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 FOREWORD

This service manual has been prepared for the purpose of assisting service personnel of
authorized NISSAN DATSUN dealers fu providing effective service and maintenance of the

1977 Datsun Pick up

fu the Datsun
Since proper maintenance and service are
absolutely essential satisfying
owners this la1 should be
inan kept fu a
handy place for ready reference and should be

carefuny studied

ma futenance 1justrnents
ac minor service operations
This la1 fucludes
man procedures for
remowl and installation and for disassembly and assembly of components

the use of Tools especially designed for

Some of these service operations require Special
effectiveperfonnance ofservice operations
tools are in the SE section
The special presented

As you read through the maintenance procedures in this service manual you will

paragraphs headed NOTE or CAUTION A NOTE is supplemental

occasionally corne across

CAUTION of steps that must

infortl1ation that is important to B particular procedure warns

and Qr to some part of your DATSUN

be fonowed to prevent personal injury damage

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

of each individual section is a table of contents which

desired section At the beginning
which each major subject begins An index is placed at the
gives the page number on

beginning of each major subject within the section

contained in this manual are based on the

All information illustrations and specifications
latest product information available at the time of publication approval If YOUT DATSUN

contained in this manual consult your NlSSAN

model differs from the specifications
DATSUN dealer for information

Rights for alteratiohat any time of specifications and methods are reserved

property damage occasioned by the use of this service

liability for any personal injury or

of way assumed by Nissan

your Datsun is in no
la1 in
man effecting maintenance or
repair
M9tor Co Ltd

using a service procedure or tool which is not specifically w

Accordingly anyone
himself that neither his safety nor the
mended by Nissan must fust completely satisfy
vehicle s safety wi11be jeopardized by the service method selected

NISSAN MOTOR CO LTD

TOKYO JAPAN

@ 1976 N1SSAN MOTOR CO LTD Printed in Japan

 I

SECTION GI

GENERAL
DATSUN PICK UP INFORMATION
MODEL 620 SERIES

GENERAL INFORMATION GI 3
I NISSAN I

NISSAN MOTOR CO LTD

TOKYO JAPAN
General Informa ion

Fig GI I Standord wheelbase model

Fig GI 2 Delux Cob

GI 2
 General Information L
GENERAL INFORMATION

CONTENTS

GI 3 APPROXIMATE REFILL CAPACITIES GI B

MOOEL VARIATION
GI 5 RECOMMENDED FUEL GI B
IDENTIFICATION NUMBERS
LIFTING GI B RECOMMENDED LUBRICANTS GI 8
POINTS AND TOWING
LIFTING POINTS GI B RECOMMENDED SAE VISCOSITY
GI 7 NUMBER GI 8
SUPPORTABLE POINTS
TOWING GI 7 LUBRICANT SPECIFICATIONS GI g

TIE DOWN GI 7

MODEL VARIATION

Differential
Pay load
Destination Class Model Engine Transmission carrier model
kg Ob
and gear ratio

I HL620TUV F4W7lB

Standard
wheelbase I HL620FTUV FS5W71 B

S
E
I HL620KTUV 3N7lB

Ol

E
u
0
0

E
I HLG620TUV F4W7lB

Long
0

0
wheelbase I HLG620FTUV FS5W71B

8 a
0
0 Ol
u I HLG620KTUV 3N7lB

Ol
u
I KHL620TUV F4W7lB

Deluxe
Cab I KHL620FTUV FS5W7lB

Hl90
KHL620KTUV 3N7lB 500 100
L20B 375
4
i
u
0 HL620TU F4W71 B

Standard
HL620FTU FS5W7l B
wheelbase

U 3N7lB
HL620KTU
S 0
0

0
E

8
I HLG620TU F4W7lB

Long
I
0
HLG620FTU FS5W7lB
wheelbase
Q u

0
Z
0 IHLG620KTU 3N7lB

KHL620TU F4W71B

Deluxe
Q KHL620FTU FS5W7l B
Cab

I KHL620KTU 3N7lB

GI 3
r General Information

Differential
Pay load
Destination Class Model Engine Transmission carrier model

and gear ratio lb

kg

HL620TUN F4W71B
Standard
wheelbase
HL620KTUN 3N71B

E HLG620TUN F4W7IB
Long
wheelbase 2 Hl90
Canada
I HLG620KTUN L20B 3N71B
375
4
500 100
1

Deluxe Z
0 I KHL620TUN F4W71B

Cab I KHL620FTUN FS5W7IB

I KHL620KTUN 3N7J B

Model identification

KHLG620KTUV

I I LU Destined for s A and Canada

U

V California model

N Canada model

T Floor shift vehicle

K Automatic transmission

F 5 speed manual transmission

0 4 speed manual transmission

G Long wheelbase
I Standard wheelbase and Deluxe Cab
o
H Equipped with L20B engine

K Deluxe Cab

Note 0 means no identification

4
GI
 General Informa tion

IDENTIFICATION Engine serllii number

NUMBERS

tW
The serial number is
engine
The unit and vehicle numbers are stamped on the right hand side of the

stamped and registered at the factory cylinder block

The engine and vehicle identifica I

tion numbers are used on legal docu L20B XXXXXX 1

ments

factory
These numbers
communications
are used
such
for
as
I Serial number
I il
j
Technical Reports Warranty Claims
Service Journals and other informa Engine model
tion
SP031

Vehicle IdentHication plate Fig GI 7 M V S S certification

k label location
The vehicle identification plate is
located at the hood ledge in the engine
compartment

Vehicle emission control

Information label

The vehicle emission control infor

mation label is stuck on the insicre of
the hood panel

SP029

Fig GI 3 Vehicle identification plat

location

Vehicle serial number

Color code number
The vehicle serial number is stamp
SP076
ed on the upper face of the right side The color code number label is
stuck the radiator support Fig GI B Vehicle emia ion control
member The number is identified by on

serial information label location

the follQwing flgUres as a

number

Manual transmission number

HL620 XXXXXX

I Serial number
The transmission serial number is
stamped on the front upper face of
transmission case
Vehicle model

Number system

x X XXXXX
GI326

I Serial number
Fig 01 6 Color code number label
location monthly

Month of
j manufacture
e

M VS S c rtlflcatlon label 2 9 XY Z

G1268
The M V S S certification label is Line code of
Fig 4 Vehicle serial number
GI
location located at the driver side lock pillar manufacture

Gl 5
 iGetneiraolnfonrml

Apply parking brake firmly and

block rear wheels if the front of the
vehicle is to be raised

Notes

Never YeDow mark

a
get under the vehicle while it
is supported only by the jack
Always use safety stands to support
WHOSO
frame or rear axle
when you case

have to get beneath the vehicle

b In no event should the jack be

Fig GI 9 Manual trammiuion number applied to any points except the

Fig GI 13 Warning ogai
t
location following specified portions over stroke

When jacking up the front side

Automatic transmission place a screw jack under side frame
number about 520 nun 5 in
20 at rear of
front axle center
The transmission serial number is

attached the Garage Jack

to right hand side of
transmission case
Note When carrying out operntions
with a garage jack be sure to
Numbering system
support the vehicle withstands in
X XXXXX a safe manner

I Serial number

monthly When jacking up the front end

apply garage jack to front cross
Month of member or center portion of sus

manufacture WT012 pension member

I 2 9 X Y Z When the end
jacking up rear

Fig GI ll Front lifting point apply the jack to rear axle case

last figure of
year of When jacking up the rear side place
manufacture a screw jack under rear axle case close
J
r
to the side of rear spring uc
I

GI075 n9
Fig GI 14 Front lifting point

AT344
WH077
Fig 01 10 Automatic trammision
number location

Fig GI 12 Reor lifting point

LIFTING POINTS
AND TOWING Notes
a When the yellow mark appean on
LIFTING POINTS
the screw jack it indicates the
maximum permissible height Do
Screw jack
not jack up further
Before using the jack proceed a b When the jack is at lower llinit do GI076

follows not add large force downward Fig GI 15 Rear lifting point

6
GI
 General Information

To tow another car connect t1ie Manual transmission

SUPPORTABLE POINTS
rope to rear leaf spring shackle
Before towing make sure the trans
The front supportable points are
mission is in neutral gear
under frame side member Notes
If the rear axle or transmission is
The rear supportable points are a A rope should not be con
towing
inoperative the vehicle should be
under rear axle case nected to any position other than
towed with its rear wheels off the
as described above
ground or the propeller shaft must be
b Avoid applying load suddenly to a
it may cause dam l1oved
re
towing rope as

age
Automatic transmission

When the vehicle is towed on its

rear wheels make sure the trans

mission is in N Neutral position

Don t exceed 30 km h 20 MPH and a

distance of Hi kin 6 miles Ifthe rear

Fig GI 16 Front supportable points axle or transmission is inoperative or

if the speed exceed the above condi

tions the vehicle must be towed with

its rear wheels off the ground or the

propeller shaft must be removed

WH131

Fig Gl 18 Fronttowing point Note When the vehicle is towed with

its front wheels on the ground the

steering wheel shouId be secured to

maintain a straight ahead position

v
GI078 TIE DOWN
Fig GI 17 Rear supportable points
The front two tie down hooks are

located under the 1st crosSInember

TOWING The hook is available as a towing
hook For rear down
tie the rear leaf
When the vehicle is to be towed
spring shackle be used lIDs point is
forward connect a rope securely to
also used as a towing point
the hook under the 1st CrosSIn ember
Before towing make sure the parking
brake is released Fig 01 19 Rear towing point

GI 7
 General Information

APPROXIMATE REFILL CAPACITIES

I Uter us measure Imper measure

Fuel tank
I 45 J IUi gal 9 Ji gal

ManUal transmission
Cooling system I 8 0J
I 8Jiqt 7 qt
with heater
Automatic tr smission
I 7 8J
I 8Y qt 6Jiqt

Engine lubrication
system
with oil f1lter
I 4 3J
I 4Ji qt 3 qt

without oil f1lter

I 3 8J
I 4 ql 3Xqt

I 4 speed transmission I 1 7J
I 3Xpl 3 pI
Manual transmission

I 5 speed transmission
I 2 0
I 4Y pt 3Mpt

Automatic transmission
I s J
5
I 5Uqt 4Uqt

Steering gear box

I 33J
0
I pt pt

Differential carrier
I 10 J
I 2M pI I pt

RECOMMENDED FUEL
Use an unleaded or low lead of 91 RON Research Octane only unleaded gasoline to protect the
gasoline with a minimum octane rating For California models
Nuniber from
use catalytic converter contamina

tion

RECOMMENDED LUBRICANTS

RECOMMENDED SAE VISCOSITY NUMBER

ENGINE on

IIO 10Vt4ll 10Wf

12O 2

I ICWII

ao 40
J
SAE 5W 20 oils ate not lecom
mended for sustained high speed
drivin

GEAR On

30 20 0 20 40 60 80 100

Temperature Range Anticipated Before

Next Oil Change OF

8
GI
 General Information

LUBRICANT SPECIFICATIONS

Item Specifications Remarks

Furthermore refer to
SAE Classification
Gasoline engine oil SAE recommended viscosity
SD or SE
table See Poge GI B

Transmission

0
and API 4
GL
steering

Differential API GL S

Automatic TIM fluid Type DEXRON

Multipurpose grea NLGI2 lithium soap base

Brake and clutch fluid DOT 3

Permanent anti freeze

Antifreeze
Ethylene glycol ba e

GI 9
 SECTION ET

ENGINE
DATSUN PICK UP TUNE UP
MODEL 620 SERIES

ENGINE TUNE UP ET 2

BASIC MECHANICAL SySTEM ET 7

IGNITION AND FUEL

ET 9
SYSTEM

EMISSION CONTROL SYSTEM ET 13

SERVICE DATA AND ET 25

SPECIFICATIONS

TROUBLE DIAGNOSES AND

H 27
I NISSAN I CORRECTIONS

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Engine Tune up

ENGINE TUNE UP

CONTENTS

LOCATION OF EMISSION CONTROL EMISSION CONTROL SYSTEM PIPING

SYSTEM COMPONENTS lNon California models 4
ET

INon California models ET 2 EMISSION CONTROL SYSTEM PIPING

LOCATION OF EMISSION CONTROL California models ET 5
SYSTEM COMPONENTS California models ET 3 EMISSION CONTROL DEVICES ET 6

LOCATION OF EMISSION CONTROL SYSTEM COMPONENTS

Non California models

I Thermal vacuum valve

2 Check valve
3 Air gallery pipe
4 Auto choke

5 Automatic temperature control air cleaner

6 Anti Backfire valve A B valve
7 Bo05t Controlled j
Deceleration Device 8C D D
8 P C V valve
9 Air relief valve
10 E G R control valve
11 Air pump air cleaner
12 Carbon canister
13 Air
pump
14 Spark delay valve AfT models ET365

Fig ET l Location of emaion control sy tern component

Non California mod I

ET 2
 Engine Tune up

LOCATION OF EMISSION CONTROL SYSTEM COMPONENTS

California models

cv

1 Thennal vacuum valve

2 Check valve
3 Altitude compensator in air cleaner
4 Air gallery pipe
5 choke
Auto qj
6 Automatic temperature control air
cleaner
7 Anti Backfire valve A B valve
8 Boost Controlled Deceleration
Device B C D O
9 P C V valve
10 Airrelief valve
11 E G R control valve
12 6 C D D control valve and solenoid
valve
13 Emergency air relief valve

14 Air pump air cleaner

IS Carbon canister
16 Air control valve
17 Air pump ET366

Fig ET 2 Location 01 emiuion control sydem component

California mod a

ET3
r

Engine Tune up

EMISSION CONTROL SYSTEM PIPING Non California models

1 Vacuum tube to distributor yellow

2 Vacuum tube to carbon canister yeUow
3 Vacuum tube to thermaJ vaCuum valve white
4 Vacuum tube
5 Vacuum tube to carburetor yellow
6 Thermal vacuum valve to E G R control
valve white

7 Vacuum tube to carburetor white

8 A B valve to vacuum connector green
9 Vacuum tube to carbon canister yellow
10 S D V to distributor yellow
11 Vacuum tube to S D V yellow

ET367

stem piping Non California models

Fig ET 3 Emi8ion control8

4
ET
 Engine Tune up

EMISSION CONTROL SYSTEM PIPING California models

1 Vacuum tube to distributor yellow

2 Vacuum tube to carbon canister yellow
3 Thermal Vacuum valve to E G R control
valve white
4 Vacuum tube to thermal vacuum valve
white
5 Vacuum tube
6 Vacuum tube to carburetor yellow
7 Vacuum hose connector to intake manifold
green
8 Vacuum tube to carburetor white
9 Air con tro valve to vacuum hose
connector green
10 A B valve to vacuum connector green
11 D C D D to control valve white

12 B C D D control valve to intake manifold

green
13 Vacuum hose connector to E A R control
valve green
14 D C D D control valve to air pump air
cleaner

ET368

Fig ET 4 Emission control system piping California models

ET5
lIIIII

mJ Crl lc Jl c0

AfT X X X X X X
x X X X X X alvc
ula 11Ie
CalifJl rlodet I I I

alvc relief

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Non X X X X X X X X X X X X
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L20H 620 H

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AfT X X X X X X X X X X X X X X X X X
Anu Emer dll u Vacu m Tup E

CalifornIa modcb I

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FlU NOll X X X X X X X X X X X X X

sy tem
recnultO
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DEVICS
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valve
contrled ulI

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1 210 aNonUfon anada

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Bo lt Tran Spark
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Automalcns temprau
X X X X X X X X X X X X X X X X

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lifomla model control

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valve

EMISON
control
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temprau vacum
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Maoulrmn Automaic Positve Thermal Combined
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numn PUlnt air valve pipe d

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Ched valve valve 500
control control
lIve
dualvQe introducinl sYltem vlcuum
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svtem tem acum waminl Remark

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Ive cut ln

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 Engine Tune up

BASIC MECHANICAL SYSTEM

CONTENTS

ADJUSTING INTAKE AND EXHAUST PERMANENT ANTI FREEZE COOLANT ET B

VALVE CLEARANCE ET 7 CHECKING COOLING SYSTEM HOSES

CHECKING AND ADJUSTING DRIVE AND CONNECTIONS ET B

BELT INSPECTION OF RADIATOR CAP ET B

ET 7
COOLING SYSTEM PRESSURE TEST ET B
RETIGHTENING CYLINDER HEAD BOLTS

MANIFOLD NUTS AND CARBURETOR CHECKING VACUUM FITTINGS HOSES

AND CONNECTIONS ET B
SECURING NUTS ET7
CHECKING ENGINE COMPRESSION ET 9
CHECKING ENGINE OIL ET B
COMPRESSION PRESSURE TEST ET 9
REPLACING OIL FILTER ET B
TEST RESULT ET 9
CHANGING ENGINE COOLANT ET B

ADJUSTING INTAKE CHECKING AND 2 Normal drive belt deflection is 8

to 12 0 315 to 0 472 in when
AND EXHAUST ADJUSTING DRIVE mm

moderate thumb pressure is applied

VALVE CLEARANCE BELT
midway between pulleys
Note After tightening cylinder head 1 Check for cracks or damage Re
bolts intake and exhaust
adjust place if necessary
valve clearances

clearance is
Valve adjustment
impossible when the engine is in oper
ation Compressor pulley
1 Loosen pivot locking nu t and
0 315 to 472
0 in
8 to 12 mm
turn pivot screw until the specified Idler pulley
clearance is obtained while cold
Water pump pulley
Using service tool tighten pivot
locking nut securely after adjustment
8 to 12 mm 0 315 to 0 472 in
and recheck the clearance
2 Warm up engine for at least
several minutes and stop it Measure
valve clearance while hot If out of

specifications adjust Air

pump pulley
Unit mm in

Alternator
Intake 0 20 0 008
Cold
Exhaust 0 25 0 010

AC456

Intake 0 25 OmO
Fig ET 6 Driue belt tension
Wann

I Exhaust 30
0 0 012

RETIGHTENING Tightening torque

CYLINDER HEAD Cylinder head bolts
1st turn
BOLTS MANIFOLD 4 0 29 ft Ib
kg m

NUTS AND 2nd turn

CARBURETOR 6 0 kg m 43 ft Ib

SECURING NUTS 3rd turn

5 to
6 5
8 kg m
STl 064000 I 47 to 61 ft lb
ET009 Refer to the following tightening
Fig ET 5 Adjusting valve clearance torque specifications
ET 7
r

Engine Tune up

ManifolJ nuts
2 When installing oil filter tighlen
I 2 to 16 kg m by hand
8 7 to I 6 ft lb
Note Do not overtighten oil flIt
Carburelor nuls
lest leakage should occur
5
0 to 10 kg m

3 6 to 7 2 fl tb

CHANGING ENGINE Fig fJ

ET l rod ioto
Teltill cop

COOLANT
COOLNG SYSTEM
PRESSURE TEST
PERMANENT ANTI FREEZE
COOLANT With radiator cap removed apply
reference pressure 1 6 kg cm2 23
Permanent anti freeze coolant is an
Fig ET 7 Tightening s quence psi to the cooling system by means

ethylene glycol base producl conlain

of a lesler to detect any leakage
ing chemical inhibilors 10 protect the
cooling system against corrosion Water capacity
The anti freeze does not contain
CHECKING ENGINE Without heater
any glycerine ethyl or methyl alcohol
OIL 7 4 liters
It will not evaporate or boil away and
can be used with either high or low
7 U US qt fImp qt
6
Check if oil is diluled with water
With heater
or gasoline Drain and refill oil if temperaturethennoslat
flows freely transfers heat effi
It 8 0 liters
necessary
8 fUS qt 7 Imp qt
ciently and will not clog passages in
Notes the cooling system
a A milky oil indicates the presence The anti freeze must not be mixed

of cooling water Isolate the cause with other products

and take corrective measure This coolant can be used through
b An oil with extremely low viscosity out the seasons of the year
Whenever coolant is the
indicates dilution with gasoline changed
cooling syslem should be flushed and
2 Check oil level If below the refilled with a new coolant
level raise it up 10 the H Check the level See the instruc
specified
level lions furnished by the manufacturer
for the mixture ratio of anti freeze 10
Engine oil capacity water
including oil filter
Maximum H leven
3 liters
4
4 MUS qt 3 Y Imp qt CHECKING COOLING CHECKING VACUUM
Minimum L level
3 liters
SYSTEM HOSES FITTINGS HOSES
3 fUS qt 2 U Imp ql AND CONNECTIONS AND CONNECTIONS
Check hoses and for loose Check the condition of filtings and
fittings
hoses Retighten or replace if neces
connections or deterioration Re

tighten replace if necessary sary

REPLACING OIL or
All vacuum hoses can be identified
FILTER by colors
The oil mter is a cartridge type and
INSPECTION OF RADIATOR White line
can be removed using Oil Filter
CAP
Wrench STI9320000 Vacuwn tube to carburetor E G R

Check for oil leaks past gasketed reference 09 Tube

I Apply pressure
by Vacuum tube to thermal vacuum
flange If leakage is found retighten kg cm2 13 psi1 to radiator cap
of if it is valve
just enough to stop leakage Ifretight means a cap tester to see

if Thennal vacuum valve to E G R

ening is no longer effective replace satisfactory Replace cap assembly
control valve
mter as an assembly necessary

8
ET
 Engine Tune up

Yellow line Different

compression in two or
I more cylinders usually indicates an
Spark delay valve to distributor
improperly seated valve or broken
Spark delay valve to vacuum tube
piston ring
Distributor to vacuum tube
9 Low
compression in cylinders can
Vacuum tube to carburetor
Vacuum tube to canister result from worn piston rings This
condition may usually be accompanied
Green line by excessive fuel consumption
Anti backfire valve to intake mani
ET010
fold TEST RESULT
Air control valve to emergency air Fig ET 10 Teding compression
pressure If compression in one or more
relief valve
cylinders is low
pour a small quantity
Intake manifold to vacuum hose
of engine oil into cylinders through
connector
Intake manifold to canister
5 Depress accelerator pedal to open the spark plug holes and retest com
throttle and choke valves pression
I If adding oil increases the
CHECKING ENGINE Note Do not pump pedal com

pression pressure the chances are that

COMPRESSION 6 Start engine as quickly as pos
rings are faulty
sible
2 If pressure stays low probable
COMPRESSION PRESSURE 7 Compression pressure cause is that valve is sticking or seating
TEST kg cm2 psi at rpm
improperly
Standard 3 If cylinder compression in any
I Warm up engine sufficiently
350
2 Disconnect all spark plugs 12 0 171 two adjacent cylinders is low and if
Minimum
3 Disconnect anti dieseling solenoid adding oil does not help the compres
9 0 128 350
valve connector sian there is leakage past the gasket

4 Properly attach a compression 8 Cylinder compression in cylinders surface

tester to spark plug hole in cylinder Should not be less than 80 of highest Oil and water in combustion cham

being tested reading bers can result from leakage

IGNITION AND FUEL SYSTEM

CONTENTS

CHECKING BATTERY ET 9 CHECKING DISTRIBUTOR CAP ROTOR

ET 11
CHECKING AND ADJUSTING IGNITION AND CONDENSER
TIMING ET 10 ET 11
CONDENSER
ADJUSTING IGNITION TIMING ET10 ADJUSTING CARBURETOR IDLE RPM

AND MIXTURE RATIO ET 11

CHECKING AND REPLACING SPARK PLUG ETlO
IDLE LIMITER CAP ET 12
CHECKING DISTRIBUTOR OPERATING
PARTS AND IGNITION WIRING ETlO CHECKING CARBURETOR RETURN SPRING ET 12

BREAKER POINTS lNon California models ET 10 CHECKING CHOKE MECHANISM

AI R GAP lCalifornia models ET11 Choke plate and linkage ET13

DISTRIBUTOR ET 11 CHECKING FUEL LINES

IGNITION WIRING etc ET 13
ET 11 Hoses pipings connections
REPLACING FUEL FILTER ET 13

I Unscrew each filler and to 0 79 in above the plates Do not

CHECKING BATTERY cap

inspect fluid level If the fluid is low overfill

Check electrolyte level in each bat add distilled water to bring the level 2 Measure the specific gravity of

tery cell up approximately 10 to 20 mm 39

0 battery electrolyte
H9
p

Tune up
Engine
r water Rinse off and dry with com CHECKING ANb
pressed air Top of battery must be REPLACING SPARK
clean to current leakage be
prevent
tween terminals and from
PLUG
positive
terminal to I Remove and clean
down
hold clamp plugs in a sand

In addition to current leakage pro blast cleaner

longed accumulation of acid and dirt 2 Inspect insulator for cracks or

on top If l l ry may ca u
iCbli t g
I
rj chips
ET002 of the material covering connector 3 Check both center and ground
Checking specific gravity electrodes
Fig E1 11 straps and corrosion of straps After
ofbottery electrolyre If they are excessively
tightening terminals coat them with worn re

Clean top of battery and terminals petrolatum vaseline to protect them place with new spark plugs
with a solution of bakin soda and from corrosion 4 Spark plug gap

Breaker points type

Full charge 0 8 to 0 9 mm
Pennissible
value 0 031 to 035 in
0
value
at 200C 680F Transistor ignition type
10 to 1 mm

Frigid climates Over 1 22 1 28 0 039 to 0 043 in

Tightening torq
Tropical climates
lOver 1 18 123 5 to 2 0
1 kg m
11 to A4 ft lb
Other climates
lOver 120 26
1

CHECKING AND
ADJUSTING
IGN ITIONTIMiNG

ADIUSTING IGNITION
TIMING

Fig ET 14 Checking spark plug point

I Check spark plugs and distributor gap
breaker points for condition
2 Thoroughly remove dirt and dust
from timing mark on crank pulley and
CHECK I G
timing indicator on front cover
3 Warin upengine sufficiently
DISTRIBUTOR
4 Imtalla timing light on No
I OPERATING PARTS
cylinder spark plug wire and install a
AND 1
tachometer
lrI9N
WIRING
5 Set idling spero toapproxintate y

750 rpm BREAKER POINTS

6 Check ignition timing with a
Non California models
timing light if it is specified value
I oo Check the distributor breaker

it as follows points for abnonnal pitting and wear

Ifnecessary adjust
Replace if necessary Make sure they
ET169
1 Loosen setscrew until distribu are properly aligned and that point
tor can be moved by hand Fig ET 13 Checking ignition timing
dwell and gap are correct Clean and
2 Adjust ignition timing to speci Ignition timing
apply distributor grease to the carn
fied value Manual transmission
lobes
0
3 Lock distributor setscrew ai1d 120 750 rpm
Note 00 not
make sure that timing is correc Non California models apply grease excessively
100
750 rpIll Point gap
California models
0 45 to 55
0 mm
Automatic transmission
Om8 to 0022 in
120 650 rpin
Owell angle
in 0 position
49 to 55 degrees

ET 10
 Engine Tune up

ped models check should be per

cap and check cable resistance only If
resistance is still more than 30 000 fonned in the D position
ohms replace cable assembly Be sure to engage parking brake and
to lock both front and rear wheels
with wheel chocks
brake
b Keep your foot down on the

pedal while depressing the accelera

tor pedal Otherwise vehicle surges
forward dangerously
EE322

Fig ET 15 Checking diltribu tor

Notes
point gap
a Do not attempt to screw the idle
EF125
AIR GAP down
Checking high tension adjusting sc ew completely
California models could damage to tip
cable Doing so cause

and which in turn will tend to cause

For inspection procedures
reference data refer to the topic Air CHECKING malfunctions
in Section EE page EE 29
b If idle limiter cap obstructs proper
Gap DISTRIBUTOR CAP
remove it
adjustment
DISTRIBUTOR ROTOR AND To install idle limiter cap refer to
CONDENSER Idle Limiter Cap
Check centrifugal advance unit for
c After idle adjustment has been
loose connection or improper opera
Note This is to be
operation per
made shift the lever to the N or
tion If it is not operating properly formed while checking distributor
the be due to a sticky P position for automatic trans
problem may for
points Inspect distributor cap
spring or excessively worn parts This mission
cracks and flashover
operation needs a distributor tester d When measuring CO percentage in
For inspection procedures and ref sert probe into tail pipe more than
External surfaces of all parts of
erence data refer to relative topic 40 em 15 7 in
secondary system must be cleaned
to
under Distributor in Section EE
reduce possibility of voltage loss All
CO idle adjustment with
If vacuum advance mechanism does
wires should be removed from distrib
check for the CD meter
not properly operate utor cap and coil so that terminals can
following items and correct the prob be inspected and cleaned Burned or Idle mixture adjustment requires
lem as required
corroded terminals indicate that wires the use of a CO meter especially for
1 Check vacuum inlet for signs of are not fully seated which causes California models When to
preparing
leakage at connection If necessary arcing between end of wire and ter mixture it is essential to
adjust idle
retighten replace minal When replacing wires in ter
or have the meter thoroughly warmed up
2 Check diaphragm for air minai be they are fully seated
vacuum sure and calibrated
before rubber down Check carburetor pipes for proper
leak pushing nipple I
If necessary replace diaphragm over tower Check distributor rotor for connection
3 Inspect breaker plate for smooth damage and distributor cap for 2 Warm up engine until water tem
movement cracks perature indicator points to the middle
If plate does not move smoothly of gauge The
CONDENSER procedure to warm up
this condition could be due to sticky I Clean outlet of condenser lead engine is not specifically recom
steel balls If necessary replace break wire and check for loose setscrew mended Either driving vehicle or oper
er plate assembly Retighten if necessary ating engine at no load will be good
2 Check condenser with 3 Make sure that water tempera
IGNITION WIRING a con

denser tester ture indicator points to the middle

Use an ohmmeter to check resist
Condenser capacity Further keep engine running at about
of secondary cables Disconnect
ance 2 000 rpm for about 5 minutes with
20
0 to 0 24 IF
cables from spark plugs and install a
in order to
Micro Farad out applying load to engine
adapter between cable and
proper Condenser insulation resistance stabilize engine condition Engine
Remove distributor cap
spark plug 5Mn Mega ohms hood should be open
and secondary cables as an assembly 4 Run engine for about 10 minutes
Do not remove cables from cap ADJUSTING at idling speed During this 10
Check resistance of one cable at a CARBURETOR IDLE minutes proceeq as described i steps
time RPM AND MIXTURE 5 to 9 below

Connect ohmmeter between spark RATIO 5 Remove air hose between 3 way

plug adapter and corresponding elec connector 5 way connector for Cali
is more Cautions
trade inside cap If resistance fornia models and air check valve as

than 30 000 ohms remove cable from a On automatic transmission equip shown in Figure ET 17 Plug the dis

T 11
r

Engine Tune up

connected hose to dust from 12 Connect air hose to air check

prevent 10 Repeat procedures as described
entering valve in steps 6 7 and 9 above until engine
If increases it
To air check valve engine speed readjust speed best idle mixture is 815 rpm
at

to the specified speed with throttle for manual transmission models and
adjusting screw 670 rpm for automatic transmission
models in D position Adjustment
CO Idle adjustment without in step 9 can be carried out right after
COmeter step 7
II Turn the idle adjusting screw
If CO meter is not available the clockwise until engine speed drops off
following procedures may be used below specified rpm
I Check carburetor pipes for proper
Fig ET 17 Disconnect air hose Engine speed drops off
connection
from ojr check valve Manual transmission
2 Wann up engine until water tern
60 to 70 rpm
6 Race engine1 500 to 2 000 rpm perature indicator points to the middle
of gauge Automatic transmission
two or three times under no load then The procedure to warm up
in D position
engine is
run engine for one minute at idling specifically recom
not
15 to 25 rpm
speed mended Either driving vehicle or oper
7 ating engine at no load will be
Adjust throttle adjusting screw good
12 Connect air hose to air check
until engine is at specified speed 3 Make sure that water temperature
valve
indicator points to the middle Further
Engine speed If engine speed increases readjust it
keep engine running at about 2 000
Manual transmission the with throttle
rpm for about 5 minutes without
to
specified speed
750 rpm
applying load to engine in order to adjusting screw
Automatic transmission
stabilize engine condition Engine
in D position IDLE LIMITER CAP
hood should be open
650 rpm
4 Run engine for about 10 minutes Do not remove this idle limiter cap
at idling peed unless If this unit is
8 Check ignition timing If neces
During this 10 necessary

minutes proceed as described in steps removed it is necessary to readjust it

sary adjust it to specifications
5 to 9 below at the time of installation To adjust
This operation need not be carried
5 proceed as follows
out at 1 600 Ian 1 000 miles service Remove air hose between 3 way
1 After
connector 5 way connector for Cali adjusting throttle or idle
Ignition timing fornia modeis and air check valve speed adjusting screws check to be
Manual transmission shown in Figure ET 17 Plug the dis Sure that the amount of CO con

120 750 rpm Non California connected hose to prevent dust from tained in exhaust gases meets the

750
100 rpm California entering established standard
Automatic transmission 6 Race engine 1 500 to 2 000 rpm 2 Install idle limiter cap in position
in D sure that the adjusting screw
position two or three times under no load then making
120 650 rpm further turn 1 8 rotation in the
run engine for one minute at idling
speed CORICH direction
9 At about 10 minutes after engine 7 Adjust throttle adjusting screw so
is idle
run at idling speed adjust that indicated
Carburetor
engine speeds are as
stopper
adjusting screw so that CO percentage below
is at specified level

CO percentage
Engine speed
Manual transmission
Manual transmission
815 rpm
tI
2 750 rpm at
Automatic transmission
Automatic transmission
D
in D in position
position
670 rpm 3lSo ldle limiter cap
tI
2 at 650 rpm
T ET031
10 Repeat procedures as described 8 Check ignition timing if neces
Fig ET 18 Setting idle limiter cap
in steps 6 7 and 9 above so that CO saryadjust it to the value
required by
percentage is at specified level Check specifications
This operation need not
CHECKING
ing idle CO in step 9 can be carried out be carried out at 1 600 Ian 1 000
right after step 7 miles service CARBURETOR
11 Race engine I 500 to 2 000 9 At about 10 minutes after engine RETURN SPRING
rpm two or three times under no load is run at idling speed adjust idle Check throttle return spring for
and make sure that specified CO per adjusting screw until maximum rpm is cracks s or defonnation if
squarene
centage is obtained obtained
necessary replace with a new one

ET 12
 Engine Tune up

that bimetal is out of order Refer All engines use a replaceable

CHECKING CHOKE or

to Carburetor in Section EF cartridge type fuel filter as an as

MECHANISM Choke sembly

plate and linkage
1 Check choke valve and mech

anism for freeoperation and clean or CHECKING FUEL

replace if necessary A binding can
LINES Hoses @
result from petroleum gum formation
on choke shaft or from damage pipings connections
2 Check bimetal cover setting etc
Index mark on bimetal cover is usually
Check fuel lines for loose con
set at center of scale
nections cracks and deterioration

Note Always align the index mark on Retighten loose connections and re
bimetal cover with the center index
place any damaged or deformed parts
mark on choke housing

3 Every day before starting engine REPLACING FUEL

depress the accelerator Pdal to see if FILTER
choke valve is closed automatically
ET011
If it fails to be closed the chances Check for a contaminated filter and
are that link movement is unsmooth water deposit Fig ET 19 Fuel filler

EMISSION CONTROL SYSTEM

CONTENTS

CHECKING CRANKCASE EMISSION ADJUSTMENT OF SET PRESSURE OF

BOOST CONTROLLED DECELERATION
CONTROL SYSTEM ET 13

REPLACING P C V VALVE AND DEVICE B CD D ET 18

FILTER ET 13 CHECKING B C D D SOLENOID VALVE ET 20

CHECKING VENTILATION HOSE ET 14 CHECKING AMPLIFIER Manual

CHECKING EXHAUST MANIFOLD HEAT transmission models ET 20

CONTROL VALVE ET 14 AIR PUMP AIR CLEANER

REPLACING
CHECKING SPARK TIMING CONTROL ELEMENT ET 20

SYSTEM ET 14 EXHAUST GAS RECIRCULA

CHECKING
SPARK DELAY VALVE TION E G R CONTROL SYSTEM ET 20

Automatic transmission models only ET 14 CHECKING EVAPORATIVE EMISSION

INSPECTION ET 15 CONTROL SYSTEM ET 22

ET 23
CHECKING AUTOMATIC TEMPERATURE CHECKING CATALYTIC CONVERTER
AIR ET 15 INSPECTION ET 23
CONTROL CLEANER
PRESSURE OF BOOST CHECKING FLOOR TEMPERATURE
OPERATING
WARNING SYSTEM ET 23
CONTROLLED DECELERATION DEVICE
B CD D I ADJUSTMENT ET 17 INSPECTION ET 23
CHECKING B C DD CIRCUIT WITH
FUNCTION TEST CONNECTOR ET 17

CHECKING
CRANKCASE
EMISSION CONTROL
SYSTEM
with the following method noise will be heard as air passes
REPLACING P C V VALVE With engine running idle remove the valve and
at through a
strong vacuum
AND FILTER ventilator ose from P C V valve If should be felt when
immediately a

Check P C V valve in accordance the valve is properly working a hissing finger is placed over valve inlet

ET 13
 Engine Tune up

2 With engine stopped visually

check E F E system for the following
items
1 Oil level gauge I Thermostat spring for dismount
CoOl 2

3
8affle pia te
Flame arrester
ing
2 Stopper pin for bend and count
4 Filter
5 P C V valve er weight stop position for dislocation
6 Steel net 3 Check heat control valve for
7 Baffle plate malfunction due to break of key that
locates counterweight to valve shaft
4 Check axial clearance between
heat control valve and exhaust mani
fold Correct clearance is 0 7 to 5
1

mm 0 028 to 0 059 in

5 Check welded portion of heat

1fiI o
control valve and valve shaft for any
indication of crack or flaking
6 Rotate heat control valve shaft
with a fmger and check for
binding
Fresh air between shaft and bushing in closing
EC716
and opening operation of heat control
Blow by gas tem
Fig ET 20 Crankcaae emi ion control8 valve If any binding is felt in rotating
operation move valve shaft in the
rotation direction several times If this
3 When heat control valve is in the
CHECKING VENTILATION does
full operation not correct binding
HOSE
open positioncounterweight
condition it is due to seizure between
moves further clockwise exceeding the

1 hoses and hose shaft and bushing and exhaust mani

Check connec position described in 1 1 above and
fold should be replaced as an assem
tions for leaks stops again coming into contact with
2 Disconnect all hoses and blow stopper pin bly
them out with compressed air

If any hose cannot be free of

obstructions replace
Ensure that flame arrester is surely ct
inserted in the hose between air
t
cleaner and rocker cover

CHECKING SPARK
CHECKING EXHAUST EC245
TIMING CONTROL
MANIFOLD HEAT 1 Counterwe ht SYSTEM
2 Stopper pin
CONTROL VALVE 3 Heat control valve
This system is installed on non

Fig ET 21 Cold operation of counte

California automatic transmission
Run engine and visually check weigh t
models
counterweight to see if it operates
properly
I For some time after starting
engine in cold weather counterweight VALVE
SPARK DELAY
turns counterclockwise until it comes
Automatic transmission
into contact with stopper pin installed models only
to exhaust manifold
Counterweight gradually moves This valve
delays vacuum spark
down clockwise engine warms up
as advance during rapid acceleration it
and ambient temperature goes higher EC246 also cuts off the vacuwn spark advance
around exhaust manifold imme iately upon deceleration The
1 Counterweight
2 When engine speed is increased valve is designed for one way opera
2 Stopper pin
discharge pressure of exhaust gases 3 Heat control valve tion and consists of a one way umbrel
causes counterweight to move down la valve and sintered steel fluidic
Fig ET 22 Hot operation of counter
ward clockwise restrictor
weight

ET 14
 Tune up
Engine

CHECKING
AUTOMATIC
Distributor side
TEMPERATURE
Brown CONTROL AIR
CLEANER

1 Air cleener element

Viscous paper type air cleaner ele

ment does not require any cleaning

opera tion until it is replaced periodi

cally Brushing or blasting operation
will cause clogging and result in enrich
lOne way umbrella valve
ment of carburetor mixture and
2 Sintered metal disc
should never be conducted For reo
EC284
Fig ET 23 Spark delay valve placement interval of air cleaner ele
ment refer to Maintenance Schedule

When installing this valve ensure INSPECTION

2 Hot elr control system
that it properly oriented This valve
should be replaced periodically Refer I Remove spark delay valve
In warm wealher it is difficult to
to Maintenance Schedule 2 through port on carbure
Blow air
find ou t malfunction of hot air control
tor side then through the other port
system In cold weather however
on distributor side Spark delay valve malfunction of air control valve d e to
is in good condition if when finger is
disconnection or deterioration of vacu
placed over port on distrib side
um hose between intake manifold and
ajr flow resistance is greater than that vacuum motor and insufficient dura

I on the other side See Figure ET 25

3 If a considerable air flow resist

bility of air con trol valve will cause
insufficient automatic control opera
ance is felt at port on distributor side
tion for intake air and result in engine
in step 2 above and if the condition of
disorder including
spark delay valve is questionable dip
To
distribut0 From carburetor
port on carburetor side into a cup
I Stall
tion
or hesitation of engine opera
fIlled with water Blow air through the
Yl r other port Small air bubbles should 2 Increase in fuel consumption
EC278 l appear 3 Lack of power

Fig ET 24 Operation ofspark delay These phenomena reveal malfunc

value tionof hot air control system If these

phenomena should occur check hot

air control system as described in the
following before carrying out inspec
tion of carburetor

2 1 Vacuum hoses

I Intake manifold to 3 way connec

I tor 3 way connector to temperature

sensor 3 way connector to idle com

Carburetor side
pensator temperature sensor to vacu
Distributor side
um motor
EC279

Fig ET 26 Checking spark delay ualue

1 Check that vacuum hoses are se

curely connected in correct position

lr
EC346

Fig ET 25 Checking spark delay value

rJmlL Note

or
Be careful

dirt into valve

to avoid entry of oil
2 Check each hose for cracks
distortion hose clip for condition
or

ET 15
 Engine Tune up

R R
3 Check that air control valve grad
Note Vacuum hose position
the ually opens to under hood air inlet
side of Nissan mark top of
on

side as engine warms up When en

sensor for intake manifold L R
vironmental temperature around tern
side of the mark is for vacuum

rootor perature sensor is low spend more

time for engine warming up operation

to facilitate smooth opera tion of air
con trol valve

If the above test reveals any prob

lem in the operation of air control
EF217 valve carry out the following test
Fig ET 28 lmpecting value position 4 Remove air cleaner cover Set
element of ther
2 2 Vacuum motor temperature sensing
Correct pC6ition of air control valve mistor or thermometer to a position
I With engine stopped disconnect
is the reverse of paragraph I above Air where tempera ture around sensor can
fresh air duct if
control valve is in correct position be measured In this case fix wiring of
Place a mirror at the end of air
under hood air inlet is closed and hot thermistor or thermometer on the bot
cleaner inlet pipe as shown and check
air inlet is open tom surface of air cleaner with adhe
to see if air control valve is in correct
3 With hot air inlet is open posi sive tape in such a manner that the set
position in
tion as descnbed paragraph 2 position of temperature sensing ele
above pinch vacuum hose with fingers ment will not be affected by airflow
and cut of air from hose In
vacuum Then install air cleaner cover
this condition check that air control
valve maintains the condition de

scribed in step 2
for more than 30
seconds and that hot air inlet is open
If diaphragm spring actuates the air
control valve by its spring force to

open under hood air inlet within 30

seconds replace vacuum motor as an

assembly since this may be resulted

EF213 from air leak at vacuum motor dia

phragm
Fig ET 27 Impecting lJalv position EF221

Fig ET 29 Checking temperotur

e
2 3 Temperature sensor ensor

Check temperature sensor for func

tion by proceeding as follows Be sure
to keep engine cold before starting 5 Carry out test as described in
test I 2 and 3 above When air
steps
Air control valve is in correct posi control valve begins to open to under
1 With engine off check air control
tion if its under hood air inlet is open hood air inlet side severa minutes
valve for condition In this case under
and hot air inlet is closed Check air after engine starting read the indica
hood air inlet is open Use a mirror for
control valve linkage for condition tion of thermistor or thermometer If
inspection as 2 2 1 above
2 Disconnect vacuum motor inlet
reading falls within the working tern
hose and connect another 2 Start engine and keep idling
perature range of temperature sensor
vacuum

hose to the inlet to apply vacuum to Immediately after engine starting If

the sensor is normaL reading ex

motor Vacuum can be ap check air control valve for correct

vacuum ceeds the the sensor
described above In this
range replace
in the hose end as position as
plied by breathing with new one

shown case correct position of air control

the end of air valve is the reverse of 2 2 1 under Note Before replacing temperature
Place a mirror at
hood air inlet is closed and hot air sensor check idle compensator as
cleaner inlet pipe and check to see if
inlet is open described in Section EF page 8
EF
air control valve is in correct position

ET 16
 Engine Tune up

OPERATI NG If voltmeter reading is zero check erly

for disconnected connector faulty If ohmmeter reading is 32 ohms or
PRESSURE OF solenoid valve or inhibitor switch above check for poor connection
BOOST CONTROLLED 2 inhibitor
of connector faulty B C D D sole
With switch OFF
noid valve or inhibitor relay
DECELERATION 41 2 D or R position
check for resistance between 3 If by above checks faulty part
DEVICE B C D D @ and or

Refer to unit is located

@ Figure ET 31 it should be removed
ADJUSTMENT If ohmmeter reading is 25 ohms or and tested again If necessary replace
below circuit is functioning prop
CHECKING a C D D CIRCUIT
WITH FUNCTION TEST
CONNECTOR

Manual transmission models

I Check for continuity between @

and@ at a speed of zero km Refer

to Figure ET 30

BC D D circuit is functioning
properly if continuity exists and volt
meter reading is 0 volt d c in step 2
l r 1 Ignition key

E
2 Fuse

below 3 Amplifier
4 Speed detecting switch
If continuity does not exist check
Above 10 mph OFF
for disconnected connector and or
Below 10 mph ON
faulty amplifier speed detecting 5 Function test connector
switch or B C D D solenoid valve
6 B C D D solenoid valve
2 Check for presence of voltage
across@ and @ at a speed of more
than 16 km h 10 MPH Refer to
EF711
Figure ET 31

Fig ET 30 B C D D circuit with function tedconnectoT

Manual transmission modela
Conduct this test by one of the

following two methods

iRaising up rear axle housing with

stand
2 Chassis dynamometer test
If voltmeter reading is 0 volt at @
a

of more than 16 km h 10
speed
circuit is
MPH functioning prop
erly
If voltmeter is not 0 volt
reading
check for disconnected connector
burned fuse faulty amplifier
BC D D solenoid valve or speed 1 Ignition key
detecting switch 2 Inhibitor switch
N P positions ON
3 If by above checks faulty part or I 2 D R positions
OFF
it should be removed 3 D C D D solenoid valve
unit is located
4 Function test connector
and tested again If necessary replace
5 Inhibitor relay

Automatic transmission EF712

models
Fig ET 31 Checking B C D D circuit with function tfst connfctor
I With inhibitor switch ON UN
Automatic transmiMion modtla
or P position check for presence of
and
voltage across @ @ Refer to
Figure ET 30

If voltmeter reading is 12 volts

c
d BC D D circuit is func
tioning properly
ET 17
r

Engine Tune up

ADJUSTMENT OF SET idling setting Refer to the item california

Non models

PRESSURE OF BOOST Idling Adjustment in page ET II

CONTROLLED DECELERATION Idling engine speed
DEVICE B CD D Manual transmission
750 rpm
Generally it is unnecessary to ad
Automatic transmission
just the B C D D however if it should
become necessary to adjust it the in D position
procedure is as follows 650 rpm
1 Adjusting screw
4 Run the engine under no load
Prepare the foUowlnB tools 2 Cover e
Increase engine speed to 3 000 to ET037
I Tachometer to measure the 3 500 rpm then
en quickly close throttle
gine speed while idling and a screw valve California models

driver 5 At the time the manifold vacuum

2 A vacuum gauge connecting pipe pressure increases abruptly to 600
mmHg 23 62 inHg or above and
Note A qui k response type boost

r
then gradually decreases to the level
gauge such as Bourdon s type is
recommended a
set at idling
mercury type 6 Check that the BC D D set pres
manometer should not be used
sure is within the specified pressure
To set the
properly B C D D set
pressure proceed as follows
Specified pressure 0 m sea level 1
I Remove the harness of solenoid Adjusting nut
and 760 mmHg 30 inHg atmos 2 Lock spring
valve EC692
pheric pressure
Fig ET 34 Adjusting Bet pressure
TO D D solenrod Manual transmission

VT FJ
BC D D solenni
510 to
20 1 to
Automatic transmission
550 mmHg
7 inHg
21
8

adjustment
Race the engine and check for

1 valve harness

J
490 to
3 to
19
530 mmHg
20 9 inHg
9
turn the
If it is lower than the set level
adjusting screw or nut until
correct adjustment is made

10 Race the and check for

engine
Note When checking the set pressure
adjustment
ri of B CD D find the specified set
y If engine speed cannot be decreased
EF262 pressure in Figure IT 36 from the to idling when checking B C D D set

g ET 32 Removing harneS5 of
F atmospheric pressure and altitutde pressure proceed as follows
solenoid valve of the given location
When the engine speed does not fall
For if a manual transmis
example it
to idling speed is necessary to
2 Connect rubber hose between sion model vehicle is located at an
reduce the negative idling pressure of
altitude of 1 000 m 3 280 ft the
vacuum gauge and intake manifold as
the manifold to lower than the set
shown specified set preSsure for B C D D
pressure of the B C D D The engine
445 mmHg 17 5 inHg
speed will not drop to idling speed
when the negative idling pressure is
7 If it is higher than the set level higher than the set pressure of the
turn the adjusting screw counter B C D D
clockwise or nut clockwise until In this the be
case engine must

correct adjustment is made labored by I road test or 2 chassis

Non California models dynamometer or 3 by raising up rear
Adjusting screw
type suspension member on a stand accel
California models erating the vehicle to 64 to 80 krn h

Adjusting nut 40 to 50 MPH in top gear manual

type
transmission or in D position auto
Fig ET 33 Connecting vacuum gauge Note When adjusting BC D D for matic transmission and then releasing
California models the accelerator pedal and letting the
turn adjusting
nut in or out vehicle decelerate After doing this
with lock spring in
3 Warm up the engine until it is
place Always set lock check whether the B C D D set pres
spring prop
heated to operating temperature erly sure is at the predetermined value or
to prevent changes in set pres
Then adjust the engine at normal sure not

ET 18
 Engine Tune up

Vacuum gauge Vacuum gauge Vacuum gauge

Intake

dJi 1
3 Raise rear axle housing by stand
2 Otassis dynamometer up
I Road te t
ET133

Fig ET 35 Testing set pressure of the B C D D

mmHg inHg inHg mmHg

30
24
750
600

29
23

28
22

700
550

27
21

26
20
650
500

25 a
19
a Co

11 1
Co
v
24
Co
g 18
0
600
450 E
8
0
23
17

22
16
550
400

2
15

0 20
14
500
350

19
13

300 1
4 5 000 6 000 ft
o 1 000 2 000 3 000 000

Altitude

10 5
1 2 0 km
o 0 5

EF55B

Fig ET 36 Changes in set pressure uersus changes in

atmospheric pre6Sure and altitude

ET 19
r

Engine Tune up

CHECKING B C D D 3 If a click is heard solenoid valve

SOLENOID VALVE is normal

4 If a click is not heard at all check

I Turn on engine key Do not start for continuity with a circuit tester If
engine discontinuity is detected replace sole
2 Ensure that solenoid valve clicks
naid valve
when intermittently electrified as

shown in Figure ET 37

CHECKING AMPLIFIER
Manual transmission EC323

models Fig ET 39 Repl4cing air cleaner

element
The amplifier is installed at the rear
of the speedometer To check proceed
as follows

1 Set circuit tester in c

d ampere
range IA min full scale connect test
probes of tester as shown in Figure
ET 38
Do not confuse positive line with CHECKING EXHAUST
Fig ET 37 Checking solenoid negative line
l uolV
GAS RECIRCULATION
E G R CONTROL
SYSTEM
Checkln E G R control
I system In Ita mounted
condition

l I
E G R
M ake a

control
thorough visual
system
check of

If necessary
M wipe away oil to facilitate inspection
1

p II
If hoses cracked
are or broken fe
o
L
A place
I of

jt J 2 With engine running check

f
E G R warning system for proper
function Make sure that E G R warn

T ing lamp light when ignition switch is

turned to START position starter mo
tor runs If E G R warning lamp does
1 Ignition key not light inspect harnesses and con
2 Amplifier
EF264 nectors or replace warning lamp Then
3 Speed detecting switch
turn ignition switch to ON position
4 B C D D solenoid valve
and check the following items
Fig ET 38 Checking amplifiu
I If odometer of detector drive
counter has not reached 50 000

counts make sure that E G R warning

lamp does not light
2 If odometer of detector drive
counter has attained 50 000 counts
make that E G R warning
sure lamp
REPLACING AIR lights
2 Turn ignition key to ON posi PUMP AIR CLEANER If warning lamp does not light
tion
3
ELEMENT check harnesses and de
connector
Ensure that tester pointer deflects
tector drive counter replace warning
when ignition key is turned on Remove air hose then detach air
cleaner from lamp or detector drive counter if
4 If tester panter does not deflect hoodledge Air cleaner
necessary
when solenoid valve and speed detect element and air cleaner lower body are

built into a unit construction Replace

ing switch circuits are functioning
air cleaner element and lower Note of E G R
properly amplifier is body as Operation warning
faulty
an assembly lamp is as follows

ET 20
 Engine Tune up

Ignition Switch Position START ON

Below Above
Detector Drive Counter
50 000 counts 50 000 counts

ON OFF ON
E G R Warning Lamp

After of 4 With running inspect

a completing inspection engine
EG R control system be sure to E G R control valve and thermal vacu

reset odometer of detector drive um valve for normal operation

counter to zero I When engine coolant tempera EC254

620 models ture is low Fig ET 41 Checking thermal

b This item applies to
Make that E G R control valve vacuum valw
except those bound for California sure

and Canada does not operate when engine speed is

increased from idling to 3 000 to
If any difficulty is encountered in
3 With engine stopped inspect 3 500 rpm
judging the condition of any compo
E G R control valve for any indication Place fingers on the diaphragm of
nent during above inspection check
of binding or sticking by movirig dia E G R control valve to check for valve
the questionable component independ
phragm of control valve upwards with operation
ently as follows
fmgers

E GR control valve

Dismount EG R control valve

from engine
I Apply vacuum to E G R control
valve referring to the following figure
If the valve moves to full position it is
normal
EG R control valve will remain
open for more than 30 seconds after
vacuum has cut off

EC253

Fig ET 40 Checking E G R control valve 0

r11

J
hC
2 When engine coolant tempera control valve ET152

ture is high Increase engine speed from idling to

I Make sure that E G R control valve 3 000 to 3 500 rpm Fig ET 42 Checking E G R control
VGlve
operates when engine speed is in Make sure that thermal vacuum

creased from idling to 3 000 to valve is open and that carburetor

3 500 Place the
rpm fingers on the vacuum is present at end
2 Visually check E G R control
diaphragm of E G R control valve E G R control valve side ofvacu
valve for damage wrinkle or deforma
to check for valve operation urn hose
tion
2 If E G R control valve does not If vacuum is weak or not present at
3 Clean the seating surface of
operate check as follows all replace thermal vacuum valve If
E G R control valve with a brush and
is present E G R
Disconnect one end E G R control
vacuum replace compressed air and remove foreign
con trol valve
valve side ofvacuum hose connect matter from around the valve and

ing thermal vacuum valve to EG R port

ET 21
 Engine Tune up

little until pressure becomes 368

CHECKING mmH20 14 5 inH20
EVAPORATIVE 5 Shut the cock completely and

EMISSION CONTROL leave it unattended

6 After 2 5 minutes measure the
SYSTEM
height of the liquid in the manometer
7 Variation of height should remain
with 25 l20
mm 0 98 inH20
Vapor Rnes and fuel vepor
8 When filler cap does not close
control valve
completely the height should drop to
zero in a short time
r EC350 Checking fuel tank vapor liquid
9 If the height does not drop to
separator and vapor vent line
filler cap is
zero in a short time when
Fig ET 43 Cleanil E G R control
l
I Check all hoses and fuel tank removed it is the cause of a stuffy
Jlue
lJ

roler cap hose

theline
2 Disconnect vapor vent
connecting carbon canister to vapor

liquid separator
a Note In case the vent line is stuffy
3 Connect a way
3 connector
Thermal VBCuum valve in fuel tank is
cock the breathing not
manometer and a or an equiva
Dismount thermal valve causing in
vacuum
lent way
3 charge cock to the end of thoroughly made thl
from engine the vent line suffICient delivery of fuel to engine

4 Supply fresh air into the vapor or vapor lock It must therefore be

Note Before dismounting drain e vent line through the cock little by repaired or replaced

gine coolant from engine

Apply vacuum to thermal vacuum

way
3 connectoT 36 mmH20 14 5 inH20
valve and check to be sure that ther
mal valve opens or closes in
vacuum

response to engine coolant tempera

lurt i i1 lt U
iYCl
Thermal valve should open
vacuum
c

at a temperature of 57 to 630C 134 I

W
to 1450F completing the vacuum

@ s
r
passage

Note Do not aUow water to get

Carbon canister
inside the thermal vacuum valve

EC786

Fig ET 45 Checking evaporative emission control By tem

Checking carbon canister purge

control valve

Check for fuel vapor leakage in the

distributor VC line at diaphragm of
carhon canister purge control valve
II

To check for leakage proceed as

L
I
follows

1 Disconnect rubber hose in the

line between T connector and carbon
canister at Tconnector

2 Inhale air into the opening of

242
EC rubber hose to VC hole in ET349
running
carbon canister and ensure that there Fig ET 46 Checking carbon cani ter
Fig ET 44 lChecki
thermallXlCuuml
valve is no leak purge control valve

ET 22
 Engine Tune up

3 If there leakisremove top

a 3 If valve is clogged or if no resist 8 Adjust idle adjusting screw until
cover from
purge contiol valve and ance is felt replace cap as an assem specified CO percentage is obtained
check for dislocated or cmcked dia bled unit Refer to page ET 12

phragm If necessary replace dia 9 Repeat the adjustment process as

r
phmgm kit which is made up of a described in steps 5 to 8 above until
retainer diaphragm and spring specified CO percentage is obtained
Note Adjustment in step 9 should be
made ten minutes after engine has

u
warmed up

10 Race engine 1 500 to 2 000

I @
ET369
rpm two
and make
or three times under
that specified CO per
sure
no load

Fig 49
ET Fuel filler cap
centage is obtained
I1 Remove and connect air
cap
1 Cover
hose to air check valve
2 Diaphragm
3 Retainer CHECKING If idlingspeed increases readjust it
4 Diaphragm spring CATALYTIC to specified speed with throttle ad
justing screw
ET350 CONVERTER Warm up
12 engine for about four
Fig ET 47 Carbon caniater purge
minutes at 2 000 rpm under n load
control valve INSPECTION
13 Measure CO percentage at idling

Preliminary inspection speed After step 12 has been com

Carbon unlster filter pleted wait for one minute before
Visually check condition of all
Check for a contaminated element making CO percentage measurement
component parts including hoses
14 If CO percentage measured in
Element can be removed at the tubes and wires replace if necessary
step 13 is less than 3
0 the catalylic
bottom of canister installed on vehicle Refer to Inspection of A IS on
converter is normal
body page EC 17 15 If CO percentage measured in

step 13 is over 03 recheck IS

A
Catalytic converter
and replace air check valve Then
Whether catalytic converter is nOf
steps 12 and 13
perform inspection
mal or not can be checked by ob 16 If CO percentage is still over
serving variation in CO percentage 03 in step 15 catalytic converter is
The checking procedure is as follows
malfunctioning Replace catalytic con

brake Shift verter

Apply parking gears
into Neutral for manual transmission
and Neutral or Park for automatic
transmission

1 Visually check catalytic converter

for damage or cracks CHECKING FLOOR

Fig ET 48 Replacing carbon
2 Remove air hose between 5 way TEMPERATURE
canister filter
connector and air check valve Plug the
WARNING SYSTEM
disconnected hose to prevent dust
from entering Refer to page ET 12 INSPECTION
3 Check carburetor pipes for proper
Fuel tank vacuum relief
connection Floor warning temperature
valve operation
4 Warm up engine sufficiently system
Remove fuel filler cap and see it 5 Race engine 1 500 to 2 000 rpm
functions properly two or three times under no load then Apply parldng brake Shift gears
into Neutral for manual transmission
I Wipe clean valve housing and have run engine for one minute at idling
and Neutral or Park for automatic
it in your mouth speed
transmission
2 Inhale air A 6 Adjust throttle adjusting screw
slight resistance ac
until engine attains to 1 Ensure that floor
companied by valve indicates that specified speed tern perature

valve is in good mechanical condition Refer to page ET 12 warning lamp lights when ignition
Note also that by further inhaling air 7 Check ignition timing If neces switch is turned to the S position
the resistance should be disappeared sary adjust it to specifications Refer If not check lamp for burned
with valve clicks to page ET 10 bul bs

ET 23
 Engine Tune up

Replace bulb if bulb is burned ou t IGU position results do not satisfy the above reo

If bulb is not burned 3 Ensure that floor place the floor temperature relay
trace wireis tem perature

back warning lamp goes out

to ignition switch Repair or
replace if necessary 4 Heat surrounding areas of floor
2 Be sure that floor temperature is temperature sensing switch with a
cool below 800C 1760F before proper heater to ensure that floor

carrying out the following procedure temperature warning lamp glows when

1 Remove rear seat

floor is heated to lh specifications as
When floor temperature
shown in the table below
2 Ignition switch is turned to the warnln8 lamp 118hts
Check floor temperature warning

Temperature Temperature lamp

Floor temperature
I
sensing switch warning lamp Open or short circuit in wiring
harness

2 Check fuel system with regard to

Contact close Off Below 1050C 22IOF the following items Refer to Inspec
tion of Fuel System
I Floa t level

Contact open On 2 Choke

Above 1050C 2210F
3 Normal fuel supply system Prima
ry and secondary
4 Accelerator pump
Note Avoid heating floor tempera temperature relay for continuity with
5 Power valve
ture sensing switch directly a circuit tester
6 BC DD
If lamp does not glow check floor Referring to the following floor
7 Fuel strainer
temperature sensing switch connector temperature relay if relay is normal
8 Air cleaner
trace wire s back to ignition switch
for continuity with a circuit tester
If continuity should exist after Repair faulty wiring 3 Check ignition system with regard
to the
heated surrounding areas offloor tern following items Refer to
cinq
sen Inspection of Ignition System
wnTP
rv Vitch
S reolace tem
I IgnItion AMI
perature sensing switch Floor temperature
rela 2 Distributor
If continuity does not exist trace
To
check floor temperature relay 3
the wiring back to relay or check the Ignition coil
remove it and proceed as follows 4
following step 3 Repair or replace High tension code
wire s 5 Spark plug
if necessary 1 Check for continuity between@
4 Check idle CO
and @ Continuity should exist adjustment Refer
Note The floor temperature sensing Check for continuity between to Inspection of Idle
D CO Adjust
switch may be heated through the roeoC
and@ Continuity should exist
floor by a proper heater Check for continuity between D
and@ Continuity should not exist Note Even if there is nothing wrong
3 Turn ignition switch to the IG 2 Apply a 12 volt doC across@and with engine warning lamp may
position disconnect floor temper
anf @ to ensure that continuity exists come on if vehicle is being driven
ature sensing connector The lamp between D and@and that continuity on a steep slope continuously in
should remain on If not check floor does not between D and @ If test lower gears at high engine speeds

4 03

UJ 2
3
To floor temperature
warning lamp
From S
From
position
GOt position
4 From ignition switch

GJO r I 141 5 To floor temperature

sensing switch
EC343

Fig 50
ET Checking floor temperature relay

ET 24
 Engine Tune up

SERVICE DATA AND SPECIFICATIONS

Ignition timing and idling

Manual transmission degree rpm 120 B T D jC750 Non Calif models
100 B T D j750
C California models

Automatic transmission

in D degree l20B T D j650

C
position rpm

Valve clearance

Cold Intake mm in 0 20 0 008

Exhaust mm in 0 25 0 010

Hot Intake mm in 0 25 0 010

Exhaust mm in 30
0 0 012

Belt tension

Fan mm in 8 to 12 315
0 to 472
0

Air pump mm in 8to 12 315

0 to 0472

Air coo compressor mm in 8 to 12 315

0 to 0 472

10 22 is applied
Pressure kg lb

Compression pressure at 350 rpm

12 0 171
Standard kg cm2 psi
Minimum kg em2 psi 9 0 128

Radiator cap relief pressure kg em2 psi 09 13

Cooling system
kg cm2 1 6 23
Leakage testing pressure Psi

680F 1 26
Battery specific gravity at 200C

Distribu tor

Point gap mm in 0 45 to 0 55 0 018 to 0 022

Air gap mm in 0 2 to 4 0 008 to 0 016

0

degree 490 to 550

Dwell angle

Condenser capacity IF 0 20 to 0 24

Mil 5
Condenser insulation resistance

Spark plug
Gap mm in 0 8 to 0 9 0 031 to 0 035
Breaker points type
10 to 1 0 039 to 0 043

Transistor ignition type

Checking CO percent at idling speed No air

Manual transmission model rpm 21 1

750
2 1 1 650
Automatic transmission model rpm

Adjustment of operating pressure of B C D D

BC D D set pressure
510 to 550 20 1 to 21 7
Manual transmission mmHg in Hg
Automatic transmission mmHg in Hg 490 to 530 3 to
19 20 9

ET 25
r
Engine Tune up

A TC air cleaner

Operating temperature OC OF 30 to 54 86 to 129

Tightening torque
Cylinder head bolts
1st turn ft b
kg m 4 0 29
2nd turn kg lll ft lb 6 0 43
3rd turn kg m ft lb 5 to 8 5
6 47 to 61

Manifold nuts kg m ft lb 12 to 1 6 8 7 to 116

Carburetor nuts kg m ft lb 0 5 to 10 3 6 to 7 2

Spark plugs kg m ft lb 1 5 to 2 0 II to 14

ET 26
 Engine Tune up

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

CANNOT CRANK Improper grade oil Replace with proper grade oiL
ENGINE OR SLOW
Discharged battery Charge battery
CRANKING
Faulty battery Replace
Loose fan belt Adjust
Malfunction in charge system Inspect

Wiring connection loose in starting circuit Correct

Faulty ignition switch Repair or replace

Faulty starler motor Repair or replace

Trouble circuit
shooting procedure on starting
Switch on the starting motor with light ON

When light goes off or dims considerably

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

When light stays bright

a Check wiring connection between battery and starter

motor

b Check ignition switch

c Check starter motor

ENGINE WILL CRANK NORMALLY BUT WILL NOT START

In this case the following trouble causes may exist but in many cases ignition system or fuel system is in trouble

Ignition system in trouble

Fuel system in troubk

Valve mechanism does not work properly
Low compussion

Trouble shooting procedure

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

Good spark occurs

Check spark plug

b Check ignition timing
c Check fuel system
d Check cylinder compression
No spark occurs Check the current f10 in primary circuit

Very high current Inspect primary circuit for short

Check breaker poiIit operation except tran

sistor ignition system

ET 27
 Engine Tune up

Condition Probable cause Corrective action

Low or no current Check for loose terminal or disconnection in

primary circuit
Check for burned points

Ign tion system out of Burned distributor point Repair or replace

order
Improper point gap Adjust

Faulty condenser Replace

Leak at rotor
cap and rotor Clean or replace
Faulty spark plug aean adjust plug gap or replace
Improper ignition timing Adjust
Faulty ignition coil Replace
Disconnection of high tension cable
Replace
Loose connection or disconnection in Repair or replace
primary circuit

Fuel system out of Lack offuel Supply

order
Dirty fuel strainer Replace
Dirty or clogged fuel pipe Clean

Fuel pump will not work properly Repair or replace

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

Improper idling Adjust

Dirty or clogged carburetor Disassemble and clean

Clogged breather pip of fuel tank Repair and clean

Malfunctioning an ti dieseling solenoid valve Check for loose terminal or wire harness

Low ion
comp sparle plug tightening
Incorrect or faulty Tighten to normal torque or replace gasket
gasket
Improper grade engine oil or low viscosity Replace with proper grade oil

Incorrect valve clearance Adjust

Compression leak from valve seat Remove head and
cyljnder lap valves

Sticky valve stem Correct or valve and valve

replace guide
Weak or damaged valve springs valve
Replace springs
Compression leak at cylinder head gasket Replace gasket
Sticking or damaged piston ring Replace piston rings
Worn piston ring or cylinder Overhaul engine
Trouble ooting procedure
Pour the engine oil from hole and then
plug measure

cylinder compression

Compression increases Malfunctiong cylinder or piston ring

Compression does not change Compression leaks from valve cylinder head
or head gasket

Except transistor ignition system

ET 28
 Engine Tune up

Condition Probable cause Corrective action

IMPROPER ENGINE
IDLING

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

order Incorrect idle adjustment Adjust
Clogged air cleaner filter Replace element

Damaged manifold gaskets or carburetor Replace gasket or insulator

insulator

Improper float level adjustment Adjust

Loose air hoses or air fuel mixture hoses of Check for loose connections
carburetor

Malfunctioning carburetor choke Check and adjust

Malfunctioning anti backfire valve Check for loose connection of vacuum hose

Malfunctioning automatic temperature con Check A r C air cleaner

trol air cleaner

Inoperative idle compensator Check for connection of idle compensator

hose or replace idle compen tor

Carbon canister purge line hose damaged or Connect or replace

disconnected

Stick E F E valve shaft Repair

Previously mentioned
Low compression

Others Incorrect valve clearance Adjust

Extremely low revolution Adjust

Faulty malfunction of the ignition system Replace

spark plug high tension cable breaker
point ignition coil etc

Incorrect basic ignition timing Adjust

Malfunction of choke valve or linkage Adjust

Malfunction of vacuum motor sensor or Check for loose hoses Replace system com

hoses of air cleaner ponents if necessary

Incorrect idle adjustment Adjust idle speed

air cleaner fdter Replace air cleaner fdter

Clogged
Malfunction of idle compensator of air Replace
cleaner

Malfunction of E G R control valve Clean or

replace
Loose manifold and cylinder head bolts Retighten bolts

High engine idle Dragged accelerator linkage Check and correct accelerator linkage
speed Incorrect idle adjustment Adjust idle speed

Malfunction of B CDD system Check for loose vacuum hose and harness
connections

Adjust or replace if necessary

Malfunction of speed switch and harness Check for loose connections Repair or

replace if necessary

ET 29
 Engine Tune up

Condition Probable cause Corrective action

ENGINE POWER NOT

UP TO NORMAL

Low compression Previously mentioned

Ignition system out of Incorrect iSnition timing Adjust

order Damaged spark plugs Clean adjust or replace plull
Dress or replace points Also check
Worn distributor points
condenser

Fuel system out of Malfunction of choke system lst

Adj
order fuel pipe floating valve Clean
Clogged or

Dirty or clogged fuel strainer Replace

Fuel pump will not work properly Repair or replace
carburetorjets Disassemble and clean
C10ssed
Malfunction of altitude compensator Check and replace

Air intake system out CIOJBed air cleaner Replace element

of order Ail inhaling from manifold gasket or Replace gasket

carburetor gasket

Emission control Malfunction of E G R valve Check and replace

Stick E F E valve shaft Repair

Overheating Insufficient coolant Replenish

Loose fan belt Adjust fan belt

Worn or oiled fan belt Replace

Inoperative thermostat Replace

Worn water pump Replace
or leaky radiator Flush repair or replace
Clogged
Worn radiator filler cap Replace
Ail in system Retighten each part of cooling system
cooling
oil Replace with proper grade oil
Improper engine grade
Incorrect ignition timing Adjust
Clossed carburetor lean mixture Overhaul carburetor

Disconnected altitude compensator hOlle Connect

O cooIing Inoperative thermostat Replace

Others Improper octane fuel Replace with specified octane fuel

L j tire pressure Inflate to specified pressure

Dragging brake Adjust

Clutch slipping Adjust

Except transistor ignition system

ET 30
 Engine Tune up

Condition Probable cause Corrective action

NOISY ENGINE

Car knocking Overloaded engine Use right gear in driving

Disassemble cylinder head and remove

Carbon knocking
carbon

Timing knocking Adjust ignition timing

Fuel knocking Use specified octane fuel

Preignition misusing of spark plug Use specified spark plug

Mechanical knocking
Crankshaft bearing This strong dull noise increases when engine This is caused by worn or damaged bearings
is accelerated To locate the place cause a or unevenly worn crankshaft Renew
Imocking
misfire on each cylinder If the noise stops and adjust or change crankshaft
bearings
the misfire this cylinder generates the Check lubrication system
by
noise

This is little noise than the Same as the case ofcrankshaft bearings
Connecting rod a higher pitched
crankshaft and also increases
bearing knocking Imocking
when engine is accelerateda misfire Cause
on each
cylinder and if the noise deminishes

almost completely this crankshaft bearing

generates the noise

of
Piston and cylinder When you hear an overlapping metalic noise This may cause an abnormal wearing
which increases its magnitude with the cylinder and lower compression which in
noise
revolution of engine and which decreases as turn will cause a lower out put power and
is warmed up this noise is caused by excessive consumption of oil
engine
piston and cylinder To locate the place
cause a misfire on each cylinder Overhaul engine

Piston pin noise This noise is heared at each highest and This may cause a wear on piston pin or

lowest dead end of piston To locate the piston pin hole

place cause a misfire on each cylinder Renew piston and piston pin assembly

This noise be caused by worn or Replace water pump with a new one
Water pump noise may
earings by the uneven surface
damaged or

of sliding parts

Air pump noise Damaged air pump Repair or replace

Others An improper adjustment of valve clearance Adjust

Noise of timing chain Adjust the tension of chain

An excessive end play on crankshaft Disassemble engine and renew main bearing

Noisy E F E valve shaft Repair

Wear on clutch pilot bushing Renew bush and adjust drive shaft

Note This noise will be heared when

clutch is disengaged

ET31
 Engine Tune up

probable cause Corrective action

Condition

ABNORMAL
COMBUSTION
backfue afterflre
run on etc

Adjust ignition timing

Improper ignition timing Improper ignition timing
Improper heat range of spark plugs Use specified spark plugs

out of Damaged carburetor or manifold gasket Replace them with new parts
Fuel system
order backfue afterfire
Disassemble carburetor and check it
Cloled carburetor jet
l

function of the float Adjust the level and check needle valve
Improper
Uneven idling Run on Adjust

Improperly adjusted B CD D set pressure Adjust

Malfunction of anti dieseling solenoid valve Check or replace

Malfunction of choke
auio Adjust

Faulty cylinder head etc

Improperly adjusted valve clearance Adjust
Excess carbon in combustion chamber Remove head and get rid ofcarbon

Damaged valve spring backfire afterflre it with new one

Replace a

Others Malfunction of A T C air cleaner Check for loose vacuum hoses Replace if

necessary

Inoperative backfue
ariti valve Replape

EXCESSIVE OIL
CONSUMPTION

Oilloak Loose oil drain plug Tighten it

it
Loose or damaged oil pan gasket Renew gasket or tighten
Renew tighten it
Loose or damaged chain cover gasket gasket or

Worn oil seal in front and rear of crankshaft Renew oil seal

Renew tighten it but not too

Loose or damaged locker cover gasket gasket or

much

of oil filter Renew gasket and tighten it with the proper

Improper tightening
torque

Loose or damaged oil pressure switch Renew oil pressure switch or tighten it

and Overhaul cylinder and renew piston

lo oil
Excessi Cylinder pioton wear
consumption Remoun t piston rings
Improper location of piston ring gap or

reversely assembled piston ring

Renew rings
Damage piston rings
Repair or renew piston and cylinder

Worn and ring Renew piston and piston ring

piston ring groove
ofvalve oil seal lip Replace seal lip with a new one
Fatigue
Worn valve stem Renew valve or guide

of engine oil Use the designated oil

Others Inadequate quality
Engine overheat Previously mentioned

ET32
 Engine Tune up

Condition Probable cause Corrective action

POOR FUEL ECONOMY

Se the xplanation
of the pow r dec

Exceeding idling revolution Adjust it to the designated rpm

Oth n

Adjust it
Inoperative acceleration recovery

Repair or tighten the connection of fuel

Fuel leakage
pipes

Malfunction of B C D D Adjust

Malfunction of A rC air cleaner Check and replace

PROBLEM IN OTHER

FUNCTIONS

D cr d oil p ssure Inadequate oil quality Use the designated oil

Overheat Previously mentioned

Disassemble oil pump and it
Worn oil pump regulator valve repair or renew

it with
Functional deterioration of oil pump Repair or replace a new one

Blocked oil f1lter Renew it

Increased clearance in various sliding parts Disassemble and replace the worn parts with
new ones

Blocked oil strainer Oeanit

it with a new one

Inoperative oil gauge pressure switch Replace

Excessive wear on the Oil pressure decreases Previousiy mentioned

sliding parts contamination of oil Exchange the oil with proper one and
Improper quality or

change element

Damaged air cleaner Change element

Overheat or overcoal Previously mentioned

Improper fuel mixture Check the fuel system

Decrease of oil pressure Previously mentioned

Scuffing of sliding
parts Insufficient clearances Readjust to the designated clearances

Overheat Previously mentioned

Improper fuel mixture Check the fuel system

Floor temperature too Problem in fuel system Refer to Inspec Check and repair

California only tion of Fuel System

high
Problem in ignition system Refer to In Check and repair

spection of Ignition System

ET33
 SECTION EM

ENGINE
DATSUN PICK UP MECHANICAL
MODEL 620 SERIES

GENERAL DESCRIPTION EM 2

ENGINE DISASSEMBLY EM 4

INSPECTION AND REPAIR EM 8

ENGINE ASSEMBLY EM 21

SERVICE DATA AND EM 2l

SPECIFICATIONS

TROUBLE DIAGNOSES AND

EM 31
CORRECTIONS

SPECIAL SERVICE TOOLS EM 33

lMlSSAN I
oJ

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Engine Mechanical

GENERAL DESCRIPTION

CONTENTS
EM 2 CAMSHAFT EM 3
MODEL L20B ENGINE
EM 3 VALVE MECHANISM EM 3
CYLINDER BLOCK
EM 3 CAMSHAFT DRIVE EM 3
CRANKSHAFT
ROD EM 3 MANIFOLDS EM 3
PISTON AND CONNECTING
EM 3
CYLINDER HEAD

out smooth dependable power CYLINDER BLOCK

MODEL L20B
The cylinder block is cast as a single
ENGINE unit deep skirting This The cylinder block a mono block
and featllres
is equipped with a single 2 special casting structure employs a
engine
The L20B engine features O H C bearing
five support system for quiet
barrel downdraft carburetor that in
valves wedge shaped combustion ness and higher durability
corporates a
special device to control
chamber aluminum head and a fully The cylinder bores are surrounded
emissions
balanced 5 bearing crankshaft to turn
by cooling jackets and machined di
rectly in the block The oil ways in the
block are arranged so that the full flow
oil filter is directly attached to the

right hand side of the block

EM536

Fig EM 2 Cylinder block

EM535

Fig EM Cross sectional view

Main specifications

L20B
CRANKSHAFT
The crankshaft is steel
Oisplacemen t cc cu in 1 1191
952 a special
forging Fully balanced it turns out

85 X 86 smooth dependable power at high

Bore x stroke in
mm
3 35 x 39
3 speed
The L20B engine uses eight balance
ratio 8 5 weights
Compression
Main bearings are lubricated by oil
750
12 pumped through the main oil gallery
Non California model and the oil holes which run in parallel
MIT
Ignition timing 750
10 bores There
with cylinder are oilways
California model
Degree B T O C rpm drilled in the crankshaft for the lubri
The center main is
AlT 12 650 in 0 position cating oil bearing
equipped with thrust washers to take

MIT Manual Transmission AIT Automatic Transmission up end thrust of the crankshaft

EM 2
 Engine Mechanical

CAMSHAFT CAMSHAFT DRIVE

The camshaft is made of a special The camshaft is driven by a double
cast iron and is located inside the roller chain driven
row by the crank
rocker cover Four aluminum alloy shaft The tension of the chain is
brackets support it Camshaft bearings controlled chain tcosioner which
by a

are lubricated from oil holes which isoperated by spring and oil pressure
lead to the main oil gallery of the The rubber shoe type tensioner damps
Fig EM 3 Crankshafl cylinder head vibration of the chain and controls its
Concentric passages are drilled in tension
the front and rear parts of the earn

PISTON AND shaft

CONNECTING ROD Oil to each earn lobe is supplied
through an oil hole drilled in the base
The pistons are of a special alumi
circle of each lobe Lubricant is sup
num casting and have struts to control

plied to the front oil gallery from the

thermal expansion compression
two
2nd camshaft bearing and to the rear
rings and one combined oil ring The
oil gallery from the 3rd camshaft
piston heads are slightly dished The
bearing These holes on the base circle
piston pil1S are a special hollow steel
of the lobe supply lubricant to the
shaft They are full floating fit to the
piston and press fit to the connecting
earn
pad surface ofthe rocker arm and
to the valve tip end The cams feature
rods
a overlap
long profile to reduce NOx
The connecting rods are of a special EM537
emission
forged steel Oil is sprayed to the Fig EM 8 Chain driving aystem
rod small ends through
connecting
drilled passages in the large ends of
rod Oil holes in the connecting rods

are located so as to insure optimum

lubrication under heavy load

0
5 01 Fig EM 6 Camshafl
MANIFOLDS
The intake manifold is of an alumi

E Moao o num cast alloy

VALVE MECHANISM The exhaust manifold is of a dual
Fig EM 4 Piston and connecting rod

The valve system has the pivot type design and incorporates a heat control
valve in it The heal control valve is
rocker arms that are activated directly
used to warm the intake manifold
by the earn mechanism this has made
CYLINDER HEAD A is installed on the outer
its moving parts considerably lighter plate
The cylinder head is made of a face of the manifold to draw hot
and provides ideal high speed perform
intake air out it The exhaust
light strong aluminum alloy with good ance through
is connected to the flanged
cooling efficiency it contains wedge Dual type valve springs are in pipe sur

type combustion chambers A special face of the exhaust manifold

stalled
aluminum bronze valve seat is used on

the intake valve while heat resistant

h
a

steel valve seat is installed on the

exhaust valve These parts are all hot

press fitted @l

if

EM407 Exhaust Intake EM084

Fig EM 9 Intak and exhaust

Fig EM S Cylinder head Fig EM 7 Valve mechanism manifolds

EM 3
r Engine Mechanical
I

I
ENGINE DISASSEMBLY

CONTENTS

PRELIMINARY CLEANING AND PISTONS AND CONNECTING RODS EM 7

INSPECTION 4
EM CYLINDER HE AD EM 7
DISASSEMBL Y EM 4

PRELIMINARY 6 Remove air pump drive belt cool

CLEANING AND front chain cover oil pan and oil filter er
compressor and idler pulley if so
gaskets lInd crankshaft and water equipped
INSt
ECTION of 7 Remove starter motor from trans
pump seals for signs leakage past
Before disassembling engine note mission
their gasketed surfaces
the following 2 Check carburetor and fuel pump 8 Visually inspect cylinder head
I Fuel oil or water may leak past for condition fuel hoses for deteriora cylinder block rocker C Ner front
head chain cover oil pan and all other outer
cylinder and block Prior to tion cracks or leakage of fuel past
check cylinder parts for oil water and fuel leaks
disassembling head their jointed or connected surfaces

breakage or missing parts such as bolts

and nuts

9 Check piping and electrical cir

cuits for deterioration breakage fit

tings discontinuity or insulation

1 1ltermal vacuum valve

2 Check valve
3 Altitude
compensator DISASSEMBLY
in air cleaner
To remove engine from vehicle
4 Air gallery pipe
S choke
Auto
refer to the instructions under the
6 Automatic temperature Engine Removal and Installation
control air cleaner ER section
7 Anti 8ackfire valve A B valve
I Remove transmission from en
8 Boost Controlled Deceleration

Device Bee D D gine

9 P cv valve 2 Remove clutch from
assembly
to Air relief valve
11 E G R control valve
flywheeL
3 Thoroughly drain engine oil and
12 B C D D control valve and
solenoid valve coolan t by removing drain plugs
13 Emergency air relief valve Store engine oil and coolant if they
14 Air pump air cleaner
are to be used again
IS Carbon canister
4 Place engine assembly on engine
16 Air control valve
stand
11 Air pump

I Remove
E T366
cooling fan
2 Remove right engine mounting
Fig EM 0 Emiuion control devic s California mod 18 bracket
3 Remove oil filter with Oil Filter
3 Remove carburetor air cleaner Disconnect air cleaner to A B valve Wrench STI9320000
Remove fresh air duct 4 Remove oil pressure swi tch
hose at air cleaner
Disconnect hot air duct from air Disconnect 5 Install
air cleaner to related engine attachment to

cleaner part vacuum hoses at air cleaner cylinder block utilizing bolt holes in

Disconnect air cleaner to air pump Loosen air cleaner band bolt and alternator bracket and water drain
hose at air cleaner remove carburetor air cleaner as hole
Disconnect air cleanef to rocker from carburetor 6 Set stand
sembly engine on

cover hose at rocker cover 4 Plug up carburetor air horn to Engine Attachment
Disconnect air cIeaner to air prevent entry of
con foreign matter ST05260001
trol valve hose at air cleaner Cali 5 Remove alternator drive belt Engine Stand
fornia models only alternator and alternator bracket ST050I SOOO

4
EM
 Engine Mechanical

9 Remove cylinder block to P C V

valve hose blow by gas hose from

cylinder block

10 Remove manifold attaching

bolts and remove intake and exhaust

manifold and gasket from

assembly
cylinder head

1 Air control valve

2 Distributor EM531

EM410
Fig EM 13 Removing air control
Fig EM II Engine on engine land valve Californio model

Remove oil level gauge

2 Remove carburetor air cleaner
6 Remove carburetor from intake
bracket
manifold
3 Disconnect vacuum hose from
1 Disconnect cylinder block to
E G R valve
C V valve hose at P C V valve
P
4 Remove check valve from air
2 Disconnect A B valve to E G R
gallery pipe
passage hose at E G R passage Fig EM 16 Removing intake and
5 Disconnect EG R tube from exhaust manifold assembly
3 Disconnect vacuum tube to

carburetor hoses white and

E G R passage and exhaust manifold
yellow at
6 Remove E G R passage and
vacuum tube
E G R valve from intake manifold
4 Disconnect fuel hose from
11 Remove intake and exhaust
carburetor
manifold attaching bolts and separate
5 Remove dash pot bracket from
intake manifold from exhaust mani
intake manifold
fold
6 Remov carburetor attaching
12 Remove air gallery pipes from
bolts and remove carburetor assembly exhaust manifold
and gasket
12 Remove left engi e mounting
7 Disconnect distributor high ten
bra et from cylinder blopk
sion cables from sparkplugs 13 Remove air pump and cooler
8 Disconnect vacuum hose from
compressor bracket
distributor and remove distributor as
14 Remove in
crankshaft pulley
sembly I E G R passage and
stalling bolt washer and then
9 Disconnect fuel hose from fuel 2 E G R tube EM532
remove pulley with a two jaw puller
and remove fuel and vacuum
pump Fig EM 14 Removing E G R tube and
15 Remove water pump assembly
hoses combined from cylinder head passage
16 Remove rocker cover
10 Remove fuel pump assembly
17 Remove spark plugs
from cylinder head
7 Remove F lC D 18 Remove fuel pump drive earn
bracket from
cylinder head if so equipped 19 Remove camshaft sprocket
8 Disconnect vacuum hoses from Refer to the following note during

thermal vacuum valve and remove operation when removing camshaft

thermostat housing and gasket from sprocket from engine installed on car
cylinder head

EM412

Fig EM 12 Removing fuel pump

IJ Remove intake and exhaust

manifold assembly from cylinder head

1 Disconnect vacuum hose from

EM089
air control valve and remove air con EM091

trol valve for California and a r hoses Fig EM 15 Removing thermostat Fig EM 17 Removing cammaf
housing sprocket
as an assembly

EM 5
r

Engine Mechanical

28 Remove cylinder head assembly 29 Invert engine 36 Remove piston and connecting
Use Cylinder Head Bolt Wrench 30 Remove oil pan and oil strainer rod a mbly Extract connecting rod
STl0120000 to remove cylinder head bearings keeping them in order
bolts Loosen bolts from CD to @ as

shown in Figure EM 18

EM094
I
Fig EM 20 Removing oil traintir
Fig EM 23 Removing pilton and
and oil pump
connecting rod aatm b y
Fig EM IS Cylinder head bolt
loosening equence

37 Remove flywheel and

31 Remove oil pump and its drive rear plate
Notes When heao
removing cylinder spindle See Figure EM 20
Be careful not to drop them
from engiJJe installed on car follow
32 Remove front cover
the instructions below
33 Remove chain tensioner and
Turn crankshaft until No I chain slack side guide
a pilton
is at TD C its
on compression
stroke
b Remove rocker Cover and fuel
pump
c To facilitate assembling o tion

scribe 8 mark on timing c 8in and

camshaft sprocket with paint be

fore removal EM415

d Loosen camshaft bolt and remove

Fig EM 24 Removing flywheel
fuel pump drive earn

e Support timing chain by utilizing

Chain Stopper STl7420001 bet
ween timiilg chains as shown in 38 Remove main bearing caps
EM095
Figure EM 19 Use Crankshaft Main Bearing Cap
This 0 peration eliminates the prob Fig EM 21 Removing chain ten ioner
Puller KVIOI04ISO to remove center
and tim ing chain
lem of realigning timing marks on and rear main bearing caps Keep them
timing chain and crankshaft in order
sprocket
34 Remove timing chain See
Figure EM 2l

35 Remove oil thrower crankshaft

wonn gear and chain drive sprocket KVIOI04IS0

EM539

EM538 Fig EM 25 Removing rear main

bearing cap
Fig EM 19 Supporting timing chain

f Remove camshaft sprocket 39 Remove two side seals from rear

g Loosen cylinder head bolts and main
Fig EM 22 Removing chain drive bearing ca p
remove cylinder head Proc et 40 Remove rear oil seal

6
EM
 Engine Mechanical

Note Be careful not to damage eam

shaft bearings and earn lobes

3 Remove valves using Valve Lifter

STl2070000

EM103 STl2070000

EM411 Fig EM 29 Remouingpi tonpin

Fig EM 26 Remouing rear oil eal

3 Keep disassembled parts in order

41 Remove crankshaft

42 Remove baffie plate and cyl

inder block net

CYLINDER HEAD
Fig EM 32 Removing ualves
I Remove valve rocker springs
Loosen valve rocker pivot lock nut and
remove rocker arm by pressing valve

spring down
Notes
a Take care not to lose valve spring
seat oil seal valve collet and valve
rocker guide
b Be sure to keep camshaft bearings
intact or the bearing center is liable
Fig EM 27 Removing baffle plate and to come out of alignment
nel

PISTONS AND
CONNECTING RODS 61
8

Remove piston rings with a ring Fig EM 3D Removing rockerarrm

remover

2 Remove locate plate and remove

camshaft

O Exhaust Intake

Fig EM 33 Value components

EM101

EM102

Fig EM 28 Removing pilton rings

EM105
2 Press piston pin out with Piston

Pin Press Stand STl3030001 Fig EM 31 Remouing cammaft

EM 7
r

Engine Mechanical

INSPECTION AND REPAIR

CONTENTS

PREPARATION FOR INSPECTION EM 8 PISTONS PISTON PINS AND

CYLINDER HEAD AND VALVE EM B PISTON RINGS EM 15

CHECKING CYLINDER HEAD MATING CONNECTING ROD EM 16

FACE EM 8 CRANKSHAFT EM 16
VALVE ASSEMBLY EM 8 BUSHING AND BEARING EM 17
VALVE SPRING EM 9 MEASUREMENT OF MAIN BEARING
ROCKER ARM AND VALVE ROCKER CLEARANCE EM 17
PIVOT EM lO MEASUREMENT OF CONNECTING ROD
VALVE GUIDE EM l0 BEARING CLEARANCE EM 1B
VALVE SEAT INSERTS EM 11 FITTING BEARINGS EM 18
CAMSHAFT AND CAMSHAFT BEARING EM 12 MISCELLANEOUS COMPONENTS EM 19
CAMSHAFT BEARING CLEARANCE EM 12 CRANKSHAFT AND CAMSHAFT
VALVE TIMING EM 12 SPROCKETS EM 19
CAMSHAFT ALIGNMENT EM 13 CHAIN TENSIONER AND CHAIN GUIDE EM 20
CYLINDER BLOCK EM 13 FLYWHEEL EM 20
HOW TO MEASURE CYLINDER BORE EM 13 FRONT COVER AND REAR OIL SEAL EM 20
CYLINDER BORING EM 14

PREPARATION FOR Note Head surface flatnes

Never remove camshaft bear
N
INSPECTI unless have
ings you a Suitable
I Before cleaning check for signs machine or boring Camshaft bear
of water and oil leaks in cylinder block ing in line If you once remove Standard Maximum
and head camshaft bearings bearing centers
2 Clean oil carbon deposits and will come out o alignment reo less than 0 05 O lmm
sealant from an parts Remove gasket
conditioning is very difficult with mm 0 0020 in 0 0039 in
3 Clean all oil holes with solvent out center borings
and dry with compressed air Make
that L Make a v isual check for cracks
sure they are not restricted
and flaws

2 Measure the surface of cylinder VALVE ASSEMBLY

head on cylinder block side for
Check each intake and exhaust
warpage If it is found to be beyond valve for worn damaged or deformed
the limit designated below regrind the valve caps or stems Correct or replace
CYLINDER HEAD affected surface with a surface grinder
any valve that is faulty
AND VALVE 2 Valve face or valve stem end

surface should be refaced with a valve

CHECKING CYLINDER grinder
HEAD MATING FACE

10 I I

L
I
EM109
EM407

Fig EM 35 Checking cylinder head Fig EM 36 Intak and exhaust valve

Fig EM 34 Cylinder head dimensions
8JJrface

8
EM
 Engine Mechanical

VALVE SPRING

H
Valve head diameter I In 42 0 to 42 2 1 654 to 1 661
1 Check valve spring for squareness
mm in
Ex 35 0 to 35 2 378
1 to 1
386 using a steel square and surface plate
If spring is out of square more than
In 114 9 to 115 2 524
4 to 4 535
Valve length 1 6 mm 0 063 in
L
replace
2 Measure free
mm in
Ex 1157 to 116 0 555
4 to 4 567 lhe length and ten
sion of each spring If the measured
In 7 965 to 7 980 3136
0 to 0 3142 value exceeds specified limit replace
Valve stem diameter
D
mm in spring
Ex 7 945 to 7 960 3128
0 to 3134
0

In 45030
Valve seat angle
a
Intake and Exhaust
Ex 45030
I
i

T
J

EM112

Fig EM 39 Measuring spring quareneu

EM110

Fig EM 37 Checking valve tern

EMll1
diameter
Fig EM 38 Regrinding valve face

1
Note When valve head has been worn

down to 0 5 nun 0 0197 in in

thickness replace the valve
Grinding allowance for valve stem EM113

end surface is 0 5 mm 0 0197 in

or less Fig EM 40 Measuring apring ten ion

Spring specifications

Valve spring free length mm in

Intake and exhaust

Outer 49 98 1 968

44 766
Inner 1
85

Valve spring pressured length

valve open in lb
mmlkg
Intake and exhaust
Outer 29 5 49 0 161
1 108
Inner 24 5 5 0 965156 2
25

Valve spring assembled height

valve close mmlkg in lb

Intake and exhaust

Outer 40 0 3
21 1575 47 0

Inner 35 12
0 3 1378 27 I

EM 9
rr

Engine Mechanical

ROCKER ARM AND

Replacement of valve guide
VALVE ROCKER PIVOT
8 3 to 8 5 dia
Exhaust I To remove old guides use a drift
0 327 to 0 335
Check pivot head and cam contact and a press under a 2 ton pressure or
and pivot contact surfaces of rocker
arm for damage or wear If damage is
1
4 a hammer
Drive them out from combustion
found replace them
faulty pivot A 3 0 I2 JL chamber side toward rocker cover
must be replaced together with its 12 223 to 12 234 Heated cylinder head will facilitate the
Intake 150 0 4812 to 0
corresponding rocker arm 1
4817 dia
operation
2 Ream
I cylinder head side guide
I
7
P hole at room temperature
VALVE GUIDE 6 to 7 8

guide
Measure clearance
and valve stem
between valve

If clearance
J 10 0 425
8
S9 0 2 323
0 299 to 0 307

1 Unit mm
dia

in
exceeds designated limit replace worn EM572

parts or both valve and valve guide In

this case it is essential to determine if Fig EM 41 Se11Jice value guide
such a clearance has been caused by a
e 5t
worn or bent valve stem or by a worn 10 6
0
E
valve guide lj
m3l 10 6 417

dl7 flH
O
IV
l
II
In take valve Exhaust valve

Stem to guide clearance 0 020 to 0 053 0 040 to 0 073

mm in 0 0008 to 0 002 0 00 6 to 0 0029

Maximum limit ofabove

01 0 0039 Unit in
clearance mm in mm EM116

Fig EM 43 Valve guide hole

As an emergency expedient a valve

can be pushed into valve guide and

moved to the right and left If its tip

deflects about 2 mm
0 For factory standard 11985 to 11996
00079 in or
valve guide 4718
0 to 0 4723
more it indicates that the clearance Guide hole inner
between stem and guide exceeds the diameter an mm in
maximum limit of 1 mm 0 0039
0 For service valve 12 185 to 12 96

in guide 4797
0 to 4802
0

Note Valve should be moved in paral

3 Carefully press new valve guide Reaming bore
lel with rocker arm Generally a
into valve so that it will fit
amount of wear occurs in this smoothly 8 000 to 8 018 rnm
large after head
heating cylinder to 150 to 3150
0 to 0 3157 in
direction
2000C 302 to 3920 F
Max allowable deflection Valve guide of 0 2 mm 0 0079 in
0 2 mm 0 0079 in oversize diameter is available for ser
n r vice as indicated above
l 18Iin
30mm

C1r Interference fit of valve

r guide guide hole

to
0 027 to 0 049 mm

0 0011 to 0 0019 in

EM115
Fig EM 42 Mea uring clearance
between valve tern
and valve gu ide
4 Ream bore with valve guide press
ed in using Valve Guide Reamer Set EM419
KVIOI039S0 Fig EM 44 Reaming valve guide

EM 10
 Engine Mechanical

5 Correct valve seat surface with Replacln valve eat In ert

new valve guide as the axis

1 Old insert can be removed by
boring it out until it collapses The
machine depth stop should be set so
VALVE SEAT INSERTS
that boring cannot continue beyond
Check valve seat inserts for any the bottom face of the insert recess in
evidence of pitting at valve contact cylinder head
surface and reseat or replace if worn 2 Select a suitable valve seat insert
excessively and check its outside diameter
Valve seat insert of 5
0 mm 0 0197 3 Machine cylinder head recess to
Fig EM 45 Correcting valve seat
in oversize is available for service as the circles in valve
concentric guide
shown below center so that insert will have the
correct fit

4 Heat cylinder head to a tempera

ture of 150 to 2000C 302 to 3920 F
q 1 5 Fit insert ensuring that it beds on
lO
I the bottom face of its and

I
recess

Intake k k i caulk more than 4 points

379 to 38 1 6 Newly fitted valve seats should be

eel
co
q
1492 to 1
500 dis
cut or ground at the specified dimen
0 597
45 to 45 613 sions as shown in Figure 47
EM
1
7 95 to 1 796 dia
Unit mm in EM573 7 Apply small amount of fine grind

ing compound to valve contacting face

and put valve into guide Lap valve
0
32 6 12835 dia against its seat until proper valve seat
ing is obtained Remove valve and then
clean valve and valve sea 1
0 295
Exhaust 5
17
I I
30 U81 dia

37 580 to 37 596 14795 to 14802 dia

Unit mm in

Fig EM 46 Seroice valve seat dimensions

Cylinder head diameter

rece
Unit mm in

For factory standard

45 000 to 45 016 1 7717 to 17723
insert

Intake
For service insert 500
45 to 516
45 1 7913 to I 7920

For factory standard 1 4567 to I 4573

37 000 to 37 016
insert
Exhaust

I For service insert 37 500 to 37 516 1 4764 to I 4770

Intake 0081 to 0 113 0 0032 to 0 0044

Interference
fit mm in
Exhaust 0 064 to 0 096 0 0025 to 0 0038

EM 11
 Engine Mechanical

600

Intake

38 1 496I dia

W 39 6 I559Ildia
18 16457 dia
45 71l1
1

Unit mm in

30

Exhaust

30 l1
811 di
32 6 2835 dia
I
34 6 1 3622 dia
137 1 4567 dia

EM121

Unit mm m

Fig EM 47 Standard value aeat dimensions

CAMSHAFT AND VALVE TIMING

CAMSHAFT BEARING This diagram applies to all cyl

inders If any valve is found out of
CAMSHAnBEARING
specifications one possibility that
CLEARANCE
carn lobe is worn or damaged This

Measure inside diameter of earn calls for replacement of camshaft

haft beating with an inside dial gauge

and outside diameter of camshaft jour

nal with a micrometer If wear is

EM119
found inside of bracket replace cyl
inder head assembly Fig EM 48 Checking cam haft bearing

Camshaft journal to bearing clearance

Standard Wear limit

0 038 to 0 067
Oil clearance mm in 0 1 0 0039
0 0015 to 0 0026

B DC

Inner diameter of earn 48 000 to 48 016 EM421

shaft bearing mm in 18898 to 18904
Fig EM 49 Value timing diagram

EM 12
 Engine Mechanical

j Using a bore gauge measure cyl

Standard Bend limit inder bore for out of round or taper If

of
out round or taper is excessive re
Camshaft bend bore cylinder walls with a boring
0 02 0 0008 0 05 0 0020
mm in I
machine Measuremen t should be
taken along bores for taper and around
bores for of round
out See Figure
CAMSHAFT ALIGNMENT
EM 52
I Check camshaft camshaft journal
and earn surface for bend wear or

X Y
damage If damage is beyond limits Qu t of round
A B
replace affected parts Taper
2 A bend value is one half of the

reading obtained when camshaft is

turned one full revolution with a dial

gauge applied to 2nd and 3rd journals

t bend
Fig EM 50 Checking camMa
M12

Fig EM 52 Measuring cylinder bore

diameter

Standard height
of tam mm in
I Intake
30
40 to 35
40

1 5866 to 1 5886
1 Exhaust 4 When wear
taper or out of round

is minor and within limits remove step

in 0 25 0 0098
Wear limit of earn height mm at
topmost portion of cylinder using
a ridge reamer or other similar tool
able difference in diam
Allo
ter

betweim max worn and min mm in 0 05 00020

worn parts of c mshaft journal

Maximum tolerance in irri

j01 mm in 0 1 0 0039
diameter
HOW TO MEASURE
CYLINDER BORE
CamShaft end play mm in 0 08 to 38
0 0 0031 to 0 0150
A bore gauge is used Measure
cylind r bore at top middle and bot
tom positions toward A and B direc
tions as shown in Figure EM 53 and

Standard Maximum tolerance record the measured values

Surface flatness less than

0 10 0 0039
mm in 0 05 0 0020 A
I
120 0 79
IlL
60 2 36

B
100
lll
3 94
el 1

Cy LlNDER BLOCK
I Visually check cylinder block for
cracks or flaws

top of cylinder block

r
2 Measure

head mating face for warp

cylinder Unit mm m

EM 22
age If warpage exceeds limits correct
it EM540

Fig EM 51 Cheching cylinder block Fig EM 53 Cylinder bort me08Uring

au rface positions

EM 13
 Engine Mechanical

Standard Wear limit

85 000 to 85 050
Inner diameter 0 2 00079
3465
3 to 3484
3

Cylinder bore
mm in Out of round ot5
O 00006

Taper 0 015 00006

Difference in cylinder bore

0 05 0 0020 0 2 0 0079
mm in

CYLINDER BORING

I When any cylinder needs boring 2 Determine oversize L

piston ac

all other cylinders must also be bored of wear of cylinder

7
cording to amount

at the same time

6 m
A
o 7323in
aboull r
Oversize pistons spec Hicetlons

Piston diameter mm in 127

84 985 to 85 035 Fig EM 55 MeCUJlJring piston skirt

Servioe standard
3459
3 to 3 3478 diameter

Rebored size calculation

0 50 0 0197 85 465 to 85 515
Oversize o A B C A 0005 to
3648
3 to 3 3667
Q25
0 mm 0 0002 to 00010 in
1 00 0 0394 where
85 965 to 86 015
oversize D Honed diameter
3844
3 to 3 3864
A Skirt diameter as measured

B Piston to wall clearance

C Machining allowance 0 02 mm

0 0008 in
3 The size to which cylinders must
be honed is determined by adding Standard clearance f im
in 0 025 to 0 045 0 0010 to 0 0018
piston cylinder
to clearance to the
largest piston diameter at
piston skirt Feeler gauge mm in 004 0 0016
in thrust direction

Extracting force kg Ib 0 2 to 1 5 O 44 to 3 31

Notes 5 Measurement of a just machined

a To prevent strain due to cutting cylinder bore requires utmost care
heat bore the cylinders in the order since it is expanded by
cutting heat
of 241 3 6 As a final step cylinders should
b Before boring any cylinder install be honed to size
main bearing caps in place and 7 Measure the finished cylinder
tighten to the specification so that bore for of
out round or tapered part
the crankshaft bearing bores will 8 Measure piston to cylinder clear
not become distorted from the bor ance

ing operation This clearance can be checked

easily by using feeler gauge and a
a
4 Do not cut too much out of spring balance hooked on feeler gauge
cylinder bore at a time Cut only 0 05 measuring the amount of force re
EM126
mm 00020 in or so in diameter at a quired to pull gauge out from between
Fig EM 54 Measuring piston diamet r
time and
piston cylinder

EM 14
 Engine Mechanical

Notes
PISTONS
a When measuring clearance slowly
PISTON PINS AND
pull feeier gaUge siraight upward
b It Is reConUnended that piston and PISTON RINGS
cylinder be hel ted to 200C 680F I Remove carbon from piston and
ring grooves with
a ca bon scraper and

a curved steel wire Clean out oil slots

00
in bottom land of oil ring groove
2 Check for damage scratches and
wear Replace if necessary

I 3 side clearance of rings in

1re
Meas1

ring grooves as each ring is installed

EM542

Fig EM 58 Measuring ring gap

Side clearance should be as follows

Notes
t a When piston ring only is to be
replaced without cylinder bore
being corrected measure gap at
f
J bottom of cylinder where wear is

rr 11 1 I
minor

b Oversize piston rings are available

EM541 for serv ce

Fig EM 56 Measuringpiaton fit

Oversize
in cylinder
05 mm 0 0197 in and
Fig EM 57 Measuring piston ring 10 mm 0 0394 in
side clearance
5 Measure piston pin hole in rela
tion to outer diameter of pin If wear
Side clearance exceeds limit replace each piston pin
Unit mm in together with the piston on which it is
installed
6 Determine the fitting of piston
Standard Wear limit
into
pin piston pin hole to such an
extent that it can be finger pressed at
0 040 to 0 073 room temperature This piston pin
Top ring
I 0 0016 to 0 0029
01 0 0039
must be a

ing rod
tight pre s fit into connect

0 030 0 070
I
to
Second ring
I 0 0012 to 0 0028

Oil ring
f
I I
4 Push ring into cylinder with pis feeler gauge
in Ring should be placed to diameter
ton so as place it
to squarely
measure ring with a at upper or lower limit of ring travel
cylinder gap

EM131

Ring gap Unit rom in Fig EM 59 Piston pin fitting

Standard Wear limit

0 25 to 40
0
Top ring 0 0098 to 0 0157

30
0 to 0 50
Second ring 1 0 0 0394
0 0 II8 to 0 0197
EM132
0 30 to 0 90
Oil ring Fig EM 60 Measuring pi ton pin
0 0118 to 0 0354
diamet

EM 15
r

Engine Mechanical

Unit mm in
CRANKSHAFT
1 Whenever crankshaft is removed
Piston pin outside diameter 20 993 to 20 998 0 8265 to 0 8267
from engine it should be cleaned
in a suitable solvent
Piston pin hole diameter 21001 to 21008 0 8268 to 0 8271 thoroughly After
cleaning check crankshaft journal and

I crank pin Jor score bias

piston clearance 0 003 to 0 015 wear or
Piston pin to 00001 to 0 006
cracks air or replace
Rep as required
If damage is minor dress with fine
Interference fit of piston
0 015 to 0 035 0 0006 to 0 0014 crocus cloth
pin to connecting rod
2 Check journals and crank pins for

taper and out of round with a micro

meter Measurement should be taken

along journals for taper and around

CONNECTING ROD journals for of
out round See Figure
I If 63
EM for detailed information
a connecting rod has any flaw 2 Check connecting rod for bend or

either side of the thrust face or the torsion rod Ifjournals or crank pins are tapered
on using a connecting aligner
end correct or it If bend or of
out round beyond limits replace
large replace or torsion exceeds the limit
with a new shaft
q rrect or replace

A B

EM133

Fig EM 61 Ch cking rod alignment

Standard Maximum Out of round XY

Taper AB
rod bend
Connecting
Unit mm in
or torsion per 100 mm 19 5 0 768
or 3 94 in length 0 03 0 0012 0 05 0 0020 27

tt
30 32
181 106 1
2 60
in
mm
43 l 69
O

3 When
I
replacing connecting rod
1
select rod so that weight difference
between
gr 0 25 oz
new and old ones is within 7

All main
E journa All crank pm
Do not use a combination of new 59 942 to 59 955
49 961 to 49 974
and former 2 3599 l 2 3604
connecting rod big end o

1 9670 to 19675
nuts and connecting rod bolts which EM424

affect specified weight variations Fig EM 63 Crankshaft and journal

4 Install connecting rods with bear dimensions

ings on to corresponding crank pins

and measure thrust clearance Ifmeas
Fig EM 62 Checking big end play
ured value exceeds limit replace

Standard Maximum

0 2 to 0 3
Big end play mm in 0 6 0 0236
0 0079 to 0 01 18

EM 16
 Engine Mechanical

Standard Maximum

STl6610001

Taper and out of round

less than
of journal and crank pin Q25
0 0 0010
0 01 0 0004
mm in

3 Crankshaft bend can be checked

by placing it on V blocks and using a EM425

dial gauge with its indicating finger Fig EM 66 Pulling outpilot

resting on center journal bushing

2 Before installing a new bushing

thoroughly clean bushing hole Press
fit bushing so that its height above
flange end is 4
5 to 5 0 mm 177
0 to
0 197 in Do not oil bushing

EM137

bend
Fig EM 64 Checking crankshaft

Standard Maximum

less than
Crankshaft bend mm in 0 10 0 0039
0 05 0 0020

EM418
Note When measuring bend use a
Fig EM 67 Press fitting new pilot
dial gauge Bend value is half of the bush ng
reading obtained when crankshaft is
turned one full revolution with a

dial gauge attached to its center

journal
BUSHING AND
4 After regrinding crankshaft finish BEARING
it to the necessary size indicated on

MEASUREMENT OF
page EM 18 by using an adequate
undersize bearing according to the MAIN BEARING CLEARANCE
extent of required repair clean all bearings and
I Thoroughly
5 Install crankshaft in cylinder check for scratches melting score or

block and measure crankshaft free end wear

Fig EM 65 Checking crankshaft end
if any fault is
play play Replace bearings
detected
2 Crankshaft journals and bearings
should be clean and free from dust and
Wear limit
Standard dirt before oil clearance is measured
3 Set main bearing on cap block

0 05 0 18
plastigage to width of bear
Crankshaft free end to
00118 4 Cut a
03
in 0 0020 to 0 0071 it in with crank
play mm ing and place parallel
pin getting clear of the oil hole Install
them
cap on the assembly and tighten
6 At the rear end of crankshaft To replace crankshaft rear pilot
together to the specified torque
for bushing proceed follows
check crankshaft pilot bushing as

bushing using Pilot Tightening torque

wear or damage Replace it if any fault I Pull out
5 to
4 5 kg m 33 to 40 ft lb
is detected Bushing Puller STl66 1000 I

EM 17
 Engine Mechanical

Bearing 011 clearance

Standard Wear limit

Main bearing clearance 0 020 to 0 062

0 12 0 0047
mm in 0 0008 to 00024

Connecting rod bearing 0 025 to 055

0
0 12 0 0047
clearance mm in 0 0010 to 00022
Fig EM 68 P14stigage

2 If clearance exceeds specified 3 Then measure bearing crush H

Note Do not tum crankshaft while value replace bearing with an under with feeler gauge See Figure EM 70
a

plastigage is being inserted size bearing and grind crankshaft jour The standard bearing crush value is
nal adequately listed below
5 Remove cap and compare width
of the plastigage at its widest part with
FiniNG BEARINGS
the scale printed in plastigage enve

Bearings are manufactured with

lope
crush to make bearing snug down into
Weight
its bore To measure this proceed as
H
follows

I Set main bearing in main bearing

cap recess or cylinder block bearing
recess correctly
2 Lock one side of bearing and

press other side until bearing back

surface touches the recess Fig EM 70 Checking bearing crum

Bearing crush

Fig EM 69 Measuring bearing All main bearings mm in o to 0 03 0 to 0 0012

clearance

All connecting rod bearings mm in 0015 to 0 045 0 0006 to 0 0018

MEASUREMENT OF 4 Handle connecting rod bearing in the same manner as above

CONNECTING ROD BEARING
CLEARANCE
I Measure connecting rod bearing
clearance in the same manner as above Main bearing undersize
Unit mm in

Tightening torque Crank journal diameter

Bearing top thickness
4 5 to 5 kg m 33 to 40 ft lb

1 827 to 1835 59 942 to 59 955

SID 2 3599 to 2 3604
00719 to 0 0722

0 25 00098 1952 to 1960 59 692 to 59 705

Undersize 0 0769 to 0 0772 2 3501 to 3506
2

50
0 0 0197 2 077 to 2 085 59442 to 59 455
Undersize 0 0818 to 0 0821 2 3402 to 2 3407

0 75 00295 2 202 to 2 210 59 192 to 59 205

Undersize 00867 to 0 0870 3304
2 to 2 3309

EM 18
 Engine Mechanical

Connectlns rod be rlns undersize Unit mm in

Bearing top thickness Crank pin diameter

1493 to 1
506 49 961 to 49 974
SID
0 0588 to 0 0593 1 9670 to 1 9675

1 618 to 1 631 49711 to 49 724

0 25 0 0098 Undersize
0 0637 to 0 0642 1 9571 to 1 9576

1 743 to 1 756 49461 to 49 474

0 50 0 0197 Undersize
0 0686 to 0 0691 1 9473 to 1 9478

1 868 to 1 881 49 211 to 49 224

0 75 0 0295 Undersize
0 0735 to 0 0741 1 9374 to 1 9379

3 Check chain for damage exces

MISCELLANEOUS
sive wear or stretch at roller links
COMPONENTS
Replace if faulty
CRANKSHA AND 4 To properly adjust chain tension
CAMSHA SPROCKETS or valve timing camshaft sprocket
has a earn locating plate and three
I Check tooth surface for flaws or
location holes Nos I 2 and 3
wear Replace sprocket if fault is
found
Camshaft sprocket is preset at
2 Install camshaft sprocket in posi No I hole at the factory If chain
Fig EM 72 Checking camshaft end becomes loose adjust it by setting
tion and check for rounout If it
play camshaft sprocket at NO 2 hole If
exceeds 0 1 mm 0 0039 in total
indicator camshaft chain is too loose adjust it by setting
reading repl ce
camshaft sprocket at No 3 hole
sprocket Also check for end play

Camshaft end play

0 08 to 38
0 mm

0 0032 to 0 0150 in

Location match

3
EMl48

Before adjustment After adju5tmen t

Fig EM 71 Checking eam haft EM311

sprocket Tunaut Fig EM 73 Adjuating camshaft aprocket location

EM 19
 Engine Mechanical

Turn
I engine until No I piston is CHAIN TENSIONER AND
at T DC on its compression stroke
CHAIN GUIDE
Determine whether camshaft sprocket
Check for wear and breakage Re
location notch comes off the left end
if necessary
of the camshaft place
oblong groove on

locating plate If the location notch is

off the left end of the oblong groove

chain stretch is beyond limits

EM426

Fig EM 76 Checking flywheel

deviation

40150 3 Check tooth surfaces of ring gear

r for flaws or wear
I
Replace if necessary

FRONT COVER AND

L REAR OIL SEAL

First check front cover an rear oil

seal for worn or folded over sealing lip
or oil leakage If necessary install a
EM147
EMl46
EM 75 Cam haft dri new seal When installing a new seal
Fig mechanilm
Fig EM 74 Camshafllocating plate pay attention to mounting direction

Note It is good practice to replace oil

seal whenever engine is overhauled

2 Turn engine until No I piston is r

at T D C on its compression stroke r

t
setting camshaft on No 2 location
hole in camshaft sprocket This No 2
Frant
notch should then be on the right end FLYWHEEL
of the oblong groove When No 2 hole I Check clutch disc contact surface
JI
is used NO 2 timing mark must also
with flywheel for damage or wear
be used The amount of the modifica
Repair or replace if necessary Front
tion is a 40 rotation ofcrankshaft 2 Measure runout of clutch disc
Real
3 When modification becomes im contact surface with a dial gauge fit EM150
possible even by transferring camshaft exceeds 0 15 mm 0 0059 in total
location hole replace chain assembly indicator reading replace it Fig EM 77 Oil eals of crank haft

EM 20
 Engine Mechanical

ENGINE ASSEMBLY

CONTENTS

PRECAUTIONS EM 21 PISTON AND CONNECTING ROD EM 22

CYLINDER HEAD EM 21 ENGINE ASSEMBLY EM 22

PRECAUTIONS Cylinder block Rear main bearing cap

I Use thoroughly cleaned parts

Especially make sure that oil holes are 20to2Smm

clear of foreign matter

2 When installing sliding parts such
Ill s
e
as bearings be s uIe to apply engine oil 00

000
to them
o
3 Use new packing and oil seals Points to be applied sealant EM151
4 Do not reuse lock washers
Fig EM 79 Applying sealanl
5 Keep tools and work benches Main bearing cap and Fig EM 81 Installing valves
clean cylinder block
and tools Notes
6 Keep necessary parts
a Ensure that valve face is free from
near at hand
3 Cylinder block Step portions at
7 Be sure to follow specified tight foreign matter
four mating surfaces cylinder block to b The L20B engine uses double type
ening torque and order
8 front chain cover and cylinder block valve springs
Applying sealant
to rear main bearing cap See Figure
Use sealant to eliminate water and
2 Valve rocker pivot assembly
EM 80
oil leaks Parts requiring sealant are
Screw valve rocker pivots joined
Front cover and corners of cyl Note
I Do not apply too much sealant with lock nuts into pivot hushing
inder block See Figure EM 78 3 Camshaft assembly
Set locating plate and carefully
install camshaft in cylinder head Do

J not damage the bearing inside Oblong

groove of locating plate must be
directed toward front side of engine

Camshaft bracket tightening

torque
1 8 to 2 0 kg in 13 to 15 ft lb

4 Install camshaft sprocket on earn

Apply sealant at hese points shaft and tighten it together with fuel
EM152 pump drive cam to specified torque
Fig EM 80 Applying sealant Tightening torque
EM153 Cylinder block
12 tol6 kg m 87 to 116 ft lb
Fig EM 78 Applying alant
Front cover and
this time check camshaft end
cylinder block

CYLINDER HEAD
Valve assembly and valve spring
Using Valve Lifter STl2070000 set
valve pring seat in position and fit
valve with oil seaL
guide
2 Main bearing cap and cylinder Assemble valve in the order shown
block Each side of rear main bearing below valve inner and outer valve
of cylinder block retainer valve collet
cap and each corner springs spring Fig EM 82 Installing camshaft
See Figure EM 79 and valve rocker guide sprocket

EM 21
 Engine Mechanical

Install rocker arms by pressing b Arrange that oil of connect 3 Install baffle plate including cyl
5 so jet
valve springs down with a screwdriver ing rod big end is directed toward inder block net

6 Install valve rocker springs right side of eylinder block Notes

7 Afterassembling cylinder head c Be sure to install piston in cylinders No 3 is
a Only center bearing a

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

flanged type
T D C on its compression stroke toward front of engine b All bearings
inter No 2 and No 4

arethe same type

2 Install piston rings
c Front bearing No I is also the
InstalI top and second rings in right
5
position with marked side up
same type as rear bearing No
The difference is that an oil hole is
Notes provided in the front bearing
a Top ring is chromium plated on d All upper and lower bearings are

liner contacting face

interchangeable
b Second ring has larger taper surface
than top ring 4 Apply engine oil to main bearing
EM1S5 c In the combined oil ring upper rail surfaces on both sides of cylinder
is the same as lower one block and cap and then install crank
Fig EM 83 Aembling cylinder head
shaft

