOWER LI NK
CONTENTS
RA 2
RA 2
RA 2
RA 3
RA 5
RA 5
RA 6
RA
6
RA 7
RA 7
SERVI CE DATA
AND
SPECI FI CATI ONS
GENERAL SPECI FI CA
TI ONS
I NSPECTI ON AND
ADJUSTMENT
TI GHTENI NG TORGUE
TROUBLE DI AGNOSES AND
CORRECTI ONS
SPECI AL SERVI CE
TOOLS
RA 8
RA 8
RA 8
RA 8
RA 9
RA lO
GI I
RearAxle REAR AXLE REAR
SUSPENSI ON
REAR AXLE
REAR
AXLE
Oi lw
I nstall
usi ng
oi lseal
dri ft KV40100300
Rearaxlecueendshi m
Beui Dg
coner
I nstalled
by
a
p i ng
force
of
29 49kN
3 5t 33 5 5 US ton
30
4
9
I mp
ton
Thi ckne
0
075 00030
0150
00059
0225 00089
030000118
I
L
llteatherCOP l
Breather
72
Fi ller
PI
1
72
SAA013
CJ22 26
2
2 2 7 16 20
Rear
axle
cue
end
shi m
CJ
78 98
8 1058 72
Beui Dg
Ax1
I
I I
ease
Axle
shafl
Beari ngcol1ar
Beari ng
spacer
fi J
Aalshaft
Beeri n8
fI ansesi de i de
1
rf
Gap
C
0i I w
W
Gap
C 001 00004
J
CJ N m
kg
mft I b
Uni t
romi n
SAA014
RA 2
REAR
AXLE
ASSEMBLY
RemovalandI natallatlon
Block front wheels Place
stands
Support
underdi fferenti alcarri erwi th
garagejack
I
I
A
2 Remove
stabi li zer
barReferto
Stabi li zerBar
fori nstallati on
4
1
I
I t
SAA017
3
Di sconnect
propeller
shaft Refer
to PO
secti on forremoval
brake
hydrauli c
li ne
and
parki ng
brakecable
CAUTI ON
When
removi ng
or
i nstalli ng
brake
tubes useToolGG94310000
t
e
c
C
SRA018
4
Di sconnect shock absorber
lower
endon
eachsi de
When
removi ng
shockabsorberlow
erend from bracket
squeeze
shock
absorberand li ft i t out
ri ght
above
toaccommodate embossment
i nsi de
bracket
F
p
c
i
I
y
I I
I
I
I
l
RA485
I t
R
A486
5 Lower
jack
andremovecoi l
spri ng
oneachsi de
jf
6
Rai se
jack to
previ ous posi ti on
Di sconnect
upper
li nk andlowerli nk
at axlecasesi de
REAR
AXLE REAR
SUSPENSI ON
RearAxle
7
Release
jack
and
pull
i t out
I nstallati on i s i n reverse
orderof
removal
Referto
Upper
Li nk and Lower
Li nk fori nstallati on of
upper
li nk and
lowerli nk
I n
p
cti on
Check axle
case for
yi eld
deforma
ti on orcracks
and
replace
i f
necessary
REAR AXLE SHAFT AND
WHEEL BEARI NG
R mov1 nd dl mbl
I Block front wheels Place stands
Remove rear
wheel
A
2 Di sconnect
parki ng
brake cable
andbraketube
3 Remove
cali per
and
rotor
Re
move
nuts
securi ng
baffle
plate
4 Draw
out axleshaft
Rear
axle
shaft
SAA026
5 Remove
oi lseal
4
SAA027
RA3
Rear
Axle
REAR AXLE REAR
SUSPENSI ON
6 Cut collar
wi th
coldchi sel
Take
carenot to
damage
axlesheft
SRA028
7 Remove wheel
beari ng
and
collar
L
l
AA492
I nspecti on
Check axle shaft for
strai ghtness
cracks
damage
wearordi storti on
Check
li p
ofoi lsealfor
damage
de
formati on
or
wear
Check
beari ng
forwear
or
damage
Assembly
and I nstallati on
I
I nstall
beari ng
spacer
wi thcham
feri de
faci ng
axle
haft
flange
I nsert
wheel
beari ng
wi thseal i do
faci ng
olli e
haft
flange
CD
SRAQ29
1 Bai t
2 Rearaxle shaft
3 Bame
plate
4
Adapterplate
5
Beari ng spacer
6 Wheel
beari ng
RA 4
2
Press new
beari ng
collar
by
a load
of 29 to49kN 3
to5 ton 3 3 to5 5
US ton 3 0
to49
I mp
I on I ons
Baffle
plate
SRA030
3
I nstalloi l
seal
packi ng
cavi ty
be
tween
seali ng li ps
wi th
recommended
multi
purposegrease
KV40100300
SAA031
4
I nsert axle
shaft
i nto
axle case
applyi ng
multi
purpose grease
tothe
outer
peri phery
of
beari ng
collarRe
move
gui de
when
di stance
A
be
tween axle
l1ange
and
beari ng
i s
70to
90mm
2
76
to
3 54i n
CD
1
J
9AJ
r
A 7090mm
12
76 354 i n
RA560
1
Rear
axleshaft
2 Rearaxleshaft
gune
ST37840000
3 Rear
axle
case
4
Oi l
seal
5
Adjust gap
C
between wheel
beari ng
andaxletube end
by
selecti ng
shi m
Gap
C
lessthan01 mm 0004i n
i
Shi mthi ckness
d
W
I I
I I I I
AA559
Rear
axle
caseend hi m
RefertoS OS
6 Measureend
play
ofaxleshaft
SAA032
Axi alend
play
005 040mm
0002000157 i n
fl
Di fferenti al
gear
carri er
fi xi ng
nut
2025 N
m
2 0
25
kg
m
14
18ft lbl
Oi l
drai n and fi ller
plug
59 98
N m
60100
kg
m
43 72ft I bl
Braketubeflarenut
15
18N m
1 5 1 8
kg
m
11 13ft
lb
Brake3
way
connector
fi xi ng
bolt
17
20N m
1 7 20
kgm
12 14
ft I bl
Wheel
nut
78 98
N
m
80100
kg
m
58 72ft I bl
REAR AXLE
REAR
SUSPENSI ON
Rear
Suspensi on
REAR SUSPENSI ON
REAR
SUSPENSI ON
dl
@
e
e
e1
1
15
2015
2
011
14
Coi l
Spri ng
lD
color
Purple
YeUow
Shock
absorber
Upper
li nk
bolt
8
051
58
dl37
5
0
038 051
2
7
37
Lower
li nk
bushi ng
Replaceable
Removed
ori nstalled
by
a
pressi ng
forceof
39 69
KN 4
11
4
4
7 7
US ton
39 69
I mp
ton
Di ffer
i n
length
fromupper
li nk
bolt
78
7
0 8051
58
Di ffer
i n
length
from
upper
li nk bolt
dl16
21 16 2
1
12
2
1
12 15
dl
Nm
kg
ft lb
SAA033
AA 5
Rear
Suspensi on
REAR AXLE REAR
SUSPENSI ON
STABI LI ZER BAR
Remoyal
Remove
stabi li zerbar
P
fI
I I
SRA017
Front
I V 16 2111621 12
I V
Nm
kg
m ft I b
SHOCKABSORBER
Remoyaland I nstallati on
I Di sconnect
upper
end
14ft
lbl
1
T
I n
trunk luggage
room
SRA037
2 Di sconnect lowerend
md
remme
shock absorber
Squeeze
shock absorberand li ft i t
out
ri ght
above to
accommodate
em
bossment i nsi debracket
RA 6
I nspecti on
I Check
stabi li zer
barfor
evi dence
of deformati on or
cracks
replace
i f
necessary
2 Check
rubber
parts
to
be sure
they
are
not
deteri orated
orcracked
replace
i f
necessary
I nstallati on
a I nstallstabi li zerbar
bei ng
careful
not toconfuse
ri ght
and left si des
b
I nstJ
U rubber
bushi ng
wi thmetal
fi ni ng
on
axle
case
li de
c I nstallbolt
attachi ng bushi ng
so
that bolt i si nsi dethecar
21
11
621
SRA035
s
C
fl
i lr
SAA038
L
7 080
kg
m 51 58ft
lbl
c
i
r
I
I
t
t
r
RA486
I nspecti on
Test
shock absorber
and
compare
wi th
speci fi cati ons
gi ven
i n S
OS
Replace
i f
necessary
Check foroi l
leakage
and cracks
Alsocheck shaft for
bendi ng
I nspect
rubber
bushi ngs
for
dam
age
cracks and
deformati on
Re
placeparts
i f
necessary
COI L SPRI NG
RemoyalendI nstallati on
I
Block front wheels Placestands
Support
under
di fferenti alcarri erwi th
garagejack
L
SRA016
2
Di sconnect shock absorberlower
end
C
I Y
LI V6
78N
ml
SRA038
L7080
kg
m51
58
ft
lbl
3
Lower
jack
slowly
and
remove
coi l
spri ngs
oneachsi de
I nspecti on
Check coi l
spri ng
for
yi eld
defor
mati on orcracks
Test
spri ng
and
compare
wi th
speci
fi cati ons
gi ven
i nS D S
Check all
rubber
parts
for
wear
cracks
damage
or
deformati on
Re
place
i f
necessary
UPPER LI NKAND LOWER
LI NK
Removal
Remove
upper
li nk orlowerli nk
alone
by removi ng
bolt
on
each
end
I t i s
possi ble
toremove one
li nk
assembly
alone
from
car
RA495
LI g
lr
j
REAR AXLE
REAR
SUSPENSI ON
Rear
Suspensi on
I nspecti on
Check for
si gns
of
cracks
di stor
ti on
orother
damage
Replace
i f
beyondrepai r
Bushi ng replacement
For
lowerli nk
only
I frubber
bushi ng
shows
evi dence of
cracks
replace
i t
usi ng
Tool
Upper
li nk
bushi ng
i s secured
by
adhesi on and cannot beremoved Re
placeas
an
assembly as
necessary
CAUTI ON
00
not
tap
endface
of
bushi ng
di rect
ly
wi th
a
hammer
as
deformati on
may
result i n
loosebolt
Removed
or
i nstalled
by
a
pressi ng
forceof
39 69KN
47144
7 7 US
ton
39 69
I mp
ton
KV40101420
BUshi ng
t
KV401O
47
a
ww
SRA039
I nstallati on
a
Securi ng
bolts foruse
wi thlower
li nk di fferi n
length
from
those
for
upper
li nk
I f
used
wrong
securi ng
bolts cannot
be
ti ghtenedsecurely
b When
i nstalli ng upper
li nk
i nstall
oneendof
upper
li nk
on
car
body
make sure that li nk
i s level and
then
ti ghten
li nk
securely Next
i n
stallthe otherend of li nk
on
axle
si de and
securely ti ghten
li nk whi le
ti res
areon
ground
c When
i nstalli ng
lowerli nk
securely
ti ghten
li nk whi le ti res
are on
ground
ti l
Shockabsorberlowerend
69 78N m
7 080
kg
m
51 58ft I bl
Upper
li nk
fi xi ng
bolt and nut
69 78N m
7
080
kg
m
51 58ft I bl
Lowerli nk
fi xi ng
nut
69 78N m
7 080
kg
m
51 58ft I bl
RA
7
Servi reDataandSpeci fi cati ons
REAR AXLE REAR
SlJSPENSI ON
SERVI CE
DATA
AND
SPECI FI CATI ONS
GENERAL
SPECI FI CATI ONS
SHOCKABSORBER
Uni t mmi n
I
Maxi mum
length
L 525 12067
I
Stroke 146 5 75
L
C
0
SRA090
COI L SPRI NG
I
Wi redi ameter mmi n
I
Coi ldi ameter
mm
i n
I
Free
length
mm
i n
I
Effecti veturns
I
Spri ng
constant
N
mm
kg
mm
I b i nl
10
0103941
90
13541
362
14
251
7 75
17
46
178 99
71
I denti fi cati on color
Yellow
1
PurPle
ll0
5
RA040
I NSPECTI ON
AND ADJUSTMENT
SHOCK
ABSORBER
I
SHOCK ABSORBER DAMPI NG FORCE at 03
m
11 0hI ls
I
Expansi on
N
kg
lbl
490686 5070110154
I
Compressi on
N
kg
I b
245 402 25 41 55 901
RA
B
REAR AXLE
End
play
mm
On
005 OAO
10
00200
01571
Thi ckness mm n Part
umber
Thi cknessof rear
xle
case endshi m
0075
1000301
43036
H5000
01SO
1000591
43036H5oo1
0225
1000891 43036HS002
03001001181
43036
H5003
TI GHTENI NG
TORQUE
Uni t N m
kg m
ft I b
Broke
tubeflare
nut
15 18 15 18
11 13
Brake
cali perfi xi ng
bolt 38 52 39 5 3 28 38
Baffle
platefi xi ng
ut 22 26 22 27 16 20
Propeller
shaft to
com
pani on flangeconnecti ng
RefertoPOsecti on
nut
Wheel
nut
78 98 80100 58 72
Drai nandfi ller
plugs
59
98
60100 43 72
I
Di fferenti al
carri erto
2025 2
025 14 18
axlllcasenut
I
Shockabsorber
upper
15 20 15 20 11 14
endnut
I
Shockabsorberlower
69 78 7 080 51 58
endnut
I
Upper
li nk
fi xi ng
bolt 69 78 7 080 51 58
I
Upper
li nk
fi xi ng
nut
69
78 7 080 51 58
I
Lowerli nk
fi xi ng
nut 69 78 7 080 51 58
REAR
AXLE
REAR SUSPENSI ON
Trouble
Di agnoses
and
Correcti ons
TROUBLE DI AGNOSES AND
CORRECTI ONS
When rearaxle and
suspensi on
i s
suspected
of
bei ng noi sy
i t
i s advi s
able
tomake
thorough
test
to
deter
mi ne whetherthe
noi se
ori gi nates
i nthe
ti res road surface exhaust
pro
Condi ti on
Noi se unusual
sound
I nstabi li ty
i n
dri vi ng
Thi s
problem
i s
also
related
tothefront
suspensi on
Fortrouble
di agnosi s
alsoreferto
theFA
secti on
Oi l
leakage
peller
shaft
engi ne
transmi ssi on
wheel
beari ngs
or
suspensi on
Noi se whi ch
ori gi nates
i n
other
places
cannot
be
corrected
by adjust
ment or
replacement
of
parts
i n the
rearaxleandrear
suspensi on
I n case of oi lleak fi rst
check i f
there
i s
any damage
or
restri cti on
i n
breather
Probable
cause
Loosewheel
nuts
Oneormore
securi ng
boltsloose
Lack
oflubri cati ng
oi lor
grease
Faulty
shock
absorber
I ncorrect
adjustment
of rearaxle shaft end
play
Damaged
orwornwheel
beari ng
Worn
spli ne
porti on
of rear
axleshaft
Loose
journal
connecti ons
etc
Unbalanceofwheel
andti re
Damage
of the rubber
parts suchas li nk
bushi ng
shock
absorber
mounti ng
bush
i ng
Faulty
propeller
shaft
journal
Breakage
of
coi l
spri ng
Loose
wheelnuts
Damaged
rearli nkrubber
bushi ngs
Worn
shock
absorber
I ncorrect
wheel
ali gnment
Spri ng wear
Damaged oi lsealonrearaxleshaft
Oi l
leakage
from
thedi fferenti alcarri er
Damagedgreasesea ofrear
axle
shaft
Correcti veacti on
Ti ghten
Ti ghten
to
speci fi ed
torque
Lubri cateas
requi red
Replace
Adjust
Replace
Replace
i f
necessary
Ti ghten
to
torque
Balance
Replace
damagedparts
Replace
as a
propeller
shaft
assembly
Replace
Ti ghten
to
speci fi ed
torque
Replace
Replace
Adjust
Replace
Replace
Replace parts
as
requi red
Replace
RA
9
Speci al
Servi ceTools
REAR
AXLE
REAR SUSPENSI ON
SPECI AL
SERVI CE TOOLS
Toolnumber
knt
Moore
No
GG943
I 0000
Toolname
Flare
nut
torque
wrench
KV4010I 0OO
J
25604
1
Rearaxlestand
ST36230000
J
25840
Sli di ng
hammer
lI T72480000
Rear
axleshaft
beari ng
puller
ST38210000
J
25869 1
Wheel
beari ng
collar
press
stand
KV40100300
J 25405
Rearaxle
oi l
seal
dri ft
ST37840000
Rear
axleshaft
gui de
@
KV40l0l4S0
Li nkrubber
bushi ng
dri ft
CD
KV4010141O Dri ft
h
V
KV40101420 Dri ft
@
KV40101430 Base
@ KV40101440 Ri ng
useless
RA
I 0
DATSUN
200SX Model
S
I I
0
Seri es
SECTI ONBR
BRAKE
SYSTEM
CONTENTS
DESCRI
PTI ON
SERVI CE
BRAKE
BRAKE PEDAL
MASTER CYLI NDER
BRAKE HYDRAULI C LI NE
BLEEDI NG HYDRAULI C SYSTEM
NP VALVE
FRONT DI SC BRAKE N22
FRONT DI SC ROTOR
REAR DI SC BRAKE AN12H
REAR DI SC ROTOR
BR
2
BR
3
BR
3
BR 4
BR 5
BR
5
BR 6
BR 6
BR
9
BR lO
BR 13
BRAKE BOOSTER
PARKI NG BRAKE
PARKI NG BRAKE
SERVI CE DATA AND
SPECI FI CATI ONS
GENERAL
SPECI FI CATI ONS
I NSPECTI ON AND ADJUSTMENT
TI GHTENI NG TORQUE
TROUBLE
DI AGNOSES
AND
CORRECTI ONS
SPECI AL
SERVI CE
TOOL
BR 14
BR 16
BR 16
BR 1B
BR 18
BR 18
BR 19
BR 20
BR 22
Refe toSecti onMA Brake
System
for
CHECKI NG FOOT BRAKE
CHECKI NG
PARKI NG 8RAKE
a
CH ri pti on BRAKE SYSTEM
DESCRI PTI ON
3way
connector
Pulli ng
hrake
lever
Brake
hOle Front di scbrake
SBR001
Thebrake
system
i s a
hydrauli cally
controlled dual li ne
type
whi ch
operates i ndependently
on
front
and
rearwheels
The brake
booster
i s
a
power
assi st
devi ce
whi chuti li zes
engi ne
i ntakemani foldvacuum
The NP valve
i s
a
pressure
control
devi cefortherear
brakes
The reardi sc brake
i s
equi pped
wi tha mechani cally
operated
parki ng
brakemechani sm
The
pad
clearances of
the
front and
rear
brakes
are
automati cally adjusted
BR
2
BRAKE
PEDAL
SERVI CE
BRAKE
I nput
rod
il
7
8 108
I nput
rodlock
nut
0
8
11
t
SnaPri n
5 8
8 0
il16
22 1
6
22
12
Pi n
il
7 8
11
8 0
8
12
5
8 8 7
L
H
I tf
Eri ng
il
7
8 108
0
8 11
5
8
Be
sure
to
i nsert
fromLHsi de
il
N m
kg
m fHb
REMOVAL
I
Remove
pedal
bracket
assembly
wi thbrake
pedal
M
T
only
2 Di sconnect clevi s from brake
pedal
When
removi ng clevi s
pi n
be careful
not to
damage
c
i p
of theclevi
pi n
SBR121
3 Remove fulcrum
pi n
Brake
pedal
can thenbe takenout
BRAKE
SYSTEM Servi ce
Brake
f
RH
il
7
8 108 0
8
11
5 8 80
108
0
8 115 8 80
Pedalbracket
ki l13
Return
spri ng
18
13
189
13
lt
Brakelamp
wi tCh
Lock
nut
il
12 15
1
2
15
9
11
Pedal
stopper
Lubri cati ng
poi nt
Brake
pedal
o
00
lf
O@
o
I
@I I
I NSPECTI ON
Checkbrake
pedal
forthe
followi ng
i tems
servi ci ng
as
necessary
SBR120
I
Check brake
pedal
forbend
2 Check return
spri ngs
for
fati gue
3
Check clevi s fordeformati on
andcrackat welded
part
SBR122
I NSTALLTI ON
I
Apply coati ng
of recommended
multi
purpose
grease
to
sli di ng porti on
andreturncoi l
spri ng
2
Adjust
brake
pedal
afteri nstalla
ti on i s
completed
Refer
to
Secti on
MAfor
adjustment
li l
Fulcrum
pi n
fi xi ng
bolt
7
8
108N
m
08 1 1
kg
m
5
8
80ft lb
I nput
rod
lock
nut
16 22N
m
1 6 22
kg
m
12 16ft lb
BR 3
Servi ce
Brake BRAKE SYSTEM
MASTER CYLI NDER
Reservoi r
cap
Fi llet
Reservoi r
teek
Yalve
88 809
058
65
DI SASSEMBLY
The brake
master
cyli nder
i s avai l
able
only
i n TOKI COmake Therei s
no
i nterchangeabi li ty
of
repai r
ki ts or
component part
betweenNABCO
and
TOKI COmakes
When
replaci ng
tha
repai r
ki t
or
component
part
rtai n tha
brand
of
thebrake master
cyli ndar
body
Ba
sure
to part
of
thesame makeas
theformerones
I
Pry
off
stopper
ri ng
L
2
Remove
stopper
screw
Pri mary
and
secondary
pi ston
assembli es can
thenbe
taken
out
BR 4
H
pi ston
return
spri ng
Secondary
pi lton
Pri m
pi lton
Pri mary
pi ston
return spri ng
88
8 09
058 65
tfJ
69 8
8 07 09
5 1 65
SBR011
3
Di sassemble
pi ston
assembly
Secondary
pi ston
Pri mary pi ston
assembly
auembly
SBR012
4
Remove
pi ston
cups
anddi scard
them
lJ
N m i i m
ft I b
SBA009
Secondary pi ston
Pri mary pi ston
SBR013
5
Unscrew
plugs
for
di sassembli ng
check valve
I NSPECTI ON
I
Clean all
parts
i n
a
brake l1ui d
2 Check the
parts
forevi dence of
abnoi malwearor
damage
3
Check
pi ston
to cyli nder clear
ance
Pi ston
li nderclearance
Lessthan0
15
mm
00059i n
ASSEMBLY
a
Replace
pi ston
cups
and
packi ng
wi th
new
ones
b
Apply
braka flui d
or
rubber
gre
to
I i di ng
contact urfaceof
ports
tofoci li tata
aaembly
of
master
cyl
i nder
iJ
Chock 01 0
plug
78 88
Nm
8090
kg m
58 65ft I bl
BRAKE
HYDRAULI C LI NE
I NSPECTI ON
Check
brake
li nes tubes and
hoses
for
evi dence
ofcracks
deteri orati on or
other
damage Replace any
faulty
parts
I f
leakage occurs
at
end
around
joi nts
I e
ti ghten
or
i f
necessary
replacefaulty parts
REMOVAL AND
I NSTALLATI ON
Toremovebrake
tube
di sconnect
flarenutsonbothends and
remove
retai ners
and
cli ps
CAUTI ON
When
removi ng
or
i nstalli ng
brake
tubes useToolGG94310000
SBROOS
Toremove
brakehose fi rst remove
l1are nut
securi ng
brake tube to
hose then wi thdraw lock
spri ng
Next di sconnect the othersi de
Donot twi st brakehoe
Braketube
Lock
spri ng
I
SBA006
a
Afteri nstallati on i s
completed
bleed brake
system
Refer
to
Bleedi ng Hydrauli cSystem
BLEEDI NG
HYDRAULI C
SYSTEM
1
Top up
reservoi rwi th
recom
mendedbrake
l1ui d
a Donot mi x twodi fferent brand
braka flui d
b C
refully
moni torbrake
flui dleel
at master
cyli nder
duri ng bleedi ng
operati on
c Donot
reuse
drai nedbrakeflui d
r
BRAKE SYSTEM SelYi ce
Brake
2
I nstall
bleeder
hose on bleeder
valve Wi thbrake
pedalfully depress
ed
open
bleedervalve to
exhaust
ai r
Then close bleeder
valve
and allow
brake
pedal
toreturn
Repeat bleedi ng
operati on
unti lno
ai r
bubbles showi n
hose
a
Be carefulnot to
pla
hbrka flui d
on
pai nted
areas
b Brakeflui d
contai ni ng
ai ri s whi te
andcontai n ai r
bubbles
c Brakeflui d
contai ni ng
no
ai r
runs
out of bleedervalve i n a soli d
stream
freeof ai r
bubbles
SBR003
3
Bleed
ai ri n the
followi ng
se
quence
Master
cyli nder
Rearwheel
Front wheel
iJ
Ai rbleeder I e
69 88N m
07 0
9
kg
m
5 1 65
ft
I bl
BR 5
Servi ceBrake
BRAKE SYSTEM
NP VALVE
Donotdi sassemble
NP val
e
e
Front
wheel
cyli nder
Front wheel
cyli nder
I f
Braketubef1erenut
15 18N m
11 5 1 8
kg m
11 13ft I bl
NP wai veto
body
39 49N m
040
5
I rg
m
2
9
3
6
ft
lbl
SBROO1
FRONT DI SC BRAKE
N22
Pi ston
eal
Replace
at eachdi sassembly
iJ12
91 1
3
9
9 53 72
Dustse a1
Apply
cfucbJake
grease
r
Cy1i nder
body
aet ai ni ngri ng
Youholder
D
I nstalled
by
pressi ng
force
196 294N
2030
leg
44 66
I b
I
1
rupj
Yoke
I I
Mi ni mum thi ckness
10
5
0413
Spri ng
21 16 2
1
12
15
Pad
WeaJ li mi t
1
J
iJ
N
m
I eg m
Jt lb
Uni t
rom i n
2 0
08 SBA014
BR 6
PAD
REPLACEMENT
I
Remove
cli p
Remove
pad
pi ns
holdi ng
spri ngs
wi th
fi nger
SBA015
2 Detach
pads
CAUTI ON
After
removi ng pads
donot
depress
brake
pedal
or
pi stons
wi ll
jump
out
SBRG16
3
Open
bleeder
valve Push
pi ston
B outer
pi ston
i n unti ldust
seal
groove
of
pi ston
B
coi nci des
wi th
end surfaceof retai ni ng ri ng
on dust
seal
CAUTI ON
Pi ston can be easi ly
pushed
i n
by
hand but i f
pushed
toofar
groove
of
pi ston
wi ll
go
i nsi de
of
pi ston
sealAt thi s
poi nt
i f
pi ston
i s
pressur
ed ormoved
pi ston
sealwi ll
be
damaged
I f
pi ston
has been
pushed
i n toofarremove
cali per
assembly
and di sassemble
i t Then
push
pi ston
out i n di recti on
shown
by
arrow
Assemble i t
agai n
referri ng
to
the
followi ng
Pi stonseal
2
Pi ston
B
Y
Normal
POSi ti On
Donot
push
too
far
BR780
4 I nstall
i nner
pad
Pull
yoke
to
outersi de
SBA230
5 I nstallouter
pad
Coat the
followi ng poi nts
wi th
recommended
pad grease
Cyli nder
body
to
pad
clearance
Pad
pi n
to
pad
clearance
Pad
pi n
holes
of
cyli nderbody
Do
not grllll8
fri cti on
faceof
pI I d
Then
i nstall
pad
ftxi ng parts pre
vi ously
removed
BRAKE
SYSTEM
Servi ceBrake
REMOVAL
I Di sconnect
braketube
2
Remove
cali per
assembly
BR
7
Servi ce
Bl1lke BRAKE SYSTEM
DI SASSEMBLY
Remove
pads
Remove
fI Xi ng
bolt
and
separate
yoke
and
cyli nderbody
0
1
D
BR740
J
BA741
2 Remove
yoke
holder
retai ni ng
ri ngs
anddust sealsfromboth
pi stons
Dust seal
8R742
3
Pushout
pi stons
from
cyli nder
SBR019
BR
B
4 Remove
pi ston
seal
Pi ston seal must be
replaced
at
eachd
bly
SBR020
I NSPECTI ON
CAUTI ON
Use
bfllke flui d
to
clean Never
use
mi nefllloi l
C
llnder
bod
I Check i nsi de surface of
cyli nder
forscore rust wear
damage
or
presence
of
forei gn
substance I f
any
surface fault
i
detected
replace
cyli nderbody
2 Mi noJ
damage
from Just of
forei gn
sub tances
may
be eli mi nated
by poli shi ng
surfacewi th
a
fme
emery
cloth I f
damage
i s
majorcyli ndCJ
assembly
must be
replaced
Yoke
Check for
wear
cracks
orother
damage Replace
i f
any
fault i detect
ed
PI ston
Check
pi ston
forscore
rust
wear
damage
or
presence
of
forei gn
sub
stances Replace
i f
any
fault i s detect
ed
CAUTI ON
Pi ston
sli di ng
surface
i s
plated
00not
poli sh
wi th
emery paper
evei li f rust
or
forei gn
matter
i s sti cked on
sli di ng
surface
Gri pper
and oke holder
Check for
wearcracks
or
other
damage
Replace
i f
any
fault i s
detect
ed
ASSEMBLY
I
Apply
rubber
grease
or
brakel1ui d
toseal
grooves
andseals I nstall
pi ston
seals
taki ng
care
not to
damage
them
SBR021
2 Apply
rubber
grease
orbrake
l1ui dtosli di ng porti ons
I nsert
pi stons
CAUTI ON
I ni ert
pi ston
A i n
di recti on shown
by
arrow
Q1 and
pi ston
B i n di recti on
shown
by
BrroW
02
B When
i nserti ng pi stons
be
careful
not toi nsert
too
far
Refer
toPad
Replacement
for
assembly
b I nstan
pi ston
A 10that i ts
yoko
groove
coi nci des wi th
yoke
groove
of
cyli nder
1
tonA
Pi stonB
t
I
Q2
3
I nstall
dust sealand
clamp
secure
ly
wi th
retai ni ng ri ng
a Apply
recommended
di sc brake
grease
toseali ng
surface
of dUlt
1
b Becarefulnot to
deformdust seal
c
Wi pe
off excess
grease
wi thalcohol
SBR022
4 I nstall
yoke
holder
to
pi ston
A
I nstall
gri pper
to
yoke
Apply
a
coati ng
of
1
soap
water
toi nner
wall
of
gri pper
and
dri vei ncollar
F
ll
T
L
BR745
5 I nstall
yoke
to
yoke
holderand
supporti ng
end
of
pi ston
B
press
yoke
i nto
yoke
holder
by usi ng press
or
hands
CAUTI ON
When
pressi ng
yoke
i nlo
yoke
holder
be sure
to
i nsert
yoke
verti cally
soas
not tocrack or
chi p yoke
holderI f
yoke
holderi s
damaged
or
pl8ui ng
forcei s out of
speci fi cati on replace
wi tha newone
Preai ng
force
196 294N
2030
kg
44
66I bl
BR959
6 I nstall
pads
RefertoPad
Replace
ment for
i nstallati on
FRONT DI SC ROTOR
REMOVAL AND
I NSTALLATI ON
Refertosecti on
FA
I NSPECTI ON
I
Sli di ng
surface
I f
thereare cracks
or
consi derable
chi ps repai r
or
replace
2 Runout
Adjust
wheel
beari ng correctly
Measure
mnout
BRAKE
SYSTEM
Se Vi ce
Brake
n
i
I
SBR232
Rotor
repai r
li mi t
Maxi mumrunout
Total
i ndi cator
readi ng
at
center
of rotor
pad
contact
surface
012
mm
00047
i n
3 Pari i lleli sm
SBR233
Rotor
repai r
li mi t
Maxi mum
paralleli sm
Ci rcumferenti al
di recti on
007
mm
00028 i n
4
Thi ckness
Standardthi ckness
125 mm 0492
i nl
Rotor
repai r
li mi t
Mi ni mumthi ckness
105 mm 0
413
i n
BR 9
o
J
Wear
li mi t
1
6
0
063
Pad
Rotor
Mi ni mum
thi ckness
8
6
0
339
ke
Retai ni ng
ri ns
Spri ng
cover
Shi m Be
sure
to
apply
brake
grease
to
both
si des
when
i nstalli ng
Anti lueal
spri ng
Yoke
I pri ng
I
Retai ner
r
CyUnder
body
A
Return
Pri ng
Toggle
lever
Uni t
mm
i n
SBA037
aI I I I I a aI tn maI I
I I I
I
I I z NZ
I
2
I
C1l m
en en
lm3
PAD
REPLACEMENT
I
Remove
cli p
Remove
pad pi ns
holdi ng spri ngs
wi th
fi nger
LL
SBR03B
2
Detach
pads
andshi ms
CAUTI ON
After
removi ng peds
donot
dep
ss
breke
pedel
or
pi stons
wi ll
jump
out
3
Retract
outer
pi ston
i nto
cyli nder
body
by turni ng
i t
clockwi seand
push
i ng
i t
i n Be careful
not to
demell8
dust seal
1
Fllt
bladescrewdri ver
BR173A
4
Move
yoke
unti lclearances
to
i n
stall
pads
are
equal
wi thalever
placed
between
rotorand
yoke
5
I nstall
pads
andshi ms
Posi ti on outer
pi ston
so
that
por
ti on
of
cutout
i s
level
and i nstall
pad
by ali gni ng
thi s
porti on
wi th
protru
si on at
backof
pad
Ali gn
I e
I
I
J
I e
1
J
Jrr rf
BR191A
D
4
7r
6
1
Coat the
followi ng poi nts
wi th
re
commended
padgrease
Cyli nderbody
to
pad
clearance
Y
oketo
pad
clearance
Pad
pi n
to
pad
clearance
Pad
pi n
tobracket clearance
8
Do
not
grease
fri cti on
faceof
pad
b Be
sure
to
apply padgrease
toboth
si des
ofshi ms
SBR234
2 Check that the
followi ng poi nts
are coated wi thsi li cone based
grease
BRAKE
SYSTEM
Servi ceBreke
Ni ssan si li cone
based
grease
or
equi va
lent
Si li conebased
greasi ng poi nts
Fri cti on
surface of
yoke
and
cyl
i nder
body
Cyli nder
body padpi n
hole
Then i nstall
pads
fI xi ng
parts pre
vi ously
removed
REMOVAL
I Di sconnect brake
tube
2 Remove
cali per
assembly
1111
I
I
SBA041
SBRD42
DI SASSEMBLY
I
Separate cyli nderbody from
yokeby
pushi ng
i t
2
Remove
retai ni ng ri ngs
and
dust
seals
BR I I
Servi ceBrake BRAKE
SYSTEM
Replace
dust sealat eachdi m
bly
Pi ston
SBA043
3
Dri ve out
pi ston assembly by
pushi ng
outer
pi ston
i n
4
Remove
pi ston
seals
Replace pi ston seal at
each
di
sembly
SBA044
5
Di sengage
pi ston
assembly by
turni ng
i nnerandouter
pi stons
BR
12
6 Di sassemble outer
pi ston by
re
movi ng
snap
ri ng
B
Snap
ri lll
SBR045
7 Di sassemble i nner
pi ston by
re
movi ng
snap ri ngs
A andC
Snap ri ng
remover
SBRD46
8 Remove hand
brake
toggle
lever
by removi ng
return
spri ng
andnut
Remove dust sealandcam
tt
Nut
Return
spong
8
Toggle
lever
Caml LDust
seal
SBR047
ASSEMBLY
I
Before
assembli ng apply
thi n
coat of
rubber
grease
tothe
followi ng
e Groovei n
push
rod
and
newO
ri ng
Strut
ends
Oi l
seal
Pi ston
seal
I nsi deof
dust seal
Securely
i nstalloi lseali n
speci fi ed
di recti on
BAlBOA
2
Engage
square
hole
i n
key plate
wi th
pushrod Also
engage
convex i n
key plate
i n
concave
i n
pi ston
SBR048
3
I nstall
spri ng
seat
spri ng
spri ng
coverand
snap
ri ng
A
wi thsui table
press
anddri ft
Dri ft
SBA235
4
When
i nstalli ng parki ng
brake
tog
gle
leverafter
assembli ng pi ston
turn
cami n
di recti on
parki ng
brake
opera
tes
Toggle
lever
5
Apply
rubber
grease
orbrakel1ui d
to
seal
grooves
andseals
6 I nstallpi ston
seals
o
SBA044
7
Apply
rubber
grease
or
brake
l1ui d
to
sli di ng porti ons
8
Apply
rubber
grease
to
onehole
Di ameter
15 mm
0059
i n
of
outer
pi ston
as the
fi gure
shows Then
i nsert
pi ston
assembly
i n
di recti on
of
arrow
1
rl
j l
out
on
I nne
pi
QI
fJ
Di
m r
1
5
mm0059i n
L
SBR245
9 I nstalldust seals and
clamp
se
curely
wi th
retai ni ng ri ngs
10
I nstall
yoke
spri ng
BR181A
I I Coat the
followi ng poi nts
wi th
si li cone
based
grease
Fri cti onal
surfaces
of
yoke
and
cyl
i nder
body
Cyli nder
body
padpi n
hole
fi
l
H
SBR243
I
Si li conebased
greasi ng
poi nt
1 Yoke
3 Pad
pi n
2
Cyli nder
body
12 Assemble
yoke
and
cyli nder
wi th
retai ner
YOke
Retai ner
r
SBR049
13 I nstall
pads
RefertoPad
Replace
ment fori nstallati on
I NSTAUATI ON
fl
Coli perfi xi ng
bolt
38
52
N m
39 5 3
kg m
28 38ft I b
Afteri nstallati on
depress
brake
pedal
few
ti mes
to
properly
adjust
brake
pad
to
rotorclearance and
check for
oi l
leakage
When brake
pedal
stroke
i s constant brake
pad
to
rotorclearance
i s
properly
adjusted
I t
wi llbe automati cally
adjusted
by
depressi ng
brake
pedal
BRAKE
SYSTEM
Servi ceBrake
REAR DI SC
ROTOR
REMOVAL AND
I NSTAUATI ON
Remove
cali per
and rotorcan be
taken
out
I NSPECTI ON
I
Sli di ng
surface
I fthere are cracks or
consi derable
chi ps repai r
or
replace
2
Runout
Adjust
wheel
beari ng correctly
Measure
runout at the
centerofrotor
pad
contact surface
Rotor
repai r
li mi t
Maxi mumrunout
Totali ndi cotor
readi ng
at
center
of rotor
pad
contact
surfacel
015 mm 0
0059
i n
3 Paralleli sm
SBR050
Rotor
repai r
li mi t
Maxi mum
paralleli sm
Ci rcumferenti al
di rocti onl
0
07 mm 00028 i n
4
Thi ckness
Sblndard
thi cknou
96
mm
0378
i n
Rotor
repai r
li mi t
Mi ni mumthi ckness
86mm 0
339
i n
BR 13
Servi ceBrake
BRAKE SYSTEM
BRAKE
BOOSTER
D
hngm
Cheek valve
I
I Jp
Pi sto
j
Valve
turn
spri ng
11
0
Fi ns
rJ
Fulcrum
plate
l
I D I
Front meD
SBR059
I NSPECTI ON
2 Start
engi ne
and
i ncrease
engi ne
speed Stop engi ne
when
vacuum
i s
66
7 kPa
500mmHg
19
69
i nHg
3
I f vacuum
pressure drops
more
than the
speci fi ed
value correct
the cause
i n
accordance
wi th
the
followi ng
chart
Ai r
ti ght
test Noload
1
Connect
a
vacuum
gauge
between
check valve and brake
booster
Maxi mumvacuum
leekege
15
seconds after
engi ne
i s
stopped
33kPa
25
mmHg
098
i nHg
J
60
coo
HI
76 J
saRD D
SBR216
Probablecause Correcti ve
acti on
Ai r
leakage
at check valve
Ai r
leakage
at
output
rod seal
Ai r
leakage
between valve
body
andseal
Ai r
leakage
at valve
plunger
seat
I nspect
check valve
Replace
brakeboosteras an
assembly
Damaged
pi pi ng
or
joi nts
Repai r
or
replace
BR 14
Ai r
ti ght
test
Underloed
Keep
brake
pedalfully depressed
Followi ng
procedures
are same
as
for
noloadcondi ti ons
Probable
cause
Ai r
leakage
at
check
valve
Damaged di aphragm
Ai r
leakage
at
poppet
assembly seat
and
valve
body
Check velve
Removecheck valve
MT
model
Wi thcooler
SBR061
2 Apply
a vacuui n
pressure
of
267
kPa
200
mmHg
7
87 i nHg
to
the
port
of check valve on
the brake
booster
si de
Mani fold
si de
I f
Brakebooster
si de
SBR062
3
I f vacuum
pressure
drops
more
than
the
speci fi ed
valuei n
15 seconds
replace
check valve wi tha newone
Maxi mumvacuumleakage
of
check 01
0
1 3kPo
10
mmHg
039
i nHg
Maxi mum
vacuumleakage
15 second after
engi ne
i
toppedl
33
kPa
25
mmHg
098
i nHg
Correcti veacti on
I nspecl
check valve
Replace
brakeboosteras
an
assembly
4
When
pressure
i s
appli ed
tothe
brake boostersi de
ofcheck
valve
and
valve does n
open replace
check
valvewi th
a
newone
ManVi fOI
de
1
c
j
@
L
Brakebooster
si de
SBR063
BRAKE
SYSTEM
Servi ce
Brake
Operetlng
test
1 Connect
an oi l
pressure gauge
to
brake li ne
at
connecti on
on master
cyli nder
2
I nstall
a
pedal
force
gauge
on
brakepedal
3 Start
engi ne
and
i ncrease
engi ne
speed
unti l
a
vacuum
pressure
of
667
kPa 500
mmHg
1969
i nHg
i s reo
gi stered
on
vacuum
pressure gauge
Wi th
a
steady
vacuum
pressure
of
667
kPa
500
mmHg
1969
i nHg
measure
oi l
pressure
wi th
respect
toeach
pedal
operati ng
force
Relati onshi p
between oi l
pressure
and
pedaloperati ng
force i si llustrated
i n
Fi g
I f test results
arenot as
speci
fi ed
check
brake
booster
for
con
di ti on i n mannerdescri bed
under
I nspecti on
before removalof
thi s
uni t
Also
check brake
li nefor
evi dence
ofl1ui d
leakage
Determi ne
whether
source
of
pro
blem i s i n brake boosteror
check
valve Before
you
reach
a
fi nalconclu
si on
always i nspect
checkvalvefi nt
M
e
e
e
u
i i
S
u
M
0
11
770
120
1 710
10190110
1
500
I
I I
I
I
9 810
100
1
420
I
8
83090
1
280
1
jj
1
850801 140
6860
101
000
I
l
I
5 88060850
f
66 jf
490050710
I
tfl
392040
510
I
2 940
30430
L
I
J
1 96020280
rJ
98010
140
td
JJ
I I
o
981
1
961
100221
200441
Rod
operati ng
force N
kg
lb
8
0
0
6 0
6
6
Pedal
operati ng
force N
kg
I b
SBR074
BR 15
S8rvi csBrake BRAKE
SYSTEM
REMOVAL
To
remove
brake
booster
detach
the
followi ng poi nts
S8A064
ADJUSTMENT
Output
rod
length
PV
senocannot
be
adjusted
as
output
rod
thread
porti on
i s
secured
by
adhesi on
Check
length
Langth
AH
975 1000mm10384
0
394i n
u
1
1
BR109A
2 I f
length
i s not wi thi n
speci fi ca
ti ons
replace
brakebooster
assembly
I nput
rod
length
Adjust lengthby turni ng
clevi s
Length
8
130
mm
5 12
i n
PARKI NG BRAKE
Front cable
BR 16
SBA066
r
j
B
BR110A
I NSTAllATI ON
I i J
M
cyli nder
to
brake
booster
7 8 108N
m
108 1 1
kgm
5
8 80ft
I bl
Brakeboosterto
body
7 8 108N m
108 1 1
kgm
5 8 80
fHbl
I nput
rod
lock
nut
16
22
N
m
116 22
kg
m
12
16
fHb
PARKI NG
BRAKE
REMOVAL
Control
lever
andfront cable
Remove
consolebox
Di sconnect harness connector
Re
movecontrollever
SBR067
2
Remove grommet
rubber
and
lock
plate
Di sconnect cable
adjuster
r
tI J
SBA068
3 Pullfront cable out
i ntodri vers
compartment
SBA069
4
I f
necessary separate
front cable
from
parki ng
brake
lever
by breaki ng
pi n
and
replace
front cable
CAUTI ON
Be
careful
not to
deformor
damage
controllever
Front
cable clevi s
pi n
and cotter
pi n
are
avai lable
as
Hrvi ce
parts
Rear
cable
Di sconnect cable
adjuster
Remove lock
plate
and
strap
or
cable
clamp
SBR071
2
Remove
lock
plate
and
di sconnect
rearcable
from lever
by removi ng
cotter
pi n
BRAKE
SYSTEM
Parki ng
Brake
L
l
SBRQ73
I NSPECTI ON
I Check control
lever
for
wear
or
other
damage
Replace
i f
necessary
2
Replace
wornor
fati gued
spri ng
3 Check wi res for
di sconti nui ty
or
deteri orati on
Replace
i f
necessary
4
Replace malfuncti oni ng warni ng
li ght
orswi tch
5
Check
parts
at
eachconnecti on
and
i f found deformedor
damaged
replace
I NSTALLATI ON
When
i nstalli ng
front cableto
le
r
u
speci fi ed
elevi s
pi n
end
cotter
pi n
I
Apply
acoat
of
grease
to
sli di ng
contact surfaces
2
Adjust parki ng
brake
system
after
i nstallati on
i s
completed
RefertoSec
ti onMA
for
adjustment
BR
17
Servi ce
OataandSpeci fi cati ons
Bf lAKE
SYSTEM
SERVI CE DATA AND
SPECI FI CATI ONS
GENERAL
SPECI FI CATI ONS
I
Type
J
Cyli nderi nner
di e mm
i n
Front
Pad mm
li n
Wi dthx
thi ckness
x
length
I
Rotorouterdi e mm
i n
I
Type
I
Cyli nder
i nner
di e mm
i n
Rear
I
Pad
mmi n
Wi dthx
thi cness
xlength
I
Rotor
outerdi
a
mm
i n
I Ma
ter
cyljnde
i nner
di e
mm
i n
I
Brak booster
type
NP valve
Spli t poi nt
kPalkg
cm2
psi reduci ng
rati o
Di scN22
5398 2
1 8
529x97x762
2083x0382x3
0001
2535
998
Di scAN12
H
40
4611 5929
I
420
x
103x56
8
1 654x0
406
x2236
269 1059
2223 7
8
P75
2452
25
356
x
04
I NSPECTI ON AND
ADJUSTMENT
BRAKEPEDAL
I
Pedal
play
8
I
Depressedhei ght
d
I
Pedal
hei ght h
PARKI NG
BRAKE
1
Pulli ng
force N
kg I bl
I
Numberof
notches
I
Stroke
mm
i n
MASTER
CYLI NDER
I
Allo N8ble clearancebetween
cyli nderand
pi ston
BR 18
Uni t mm
i n
5
004
0
201
Morethan602
36
155 t6t 610634
196 20
441
7 8
90
100
354
3941
mmOnl
Less than
I
015
00059
BRAKE BOOSTER
Maxi mumvacuum
leakage 15s8cond after
engi nei utopped
kPa
mmHg
i nHg
Output
rod
length
A
mmli n
I nput
rod
length S
mmli n
33 25 0
981
9
75 1000
0
3839
0
39371
1305 12
r
r
I W
J
J
I
r
B
BR109A 8Rll0A
CHECKYALYE
Maxi mum
vacuum
leakage 15
seconds
after
267 kPa
200
mmHg
787
i nHg pressure
i s
appli a tJ
kPa
mmHg i nHg
DI SC BRAKE
Type
I tem
I
Pad
wearli mi t
Mi ni mum thi ckness
N22
200079
Rotor
repai r
li mi t
Maxi mumI unout
0
1210
0047
Maxi mum
pal
alleli sm 0
07
0
00281
Mi ni mumthi ckness 105 0413
13
to0391
Uni t mmi n
AN12H
16
100631
015 10
0059
8
60339
BRAKE SYSTEM Servi ceOat1land
Speci fi cati ons
TI GHTENI NG
TORQUE
Uni t
N m
kg
m
ft I b
Braketubeflarenut
15 18 15 18 11
13
I
Brakehose
connector
17 20 17
20
t2
t4
I
Ai r
bleedervalw 69 8
8
07 09 5
1 6
5
Fulcrumpi n fi xi ng
bolt 78 108 08
11 5 8 80
Brakebooster
tobody 7B 108 OB 11 5 8 80
I
nput
rodlocknut 16 22
1
6
22
12
16
Flange
toshell ver
7 8 108 08 11 5 8 8
0
I
Mascyli nder
tobroke
78 108 08 11 5 8 80
booster
I
Front di sc
per
I I XI
I
72
97 7
3
9
9
53
72
bolt
I
Front di scrotor
fi xi ng
36 52 39 5 3
28
38
bolt
Rear
di sc
cali perfi xi ng
38
52
39
5
3
28
38
bolt
Baffleplate
fi xi ng
bolt 22
26 2
2 2
7 18 20
I
Brake
lamp
swi tchlock
12 15 1 2 1 5 9 11
nut
I
3way
connectOr
bol
t
17
20
1 7 20 12 14
I
NP valve
to
body
39
4
9 0405 2
9
36
BR 19
TroubleDi agnoses
and
Correcti ons BRAKE
SYSTEM
TROUBLE
DI AGNOSES AND CORRECTI ONS
Condi ti on
Probable cause
Excessi ve
pedal
travel
Low brake l1ui d levelor
empty
master
cyli nder
reservoi r
Leakage
i nmaster
cyli nder
Deteri oratedcheck
valve
Ai ri n
system
Faulty
brake
adjustment
Excessi ve lateral
play
on di sc caused
by
loose
orworn
wheel
beari ngs
or
steeri ng
parts
Spongy pedal
Low
flui dlevel
i n
mastercyli nder
Ai ri n
system
Faulty
brake
adjustment
Reservoi rfi ller
cap
vent hole
clogged
SwaDen hose duetodeteri orati onoruse
of
poorquali ty
hose
Di storted brake moes orexcessi vely
worn
or
crackedbrakedrum
Soft orswaDen
cali per
seals
Use of a brake l1ui dwi th
too
low
boi li ng
poi nt
Poor
braki ng
effect
Flui d
leakage
i nbrake
li ne
Low brake flui d levelor
empty
master
cyli nder
reservoi r
Ai ri nbrakeli nes
Grease
oi lmudor
water
on
pads
Deteri orati onof
pads
Localfi t
of
pads
Pads
excessi vely
worn
Master
cyli nder
Or
cali per
assembly
i n
poor
condi ti ons
Frozen
orsei zed
cali per
pi stons
on di sC
brakes
Bi ndi ng
mechani cal
li nkage
at brake
pedal
BR
20
Correcti veacti on
Fi llandbleed as
necessary
Test for
source
of
leakage by exami ni ng
aI llmesandconnec
ti ons
Overhaulmaster
cYli nder
Replace
check valveandbleed
system
Bleed
system
Adjust pad
torotor
clearance
I nspect
auto
adjusteroperati on
Replace
or
adjust
faulty
parts
JoP
wi thflui dand
i nspect
fa
leakage
Correct
as
necessary
Adjust pad
torotorclearance
I nspect
auto
adjusteroperati on
Clean and
bleed
system
Replace
hoseandbleed
system
Replace
faulty
parts
Drai n
hydrauli c
system
l1ushwi th
alcohol
andreplace
ai lseals
Replace
wi th
speci fi ed
brakeflui dandbleed
system
Checkmaster
cyli nder
pi pi ng
and
cali per
for
leaks and
repai r
Fi llandbleedas
necessary
Bleed
system
Clean brake
mechani
andcheck for
cause
of
problem Replace pads
Replace
Shaveor
replace
Replace
Repai r
orreplace
Di sa
semble
cali per
and free
up
a
requi red
Free
up
as
requi red
Condi ti on
Unbalanced
brakes
Brakes fade
Brakes
drag
BRAKE
SYSTEM Trouble
Di agnoses
and
Correcti ons
Probablecause
I mproper
ti rei nflati on
I mproper
auto
adjustment
of
pad
torotor
clearance
Grease oi lmudor
wateron
pads
Mudi nrotor
Deteri orati on of
pads
Excessi vewearof
pads
Cali percyli nder
i n
poor
condi ti on
Looseness of
cali perassembly securi ng
bolts
Scored
or
out of
round
rotor
I ncorrect
adjustment
of wheel
beari ngs
I ncorrect
adjustment
of
wheel
ali gnment
Brakel1ui d
has too
low
boi li ng
poi nt
Useof
i mproperpads
Brake rotori s
out of
round
Hydrauli c
connecti ons
mastercyli nder
and
cali percyli nders
arecorroded
or
damaged
Bleed
screwi s
open
Pedal
li nkage
i s
bi ndi ng
or
output
rod
adjust
ment i s too
long
Master
cyli nder
compensatorpart
i s ob
structed
Sei zedmaster
cyli nderpi ston
Poor
padcondi ti on
Poor
cali percyli ndercondi ti on
Deformati onof
pi ston cups
Poor
condi ti on of
cali per
because of
faulty
pi ston
seals
Excessi veronout ofrotor
Handbrakewi llnot
return
Clogged
master
cyli nder
return
port
Clogged
brake
li nes
I ncorrect
adjustment ofwheel
beari ngs
I mproperpad
to
rotorclearance
No
free
travel
i n
brake
pad
return
Correcti veacti on
I nflatetocorrect
pressure
Readjust
Clean brake mechani smand
check forcause
of
problem
Replace
pads
Clean
Replace
Replace
Repai r
or
replace
Fasten
or
replace
Recondi ti on
or
replace
rotoras
requi red
Check for
i mproperpad
contact
wi th
rotor
and
gri ndpad
i f
necessary
Adjust
or
replace
Adjust
Drai n
and
flll
system
wi th
approved
l1ui d
Replace
Repai rorreplaceas
necessary
Repai r
as
necessary
Closescrewand
bleed
system
Lubri cate
li nkage
check
pedal
return
spri ng
for
condi ti on and
adjust output
rodas neces
sary
Blowout
forei gn
matter
wi th
compressed
ai r
Di sassemble master
cyli nder
and
replace
pi ston
Bleed
system
Clean
and
repai r
Repai r
or
replace
Replace
Replacepi ston
seals
Turnrotor
on
lathe
or
replace
Checkand
repai r
Clean
Check
and
clean
Adjust
or
repai r
Adjust
Adjust pedalhei ght
BR
21
Speci afServi ce
Tool BRAKE
SYSTEM
Condi ti on
Brakechatters
Brake
squeal
Pedal
pulsates
Rear
lock
under
li ght
brake
pedal
force
Rearlock
under
heavy
brake
pedal
force
Toolnumber
Kent Moore
No
GG94310000
BR22
Probable
cause
Grooveor out of roundrotor
Loose
orbent
support
plate
Di storted
pads
Greaseor
brake
flui don
pads
Di rty
or
scored rotor
Bend
support plate
Glazedorcontami nated
pad
LateralroDout
of brake
rotor
i s excessi ve
Excessi ve vari ati on
i n thi ckness of
brake