5 Install main bearing cap and tight

bolts to specified torque

j c6J
en

PISTON AND Tightening torque

5 to 5 kg m 33
4 to 40 ft lb
CONNECTINGROD
Notes
1 Assemble pistons piston pins and
connecting rods on the ignated
de a Apply sealant to each side of rear
EM158 main bearing cap and each comer
cylinder
of eylinder block as shown in
Fig 86
EM lalling pidon rings
Figure EM 79
b Arrange parts so arrow mark on
3 Fix bearings on connecting rod
and connecting rod cap bearing cap faces toward front of
engine
Note Clean back side of bearing care c Prior to tightening bearing cap
STl3030001 fully bolts place bearing cap in proper
position by shifting crankshaft in
the axial direction
d cap bolts gradually
Tighten bearing
EM156
ENGINE ASSEMBLY in two to three stages outwardly

84
EM Installing piston pin from center bearing in the sequence
Fig
The first step in engine assembly 88
EM
as shown in Figure
is to bolt Engine Attachment
e After securing bearing cap bolts
ST0526000 I to right hand ide of
ascertain that aankshaft turns
cylinder block Next install block on
smoothly
another Engine Stand ST0501S000
with engine bottom up
2 Set main the proper
bearings at
portion of cylinder block
@
EM157 Rear Front

Fig 85
EM Assembling piston and
connecting rod III III m It IlL
Notes
a Piston is pressed into connecting
D D D D D i
rod with fitting force of 0 5 to 5 d
tons aid of Piston Pin Press
Stand STl303000 I is necessary l

When pressing piston pin into con 15 4

1 13 12 11
j 1 @EM543
necting rod apply engine oil to pin EM159
Fig EM 8S Torque sequence 0

bolt
and small end of connecting rod Fig EM 87 Main bearings cap

EM 22
 Engine Mechanical

6 Make sure that crankshaft has Note When installing oil seal give
coating of oil
proper end play engine to mating
shaft to prevent scratches and fold
Crankshaft end play
ed lip Also give coating of oil to
0 05 to 18
0 mm

0 0020 to 0 0071 in periphery of oil seal

9 Install end
rear
plate
10 Install
flywheel securely and Fig EM 94 Installing connecting rod
tighten bolts to specified torque cap

Tightening torque
14 to 16 kg m
Note Install connecting rods and con
101 to 116 ft lb
necting rod caps 80 that their as
II Insert pistons in corresponding signed numbers are positioned on

cylinder using Piston Ring Compressor the same side and in the SlIme

EM03470000 direction with respect to cylinders

13 Make sure that connecting rod

big end has proper end play
EM03410000
Fig EM 89 Checking crankshaft
end play
I

7 Install side oil seals into rear main

bearing cap Prior to installing apply

sealant to seals

EM544

Fig EM 92 Installing pi8ton rod

Sembly
a

Fig EM 95 Checking big end play

Notes
oil to
a Apply engine sliding parts Big end play
b Arrange 80 that notch mark on
0 2 to 3 mm
0
piston head faces to front of en
0 008 to Ql2
0 in
gine
14 Install cylinder head
Install at 1800 to each assembly
c piston rings
other avoiding their fit in the
thrust and piston pin directions
Fig EM 90 Driving side oil seal

8 Install rear oil seal using Crank Top ring

6
shaft Rear Oil Seal Drift STI5310000

r
I iilring
Piston pin ireClioJ Fig EM 96 Tightening sequence 01
cylinder head bolts

STl5310000
EM165

Fig EM 93 PUtan ring direction

J Thoroughly clean cylinder block
r
and head surface
12 Install connecting rod caps Do not sealant to any other
apply
head sur
EM163 Tightening torque part of cylinder block and
Fig EM 91 Installing rear oi seal 4 5 to 5 kg m 33 to 40 ft lb face

EM 23
 Engine Mechanical
b Install Cront cover with head gasket
2 Turn crankshaft until No I pis 17 Install chain slack side guide to
in place
ton is at TD C on its compression cylinder block
c Check height diCCerence between
stroke 18 Install chain tensioner
cylinder block upper Cace and Cront
3 Make sure thai camshaft sprock
notch and plate oblong
Note Adjust protrusion oC chain ten cover upper Cace DifCerence must
et location
correct
sionerspindle to 0 mm 0 in be less than 15
0 mm 0 0059 in
groove are aligned at their
d Note that difCerent types oC bolts
positions are used
4 When installing cylinder head
e Before installing front cover on
make sure that all valves are apart
cylinder block apply coating oC
from heads of pistons
engine oil 10 sealing lip of oil seal
5 Do not rotate crankshaft and
camshaft separately or valves will hit
heads of pistons
6 Temporarily tighten two bolts
sJiown in Fig
re EM 96
CD V
Tightening torque
2 kg m 14 ft b
Fig EM 98 lmtalling chain tensioner
15 Install crankshaft sprocket and
and fit oil
oil pump drive gear
thrower EMS11

19 Press new oil seal in front cover

Fig EM lOD Front cover bolts
Note Make lhat maling marks of
sure
Notes
crankshaft sprocket face 10 Cront
a Front cover oil seal should be reo Tightening torque
Size M8 315
0 in
16 Install timing chain placed when Cront cover is disas
10 to 13 kg m 7 2 to 9 4 ft lb
sembled
Noles
b BeCore pressing oil seal into Cront Size M6 236
0 in
a Make sure that crankshaft and cam
to 2 9 to 4 3 ft lb
cover give coating of engine oil 4 to 0 6
0 kg m
shaft keys point upwards
periphery of oil seal
21 Install crankshaft pulley and
c This oil seal isthreaded seal type
a
water pump assembly then set No I
which has improved sealing charac
piston at ToO C on its compression
teristics Do not apply grease to
stloke
sealing lip
Crankshaft pulley nuI

20 Install front cover with gasket in tightening torque

Fuel pump drive
earn
place 12 to 16 kg m B7 to 116 ft lb

2 Chain guide
3 Chain tensioner
4 Crank sprocket
5 earn sprocket
6 Chai guide
EM439

b Set timing chain by its

OOgning
mating marks with those oC crank
1 Timing mark EM546
shaft sprocket and camshaft sprock 2 Timing mark
EM545 Fig EM Ol lnstallingcran haft
et at the right hand side There are
Fig EM 99 Installing fronl COlHlr pulley and
forty four chain links between two water pump
mating marks of timing chain
c NO 2 hole is Cactory adjusted 22 Finally tighten head bolts to

When chain stretches excessively the specified torque in three steps

Notes to the
adjust camshaft sprocket at No 3 according lightening sequence
hole a Apply sealant to Cront cover and shown in Figure EM 96
d Use of marks and corners oC upper section of cylinder Note thai Iwo types of bolts
a set timing are

location hole numbers block as shown in Figure EM 78 used

EM 24
 Engine Mechanical

ol Cylinder Head Bolt Tightening torque

Speci
Wren h 8110120000 Oil strainer bolts
0 8 to I l 5 8 to 8 0 ft lb
kg m

Tightening torque Oil pan bolts

1st turn
0 6 to 0 9 kg m 3 to
4 5 ft lb
6
4 0 kg m 29 ft lb

2nd turn

I
43 ft lb Notes
6 0 kg m

3rd turn a Apply sealant to the step portions

6 5 to 8 5 kg m at four mating surfaces as shown in

47 to 61 ft lb Figure 80
EM
should be in
b Oil pan tigh tened
cross
criss pattern to a final torque
of 0 6 to 0 9 kg m 4 3 to 6 5 ft lb
O A
B

A 26 Adjust valve clearance to the

O
B
specified dimensions
B
B O
Special tool
O A Pivot Adj iier STl064000l
R

Tightening torque
A
5 0 to 6 0 kg m 36 to 43 ft lb

EM 176

Fig EM I02 Cylinder head boll EM I04

Fig 11l6lalling oil pump

24 Install fuel pump water inlet

Notes elbow and front engine slinger in their

a Be sure to tighten two small bolts positions
b After engine has been operated for Fuel pump tightening torque
several minutes retighten if neces 12 to 1 8 kg m

sary 8 7 to 13 0 ft lb

23 Install oil pump and distr butor Note Do not forget to install fuel
Fig EM I05 Adjusting valve clearance
driving spindle in front cover between
pump spacer and packing
Tightening torque spacer and block spacer and fuel
b After engine has been assembled
1 to 1 5 kg m pump
run it for at least several minutes
8 0 to 10 8 ft lb
Install oil strainer oil pan gasket and to the
25 finally adjust clearance
and oil pan warm specifications

Notes
a Assemble oil pump and drive spin
die aligning driving spindle face
with oil pump hole
b Install oil pump together with drive

spindle so that the projection on its

top is located at the II 25 a m

position At this point the smaller 27 Install rocker cover to cylinder 29 Install intake manifold to ex

shape
bow will be facing toward the haust manifold The intake manifold
head
front face which comes into contact with
Note Make sure that one of the
Do not forget to install gas et with that of
c
than the gasket should be even
rocker cover bolts is longer
exhaust manifold Note that two dif
others It secures IC D
F assist
ferent sizes of attaching bolts are used
bracket

28 Install air pump bracket and Tightening torque

block 2 5 kg m 18 0 ft lb
cooler compressor to cylinder

EM 25
 Engine Mechanical

30 Install heatshieid plate on mani 45 Install dash pot bracket and

fold assembly dash pot to intake manifold

31 Install air gallery pipe on ex 46 Connect all air vacuum and fuel
haust manifold hoses and then secure with clamps
32 Install manifold gasket and I Cylinder block to P C V valve

manifold assembly on cylinder head hose

2 A B valve to E G R passage vac

Tightening torque
uum hose
1 2to 1 6kgm
8 7 to 116 ft lb
3 A B valve to E G R passage air
I
hose
I
33 Install blow by gas pipe on cyl 4 Vacuum tube to carburetor vac
KV30100200
inder block and tighten with rear EM440
uum hoses

engine slinger 5 Fuel ube carburetor

to fuel
Fig EM I07 In talling clutch embly
34 Install thermostat housing gas hose
ket thermostat housing and thermo 6 Fuel tube to fuel pump fuelhose
stat 7 Distributor to vacuum switch or
hose
35 Install thermal vacuum valve on spark delay valve vacuum
53 Using an overhead hoist and
thermostat housing Before installing 8 Air control valve vacuum hose
lifting cable hoist engine away from
apply a liquid packing slightly to the 9 Check valve to air control valve
engine stand and then down onto
threads hose
engine carrier
36 Install FJ C D bracket on cylin 10 Thermal vacuum valve to
54 Install right engine mounting
der head E G R valve vacuum hose
bracket oil filter oil pressure switch
37 Install EGR passage and I I Thermal vacuum valve to
oillevel gauge and water drain plug
E G R valve on intake manifold vacuum tube hose
When installing oil filter fasten it to
38 Connect E G R tube to E G R 47 Install carburetor air cleaner on
cylinder block by hand
tube and exhaust manifold carburetor and then connect air and
Install check valve Note Do not overtighten
39 on air gallery vacuum hoses as follows flit or oil
pipe leakage may occur
I Air cleaner to exhaust manifold
40 Install air cleaner bracket on 55 Install alternator bracket adjust
hot air duct
intake manifold ing bar alternator cooling fan and
2 Air c1eaner to air pump hose
41 Install air control valve on air belt
3 Air cleaner to rocker cover hose
cleaner bracket California models 56 Adjust the deflection of drive
4 Air cleaner to air control valve
42 Install vacuum and fuel tubes belts when thumb pressure is applied
hose
combined on cylinder head midway between pulleys A pressed
5 Air cleaner toA B valve hose
43 Install distributor assembly force is above 10 kg 22 0 lb
6 Other vacuum hoses
44 Install heatshield plate joint Deflection ofdrive belts
seat and carburetor 48 Install spark plugs in place
8 to 12 mm
49 Connect all distributor high ten
Carbure10r tightening torque 315
0 to 472
0 in
sion cables to
5 to 1 0 kg m 3 6 to 7 2 ft lb
0 spark plugs
50 Install air pump drive belt cool
Note When be
instalUng joint seat er compressor and idler pulley
sure to put the duct into primary 51 Install left engine mounting
hole in intake manifold
bracket
52 Install clutch assembly on
S
flywheel with Clutch Aligning Bar

KV30100200

Tighteningtorque
2 to 2 2 kg
1 m

8 7 to 15 9 ft lb

EM613

J Heatshield plate 4 Joint seat Fig EM lOB Fan belt tension

2 Primary hole 5 Secondary hole
3 Duct
EM534
57 Fill engine oil up to specified
Fig EM I06 Installing carburetor
joint seat level

EM 26
 Engine Mechanical

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS

L20B
Engine model
4 in line
Cylinder arrangement
1 952 J 19 1
co in
Displacemen t cc

85 x 86 3 35 x 3 39
Bore and stroke mm in

O HC
Valve arrangement

I 42
3
Firing order

Engine idle rpm

750
Manual transmission
D 650
Automatic transmission in range

8 5
ratio
Compression

Oil pressure Warm at 2 000 rpm

3 5 to 4 0 50 to 57
kg cm2 psi

SPECIFICATIONS
a Valve mechanism

Valve clearance Warm mm in

Intake 0 25 0 010
30
0 0 012
Exhaust

Valve clearance Cold mmOn

Intake 0 20 0 008

Exhaust 0 25 0 010

Valve head diameter mm in

42 0 to 42 2 1 654 to 1 661
Intake
35 0 to 35 2 1 378 to 1
386
Exhaust

diameter mm in
Valve stem
7 965 to 7 980 3136
0 to 3142
0
Intake
Exhaust 7 945 to 7 960 3128
0 to 3134
0

Valve length mmOn

114 9 to 115 2 524
4 to 4 535
Intake
555
4 to 4 567
Exhaust 115 7 to 116 0

Valve lift mmOn

Intake and exhaust 5
10 413
0

Valve spring out of square mm in less than 1 6 0 063

Valve spring free length mm in

49 98 1968
Intake and exhaust Outer

Inner
44 85 J 766

EM 27
 Engine Mechanical

Valve spring pressured length

valve open mm kg in lb
Intake and exhaust

Outer 5 49 0 1
29 IM 108
Inner 24 5 25 5 0 965 56 2

Valve spring assembled height

valve close mm kg lb
in
Intake and exhaust
Outer 40 0 3 1575 47 0
21
Inner 35 0 12 3 378
1 27 I

Valve guide length mm in

59 0 323
2
Intake and exhaust

head surface in 10 6 417

0
Valve guide height from mIll

Valve guide inner diameter mm in

8 000 to 8 018 0 3150 to 3157
0
Intake and exhaust

Valve guide outer diameter

service parts mm in
Intake and exhaust 12 223 to 12 234
4812
0 to 4817
0

Valve guide to stem clearance mm in

Intake 0020 to 0 053 0 0008 to 0 0021

Exhaust 0 040 to 0 073

00016 to 0 0029

Valve seat width in

mm
14 to 16 0 0551 to 0 0630
Intake
1 8 to 2 2 0 0709 to 0 0866
Exhaust

Valve seat angle

Intake and exhaust 450

Valve seat interference fit mm in

Intake 0 081 to 0 113 0 0032 to 0 0044

Exhaust 0 064 to 0 096 0 0025 to 0 0038

Valve guide interference fit mm in 0 027 to 0 049 0 0011 to 0 0019

b Camshaft and timing chain

Camshaft end rnm in 0 08 to 038 00032 to 00150

play
Camshaft lobeift rnm in
7 0 0 276
Intake and exhaust

Camshaft joumal diameter mm in

1st 2nd 3rd and 4th 47 949 to 47 962

1 8877 to 1 8883

Camshaft bend mm in 0 02 0 0008

Camshaft journal to bearing clearance mm in Q38 to 0 067 0 00 I 5 to 00026

0

Camshaft bearing inner diameter rnm in

1st 2nd 3rd and 4th 48 000 to 48 016
1 8898 to 18904

EM 28
 Engine Mechanical

c Connecting rod

Center distance mm in 146 5 748

Bearing thickness Standard mm in 1493 to 1 506 00588 to 00593

Big end play mm in 0 20 to 30

0 0 008 to 0 012
Connecting rod bearing clearance mm in D25 to 0 055 0 0010 to 0 0022
0

Connecting rod bend or torsion per 100 mm or 2 937 in

mm in less than 0 03 0 0012

d Crankshaft and main bearing

Journal diameter mm in 942 to 59 955 3599

2 io 3604
2

Journal taper out ofround mm in less than 0 0 I 0 0004

59
Crankshaft free end play in
mm 0 05 to 0 18 0 0020 to 0 0071

Wear limit of dittoed play mm in 3

0 0118
0
Crank pin diameter in
mm 49 961 to 49 974 1 9670 to 19675

Crank pin taper out of round mm in less than 0 01 0 0004

Main bearing thickness StJlndard in

mm 1 827 to 1 835 0 0719 to 0 0722

Main bearing clearance mm in 0 020 to 0 062 0 0008 to 0 0024

Wear limit of dittoed clearance mm in 0 12 0 0047

Crankshaft bend mm in 0 05 0 0020
Flywheel runout at clutch disc contact face

mm in less than 0 15 0 0059

e Piston

Pistondiarneter Service standard in

mm 84 985 to 85 035
3 3459 to 3478
3
0 50 0 0197 Oversize in
mm 85 465 to 515
85

3648
3 to 3667
3
100 0 0394 Oversize mm in 85 965 to 86 015
3 3844 to 3 3864
Ring groove width mm in

Top 2 030 to 2 050 00799 to 0 0807

Second 2 020 to 2 040 00795 to 0 0803
Oil 4015 to 4 040 0 1581 to 0 1591
Piston to bore clearance mm in Q25 to 0 045 0 0010
0 to 0 0018
Piston pin hole set
off mm in 0 95 to 1 05 0 0374 to 0 0413

Piston pin hole diameter mm in 21001 to 21008 0 8268 to 0 8271

f Piston pin

Pin diameter mm in 20 993 to 20 998

0 8265 to 0 8267
Pin length in
mm 72 25 to 73 00
2 8445 to 2 8740

Piston pin to piston clearance mm in 0008 to om 0 0 0003 to 0 0004

Interference fit of piston pin to
connecting rod bushing
mm in om 5 to 035
0 0 0006 to 0 00I 4

EM 29
 Engine Mechanical

g Piston ring
in
Ring height mm

1977 to 1 990 0 0778 to 0 0783

Top and second
Side clearance mrn in

Top 0 040 to 0 073 0 0016 to 0 0029

Second 0 030 to 0 070 0 0012 to 0 0028

Ring gap mm in
Top 0 25 to 040 0 0098 to 0 0157

Second 0 30 to 0 50 0 0118 to 0 0197

Oil 30
0 to 0 90 0 0118 to 0 0354

h Cylinder block

Cylinder bore inner diameter in

mm 85 000 to 85 050
3 3465 to 3484
3

Wear limit of dittoed inner diameter mm in 0 2 0 0079

Cylinder bore taper and out of round mm in om 5 0 0006

Difference in cylind bore mm in 0 05 0 0020

Surface flatness mm in less than 0 05 0 0020

i Cylinder head

Surface flatness in
mm less than 0 05 00020

TIGHTENING TORQUE
head bolts kg fl lb 5 to
6
Cylinder m 5
8 47 to 61

Connecting rod big end nuts kg m ft Ib 5 to 5 5

4 33 to 40

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

Main bearing cap bolts kg m ft lb 5

4 to 5 33 to 40

Camshaft bracket bolts ft lb 1 8 to 2 0 13 to 15

kg m

Camshaft sprocket bolt ft lb 12 to 16 87 to 116

kg m

Oil pan bolts kg m ft 1b 0 6 to 0 9 3 to 6 5

4

Oil pump bolts kg m ft lb J to 1 5

I 8 0 to 10 8

Oil strainer bolts kg m ft lb 0 8 to 1 5 8 to 8 0

Oil pan drain plug kg m ft lb 2 0 to 3 0 14 to 22

Rocker pivot lock nuts ft Ib 5 0 to 6 0 36 to 43

kg m

ft lb 0 6 to 0 9 3
4 to 5
6
Camshaft locating plate bolts kg m

Carburetor nuts kg m ft lb 5 to 1 0 3 6 to 7 2
0

Manifold bolts kg m ft lb 2 to 16 8 7 to 116

1

ft lb 1 2 to 18 8 7 to 13 0
Fuel pump nuts kg m

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

Water pump bolts kg m ft Ib 4

0 to 05 2 9 to 3 6

Front cover bolts kg m ft lb 8 mm 315

0 in dia 3 7 2 to 9 4
1 0 to 1

6 mm 0 236 in dia 4 to 0 6 2 9 to
0 3
4

EM 30
 Engine Mechanical

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

I Noisy engine
Loose main bearing Replace
Knocking of crankshaft
and bearing Seized bearing Replace
Bent crankshaft Repair or replace

Uneven wear of journal Correct

Excessive crankshaft end play Replace cen ter bearing

Knocking of piston Loose bearing Replace

and connecting rod Seized bearing Replace
Loose piston pin Replace pin or bushing

Loose piston in cylinder Recondition cylinder

Broken piston ring Replace

Improper connecting rod alignment Realign

Camshaft knocking Loose bearing Replace

Excessive axial play Replace bearing thrust plate

Rough gear teeth Repair

Broken eam gear Replace

Timing chain noise Improper chain tension Adjust

Worn and or
damaged chain Replace
Worn sprocket Replace

Worn and or broken tension adjusting Replace

mechanism

Excessive camshaft and bearing clearance Replace

Camshaft and valve Improper valve clearance Adjust

mechanism knocking Replace
Worn adjusting screw

Worn rocker face Replace

Loose valve stem 1 guide

i1 Replace guide
Weakened valve spring Replace
Seized valve Repair or replace

Water pump knocking Improper shaft end play Replace

Broken impeller Replace

II Other mechanical troubles

Stuck valve Improper valve clearance Adjust

Insufficient clearance between valve stem Clean stem or ream guide
and guide
Weakened or broken valve spring Replace
Replace clean
damage of valve stem or
Biting or

Poor Quality of fuel Use ood fuel

EM 31
 Engine Mechanical

Condition Probable cause Corrective action

Seized valve seat

Improper valve clearance
Adjust
Weakened valve spring Replace
Thin valve head edge valve
Replace
Narrow valve seat Reface

Overheating Repair or replace

Over speeding Drive at proper speeds
Stuck valve guide Repair

Excessively worn Shortage of engine oil Add or replace oil

cylinder and piston
Dirty engine oil Clean crankcase replace oil and oil niter
element

Poor quality ofoiL Use right oil

Overheating Repair or replace

Wrong assembly of piston with connecting Repair or replace
rod

Improper piston ring clearance Adjust

Broken piston ring
Replace
Dirty aii cleaner Clean

Mixture too rich

Adjust
Engine over run Drive at proper speeds

Stuck choke valve Clean and adjust

Overchoking Start correct way

Faulty connecting Shortage of engine oil Add oiL

rod
Low oil pressure Correct

Poor quality of engine oil Use proper oil

Rough surface of craokshaft Grind and replace bearing

Clogged oil passage Clean

Bearing worn or eccentric Replace

Bearingimproperly assembled Correct

Loose bearing Replace

Connecting rod alignment incorrect Repair or replace

Faulty crankshaft Shortage of engine oil Add or replace

bearing Low oil pressure Correct

Poor quality of engine oil Use proper oil

Craokshaft journal worn or of
out round Repair
Clogged oil passage in crankshaft Clean

Bearing worn or eccentric

Replace
Bearing improperly assembled Correct
Eccentric craokshaft bearing
or Replace

32
EM
 IFfIDrnJrnJ 1r DfA 1r ijJJlk1 PlfIDrnJ1r
1
3u e u
Sa e
S
WHIPPL E AT VETERANS TEL EPHONE 3155 6390

480 VETERANS BL V D REDWOOD CITY CALIFORNIA 94063

NAME DATE I r
DDR E55 CU5T ORDER NO

CHARGE RETAIL WHOLESAl E

OUAN
I PART NO
rETe rDS I DESCRIPTION
I J
LIST NET

1 I 1
fr C Q 11 11 s
vnAAwf AI v
1
r
k I w

r Ji i idP
I II
I
J JJ
HI 1 ll
tl Y J
plt
h

1 Ii If

is

NO REFUND AFTER 30 DAYS TAX

NO REFUND ON ELECTRICAL OR CARBURETOR PARTS

RESTOCKING CHARGE ON REFUNDED MER HANDISE

10

NO REFUND

WITHOUT THIS INVOICE REC O BY

 Engine Mechanical

SPECIAL SERVICE TOOL

For Reference
Tool number
page or
No Description use

tool name Unit mm in

on Figure No

This engine stand assembly is used for disassembling or All Fig EM II

ST050lS000
models
assembling engine block or differential carrier throughout
Engine stand 3600 in all directions
assembly

ST050 11000

Engine stand

ST050 12000

Base

SE184

EM II
2 ST0526oo0l This engine attachment is installed to engine stand Ll6 Fig
ST0501S000 in disassembling or assembling engine Ll8
Engine attachment L20B
Q

li

SE185

EM 18
3 STl 0120000 Special hollow set bolts are used in tightening cylinder heads All Fig
in series
L engines This wrench is used to torque cylinder L series
Cylinder head bolt head bolts and its head can be inserted into the torque
1 rench wrench

10 0 39 SE186

in Fig EM 105
4 STl 064000 I This tool is used togetller with a torque wrench
tightening pivot lock nut for valve clearance adjustment series
L

Pivot adjuster

33
EM
SE187

Al
 Engine Mechanical

Tool number For t

Referenl
No Description use page or

Unit mm in on Figure No
tool name

S KV10 1039S0

Valve This guide is used for All Fig 44

EM
guide reamer

set Lseries
o Pressing used guide out of place
and
0 Driving a new guide into place
STIlO81000 A series
0 Finishing the bore of new guide
Reamer

12 2 mm dia

STlI 032000

Reamer

8 0 mm dia

STl1320000

Drift

V
SE192

6 STll6S0001

refinish valve seat All Fig 4S

EM
Valve seat cutter set This valve seat cutter set is used to or a
L series

SE193

7 STl2070000

Valve lifter This ol is used to compress valve spring by the combined

t All Fig EM 32

action of its eam and lever thereby facilitating the removal models Fig 8l
EM

or installation of valve collet for general use

SE194

34
EM
 Engine Mechanical

Tool number For Reference

No Description use page or

tool name Unit mm in on Figure No

8 ST13030001 This tool is used with a press to drive pin into or out of All Fig EM 29
L series Fig EM
84
connecting rod
Piston pin press stand

1 20 0 79
I
8
M

120 4
0
722
SE1BS

EM 9l
9 ST153 10000 This tool is used to push a lip type rear oil seal for Lseries All Fig
engine into place by giving hammer blows series
L
Crankshaft rear oil

seal drift

SE189

10 KVI01041S0 This tool is used to remove the cap from main bearing All Fig EM 25

When using thds tool turn its adapter into the threaded hole Lseries
Crankshaft main in main bearing cap
bearing cap puller

KVI0104110
Body
250 9 8

l
ST165 12001

Adapter
se1g0

II ST166 10001 This tool is used to out of place All Fig 66

EM
pull pilot bushing
L series
Pilot bushing puller

SE191

35
EM
r

Engine Mechanical

Tool number For Reference

No Description use page or

tool on
name
Unit mm in Figure No

12 STl742000l This tool is used to prevent chains from falling out of place All Fig EM 19

in removing cylinder heads or earn gears and shafts series

L
Chain stopper

40 S1
1

r SE196

13 STl9320oo0 This tool is used to take oil filter out of place All
n
tightening Page EM4
the filter do not this tool to prevent models
Oil filter wrench
use excess tightening

120 4 7

SE197

14 KV30100200 This tool is used to install clutch assembly to engine All Fig EM 107
Lseries
Clutch bar
aligning

SEGOl

15 EM03470000 This tool is used to compress piston rings while piston is All Fig EM 92
being inserted into cylinder models
Piston ring

compressor

SE199

36
EM
 SECTION EL

ENGINE
DATSUN PICK UP LUBRICATION
MODEL 620 SERIES
SYSTEM

ENGINE LUBRICATION SYSTEM EL 2

SERVICE DATA AND EL 5

SPECIFICATIONS

TROUBLE DIAGNOSES AND EL 5

CORRECTIONS

SPECIAL SERVICE TOOLS EL 6

I NISSANJ

NISSAN MOTOR CO LTD

TOKYO JAPAN
 ENGINE LUBRICATION SYSTEM

ENGINE LUBRICATION SYSTEM

CONTENTS

LUBRICATION CIRCUIT EL 2 Inspection EL 3

01 L PUMP EL 2 OIL PRESSURE REGULATOR VALVE EL 4
Removal EL 2 OIL FILTER EL 4
Installation EL 2 RELIEF VALVE EL 4

Disassembly and assembly EL 3

From this gallery oil holes go

directly to all camshaft bearings
through cam brackets
Oil supplied through the No 2 and

No 3 camshaft bearings is then fed

to the rocker arm valve and eam

lobe through the oil gallery in the

camshaft and the small channel at the

base circle portion of each earn

OIL PUMP
The oil pump is secured on the
bottom of the front cover with four
bolts and driven by the oil pump drive

spindle assembly which is driven by

the helical gear on the crankshaft
The oil pump assembly consists of
an oil pressure regulator valve and
E L049
outer and inn r rotors
Fig ElrI Lubricating circuit The spring loaded oil pressure regu
lator valve limits the oil pressure to a

LUBRICATION maximum of 5 6 kg
em 80 psi
CIRCUIT
The pressure lubrication of the cylinder head to provide lubrication
engine is accomplished by a tro of the valve mechanism and timing
choid type oil pump This pump chain as shown in Figure EL2
draws the oil through the oil strainer Removal
into pump and then forces it
housing I Remove distributor
through the full flow type oil filter 2 Drain engine oil if necessary
into the main oil gallery Part of the 3 Remove oil pump body with
oil is supplied to all crankshaft drive spindle assembly
bearings chain tensioner and timing
chain Oil supplied to crankshaft
bearings is fed to connecting rod
bearings through the drilled passages
in the crankshaft Oil injected from
jet holes on connecting rods Iubri Installation
cates the cylinder walls and piston
I Before
The
installing oil pump on
pins other part of the oil is
ELOSO engine turn crankshaft so that No I
brought to the oil gallery in the
is at TD C
Fig EL 2
Lubricating vallie mechanism piston

EL 2
 ENGINE LUBRICATION SYSTEM

wear
2 Fill housing with engine
pump Disassembly 3 Check inner rotor shaft for
oil then align punch mark of spindle
shown in
and assembly looseness in pump body
with hole in oil pump as
4
Figure EL 3 I Remove pump cover attaching Inspect regulator valve for wear

bolts pump cover and cover gasket or scoring

and slide out pump rotors 5 Check regulator spring to see that
2 Remove regulator cap regulator it is not worn on its side or collapsed
valve and spring 6 Using a feeler gauge check tip
3 Install pressure regulator valve clearance 2 and outer rotor to body
Punch mark and related parts clearance I shown in Figure EL 7
4 Install outer rotor inner rotor

and shaft in pump body and do not

turn cover gasket up

EL009
CD
Fig EL3 Aligning punch mark
and oil hole

3 Using install oil

a new
gasket
pump and drive spindle assembly so El012

that the projection on its top is

located in II
this time
25 a m position
the smaller bow shape will
at

@
r
@ CD@ 1 Outer rotor to body clearance
be placed toward the front as shown
2 Tip clearance
in Figure EL 4 1 Oil pump body 6 Regulator spring
Inner rotor and shaft 7 Washer
3 Gap between rotor and straight edge
2
JI 8 4 Gap between body and straight edg e
c I 3 Outer rotor Regulator cap
J V 4 Oil pump cover 9 Cover gasket Fig EL 7 Checking rotor clearance
5 Regulator valve

J 9@
@
tr
Fig EL 6 Oil pump
7 the
Place a straight edge across
Front

i
L It
d
I
face of pump and depress it slightly as
shown in Figure EL 7 Check gap 4
between body and straight edge or gap
Inspection 3 between rotor and straight edge
I EL010 Wash all parts in cleaning solvent The gap should be 0 03 to 0 06
Fig EL 4 Setting drive pindle and dry with compressed ir mm 0 0012 to 0 0024 in then

o I Inspect pump body and cover rotor side clearance rotor to bottom
for cracks or excessive wear cover clearance with gasket should
2 Inspect pump rotors for excessive satisfy the specifications

Standard Wear limit

EL011 Rotor side clearance 0 04 to 0 08

Olm in 020 0 0079
Fig EL 5 Imtalling oil pump rotor to bottom cover 0 0016 to 0 0032

Ascertain whether or not the en

Less than
0 20 0 0079
gagement is in order by checking the Rotor tip clearance @ mOl in
0 12 0 0047
top of spindle through distributor fit
ting hole Outer 0 15 to 0 21
rotor to body 0 5
4 mm inl 0 0197
Tighten bolts securing oil pump 0 0059 to 0 0083
clearance D
to front cover

EL 3
 ENGINE LUBRI CATION SYSTEM

Note Pump rotors and body are not OIL PRESSURE

serviced separately If pump rotors
REGULATOR VALVE
or body are damaged or worn

replacement of the entire oil pump

assembly is necessary The oil pressure regulator valve is
not adjustable At the released
position the valve permits the oil to
by pass through the passage in the
pump cover to the inlet side of the
EL014
pump Check regulator valve spring to
ensure that spring tension is correct Fig ELB Regulator value

Tightening torque

Oil pump mounting bolts kg m ft Ib l to 15 8 0 to 11

Oil pump cover bolts kg m ft lb 07 to 10 5 Ito 7 2

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

Specifications
to 40
Oil pressure at idling kg cm2 psi 0 8 to 2 8 II

Regulator valve spring

Free mm in 525 2 067

length
in 34 8 370
1
Pressured length mm

em2 35 to 5 0 50 to 71
Regulator valve opening pressure kg psi

OIL FILTER RELIEF VALVE With oil fIlter removed check

The relief valve located at the

valve unit for operation Inspect for a
The oil filter is a cartridge type cracked or broken valve If replace
The oil filter element should be reo center portion securing oil fIlter to
ment is necessary remove valve by
placed periodically with the use of Oil the cylinder block by passes the oil
prying it out with a screwdriver
Filter Wrench ST19320000 into the main gallery when the oil
Install a new valve in place by
When installing an oil filter fasten fIlter element is excessively clogged
it
tapping
it to cylinder block by hand

Note Do not overtighten filter or oil

leakage may occur

STl9320000

EL016
EL015

Fig EL JO Relief lJOlue

Fig EL 9 Removing oil filter

4
EL
 ENGINE LUBRICATION SYSTEM

SERVICE DATA AND SPECIFICATIONS

Oil pump
Standard Wear limit

Rotor side clearance 0 04 to 0 08 0 20

mm in
0 0016 to 0 0032 0 0079
rotor to bottom cover

in less than 0 12 0 0047 0 20 00079

Rotor tip clearance mm

0 15 toO 21 05
Outer rotor to body clearance mm in
0 0059 to 0 0083 0 0197

Oil pressure regulator valve

Oil pressure at idling kg cm2 psi 0 8 to 2 8 II to 40

Regulator valve spring

Free length mm in 52 5 2 067

34 8 1370
Pressured length mmOn
kg em2 psi 5 to 5 0 50 to 71
3
Regulator valve opening pressure

Tightening torque
Oil pump bolt kg m ft lb 1 to 5 8 0 to 10 8
1

ft lb 0 7 to 1 0 5 1 to 7 2
Oil pump cover bolt kg m
ft Ib 4 to 5 29 to 36
Regulator valve cap nut kg m

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable causes Corrective actions

Oil leakage Damaged or cracked body cover Replace

Oil leakage from gasket Replace
Oil leakage from regulator valve Tighten or replace
Oil leakage from blind plug Replace

Decreased oil Leak of oil in engine oil pan Correct

pressure Clean or replace

Dirty oil strainer

Damaged or worn pump rotors Replace

Faulty regulator Replace
Use of poor quality engine oiL Replace

Warning light Decreased oil pressure Previously mentioned

remains on
Oil pressure switch unserviceable Replace
engine running
Electrical fault Check circuit

Noise Excessive backlash in pump rotors Replace

EL 5
 ENGINE LUBRICATION SYSTEM

SPECIAL SERVICE TOOL

Tool number For Reference

No Description use or
page
tool name
Unit nun in on Figure No

STl9320000 This tool is used to take oil f1Iter out of place In tightening All EL 9
Fig
the f1Iter do not use this tool to prevent excess tightening models
Oil filter wrench

I 120 4 7

SE197

6
EL
 SECTION CO

COOLING
DATSUN PICK UP SYSTEM
MODEL 620 SERIES

COOLING SYSTEM CO 2

SERVICE DATA AND

CO 6
SPECIFICATIONS

TROUBLE DIAGNOSES
CO 7
AND CORRECTIONS
LNISSAN I

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Cooling System

COOLING SYSTEM

CONTENTS

DESCRIPTION CO 2 OISASSEMBL Y 4
CO
COOLANT LEVEL CO 2 INSPECTION 4
CO
DRAINING AND FLUSHING THE TEM COUPLlNG 4
CO
COOLING SYSTEM CO 2 INSPECTION CO 5
WATER PUMP CO 2 THERMOSTAT CO 5
REMOVAL AND INSTALLATION CO 3 REMOVAL AND INSTALLATION CO 5
DISASSEMBLY CO 3 INSPECTION CO 5
INSPECTION AND ADJUSTMENT CO 3 RADIATOR CO 5
TORQUE COUPLING CO 3 REMOVAL AND INSTALLATION CO 5
REMOVAL AND INSTALLATION 4
CO INSPECTION CO 6

DESCRIPTION
The cooling system is of the con the of the
creases cooling efficiency If it is necessary to remove radiator
ventional pressure type A centrifugal radiator cap wben radiator is hot turn cap
pump installed on the timing chain When the thermostat is closed the slowly counterclockwise to the r
cover serves to circulate the coolant coolant remains in the cylinder head step After all pressure in the cool
The pressure type radiator filler cap and block for swift warming up of the
ing system is released tom cap
installed on the radiator operates the engine After it reaches normal oper passing the stop and remove it
cooling system at higher than atmos ating temperature the coolant circu
pheric pressure latesthrough the radiator
The higher pressure raises the The cooling fan drive is of a

boiling point of the coolant and in coupling type

DRAINING AND FLUSHING

THE COOLING SYSTEM

To drain the cooling system re

move radiator cap release drain cock

at the bottom of radiator and drain

plug on the right side of cylinder

block If the heater system is installed
set heater temperature control valve to

open position After the coolant is

drained completely close drain cock
and plug and refill the system with
clean soft water

C0055

Fig CO I Cooling ry lem

WATER PUMP
The water pump cooling fan pulley
COOLANT LEVEL
Caution To avoid serious personal and torque coupling are a unitized
The coolant level should be check
injury never remove I3diator cap construction
ed and maintained at SO mm 197 in
quickly whenengine is hot Sudden The water pump is of
below the upper face of filler neck
a centrifugal
release of cooling system pressure is
type which is mounted on the engine
when the engine is cold
very dangerous front cover

CO 2
 Cooling System

The pump shaft is supported by a Tightening torque Adjustment

double row of ball bearings
press fit in 4 to 0 5
0 kg m Fan belt should be properly ad
an aluminum die cast pump body The 3 0 to 3 6 ft lb at all times belt
justed A tight causes

bearings are permanently lubricated of alternator and water pump

2 Fill cooling system and check for wear
and sealed to prevent loss oflubricant
leaks at pump bearings A loose belt brings about
and entry of dirt
3 Install fan blade and improper cooling fan water pump
The tighten at
pump is provided with an and alternator operation
taching bolts securely Install belt and
impeller which turns on a steel shaft Check the belt slack between alter
The steel shaft rotates together with adjust for specified tension
nator and fan pulley by force of 10 kg
4 Operate the engine at fast idling
the torque coupling wheeL The volute
22 lb
and recheck for leaks
chamber is built in the engine front
5 Install fan shrouds Slackness of fan belt
cover assembly
8 to 12 mm
The inlet of the pump is connected Note Ensure that clearance between
to the radiator s lower tank 0 31 to 47 in
0
by a hose shroud and Can is even at any place
If adjustment is necessary loosen
bolt retaining alternator adjusting bar
DISASSEMBLY to alternator Move alternator toward

or away from engine until the correct

Water pump is made of aluminum
tension is obtained
and its bearing outer race is of a press
fit type For this reason water pump
should not be disassembled
i
o
TORQUE COUPLING
INSPECTION AND
CQ047 Except air
ADJUSTMENT
Fig CO 2 Water pump and engine conditioner equipped
front cover
Inspection models
REMOVAL AND Inspect pump assembly for the fol The torque coupling keeps the fan
INSTALLATION lowing conditions and replace if nee
speed at 2 500 rpm rated or below to
essary
Removal conserve horsepower at high engine
1 Badly rusted or corroded body It also reduce fan noise to
as
speed helps
in to a clean con
sembly and vane a minimum during high speed opera
2 Excessive end play or roughness of tion

bearings in operation This unit is filled with a special

3 Reduced cooling efficiency due to silicone oil used as a fluid coupling
deteriorated silicone oil which controls the fan speed Silicone
Oil leakage in torque oil can not be
4 coupling replenished
assembly

CQ048

Fig CO 3 Removing water pump

1 Torque coupling wheel

Installation 2 Torque coupling cover
3 Torque coupling bearing
1 Be sure to clean the gasket sur
4 Pulley
faces in contact with pump and front
5 Water pump
cover Always use new gaskets when

Be C0060
installing pump assembly sure to

bolts Fig CO 4 Sectional view of torque coupling and water pump

tighten

00 3
 Cooling System

REMOVAL AND DISASSEMBLY INSPECTION

INSTALLATION The torque coupling is so designed Inspect torque coupling for oil
If necessary
To replace the torque coupling that it can not be disassembled leakage replace
follow the procedure as in the
same

water pump The torque coupling can

not be separated from the water

pump

TEM COUPLl G For air conditioner equipped models

1 Bi metal thermostat
2 Slide valve
3 Reserve chamber for OFF
6 4 Bearing
5 Driving chamber for ON
6 ouplingpart labyrinth

coon

Fig CO 5 CrQM sectional view of coupling

Tem

is ation is
coupling
Tem a type of fan placed under OFF condition system is placed under ON con

coupling which is provided with a and the fan slips at about 1 650 rpm dition
temperature control system The coiled bimetal thermostat When the valve closes silicone oil is
The conventional coupling always installed the front center portion of
on not supplied to the driving chamber
slips the fan at a high speed under a the Tem coupling detects temperature oil in the driving chamber is accumu
constant ratio regardless of the engine of air passing through the radiator lated on periphery due to the centrif
cooling requirement The air temperature is directly ugal force and led into the reserve
The slipping ratio of the Tern relative to the engine coolant tempera chamber Now oil is eliminated from
coupling however is properly changed ture and the inside slide valve is the driving chamber and the system is
with the cooling requirement closed
opened or as required and thus placed under OFF condition
ON denotes that cooling is re the ON OFF control With this system when fan cooling
is performed
quired and the fan operates up to When the air is not required the is
temperature rises the output loss
about 2 150 rpm When high
cooling is bimetal is expanded and the valve is minimized and noise can be far
not required during cold season with opened silicon oil is forwarded to the reduced
the engine warmed up etc the oper groove that transmits torque and the

4
CO
 Cooling System

4 After checking thermostat re mostat should be inspected to make

install with a new housing gasket in sure that it is in good condition
place 1 Measure coolant temperature
Conventional COUplin9
when thermostat valve starts to open
5 Reinstall water outlet
2 Measure the maximum lift of
6 Replenish coolant and check for
WATER PUMP SPEED thermostat valve
leaks

F INSPECTION
Z
Tern coupling A sticking thermostat will prevent
WATER PUMP SPEED the cooling system from functioning
properly If the thermostat sticks in
C0029
the open position the engine warms
Fig CO 6 Characteristic of
Tern coupling up very slowly If the thermostat
sticks in the closed position over

INSPECTION heating will result Therefore the ther Fig CO S Impecting therm06t t

Check Tem coupling for oil leakage

or bend of bimetal
If the above symptoms are found Temperate Frigid Tropical
replace it with a new one as an type type iype
assembly Valve opening
80 5 to 5
83 5 to 89 5
86 75 to 78
temperature
THERMOSTAT 177 to 183 187 to 193 167 to 172
oC OF
thermostat is
A wax pellet type
Maximum valve lift 8 95 1 00
8 8 90
mounted in the thermostat housing at
the water outlet mm oC inF 31
0 203 31
0 212 31
0 194
cylinder head
The function of the thermostat is
to control the flow of coolant facili

tating fast engine warm up and regu

If thermostat does not at On models with
lating coolant temperature The ther operate equipped auto

mostat is designed to open and close at

the above specified temperature it matic transmission the oil cooler is

and if must be replaced because it cannot be combined with the radiator to cool
predetermined temperatures
should be re repaired transmission fluid
not operating properly
moved and tested as described below

REMOVAL AND
REMOVAL AND
INSTALLATION
INSTALLATION RADIATOR
Drain coolant into a clean con
I Drain coolant partially The radiator is a conventional down
tainer
2 Disconnect upper radiator hose at flow type having top and bottom
2 Disconnect radiator upper and
water outlet tanks to distribute the coolant flow
lower hoses On models with auto
3 Remove bolts and remove water uniformly through the vertical tube of
matic transmissions disconnect cooler
outlet gasket and thermostat from radiator core

inlet and outlet lines from radiator

thermostat housing The radiator filler cap is designed to
3 Remove fan shroud retaining
maintain a
pre set pressure 09
bolts and remove fan shroud
kg cm2 13 psi above atmospheric
4 Remove front grille
pressure
5 Remove radiator retaining bolts
The relief valve of
consisting a
and then remove radiator upward
blow off valve and a vacuum valve
6 Install radiator in the reverse se
helps to prevent the coolant from
of removal Note the fol
it How quence
boiling by giving pressure to
lowing
ever when the pressure is reduced
below atmospheric the vacu I Insert hoses in their positions
pressure
um valve allows air to re enter the until they bottom

radiator preventing the formation of a 2 Ensure that arrow marks on

t vacuum in the hoses are clearly visible from upper

Fig CO 7 Removing therm06t cooling system

CO 5
r

Cooling System
direction when hoses are assembled after cleaning it Then install radiator If a leakage is detected repair or

3 Ensure that clearance between cap on a tester If cap does not hold or replace radiator
radiator hose and any will release at the specified pres
adjacent parts is not

30 mm I 181 in minimum On mod sure replace cap

els equipped with air conditions a
minimum clearance of 18 mm 0 709

in should exist between

compressor
and hose
4 Ensure that clearance between
shroud and fan is even at any place

Note Be careful not to radia

damage
tor fins and core tube when in

stalling

INSPECTION Fig CO 9 Telting radiator cap

Radiator cap should be checked for

working pressure at regular tune up Also inspect radiator for leakage
intervals First check rubber seal on using cap tester and applying a pres Fig CO IO Testing cooling 6ystem
cap for tears cracks or deterioration sure of 1 6 kg cm 22 8 psi pUSure

SERVICE DATA AND SPECIFICATIONS

Thermostat
Temperate Frigid type Tropical type
type
Valve oC F 5 to 83 5
80 5 to 89 5
86 75 to 78
opening temperature
177 to 183 187 to 193 167 to 172

Maximum valve lift mm oC inj F 8 95 8 100 8 90

31
0 203 31
0 212 31
0 194

Radia tor

Type
Manual transmission Corrugated fin type
Automatic transmission fin type equipped with oil cooler
Corrugated
Cap relief pressure kg em psi 0 9 3
1

Cooling system

Leakage testing pressure kg em psi 1 6 22 8

Capacity with heater without heater

Manual transmission liters US qt Imp qt 8 0 8 Ii 7 74 i6
7J 1i
Automatic transmission liters US qt Imp qt 7 8 8 Y 6 J
i 7 2 7 X 6 X

Fan

Number of blades x outer diameter

Without air conditioner mm in 7 380

x
15
With air conditioner mm in 8 x 380 15

6
CO
 Cooling System

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

Loss of water Damaged radiator seams Repair

Leaks at heater connections or plugs Repair
Leak at water temperature gauge Tigh ten
Loose joints Tighten

Damaged cylinder head gasket Replace

Check engine oil for contamination and refill
as necessary

Cracked cylinder block Replace

Check engine oil in crankcase for mixing
with water by pulling oil level gauge

Cracked cylinder head Replace

Loose cylinder head bolts Tighten

Poor circulation Restriction in system Check hoses for crimps and clear the system
of rust and sludge by flushing radiator

Insufficient coolant Replenish

Inoperative water pump Replace
Loose fan belt Adjust

Inoperative thermostat Replace

Use soft clean water Rain water is satis

Corrosion Excessive impurity in water
factory

Cooling should be drained and

Infrequent flushing and draining of system system
flushed Permanent anti freeze
periodically
be used
Ethylene glycol base can through
out the seasons of the year and change
periodically at intervals recommended

Overheating Inoperative thermostat Replace

Radiator fin choked with mud chaff etc Clean passage thoroughly by using air
out air

pressure from engine side of radiator

Incorrect ignition and valve timing Adjust

Dirty oil and sludge in engine Refill

Inoperative water pump Replace

Loose fan belt Adjust
Restricted radiator Flush radiator

Inaccurate temperature gauge Replace

Impurity in water Use soft clean water

Overcooling Inoperative thermostat Replace

Inaccurate temperature gauge Replace

CO 7
 SECTION EF

ENGINE FUEL
DATSUN PICK UP
MODEL 620 SERIES

AUTOMATIC TEMPERATURE
CONTROL A T Cl H 2
AIR CLEANER

IDLE COMPENSATOR H 7

FUEL FILTER H 8

MECHANICAL FUEL PUMP H 9

ELECTRIC FUEL PUMP H ll

CARBURETOR H 14
l NISSAN I

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Engine Fuel

AUTOMATIC TEMPERATURE CONTROL A T C

AIR CLEANER

CONTENTS

DESCRIPTION EF 2 VACUUM MOTOR AND AIR

OPERATION EF 3 CONTROL VALVE EF 5
A T C AIR CLEANER HOT AIR REMOVAL AND INSTALLATION EF 5
OPERATION EF 3 TEMPERATURE SENSOR EF 5
AT C AIR CLEANER COLD AIR VACUUM MOTOR EF 5
OPERATION EF 4 FRESH AIR DUCT EF 5
A T C AIR CLEANER COLD AND AIR CLEANER EF 6
HOT AIR OPERATION EF 4 INSPECTION EF 6
TEMPERATURE SENSOR EF 5 1 AIR CLEANER ELEMENT EF 6
2 HOT AIR CONTROL EF 6
SYSTEM

DESCRIPTION

The air cleaner removes dust and and to remove carburetor icing between the exhaust manifold and hot
dirt from the air before it enters the The A T C air cleaner system con air duct is led to the air cleaner
carburetor and engine It also muffles sists of the following devices the hose
through
noise resulting from the intake of air 1 Air cleaner element
4 Blow by gas filter
into the engine The air cleaner element employed is The blow by gas nIter removes dirt
The air cleaner especially designed a viscous paper type It requires only and oil from the blow by gas sucked in
for improved exhaust emission control periodical replacment and should not the air cleaner from the engine rocker
is referred to as Automatic be cleaned
Tempera cover
ture Control Air Cleaner In order to 2 Automatic control 5 Fresh
temperature air duct Except for
reduce HC emission when the under air cleaner Canada
hood temperature is below 300C In the A T C air cleaner the air The fresh air duct leads the outside
860F the automatic temperature control valve is actuated by intake fresh air directly to the air cleaner
control system maintains the tempera manifold to control the intake Idle compensator
vacuum 6
ture of air to be sucked in the carbure air flow circuit The temperature sen See Idle Compensator
paragraph
tor at 30 to 540C 86 to 1290F sor detects the temperature inside the Page EF 7

thereby enabling lean for air cleaner and opens or closes the
setting 7 Altitude compensator California
carburetor calibration n addition to vacuum models
passage
this the automatic 3
temperature con Hot air duct Seeparagraph Altitude Compensa
twl system is effective to improve The hot air duct is mounted on the tor Page EF 20
warm up characteristics of the engine exhaust manifold The air warmed up

EF 2
 Engine Fuel

1 Fresh air duct Except for Canada

2 Air inlet pipe
3 Vacuum motor assembly
4 Air control valve

5 Hot air pipe

6 Idlecompensator
7 Blow by gas fiI teT

8 Temperature sensor assembly

9 Altitude compensator
California models

EF713

Fig EF 1 Automatic temperature control air cleaner

OPERATION
The automatic temperature control load condition of the engine The inlet ated by the engine intake vacuum

system of the air cleaner is controlled air temperature is detected by the

by the inlet air temperature and the sensor and the vacuum motor is actu

Under hood air Sensor vacuum at Air control valve

Sensor operation
vacuum motor side operation
temperature

Below 60 mmHg
Open cold air
Below 300C 36
2 inHg
Close
860 F
Above 210 mmHg
Close hot air
8 27 inHg

30 to 540C Half open

Open
86 to 1290 F cold air hot air

Above 55 oC
Open cold air Open
1310F

A T C AIR CLEANER HOT

AIR OPERATION

the to intro
When the under hood air tempera the intake manifold and vacuum vacuum motor diaphragm
ture is low the sensor air bleed valve motor With this condition the vacu duce hot air into the air cleaner

remains in the closed position and urn at the intake manifold side actu through the hot air duct on the ex

establishes vacuum
passage between ates the air control valve attached to haust manifold

EF 3
 Engine Fuel

A T C AIR CLEANER
COLD AIR OPERATION

f l I When under hood air temperature

f Air inlet pipe
Air con trol valve
is low

l Hot air pipe

Diaphragm
in the
The sensor air bleed valve remains

closed position and vacuum

ID s
6
Vacuum hose passage is established between the in
Diaphragm spring take manifold and the vacuum motor

Cif Air bleed valve and the intake manifold vacuum is

Ittl ID closed
Temperature sensor
applied to

phragm When the

the vacuum

vacuum
motor dia

is small or
Holair assembly
when the engine is
EF114 operating under
Fig EF 2 Hota r delivery mode During cold engine operation 1004 the air control valve opens
eavy
widely irrespective of the temperature
around the sensor to introduce the
under hood air cold air for increased
7
power of the engine
2 When under hood air temperature
To manifold Small vacuum is high
Dr 1 Air inlet pipe The sensor air bleed valve opens
2 Air control to shut off the vacuum passage
air
Underhood
valw fully
3 Hot air pipe
between the intake manifold and the
4 Diaphnp
I motor Due to the force of the
@ S V leuum hoses vacuum

motor the
6 Diaphragm prinl vacuum
diaphragm spring
7 Air bleed valve air control valve closes the hot air pipe
closed of the air cleaner and introduces the
II Temperature senSOr
under hood air cold air
assembly EF20S

Fig EF 3 Cold air delivery mode During cold engine operation

A T C AIR CLEANER COLD

AND HOT AIR OPERATION

f liP omanifold
1
2
Air inlet

Air
pipe
control valve When the sensor air bleed valve is

J Hot air pipe

Diaphragm
partially opened opening of the
control valve varies with the vacuum
air

Underhood
air Vacuum hoses
of the intake manifold With the air
Diaphragm spring
I Air bleed valve control valve open
half the cold air
@ fully open and hot air are sucked together and
8 Temperature mixed for of the air tem
sensor
controlling
assembly of the air to be introduced to
EF715 perature
Fig EF 4 Cold air delivery mode During hot engine operation the air cleaner

ID
f
@ fjr
ow
R lfl Air inlet pipe
2 Air control valve

5 Hot air pipe

underh r Diaphragm
Vacuum hose
Diaphragm spring
rv
Ittiair
Hot
ID Air bleed valve
partially opened
8 Temperature sensor
assembly
EF716

Fig EF 5 Regulating air delivery mode

4
EF
 Engine Fuel

hose to 2 Insert clip into vacuum tube of

TEMPERATURE SENSOR neeting vacuum sensor vacuum

tube sensor After installing each vacuum

The is attached
temperature sensor hose secure hose with the clip
to the inside of the air cleaner The
bimetal built in the sensor detects the I Pipe Note Be sure to install vacuum hose
under hood air temperature and opens 2 Calch Correct position is R H
correctly
or closes the vacuum passage in the 3 Fixed with mark at the top
side to Nissan
adhesive
sensor face of sensor for intake manifold
4 Hose
The construction of the tempera L H side for vacuum motor
5 Tab
ture sensor is shown in the following 6 Clip
7 Gasket
EC019
CD V 00 @
I Fig EF B Removal of semor
I
2 Disconnect hose from sensor VACUUM MOTOR
3 Take off clip from sensor vacuum
1 Remove screws securing vacuum
tube and dismount sensor body from
motor to air cleaner
air cleaner
I 2 Disconnect valve shaft attached
Protector cover Note The gasket between sensor and air
j
@ to vacuum motor diapluagm from
I Screw
air cleaner is bonded to the air valve
control and remove cacuum
Adjusting frame
1 Air temperature bimetal
cleaner side and should not be motor assembly from air cleaner

Rivet removed 3 To install reverse the removal

Valve seat frame
procedure
Lower frame Inatallatlon
Air bleed valve
EF206 Gasket Mount sensor on the specified
position
Fig EF 6 Temperature senior
For mounting position of sensor FRESH AIR DUCT
see the following
VACUUM MOTOR AND I Disconnect fresh air duct at air

AIR CONTROL VALVE cleaner

2 Fresh air duct is provided with
The pressure which varies
vacuum
air inlet side end
projections on its
with opening of the carburetor throt
Hold fresh air duct with a hand and
tle acts upon the vacuum motor dia
carefully pull out from radiator core
phragm The valve shaft attached to
support while turning it in either
the diaphragm is then moved up or
direction
down in response to the vacuum on
3 To install reverse the removal
the diaphragm This movement of the
Be sure to insert projec
valve shaft actuates the air control
procedure
lions of fresh air duct securely into
valve to control the temperature of the in radiator core sup
EF717
mounting hole
air to be introduced into the air
Fig EF 9 lalling se or
port
cleaner

to
pr
I

1 Valvespring
2 Diaphragm
00
@ 3 Retainer

E F 207 4 Valve shaft

Fig EF 7 Vacuum motor

REMOVAL AND Fresh air duct

Air cleaner
INSTALLATION Duct mounting hole
Radiator
TEMPERATURE SENSOR Radiator core support

Removal
EF518
Using pliers flatten clip con Fig EF I0 Removal offresh air duct

EF 5
r

Engine Fuel

AIR CLEANER These phenomena reveal malfunc

tion of hot air control system If these
1 Loosen bolts securing air cleaner
phenomena should occur check hot
to air cleaner bracket
air control system as described in the
2 Loosen air cleaner lock bolt and
following before carrying out inspec
remove air cleaner from carburetor
tion of carburetor
Disconnect the following hoses when

dismounting air cleaner

2 1 Vacuum hose
Under hood air inlet hose
Intake manifold to 3 way connec
Hot air inlet hose
tor 3 way connector to EF217
Vacuum hose Sensor to intake temperature
sensor 3 way connector to idle com Fig EF 12 Inspecting valve position
manifold
pensator temperature sensor to vacu
Vacuum hose Sensor to vacuum

um motor Correct position of air control valve

motor
is the reverse of above Air
Vacuum hose Idle compensator to
I Check that vacuum hoses are se Jpar graph
control valve is in correct position if
intake manifold curely connected in correct postion
2 under hood air inlet is closed and hot
Hose Air pump to air cleaner Check each hose for cracks or

distortion hose clip for condition air inlet is open

Hose AB valve to air cleaner
3 With hot air inlet in open posi
Hose Carburetor to air cleaner
tion in
Blow by hose Air cleaner to rocker Note Vacuum hose position RH as described paragraph 2
side of Nissan above pinch vacuum hose with fingers
cover mark the top of
on

Hose Air air sensor is for intake manifold L U and cut off air from vacuum hose In
control vaive to
cleaner California models only side of the mark is for vacuum
this condition check that air control
motor valve maintains the condition de
3 To install reverse the removal
scribed in step 2 for more than 30
procedure
2 2 Vacuum motor seconds and that hot air inlet is open
If diaphragm spring actuates the air
INSPECTION I With engine stopped disconnect control valve by its spring force to
1 AIR CLEANER fresh air duct under hood air inlet within 30
open
ELEMENT Place a mirror at the end of air seconds replace vacuum motor as an
cleaner inlet pipe as shown and check assembly since this may be resulted
Viscous paper type air cleaner ele
to see if air con trol valve is in correct from air leak at vacuum motor dia
ment does not require any cleaning
position phragm
operation until it is replaced periodi
cally Brushing or blasting operation
will cause clogging and result in enrich
2 3 Temperature ensor
ment of carburetor mixture and
should never be conducted For reo
Check temperature sensor for func
placement interval of air cleaner ele tion by proceeding as follows Be sure
ment refer to Maintenance Sched
to keep engine cold before starting
ule
test
I With engine off check air control
2 HOT AIR
valve for condition In this case under
CONTROL SYSTEM EF213 hood air inlet is open Use a mirror for
In warm weather it is difficult to Fig EF 11 Inspecting valve position inspection as 2 2 1 above
find out malfunction of hot air control 2 Start engine and keep idling
system In cold wea thee however Air control valve is in correct posi Immediately after engine starting
malfunction of air control valve due to tion if its under hood air inlet is open check air control valve for correct
disconnection or deterioration of vacu and hot air inlet is closed Check air described above In this
position as
um hose between intake manifold and control valve for condition of air control
linkage case correct
position
vacuum motor and insufficient dura 2 Disconnect inlet valve
vacuum motor is the reverse of 2 2 I under
bility of air control valve will cause vacuum hose and connect another hood air inlet is closed and hot air
insufficient automatic control opera hose to the inlet to apply vacuum to inlet is open
tion for intake air and result in engine vacuum motor Vacuum can be ap 3 Check that air control valve grad
disorder including plied by breathing in the hose end as ually opens to under hood air inlet
I Stall hesitation of engine oper
or shown side as engine warms up When en
ation Place mirror at the end of air
a vironmental temperature around tern
2 Increase in fuel consumption cleaner inlet pipe and check to if
see perature sensor is low spend more
3 uck of power air control valve is in correct time for
position engine warming up operation

6
EF
 Engine Fuel

to facilitate smooth operation of air element will not be affected by air 5 Carry out test as described in
control valve flow Then install air cleaner cover steps I 2 and 3 above When air
If the above test reveals any prob control valve begins to open to under
lem in the operation of air control hood air inlet side several minutes
valve carry out the following test after engine starting read the indica
4 Remove air cleaner cover Set tion of thermistor or thermometer If

temperature sensing element of ther reading falls within the working tern

mistor or thermometer to a position perature range of temperature sensor

where temperature around sensor can the sensor is normal If reading ex
ceeds the range the
be measured In this case fIx wiring of replace sensor

thermistor or thermometer on the with new one

bottom surface of air cleaner with

adhesive tape in such a manner that Note Before replacing temperature
Fig EF 13 Checking temperature
the set position of temperature sensing sensor sensor check idle compensator as

described in Idle compensator

IDLE COMPENSATOR

CONTENTS

DESCRIPTION EF 7 REMOVAL AND INSTALLATION EF B

OPERATION EF 7 INSPECTION EF 8

DESCRIPTION The idle compensator operates in

response to the under hood air temper

The idle compensator is basically a ature as shown below

thermostatic valve which functions to

introduce the air directly from the air
q
cleaner to the intake manifold to

compensate for abnormal enrichment

of mixture in high idle temperature
The bi metal attached to the idle

compensator detects the temperature 1 Orifice

of intake air and opens or closes the 2 Bi metal

3 Rubber valve
valve Two idle compensators having EF222

different temperature characteristics

Fig EF 14 Structure of idle
are installed one
opens at an intake air
compensator
temperature of 60 to 700C 140 to
l580F and the other at 70 to 900C
158 to 1940F Bi metal Intake air temperature Idle compensator operation

Below 600C 1400F Fully closed

OPERATION No 60 to 70 C
1 Close to open
140 to l580F

The construction of the idle com OF

Above 700C 158 Fully open
pensator is shown in the following
Below 700C 1580F Fully closed

70 to 900C
No 2 Close to open
158 to 1940F

Above 900C 1940F Fully open

EF 7
 Engine Fuel

Note When checking idle compensa

REMOVAL AND INSTALLATION
tor on vehicle disconnect hose

leading to idle compensator and

connect other hose then carry out
check as bed
descn above

2 bi metal
When temperature is
above the specified operating tempera
ture visually check to see if the valve
is in open position If valve is not

open replace idle compensator as an

assembly

EF718
Watcr
Fig EF 15 Location of idle compenl otor Observe temperature
valve
Remove air cleaner cover air If excessive air leakage is found at No 1 Bknctal
2 Remove hose connecting idle the valve replace idle compensator as 60 to 70De

11t
3 way connector 140 to 1580F
compensator and an assembly Note that two idle com
NO 2 metal
Bi
3 Loosen screws securing idle com
pensators are mounted to air cleaner
70 to 900C
pensator to air cleaner then remove and that it is necessary to plug the 158to 1940F
idle compensator valve of one of these idle compensa
tors so as to prevent air leak while EF226
Notes checking the other one
a When removing idle compensator Fig EF 17 Checking idle compensator
remove gasket and plate
b When removing screw securing idle
@
compensator to air cleaner be care

ful not to miss the saew CD

3 Others

4 To install reverse the removal I I Check hoses for correct installa

tion distortion or cracks
procedure

INSPECTION
tl 2 Check rubber valve seat of idle

compensator for sticking or any other

faulty conditions
I Check tha t valve IS m closed 1 Orifice
position when bi metal temperature is 2 Rubber valve
EF225
lower than operating temperature To
check breathe air into tube or suck Fig EF 16 Checking idle compelll lor

FUEL FILTER

DESCRIPTION REMOVAL

Disconnect inlet and outlet fuel

The fuel fJlter is a cartridge type It
lines from fuel fJlter and remove fuel
uses paper element which can be
a
fJlter
checked for condition from the out
side

2
3
1 Body
Paper element
Cover
1 EFOO5
Note Before disconnecting fuel lines

Fig EF 18 Sectional view ofcartridge use a container to receive the fuel

type fuel filter remaining in lines

EF 8
 Engine Fuel

MECHANICAL FUEL PUMP

CONTENTS

DESCRIPTION EF 9 REMOVAL AND DISASSEMBLY EF 10

FUEL PUMP TESTING EF 9 INSPECTION EF 10

STATIC PRESSURE TEST EF 9 ASSEMBL Y EF 11

CAPACITY TEST EF 10

DESCRIPTION
1
The fuel pump transfers fuel from
the tank to the carburetor in sufficient
quantity to meet the engine require
ments at any speed or load
The fuel pump is a pulsating type
designed for easy maintenance It con

sists of a body a rocker arm assembly

a fuel diaphragm a fuel diaphragm
spring seal inlet and outlet valves

Figure EF 19 shows a cross sectional

view of the pump

The fuel consists of

diaphragm
specially treated rubber which is not
affected by gasoline and held in place
by two metal discs and a pull rod
1 Outlet valve
2 Diaphragm
3 Diaphragm spring
EF006
4 Inlet valve
S Rocker ann

Fig EF 19 Schematic view offuel pump

FUEL PUMP
TESTING
A fuel pump is operating properly STATIC PRESSURE TEST
when its pressure is within specifica The static pressure test should be Note Locate this Tconnector as

tions and its is to the

capacity equal made as follows close to carburetor as possible
engine requirements
s at all speeds I Disconnect fuel line between car

Pressure and capacity must be deter buretor and fuel pump

mined by two tests while the pump is 2 Connect a rubber hose to each 3 Connect a suitable pressure gauge
still mounted on the engine Be sure open end of a T connector and con
to the opening of Tconnector and
there is fuel in the tank when carrying nect this connector hose assembly be fasten hose between carburetor and
out the tests tween carburetor and fuel pump T connector with a clip securely

EF 9
 Engine Fuel
4 Run the engine at varying speeds 2 Take off cap and cap gasket by
5 The gauge indicates removing cap screws
pressure
staticfuel pressure in the line The 3 Unscrew elbow and connector

gauge reading should be within the 4 Take off valve retainer by un J

two retainer screws and re
following range screwing
move two valves
0 21 to 0 27 kg em2
3 0 to 3 8 psi
5 To remove diaphragm press
down its center against spring force
With down tilt it
Note If the fuel in carburetor float diaphragm pressed
out and until the end of pull rod touches the EFOO7
chamber has run engine has
inne wall of Then release
stopped clip and pour fuel body Fig EF 20 Remouing pull rod
diaphragm to unhook push rod Be
into carburetor Fasten clip secure
carefulduring this operation not to 6 Drive rocker arm pin out with a
ly and repe 1 static pressure test
damage diaphragm or oil se L press or hammer

Pressure below the lower limit indi

cates extreme wear on one part or a

each
i
small amount of wear workingon

part It also indicates ruptured dia

phragm worn warped dirty or gum
ming valves and seats or a weak

diaphragm return spring Pressure

above the
upper limit indicates an
excessively strong tension of dia

8
phragm return spring or a diaphragm
that is too tight Both of these condi
tionsrequire the removal of pump
assembly for replacement or repair
o

CAPACITY TEST
I fuel pump cap
2 Cap gasket
The capacity test is made only 6 3 Valve packing
when static
pressure is within the 4 fuel pump e
val

specifications To make this test pro 7 assembly

S Valve retainer
ceed as follows
8 6 Diaphragm assembly
1 Disconnect pressure gauge from 7 Diaphragm spring
T connector and in its vacant place 8 PuRro
install a suitable container as a fuel 9 Lower body seal
washer
sump
Run engine at 1 000 rpm 10 Lower body seal
2
11 Inkl connector
3 The pump should deliver 1 000 cc
12 Outlet connector
11
2 US pt of fuel in one minute or
13 Rocker arm spring
less 14 Rocker arm

If little or no fuel flows from the IS Rocker artyl side pin

16 Fuel pump packing
open end of pipe it is an indication
that fuel line is clogged or pump is 17 Spacer fuel pump
fo cylinder block
malfunctioning
EF510

@
REMOVAL AND Fig EF 21 ure
Slruc offuel pump

DISASSEMBLY

Remove fuel pump assembly by

unscrewing two mounting nuts and 2 Check valve assembly for wear on
INSPECTION
disassemble in the following order valve and valve spring Blow valve
1 Separate upper body and lower I Check assembly with brea th to examine its
upper body and lower
body by unscrewing body set screws body for cracks function

EF 10
 Engine Fuel

3 Check diaphragm for small holes 3 To test the function

ASSEMBLY proceed as

carcks or wear follows

4 Check rocker for wear at the
arm Reverse the order of disassembly Position fuel pump assembly about
mating portion with camshaft I meter 3 ft above fuel level of fuel
Closely observe the following instruc
5 Check rocker pin for wear A tions strainer and connect from
arm a pipe
worn pin may cause oil leakage L Use new gaskets strainer to fuel pump
6 Check all other components for 2 Lubricate rocker ann rocker arm Operate rocker arm by hand Iffuel
any abnormalities and if link and rocker is drawn up soon after rocker arm is
replace neces arm pin before installa
sary tion released fuel pump is functioning
properly

ELECTRIC FUEL PUMP

CONTENTS

DESCRIPTION EF 11 DISASSEMBLY EF 12
INSPECTION EF 11 ASSEMBL Y EF 12
REMOVAL AND INSTALLATION EF 12 TROUBLE DIAGNOSES AND
CORRECTIONS EF 13

DESCRIPTION
The electric fuel pump is adopted The silicon transistor type fuel pump noid a
pump mechanism and filter
on air conditioner models consists of a transistor diodes a sole
equipped parts

J
ev

I T nsistor

2 Re f ist I

3 Dinde

4 Signal coil

5 Main coil

6 Resistor 3

7 Zener dlOdl
I Tr lOsistor 6 Ou tIet valve 8 Resistor 2
2 Plunger 7 Return spring
3 Diaphragm 8 Filter
4 Diode 9 Magnet
5 Magnet coil 10 Inlet valve EF719

Fig EF 22 Construction of electric fuel pump

INSPECTION
I Disconnect fuel hose at pump Note If diameter is too small the 3 With hose outlet in
higher posi a

outlet following proper delivery capacity tion than pump

operate pump and
2 Connect suitable hose
a approxi cannot be obtained even if pump check delivery capacity for more than
mately 6 mm 0 24 in inner dia functions properly 15 seconds
meter to pump outlet 4 The capacity should be I 400 cc

EF 11
 Engine Fuel

854 co in in one minute or less b Do not let fall pump as it may ASSEMBLY
If no gasoline or only a little flows damage electronic components
from open end of pipe with pump c Do not apply overvoitage max I Before assembly clean all parts
l8Y Overvoltage starting by
operated or if pump does not work with gasoline and compressed air com

perform the following diagnosis quick charge or tage running pletely

would deteriorate or damage elec
Notes Notes
tronic components
3 Do not connect battery in reverse a If d fdterare faulty
t an r
Fuel maximum gask
polarity which if left for a long pressure
place
would transitor 0 32 kg cm 46 psi
time damage b Clean magnet and cover for fault
circuit and disable pump c Take care not to defonn thin tube
d Assemble plunger return spring
REMOVAL AND INSTALLATION inlet valve Oring washer and set
To carburetor spring retainer in that order
e Assemble filter gasket and cover

with
f Tighten cover with wrench to the

stopper

If component parts are dirty after

disassembly clean as follows
1 Elecuic fuel pump Wash fIlter and strainer with clean
Flom fuel tank
2 Mounting bracket and blow with compressed
gasoline
3 Fuel mter
air When cleaning parts check
EF72D fllter for fault If faultyreplace
Fig EF 23 Electric fuel pump Wash plunger plunger cylinder and
inlet valve with clean gasoline and
blow dust off with compressed air
Electric fuel pump is installed on DISASSEMBLY
2 Check c v m lI
parts for wear
bracket with two bolts This bracket is
Do not disassemble unless pump is or damage
located on R H side member adjacent
faulty If they are found faulty replace
to fuel tank
I Remove cover with wrench and them
I Remove inlet hose from fuel
take out cover gasket magnet and 3 Insert plunger assembly into
pump Also remove outlet hose run
filter from pump body plunger cylinder of body and apply
ning to engine Receive fuel remaining
2 When removing plunger take out electric current to it
in fuel hose in a suitable container
spring retainer from plunger tube Move the assembly up and down
2 Disconnect harness at connector
3 Then take out washer O ring If the assembly does not move it
3 Remove bolts securing fuel pump
inlet valve return spring and plunger shows that the electric uuit is faulty
to bracket and detach fuel pump
from tube and it must be replaced
4 Installation is the reverse order of
removal Note Do not disassemble electronic
components If n replace
with new ones

@
1 Cover 8 Oring
2 Magnet 9 Inlet valve
3 Cover gasket 10 Retutn PIing
4 Filter 11 Plunger
5 Gasket 12 Plunger cylinder
6 Spring retainer 13 Body
7 Washer EF721

Fig EF 24 Exploded view of electric fuel pump

EF 12
 Fuel
Engine

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

Fuel pump fails to Terminals or connections loose Retighten

operate Rust on terminals or grounding metal Clean

Frozen in or Clean plunger assembly Replace pump if

liquid plunger pump
plunger is stuck or seized

Clogged filter Clean pump interior Clean and if necessary

Fuel pump fails to
discharge sufficient replace fIlter
flow Insufficient fuel Replenish

Insufficient fuel Air in fuel hose through connections Apply a coating of end sealing compound to

discharge during connections and retighten

high speed travelling

Low float level Hose necked down or bent Check and correct

at idling Fuel tank breather tube bent or necked Check and correct
down

Weakened return spring Replace

Fuel pump is actuated Air sucked through connection fuel hose Apply a coating of end sealing compound to

connection and retighten

more and fuel pump joint

frequently than Fuel hose on suction side bent Check and correct
under normal condi Clean
fIlter or replace fIlter
tion Clogged

Rattling noise Mounting bolts loose Retighten

EF 13
 Engine Fuel

CARBURETOR

CONTENTS

DESCRIPTION EF 14 CHOKE UNLOADER EF 23

STRUCTURE AND OPERATION EF 14 ELECTRIC AUTOMATIC CHOKE EF 24
PRIMARY SYSTEM EF 15 INTERLOCK OPENING OF PRIMARY AND
SECONDARY SYSTEM EF 16 SECONDARY THROTTLE VALVE EF 24
ANTI DIESELING SYSTEM EF 17 DASH POT EF 25
FLOAT SYSTEM EF 18 ACCELERATING PUMP EF 25

BOOST CONTROLLED DECELERATION ANTI DIESELING SOLENOID VALVE EF 25

DEVICE B CD D EF 1B BC D D CIRCUIT WITH FUNCTION
ELECTRIC AUTOMATIC CHOKE EF 20 TEST CONNECTOR EF 25
DASH POT SYSTEM EF 20 ALTITUDE COMPENSATOR
ALTITUDE COMPENSATOR EF 29
California modelsl
California models MAJOR SERVICE OPERATION EF 29
EF 20
ADJUSTMENT AND INSPECTION EF 21 REMOVAL EF 29

CARBURETOR IDLE RPM AND DISASSEMBLY AND ASSEMBLY EF 30

MIXTURE RATIO EF 21 CLEANING AND INSPECTION EF 34
FUEL LEVEL EF 22 SERVICE DATA AND SPECIFICATIONS EF 35
FAST IDLE TROU8LE DIAGNOSES AND
EF 22
VACUUM BREAK EF 23 CORRECTIONS EF 36

DESCRIPTION STRUCTURE AND

OPERATION
The carburetors of down draft 3 A
are BC D D device for reducing These carburetors consist of a
two barrel
types which produce the hydrocarbon H C emissions primary system for normal running
optimum air fuel mixture under all 4 An and a secondary system for full load
electric automatic choke to
operating conditions facilitate cold starting and to reduce running
They present several distinct exhaust emissions A float system common to both
features of importance to the vehicle 5 An anti primary and secondary systems a
dieseling solenoid to se

owners eliminate dieseling run on condary switch over mechanism an

A summary of the features is 6 A
as
power valve or vacuum actu accelerating mechanism etc are also
follows ated booster to ensure smooth high attached
1 A slow economizer to make a An anti
speed operation dieseling solenoid valve and
smooth connection with acceleration 7 The carburetor a valve mechanism also
comes equipped power are
or deceleration during light load run
with dash pot which ensures smooth installed
ning deceleration without The hand operated altitude
engine stall com
It also assures stable low speed under alloperating conditions pensator corrects air fuel mixture to
performance 8 The hand operated altitude com an optimum ratio
2 An idle limiter to reduce harmful
pensator is installed in the California
exhaust emissions to a minimum models

EF 14
 Engine Fuel

jli@
I

tZrJ

I III

I Fuel nipple
2 Fuel filter

3 Needle
4 Float

S Primary main jet

6 Idle adjust screw

7 I die hole 12 Air bleed 19 Choke valve 25 Secondary main nozzle

8 Primary bypass hole 13 Primary slow jet 20 Primary small venturi 26 Secondary small enturi
9 Primary throttle valve 14 Plug 21 High speed enricher air 27 D C D D a
sembly
10 Primary altitude compensator 15 Primary slow air bleed bleed 28 throttle valve
Secondary
pipe California models 6 Primary main air bleed 22 Richer nozzle
11 Secondary altitude compensator air vent
17 Primary pipe 23 Richer jet
pipe California models 8 Primary main nOlzle 24 Secondary air vent pipe EF722

Note Do not remove the parts marked with an asterisk

Fig EF 25 Sectional view of carburetor

PRIMARY SYSTEM into the engine through the idle hole the idle hole and bypass hole via the
and bypass hole sow sysem passage
main
Prlmar sstem
Adoption of the submerged type of
Theprimary main system is a slow jet eliminates such hesitation as
Stromburg type Fuel flows as shown occurs on sudden deceleration of the
in Figure EF 25 through the main jet vehicle
mixting with air which comes in from Slow economizer system obtains
the main air bleed and passes through Accele atlns mechanism
smooth deceleration at high speeds
the emulsion tube and is pulled out Small opening of the throttle valve
with the
into the venturi through the main at idling or partial load creates a large The carburetor is equipped
mechanism
nozzle vacuum pressure in the intake mani piston type accelerating
linked to the throttle valve When the
fld
throttle valve shown in
By this vacuum pressure fuel is primary
IdUns and slow sstem
measured through the slow jet located Figure EF 26 is closed the piston
low engine speed as shown and fuel flows from the float
During behind the main jet And air coming goes up
in Figure EF 25 fuel flows through from the 1st slow air bleed is mixed chamber through the inlet valve into
the slow jet located on rear right side with fuel in the emulsion hole the space under the piston When the
of main nozzle mixing with air com This mixture is further mixed and throttle valve is opened the piston
ing from the 1st slow air bleed again atomized with air coming from the goes down opening the outlet valve

mixing with coming from the

air 2nd 2nd slow air bleed The atomized and fuel is forced out through the
slow air bleed and then is pulled out mixture is supplied to the engine from injector

EF15
 Engine Fuel

1
L

if

1 Pump injector
2 Piston
3 Spring
4 Weight
5 Damper spring
6 Piston return spring
7 Inlet valve
8 Outlet valve

EF023

Fig EF 26 Acceleration mechanism

Power valve mechanism

SECONDARY SYSTEM

The power valve mechanism so

Secondary main lIYlltem
pulled out through the main nozzle
called vacuum piston type utilizes the
into the small venturi
vacuum below the throttle valve
The secondary main system is a Due to the double venturi of the
When the throttle valve is slightly
Stromburg type secondary system the higher velocity
opened during light load running high
Fuel air mixture produced by the air current passing through the main
vacuum is created in the intake mani
functions of the main jet main air nozzle promotes the fuel atomization
fold This vacuum pulls the vacuum
bleed and emulsion tube in the same The structure is almost the same as
piston upward against the spring
manner as in the primary system is the primary side
leaving the power valve closed When
the vacuum below the throttle valve is
lowered during full load or accelerat
ing running the spring pushes the
vacuum piston downward opening the

power valve to furnish fuel

I
1
11
1

1 Primary vacuum port

2 Secondary vacuum
port
3 Diaphragm chamber
cover
I

of

llW l
11
1
Diaphragm spring
S Diaphragm
6 Secondary throttle
valve
7 Primary theo nle
1 Vacuum piston
2 Power valve a
ET02 v valve

512
EF
Fig EF 27 Sectional view of po r

valve EF 28 Full throttle al high peed

Fig

EF 16
 Engine Fuel

Step system HI h speed circuit richer jet high speed enricher air

The high speed circuit improves bleed and richer nozzle When the
velocity of suction air flowing through
The construction of this system high engine output performance
during high speed driving the carburetor secondary bore in
may correspond to the idling and slow
This circuit operates only when creases additional fuel is drawn out of
system of the primary system
the richer nozzle
Tlris system aims at the proper driving at high speed It consists of a
filling up of the gap when fuel supply
is transferred from the primary system @ 2
to the secondary one The step port is

located near the secondary throttle

valve edge in its fully closed state

Secondary switchover mechanism

The secondary throttle valve is

linked to the diaphragm which is

actuated by the vacuum created in the
venturi A vacuum jet provided atis

each of the primary and secondary

venturies and the composite vacuum

of these jets actuates the diaphragm

As the linkage causes the secondary
throttle valve to close until the prima
ry throttle valve opening reaches ap

proximately 500 fuel consumption

during normal operation is not exces
sive
EF234
During high speed running as

shown in Figure EF 28 as the vacuum Secondary

I Richer jet
Primary
at the venturi is increased the dia 2 High speed enricher

air bleed
is pulled against the diaphragm
phragm 3 Richer nozzle
spring force and then secondary throt
tie valve is opened Fig EF 29 High speed circuit
The other side
during low speed
running as the primary throttle valve
ANTI DIESELlNG SYSTEM
opening does not reach 500 the is brought into operation shutting off
secondary throttle valve is locked to The carburetor is equipped with the
an supply of fuel to the slow circuit
close completely by the locking arm anti dieseling solenoid valve As the The following figure shows a see
which is interlocked with primary ignition switch is turned off the valve tiorial view of this control
throttle arm by linkage
When the primary throttle valve
opening reaches wider position than
500 the secondary throttle valve is
CD
ready to open because the locking
arm revolves and leaves from the se 1 g
condary throttle arm
1

@eI
EF230

1 dieseling
Anti solenoid va1
2 Ignition switch
3 Battery @
l
Fig EF 30 Schematic drawing of anti dieseling sydtm

EF 17
 Engine Fuel

FLOAT SYSTEM determined value the B C D D intro The amount of the mixture is con

duces an additional mixture of opti trolled by the servo action of the

There IS only one float chamber
mixture ratio and
mum quantity into mixture control valve CID and vacuum
while two l arburetor systems primary
the manifold by opening a separate control valve
Jnd stl ondary are provided @ so that the manifold
mixture in the carburetor be
Fuel fed from the fuel pump flows
passage vacuum may kept at the pre
Complete combustion of fuel is assist determined value
through the filler and needle valve into ed by this additional mixture and the The amount of mixture
the flo t chamber A constant fuel depends
amount of H C contained in exhaust mainly upon the coasting air bleed
level is maintained by the float and
needle valve gases is dramatically reduced II@ while the mixture ratio is deter
mined by the
During the transition period from coasting jet @ and
Because of the inner air vent type
See
coasting to idling the transmission coasting air bleed @ Figure
of the float chamber ventilation the
produces a signal which turns on the EF 31
fuel consumption will not be in
vacuum control solenoid valve As this
fluenced by some dirt accumulated in
takes place the valve is lifted off its
the air deaner
seat opening the vacuum chamber to
The needle valve includes special
the atmosphere The mixture control
hard steel ball and will not wear for all
valve is then closed returning the
its considerably long use Besides the engine to the predetermined idling Vacuum control solenoid
inserrion of a spring wiU prevent the
speed valve operation
flooding at
rough road running On manual transmission models
this system consists of B C D D vacuo Manual transmission models
urn control solenoid valve speed de The vacuum control solenoid valve
tecting switch and amplifier is troDed by
con a speed detecting
BOOST CONTROLLED On automatic transmission models
switch that is actuated by the speed
DECELERATION DEVICE it consists of B C D D vacuum con
ometer needle
B C D D trol solenoid valve and inhibitor
As the vehicle speed falls below 10
switch
A Boost Controlled Deceleration MPH this switch is activated pro
Device BC D D serves to reduce the ducing a signal This signal actuates the
BC D D operation
hydrocarbons He emitted from en amplifier to open the vacuum control

gine during coasting I Qj monitors the mani solenoid valve

Diaphragm
The high manifold vacuum during fold vacuum and when the vacuum

coasting prevents the mixture from exceeds Automatic transmission models

a fetermined
pre value acts so

complete combustion because of the as to open the vacuum control valve When the shift lever is in N or
reduced of mixture per cyl
amount @ This causes the manifold vacuurn P position the inhibitor switch
inder per rotation of engine with the to be introduced into the second mounted on the transmission turns on
result that a large amount of hydrocar vacuum chamber and actuates dia to open the vacuum control solenoid
bons is emitted into tile atmosphere
phragm ll@ valve
The B C D D has been designed to When diaphrngm II operates the
correct this problem mixture control valve @ opens the
It opern tes as follows when the passage and introduces the additional
manifold vacuum exceeds a pre mixture into the manifold

EF 18
 Engine Fuel

I Airjet 12 Secondary main jet

2 Diaphragm II 13 Coasting jet
3 Mixture control valve 14 Coasting air bleed I
air bleed II 15 Inhibitor switch N P
4 Coasting
5 Mixture air
passage ON for automatic
6 Secondary baHel transmission
7 Intake manifold 16 Amplifier
8 Boost passage 17 Speed de tecting swi tch below

9 Vacuum control solenoid 10 M P H ON for manual

valve transmission

10 Vacuum control valve 18 switch

CID
Ignition
II Diaphragm I

11
6
I
@

fI3 r
101

1
j @ i
W @
r

JJ

I
t i J
l

Note Broken line applies only to Automatic Transmission EF231

Fig EF 31 Schematic drawing of B C D D Non California models

I Ignition switch
2 Amplifier
below
3 Speed detecting switch
10 M P H ON for manual
transmission ru
I
r

4 Inhibitor switch N p

ON for automatic
transmission lJ
i7
5 Solenoid valve
6 Vacuum control valve
7 Altitude corrector

I To intake
manifold

1
J
To air
cleaner

I
LlJ
I

l f L8 J
l
E F235

Note Broken line applies only to Automatic Transmission

Fig EF 32 Schematic drawing of RC D D California models

EF 19
 Engine Fuel

The construction and function of bi metal which

ELECTRIC AUTOMATIC controls the air fuel
each part of this carburetor are as mixture ratio
CHOKE required for starting
follows
An electric heater wanns a bi metal
l Bi metal and heater in choke
interconnected to the choke valve and DASH POT SYSTEM
cover
controls the position of choke valve
Electric current flows through the These carburetors are equipped
and throttle valve in accordance with
the time ttea r as le
t engine tl 1SI nd war with a dash pot ked wi h the
interl
elapsed the warm up condi
the bi metal The deflection of the primary throttle valve through a link
tion of the engine and the outside
bi metal is transmitted to the choke mechanism The dash is intended
ambient temperature pot
valve through the choke yalve lever to prevent engine stall resulting from
When outside ambient temperature
2 Fast idle cam quick application of the brake or
is above operating temperature the
The fast idle cam determines the from the quick release of the accele ra
automatic choke control serves to fur
opening of the throttle valve so that tor pedal after treading it
slightly
ther reduce exhaust gasemission the proper amount of mixture cor In such a situation a throttle lever
during warm up by automatically
responding to the opening of the strikes against the dash pot stem and
selecting one of the two choke opera
choke valve will be obtained The makes the primary throttle valve close
tion modes fast acting or slow acting
the
opening of the choke valve is depend gradually thus keeping engine
ent upon the warm up condition of running
the engine
Slow acting choke operation 3 Fast idle adjusting screw

When ambient temperature is low This screw adjusts

the opening of
electric flows the the throttle valve of the fast idle earn
current through ALTITUDE COMPENSATOR
4 U nloader
automatic choke relay to the P T C California models
heater A and the When accelerating the engine during
gradually warms
the warm up period that is before the
bi metal This causes the choke valve The higher the altitude the richer
choke valve
opens sufficiently this the air fuel mixture ratio and there
to open slowly
unloader forces the choke valve open a fore the higher exhaust gas emissions
liUle so as to obtain an adequate even though the engine is properly ad
air fuel mixture
justed for low altitude driving
5 Vacuum
Fast acting choke operation
diaphragm The altitude compensator is design
After theenginThas been started ed to meet EiiriSSion S13ndards for
When ambient temperature is high
by cranking this diaphragm forces the driving in both low and high altitudes
the bi metal switch is in on This choke valve open to the predetermined At high altitudes additional air is sup
causes electric current to flow through extent so as to provide the proper plied to the carburetor by the altitude
the automatic choke relay to the air fuel ratio compensator When the altitude com
PT C heater A and heater B result 6 metal
Bi case index mark pensator lever is set at H air is
ing in quick opening of the choke The metal
bi case index mark is conducted through an air passage to
valve used for setting the moment of the the carburetor The air passage is
closed when the lever is set at L

D H L Lever

When operating the H L lever fol

r low these instructions

Il
H position
@@
r Should be used for general driving
EF232 in those areas designated by law as
1 Alternator High Altitude Counties
2 Automatic
choke relay
3 Automatic
choke cover L position
4 P T C heater A

5 Bi metal switch outside those

For use areas desig
6 P T C heater B
@ 7 Bi metal
nated as High Altitude Counties
8 Choke valve

Fig EF 33 Schematic drawing of electric automatic choke heater

EF 20
 Engine Fuel

Notes b Counties 1 219 m 4 000 ft or shown in Figure EF 35 Plug the dis

a The idle rpm and CO vary accord more above sea level have been connected hose to prevent dust from

High Altitude
ing to the altitude Therefore they designated by law as entering
when Counties For further details refer
should be properly adjusted 0

the position of the H L lever is to 1977 OATSUN PICK UP Service

Bulletin Pub No 257

changed
Air cleaner o

rID
mOl

If Low altitude Ll

n
n
0
I

EF259

Fig EF 35 Disconnecting air hose

L from air check valve
n
6 Race engine I 500 to 2 000 rpm

two or three times under no load then

run engine for one minute at idling

speed
7 Adjust throttle adjusting screw
until engine is at specified speed

EF729 Fig EF 34 Engine speed

Manual transmission
750 rpm
Automatic transmission
sertprobe into tail pipe more than
ADJUSTMENT
40 em 15 7 in in 0 position
AND INSPECTION 650 rpm

CARBURETOR IDLE R P M Idle adjustment with

CO
CO meter 8 Check ignition timing If neces
AND MIXTURE RATIO
sary adjust it to specifications
Idle mixture adjustment requires This operation need not be carried
Cautions the use of a CO meter especially for out at 1 600 Ian 1 000 miles service
3 On automatic transmission equi California models When preparing to
is essential to Ignition timing
ped models check should be per adjust idle mixture it
Manual transmission
formed in the 0 position have the meter thoroughly warmed up
120
750 rpm Non California
Be sure to engage parking brake and and calibrated
I 750
100 rpm California
to lock both front and rear wheels Check carburetor pipes for proper
Automatic transmission
with wheel chocks connection
in 0 position
b Keep your foot down on the brake 2 Warm up engine until water tem
120 650 rpm
pedal while depressing the accelera perature indicator points to the middle
tor pedal Otherwise vehicle surges of gauge The procedure to warm up
9 At about 10 minutes after engine
forward dangerously engine isspecifically
not recom

is run at idling speed adjust idle

mended Either driving vehicle or oper

adjusting screw so that CO percentage

Notes ating engine at no load will be good
is at specified level
a 00 not attempt to screw the idle 3 Make sure that water tempera

adjusting screw down completely ture indicator points to the middle CO percentage
could damage to tip Further keep engine running at about Manual transmission
Ooing so cause

which in turn will tend to cause 2 000 rpm for about 5 minutes with tl
2 at 750 rpm
Automatic transmission
malfunctio11ll out applying load to engine in order to
b If idle limiter cap obstructs proper stabilize engine condition Engine in 0 position
hood should be open tI
2 at 650 rpm
adjustment remove it
Run engine for about 10 minutes
To install idle limiter cap refer to 4

speed Ouring this 10 10 Repeat procedures as described

Idle Limiter Cap at idling
After idle has been minutes proceed as described in steps in steps 6 7 and 9 above so that CO
c adjustment
percentage is at specified level Check
made shift the lever to the N or 5 to 9 below

P position for automatic trans 5 Remove air hose between 3 way ing idle CO in step 9 can be carried out

mission connector 5 way connector for Cali right after step 7

and air check valve II Race engine 1 500 to 2 000
d When measuring CO percentage in fornia models as

EF 21
 Fuel
Engine

rpm two or three iimes under no load is run at idling speed adjust idle in Figu re EF 37
and make sure that specified CO per adjusting screw until maximum rpm is When H is approximalely 7
0 283
centage is obtained obtained mill in lOp float position is
correct
12 Connect air hose to air check 10 Repeat procedures as described
valve in steps 6 7 and 9 above until engine The top float position can be ad

If engine speed increases readjust it speed at best idle mixture is 815 rpm justed by bending float seat
for manual transmission
to the specified speed with throttle models and Upon completion of the adjust
adjustingsqew 670 rpm for automatic transmission ment check fuel level wi th attached
models in D position Adjustment level gauge
COidle edJustment without in step 9 can be carried out right after
p
CO meter step 7

11 Turn the idle adjusting screw

If CO meter is not available the clockwise until engine speed drops off
following procedures may be used j
below specified rpm i
L Check carburetor pipes for proper
Engine speed drops off
connection

2 Warm up engine until water tem

Manual transmission I
60 to 70 rpm
perature indicator points to the middle
of gauge Automatic transmission it
The procedure to warm
up
in D position
engine is not
specifically recom
15 to 25 rpm
mended Either driving vehicle or oper

ating engine at no load will be good I Float seat

12 Connect air hose to air check 2

3 Make sure that water Float
temperature
valve 3 Float chamber
the middle Further
indicator points to
4 Needle valve
IIf
I
t
If engine speed increases readjust it ET032
keep engine running at about 2 000
to the specified speed with throttle Fig EF 37 Adjusting float level
rpm for about 5 minutes without

applying load to engine in order to adjusting screw

2 Adjust bottom float

stabilize engine condition position so
Engine
Idle limiter cep that clearance h between float seat
hood should be open

4 Run and needle valve stemis I 3 to L7 mm

engine for about 10 minutes Do not remove this idle limiter cap
0 051 to 0 067 in when Iloat is fully
at idling speed unless If this unit is re
During this 10 necessary
minutes proceed described in steps
as moved it must be readjusted at lime rals n Jloa t goppe q
re

3 After adjustments in
5 to 9 below of installation To adjust proceed as steps I and
2 above have been made make sure
5 Remove air hose between 3 way follows
5 way connector for Cali that when fuel is delivered to the float
connector I After
adjusting throttle or idle
chamber the fuel level is maintained
fornia models and air check valve speed adjusting screw check to be sure
within the range of23 mm 0 91 in
shown in Figure EF 35 Plug the dis that the
as
amount of CO contained in
shown in FigureEF 38
connected hose 19 prevent dust from
exhaust gases meets the established
entering standard
6 Race engine 1 500 to 2 000 rpm 2 Install idle limiter cap in position
two or three times under no load then
making sure that the adjusting screw
run engine for one minute at idling can rotate another 1 8 turn in the
speed CO RICH direction
7 Adjust throttle adjusting screw so
Carbo to per CO rich
that engine speeds are as indicated
below
rotation
450 lIS
Engine speed
Manual transmission H 23 mm 0 91 in EF260
CO lean
815 rpm
Automatic transmission

in D
670 rpm
position t J
SQ
1dle lim Iter
Fig EF 38 Checking ruellevel

ET031 cap
FAST IDLE
Fig EF 36 Setting idle limiter cap
8 Check ignition timing if neces
I With carburetor assembly reo
it to the value required by
sary adjust moved from engine measure throttle
specifications This operation need not FUEL LEVEL
valve clearance A with a wire gauge
be carried out at 1 600 km 1 000 1 Turn down float chamber to al placing the upper side of fast idling
miles service low float to come into contact with screw on the first step on fast idling
9 At about 10 minutes after engine needle valve and measure Hu shown cam

EF 22
 Engine Fuel

Fast idling earn steps

04th
Fast idling carn

Nut

EC527
l1st
2nd
Fast idling screw
Choke valve
Choke connecting
rod
Z
EC528 Throttle valve
Fig EF 39 Mea uring throttle valve
clearance Fig EF 40 Fast idling cam steps
ET033

2 The clearance should be specified

value in the following table Ifnot ad

just the clearance by turning fast Fig EF 41 Adjusting the clearance

idling screw of throttle valve

Clearance A mm in Fast idling earn

MfT 1 33 to I 47 0 0524 to 0 0579

1st step

AfT 1 58 to 1 72 0 0622 to 0 0677

A in
3 To check fast idling cam setting fast idling cam at 2nd step and read specifications below Clearance

by engine speed proceed as follows engine speed Fast idling cam is prop 2nd step is reference value
Warm up engine sufficiently Set erly set if engine speed is within

Fast Clearance A mm in
Engine speed rpm idling earn

I 900 to 2 800 0 94 to 18
1 0 0370 to 0 0465
MfT
2nd step

AfT 2 200 to 3 200 L16 to I 40 0 0457 to 0 0551

VACUUM BREAK CHOKE UNLOADER

B
I Close choke valve completely S Close choke valve completely
2 Hold choke valve by stretching
rubber band between choke piston
a

j
iXo
CK 2
rubber
Hold choke valve by stretching
band between choke piston
a

lever and stationary part of carburetor lever and stationary part of carburetor
3 Grip vacuum break rod with 3 Pull throttle lever until full open
pliers and pull straight
4 Under this condition
out

adjust the
LL r I ance
Under this condition
between choke valve and carbure
adjust clear

il
clearance between choke valve and
J L torbody to 2 45 mm 0 096 in by
carburetor body B in Figure bending unloader tongue
42
EF to specified value by bending
vacuum brake rod Note Make sure that throttle valve
EF516
is mounted
opens when carburetor
1 Choke piston rod 4 Diaphragm cover on the vehicle
2 Choke spring 5 Choke piston lever
If throttle valve rails to open un
3 Choke piston 6 Choke valve
loader becomes inoperative resulr
break in poor acceleration after
Fig EF 42 Adjusting vacuum
ing engine
is started

EF 23
 Fuel
Engine
2 Make an operational check of
ELECTRIC AUTOMATIC Automatic choke
automatic choke relay as shown in
CHOKE de
I Before starting engine fully
Figure 46
EF
celerator pedaJ to ensure that
Checklna automatic choke press al 2 volts across termi
Apply c
d

heater circuit with function choke valve doses properly

nals I and 3 to ensure that
test connector Push choke valve with a finger exists between terminals
i ontinuity
and heck for binding 4
Caution Do not altach test leads of a 2 and
3 Check 0 be sure that bi rnetal
Check t lal continuity does not
circuit tester to those other than
cover index mark is set at the cenleT of
Refer to 43
Ef exist between terminals 2 and 4
designated figure
choke housing index mark as shown in
is
when no voltage applied across

Figure 44
EF them If results satisfies the above
I engine not running check
With
automatic choke relay is functioning
for continuity between A and B as Note Do not set b metal cover index
properly if not replace choke relay
shown in figure 43
Ef mark at any position except the
If continuity exists heater is func center of choke housing index

tioning properly marl

If continuity d s not exist check

for disconnected connector or open

2
P T e heater circuit

With engine running at idle check

tE jL 1 2
for presence of voltage across A and B

y
J
as shown in figure 43
EF 3 4

If voltmeter reading is 12 volts

c
d heater circuit is functioning
EF723
Thermostat
properly cover

If vohmeter reading is zero check Bi metal chamber Fig EF 46 Checking automatic choke
2 Thermostat housing relay
for disconnected connector open ET034
3 Groove
circuit or faulty automatic choke
Fig EF 44 Bi tting
metol Automatic choke heater
relay
I Measure resistance of choke
3 Replace faulty parts heater as shown in figure 47
EF

ified san ce is 3 7 to 8 9
spe re

4 Check automatic choke heater ohms

source wiring for proper connection

then start engine
5 After warming up the engine see

that choke valve is fully open

6 If automatic choke heater source

wiring is normal and choke valve does

not operate after warm up replace

hi metal t er
co

Automatic
FEF261
choke relay

J Fig EF 47 Automatic choke heater

j automatic choke
I Remove relay check

2 If measured value is not within

Auto choke heater relay

the specification replace bi metal
cover

j INTERLOCK OPENING OF
1 ignition key
2 Automatic choke relay PRIMARY AND SECONDARY
Engine stop OFF THROTnE VALVE
Engine start ON
3 Automatic choke heateI Figure 48
EF shows primary throt
EF710
4 Function test connector tie valve SO When primary
opened
5 Altema tor
EF278 throtlle valve is opened 50 the adjust
Fig EF 43 Checking oulomalic
plate integrated with throttle valve is
choke heater circuit with Fig EF 45 Location of automatic
led connector choke relay in contact with return plate at A
fu nc non

EF 24
 Engine Fuel

When throttle valve is opened fur B C D D CIRCUIT WITH

ther detached from
locking arm is FUNCTION TEST CONNECTOR
secondary throttle arm permitting see
Caution Do not attach test leads of a
ondary system to start operation circuit tester to those other than
Linkage between primary and see designated Refer to Figure EF 50
ondary throttles will function properly
if distance between throttle valve and Menuel trensmlsslon models
inner wall of throttle chamber is 74 I Check for continuity between A
mm 291
0 in
and B when vehicle is brought to a
Adjustment is made by bending complete stop Refer to Figure EF 50
connecting link BC D D circuit is
functioning
@ properly if continuity exists and volt
I
Fig 49
EF Adjusting dash pot meter reading is 0 volt d c in
step 2

L
l below
If continuity does not exist check
for disconnected connector and or

1 faulty amplifier speed detecting

ACCELERATING PUMP switch
4 CAl or B C D D solenoid valve

Secondary prm ary I

I Visually inspect accelerating 2 Check for presence of voltage
I pump cover for any sign of fuel leaks across A and B a speed of more
at

Jl 2 If fuel leaks are found check

gasket and replace if necessary

than 16 km h 10 MPH Refer to

t
7
Figure EF 50

Conduct this test by one of the

following two methods

1 Roller 4 Adjust plate ANTI DIESELING I Raising up rear axle housing with
2 Connecting lever stand
5 Throttle c amber SOLENOID VALVE
3 Return plate 6 Throttle valve If engine does not stop when igni 2 Chassis dynamometer test
Fig EF 48 Adjusting interlock opening tion switch is turned off this indicates If voltmeter reading is 0 volt at a

that a closed solenoid valve speed of more than 16 km h 10

striking
is shutting off supply offuel to engine MPH circuit is functioning prop

If harness is in good condition erly

replace solencid valve as a unit If voltmeter reading is not 0 volt
DASH POT check for disconnected connector
Notes
1 Idling speed of engine and mix burned fuse faulty amplifier
a Tightening torque is 18 to 3 5
ture must be well tuned and B C D D solenoid valve or speed
up
kg m 13 to 25 ft Ib
engine sufficiently warm detecting switch
b After engine and
2
replacement star
Turn throttle valve by hand and
check to be sure that fuel is not 3 If by above checks faulty part or
read engine speed when dash pot just
leaking and that dieseling
anti sol unit is located it should be removed
touches stopper lever
noid is in good condition and tested again If necessary replace
3 Adjust position of dash pot by
turning nut until engine speed is in the
specified range

Specified engine speed

Manual transmission
1 900 to 2 100 rpm
1
4
Automatic transmission

1 650 to 1 850 rpm

Tighten lock nuts

P4
11 0

8
3
4
1
2
Ignition Icey
Fuse
Amplifier
Speed detecting switch
Above 10 mph OFF
5 Make that
sure engine speed Below 10 mph ON
drops smoothly from 2 000 to 1 000 5 Function test connector

rpm in about three seconds

l 6 B C D D solenoid valve

EF711

Fig EF 50 Checking B C D D circuit with function test

connector for manual transmission

EF 25
 Engine Fuel

AUtomatic trailamlsalon modela check for resistance between A and B 3 Warm up the until it is
engine
I With inhibitor switch ON UN Refer to Figure EF 51 heated to operating temperature
P check for presence of Then
or position If ohmmeter reading is 25 ohms or adjust the engine at nunnal
voltage across A and B Refer to below circuit is idling setting Refer to the item
functioning prop
Figure EF 51 erly Idling Adjustmenl in page EF 21

If ohmmeter
If voltmeter ading is 12 volts readingis 32 ohms or Idling engine speed
above check for poor connection
dc BC D O circuit is func Manual transmission
of connec or faulty B C D D sole
tioning properly 750 rpm
If voltmeter noid valve or inhibitor relay Automatic transmission
ading is zero check

for disconnected connector 3 If by above checks in D position

faulty faulty part or

solenoid valve m inhibitor switch unit is located it should be moved 650 rpm

and tested
2 With inhibitor switch OFF again If necessary replace 4 Run the engine under no load
HI 2 IY oR Increase engine speed to 3 000 to
or position
3 500 rpm then quickly close throttle
@
valve

yu 5

mmHg
At the time the manifold

p ssure increases
abruptly to
23 62 inHg or
600
above and
vacuum

then graduaUy decreases to the level

set at idling
6 Check that the B C D D set pres
1 Ignition key sure is within the specified pressure
2 T switch
Inhibit Specified pressure 0 m sea level
@ N P positions ON and 760 mmHg 30 inHg atmos
I 2 D R positions OFF
pheric pressu
3 D C D D solenoid valve
4 Function test connector
Manual transmission
5 Inhibitor relay
510 to 550 mmHg
EF712
20 1 to 7inHg
21
Fig EF 51 Checking B C D D circuit with unction t st connector
Automatic transmission
for automatic transmision
490 to 530 mmHg
Set pressure To B D D
19Tto 20 9 inHg
solenoid valve
of Boost Controlled
Deceleration Device B C D O 1 Notes
BC D D olenoid valve
a When atmospheric pressure is
Generally it is unnecessary to ad harness
known operating pressure will be
just the B CD D however if it should
found by tracing the arrow line
become necessary to adjust it the
A See Figure EF 56 When alti
procedure is 3S follows
tude is known operating pressure
will be found by tracing the arrow
Prepare the foUowing tool EF262
line B See
Fig EF 52 Removing harness of
FiguEF 56
I Tachometer to the b When the set of
measure en
solenoid valve checking pressu
gine speed while B CD D find the specified
idling and a screw set
2 Connect rubber hose between
driver in Figure EF 56
pressu from the
vacuum gauge and intake manifold as and altitude
2 A vacuum gauge and connecting atmospheric pressure
shown
of the given location
pipe
if an automatic trans
For example
Note A quick hoost
response type mission model vehicle is located at
gauge such as Bourdon s type is an altitude of 1 000 m 3 280 ft
recommended a mercury type the set for
specified p ssu

manometer should not be used

BC D D is 445 mmHg 17 5

To properly set the B C D D inHg

set

pressure proceed as follows

I Remove the harness of solenoid

valve
7 If it is higher than the set level
turn the adjusting screw or nut until

Fig EF 53 Connecting vacuum gauge correct adjustment is made

EF 26
 Engine Fuel

Non California models Note When adjusting B C D D for In this the

case engine must be
Adjusting screw California models turn adjusting labored by I road test or 2 chassis
Counterclockwise nut in or out with lock spring in dynamometer or 3 by raising up rear
California models place Always set lock
spring prop suspension member on a stand accel
Adjusting nut erly to prevent changes in set pres erating the vehicle to 64 to 80 km h
Clockwise sure 40 10 50 MPH in top gear manual
California
Non models transmission or in 0 position auto
1 2 8 Race the and check for
engine matic transmission and then releasing
adjustment the accelerator and
pedal letting the
9 If it is lower than the set level vehicle decelerate After doing this
turn the adjusting screw or nut until check whether the B C O D set pres
correct adjustment is made sure is at the predetermined value or
10 Race the engine and check for not

adjustment
1 Adjusting screw s CD If engine speed cannot be decreased
2 Cover e
to idling when checking B C D D set
ET037
California models pressure proceed as follows

When the engine speed does not fall

to idling speed it is necessary to

t
reduce the negative idling pressure of

the manifold to lower than the set

pressure of the B C D O The engine
will drop to idling speed
speed not
1 Adjusting nut when the negative idling pressure is
2 Lock spring EC692 higher Ihan the sel pressure of the
Fig EF 54 Adjusting et pressure B CO O

vacuum gauge acuum gauge Vacuum gauge

Intake

M
Intakema
gjl 11 Road test
V 9iI
21 Chas amomeler 3
iY
n
Raise up rear axle housing by stand
ET133

Fig EF 55 Testing sel ure of the B C D D

pre

EF 27
 300 n 6 000 ft
1 3 000 4 000 5 000
o 000 2 000

Altitude

1 5 2 0 km
o 0 5 10

EF558

Fig EF 56 Changes in set pres ure versus changes in

atmospheric pressure and altitude

3 If a dick is heard solenoid valve

B C D D solenoid
is normal
valve
4 I f a dick is not heard ar all check
I Turn Do not start
on engine key for continuity with a circuit tester If
engine discontinuity is detected replace sole
Ensure that solenoid valve clicks noid valve
when intermittently electrified as

shown in Figure EF 57 Amplifier Manual

transmIssIon models

The amplifier is installed at the rear

EF262 ofthe speedometer To check proceed
as follows
Fig EF 57 Checking solenoid valve

EF 28
 Engine Fuel

b Counties 1 219 m 4 000 ft or

I Set circuit tester in d c ampere 3 Ensure that tester pointer deflects
when is turned on more above sea level have been
range IA min fuU scale connect test ignition key
4 If tester pointer does not deflect designated by law as High Altitude
probes of tester as shown in Figure
detect Counties For further details refer
EF 58 when solenoid valve and speed
to 1977 DATSUN PICK UP Service
Do not confuse positive line with ing switch circuits are functioning
line properly amplifier is faulty BuUetin Pub No 257
negative
2 Turn ignition key to ON posi
tion

I v

t
Q0
1
EF733

EF264
Fig EF 61 Checking altitude
1 Ignition key compensator
2 Amplifier
3 Speed detecting switch

4 B C D D solenoid valve

Fig EF 58 Checking amplifier MAJOR SERVICE

Inhibitor switch If results satisfy the above inhi OPERATION
Automatic transmission bitor relay is functioning properly if
The perfectly adjusted carburetor
inhibitor relay
models not replace delivers the proper fuel and air ratios
Refer to the AT section at all speeds for the
particular engine

@ for which it designed By com

was

Inhibitor relay
Automatic transmission
it pletely disassembling which will allow
deaning of all parts and passages the
carburetor can be maintained its origi

nal condition and will continue to

I jj l deliver the proper ratios

models
To maintain accurate carburetion
oJ 44 11 4
L of passages and discharge holes ex

EF287 treme care must be taken in cleaning

Use only carburetor solvent and
Fig EF 60 Checking inhibitor relay
compressed air to clean all passages
ALTITUDE COMPENSATOR and discharge holes Never use wire or
other pointed instrument to clean or
California models
carburetor calibration will be affected

Make that altitude com

sure

pensator to carburetor hoses are con

nected properly and that they are not REMOVAL
Inhibitor relay cracked and obstructed
Remove carburetor from engine
EF724 2 Check that altitude compensator
taking sufficient care to the following
Fig EF 59 Location of inhibitor relay is properly set
At low altitudes Close Precautions
2 Make an inhibitor relay check as

At high altitudes
shown in Figure 60
EF Open a When disconnecting fuel lines do

Apply 12 volts c
d across termi Notes
not spill fuel from fuel pipe
that continuity b When removing carburetor do not
nals 1 and 4 to ensure a The idle Pm and CO vary accord
exists between terminals 2 and 3 ing to the altitude Therefore they drop any nut or bolt into intake
manifold
that continuity does not should be
Check properly adjusted when
c Be careful not to bend or scratch
exist between terminals 2 and 3 when the position of the H L lever is
is them any part
no voltage applied across changed

EF 29
 Engine Fuel

DISASSEMBLY AND ASSEMBLY

1 Lock lever 11
A Choke chamber High speed enricher air bleed
B 2 Filter set screw 12 Choke valve
Center body
3 Fuel filter 13
C Throttle chamber Accelerating pump lever
4 Fuel nipple 14 Throttle return spring
5 Needle valve body 15 pump rod
Accelerating
ff
oI
C
6
7
Needle valve

Fuel chamber
16

17
Automatic choke
Automatic choke body and
cover

parts
8 Accelerating pump parts diaphragm chamber

Q
@
f 9 Altitude compensator pipe
California models

tng
ail bleed adJ
18Richer jet
19 Coasting air bleed I
20 Primary main jet
21 Secondary main jet
22 Secondary slow air bleed

J
ID
23 Secondary slow jet

@ 24 Plug
25 Air bleed

tJ
@ 26 Coasting jet
@ @1 27 Secondary main
28
29
Power valve
Primary main air bleed
air bleed

@ 30 Plug
31 Primary slow jet
32 No 2 primary slow air bleed

33 Primary and secondary small

I 34
35
venturi

Venturi stopper screw

Choke connecting rod
36 dieseling
Anti solenoid valve
37 Fast idle cam

38 Diaphragm chamber parts

39 Idle limiter cap
40 Idle adjust screw

41 Idle adjust screw spring

42 Throttle adjust screw

J 3 Thr9ttle dj t
5Crew
spring
44 Primary and secondary throttle
valve
45 B C D D California models
46 Vacuum control solenoid valve
47 B C D D Califomia
Non models

Note Do not remove the parts

marked with an asterisk

Ill
@

EF725

Fig EF 62 Carburetor part

@ff
EF30
 Engine Fuel

Disassembly screws and nuts and care must be 3 Do not attempt to remove any
Properly filling wrenches and ex ercised not to damage any parts parts marked with an asterisk CO in
screwdrivers be used the 2 Clean the carburetor
must on thorougWy Figures EF 62 EF 63 EF 64 and
nozzles and jets as well as on the beiore disassembly EF 66

Choke chamber parts

1 Coasting air bleed adjusting screw

2 High speed enricher air bleed
3 Choke valve
4 AcceJera ing pump lever
5 Throttle returnspring
6 Accelerating pump rod
7 Automatic choke cover

8 Richer jet
9 Automatic choke body and
diaphragm chamber
10 Coasting air bleed

@
Note Do not remove the parts

marked with an asterisk

fi

1i
8 I
J
l
EF 225

Fig EF 63 Removing choke chamber parts

EF 31
 Engine Fuel

Vacuum control solenoid

Center body parts valve

Sets 2 B CD D
3 Coasting jet
4 Secondary slow jet
5 ptug
6 Air bleed
1 Secondary slow air bleed
8 Secondary main air bleed
9 Power valve
10 Primary main air bleed
11 Weight and outlet valve
12 ptug
13 Primary slow jet
14 slow air bleed
Ptirnar
15 Accelerator pump assembly
16 AntkUeselingsolenoid vain
17 Fast idle earn
18 Choke connecting rod
19 Fast idle earn shaft
20 Ventuci stopper screw

1 21 Primary and secondary

small venturi

@
l Note Do not remove the parts
marked with an asterisk

It
EF726

Fig EF 64 Removing jets

Float

i
i j

1 L 4 S JlJ

4 2
V @ I
Ji

c 4 6
@

11
e4
Yr
Qll1D
J 1 tt
c 1
@5
1
lil I
1 Secondary main jet
u
p r
i r 2 Primary main jet
1 CJi 3 Float chamber parts
U 4 Fuel inlet assembly

to1 4 1 Lock lever

if
I
7 4

44
45
Hi
2
3

5
Filter set
Fuel f1Iter
Fuel nipple
screw

Needle valve body

Needle valve

Diaphragm chamber aiSembly

lv
8rtj Fig EF 65 Removing float
EF227

EF 32
 Fuel
Engine

Throttle chamber parts

I Idle limiter cap

2 Idleadjust screw
3 Idleadjust screw sprinl
4 Throttle adjust screw
5 Throttle adjust screw sprini
6 Primary and secondary
throttle valves
7 Nut

Notc Do not remove the parlS

marked with an asterisk

@ff EF827

Fig EF 66 Removing throttle chamlHr parta

Assembly

To assemble the disassem one

appear hard or brittle if edges
reverse or are

bly procedcre taking to the 4 After reassembling carburetor

care torn or distorted
following If any of such undesirable condi check each rotating portion or sliding

tions is noted they must be replaced portion for smooth operation

I Thoroughly wash all the parts
before assembling 3 Install jet and air bleed having the

if same size number as that of original

2 Inspect gaskets to see they

EF 33
 Engine Fuel

I Check float needle and seat for accelerating nowe

CLEANING AND
7 Push connecting rod of dia
INSPECTION wear If wear is noted assembly must

be replaced phragm chamber and block passage of

Dirt wuler or l arbon con 2 Check throule and choke shaft vacuum with finger When connecting
gum
taminatiun in or on exterior moving bores in throtlle chamber and choice rod becomes free check for leakage of
air or damage to diaphragm
parts of a arburctor arc often respon chamber for wear or of roundness
out

sihk for unsatisfactory performance 3 Inspect idle adjusting needle for

Jets
For this reason efficient carbutetioll burrs or ridges Such a condition re

careful and
Carburetor performance depends
dcpends upon cleaning quires replacemen 1 That is why
on jet and air bleed
inspection while servicing if they
3 Inspect gaskets 0 see
these components must be fabricated
I Blow all and or briUle or if edges are
passages castings appear hard with utmost care To clean them use
with compressed air and blow off all torn or distorted If any such condi solvent and blow air on them
cleaning
parts until dry tion i noted they must be replaced numbers the
Larger inner tamped on

4 Check filter screen for dirt or lint indicate larger diameters Ac

jet
Note Do not pass drills or wires is distorted
Clean and if screen or
cordingly main and slow jets with
through calibrated jet or passaaa
as this may enlarge orirlce and
remain plugged replace lalger nUmbers provide richer mixture
5 Check linkage for operating the smaller the numbers the leaner the
seriously affect carburetor calibrs
condition mixture Conversely the main and
lion
6 Inspect operation of accelerating slow air bleeds through which air to
2 Check all parts for wear If wear pump Pour f el into jloat chamber passes through make the fueLleaner if

is noted damaged parts must be re and make throtlle lever operate Check they bear larger numbers the smaller
placed the following condition of fuel injection from the the numbers the richer the fuel
Note especially