rotor
surfaces
I mproper
ti re
pressures
Excessi vewear
of
ti res
Faulty
NP valve
I mproper
ti re
pressures
Excessi ve
wear
ofti res
Poorfront
braki ng
effect
Grease
oi l
mudor
wateron
pads
Excessi ve
wear
pads
Localfi t
pads
Master
cyli nder
or
cali per
cyli nder
i n
poorcondi ti on
Correcti veacti on
Gri nd
or
replace
as
requi red
Ti ghten support plate bolts to
speci fi ed
torque
or
replace
plate
Replace
as
necessary
Replacepads
Blowout
assembly
wi th
compressed
ai r
or
refmi shrotor
Replace faulty
uni t
Gri nd
pad
toeli mi nate
glaze
I fi t doesn t
replace
pad
Check wi thdi ali ndi cator
turrti ng
di sc
by
hand
I frunout
exceeds
speci fi cati on
repai r
or
replace
di sc
Measure around
di sc
face wi thmi crometer
Replace
di scas
requi red
Check
and
adju
t
Check
and
replace
Replace
Check and
adjust
Check and
replace
Clean or
replace
Replace
Shaveor
replace
Repai r
or
replace
SPECI AL SERVI CE
TOOL
Toolname
Flarenut
torque
wrench
u
I
DATSUN
200SX
Model
SI lO
Seri es
SECTI ONST
STEERI NG SYSTEM
STEERI NG
SYSTEM
STEERI NG WHEEL AND
COLUMN
STEERI NG WHEEL
STEERI NG LOCK
STEERI NG COLUMN
Collapsi ble
type
STEERI NG GEAR ModelVRB47l
POWER STEERI NG GEAR
Model
I P S 56l
AI i I D Oi lPUMP
STEERI NG LI NKAGE
CONTENTS
ST 2
ST 3
ST 3
ST 3
ST 4
ST 6
SERVI CE DATA AND
SPECI FI CATI ONS
GENERAL SPECI FI CATI ONS
I NSPECTI ON AND
ADJUSTMENT
TI GHTENI NG TORQUE
TROUBLE
DI AGNOSES AND
CORRECTI ONS
SPECI AL SERVI CE TOOLS
ST 23
ST 25
ST 21
ST 21
ST 21
ST 22
ST
10
ST 19
a
@
si 1 ll
r
I
t
lon
Steetlng
Vlbeel
1
5
3
8
5
2
21
8
DO
not
stti k
end
of
steeri ni
column
thaft
Wi th
a
tuu
omer
StI lldt
nO
wi ll
dam
age
needle
bea I I D
or
co
uUl
shaft
fi e
cltefu
not
to
di
m
age
cancel
pole
SI d
tOd
em1M
V
1I
54
98
5
5
0
0
40
12
1
0
gnuc
de
nt11l
and
eto
s
rod
Ste
S
column
mount OS
bracl et
B
18
I
1
8
9
B
2
8
9
24
28
0
3
tub
haft
Steeti tll
u
I Y
r
S
56L
52
62
503
6
38
46
0
bOdY
tattle
Steeti ng
eo
umntube
Ne ef
i n
at
case
snou d
UI
4ue
ttt S
be
appli ed
to
stee1
i n
co
utJ
ll
n
al
a
di recti on
Wheni nsu li ns
do
not
ap P
bendi n5
fotc
e
to
tcet n8
column
Q
31
jael et
tube
bt1
c101
34
44
0
35
0
35
045
2
5
3
3
141
81m
3
42
3
2
4
3
23
0
bOdy
tame
tlU lbCl
coupUns
39
49
4
0
5
0
29
36
10
wor1
haft
teerl
nllpt
a
ternbW
Vv
lI 1L
52
62
5
3
6
3
8
46
0
bOdY
frame
cer
52
62
5
3
603
38
46
1l gl
pte
uto
10
I l
d
pi pi ns
1J VI
ute
hot
d
pi pi ns
Si de
tad
bly
11
J
54
9s
5
5
10
0
40
12
ol
nuc d
atm
nd
055
tad
18
98
8
0
0
0
58
12
1
0
KnUc
e
arm
and
ClOSS
tod
Si de
tad
I Y
29
69 3
0
1
0
22
51
to
t
n1C
a
rm
and
ctOS
fod
00
tad
29
69
3
0
1
0
22
51
To
eaI
aun
and
i dle
ann
I ti
Cl
lTI
fft
r
Wi
tj
m
1g
n
I
@
MoI ti
Purl
gteaoi lll
pO
SST
50
St
tlnS
meel
cOlumn
I l
d
oteeri t
S
I
When
temovlng
nd
t
lli ng
di sconnect
laltetY
gtound
ca lle
Eacb
dutt
COvel
nnll
and
i natl1 fi f4
be
ro lleJ
STEERI NG SYSTEM
Steeri ng
Wheel
andColumn
STEERI NG WHEEL
AND
COLUMN
STEERI NG
WHEEL
REMOVAL
I
Di sconnect
battery
ground
cable
2 Remove
horn
pad
and
steeri ng
wheelnut
SST067
3
Remove
steeri ng
wheel
usi ng
Tool
CAUTI ON
Donot stri ke
endof
steeri ng
column
shaft
wi tha hammer
Stri ki ng
shaft
wi ll
damagebeari ng
orcolumnshaft
80001
SST068
I NSTALLATI ON
I nltall
ltaeri ng
wheel
i n the
reverse
orderof removalObserve
the
followi ng
i nstructi ons
I
Apply
grease
to
sli di ng
porti ons
SST069
2
I nstallsteeri ng
wheel
on column
shaft i n a
strai ght
ahead
posi ti on
SSTU70
3
Ti ghtensteeri ng
wheelnut
lJ
n51 N
m
13B 5
2
kg
m
27 38
ft lb
SST071
4 After
i nstalli ng steeri ng
wheel
bJm i t clockwi se
and
counterclock
wi se
checki ng
forcatchor
drag
Also
check
horn
operati on
STEERI NG LOCK
REMOVAL
Before
removi ng steeri ng
lock di s
connect
battery ground
cable
I Remove
steeri ng
wheel
usi ng
Tool
8T27180001
2 Remove
steeri ng
column shell
cover
y
1
Upward
I gi
I i
SST072
3
Break
selfsheartype
screws
wi th
a
dri llorother
appropri ate
tool
4
Remove screws and
di sconnect
steeri ng
lock
Self
shear
type
screw
Screw SST073
I NSTALLATI ON
I
Ali gnsteeri ng
lock
holei n
steeri ng
column tube
wi th
mati ng
porti on
of
steeri ng
10cL
2
I nstallscrews and
self
shear
type
screws and thencut off
self
shear
type
screwheads
V
V
Selfshear
screw
SST074
ST3
Steeri ng
Wheel
and
Column STEERI NG SYSTEM
STEERI NG
COLUMN
Collapsi ble
tYPe
Steeri ng
column
asRmbly
Never
i n
any
case should
undue
stress be
appli ed
to
steeri ng
column
i n
axi aldi recti on
When
i nstalli ng
donot
applybendi ng
forceto
steeri ng
column
fJ 37 51
38
S
Steeri nj
k
Cn tte
Steeri ns
eel
oolw
Jacket
tubebracket
fJ 3
4 44
035 0
45
2 5
To
dash
panel
Cnupli nj Plat
j
fJ 39
49
40
5
029 36
Towormshaft
@
N
m
kj rn
ft
Jb
SST125
REMOVAL
I
Di sconnect
battery ground
cable
2 Remove
bolt
securi ng
stub shaft
orwormshaft and uni versal
joi nt
or
rubber
coupli ng
al
SST076
3
Remove
steeri ng
wheel
Refer
to
Steeri ng
Wheel
ST 4
S
eeri llj oolumn
bly
ti J 13 18 131
8
9
13
To
i nstrument
panel
16
4
Remove
steeri ng
column shell
covers
5 Remove combi nati on swi tchas
sembly
Steeri llj
oolumn
aaembly
Column
band
Z32
38 3 3
3
9 24 28
Tostub
shaft
Modell P
S 56L
only
6
Remove
heaterduct from dash
panel
si de
SST078
I
7 Remove
jacket
tubebracket
from
dash
panel
J
SST079
8 Remove
bracket
column mounti ng
p
j
I
or
SST139
9
Drawout
steeri ng
column assem
bly
fromroom
si de
I NSTALLATI ON
I nstall
steeri ng
column
i n
reverse
orderof removal
I Remove column band and then
i nstall
centeri ng
band
lP
S 56L
equi pped
model
only
@
Centeri ng
band
SST126
STEERI
NG SYSTEM
Steeri ng
Wheeland
Column
2 Set
wheels i n
a
strai ght
ahead
posi ti on
3 Fi t
steeri ng
column
assembly
on
tostub
shaft
or
worm
shaft
Carefully
i nstall
so
that
punch
mark
at
top
ond of column haft fece
upward
4
Ti ghten
stub shaft
orworm
shaft
securi ng
bolts
temporari ly
to
upport
upper
si de
of
steeri ng
column
assem
bly
5
Ti ghten
column
mounti ng
bracket
temporari ly
6 After
sli di ng jacket
tube bracket
to
dash
panelti ghten
nuts toretai n
i t
I i l
34 44N m
035 0
45
kg m
2 5 33
ft I bl
7
Ti ghten
stub
shaft orworm
shaft
securi ng
bolts
andthen
ti ghten
column
mounti ng
bracket
securi ng
bolts
JJ
Worm
shaft to
coupli ng
Model
VRB4711
39 49N m
405 0
kg
m
29 36ft I bl
Stub shaft touni versal
joi nt
ModellP S
56Ll
32 38N m
33 39
kg
m
24 28ft
I bl
Column
mounti ng
bracket
13
18N m
1 3 1 8
kg
m
9 13ft
I bl
CAUTI ON
I Mi keRi fethat
I ny
undue
strea
i s
not
I ppli ed
torubber
coupli ng
b ToI voi d
dlmlgi ng
bolt orserrl
ti ons
ali gn
groove
i n stub shaft or
wormshaft wi thbolt holei n rubber
coupli ng
9 Remove
centeri ng
band
and then
i nstall
column band lP S 56L
equi pped
model
only
10I nstall
steeri ng
wheel
Referto
Steeri ng
Wheel
8 After
i nstallati on
make
surethat
steeri ng
wheel
turns
smoothly
I NSPECTI ON
I When
steeri ng
wheel
can
not be
rotated
smoothly
check the
steeri ng
column for
the
followi ng matters
and
replacefaulty parts
I
Check column
beari ngs
fordarn
age
orunevenness
I f
so
lubri cate
wi th
recommendedmulti purpose
grease
or
replace
wi th
a
new one as
steeri ng
column
assembly
2
Check
jacket
tube fordeforma
ti onor
breakage
and
replace
i fneces
sary
3
Check column
spri ng
and
replace
i f
damaged
or
weakened
2 When the carcomes i nto
li ght
colli si on check the
followi ng parts
and
replace
i f
necessary
I
Jacket tube
Measuredi mensi on
L
When
jacket
tube
i s crushed
di mensi on
L
i sreduced
tL1
LL F
J
Column
length
L
ModelVRB47L
179
mm
705 i n
ModoI I
P S 56L
180mm7 09i n
SSTOBO
2 Column
mounti ng
bracket
Make sure column mounti ng
bracket touches
block
Standard
B di mensi on i s
0mm 0
i n
When
jacket
i s crushed di mensi on
B i s
i ncreased
jg
ST835
ST
5
Steeri ng
Gear
ModelVRB47L
STEERI NG SYSTEM
m
STEERI NG GEAR Model
VRB47L
Lo
5 314 25 32 181
231
Oi l
I
Removed
oi l
sealmust not beused
agJ
l1L
Adjusti ns
Pi lla
When
adjust
wonn
beari ng
preload
usei t
BaD nut and worm
assembly
Be
a
rcful
not toallowballnut torun
downtoei ther
end
of worm
Theend ofba1l
gui des
wi llbe
lamag
i f nut
i s
rotated
unti li t
stops
at
the
em
of wonn
Donot
detachball
nut fromwormshaft
assembly
I f
necessary replace
ballnut andworm
assembly
wi th
sector
shaft
Lock nut
cp 29
39130
4
022
29
F
d1erpl l1
J
15 25
15 25
11 18
SeetorsI WlCOV
vto
0
rt J
Goskel
Adjustm
shi m
Refer
toS O
S
Sector
shar
adjusti ng
saew 0
When
adjusti rj
backla husei t
Sectormaft
Steeri ng gearhousi ng
147
15 94 108
REMOVAL
AND
I NSTALLATI ON
Wormshaft
to
rubber
coupli n
IJ 39 49
40
5 029 36
Ali gn
the
groove
i nwormshaft
wi th
thebolt
holei nrubber
coupli ng
flange
yoke
and
prcssooupli ng
bolt
through
the
undercut secti on of wonnshaft
Undercut secti on
1
Sectorshaft to
i dler
arm
IJ
127 147
13 15
94 108
Removegear
arm
Sf29020001
I nstall
gear
arm
Ali gn
four
grooves
of
gear
arm
serrati ons
wi thfour
projecti ons
of sectorshaft
serrati ons
and
i nstall
and
ti ghten
lockwasher
andnut
ST 6
IJ
N
m
q
mft I b
SST081
Gearhousi ng
toframe
1J52
62
5
3
63 38 46
IJ
N
m
qm
ft
I b
SST082
DI SASSEMBLY
Before
di sassembli ng by
hand
make
sure
external
i s clean and free
from
dust
and di rt and
thoroughly
drai n
gear
flui d
by removi ng
fi ller
plug
1
Place
steeri ng
gear
i n a vi ce
usi ng
ToolKV48100301
i n
place
2 Set
wormgear
i na
strai ght ahead
posi ti on
ST725
3 Remove sector
shaft cover
fi xi ng
bolts
KV48100301
4f
L
4 Remove sectorshaft
wi thsector
shaft cover
CAUTI ON
a When
pulli ng
sectorshaft out
be
carefulnot to
damage
oi lsealor
associ ated
parts
b
00not
removesector
shaft needle
beari ngs
from
steeri ng
gear
housi ng
I f
necessary replace gearhousi ng
assembly
STEERI NG SYSTEM
Steeri ng
GearModel
VR847L
7fY
0
SST083
5 Remove sectorshaft coverfrom
sectorshaft
6
Remove sector
shaft oi l
seal i f
necessary
SST084
7 Loosen
adjusti ng plug
lock nut
usi ng
Tool
SST085
8 Draw out
worm
gear
wi thworm
beari ng
CAUTI ON
a Be carefulnot toallowballnut to
run down toei ther
endof
worm
Ends of
ball
gui des
wi llbe
damaged
i f nut i s unti li t
stops
I t
end
of worm
b Do
not detachballnut
fromworm
shaft
assembly
I f
necessary
replace
enti reuni t as
en
assembly
c Donot remove
sector
shaft
needle
beari ngs
from
steeri ng
gear
housi ng
I f
necessary replace
enti re
gear
housi ng
I San
asSembly
SST086
9
Remove
oi l
sealfrom
adjusti ng
plug usi ng
Tool
ST35322000
SST087
ASSEMBLY
AND
ADJUSTMENT
Before
assembli ng
and
adjusti ng by
hand meke ure each
pert
i
elean
and
lubri cate wi th
geer
flui d
Fi ll
paee
between
I i ng
li p
of
new ctorhft and
adju ti ng plug
oi l 1 wi thrlI COmmendad
multi
purposegrease
ST7
Steeri ng
Gear
fModel
VR847U STEERI NG
SYSTEM
Wormbeari ns preload
1
Fi t worm gearassembly
wi th
worm
beari ng
i n
gear
housi ng
SST088
2 I nstall
adjusti ng
plug usi ng
Tool
KV48101400
3
Adjust
worm
beari ng
preload
usi ng
Tools
CAUTI ON
Always adjust
worm
beari ng preload
by turni ng adjusti ng plug
i n
ti ghten
di recti on
Rotate wormshaft a fewturns i n
bothdi recti onstosettle down
worm
beari ng
and
measure
preload
Wormbeari ng preload
wi thoi lsean
039 059N
m
4
060
kg
em
35 52 lb
4
Apply
sui table
li qui d
sealant
around
lock nut i nner
surface
Apply
sealant
Adj usti ng plug
Locknut
SST090
ST 8
5
Ti ghten
lock nut
usi ng
Tooh
KV48101500
KV48101400
SST091
6
After
ti ghteni ng
lock
nut
check
worm
beari ng preload
to
make sure
i t i swi thi n
speci fi cati on
Sectorshaft
end
play
Select sui table
adjusti ng
shi m and
adjust
end
play
between sectorshaft
and
adjusti ng
screw
Sector
shaft
adjusti ng
screwshi ms
RefertoS OS
Adjusti ng
hi m
Upper
I
sector
cover
si de
Sectorshaft end
play
OOl003mm
100004 00012 n
Steeri ng gearpreload
I
Press oi lseal to
steeri ng
gear
housi ng usi ng
Tool
Before
pressi ng
oi lseal coat seal
contacti ng
face
of oi lsealwi th
gear
flui d
2
I nstallsectorcover
oi l
adjusti ng
screw
wi th
sectorshaft
Adjusti ng
screw
SST094
3
Set
worm
gear
i n a
strai ght
ahead
posi ti on
4
I nsert sector
shaft
and sector
cover
assembly
wi th
gasket
i nto
gear
housi ng
Carefully
i nsert
sectorshaft
i n
place
usi ng
carenot toscratchoi lseal
5
Ti ghten
sector
cover
to
gear
housi ng
f
1i J15
25 Nm
11 5 25
kg
m 11
6 Pourrecommended
gear
oi li nto
assembly through
flllerhole
and
i nstallftller
plug
Speci fi ed
refi ll
capaei ty
Approxi metely
028
li ter
5
8US
pt
112
I mp
pt
7
Ti ghten
adjusti ng
screw
sothat
gear
preload
i s wi thi n
speci fi cati on
CAUTI ON
Always adjust
steeri ng gearpreloadby
turni ng adjusti ng
screw i n
ti ghten
di recti on
Rotate
worm
gear
a
fswturn i n
bothdi recti onstosettledown steeri ng
gear
and then measure steeri ng
gear
preload
i na
strei ght lhead
posi ti on
LScrewdri ver J
Steeri nllli lear
totalpreload
wi thoi l 1
Lessthan
1 23N
m
12
5
kg c
m
109i nI b
04 06N
m
46
kll cm
3
5 5
2
i n
I b
hi gher
than
at
worm
beari ng
prai a
SST097
8
I f
found
to
be
outsi de
of above
steeri ng gearpreload
speci fi cati ons
readjust
adjusti ng
screw
unti lcorrect
steeri ng gearpreload
i s
obtai ned
I NSPECTI ON
Washclean allthe
di sassembled
parts
i n solvent and check forcondi
ti on
STEERI NG SYSTEM
Steeri ng
Gear
ModelVR841Li
Sectorshaft
Check
gear
tooth surface for
pi tti ng
burrs cracks or
any
other
damage
and
replace
i f
necessary
2
Check sectorshaft fordi storti on
on
i ts serrati on and
replace
i f neces
sary
Also
check
gear
housi ng
for
deformati on
Steeri ng
worm
assembl
I
I nspect
ball
nut
gear
tooth
sur
face and
teplace
i f
pi tti ng
burrs
wear
or
any
other
damage
i s found
2 Ball
nut
must rotate
smoothly
on
worm
gear
I ffoundtoo
ti ght
assem
bly
should
be
replaced
Check
rotati on of ball
nut
as
follows
I Move
ball
nut to
ei ther
end
of
worm
gear
and
gradually
stand
wormshaft andballnut
assembly
unti l
ballnut moves downward on
worm
gear
under
i ts
own
wei ght
Downward
J
own
wei ght
SST098
2
I fballnut
does not
move
freely
over
enti re stroke
replace assembly
Be carefulnot to
damage
ballnut
gui de
tubawhi I e check i s
bei ng
made
CAUTI ON
Becaraful
not to
allow
ball
nut torun
downtoei ther
endofworm
Beulng
I
I nspect
worm
beari ng
forwear
pi tti ng
or
any
other
damage
Replace
as
requri ed
When
replaci ng
worm
beari ng
replace
i t as 8 set
of
beari ng
and
outer
race
2
I fsector
shaft needle
beari ngs
are
worn
ordamaged
replace
as an as
sembly
of
gear
housi ng
and
beari ngs
Oi leal
Di scard
any
oi lsealwhi ch
has
once
been removed Replace
oi lseali f
seali ng
li p
i s deformed
or
cracked
Alsodi scard oi lseali f
spri ng
i s fa
ti gued
ordi slocated
ST 9
Power
Steeri ng
lear
ModelI P S 56L andOi l
PUTflP
STEERI NG
SYSTEM
POWER STEERI NG
GEAR
Model
I
P S 56L
AND OI L PUMP
DESCRI PTI ON
Po
r
steeri ng
s stem
The
power
steeri ng gear
i s
li censed
I 1Y
ZF
company
i nWest
Germany
The
i ntegral
power
steeri ng
uni t
i s
a
gearhousi ng
i nto
whi ch
a
controlvalve
2pool
valve
type
and
power
cyli n
der
are
bui lt
compactly
The
major
Reservoi rtank
cfl2 9
4
9
03 05 2
2
3
6
components
areas
folloW
Oi l
pump
Reservoi r
tank
Power
steeri ng
gear
Oi l
pi pi ng
cfl
32 38
3 3 3 9 24
Tostub shaft
Gearassembly
cfl
49 69 5 07 036
51
To
each
hoses
cfl52 6i 5 3 63 38 46
To
body
frame
Hi ghpressure
hose
andpi pi ng
cfl
2 9 4 9 03
05
22
36
To
suspensi on
aossmember
cfl
N
m
kg
mft tb
Power
steeri ng
gear
Thei ntegral
powersteeri ng gear
i s
an accurate oi l
pressure
mechani sm
I n
di sassembli ng
i t be carefulto
keep
dust i ron
powder
and other
forei gn
parti cles
out ofthe
gear
housi ng
Only
the
seali ng parts
of the
gear
assembly
can be
replaced
The
remai n
i ng parts
must
be
replaced
as an
gear
assembly
ST10
CAUTI ON
a The
parts
whi ch
can
be
di sassem
bled are
strongly
J and
never
di sassemble
other
parts
than
the
speci fi ed
ones
I f
parts
not
i ndi cated i n the manualare also
d I ed
replace
the
assembly
i nstead of
bli ng
those
parts
b
Di sassembly
of
i ntegral
power
steer
i ng gear
should be
performed
i n
a
place
l5
dean
as
p
ssi ble
although
a
dust
preventi ng
devi ce
i s not reo
qui red
SST12T
Co
Should
di sassembly
of
i ntegral
powersteeri ng
gear
remai n un
fi ni shed
for
any
reason
i ndi catei t
as Half Di sassembled
andCOVllr
parts
wi tha
cleancover
d Hands should
be
cleaned
i mmedi
ately
before
di sassembly
e Donot use a
rag
Be
sure
touse
nylon
or
paper
cloth
f Be sure to
followprocedures
and
cauti ons
i ndi cated i n the
Servi ce
Manual
STEERI NG SYSTEM
PowerSteeri ngGear
ModelI
P S
56L
andOi lPump
Breather
screw
il
6
9
88
0
7
Breather
cap
Sectorshaft
adjusti ng
screw
Sectorshaft
Wormend
nlve
mbly
Wi th
i nterm t
i te
covl
ru
2
7 3 3
20
24
0i l1e3
1
I n
rearcover
Onceremoved
must not beused
agai n
il
N
m
I cg
mft lb
011
pump
andrvolr
tank
Malfuncti oni ng
Replace
as an oi l
pump
assembly
I
Ori ng
lock nut
cf
il
28 34 2 9
3
5 21 25
Copper
washer
@
il26 32
J
V
2
7 3 3 20
fi ll
@
24
Ori ns
Between
sector
coverto
gear
housi ng
o
o
Speci al
washerSmall
OUseal
0
Speci al
washer
La I Jle
DUst
sea1
apri ng
ospri ng
washer
Nut
ItY
il127 147 13 15
94 108
To
gear
armandsectorshaft
SST033
STll
REMOVAL
Power
Steeri ng
GearModel
I P
S 56L andOi l
Pump
STEERI NG SYSTEM
Before
removi ng
clean exteri on
of
gear
housi ng
and oi l
pump
wi thsteamand
dry
wi th
compressed
ai r
Steeri ng gear
Joi nt
to
stub shaft
tJ
32 38 3 3 39 24 28
SectorsI WI
to
sou
ann
tJ
127
147 13
15 94 108
i
I nstall
gear
arm
Ali gn
fOUI
grooves
of
gear
arm
serrati ons wi thfour
projecti ons
of sectorshaft
serrati ons
and
i nstall
and
ti ghten
lockwasher
and
nut
Oi l
pump resevoi r
tank
and
each
hose
1
Removeai rduct
at
ai rcleaner
2
Loosen oi l
pump pulley
lock
nut
Turn belt
adjusti ng
bolt
counter
clockwi se
3
Removeoi l
pump
belt
4
Loosen
not
remove hoses
at
pump
ST 12
5
Remove
oi l
pump
and
reservoi r
tank
51
j1
Plug openi ngs
of
gearhousi ng
and
securely
locatehose
connectors
at a
posi ti on hi gher
than
oi l
pump
and
cover
wi th
rag
Beextremely
cucful
to
prevent
entry
of
forei gn
matter
i nto
hoses
through
connectou
tJ
N
m
kg m fHb
R
g poi nts
SST128
6 Di sconnect
hoses fromoi l
pump
7 Remove oi l
pump
brackets
and
other
brackets from
engi ne
8 Unfasten
hose
clamps
and
remove
hosesfrom
suspensi on
crossrnember
I NSTAUATI ON AND
ADJUSTMENT
I n
tall
steeri ng gear
i n
the reverse
orderofremoval
STEERI NG SYSTEM
Power
Steeri ng
Gear
ModelI P
S
56LJ and
Oi l
Pump
Flui d level
I
Check
flui d level
i n oi l
pump
assembly
wi th
di psti ck
whetherflui d
level
i s onHOT si de
at normal
operat
i ng temperature
or
on COLD
si de
when oi li scold
1
llllllm Add I OK
4
Q
OK
SST133
Donot
overfi llwi thflui d
Nanna
operati ng temperature
i 60
to8o
C 140to
1760F
When
runni ng engi ne
make
sure
flui d level
vari ati onsi n
openi ng
oi l
pump
ere
I e
than2 mm 008i n
2
Check
flui dleveland
leakage
Recommended flui d i s Automati c
Transmi ssi on Flui d Oexron
Type
RefertoSeeti on MA
forRecom
mended Lubri cant
Flui d
capaci ty
wi thoi l
pump
reservoi r
tank
eachhose and
steeri ng gear
assembly
Approxi mately
1 2
1 1 4US
qt
1 118
I mp qt
Pump
belt
edJustment
Adjust
oi l
pump
belt
tensi on
Pump
belt adjusti ng
bolt
Thumb
pressure
911Nj10kg
221b
71
I
Lock
nut
G
I J
I
Oi l
pump
belt deflecti on
8
12
mm
10
31 OA7 i n
SST134
Check flui d
leekege
I Run
engi ne
at i dle
speed
or
1
000
rpm
2 Turn
steeri ng
wheel
to
ri ght
to
left
several
ti mes
3
Hold
steeri ng
wheel
at
each
lock
posi ti on
forfi veseconds and
carefully
check the
followi ng
poi nts
forflui d
leakage
Oi lsealat rearcover
I ntermedi atecover
Adjusti ng
screwlock nut
Sectorshaft
oi l
seal
SectorcoverO
ri ng
Oi l
pressure
li neconnectors
e
Oi l
pump
and
reservoi rtank
CAUTI ON
Donot hold
steeri ng
wheelat
lock
posi ti on
formorethi n
fi fteenseconds
I t I ti me
Hydreuli c
system
check
Todetermi ne whether
problem
i s
i n
steeri ng gear
oroi l
pump
measure
operati ng
pressure
Before
conducti ng hydrauli csystem
test
carefully
check belt tensi on and
condi ti onof
dri vi ng pulley
Ti res must be i nflated tonormal
pressu
reo
I Check
flui d leveland
flui d leak
age
addi ng
oi li f
necessary
2 Run
engi ne
Make
sure
temperature
of flui
d i n
pump
ri ses to60to
800C
140
to
1760F wi th
a
tamperature
i ndi cator
3
Stop engi ne
4
Set
Tool
Gauge
must be between
shut
fl
valve
and oi l
pump
Pressuregauge
cali brate
9807
kP
100
kg
em2
1 422
psi
Tocontrol
t
valve
Y
To
oi l
pump
outlet
f
STi 7091000
Shut offvalve
SST036
5
Open
shut off
valve
at Tool
ST27091000
6
Check flui d level
addi ng
flui d i f
necessary
7
Run
engi ne
at
i dle
for3to5
seconds
8
Stop engi ne
and check flui d
level
addi ng
flui d i f
necessary
9 Run
engi ne
and check
flui d level
agai n addi ng
oi li f
necessary
10Turn
steeri ng
wheel
fully
i n left
or
ri ght
unti lflui dreaches
operati ng
temperature
Be
sure that all
connecti ons are
ti ght
Expelany
ai rfrom
system
I I
Slowly
close shut
off valve wi th
steeri ng
wheel
fully
turned i n left or
ri ght
and
li ghtly
touchwheel
stopper
CAUTI ON
Do
not close shut
off
valve
for
more
thi n
fi fteen
seconds as thi s would
abnormally
i ncrease lubri cant tem
perature
and
causeundue
pump
wei r
Wi lhvalve
fully
closed
pump
pres
sureshouldbeat
maxi mum
Normal
preuure
About 5 394
kPa
55
kg
cm2
782
psi
at
i dli ng
ST
13
Power
Steeri ng
Gear
Model
I P
S 56LJ
andOi l
Pump STEERI NG SYSTEM
12 I f
pressure
i ncreases
beyondupper
li mi t
pressure
reli ef valve
i n
oi l
pump
i s not
functi oni ng properly Replace
as
oi l
pump
assembly
13
I fwi thshut offvalve
fully
closed
pressure drops
the
problem
i s i n
pump Replace
as
oi l
pump assembly
pump assembly
After
checki ng hydrauli c system
addflui d
as
necessary
then
complete
ly
bleed
ai rout of
system
Bleedi ng
hdraullc
s
stem
I
Rai sefront end
ofcar
unti lwheels
clear
ground
2 Run
engi ne
Make
lure
temperature
of flui d
i n
pUmp
ri ses
to
60
toBOOC 140to
176
o
F wi thB
temperaturei ndi cator
3 Check
flui d level
addi ng
flui d
i f
nece
sary
4
Run
engi ne
for
3
to
5
seconds
5
Stop
engi ne addi ng
flui d
i f nes
sary
6
Qui ckly
turn
steeri ng
wheelallthe
way
to
ri ght
and left
ten ti mes end
li ghtly
touchwhee
stoppen
7 Check flui dlevel
addi ng
flui d
i f
necessary
8 Start
engi ne
at i dle
Repeat
steps
4
through
8
unti lai r
wi llbe bled
from
pump
9
Wi th
steeri ng
wheel
fully
turned
toleft
open
bleeder
screw to
expel
ai randthen
ti ghten
bleederscrew
ST 14
I
I
SST137
Operati on
should be
perfonned
maki ng surethat flui dleveli s
kept
wi i n
speci fi edli mi t
Repeat
thi s
operati on
unti l ai r
bleedi ng
i s
completed
10
I f
ai r
cannot
be
bled
completely
i n
steps
1
through
9
proceed
as fol
lows
I Wi th
engi ne
runi ng
at 1 000to
1 500
rpm repeat step 9
2
Turn
steeri ng
wheelto
ri ght
and
left
from lock to lock fi ve toten
ti mes
Carefully
check flui d
leakage
wi th
steeri ng
wheel
held at eachlock
posi ti on
forfi veseconds
CAUTI ON
00
not hold
steeri ng
wheel
at lock
posi ti on
for
morethan
fi fteen
seconds
at a ti me
Steeri ng
wheel
turni ng
torque
check
I
Park caron
a level
dry
surface
andset
parki ng
brakefi rmly
2
Bri ng powersteeri ng
flui d
up
to
adequate operati ng temperature
Ap
proxi mately
60to80C 140to
1760FI I
I t
i s
easy
to
bri ng powersteeri ng
flui d
up
to
adequate operati ng
tern
perature by i dli ng engi ne
andat the
same
ti me
turni ng steeri ng
wheel
from left
to
ri ght
forabout two
mi nutes
Alternati vely
dri ve
car
severalmi les
Ti res
must be i nflatedtonormal
pressure
3 Check
steeri ng
wheel
turni ng
tor
que
when
steeri ng
wheelhas been
turned 3600
from
strai ght
ahead
posi
ti on
Steeri ng
wheel
turni ng
force
294 343N
3035
kg
6
6 7 7 I b
at
ci rcumference
of
steeri ng
wheel
SST13B
I NSPECTI ON AND
ADJUSTMENT
Washdean alld bled
parts
i n sui table
cleani ng
solyent
andch k
thejr
condi ti on
Check
Seali ng
porti on
Adjusti ng
screwnut O
ri ng
Sectorshaft coverO
ri ng
Sector
sl1aft
oi lseals
Rear
housi ng
oi lseal
I ntermedi atecoverQ
ri ngs
Di scard
any
oi lsealand
O
ri ng
whi chhaveoncebeen removed
Replace
oi lsealandO
ri ng
i f
seali ng
surface
i s
deformedorcracked
Steeri ng gearturni ng
torque
measurement
I Measure
turni ng torque
at
3600
posi ti on
I I nstall
steeri ng gear
onTool
SST040
2
Turn stub
shaft allthe
way
to
ri ght
andleft several
ti mes
3
Measure
turni ng
torque
at
3600
posi ti on
from
strai ght
ahead
posi ti on
usi ng
Tool
4
m
Stub shaft
can
be
turned
by wrap
pi ng vi nyltape
around serrati on
area
of stub shaft and
fi tti ng
wrenchlOcket
I f i t i s
beyond speci fi cati on gear
must be
replaced
as
an
assembly
2 Measure
turni ng torque
at
strai ght
ahead
posi ti on
I Set worm
gear
i na
strai ght
ahead
posi ti on
Strai ght ahead
posi ti on
i s
8posi ti on
where
stub shaft
i s
turned twoturns
by
450fromlock
posi ti on
2 Measure
turni ng
torque usi ng
Tool
Turni ng
torque
at
strei ght
h
d
posi ti on
il
010039N m
1 4
kg cm
09 35 i nlb
hi gher
than t 3600
LJJ
5 After
adjustment
i s
completed
ti ghten
lock nut
STEE I NG SYSTEM
Power
Steeri ng
Gear
Model
I P S
56LJ
andOi l
Pump
I
il
28 34Nm
12
9 35
kg
21 25 h
I bl
SST043
Measure
turni ng torque
I f
they
are
not wi thi n
speci fi cati ons
replace
gear
assembly
DI SASSEMBLY
Before
di sassembly
measure
turn
i ng torque
I f
they
are not wi thi n
speci fi ca
ti ons
replacesteeri ng
gear
assembly
CAUTI ON
Each oi l
seali ng parts
dust seal
speci al
washers and
snap ri ng
once
removedmust not beused
agai n
AdJusti ng
screwlock nut se
1
Remove
adjusti ng
screw lock nut
and
replacea
ri ng
O
mg
Lock
nut
Copper
washer
SST044
Sectorshft 011 se 1
I
I nstall
steeri ng gear
on Tool
KV48l00301
2
Set stub shaft
i n a
strai ght
ahead
posi ti on
Strai ght
ahead
posi ti on
i s8
posi ti on
where
stub shaft i s turned twoturns
by
450fromlock
posi ti on
3
Di sconnect
sectorshaft
cover
bolt
Donot loosen
adjusti ng
screwlock
nut
Donot turnlock nut unless
neces
sary
otherwi se i t wi ll
damage
O
ri ng
resulti ng
i nan oi lleak
J
4
Drawout sectorshaft
Knock out end of sectorshaft
approxi mately
20mm 079i n
20mm
079
nl
SST046
5
Connect a rollof
plasti c
fI lm
to
sectorshaft
Plasti cfi lm
Thi ckness 01
mm
0004i n
Length
x wi dth
200x 200mm 7 87 x 7 87 i n
1
Plasti cfi lm
SST065
ST
15
PowerSteeri ng
GearModel
I P S 56LJ end
Oi l
Pump
STEERI NG SYSTEM
6 Pui I out sectorshaft
by
hari d
Attachplarti e
fi lmtotwo
beari ngs
locat
ed
i nsi de
gearhousi ng
whi le
si muttaneously
pulli ng
out sector
shaft
so
that
beari ngs
wi llnot
drop
i nto
housi ng
7 Remove
snap
ri ng
fs
SSTQ47
8
Remove dust seal
speci al
wash
ers andoi lseal
Apply
blade of
screwdri ver
tooi l
sealI
i ghtly
sothat i t wi llnot
damage
i nnersi de
of
gearhousi ng
0
Speci al
washerA
Smai l
n
Oi lsea
L4i
d
Speci al
ru
lL
B
Dustseal
w
snapri ng
SST048
9
Removea
ri ng
SST049
ST
16
Rearhousi ng
seal
I nstall
gear
on
Tool
KV48l00301
i n
a
vi se
2 Loosen
not remove rearcover
bolts
ST697
3 Turn sector
shaft
clockwi sesli ght
ly
torai se
i ntermedi ate
cpver
through
pi ston
Q
g
I
I J
t
I
SST050
4
Turn
stub shaft
counterclockwi se
and
place pi ston
worm gear
i n i ts
strai ght
ahead
posi ti on
S Remove
sectorshaft
RefertoSeetor
Shalt Sealfordi sas
sembly
6
Removerearcover
bolts
7 Pullout rearcover
i ntermedi ate
coverwi thworm
gear
assembly
ST700
CAUTI ON
a When
worm
assembly
i s removed
pi ston may
turn and
come off
underi U
own
wei ght
Hold
pi ston
to
prevent
i t from
turni ng
I f
pi ston
toi ntermedi ate
cover
clearance
exceeds 45 mm 1 77 i n
by looseni nll
reci n ulati ng ballwi ll
be out
of
groove
ofworm donot
rei nstall
pi ston
but
replace
theen
ti re
assembly
b Takecarenot
to
damage
tellon
ri ng
at
pi ston
endwi len
removi ng
8 Remove
rearcoverturnwormas
sembly upsi de
down and
li ghtly tap
stub shaft end on
top
of workbench
CAUTI ON
Do
not stri ke
shaft
wi tha hammeror
pry
i t wi tha
screwdri ver
ST701
9
Remove
rear
housi ng
oi lseal
ST702
STEERI NG SYSTEM
Power
Steeri ng
GearModelI P S 56LI
and
Oi l
Pump
10
Remove O
ri ng
on
bothsi des
of
i ntermedi ate
cover
I ntermedi ate
cover
SST051
ASSEMBLY
AdJusti ng
screwlock
nut se 1
I nsert
new a
ri ng
i nto
adjusti ng
screwlock nut
Before
i nserti ng apply
a
thi n
coat
of vaseli neto
O
ri ng
I nort
C
ri ng
tomake
sure
i t fi ts
i nto
groove
r
o
ri ng
L
Adjusti ng
screw
locknut
SST052
Rerhousi ng
se 1
I
I nstall
rear
housi ng
oi lseal
usi ng
Tool
Before
i nstalli ng
oi lseal
apply
recommended multi
purpose greM
to
li ps
SST053
2
I nstall
O
ri ngs
on
both
si des of
i ntermedi atecoverwi thnewones
Apply
a thi n coat of vaseli ne
to
new
C
ri ngs pri or
tothei r
i nstalla
ti on
Be carefulnot to
i nstall
wrong
O
ri ngs
as
some of them
resemble
i nsi ze
t J
SST054
3 Fi t rearcoveronto
i ntermedi ate
cover
wi th
worm
gearassembly
CAUTI ON
a
Donot ti lt ball
beari ng
b
Makesurethat O
ri ngs
arenot
pro
trudi ng
or
extrudi ng
ST705
4 I nsert worm
gear
assembly
wi th
rearcover
and
i ntermedi ate cover
i nto
gearhousi ng
CAUTI ON
a
Be carefulthat teflon
ri ng
at
pi ston
end i s
not
damagedduri ng
i nserti on
of
gearhousi ng
b When
worm
assembly
i s
halfway
i nserted
teflon
ri ng
i s deflected
I nsert
remai ni ng part
of wormas
sembly payi ng parti cular
attenti on
Take carenolto
damage
teflon
ri ng
oncorner
of
sector
hole
Be surethat
teflon
ri ng
settlesi n i ts
correct
posi ti on
5
Gradually ti ghten
rear
housi ng
boltsi n a cri ss
cross
fashi on
Cri ss cross fashi on
SST055
ST
17
Power
Sreeri ng
Gear
ModelI P S
56LJ
and
Oi l
Pump STEERI NG
SYSTEM
CAUTI ON
L
I f
bolts are
ti ghtened
whi le
wonn
assembly
i s ti lted i nner
seals wi ll
be
dam8lll
d
Ti ghten
bolts whi le
assembly
i s level
I f
wonn
assembly
i s ti lted
stub
shaft
s
turni ng torque
wi llbe i n
creased
b Check
O
ri ngs
toensurelhat
they
do
not
protrude
orextrude
6
I nstallsectorshaft
i nto
gear
hous
i ng
RefertoSectorShaft Oi lSealfor
assembly
7 Check
turni ng
torque
Referto
I nspecti on
and
Adjust
ment
Sectorshaft 00se 1
I
Press new
oi l
sealanddust cover
usi ng
Toot
When
i r
stalli ng
be
lure
to
usenew
oi lseal
dust cover
and
speci al
washen
Before
i nstalli ng apply
a
thi n coat
of vueli netonewoi lsealand dust
seal
Speci al
washer
Small
00
SST056
ST 18
2 I nstall
a new
snap
ri ng
i nto
gear
housi ng
CAUTI ON
a
Turn
soap ri ng
tomake
surei t fi ts
i nto
groove
b
Always
i nslllll
snap ri ng
wi th
i ts
rounded
edges faci ng
oi l
seal
R
face
I mi de
snap ri ng
Outsi de
I
talli ng
snap
ri ng
SST058
3
Fi t
new O
ri ng
i nto
sectorshaft
cover
Before
i nstalli ng apply
a thi ncoat
of vaseli netoO
ri ng
Make
certai n that O
ri ng
i si nstalled
properly
and
not
damagedby
sec
torshaft
ST695
4
Set
pi ston
worm
gear
at
strai ght
al1ead
posi ti on
Turn
pi ston
rllck about 100to150
toward
youself
wi th
yourfi nger
Thi s i s
for
smoothi nserti onof
lec
tor
gear
Q
G
ST696
5
Wrap vi nyltape around
serrati on
area
of
sectorshaft
The
reason
i s that
vi nyl
tape pre
vents oi lseal
li p
from
bei ng damaged
duri ng
i nserti on
6
Gradually
i nsert
sector
shaft
i nto
gear
housi ng
bei ng
carefulnot
todam
age
oi lseal
When
i nseni ng
seetor
shaft i nto
gearhousi ng
remove
plasti c
fi lm 8e
careful
not to
drop
beari ngs
i nto
gear
housi ng
7
Ti ghten
sectorcoverbolts
I I i
24ft lb
8 Check
steeri ng gearturni ng
torque
Referto
I nspeeti on
and
Adjust
ment
I f there
i s
8
great
di fference
be
tween
values
of
turni ng torque
be
fore and after
di sassembly
i t must
beassumed
that somenew
problem
has occurred I t wi ll
be
nece
ary
to
replace
the
enti re
assembly
Outer
ball
joi nt
I i J 78
98
8
010
0
58 72
CroSlrod
Front
@
Multi lurposegreasi ng poi nts
I i J
Nm
ks m
ft I b
REMOVAL
AND
I NSTALLATI ON
L Jack
up
front of
car
and
support
i t nthe
safety
stands
2
Block rearwheelswi thchocks
3 Remove
gear
arm
usi ng
tool
Gear
housi ng
Geararm
n
SST0100
4
Removei dlerann
assembly
STEERI NG SYSTEM Steeri ng
Li nkage
STEERI NG
LI NKAGE
Si de
rod
adjusti ng
bar
I nnerball
joi nt
I i J
31 42
I
32
4
3 23 31
To
body
frame
@
I i J 29 69
3 0
7 0
22 51
To
cros rod
Gear
ann
J
Cotter
Pi nV
Si derod
assembly
I i J Model
vRB47L
29 69 30 7 022 51
Toknucklearmandcross rod
Modell P
S
56L
54 98
5 5 1004072
Toknuckle
arm
andcrossrod
SST010
5 Remove si de rod
from knuckle
ann
usi ng
Tool
STa8l
BaD
joi nts
Becarefulnot to
damage
dust
cover
Ti ghten
nut to
the
speci fi ed
torque
and
ali gn
thecotter
pi n
hole
i nthe
ti ghteni ng
di recti on
Be
sure
toi nsert newcotter
pi n
and
bend i t
ecurely
Si de
rod
adjusti ng
bar
When
adjusti ng
toe
i nuse i t
Make
surethat si de
rod
bar
i s
crewed i n
socket
25
mm
098
i nOJ more
SST099
6
I nstall
steeri ng
li nkage
i n the
reverseorder
ofremoval
GJ
Gear
arm
toseetorshaft
127 147 N m
13 15
kg
m
94 108lt lb
I dler
arm
to
body
frame
31
42N m
32 43
kg
m
23
31lt
lbl
Si derodto
knucklearm
Model
VRB47L
29 69
N m
13
07 0
kg m
22 51lt lb
ModellP S 56L
54 98N m
5 5
100
kg
m
4072ft I b
7
After
i nstalli ng steeri ng
li nkage
check wheel
ali gnment
and i f
neces
sary
adjust
RefertoSeeti on MA for
adjust
ment
ST 19
Steeri ng Li nkage STEERI NG SYSTEM
DI SASSEMBLY
Si de rod
I
Remove bothsi derods fromcross
rod
usi ng
ToolHT72520000
2
Separate
outer
and
i nnerball
joi nts
fromsi de
rod
adjusti ng
bar
I nnerball
joi nt
Lock
nut
SST102
I dlerarm
assembly
Remove
nut
and
separate each
part
e
Nut
o
BU5hi ng
I dler
ann
SST013
ASSEMBLY
Assemble
steeri ng li nkage
i n the
reverse
orderof
di sassembly observi ng
the
followi ng
i nstructi ons
I dler
erm
assembly
Toassemble
i dlerarm
proceed
as
follows
I
Apply
coat
of
multi
purpose
grease
to
bushi ng
ST20
@@
w
I
Z
J
I
J
i
SST104
2
Press
bushi ng
i ntoi dler
body
and
i nsert
shaft of i dlerarm bracket
catefully
unti l
bushi ng
protrudes
tJ
54 69N
m
5 5 7 0
kg
m
4051 ft b
Cross rod and si derod
I When si de rod ball
joi n
ts
and
si de
rod
adjusti ng
barare
separated
adjust
si derod
length
correctly
Adjustment
should
be done be
tweenlock nuts
StandardJength
A
71
mm
12
80
i n
t
SST105
Uni t
mm
i n
2
Ti ghten
si de rod
adjusti ng
bar
lock nut
rl
78 98N
m
180100
kg
m
58
72ft b
a
Lock si de rod
adjusti ng
bar
lock
nut so that ball
joi nt
on
outer
socket
i s
770
wi th
respeet
tothat
oni nnersocket
b Make
sure that
adjusti ng
bari s
saewed i neachsocket at least 25
mm 098i nl
I NSPECTI ON
AND
REPAI R
Ball
joi nt
I
When ball
stud i s worn
oraxi al
play
exi sts
replace
si de rod
ball
joi nt
wi tha new
one
2 When dust coveri s broken
or
deformed
be sure to
replace
wi tha
newone
I ni ti al
turni ng torque
Ball
joi nt
05 2 5 N m
5
25
kg cm
43 21 7 i n b
Swi velpi n
Le
than
25 N m 25
kg cm
22i n b
I dlerarm
essembly
Check
rubber
bushi ng
of
i dler
arm
for
breakage
wearor
play
and
i f
necessary replace
I ni ti al
turni ng torque
Lessthan
7 8N
m
80
kg cm
69i n
bl
Apply grease
to
i dler
arm
assembly
at recommendedi ntervals
Cross rod andsi derod
Check si derod
and cross
rod
for
breakage bend orcrack
and
replace
wi th
anewone
i f
necessary
Flxlns
locati on
Check
fi xi ng
locati on nuts and
cotter
pi ns
forlooseness
play
or
breakage
When looseness or
play
i s
found
check forwearon
tapered
porti on
ofballstud
gear
arm
of i dler
arm
When
reassembli ng
eachball
joi nt
use newcotter
pi
s
STEERI NG SYSTEM
Servi ce
Dataand
Speci fi cati ons
SERVI CE DATA AND
SPECI FI CATI ONS
GENERAL
SPECI FI CATI ONS
Steeri ng
column
Standardcolumn
length
L
mm
i n
VRB47L
equi pped
model
I P S 56L
equi pped
model
Collapsi ble
column
179 7 05
180
7
09
I
LL
h L
SST080
I
Steeri ng gear
model
I
Turnsof
steeri ng
wheelanthe
car
Lock lock
I
Steeri ng
gear
rati o
VR847L I P S 56L
35 31
180205 17 0
I NSPECTI ON
AND ADJUSTMENT
Front wheelfull
turni ng angle
I nnerwheel
degree
Outerwheel
degr
e
Mi ni mum
turni ng
radi us
Wallto
wall
mlttl
Steeri ng
wheelaxi al
play
mm
i n
Steeri ng
wheel
play
mm
i nl
VR847L I P
S 56L
33
350
33
350
270
290
270
290
5 7 1871
001
Lessthan35 1
381
On
powersteeri ng
models
Wheelturni ng
force
at
ci rcumference
of steeri ng wheel
of
98
147 N 1015kg 22
231b wi th
engi ne
at
i dle
STEERI NG GEAR
ModelVRB47L
Worm
beari ng preload
Wi thoi l
seal
N
m
lkg cm
I bl
Steeri ng gearpreload
Wi thoi l
seall
Nm
kg cm
i nI b
Backlash
at
gear
arm
top
end
I n neutral
mm
li n
End
play
Between sector
shaft
and
adjusti ng
screw mmti nl
04
06
14
635
5
21
Lessthan
1
23112
5 10 9
o01 00004
001 0
03
00004
0
00121
Adjusti ng
shi mthi ckness
Thi ckness
mm
i n
1575 160010062000630
1
550
1575 00610
0
06201
1 525 155010
060000610
15001 525
10
0591 0
06001
1475 150000581 00591
14501
475
00571 0
0581
I
01
pad y
I I US
p I mp p
ModelI P 5 56L
Oi l
pump
belt deflecti on
mm i nl
Steeri ng
wheel
turni ng
force
At ci rcumference
of
steeri ng
wheel
N
kg
I b
Part No
48213 80100
48214 60100
48215
80100
48216
80100
48217 80100
48218
80100
Approx
026
15
8 1 2
8
1210
31 047
at 98N
110kg
22I b
29 4343
13035 667
71
I
Oi l
pump
maxi mum
pressure
kPa
kg
cm2
psi
5
394
55 782
I
Normal
operati ng temperature
at flui d
I
Oc10FI
60801401761
I
Flui d
capaci ty
USqt lmpqt
I APprox
1 2 1 1 4 1 1 8
Steeri ng
gearturni ng
torque
N m
kg cm
I b
3600
posi ti on
from
strai ght ehead
posi ti on
Strai ght ahead
posi ti on
Ascom
pared
wi th
steeri ng
wheelturned
3600
STEERI NG LI NKAGE
I ni ti al
turni ng torque
N
m
kg cm
i nI b
Ball
joi nt
Swi vel
pi n
I dlerarm
Standardsi derod
length
mm jnl
Less
than 1 2 12
101
0100
3911 4
09
35 hi gher
05 25 15
25 43 21 7
Lessthan25 25
221
Lessthan
7 8
80
69
71 012 795
ST 21
Servi ce
Dataand
Speci fi cati ons
STEERI NG SYSTEM
TI GHTENI NG
TORQUE
ModelI P S 56L
STEERI NG COLUMN
Uni t
N
m
kgm
ft lb
Uni t Nm
kg m
ft I b
Stub
shaft
to
joi nt
32 38 33 39 24 28
I
Steeri ng
wheel ut 37 51 385
2 27 38
I
Stee
i ng
ge
housi ng to
52 62 5363
I
38
bOOy
frame
46
I
05 0
451
I
Jacket
tubeblacket to
34 44
25 33
I
Sector
shaft
togear
arm
I
dush
panel
127 147 13 15 94 108
I
Stee
i ng
column mount
13 18
11 3
18
I
9 13
I
Rea cove
togea
26 32 2
7 33
I
2024
i og
bracket
housi ng
I
Jacket
tube
mounti ng
I
344
4 035 0
451
25 33
Sectoshaft
cove
to
goa
I
26 32
27 33
I
2024
bracket
housi ng
Coupli ng
fi xi ng
nut
Sector
shaft
adjusti ng
28 34 2
9
3
5
I
21
25
VRB47Lequi pped
15 22
1 5 22 11 16
screw
locknut
mod 1
only
I
0
pump
to
bracket 27 37
I
20
27 26 36
I
Hoseto
oi l
pump
29 49 305
0
I
22 36
I
Oi i seoi tank toen
29 49
0305
I
22
36
glnecompartment
Hoseto
suspensi on
coss
l
29 4
9
03 05
I
2
2
3
6
member
STEERI NG GEAR
Model
VRB47L
Hoseto
gearhousi ng
49 69
5
070
I
36 51
Uni t Nm
kg m
ft lb
I
Worm
shaft to
coupli ng
STEERI NG
LI NKAGE
39 49 4
5 29
35
Steeri ng gearhousi ng
to
Uni t Nm
kg n
ft lb
52 52 5 3 53 38 46
body
frame
I dler
arm
to
body
frame 31
42
32 43 23
31
Sector
shaft to
gear
arm
127 147 13 15
94 108
8allstudendswi VI I I
pi n 29 59 30
7 0 22 51
Adjusti ng plug
locknut 245 314 25 32
181 231
I
I dler
arm
nut
54
69
5 5 70
4051
Sectorshaft cover