EF 34
 Engine Fuel

SERVICE DATA AND SPECIFICATIONS

Nl n
California modell California modeb

Manual transmiSsion
I Automatic transmission Manual transmission
I Automatic transmission

Airclelllcr

Ail control val partially opem Oc oF 30 to 54 86 to 129 30 to 54 86 to 129

Air ntrol valve fuUy opens oCeF above 55 131 above 55 131

Idle ompensatoI partially opens oCeF

Hi mettiNo l 60 to 70 140 to 158 60 to 70 140 to 158

metal
Bi No 2 70 to 90 158 to 194 70 to 90 158 to 194

Idle tor fully opens

ompen Oc OF
metal
Bi No 1 above 70 158 above 70 158
Hi metd No 2 above 90 194 above 90 194

Fuels
Stem
Fuel prtuure kpJcm2 poi 0 21 to 0 27 2 99 to 3 84 0 21 to 0 27 2 99 to 3 84

Fuel pump apacHy US pt min at rpm t OOO i I OOO

2 1 000 i
2 I OOO

C rbu tor

C rbu tor type Strombcra type Stromt

rg type

Carburetor model OCH340 7A 48A

DCH340 45B
DCH34Q 46A
DCH340

Primary Secondary Primary Secondary Primary Secondary Primary Secondary

Outlet diameter rom in 30 I8t 340 339 1 181

30 34 1339 30 181
1 34 1 339 1
30 181 34 1339

Venturi diameter in
mm 24 0 945 310 220 24 0 945 31 1 220 24 0 945 31 1220 24 0 945 31 1220

Main jet 199 1160 199 1160 1101 1160 101 1160
Main air bleed 170 160 170 160 170 60 170 60
1
Slowjet 148 1100 148 1100 148 1100 148 180
Power val 143 143 140 140
Float level U mm in 23 0 906 23 0 906 23 0 906 23 0 906

fuel preuure kg cm2 psi 0 17 2 408 0 17 2 40B 0 17 2 408 0 17 2 408

Adjustment
Engine idling Ignition timingIdle speed COat 120 650 rpm 0 120 650 rpm 0
1201750 rpm CO 2 1 750rpm
100 t 1
C02
mloro position CO t 1
2 position CO t
2 1

Fuel level adjustment

at
Gap between Ive stem and noat mm in

H 7 2 0 283 7 2 0 283 7 2 0 283 7 2 0 283

H 23 0 906 23 0 906 23 0 906 23 0 906

h 13 to 17 1 3 to 17 13 to 17 13 to 17
0 051 to 0 067 0 051 to 0 067 0 051 to 0 067 0 051 to 0 067

Fast idle adjwtmcnt Fast idle earn tint step

Gap between throttle IYe and carburetor body 33

1 to 147 158 to 172 133 to 147 158 to 172

in
mm 0 0524 to 0 0579 0 0622 to 0 0677 0 0524 to 0 0579 0 0622 to 0 0677

Vacuum break adjustment

Gap between choke alve and carburetor body 1 42 0 056 142 0 056 1 5 0 059
142 0 056
mm in

Choke unloadel adjusttncnt

Gap between choke alw and carburetor body 2 45 0 096 2 45 0 096 24 0 096 2 45 0 096
rom in

Bi metalsettinl

metal
Bi resistance at 2Ioe 700F n 3 7 to 89 3 7 to 8 9 3 7 to B 9 3 7 to 8 9

metalsettina
Bi Center of the ndex mark Center of the index mark

lnterloc k opcnina of primary and secondary

mmOn 7 38 0 291 7 38 0 291 7 38 0 290 7 38 0 291
throtUc valves

to 650
1 to 850
1 1 900 to 2 100 1 650 to 1 850
Duh pot adjustment without loadin Im 900
1 2 100

diclClinasolenoid
Anti C
valV
tiahtenina torque 180 350 304
180 to 350 156 to 304 180 to 350 156 to 304 180 to 350 156 to 304 to 156 to
ka m lb
in

to 490 to 510 to 550 490 to 530

cD D
a set p
JSure 0 m sea level and 760 mmHg 510 550 530
20 1 21 7 19 3 20 9 20 1 to 21 7 19 3 to 20 9
atmospheric pressure J mmHa inHg to to
30 inlla
20 to 40 17 4 to 34 1 20 to 40 11 4 to 34 7 20 to 40 17 4 to 34 7 20 to 40 17 4 to 34 1
RC D D tiahteninl torque kg m n b

EF 35
 Engine Fuel

toms and causes of carburetor troubles

TROUBLE appears to have some problems when
and remedies for them are listed to actually the electric system is at fault
DIAGNOSES AND facilitate quick repairs Therefore whenever the engine is mal
CORRECTIONS There are various causes of engine functioning the electrical system
malfunctions It sometimes happens should be checked rust before adjust
In the following table the syml that carburetor which has no fault
a
ing carburetor

Condition Probable cause Corrective action

Overflow Dirt accumulated on needle valve Clean needle valve

Fuel pump pressure too high Repair pump

Needle valve improperly seated Re place

Excessive fuel Fuel overflow See condition overflow

consumption Slow jet too large each main jet

on Replace
Main air bleed clogged Clean

Choke valve does not open fully Adjust

Outlet valve seat of accelerator pump Lap
improper
Linked opening of secondary throttle valve Adjust
opens too early

Power shortage Main jets clogged Clean

Every throttle valve does not

open fully Adjust
Idling adjustment incorrect AdjusL
tr
FIICI clogged ir
pa
Vacuum jet clogged Clean

Air c1eane clogged Clean

Diaphragm damaged Replace

Power valve operating improperly Adjust
Altitude compensator setting incorrect Cali Correct H L lever position
fornia models

Improper idling Slow jet clogged Clean

Every throttle valve does not close Adjust

Secondary throttle valve operating im Overhaul and clean

properly
Throttle valve shafts worn Replace
Packing between manifold carburetor fauJiy Replace packing

Manifold carburetor tightening improper Correct tightening

Fuel overflow See l ondition ov rl1ow

BC D D adjustment incorrect
Adjust
Vacuum control solenoid damaged Replace
Stuck anti stall dash pot Replace

EF 36
 Engine Fuel

Condition Probable cause Corrective action

Engine hesitation Main jet or slow jet clogged Clean

By pass hole idle passage dogged Clean tube

Emulsion tube dogged Clean

Idling adjustment incorrect Adjust

Secondary throttle valve operating im Overhaul and clean

properly
Altitude compensator setting incorrect Cali Correct H L lever position
fornia models

Engine does not Fuel overflows See condition overflow

start
No fuel Check pump fuel pipe and needle valve

Idling adjustment incorrect Adjust

Fast idle adjustment incorrect Adjust

Damaged dieseling
anti solenoid Replace

EF 37
 SECTION EC

EMISSION
DATSUN PICK UP CONTROL
MODEL 620 SERIES SYSTEM

GENERAl DESCRIPTION EC 2

CRANKCASE EMISSION
EC 2
CONTROL SYSTEM

EXHAUST EMISSION EC 3
CONTROL SySTEM

EVAPORATIVE EMISSION
EC 30
CONTROL SYSTEM

SPECIAL SERVICE TOOLS EC 32

I NISSANI

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Emission Control of System

GENERAL DESCRIPTION

There are three types of control 2 Exhaust emission control system seCV1Clng of these systems should be
system These are 3 Evaporative lhsion
ell control sys carried out to reduce harmful emis
tem sions to a minimum
J Closed type CIllnkcase emission
control system Pericxiic inspection and required

CRANKCASE EMISSION CONTROL SYSTEM

DESCRIPTION INSPECTION
The ventilating air is then drawn
to from the dust side of the cadlUretor P cV VALVE AND FILTER
This system returns blow by gas
air cleaner tluough the tube con
both the intake manifold and carbure Checking P C V valve in accord
tor air cleaner necting carburetor air cleaner to rock
into the crankcase
ance with the following method
er cover
The positive crankcase ventilation With engine running at idle remove
C V valve is provided to conduct Under full tluottle condition the
p the ventilator hose from P C V valve
manifold vacuwn is insufficient to
crankcase blow
by gas to the intake if the valve is working a hissing noise
manifold draw the blow by flow tluough the
air passes
and its flow goes through the
will be heard as through the
During partial throttle operation of valve
valve and a strong vacuwn should be
the engine the intake manifold sucks tube connection in the reverse diree
felt immediately when a fmger is
the blow by gas through the P C V tion
placed over valve inlet
valve On vehicles with an excessively high
Replace P C V valve and filter in
Normally the capacity of the valve blow by some of the flow will go
accordance with the maintenance
is sufficient to handle any blow by and through the tube connection to carbu
schedule
retor air cleaner under all conditions
a small amount of ventilating air

4
VENTILATION HOSE

1 Check hoses and hose connec

tions for leaks

01
c

2 Disconnect all hoses and clean

with compressed air

Lkf 1
If any
obstructions
hose
replace
cannot

Ensure that flame arrester is surely

be free of

If inserted in hose between air cleaner

and rocker cover

II tll

TIL 1j
c Fresh air
GUuuu
1 Sealtypc oil level gauge
2 Bame plate
Blow by gas
3 Flame arrester
4 Filler
5 P C Y valve
6 Steel net
7 Bame plate
EC716

Fig EC l Crankcase miaion control ay tem

EC 2
 Emission Control System

EXHAUST EMISSION CONTROL SYSTEM

CONTENTS

DESCRIPTION EC 3 EXHAUST GAS RECIRCULATION

EARLY SYSTEM CONTROL SYSTEM E G R EC 19

FUEL EVAPORATIVE
6 DESCRIPTION EC 19
E F E EC
EC 6 OPERATION EC 19
DESCRIPTION
OPERATION EC 6 REMOVAL AND INSTALLATION EC 23

REMOVAL AND INSTALLATION EC 7 INSPECTION EC 24

7 CATALYTIC CONVERTER EC 26
INSPECTION EC
SPARK TIMING CONTROL SYSTEM EC 7 DESCRIPTION EC 26
7 OPERATION EC 26
DESCRIPTION EC
REMOVAL AND INSPECTION EC 27
SPARK DELAY VALVE
EC 7 EC 27
Automatic transmissiom models only INSTALLATION
INSPECTION EC 8 FLOOR TEMPERATURE WARNING
EC 27
AIR INJECTION SYSTEM EC 8 SYSTEM
EC 27
DESCRIPTION EC 8 DESCRIPTION
EC 28
OPERATION EC12 OPERATION
EC 28
REMOVAL AND INSTALLATION EC 14 REMOVAL
EC 29
DISASSEMBLY AND ASSEMBLY EC 14 INSTALLATION
EC 29
INSPECTION EC 17 INSPECTION

4 Exhaust gas recirculation E GR 7 Altitude compensator California

DESCRIPTION models
control system
The exhaust emission control sys 5 Catalytic converter California
tem is made up of the following models
6 Boost controlled deceleration de As regards the last two units refer
I Early fuel evaporative system
vice B C D D to the Engine Fuel section
2 Spark timing control system
3 Air injection system A IS

3
EC
 Emission Control System

IV

ID

I Thermal vacuum valve

2 Check valve
3 Air gallery pipe
4 Auto choke
5 Automatic temperature control air c
canet
6 Anti Backfire valve A B valve
7 Boost Controlled
Deceleration Device 8C D D
8 PC V valve
9 Air relief valve
10 E G R control valve
11 Air pump air cleaner
12 Carbon canister
t3 Air pump
ET365
14 Spark delay valve AfT models

models
Fig EC 2 Exhaust emission control system Non California

4
EC
 Emission Control System

1 Thermal acuurn valve If

2 Check valve
3 Altitude compcnlator in air cleaner
4 Air gallery pipe
5 choke
AutQ
6 Automatic temperature control
air cleaner
1 Anti 8ackfue valve A B valve
8 Boost Controlled Deceleration
DeVice B C D D
9 P C V valve
10 Air relief valve
II E G R control valve
12 B C D D control valve and

solenoid valve
13 Emergency air relief valve
14 Air pump air cleaner
15 Carbon canister
16 Air control yai e
17 Air pump
ET368

Fig EC 3 E hau t emilsion controlay tem California mod ls

EG S
 Emission Control System

EARLY FUEL
EVAPORATIVE
4
EC A control valve welded to the spring and counterweight which are
SYSTEM E F E valve shaft is wtalled on the exhaust assembled on the valve shaft projecting
manifold through This the outside of the exhaust
DESCRIPTION bushing con to rear

trol valve is called Heat control manifold The counterweight is se

Construction of the early fuel evap valve The heat control valve is ac cured to the valve shaft with key bolt
orative system is shown in Figure luated by the coil spring thermostat and snap ring

rI 1 @

rW

1 Intake manifold 9 Sc w

2 Stove 10 Thennostat spring

gasket
ManifoktstOve 11 Coil spriiig
4 Heat shield plate 12 Control valve shaft
5 Snap ring 13 Heat control valve
6 Counterweight 14 Bushing
7 15 Cap
Key
g Stoppel pin 16 Exhaust manifold

EC532

Fig 4 Early Fuel

EC Evaporutive tem E FE

The early fuel evaporative system is is changed in direction as shown by With this condition the heat control

provided with a chamber above a the solid lines in Figure 4 The

manifold stove moonted between the
intake and exhaust manifolds During
engine warming up air fuel mixture in
the carburetor is heated in the cham
bet by exhaust gases This results in
improved evaporation of atomized fuel
droplets in the mixture and in smaller
EC valve is in the fully closed position
exhaust gas heats the manifold stove obstructing the flow of exhaust gas As
of the
close
Open operation heat engine tempera lure goes up and the
control valve byis controlled the ambient temperature becomes high
counterweight and thermostat spring enough to actuate the thermostat
which is sensitiveto the ambient tem
spring the counterweight begins to
perature around the exhaust manifold rotate clockwise and again comes into
con tact with the stopper pin With this

content of hydrocarbons He in the condition the heat control valve is in

exhaust gas especially in cold weather
operation
The exhaust gas flow from the
engine is obstructed by the heat con
trol valve in the exhaust manifold and
OPERATION
the full open position and exhaust gas
The counterweight rotates counter
passes through the exhaust manifold as
clockwise and stops at the stopper pin shown by the dotted lines in Figure
mounted on the exhaust manifold 4 without heati ng the manifold
EC
while the engine temperature is low stove

6
EC
 Emission Control System

2 With engine stopped visually

REMOVAL AND INSTAUATION
check E F E system for the following
items

1 Thermostat spring for dismount

ing
2 Stopper pin for bend and count
er weight stop position for dislocation

3 Check heat control valve for

malfunction due to break of key that
locates counterweight to valve shaft
4 Check axial clearance between
heat control valve and exhaust mani
1 Snap ring fold Correct clearance is 0 7 to 1 5
2 Lock bolt
mm 0 028 to 0 059 in
3 Key
5 Check welded portion of heat
4 Counterweight
5 Thermostat spring control valve and valve shaft for any
6 Coil spring indication ofcrack or flaking
7 Heat control valve 6 Rotate heat control valve shaft
8 Valve shaft
by a finger and check for binding
9 Stove gasket
between shaft and bushing in closing
10 Manifold stove
and opening operation of heat control
EC533 11 Heat shield plate
valve If any binding is felt in rotating
stem
Fig EC 5 Exploded view of E F E operation move valve shaft in the
rotation direction several times If this
Remove snap ring D and lock bolt position described in 1 1 above and operation does not correct binding
@ and the following parts can be stops again coming into con tact with condition it is due to seizure between
detached from heat control valve stopper pin shaft and bushing and exhaust mani
shaft fold should be replaced as an assem
Key 00 bly
Counterweight @
lostat
TherI spring CID j
Coil spring @ CHECKING SPARK
descnoed heat
Note As previously TIMING CONTROL
control valv 1 is welded to valve
SYSTEM
shaft @ at exhaust manifold and
cannot be disassembled
DESCRIPTION
install the removal pro EC246
To reverse

cedure The spark tirnin control system

1 Counterweight
serves to control the distributor vacu
INSPECTION 2 S topper pin
3 Heat control valve um advance under varying travelling
I Run
engine and visually check conditions so as to reduce HC and

counterweight to see if it operates Fig EC 6 Operation of counterweight

NOx emissions
when engine is cold
properly This system is installed on non

1 For some time after

starling California automatic transmission
engine in cold weather counterweight models
turns counterclockwise until it comes

into contact with stopper pin installed

to exhaust manifold SPARK DELAY VALVE
Counterweight gradually moves Automatic transmission
down clockwise engine warms up
as models only
and ambient temperature goes higher
This valve delays vacuum spark
around exhaust manifold
2 When engine speed is increased
advance during rapid acceleration it
EC246
also cuts off the vacuwn spark advance
discharge pressure of exhaust gases
causes counterweight to move down 1 Counterweight immediately upon deceleration The
2 Stopper pin valve is for
ward clockwise designed one way opera
3 Heat control valve tion and consists of a one way umbrel
3 When heat con trol valve is in the
counterweight la valve and sinlered steel fluidic
full open position Fig EC 7 Operation of counterw ight
moves further clockwise exceeding the when ngine is hot restrictor

EC 7
 Emission Control System

C bur tor
I Distributor side

EC219
1 way
One umbrella valve
2 Sintered metal disc Fig EC 11 Checking spark d tay valve
EC284
Fig EC 8 Spark delay valve

Note Be careful to avoid entry of oil

or dirt into valve

When installing this valve ensure is in good condition if when finger is

that it properly oriented Tlus valve placed over port on distributor side

shuuld be replaced periodically Refer air flow resistance is greater than that

to Maintenance Schedule on the other side See Figur ET lO

3 If a considerable air flow resist
Note Carburetor sideBlack
ance is fell at port on distributor side
DisInDutor sideBrown AIR INJECTION
in step 2 above and if the condition of

spark delay valve is questionable dip SYSTEM

port on carburetor side into a cup
horn distributor
DESCRIPTION
To carburetor filled with water Blow air through the
other port Small air bubbles should The Air Injection System A LS is

appear aeSigiieino iiiject coinpressed air sec

ODllary air corning from the air pump
into the exhaust manifold to reduce

TOdi
ribUI0 carburClor hydrocarbons and carbon monoxide in
exhaust lris through combustion
re

EC
lCiJr There

and the
are

type is mounted
two

other is
types of
on
A I
S
One
California models
on non California
Fig EC 9 Operation 01 park delay models The non California type con
value Carburetor side sists of an air pump air cleaner an air
Distributor side
pump a relief valve a check valve an
anti backfIre valve an air gallery and

hoses The California type has in

INSPECTION
addition to the components of the
Remove spark delay valve non California type an air control
2 Blow air through port on carbure valve and an emergency air relief valve

tor side then through the other port EC346 These valves prevent ahnonnal tem
on distributor side Spark delay valve Fig EC IO Checking park delay valve perature rise of the catalytic converter

8
EC
Emission Control System

1 Check valve
2 Air gallery pipe
3 Automatic temperature control

air cleaner

4 Air hose carburetor air cleaner

to A B val
5 Anti backfire valve A B valve
6 Air hose A B valve to intake
manifoW
7 Air hose carburetor air cleaner
to aU hose connector

8 Air hose check valve to air hose

connector

9 3 way connector
10 Air hose air hose connector to
air pump

11 Air hose air pump to air pump

air cleaner
12 Air pump air cleaner
13 Air pump

EC776

Fig EC 12 Non California type A IS

1 Air control valve

2 Check val
3 Air hose check valve to air hose
connector

4 Air gallery pipe

5 Automatic temperature control
air cleaner
6 Air hose carburetor air cleaner
to A B val
7 Anti backfire valveA B valve

8 Air hose A B valve to intake

manifold
9 Air relief valye
10 Air hose carhuIetor air cleaner to
air control valve
11 Air hose air relief valve to air
hose connector

12 Air hose air hose connector to

emergency air relief valve

13 Emergency air relief valve
14 Air pump air cleaner
15 Air hose air hose connector to

air pump
16 Air hose air pump to air pump
air cleaner
17 Air pump

EC777

Fig EC 13 California typo A I S

EC 9
 Emission Control System

Air pump aIr cleaner The die cast aluminwn air pump the outlet cavity Subsequently it
The air cleaner element is assembly attached to the front of the passes the stripper and a section of the
a viscous
engine is driven by air pump drive that separates the outlet and
paper lype and requires periodic re
an
housing
belt A rotor shaft drive hub inlet and inlet cavities and again reaches the
placement The air pump air cleaner is
outlet tubes are visible on the inlet cavity to
bolted to the left front of the hood pump repeat the pumping
exterior A rotor vanes carbon shoes cycle
ledge
and shoe make up the rotating Carbon shoes
springs in the slots of the
unit of the pump The rotor located in rotor support the vanes They are
the center of the pump is driven
belt designed to penni t sliding of the vanes
The vanes rotate freely around the and to seal the rotor interior from the
ofT center pivot pin and follow the air cavities Leaf springs which are

circular shaped pump bore In the behind the leading side of the shoes
two vane type the vanes form two compensate for shoe abrasion
chambers in the housing Each vane The rotor ring is a steel bolted to

pumping cycle in every

completes a
the rotor end It positions ihe rotor
revolu tion of the rotor Air is drawn and holds the carbon shoes
into the inlet cavity through a tube The needle All
vane uses bearings
connected to the air pump air cleaner
bearings have been greased
EC778 Air is sealed between the vanes and There are two typCg of bearing
moved into a smaller cavity the com
Fig EC 14 Air pump air c
leantr which support the rotor Ball bearing
pression area is used for the front one and the
After compression a vane passes needle bearing is used for the rear
Air pump

The air pump is a two vane type It

has two positive displacement vanes
which requires no lubricating seJVice

i
I
lJ1
Jr
l

j j
1 Air pump drive hub 7 Shoe spring
2 HOII ing 8 Stripper
3 Rotor ring Rotor shan
9
4 End cover with needle 10 Ball bearing
bearing II Front bearing cover

5 Vane 12 Pulley
6 Carbon shoe 13 PuDey for air con itioner

EC560

Fig EC 15 Stctionol view ofoir pump twtrvone type

EC IO
 Emission Control System

the combustion chambers and 2 When relief valve spring fails

Air control valve from
burns with the aid of high temperature Construction is shown in
CalifornIa models Figure
and injected air which causes backfire EC 18
The air control valve con troIs the

quantity of
secondary air fed from the

air pumpaccording to engine speed

and load condition and prevents ex

cessive temperature rise of the cataly

tic converter c
I Tointake
manifold
vacuum
F rom
m

in pump
The construction is as shown

Figure EC 16 The intake manifold I L

and air pump discharge pres
vacuum
AirdisChaJ1le I
1 Spring
Secondary air
to the diaphragm chamber 2 Rubber valve
sure applied to mtake
3 Seat
actuate the valve which is coupled to manifold From air Exhaust gas
cleaner
the diaphragm and control the quanti
EC292
into the
ty of secondary air to be fed ECQ69
the Fig EC 1B Check valve
exhaust manifold in response to valve
Fig EC 11 Anti back ir
engine condition
Check valve AIr InJaction Into axhaust port

A check valve is located in the air The secondary air fed from the air
The valve pre
pump discharge lines pump goes through the check valve
to

ven ts the backflow of exhaust gas the air gallery where it is distributed to

which in one of the following each exhaust port The air

occurs secondary
is then
cases injected from the air injection
From 1 When the air pump drive belt nozzle into the exhaust port near the
air pump exhaust valve
fails
To carburetor

c lr J
air cleaner

n
EC291

Fig EC 16 Air control valve

Anti backfire valve

This valve is con trolled

manifold vacuum to
by intake
prevent backfire
y
in the exhaust system
of deceleration
at the ini tial
L
period
At this period the mixture in the
intake manifold becomes too rich to

and burn in the combustion

ignite
chamber and burns easily in the ex

haust system with injected air in the

exhaust manifold
The anti backfire valve provides air
r
to the intake manifold to make the

air fuel mixture leaner and prevents

backfire I Air
gallery
A schematic drawing of the anti 2 Exhaust port
shown in 3 Air jnjection
backfire valve is Figure nozzle
V 3 4 Exhaust manifold
EC 17
The anti backfire valve inlet is con EC293

nected to the air cleaner and the outlet Fig EC 19 Air injection into exhaust port

to the intake manifold

Th correct function of ItjS valve running high speed under a heavily
at

Air pump relief valve loaded condition It accomplishes the

reduces hydrocarbon emission during
aeceleration The air pump relief valve controls following functions without affecting
the effectiveness of the exhaust emis
If the valve does not work properly the injection of the secondary air into
mixture will be emitted the exhaust system when the engine is sion control system
unburned

EG 11
 Emission Control System

California type The California stand

Minimizes exhaust gas tempera Emargency air retial valve
rise E AR Valve ard type includes a system which
lure

2 Minimizes losses controls injection of secondary air so

horsepower re California models
into the as to assure proper function of the
suiting from air injection
The emergency air relief valve con
catalytic converter and a system
exhaust system
trols the quantity of secondary air fed of second
3 Protects pump from excessive which controls the supply
from the air pump according to load
back pressure ary air to prevent abnormal tempera
condition and it discharges the see
tUfe rise in the catalytic converter
The air pump relief valve is installed ondary air atmosphere to
into the consists of the following
The A IS
as shown in Figure EC 20
prevent overheating of the catalytic systems
The secondary air is discharged converter
L A system which allows injection
from the air pump relief valve to the The emergency air relief valve con
of secondary air into the exhaust port
dust side of the carburetor air cleaner sists of diaphragm a spring and a
a

which is coupled to diaphragm

2 A system which bypasses sec
valve
ondary air from the air pump relief
valve to the carburetor air cleaner

during high speed engine operation

To carburetor 3 A system which supplies air from
air cleaner the carburetor air cleaner to the intake
Secondary
air manifold by means of the anti backfire
valve so as to prevent after fire during
deceleration
4 A system which controls injection
of the secondary air by means of the
1 Diaphragm
air control valve so as to maintain the
2 Val
3 Spring catalytic converter optimum
at an

4 Diaphragm chamber temperature level under lightly loaded

To carburetor condi tions
air cleaner erCOndary EC536

J Fig EC 21 mergency air relief valve

Califomia type only

r 5 A system which controls the sup

r
ply of secondary air through the emer

gency air relief vilve pfevent

io ab
OPERATION
normal temperature rise of the cataly
As mentioned previously there are tic converter
EC294 California type
two
types of Air Injection Systems only
IS
A California
non A I operation is follows
Fig EC 20 Air pump relief valve a
type and a S as

I
I
t
1
r

I Air 6 Check valve

pump
2 Air pump air deaner 7 Air gallery pipe
L

I 0 3 Air relief valve 8 Injection non e

4 Air cleaner 9 Exhaust manifold
r
5 Carburetor 10 Anti backflIe valve
EC179
Fig EC 22 Non California type A IS

EC 12
 Emission Control System

The non California type operates as

follows secondary air is sucked

through the air pump air cleaner into
the air pump driven by the crank To intake To intake
pulley It is then discharged through manifold manifold
the check valve to the air gallety where
it is distributed to each exhaust porL

The secondary air is then injected

Air diSlcharge to
from the injection nozzle into the
intake manifold
exhaust port near the exhaust valve Secondary
air
The air relief valve opens only when
the discharge pressure of the air pump
EC297
surpasses the spring force of the air
Fig EC 23 Operation of A B lve
relief valve during high speed opera
tion When the air relief valve opens
The California type includes in the air control valve and
the secondary air is discharged in to the stops dis
addition to the the
carburetor air c1eaner components of the charging secondary air Figure
non California type an air control
The anti backfire valve opens when EC 25
valve and
the intake manifold vacuum reaches a an
emergency air relief valve When the intake manifold vacuum

value during decelera The air control valve opens when

predetermined applied to the diaphragm reaches a
tion and permits fresh air to now into the sum of the air pump discharge E A R valve
predetermined level
the intake manifold from the air pressure and the intake manifold vacu operates to discharge the secondary air
cleaner um applied to the diaphmgm reaches a into the atmosphere When the pres
predetermined level and discharges becomes
sure
high the valve closes by
the secondary air into the air cleaner spring tension of EA R valve and
When the pressure becomes low the stops discharging the secondary air
valve doses with the
spring force of

fl
f
I t
Qj
riu
Jl
rn l

3
j I
@

I Air 5 Air cleaner

pump 9 Air control valve
2 Air pump air cleaner 6 Check valve 10 Injection nozzle
3 Emergency air relief valve 7 Airgallery pipe II l Exha t manifold
4 Air relief valve 8 Carburetor 12 Anti backfire valve
EC780

Fig EC 24 California type IS

A

EC 13
 Emission Control System

To intake

o jJ To

vacuum
Intake mamfold
manifold
lm
vaCUl

rF
r

To air cleaner
r

To air cleaner

From air pump

9
Y 9
4 Gf
From air T
pump
l
h 1 I I

Actuated EC299
Not actuated
Fig EC 25 Operation of air control value

REMOVAL AND Notes

011 to rews several
INSTALLATION
a
Apply engine
times during above work

Air p mp sir cleaner b Be atreful not to damage other

Remove air hose then detach air parts
cleaner from hoodledge Air cleaner
3 Unfasten injection nozzle
air
element and Ii r deancr lower
body are
from cylinder head applying engine oil
built into a unit construction Replace
to screwed portion several times
air cleaner clclnen and lower body as
4 Check air gallery and nozzle for
an assembly
fractures or leakage Clean air injection
EC781
nozzle with a wire brush
Fig EC 27 Locotion of E A R wive
5 At time of installation hold air

injection nozzle hexagon head with a

Antl backflravalve wrench and tighten air gallery flange
screw to a torque of 5 0 to 5 9 kg m
Disconnect air hose and vacuum
36 to 43 ft lb
JJ hose from anti backfire valve
6 Check cylinder head air injection
tt c
o J
323
EC
t nozzle and air gallery for leaks with

engine running
Fig EC 26 Replacing oir cleaner Check valve
element
Disconnect hose and remove check
Air pum valve from air gallery pipe Air pump relief vslve

Remove air hoses from air pump Loosen carburetor air cleaner
2 Loosen air pump adjusting bar mounting sc ews and remove air
Air ganery pIpe andinJactlon
mounting bolts and air pump mount pump relief valve
then remove air pump drive nozzles
ing bolts
bell
It is very difficult to remove the air InstallatIon
3 Remove air pump pulley
gallery from the exhaust manifold
4 Remove air pump from bracket Install in the reverse order of reo
without bending the pipe which could
moval
result in fractures or leakage There
Air control valve
fore
removal of the air gallery pipe
California models DISASSEMBLY AND
and injection nozzles should be under
l Disconnect air hoses and a vacu taken only when they are damaged ASSEMBLY
um hose from air control valve
I Lubricate around the connecting
2 Remove air con trol valve from Disassembly of air pump
portion of air
injection nozzle and air
bracket Remove four drive bolts
gallery with engine oil 1 pulley
Hold air injection nozzle and remove pulley from hub
2 hexagon
E AR valve California modela 2 Secure air pump drive hub in a
head with a wrench and unfasten flare
vise as shewn in Figure EC 28 and
Remove vacuum pipe and air hose screw connecting ait gallery to injec
tion nozzle Remove air remove four end cover bolts
and dismount E A R valve gallery

EC 14
 Emission Control System

the aluminum b Discard screws which were re 8 Remove four screws securing
Note Never clamp on

moved when front bearing cover in place and de

housing Always use new ones

installing tach bearing cover

9 Support the rear end face of air

pump housing with Rotor Adapter
5 Remove vane from rotor STl9890000 Drive rotor out by push

ing rotor shaft with Bearing Pressing

Tool STl9940000

STl9940000

EC302 EC661 1Ul STl9890000

Fig EC 28 Removing cover Fig EC 30 Remooing vanes

I I
3 Remove end by carefully
cover 6 Remove four carbon shoes and EC303

tapping around dowel pin with a plas two shoe springs from rotor using Fig EC 32 Removing rotor shaft
tic mallet and lift up straight needle nose pliers or tweezers
match marks 0 rotor
4 Put on 10 Support the front end face of
ring and side of rotor to ensure correct Note Carbon shoe A is I mm housing with Bearing Adapter
reassembly and remove four screws 0 039 in wider than B Do not STl9930000 Attach Bearing Driver
that retain rotor ring to rotor using a STl9910000 to front bearing on the
confuse them
Hexagonal Wrench STl9810000 inside of air pump housing iuid press
out
Notes
a Generally match marks are indi ll
cated on both rotor ring and rotor
I I
by the manufacturer
STl9910000

9930000

J 1
EC304

Fig EC 33 Remouing ball bearing

If replacement of front bearing is

necessary proceed as follows

ECll1 7 Remove air pump drive hub with 11 Keep disassembled parts in

Fig EC 29 Removing rotor ring standard puller rder

EC 15
 Emission Control System

EC562

Fig EC 34 Componenbr of two vane type

Assembl of air pump Press drive hub into place with a

I Front bearing
1
C preand Bearing Driver STI 991 0000
until the end face of drive hub touches
Support the rear end face of air
froE c ing in n c

pump housing with RotOL Adapter ST 19910000

STl9890000 Press front bearing into

placewith a press arid Bearing Ptessing

Tool STl9940000 j
I I

ST19920000
STl9940000 STt9910000

I EC3Q7

Fig EC 36 Pressing rotor shaft

L
e
Notes

X8 03
STl9920000
a Be sure to drive front bearing inner r

race in
EC308
Fig EC 35 Pressing ball bearing b After rotor is installed in place
ensure that the rotor end is Fig EC 37 Pressing air pump drive hub
pos
2 Bearing cover
tioned below the end face of air
Torque four bearing cover securing
pump housing
bolts to 0 1 to 0 2 kg m 0 7 to 4
1 5 Carbon shoe
ft lb Position of rotor end below air
1 Place air pump drive hub in a

3 Rotor shaft
pump housing vise
0 050 to 150
0 mm
2 etc from
Support the inward bottom of Clean carbon dust
00020 to 0 0059 in
rotor with Rotor Stand STl9920000 shoe grooves
Press rotor into place with a press 3 Align rotor with housing proper
and Bearing Drive STl9910000 until 4 Air pump drive hub ly Refer to Figure EC 38 Then insert
the stepped portion of rotor shaft Support the inward bottom of carbon shoes into place noting their

touches front inner race rotor with Rotor Stand STl9920000 directions
bearing

EC 16
 Emission Control System

Notes

a Do not apply an tue

u stress to

vane shaft when inserting

b If two vanes are dislocated when
inserting vane shaft correctly
align
vanes by inserting dummy shaft
Then draw out dummy shaft and
insert vane shaft
c When wear occurs on vane shaft or

i when replacement of rear bearing is

111
11 necessary replace rear cover as
EC540 EC123 sembly
Fig EC 38 Install carbon shoe Fig 40
EC Installing shoe spring
Jl End cover

Position end cover in place Snugly

Note When instaUing a shoe spring
Notes the bolt close to the dowel
make sure that the outward bend tighten
a Carbon shoe A is 1 mm 0 039 Then tighten four bolts to the speci
in wider than ing side faces in shoe and that both
B Do not confuse
ends fied torque
of spring face in the wall of
them
shoe groove Tightening torque
b If carbon shoes are exposed beyond Be sure to push spring in so that 0 7 to 0 9 kg m
the rotor end face remove carbon 5 1 t06 5 ft4b
shoes and clean shoe grooves spring end face is flush with rotor
Reassemble carbon shoes
8 Rotor ring
Install rotor ring by correctly align
6 Vane ing the rear end face of rotor with the

0 mark in rotor
1 Pack vane bearing with high ring and tighten
melting point grease MIL G 3545 A four screws to the specified
torque
Esso ANDOK260 or equivalent and with Hexagonal Wrench ST19810000
insert dummy shaft into the Vane
Tightening torque
bearing 5 to 0 7
0 kg m

STl9900000 3 6 to 5 1 ft lb

EC302

Fig EC 42 ling
Insla end cover

12 Pulley
Tighten four pulley securing bolts
to the specified torque
5T19810000

EC563 Tightening torque

0 7 to 0 9 kg m
Fig EC 39 Vane assembly
5 lt06 5 ft lb

2 Install vane in place on rotor

using Dummy Shaft STl9900000 as a EC124 INSPECTION

guide Fig EC 41 In8talling rotor ring
Air InJection system hosas
Note The may require 6 to 16
vanes

km 4 to 10 miles wear in running Check air system hoses for loose

9 Removal of dummy shaft
time In the event a slight squeaking connections cracks or deterioration
Carefuny withdraw dummy shaft
still remains drive the car about 64 Retighten or replace if necessary
from vane
to 80 km h 40 to 50 MPH In
10 Vane shaft
most cases 6 to 16 km 4 to 10
Pack rear bearing with high
miles will be sufficient for wear in Air ystem manifold
melting point grease G 3545 A
MIL
so ANDOK 260 or equivalent Check air gaUery pipe and injection
7 Shoe spring
Apply thin coating of grease to vane nozzles for loose connections and
Place shoe springs in deeper groove cracks
shaft and rotor ring and insert vane Retighten or replace if neces
of shoe shaft into its bearing sary

EC 17
 Emission Control System

must be determined that the engine as Air control valve

Air pump
C U ornla models
reaches
a unit is functioning properly
I Operate engine until it
I Warm up engine thoroughly
normal operating temperature
2 Before checking air control valve
2 Inspect all hose hose connec
Check valva check all hoses for loose connection
tions and air gallery for leaks and
leaks etc and repair or correct if
correct if necessary before checking Warm up engine thoroughly
2 Disconnect hose leading to check necessary
air injection pump 3 With engine idling disconnect the
3 Check air injection pump belt valve from air hose COJUlector
outlet side hose of the air control
3
tension and adjust to specifications if Check hose opening for any indi
valve and place your hand on the air
cation of exhaust gas leaks Ifleaks are
necessary
hose outlet to check for air If no air is
4 Disconnect air supply hose at detected replace check valve
4 felt replace the air control valve
check valve Race the engine lightly at about
4 Pull vacuum hose off from air
5 Disconnect vacuum hose from the 2 000 cpm and then return it to
con trol valve If discharge of air from
air control valve California idling VisuaDy check the hose for any
type
indication of exhaust gas leaks before
air hosestops the air con trol valve is
only
the engine returns to idling speed If normaL Ifdischarge is still felt replace
6 Insert open pipe end ofAir Pump
the valve
Test Gauge STl9870000 in leaks are detected replace check valve
Adapter
Plug up the removed vacuum hose
air supply hose Clamp hose securely to stabilize engine running
to
adapter to prevent it from blowing
out Position adapter and test lliuge so
that air blast emitted through drilled
pipe plug will be harmlessly dissipated
7 Install a tachometer on engine
With engine speed at 2 600 rpm ob

serve pressure produced at test gauge

Air pressure should be 100 mmHg
3 94 inHg or more

8 If air pressure does not meet EC310

above specifications proceed as fol Fig EC 43 Checking check valve
lows

I Repeat 2 and 3 above

Air pump raIle valve
2 Disconnect air
supply hose at
backfire
anti valve Plug air hose open After completing inspection of air

ing and screw with a clamp Repeat pump check air pump relief valve in

pressure test the following steps

3 With engine speed at 1 500 rpm J Disconnect hoses leading to check

close hole of test gauge with finger If valve and air control valve from air
a leaking sound is heard or leaking air
hose connector and install blind cap
is felt by ftnger at relief valve relief to the connector EC312
valve is malfunctioning Relief valve 2 With engine running at about Fig 45
EC Checking air control valve
should be replaced or repaired 3 000 rpm under no load place your
Emarsancy air rella valve
4If air injection pump does not hand the air outlet of air pump
on
meet minimum requirement of pres E AR Valve
relief valve to check for discharged air
sure test it should be replaced lCalHornla models
If no air is felt replace the air pump
relief valve L Warm up engine thoroughly
2 Before checking air control valve
Control valve
check all hoses for loose connection
The
following procedures are reo leaks etc and repair or correct if
commended for checking and or as necessary
certaining that the various components 3 Race engine approximately
of the exhaust emission system con Irol 2 000 rpm under no load Place your
areoperating properly hand on air outlet of E A R valve to
The engine and all components check for presence of discharged air If
must be at normal operating tempera no air is felt E A R valve is normal

tures when the tests are performed EC311 4 Disconnect vacuum hose from
Prior to performing any extensive diag Fig 44
EC Checking air pump relief B A R valve as shown in Figure EC
nosis of the exhaust control system it valve 46

EC 18
 Emission Control System

2 000 ing system which indicates when the

Race engine approximately tXHAUST GAS
under no load
Place your hand E G R control system must be in
rpm
RECIRCULATION also installed in all 620
on air outlet of E A R valve to check spected is

for presence of discharged air If air is CONTROL SYSTEM models except those bound for Coli
felt E A R valve is normaL E G R fornia and Canada
5 If E A R valve does not function When the E G R con trol valve is

properly at above steps replace E AR DESCRIPTION open some of the exhaust gas is led
valve from the exhaust manifold to the
In the exhaustgas recirculation EG R chamber through the E G R
system a part of the exhaust gas is The exhaust gas is then con
passage
returned to the combustion chamber in R
trolled quantity by the E G
to lower the spark flame temperature valve and is introduced into the intake
in
during combustion This results a
manifold
reduction of the nitrogen oxide con c1ose operation of the E G R
Open
tent in the exhaust gas control valve is controlled by the
To air

pump
The exhaust gas recirculation sys thermal vacuum valve which opera tes
tem consists of an E G R passage
I on carburetor vacuum and engine cool
E G R trol valve thermal vacuum ant
con temperature
volve EG R tube and hose A warn

ET267
1 D
t
Fig EC 46 Cheeking E A R volve

@
I I Y1
VI
Anti backfire valve A valve

Warm up engine
I ID 4

thoroughly
2 Disconnect hose from air cleaner
JO 0

and finger the outlet

place a near

3 Run engine at about 3 000 rpin

under load then cetum it
no
quickly
to idling If you feel
pull or suction
a

force on finger the anti backfire

your
valve is functioning normally If no

suction is felt replace the anti backflre

valve
2 E C R control valve
3 E C R passage
4 Intake manifold

5 Thermal vacuum valve

6 E C R tube

7 Exhaust manifold EC349

Fig EC 4 Exhaust Gas Recirculation system E G R

OPERATION

Operation of E G R system is as

shown below
Fig EC 47 Checking anti backfire valve

Intake manifold E G R
E G R system operating Thermal Remarks
EG R control valve
water temperature oC OF valve
vacuum vacuum

Close Close
Below 570C 135OF

california
Non
Above models Idling
MfT only
Not Above 57 to 630C 70 mmHg Close
Open 76 inHg
actuated 135 to 145OF
California models
Below and N on Fullthrollle
f alifomia
AfT
models
Above 57 to 6 oC Above 50 mmHg Open
Actua ted Open 197 inHg
135 to 145OF

EC 19
 Emission Control System
E G R OFF operation this recirculation of exhaust gas must It remains closed while engine coolant
When off for a few minutes after temperature is low and keeps the
engine coolant temperature be cut

is low recirculated exhaust gas causes engine has started The thermal vacu E G R control valve closed thereby

irregular engine operation To prevent um valve is provided for this purpose culling off the E G R circuit

rn I
jS
11
lW
r
L 1 Throttle valve

e7

Thermal vacuum valve close

Note m Vacuum condition

j EC227

E G R controlval
le clo R not
Fig 49
EC E G actuated

2 When engine coolant temperature of the throttle valve enginedu ring though intake manifold vacuum is
is abovethe working temperature of idling for improved idling operation high and E G R control valve remain
the thermal vacuum valve At this point vacuum does not closed
I The valve port come to the top actuate the E GR control valve

D
T l
J
JllrI
L

t
i
Throttle valve
r

II

Thermal vacuum valve

ope

E G R control valve close

EC228

Fig EC 50 E G R nol actualed

2 In the full throttle driving posi um passage does not surpass the vacu control valve
tion the suction vacuum the
on vacu um required to actuate the E G R

EC 20
 Emission Control System

6
Thermal vacuum valve Open

Note Vacuum condition

I
E GR control valve Close EC793

Fig EC 51 E G R not actuated

E G R ON operation

The E G R circuit is completed is above the working temperature of retor suction vacuum is large enough
only when engine coolant temperature the thermal vacuum valve and carbu to open the E G R control valve

l fj 1t 3 0 l P@ 0f Y f
1
i0 Wg

i3
m
Y
m

iiA
EN
d
ti t1f
nk il i
1
Throttle valve

L r

Thermal vacuum valve Open

Note iiiI Vacuum condition

EC794

EG R control valve Open Fig EC 52 E G R actuated

E G R control valva in response to the and destination For identification

is applied opening car

the part number is stamped

The EG R control valve controls of the carburetor throttle valve The purposes
on the recessed portion at the top of
the quantity of exhaust gas to be led E G R control valve is installed on the
to the intake manifold through vertical E G R passage through a gasket the valve

movement of the taper valve connect E G R con trol valve construction The construction of the EG R

control valve is shown below

ed to the diaphragm to which vacuum and type vary with transmission type

EC 21
 Emission Control System

the E G R control system must be

checked

The E G R warning system consists

j o
0

o
of an odometer switch detector drive

counter
harnesses
E G R

When the
warning
earn
lamp
in the odom
and

o
o
m o
eter switch connected
ometer turns once for each OAkm 4
to the speed

mile the contact point of the elec

trica circuit closes allowing electric
current to flow through the magnet
coil of the detector drive counter
Thus energized the magnet coil ac
Wates the latchet to turn the c unter

l 1
2
Diaphragm spring
Diaphragm
wheel by one pitch When the number
of counts reaches 50 000 the latchet

l @
4
3 Valve shaft
Valve
drops in a groove provided on the

periphery of the counter wheel to

5 Valve Seat
activate the detector drive counter
6 Valve cham ber

EC231
switch
Fig EC 53 E G R control value Then the EG R warning lamp
comes on indicating that the E G R
control system Should be checked
The detector drive counteT is equip
ped with an odometer which can tell
Thermal vacuum valva when to service the E G R contr0 I
When the vacuum passage is open the

The thermal valve is carburetor suction is system

vacuum vacuum applied
mounted in the the Aftercompleting periodic check
engine thermostat to diaphragm of the EG R con
reset the odometer
to zero by hand
housing It detects engine coolan t tem trol valve to actuate the taper valve

perature by means of a built in bi connected to the proceeding as follows

diaphragm
1 Remove grommet installed on
metal and opensor closes the vacuum theconsiiiictlo nlie thermal
the side surface of detector drive
passage in the thermal vacuum valve vacuum valve is shown below
counter unit

2 insert a bar or a screwdriver tip

into the hole from which grommet has

been removed and press down knob

mt
To E G R control valve
li provided
for resetting
in the detector drive counter

The E G R warning lamp comes on

under the following circumstances

From carburetor 1 When the number of counts has

reached 50 000 In this case the lamp
indicates that E G R control system
must be checked

2 When operating starter motor

1 Spring Notes
2 Bi metal
3 Oring t a It is an indication of problem in the

E G R
t warning lamp or problems
00 EC232 in the point or in the harnesses if
Fig EC 54 Thennal vacuum valve the lamp does not light at 50 000
counts

b The E G R warning system is

E G R warning system ed independently of the E G R con mounted all 620 models except
on

trol system monitors the distance the those bound for California and
The E G R warning system install car has travelled and indicates when Canada

EC 22
 Emission Control System

1 1I
I

I Ignition switch
1 v v E G R warning lamp
I I
I
I
I f
I
I
I
I
Ignition switch start position 1
I Odometer switch
I
I Fuse 1 A r
I
I
I I
0 v
I I
I
I I
I
I

U
EC541
I I
I
I
I
Magnet coil i lQ 1 Fig EC 57 Removing E G R passage
I
L mi
L J
Detector drive counter

EC233 3 Thermal vacuum valve

Fig EC 55 E G R warning circuit
After removing the following parts
the thermal vacuum valve can be dis

mounted
REMOVAL AND
Vacuum hose carburetor to ther
INSTALLATION mal vacuum valve

Remove air cleaner before removing Vacuum hose thermal vacuum

For removal valve to E G R control valve

E G R control system
and installation of air cleaner refer to
Note Drain engine coolant before dis
Air Cleaner section Page EF S
mounting thermal vacu m valve

EC234
Removal
Fig EC 56 Removing KG R control
valve
I E G R control valve

After removing the following parts 2 E GR pass ge

the E G R controi valve can be dis
After removing the following parts
mounted
the E G R passage can be dismounted
Vacuum hose thermal vacuum
Exhaust gas return tube exhaust
valve to E G R control valve
manifold to E G R passage
EG R control valve mounting nut
B1ow by hose cylinder block to

Note To remove vacuum hose flat P v valve

C Fig EC 58 Removing thermal
vacu um valve
hose to Vacuum hose AB valve to E G R
ten clip connecting vacuum

EG R control valve and pull the passage

hose off with hand E G R passage mounting bolt

EC 23
 Emission Control System

4 EGR warning system

CID

V r

1 Detector drive counter

2 E G R warning lamp
3 Speedometer

EC251

Fig EC 59 E G R warning y tem

Detector drive counter 3 Odometer switch INSPECTION

Detecfor drive counter is secured Odometer switch is mounted on the Checking E G R control system in

on the top of R H hoodledge panel in back side of speedometer Cam in the its mounted conditionS
rotated by the
engine room To remove detector drive odometer switch is I of
Make a thorough visual check
To dismount odometer
counter disconnect w COJUlector speedometer E G R control system If necessary
and loosen two bolts securing detector switch proceed as follows
wipe away oil to facilitate inspection
drive counter to hoodledge I Dismount combination meter as
panel If any hoses are cracked or broken
2 E G R warning lamp sembly replace
E G R warning lamp is mounted at 2 Remove meter front cover and 2 With engine running check
the top cen ter of instrument pad To take off clips and screws to dismount E G R warning system for proper
remove E G R warning lamp proceed shadow plate function Make sure that E G R warn

as follows 3 Loosen screws securing speed ing lamp lights when ignition switch is

ometer to printed circuit housing then turned to START position starter mo

1 Remove masking panel
On models equipped with radio remove speedometer tor runs If E G R wanung lamp does
remove warning lamp from under in 4 Remove two screws securing not inspect harnesses and con
light
strument panel odomete switch to the back side of nectors or replace warning lamp Then

2 E G R warning lamp is a twist speedometer and detach odometer turn ignition switch to ON position

type switch and check the following items

Remove lamp and socket as an

I If odometer of detector drive
assembly Push and twist lamp off counter has not reached 50 000

counts make sure that E G R warning

lamp does not light
2 If odomete of detector drive

can counter has attained 50 000 counts

make sure that E G R warning lamp

lights
If warning lamp does not light
check harnesses connectors and de

EC239 tector drive counter replace warning

Fig EC 61 Removing odometer switch lamp or detector drive counter if
necessary

InstaUatlon
Notes
EC554

To install reverse the removal pro Operation oC E G R warning lamp

Fig EC 60 Removing E G R warning
cedure is as Collows
lamp

EC24
 Emission Control System

START ON
Ignition Switch Position

Detector Drive Counter Below Above

50 000 counts 50 000 counts

E G R Warning Lamp ON OFF ON

4 With running inspect

b After inspection of engine
completing
be sure to E G R control valve and thermal vacuo
E G R control system
um valve for normal operation
reset odometer of detector drive EC254
When
counter to zero
1 engine coolant tempera Fig EC 63 Checking lhermal
ture is low valve
to all 620 models vacuum
c This item applies Make sure that E G R control valve
except those bound for California does not operate when engine speed is
and Canada
increased from idling to 3 000 to
If any difficulty is encountered in
3 500 rpm
3 With engine stopped inspect judging the condition of any compo
Place a fmger on the diaphragm of
E G R control valve for any indication nent during above inspection check
EGR control valve to check for valve
of binding or sticking by moving dia the questionable component independ
phragm of control valve upwards with operation ently as follows
a finger

E GR control valve

Dismount E G R control valve

from engine
I Apply vacuum to E G R control
valve referring to the following figure
If the valve moves to full position it is

normal
EG R control valve will remain
open for more than 30 seconds after
vacuum has cut off

EC253
la
Fig EC 62 Checking E G R control valve
ET152

2 When engine coolant tempera control valve

Fig EC 64 Checking E G R control
ture is high Increase engine speed from idling to
ualue
I Make sure that E G R control valve 3 000 to 3 500 rpm

operates when engine speed is in Make su re that thermal vacu um

creased from idling to 3 000 to valve is open and that carburetor

500
3 rpm Place a fmger on the vacuum is present at the end
2
R control Visually check E G R control
diaphragm of E G valve E G R control valve side of vacu
valve for damage wrinkle or defonna
to check for valve operation um hose
tion
2 If E G R control valve does not If vacuum is weak or not present at
3 Clean the surface of
seating
operate check as follows all replace thermal vacuum valve If
E G R control valve with a brush and
vacuum is present replace E G R
Disconnect one end E G R control compressed air and remove foreign
control valve
valve side of vacuum hose connect matter from around the valve and
ing thermal vacuum valve to E G R port

EC 25
 Emission Control System

CATALYTIC and water H20 This chemical reac

tion
CONVERTER process requires the proper a
mount of air which is supplied by the

DESCRIPTION
air pump Refer to the item AJ S

The catalytic converter accelerates This air is caUed secondary air The

the chemical reaction of hydrocarbons catalytic converter is mounted on the

HC and carbon monoxide CO in vehicles destined for California Refer

the exhaust gas and changes them into to Figure 67
EC
non harmful carbon dioxide C02

EC350
3 4

Fig EC 65 Cleaning E G R control

valve

Thermal vacuum valve

Dismount thermal vacuum valve

from engine

Note Before dismounting drain en

gine coolant from engine

1 Front tube 4 Main muffler
Apply vacuum to thermal vacuum
2 Catalyti converter 5 Rear tube
valve and check to be sure thaI ther 3 Center tube
EC782
mal vacuum valve opens or closes in
Fig EC 67 Location ofcatalytic converter
response to engine coolant tempera
ture as specified
Thermal vacuum valve should open

630C car ons He and carbon monoxide

at a temperature of 57 to 135 OPERATION
1450F the CO in the exhaust gas are gradually
to completing vacuum
oxidized with oxygen 02 in the
passage
secondary air and converted into non
Exhaust gas emitted from the en

Note Do not allow water to harmful carbon dioxide and

get gine contains some harmful substances C02
inside the thermal vacuum valve
due to incomplete combustion in the
water H20
combustion chamber The air injection Thecatalytic converter further
system is designed to reduce the con cleans engine exhaust gas Through
tent of such substances in the exhaust catalytic action it changes residual
gas In this system the secondary air is hydrocarbons and carbon monoxide
led from the check valve and injected contained in exhaust gas into carbon
into the exhaust manifold With this dioxide and water before exhaust gas
injection of the secondary air hydro is discharged to the atmosphere

c Secondary air

Carbon monoxide
hydrocarbon
Carbon dioxide gas
water

EC242 EC444

Fig EC 66 Checking hennal vacuum

valve F EC 68 Operution ofcatalytic corwerter

EC 26
 Emission Control System

REMOVAL AND 2 Remove air hose between 5 way 16 If CO percentage is still over
in
INSPECTION connector and air check valve Plug the 03 step 15 catalytic conyerter is
disconnected hose to prevent dust malfunctioning Replace catalytic con
Removal and inspection can be
from entering Refer to page ET 12 verter
done as follows
3 Check carburetor pipes for proper
connection

Removal 4 Warm up engine sufficiently

5 Race engine 1 500 to 2 000 rpm
Catalytic converter
two or three times under no load then INSTALLATION
1 Apply parking brake
run engine for oe minute at idling
To install reverse the removal pro
2 Place wheel lock under each tire speed cedure
3 Jack up the vehicle 6 Adjust throttle adjusting screw
4 Remove lower shelter of catalytic until engine attains to specified speed
converter Refer to page ET 10 Bolt lightening torque

5 Dismount catalytic converter 7 Check ignition timing If neces specifications

sary adjust it to specifkations Refer Tightening torque
to page ET 10 Catalytic converter
B Adjust idle adjusting screw until 2 6 to 3 4 kg m
specified CO percentage is obtained to 25 ft Ib
19
Refer to page ET 12
9 Repeat the adju stment process as
described in steps 5 to 8 above until

specified CO percentage is obtained

Note Adjustment in step 9 should be

EC453
made ten minutes after engine has
Fig EC 69 Removing catalytic wanned up
conuerter

10 Race engine 1 500 to 2 000

Inspection rpm two or three times under no load

and make sure that specified CO per FLOOR

Preliminary inspection centage is obtained
Remove connect air
TEMPERATURE
Visually check condition of all 11 cap and

including hose to air check valve WARNING SYSTEM

component parts hos
tubes and wires replace if necessary If idlingspeed increases readjust it DESCRIPTION
Refer to Inspection of A IS on to specified speed with throttle ad
The floor temperature warning
page EC 17 justing screw

12 WaRn up engine for about four system consists of a floor temperature

minutes at 2 000 rpm under noload sensing switch installed on the vehi
Catalytic converter cle s floor floor temperature relay and
13 Measure CO percentage at idling
Whether converter is nor
catalytic After step 12 has been coin a warning lamp on the instrument
mal or not can be checked by ob
speed
wait for minute before panel and wires that connect these
in CO pleted one
serving variation percentage
making CO percentage measurement parts
The checking procedure is as follows
14 If CO percentage measured in When the floor tempera ture rises to
Apply parking brake Shift gears 13 is less than 3
0 the catalytic an abnormal level the warning lamp
step
into Neutral for manual transmission converter is normal will light to call the attention of the
and Neutral Park for automatic driver The wiring diagram of this
or
15 If CO percentage measured in
transmission of the floor
step 13 is over 3
0 recheck A IS system and location

1 Visually check catalytic converter and replace air check valve Then temperature sensing switch are ilIus
for damage or cracks perform inspection steps 12 and 13 trated in Figures EC 70 and EC 71

EC 27
 Emission Control System

The lamp is functioning sa tis

if it is remains
I factorily on while the
is in
starting motor
operation The
lamp goes out when the ignition
Ignition switch Ignition key Off switch is in IG position
The foUowing chart furnishes the
T information on the relationship be
I
I tween floor temperatures warning

J
I Battery
I Relay lamp and sensing switch
J

Floor
L
temperature
warning
77 77
Floor temperature lamp
sensing swi tch

Contact close
ECJ40
77 77

EC 70
EC332
I
Fig Win ng diagram offloor temperature warning system

rl Contaclopen

Fig EC 72 Operation of floor

t mperature sen6ing
ECJ41

@ 6witch

J 1

Floor temperature
REMOVAL

Floor temperature sensing

switch

1 Remove seat as outlined in the

Seat section of Body and Frame
service manual

2 Remove floor temperature

sensing sWitch

Ij Floor temperature relay

cr From under relay cover remove

EC556 this part Refer to Figure EC 73

Fig EC 71 Location of iJoor temperature sensing switch

Floortemperature
OPERATION
and the ignition switch line to turn on
Floor temperature will exceed nor as a result the floor temperature

mal level when temperature rise in the warning lamp comes on

exhaust system succeeding the cata When the floor temperature is

lytic converter is caused byeilher an lower t an the specific temperature

engine malfunction or severe driving the floor temperature sensing switch
conditions Under this condition the turns on The ignition line of the floor

floor temperature sensing switch turns temperature relay turns off while the EC783

off causing the starting switch line of starting switch side is in on The floor Fig EC 73 Location of floor
the floor temperature relay to turn off temperature warning lamp goes out ttmperature relay

EC 2B
 Emission Control System

Floor temparature warning

lamp Temperature Temperature Floor temperature
sensing switch warning lamp
Refer to Figure EC 74 for the loca
Contact close Off Below 1050C 221 OF
tion of this part

Contact open On Above 1050C 221 OF

L

1t
Note Avoid heating floor tempera a circuit tester

1 ture

If
sensing

lamp
switch directly
does not glow check floor
temperature sensing switch connector
Referring
temperature relay
trace wire s
to

back
the
if
to
following floor
relay is normal

ignition switch

RAt
for continuity with a circuit tester Repair faulty wiring
If continuity should exist after
heated surrounding areas of floor tem Floor temperature relay

perature sensing switch replace tem When checking floor temperature

perature sensing switch relay for unit remove it and proceed
Fig EC 74 Location of floor If con tinuity does not exist trace as follows
temperature warning lamp the wiring back to relay or check the 1 Check for continuity between @
following step 3 Repair or replace
INSTALLATION wire s if necessary
and ID Continuity should exist
Check for continuity between CD
the order of
To install reverse
Note The floor temperature sensing and@ Continuity should exist
removaL Check for continuity between CD
switch may be heated through the
and should notexist
floor by a proper heater @ Continuity
2 Apply a 12 volt doc across
@ and
that exists
INSPECTION 3 Turn ignition switch to the IG ID to ensure continuity
position and disconnect floor temper between CD and @ and that con ti

does not between and

Floor warning temperature ature sensing connector The lamp nuity CD @ If
should remain on If not check floor test results dn not satisfy the above
system
replace the floor
temperature relay for continuity with temperature relay
Apply parking brake Shift gears
into Neutral foI manual transmission 2 00
and Neutral or Park for automatic

transmission

1 Ensure that floor temperature

r I 141
warning lamp lights when ignition
switch is iumed to the

bulbs
If not check lamp
S position
for burned
J To floor temperatwe

Replace bulb if bulb is burned out warning lamp

2 From S
If bulb is not burned trace wire s position
O 3 From IG
position
back to ignition switch Repair or
4 From ignition switch
replace if necessary 5 To floor temperature
2 Be sure that floor temperature is sensing switch

EC344
cool below 800C 1760Fj before
carrying out the following procedure Fig EC 75 Checking floor temperature relay

I Remove rearseat

2 Ignition switch is turned to the When floor temperature 1 Float level

IG position warning lamp lights 2 Choke
3 Ensure that floor temperature 3 Normal fuel supply system Prima
Check floor temperature warning
warning lamp goes out ry and secondary
lamp
4 Heat surrounding areas of floor 4 Accelerator pump
1 Open or shorj circuit in wiring
temperature sensing switch with a 5 Power valve
harness
heater to ensure that floor 6 BC D D
proper
2 Check fuel system with regard to
temperature warning lamp glows when 7 Fuel strainer

floor is heated to the specifications as the following items Refer to Inspec 8 Air cleaner
shown in the table below lion of Fuel System

EC 29
 Emission Control System
3 Check ignition system with regard 3 Ignition coil Note Even if there is nothing wrong
to the
following items
Refer to 4 High tension code with engine the warning lamp may
Inspection of Ignition System 5 Spark plug come on if vebicle is being driven
1 Ignition AMP
4 Check idle CO adjustment Refer
on a steep slope continuously in
2 Distributor
to Idle CO lower gears at high engine speeds
Inspection of Adjustment

EVAPORATIVE EMISSION CONTROL SYSTEM

CONTENTS

DESCRIPTION EC 30 CARBON CANISTER PURGE CONTROL

OPERATION EC 30 VALVE IEC 32
INSPECTION EC 31 CARBON CANISTER FILTER IEC 32
FUEL TANK VAPOR LIQUID SEPARATOR FUEL TANK VACUUM RELIEF VALVE EC 32
AND VAPOR VENT LINE EC 31

carbons is accomplished by activated 2 Vapor liquid separator

DESCRIPTION charcoals in the carbon canister 3 Vapor vent line
The emission control This system is made up to the 4 Carbon canister
evaporative
system is used to reduce hydrocarbons following 5 Vacuum signal line
emitted to the atmosphere from the I Fuel tank with positive 6 Canister purge line
sealing filler
fuel system This reduction of hydro cap

1 Fuel tank 4 Vapor vent line

2 Fuel nIler cap with vacuum 5 Canister purge line
relief valve 6 Vacuum signal line
3 liquid vapor separator 7 Carbon canister

EF274

Fig EC 76 Schematic
drawing of lIaporotive emiaion control6ydem

OPERATION
Fuel vapors from the sealed fuel The canister is fined with activated when the engirie is at rest or at idlin
ll
tank are led into the carbon canister charcoals to absorb the fuel vapors See Figure EC 77

30
EC
 Emission Control System

Close at idling
Open at rest

J
i
i
j
J
f
17
Fuel vapor

12 Filter
1 Fuel tank 6 Canister purge line
2 Fuel f1l1er cap with vacuum 7 Throttlevalv 13 Purge control valve
14 Spring
relief valve 8 Engine
3 9 Carbon canister 15 Diaphragm
Liquid vapor separator
4 16 Fixed orifice
Vapor vent line 10 Activated carbon

5 Vacuum signalUne 11 Screen EC784

Fig EC 77 Evaporative emu ion control sy tem

Fuel vapor flow when engine i6 at red or idling

As the throttle valve opens and the purge control valve to open and intake manifold through the canister

vehicle increases admits an orifice to intake manifold

speed vacuum
pres purge line See Figure EC 7B
sure in the vacuum signal line forces and fuel vapor is then drawn into the

JL

rHL I

J
o I

Fuel vapor

Fresh air
EC785

Fig EC 78 Evaporative emiuion control system

Fuel vapor flow when engine i running

manometer and a cock or an equiva with 25 mmH20 0 98 inH20

INSPECTION
lent 3 way charge cock to the end of 8 When filler cap does not close
the vent line completely the height should drop to
FUEL TANK
4
VAPOR LIQUID SEPARATOR Supply fresh air into the vapor zero in a short time

vent line through the cock little by 9 I f the height does not drop to
AND VAPOR VENT LINE
little until pressure becomes 368 zero in a short time when filler cap is
I Check all hoses and fuel tank mrnH20 14 5 inH20 removed it is the cause of a stuffy
mler cap 5 Shut the cock and hose
completely
2 Disconnect the
vapor vent line leave it unattended
connecting carbon canister to vapor 6 After 2 5 minutes measure the Note In case the vent line is stuffy
the in fuel tank is
liquid separator height of the liquid in the manometer breathing not

3 Connect a 3 way connector a 7 Variation of height should remain thoroughly made thus causing in

EC 31
 Emission Control System

sufficient delivery of fuel to engine repaired or

replaced
or vapor lock It must therefore be

1 connectur
3
368 mmH20 14 5 inH20

LL
COCk

Air Manometer liqUid epoo

IPO
@ 36 ET37Q

Carbon canister

Fig EC 79 Checking evaporative emmion control

syatem
r EC786
Fig s2
EC Replacing carbon
canuter filter

CARBON CANISTER PURGE 3 If there is a leak remove top

CONTROL VALVE cover from purge control valve and
check for dislocated or cracked dia FUEL TANK VACUUM
Check for fuel vapor leakage in the
phragm If necessary replace dia RELIEF VALVE
distributor vacuum line at diaphragm
phragm kit which is made up of a
of carbon canister purge control valve Remove fuel filler cap and see it
retainer a diaphragm and a spring
To check for leakage proceed as functions properly

follows
I Wipe clean valve housing and have
I Disconnect rubber hose in the it in your mouth
@
line between T connector and carbon 2 Inhale airA slight resistance ac

canister at Tconnector companied by valve indicates that

2 Inhale air into the opening of @ valve is in good mechanical condition
Note also that by further inhaling air
rubber hose running to vacuum hole in
the resistance should be
carbon canister and ensure that there disappeared
with valve clicks
is no leak
3 If valve is clogged or if no resist
1 Cover ance is felt replace cap as an assem
2 Diaphragm bled uni t
3 Retainer
4 Spring
ET350

Fig EC 81 Carbon catU ter purge

control valve

l u

CARBON CANISTER FILTER

Check for a contaminated element

ET349 Elementcan be removed at the
bottom of canister installed on vehicle ET369
Fig so
EC Checking carbon canuter
purge control valve body Fig EC 83 Fuel filler cap

32
EC
 Emission Control System

SPECIAL SERVICE TOOLS

Tool number For Reference

No Description use page or
tool name on Figure No

STI98 10000 For removing and installing the rotor ring assembly L20B Fig EC 29
A14 Fig 41
EC

Hexagon wrench

SE279

2 ST 19900000 For assembling the vanes L20B Fig EC 39

A14

Dummy shaft

SE284

3 STl9890000 Used as a mount when rotor is removed and when bearing is installed L20B Fig EC 32
A14 fig IlC 35

Rotor adapter f
SE347

4 STl9940000 Used when rotor is removed and when front bearing installed L20B Fig EC 32
A14 Fig EC 35

Bearing Pressing
tool

d
9E348

This service tool is designed for use in disassembly and assembly of the air pump

33
EC
 Emission Control System

Tool number For Reference

No Description use page or

tool name on Figure No

5 STl9930000 Used as a mount when front bearing is removed L20B Fig EC 33

Al4

Bearing adapter

E9 SE349

6 STl9910000 Used as a drift when front bearing is installed Also used as a support L20B Fig EC 33
when rotor is installed Al4 Fig EC 36
Fig EC 37

Bearing driver

SE350

7 STl9920000 Used as a drift when rotor is installed L20B Fig EC 36

AI4 Fig C 37

o
Rotor stand

SE351

8 ST19870000 Used as a adapter when air injection pump pressure is tested L20B Page EC 18

Al4
Air pump test

gauge adapter

SE389

EC 34
 SECTION EE

ENGINE
DATSUN PICK UP ELECTRICAL
MODEL 620 SERIES
SYSTEM

BATTERY EE 2

STARTING EE 4
MOTOR
CHARGING CIRCUIT EE 12

EE 15
ALTERNATOR
REGULATOR EE 20

IGNITION CIRCUIT EE 26

DISTRIBUTOR
EE 30
Non California models

DISTRIBUTOR California models EE 33

TRANSISTOR IGNITION UNIT

EE 36
California models

IGNITION COIL EE 46

I NISSAN I SPARK PLUG EE 47

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Engine Electrical System

BATTERY

CONTENTS

EE 2 BATTERY FREEZING EE 3
REMOVAL
EE 2 CHARGING EE 3
CHECKING ELECTROLYTE LEVEL
EE 2 INSTALLA TION EE 3
CHECKING SPECIFIC GRAVITY

REMOVAL
I Disconnect negative and positive
cables
2 Remove nuts from battery
clamps take off clamps
Read top level
3 Remove battery with scale

1 Thermal gauge
feOOl
2 Hydrometer
CHECKING
ELECTROLYTE LEVEL Fig EE l Checking pccme gravity

Remove six vent plugs and check S St 0 0007 t 20

20

for electrolyte level in each cell Where Converted specific gavity 20

If pour distilled water
nccessaJ
St Specific gravity of electrolyte
1Je
at tOe
520 Specific gravity of electrolyte 1 28

corrected at 200e 680F @

126
t Electrolyte temperature S

For example A hydrometer Sow

E
reading of 1
260 at 300e 860F l
l
would be 1 267 corrected to 200e
6goF indicating fully charged u
o

battery On the other hand a hydro

o
meter reading of 1220 at lOoe
l
CHECKING 140 F would be 1 199 corrected to
e
SPECIFIC GRAVITY 200e 680F indicating a partially u

Specific gravity of battery electro charged battery 0

lyte is tested by a hydrometer If the The state of charge of battery

U21101
can

srate of charge of battery is 60 or be determined by the following table 1

I
specific gravity reading is below 1 20 if the specific gravity of electrolyte is
dOldlOiJ OSQ
corrected at 200e 680F bat known BefOIe checking be sure that
as
Electrolyte temperature oC
tery must be recharged or battery cells are filled to correct level
EEOO3
electrolyte concentration adjusted
U
G
Add or subtract gravity points EE 3 Specific lNWity at
o
N
Fig
to whether the electrolyte

m
according b t eiectroly te temperature
temperature is above
680F standard
or below 200e E
u JI I I
ol I
lilt I
1
The gravity of electrolyte chlll ges J 1 I

I i J Sf to 1
7 II It 100

0 0007 for 1 80F

every Ioe
COJJditioD
tem 0wJIztI

petature A correction can then be EE002

EE 2 condition
made by using the following formula Fig ffing
ChaJ

EE 2
 Engine Electrical System

nals should be cleaned with a brush

BATTERY FREEZING
and common baking soda solution In
indication that battery is completely items should
Battery electrolyte freezing point addition the following
discharged and will freeze
readily
varies with acid concentration or its be observed while battery is being
when temperatures fall below freezing
specific gravity A battery with an charged
insufficient charge will freeze at lower Note Use extreme caution to avoid I Be sure that electrolyte level is
temperatures If specific gravity of
a
freezing battery since freezing will above top of each plate
falls below 11 this is an
battery generally ruin the battery 2 Keep removed plugs in a safe
place
0 3 Do not allow electrolyte tempera

ture to go over 450C I130F

10 4 After charging check to be cer
tain that specific gravity does not
20
exceed 1260 at 200C 680P Cor

30 rection can be made by adding dis

g
u

il 40
I tilled water into cells
5 Keep battery away from open
as necessary

e SO
I flame while it is being charged
6 After all plugs have been
vent

tightened clean all sprayed electrolyte

0 60
E off upper face of battery

70

80

100
1104 108 l2
t 1 16 t 20 24
1 28
1 1 32
EEOQ4

Specific gravity of electrolyte

INSTALLATION
Fig EE 4 Froezing point of electrolyte
1 Install and tighten clamps secure

CHARGING Iy
it up to full charge the opera 2 After clamps have been tightened
If electrolyte level is satisfactory bring
clean battery cable terminals and
tion should be carried out with nega
battery must be charged when electro to retard formation of
tive cable removed apply grease
lyte gravity reading falls below 1 20 If
to Prior to charging corroded termi corrosion
battery on car is quick charged

EE 3
 Engine Electrical System

STARTING MOTOR

CONTENTS

DESCRIPTION EE 4 OVERRUNNING CLUTCH ASSEMBLY EE 9

OPERATION EE 6 BRUSH HOLDER TEST FOR GROUND EE 9

CONSTR UCTI ON EE 7 BEARING METAL EE 9

REMOVAL EE 7 MAGNETIC SWITCH ASSEMBLY EE 9

DISASSEMBL Y EE 7 ASSEMBLY EE 9

CLEANING AND INSPECTION EE 8 TEST EE 9

TERMINAL EE 8 PERFORMANCE TEST EE 9

FIELD COIL EE B MAGNETIC SWITCH ASSEMBLY TEST EE O

BRUSHES AND BRUSH LEAD WIRE EE B SERVICE DATA AND SPECIFICATIONS EE

BRUSH SPRING TENSION EE B TROUBLE DIAGNOSES AND CORRECTIONS EE 11
ARMATURE ASSEMBLY EE B

DESCRIPTION
The function of the starting system
5 @
which consists of the battery ignition
switch motor and solenoid is
starting
to crank the engine The electrical
energy is supplied from the battery
the solenoid completes the circuit to I Brush
operate the starling motor and then 2 Field coil
the motor carries out the actual crank 3 Magnetic switch
4 Pludgcr
ing of the engine
5 Torsion spring
6 Shifll r

7 Overrunning clutch
8 Pinion

9 9 Armature
EE315

Fig EE 5 Sectioool view of slarting motor Sl14 180B

4
EE
 Engine Electrical System

INHIBITOR RELAY

INHIBITOR SWITCH
FUSIBLE LINK
A
O
1Y b Y
I J
@
I
A

BATTERY rJ

f
l
STARTING MOTOR

BWI
000

rBW 000

ggg For California

fB WBBYBY

@@@@
B

I
I
I
j
EARTH POINT CJ
Bd
f
FUSIBLE lIN
BW

T
H
f
00
00
00

r
00

BATTERY

Q
I I I BW
I
@@@ @ @
Y B Y BY

l
BY
BW

9
IGNITION SWITCH

BY BWWB BY WB BY BY

@@@ @ @ @ @
I I I BW
I
AfT Equipped with cooler @ M T Equipped with cooler

COLOR CODE
I a

b
Notes

@
@
T only
M
A T only
Inhibitor switch is
B Black on in neutral
OW Black with white stripe
BY Black with yellow stripe
W White

L
WB White with black stripe

INHIBITOR SWITCH STARTER MOTOR

eE491

Fig EE 6 Circuit diagram 0 starting systom

EE 5
 Engine Electrical System

OPERATION
When the ignition switch
turned

clockwise to the START posi

fully
tion battery current flows through
cp
series
and shunt coils of the
solenoid magnetizing the solenoid
The plunger is pulled into the solenoid
that it
so operates the shift lever to
move the drive pinion into the

flywheel ring gear Then the solenoid

I o

switch contacts close after the drive

pinion is partially engaged with the
r
1 I I
ring gear
Closing of the solenoid switch W
contacts c uses the motor to crank the

engine and also cut out the series

Fl
coil of the solenoid
of the shunt
the magnetic
coil being sufficient to
pull m
hold thepinion in mesh after the EE274

shifting has been performed

8 Shunt coil
After the engine starts running the
I Ring gear
2 Shift lever guide 9 Plunger
driver releases the ignition key and it 10 switch
3 Armature Ignition
automatically returns to the ON posi 4 Battery 11 Series coil
tion 5 Field coil 12 Torsion spring
6 13 Shift lever
The torsion spring then actuates the Stationary contact

7 Monble contactor 14 Pinion

shift lever to pull the pinion which
allows the solenoid swi tch contacts to
open Consequently the starting mo Fig EE 7 Starting motor circuit
tor stops

More positive meshing and into or out of mesh with the ring gear
demeshing of the pinion and the ring teeth The
overrunning clutch is de
gear teeth are secured by means of the signed to transmit driving torque from

overrunning clutch The overruIUling the motor armature to the ring gear
clutch employs a shift lever to slide but prevent the armature from over
the pinion along the armature shaft running after the engine has started

6
EE
 Engine Electrical System

CONSTRUCTION

V
S
4
O

o
8

f
w
il

I
jl
I

Magnetic switch assembly 13 Brush spring jj

1
JI
2 Dust cover t4 Brush

15 Yoke
Adjusting washer P
t6 Field coil assembly
3 Torsion pring
4 Shift lever 17 Armature assembly
5 Dust cover
18 Center plate SI14 1808 only

6 Thrust washer 19 Pinion assembly

7 E 20 Dust cover
ring
Rear metal 21 Pinion stopper
8 cover

9 Through bolt 22 Stopper clip

10 Rear cover 23 Gear case

24 Gear case metal

tl Brush holder assembly
12 Brush
EE316

view ofstarting motor

Fig EE B Exploded

bolts and
REMOVAL 4 Remove two through
rear cover
Disconnect battery ground cable
Disconnect black wire with 5 Remove b rushes from their hold
yellow
stripe from magnetic switch terminal er by moving each brush spring away

and black battery cable from battery from brush with a hook
Remove brush holder
terminal of magnetic switch
2 Remove two bolts securing start
@ 6 Remov yoke assembly and with
ing motor to transmission case Pull @ draw armature assembly and shift
starter assembly forward and lever

O
remove

motor 7 Remove pinion stopper located at

starting EE317

E ring the end of armature shaft To remove

Fig EE 9 Remouing dUlt cover

and thrust washer s stopper first move stopper toward

pinion and after removing stopper clip

DISASSEMBLY 3 Remove two screws securing remove stopper with overrunning
brush holder
Disconnect assembly clutch assembly from armature shaft
I connecting plate from
M terminal of magnetic switch Re
move two screws securing magnetic
switch and remove magnetic switch
assembly
2 Remove dust cover E ring and
thrust washer s

Pinion stopper

Pinion stopper clip

EE318
EE277
Fig EE IO Removing brush holder
d crt w Fig EE l1 Removing pinion stopper

EE 7
 Engine Electrical System

CLEANING AND Check brush holders and spring cUp

to see if they not deformed
INSPECTION are or

bent and will properly hold brushes

Clean all disassembled parts but do
against the commutator
not use grease dissolving solvents for If brushes or brush holders are

cleaning overrunning clutch annature dirty they should be cleaned

assembly magnetic switch assembly
and field coils since such a solvent
would dissolve grease packed in c1u tch
mechanism and would damage coils or
BRUSH SPRING TENSION
EE017
other insulators
Check brush spring tension by a
Check them for excessive damage Fig EE I3 Testing rU ld coil spring scale as shown in Figure EE 13
or wear and replace if necessary for ground
The reading should be 1 6 kg 3 5 Ib
Replace spring if tension is lower than
I 4 kg 3 1 Ib
TERMINAL

Check terminal for damage and

wear and replace magnetic switch
assembly if necessary
ARMATURE ASSEMBLY

FIELD COIL Check external appearance of

armature and commutator
Check field coil for insulation If
1 Inspect commutator If the sur
the insulation of coil is damaged or
face of commutator is rough it must
worn it should be
replaced
be sanded lightly with a No 500
emery cloth If the depth of insulating
Testing field coil for BRUSHES AND BRUSH mica is less than 0 2 mm 0 0079 in

continuity LEAD WIRE from commutator surface insulating

Check the surface condition of mica should also be undercut so that
Connect the probe of a circuit
brush contact and wear of brush If a its depth is 5 to 0 8 mm
0 0 01 97 to
tester or an ohmmeter to field coil
loose contact is found it should be 0 0315 in
positive terminal and positive brush
replaced The wear limit of commutator dia
holder
Ifbrush is worn so that its length is meter is 2 mm 0 0787 in If the
If tester shows no continuity field
less than 12 mm 0 472 in replace diameter of cammu tator is less than
circuit or coil is open
Check the connection of lead clip 31 mm 1 220 in replace annature

and lead wire assembly

EE016
o
Fig EE I2 Testing field coil
for continuity

@
TestIng field coD for ground
Place one probe of circuit tester
EE018
onto yoke and the other onto field
coil lead positive tenninal Fig EE 14 Inspecting brush spring tension
If very little resistance is read field
coil is grounded

8
EE
 Engine Electrical System

l File
0

L0 5 to 0 8 mm Commutator

Segmen t

71j
Correct
IWMica
Incorrect
Fig EE 19 Testing brush for
Ee026

round
EE021

BEARING METAL
Fig EE 15 Undercutting i118ulating mica
Inspect bearing metal for wear or

side play If the clearance between

2 Inspect soldered connection of 5 Check armature for continuity by bearing metal and armature shaft is

armature lead and commutator If placing probes of tester on two seg more than 0 2 mm 0 0079 in replace
loose connection is found solder it ments side by side If tester shows no metal

using resin flux continuity the circuit is open

3 MAGNETIC SWITCH
Armature test for ground
ASSEMBLY
Using a circuit tester place
one test

1 Using circuit tester check con

probe onto armature shaft and other a l

OVERRUNNING CLUTCH
onto each commutator bar tinuity between S terminal of mag
ASSEMBLY netic switch and switch body metal If
If tester shows continuity armature

is and must be replaced continuity does not exist shunt coit is

grounded Inspect pinion assembly and screw

sleeve Screw sleeve must slide opened

freely
shaft If Replace switch assembly
along armature splines
2 In the same manner as above
damage is found or resistance is felt
check continuity between terminals
when sliding it must be repaired
S and M If continuity does not
Inspect pinion teeth If excessive rub
exist series coil is
bing is found on teeth replace opened
Replace switch assembly
Flywheel ring gear also must be in
spected

ASSEMBLY
EE022

starting motor in re
Reassemble
Fig EE 16 Testing annature for
verse sequence of disassembly
ground
When assembling be sure to apply

grease to gear case and rear cover

4 Check armature for short by bearing metal and apply oil lightly to

placing it on armature tester growler pinion

with a piece of iron over armature l
core rotating armature If the plate EE278
vibrates armature is shorted
Fig EE 18 Overrunning clutch TEST
auem bly
PERFORMANCE TEST

Starter motor should be subjected

BRUSH HOLDER TEST
to a no load test whenever it has
FOR GROUND
been overhauled to ensure that its
Using a circuit tester place one test performance will be satisfactory when
probe onto negative side of brush installed on engine Starter motor

j l holder and another onto positive side should also be subjected to the test
EE023 If tester shows continuity brush when the ofabnormal operation
cause

Fig EE 17 Testing annature for holder is shorted to ground Replace is to be determined A brief outline of
ahort brush holder the test is given below

EE 9
 Engine Electrical System

load
No test MAGNETIC SWITCH
ASSEMBLY TEST
Connect starting motor in series Specified current draw and revolu
12 volts tion in these test shown in
with specified battery and are

Switch
an ammeter capable of indicating Specifications
1 000 amperes
o
Switch
Battery

6 Et IB I

Starter motor
Fv I D
Battery Starter motor

EE351

FiN EE 21 Circuit ofmagndic awitch

assembly ted

If the starting motor check is

Voltmeter Ammeter
OK check magnetic switch as

sembly Connect cables between

Ee026
negative battery tenninal and start
ing motor M terminal positive
Fig EE 20 No load l ting battery terminal and starting motor
S terminal connecting a switch in
series as shown in Figure EE 21

Diagnoses of test With the switch on push pinion

1 Low speed with no load and high following back to remove all slack and measure
result from the I A grounded or open field coil
current draw may the clearance l between pinion
Inspect the connection and trace
following front edge and pinion stopper The
circuit with a circuit tester
1 Tight dirty or worn bearings clearance should be held within 3
0 to
2 Bent armature shaft or loosened 2 Armature coil does not operate
15 mm 0 012 to 0 059 in If neces
Inspect commutator for excessive
field probe sary adjust it by changing or adding
3 Shorted armature burning In this case arc may occur on
adjusting washer s Adjusting washers
Check armature further damaged commutator when motor is
are available in to two different sizes
4 A grounded armature or field operated with no load 5
0 mm 0 020 in and O S mm 0 031
a Remove input tenninal 3 Burned out commutator bar in
b Raise two negative side brushes Weak brush spring tension broken 0 3 to IS rom

from commutator brush spring rubber bush thrust out 0 012 to 0 059 in
l
c Using a circuit tester place one of mica in commu tator or a loose
probe onto input tenninal and the contact between biush and com

other onto yoke mutator would cause commutator bar

d If tester indicates continuity to burn

raise the other two brushes and check 3 Low current draw and low
field and armature separately to noload speed would cause high
determine whether field or armature is internal resistance due to loose con

grounded nections damaged leads dirty corn

Fallure EE029
2 to operate with high mutator and causes listed on item

current draw may be caused by the 23 Fig EE 22 MeO uring clearance t

EE10
 Engine Electrical System

SERVICE DATA AND SPECIFICATIONS Automatic

transmission

Optional
Manual for manual
transmission transmission

S114 170B SII4 ISOB

Type

v 12
System voltage

No load

V 12
Terminal voltage

Current A Less than 60

More than 7 000 More than 6 000

Revolution rpm

Outer diameter of commutator mm in More than 39 1 54

in More than 12 47
0
Brush length mm

Ib 4 to IS
1 3 1 to 4 0
Brush spring tension kg

Clearance between bearing metal and

in Less than 0 2 O OOS
armature shaft mm

Clearance L between pinion front

in 3 to 1 5
0 0 012 to 0 059
edge and pinion stopper mm

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

Starting motor will Discharged battery Charge or replace battery

not operate solenoid switch
Damaged solenoid switch Repair or replace
Loose connections of terminal Clean and tighten terminal

Damaged brushes Replace brushes

Starti Remove starting motor and make test

g motor inoperative

Noisy starting motor Loose securing bolt Tighten

Worn pinion gear Replace

Poor lubrication Add oil

Worn commutator Replace

Worn brushes Replace

Starting motor Discharged battery Charge

cranks slowly Clean and tighten
Loose connection of terminal

Worn brushes Replace

Locked brushes Inspect brush spring tension or repair brush

holder

EE ll
 Engine Electrical System

Condition Probable cause Corrective action

Starting motor Dirty or worn commutator Clean and repair

cranks slowly Armature rubs field coil Replace assembly
Damaged solenoid switch Repair or replace

Starting motor Worn pinion Replace

operates but does Locked pinion guide Repair
not crank engine
Worn ring gear Replace

Starting motor will Damaged solenoid switch Repair or replace

not disengage even if
Damaged gear teeth Replace damaged gear
ignition switch is
turned off

CHARGING CIRCUIT

The charging circuit consists of the marks Then the warning lamp lights P2 is separated from the primary
battery alternator regulator and When the alternator begins to op side PI
contact by the magnetic
necessary wiring to connect these erate three phase alternating current is force of coil VC2 Therefore
parts The purpose of this system is to induced in the stator armature coil registor RIapplied into the rotor
is
convert mechanical energy from the This alternating current is rectified by circuit and output voltage is decreased
into electrical energy which is the and silicon
engine positive negative AJ the output voltage is decreased the
used to operate all electrically operat diodes The rectified direct current
movable contact point P2 and
ed units and to keep the battery fully output reaches the alternator A and primary side contact Pin comes into
E terminals
charged contact once again and the alternator
When the ignition switch is set to On the other hand the neutral increases
voltage Thus the rapid
current flows from the battery reaches N and E
ON point voltage vibration of the movable contact point
to ground through the ignition switch terminals nearly a half of the output IPl maintains an alternator output
voltage regulator IG terminal primary voltage and current flows from
voltage constant
side contact point PI movable voltage regulator N terminal to E When the alternator speed is further
contact point P2 voltage regulator terminal or ground through the coil increased the
or voltage starts to rise
IF terminal alternator IF terminal VCI as shown in Figure EE 24 by
excessively the movable contact point
rotor field coil and alternator E the dotted line arrow marks Then the P2 comes into contact with
terminal shown in Figure EE 23 by
as coil VCI is excited and the side P3
secondllJ contact point
full line arrow marks Then the rotor movable IPS Then the rotor current is shut off and
contact point comes
in the alternator is excited On the into contact with voltage winding side alternator output voltage is decreased
other hand current flows from the contact P6 This action causes
point immediately This action causes
battery to ground through the ignition to turn off the warning lamp and movable contact n to separate
switch warning lamp voltage regula the voltage winding circuit
complete from secondary contact P3 Thus
tor L terminal lamp side contact as shown by the full line arrow marks the rapid vibration of the movable
point P4 movable contact P2
point When the alternator speed is in contact point or breaking and
P5 and voltage regulator E termi the rotor circuit
creased or the voltage starts to rise completing maintains
nal as shown by dotted line arrow alternator output
excessively the movable contact point an voltage constant

EE 12
 Engine Electrical System

r l
I I
I

i r Ye
Ff p

Stator ma ture coiJ

I
11
c t
FF vw Fusible link
I
I RI t 8
L c
5 9 J
c c
R
Rot r field Coil

i
e 0

I I J
Battery
I I u

Alternator
I
J 1

Voltage regulator
J
t
EE029

Fig EE 23 Charging circuit II

ns

p
Slator ar ature coil
teJ I
U 2iI I

Roto field coil

I
A3 R2
l
R
r 0 Fusible link

e PS

I
I
t I I

g
M j t
i H
U

Battery

Lh J
A l a o
L V
It g t
f
EE030

Fig EE 24 Charging circuit II

EE 13
 Engine Electrical System

WR

WL

L2
VOLTAGE REGULATOR

co

I WLI

LW LW

cJ IB
P
r
m
I
B
WR WR
FUSIBLE LINK

t
EARTH POINT

CHARGE

00 WARNING lAMP
m g
00000

I I I I m
CLB
Equipped with cooler TjT W

WB B YWR

I I I I
I
W

1 l LW
I
BW
BwtIl IGNITION SWITCH
B

ALTERNATOR
rn j
M IG
J
COLOR CODE lOA
C o 0 0 0
B Black
0 0 FUSE BLOCK
o
OW Black with white stripe
W White M 0 0 0
lOA
WB White with black stripe
WR White with red stripe
Ii
WL White with blue stripe
California models
LO Blue with black stripe
LW Blue with white stripe
Y Yellow

E E492

Fig EE 25 Circuit diagram of charging lfY t m

EE 14
 Engine Electrical System

ALTERNATOR

CONTENTS

EE 15 INSPECTION OF DIODE EE 17
DESCRIPTION
REMOVAL EE 16 INSPECTION OF BRUSH EE 1B

DISASSEMBLY EE 16 SPRING PRESSURE TEST EE1B

ASSEMBL Y EE 1B
INSPECTION AND REPAIR EE 16

ROTOR INSPECTION EE 17 ALTERNATOR TEST EE19

INSPECTION OF STATOR EE 17 SERVICE DATA AND SPECIFICATIONS EE 19

DESCRIPTION
field is like way valve for electricity tive and
so
In the alternator a
magnetic a one negative conjunction
the rotor which consists that charging current passes easily but mounted the
produced by They are on two

of alternator shaft field coil pole reverse current is shut out plates which combine the function of
and slip rings The slip rings heat dissipating plate and
pieces In this alternator pack type silicon positive
pressed in the shaft conduct only a di odes are used negative terminals and are light in
small field current Output current is Six diodes three negative and three weight and easy to service

generated in the armature coils located positive are installed in positive and The pulley mounted on the air

in the stator The stator has three negative plates as an assembly conditioner models is different from
three that the standard models without
windings and generates phase These diodes are direct soldered at on

their tips and constructed with posi air conditioner

alternating current Silicon diodes act

@God

tfff
A
3

2 1 Pulley usem bly

2 Front cover

3 Front bearing
4 Rotor
5 Rear bearing

4 6 Stator
7 Brush assembly
I Rear
8 cover
e
9 Diode set plate assembly
o
e
10 Diode cover

9 11 Through botrs

EE345

Fig EE 26 Exploded view

EE 15
 Engine Electrical System

REMOVAL 3 Remove through bolts Separate 6 Remove diode cover fIXing screw

front cover with rotor from rear cover and remove diode Disconnect
cover
1 Disconnect negative battery ter three stator coil lead wires from diode
with stator by lightly tapping front
minaL terminal with a soldering iron
bracket with a wooden mallet
2 Disconnect two lead wires and
7 Remove A tenninaJ nut and diode
connector from alternator installation nut and remove diode
3 loosen adjusting bolt assembly
Remove alternator drive belt J
4 J
5 Remove parts associated with
alternator from engine
CD
6 Remove alternator from vehicle

DISASSEMBLY
4 AJ
1 Remove pulley nut and pulley
EE035
C

O
e
f ecA

1 Diode assembly
assembly Fig EE 29 Separating front cover
oo

2 Diode cover
with rotor from rear cover EE039

11 Fig EE 32 Removing diode 088embly

4 Remove three set screws from

bearing retainer and separate rotor

Note Use care in
from front cover handling diode
assembly to an undue st

C on it

@@@ EE033

Fig EE 27 Removing pulley ond fan INSPECTION AND

REPAIR
Remove alternator from car and
connect a circuit tester between F
2 Remove brush holder fIxing
screws and remove brush holder Q
DO EE036 tenninal and E terminal
Fig EE 3D Removing rotor When the resistance is approxi
cover Pull brush holder fOIWard and
remove brushes together with brush mately 5il the condition of brush and
5 Pull out from rotor
rear bearing fIeld coil is satisfactory When no
holder
assembly with a press or bearing continuity exists in brush or fIeld
puller coil or when resistance differs
Note Do not disconnect N tenninaJ
significantly between those parts dis
from stator coil lead wire
assemble and inspect

L I EE037
E A
O o

1
EE346
1 N terminal

2 Brush holder ld
3 Brush holder co r Q
EE040

Fig EE 28 Remouing brush Fig EE 3I Pulling out of roar bearing Fig EE 33 Inspecting alternator

EE 16
 Electrical System
Engine
2 Ground test INSPECTION OF DIODE
ROTOR INSPECTION
If each lead wire of stator coil
1 Continuity test of rotor coil Perform a continuity test on diodes
including neutral wire is not conduc
in both directions
Apply tester between slip rings of using an ohmmeter
tive with stator core condition is
rotor as shown in Figure EE 34 If A total of six diodes are used three
satisfactory If there is continuity
there is no continuity field coil is are mounted on the positive EEl plate
stator coil is grounded
open
and other three are on the negative e
Replace rotor assembly plate The continuity test should be

performed on each diode between the

terminal and plate

Stator core
Ee044

EE041
Fig EE 37 Teding stator for
Fig EE 34 Continuity test of rotor Ound
P
coil

2 Ground test of rotor coil

Check continuity between slip ring
Conductive direction
and rotor core If continuity exists
rotor assembly because rotor
replace
coil or slip ring may be grounded

I plate
2 ptate
3 Diode
EE045

Fig EE 35 Testing rotor coil for

diode
round Fig EE 38 Conductive direction of

INSPECTION OF STATOR

1 Continuity test
Diode installed e plate is a
Diode installed on EEl plate is a on
Stator is normal when there is
positive diode which allows current negative diode which allows current
continuity between individual stator
flowing from terminal to EEl plate flowing from e plate to terminal
coil tenninals When there is no conti
current does not
only In other words current does not only In other words
nuity between individual terminals
flow from EEl plate to terminal flow from terminal to e plate
cable is broken
Replace with stator assembly
v

1 ptate
EE046
2 Terminal I plate
EE043 EE047
2 Terminal
Fig EE 36 Testing stator for
EE 39 Inspecting positive diode diode
continuity Fig Fig EE 40 Insp cting negative

EE 17
 Engine Electrical System
If current flows in both positive If there is faulty diode ASSEMBLY
a
replace all
and negative directions diode is short diodes ix diode as an assembly Reassemble alternator in the reverse
circuited If current flows in one direc See table below These diodes are
sequence of disassembly noting the
tion diode is in good condition unserviceable
only
following
I When soldering each stator coil
lead wire to diode assembly terminal
Test probe of a circuit t ter
carry out the operation as fast as
Conduction pas
sible
e Gl 2 When installing diode A terminal
install insulating bush correctly
terminal EEl plate o

EJ plate terminal

terminal e plate

e plate terminal o

e plate @ plate o

Xl plate e plate

1 Imulating bush
INSPECTION OF BRUSH SPRING PRESSURE TEST 2 A terminal bolt
3 Diode cover
Check movement of brush and if With brush projected approximate 4 Rear cover

movement is not smooth check brush ly 2 mm 0 079 in from brush holder 5 Diode a
sembly
EE347
holder and clean if necessary measure brush spring pressure by the
Check brush for Fig EE 43 Sectional view of diode
wear If it is worn use of a pring balance Normally the
down to less than the specified limit and A term inal
rated pressure of a new brush spring is
replace brush assembly 255 to 345 gr 9 0 to 12 202
Check brush pig tail and if dam Morevover when brush is 3
worn Tighten pulley nut with tighten
aged replace pressure decrease approximately 20 g ing torque of 3 5 to 4 0
kg m 3 to
25

Brush line
0 7 02 per 1 mm 0 0039 in wear 29 0 ft Ib When pulley is tightened
wear limiting
make sure that deflection of V groove
is less than 3 mm 0 01 IS in
0

t m 0 079 in

q
or f

EE127
EEO
9 t
ffl EE051

Fig EE 41 Bnlsh wear limil Fig EE 42 M CJuring pring preaure Fig EE 44 Tightening pulley nut

EE lB
 Engine Electrical System

ALTERNATOR TEST
Before conducting an alternator A 30 V olt voltmeter and suitable Figure EE45 and test auernator in the
make th tthe
test sure battery is fully test probes 3re
necessary for the test manner indica ted in the flow chart

charged Set up a test circuit as shown in below

1 Disconnect connectors at alternator

2 Connect A terminal to F terminal
3 Connect one test probe from voltmeter positive terminal to terminal Connect the other test probe
A to ground
Make sure that voltmeter registers battery voltage
4 Turn on headlights and switch to High Beam
5 Start engine
6 Increase engine speed gradually until it is approximately 1 100 rpm and take the voltmeter reading

Measured value Below 12 5 Volts Measured value Over 5 Volts

12
Alternator is in trouble remove and check it Alternator is in good condition
for condition

Notes
a Do Dot run engine at the speed of
more than 1 100 rpm while test is

being conducted on alternator

b Do not race engine

l
Battery
i 9

I
IV
EE052 Voltmeter

Fig EE 45 Testing alternator

SERVICE DATA AND SPECIFICATIONS

IB
LT138
Type LTl35 36B For air conditioner

Nominal rating V A 1235 12 38

Ground polarity Negative Negative

Minimum revolution when generating

14V with no load rpm 1 000 1 000

Hot output current Nrpm 28 2 500 30 2 500

35 5 000 38 5 000

Pulley ratio 2 25 2 25

Brush

Length mm in More than 5 0 295

7 More than 5 0 295
7

Spring pressure gr oz 255 to 345 255 to 345

9 0 to 12 2 9 0 to 12 2

Slip ring outer diameter mm in More than 30 181

1 More than 30 181
1

EE 19
 Engine Electrical System

REGULATOR

CONTENTS

DESCRIPTION EE 20 CHARGING RELAY EE 23

MEASUREMENT OF REGULATOR SERVICE DATA AND SPECIFICATIONS EE 24

VOLTAGE EE 20 TROUBLE DIAGNOSES AND

ADJUSTMENT EE 23 CORRECTIONS Including alternatorl EE 25
VOLTAGE REGULATOR EE 23

DESCRIPTION
The regulator consists basically of a field circuit direct to ground and the

voltage regulator and a charge relay upper contacts when closed complete
The voltage regulator has two sets of the field circuit to ground through a
contact points
upper set to control alternator volt
a lower set and an resistance

alternator output
field coil and produce
v
age An armature plate placed between The charge relay i similar in

the two sets of contacts moves upward construction to the voltage regulator
or downward or vibrates The lower When the upper contacts are closed 1 Charge relay
2
contacts when closed complete the charge warning lamp goes on Voltage regulator
EE285

Fig 46
EE View of removing cover

As regards the construction the

voltage regulator is very similar to the

charge relay as shown in Figure EE47

@ Q ID@
@ ID@

GJ I
IjDC@V J
r

CD @ JbL
r
T
t
r
L
CD
@
@ j 1
@

@ @
@
gf
@ @ @ EEJ97

J I1Jlccting spring 9 3111111 0 118 ill di I Point gilp 9 Adjusting screw

10 41l1I11W 157in c1ia few

2
2 Y kt gp Charge relay contllct 10 Lock nut

3 Armaturc II Cuil 3 Core gap 11 Coil

4 Core go 12 lock nut 4 ArlllatlJre 12 4mm 0 157 in dia screw

5 Low Sllccd lnlacl J3 Adjllslin screw 5 Connecting 13 3mm 0 118 in dla

sprin crew

h Point ap
14 Adjll sting sprin 6 Yoke gap 14 Contact iet
7 conlat
t 15 Yoke 7 Yoh
High speed 15 Voltage cgulatm contact
8 Contact c B Adjusting pring

Tlll tion f
a
Cnl1 lltagl l
jllIOltllT b Construction of charge relay

Fig EE 47 Structural vi w

EE 20
 Engine Electrical System

MEASUREMENT
OF REGULATOR Rqulator

VOLTAGE
Genera tor
Regulator voltage is measured with
regulator assembled with alternator
When measuring voltage with regulator A Connector
mounted on car it is necessary to
rotate engine
Connect
at high speed
DC voltmeter l5 30Y
r
iJ Wire harness
circuit
Short here
fuse side tenninal and
between

DC ammeter l5 30A battery and a

terminal of ammeter before
O 25fl resistor rated at 25W with starting the operation
IG
cables as shown Fuse box
I Check to be sure that all electrical B
i
loads such as lamps air conditioner

radio etc are turned off V

2 Before starting engine be sure to
Ammeter Voltmeter 30V
make short circuit with a cable be lOA
tween fuse side terminal of resistor
EE055
O 25fland negative side terminal of
ammeter Failure to follow this pre Fig EE 48 Measuring regulator voltage with regulator on vehicle

caution will cause needle of ammeter

to swing violently resulting in a dam 3 Refer to the chart parts are in good condition
following to

aged ammeter determine if regulator and relative

EE 21
 Engine Electrical System

I Start engine
2 Rotate engine at 2 500 rpm for several minutes

Mter racing for several minutes ammeter

reading After racing for several minutes ammeter
below SA
reading
over 5A

Fully charged battery available Fully charged battery not available

I Replace with fully charged battery I Connect a 0 25 ohm resistor in series
2 Check to see if current falls below SA

Current falls below SA Current does not fall below SA

Recharge battery and see if current falls below

SA

Reduce engine speed to idling and then raise it to 2 500 rpm while
observing needle of voltmeter

Needle of voltmeter held within limits shown in the below

Needle of voltme ter ou t of limits shown in
table the following chart
Regulator functioning properly Adjust or replace regulator

Regulator type TLI Z 85C

speed
c Voltage may be approximately
Temperature Oc OF V
Voltage 3V
0 higher than rated for two to
three minutes after engine is start
10 14 14 75 to 15 75 ed or more specifically when regu
0 32 14 60 to 15 60 lator becomes self heated Measure
ments should then be made within
10 50 45
14 to 1545
one minute after starting engine or
20 68 14 30 to 30
15 when regulator is cold
30 86 14 15 to 15 15 d The regulator is of a temperature
40 104 14 00 to 15 00 compensating type Before meas
uring voltage be sure to measure
surrounding temperature and cor
rect measurements according to the

table at left
Notes is cold
regulator
Do not measure
3 voltage immediate b To measure voltage raise engine
ly after driving Do this while
speed gradually from idling to rated

EE 22
 Engine Electrical System

ADJUSTMENT 4 Adjusting point gap CD

Loosen screw 3 mm lIS
O in

VOLTAGE REGULATOR diameter used to secure upper con

tact and move upper contact upward
When regulating voltage as meas
or downward as necessary See Figure
ured above deviates from rated value
EE 50
in accordance with the
adjust regulator
following instructions
Point gap EE400

I Inspect contact surface and if 035 to 45

0 mm
I Wrench
rough lightly polish with fine emery 0 014 to D1S
O in
2 Crosshead screwdriver
paper 1 500 or 600 3 screw
Adjusting
2 Measure each gap and adjust if 4 l ock nut

necessary Adjust core gap and point

Fig EE 51 AdjUJJting Ulating
rel voltage
is
gap in that order No adjustment
required for yoke gap
3 Adjusting core gap
Loosen screw 4 mm 0 157 in

diameter which is used to secure CHARGE RELAY

contact set on yoke and move contact

Nonna relay operating voltage is S
upward or downward properly See
EE399 to IOV as measured at alternator A
Figure 49
EE I Thicknes tenninal Relay itself however oper
gauge
Core gap 2 3 mm 0 118 in dia ates at 4 to 5V
0 6 to 10 mm screw
Use a DC voltmeter and set up a
3 screwdriver
0 024 to 0 039 in
Sshelld
Cro

4
circuit as shown in Figure EE 52
Upper contact
Adjust charge relay in the same
Fig EE 50 Adjusting point gap manner as that for voltage regulator

5 Adjusting voltage
Adjust regulating voltage as

follows
Loosen lock nut securing adjusting
EE398
I Contact set screw Turn this screw clockwise to
2 ThicknesJ gauge increase or counterclockwise to
3 4 0 157 in dia screw decrease See
mm
regulating voltage
4 Crosshead Jcrewdriver
Figure EE 5 J
core gap
Fig EE 49 AdjUJJting

lead connector N tenninal with negative terminal

L Connect positive tenninal of voltmeter to regulator
grounded
2 Start engine and keep it idle
3 Take voltmeter reading

Below 5 2 Volts Over 5 2 Volts

o Volt

Check for Charge warning lamp on Charge warning lamp on

I continuity be
terminals of re I Check fan belt tension Charge relay coil or contact
tween
If correct regulator points out oforder
gulator and alternator 2 remove

and adjust necessary Replace regulator

2 Alternator circuit inopera as

tive if continuity exists

Over 5 2 Volts

Charge warning lamp off

Charge relay assembly is in good condition

EE 23
 Engine Electrical System

Yellow terminal
RegulatoI r

A W L WR IG WL

Voltmeter

N Y E B F WB

EE348

Fig EE 52 Tuting charging Qy

re

SERVICE DATA AND SPECIFICATIONS

Voltage legulator
Type TLl Z S5C

Regulating voltage with fully charged battery v 3 to 15 3 at 200C

14 680F

Voltage coil resistance 5 at 200C 680F

10

RotOI coil inserting resistance fl 10

Voltage coil series resistance 31

Smoothing resistance 40

COle gap nun in 0 6 to 1 0 0024 to 0 039

Point gap nun in 35

0 to 45
0 0 014 to O OIS

uge
Ch lay

Release voltage V 4 2 to 5 2 at N terminal

Voltage coil resistance fl 37 S at 200C 680F

Core gap nun in 0 8 to 10 0031 to 0039

Point gap mID in 4 to 0 6 0016 to 0 024

0

Standard tempelatUIe gIlIdient O OISV oC

EE 24
 Engine Electrical System

TROUBLE DIAGNOSES AND CORRECTIONS Including alternator

Condition Probable cause Corrective action

No output Sticking brushes Correct or

replace brushes and brush springs
Dirty brushes and slip rings Clean

Loose connections or broken leads Retighten or soldef connections

Replace leads if necessary
Open sta tor winding Repair Of replace stator

Open rotor winding Replace rotor

Open diodes Replace

Shorted rotor Replace rotor

Shorted stator Repair or replace

Grounded A terminal insulator
Replace
Broken fan belt Replace

Excessive output Broken neutral wire COIOf of wire is yellow Replace

Voltage fegulator breakdown Check regulator operation and repair or

replace asrequired
Poor grounding of alternator and voltage Retighten terminal connection

regulator En terminal
Broken ground wire color of wire is black Replace

Low output Loose or worn fan belt Retighten or replace

Sticking brushes Correct or replace brushes and springs if

necessary

Low brush spring tension Replace brush springs

Voltage regulator breakdown Check regulator OpefatiOn and repair or

replace as required
Dirty slip rings Clean

in stator
Partial short ground or open stator Replace
winding

Partially shorted or grounded rotor winding Replace rotor

Open or damaged diode Replace diode

Noisy alternator Loose mounting Retighten bolts

Loose drive pulley Retighten

Broken ball bearing Replace

seated brushes Seat correctly
Improperly

EE 25
 Engine Electrical System

IGNITION CIRCUIT

CONTENTS

NON CALIFORNIA MODELS EE 26 CALIFORNIA MODELS EE 2B

NON CALIFORNIA MODELS

The ignition circuit consists of the secondary winding of the ignition coil cap
ignition switch coil distributor high tension wiring distributor rotor Then the spark obtains while the
wiring spark plugs and battery and cap high voltage current jumps the gap
The circuitis equipped with When the is turned between the insulated electrode and
a ignition switch
resistor electrical and the distributor contact
During cranking on points the ground side electrode of the spark
current bypasses the resistor thereby are closed the primary current flows plug This process is repeated for each
connecting the ignition coil directly to through the primary winding of the power stroke of the engine
battery This provides full battery coil and through the contact points to The distributor contact point and
voltage available at coil and keeps ground spark plugs should be inspected clean
ignition voltage as high as possible When the contact points are opened ed and regapped at tune up They
The low voltage current is supplied by the revolving distributor earn the should also be replaced periodically as
by the battery or alternator and flows magnetic field built up in the primary specified in the Maintenance Sched

through the primary circuit It consists winding of the coil moves through the ule In addition apply grease NLGl
of the ignition switch resistor secondary winding of the coil inducing consistency No I containing MoS2 or
primary winding of the ignition coil high voltage The high voltage is equivalent to distributor shaft and
distributor contact points condenser produced every time the contact grease MIL G l0924B containing
and all connecting low tension wiring points open The high voltage current MoS2 or equivalent to cam as reo

The high voltage current is pro flows through the high tension wire quired
duced by the ignition coil and flows to the distributor cap Then the rotor The remainder of the ignition
through the secondary circuit result distributes the current to one of the component parts should be inspected
ing in high voltage spark between the spark plug terminals in the distributor for only their operation tightness of
electrodes of the spark plugs in engine electrical terminals and wiring con

cylinders This circuit contains the dition

The ignition circuit is shown below

0
Battery
cl IR
IB I
is 21
g
J
Re5istor

To starter

Ignition coil
Secondary winding
Cap

Breaker point

f
Rotor head

Distributor

EE060

Fig EE 53 Ignition ydem circuit diagram

EE 26
 Electrical System
Engine

E
CJI2t
W

Bf o R
00
00

fOl

FUSIBLE LtNK

Wj
BW

BR

IGNITION SWtTCH

BL
I DISTRtBUTOR

L
oj

ti
J
C
L

RESISTOR

IGNITION COIL

COLOR CODE

B
OW

DR
Black
Black with white stripe
Black with red stripe
jjjSPARK PLUGS

aL Black with blue stripe

W White

EE493

Fig EE 54 Circuit diagram ofignition ByJt m Non California models

EE 27
 Engine Electrical System

CALIFORNIA MODELS
The ignition circuit consists of igni resistor voltage is produced time the
primary winding of the igni every
tion switch transistor ignition unit tion coil transistor ignition unit and primary circuit opens
distributor wiring spark plugs and all connecting low tension wiring The high voltage current flows
battery The high voltage current is pro through the high tension wire to the
The distributor is of the contactless duced by the ignition coil and flows distributor cap then the rotor distri
and is equipped with pick butor cap then the rotor distributes
type a up through the secondary circuit result
coil which electrically detects the igni ing in high voltage spark between the the current to one of the spark plug
tion timing signal in place of the electrodes of the spark plugs in engine terminals in the distributor cap
circuit breaker of the conventional Then the spark occurs while the
cylinders
distributor The transistor ignition unit This circuit contains the secondary high voltage current jumps the gap
is a new addition which generates the winding of the ignition coil distribu between the insulated electrode and
signal required for the make and break tor high tension wires to coil and the ground side electrode of the
spark
of the primary electric current for the
spark plugs distributor rotor and cap plug This process is repeated for each
ignition coil When the ignition switch is turned power stroke of the engine
The circuit isequipped with a and the distributor reluctor rotates
on The sparkplug should be inspected
resistor During cranking electrical the primary current flows through the cleaned and regapped at tune up
current bypasses the secondary resis
primary winding of the coil and Spark plugs should also be replaced
tor thereby connecting the ignition through transistor ignition unit to periodically as specified in the Main
coil through the primary resistor This
ground tenance Schedule
makes battery voltage available at ef When the prim ary circuit is opened The remainder of the ignition com

ficiently and keeps ignition voltage as
high as possible
The primary resistor selVeS to pro
tect transistor ignition circuit
The low voltage current is supplied
by the battery or alternator and flows
by circuit of transistor ignition unit ponent parts should be inspected for
the magnetic field built up in the only their operation air gap of distri
primary winding of the coil moves butor tightness ofelectrical terminals
through the secondary winding of the and wiring condition
coil inducing high voltage This high Apply grease NLGI consistency
No I containing MoS or equivalent

through the primary circuit to distributor rotor shaft as required

It consists of the ignition switch

Primary Secondary
Battery
I

Primary winding Resistor

1 To starter

Ignition coo
I
Secondary winding

Transis tor
ignition I
r unit I

rcoil
Pick up

r
Rotor head

R5 nl
1 U1f J
Retuctor oi
r l f
S park plugs

EE287

Fig EE 55 Ignition 8Y3tem circuit diagram

EE 28
 Engine Electrical System

TRANSISTOR IGNITION UNIT

IHIIl II II

BW BW
BBV RG
EARTH POINT

r
I I

111
a B

lof1 @
00

00
W 00 SR
00

b 00

Et liiI

FUSIBLE
LINK

BATTERY

TERMINAL BLOCK

c
r
BR
B

ml
lliJ LldJ0
IGNITION SWITCH

d
L
l
j
ilR

i in D1STRliUTOR
@
BW
10
c 0

RESISTOR
i9
IGNITION COIL

COLOR CODE

OW

DR

R
Black
Black with white stripe
Black with red stripe
White

Blue

Red
J SPARK PLUGS

G Green
EE494

Fig EE 56 Circuit diagram of ignition system California models

EE 29
 Engine Electrical System

DISTRIBUTOR Non California models

CONTENTS

CONSTRUCTION EE 30 ADVANCE MECHANISMS EE 31

CHECKING AND ADJUSTMENT EE 31 DISASSEMBL Y EE 32
CAP AND ROTOR HEAD EE 31 ASSEMBLY EE 32
CONTACT POINT EE 31 SERVICE DATA AND SPECIFICATIONS EE 33
CONOENSER EE 31

CONSTRUCTION
The distributor consists of breaker
plate with contact points centrifugal
advance mechanism vacuum control
ler distributor shaft and rotor

i
@

t Cap assembly
2 Rotor head assembly

3 Condenser assembly
4 Ground wire assembly
5 Lead wire assembly
6 Contact set

7 Breaker plate assembly

8 Packing
9 earn assembly
10 Governor spring D
11 GoVernor weight
12 Shaft assembly
13 Vacuum controller @
14 Terminal assembly
IS Housing
16 Fixing plate
17 Oring
IS Collar
EE32Q

Fig EE 57

EE 30
 Engine Electrical System

set screws 1 to 1 5 CONDENSER

CHECKING AND First turn out

turns at contact arm and primary lead

ADJUSTMENT Satisfactory performance of con

wire connection just for enough to denser depends on capacity and degree
CAP AND ROTOR HEAD pull primary lead terminal
out
of insulation requiring attention to be

Referring to Figure EE 59 unSCrew

Cap and rotor head should be in that terminals clean and
sure are set
two contact set fixing screws and
in the tight
spected periodically as specified screws are
remove lead wire
Maintenance Schedule Remove cap Checking of condenser is made by a
While holding contact arm by
and clean all dust and carbon deposits condenser tester
fingers pull out contact set toward
from cap and rotor If cap is cracked
you by
raising slightly it Contact
or is leaking replace with a Deone

point and afm can then be removed

together

CONTACT POINT Install new contact point and arm

assembly in reverse sequence of

Contact point should be replaced in
removal Coat cam with a light coating
accordance with the Maintenance
of grease
Schedule
Standard point gap is 45
0 to 0 55
ADVANCE MECHANISMS
mm O OIS to 0 022 in In case size

is off the standard adjustment is made Specifications

by loosening point screws Gap gauge
is required for adjustment D4A4 06 D4A4 07
When point surface is rough take D4A6 07 D4A6 0S
off any irregularities with fine sand
500 or 600 or with oil Automatic
paper of No Manual transmission
Application transmission
stone

When wear on contactpoints is

noticeable replace points together Vacuum advance
00 150 5 91 00 170 6 69
with contact arm To replace proceed Distributor degrees distributor
30 250 9 S4 6 50 300 1I S1
as follows mmHg inHg

Centrifugal advance 00 600

00 550
Distributor degrees 0
11 2 300 110 1 950
distribu tor rpm

For Canada

Vacuum advance mechanism

Centrifugal advance
EE322
mechanical parts mechanical parts

Fig EE 58 Adju ting point gap If vacuum advance mechanism fails When cause of engine malfunction
to operate properly check for the is traced to centrifugal advance me
following items and correct the mal
chanical part use distributor tester to
function as required check its characteristic
1 Check vacuum inlet for signs of See the specifications above
leakage at its connection Ifnecessacy When nothing is wrong with its

retighten or replace with a new one characteristic conceivable causes are

2 Check vacuum diaphragm for air break down abnormal of

wearing
out
leak driving part or others So do not

If leak is found replace vacuum disassemble it

controller assembly In case of improper characteristic
3 Inspect breaker plate for smooth take off contact breaker assembly and

moving check closely cam assembly governor

If pia te does smoothly

not move weight shaft and governor spring etc
EE321

I this condition could be due to sticky In case centrifugal advance me

Primary lead termina
Ground lead wire chanical part is reassembled be sure to
2 steel balls or pivot Apply grease to
3 Set screw if necessary check advance characteristic by dis
steel balls or replace
4 Adjuster
breaker plate as an assembly tributor tester
5 Screw Fig EE 59 Breaker

EE 31
 Engine Electrical System

DISASSEMBLY 4 When breaker plate is removed

be careful
not to lose steel balls
To disassemble follow the below
between breaker spring and breaker
proccd ure
plate
I Take off cap and disconnect rotor
5 Pul roll pin out and siconnect
head the entire rotating
collar to remove
2 Remove vacuum controller
parts

EE075

Fig EE 65 Removing cam

7 When governor weight and spring

are disconnected be careful not to
EE291
stretch or deform governor spring
Fig EE 60 Removing vacuum
to
controller
After disassembling apply grease
EE325 governor weights
3 Remove contact set Fig EE 63 Removing rollpin
Refer to Page EE 31 when contact
set i removed

ASSEMBLY
To assemble reverse the order of

disassembly Carefully observe the fol

lowing instructions
Align match marls so that parts
are assembled to their original posi
tions
EE323
2 Apply grease to the top of cam
Fig EE 61 Removing contact tel
assembly as required
EE326
3 Check the operation of governor
Fig EE 64 Removil1l rotation paTta
before installing distributor on engine

4 Adjust ignition timing afteT dis

tributor is installed on engine

6 Remove packing from the top of

cam assembly and unscrew earn astern

bly setscrew Put match mark across

EE324 earn and shaft so that original combi

EE 62 Removing breaker plate nation can be restored at assembly

Fig

EE 32
 Engine Electrical System

SERVICE DATA AND SPECIFICATIONS

D4A4 06 D4A4 07
D4A6 07 D4A6 08
Type

Firing order 1 42
3 4 2
13

Counterclockwise Counterclockwise
Rotating direction

Owen degree 490 to 550 490 to 550

angle
0 45 to 0 55 45
0 to 55
0
Point gap mm in
0018 to 0 022 0 018 to 0 022

0 40 to 0 55 0 40 to 0 55
Point pressure lb
kg
0 88 to 121 0 88 to 121

0 20 to 0 24 0 20 to 0 24
Condenser capacity JlF

Mrl 5 5
Condenser isolate resistance

Mrl 50 50
Cap isolate resistance

50 50
Rotor head isolate resistance Mrl

mm in 10 39
0 10 0 39
Cap carbon point length

For Canada

DISTRIBUTOR California models

CONTENTS

EE 33 ADVANCE MECHANISMS EE 33
CONSTRUCTION
EE 33 DISASSEMBLY EE 35
CHECKING AND ADJUSTMENT
CAP AND ROTOR HEAD EE 33 ASSEMBLY EE 35

AIR GAP EE 33 SERVICE DATA AND SPECIFICATIONS EE 36

CONSTRUCTION
In the conventional distributor the piece faces the protrusion of the re unit utilizes this electric signal to

is detected by the cam luctor and then the electrical signal is restore the primary coil to the original
ignition liming
state after cutting off the primary
and breaker arm while in this transis generated in the pick up coil
tor ignition unit it is detected
by the This electric signal is conducted current for a fIXed time

reluctor on the shaft and the pick up into the transistor unit which The centrifugal and vacuum ad
ignition
coil provided in place of the breaker in turn breaks tI e primary coil current vance mechanisms employ the con

The pick up coil consists of a magnet running through the ignition coil and ventional mechanical type The con

coil etc The amount of magnetic flux generates high voltage in the secondary tactor is used to eliminate vacuum

passing through the pole piece in the winding Also this transistor ignition and centrifugal advance hysteresis
coil is changed at the moment the pole

I
EE 33
 Engine Electrical System

@
tl t3 l

1 Cap assembly
2 Rotor head a55embly
9 3 Roll pin
4 ReJuctor
S Pick up coil
6 Contactoi
7 Breaker plate assembly
8 Packing
9 Rotor shaft
10 Governor spring
11 Governor weigh t
l
12 Shaft Jscmbly
a

13 Cap setter

J @ 14 Vacuum controller

r
9
15 Housing
V 16 Fixing plate
@ fW
17 O ring
18 Collar
@
EE327

Fig EE 66 Exploded view of di3tributor

CHECKING AND assembly and distributor harness to

their positions
ADJUSTMENT

CAP AND ROTOR HEAD

Cap and rotor head must be in

the
spected periodically as specified in
Maintenance Schedule Remove cap
and clean all dust and carbon deposits
from cap and rotor from time to time EE328

If cap is cracked or is leaking replace

Fig EE 67 Checking oir gap
with a new one

EE329
To remove pick up cail disconnect
distributor harness at terminal block Fig EE 68 Remouing pick up coil
and remove screw securing pick up coil
AIR GAP
ADVANCE MECHANISMS
Standard air gap is 0 2 to 4 mm
0
Specifications
0 008 to 0 016 in
If the gap is off the standard Type D4F4 04 Q3
D4F4
mould be made by loos
adjustment
ening pick up coil screws Item Manual Automatic
is required for adjust
Gap gauge
ment Air gaps must be checked from Vacuum advance
00 150 5 91
time to time Distributor degrees 30 250 9 84
Distributor mmHg inHg
Air gap 0 2 to 4
0 mm

0 008 to 0 016 in Centrifugal advance

00 550 00 600
Distributor degrees 110 2 300 1 950
110
Distributor cpm

EE34
 Engine Electrical System

Vacuum advance mechanism

mechanical parts

If vacuum advance mechanism fails

to operate properly check for the
items and correct the prob
following
lem as required
1 Check vacuum inlet for signs of

leakage at its connection If necessary

retighten or replace with a new one
EE075
2 Check vacuum diaphragm for air EE291

leak Fig EE 69 Removing vacuum Fig EE 72 Removing rotor shaft

If leak is found replace vacuum controller

controller assembly
3 Inspect breaker plate for smooth 3 Remove pick up coil assembly
moving 4 9 Mark one of the governor springs
Using two pry bars pry reluctor
If plate does not move smoothly and its bracket Also mark one of the
from shaft Be careful not to distort or
this condition could be due to sticky
the teeth of reluctor governor weights and its pivot pins
damage
steel balls or pivot Apply grease to
Remove roll pin 10 Carefully unhook and remove
steel balls or if necessary replace S Remove breaker plate setscrews governor springs
distributor assembly 11 Remove governor weights
and remove breaker plate assembly
Apply grease to governor weights
after disassembling

Centrifugal advance
mechanical parts

When cause of engine malfunction ASSEMBLY

is traced to centrifugal advance mecha
tester to
To assem ble reverse the order of
nical parts use distributor
disassembly Carefully observe the fol
check its characteristics See to the
instructions
specifications above lowing
If nothing is wrong with its charac E330 1 Align match marks so that parts
teristics conceivable causes are faulty are assembled to their original posi
Fig EE 70 Removing breaker plate
of driving part tions
or abnormal wear or etscrews
2 If for any reason contactor is
others So do not disassemble it
removed from breaker plate adjust
improper character
In the event of
6 Pull roll pin out and remove
istics checkclosely rotor shaft assem cam contactor
to clearance to 3 mm
0
collar
bly governor weight and shaft 0 012 in as shown in Figure EE 73
7 Remove rotor shaft and drive
If any of above parts are malfunc after installation
shaft assembly
tioning replace distributor assembly

T
DISASSEMBLY

To disassemble follow the pro

EE298
cedure below
Fig EE 73 Cam contactor
to
1 Take off cap and remove rotor EE331 clearance
head
Fig EE 71 Removing rotorshaft and
2 Remove two screws shown in Ensure that reluctor is
drive shaft assembly 3 properly
Figure EE 69 and detach vacuum con orien ted when installing on shaft
troller in roll its slit
8 Mark rotor shaft and drive shaft Always drive pin with
Remove packing from the top of toward the outer end of shaft See
rotor shaft and unscrew rotor shaft Figure EE 74 Be sure to use a new roll

setscrew pin
EE 35
 Engine Electrical System

4 Apply grease to the top of rotor

shaft as required
5 Check the operation of governor
before installing distributor on engine
6 Adjust ignition timing after distri
butor is installed on engine

EE299

Fig EE 74 Driving in rollpin

SERVICE DATA AND SPECIFICATIONS

Type D4F4 03 04
D4F4

Firing order 1 4 2
3

Rotating direction Counterclockwise

Duty 70 20 to 40 at idling
Air gap mm in 0 2 to 0 4 O OOS to 0 016

Cap insulation resistance MU More than 50

Rotor head insulation resistance MU More than 50

Cap carbon point length mm in 10 39

0

TRANSISTOR IGNITION UNIT California models

CONTENTS

DESCRIPTION EE 36 2 CONTINUITY CHECK OF PRIMARY

TRANSISTOR IGNITION UNIT EE 36 CIRCUIT EE 36
REMOVAL AND INSTALLATION EE 37 3 PICK UP COIL CONTINUITY CHECK EE 38
INSPECTION EE 37 4 PICK UP COIL POWER SIGNAL
1 POWER SUPPLY WI RING AND PULSE CHECK EE 38
BATTERY CHECK EE 37 5 TRANSISTOR UNIT CHECK EE 39
IGNITION

DESCRIPTION
is provided This cuts off the
TRANSISTOR IGNITION 2 The duty control circuit sets the ing
rate of make and break within one prilnaCY electric current in the ignition
UNIT
cycle ie this maintains good ignition coil when the ignition switch is turned
The transistor ignition unit provides
characteristics of engine from low on with the engine not running
the following functions speed high speed and is equal to
to Each component part of this unit is
L It makes and breaks the electric the dweU angle in the conventional however
highly reliable should any
current in the primacy circuit of the breaker type distributor part be found faulty the entire assem

ignition coil 3 A circuit

preventive against lock bly must be replaced

EE 36
 Engine Electrical System

The items are classified by numerals

in accordance with the objective of
Transistor ignition unit
checks to be performed Several wiring
diagrams arefound on pages 41 to
EE

45
EE The thick lines indicate the
objective of each individual item
Power Duty Spark timing Lock
check

1 1 j
r1
switching control Signal mom preven ling When checking a circuit with an
circuit circuit toring circuit circuit
oscilloscope or a circuit tester be

careful not to confuse the polarity of

the lead wires if potential difference
exists between
the check points at
To starter To distributor
which the lead wires are to be con
tacted Also do not attempt to con

nect the lead wires to any points in the

nm circuit other than those designated
Careless handling of the lead wires will
Distributor result in transistor
damage to the
Ba Ignition coil ignition unit as well as to the oscillo
ttery
EE437
scope or circuit tester

The connection of a tachometer or

Fig EE 75 Transistor ignition unit circuit diagram a timing light in parallel with an

oscilloscope or a circuit tester is al

lowable provided that such a connec
REMOVAL AND INSPECTION tion is made with due consideration to

INSTALLATION If the engine does not run due to wiring connections

Transistor ignition unit is located faulty ignition system check the igni
tion system as follows
on the right hand dash side panel in

passenger compartment Check for a cracked distributor

1 POWER SUPPLY WIRING
Disconnect battery negative cable rotor or cap and corroded tenninals
tension wires for AND BAnERY CHECK
2 Disconnect wiring harness from Visually inspect high
unit condition and if necessary use an See wIrIng diagram
3 Remove two setscrews and te ignition oscilloscope or a circuit tester In FIgure EE 88

move unit to make performance checks Check

and adjust gaps Procedure
4 To install reverse the order of spark plugs as neces

removal sary I Turn on ignition switch

Be sure to connect Replace a spark plug which is not 2 Connect a circuit tester or an
Note wiring har
suitable for further use If the above
nesses to their oscilloscope as shown in the figure
proper positio checks cannot correct the problem below
Failure to do so will damage the
unit
check the entire ignition system with
circuit tester
Refer to EE 76
an oscilloscope or a
Figure

CHECKING WITH AN
OSCILLOSCOPE DC 50 volt range

L
An oscilloscope can be used for
checking almost all the items in a

transistor ignition system

CHECKING WITH A CIRCUIT EE302

TESTER
Fig EE 77 Checking power supply
A circuit tester can not be used for wiring and batt ry
the duty control circuit and power
tests Criterion
t18nsistor performance Both
Fig EE 76 External view of ignition
methods use of an oscilloscope and a When power source battery
unit
circuit tester are described in this voltage is indicated OK
section Lower or no indication N G

EE 37
 Engine Electrical System
If the result is N C Take the harness respectively for proper con

ductance
following measures

2 Check resistor and ignition coil

I Check BW and B color wire
terminals for loose contact
harness respectively for proper con
3 Check resistor and ignition coil Resistance
ductance
for 10 range
2 Check battery terminals for discontinuity
4 Check WB color wire harness
proper connection
of ignition coil assembly for proper
3 Check charge condition of bat fp
continuity
tery if an
excessively low voltage is
EE305
indicated

2 2 Chacklng IgnitIon coil Fig EE BO Checking pick up coil

auembly See wiring

Criterion
diagram In Fig EE 90
When approximately 720 ohm
Procedure is indicated OK
I Disconnect ignition coil and dis Far less than or more than
tributor harness from ignition coil 720 ohm N C

2 CONTINUITY CHECK OF external resistor

If the result is N C
PRIMARY CIRCUIT
2 Connect a circuit tester as shown Replace
in the pick up coil assembly
figure below
2 1 CheckIng prImary
circuit See wiring diagram

In Fig 89
EE Resistance
4 PICK UP COIL POWER
1 range

Proced ure SIGNAL PULSE CHECK

I Disconnect L color wire from

Q
Procedure
ignition unit fD
o
2 I Disconnect anti
Turn on ignition switch dieseling solenoid
3

oscilloscope
C ooneet
as
a cireui t tester

shown in Figure EE 78
or an
ro valve connector
2

in the
Connect a circuit tester as shown

EE336 figure below

3 Rotate starter motor
Fig EE 79 Checking ignition coil 4 Read the tester indication
assembly

DC 50volt range
Criterion
S
tf When approximately 1 6 to
2 0 ohm is indicated
OK AC 2 volt
S range
More than 2 0 ohm N C
EE303

If the result is N C Replace

ignition coil
Fig EE 78 Checking primary circuit assembly EE306

Fig EE 81 Checking pick up coil power

3 PICK UP COIL
aignal pulse
CONTINUITY CHECK See
Criterion
wirIng dIagram In Criterion
When Donnal power Source
Figure EE 91
When pointer deflects
battery voltage is indicated OK
Lower or no indication N G Procedure slightly OK
When pointer does not deflect
If the result is N C Take the Disconnect R and G color at all N C
following measures wires from ignition unit
2 Connect a circuit tester as shown If the result is N C
1 Check BW
Replace
and L color wire in the figure below pick up coil assembly

EE 3B
 Engine Electrical System

Procedure with an oscilloscope

Ignition coil terminal
1 Disconnect anti dieseling solenoid
valve connector
2 Connect
oscilloscope
a

to
positive lead of
R olor wire and
an

a
Oscilloscope
8W
o 8
r
negative lead of an oscilloscope to
0
G color wire 0
3 Set a SLOPE select switch of EB C

an oscilloscope to the positive side If

EB
80
so equipped
4 Rotate starter motor
5 Check the wave form as shown in
the figure below To body metal

EE307

Fig EE 83 Checking operation of transistor ignition unit

EE268

Fig EE 82 Wave form ofpick up coil

Criterion @
When the wave form takes
the shape of a full line OK
When the wave form takes the
shape of dashed line when
a or
@
there is no wave form N G
EE452

If the result is N G Replace

pick up coil assembly Fig EE 84 W uve form ofpulse

5 TRANSISTOR IGNITION 2 harness to the If an oscilloscope is not avail

Connect wiring
UNIT CHECK See wiring able
ignition unit

3 Disconnect anti dieseling solenoid

diagram In Figure EE 92
valve connector Procedure
Check items 5 1 and 5 2 with an
shown in
4 Connect oscilloscope as 1 Connect ignition coil and dis
oscilloscope EE 83 rotate the starter motor tributor harness
Where an is not availa Figure to
ignition coil exter
oscilloscope the
and observe the wave form on nal resistor
ble check to make sure that all previ
oscilloscope 2 Connect wiring harness to igni
ous tests are satisfactory and that no
tion unit
spark is issuing from the secondary
3 Disconnect anti dieseling solenoid
high tension wire
valve connector
If everything else is satisfactory
4 Keep the secondary high tension
then the transistor ignition unit is Criterion wire end 4 to 5 mm 0 16 to 0 20 in
faulty or there is discontinuity in the
away from engine block rotate the
secondary high tension wire Replace See Figure EE 84
starter motor and check whether
the faulty part After replacement
When a wave form similar to
sparks fly across the clearance
check the sparks from the secondary a is observed OK
cord When a wave form similar to b is Criterion
5 1 Checking operatIon obseIVed or when no wave form is Where sparks issue OK
of transIstor Ignition unit observed N G N G
Where no spark issues

Procedure If the result is N G the fault lies If the result is N G the fault
either in the transistor unit or in the
I Connect coil and dis lies either in the transistor unit or in
ignition
secondary high tension wire
tributor harness to ignition coil exter the secondary high tension wire

nal resistor Replace these parts Replace these paris

EE 39
 Engine Electrical System
5 2 Checking operation
of duty DC 50 volt range

Procedure B fJ
rC
O

BW

Connect anti dieseling solenoid tor

Transi
L unit
valve connector ignition
o

the
While the
wave ronn
engine
on
is idling
the oscilloscope in
observe

8
t 1 V
the same way as stated in item 5
Figure EE 83 Determine the ratio tiT
as shown in Figure EE 85

I
x 100 20 to 1
401
T
EE357
at idling
Fig EE 86 Checking lock p uentive circuit

h
T
1
Lt Criterion

When power source voltage

tion in the

Figure EE 83
same

or
way as

Figure 86
EE
shown in
Turn
is indicated OK on ignition switch
When Check to see whether the wave
EE257 approximately zero voltage
form the
is indicated N G on oscilloscope rises up to
Fig EE 85 Wove form ofduty pulse the power source voltage within about
If the result is N G Take the 10 seconds after is
ignition switch
following measures turned on
Criterion
Replace transistor ignition unit
When a standard ratio of about
20 to 40 is obtaiiied If
OK an oscilloScope is uSetl
When the ratio obtained is
less than 20 Procedure Criterion
or

more than 40 N G I When using in The described before for

an oscilloscope same as

stead of a tester arrange the connec use of a tester

If the result is N G Replace
transistor ignition unit

5 3 Checking lock Power source voltage

preventive circuit

If a circuit tester is used

Oy
Procedure
1 Connect a circuit tester as shown
t
in Figure 83
EE or EE
86 positive Ignition switch ON
terminal of tester is connected to L EE430
color wire and negative terminal of Fig EE 87 Wave form of lock preventive circuit
tester is grounded

2 Turn on ignition switch Check to

see whether the tester indicates the
volage of source ba t1ery
power
as soon as ignition switch is turned on

40
EE
 1 Al13 c

n
l1
5 l1
rn
bat e
c

E438
E

and
r I

y
1

switching control unit

uPP
Duty circuit
er
PO

Power dtCuit 19niton l

o
timing
prev nti g item
for
lonltoriOi
l
1
sign
t
oClt cl cuit ram
sparlt circui l8
di

Wiring
P 88
am
c
EE
s

Fill
Harne
L R G

II
llW

oC

r b

Terminal
auemblY
coil
BR
IgnitOn Utstnot
tC
l

nitonS o i

It

11
 3
0c f
3D WC
l
rn llO
0
439
eE

con o
switcnlOS DUtY circuit
unit
on

powet cucuil o nit

19

lng
tiR monitrng cltCuit Itev nti s circuit
1
K
Loc

Spade oIgn

alnP
c
o

Harnes
L R G
Il IlW

r
k
OC

Terminal
asemblY
coil
IlR
igniton
o DistrbuO

Wb
 l IlS3 blY
O

rn l0
r Wo
EeA40 ncoi1
0
1

ing
tdl cont o unit
Iln1
i

nll

putY ciIcuit
sVI R

rowel citCuit Igniton CMC

2

o oth1
t

tunin tnoo ptel nu t ite

for
cirCuit
K
lflc

a
sign
atK
S1 citcuit dioS

Wirinl
clarnp 90
@ EE
rnesSa
H
Fig

G
R
ll L

OC

r
o
ina

let1

uW
auefC
coll
P
iUO

llR 19t

Dutot
tri

o
sWitch
O
gn1t10

b
 01Il f
I Iu 5
l
l lll
EE44
o

lTcofO
l
unl

swilchln DUtY tCU C o1

l

powet CltCU1l
tn

o
onitoifl preyen
f

t
titrllt

LOCK circuit
tl

l
St signacircuit

cump
@ e

Ratt

l G
I

B
BW

blocK
r oa

Ter n

I
rntM
a

CO

l
ll
Of
t

f1

bUlot
o OliU
Witch
s

on

gni

Wt
 it
l
svstel
O
El19ine
ElectriCal
j

g
j

0 15
l i
0
5
l
J

i CI C
g

t 0 e
0
t

l
l
2
0
l t
a a I S l
e
ll 1
t
ll u
1
oJ

ll

foil

i
i
0

0
u

0 S

a
CD 0
0

4S
EE
 Engine Electrical System

IGNITION COIL

The ignition coil is an oil f1l1ed

California models califomia
Non models
type The ignition coil case is filled
with oil which has good insulating and
heat radiating characteristics
The ignition coil has a greater ratio
between the primary and secondary

windings step up battery voltage t

to
f ID
high voltage This causes stronger
sparks to jump the spark plug gap
The is made of
@
cap alkyd resin
which offers high resistance to lectric J
arc and increased insulation
C

The ignition coil and resistor should ID

be handled as a matched set
I 1W
When high tension wire is installed
to ignition coil there should be no

clearance between their caps

EE314
1 R bber cap for ignition coil 8 Side core

2 Secondary terminal 9 Insulator coil

3 Cap 10 Center core

4 Primary terminal 11 Segment

5 Spring 12 Case
6 Secondary winding 13 Rubber cap Cor terminal
7 Primary winding

Fig EE 93 Sectional view of ignition coil

Notes

Do disconnect
a not high tension
wires from spark plugs during en
gine mnning California models

only
I EE354
b RoD up high tension wire mbber
1 High tension wire
2 Rubber cap
cap and instaD high tension wire to
ignition coil securely Refer to
Figure EE9S
Fig EE 94 Correcl installation of high
t Mjon win Fig EE 95 Installing high tension wire

SPECIFICATIONS
Non California
California models
models

Type 618
C6R HS 15 18 CIT 16 STC 9

Primary voltage V 12 12

Spark gap mm in more than 7 0 28 more than 7 0 28

Primary resistance at 200C 680F n 108 to 1

32 45
0 to 55
0

Secondary resistance at 200C 680 F KSl 8 24 to 4

12 5 to 12 7
8

External resistor at20 C 680F n 5

1 3
1 4
0 09

46
EE
 Electrical System
Engine

SPARK PLUG

CONTENTS

EE 4B
DESCRIPTION 47
EE SERVICE DATA AND SPECIFICATIONS
EE 47 TROUBLE DIAGNOSES AND
INSPECTION
CORRECTIONS 4B
EE
CLEANING AND REGAP 47
EE

in spark plugs low fuel pump pres

DESCRIPTION Overheating White or light gray
sulator with black gray brown
or sure wrong selection of fuel a
The spark plugs are of the conven hotter
spots and bluish burnt electrodes plug etc
0 551 in with
tional type having 14 mm
indicate engine overheating More It is advisable to replace plugs
1 0 to
threads The spark pluggaps are
over the appearance results from having colder heat range
1 mm 0 039 to 0 043 in on Cali
incorrect ignition timing loose
fomia models and 0 8 to 09 mm

0 031 to 0 035 in on non California

models The inspection and cleaning
should be made every suitable mainte
If necessary replace
Ir
nance period i

Note All spark plugs installed on an

engine must be of the same brand

and the same number of heat range Carbon fould

Normal

INSPECTION
L Remove spark plug wire by
pulling on boot not on wire itself

2 Remove spark plugs

3 Check electrodes and inner and
outer porcelains of plugs noting the
of Worn
type deposits and the degree of Overheating
electrode erosion Refer to Figure EE079
Fig EE 96 Spark plug

EE96

Normal Brown to grayish tan de

4 After cleaning dress electrodes discard plugs
posits and slight electrode wear

indicate heat with a smaU fine file to flatten the After cleaning spark plugs renew
correct spark plug
surfaces of both center and side firing surface of electrodes with me
range
electwdes parallel Set spark plug
in mentioned aboVe Then gap spark
Carbon fouled Dry fluffy carbon
to specification plugs to specified values with a round
deposits on the insulator and gap
electrode usually caused by
are
5 InstaU spark plugs and torque wire feeler gauge All spark plugs new

each plug to L5 to 2 0 kg m 11 to 14 or used should have the gap checked

slow speed driving in city weak
ft Ib and reset by bending ground electrode
mixture
ignition too rich fuel
Connect spark wires
dirty air cleaner etc
6 plug
with
It is advisable to replace plugs
having hotter heat range
Oil fouled Wet black deposits indi
cate excessive oil entrance into
CLEANING
combustion chamber through worn AND REGAP
Clean in a sand blast
rings and pistons or excessive clear spark plugs
ance between valve guides and type cleaner Avoid excessive blasting
stems If the same condition re Clean and remove carbon or oxide
but do not EEOBO
mains after repair use a hotter deposits wear away

If deposits too stubborn Fig EE 97 Setting park plug gap

plug porcelain are

47
EE
 Engine Electrical System

SERVICE DATA AND SPECIFICATIONS

Non California models

California models For Canada
except for Canada

BP6ES ll BP6ES
Standard BPR6ES
L45PW ll L45PW

BP4E ll BP5ES ll BP4E BP5ES BPR4ES

Type Hot type
L46PW ll L47PW ll L46PW L47PW BPR5ES

BP7ES ll BP7ES
Cold type BPR7ES
LMPW ll LMPW

10 to l 0 8 to 0 9 0 8 to 0 9
Plug gap mm in 0 039 to 0 043 0 031 to D35
0 0 031 to 0 035

Tightening torque kg m ft Ib
I 5 to 2
1 11
0 to 14

TROUBLE DIAGNOSES AND CORRECTIONS

Note On California models discon

When engine does not start spark plug starting engine and ob nect anti solenoid
dieseling valve
If there is in fuel
no problem serving condition of spark that occurs connector to cut off supply of fuel
system ignition system should be between high tension wire and spark to and then observe
engine the
checked This can be easily done by plug terminal After checking this condition of spaIks while starter
detaching a high tension wire from
repair as necessary motor is in operation

Condition Location Probable cause Corrective action

No spark at all Distributor Faulty insulation of condenser Non Cali Replace

fomia models

Breakage of lead wire on low tension side Repair

Poor insulation of cap and rotor head Replace
Seized points Non California models Repair

Open pick up coil California models Replace

Air wider than specification Cali
gap Adjust
fornia models

Ignition coil Wire breakage or short circuit of coil Replace with new one

High tension wire Wire coming off Repair

Faulty insulation Replace

Transistor ignition Faulty transistor ignition unit Replace
unit California

models

4B
EE
 Engine Electrical System

Location Probable cause Corrective action

Condition

Distributor Point gap too wide California

Non mo Correct
Spark length
dels
I to 2 rnm 0 039

to 0 079 in Of Oil on point California

Non models Clean

irregular Burned points Non California models Replace

More than 6 rnm Spark plugs Spark plug gap too wide Correct or replace
0 236 in Too much carbon Clean or replace

Broken neck of insulator Replace

Expiration of plug life Replace

Distributor Air gap too wide California models Correct

Transistor ignition Faulty transistor ignition unit Replace

unit California

models

2 Engine rotates but does not run system or other engine condi Hons not complete inspection of ignition system
related to ignition Therefore first a should be carried out
smoothly
This may be caused by the ignition

Condition Location Probable cause Corrective ac ion

misses Distributor Dirty point Non California models Clean

Engine
mattef on pick up coil California Clean
Foreign
models

Non California Correct

Improper point gap mo

dels

Impropef air gap California models Correct

Leak of electricity at cap and rotor head Repair or replace

Damaged insulation of condenser Non Replace

California models

Malfunctioning contact arm Non Cali Oil shaft

fornia models

contact arm spring Non Cali Replace

Faulty
fornia models

Breakage of lead wire Non California Replace

models

Breakage of pick up coil lead wire Cali Replace

fornia models

Worn or shaky breaker plate Replace assembly

Worn or shaky distributor driving shaft Replace assembly

inferior quality Replace with good one

Ignition coil Layer short circuit or

coil

High tension wire Deterioration of insulation with con Replace

sequent leak of electricity

49
EE
 Engine Electrical System

Condition Location Probable cause

Corrective action

Spark plugs Fouled Clean

Leak of electricity at
upper porcelain Repair or replace
insulator

Transistor ignition Faulty transistor ignition unit

Replace
unit California

models

Engine causes Distributor Improper ignition timing too advanced Correct

knocking very off
often Coming or breakage of governor Correct or replace
spring
Worn pin or hole of governor Replace

Spark plugs Burnt too much

Replace

Engine does not Distributor Improper ignition timing too retarded Correct
deliver enough
Improper functioning governor Replace assembly
power
Point gap too narrow Non California Correct
models

Foreign particles stuck in air gap Cali Oean

fornia models

Spark plugs Fouled Oean

EE 50
 SECTION ER

ENGINE
DATSUN PICK UP REMOVAL
MODEL 620 SERIES INSTALLATION

ENGINE REMOVAL AND

ER 2
INSTALLATION
I NISSANJ

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Engine Removal Installation

ENGINE REMOVAL AND INSTAllATION

CONTENTS

REMOVAL ER 2 FRONT INSULATOR 4

ER
INSTALLATION ER 3 REAR INSULATOR 4
ER
ENGINE MOUNTING INSULATORS ER 3 TIGHTENING TORQUE 4
ER

REMOVAL Disconnect air deaner to A B valve

hose
It is much easier to engine remove
Disconnect air cleaner ta vacuum
and transmission single unit than
as a
hoses
to remove them separately After re

moval engine can be separated from

Note Protect carburetor from dust
transntission assembly
and foreign matter by placing cover

over air inlet opening

Notes

a Be sure to hoist engine and jack Fig ER l

up
transmission in a safe manner

b Use fender Automatic transmission models

to
cove protect vehicle
I Disconnect selector range lever
body
from manual shaft
1 Remove battery 9 Disconnect fuel 2 Disconnect wires at inhibitor
pump to fuel
2 Scribe hood hinge location for fdter hose and return hose switch and down shift solenoid
reinstallation and remove 10 Disconnect carbon canister hose 14 Air conditioner
proper equipped
hood on engine side models need following procedures
II Disconnect air pump air 1 After removing flexible hose
Note Have an assistant help you so as C1eaner to al p p hose remove
support four comi
ressor se
to prevent damage to body 12 Disconnect following cables curing bolts Then move the com

wires and hoses pressor to battery support

3 Drain radiator coolant 2 Remove
Engine ground cable vacuum hoses of
4 Disconnect and lower F LC D solenoid valve
upper Accelerator wire at carburetor
radiator hoses from engine High tension cable between 3 Remove F LC D actuator
ignition
5 Remove two oil cooler hoses coil and distributor 15 Remove two bolts securing
from lower end of radiator Auto Wire distributor at
to body ter clutch operating cylinder Then dis
matic transmission models only minal connect operating cylinder and flexi
6 Remove radiator shroud Wire to oil pressure switch ble tube
as an assembly Manual
7 Remove four bolts securing radia Wires to thermal transmitter transmission models only
tor and detach radiator Wires to B C p D cut solenoid 16 Disconnect front exhaust tube
Non California models only from exhaust manifold
Note Always tighten securing bolt at autochoke heater and anti
dieseling 17 Remove propeller shaft
upper right hand side together with solenoid I Disconnect shaft
propeller
body harness terminal Wires to alternator
center bearing bracket from third
Wires to starter motor crossmember
Heater inlet and outlet hoses if so 2 Disconnect propeller shaft from
8 Remove carburetor air cleaner as equipped companion flange of differential
follows Vacuum hose of Master Vac at in carrier
Remove fresh air duct taJce manifold
3 Remove propeller shaft from
Remove hot air duct Wires for back up lamp switch transmission and plug up rear end of
Loosen air cleaner band bolt and air Cable to speedometer
extension housing of transmission to
cleaner supporting bolts 13 Remove transmission control
prevent oil leakage
Disconnect air cleaner ta air pump linkage from transmission
18 Attach a suitable wire or chain
hose Manual transmission models
to lift engine
Disconnect air cleaner to rocker I Detach rubber boot
19 Remove front engine mounting
cover hose at rocker cover 2 Remove E ring and control lever
bolts at engine mounting front sup
Disconnect air cleaner to air control pin from transmission striking rod
port
valve hose California models only guide and remove control lever

ER 2
 Engine Removal Installation

ER207

Fig ER 2 Removing front engine

mounting bolts

20 Place a jack under transmission

and jack it up
21 Loosen two rear engine mount
E R367

ing bolts CD
Loosen two exhaust tube Fig ER 5 Lifting engine
22 hanger
bolts V California models only
23 Remove four bolts CID securing

engine mounting rear support to side INSTALLATION

member and detach rear
support Install engine with transmission in engine mounting support to body
reverse order of removal observing the 2 Refer to applicable section when
jr
O
following installing and adjusting any parts
I When installing first secure rear

ER271

Fig ER 3 Removing rear engine

mounting support

24 Remove steering idler arm secur

Front
ing bolts and push down cross rod

1 Bracket RH
2 Insulator R H @
3 Bracket LH
4 Heat shield plate
5 Insulator L H

6 Rear support
iC 7 Rear insulator
E A279
8 Exhaust tube hanger
California models only Fig ER 6 Structual view of engine mounting
EA278

Fig ER 4 Removing idler arm

25 Pull engine towards front as far ENGINE MOUNTING

as possible and carefully raise if and
INSULATORS
transmission with a hoist and cable
Three insulators are used to mount Replace any insulator that shows

Note In this r
an care should the engine and transmission two are signs of separation or deterioration

always be taken not to allow the located at the left and right of the Be sure to keep insulator free from
hit cylinder block and at the transmis oil or
unit to against any adjacent one grease
sion rear extension housing
parts

ER 3
 Engine Removal Installation

FRONT INSULATOR 7 To install reverse order of re and jack it up slightly

moval 2 Loosen two rear engine mounting
Removal and installation bolts
3 Loosen two exhaust tube hanger
1 Disconnect battery ground cable
bolts California models only
2 Remove hood
4 Remove rear mounting insulator
3 with wire REAR INSULATOR
Suspend engine or
at transmission rear extension after
chain
Ramoval and Installation removing insulator securing bolts
4 Loosen front engine mounting 5 To install reverse order of Ie
insulator upper nuts both sides
1 Place a jack under transmission moval
5 little with
Carefully raise engine a

a hoist and cable

6 Remove front
mounting insula
tors at frontsupports after removing
front mounting bolts

TIGHTENING TORQUE

Fixing bolts and nuts

Front mounting bracket to cylinder block kg m ft lb 2 6 to 3 6 19 to 26

Front mounting in lator to brac t kg m ft Ib 2 6 to 3 6 19 to 76

Front mounting insulator to front support kg m ft lb 14 to 18 10 to 13

Rear insulator to transmission

mounting kg m ft lb 3 2 to 3 7 23 to 27

Rear mounting insulator to rear ft Ib 16 to 2 2 to 16

support kg m 12
Rear support to frame kg m ft lb 3 2 to 3 23 to 31
4

Clutch operating cylinder to transmission kg m ft Io 2 5 to 3 5 18 to 25

Exhaust front tube to exhaust manifold kg m ft lb 19 to 2 5 14 to 18

Center bearing bracket to crossrnember kg m ft lb 16 to 2 2 12 to 16

Propeller shaft to companion flange kg m ft lb 2 4 to 3 17 to 24

4
ER
 SECTION CL

CLUTCH
DATSUN PICK UP
MODEL 620 SERIES

CLUTCH CL 2

CLUTCH CONTROL CL 5

SERVICE DATA AND

CL 9
SPECIFICATIONS
TROUBLE DIAGNOSES AND
CLIO
CORRECTIONS

LNISSAN I SPECIAL SERVICE TOOL CL12

NISSAN MOTOR CO LTD

TOKYO JAPAN
 CLUTCH

CLUTCH

CONTENTS

CL 2 DISASSEMBLY AND ASSEMBLY CL 3

DESCRIPTION
Cl2 D isassemb I y Cl3
REMOVAL AND INSTAllATION
CL 2 Assembly CL 3
Removal
CL 3 INSPECTION CL 4
Installation

thrust rings clutch

diaphragm spring It consists of phragm spring
DESCRIPTION using a
and clutch release bearing
the clutch disc pressure plate dia cover I

The clutch is a single dry disc type

e
M
0

s 8 62
o
2 44
8
dia
6
I
l150 5 91 dia
225 8 86 dia 260 10 2 dia
o
CL231
C

Unit mm in

Fig CL l Construction of clutch disc and COller assembly

portant to support weight of clutch

REMOVAL AND disc during further steps See Figure
I NSTALLATIO
CL 2
3 Loosen six screws attaching
Removal clutch cover to flywheel one turn at a
is re
from time each un til spring pressure
1 Remove transmission ve

leased Be sure to turn them out in a

hicle
crisscross fashion
For details oftransmission removal
refer to Transmission Section
Note Exercise special care to avoid
2 Insert Clutch Aligning Bar
or on getting on clutch
KV30100200 into clutch disc hub grease
clutch assembly
It is im linings Fig CL 2 Supporting
until it will no longer go

CL2
 CLUTCH

Installation disassembled since diaphragm spring is

securely reveted to clutch cover and
I Apply a light coat of lithium base
clutch cover assembly is balanced
grease containing molybdenum disul
If necessary replace clutch cover
phide on transmission main drive gear

splines assembly as a complete unit

2 Remove clutch release mechanism
Slide clutch disc on main drive gear
several times Remove clutch disc and as follows See Figure CL4
Remove dust from clutch
wipe off excess lubricant pushed off 1 cover

by disc hub houisng CLOSS

clutch 2 Remove withdrawal lever from

2 Install clutch disc and Fig CL 6 Removing pilot bu hing

assembly clutch housing

cover on flywheel Support
two assemblies with Clutch Aligning 3 Remove retainer spring from Asse bly
Bar KV30100200 See Figure CL 3 withdrawal lever
4 Release mechaniam
Remove release bearing bearing
Note Be keep disc facings
sure to sleeve and holder spring from clu tch 1 When assembling release
and
bearing
flywheel pressure plate clean housing as an assembly sleeve
on use a press and seat bearing
and dry 1 squarely on sleeve See Figure CL 7

00
l J
lo
I
7
R
1 Release bearing
I
2 Release

sleeve
bearing
1
3 Holder spring J
rr CL109
4
5

6
Dust cover

Withdrawal

Retainer
lever
spring CL119
Fig CL 7 1
1
tailing
CL215

e bearing
rele
Fig CL 3 l talling clutch cover

assem bly Fig CL4 Exploded view ofclutch 2 Before or during assembling lu
releaae mechaniam
bricate the following points with a
3 Install six bolts to tighten clutch
light coat of multi purpose grease
cover assembly to flywheel squarely 3 Take clutch release
Each bolt should be
out bearing
tightened one
from bearing sleeve using a universal I
turn at a time to the specified torque Inner groove of release bearing
puller See Figure CL 5 sleeve See Figure 8
CL
15 to 2 2 kg m II to 16 ft Ib

Note Three dowels are used to locate

clutch cover on
flywheel properly
4 Remove Clutch Aligning Bar

KV30100200 after the

Lf
tightening
bolts securely
5 Install transmission

Note Make certain that withdrawal

lever engages lever ball pin
I

Connect n
6 push rod of clutch op
erating cylinder to withdrawal lever

Fig CL 5 D embling
b
C L014

e
rele
JQt CL216

aring Fig CL B Lu bricating ee of

DISASSEMBLY AND bearing slee

ASSEMBLY
4 Remove pilot bushing in crank 2 Contact surfaces of withdrawal
shaft by Pilot Bushing Puller lever lever ball pin and bearing sleeve
Disassembly ST16610001 if necessary See Figure 3 Contact surfaces of transmission
I Clutch cover assembly can not be 6
CL front cover See Figure CL 9

CL3
 CLUTCH

I If facings are oily the disc should If excessive wear is found replace
be replaced In this case inspect trans clutch cover as an assembly

lt
mission front cover oil seal pilot 2 Measure the height of diaphragm
bushing engine rear oil seals and other spring as outlined below See Figure
points for oil leakage CL 12
tJ I

The disc should also be

P 2 replaced
a Place Distance Piece ST20050100
o
when facings are worn locally or worn
0 mm 0 0118 in at on Base Plate ST20050010 and
CUll down less than 3
then clutch assembly
revels See Figure CL IO tighten cover

Fig CL 9 Lubricating poinu of on the base plate by using Set Bolls

withdrawal lever and
ST20050051
front cover
I
l
DePth b Measure spring toe
4 Contact surfaces of transmission
diaphragm
gauge II
main drive gear splines lithium base 1 i h height A at several points with a
1 vernier caliper depth gauge
grease including molybdenum disul j1 t

f
phide Above 0 3 rom STl0050100
10 012 in
Note Very IIIIJllII amount of grease
I Tl 05001O
should

points
be
If too much
ated to the above
iubricant is
rJrf
f
applied
friction
in d
it will

plates
run

when hot
dutch disc
out on

resulting
the

Fig CL I0 JIuringclutch
Me
CL089

lining C L23
7
STl005Q051
gi facings
Fig CL 12 uring the height of
Me
3 Install retainer spring to with 3 Check disc plate for runout when
diaphragm pring
drawal lever Fit holder the old disc a is
spring to ever or new one

release bearing and sleeve assembly installed

then assemble withdrawal Iever and If runoutexceeds the If the height of spring end is
4 specified A
bearing sleeve as a unit Install this value at the outer circumference Ie beyond the specified value of 33 to 35
123 to 1
38 in
assembly on transmission case Then place or repair disc See Figure CLII mm adjust the spring
with
install dust cover
Runou t height Diaphragm Adjusting
Wrench ST20050240 See Figure
Pilot bushing 5
0 mm 0020 in
CL 13
total indicator reading
Before
installing a new bushing If necessary replace clutch cover as
R from the hub center
thoroughly clean bushing hole Install 5
107 mm 4 23 in
an assembly Also unevenness of dia
bushing in crankshaft using a soft phragm spring toe height should be
hammer Bushing need not be oiled less than 05 mm 0 020 in

ST20050240
INSPECTION
Wash all the disassembled parts

except release bearing and disc assem

bly in suitable cleaning solvent to
remove dirt and grease before making
and
inspection adjustment
CL112

Flywheel and pressure plate Fig CL ll MeOlUring disc runout

Check friction surface of flywheel 5 Check the fit of disc hub on
CL152
and pressure plate for scoring or transmission main drive gear for
Fig CL 13 AdjlUting the spring height
roughness Slight roughness may be smoothly sliding If splines are worn

smoothed by using fme emery cloth clutch disc or main drive gear should
3 Inspect thrust rings for wear or
If surface is deeply scored or groov be replaced that is backlash exceeds
damage As these parts invisible are

ed the part should be replaced 04 mm 0 016 in at the outer edge of from outside shake cover assembly up
clutch disc and down to listen for chattering
Clutch disc llembly
at
noise or lightly hammer on rivets for a
Clutch cover
Inspect clutch disc for worn or oily assembly slightly cracked noise Any of these
facings loose rivets and broken or I Check the end surface of dia noises mean requirement for replace
loose torsional springs phragm spring for wear ment as a complete assembly

4
CL
 CLUTCH

Pilot When bushing is faulty be sure to

Release bearing and sleeve bushing
in crankshaft check transmission main drive gear at
Check for abnormal wear on con Check pilot bushing
the same time
roughness If necessary
tact surface of withdrawal lever ball for wear or

it
pin and bearing sleeve replace

CLUTCH CONTROL

CONTENTS

DESCRIPTION CL 5 Inspection CL B

CLUTCH PEDAL CL 6 OPERATING CYLINDER CL B

CL 6 Removal and installation CL B
Removal and installation

I nspection and adjustment CL 6 Disassembly and assembly CL B

CLUTCH MASTER CYLINDER CL 7 Inspection CL B

Removal and installation CL 7 BLEEDING CLUTCH SYSTEM CL B

Disassembly and assembly CL 7

forwards clutch fluid to the operating adjustable type that uses no return
DESCRIPTION unit the withdrawal to
The cylinder via a pipe line The movement spring In this
hydraulic clutch control con is
sists of a pendent pedal a master
of the operating cylinder piston push rod play adjustment is not neces
transmitted to the withdrawal lever sary since the 8 as shown in Figure
cylinder an operating cylinder and a CL 15 serves automatically compen
through the push rod thus disengaging to
withdrawal lever
the clutch sate for wear on the clutch disc
When the clutch pedal isdepressed
the master cylinder
The operating cylinder is a non
piston of the

l 5

1 Clu tch pedal 6 Push rod

7 Withdrawal lever
2 Return spring
Clutch master cylinder 8 Release bearing
3
4 Clutch piping 9 Clutch cover Cl305

10 Clutch disc
5 Operating cylinder
Fig CL14 Clutch operating system

CL 5
 CLtJTCH

Stroke 30 mm

18
1 in
I
i
Jt
Sj 1

Fig CL 15
J
i
Non adj table operating
o

cylinder
1 Lock nut A
2 Lock nut 8
CLUTCH PEDAL
Pedal beiBht a 53 mm 6 02 in
Removal and Pedal full stroke b 117 10 23 4 6 104 84 in

installation
Removal See Figure CL 16
@ Multipurpose grease

1 Pry off cotter pin and take out

clevis pin disconnect push rod from CL102

pedal assembly Fig CL 17 Adju ting pedal height

2 Unhook return spring Loosen off
fulcrum pin and remove pedal as
Note Refer to Figure Clot8 for the 1 Adjust the
pedal height to 153
sembly
correct direction of return spring mm 6 02 in by adjusting pedal stop

CfJ 6
3 per and tighten lock nut A to the

W5
specified torque 0 8 to 12 kg 5 8
ch m

fD to 8 7 ft lb

ij ll 2 Turn in or out push rod adjusting

1 aevis pin
screw until a play of I to 3 mm 0 039
2 Cotter pin
to 0 118 in at clevis pin is obtained
3 Return spring
4 Pedal boss Then tighten lock nut B to the
S Pedal assembly
A
i specified torque 0 8 to 12 kg m 5 8
6 Bush to 8 7ft Ib
7 Nut
8 Push rod 1 Pedal assembly
9 Fulcrum pin 2 Push rod
Fig CL 16 Exploded view of clutch 3 Return spring
eL116
pedal
Note Before removing clutch pedal Fig CL 1B Hooking return Note Exercise in
pring care adjusting the
note toe board clearance at pedal play not to block the port or
pad master cylinder A blocked port
may result if too small play at clevis
Installation pin exists
To install the
reverse order of
3 After adjusting check the pedal
removal multi purpose grease
Apply full stroke is in 117 to 123 mm 4 61
to the friction surfaces of the disas

sembled parts as shown in

Inspection and to 4 84 in
Figure
CL 17 adjustment
Tightening torque Clean all the following parts in
Pedal installation bolt cleaning solvent and check for wear
Note Depress and release clutch
Fulcrum pin damage or any other abnormal condi
19 to tion pedal over its entire stroke to en
4
2 kg m Replace the parts which are
sure that the clutch
linkage op
14 to 17 ft Ib faulty
1 Return spring
erates smoothly without squeak
Lock nuts A and B
noise interference and binding
0 8 to 12 2 Bush
kg m
3 Pedal boss etc
5 8 to 8 7 ft lb

CL 6
 CLUTCH

CLUTCH CYLINDER cylinder to the vehicle and dismount 2 Bleed air out of hydraulic system
master cylinder
MASTER Tightening torque
Note Remove dust cover from master Master cylinder to dash panel
Removal and cylinder body on the side of driv 0 8 to 1 2 kg m
er s seat 5 8 to 8 7 ft lb
installation
Installation Clutch tube connector Flare nut

Removal 5 to 1 8
1
install kg m
To reverse the order of
II to 13 ft lb
I Remove clcvis pin at push rod removal observe the
Closely following
2 Disconnect clutch tube from instructions 3 Flare Nut
Using Torque Wrench
master cylinder and drain clutch fluid 1 Adjust pedal height by changing GG94310000 tighten each connector
3 Remove bolts master
securing pedal stopper length to the specified torque

Disassembly and assembly

1 Reservoir cap
2 Reservoir
3 Reservoir band
4 Cylinder body
5 Supply valve stopper
6 Return spring
7 Spring seat
8 Valve spring
9 Supply valve rod
10 Supply valve
11 Primary cup
12 Piston
13 Push rod
14 Secondary cup
15 Stopper
16 Stopper ring
17 DU5t cover

18 Lock nut

CL265

Fig CL 19 Exploded view of maater cylinder

Disassembly Assembly Note The clutch master cylinder is

1 Remove dust cover and remove To assemble reverse the order of available in both NABCO make and
TOKICO make There is inter
stopper ring from body disassembly Closely observe the fol no

2 Remove rod and piston of kits com

push as
lowing instructions changeability repair or

sembly between NABCO and

ponent parts
I
3 Take off piston cups Dip piston cup in brake fluid TOKlCO makes
before installing Make sure that it is
4 Remove spiing seat from piston the kit
When replacing repair or

and take off supply valve if necessary correctly faced in position ascertain the
component parts
2 Apply a coating of brake fluid to
See Figure CL 19 brand of the clutch IIIBSter cylinder
cylinder and piston when assembling
body Be sure to use parts of the
Note Discard piston cup supply 3 Press piston into spring seat when
same make as the former ones
valve and spring seat after removal assembling

CL 7
 CLUTCH

Inspection Disassembly and damaged too badly beyond speci

fications
Note To cleanor wash all parts of
assembly
master cylinder operating cylinder
and piping clean brake fluid must Disassembly
be used Never use minera10ils llUch
1 Remove rod with dust
push
and kerosene It will
as gasoline cover BLEEDING CLUTCH
ruin the rubber parts of the hydrau 2 Remove piston assembly and pis SYSTEM
lic system ton spring
I Check cylinder and piston for 3 Remove bleeder screw The hydraulic clutch system must

uneven wear or damage and if neces be bled whenever clutch line has been
disconnected or air has entered it
sary replace
If the clearance between When pedal action has a spongy
2 cylinder
and is than 15
0 feeling it is an indication that air has
piston more mm

0 0059 in replace cylinder entered the system

3 Renew piston cup when dis Bleeding clutch system is an es

assembled It must also be sential part of regular clutch service

1
replaced 6
when wear or deformation due to I Remove reservoir cap and top up
fatigue or damage is found with recommended brake fluid
Cl11B
4 Damaged dust cover oil reservoir
1 Push rod 5
2 Thoroughly clean mud and dust
Piston cup
or capshould be replaced of operating cyl
2 Dust cover 6 Operating cylinder from bleeder screw
Return spring and valve spring must 3 Piston spring 7 Bleeder screw inder so that outlet hole is free from
also be replaced when they are broken 4 Piston
any foreign rnaterial Install bleeder
or weak Fig CL 20 Exploded view of
hose vinyl hose on bleeder screw
5 clutch hose and tube if operating cyUnder
Replace Place the other end of it in a clean
any abnormal sign of damage or de
container
fro ti is found
n
Assembly 3 Have a co worker depress clutch
Assemble in the order of pedal two three times With clutch
OPERATING reverse
or

loosen bleeder
disassembly Closely observe the fol pedal depressed fully
CYLINDER to bleed air out of clutch sys
lowing instructions screw

tern
Removal and 1 Prior to assembly dip piston cup
in clean brake fluid
4 Close bleeder screw quickly as
installation clutch is on down stroke
When particular pedal
installing cup pay
Allow clutch
Removal attention to its direction
5 pedal to return

slowly with bleeder screw closed

1 Detach clutch hose from operat 2 Dip cylinder and piston in clean
5 until no air
6 Repeat steps 4 and
ing cylinder brake fluid before assembly
bubble shows in the vinyl hose
2 Remove two bolts securing op
7 Operate clutch several times
to clutch Notes
erating cylinder housing
Be sure to install then check connections for external
a piston assembly
hydraulic leaks
Installation with piston spring place in

b The clutch operating cylinder is Notes

Install in the reverse order of re
available in both NABCO make and a Brake fluid containing air is white
moval
TOKICO make There is no inter and has visible air bubbles
Observe the following instructions
changeability of repair kits or com b Brake fluid containing no air runs

Bleed air thoroughly from clutch ponent parts between NABCO and out of bleeder screw in a solid
hydraulic system TOKICO makes stream without air bubble
2 Do not install return When replacing the repair kit
Pay close attention to clutch fluid
or
spring or c
clutch will be component parts ascertain the
not disengaged level in reservoir during bleeding
properly brand of the clutch operating cyl operation
inder bndy Be sure to use parts of d Do not brake fluid drained
Tightening torque reuse
the same make as the former ones
during bleeding operation
Operating cylinder securing bolt Exercise care not to splash brake
e
5 to 3
2 5 kg m 18 to 25 ft lb
fluid on exterior fInish as it will
Bleeder screw

0 7 to 09 m 5 1 to
kg 5 ft Ib
6
Inspection damage the paint
Visually inspect all disassembled f Pour brake fluid into reservoir up
Clutch hose connector
to specifIed level
parts replacing those found worn or
17 to 2 0 kg m 12 to 14 ft b

rl Q
 CLUTCH

SERVICE DATA AND SPECIFICATIONS

Clutch cover

Clu tch cover type Diaphragm C225S

distance in 33 to 35 1 23 to 1
38
Diaphragm spring to flywheel mm

Unevenness of diaphragm spring toe height mm in less than 0 5 0 020

Full load kg Qb 400 882

Out of flatness of pressure in 0 1 0 004

plate mm

Allowable limit of pressure in 1 0 0 040

refacing plate mm

Clutch disc

Facing size

Outer dia x inside dia x thickness mm in 225 x 150 x 3 5 8 86 x 5 91 x 0 138

Thickness of disc assembly

Free mm in 8 3 to 8 9 327
0 to 0 350

Compressed mm in 7 6 to 8 0 0 299 to 0 315

Number of torsion springs 6

Allowable minimum of
depth mm in 3
0 0 012
rivet head from surface

Allowable in 5
0 0 020
facing run out mm

Allowable free play of spline

mm in 4 0 016
0
at the outer edge of disc
Clutch pedal

Pedal height mm in 153 6 02

Play at clevis pin mm in I to 3 0 039 to 0 118

Full stroke mm in 117 to 123 4 61 to 4 84

Clutch master cylinder

Dia of master cylinder mm in 15 87 5 8

Allowable maximum clearance between
mm in 0 15 0 0059
cylinder and piston
Clutch operating cylinder
Dia of operating cylinder mm in 19 05 Yo

Tightening torque
Clutch assembly to flywheel securing bolt kg m ft lb 1 5 to 2 2 lito 16

Pedal installation bolt Fulcrum pin ft Ib

kg m 19 to 2 4 14 to 17

Pedal stopper lock nut ft b

kg m 0 8 to 1 2 5 8 to 8 7

Push rod lock nut ft lb 0 8 to 12 5 8 to 8 7

kg m
Master cylinder to dash panel securing bolt kg m ftIb 0 8 to 12 5 8 to 8 7

Clutch tube connector Flare nut ft lb 1 5 to 18 11 to 13

kg m

Clutch hose connector ftlb

kg m 17 to 2 0 12 to 14

Operating cylinder to clutch housing securing

bolt kg m ft lb 5 to
2 5 18 to 25
3

Bleeder screw
kg m ft Ib 0 7 to 0 9 5 1 to 6 5

CL 9
 CLUTCH

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause and testing Corrective action

Clutch slips Slipping of the clutch may be noticeable when any of the following symptoms is encountered
during operation
I Vehicle will not respond to engine speed during acceleration
2 Insufficient vehicle speed
3 Lack of power during uphill driving

Some of the above conditions are also experienced when engine problem is oc urring First
detennine whether engine or clutch is causing the problem
If slipping clutch is left unheeded wear and or overheating will occur on clutch facing until it is
no longer serviceable
TO TEST FOR SLIPPING CLlJfCH proceed as follows
During upgrade travelling engine run at about 40 to 50 km h 25
to 31 MPH with
gear shift
lever in 3rd speed position shift into highest gear and at the same time rev up engine If clutch
is slipping vehicle will not readily respond to depression of accelerator pedal

Clutch facing worn excessively Replace

Oil or grease on clutch facing Replace
W r d clut h lace
cov r
pressure plat tpa o e

Clutch drags Dragging clutch is particularly noticeable when shifting gears especially into low gear

TO TEST FOR DRAGGING CLlJfCH proceed as follows

I Start engine Disengage clutch Shift into reverse gear and then into Neutral Gradually
increase engine speed and again shift into reverse gear If clutch is dragging gear grating
is heard when shifting from Neutral into Reverse

2 Stop engine and shift gear Conduct this test at each gear position

3 Gears are smoothly shifted in step 2 but drag when shifting to 1st speed position at

idling
a If dragging is encountered at the end of shifting check condition of synchro
mechanism in transmission
If dragging is encountered at the beginning of shifting 4 below
b proceed to step

4 Push change lever toward Reverse side depress pedal to check for free travel

a If pedal can be depressed further check clutch condition

b Ifpedal cannot be depressed further proceed to step 5 below

5 Check clutch control pedal height pedal free travel withdrawal lever play etc

If no abnonnal condition exists and if pedal cannot be depressed further check clutch
condition

Clutch disc runout or warped Repair or replace

Wear or rust on hub splines in clutch disc Clean and lubricate with grease or replace
Diaphragm spring toe height out of ad Adjust or replace
justment or toe tip worn

Worn or improperly installed parts Repair or replace

CL10
 CLUTCH

Probable cause and testing Corrective action

Condition

is rolled off with clutch partially

Clutch chatters Clutch chattering is usually noticeable when vchicle just
engaged
Weak or broken clutch disc torsion Replace
spring
Oil or grease on clutch facing Replace
Clutch facing out of proper contact or Replace
clutch disc runout

Loose rivets Replace

Warped pressure plate or clutch cover Repair or replace

surface

Unevenness of diaphragm spring toe Adjust or replace

height
Loose engine mounting or deteriorated Retighten or replace
rubber

A noise is heard after clutch is disengaged

Noisy clutch

Damaged release bearing

I Replace

A noise is heard when clutch is disengaged

Insufficient grease on the sliding surface Apply grease

of bearing sleeve

Clutch cover and bearing are not installed Adjust

correctly

A noise is heard when vehicle is suddei11y staited offwith clutch partially engaged

Replace
Damaged pilot bushing
I
off from standing start
Clutch grabs When grabbing of clutch occurs vehicle will not start smoothly a or

clutch is engaged before clutch pedal is fully depressed

Oil or grease on clutch facing Replace

Clutch facing worn or loose rivets Replace
Wear or rust on splines in drive shaft and Clean or replace
clutch disc

Warped flywheel or pressure plate Repair or replace

Loose mountings for engine or power Retighten
train units

CLll
 Ul CFf
Cl

SPECIAL SERVICE TOOLS

Tool number For Reference

No use page or
Description No
tool name on Figure
Unit mm in

ST20050010 620 Fig CL 12

B210
Base plate
00 710
610

y S30

2 ST20050051

Set bolt

SE002

q
3 ST20050 100

Distance
@
piece 7 8 mm

0 31 in

@1 @J SEOQ3

4 ST20050240 620 Fig CL 13

B210
Diaphragm
710
adjusting
wrench 610
S30

SE032

5 KV30100200 This tool is used to conduct disc centerilg by inserting the tool 620 Fig CL 2
into pilot bush in flywheel when installing clutch assembly to 710
Clutch Fig CL 3
flywheel 610
aligning bar
S30

SEaOl

6 STl6610001 620 Fig 6

CL

Pilot bushing 710

610
puller
S30

SE191

CL 12
 CLUTCH

For Reference
Tool number use page or

No Description
on Figure No
tool name Unit mm in

All Page CL 7
7 GG94310000 This tool is used to tighten and loosen brake and clutch tube flare
models
torque limiting wrench is provided to
assure torque
nut A built in
Flare nut
accuracy
torque wrench

y SE227

CL 13
 SECTION MT

MANUAL
DATSUN PICK UP TRANSMISSION
MODEL 620 SERIES

SPEEo
4 TRANSMISSION
MT 2
TYPE F4W71 B

5 SPEED TRANSMISSION
MT 14
TYPE FS5W71 B

SERVICE DATA AND

MT 21
SPECIFICATIONS

TROUBLE DIAGNOSES AND

MT 23
toRRECTloNS

I NIS SPECIAL SERVICE TOOLS MT 24

J
NISSAN MOTOR CO LTD
TOKYO JAPAN
 Manual Transmission

4 SPEED TRANSMISSION TYPE F4W71B

CONTENTS

DESCRIPTION MT 2 GEARS AND SHAFTS MT 8

REMOVAL BAULK RING
MT 4 MT 9
DISASSEMBL Y MT 4 Oil SEAL
MT 9
TRANSMISSION CASE DISASSEMBLY MT 4 ASSEMBL Y MT 9
D ISASSEMBL Y OF GEAR ASSEMBLY FRONT COVER ASSEMBLY
MT 5 MT 9
REAR EXTENSION DISASSEMBLY REAR
MT B EXTENSION ASSEMBLY MT 9
ADAPTER PLATE DISASSEMBLY ADAPTER
MT 8 PLATE ASSEMBLY MT 9
INSPECTION MT 8 GEAR ASSEMBLY MT 9
TRANSMISSION CASE AND TRANSMISSION ASSEMBLY MT13
REAR EXTENSION HOUSING MT B INSTALLATION MT14
BEARING MT 8

DESCRIPTION
The transmission is of a 4 speed pUshed the inner teeth of the coupling The transmission assembly consists
forward fully synchronized constant sleeve slide over the synchronizer hub of three main parts a transmission
mesh type that uses helical gears and mesh with the outer teeth which case with clutch housing adapter plate
The reverse gear is ofa sliding mesh are provided on the mainshaft gear to which an gears and shafts are

type using spur gears The synchronizer hub is fitted to installed and rear extension

In construction the main drive gear the mainshaft by splines so the main The cast iron adapter plate supports
is meshed with the counter drive gear shaft gear turns together with the the mainshaft countershaft reverse

which is keyed to the countershaft mainshaft idler shaft and three fork rods and
The forward speed gears on the coun The baulk ring serves to synchro bolted at the front to the transmission
tershaft are in constant mesh with the nile the coupling sleeve and mainshaft case and at the rear to the rear

mainshaft gears which ride on the gear extension by means of through bolts
mainshaft freely through the needle Placing the control lever in reverse By removing these bolthroughts all
When is position brings the idler gear
bearing shifting accom reverse gears and shafts are stripped
into mesh with mainshaft reverse gear

TM 858

1 Front cover

2 Transmission case

3 Adapter plate
4 Bearing retainer
5 Rear extension hOUsing

Fig MT 1 F4W71B lrammiasion case compon nt

MT 2
 Manual Transmission

o
cCl

1 Main drive gear

2 Baulk ring
3 Synchronizer hub 3 r d 4th

4 Shifting insert spnng

5 Shifting insert
6 Coupling sleeve
7 3rd main gear
8 Mainshaft
9 2nd main gear
10 1st main gear
11 ht gear spacer

12 Reverse main gear

13 Counter drive gear

14 Countershaft
15 Reverse counter gear

16 Reverse idler shaft

TM857 Reverse idler gear
17

Fig MT 2 F4W71B transmlsBIO n gear component

@
4
@ 1 Striking lever
fl 2 Lock pin
3 Oring
4 Striking guide
5 Oil sea1
6 Striking rod
E ring

t
7
8 Stopper guide pm
@ 9 Return spring plunger

10 Return spring
11 Reverse check spnng
12 Return spring plug
13 Check ball plug
14 Check spring
15 Check baD
16 Interlock ball
o
17 Retaining pin
18 1st 2nd shift ork

19 ht 2nd fork rod

f1f@ 20

21
22
23
3rd
Reverse

3rd
4th fork rod
fork rod
4th shift fork

Reverse shift fork

24 Con trollever
25 Control lever b shmg
n
26 Control lever p n

27 Control lever bushmg

@

TM045A

Fig MT 3 F4W71 B transmuswn shift controI components

3
MT
 Manual Transmission

REMOVAL 9 Remove bracket holding center

bearing on 3rd crossmember by

In dismounting transmission from
follows loosening off attaching bolts See
the vehicle proceed as

Figure 6
MT
I Disconnect battery ground cable

from terminal
2 Place transmission control lever in
neutIal position
3 Remove E ring and control lever
pin from transmission striking rod
guide and remove control lever See
E A277
Figure 4
MT
Fig 8
MT Removing engine mounting
rear support

15 Remove starter motor

PD219 16 Remove bolt securing transmis
sion to engine
Fig MT 6 Removing center balring
holding brucket After removing these bolts support
the engine and transmission with jacks
10 propeller shaft from
Uetach and then slide tra ion rearward

companion flange of gear carrier by away from engine and remove from

removing four bolts See Figure MT 7 the vehicle

TM335
Note Take care in dismounting trona
Fig MT 4 Remouing controllelJ Not
r

a Remove propeller shaft

carefully so mission not to strike any adjacent
as not to damage spline sleeve yoke parts and main drive shaft
and rear oil seal
4 Jack up the vehicle and support
b Plug up the opening in the rear of
its weight on safety stands Use a DISASSEMBLY
rear exteDSion housing to prevent
hydraulic hoist or open pit if avail
oil from out
able flowing
TRANSMISSION CASE
Confirm that safety is insured DISASSEMBLY
5 Disconnect exhaust front tube
wires from
I Prior to disassembling transmis
6 Disconnect reverse
sion thoroughly wipe off dirt and
lamp switch See Figure MT 5
cable grease from it
7 Disconnect speedometer 2 Drain oil thoroughly
from rear extension housing See
3 Remove dust cover from trans
Figure MT 5
mission case
8 Remove clutch operating cylinder
Remove release bearing and with
from transmission case See Figure drawallever
MT5
4 Remove reverse lamp switch
P0220
5 Move gear to Neutral
6 Remove speedometer pinion and
Fig MT 7 Remouing four bolt
O pinion sleeve by taking off lock plate
m 6ecuring prop ller shtJft to
companion ltJnge 7 Remove E ring and stopper guide
J pin from rear end of ll extension
re
11 Support engine by locating a
MT 9
See Figure
jacft pan with a wooden
under oil
block used between oil pan and jack
12 Support transmission with a

@ transmissionjack
13 Remove exhaustpipe btacket
by unscrewing attaching bolts 2
California models only See Figure
8
MT
1 Speedometer cable
2 Reverse lamp switch 14 Remove rear engine mounting
3 Outch operating cylinder insulator securing bolts I and rear TM337

TM774 mounting member securing bolts 3 Fig MT 9 Removing triking rod

8
MT E ring and topper pin
Fig MT 5 Bottom view of car See Figure

4
MT
 Manual Transmission

8 Remove return spring plug return

spring reverse check spring and plung

er from rear extension See Figure
Fork rod
MT 10
ht 2nd

qJiiiiiI

TM341

Fig MT 13 Removing trammission

case Interlock
ball
13 SetSetting Plate Adapter
up
ST238 1000 I on adapter plate

TM338 With countershaft side up place the

above assembly in a vise See Figure
Fig MT 10 Removing return spring
plull MT 14

TM344

Fig MT 16 Layout o ch ck boll

9 Remove rear extension securing and interlock ball
bolts and turn the striking rod toward
left
Drive out rear extension backward
Gear assembly
by lightly tapping around it with a soft
hammer See Figure MT 11 I With gears doubly engaged draw
out countershaft front bearing using a
TM342

mbly suitable gear puller See Figure

Fig MT 14 Attaching l or

to special tool MT 17
2 Remove counter drive gear snap

ring
DISASSEMBLY OF GEAR
3 Draw out counter drive gear com

ASSEMBLY with main drive gear

plete assembly by
Fork rod means of a gear puller

When drawing out main drive gear

Drive out retaining pins from
assembly be careful not to drop pilot
each fork rod with Fork Rod Pin
TM339 needle bearing onto floor from the
Punch ST23540000 See Figure
Fig MT 11 Removing rear extension front end of mainshaft See Figure
MT 15
MT 18

10 Remove front cover securing

bolts and remove front cover S
Detach countershaft front bearing
shim
II Remove main drive bearing snap

ring with Expander See Figure MT 12

ST23540000
TM343

Fig MT 15 Drive out retaining pim

TM398

2 Remove three 3 check ball piugs Fig MT 17 Removing countershaft

and drive out fork rods from adapter front b aring

pia te by lightly tapping on the front

end

j Be careful not to lose three 3

check balls and four 4 interlock balls
See Figure MT 16

Note Each gear and shaft can be TM345

12 Separate transmission case from
detached from adapter plate with
adapter plate with a soft hammer See Fig MT 18 Removing count r drive

Figure MT 13 out removing each fork rod

gear and main drive gear

MT 5
 Manual Transmission

4 Remove snap ring and then thrust sembly together with countershaft by 2 Press out I st gear mainshaft bush

washer from mainshaft front end lightly tapping the rear end with a soft ing together with 2nd gear and 1 st
Draw out 3rd 4th synchronizer hammer while holding the front of 2nd speed synchronizer using Bearing

assembly and remove 3rd gear as mainshaft gear assembly by hand Puller STJ0031000 See Figure
Be careful not to drop off gear
sembly MT 2l
5 Release caulking on mainshaft shaft See Figure MT 20
nut and loosen it See Figure MT 19 Note When r
out bushing
h ft
hold by hand so as not to
drop it

IJ H

t I

TM346
TM347
Fig MT 19 Removing maimhaft nut
Fig MT 20 Driving out gear Cl embly
30031000
S1

6 Remove mainshaft nut thrust

washer and mainshaft reverse gear Mainshaft assembly

7 Remove snap ring from counter 1 Remove thrust washer steel ball
shaft rear end and remove reverse I st gear and needle Be careful
bearing TM049A

idler gear not to lose steel ball retaining thrust Fig MT 21 R moving lItgear
8 Draw out mainshaft gear as washer mtUlIIhaft bu hing

12

1 Pilot bearing

2 3rd 4th synchronizer

assembly
3 Baulk ring
4 3rd main gear
5 Needle bearing
6 Mainshaft
7 Needle bearing
8 2nd main gear
9 1st 2nd synchroni r

assembly
to Coupling sleeve
II Shifting insert
12 Shifting insert spring
13 Synchronizer hub
14 1st main gear
15 Needle bearing
16 1st gear bushing
17 Thrust weher
18 Maimhaft bearing
19 ReftllSe main gear
20 Thrust washer
21 Nut
22 Steel ball
23 Thrust washer
24 Snap ring

TM348

Fig MT 22 Explod d view of haft

main mbly

6
MT
 Manual Transmission

M in drlv g r Count r h ft mbl

1 Remove main drive gear snap ring Install Bearing Puller STJOO31000

and spacer on countershaft rear bearing press out

2 Remove main drive bearing with countershaft rear bearing through a

rod
Bearing Puller ST30031000 and a suit
able piess See Figure MT 23 See Figure MT 25

Note When pressing out bearing hold

1 Main drive bearing
2 Main drive gear shaft by hand so as not to drop
TM349
shaft onto floor
Fig MT 23 Removing main drive
bearing

III

cl iiiiiE l

1 Snap ring 3 Main drive bearing with snap ring

2 Spacer 4 Main drive gear

TM351

TM350
Fig MT 25 Removing countershaft
Fig MT 24 Exploded view of main drive gear bearing

q
e 1 f

@ @

1 Countershaft front bearing

shim
2 Countenhaft front bearing

j
3 Snap ring
4 Countenhaft drive gear
5 Woodruff key
6
1
Countenhaft
Countershaft rear bearing
i
TM352
8 Reverse counter gear
9 Snap ring

Fig MT 26 Exploded view of haft auembly

counte

MT 7
 Manual Transmission

REAR EXTENSION Note 00 not diSlssemble rear exten

DISASSEMBLY sion bush from rear extension
Remove lock pin from striking
lever and remove striking rod

e 2
1 Control lever
Striking rod guide
3 Striking rod
4 Striking lever
5 Return spring plug
6 Stopper pin

TM353

Fig MT 27 Exploded view ofshifting mechani6m

ADAPTER PLATE Remove all nicks projection or 2 Check shaft for bending crack
DISASSEMBLY sealant with a frne stone wear and worn spline if necessary
I Remove six 6 3 If extension bush is
bearing retainer rear worn or replace
attaching screws with an impact cracked replace it as an assembly of 3 Measure backiasii in gears
wrench and remove bearing retainer bush and rear extension housing Standard
from adapter plate 005 10mm
to0
2 Remove reverse idler shaft BEARING
0 0020 to 0 0039 in
3 Remove mainshaft bearing from
I clean bearing and dry
the rear extension side Thoroughly If the above limits are exceeded
with a compressed air drive and driven gears
replace as a set

2 When race and ball surfaces are 4 Measure gear end play
worn or rough or when balls are out 1st gear
INSPECTION of round or rough replacebearihg 0 32 to 39
0 mm
with See MT 28
Wash all parts in a suitable cleaning
a new one Figure 0 0126 to 00154 in
solvent and check for wear damage or 2nd gear
other faulty conditions 0 12 to 19
0 mm

0 0047 to 00075 in
Notes
3rd gear
a Be careful not to damage any parts
0 13 to 37
0 mm
with scraper
0 0051 to 0 0146 in
b 00 not clean wash or soak oil seals
in solvent

I
TM372
TRANSMISSION CASE AND
Fig MT 28 l pecting ball bearing
REAR EXTENSION HOUSING

I Clean with solvent thoroughly 3 Replace needle if worn or

bearing
and check for cracks which might damaged
cause oil leak or other faulty con
ditions
GEARS AND SHAFTS
2 Check mating surface of the case
to engine or adapter plate for small I Check all gears for excessive wear
TM374
nicks projection or sealant chips or cracks replace as required Fig MT 29 Measuring end play

8
MT
 Manual Transmission

5 Check for 2 to withdrawal lever 2 Insert reverse idler shaft in adapt

stripped or damaged Apply sealant
speedometer pinion gear If necessary ball pin screw Install withdrawal lever er plate
ball pin to front cover and tighten Make sure that the cut out portion
replace
screw to 16 to 2 1 kg m 12 to 15 of reverse idler shaft is lined up with
BAULK RI NG ft lb torque inner face of adapter plate

I if found to be 3 Install bearing retainer in adapter

Replace baulk ring
deformed cracked or otherwise dam plate
REAR EXTENSION
aged excessively Align bearing retainer with reverse
ASSEMBLY idler shaft at the cut out portion of
2 Place baulk ring in position on
this shaft torque screws to 1 9 to 5
2
gear cone 1 Wipe clean seal seat in rear exten
sion kg m 14 to 18 ft lb and stake each
While holding baulk ring against housing press fit oil seal in place
gear far as it will go measure Coat oil seal and bushing with gear screw at two poin Is with a punch See
as gap
between baulk ring and outer gear oil for initial lubrication Figure MT 34
If gap is small discard baulk ring
See Figure MT 30

25 to 160 rom
lr
5 1 0 0492 to 0 0630 in
Front
Baulk ring

h
TM355

Fig MT 32 Rear extemion oil seal

TM400

Fig MT 34 Staking SCN W

TM375
2 Apply grease to O ring and plung
Fig MT 30 Baulk ring to cone gap er grooves in striking rod 4 Install countershaft bearing
rear

OIL SEAL Insert striking rod with striking rod in adapter plate by lightly tapping
guide through rear extension around it with a soft hammer
Discard O ring or oil seal which is
3 Install striking lever on front end
once removed Replace oil seal if of striking rod Install lock pin and
sealing lip is deformed or cracked
torque screw to 0 9 to 12 kg m 7 to
Also discard oil seal if spring is out of
9 ft Ib
position

GEAR ASSEMBLY
ADAPTER PLATE ASSEMBLY
ASSEMBLY Clean all parts in solvent and dry
1 Place dowel pin mainshaft bear with compressed air
To assemble reverse the order of
ing and oil gutter on adapter plate and
disassembly Observe ihe following
tap with a soft hammer until they are Synchronizer 888embly
instructions
properly positioned in place
Assemble synchronizer assembly
Use a new dowel pin
COVER ASSEMBLY Position shifting insert springs and
FRON1 Bend oil gutter on front side and
shifting inserts in three 3 slots in
clean seal front expand on rear side See Figure
I Wipe seat in
synchronizer hub put coupling sleeve
cover then press fit oil seal in place MT33 on synchronizer hub

Coat oil seal with gear oil to

provide initial lubrication

Front
J
Upper
Front

r
J f
Front r
7

M356
3rd 4th 15t 2nd

TM351
J
C
TM354 MT 35 Installing synchronizer
Fig
MT 31 Front cov oil eol Fig 33
MT Oil gutter hub
Fig

MT 9
 Manual Transmission

Malnshaft assembly Countershaft assembly Main drive gear assembly

I Assemble 2nd gear needle bear I Place new woodruff keys in 1 Using Transmission Adapter
ing 2nd gear baulk ring 1st 2nd grooves in countershaft and tap them ST23800000 press main drive bearing
speed synchronizer assembly st gear lightly until they are seated securely onto the shaft of main drive gear
baulk ring I st gear bush needle bear Use a soft hammer to avoid dam Make sure that snap ring groove on

ing I st gear steel ball and thrust aging keys shaft clears bearing
washer on mainshaft Before installing 2 Place main drive bearing spacer
2 Place adapter plate assembly and
main
a steel ball apply grease to it See mainshaft assembly so that counter on main drive bearing and secure
Figure MT 36 shaft
drive bearing with thicker snap ring
rear bearing rests on Transmis
that will eliminate end play See
sion Press Stand KV31100400 prop
Figure 4l
MT
erly
3 Install countershaft into adapter
See Available snap ring
plate by pressing it Figure MT 39

No Thickness mm in

1 80 0 0709

2 1 87 0 0736
TM358

3 1 94 0 0764
Fig MT 36 l talling thrust washer
4 2 01 0 0791
2 Set Transmission Press Stand
KV311 00400 and place adapter plate 5 2 08 0 0819

assembly it See MT 37
on Figure TM440 6 2 15 0 0846

Fig 39
MT l talling countersha
t

4 Position 3rd gear needle

bearing
For counterman and reverse idler shaft ifnOai Sfdh
gear baulk ring and 3rd
For main5haft and reverse
4th synchronizer assembly on the
tdler haft
front of mainshaft
S Insiall thrust washer on mainshaft
CD
and e ure it with snap ring of proper I
V31100400 thickness that will fit the groove in
mainshaft See Figure MT 40

J UJ TM438 Available snap ring

V Holes for reverse Idler shaft TM364

Fig MT 37 Tromminion PreS3 S tond No Thickness mm in

3 Install mainshaft to Fig 41

MT Installing snap ring
assembly I 14 0 055
adapter plate assembly Be sure to
2 5
1 0 059 3 Position baulk ring on cone sur
place bearing squarely against shaft
and press it into place on shaft gradu 3 16 0 063 face of main drive gear Apply gear oil
MT 38 to mainshaft pilot bearing and install it
ally See Figure
on mainshaft
Assemble main drive gear assembly
on the front end ofmainshafl

4 Press counter drive onto

gear
countershaft with Counter Gear Drift
ST23860000 by meshing gears and
secure counter drive gear with thicker

snap ring See Figures MT 42 and

KV31100400 43
MT

Note Be sure to drive in counter

TM439

38
MT Installing haft TM441 drive gear and main drive gear
Fig mai
em bly Fig 40
MT l talling snap ring simultaneously

MT l0
 Manual Transmission

in a vise Explanation of converted torque

6 Support adapter plate
with Setting Plate Adapter
Mainshaft nut should be tightened
ST238 10001 with mainshaft facing
to 14 to 17 kg m 101 to 123 ft lb
ST23860000 down
torque with the aid of Wrench
7 Install mainshaft reverse gear ST22520000 When doing so the
plain washer on the rear of mainshaft
amount of torque to be read on
and install mainshaft nut
wrench needle should be modified
Tighten mainshaft nut temporarily according to the following formula
8 Install counter reverse gear on the
rear of countershaft and secure with

map ring
TM442 L
Use snap ring to give a minimum C kg m 14 x to
Fig 42
MT l talling haft
counte
drive gear gear end play See Figure MT 45 L O lO

L
Available counter drive gear map ring 17 x

L 10
0
No Thickness mm in

No Thickness mm in or
I 14 0 055
L
I 14 0 055 2 15 0 059 C ft lb 101 x to
L 33
0
2 15 0 059 3 16 0 063 L
16 0 063 123 x
3
L 33
0

II
Where

C Value read on the torque wrench

kg m ft lb
L Effective length of torque
wrench m ft

ST22520000 c
Torque wrench

Fig 45
MT Imtalling
o
counter

gear
TM361

reverse

nap ring
Lm ft
h I

9 Install reverse idler gear on re O IOm

TM366
0 33 ft TM587
Fig 43
MT Installing nap ring verse idler shaft
10 With 1st and 2nd gears doubly Fig 47
MT Setting wrench
5 Press countershaft front bearing engaged tighten mainshaft nut to the

onto countershaft with Drift C converted torque Cn See Figure

ST22360002 See Figure MT 44 MT 48 using Wrench ST22520000

See Figure MT 47

Example
When a 0 40 m 31
1 ft long tor

que wrench is used the Cn in

ST22360002
Figure MT 48 will be 112 to 13 6
kg m 81 to 98 ft lb

ST22520000

KV3 II00400

TM443
haft TM768
Fig 44
MT Installing counte
front bearing Fig 46
MT Tightening mainshaft nut

MTll
 Manual Transmission

Secure 1st 2nd fork rod to shift

s fork with a new retaining pin
S 2 Install check ball check ball
15 spring and check ball plug Prior to
I
Upper limit line tightening check ball plug apply
110 sealant to check ball plug
15
I Align notch in 1st 2nd fork rod

6 1r
c
with check ball See Figure MT 50
u
c
14
100

9 13
f fdl
Converted torque

S
c
90
o

I
Lower limit line
80 11 TM367

U
Fig MT 50 l talling 1st 2nd
fork rod

70
10

V 3 Slide 3rd 4th fork rod through

and 3rd
9 adapter plate 4th shift fork
0 2 0 3 0 4 05 0 6 0 7 0 8 m
and secure with a new retaining pin
10 5
1 2 0 2 5 It
Note Prior to a mbling 3rd 4th
fork rod install 2 interlock
L Effective length of torque wrench two
balls into dap er plat own in
Fig 48
MT CO 1Vert d torque
Figure MT 16

4 Install check ball and check ball

spring
11 Tighten mainshaft nut to 14 0 Note The main drive gear and coun

ter driVe gear should be handled as Apply sealant to check ball plug
to 17 0 kg m 101 to 123 ft lb
matched set and install it in place
torque and stake mainshaft nut to a
Align notch in 3rd 4th fork rod
groove of main shaft with a punch See When you replace a main drive gear
counter drive gear with check ball by sliding 3rd 4th
Figure MT49 or be sure to

set of main drive gear fork rod as necessary See Figure

replace as a

and counter drive gear MT51

ShUt fork nd fork rod

mbly
I Place 1st 2nd shift fork in
in 1st 2nd sleeve
groove coupling
and slide 1st 2nd fork rod through

adapter plate and 1st 2nd shift fork

Prior to installing 1st 2nd fork rod
TM362
TM368
install 3rd 4th shift fork in groove in

Fig 49
MT Staking haft nut
mai 3rd 4th coupling sleeve Fig MT 51 Installing 3rd 4th
fork rod
Note Shift forks for 1st 2nd and
3rd 4th are one and the same

12 Measure gear end play and back parts

lash Make sure that the long end of shift 5 Place reverse shift fork in reverse

Make sure that they are held within fork for lot 2nd is the idler gear
placed on

the specified values counter gear side and the end Slide reverse fork rod
long through re
For details refer to the instructions for 3rd 4th is the shift fork and
on e verse adapter plate and
under topic Inspection side with
secure a new retaining pin

MT12
 Manual Transmission

Note Prior to assembling reverse fork Front eov r s mbly

rod instaU two 2 interlock balls
I Select countershaft front bearing
into adapter piate as shown in
shim follows See Figure MT 54
as
Figure MT I6
from front
1 Measure depth A

6 Install check ball and check ball end of transmission case to counter

spring shaft front bearing

Apply sealant to check ball plug 2 Select a shim of thickness A

and install it in place measured

Align notch in reverse fork rod with

check ball See Figure MT 52
Fig MT 53 Fitting main drive
bearing snap ring

R ar xt nslon ass mbly

I Clean mating surfaces of
adapter D
plate and fear extension
JJ
A
ID
Apply sealant to mating surfaces of @
adapter plate and rear extension 2J1
2 With fork rods in their neutral I Transmission

positions graduaUy slide rear exten case

TM369
sion onto 2 Countershaft
adapter plate making sure
front bearing
Fig MT 52 Installing reverse fork that speed change cross lever engages
3 Countershaft
rod with fork rod brackets
correctly 4 Shim
3 Install washers and through bolts TM371
and torque to 1 6 to 1
2 kg m 12 to
7 Torque each check ball plug Fig MT 54 Selecting countershafl
to
15 ft lb front bearing shim
1 9 to 5 kg m 14 to 18 ft Ib
2

Note BaD plug for ht 2nd fork rod Available shim

is longer than those for rev shift
fork rod and 3rd 4th fork rod
Countershaft front
No A
8 Apply gear oil to all sliding sur rnm in bearing shim mm in
faces and check to see that shift rods
and I 2 92 to 3 01 0 1150 to 0 1185
operate correctly gears are 0 6 0 024

engaged smoothly 2 3 02 to 3 11 0 1189 0 1224

to 5 0 020
0

3 3 12 to 3 21 0 1228 to 0 1264 0 4 0 016

4 3 22 to 3I 0 1268 to 0 1303 0 3 0 012

5 3 32 to 3 41 0 1307 to 0 1343 0 2 0 008

TRANSMISSION ASSEMBLY 42
3
6 to 3 5 I 0 1346 to 0 1382 0 1 0 004

7 3 52 to 3 61 0 1386 to 0 1421
lon
Tranmis ea mbly
8 3 62 to 3 71 0 1425 to 0 1461

1 Clean mating surfaces of adapter

plate and transmission case
Apply sealant to mating surfaces of
adapter plate and transmission case
2 Slide transmission case onto 2 Clean mating surfaces of front 3 Install speedometer pinion assem

adapter plate by lightly tapping with a cover and transmission case bly on rear extension After making
soft hammer until case bears against Apply grease to shim selected to Sure that lock plate is lined up with
adapter plate retain it on front cover install front groove in speedometer pinion sleeve
Carefully install main drive bearing transmission with gasket install
cover to case
through bolts and torque to 04
and countershaft front bearing in place to 0 5 kg m 3 to 4 ft lb
Make certain that mainshaft rotates Install through bolts with washers 4 Install back up lamp switch and
freely under them and tighten to 1 6 to 2 1 torque to 2 0 to 3 0 kg m 14 to 22
3 Fit main drive bearing snap ring kg m 12 to 15 ft lb torque ft lb
to groove in main drive bearing by sealant threads of Be
Apply to sure to apply sealant before
using Expander See Figure MT 53 through bolts before installation installation

MT13
 Manual Transmission

5 Apply a light coat of multi 4 to 5 9 kg 32 to 43 ft Ib

INSTALLATION m

purpose grease to withdrawal lever

release bearing and bearing sleeve in Install the transmission in the reo
1
stall them on clutch housing verse order uf removal paying atten

After connecting them with holder tion to the following points

spring instaU dust clutch 1 Before dean

cover on installing mating
housing surfaces of engine rear plate and trans
6 Install control lever temporarily mission case
and shift control lever through all 2 Before installing lightly apply
gears to make sure that gears opera Ie to parts of clutch disc
grease spline
smoothly and main drive gear 0 9 to 2
1 kg m 7 to 9 rt lb TM773

3 Tighten bolts trans Fig MT 55 Tightening torque

securing
Note Install drain plug and filler plug mission to engine to specifications See
ith sealant in place 4 Remove filler plug and fIll trans
Figure MT 55
mission with recommended gear oil to

the level of the plug hole Approxi

mately I 7 liters 3 pt 3 pt

5 SPEED TRANSMISSION TYPE FS5W71B

CONTENTS

DESCRIPTION MT14 MT19

BEARING
REMOVAL MT17 GEARS AND SHAFTS MT19
DISASSEMBL Y MT17 BAULK RING MT19
TRANSMISSION CASE DISASSEMBLY MT17 OIL SEAL MT19
DISASSEMBL Y OF GEAR ASSEMBLY MT17 ASSEMBL Y MT19
REAR EXTENSION DISASSEMBLY MT18 FRONT COVER ASSEMBLY MT19
ADAPTER PLATE DISASSEMBLY MT19 REAR EXTENSION ASSEMBLY MT19
INSPECTION MT19 GEAR ASSEMBLY MT19
TRANSMISSION CASE AND REAR TRANSMISSION ASSEMBLY MT 20
EXTENSION HOUSING MT19 INSTALLATION MT20

DESCRIPTION
The transmission is of a 5 speed overdrive position of it in over
Placing the control lever
forward with overdrive 4 OD The overdrive gear rides the drive position brings the
on reverse OD
speed fully synchronized constant mainshaft freely through the needle coupling sleeve reverse main
gear on
mesh type that uses helical gears roller bearing and counter overdrive shaft into mesh with overdrive clutch
The 5 speed transmission covered in gear is fitted to the countershaft by gear The reverse OD synchronizer
this section is similar in all respects to splines hub is fItted the mainshaft
to by
the 4 speed transmission type The overdrive synchronizer system splines so the overdrive gear on main

F4W71B stated previously except the is on the mainshaft rear side shaft turns together with the main

shaft

MT14
 Manual Transmission

j
I

@
00
b
7
@
f

1 Front cover

2 Front cover oil seal

3 Front cover gasket

4 Transmission case

5 Adapte plate
f 6 Maimhaft bearing
7 Bearing retainer
8 Rear extension
9 Breather

10 Rear extension oil seal

11 Sleeve yoke dust cover

@3

TM046A

Fig MT 56 FS5W71B transmission case components

MT15
 Manual Transmission

W
h
I

l
1 Main drive gear
2 Baulk ring
3 Shifting insert
4 Shifting insert spring
5 Synchronirr
c hub
6 Coupling slee
7 3rd main gear
g Needle bearing
9 Mainshaft
10 2nd main gear
11 Bushing
12 1st main gear
13 O revcrse synchronizer hub
14 Rever gear
15 Circlip
16 Thrwt block
t7 Brake band
18 Synchronizer ring
19 Overdrive main gear
20 Overdrive gear bushing
21 Washer
22 Mainshaft nut
13 Overdrive mainshaft bearing
24 Speedometer drive gear
25 COlplteBhaft mt bearing shim
fr
26 Countershaft front bearing
27 Countershaft drive gear
28 Coontcrshaft
29 Countershaft bearing
30 Reverse counter gear spacer
31 C counter
Rever gear
32 rdrive counter gear
33 Countershaft zear bearing
34 C untershaft nut
3S Reverse idler lIhaCt
36 Reverse idlcrthrust washer
37 Reverse idler gear
38 nc idler gear bearing
Reye

39 Reverse idler thrust w8her

TM041A

Fig MT 51 FS5W11B trumiasion gear componenta

MT 16
 Manual Transmission

I Striking lever
2 Lock pin
3 Q ring
4 Striking guide
5 Oil seal
6 Striking rod
7 Expansion plug

t j 8
9
10
Stopper guide pin
Return spring
Return spring plug

e
11 Return spring plunger
12 Check ball plUS
13 Check spring
@ 14 Check ball
Retaining pin
CD Interlock ball
17 ist 2nd shift fork
18 1st 2nd fork rod
19 3rd 4th fork rod
20 Reverse OD fork rod
4th shift fork
o

O
21 3rd
Revene OD shift fork
Con trol1ever
24 Con trol1cver pin
25 Con trollever bushing

TM048A

control component
Fig MT 58 FS5W71B trammi ion shift

3 Draw out counter drive gear com

plete with main drive gear assembly by

Same for the F4W71B

REMOVAL
as means of a gear puller

When drawing out main drive gear

DISASSEMBLY assembly be careful not to drop pilot
needle bearing onto floor from the
TRANSMISSION CASE front end of mainshaft See Figure
DISASSEMBLY
60
MT
TM756

Same as for the F4W71 B Fig MT 60 Removing counter drive

gear and main drive gear

DISASSEMBLY OF GEAR
ASSEMBLY 4 Rem6vesnap ring and then thrust
washer from mainshaft front end
Fork rod Draw out 3rd 4th synchronizer
assembly and remove 3rd gear assem
Same as for the F4W71 B
bly
5 Remove snap ring and then draw
Geer sembi
out speedometer gear and bearing
I With gears doubly engaged draw from mainshaft rear side

out haft front bearing using a

counte 6 With gea doubly engaged re
suitable gear puller See Figure MT 59 TM398
lease caulking on countershaft and
2 Remove counter drive gear snap mainshaft nuts then loosen them
Fig MT 59 Removing countershaft
front bearing Remove countershaft nut
ring

MT 17
 Manual Transmission

II Remove reverse idler gear

12 Remove snap ring of mainshaft

end bearing Draw out bearing using
Mainshaft Rear Bearing Puller
KV32101330 Remove other snap ring
of mainshafl end bearing See Figure
MT64

IT
TM757

Fig 61
MT Removing counterahaft
nut
TM761

Fig 65
MT Driving outgear sembly

tw Malnahaft
Note When mainshaft
removing as
KV32101330
sembly loosen mainshaft nut TM160
Same as for the F4W7IB

Fig MT 64 Removing haft

mai
7 Draw out counter overdrive gear nd bearing Main drive ear

and bearing from countershaft rear

Same as for the F4W71 B
end by using a suitable gear puller See
Figure MT 62 Counterahaft aaaembly
13 Remove mainshaft nut thrust
Same as for the F4W7l B
washer mainshaft reverse gear OD
synchronizer and overdrive gear REAR EXTENSION
14 Draw out mainshaft gear assem DISASSEMBLY
bly together with countershaft by
lightly tapping the rear end with a soft Remove lock pin from striking
hainmer Me holding the front of lever and remove sirikingrod
mainshaft gear assembly by hand
Be careful not to drop off gear Note Do not disassemble rear exten
shaft See Figure 65
MT sion bushing from rear extension
TM758

Fig MT 62 Removing count r

overdriv gear and bearing

k
8 Remove counter reverse idler gear
and spacer
9 Remove countershaft by lightly
J
l
tapping the rear end with a soft
hammer
Be careful not to drop off gear J
shaft
10 Remove reverse idler gear snap

ring

r 1

2
3
Striking lever
Striking rod
Stopper pin
4 Control lever
5 Striking rod guide
6 Reverse select plunger
7 Reverse select plug
TM759

Fig 63
MT Removing reverse idler TM767
gear nap ring Fig MT 66 Exploded view of shifting mechanilm

MT1B
 Manual Transmission

ADAPTER PLATE If the above limits are exceeded 3 Install striking lever on front end
DISASSEMBLY replace drive and driven gears as a set of striking rod Install lock pin and
4 Measure gear end play torque screw to 0 9 to 1 2 kg m 7 to

Same as for the F4W71 B 9 ft lb

1st gear
4 Install filainshaft bearing by
32 to
0 39
0 mm

lightly tapping around it with a soft

0 0126 to 0 0154 in
hammer
2nd gear
5 Insert reverse idler shaft in adapt
0 12 to 0 19 mm
er plate
0 0047 to 0 0075 in
3rd gear Make sure that the cut out portion

0 13 to 37
0 mm of reverse idler shaft is lined up with

0 0146 in inner face of adapter plate

0 0051 to

6 Install bearing retainer in adapter

OD gear on mainshaft
32 to 0 39 mm
0 plate
Align bearing retainer with reverse
0 0126 to 0 0154 in
Fig MT 67 Removing screws
idler shaft at the cut out portion of
this shaft torque screws to 1 9 to 2 5
BAULK RING
kg m 14 to 18 ft lb and stake each
INSPECTION
Same as for the F4W7IB screw at two points with a punch See
Wash all parts in a suitable cleaning MT 69
Figure
solvent and check for wear damage or OIL SEAL
other faulty conditions
Same as for the F4W71 B

Notes ASSEMBLY
a Be careful not to damage any parts
To assemble reverse the order of
with scraper
disassembly Observe the following in
b Do not clean wash or soak oil seals
structions
in solvent

FRONT COVER ASSEMBLY

TRANSMISSION CASE AND
REAR EXTENSION HOUSING
Same as for the F4W7l B
TM764
Same as for the F4W71 B
REAR EXTENSION Fig MT 69 Stahing screw

ASSEMBLY
BEARING I Wipe clean seal seat in rear exten 7 Install countershaft rear bearing
Same as for the F4W7l B sion housing press fit oil seal in place in adapter plate by lightly tapping
Coat oil seal and bushing with gear around it with a soft hammer
oil for initial lubrication See Figure
68
MT GEAR ASSEMBLY
GEARS AND SHA S
r Clean all parts in solvent and dry
I Check all gears for excessive wear
with air
I compressed
chips or cracks replace as required Front
2 Check shaft for bending crack
Synchronlz r embly
wear and worn spline if necessary
Same as for the F4W71 B
replace
3 Measure backlash in gears
r
Ov rdrlve r ynchronlz
TM355 mbly
Main drive and
Fig MT 68 R ar extemion oil sea
I Assemble reverse OD synchro
counter drive gear
nizer assembly
0 05 to 0 10 mm
2 Apply multi purpose grease to 2 Assemble overdrive gear assem
0 0020 to 00039 in
and
1st 2nd 3rd 5th and
O ring plunger grooves in striking bly
rod Position synchronizer ring band
reverse gears
Insert striking rod with striking rod brake thrust block and anchor block
0 05 to 0 20 mm
rear extension overdrive clutch gear install circlip
0 0020 to 0 0040 in guide through on

MT19
 Manual Transmission

2 Assemble OD reverse synchro

Synchro ring
nizer assembly OD gear bushing
needle bearing OD gear assembly
8andbrake
sreel ball and thrust washer on main
shaft rear side Before installing steel
Circlip ball apply grease to it
3 Install new mainshaft nut and

tighten it temporarily
4 Install counter reverse gear
counter 5 th gear bearing and new

countershaft nut Tighten nut tem

Anchor block porarily
5 Tighten mainshafl and counter

shaft nuts and stake nuts at groove in

TM449 shafts with a punch Tightening proce
Fig MT 70 Imtalling overdrive gear assembly dures for mainshaft nut are the same

as those for the F4W7IB

Malnshaft assembly Install needle
snap ring spacer
roller bearing reverse idler gear spacer Shift forks and fork
Same as for the F4W7IB
and snap ring rods assembly

Countershaft assembly Same for the F4W71 B

as

h I
Same as for the F4W71 B

L
Main drive gear assembly

u TRANSMISSION ASSEMBLY
Procedures are the same as for the

F4W7IB trans i n except as Same as for the F4W71 B

follows
I Insert countershaft and mainshaft TM4S1 INSTALLATION
into adapter plate and place adapter
Fig MT 71 R idler gear
lJerse Same as for the F4W71 B
plate in a vise with setting plate

MT 20
 Manual Transmission

SERVICE DATA AND SPECIFICATIONS

GENERAL SPECIFICATIONS

Transmission type F4W71B FS5W71B

Synchromesh type Warner 1st to 4th Warner 5th Servo

1 3 1 3 5
II

Shift type
T
i i 1

2 4 R 2 4 R

Gear ratio
1st 592
3 321
3
2nd 2 246 2 077
3rd 1 415 308
1

4th 1000 1000

5th 0 864
Reverse 3 657 382
3

Final gear ratio 375

4 375
4

Speedometer gear ratio 20 6 20 6

Oil capacity US pt Imp pt I 7 3 3 2 0 4X f

3

MT 21
 Manual iTransmission

TIGHTENING TORQUE

Installa tion Unit kg m ft lb

Engine to transmission installation bolt 4 to 5 9 32 to 43

Transmission to engine rear plate bolt 0 9 to 1

2 7 to 9

Clutch operating cylinder installation bolt 2 5 to 3 0 18 to 22

Rear mounting insulator to transmission installation bolt 0 8 to 1 6 to 8

Crossmember mounting bolt 3 2 to 43 23 to 31

Propeller shaft to diff installation bolt 4 to 33

2 17 to 24

Gear assembly

Rear extension installation bolt 16 to 2 1 12 to IS

Front cover installation bolt 1 6 to 2 1 12to IS

Bearing retainer to adapter plate screw 19 to 2 S 14 to 18

Main haft nut 14 0 to 17 0 101 to 123

Check ball plug 1 9 to 2 S 14 to 18

Stri lever lock pin 0 9 to 1 2 7 to 9

Reverse select return plug 09 1 2 7 to 9

Speedometer sleeve locking plate nut 0 4 to O S 3 to 4

Reverse lamp switch 2 0 to 3 0 14 to 22

year oil Ier 2 S to 3 5

plg 18 t02S
Ge r oil drain plug 2 S toTS l8 to 2S
or

SPECIFICATIONS

Gear backlash Unit mm in

Maindrive gear to counter drive gear 0 05 to 0 10 0 0020 to 0 0039

1st gear 0 05 to 0 20 00020 to 0 0079

2nd gear O OS to 0 20 0 0020 to 0 0079

3rd gear 0 05 to 0 20 0 0020 to 0 0079

OD gear 0 05 to 0 20 0 0020 to 0 0079

Gear end play
1st gear
32
0 to 39
0 0 0126 to 0 0154
2nd gear 0 12 to 0 19 0 0047 to 0 0075
3rd gear 13
0 to 37
0 0 0051 to 0 0146
OD gear 32
0 to 39
0 0 0126 to 0 0154
Counter gear 01 to 0 21
0 0 0004 to 0 0083
Reverse idler gear 0 05 to 0 20 0 0020 to 0 0079
Clearance between baulk ring and
gear
All gears 125 to 1 60 0 0492 to 0 0630
Counter bearing adjusting shim 0 6 0024
0 5 0 020
0 4 0 016
3 0 012
0
0 2 0 008
01 0 004

MT 22
 Manual Transmission

TROUBLE DIAGNOSES AND CORREGTIONS

Condition Probable cause Corrective action

Difficult to intel11lesh gears

Causes Jor difficu t gear shifting are classi Worn gear shaft and or bearing Replace
fied to troubles concerning control system Insufficient operating stroke due to worn or pair or replace
and When gear shift lever is
transniissioo loose sliding part
heavy and it is difficult to shift gears clutch
Faulty or damaged synchronizer Replace
disengagement may also be unsmooth First
make sure that clutch operates correctly
and inspect o
transmissi

Gear slips out of mesh

In most cases this trouble occurs when Worn interlock ball Replace
interlock b all check ball and spring is
or Worn check ball and or weakened or broken Replace
worn or weakened or when control system
spring
is faulty In this case the trouble cannot be
Wom fork rod ball groove Replace
corrected by replacing gears and therefore
trouble shooting must be carried out care Wom or damaged bearing Replace
fully It should also be noted that gear slips Worn or damaged gear Replace
out of mesh due to vibration generated by
weakened fron t and rear engine mounts

Noise
When noise occurs with engine idling and Insufficient or improper lubricant Add oil or replace
when with designated oil
ceases when clutch is disengaged or

noise occurs while shifting gears it is an Oil leaking due to faulty oil seal or sealant Clean Of replace
that th e noise is from transmis
indicati90 clogged etc
breather
sion
Worn bearing High humming occurs at a Replace
Transmission may fa ule during engine
t high speed
idling
Damaged bearing Cyclic knocking sound Replace
Check air fuel mixture and ignition
also
occurs at a 19W speed
timing
After above procedure readjust engine Worn spline Replace
idling Worn bushing Replace

MT 23
 Manual Transmission

SPECIAL SERVICE TOOLS

For Reference
Tool number
Description or
No use page
Unit mm in
on Figure No
tool name

For removal of fork rod retaining pin All Fig MT 15

ST23540000
models
Fork rod pin
punch
150 5 91

L i

10 0 39 dia

For assembly of counter drive bearing M

llBT Fig 44
MT
2 ST22360002
FS5W
Drift C
63A

oOler dia 32 126

SE034
inner dia 23 0 91

For assembly ofmain bearing All Page MT 1O

3 ST23800000
models
Transmission
adapter

480 18 90

outer dia 44 1 73
SE037
inner dia 31 122

vise 71BT M Fig MT 14

4 ST238 10001 For setting adapter plate in a

Fig MT 15
Setting plate 45
MT
Fig
adapter

74 2 SE132
91

MT 24
 Manual Transmission

For Reference
Tool number
Description use page or
No Unit mm in
on Figure No
tool name

71BT M Fig MT46

5 ST22520000 For removal and assembly of mainshaft nut
63A TIM Fig MT47
Wrench
38mm
50
1 in

SE313

7IBT M Fig MT42

6 ST23860000 For assembly of counter drive gear

Counter gear
drift

outer dia 38 50
inner dia 331
30 SE039

drive gear and M

7IBT Fig MT 37
7 KV31100400 For assembly of rnainshaft countershaft counte
counter drive Fig MT 39
bearing
Transmission
Fig MT44
48 189 75 2 95
press stand

0 Q 0
J
I
0 TM438

All Fig MT 21
8 STJ0031000 For replacing bearing
models Fig MT 23
Bearing puller Fig MT 25

80 3 15
50 1 97

SE041

MT 25
 Manual Transmission

Tool number For Reference

No Description use page or

tool name Unit mm in on Figure No

9 KV32101330 For removal of mainshaft end b lg

ari counter overdrive gear and 63A fM
l Fig 64
MT

bearing FS5W
Bearing puller
7IBT M

11
300 81

SE308

MT 26
 SECTION AT

AUTOMATIC
DATSUN PICK UP TRANSMlsSIO N I

MODEL 620 SERIES

DESCRIPTION At 2

HYDRAULIC CONTROL SYSTEM AT 4

REMOVAL AND INSTALLATION AT 33

MAJOR REPAIR OPERATION AT 36

TROUBLLDIAGNOSES AND
AHD
ADJUSTMENT

SERVICE DATA AND

AT 59
SPECIFICATIONS

SPECIAL SERVICE TOOLS AT 62

I NISSAN I
I
NISSAN MOTOR CO LTD
TOKYO JAPAN
 Automatic Transmission

DESCRIPTION

The model 3N7l B automatic trans 2 2 range provides performance

mission is a automatic unit con for driving surfaces
fully on slippery 2
sisting primarily of 3element hydrau range can also be used for engine
lic torque converter and two planetary braking
gear sets Two dimulstipcle clutches a 2 range can be selected at any

dimulstipcle brake a band brake and vehicle speed and prevents the trans
a one way sprag clutch provide the mission from shifting out of second
friction elements required to obtain gear
the desir d function of lhe two plane I I can be selected at
range
AT344
tary gear sets any vehicle speed and the transmission
The two planetary gear sets give will shift to second gear and remain in Fig AT I Identification number
three forward ratios and one reverse
second until v hicle speed is reduced
Changing of the gear ratios is fully 10 40 50 kmfh 25
approximately to
automatic in relation to vehicle speed to 30 MPH
and engine torque input V chide speed
I range position prevents the Identification of number
and engine manifold vacuum signals
transmission from shifting out of low
are constantly fed to the transmission Arrangements
gear This is particularly beneficial for
toprovide the proper gear ralio for See below
maintaining maximum engin braking
maximum efficiency and performance
when continuous low gear operation is
at all throttle openings desirable
The model 3N71 B has six selector
The torque converter assembly is of
1 R N D 2 1
9sition
LP welded construction and Model code
can nOlbe
disassembled for service
I Park position positively locks
the output shaft to the transmission JAPAN AUTOMATIC
case by means of a locking

prevent the
pawl to
vehicle from rolling in
0J TRANSMISSION CO LTD

either direction I MODEL X2402 I

This position should be selected
I NO 4912345 I
whenever the driver leaves Ihe vehicle
Thc engine may be slarted in Park

position
FLUID RECOMMENDATION
Use automatic transmission fluid
J
having DEXRON identifications
Unit number
R Reverse enables the only in the 3N71 B automatic transmis
range
sion
vehicle to be operated in a reverse

direction Number designation

N Neutral position enables the 4 9 I 234 5

to be started and without
IDENTIFICATioN NUMBER
engine run
L Serial production
driving the vehicle
number for the month

0 Drive range is used for all Stamped position Month of production

X Oct Y Nov Z Dec
normal driving conditions The plate is attached to the right
Drive range has three gear ratios hand side of transmission case as last figure denoting
from the starting ratio to direct drive shown io Figure AT I the year A D

AT 2
 Automatic Transmission

J
o

II
IIlI

r
I
r

AT288

II Governor Tightening torque T of

I Transmission ca e

2 Oil 12 Output shaft bolts and nuts kg m ft lb

pump
3 Front clutch 13 Rear extension
@ T 4105 29 10 36
4 Band brake 14 Oilpan @ T 10110116
141016
5 Rear clutch IS Control valve
@ T 4 5 to 5 5 33 1040
6 Front planetary gear 16 Input Jlihafl @ T 0 6100 8 4 106
7 Rear planetary gear 17 Torque converter
@ T 0 5 to 0 7 4 10 5
8 One way clutch t8 Converter housing T 2 5 14 10 18
0102
9 Low Rever5e brake 19 Drive plate
@ T 3 10 18 9 10 13
1
10 Oil distributor T 0 55100 75 4 105

CD T 0 25 10 0 35 2 to 3

Fig AT 2 Cross sectional view of 3N71B automatic transmission

AT3
 Automatic Transmission

HYDRAULIC CONTROL SYSTEM

CONTENTS

FUNCTIONS OF HYDRAULIC CONTROL P RANGE PAR K AT14

UNIT AND VALVES AT 4 R RANGE REVERSE AT16
OIL PUMP AT 4 N RANGE NEUTRAL AT18
MANUAL LINKAGE AT 4 RANGE LOW GEAR
D1 AT 20
VACUUM DIAPHRAGM AT 5 D2 RANGE 2ND GEAR AT 22
DOWNSHIFT SOLENOID AT 5 D3 RANGE TOP GEAR AT 24
GOVERNOR VALVE AT 5 D RANGE KICK DOWN AT 26

CONTROL VALVE ASSEMBLY AT 6 2 RANGE 2ND GEAR AT 28

HYDRAULIC SYSTEM AND t RANGE LOW GEAR AT 30

MECHANICAL OPERATION AT13 12 RANGE 2ND GEAR AT 32

tains an oil
FUNCTIONS OF pump for packing p oil solenoid These parts work in conjunc
from the oil pan through the oil tion with valves in the valve
HYDRAULIC CONTROL A shift control is provided by
body
strainer assembly located in the base of the
UNIT AND VALVES two centrifugally operated hydraulic transmission The valves regulate oil
governors on the output shaft vacuum pressure and direct it to appropriate
The hydraulic control system con control diaphragm and downshift transmission components

I I I
Oil pump
I I
Control valve
I
Torque converter
1
Manual linkage Front clutch
I Rear clutch
Vacuum diaphragm

Downshift solenoid
I Low and reverse brake

Band brake

Governor valve
I
I Lubrication
r
OIL PUMP housing delivery port Transmission MANUAL LINKAGE
case delivery port Lower body
delivery port Control valve line The hand lever motion the hand
The oilpump is the source of
pressure circuit lever is localed in the driver s
compart
control medium i oil for the
e ment mechanically transmitted from
control system
lhe remote control linkage is further
The oil pump is of an internal transmitted to the inner manual lever
involute gear type The drive sleeve is a
in the transmission case from the
range
part of the torque converter pump selector lever in the right center par
impeller and serves to drive the pump tion of the transmission case through
inner gear with the drive sleeve direct
the manual shaft The inner manual
ly coupled with the engine operation lever is thereby turned
The oil flows through the following A pin installed on the bottom of
route
AT071 the inner manual lever slides rhe manu
Oil pan Oil strainer bottom of the al valve spool of the conlrol valve thus
I Housin 4 Inner gear
control valve Control valve lower positioning the spool opposite rhe
2 Cover 5 Crescent
body suction port Transmission case 3 Ouler gear appropriate select posilion
suction port Pump housing suction The parking rod pin is held in rhe
port Pump gear space Pump Fig AT 3 Oil pump groove on the top of Ihe inner manual

4
AT
 Automatic Transmission

plate The rod

parking
pin operates the vacuum reaction increases since the
rod p
range and operates the
at flow velocity of mixture inside the
I
mechanical lock system intake m mifold is slow Contrarily c C
11
The above described manual shaft is r
when the engine speed increases and Kickdown
h switch
further equipped with an inhibitor the flow velocity of the mixture in
Dowri shift solenoid
switch A rotor inside the inhibitor creases or when the carburetor is
switch rotates in to each closed the manifold negative pressure
response
range When tne range is selected at increases Le tends towards vacuum
AT089
p or N the rotor closes the and the vacuum reaction is reduced
Fig AT 6 Downshifl80lenoid
starter magnet circuit that the Thus
so a signal to generaIe hydraulic
engine can be started When the range pressure P rfe tly suited to the engine
is selected at R the rolor closes the at control valve is trans
loading trye GOVERNER VALVE
back up lamp circuit and the back up mitted from the vacuum diaphragm
lamp lights and the most suitable timing for speed The primary and secondary gover
nor valves are installed separately on
change and lin e pressure is obtaine so
the back of the oil distributoron the
that the most proper torque capacity
is obtained against the transmitting
transmission ft
sha tn y op
outp t

erate al the
speed as thar iJf tile
same
torque
output shaft thai is they operate at a
speed in proportion 10 the vehicle
To lkc
inl manifold speed The line press retis applied to
those valves s the input from the
control valve through the transmission
case rear flange and oil distributor
CD
The governor pressure in proportion
to the ouiput shaft speed vehicle
ATOB7
speed is led to the shift valve ofthe
1 Manual pia te Parking rod

2 Inhibitor switch
AT088 control valve through the opposite
Manual shaft
route of the output In this manner

Fig AT 5 Vacuum diaphragm and line pressure

Fig AT 4 Manual linkage speed change are

controlled

VACUUM DIAPHRAGM DOWNSHIFT SOLENOID

The vacuum diaphragm is installed T e downshift solenoid is of a Operation of secondary
on the left center portio n of the magnetic type installed on the left re r governor valve
transmission case The internal con portion of the transmission case When
T e secon ary valve is a contro
struction of the vacuum a driver requires
diaphragm is accelerating power valve Y hich receives line pressure
as follows and the
dePresses accelerator pedal
an cqQ rols the governor pressu e
down to the kickdown
A rubber diaphragm forms a parti stopper a
When the manual valve is selected
tion in the center The intake switch 19ca ted in the middle of the
engine at D 2 or l range line pressure
accelerator link is depressed by a push
manifold negative pressure l led is applied t the ri g sh aped area of
tube and spring rod he kickdown switch doses cur
through a vacuum this valve from circuit I l and this
rent flows to the solenoid the sole I
force isapplied to the front surfaceof v Jy is depressed lOW
jr tI c
noid push rod is fer
the rubber diaphragm while atmos depressed the down
Movemcnt of this valvl III a cr in
pheric pressure is applied to the back shift valve of the control valvc insidc
positillll doses the dr uit from Olto
the transmi ssion case is
surface The difference between pres depressed nd
the
15 while simultaneously making a
sure
I applied
to the front and ba K speed is
changed forcedly fmm sr rronl IS to Iii center dniin
surfaces reactIOn 3rd to 2nd within a cerlaill vehi
causes a vacuum
port and press re in tllc cirJ it l5j is
which activates the throttle valve of cle speed limit lowered
the control inside
valve the transrhis Note Since theki kdown switch When thc vehicle is stopped 1 d the
sion case closes when the accelerator is
pedal cenlrifugal force of this valve is zero
Wheri accelerator pedal is fully de depr ssed from 7 i t I S I 6 of tiie lve is balanced
the v At this poini a

pressed and the buretor is fU IIy whole stroke the a ccel rator 1
ped govcr lOr pressurc yhich bali1 nced
opened but th engirie sp eed is not should be correctly adjusted so as with th spr ng force occurs on IS
the manifold I

increased arf rd omplete stro

suificientl a e Wh n thc vehicle is st rted nd the
negative plre sure lowers Le tends The arrangement of the swit h
centrifugal
and the fqr incre ses this valve
towards atmospheric pressure wries ccording m eI movcs slightly 10 Ihc oUlSide and as

AT S
 Automatic Transmission

the space from I to IS increases

To onlml valve

space from 15 to the drain port l Governor

D@
j
1I5
resull
I
decreases As a S1I
pre
simultaneously
governor pressure of 15 increases
J
J
Q
and the governor pressure is balanced
with the sum of centrifugal force and
1 1
f Ai09

CID Fig AT S Output shaft with oil

spring force The governor pressure distributor and overnor
thus changes in response to the vehicle l
speed change centrifugal force

m r @
Line t
pressure @

l
0
AT090

V
Operation of prlmar
I

2
Primary governor
Secondary governor
4

5
Oil di lributor
Output lft
sh
aBUlllI8
iUQlli
3 Governor valve body
governor valve
JlAU AT092

The valve is an OFF

ON valve Fig AT 7 Cr05s sectionallliew of I Oil distributor 3 Primary governor
which closes the
governor pressure governor 2 Governor nlve valve

body 4 Secondary governol

IS regulated by the secondary gover
valve
nor valve when the vehicle reaches the
Fig AT 9 Exploded view of governor
minimum speed and when the vehicle
exceeds certain level the
speed a

governor opens and forwards the gov CONTROL VALVE ASSEMBLY

ernor pressure 15 to the control
valve Flow cbar of control valve system
When the vehicle is stopped the
governor pressure is zero However
when the vehicle is running slowly
Oil from pump
this valve is depressed to Ihe center
and the groove to 15 is closed since
the governor pressure applied to the i j Regulator valve 1
I

ring shaped area is higher than the l

I I
centrifugal force of this valve When I I

the governor speed exceeds a certain

revolution the governor pressure in
I
I
Throttle valve
I I Manual valve
II Auxiliary valve t
t
I
I

the circuit 15 also increases How I

I Line pressure I
I
ever as the centrifugal force increases I
I

and exceeds the governor pressure this

L L Speed change Governor I

j I
n

valve moves toward the outside and valve I valve I

I I
the governor pressure is transmitted to L L 1

the circuil 5

Two different valves are employed j Clutch and brake

in the governor so that it will inde

pendently speed at high

control the
and low speeds That is within the low
The control valve assembly receives tion changeover valves including ON
speed range the governor pressure is
oil from the pump and individual OFF valve and regulator valves are
not generated because of the primary
from the vacuum diaphragm newly reformed to a throllle system
valve whereas at the high speed range signals
and transmits the individual line pres oil pressure and operate other valves
above the breaking point governor
sures to the transmission friction ele Finally the line pressure is transmilled
pressure is regulated by the secondary
ment torque converter circuit and to the required dutch or brake servo
valve
lubricating system circuit as outputs pisJon unit in response to the individu
The breaking point is the point at More specifically the oil from the oil af running conditions after re ejving
which the function of one of the pump is regulated by the regulator signals from the va uum diaphragm
line pressure build up the line downshift solenoid dlvc
governor is transferred to the other valve V
as governor
as the speed changes from the pressure is fed out from the control and or manual linkage
to the high speed range valve various direc
low speed assembly through
6
AT
 Automatic Transmission

the line pressure 6 and the throttle

The control valve assembly consists
to 18
of the following valves See Figure pressure 16 is equal
AT 20

I Pressure regulator valve PRV Manual valve MNV

2 Manual valve MNV The manual lever turning motion is
3 I st 2nd shift valve FSV converted toreciprocating motion of
4 2nd 3rd shift valve SSV
the manual valve through a pin and
5 Pressure modifier valve PMV the MNV is positioned so that the line
6 Vacuum throttle valve VTV the indi
pressure 7 is distributed to
7 Throttle back up valve TBV vidual line pressure circuits at each
8 Solenoid downshift valve SDV
P R N D 2 or I range
9 Second lock valve SL V
as shown below
10 2nd 3rd timing valve TMV