bolt 15 25 15 25 11 18
I
Si derodbarlocknut 78 98
80100 58 72
I
Sect
shaft
adjusti ng
29 39 3
0
40
22
29
I
P S
56Lequi pped
model
only
screwlocknut
Si de
rod
assembly
54 69
Nm
15
5 7
0
kg
m40
511t
b
ST
22
STEERI NG SYSTEM
TroubleOi agnoses
and
Correcti ons
TROUBLE DI AGNOSES
AND CORRECTI ONS
Except
for
the
followi ng probalbe
causes and correcti ve acti ons
referto
Trouble
Di agnoses
andCorrecti ons
i nFront AxleandFront Suspensi on
secti on
Condi 1i on
Excessi ve
wheel
play
Vi brati on shock
or
shi mmyi ng
of
steeri ng
wheel
Carpulls
to
ri ght
or
left
Sti ff
or
heavy steeri ng
wheel
Probable
cause
I nsuffi ci ently
ti ghtened
or
i mproperly
i n
stalled
steeri ng gearhousi ng
Damagedsteeri ng li nkage
orball
joi nt
I ncorrect
adjustment
of
steeri ng gear
I nsuffi ci ently ti ghtened
or
i mproperly
i n
stalled
steeri ng
gear
housi ng
Wearof
steeri ng li nkage
Damaged
i dlerarm
Worn column
beari ng
weakened column
beari ng spri ng
orloose
clamp
Deformed
steeri ng li nkage
andor
suspensi on
li nk
I nsuffi ci ent
lubri cants or
mi xi ng i mpuri ti es
i n
steeri ng
li nkage
or
excessi vely
wornsteer
i ng li nkage
Worn
or
damaged
steeri ng
gear
and
beari ng
I ncorrectly
adjusted
steeri ng
gear
Deformed
steeri ng
li nkage
I nterference
of
steeri ng
column wi thturn
si gnal
swi tch
Correcti veacti on
Reti ghten
Replace
faulty
parts
Adjust
Reti ghten
Replacefaulty
parts
Replace
Replace
or
reti ghten
Replace
Repleni sh
grease
or
replace
the
part
Replace
Adjust
Replace
Adjust
ST 23
Trouble
Di agnO tJS
and
Correcti ons
STEERI NG
SYSTEM
POWER STEERI NG
Condi ti on
Oi l
pressure
does
not
bui ld
up
Steeri ng
wheelmoves
heavi ly
Steeri ng
wheelfai ls to
return
Steeri ng
effort i s
not
thesamei n
both
di recti ons
Unstable
runni ng
Noi sy
pump
ST 24
Probablecause
Pump
dri ve
belt
sli ppi ng
on
pulley
Pump malfuncti oni ng
Oi l
leaki ng
through
hose
joi nts
Oi l
leaki ng
through
power
steeri ng
Lackofoi li n
oi l
pump
Ai r
present
i n oi l
Oi l
pressure
toolow
Wheel
ali gnment
out of
speci fi cati ons
or
ai r
pressure
i nti res
too
low
Steeri ng gears i mproperly engaged
Steeri ng
columnout of
ali gnment
Worn
or
damaged
ball
joi nt
at
suspensi on
and
steeri ng
li nkage
I dlerarm
draggi ng
Refertoi tems marked
above
Front wheelcaster
i mproperly adjusted
I nternal
gears dragged
or
gouged
Oi l
leakage
i n
steeri ng gear
Stuffy
oi l
passage
i n
steeri ng gear
Wheel
beari ng
not
properly adjusted
Stuck or
damaged
control
valve
i n
steeri ng
gear
Front wheel
ali gnment
not
properly
Excessi ve
steeri ng
gear
play
Play
at
suspensi on
and
li nkage
ball
joi nt
Lack ofoi li n
oi l
pump
Hoses oroi lfi lter
clogged
Loose
pulley
Belt
noi sy
or
slappi ng
Broken
pump part
r
Correcti veacti on
Readjust
belt
tensi on
Replace
Replaceor
reti ghten
copper
washer
Replace
seali ng
parts
at
steeri ng gear
Refi ll
Bleedai r
See
Hydrauli c
system
check
Re
a1i gn
or
i nflateti res tocorrect
pressure
Replace
gearassembly
Repai r
or
replace
Replace
Repai r
or
replace
Readjust
Replacegearassembly
Replace seali ng
parts
Replacegearassembly
Readjust
Replacegearassembly
Readjust
Readjust
backlashor
replacegear
assembly
Replace
Refi ll
Clean
ori f
necessary
replace
Repai r
Readjust
tensi on
Replace
STEERI NG
SYSTEM
Speci al
Servi ce
Tools
SPECI AL
SERVI CE
TOOLS
Uni t
appli cati on
Toolnumber
Kent MooreNo
Tool
name
ModelVRB47L
Modell P S 56L
ST27l80001
125726
Steeri ng
wheel
puller
1i
KV48
100301
125729
Strut
steeri ng gear
box
attachment x x
ST3127S000
Preloadgauge
See125765
Torque
wrench
CD i CD GG91030000
Socket
adapter
See
125765
Socket
adapter
X X
@HT62940000
@
@HT62900000
ST29020001 Steeri ng gear
armpuller
J25725
X
X
HT72520000
Ball
joi nt
remover
KV48101500
Locknut wrench
X
KV48101400
Adjusti ng
plug
wrench
X
ST27091000
Pressure
gauge
X
Shut ff valve
ST
25
Speci al
Servi ce
Tools
STEERI NG SYSTEM
Tool
number
Toolname
Kent Moore No
KV48I 009S0
Oi lsealdri ft set
126367
CD KV48lO091O
Dri ft
@KV48100920
Adapter
@ KV48100930
Adapter
CDsT35322000 Front wheel
beari ng
dri ft
@ST35325000
Dri ft bar
ST
26
I
Uni t
appli cati on
I
ModelVRB47L
Model
I P
S
56L
x
x
DATSUN
200SX
Model
SI I 0
Seri es
SECTI ONBF
BODY
CONTENTS
BODY FRONT
END
FRONT BUMPER Shock absorber
type
RADI ATOR GRI LLE
FRONT
APRON
FRONT SI GHT
SHI ELD
FRONT FENDER
HOOD
DOOR
DOOR
BODY REAR END
REAR BUMPER Shock absorber
type
TRUNKLI D
Hardtop
BACK DOOR Hatchback
WI NDSHI ELD AND
WI NDOWS
WI NDSHI ELD
REAR OUARTER WI NDOW
Hardtop
REAR QUARTER WI NDOW Hatchback
OPERA WI NDOW
Hardtop
OPERA WI NDOW Hatchback
BF 2
BF 2
BF 3
BF 3
BF 3
BF 3
BF 4
BF
6
BF 7
BF11
BF11
BF12
BF13
BF16
BF16
BF19
BF21
BF22
BF22
REAR WI NDOW
Hardtop
BACK WI NDOW Hatchback
TRI MAND MOLDI NG
ROOMTRI M
BODY SI DE TRI MAND MOLDI NG
REAR PARCEL SHELF
Hardtop
I NSTRUMENT AND SEAT
I NSTRUMENT
CONSOLE BOX
SEAT
SEAT BELT
SUN RDOF
REMOVAL
AND I NSTAllATI ON
BODY ALI GNMENT
DESCRI PTI ON
ENGI NE COMPARTMENT
UNDERBODY
SPECI ALSERVI CE
TDOLS
BF22
BF
24
BF26
BF26
BF27
BF28
BF29
BF29
BF31
BF31
BF32
BF34
BF34
BF
35
BF35
BF35
BF36
BF37
a
Body
FronrEnd BODY
BODY
FRONT END
FRONT BUMPER
Shock absorber
type
Front bumper
REMOVAL
AND
I NSTAUATI ON
I Di sconnect
battery ground
cable
2 Di sconnect front combi nati on
lamp
connectOI s
3 Remove
speci al
bolts
securi ng
shock absorber
to
front
bumper
assem
bly thenremove
front
bumper
assem
bly
4 Remove shock
absorber
fromcar
body
CAUTI ON
The shock absorber
i s fi lled
wi th
a
hi ghpressure gas
and should not be
di sassembled dri lled or
exposed
to
an
open
flame
5 I nstallati on
i s i n reverse orderof
removal
ADJUSTMENT
Bumper
hei ght
I
Adjust
bumper
hei ght
so that
BF
2
Shock
absorber
31 42
3
2 4
3
23
31
59
78
60
8
043 58
B wq
bu
cket
OYerri der
N
m
I cg rn
ft
lb
SBF126
di stance
from
top edges
to
ground
meetsthe
speci fi cati ons
p p
t
Uni t 111m i n
Secti on
A A
SBF121
Place
car
OB I I
flat surfaceunder
curb
wei ght
condi ti ons
Ti res must
be
i nflatedto
rated
pressure
2 After
adjustment ti ghten
bolts
andnuts
securely
RADI ATOR GRI LLE
REMOVAL AND
I NSTALLATI ON
1
Open engi ne
hood
2 Removeradi ator
gri lle
3
I nstalladon i s
i n reverse
orderof
removal
CAUTI ON
a Radi ator
gri lle
i s made of
plasti c
sodo
not
use
excessi veforce
b
Take Clre to
keep
oi l
away
from
radi ator
gri lle
FRONT FENDER
Secti on
A A
FRONT APRON
REMOVAL AND
I NSTALLATI ON
1
Remove front
bumperassembly
RefertoFront
Bumper
forremoval
2
Remove
front
apron
1
SBF129
3
I nstallati on
i s
i n
reverse
orderof
removal
When
i nstalli ng
front
apron
be
sure
to
sea
mati ng
surfaceof front fender
andfront
apron
Seal
completely
to
mati ng
surfaceof
fenderand
hoodJedse
BODY BodyFront End
FRONT
SI GHT
SHI ELD
REMOVAL
AND
I NSTALLATI ON
1
Remove
headJamp
fmi sherand
headlamp
2 Removeradi ator
gri lle
3 Removefront
bumperassembly
4
Removefront
si ght
shi eld
Jf
Q
1
SBF130
5
I nstallati on i s i n reverse
orderof
removal
I R
a
ff
J1
Ji
A
b
SBF131
BF
3
Body
Front
End
BODY
REMOVAL AND
I NSTALLATI oN
I
Di sconnect
battery
ground
cable
2
Remove front
bumperassembly
Referto
Front
Bumper
Assembly
for
removaland
i nstallati on
3
Remove fender
protectorsi ght
shi eld front
apron
andfender
stay
4
Remove bolts
attachi ng
front
fenderandthen remove
front fender
HOOD
Hood
Stri ker
Hoodlouver
Torsi on bar
Hood
hi nv
Cowl
gri lle
Hood
lock
REMOVAL AND
I NSTALLATI ON
Hoodcontrol
cable
Hood
I
Open
hood
and
remove washer
tube
2
Support
hood
and
remove bolts
attachi ng
hood
hi nge
andthenremove
hood
BF4
CAUTI ON
Fender
panel
and
hoodledge
are
securedwi thsealant Before
removi ng
front
fender
be suretoremove
seal
ent
I
7
lI B
21 Nm
11 6 21
kg m
12
15fHb
S8F133
5 I nstallati on i s
i n reverse orderof
removal
When
i nstalli ng
front fender
apply
sealant to
mati ng
surface of front
lenderand
hoodledge
Hoodrear
moldi ng
SBF132
3 I nstallati on i s
i n
reverse orderof
removal
Adjust
hood RefertoAd
justment
Torsi on bar
I
Open
hood
2
Support
hood
and remove each
torsi on
bar
by
di sengagi ng
end of
torsi on barfrom
hood
hi nge
Use a
sui table
screwdri ver
SBF134
3
I nstallati on
i s i n reverse orderof
removal
Lubri cate sli di ng
surface of tor
si on bar
Hood
hi nge
I Remove
engi ne
hood
2 Remove
wi per
arm
and
then re
move
wi ndshi eld
lower
gri lle
3 Remove
torsi on
barand
then
remove
hood
hi nge
CAUTI ON
Remove
hi nge
onlv
aftertorsi on bar
hasbeen
removed
t7 2
SBF135
4 I nstallati on i s i n
reverse
orderof
removal
fj
Hi ngeattachi ng
bolt
39 49N m
04 0
5
kg
m
2 9 3
6
ft
lbl
Hood
lock and lock
control
I Remove bolts
attachi ng
hood
lock
2
Di sconnect lock control
wi refrom
hood
lock
and
then
remove
hood
lock
SBF136
3
Remove left i nstrument
lower
coverReferto
I nstrument Lower
Coverforremoval
4 Remove
hood
lock
controlknob
and then drawcable out
throughpas
sengercompartment
5
I nstallati on
i s i n reverse orderof
removal
Adjust
hood RefertoHood
Adjustment
fj
Hoodlock
attachi ng
bolU
16 21 N m
1 6 2 1
kg
m
12 15 ft lb
Check
hoodlockcontrol
operati on
ADJUSTMENT
Hoodandlock
I Loosen bolts
attachi ng
hood
hi nge
and
move hood forward or
backward
and si de tosi de unti l
i t i s
set
i n
opti mumposi ti on
SBF137
BODY
Body
F
ontEnd
2 Loosen
bolts
attachi ng
hoodlock
and move hood
up
or
down
and
si de
tosi de unti l
i t i s set i n
opti mum
posi
ti on
whenopened
andclosed
JLlI
t
SBF138
After
hood
adjustment
ensure
that clearance
between hood
and
fenders
i s
nearly
equal
at all
poi nts
Bumper
rubber
Rai se
two
hood
bumpers
unti l
hood
i s
flush
wi thfenders
alaI
1
Fender
0101
JJ
I
@
I
@
HO
d
7
I
Uni t
mm i n SBF139
1
Adjust
bolt
2
Bumper
rubber
3 Lock
nut
4 Weldnut
Ensure
that
rubber
bumpers
come
i n
contact wi thmati ng
panels
BF5
Door
BODY
DOOR
Outsi de
haodle
Door
gtus
Door
outsi de
mouldi ng
Doot
stabi li zer
i 1 I I
Front
gui de
rai l
li ar
npper
I t
i
@
t
lnad
hand1e
J
screen
Ann
Door
fmi sher
SBf140
BF
6
DOOR
REMOVAL AND
I NSTAlLATI ON
Door
aasembly
Support
door
wi th
a
standor
jack
Place
a
rag
between
door
and
stand
or
jack
2 Remove
doorfrom
hi nges
I
I
00
W
r
JL
0
C
SBF141
3 I nstallati on i s i n reverse order
of
removal
Adjust
Door
RefertoAd
justment
tl
Door
hi ngesecuri ng
bolts
16
22N m
1 6
22
kg
m
12
16ft lb
Front
doortri m
1 Lowerdoor
glass
fully
2 Removeann rest
and
doori nsi de
handle
escutcheon
3
Remove
regulator
handle
by pry
i ng
out set
pi n
o
Front
t
SF879B
4
Remove doorfmi sherwi thsui t
able tooland
pry
doorfmi sher
cli p
offdoor
i nner
panel
SBF142
5
Remove
seali ng
screen
When
removi ng seali ng
screen be
carefulnot
to
allowi t
tocome
i n
con
taet
wi th
adjacent parts
6
I nstallati on
i s i n
reverse
orderof
removal
8
To
prevent
waterfrom
enteri ng
passengercompartment
affi x seal
i ng
SCreen
fi rmly
wi thadhesi ve
tape
or
bondi ng
agent
b Wi thdoorwi ndow
closed use
set
pi ns
to
i nstall
regulator
handle as
showni n
Fi gure
below
Front
300
r
BF879B
Door
glass
and
regulator
I
Remove
doortri m
2
Removedoorouter
moldi ng
3 Remove both front
and rear
upperstoppers
I Y
hf
I
J
Rearuppe
opper
Front
upper
stopper
SBF143
BODY Door
4
Removebolts
attachi ng
door
wi n
dowto
gui de
channel
O
c
SSF144
S
Remove
doorstabi li zer
6 Remove
door
glass
by pulli ng
i t
upwards
and
away
fromdoor
7
Remove
regulator
attachi ng
bolts
SBF145
8
Remove
through
large
panel
regulator assembly
access hole i n
door
r
SBF146
9 I nstallati on
i s i n
reverse orderof
removal
Door
glass adjustment
Refer
to
Adjustment
Apply grease to
sli di ng surfaces
of
regulator
and
gui dechannel
BF7
Door
BODY
Doorlock andlock control
Dooroutsi de
handle
J
I
Jb
Key cyli nder
t
l
Doorlock
Removedoortri m
2
Remove door
glass
RefertoDoor
Glass forremoval
3
Jl
emove
door
i nsi de handle at
tachi ng
screws doorlock
assembly
attachi ng
screws and bell crank attach
i ng
screw
4
Di sconnect
key
rod
from
key
cyli nderand then removedoorlock
andlock control
5
Removedooroutsi de
handle
6 I nstallati on
i s i nreverse orderof
rcptoval
Apply
grease
to
sli di ng
surfaces of
leven and
spri ngs
BF
B
ADJUSTMENT
Door
assembly
I nsi delockknob
s
I mi dehandleescutcheoD
j
4
i
d
Il
I
Loosenbolts
attachi ng
door
hi nge
to
body
si de
Move door
up
ordown
and forward
orbackward unti l
i t i s
correctly
posi ti oned
Usi ng
an
offset wrendl
remove
I mi de
handle
SBF147
SBF148
bolts
attachi ng hi nge
to
rear
of
front
lender
2
Loosenbolts
attachi ng
door
hi nge
todoorsi de Move doorfrom
si de
to
si deunti l
i t
i sset i n
opti mumposi ti on
Door
glas
Before
adjusti ng
door
wi ndow
glass
check
body
si de
weatherstri p
toensurl
that
i t
i s
properly posi ti oned
as
i m
@1f
@
I n
out
adjustment
At wai st
area
1 Loosen
nuts
securi ng
upper
ends
of
both
front
and rear
gui de
rai ls
rfjV
i di
I
I I
I
l
ll
t
J
Jr
j
C
Front
SBF150
2
Rai sewi ndow
completely
3
Turn
upperadjusti ng
bolts
i n
one
di recti on
or
the otherunti ldi stance
between
glass
andrubbersealfor
door
wai st
moldi ng
i s
112
mm 0441 i n
as shown
i n
Fi gure
below
proper
posi ti oni ng
may
cause
wateror
dust leaks
Adjust
wi ndow
glass
as
follows
1 ln
ut
adjustment
at
wai st area
2 I n Gut
adjustment
upper
si de
ofgalss
3 Ti lt
adjustment
upper
si de of
glass
4 Glass
upperstop
adjustment
5
Glass fore
and
aft
adjustment
SBF149
11 2mm
0441 i n
SBF151
I n out
adjustment Upper
si deof
glass
1 Loosennuts
securi ng
lower
end
of
gui de
rai l and turn
adjusti ng
bolts
unti l
glass
i s
set
i n
posi ti on
as showni n
Fi gure
below
Si deroofrai l
crt
14 17mmLn
g
1055 067
i nlrOoorgla
SBF152
BODY
Ooor
Ti lt
adjustment
Upper
si deof
glass
I Loosen front and rear
upper
stopper
securi ng
bolts andfront and
rear
gui de
rai l
securi ng
nuts
2
Adjust
door
regulator
so
that
upper
si de of
glass
i s
parallel
wi th
body
si de
weatherstri p
Regulator
SBF153
3 After
adjustment
ti ghten gui de
rai l
securi ng
nuts
and
gui de
channel
securi ng
bolts
Glass
upper
stop adjustment
I
Adjust
rear
hei ght
of
glass by
changi ng upper
rear
stopperposi ti on
Si de
roof
rai l
Door
glass
SBF154
BF9
Door
BODY
2
Adjust
front
hei ght
of
glass by
changi ng
upper
front
stopperposi ti on
@
ri
i l
After
completi ng adjus1ment
en
sure that each
adjustment
i s wi thi n
speci fi ed
li mi t
BF
l0
Doorlock andlock control
I Move
bell
rank front and rear
unti lfree
play
of
lock knob
i s mi ni
mum Check lock
knob and i nsi de
handle to
i nsure
that
they are
flush
wi theachotherwhen lock i s
engaged
Ti ghten
lockknob
attachi ng
screws
11i
U
I
I I
J
P
SBF157
2 Turn
adjusti ng
nut unti lclearance
between outsi de
handle rodand
door
lock leveri s 0
to
I mm 0
to004i n
Adjust
nut
U 0
1mm
0
004
i nl
SBF158
Mter
adjustment check todeter
mi ne
i fdoorlock
operates correctly
BODY Body
RearEnd
BODY
REAR END
REAR
BUMPER
Shock absorber
type
i f
iJ
31 42
3 2
4
3 23 31
Shock absorber
umper mounti ll
bracket
Rearbumper
iS
Omder
Bumperface
13
7
9
iJ 59
78
6 8
43
58
t
si de
moldi ng
iJ
Nm
kg
m fHb
SBF159
REMOVAL AND
I NSTALLATI ON
I Di sconnect
battery ground
cable
2
Di sconnect
reverse
lamp
harness
3
Remove
speci al
bolts
securi ng
shock absorberto
bumper
assembly
anddetach
bumper
assembly
4 Remove
shock
absorberfromcar
body
M 60023
621
M
600
2362
CAUTI ON
The shock absorberi s fi lled wi tha
hi ghpressure gas
and should not be
di sassembled
dri lled or
exposed
to
an
open
flame
512 544
2016 2142
t
t
5 I nstallati on i s i n
reverse
order
of
removal
ADJUSTMENT
Uni t
mm
i n
Secti on
A
A
SBF160
Bumperhei ght
I
Adjust
bumperhei ght
so that
di stance from
top
edges
to
ground
meetsthe
speci fi cati ons
Place
caron
a flat surface
under
curb
wei ght
condi ti ons Ti res
must
bei nflatedtorated
pressure
2 After
adjustment ti ghten
bolts
andnuts securely
BFll
Body
RearEnd
BQDY
TRUNK
LI D
Hardtop
REMOVAL AND
I NSTAUATI ON
Trunk li d
I
Open
trunk li d and remove
trunk
opener
cable
2
Support
trunk li d and remo
bolts
attachi ng
trunk li d to
hi nge
thenremovetrunkli d
I I I
3 I nstallati on
i s i n
reverse order
of
removal
AdjUst
trunk
li d
Refer
toAdjust
ment
Gi
Trunkli d
securi ng
bolts
3
9 49N m
04 05
kg
m
29 36ft lb
Torsi on bar
I
Open
trunkli d
2
Support
trunk li d and
remove
each
torsi on
bar
by
di sengagi ng
end
of to
i on
barfrom trunk li d Use a
sui tablescrewdri ver
L
BF12
3
I nstallati on i s i n reverse orderof
removal
Trunk li d lock endstri ker
I Remove
trunk
rear
fmi sher
2
Remove
trunk
li d
attachi ng
bolts
andthen
removestri ker
3
Remove lock
attachi ng
bolts and
thenremove
lock
Trunk li d
opener
1
Remove
rearseat cushi on and
rear
seat back
2
Remove
ki cki ng plate
3 Remove trunk li d
lock
attachi ng
boltsandthen remove
trunkli dlock
4
Trun
up
floor
carpet
neartrunk
li d
opener
handle
S
Remoye
trunk li d
opener
handle
6 Removetrunk li d
opener
cable
7
I nstallati on
i s
i n
reverse orderof
removal
Fasten
trunk
openercable
securely
wi th
adhesi ve
tape
I
l
i
SBF163
4
I nstallati on i s i n reverse
orderof
removal
SBF164
ADJUSTMENT
T
u
n
I
l
an
oc
k
I Loosen
bolts
attachi ng
trunk li d
hi nges
Move trunk li d forward or
backward and
si de
tosi de unti l
i t i s
set
i n
opti mumposi ti on
v
SBF166
2
Loosen bolts
attachi ng
trunk li d
lock
Move
trunk li d lock forward
or
backward and si de to
si de
unti l
i t i s
correctly
posi ti oned
when
opened
and
closed
I
J
39 49N m
10
4 05
kg
m
29 36f1 lbl
SBF166
Trunk li d
opener
Adjust
trunk li d
opener
unti lclear
ance
between
trunk
li d controlcable
end
and
control
lever
i s wi thi n
1 mm
004
i n whentrunklock
i s
engaged
Clearance
Lessthan
1
mm004i n
Lock
Locki ng
lever
A
AdjusUble
5mm
110
20
i nl
SBF167
BACKDOOR
Hatchback
REMOVALAND
I NSTALLATI ON
Back door
SBF168
Open
back
door
2 Mark
hi nge
locati ons on
body
for
proper
rei nstallati on
3
Support
back
door
by
hand and
remove back
door
toback doorstay
bolts
Remove rearroof rai ltri mand
di sconnect rear
defogger
and rearwi n
dow
wi per
harness connectorand
hose
4
Support
back door
by
hand
and
removeback
door
toback door
hi nge
attachi ng
bolts Then remove
back
doorThi s
operati on requi res
two
men
CAUTI ON
Place
rags
between roof
and
upper
end
ofback doortoavoi d
damagi ng pai nt
ed
surfaces
5 I nstallati on
i s i nreverse orderof
removal
tl
Back door
stay
retai ni ng
bolt
16 21 N
m
1
6
2 1
kg
m
12
15 ft lb
BODY Body
RearEnd
CAUTI ON
a
Be carefulnot toscralchback door
staV
when
i nstalli ng
A scralched
staV mav
cause
gas
leakage
b Back door
staV
contents
are
under
pressure
00not take
apart punc
ture
applv
heat orfi re
Back doorlock endlock
cyli nder
I
Open
back door
2 Remove
luggage
rearfmi sher
3
Remove back doorlockfromrear
panel
1
0
i
0
Q
SBF169
4 Remove rear
combi nati on lamp
and
thenremove
lock
cyli n4er
5
I nstallati on
i s i nreverse
order
of
r
mova
Adjust
back door
referri ng
toBack
Doorfor
adjustment
BF
13
8OdyRearEnd
BODY
Back door
opener
I
Open
backdoor
2 Remove
luggage
rearfi ni sher
3
Remove back doorlock from
rear
panel
4
Remove rearseat cushi on and
rearseat back
5
Remove
ki cki ng plate
6 Turn
up
floor
carpet
ri ear
back
door
opener
handle
7
Turn
up
luggage
room
carpet
and
removeback
door
opener
handle
8
Removeback
door
opener
cable
9
I nsta1I ati on
i s i n
reverse orderof
removal
Fastan back door
opener
control
cable
securely wi th
adhesi ve
tape
ADJUSTMENT
Back doorendstri ker
Back doorcan be
adjusted
wi th
bolts
attachi ng
backdoortobackdoor
hi nge
and
backdoorlock
I
Loosen bolts
attachi ng
back door
to
backdoor
hi nge
BF14
Back
doorlock
cable
2 Tomake si de
to
i de
adjustment
move back doortoleft or
ri ght
as
requi red
toobtai n an
equal
clearance
between
back doorandrearfender
on
bothsi des
3
To
make fore and aft
adjustment
move back door
i n
fore and aft di rec
ti on
requi red
toobtai n an
equal
clearancebetweenbackdoorandroof
P
U
BF6848
4 After
ali gnment
i s
properly
made
ti ghten
bolts
securely
SBF171
5 Toobtai na
snug
fi t between
back
door
and
weatherstri p
loosen
down
stopper
securi ng
screw Loosenback
doorlock
attachi ng
bolts
enough
to
move
lock
worki ng
lock
up
ordown
andfromsi de
to
si de
as
requi red
h
7
1f
0
y
l4 P
SBF172
6 Afterdesi red
adjustment
i s
ob
tai ned
ti ghten
back doorlock attach
i ng
bolts
securely
7
Adjust
down stopper
toset wi th
hollow
of back
doorthen
ti ghten
down
stoppersecuri ng
screws
BF6868
Back doorlock
Adjust
back
doorlock
and
key
rod unti l
they
arecorrectly
posi ti oned
when
door
lock
i s
engaged
as
shown
i n
Fi gure
below
I I
JC
c
0
mm
0004
i nl
Key
rOd
Adjust
nut
SBF173
BODY Body
RearEnd
Bali k
door
opener
Adjust
clearance
betweenrear
door
opener
cable
end and
locki ng plate
whendoor
i s locked unti l
i t i s
wi thi n
range
i ndi catedi n
Fi gure
below
rv
o
0
0
o
Locki ng
lever
SBF174
BF
15
Wi nrhhi eldand
Wi ndows BODY
WI NDSHI ELD
AND WI NDOWS
WI NDSHI ELD
A
pre
mi xed one
part
sealant
to
cement
wi ndshi eld
glass
to
wi ndshi eld
openi ng
i savai lable
After
usi ng
thi ssealant
i t
i s hi ghly
recommended that thecar
shouldreo
mai n
stati onary
for
about 24hours
so
that
the
sealant can cure
welL
Upper
wi ndshi eld
moldi ng
i s
i n
stalledwi tha
conti nuous
plasti c
mold
i ng
fastener
I
Wi ndshi eld
glass
2 Wi ndshi eld
moldi ng
3
Body
4 Double
facedadhesi vetape
5
Moldi ng
falteDU
6
Sealant
7 Dam
CAUTI ON
a
Use Genui ne Ni ssan
Sealant
Ki t
72891
U7425
or
equi valent
Seal
ant
ki t
consi stsof Pi i mer
A Pri mer
E
dam
cauti on labelandsealant
whi chi s made
from
si li cone
Usi ng
thi s
ki t
proceed
to
operati ons
de
scri bed
i n removalandi nstallati on
b Do
not
usesealant
i f i t i s
more
than
si xmonths old
c
Open cartri dge
only
at the
ti me
of
use
d
Keep
Pri men
andsealant i na
cool
dry place ldeally
sealant
shouldbe
storedi na
refri gerator
WARNI NG
Keep
heat or
open
flames
away
I S Pri men
areflammable
BF16
REMOVAL
I
Protect hood
front fenders
i n
strum
tpanelandftoot
ns
th
covers
2 Remove
ndshi eld
pers
front
pi llargami shes
andwi ndshi eld
garni sh
Referto Roof
Tri mmi ng
forre
moval
3 Remove front
pi llar
moldi ngs
4
Wi th
a
sharp cutti ng
kni fe cut
off
caulki ng
ma1eri algttached
to
upper
and lower
moldi ngs
Then reo
move
moldi ngs
Cut here
BF330B
5
Reachi ng
from i nsi de carstri p
dam
rubberfrom around
wi ndshi eld
glass
YeI
I
Bf288B
6 Wi tha
sharp
cutti ng
kni fe
cut
off
caulki ng
materi al
along
edge
of
enti re
wi ndow
openi ng
BF331
B
1 Adhesi vecaulki ng
materi al
2
Glass
3 Kni fe
cur
7
Cut off
caulki ng
materi al
around
enti re
peri meter
of
glass
as
follows
I
Usi ng
a kni fe
cut
through
part
of
caulki ng
materi al
2
Secure one
end of steelmusi c
re 0
5
mm 0020i n
i ndi ameter
toa
pi ece
of woodthat can serveas a
handle
Usi ng
long
nose
pli ers
i nsert
other
end of
re throughcaukli ng
materi al
at
edge
of
glass
then secure that
end
of retoanother
woodhandle
3 Wi th the ai d
of an assi stant
carefully
cut
puJi
re through
caulk
i ng
materi alaroundenti re
peri meter
of
ndow
usi ng
a
sawi ng
moti on
1
BF35 B
S From i nsi de car
pushglass up
andout ofwi ndow
openi ng
9
Usi ng
a razor
blade or
sharp
scraper
remove caulki ng
materi al
along
enti re
edge
of wi ndshi eld
openi ng
leavi ng
i t about 10to20
mm
0039to0079
i n thi ck
I f
mi llual
sealant
i i li con re
move
alltracesof
i t
CAUTI ON
a When
body
pai nted
surface i s
scra1Ched
be sure
to
repai r
wi th
pai nt
b I denti fi ceti on
of used adhesi ve
materi al
can be
accompli shed
as
follows
1 Cut e smell
pi ece
of gxcess
sealant from
glass
orwi ndshi eld
openi ng flange
2 Sti ck small
pi ece
of sealant on
the
end
of kni feor
theli keand
holdi t over
flamefrommatch
or
I i ghler
unti li t
i gni les
Polysulfi de
burns wi tha clear
flamg anda
very
smallamount
of whi tesmokeornosmokeand
i ts odori s
very
objecti onable
heavy
sulfurdi oxi de
Polyurethane
burns
wi th a
di rty
flame and emi t black
smoke
and
very
li ttleodor
Si li cone
glows
wi thli ttle or
no
flameandemi tswhi tesmoke
and
very
li ttleodor
Burnt resi duei swhi teash
I NSTALLATI ON
L
Clean
contacti ng
face of
body
wi th
non
lead
gasoli ne
CAUTI ON
00not allowoi l
grease
or
waler
to
get
on clean surfaces
from
di rty
hands
ortools
2
I nstall
moldi ng
fasteneron
upper
wi ndshi eld
openi ng
as follows
1
Heat
moldi ng
fastenerandcon
tacti ng
face of
body up
to
about 400C
I
040
F
usi ng
a heat
gi ltl
2
Attach
moldi ng
fastener
to
body
and
press
i t
more than 490kPa
5
kg
em
71
psi usi ng
a sui tableroller
Make
certai n
that
moldi ng
fastener
does
t
not come
off from
body
as
shown
Moldi ng
fastener
3
Apply
glass
sealant
besi de
mold
i ng
fastener
Sealant
8F
3338
3 Clean
glass
surface where
the
sealant
wi llbe
appli ed
anddam
wi th
non
lead
gasoli ne
About
20mm
0
79
i n
Cleani ng
area
BF531
4 I nstall
dam rubberto
i ni de
of
wi ndshi eld
glass
8 mm
031 i n
i nboardfrom
edge
of
glass
and
cut off
excessamount at i tsends
hADam
GlaSS
Dam
Uni t
mm i n
8F955
BO
DY Wi ndshi eld
andWi ndows
5
Wi th
sponge
furni shed wi th
Pri merA
apply
a
li ght
coat ofPri mer
to
cleaned
area of
glass
I lI MERA
BF376B
CAUTI ON
00not
apply
Pri mer
A to
glass open
i ng flanges
6 Wi th
sponge
furni shed wi th
Pri mer
E
apply
a
li ght
coat of
Pri mer
to
ori gi nalcaulki ng
materi alleft
on
glassopeni ng flange
Resi dualsealant
i j
I MERE
WJ
BF377B
I f resi dualsealant i s si li cone
r8
movealltracesof i t
CAUTI ON
Allow Pri mers
to
dry
for
10
to15
mi nutes
before
proceedi ng
tothenext
step
7 I nsert
cartri dge
i n
Caulki ng
Hand
Gun ST08810000and
place
smooth
conti nuous bead on
glass
11
mm
043
i n
above
glass
surfaces
BF17
Wi ncMi eldandWi ndows
BODY
d
Dam
mmo nl
Secti on
A A
BF782B
Cut
off
nozzle
end
of
cartri dge as
shown below
7
0
h
1
0
311
Uni t mmi n
BF957
Pi erce
seali ng
fi lm wi thneedle
i nstall
cartri dge
on
hand
gun
CAUTI ON
Sealant starts toharden 15
mi nules
afteri t i s
appli ed
1herefore
wi nd
shi eld
glass
should be i nstalled
i n
wi ndshi eld
openi ng
i n
body
wi 1hi n
15
mi nutes
of
applyi ng
sealant
8
Support
wi ndshi eld
glass
wi th
SuckerST08800000
9 I nstall
wi ndshi eld
glass
on
openi ng
flange so
that clearances be
tween
wi ndshi eld
glass
and
body
are
about
7mm 028
i n
BF18
BF335B
10
Apply
pressure
on
glass
10ai d
i n
seati ng
on
plate
I I
Wi pe
excess
caulki ng
materi al
off
moldi ng
fasteners
edges
of
glass
and
body
12 Remove
protecti ve
covers
13 Watertest i mmedi ately usi ng
a
coldwater
spray
Donot
di rect
stream of water
at
freshadhesi ve
materi alAllowwater
to
spi ll
over
edges
of
glass
I fleaks are
encountered
use Caulki ng
Hand Gun
towork
i naddi ti onal
caulki ng
materi al
at leak
poi nt
14 I nstallall
previ ously
removed
parts
After
i nstalli ng
attachcauti on
label
to
glass
surface
CAUTI ON
LEAVE ONE WI NDOW
OPEN
SLlGtlTlT
FOR
THREE OATS
Thi s
i s
to
protett
f04
ewwfndshi eld
nstallati onfrom pre
urelnduC8d
I uksbefore
the
ubb
1 hascom
pletely ulconi zecl
BF6988
Be
lure
that i t does not obstruct
vi si bi li ty
The label
noti ng
the faet
that
seali ng
wi llbe
i mpai red
i f
door
i s
opened or
osed wi th
wi ndow
dosed before
sealant
has dri ed wi ll
be
furni shed
wi ththeki t
CAUTI ON
Advi SB
the user
of
the fact that car
should not be dri ven
on
rough
roads
or
surfaces
unti lsealant has
properly
wlcani zed
Reference Peri od
requi red
forsealant
to
dry
to
desi redhardness
Uni t
days
Relati ve
humi di ty
90
50 25
Temperature
oC F
25
77 15
25 6
1050
3 53
10
1014
10 17 34
REPAI RI NG LEAKS
Leaks can
be
repai red
wi thout
reo
movi ng
and
rei nstalli ng
glass
i n
the
followi ng
manner
I To
stop
leaks
li nt remove
mold
i ngs
i narea ofleak
2 Marklocati on
ofleak
I fwateri s
leaki ng
between
caUlki ng
matari al
and
bKfy
orbetween
glass
and
caulki ng
materi al
ci etermi ne
ex
tent
of
leak
by
pushi ng glass
outward
Apply
water
to
leak area
whi le
pushi ng
on
glass
Mark extent
of
leak
poi nt
3
Apply
Pri merandthen
sealant to
leak
poi nts
followi ng procedures
shown below
CAUTI ON
Donot
apply
Pri mar
tooldsi l
one
sealant
BODY Wi ndshi eld
and
Wi ndows
TrUn
1
PrUner
E
PDI Ylulphi de
or
polyureth
ne
sulant
Work
i nto
joi nts
4
l
Si li cone
81lant
BF498B
REAR
QUARTER
WI NDOW
Hardtop
REMOVAL
AND I NSTALLATI ON
I
I
J
I
tJf J
Rear
upperstopper
Front
upper
stopper
0
V
D
Gui de
plate
Rear
quarter
wi ndow
glaM
Annrest
Regulator
handle
SBF175
BF19
Wi nchhi eldandWi ndows
BODY
L
Remove
rearseat cushi on and
rearseat back
2
Remove
regulator
handle and
rear
si defi ni sher
3
Remove ai routlet
gri lle
and
seaI
i ng
screen
4 Remove
upperstoppers
andnuts
attachi ng glass
to
reguI
tor
Remove
gui deplateattachi ng
nuts
5
Remove both
quarter
wi ndow
glass and
gui de
plate tI uoughtop
openi ng
SBFl77
6 Removebolts
attachi ng
regulator
7
Draw
out
regulatortI uough
lower
openi ng
BF
20
8 I nstallati on
i s i n
reverse orderof
removal Glass
adjustment
referto
Adjustment
Apply grease
to
sli di ng
surfaces
of
regulator
and
gui de
channel
ADJUSTMENT
I n out
adJu
tment
At
wa
t
erea
Close rear
quarter
wi ndow com
pletely Adjust
posi ti on
of
adjusti ng
bolt
securi ng
upper
end of
gui de
plate
unti ldi stance between
glass
andrear
quarter
wai st
moldi ng
rubber
seal
i s I 1 2mm
0
441i n
as shown
11 2mm 0441 i n
SBF161
Narrow
I
L
Glass
adjusted
toofartoforward
I D
em
Glassi ncli ned
li D
I n ci ut
adJu
t
nt
Upper
lde of
g
Adjust rear
quarter
wi ndow
glass
posi ti on
as
shown
i n
Fi gure
below
usi ng
adjusti ng
bolt locatedon lower
endof
gui deplate
Si de
roof
rai
I
r
14 17
mmLn
g
055 061
i nlV
Door
glass
SBFl52
AngleadJu tment
Close door
glasses
andrear
quarter
wi ndow
glass
completely
toensure
that
tear
quarter
wi ndow
glass
i s
ali gn
ed wi thdoor
glasses
and fi ts
body
si de
weatherstri ppi ng
Rear
quarter
wi n
ow
glass
I
Wi de
L
Door
wi ndow
glass
Gla sI
adjusted
toofartorear
UD
SBF179
G1 ss
upperstop dJustment
Adjust
two
upperstoppers
unti l
glass
and si de
roof
rai ls are set at
Si de
roof rai l
Door
glass
SBF154
di mensi ons
glass
fully
rai sed i ndi
catedi n
Fi gure
below
y
Q
SBF180
REAR
QUARTER
WI NDOW Hatchback
REMOVAL
AND I NSTALLATI ON
Quarte r
wi ndow
regulator
1
Remove
rearseat cushi on and
sealback
2 Remove
regulator
handle
rear
si de
fmi sherand
top
luggage
si de
fi ni sher
andremove
seali ng
screen
3 Remove bolts
attachi ng glass
to
regulator
b
SBF181
I
f
SBFl
2
BODY
Wi ndshi eld
andWi ndows
4 Remove
regulator
attachi ng
bolts
anddetach
regulator
f
00
0
0
0
06
I I I
5l
SBF18
5 Remove ai routlet gri lle
andrear
fendermoldi ng
SBF184
6 Remove
rear
body
si de
retai ner
SBF185
7
Remove
quarter
wi ndow
attachi ng
screws then
remove
quarter
wi ndow
BF
21
Wi ndli li eldandWi ndows
BO
DY
8 I nstallati on i s i n reverse
orderof
removal
To
prevent
water
leakage
through
door
fasten
seali ng
screen
securely
usi ng
adhesi ve
tape
or
bondi ng
agent
OPERA
WI NDOW
Hardtop
REMOVAL
AND
I NSTALLATI ON
1 Remove rearseat cushi on
seat
back andrear
si defmi sher
2
Remove
assi st
gri p
andrearcorner
fmi sher
SB 187
3
Remove
opera
wi ndow
attachi ng
nuts thenremovewi ndow
SBF188
4 I nstallati on
i s
i n
reverse
orderof
removal
BF22
OPERA
WI NDOW
Hatchback
REMOVAL
AND
I NSTALLAnON
1
Remove rearseat
cushi on
seat
back rear
si de
fi ni sher
and
luggage
si de
upper
fI ni sher
2 Removeai routlet
gri lle
3
Remove
opera
wi ndow
attachi ng
nuts thenremovewi ndow
REAR WI NDOW
Hardtop
Sedan
CD
Rubber
Glass
y
1
SBF189
4
I nstallati on i s i n reverse
order
of
removal
1
Weatherstri p
2
Wi ndow
glass
3
Moldi ng
set
4 Roof
panel
5 Outer
panel
REMOVAL
L
Place
protecti ve
covers on back
doorandrearfenders
2
Rem
ve
parsel
shelf
lUI d
rearsi de
garni shes
after
removi ng
rearseat
cushi on and back from
body
Then
di sconnect rear
wi ndow
defogger
har
@
SBF361
ness at
coMectors
Place
protecti ve
co
ronrear
panel
3
Remove rear
wi ndow
moldi ng
by
pryi ng
out
moldi ng
4
Attachtwo
Suckers ST08800000
to
glass beforehand for
conveni encei n
li fti ng
out rear
wi ndow
glass
5
From i nsi de
passengercompart
ment
apply
hand
pressure
to
edges
of
rear
wi ndow
glass
andremoveweather
stri p
li p
from body flange
starti ng
from
top
tosi des
Use
a
conventi onal
screwdri ver
covered wi th
clothor
other
sui table tool
and
carefully
put
weatherstri p
over
body
flange
J
rO
8F229B
6 Afterrear
wi ndow
weatherstri p
i s
free from
body flange
wi thai d
of a
helper
carefully
remove rearwi ndow
glass
wi th
Suckers
ST08800000
I NSTALLATI ON
I t i s
i mportant
that rearwi ndow
openi ng
i n
body
bechecked
throughly
before i nstallati on
of
rear
wi ndow
glass
Procedurebelow
i ncludes
checki ng
ofrear
wi ndow
openi ng
i n
body
L
Check
refwi ndow
weatherstri p
and
rearwi ndowopeni ng
i n
body
for
any
i rregulari ti es
2
Sti ck Suckers
ST08800000on
rearwi ndow
glass
Wi th
ai dofanother
person
carefully posi ti on
glass
i n
openi ng
i n
body
CAUTI ON
Care
should be
exerci sed
tomake
Certai n
glass
does not
stri ke
body
metal
duri ng
i nstallati on Edge chi ps
can
lead
to
futurebreaks
3 Wi threarwi ndow
glass
supported
and centered
i n
openi ng
i n
body
check
relati onshi p
between glass
and
openi ng
around
enti re
peri meter
of
glass
1
Enti re i nsi de surface of
glass
shouldbei ncontact wi th
openi ng
2 Curvature of
glass
should con
formto
that
of
openi ng
3 Mark
any
secti on
of
openi ng
to
be
reformed
Remove
glass
and
reform
openi ng
as
requi red
4 I nstall rear
wi ndow
glass
as
follows
1
I nstall
rear
wi ndow
weatherstri p
to
glass
t
BF647
2 I nsert a
strong
cord
i n
groove
of
weatherstri p
where
openi ng flange
fi ts
I nsert
Cord
sothat i b ends
areat
bottomcenterof
glass
BF648
1
Wi ndshi eld
glass
2 Draw cord
3
Weatherstri p
BO
OV
Wi ndshi eld
andWi ndows
3 Wi thai d of a
helpercarefully
posi ti on
andcenterrearwi ndow
glass
i n
openi ng
i n
body supporti ng
i t
wi th
Sucker
ST08800000
4 When
glass
and
weatherstri p
are
properly
posi ti oned
i n
openi ng slowly
pull
ends
of cordwi th
another
person
pushi ng glass
from outsi de
starti ng
fromlowercenterof
rear
wi ndow
glass
toseal
li p
of
weatherstri p
on
openi ng
flange
Cord
should be
pulled fi rst
across
bottom
of
glass
then
up
each
si de and
fmally
across
top
5
Carefully tap
around
rear
wi ndow
glass
to
assi st i n
seati ng weatherstri p
on
flange
Never
tap or
hammerat
glass
to
posi ti on
BF650
BF649
5
I nstall all
previ ously
removed
parts
BF23
Wi ndshi eld
andWi ndows BODY
BACKWI NDOW
Hatchback
REMOVAL
l
Remove
both
de
moldi ng
and
cornermoldi ng
2 Remove
four
glass
retai ners
3
Di sconnect rear
defogger
harness
i f
so
equi pped
4
Remove
welt
from i nsi de
pas
senger
compartment
S Remove
butyl
tape
wi tha
putty
kni fe then remove
back
wi l 1do
glass
r5
J
r
SBF191
I NSTALLATI ON
Use
butyltape
of
8mm
0
31
i n
or
equi
alent when
replaci ng glass
BF
24
lumm
1
Wi pe any
trace
of
butyltape
off
glass
anddoor
panel
usi ng
non
leaded
gasoli ne
2 Affi x
butyltape
toenti re
surface
of
glass
as shown
i n
Fi gure
below
1
C
B
Jr
tyltape
6
mm
024i n
Cross
secti on B
B
Besure
to
affi x
butyltape
starti ng
at poi nt
A
fi gure
bon
and
endi ng
at
poi nt
A
and
overlap
some
length
of
tape
at
poi nt
A
Usecaretoaoi dtouchi ng
adhesi ve
si de of
butyltape
wi th
fi ngen
as
fi ngerpri nts
orstai ns
may
reduce
adhesi
e
forceof
tape
Back wbldow
gWs
S8F19Q
3
Usi ng
aheat
gun
heat adhesi ve
si deof
butyltape
to700C
I S80F
4
Apply
bondi ng
agent
to
poi nts
of
glass
as showni n
Fi gures
below
SBF193
t
I
I
2OO
mm7 41i n
4
poi nts
O
SBF194
5
Support
rearwi ndow
glass
wi th
SuckerST08800000
6 Wi th the
help
of
an
assi stant
bri ng
rear
wi ndow
glass
closeto
open
i ng flange
ofrearwi ndow andconnect
rearwi ndow
defogger
harness
7
Carefully
posi ti on
rear
wi ndow
glass
on
openi ng
flange
of
rear
wi n
dow
Check
rear
wi ndow
glass
toensure
that allsi de
dearances
upper
si de
lower
si de left
si de and
ri ght
si de
are
equal
8
Temporari ly
ti ghten
four
reo
tai ners and
li ghtly
tap
around
glass
wi tha rubberfaced
haJ11ffi er
unti l
glass
fi ts
panel
at all
poi nts
as shown
Becarefulnottoscratch
moldi ng
4 5mm
016 o20i n
G S
c
Butyltape
ml J
Backdoor
panel
SBF195
BODY
Wi ndshi eldandWi ndOM
9
Ti ghten
allfourretai ners
securely
andattach
corner
moldi ng
10
Donot
apply
vi brati on
or
shocks
to
glass
forat least one hourafter
glass
has
been i nstalled Di rect water
toward
peri phery
of
glass
to
deter
mi ne
i f there
i s water
leak
i nsi de
passenger
compartment
I I Remove
excess
or
protruded
butyl
tape
1
BF25
Tri mand
Moldi ng BODY
ROOMTRI M
Sun
ri ser
REMOVAL
AND
I NSTALLATlqN
I
Removefront
pi llargarni sh
r
BF197
2 Remove
sun
vi sor
andholder
3 Removeroom
lamp
assembly
4 Remove
roof si de
garni sh
BF
26
TRI MAND
MOLDi NG
HeadI i ni ns
Room
lamp mbly
Wi rul hi eJd
upper
prni sh
I
i f
i i
1 tl
SBF198
5 Remove
rearseat cushi on and
back
6 Remove
assi st
gri p
Hardtop
or
coat
hanger
Hatchback
7 Removerearsi defi ni sher
8 Remove rearcorner fi ni sher
Hardtop
or
luggage
upper
si de
fi ni sherHatchback
Hardtop
Assi stgri P
Rear L
upper
garni sh
SBF196
9 Remove
rearwi ndow
uppergar
ni sh
r
SBF199
10Removehead
li ni ng
I I
I nstallati on
i s
i n reverse orderof
removal
BO
DY
Tri mandMoldi ng
BODY SI DE TRI MAND MOLDI NG
HARDTOP
Rear
si d fi ni sher
Ki cki ng plate
SBF200
HATCHBACK
Rear
body
si deretai ner
Rear
si de
fi ni sher
SBF201
BF27
Tri m
and
Moldi ng BO
DY
REAR PARCEL SHELF
Hardtop
SBF202
BF
28
dSeat
ent
an
600
I ri slflJ
EA1
AND
S
NS1
RUtAEN1
ft
EtlT
STR
U
i
a
I I
1
u
ll
g
I I
i
5
g
J
u
I I
8
e
g
c
u
a
0
li t
l
s
I nstrument
and
Seat BODY
REMOVAL
AND
I NSTALLATI ON
I nstrument
panel
Di sconnect
battery ground
cable
2 Remove
steeri ng
wheelReferto
Steeri ng
WheelST
secti on
forre
moval
3 Remove
shellcoverand com
bi nati on swi tch
4
Remove
i nstrument lower
cover
andsi deventi latorduct
S Remove clusterli d D
Remove
consolebox
6 Di sconnect
wlOng
connectors
from
juncti on
block
7
Di sconnect
speedometer
cable
harness connectors
and
antenna cable
BF
30
SBF204
8 Remove
heater
control
attachi ng
screws andfloor
attachi ng
bolts
9 Removedefroster
gri lle
10
Remove i nstrument
securi ng
bolts
and thenremove
i nstrument
assembly
by pulli ng
i t out
11 I nstallati on i s i nreverse orderof
removal
j
SBF205
BODY
lnStromentBndSeat
CONSOLE
BOX
SBF206
REMOVAL
AND
I NSTALLATI ON
I
Remove screws
attachi ng
console
boxandsli de
console
box
rearward
2 Remove
parki ng
brake and li ft
out consolebox
SEAT
FRONT
SEAT
I
11
S6F207
i fi 16
22N m
11
6
22
kg m
12
3
I nstallati on i s i n reverse orderof
removal
SBF208
BF
31
I nstrumenund
Seat
BO
DY
REAR SEAT
Hardtop
SBF209
Hatchback
l
i i i J
rJ
SBF210
BF
32
SEAT BELT
FRONT SEAT BELT
SBF211
i tJ
Seat
belt
anchorage
bolt
24 31
N m
24 32k
17
23
ft I b
REAR
SEA
r
BEL r
HARDTOP
I
1J2434N
m
12
432k
17
gm
23ft
lbl
HATCHBACK
BODY
I nstrument and
Seat
IJ
24 34N m
24 32k
g
m
17 23ft
lbl
SBF212
BF
33
Sun
Roof BODY
REMOVALAND
I NSTALLATI ON
SUN
ROOF