P range
7 4 SDV and TBV
5 FSV 12 TBV and
Pressure regulator valve Low reverse brake
PRV
R range
Thepressure regulator valve re 7 4 same as above
ceives valve spring force force from 5 same as above
the plug created by the throttle pres 6 PRY and SSV F C
and line
sure 16 pressure 7 and and band release
force of the throttle pressure 18 N 7 None
With the interaction of those forces 11 range

the PRY regulates the line pressure 7 D range

7 I Governor valve FSV
to that most suitable for individual AT095
and rear clutch
driving conditions Fig AT 10 Pressure regulator ualue 2 SLY
The oil from the oil pump is ap
3 SL V and SSV
plied to the ring shaped area through
When the range is selected at R
orifice 20 As result the PRV is
a 2 range
Reverse the line 6 is
downward and from pressure
depressed moves 7 I Same as above
applied 10 the plug in a manner identi
port 7 up to such extent that the 2 SL V 9 Band
caito the throttle pressure 16 and is
space to the next drain port marked applied
with X in Figure AT 10 added 10 the spring force Consequent 4 SDV and TBV
opens
the line 7 further in
slightly Thus the line pressure 7 is ly pressure
I
creases range
balanced with the spring force there
When vehicle increases and 7 I Same as above
by balancing the PRV In this opera speed
4 Same as above
tion Ihe space the governor pressure rises the theot
from port 7 to the
5 FSV
tle pressure 18 is applied to the port
subsequent converter oil pressure 14
As on the top of the PRV and pressure is
circuit has also been opened a
1 3 4 5
result the converter is filled with applied contrarily against the spring Moreover 2 and
force As athe line pressure 7
result 6 are always drained at a position
pressurized oil in circuit 14 and this
decreases Moreover at individual con where the line is not dis
is further used for lubrication of pressure
oil
7 tributed from 7
ditions the line pressure is equal to
the rear unit Moreover part of the oil
is branched and used for lubrication of

the front unit for the front and rear

clutches
When

presscd
Ihe accelerator
the throttle pressure 16 in
pedal is de
u 1dIil lt
JJX dlMIi W ld IiIb
g4Vhl It i B J
as described in the preceding
j L@
l tJj fitMi td
creases x
x
jj
is
jd
paragraph oil pressure applied to

the plug through orifice

pressure is added to the spring force

As a result

forced upward
the PRV is contrarily
21

space to the drain

and this

port
P R N 17 l AT096

is reduced and Ihe line pressure 7

increases Fig AT 11 Manual ualvp

AT7
 Automatic Transmission

1st 2nd governor pressure 15 is considerably speed is shifted to 3rd

shift valve FSV
high the valve is forced completely When the accelerator pedJI is de
The FSV is transfer valve which toward the right and the FSV is
a prcssed both the line pressure 3 and
shifts gears from low returned to the Low position This the throttle
to second When pressure 19 are high allll
Ihe vehicle is the operation is alled Kickdown shift the SSV is thus retained in
stopped FSV is nd

depressed to the right side by force of unless the governor pressure 15 ex

a spring located on the left side 15 ceeds the line pressure 3 and the

putting the FSV is in the low throttle pressure 19

j

position In the 3rd position force de

When vehicle speed increases the pressing ihe SSV toward the right is

1 c5
governor pressure 15 is applied to retained only by the throttle pressure
Ihe right side of the FSV and the FSV 13 16 and the throttle pressure 16 is
is forced toward the left Contrarily slightly Idwer than that toward the
the line pressure I togelher with the right which is while
applied shifting
spring force force the FSV toward the from 2nd to 3rd
right opposing the governor pressure I Consequently the SSV is returned
15 0 to the 2nd position at a slightly
When the vehide speed exceeds a lower from 3rd
speed Shifting to
certain level the governor pressure 2nd occurs at a speed slightly lower
15 exceeds the sum of the throttle t 1 than that for 2nd to 3rd shifting
pressure and Ihe spring force and
FSV is forced toward the left
the r
I When kicked down at 3rd line
I pressure 13 is led from the SDV and
When the FSV is depressed 10 a
SSV
certain
q the is forced toward the right
position the lire pressure I is AT091 Although the governor pres ure is con
closed and only the spring depresses siderably high the valve is forced
the FSV toward the right and it is Fig AT 12 lsl 2nd shift valve loward the right and tht
completely
depressed to the end for a moment As
2nd 3rd shift valve SSV is thus returned to 2nd posi
SSV
the
a
resull line p ressure lJ is for tion fhis operation is called K cli
warded to 8 the band servo is The down shift
SSV is a transfer valve which
engaged through the SLY and the shifts gears from 2nd to 3rd When the shift iever is shifted to

speed is shifted to 2nd With the When the vehicle is the SSV 2 or I range at the 3rd speed
stopped
accelerator pedal depressed the FSV is forced toward the line pressure 3 if diained at the
the right by the
remains iIi the Low position unless spring and is in the 2nd position It MNV Consequently the front clutch

the governor pressure IS increases to is so d however and band servo releasing oils are
design that the FSV
a high leVel corresponding to the line can decide to shift either to Low or
drained As a result the transmission is

pressure I since the line pressure I 2nd shifted to 2nd or low speed ai
increase when the accelerator pedal is When the vehicle is running the though the SSV is in the 3rd posi
tion
depresse9 governor pressure 15 is applied to
Contrarily when vehicle speed de When the specd IS shifted io the
the right end surface and th SSV is
creases the governor pressure 15 forced toward the left Contrarily the 1
3r a one way orifice 24 on the
decrease Howeve f the gear is not topof the SSV relieves oil transmitting
l force
Spri line pressure 3 and
shifted to Low nless the governor throttle press re 19 force the SSV velocity from the line pressure 3 to

pressure 15 becomes zero since the toward the right the line pressure 10 and reduces the
force depressing the FSV toward the When vehicle speed exceeds a cee shock generated fioni the shifting
right is being delivered only by the tain level the governor
pressure sur Contrarily when the lever is shifted

spring passes the sum of the spring force line to 2 or I range and the speed is
Low
in range I is led to the pressure and throttle pressure and the shifted from 3rd to the 2nd the
low and reverse clutch from line pres valve is forced toward the left The orifice checking valve spring 24 is

sure 5 through line prbssure 12 line pressure 3 is then closed Con depressed the throttle becomes in
2nd is simultaneousiy led to the ieft sequently the forces being rapjdly effective the line pressure 10 is
end spring unit Consequently al unbalanced the force depressing the drained quickly and delay in shifting
thougp the goverflor pressure in SSV toward the right decreases and speeds is thus eliminated
creases the valve is still forced toward thus the SSV is depressed to the l ft The throttle of line pressure 6
the right and the SFV is fixedjn the end for a moment With Ihe SSV transmits Hie oil transmitting velocity
Low position When kicked down to depressed toward the left end lhe line from line pressure 6 to line pressurc
the 2nd speed the SDV operates pressure 3 is connected with the line 10 wtien the lever is shifted to the
and the line pressure 13 forces the pressure 10 the band servo is re R range and transmits drain veloci
FSV toward the right Although the leased the front clutch is engaged and ty from line pressure 10 to line

8
AT
 Automatic Transmission

pressure 6 when shif ing from 3rd generated the piessure loss is added to 16to circuit 18 This throttle
to 2nd at D range Thus the the spring force and the plug is lhus pressure 18 is applied to the top of
throttle of line pressure 6 reduces forced back from the right to the left the PRV and the force of the line
the shock generated When this pressure 19 increases ex pressure source 7 is reduced Contra
froshifting
A plug in the SSV left end readjust cessively the plug is further depressed rily when the vehicle speed decreases
the throttle piessu e I 6 which varies toward the left space from the lhrot arid the governor ipressure 15 de
tle pressure 19 to the drain circuit creases the force toward the fight
depending on the engine throttle con

dition throttle pressure

to a
19 13 increases and the throttle press exceeds ithe governor pressure the
suiled to the sp ed change control ure 19 decreases Thus the plug is valve is forced back toward the right
balanced imd the throttle and the throttle pressure 18 is
Moreover the plug is a valve which pressure

19 is Ii certain value drained to the spring unit

applies line P esspre 13 in lieu of the reduced to

against the throttle pressure 6 This valve is sWitched when the

throttle pressure to the SSV and the

FSV when kickdowri is performed Wheri performing kickdowri the throttle pressure and the governor

pressure high when tIiey

When throttle
pressure 16 is
the SDV moves a
high line pressure is led are or are

the from the line both Tow i

applied to the left side of this plug to circuit 19
and the plug is epressed toward the pressure circuit 13 which had been
i 11
the plug is forced toward the
I
the drained
right a space is formed from
slight 16
6 10 19 A throt left and circuit 19 becomes equal to 18
throttle pressure
tIepressu 19 is lower by the the line pressure 13
1iFh
w
to this space is n

pressure loss equivalent

I
3 15
f ng valve AT099

1
Jit 24

3
I
15

I
Fig AT 14 Pre

Vacuum thro

The vacuum t
ure

le valve

rottle
modifier valve

VTV

valve is a

regula tor valve whiCh uses the line

W
7 for the pressure source
pressure
and regulates the throttle pressure 16

L
I

l which is proportioned t the force of

I i
I Js the vacuum

dia

engine
phragm yories
diaphragm

throt le
depending
condition
The vacuum

on

negative
the

t
ATOgS
ilr
pressure in the inta e line
rH
When the line pressure 7 is ap
Fig iT 13 2nd 3rd shift vallJe
plied to the bottom through the valve

hole and the va ve is forced upward

1
space from the line pressure 7 to the
I
throttle pressure 16 is dosed and
Pressure Odifier valve PMV When the governor pressuie IS the space from the Ihrottle pressure
I

Compared to the operating pressure which is applied to the right side of 16 to the drain circuit 17 is about
the PMV is low the valve is forced the throttle
required in starting th vehicle the to
open In this operation
toward the right by the throttle ines becomes lower than the
ppwer trimsinitting capacity of the pressure 16

clutch that is required operating pres sure 16 applied to the area differ ureY btthe
s
p e sur
9 iv

of the value and the spring foice

linep
of the loss of and Ihe
sure may be lower when the vehicle is ence alenl space
once started When the line pressure is and t he circuit from circuit 16 to force depressing tlie
rod if thevaeuum

retained at a high level up to a high circuit 18 is closed However when diaphragm is balanced wit Ii thethrot
vehicle speed shock gerieraled from vehicle speed increases andl the gaver tie pressure 16 a pplied upward tOlthe

the shirring increases arid the oil nor pressure 15 exceeds a certain bottom

pump loss also jncrdases In order to level the governor pressure toward the When the erigine torque is high Ihe
prevent his the t lrott pressure must
le left which is applied to the right side negative pressure in the intake iirie
be l hanged over with the operation of exceeds the spring force and the throt rises tending ioward atmospheric
the governor pressure 15 to reduce tle pressure 16 toward thc right the pressure and the force of the rod to
Ihe line pressure The PMV is used for valve is depressed loward the lefi and depress the valve increases As a result

this purposc the throttle pressure is led from circuit the valve is depressed downward the

AT 9
 Automatic Transmission

space from the throttle pressure 16 17 to Ihe upper drain about to open
to the drain r
17 decreases and the the back up pressure 17 which is
space from the line pressure 7 to Ihe lower than the line pressure 4 by the
throttle pressure 16 increases loss due to the space from
pressure
Consequently the throttle pressure circuit 4 to circuit 17 is balanced
16 increases and the valve is bal with the spring force
anced Contrarily when the engine Further when gear is shifted from
torque lowers and the negative pr 2nd to Low at the range I line
sure in the intake line lowers
tending pressure is led from circuit 12 and
toward vacuum the force of the rod the line pressure is applied pward to
depressing the valve decreases and the the bottom of the valve through the
throttle pressure 16 also decreases valve hole Consequently the valve is
When pressure regulated by the throt forced upward and locked As a

tle p valve
back described in the result the space from the line pressure
subsequent paragraph is led to circuit 4 to the back up pressure 17 is
17 a high pressure is applied through closed completely and the back up
the space from the circuit 17 to the 17 is drained upward
pressure
throttle pressure 16 Consequently
AT102
the VTV is unbalanced the throttle
Fig AT 17 Solenoid hift valve
dow
pressure 16 becomes equal to the
back up pressure 17 and the valve is Second lock valve SLY
locked upward This valve is a transfer valve which
assists the shift valve in determining
the fixed 2nd speed at the 2

range
In the D the sum of the
range

spring force and line pressure 3

APplied upward xce ds the linepres

sure 2 which is applied to the valve

area difference as a downward force

As a result the valve is locked
AT101 upward
and the circuit from line pressure 8
Fig AT 16 Throttle back up Jlve
lJ to line pressure 9 is opened
Consequently the FSV becomes
the 2nd speed condition and line
I
is led to the band
pressure servo

16 engaging circuit 9 only when line

pressure 1 is released to line pressure
Solenoid downshift valve 8
SDY In the 2 the force
range upward
is retained only on the spring and the
AT100 This valve is a transfer valve which
III
leads the line pressure 7 to 13 and downward line pressure 2 exceeds

transmits the same to the FSV and the upward force

Fig AT 15 Vacuum throttle valIN
SSV when kickdown As a result Ihe valve is locked
a signal is re

from the downshift solenoid downward line pressure 2 is released

ceived
to 9 regardless of the operating
Usually the solenoid push rod and
condition of the FSV and the band
valve are locked upward by the spring
Throttle back up valve TBY servo is engaged
in the lower end and the circuit from J

Usually this valve is depressed line pressure 4 to line pressure 13 is

downward by the spring force and opened
circuit 17 is drained upward When kickdown is performed the 2
As soon as the lever is shifted either push rod operates Ihe valve is de
to 2 or I range line pressure is pressed downward and the circuit
led from circuit 4 the line from line pressure
pressure is 7
line pressure to
8
applied to the area difference of the 13 opens Line pressure 13 opposes
valve the valve is forced upward the the governor pressure 15 at Ihe SSV
space from circuit 4 to circuit 17 is and FSV thus
accomplishing the ATl03 3
closed and with the space from circuit downshift operation Fig AT 18 Second lock Jlve
lJ

AT 10
 Automatic Transmission

2nd 3rd timln valve TMV the upward force exceeds the down
ward force the valve is locked upward
This valve is a transfer valve which and passage from circuit l0 2nd

switches the by circuit of the from the Top to circuit II is

pass
orifice 22 in the front clutch pres closed Consequently the line pressure
10 is led to the front clutch circuit
sure circuit II in response to vehicle
II the orifice 22
speed and throttle condition A force through and the
created when the governor pressure oil pressure is thus transmitted slowly

IS is to the bottom of the However under normal shifting the

applied
TMV constitutes the upward force throttle pressure 16 has a pressure
and a force created when the spring exceeding a certain level and the
force and the throttle pressure are downward force exceeds the upward
applied to the top of the TMV consti force As a result the valve is locked
AT104
tutes the downward force downward the passage from circuit
When the throttle pressure 16 is 10 to circuit II is opened and the

lower than the governor pressure IS orifice 22 is bypassed Fig JlT 19 2nd 3rd timing valve

ATll
 Automatic Transmission

ern

d
n
lLU J
I

A1094

1 Pressure regulating valve PRV 6 Vacuum throttle valve VfV

2 Manual 7 Throttle back up valve TBV

val MNV
8 Solenoid down shift valve SDV
31st 2nd shift val fSV
4 9 Second lock valve SL V
2nd 3rd shift val SSV
5 PMV 10 2 3 timing val TMV
Pressure modifier valve

Fig AT 20 Controloolve

AT 12
 Automatic Transmission

HYDRAULIC SYSTEM
AND MECHANICAL
OPERATION
The operating system of oil pres
sure in each range is described below

The oil pressure in each circuit

shown in the illustration is classified as

follows according to the function

fhe numeraJs show the circuit num
Oil pump suction hole
bers

Pressure source of the line 7

Operating Iinc prcssure

ATl06
for friction elements
123456 8910 1112
Fig AT 22 Identification of oil channels in case front face
Auxiliary line pressurc 13

Throttle system pressure

16 17 18 19

Others 14 15

Oil pump discharge hole 7 I o

Oil pump dischar

hole 7
Governor pressure 15
Cd I9JM c1L
Torque converter
Os ervo Ie I ease

f
0

pressure 14 pressure 10
Torque converter pressure 14 0
Governor feed pressure l
Rear clutch Servo t ightening
Rear iutch surc
prc 1
pressure l
ho L
0 1 pressure 9 lJ L
I
c

FTOOI c1 tL h prc ur It I
IT reverse brake pressure 12
J1 011 pump Sllctlon hole Front clutch
U 0

r
F T
LIO

M
pressure 11 rrOil J
pump suction hol
CJf
JC II
O

An07
IIJ1iIII AT105

Fig AT 21 Identification of oil channels in oil pump Fig AT 23 Identification of oil channels in case face

AT 13
 Automatic Transmission

P RANGE PARK

The operation of clutches and band

are functionally the same as in Neu
tral
In parking however when the
parking pawl meshes in a gear which is
splined to the output shaft the output
shaft is mechanically locked from
Free Lock
rotating

AT086

Fig AT 24 Parlling mechanum

The oil discharged from the oil Clutch Low Band ervo On
Gw Parkin

pump is fed to each in similar

a IlYer5e
part Range
atia
r
pawl
Fron Rear brakt Operation Release clutch
manner to that of the
range The N
oil having the line pressure 7 which on
Park
has been introduced into the manual
on
I st 2nd shift 2 132
valve Il reaches the
on on
Re er

valve CID through the line pressure

Neutral
circuit 5 As the 1st 2nd shift
on
to th hand ide PI Lw 2 3
valve s force right
by the spring the line pressure 5 and Drive P2 Second 14S3 on on

12 actuates the low and reverse

Also Ihe 03 Top 1 000 on on

brake through the groove
parking pawl engages with the outer
2 Second 458
1
teeth of the oil distributor by means
on
12 Second 1458 on
of the manual lever mechanically
locking the output shaft Low 453
2 on
II

AT 14
 Automatic Transmission

P range Park

A
L
r k

8r k

ll
FrOl

I
ter
Torqu Con Clutch Au

tth
0
I ump

rr
f
4

1 1
r

I
I
r
CID VK

TIlro
to Sol
BI Cow
n

1ft v t
I V lv

011 Coo
I 1
AM Lubr tlo
1111
I j
II

D
i
1111 III il
t V l

I
Front

o v

n Llrll r I Orlflc

v
K

rt Throttl
Dr ln
2
ID Mocl

1 5
v

II

I
@
11 2nd 3
5

d
Timing
J
w
V l

JQ
I

r R I 3J
IKOnd Lock V l

I
II I l rr
t rJ I q 3
D
R tOl V
II
V V l
nu l
I
u J2 n
ll
J
L II P 21 r A J1
I
I
J
Not

LlMl pr
t rk

r
Or ln

10010r
1
BIeOM IV
I Irlmarv
OOllnor Y M OoverrwJf VIIfve
Oo or It

Torqu conv ner

Throttl

A T 25 Oil circuit diagram P Parh

Fig pressu range

AT 15
 Automatic Transmission

R RANGE REVERSE
R
In R the front clutch and
range
the low and reverse brake are applied
The power flow is through the input
shaft front clutch and connecting
shell to the sun gear Clockwise rota

tion of the sun gear causes counter

clockwise rotation of the rear planeta

ry gears With the connecting drum
held stationary by the low and reverse

brake the rear planetary gears rotate

the rear internal gear and drive the
flange counterclockwise The rear

drive flange splined to the output shaft

rotates the output shaft counterclock

reduced with Fig AT 26 Power tranamis ion during

wise at a
speed an R range
increase in torque for reverse gear

m i

1
ATOBS

Fig A T 21 Optrationof each mechanism during R range

When the manual valve V is posi

Clutch Low Band servo One
tioned at R range the oil having the
Gear Partina
Ranae ralio
re ne way
line pressure 7 is directed to line Front Rear Relulie plwl
brake Openlion clutch

circuits 5 and 6 The

pressure
Park on on

pressure in the circuit 5 actuates the

low and reverse brake after being Ruene 2 182 on on on

introduced into line pressure circuit

Neutral
12 through the I st 2nd shift valve
ID The pressure in the circuit op DI Low 2 458 on on

erates the release side of the band

Driowe D2 Second 1458 on on
servo and the front c1u tch after being
led to line pressure circuit 0 D3 Top 1000 on on on

through the 2nd 3rd shift valve @ 2 Second 1458 on on

The throttle pressure I 6 and the line

pressure 6 which vary with the 12 Second S8 on on

degree of accelerator pedal depression

II Low 2 458 on on
both act on the pressure regulator
valve CD and press against its valve CD
increasing line pressure 7 In Rn
range the governor pressure is absent
making all such valves as the 1st 2nd
shift valve ID lnd 3rd shift valvc

@ and pressurc modifier valve

inoperative

AT16
 Automatic Transmission

R range Reverse

Low a Aev
Br k

B k

I
Con Front
Torq R
ltc
Cll Il
Clutch

r f

rr
III I

CID VEL 1
Thrc r
V I I
Oil Cool r

I 1
11
A r Lubtlcetlon
IU 11

111
T

Ilrfl
o
iL
0

Vel
I Front
Ir l II

II I
r
Orlflc

LJ
r
Check

n
jL
Velve
or ln l

J
ID
Throttl
D ln p e
Mc lf v
2f
v
If I

@lnd 3rdShlft
v

22
n D h

x
@ 2nd 3n
l lil
Timl
I
5
r
II 1i t
Q
A uletor Val
U
nu

rII
ni
l3
1 15 15

NIJte kld O eln

p O nOl ft p
L Ll r

a nor v Q V 1ve
Goy l norpreat

Torque rmrp

Throttl p

Fig A T 28 Oil preBBure circuit diagram R range Reverie

AT 17
 Automatic Transmission

N RANGE NEUTRAL

In N range none of the clutches

Clutch Low 4 Band crvo One
and band are applied thus power is
no
R
Geu
WI
Pultin
atio pawl
transmitted to the output shaft Front Rear brake Operation Release clutch

Park on on

The pressure of oil discharged from Reverse 2 182 on on on

the oil pump is regulated by the

Neutral
pressure regulator valve Dto maintain
the line pressure 7 and the oil is led Dt Low 2 458 on on

to the manual valve @ vacuum throt

Drive D2 Second 1458 on on

tie valve @ and solenoid down shift

valve @ The oil is further introduced m Top 1000 on on on on

into the converter at its

torque op
2 Second 1458 on on
erating pressure 14 and a portion of
this oil is distributed to each part as 12 Second 1458 on on

the front lubricant The oil which has

II Low 2 458 on on

been from the torque con

discharged
verter is also distributed to eacn part

as the rear lubricant

As the oil pump rotates at the same

speed as the engine the oil pump

discharge increases with engine speed
But the surplus oil is returned to the
oil pan by the pressure regula tor valve

AT la
 Automatic Transmission

P range Park

Brllk

ar
Front Bond
Con
Torqu u
Cluteh

ID VK
Th o I
IftY
V II

all Coo

A k tlon
Lb

II
1 e
I Front
n
LubrkIt Orltlc
Check

O ln I V

ThrOttle
D ln
V

21

j r

tUI lor V h

@ V hI

5
I

I
N01 M

Line
rked X

pr
r D ln

Go nor tdpr
y
Iecond
I X

no V Gover V
Ocw
J
L Q RO p

J
c Torq co p f

Th ottl p

Fig A T 25 Oil pressure circuit diagram P range Park

AT IS
 Automatic Transmission

R RANGE REVERSE
R
In R range the front dutch and

the low and reverse brake are

applied
The power flow is through the input
shaft front clutch and connecting
shell to the sun gear Clockwise rota
tion of the sun gear causes counter

clockwise rotation of the rear planeta

ry gears the connecting drum
With
held Slationary by the low and reverse
brake the rear planetary gears rotate

the rear internal gear and drive the C

flange counterclockwise The rear

drive flange splined to the output shaft

rotates the output shaft counterclock
Fig AT 26 Power transmi ion R
wise at a reduced speed with an during range

increase in torque for reverse gear

ATOS5

Fig AT 27 Operation attach mechanism during R range

When Ihe manual valve CV is posi

Clutch Low A Band servo One
tioned at R range Ihe oil having Ihe G wa
Parkin
Ran no
ratio plwl
line pressure 7 is directed to line Front Rear brake Operllioo Rdr ue clutch

and
pressure circuits 5 6 The
k on on

pressure in the circuit 5 actuates the

low and reverse brake after being Revctte 1 181 on on on

introduced into line pressure circuit

Neutnl
12 through the I st 2nd shift valve

@ The pressure in Ihe circuit op DI Low 1 418 on on

erates the release side of the band

Driw D2 Second 1458 on on
and the front clutch after
servo being
led to line pressure circuit 10 DJ Top 1000 on on on on

through the 2nd 3rd shift valve @

2 Second 1 458 on on

The throtlle pressure 16 and the line

pressure 6 which vary with the Second 1458
12 on on

degree of acceJerator pedal depression I

II Low 2 458 on on

both act on the prcssure regulator

valve CD and press against its valve CD
increasing line pressure 7 In R
range the governor pressure is absent

making all slldl valves as the J SI 2nd

shift valve @ 2nd 3rd shift valvc

@ and pressure modifier valve j

inoperative

AT 16
 Automatic Transmission

R range Reverse

LowaoA
B k

e k

Front B
TOlQuaConverter
Clutdt Clutch
0

o
IIi
ou

14

ID VK
n @ ftV 1
V lv

FI Lu IUt O I

j
Front

Lub lc Otlflce
Check
V III
O lnV ly

Throttle

O in
V

@lnd 3rdShih
V

zz

If @ 2nd
V Iy
rd TIm

Second Lock V

I
3
Zl

R MO V l

Not M dX
k er 0 1

LI p O nOf f P co
s 0

O V O V
G preau

J Torqu
I 00 pr

Throttl p 1

II

Fig A T 28 Oil pressure circuit diagram n range Reverse

AT 17
 Automatic Transmission

N RANGE NEUTRAL

In N range none of the clutches

Clutch Low Band servo One
and band thus no power is Pukiq
are applied R
G
w
ntlo pawl
transmitted to the output shaft Front Rur br ke Optruion Release clutch

PIlIi on on

The pressure of oil discharged from Reverse 2 182 on on on

the oil pump is regulated by the

1
Neut
pressure regulator valve CD to maintain
the line pressure 7 and the oil is led 01 Low 2 458 on on

to the manual valve V vacuum throt

Drive 02 Second t458 on on

tle valve @ and solenoid down shift

valve @ The oil is further introduced 03 Top 1 000 on on on on

into the torque converter at its op

2 Setond 1458 on on

erating pressure 14 and a portion of

this oil is distributed to each part as 12 Second 1 4
58 on on

the front lubricant The oil which has 1

II Low 2 458 on on

been discharged from the torque con

verter is also distributed to eacn part

as the rear lubricant

As the oil pump rotates at the same

speed as the engine the oil pump

discharge increases with engine speed
But the surplus oil is returned to the
oil pan by the pressure regulator valve

CD

AT 18
 Automatic Transmission

N ranee Neutral

I a
a

nd

VK

Th o
J
Vtlv
@

I
Vtlv
011 Coolei

Lubrlc tlon

11
D ln I

D lnV
Ol

I
v

OIIt

Lubrlut O lfIC
Check
Vtlv
I
T uott

O in
v

8Jl

12
ht 2nd Shift y tve

CD
Rl9UlttO Vtlv

Nott M

1
rkedX

or

no
oov
r

p
D in

IOonOf fNd IH
liia cs
ond
a Ol
y
V o V tve

z
c Torqu con
er pr

Throttl p

Fig AT 29 Oil pressure circuit diagram N range Neutral

AT 19
 Automatic Transmission

D RANGE LOW GEAR

The low gear in D range is

somewhat different from that in I

range
The rear c1utdl is applied as III
I range but the one way clutch
holds the connecting drum The power
now is the same as in 1
J range That
is the power now takes place
through
Ihe input shaft and into the rear

clutch The input shaft is splined to

the rear clutch drum and drives it

Rotation of Ihe rear clutch drives the

ATOSO
rear clutch hub and front internal gear
The front internal gear rotales the
front Fig AT 30 Power transmission during DJ
planetary gears clockwise to range
cause the sun gear to rotate counter
clockwise Counterclockwise rotation
of the gear turns the rear planetary
sun

gears clockwise With the rear plane

tary carrier held stationary by the
one way clutch the clockwise rotation
of the rear planetary gears rotates the
rear internal gear and drives the flange liIIl

clockwise The internal drive I IW L

flange is
splined to the outpul shaft and rotates
AT08l
the output shaft clockwise
Fig AT 31 Operation of each mechanism during VJ range

When the manual valve is posi

tioned D
the line pressure 7
at
Clutch low Band servo On
Cur Parking
introduced into the manual valve is led Ran Rllelle way
ratio pawl
to the line pressure circuits l Front Rur brake Operation Rekase ch lch
2
and 3 The pressure in the circuit I
Park on on

acluates the rear clutch and the gover

nor and al the same time RellerK 2 t82

operates the on on on

1st 2nd shift valve CID to change the

Neutral
speed The circuit 2 leads to the
second lock valve @ The circuit 3 01 low 2 S8 on on

actuates the 2nd 3rd shift valve @ Orivt 02 Second 1 458 on on

for the 2nd 3rd speed change and

at the same lime locks the second OJ Top 1000 on on on on

lock valve @ 2 Second 1458 on 00

The throttle pressure 16 which

changes with the degree of accelerator t2 Second 1 458 on on

t
pedal depression presses Ihe pressure
tt low 2 458 on on

regulator valve CD and increases the

line pressure 7 When Ihe speed of
the vehicle has increased the
governor pressure actsagainst the force of the l and the spring which are exerting
pressure 15 introduced from the line spring of the pressure regulator valve against t
1e governor pressure There
circuit I
pressure actuates the CD and also against the throttle pres fore when the governor pressure ex
I SI 2nd shift valve CID 2nd 3rd sure 16thus lowering the line pres ceeds Ihis pressure the speed is shifted
shift valve @ and pressure modifier sure 7 from the I st gear to the 2nd
gear
valve ID When the governor pressure The governor pressure also increases The further the accelerator pedal is
is the pressure modifier valve
high ID with the speed of Ihe vehicle exerting depressed the becomes the
higher
acls in such a direction as to compress a
pressure on one side of the throttle pressure 19 increasing the
the spring and the throttle
pressure is lst 2nd shift valve and counter acts and
led to the throttle pressure 18 This
governor pressure shifting the
the Ihrottle pressure 19 line pressure speed change point to the higher side
AT 20
 Automatic Transmission

0 range Low gear

L A

Front

I
Torque Conven
Clul
Clutch

Q
TIC 011 p
V

ID Th O
v

V
011 Cool

RUf LubtJuflon

n
IO lln Ii
V l

F ont

Lub lclt n Orifice

D nV V
l

ThroW
L
01
V I

13

12
tt llttY
2NtSt

Q P P

tOO V

Note U

Llnep
X Ir or

IO
n

nor feed
Iecotodary
nOl V
QoY
i Y
roo
Oew v

no
GoY p

Torque co p

Th on

uD 1 Low gear
Fig A T 32 Oil pressure circuit diagram range

AT 21
 Automatic Transmission

D RANGE 2ND GEAR

In this case
rear the h
c1ut IS
applied and the band brake holds the

fronl h drum
dUh the connecting
shell and the gear from rotating
sun

The power flow lakes place through

the input shaft into the rear clutch and
the front internal gear With the sun

gear held stationary the front planeta

ry gears rotate around the sun gear

carrying the front planet carrier with

them The fronl carrier

planet being
splined to the output shaft causes

clockwise rotation of the output shaft

at a reduced
speed compared with the Fig AT 33 Power transmission during Dz range
speed of the input shaft with an
t
increase in torque As the low and
reverse brake is not applied the clock
wise rotation of the output shaft
causes clockwise rotation of rear inter
nal gear and the rear planet carrier also

rotates around the sun gear in a

clockwise direction The one way

clutch will act to allow the clockwise
rotation of connecting drum
AT079

Fig AT 34 Operation of each mechanism during D range

Clutch Low Band servo On

G Patking
Range reverse w

ratio pawl
Fronl Rur brake Optrltion Release clutch

PlIk on on

Revtne 2 182 on on on

Neutral
When the car speed increases while

running at D range I st gear the 01 Low 2 4S8 on on

st 2nd shift valve ID moves allow

Drive 02 Second 1 4S8 on on

ing the line pressure I to be intro

duced into the line pressure 8 OJ Top 1000 on on on on

Ihrough itself The line pressure 8 is on

2 Second 14S8 on

further led to the line pressure 9

through the second lock valve @ and 12 Second 14S8 on on

1
by locking the band servo obtains the Low 4S8
2 on on
II
2nd gear condition

AT 22
 Automatic Transmission

0 ran e 2nd ear

I
I
I

7 Throttle

V
k up
lftV

II

I ont
Lubtlclt n Orifice

CKk
C alnV I
Val

Th ottle
O n 2
S Mod V l

Valve
IS

13

@2rlCl 3 dShlft
V

13

2nd Shift V l
311ft
S

CD
Regulator V

Manual
V

PR

Nota M

LI p

norp
Gov
X r Dr

r
nor
IGov fINd P
ieconoery
Gov nor V
I n
1 O nof Vaw
i

J
c 00
TORI pr

Iiiiiiiiiiiiiii Thronle pr

Fig A T 35 Oil pressure circuit diagram D z range 2nd gear

AT 23
 Automatic Transmission

D RANGE TOP GEAR

OJ
In 3rd gear
position the front and
rear dUlches are engaged The power
a
now takes place through the input
shaft into rear clutch drum The rear

clutch drum rotates the steel drive

plates of the rear clutch and the lined

drive plates of the rear clutch and the
lined drive plates of the front clutch
The rear clutch directs the power flow
through the rear clutch hub and front

internal gear to the front pl net

carrier

The front clutch directs Ihe power

Fig AT 36 Power transmission during DJ range
now through the connecting shell to
the sun gear Wilh the sun gear and the
rear clutch hub driven at the same

speed the front planet assembly is

forced to rotate the output shaft at

the in the direction

same speed to

provide the top gear

A T083

Fig AT 3 Operation of aeh mf hani5m UDJ range

When the car speed further in

Low Band KrVO One
Clulch Parking
em
creases while running at D2 range 8t
Ral
reverK w
pawl
ratio Rdene
and the governor pressure Front Rear brake Operation clutch
2nd gear

15 exceeds the combined force of on

on
Park
the spring of the 2nd 3rd shift valve
19 the
@ and the throttle pressure Reverse 2 182 on on on

2nd 3rd shift valve @ moves and

Neutral
the line pressure 8 acts to release the
front clutch and band servo through 01 Low 24S8 on
on

the line pressure 10

Drive 02 Second 14S8 on on

on on
03 Top 1000 on on

1 Second t 4S8 on on

12 Second 1 458 on on

t
I Lo 2 458 on on

AT 24
 Automatic Transmission

0 range Top gear

Low A

lI eke

e
B

I
I

011 COO

R Lubfkatlon
VK

Thro
V
mf J
V va
J
y
o Ot al

oi v
L

Front
Lubric 1 n Oriliu
Check

O nV 1 1

Th onla P M lflM V I
O eln 2
Vah 5

22

i2J
1n 2nd Shift v 1Ye
3
5

j Pr

R I Of 1 1

Manue

Val

5
PRND2

Nota

11

Oo no p
r
Marked
Dr ln

IOono feold P

G
ond
y
nor Val
rs Goy
l
y
rnor Val

c on np
Torq

Th onl pr

Fig A T 38 Oil pressure circuit diagram uD J range Top gear

AT 25
 Automatic Transmission

0 RANGE KICKOOWN

While operating at speeds below Clutch La Band servo On

lnl
Parll
Cur
80 to 90 kmfh 50 to w

appruximately Ran e
nUo
ltr5e
rf

Release clutch
pawl
Fronl Rear brake Opcullon
55 MPII a kick 3rd 2nd downshift
by fully de
an be accomplished Park on
on

the accelerator
pressing
on
A kick 3rd lst or 2nd lst Reverse 2 82 on on

downshift can also be accomplished Neutral

below approximately 40 to 50 kmfh
on
25 to 30 MPII Dt low 2458 on

When kickdown is performed the Drive 02 cond 1 458 on on

f push rod operates by the solenoid the on on

D Top t ooo on on

valve is depressed downward and the

r circuit from hne pressure 7 to

the

the hne pressure 13 opens The h e

2 Second 1458 on on

t on
12 Second 1 458 on

press e 13 3 plus the force of the

t
4 on
2nd 3rd shift valve spring oppose tl low 2 8 on

f
the governor pressure 15 thc at

2nd 3rd shift valve @ and thus

3rd 2nd downshift op
performs
eration

Moreover the hne pressure 13

the force of the lst 2nd shift
plus
valve spring oppose the governor pres
sure 15 at the I st 2nd shift valve

ID and thus perform 3rd 2nd or

2nd st downshift operation

AT 26
 Automatic Transmission

0 range kickdown Shift valves In 2nd gear position

Low a A
8

e e
8
Front a
To queeO t Clutch

14

Oil COO
VK
Th

V
o

lv
7 Throttle

BKk up
V hl
ID So COw
e
1 iftV 8

R Lubrication

n
0
Drain 4
1
j v

I
Front
Lub icet P Ifk

Check

p o
n I V I

5
1
Mod Yo
Thron
24
p ain

I
V I

@2nCl lilr
3rdSl

12
ht 2nd Shih V
3
5

j V I
gu
R ato I
r
1
M
0
nual
I
J
f4fL

PR

L
Not Ma

Li
ked X

pr
r p

IGo
n

no fdp l COnd
S
I Primary
X

norValve
G rw Va Gov

Governor p

c Torque CO I1 p

ThrOWepr

D ronge kickdown shift values in 2nd gear position

Fig AT 39 Oil pressure circuit diagram

AT 27
 Automatic Transmission
2 RANGE 2ND GEAR

In 2 range the gear rario is IOI keJ

III the 2nd forward speed In this case

the rear dutch is engaged and the band

brake holds the front clutch drum the

connecting shell and sun gear from

rotating
The power flow takes place through
the input shaft inlo the rear clutch
and the front internal gear With Ihe
sun gear held stationary the front
planetary gears rotate around the sun

gear carrying the front planet carrier

with them The front planet carrier AT078

being splined to the

output shaft
causes clockwise rotation of the OUI
Fig AT 40 Powu tTansminion during 2
H

range
put shaft at a reduced speed compared
to the speed of the input shaft with
an increase in torque As the low and
reverse brake is not
engaged the clock
wise rotation the of
output shaft
causes clockwise rotation of fear inter
nal gear and the rear
planet carrier also
rotates around the sun in
gear a

clockwise direction The one way

clutch will act to allow clockwise
rotation of connecting drum
A1079

Fig AT 41 Operation of each mechanism during 2 range

When the manual valve V is posi
tioned at 2 the line pressure 7 is Clutch Low Band ser o On
introduced into the line pressure cir Gw Parking
Ran8t w
utio pa
cuits I 2 and 4 The line pressure Front Rear brake Operalion Release dutch

I is led to the governor rear clutch

Pui on on
and I st 2nd shift valve CID as in the
case of D
range The line pressure
e
Revtrs 2 182 on on on

2 locks the second lock valve @and

Neutral
is led to thc tightening side of Ihe
band servo 01 Low 2 458 on on

The 2nd gear is therefore fixed

Drive 02 Second 1 458 Oft Oft

regardless of vehicle speed When

DJ range 3rd gear is shifted to 2 OJ Top 1000 on on on on

range the line pressure 4 enters Ihe

1 Second 1458 on Oft
throttle back up valve V and produces
a
high pressure in the circuit 17 12 tocond 1458 on on

J
increasing thc throttle pressure li 6
tt Low 2 458 on on
The line pressure 7 is therefore
increased and the
quickly tightens
band

2 position causing the line pres decrease from 3rd gear to 2nd
sure circuit 3 to be drained In this case the speed
N 3rd gear
gear change
e
DJ range to 2 Therefore the line pressure circuit takes
quickly place because the line
range is situated at the release
10 which pressure 7 and other pressure are
If DJ 3rd gear is shifled
range side of the front clutch and servo is
2
heightened by the action of the line
to the
range during operation also drained through the 2nd 3rd pressure 4 in the same manner as
manual valve V is also shifted to shift val e @ forcing the speed to described under 2 range
AT 28
 Automatic Transmission

2 range 2nd gear

l ow A

B ke

Br

Fron
Torqu Con
Clutch

12
i
12

7
ID v

Th ot
T onl
Beck up ID So
0
Id
1ft v

IL Valve
V

011 Cool

Front
Orltic
Lubric t
Check

e Va
Or lnVal

P Va
Modif
Throttle
15
Dr in

V l

BJl
If @ 2nct 3rd

Ve
Tim

12
2nd Stolt
3 1

21

Se l onc Lock Va

I
3

J I r

Gr v
A ul

2 w

Valve

PR 02 1
Jl
I
s

Note Merltedl

Line p
D a n

d pr
nOf f
IOo ond
I G v
a nor v
r
G no p

oTorque
c con pr

re
Thron p

2nd gear
Fig A T 42 Oil pressure circuit diagram 2 range

AT 29
 Automatic Transmission

1 RANGE LOW GEAR

Wilen slJrting in I range the

drlvlIlg gear is IOlked to the low gear

fJIIIJ
H

In range the rear clutch is

engJged and the low and reverse brake

hulds he onnecting drum and feac

planet from rotating

carrier The

power tlow lakes place through the

input shaft and into lhe rear clutch

ROlalion of the
rear clutch drives lhe

dutch hub and front internal gear

rear

The front internal gear rotates the C

front planetary gears clockwise to AT076

cause the sun gear to rotate counter

clockwise
Fig AT 43 Power transmission during 1 J
range
Counterclockwise rotation of the
sun gear turns the rear planetary gear
clockwise
The planet carrier splined to
rear Fai1
the connecting drum is held from
rotating by the low and reverse brake
The clockwise rotation of the rear

planetary gears therefore rotates the

f
rear internal gear and internal drive

tlange The internal drive tlange is

splined to the output shaft and rotates

ATOn
the uutput shaft clockwise However

the output shaft rotates at a lower Fig AT 44 Operation of each mechanism during JJ range

speed compared to that of the input

shaft This is caused by the fact Ihat
Clutch Low Band servo On
the front planet carrier rotates at the Gm
Range reverse w
Parking
ratIO
Ihe OUlput shaft in the pawl
same speed as Front Rur brake Operatlon Release clulCh

same direction since the carrier is

Park on on
splined to the output shaft The front
internal gear and planetary gear assem Reverse 2 182 on on on

bly are rotating in the same direction

Neutral
but the planet carrier is
rotating at a
speed slower than the ring gear So the 01 low 2 458 on on

gear ralio of this speed range is a

Drive 02 Second 1 458 on on
combination of the ratios provided by
the front and rear planetary gear as 03 Top 1000 on on on on

semblies
2 Second 1 458 on on

2 Second IAS8 on on

1 low 458
2 on on

When the manual valve Vis posi the rear clutch and governor The line pressure 15 which acts on the
tioned at I the line pressure 7 4
is pressure acts in the same manner as I st 2nd shift valve does not increase
applied into the line pressure circuits in 2 range until it overcomes the combined force
I 4 and 5 The oil pressure in 5 Similar to that of the D range of the line 12 and the
pressure
actuates the luw and reverse brake the line pressure reases with the
inr spring causing no st 2nd speed
after being introduced into the circuit
degree of accelerator pedal depression cha nge
12 through Ihe 1st 2nd shift valve and the line pressure decreases with
ID and the line pressure I acts on the increase of car speed The governor

AT 30
 Automatic Transmission

1 range Low gear

ift
Down
Oid
llll

14

VK

Th o @50 D
I

IttV
10 v

il
Dr in 14

I Front

Lubrlc t Oritlc
ChKk
V
O mV I i

P Modif t
Th on

0 1
11 IS
V

1M 2nd hlf

23

J
6
g M

V l
nu

PR

i
NOI M

11
keel X

P
Ir 0 1
11

nOt
IOov tMod P
sond
I I V
v
V Oov
Of
1
O
no
O p

Torqul con pr

Tn ont pr

II

Fig A 45
T Oil pressure circuit diagram II range Low gear

AT 31
 Automatic Transmission

1 ran 2nd ar

L l
ak

v u Co nro O h
0
So OId

r fi v

Th o IhV
ou Coo V we

L UIIoft

O ein

iv

Lubolcat
OtHIc
0 v CO
v

Tlwont MOdIf
Q in
v

1
0 V joy
h1
ll v

iJl

N 8I1l 1
0

L1 p 10011 0 fdP
lli Onct Y
a v 0 V
nor
a no

Torq conv

Th on pt

Fig A 46
T Oil pr ure circuit diagram 1 z range 2nd gear

AT J2
 Automatic Transmission

REMOVAL AND INSTALLATION

CONTENTS

TRANSMISSION ASSEMBLY AT 33 TRANSMISSION CONTROL LINKAGE AT 35

REMOVAL AT 33 REMOVAL AND INSTALLATION AT 35

AT 33 ADJUSTMENT AT 35
INSTALLATION

TRANSMISSION 8 Disconnect vacuum tube from bolts support engine and transmission
vacuum diaphragm and wire connee with jack and lower the jack gradually
ASSEMBLY lions at downshift solenoid until transmission can be removed and
When the automatic cable take out transmission under the car
dismounting 9 Disconnect speedometer
transmission from vehicle at from
a pay rear extension

tention to the following points 10 Disconnect oil charging pipe Note Plug up the opening such as oil
II Disconnect oil cooler inlet and charging pipe oil cooler tubes
1 Before dismounting the trans
etc
mission rigidly inspecl it by aid of the outlet tubes at transmission case

12 Support engine by locating a

Troubleshooting Chart and dis
INSTALLATION
mount it only when considered to be jack under oil pan with a wooden
block used between oil pan and jack Installation of automatic transmis
necessary
sion vehicle is order of
Support transmission by means of a on reverse
2 Dismount the transmission with
transmission removal However observe the follow
utmost care and when mounting jack
the 13 Detach converter housing dust ing installation notes
observe tightening torque indi
another table not to exert cover Remove bolts securing torque Drive plate runout
cated on

excessive force converter to drive plate See Figure Turn crankshaft one full turn and

4
AT t with indi
measure drive plate mnou

finger of dial gauge rested

cating a

against plate See Figure 48

AT
plate if in of
Replace drive excess

REMOVAL 0 5 mm 0 020 in

In dismounting automatic transmis

Maximum allowable mnout
sion from vehicle proceed as follows
0 3 mm 0 012 in
I Disconnect battery ground cable
from terminal
2 Disengage torsion shaft from ac

celerator linkage AT261

3 Jack up vehicle and support its

weight safety stands Recommend a

on Fig AT 47 Removing torque conv rter
attaching bolts
hydraulic hoist or open pit be utilized
if available
Make that safety is insured Before con
sure Note removing torque
4 Remove propeller shaft verter scribe match marks on

two parts so that they may be

A T262
replaced in their original posi
Note Plug up the opening in the rear tions at assembly Fig AT 48 MeCJ uring drive plate
extension to prevent oil from runout

out
flowing
2 Installation of torque converter
14 Remove rear engine mount

securing bolts and crossmember Line up notch in torque converter

5 Disconnect front exhaust tube
with that in oil pump Be extremely
6 Disconnect selector range lever mounting bolts
15 Remove starter motor careful not to cause undue stresses in
from manual shaft
in installing converter
wire connections at 16 Remove bolts securing transmis parts torq e
7 Disconnect
See Figure 49
AT
inhibitor switch sion to engine After removing these

AT 33
 Automatic Transmission

4 Bolt converter to drive plate Starter should be into op

brought
eration only when selector lever is in
P and N it should not
positions
marks
Note Align chalk painted a be started when lever is in D 2
cross both parts during disas I and R positions
sembling processes Back up lamp should also light
when selector lever is placed in R
position
S After converter is installed rotate
10 Check level of oil in transmis
AT116 crankshaft several turns and check to
sion For detailed procedure see
be sure that transmission rotates freely page
AT48
Fig AT 49 Torque converter without binding
II Move selector lever through aU
aligning cu t
6 Pour recommended automatic
positions to be sure that transmission
transmission fluid up to correct level
3 When connecting torque can operates correctly
through oil charge pipe
verter to transmission measure dis With hand brake
7
applied rotate
A Connect manual lever to shift
tan to be certain that they are
engine at idling Without disturbing
d S F rod
Opeiationsliould oecaTrie fbue
correctly mbi the above sclUng ffiovTSelector lever
with manual and selector levers in
AT 50 through N to D to 2 to I
Distance A N
and to R A slight shock should be
8 Connect inhibitor switch wires
More than 215 mm 0 846 in felt by hand gripping selector each
time transmission is shifted

Notes Refer Note See page AT 49 for checking

a to covering topic
under Checking and adjusting engine idling
n

inhibitor switch on page

AT 49
b Inspect and adjust switch as
12 Check to be that line pres
sure
above whenever it has to be
sure is correct To do this
refer to
removed for service
relative topic under Testing line pres
ATl17 sure on page AT 52

9 Check inhibitor switch for op 13 Perform stall test as per the

Fig AT 50 Installing torque converter eration instructions on page AT 50

AT 34
 Automatic Transmission

TRANSMISSION CONTROL LINKAGE

4 j B

L120N
p

4 G

AT273

of
1 Control lever knob Tightening torque 1
2 Pusher nuts and screw kg m ft lb

3 Control lever assembly

4 Selector range lever @ T 07 to
0 13
0 0 5 to 0 9

5 Control lever bracket @ T 16 to 2 2 12 to 16

T 3 to 4 22 to 29
6 Selector rod
@ T 0 35 to 0 45 5 to 3 3
2

C8i T 0 8 to 1 6 to 8

Fig AT 51 Control i kage

f tem
sy

REMOVAL AND
important as Inspection of oil level 3 Loosen adjust nuts @ Set
INSTALLATION
for the automatic transmission control lever @ and selector lever @
1 Disconnect control knob from Therefore should be at N position moreover set the
great care J

control lever by removing two 2 clearance C to I mm 0 039 in by

exercised because faulty adjustment
screws
will result in the breakdown of the turning in or out adjusting nuts at

2 Remove console box transmission trunnion with connects selector rod

3 Remove selector rod selector @
1 Prior to installing control knob
range lever and control lever assembly set the dimension A to II to 12 mm After adjusting make sure that
with bracket 0 43 to 0 47 in control lever be set in any position
can

To install reverse the order of 2 Install control knob on lever At correctly and that selector lever oper
removal the same time check the dimension ates properly without any binding
B and adjust it to 1 to
0 1 mm If levers do not operate satisfactori
ADJUSTMENT 0 004 to 0 043 in by turning pusher ly readjust or replace parts as neces

@ See Figure AT 51 sary

The adjustment of linkage is as

AT 35
 Automatic Transmission

MAJOR REPAIR OPERATION

CONTENTS

SERVICE NOTICE FOR DISASSEMBLY COMPONENT PARTS AT 40

AND ASSEMBLY
AT 36 FRONT CLUTCH 40
AT
TORQUE CONVERTER AT 36 REAR CLUTCH 41
AT
INSPECTION AT 36 LOW REVERSE BRAKE 42
AT
TRANSMISSION AT 36 SERVO PISTON 42
AT
DISASSEMBL Y AT 36 GOVERNOR 43
AT
INSPECTION AT 38 OIL PUMP
43
AT
ASSEMBL Y AT 38 PLANETARY CARRIER AT 44
CONTROL VALVE AT44

SERVICE NOTICE INSPECTION 2 Remove bolts securing converter

FOR DISASSEMBLY 1 Check torque convertf for any housing to transmission case Remove
converter
AND ASSEMBLY sign of damage bending oil leak or torque
deformation If necessary replace 3 Remove speedometer pinion
I It
is advisable that repair opera
2 Remove rust from pilots and sleeve bolt Withdraw pinion
tions be carried out in a dust proof 4
bosses completely Remove downshift solenoid and
room
If torque Do not leave dia
converter oil is fouled or vacuum diaphragm
2 Due to the differences of the
contaminated due to burnt clutch phragm rod this stage of disas
at
engine capacities the specifications of flush the torque converter as follows sembly Rod is assembled in top of
component parts for each model s See
Drain oil in torque converter
vacuum diaphragm Figure
transmission may be different They I
AT 53
2 Pour non lead gasoline or kero
do however have common adjust
ment and repair sene into torque converter approxi
procedures as well as
and mately 5 liter
0 I U S pt U Imp
cleaning inspection procedures
outlined hereinafter pt
3 Blow air into torque converter
3 During repair operations refer to
and flush and drain out
Service Data and Specifications see gasoline
tionfor the correct parts for each 4 Fill torque converter with

model torque converter oil approximately

5 liter
0 I V S pt U Imp pt
4 Before of subas
removing any
semblies 5 Again blow air into torque con
thoroughly clean the outside Fig AT 53 Down hilt olenoid and

of the transmission to verter and drain torque converter oil

prevent dirt vacuum dilJphragm
from entering the mechanical parts 5 Remove bolts which hold valve
5 Do not use a waste rag Use a
body to transmission case See Figure
nylon orpaper cloth TRANSMISSION AT 54
6 After disassembling wash all dis
assembled parts and examine them to DISASSEMBLY
see if there are any worn damaged or
I Drain oil from the end of rear
defective parts and how they are
extension Mount transmission on
affected Refer to Service Data for
Transmission Case Stand ST07870000
the extent of damage that justifies or ST07860000 Remove oil pan See
replacement
7 As rule seals and
Figure AT 52
a packings
similar parts once disassembled should
be replaced with new ones

AT 54
Fig Removing valve body

6 Loosen lock nut @ piston

TORQUE CONVERTER on

stem D as shown in Figure AT 55

The torque converter is a welded Then tighten piston stem in order to
construction and can not be disas AT118 prevent front clutch drum from falling
sembled Fig AT 52 Removing oil pan when oil pump is withdrawn

AT 36
 Automatic Transmission

Ii AT127
AT124
AT121
Fig AT 61 Remouin rear extension

Fig AT 58 R mouin connectin shell

band seruo
Fig A T 55 Loosenin

12 With the aid of Snap Ring Re 16 Pull out output shaft remove oil
7 Pull out input shaft
8 Withdraw oil pump using Sliding mover HT69860000 pry snap ring off distributor CV together with governor
Hammer ST25850000 Do not allow output shaft See Figure AT 59 valve CD See Figure AT 62

front clutch to come out of position

and drop onto floor See Figure
AT 56

Fig AT 62 Remouinggouernorand
Fig AT 59 Remouing sruzp ring oil distributor
AT122

Fig AT 56 Removing oil pump 13 Remove connecting drum and 17 Pry off snap ring using a pair of
inner gear of rear planetary carrier as pliers Remove retaining plate drive
an assembly See Figure AT 60 plate driven plate and dish plate in
that order See Figure 63
AT
9 Remove band strut This can be
done stem further
by loosening piston
See Figure AT 57

AT126

Fig AT 60 Remouing connecting Fig AT 63 Remouing driue and

drum driuen plates

Fig AT 57 R moving band strut

14 Remove snap rings and then 18 Reaching through back side of
remove rear planetary carrier internal transmission case remove hex head

front gear connecting drum one way clutch slotted bolts as shown in Figure
10 Remove brake band
outer race and one way clutch in that AT 64 To do this use Hex head
clutch and rear clutch as an assembled
oroer Extension ST25570001
unit
by ST25570000 One way clutch inner
11 Remove connecting shell rear 15 Remove rear extension
return
race thrust washer piston
clutch hub and front planetary carrier loosening securing bolts See Figure
spring and thrUst spring ring can now
as a unit See Figure AT 58 61
AT
be removed
AT 37
 Automatic Transmission
Clearance
j
i 0
Up
I

t
V
@ J1i 1
Seal dng
ll J
iL
ST25570001
1

0
t
lli
I1
l
Ii
@
P
i
p
l 1
l
0
61 j
j rr
Lj Y l
i

J ry
j J

w h
1 AT130 Fig AT 67 Removing manual plate
AT133 I
I
Fig AT 64 Removing hex head slotted
bolt
22 Remove inhibitor switch and
manual shaft by loosening two secur
19 Blowout low and reverse brake
ing bolts AT134
piston by directing a jet of air into
ig r 68
A Me qsuringseal ring to
holeJn cylinder See Figure AT65
ring groove clearance

ASSEMBLY

Assembly is in reverse order of

disassembly However observe the fol
lowing assembly notes
After installing piston of low and
INSPECTION
reverse orake assemble thrust spring

Torque converter housing ring return spring thrust washer and

one way clutch inner race Torque
transmission case and
hex head slotted bolt to L3to 18 kg m
rear extension
9 to 13 ft ib using Hex head Ex
I Check for damage or cracking if
Fig AT 65 Removing piston tension ST2SS7000 ST2SS70000
necessary replace Wrench GG93010000 and
Torque
2 Check for dents or score marks
ST2S490000
Socket Extension
20 Remove band servo loosening on mating surfaces Repair as nee
ST2SS 12001 See Figure AT 69
attaching bolts essary

3 If rear extension bushing is worn

Note If difficulty is encountered in
or cracked replace it as an assembly of
removing retainer direct a jet of air
bushing and rear extension housing
toward release side as shown in
ST2557000t
Figure AT 66 ST25490000
I
GG930JOOOO

II Gaskets and O ring

1 Always use new gaskets when the

units are to be disassembled

2 Check O rings for burrs or crack

A T135

ing If necessary replace with new

Fig AT 69 Installing ont woy clutch

AP rings
inner race

fWl1
011 distributor 2 After low and reverse brake has
AT132
been assembled measure the clearance
I Check for signs of wear on seal
Fig AT fiB Removing bond servo between snap ring CD and retaining
ring and ring groove replacing with
plate @ Select proper thickness of
new ones if found worn beyond use
retaining plate to give correct ring to
21 Pry snap rings CD from both Check that clearance between seal
plate clearance See Figure AT 70
ends of parking brake lever @ and ring and ring groove is correct If out
is Low and reverse brake
remove the lever Back off manual of specification replace whichever
limits Correct clearance clearance
shaft lock nut ID and remove manual worn beyond
is from 0 04 to 16
0 mm 0 0016 to 0 80 to 1 05 rom
plale @ and parking rod CID See
67
AT 0 0063 in See Figure 68
AT 0 0315 to 0 0413 in
Figure
AT J8
 Automatic Transmission

7 Install rear clutch hub and front

carrier shown in Figure
planetary as

AT 72

Rear
c
i
clutch

N edle bearing

Bearing race
I AT139
Fig AT 70 Measuring ring to plate Fig AT 75 Measuring the distance
clearance
A and C

AT142
2 Measure the distance B and
Available retaining plate
Fig AT 72 Installing planetary carrier D of oil pump cover as shown in

Figure AT 76
Thickness mm in 8 Assemble connecting shell and
other parts to front Clutch in

IL
up

1l8 0 465 reverse order of disassembly

12 0 0472

12 2 0480 I Oiipi mp
124 0488

12 6 0496

12 8 0 504
AT140

Fig AT 76 Measuring the distance

B and D

For for low AT143

inspection procedure Adjustment of total end play
and reverse brake see page 42
AT for
Fig AT 73 Installing connecting shell Select oil pump cover bearing race
Assembly
by calculating the following formula
3 Install one way clutch so that the
mark is toward front of total end play and front A B W
arrow 9 Adjust TT
vehicle It should be free to rotate end playas follows where
only in clockwise direction See Figure
TT Required thickness of oil pump
AT 71
cover bearing race mm in
Front end play
A Measured distance A mm in
L
r B Measured distance B mm in

mITIJ
L W Thickness of bearing race

I inserted mm in
temporarily
r
CD
Available oil pump cover bearing
L
o oml AT137
Total end
I
play
@
J

1
race

Thickness mm in

2
1 047
0
Fig AT 71 One way clutch
I 4 0 055
AT138
4 Afterinstalling rear extension Front clutch 5 Trammission case 1 6 0 063
torque attaching bolts to 2 0 to 2 5 thrust washer 6 Oil pump gasket 1 8 0 071
2 Oil pump cover
kg m 14 to 18 ft lb Place manual 7 Oil pump cover
3 Front clutch bearing 2 0 0 079
range and check to be sure
race
lever in P
4 Rear clutch
that rear output shaft is securely 2 0 087

blocked Fig AT 74 End play

5 retainer temporari
Tighten servo

ly at this
stage of assembly 1 Measure the distance A and Specified total end play
vernier shown in 25100
0 50 mm
6 Place rear clutch assembly with C by calipers as

needle bearing on front assembly AT 75 0 0098 to 0 0197 in

Figure
AT 39
 Automatic Transmission

12 After inhibitor switch is in i

Adjustment of front end play i

H
n
stalled check to be sure that it op

ni i
t front dutch thrust washer by
Sele For
erates properly in each range
calculating the following formula
detailed procedure page AT
refer to
II
TF C D 02 mm
49 for ing
Checl and Adjusting Inhibi
c A
iif
where tor Switch
between L
L
TF Required thickness of front 13 Check the length 1

in case end to rod end ofvacuum

throllle AT145
clutch thrust washer mm

valve fully in Then select

C Measured distance C mm in pushed
of corre
D Measured distance D mm in adequate diaphragm rod
Fig AT 77 Measuring the distance
sponding measured length See Figure L
AT 77

Available diaphragm rod

Available front clutch thrust

Diaphragm rod in
washer Distanl e measured L ITIm in length mm

29 00 142
u

Under25 55 l OO59
Thickness mm in
25 65 to 26 05 1 0098 to 1 0256 29 1161
5
5
1 0 059
15
26 to 55
26 10295 to 1 0453 30 0 1 81
I 7 0 067
26 65 to 27 05 10492 to 1 0650 30 5 1201
1 9 0 075
Over 15
27 1 0689 310 I O
2 1 0 083

23 0 091

5
2 0 098 COMPONENT PARTS I Pry off snap ring D with a

The transmission cons sts of many suitable screwdriver or a pair of pliers

27 106
0
small that are quite alike in Remove a retaining plate @ drive
parts
construction yet machined to very plate CID driven plate @ and dished

close tolerances When disassembling plate @ in the order listed as shown

Specified front end play in Figure AT 78
0 8 mm parts be sure to place them in order in
0 5 to I
in
0 020 to 0 031 in part rack so they can be restored 2 Compress clutch springs using
the unit in their proper positions It is Clutch Spring Compressor
also very important to perform func ST25420001 or 25420000
51 Re

tianal test whenever it is designated move snap ring @ from spring

re

Notes tainer using Snap Ring Remover

a Correct thickness of bearing race
FRONT CLUTCH ST2532000 I See Figure AT 79
and thrust washer is always the one
which is nearest the calculated one
Disassembly
b Installed thickness of oil pump gas
ket is 0 4 mm 0 016 in
Front

clutch drum

10 Check to be sure that brake I

Pinon
freely For detailed
piston
lcz
servo moves

ptocedure refer to page AT42 for AT147

Servo Piston Use care to prevent

piston from coming out of place dUI
Fig AT 79 Removing snap ring
ing testing since servo retainer is not
tightened at this point of assembly
II Make sure that brake band strut
t
AT146
is correctly installcd Torque piston
1 Snap ring S Dished plate
stem to 12 to 5 kg
1 m 9 to 11
2 Retaining plate 6 Snap ring
Note When Clutch Spring Compres
f1 lb Back off two full lurns and 3 Drive plate 7 Spring retainer
sor ST25420000 is to be used cut
secure with lock nut Lock nut tight 4 Driven plate 8 Coil spring
5
1 4 0 II to
the toe tips of three legs by a
ening torque is to kg m
Fit AT 78 Sectional view of

9 f1 lb front clu tch grinding wheel See Figure 80

AT

40
AT
 Automatic Transmission

L 1
1 E 5
Eo

20 l mm
AT148 3 0 079 in

Cut off hatched portion

Fig AT SO Modifying coil spring

compres or

AT150
Lub ication hole
3 spring retainer f and
Take out
Fig AT B4 Testing front clutch
spring @ See Figure AT 78
Fig AT 82 Inserting clutch plate
4 Blowout piston by directing a jet
of air inlO hole in clutch drum See
AT 8l REAR CLUTCH
Figure 3 After clutch is assembled make
sure that clearance between snap
ring
and Disassembly
CD retaining plate @ is held
within specified limits If necessary

try with other plates having different

thickness until correct clearance is

obtained See Figure AT 83

Specified clearance
I 6 to 1 8 mm

0 063 to 0 071 in

AT149 Available retaining plate

Fig AT 81 Blowing out piston

Thickness mm in

10 6 0417

AT153
10 8 0425
Inspection
1 Rear clutch drum 6 Driven plate
I Check for signs of wear or dam 11 0 0 433
2 Front clutch piston 7 Dished plate
to clutch drive plate facing If
age 112 0441 3 Snap ring 8 Spring retainer
found worn or damaged excessively 4 Retaining plate 9 Coil spring
II 4 0 449
discard See Service Data for limits 5 Drive plate

2 Check for on snap ring and 116 0457

wear Fig A T 85 Sectional view of
for weakened or broken coil spring rear clu tch

If necessary replace with new ones I Take out snap ring @ retaining
Spring retainer should also be in plate @ drive plate @ driven plate
spected for warpage @ and dished plate f Same tech
nique can be applied as in disas
sembling front clutch See Figure
Assembly AT 85
2 Remove snap ring from coil
I Assembly is in reverse the order
spring retainer See Figure AT 86
of disassembly Dip all parts in clean
automatic transmission fluid before
AT151
installing
2 Line up driven plates so that
Fig AT 83 Measuring ring to plate
stripped arcs are properly aligned clearance

paying particular attention to the loca

tion of oil holes in clutch drum See

Figure AT 82 4 Testing front clutch

Note The number of drive and driven With front clutch assembled on oil ST2532001

plates varies with the type of vehi

cle For detailed information see
pump cover direct a jet of air into
hole in clutch drum See Figure Xf
Service Data Specifications AT 84 Fig AT 86 Remolling snap ring

41
AT
 Automatic Transmission

3 Blowout piston by directing a jet 3 Without disturbiilg the above

of air into hole in clutch drum See 1
w setting check to be sure that clearance

Figure AT 87
Ai 1
between snap ring and retaining plate
I i is within specified limits If necessary
i
j
3 use other plates of different thickness
until correct
P2 clearance is obtained

V i Specified clearance
0 80 to 1 05 rom

J
i 0 0315 to 0 0413 in
AT157

j 4 Blow air into oil hole

Fig A T 89 Testing rear C U tch
compressed
in low reverse brake to test for
AT155
definite brake operation as shown in
Figure AT 90
Fig AT 87 Blowing out piston

Inspectl ioW S REVERSE BRAKE

Refer to page AT41 for Inspection
Disassembly
ofFront Clutch
1 Fllow steps as described in page
AT 36 for Transmission Disassembly
Assembly 2 mow out piston by directing a jet
of air into oil hole in clutch piston
Assemble in reverse the order of

disassembly Dip all parts in clean

automatic transmission fluid before
Fig AT 90 Testing low reverse
Note that the number of
assembling brake
drive and driven plates varies with type
of vehicle F or details refer to Serv Inspection
ice Data Specifications I plate facing for wear
Check drive SERVO PISTON
I After rear clutch is assembled
or damage if necessary replace Refer
check to be sure that clearance be
to Service Data Specifications for Disassembly
tween snap ring D and retaining plate tolerances
l is held within prescribed toler I Blowout piston by directing a jet
2 Test pistonspring for
return
ances See Figure AT 88 of air into hole in release side of
weakness Discard if weakened beyond
piston
use
clearance 2 Remove piston
Specified with
servo return
1 0 to 15 rom
3 Replace faulty parts new
spring
ones
0 039 to 0059 in

Inspection
Assembly
Check piston for wear damage or
I After low piston is reverse
other faults which might interfere with
installed assemble thrust spring ring
proper brake operation
retum spring thrust washer and
one way clutch inner race Using
Hex head Extension ST25570001
v
ST25570000 torque hex head slot r 0
ted bolt 3 to
I 18 9 to 13
kg m
AT156 111
ft lb
Fig AT SS Measuring ring to plate 2 Insert dished plate driven plate
clearance drive plate and retaining
transmission case in that order
plate into
Install
Ll 7
2 Testing rear clutch
sn p ring to secure the installation J
Install rear clutch on oil I
pump
cover Note The number of drive and driven
Blow compressed air into oil hole plates wries with type of vehicle AT159

to test for defInite clutch For detailed information refer to

operation as

shown in Figure 89
AT Service Data Specifications Fig AT 91 Removing pi3ton

AT42
 Automatic Transmission

3 If primary governor is to be dis

assembled for any purpose remove

valve
spring seat primary governor

spring and spring seat

j
i
r 1 Anchor end pin Inspection
2 Band strut

3
I Check valve for faulty condition
Apply
4 Release Replace spring if found weakened

11 5

6
7
Return

Band
spring
piston
servo

Band servo piston

stem
beyond use Faulty piston should also
be replaced with a new one

2 Examine to see if primary gover

@ @
I 8
9
Servo retainer
Brake band assembly nor slides freely without binding

3 To determine if secondary gaver

10 Transmission case

AT290
nor is in good condition blow air
Fig AT 92 Sectional view ofseruo piston under light pressure into hole at A
and listen for noise like that of a

Assembly model plane

I Prior to assembly dip all parts in
clean automatic transmission fluid 7
o
Assembly
Reverse disassembly procedure to J

assemble brake I
i 1S Reverse disassembly procedure to

assemble governor
avoid dam Y
2 Use extreme care to

when installing seal

z 1 Note Do not confuse primary gover
aging rubber ring 1 secondary governor After
lace i nor with

3 Blow compressed air from apply t 9c fa installation check that spring is not

side of piston to test for definite AT161 deflected

Fig AT 94 Testing piston
piston operation as shown in Figure
Release side
AT 93

GOVERNOR

OIL PUMP
Disassembly

i8 I Separate governor from oil dis Disassembly

c
1r
ror1

f
7 f A
tributor

nor
by unscrewing attaching bolts
To disassemble secondary gover
remove spring seat spring and
I Free pump

housing by removing attaching

2 Take out
cover from

inner and outer gears

pump
bolts

1 secondary governor valve from valve

J

0 II from pump housing

c
r
1 body in that order as shown in Figure

1 I @ AT 95

1
O j To control 3
L IV I
val Inspection
iJ fl

i
n
0

I Inspect for wear or damage to

5MI
AT160

n
Fig AT 93 Testing piston gear teeth Replace rubber ring if
Apply side found damaged beyond use
r
ID 2 Using a straight edge and feelers
Ii
I measure pump and gear clearances as

follows

Clearance between inner or outer

gear and pump cover See Figure

4
AT 96
From control valve
4 With apply side of piston plugged Line pre sure I ATOgO Standard clearance
I
with thumb blow air into
compressed I Primary governor 4 Oil distributor 0 02 to 0 04 mm
cylinder from release side as shown in
2 Secondary governor 5 Output shaft 0 0008100 0016 in
Figure AT94 If retainer is raised a 3 Governor valve body
0 11
00
little it is indication that attaching Replace if over 0 08 mm
an Fig AT 95 Testing secondary
in
bolts are loose calling for retightening govemor

43
AT
 Automatic Transmission

Replace if over 0 80 mm 0 0315

in

CONTROL VALVE

ST255801JOO
u AT264
The control valve assembly consists
of many preci ion parts and requir s
extreme care when it has to be reo

moved and serviced It is good practice

Fig AT 99 Measuring runout
AT 96
to place parts in a part rack so that
Fig Measuring clearanc
they can be reassembled in valve body
5 in their proper positions Added
Tighten pump securing bolts to care

specified torque 0 6 to 0 8 kg m 4 should also be exercised

prevent to
Clearance between seal ring and
to 6 ft Ib springs and other small parts from
ring groove See Figure AT 97
being scattered and lo t
Standarddearance Note Be sure to a1ign converter
Before assembly dip all parts in
0 04 io 16
0 mm housing securing bolt holes
clean automatic transmission fluid and
0 0016 to 0 0063 in check to be certain that they are free
6 Again check the runout of oil
cover
of lint and other minute particles If
pump
learance clutch or band is burnt or if oil

I Seal ring
Note When
sembling Gauge
former Oil Pump
is to be used make
As
becomes fouled
sembly should be
the control valve as

di ssembled and
q

a screw hole in side of it

flushed

Disassembly
I PLANETARY CARRIER
I Remove bolts and nuts which
The

1n l
planetary carrier cannot be retain oil Bolts may be
trainer re

divided into its individual

AT 5
components moved with a screwdriver but it is
If any part of component is
Fig AT 97 faulty recommended that Hexagon Wrench
Measuring clearance
replace the carrier as a unit HT610oo800 and Spinner Handle
HT62350000 be used See Figure
Assembly
AT 101
Inspection
I Set up pump housing with inner
and outer pump gears on it Check clearance between pinion
2 washer and planetary carrier with a
Using Oil Pump Assembling
ST25580000
instail pump feeler See Figure AT 100
Gauge
coverta pump housing as shown in Standard clearance
Figure AT 98 0 20 to 0 70 mm
0 0079 to 0 0276 in
ST 5

J
000
Clearance

I HT61000800
I I

1 Fig AT 101 Disassembling valve body

JL
AT166
11 2 Remove attaching bolts With

Fig AT 98 Centering oil pump

Jr r bolts

separate
are
removed

free
plate
for
lower
and upper valve
removal
valve

See
body
body
Figure
3 Temporarily lighten
ing bolts
pump secur
I AT 102

Note Do not allow orifice check

4 Set the runout of oil AT167
pump cover vah e and valve spring in lower valve
within D7 mm
0 0 0028 in total
Fig AT 100 Measuring pinion washer body to be scattered and lost when
indicator reading See AT 99
Figure to ca ier clearance removing separate plate
44
AT
 Automatic Transmission

Note Do not it
I w
off with screw

drivers To avoid darnagingmachine

do work it ff with

1
screws not
screwdriver

F D
l t
a

f
J n
Ull IU P
C
19l1 J
o

IODrR
SJQIl2J
CJ
CC t
lhl
fB LL6 rt
AT169
Fig AT 103 Removing manual val

5 Remove side plate

Fig AT 102 Removing separate pllJte
pull out pres
sure regulator valve second lock valve
pressure regi1lator plug and two valve
springs
3 Pull out manual valve as shown in 6 Remove side plate With side
Figure Ar103 plate removed solenoid downshift
4 Remove side Take
plate out valve throttle back up valve vacuum
1st 2nd shift valve 2nd 3rd shift throttle valve 2 d 3rd t ing valve
AT1 1
valve HT61000800
pressure modifier valve and and three valve springs are free for
three valve springs See Figure AT 104 Fig AT 104 Removing side plate removal

p e eguJa Of le6Ve or essure

r reguJl oL

f
@iO
I g
y

hl
2I r
l J
JI t Io j

SecOni
J lOCltvalYi 1
i

S
2nd 3rd taltimivneg
0 r
r
x
en
t
i i
C 1iJrilth rottle lI
lY e
3 1
a
M

2i1d
st 2nd S

dSt1itLvalv
3
ft
alVSY
aIvel
I j1
If
f
2i 3 CP g

fI
so iit a stiift i
V81v
hrottle
f
iicnjp yi
VB
P ie mo i

Fig AT 105 Components ports of control uolue

Inspection
r

I Check valves for sign of burning tension if necessary replace 5 Check oil passages in valve b dy
and if necessary replace 4 Examine for any sign for sign of and other condi
oLdamage damage
2 Check to be certain that oil marks on separate plate If tions which
or score might interfere with prop
strainer is in good condition If found left unheedcd oiL will bypass correct er valve operation
damaged in any manner disCard oilpassages causing many types of 6 Check bolts for threads
stripped
3 Test valve for weakened
springs abnormalities in thesystem
Replace as required

AT45
 Automatic Transmission

Valve spring chart

Installed
Mean coil
Wiredia No of free length
Valve spring dia
in
mm active coil
mm in
mm in Length Load
mm in kg lb

3
1 6 0 15 0
Manual detent 4
32 26 5 5 5
0 051 0 236 1276 1043 1
12

2
1 5
10 13 0 43 0 5
23 2 8
Pressure regulator
0 047 413
0 1 693 0 925 6 2

4
0 80 5 0 5
18
Pressure modifier 9 0 0 1
0 016 0 315 0 728 354
0 02

06 6 0 6 0 32 0 16 0 0 625
1st 2nd shift
0 024 0 236 1 260 0 630 378
1

07 6 2 80 410 17 0 1 40
2nd 3rd shifl
0 028 0 244 1 614 0 669 3 09

0 7 5 5 15 0 5
32 27 0 0 55
2nd 3rd timing
0 028 0 217 1280 1 063 21
1

08 6 5 14 0 36 0 18 8 1 92
Throule back lIP
0 031 0 256 1417 0 740 4 23

55
0 5 0 12 0 22 0 0 60
Solenoid downshift 12 5
0 0217 0 197 0 866 0 492 32
1

0 55 5 0 16 0
Second lock 33 5 210 0 60
0 0217 0 197 319
1 0 827 32
1

0 9 5 6 14 0 26 8 19 0 2 9
Throule relief
0035 0 220 1055 0 748 483

0 23 4 77 12 0 J5 5 11 5 01
0
Orifice check
0 0091 1878
0 0 610 453
0 0 02

45
0 3
8 5 0 21 8 5
7 0 215
Primary governor
0 0177 327
0 0 858 295
0 474
0

0 7 8 5 5 5 25 1 10 5 I 10
Secondary governor
0 028 335
0 0 988 413
0 43
2

Free
Assembly ifications when designated
A installed

f
i
n
n
lenglhm DO
ri
Wire dia
Assemble in reverse order of disas
sembly However observe the follow
ing assembly noles Refer to Valve
Spring Chart and illustralion in as
I Slide valve into valve

particularly careful
forced in any way
2 Install side plates
that

using Torque
body arid
they are
be
not

AT172 sembling valve springs Dip all parts in Driver ST25160000 Hexagon
and
clean automatic transmission fluid Wrench HT6 I 000800 See Figure
Fig AT 106 Value spring before assembly Tighten parts to
spec AT l 07

AT46
 Automatic Transmission

Note Install check valve and relief

spring so that they are properly

positioned in valve body L

ST25160000

HT6 1 000800
4 Install upper and lower valves
AT174
See Figure AT 108
Fig AT 108 Installing valve body
J Tightening torque
AT173
0 25 to 35
0 kg m
Fig AT 107 Installing side plate 2 to 3 ft lb
5 Install oil strainer

3 Install orifice check valve valve Reamer bolt tightening torque Tightening torque
25
0 to 35 kg
0 m
spring throttle relief valve spring and 5
0 to 0 7 kg m

2 to 3 ft Ib
steel ball in valve body 4 to 5 ft lb

AT47
 Automatic Transmission

TROUBLE DIAGNOSIS AND ADJUSTMENT

CONTENTS

INSPECTION AND ADJUSTMENT ROAD TEST AT 51

BEFORE TRQUBLE DIAGNOSIS AT 4B VEHICLE SPEED AT GEAR SHIFT AT 51
TESTING INSTRUMENT FOR INSPECTION 48
AT CHECKING SPEED CHANGING
CHECKING OIL LEVEL 4B
AT CONDITION AT 52
INSPECTION AND REPAIR OF CHECKING ITEMS DURING SPEED
OIL EAKAGE AT49 CHANGE AT 52
CHECKING ENGINE IDLING SHIFT SCHEDULE AT 52
REVOLUTION 49
AT LINE PRESSURE TEST AT 52
CHECKING AND ADJUSTING KICKDOWN LINE PRESSURE governor feed pressure AT 53
SWITCH AND DqWNSHIFT SOLENOID 49
AT JUDGEMENT IN MEASURING LINE
N JJ Qt
CII8li p JYSTMs T OF
L PRESSURE 3
AT
MANUAL LINKAGE 49
At TR6 uBLE SHOOTINC CHART AT 53

CHECKING AND ADJUSTING INHIBITOR INSPECTING ITEMS AT 53

SWITCH AT49 TROUBLE SHOOTING CHART FOR 3N71B

STALL TEST AT 50 AUTOMATIC TRANSMISSION AT 54

STALL TEST PROCEDURES AT 50 TROUBLE SHOOTING GUIDE FOR 3N71B

JUDGEMENT AT 50 AUTOMATIC TRANSMISSION AT 57

Since most automatic transmission 3 Oil pressure gauge SO

ing temperatures o temperature
troubles can be repaired by simple to 800C 122 to l760F
It is convenient to install these Approxi
adjustment do not disassemble im
mately ten minute of operation will
instruments in a
way that allows meas
mediately raise the temperature to this range
urements to be made from the driver s
Firstly inspect and
adjust the auto and engine idling conditions are stabi
seat
matic transmission in place utilizing lized Then the brakes and
apply
the Trouble Shooting Chart move the transmission shift lever
If the trouble can not be solved by through all drive positions and place it
this procedure remove and disas in park P position In this inspec
CHECKING OIL LEVEL
semble the automatic transmission It tion the car must be level
placed on a

is advisable to check overhaul and In checking the automatic transmis

surface
sion the oillevel and the condition of
repair each part in the order listed in The amount of the oil varies with
the Trouble oil around the oil level gauge should be
Shooting Chart the temperature As a rule the oil level
examined This is an easy and effective
I In the Trouble must be measured after its temper
Shooting Chart since some
trouble shooting procedure ture becomes sufficiently high
the diagnosis items are arranged ac changes in oil condition are often
cording to difficulty from easy to linked with 1 Fill the oil to the line H The
developed troubles
difficult therefore please follow these difference of capacities between both
items The transmission should not be For instance is
H and L approximately 0 4
removed unless necessary Lack of oil causes faulty operation liter Ji VS p Y Imp pl and
2 Tests and adjustments should be by making the clutches and brakes therefore do not to fill beyond the
made on the basis of standard values slip resulting in severe wear line H
and the data should be recorded This is because the oil pump sucks 2 When topping up and changing
air causing oil foaming thus oil should be taken to
rapidly care prevent
deteriorating the oil quality and pro mixing the oil with dust and water

INSPECTION AND ducing sludge and varnish

Excessive oil is also bad because of
ADJUSTMENT oil foaming caused by the gears stirring InspectIng 011 condition
BEFORE
up the oil During high speed driving The condition of oil sticking to the
TROUBLE DIAGNOSIS excessive oil in the transmission often
level gauge indicates whether to over
blows out from the breather haul and repair the transmission or
look for the faulty part
TESTING INSTRUMENT FOR
If the oil has deteriorated to a
INSPECTION Measuring 011 level varnish ike it causes the con
quality
I tachometer
Engine To check the fluid level start the trol valve to stick Blackened oil indi
2 Vacuum gauge engine and run it until normal operat cates a burned clutch brake band etc

AO
T
 Automatic rransmission

In these cases the transmission must Wipe off the leaking oil and dust INSPECTION AND

be repaired and deiecl the spol of oil eakage lse

ADJUSTMENT OF MANUAL
nonflammable organic solve t s ch as
Notes LINKAGE
carbon tetrachloride for wiping
a In checking oil level use special The adjustmcnt of manual linkage
cloth to handle the level
Raise tcmperalure by op
the oil is equaUy important as Inspection of
paper
erating the engine and shift the lever for the automatic transmis
gauge and be careful not to let the Oil Level
to D to increase the oil
scraps of paper and cloth stick to
pressure sion Thereforc
great care should be
The spot of oil lcakage will then be
the gauge exercised because incorrect adjustment
found more easily in the brcakdown of the
b Insert the gauge fully and take it will rcsult
out quickly before splashing oil Note As oil leakage from the breaih
transmission

adheres to the gauge Then observe does not take

er place except when
the level
running at high speed it is impos
c Use automatic transmission fluid sible to locate this leakage with Inspection
having DEXRON identifications vehicle stationary Pull the selector lever toward you
only in the 3N71B automatic trans
and turn it as far as P to I range
mission
wherc clicks will be felt by the hand
d Pay attention because the oil to be CHECKING ENGINE IDLING
This is the detcnt of manual valve in
used differs from that used in the REVOLUTION the valve and indicates th
body
Nissan Full Automatic TranSJTIis
Theengine idling revolution should correct position of the lever
sion 3N71A Never mix the oils
be properly adjusted Inspect whether the pointer of
If the engine revolution is too low selector dial corresponds to this point
the engine does not operate smoothly and also whether the lever comes in

and if too high a strong shock or alignment with the stepping of posi
INSPECTION AND REPAIR
tion plate when it is released
creep develops when changing over
OF OIL LEAKAGE
from N to D or R
leakage takes place the
When oil
portion near the leakage is covered Adjustment
with oil presenting difficulty in This be accomplish
CHECKING AND ADJUSTING procedure can

detecting the spot Therefore the to AT 35 for

ed by refcrring page
KICK DOWN SWITCH AND
places where oil seals and gaskets are
Removal and Installa tion
equipped are enumerated below DOWNSHIFT SOLENOID

11 Converter housing
Rubber ring of oil pump housing When the kickdown operation is
Oil seal of oil pump housing not made properly or the speed chang CHECKING AND ADJUSTING
Oil seal of engine crankshaft ing point s too high check the kick INHIBITOR SWITCH
Bolts of converter housing to case
down switch downshift solenoid and
The inhibitor switch lights the re
the
2 Trarismission and rear extension wiring between them When igni in the R of the
verse lamp range
ion and rear li n key is pqsitioned a t the I st stage
Junction of transm ss transmission peratio and also rotates
ol
extension J nd the accelerator pedal is depressed the starter motor in the ranges N
deeply the switch contact should be
Oil cooler tube connectors and P
closed and the solenoid should click If
Oil pan
it does not click it indicates a defect
CD
Oil pressure inspection holes Refer
Then check each part with the testing
toFigure AT il2
instruments See Figure ATl09 @
Mounting portion of vacuum dia
@ b ell If
phragm and downshift solenoid L t dl

@
Breather and oil charging pipe

Speedometer pinion sleeve

d I
7
4l
Oil se l of rear extension
@ 1l
To exactly locate the place of oil
proceed as follows
j7 @ AT109

leaka
le t
6 Washer
t Inhibitor switch
Place the vehicle in a pit and by 7 Nut
2 Manual shaft
AT10S
the leaked oil determine if it Inhibitor switch
sampling 3 Washer 8

the 9 Range select lever

is torque converter oil The torque Fig AT 109 Downshift solenoid 4 Nut

5 Manual plate
converter oil has a color like r d wine
So it is easily distinguished from engine Note Watch for oil leakage from Fig AT 110 Construction of inhibitor
switch
oil or gear oil transmission case

4Q
AT
 Automatic Transmission

Chcck whether the reverse lamp vehicle is held in a stalled condition test for the four ranges 0 2

and the starter motor operate normal The carburctor is in full throttle opera I and R

ly in these ranges If Ihere is any tion with the selector lever in ranges
lrouble first check the If f 2 and
linkage no I respectively Com
JUDGEMENT
fault is found in the linkage check the pare the measured results with the
inhibitor switch slandard values High stall revolution more than

Separate the manual lever from Ihe standard revolution

remote control selector rod and turn Components to be tested and If the engine revolution in stall
the range selcct lever to N test items condition is higher than the standard
Note N I Clutches brake and band in trans values it indicates that one or more
In the position the slot of
the manual shaft is vertical mission for clutches in the transmission are
slipping
2 Torque converter for proper fune slipping and therefore no further test

Using the tester check the two

tioning is required
black yellow BY wires from the in 3 Engine for overall properly For the following abnormalities
hibitor switch in the ranges N and
the respective causes are presumed
I and the twre d black RBj wir s
High rpm in all ranges low Iine
in the range R for continuity Turn
range select lever in both directions STALL TEST PROCEDURES pressure
High rpm in D 2 and I and
from each lever set position and check
Before Icsting c heck the engine oil normal rpm in R Rear clutch
each continuity range It is normal if
and torque converter oil warm up the
the slipping
electricity is on while the lever is
engine cooling water to suitable tem High rpm in 0 and 2 and
within an angle of about 30 on both
perature by running at 1
200 rpm with normal rpm in I One way
sides from each lever set line How
the selector lever in the range P for clutch
if its slipping
ever
continl ity range is obvious several minutes Warm up the torque High rpm in R only Front
ly unequal on both sides adjustment is
converter oil to suitable temperature clutch or low and reverse brake
required 6010 1000C 140 to 2l20F
If any malfunction is found un
slipping
I Mount the engine tachometer at a
the nut of the range To determine which is slipping
screw fastening
selector lever and two location that allows good visibility front clutch or low and reverse brake
fastening bolts
fro the dri er s seat and put a mark
of the switch body and then remove a road test is nceded
the machine screw under the switch
on specified revolutions on the meter
If whilc coasting after starting
2 Secure the front and rear wheels
body Adjust the manual shaft correct with the lever in 1 range engine
ly to the position N by means of the
with chocks and apply the hand brake braking does not work properly the
Be sure to depress the brake pedal low and brake is slipping
selector lever When the slot of the reverse

fumly with the left foot before de Otherwise the front clutch is slipping
shaft becomes vertical the detent
works to position the shaft pressing the accelerator pedal Slipping of the band brake is diffi
correctly
with
3 Throw the selector lever into the cult to ascertain However if it
a
clicking sound occurs

range 1 with the lever in 2 range engine

MSlVe the switch slightly asjJe so

that the screw hole will be aligned

4 Slowly depress the accelerator revolution increases Jp to thesarne

pedal until the throttle valvc is fully level in I strange It is

with the pin hole of the internal rotor as impossible
combined with the manual shaft and opened Quickly read and record the to check it in the stall test

engine revolution when the engine

check their alignment by inserting a
2 Standard stall revolution
5 mm 0059 in diameter pin into
1 begins to rotate steadily and then

the holes If the alignment is correct release the accelerator pedal If the engine revolution in stall
5 Shift the selector lever to N condition is within the standard
fasten the switch body with the bolts
and operate the engine at approxi values the control elements are nor
pull out the pin tighten up the screw

in the hole and fasten the selector mately rpm 200

1 for more than one mally operating in the ranges 0

lever as before Check the continuity minute to cool down the torque con 2 I and R
verter oil and coolant Also tIle engine and one way
again with the tester If the malfunc
6 Make similar stall tests in ranges clutch of the converter
tion still remains replace the inhibitor torque are

switch 2 I and RIO normal in and operation

performance
The one way clutch of the torque
Note The stall test operation as speci converter however sometimes sticks
item 4 should be I
fd in l3de This is determined in the road test
STALL TEST wiihin five seconds If it takes too
an the 3 Lower stall revolution than stand
The purpose of this test is to check long the oil deteriorates
brake and band ad ard revolution
the transmission and engine for trou clutches are

ble by measuring the maximum num versely affected Sufficient cooling If the engine revolution in stall
bers of revolutions of the engine while time should be given between each condition is lower than the standard

AT 5O
 Automatic Transmission

values it indicates that the engine is in

2 torque converter s one
If the ROAD TEST
abnormal condition or the torque con way clutch sticks vehicle speed can
An accurate knowledge of the auto
not exceed approximately 80 km h
verter s one way clutch is slipping
ltic
l
JT transmission is required for an
50 MPH in the road test In such a

4 oil tem exact diagnosis

Others case the torque converter
It is recommended that a diagnosis
rises abnormally and so
1 If the accelerating performance perature
guide chart with the standard vehicle
is poor until vehicle speed of approxi special required
care is
speeds for each stage of the up and
mately 50 km h 30 MPH is attained 3 transmission does not op
If the
down shiftings be prepared Measured
it erate properly at all vehicle speeds it
and then normal beyond that speed vehicle speeds are to be filled in the
that the torque con indicates poor engine performance
can be judged adjoining column after each testing
verter s one way clutch is slipping
Also it is advisable to mount a

stopper for positioning the throttle

opening

VEHICLE SPEED AT GEAR SHIFT

Throttle opening mmHg Gear shift Vehicle speed km h MPH Propeller shaft rpm

51 to 65 32 to 40 1 840 to 2 340
Dl D2
92 to 106 57 to 66 3 340 to 3 840
0
D2 D3
Kickdown
96 to 82 60 to 51 3 460 to 2 960
D3 D2
49 to 36 30 to 22 1 790 to 1 290
D2 Dl
9t023 6toI4 330to 830
Dl D2
48 to 61 30 to 38 1 720 to 2 220
D2 D3
Half throttle 200
D3 D2 or
37 to 24 23 to 15 1 350 to 850

D3 Dl
19 12 700 Max
D2 Dl
I 51 to 38 32 to 24 1 860 to 1 360
Fuol throttle 0
12 1

Minimum throttle 450 I 51 to 38 32 to 24 1 860 to 1 360

12 1

Reduce the speed by shifting to I range from D range output shaft 2 000 rpm

Note Vehicle speed can be calculated by the following formula

2x 1f x rx Np x 60
V
RF x 1 000

where V Vehicle speed h

km
Np Propeller shaft revolution rpm
R Final gear ratio
r Tire effective radius m

TT The ratio of circumference of a circle to its diameter 14

3

375
4
RF
r 0321 6 00 14

AT 51
 Automatic Transmission

CHECKING SPEED SHI SCHEDULE

CHANGING CONDITION

hk
3

The driver s feeling during gear

12 I 2
changes should also be checkedatten 100 J
I
1
tively 2 I
I
I 2 3
I
I sharp shock or unSffioothness is
A c
oo
I
felt during a gear change E
I

2 A gear change is made with a long I

300
I
Z 5
and dragging feeling L1
that mmHg t
These indicate the tIuottle
400 I
pressure is too low or some valve I
3SA
connected to the throttle is faulty 1
500 000

Output shaft speed rpm

CHECKING ITEMS DURING km hO 1O 20 30 40 50 60 70 80 00

90100
SPEED CHANGE
MPH Ii io io 30 40 0 60
I In D range gear changes DI Vehicle speed R 4 315 r 321
0 6 00 14 ATll0

D2 D3 effected In
are
R
Fig AT 111 Shift IChedule
increase
range the speed does not
2 The kickdown operates properly
LINE PRESSURE TEST
3 By moving the lever from D to
I gear changes D 12
2 1 When any slipping occurs in clutch

effected In the ranges and

are 12 or brake or the feeling during a speed
I the engine braking works prop change is not correct the line pressure
must be checked t
I
erly
4 In I the speed does not in Measuring line pressure is done by a

1
I
crease pressure gauge attached to two pres
5 Should be quickly fixed at 2 sure measuring holes after removing l
1
blind
c
D
plugs
c

located at transmission 7
range
o

6 In P vehicle can he parked case See Figure AT 112 jf

Theline pressure measurement is CV
properly
If any malfunction occurs in second begun at idling and taken step by step
is if by enlarging the throttle opening
gear during the road test that ATl13

vehicle shakes drags or slings while I sharp shock in up shifting or

A
1 Lige pressure
from D to too high changing speeds are caused
shifting up directly 2 Governor feed
D or in up from D
shifting to mostly by too high throttle pressure 3 SerVo release pressure
D2 the brake band should be ad 2 Slipping or incapability of opera
If these troubles remain after tion is mostly due to oil pressure Fig AT 112 uring line preuure
justed MeCJ
leakage within the gear trains spool
the brake band is adjusted check the or

servo piston seal for oil leakage valve

AT S2
 Automatic Transmission

LINE PRESSURE GOVERNOR FEED PRESSURE

At cut back point After cut back

Range Throttle opening under approximately over approximately

15 kmfh 10 MPH 35 kmfh 22 MPH

Unit mmHg Unit kgfcm2 psi Unit kgfcm2 psi

Full throtlle 0 9 4 to 110 134 to 156 5 to 5

6 78 to 92
D
Minill1um throttle 450 3 0 to 4 0 43to 57 3 0 to 4 0 43 to 57

10 0 to 12 0 5 5 to 7 0 78 to 100
Fulllhrotlle 0 142 to 171
2
Minimum throttle 450 6 0 to 12 0 85to171 5 5 to 70 78 to 100

Full throtlle 0 14 0 to 16 0 199 to 228 14 0 to 16 0 199 to 228

R
3 0 to 5 5 43 to 78 3 0 to 5 5 4 lo 78
Minimum throttle 450

Notes a The line pressure during idling corresponds to the oil pressure before cut down at minimum throttle
b The oil pressure After cut back means that after the pressure modifier valve has operated

JUDGEMENT IN MEASURING pressure due to a sticking regulator A Oil level

valve B lge
Ra select linkage
LINE PRESSURE checked C Inhibitor switch and wiring
Vacuum leakage is by
directly measuring the negative pres D Vacuum diaphragm and piping
Low idling line pressure in the
sure after removing the vacuum pipe E Downshift solenoid kickdown
ranges D 2 I R and pH
A of the dia switch and wiring
puncture vacuum
This can be atlributed to trouble in F
phragm can be easily ascertained Engine idling rpm
the pressure supply system or too low
because the oil is G Oil pressure throttle
torque converter
output of power caused by H Engine stall rpm
absorbed into the engine and the
I A worn oil pump exhaust pipe emits white smoke I Rear lubrication
2 oil pressure leak in the oil
An J Control valve manual
4 Items to be checked when the
valve body or case K Governor valve
pump line pressure is increasing
3 A sticking regulator valve L Band servo
In this check the line pressure
M Transmission air check
2 Low idling line pressure in cer should be measured with vacuums of
N Oil quantity
tain ranges only 450 mmHg and 0 mmHg in accordance o Ignition switch and starter motor
This is presumably caused by an oil with the stall test procedure
leak in the devices circuits con P Engine adjustment and brake in
or I If line pressure do not n
nected to the relevant ranges
the spection
crease despite the vacuum decrease
check whether the vacuum rod is
I When there is an oil leak in the 2 Inspection after inspecting auto

rear clutch and governor the line incorporated matic transmission on vehicle

2 and I are low 2 If the line pressure do not meet

pressure in D
m Rear clutch
the standard it is caused mostly by a
but the pressure is norrrial in R
n Front clutch
2 When an oil leak occurs in the sticking pressure regulating valve pres
sure regulating valve plug or amplifier q Band brake
low and reverse brake circuit the line
r Low and reverse brake
pressure in R and P are low but
Oil pump
s
the pressure is normal in D 2 and
TROUBLE SHOOTING t Leakage of oil passage
I One way clutch of troque coilVerter
CHART u

3 High idling line pressure v One way clutch of transmission

This is presumably caused by an w Front clutch check ball
increased throttle INSPECTING ITEMS Parking linkage
vacuum pressure x

owing to a leak in the vacuum tube or 1 Inspection with automatic trans

y Planetary gear
dia phragm or by an increased line mission on vehicle

AT 53
 Automatic Transmission

TROUBLE SHOOTING CHART FOR 3N718 AUTOMATIC TRANSMISSION

be taken up
The number shown beluw indicates the sequence in which the checks should

Trouble ABeD
EFGHIIJKL MNOP tnnqr stuv wxy

P
ngine does not start in N
2 3 1
ranges

Engine starts in other range than N 1 2

and P

from N
Sharp shock in shifting to
2 1 3 4 @
0 range

Vehicle will not run in D range bul I 2 3

TUns in 2u l and R ranges

Vehicle will not run in 0 1 2

ranges bul runs in R range 1 2 4 5 6 3 7 @ @
Clutch slips Very poor acceleration

Vehicle will nol run in R range bul

runs in 0 2 and I r nges 1 2 3 5 6 4 @@ 1 @ @
Iukh slips Very poor acceleration

Vehicle will not run in any range 1 2 3 5 6 4 1@ @

somewhat

I
Clutches brakes slip
or
1 2 6 3 5 7 4 @@
in starting
I 3 2
Vehicle in N
runs range

allained
Maximum speed not
1 2 4 5 7 6 3 8 OO I@
Acceleration poor

Vehicle braked by Ihrowing Icver inlo

R range
3 2 1 @
I
I
@

1
Excessive creep

No creep al all I 2 3 5 4 @@ 1
@

Failure 10
dumge gear from 2nd
I 2 3 5 6 8 7 4 @ @
to 3rd

Failure tllchJllgC gear from 11 1 2 3 5 6 8 7 4 @ @ @

to 2ud

Too high a gear change poinl from

I sC to 2nd from 2nd to 1 2 3 5 6 4 1
3rd

Gear change directly from lsl to

2 4 3 1 @ @
rd occurs

AT 54
 Automatic Transmission

I J KL MNOP mnqr s t u v w x y
Trouble ABCD EFGH

Too sharp a shock in change from

1 2 4 5 3 @
l1st to 2nd

Too sharp a shock in change from

1 2 3 3 5 4 @
2nd to 3rd

Almost no shock or clutches

slipping in change from 1st to 1 2 3 4 6 8 7 5 @ @

2nd

Almost no shock or slipping in

change from 2nd to 3rd 1 2 3 4 6 8 7 5 @ @ @

Engine races extremely
Vehicle braked by gear change from 2 1 V @
1st to 2nd

Vehicle braked by gear change from

3 2 1
2nd to 3rd

Failure to
change gear from 1 3 4 6 5 2 1@ @
3rd to 2nd

Failure 10 change gear from 2nd

I 3 4 6 5 2 1 @
to 1st or from 3rd to lIst

Gear change shock felt

during
deceleration byreleasing 1 2 3 4 5 6 f
accelerator pedal

Too high a change point from

3rd to 2nd from 2nd to I 2 3 4 5 6 f
1st

Kickdown does not operate when

depressing pedal in 3rd within 2 1 4 5 3 @ f

kickdown vehicle speed

Kickdown operates or engine over

runs when depressing pedal in

3rd beyond kickdown vehicle

1 2 3 5 6 7 4 @ @
speed limit

I
Races extremely or slips in changing
from Jrd to 2nd when 1 2 4 6 5 3 f@ @ @
depressing pedal
Failure to change from 3rd to nd
when changing lever into 2 range
I 2 4
51 3 @ j

Gear change from 2nd 10 1st

I 2 3
or from 2nd to 3rd in 2

range

55
AT
 Automatic Transmission

Trouble ABeD E F G H I J K L
1M NO P
1m n q r s t u v

Iw x
y

No shock at change from I to 2

I 2 3 4 I 7 5
I
or engine races extremely
6 @ @
range

Failure to change from 3rd to 2nd

I 2 1 57 6 3 @@ @
when shifting lever into I range

brake does not in

Engine upcrate I 4
1
2 5 3 @ f
range

Gear frum I sr
change lu 2nd
from 2nd to 3rd in I 1 2
or
@
range

Does not change from 2nd

1 2 4567 3 @ 2
to 1st in range

Large shock changing from 2nd

to 1st in
1 2 4 3 @
range

Vehicle moves when changing

into P
range or parking gear does I 2
not disengage when shifted out of

P range

Transmissic m overheats I 3 4 2 6 8 7 5 @@@ Q@@ @

Oil shoots out during operation

I 3 2 7
White smoke emitted from exhaust 5 6 8 4 @@@ Q@@ @
pipe during operation

Offensive smell at oil charging pipe 1 2 OG@@ f@@ @

Transmission noise in p and N

ranges
1 2
10 I
Transmission noise in D 2 I
and R
I 2 0 G @ @
ranges

AT 56
 Automatic Transmission

TROUBLE SHOOTING GUIDE FOR 3N71B AUTOMATIC TRANSMISSION

Order Test item Procedure

Checking Oil level gauge Check gauge for oil level and leakage before and after each
test

2 Downshift solenoid Check for sound of operating solenoid when depressing

accelerator pedal fully with ignition key ON

3 Manuallinkage Check by shifting into P lR IN D 2 and I

L

ranges with selector lever

4 Inhibitor switch Check whether starter operates in N and p ranges only

and whether reverse lamp operates in R range only

5 Engine idling rpm Check whelher idling rpm meet standard

6 Vacuum pressure of vacuum Check whether vacuum pressure is more than 450 mmHg

in and whether it decreases with increasing rpm

pipe idling

7 in each range Check whether transmission engages positively by shifting

Operation
N 0 N 2 N l I and N R range

while idling with brake applied

8 of vehicle Check whether there is any creep in D 2 and
Creep
R ranges

1
Stall test I Oil pressure before tesling Measure line pressures in D 2 I and R range while
idling
2 Stall test Measure engine rpm and line pressure in D 2 I and
R ranges during full throttle operati n

Notes
a Temperature of torque converter oil used in test should
be from 600 to 1000C 1400 to 2120F i e sufficiently
warmed up but not overheated
b To cool oil between each stall test for D 2 I

and R ranges idle engine ie rpm at about 1 200

P range Measurement
rpm for more than 1 minute in
time must not be more than 5 seconds

3 Oil pressure after testing Same as item I

Road test Slow acceleration Check vehide speeds and engine cpm in shifting up Ist
lever in
I st 2nd 2nd range and Jo3rd
2nd range while running with
200 I11I1lHg
2nd3rd D range and engine vacuum pressure of about

2 Quick acceleration Same as item 1 above except with engine vacuum pressure
lst 2nd of 0 mmHg ie in position just before kickdown

2nd3rd

3 Kick down operation Check whether the kickdown operates and measure the time

3rd 2nd or 2nd1st delays while running at 30 40 50 60 70 km h 18 25 30

37 43 MPH in D3 range

AT 57
 Automatic Transmission

Order Test item Procedure

4 Shift down Check vehicle speeds and engine rpm in shifting down from

Dr O2 0 3rd 2nd I st sequentially while coasting with

accelerater pedal released in D3 range and engine vacuum

pressure of about 450 mmHg

5 Shift down Check for shifting down OJ 12 and engine braking and
1 further for shifting down 12 I and engine braking after
DJ 12
shifting I range with the accelerator pedal
the lever into
released and the engine vacuum pressure of 0 mmHg while
driving at about 50 km h 30 MPH in OJ range

6 Shift down Check for quick shifting down 0 2 and engine biaking
DJ 2 after shifting the lever into 2 range while driving at about

50 km h 30 MPH in OJ range
Further check for locking of the transmission in 2nd gear
ratio regardless of vehicle speed
7 Shift up Check for failure of the transmission to shift up during
I 12 acceleration when starting in I range

8 Shift up or down when start Check the transmission for not shifting up or down during
iog in 2 range acceleration or deceleration when starting in 2 rang

9 Parking Confirm that vehicle will not move on

grade when shifting
to P range

Others Abnormal shock oil leakage Enter into record conditions observed during these tests
such as gear noise abnormal clutch noise and acceleration

performance

58
AT
 Automatic Transmission

SERVICE DATA AND SPECIFICATIONS

General specifications AfT

Torque converter
Type Symmetrica13 element I stage
2 phase torque converter

Stall torque ratio 20 I

Transmission

Type 3 speed forward and one speed

reverse with planetary gear train
Control elements Multiple disc clutch 2

Band brake I

Multiple disc brake I

One way clutch I

Gear ratio 1st 2 458

2nd 1458
3rd 1 000

Reverse 2 182

Selector positions P Park Transmission is placed in neutral

Output shaft is fIXed

Engine can be started
R Reverse Backward running
N Neutral Transmission is in neutral
Engine can be started
o Drive Up or downshifts automatically to

and from I st 2nd and top

2 2nd lock Fixed at 2nd
I Lock up Fixed at low or downshifts from
2nd

Oil pump

Type Internally intermeshing involute

gear pump

Number of pump

Oil Automatic transmission fluid

DEXRON type

Capacity 5 5 liters

4Ulmp qt
s qt
SUU

Approximately 2 7 liters
s qt 2XIrnp qt
2UU
in torque converter

Hydraulic control system Controlled by measuring the nega

tive pressure of intake manifold

and the revolution of output shaft

Lubrication system Forced lubrication by an oil pump

Cooling system Water cooled by a circulation type

auxiliary cooler located at the

radiator

AT59
 Automatic Transmission

Specifications and adjustment AfT

Automatic transmission assembly

Model code number X2402

Torque converter assembly

Stamped mark on th e TiC 16 B

Front clutch

Number of drive plate 3

Number of driven plates 3

Clearance mOl in 16 to 18 0 063 to 0 071

Thickness of retainin g plate mm in 10 6 0 417

10 8 42S
0
11
0 0 433
112 441
0
114 0 449
116 0 4S7

Rear clutch

Number of drive plates 4

Number of driven plates 4

Clearance mOl inJ 1 0 to 5 0 039 to 0 OS9

1
Thickness of retaining plate mOl in 4 8 0 189

Low reverse brake

Number ofdrive plates 4

Number fdriven pla es 4

Clearance mOl in 0 80 to 10S 0 0315 to 0 0413

Thickness of retaining plaie mOl in 118 0 46S

12 0 0 472

12 2 0480
12 4 0 488
12 6 0496

12 8 O S04

Brake band

Piston size mOl in

Big dia 64 2 S2
S all dia 40 1
57

Control valve assembly

Stamped mark on slraine E

Governor assembly

mark on governor body

Stamped 35

60
AT
 Automatic Transmission

Engine Idling and stall revolution

Idling revolution rpm 6S0 ai 0 position

Stall revolution rpm 2 000 to 2 200

TIghtening torque kg m ft lb

Drive plate to crankshaft 14 0 to 16 0 101 to 116

Drive plate to
torque converter 4 0 to 5 0 29 to 36
Converter housing to engine 4 0 to S O 29 10 36
Transmission case to converter housing 4 S to 5 5 33 to 40

Transmission case to rear extension 2 0 to S 14 to 18

Oil pan to transmission case O S to 0 7 4 to S

Servo piston retaine T to transmission case OS to 07 4 to S

Pislon slem when adjuting band brake 2 to 15

1 9 to 11
Piston stem lock nut
5 to
1 4 0 I I to 29
One way clutch inner race to transmission case 3 to 1 8
1 9 to 13

Control valve body to transmission case 0 5S to 0 75 4 to S

Lower valve body to upper valve body 0 25 to 3S
O 2 to 3
Side plat to control valve body 0 25 to 35
0 2 to 3
Nut for control valve reamer bolt O S to 0 7 4 to S

Oil strainer to lower valve body 0 25 to 35

0 2 to 3
Governor valve body to oil distribu tor D S 100 7 4 to 5
Oil pump housing to oil pump cover 0 6 0 8
to 4 to 6
Inhibitor switch to transmission case 5
0 to 0 7 4 toS
Manual shaft lock nut 3 0 to 4 0 22 to 29

Oil cooler pipe to transmission case 3 0 to S O 22 to 36

Test plug oil pressure inspection hole

I 4to 2 1 10 to IS

Support actuator parking rod inserting position to rear extension 0 8 to I 1 6 to 8

I
Oil charging pipe to case 5S
O to 0 7S 4 to S

Dust cover to converter housing 5S

O to 0 75 4 to S
Selector range lever to manual shaft
3 0 to 4 0 22 to 29

Turn back two turns after tightening

61
AT
 Automatic Transmission

SPECIAL SERVICE TOOLS

For Reference
Tool number
use page or
No Description
tool name
on Figure No

3N71B AT 11 2
ST2S0SS001 Use for checking hydraulic pressure Fig
and
Oil pressure gauge 3N71A
set AfT

SE119

ST07870000 Use for setting transmission 3N71 B Page AT 36

2
AfT
Transmission
case stand

SE120

ST2S850000 Use for oil pump 3N7IB Fig AT S6

3 removing
and
Sliding hammers 3N71A
AfT
J

JIB

SE121

front and rear clutch 3N71B Fig AT 79

4 ST2S42000I Use for assemblilJg or disassembling
and Fig AT 86
Clutch spring 3N7lA

compressor AIT

SE 122

Use for correct torque 3N71B Fig 69

AT
S GG93010000 tightening
46 0 33 ft lb and
Max torque kg m

Torque wrench 3 8 square 3N71A

Drive angle
AlT

SE123

62
AT
 Automatic Transmission

Tool number For Reference

No use or
Description page
tool name on Figure No

6 ST2S490000 Socket extension to connect torque wrench GG93010000 with 3N71B Fig 69
AT
W square socket wrench AIT
Socket extension

V SE124

7 ST2S160000 Use for tightening correct torque 3N71B Fig AT 107

90 ft lb A T AT 108
Max torque 1 04 kg m Fig
Torque driver and
3N71A

SE125

3N71B AT S9
8 HT69860000 Use for removing and replacing snap ring Fig
and
Snap ring remover
3N71A
AIT

SE126

9 ST2S320001 Use for removing and replacing snap ring 3N71B Fig AT 79
and Fig AT 86
Snap ring remover
3N71A
AIT

SE305

10 ST2SS70001 Use for removing and installing one way clutch inner race with 3N71B Fig 64
AT
AIT Fig AT 69
torque wrench
Hex head flat width Page 42
AT
Drive angle W square and 6 mOl across
extension

SE128

AT I
 AutomaJic Transmission

Tool number For Reference

No Description use or
page
tool name on
Figure No

II HT623S0Q00 Use for disassemlbing and control valve

assembling 3N71B Fig AT IOI
and Fig AT I04
Spinner handle 3N71A
AIT

SE129

12 HT61000800 Use for disassembling and assembling control valve 3N71B Fig AT IOI
and Fig AT 104
Hexagon wrench
3N71A Fig AT I07
AIT Fili AT 108

0
SE130

13 ST2SS80000 Use for centering oil pump 3N71B Fig AT 98

and Fig AT 99
Oil pump
3N71A
Ssemlbing
l gauge
AIT

SE131

AT 1l
A
 0

SECTION PD

PROPELLER
DATSUN PICK UP SHAFT
MODEL 620 SERIES DIFFERENTIAL
CARRIER

PROPELLER SHAFT AND

PD 2
CENTER BEARING f

DIFFERENTIAL CARRIER
PD 5
TYPE H19D

TROUBLE DIAGNOSES AND

PD 14
CORRECTIONS
I

SERVICE DATA AND PD 16

SPECiFiCATIONS

I NISSAN I SPECIAL SERVICE TOOLS PD 19

NISSAN MOTOR CO LTD

TOKYO JAPAN
 PROPElLER SHAFT DIFFERENTIAL CARRIER

PROPELLER SHAFT AND CENTER BEARING

CONTENTS

DESCRIPTION PD 2 CHECKING AND CORRECTING

REMOVAL AND INSTALLATION PD 2 UNBALANCED PROPELLER SHAFT 3

PD
DISASSEMBLY AND ASSEMBLY PD 3 SERVICE DATA 4
PD

INSPECTION PD 3 TROUBLE DIAGNOSES AND

CORRECTIONS 4
PD

i 2

t tl J
I
I O

750 53
29
148 5 5 85 483 19 02 987 38 86 35
38
1
Long wheelbase and

Rea Deluxe cab models

Front Unit mm in
1 Sleeve yoke assembly 5 Companion flange 9 Bearing race assembly
2 Center bearing 6 Plain washer 10 Snap ring
3 Center bearing insulator 7 Self locking nut 11 Journal assembly
4 Center bearing bracket 8 Flange yoke PD218

Fig PD l ctional
Crou v w of propelkr hafl

DESCRIP TION REMOVAL AND 3 Remove bolts connecting shaft to

The
propeller shaft on the 620 INSTALLATION companion flange of differential car
series is 3 rier See Figure PD 3
joint type I Raise vehicle on hoist Put match
The propeller shaft and universal marks both on propeller shaft and
joint assembly is carefully balanced companion flange so that shaft can be
during original assembly that is the reinstalled in the original position
dynamic unbalance is under 35 cm
gr 2 Remove bolts retaining center
49
0 in oz at S 800 rpm bearing bracket See Figure PD 2
If the propeller shaft has to be
assembled it must be made carefully
so that the above limit is not ex

ceeded Therefore when the vehicle is

to be undercoated the
cover propeller PD220
shaft and universal joints to prevent
Fig PD 3 Removingpropclkr t
cha
application of the undercoating ma
terial
4 Withdraw shaft sleeve
propeller
PD219 yoke from transmission by moving
PD2 Removing center shaft rearward passing it under rear
Fig bearing
bruckel axle

PD 2
 PROPELLER SHAFT DIFFERENTIAL CARRIER

Note When removing journal from Install and assemble components

Watch for oil leakage from trans

mission end yoke be careful not to damage correctly that joint moves under
so

journal and yoke bole friction resistance of less than is o

Notes
kg em 13 in lb
a Remove propeller shaft carefully When disassembling and repairing When the above steps are complete
so as not to damage spline sleeve center bearing are required the follow
place the shaft in a balancing machine
yoke and rear oil seal ing procedures are applied and adjust unbalance less than 3S
b Plug up the opening in the rear of
1 Put match marks on flange and gr
cm 49 in oz at
0 800
S rpm
rear extension housing to prevent front propeller shaft Remove bolts Center bearing assembling pro
oil from flowing out follows
connecting flange yoke to companion cedures are as

install the flange I Install center bearing in center

To reverse foregoing Drive Pinion
2 Applying Flange
removal procedure bearing insulator
Wrench ST3lS30000 loosen off lock 2 Install center bearing assembly
1 Align propeller shaft with com ing nut and remove center bearing See front shaft
and companion flange on
panion flange using reference marks Figure PD 5 usiug reference marks established in
prescribed in removal procedure and
disassembly procedure
assemble with bolts
3 Install washer and locking nut on
Tightening torque front shaft and tighten nut using Drive
4 to
2 3 kg m Pinion Flange Wrench ST3IS30000 to
17 to 24 ft Ib specified torque
2 Insert bolts through the holes of
Tightening torque
center beariug bracket and torque nuts 20 0 to 24 0 kg m

to retain center bearing on cross

I4S to 174 ft lb
member
4 Join companion flange of front
ST31530000
Tightening torque P0172
shaft with f1ange yoke of rear shaft
1 6 to 2 2 kg m nut
Fig PD 5 Remouing locking and tighten connect bolts to specified
12 to 16 ft Ib
torque
Tightening torque
DISASSEMBLY AND To assemble reverse the foregoing 2 4 to 3 3 kg m
ASSEMBLY procedure using reference marks pre 17 to 24 ft Ib

do not disassemble pro scribed in disassembly procedure

Primarily S Install center bracket
not be lubricated
bearing on
shaft because it is balanced as an New bearing need
peller center bearing
since it is lubricated for life Fill joint
assembly
However check propeller shaft with recommended multi purpose

propeller shaft is
with journal for movement When grease whenever
overhauled
journal does not move smoothly dis INSPECTION
assemble Use related snap rings of the same
I Check journal pin for dent or
thickness and be sure that play is
1 Mark propeller shaft and journal brinell marks and yoke hole for sign
below 0 02 mm 0 0008 in
so that the original combination can of wear or damage
be restored at assembly Snap ring bearing and seal ring
Available snap ring
2 Remove snap ring with a standard should also be inspected to see if these
screwdriver deformed Re
are damaged worn or
Thickness Color
3 Lightly tap base of yoke with a place if necessary
mm in identification
hammer and withdraw bearing race 2 heck center bearing by rotating
See Figure 4
PD bearing race If it is rough noisy or
2 00 00787 White
damaged discard Cracked bearing
2 02 0079S Yellow insulator cannot be tolerated here
Q4 0 0803
2 Red 3 Check propeller shaft tube sur

2 06 0 08 II Green face for dent or crack Change if

2 08 0 0819 Blue necessary

10
2 0 0827 Right Brown
12
2 0 83S No paint
PDOO5 2 14 00843 Pink
Fig PD 4 Remo i bearing

PD 3
 PROPELLER SHAFT 8l DIFFERENTIALCAAR ER

CHECKING AND anced propeller shaft proceed as road test disconnect propeller shaft at
CQRRECTING follows differential carrier companion flange
UNBALANCED I Remove undercoating and other rotate companion flange 180 degrees
PROPELLER SHAFT foreign materials which could upset and reinstall propeller shaft
shaft balance and check shaft vibra 3 check shaft vibration
Again If
tion by road test vibration still persists replace pro
To check and correct an unbal 2 If shaft vibration is noted during peller shaft assembly

SERVICE DATA

Pe issible dynamic unbalance gr cm in oz 3S 0 49 at S 800 rpm

Axi play of spider journal mm in Less than 0 02 0 0008

Journal swinging torque kg em in Ib Less than IS O 13

Propeller shaft front and rear out of round mm in Less than 0 6 0 024
Tightening torque
Shaft to conipanion flange Gear carrier bolt kg m ft lb 2 4 to 3 17 to 24

Self locking nut front shaft kg m ft Ib 20 0 to 24 0 l4S to 174

Flange yo e rear shaft to companion flange

kg m ft lb 2 4 to 3 17 to 24
front shaft bolt

Center bearing bracket to cross member bolt kg m ft lb 1 6 to 2 2 12 to 16

TROUBLE DIAGNOSES AND CQRRECTIONS

Condition Probable cause Corrective action

Vibration during at Worn or damaged universal joint needle Replace

medium or high speed bearing
Unbalance due to bent or dented propeller l
Ieplace
shaft

Loose propeller shaft installation Retighten

Worn transmission rear extension bushing Replace
Damaged center bearing or insulator Replace
Tight universal joints Impact yokes with hammer to free up
Replace joint if unable to free up or ifjoint
feels rough when rotated by hand

Undercoating or mud on the shaft causing Clean up shaft

unbalance

Tire unbalance Balance wheel and tire assembly or replace

from known good vehicle
Balance weights missing
Replace

PD 4
 PROPELLER SHAFT DIFFERENTIAL CARRIER

Condition Probable cause Corrective action

Knocking sound during Worn damaged universal joint Replace

starting or noise during Worn sleeve yoke and main shaft spline Replace
coasting on propeller
Loose propeller shaft installation
shaft Retighten
Loose joint installation Adjust snap ring
Damaged center bearing or insulator Replace
Loose or missing bolts at center bearing Replace or tighten bolts
bracket to body

Scraping noise Dust cover on sleeve yoke rubbing on Straighten out dust cover to remove inter
transmission rear extension Dust c ver on
ference
companion flange rubbing on differ mtial
carrier

Whine or whistle Damaged center bearing Replace

DIFFERENTIAL CARRIER TYPE H190

CONTENTS

DESCRIPTION PD 5 ASSEMBlY OF DIFFERENT Al

REMOVAL PD 7 CASE 8
PD
PRE DISASSEMBLY INSPECTION PD 7 ADJUSTMENT OF DRIVE PINION
DISASSEMBLY PD 7 HEIGHT 9
PD
INSPECTION PD 8 ADJUSTME NT OF DRIVE PINION
ASSEMBLY AND ADJUSTMENT PD t
PRELOAD PD lO
PRECAUTIONS IN REASSEMBLY PD 8 ADJUST ENT OF SIDE 8EARING
ASSEMBLY OF DIFFERENTIAL CASE PD 8 SHIMS PD 11
INSTAllATION PD 13

REPLACEME NTOF FRONT Oil SEAL PD 13

DESCRIPTION

The differential carrier on the 620 the drive pinion and the rear bearing these shims
varying The ring gear is
series has a gear ratio of 37S
4 The differential case is supported in bolted to the differential case The
The drive pinion is rnounted in two the carrier by two tapered roller side case houses two side gears in mesh
tapered roUer bearings which are pre bearings These are preloaded by in with two pinion mates mounted on a

loaded by pinion bearing adjusting serting shims between the bearings and pinion shaft The pinion shaft an
spacer and washer during assembly the differential case The differential chored in the case by lock pin The
The drive pinion is positioned by a case assembly is for proper
positioned mates and side gears are backed
pinion
washer located between a shoulder of ring gear and drive pinion backlash by by thrust washers
The carrier is of malleable cast iron

PO 5
 CARRIER
8 DifFERENTIAL
PROPEllEff SAAFT

TYPE H19O

Q@

nut
1 Drive pinion
4
2 Companion flange
3 Oil al

4 Front bearing
adjusting washer
@ 5 DIive pinion bearing
Adjust pinion bearing preload by
ecting @ and @
@ 6 Drive pinion beating spacer

1 Drive pinion
8 Rem bearing
wamer
9 Drive pinion adjusting
10 pin
loci
mint
11 Side bearing adjusting
and
side bearing preload
@ Adjust
@ backlash betwam ring geu
ting @
and cIrive pinion by
12 Side bearing
@@ @ 13 Side gear
14 nUust washer
mate to side gear
Adjust pinion
backlash Of the clearance
face of side
between the teat
washer to 0 02 to
ttuust
gear and
10 0 0031 in
0 08 nun 0 0008
@ by@
15 Differential cast

16 Thrust washer

@ 17 Pinion mate

18 Pinion sbaft
19 Ring gear
Backlam between ring gear
and drive pinion
0 t5 to 0 20 nun
in
0 0059 10 0 0079
cap boll
20 Bearing
21 Thrust block
22 Ring gear bolt
23 Lock strap

of
Tightening torque f
m ft lb
bollS and nut kg
101 to 123
@T 14 0 to t7 0
36
@T 4 0 to 5 0 29 10

L
@ @T 7 0108 0 5110
58

4010
198 198 55 nun
L
in
1 8110107 8169

P0229

carner
uiew of differenwl
Fig PD 6 croectional

6
PD
 PROPELLER SHAFT DIFFERENTIAL CARRIER

5 Hold rear bearing inner race with

REMOVAL DISASSEMBLY
Drive Pinion Rear Bearing Inner Race
I Jack up rear of vehicle and sup I Put match side bearing
tpark on
Puller ST30031000 and extract from
safety stand under and
port it by placing a
caps and carrier remove side
drive pinion with a press
Drain gear oil
rear axle case bearing caps and take out differential

2 Remove propeller shaft and rear case assembly

axle shafts These works can be done

by referring to Rear Axle and Rear

Suspension
3 Loosen off bolts securing differ
ential carrier to rear axle cas and
STJ0031000
take out differential carrier assembly

PD205
PRE DISASSEMBLY P0203
Fig PD 10 Removing pinion rear
INSPECTION Fig PD B Removing differenlwl bearing inner race

Differential carrier should be in case assem bly

6 To remove outer races of both
spected before any parts are removed
front and rear
bearing apply a brass
from it
drift to race side surface and with
These inspections are helpful to
Note Care should be taken not to draw them by tapping the top of drift
fmd the cause of a problem and to
hand
confuse the left and right with a hammer
determine the corrections needed
bearing caps and bearing outer race
I Mount differential carrier on Dif so that reassembly will be easily
ferential Attachment ST063 I 0000 carried out with the same parts in
the original position

2 Remove drive pinion nut using

Drive Pinion Flange Wrench
ST31530000 and pull off companion
flange using a standard puller

Fig PD l1 Removing pinion front and

ST063 10000
rear bearing outer races

canier
Fig PD 7 Holding differential

2 Visually inspect parts for wear or

Dissssembly of dHferentIeI
damage case
3 Rotate gears to see if there is any
1 When replacing side bearing use
roughness which would indicate dam
Check Differential Side Bearing Puller Set
aged bearings or chipped gears
ST3306S00 I set of ST330S100 I and
the gear teeth for scoring or signs of
of ST33061000
abnormal wear Measure preload Fig PD 9 Removing drive pinion
drive pinion See Figure PD 19 nul

4 Set up a dial indicator and check

the backlash at several points around
15
0
3 Extract drive pinion assembly to
ring gear Backlash should be to
the rearwards by tapping the front end
0 20 mOl 0 00S9 to 0 0079 in
with a soft hammer Drive pinion can
S Check the gear tooth contact
be taken out together with rear bear
with a mixture of ferric oxide and
ing nner race bearing spacer and
ring gear teeth
g ar oil to all washer
For the tooth contact pattern see
4 Remove oil seal and take out
paragraph dealing with tooth contact front bearing inner race

pattern adjustment
Note Oil seal must not be used Fig PD 12 Removing ide bearing

PD 7
 PROPElli ER SHAfT DIFFERENTIAL GARRIERf

Notes Note Drive and

pinion ring gear are ASSEMBLY OF
a PUller should be handled with care
supplied for replacement as a set DIFFERENTIAL CASE
in the of
catchins edge bearing therefore should either part be
inner race I Assemble mates side
damaged replace as a set pinion
b Be careful not to confuse left and gears thrust block and thrust washers
right hand parts 2 Check pinion shaft and pinic m in differential case

mate for scores and signs of wear and 2 Fit pinion shaft to differential
2 Remove ring gear by spreading
replace as
required case so that it meets lock pin holes
out lock strap and loosening ring gear
Follow the same procedure for side 3 Adjust pinion mate toide gear
bolts in diagonally
gear and their seats on differential backlash or the clearance between the
3 Punch off pinion mate shaft lock
case rear face of side gear and thrust
pin from ring gear side using Solid 3 all washer to 0 02 to 0 08 mOl
Inspectbearing races and 0 0008
Punch ICV31100300 to 0 0031 in
rollers for
scoring chipping or evi by selecting side gear
dence of excessive wear They should thrust washer
be in tiptop condition such as not
Side gear thrust WlISber
worn and with mirror like surfaces
Replace if there is a shadow of doubt
oil their efficiency as an incorrect Thickness nun in
bearing operation may result in noises
and gear seizure Over 0 7S to 0 80 0 029S to 0 03IS
4 Inspect thrust washer faces Small
KV31100300 Over 80
0 to 8S
O Om IS to 0 033S
faults can be corrected with sand
Over 0 8S to 090 0 033S to 003S4
paper If pinion mate toide gear
backlash or the clearance between Over 090 to 0 9S 0 03S4 to 0 0374
PD022 side gear and thrust washer exceeds
limits 0 02 to 0 08 nun 00008 to
4 Lock pinion shaft lock pin using a
Fig PD 13 Removing lock pin 0 0031 in replace thrust washers
S punch after it is secured into place
Inspect carrier and differential
S Apply oil to gear tooth surfaces
case for cracks or distortion If either
Note Lock i cauIked at pin hole
pin and thrust surfaces and check if they
condition is evident replace faulty
mouth on differential case Do not turn properly
parts
punch it off forCibly without 6 Place ring gear on differential case
6 As a
general rule oil seal should
checkins how it is uIked and install bolts and lock washers
be replaced at each disassembly
Torque bolts to specification and
4 Draw outpinion shaft and re bend up lock strap
move thrust block pinion mates side
gears and thrust washers Tightening torque
ASSEMBLY AND 7 0 to 8 0 kg m

Note Put marks gear and thrust

on ADjUSTMENT S1to Sifft Ib
Wasliersotliat they can be reinstaD
Assembly can be done in the reo
ed in their original positions from verse order of disassembly The foDow
which they were removed Notes
ing directions for adjustment and ao Use only genuine ring gear bolts
usage of special tools enable to obtain
and new lock strap
a perfect differential operation b bolts in fashion
Tighten cross
criss

lighdy tapping fOund bolt Js

heac
INSPECTION with a hammer

Thoroughly clean all disassembled PRECAUTIONS IN

parts and examine them to see if they REASSEMBLY
8re worn damaged or otherwise
I Arrange shims w shers and the
faulty and how they are affected 7 When replacing side
like to install them correctly bearing
Repair or
replace ail faulty parts measure bearing width using a stand
2 Thoroughly clean the surfaces on
whichever is necessaiy ard 20 00 nun 0 7874 in
which shims washers and gauge
bearings 5
2
I Check teeth for thickness and a weight block kg
gear scoring bearing caps are installed
cracking and and make S S Ib prior to installation See
chipping sure 3 Apply gear oil when installing
PD I4
that tooth contact pattern indicates
bearings Figure
correct meshing depth If any fault is 4 Pack grease cavity between lips Standard bearing width
evident replace parts as required when fitting oil seal 20 00 nun 0 7874 in

8
PD
 PROPELLER SHAFT DifFERENTIAL CARRIER

Rear Where
ST306 II 000 and T Required thickness of rear bearing
ST3062I 000
adjusting washers mOl
I
N Measured value with thickness
1
2 Fit rear bearing on carrier and mOl
gauge
install Dummy Shaft Sf3 I 942000 and H Figure marked on the drive pinion
Standard Collar ST3197oo00 on rear bearing head See Figure PD 18
gauge and place Height Gauge ST31941000 0 Figure marked on the dummy
on carrier shaft
S Figure marked on the height
gauge

ST31941000
Fig PD 14 uring bearing width
Me 0 and S
Figures for H are dimen
sional variations in a unit of 1 100 mOl

against each standard measurement

8 Press fit side bearing cone into
differential case using Differential Side

Bearing Drift ST33230000 and Adapt

er ST33061000

Set numblr
PD2 b

J
t Head
number
ST33230000 Fig PD 16 Adjusting pinion height
HI
I
P0186

3 Measure the clearance N be

io o1 tween the tip end of height gauge and Fig PD 18 Variation number on

drive pinion
the end surface of dummy shaft using

thicknes
a gauge

Examples of calculation
P0244
Ex I
Fig PD 15 ln talling side bearing
N 0 5Imm H 2 0 1
cone

S O

T N D S xO 01
H
2 18

51
0 2 I 0

x ol
O 18
2

ADJUSTMENT OF DRIVE O SI 2 t 1 0 x 0 01
P0235 18
2
PINION HEIGHT
51
0 3 x 0 01 2 18
Adjust the pinion height with
51
0 0 03 18
2
washer provided between bearing
rear Fig PD 17 Measuring clearance
2 66 mOl
inner race ld
a the back of pinion gear

Press fit front and rear bearing

outer races into gear carrier using
Drive Pinion Ou ter Race Drift
4 Tlie thickness of drive pInIOn
The correct washer is 2 67 mm
height adjusting wa shers can be ob
thick See
following table for drive
tained from the following formula
pinion adjusting washer
Front
T N H 0 S x 0 01
ST306 I 1000 and
Sf30613oo0 2 18

PD 9
 PROPELLER SHAFT DIFFERENTIAL CARRIER

Ex 2 Drive pinion adjusting washer Note Replace bearing washer and

N O 68mm H 3 D I with thicker ones if pinion
spacer
S 2 Thickness mm in cannot be turned by hand while it
is heing tightened
T N H 0 58
2 0 1016
S x 0 01
2 Measure pinion bearing prelo d
218 2 61 0 1028
using Preload Gauge ST3I 27S000 and
068 3 1 2 2 64 1039
0
select washer and spacer that will
Om 18
2
x
2 67 0 1051 provide required preload
0 68 3 1 2 x 0 01
70
2 0 1063
18
2
2 73 0 107S
0 68 2 x 0 01 18
2
2 76 1087
0
0 68 02
0 N8

0 68 02
0 2 18 2 79 0 1098
Preload without oil seal
i88 mm 82
2 0 1110
10 0 to 13 0 cm
kg
The correct washer is 2 88 mm 2 85 OJ 122 8 7 to II in lb
thick 2 88 OJ 134 At companion flange bolt hole
2 9 to 3 7
2 91 0 1146 kg
Ex 3 4 to8 2Ib
6
2 94 1IS8
0
N 0 70mm H O 0 0 2 97 1169
0
S O
3 00 1181
0

T 3 03 0 1 193 Note Preload of old bearing is the

N H 0 S x 0 01
2 18 3 06 1205
0 same value as that of a new bearing
0 70 0 0 0 x 0 01 3 09 0 1217

2 18
3 12 0 1228
0 70 0 x 0 01 2 18 3 IS 0 1240
0 70 0 2 18
3 18 0 I2S2
0 70 2 18
2 88 mm
S Fit determined drive pinion ad
The correct washer is 2 88 mm justing washer in drive pinion and
thick preSs fit rear bearing inner race in it

using Base ST30901000

ADJUSTMENT OF DRIVE
IPIENLOADIONPI
Note If lues signifying H D and S
are not given regard them as zero AdjUst the preload of drive pinion Fig PD 19 Measuring pinion preload
and After with spacer and washer between front
n C
r
e
assembly
check to see that tooth contact is and rear
bearing inner races
If not For the This procedure has nothing to do
correct readjust
tooth contact with thickness of drive pinion adjust
pattern see page
PJ
12 for Contact Pattern ing washer
Pinion bearing adjusting spacer
This adjustment must be carried
out without oil seal inserted

I Lubricate pinion front and rear in

Length mOl

bearings Install drive pinion in gear

carrier Be sure that spacer washer t 50
S4 14S7
2
front bearing inner race Companion S4 80 2 IS7S
flange and flat washer are fitted on
SS IO 2 1693
pinion Tighten nut to specified torque
and confum preload 5S 40 2 1811

SS 70 2 1929
Tightening torque
14 0 to 17 0 kg m S6 00 2 2047
101 to 123 ft lb

PD l0
 PROPELLER SHAFT DIFFERENTIAL CARRIER

Drive pinion washer T A C D H xO OI Examples of calculation

bearing adjusting
l7S
O E Ex I

T2 B D H xO OI
A I B 2 C 2 0 3
Thickness O ISO F
mm in
E 0 11 mm F O IS mm

H 2
over 3 80 to 3 82 0 1496 to lS04
O Where
over 3 82 to 3 84 lS04
O to 0 ISI2 T1 thickness of left side
Required
over 84
3 to 86
3 lSI2
O to 0 IS20 bearing adjusting shim mm
3 86 to 3 88 O IS28 T2 Required thickness of right side
over lS20
O to
Left side
bearing adjusting shim mm
over 3 88 to 3 90 lS28
O to 0 IS3S
T A C 0 H 0 01
A Figure marked on the left side x

over 3 90 to 3 92 0 IS3S to O IS43 liS

O E
bearing housing of gear carrier
over 3 92 to 3 94 0 IS43 to lSS
O I
B Figure marked on the right side 1 2 3 1 x 0 01
over 3 94 to 3 96 lSSI
O to lS59
O 0 17S 0 11
bearing of gear carrier
2 3 2 OO
over 3 96 to 3 98 lSS9
O to 0 IS67 C 0 Figure marked on the differ 1 x

3 98 to 4 00 lS7S
O entia case l7S
O 0 11
over lS67
O to
E F These are differences in width 4 x 0 01 0 175 11
0
over 4 00 to 4 02 0 S7S to lS83
O
of left or right side bearing against 0 04 1 7S
0 0 11
over 4 02 to 4 04 lS83
O to 0 IS91
the standard width 20 00 mOl
over 4 04 to 4 06 lS9I
O to 0 IS98 32S
0 mOl
mOl

over 4 06 to 4 08 lS98
O to 0 1606 If bearing width is 19 89 the differ
over 4 08 to 10
4 1606
0 to 1614
0 ence will be as follows

20 00 19 89 0 11
3 Check and adjust tooth contact The correct shims are as follows
H Figure marked on the ring gear
pattern when former adjustment of
See Figures PD 20 and PD 2 I Thickness Quantity
bearing preload is completed Unless
07
0 x 2 0 14
anything wrong is found remove drive
for A B C 0 and H are 0 20 I 0 20
Figures x

pinion nut and companion flange and

dimensional varia tions in a unit of
press n oil seal into gear carrier
Total thickness 34
0 mOl
Tool
1 100 mm against each standard meas
using Oil FittingSeal
urement
KV38I02SS0 Apply grease cavity be
tween seal lips
@ a
4 Again install companion flange
and washer and tighteh nut to speci
fied torque 14 0 to 17 0 kg IO
m to
rj
f Right
T2
side

B 0 H x 0 01
123 ft lb
S Measure preload again
71 Mark B
2
lSO
O

O ISO
3
F

0 15
2 x 0 01

Preload with oil seal

I 1 0 to 14 0 cm
kg Markj 2

O ISO
3 2
0
x

15
0 01

9 S to 12 in lb O IS
3 x O OI O ISO
At companion flange bolt hole 0 03 lSO
O lS
O
1 to 4 0 kg
3 Mark C 0 0 27 mm

6 8 to 8 81b
P0214
The correct shims are 0 07 plus
20
0 mm thick
Fig PD 20 Thickn of shim on l ft
and righ t sides
ADJUSTMENT OF SIDE
BEARING SHIMS
I If hypoid gear set carrier dif
ferential case or side bearing has been

replaced with new one adjust the side

bearing preload with adjusting shim
The required thickness of adjusting
shim can be calculated by the follow Fig PD 21 Variation number on

ing formulas ring gear

PD ll
 PROPELLER SHAFf DIFFERENTIAL CARR IER

Ex 2 2 Fit determined side If preload does not accord with this

bearing
A 0 B 3 C I 0 0
adjusting shim on differential case and specification adjust it with side bear
0 20 mOl press fit left and right side bearing ing shims
E F 0 17 mOl
inner it
H 2 races using Side Bearing
on 7 Check and adjust the tooth con

Drift ST33230000 and Adapter tact pattern of ring gear and drive
ST33061000 pinion
Left side 3 Install differential I clean ring and drive
case assembly Thoroughly
into gear carrie
TI A C tapping with a rubber pinion gear teeth
D H x om
mallet 2 Paint ring gear teeth lightly and
0 17S E
4 mark
0 I 0 2 x 0 01
Align on bearing cap with evenly with a mixture of ferric oxide

that on gear carrier and install bearing and gear oil to produce a contact
0 I7S 0 20
cap on carrier And tight n bolts to
0 I 0 2 x 0 01 pattern
specified torque 3 Rotate pinion through several
17S
0 0 20
revolutions in the forward and
3 Om 17S
0 0 20
reverse

directions until a defmite contact pat

0 03 0 17S 0 20
O 34S Tightening torque tern is developed on ring gear
mrn
4 0 to S O kg m 4 When contact pattern is incor
The correct shinjs are O OS plus 29 to 36 fHb rect readjust thickness of adjusting
0 10 plus 0 20 mrn thick washer
S Incorrect contact pattern of
teeth can be adjusted in the following
Right side manner

B D H xO 0l
T2 S Measure ring gear drive
to pinion
O ISO F
backlash
3 0 2 x om
If backlash is too small remove
O ISO 0 17 a Heel contact
shims from left side and add them to
3 0 2 x om
right side To reduce backlash remove To correct increase thickness of
0 150 17
0
shims from right side and add them to pinion height adjusting washer in order
S x 001 0 ISO 0 I7
left side to bring drive pinio close to ring gear
O OS 1S0
0 0 17
37
0 mrn

The correct shims are 0 07 plus Backlash

1 0 plus 0 20
0 mm thick 1S
O to 0 20 mrn

000S9 to 0 0079 in

Note If w1ues signifying A B C 0 P0193

and H are not given regard them as Fig PD23 Hul contact
zero and compute

Aftassembly check to see that

preload and backlash are correct If
not readjust

b Toe contact

To correct reduce thickness of

Side bearing adjusting shim
pinion height adjusting washer in order
to make drive pinion go away from

ring gear
Thickness mm in
Fig PD 22 Mccuuring back1aah

O OS 00020

6 At the same time check

0 07 00028 side

10
0
bearing preload Bearing preload
0 0039
should read 12 0 to 20 0 10 to
cm
kg
0 20 00079 17 in lb of
rotating torque 3 S to
S 8 7 7 to 12 8 Ib at ring P0194 1
50
0 00197 kg gear bolt
hole Fig PD 24 To contact

PD 12
 P ROPELLER SHAFT DIFFERENTIAL CARRIER

c Flank oontact INSTALLATION

Adjust in the same manner as in b can be done in the reverse
Installing
order of removal

Tightening torque
Gear carrier to rear axle case

17 to 5 kg
2 m

cV t 12 to 18 ft lb
Drain and filler P0238
PD195 plug
6 0 to 10 0 kg m
Fig PD 29 Removing companion
Fig PD 25 Flank contact flange
43 to 72 ft lb

Gear oil capacity 10 liter

2 US I Y Imp pt
pt

6 Remove oil seal

7 Set new oil seal in position using
d Face contact Oil Seal Fitting Tool KV38102SS0
in the same manner as in a
REPLACEMENT OF Apply grease in between seal lips
Adjust
FRONT OIL SEAL 8 Fit companion flange and flat
w sher on drive pinion and secure
Replacement of front oil seal with
carrier assembly installed them in position by tightening nut to
difer ntial
on the vehicle
the given torque confirming specified
When front oil seal do preload using Drive Pinion Flange
replacing as

follows WrencliST31530000

1 Drain gear oil

P0196
t 2 Raise the rear end of vehicle and

support it with safety stands Tightening torque

Fig PD 26 Face contact 14 0 to 17 0
3 Detach propeller shaft from com kg
panion flange of carrier 101 to 123 ft Ib
4 Pinion bearing preload
Rove drive pinion n t holding
1
with oil seal
companion flange with Drive Pinion
110 to 14 0 cm
kg
Flange Wrench ST31S30000
5 to 12 in lb
9
At companion flange bolt hole
1 to 4 o g
3
6 8 8 8Ib

e Correct tooth contact

Notes

a Preioad of old bearing is the same

value as that of a new bearing

b If the desired nut tightening torque
P0237 can ot be obtained renew nut and

readjust

Fig PD 27 Correct contact Fig PD 28 R moving drive pinion

nut

Note Change in thickness of adjWll

ing washer is accompanied by
8 Reinstall propeller shaft and fill
change in backlash Oled it when S Extract companion flange using a

standard up differential carrier with gear oil

instaIIi
gear puller

PD 13
 PROPELLER SHAFT DIFFERENTIAl CARRIER

TROUBLE DIAGNOSES AND CORRECTIONS

When a differential carrier is sus tires road surface exhaust universal places cannot be corrected by adjust
pected of being noisy it is advisable to joint propeller shaft wheel bearings ment or replacement of parts in dif
make a thorough lest to determine engine transmission or differential ferential carrier
whether the noise originates in the carrier Noise which in other
originates

Condition Probable cause Corrective action

Noise on drive of oil

Shortage Supply gear oil Rebuild gear carrier if
coast and float
necessary
Incorrect tooth contact between ring gear Adjust tooth contact or replace the hypoid
and drive pinion gear set

Incorrect backlash between ring gear and Adjust backlash the

or replace hypoid gear
drive pinion set if necessary

Seized up or damaged ring gear and drive the hypoid gear set
Replace
pinion
Seized up damaged or broken drive pinion Replace the pinion and faulty parts
bearing
bearing
Seized up damaged or broken side bearing Replace the side bearing and faulty parts
Loose bolts or nuts fIXing ring bearing Clamp them to specified torque and
gear replace
cap etc faulty parts

Noise on turn Seized up damaged or broken side and Replace faulty parts
pinion mate

Seized up damaged or broken side gear and Replace faulty parts

pinion thrust washer
Pinion mates too tight on their shaft Replace faulty parts

Knocking sound during Excessive backlash

starting or gear shifting Incorrect backlash ring ar to drive Adjust backlash
pinion or side gear to pinionmate

Worn gears or case

Replace worn parts
Worn rear axle shaft and side gear spline
Replace worn parts

Drjve pinion bearing under preload

Adjust preload
Loose drive pinion nut
Repair or replace
Loose bolts or nuts ftxing ring bearing
gear Clamp them or replace if necessary
cap etc

PD 14
 PROPELLER SHAFT IFFERENTIAl CARRIER

1
j

Condition Probable cause Corrective action

Seizure of breakage Shortage of oil or use of unsuitable oil Replace faulty parts and use reconunended

gear oil

Excessively small backlash Adjust backlash and replace as required

Incorrect adjustment of bearings or gears Replace faulty parts
Severe service due to an excessive loading Replace faulty parts
improper use of clutch

Loose bolts and nuts such as ring gear bolts Replace faulty parts

Oil leakage out

Worn damaged or improperly driven Replace faulty oil seal Repair the affected
front oil seal or bruised dented or abnor flange with sandpaper or replace if nee
mally worn slide face of companion flange essary

Loose gear carrier bolts Tighten the bolts to specified torque

Faulty gasket Replace faulty gasket with new one

Loose fIller drain Tighten the plug

or
plug
Clogged or damaged breather Repair or replace

PD 15
 PROPELLER SHAFT DIFFERENTIAL CARRIER

SERVICE DATA AND SPECIFICATIONS

Type HI90

Ge ar carrier material Malleable cast iron

Gear ratio number of teeth 4 375 3S 8

Drive pinion preload adjusted by Spacer and washer

Drive pinion
Preload cm in Ib
kg
without oil seal 10 0 to 13 0 8 7 to II
with oil seal 110 to 14 0 5 to 12
9

At companion flange olt hole kg Ib

without oil seal 2 9 to 3 7 6 4 to 8 2
with oil seal 1 to 4 0 6 8 to 8 8
3

Thickness of drive pinion adjusting

washer nun in 2 S8 1016
0
2 61 0 1028
2 64 0 1039
2 67 0 IOSI
2 70 0 1063
2 73 O I07S
2 76 0 1087
2 79 0 1098
2 82 0 1110
2 8S 0 1122
2 88 0 1134

2 91 1146
0
2 94 0 1158
2 97 0 1169
3 00 0 1181
3 03 0 1193
3 06 0 120S
3 09 0 1217
3 12 0 1228
3 IS 0 1240
3 18 0 12S2

Length ofdrive pinion bearing

adjusting spacer nun in 50
S4 2 14S7
54 80 2 IS7S
SS IO 2 1693
SS 40 2 1811
SS 70 1929
2

S6 00 2 2047

PD 16
 PROPELlER SHAFT DIFfERENTIALCARRI ER

Thickness of drive pinion bearing

adjusting washer mm in over 3 80 to 3 82 0 1496 to O IS04

3 82 to 3 8 IS04
to
over
HO OcISI2
over 3 84 to 3 86 0 ISI2 to 0 IS20

over 3 86 to 3 88 0 1520 to 0 IS28

over 3 88 to 3 90 0 IS28 to 0 IS3S
over 3 90 to 3 92 0 IS3S to 1S43
0
over 3 92 to 3 94 0 1543 to O ISSI
over 3 94 to 3 96 0 I5si to 0 ISS9

over 3 96 to 3 98 0 I5S9 to 0 IS67

over 3 98 to 4 00 0 1567 to 0 IS7S

over 4 00 to 4 02 0 157S to 0 IS83

over 4 02 to 4 04 0 IS83 to 0 IS91

over 4 04 to 4 06 0 IS91 to 0 IS98

over 4 06 to 4 08 0 1598 to 0 1606
over 4 08 to 4 10 0 1606 to 1614
0

Side gear and pinion mate

Thickness of side gear thrust washer mOl in over 0 7S to 0 80 0 029S to 0 03IS

over 0 80 to 0 8S 0 03IS to 0 033S
over 0 8S to 0 90 0 0335 to 0 03S4

over 0 90 to 0 9S 0 03S4 to 0 0374

Pinion mate to side gear backlash or

clearance between side gear and thrust

washer mOl in 0 02 to 0 08 0 0008 to 0 0031

Ring gear

Ring gear to drive pinion backlash mm in 1S

O to 0 20 0 00S9 to 0 0079

Thickness of side bearing adjusting

shim mOl in O OS 0 0020
07 0 0028
0
10
0 0 0039
0 20 0 0079
0 50 0 0197

Side bearing standard width mm in 20 00 0 7874

ft Ib
TIghtening torque kg m
14 0 to 17 0 101 to 123
Drive pinion nut

gear bolt 7 0 to 8 0 SI toS8

Ring
Side bearing cap bolt 4 0 to S O 29 to 36

17 to 2 S to 18
Differential carrier to axle case 12
Companion flange of front shaft and
flange yoke connecting nut 4 to 3 3
2 17 to 24

Center bearing bracket ut 1 6 to 2 2 12 to 16

Companion flange to propeller shaft 4 to 3 3

2 17 to 24

Oil drain and filler plug 6 0 to 10 0 43 to 72

PD l1
 PROPELLER SHAFT DIFFERENTIAL CARRIER

Oil capacity about liter US pt Imp pt 1 0 2Ji I Y

Adjusting methods
Variable numbers expressed by 100
1 mOl

Dummy shaft Use

Drive pinion fonnula

adjusting T N H 0 S x 0 01 18
2

Side bearing adjusting fonnula TI A C D H xO OI

0 17S E

T2 B 0 H x 001 0 150 F

PD 18
 PROPELLER SHAFT 8i DIFFERENTIALCARRIER

SPECIAL SERVICE TOOlS

For Reference
Tool number
use page or
Description
No
on Figure No
tool name Unit mOl in

disassembly 620 Fig PD 7

This tool is used for attaching gear carrier to
or
I ST063 10000 ease
610
Diff assembly
attachment

SE023

2 ST3I 94S000 These tools are used to adjust the pinion height 620 Fig PD 16
610 Fig PD 17
Drive pinion
setting gauge
assembly

@
H190

ST31942000

Dummy
SE209
shaft

ST31941000

Height
gauge

SE210

620 Fig PD 16
3 ST31970000 This tool is used for Type H 190 to adjust the pinion height
610
This tool is used with ST3I 94S000
Collar

35 1 38 di

30 18
1
dia

1
27 1 06

620 Fig 13
4 KV311 00300 For driving out oflock pin of pinion shaft PI
610
Solid punch 710
S30

4 5 0 177 di
95 3 74

Y
65 2 56

PD 19
 PROPELEER SHAFT GIFFERENTIAl CARRIER

Tool number
Fur Reference
No Description use page or
tool name
on Figure No
Unit nUll in

5 Drive pinion outer These tools are used when drive pinion outer
assembling race 620 Page PD 9
race drift
610
ST30611000
0 0
Bar 350 13 78
i
ST306130qo
i Wt UWrflIfl
UU ti
t
l 2 83 dia

Adapter
L J2

0 0
ST30611oo0 350 13 78
1
L
j
Bar

ST3062 1000
I I II
e
G gI 2l 79

j
3 11 dia

Adapter

6 ST309OS000 This assembly clamps rear bearing inner race and pulls it out by a 620 Fig PO IO
Drive pinion hydranlic press 610 Page PD IO
Before insertion place another drift facing inner race and then
rear bearing S30
press fit
inner race

puller lb 45 1 17 dia

35 2 1 386 dia
ST3003Ioo0

Puller

ST30901000

Base l 24 0 94
80g 5 dia

7 KV38102SSO For installing the front oil seal

620 Page PO U

Oil seal 610 Page PO l3

filling
tool

ST30720000

Drift

KV38102SIO

Drift

55 5 2 185 dia

PD 20
 PROPELLER SHAFT DIFFERENTIAL CARRIER

Toollltlltlbcr For Reference

No Description use page or

tuol nallle Unit mOl in on Figure No

8 ST3 1530000 This tool is used to hold the Ilange to case the operation of tightening 620 Fig PD 5
and lousening drive piniun nut 8210 Fig PD Y
Drive pinion
610 Fig PD 28
flange wrench
710
SJO
b
l

54 2 13

9 ST3127S000 This toul is used to the preload of piniun All

Ilwasure
bearing Fig PD 19
models
Preload gauge

GG91030000
CD
Turque wr nch
L
2 IIT62940000 O

Socket adapter
lJ
ct
J IIT62900000 1 4 II J x 3 8
3 8 UJ
L 2
1 r

Socket adapter

10 ST3J06S001 This tool is lIsed to Jut oul side bearing 620 PD 12

Fig
610 PD I 5
Diff side Fig
SJO
bearing puller
set

ST3JOSIOOI
Diff side

bearing
puller
STJ306 I 000 38 1 50 di

Adapter

II ST33230000 Use of this tool makes it possible to drive in bearing without 620 Fig PD IS

Diff side damaging it 610

bearing drift

0ll
5t 1B 1
2 0t di

PD 21
 r

SECTION FA

FRONT AXLE
DATSUN PICK UP FRONT
MODEL 620 SERIES SUSPENSION

FRONT AXLE AND

FA 2
FRONT SUSPENSION
SERVICE DATA AND
FA 13
SPECIFICATIONS

TROUBLE DIAGNOSES AND

FA 14
CORRECTIONS

SPECIAL SERVICE TOOLS FA 17

lNISSAN I

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Front Axle Front Suspension

FRONT AXLE AND FRONT SUSPENSION

CONTENTS

GENERAL DESCRIPTION FA 2 REMOVAL AND INSTALLATION FA 8

FRONT AXLE FA 3 INSPECTION FA 9
REMOVAL AND INSTALLATION FA 3 TORSION BAR SPRING FA 9
WHEEL BEARING ADJUSTMENT FA 4 REMOVAL AND INSTALLATION FA 9

DISASSEMBLY AND ASSEMBLY FA 4 INSPECTION FA 9

INSPECTION FA 5 UPPER AND LOWER LINKS FA 10

SHOCK ABSORBER FA 8 FjEMOVAL AND INSTALLATION FA l0

REMOVAL AND INSTALLATION FA 8 DISASSEMBLY AND ASSEMBLY FA ll

INSPECTION FA 8 INSPECTION FA ll

STABILIZER FA 8 ADJUSTMENT FA Il

REMOVAL AND INSTALLATION FA 8 VEHICLE POSTURE FA ll

INSPECTION FA 8 WHEEL ALIGNMENT FA 12

TENSION ROD FA 8 STEERING ANGLE FA 12

GENERAL DESCRIPTION

uUl

FA224

Fig FA j SectionallJiew of xle

fronta and fron t suspension

FA 2
 Front Axle Front Suspension

The design of the front suspension

FRONT AXLE
adopts the independent double
wishbone type suspension used the
REMOVAL AND
torsion bar spring Both the upper and
INSTALLATION
lower links are installed on the bracket
which is welded on the frame the
1d
A
above links swing to allow the knuckle Removal
spindle to move freely in a vertical

dimension I Jack up and support vehicle on

the stands at the frame in a safe

manner

The top and bottom of the knuckle 2 Remove front wheel

Re FA226
spindle support are connected to the 3 ove brake hose together with

Fig FA 3 R moving knuckle piridle

upper link through rubber bushing and connector from wheel cylinder
to the lower lick through screw 4 Remove brake drum
S Remove hub cap and then remove
bushing
The tension rod held by the brack cotter pin adjusting cap and spindle
ets on the chassis frame and lower lick nut from knuckle spindle Installation
wiih rubber bushings bears the force 6 Remove wheel hub outer and

of fore and aft direction inner wheel bearings bearing washer Install front axle in reverse se

The front end of the torsion bar and grease seal from knuckle spindle quence to removal by noting the fol
spring is installed to the 7 Remove brake disc assembly from lowing matters Furthermore when
torque arm

which attaches to the lower link The the flange of knuckle spindle installing front axle lightly coat grease

is installed to the 8 Remove knuckle arm from to sliding parts

opposite end spring
anchor that secures to chassis frame knuckle spindle
I Insert O ring on the lower end of
9 Remove king pin lock bolt
firmly The both ends of the torsion knuckle spindle support Install thrust
bar spring are serrated
bearing and spindle shim together with
The shock absorber is double
knuckle spindle to knuckle spindle
action telescopic hydraulic type support
The upper stem is attached to the
In this operation select spindle
bracket of the chassis frame The
shims to obtain the specified clearance
lower insulated bracket is bolted to
between knuckle spindle and knuckle
the lower lick
spindle support To measure the Clear
The bumper rubber secured to the
ance with a filler gauge jack up the
bracket Of the frame limits the verti
bottom of spindle slightly
cal motion of the suspension lick
Standard clearance
0 1 mOl 0 004 in less
spindle is connecied
or
The knuckle to

the k ufkle spindle arm by the king FA225 Note Be sure to iristsll thrust bearing
pin The king pin bushings are fitted to Fig FA R mol1ing king pin loch nut to face coverea side upward
the upper and lower arm portIOns of
the knuckle and seals
spindle are

2 Line locking bolt hole of

provided at the portions mentioned to up

keep water and dirt from enteri g knuckle spindle support with the
The knuckle arm is connected to 10 After removing air breather re
notch in king pin and secure lock bolt
Be sure to check killJckle spindle for
the lower end of the knuckle spindle move plug from the top of king pin
transmit of the smooth movement Be certain to move
to ttLe movement with the following method Drill a

steering wheel to the knuckle spindle 5 mm

10 413
0 in diameter hole on
knuckie spindle smoothly and reailjust
The wheel hub is shim if necessary In addition check
supported by two the plug thread hole with a tap
taper roller bearings on the knuckle M 12 1 2S screw a bolt into threaded bushings and king pin as required
Tlie brake drum and wheel are 3 Press fit plug to the upper of
hole and pull out the plug
spindle
secured to ihe hub by the hub bolts knuckle spindle Then install lower
II Apply drift to the top ofking
plug to the lower knuckle spindle
pin and drive out king pin along with

lower plug lower

Note Make sure to place plug
12 Tap spindle with a soft haJnmer conectly
and detach it from knuckle spindle

support Take care not io drop thrust

4 Secure knuckle arm to knuckle
bearing

FA 3
 Front Axle Front Suspension

spindle and torque bolt to 3 to

10 To attain proper preload on wheel
12 1 kg m 75 to 88 ft lb Bend lock bearings proceed the following opera
plate to engaged flats on boll head tions

I 3 0 to 3 S
Note When disassembled discard Torque spindle nut to

kg m 22 to 25 ft lb using torque
used lock plate
wrench
5 Pack to the r and
grea upP
lower bushings on knuckle spindle
until grease c omes out from grease
seal
fA22S
6 Fill wheel hub and cap with
Fig FA 6 Meauring bearing rotation
the described level See
grease up to atarting torque
Figure F A
4

S Install Bend the

a new cotter pin
FA227 ends of coller pin around the castel

Fig FA 5 Tightening apindle nut lated flange of adjusting cap Then

install hub cap

2 Rotate wheel hub a few turns

FA141
clockwise and counterclockwise to
Fig FA 4 ing wheel hub
Gre Then retighten spindle
seat bearings
nut to the same tightening torque Be
certain to rotate hub
smoothly DISASSEMBLY AND
3 Back off spindle nut in range ASSEMBLY
from 40 to 70 degrees Locate adjust
7 Pack roller and cone assembly
ing cap on spindle nut so as to align Knuckle spindle
and the cavity of grease seal lip with
the castellation on the cap with the
grease I Drive spindle bushing and grease
8 Coat to the thread of
cotter pin hole in the spindle
grease seal out of knuckle spindle with KiTlg
4 Check the hub rotation If hub
knuckle spindle bearing washer and
Pin Bush Drift ST3S380000 Discard
lock nul
rotates properly measure bearing rota
bearing bushing and grease seal when disas
tion starting torque If measured
9 Secure wheel hub bearings bear sembled
torque is deviated from the specified
ing washer and spindle nut on knuckle 2 After
value r place beari gs r re dju
st
cleaning king pin bores
spindle and adju t bearing preload
The starting torque can be mea thoroughly install bushing carefully
referring to the paragraph Wheel
sured by a spring balance as shown in by using the above special tpol Posi
bearing adjustment tion bushing in accordance With the
Figure F A6
Note Be sure to obtain correct pre instructions fIlled in Figure FA 7 and
Spring balance indication at hub bolt
load wheel 8
FA
on bearings for the New bearing
pu rpose of ving their long life 2 1 kg 4 Ib o ess
taking care to keep wheel be8rlngs Used bearing
grease seal bearing washer and spin 34 Upper side in
10 kg 2 2 lb or less mm

in lower boss
dle nut clean when installing them 34
1

I
Notes I 1
a When measuring the starting force

WHEEL BEARING
D
TM NT
pull the spring balance toward tan
gential direction against normal line
II
connected between hub boll and Pla ce this position in line with

Wrong adjustment of wheel bear spindle center I grease nipple hole

ing abnonnal and b to exist in Upper side in upper boss

causes wear score Axial play is permissible FA229

on the bearings and knuckle spindle 1

0 mm 0 004 in or less Fig FA 7 King pin bu hing

4
FA
 Front Axle Front Suspension

Wheel hub INSPECTION

Level line
1 After removing grease seal with King pin and bushing
cir
screwdriver lightly tap outer race
Check and replace king pin andlor
cumference with a hammer by ap if tne following faulty condi
bushing
plying a brass bar and remove outer tion is detected deformation scores

bearing race from hub When

tapping and excessive clearance
partial wear

outer race circumference tap evenly

between king pin and bushing in dia
2 Remove all traces of old grease
meter direction exceeding limit listed
from hub and knuckle
Level line bearings below
FA230 spindle
Fig FA 8 Bushing location 3 Install inner and outer bearing
Clearance limit
races in hub with a suitable tool Be
0 15 mOl 0 00S9 in
sure to seat the races properly in hub

4 Pack the inside of hub and hub Standard dimensions

3 Remove nipple and drill
grease grease to the de King pin outer diameter
cap with specified
grease hole on bushing through thread 19 979 to 20 000
scribed level See Figure FAA Also mm

ed grease nipple hole When grease 0 7866 to 0 7874 in

pack the bearing cone and roller as
hole is drilled remove metal chip and lubricant inner diameter
semblies with the same Bushing
burr thoroughly 20 010 to 20 035 mOl

0 7878 to 0 7888 in
Drilling diameter
118
0 in
approximate 3 mOl

Note When has

a
spindle bushing a
2 Wheel bearing
nipple hole in it ad
grease an
ThorougWy clean grease and dirt
ditional hole need not be drilled from wheel bearing with cleaning sol
When it into
pressing position align vent and dry with compressed air free
nipple hole with that in Check wheel bearing to
grease of moisture
spindle bushing see that it rolls freely and is free from
Also
4 Ream the inside of bushing to the FA009
noise crack pit ing or wear

for condition Re
check outer race

specified value with King Pin Bush Fig FA 10 Greasing bearing cone and
moval of outer race from drum is not
Reamer HT56802000 roller assembly

diameter necessary
Bushing inner
Shown below is the cha rt which
when fitted 5 Place inner bearing cone and rol

20 010 to 20 03S mOl ler assembly in hub Coat grease slight furnishes the necessary information on

0 7878 to 0 7888 in ly to the lips of new grease seal and Visual Serviceability Standard for

seat it Wheel Bearing

properly
Note Carry out reaming from both
upper and lower bushings When
reaming upper side use lower side
as reaming guide and when reaming

lower side use upper side as ream Visual serviceability standard for wheel bearing
ing guide to align the center line
correctly @ J
5 Press fit grease seal on arm
upper
with King Pin Grease Seal Drift @
@
ST35390000 In installing grease seal 1 Outer race

take care not to damage seal lip 2 Roller

@ @ 3 Small collar
35390000
51 4 Inner race fitted surface

5 Collar surface
6 Inner race surface
7 Outer race tilted surface

A 8 Outer race lcc

surf

@ 9 Roller rolling surface

10 Inner race

jJ 11 Large collar
2

CD
Q @
12 Supporter

FADD6
FA231
Fig FA 11 Wheel bearing assembly
Fig FA 9 Installing grease seal

FA 5
 Front Axle Front Suspension

X Unserviceable
Judgement 6 May be used when minor

Rust should be removed with 0 emery paper

Race and roller

C Cause
E
Components 2
e 0
0
0
0
0 u CIl

Flaking X Service life due to rolling fatigue However this symptom occu before
the service life The following causes are considered

Abnormal load overload

Fig a b Improper handling or installing

Crack X X X Excessive tightening

Excessive gap and a considerable shock received from the outside

Rapid heat generation on the race due to creep

Bitten supporter with seizing rollers

Abnormal thrust load

Fig c d Tapped with a hammer while removing

Seizure X X X n the most cases seizure occurs as the result of grown

discoloring or

flaking

Scratch 6 6 6 Shock is given carelessly during installation

Bit foreign matter

Recess or wear 6 6 6 Careless installation removal or other rough handling scar due to
made by pressing striking
orstriking Recess made by foreign matter
Fig e f g

Wear 6 6 6 Poor lubricant quality or deteriorated lubricant

Intrusion of dust Fitted surface is worn remarkably

Wear due to excessive preliminary pressure

Biting 6 6 6 Excessive preliminary pressure or faulty lubrication

Fretting 6 6 6 The fitted part is discolored to brown or black

corrosion fitted part fine relative

Fretting rust on means slip on

metal contact surface

FA 6
 Front Axle Front Suspension

Race and roller

u
u

e Cause
Components 2
2 0

3
0
c t

Rust 6 6 6 Temperature increased during operation lowers when the bearing

stops moisture inside the bearing is condensed becoming fine drips
and the grease is moistened

The bearing has been placed in a highly moistened place for a long
period of time
Intrusion of moisture chemicals etc or the bearing is touched with
Fig h bare hand and no rustproof action has been taken

Discoloring The wheel bearing is serv Slight discoloring may become like oxidized oil stain due to grease

iceable if discoloring can

In the most cases this occurs when preliminary pressure is too high
be removed with solvent

or by polishing

I
1
I I

v
n
dJ
i

f
a Inner race flaking b RoUer flaking c Cracked inner race

t c

fJ Jt
v l

d Cracked roller Recess

e on inner race f Recess on outer race

t
iT
F 1ll
t 1
tt j J JJ
I
1
t 11 I l
t
1
1
ollf
c
oe

g Recess on foDer h Rust outer race

F A007

Fig FA 12 Defective conditions of bearing

FA 7
 Front Axle Front Suspension

SHOCK ABSORBER Specifications for shock absorber

REMOVAL AND Model

All models
INSTAUATION Item

1 Raise vehicle on a hoist or stands Piston stroke mm in 110 4 3

2 Remove wheel
Damping force kg lb
3 Holdthe upper stem of shock
3 m sec
0 0 98 ft sec j
absorber and remove outs washer and
rubber bushing Rebound 76 168

4 Remove bolt from the lower end Compression 38 84

of shock absorber

STABILIZER and rubber bushings for crack wear

and deterioration Replace if ne
cessary
REMOVAL AND
INSTAUATION

I Raise vehicle on a hoist or stands

FA232
2 Remove wheel
Fig FA 13 Shock absorber
3 Loosen secUring nut at the lower
link side of stabilizer
4 Remove bolt securing stabilizer TENSION POD
S Retain lower rubber bushing in mounting bracket to chassis frame
REMOVAL AND
position install the lower end of shock
INSTALLATION
absorber to the bracket of lower link Install stabilizer in the reverse se

and torque the bolt to 3 1 to 4 1 kg m quence to removal noting the follow

I Raise vehicle on a hoist or stands
23 to 30 ft lb ing instructions
2 Remove wheel
S Attach stabilizer mounting brack
Note Insert the bolt from the front 3 from both ends
et to chassis frame tightening bolt to Remove nuts
CD
side of vehicle
16 to 2 2 kg m 12 to 16 ft lb of tension rod

torque
4 Remove bracket bolt @ from the
6 Install the upper end of shock front end of tension rod and remove
6 Install stabilizer lower link side to
absorber to body bracket and tighten tension rod with bracket
connecting rod and tighten nut to the
lock Jt
n to the specifjcations specifications as shown in Figure
Tightening torque FA 14 Then torque lock nut toJ 6
CD
1 6 to 2 2 kg m 121016 ft lb to 2 2 kg m 12 to 16 ft lb

INSPECTION

I Check shock absorber for visible

defects and oil leaks Place shock
absorber vertically in a vise and hand
stroke shock absorber as outlined be f A234

low Fig FA 15 Ten ion rod

Extend and compress shock ab
sorber as faI as possible travelling as F A233

long as possible Fig FA 14 Stabilizer detail

If smooth hydraulic resistance is
not present in bqth Iirection replace
absorber INSPECTION Install tension rod in reverse 00

2 Replace rubber bushing if crack qunce to removal noting the following

or deterioration is detected Check stabilizer for deformation instructions

FA S
 Front Axle Front Suspension

s Install tension rod at rear end 4 Remove dust cover at the rear Anchor arm setting post ion A

tighten nut to make the distance of end of torsion bar spring and detach ISt02Smm

rubber bushing to be 4 mm 1 315

33 snap ring 59
0 to 0 98 in
in and torque lock nut to 1 6 to 2 2 distance
S Withdraw torsion bar spring rear Temporary tightening B

kg m 12 to 16 ft lb 60 to 70 mOl
ward after pulling ou t anchor arm
6 Install tension rod bracket to 36
2 to 2 76 in
realWard
chassis frame bracket and torque nut

to 1 6 to 2 2 kg m 12 to 16 ft lb Installalation
When two rubber bushings are dif

UjP je
ferent in size Install torsion bar spring in the
arrange adjusting nut
of removal
Standard dimension is 11 0 mOl 433
0 reverse sequence noting Rebound bumper
the
in as shown in Figure FA 16 Torque following instructions
rubber
I Coat grease the serrations of
lock nut to 1 6 to 2 2 kg m 12 to 16 on
j
torsion bar
ft lb spring and install it to

torque arm

Il 0 11 0 433
0
Note Be sure to install right and left 4W
torsion bar springs correctly They
t lP can

and
be identified with
L Left marked
R

on
Right
the end
Fig FA 18 Setting procedure

surface
Notes

A and 8
4 1
33 315
2 Install anchor and
3
specifications are
arm tighten the
I only preliminary rough settings
adjusting nut to obtain A dimen
directions for performing the final
11 0 433
0 1 011 0 0 433 sion See Figure FA 17 When anchor
adjustment that determines the ride
is A
Adjusting nut
arm properly adjusted to
height are found on page FA II
specification upper link should be in under Adjustment
contact with rebound bumper rubber
i
Y b Discard old snap ring after re
See Figure FA 18 Install snap ring and
moving it Replace with
w
new one
dust cover Temporarily tighten adjust
during reinstallation
ing nut until B specification is
reached 3 Install wheel and lower vehicle
36 6 l 441
Adjust vehicle posture at curb weight
Unit mm
in full fuel tank no refer
FA235 passengers
Fig FA 16 Tension rod detail ring to
Adjustment
4 Torque lock nut to 3 1 to 1
4
I
kg m 22 to 30 ft lb

INSPECTION
I
INSPECTION
I
I Check tension rod for bend and Check torsion bar spring for wear
the thread for faulty condition Repair twist etc When adjusting vehicle
or replace as required
posture replace torsion bar spring
2 Check bushing rubber for wear FA236
with a new one if the specified height
and deterioration Replace if neces can not be obtained
Fig FA 17 Installing anchor arm

sary

TORSION BAR Specifications for torsion bar spring

SPRING
REMOVAL AND
All models
INSTALLATION

Removal
Diameter in 219 830 0 862 x 32 68
1 Raise vehicle on a hoist or stands
x
length mOl x

2 Remove wheel
Torsional rigidity
3 Loosen nuts anchor 3 74 27 I
at spring kg m deg ft lb deg
bolt

FA 9
 FrClnt Axle Front Suspension
4 Install upper link spindle to upper
UPPER AND LOWER
link mounting bracket with used
LINKS camber shims and bolts
adjusting
Torque bolt to 7 0 to 9 0 kg m SI
REMOVAL AND to 6S ft lb
INSTALLATION S Install dust seat to the lower end

of j
nuckle spindle support
Removal
6 Coatgrease on the thread of
I Raise vehicle on a hoist or stands fulcrum pin and line up the notch of

2 Remove wheel and brake drum as FA238 fulcrum pin with knuckle spindle sup

an assembly Fig FA 20 Removing upper link port for inserting cotter pin Fit
3 Remove wheel hub Refer to see spindle fulcrum pin to spindle support with a

tion Front Axle soft hammer Secure cotter pin and

4 Loosen bolts retaining brake disc torque lock nut to 0 8 to 1 kg m
to knuckle spindle and remove brake 12 Remove nut retaining lower link S 8 to 8 0 ft lb

disc spindle and remove lower link spindle 7 Coat grease to the tIuead portion
5 Remove knuckle arm torsion bar Remove lower link with torque arm of screw bushing inside liberally Posi
spimgJ stabilizer shock absorber and from mounting bracket tion knuckle spindle support at the

tension rod in t
ili order referring the 13 Using Transverse Unk Bushing center of lower link and secure screw

related sections Replacer ST36070000 to lower link bushings temporarily by hand Mter
it with hammer and ascertaining the dimensions become
6 Remove upper fulcrum bolt se bushing tap a

drive lower link from shown in Figure FA 22

curing knuckle spindle support to out bushing correct as

bracket torque screw bushings to 20 to 30

upper link assembly and disassemble
them kg m I4S to 217 ft lb
7 Remove upper link bushings from
knuckle spindle support
8 Remove screw bushings from
both ends of lower link fulcrum pin
9 Loosen nut at lower portion of
knuckle spindle support from inside
and pull out cotter pin retaining ful
crum pin

3
10 Pull out fulcrum pin with drift
and remove knuckle spindle support

with knuckle spindle from lower link F A239

Then detach dust cover FA 21 9 05 to 11 05
Fig Removing lower link 36 5 9 05 to 1105
0 3563 to 04350 0 3563 to 04350
bushing 1 431
FA240

Fig FA 22 In tailing IICrew bu hing

InstallatIon

Install upper and lower links in the

8 filler
reverse
sequence to removal noting Replace plug with grease

the following instructions nipple and pack grease until grease

comes out from dust cover Reinstall
I When the collar inside of lower
filler plug
link mounting bracket and bushing
outside 9 Upon installation make sure that
are rusted remove rust with
fulcrum pin operates smoothly with
emery paper
the following torque
2 Fit lower link into lower
FA237 bushing
Fig FA 19 Removing fulcrum pin link mounting bracket using Trans Operating torque
verse Link Bushing Replacer Less than 5 kg
0 m 3 6 ft lb
ST36070000 When tapping the frift
with a hammer be careful to hit the 10 Install upper link bushing to
drift squarely knuckle spindle support
II Remove bolts retaining upper 3 Secure lower link to lower link II Install knuckle spindle support
link spindle and remove upper link bushing with lower link spindle and to upper link insert fulcrum bolt and

spindle with camber adjusting shims torque nut to 74 to 8 0 kg m 54 to

torque nut to 3 9 to 3
S kg m 28 to

from body bracket S8 ft Ib 38 ft lb

14 1n
 Front Axle Front Suspension

Note When installing fulcrum pin 4 Make sure to operate upper link Check the screw of upper link
insert it from rearward of vehicle spindle smoothly after installation spindle fulcrum pin and screw bush
5 Replace filler plug with grease ing and repair or replace if necessary
nipple and pack grease until grease
12 Install tension rod shock ab comes out from dust cover
Note Discard dust cover and dust seal
sorber I stabilizer torsion bar spring Reinstall f1ller plug
when disassembled
and knuckle arm referring to the
related paragraphs
Lower link
13 Install brake disc to knuckle
spindle and torque securing bolt to 4 2 When installing torque arm on

to 5 0 kg m 30 to 36 ft Ib lower link tighten it to the following

14 Install wheel and brake drum as specifications ADJUSTMENT
and
an assemblytorque knuckle spin Serration boss
dle nut to 8 0 to 9 0 kg m 58 to 65 VEHICLE POSTURE
1 8 to 2 6 kg m
ft Ib
13 to 19 ft Ib Vehicle posture may be incorrect
Arm head due to weakened spring or other faulty
2 7 to 3 7 kg m condition The following procedures
20 to 27 ft tb are necessary when adjustment is Ie
quired
That is
the vehicle posture can be
adjusted by obtaining only the speci
INSPECTION
DISASSEMBLY AND fied H dimension changing the
ASSEMBLY length of anchor bolt
Upper link spindle fulcrum pin I Raise front of vehicle on stands
Upper link andscrew bushing
2 H dimension with turn
Adjust
Apply screw bushing to upper link ing nut
adjusting anchor bolt H
I Detach upper link from
spindle spindle or fulcrum pin and measure dimension changes approximately 5
3
upper links and remove clamp dust 0 J38 in
axial end play between them mm vertically when adjust
cover and dust seal Secure upper link nut is turned one
When the end play exceeds 35
0 complete turn
in a vise and loosen screw bushing To make the best vehicle
mm 0 0138 inreplace upper link 3 posture
spindle or fulcrum pin together with H dimension must be in the follow
Assemble link spindle in reverse screw bushings ing range
sequence to disassembling noting the

following instructions
2 Torque screw bushing on upper H dimension mOl in
link to 3S to 55 kg m 253 to 398
ft Ib Install new dust seal and dust All models
Condition
cover and secure them with clamp
3 Coat grease to screw bushing in
Vehicle empty no payload 79 to 84 3 11 to
side and the thread portion of upper 31
3

link spindle liberally Screw front and

rear links to
upper link spindle in the Vehicle loaded 5 2 15
54
same length to obtain the speci
so as

fied figures as shown in Figure FA 23

Notes i
a Vehicle empty no payload consists o
of the following conditions
I Full tank of gasoline radiator
f1lled and engine oil level full
2 Spare tire wheel jack and jack
handle in design position
b Vehicle loaded consists of the fol
Unit mm in I
lowing conditions
44 6 1 1
56 FA2 FA242
Fig FA 23 Upper link and upper link For all models 2 persons and SIlO Fig FA 24 Dimension for standard
spindle 103lb
leg I payload vehicle postl4re

FA
 Front Axle Front Suspension

WHEEL ALIGNMENT When cross rod is turned to opposite

side toe in is increased
Correct front wheel alignment
After correct toe in is obtained
attains proper vehicle handling charac
tighten lock nut to 8 0 to 10 0 kg m
teristics and the least steering effort
S8 to 72 ft Ib
with a minimum amount of tire wear
Before adjusting front wheel align
ment make
liminary inspection
sure to carry out a
pre
of the front end
rJ r CD 0
parts for the following conditions
HI I
r
FA243
1 Tire pressure and balance e
Fig FA 25 Adjustingcamberand
2 Wheel bearings and nuts
cCJ ter f
3 Steering gear play
4 Steering gear housing at frame
Notes
S Steering linkage and connections
a Do not make difference between
6 Shock absorber action FA244
front and rear shims in thickness Fig FA 26 Adju6ting toe in
beyond 2 mm 0 079 in on a
upper
When using the equipment for front
link spindle
wheel alignment inspection follow the STEERING ANGLE
b Umit shim thickness for anyone
inst
c tions furnished with the equip stack within 6 nun 0 236 in
ment Furthennore the Check steering angle and use the
inspection c Do not use shims for anyone stack
should be made with the vehicle level follow ng procedures if necessary
more the 2 sheets
and at curb weight Loosen lock nut at stopper bolt and
adjust steering angle with stopper bolt
Mter obtaining correct steering angle
Toe in
secure lock nut firmly

Camber and caster Measure toe in and adjust if neces

sary For adjustment carry out the
Measure camber and caster and
follOWIng procedures
adjust them in accordance with the Turn steering wheel to straight
following procedures if necessary ahead position with front wheels in
Both camber and caster are ad
the same position Then check steer
justed by increasing and decreasing ing gear straight ahead position
thickness of adjust shim inserted be
tween
Loosen lock nuts @ left hand
link spindle and upper
upper
thread and ID right hand thread
link mounting bracket
and turn cross rod CD to adjust toe in
To adjust caster make a difference Turn cross rod to forward direction as FA245
between thickness of front and rear
shown by arrow and toe in is reduced Fig FA 27 Adjusting steering angle
shims By adding a shim I mm 0 039
in at front side caster will be de
creased by 33 At the same time
camber will also be decreased 6 S
by
Item
To adjust camber add Model All models
or remove an

equal amount of shims to front and

mOl in 1 2 to 3 0 079 to 118
0
sides By adding
rear a pack of shims I Toe in
mOl 0 039 in thick at both sides degree 2 10 to 16
camber will be decreased
by 13
Shims Camber lOIS Io
are available in I mm 0 039
in 2 mOl 0 079 in and 4 mOl 157
0
in thickness Caster 10SO 4S

incIinal10n 60IS
Kingpin

Steering angle
I Innerwheel 10
360

I Outer wheel 10
310

1 The extreme front and rear of the tire center

Unladen
2 The total angle of the both tires

FA 12
 Front Axle Front Suspension

SERVICE DATA AND SPECIFICATIONS

King pin
Clearance limit between the king pin
and in 0 15 0 0059
bushing mm

Bushing inner diameter when fitted in

mm 20 010 to 20 035
0 7878 to 0 7888

Clearance between the knuckle spindle

in less than 0 1 0 004
support and spindle mm

Wheel bearing

ft Ib 3 0 to 3 S 22 to 2S
Tightening torque kg m

40 to 700
Spindle nut returning angle
Wheel bearing rotation starting torque
When both bearing and seal are new in Ib less than IS 13 0
kg em

kg em in lb less than 7 6 1
When readjusted
At the hub bolt
kg lb less than 2 1 4 6
When both bearing and seal are new

When kg lb less than 10 2 2

readjusted

Suspension link

kg ft Ib less than O S 3 6
Upper link sliding resistance m

ft lb less than O S 3 6
Lower link sliding resistance kg m

lightening torque kg m ft Ib

19 to 2 S 14 to 18
Brake hose connecting nut

Wheel bearing lock nu t 3 0 to 3 5 22 to 2S

4 2 to S O 30 to 36
Brake disc fIXing bolt

Knuckle arm fixing bolt 3 to 12 1

10 74 to 88

2 1 to 2 S IS to 18
King pin lock bolt

Torque arm

Arm end 2 7 to 3 7 20 to 27

Serration boss 18 to 2 6 13 to 19

74 to 8 0 S4 to 58
Lower link spindle nut

24 to 35 174 to 2S3
Upper link screw bushing
to bracket 7 to 9 51 to 6S
Upper link spindle bolt fIXing
Cotter pin lock nut 0 8 to l 5 8 to 8 0

Lower link 25 to 32 181 to 231

screw bushing
Fulcrum bolt 3 9 to 3 28 to 38
S

Tension rod
Lock nut 16 to 2 2 12 to 16
1 6 to 2 2 12 to 16
Bracket bolt

Shock absorber
1 6 to 2 2 12 to 16
Lock nut of the upper end
Lower end 3 1 to 4 1 22 to 30

Stabilizer
Bracket bolt 16 to 2 2 12 to 16

Lock nut of the anchor bolt 3 1 to 4 1 22 to 30

0 8 to l 5 8 to 8 0
Bumper rubber bolt

FA 13
 Front Axle Front Suspension

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

Vibration Too much backlash of steering gear wear

Vibration shock and shimmy
ing of steering wheeL of each part of linkage and vibration of front
wheels are in many cases transmitted to the
is Very much noticeable when
steering wheel This
traveJling over bad roads and at higher speeds
Shock When the front wheels are travelling over

bumpy roads the play of the steering linkage is

transmitted to the steering wheel This is especially
noticeable when travelling rough road

Shimmy Abnormal vibrations of the front suspen

sion group and the whole steering linkage which
occur when a specific speed is attained

Improper air pressure of tire Adjust

Unbalance and deformation ofroadwheel Correct the unbalance or re

place
Unevenly worn tire or insufficient tightening Replace or tighten

Improperly adjusted or worn front wheel bearing Adjust or

replace
Faulty wheel alignment Adjust
Worn or loose suspension link screw bushing Replace
Damaged idler arm Replace

Insufficiently tightened steering gear housing TIghten

Worn steering linkage Replace ball joint

Improper steering gear adjustment insufficient back Adjust

lash

Faulty shock absorber or loose installation Replace or tighten

Unbalanced vehicle posture Adjust

Vehicle pulls to right or left When driving with hands off the steering wheel on a
fiat road the vehicle gently swerves to right or
left

Note A faulty rear suspension may also be the cause

of this condition and therefore see also the

chapter dealing with the rear suspension

Improper air pressure of tire or insufficient tightening Adjust or tighten

of wheel nuts

tires
Difference in height of right and left tire treads Replace

Incorrect adjustment or abrasion of front wheel Adjust or replace

bearing
Weakened front torsion spring or deviation from Replace
standard specification
Improper wheel alignment Readjust
Worn or loose suspension link screw bushing Replace

FA 14
 Front Axle Front Suspension

Condition Probable cause Corrective action

Vehicle puBes to right or left Deformed of steering and suspension link

linkage Replace
Unbalanced vehicle level Correct the unbalance

Instability of vehicle Improper air pressure of tire Adjust

Worn or loose suspension link screw bushing Replace
Incorrect wheel alignment Adjust
Worn or deformed steering linkage and suspension Replace
link

Incorrect adjustment of steering gear Adjust

Deformed unbalanced wheel Correct or replace

Stiff steeirng wheel Check and correct in the following manner

Jack up front wheels detach the steering gear and

operate the steering wheel and
a If it is light check steering linkage and suspension
groups
b If it is heavy check steering gear and steering
column groups

Improper air pressure of tire Adjust

Insufficient lubricants or mixing impurities in steering Replenish grease or replace
linkage or excessively worn steering linkage the part

Insufficient lubricant in gear box or contaminated Add or replace gear oil

lubricant

Unsmooth king pin damaged part Or insufficient Replace

lubrication

Worn or incorrectly adjusted wheel bearing Replace or

adjust
Worn damaged steering gear and bearing Replace
Incorrectly adjusted steering gear Adjust
Deformed steering linkage Replace
Incorrect wheel alignment Adjust
Interference of steering column with turn signal Adjust
switch

Excessive steering wheel Incorrectly adjusted steering gear Adjust

play Worn steering linkage idler arm Replace
Improperly fitted of gear box Retighten

Incorrectly adjusted wheel bearing Adjust

Worn or loose suspension link screw bushing Replace

Noise Improper air pressure of tire Adjust

Insufficient lubricating oil and grease for suspension Replenish lubricating oil and
link screw bushing and steering linkage or their grease or replace

breakage

FA 15
 Front Axle Front Suspension

Condition Probable cause Corrective action

Noise Loose steering gear bolts linkage and suspension Retighten

groups

Faulty shock absorber Replace

Damaged wheel bearing Replace

Worn steering linkage and steering gear Replace

Worn ofloose suspension link screw bushing Replace

Grating tire noise Improper air pressure of lire Adjust

Incorrect wheel alignment Adjust

Deformed knuckle spindle and suspension linkage Replace

Rough driving Avoid rough driving

Jumping of disc wheeL Improper air pressure of tire Adjust

Unbalanced wheels Adjust

Faulty shock absorber Replace

Worn tire Replace

Deformed wheel rim Replace

Improper air pressure of tire Adjust

Excessively or partially worn

tire
Incorrect wheel alignment Adjust
Damaged wheel bearing Replace

Incorrect brake adjustment Adjust

Improper tire shifting rotation Adjust
Rough and improper wiving manner Drive more gently

FA 16
 Front Axle Front Suspension

SPECIAL SERVICE TOOL

Tool number For Reference

No Description use page or
tool name on
Figure No
Unit mOl in

ST35380000
22 2 dia
0 874

King pin bush This tool is used to drive out 620 Page FA 4

drift king pin bushing

SE234

2 HTS6802000

King pin bush This tool is used to correct 620 Page FA S

reamer king pin bushing

FA 17
 SECTION RA

REAR AXLE
DATSUN PICK UP REAR
MODEL 620 SERIES SUSPENSION

REAR AXlE AND

RA 2
REAR SUSPENSION

SERVICE DATA AND

RA 7
SPECIFICATIONS

TROUBLE DIAGNOSES
RA 8
AND CORRECTIONS

I NISSAN I SPECIAL SERVICE TOOLS RA 9

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Rear Axle Rear Suspension

REAR AXLE AND REAR SUSPENSION

CONTENTS

DESCRIPTION RA 3 Shock absorber RA 6

REMOVAL AND INSTALLATION RA 3 tNSPECTION fJ

RA

Rear axle RA 3 Rear axle shaft and wheel bearing RA 6

assembly
Rear axle shaft and wheel bearing 4
RA Rear axle case RA6
Rear axle case RA 5 Rear spring fJ
RA
RA 5 Shock absorber fJ
RA
Rear spring

J
I

i I
LJ

o
1 @
RA132

1 Air breather 14 Wheel bearing 28 Rear axle case

2 Thrust block 15 Rear axle bearing grease seat 29 Filler ptug

3 Nut Supply wheel bearing grease to T 6toIOkg m

T 3 1 to 4 1 kg m oil seal lip when assembly 43 to 72 ft4b

22 to 30 ft lb 16 Rear axle Oil capacity liter
bearing spacer about 10
4 Shock absorber mounting rubber 17 Rear axle shaft 1 7 8 Imp qt
US qt
bush 18 Grease catcher 30 Drain plug
5 Rear spring clip V bolt 19 Bearing cage bolt T 6to 10kg m

6 Rear axle oil seal spacer 20 Rear axle case end shim 43 to 72 fHb
7 Rear axle shaft oil seal 21 Nut Nut
31
Supply wheel T 5 4 to
6 4 kg m
bearing grease to T 5 to 13 0 kg
11 m

oil seal lip when assembly 391046 ft lb 83 to 94 fHb

8 Rear axle bearing lock nut 22 Rear spring pad Rear spring rear bush
32
T 15 to 20 kg m 23 Rear spring 33 Rear spring
10810 145 ft b 24 Nut 34 Rear spring shackle
9 Rear axle bearing lock washer T 7 3 to 9 9 kg m 35 Nut
10 Plain washer 53 to 72 ft4b
T 1 15 to13 0 kg m
11 Rear axle bearing cage 25 Nut 83 to 94 fHb
12 Road wheel bolt T 1610 2 2kg m 36 Rear spring
13 Road wheel nut 12 to 16 fHb 37 Rear spring front bush
T 8t09kg m 26 Shock absorber rubber bush
38 Rear spring front pin
58 to 65 fl Ib 27 Shock absorber
TTightening torque
Fig RA I Crou uctional view of rear a xl and uapension

RA 2
 Rear Axle Rear Suspension

DESCRIPTION 2 Mark relationship across

propeller three clamps ID and connector @
shaft flange and companion Slide front cable rearward and discon
The rear axle assembly is of the flange of
semi floating type in which the vehicle differential carrier so that the original nect rear cable @ at connector ID by
weight is carried on the axle shafts combination is restored assembly at removing three clamps ID
3 Remove bolts retaining center 5 Disconnect
through bearings enclosed in the bear rear brake hose at

ing cages on outer rear axle case The bearing bracket and connecting shaft frame @ Cover brake hose and pipe
axle is pressed steeJ to companion flange Withdraw pro openings to
case a
Banjo prevent entrance of dirt
type housing peller shaft sleeve yoke from transmis 6 Disconnect shock absorbers at
The rear axle assembly is attached sion the shaft rearward lower end f and push shock ab
by moving
to the frame passing it under rear axle sorbers up out of the way
through semi elliptic leaf
and 4 Disconnect hand brake cable 7 Lower jack under axle
springs telescopic hydraulic shock rear case Re
absorbers Rubber bushings at either Q by removing adjusting nut @ move U bolts
spring clips @ to

end of the leaf springs and shock separate axle case from spring
absorbers are designed to absorb vibra
tion and noise

The rear axle shaft splines engage

the differential side gears with a float
ing fit The outer ends are supported
in the bearing cages by tapered roller
bearings
The bearings are lubricated by
wheel bearing grease The axle shaft oil
seals are located outboard and inboard
of the bearing The bearings are se

cured against shoulders on the shafts

by press fit and held in place by a

large nuts

The bearing cages hold the bearings

against shoulders on the axle case

Whee side thrust is taken at the

wheel bearings through the thrust
block so an axle shaft may be re

moved simply by removing the bolts

holding the brake disc to the bearing
cage and the rear axle case

RA312

Fig RA 2 Under view

8 Place
jack under center of axle
a
Tightening torque
Pass axle
through space
REMOVAL AND case case
U bolt Spring clip
above spring and take it out to the
INSTALLATION 3 to 9 9
7 kg m
side
53 to 72 ft lb
REAR AXLE ASSEMBLY
Shock absorber lower end nut
It is notnecessary to remove the
1 6 to 2 2
reaT axle assembly for any normal kg m

12to 16ft Ib
repairs
However if the axle case is dam Brake pipe flare nut
aged the rear axle assembly may be IS to 18 kg m

removed and installed using the fol II to 13 ft Ib

lowing procedures Propeller shaft to companion

I Raise of vehicle high enough
rear
flange connecting bolt
to permi t working underneath Place a 20 to
RA134
2 7 kg m
jack under center of axle case so it just Fig RA 3 Removing
14 to 20 ft Ib
rear axle
starts to raise rear axle assembly assembly Center bearing bracket
Place stands solidly under frame holt
fixin
members on both sides Remove rear 9 Install the axle in
case assembly 1 6 to 22 kg m
wheels the order of removal
reverse
12 to 16 ft Ib

RA 3
 Rear Axle Rear Suspension
8 Position axle shaft in vise with I Fit wheel
REAR AXLE SHAFT AND bearing outer race by
Rear Axle Stand ST07630000
WHEEL BEARING tapping with a brass hammer evenly
9 Unbend lock washer with a screw while fitting
I Raise rearof vehicle and support
driver 2 Install
under axle case on stands Remove a new oil seal in bearing
wheel Note Do not use used lock washer cage Lubricate cavity between seal
rear

2 Disconnect rear hand brake cable again lips with wheel bearing grease after

by removing adjusting nut and clamps fitting seal

3 Disconnect 3 Place bearing cage with brake disc
brake tube at rear

wheel cylinder Cover brake tube and and bearing spacer on axle shaft and

wheel fit bearing cone To install bearing

cylinder openings to prevent
entrance of dirt
cone apply a brass drift to race side
4 Remove brake drum surface and tapping the top of drift
with a hammer

Not If brake drum cannot be easily

removed return brake adjuster
install two bolts M8 x I2S in RAl38

holes the face of brake Fig RA 6 Unbending lock washer

on flange
drum and tighten bolts evenly until
10 Remove lock nut using Rear
brake drum is driven out
Axle Bearing Lock Nut Wrench
ST38020000
5 Remove wheel
nuts retaining
bearing cage to brake disc
I
AA141

Fig RA 9 Installing whetl bearing

4 Place bearing lock washer Q and

bearing nut lock washer @ on axle
shaft and tighten lock nut @ using
Rear AJde Bearing Lock Nut Wrench
AA139
I ST38020000 and bend up lock wash
Fig RA 7 R mouing lock nut er

Jq AA135
II Withdraw wheel bearing to Notes
a Be careful to the faced side of
Fig RA 4 Removing nuts gether with bearing cage and brake place
disc Axle Shaft Bearing nut to washer side that washer is
using Rear so

Puller HT72480000 not damaged

b Coincide washer lip with nut groove
correc ly by
tightening nul and
HT72480000
bend washer carefuljy so that lip
will nol be damaged

r
t

Tightening torque
Rvr IS to 20 kg m

G o
J08 to 14S ft Ib
l AA343

Fig RA 8 Removing bearing

i
12 Remove oil seal in
if necessary
bearing cage
t i
fifii Litf
4

AA418
13

race
To
after
remove wheel
removed oil seal
bearing outer
S
apply a

Fig RA 5 Removing rear axle shaft brass drift to race side surface and i
assem bly withdraw
drift with
it

a
by tapping the lop of
hammer
11 iI j

t
J
7 Remove oil seal in axle case if i pu y Mf
Installing can be proceeded in the I

necessary and install new seal Insure reverse order of removal procedure as AA142
against damaging the seal lip follows
Fig RA IO Layout ofock nut

4
RA
 Rear Axle Rear Suspension

Install shaft in opposite side and Installing can be proceeded in the

S Apply wheel bearing grease in 8

wheel bearing and recess of axle case adjust axial end play by applying shim reverse order of removal procedure
end Axial end play 0 02 to O IS mOl Tightening torque
0 0008 to 0 0059 in Differential carrier to axle case

fixing nut I 7 to 2 5 kg m
Tightening torque of
12 to 18 ft Ib
bearing cage fixing nut
5 4 to 6 4 kg m Oil drain and fIller plug
39 to 46 ft Ib 6 to 10 kg m

43 to 72 ft lb

Lubricating portion
AA143
REAR SPRING
Fig RA l1 Lubricating portion in and
around wheel bearing 1 Raise rear of vehicle and support
under both frame members with

stands
2 Disconnect shock absorber at
U bolts
6 gear oil to the spline at the
lower end CD and remove
Apply
inner end of axle shaft Apply a coal Spring clips 2
of wheel bearing grease on the seal
Fig RA 13 Measuring axial end play
surface of the shaft
7 Install left or right shaft and
9 Install other parts in reverse se
adjust axial end play by applying rear quence to removal
axle case end shim indicated by arrow
mark

Axial end play 3 to 0 9

0 mOl

0 012 to 035
0 in

Standard shim thickness REAR AXLE CASE

5 mm 0 059 in
1 Rear axle case may be removed and

Tightening torque of installed using the following pro

bearing cage fIXing nut cedures

54 to 6 4 kg m
I Raise rear of vehicle and support
39 to 46 ft lb securely under both frame members
with stands

2 Remove rear axle assembly See 3 Position jack under rear axle case

removal of rear axle assembly Raise jack and float axle case from
3 Remove rear axle shaft at both spring
sides See removal of rear axle shaft 4 Disconnect rear spring shackle by
and wheel bearing removing nuts

4 Remove differentiai carrier as

sembly

w
Fig RA 12 Installing rear
AA144

axle shaft
Installing
reverse
can

order of removal
be proceeded in the
procedure
Another is available
procedure as

listed below
Rear axle case end shim
I Raise rear of vehicle and support
under both frame members with
Thickness mOl in
stands
O OS 0 0020 both
2 Remove ear axle shaft at AA147

0 07 0 0028
sides Fig RA 15 Removing spring shackle
0 10 00039 3 Remove differential gear carrier
0 20 0 0079
assembly 5 Disconnect spring from body by
O SO 0 0197 4 Remove rear axle case removing spring front pin

RA 5
 Rear Axle Rear Suspension

I Check axle shaft for straightness

SHOCK ABSORBER
cracks damage wear and distortion
Raise rear of vehicle and support
2 Check the lip of oil seal for
under axle case on stands It is recom
damage deformation and wear
mended that a hydraulic hoist or open
3 Check bearing for wear and
pit be utilized if available
damage
2 Disconnect lower end of shock
absorber by removing nuts Q at

spring seat
REAR AXLE CASE
3 Disconnect upper end of shock
Check axle case for yield deforma
RA148 absorber by removing nut
2 at frame
tion cracks or oil leakage and replace
Fig RA 16 Remvoing spring pin
if necessary

6 Remove rubber bush in spring if

REAR SPRING
necessary and install new bush Coat
rubber hush with a soapy solution Clean all rust and dirt from spring
prior to assembly leaves using a wire brush if necessary

1 Examine spring leaves for frae

InstaH spring in the reverse
rear
tures or cracks
order of removal noting the following 2 Check front bracket
pin and
poinc shackle U bolts and
spring seat for
RA146
Vehicle weight must be on rear wear cracks straightness and damaged
Fig RA J 7 Removing shock absorber
wheels when tightening front pin threads If faulty parts are found
shackle and shock absorber lower end replace with new ones
in Installation of shock absorber in
nut in order to clamp rubber bush a 3 Inspect all rubber parts for wear
neutral or unloaded position the reverse order of removal
damage separation and deformation
Note Vehicle weight must be on Tear Replace them if necessary
Tightening torque wheels when tigtrtening shock ab
Spring fTont pin nut sorber upper and lower ends in
11 5 to 13 0 kg m
order to clamp rubber bushings in a SHOCK ABSORBER
83 to 94 ft Ib neutral or unloaded position I Test shock absorber and compare
Spring shackle nut
with the specifications given in Service
11 5 to 13 0 kg m
Data and Specifications Replace if
83 t094 ft b INSPECTION
necessary
U bolt 3 to 9 9
7 kg m
2 Check for oil leakage and cracks
REAR AXLE SHAFT AND
S3 to 72 ft lb Also check shaft for straightness
WHEEL BEARING 3
Shock absorber lower end nut Inspect rubber bushings for dam
1 6 to 2 2 kg m Inspect the following parts for age s and deformation
cracl Replace
12 to 16 ft lb faults and replace as required parts if necessary

RA 6
 Rear Axle Rear Suspension

SERVICE DATA AND SPECIFICATIONS

Applied model
All models
Item

Rear shock absorber

Stroke x Maximum length 190 x 47S 7 48 x 18 70

mOl in

Damping force
at 3 m
0 10 ft sec

75 to 101 165 to 223

Expansion kg lb

Compression kg lb 3S to S3 77 to 1l7

Standard Option

Rear leaf spring

1 200 6 3 1 200x60x 72
x 60 x
5 1 6 1

13 1 13 2
Dimensions Length x Width
Thickness Number of leaves 47 24 x 36
2 x 0 243 47 24 x 36
2 x 0 28 2
x

mOl in 0 20 1 0 24 1
0 51 1 0 512

Free camber mOl in IS3 60 140 5

S

Laden camber mmlkg in lb 6 440 0 24 970 24 440 0 94 970

in 2 1 to S O 118 to 280 2 6 to 10 0 146 to S60

Spring constant kg mOl lb

Rear axle

End play mOl in 0 02 to O IS 0 0008 to 0 0059

O OS 0 0020
0 07 0 0028
Rear axle case end shim
0 10 0 0039
thickness mm in
0 20 0 0079
50
0 0 0197

Recommended for use on heavy load under high center of gravity such as camper loading

Tightening torque

Shock absorber upper end nut kg m ft lb 3 1 to 4 1 22 to 30

Shock absorber lower end nut ft Ib 1 6 to 2 2 12 to 16

kg m

Rear U bolt ft lb 3 to 9 9
7 53 to 72
spring Clip kg m

RA 7
 Rear Axle Rear Suspension

Spring front pin kg m ft lb 5 to 13 0

11 83 to 94

Spring shackle ft Ib
kg m 115 to 13 0 83 to 94

Bearing cage fIXing bolt kg en ft lb S 4 to 4

6 39 to 46

Wheel bearing lock nut

kg m ft Ib IS to 20 108 to l4S

Air breather kg m ft Ib 0 7 to 0 9 S I to 6 S
Differential gear carrier to axle case nut kg ft Ib 17 to 2 7
m 12 to 20

Propeller shaft flange bolt kg ft Ib 2 0 to 2 7

en 14 to 20

Drain and filler plug kg m ft Ib 6 to 10 43 to 72

Bumper rubber fixing bolt kg m ft Ib 1 6 to 2 2 12 to 16

Wheel nut
kg m ft lb 8 to 9 S8 to 6S

TROUBLE DIAGNOSES AND CORRECTIONS

When axle and suspension is shaft rear axle
rear engine transmission universal and rear suspension
suspected of being noisy it is advisable of oil
joint wheel bearings
suspension or In case leak first check if
to make a
thorough test to determine Noise which originates in other there is any damage or restriction in
whether the noise originates in the places can not be corrected by adjust breather
tires road surface exhaust propeller ment or replacement of parts in the

Condition Probable cause Corrective action

Noise Loose wheel nuts Tighten the wheel nuts

Loose one or more securing bolts Tighten the bolts to the specified torque
Lack of lubricating oil or grease Lubricate as required
Faulty shock absorber Replace the shock absorber

Incorrect adjustment of rear axle shaft end Adjust the rear axle shaft end play
play
Damaged wheel bearing
or worn Replace wheel bearing
Worn spline portion of rear axle shaft Replace if necessary

Broken leaf spring Replace leaf spring

Loose journal connections or so no Tighten to the given torque

Wheel and tire unbalance Balance wheel and tire

Damaged rubber parts such as leaf spring Replace the required parts
bush shock absorber moun ting bush

Faulty universal joints Adjust or replace

Instability in driving Loose wheel nuts Tighten to the given torque

Worn shock absorber Replace faulty shock absorber

Worn or broken leaf spring Replace leaf spring

Oil leakage restricted air breather Clean

Damaged or or replace air breather

Damaged oil seal in rear axle case or differ Replace the damaged oil seal
ential carrier

Oil leakage from between the differential Tighten to the specified torque or
replace
carrier and axle case gasket

8
RA
 Rear Axle Rear Suspension

SPECIAL SERVICE TOOLS

For Reference
Tool number
Description use or
No page
Unit mOl in
tool name on
Figure No

KV40101000 This tool is used to remove rear axle shaft All Fig RA S

Use with sliding hammer ST36230000 models

Rear axle

stand

SE402

axle shaft All Fig RA S

2 ST36230000 This tool is used to remove rear

Use with rear axle stand KV40101000 models

Sliding hammer

SEll1

This tool is used to loosen and tighten rear axle bearing lock nut 620 Fig RA 7
3 ST38020000

Bearing lock
nu t wrench

SE238

All Fig RA 8
4 HT72480000 This tool is used to drive out rear axle shaft bearing rigid
axle car

Rear axle shaft models

axle
bearing puller parts Iools are used for other rear Iype

SE382

RA 9
 SECTION BR

BRAKE SYSTEM
DATSUN PICK UP
MODEL 620 SERIES

GENERAL DESCRIPTIDN BR 2

ADJUSTMENT BR 2

SERVICE BRAKE BR 4

HAND BRAKE BR 18

SERVICE DATA AND

BR 2D
SPECIFICATlDNS

TROUBLE DIAGNDSES
BR 22
AND CORRECTIONS

SPECIAL SERVICE TOOLS BR 25

4ISSAN
l I

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Brake System

GENERAL DESCRIPTION

The 620 series vehicles are equip brake The mechanical hand brake is are standard equipment on all models

brakes on the four controlled by a hand brake lever locat The Master Vac is installed to increase
ped with hydraulic
wheels and mechanical hand brakes ed in the driver s compartment braking force The N LS V ensures

on the rear wheels The front brake is For added safety the tandem greater safety and reliability

the and the the 1lI3ter

I cylinder Master Vac and
servo
uni type rear

Nissan Load Sensing Valve N LS V

duo servo with the built in hand

ADJUSTMENT

CONTENTS

BRAKE PEDAL BR 2 HAND BRAKE Parking brake BR 3

FRONT BRAKE BR 2 BLEEDING HYDRAULIC SYSTEM BR 3

REAR BRAKE BR 3

BRAKE PEDAL 3 After completing adjustment

operate brake pedal several times to
ensure that it travels over its entire
stroke of 137 mm 5 39 in smoothly
showing squeak noise twist
Qi without

f
ing or interference

l Free height A 148 5 83

II Full stroke at pedal pad B 134 10 140

5 28 to 5 51
FRONT BRAKE

t Depressed height C 43 to 49
1 69 to 193
1
floor
Raise vehicle until wheel clear

2 Remove rubber boot from brake

1 Push rod adjusting nut disc

2 Switch adjusting nuts 3 Ughtly tap adjuster housing and
3 BraKe lamp switch move it forward Turn down adjuster
wheel with a screwdriver and spread
brake shoes Stop turning adjuster
Unit mm in BA765
wheel when a considerable drag is Jelt
and lock up brake drum
Fig BR l Adjusting brake pedal

Note For both right and left brakes

I Under the condition that the with its adjusting nut so as to become brake shoes spread when adjuster
push rod of brake lamp swi tch is 0 6 to 12 mOl 0 024 to 0 047 in in wheel is turned downward
pushed in position the height of brake play Then tigh1en nut securely
pedal from toeboard to 148 mm 5 83 Tightening torque 4 Return adjuster wheel 12 ratches
in operating the switch adjusting 1 6 to 2 2 kg m to obtain correct clearance between
nuts Then tighten nuts securely drum and brake shoes Turn
12 to 16 ft lb brake

Tightening torque brake drum and make sure that brake

1 2 to 5 kg
1 m drum turns without dragging when

9 to I I ft Ib Note Take care not to allow the push brake shoes interfere with brake drum
rod to get into master cylinder in then readjust clearance

2 Adjust the length of push rod free condition 5 Install rubber boot

BR 2
 Brake System
I Clean all dirt around master cyl

t inder reservoir remove cap and top up

I

t
1 reservoir

fluid

2
with

Thoroughly clean mud

recommended brake

and dust

6 0
from bleeder valve so that outlet hole
0
I
is free from any foreign material
o c
bleeder valve

nJ
Install a bleeder hose on

Place the other end of hose in a

BA655 container filled with brake fluid

nut
3 Depress brake pedal two or three
Fip BR 2 Adjusting front brake Fig BR 4 Adjusting lock
times then keep pedal fully depressed

4 With brake pedal fully depressed

open bleeder valve to expel air

REAR BRAKE
3 Fully release hand brake and Notes
With hand brake fully released rotate rear wheels No drag should be a Pay attention to brake fluid level in
brake shoe clearance For master cylinder reservoir during
adjust rear present
the service procedures refer to Front bleeding operation
Brake Notes b Do not reuse brake fluid drained

a Before adjusting hand brake com during bleeding operation

plete the adjustment of rear brakes c Bleed air as follows

b After adjusting hand brake operate 1 Master cylinder front

the brake lever to make cable 2 Master cylinder rear
stable 3 N LS V front
be 4 Front wheels
c Hand brake must operated
while being S Rear wheels left first
smoothly pulled and one

Make that abnor 6 N LS V rear

released sure no

7 N LS V center
mal noise dragging twisting or

other faulty condition occurs d Exercise care not to splash brake

fluid on exterior finish as it will

damage the paint

brake
Fig BR 3 Adjusting rear 5 Close bleeder valve quickly as

brake pedal is on down stroke

6 Allow brake pedal to return slow

ly with bleeder screw closed

HAND BRAKE BLEEDING 7 Repeat bleeding operations until
air bubbles show in hose
Parking brake HYDRAUL Ie SYSTEM no

I Raise vehicle until wheels are

Hydraulic brake system be Notes
rear must
clear of the floor bled whenever any line has been dis a Brake fluid containing air is white
2 Apply hand brake lever operate connected or air has entered into and has visible air bubbles

lock nuts to be 80 to 100 mrn lS

3 to
system b Brake fluid containing no air nms

3 94 in in hand brake lever stroke When action has out of bleeder valve in a solid
pedal a spongy
and tighten lock nuts securely feel it is an indication that air has stream free of air bubbles

Applying force to hand brake entered the system

8 the
lever Bleeding the hydraulic system is an Repeat above steps on re

essential part of regular brake service maining brake lines to expel all air
20 to 30 kg 44 to 661b

BR 3
 Brake System

SERVICE BRAKE

CONTENTS

BRAKE PEDAL BR 4 REMOVAL BR lO

BR 4 DISASSEMBl Y AND ASSEMBLY BR 1O

REMOVAL
BR 4 INSPECTION BR lO
INSPECTION
BR 4 INSTAllATION BR ll
INSTAllATION
MASTER BR 5 REAR BRAKE BR 12
CYLINDER
BR 5 REMOVAL BR 12
REMOVAL
DISASSEMBl Y AND ASSEMBLY BR 6 DISASSEMBLY AND ASSEMBLY BR 13

6 INSPECTION BR 13
INSPECTION BR
BR 5 INSTAllATION BR 13
INSTAllATION
7 MASTER VAC BR 14
BRAKE LINE BR
B DESCRIPTION BR 14
REMOVAL BR
B INSPECTION OF OPERATION BR 14
INSPECTION BR
B REMOVAL BR 16
INSTAllATION BR
DISASSEMBLY BR 16
N LS V BR 9
9 INSPECTION BR 17
DESCRIPTION BR

N LS V TEST BR 9 ASSEMBl Y AND ADJUSTMENT BR 17

INSTAllATION BR IB
FRONT BRAKE BR lO

BRAKE PEDAL

b
REMOVAL

Remove pedal return spring

i t
5

2 I Fulcrum pin
3 2 Return spring
4 BR657 3 Pedal bushings
BR766
4 Clevis pin

Fig BR 5 Broke pedal mounting 5 Brake pedal

Fig BR 6 Broke pedal

2 Remove cotter pin from clevis INSPECTION INSTALLATION

pin and separate pedal from Master
Check brake pedal for the following
Vac push rod Install brake pedal in the reverse
items servicing as necessary attention
3 Remove fulcrum pin and pedal sequence of removal paying
I Check pedal bushing for wear
to the following instructions
deformation or damage 1 Insert fulcrum pin into hole in
Note Loosen fulcnun pin clockwise 2 Check shaft sleeve for wear
pedal brake pedal and bracket from right
or roughness side
3 Check for bent brake pedal 2 Install clevis pin from left hand
4 Check for fatigued return spring side

4
BA
 Brake System
To install it follows 2 Align the in retention
3 Hook return spring to brake pedal proceed as projection
Turn retention used in the cap with the slit in the reservoir tank
assembly from accelerator pedal side I ring
of recommended retention cap fully in the REMOVE and push retention cap in the tank
4 Apply a coating
multipurpose grease to the inner and direction 3 Turn retention ring fully in the

clevis TIGHTEN direction

outer faces of pedal bushing

pin and hooks of return spring

Tokico
Charge the clearances in bushings with
1
j

1tr
grease

@
Grease
I

m n L I
I

g
U 00 CD
1

2
Reservoir cap

Reservoir tank
BR298 Nabco 3 Secondary piston return
5pring
Fig BH 7 Greasing place 4 Stopper screw

5 Secondary piston
6 Primary piston return
5 lnstali brake lamp switch spring
6 the brake after in 7 Primary piston
Adjust pedal BR926

stallation Refer to the instructions

under Adjustment Fig BR B Sectional view of tandem

master cylinder

Tightening torque
Fulcrum pin
1 9 to 2 4 kg m

14to 17ft ib
REMOVAL

1 Disconnect front and rear brake

tubes from master cylinder

Notes
MASTER CYLINDER a When removing brake tubes use

The diameter of cylinder is 19 05

Flare Nut Torque Wrench
GG94310000
mm y in for all models The tandem
Never use open end or adjustable
master cylinder contains two fluid
wrench
reservoirs which connect the front and
o
b When disconnecting brake tubes be
rear brake lines independently
sure to use a container to receive
Braking force is constantly main BR658
draining brake flnid Use of rags is
tained when failure occurs in either Fig BR 9 Master cylinder
also suggested to keep adjacent
the front brake system or the rear
parts and area clean
brake Failure in the front
system
brake system will leave the rear brake 2 Remove master cylinder securing
still operative or failure in the rear nut Then master cylinder can be
brake system will leave the front brake taken out

system still operative

The reservoir is equi pped with a

retention cap
To remove this cap proceed as

follows
Tum retention ring fully in the
I
REMOVE direction
2 Pull out retention cap

BR 5
 Brake System

DISASSEMBLY AND ascertain the brand of the brake

ASSEMBLY master cylinder body Be sure to

use parts of the same make as the

former ones

1
INSPECTION

Thoroughly clean all in

parts a

00 suitable solvent and check for WOol or

oC 1 damaged parts Replace any part that

00 11I
is faulty
O
Note Do not clean robber parts with

b 01 minerai oil
sure
since this will be the

way of deteriolllting parts Use

r L
r brake fluid or alcohoL When alco
hol is used for leaning these parts
do not immerse them in it longer
than 30 seconds After parts are

cIeaned dry with compressed air

I Check cylinder and position for

evidence of abnonnaI wear or damage
BA927
Replace if found faulty
1 Reservoir cap 6 2 Check piston to cylinder clear
Secondary piston stopper 11 Primary piston
2 Oil mter 7 Bleeder screw 12 Piston stopper ance If it is more than O IS mm
3 Oil reservoir 8 Secondary return spring 13 Piston stopper ring 0 OOS9 in either piston
4
replace or

Packing 9 Secondary piston

cylinder
5 Valve cap 10 Primary return spring
Master cylinder inner diameter
Fig BR 10 Master cylinder
19 0S mm Yoin

3 Check for weakened fatigued or

1 Remove reservoir cap and filter Tightening torque damaged springs and replace if neces
and drain out brake fluid Valve cap sary

2 Pry off ring using Tokico 4 When master cylioder is disassem

stopper a

screwdriver 8 t09 kg m
bled be sure to discard cups and
3 Remove stopper screw and take S8 to 6S ft Ib valves Replace any other part which
shows evidence of deformation wear
out stopper primary piston assembly Nabco

spring and secondary piston assembly 5 to 3 S kg

2 m
or damage
S Replace damaged oil reservoirs
in the order shown 18 to 2S ft Ib
Bleeder and caps

Note Discard piston cup if it is re 0 7 to 0 9 kg m

moved from piston sembly and S to 7 ft lb

use a new one INSTALLATION
Notes
Install master cylinder in the re
4 Unscrew plugs to gain a Replace gaskets and packings with
access to
check valve for disassembling new ones verse sequence of removal
b Bleed air out of master cylinder by
Apply brake fluid or rubber grease
contact surfaces of loosening bleeder screw after it is
Note Never detach reservoir tank U to sliding parts
facilitate of master installed in its original position
it is removed for any reason dis to assembly
canI it and install a new one cylinder Tightening torque
c The blllke master cylinder is avail Brake master cylinder attaching
S Assemble master cylinder in the able in both NABCO make and nut
reverse sequence of disassembly pay TOKlCO make There is no inter 0 8 to 1 kg m

ing particular attention to the follow changeability of repair kits or com 6 to 8 ft Ib

ing notes ponent parts between NABCO and Brake tube connector
TOKlCO JIIlkes When replacing IS to 18 kg m

the repair kit or component parts II to 13 ft Ib

BR 6
 Brake System

BRAKE LINE

Detail A Detail D Detail G

Detail B Detail E Detail R Detail K

Detail C Detail of Detail 1 L

Detail

BA767

Fig BR ll Brake line

BR 7
 Brake System
stead
REMOVAL replace copper washer with a
new one after checking for sign of
1 Removing flare nuts on both ends
damage on seating surface Never reuse
and clips effects the removal of brake
an old copper washer
tube and brake hose

2 Rear brake hose can be removed

INSTALLATION
by disconnecting the tube and then

turning round the hose Brake hose

Note When removing brake tubes and Front brake hose

hoses use Flare Nut Torque Fig BR 13 Rear brake ho e

Wrench GG943IOOOO In brake hose first jack

installing
Never use an OpeD end or an adjust up vehicle to take off the weight of After brake hose has been installed
able wrench vehicle from wheels so that suspension check to be that there is
sure enough
is in rebound wheel should
Steering clearance between hose and adjacent
also be kept in straight ahead position
parts to avoid contact with other ones
INSPECTION To connect brake line first connect The check should be carried out while
brake hose to wheel cylinder with the moving wheel up and down through its
full stroke and rotating steering wheel
1 Examine all hoses for swell specified torque
between two extreme lock positions
rubbing marks or cracking
ozone re Tightening torque
those with The wow clearance must be as
placing found any ofabove 7 to 2 0
1 kg m

follows
badly beyond use Also inspect end 12 to 14 ft Ib

fittings and be sure that no fluid leak Hose to rotating or mOving parts
through staked end has taken place Then secure brake hose to the such as tire and rim

replace if necessary Hose with badly bracket with lock plate so as not to 40 mm 57 in and
1 more

rusted fitting should also be replaced twist or abnormally bend the hose Hose to stationary part
with a new one 2S mm 0 98 in and more

2 Clean all tubes to remove dust Note After brake hose at

connecting
and dirt with isopropyl alcohol check both eiuIs In that the above
pay keen attention not case clearance

ing for collapse wear cracking swell to twist the hose when additional cannot be obtained it may be caused
is hose
or rusting Replace if foun d with any tightening required by the twisted Accordingly
of wove Use care not to damage carry out the correction with hose
brake tubes while operation connection again following the above

Check if tubes are clamped secure instructions

ly
Mter all brake lines have been Brake tube
installed retighten aU connections if
In installing a brake tube use care
necessary to assist in obtaining correct
to locate its end mating
torque In retightening at front wheel squarely on

cylinder first remove hose clamp and seat noting the fact that nut can be
loosen flare nut on opposite side to turned freely by a light finger twist

avoid twisting hose Then tighten to correct torque with a

Brake Pipe Torque Wrench
Hold pedal as far downward as
GG943 10000
possible 80 kg 176 lb or more
Fig BR 12 Front brake hose
examining evidence as to whether fluid
is leaking through brake lines or con
Tightening torque Flare nut
nections Leakage in any manner can
5 to 1 8 kg m
1
not be permitted here In case fluid Rear brake hose
11 to 13 ft Ib
leaks tightening to specified torque
First secure rear brake hose to
tighten additionally up to 2 5 kg m In addition care should also be
3 way connector on rear axle case to
J 8 ft lb Under no circumstances
exercised to damaging or col
avoid
the specifications Mter connecting
should not be tightened over 25 kg m
lapsing brake tube
during operation
18 ft Ib torque since this elongates
hose do not tighten it at 3 way
Be sure to make enough clearance
connector additionally since this oper
end fitting making it impossible to between all tubes and other adjacent
ation causes hose to be twisted
reuse brake tube
parts to avoid contact
Under no circumstances should rear Tightening torque In installing tube through hood
brake hose and 3 way connector be I 7 to 2 0 kg m
ledge grommet be sure to position it
retightened over specified torques In 12 to 14 ft Ib at the center of grommet

BR 8
 Brake System

be The N LS V is installed on the summary of the N L S v operation is

After connecting brake tube
inclined at 10 A in Figures BR 14 and BR 15
sure to check the clearance to prevent frame being degrees given
from damage The clearance at the

following portions must be specified

distance or more

and frame
Master TI II
Tube to body panel cylinder
I
Over 5 mm 0 20 in

Tube to edge ofeach panel y

Over 10 39
0 r
Tube to tube
mm in
1
Loop pitch
OVer 5 mm 0 20 in
J
Between front tube and

rear tube
Over 9 mOl 35
0 in
Tube to moving parts
Over 10 mm 39 in
0
I
Loop tube to hood ledge panel Attaching angle

Notes
Over 10 mm 39
0 in

l
a Brake tubes are shaped at factory D Wheel cylinder
to secure specified clearance and
may not require reshaping Discard
if they call for excessive reshaping
b In reshaping a brake tube take care

to avoid damaging galvanization or

collapsing section

Mter brake lines have been asssem

BR928

bled check to make sure that all

fittings and flare nuIs ale lightened to Fig BR 14 Construction of N L S V

correct torques
Performance curve of brake fluid
Tightenint torque
Brake tube to connector pressure is as follows

ISton kg m
0
A
II to 13 ft Ib S
c
Brake tube to brake hose
0
17 to 2 0 kg m C

12 to 14 ft lb U1U oadea
o

Connector and clip fixing bolt

l 0

3S
O to 4S
O kg m

5 to
2 3 ft lb
Front wheel cylinder
3 way connector fixing bolt fluid BR769
pressure
on rear axle case
Fig BR 15 Perfonnance curve offluid pressure
0 8 to 1 kg m

6 to 8 ft lb
N L S V TEST
the following occurs
N L S V When rear wheels lock stopping
Operating test distance is shorter than 13 1 m 43 0
DESCRIPTION
The test should be conducted under ft whether loaded or unloaded
be measured
The Nissan Load Sensing Valve these conditions Stopping distance should
N LS V serves to change braking Drive a vehicle with pay load and from the place where the brake pedal
in response flat is first applied to the place the vehicle
power of the rear wheels then with only driver a dry on

actually Front wheels lock

to changes in the load and fluid concrete or asphalt road applying the stops
at 40 km h 25 MPH simultaneously with or ahead of rear
pressure improving braking stability brake suddenly
and shortening stopping distances N LS V is functioning normally if wheels

BR 9
 Brake System

Ibove mentioned op entire brake system except Wheel cylinder can be disassembled

st is available when the N L S V is correctly adjusted simply by the following procedures

described below
Remove retainer and dust cover

and take out piston from wheel cyl

inder Be careful not to damage sliding

FRONT BRAKE part of piston and

piston cup
Thoroughly wash u disassembled
parts in brake fluid or alcohol

Note Do not wash rubber parts with

mineral oil since they are deterio
rated
After shoe return spring When alcohol is used however do
Adjuster assembly not immerse rubber parts in alcohol
8 Adjuster head
longer than 30 seconds After parts
9 Adjuster head shim
10 Lock spring are cleaned dry them with com

Adjuster housing air

1 Brake disc 11 pressed
2 Brake shoe assembly 12 Adjuster wheel
3 Wheel cylinder assembly 13 Adjuster screw Assemble wheel in reverse
cylinder
4 Brake shoe upper return 14 Retaining spring
spring 15 Lock plate sequence of diassembly
When securing connector bolt in
5 Brake shoe lower return 16 Adjuster shim
spring 17 Rubber boot sert its location tip to the hole of
wheel cylinder firmly and tighten it

Fig BR I6 Front brake securely

Carry out operations carefully so
that component parts are not damaged
REMOVAL or no dust and other foreign materials

enter cylinder

I Jack up front of vehicle just high

enough to remove tire and support it
with safety stands wheel is
Note The brake cylinder
2 Remove wheel and brake drum If available in both NABCO make and
brake drum cannot be easily removed TOKICO make There is no inter
return brake adjuster install two bolts of kits
1 Brake hose changeability repair or com

M8 x 1 25 in holes on the flange face 2 Wheel cylinder attaching ponent parts between NABCO and
of brake drum and tighten bolts even bolt BA312 TOKICO makes
ly until brake drum is driven out 3 Rubber boot
When replacing the repair kit or
3 In order to ease operation re
Fig BR 17 Removing wheel cylinder ent ascertain the
parts
move hub assembly from knucRle
brand of the brake wheel cylinder
Refer to Front Axle DISASSEMBLY AND
spindle body Be sure to use parts of the
4 Unhook upper lower and after ASSEMBLY
same make as the former ones
shoe return springs and then remove

brake shoe assemblies Wheel cylinder

S Disconnect brake hose from

rr l
wheel cy linder
@
6 Loosen securing nut and remove

wheel cylinder

t
7 Remove rubber boot adjuster @
shim lock plate and retaining spring
and then
from brake disc
remove adjuster assembly a INSPECTION
BR649

Wheel cy linder 6 Connector Brake drum

7 Packings
housing
2 Piston 8 Connector bolt I Replace brake drum whose dia

3 Piston cup 9 Bleeder screw meter is beyond the limit of 1 5 mm

10 Bleeder cap
4 Dust cover 0 OS9 in with respect to the standard
5 Retainer inner diameter of 2S4 0 rom 10 00

Fig BR 18 Front wheel cylinder in

SR tO
 Brake System

2 The allowable maximum out of Standard dimensions of shoe springs

round of brake drum is 0 02 mm

0 0008 in Installed
Free length Dia of spring No of
Re condition or
replace brake drum Item
in
lengthlload
mOl in mOl coils
if specified limit is exceeded mm kg in lb

3 Measure for tapered brake drum

5
136 IS9 S 14 to 16
If specified limit of 0 02 0 0008 2 0 0 079
mm Upper 37
S 37 6 28 31 to 3S
in is exceeded as measured at a

position where the distance of 4S mm

134 S 5 21 to 23
IS9
from inlet Lower 3
2 091
0 35
177 in is kept away 30
5 28
6 46 to Sl
re condition or replace brake drum
4 Contact surface with which 83 2 99 4 to S
After shoe 14 O OSS 27 S
into contact should be 3 28 3 90 9 to II
linings come

finished to such an extent that it is

ground by a No 120 to 150 sand

paper
S Using a drum racer finish brake
drum by machining if it shows any Wheel cylinder Adjuster sliding resistance
sign of score marks partial wear or
S to 12 kg II to 261b
stepped wear on its contact surface I Replace any cylinder or piston
which is scratched scored or worn on

Note After brake drum is completely its sliding contact surface

conditioned or renewed check 2
re
Replace worn parts if piston to
drum and shoes for proper contact 2 When installing wheel cylinder be
cylinder clearance is beyond O IS mm

pattern 0 OOS9 in sure to secure the cylinder with R

mark to right hand disc and the one

Wheel inner diameter

cylinder with L mark to left hand disc
19 0S mOl Y in
Otherwise brake hoses may interfere
with other adjacent parts As to the
3 Replace piston cup which is worn instructions of brake hose
connecting
or otherwise damaged
no twist or contact is existed on brake
4
Brake assembly Replace if contacting face of cyl hose referring the related topic Brake
inder and shoe is worn locally or in
line
I When brake shoe linings are step Tightening torque
cracked seated S Replace damaged dust cover
incompletely uneven
Wheel cylinder
Iy worn andlor deteriorated due to fatigued piston spring or faulty SA to 6 6 kg m
excessive heating or soiled with oil threaded parts
39 to 48 ft lb
grease and brake fluid replace 6 Replace tube connector which is Connector bolt
2 Replace linings if the thickness is worn on its threaded portion 19 to 5 kg
2 m

worn down to less than 1 0 mm 0 039

14 to 18 ft Ib
in
Brake hose
1 7 to 2 0 kg m
Note When brake shoe lining is in
INSTALLATION 12 to 14 ft lb
stalled grind brake shoe lining face
Air bleeder
to diameter equal to that of brake Install front brake in the reverse 0 7 to 0 9 kg m
drum sequence of removal paying particular 5 to 7 ft Ib
attention to the following instructions Brake disc
lining dimension
I When assembling adjuster assem
Width Thickness 4 2 to S O kg
x x
Length m

4S x 4S x 244 mm bly apply brake grease to adjuster 30 to 36 ft lb

177 x 0 177 x 9 61 in housing bore adjuster wheel and ad

juster screw 3 Before installing brake shoe as

3 Check adjuster for smooth oper When installing adjuster assembly semblies apply brake grease to wheel
ation brake grease to cylinder and adjuster brake shoe in
to brake disc apply
4 Replace shoe return springs which disc adjuster and retaining spring slid stalling grooves and brake disc and
broken fatigued brake shoe assembly contact faces
are or
ing surfaces to slide adjuster smoothly
adjuster sliding
Measure resistance two places Exercise care not to

allow grease to come into contact with

Adjust by adjuster shim when sliding
resistance is in rrect linings and adjuster

BR ll
 Brake System

4 Adjust brake shoe clearance and

bleed brake system Refer to the
instructions under topic Adjustment in

this section

Upon completion of the above ad

justments make sure that brake oper
ates correctly and no brake fluid leaks

BA313

Fig BR 19 Greasing points

REAR BRAKE
1 Brake disc
2 Brake shoe assembly
3 Wheel cylinder assembly
4 Return upper spring
5 Return lower spring

6 After shoe return spring

7 Retainer

8 Antirattle spring
9 Spring seat
10 Adjuster assembly
11 Adjuster head
12 Adjuster head shim
13 Lock spring
14 Adjuster housing
15 Adjuster wheel
16 Adjuster screW
17 Toggle lever
18 Extension link
19 Return spring
20 Adjuster spring
21 Lock plate
22 Adjuster shim
23 Rubber boot
BA315 24 Antirattlc pin

Fig BR 20 Reor brake

REMOVAL toggle lever withdraw clevis pin 8 Disconnect brake tube at wheel
from
7 Disconnect toggle lever cylinder by loosening flare nut
I Jack up rear of vehicle just high hand brake rear cable 9 Remove wheel cylinder from
to remove lire and it
enough support brake disc by loosening installation
with safety stands nuts
2 Remove wheel loosen hand brake
10 Remove rubber boot
adjuster
and detach brake drum shim lock plate and adjuster springs
3 Turn pin by 900 and remove
and remove adjuster assembly from
antirattle springs brake disc
4 Open brake shoe assemblies out
ward against return spring and remove
extension link
S Remove return springs
6 Remove brake shoe assemblies
Note that after secondary brake shoe
assembly must be separated from BR316

toggle lever When separating after

secondary brake shoe assembly from Fig BR 21 Remouing toggle leuer

BR 12
 Brake System

3 Check smooth oper 4 Replace shoe return

DISASSEMBLY AND adjuster for springs which
ASSEMBLY ation are broken or fatigued

Wheel cylinder
Standard dimensions of shoe springs
Remove dust cover and pull out

piston head and piston assembly Installed

Free length Dia of spring No of
Refer to Wheel Cylinder of Front Item
in in lengthlload
Brake mOl mOl coils
mmlkg in lb
175 11
184 to 13
Upper 2 0 0 079 5
32
6 89 24 24 to 29
7

158 176 18 to 20
Lower 2 3 0 091 30
6 22 6 93 40 to 44
ID
CD l After shoe
83 2
14 0 055 5
27
99 4 to S

345 0 3 276 3 90 9 to II

5
20 12 3 S to 5
4
AntiratUe 1 6 0 063 3 5
1 Dust cover 0 807 47
0 8 to 9 9
BR318
2 Piston head
3 Piston

4 Piston Cll
p
5 Wheel cylinder housing
6 Bleeder cap Wheel cylinder 2 When assembling toggle lever and
7 Bleeder screw
after brake shoe assembly adjust clear
8 Connector I Replace cylinder
any or piston ance between toggle lever and after
9 Washer
which is scratched scored or worn on
10 Connector bolt brake shoe assembly to 0 to 3
0 mOl 0
itssliding contact surface to 0 012 in with a selected
2 properly
Replace worn parts if piston to
Fig BR 22 Rear wheel cylinder toggle pin washer
cylinder clearance is beyond O IS rom
0 00S9 in

INSPECTION Wheel cylinder inner diameter

19 0S rom Xin
Toggle pin washer
Brake drum
3 Replace piston cup which is worn
Check brake No Thickness rom in
drum in the same
or
damaged
manner as outlined in the Front Brake 4 Replace if contacting face of cyl I 2 0 0 079
Drum
inder and shoe is worn locally or in
2 3
2 0 091
step
Brake assembly 3 2 6 0 102
5 Replace damaged dust cover

I When brake shoe linings are fatigued piston spring or faulty 4 2 9 0 114
threaded parts
cracked incompletely seated uneven S 3 2 0 126
6 Replace tube connector which is
ly worn andlor deteriorated due to
worn on its threaded portion
excessive heating or soiled with oil
grease and brake fluid replace
2 Replace linings if the thickness is
3 Before installing brake shoe as
WOol down to less than 1 0 rom 0 039
semblies apply brake to the
in grease
INSTALLATION following places
1 Brake shoe installing grooves of
Note When brake shoe lining is in Install rear brake in the reverse
adjuster and wheel cylinder
stalled grind brake shoe lining face sequence of removal paying particular 2 Extension link installing grooves
to diameter equal 10 lha I of brake attention to the following instructions 3 Lower surface of spring seat
drom I Rear adjuster assembly is the 4 Contact surfaces between brake
dimemion same as front Refer to the paragraph
Lining disc and brake shoe assembly six
Width x Thickness x Length covering Front Brake Installation
places
4S x 4 5 x 244 rom
Adjuster sliding resistance At this time be sure not to coat
177 x 0 177 x 9 61 in S to 12 II to 261b brake grease to brake linings
kg

BR 13
 Brake System
f

Note The Master Vac diaphragm dif Master Vacs are identified by the
fers from fonner ones for improved label color as follows

braking force Do not install fonner 1976 model Caution Label

Master Vac on 1976 models The
Former models YeJlow

BR317

Fig BR 23 ing point

Gre

4 Tightening torque
Wheel cylinder
S to 1 8 kg
J m
BR321
II to 13ft Ib
11 Valveoperating rod
Connector bolt
12 Valve return spring
1 9 to 5
2 kg m
13 Poppet return spring
14 to 18 ft Ib 1 Plate and seal 6 Seal 14 Exhaust valve

Brake tube 2 Push rod 7 Vacuum valve 15 Valve plunger

3 Diaphragm 8 16 Reaction disc
5 to 1 8
1 kg m Poppet assembly
4 Rear shell 9 Valve body guard 17 return
II to 13 ft Ib Diaphragm spring
5 Diaphragm plate 10 Air silencer filter 18 Front shell
Air bleeder
0 7 to 0 9 kg m Fig BR 24 Sectionall1iew of Master Vac
S to 7 ft Ib

Brake disc
5 4 to 4 kg
6 m INSPECTION OF OPERATION
39 to 46 ft Ib
Checking yscuum pressure
S Adjust brake shoe clearance and
I Connect a vacuum gauge in the Vac as shown in Figure BR 25
bleed brake system Upon completion
of the above line between check valve and Master
adjustments make sure

that brake operates correctly and no

brake fluid leaks

MASTER VAC
1 Check valve
2 Vacuum gauge
DESCRIPTION

A vacuum suspended Master Vac is

installed behind the master cylinder

BA169
As the brake pedal is depressed fluid
is forced under high pressure through Fig BR 25 Air tight t t t up

the brake pipes to the wheel cylinders

to retard or stop the vehicle
2 Start engine and increase engine Air tight test
The Master Vac contains a spring
loaded speed Stop engine when vacuum
diaphragm of IS2 4 mm 6 in I Fifteen seconds after engine is
gauge indicates SOO mmHg 19 69
in diameter It operates on negative stopped observe the rate of drop in air
n the
inHg
pressure produced engine intake pressureregistered by vacuum gauge
manifold If pressure drop of 25 mmHg 0 98
a

The tandem master cylinder is inHg is exceeded refer to the follow

capable of producing high pressure ing chart to determine the cause of
even if the Master Vac is faulty failure

BR 14
 Brake System

Probable cause Corrective action

1 I
I Air leakago at check valve Replace check valve

2 Air leakage a t push rod seal Replace seal

Manifold side Master Yac side
3 Air leakage between valve body and Repair or replace faulty
1 Spring 2 Valve BA289
seal partes
Fig BR 27 Sectional view of check
4 Air leakage at valve plunger seat Repair or replace seat
valve

5 Damaged piping or joints Repair or

replace Operating test

1 Connect an oil pressure gauge in

brake line at connection on master
2 Fifteen seconds after engine is If a pressure drop of 25 mmHg
cylinder
stopped and brake fully applied ob 0 98 is exceeded refer the
inHg to
2 Install a spring scale on brake
serve the rate of drop in air pressure following chart to determine the cause
pedal
registered by vacuum gauge of failure
3 Start engine and increase engine
speed until a vacuum pressure of 500
Probable cause Corrective action mmHg 19 69 inHg is registered on
vacuum pressure gauge With a vacuum

pressure of 500 mmHg 19 69 inHg

1 Air leakage at check valve Replace check valve
held measure an oil pressure with

2 Damaged diaphragm Replace respect to each pedal operating force

Relationship between oil pressure

3 Reaction disc dropped off Reinstall and check push rod
and pedal operating force is illustrated
for proper turn
in Figure BR 28 If test results are not
4 Air leakage at poppet assembly seat Replace faulty part s as specified in Figure BR 28 check
and valve body Master Vac for condition in a manner

as described under Inspection before

removal of this unit

Also check brake line for evidence

Note When replacement of any part 15 seconds replace check valve with a of fluid leakage
is required be sure to renew new one

Master Vac as an 3 When

assembly pressure is applied to the Note Determine whether malfunc
Master Vac side of check valve and tion occurs in Master Vac or in

Inspecting check valve valve does not open replace check check valve Always inspect check

valve with a new one valve fiTlit

Remove clip and disconnect hoses
at connections The check valve can 120 I 7IG
now be removed
110 1 560
1
100 I 420
I
I
i
u
90 1 280

80 1 140
I 17 I
yr I
70 1 000

60 850
I f I I
0
Z I I y1 I
7I
0 50 710
5

BA3 40 570
I I I I I
Fig BR 26 Location of check valve a 30 430
I I I I I
20 280
I y1 II I
2 Using a Master Vac tester
apply a 10 140
I I I I I
vacuum pressure of 200 mmHg 7 87 L
I L
I
inHg to the port of check valve on the 5 to 15 20 25 30 35 40 45 50 55 60
22 44 66 88 110 132
Master Vac side If a pressure drop of
Pedal operating force kg lb BR772
10 mmHg 39
0 inHg is exceeded in
Fig BR 28 Performance curves of Master Vac

BR 15
 Brake System

REMOVAL 3 Identify front shell and rear shell

clearly so that they may be reassem
Referring to Figure BR 29 remove
bled in their original positions from
parts in numerical order enumerated
which they were withdrawn Bolts
attached on dashboard are not the
same in pitch
4 Using Master Vac Wrench

ST08080000 remove rear shell seal

1 assembly and disassemble diaphragm
cD 2 plate assembly front shell assembly
FlIf BR 33 Separating diaphragm
BA079

diaphragm spring and push rod assem

bly

BR17S 2 Using a screwdriver as shown

evenly pry air silencer retainer until it
Fig BR 29 Removal method of
Mcuter Vae is detached from diaphragm plate as

sembly
DISASSEMBLY

When disassembling Master Vac ob Note Never use a hammer to remove

serve the following instructions this retainer since this win be the
a Thoroughly clean mud or dust from sure y of damaging it
Master Vac

b Extreme care should be taken not

to allow dirt dust water or any

f Q BA076

Fig BR 31 Removing reor shell

other foreign matter into any com

ponent parts
Be sure to select a clean place
before disassembly Rear shell seal
or assembly
c Mark mating joints so that they off retainer with of screw
Pry use

may installed exactly in their

be
driver as shown and detach bearing
original positions and seal
d Keep all disassembled parts BA322

arranged properly so that they may Do not disassemble seal assem Fig BR 34 Removing air silencer
Note
be assembled at any time retainer
readily unless
bly absolutely necessary
e Clean rubber parts and synthetic
Whenever this is to be removed use
resin 3 Pull out valve plunger stop key
parts in alcohol care not to damage it
f Mter all disassembled parts are and withdraw silencer and plunger
cleaned in a suitable clean solvent assembly
place on a clean work bench Use
care not to allow dirt and dust to Note To valve plunger stop
remove

come into contact with these parts key properly proceed as follows
With key hole facing down lightly
1 Install spacer on rear shell spacer

temporarily Place Master Vac in a push valve operating rod simulta

vise Use soft jaws neously while applying vibration to
it
2 Remove clevis and lock nut De
tach valve body guard

rW ID
Fig BR 32 Removing retainer
BRD7S

Diaphragm plate

1 Clevis Place
3 Valve body guard diaphragm plate assembly
2 Lock nut BRD7S BA180
on a clean work bench Detach dia
Fig BR 30 Removing rear hell phragm from groove in plate as shown Fig BR 35 Pulling out top key