1 To
unlock
safety
catch
sli de
the
safety
catchknob allthe
way
tothe
left
2
Depress
sun roof handle knob
and
push
handle
up
to
di sengage
i t
fromli nk
3
Remove
sun roof
4
I nstallati on i s i n reverse orderof
removal
BF 34
SUN
ROOF
Bndet
EI Cutcheon
Sun
roofhandle
Safety
catch
Sun
roof
rmi 5her
SBF213
DRAI N
HOSES
o
SBF215
SBF214
I Remove roof
tri m
front
pi llar
tri m
rear
pi llar
tri m and
da
si de
tri m
andthen
removedrai nhoses
2 I nstallati on
i s
i n reverse orderof
removal
After
i nstalli ng
drai n
h
s emure
1hat
watari s
property
drai ned
outsi de
car
wi thno
seepage
i nto
passenger
compartment
DESCRI PTI ON
DI MENSI ON
LI NES
Alldi mensi ons
i ndi cated i n
the
drawi ngs
i llustrati ons
arethe
standard
desi gn
values
I
Black di mensi on
li ne
I ndi cates
a
di stance
from a
phantom
li ne of the
car
body
toa
poi nt
tobe
measured
andcannot
be
measuredwi th
a meas
uri ng tape
or
tram
tracki ng
gauge
2 Thi n
li ne I ndi cates
a di rect or
an
actual di stance or
length
between
two
poi nts
andcan
be
measured
wi th
a
measuri ng
tape
ortram
tracki ng gauge
An asteri sk followi ng
thevalue
at the
measuri ng
poi nt
i ndi catesthat
the
measuri ng poi nt
on the othersi de
i s symmetri cally
the same value
ENGI NE COMPARTMENT
BODY
ALI GNMENT
MEASUREMENT
OPERATI ONS
When car
body
measurements
are
taken i n accordance wi ththe
thi ck
li ne carefulconsi derati on
should be
gi ven
to
the
followi ng poi nts
1 Measurement
method
I When
a tramtracki ng gauge
i sused
adjust poi nte
A
and
B
to
equal
lengths
as shown
i n
the
fi gure
be
low
Check
the
poi nte
and
gauge
i tself to
make
sure
therei s
nofree
play
I
A
f
I
B
BODY BodyAli gnment
2 When a
measuri ng tape
i s used
check
to
be sure
therei sno
elonga
ti on
twi sti ng
or
bendi ng
I f a
part
or
parts
of the car
body
i nterferes
wi th
measurement
when
usi ng
the measuri ng tape you
cannot
measure
the di stance or
length
accu
rately
2
Measurement poi nt
Measurements
should
be taken
at
thecenterof
mounti ng
holes
Uni t
mm
i n
SBF216
BF35
cl
I f
n
J
U
i
1
L
o
1
i
I
R
H
n
Fm
I 4
g
i g
l
I l
N
i f
76
1i
i
r
Jlf
1
I
ol
v
l
0
f
N
l
I
y
I
0
51
Cu
Nol
N
I
I
t
i
m7
1
l
db
no
I
I
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o
q
L
H
r
V
I
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0
I h
I
0
1
i
h
J
II
u
c
i l
9
t
t
O
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J
c
q
69
I
8
9
0
7
I
l
4J
r
r
2
t
I S
51
Seeti onB
B
ScttlonC
C
9
8
rr
p
Seeli on
A
A
ntf
n
m
24
0
0
945
Front floor
Fronlu
1C
ocnI crli nc
I
RCLUI e centerli ne
Oalumli n
en
r
2
4
t
sOtO
2
t
h
1
91tO
008l
0
02
i f
rl
J
197tO
008
tt
I
0
93tO
2
28
1l1
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c
I
11
s5
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3
6610
008
o
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ALLOWANCE
FOa
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PI XI NG
I
L
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SI DE
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i
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91
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11
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8
70
917
D
tum
li ne
695
17
36
R
H
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109
68
7
i
70S
8
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19
I
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37
31
69
161
1
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lde
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611
14
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9
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Uni t
rnmli n
cz
I I I aI I o
i
t
I
tD
o
o
I
j
Toolnumber
Kent
MooreNo
ST08800000
ST08810000
SPECI ALSERVI CE
TOOLS
Toolname
Sucker
8W
Caulki ng
hand
gun
BODY Speci al
Servi ce
Tools
BF
37
DATSUN
200SX
Model
S11
0
Seri es
SECTI ONHA
HEATER
AI R CONDI TI ONER
CONTENTS
I
HEATER
I
DESCRI PTI ON
HEATER SYSTEM
HEATER COMPONENTS
AI R
FLOW
SERVI CE PROCEDURES
HEATER CONTROL
ASSEMBLY
HEATER UNI T
BLOWER UNI T
RESI STOR
HEATER DUCT
REAR HEATER DUCT
DEFROSTER NOZZLE
VENTI LATOR DUCT
ELECTRI CAL CI RCUI T
SCHEMATI C
WI RI NG DI AGRAM
TROUBLE DI AGNOSES
AND CORRECTI ONS
I
AI R
CONDI TI ONER
I
DESCRI PTI ON
REFRI GERATI ON
CYCLE
AI R CONDI TI ONI NG
COMPONENTS
LOCATI ON
OF
ELECTRI CAL
AND VACUUM
UNI T
AI R
FLOW
GENERAL SERVI CE
PRECAUTI ONS
I NSTALLI NG MANI FOLD
GAUGE
HANDLI NG REFRI GERANT
SERVI CE
CAN
TAP
DI SCHARGI NG REFRI GERANT
EVACUATI NG
AND
CHARGI NG REFRI GERANT
SYSTEM
COMPRESSOR
OI L LEVEL CHECK
PERFORMANCE TEST
PERFORMANCE CHART
PERFORMANCE
TEST
DI AGNOSES
HA 2
HA 2
HA 2
HA 3
HA 4
HA 4
HA 5
HA 6
HA 6
HA 7
HA 7
HA 7
HA 7
HA B
HA 8
HA 8
HA 9
HA l0
HA l0
HA ll
HA 12
HA 12
HA 13
HA 13
HA 13
HA 14
HA 14
HA 14
HA 16
HA 17
HA 17
HA20
SERVI CE PROCEDURE
PRECAUTI ONS
FOR REMOVAL
AND
I NSTALLATI ON
REFRI GERANT LI NES
COMPRESSOR
I DLER PULLEY
COMPRESSOR
CONDENSER
RECEI VER DRI ER I LlOUI D TANK
FAST I DLE ACTUATOR
COOLER RELAY
COOLI NG
UNI T
AMBI ENT SWI TCH
EXPANSI ON VALVE AND
SUCTI ON
THROTTLE
VALVE
AI R CONDI TI ONER CONTROL ASSEMBLY
BLOWER UNI T
RESI STOR
MAGNET VALVE
COMPRESSOR SWP167
PRECAUTI ONS
COMPRESSOR CLUTCH
SHAFT SEAL
SI DE
COVER
REAR
END COVER AND
REAR
CYLI NDER
HEAD
REPLACEMENT OFCYLI NDER
ELECTRI CAL
CI RCUI T
SCHEMATI C
WI RI NG DI AGRAM
TROUBLE DI AGNOSES
AND CORRECTI ONS
AI R CONDI TI ONER
DI AGNOSES
BLOWER MOTOR
DI AGNOSES
COMPRESSOR CLUTCHDI AGNOSES
COMPRESSOR DI AGNOSES
FAST
I DLE CONTROL
DEVI CE
DI AGNOSES
SERVI CE DATA
AND SPECI FI CATI ONS
GENERALSPECI FI CATI ONS
I NSPECTI ON ANOADJUSTMENT
TI GHTENI NG TOROUE
SPECI AL
SERVI CE
TOOLS
Ref to
Secti on
MA HeaterandAi rCondi ti onerfor
CHECKI NG REFRI GERANT LEVEL
CHECKI NG REFRI GERANT LEAKS
ReflrtoSecti onMA Basi cMechani ClI
Systam
for
CHECKI NG AND ADJUSTI NG DRI VE
BELTS
HA 24
HA 24
HA
25
HA 25
HA 26
HA 26
HA 26
HA 27
HA27
HA
27
HA27
HA
28
HA28
HA28
HA
28
HA2B
HA29
HA30
HA30
HA32
HA33
HA34
HA35
HA 37
HA37
HA38
HA 39
HA 39
HA 4l
HA 43
HA 45
HA 47
HA 48
HA 48
HA 48
HA 48
HA 4
r
Desrri pti on HEATER
DESCRI PTI ON
HEATER SYSTEM
To
defrosternozzle
Toventi lator
duct
ToYenti lator
duct
Floor
door
To
floor
Freshai r
c o
t
I ntakedoor
Jr
5L lLJU
J
e
J
I
eci Jculati OD
L
UlT
nn
J
au
J
j
i
1I 11
hJ
L
1b
To
ear
L
Ai rmi x
r
S
er
I
door
Blower
motor
Tofloor
Tofloor
To
rear
heater
duct Heatercore
Si devi ew
SHA113
HEATI E
R
COMPONENTS
Si de
defroster
QDterddroster
oo
Si de
defrolter
Heatercore f
I I Jrffi 5
noule
Heater
control
assembly
IIoClfj
Blowermotor
Watercoet
Heaterduct
0
fr
i tch
Ai rui de
Ai rSUi de
C eonaol
ti ni aher
Si deventi latnr
duct
J
SHA114
HA 2
AI R FLOW
VENT
posi ti on
FRESH
posi ti o7n
VE
po
t
n
r
o
o
tj J
i f 5
to
thedesi red
posi ti on
BI L
BI
I evelposi ti on
br
o
ll
rr
L
Move thelever
the
desi red
pos O
DEF
posi ti on
DEF
POsi ti on
FRESH
posi ti xJD1
3
1ky
o
E
Move
thelever
the
desi red
posi ti on
HEAT
posi ti on
FRESHPOsi t
7
HEAT
POsi ti oo
J
tb1
o
I I
4
Move
thelever
dai red
POI
V
REC
posi ti on
REC7
i ti on
TpoI i ti on
r
oo
J
0
Move
the
I e
the
desi red Ji i o Y
I
li
C
Si de
vi ew
HEATER
Descri pti on
Freshai r
1
j
1
l
H
111111111111
rlrl
1I
I l
Jc
TOVenti l
torduc
roster
17
1
ljfd
o
l
i
i j
L
To
floor
Torear
Tofloor
heater
duct
l
r
To
defroster
nozzle
L
Tofloor
Torear
Tofloor
heaterduct
Reci rculati on
Tfrl
oo
jJ
I l tjfT
J
LTCi
t
lllllll
I J
r
I f
sL
SHA116
HA J
SHA116
@
I Dumi nati on
4 Remove
pi vot pi n
lamp
I
OFF
I I
2 3
I
Termi nal
L
I
@
I
I
@
I I
I I
0
I
I
@
I
i 1
I
QD
I I
@
I v
16
I
ServkeProcedut f
HEATER
HEATER CONTROL
ASSEMBLY
REMOVAL AND
I NSTAUATI ON
I Remove i nstrument lower
covers
andcluster
li ds
2 Di sconnect
controlcables
from
heater
uni t
andblower
uni t
3 Di scOnnect
harness connectors
and
ground
wi re
termi nal
SHA117
5 Remove heatercontrol
assembly
6 I nstallati on
i s i n
thereverse
order
ofremoval
Alter
i nstalli ng adjust
control
cable
by
ref
ri ng
to
Adjusti ng
Heater
Con
trol
I NSPECTI ON
Fan swi tch
Test
conti nui ty through
swi tch
wi thatest
lamp
or
ohnuneter
HA 4
SERVI CE PROCEDURE
Always
conduct
I
Tenn
IDI Q
@ I
r
Wunti nati oo
lamp
SHA118
ADJUSnNG
HEATER
CONTROL
REC
posi ti on
I
I nbkedoorcontrolcable
I Set ai ri ntakeleverat REC
posi
ti on
2 Connect controlcable to
ai ri n
take doorleverwhi le
pushi ng
leverto
i ts Closed
posi ti on
3
Securely
clamp
the cable
whi le
pushi ng
cable outercase i n di recti on
ofarrow
SHA119
Ai rmi xdoor
controlcable
I Set
temperature
leverat max
COLD
posi ti on
2
Connect controlcable toai r
mi x
door
lever
whi le
pushi ng
lever
to
i ts
full
open
posi ti on
3
Securely
clamp
the
ca ble
whi le
pushi ng
cable outercase
i n
di recti on
ofarrow
MM
Max COLD
posi ti on
l
SHA18Q
A1rcontrolceble
I
Set ai r
control
leverat DEF
posi ti on
2 Connect
controlcable to
si de
li nkage
whi le
pushi ng
the
li nkage
i n
di recti on of
arrow
3
Securely
clamp
the
cable whi le
pushi ng
cable
outercase
i n di recti on
of arrow
DEF
posi ti on
I
I
SHA121
Watercock
control
li nkage
I
Set
ai r
mi x door
leverat max
COW
posi ti on
2
Securely
clamp
controlrod whi le
pushi ng
water
cock
lever
to
i ts
full
closed
posi ti on
1
c
cI 4f
a
Max
COLD
posi ti on
Adjusti ng
saew
r
SHA122
HEATER UNI T
REMOVAL
AND
I NSTALLATI ON
I
Set TEMP
lever
to
max HOT
posi ti on
anddrai n
engi ne
coolant
2 Di sconnect
heaterhoses from
heater
uni t
3 Remove
foUowi ng Wi s
I
Front seats
2
Consolebox
3
Floor
carpet
4
I nstrument lower
covers and
clusterli ds
5
Si de venti latorduct
on the
left
handsi de
SHA123
H
EATER Servi ceProcedures
6
Radi o
sound balancer
andstereo
cassette deck
7
Stay
ofi nstrument
panel
I
8
Rearheaterduct
SHA125
19
Centerventi latorduct
I
1
SHA126
HA 5
Servi ceProcedures HEATER
10
Ai r
gui des
at loweroutlets
Ri ght
si de
gui de
1
SHA127
4
Di soonnect wi re harness connec
ti ons
5 Remove heater
1J1i t
wi th
heater
lntrohssembly
SHA128
6 Remove heater
control
assembly
Refer
to
thei tem
o
HeaterControl
Assembly
7
I nstallati on i s i n
the
reverseorder
ofremoval
After
i nstalli ng
heateruni t
lKljust
controlcoble
by referri ng
to
Adjusti ng
HeaterControl
DI SASSEMBLY AND
ASSEMBLY
I
Remove heatercore
wi tli
water
cock
HA 6
r
SHA129
2 Remove
ai r
controlli nkage
secur
i ng
screws
SHA130
5eparate
heater
uni t case
by re
movi ng cli ps
4
Assemble heater
uni t i n
the reo
verseorder
of
di sassembly
a After
i nstalli ng
heater
core
and
watercock
lKljust
watercock
co
trol
li nkage by referri ng
to
Adjust
i ng
HeaterControl
b When
assembli ng
ai rcontrol
li nk
age
set
i t as i llustrated
SHA131
I NSPECTI ON
Cee
I f i t i s cracked ordeformed re
place
rI l core
Clean fmsandcheck forwater
leak
age
BLOWER UNI T
REMOVAL
AND
I NSTAlLATI ON
I
Remove i nstrument lower
oover
andclusterli dontI i e
ri ght
hand
2 Di sconnect control cable
and
harness
connectorfrom blower
uni t
3 Removebloweruni t
I
SHA132
4
I nstallati on
i si n thereverseorder
of removal
Adju 1
r
corrtrolcablebi
referri ng
to
Adjusti ng
Heater
Control
DI SASSEMBLY
I Removeblower
D
otor
2
Separate
blower
uni t
case
by
reo
movi ng
cli ps
RESI STOR
REMOVAL AND
I NSTALLAnON
I Remove
i nstrument
cluster
li d
2
Removeresi stor
fromheateruni t
Temperature
fuse
Resi storw
SHA134
3 I nstall
resi storso
that
temperature
fuselocates
at
upper
si de
I NSPECTI ON
Test
conti nui ty usi ng
test
lamp
or
ohmmeter
JI
T jf
@
o@ uCD
HEATER DUCT
REMOVAL
AND
I NSTALLATI ON
Proceed after
removi ng
i nstrument
lower
cover
and
clusterli d
onthe
ri ght
handsi de
SHA136
REAR HEATER
D CT
REMOVAL AND
I NSTALLATI ON
Refertothe
i tem
on
Heater
Uni t
DEFROSTER NOZZLE
REMOVAL
AND
I N TALLATI ON
Front wi ndowdefroster
nozzle
Proceed afterreJlK
vi ng
i nstrument
assembly
SHA137
Si dewi ndowdefrosternozzle
Proceed after
removi ng
i nstrument
lowercoversandclusterli ds
Left si de
Ri ght
si de
HEATER Servi ce
Procedures
VENTI LATOR
DUCT
REMOVAL AND
I NSTALLATI ON
Centerventi lator
duct
Refertothe
i tem
on
Heater
Uni t
Si deventi lator
duct
Left i de
Refer
tothei tem
on
Heater
Uni t
Ri ghUi de
Proceed after
removi ng
i nstrument
assembly
3
F
J
c
SHA139
Foot venti latorduct
I
SHA
140
HA
7
Electri calCi rwi r
HEATER
ELECTRI CAL CI RCUI T
SCHEMATI C
RESI STOR
I
FUSE
I SA
MOToR
u
O
c
TO
WI PER
TO
AI
R
CONOlTlONER
SWI TCH
BLOWER
I
1M
Jl
n
u
LAM
FAN SWI TCH
L
1
IW
r
I GNI TI ON
RELAY
I
c
J
15 1
r
I LLUMI NATI ON
CONTROL
SWI TCH
BATTERY
I GNI TI ON
SWI TCH
B Q
I
FUSI BLE LI NK
SHA141
WI RI NG
DI AGRAM
BLOWER
j
MOTOR
RESI STOR
4J
LHJ
TO
WI
PfR
G
ow
LI GHTI NG
SWI TCH
3
J
JI
TOAI R
CONDI TI ONER
SWI TCH
00
4e
FUSE
2
I t
f
j
FAN
SWt
reH
I LlUMlNATI ONC
J
CONTROL
SWI reH
t
l
GN T
ON
RELAY
1
I
G I I TI ON
SWI TCH
I UUI I I I NATI ON
L
P
FUSI BLE LI NK
i
fBATTERY
SHA14
HA S
HEATER Trouble
Di agnoses
andCorrecti ons
TROUBLE DI AGNOSES AND
CORRECTI ONS
Condi ti on
I nsuffi ci ent
heati ng
performance
Noheatedai r
di scharged
I nsuffi ci ent ai rflow
tofloor
I nsuffi ci ent
defrosti ng
performance
Coldai r
di scharged
I nsuffi ci ent
ai r
flow
todefroster
Heatedai r
di scharged
wi thlever
i nVENT
Blowermotor
does
not
operate
Controllever
drags
Outsi de
ai r
comes
i n
wi th
AI Rcontrol
leverREC
Noi se
from
blower
motor
Probab
I e
cause
Cooli ng
water
temperature
toolow
Heatercore
plugged
I nsuffi ci ent cOoli ng
waterlevel
Malfuncti oni ng
ai r
mi x
door
Malfuncti oni ng
watercock
Blowermotorspeedtoo
low
Malfuncti oni ng
floor
door
Referto
No
heated
ai r
di scharged
Malfuncti oni ng
floor
dooror
faulty
seal
Defrosternozzle
plugged
Leak
at defrosterduct tonozzle
connecti on
Watercock
not
operati ng properly
Mode door
not
operati ng properly
or
seal
damaged
RefertoTroubleDi agnoses
andCorrecti ons
Ai rcondi ti oner
I nnerwi re
rubbi ng agai nst
outercase
end
Controlcablebent
excessi vely
Malfuncti oni ng
doorn doorlevers etc
Ai r
i ntakedoor
not
operati ng properly
Controlcableout
of
adjustment
Loosebolt i nblowermotor
Correcti ve cti on
Check
thermostat
Replace
as
necessary
Clean
Refi ll
Adjust
controlcable
Adjust
control
cable Check watercock
Replace
as
necessary
Checkmotor
termi nal
voltage
Repai rpoor
connecti on
and
di sconti nui ty
Replace
motori f
necessary
Adjust
controlcable
Adjust
control
cable
Clean
Correct
Adjust
controlcable Check watercock
Replace
as necessary
Adjust
controlcable
Adjust
controlcable
Correct
Check andcorrect
Repai r
or
rep
ce
Adjust
control
cable
Check and
ti ghten
loosebolts
HA
9
Descri pti on
AI R CONDI TI ONER
DESCRI PTI ON
REFRI GERATI ON
CYCLE
Compressor
The
low
pressure
refri g
erant
i s
compressed
to
a
hh
pJe SU1
C
and
hi gh
Jle
i
N
V
I s
I
l
Outsi deai r
u
lPI l
I vxyyv
I
R dri er
JJ
r
l
Condenser
The heated and com
pressed refri gerant
gas
from the
compressor
condenses to
a
li qui d
Stores the
li qui drefri g
erant and removes
moi sture
and
forei gn
parti cles
as the
refri g
erant ci rculates
wi thi n
thesystem
i
Hi ghpressure
valve
Di scluuges
refri gerant
to
atmosphere
at
pres
lfes
above 3 727 I cPa
38
kgfem2
540psi
Low
pmmue
swi tch
Tums
OFFat
pressures
below 196
I cPa
2
81
em
2
28
psi cutti ng
compressOI power
supply
HA l0
w
w
q
vi
t e
w
fL
w
tmfJ
Hi gh
pressure
gas
t
l
Hi ghpresswe
li qui d
Evaporator
The
refri gerant
evaporates
and
theai r
li qui d
cools
o
Expansi on
valve
Deli Vers
sprayedrefri g
erant tothe
eVaporator
tofaci li tate
refri gerant
hhl
and con
trols the amount of re
fri gerant possi ng
the
ori fke
Low
pressure
li qui d
1 01
Low
pre
sure
gas
Reci rculati onai r
V
I
J b
Blowermotor
Controls
the
enporat
i ns pressure
and
pi
vents e fomati on
of
thefrost
SHA142
AI R CON
DI TI ONER
Descri pti on
AI R CONDI TI ONI NG
COMPONENTS
a
o
I
1I
5
l
s
a
o
5
2
e
l
L
e
8
j
j
u
8
SH 143
HA ll
Desr ri pti on AI R
CONDI TI ONER
LOCATI ON
OF
ELECTRI CAL
AND VAcuuM
UNI T
L
SHA1
AI R
FLOW
Ai r
flow
at
any
posi ti on
VENT
B
L
HEAT DEF and REC i s the
same as that of
HEATER
except
that
passes
through
cooli ng
uni t
aU
ai r
di scharged
wi thblower
uni t
To
To
O i deai r
defroster
venti lator
n
Venti lator
door
nozzlll
duct
Todeli o
tornow
1
1
r
1t
ti
7u
1Mi
T
lJ
7
i I llJlL
1 i
ll
Qjr lr
mower
motor
Tofloor
Tof1oor
To
Tofloor
Si de
vi ew
rear
heater Heatercore
duct
SMA
146
J
HA 12
J
PRECAUTI ONS
WARNI NG
1 Si ncedi rect conlllct
of
the
li qui d
refri gerant
wi th
your
ski n wi ll
muse
frostbi te
always
becareful
when
handli ng
the
refri gerant
Always
wear
goggles
to
protect
youreyes
when
worki ng
around
the
system
2 The
refri gerant
servi ceconllli ner
has
a safe
strength
Howeveri f
handled
i ncorrectly
i t wi llex
plode
Therefore
always
follow
the i nstructi ons on thelabelI n
parti cular
neverstorei t i na hot
locati on
above
S20C 1260F
or
drop
i t froma
hi ghhei ght
3 The
refri gerant gas
i s odorless
and colorless andbreath
i ng may
become
di ffi cult
duetothelack
of
oxygen
Si ncethe
refri gerant
gas
i s heavi erthan ai randwi ll
lay
close tothefloorbe
espe
ci ally
carefulwhen
handli ng
i t i n
smallconfi ned
spaces
4The
refri gerant
i tsei t
i s
nonflam
mable
Howevera
toxi c
gas
phosgenegas
i s
produced
when
i t
conlllCb
fi reand
speci al
carei s
therefore
requi red
when check
i ng
for
leaks i nthe
system
wi tha
hali de
torch
5 Donot
steam
clean
on
the
sys
tem
especi ally
condenser
si nce
excessi vely hi gh pressure
wi ll
bui ld
up
i n the
system resulti ng
i n
explosi on
ofthe
system
Connecti on to
servi cevlve
I
Funy
close bothvalves of
mani
fold
gauge
Connect
hi gh
and
low
pressure chargi ng
hoses to
mani fold
gauge
2 Remove
caps
from
servi ce valves
Connect
hi gh
andlow
pressure
charg
i ng
hosestoservi ce valvesi n
system
i
i
GENERAL
SERVI CE
r
AI R
CONDI TI ONER
General
Servi ce
I NSTALLI NG MANI FOLD GAUGE
Hoses for
the
low
pressure
valve sucti on
valve
and
hi gh
pressure
valve
di scharge
valve
should
beconnected
securely to hi gh
and low
respecti vely
on
the mani fold
Refer
toi denti fi cati on
markson
compressor
Low
pressure
gauge
Hi gh
pressure
gauge
Mani fold
gauge
Before
connecti ng
hoses
closevalves
completely
Q
1fT
oen
R 12
Vacuum
pump
r
S
Close
I
Cap
2
Servi ce
valve
3
Cha
rgi ng
hose
4
Packi ng
5
Check
valve
Refri gerant
can
SH
A045
Di sconnecti on from
servi ce valve
I
Fully
close bothvalves of mani
fold
gauge
2
Qui ckly
di sconnect
two
chargi ng
hoses from servi ce valves and i nstall
caps
on
servi ce
valves
CAUTI DN
Donot over
ti ghten
valve
cap
HA 13
GeneralServi ce
AI R
CONDI TI ON
ER
HANDLI NG
REFRI GERANT
SERVI CE
CAN TAP
The
foUowi ng
procedures
apply
to
conventi onalcan
taps
Forcorrect
usage
referto the
manufacturersi nstructi ons
I Connect
chargi ng
hose between
mani fold
gauge
and can
tap
2
FuUy
turn
i n
close valvestemof
mani fold
gauge
3
Attachcan
tap
to
refri gerant
can
by turni ng
can
tap
handle
fuUy
counterclockwi se
4 Make a hole
i n
refri gerant
can
by
turni ng
can
tap
handle clockwi se
n
Needle
Car
tap
handle
Refri gerant
an
r
SHA046
5
TUrn the handle
fully
counter
clockwi seto
rai se
theneedle
Refri ger
ant
gas
wi llflow
up
tothe
mani fold
gauge
n
SHA041
6
Purge
ai rfrom
chargi ng
hose
by
looseni ng
chargi ng
hose
nut at mani
fold
gauge
HA 14
I
Purgi ng
ai r
W
Add
Fl12
SHA04S
DI SCHARGI NG
REFRI GERANT
The
pressuri zed refri gerant gas
i n
si de
the
system
must
be
di scharged
at
a
pressure approachi ng atmospheri c
pressurepri or
to
evacuati ng refri gerant
i nsi dethe
system
I
Close
hi gh
and low
pressure
valves
ofmani fold
gaugefuUy
2 Connect two
chargi ng
hoses of
mani fold
gauge
to
thei r
respecti ve
servi cevavles
WARNI NG
Securely
connect
hi ghpressure
di s
charge
servi ce valve to that of
mani fold
gauge
wi tha hose also
cOnnect low
pressure
sucti on
servi ce valve
tothat of mani fol
gauge
3
Open
bothmani fold
gauge
valves
and
di scharge refri gerant
from
system
LO
rJ
Hi gh
1
Slowly
Slowly
40
SHA949
EVACUATI NG AND
CHARGI NG
REFRI GERANT
SYSTEM
EVACUATI NG REFRI GERANT
SYSnW
I
I nstaU mani fold
gauge
on
system
and
di scharge
refri gerant
from
system
unti l
pressure
reaches
atmospheri c
pressure
WARNI NG
Securely
connect
hi gh
pressure
di s
charge
servi ce
valve
tothat of
mani fold
gauge
wi th
a hose also
conn
ect
low
pressure
sucti on
servi ce valve to
that
of
mani fold
gauge
2 Connect center
chargi ng
hose
to
vacuum
pump
3 Close bothvalves of mani fold
gauge
fuUy
Thenstart
vacuum
pump
4
Open
low
pressure
valve
and
SlI ck
old
refri gerant
from
system
p
Open
Oose
40
U0
SHA060
5
When low
pressure gauge readi ng
hasreachedto
approxi mately
667
kPS
500
mrnHg
1969
i nHg
slowly
open
hi gh
pressure
valve
Low
0
lli gh
W
lOpen
00
SHA051
6 When
pressure
i nsi de system
has
dropped
to94
6 kPa 710
mmHg
27 95
i nHg
fully
close bothvalves of
mani fold
gauge
and
stop
vacuum
pump
Let i t
standfor
5 to
10
mi nutes
i n thi s state and
confI rm that the
readi ng
does
not
ri se
B The low
pressure
gauge
reads lower
by
33
kPa 25
mmHg
098
i nHg
per
300m 1 000i tlelevati on
Perform evacuati on
accordi ng
to
the
followi ng
table
Elevati on
m ft
00
300I 000
6002000
9003000
Vacuumof
system
kPa
mmHg i nHg
946
71027 95
91 3685 2697
88 066025 98
846635
25 00
Valuesshow
readi ng
ofthe
low
pressuregauge
b The rate of ascensi on of
the low
pressure
gauge
should
be
leI S than
33 kPa 25
mmHg
098
i nHg
i n
fi ve
mi nutes
I fthe
pressure
ri ses
or
the
speci fi ed
negati vepressure
ean
not
be
obtai ned
there
i s
a leak i n the
system
I n
thi s
ease repai r
theleak
as
descri bedi nthe
followi ng
I
Charge
system
wi tha can of
refri gerant
about 0
4
kg
09 I b
Referto
Chargi ng Refri gerant
2 Check for
refri gerant leakage
wi th
a leak detector
Repai rany
leakages
found Referto
Checki ng
for
Leaks
MA
secti on
3
Di scharge refri gerant agai n
and
thenevacuate
system
CHARGI NG
REFRI GERANT
SYSTEM
I
Evacuate
refri gerant system
2
Close mani fold
gauge
valves
securely
anddi sconnect
chargi ng
hose
from
vacuum
pump
3
Purge
ai r
from
center
chargi ng
hose
I Connect center
chargi ng
hose to
refri gerant
can
through
can
top
2
Break sealof
refri gerant
can and
purge
ai r
I
1
Purgi ng
ai r
k
R 12
SHA048
4
Chargerefri gerant
i nto
system
I I ncaseof
chargi ng
re
i gerant
gas
Open
hi gh
and low
pressure
valves
of mani fold
gauge
and
charge refri ger
ant
i nto
system
Low
lt lt
o
W
O n
9ft
Open
t
r
SHA052
AI R CONDI TI ONER GeneralSefYi ce
When
refri gerant chargi ng peed
i
slow i mmerse
refri gerant
can i nwater
heated toa
temperature
of about
400cI 1Q4OFlfora short ti me
WARNI NG
a
Undernoci rcumstances the
re
fri gerant
can bewannedi nwater
heated to
a
temperature
of
over
520C 1260F
b A blow torch or
stove
must
neverbeused to
warm
up
the
can
I mmerse
izl
i n
water
heated to
about
r
400C
1040F
fora short
ti me
A 12
AC184A
2 ln
case
of
chargi ng li quefi ed
re
fri gerant
Open hi gh
pressure
valve
of mani
fold
gauge
and
charge li quefi ed
reo
fri gerant
i nto
system
wi thcan
upsi de
down
CAUTI ON
When
chargi ng
li quefi ed refri gerant
i ntothe
system
wi ththecan
turned
upsi de
down
toreduce
chargi ng
ti ma
charge
i t
only
through
hi ghpressure
di scharge
servi ce valve Aftercom
pleti on
of
chargi ng
the
compressor
should
always
beturnedseveralti mes
manually
10
Close
Open
t
SHAOS
HA
15
GeneralSefVi ce
AI R
CONDI TI ONER
5
When
refri gerant chargi ni J sPeed
slows down
charge
i t whi le
runni ng
the
compressor
forease of
chargi ng
After
havi ng
taken
the
steps up
to
3
above
proceed
wi th
cahrgi ng
i n
the
followi ng
order
I
Shut off
hi gh
pressure
valve of
mani fold
gauge
2
Run the
engi ne
at
i dli ng speeds
below
1500 rpm
3 Set
mode di al
temperature
di al
and fan leverat maxi mum 0001
and
speed
respecti vely
4
Charge refri gerant
whi le oon
trolli ng
low
pressure
gauge
readi ng
at
275 kPa 28
kg
em2 40
psi
orless
by turni ng
i n
or
out
low
pressure
valve
ofmani fold
gauge
WARNI NG
NgVl l
wrge
mri gerant through
hi ghpressure
si de
di scharge
si de
of
systerri
si nce
thi s
wi ll
fon ent
fri gerant
back
i nto
refri gerant
can
and
can
may explode
Run
at
i dli ng
1
w
aose
T
t
Q SHA054
6 When
refri gerant
can
i s
empty
fully
close bothvalves of mani fold
gauge
and
replace refri gerant
can wi th
anewone
Before
chargi ng refri gerant
ftom
newcan
purge
ai rfrom
i nsi de
charg
i ng
hose
7
Charge
the
speci fi ed
amount of
refri gerant
i nto
system by wei ghi ng
charged refri gerant
wi th
scale Owr
chargi lg
wi llcause
di scharge pressure
to
ri se
HA
16
Refri gerant
capaci ty
09 1 1
kg
2 02 4I b
Measure
thea
mountor
chargedrefri ger
ant
wi th
a scale
Make
a
note
of
the
amount
charged
from
can
AC252
The state of the bubbles
i n
si ght
glass
should
only
be used for
checki ng
whgtherthe
amount
of
charged
r
fri gerant
i s small
or
not Refer
to
Checki ng Refri gerant
Level Secti on
MAl
The
amount
of
charged
refri ger
ant
can
be
correctly judged
by
means
of
di schargepressure
8 Closemani fold
gauge
valves Then
detach
chargi ng
hoses from
servi ce
valves of
system
Be sure toi nstall
valve
cap
on
servi ce
valve
9 ConI umthat therearenoleaks
i n
system
by
checki ng
wi tha leak
detec
tor
Referto
Checki ng
forLeaks MA
secti on
Conducti ng a
performance
test
pri or
to
removi ng
mani fold
gauge
i s
8
good
servi ce
operati on
RefertoPer
formance
Test
COMPRESSOR OI L
LEVEL CHECK
The oi l
used
tolubri catethe
com
pressor
ci rculate i ntothe
system
from
the ai l
sump
whi le
compressor
i
operati ng
Therefore to
correctly
measure
compressor
oi lthe
amount of
oi l
flowi ng
i n the
system
must
be
consi dered
I f
a consi derable
amount
of
leakage
of
refri gerant gas
occurs
tha
leakage
of
compressor
oi li s also
consi dered
When
checki ng
the levelof oom
pressor
oi l
or
when
replaci ng
any
w
r
ent
part
ofthe
system
use
the
followi ng
servi ce
procedure
Thi s
helps
toreturnoi lto
oompressor
I
Fully open
allwi ndows or
all
doors of car
Opernte compressor
at
engi ne i dli ng speed
1 000
rpm
orbe
low wi th
controls set formaxi mum
cooli ng
and
hi gh
blower
speed
for20
to30
mi nutes
i n
ordertoreturncom
pressor
oi lto
compressor
ON
i
1
11
MAX COLD
MAX
FAN SPEED
SHA376
2
Stop
the
engi ne
and
di scharge
re
fri gerant
of
system
and then remove
oompressor
fromthecar
3 Remove
oompressor
drai n
plug
Drai n
compressor
oi lfrom
oompressor
oi l
si unp
andmeasuretheamount
SHA056
Resi dual
oi lle
l
160
190
m
5 4 64US
OZ
5 6 67
I mp
fl
ozl
4 I ftheamount
i s
belowtheabove
values
refri gerant
may
have leaked
Conduct leak tests
on
connecti ons of
each
system
andi f
necessary
repai r
or
replacefaulty parts
5 Check the
puri ty
of theoi lI fthe
oi lcontai ns
chi ps
orother
forei gn
materi alclean oi l
sump
wi thnewoi l
6 Di scard theused oi landfi llwi th
the sani e amount of new oi las
was
drai nedwhen
removi ng compressor
I f
the resi dualoi lleveli s below the
mi ni mum leveladdaddi ti onaloi lto
reachthemi ni mumlevel
PERFORMANCE
CHART
TEST
CONDI TI ON
Testi ng
must
be
performed
as follows
Carlocati on
Doors
Doorwi ndow
Hood
MODE
di al
TEMP
di al
FAN lever
Engi ne
speed
Mani fold
gauge
Measurement
of
di scharge
ai r
temperature
Measurement ofi nsi de
ai rrelati ve
humi di ty
and
temperature
Measurement ofambi ent
ai r
relati ve
humi di ty
and
temperature
AI R
CONDI TI ONER
Performance Te t
PERFORMANCE
TEST
I ndoors or
i nthe
shade
outsi dewi nd
veloci ty
Lessthan
2
m
7
ft sec
Closed
Open
Open
Max COLD
posi ti on
Max COLD
posi ti on
4
posi ti ons
1 500
rpm
constant
Connect mani fold
gauge
to
hi gh
di scharge
andlow sucti on
servi ce
valves
Centeroutlet
gri lle
Blower
assembly
i nlet
A
poi nt
1
m
3
ft
i nfront
ofcondenser
0
HA 17
Performance
Test
AI R
CONDI TI ONER
TEST
READI NG
I nsi de
ai r
Reci rculati ng
ai r
at blower
assembly
i nlet
Di scharge
ai r
temperature
at centerventi lator
Relati ve
humi di ty
Ai r
temperature
oC
oF
Oc
OF
15 59
4
5
5 2
40
41
2068
65 75 44 46
25 77
8
7
98
48 50
4050
3086
10 8 12 2 51
54
35 95
129
14
5
55 58
40
104
15 0
17
059
63
15 59
5
2
5
8 41 42
20
68 75
85 46
47
25 77
98 110
5052
5060
3086 12
2 13 5
54
56
35 95
14 5 162 58 61
40
104
17 0189 63 66
15
59
5
8 6
5
42
44
2068
85 94 47
49
25 77 11
012 3 52 54
6070
15 2 56
3086
J3
5
59
35 95
162
18
2 61 65
40
104
189 21 1
66 70
15
59
65 71 44 45
2068
94
10 3 49
51
25 77
123
13
7
54 57
7080
3086
15 2 17 0
59
63
35
95 18 2 20 2
65 68
40
104
21 1235 70
74
15
59
71
79
45 46
I
25 68
10 3
n
5
51
53
I
3077
137 15 0
57 59
8090
I
35 86
17
0186 63
65
r
4095
202 222
68 72
I
45
104
23
5
26074 79
HA 18
AI R
CONDI TI ONER
PerformanceTest
Ambi ent ai r
Pressure
hi ghDi scharge
si de Pressure lowSucti on
si de
Relati vehumi di ty Temperature
kPa
kg
cm2
psi
kPa
kg
em2
psi
oCF
15 59
500
657
932
98 1
51 6
7
73 95
095 1
00
13 5 14
2
2068
755
834 1030
112
8
7
7 85 109 121
105 115
14
9 164
25 77
922
1
010
l22
1i
137 3
4065
94 10 3
134
146
125 I 40178 19
9
30
86
1
079
1 196 1422 156
9
11
012
2 156 173
I
45 160206 228
35 95
1 245
1
373
1569
176 5
12 7
140
181 199
1
60
1
80
228 25
6
40104
1
393 1
550 176 5
196 1
14
2
15
8 202 225 180200
25
6
28 4
15 59
657 726 98 1 li 28
6
7 74
95
105 i 64 1
0001 15 14
2
1
20
68
834 922
112 8 132 4
85 94121 134 115 135 16
4 19 2
25 77
1 0101 118 137 3 152
0
65 90
10 3 I I 4
146 162
140
155 199
220
3086
1
196 1 314
156
9 171
6
122 13 4173 191 160175 22
8 249
35
95
1
372
1 510 1765 196 1
14
0154 199 219 1802 0025 6
28 4
40
104
1
550
1
716
196 1 220
7
15 8 17 5
225 249
200225 28
4
320
a
The
pressure
wi ll
change
i n the
followi ng
manner
wi th
manges
i n
condi ti ons
When
blower
speed
i s low
di s
chargepressure
wi ll
drop
When the
relati ve
humi di ty
of
i n
take ai ri s low
di scharge pressure
wi ll
drop
b The
temperature
wi ll
change
i n the
followi ng
manner
wi th
changes
i n
condi ti ons
When the 8rrmi ent
ai r
temperature
i s low the outlet
ai r
temperature
wi llbecomg low
I f the
test
reveals that therei s
any
abnormali ty
i n
systempressure
i solate
the cause and
repai r
RefertoPer
formanceTest
Di agnoses
HA 19
Perfonnance
Te t AI R
CONDI TI ONER
PERFOR
NCE
TEST DI AGNOSES
Characteri sti cs revealed on the
mani fold
gauge rcadi ng
forthe ai r
condi ti oni ng
system
are shown i n the
followi ng
Condi ti on
As tothemethodof a
performance
test referto
the
i temof Performance
Test
i ndi cateS
a
range
baSedon
the
li ssump
ti onthat theai r
condi ti oni ng system
i s
i n
good
order
Thi s
range
i s descri bed
i nPERFORMANCE CHART
I n
the
followi ng
table
the
porti on
smearedwi thi nk onsam
gauge
scale
I
I NSUFFI CI ENT REFRI GERANT CHARGE
1
00
@
@
AC352A
ALMOST NO
REFRI GERANT
I
00
@
@
AC353A
I
FAULTY
EXPANSI ON VALVE
I
0
@
@
AC354A
HA 20
I nsuffi ci ent
cooli ng
Bubbles
appear
i n
si ght
glass
No
cooli ng
acti on
I n
si ght
glass
appear
a lot
of bubbles
or
somethi ng
li kemi st
Si ght cooli ng
Sweati ng
orfrosted
expan
si on
valvei nlet
Probable
cause
Refri gerant
i s small
or
leaki ng
a li ttle
Seri ous
refri gerant
leak
Expansi on
valve restri cts
refri gerant
flow
Expansi on
valvei s
clog
ged
Expansi on
valve i s
i n
operati ve
Valve stuck closed
Thermalbulb has
lost
charge
Correcti veacti on
I Leak
test
2
Repai r
leak
3
Chargesystem
EVKUatB
as
necessary
and
rechargesystem
Stop compressor
i mmedi
ately
1 Leak test
2
Di scharge
system
3
Repai r
leak s
4
Replace
recei verdri eri f
neCessary
5 Check
oi l
level
6 Evacuate
and
recharge
system
I f
valvei nlet reveals sweat
orfrost
I
Di scharge system
2 Removevalveandclean
i t
Replace
i t
i f neces
sary
3
Evacuate
system
4
Chargesystem
I fvalvedoesnot
operate
I
Di schargesystem
2
Replace
valve
3 Evacuate and
charge
system
Condi ti on
010
@
f
AC355A
@
fg
fi
0
@
@
AC356A
I
FAULTV SUCTI ON
THROTTLE VALVE
C0
@ @
AC357A
0
@ @
AC358A
I nsuffi ci ent
cooli ng
Sweated
sucti on li ne
No
cooli ng
Sweati ng
or
frosted
sue
ti onli ne
I nsuffi ci ent
cooli ng
Frosted
evaporator
I nsuffi ci ent
cooli ng
AI R CONDI TI ON
ER Performancerest
Probablecause
Expansi on
valveallowstoo
much
refri gerant through
evaporator
Faulty expansi on
valve
Sucti on throttle valve
i s
i noperati ve
Sucti on throttle
valve
restri cts
refri gerant
flow
CorreCti ve
acti on
Check
valve for
operati on
I f
sucti on si de does not
show
a
pressure
decrease
replace
valve
L
Di scharge
system
2
Replace
valve
3
Evacuate
and
replace
system
I
Di scharge
system
2
Replace
valve
3 Evacuate and
charge
system
I
Di scharge system
2
Replace
valve
3
Evacuate
and
charge
system
HA
21
Perfonnance
Test AI R
CONDI TI ON
ER
Condi ti on
I
AI R I N SYSTEM
I
r
010
@
@
AC359A
I
MOI STURE I N SYSTEM
I
010
@ @
AC360A
I
FAULTY CONDENSER
I
t
00
@ @
AC361A
HA
22
I nsuffi ci ent
cooli ng
Si ght glass
shows
occasi on
al
bubbles
After
operati on
fora
whi le
pressure
on
sucti on
si de
may
show vacuum
pressure readi ng Duri ng
thi s condi ti on
di scharge
ai r
wi ll
be
warm As a
warni ng
of
thi s
readi ng
shows
39kPa 04
kg
cm2
6
psi
vi brati on
No
cooli ng
acti on
engi ne
may
overheat
Bubbles
appear
i n
si ght
glass
of dri er
Sucti onli nei
very
hot
Probable
cause
Ai rmi xed
wi th
refri gerant
i n
system
Dri er
i s
saturated wi th
moi sture
Moi sturehas fro
zen at
expansi on
valve
Refri gerant
flowi srestri ct
ed
Usually
a
malfuncti oni ng
condenser
Correcti ve
acti on
I
Di scharge
system
2
Replace
recei verdri er
3 Evacuate and
charge
system
I
Di scharge system
2
Replace
recei verdri er
twi cei f
necessary
3
Evacuate
system
com
pletely
Repeat
30
mi nute
evacuati ng
three
ti mes
4
Recharge
system
Check fan belt
and
flui d
coupli ng
e
Check condenserfor
di rt
accumulati on
Check
engi ne
cooli ng
system
foroverheat
Check for
refri gerant
overcharge
I f
pressure
remai ns
hi gh
i n
spi te
of allabove
ac
ti ons taken
remOW8
and
i nspect
the condenserfor
possi ble
oi l
doggi ng
Condi ti on
I
HI GH
PRESSURE
LI NE BLOCKED
I
6
@
@
AC362A
I
FAULTY
COMPRESSOR
I
00
@
@
AC363A
TOOMUCHOI L I N
SYSTEM
Excessi vel
r
0
@
@
AC364A
I nsuffi ci ent
cooli ng
Frosted
hi gh pressure
li qui d
li ne
I nsuffi ci ent
cooli ng
I nsuffi ci ent
cooli ng
AI R
CONDI TI ONER SelVi ceProceduref
Probable
cause
Dri er
clogged
orrestri e
ti on i n
hi ghpressure
li ne
I nternal
problem
i n com
pressor
or
damagedgasket
andvalve
Too much
oi lci rculates
wi th
refri gerant causi ng
the
cooli ng capaci ty
ofthe
system
tobe reduced
Correcti veacti on
I
Di scharge system
2
Remove recei ver
dri er
or
strai ner
and
replace
i t
3 Evacuate and
charge
system
I
Di scharge
system
2
Remove and
check
compressor
3
Repai rorreplace
com
pressor
4
Check oi llevel
5
Replace
recei ver
dri er
6
Evacuate
and
charge
system
RefertoOi l
Level
Check
for
correcti ng
oi llevel
HA 23
Servi ceProcedu
s
AI R
CONDI TI ONER
PRECAUTI ONS FOR
REMOVAL AND
I NSTALLATI ON
When
replaci ng refri gerant cycle
components
observethe
followi ng
1
Di scormect
battery ground
cable
2
Before
starti ng
work be sure
to
di schargesystem
WARNI NG
Gradually
loosen
di scharge
si de
hOse
fi tti ng
and remove i t
after
remai ni ng pressure
has been re
I lI I sed
3
When
di sconnecti ng or
connecti ng
tubes be
sure
to
use
wrencheson
bothtubes
SHA057
HA 24
SERVI CE
PROCEDURE
4 After
di sconnecti nll
tubes
plug
all
openi ngs i mmedi ately
to
prevent
entrance
of di rt and moi sture
Plug
SH
A058
5
Compressed
ai r
must never
be
usad
to
dean
di rty
li ne Clean wi th
refri gerant gas
6
When
connecti ng
tubes i nstall
new
a
ri ng
neverreuse
used
one
i nto
connecti on and be
sureto
apply
com
pressor
oi lto
seati ng
surfaceand 0
ri ng
I
uamnr s
SHA059
7
Check
ti ghteni ng torque
of
con
nedi onsto
lpeci fi cati on
8 Make
sure
refri gerant
li ne
i s
clampedsecurely
Check all
componenb
t
i nsure
they
are
nei ther
damaged
nori nterfere
wi th
adjacent parts
9
Conduet leak test
and
makesure
that
therei s
no
leak fromconnecti ons
10
Determi ne
quanti ty
of oi ltobe
charged
i nto
compressor
by referri ng
to
Compressor
Oi lLevel
Check
i n
GeneralSerYi
AI R
CONDI TI ONER Servi ceProcedure
REFRI GERANT
LI NES
iJ
N
m
kg
m
ft lb
I nsullnew
O
i ng
i ntoeachconnecti on
of tubes
OloUng uni t
108
08 115 8
80
iJ15
20
15
2
0
11 14
iJ125
29 25 3
018
22
SHA148
COMPRESSOR
I DLER PULLEY
Loosen
REMOVAL AND
I NSTAlLATI ON
1 Rem eundercover
2
Loosen
i dler
pulley lock
nut
and
fully
loosen
adjusti ng
bolt
3 Remove
dri ve
belt
4
Removei dle
pulley
assembly
5
I nstallati on i s i nthereverseorder
ofremoval
Referto
Secti on MA for
adjusti ng
dri vebelt
Adjusti ng bolt
SHA149
HA
25
Servi ceProcedures
AI R
CONDI TI ONER
COMPRESSOR
Q
N m
kg m
ft lb
R MOVAL AND
I NSTALLATI ON
I
Operatecompressor
i f
possi ble
at
engi ne
i dli ng
peed
wi th
ai r
condi
ti onercontrols
set formaxi mum
cool
i ng
and
hi gh
blowerspeed
for10toI S
mi nutes
wi thallwi ndows
open
to
return
oi l
i nto
compressor
2 Remove
compressor
dri vebeh
Refertothe
i tem on
Compressor
I dler
Pulley
3
Di sconnect
hi gh di scharge
and
low ucti on fleXi ble
hose fromcom
pressor
4
Di ScOnnect compressor
clutch
harness
5 Remove
compressor
1
Di Sconnect
ai ri nducti on
pi pe
J
5HA317
2 Remove
i gni ti on
coi ls
HA26
401
54145
SHA150
3 Remove
compressor
wi th
i t
clutch
faci ng up
CAUTI ON
Do not
attempt
to
leave the
com
pressor
on i ts
si deor
upsi de
down for
more
than 10
mi nutes I S
1I I e
com
pressor
oi l
wi llenter
thelow
pressure
chambers
I f underthat condi ti on
compressor
should
be
operated
sud
denly
i nterllll
damage
would result
To
expel
oi l
from
chambers
hand
crank
compressor
severalti mes
i n i ts
i nstalledcondi ti on
6 I nstallati on
i s i n
the
reverseorder
ofremoval
When
conneeti ng hi gh
and
low
flexi ble
hoses to
compressor
i nstall
new
O
ri ng
i ntoconnecti Qn
CONDENSER
REMOVAL AND
I NSTALLATI ON
I Removeradi ator
gri lle
2
Remove
stay
forhood locI
upport
3 Di sconnect
refri gerant
li nes from
condenser
4
Remove
condenser
5 I nstallati on
i s
i n
thereverse order
of
l
l
I NSPECTI ON
I nspect joi nts
of i nlet
and
outlet
pi pes
forcracks andscratches
Upon
rmdi ng
any
problem
whi ch
may
cause
gas
toleak
repai r
or
replace
con
denser
Condenser
fI ns orai r
passage clog
ged
wi thdi rt i nsect orleaves
wi ll
reduce
cooli ng
effI ci ency
of
con
denserI nsucha case
cleanfmsor
a
passages
wi th
compr
edai r
CAUTI ON
Do
not
cleancondenserwi th
steI I m Be
sure
to
use
cold
wateror
compressed
ai r
RECEI VER
Di llER
Li qui d
tank
SHA152
REMOVAL AND
I NSTALLATI ON
I
Di sconnect
refri gerant
li nefrom
recei ver
dri er
CAUTI ON
Plug
all
openi ngs
to
enttem e
of di n and
moi stUre i ntol1lC
i ver
dri er
2 Di sconnect harness forlow
pres
Sureswi tch
3
Remove
recei verdri er
4 I nstallati oni s i nthe
reverse order
ofremoval
I NSPECTI ON
Check
recei ver
dri erforleaks
or
damage
I f
necessary replace
FAST
I DLE
ACTUATOR
Q
From
F
I CD
magnet
valve
FrOmai r
regulator
tube
I ntakemani fold
SHA
153
I NSPECTI ON
Referto Trouble
Di agnoses
and
Correcti ons
COOLER
RELAY