BR 16
 Brake System

ASSEMBLY AND
ADJUSTMENT
1
Assemble in the reverse sequence of

disassembly SR1S6

Fig BR 41 Requiring grease place

Rear shell seal

BA1Bl 2 Install
1 Apply a coating of Master Vac plunger assembly and
Fig BR 36 Remouing ualue operating grease to the sealing surface and lip of silencer in
diaphragm plate and lightly
rod assembly
seal and install that seal in rear shell push plunger stop key in place
with the use of Master Vac Oil Seal
Retainer Drift ST08060000 Note Diaphragm plate is made of
4 Withdraw reaction disc bakelite Exercise care in instaJJing
plunger assembly not to damage
diaphragm plate

BA286

Fig BR 37 Remouing reaction disc

Fig BR 39 Installing oil seal

BROB3

Note Fig BR 42 Inserting stop key

Referring to
Figure BR 40 in
Front shell seal
stall seal in
place by properly
I Detach flange from front shell aligning the pawl of special tool
with seal hole Adjustment is cor 3 Before installing diaphragm into
assembly
rect when specified length at A is position apply a thin coating of mica
obtained power to it except outer diameter and

A seating portion with which shell comes

Length
into contact
6 7 to 7 Omm
0 264 to 0 276 in 4 Before installing reaction disc in
place on diaphragm plate apply a thin
coating of Master Vac grease

Front shell seal

g Before installing front seal

shell as
BR287
sembly apply a coating of Master Vac
Fig BR 38 Removing lange
grease to the inner wall of seal and
front sheU with which seal comes into

contact
2 Withdraw front seal assembly

Final sssembly
INSPECTION
BA1S5
Apply thin coating ofMaster Vac
I Check poppet assembly for condi Fig BR 40 Length at A
grease to the outer edges of diaphragm
tion If it shows evidence of wear or with which rear and front shells come
damage replace it and valve operating into contact before instaIling dia
rod assembly
Diaphragm plate phragm in
position
2 Check other component parts for 2 Before installing push rod assem
condition If any part shows evidence I Apply a thin coating of grease to bly in place apply a coating of
of wear or damage replace it with a the sliding contact portion on the Master Vac grease to the sliding con
new one
periphery of plunger assembly tact surface of diaphragm plate

BR 17
 Brake System

in the INSTALLATION
3 Align marks scribed rear Length B

shell and front shell Carefully turn the 10 0 to 5

10 mID
Install in the reverse sequence of
Master Vac Wrench ST08080000 394
0 to 413
0 in
removal
clockwise until it reaches notch in
shell retainer Tightening torque
Master cylinder to Master Vac

rl 0 8 to I 1 kg m

6 to 8 ft lb
Master Vac to body

J 0 8 to 1 kg
6 to 8 ft Ib
m

Note After Master Vac is properly

installed on vehicle be sure to

conduct air tight test and oper

an

BA290 ation test described previously in

at this section
Fig BR 44 Lelllth B

Fig BR 43 Tightenilll reor shell

4 After assembly length

adjust the

of push rod to less than the specified

value indicated below Length adjust
ment of push rod is made at the tip of
push rod Fig BR 45 Adjusting push rod length

HAND BRAKE

CONTENTS

HAND BRAKE Stick lever typ e BR 18 INSPECTION BR 19

REMOVAL BR 19 INSTALLATION BR 19

HAND BRAKE
Stick lever type

The hand brake system is of a cable wheel brake shoes All the cable ad only adjusting nut at balance lever

reaction type which actuates rear justment can be made by operating

BR 18
 Brake System

k 1

BR663

Fig BR 48 Balance lever

Rear cable

Fully release control stem

2 Remove both rear brake drums
and disconnect rear cable from toggle
lever
3 Detach spring and spring retainer
4 Remove rear cable from brake
disc
5 Disconnect rear cable from
1 Control bracket
2 Control lever balance lever bracket
3 Control stem 6 Detach cable and
clips remove
4 Front cable
rear cable
5 Balance lever
6 Rear cable R H
7 Rear cable LH BAS6l INSPECTION
Fig BR 46 Hand brake linkage 1 Check control stem and ratchet
for evidence of wear or other damages
REMOVAL Replace parts which are faulty
2 Replace worn or fatigued springs
Control stem 3 Check wires for evidence of dis
continuity or other deterioration Re
I Disconnect terminal from hand 3 Pull out lock pin and colter pin
place if necessary
brake warning switch and then remove control stem assem
4 Replace faulty warning light
2 Remove nuts securing control bly and or switch
bracket in place on dash panel S Check parts at each connection
and if found deformed or damaged

J replace
y

i1
b INSTALLATION

Install hand brake assembly in the

I

I 1
reverse sequence of removal by closely

l
observing the following instructions
II When installing apply a coating
i of grease to sliding contact surfaces
I BR773
Make Sure that each sliding part func
Fig BR 47 Control stem lions smoothly

Front cable 2 Upon completion of installation

of hand brake assembly adjust the
Fully release control stem 5 Disconnect rear cables R H and entire system referring to the instruc
2 Loosen adjusting nut at balance LH from balance lever brackets See lions described under topic Adjust
lever Figure 48
BR ment
3 Disconnect front cable from con 6 Remove balance lever brackets 3 Make sure that each cable is not
trollever from crossmember interfered with by any adjacent parts
4 Remove retainer at cable 7 Detach front cable and pull
spring clip Do not apply an undue stress to
guide bushing front cable rearward cables

BR 19
 Brake System

SERVICE DATA AND SPECIFICATIONS

Brake pedal
Free height mOl in 148 S 83

in I to 3 0 04 to 0 12
Free play at pedal pad mOl

Full stroke at pedal pad mOl in 134 to 140 5 28 to 51

S

in 43 to 49 169 to 193
Depressed height mm

Brake adjustment notches

12
Front

Rear 12

Master cylinder
Inner diameter mm in 19 0S Yo

Piston to cylinder deaJance mm in O IS 0 OOS9

Master Vac

Diaphragm diameter mOl in 4 6

152

Maximum vacuum leakage after 15 sec mmHg inHg 2S 0 98

Shell seal in 6 7 to 7 0 0 264 to 0 276

depth A mOl

Push rod length B mOl in 10 0 to 5 0 394 to 0 413

10

Front drum brake

Uni servo
Type
Wheel cylinder inner diameter mm in I9 0S Yo

Lining 45 x 4 x 244
5
mOl in
Width x Thickness x Length 77
1 x 0 177 x 9 61

in 1 0 0 039
Lining wear limit mm

Rear drum brake

Duo servo
Type
Wheel cylinder inner diameter mOl in 19 0S Yo

Brake drum

Inner diameter mm in 254 0 10

Repair limit of thickness mOl in 2SS S 10 06

Inside runout mOl in 0 02 0 0008 maximum

PaJking brake

Type Stick type

Stroke mm in 80 to 100 lS
3 to 3 94

S to 12 11 to 26
Adjuster sliding resistance kg lb

BR 20
 Brake System

Tightening torque
Master cylinder to Master Vac kg m ft Ib 0 8 to l 6 to 8

Brake tube flare nut kg m ft Ib IS to 18 II to 13

Brake hose connector kg m ft lb 1 8 to 2 1 13 to IS

Air bleeder valve kg m ft lb 0 7 to 0 9 S to 7

Fulcrum pin of brake pedal kg m ft Ib 5 9 to II

2 to 1
1

Connector and clip fIXing bolt kg m ft lb 0 35 to 4S

O 5 to
2 3

3 way connector fIXing bolt

ft Ib
kg m 0 8 to l 6 to 8
on rear axle case

Brake pedal stopper lock ft Ib 12 to 1

5 9 to II
nut kg m

N LS V to body kg m ft Ib 0 8 to l 6 to 8

Wheel cylinder mounting nut

Front ft Ib S 4 to 6 6 39 to 48
kg m

Rear kg m ft Ib 5 to 1 8 II to 13
1

Wheel cylinder connector bolt kg ft lb 1 9 to 5

2 to 18
m
14
Brake disc Back plate nut

Front kg m ft Ib 4 2 to S O 30 to 36

Rear ft Ib S 4 to 6 4
kg m 39 to 46

Master Vac

Master Vac to body nut kg m ft lb 0 8 to l 6 to 8

Flange to shell cover nut kg m ft lb 0 8 to 1 6 to 8

Operating rod lock nut kg m ft Ib 16 to 2 2 12 to 16

Push rod kg ft Ib 1 9 to 4 14
2 to 17
adjusting nut m

BR 21
 Brake System

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

Excessive pedal travel Low brake 1uid level or empty master Fill and bleed as necessary Test for source

cylinder reservoir of leakage by examining all lines connec

tions and wheel cylinder

Leakage in master cylinder Overhaul master cylinder

Deteriorated check valve Replace check valve and bleed system

Air in system Bleed system

Faulty brake adjustment Adjust shoe to drum clearance Inspect

autoadjuster operation

Spongy pedal Low 1uid level in master cylinder Top with 1uid and inspect for leakage
Air in system Correct as necessary

Faulty brake adjustment shoe to drum clearance

Adjust Inspect
aut adjuster operation
Reservoir filler cap vent hole clogged Clean and bleed system

Swollen hose due to deterioration or use of Replace hose and bleed system
poor quality hose
Distorted brake shoes or excessively worn Replace faulty parts
or cracked brake drum

Soft swollen
or caliper seals Drain hydraulic system flush with alcohol
and replace all seals

Use of a brake 1uid with too low boiling Replace with specified brake 1uid and bleed

point system

Poor braking effect Fluid leakage in brake lines Check master and wheel
cylinder pIpIng
cylinder for leaks and repair
Low brake 1uid level master Fill and bleed
or empty as necessary
cylinder reservoir

Air in brake lines Bleed system

Excessive shoe ta drum clearance Adjust

Grease oil mud or water on linings or pads Clean brake mechanism and check for cause

of problem Replace linings or pads

Deterioration of linings or pads Replace

Local fit of linings or pads Shave or replace

Linings or pads excessively worn Replace
Master cylinder or wheel cylinders in poor Repair or replace
condition

Binding mechanical linkage at brake pedal Free up as required

and shoes

Brakes drag Clogged brake lines Check and clean

Incorrect adjustment of wheel bearings repair

Adjust or

Improper shoe t drum clearance Adjust

Weak shoe return springs Replace
No free travel in brake shoe return Adjust pedal height

BR 22
 Brake System

Probable cause Corrective action

Condition

Brake chatters Groove or out of round brake drum Grind or replace as required
Loose or bent brake disc Tighten support plate bolts to specified
torque or replace plate
as
Distorted brake shoes or pads Replace necessary

Grease or brake fluid on linings Replace linings

Brake squeals Dirty or scored brake drums Blowout assembly with compressed air or

refinish drum

Distorted brake shoes or bent support plate Replace faulty unit

Weak or broken brake shoe retaining spring Replace if faulty
or return spring
If it
Glazed or contaminated brake lining Cam ground lining to eliminate glaze
doesn t replace linings

Turn drum
Pedal pulsates Out of round or off center drum or
replace as necessary

Brakes fade Brake fluid has too low boiling point Drain and fill system with approved fluid

Use of improper linings or brake linings are Replace linings

contaminated

Brake drums are out of round Repair or replace as necessary

Hydraulic connections master cylinder and Repair as necessary

wheel cylinders are corroded or damaged

Bleed screw is open Close screw and bleed system

Brakes drag Pedal linkage is binding or push rod adjust Lubricate linkage check pedal return spring
ment is too long for condition and adjust push rod as neces

sary

is ob Blowout foreign matter with compressed

Master cylinder compensator part
structed air

Seized master cylinder piston Disassemble master cylinder and replace

piston Bleed system

Poor shoe condition Clean and repair

Poor wheel cylinder condition Repair or replace

Deformation of piston cups Replace

Hand brake will not return Check and repair

Clogged master cylinder return port Clean

Unbalanced brakes Improper tire inflation Inflate to correct pressure

Improper adjustment of shoe to drum clear Readjust

anee

Grease oil mud or water on linings or pads Clean brake mechanism and check for cause

of problem Replace linings or pads

Mud in brake drum Clean

Deterioration of linings or
pads Replace
Excessive wear of linings or pads Replace

BR 23
 Brake System

Condition Probable cause Corrective action

Wheel cylinder in poor condition Repair or replace

Poor condition of brake shoe
sliding Adjust
Looseness of cylinder body or back plate Fasten or replace
securing bolts
Scored or out of round drums Recondition brake drum
or replace as reo

quired Check for improper lining contact

with drum and grind lining if necessary

wheel cylinder
Sticking cups Recondition or replace cylinder
Deformation of back plate Replace
Incorrect adjustment of wheel bearings Adjust or replace
Incorrect adjustment of wheel alignment Adjust
Looseness of leaf spring securing U bolts Tighten or replace
Faulty N LS V Replace

Pedal yields under Deteriorated check valve Replace check valve and bleed system
slight pressure Ex ternalleaks Check master cylinder piping and wheel

cylinder for leaks and repair

Leakage on master cylinder Overhaul master cylinder

BR 24
 Brake System

SPECIAL SERVICE TOOLS

For Reference
Tool number
use
No Description page or

tool Unit mOl in on Figure No

name

1 GG943 10000 This tool is used to tighten and untighten brake tube flared nut All Page BR 8

A built in torque limiting wrench is provided to assure torque models

Flare nut
accuracy
torque wrench

SE227

This tool is used to remove shell after aligning rear shell stud All Fig BR 3l
2 ST08080000 rear

bolt with the opening in this tool models

Master V ac
wrench

SE073

ST08060000 This tool is used when rear shell seal is driven into position All Fig BR 39
3
models
Master Vac
Note Make sure that this tool is pushed in until rear guide of this
oil seal
tool touches rear shell
retainer drift

SEll5

BR 25
 SECTION WT

WHEEL AND TIRE

DATSUN PICK UP
MODEL 620 SERIES

WHEEL AND TIRE WI 2

TROUBLE DIAGNOSES AND

WI 5
CORRECTIONS
I NISSANJ

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Wheel and Tire

WHEEL AND TIRE

CONTENTS

DESCRIPTION WT2 TIRE ROTATION WT3

MAINTENANCE AND SERVICE WT 2 CHANGING TIRE WT3
TIRE INFLATION WT2 INSPECTION WTA
TIRE REPAIR WT2 WHEEL BALANCE WTA
WHEEL REPAIR WT 2 WHEEL AND TIRE WT 4
WEAR WT 2

DESCRIPTION TIRE REPAIR

The 620 series models are equipped In order to inspect a leak apply
with 4lV 14 wheels with 25 0 98 soapy solution to tire
mOl tire
or
submerge
in offset All tires are tubeless and wheei in the water after inflating
tireto specified pressure Special in
Tire size spection for leaks should be carried

out around the valve wheel rim and

Model Tire size Wheel size along the tread Exercise care to bead
and rim where leakage occurs Wipe
All models 6 00 I 4
6PR Tubeless 4UJ 14 out water from area which leaks air

bubbles and then mark the place with

chalk
Tire pressure 2 After removing the materials which
Unit kgl em psi
caused puncture seal the point When
Vehicle speed km h MPH Under Over repairing the puncture use the tire
100 h
km 100 km h repair kits which are furnished from
Model 60 MPH 60 MPH tire dealers following the instructions
provided with the kits In case that a

Front 15 21 18 26 puncture becomes large or there is any

Unloaded other damage on the tire fabric repair
Rear 175 25 2 25 32 must be carried out authorized tire
by
All models dealers
Front 15 21 18 26
Loaded
Rear 3 0 42 15
3 4S
WHEEL REPAIR

Note Tire inflation pressures should underinflation promotes wear at cen Inspect the wheel rim flange for
be measured when tires ter tread or shouider of tire bend or dents
are cold
If aU The flange should be cleaned by a
tires are
inspected frequently
wire brush when rust is found on the
and maintained correct tire pressure it
is possible to detect sharp material in flange Furthermore if excessive

pitting occurs on the rim eliminate it

the tread Also the above check avoids
with a file
abnormal wear which invites serious
MAINTENANCE AND problem If tires indicate abnormal or

SERVICE uneven wear the cause of problem

should be detected and eliminated
TIRE INFLATION After inflating tires leakage in valve WEAR
should be checked Without valve caps
Correct tire pressure is very im Missilgnment
leakage will occur due to dirt and
portant to ease of steering and riding water resulting in underinflation Ac When the front wheels align in
comfort This also reduces driving excessive toe in toe out condition
cordingly whenever tire pressure is or

sound minimum
to a resulting in checked be sure to tighten valve caps tires scrape the tread rubber off The
longer tire life that is overinflation or of tread appears feathered edge
firmly by hand wear

WT 2
 Wheel and Tire

Center and on the other hand camber causes Tire tread

Tread indicator
wear only on one side of treads For wear

This wear is caused by overinflation

cornering tread wear the driver must
of the tire The inflation pressure must I
value
operate vehicle slowing
down on
0E
be kept at the specified curves
c

Shoulder Uneven
Uneven wear is caused by incorrect WH024
The wear may be caused by under
incorrect wheel camber or camber or caster malfunctioning sus
inflation Fig WT 4 Tread wear indicator
pension unbalanced wheel out of
continuous high speed driving on

round brake drum or other mechani

curves In general the former two

causes are common Underinflation cal conditions To repair this abnormal

occurs on both sides of treads wear correct the above faulty parts
wear

I
J CHANGING TIRE

I i
To change tire with wheel using a

in the safe manner observe the

jack

d
following procedures
I

Toe in or toe out

Ii
wear
1
I
Overinllation
1
wear
1

rod to
To remove spare tire

guide
insert

and then turn it counter

jack

clockwise When installing lighten a

1 little strong after lifting up and lock

I nf I
I

Underinnation wear
t
Uneven

Fig WT 1 A bnormal tire

wear WT007

wear

TIRE ROTATION Fig WT 5 Removing spare tire

Tires unevenly and become different brand

wear The spare lire has a

unbalanced according to running dis from 4 tires on the vehicle

tance Uneven tire wear often results 2 It is necessary to remove wheel
in tire noise which is attributed to rear Right front Right rear
and temporarily to loosen wheel
cap

axle gears bearing etc Meanwhile the I nuts before vehicle is jacked up

unevenly 3 To up front place jack under

front tires tend to wear jack
because

wheel
of improperly aligned front
xJ r
@ Spare side frame

rear
about S20 mOl

of front axle center after

5 in at
20

apply
Accordingly tire ing parking brake and blocking rear
to equalize wear

Left front Left rear

it is necessary to rotate tires peri wheels

odically
The pare tire should be used
All the tires including the spare tire in an emergency only

are of the same type

Right front Right rear Fig WT 3 Tire rotation 2

g 1
141 I
The tires are provided with tread

t 1 1
@ Spare
wear

J in
indicator
tire circumference

tread
at six places around

depth
indicating
When
1 6 mm

the tires

t wear and then the marks appear re

Left front Left rear place them with new ones See Figure WT012

Fig WT 2 Tire rotation 1 WT 4 Fig WT 6 Jacking up front side

WT3
 Wheel and Tire

4 To jack under Proper tire balance is necessary

up rear
place jack Thoroughly remove rust dust
rear axle case close to the side of rear when driving the vehicle at high oxidized rubber or sand from wheel
spring after applying parking brake speeds Consequently the wheel and rim with wire brush emery cloth or
and blocking front wheels tire assembly should be properly re Use
paper dial gauge to examine
balanced whenever puncture is re wheel rim for lateral out
run

paired
The wheel and tire Lateral run Qut limit
assembly be
Less 5mOl
1 0 059
comes out of ba1ance according to tltan il total
uneven tire wear Severe acceleration indicator reading
and braking or fast cornering is the
cause of wear tire in
on resulting
unbalance of tire and wheel assembly
The symptom ofunbalance appears
as tramp vehicle shake and steering
malfunction
WH077
To correct unbalance use proper
Fig WT 7 Jacking up rear side wheel balancer

Maximum allowable unbalance

S Remove wheel nuts and wheel
177 gr cm 5 in
2 oz
from drum
10 gr 3S
O oz at rim circumferences
6 To install wheel reverse the WTOO5

above steps Balance weight

Fig WT B Whetl rim run out check
Tighten wheel nuts in cross
criss 10 to 60 gr 3S
O to 12
2 oz
points
fashion to 8 0 to 9 0 kg m S8 to 6S at 10 gr 0 3S oz intervat
ft Ib

Note Nerer under the vehicle Note Be

get sure to place the correct
while it is supported only by the balance weights on the inner edge
jack Always use fety stands
S8 to of rim as shown in Figure S
WT Note In replacing tire t e extra care
support the side member of body 00 not put more than two weights not to damage tire bead rim flange
construction when you must get on each side and bead seat
beneath the vehicle Do not use tire irons to force beads

away from wheel rim flange that is

always use tire replacement device
whenever tire is removed

INSPECTION WHEEL AND TIRE

2 Discard when any of the follow
In order to ensure
WHEEL BALANCE satisfactory ing problems occur
steering condition as well as maximum 1 Broken bead wire
or damaged
The wheel arid tire tire life proceed follows
asSembly should as
2 Ply o treairsepanitiori
be kept balanced statically and dynam Check wheel rim for rust distor 3 Cracked or damaged side wall
ically tion cracks or other faults etc

4
WT
 Wheel and Tire

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

Wheel wobbles Improper tire pressure Measure and adjust

Damaged tire or distorted wheel rim

Repair or replace
Unbalanced wheel Balance

Loose wheel nuts Tighten

Worn or damaged wheel bearing or excessive Correct play or replace wheel bearing
play of wheel bearing

Improper front wheel alignment Align

Worn or damaged ball joint Replace
Excessive steering linkage play or worn
Adjust Or replace
steering linkage
Loose steering linkage connection Tighten nuts to rated torque or
replace
worn parts if any
Broken suspension spring Replace
Damaged shock absorber Replace

Unevenly or tire rotation Conduct tire rotation

Improper periodically
excessively worn
Improper tire pressure Measure and adjust
tire
Unbalanced wheel Balance or replace
Improperly adjusted brake Adjust
Improper wheel alignment Align
Excessively distorted or improperly installed Repair replace or if necessary reinstall
suspension link

High speed on curves Reduce speed

Sudden start and improper speed due to Follow correct and proper driving manner

rapid acceleration or improper brake ap

plication

Tire squeals Improper tire pressure Measure and adjust

Improper front wheel alignment Align
Distorted knuckle or suspension link Repair or replace

WT 5
 SERVICE
SECTION ST
MANUA L 4

STEERING
DATSUN PICK UP SYSTEM
MODEL 620 SERIES

STEERING ST 2

SERVICE DATA AND

ST 8
SPECIFICATIONS

TROUBLE DIAGNOSES AND

ST 9
CORRECTION

I NISSAN I SPECIAL TOOLS ST 10

NI55AN MOTOR CO LTD

TOKYO JAPAN
 STEERING SYSTEM

STEERING

CONTENTS

DESCRIPTION ST 2 Inspection and repair ST 5

STEERING GEAR ST 3 STEERING LINKAGE ST 6

al and installation
Remo ST 3 Removal and installation 6
ST
Disassembly and assembly 4
ST Inspection and repair ST 7

DESCRIPTION The other end of the cross rod is ly and independently steering can be
linked to the idler arm connecting safely maintained

The with the side member located on the Steering wheel rotation is converted
steering gear used on this
opposite side of the steering gear The to gear arm motion in proportion to
model series vehicles is e same re

two side rods serve to connect the the gear ratio by the steering gear The
circulating type This steering gear is
designed especially for easy operation steering gear arm and idler arm to the gear arm motion operates the side rod
both knuckle and left hand on the same side At the same time
and high durability arms right
sides the idler arm is moved through the
The steering linkage is of a relay
arm is
With this construction even if the cross rod and the opposite side rod is
design of which gear connected
left andlor wheel vertical also moved
to one end of the adjustable cross rod right moves

1 Steering column shaft 7 Cross rod

2 Steering column jacket 8 Cross rod socket
3 Steering wheel 9 Idler arm assembly
4 Column clamp 10 Side rod
S Post llmet
gro 11 Steering gear assembly
6 Steering gear arm

ST528

Fig ST I Structural u w of l
teeriTl tem

sr 2
 STEERING SYSTEM

STEERING GEAR

A
p
u
i
I
1

jj
@ @
@l
ST199

Sector shaft adjusting 9 Worm assembly

J screw ball nut assembly
2 Filler plug 10 Worm bearing adjusting
3 Sector shaft cover shim
4 Sector shaft adjusting 11 Column jacket
screw shim 12 Steering column shaft
5 Gear housing 13 Column jacket bushing
6 Sector shaft 14 ring
7 Oil l 15 Worm bearing
8 Gear housing bushing

Fig ST 2 Sectional view of steering gear

3 Remove steering wheel with 6 Remove column clamp fixing

Removal and
Steering Wheel Puller ST27I80001 bolts
installation after backing off steering wheel fIXing
nut
Removal
c @
I Disconnect battery ground cable
from the terminal
2 Remove horn pad by unscrewing
two bolts from the rear side of steering I
wheel bar c f
I
Note Be sure mark with
to punch 1
I

the top of steering column

0

shaft
on

i
1
T201

Fig ST 5 Removing column clamp

Fig ST 4 Removing teering wheel

Note Be sure not to hammer the

tool while removing 7 Remove four bolts securing steer
special
ing post grommet to dash panel
4 Remove upper and lower steering 8 Remove nut securing gear arm to
column shell covers sector shaft and then withdraw gear

S Remove turn signal switch as arm with the use of Pitman Arm Puller

Fig ST 3 R moving horn pad sembly ST2902000I

ST3
 STEERING SYSTEM

Disassembly and 9 Pry out sector shaft oil seal from

and discard it
gear housing
assembly 10 Remove O ring from the rear

Disassembly cover of column jacket and discard it

11 Remove column jacket bushing
I Drain oil in steering gear housing
by unscrewing fIller plug
2 Place steering gear assembly in a
Notes
vise securely
a Do not remove sector shaft bushing
3 Loosen lock nut and turn sector
from housing If necessary replace
shaft adjusting screw a few turns coun
ST202 as a gea2 nousing assembly
terclockwise
Fig ST 6 Withdrawing gear ann b Do not disassemble ball nut and
Remove sector shaft cover by un
Note Before removing steering gear worm geir If necessary replace
scribe match marks screwing four fixing bolts
arm on arm them with new ones as a worm gear
and housing so that theyeasily
can assembly
be in their original posi
replaced
tions at assembly

9 Remove three
bolts securing

steering gear housing to frame

10 Withdraw steering gear assembly
toward engine compartment

rnST203

Fig ST 7 Remouing sector haft couer

Installation
4 Turn sector shaft
Install steering gear assembly in the adjusting screw
Fig ST 9 Removing steering worm
a few turns clockwise and pull sector
reverse order of removal observing the assem bly
shaft cover together with sector shaft
following instructions
from gear housing
I When installing steering gear
Assembly and adjustment
housing securing bolts insert two bolts
Apply recommended gear oil to all
through gear housing to frame
disassembled parts
2 When installing steering gear arm
align four grooves of gear arm serra 1 Fit column jacket bushing to
tions with four projections of sector column jacket in place
shaft serrations
3 Tightening torque
ST204 Note When fitting apply adhesive to
Steering gear housing exterior and grease to in
Fig ST B PuUing out ector haft
bushing
4 6 to 3 kg m 33 to 38 ft lb
S
terior
Gear arm
2 Fill the space between new sector
13 to IS kg 94 to 108 ft lb
m S Separate sector shaft adjusting shaft oil seal lips with grease and fit it
screw and shim from cover
Steering wheel to gear housing
7 0 to 7 S kg m 51 to 54 ft Ib 6 Remove jacket tube by unscrew
3 Place steering worm assembly in
ing three fixing bolts
position in gear housing together with
7 Remove steering
4 With front wheels set in a straight
worm assembly worm bearings
from gear housing
ahead position make that punch
sure 4 Install column jacket on gear
8 Detach worm
mark on the upper end surface of bearings and worm
housing with O ring and worm bearing
steering column shaft is at the center bearing adjusting shims from worm shims
of the gear assembly and column jacket Be sure to install thicker shims to
upper side in its installing
portion the gear
Note Be careful not to allow ball nut housing side
S When installing steering wheel to down to the
run worm end If Standard shim thickness
apply grease to sliding parts ball nut rotates suddenly to the 5 mOl 0 OS9 in
1
6 After installing make sure that worm end the ends of ball guides Tightening torque
steering wheel turns smoothly may be damaged 5 to 2 S
1 kg m 11 to 18 ft Ib

ST 4
 STEERING SYSTEM

8
Available worm bearing adjusting Install sector shaft cover to gear
Inspection and repair
shim housing Be sure to apply sealant to
Wash clean all the disassembled
each face of sector shaft cover packing in solvent and check for condi
parts
No Thickness mOl in when installing cover
tions

I 0 762 0 0300 9 By turning adjusting screw coun

2 0 2S4 0 0100 terclockwise attach sector shaft cover

3 0 127 0 0050 to gear housing and then temporarily Sector shaft

O OSO secure it with its fixing bolts
4 0 0020
1 Check gear tooth surface for pit
10 Pull sector shaft toward cover

2 to 3 0 08 to ting burrs cracks or any other dam

approximately mOl

age and replace if faulty

12
0 in by turning adjusting screw
2 Check sector shaft for distortion
5 the counterclockwise and tighten sector
Adjust bearing preload
worm
5
2 of its serration and if necessary re
with Preload Gauge ST3127S000 by shaft cover fixing bolts to lS to
place In this case be sure to check
kg m
11 to 18 ft Ib
selecting suitable bearing shims so that
II Push sector shaft against ball nut gear housing for deformation
the initial turning torque of steering
column is the value gear by gradually turning adjusting
specified
Initial of
screw clockwise until sector shaft gear
turning torque steering
lightly meshes with ball nut gear and Steering column shaft
column shaft
then temporarily secure adjusting assembly
screw with lock nut
1 Inspect the ball nut gear tooth
New worm bearing 12 Install gear arm to sector shaft surface and replace if pitting burrs
4 0 to 6 0 kg em S6 to 83 in oz and move sector shaft several times
wear or any other damage is found
from the side of gear and make
Used worm bearing arm
2 Ball nut must rotate smootWy on
4 to
2 4 kg em 33 to 61 in oz sure that it turns smoothly If found too
worm gear tight assem
13 the backlash at the neu
Adjust bly should be replaced Check as fol
tral position of gear arm by turning in
lows
6 into the or out adjusting screw so that the
Insert adjusting screw
is
Move ball nut to either end of
movement of the gear arm top end
T shaped groove at the sector shaft
less than 0 1 mOl 0 004 in worm gear and gradually stand steer
head and adjust the end play between
ing column shaft assembly until ball
sector shaft and adjusting screw until
nut moves downward on worm gear
it is within 0 01 to 0 03 mm 0 0004
under its own weight In the above
to 0 0012 in by choosing suitable test if ball nut does no move freely
adjusting shims over entire stroke assembly may be

damaged Replace with a new one as

an assembly

Available sector shaft adjusting Note In this inspection be careful

screw shim not to dama e ball nut guide tube

No Thickness mOl in Bearings and bushings

I 57S
1 0 0620 I Replace worm bearings if pitting
2 550
1 0 0610 wear or any other damage is found on
3 525
1 0 0600 0 ST207 them

4 IS00 0 OS91 Fig ST 10 Mea uring backlash 2 Repiace column bushing which is
S 1 475 0 0581 excessive worn or deformed
If sector shaft in gear
6 I 4S0 0 0571 3 bushings
housing are found worn or damaged
14 Turn adjusting screw approxi replace as an assembly of gear housing
mately 1 8 to 1 6 turn clockwise and and bushing
then retighten lock nut to 3 0 to 4 0
Oil seal gasket and
7 Rotate ball nut by hand until it is kg m 22 to 29 ft Ib
O ring
in the center of its trovel then install Fill recommended gear oil ap
IS
sector shaft together with adjusting 33
0 liter X U S pI Do not reuse above parts which are
proximately
screw in gear housing ensuring that X Imper pt gear assembly
into removed once

the center gear of sector shaft engages Be sure to at each

through the filler hole and install filler parts
use new

with that ofball nut reassembly

plug

ST 5
 STEERING SYSTEM

2 When cross rod sockets and cross

STEERING LINKAGE 6 Cross rod both side rods and the
then be freed from rod separated
are adjust rod
adjacent parts can cross

Removal and the vehicle as an assembly length correctly

Adjustment should be done be
installation 7 Then separate the ball joints of
tween the centers of ball joints at the
steering linkage assembly following the
Removal both end of cross rod assembly
procedure for removal ofthe side rods
I Jack up the front of vehicle and ball joints at knuckle arm sides Standard rod
cross length
support it on the safety stands 516 rom 31
20 in
2 Remove cotter pins and nuts fas
3 toe in and steering angle
rod ball stud
Adjust
tening side to knuckle
The procedures of toe in and steer
arms
Assembly
ing angle adjustments Ie described in
3 To detach side rod ball studs Install steering linkage in the reo
Section FA
from knuckle arms insert Ball Joint verse sequence of removal observing
Remover HT72520000 between them the following notes
Toe in
and separate them by striking the top
Tightening torque 1 to 5
of this tool with a hammer If this
mm 0 04 to 0 20 in
Ball stud S S to 10 0 kg m
operation must be done without this
40 to 72 ft lb
tool strike the knuckle arm boss with
Idler arm assembly
a hammer backing up the opposite side Steering angle
3 2 to 3 7 kg m
of it with a large hammer and bail stud

23 to 27 ft lb Inner wheel 3S030 to 36030

is freed from knuckle arm Must not
Cross rod adjust bar lock nut Outer wheel 30030 to 31030
strike the baIl stud head the ball
8 to 10 kg m
socket of side rod and side rod with a

hammer and so on in this operation 72

1 Cro s rod
2 f
fL 5t6 mm 20 31 in

2 Side rod
3 Cross rod socket Mter adjustment of toe in be sure that dimension A at
4 Idler assembly
arm
both ends of cross rod is not less than 20 nun 0 79 in
5 Gear housing
Fig ST 11 Ball joints Ic ann side
assembly ST210

4 Remove riut securing gear armOD Fig ST 13 Adjusting cross rod assembly
sector shaft and remove gear arm with
the use of Pitman Arm Puller Idler ann
assembly
ST29020001 See Figure ST 6
S Remove idler arm assembly from
frame by backing off fixing bolt and @
nut

1 Idler body
2 Collar welded to
idler body
A 3 Plain bushing
4 Screw bushing

T529

Ffa ST 12 Removing idler ann Fig ST 14 Sectional W of idler arm sembly

as

ST 6
 SYSTEM

1 Apply recommended grease to nipple and reinstall filler plug To renew

sary grease remove
screw bushing interior plain bushing 3 In installing idler arm assembly grease cap and apply recom
nipple
interior dust seal inside and bushing make sure that the standard dimension mended grease to ball joint through
sliding surface of idler ann A is adjusted correctly grease nipple until grease is forced
Screw bushing tightening torque Standard dimension A out at the grease vent hole
12 kg m 87 ft lb 137 8 to 139 8 mm

S 42S to 504
S in
2 Before
installing idler arm assem
Idler
bly replace f iller plug with grease See Figure ST 14
arm
3B8embly
nipple and apply recommended grease Furthermore be sure to install Remove old grease and dirt and
to idler ann through this grease nipple washers correctly check idler ann assembly for wear
See Figure ST IS
until grease is forced out at the lower deformation and damage
end of the dust seal lip Remove grease
CrOBS rod side rod and

STERING
arm
gear
Check them for bending damage
and crack and replace as
necessary

Inspecting steering system on

the vehicle which comes into

I I collision

I Steering system is very important

J for driving vehicle When the vehicle

I a

8 I
L6 comes into collision especially
front of the vehicle is damaged special
the

inspection should be done for the

following matters
Spring washer
If any component parts of steering
Frame
3 Plain washer system is found to be damaged re
4 Weld nut place them with new ones

5 Self locking nut 1 Steering angles correctness

FIODt Inspect side rods and cross rod for
bend and sector shaft for distortion
ST212 2 Level of steering wheel bar with
the front wheels in a straight ahead
Fig ST 15 Locations of washers
position
Ifits deflection is more than about

Inspection and repair Initial swing torque 5 to 15

cm
kg
90 degrees the bend or distortion of
sector shaft and column shaft can be
70 to 209 oz
in

seen

Ball joint 3 Noise during operation of steering

1 When ball stud is worn or axial wheel

Inspect column shaft and jacket

play is too excessive replace cross rod

socket or side rod with a new one

tube for bend

2 When dust cover is broken or

4 Smooth operation of steering
defonned be with wheel
sure to replace a

new one Inspect sector gear for breakage

ball nut screw for dint and column
Axial end play 0 1 to 5 mm
0
shaft for bend
0004 to 0 020 in
S Gear armbreakage
Initial swing torque 6 Gear housing
ST213
breakage
S to 15 cm
kg 70 to 209 oz
in In addition inspect gear housing
f
IXing bolts for looseness
7 Distortion of sector shaft serra

tion
8 Sector gear breakage

ST 7
 STEERING SYSTEM

9 Column shaft breakage on the 10 Deformation of body construc steering system on the body construe
welded section tion and frame tion and frame for deformation or any
In addition inspect column shaft Inspect the installation portion of other faulty conditions
for scratch

SERVICE DATA AND SPECIFICATIONS

SPECIFICAnONS

Gear type ball type

Recirculating
Gear ratio 19 8 I

SERVICE DATA

Standard thickness of worm bearing

adjusting shims mOl in 5 0 OS9
1

Initial turning torque of steering column

New worm bearing kg em in lb 4 0 to 6 0 5 to S 2

3
Used worm kg in lb
bearing em 2 4 to 4 2 1 to 3 8

End clearance of sector shaft

adjusting screw rom in om to 0 03 0 0004 to 0 0012

Backlash at the gear arm top end rom in o to 0 1 0 to 0 004

Oil capacity t U S pt Impel pt 0 33 J X

Bail joint axial end play rom in 0 1 to 0 5 0 004 to 0020

Standard cross rod length rom in 516 31

20

Toe in rom in I to S 004 to 0 20

Steering arigle
Inner wheel 35030 to 36030
Outer wheel 30030 to 31030

Tightening torque
Unit kg m ft lb

Steering column jacket to gear housing 1 5 to 2 S II to 18

Sector shaft cover IS to 2 S II to 18

Sector shaft lock nut 3 0 to 4 0 22 to 29

Gear housing 4 6 to 3
5 33 to 38

Gear arm
94 to 108
13 to IS

Steering wheel 7 to 7 S SI to S4
Bail studs of cross rod S S to 10 0 40 to 72

Ball studs ofside roo

Knuckle arm side S S to 10 0 40 to 72
Gear or idler arm side 5 to 10 0
S 40 to 72

ST 8
 STEERING SYSTEM

TROUBLE DIAGNOSES AND CORRECTIONS

Condition Probable cause Corrective action

Steering wheel moves Wheel alignment out of specifications or air Align or inflate tires to correct pressure

heavily pressure in tires too low

Steering linkage out of adjustment Adjust and see relative topic under Front
Suspension

Steering column out of alignment Repair

Steering wheel turns Wheels out of alignment or air pressure in Repair or inflate tires to correct air pressure
but sluggishly tires too low

Damaged steering linkage Replace and see relative topic under Front
Suspension

Vehicle pulls to one Wheels out of proper alignment Align

side
Wheel bearing out of adjustment Adjust

Damaged steering linkage and see relative under Front

Replace topic
Suspension

ST 9
 STEERING SYSTEM

SPECIAL SERVICE TOOLS

Tool number For Reference

No Description use page or

tool name Unit in

mOl on
Figure No

ST27I80001 This tool is used to drive out steering wheel All Fig ST4
Steering wheel models

puller Caution Do not hammer on steering column shaft

v
o

J
SE 116

2 ST29020001 This tool is used to remove steering pitman arm from steering 620 Fig 6
ST

Pitman arm
sector shaft B210

puller 710
610

SE401

3 ST3I 27S000 This tool is used the

to measure worm bearing preload All Page ST 5

Preload gauge models

GG91030000

Torque
D
wrench
I
2 HT62940000

Socket
IJ
t
adaptor 114 3 8 YID
Go

318 1 2
3 HT62900000

Socket

adaptor

4 HT72520000 This tool is used to remove ball joint All Page ST 6

Ball joint models
remover

SE399

ST 10
 SECTION FE

ENGINE
DATSUN PICK UP CONTROL FUEL
MODEL 620 SERIES EXHAUST
SYSTEMS

ENGINE CONTROL SYSTEM FE 2

FUEL SYSTEM FE 4

l NISSAN I EXHAUST SYSTEM FE 6

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Engine Control Fuel Exhaust Systems

ENGINE CONTROL SYSTEM

CONTENTS

DESCRIPTION FE 2 INSPECTION FE 3

REMOVAL AND INSTAllATION FE 3 ADJUSTMENT FE 3

DESCRIPTION
The accelerator control system is of operates smoothly and the system is The choke system is automatically
flexible cable type so that the linkage not affected by engine vibration controlled

ul @
i
L
f
4 @ p
I
@ @

CV
j

Arrow B

E 78 mm 3 07 in
T 2 to 4 mm 0 08 to 0 16 in

MUlti purpose grease I II

Accelerator pedal Screw
2 Accelerator pedal bracket 12 Pedal stopper bolt
and return FE260
spring 13 Kickdown switch striker
3 Accelerator pedal arm Automatic transmission
4 Pedal stopper lock nut models only
5 S pring clamp 14 Kickdown switch
6 Lock nut Automatic transmission
7 Adjust nut models only
8 Wire holder 15 Switch stopper nu t

9 Accelerator wire 16 Carburetor

10 Accelerator wire outer case

Fig FE l Accelerator control sy t m

FE 2
 Engine Control Fuel Exhaust Systems
REMOVAL AND E 78 mOl 3 07 in then automatic choke effect will be

INSTALLATION released
Tightening torque 01 nut
3 Set throttle valve to completely
38
0 to 0 4S kg m
Accelerator wire closed position and with wire suf
2 7 to 2 ft b
3
ficiently slackened lighten adjust nut
I Remove air cleaner assembly
until throttle lever is about to move
2 Disconnect accelerator wire from
2 Accelerator pedal play is zero at this
Release auto choke effect since
carburetor lime See FE 2
throttle lever is Figure
3 Loosen lock nut and disconnect opened by fast idle
4 Unscrew
until adjust nut approxi
accelerator wire outer case from wire earn engine warms up
mately two and a half turns so that
holder See Figure FE I accelerator pedal play is 3
I Keep choke valve fully open mOl 0 012
4 Remove spring clamp and discon with in Tighten lock
fingers nut securely See
nect accelerator wire from accelerator 2 Pull throttle lever up by hand Figure FE 2
pedal arm

S Remove two screws securing ac

celerator wire outer

detach accelerator wire
case to body and
1 I
6 To install reverse the order of
removal Apply recommended multi
purpose grease slightly to portion
MG shown in Figure FE I

Accelerator pedal assembly

I Remove spring clamp then dis

1
connect accelerator wire from tip of

pedal ann

2 Remove two screws securing ac

1 Adjust nut
celerator bracket to body
pedal 2 Lock nut @
3 Remove accelerator from
pedal 3 Accelerator wire
CD
dash See Figure FE I
panel 4 Dust co r

4 To install reverse the order of FE184

removal
Fig FE72 AdjU6ting accelerator wire play

INSPECTION
I Check accelerator pedal return

spring for rust fatigue or damage

Replace if necessary
2 Check accelerator wire cases and 5 After completing the adjustment 4 Apply recommended multi

fastening locations for rust damage or as previously explained check the purpose grease slightly portion on the

looseness following as shown in Figure FE I Also refer to

Repair or replace if necessary I Make that accelerator

sure the periodic maintenance schedule
system functions smoothly and quietly
without disturbing any adjacent parts
ADJUSTMENT 2 Depress accelerator pedal down Kickdown switch Automatic
until throttle valve fully opens Make
transmission models only
sure that the clearance T between
Accelerstor pedal and wire
accelerator pedal reverse side and dash Kickdown switch adjustment is cor

Adjust pedal stopper bolt floor is 2 to 4 mm 0 08 to 0 16 in rect if it is actuated by kickdown

Section A so as to obtain specifi without floor mat Adjust pedal stop switch striker when accelerator pedal
ed height E as shown in Figure per bolt and lock nut if beyond limits isfully depressed
FE I Secure pedal stopper bolt with 3 Check throttle lever if it returns Always tighten switch stopper nut
stopper lock nut Refer to Figure to the original position as soon as securely after proper adjustment is
FE I accelerator pedal is released obtained

FE 3
 Engine Control Fuel Exhaust Systems

FUEL SYSTEM

CONTENTS

DESCRIPTION FE 4 INSPECTION FE 6

REMOVAL FE 5 INSTALLATION FE 6

DESCRIPTION
The fuel tank is4Sliters II Ji s
U The filler shutter is installed to the For the electric fuel pump refer to
gal 9 Ji Imper gal in capacity The filler tube on California models Section EF
tank unit is mounted to the right side The electric fuel pump is adopted
of the rear floor on air conditioner equipped models

1 Fuel tank
2 Drain plug
3 Filler tube
4 RescfYOir tank
5 Filler hose
6 Breather hose
7 Ventilation hose
8 Evaporation hose
9 Fuel outlet hose and tube
10 Fuel tank gauge unit
11 Protector
12 Bracket
13 Retainer

14 Return tube

FE194

Fig FE 3 Fuel tank

4
FE
 Engine Control Fuel Exhaust Systems

4
Detail A Detail e
Detail Bn

Detail G

@
Detail E

Detail D

Detail U

Detail F Detail T

FE261

Fig 4 Fuel piping

FE

REMOVAL Note Plug hose and tube opening to

l prevent entry of dust or dirt while
prevent entry of dust or dirt while removing
Fuel tank See Figure FE a removing
3 Unfasten clips that hold tube on
I Disconnect battery ground cable Fuel tank gauge unit under body and remove tube from the
2 Remove drain plug and receive vehicle
the fuel into a suitable Disconnect battery ground cable
remaining
2 Disconnect wires from fuel tank
container Fuel filter
3 Disconnect filler tube frofiller gauge unit
3 Remove fuel tank For details I Disconnect fuel hoses from fuel
hose
refer to fuel tank removal filter by removing clamps See Figure
4 Remove fuel tank securing bolts
4 Unit gauge is FE 5
5 Disconnect two ventilation hoses a bayonet type and
fuel return hose and fuel outlet hose
can be removed by turning it counter

from fuel tank clockwise with screwdriver

6 Disconnect fuel tank gauge unit

wires at connector

Remove fuel tank Fuel piping See Figure 4

FE
7

Note Plug hose and tube opening to

l Fuel tubes are serviced as an as

prevent entry of dust or dirt while sembly so that replacement of fuel

removing tube can be easily done However do

not disconnect any fuel line unless
ReservoIr tank
absolu tely necessary
1 Disconnect cable I Drain fuel from fuel tank
battery ground
2 Disconnect two ventilation hoses 2 Loosen fuel hose clamps and dis

evaporation hose and breather hose connect fuel tubes on each end FE18S
3 Remove reservoir tank securing
bolts and remove tank with protector Note Plug hose and tube openings to Fig FE S Removing fuel filter clamps

FE 5
 Engine Control Fuel Exhaust Systems

2 Remove fuel filter Fuel filter is of a cartridge type 4 Install fIller hose after fuel tank
and cannot be cleaned Always replace has been mounted in place Failure to
with follow this caution could result in
INSPECTION a new one

5 Fuel tank gauge unit leakage from around hose connections

Fuel tanle When installing fuel tank gauge
Check gauge unit for rust deforma 5
Check fuel tank for cracks or
tion or deterioration If necessary unit align the projection of tank gauge
deformation If necessary replace unit with the notch in fuel tank and
replace
2 Fuel hose
tighten it securely Be sure to install
Inspect all hoses for cracks fatigue gauge unit with O ring in place
sweating or deterioration Replace any 6 Run engine and check for leaks at
hose that is damaged INSTALLATION connections
3 Fuel tube

Replace any fuel tube that is crack To install reverse the order of Tightening torque
ed rusted collapsed or deformed removal Observe the following Drain plug
I Install hose Do 5 0 to 6 0
clamps securely kg m

Note Inspect hoses and tubes ac not tighten excessively to avoid 36 to 43 ft Ib

cording to the periodic mainte damaging hoses Fuel tank securing bolt
nance schedule 2 clips holding fuel tube on
Fasten 8 to 1
0 Ikg m
under body securely Failure to follow 6 to 8 ft Ib
4 Fuel filter this caution could result in damage to Reservoir tank securing
Replace fuel filter according to the surface of fuel tube bolt
the periodic maintenance schedule or 3 Do not kink or twist hose and 032 to 0 44 kg m
when it is clogged or restricted tube when they are routed 2 to 3 ft Ib

EXHAUST SYSTEM

CONTENTS

DESCRIPTION FE 6 INSPECTION FE 8
REMOVAL FE 8 INSTAllATION FE 8

DESCRIPTION California
Non models California models

The exhaust exhaust system consists of

systems installed on The a The exhaust system cOllsists of a

the California models differ in front exhaust tube main muffler front exhaust tube
non a a catalytic conver

specifications from those installed on assembly with rear tube mounting ter assembly a center tube a main
the California models hangers brackets and a heat insulator muffler assembly with rear tube

mounting hangers brackets and heat

insulators
The catalytic converter is COD

nected to the front tube and the

center tube with bolts and nuts

FE 6
 Fuel Exhaust S ys tems
Engine Control

Califomia
Non model

Qf l
tr
Qf tIJ
Si
Si
@
Qf

i I

j
l l
tr

l Qf l
i
Si
r l

t I
1 l
tr

1 Front tube

9r 2

3
Exhaust

Rear
tube clamp
tube assembly
4 Muffler assembly
8
5 Rear tube mounting
1Bi
6 Front tube mounting

California model

6
8
@@
Qf @ fit 0
J
I

1 Front tube
2 Catalytic converter

Center tube
Muffler assembly
Diffuser
I Rear tube mounting
7 Front tube mounting

FE390

Fig FE 6 t
r
E ha system

FE 7
 Fuel Exhaust
Engine Control Systems

REMOVAL INSTALLATION

California
Non models Install the exhaust system assembly
ijl in reverse order of removal Observe
I Remove exhaust tube U bolt
the following
clamp
2 Break sealant off at front tube to
Notes
main muffler connectio n
a Insert front tube until it touches
3 Remove rear tube mounting bolt
emboss
and remove muffler assembly with rear
b When there is 110 clearance between
tube
front tube and floor or propeUer
4 Remove front tube heat insulator
shaft turn tube along center line of
5 Remove nuts securing front tube 4 tube the manifold
to exhaust manifold and remove front
in connecting
unit and obtain proper clearance
tube mounting bolts Then detach FE189
c Check all tube connections for ex
front tube
Fig FE 9 Tapping muffler with haust gas leaks and entire system
When disconnecting the exhaust Q rubber hammer for unusual noises with engine
tube connections pay attention to the
running
following point d After installation check that
I Break lse
antold
off at t1e mounting brackets and mounting
connection by lightly tapping around California models rubbers are free from undue stress
the tube witlJ a hammer and twisting
If any of the above parts is not
I Remove all heat insulators
muffler See Figures FE 7 and 8
FE
installed properly excessive noises
2 Remove exhaust tube U bolt
2 Using a rubber hammer tap on or vibrations may be transmitted to
the front end of muffler while pushing clamp the vehicle body
it toward rear The mumer assembly 3 Break sealant off at center tube

can then be taken out See Figure to main muffler connection e Tightening torque
4 Remove rear tube mounting bolt Exhaust manifold to
FE 9
and remove muffler assembly with rear front tube nut
tube 19 to 5 kg
2 m

14 to 18 lb
ft
5 Remove bolts securing catalytic
converter to center tube and remove U bolt securing nut
center tube mounting bolts 19 to 2 1 kg m
14 to 15 ft lb
Then detach center tube
Mounting bracket bolt
6 Remove bolts and nuts securing 1 0 to 1
2kg m
catalytic converter to front tube and
710 9 ft lb
detach catalytic converter
Front tube mounting bracket
7 Remove nuts securing front tube
bolt california models
to exhaust manifold and remove front
19 to 2 1 kg m
tube mounting bolts Then detach
FE187 14 to 15 ft lb
front tube
Fig FE 7 Breaking Bealant Catalytic converter to front

and center tube bolt

California models
3 2 to 3
4 kg m

23 to 31 ft Ib

INSPECTION

I Check muffler and tubes for If exhaust tubes are separated at

cracks Qr connection t renew muffler

damage assembly
Replace any part that is damaged etc use the Genuine Nissan Sealant

beyond limits Exhaust Sealant Kit 20720 N2225

2 Replace bracket and mounting or equivalent See Figure FE IO to

FEl88 insulator that are cracked fatigued or eliminate gas leakage at the joint Be
8
FE sweated sure to observe the following
Fig Twisting muffler

FE 8
 Engine Control Fuel Exhaust Systems

7 Start engine and let it idle slowly

for ten minutes minimum to hilfden
sealant with the heat of exhaust gas
Sealant tube polyethylene 8 Check the condition of sealant
before driving the vehicle It is also
Injector
essential that the vehicle should not be
accelerated sharply for 20 to 30
minutes subsequent to this operation

Noles
a The sealant should be used within
term indicated on the kit
guaranty
Fig FE IO Exhaust sealant kit
case

b Exposure of sealant to the skin may

cause a rash Wash sealant off the
the contact por Be sure to place cap back to sealant
I Wipe clean all skin with water
allow them to dry tube since sealant will dry
tions of tube joints c Do not keep the sealant tube in a

thoroughly place where the ambient tempera

2 mount in place 400C I040F A
Temporarily ture is above
muffler assembly as an assembled unit sealant hardened above 4QoC
on the vehicle I040F cannot be used The most i
3 Insert front tube until it touches suitable storage temperature is from
emboss 15 to 350C 59 to 950F If sealant
becomes hardened because of low

temperatures wann the sealant

Approximately tube with lukewarm water until the
5 0 31 in
cc Cll
sealant is softened Do not warm

b nlfrnnjj
m
FE1l1
tube at a temperature over 400C
Fig FE 12 Squeezing sealant to
lJ Ij 1040F for a long time
mm
injec tor
J
@L d Thoroughly read the instruction
6 Position nozzle of injector to the sheet furnished with the kit before
FE263

Exhawt tube connection

guide and press it there firmly Inject using the sealant
Fig FE ll
sealant slowly until sealant begins to
flow out of the slit of tube This
4 indicates that the bead requires no
Torque nut securing the male and
female tubes at the connection further sealant Excessive sealant can

clogged tube See

Tightening torque is 1 6 to 2 0 kg m cause a Figure
12 to 14 ft lb FE 13
5 CC After injecting wash injector
5 Squeeze approximately 31
0
thoroughly in clean water to remove
cu in of sealant into injection from
all traces of sealant
sealant tube See Figure FE 12

FE191

Fig FE 13 Injecting sealant

FE 9
 SECTION BF

BO DY FRAME
DATSUN PICK UP
MODEL 620 SERIES

CAB BODY AND FRAME BF 2

REAR BODY BF 5

BODY FRONT END BF 7

HOOD BF 8

DOOR BF 11

WINDSHIELD GLASS BF 16

INSTRUMENT PANEL BF 17

INTERIOR TRIM AND

BF 18
CENTER CONSOLE

SEAT BF 19
I NISSAN I

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Body Frame

CAB BODY AND FRAME

On the 620 series models chassis The frame consists of right and left heavy loads The second crossmember
frames classified into three types
are side members which are linked to is located somewhat to the rear to
the standard wheelbase model long gether with crossmembers to form a permit individual replacement of the
wheelbase model and Deluxe Cab rigid structure that can withstand transmissiol

FRAME ALIGNMENT

STANDARD WHEELBASE MODEL

1 587 5
J 1
r1
I

f
X 62 50
b q JA 1 I
7 Ib
9 9 8 I
1
e
e r

rd r
0

1sol
ij 6
t
00
9ClSCl 1
1
085 42
721

11
1 H
OO
1 I

l i11
175
1 4
069 42 10 1 5 37 11
942
6 89

I 284
1007 39 65
295
18
11 11 61

r r

L r
T c

8
d 8 o

BF025B

Fig BF I Underbody dime1l8ion Standard whee b e

SF 2
 Body Frame

LONG WHEELBASE MODEL

l1
4 1 873 8
Ir

In
mrn
I
0 IN1
bi
b
I
o
M I f
p
v v M
0
y
r v
t c G
c
D M
IS S 0
t
r
y
M J
0
1 I 10
So
9 raj p

1
085 42
72
VN

1 350
78
Ii
I
I

I
20 63
1 d3 1

U T
r
II
L t J
n
I

e o

C
M
BF0268
o

Fig BF 2 Underbody dimensions Long wheelbase

DELUXE CAB

17 iO P b t
r

1 b c
u
N
tl 0
l
f
0 l

Jr
C y 0
I
M

t
r M 2 V 00 0
0
dJ JSO 0
o
1 00 N It
r

S
1 b t 8Qa 3
OS
o

1 085
42 72 A b U
n
j
I I li4
I
1 069 4 42 10 942 5 37 11 1 007 39 65
284 1
18
11 1161

1 I
bu I
c r

M
I
T

8
o
It
R
M

o
BF027B

Fig BR 3 Underbody dimensiom Cab

Delu

BF 3
 Body Frame

CAB BODY

2nd mounting

Ist mounting

1 Bolt
2 Plain washer
3 Rubber washer
4 Upper rubber

5 Bottom rubber
6 Plain w er

7 Upper washer

8 Lower washer

BF472A
Unit mm in
1st mounting 2nd mounting 3rd mounting

Fig BF 4 Cab body mountings

REMOVAL AND II Remove 23 Loosen hand brake control cable

steering gear housing
INSTALLATION from frame and pull it out into engine at brake control lever Then discon
compartment nect cable from dash panel
12 Disconnect speedometer cable at
Remove battery from engine transmission Note Place blocks against front and

compartment 1 3 Disconnect carbon canister rear wheels to prevent vehicle from

2 Disconnect oil cooler hoses from off accidentally
hoses between canister to vacuum rolling
radiator automatic transmission
gallery and canister to intake manifold
model only at canister 24 Free accelerator wire from car

3 Disconnect air conditioner tubes 14 air buretor

Disconnect pump to air
from condenser if so equipped 25 Disconnect heater hoses at
pump air cleaner hose at air cleaner
4 Drain water from cooling system 15 Disconnect air conditioner hoses engine side
completely and remove radiator and from compressor if so equipped 26 Disconnect wire harnesses from
condenser if so equipped 16 Disconnect air cleaner duct from related engine electrical parts
5 Remove engine hood from hood 27 Disconnect engine and chassis
body
hinges after scribing hood for rein 17 Disconnect harnesses at their connection on right
Master Vac vacuum
stallation sidemember near rear engine mounting
hose at intake manifold
6 Remove from frame
bumper stay 18 Remove member
snap ring and control
and remove front bumper lever 28 Remove six bolts securing body
pin from transmission striking
7 Remove radiator grille
guide and remove control lever to frame
8 With the aid of Steering Wheel 29 With the use of suitable ropes
19 Disconnect fuel hoses at fuel
Puller ST27 180001 remove steering and overhead hoist lift cab
strainer an body
wheel from steering shaft and
20 Disconnect fuel return hose and straight up slowly place it on a
9 Remove steering gear arm from level surface
evaporation hose at connectors
steering sector shaft using suitable 21 Disconnect brake and clutch
puller tubes from each master Note In
cylinder lifting up cab body use care
10 Remove screws securing steering 22 Remove all not to dash it
clips securing fuel against engine or rear
shaft dust seat and insulator in posi tubes brake tubes and clutch tube at Cab body weighs approxi
body
tion cab body 220 485 Ib
mately kg

4
BF
 Body Frame

30 For installation reverse above

steps However observe the following
instructions
i Ifthe cab body is to be replaced
note position and location of insula
tors and washers used See Figure i
2

perly
3
4
BF

Adjust

Air
hand

bleed
brake stroke pro

brake and clutch

o k q

system thorougWy
Cab body to frame mounting
j
1Q
b
bolt torque

crru 8F630
1 6 to 2 2 kg V J
rr1
m

12 to 16 ft Ib
4 n Fig BF 5 Lifting up cab body

REAR BODY

1 Bolster
2 Shim B
3 Bolster
4 Shim A
5 Frame
6 Rubber washer
7 Plain washer

BF664

Fig BF 6 Rear body mountings

REAR BODY
REMOVAL AND tank Remove fuel tank from rear 5 Remove eight rear body attaching
INSTALLATION body bolts

The rear body is securely fastened

to the frame at eight places It should
be hoisted after the fuel tank is re
moved from the rear body
Use the following procedures as a

guide when removal or installation of

rear body is necessary
I Apply parking brake
2 Disconnect cables from battery
3 Disconnect rear combination
lamp wiring harness at connectors BF665

4 Disconnect fuel hoses from fuel

Fig BF 7 Rear body mountings

BF 5
 Body Frame

6 Attach ropes to hooks in

lifting REAR GATE 00
rear body as shown in Figure 8
BF
REMOVAL AND INSTAllATION
and lift up rear body slowly and
carefully 1 W

Notes
a When lifting rear body make sure

that it is in a good balanced cond

ition

not to allow 1 Rear gate chain

b While lifting use care
2 Rear gate chain bolt
rear body to hit against cab body or
3 Rear body
any adjacent parts 4 Shim
c The rear body weighs approxillllte S Hook handle

Iy 130 kg 286 Ib @ 6 Reargate

BF661

Fig BF 9 Rear gate

I Open rear gate 2 To in the left and

adjust rear gate
2 Remove rear gate chain from ear right directions loosen rear gate hinge
gate attaching bolts and move rear gate as
3 Remove rear gate hinge attaching required
bolts and take out rear gate and rear 3 To adjust rear gate hook loosen
gate hinge shims two attaching bolts and move rear gate
4 To install rear gate reverse the hook down
up or left right in elon

order of removal gated holes as required

ALIGNMENT
GUARD FRAME
The rear gate should be
adjusted so
BF0288 that there exists an equal clearance
Optional
REMOVAL AND
Fig BF 8 Lifting up rear body between body and the periphery of
INSTAUATION
rear gate There should be no stepped
Theguard frame is furnished as an
portion at any points
the of rear gate optional equipment
I To adjust height
add or remove shims at rear gate hinge I Remove nine guard frame at
Two sizes of shim are available in taching bolts and detach guard frame
7 To install body reverse the 2 To install optional guard frame
rear thickness 1 6 mm 0 0630 in and 0 8
order of removal Carefully observe rom 0 0315 in reverse the order of removal

the following instructions

Make sure that spacers and shims

rr
used with bolts
in their
are

original positions Refer to

Figure BF 6 for the location of these
properly placed
r
parts
The rear body to frame attaching
bolts should be torqued to 3 to 4 2 f
kg m 24 to 30 ft Ib r
@
L

C s

i
SF673

Fig BF lO Guard frame

6
BF
 Body Frame

BODY FRONT END

ZID
@

1 Hood
2 Hood support rod @
3 Hood bumper 7
Fender
4
@
5 Bumper bracket shim
6 Bumper side bracket
7 Bumper
8 Bumper stay
9 Front apron BF029B
10 Radiator grille
Fig BF 11 Body front end

3 For installation reverse above FRONT APRON

FRONT BUMPER
steps observing the following
REMOVAL AND
REMOVAL AND I Check to be certain that six
INSTALLATION
INSTALLATION guide studs enter holes in radiator
I Remove front
L Remove bumper to fender at support lower frame before tightening bumper
2 Remove radiator
taching bolts top screws grille
Disconnect front turn wire
2 Remove four bumper stay to side
3 signal
harness at connector
frame front attaching bolts Pull bum CD
forward
4 Remove front apron by removing
per assembly straight
above attaching bolts
3 For installation reverse
@ For installation reverse above
S
steps Align bumper with front fender
and apron then tighten them up steps

B 632

1 Radiator grille
RADIATOR GRILLE 2 Guide stud
3 Guide stud hole
REMOVAL AND
4 Radiator support lower
INSTAUATION
frame

I Remove radiator grille by re

Fig BF 12 Radiator grille guide
moving attaching screws six on top studs

and two on both ends

Remove ornament on radiator
nuts from behind 2 Align grille with head lamps and
grille by removing
fenders
radiator grille

BF 7
 Body Frame

However observe the following items

COWL TOP GRILLE
I When installing air box drain

@ @ apply adhesive to its lower end

2 Align cowl top grille with fend
ers

1 Cowl top grille

FRONT FENDER
2 Cap REMOVAL AND
3 Air box dtain seal
INSTALLATION
4 Cowl top
5 Air box drain
6 Screw I Remove front bumper
6F633 2 Remove radiator grille
3 Remove front apron
Fig BF 13 Cowl top grille 4 Remove cowl top grille
S Remove hood bumpers two on
REMOVAL AND
INSTALLATION each side

hood screws Pull grille straight forward to 6 Remove nine screws attaching
I Open engine
windshield remove front fender to hood ledge See Figure
2 Remove two wiper
4 Remove air box drain BF ll
blad
above 7 To install reverse above steps
Remove cowl top 5 To install reverse steps
3 grille attaching

HOOD

HOOD
5
REMOVAL AND
INSTALLATION
1 Place protective covers over front
fender and cowl top grille
2 Open engine hood Mark hinge 1 Female lever

locations on hood and loosen offfour 2 Safety catch lever

3 Return spring
bolts securing hood to hood hinge Use
4 Dovetail bolt
caution avoid
extra to damaging S Lock nut
painted surfaces of fender and cowl 6 Hood lock pring
top grille J 7 Spring
3 Remove engine hood
BF641A
4 To install reverse above pro
Fig BF 14 Hood lock male and female
cedures

ADJUSTMENT
Loosen hood to hinge bolts just
Four slotted holes in hood hinge
far enough to permit movement of
provide for fore aft and side adjust
hood
ment to correct space between hood
and fender

grille
and hood and cowl top
2 Shift hood in elongated hole until

parallel space is reached between

hood j I

and fender or cowl top grille Tighten

Loosen four bolts just enough to
bolts securely
move engine hood and move hood to
desired position if necessary to correct
space
To make vertical adjustment adjust 8F635
height of dove tail bolt at hood lock
male until hood is flush with fender Fig BF 15 Engine hood alignment

BF 8
 Body Frame

5 lock firmly while

Note Vertical adjustment should be Tighten nut

carried out after hood lock male holding dove tail bolt with a screw

and female adjustment has been

D driver to secure adjustment

3
completed

To correct hood lock alignment

loosen two hood lock male

bolts and move

attaching
hood lock male and

female in the lateral and fore and aft

r
1r BF642A
Tightening torque
Lock nut of dove tail

1 9 to 2 6
14 to 19 ft lb
kg m

directions as required Fig BF 16 Adjusting hood lock

male

Tightening torque 4 Dove tail bolt at hood lock male

Male and female attaching bolts provides for vertical adjustment in

0 45 to 0 60 kg m aligning hood to make it flush with
3 to 3 ft Ib
4 fender To correct loosen lock nut on
1 Lock nut BF643A

dove tail bolt and turn dove tail bolt in 2 Hood lock male 3 Safety catch

or out as necessary to obtain a correct Fig BF 17 Doue tail bolt height

height adjustment

HOOD LOCK CONTROL

JI

I
I

lPP J
jJ
i J
r
J
Sr 1
2
Dove tail bolt seat

Lock nut
I
aj I
I
J
3 Cushion rubber

f ifryI
ff U ii1iiilliiijiWI 4 Spring
r 5 Spring retainer

Y 6 Dove tail bolt

f
j 7 7

8
Clamp
Clamp
9 Hood lock female

j 1 10 Control cable assembly

JJ BF644A

Fig BF 18 Hood lock and control cable

8F 9
 Body Frame

REMOVAL AND I Check safety catch lever and

INSTALLATION spring for deformation fatigue or

rusting
I Remove hood lock male by re
2 Check female lever and return
moving two attaching bolts
spring for deformation fatigue or rust
2 To remove hood lock female first
ing Improper operation of female
remove radiator grille Back off two
lever may cause disengagement be
bolts securing hood lock female in tween female lever and dove tail bolt
position Hood lock female can now 3 Make that
sure safety catch
be taken out @ hooks engine hood properly when
3 Remove two bolts attaching hood BF645A
hood latch has been disengaged
lock handle assembly to dash side 1 Hood tock handle 3 Clamp
2 Hood lock handle 4 Hole
paneL
bracket 5 Attaching bolt

0l
Disconnect cable at hood lock
female and remove cable clamps Pull Fig BF 19 1MtalIing hood lock handle
cable out into cab brocket

4 To install hood lock male and

female reverse removal procedure
Mter installation check to insure that

I
ADJUSTMENT AND BF409A
11 mm nun
they are properly aligned INSPECTION 433
0 in
5 To 0 3t5 in
install hood lock handle as
I If hood lock handle is heavy turn
sembly reverse steps observing the Fig BF 20 Safety catch lever to
dove tail bolt of hood lock male coun radiator upper support
following notes
terclockwise to reduce tension of hood acVu5tment
I Check to be certain that cable
lock spring
clamps are tight and secure
Lubrication
2 Install hood lock handle bracket Lock nut of dove tail bolt should

two of four holes fust be loosened When checking adjusting the

in place by using or

See Figure BF 19 If looseness is noticed hood is not hood lock lubricate the pivot catcher

tight and will vibrate To correct this and return spring of secondary latch

turn bolt clockwise and recheck Also lubricate the lever of

thoroughly
2 Check hood lock mechanism as the hood lock female for smooth and
follows correct operation

BF 10
 Body Frame

DOOR
CONTENTS

DESCRIPTION BF12 DOOR GLASS AND REGULATOR BF14

DOOR BF 12 REMOVAL AND INSTALLATION BF14
REMOVAL AND INSTALLATION BF 12 ADJUSTMENT BF14
ALIGNMENT BF12 DOOR LOCK BF 14

DOOR TRIM AND SEAL BF12 REMOVAL AND INSTALLATION BF15

REMOVAL AND INSTALLATION BF12 ADJUSTMENT BF 15

GLASS RUN BF13 DOOR LOCK STRIKER BF 15

REMOVAL AND INSTALLATION BF 13 WEATHERSTRIP BF 15

DOOR VENTILATOR WINDOW Optional BF13 DESCRIPTION 8F 15

REMOVAL AND INSTALLATION BF13 REMOVAL AND INSTALLATION BF 15

CD

CV
CID @
@
@
1 Door sash
2 Window outside weatherstrip
3 Wmdow inside weatherstrip
4 Door weatherstrip
5 Rear glass run rubber
6 Door finish holder
7 Rear lower sash
8 Seal screen

9 Door weatherstrip clip

10 Frontglass run rubber
11 Lower door hinge

12 Upper door hinge

13 Front lower sash
14 Door glass
15 Glazing rubber
j 16 Door glass bottom channel

BF030B

Fig BF 21 Door without ventilator window

BF 11
 Body Frame

@
CD
I

r 1
@ 1 Door sash

L 2 Window outside weatherstrip

@ 3 Window inside weatherstrip

c 4 Door atherstrip
ID 5 Rear glass run rubber
@ @ 6 Door finish holder

7 Rear lower sash

AJ 8 Seal screen
9 Door weatherstrip clip
10 Front glass run rubber
11 Lower door hinge
12 Upper door hinge
13 Front lower sash
14 Door glass

15
@ Glazing rubber
16 Door glass bottom channel

@ 11 Lower support
18 Upper support
19 Door ventilator assembly

BF031B

@
Fig BF 22 Door with ntilator window Optional

4 To install reverse removal pro

DESCRIPTION cedure

The door consists of inner and ALIGNMENT

outer panels welded together to form a

rigid structure Elongated holes three each in

door hinge and door
lock striker pro
The curved glass provides greater
vide for up and down forward and
shoulder room
backward and or sideways adjustment
A door that ventila
incorporates a
to assure proper door fit to door
tor window is also available as an
BF023

option opening
Fig BF 23 Supporting door To door
The weatherstrip is inserted into adjust alignment loosen

the groove on the door sash side and is bolts and move door to desired posi
lion to obtain a
attached by clips the door side 2 parallel space between
on Separate lower door hinge hole
door sides and door opening Also
cover from dash side trim
3 check to be certain that weatherstrip
While supporting door as above
DOOR back off
contacts body opening evenly to pre
body to upper and lower
vent
REMOVAL AND hinge attaching bolts accessible from entry ofmud and water
INSTALLATION inside cab three each Door can now

be taken out from cab body

I With door in full open position DOOR TRIM AND
place a
garage jack or stand beneath SEAL
door to support its weight when bolts
REMOVAL AND
are removed Place rag between door I
t

I
INSTALLATION
and jack or stand to avoid damaging lf
p1JJ
W 1 Remove securing inside

1
screw

painted surface door handle escutcheon remove es

i cutcheon
2 Remove screws which hold pull
handle and arm rest in position Pull

Sl
handle and arm rest can then be taken

j out
3 Pull off regulator
retaining spring
Fig BF 24 Removing door hinge handle Take out regulator handle and
bolt seat washer

8F 12
 Body Frame

5 Remove door glass

6 Remove glass run rubbers from
front and rear lower sashes and from
those of fixed door
Use caution to avoid damaging
rubbers during removal operation
7 Remove front and rear lower
door sashes when ventilator window
is not provided
8 On vehicles equipped with venti

1
lator window remove ventilator
window frame and rear lower door
Seat washer
sash
Regulator handle
3 9 To install removal pro
BF640 Retaining spring reverse

cedure However observe the follow

Fig BF 25 Removing regulator handle ing notes
I Before applying adhesive clean
4 When removing door finish it is the inside ofdoor sash

I
important that inside door panel and 2 adhesive glass
Adhesive Apply to run

door finish are not rubber door sash contacting face

With
damaged
screwdriver off
i on

and fit it correctly Particularly care

f
a re
pry

taining clips exercising care not to should be taken at corners and contact
face to assure
damage clips f a good fit
nil
Section A A Ii
ir coil
IIIII I CD
J
A
JJ
A
iif lUJJ

BF641
J
I I
a

ldI
I L Fig BF 27 Adhesive for seal screen

jl 2 With door glass up set regulator

CID
BF641

II handle at an angle shown in Figure 1

2
Door sash
Glass run rubber
BF 28
3 Adhesive

Fig BF 29 Applying adhesive to

d
Spring
glass run ru bber

Fig BF 26 Removing door finish

1 J
900 DOOR VENTILATOR
5 Separate water seal
inside door
screen from l WINDOW Optional
panel BF462 REMOVAL AND
6 To install reverseremoval pro
INSTALLATION
cedure However observe the follow Fig BF 28 Installation angle of
regulator handle
ing instalJation notes I Remove five ventilator window
i When water seal screen is to be frame attaching bolts Lift frame out
replaced be Sure to cement it back GLASS RUN of door For detailed procedure refer
into position securely to ensure a
REMOVAL AND to relative topic under Door Glass
water sealed door This be done and Regulator
can by INSTALLATION
evenly applying adhesive to grooves in I With door in full out position 2 Remove nuts and spring securing
inside door panel lower glass all the way lower end of ventilator window to
Broken screen Or one suspected to 2 Remove pull handle arm rest and frame
be leaking must be replaced with a
regulator handle 3 Work off rivets which hold upper
new one 3 Remove door fmish and water end of ventilator window to frame
seal screen take out window
4 Remove outer and inner weather 4 To install reverse removal pro

strips from door cedure

BF 13
 Body Frame

DOOR GLASS AND REGULATOR

CD
j

fffi I BF035

Fig BF 32 Removing door glass

12 To install reverse removal pro

cedure

ADJUSTMENT
Fig BF 30 Door gl and regulator
I In and out and fore and aft ad

justment can be made by moving

REMOVAL AND 10 On door equipped with venti front or rear sash and guide channel as
INSTALLATION lator remove three bolts securing door required
bottom channel then let glass with which window
glass go The ease assem

L Open door lower glass all the to the bottom of door bly raises and lowers depends on ad
way Remove ventilator frame attaching justment of rear lower sash Rear
2 Remove iflllide door handle es
bolts and lift frame straight up out of lower sash should be parallel with
cutcheon door Remove door glass by lifting it front lower sash
3 Remove pull handle is deter
straight up 2 Fore and aft adjustment
4 Remove arm rest
11 Back off the five guide channel mined by position of guide channel
5 Remove regulator handle base and front lower sash Moving front
toregulator attaching screws
6 Remove door finish
Take out regulator assembly through lower sash backward reduces play in
7 Peel off water seal screen
window
large access hole in inside door panel assembly
8 Work off outer and inner weath
erstrips from door being sure not to
scratch door paint during operation
suitable screwdriver
DOOR LOCK
Use a plain or

similar flat bladed tool io remove and

place a piece of rag between screw

driver and door panel

CID

@
1 Outet weatherstrip
BF643
2 Screwdriver
3 Piece of rag

Fig BF 31 Removing outer 1 Escutcheon 8 Nylon nut

weather trip 2 Inside handle 9 Locking plate ring
3 Spring 10 LOcking plate
4 Door lock knob 11 Door lock cylinder

9 Remove three door glass bottom 5 Knob grommet 12 Door lock

BF410A
6 Outside handle 13 Stopper
channel attaching bolts Remove door
7 Outside handle rod
glass by lifting it straight up Fig BF 33 Door lock mechonillm

BF 14
 Body Frame

REMOVAL AND ADJUSTMENT

DOOR LOCK
INSTALLATION
OutsIde door handle STRIKER
I Open door
2 Remove inside door handle es of Adjustment of door lock striker
Adjustment play in outside door
should be made after door hinge has
cutcheon handle is controlled by play adjust
3 been adjusted correctly
Remove pull handle ment of nylon nut on threaded end of
Elongated holes three provide for
4 Remove arm rest outside door handle rod
handle up and down or fore and aft adjust
5 Remove regulator Correct play is 10 mm 0 039 in
ment to establish proper engagement
6 Remove door finish below
or as measured between nylon
between door lock striker and door
7 Peel off water seal screen
nut and
locking plate lock latch
8 Raise door glass to full up posi
tion
Inside door handle WEATHERSTRIP
9 Remove inside door lock knob
10 DESCRIPTION
Remove rear lower sash attach Elongated hole in inside door
iog bolts handle provides for play adjustment of The weatherstrip is retained by
11 Disconnect remote control rod inside door handle to the door sash and 19 clips
clamp by
from key cylinder and outside door 0 039 ill to the door
Correct play is 10 mm panel No adhesive is used
handle or below as measured at control rod to retain the weatherstrip to door
12 Remove three door lock assem
A
bly attaching screws

13 Remove two inside door handle L A

attaching screws

14 with inside door

Together
handle take out door lock as an

assembly through large access hole in

door panel
15 Remove two outside door Section A A
handle attaching nuts Outside door j

handle can then be taken out

16 Remove lock plate from key
and detach I
cylinder key cylinder
17 To install door lock assembly
1
outside and inside door handles and
key cylinder reverse removal pro
cedure
rB B
Section B
18 Lubricate door lock with grease
which meets the requirements of MIL I B BF645

G I0924B or
equivalent as listed
below Fig BF 34 Door weatheratrip

ALVANIA GREASE RA SHELL

REMOVAL AND
BEACON 325 ESSO 3 Pry off clips from door
INSTAUATION panel
MOBILE GREASE 22 MOBIL I Open door remove weatherstrip
2 Free weatherstrip from door sash 4 To instaH reverse removal pro
clamp cedure

BF 15
 Body Frame

WINDSHIELD GLASS

5 Working from inside vehicle push 3 With aid of a helper press wind
WINDSHIELD GLASS
windshield glass out of body opening shield assembly against body opening
by hand starting at right and left from outside being sure weatherstrip
DESCRIPTION toward lip aligns ith body opening flange
upper COIners and working out
is retained in ends 4 Slowly pull cord ends from inside
The windshield glass
the 6 After removing weatherstrip from to overlap weatherstrip channel on
the body glass opening through
weatherstrip There are twelve water top and sides of body opening lift body opening flange starting at center
drain holes one on each side of the glass up sufficiently to permit removal top and working out toward ends This
bottom of the glass opening and ten of weatherstrip from bottom flange operation should be done while one
along the length of the weatherstrip pry weatherstrip out of position man pushes glass against body opening

This operation requires two men from outside

The same technique should be ap

INSPECTION plied right

to left and bottom wea th

Prior to windshield glass erstrips

installing
make the following checks on body
glass opening and weatherstrips
I Clean weatherstrip channels re

placing those found with cracks

or

signs of deterioration
2 Clean body openings noting if
1 Weatherstrip these are distorted or corroded
BF473A
2 Windshield glass
3 Water drain hole
INSTALLATION
Fig BF 35 Windshield glass and
L Fit
weatherstrip weatherstrip on glass making Fig BF 39 Fitting weatherstrip top
it is
sure properly seated and posi
REMOVAL tioned Adhesive need not be applied

Place covers over en

1 protective
gine hood front fender seat and in
strument panel
2 Remove inside rearview mirror

and sun visor

0
3 Remove windshield mouldings if
so equipped
4 Using a putty knife or similar
BF650
flat bladed tool pry lips of weather
BF641 Fig BF 40 Fitting weatherstrip
strip out of place from top and side
Fig BF 37 Fitting weatherstrip on bottom
flanges of body opening
If glass
weatherstrip is to be reused it is
important that it not be damaged 2 Insert a draw cord completely
during this operation 5 Install windshield moldings on
around weatherstrip outer channel
weatherstrip if so equipped
6 Install inside rearview mirror and
sun visor
i
I

Q dYii BACK WINDOW

GLASS AND SIDE
1 Windshield glass WINDOW GLASS
2 cord
Draw
8F648
3 Weatherstrip Refer to relative topics under Re
BF041
moval Inspection and Installa
Fig BF 38 In8erting draw cord around
Fig BF 36 Removing weatherstrip weatherstrip outer channel tion of windshield glass

BF 16
 Body Frame

INSTRUMENT PANEL

wiring harnesses at connectors

1 5

nesses
Disconnect relative

from instrument panel at

wiring har
con

nectors

6 Remove steering column shell

Removal of steering wheel at this stage
facilitates further removal of instru
ment panel
7 Remove two side ventilator
knobs Remove package tray attaching
bolt and detach package tray

Bracket welded to dash

panel
2 Nut
BF646A 3 Instrument panel assembly

I Package tray
Fig BF 41 Instrument panel assembly
2 Side ventilator knob

Fig BF 42 Package tray

8 Support instrument panel assem

bly and remove five attaching bolts
INSTRUMENT PANEL 2 Disconnect heater control cables from it
from heater assembly 9
REMOVAL AND Withdraw instrument panel as
3 Disconnect speedometer cable
INSTALLATION on
sembly while lifting it slightly
the back of speedometer 10 To install reverse the order of
Disconnect battery cables 4 Disconnect antenna and speaker removal

8F 17
 Body Frame

INTERIOR TRIM AND CENTER CONSOLE

HEADLINING
DESCRIPTION
The headlining assembly is of a by listing wires The design is quite 2 Install listing wires in place on

roof rail
suspension type which is held in place similar to that used in a car
passenger
3 First attach front headlining to

the flanged portion of roof rail

Secondly attach the rear edges of
headlining in place while pulling the
headlining material to avoid wrinkles
4 Attach the right and left edges of

headlining material to the flanged por

tions using care to avoid wrinkles
ct
5 Cut excess headlining material ex

at the upper areas of

cept for that
front center and rear pillars not

covered by body side welt The edges

of headlining material at these areas
should be so cut that it can be folded

properly place
in

I 6 Install garnish on the extreme end

2 of headlining at rearpillar
3 where
7 Drill a hole in headlining
4
is located Install
5
room lamp room

6 A lamp
7 8 Install body side welts
8 9 Install windshield
BF648A glass
9
10 Install back window glass
11 Install assist rail sun visor and
Fig BF 43 Headlining
inside rearview mirror

REMOVAL BACK TRIM AND

1 Remove two inside rearview mir BACK INSIDE
attaching and detach FINISHER
rhir
ror screws rear

view mirror CD
DELUXE CAB
2
screws
Remove three
and detach
sun

sun
visor attaching
visor J I REMOVAL AND
3 Remove two assist rail attaching I INSTALLATION
and detach assist rail I
CID
screws

4 Remove room lamp

II BF661
Back trim

1
Headlining cloth 4 Door glass I Move floor carpet aside
5 Open doors and remove body side 2 Clip 5 Back window glass Remove four bolts attaching back
welts on each side 2
3 Garnish
trim to floor
6 Remove windshield glass and
Fig BF 44 Removing gami8h
3 Remove five trim clips and detach
weatherstrip
7 Remove back window and weath back trim
9 Detach all cemented edges of 4 Installation is the reverse order of
erstrip headlining from flanged portion of
8 Remove the end removal
garnish securing roof rail
of headlining to rear pillar 10 Disengage listing wires from roof
Back Inside finisher
rail and detach headlining
I Remove seat belt retractor
INSTALLATION 2 Remove five trim clips and detach
I Apply adhesive cement to the back inside fmisher
outer surface of and 3 Installation is the reverse order of
flange headlining
attaching surface evenly removal

8F 18
 Body Frame

Air conditioner equipped

models

I Remove two bolts from front of

center console
2 Remove two bolts from the rear
2
and remove center console

CONSOLE WITH
ARMREST

3
Back trim
Back inside imisher
Clip
1 DELUXE CAB
REMOVAL AND
INSTALLATION

I Remove two bolts from front of

BF0328
console armrest unit
Fig BF 45 Back trim and back inside finisher
2 Remove one bolt in the console

box and remove center console

3 Installation is the reverse order of

removal
CENTER CONSOLE
REMOVAL AND
INSTALLATION

Except for air conditioner

equipped models
I Remove two bolts from rear of
center console

2 Remove center console by pulling

it back

3 To properly install center con

sole insert its front portion into

BE033B BF034B
bracket on the floor and install and
tighten rear attaching bolts Fig BF 46 Removing center console Fig BF 47 Console with annrest

SEAT

SEAT BENCH SEAT

DESCRIPTION

There are two of seats semi

types a

separate bench seat for the standard

wheelbase and long wheelbase models
and a separate seat for the Deluxe Cab

models JJ
CAUTION t qJ
In conforming with M Y s
S No
302 be sure to remove the thin 1 Seat assembly

polyethylene covers from seat 2 Seat slide

3 Seat slide lock handle
cushions seat backs and head
4 Seat slide lock wire
restraints at the time of
a delivery
Pre service BF474A

b Parts replacement Fig BF 48 Bench seal

8F 19
 Body Frame

Removal and installation DESCRIPTION

assembly
1 Remove four bolts retaining seat 2 To install seat reverse above re belt is three
The seat point type
a

slide assembly to floor take out seat moval procedure consisting essentiaily a lap shoulder of

belt and an inner lap belt

SEPARATE SEAT The lap shoulder belt is fitted with

an emergency locking retractor which

senses the speed at which the webbing

s is being pulled and the deceleration of

the vehicle
1 Head re5traint
The inner lap belt has a buckle The
2 Seat assembly
3 Reclining device buckle of the driver s seat belt includes
4 Seat slide outer a switch which functions as a seat belt
5 eat slide inner
warning device

J
CAlJI10NS
a In conformity with M V S S No
302 be sure to remove the thin

polyethylene covers from seat belts

at the time of
j I delivery
Pre service
2 Parts replacement
b If the vehicle has overturned or

been in a collision replace the

BF0358
entire belt of
assembly regardless
Fig BF 49 Separate seat
nature of accident
c If the condition of any component
Removal and installation of a seat belt is questionable have
entire belt assembly replaced rather
I Remove two nuts attaching front 3 Then remove seat with seat slides
than attempting to repair seat belt
of seat slide to floor from the vehicle
d If webbing is cut frayed or dam
2 Remove two bolts attaching rear 4 Installation is the reverse order of
aged replace belt assembly
of seat slide to floor removal
e Do not spill drinks oil etc on

inner lap belt buckle Never oil

tongue and buckle

SEAT BELT f Use only a genuine Nissan seat belt

assembly

REMOVAL AND
INSTAUATION

I Disconnect battery ground cable

2 Disconnect buckle switch harness
at connector under seat

3 Loosen bolt retaining inner lap

belt and remove inner lap belt
4 Remove bolt securing emergency
locking retractor
5 Remove shoulder anchor bolt

and remove lap shoulder belt assem

bly
1 Inner belt 6 Installation is the reverse order of
2 Tongue stopper removal
3 Emergency locking retractor
4 Outer anchor plate Tightening torque
5 shoulder
Lap belt Anchor bolts
6 Shoulder through anchor BF036B
2 5 to 3 0 kg m

Fig BF 50 Seat belt 18 to 22 ft lb

BF 20
 Body Frame

Note When installing emergency INSPECTION OF

locking retractor make sure that it
BUCKLE SWITCH
is set vertically

@ The contacts of the buckle switch

are normally closed Whentongue

g@
I latches the buckle tip end of the
tongue pushes the push rod to open
the switch contacts

I Disconnect battery ground cable

2 Disconnect buckle switch wire
harness

3 Using a test light check buckle

switch for proper operation The light
should go out when tongue of outer
lap belt latches buckle and go on

when it unlatches buckle Replace belt

assembly if necessary

Note When checking buckle switch

operation make sure that power is
held below 16 volts and 13 mA

BF650A

Fig BF 51 Seat belt anchorages

8F 21
 SECTION BE

BODY
DATSUN PICK UP ELECTRICAL
MODEL 620 SERIES SYSTEM

BODY ELECTRICAL WIRING BE 2

LIGHTING AND SIGNAL BE 3

LAMP SYSTEM
METERS AND GAUGES BE 14

ELECTRICAL ACCESSORIES BE 21

EMISSION WARNING SYSTEM BE 43

California models
I NISSAN I

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Body Electrical System

BODY ELECTRICAL WIRING

6 Each grounding bolt is firmly MAINTENANCE

DESCRIPTION
pbnted INSTRUCTIONS
Cables are covered with color coded 7 Wiring is kept away from any
vinyl for easy identification In the Fuse
adjacent parts with sharp edges or high
wiring diagram colors are indicated by temperature parts such as exhaust
The fuse block is installed under
one or two alphabetical letters pipe the instrument panel on the left hand
It is recommended that the battery 8 Wiring is kept away from any drive vehicle
be disconnected before performing
rotating or working parts fan pulley
other than bulb
any electrical service
fan belt etc
or fuse replacement 9 Cables between ftxed portions
In addition to fuses a fusible link
and moving parts are long enough to
has been installed
protect wiringto
withstand shocks and vibratory forces
The fusible link functions almost the
same as a fuse though its eharac
teristics are slightly different than Notes
normal fuses
a Before starting to inspect and repair
any part of electrical system or
other parts which may lead to a
CABLE COLORS short circuit disconnect cables at
BE848A
battery terminals as follows
Cable colors are indicated by one or
Disconnect cable at negative Fig BE 1 Fuse block
two alphabetical letters terminal and then disconnect cable
B Black Be Brown G Green at positive terminal
L Blue Lg Light green Before cables to battery
connecting When for one reason or another
R Red W White Y Yellow terminal be to clean terminals
sure fuse has melted use systematic pro
with Fasten cable at
a rag positive cedure to check and eliminate cause of
The main cable is generally coded terminal and then ground cable problem before installing new fuse
with a single color The others are terminal Apply
at negative
coded with two tone color top of these terminals to
a as grease to
Notes
follows from
prevent rust developing on
a If fuse is blown be sure to elimi
BW Black with white stripe them
nate cause of problem before in
b Never use a screwdriver or senrice
gR Light green with red stripe stalling new fuse
tool to conduct a continuity test
b Use fuse of specified rating Never
Use test leads
use fuse of more than specified
INSPECTION c Never ground an open circuit or
rating
circuits under no load Use a test
Inspect all electrical circuits refer Co Check condition of fuse holders If
lamp 12V 3W or circuit tester as a
much rust or dirt is found thereon
ring to wiring or circuit diagrams load
Circuits should be clean metal parts with fine grained
tested for conti
nuity or short circuit with a conven sandpaper until
proper metal to
tional test or low metal contact is made
lamp reading volt
Before Poor contact in any fuse holder will
meter inspection of circuit
ensure that often lead to voltage drop or

I Each electrical component part or heating in the circuit and could

cable is securely fastened to its con result in improper circuit operation
nector or terminal

Each connection is
FUSE AND
2 firmly in place
and free from rust and dirt FUSIBLE LINK
3 No cable covering shows any DESCRIPTION
evidence of cracks deterioration or

other damage The fuse and fusible link are protec Fusible link
4 Each terminal is at a safe distance tive devices used in an electrical cir

away from any adjacent metal parts cuit When current increases beyond Fusible link protects lighting
5 Each cable is fastened rated amperage fusible metal melts charging and cir
to its starting accessory

proper connector or terminal and the circuit is broken cuits

BE 2
 Body Electrical System

A melted fusible link can be de Notes

tected either by visual inspection or by a If fusible link should melt it is
c
feeling with finger tip If its condition possible that critical circuit power
is questionable use circuit tester or large
supply or current carrying
test lamp as required to conduct circuit is shorted In such a case

continuity test This continuity test carefully check and eliminate cause

can be performed in the same manner of problem

for any conventional fuse b Never
as wrap periphery of fusible
link with vinyl tape Extreme care
should be taken with this link to
ensure that it does not come into
BEB49A
contact with any other wiring har
ness or vinyl or rubber parts Fig BE 2 Fusible link

LIGHTING AND SIGNAL LAMP SYSTEM

CONTENTS

DESCRIPTION BE 4 INSPECTION BE 9
LIGHTING ILLUMINATION LAMP BE 10
SYSTEM CIRCUIT DIAGRAM BE 4 KN08

HEADLAMP BE 5 BULB REPLACEMENT BE 10

HEAD LAMP BEAM REPLACEMENT BE 5 LAMP BODY REPLACEMENT BE10

BE 5 TURN SIGNAL AND DIMMER SWITCH BE 10
AIMING ADJUSTMENT
8E 7 REMOVAL AND INSTALLATION BE 10
FRONT COMBINATION LAMP
BE 7 INSPECTION BE 10
BUL8 REPLACEMENT
BE 7 LAMP SWITCH BE 10
REMOVAL AND INSTALLATION STOP
8E 7 REMOVAL AND INSTALLATION BE 10
SIDE MARKER LAMP
BE 7 INSPECTION BE 10
BUL8 REPLACEMENT
8E 7 DOOR SWITCH BE 10
REMOVAL AND INSTALLATION
BE 8 REMOVAL AND INSTALLATION BE 10
ROOM LAMP
BE B BE 11
BULB REPLACEMENT INSPECTION
8E 8 HAZARD SWITCH BE 11
REMOVAL AND INSTALLATION
BE 8 BE 11
REAR COMBINATION LAMP REMOVAL AND INSTALLATION
8E 8 INSPECTION BE 11
BULB REPLACEMENT
8E 8 FLASHER 8E 11
REMOVAL AND INSTALLATION UNIT
8E 8 BE 11
LICENSE LAMP REPLACEMENT
8 BE 12
BULB REPLACEMENT BE 8ULB SPECIFICATIONS
8E 8 TROUBLE DIAGNOSES AND
REMOVAL AND INSTALLATION
BE 9 BE 12
ENGINE COMPARTMENT LAMP CORRECTIONS
BE 9 HEAD LAMP BE 12
LIGHTING SWITCH

REMOVAL AND INSTALLATION BE 9 TURN SIGNAL LAMP BE 13

8E 9 TAIL LAMP STOP LAMP AND
INSPECTION
8E 9 BACK UP LAMP 8E 13
ILLUMINATION CONTROL RHEOSTAT
REMOVAL AND INSTALLATION 8E 9

BE 3
 Body Electrical System

DESCRIPTION
LIGHTING SYSTEM CI RCUIT DIAGRAM

Headlamp tail lamp and license lamp system

FRONT SlOE REAR SIDE

lIIIARI ER LAMP
MARKER LAMP
IR H R 1

G
jSTOPBrURH
I STOP 8 TURN

HEAOLAMP R H l TAIL
LIGHTING
SWITCH
TAIL
ll
lJ f

o 1121 BSAOC
REAR COMBINATION
UP

CR H
LllHTINIi A
r

1 I x
LAMP R H
nn
j iNAnON 8A
DIMMER
SWITCH

1
r
I J
LICE NSf
LAMP

101 ON
I
LAMP

USl LE
0
LINK I
t
lOA
CJ I3 BACIC UP
LIU

CIl
@ CJ
CJ
154

CJ
TA

ST
L

OP8TURN
TAIL
FUSE BLOCK
STOP8TURN
HEADl AMP LH

REAR COMBINATION
LAMP ILH
METE

i
EA

e LAMP ILLUMINATION
LAMP

I
Q REAR SIDE
n
I 2 IR fMP NAR

IL H l tAMP
BEBSOA

Fig BE 3 Headlamp tail lamp and liceme lamp ay6t m

Turn signal hazard warning lamp stop lamp and back up lamp system

REAR COMBINATION
LAMP R H

BATTERY
BACK UP LAMP
SWITCH n TA I L

8ACK UP

@ 4j
Jl
P
W
FRONT
COM8IfUl1ON

E
FUSIBLE
LAMP H LINK HAZARO
FLASHER
UNIT

ON

I a 2
3
HAIARD
WA NING
SWITCH

@
FRONT
COMBINATION
h
FUSE BLOCK
FUSE

FROM IGNITION
SWITCH
r
TU N SIGNAL
FLASHER UNIT
G BACK UP

JTA
LAMP L H STOP8TURN

t CJ TAIL
J
H
EL STOP 8 TURN

LH I U t
N

I
REAR COMelNATlON
LAMP IL H
I

iH ij
TURN SIGNAL
INDICATOR
LAMP

STOP

TURN SIGNAL SWITCH

BE851A

Fig BE 4 Turn signal Juuard warning lamp stop lamp and back up lamp system

4
BE
 Body Electrical System

Room lamp and engine compartment lamp system

FUSE BLOC K
ENGINE
1 100 I 2 I
ROOM LAMP
J QA
C
I t1
J CJ
C
I 0
I
CJ CJ Wf fi
t HOOD
1
SWITCt
f

FUSIBLE
ROOM LAMP
LINK

6
t I I 1 lA
II C
o
BATTERY FUSE

I I I c
I
DOOR SWITCH LH l DOOR SWITCHIR H l

BE852A

Fig BE 5 Room lamp and engine compartment lamp system

connector from behind beam

HEADLAMP
Note Rubber cover is installed at
back of headlamp beam The con

nector is located in the cover

5 Change headlamp beam and con

nect wiring connector to new beam

6 Place headlamp beam in position

so that three location tabs behind

beam fit in with three hollows on

mounting ring Make sure that sign

Top of beam lens i on upper side
7 Install headlamp retaining ring
and tighten retaining screws
8 Place radIator grille in position
and tighten retaining screws

AIMING ADJUSTMENT
if

Fig BE 6 Head amp

BE300
lJ

ii i tooi
HEADLAMP BEAM
Note Do not disturb aiming adjust
REPLACEMENT
I Remove radiator grille retaining
screws
1
J i 4
Y nnn
and radiator 3
I
4
Horiz tal adjustment
screws remove grille Remove retaining ring by rotating
2

ring
Loosen three
screws
headlamp retaining
It may be unnecessary to
it clockwise
4 Remove headlamp beam from
l BE30l

remove screws mounting ring and disconnect wiring Fig BE 7 Aiming adjustment

8E 5
 Body Electrical System

To adjust vertical aim Keep aU tires inflated to correct When

use adjusting a
performing headlamp aiming
screw on upper side of headlamp and pressures adjustment use an aiming device
horizontal aim b Place vehicle and the same
to adjust use adjusting tester on aiming wall screen or headlamp tester
screw on side of head lamp flat surface For operating instructions of any
c See that there is no load in vehicle aimer refer to respective operation
Notes
I Gasoline radiator and engine oil manuals supplied with the unit
Before making headlarnp aiming ad
pan filled up to correct levels
observe the in
justment foUowing 2 Without passenger
structions

DRIVING BEAM HIGH BEAM

G
L
wt

hi i
H iiI

10 m 32 8 ft

PASSING BEAM LOW BEAM

10 m
02 8 n

W2
d

20

I
h2
H2
02
I
10 m 32 8 ft
I
f

Driving beam High beam Passing beam Low beam

HI WI 01 hI H2 W2 O2 h2 d
mm mm mm mm mm mm mm
0
CO
in in in in in in in

715 780 48 140 715 160

I 392 349
All models
28 15 30 71 51
5 I 28 15 11 45 67 12018 is 43 13 74
BE302

Fig BE 8 Aiming adjustment

BE 6
 Body Electrical System

FRONT
COMBINATION LAMP
BULB REPLACEMENT

1 Remove two retaining screws and

lens
2 Push in on bulb turn it counter

clockwise and remove it from socket

3 Insert new bulb into socket press

it inward and rotate it clockwise Make
sure that bulb is locked in its socket

4 Place packing to lamp body in

position and install lamp body with
packing lens and two retaining
screws

REMOVAL AND
INSTALLATION
1 Screw
To remove lamp body disconnect
2 Lens
wiring at connector and remove wire
3 Bulb

grommet from panel Remove two 4 Lamp body

retaining screws and lens and withdraw
lamp body from vehicle BE698B
Install new lamp assembly in the
Fig BE 9 Front combinntion lamp
reverse sequence of removal

SIDE MARKER LAMP

BULB REPLACEMENT

1 Remove two retaining screws

lens and rim

2 Push in on bulb turn it counter

clockwise and remove it from socket

3 Insert new bulb into socket press

it inward and rotate it clockwise Make
sure that bulb is locked in its socket
4 Place packing to lamp body in
position and install lamp body with
packing lens and two retaining
screws

REMOVAL AND 2
INSTALLATION

To remove lamp body disconnect

two lead wires at connectors and

1 Packing
wire grommet if so
remove equipped 2 Lamp body
from panel 3 Rim
5
Remove two retaining screws lens 4 Bulb

5 Lens
and rim and withdraw lamp body from
6 Screw
vehicle
BE699B
Install new lamp assembly in the
Fig BE IO Side marker lamp
reverse sequence of removal

BE 7
 Body Electrical System
REMOVAL AND
ROOM LAMP
INSTALLATION
BULB REPLACEMENT
I Disconnect wiring assembly at

cormector

2 Remove two nuts from combina

tion lamp mounting studs
3 Dismount combination lamp as

sembly from vehicle

4 Replace lamp assembly with a

new one
J Install in the
5 new lamp assembly
reverse sequence of removal

CD
1 Lens

2 Bulb
3 Lamp body O lux Cab
4 Screw
8E700B

LICENSE LAMP
Fig HE ll Room lamp
BULB REPLACEMENT

Remove lens from lamp housing housing from roof rail and disconnect

2 Pull bulb forward and remove it two wires at connectors

Install in the
from socket new lamp assembly
3 Push new bulb into socket reverse sequence ofremoval
4 Install lens

REMOVAL AND
INSTALLATION
To remove lamp assembly discon REAR

J
i
nect battery ground cable remove two COMBINATION LAMP
retaining screws with lens removed
from lamp housing dismount lamp BULB REPLACEMENT
1 Screw
2 Bracket
3 Lens
4 Bulb BE702B

Fig HE 13 License Iomp

1 Remove lens retaining screw if so

equipped and remove lens

2 Pull out bulb and it with
replace a

new one
1 Screw

2 3 Install lens
Lens

3 Bulb
4 Rim
5
Lamp body REMOVAL AND
I NSTALlATI ON
@ BE70tB

1 Disconnect lead wire at con

Fig BE 12 Rear combination lamp
nector

1 Remove six lens 3 Insert new bulb into socket press

2 Remove lamp bracket retaining
retaining screws

it and rotate it clockwise screws and

lamp assembly
and lens inward
3 Install new lamp assembly in the
2 Push in on bulb and turn it Make sure that bulb is locked in its
counterclockwise to remove it from socket reverse sequence of removal

socket 4 Place lens into position and install

retaining screws

8E 8
 Body Electrical System

ENGINE INSPECTION Removal and Installation

Test continuity through
COMPARTMENT lighting
Remove lighting switch from vehi switch by using test lamp or ohm
LAMP cle following the procedures given in meter

SWITCH
I
I P T10N
TERMINAL
2
F
ICI

I I
2
6 terminal
I 4
I I b
1
I 3
Screw
2

3
Bracket
Bulb
I 6

BE 7038

Fill BE 14 Engine compartment lamp

Bulb can be replaced by pushing in

on bulb and turning it counterclock 3 terminal

wise
4 terminal
To replace engine compartment 1 terminal
Switch position
lamp assembly remove one SCrew BE855A

retaining lamp bracket to upper dash Fig BE 15 Lighting switch

panel and disconnect wires at connee
tors

Engine compartment lamp switch ILLUMINATION tion lamps of the combination meter
can be replaced by disconnecting lead
heater
wire at connector and switch CONTROL RHEOSTAT control wiper and lighting
pulling
switch knob it is a variable resistor
assembly out of its bracket To install
This illumination control rheostat and its value be controlled
switch assembly to bracket clean dirt
can by a
controls the brightness of the iliumina knob
dust and rust from the opening groove
of bracket and press down on switch
head until it fits in with bracket

LIGHTING SWITCH 0@
REMOVAL AND BE 7048

INSTALLATION Fig BE 16 Illumination control rhe08tat

I Disconnect battery ground cable

2 Press in switch knob turn it REMOVAL AND INSPECTION
counterclockwise and pull it out of INSTALLATION
Test continuity between two lead
switch
wires with
3 Unscrew escutcheon and remove
I Pull out knob of switch a test lamp or an ohm

escutcheon and spacer 2 Remove ring nut retaining switch meter When switch is in the OFF

4 Reach up from underneath instru to instrument panel position continuity must not exist In
ment panel disconnect lighting switch 3 Disconnect lead wires for switch the ON position resistance between

at connector the two lead wires must be between 0

multiple connector from instrument
4 and 3512
harness wiring assembly and remove Switch body can be taken out
spacer and lighting switch from behind instrument panel
5 Install new switch in the reverse 5 Installation is in the reverse se

sequence of removal quence of removal

BE 9
 Body Electrical System

2 Unhook wiring assembly from 7 Tighten two attaching screws

KNOB ILLUMINATION
that retains wiring assembly to 8 Install shell covers
clip
LAMP lower instrument panel 9 Connect multiple connector and

The illumination lamp is located on 3 Disconnect multiple connector lead wire to instrument harness wiring
the illumination control rheostat and lead wire from instrument harness 10 Clip wiring assembly at lower
This lamp illuminates the knob of wiring instrument panel

the wiper switch and lighting switch II

4 Remove shell covers Upper and Install steering wheel
with fiberscopes Lower

The fiberscopes between the knobs 5 Loosen two screws attaching

and cap of the illumination lamp carry switch assembly steering column
to

the light through their tubes with the jacket and remove switch assembly INSPECTION
inner reflective walJ 6 Position switch assembly to steer

ing column jacket Make sure that a Test continuity through lighting
location tab or screw fits in with switch by using test lamp or ohm

hole of steering column jacket meter

3 terminal
4 terminal
7 terminal Dimmer

CID

1 Bulb socket

2 Screw
3 Lamp body 8E705B

Fig BE 17 Knob illumination lamp

BULB REPLACEMENT
Ll r vt
I
I Reach up from under the instru
ment panel and pull out socket with
I 4JN l
ER L
PlOSITlON RI

j LASH n I I
bulb from lamp body 12 STOP 9 91
2 Pick up bulb and install a new I JFRe I I II
one L I III 11
3 Installation is in the R I II 161
I
reverse se

I 61616
quence of removal
BE706B

LAMP BODY REPLACEMENT Fig BE IS Turn signal and dimmer switch

1 Remove illumination control

section of illumina contacts are
rheostat Refer to
STOP LAMP SWITCH leased stop lamp switch
ti on control rheostat for removal open On the contrary contacts are

2 Disconnect lead wires for REMOVAL AND closed with plunger projected
illumination lamp at connector INSTALLATION
3 Remove screw retaining lamp
Stop lamp switch is mounted at the DOOR SWITCH
body to instrument panel Lamp body
bottom of pedal and steering post
can then be taken out easily Door switch is installed on both
bracket
4 Installation is in the reverse se
H and R H front door pillars
L
quence of removal I Disconnect battery ground cable
2 Disconnect lead wires at coonee

tors REMOVAL AND

3 Loosen lock nut unscrew switch INSTALLATION
TURN SIGNAL AND assembly and remove switch assembly I Disconnect battery ground cable
Install switch assembly de
DIMMER SWITCH 4 as
2 To pull switch assembly out of
scribed under Brake Pedal in Section
lower pillar withdraw switch and
REMOVAL AND BR
wiring assembly
INSTALLATION 3 Disconnect lead wire at cannee

INSPECTION
I Remove steering wheel tor

Refer to the related section When plunger is pressed into switch 4 Installation is in the reverse se

Steering assembly when brake pedal is reo quence of removal

8El0
 Body Electrical System
2 Remove shell covers
INSPECTION Upper FLASHER UNIT
3 Remove two screws attaching
Test continuity through door switch to lower shell cover and remove There are two flasher units One is
switch by using test lamp or ohm switch for turn signal and the other for
meter 4 Install hazard switch in the re hazard
When plunger is pressed into switch verse sequence of removal They are located at both sides of
door switch contacts
assembly are instrument panel near steering column
Contacts closed when
open are
They can be distinguished from each
plunger is projected other by their shape

The large one is for turn signal the

HAZARD SWITCH INSPECTION smaller for hazard See Figure BE 20

REMOVAL AND Test continuity through hazard

switch ohm
INSTALLATION by using test lamp or

meter
1 Disconnect multiple connector

and lead wire from instrwnent harness

wiring

SWITCH

I
POSITION
TERMINAL
OFF ON

I
I 2
li ill

I 5
1 Hazard flasher unit

I 4 2 Turn signal flasher unit BE707B

Fig BE 20 Flasher unit

ON
I 5

I 8

7 terminal
I 7
I
REPLACEMENT
To flasher unit

3 terminal 1 terminal I Disconnect battery ground cable

2 Disconnect connector fitted to

bottom of unit
4 terminal
3 Remove screw retaining flasher
5 terminal
unit
BE308
6 terminal 4 Installation is in the reverse se

Fig BE 19 Hazard switch quence of removal

BE 11
 Body Electrical System

BULB SPECIFICATIONS

Bulb

Item
Wattage SAE trade number
Candlepower

Inner 5W
37 4001
Headlamp 5 S0W
37 4002
Outer

Front combination lamp

23 8W 32 3C 1034
Turn signal and parking lamp

Side marker lamp

8W 67
Front 4C
Rear 8W 4C 67

Rear combination lamp

Turn signal lamp A B A 23W 32C 1073

Tail lamp B C B 23j8W 32j3C 1034

A B C 8W 4C 67
Stop lamp
Back up lamp D D 23W 32C 1073

License plate lamp 7 SW 6C 89

Engine compartment lamp 6W

5W
Room lamp

Combination meter illurnina

iC
17W x3 161
tion

Knob illumination lamp 3 4W 2C 158

Heater control illumination

4W
3 2C 158
lamp

TROUBLEDIAGNOSE AND CORRECTIONS

HEADLAMP

Condition Probable cause Corrective action

Headlarnps do not Burnt fuse Correct cause and replace fuse

light for both Loose connection or open circuit Check wiring and or repair connection

high and low beams Conduct continuity test and if neces

Faulty lighting switch replace
sary
Faulty dimmer switch

Faulty light relay Check light relay for proper operation and

replace if necessary
No ground Clean and tighten ground terminal

High beam cannot Faulty dimmer switch Conduct continuity test and replace if neces

be switched to low sary

beam or vice versa Check light relay for proper operation and
Faulty light relay
replace if necessary

BE12
 Body Electrical System

Condition Probable cause Corrective action

Headiamps dim Partly discharged or faulty battery Measure specific gravity of electrolyte and
recharge orreplace battery if necessary

Faulty charging system Measure voltage at headlamp terminals

If it is less than 12 8V check charging
system for proper operation

Poor ground or loose connection Clean and or tighten

Burnt sealed beams Replace

in Loose headlamp connection Repair

Headlamp only one
side lights Damaged sealed beam Replace

TURN SIGNAL LAMP

Probable Corrective action

Condition cause

do Burnt fuse Correct cause and replace

Turn signals
not connection
operate Loose connection or open circuit Check wiring and or repair

Faulty flasher unit Replace

if
Faulty turn signal switch Conduct continuity test and replace neces

sary

with
Flashing cycle is Bulbs having wattage other than specified Replace specified one

too slow wattage are used

Pilot lamp does Burnt bulbs Replace
not go out or

Loose connection Repair

too fast

Inoperative flasher unit Replace

Flashing cycle is Burnt bulb Replace

irregular Loose connection Repair
with
Bulb having wattage other than specified Replace specified one

wa ttage is used

TAIL LAMP STOP LAMP AND BACK UP LAMP

Condition Probable cause Corrective action

Correct and
Both right and left Burnt fuse cause replace
lamps do not light Conduct continuity test and replace if neces
Inoperative stop lamp switch
sary

Falllty back up lamp switch Conduct continuity test and replace if neces
sary

Check wiring and connection

Loose connection or open circuit
or repair

Lamp in only one side Burnt bulb Replace

lights Loose bulb Repair lamp socket

BE13
 Body Electrical System

METERS AND GAUGES

CONTENTS

COMBINATION METER BE 14 CHARGE WARNING LAMP BE 17

COMBINATION METER CIRCUIT DESCRIPTION BE 17
DIAGRAM BE 14 HAND BRAKE WARNING LAMP BE 18
REMOVAL AND INSTALLATION BE 16 DESCRIPTION BE 18
SPEEDOMETER BE 16 HAND BRAKE SWITCH 8E 18
REMOVAL AND INSTALLATION BE 16 METER ILLUMINATION INDICATOR
ODOMETER SWITCH BE 16 AND WARNING BULBS 8E 18
REMOVAL AND INSTALLATION 8E 16 REMOVAL AND INSTALLATION BE 18
FUEL GAUGE AND WATER TEMPERATURE 8ULB SPECIFICATIONS BE 18
GAUGE BE 16 TROUBLE DIAGNOSES AND
DESCRIPTION BE 16 CORRECTIONS BE 18
REMOVAL AND INSTALLATION BE 16 SPEEDOMETER BE 18
OIL PRESSURE WARNING LAMP 8E 17 WATER TEMPERATURE AND FUEL
DESCRIPTION BE 17 GAUGES BE 19
01 L PRESSURE SWITCH BE 17 OIL PRESSURE AND CHARGE WARNING
LAMPS BE 20

COMBINATION METER
Meter illumination lamps
COMBINATION METER
Turn signal M T only
CIRCUIT DIAGRAM
indicator lamp
L H
9 9 Turn sq nal
indicator lamp

lL J R H

Tj

iJ
O
l
rl8 i
o
I
I
g
J Voltage
regulator

OIL CHG
TEMP
0
BEAM

FUEL
0

C
BRK Q Speed
switch

BE856A

I Speedometer
2 Thermometer
3 Fuel meter

4 Tachometer Option
5 Cluster lid
6 Speedometer cable
7 Speed switch amplifier
Manual transmission only

BE6828

Fig BE 21 Cuit
Ci1 diagram of combination meter

BE 14
 Body Electrical System

Circuit diagram of combination meter system

IGNITION SWITCH

1 lOA
0 I
BATTERY

r
FUSIBLE
Jon
LINK g lOA r 0 HAZARD

KG FLASHER
G 0 I 15A t
r j UNIT
15A i Z
a J
L
l
J

J
I IIl
Z2 ll Z ll Z
LlJ
lIa LlJ
I
LlJ J a J a
IZ J
I I
I I
Z 1 1
az Z
J
z a

i 5a 00
Zza

7
HAZAR D
g LlJ
z
u
a a LlJLlJ
ll ll a a SWITCH
o a I
ll I aa
I 04LlJ I OFF ONI
l1

B FUEL TANK J
o l I I
S 02 I 2 I
M u3
I 3 I
D
14
ii
LIGHT
RELAY I 5 61
6

i2i 16 9 I
mm
76 I
S FROM
J
AMP FLASHER
e UNIT
l1 l1

J
J
CJ
00
TURN SIGNAL
LlJLlJ
z z
SWITCH
I L RI
B COO CUT
n lFLA I
SOLENOID
i IR R I
OIL IR L I
PRESSURE
SWITCH f IF
IF
R

L u
u I
I
THERMAL a VOLTAGE HAND FROM L1GHT
TRANSMITTER
REGULATOR BRAKE RELAY DIMMER
I SWITCH SWITCH

J IOFF
TO LIGHT
RELAY
TERMINAL
l
B 21
I
I
I X X
LIGHT
SWITCH

BEB57 A

Fig BE 22 Circuit diagram of combination meter ayatt m

BE 15
 Body Electrical System

REMOVAL AND 2 Remove meter front cover and The water temperature gauge con
INSTALLATION shadow plate by removing clips and sists of a gauge and thermal transmit

screws ter located in the engine block The

I Disconnect 3
battery ground cable Remove screws retaining speed thermal transmitter is equipped with a
2 printed circuit housing and thermistor element
Working through meter openings ometer to which converts
of cluster lid remove three screws remove speedometer cooling water variation to
temperature
retaining cluster lid to instrument 4 Install speedometer in the reverse a resistance and thus the thermal

panel sequence of removal tr t c

rtrols cUfTent flowing to
3 From underneath instrument the gauge
panel remove one screw retaining me The fuel gauge and water tempera

ter assembly to lower panel of instru ture gauge are provided with a bi metal
ment arm and heater coil When the ignition
4 Withdraw cluster lid slightly For switch is set to ON current flows to

ccess to switches knobs etc follow the heat coil and the heat coil is
the procedures given in each section ODOMETER SWITCH heated With this heat the bi metal
5 From behind combination meter is bent and thus the
arm pointer
disconnect cable REMOVAL AND connected to the bi metal arm is oper
speedometer at

speedometer head and multiple con INSTALLATION ated The characteristics of both
nector instrume nt wire assembly
I Remove speedometer as outlined gauges are the same
from printed circuit under A tolerance may occur on the water
Speedometer
6 On vehicle with clock disconnect temperature gauge or fuel gauge due to
2 Remove odometer retaining
wires at each connection on meter source voltage fluctuation The voltage
screws
printed circuit
3 Install odometer in the reverse regulator is used to supply a constant
7 Remove four screws retaining that the water
sequence of removal
voltage so temperature
me ter assembly to cluster lid gauge and fuel gauge operate correctly
8 Remov combination meter The operating part of the
as regulator
sembly consists of a bi metal arm and a heater

9 When installing combination me coil When the ignition switch is

ter assembly follow the reverse se turned on the bi metal arm is heated

quence of removal and bent by the coil opening the

contact Consequently current to the

coil is interrupted As the bi metal

cools the contact closes The repeti
tion of this operation produces a

pulsating voltage of 8 volts which is

applied to the water temperature and
fuel gauges
BE342A If both the water temperature
Fig BE 24 Odometerswitch gauge and fuel gauge become faulty at
the same time this may be attributed

to problem in the voltage regulator

Fig BE 23 eluster lid

Removing
FUEL GAUGE REMOVAL AND
AND WATER INSTALLATION

TEMPERATURE 1 Remove combination meter as

GAUGE sembly Follow the procedures under

Removal and Installation in Combina
DESCRI PTION
tion Meter
SPEEDOMETER
The fuel gauge consists of a tank 2 Remove meter front cover and
unit located in the fuel tank and fuel shadow plate by removing clips and
REMOVAL AND
gauge The tank unit detects fuel level screws
INSTALLATION
with its float converts fuel level varia 3 Remove retaining nuts at the
1 Remove combination meter as tion to a resistance of slide resistor back side of combination meter as

sembly Follow the procedures under installed on the float base and thus sembly and remove meter
Removal and Installation in Combina controls current to the fuel 4 Install meter in the reverse se
flowing
tion Meter
gauge quence of removal