f
6
r
SHA154
COOLI NG UNI T
REMOVAL
AND
I NSTAlLATI ON
I
Remove
i nstrument
lowercover
andclusterli d
AI R CONDI TI ONER Servi ceProcedures
2 Di sconnect
refri gerant
li nes from
cooli ng
uni t
3 Remove
cooli ng
uni t wi thdrai n
tube
V
Drai n tu
SHA155
4 I nstallati on
i s i n
the
reverse order
of removal
DI SASSEMBLY
AND
ASSEMBLY
Expansi on
valve
Thermo
bulb
SHA378
I
Remove
cli ps fI xi ng upper
case
to
lowercase
2
Wi thdraw
evaporator
assembly
3
Assembly
i s i nthe
reverse
orderof
di sassembly
I NSPECTI ON
c
Check forcracked ordeformed
case
Ev
por
tor
mbly
I
Clean fms and check forcorro
si on
I f
fi nsarecorroded
replace
CAUTI ON
Donot clean
evaporator
wi thsteam
Be sure touse cold I I I I I terorcom
pressed
li r
2
Check for
gas
leaks
at
expansi on
valve and sucti on throttle valve
I f
thereareleaks
reti ghten
or
replace
the
defecti ve
part
wi tha
new
assembly
AMBI ENT
SWI TCH
REMOVAL AND
I NSTALLATI ON
SHA157
I
Remove
i nstrument lowercover
andclusterli d
2
Di sconnect harness connectorand
removeambi ent
swi tch
3
I nstallati on i s i nthereverse order
of
removal
HA
27
Servi ceProcedvres
AI R
CONDI TI ONER
I NSPECTI ON
r
1101
Ambi ent
temperatwe
Conti nui ty
Above
2
SoC
36 410F
Ves
BelowO 30C
0370F
No
SHA158
EXPANSI ON
VALVE
AND SUCTI ON
THROTTLE
VALVE
Thermo
bulb
Clamp
andwrap
wi th
heat i nsulator
lnle
I I I
I lJ
outle
Sucti on
throttlevalve
L
Servi ce
valve
SHA169
Donot
di sassemble
val
neces
sary
replace
as
I y
HA28
AI R CONDI TI ONER
CONTROLASSEMBLY
REMOVALAND
I NSTALLATI ON
RefertoHeater
Control
Assembly
I NSPECTI ON
Fan swi tch
Referto
Fan
Swi tchi nHeater
Ai r
condi ti onerswi tch
Electri cal
conducti vi ty
Ch
CD
2
3
@ CI D
c
ON 00
0
OFF
I Uwni nati on
lamp
i s
locatedbetween
CD
anCl
00
SHAle1
BLOWER UNI T
Refer
toBlowerUni t
i nHeater
RESI STOR
Referto
Resi stor
i n
Heater
MAGNET VALVE
I NSPECTI ON
00
@
Ai r
passi ng
I
Appli ed
voltage
I
OV
I
12V
CDOO@
0
10
I
SHA162
v
@
1
8
rn
f
f
0
f
14
I I
l
en
0
t
Z
10
j
5
zrn
I I
I
C
l
ti l18
21
1
8
2
1
13
15
@JJ
tl ji 1
ti l29
@
34
3
0
35
22
25
@
i JJ
ti l18
20
1
8
2
0
13
14
j
ti l
N
m
k8
m
f
4b
1
Gasket
11
Oll
pi pe
20
LOCK
nut
29
Shaft
seal
seat
and
Ori ng
2
jnock
pm
12
Rear
cyli nder
head
21
LOCK
washet
30
Shaft
seal
3
Front
cyli nder
head
13
Gear
pump
as5fmb1y
22
PulloY
and
beari ng
31
Compressor
s
hell
4
sucti on
valVe
plate
14
Rear
end
cover
assembly
32
D
a
i n
plug
lnd
gas
ket
5
Gaslo
et
15
Rear
end
cover
ili ng
bolt
23
Coi l
assemblY
33
Si lencer
pi ece
li ng
6
Key
a
nd
w9 8her
24
Gasket
34
Si lencer
pi ece
7
Compressor
cyli nder
assemblY
16
Shan
nut
2S
Front
end
cover
3S
Si lencer
spri ng
l
8
Gasket
11
Hub
nut
26
Coi l
mounti ng
screw
36
Gasket
t
9
Rear
end
covet
O
ri ng
18
Spaoet
21
Felt
37
Si de
cover
10
on
pi pe
o
ri ng
19
Qutch
hub
2
Retai ner
ri ng
38
Si de
cavet
fi Xi ng
bOlt
ti l
25
21
2
5
2
8
18
20
ti l16
11
1
6
L1
I
6
12
3
ti l2
1
3
4
0
28
0
35
2
0
2
5
Compressor
SWP167J
AI R
CONDHI ONER
2 3
oCl
PRECAUTI ONS
I
Plug
all
openi ngs
i n
compressor
to
prevent
from
enteri ng
ofmoi sture
and
forei gn
matter
2
00
nc tleave the
compressor
on
i ts
si de
orupli de
down for
morethan
10mi nutes
as
the
lubri cati ng
oi lwi ll
enterthe low
pressure
chambers
I f
underthat condi ti on
compressor
shouldbe
operated suddenly
i nternal
damage
would result
To
expel
oi l
from chambe
hand crank com
pressor
severalti mes i n
i ts i nstalled
condi ti on
3
Before
replaci ng
wi th
the new
compressorcomplately
drai n oi lfrom
the
new
compressor
and fi llwi th
an
emount
of oi l
equali ng
that
remai ni ng
i ntheold
compressor
4 When
replaci ng parts
oroi l
always
replacegaskets
O
i ng
and
oi l
eal
wi th
new
ones
5 When
stori ng
a
compressor
be
sure tofi lli t
wi th
refri gerant
to
pre
vent
rusti ng
Add
refri gerant
at the
HA 30
Yr
i 1l
f
Jl
i
I
i Mt
A
l
r
YJ t
ttf
4
I I
11 J I
lc
4
1
@l
low
pressure
si de and
purge
ai rat
the
hi gh
pressure
si de
COMPRESSOR
CWTCH
The
most common
problem
i s
clutch
sli ppage
Servi ce
procedures
areli sted
belowExerci secare
I
Clearancebetween clutch
hub
and
pulley
should
be
0
5
to08
mm
0D20
to
ODJI
i n at
all
peri pheralpoi nts
2 Makesurethat there
i s
nooi lor
di rt on fri cti on
surfaces
of clutchdi sc
clutchhub and
pulley
Remove
any
oi lordi rt wi tha
dry rag
1
Shaft nut
2
Hub
nut
3 Clutchhub
4
Key
5 Shaft
seal
seat
6 Shaft
seal
7 Front
end
cover
8 Front
cyli nder
head
9 Sucti on valve
plate
10Si lencer
spri ng
11 Si lencer
pi ece
12
Thrust
beari ng
13 Si decover
14 Rear
cyli nderhead
15
Compressor
shaft
16 Rearendcover
17
Oi lpump
18
Rear
cyli nder
19
Oi lpi pe
20Swash
plate
21
Shoe
di sc
22
Front
cyli nder
23
Dri ve
ball
24 Shell
2S Needle
beari ng
26 Clutchcoi l
27
Pulley
and
beari ng
assembly
SHAl64
3 Make surethat termi nal
voltage
at
magneti c
coi l
i s
above
105V
REMOVAL
I
Usi ng
ToolKV99412302
hold
clutch hub Wi th
sui table socket
wrenchremoveshaft nut from
shaft
2 Then
usi ng
Toolremoveclutch
hub
nut
Remove
spacers
AC024A
3
Usi ng
Tool remove clutchhub
Thread tool
i ntothebore
of
clutch
hub hold toolwi thwrenchand then
threadi ncenterbolt
ACQ25A
4
Wi th an
ordi nary
screwdri ver
flatten lock
washertab
AC026A
5
Usi ng
Toolloosen
lock nut Re
movelocknut andlockwasher
AC027
A
6 Remove
pulley
and
beari ng
as
sembly
When the
assembly
can not be
removed
by
hand
usea
puller
Tooi
KV994123I 3
and
ToolKV99412312
AI R
CONDI TI ON
ER
Compressor
SWPI 67J
AC028A
7
Usi ng
an
i mpact
toolloosen
si x
coi l
mounti ng
screws Use
of thei m
pact
tool
i s
advi sable as screws
have
been
calked
AC680
8
Remove
coi l
mounti ng
screws
and
separate
coi l
assembly
I NSPECTI ON
I Check the
fri cti onsurfaces ofthe
clutchfor
damage
due to excessi ve
heat o
excessi ve
groovi ng
due
to
sli ppage
I f
necessary replace
coi l
pulley
and
beari ng
assembly
and
dutch
hub as a set
2 Oi lordi rt
n
thefri cti on
surfaces
should be cleaned
wi th
a
sui table
solvent anda
dry rag
3
Check coi lforshortedor
opened
bi ndi ng
leads
I NSTALLATI ON
I
Usi ng
a
Phi lli ps
screwdri ver
ti ghten
coi l
assembly mounti ng
screws
i n
an
alternati ng pattern
Afterscrews
havebeen frrmly
ti ghtened
puncWock
eachat one
locati onto
prevent
loosen
i ng
i fJ
Coi l
mounti ng
screw
2 7 3A Nm
028 035
kg
m
2
025 ft lb
AC029
2
Usi ng
a
plasti c
mallet dri ve
pulley
and
beari ng assembly
onto
the
neckof
the i nstalled coi l
assembly
Turn the
pulley
maki ng
sure that there
i s no
noi se
and
that rotati on i s free Also
make surethat therei s no
pulley play
3 Posi ti on
lock washerand lock nut
i n
place
Usi ng
ToolKV994123I O
ti ghten
lock nut
fi rmly
Wi thlock
washer
tab and
lock nut cutouts
matched
bend
the
tab
wi ththescrew
dri ver
Proceed
carefully
to avoi d
beari ng
cage
damage
i fJ
Locknut
25 27
N m
2 5
1
8
kg
m
18 20I t lb
4 Fi t
key
and clutchhub tothe
shaft Select
adjusti ng spacer
whi ch
gi ves
the
correct clearancebetween
the
pulley
andclutchhub
i fJ
Hub nut
18 21 N
m
1
8
2 1
kg m
13 15lt lb
5
Ti ghten
shaft nut wi thlocki ng
agent
i n
place
i fJ
Shaft
nut
16
17 N
m
1 6
1
7kg m
11 6
12
3lt
lb
6 Usi ng a
thi ckness
gauge
measure
the
clutchhub to
pulley
clearance
Hub to
pulley
clearance
05 08mm
0020 0031i n
HA 31
Comprt lSOr
SWPI 67 AI R
CQN
OI TlONER
I f the
speci fi ed
clearance i s not
obtai ned
replace
adjusti ng
spacer
and
rcadjust
AC029A
When
replaci ng compressor
dutch
a
embly
do not
forget br
k i n
operati on accompli shed
by engagi ng
and
di sengagi ng
theclutch
some
thi rty
ti mes Break i n
operati on
rai ses the
levelof transmi tted
torque
SHAFT SEAL
REMOVAL
I
Remove
drai n
plug
thereby
drai n
i ng
theoi l
2
Remove clutchhub
pulley
and
beari ng
assembly
and coi l
assembly
Proceed
accordi ng
to i nformati on
under
Compressor
Clutch
3
Usi ng
snap ri ng
pli ers compress
andremove
retai ner
ri ng
4
Toremoveshaft sealseat
proceed
as follows
I
Plug hi gh di scharge
and low
sucti on
pressure openi ngs
of com
pressor
usi ng
ToolKV994C4548 or
bli ndcover
and
gasket
whi chare
i n
stalled
on
servi ce
compressor
HA
32
2 Cormect
chargi ng
hose to re
fri gerant
can I nstall Tool
KV994CI 552
toother
end
of
chargi ng
hose and i nsert i t i nto
hole
i n
mi ddle
ofbli ndcoverat
low
pressure
si de
5
Wrap
shaft end wi th
ra8 Apply
refri gerant pressure
of 196to490kPa
2to5
kg
em 28to
71
psi thrnugh
low
pressure
li ne of
compressor
unti l
shaft sealseat i srecei vedat
rag
CAUTI ON
a Do
not
use
ai rto
prevent entry
of
moi sture
dust
ete
b I fshaft slllllseat i s
not
pluckedout
i ns lllli t
agai n
and
apply
refri gerant
pressure
KV994C1552
KV994C4531
KV994C4533
KV994C4559
SHA165
6 I nsert
Tool
through
the
open
end
of front endcover
Depress
thecarbon
sealandhook thetoolat
the
case
pro
jecti on
of shaft seal
Slowly pull
out
the tool
thereby removi ng
shaft seal
KV994U32
I NSPECTI ON
I
Check thecarbon sealsurfaceof
shaft
seal
for
damage
Carbon
seal
Contact surCace
AC035
2 Check Q
ri ng
andthecarbon seal
contact surface of shaft
sealseat for
damage
Makesurethat O
ri ng
contact
surface at front end coveri s not
damaged
Contact
surface
ACS05
I NSTALlATI ON
Donot
reuse shaft
sealseat and
shaft seal
CAUTI ON
I n
placi ng
a new
seal
on the I I I I I rk
beli ch mllke sure that the contact
surface faces
upwerd
Take
necessary
steps
toavoi d
damage
I Make surethat theshaft sealcon
tact surfacei s free of
di rt
and
amply
lubri catedwi th
compressor
oi l
2
Cap
ToolKV994l2322tothe
top
end
of
compressor
shaft
3
Usi ng
Tool
KV9941232l i nsert
shaft sealwi th
shaft sealcaseandshaft
cutout ali gned
Apply
forcetoturn thesealsome
what
to
the
left and
ri ght
I nsure
that
shaft sealseats
properly
i n the shaft
cutout
AC037
4
Fi t O
ri ng
totheoutsi de
groove
of
shaft sealseat
maki ng
sure that
i t
scats
properly
5
Apply
an
ample
coat of
oi l
to
contact surfaceandshaft seal t
so
that seat
easi ly
sli des
on
i nner
si de of
front
endcover
Also
apply
a thi n coat of
grease
or
oi ltoshaft Push
shaft
seal
seat i i lto
front end
cover
unti li t bottoms
up
to
land
6
Usi ng snap ri ng pli ers
compress
retai ner
ri ng
andfi t
i t i nto
front end
coverSeat
retai ner
ri ng fi rmly
i n
the
groove
7
I nstall
ToolKV99412329
to
com
pressor
shaft and turn
shaft
5 to6
turns
clockwi se Then check for
gas
leakage
as
follows
I Plug hi gh
andlow
pressure joi nts
i nto
compressor
Usi ng
Tool
KV994C4548 orbli nd coverand
gasket
whi chare i nstalled on servi ce
compressor
2
Connect
chargi ng
hose to
low
pressure gauge
of
mani fold
gauge
I nstallToolKV994C1552 toother
end
of
chargi ng
hoseand
i nsert i t i nto
hole
i n
mi ddle
of
bli nd
cover
at low
pressure
si de
Connect
centerhose of mani fold
gauge
to
referlgerant
can
AI R
CONDI TI ONER Compressor
SWPI 67
3
Open
valve
of can
top charge
refri gerant
fromlow
pressure
si de
and
purge
ai r
from
hi ghpressure
si de
by
looseni ng
bli nd
cap
4
Conduct
a
leak test I f
therei s
a
leak removeandtheni nstall
agai n
KV994C4531
KV994C1552
KV994C4534
KV994C4559
t
lbi J
SHA166
SI DE
COVER
REMOVAL
I
Drai n oi l
2 Loosen and remove
ei ght
si de
cover
mounti ng
bolts
i n
an
alternate
pattern
Notethat twosi lencer
spri ngs
i nsi de
the coverwi llforce up
si de
cover
AC687
3 Remove si de
cover
andsi decover
gasket
Di scardthe
gasket
4
Remove
si lencer
spri ngs pi eces
and
O
ri ngs
Donot
damage
O
ri ng
surface of si lencer
pi ece
duri ng
thi s
process
Di scardusedO
ri ngs
9
O
ri ng
Pi ece
Si lencer
pnng
AC207
I NSPECTI ON
I
Make surethat
si de cover
gasket
surfaceandshell
gasket
surfacearenot
damaged
2 Make surethat si lencer
pi eces
and
shellcontact surfaces
i n
contact
wi th
O
ri ng
arenot
damaged
3 Do
not reuse
old
gasket
andO
ri ngs
I NSTALLATI ON
Donot
tap
on
the
compressor
shalt
I Place
the
mounti ng
swface
of
si de
cover
upward
2
Make surethat holesof
cyli nder
and shellare
ali gned
and i nstallO
ri ngs
3
Coat
O
ri ng
and
the
area around
shellhole wi th
an ample
amount of
compressor
oi l
Usi ng
Tool
KV99412328 i nstallO
ri ng
i ntothe
shellhole Then i nstallsi lencer
pi ece
wi thToolKV99412327
4 Coat the
gasket
surface of shell
wi th
compressor
oi land
posi ti on
gasket
andsi decover
5 Hold si de cover
i n
place
by
hand
and thread
i n
ei ght
mounti ng
bolts
Ti ghten
these boI ts
evenly
i n
an alter
nati ng
pattern
lfJ
Si decover
bolt
18
20N
m
1
8 20
kg m
13 14lt lb
6 Fi llwi th
compressor
oi l
7
Upon completi on
of the above
operati ons
cOnduct
a
gas
leak test
by
HA 33
Compressor
SWP167
AI R
CONDI TI ON ER
referri ng to
the
i tem I nstallati on
under
the
topi c
Shaft Seal
AR
Np
CQV
AND REAR
CYLI NDER HEAD
REMOVAL
L
Drai noi l
2
Remove fi ve
rear
end
cover
mounti ng
bolts wi thTool
Starti ng
at
the
lop
loosen allboltsoneturni nan
alternati ng pattern
Thenremovebolts
i n
turn
AC68
3
Grasp
rear
end
coverand
carefully
separate
i t
from
compressorTap
the
flange
li ghtly
and
alternately
as reo
qui red
wi tha
plasti c
mallei
Do
not
reuse
old
gasket
and Ori ng
AC689
4 Remove
pump
gear
Donot allow
pump gear
to
damage
thesurface
HA
34
AC042
5 Remove
O
ri ng gasket
and two
pi ns
Di scardthe Ori ng
and
gasket
6 Remove
rear
cyli nder
head
sucti on
valve
plate
and
gasket
Di scard
the
gasket Carefully remove
sucti on
valve
plate
avoi di ng
defonnati on
7
Whenremoval
proves
di ffi cult use
Tool
I nsert thi stooli ntoholei n
cyl
i nder
head
Wi ththenut
i n
frrm
con
tact
wi ththe back si de of
cyli nder
head
ti ghten
thebolt
slowly
tobreak
loose
thehead
AC210
I NSPECTI ON
I
Make surethat the
gasket
contact
surface
i s
free of
damage
2 I f
replacement
of rearend cover
connectorand check valve
i s
neces
sary
replace
rearendcoverwi thanew
one
3 Check sucti on valve
plate
and
cyli nder
head forbroken valves
4 Check
pump gear
forwearand
damage
I NSTALLATI ON
Donot
reuse
old
gasket
and Ori ng
I
Usi ng
sui table blocks
posi ti on
compressor
wi ththefront facedown
wardand
the
rear
upward
2 I nsert two
pi ns
i n the
rearof
cyli nder
3
Coat bothsurfaces of
cyli nder
head
gasket
wi th
compressor
oi land
ali gn
gaaket
wi th
cyli nder
4 I nstallsucti on
valve
plate
maki ng
sli fe
that the three
valV S
properly
ali gn
wi th
cyli nders
and
gasket
cut
outs
AC224
5 I nstall
cyli nder
head
gasket
and
Ori ng
i n
theorderli sted
q
at
gasket
and Ori ng beforehand wi than
ample
amount of
compressor
oi l
AC045
6
Fi t
pump
gear
torearendcover
7
Carefully
fi t
rearend cover
tothe
rearof
compressor
AC211
8
Usi ng
Tool
KV99412330
ti ghten
up
fi vebolts
i n
an alternati ng
pattern
starti ng
at the
top
Do
not
f9rget
lock
washers
fl
Rear
end
cover
bolt
29
34N m
3035
kg
22 25 I t lb
9
Fi llwi th
compressor
oi l
10
Upon completi on
of the above
operati on
conduct a leak test
by
re
ferri ng
to the
topi c
underShaft
Seal
REPLACEMENT OF
CYLI NDER
REMOVAL
I
Drai noi l
2 Remove
compressor
clutchassem
bly
Referto
Compressor
Clutch
3
Usi ng
snap
ri ng
pli ers
remove
shaft seal
retai ner
ri ng
Then
remove
shaft seal
seat Referto Shaft Seal
Removalof
shaft seal
i s
not
absolutely
necessary
I t
may
be removed when
cyli nder
assembly
i
removed from
front end
coverI n fact thi s
approach
faci li tateswork
4 Remove
si de
coverReferto Si de
Cover
5
Remove rear
end coverReferto
RearEnd Coverand
Rear
Cyli nder
Head Remove O
ri ng gasket
two
pi ns
cyli nderhead sucti on valve
plate
and
gasket
i n the orderli sted
Thi s
exposes
therear
part
of
cyli nder
AI R CONDI TI ONER Compressor
SWP167
6
Usi ng long
nose
pli ers
orother
sui tabletool
pull
out oi l
pi pe
Proceed
carefully
as oi l
pi pe
i s
easi ly
bent
CAUTI ON
Unless oi l
pi pe
hI S
been
removed
do
not
attemp
t
the
followi ng steps
AC212
7
Wi th
the front
faci ng
downward
support compressor
shell
Usi ng
a
plasti c
mallet
tap
at
the rear
end
of
the shell
flange dri vi ng
shell
strai ght
downward Di scard
front end
cover
gasket
AC213
8 Detach front end coverfrom
cyli nder
assembly
Usi ng
a
plasti c
mallet dri ve end cover
upward
Re
frai n from
excessi ve force
toavoi d
cover
damage
AC050
9
Removeshaft sealfrom
theshaft
10
Remove
two
pi ns gasket
cyli nder
head
sucti on
valve
plate
and
gasket
When
removi ng
two
pi ns
proceed
carefully
to
ami d
cyli nder
head
damage
Donot deformsucti on
valve
plate
i n
removi ng
sucti on valve
plate
Di scardoi l
gasket
CAUTI ON
Do not deform R1cti on
valve
plate
when
removi ng
i t
I NSTALLATI ON
I
Usi ng
sui table blocks face
cyli nder
assembly upward
I nsert two
pi ns
Posi ti on
gasket
and
sucti on valve
plate
i n
theorderli sted
whi le
maki ng
sure that three
valves of sucti on valve
plate
are
ali gned
wi ththe
cyli nder
and
gasket
cutouts Coat gasket
wi thcom
pressor
oi l
pri or
to
assembly
Gaskets
and sucti on valve
plates
are thesame
for
front and
rearThe
cyli nder
head
wi ththesmallernumbers
of holes
goes
to
the front
Do
not mi xfront
an
rear
parts
bBJ
l1
ACOS1
tj
1
AC052
2
Ali gn
shaft sealwi ththe
shaft
cutaway Fi rmly
seat shaft seal
at
the
shaft land
Attempt
toturn
shaft seal
totheleft and
ri ght
confi rmi ng
that
i t
i s seated
properly
HA
35
Compre r
SWP767 AI R
CONDI TI ON ER
3 Place
gasket
on cyli nder
head and
i nstallfront end coverCoat
gasket
wi th
compressor
oi l
beforehand
Gasket di ffers forthe front
and
rear
Make sure that the correct
gasket
i s
used After
completi ng
thi s work
gasket protrudi ng
from front
end
coverand
cyli nder
head should be
adjusted
by
hand
D
t
OJ
SI lencer
hole
J
AC053
4 Fi t
gasket
tofront end cover
Then
bri ng
the shelli nto
place
over
the
cyli nderassembly
At
thi s
ti n1e
make
sure
that
the
twoholes ofsi de
coverand the
cyli nder
holes are
matched Note
that
later
adjustment
wi llno
longer
be
possi ble
as i nsi de
and
outsi dedi ameters of theseare
not
perfectly
round Notethat
movi ng
the
shen
up
and down
may
cause the
gasket
to
sli p
out of
place
HA36
AC690
5
TurnovertheasSembled shelland
cyli nderassembly
so
that the
front
may
face
downward
6 Coat oi l
pi pe
and
Ori ng wi th
an
ample
amount of oi lI nsert oi l
pi pe
at
the
rear
of
the
cyli nder
After
maki ng
surethat thehole li nesarematchedas
speci fi ed
i n
step
4 conti nue
wi th
stepp
6work
AC226
7 Conti nue wi th
work
up
to
i nstal
lati on of
rear
end
cover
accordi ng
to
I nstallati on
under
RearEnd
Cover
and Rear
Cyli nder
Head
8 Conti nue wi thwork
up
toi nstal
lati on of si de cover
accordi ng
to
I nstallati on underSi de
Cover
9 I nstallshaft seal
s
t
accordi ng
to
i nstructi ons i n I nstallati on under
Shaft Seal
10 I nstalland
adjust compressor
clutch
acoordi ng
to i nstructi ons i n
I nstallati on under
Compressor
Clutch
I I Fi llwi th
oompressor
oi land
ti ghten
oi l
plug
wi th
copper
gasket
i n
place
ti l
Oi l
plug
18 20Nrn
1820
kg rn
13 14ft lb
12 Conduct
a leak
te st
by
referri ng
to
the
topi c
underShaft Seal
AI R CONDI TI ONER
Electri caI Ci rr ui t
ELECTRI CAL
CI RCUI T
SCHEMATI C
OFF
posi ti on
OFF
0
D O
D
7
ft
tJ
VENT B
L HEAT
DEFand RECI RC posi ti on
OFF
DO
G
0fl 8
S
2
n fP
AC posi tI on
ON
r
GJ
A
I
DDonOa
n
RESI STOR
BLOWER
MOTOR
M
FUSE
20A
5A
AI C
SWI TCH
I GNI TI ON
RELAY
COMPRESSQR
MAGNET
CLUTCH
RESI STOR
OFF
FAN
SWI TCH
COMPRESSOR
MAGNET
CLUTCH
RESI STOR
COMPRESSOR
MAGNET
CLUTCH
AMBI ENT
SWI TCH
LOW
PRESSURE
SWI TCH
I
COOLER I e 01
RELAY
1
11
L
BATTERY
R
FUSI BLE
LI NK
I GNI TI ON
SWI TCH
o
F I CO
MAGNET
VALVE
BLOWER
MOTOR
M
FUSE
20A
F I C O
MAGNET
VALVE
AMBI ENT
SWI TCH
LOW
PRESSURE
SWI TCH I GNI TI ON
SWI TCH
D
BATTERY R
FUSI BLE
LI NK
BLOWE R
MOTOR
M
BATTERY
G
I GNI TI ON
SWI TCH
G
R
F I C O
MAGNET
VALVE
FUSI BLE
LI NK
SHA146
HA 37
JJ
i
9
I I
Cl
1
Co
z
o
5
z
RESI S10R
M010R
I l
4I ER
ll
Gll
01
PRESSURE
SI I 11CI
I
oO
ERRE
Gf
lla
COlolPRESSOR
I oI
GI le
l
C
UCI I
lll
I l o
O
c
tJ
I oI
GI le
l
11 1
all
aN
Ul J
lEI I
115
I RO
1I 01l
C
UI
I
t
MP
SI I 11CI
I
f
ll
UI
I I l
1I 01l
lOI lER
tkMP
COllOl1
lf
ON
I R
lCI I
0
SI lI
I GI I I I I lG
SI I 11CI
I
aJJ
I t
SI l11CI
I
I Gllll101l
SI l11CI
I
fUSI ll
E
I
t
I u
UI
I
1l
1I 01l
COlllRO
SI ll1CI
I
JI
AI R
CONDI TI ONER
TroubleOi agnosesandCorrecri onr
TROUBLE DI AGNOSES AND
CQRRECTI ONS
AI R CONDI TI ONER
DI AGNOSES
I nsuffi ci ent
cooli ng
Bubbles
i n
si ght
glass
Check
refri gerati on
li nefor
gas
leaks
and
repai r
leaks
i f
any Charge
reo
fri gerant
tocorrect level
I ncase
oftoo
many
leaks
stop compressor
di g
charge
the
system
evacuate
and
recharge
the
system
As
necessary
replace
recei verdri er
Ai r
i n
systemmay
causebubbles
i n
si ght glass
Systempressure
and
temperature
of
di scharge
ai rare
abnormalRefer
to
PerformanceTest
Di agnoses
for
detai l
Sucti on
pressure
i s
hi gh
Di schargepressure
i s
hi gh
Expansi on
valve
i s
open
exces
si vely
Replace
expan
si an valve
Overcharge
of
refri gerant
Di scharge somerefri gerant
tocorrect level
Ai r
i smi xedi n
Di scharge sys
tern
and
replace
dri er
Evacuateand
rechargesystem
Condenser
s
fi ni sdented
or
clogged
wi thdust
Cleanexteri orsurfacewi th
water
Sucti on
pressure
i s low
Sucti on
pressure
i s
hi gh
whi le
di schargepres
surei s
low
Valveor
gasket
of
compressor
i s
damaged
Repai r
or
replace
compressor
Pi pe
at
recei ver
dri eroutlet has
low
temperature
Recei verdri er
i srestri cted
Replace
recei ver
dri er
Fi n
and
tllbeof
evaporator
have
some
dents
Replace
or
repai revaporator
Nobubbles
i n
si ght glass
Wi th
mani fold
gauge
check
system
pressures
Measure
temperature
of
di scharge
ai r
Referto PerformanceTest
Temperature
of
di scharge
ai ri s ab
normalbut
system
pressure
i s
normal
Check
ai r
flow
system
Check
grommets
on
cars
dashpanel
forai rleaks check otherseals of
car
Expansi on
valvei s close
excessi vely
or
gas
leakage
fromthermobulb
Replace
expansi on
valve
HA
39
Trouble
Di agnoseund
Conecti om
AI R CON
DI TI ON
ER
Compressor
OFF
Beari ngs
of
compres
sor
clutch
or
i dler
pulley
make
noi se
Repai r
HA 40
I
Blower
motormakes
noi se
Repai r
or
replace
blower
motor
Blowermotor
does
not
rotate
RefertoBlower
Motor
Di agnosesu
FI C D doesnot
operate
Refer
to
Fast
I dle
ControlDevi ce
Di agnoses
Noi sy
Belt
i s
loose
Adjust
belt
Compressor
ON
r
Compressor
i tself
makesnoi se
Repai r
or
replace
compressor
Compressor
does not
run
When
engi nerpm
I s
changed
thereare
resonant sounds
Reti ghtencompres
sorbracket bolts
Referto
Compressor
Clutch
Di agnoses
and
CompressorDi agnoseS
AI R CONDI TI ONER
TroubleDi agnosesand
Correcti ons
BLOWER
MOTOR DI AGNOSES
Test condi ti ons
I I I I
Condi ti on
Check
Battery
Fusi bleli nk Redand
green
I gni ti on
swi tch
I gni ti onrelay
Fuse20A
i n
fuse
block
O
K
O
K
OK
OK
OK
Probablecause
Qui ck
check
Check that
wi per
andwasher
operate
I f
they
do
not
operate
check fusel5A
i n
fuse
block
at
fi rst
Posi ti onof
i gni ti on
swi tch
ACC
Posi ti onoffansWi tch
ON
I I
Blowermotordoes
not run
I I
Removei nstrument lowercoverand
clusterli d
Connect
test
li ght
toblue
whi te
wi re
leadi ng
to
blowermotor
I
I
Ught
ON Ugh
OFF
Ground SHA168
Ground blueblack wi re
leadi ng
to
blowermotor
SHA169
I
Motor
does
not
fun
I
Motorruns
I
Faulty
blower
motorwi thout
problem
i nlead
wi reconnecti on
t
Replace
@ @
HA 41
Troubi eDi agnosesandCorrecti ons
AI R
CONDI TI ONER
Brokenlead
wi re
between
i gni ti on
relay
andblower
motor
t
Repai r
Faulty
fanswi tchwi thout
problem
I
i n
leadwi re
connecti on
t
Replace
Faulty
resi stor
wi thout
problem
lead econnecti on
Replace
Checkfan
swi tchforcon
ducti vi ty
Refer
to
FanSwi tch
I
Motor
runs
I
I
Motor
doesnot
run
Checkresi storfor
conducti vi ty
Refer
toResi stor
I
N
G
I
ot
Checkother
lead
wi reand
connecti on
I
Speed
ofblower
motor
does
not
change
J1
Remove
i nstrument lower
cover
and
clusterli d
Check
resi storonheater
uni t
Referto
Resi stor
Faulty
resi stor
wi thout
problem
i n
lead
wi reconnecti on
l
Replace
HA 42
N
G
I
O
K
I
t
Checkotherleadwi re
andconnecti on
AI R CON0I TI ON ER
Trouble
Di agnosesand
Correcti ons
COMPRESSOR
CLUTCH
DI AGNOSES
Test condi ti ons
Battery
Fusi ble
li nk
Red
and
green
I gni ti on
swi tch
I gni ti onrelay
Fuse
I
SA
i n
fuseblock
Posi ti onof
i gni ti on
swi tch
ACC
Posi ti onoffanswi tch
ON
Posi ti onof
ai rcondi ti onerswi tch
ON
O
K
OK
OK
OK
O
K
I I
J
Condi ti on
I I
Check
I
I
Probablecause
Qui ck
check Check
that
wi per
andwasher
operate
I I
AC371A
I
Compressor
clutch
i snot
engaged
Connect two
wi res
leadi ng
tolow
pressure
swi tch
I
Clutch
i s
engaged
1
Check
refri gerant
level
I I
O
K
N
G
L
Faulty
low
pressure
swi tch
wi thout
problem
lead
y
i reconnecti on
Replace
I nsuffi ci ent
re
fri gerant
t
Add
Ground
earth
termi nals
leadi ng
to
magnet
clutch
Clutchi s
not
engaged
Clutch
i s
engaged
I
Clutch
i s not
engaged
o
Connect
test
li ght
to
blueblack
wi re
leadi ng
to
magnet
clutch
I
li ght
ON
I
li ght
OFF
AC373A
Connect
wi re
between
twotermi
1
000re
@j
Clutch
i s
Clutchi
@
engaged
not
engaged
I I
@ @
SHA17G
HA43
Trouble
Di agnore
end
Correcti on AI R
CONDi TtONER
@
I i
Faulty magnet
clutch
wi thout
pro
blem
i nleadwi reconnecti on
t
Repai r
Broken
ground
wi reof
magnet
clutch
t
Repai r
Faulty
cooler
relay
wi thout
problem
i n
lead
wi re
connecti on
Replace
Faulty
ambi ent
temperature
swi tch
wi thout
problem
i n
lead
wi re
connecti on
Replace
Faulty
ai r
condi ti oner
swi tch
wi thout
problem
i nlead
wi re
connecti on
Replace
HA44
@
Remove
i nstrument
lowercover
and
clust rli d
leadi ng
toambi ent
temperature
swi tch
I
Clutchi s
engaged
I
I
Clutch
i s
not
engaged
Connect wi rebetween
green
and
bluewi re
leadi ng
toai rcondi ti oner
swi tch
I
Clutch
i s
engaged
J
ClutCh1i s
no
engaged
U
Check
other
lead
wi re
and
connecti on
SHA174
SHA175
AI R
CONDI TI ONER
Trouble
Di agnosesand
Correcti ons
COMPRESSOR
DI AGNOSES
Compressor
clutch
i s
engaged
but
compressor
does not
run
I
Clutch
sli ppi ng
I
I
Belt
sli ppi ng
I I
Sei zuredcompressor
Checkand
readjust
gap
of
clutch
Clean oi lordust
on
contact
sur
face ofclutch
I f
sli ppi ng
conti nues
replace
com
pressor
clutch
Checkbelt
tensi on
and
adjust
i t
I fbelt
i s
wornout ordamaged
replace
i t
I nternal
problem
i n
compressorcyl
i nder
Check
system
Repai r
or
replace
i f
necessary
Hi ghtorque
Overcharge
of
refri gerant
11
Ai ri n
refri gerati on
system
Di scharge refri gerant gas
toan
extent that
si ght glass
of
recei ver
dri erhas
only
a fewbubbles
Engi nespeed
1
500
rpm
Di scharge system
from
servi cevalveon
di scharge
si de
Evacuate
and
recharge
the
system
Checkfor
di schargepres
sure
OK
i f
di schargepres
sure
i s
reduced
Di scharge
pressure
i s
not
reduced
I
When
torque
i s sti ll
great
repai r
or
replacecompressor
I
HA 45
Trouble
Di agnoseund
Correcti ons AI R CONDI TI ONER
Compressor
oi l
leaki ng
Ai rblowon
spot
where
oi llcak evi dence
i s
found
Then
check
for
refri gerant
leaks
usi ng
leak detecror
I
Refri gerant leaki ng
No
refri gerant leaki ng
Repai r
or
replace
compressor
Wi pe
cleanoi lwi th
rag
HA 46
Compressor
i s
noi sy
Noi sy only
whenclutch
i s
engaged
Check
forloose
compres
sor
mounti ng
bolts
Reti ghten
bolts
Compressor
dri vebelt
i sloose
Adjust
belt
tensi on
I f
compressor
i s
sti ll
noi sy repai r
or
replace
compressor
Noi sy
whenclutch
i s
not
engaged
Remove
compressor
belt
Turn
pulley
of
compres
sorclutch
by
hand
and
check
fornoi se I fnoi se
i s
heard
repai r compres
sor
clutch
AI R
CONDI TI ONER Trouble
Di agnoses
and
Correcti ons
FAST I DLE
CONTROLDEVI CE DI AGNOSES
Test
condi ti on
Battery
Fusi bleli nk Redand
green
I gni ti on swi tch
I gni ti on
relay
Fuse
I S
i nfuseblock
OK
O
K
OX
O
K
OX
Qui ck
check
Checkthat
wi per
and
washer
operate
Posi ti onof
i gni ti on
swi tch ACC
Posi ti onoffan
swi tch
ON
Posi ti onof
ai rcondi ti onerswi tch ON
F
LC D
i s
not
operated
I I
Check
operati on
of
compressor
clutch
I
Clutch
i s
not
engaged
Checkelectri cci rcui t of clutchreo
ferri ng
to
compressor
clutchdi a
gnoses
Faulty
FlC D
magnet
valve
Replace
Faulty
Fl
C
D
devi ce
Replace
I I q
Condi ti on
I
I
Check
I
I
Probable
cause
I
Outchi s
engaged
j
D
Run
engi ne
at
i dle
speed
Di sconnect vacuum FLC D
magnet
valvetoF
LC
D
devi cehoseat
F
LC
D
magnet
valveandcheck
vacuum
I
VacuumN
G
I
I
VacuumOK
Di sconnect vacuum
Fl
C D
magnet
valvelo
F
LC D devi ce
hoseat
FlC D devi ceandcheck
vacuum
I
VacuumO
K
j
I
Vacuum
N G
1
J I
Broken vacuumhose
J
Repai r
SHA177
7
Check
vacuum
F
lC
D
devi ce
SHA17S
HA 47
Setvi ce
Dataand
Speci fi cati ons
AI R
CONDI TI ONER
SERVI CE
DATA
AND SPECI FI CATI ONS
GENERAL
SPECI FI CATI ONS
TI GHTENI NG
TORQUE
COMPRESSOR
Uni t N
m
k
ft
lb
Model
SWP167
Compressor
bracket to
44 54
45 55
33
40
cyli nder
block
TVpe Swash
plate
I
Compressor
to
44 54 45 55
33
40
Di splacement
cm3
cu i nl
rev
167110191
compressor
bracket
I
Cyli nderbore
x
stroke
mm i n
37
2
25 7
Refri gerant
li ne
connec
11 465x1
0121 ti on
I
Low
pressure
li ne 25 29 25
3
0 18 22
Di recti on
of
fotati on
ClOckwi se
I
Hi gh
pressure
li ne 15 20
11 5
20 11 14
Type
of
dri vi ng
belt
A type
flexi ble
hoseto
lOB
cori lpreuor
78
10
8 1 1 5
8
0
LUBRI CATI NG OI L
Compressor
I
028 035
1
I
Coi l
mounti ng screw
2
7 34 2025
Type
SUNI SO
5GS
12
5
I
I
Lock nut 25
27 28
18
20
Capaci ty
mlUS flOZ
I mp
fI 02
270191 9
51
Hub
nut 18 21
11
8 21
I
13 15
REFRI GERANT
Shaft nut 16 17
11 6
1 7
111
6
12 3
Type R
12
Si decover
bolt 18
20
11
8 20
I
13 14
Capaci ty kg UbI
09
111202411 Reaf end
coyer
bolt
29 34
13
0
3
5
I
22
25
Oi l
plug
18 20
11
8 20
I
13
14
I NSPECTI ON AND
ADJUSTMENT
ENGI NE I DLI NG SPEED
Uni t
rpm
Transmi ssi on
When
Ale
i sON
Manual
About 900
Non ci djustablel
Automati c At N
rangsl
About
1000
Nori adjustable
BELT TENSI ON
Fan
belt
Appli ed
pressure
mm
Unl
N
kg I bl
18
1210
31
04711
98
110221
COMPRESSOR
Clutchhub
topulley
clearance
mm i n
0
5 0
8
10
0200
0311
HA 48
Toolnwnber
Kent MooreNo
KV99412302
J94878
1
AI R
CONDI TI ONER
Speci alServi ce
Tools
SPECI AL
SERVI CE
TOOLS
Toolname
Clutchhubwrench
KV99412305
Hub nut socket
1248782
KV99412306 Clutchhub
puller
124878
3
KV99412310
Locknut socket
QD
1248784
KV99412313 Puller
adapter
126066
KV99412312
125472
KV994C1552
KV994C4548
CD
KV994C453I
@KV994C4532
@
KV994C4533
@
KV994C4534
@KV994C4559
Puller
pi lot
Charge
nozzle
Bli ndcoverset
Bli ndcover
Gasket
Useless 3 @
1
c
11 1
0
39
039 061
0
51
Gasket
Gasket
Bolt
@
Uni t rom
i n
HA49
Speci al
Servi ce
Tools
AI R
CONDI TI ON ER
Toolnumber
Kent Moore
No
KV9941232I
126067
KV99412322
125473
KV99412329
126072
KV99412327
KV99412328
KV99412330
KV99412315
HA
50
Tool
name
Shaft sealremoverand
i nstaller
Shaft seal
pi lot
Shaft handlesocket
Si lencer
pi ece
i nstaller
O
ri ng
i nsta11er
Allensocket
Cyli nderheadremover
o
DATSUN
200SX
Model
S J J 0Seri es
SECTI ONEL
ELECTRI CAL
SYSTEM
CONTENTS
POWER SUPPLY ROUTI NG
EL 2
SERVI CE
DATA
AND SPECI FI CATI ONS EL 37
SCHEMATI CI POWER SUPPLY ROUTI NG
EL 2
LI GHTI NG
SYSTEMS EL 38
FUSE
EL 3 BULB SPECI FI CATI ONS EL 38
FUSI BLE LI NK
EL 3 COMBI NATI ON
SWI TCH
EL
38
I GNI TI ON
SWI TCH
EL 3
HEADLAMP
EL
40
I GNI TI ON
AND
ACCESSORY RELAY EL 3
EXTERI OR LAMPS
EL
43
BATTERY
EL 4 I NTERI OR LUGGAGE COMPARTMENT
CHECKI NG ELECTROLYTE LEVEL
EL 4 AND STEP LAMPS
EL
51
CHECKI NG
SPECI FI C GRAVI TY EL 4
I NSTRUMENT
PANEL I LLUMI NATI ON
EL 54
CHARGI NG
EL 5 METERS
GAUGES AND
BATTERY
FREEZI NG EL 5
WARNI NG SYSTEMS
EL 56
BATTERY TESTI NG EL 5
COMBI NATI ON
METER
EL 56
SERVI CE
DATA AND
SPECI FI CATI ONS
EL 7 WARNI NG
DI SPLAY
EL
65
STARTI NG
SYSTEM EL 8 WARNI NG
CHI ME
EL 70
SCHEMATI C
EL B WI PER
AND WASHER EL 73
WI RI NG
DI AGRAM EL 8 WI NDSHI ELD
WI PER AND
WASHER EL
73
STARTI NG
SYSTEM
REAR WI NDOW
WI PER AND WASHER
EL 79
TROUBLESHOOTI NG
EL
9
ELECTRI CAL
ACCESSORI ES EL 81
STARTER
MOTOR
ELla
REAR WI NDOW DEFOGGER EL 81
SERVI CE
DATA AND
SPECI FI CATI ONS
EL 16
REMOTE
CONTROL
DOOR MI RROR
EL 83
CHARGI NG SYSTEM
EL17 CLOCK
EL 85
DESCRI PTI ON
EL17 HORN
EL
87
SCHEMATI C
EL18 AUDI O
EL 89
WI RI NG DI AGRAM
EL18 AUTOMATI C
SPEED
CONTROL
CHARGI NG SYSTEM DEVI CE
A S CD
EL 94
TROUBLESHOOTI NG
EL19
DESCRI PTI ON
EL 94
ALTERNATOR EL20 TROUBLE
DI AGNOSES EL
95
I C
VOLTAGE
REGULATOR EL
23 COMPONENT PARTS EL
99
SERVI CE
DATA AND
SPECI FI CATI ONS
EL25
ELECTRI CAL
UNI T
LOCATI ON EL104
I GNI TI ON SYSTEM
EL
26
WI RI NG HARNESS
EL 106
I C
I GNI TI ON SYSTEM CABLE COLORS
EL106
TROUBLESHOOTI NG EL28
HARNESS
LAYOUT
EL106
DI STRI BUTOR
I C
type
EL31
I C
I GNI TI ON
UNI T
EL35
Power
Supply
Routi ng
ELECTRI CAL SYSTEM
POWER SUPPLY
ROUTI NG
CAUTI ON
Before
starti ng
to
worll
on
any
J
system
di sconnect
battery
ground
cable
SCHEMATI C
POWER SUPPLY
ROUTI NG
1
w
a
EL
2
V
a
o
z
a
w
J
w
t
u
w
f T
ci
C
CD FUSI BLE
LI NK
t
Q
1
8
BATTERY
J
I
I
srOr locc
E1
BOg
0
I GNI TI ON SWI TCH
A
I
0
I
16
Q
S
5
I
I GNI TI ON AND
ACCESSORY
RELAY
ll
i n
i r
1
f
I
I
FUSE BLOCK
o
L
HEADLAMP
STOP
LAMP
i
HAZARD
FLASHER
HORN
CI GARETTE
LI GHTER
CLOCK
LAMP MONI TOR
VOLT GAUGE
z
0
w
t
z
i
I NTERI OR LAMP
STEP
LAMP
LUGGAGE
COM
PERTMENT
LAMPS KE
WARNI NG
TAI L
CLEARANCE
SI DE
MARKER
AND LI CENSE
PLATE
LAMPS
METER I LLUMI NATI ON
7HEATER
OR AI R
CONDI TI ONER
BLOWER MOTOR
7
AI R
CONDI TI ONER
WI PER
AND
WASHER WI NDSHI ELD
AND REARl
RAOI O
POWER
ANTENNA
REAR
WlNDOW
DEFOGGER
TURN
SI GNAL
BACK
UP
LAMPS
WARNI NG
LAMPS
TACHOMETER
GAUGES SEAT BELT WARNI NG WARNI NG
DI SPLAY
SEL365
FUSE
LOCAnON
SEL275
I NSPECTI ON
c
l
l
CI
c
SE L276
8
I f fuse i s
blown be suretoeli mi
nate cause of the
problem
before
i nstalli ng
newfuse
b Neverusefuseof
more
than
speci
fi ed
rati ng
c
Donot i nstallfuse i n
obli que
di recti on
always
snap
i t i nto
fUle
holder
properly
I GNI TI ON
SWI TCH
S 1G
ELECTRI CAL
SYSTEM
Power
Supply
Routi ng
FUSI BLE UNK
SEL277
CAUTI ON
a I f fusi ble li nk
should melt i t i s
possi ble
that cri ti calci rcui t
power
supply
or
large
current
carryi ng
ci rcui t i s shorted I n such
a case
carefully
check andeli mi natecause
of
problem
b Never
wrap peri phery
of
fusi ble
li nk wi th
vi nyltape
Extreme
care
should be taken wi ththi s
li nk to
ensure
thet i t
does
not
come i nto
contact wi th
any
other
wi ri ng
har
ness or
vi nyl
or
rubber
parts
A
melted fusi bleli nkcan
bedetect
ed
ei ther
by
vi sual
i nspecti on
or
by
feeli ng
wi thfmger
ti p
I f
i ts
condi ti on
i s
questi onable
use ci rcui t tester
or
test
lamp
B A
sr
t
T
01
g
Q
B
From
battery
5
A
ToaccessOI Y system
o
I G To
ti onsystem
5 s
To
starti ng system
c
s
k
U
Key warni ng
swi tch
I N
OUT
I
g
SEL369
I GNI TI ON AND
ACCESSORY RELAY
LOCATI ON
The
i gni ti on
and
accessory relay
are
located
on
the
ri ght
si de of the
dash
panel
Referto
page
EL
104
I NSPECTI ON
Ground
i s made
at case
attachi ng
bolt
andtenni nal
rJ
SE
L279
I
n
EL3
Battery
ELECTRI CAL SYSTEM
WARNI NG
Navertouch
posi ti ve
and
negati ve
termi ll8ls
at the same ti me wi th
bare
hands Thi s could result i n
i njury
CAUTI ON
a I fi t
becomes
necessary
tostart the
engi ne
wi th
a booster
battery
end
jumper
cables the
booster
battery
voltage
must not ex
12
volts
orthe control
uni t of the fuei
i njecti on
system
andotherelectri c
components
wi llbe
damaged
b I f
the
battery
cables are
di scon
nected
they
should
be
ti ghdy
clamped
to
the
battery
termi nalsto
secure
a
good
contact
CHECKI NG
ELECTROLYTE
LEVEL
Check for
electrolyte
level
i n
each
cell
Overflow Correct
Shomse
t
j
t
1
t
EE358
I fthelevel
i s
low fUI wi th
di sti lled
water
EL
4
BATTERY
CHECK G
SPECI FI C
GRAVI TY
J
Read hydrometer
and
thermal
gauge
i ndi cati onsat
eye
level
Reedtop
levelwi thleale
r
Thermal
gauge
SEL045
2 Correct
speci fi cgravi ty
et 200C
1680Fl
O
St
0
0007 t 20
Where
St
S20
Speci fi cgravi ty
of
electrolyte
at tOC
Speci fi cgravi ty
of
electrolyte
corrected
at 20C
680F
Electrolytetemperature
t
Examples
1
When
electrolyte temperature
i s
350C 950F
and
speci fi cgravi ty
of
electrolyte
i s
L2O
speci fi c
gravi ty
corrected
at
20C
680F i s 1
243
2 When
electrolyte
temperature
i s
Oc 320F and
speci fi c gravi ty
of
electrolyte
i s
1210
speci fi c gravi ty
correctedat 200C 680F i s 1196
1
30
j
speci fi cgravi ty 5
0
1
@
1
28
E
u
Co
E
B
u
g
o
u
o
114
Co
1121
110
I
I
10
14
I
o
32
I
10
SO
I
SO
122
r
40
104
Electrolyte
temperature
oC
OF
SEL096
3
Determi ne chargi ng
state
of
bat
tery
Examples
Chargi ng
state
of
battery
whose
max
chargi ng speci fi cgravi ty
i s 126
and whose
speci fi c
gravi ty
correctedat
200C 680F i s 1243
i s
92
For
battery
whose
m
chargi ng
speci fi cgravi ty
i s
128
chargi ng
state
i s
82 at a
corrected
speci fi c
gravi ty
of
200C
680F
Speci fi cplvi ty
20oC
680F
708090100
Charsi n
ndi ti an l
SEL097
4
Recharge
battery
i f
i ts
rate
drops
below
7moffull
charge
CHARGI NG
CAUTI ON
a
Carry
out
chargi ng
wi th
negati ve
cabI eremoved
b Donot
allow
electrolyte
tempera
tureto
go
over
450C
1130Fl
Clean
corroded
termi nalwi th
e
brush
and
common
baki ng soda
solu
ti on
WARNI NG
a
Keep
battery
away
from
open
flamewhi lei t i s
bei ng charged
b When
connecti ng charger
con
nect leads
fi rst
then turn on
cherger
00not turn on
charger
fi rst
as thi s
may
causea
spark
BATTERY
FREEZI NG
CAUTI ON
Usa
extremecauti on
to
avoi d
freezi ng
battery
0 1
U 10 14
o
204
00
0
22
400
o
SO
55
O
I
60
76
70
94
I
80
1I 2
L I
I to
108 116
124
132
1
04
112 120
128
EE004
Speci fI C
I flvi l
oreleclrolyte
BATTERY TESTI NG
I PRELI MI NARY CHECKS Vi sual
I nspecti on
Clogged
I
Di rt
vents
lfi lfi l
W
Check
Corrosi on
r 8
A M
rati ng
Cracks
I
Y
I
Warped
case
SEL046
1
Check
battery rati ng agai nst
that
of
ori gi nal
factory equi pment
2 Check forcracks and
warpage
of
the
case
3 Make sure cables are clean and
ti ght
4 Checkaci dlevel
5 Make sure vents are not
clogged
6 Makesure
top
of
battery
i s
clean
2 BATTERY
LEAKAGE
TEST
Check tomake sure
battery
i s
not
di schargi ng
across
top
between
two
posts
ELECTRI CAL
SYSTEM Battery
11 JI
J
I e
0
4@
QoI
SE L047
1
Set voltmeterto low
range
2 Touch
negati ve
lead of voltmeter
to
negati ve
battery
post
3
Touch
posi ti ve
lead of voltmeter
to
top
of
battery
andmove
i t
around
I f
readi ng
goes
over
05 volts then
clean off
top
of
battery
and retest
3 BATTERY CAPACI lY TEST
SEL048
1
Wi th
battery
connected
to
tester
as shown turnload
knob
unti la draw
of
3
ti mes
the
battery rati ng
i s
shown
Example Battery rati ng
60AHTurn
loadto180Adraw
2
Hold thi s draw for
15 seconds
thi m
look at
voltage
I f
voltage
re
mai ns
at 96
volts
orabove THE
BATTERY I S GOOD You need not
perform
any
furthertests I f
voltage
drops
below96volts then
proceed
to
next test
4 THREE MI NUTE CHARGE
TEST To be
performed only
i f
battery
has fai led
Capaci ty
Test
i n
step
nwnber3
1
Connect a
goodquali ty battery
Removecell
caps
2
Tum
charger
to
a fast
charge
rate
not over40
A
EL
5
Battery
ELECTRI CAL SYSTEM
I
o
0Jol
nnlol
J
SEL049
3
After
three
mi nutes check
volt
meter
readi ng
I f
i t i s
over
15 5
volts
16 5
forMai ntenanceFreeBatteri es
battery
should
be
replaced
I f
i t
i s
below 15 5 volts then
proceed
to
step
nwnber5
5 CELL TEST
UNPER
CHARGE
Connect tester
and
battery
charger
as
i n
step
number4Set tofast
charge
rate 35 40
A
I Turn
tolow
range
voltmeter
2 Attach
speci al
cell
probes
to
voltmeterleads
3
Touch
posi ti ve probe
to
battery
posi ti ve
termi nal
4
Sti ck black
probe
i n
battery
cell
nearest the
battei y
posi ti ve
post
WRI TE DOWN voltmeter
readi ng
SEL050
EL 6
5 Now
put
posi ti ve probe
i n ceU
nearest the
posi ti ve
post
Put
negati ve
probe
i n next celldown Record
readi ng
SEL051
6 Conti nue on
down
the
battery
recordi ng
readi ng
eachti me
SEL052
7
When
you
get
to
poi nt
where
posi ti veprobe
i s i nlast cellof
battery
touch
negati veprobe
to
negati vepost
Recordthi s
readi ng
ee
9
SE
L053
8
You
should now have
seven
readi ngs
NowaddthefI rSt
readi ng
to
thelast
thi swi ll
gi veyou
si x
readi ngs
They should aU be wi thi n 02 two
tenths
volt of eachotherI fonecell
vari es
more
thanthi s
amount from
any
otherthen
battery
i s
badandmust be
replaced
2
4
26
26
26
2
6
26
0
2
24
02
26
i
V
J lh
t
S
lE
1
rA
AND
SPE
I
rH
r
T
C
l
BA r
E
l
t
g
0
w
ri
N50Z NS70
I i r
A
ffli i odel
U S
A
tf r
nada
f
i
cr
p
aci fy
AH
1260
1
fJth65
i li ffAf
A
Fi I
f
n
s c
fi cI 26f
1
i 28
g
i li YJa
6
F
1
t
t
a
4
f
c
li Y
t
C r1 i I CALL
STEM
Battri ry
9
j
1
N
i
i
J
t
r
I l
7i
r4
ti
tt
I
f
1
l
1
L
j
yj
t
I
i
fT
t
lI
f
r
o
O
t
tYt f
I i
1I i t
o
4
Jt
rl
t
e
t
j
1i
el f
V
6 ft
i
t
j
V
M
7r
1
rt
l
f
7 t
j
C
I
t
w
l
rJf
j
GI
I tX9 I i
i
c
p
J
l
I
fi
Ji i
t
135
L
ht
cf
c
S
ti
a
i
Co
jt
1 j
lti i
H
J
t
t
i t
AAi
j
i
y
H
3
b
ttjjt
1
EI i
7
1 L
7
Starti ng System ELECTRI CALSYSTEM
STARTI NG SYSTEM
SCHEMATI C
OFF Ace ON ST
g
I e
sr 5
lC
FUSI BLE
LI NK
1
I GNI TI ON
SW
I
o
1
C
0
cI
FUSE
I GNI TI ON AND
ACCESSORY
RELAY
1 1
FUSI BLE
LI NK
@
I NHI BI TOR
SW
o 0
STARTER
MOTOR
1
BATTERY
@I NHI BI TOR
RELAY
SEL098
WI RI NG DI AGRAM
re
Cf
R
o
BATTERY FUSI BLE
LI NK
@
srON
Ace
Off
g
DD
I EI
BW
J
6
I e
r
ey
5
s
r
WR
@
@ll
wI D1
WB
BW
oJ
I t
@
I GNI TI ON
AND
ACCESSORY RELAY
I GNI TI ON
SW
r
0
O
Q
tJl
000
0 0 0 0
o 0 O i j i j i j
i j
o
o
0COO
0000000 000
0
FUSEBL
CK
Ji
E
@
@
@ri g@
@I NHI BI TORRELAY
@
t1
e@
a
m
al 3
lD
g
o
g
@
@
@WB
ao
LW ao
I
We
SEL099
STARTER MOTOR
@ I NHI BI TOR
SW
EL8
STARTI NG
SYSTEM
TROUBLE
SHOOTI NG
I
Check
the
battery
Fully
charged
I
Te
ti ng
tarter
current
drew
I
Turn
key
to
start
r
Cli ck
or
t
I
Di sconnect
battei y
posi ti ve
cable
I
Starter
turns
at
starter
N
I
k
2
Connect
ammeter
500A
range
oc
1
between
thI S
cable
and
starter
termi nal
3
Pull
out
coi l
wi re
from
di stri butor
cap
Not
from
coi l
4
Crank
engi ne
read
current
draw
Pull
i gni ti on
Ustart
wi re
Usually
Black
Yellow
off
at
starter
Connect
test
li ght
between
thi s
lead
and
battery
negati ve
termi nal
Have
someone
turn
key
Li ght
t
I
No
li ght
1
Testi ng
for
voltage
drops
i n
i gni ti on
I wi tch
Starter
magneti c
swi tch
ci rcui t
I
Turn
voltmeter
to
low
scale
2
Connect
posi ti ve
lead
to
posi ti ve
termi nal
of
battery
3
Connect
negati ve
lead
to
bayonet
connector
Black
Yellow
at
magneti c
swi tch
Leave
B
Y
wi re
connected
4
Ground
coi l
wi re
5
Crank
engi ne
mreO
More
than
lSV
More
than
l50A
I
Less
than
I SOA
Speed
slow
l
More
than
4
I V
Testi ng
for
voltage
drops
i n
starter
posi ti ve
ci rcui t
I
Turn
voltmeter
to
low
scale
2
Touch
posi ti ve
lead
to
posi ti ve
post
of
battery
Not
to
cable
3
Connect
negati ve
lead
to
magneti c
swi tch
uM
termi nal
Termi nal
connected
to
starter
4
Pull
coi l
wi re
out
of
di stri butor
cap
and
ground
i t
5
Crank
engi ne
Less
than
I V
Less
than
05
Less
than
I5V
Connect
jumper
wi re
between
battery
posi ti ve
termi nal
and
the
s
termi nal
on
magneti c
swi tch
Less
than
150A
Speed
normal
Plug
coi l
wi re
back
i n
Start
engi ne
but
hold
key
over
to
start
so
that
starter
docs
not
stop
Starter
turns
rt
fast
less
than J
60A
Starter
draws
more
than
60A
More
than
I
V
J
Move
negati ve
lead
to
B
termi nal
of
magneti c
swi tch
Termi nal
connected
to
battery
Crank
engi ne
Testi ng
f
r
voltage
drops
i n
starti ng
ground
ci rcui t
I
Turn
voltmeter
to
low
scale
2
Connect
negati ve
lead
to
negati ve
termi nal
of
battery
3
Hold
posi ti ve
lead
to
starter
housi ng
Make
good
conneCti on
4
Crank
engi ne
Less
than
I V
More
than
O
SV
No
cli ck
Starter
does
not
turn
Cli ck
starter
turns
0
Starter
O
K
Ti ght
engi ne
Mechani cal problem Short
i n
starter
Overhaul
Bad
connecti on
between
battery
and
magneti c
swi tch Magneti c
swi tch
bad
Remove
and
replace
magneti c
swi tch
Bad
ground
Check
battery
termi nal
cable
ground
connecti ons
and
starter
bolts
J
Open
i n
starter
1
Overhaul Bad
magneti c
swi tch
and
starter
Overhaul
Open
i n
ci rcui t
I gni ti on
s
i tch
connectors
i nhi bi tor
swi tch
and
relay
Automati c
transmi ssi on
mrm0I I 1n rrn rnI ms
I
i llg
StBrti ngSystem ElECTRI CALSYSTEM
STARTER MOTOR
Non Reductlon
ear
type
lJ
74
9 8 0
75 1
00
5
4 7 2
I leu
00
metal
Through
bo
Brush
Brush
mi n
length
12 047
Mqneti c
lWi tclasoembly
Ocarance Q between
Pi ni onfront
edge
and
pi ni onstopper
03 2 5 0
012
0
098
Dust 00
Adjlllli n8
er
Adjust
clearance
2
Washer
thi ckness
05 0020
08 0031
Dust cover
Eri ng
Brush
spri ng
Tensi on 137
17 7N
1
4
1
8
kg
3
1 4
0I b
lJ3
7
5
0
038 0
51
27
Commutator
mi n
di a
39 154
Center
bracket
5114 180F
only
Pi ni on
assembly
Pi ni on
stopper
Depth
of
i nsulati ng
mi ca
05 08 00200031
Armatureshaft bend
Les sthan008 00031
lJ
N m
lcg
m ft4b
Uni t
mm
i n
SE
L007
EL10
ELECTRI CAL SYSTEM Starti ng System
Reducti on r
typo
Qri ng
Dust cover
Adjusti ng
washer
Adjust
clearance
washerthi ckness
05 0020
08 0031
v
Through
bolt
f
co
Commutator
mi n
di a
29 114
Depth
of
i nsulati ng
mi ca
05 0
8
00200
031
Drush
Brush
mi n
length
11
043
Center
beari ng
Brushholder
Brush
spri ng
Tensi on 15 1
196
N 16
2 0
k8
35
4
41b
Fi eld
coi l
3 1
Ci
6 3 83
0
64 085
4
6
Ori ng
Ci
N
m
kg
m fHb
Uni t
mm
i n
Pi ni on
gear
Di fference
i n
hei ght
of
pi ni on
Packi ng
03 15
0012 0059
Gear ca
SE
LOOS
ELll
r
Starti ng System ELECTRI CAL
SYSTEM
DI SASSEMBLY
Non ucUon
r
tJP
1 Remove
magneti c
swi tch
2
Removerearcover
1
Remove dust
coverE
ri ng
and
thrust
washer
s
2 Remove brushholdersetscrews
3 Remove
through
bolts
SE LOtO
I
3
Li ft
p
brush
spri ngs
EEt50
4 Remove
brushholder
EL12
SEL011
5
Remove
yoke
6 Wi thdraw armature and shi ft
lever
SE L019
7
Remove
overrunni ng
clutch
Remove
pi ni on stoppercli p push
i ng pi ni on stopper
toward clutch
si de
EE277
Pi ni on
stoppercli p
RedueUon
rtJpe
I Remove
magneti c
swi tchassemb
ly
2
Removetorsi on
spri ng
3 Remove
through
bolts and rear
cover
CAUTI ON
Bacareful
not to
damage
Ori ng
4
Remove
yoke
armatureandbrush
holderas an
assembly
from center
housi ng
CAUTi ON
Be carefulnot
toknock brushcom
mutatororcoi l
agai nst
I ny
edjacent
plrt
EE616
5 Removecenter
housi ng
6 Remove
pi ni on gear
7 Li ft
up
brush
spri ngs
8 Remove brushes
from brush
holder
EE616
9 Removebrushholder
10Remove
yoke
I NSPECTI ON
Fi eld coD
I
Conti nui ty
test
between
fi eld
coi l
posi ti ve
termi naland
posi ti ve
brushes
SEL107
No
conti nui ty
Replace
fi eldcoi l
2
Ground test
between
fi eld coi l
posi ti ve
termi naland
yoke
Posi ti ve
termi nal
SEL
1
oS
Conli nui ty
exi sts
coi l
Replace
fi eld
Bru h
Check the surface condi ti on
of
brush
contact
Loosecontact
Replace
Checkwearofbrush
Mi ni mwn
length
ofbrush
Non
reducti on
goortypo
12
mm
047 i n
Reducti ongoortypo
1
mm
043i n
Excessi ve
wear
Replace
ELECTRI CAL SYSTEM
Starri ng System
SE L030
Bru h
prlnll
Checkbrush
spri ng
tensi on
Spri ng
tensi on
Non reducti on
geartype
137 17
7 N
141 8
kg
3
1
40I b
Reducti on
geartype
15 7 19
6N
1 6 2
0
kg
35 44I b
Not i nthe
speci fi ed
value Repai r
or
replace
Spri n
scale
WI
SEL109
Arm
ture
mbl
I
Check
commutatorsurface
Rough Sandli ghtly
wi thNo
500
sandpaper
2 Check
depth
of
i nsulati ng
mi ca
from
commutator
surface
Less than 0
2
mm
0008 i n
Undercut
to05 0
8mm 0020
0031i n
t
J
0
5
08
mm
i
Correct
f
l
1
Commutator
1T1i n
i
I ncorrect
EE021
3 Check
di ameterof
commutator
Commutatormi ni mum
di ameter
Nonreducti on
geartYpe
32mm
11
26i n
Reducti on
geortype
29mm11 14i nl
Less than
speci fi ed
value
Replace
SEL031
4
Ground test
between
eachcom
mutator
bar
and
shaft
EE022
EL
13
Scarti ng System ELECTRI CAL SYST M
Conti nui ty
exi sts
Replace
5
Short test wi thannature tester
growler
and a
pi ece
of
i ron
over
armaturecore
EEQ23
Platevi brates
Replace
6
Conti nui ty
test
between
two
segments
si de
by
si de
No
conti nui ty Replace
rrunnln clutch
mbly
1
I nspect
smooth
sli di ng
of
pi ni on
gear
Abnormal
resi stance
Repai r
2
I nspect pi ni on
teeth
Excessi ve
rubbi ng Replace
CAUTI ON
Flywbeelri ng
gear
also
must be i n
spected
Brushhold
r
Ground test
between negati ve
si de
of brushholderand
another
posi ti ve
si de
EE025
Conti nui ty
exi sts
Replace
EL14
PI nI On caN buri n I i i 8taoI
Non ndi lctlon ear
type
Check clearance between
beari ng
metalandarmatureshaft
II eari ngmetlll toI rmatui nhaft
dearance
Lessthi n
0
2 mm
0
008i n
More
than
speci fi ed
value
Replace
Ballb rln
Reducti on
ar
tyP
Holdi ng
outerrace wi th
fmger
rotate
beari ng
Any play
orbi nd
Replace
Me n tI cswi tch
mbly
I
Con1i nui ty
test
between
sn
termi nalandswi tch
body
No
conti nui ty
Replace
2
Conti nui ty
test
between
tenni
naI s S and M
No
conti nui ty
Replace
ASSEMBLY
Apply gre
e to
gear
case
and
rear
cover
beari ng
metalond
I pply
oi l
to
pi ni on
sli ghtly
Non
ducti on
I l 8type
Wi ththe
swi tchon
push
pi ni on
back
toremoveallslack ond meure
the clearance en between
pi ni on
front
edge
and
pi ni on
stopper
Cleari nce
2
03
25mm
0012 0
098i n
r
I
J
L
e
SEL015
Not
i nthe
speci fi ed
value
Adjust
by
adjusti ng washer
s
Reducti on
gear
type
Compare
di fference en i n
hei ght
of
pi ni on
when i t u
pushed
out wi th
magneti c
swi tch
energi zed
and
wheni t
u
pulled
out
by
handunti li t touches
stopper
Di fference 1
H
03 1 5
mm
0012
0
059i nl
PoD out
by
hand
unti l
pi ni on
stops
Pushoutwi tb
electri c
current
1
r
0
r
Di fference
L
e
SEL016
Not i n
the
speci fi ed
value
Adjust
by
adjusti ng washer
s
Adjusti ng
washer
thi elmo
06
mm10020
i n
08mm
0
031
i n
TESnNG
Perform
nc tut
No load test
p
btJ
VoltmeterAmmeter
Capaci ty 300A
SELOSS
Speci fi cati ons
Referto sn s
Dlqnos of test
I Low
speed
wi th no lold and
hi gh
current draw
I
Ti ght di rty
orworn
beari ngs
2 Bent annature
shaft
orloosened
fi eld
probe
3 Shortedarmaturecoi l
4
A
grounded
armatureoffi eldcoi l
2 Fai lureto
operate
wi th
hi gh
cur
rent draw
I A
grounded
or
open
fi eld coi l
2 Burned out commutator
bar
Weak brush
spri ng
tensi on
Thrust out ofmi ca
i n
commutator
Loose contact between brushand
commutator
3 Low current
draw and lowno
load
speed
I Looeconnecti ons
2
Di rty
commutator
3 Burnedout commutator
bar
netlc
wttch
r
rn
bllltr
I Di sconnect lea
wi refrom termi
nalM
of
magneti c
i wi tch
2 Connect
termi nal M and
posi
ti ve tJ termi nalof
battery
wi th
a
jumper
lead
wi re
3 Connect startermotor
body
and
negati ve
etermi nalof
battery
wi th
a
jumper
lead
wi re
4
Pull
pi ni on
gear
allthe
way
out
wi th
your
hands
5 Release
your
hand from
pi ni on
gear
6
I f
pi ni on gear
returns
toi ts
ori gi
nal
posi ti on magneti c
swi tch
i s
pro
perly functi oni ng
1 CI
ELECTRI CALSYSTEM
Sta i ng
Sysrem
jrJ
SEL012
S rle coi l
I
Connect
termi nal M of
magne
ti cswi tch
and
negati ve
e
termi nalof
battery
wi tha
jumper
lead wi re
2 Connect termi nalS of
magneti c
swi tchand
posi ti ve
tJ
termi nalofbat
tery
wi th
a
jumper
wi re
3 Wi th these
connecti ons
havi ng
been made i f
plunger
i s
pulled
i n
by
force seri es coi li
properly
functi on
i ng
t
SEL013
Shunt
co
1
Di sconnect
lead
wi re
whi chcon
nects
termi nalM of
magneti c
swi tch
and
starti ng
motorteoni nalandcon
nect a
jumper
wi rei ni ts
place
2 Connect
termi nalS of
magneti c
swi tchand
posi ti ve
tJ termi nalofbat
tery
wi tha
jumper
wi re
3 Connect
negati ve
etermi nalof
battery
and
starti ng
motor
body
wi th
ajumper
wi re
Plunger
shouldbe
pull
ed
i n
by
force
4 Di sconnect
jumper
wi re
fromter
mi nal
M
5
I f
plunger
conti nues
to
be
pulled
i nwi th
jumper
wi re
di sconnectedfrom
termi nalM shunt coi l
i s
properly
functi oni ng
oJ
i
1
CI
SEL014
EL15
Starti ng System
ELECTRI CAL
SYSTEM
SERVI CE DATA AND
SPEci FI CATI ONS
STARTER
MOTOR
Type
S114l80F
I
S114
229E
S114255A
Nonreducti on
geartype
Red
cti on
gear
type
Appli ed
model
Us
A A
T
I
U S A
MfT Canada
A T
MfT
V
12 Systemvoltage
Termi nal
voltage
V 115 11
No
load Current A
Lessthan
60
I More
th
6
ooolMore
than
7
000
I
Morethan39 154
1
12 047
137 17 7
14 18
3 1 4
0
Less than100
Revoluti on
rpm
More
than3900
Outerdi amet rof
commutator mm i n
mm i n
Morethan
29 114
Mi ni mum
length
ofbrush
11 043
Brush
spri ng
tensi on
N
kg
lb
15 7 19 6
1
62035 44
Clearance
between
beari ng
metal
andarmature
shaft
mm
i n
Lessthan
02 0008
Clearance between
pi ni on
front
edge
and
pi ni on
stopper
mm
i n
03 25 0012 0098
Di fference
i n
hei ght
of
pi ni on
mm
i n
0315
0012 0059
EL16
DESCRI PTI ON
The chargi ng
ci rcui t
consi sts
of a
battery
an
alternator
i ncorporati ng
an
I C
voltage regulator
and
wi ri ng
that
connects i hese
parts
I
Wi th
the
i gni ti on
swi tch
i n
ON the
ci rcui t between
transi storTr
I
ofthe
I C
voltage
regulator
and
ground
i s
closed Current
from the
battery
then
flows
along
i he route shown
by
the
arrow
i n
Fi gure
turni ng
onthe
charge
warni ng lamp
and
flowi ng
on
through
termi nalL
toexci tetherotor
When i he
alternator
begi ns
to
oper
ate threephase alternati ng
current
i s
produced
i nthestatorcoi lThi s
alter
nati ng
current
i s
recti fi ed
by
the
posi
ti veand
negati ve
si li con
di odes
ELECTRI CAL
SYSTEM Chargi ng
System
CHARGI NG SYSTEM
When the
voltage
at termi nal
B i s
hi gher
than
battery voltage
current
produced
at
the
stator
flows
to
re
charge
the
battery
Whi le thebattery
i s
bei ng
re charged
the
voltage
at termi
nal L i s
equal
to
that of termi nal
B At thi s
poi nt
there
i s no
voltage
di fferenti alonei thersi de
ofthe
charge
warni ng
lamp
whi chcausesthe
charge
warni ng
lamp
toturn off
I n
other
words current does
not flowfrom
the
battery
to
termi nal
L
Accordi ngly
current flowthrough
therotor
i s
taken
over
by
current
produced
at thestator
The ci rcui t between termi nalF
and
Tr
1
i sthenclosed
The
I C
voltage
regulator
moni tors
generati ng voltage
tobe
appli ed
to
the
battery
at termi nalS
When current
I
0
D3
J
7
t
0
0
a
0
a
t010
STATOR COI L D4 Di
ALTERNATOR
i tT
exceeds
the
speci fi ed
value
i t
then
flows through
the
zenerdi ode ZD
closi ng
the
ci rcui t
consi sti ng
oftransi s
tor
TrJ
and resi storR1
At thi s
poi nt
current
nei therflows
through
transi stor
Trto
ground
nortothe
rotorthereby reduci ng
the
voltage
generated
at
thestator
When voltagegenerated
at termi nal
S
i s reduced tothe
speci fi ed
value
transi stor
allows current to flow
through
the rotor
i ncreasi ng
the
generati ng
voltage
I n thi smanner
output voltage
from
the
alternatordoes not
ri se
above
the
speci fi ed
value
by
the
ONOFF
opera
ti on
of the rotor
coi l
through
theI C
voltage regulator
RJ
I B
1
i s
011
CHARGE LAMP
L
R
Q
T
T
zo
I GNI TI ON
Wv
SW1TC1
R 67
BATTERY
e
R
@
R2
A
F
ld
T
T
I C VOLTAGE
REGULATOR
AI
E
SELOSS
EL 17
ELECTRI CAL
SYSTEM
Chargmg System
SCHEMATI C
FUSI BLE
LI NK
OFF ACC ON sr
g
g
Sf
I GNI TI ON
1m
1
I
BATTERY
FUSI BLE
LI NK B
E
ALTERNATOR
I
I GNI TI ON AND
ACCESSORY RELAY
t
L 5
WI RI NG DI AGRAM
f8
t
l
m
R
BATTE
RY
fUSI BLE
L1NK@
i AgCOFF
lffLBW
J
1
6
I G
ri f
WR 6 s
@l
I GNI TI ON
SW
c
a
s 00000
OJCJ
0
00
0
00 0 0 0 0
0
u
FUSE BmCK
c
WB
G
B
@
fi i l
CJ
L
CONDENSER
v
E W
fi l WR LJ fi lWR
W
S W
d
B
Si
I
ALTERNATOR
ELlS
I I
I f
ilrt
I WhI te
@
a
I
I I
r
FUSE
CHARGE
WARNI NG
LAMP
SEl100
Bj
1
BW
I GNI TI ON
AND
t
ACCESSORY RELAY
R@
f@t
I
COMBI NATI ON
METER
@
C
RGE
@
J
1
G
@
Forradi o
noi se
prewnti on
SEL10
I I I
ELECTRI CAL SYSTEM Chargi ng
System
CHARGI NG
SYSTEMTROUBLE SHOOTI NG
Before
conducti ng
an
alternator
test make
surethat
tli e
battery
i
fully
charged
A
30Volt
voltmeterand
sui table
test
probes
are
necessary
forthetest
The alternator
can bechecked
eaSi
ly
by referri ng
to
the
I nspecti on
Table
@
Wi thalternator
si de L
termi nal
grounded
i nternal
short occurs
when
di ode
i sshort ci rcui ted
Di sconnect
Li ght
OFF
L ht OFf
connector
5
11
L
and
g
ound
Connect con
J
Li oht
ON
I
Faulty
I C
RG
I
L
lead
wue
L
ht ON
e
R
I
Checl
li ght
ag
I
nec
orS l
ep
ace
li ght
ON
for
operati on
and
round
F
term
mal
Li gh
OFF
1
F
I
CG
I
I
Che
ck
li ght
t
au
ty
A
Di m
li ght
foroperali on
t
rs
1
I
Faulty
A CG
l
J
Li ght
ON
I Contact
posi ti ve
lead
ofvoltmcter
on
B
termi nal
and
negati ve
lead to
Ltermi nal
Bumed out
bulb
Replace
and
Proceed
to A
I gni ti on
swi tchON
Check
li ght
for
operati on
Engi nei dli ng
Check
li ght
for
operati on
Di m
li ght
OFF
J
Mure
than
I S SV
I
Faulty
1C RG
1
Engi nespeed
Replace
1
500
rpm
Measure8
teoni nal
volt
13
to15V
age
Engi ne
i dli ng
Measurethe
voltage
across
8
and
L
termi nals
More thanO 5
I
Faulty
A
C G
I
Li ght
OFF
1
Engi nespeed
1
500
rpm
Li ghti ng
swi tch ON
Check
li ght
for
operati on
LessthanOSV
I
OK
Li ght
11
Uao
fully cli o be
21
Li ght
mi ng
li th
ACG Ar
porta
t I C
ngulo
I lRG
I C
ngulOtor
O
K I CI i si n
good
condi ti on
3 WMn
I
F
tty
AC
G
ren I Oft1118r
natoI
fromcarend da nble i nspect
and
correct or Ie
eultvparts
4 Modof
ndi ng
F
18rmi MI
Contlct
ti p
of r
wi th
brushand ttKh
to body
Makesure
S
tenni nali scon
nected
correctly
Engi ne
i dli ns
Li ghti ng
swi tchON
Check
li ght
foroperati on
Li ght
ON
I
Faulty
A e
G
I
Li ght
OFF
I
OK
61
T S
L SAT E
onrearcoverof
El19
111
Chargi ng
System
ELECTRI CAL
SYSTEM
ALTERNATOR
LRl60 Sli p i ngdi a
more
than
31
60244
Re li stancc at
lOoe 680f
I
38
nRear
beari ng
Rotor
Front
beari ng
60
lcg
m 33 43
ft
lb
Uni t
mm
i n
DI SASSEMBLY
I Remove
through
bolts
2
Separate
front
cover
cover
from rear
UD
1
SELOSl
3 Remove
pulley
andfan
I
Placerearcover
si de ofrotori na
vi ce
2
Remove
pulley
nut
EL20
Resi stanceperphuc
la
200C 680
I
0051
n
Rearcover
I e
ro1usertBulator
Brushassembly
Mi n
brush
length
7
5 0295
Spri ng pressure 2 501 3 383N
Di ode
SOl
plate
a
mbly
255
345
I
899 12 17
oz
SEL060
SE L062
4
Separate
rotor
front cover
Remove setscrews
from
beari ng
re
tai ner
SEL083
5 Pull
rear
beari ng
off rotorassem
bly
fA
J
l
SEL064
SEL06S
6 Di sconnect
statorcoi llead
wi res
from
di ode
termi nals
EE623
7 Remove brush
assembly
wi thI C
regulator
8 Removedi odeholder
CAUTI ON
Pllce
pecki n
I nd
i nsulltoni n order
10thlt
they
cen be
placad
back i n
thei r
ori gi nll
p orlocati ons from
whi ch
they
wereremoved
t
e
j
0
I
ca
l
0
EE624
ELECTRI CAL
SYSTEM Chargi ng
System
2 Groundtest
SEL069
Conti nui ty
exi sts
Replace
rotor
Stator
I
Conti nui ty
test
SEL070
No
conti nui ty Replace
stator
Di ode
Performa
conti nui ty
test ondi odes
i n
bothdi recti ons
usi ng
an ohmmeter
Ci rcui t tester
termi nal
Conducti on
Posi ti ve
Negati ve
plate
I
Di ode
Yes
Holder
plate
termi nal
Di ode
I
plate
Nn
termi nal
Holder
plate
plate
I
Di ode
No
Rear
cover
termi nal
Di ode
I
plate
Yes
termi nal Rearcover
Poltlvedlod
EE536
1
Di ode
holder
plate
2
Posi ti ve
di ode
Conducti on
test
i sN
G
di ode
assembly
Replace
I NSPECTI ON
Me
tlvedi ode
Rotor
Conti nui ty
test
SEL068
No
conti nui ty Replace
rotor
2 Ground
test
SEL071
Conti nui ty
exi sts
Replace
stator
@
EE537
3 Rear
cover
4
Nega
li vedi ode
Conducti on test i sN G
di ode
assembly
Replace
EL21
Chargi ngSY
tWn
ELECTRI CAL SYSTEM
Sub dlode
Di recti onof
current
Conducti ontest
i sN G
sub di ode Replace
CAUTI ON
I fi t
i sneceSSlry
toremove sub i li ode
pi nch
di ode
lead wi rewi th8
pai r
of
pli en
to
prevent
heat transferfrom
solde
i ng
i ronto
di l
de
when
unsolder
i ng
connecti on
Brush
I Check smooth movement of
brush
Not smooth Check brushholder
andclean
2 Checkbrushforwear
Mi n brush
length
7 5
mm
0
295
i n
EE651
Less thanthe
speci fi ed
value
Re
place
EL22
3 Checkbrush
pi g
tai lfur
damage
Damaged
Replace
4 Checkbrush
spri ng
pressure
Measure brush
spri ng
pressure
wi th
brush
projectedapproxi mately
2mm
0
08i n frombrushholder
Spri ng pressure
2
501
3383N
255 345
g
8
99
1217
0
When brushi s worn
pressure
de
crease
epproxi matoly
0196N 20
g
0710
1
per
lmmO
04i n r
2mm10
08
i n
nT
I
eeOEf
Not i n the
speci fi ed
value Re
place
ASSEMBLY
Assemble alternatori n the reverse
orderof
di sassembly noti ng
the
follo
ng
1 When
solderi ng
eachstatorcoi l
lead wi re
to
di ode
assembly
termi nal
carry
out
the
operati on
as fast as
possi ble
2 When
i nstalli ng
di ode A ter
mi nali nstall
i nsulati ng bushi ng
cor
rectly
3
Ti ghten pulley
nut andmakesure
that deflecti onof
V
groove
i s
proper
Cl
Pulley
nut
44
59NofI I
5
60
kg m
33 43 ft lb
Vllroove
deflecti on
03mm 0012i n
4
Before
i nstalli ng
front and rear
si des of alternator
push
brush
up
wi th
fmgers
and retai n brush
by
i nserti ng
brushli ft
i nto
brushli ft hole from
outsi de
Bru
00 1
o
i
EE541
5
After
i nstalli ng
front and
rear
si des of alternator
pull
brushli ft
by
pushi ng
towardcenter
Donot
pull
brushli ft
by pushi ng
toward outsi de of
coveras
i t
wi ll
damagesli p ri ng sli di ng
urface
6
Ti ghten through
bolt
ClThrough
bolts
34 3
9
N
m
035
040
kg
m
2 5 2
9ft
I b
I C
VOLTAGE
REGULATOR
DESCRI PTI ON
The
regulator
consi sts
essenti ally
of
i ntegrated
ci rcui ts
i ncorporati ng
tran
si stors
These transi stors
i nterrupt
and
admi t current flowtothealternator
rotorcoi l
thus
mai ntai ni ng
i ts
output
voltage
at a constant value Unli kei na
mechani cal
typeregulator
anelectron
i c
relay employi ng
transi stors
i s
uti li zed These
ransi stors are
enclosed
i n
a
very
compact
sealed case The
electroni c
relay
i s soldered to
the
brush
assembly
i nsi de thealternator
Should
any problem
wi ththe
relay
ari se
i t
should
be
replaced together
wi th
the
brush
assembly
On
the
chargewarni ng lamp
ci rcui t a
di odei s
attached
to
the
stator
coi lto
moni tor
generati ng
voltage
at
thestatorsothat
when the moni tored
voltage
and
chargi ng
voltage
are
equal
duri ng
re
hargi ng
the
chargewarni ng lamp
i s
turned off
Accordi ngly
a
charge
warni ng relay
i s
not
employed
i n
thi s
ci rcui t
EFLSB
SELOB6
I NSPECTI ON
Remove
I C
regulator
and
brushes
at
the same ti me
as outli ned i n
Di s
assemb4t
and
Assembly
secti on
under
the
headi ng
Alternator
CAUTI ON
When
performi ng
test
conti nuously
resi stor
may generate heat
I f
i t
becomes
hi gh
temperature
stop
test
i ng
fora whi le to
avoi d
burni ng
I
The
followi ng
test
equi pment
and
accessori esare
requi red
ELECTRI CAL
SYSTEM Chargi ng System
1
Resi stor
R
1
10
ohms
20watts
x I
2
Vari ableresi stor
Rv
O
to300
ohms
20
watts
x
I
3
Batteri es
I
and
2
12volts x2
4
DC
voltmeter
oto30
volts
x 1
2
Measure
voltage
V
I
at
battery
Not wi thi n
10
to
13 volts
Re
charge
or
replace
battery
1
JI
I e
regulator
L
r
3
I
crT I
SE
LOB7
3 Measure
voltage
V
2
Below
2
0
volts
Regulator
i s
functi oni ng properly
1
I c
egulato
1
L
n
cr l
r
SE
LOBB
4
Measure
voltage
V
3
Not wi thi n 20to
26 volts
Re
charge
or
replace
ei ther
orboth
batteri es
1
I e
regu la
tor
I I
L
i
T
SEL089
S
Gradually
decrease resi stance of
vari able
resi stor
Rv
from 300ohms
and
measure
voltage
V
2
between
termi nals
E andF
Voltage
V
2
should i ncrease
at
a
certai n
poi nt
toas
hi gh
as
voltage
V
I
10
to13
volts
I f
there
i s
such
a vari ati on
Regulatori s
functi oni ng properly
No
vari ati on
Regulator
i s out
oforder
L
1
L
l
J1
I e
regulator
SEL090
6 Hold
vari able
resi stor
Rvat
the
same
voltage
as
VI
10
to
13
volts
Measure
voltageV4
L
I C
e
umlol
11
1
t
t
J
SEL091
Voltage
V
4
i s wi thi n
speci fi ed
range
i ndi catedi n
Fi gure
EL
23
Chargi ng System ELECTRI CAL SYSTEM
Example
When
temperature
of
regulator
case
i s
4O
C I 04OF
regulator
i s
normali f
voltage V4
i s wi thi n
range
ofl4to15
volts
o
o
o
o
0
z
o
u
1
I U
I
m M 10
cHI I I I I I M
ll21lIwI CI JlI CI UI CI MllllllUlGl
Rc
ul
torcase
temperature
Oc OF
SEL092
EL
24
7
Reconnect
wlftng
as shown i n
Fugure
and
repeat steps
5 and
6
I f
voltage
V
4
i s 05
to20wolb
hi gher
than that i n
step
6
regulator
i s
functi oni ng
properly
I f i t i not
replace
1
j
I e
regulator
J
r
SEl093
SERVI CE
DATA AND SPECI FI CATI ONS
ALTERNATOR
Type
Appli ed
model
Nomi nal
rati ng
V
A
Ground
polari ty
Mi ni mumrevoluti on undernoload
When
14
volts
i s
appli ed
rpm
Hot
output
current
A
rpm
Pulley
rati o
Regulated
output voltage
v
Mi ni mum
length
ofbrush mm
i n
Brush
spri ng pressure
N
g
oz
Sli p
ri ng
outerdi ameter mm i n
ELECTRI CAL
SYSTEM Chargi ng System
lR16047
All
12 60
Negati ve
Less
than 1 050
Morethan
45 2
500
Morethan 60
5 000
2
09
144 15
0
7 5 0
295
2501 3383
255 345 8
99
12 17
316 1244
EL
25
I gni ti on
System ELECTRI CAL
SYSTEM
I GNI TI ON SYSTEM
e t
1
o
g
R
B
I GNI TI ON SW
rw
i E
o o
Q
o
0000 0 0000 0
0 0 0 0 0 0 0
o
f r
FUSE BLOCK
f
l
f i amodels
Q
CI l
I
@L
I
J
@
ff
I GNI TI ON
COI L
EL26
8
Q
@
TERMI NAL
BLOCK
VB
O
G
a
L
a
@
e
Ji lj lJ1J1J
@
SPARKPLUGS
I GNI TI ON COI L
wi P
t
WB
BW
0
0
@
lJlJ Jf
I GNI TI ON AND
11
ACCESSORY RELA
9
@
@
@
Cali forni a models
@
Non
Cali forni a
models
I Non Cali fomi a
models
DI STRI BUTOR
we
L
@
0
B cJ
I n
I
i f
0
u
@L
J j
SPARK
PLUGS
J
@
ff
I GNI TI ON COI L
SEL102
CHECKI NG
PROCEDURE
Nostart
condi ti on
Sparki ng
oncecheck
1
Turn
i gni ti on
swi tchto OFF
posi ti on
2 Di sconnect
EF1
fusi ble li nk
con
nector
CAUTI ON
Before
di sconnecti ng
EFI fusi ble li nk
connector
enlllre
thet
i gni ti on
swi tch
i s i n
OFF
posi ti on
3
Di sconnect
hi gh
tensi on cablefrom
di stri butor
4
Keepi ng
hi gh
tensi on cable end
4
to
5
mrn 016
to020i n
away
from
engi ne
block
rotatestartermotorand
check whethersparks occuracross
the
clearance
ELECTRI CAL SYSTEM I gni ti onSystem
JUDGMENT
Spark
occur
1C
i gni ti on system
OK
I n thi s
case 1C
i gni ti on
system
and
component parts
neednot bechecked
beyond
thi s
No
spark
occurs on
sparks
are
i ntermi ttent
1C
i gni ti on
system
N
G
Proceedwi thtestsbelow
Manual
testlna
of
I C
lanltlon
s
stem
uslna
avoltmeter
1C
I gni ti on System
i s
best checked
usi ng
J 26350Transi stor
I gni ti on
Analyzer
However
i f an
analyzer
i s
not avai lable a
volt ohm
mi lli ammeter
V
OM
may
be used
to
di agnose
transi stor
i gni ti on
malfuncti onsWhi le
thi smethod
requi res
more
ti me i t
can
nevertheless
provi de
accurate
results
Follow the
steps
i n the
sequence
i ndi cated I f a fault i s found correct
the
problem
before
conti nui ng
I fall
tests i ndi cate OK
replace
the
I e
I gni ti on
Uni t DONOT REPLACE
THE UNI T
UNTI LL ALL TESTS
HAVB BEEN COMPLETED AND
I NDI CATE
OK
1 When
performi ng
the
followi ng
teltS
USI
a
multi testerwhi ch
can
measure
accurately
i n the
followi ng
ronge
0to20V D C 0to1 00000
to10VA C 0to
50 oOOn
2 I f
possi ble
tart
the vehi cles and
let i t run for5 to
15
mi nute
wi th
the hood closed Thi wi ll
bri ng
all
componenu
to
normal
operati ng
tem
perature
and wi ll
make
i t
easi er
to
di agnose
i ntermi ttent
problems
3 I t i s not
necessary
todi sconnect
theharness connecton
when
perform
i ng
the tests whi chfollow
Si mply
i nsert the meter
probes
i nto
theback
of
appropri ate
connector
cavi ty
EL27
I gni ti onSyrnJm
ELECTRI CAL SYSTEM
I C I GNI TI ON SYSTEMTROUBLE
SHOOTI NG
TEST
1
Battery Voltage
noload
2
Battery
Cranki ng
V
oUage
3
Secondary
Wi ri ng
4
I gni ti on
Coi l
Secondary
Ci rcui t
S Power
Supply
Ci rcui t
Non cati fomi a
models
only
EL28
TEST METHOD
Readi ng
12
olts
J
Hi ghscale
Low
t
Scale
scale selector
1
Red
posi ti
e
Black
negati ve
pOli ti ve
l
I
SEU03
Termi nal
SEU04
Reaeptacle
5EL078
EF125
CONDI TI ONS
I gni ti on
key
i n OFF
posi ti on
2
Connect voltmeter
as
i lI usua
ted
tnd
sct to
appropri ate
scale
3
Read andrecord
battery
voltagereadi ng
Battery voltage
D
I Connect
yoltmeter
as
i llustratedandset to
appropri ate
scale
2
Remove
coi lwi refrom
di stri butor
cap
and
ground
i t
3
Read
voltmeter
whi le
cranki ng engi ne
f9
I
ap
proxi mately
15
seconds
4
Record
voltagereadi ng
Battery cranki ng
D voltage
1
Conneelohmmeteras
i llustratedandmeasure
the
resi stanceof each
hi gh
tensi on cable
I
I gni ti on
key
i n
OFF
posi ti on
2
Coi l
wi re
removedfrom
coi l
3
Connec
t ohmmeter
as
i llustrated
L
Connect voltmeter
35
i llustrated
and
set to
appropri ate
scale
2 Turn
i gni ti on key
to
ON
posi ti on
RESULT
11 5 12
5volts
Below
11 5 yolts
Voltagereadi ng
greater
than
96
volts
Voltagereadi ng
less
than 96
volts
Resi stance
readi ngs
less
than
30000
ohms
Resi stance
readi ngs
greater
than
30
000ohms
Cali forni a
models
7 400
11 000
ohms
Non Glli forni a
models
8 20012400
ohms
Resi stance
readi ng
not
between
7
40011000
ohms
Cali forni a
models
or
8 20012
400
ohms Non
Cali forni amodels
115
12
5 yolts
Below
11 5
volts
ACTI ON
Proceed to
Step
2
Battery
chargi ng
system
or
starti ng
system Faulty
Refer
to
appli cable
secti ons i nSeni ce
Manual
tocorrect
the
si tuati on
Battery
O
K
Proceed
to
Step
3
Battery chargi ng
system
or
starti ng
system Faulty
Refer
to
appli cable
secti 9ns
i n
rvi ce
Manual
tocorrect
the
si tuati on
Di sti i butorcap and
hi ghtensi oocables
Q
K
Proceed to
Step
4
Replacehi gh
tensi ou
cable s and
or
di stri butor
cap
as
requi red
I gni ti on
coi l
sec
ondary wi ndi ttp
O
K
Proceed to
step
8
forCali forni a
Faulty i gni ti on
coi l
replace
Proceed
to
Step
6
Check
wi ri ng
from
i gni ti on
swi tchto
I Cuni t
Conti nued
n
xt
page
ELECTRI CAL SYSTEM
I gni ti on
System
TEST
TEST METHOD
CONDI TI ONS RESULT
ACTI ON
6
Power
Supply
Ground
coi l
output
wi re
Connect
voltmeter
as
Voltagereadi ng
i s
Ci rcui t
whi le
performi ng
test
i llustrated
andset
to lessthan1 volt
Cranki ng
appropri ate
sCale
below
battery
Proceedto
Step
7
2 PUU out coi l
wi re
from
cranki ng voltage
di stri butor
cap
and
andi s
greater
ground
i t
t
an 8
6
volts
3
Tum
key
to START
Voltage
readi ng
i s Check
i gni ti on
swi tch
posi ti on
and observe more than
I volt and
wi ri ng
from
voltmeter
whi le
engi ne
below
battery
swi tch
toI euni t
i s
cranki ng cranki ng voltage
Non canforni a
andori sbelow
modelsonly
SE L079
8
6
volts
7
I gni ti on
Connect
voltmeteras
Pri mary
i llustrated
andset
to
11 5
125
volts
Proceed
to
Step
9
Ci rcui t appropri ate
scale
2 I gni ti on
key
i n
ON
Below115 volts
Proceed
to
Step
8
posi ti on
Non cali forni a
mode1sonly SELOBO
8
I gni ti on
Coi l
1
range
I gni ti on
key
i n OFF
Cali forni a
models
I gni ti on
coi l
pri mary
Pri mary
posi ti on
104
127 ohms
wi ndi ng
OK
Ci rcui t
2
Coi lwi re
removedfrom
Non cali forni a
Check
i gni ti on
swi tch
coi l
models
and
wi ri ng
from
084
102
ohms
i gni ti on
swi tchto
3
Connect ohmmeter
as
i llustrated
Resi stance
readi ng
coi landI C
uni t
not
between
104 127
ohms Faulty
i gni ti on
coi l
Cali forni a models
replace
or
084
1
02
ohms
Non cali forni a
EE567
models
9J
C Uni t
I Connect
voltmeteras
Ground
i llustrated
andset to
0
5 voltsorless
Proceed to
Step
10
Ci rcui t appropri ate
scale
2 Pullout coi l
wi re
from Check di stri butor
di stri butor
cap
and
ground
wi ri ng
from
ground
i t
Morethan
05
chassi s
ground
to
3 Tum
key
to START volts
battery i ncludi ng
posi ti on
andobserve
battery cable
Non ca ti fomi a
voltmeter
whi le
engi ne
connecti ons
modelsonly
SELOS1
i s
cranki ng
10
Pi ck up Coi l
Ground
coi lseoondary
I
Engi ne
i sat orabove
Approxi mately
Proceed to
Step
11
Resi stance
whi le
cranki ng
normaloperati ng
400
ohms
l
temperature
0
2
I gni ti on
key
i n
OFF
Ohmmeterreadi ng
Check
pi ck op
coi l
posi ti on
substanti ally
ex
and
wi ri ng
to
i t
3 Connect ohmmeter
as
ceeds
or
fallsbelow
Non cali forni a
dD i llustrated
and
set to
the400ohms
models
only
arrr
tescale
speci fi cati ons
SEL082
I I Pi ck up
Coi l
Ground
coi l
secondary
whi le
cranki ng
I
Engi ne
i sat orabove
Needle
I f No
Spark
Output
normal
operati ng
Wavers
@
condi ti on
sti D
exi sts
temperature
replace
I C
2 Connect
voltmeterand
i gni ti on
uni t
set tothelowac
volt
Needlesteady
Check physi cal
con
scale
J Sj
di ti on of
pi ck
up
3
Turn
key
to START
coi landreluctor
posi ti on
and
observe the
@
Check wi ri ng
and
needle
movement whi le
connecti ons
between
Non cali forni a
the
engi ne
i s
cranki ng
pi ck up
coi landI C
modelsonly
SEL083
SEL105
i gni ti on
uni t
Conti nued
nxt
pI I g
EL
29
I gni ti onSystem
ELECTRI CAL
SYSTEM
TEST
12 Power
Supply
Ci rcui t
Cali forni amodels
only
EL30
TESTMETHOD
I e
i gni ti on
uni
SEL084
CONDI TI ONS
1
Connect voltmeteras
i llustrated
and
set to
appropri ate
scale
2 Turn
i gni ti on
key
to
ON
posi ti on
RESULT
I I S
12Svolts
Below 11 5 volts
ACTI ON
Check
wi ri ng
from
i gni ti on
swi tch
Co
I Cuni t
letype DI STRI BUTOR
Cali forni amodels
Shaft
a
mbly
Cap
setter
i t
Cl
COllaJ
se
YSTEM I gni ti onSystem
ELECTRI CAL
S
Cap aSJembly
Carbon poi nt
g
Y
Roorhead
I
RoUpi n
RelUclor
S
tor
r
Magnet
I Ci gni ti onuni t
j G
J
Setter
uni t
Ell ll
J
m
controller
Vacuu
ow
connecti ng
Q
Breaker
plate
I
I l
assembly
@
Packi ng
rli @
Rotorshaft
1
sembI Y
Thru t
w
er
GovernorWei ght
@
Governor
ng
c
SE lOOl
EL31
Rotorbead
usembly
RoUpi n
Reluctor
0
Stator
Magnet assembly
Pi ck up coi l
usembly
Vacuum
controller
Breaker
plate
mbly
Rotorshaft
usembly
Governor
Pri ns
Governor
wei sht
SEL201
I gni ti on
Symm
ELECTRI CAL SYSTEM
Non CaJi fomi a models
6
J
Shart
uoembly
Housi ng
Grommet
I e
i gni ti on
uni t
CoUar
CHECKI NG AND
ADJUSTMENT
Vacuum
ad
ce mechani sm mecha
ni cal
parts
I
Check vacuum i nlet for
si gns
of
leakages
at i ts
connecti on
2 Check vacuum
di aphragm
for
ai r
leak
I f leak i s found
replace
vacuum
controller
assembly
3
I nspect
breaker
plate
forsmooth
movi ng
I f
plate
doe
not
move
smoothly
thi scondi ti on
couldbedueto
sti cky
Cap
and rotorhead
Check
cap
and rotorheadfordust
carbon
deposi ts
andcrack
Advance
mechanlsma
Speci fi cati ons
Referto
D
EL32
cap mbly
st elballs or
pi vot Apply grease to
steelballs
or
i f
necessary
replace
breaker
plate
as an
assembly
Centri fugal
ad
ce
mechani l al
parts
When cause of
engi ne
malfuncti on
i
tracedto
centri fugai
advancemecha
ni cal
parts
use di stri butortester
to
check i tscharacteri sti cs
I f
nothi ng
i s
wrong
wi thi ts
charac
teri sti cs concei vablecausesare
faulty
or
abnonnal
wear
of
dri vi ng part
or
others So do not di sassemble
i t
I n the
event of
i mproper
character
i sti cs
check
c
osely rotor
shaft assem
bly governor
wei ght
andshaft
I f
any
of the
above
parts
are
mal
functi oni ng
place
the
parts
DI SASSEMBLY
Cali forni a
models
I
Take off
cap
and
remove rotor
head
2
Pry
reluctor
fromshaft
SEL002
CAUTI ON
When
removi ng
reluctorbe careful
not todi stort or
damage
thateeth
3
Remove
I C
i gni ti on
uni t
and
uni t
setter
4 Remove
statorand
magnet
SE L003
5
Remove
vacuum
controlassem
bly
6 Remove braker
plate
Before
di sassembli ng
be sure to
mark
housi ng
and
fi xi ng plate
ELECTRI CAL SYSTEM
I gni ti onSystem
SEL004
7 Remove
fi xi ng plate
Mark
housi ng
and
fi xi ng
plate
SE
LOOS
8 Remove
collar
EE104
9
Remove rotorshaft and dri ve
shaft
EE705
10Mark rotor
shaft and dri veshaft
Remove
packi ng
fromthe
top
of
rotor
shaft
and
removerotor
shaft
EE706
I I Mark one of the
govemor
spri ngs
and
i ts bracket Alsomark one
of
the
governor
wei ghts
and
i ts
pi vot pi ns
12
Carefully
unhook and
remove
governor
spri ngs
13 Remove
governor
wei ghts
Apply
grease
to
governor
wei ghts
after
di s
assembli ng
Non Cali forni a models
1
Take
off
cap
androtorhead
2
Remoye
I C
i gni ti o
uni t
3 Removestatorand
magnet
4
Remove
vacuu controller
EE746
5
Usi ng
two
pry
bars orsui table
puller
pry
reluctorfromshaft
CAUTI ON
When
removi ng
reluctor
be careful
not todi stort or
damage
the teeth
6 Removeroll
pi n
7
Remove
pi ck up
coi l
assembly
EL33
8
Remove breaker
pi ate assembly
I gni ti onSystem
ELECTRI CAL
SVSTEM
EE703
9 Punchknock
pi n
out and
remove
pi ni on
@W
EE704
10Remove rotorshaft
and dri ve
shaft
assembly
EE705
11
Mark rotorshaft
and
dri ve
shaft
Remove
packi ng
from
the
top
ofrotor
shaft andunscrew
rotor
shaft setscrew
Removerotorshaft
EL34
EE706
12 Mark one ofthe
gov
rnor
spri ng
and i ts bracket Also mark one
of the
governor
wei ghts
and
i ts
pi vot
pi ns
13
Carefully
unhook and remove
governorspri ngs
14
Remove
governor
wei ghts
Ap
ply grease
to
governorwei ghts
after
di sassembli ng
ASSEMBLY
To
assemble reverse the
order
of
di sassembly Carefully
observethefol
lowi ng
i nstructi on
CAUTI ON
Before
i nslalli nglC i gni ti on
uni t make
suremati
R1rfaces
of
I C
i gni ti on
uni t
and
di stri butorarecleanandfreefrom
dust sandandmoi sture
Ali gn
matchmarks sothat
part
are assembled
to
thei r
ori gi nalposi
ti ons
2 Ensure that reluctori s
properly
ori ented when
i nstalli ng on
shaft Al
ways
dri ve i n new roll
pi n
as shown
i n
Fi gure
3
When
i nstalli ng pi ni on
on shaft
be
sure
to
i nstall
pi ni on
gear
correci ly
to
posi ti on
where
i t
was i nstalled
4
Apply
grei S
to
the
top
ofrotor
shaft
as
requi red
5
Check the
opera1i on
of
governor
before
i nstalli ng
di stri butoron
engi ne
6
properly
ienter
statorand reluc
torbefore
ti ghteni ng
Stenderdei r
gep
03 05 mm
0012 0020i n
CeI i fomi amodel
3
03
05
mm
SEL0ll6
10 012 0020
i n
Non Celi fomi a
model
EE148
7
Adjust i gni ti on ti mi ng
after
di stri
butor
i s
i nstalledon
engi ne
I C I GNI TI ON
UNI T
DESCRI PTI ON
Cali forni a modals
I n the conventi onaldi stri butorthe
i gni ti on
ti mi ng
i s
detected
by
thecam
andbreaker
arm
whi lei nthi sdi stri bu
tor
i t i s
detected
by
thereluctoron
the
shaft and the
pi ck up
coi l
provi ded
i n
place
ofthe
breaker
The
amount
of
magn
ti c
flux
passi ng through
the
pi ck up
coi l
i s
changed
when the
reluc
torrotates and
then the electri cal
si gnal
i s
generated
i n the
pi ck up
coi l
Thi s electri c
si gnal
i
s conducted
i ntothe I e
i gni ti on
uni t
whi ch
makes
and breaks
the
pri mary
current run
ni ng through
the
i gni ti on
coi l
and
generateshi ghvoltage
i n the
secondary
wi ndi ng
The centri fugal
and
vacuum
ad
vance mechani smsemploy
theconven
ti onal
mechani cal
type
The
I e
i gni ti on
uni t uti li zesa semi
Cali forni amodels
I gni ti on
swi hh
8
Battery
ffi
8
Spark ti mi ng
si gnal
moni tori ng
ci rcui t
Lock
prevellti ng
ci rcui t
ELECTRI CAL
SYSTEM I gni ri on System
conductor
I e
devi ce and i s mounted
i n the
di stri butor
The
I C
i gni ti on
uni t has the fol
lowi ng
ci rcui ts
Spark
ti mi ng
si gnalffi 9ni tori ng
ci rcui t
Thi s
ci rcui t
detects the
i gni ti on
si gnal
sent from the
di stri butor
pi ck
up
coi land
ampli fi es
the
si gnal
2 Lock
preventi ng
ci rcui t
Thi s ci rcui t cuts off the
i gni ti on
coi l
pri mary
current when the