BE16
 Body Electrical System
Fuse M OIL PRESSURE SWITCH
Meter voltage regulator
YR
To replace oil pressure switch dis
connect lead wire from switch termi
lffi

r@
Water temperature gauge
YW l nal and unscrew switch from engine
Ignition B f cylinder block
switch
Prior to installing switch to cylinder
1 Y Fuel gauge
block be sure to apply conductive
sealer to threads of new switch
Fusible
I link
YW

Thermal transmitter
t L Fuel tank
BE261

Fig BE 25 Circuit diagram offuel gauge and water temperature gauge

pressure falls below 4 to 0 6

0 kg cm2
OIL PRESSURE 5 7to 5
8 Under normal opera
psi CHARGE WARNING
WARNING LAMP tion
when the engine is
stationary the
LAMP
DESCRIPTION ligh glows with the ignition switch
turned on When the e gine is running DESCRIPTION
The engine lubricating system in and oil reaches the above
pressure The charge warning lamp glows
corporates an oil pressure warning range the circuit opens and the light
when ignition switch is set to
the
lamp which glows whenever engine oil goes out
ON with the engine shut down or
when the generator falls to charge with
FUSE BOX
YR the engine operated
SA TO METER VOLTAGE REGULATOR
is set to
IGJ G I When the ignition switch
TO OTHER WARNING
G lAMPS ON the charge warning circuit is

and current flows from the

closed

IGNITION
jt ignition switch to the warning lamp
and grounds through the regulator
SWITCH Oil PRESSURE
BE 27 1 When the engine is
WARNING LAhlP Fig
started and the generator comes into
YB YB

operation the generator output cur

FUSIBLE LINK
I O J BROWN N flowing
rent opposes th current

FROM from the warning lamp as the current

tl
BATTERY
N increases the solenoid is more
energized and the pilot lamp relay
contacts are open in effect it oreaks

PRESSURE PRESSURE BE263 the warning circuit ground connection

and the lamp goes out Fig BE 27 2
Fig BE 26 Circuit of oil prelSure warning system

Fuse box

Fuse box Fusible link M

From
From Fusible link
M battery
battery Ignition
To battery
Ig ition witch YR
To battery swllch
I YR
ru nu

i
J other

ft
t
To other

UTO
A A
warrung

hr
warning
r
L ignition lamps

J
To ignition
coil WR
IQlamps r Glj fCOil
i
WR Charge
tI j
Charge warning lamp
Warning lamp relay
warning lamp
f
T
J
T
I
War

I
lamp relay
I BE264
Generator
Generator v bt Voltage regulator Fig BE 27 2
ge
it e
g Fig BE 27 1
Circuit ofcharge warning system

BE17
 Body Electrical System

HAND BRAKE SWITCH METER

HAND BRAKE
To hand brake switch dis
WARNING LAMP remove
ILLUMINATION
connect lead wire pull switch out of
hand brake control bracket and with
INDICATOR AND
DESCRIPTION
draw switch and wiring assembly WARNING BULBS
The hand brake warning lamp glows
when the hand brake is applied REMOVAL AND
When the ignition switch is set to INSTALLATION
ON current flows from the ignition To replace bulb turn bulb socket
switch to the warning lamp When the counterclockwise to dismount it from
hand brake is applied hand brake combination meter if necessary dis
warning switch is closed and warning connect lead wire connector from
lamp glows printed circuit and remove bulb from
socket

Fuse M BULB SPECIFICATIONS

Ignition 5 tch
I Item
SAE Trade
Bulb No
Wattage
Candle power
W e

Fusible link Meter illumination 161 7I

1 x3
lamp
YG Turn signal indicator lamp 161 7
1 I

High beam indicator

1 lamp 161 17 I
From battery
1 Oil pressure warning lamp 161 I 7 I

Hand brake sWitch Charge warning lamp 161 7

1 I
BE314 Hand brake warning lamp 158 34 2
Fig BE 28 Circuit of hand broke Clock illumination lamp 158 4
3 2
warning Iystem

TROUB E DIAGNOSES AND CORRECTIONS

SPEEDOMETER

Condition Probable cause Coirective action

Speedometer pointer Loose speedometer cable union nut Retighten

and odometer do not
Broken speedometer cable Replace
operate
Damaged speedometer drive pinion gear Replace
Transmission side

Inoperative speedometer Replace

Unstable speedometer Improperly tightened or loose speedometer Retighten

pointer cable union nut

Faulty speedometer cable Replace

Inoperative speedometer Replace

Unusual sound occurs ExceSjvelybent twisted speedOmeter

or Replace or lubricate
in response to in cable inner wire lack of lubrication
or

in
crease driving speed
Inoperative speedometer Replace

8El8
 Body Electrical System

Condition Probable cause Corrective action

Inaccurate speedometer Inoperative speedometer Replace

indication

Inaccurate odometer Improperly meshed second and third gear Replace speedometer
worn gears
operation
Faulty feeding due to deformed odometer Replace speedometer
and pinion carrier

WATER TEMPERATURE AND FUEL GAUGES

Probable Corrective action

Condition cause

fuse
Both water temperature Burnt fuse Correct cause and replace
gauge and fuel gauge Replace water temperature gauge
Inoperative gauge voltage regulator
do not operate

water temperature gauge

Both water temperature Inoperative gauge voltage regulator Gauge Replace
gauge and fuel gauge pointer fluctuates excessively
indicate inaccurately Loose of poor connection Gauge pointer Correct connector contact
fluctuates slightly
Correct conn

Water temperature

gauge
loose terminal thermal transmitter or correct
Water temperature Faulty thermal transmitter or Replace
gauge does not connection terminal connection
thermal transmitter yellow white
operate When
wire is grounded gauge pointer fluctuates

wtater temperature gauge

Faulty water temperature gauge Replace
Open circuit

Gauge indicates only Faulty thermal transmitter Replace thermal transmitter

maximum Gauge pointer returns to original position
temperature when ignition switch is turned off

Faulty water temperature gauge Replace water temperature gauge

Gauge pointer indicates maximum tempera
ture even after ignition switch is turned off

Connect a usn resistance between ther

Water temperature Faulty water temperature gauge
mal transmitter yellow white wire and
gauge does not Faulty thermal transmitter
operate accurately ground When gauge indicates approximately
500C i220F gauge is serviceable

Correct gauge terminal contact

Loose or poor connection

BE 19
 Body Electrical System

Probable cause
Corrective action
Condition

Fuel gauge

unit loose unit terminal Replace tank unit or correct terminal con
Fuel gauge does not Faulty tank or

connection nection
operate
indicates half level when a 35U
pointer a

resistance is connected between tank unit

yellow wire and ground

Faulty fuel gauge Replace fuel gauge

Poor or loose cormection Conect connector terminal contact

Open circuit

unit Replace tank unit

Pointer indicates only Faulty tank
lowers below E mark when igni
F position pointer
tion switch Is turned off
Faulty fuel gauge Replace fuel gauge

pointer still indicates F position when

ignition switch is turned off

OIL PRESSURE AND CHARGE WARNING LAMPS

Condition Probable cause Corrective action

Oil pressure wamiug

lamp
Inoperative oil pressure switch or loose Replace switch OJ correct terminal connee
Lamp does not light
switch terminal connection tion
when ignition switch is

set to ON When switch yellow black wire is grounded

warning lamp lights
Burnt bulb or loose bulb Replace bulb or correct bulb socket

Open circuit

Lamp does not go out
while engine is being
operated
Lack of engine oil Check oil level and add oil as required
Oil pressure too low Inspect engine oil pressure system
Inoperative oil pressure switch Replace oil pressure switch

OIarge warning lamp

Burnt bulb loose bulb Replace bulb or correct bulb socket
Lamp does not light or

when ignition switch is Warning lamp does not light when voltage
set to ON regulator white red wire is grounded

Open circuit

Lamp does not go out Faulty charging system Inspect charging system
when engine is started

BE 20
 Body Electrical System

ELECTRICAL ACCESSORIES

CONTENTS

BE 21 HEATER CORE 8E 29
HORN
BE 29
DESCRIPTION BE 21 FAN MOTOR
BE 29
REMOVAL AND INSTALLATION BE 21 CONTROL ASSEMBLY
8E n 8E 29
IGNITION SWITCH ADJUSTMENT
BE 22 SPECIFICATIONS BE 30
REMOVAL AND INSTALLATION
BE 22 TACHOMETER BE 30
INSPECTION
BE 30
AND WASHER BE 23 REPLACEMENT
WINDSHIELD WIPER
BE 23 8UL8 REPLACEMENT 30
8E
REMOVAL AND INSTALLATION
8E 31
BE 23 SEAT 8ELT WARNING SYSTEM
INSPECTION
BE 31
BE 25 DESCRIPTION
RADIO
AND INSTALLATION BE 31
REMOVAL AND INSTALLATION BE 25 REMOVAL
LAMP BULB REPLACEMENT 8E 31
BE 25 WARNING
ADJUSTMENT
8E 31
BE 25 INSPECTION
CLOCK
REMOVAL BE 25 TROUBLE DIAGNOSES AND
BE 33
I NST ALLATION BE 26 CORRECTIONS
HORN 8E 33
HEATER BE 26
8E 34
DESCRIPTION BE 26 WINDSHIELD WIPER AND WASHER
BE 35
AIRFLOW BE 28 RADIO
HEATER UNIT ASSEMBLY BE 29

HORN the In the

REMOVAL AND
horn button to ground
other circuit terminal H the current INSTALLATION
DESCRIPTION
flow is supplied through the relay Horn
The horn circuit includes a horn contacts and horn Horn bracket
I Disconnect battery ground cable
relay Current from the battery flows serves as a grounding
When the horn button is 2 Disconnect horn wire at terminal
through the fusible link and fuse to pressed
on horn body
the horn relay terminal B where it is current from the battery energizes the
3 Remove horn retaining bolt
shunted by the two circuits In one solenoid As the solenoid is energized
the closed This 4 Install horn in the reverse se
circuit terminal S the current flow is relay contacts are

supplied through the solenoid and allows the current to flow to the horn quence of removal

Horn relay

The horn relay is installed on the

hoodIedge on the right side of the

Fusible link
engine compartment
I Disconnect battery ground cable

Qi
Fu
2 Disconnect horn relay wire con

nector at terminals on horn relay

att
Horn button 3 Remove retaining screws
H
4 Install horn relay in the reverse

sequence of removal

HIBQ
I
J
t
JJI
Qm L J
Hornrelay

BE859A

Fig BE 29 Circuit diagram of horn sy tem

BE 21
 Body Electrical System

1 Voltage regulator
2 Horn relay
3 Headlamp relay
4 Ignition relay California only
5 choke
Auto heater relay

6 Compressor relay
Au conditioner equipped model
7 Floor sensor relay California only
8 Inhibitor relay Automatic
tran5mission only

BE683B

Fig BE 30

Horn switch INSPECTION

The horn switch is integral with the

and dimmer switch as ContInuity test
turn signal
sembly Remove switch assembly as Test continuity through ignition
outlined in Turn Signal and Dimmer switch by using test lamp or ohm
Switch meter

BE861A

Fig BE 3 I Removing ignition switch

IGNITION SWITCH

REMOVAL AND
INSTALLATION

I Disconnect battery ground cable

C
from battery
2 Unscrew and remove escutcheon
R terminal
from the front of ignition switch
3 Withdraw ignition switch and

wiring assembly with spacer from 1G terminal

BE 3
KEY FOSITlON t
shell cover as shown in Figure TERMINAL 0 A

4 Disconnect wiring
from the back of ignition
connector

switch
ST terminal
A terminal F
F
C
C 1
B terminal B o
5 Replace ignition switch with a
IG

j
new one
ST
6 Connect ignition switch to wiring
connector A u u I
7 Position ignition switch to shell R
I
cover opening install and tighten BE6848
escutcheon and secure ignition switch
Fig BE 32 Ignition witch
to shell cover

8E 22
 Body Electrical System
Washer pump
WINDSHIELD WIPER AND WASHER
The washer pump and washer fluid
REMOVAL AND INSTALLATION
tank are integral parts and are serviced

as an assembly

Caution for windshield waBher

operation
I Be sure to use only washing solu
tion
Never mix or
use powder soap
detergent with solution
1 Windshield wiper blade 2 Do notoperate windshield washer
2 Windihield wiper arm
3
continuously more than 30 seconds or
Wiper motor
without washer fluid This often
4 Wiper motor bracket
5 Connecting rod causes improper windshield washer
6 Pivot
operation Normally windshield wash
should be 10 seconds
BE685B er operated or

less at one time

Fig BE 33 Wind hield wiper
I Disconnect two washer pump

Wiper linkage Wiper motor lead wires at connectors

2 Remove hose from washer pump
I Remove wiper blade and arm I Remove cowl
top grille and drain washer fluid
assembly from pivot 3 Remove stop ring that connects
Remove cowl
3 Pull out washer tank and motor
2 top grille See Sec wiper motor arm to connecting rod
tion BF 3 From under assembly from tank bracket
instrument panel tank
4 Install washer and motor
3 Remove two flange nuts retaining disconnect wiper motor harness at
assembly in the reverse sequence of
pivot wiper linka e to cowl top connector on wiper motor body
Remove stop ring that retains removal
4 4 Remove three retaining screws

connecting rod to wiper motor arm and pull out wiper motor forward Washer nozzele
5 Remove wiper motor linkage as 5 Install in the reverse
wiper motor
Access for washer nozzle removal is
sembly sequence of removal
obtained by disconnecting vinyl tube
6 Install wiper motor linkage in the
and removing washer nozzle retaining
reverse sequence of removal
screw from cowl top
When washer nozzle is installed or

when washer fluid is not sprayed

properly adjust nozzle direction by
bending nozzle tube so that washer
fluid is in range indicated in
sprayed
Figure BE 37

450 450
72 1772
r l
j217
Fig BE 36

BE 34 270
Ii 1 00 Li
L
1 3 94
L J
Fig Removing wiper linkage Wiper and washer switch to 63
1
7 Install wiper arm and blade Press in switch knob turn it
1
assembly in correct sweeping angle counterclockwise and pull it out of
Unit in
See Figure BE 35 for correct installing switch
nun
BE863A

dimensions 2 Unscrew escutcheon and remove Fif BE 37 Waaher nozzle adjuatment

escutcheon and spacer
3 Reach up from underneath instru INSPECTION

JCI r
ment panel
multiple connector
disconnect wiper switch

harness wiring assembly and

from instrument

remove I
Wiper motor

Disconnect wiring connector

25 mm 0 984 in
i BE862A
spacer and switch
4 Install new switch in the reverse
from wiper motor
2 Connect test lead between B ter
Fig BE 35 Wip J arm irutallation sequence of removal minal on motor ide and battery posi

BE 23
 Body Electrical System

tive terminal or B terminal and blue

red wire terminal in wiring connector

plug
3 To check wiper low speed opera
Blue white
tion connect L terminal to ground
with ground cable or connect L termi

nal to black wire terminal make sure

that wipers sweep at low speed

4 To check wiper high speed opera
tion connect ground cable to H termi

nal in the in 3
same manner as step
make sure that wipers sweep fast
5 During low speed operation con H tenninal
nect E terminal to ground and conlect
o @
P and L terminals with lead wire as

shown in Figure BE 38 At this time

make sure that auto stop mechanism
actuates to stop wiper blade at the

position C
specified
6 Wiper is in good condition if BE864A

above tests are made as indicated Fig BE 38 Wipftrmotor

Fusible link Wiper and washer switch

rt Battery
Cl e Ignition witch

Continuity test
Remove wiper switch from vehicle
as outlined in Wiper Switch
WQ5hcr motor Test continuity through wiper
Fuse box
I switch by using test lamp or ohm
O
Y meter
Dj
Wiper motor switch
Wiper

LR B terminal
y P tenninal
1
21
I L L terminal
b I

191 1
E terminal
w rmjrW

r II
H t

I r
J BE865A

Fig BE 39 Circuit diagram of windshield wiperwtUher sy te7tl

I SlOIT01 POSIl10N I
TERMINAL
I OFF 2

I 1 2

b
4 5
Switch position

ii
2 I
Z
I
Z I
I
I
I
10 I
I
I m
3 2

BE686B

Fig 40
BE Wi r witch
8E 24
 Body Electrical System

2 Remove radio holding nuts and

RADIO
washer from radio control shafts
REMOVAL AND 3 Remove radio bezel from the
INSTALLATION front of radio

4 From under instrument panel

Radio
disconnect antenna cable and lead

Removal
Pull radio knobs offradio control

shafts
wires
5

panel
power lead
Remove radio
and speaker
from
lead
instrument

t BEB67 A

Fig BE 42 Radio ant nna

ADJUSTMENT

Antenna trimmer

When a new radio receiver antenna

or antenna feeder is installed antenna

trimmer should be adjusted

Extend antenna completely
2 Tune in the weakest station be

tween 12 and 16 1 200 to 1 600KC

on dial
Noise may be generated but dis

regard it

3 Turn antenna trimmer to right

and left slowly and set it at a position
aE323 where receiving sensitivity is highest

Fig BE 41 Radio

Installation Installation

m
Fr behind instrument panel Remove rubber plugs that cover
position radio to instrument panel antenna mounting opening in front
2 Install radio bezel to the front of pillar when installing radio antenna
on vehicle that is not equipped with
radio
SE133
3 Install washers and nuts on radio radio

control shafts and them 2 Thread mounting stud of antenna Fig BE 43 Adjwting antenna trimmer
tighten secure

ly Then install control knobs clip into upper antenna mountins

4 Connect antenna cable and lead opening
wires power lead and speaker lead 3 Insert antenna cable into lower
antenna mounting opening and place
ant nna base in position CLOCK
4 Install antenna base retaining
screw
REMOVAL
Antenna and antenna cable
5 Route antenna cable along upper Remove battery cable
ground
dash panel to radio cluster lid
Removal 2 Remove following
6 Connect antenna cable at con instructions in I to 4 of Removal
From behind instrument steps
panel nector in Combination Meter
disconnect antenna cable at conne tor
3 Disconnect three wire connectors
2 Remove plug on antenna base and
of clock from combination meter
remove antenna base retaining screw
circuit and instrument harnes
3 Remove antenna and cable as printed
wiring
sembly from ont
fr pillar
4 Remove three s rews and remove
4 Unscrew antenna clip from front
clock from cluster lid
pillar if necessary

BE 25
 Body Electrical System

INSTALLATION

I Position clock to cluster lid and

install three screws

2 Connect three wire connectors of

clock each connection two to
to
combination meter printed circuit one

to instrument h ness wiring

3 Install cluster lid to instrument

panel
cable
4 Connect battery ground

Fig BE 44 Clock

HEATER

DESCRIPTION

7 Ventilator knob
1 Defroster nozzle L U
8 Heater core
2 Deflortcr duct LR
Heater 9 Conuol cable clip
3 control
4 10 Heater cock
Resistor
11 Defroster duct R H
5 Heater motor
12 Defroster nozzle R H
6 Heater case BE687B

Fig BE 45 Heater comtruction

BE 26
 Body Electrical System

Operation of the heater is control the heater unit and the other for the cock opens in proportion to the lever
led by two control levers located on operation of the fan motor When the setting and allow engine coolant to
the instrument panel and a hand op lever is in the OFF position the water flow into heater core

erated knob on the center of the cock is closed and the circulation of To control the fan motor opera
tion
heater unit engine coolant through the heater core push pull the lever knob Two
or

stops When the lever is slided to any speeds provided for the fan motor
The AIR LEVER controls the air
are

valve by its other position than OFF the water by using a three position switch
intake valve and or room

lever positions OFF DEFROST and

ROOM through the control cables

valve draws the fresh FUSE
UlwlHI
The air intake

outside air from the cowl top grille

IOfF
and supplies the air into the heater 1
unit The room valve is located at the

bottom of the heater unit The air

ON
SWITCH
t
coming through the air intake valve f u

opening is forced through the heater

rl
FUSIBlE HEATE R
core to the room valve where the air is
LINK SWITCH
distributed to the floor outlet and or

defroster outlets
position of the room
depending
valve
on the
is luJ
The VENT KNOB is

to the vent
directly linked
valve which provides fresh
air for the passenger Push the knob all

the way in to open the valve The fresh

BATTERY
G
HEATER MOTOR

ventilating air comes out of the heater

center outlet
H EATER UN IT
The TEMP lever is adual pur BE868A

is for regulating the

pose control one
flow of engine coolant flowing into Fig BE 46 Circuit diagram of heater

8E 27
 Body Electrical System

AIRFLOW

OFF VENTILATING

Vent valve

Push

Heater core

c n
IUl
J u

NlL
fAl

e u
c g

Push Pull

DEFROSTING VENTILATING HEATING

Pull
Push

tTIlsl
J
IU lI g

0 D WI IIt
L
I I

Pull Pull

DEFROSTING HEATING

IU ff
UIUI

I
n
HU J
C
n J CIl
C JIlT
11 Ill

Pull Pull
BE397

Fig BE 47 Airflow

8E 28
 Body Electrical System

2 Disconnect three lead wires from

HEATER UNIT ASSEMBLY
each connector plug
Removal 3 Remove radio bezel from the

front of radio following instructions

L Disconnect battery ground cable
in steps I to 3 in Removal of Radio
2 Drain engine coolant 4 Remove heater control knobs and
3 Remove defroster hoses heater bezel
4 Remove three cable retaining 5 Remove two retaining bolts and
clips and disconnect control cables
heater control assembly
from valves and water cock
6 Install control assembly in the
BE869A
5 Disconnect two fan motor lead
reverse sequence of removal When
wires from each connector Fig BE 48 Removing front cov r
connecting control cables to valves and
6 Disconnect two resistor lead wires
cock adjust control cable length as
from each connector S Withdraw heater core from heater
outlined in Adjustment
7 Disconnect water hoses from core
housing
and water cock

8 Remove three heater housing

bolts and dismount heater
mounting
unit from vehicle ADJUSTMENT

AIR lever

L Move AIR lever to the DEF

position
Installation 2 Open air intake valve and connect

control cable to air intake valve

1 Position heater unit under instru
BE870A control cable with cable
and install three heater
3 Clip re
ment panel BE 49 Removing heater
Fig core
taining clip
unit securing bolts
2 Install water hoses 6 Install heater core in the reverse
3 Position heater control cables to
sequence of removal
room valve air intake valve and water
cock

4 Adjust control cable length for

as outlined in
proper operation Adjust FAN MOTOR
ment
5 Connect fan motor wires and Removal and Installation
resistance wires to each connector
L Dismount heater unit assembly
plug
from vehicle as outlined in Removal of
6 Install defroster hoses
Heater Unit Assembly
7 Connect battery ground cable Fig BE 50 A iT intake valve
2 Remove spring clips
nine and
8 Fill cooling systeIT
disassemble heater housing
9 Run engine at 2 000 rpm with 4 Pull room valve upward and con
3 Remove fan from fan motor
AIR lever in the HOT position nect control cable to room valve
4 Remove fan motor retaining
Make sure that engine coolant is fIlled 5 Clip control cable with cable re
screws and fan motor
up to correct level
S Assemble heater housing and in taining clip
stall heater unit to vehicle in the
reverse sequence of removal as out
lined in Installation of Heater Unit

Assembly
HEATER CORE I
Removal and installation
CONTROL ASSEMBLY
L Drain engine coolant
2 Remove defroster hoses
Removal and Installation
3 Disconnect water hoses from inlet
and outlet pipes of heater core I Remove three cable retaining
BE871A
4 Remove four clips and front clips and disconnect control cables
Fig BE 51 Room valve
cover from valves and cock

BE 29
 Body Electrical System

TEMP lever 2 RG The red with green lead

stripe
wire must be connected to
the OFF
1 Move TEMP lever to
flat plate terminal at back of
position
combination meter
2 Connect control cable to the lever
3 B The black lead wire must be
of water ock when water cock lever is
connected to T
pulled forward fully closed shaped ter

cable water minal at back of combination

3 Install control on
meter
cock bracket with cable retaining clip
4 YR The yellow with red stripe
BE872A lead wire must be connected
Fig BE 52 Water cock to pole terminal at back of
combination meter

SPECIFICATIONS
6 Pass tachllmeter wires through
grommet on hood lock control wire
Extremely cold
Item General use and connect to negative terminal of
weather use
ignition coil
FAN MOTOR Notes
Rated power consumption 12V less than 36W 12V less than SSW a Fix grommet with an adhesive tape

Revolution rpm 3 600 2 SOO

or a sealing compound to prevent
water leakage
Fan dia mm in 110 433 110 33
4 b Attach tachometer wires to hood
lock control wire with an adhesive
tape
3 Disconnect four tachometer lead
TACHOMETER
wire connectors They are connected
to combination meter and tachometer
The tachometer is optional on
cable
model HL620 It is of BULB REPLACEMENT
an integral part 4 Remove three screws and then
the ignition system It counts the I Remove tachometer
remove tachometer from cluster lid as previously
pulses entering the ignition coil and
5 Install in described
sequence of re
reverse
indicates the number of engine revolu 2 Twist illumination bulh socket at
moval When connecting lead wire
tions
note the back of tachometer Bulb with socket
following
can then be easily removed
3 Remove bulb
REPLACEMENT 4 Install new bulb in reverse se
1 BW The black with white striped
I Remove battery ground cable lead wire must be connected quence of removal
2 Remve cluster lid following to identically colored ta Bulb wattage
instructions iri steps I to 4 of Removal chometer cable from Tachometer illumination
coming
in Combination Meter
engine compartment lamp 3 4W

BE965

Fig BE 53 Tachometer

BE 30
 Electrical System
Body
to the ON position the warning
SEAT BELT Warning lamp body
lamp comes on and the warning buz
WARNING SYSTEM zer sounds if the driver s seat belt is Warning lamp is located on instru
not fastened properly ment panel
DESCRIPTION
The seat belt warning system con I Remove cluster lid
sists of a driver s belt switch a warning 2 Disconnect lead wire at connee
Except Canada
buzzer a warning lamp and an igni tor
When the ignition switch is turned tion switch 3 Remove two screws retaining
to the ON position the warning lamp body
lamp comes on and remains on for 4 4 Installation is in the reverse se
8 seconds The buzzer
to warning quence of removal
REMOVAL AND
sounds for 4 to 8 seconds intermittent
INSTALLATION
ly if the driver s seat belt is not
fastened properly
Ignition switch
The seat belt warning system con
sists of a driver s belt switch a warning Refer to page BE 22 for Removal
buzzer a warning lamp a timer unit and Installation
and an ignition switch WARNING LAMP BULB
Timer unit REPLACEMENT
For Canada
Timer unit is fIXed on a reinforce
I Remove cluster lid
When the switch is turned ment behind glove box
ignition 2 Twist lamp socket
warning
Socket with bulb can then be taken
out
3 Pick up bulb from socket
4 Install new bulb in the reverse

sequence of removal

Bulb wattage
Seat belt warning lamp I 7W

INSPECTION

Warning buzzer

Apply 12V direct current between

BE282B
BE688B
CD and @ and check whether buzzer
Fig BE 54 Timer unit
sounds or not

I Disconnect battery ground cable The buzzer must sound when CD

2 Remove glove box and @ are connected to power
circuit See Figure BE 55 for
3 Disconnect timer unit connector warning
4 Remove two screws retaining buzzer
timer unit on reinforcement Timer

unit can then be taken out Note Make sure that negative
S Installation is in the reverse se terminal of power circuit is always
connected to @ terminal
quence of removal

Warning buzzer Timer unit

Turn the ON
Warning buzzer is fIxed on a re BE967A ignition key to

inforcement behind glove box Fig BE 55 Warning buzzer position The voltage between @ and
Refer to the preceding timer unit ground must be 12V for 4 to 8
for Removal and Installation Driver s seat belt switch seconds and then go out See Figures
BE 54 and BE 56
I Remove seat belt ecuring bolt
2 Disconnect belt switch lead wire Belt switch
at connector
3 Seat belt can then be taken out Test continuity between two lead
4 Installation is in the reverse se wires from seat belt switch with ohm

quence ofremoval meter or test lamp

BE 31
 Body Electrical System

Circuit diagram of seat belt warning system

Non California modela except for Canada

FUSE
FUSIBLE LINK lOA

p c

DRIVER S
o @ BELT SWITCH
BATTERY
@I I@
9
TIMER

f
IGNITION SWITCH UNIT
I

WARNING fS
BUZZER
LAMP
2
l

California modela

IGNITION RELAY
FUSIBLE LINK FUSE
lOA
F 9
lC 1
1

ORIVE R S
BELT SWITCH
BATTERY

f IGNITION SWITCH
9
WARNING r
i BUZZER
LAMP
J
2
I

Canada modela

DRIVER S
BELT SWITCH
LINK FUSE
FUSIBLE
lOA
aP c

9
o
BATTERY
N WARNING fS BUZZER

Cf
LAMP
J
2
I

f
IGN ITION SWITCH

BE689B

Fig BE 56 Circuit diagram of seat belt warning system

BE 32
 Body Electrical System

TROUBLE DIAGNOSES AND CORRECTIONS

HORN

Condition Probable cause Corrective action

Horn does not Discharged battery Recharge or replace battery

operate Measure specific gravity of electrolyte
Burnt fuse Correct cause and replace fuse

Faulty horn button contact Repair horn button

Horn sounds when horn relay terminal s is

grounded
Inoperative horn relay Replace horn relay
Horn sounds when B and H horn relay
tenninals are connected with a test lead

Damaged horn or loose horn terminal con Correct horn te inal onnection or
replace
nection horn

Horn sounds Short circuited horn button and or horn Repair horn button or its wiring
continuously button lead wire

When light green lead wire is disconnected

from horn relay terminal s horn stops to
sound

Inoperative horn relay Replace horn relay

Reduced volume Loose or poor connector contact Repair

and Fuse relay horn and or horn button
or tone quality
Damaged horn Replace

BE 33
 Body Electrical System

WINDSHIELD WIPER AND WASHER

Condition Probable cause Corrective action

Windshield wiper Burnt fuse Correct cause and replace fuse

motor does not
Damaged motor Replace wiper motor
operate Check wiper motor as outlined in Inspec
tion

Loose connection Repair

Faulty wiper and washer switch Replace

Test continuity through switch as outlined
in Inspection

Open power circuit or ground circuit Repair

Wiper operating speed Damaged motor Replace motor

is too slow
Loose or poor connection Repair
Seized or rusted wiper linkage Lubricate or replace
Humming occurs on motor in wiper blade
operating cycle

Wiper blades stick on windshield glass Clean windshield glass and or replace wiper
Raise arm and operate wiper without load blade

Wiper speed cannot Faulty wiper switch Replace

be changed correctly
Damaged motor Replace

Remove and check

Wiper motor continues Faulty auto stop operation auto stop device cover

to run after switch relay contacts

is turned off or wiper Clean dirty contacts or repair relay plate

blades do not return bending if necessary
to correct position Poor connection Repair

Faulty switch Replace

BE 34
 Body Electrical System

RADIO

Noise prevention
Position vehicle in an open area away from steel buildings run engine extend antenna to its maximum length set volume
control to maximum and set dial at a medium point without catching broadcasting wave

Condition Probable cause Corrective action

Ignition system
Noise occurs when engine is op High tension wire Install new high tension wire

erated

Ignition coil Install 0

a 51lF capacitor to primary side
terminal of ignition coil

Note Be careful not to install capacitor to

secondary or primary breaker side other

wise engine becomes improper

Install bond strap

Distributor Secure contact of carbon electric and

pole
rotor

Eliminate sharp tip on rotor pole or cap pole

by scrubbing with a screwdriver

Check stagger between rotor and stator

Charging system
Sound of alternating current pre Alternator Install a 0 51lF capacitor to charging termi

sents nalA

Note Do not use a larger capacitor

If capacitor is installed to terminal F
alternator coil will be damaged

When accelerator is Install 0 to IGN terminal

pedal depressed Regulator a 51lF capacitor
or released noise presents of voltage regulator

Supplement equipment
When engine starts noise presents Operative noise of water tem Install O IIlF capacitor between terminal and
Noise still presents even after perature and fuel gauges ground wire
stop
ping engine If
Note a capacitor having a larger capacity
is used indication of gauge will be de
viated

Notes b Cut lead wire as short as possible securely

a Be sure to locate capacitor as close c Ground wire should be attached on e Carefully identify IN

as to noise source and connect in the body completely or OUT mark

parallel d Make installation and connection

35
BE
 i
to o Q m r0 C 1 Ql CIl Il l3

@ @
D v

only
models
H
L
Californa C a l i f o r n a models
lamp
distrbuo resi tor only
2
B

type
L

lamp olenoid and

California
Non

conetr marker combinat

U
L

Low High D
cut
tcrminal only coil coil models
check headl mp block igniton condesr igniton Californa
D

sido front horn horn C

only models
B

To To To To To To To To To To To

30 3t 32 33 34 3S 36 37 38 39 40

only

n
R
models California
Non

2 lamp 2
n
1 1

type type
solenid
R

No California
Non
type
link harnes c o m b i n a
H
R

t
lamp
marker
B
R
transmiter D
cut solen id
heater
only cut choke
R
L

batery fusible engine altern o headlmp headlmp ground thermal distrbuo models fuel auto headl mp
D

front side C
8

To To To To To To To To To To To To To To To
9 1

IS 16 17 18 1 20 22 23 i4 is 26 27 28 29

only
Can da only modeb
for
models
I

j
lamp
relay except CCaliforna aliforna only
harnes amplifer heater counter model relay relay relay
T
only A

models switch compart en mot r relay senor lamp relay regulator cable
@
dri
e

tinstrumen ransitor ho d washer igniton floor inhbitor voltage

engine det cor
cauthokoe

To To Californ a To To To To
full Califunia
Non
head horn co ler
To To To To To To To To
1 2 3 4 S 67 89
10 II 12 13 14

OJ m e OJ

ll0
ll n g
t

CDm Cl
 l3
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only
18
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Non
l8

A
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Califotl a
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0 DEI 11
6

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on

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 OJ o Q m OQ CIl II D 3

I
HARNES
I
J

n ENGt E RO M
L TO

cf
w

AlT
AfT
solenid switch cable slinger cable
Kickdown Inhibtor
1
Oip
23 45678
Oip Engine Batery Engine Batery

ii bll l if 3i

m
 to o c m r0 O O Dl CJ lti 3

B
BY

solenid Transmi o switch Tranmiso switch Transmi o switch mot r harrnoesm Transmi o harrnoesm Transmi o
RB I r LB BY

RB
WB
RB 1 BW

@
RB@RB YB
kicdown Automaic rev se Manual inhbitor Automaic presu stare engine Manual engine Automaic
oil
RB 2 To fOT To for To for To To To for To for

YB
Automaic Transmi o
For fBYB
1 2 3 4 56 7

Manual
For Transmio RB BY

BY

stripe
stripe red
white with
gre n with gre n
CODE Black Brown Gre n Blue Light Red White Yelow Black Light
Transmio COL R B BI G L Lg R W Y BW LgR

Automaic
For

LB

Automaic Transmio
For
B

Transmio
Manual
For m

to l0c l s Q3

mW D
 Jo Q
o m CD n Ql en Ii3

1
1
I

I
lL
flll
I

J
peratuJe
ilumnato lamp
lamp floor
te
lamp Olodels
switch
A

only harnes
ilumnato ilumnato
S
or

r light warni g models U

timer
AfT

comparten
H
R
R
lamp
switch switch lighter control control and models control warni g harnes mot r switch harnes
G
E
I
j

II

wiper wiper cigar heater radio heater belt heater buz er belt indcator co ler wiptr door engine floor
1
U IT

L
To lamp To To To To To To
California
Non

Californa To To To To To To To To To
U I
19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

L
@
U@
rL Qj Can da
for

switch except onlAfTy rheosta

only instrumen
clock unit mode15 met r switch switch control
cable switch switch d i m e r
flasher lamp switch and conetr
or

brake mot r
T

Jamp switch unit

ro m light fuse tachomet r haz rd stop igniton haz rd check AMP CNonaliforna flasher kic down hand heater
combinat combinat ilumnato
M

tU
@
To To To To To To To To To To To To To To To To To To
1 2345 6789
10 11 11 13 14 IS 16 17 18

tot
lQ E S

mJ c
 CD o c m o O II fJl 13

IIY

engine
comparten harnes Lt
r

J
l YA To G wRfl

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ll

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LIB

GL

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only
T
A
B

LW

AL

LW

j onl y
Can da
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BG T
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@ California
Non
except
except G GR
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california
Non

GW
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GL R GW
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B BW

t4 LG
4 LR
LW 4D @
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ii b
l l l

CD m
 13
i rJl
tp o c TS O
l

H lt
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ll

y
H
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s
ou
lamp lamp
switch
combinato combinato market
@
haltl
@ harnesS sensor models belt unit marker amp
e
cens

1ii
Gt
instrUment co ler floorCalifornia driver tank side reat i

to To To 10
rear side

d8
0

0 fo To To 1
1 To 9

45
67 10

Gt QR 1 1

@
@
J

G
Q8
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RB
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 Body Electrical System

EMISSION WARNING SYSTEM

California models

CONTENTS

FLOOR TEMPERATURE WARNING WARNING LAMP 43

BE
SYSTEM California models BE 43 TROUBLE SHOOTING GUIDE 44
BE
DESCRIPTION 8E 43

FLOOR The warning also 4

lamp comes on Installation is in the reverse se

TEMPERATURE during operation of the starter motor quence of removaL

WARNING SYSTEM permitting inspection of the lamp s Bulb wattage

condition The lamp goes out after the
California models Floor temperature warning
engine starts
DESCRIPTION Refer to Section EC for details
lamp
17W
The floor temperature warning
system consists of a floor temperature

sensing switch installed on the vehicle WARNING LAMP Lamp body replacement
floor a floor temperature relay a
I Remove cluster lld
floor temperature warning Bulb replacement
lamp and 2 Disconnect lead wire at connee
harnesses
I Remove cluster lid tor
When the floor temperature rises to
2 Twist ng
warni lamp socket 3 Remove two screws retaining
an abnormal level the warning lamp Socket with bulb can then be taken lamp body
will come on to call the attention of out 4 Installation is in the reverse se
the driver
3 Pick up bulb from socket quence of removal

IGNITION RELAY
FUSIBLE LINK
I
P
I
i BATTERY
IGNITION
SWITCH
FLOOR l
SENSOR
I I
f
RELAY

I FLOOR SENSOR

WARNING ON FLOOR
LAMP TEMPERATURE
LOW
OFF FLOOR
TEMPERATURE
HIGH
7

BE697B

Fig BE 64 Circuit diagram of floor temperature warning system

43
BE
 Body Electrical System

TROUBLE SHOOTING GUIDE

Condition Probable cause Corrective action

Warning lamp does not Burnt or loose bulb Replace bulb or correct bulb socket
light in START posi
Faulty f1o r temperature relay Conduct continuity test and repair or reo
tion of ignition switch
place
Refer to Section EC

Loose connection or open circuit Check wiring and or repair if necessary

44
BE
 SE B V I C E 1

SECTION AC
M A N IuI A71i
I
W

i L
AIR
DATSUN PICK UP CONDITIONING
MODEL 620 SERIES

DESCRIPTION AC 2

TROUBLE DIAGNOSES AND

AC 19
CORRECTION

REMOVAL AND INSTALLATION AC 25

COMPRESSOR AC 33

SPECIAL SERVICE TOOLS AC 39

lmSSANJ

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Air Conditioning

DESCRIPTION

CONTENTS

OUTLINE OF AIR CONDITIONER AC 2 DESCRIPTION AC 5

REFRIGERATION SYSTEM AC3 MAIN RELAY AC 7

CONDENSER AC 3 FAN SWITCH AC 7

COMPRESSOR AC3 THERMO SWITCH AC 7

RECEIVER DRYER AC4 PRESSURE SWITCH AC 7

COOLING UNIT AC4 COMPRESSOR RELAY AC 7

ELECTRICAL CIRCUIT AC 5 F I C D SOLENOID VALVE AC 7

OUTLINE OF AIR
CONDITIONER ment through the three outlets at the the radiator in the engine compart
The air conditioner consists es instrument panel ment

sentially of a cooling unit compressor The compressor to compress The receiver

serves dryer serving as a

condenser receiver dryer and piping the vaporized refrigerant and is attach reservoir for storage of the liquid sent

The cooling unit secured with ed through the bracket to the loca by the condenser is located on the
three brackets is ttached to the tion occupied by the mechanical fuel
a
right in the engine compartment
location occupied by the package tray pump on the engine The piping consists of two flexible
in the dash panel The condenser cools the compres hoses and five copper tubes which
The cooled air from the duct is sed the
refrigerant vapor sent by com connect various components of the air
directed into the passenger compart pressor and is located on the front of conditioning system

I Cooling unit 5 Condenser

2 Expansion valve 6 Duct
3 Receiver dryer @ Flexible hose
4 Comressor @ Copper tube

AC724

Fig AC 1 Cooling system

AC 2
 Air Conditioning

used is the
REFRIGERATION perature inside the box will drop This pIe The liquid refrigerant
is because the alcohol is evaporated R 12 The heat inside the passenger
SYSTEM
If you were to paint your finger absorbing the heat from the air insidc compartment is absorbed by changing
with alcohol your finger would feel the box If the gaseous alcohol is the refrigerant from a liquid to a gas
collected and cooled with cold and then dissipated to the outside
cold This is because the liquid alcohol water by
takes heat away from
your finger it will be changed back into a liquid by changing the refrigerant from a gas
heat back to
while it evaporates Ifa quickly evapo absorption of its by the cold a
liquid
The refrigeration system is shown
rating liquid such as alcoliol is placed water

box the The cooler this princi in Figure AC 2

in a container inside a tem operates on

Low pressurt
V7777 High
J pressure
l gas
lLLLLL liquid
1
Low pressure
High pressure

I
I I
L2
gas
liquid
Inside air
Outside air

i
U Condenser

i
Compressor
li
11
J6G1
1 I
ilill
t1
I
J

i
LlJ
JJ l
u
r
7 t

qIrJ
It J
ttLJ L
U Blower motor
Evaporator
1 J

Receiver dryer f 9
d
lUr
I Expansion valve
AC458

h w
t Fig AC 2 Refrigeration cycle

CONDENSER
COMPRESSOR
The condenser is installed to the compressor condenses to a liquid by
compressor is installed to the
The
front of the radiator The heated and being cooled by air passing between
side of the engine and is driven by
compressed refrigerant gas from the the fins of the condenser
crank pulley through a belt The refrig

erant gas leaving the evaporator is

forced out to the condenser by com
1 GJ 7 pressor and the low pressure refrig
erant is to a high
compressed
gas
pressure and high temperature
vlmnn The driving force is transmitted by
an electrical clutch Because engine
iii plI rpm is very low during idling the
clutch will not transmit the driving
d1i 1il Ac459 force thus ensuring smooth engine

Fig AC 3 Condenser idling

AC3
 Air Conditioning

AC728

Fig A C 4 Compressor

RECEIVER DRYER

The receiver dryer serves the pur

pose of storing the liquid refrigerant To e
ran ion alve
The amount of the liquid refrigerant
flowing through the system varies with

the operating condition of the air

conditioner To be accurate the

receiver dryer stores excess amount of
refrigerant when the heat load is
lowered It also releases stored refriger
From condenser
FJi
c 5
ant when additional cooling is needed i

thus maintaining the optimum flow of

refrigerant within the system 1
The receiver dryer includes a

strainer and desiccant They have the Z

job of removing moisture and foreign i
c
3
particles as the refrigerant circulates
I
o

within the system o

The pressure switch is installed L

o
3
beside sight glass of receiver dryer The 7
R o

W
purpose of the switch is to stop the
compressor operation in the event an
I Prc surc switch
excessive system pressure builds
up on r 2 Sight glass
the high pressure lines
t J J
AC230
3
4
Strainer
De kcant

Fig AC 5 Receiver dryer

COOLING UNIT The liquid refrigerant evaporates in

the with
the aid of the
evaporator
The unit includes
cooling an evapo expansion valve Consequently the air
rator and an
expansion valve From drawn by the blower motor is cooled
the electrical point of view the in passing through the evaporator
cooling unit consists of a blower The expansion valve restricts the
motor a resistor for fan speed control liquid refrigerant as it passes through it
and some switches and relays and delivers sprayed refrigerant to the

evaporator for facilitating refrigerant

evaporation

4
AC
 Air Conditioning

The refrigerant within the thermo

bulb changes in pressure through the
super heat condition of vaporized re

frigerant gas which comes out of the

evaporator causing the deflection of

the diaphragm The lift of the ball
valve attached to the diaphragm is
changed by the deflection of the dia
phragm thus controlling the amount
of refrigerant passing the orifice Diaphragm
Orifice
Valve ball

AC729 4
Sensing bulb
Fig A C 6 Expansion value

000

1 Motor 8 Resistor
2 Fan 9 Main relay
3 Lower case 10 Thermo switch
4 Cooler duct II Cable clamp
5 Evaporator 12 Cable
6 Expansion valve 13 Harness

7 Upper case

AC725

Fig AC 7 Cooling unit

The following wiring diagram pro pressure switch and compressor relay
ELECTRICAL CIRCUIT
The blower motor fan speed is con
vides a complete description of the
whole circuit trolled by the fan switch and resistor
DESCRIPTION
When the ignition switch and the The solenoid valve is also activated
This in turn the fast idle control
The electrical circuit of the air fan switch are ON the main relay is causes

device F lC D to increase engine

conditioner consists of four switches activated causing battery power to

fan flow the fan motor and the speed when the vehicle is at rest with
two relays a solenoid valve a through
the engine ON
motor and a compressor magnetic magnetic clutch The magnetic clutch
clutch is activated by the thermo switch

AC 5
 Air Conditioning

J
c
BW
BW ELECTRIC

oB L FUEL PUMP

B m b@ tl
n
00

B ILLUMINATION
L I
GL CONTROL
RHEOSTAT

t
FROM LIGHT SWITCH
lL
GL1J 3
ILLUMINATION
LAMP

J
c
I I MAIN RELAY

FAN SWITCH

2
LW L
W

fZP I
rRL FUSE 15A
I

D CJ B
J
r
1 I
1 H
UE
THERMO SWITCH
I I
6 1 COMPRESSOR RELAY COLOR CODE
B Black

I BW

L
Black with white

Blue
stripe

i
LW Blue with white stripe
BA RY LR Blue with red stripe
W White

G Green

GL Green with blue stripe

@ IC PRESSU 1
RL Red with blue stripe

rlTCH IG

D J oc
c
G

t1 n
BW
m
I
F IC D SOLENOID f
L
COMPRESSOR LR
FUSE I IGNITION SWITCH
O 0
W J
ov 0
BW
OVJ

IIG

AC727

Fig A C B Wiring diagram of air conditioner system

AC 6
 Air Conditioning

MAIN RELAY COMPRESSOR RERAY

The main relay is located on the tacts in the relay are closed Then The compressor relay is attached to

cooling unit electrical power from the battery is the receiver dryer bracket on the right
When the ignition switch and fan the blower motor and the side of the engine compartment This
supplied to

switch are both turned on the COll electrical clutch for the compressor relay is actuated by the fan switch
thermo switch and pressure switch to
turn on and off the compressor

magnetic clutch

@
Dc
1 1 l@
cv
IDe
@ ID

@e
L J
AC465

Fig A C 9 Main relay

FAN SWITCH set by the control lever

temperature 1
it automatically turns off When the 2 AC731
The fan switch serving as a control off the
switch is turned magnetic
unit is installed on the center console Fig A C 11 Pressure switch and
clutch is turned off stopping the flow
compressor relay
This switch controls the blower motor
of refrigerant inside the cooling system
speed through the resistor It is also and increasing the cooling system tem

used as a main relay switch perature

When the air rises to the pre F I C D SOLENOID VALVE
determined temperature the thermo
switch automatically turns on In this The lC D
F solenoid valve is at

way the temperature of the air dis tached to the dash panel in the engine

charged from the cooling unit is auto compartment This valve supplies vacu

matically controlled as desired um to the F IC D diaphragm through

the vacuum hose connected to the

engine intake manifold when the

engine is at idle and thecooling system

PRESSURE SWITCH
is ON thereby raising idle speed to the
The pressure switch is turned off
predetermined rpm 800
when refrigerant pressure in the
cooling system rises to an abnormally
Fig AC I0 Fan switch high level 28 kg cm2 398 psi This IW
r
in turn turns off the compressor e
THERMO SWITCH magnetic clutch actuating the com
pressor relay and gradually decreasing
s
The thermo switch is located on the pressure in the cooling system When
upper side of the cooling unit and is the pressure drops to or below 24
I
controlled by the cable and the con kg cm2 341 psi the pressure switch
trollever attached to the console box again turns on
It is so designed that when the air Thus cooling system refrigerant 1
AC132
passing through the evaporator core is pressure is automatically maintained at
cooled down to the predetermined the proper value at all times Fig AC 12 F l C D solenoid value

AC 7
 Air Conditioning

GENERAL SERVICE

CONTENTS

REFRIGERAiH R 12 AC 8 EVACUATING SYSTEM AC12

COMPRESSOR OIL AC 8 CHARGING REFRIGERANT AC 13
MAINTENANCE AC 8 CHECKING FOR LEAKS AC15
PERIODIC MAINTENANCE AND HALIDE LEAK DETECTOR AC15
SEASON IN INSPECTION AC 8 ELECTRIC LEAK DETECTOR AC16
GENERAL SERVICE INSTRUCTION AC 8 REFRIGERANT LEVEL CHECK AC 16
SAFETY PRECAUTIONS AC 9 SIGHT GLASS AC16
EV ACUATlNG AND CHARGING SYSTEM AC 9 PERFORMANCE TEST AC 17
HANDLING MANIFOLD GAUGE AC 9 COMPRESSOR OIL LEVEL CHECK AC17

HANDLING SERVICE VALVE AC10 PERFORMANCE TEST AC 17

HANDLING CAN TAP AC 11 REFRIGERANT LEAKS AC18
DISCHARGING SYSTEM AC 12

REFRIGERANT R 12 MAINTENANCE refrigerant leakage by periodically

The refrigerant used in the air checking for refrigerant gas leak even
PERIODIC MAINTENANCE
out of season
conditioner is generally called Re AND SEASON IN
2 Turn the
frigerant 12 R 12 No other refrig compressor for 10
INSPECTION minutes at least once a month by
erant than the above refrigerant should
Both periodic maintenance and running the engine at 1 500 rpm
be used
season in inspection are most essential
This refrigerant is usually available
to enable the air conditioner to
in a small can or a cylinder In either give
it is
full performance c ENERAL SERVICE
case liquefied under high pressure
in the container
Perform the following checks INSTRUCTION
Start engine and check refrigerant The servicing of the air conditioner
Refrigerant evaporates easily has a
level through sight glass receiver should be carried out
low evaporation point and moreover on
only by well
dryer For details refer to relative trained servicemen This de
since the latent heat of the refrigerant chapter
is it can abSorb a topics under Refrigerant Level scribes essential points of servicing
large large amount
of heat Check
wherr e vaporating Extreme Jf amount of dirt and sand
2 Check the entire
a Jarge
care must be exercised when handling sysiein
for sign
enter the will be
system they
of refrigerant leaks Refer to relative
the refrigerant carried with refrigerant and may
topics under Checking for Leaks
clog the system or scratch rotating
and Refrigerant Leaks
parts This points out the need for
COMPRESSOR OIL If any trace of oil is noted at and
care in servicing the system That is
around connection fittings it is a sure
The SUNISO 5GS or SUNISO disconnecting joints should be
indication that refrigerant is leaking
351 should be used as refrigeration carried out in a dean place
This condition can be corrected
lubricant easily Water should not be allowed to get
Mixing of the two is allowable by retightening the joints If any joint
inside the system The refrigerant
on line is
The refrigeration lubricant should suspected of small amount of does mix with water
not readily
be used to assure the successful com
leakage use a leak detector to locate
However the presence of even a

pressor operation Use of oils other leaking points

minute amount of water will cause
3 Check compressor drive belts for
than recommended or mixing of the chemical reaction at
a high tem
oil with other oils would cause
proper deflection
perature which will in turn produce
chemical reaction or lead to lowered acid Since
Season off hydrochloric HCl
viscosity or deficient lubrication acid is highly
hydrochloric corro
The oil absorbs moisture as it con Observe the following maintenance sive to metals the aluminum and
tacts the air This points out the need tips to allow the air conditioner to will become
copper piping etc
for not to expose it
care to atmos operate normally in the next season corroded and the refrigeration
phere for an extended period of time I Keep the entire system free from system will become clogged

8
AC
 Air Conditioning
Water in the system will ice the may be the cause of gas leakage dent training Therefore it is of first

orifice when the high pressure re Before connecting pipes be sure to importance that any other personnel
frigerant changed to low pressure
is give coating of compressor oil to the than a well trained serviceman should
not be allowed to handle the refrig
refrigerant by expansion valve etc sea ting surfaces
and will obstruct the erant
refrigerant
flow

SAFETY
The following items are general PRECAUTIONS EVACUATING AND
instructions to be closely observed in
I Since direct contact of the liquid CHARGING SYSTEM
servicing the system
refrigerant with your skin will cause During servicing use caution to
I When
system line is discon
a
frostbite always be careful when keep air from getting into refrigerant
nected plug the opening immediately
handling the refrigerant Wear gloves When air enters the system all refriger
This is especially necessary to prevent
around service ant must be evacuated from
moisture condensation from forming
or wrap a piece of cloth system
valve to protect your fingers against prior to charging new refrigerant Air
in the line and to keep out dirt and
in has the following delete
dust It is also necessary the frostbite by refrigerant If any of the refrigerant
keep
to
rious effects
line at and above surrounding air refrigerant should get into your eyes
when charging the refrigerant I Since the condensation tempera
temperatures times at all When con splash
ture of the air is extremely low the air
your eyes with cool water to raise the
necting system lines do not attempt will not be condensed when
to remove the plug from the opening temperature gradually Apply a protec refrigerant
tive film to the eye to avoid infection gas is condensed in the condenser and
until ready for immediate use
the air will thus remain in gaseous
2 Do not rub your eyes Consult an eye
Always keep the working place
form Consequently the effective
clean and dry and free from dirt and specialist Always wear goggles or
thermal transmission area of condenser
dust Wipe water off with a clean glasses to protect your eyes when
for refrigerant gas will be red uced and
cloth working around the system Should
be condensed will be
refrigerant strikes your body splash refrigerant gas to
3 Have all necessary tools in pre
red ueed The pressure rise will become
on cool water and apply a protective
paration beforehand and have tools
film proportional to the volume of the air
clean and dry
in system
2 The
4 The compressor oil will easily refrigerant service container
2 When air and refrigerant are
absorb moisture when exposed to air has a safe strength However if han
mixed in system a chemical reaction
dled incorrectiy it wili explode
Immediateiy close the opening of the
Therefore will be produced and hydrochloric
container after use It is also necessary always follow the instruc
tions the label In acid which will adversely affect the
to observe the following notes
on
particular never

aluminum iron and other

stpre it in a hot location above S20C copper

l250F drop it from materials in system may be generated

or a high
height
3 The
Notes refrigerant gas is odorless and
colorless and breathing may become
a The oil should not be transfused
difficult due to the lack of oxygen HANDLING MANIFOLD
from a container into another as
GAUGE
the failure will
Since the refrigerant gas is heavier than
possibly cause mois
air and will lay close to the floor be The pressure at the high and low
ture to mix with the oil

b The used oil should not be returned especially careful when handling it in sides of system should be measured
small confined spaces when evacuating and charging refrig
into a container
4 The refrigerant itself is nonflam erant and when diagnosing trouble in
c The oil should not be used if its
mable However a toxic gas the system The manifold gauge is used
state of preservation is not clear phosgene
gas is produced when it contacts fire for these purposes A manifold gauge
enough
and is therefore has two pressure gauges a low pressure
special care required
5 When connecting or disconnect
when checking for leaks in the system gauge and a high pressure gauge These
ing pipes from the refrigeration sys with a halide torch gauges are connected to the high and
tem use two wrenches One wrench is 5 Do the sys low side service valves of system
not steam clean on

used for holding the fixing nut in place hoses

tern especially condenser since exces through flexible charging The
while the other for turning the mating construction of manifold is
sively high pressure will build up in the gauge
flare nut Failure to do so may result shown in AC 13
system resulting in explosion of the Figure
in a twisted tube or may damage system When valve stem is fully screwed
connection
the valve is front seated and valve path
6 Also use care not to give scratches The above precautions are essential and the center path are blocked When
to the seating surface at connections in of Refrigerant l 2 and valve stem is backed off the
handling paths are

A small scratch on the seating surface their strict observation requires suffi opened

AC 9
 Air Conditioning

Low pressure gauge

Compound pres lIrt
gaug High ure
rHe g Uge

c 7 I

Back se ted Front seated

Full counter
clockwise
J Full clockwise

Ji
r gL r
rr1
rnFW
g
low side

rvicc valve
To vacuum

refrigerant
t
2
pump
can
OI To high

service va
ide

lve
AC243

Fig AC 13 Manifold gauge

Connection to service valve HANDLING SERVICE VALVE 2 Check valve will be half opened
during connection and disconnection
An automatic check valve is built
I Fully close both valves of mani of hoses and
into valve When this valve charging refrigerant will
fold gauge Connect high and low service
be forcefully discharged Therefore
hoses to manifold presses against the connection fitting
pressure charging connect and disconnect charging hoses
that is when charging hose is con
gauge quickly while pressing flare nut of
nected to service valve the valve is
2 Remove caps from service valves charging hose against service valve
open When charging hose is discon
Connect high and low pressure charg
nected the valve is closed automatical

To
ing hoses to service valves in system the Caution Work with fingers protected
ly Always observe following usage
The refrigerant gas wili be discharged with cloth against frostbite by re
since check valve is open when precautions
frigerant
pressing charging hose onto service install valve after
Always cap
valve service valve
3 Since close contact between the
using
thread of valve eap and the thread of
3 Next loosen the connection fit When high speed opera tion is per
servicevalve will prevent gas leakage
ting of charging hose at manifold formed without valve cap a negative
keep these sections clean and free of
build up at the
gauge side for 2 to 3 seconds
to
purge pressure will gradually
air inside charging hose by the side of system and air scratches and damage
any low pressure
addition dirt and 4 Since packing of charging hose
pressurized gas in system may be sucked in In

enter the valve result will be lost during long use always
dust will easily
the check packing prior to installing charg
ing in foreign matter entering
system ing hose J

Disconnedion from
service val v
17
mani
I Fully close both valves of
fold gauge
t
2 Disconnect two charging hoses 1
from service valves At this time the 1
L
gas will be discharged until check valve 5V t Cap
is closed Therefore disconnect hose
2 Service valve
quickly

Caution Work with fingers

with cloth against
protected
frostbite by re
j Close Open
3 Charging hose

AC733

AC 14 Service oolve
Fig
fant
l
fri
AC l0
 Air Conditioning

HANDLING CAN TAP terclockwise so that the needle is

A wide variety of can taps are pulled up

3 Attach to
available The following procedures
can tap refrigerant can

apply to
conventional can taps firmly
4 Turn handle
For the correct usage refer to the can tap fully clock
manufacturer s instructions wise to make a hole in refrigerant
can

5 Turn the handle

b fully counter

Caution Use can tap of good quality clockwise to raise the needle
r r Refriger
ant gas will
flow up to the center
AC734
I Connect charging hose to the fitting of manifold gauge

Fig A C 15 Service value 6 Loosen the connection a t the

center fitting of manifold gauge At
this time confirm that both stems are
center fitting of manifold gauge for a

turned in front seated few seconds purge air inside

to charg
fully
ing hose See Figure AC 16
2 Turn can tap handle fully coun

docK wise Counterclockwise

n
s

1 Can tap handle

2 hose
Charging
r 3 Needle
@ 4 Refrigeran t can

AC246

A rn

Purging air
n
R I2

AC247

Fig AC 16 Can tap and pwging air

q

AC
 Air Conditioning

DISCHARGING SYSTEM EVACUATING SYSTEM b The rate of ascension of the low

less than
1 Connect and low pressure pressure gauge should be
The pressurized refrigerant gas Ul high
2S mm Hg I in Hg in five min
side system must be discharged to a charging hoses of manifold gauge to
utes
pressure approaching atmospheric their respective service valves of sys

pressure prior to evacuating refrigerant

tern and d ischarge refrigerant from

inside system This operation should system Refer Discharge System

to

2 When refrigerant has been dis

be made to permit safe re oval when
replacing system components charged to a pressure approaching at the
If the pressure rises or specified
I Close high and low pressure mospheric pressure connect center be obtained
negative pressure can not

valves of manifold gauge fully charging hose to a vacuum pump there is a leak in the system In this
2 Connect two charging hoses of 3 Close both valves of manifold
case immediately charge system with
gauge fully Then start
pump vacuum
manifold gauge to their respective refrigerant and repair the leak de
4 Open low pressure valve and suck
service valves scribed in the following
3 both manifold gauge valves old refrigerant from ystem See Confirm that both valves of
Open I
slightly and slowly discharge refriger Figure AC 18 manifold gauge are fully closed and
S When low pressure gauge reading hose
ant from system See Figure AC 17 then disconnect center charging
has reached to approximately 500 from vacuum pump
mm Hg 20 in Hg slowly open high 2 Connect center hose to can tap
pressure valve See Figure AC 19 of Attach
Note Do not allow refrigerant to rush
in place vacuum pump
6 When pressure inside system has refrigerant can to can tap and pass
out Otherwise compressor oil will
dropped to 710 mm Hg 28 in Hg refrigerant to manifold gauge
be discharged along with re
fully close both of valves of manifold 3 Loosen the connection of center
frigerant
and stop Let
gauge vacuum pump fitting of manifold gauge to
purge air
stand it for 5 to 10 minutes in this from center hose
state and confirm that the reading 4 low pressure valve of mani
Open
does not rise fold gauge and charge refrigerant into

Notes system After one can about 0 4 kg I

a The low pressure gauge reads lower Ib of refrigerant has been charged
into system close low pressure valve
by 2S mm Hg I in Hg per a 300 m
5 Check for refrigerant leakage
1 000 ft elevation Perform evacu
the with a leak detector Repair any leak
ation according to following
table ages found Refer to Checking for
Leaks and Refrigerant Leaks
6 Confirm that both valves of
manifold gauge are fully closed and
then change center charging hose from
Elevation Vacuum of system
can tap to vacuum pump
m ft mm Hg in Hg 7 Open high and low pressure
valves and operate to
vacuum pump
0 0 710 28
suck refrigerant from system When
300 27
I 000 68S the pressure in system has dropped to
600 2 000 660 26 710 mm Hg 28 in Hg fully close
both valves of manifold gauge
900 3 000 635 25
7 The above
operation completes
Note Values show readings of the evacuation of
system Next charge
AC735
low pressure gauge refrigerant Refer to Charging Refrig
Fig AC 17 Discharging system erant

Caution Protect fingers with cloth

against frostbite by refrigerant
when connecting the charging hose
to the service valve or disconnecting

it therefrom

AC 12
 Air Conditioning

1
j
J
J jJ
lJ i

R
j

I1
J
g j

AC736
ru AC737

Fig A C l8 Euacuating system First step Fig AC 19 Euacuatingsystem Second step

CHARGING REFRIGERANT

I Install manifold gauge to system

Refer to
Handling Manifold

Gauge
Notes
a Be sure to purge air from the high
and low pressure charging hoses
b If air is mixed with refrigerant gas
in system evacuation of system
should be performed Refer to

Evacuating System

2 Attach center of
charging hose

manifold gauge refrigerant can

to
AC738
through can tap Break seal of refriger
ant can to allow refrigerant to enter
Fig AC 20 Charging refrigerant
manifold gauge Loosen charging hose
slow immerse refrigerant can in
at the center fitting of manifold gauge
water heated to a temperature of
and air from inside charging
purge
hose Refer Handling Can Tap
to
about 400C l040F However
note that this is dangerous when
3 Open high and low pressure
water is hot See Figure AC 21
valves of manifold gauge and charge
R
refrigerant into system See Figure

121
Cautions Immerse in water
AC 20
a Under any circumstances the refrig heated to about

erant can must not be warmed in 400C 1040F

Note that hot
water heated to a temperature of
water is
over 520C l2S0F
dangerous
AC252
Notes b A blow torch or stove must never

a When refrigerant charging speed is be used to warm up the can Fit AC 21 Heating refrigerant

AC13
 Air Conditioning
When is
b When low pressure 3 he 5 refrigerant can empty
charging hquefied refrigerant
After completion of charging the fully close both Ives of manifold
into the system lith the can turned
be turn gauge and replace refrigerant can with
upside down to reduce charging compressor should always
ed Several times manually See a new one
time charge it only through high
valve but not through Figure AC 22 Before opening manifold gauge
pressure
valve to charge refrigerant from new
can be sure to purge air from inside
charging hose

6 Charge the specified amount of

refrigerant into system by weighing
charged refrigerant with scale Over
charging will cause discharge pressure
to rise

UL Q

v1ifl j

Fig A C 22 ClUJrging refrigerant First step

AC739

4 If refrigerant charging speed slows back into refrigerant can and can
AC255
down charge it while Iunning the may explode
of charging After Measure the amount of charged
compressor for ease 2 Run the engine at idling speeds refrigerant with a scale
having taken the steps up to 3 above Make a note of the amount charged
about 1 500 rpm
proceed with charging in the following Set the control
from can
3 temperature
order
lever and fan switch at maximum
I Shut off high pressure valve of Fig AC 24 Measuring refrigerant
cool and maximum speed respectively
manifold gauge
4 Charge refrigerant while con
trolling low pressure gauge reading at
Caution Never charge refrigerant 8 kgfcm2 40 psi or less by turning
2
in out low pressure valve of mani Refrigerant capacity
through high pressure side of sys
or

tem since this will force refrigerant fold gauge See Figure AC 23

Unit lb
kg

Refrigerant Minimum Maximum

R 12 0 7 15 0 9 2 0

Note The presence of bubbles in

sight glass of receiver dryer is an
unsuitable method of checking the
amount of refrigerant charged in
system The state of the bubbles in

sight glass should only be used for

checking whether the amount of
t charged refrigerant is small or not
The amount of charged refrigerant

AC740 can be correctly judged by means

of discharge pressure Refer to Re

Fig A C 23 Charging refrigerant Second step frigerant Level Check

AC 14
 Air Conditioning
7 After the specified amount of Refrigerant is a colorless odorless I Discharge refrigerant in one or

refrigerant has been charged into sys gas and leakage from system is diffi two seconds to ascertain that system
tem close manifold gauge valves Then cult to detect Accordingly the use of has a sufficient needed for
pressure
detach charging hoses from service a leak detector facilitates check for leak detection Charge
kg I with 04
valves of system Be install leaks Two methods of checking of
sure to are lb refrigerant if necessary
valve cap to service valve available one employs a halide leak 2 Light leak detector Adjust the
8 Confirm that there are no leaks in detector which burns propane gas or height of the ilame between flame
butane gas and the other is an electric
system by checking with a leak detec adjusting lines at the top and bottom
tor type leak detector of combustion tube A reactionplate
Refer to Checking for Leaks will immediately become red hot
3 Place the end of sampling tube
Note Conducting a performance test HALIDE LEAK DETECTOR near the point of the suspected leak in
prior to removing manifold gauge is Since the propane leak detector and
system
a good ice
sen operation Refer to butane leak detector are the same in
Performance Test Notes
respect to their operation this section
describes the operation of the propane a Since refrigerant gas is heavier than
air small leaks can b easily detect
leak detector
The copper screen is heated by the ed by placing sampling tube direct
CHECKING FOR ly below the check point
burning of propane Refrigerant gas
LEAKS decomposes to color the flame when it
b Suitable ventilation is required If
refrigerant is mixed with the
Conduct a leak test whenever leak contacts the heated screen The gas to gas

be checked is drawn into the sampling surrounding air leak detector will
age of refrigerant suspected and
is

when conducting service operations tube and sent out to the burner A always a
response and
indicate
detection of the actual leak will be
which are accompanied by disassembly refrigerant leak can clearly be detected
difficult
Dr loosening of connection fittings by variations in the color of the flame
c Never bold leak detector at an

angle
Cautions
a Never inhale the fumes produced
by combustion of refrigerant gas
since they are toxic
b Never use halide torch in a
place
where combustible or explosive gas
is present

4 The ilame will be almost colorless

when there is no refrigerant gas being

burned When there is a small refriger
ant gas leak the ilame will be green or

yellowgreen When refrigerant gas leak

age is large the ilame will be brilliant

blue or
purple Since the color of the
1 Copper reaction plate
2 Flame adjusting lines
ilame yellow when dust is
will be
3 Burner being burned
there is aging scale on
Or

4
Sampling tube copper reaction plate always keep the
AC010
5 Strainer strainer of sampling tube and reaction
6 Gas bomb
plate clean
7 Flame adjuster 5 Major check points

Fig A C 25 Checking for leak

I Compressor
Compressor shaft seal rotate the

compressor by hand
Oil filler plug
Butane type Flexible hose connections
Propane type
Rear cover and side cover gaskets
NO LEAK Greenish blue Pale blue Service valve
2 Condenser
SMALL LEAK Yellow Bright blue Condenser pipe fitting
LARGE LEAK Purple Vivid green Condenser inlet and outlet pipe
connections

AC 15

I
 Air Conditioning

3 Piping REFRIGERANT 2 Set temperature control lever to

maximum position
Flared section of high pressure and LEVEL CHECK
3 Set blower to maximum speed
low pressure flexible hose
connections 4 Check sight gla after the lapse
Pipe SIGHT GLASS
rvice valve of about five minutes Judge according
Sight glass provided at the top of
is to the following table
4 Evaporator housing receiver dryer One guide for whether
Jnlet and outlet pipe connections
there is enough refrigerant in system is
Expansionvalve given by observing refrigerant flow
glass However this
through sight
ELECTRIC LEAK DETECTOR
method is unsuitable for judging the
for the operational procedures amount of refrigerant The correct
refer to the instructions furnished with level
refrigerant can be judged by
each electric leak detector
measuring t e system pressures in ac

cordance with the procedures de

scribed Performance Test
I Start the engine and hold engine AC741

speed at 1 500 rpm Fig AC 26 Temperature control lever

Amount of
refrigerant Almost no reftigerant Insufficient Suitable Too much refri crant

Check item

Temperature of high pressure Almost no difference High pressure side is High pressure side is High pressure side is
and low pressure pipes between high pressure warOl and
low pressure hot and low pressure abnormally hot
and low pressure side side is fairly cold side is cold

temperature

The bubbles are seen Almost transparent No bubbles can be seen

State insightglass Bubbles flow continu
Bubbles will at intervals of 1 2 Bubbles may appear
ousty
seconds when engine speed is
a nd some
disappeu
mist raised and lowered
thing like will
now when rerrigeran
No clear difference exists between these two
is nearly gone
conditions

A A M
I I r I II I

AC258
AC256 AC257

Pressure of system High pressure side is Both pressures on high Both pressures on high Both pressures on high

abnormally loW and low preSure sides and low pressure sides and low pressure sides
are slightly low are normal are abnormally high

Repa ir Stop compressor and Check for gas leakage Discharge reftgerant
conduct an overall repair as required re from service valve of
check plenish and charge 11
10 pressure side
system

AC 16
 Air Condit onin
j

and high blower for 10 to 15 2 Open all the windows of the

Notes speed
minutes in order to return compressor vehicle fully However close the
a The bubbles seen through the sight
oil to doors
glass are influenced by the ambient compressor
2 3 Open the hood
temperature Since the bubbles are Stop the engine and discharge
hard to show up in comparatively refrigerant of system and then remove 4 Connect manifold gauge to high
from the vehicle of the
low temperatures below 200C 6S0 compressor and low side service valves
3 Remove compressor fIller plug Refer
F it is slightly
possible that a system to Handling Manifold
Drain compressor oil from compres Ga uge
larger amount of refrigerant would
sor oil sump and measure the amount
be filled if supplied according to 5 Set fan control lever to maxi
4 Compressor oil is satisfactory if
the sight glass Be sure to recheck mum
the following amount of oil remains in
the amount when it exceeds 200C 6 Set temperature control lever to
In higher temperature the the compressor
680F max cool position
bubbles are easy to show up Residual oil 7 Start the engine and hold engine
b When the screen in the receiver S5 to 128 gr 3 to 4 oz at 1 500 rpm
speed
dryer is clogged the bubbles will S After the air conditioner has been
5 Check the cleanliness of the oil If
appear even if the amount of refrig the oil contains chips or other foreign operated for about 10 minutes

erant is normal In this case the measure system pressures at high pres
material clean oil 5ump with new oil
of the receiver
outlet side pipe 6 Discard the used oil and fili with
sure discharge side and low pressure
becomes considerably cold side
dryer the same amount of new oil Add oil if suction
9 Measure the temperature of dis
found less than above amount
charge air at outlet grille
10 Measure the of
PERFORMANCE TEST temperature
capin
Check for the amount of refrigerant
11 Measure ambient temperature
in the system can be made by meas
and humidity one meter 3 ft away
uring pressure ondischarge side
from condenser front Be careful not
The correct amount of refrigerant is
to expose dry buib and wet bulb to
in the if pressure on the
system
direct sunlight
discharge side is within the specified
12 Check for any abnormalities by
range For details refer to Perform
ance Test described later comparing the test results with stand
ard pressure in Performance Chart
Overcharging will show up in higher
pressure on discharge side
Fig AC 27 Filler plug

COMPRESSOR OIL
LEVEL CHECK If compressor is inoperative due to
faulty compressor or heavy loss of
The oil used to lubricate compres
refrigerant remove compressor and
sor circulates into system from the oil Notes
repair as necessary Then pour oil up
sump while c9mpressor is operating a The pressure will change in the
to correct level and install on engine
The efore to correctly measure com followi g manner with changes in
After above steps have been complet
pressor oil the amount of oil flowing conditions
oil level drain oil to
ed recheck is dis
When speed low
to
system must be considered If a excessively high
blower
correct level if level is
considerable amount of leakage of charge pressure will drop
the leakage of When the relative humidity of in
refrigerant gas happens
compressor oil is also considered take air is low discharge pressure
There will be no compressor oil leak will drop
b The temperature will change in the
age from completely sealed system
a
PERFORMANCE TEST
When system operates under satisfying following manner with changes in
The cooling performance of the air
condition the oil level conditions
compressor
conditioner changes considerably with
check is unnecessary When the ambient air temperature
changes in surrounding conditions
When checking the level of com is low the outlet air temperature
must be using the
oil or when replacing any
Testing performed will become low
pressor This is used to
correct method test
component part of the system use the
whether system is operating cor reveals that there is any
following service procedure This fa judge If the test

rectly and can also be used as a guide abnormality in system pressure isolate
cilitates to return oil to compressor
in checking for problems the cause and repair by reference to
I Operate compressor at engine
in the the Trouble Diagnoses and Cor
idling speed 1 000 rpm or below I Park the vehicle indoors or

rections
with controls set for maximum cooling shade

AC 17
 Air Condition ing

REFRIGERANT
LEAKS
If leaks are noticeable leaky parts time receiver dryer must be replaced the fitting has been retightened dis
should be repaired Then system If leaks are slight and no air is present charge refrigerant from system discon
should be filled with refrigerant Do in system add refrigerant as necessary nect the fittings and check its seating
not operate compressor with refriger To detect leaks refer to relative face for damage Always replace even
ant level cessively low
e
topics under Checking for Leaks if damage is slight
If this caution is neglected a burnt Here is how leaks are stopped 3 Check compressor oil and add oil
compressor will result since heavy loss I Check torque on the connection if required
of refrigerant usually indicates heavy
fitting and if too loose tighten to the 4 Charge refrigerant and recheck
loss of compressor oil
proper torque Check for gas leakage for gas leaks If no leaks are found
If system has been with a leak detector
exposed to evacuate and charge system
atmosphere for an extended period of 2 If leakage continues even after

AC 18
 Air Conditioning

TROUBLE DIAGNOSES AND CORRECTION

CONTENTS

COOLING DIAGNOSES AC19 COMPRESSOR DIAGNOSES AC 22

AC 20 NOISE DIAGNOSES AC23

FUNCTION TEST
PERFORMANCE AC 20 BLOWER MOTOR DIAGNOSES AC24
STANDARD
PERFORMANCE TEST DIAGNOSES AC21

COOLING DIAGNOSES

INSUFFICIENT COOLING
I
I
Check amount of discharged air

j
No or insufficient discharged air
IfOK

1
Check sight glass for bubbles ChecK blower

I I
I I

Many bubbles I No or few bubbles

I If OK
I Blower stops

I I
Check refrigeration line for leakage Performance test Repair cooling Refer to Blower motor
Refer to performance unit diagnoses
Note If there are too many bubbles
test on the following
stop compressor and check for
leaks page

Then evacuate and recharge

system

IfOK lfleaks

Discharge the system Repair leaks and

Evacuate and recharge recharge

AC 19
 Air Conditioning

FUNCTION TEST
STANDARD PERFORMANCE TEMPERATURE

The air conditioner on the model

Intake In the cabin Discharged air Pressure
620 has the below performance char
in
acteristics when all systems are good 160C 61 OF 30C 37OF 12 kg cm2 170 psi
condition Compressor pressure is also
indicated below ISoC 64OF 50C 4IOF 13 kgcm2 185 psi
N

E 24 220C 72OF 70C 45OF 15 kg cm2 213 psi

23
j
22 270C SIOF 100C SOOF IS kg cm2 256 psi
21
20

19
Note 1 500 rpm
18 Engine
FAN 3 position
17
16 TEMP Cold Max
15
14
13
I
12

0 6 0
5 0
40

3 0
2 0

10

20 25 30 35 40 45

Temperature of outside air

REFRIGERANT PRESSURE

ENGINE 1 500 rpm

Pressure suction
FAN MAX 0
Temperature outside Pressure discharge
a
TEMP Fun Cotd

Oc 250C 77OF 18 kg cm2 256 psi 1 0 kg cm2 14 psi

35 u
Co 300C S6OF 15 kg cm2 213 psi 2 kg
1 cm2 17 psi
S

30 350C 95OF 13 kg cm2 IS5 psi 1 4 kg cm2 20 psi

25
400C J05OF J2 kg cm2 170 psi 16 kg cm2 21 psi

20

IS

20 15 10 5 0
Oc
air
Temperature of dischuge

AC 20
 Air Conditioning

PERFORMANCE TEST DIAGNOSES

Condition Probable cause Corrective action

Discharge air too warm

Both and suction pres Air mixed with refrigerant in Evacuate and charge system
a discharge
sure too high system

Overcharge of refrigerant Discharge some of refrigerant to

correct level

Loose fan belt or engine over Adjust fan belt or check cooling

heating system
Obstructed or dirty condenser fins Clean exterior surface with water

b Both and suction pres Insufficient refrigerant charge Add refrigerant

discharge
sure too low

c Discharge pressure too high and Over filling of compressor oil Drain oil and correct oil level
suction pressure too low Refer to Compressor oil level
check

d Suction pressure too high and Damaged compressor valve or pack Repair or replace compressor Refer
to Compressor
discharge pressure too low ing

Loose compressor drive belt Adjust

Clutch slippage Repair Refer to Compressor

Faulty expansion valve Reinstall sensing bulb correctly to

e Discharge pressure normal and
keep it tight to pipe
suction pressure too high
Replace

valve strainer Clean strainer

t Discharge pressure normal and Clogged expansion
luction pressure too low Water has frozen at expansion Evacuate and charge system
valve

Faulty expansion valve Replace

g Suction pressure normal and Faults of both a and h exist

discharge pressure too high

h Both discharge and suction pres Air leaks from engine com Correct sealing
sure normal partment
Air conditioning is operating
properly

Discharge air normal

or too cold

normal and Restricted air flow through evapo Clean evaporator fins
a Discharge pressure
suction pressure too low ratof

Slow blower motor speed Check and repair blower motor and

wiring

AC 21
 Air Conditioning

COMPRESSOR DIAGNOSES

I COMPRESSOR TROUBLE

Turn the compressor dutch wheel by hand

I

I j
If OK Will not turn

I
Apply 12V direct current to compressor clutch Internal problem in compressor cylinder
Then check clutch engagement Repair or
replace compressor
I

If OK
I Clutch does not
engage

I
Check voltage oflead wire for compressor on Clutch is damaged
cooler cable Repair or replace dutch assembly
I
I

IfOK No voltage

I
Internalproblem in compressor Check or repair wiring system for compressor
Repair or replace compressor clutch

AC 22
 Air Conditioning

NOISE DIAGNOSES

NOISY
I
I
I Set fan switch on

2 Change the engine rpm frequently

Detect the source of noise
I

From engine compartment From cabin unit

Cooling

j
Check the resonant sound when the engine rpm is
j
Blower motor makes noise

changed Replace or repair blower

I
I

No resonant sound
Resonant sound
Compressor itself makes noise

Repeat compressor clutch ON and OFF Retighten compressor bracket bolt

This checking can be performed by changing Ifpiping is resonating add clip
engine rpm while fan switch is set at ON

Noisy only when clutch is engaged Noisy when clutch is not engaged

I
Check drive belt for slackness Remove compressor belt then turn compressor

Check for loose compressor mounting bolts pulley by hand If noise is heard repair com

I pressor clutch
I

If OK If loose

Compressor itself makes noise

Retighten or adjust
Repair or replace compressor

Nl1
 Air Conditioning

BLOWER MOTOR DIAGNOSES

Blower motor inoperative

Check fuse
In fuse block 15AW
unit
Single fuse 15A at cooling
I
j
IfOK mown fuse

Check the continuity and offan switch Replace fuse

fitting
I

I j
If OK If damaged I
I
I
I
Connect fan switch to wiring harness Replace fan switch

2 Turn the ignition switch ON IG

3 Set fan switch at ON 1 2 or 3 position

Check the voltage for blower motor

Blue lead wire is poweI source
Blue wire with white stripe is for grounding
I

No voltage
I Voltage
I
I Replace main relay
Check the continuity and fitting of resistance on

cooling unit

I
Ifdamaged
I If OK

I I
resistance
Replace blower motor Replace

AC 24
 Air Conditioning

REMOVAL AND INSTALLATION

CONTENTS

COMPRESSOR AC 25 REMOVAL AND INSTALLATION AC29

REMOVAL AC25 INSPECTION AC29

INSTALLATION AC26 WIRING HARNESS AND COMPONENTS AC30

IDLER PULLEY AC 27 WIRING DIAGRAM AC30

FAN BELT TENSION ADJUSTMENT AC 27 MAINTENANCE AC31

REMOVAL AND INSTALLATION AC27 MAIN RELAY AC31

INSPECTION AC 27 COMPRESSOR RELAY AC31

COOLING UNIT AC27 FAN SWITCH AC31

REMOVAL AND INSTALLATION AC 27 RESISTOR FOR FAN SWITCH AC32

DISASSEMBLY AND ASSEMBLY AC 2B THERMO SWITCH AC32
INSPECTION AC 29 I
F D
C SOLENOID VALVE AC 32

RECEIVER DRYER AND PIPING AC 29

5 Remove flexible hose fixing plate

COMPRESSOR
and disconnect low and high pressure
REMOVAL flexible hoses from compressor

I Remove battery Notes Y 1

2 Disconnect compressor lead wire

at connector
a Use two wrenches when disconnect

ing pipe joints

L
3 Loosen idler pulley lock nut then b Plug flexible hose and compressor
adjusting bolt Remove compressor
joint openings immediately after
drive belt from compressor pulley disconnection to prevent entry of
dust moisture laden air etc
AC744

7 Remove four bolts securing com

pressor to its bracket Compressor and

attachment can now be detached as an
assembly

Notes

AC477 a There are a total of four bolts two

on upper side of bracket and two
Fig AC 28 Removing drive belt
on lower side of compreSsor
Loosen upper bolts and remove
Fig AC 29 Disconnecting ftexible
hoses from compressor lower bolts When removing upper
bolts securely hold compressor
4 Discharge system Refer to Dis with one hand
tube
charging System under General Service 6 Remove bolts securing fuel b When installing temporarily tighten
section to compressor attachment
upper bolts then tighten lower
bolts

AC 25
 Air Conditioning

R
C7
c
L 1 attachment
Compressor
2 Compressor
3 Compressor bracket

PJJ
4 AHernator

5 Idler pulley bracket

I
AC745
8
Fig AC 31 Removing compressor

INSTALLATION Tightening torque 6 Evacuate cooling system then re

a c J l i rp Flexible hose to compressor charge with

refrigerant Refer to
To install compressor reverse the
order of removal Observe the follow
dlt kg J
l
IQ Evacuating
l
and Charging System under
r

e trorf 1001 1 Tf es oriti ra Lbolts Gen efal ectioo

Servic
nhlJo vom R iI
f t
ing
fo
IbP
F
o15g J 7 Whenever
J
remoV compres r
in3
m
linpt J
Wheliqli
liiAniitg fiil l
o20 iil
f6i f be su t8 C6itiu tUa t st make
idie
sam
tiiel efuouiitITof b11 1fasitlult r J I i
mV 1rJ
witlil r aGket engine adjustril rit
and
adjwt beJf tension
used previously v d rnl 2
Dons 11 rt
16 1l 0
yv
r 1Y

Oil capacity new compressor 11 3 5 V No s 9

l11fd
h
r
910 1 v

owt llllt blj O

Hw
f
f 3
42 3U llif
Yl a For compressor diive belt and
s 013 5 rlT s I
u

tOoling fan belt tensions refer to

boc 19 bB1rllo y j
111
0

e l bffik kuanM
bi2 qqll
mpdi x
no

of 3 D not remove IJgs orflexibie 1 Ildlet Yt WI

j cS t q

1i6 e before ready for immediate use b Cheok refrigerant leakage if neces
Jli oln L
il 1Ilf i Orb
m fler ot oldm 4l di
F n Cheo undeF r n al iturn sary correct
Wheniiinstallingccomptess
1 aQ t31
Jt
r1tIU HClJI1f t JIVU irlUI
it serWfiPtiffies SlOt

1o ifm qt
ft 31U
VI S ltlod
5 When connecting flexible hose to
dO wl Twl
bnM UfO l W I rt f r2
coat of Hfresh
kldf ti WIf nl lL lil g ncn d 9mPr
JU
ssor
UI apD t 2JIUU
l1Il
v a
r
uOHltl fl iVl 2 i l n U l bnu 1 1Z2 gf ign rb
oressor
l9Wul

necessary
CJiJi
fb
M
re
l
i
et
1Ttio
Ighten
botts if
illpuntinl
fI
qqlJ I l l
compressor

joints
1n
1
0 to
1l11 fs
JJ
aHn lurfaces of
f
J PJU Ht UlUJ jJ nojJ 2

I d
210

AC26
 Air Conditioning
and 0 47 in
IDLER PULLEY 32
0 when depressed
with thumb pressure midway between
FAN BELT TENSION
the crankshaft and compressor pulleys
ADJUSTMENT
If necessary turn adjusting bolt to
The standard compressor drive belt move idler pulley up or down until
tension is between 8 and 12 mm belt tension is correct

AC766

Fig AC 34 Removing cooling unit

cover

7 Remove three ducts from cooling

Idler pulley
unit
Crankshaft pulley
AC480

AC456

Fig AC 32 Adjustment of bolt tension

Note Be sure to loosen locking nut 3 Connect low and high pressure
before turning adjusting bolt Re

tighten it after adjustment

pipes to their proper
engine compartment
positions in
i j
l

REMOVAL AND
Notes
3 Be sure to use two wrenches when
I 11 AC767
INSTALLATION
connecting pipe joints Fig A C 35 Removing cooler ducts
Remove drive belt b Plug pipe opening immediately
To do this loosen locking nut after pipe disconnection Remove thermo
8 switch control
before Be careful
loosening adjusting bolt Drive c not to break expansion cable from connector
belt will then be detached valve This valve is wrapped with 9 Remove cooling unit and bracket
2 Remove idler pulley from bracket heat insulating tape as an assembly
by r
J1evM or king nut
t
jiwT9ff llil reverse the order of
rerr oval jldJ 1 t

Jldr J I

INSPECTiON

Oheck idler pulley for smooth rota

tion 0
llfHt H Y H 1
t
u W n l G ot Jrk l H

Check i dler pulley bracket for

0
cracks

Replace arts iffound damaged

flOJ gD IlI J l gtt flvlnv nOj IH q g
c

J JWu

cll dE m J

m
Jbm Ufl
1 ld
2

8
J

1
lEldgJ
I

v Jwm j y J51d l2u

n
AC768
t

COOLING UNIT 1
lc rf 1551
C765
fi vorr r
X fIlO
1i qJ j gnjlcfu2fIJ FIg lIJAh Cr P
36 R
1 7
coo mg um l51
l
vmg
emo
REMOVAL AND oM1 1UJ flip 1h tqnPff i2n
Wfi V1c ip
i j r n I1iBITJ 0HJ
Jl t

dW rbtivl2 IIfj 51 f
A1lIONI
INSTALl gnillslUli n C at 3duJ lsIliqrJ wlrv n
irWfiqX ani Ofm wom
L olIJgjjJpn
19qm91 crft llU2 3 6rn Gl0ql
f01
qiq H f 1I SH tc
pj ni
DiScoimecprlY ferY lgroUR hable e tworgromllets from dash
vehicleG bn y with
five rews
4q v Remo 2tl i
O
r Jv a8f1l1 q
2 Disbhargiou y tem iRefrflsll Qis panel lots n J a I ld 1 51 nc
b

chargingrSystemiillidenGeneral S ervicel 5 lRemove glovelbox

lBl n1 oT 0 IOJni
QisconnecEf twonleadliwif
eUcon 1
10 6 Detach cooling unit
sectiom5qiq 9
2 fl 1U 1Ii
n 2 oj liD cover Icyom n nectars from cooling unitqiq iuo
s UHf

AC ZA
 Air Conditioning

11 To install cooling unit reverse d Check refrigerant leakage if neces

I the order of removal sary repair Refer to Checking for
Leaks under General Service sec

Notes tion
a Apply a coat of fresh compressor
oil tosealing surfaces when COD
Tightening torque
necting pipe joints Copper tube joint nut
b Use two wrenches when connecting High pressure side 3 8 in

cooling pipes 2 5 to 3 5 kg m

c Evacuate cooling system then re 18 to 25 ft lb

chaJge with refrigerant Low pressure side I 2 in

o Refer fo Evacuating and Charging 5 to 4 0 kg

2 m

System under General Service see

18 to 29 ft lb

Fig AC 37 Disconnectirt connector

3 tion

DISASSEMBLY AND ASSEMBLY

00

1 Motor
2 Fan
3 Lower case
4 Cooler duct
5 Evaporator
6 Expansion valve
7 Upper case
8 Resistor
9 Main relay
10 Thermo switch
11 Cable c mp
12 Cable
3 Harness

AC725

Fig A C 38 Disassembling cooling unit

I Remove bracket and lead wire 7 Upper and lower cases can now Expansion valve tightening torque
connector main relay thermo switch be separated 5 kg m 36 ft Ib
resistor motor etc from cooling 8 Remove motor and fan as an

unit assembly Also remove evaporator

2 Remove five screws and duct 9 insulating tape from ex
Peel heat
3 Remove main relay pansion valve and unfasten clip secur Notes
4 Remove thermo switch ing expansion valve capillary tube to a When installing expansion valve on

5 Remove three and five evaporator make sure that temper

screws pipe
springs securing upper case lower case Remove expansion valve from evap oensing
ature capillary tube is in its
and rear bracket orator proper position on outlet side
6 Unfasten fittings securing inlet 10 To install reverse the order of b Apply a coat of fresh compressor
and outlet pipes removal oil to sealing surfaces of pipes

AG28
 Air Conditioning

INSPECTION Notes Tightening torque

a Apply a coat of fresh compressor Flare nut for copper tube
Evaporator oil to sealing surfaces when con from compressor
necting cooling pipes 5 to 4 0 kg m
2
Check evaporator for leakage or b Use two wrenches when connecting to 29 ft Ib
i8
damage If damaged replace Flare nut for copper tube
cooling pipes
c Evacuate cooling system then re to receiver dryer
Expansion valve charge with refrigerant 2 5 to 3 5 kg m
Refer to Evacuating and Checking i8 to 25 ft lb
Check expansion valve for leakage
System under General Service sec
or clogging If clogged clean filter in
tion Notes
expansion valve If damaged replace
d Check refrigerant leakage if neces a When disconnecting and connecting
sary repair cooler pipes be sure to use two
RECEIVER DRYER Refer to Evacuating and Charging wrenches
AND PIPING b
System under General Service See Apply a coat of fresh compressor
REMOVAL AND tion oil to
sealing surfaces when con

INSTAUATION necting cooler pipes

Condenser c To prevent possibility of explosion
Receiver dryer
due to high pressure within cooling
Disconnect battery ground cable
I Disconnect battery ground cable system do not clean condenser
2 Discharge system Refer to Dis
2 Discharge system Refer to Dis with steam Always use cold water
charging System under General Service
charging System under General Service or cold compressed air
section
section d Evacuate
3 Drain engine coolant cooling system then re
3 Disconnect compressor lead wire with
4 Remove radiator grille charge refrigerant
at connector Refer to Evacuating and Charging
5 Remove radiator and
shroud
4 Disconnect System under General Service sec
cooling pipes at
radiator
tion
joints On automatic transmission models
e Check refrigerant leakage if neces
disconnect both torque converter oil
sary repair Refer to Checking for
hoses
Leaks under General Service sec

tion
Note While cooling water is hot take
precautions against scalding INSPECTION

6 Disconnect two pipes from con RecelYer dryer

denser remove two screws securing

Check for refrigerant leakage or
condenser
damage
Condenser can now be removed
Check for proper connection of
two lead wires running to pressure
switch
Acno If any component part is found

Fig AC 39 Diaconnecting coo ing damaged replace receiver dryer and

pipes pressure switch as an assembly
Notes
Condenser
a Plug all piping joints immediately
after I Check inlet and outlet pipe joints
pipe disconnection to prevent
entry of dust or moisture laden air and sealing surfaces for damage Re
into receiver dryer or air aJOdi place parts if damaged or leaky
2 Clogged condenser fins or air
tioning system AC485 pas
b Use two wrenches when dIsconnect sages may reduce cooling efficiency of
Fig AC 40 Removing conden er

ing cooling pipes condenser Clean these areas with dry

Notes
air
Use two wrenches when disconnect
compressed
a
5 Remove four screws securing
receiver ing pipe joints Piping
dryer bracket to vehicle body
b Plug openings immediately after
and detach compressor relay and pres Check piping for leakage If leakage
sure switch as an assembly
disconnecting pipes
occurs at connections retighten
6 To install receiver dryer and 7 To install the order of
reverse connecting nuts Replace if leakage
piping reverse the order of removal removal persists

AC 29
 Air Conditioning

WIRING HARNESS AND COMPONENTS

WIRING DIAGRAM

J
c
BW ELECTRIC
BW
ii k
gg
B
FUEL PUMP

La gg 1 liii
J
B
l
1 i
Ii

ILLUMINATION
GL @ CONTROL
RHEOSTAT

FROM LIGHT SWITCH

CJ Id

f 8W
lW L

@
rRl I FUSE 15A

D CJ B
J

1 B W l
1t
Ll1 THERMO SWITCH

I
o I
I
COLOR CODE

J B

BW
Black
Black with white stripe

L Blue

LW Blue with white stripe

B y
vi
i jqt J
0
W
LR Blue with red stripe

White

noc I no 1 mcl y tll G riC

GreeMnQ O1 r
jblr GL Green with blue stripe
yldru ao 11
J
H WJ1 l
J
RL Red ith blue stripe
201011
q 2f br t
r
lIt m J

tH o hm I l i I
lH iot f1 I
1 rf l t f r W

dt ll II h J
IiJl I
d hi s n Jq tfli
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w
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i DDj
i It U JI1 GH Jdf J t ggo
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I
o
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10 lHohfth lUb
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19 b wt t IO l lo J1I l Ub OW If
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b
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Y1
lStO
1 t J I
FUSE YR IGNITION SWITCH
II nlWI I bn f w 1
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i Ji
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J
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O

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nq LnJ
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tldmoGl
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luil
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nG III
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mpHO
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rbliw7 tHO
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lb
D
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JIIgiJ IG
AC727
1 mtlm
f
8 rj J l1
dj Jlt d HInO to l VFJ r1 rjJ 1
Jh nI 0 i b ns j 1 fJb l YI l 0I

1
il i21 IEvUID l lfi fI
IO ljg h54 MjVj pi
IJC Wi1q

MN
 Air Conditioning
When 12 volt d is
MAINTENANCE a c
applied across

points 3 and 4 continuity between

Replace any wiring harness which is
points I and 2 should also exist
deteriorated in
cracked or
poorly
sulated
CD
wire with those of @
Always replace
the same diameter Do not use wire of
CDe
I ul JOO
smaller diameter
securely retain IDe
Where necessary 00 ID
wire harnesses with clips or tapes so
be frayed or worn
that they will not @e
by vibration L
Notes AC465

a Repair or replace any electrical part

Fig AC 42 Main relay
which is questionable or likely to
cause a short circuit

When disconnecting battery cables COMPRESSOR RELAY Inspection

always disconnect ground cable be
Removal and installation Using a test lamp or an ohmmeter
forepositive cable Clean battery
make sure that compressor relay con
and terminals before connecting
Disconnect compressor relay lead tacts open and close con tinuously
cables then connect cable
positive wires at connector
cable in that order Continuity always exists between
and ground 2 Remove two screws securing com
of grease to terminals points 3 and 4 When current flows
Apply a coat receiver dryer and
pressor relay to
through points 3 and 4 points 1
to prevent rust formation detach compressor relay and 2 close This causes current to
b Do not attempt to conduct a con
3 To install compressor relay reo
and 2
flow through 1
tinuity test with a screwdriver or verse the order of removal
service tools always use test lead
wires

c Do not ground terminals when

circuits are open or unloaded
test lamp 12V 3W
always use a

or circuit tester as a load

MAIN RELAY

v
t
Removal and Installation

The main relay is attached to the

iJ
cooling unit
I Disconnect battery cable AC489
ground
2 Disconnect main relay lead wires
Fig AC 43 Compressor relay
at connector
3 Remove cooling unit assembly
Refer to Removal and Installation FAN SWITCH
under Cooling Unit
4 Remove the screw securing main Removal and installation

relay to unit and detach main

cooling
1 Disconnect battery ground cable
relay
5
2 Remove screws securing console
To install main relay reverse the
box Withdraw console box forward
order of removal
and disconnect lead wire connector
3 Detach switch knob
Inspection 4 From rear side of console box
To check continuity in relay remove screws securing switch and

or an ohm remove switch

circuit use a test lamp AC771
3 5 To install fan switch reverse the
meter Continuity between points
and 4 should exist order of removal Fif AC 44 Removing fan switch

AC 31
 Air Conditioning

5 Remove resistor assembly from Inspection

Inspection
unit Resistor is
upper side of cooling I thermo swirch lever
Fully move
Check continuiry in fan switch inserted into case
to COLD
circuit with a test lamp or an ohm 6 To install resistor for fan switch
2 Test continuity between ter
meter reverse the order of removaL
minals with ohm
a test tamp or an

meter Continuity should exist

3 Dip capillary tube end into ice
Inspection
water Test continuity between ter

Test continuity between resistor minals Continuity should not exist

and fuse 4 Replace if switch is found dam
aged

F I C D SOLENOID VALVE

Removal and installation

I 011 I 2 3 THERMO SWITCH
I Disconnect battery ground cable
ICD
Removal and installation 2 Disconnect lead wires and vacu

Tt 1 Disconnect battery ground cable

um

3
tube
Remove two screws securing sole
Remove glove box
tt 2
noid valve and remove solenoid valve
AC772 3 Remove duct from cooling unit

Fig AC 45 Fan switch 4 Disconnect thermo switch control

cable and lead wires
RESISTOR FOR FAN SWITCH 5 Remove thermo switch

Removal and Installation

Note Capillary lube is fitted into

I Disconnect battery ground cable groove in cooler unit

2 Remove glove box
6 To install thermo switch
3 Remove cooling unit Refer to reverse

Removal and Installation under the order of removal

Cooling Unit
4 Disconnect resistor lead wires at
connector AC77 4

Fig AC 48 Removing lC D
F
@ solenoid valve

4 To install solenoid valve reverse

the order of removal

Inspection

1 Test in solenoid valve

continuity
3n
I
O sn circuit with test lamp or an ohm
I a
I
meter

2 Turn both fan switch and thermo

switch on

3 Run engine at idle and check to

CD 00 @ AC773 be sure that vacuum is present in line
AC492
Fig AC 47 Removing thermo switch between solenoid valve and diaphragm
Fig AC 46 Resistor for fan switch

AC 32
 Air Conditioning

COMPRESSOR

CONTENTS

DESCR IPTIDN AC33 SHAFT SEAL ASSEMBLY AC36

AC34 REMOVAL AC36

COMPRESSOR CLUTCH
REMOVAL AC34 INSTAllATION AC36

AC34 INSPECTION AC37

INSTAllATION
DISASSEMBLY AC35 CYLINDER HEAD AND VALVES AC37

AC 35 REMOVAL AC37
ASSEMBLY
INSPECTION AC35 INSTAllATION AC37

DESCRIPTION

Model CF206 is a crank type

with
compressor specially designed
minimum size and light weight for use

on compact vehicles
The compressor crankshaft is driven

by a belt from the crankshaft pulley

through the electromagnetic clutch
Two pistons positioned in line are

actuated by connecting rods coo

nected to the crankshaft
Discharge and suction valves are

mounted in the valve liner between the

crankcase and cylinder head

As a lubricant SUNlSO NO 5 is

used Simplified
positive pressure
lubrication utilizes existing pressure
differential between suction intake
and crankcase to provide a film of
lubricating oil to bearings All internal
components have been designed to
provide more than adequate lubrica
tion to cylinder walls connecting rod

bearings and seal assembly The result AC728

is improved lubrication lower seal
Fig AC 49 Sectional view of compressor
temperatures reduced oil pumping
and a reduction in the number of
moving parts

AC33
 Air Conditioning

1 Clutch wheel bearing

2 Snap ring
3 Clutch wheel assembly
4

7
Magnet coil

Shaft seal assembly

Service valve
Flange valve O ring
1foo 1

1t
LV
8 Cylinder head t7
9 Cylinder head gasket
I
10 Cylinder gasket
11 Valve plate assembly

12 Base plate gasket

13 Base plate
14 Oring

15 Oil filler plug

16 Clutch assembly
17 Compressor assembly

H AC775

@ @
COMPRESSOR Fig A C 50 Exploded view of compressor

CLUTCH 3 Loosen four electromagnetic coil

mounting screws Coil assembly can

The mostlikely source of problem
then be taken out easily
is clutch slippage Factors are listed

here Exercise ample care

I Clearance between clutch hub

and pulley should be 4 to 0 6
0 mm

0 016 to 0 024 in at all peripheral

points
2 Make sure that there
is no oil or

dirt on friction surfaces of clutch disc AC776

clutch hub and pulley Remove oil or

Fig AC 51 Remouing bolt
dirt with clean lint free cloth
2 Then using Clutch Removing
3 Make sure that terminal voltage at
Bolt remove clutch assembly from
magnetic coil is above 5V
IO
cmnkshaft
Fig A C 53 Removing magnetic clutch

REMOVAL INSTALLATION

Locate the electromagnetic coil at

I Using Clutch Spanner Wrench
the correct
hold clutch hub With suitable socket position on compressor
housing Then secure four electro
wrench remove bolt retaining clutch
hub to crankshaft magnetic coil mounting screws

Tightening torque
Electromagnetic coil mounting
screws

Fig AC 52 Removing clutch 0 7 kg m 1 ft Ib

5

AC34
 Air Conditioning

the
2 Install the clutch assembly on

crankshaft
ST02371000
Note Key should be set on crank
shaft before installing clutch assem
9

bly

3 Using Clutch Spanner Wrench

hold clutch hub With socket wrench

secure clutch hub securing bolt

Tightening torque AC502

Clutch hub securing bolt AC503

Fig AC 56 Removing V pulley from
5
1 kg m II ft lb clutch
Fig A C 57 Installing bearin

DISASSEMBLY 2 Install outer snap ring in groove

of V pulley
1 Remove two snap rings retaining
bearing They are located inside of 3 Using Installer KV99100610 and
clutch wheel Stopper ST33061000 press clutch
ASSEMBLY
wheel into V pulley
I Press bearings into V pulley with 4 Install inner snap ring in groove

Bearing Installer ST02371000 of clutch wheel

AC500

Installer

t
Fig AC 54 Removing snap rings KV99100610
2 Stopper
ST33061000

AC504

2 Using Clutch Wheel Remover

KV99100700 and conventional puller
remove V pulley with bearings from
Fig AC 58 Installing clutch wheel
clutch wheel

INSPECTION

Check friction surface of clutch 3 Oil or dirt on friction surfaces of

for damage due to excessive heat or clutch wheel and V pulley should be
If cleaned with a clean lint free cloth or
excessive grooving due to slippage
clutch wheel and suitable solvent
necessary replace
V set 4 Check coil for shorted or
opened
pulley as a
KV99100700 The clearance between V lead wire Pay particular attention to
2 pulley
and clutch wheel should be 4 to 0 6
0 grounding part of coil If there is no
0 016 to 0 024 in continuity replace electromagnetic
mm

clutch wheel coil

If not replace assem
AC501
bly
Fig A C 55 Removing clutch wheel
bearings

Bearing Remover
3 Using
ST33061000 press clutch wheel bear
ings out from clutch wheel

AC 35
 Air Conditioning

3 Push seal assembly except carbon

jpL ring
ring
over end of shaft with carbon

retainer facing out

i
L

0
Y 4

on
Move seal

shaft
assembly into position

I
I I
0

Ace07

Fig AC 61 Removing s
wft key

AC506
1
Fig AC 59 Grounding point of coil 4 Remove seal plate I

5 If clutch assembly must lie re

placed remember that break in opera Fig AC 64 Inserting wft al

tion is necessary The break in ass mbly

opera
tion consists of engaging and disengag
5 Place carbon ring in ring retainer
ing the clutch some tirty times
so lapped surface is facing outward

Note The indentions in outside

SHAFT SEAL edge
of carbon ring must engage driving
ASSEMBLY AC80e
lugs and be firmly seated in re

The shaft seal assembley of this tainer

Fig AC 62 Removing seal plate
compressor is of a simplified design
tight sealing and 5 With the 6 Install new D ring in groove of
yet long lasting Compressor Seal Puller
seal plate
pull out seal gland and discard

Note Use oil to make it

Notes refrigeration
REMOVAL a Discard all parts of the seal includ adhere to surface

ing the O ring

It is recommended that the com 7 seal
b Do not use screwdriver to pry
a Space plate with equal clear
pressor be removed from the vehicle
ance around shaft and insert
shaft seal from shaft as damage to cap
for shaft seal replacement shaft may result screws
I Remove oil filler plug with D ring 8 Tighten these screws evenly
and drain the compressor oil
Tightening torque
Seal plate securing cap screws

0 7 to 1 0 kg m

5 to 7 ft Ib

AC809

Fig A C 63 Removing wft

s eal

Fig AC 60 Removing filler plug

2 Remove clutch Refer to Com INSTALLATION AC811

pressor Clutch Removal 1 Clean shaft and seal cavity with Fig AC 65 8pcing 01 plate and
3 Remove shaft key tightening cap screws
clean lint free cloth
2 Dip seal gland in clean 9 Install clutch Refer Com
refrigerant to
oil pressor Clutch Installation

AC 36
 Air Conditioning

INSPECTION INSTALLATION

follows Valves and valve plates are furnish

Check for gas leakage as

I Plug high and low pressure joints ed only as a complete assembly

I Apply a thin film of clean refrig
on compressor with blind caps
eration oil on area of crankcase to be
2 Connect charging hoses in lines
covered by cylinder gasket
between manifold gauge and high and
2 Place cylinder gasket in position
low pressure service valves
on cylinder so dowel pins in crankcase
Connect refrigerant can to middle
go through dowel pin holes in cylinder
hose of manifold gauge
gasket
3 Open valve of can tap and charge AC813
filler 3 Apply a thin film of clean refrig
refrigerant Loosen oil plug at
head
side of compressor to purge air out of Fig A C 6 7 Removing cylinder eration oil to top and bottom valve
bolts
plate areasto be covered by gaskets
compressor Remove head
3 valve plate and
4 Turn shaft 5 or 6 turns Then
does
from cylinder by prying or tapping
confirm that not
pressure from
under the ears which extend
decrease on gauge If
low pressure
valve plate
gauge indicates a pressure decrease
If head and valve plate adhere hold
there is a leak Conduct a leak test
and head and tap valve plate ears away
Under such a condition remove
from head with a soft hammer
then install parts again

Note Do not hit or tap head to

separate head and valve plate be

CYLINDER HEAD 3use damage to head may result

AND VALVES
Insufficient refrigerant compression
is likely by damaged head
to be caused

gasket damaged
or valves AC816
Prior to servicing the head and valve
Fig A C 70 Applying clean
plate both service valves should be refrigeration oil
opened to free any gas pressure which

may be in the compressor

Fig AC 68 Removing valve plate

REMOVAL
and head

I Remove the bolts from flanged

type service valves using Torx Driver 4 When removing the gaskets use a

Place valve in position

Bit knife
4 plate on

sharp edged
cylinder gasket so discharge valve as

semblies ie smaller diameter assem

Note The direction of flanged type Notes
blies with restrainer over valve reed
service valves should be noted for
a In removing head gasket be very
reinstallation are facing up and locating dowel pins
careful not to damage machined
go through dowel pin holes in valve
sealing surface
plate
b Do not reuse gaskets

AC812

Fig AC 66 Removing service valves

AC815
2 Remove the remaining bolts in

the head Fig A C 69 Removing gasket Fig A C 71 Placing valve plate

AC37
 Air Conditioning
5 Place head gasket in position on 8 Apply thin fihn of clean
a
refrig case

valveplate dowel
pins go through 11 Insert remammg head screws
so eration oil to service valve flanges
dowel pin holes in gasket 9 Place and run in all screws until the heads
flange valve O ring in posi
6 Apply a thin film of clean refrig make contact
tion on cylinder head
eration oil on the machined surface of 10 Place service valves in position
head which
Tightening torque
cylinder matches head on proper service valve ports suction Head and service valve screws
gasket or discharge and insert two longer 2 1 to 3 2 kg m
7 Place head on cylinder head valve mountiing
screws through service 15 to 23 ft lb
gasket so dowel pins go into dowel pin pads head valve plate and into crank
holes in head

AC 38
 Air Conditioning

SPECIAL SERVI CE TOOLS

Tool number For Reference

No Description use page or

tool name Unit mm in on Figure No

KV99100700 To remove clutch wheel from V pulley 620 Fig AC 55

Clutch wheel
remover

BE436

2 KV991006S0 To install clutch wheel into V 620 Fig AC 58

pulley
Clutch wheel 38 1 50 1

installer set

KV99100610

Installer

ST33061000

Stopper
BE437

ST33061000 To remove clutch wheel from V pulley 620 Fig AC 56

3 bearing

Bearing
remover 38 50
1

BE438

into V 620 Fig AC 57

4 ST02371000 To install clutch wheel bearing pulley

Bearing
installer 50 1 96

Co

tJ BE439

AC 39
 Air Conditioning

Tool number For Reference

No Description use page or
Remarks
tool name Unit mm in on Figure No

5 Clutch To hold clutch wheel when removing clurch wheel 51

620 Fig AC 124878 1
spanner wrench

BE440

6 Clutch removing To remove V pulley from crankshaft 620 Fig AC 52 126344

bolt

BE441

7 Compressor seal To remove shaft seal from crankshaft 620 AC 63

Fig J 10549

puller

BE442

8 Torx driver bit To remove flange bolts 620 Fig AC 66 124392

B E443

9 Oil dip stick To inspect oil level 620 110545

BE434

40
AC
 SECTION SE

SERVICE
DATSUN PICK UP EQUIPMENT
MODEL 620 SERIES

SERVICE EQUIPMENT SE 2
I NISSAN I

NISSAN MOTOR CO LTD

TOKYO JAPAN
 Service Equipment

SERVICE EQUIPMENT

GENERAL CLASS REMARKS

DESCRI PTION
Indicated in this column are classi As regards special tools which are

Special Tools play very important fication also applicable to models other than
ftg1lles in accordance with
role in the maintenance of vehicles
Classification of Speciai Tool those dealt ith U this inual
m this
These are essential to the safe accu
coluITUl names those other models
rate and speedy servicing
The working times listed in the col
umn under FLAT RATE TIME in CLASSIFICATION OF SPECIAL TOOL
FLAT RATE SCHEDULE are com

based the of Special Classification

puted on use

Tools
Important General
The identification code of mainte
nance tools is made up of 2 alpha I Inspection and minor repairs 4

betical letters and 8 digital figures

11 General disassembly and assembly 2 5
The heading two letters roughly
classify tools or equipment as fol Ill Special disassembly and assembly 3 6
lows
A Important 11 General and
disassembly assembly
STOOOOOOOO Special Tool a Exclusive with no alternative
General disassembly such as
engine
KVOOOOOOOO Special Tool b Parts will be damaged if repaired transmission and differential
Recently established without special tool
111 Special disassembly and assembly
EMOOOOOOOO Engine Overhauling c Gauges
Machine
a
Disassembly of exclusive parts
such as automatic transmission
GGOOOOOOOO General Gauge B General
and electrical accessories
HTOOOOOOOO Hand Tool To facilitate servicing
I b Special work such as boring and
Inspection and minor repairs
a Inspection and maintenance welding
HOW TO READ c Work very rarely required
b Unit replacement
SPECIAL TOOL LIST c Minor unit disassembly

APPLIED VEHICLE OR UNIT

In this column word All is given SPECIAL TOOL SET SET 3N71B KV0010l000
for tools applicable to all vehicle mod
See attached tool list This set is designed for use on the
els and unit types treated in this manu
The set is available for and 3N71B automatic transmission It con
al for tools applicable only to particu new

sists of the same service tools as those

lar models or units those vehicle other dealers who must go through
models unit indicated initial preparation previously available separately
or types are

SET 77 620NA KV00102000

NEWLY ADDED
This set is designed for the chassis

X put in this column shows and body of the 620 models without
newly added tools regard to their destination

SE 2
 Service Equipment

TOOL LIST

ENGINE TOOL

Tool Number Tool Name Newly added Class Remarks

FIO B2iO 610 710

5
ST050 I SODa Engine stand assembly S30

tST05011000
ST050 I 2000
Engine
Base
stand

5 610 710
ST05260001 Engine attachment
STlOl20000 2 610 710 S30
Cylinder head bolt wrench
STl 0640001 Pivot adjuster I 610 710 S30

FiO B210 610 710

KVIOI039S0 Valve guide reamer set 3
S30

STl1081 000 Reamer 12 2 mffi 480

0 in dia J
STl1032000 Reamer 8 0 mffi 0 315 in dia

STl1320000 Drift
2 610 710 S30
STll650001 Valve seat cutter set

STl2070000 Valve lifter 5 B210 610 710 S30

STl3030001 Piston pin press stand 2 610 710 S30

2 610 710 S30

STl53 10000 Crankshaft rear oil seal drift
2 610 710 S30
KVI01041S0 Crankshaft main bearing cap puller

KVIOI04110 Crankshaft main bearing puller

STl6512001 Adapter

STl6701001 Adapter
STl6610001 Pilot bushing puller 3 610 710 S30

2 610 710 S30

STl7420001 Chain stopper
FIO B210 610 710
STl9320000 Oil filter wrench
S30

STl9870000 Air pump test gauge FI0 B210 610 710

STl98 10000 3 FIO B2iO 610 710

Hexagonal wrench
STl9890000 Rotor adapter 2 FIO B210 610 710

shaft 2 FIO B210 610 710

STl9900000 Dummy
2 FIO B210 610 710
STl99 10000 Bearing drift
STl9920000 Rotor stand 2 FIO B210 610 710

2 FIO B210 610 710

STl9930000 Bearing adapter
3 FIO B210 610 710
ST I 9940000 Bearing pressing tool
FIO B210 610 710
EM03470000 Piston ring compressor 2
S30

SE 3
 Service Equipment
CHAssis AND BODY TOOL

Applied Ser 17 620NA

Newly
No Tool Number Tool Name 1e
vehic Class Remarks
added
or unit KYOO 1 02000

Clutch

5Tl 66 1000 I Pilot bushing puller All X 3 610 710 530

KV30100200 Clutch aligning bar All X 2 610 710 530

5T200500 10 Base plate All X 5 B210 610 710 530

5T20050100 Distance piece All X 5 B210 610 710 530

5T20050051 5et bolt All X 5 B210 610 710 530

5TZ0050240 wrench All X 5 B210 610 710 530

Diaphragm adjusting
FIO B210 610 710
GG943 10000 Flare nut torque wrench All X 2
530

2 Manual
transmission

5TZ2360002 DriftC All X 2 B21O 530

FIO B210 610 710

5T23540000 Fork rod pin punch All X 2
530

FIO B210 610 710

5T23800000 Transmission adapter All X 2
530

5T23810001 5etting plate adapter All X 5 530

5T22520000 Wrench All X 2 B2iO 530

5T23860000 Counter gear drift All X 2 530

KV311 00400 Transmission press stand All X 5 530

FIO B210 610 710

5T30031000 Bearing puller All X 2
530

KV32101330 Bearing puller FSSW71B X X 2 B21O 530

3 Differential

ST063 I 0000 Diff attachment All X 5 610

ST31530000 Drive X 2
pinion flange wrench All B210 610 710 S30

ST3306S001 Diff side bearing puller All X 2 610 S30

ST33051001 Puller

ST3306 I 000 Adapter

Orive pinion rear bearing inner race

ST3090S000 All X 2 610 S30
replacer
ST30031000 Puller

ST30901000 Base

ST33230000 Diff side bearing drift All X 2 610

ST3194S000 Drive All X 2 610

pinion setting gauge ass y

ST3l941000 Height gauge

5T3l942000 Dummy shaft

SE 4
 Service Equipment

Applied Ser 77 620NA

Newly
No Tool Number Tool Name vehicle Class Remarks
added
or unit KVOO 102000

All X 2 610
ST31970000 Collar

X 2 610
ST30611000 Drive pinion outer race drift bar All

drift adapter All X 2 610

ST30613000 Drive pinion outer race

Drive drift adapter All X 2 610

ST3062 1000 pinion outer race

Solid All X 2 610 710 S30

KV311 00300 punch
ST3127S000 Preload gauge All X 2 B21O 610 710 S30

All X 2 610
KV381025S0 Oil seal fitting tool

4 Front axle

All X 2
ST35380000 Kingpin bushing drift
HT56802000 All X 2
Kingpin bushing reamer

ST36070000 Transverse link bushing replacer All X 2

X 2
ST35390000 Kingpin grease seal drift All

5 Rear axle

All X 2
ST38020000 Bearing lock nut wrench

Rear axle stand All X 2 B210 610 710 S30

KV40101000

All X 5 B210 610 710 S30

ST36230000 Sliding hammer
All X 2 B210 610 710 S30
HT72480000 Rear axle shaft bearing puller

6 Steering
ST2902000 I Pitman arm All X 2 B210 610 710 S30
puller
FIO B210 610 710
2
ST27 180001 Steering wheel puller All X
S30

FIO B210 610 710

HT72520000 Ball joint remover All X 2
S30

FlO B210 610 710

ST3127S000 Preload gauge All X
S30

7 Brake

GG943 10000 Brake pipe torque wrench All X 2 B210 610 710 S30

ST08060000 Master Vac oil seal retainer drift All X 3 B210 610 710 S30

ST08080000 Master Vac wrench All X 3 B210 610 710 S30

SE 5
 Service Equipment

AUTOMATIC TRANSMISSION TOOL

Applied Set 3N71B

Newly
Tool Number Tool Name vehicle Class Remarks
added
or unit KVOOlO1OOO

ST07870000 Transmission case stand All X 3

ST2505S001 Oil pressure gauge set All X I

ST25 I 60000 Torque driver All X 3

ST2532000l Snap ring remover All X 3

ST25420001 Clutch spring compressor All X 3

ST25490000 Socket extension All X 3

ST2557000l Hex head extension All X 3 8210 610 710 S30

ST25580000 Oil pump assembling gauge All X 3

ST25850000 Sliding hammers All X 3

GG930 I 0000 Torque wrench All X 3

HT6 I 000800 Hexagon wrench All X 3

HT62350000 Spinner handle All X 6

HT69860000 Snap ring remover All X 3

SE 6
 WIRING DIAGRAM

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sued September 1976 070795

Printed in Japan Publication No SM7E 0620liO