i gni ti on
swi tchi s ON
and the
engi ne
i s sta
ti onary
I f
the
i gni ti on
coi l
pri mary
current
i s
allowed
toflowundersuchcondi
ti ons
excessi ve
current
wi ll
be drawn
because of
low i nternalresi stance
of
the
i gni ti on
coi l
Thi s can
result
i n
an
abnormal
temperature
ri se i n the
i gni ti on
coi l
or
di scharged battery
These malfunc
ti ons can
be
prevented
by
thi s
lock
preventi ng
ci rcui t
3
Duty
cori trol
ci rcui t
Thi s ci rcui t
contn
ls
the rati o
of the
i gni ti on
coi l
pri mary
current ON OFF
ti me
peri ods
i n one
cycle
of
i gni ti on
operati on
Thi s
i s
equi valent
to
thedwell
angle
of
the
conventi onal
poi nt type
di s
tri butor
I n order
to
provi de hi gh
performancespark fi ri ng
overa
wi de
range
of
dri vi ng speeds
thi s
duty
can
be
controlled
by
the
source
voltage
and the ambi ent
temperature
as well
as
by
the
engi ne rpm
4 Power
swi tchi ng
ci rcui t
Thi s ci rcui t
i s used
to make or
break
di rectly
the
pri mary
ci rcui t cur
rent
of
the
i gni ti on
coi l
To
ensure
effi ci ent
operati on
of
the
I e
i gni ti 9n
uni t thesefourci rcui tsare
manufactured
i none
assembly
A
Todi stri butor
Exsi de
f 8
I I
I I
101
101
I
I
I gni ti on
coi l
s
Todi stri butor
I n
si de
f 8
I r
Lo
1
1
01
I I
I gni ti on
coi l
E
i ll
j
ClfCU
Duty
control
SEL085
EL35
NonCali forni a models
I gni ti on
Smem ELECTRI CALSYSTEM
The I e
i gni ti on
uni t uti li zes a
mi conductor I e devi ce and i s
mounted
on
the si de
surface of the
di stri butor
The
I C
i gni ti on
uni t
hasthe
follow
i ng
ci rcui ts
I
Spark
ti mi ng si gnal
moni tori ng
ci rcui t
Thi s
ci rcui t
detects
the
i gni ti on
si gnal
sent from
the
di stri butor
pi ck
up
coi land
ampli fi es
the
si gnal
2 Lock
preventi ng
ci rcui t
Thi s
ci rcui t
cuts off the
i gni ti on
coi l
pri mary
current when
the
i gni ti on
swi tchi s ON
andthe
engi ne
i s stati on
ary
I f
the
i gni ti on
coi l
pri mary
current
i s
allowed toflowundersuchcondi
ti ons
excessi vecurrent wi llbedrawn
because of lowi nternalresi stance of
the
i gni ti on
coi l
Non Cali fomi a
models
Battery
CD
i
Thi s can result
i n an
abnormal
temperature
ri se
i n the
i gni ti on
coi lor
di scharged battery
These
malfunc
ti ons can be
prevented
by
thi s
lock
preventi ng
ci rcui t
3
Duty
controlci rcui t
Thi s
ci rcui t
controlsthe
rati o
ofthe
i gni ti on
coi l
pri mary
current ON OFF
ti me
peri ods
i n
one
cycle
of
i gni ti on
operati on
Thi s i s
equi valent
tothe
dwell
angle
of the conventi onal
poi nt type
di s
tri butor
I n orderto
provi de
hi gh
perfonnancespark fi ri ng
overa wi de
range
of
dri vi ng speeds
thi s
duty
can
be controlled
by
the source
voltage
andthe ambi ent
temperature
as well
as
by
the
engi ne
rpm
4 Power
swi tchi ng
c
rcui t
Thi s
ci rcui t i s used
tomake or
break
di rectly
the
pri mary
ci rcui t
current ofthe
i gni ti on
coi l
I ge51Ch
eh B
I
I J
101
101
LJ
I gni ti on
coi l
r
Pi ck
up
coi l
Lu
Di stri butor
EL36
Spark
ti
i ng si g
al
G
moni tori ng
ClI CUlt
R
Duty
control
ci rcui t
Lock
Preventi ng
ci rcui t
I C
i gni ti on
uni t
5 Current
li mi ti ng
ci rcui t
Thi s
ci rcui t
controls the current
valuesothat
excessi vecurrent wi llnot
flow
trough
the
power
wi tchi ng
ci rcui t
Toensureeffi ci ent
operati on
of
the
I C
i gni ti on
uni t these fi ve ci rcui ts
are
manufacturedi n
one
assembly
The semi conductor I C
i s
uti li zed
forallthese
ci rcui ts
except
the
power
swi tchi ng
ci rcui t
The
powerwi tchi ng
ci rcui t uses one
power
transi stor
and
the
ci rcui t i s
arranged
on thecerami c
substrate
together
wi thresi stors
capa
ci tors
and
di odes
Each
component part
ofthi s
uni t i s
hi ghly
reli able howevershould
any
part
be found
faulty
the
enti re
assembly
must be
replaced
2P
rOl
I I
connector
rBCl
Power
swi tchi ng
ci rcui t
Current
ti mati ng
ci rcui t
SEL094
ELECTRI CAL
SYSTEM I gni ti on
Sysrem
SERVI CE
DATA AND SPECI FI CATI ONS
DI STRI BUTOR
I
Type
I
ppli ed
model
I
Transmi ssi on
I
Fi ri ng
order
I
Rotati ng
di recti on
I
Ai r
gap
I
Ca
i nsulati on
resi stance
Rotor
headi nsulati on
resi stance
I
I
I
mm
i n
1
Mn
I
Mn
I
cap
carbon
poi nt length
mm
i n
I
Vacuumadvance
Di stri butor
degree
di stri butor
kPa
mmHg
i nHgH
Centri fugal
advance
Di stri butor
degree
di stri butor
rpm
I GNI TI ON COI L
Type
Appli ed
model
Pri mary
voltage
Spark gap
Pri mary resi stance
at
200C
680
F
Secondary
resi stance
at
200C
680F
SPARKPLUG
Appli ed
model
Type
v
mm
i n
n
Standard
Hot
Cold
Si ze
Screwdi a x reach
mm
i n
Plug
gap
mm i n
D4N9 o5
D4N9 04 D4K91O D4K9 09
Cali forni a Non Cali fomi a Canada
A T
I
A
T
MT
MT
1342
Counterc10ckwi se
030
5 0
012 0020
More
than50
Morethan50
10039
12 0
47
0093 00
93 0093 0093
70
2
76 70276 70276 70276
350
120
350
120 250 120 250 120
903
54
90
354
90354 90354
3
50 13 3 3 50
133 2
50147
250 14
7
100
3
94
100
394
110433 110433
100
33 3
100 33 3
1033 3 100 33 3
250984
250
9
84
250984 250984
00
900
00 700 00 700 00 700
501
700
350
1
100
301
000
301
000
501 500 60
1 600
601
600
CI T
38 CI T 30
Cali forni a
Non Cali forni a
12
Morethan7
028
104
127
084
1
02
74
110 8
2
12 4
Us
A
BP6ES
BP5ES BP4ES
BP7ES
Canada
BPR6ES
BPR5ES BPR4ES
BPR7ES
14x
19 0
55 x
075
08 09 0031 0035
Opti onal
forUsA
EL37
Li ghti ng Systems ELECTRI CAL SYSTEM
LI GHTI NG SYSTEMS
CAUTI ON
Before
starti ng
towork
on
any
part
of electri cel
system
di sconneet
battery ground
ceble
BULB SPECI FI CATI ONS
I tem
Headlamp
Type
I
Hi gh
Type
11
Hi gh
Low
Front
combi nati on
lamps
Tum
si gnal
Clearance
Rearcombi nati on
lamps
Stoprrai l
Turn
si gnal
Si demarker
lamp
Front
Rear
Back
uplamp
li cense
platelamp
I nteri or
lamp
Spot lamp
Step lamp
Luggage
compartment
lamp
Hatchback
Hardtop
Combi nati on meter
I llumi nati on andbrake
warni ng lamp
Wami ng
and
moni tor
lamp
Turn
si gnal
andbeami ndi cator
lamp
Ci garette
li ghter
i llumi nati on
lamp
Heater
Ai r
on
control
panel
i llumi nati on
lamp
Glovebox
lamp
Crui secontrolswi tch
lamp
Selectorleveri llumi nati on
lamp
AT
model
EL38
Wattage
50
4060
27 8
27 8
27
34
34
27
80r10
10
8
5
5
34
34
2
34
1
4
34
34
14
34
SAE
tradenumber
4651
4652
1157
1157
1156
158
158
1156
67
158
158
158
158
158
158
COMBI NATI ON
SWI TCH
REMOVAL AND
I NSPECTI ON
1
Remove
steeri ng
wheel
2 Remove
steeri ng
column
cover
3 Di sconnect allcombi nati onswi tch
wi res
4
Loosen
retai ni ng
screw
and
re
movecombi nati onswi tch
5
To
i nstallcombi nati on swi tch
a1i gn protrusi on
on
swi tch
body
wi i h
hole
on
steeri ng
column and
ti ghten
retai ni ng
screw
SE
L283
I NSPECTI ON
Test
conti nui ty
through
swi tch
wi th
a
test
lamp
orohmmeter
1st
OFF
2nd
N
L
OFFI
ON
ELECTRI CAL SYSTEM Li ghri ngSystems
o
JI
I
1r
111f
UUJUUU
I
TURN SI GNAL
SWI TCH
1
LEVER
I
I
i
NI L
I f
LI GHTI NG SWI TCH
1
1
OFF 1ST 2ND
I
ABC
A BeA 8 C
zuni
I
0
I
tf
M
UMJ
o
i F
90
ON
OFF
WI PER
AND
WASHER SWI TCH
1
1
WI PER
I OFF
I NT
L
O HI
111
l
12
WI TH
1i
X
TI NE CONTRod
f
rq
tJtu
AAQ
SWI TCH
nON
22
SEL310
EL39
Li ghti ng Systems
ELECTRI CAL SYSTEM
HEADLAMP
SCHEMATI C HEADLAMP
HEAOLAMP A H
@
C0
HEAD
LAMP LH
CD
@
FUSI BLE LI NK
FUSE
rc
l
BATTERY
I
oc
FUSE
t
rI
TROUBLE
DI AGNOSES
AND
CORRECTI ONS
Condi ti on
Headlamps
donot come
onei ther
hi gh
orlow
beams
Hi gh
beam
cannot
be
swi tchedtolow
beam
or
vi ce
versa
Headlamps
di m
Headlamp li ghts
on
only
onesi de
EL40
Probable
cause
Burnt fusi bleli nk
Burnt fuse
Looseconnecti on or
open
ci rcui t
Faulty li ghti ng
swi tch
Hi gh
low
beam
comes
on when
CD
and
@
CD
and
@
termi nals of
hamess con
nectorto
li ghti ng
swi tch
areconnectedwi th
test lead
i ncludi ng
lOAfuse
Faulty headlamp
sensor
No
ground
Faulty
li ghti ng
swi tch
Hi gh
low
beam comes on when
CD
and
@
D
and
@
termi nals of hamess con
nector
to
li ghti ng
swi tch
are
connected
wi th
test
lead
i ncludi ng
lOAfuse
Partly di scharged
or run down
battery
I noperati ve
chargi ng system
Poor
ground
orloose
connecti on
Loose
headlamp
connecti on
Faulty headlamp
udi
LI GHTI NG SWI TCH
HEADLAMP
MONI TOR
lj
HEADLAMP
SENSOR
1
SEL371
Correcti veacti on
Correct causeand
replace
fusi bleli nk
Correct causeand
replace
fuse
Check
wi ri ng
andor
repai r
connecti on
Replace
i f
necessary
Replace
i f
necessary
Clean
and
ti ghten
ground
termi nal
Replace
i f
necessary
Measure
speci fi c gravi ty
of
electrolyte
and
recharge
or
replace
battery
i f
necessary
Measure
voltage
at
headlamp
termi nals
I f i t
i s
less
than
12
8V check
chargi ng
system
for
proper
operati on
Clean andor
ti ghten
Repai r
Replace
WI RI NG DI AGRAM
HEADLAMP
i ll
R
OW
FUSI BLE
@
LI NK
ELECTRI CAL
SYSTEM
Li ghti ng
Systems
o
BATTERY
t
HEADLAMP R H
fi i r
RY
RR
@
Tr 1
RW
R
@
HEADLAMP
LH
0
@
@
RY
RL
RW
@
I I
Whi te
QrJ
g g
gi J
@
I
I
r
@
V
RY1th
j
R
I
Y
RW
LI GHTI NG SWI TCH
I
OFF 1ST 2ND
4 R r4 R
r
4
I
a
lL
661
t
D
Ll3
0
H
gXZ
66
g
I I
r
Green
J
I
l
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I
@
I
COMBI NATI ON
METER
O
U
@
HEADL MP
MONI TOR
HEADLAMP
SENSOR
@l
D
DO
DO
@
SE L372
EL41
Li ghti ng
Systems
ELECTRI CAL SYSTEM
LI GHTI NG SWI TCH
Refer
to
Combi nati on Swi tch
HEADLAMP
SENSOR
Locati on
The headlamp
sensor
i s
locatedon
the
relay
bracket Referto
page
EL
105
I nspecti on
Ught
swi 1chon
Before
checki ng headlamp sensor
ensure
that 11
bulb meet
speci fi
cati ons
Allbulbsi n
good
ordllr
Bulbremoved
e
2volts
12volu
SEl373
EL42
AI MI NG
ADJUST
ENT
To
adjust
verti cal
ai m
use
adjusti ng
screw on
upper
si de
of
headlamp
and
to
adjust
hori zontal
ai m
use
adjusti ng
screwonsi deof
headlamp
CD
Q2
i
i l
i
Gwu
1
SEL291
1 Verti cal
adjustment
2 Hori zontal
adjumnent
Baform
ki ng
headl
mp
I mlng
djustment
ob
rve
the
followi ng
i nstructi on
Keep
11 ti res i nflted to
correct
pressures
b Place
carand tester
on one
and
same
flat
urf
c See tht
there
i s
no
load i n
car
coolnt
engi ne
oi l
fi lled
up
to
correct
leveland
full
fueltank
other
than thedri ver
or
equi valent
wei ght pl
ced i n dri ver
s posi ti on
When
performi ng headlamp ai mi ng
adjustment
use an
ai mi ng
machi ne
ai mi ng
wallscreen or
headlamp
tester
For
operati ng
i nstructi ons of
any
ai meri t
should be
i n
good
repai r
cali brated
and used
accordi ng
to
respecti ve operati on
manuals
suppli ed
wi ththeuni t
I f
any
ai mer
i s
not
avai lable
ai mi ng
adjustment
can be
doneas follows
Lowbeam
Turn
headlamp
lowbeamon
U
Hori zotal
n
230
4843
centerli ne
I
Ofheadlam
p Wf
Th
fP t
s
7
R j
W
Uni t nun i n
BE298D
Adjust
headl
mps
SO
that
upper
edge
of hot
pot
i s
equ
1 i n h
i ght
to
heedl
mp hei ght
b Dotted li nes i n i llustrati on show
canterof headl
mp
Hi gh
beam
Wi th
type
I I uni t
lamps
outer
lamps
covered tum headlamps to
hi gh
beam
U
H
Uni t mm i n
BE2990
8
Adjust hi gh
beams
so
that mai n
axi s
of
li ght
i s
p
ralleltocenterli neof
body
b Dotted li nes i n i llustrati on
show
center
of
headl
mp
EXTERI OR LAMPS
ELECTRI CAL
SYSTEM Li ghti ng
Systems
CAUTI ON
Do
not
wi pe
lens
surface
usi ng
cloth
dampered
wi th
gesoli ne
SCHEMATI C TAI L
CLEARANCE
SI DE MARKER LI CENSE PLATE AND
STOP
LAMPS
FRONT
SI DE
MARKER
LAMP R H
oc
FUSE
@
I
CLEARANCE
r
fJ
CLEARANCE
oc
FUSE
oc
FUSE
I FUSI BLE
LI NK
T
I BATTERY
L
I
EJ
FRONT
SI DE
MARKER LAMP LH
2t oI
1ST
OFF
jlmfr
i
STOP
LAMP
SWI TCH
TAI LLAMP
MONI TOR
STOP LAMP
MONI TOR
r
TAlLANOSTOP
LAMP SENSOR
SCHEMATI C TURN
SI GNAL AND HAZARD WARNI NG LAMPS
OACC
ro4
c
FUSleLE
LI NK
Sf
oc
FUSI BLE
LI NK
T
I
BATTERY
L
I
TURN
fl
FRONT
COMBI NATI ON
l
LAMP
TURN
E1
oc
FUSE
I GNI TI ON
SWI TCH
1
L
I GNI TI ON AND
ACCESSORY RELAY
C 00
FUSE
Fl
HAZARD
FLASHER
UNI T
Fl
TURN
SI GNAL
FLASHER UNI T
PI LOT LAMP
RH
PI LOT
LAMP
LH
REAR SI DE
MARKER
LAMP RH
STOP
j
@
TAI L
LI CENSE
PLATE LAMP
@
@
l
TAI L
I l
STOP
REAR SI DE
MARKER
Q
LAMP LH
SE
L315
g
HAZARD SWI TCH
I N
f
g
TURN SI GNAL
SWI TCH
@
TURN
RER
COMBI NATI ON
LAMP
TURN
t3eL37
EL
43
Li ghti ng Systems ELECTRI CAL SYSTEM
WI RI NG
DI AGRAM
TAI L
CLEARANcE SI DE MARKER AND UCENSE PLATE LAMPS
R
I
FUSI BLE LI NK
@
Et
BATTERY
1
FRONT SlOE
MARKER
LAMP
R H
n
@89
ll
FRONT COMBI NA
TI ON LAMP R H
1
GW
8
@
@
i l
FRONT COMBI NA
TI ON LAMP LH
GB
@
@I
FRONT SI DE
Y
MARKER LAMP
LH
ELM
W
I
J
I
GW
I
I OF 1ST 2ND
ABCABCABC
Lg jI
00
1
I
00
3
4
5
LI GHTI NG SWI TCH
GW
00
00
00
1B
00
V
00
ft
Whi te
@
@
I
G
LI CENSE PLATE
LAMP
l
e
r
GW ilI
ltJ
i ll
@
I j
f
i ll
@o
WL
@
e
gg
@
00
g g
Black
i 5 O
g
r
TAI L
WGH
HATC CK
M
B I
ry
I
wARD
TOP
TAI L
LA P
WG
LH
I
I a
f
B
14
Gll
L@j
JJ
@
@j
Gf
REAR SI DE MARKER
I
LAMP
LH
I I
JtU@
W
l
TAI LAND
STOP
LAMP SENSOR
SEL316
WI RI NG DI AGRAM
STOP LAMP
BATTERY
01
I U
G
I
FUSI BLE
LI NK
@
0 0
l
W
w
I
10
15
10
20
10
10
15
FUSE
BLOCK
STOP LAMP
SWI TCH
ELECTRI CAL SYSTEM Li ghti ng
Systems
COMBI NATI ON METER
L
Au2
y
U
CI D
I
I
@
J@
ggggllggt
Bluel
Whi te
@
I I
J
I I F
@
J
J
GY
L
c
LI i
Whi te
OOI I OOOO I qj
oo
0000 11
@
I
f
I
tf11
@
TAI L
AND
STOP
LAMP
SENSOR
SEli 71
B
YG
STOP
LAMP
MONI TOR
HATCHBACK
STOP
AND
TAI L
LAMP
R
H
@
f
HARDTOP
f
YG
I
fB
41
tJ
I
@
L
STOP
LAMP
I
R H
HATCHeACK
STOP AND
TAI LLAMP
@
LH
J
r
I I J
Black
o ooooo
OJ
rO@
I
B1
@
Ci ll
u
B
l
YG
r
HARDTOP
@I
@
I
I
STOP
LAMP
L
LH
EL
45
GBbTCHBACK
l
B
m
J
HAZARD
SWI TCH
r
l
I HARDTOP
2
0
8
GB1
I O
I
J
G
3
D
4
0
8
t I
I
u
GB S I
L J
REAR
COMBI NATI ON
LAMP R H
Li ghri ngSystems ELECTRI CAL SYSTEM
WI RI NG
Di AGRAM
TUm
SI GNAL
AND HAZARD
WARNI NG
LAMPS
@i
R
FUSI BLE
LI NK
i
rn
@
G1
@
W
I
WB
BW
BATTERY
3
FUSE
BLOCK
B
HAZARD
FLASHER UNI T
@
rJ
B
GB
@ jI
BI
l
cofP
1
GY
tJ
FRONT
COMBI
NATI ON LAMP R H
TURNSI GNAL
FLASHER
UNI T
L
G C
B
TURN SI GNALSWI TCH
@
LN
R
f1t
i
I
GB Y
@
j
I
i
I I
CD aJ
I @ I Whi
e
6
I lt@
00
Whi te
Y
oc
I
00
Ill
fi
a
I G
een
I
1
i
FRONT COMBI
NATI ON
LAMP
LH
OOllOO
Oi lfJ
I
000000co
i ll
@
COMBI NATI ON
METER
L
H RH
jJi f
GR
PI LOT
LAMP
@
R
@
a
I
I
EL 46
I GNI TI ON SWI TCH
I
CJT
i I tI CJN ST
U9Q
A
00
J
I G b
Q
s
I GNI TI ONAND
ACCESSORY
RELAY
r
I @
t@
REAR
COMBI NATI ON
LAMP LH
r
c
l
111
1
GR
I
I
1
B
L
@2 J
ro
I
GRi
fll
l r1
i
B
tI D
JP
I
L
8
SEL379
ELECTRI CAL SYSTEM
Li ghti ng Systems
SCHEMATI C
BACKUP LAMP
FUSI BLE
LI NK
oc
OACC
i fCON
I GN1TI 0N
SWI TCH
1
BACKUP LAMP
R H
@
I
BATTERY
L
I
FUSI BLE
LI NK
C C
BACK
UP
LAMP
LH
I GNI TI ON
AND
ACCESSORY
RELAY
BACKUP LAMP
@
SWI TCH
I NHI BI TOR
SWI TCH
@
13
SEL380
WI RI NG DI AGRAM
BACKUP LAMP
FUSE
BLOCK
1
I GNI TI ON
AND
9
ACCESSORY
RELAY
Jl @
@
@@
RB 00RB
00
i
Whi te
BACKUP LAMP
R
H
F
T
I GNI TI ON
SWI TCH
@
BW
WR
BB t
@
@
o
tf
R
FUSI BLE
LI NK
G
@
B
RB
B@@
I @
1@
o
BATTERY
I NHI BI TOR
SWI TCH
@
I
ll ll
C
a
a
C
9 Q@
0O@
11
11
t
I @
BACKUP
LAMP
SWI TCH
RBB t
@
BACK UP LAMP
@
LH
SEL381
EL 47
Li ghti ng Systems
ELECTRI CAl
YSTEM
TROUBLE
DI AGNOSES
AND
CORRECTI ONS
Clearance si demarkerlleense
plateand tai l
lamps
Condi ti on
Nei therleft
nor
ri ght
lamp
li ghts
Lamp
on
only
one
si de
li ghts
Stop lamps
Condi ti on
Nei therleft nor
ri ght
lamp li ghts
Lamp
on
only onesi de
li ghts
EL48
Probablecause
Burnt fuse
Loose connecti on
or
open
ci rcui t
Faulty
li ghti ng
swi tch
Lamps
li ght
when
CD
and
@
termi nals of
harness connectorto
combi nati onswi tchare
connected wi thtest lead
i ncludi ng
15A
fues
Fa1llly
tai land
stop lamp
sensorTai l
lamp
only
Burnt
bulb
Loosebulb
Looseconnecti on or
open
ci rcui t
Probable
cause
Burnt
fuse
Faulty
stop
swi tch
Faulty
tai l
and
stop
lamp
sensor
Stop lampsli ght
when
@
and
@
termi nals
of mai n harness
connectortotai land
stop
lamp
sensor
are
connected
wi thtest
lead
i ncludi ng
lOA fuse
Looseconnecti on
or
open
ci rcui t
Bumt bulb
Loosebulb
Looseconnecti on or
open
ci rcui t
Correcti ve
acti on
Correct causeand
replace
Check
wi ri ng
and or
repai r
connecti on
Replace
i f
necessary
Replace tli 1
and
stop hunp
sensor
Replace
Repai r
lamp
socket
Check
wi ri ng
and
or
repai r
connecti on
Correcti ve
acti on
Correct
causeand
replace
Conduct
conti nui ty
test and
replace
i fneces
sary
Replace
i f
necessary
Check
wi ri ng
and
or
repai rconnecti on
Replace
Repai r
lamp
socket
Check
wi ri ng
andor
repai r
connecti on
Turn
slgnsl
and hazard
warnI ng
flasher
lamps
Condi ti on
Turn
si gnals
donot
operate
Hazard
wami ng
lamps operate
Hazard
warni ng
lamps
do
not
operate
Turn
si gnals
operate
Turn
si gnals
and
hazard
warni ng lamps
do
not
operate
No
flashercli ck i s
heard
Flashi ng
cycle
i s too
slow
pi lot
lamp
does
not
go
out ortoo
fast
Flashi ng
cycle
i s
i rregular
Probablecause
Bumt fuse
Loose
connecti on
or
open
ci rcui t
Faulty flasher
uni t
Faulty
turn
si gnal
swi tch
Faulty
hazardswi tch
Turn
si gnals operate
when
CD
and
@
termi nals
of
harness connector
to
hazard
swi tch
areconnectedwi thtest lead
i ncludi ng
lOAfuse
Burnt fuse
Faulty hazard
warni ng
flasheruni t
Faulty
hazardswi tch
Left
Ri ght
si de
lamps
operate
when
@
@
and
@
termi nals of harness connector
tohazard swi tchare
connected
wi th
test
lead
i ncludi ng
lOA fuse
Faulty
hazardswi tch
Looseconnecti on
Burnt bulb
Faulty
flasheruni t
Loose
connecti on
Bulb other
than
speci fi ed
wattage
bei ng
used
Burnt bulbs
Loose connecti on
Faulty
flasheruni t
Burnt bulb
Loose connecti on
Bulbs other
than
speci fi ed
wattage bei ng
used
Faulty
flasheruni t
ELECTRI CAL SYSTEM
Li ghti ng
Systems
Correcti veacti on
Correct
causeand
replace
Check
wi ri ng
and
or
repai r
connecti on
Replace
Conduct
conti nui ty
test and
replace
i fneces
sary
Replace
i f
necessary
Correct
cause
and
replace
Replace
Replace
i f
necessary
Replace
i f
necessary
Reconnect
fi nnly
Replace
Replace
flasheruni t
Reconnect
fi nnly
Replace
wi thone
speci fi ed
Replace
Reconnect
fi rmly
Replaceflasheruni t
Replace
Repai r
Replace
wi thone
speci fi ed
Replace
flasher
uni t
EL49
Li ghti ng Symms ELECTRI CAL
SYSTEM
LI GHTI NG
SWrTCH
AND
TURN SI GNAL SWI 1 Ct1
Referto Combi nati onSwi tch
STOP
LAMP
SWI TCH
I nspecti on
Test
conti nui ty
through
swi tch
wi than ohmmeter
CD
@
NORMAL
POSI TI ON
PUSH
PLUNGER
6
SEL36S
Adjustment
RefertoMAsecti on
TAI LAND STOP LAMP
SENSOR Transi storbui lt I n
Removalandi nstallati on
Before
removi ng
tai land
stop
lamp
sensordetach
rear
wheelhouse
fI ni sherSee
page
EL105
Before
checki ng
tai lend
top lamp
senI Oren ure
that aU bulb
meet
speci fi cati ons
I nspecti on
Stop lamp
Stop lamp
swi tchon
EL
50
VJ
Bulb
i n
good ord
Ap
2volts
Approx
12wofts
SEL385
Bulb
removed
Tai l
lamp
li ght
swi tchon
Bulb
i n
goodordr
Approx
2volts
Approx
12voltl
SEL386
Bulb nmoved
HAZARD SWI TCH
I nspecti on
lt
145
OM
OF
SEL296
TURN SI GNAL
FLASHER
UNI T
AND
HAZARD
FLASHER
UNI T
Locati on
Steeri ng
column
Turn
si gnal
flasher
Hazardflasheruni t
uni t
SEL Z97
BACKUP LAMP
SWI TCH
Automati ctransmleslon
The back up
lamp
swi tchi s bui lt
i ntothe i nhi bi torswi tch
Referto
AT
secti on
Manualtransmlealon
The back
up
Jamp
swi tchI S I D
stalled on
the manual
transmi ssi on
case
OJ
on
SEL298
ELECTRI CAL
SYSTEM
Li ghti ng Systems
I NTERI OR
WGGAGE
COMPARTMENT AND
STEP LAMPS
CAUTI ON
00
not
wi pe
lens
surface
usi ng
cloth
dampered
wi th
gasoli ne
SCHEMATI C
I NTERI OR LUGGAGE
COMPARTMENT
AND STEP
LAMPS
Hatchback modelwi th
I nteri or
lamp
ti mer
I NTERI OR LAMPS
WI TH
SPOT
LAMPI
6
6 6
i j
011
STEP LAMP RH
I NTERI OR
LAMP
TI MER
1
o
DOOR SWI TCH
RH
FUSE
oC
j
DOOR
SWI TCHLH
FUSI BLE
LI NK
LUGGAGE
COMPARTMENT
LAMP
1
o0
1
BATTERY
I I I
L
STEP LAMP LH
n
SEL3a7
EL51
Li ghti ng
Systems ELECTRI CAL
SYSTEM
WI RI
NG DI AGRAMI NTERI OR
LAMP STEP LAMP
AND LUGGAGE
COMPARTMENT LAMP
81
i
BATTERY
11
US BL
u
I
LI NK
@
0 0 0 0
FUSE
BLOCK
l
lG
I WI THI NTERI OR LAMP TI MER
I NTERI OR
LAMPS
I NTERI OR 6 b 6
LAMP TI MER
1f
Wl@
I I
ri f31
I I
W
aU
Black CD
4 Hgg
I @
fY
@
CC
CD
CD
a
a
RG
RB
l
I
H
@
on
Whi te
19b
21
Ii 7I
Y
B
B
i b
@
@
1k9
I rO
jl
a
I I
CD
a
co a
W
Whi te
@
r9l@
0
I I
tI
00
a
CD
I
i
LUGGAGE
COMPART
MENT
LAMP I HA
TCHBACK
RG
B D
0QJ
i
@
@
TRUNK
ROOMLAMP
HARDTOP
@
RG
ao @to
L
@
@
EL52
@
lR
lG
i
STEP LAMP A
H
00
BR
ro
I A
RG cJ
LUGGAGE COMPART
@@
MENT LAMP HATCHBACK eR
@
RG
DOOR
nO
fB@
O
CH
4
@
TRUNKROOMLAMP
HARDTOP
1
@
RG
11
@
Rr
I
Whi
000 1
0
ohi B tSi B
V
R
DOOR
SWI TCHLH
BR
W
@I
@
6
l
i R
tt
ER
@
STEP LAMP LH
00
BR cJ
RG cJ
WI THOUT I NTERI OR
LAMP
TI MER
I NTERI OR LAMP
BR J
oh
@
DOOR
@
SWI TCH
R H
DOOR
SWI TCHLH
00
lR J000
2
@
@
SEL388
I NTER
I OR LAMP
Bulb
replacement
Wi thout
spot lamp
Remove
lens by
i nserti ng
a f1at
bladescrewdri ver
i ntoswi tchhole
To
avoi d lens
damage
blade
porti on
shouldbe coveredwi th
a
clothbefore
i nserti on
Wi th
spot lamp
1
Open
coverwi th
a f1at blade
screwdri ver
i nserted i nto front of
coverToavoi d
cover
damage
blade
porti on
should
be covered wi th
a
clothbeforei nserti on
2 Remove
attachi ng
bolts and de
tachi nteri or
lamp assembly
ELECTRI CAL SYSTEM Li ghti ng
Systems
DOOR
SWI TCH
I nspecti on
Doorswi tchL
R
@
SEL391
I
DOOR I
CLOSE OPEN
I 0
126
g
I
FOR USE
KEY AND
LI GHT
WARNI NG
I NTERI OR
LAMP
I NTERI OR
LAMP TI MER
I c
bui lt I n
Locati on
The
i nteri or
lamp
ti meri s
attached
to
the
upper
si deof
i nstrument
frame
Referto
page
EL
104
I nspecti on
SEl393
Ci rcui t
tester
i ndi cati on
As doori s closed testeri ndi cati on
should
li nearly
i ncrease from0to
ap
proxi mately
10volts after10seconds
EL
53
Li ghti ng
Systems ELECTRI CAL SYSTEM
I NSTRUMENT
PANEL
I LLUMI NATI ON
SCHEMATI C
I NSTRUMENT
PANEL
I UUMI NATI ON AND
CI GARETTE
LlGHlER
FUSE
I
I
i
FUSI LE
bLI NK
T
I
BATTERY
L
I
LI GHTI NG
I
Off
1ST 2ND
SWI TCH
ABC
ABC ABC
I UUMI NATI ON I ROL
RHEOSTAT
Transi stor
bult ln
8pectlon
fe
Battery
EL
54
J
E
SEL303
FUSE
c
COMBI NATI ON
METER
OPTI CAL
FI BER
r
KEY
I LLUMI NATI ON
o
I LLUMI NATI ON
CONTROL
RHEOSTAT
8
TEMPERATURE
CONTROLPANEL
A
S
C D
MAI N SWI TCH
CI GARETTE
LI GHTER LAMP
3
CI GARETTE
LI GHTER
LAMP
13
ASHTRAY LAMP
3
GLOVE
BOX
LAMP
13
RADI O
I LLUMI NATI ON
3
AfT POSI TI ON
I NDI CATOR LAMP
SEL396
ELEC rRI CAL SYSTEM Li ghti ng
Systems
WI RI NG DI AGRAM
I NSTRUMENT PANEL
I LLUMI NATI ON
AN
CI GALETTE
LI GHTER
@
SleLE
K
Eli
8
T
BATTERY
FUSE eLOCK
0
0
l
@
a
B
SI GW
AfT POSI TI ON
I NDI CATOR
LAMP
GW
Lg
1
1i ll
@
@
L9B1
t
GW
0
00
00
@
AS C
D
MAI N
SWI TCH
I LLUMI NATI ON
@r
r
HEATER CONTROL
PANELI LLUMI NATI ON
@
@
B
flJ
Lgg
Lv i
l
I
GW
Whi te
LgB
f
@
Bluel
@
@
AS C
D
equi pped
models
@
I AO
f
C
A
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A
2i
a
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6
06 0
aa
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LI GHTI NG
SWI TCH
@
0
fi
@
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0
I
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I
GW
METER I
LgS
AND KEY
I llUMI NATI ON
COMBI NATI ON
METER
Ci D
G i j
D
LgB
I LLUMI NATI ON
CONTROLRHEOSTAT
@
LY l
l
BJo
GW
B
CI GARETTE
LI GHTER
LY
S D
GW
@GLOVEBOX
LAMP GW I
LgB B
Gw e
I
@
ASH
TRAY LAMP
GW
I I aa
L9 V
191
RADI O
I LLUMI NATI ON
SEL396
EL
55
Meters
GaugesafldWarni ng Systems
ELECTRI CAL
SYSTEM
METERS
GAUGES
AND WARNI NG SYSTEM
CAUTI ON Before
starti ng
to
work
on
eny part
of
electri cal
system
di sconnect
battery ground
cable
COMBI NATI ON METER
R O
A
ANI
1
tTA
TI ON
SEL397
EL
56
ELECTRI CAL
SYSTEM Meters
Gauges
andWarni ng
System
I NSPECTI ON
3
0
80
o
@I D JO
o
rei 0
so
o
lU
TI
Sr5Tl
OUAFlTZ
1
ReaI
defogger
J
i ndi cator
lamp
lli umi nati on
lamp
w
i lljJ
UJ EJ
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b
mJ
rnm
mi ll
Beami ndi cator
f1Q
m
lamp
I TJ
m
0
i
Opti cal
fi ber
Key i llwni nati 9
w
lli
ll
mI llJ
I llumi nati on
lamp
Chargewarni ng
lamp
G
111
w
0
0
0
0
u
0
ll
o
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I I
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1
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1
A A
ll
@
1
Temperaturegauge
2 Seat belt
warni ng lamp
4 Power
source
5
Ri ght
twni ndi cator
lamp
6
Fuel
gauge
7
Beami ndi cator
lamp
8 Tachometer
Si gnal
10Ground
12 Left
turn
i ndi cator
lamp
13
Charge
WaI ni ng
lamp
14
Rear
defogger
i ndi cator
lamp
I S I Dumi nati on
lamps
16 I llumi nati on
lamps
17 Tai l
lamp
moni tor
lamp
18
Headlamp
moni tor
lamp
19
Stop lamp
moni tor
lamp
20Clock Powersource
21 Oi l
pressurewarni ng lamp
22 Clock
I llumi nati on
24 Brake
warni ng lamp
25 OU
presswe
gauge
28
Door
warni ng lamp
SE
L398
EL57
Merers
Gauges
and
Warni ng Systems
ELECTRI CAL SYSTEM
SCHEMATI C
TACHOMETER
GAUGES AND
WARNi NG
LAMPS
T
I
BATTERY
I
1lja
0
o
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a
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Ga
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w
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FUSI BLE
LI NK
FUSI BLE
LI Nk
0
I GNI TI ON
SWI TCH
UUUUUJ
FUSE
0C
Od
I GNI TI ON
AND
ACCESSORY
RELAY
A
VOLT GAUGE
o
ALTERNATOR
115
4
CI J
C t
I I
I DCI
J
a
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10
WI RI NG
DI AGRAMTACHOMETER
I
Et
e
T
l
R
G
FUSI BLE
LI NK
a
a
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BATTERY
0
0
I GNI TI ON
SWI TCH
a
S1 ON ACe OFF
@
i
0
B
I
I
I I
BW
I T WR
I GNI TI ON AND ACCESSORY RELAY
CJ
@
EL58
@
WB
FUSE BLOCK
J
6f
T
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N
COI L
RESI S
TOR
a
CI
Z
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za
0
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GD
L
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TACtOYETER
COMBI NATI ON METER
II h
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tf7i
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SEL405
ELECTRI CAL
SYSTEM
Meters
Gauges
and
Warni ng Systems
WI RI NG
DI AGRAM
OI L PRESSURE GAUGE AND WARNI NG
LAMP
WATER TEMPERATURE
FUEL AND VOLT
GAUGE
CfW
FUSI BLE
LI NK
E9
BATTERY
t
FUSE
BLOCK
I
i @
@
JU
f
r
1
Whi te
G
Jr
B
@
lJg
Jlgg
LY
Y
Green
I
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s co
V
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1
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OI LPRESSURE
THERMAL
SENDI NG
UNI T
TRANSMI TTER
WR rn
BW
I I
I I
rn
I
I
I
10
ACQON
Sf
1
6
O
I
6t
S
6
1l
J@
B
@
@
y
I
@
I GNI TI ON
SWI TCH
I GNI TI ON AND
ACCESSORY
RELAY
FUELTANK
GAUGE UNI T
J
0
I
COMBI NATI ON
METER
VOLTGAUGE
OI L
PRESSURE
VOLTAGE
GAUGE
EGULATOR
VOLTAGE
REGULATOR
0
I
LY
@
7
RC
B
0
Y 8
1l
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@
362
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4
5
o
TEMPERATURE
AUGE
@
6Hv
FUEL
GAUGE
@0
OI LPRESSURE
WARNI NG LAMP
SEL404
EL
59
Mere17i
Gauges
and
Warni ng
Sysrems ELECTRI CAL SYSTEM
WI RI NG DI AGRAM
CHARGE
DOOR AND BRAKE WARNI NG LAMP
I
o
t
I GNI TI ON SWI TCH
Off IXON 5T
m
J
WJ
FUSI BLE
LI NK
@
WR
BW rn
B
9
Q
D
6
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g
t1
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BATTERY
@
w
1
WB
BW
I
m
r
FUSE
BLOCK
I
I
@li l
1Wh
el jJ
00
00
00
i s C
BULB CHECKRELAY
i
BRAKE FLUI D
LEVEL
SWI TCH
rr
t
B
s
4
@
I
R Br
B
I
R
G
G
BR
@
@
L
Qtl YG
Green
@
rOO
BJ
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gfgfllg
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8
Whi te
WR
JI
i ll
PARKI NG
BRAKE SWI TCH
o
D
YG
l
@
ALTERNATOR
L
TERMI NAL
EL
60
@
G
@
W
@
wr
@
BR
d
@
G
I GNI TI ON
AND
ACCESSORY
RELAY
DOOR
SWI TCHR H
BR J4
04
@
1
@
@
DOOR SWI TCH
L
H
@
BR J elI 00
4
a
J
2
3
COMBI NATI ON METER
w
2
a
W
a
0
J 0
a
u 0
m
SEL368
ELECTRI CAL SYSTEM
Meters
Gauges
and
Warni ng Systems
TROUBLE DI AGNOSES
AND
CORRECTI ONS
Condi ti on Probablecause
Water
temperature gauge
Gauge
doesnot
Faulty
thermal
transmi tter
orloose
termi nal
operate
connecti on
When
wi re
tothermal
transmi tteri s
ground
ed
gauge
poi nter
fluctuates
Faulty
water
temperature
gauge
Faulty
thermaltransmi tter
Gauge poi nter
returns to
ori gi nal
posi ti on
when
i gni ti on
swi tchi s turnedoff
Faulty
water
temperaturegauge
Gauge poi nter
i ndi catesmaxi mum
tempera
tureeven after
i gni ti on
swi tch
i s
turned off
Gauge i ndi catesonly
maxi mum
temperature
Gauge
does not
operate
accurately
011
pressuregauge
Oi l
pressure
gauge
does not
operate
Gauge
i ndi cates
only
maxi mum
pressure
Fuel
level
gai lge
Fuellevel
gauge
doesnot
operate
Poi nteri ndi cates
only
F
posi ti on
Fuellevel
gauge
does
not
operate
accurately
Volt
gauge
Volt
gauge
does not
operate
or
abnormally
i ndi cates
Faulty
water
temperaturegauge
Looseor
poor
connecti on
Faulty
oi l
pressure sendi ng
uni t
orloose
termi nalconnecti on
Faulty
oi l
pressure gauge
uni t
Gauge poi nter
retums to
ori gi nal
posi ti on
when
i gni ti on
swi tch
i s
tumedoff
Faulty
oi l
pressure
gauge Gauge poi nter
i ndi cates maxi mti m
pressure
even
after
i gni
ti onswi tchi s turnedoff
Faulty
fuel
gauge
tank
uni t
Poi nterdeflects when
fuel
gauge
tank uni t
yellow
wi rei s
grounded
Faulty
fuellevel
gauge
Looseconnecti on
or
open
ci rcui t
Faulty
fuel
gauge
tank uni t
Faulty
fuellevel
gauge
Faulty
fuel
gauge
tank uni t
Faulty
fuel
gauge
Poor
orlooseconnecti on
Faulty gauge
voltage
regulator
Faulty
volt
gauge
Loose or
poor
connecti on
Correcti ve
acti on
Replace
thermal
transmi tter
or
correct
ter
mi nalconnecti on
Replace
water
temperaturegauge
Replace
thermaltransmi tter
Replace
water
temperaturegauge
Replace
water
temperaturegauge
Correct connectortermi nalcontact
Replace
oi l
pressure sendi ng
uni t orcorrect
termi nalconnecti on
Replace
Replace
Replace
fuel
gauge
tank
uni t
Replace
Check
wi ri ng
and
or
repai r
connecti on
Replace
Replace
Replace
Replace
fuellevel
gauge
Correct connectorteoni nalcontact
Replace gaugeassembly
Replace
Check
wi ri ng
andor
repai r
connecti on
EL
61
Meters
Gauges
and
Warni ng System
ELECTRI CALSYSTEM
Charge
and brake
warni ng lamps
Condi ti on
Lamp
doesnot
glow
when
i gni ti on
swi tch
i s turned
ON
wi th
out
runni ng
engffi
e
Chelllewerni ng lemp
Lamp
does
not
go
out
when
engi ne
i s
started
Brake
warni ng
lamp
Lamp
does not
go
out
Probablecause
Burnt bulb
orloosebulb
Looseor
poor
connecti on
Faulty pri nted
ci rcui t
board
Faulty
bulb check
relay
Faulty
alternator
Faulty
chargi ng system
Faulty parki ng
brake swi tch
When
parki ng
brake
lever
i released
Faulty
brake flui dlevelswi tch
When
brake
flui dleveli s
nonnal
Oi lpre
sureanddoor
warni ng lamps
Condi ti on
Ojl
pressurewarni ng
lamp
Lamp
doesnot
li ght
when
i gni ti on
swi tch
i s set to
ON
Lamp
doesnot
go
out
whi le
engi ne
i s
bei ng
operated
Door
warni ng lamp
Lamp
does not
glow
wi thdoor
opened
and
engi nerunni ng
Tachometer
Condi ti on
Tachometer
poi nter
deflects
Tachometer
poi nter
wi llnot
move
EL62
Probablecause
Faulty
oi l
pressure
sendi ng
uni t
or
loose
termi nal
connecti o
r
When lead
wi reconnected
to
sendi ng
uni t
i s
grounded
warni ng
lamp li ghts
Burnt
bulb
orlooSe
bulb
Lack
of
engi ne
oi l
Oi l
pressure
too
low
Faulty
oi l
pressure
sendi ng
uni t
Faul1y
door
swi tch
Burnt bulb
orloosebulb
Probablecause
Loose
or
poor
connecti on
Faulty
resi stor
Faulty
tachometer
Looseor
poor
connecti on
Faulty
tachometer
Correcti veacti on
Replace
bulb orcorrect
Correct connectortermi nal
contacts
Replace
Replace
Repai r
or
replece
I nspect chargi ng system
Replace
Replace
Correcti ve
acti on
Replace
orcorrect connecti on
Replace
bulb orcorrect
Checkoi llevel
andaddoi las
requi red
I nspect engi ne
oi l
pressuresystem
Replace
Replace
Replace
bulb orcorrect
Correcti ve
acti on
Repai r
Replace
resi stor
Repai r
or
replace
tachometer
Repai r
Repai r
or
replace
tachometer
pe
dometer
Condi ti on
Nei ther
speedometer
poi nter
nor
odometer
ol
erates
Unstable
speedometer
poi nter
Unusualsoundoccurs
i n
response
to
i ncreasei n
dri vi ng speed
I naccurate
speedometer
i ndi cati on
I naccurate
odometer
operati on
FUEL
TANK
GAUGE
UNI T
RemovalandI nstallati on
Referto
FE secti on
ELECTRI CAL SYSTEM Merers
Gauges
andWarni ng
System
1
11
E
t
2
e
l
i
d
Empty
L
Probablecause
Loose
speedometer
cableuni on
nut
Broken
speedometer
cable
Meter
si de
or
Transmi ssi onsi de
Damaged
transmi ssi on
speedometer
pi ni on
gear
Faulty
speedometer
I mproperly
ti ghtened
or
loose
speedometer
cable
uni onnut
Damaged
speedometer
cable
Faulty speedometer
Excessi vely
bent
or
twi sted
speedometer
cable
i nnerwi re
orlack
oflubri cati on
Faulty
speedometer
Faulty
speedometer
Faulty speedometer
a
Float
Forfuel
gauge
Full
I napectlon
Fueltank
gauge
uni t
has
twofunc
ti ons
I I
SEL311
1 4
nVi
f
Correcti ve
acti on
Reti ghten
Replace speedometer
cable
Repl
ce
transmi ssi on
speedometer
pi ni on
gear
Replace
speedometer
Reti ghten
Replace
speedometer
cable
Replace
speedometer
Replace
or
lubri cate
j
Replace
speedometer
Replace
speedometer
1
Replace
speedometer
Uni t mmi n
SEL312
EL
63
Maters
Gauges
and
Warni ng Systems
ELECTRI CAL
SYSTEM
b
Thermi stor
For
multi
warni ng
di splay
Test
lamp
s
Water
SEL313
Test
lamp
should come on i n
ap
proxi mately
t1uee
mi nutes afterre
movalofthermi storfrom
water
PARKI NG
BRAKE
SWI TCH
Pli rklng
bri ke
p
lI ed
Parki ng
bnke
released
on
n
SEL309
BRAKE
FLUI D LEVEL
SWI TCH
Float
I
Float 1
Approx
zson
Approx
on
SEL310
EL64
BULB
CHECK
RELAY
LocaUon
The
bulb check
relay
i s
attachedto
the
relay
bracket Referto
pa
EL
105
I nspecti on
l
f
I
t
I
i
lll
L
w
lI
@
SEl406
DI ODE
For
chargewarni ng lamp
Locati on
The di odefor
charge
warni ng
lamp
i s
fastened toharness wi th
tape
on
the
ri ght
si de
of
thedash
panel
Refer
to
page
EL109
DOOR
SWI TCH
Referto
page
EL
53
TACHOMETER
Removal dI nstallati on
1 Removecombi nati onmeter
2
Remove tachometer
attachi ng
bolts
3 Remove tachometerfrom com
bi nati onmeterlower
housi ng
4
I nstallati on
i s
i n
thereverseorder
ofremoval
Power
sowce Earth
SEL314
RESI STOR
FOr
tachometer
and
EFI
system
A 22 kfl
resi storfortachometer
and EFI
system i s
located
nearthe
i gni ti on
coi l
ELECTRI CAL SYSTEM
Merers
Gauges
and
Warni ng Systems
SPEEDOMETER
Cable
layout
Cable
Speedometor
SEL410
For
detai led
i nformati on
regardi ng
I peed
len or
I A
S
C D referto
page
EL102
WARNI NG DI SPLAY
I gni ti on
swi tch ON
DESCRI PTI ON
Warni ng li ghts
comeon
toread
aU i tems
i nsuccessi on one at a
ti mefor
2
seconds
The
warni ng di splay
system
con
si sts
of
a
warni ng
i ndi cator
a
warni ng
di splay
ampli fi er
andsensors
When
i gni ti on
swi tch
i s
ON warn
i ng di splay
operates
as follows
J
YES
NO
Ii ght
OFF
I
Abnormali ty
I
Abnormali ndi cati on
I
Eli mi nate
abnormali ty
I
EL
65
Msters
Gauges
aM
Wa11I i ng Systems
ELECTRI CAL SYSTEM
Di splay
modes
I denti fi cati on
I
FUEL
fBf I
I
TTe BA
WATE
lllli i D
I WASH
Color
Red
Orange
Orange
Orange
SCHEMATI C
WARNI NG
DI SPLAY
BATTERY LEVELSENSOR
1
e
1 f
H
I GNI TI ON SWI TCH
OACX
i f
CON
qI
I GNI TI ON AND
ACCESSORY
RELAY
EL
66
I tem
Fuellevel
warni ng
Battery electrolyte
level
warni ng
Coolant level
warni ng
Washer
flui d
level
warni ng
WASHER LEVEL
SENSOR
I r
b
o
WARNI NG
DI SPLAY
AMPLI FI ER
FUSE
Warni ng
I ndi catesthat fueli s
lessthan
vmately
10
li ters 2
5 8
US
gal2
1 4
I mp gal
I ndi cates
that
battery
electrolyte
i s
lessthan
speci fi ed
level
I ndi catesthat
engi ne
coolant i nradi atorreservoi r
tank
i s less than
speci fi ed
level
I ndi catesthat wi ndshi eldwasherflui d
i s
lessthan
speci fi ed
level
RADI ATOR
LEVEL
SENSOR
i Lr
lJl
FUEL
LEVELSENSOR
b
E
WARNI NG I NDI CATOR
BATT
SEL411
ELECTRI CAL
SYS rEM
Meters
Gauges
andWami ng
Systems
WI RI NG
DI AGRAM
WARNI NG DI SPLAY
EJ
BATTERY
t
WASf jER
SENSOR
0ClI
JClI
RADI ATOR
SENSOR
tfW
WR
I I
@
FUSI BLE
LI NK
FUSE eLOCK
BL
J
@
1
B
J
BATTERY
SENSOR
i @
LnCBY
@
YL
@
EYL
00
I
g
Black
00
@
@
J
fj
i @
I GNI TI ON SWI TCH
WR
BW
1i ll
@
1
I GNI TI ON
AND
ACCESSORY
ffEU V
t
n
I
@
L
LY
Lvi
lB
LR
f
WARNI NG
I NDI CATOR
WARNI NG
DI SPLAY
AMPLI FI ER
@
RY
B
BL
LW
LV
LR
LB
L
G
YL
BY
o
0
0
0
0
0
@
YL
B
I
@
i ll
FUEL
TANK
GAUGE UNI T
SEL412
Et
67
i1
TROUBLE DI AGNOSES AND
CORRECTI ONS
MI 1te GaugesandWami ng ELECTRI CAL SYSTEM
No
warni ng
i ndi ca1Bd
Chec
f11se
lO
K
Check forlooseconnecti onat
I
warni ng
i ndi catorand
ampli fi er
OX
Replacewarni ng
di splay ampli fi er
I
N G
r
Repla
fuse
N G
Re
ct
r
pan
conne or
When
i gni ti on
wi tchi
turned
to ON
warni ng li ghts
comeon
to
readalli tems
i n succeui on one at
a
ti mefor2seconds However
warni ng li ghts
wi llnot
come
oneven
th
ugh
therei
I bnormali ty
1
Check sensor
lOX
Check forlooseconnecti on
or
open
ci rcui t
lOX
Check
warni ng
i ndi catorfor
burnt bulb
Replace
warni ng
di splay ampli fi er
N G
Re
I
pan
or
rep
ace sensor
N G
Repai r
or
replace
N G
Replace
warni ng
i ndi cator
I
Warni ng li ght
remai n
oneven
though
th i
no
I bnormaJi ty
1
Checksensor
lO
K
Check forlooseconnecti on
or
open
ci rcui t
lOX
Replace
warni ng
di splay
ampli fi er
EL68
N G
I
Repan
or
rep
acesensor
N G
Repai r
or
replace
MULTI
WARNI NG I NDI CATOR
Locati on
The multi
warni ng
i ndi cator
i s
locatedi n thecombi nati on
gauge
I nllPectlon
o
j Washer
@
@
Radi ator
Fuel
eI D
Battery
SEL413
MULTI WARNI NG AMPLI FI ER
JC
bullt ln
Locati on
The multi
warni ng ampli fi er
i s at
tached tothei nstrwnent
panel
frame
Before
removi ng
i t
remove cluster
li dC Referto
page
EL104
ELECTRI CAL SYSTEM
Mete Gauges
and
Warni ng
Systems
FUELLEVEL SENSOR
I nllPectlon
Referto
pages
EL63and
64
WASHER
LEVEL
SEN R
Locati on
The washerlevelsensor
i s located
onthe
bottomof the
washertank
I nllPectlon
Q
SEl414
COOLANT
LEVEL
SENSOR
Locati on
The coolant levelsensor
i s
located
on the
bottom
of
theradi atorreser
voi rtank
I nllPectlon
Coolant level
sensor
i s uni ted wi th
the reservoi rtank and
cannot
be re
movedalone
w
Empty
Norm llevt
on
n
SEL415
BATTERY
LEVEL SENSOR
I nspecti on
Before
i nspecti on
make
surethat
the
battery
i s
charged
andtheflui d
i s
ftlled
up
tocorrect level
1 Di sconnect
sensor
ha
essconnec
tor
2
Makesure that there
i s
about 8
volts
when
voltmeter
posi ti ve
and
negati ve
teoni nals are connected
to
battery
flui d level
sensor
and
battery
negati ve
termi nals
respecti vely
8Y
BES07D
EL69
Meters
GaugesandWami ng
ms
ELECTRI CAL SYSTEM
WARNI NG
CHI ME
l
SCEMATI C SEAT BELT
KEY
AND LI GHT WARNI NG
Jc
FUSI BLE LI NK
FUSI BLE LI NK
L
BATTERY
I
6 SEAT
BELT
SW
I TCH
o
ON
C
a
cON
0srJ
I GNI TI ON
SWI TCH
L
L
oc
FUSE
oc
I GNI TI ON
AND
ACCESSORY RELAY
FUSE
rc
FUSE
SEAT BELT WARNI NG
TI MER
WARNI NG CHI ME
SEAT
BELT
@
I NG
I I
TROUBLE
DI AGNOSES AND CoRRECTI ONS
Condi ti on
Li cht
and
key
Warni ng
chi medoe
not soundwi th
i gni ti on
key
i n
i gni ti on
swi tch
or
li ghti ng
swi tch
on
whendri ver
si dedoor
i s
open
Seat belt
Chi medoes not sound
and
warni ng
lamp
does
not
glow
wi th
i gni ti on
swi tchon
Ei ther
chi meor
warni ng
lamp
doesnot
operate
wi th
proper
condi ti on
EL
70
Probable
cause
Faulty
warni ng
chi me
Loose
connecti on or
open
ci rcui t
Faulty
doorsWi tch
Faulty
key
warni ng
chi meswi tch
Faulty
li ghti ng
system
Clearance
lamp
does
not
li ght
Faulty
eat belt swi tch
Faulty
seat belt
warni ng
ti mer
Looseconnecti on
or
open
ci rcui t
Loose
connecti on
or
open
ci rcui t
Burnt bulb
Faulty
chi me
A
LI GHTI NG
SWI TCH
OFf
1ST
2ND
A
a
CAB C
Ala
c
g8g2@
KEY
WARNI NG
SWI TCH
DI ODE
I
I I
DOOR
SWI TCH
L
H
SEL416
Correcti ve
acti on
Replace
Correct connectortermi nal
contacts
Repai r
or
replace
Repai r
or
replace
Correct
Repai r
or
replace
Replace
Correct
connector
termi nal
contacts
Correct
connectortermi nalcontacts
Replace
Replace
ELECTRI CAL SYSTEM
Meters
Gauges
and
Warni ng
Systems
WI RI NG
DI AGRAM
SEAT BELT KEY AND
LI GHT
WARNI NG
I t O
R
FUSI BLE
LI NK
G
BATTERY
n
e I
1
a
5 5
I
I
WR
aw 41
41
@
@
aJl
W I
WB
aw
DOOR SWI TCH
LH @
rVR
nJ no
ooYR
JtGW
U9
Uo
GW
GW
I @
@
lVR
GW
GW
SEAT BELTTI MER
A
YB
WARNI NG
CHI ME
R
a
@
SEAT
BELT
SWI TCH
gm
2k
YB
Br
@
Whi te
11
GW
Lg 41
41
@
i llY
Blue
@
i l
w
l@
e
rtfJ1
J
t J
fi l
Whhe
@
1
1
I i llJJ l4
15
I GNI TI ON SWI TCH
I
I B
i A
I G
I S
Of aa
ON S1
g
o
g
I GNI TI ON AND
ACCESSORY
REALY
I i
O@
LI GHTI NG SWI TCH
I OFf
r
1ST
I
2ND
ABCABCAB
9 0009
o
oObo
888
g
gg
KEY WARNI NG
SWI TCH
RG
ai O
oon
wDlJc
U
COMBI NATI ON
METER
L9Y
GD
2
2
B
SEAT BELT
WARNI NG LAMP
SEL417
EL71
Mete
Gauges
andWarni ng
Systems ELECTRI CAL SYSTEM
Referto
I gni ti on
swi tch
KEY
WARNi NG
SWI TCH
DOOR SWI TCHLH
Refer
to
page
El
53
SEAT BELT SWI TCH
EL72
l
UTl I ElTl
OUT
I
I
I
SEL418
SEAi BELT WARNI NG
TI MER
Locati on
The seat belt
warni ng
ti mer
i s
locatedon
the
back
si de of the
dash
board
onthe
ri ght
si de
Referto
page
EL104
I nspecti on
After
about 6
secondl
SEL41
WARNI NG
CHI ME
Uc
bui lt I n
Locati on
The
warni ng
chi me i s located on
the back si de
of
thedashboard
on
the
ri ght
si de
I nspei ctloi l
Battery
w
Battery
w
SEL420
DI ODE
For
doorawltch
Locati on
The di ode forthe door
swi tch
i s
fastened to
body
hamess
wi th
tape
nearthe
i njecti on
block
ELECTRI CAL SYSTEM Wi per
and
Washer
WI PER AND WASHER
CAUTI ON
Before
starti ng
towork on
any part
ofelectri cal
system
di sconnect
battery
ground
cable
SCHEMATI C
WI NDSHI ELD WI PER AND
WASHER
Wi thti me
control
JC
FUSI BLE LI NK
FUSI BLE
LI NK
I
SA
TTERY
L
I
WI PER SWI TCH
11
WI PER
f
HI LO
I NI p
o
gg
8
JU
1r
OACC
fCON
OJ
I GNI TI ON
SWI TCH
1
o
c
rc
FUSE
I GNI TlON AND
ACCESSORY RELAY
I NTERMI TTENT
WI PER AMP
WASHER MOTOR
@
1
WI PER MOTOR
AUTO
RETURN
DEVI CE
SE
L422
EL73
Wi per
andWasher
ELECTRI CAL SYSTEM
WI RI NG
DI AGRAM
WI NDSHI ELD
WI PER AND WASHER
@f
R
@
FUSI BLE
LI NK
o
BATTERY
t
I
J
I
WR1
LB
B
BL
4
@
FUSE BLOCK
J
WI PER MOTOR
lo
@
M
L
I
I
I
Le
1
G
GL
I NTERMI TTENT
WI PER AMPLI FI ER
@
I t
i ll
I
G
ga
I
B
80
I LV
00 I LR
L
I
@
LW
WASHER
MOTOR
U
W
@
Ji @
EL74
I GNI TI ON
SWI TCH
OfF
i C i
r
rl
lG
0
P
I
Sf
0
I GNI TI ON
AND
ACCESSORY
RELAV
ld
O@
WI P
ER SWI TCH
WI
PER
W
ff
I NI lOHI
I
L
gg
LJ
T og9
lli fl
5I JO
l
OOO
LB
@j
LR
L
LV
LW
L
LI
@
@
@
Wi thti mecontrol
SEL423
TROUBLE
DI AGNOSES AND
CORRECTI ONS
Condi ti on
Wi ndshi eld
wi per
does not
operate
Wi ndshi eld
wi peroperat
i ng
speed
i s
tooslow
Mqtor
Power
supply
and
cable
Probablecause
Broken armature
worn
motorbrushor
sei zedmotorshaft
Blownfuse
Loose
open
orbroken
wi ri ng
I mproper
groundi ng
Swi tch
I
I mproper
swi tch
contact
li nk
Ci rcui t
breaker
Motor
Power
supply
and
cable
li nk
Swi tch
Ci rcui t
breaker
Wi ndshi eld
dotor
wi perspeed
9
n
not be
adjusted
correctly
c
c
0
v
900
2
c
e
0
0
u
Stops
any
where
Does
not
stop
Washermotor
does
not
operate
when
pushi ng
washer
swi tchon
Motor
dotor
Washermotor
operates
but
washerflui di s
not
ejected
Forei gn
materi al
i nterrupts
movement of
li nk mechani sm
Di sconnect li nk rod
Sei zedorrusted
armshaft
Faulty
ci rcui t
breaker
Short
ci rcui t
of motorarmature worn
motorbrush
orsei zed
motorshaft
Low
source
voltage
Hummi ng
occursonmotori nann
operat
i ng cycle
due
tosei zedarmshaft
I mproper
swi tchcontact
Faulty
ci rcui t breaker
Motorbrushforei therlow
or
hi ghspeed
i swom
Contami nated autoreturn relay cotacts
or
i mproper
contact due to
forei gn
mat
ter
I ncomplete
auto
return
operati on
Con
tact
i snot
i nterrupted
Bumt
fuse
Faulty
swi tch
Faulty
washermotor
Loose or
poor
connecti on contact at
motororswi tch
Clogged
washernozzle
ELECTRI CAL SYSTEM
Wi per
andwsher
Correcti ve
acti on
Replace
motor
Check
short ci rcui t
bumt
component
i n
si de motororother
part
for
operati on
andcorrect
problem
Correct
Correct
Correct
Correct
Correct
Lubri cate
or
replace
armshaft
Replace
ci rcui t
breaker
Replace motoror
lubri cate
beari ng
wi th
engi ne
oi L
Measure
voltage
check otherelectri cal
parts
for
operati on
andtake
correcti ve
acti on
for
powersupply
i f
necessary
Lubri cate
or
replace
Conduct
conti nui ty
test and
replace
i f
necessary
Replace
ci rcui t
breaker
Replace
motor
Remove
autoreturn
devi ce
cover
and
clean contacts carefully
soas not
to
de
form
relay plate
Remove autoreturn devi ce
Cover
and
correct
relay pla
e
bendi ng
Corre t
c useand
replace
fuse
Replace
Replace
Repai r
Clean nozzle
or
replace
EL75
Wi perandWasher
ELECTRI CAL SYSTEM
I ntermi ttent wi ndshi eld
w1p
The
si gn
for acti on
A Measure
voltage
across
posi ti ve
and
negati ve
termi nals of
i n
termi ttent
ampli fi er
wi tha
ci rcui t
tester
Condi ti on
Wi pers
do
not
operate
i ntermi ttently
but
operate
at
Lowand
Hi ghspeeds
I ntermi ttent
speed
i s
tooshort for
proper
wi pi ng
I ntermi ttent
speed
i s
too
long
for
proper
wi pi ng
Wi pers
do
not shut off
Wi pers operate i ntermi ttently
wi th
wi per
swi tchOFF
I ntermi ttent
speed
i serrati c
Wi pers
make
a
completewi pi ng
stroke
only
one
ti mewi th
wi per
swi tch
ON
but do
not
conti nue
operati on
Wi per
motori s
not i nterconnected when
washerswi tchi s
depressed
but i ntermi ttent
operati on
i s normal
Wi pers
donot make a
complete Wlpmg
strokewhen washerswi tchi sfI rst turnedon
andi s
qui ckly
turnedoff
EL76
B
Check
conti nui ty
of all
wi per
swi tch
posi ti ons
C Check
conti nui ty
of termi nals of
wi per
motor
wi per
swi tchand
Probable
cause
li ne
voltage
below10volts
Faulty
wi per
swi tch
Faulty
wi ri ng
Faulty
i ntermi ttent
ampli fI er
Faulty wi per
swi tch
li ne
voltage
too
hi gh
Faulty wi per
motor
Faulty
i ntermi ttent
ampli fi er
Faulty wi per
swi tch
li ne
voltage
below10volts
Faulty wi per
swi tch
Faulty wi ri ng
Faulty
i ntermi ttent
ampli fi er
Faulty
wi per
swi tch
Faulty
wi per
motor
Faulty
i ntermi ttent
ampli fi er
Faulty
wi per
swi tch
Faulty wi ri ng
Faulty
i ntermi ttent
ampli fi er
Excessi veli ne
voltage
fluctuati on
Faulty wi per
swi tch
Faulty
wi ri ng
Faulty
wi per
motor
Faulty
i ntermi ttent
ampli fI er
li ne
voltage
below10volts
Faulty
i ntermi ttent
ampli fi er
Poor
connecti ons
Faulty
i ntermi ttent
ampli fi er
Faulty
i ntermi ttent
ampli fi er
i ntermi ttent
ampli fI er
D Check
conti nUi ty
i n
wi per
motor
ci rcui t
E Altematoror
battery
i s
faulty
Correcti ve
acti on
A
Replace
i f necessary
B Correct
or
replace
i fneceuary
A e
Repai r
or
replace
i f
necessary
Replace
Replace
A
Replace
i f
necessary
D
Replace
i f
necessary
Repbce
Replace
A
Replace
i f necessary
B
Correct or
replace
i f
necessary
A
e
Repai r
or
replace
i f
necessary
Replace
Replace
D
Replace
i f necessary
Replace
B Conect or
replace
i f
neCessary
A e
Repai r
or
replace
i f
necessary
Replace
E Correct or
replace
i f
necessary
B
Correct or
replace
i f
necessary
A C
Repai r
or
replace
i f
necessary
D
Replace
i f
necessary
Replace
A
Replace
i f necessary
Replace
c
Repai r
or
replace
i f necessary
Replace
Repbce
ELECTRI CAL
SYSTEM Wi per
andWasher
WI NDSHI ELD
WI PER
Removaland I nstallati on
OJ
SEL319
CAUTI ON
Becareful
not
tobendli nkageduri ng
removal
I nspecti on
9
uL
urff
M
P
B
Motorshould
run
t low
speed
SEL321
Autoreturn
deVi cez
Stop
posi ti on
I
I i
M E
Motorshould
run
at
hi ghspeC
SEL322
EL77
Wi per
BndWasherELECTRI CAL
SYSTEM
WI PER
AND WASHER
SWI TCH
SE L323
Adjustment
20
10791
20
10
191
Uni t mmi n
SEL324
WI NDSHI ELD
WASHER
Washrnozzl
adJus
11018
69
i
11016
69
F
10013941di li
100
3
94
41
1
rPr1
I I
i
410116
141
1
10116
W
Uni t
mmi n
SEL325
EL78
Referto
Combi nati on
swi tch
I I nERMI
AMPLI FI ER
I C
bullt ln
WI PER
Locati on
The
i ntenni ttent
wi perampli l18r
i s
attached
tothe
relay
bracket Referto
page
EL105
I nepectlon
Be
careful
not toconnect
lead
wi r
to
i ncorrect te
mi nals
Connect
test lead
wi re
JI DECO
BE L326
2 Make sure
that
test
lamp
comes
oi lwhen
negati ve
lead
wi re
A i scon
nected
1
OnlY
ti me
controltYP
D
I
e
1
A
i
B
JI DECO
Test
lamp repeatedly
comesOD
SE 27
3
Di sconnect leadwi re
B
Test
lamp
should
go
out and come
back on
i na fewsecond
JI DECO
I
SEL 28
J
A
Only
ti me
li
controltype
1
FJf
JlDECO
I
I
SEL329
REAR WI NDOW
WI PER AND WASHER
r
SCHEMATI C
REAR WI NDOW WI PER
AND
WASHER
FUSI BLE
LI NK
I GNI TI ON SWI TCH
o
ACC
yC
ON
Osr
FUSI BLE
L1N
I
I
I
BATTERY
W
C Jo C
c
FUSE
I GNI TI ON AND
ACCESSORY
RELAY
ELECTRI CALSYSTEM Wi pe
and
Washer
REAR
WI NDOW
WI PER
MOTOR
REAR
WASHER
MOTOR
@
WI RI NG DI AGRAM
REAR
WI NDOW
WI PER
AND
WASHER
Eflf L
o
1
BATTERY FUSI BLE @
LI NK
Age
Off
J
D
ci
o
6
I G
I
o
S
LB
I GNI TI ON
SWI TCH
I
rc
B L
o 0 0
o
o
0
WR
r
o
FUSE
BLOC
J
Lvi
8
REAR WAS i ER
MOTOR
@
LB
to
o
U
5
L
CD
1P1
LB
REAR
WI NDOW
WI PER
ANOWASHER
SWI TCH
lw
RWI P
V
tlI a f N
I
1
i
b
0
J
L
@
L Y
LW
L
AUTORETURN
DEVI CE
WI
PER WASHER
ON
OFF
ON f
b
r
o
REAR WI NDOW
WI PER
AND
WASHER
SEL434
@
E3
Uf
W
LB
L
B
v
1
LB
W LW
L
19y
00
Lg
ru
0
REAR
WI NDOW
WI PER
MOTOR
I GNI TI ON
AND
ACCESSORY
RELAY
i
hl@
I
DcQ
L
@
LA
@
1@
SEL 35
EUll
WtperandWasher
ELECTRI CAL
SYSTEM
REAR
Wlfi i DOW
WI PER
RemovalandI nstallati on
r
u
i
U
7
t
1
i
i
SEL367
I
spectlon
0
I
j
I
i
t 1
J
I
B
I Oreturndevi ce
t
Stop posi ti on
BXP
S
E
1
I nspecti on
REAR
WI NDOW
WI PER
SWI TCHAND WASHER
SWI TCH
Washeron
Autoreturn
Wi r
EL80
S
PE
SEL332
r
I
Washer
I
Wi per
I OFF ON
OFF
I
ON
I
X
ttl
SE
L336
ELECTRI CAL SYSTEM Electri calAccessori es
ELECTRI CAL
ACCESSORI ES
CAUTI ON
Before
muti ng
towork on
any part
of electri cal
system
di sconnect
battery
ground
cable
REAR WI NDOW
DEFOGGER
SCHEMATI C
REAR
WI NDOW
DEFOGGER
oc
FUSI BLE
LI NK
oc
FUSI BLE LI NK
I BATTERY
L
I
Ace
c
O
ON
I GNI TI ON
SWI TCH
L
I GNI TI ON
AND
ACCESSORY
RELAY
wu
Q
C
REAR WI NDOW
00DEFOGGER
FUSE
@
1
MON I TOR LAMP
DEFOGGER
1
SWI TCH
00
SEL436
WI RI NG DI AGRAM
REAR WI NDOWDEFOGGER
i J
i
g
R
FUSI BLE
LI NK
BATTERY
0 I
I
FUSE
BLOCK
I GNI TI ON SWI TCH
WR
BW
I I
14
@
I GNI TI ON AND
ACCESSORY RELAY
@
I
W
I
WB
BW
Ji
J
LB LB
@
@
r
li
@
gg
Whi te
8
e
o
00
t4LB
e
LB
L
L
e
Ble
@
L
Whi te
J
00
B
0
LB
J
co
LB
00
@
d
gg@
LB
@
@
cJ@ocr
i J
@
2
4
190I
1
DEFOGGER
i N
SWI TCH
e
8
rl
REAR
WI NDOW
DEFOGG
ER
COMBI NATI ON
METER
@
J
1
@
2
MONI TOR
LAMP
rD@
i @
B
SEL437
EL81
Elli Ctri calAccessori es
ELECTRI CAL SYSTEM
REAR
WI NOOW DEFOCCER
SWI TCH
I nspecti on
12
ON
0
0
OFF
SEL338
REAR WI NDOW
DEFOGGER
FI LAMENTS
I nspecti on
I
Attach
probe ci rcui t tester i n
volt
range
tomi ddle
porti on
of each
fi lament
H
r
m
j
Z
I
V
6Volts normllfi lam nt
SEL 263
ELB2
2
I f
a
mai ri eni i s
burned
oi ll
Ci rcui t
tester
regi sters
0
or
12
volts
H
lffl
V
12Volt
SEL264
1 1 H
rTI
l
I V
aValt
E l265
3 To
locate
burnedout
poi nt
move
probe
toleft
and
ri ght
along
fi lament
todetermi ne
poi nt
wheretesterneedle
swi ngs
abruptly
J
1
1M
0
j
VJ
SEL266
FUament
mai ntenance
Repai r
equi pment
1 Conducti ve
si lver
composi ti on
Dupont
No4817 or
equi valent
2 Ruler
30em 12i n
Jong
3
Drawi ng pen
4
Heat
gun
5 Alcohol
6Cloth
Repai rpI
L
I
Wi pe
broken heat wi re and
i ts
surroundi ng
area clean wi th
a
cloth
dampened
i n
alcohol
2
AppJy
snui llam
tof
c duc
ti vesi lver
composi ti on
to
ti p
of draw
i ng
pen
Shake
si lver on
contai ner
beloreuse
3 Place ruleron
glass along
broken
li ne
Deposi t
conducti ve si lver
com
posi ti on
on break wi th
drawi ng pen
Sli ghtly
overlap exi sti ng
heat
wi re
on
bothsi des
preferably
5
mm
0
20
i n
ofthebreak
00
Heat wi re
reak
1
Lf
Drawi ng pen
Uni t mm i n
eE540
4
Wi pe
clean si lver
composi ti on
from
ti p
of
drawi ng
pen
5 After
repai r
has been
completed
check
repai red
wi re
for
conti nui ty
Thi s
chck should be conducted 10
mi nutes aftersi lver
composi ti on
i s
deposi ted
Donot
touch
repai red
rea
whi le
test
i s
bei ng
conducted
6
Apply
a constant streamof hot
ai r
di rectly
tothe
repai red
area for
approxi mately
20mi nutes wi tha heat
gun
A mi ni mum di stance of 3em
12 i n should be
kept
between re
pai red
area andhot
ai r
outlet I fa heat
gun
i s
not avai lable
let
the
repai red
area
dry
for24hours
REMOTE
CONTROL DOOR
MI RROR
SCHEMATI C REMOTE CONTROL DOOR MI RROR
FUSI BLE
LI NK
FUSE
DOOR MI RROR
SWI TCH
R H
1
I
BATTERY
L
i
DOOR MI RROR
Removaland I natallatlon
Remove doormi rror
securi ng
bolt
anddi sconnect harness connector
S L442
I
I
R l
I
u 0
0000
9
0
uO
10
0
0
0
OQ
r@
DOOR MI RROR RH
ELECTRI CAL
SYST
M
Electri calAccessori es
1
DOOR MI RROR SWI TCH
I nspecti on
4
5
a
1
R L U 0
I
11
9
I
I
I
I
0
1
I
I
6
c
I I
15
J 0oJ
I
EL444
DOOR MI RROR
SWI TCH
LH
I
R l
U
0
oOOob
J
00
bo
0
i
I QO
r@
DOOR
MI RROR L
H
SEL440
o
Ell8J
Electri cal
Accessori es
ELECTRI CAL SYSTEM
WI RI NG DI AGRAM
REMOTE
CONTROL DOOR
MI RROR
9
rrR
@
o@w
FUSE BLOCK
1
BATTERY
DOOR MI RROR
SWI TCHLH
DOOR MI RROR
SWI TCHR H
RLUD
RLI UD
rU
U
r
tJ
a
@
a
r11
CJ
t
CO
5
I
I
CO
I
I I I
@
I I
a
Clco
i
@
rm
i l
@
rTI l
i i l
R
J
I I I
DOOR
MI RROR
RH
DOOR MI RROR
LH
SEL441
ELB4
aOCK
SCHEMATI C
CLOCK
Di gi tal
L
l
C
FUSI BLE
LI NK
T
BATTERY
I
L
I
rJ
FUSI BLE
LI NK
ELECTRI CAL SYSTEM
Electri cal
Accessori es
I GNI TI ON
SWI TCH
C
ACe
o
OST
FROM
LI GHTI NG SWI TCH Day
li ght bri ghtness
selecti on for
di gi taldi splay
DI GI TAL CLOCK
Adjustment
SELECT knob
Depress
the SELECT knob and
di splay
wi ll
project
HOUR MI N
MONTH
DAY
and M1N SEC
i nthat
sequencec
ADJUST knob
To
adjust
the
ti me
fust select
HOUR
MI N
wi th SELECT
knob then use the ADJUST knob
i n
the
followi ng manl
er
Turn i t counterclockwi se for
hour
adjustment
Turn
i t clockwi se formi nute
adjustment
Push
i t
to set the
ti me
tothe
nearest hour
For
example
when
adjusti ng
the
ti me for1000fi rst set
the
ti mebe
tween 9
30and
1029 Then
push
the knob
si muJt usly
wi ththe
annou lcement
of 1000
To
adjust
the
day
fi rst select
MONTH DAY wi ththe SE
LECT knob then tum the AD
JUST
knob counterclockwi se for
MONTH
adjustment
orclockwi se
FUSE
a
5
FUSE
s
0
u
I I
I n
I Ll
I I
LI
1
SEL438
forDAY
adjustment
To
adjust
the current mi nute
and
second select MI N SEC wi ththe
SELECT
knob and
depress
the
ADJUST knob toset the ti me
to
0000
When the
battery
cable
i s detached
and rei nstalled the
di splay
wi llauto
mati cally
returnto1200
EL85
Electri calAccessori es ELECTRI CAL SYSTEM
WI RI NG
DI AGRAM
CLOCK
EL86
@I 1ll
D
FUSI BLE
LI NK
WR
W
BATTERY
I
1
WR
LB
ST ON lCCOff
000
B
J
00
8
b
I
I GNI TI ON
SWI TCH
I
J
W
W
u
iw
CI
I J
1
@
j
J
I
J
L
j@
Green
J
j
Whi te
1I i 00
0L
01
O@
L
@
TOL1GHT
SWI TCH
@
li OOOOI I O
ho
oooo o
@
J
I
@
e
@
L
@
o
g
COMBI NATI ON
METER
H
G
J
3
2
4
HORN
SCHEMATI C HORN
1
f
FUSI BLE
LI NK
SATTERY
I
WI RI NG
DI AGRAMHORN
r
8
0
BATTERY
HORN
RELAY
D
G
r
@
HORN RH
@G
HORN
LH
0
FUSE
ELECTRI CAL
S
YSTEM EI ectncal
Accessori es
Surge
ki ller
HORN
RELAY
I
o
C
1
HOr
B
TN
1
Q
HORN
Q
HORN
SEl445
6Bfl
gW
LI NK
@
i
@
f
I
lD
BG
FUSE BLOCK
1
a
J
I
l N
D
@l
l
3
I
U
HORN BUTTON
0
I
COMBI NATI ON
SWI TCH
2
SEL446
EL87
Electri cal
Accessori es ELECTRI CAL SYSTEM
TRoUli LE DI AGNOSES AND
CORRECTI ONS
Condi ti on Probable
cause
Nei ther
hi ghnor
low
horn
operates
Burnt fuse
Faulty
hombutton contact
Hom
sounds when
CD
termi nalof
i nstru
ment
harness
connctortocombi nati on
swi tchi s
grounded
Faulty
hom
relay
Homsounds when
@
and
@
termi nals of
engi ne
harness tohorn
relay
are connected
wi tha test lead
i ncludi ng
lOA fuse
Looseconnecti on
or
open
cfrcui t
Hi gh
Lowhorn
doesnot
operate
Faulty
horn orloosehom
termi nalconnec
ti on
Breaki nwi re
tohorn
Horndoes
not
stop
to
sound
Short ci rcui ted
horn button andorhom
button leadwi re
When i ns1rument harness i s
di sconnected
fromcombi nati on
swi tchhorn
stops
sound
i ng
Faulty
hom
relay
Reduced volume
and
ortone
quali ty
Looseor
poor
connectorcontact
Fuse
relay
horn
and
orhorn button
Faulty
homo
HORN
I nspecti on
rJ
@CD@
HI to
SEL340
HORN RELAY
Locsti on
The horn
relay
i s
locatedbeneath
the
relay
bracket Referto
page
EL
105
Battery
EL
88
Correcti veacti on
Correct causeand
replace
fuse
Repai r
hornbutton
Replace
Check
wi ri ng
and
or
repai r
connecti on
Correct horn termi nalconnecti on
or
replace
horn
Repai r
Repai r
hornbutton or
i ts
wi ri ng
Replace
Repai r
Replace
HORN BUTTON
The
horn button
i s
attached
tothe
combi nati on
swi tch Referto
page
EL39
AUDI O
SCHEMATI C AUDI O
E
LI NK
BATTERY
I
L
DOOR SPEAKER
R H
DOOR SPEAKER LH
SCHEMATI C POWER ANTENNA
1
FUSI BLE LI NK
BATTERY
I
L
RADI O
I GNI TI ON
SWI TCH
C
ACC
CON
OST
ELECTRI CAL
SYSTEM
Elecrri cal
Accessori es
y
OST
I GNI TI ON
SWI TCH
m
I
000000
6
J01
V
t
POWER ANTENNA
SWI TCH
I
u N
0
o
FUSE
0
0
u
I I
OeCK
REAR
SPEAKER R H
I I
E
REARSPEAKER LH
SEL447
l
ft
POWER
ANTENNA
3
MOTOR
SEL449
EL
89
Electri cal
Accessori es
ELECTRI CAL SYSTEM
WI RI NG
DI AGRAMAUDI O
ffi h
o
BATTE Y
U
FUSI BLE
LI NK
Sf
o
LW
i llY
4YJ
LyR
B
I
a
I
J 001
I Blue
I
a
m
a15i
J 0
t
J
DOOR
SPEAKER
LH
I I
I I
I
YUi
U
@
@
I rml
9
00
FUSE
RADI O
EL90
DWR
@
Block
J
lgW J
I
v
LR
LB
@
i
l@
I
L
Green
0000
000000
@
@
DECK
REAR
SPEAKER
R
H
1J
I
@
@
I
I
tk@Y @
m
rT
REAR
SPEAKER
L
DOOR
SPEAKER
R H
SE1448
ELECTRI CAL
SYSTEM Elecrri calAccessori es
WI RI NG DI AGRAM
POWER ANTENNA
1
BATTERY
re I
I GNI TI ON
SWI TCH
ST ON ACC Off
I
8
g
J
I
FUSI BLE
LI NK
GD
ftWR
@
mtl @
1
1
WR
LBi
FUSE BLOCK
s
L
n
@
J I l
li
Whi te
@
I fg lI gg1gi tl
Whi tel@
i ll
I
s
s
Ql
0
a
cO
@B
I
I
i
nht
0
Bluel
Green
000000
@
1
1I 000i ll
lI t
o
@
I I
I
CD
CD
@L1f3J
I
U N
D
I g
POWER
ANTENNA
SWI TCH
I
s
I
I
s
RW
B W
s
c
a
w
@
@
@r
POWER
ANTENNA
MOTOR
SEL450
EL91
Electri cal
Accessori es
ELECTRI CAL
SYSTEM
RADI O
RemovalandI nataUatlon
Pri orto
removi ng
radi oand
sound
balancerremove
clusterli dC
I nspecti on
POWER ANTENNA
Feeder
cable
routi ng
Antenna
tri mmer
adjustment
The antenna tri mmer
should be
adjusted
i n
the
followi ng
cases
Fadi ng
and
weak AM
recepti on
Mteri nstallati on
of
n
wantenna
feedercableorradi o
recei ver
Before
adju i ngt
be sure tocheck
harness and
antenna
feeder
cable
con
necton
for
proper
connecti on
1
Extendantenna
completely
2 Turn radi oon andturn volume
controlto
i ncrease
speaker
volume
3 Tune
i n
theweakest sta1i on
bare
ly audi ble ondi alat the
range
around
14
1 400kHz
4
Turn antenna tri nunertoleft or
ri ght
slowly
and set i t i n
the
posi ti on
where
recepti on
i s
strongest
Alway
route
feeder
cable
away
from
otherharne
EL92
SEL4S3
CAUTI ON
00
not turn antenna tri mmermore
than one half turn
J
t
SEL346
HI 4
rl3C
kQTY
OI lUl
I
f
1
c
74654
CI OST
YEO
u s YAX
T S I PI
5
n
c
O
I
CT
DJO
Q
l
f
O o
E
SC
R
I P
T
I O
N
r
r
r
s
20082
20081 Combi ned 1I I lI DtJ81
80
D271
26 9 c
ANY I TEMS NOT SHI PP ARErI MMED1ATELY BACKORDERED NO
CLAI MSAI WED UNLESS
MADE
WI THI N
10DAYS FROMDATE off I NVOI
CErfoUNAUTHORI ZED RETURNS
ACCEPTED
Thi S i sto
rti ty
that the
900ds
herei n
were
produced
I n
omplli lnce
wi thall
provi si ons
of theFai rLaborStandards Act of 1938
amended I t i s
I ntenti on
o
amply
ndthe
pri ces
here I nvoi ceddo
comply
to
tJ1e
best
of
knowledge
wi th
sti ng pri ce egulati ons
SHI PPI NG 114l
Power
antenna
motor
I I
Securely
ti ghten
antenna
groundi ng
bolts
SE L348
ELECTRI CAL SYSTEM Electri calAccessori es
CAUTI ON
Donot allowmotorto
keep
runni ng
when antennarod i s
fully
extended
or
retrected
Power
antenna swi tch
The
power
antenna
swi tch i s
locatedon clusterli d
C RefertoBF
secti on
v
@CD
i
SEL349
TROUBLE
DI AGNOSES AND
CORRECTI ONS
I
Fadi ng
andweak radi o
recepti on
Check feedercable
connecti ons
O
Kl
N
G
I
Connect
or
repai r
Noi sy
radi o
recepti on
1
Stop engi ne
andturn
off
all
other
I
swi tches
Revi sed
1
I
Check
i gni ti on
cables
O
KJ
I
N G
I
T
gh
I 1 ten secure
y
OK
l
Check antenna
ground
Adjust
antenna tri mmer
O
Kj
Replace
radi o
Revi sed
1
Faulty
radi o
Check
noi se
preventi onparts
Condenser
bondi ng
wi re
O
Kl
Check
spark
plugs
O
K
I
Faulty speaker
Unchanged
O
K
Check
feedercable
routi ng
Replace
radi o
Revi sed
Faulty
radi o
I
Unchanged
NOI SE PREVENTI ON
PARTS
Condenser
I gni ti on
coi l
Alternator
Bondi ng
wi re
Body
to
engi ne
rockercover
See Fadi ng
and
weak
recepti on
Unchanged
I
N G
Replace
Reti ghten
or
replace
N
G
Replace
N G
Repai r
N
G
I
Faulty speaker
EL
93
Automati c
Speed
ControlDevi ce AS C
D
ELECTRI CAL SYSTEM
AUTOMATI C
SPEED CONTROL DEVI CE AS C D
CAUTI ON
Before
starti ng
towort
on
any part
ofe1ectri cel
system
di sconnect
battery ground
ceble
DESCRI PTI ON
The
Automati c
Speed
Control
Devi ce
subsequently
referred toas
A S C D i a combi ned uni t of
electroni c ci rcui ts
wi th
vacuum me
chani sms
SCHEMATI C
A
S
C D
Theconstructi on
ofthi s
system
and
the
locati on
of each
component part
are
shown
on
page
ELI 04and105
The
ASC D controller
generates
an
electri cal
si gnal
equi valent
tothe
di fference between the
preset
speed
and theactual
speed pi ckedup
by
the
speed
sen or
The rvo
valveconvertsthi s
si gnal
i ntocorre
pondi ng
vacuumand
oper
ates the actuatorwhi ch
adjusts
the
throttlevalve
openi ng
I GNI TI ON SWI TCH
ON
r
OFF
@
I
ON
rc Y
FUSI BLE LI NK
YL
FUSI BLE
LI NK
BATTERY
FUSI BLE LI NK
cY C
1
I
OACC
I
Y
g
r
L
MAI N SWI TCH
Neutralxmti on
I
ll
RELAY
EJ
STOP
LAMP
SWI TCH
I I
STOP
SWI TCH
8
o 0
I NHI BI TOR
RELAY
I NHI BI TOR
SWI TCH
EL94
FUSE
I
I
FUSE
YO
I GNI TI ON
AND
ACCESSORY RELAY
TO
LI GHTI NG
I
SY
TE
SOLENOI D
VALVE
l
CRUI SE
@
L
TO
ACl JATOR
I NTAKE
MANI FOLD
SERVO
VALVE
rI
SET
SWI TCH
I Q
OPEN
CLOSED
CONTROLLER
t
THROTTLE
LEVER
SPEED
I
SENSOR
SELAOO
r
FUNCTI ON AND OPERATI ON
M
ln
swttch
Themai n
swi tch
has
a
holdi ng type
ofci rcui t
When the
mai n
swi tch
i sturnedON
wi lh lhe
i gni ti on
swi tch
ON
lhe
exci ti ng
coi l
of
therelay
wi llbeener
gi zed
and therelay
wi llturn ON lhus
supplyi ng
current to lhe
system
Although
themai n
swi tchautomati cal
ly
retums to
i ts
ori gi nal
posi ti on
the
current i s
sent
through
lhe
relay
and
fed
to
the
exci ti ng
coi l
vi a
lhemai n
swi tch
i n
thi s
way
lhe
relay
wi ll
remai n ON When the
i gni ti on
swi tch
i s tumed
off lhe
relay
wi llalsoturn
off And
the
relay
wi llremai n
i n
operati ve
unti llhe
mai n
swi tch
i s
turnedON even i fthe
i gni ti on
swi tch
i s set toON
S
t
swttch
The
set swi tchhas an ON OFF
swi tch
type
ofci rcui l
When the set swi tch
i s
depressed
lhe CRUI SE
li ght
i llumi nates
Wi lh
TROUBLE
DI AGNOSES
TEST CONDI TI ONS
I fa malfuncti on
i s
found
besure
tocheck lhe
followi ng
before
perform
i ng
the
system
tesl
I All
wi ri ng
harness
connectors
must be
securely
connected
ELECTRI CAL
SYSTEM Auramati c
Speed
Control
Devi ce AS
C
D
lhe swi tch
depressed
lhe controller
cancels the
preset
car
speed
The controllerwi ll
preset
lhe car
speed
at
whi chlhecar
i s
runni ng
when
theswi tchi s released
Speed s
nsor
Contaln dI n speedom
t r
The
speed
sensor
i s
generati ng
two
pulses per
revoluti on of the
meter
cable
The
output
voltage range
andlhe
duty cycle
must be
controlled
prop
erly
S ryoy ly
TransdUcr
The servovalve causes thevacuum
valveand
atmospheri c
valveto
open
or
close
accordi ng
tothe
i nput
current
and
adjusts
the
vacuum
from the
i ntakemani fold
Controllr
The
controller
compares
the
preset
speed
wi th
the
actualcar
speed
and
mai ntai ns the
preset speed
by
i n
creasi ng
or
decreasi ng
the
current
flowi ng through
theservovalve
2 A S
C
D
cable
must be
securely
i nstalledwi th
proper
adjustment
3
Vacuum
hoses must be
properly
attachedwi lhno
abnorrri alcondi ti ons
such
as vacuum
leakage sharp
bends
orki nks
R I
y ly
The release vve i s
lhe
safety
valve wli i chshutsoff
the
atmospheri c
passage
to
lhe
vacuum
li ne
when the
system
acti vates
Actu
tor
The actuatorcauses i hethrottle
to
open
and close
by
vacuum
through
lheservovalve
Stop
wttch
The
stop
swi tch
i s used
torelease
lhe
system
When
thebrake
pedal
i s
depressed
thi s swi tchcuts off
lhe
powersupply
to
theA S
C D
ci rcui l
Stop
I
mp
swi tch
Thi s swi tchcauses
the
stop
li ght
to
operate
At thesame
ti me the
oper
ati ng
si gnal
of the
stop
li ght
ci rcui t i s
sent tolhe
controller
i n
ordertore
leasethe
system
I nhi bi torr
lli y
The i nhi bi tor
relay
releases
the
AsC D
system
when the
selectori s
set toN or
P
posi ti on
DI AGNOSI S
WARNI NG
All
followi ng
system
tests can be
performed
wi thoutrunni ng engi ne
Avoi d
maki ng
test
whi le
dri vi ng
car
or
runni ng engi ne
I ndi cator
li ght
wi llnot
glow
even
i f ON buttonof
mai nswi tchi s
depressed
wi th
i gni ti on
swi tchON
1
Burnt
bulb Faulty
mai n
swi tch
L
Faulty
A S C D
relay
EL
95
Automati cSpeed
Control
DBVi ce
A
S
CD
i
ELECTRI CAL
SYSTEM
r
Crui se
li ght
wi llnot
glow
eyen
i f let swi tch
i s
depressed
andreleased 81
proper
car
speed
wi thmai n
swi tchON
Speed
not
set
i n
system
1
1
Wi thmai nswi tch
ON
battery
voltage
12V
i s
present
between
termi nals
@
and
V
of
harness
conn
ector
Set automati c
transmi ssi on
selector
lever
at
any
posi ti on
other
than
I p and
INW posi ti on
YES
to
Open
ci rcui t
I
Faulty
or
unproperly
adjuSted
stop
swi tch
When set swi tch
i s
depressed
wi thmai nswi tch
ON
battery
voltage
12V
i s
present
between
termi nals
@
and
V
ofhamess connector
YES
1
NO
Faulty
set swi tch
Wi thmai n
swi tchON
manually
rotatemetercable
slowly
Con1i nui ty
between termi nals
CD
and
@ofharness
connectorexi ststwo
ti mesa
rotati on
YES
1
to
Faulty
controller
Faulty speed
sensor
EL96
Faulty
i nhi bi torswi tch
ELECTRI CAL SYSTEM Automati cSpeed
ControlDevi ce AS
C D
Crui se
li ght
i llumi nates
when
speed
setti ng operati on
i made
but
peed
i s
not actually
set
When
battery voltage
12V
i s
appli ed
tothe
releasevalve
termi nalthe
followi ng
are
possi ble
1
Wi th
A closed nosucti oni s
possi ble
at B
2 Wi th A
opened
sucti oni s
begun
at B
YES
to
Faulty
releasevalve
I t
Servo
valve
operates
normally
Referto
ServoValve
for
I nspecti on
YES
1
NO
Faulty
servovalve
Actuator
operatessmoothly
when
actuator
vacuum
port
i s
sucti oned
TI ti s
operati on
must
be
performed
wi th
A
S CD cablereleased
YES
1
Faulty
controller
lNO
Faulty
actuator
tl
LL
I
LJ
A
To
servo
valve
1
I
To
actuator
B
BE089D
EL97
Automati c
Speed
ControlDevi ce A
SC
D
ELECTRI CAL SYSTEM
OthermaHunctlon
Condi ti on
Set
speed
i scancelled
Pulsati onofset
speed
Excessi ve
setti ng
error
Speeddropsi mmedi ately
after
setti ng
Probablecause
Bent
metercable
excessi ve
meterneedI e
deflecti on
Faulty
controller
Excessi ve
play
or
bi ndi ng
of A S C D
cable
Leakage
or
cloggi ng
i n
vacuumhose
Bi ndi ng
i nactuator
Faulty
servovalve
Faulty
controller
Excessi ve
play
or
bi ndi ng
i n AsC D
cable
Leakage
or
cloggi ng
i nvacuumhose
Faulty
actuator
Faulty
servovalve
Faulty
controller
Faulty speed
sensor
Excessi ve
play
i nA
S C
D
cable
Leakageor
cloggi ng
i n
vacuum
hose
Faulty
release
valve
Faulty servo
valve
Faulty
controller
Cancelci rcui t
i noperati ve Faulty
controller
EL98
Correcti veact on
Check and
repai r
metercable
orrenew
cable
Renew
Adjust
Check
and
repai rpi pi ng
route orrenew
hose
Renew
actuator
Renewservovalve
Renew
controller
Readjust
Check and
repai r
pi pi ng
route
orrenew
hose
Renewactuator
Renewservovalve
Renewcontroller
Renew
speed
sensor
Readjust
Check
and
repai rpi pi ng
route orrenew
hose
Ren w
rele valve
Rene y
servo
valve
Renewcontroller
Renewcontroller
ELECTRI CAL
SYSTEM Automati c
Speed
Control
Devi ce A S C D
COMPONENT
PARTS
VACUUMROUTI NG
Adjusti ng
nut
Lock nut
o
f
I
Actuator
Tovacuum
check
valVe
Ai rcondi ti oner
equi pped
model
ToFI CD
SEL392
EL99
Automati c
Speed
ntrol
Devi ce
I A
S
C
D
ELECTRI CAL
SYSTEM
Wi lti NG OI AGRAM1A
S CO
f
TT ffi
FUSI BLE
LI NK
W
I GNI TI ON ANDACCESSORY
RElAY
lJWR
rD
t3@
@
J
1T
B
WR
5T
ON
ACC
Off
J
t g
g
I
sl
o
s
tf
I GNI TI ON TCH
r
W
we
o 0
QI
FUSE
0
BLOCK
STcp LAMP
1
SWI STeP SWI TCH
C1
SET SWI TCH
RELEASE SERVO
LU
v V E
A
S C
D
CONTROLLER
I
r
I
I I @
jG
I
J a
J
CD a
J CD
a C a
J
I
I
i
1
W
@
VB
A5CD
f
@
m
I
I NHI BI TOR
RELAY
@
YL
I
@
@
I
I
L
BL
1
i
m
vn
I
lOr
LgB
J m
l@
@
i J
1
m
J
CD
C C
@
I
@
l
I
W
@
XI
Cl
I I I
11
1
0
J
AS
C
D
MAI N
SWI TCH
EUOO
m
Cl
W
Whi ts
171
Y
@1r
I
SPEED SENSOR
SEL3M
A S C D CABLE
Removaland I natallatlon
I
Di sconnect cable fromactuator
1
Loosen
locknut at actuator
2
Remove
rubber
boots
1 Actuator
2 Rubber
boot
3 Cable
4
Locknut
2
Loosen lock
nut at i ntake mani
foldbracket
3 To
i nstallthe cable
reverse
the
orderofremoval
Exerci se care when
removi ng
and
i nstalli ng
wi re soas not
to
deform
wi reend
Adjustment
When i nstalli ng adjust
A
S C
D
cable
as follows
Wi thout
depressi ng
the
accelerator
pedal
adjust
the
adjusti ng
nut
unti l
cablefree
play
i swi thi n
speci fi ed
value
at
throttle
lever
Then
ti ghten
lock nut
Free
play
23m
008
012i n
Donot i nc
ease
tensi on of cable
excessi vely as
thi s
may
causethrottle
lever
to
rotate
ACTUATOR
Removaland
I nstallati on
I
Di sconnect
battery ground
cable
2
Di sconnect cable
from
actuator
Referto
A
S C
D
cable forreo
moval
3
Di sconnect vacuum
hose from
A
S C D release
valve
4
Remove bolt
attachi ng
actuator
to
body
5 To
i nstall
actuator
reverse
the
orderofremoval
ELECTRI CAL SYSTEM
Automati c
Speed
ControlDevi ce AS C D
I n
ectlon
I
Vi sually
check
actuatorfor
dam
age
Or
deformati on
2
Make
sure
that actuatormoves
smoothly
wi thout
bi ndi ng
when di a
phragm
i s
pushed
by
hand
3
Apply
vacuum
to actuator
I f
di aphragm
movesto
full
posi ti on
i t i s
normal
Plug hose wi th
vacuum
appli ed
Make sure
that
act laJor
remai nsi nfull
posi ti on
BE100D
CAUTI ON
When
checki ng
actuator
by applyi ng
vacuum donot
apply engi na
vacuum
di rectly
RELEASE
VALVE
Locati on
Referto
page
EL
99
I n
cti on
1
Measure the
resi stance between
termi nals
Ci rcui t tester
i ndi cati on
25
30n
2
Check tobe
sure
that thevalve
opens
or
closes
by blowi ng
ai r
through
port
onactuatorsi de
Battery 12V
1
Actuatorsi de
2 Seri ovalve si de
3
Atmosphere
si de
I
CD
n
ZP
S
E
L409
I
Normalcondi ti on
Check
ports
Ai rflow
CD
V
CD @
Yes
V
@
2 12V
di rect
current
i s
appli ed
be
tween termi nals
Check
ports
Ai rflow
CD V
Yes
CD @
No
V
@
SOLENOI D
VALVE
Locati on
Referto
page
EL
99
I n
ctlon
1
Measure
the resi stance
between
termi nals
Ci rcui t testeri ndi cati on
25 30n
2 Check to
be sure that
output
vacuumof
valvei s
proper
Thi s check
should be
performed
wi ththevalve i nstalledon
car
CAUTI ON
Wi thservovalve
connected to
system
donot
apply
current to
servo
valve Be
suretodi sconnect solenoi dvalvesi da
vacuumhose
i
Di sconnect
solenoi d valve si de
vacuum hose at solenoi d valve
and
connect vacuum
gauge
2 Start
engi ne
andwarm
up engi ne
unti lwater
temperature
i ndi cator
poi nts
to
the
mi ddleof
gauge
3
Apply O3A di rect current be
tween tenni nals
Usi ng
about
20n5W
vari able
resi s
tor
adjust
sothat
a
current
of 0
3A
wi llflow
EL101
Automati c
Speed
Control
Devi ce
AoS
CO
ELECTRI CAL SYSTEM
Vari able
resi stor
I I
Ammeter
O3A
I r
l
Battery
12V
SPEED
SENSOR
Lead
swi tchtype
Locati on
The
speed
sensor
i s
bui lt
i nto
the
speedometer
I nspecti on
I nspecti on
must
be made wi th
speed
sensori nstalledto
speedometer
TurDi ng
speedometerSlowlY by
hand test
conti nui ty
of
speed
sensor
ci rcui t
Conti nui ty
exi ststwoti mes
a
turn
OK
A
nro
9JD
EL
102
0
I lL
I
I
I
l
Servovalve
MAI N
SWI TCH
e
Yacuumgauge
1
I I
7
3 11 3kP
55 85
mmHg
2
17 3
35
i nHg
Solenoi dvalve
si de
Toi ntake
mani fold
BE730D
I nspecti on
Test
conti nui ty through
swi tchor
f
2Er
Swi tch
posi ti on
Checktermi nal
Q @
Q @
@
@
I D @
@ j
@ j
li ght
wi thanohmmeteri n accordance
wi ththe
followi ng
chart
l3
I
I Off
I I
li eAulSE
CI N11lfi
I l
OND
1I l1
SEL424
Normal ON OFF
No Yes
No
No Yes
No
Yes Yes No
Yes
Yes
Yes
Yes
Conti nui ty
shouldexi st
No
Conti nui ty
shouldnot
exi st
SET
SWI TCH
I nspecti on
Test
conti nui ty through
swi tch
wi th
an
ohmmeter
r
NORMAL
PUSH
1
OPSTI ON SWI TCH
11
9
12
6
SE L425
STOP SWI TCH
I nspecti on
Test
conti nui ty
through
swi tch
wi thanohmmeter
NORMAL
POSI TI ON
f
11
9
126
@
PUSH
PLUNGER
SEL431
Adjustment
Adjustment
of the
stop
swi tch
i s
thesameasthe
stop lamp
swi tch
RefertoMA
secti on
STOP
LAMP SWI TCH
I nspecti on
Roferto
page
El
sO
ELECTRI CAL SYSTEM
Automati c
Speed
ControlDevi ce AS C D
Adjustment
RefertoMAsecti on
A S C D
RELAY
Locati on
The
A
S
C D
relay
i s
located
on
the
relay
bracket
Referto
page
EL
105
I NHI BI TOR
RELAY
ForA S C D
Locati on
The i nhi bi tor
relay
i s
located on
the
relay
bracket Referto
page
EL
105
I nspecti on
a
r
c
1
@
@
a
0
o
t
LI
Gr
@
SEL433
Checktermi nals
Normalcondi ti on
l2Vdi rect current i s
appli ed
between
termi nals
@and@
@
@
CD
@
@
@
Yes
Yes
No
No
Yes
Yes
Conti nui ty
should
exi st
No Conti nui ty
should
not exi st
A
S C D CONTROLLER
lC
bui lt I n
Locati on
The
controller
i s
locatedon
theleft
dashsi de
panel
Referto
page
ELI 04
I nspecti on
Controllermust not bechecked
as a
si ngle
part
Check
controllerfor
opera
ti on
as a
system
referri ng
to
Di ag
nosi s
CAUTI ON
Do
not
touch
theci rcui t
tester
probe
to
eny
unnecessery
termi nalon con
troller
Doi ng
so
couldcause
damage
to
controller
a
Handlecontroller
carefully
toavoi d
damage
b
Keep
controlleraway
fromelectri c
noi se
source
to
prevent
A S C D
system
from
malfuncti oni ng
andI e
ci rcui t etcfrombei ng degraded
EL103
Electri calUni t Locati on
ELECTRI CAL
SYSTEM
ELECTRI CAL
UNI T
LOCATI ON
I gni ti on
ari d
accessory
relay
sea
tbelt
ti mer
HI
control
uni t
I
to C
v
SEL432
EL104
cJ
EFI relay
relay
l
Fuel
pump
A S
C D
relay
I I I
I
@
Headlamp
sensor
I nhi bi tor
relay
I ntermi ttent wi per
ampli fi er
Hatchback
lamp
nso
I
Tai 1
and
stop
I
Uni t
Locati on
M Electrlca ELECTRI CAL SYSTE
Ai rcondi ti oner
relay
alve Ai rcon
Magnet
v
H
7
lardtop
114
p
sensor
Tai l
nd lam
EL105
Wi ri ng
Harness
ELECTRI CAL
YStEM
WI RI NG HARNESS
CABLE COLORS
Cable colors
are
generally
used as
shown
i n
the
followi ng
table
Ci rcui t
system
Basecolor
Starti ng
and
i gni ti on
system
B
Black
W
Whi te
R
Red
G
Green
Y
Yellow
Chargi ng
system
li ghti ng
system
Si gnalsystem
I nstrument
system
Others
L
8r
Lg
Blue
Brown li ght
green
B
mack
Groundi ng
system
HARNESS LAYOUT
For
easy
i denti fi cati on connectors i ndi catedi n the
system
wi ri ng
di agram
havethe
same
numbers
as
thoseusedi nthehar
ness
layout
schemati c
@
@@
I
i
YG CJ QOYG
@@
w
Wi ri ng di agram Mai n
harness
I nstrument harness
SEL461
SEL 2
EL
106
ELECTRI CAL SYSTEM Wi ri ngHBrn8S
SCHEMATI C
Hatchback
4
1
Mai n harness
2 I nstTumcnt harness
3 EFI harness
4
Body
harness
S Doorharness
6
Console
harness
7
Back door
harness
8
Fuel
pump
harness
SE
L463
Hardtop
EL107
e
CO
ar
n
I l
e
i
I
10
I s
ELEClf
CALS I
SlE
tJ
ttA
RtlESS
i
g
e
0I
0
s
e
n5
a
i i o
U
6
e
Z
ot
t
I 1i
ll
tt
li
i J
s
aa
g
g
9
e
5
i
S
u
11
li i
i
t
u
ti a
e
I I
a
d
0
i
5t
@
@
@@
j
@
@
i u
I i
l
s
U
@@
@
et
ooo g
a
r
ucn
@
@
@@
g9
l
a
i
Ol
c
dod
U
1l
a
tA
l
0o
9
a
5e
S6
j i
a
ei l
eJ
d
0
a
otI S
i
p
p
tt
J
@@@
@
i
i
a
Po
Po
Po
a
I I i
e
2l
JJ
tJ
8c
4
58
Po
e
g
e
q
s
s
5
s i
i
s
I I PoPoal
e
i
5
1
l1
nl
gi
1i
n
SE
@@@@@@@@@
@@@
d
@
Warni ng
chi me
@
To
i nteri or
lamp
harness
I gni ti on
and
accessory
relay
Earth
@
I gni ti on
and
accessory
relay
@
Seat
belt
ti mer
@
To
door
harness
R
H
@
Fuse
block
@
Heater
motor
@
Thermo
swi tch
Ai r
condi ti oner
uni t
To
@
Whi te
To
@
Green
@
To
@
Black
@
To
@
Blue
@
To
@
@l
Whi te
@
To
@
lI D
Black
@
Parki ng
brake
swi tch
8
Seat
belt
swi tch
I ndi cator
lamp
Am
To
console
harness
@
Heater
control
panel
1Jjl
To
door
harness
L
H
@
A
S
C
D
controller
@
A
S
C
D
controller
@
To
EFI
harness
Hazard
flasher
uni t
Turn
si gnal
flasher
uni t
@
Door
mi rror
5Wi tch
L
H
@@
@i @
@@
Door
mi rror
swi tch
R
H
A
S
C
D
mai n
swi tch
A
Hazard
swi tch
r
I gni ti on
swi tch
Wi ndshi eld
wi per
swi tch
mrmnl0n r
Ul Ul
lms
I
5
m
i f
m
3
0CO
r
c
c
@Bl
t
@
2
m
zI I I I
Q
C
I
I
m mn
z
t
e
I J
n I
m3
I I I mI I I I
@
mumi nadon
control
rheostat
@
To
combi nati on
meter
@
To
combi nati on
meter
@
To
combi nati on
meter
@
A
S
C
D
peed
aenlOr
@
I nteri or
lamp
ti mer
@
Multi
wambtg
i ndi cator
I D
Audi o
@
Power
antenna
swi tch
@
garette
Ughter
@
Ash
tray
i llumi nati on
@
Wamlns
dl
pby
ampli fi er
@
Glove
box
lamp
@
To
@
I
Bbck
@
To
@
Blue
@
To
8
Green
@
To
@
Whi te
@
To
8
Whi te
@
To
@
Black
@
Door
swi tch
R
n
@
To@
@
To@
@
Rear
speaker
R
H
@
Tai l
and
stop
lamp
sensor
@
Tai l
and
stop
lamp
sensor
@
Si de
marker
lamp
R
H
@
Rear
combi nati on
lamp
R
H
i ll
Rear
combi nati on
lamp
R
n
i ll
Li cense
lamp
R
H
@
Back
up
lamp
R
H
@
Li cense
lamp
L
U
i ll
Rear
combi nati on
lamp
L
R
J
Tr
l
mr
m
rI n
@
Rear
combi nati on
lamp
L
n
@
Back up
lamp
L
U
@
Power
antenna
ffi
Si de
marker
lamp
L
R
@
Luggage
ompartment
lamp
@
Rear
speaker
L
U
@
Door
swi tch
L
R
@
To
fuel
pump
harness
i ll
Fuel
tank
gauge
uni t
@
Body
earth
Back
door
hameu
@
To@
@
To@
@
Rear
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of
for
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mm
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100
2
54 610 15 49 1 0394
51 2
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110
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79
620
15 75 2 079
52 2 047
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630 1600
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130 330 640 1626
4 157 54 2 126
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140 356
650
1651 5
197 55 2 165
150 381
660 1676
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236
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205
160
406 670 17 02
7 276 57 2 244
170
432
680
17 27
8 315 58 2 283
180
457 690 17
53 9 354 59
2323
190 483
700
17
78 10 394 60
2362
200
5 08
710 1803 11 433 61 2402
210 5
33 720 1829 12 472 62
2441
220 5
59 730 1854 13 512 63
2480
230
5 84 740 1880 14 551 64
2520
240 610 750
1905
15 591
65 2 559
250
635
760 1930
16 630
66 2598
260
660
770 19 56
17 669
67
2
638
270
686 780 1981 18 709 68
2677
280
711 790 2007 19 748 69
2 717
290
7 37 800 20
32
20
787 70 2756
300
7 62 810 20 21
827 71 2 795
310
7 87 820 20
83
22 866
72 2835
320 813
830 21 08 23
906
73
2
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330 838
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370 940 880
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380
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900
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150
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I ssued
February
1 811
020200
Publi cati on
No
SMOE Bll
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