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Service Manual Datsun 510 1969-1973

Contents

1. 123 ELECTRICAL 123 MANUAL TRANSMISSION 127 CARBURETOR 131 CLUTCH onere REPE 134 ENGINE TORQUE amp INFORMATION 136 TUNE UP en tee 138 LUBRICANTS SAE 138 CAPACITIES amp PRESSURES 139 AUTOMATIC TRANSMISSION 140 PROPELLER SHAFT 144 BRAKE CHASSIS amp WHEEL ALIGNMENT 146 deese xu E Cf 147 119 _ Specifications Model Type Voltage Output Starting current Voltage No load current Voltage No load starter revolution Shift type of pinion gear Number of teeth on pinion gear Number of teeth on ring gear We ight STARTER HITACHI 5114 103 For manua transmission 12 Volts 1 0 KW Less than 430 amps 6 Volts Less than 60 amps 12 Volts rpm More than 7 000 Magnetic shift 9 120 kg Ib 5 1 10 42 SPECIFICATIONS AND SERVICE DATA Specifications Applicable to Maker Nominal rating Ground polarity 120 LT150 05B 510 and 610 models except for Canada for Canada 12V 50A 12V 60A Negative LT160 19 510 and 610 models 116 and L18 engines 114 126 For automatic transmission 12 KW Less than 540 amps 5 Volts More than 6 000 5 8 12 8 LT135 13B 620 model 12 35 D
2. 109 INSTALLATION 111 4 SPEED TRANSMISSION 113 Removal and Installation 113 RECOMMENDATIONS 113 Transmission Fig 159 3 Forward Speed Transmission Fig 160 4 Forward Speed Transmission REMOVAL When removing the transmission from the vehicle it is necessary to follow the undermen tioned procedure Jack up the vehicle and support it with four stands If available a hydraulic hoist or open pit can be utilized Disconnect the hand brake wire at the equalizer pivot as shown in Figure 163 Loosen the two exhaust center pipe clamps and turn the premuffler complete with center pipe to the left as shown in Figure 164 This will allow sufficient room for the propeller shaft to be removed Remove the propeller shaft by disconnecting the four securing bolts at the companion flange of the gear carrier Seal the end of the rear extension housing to prevent oil leakage Transmission E UNE AI Fig 162 Underside of Vehicle Transmission Disconnect the speedometer drive cable from the adapter in the transmission extension housing See Fig 165 Disconnect the lower shift rods from the shift levers and remove the cross shaft assembly from the transmission case See Fig 166 Remove the clutch operating cylinder from the clutch housing Support the engine with a jack placed under the oil pan Do not loca
3. 41 44 VOLTAGE REGULATOR 44 Description 44 Measure of Voltage 45 47 Charging Relay 48 49 FUSES amp FUSIBLE LINKS 49 EMISSION CONTROL DIAGRAMS 50 DISTRIBUTOR 52 Construction 52 Disassembly 52 Assembly 53 IGNITION COIL 56 Construction 56 Description 57 SPARK PLUGS 57 Description 57 Inspection 58 Cleaningand 58 TROUBLE SHOOTING IGNITION 58 HEATER UNIT REMOVAL 59 TROUBLESHOOTING HEADLIGHT 62 TROUBLESHOOTING HORN 63 RADIO 63 63 TROUBLESHOOTING SPEEDOMETER 64 TROUBLESHOOTING HEATER 65 TROUBLESHOOTING RADIO 65 NOISE PREVENTION CHART 66 FUEL SYSTEM AIR CLEANER ELEMENT 68 AUTOMATIC TEMPERATURE CONTROL AIR CLEANER 68 AIR CONTROL VALVE 68 Idle Compensator
4. 56 Construction 56 Description 57 SPARK PLUGS 57 Description 57 Inspection 58 Cleaning and Regap 58 TROUBLE SHOOTINGIGNITION 58 HEATER UNIT REMOVAL 59 TROUBLESHOOTING HEADLIGHT 62 TROUBLESHOOTING HORN 63 RADIO date dah ste ear T 63 63 TROUBLESHOOTING SPEEDOMETER 64 TROUBLESHOOTING HEATER 65 TROUBLESHOOTING RADIO 65 NOISE PREVENTION CHART 66 Electrical System STARTER 007 Fig 76 Exploded view of starting motor L Shift lever pin Pinion stopper 2 Gear case 14 Pinion 3 Dust cover 15 Over running clutch 4 Shift lever 16 Field coil 5 Dust cover 17 Yoke 6 Magnetic switch Assy 18 Brush 7 Armature 19 Brush 8 Thrust washer 20 Brush spring 9 21 Brush holder 10 Thrust washer 22 Meta 11 Stopper washer 23 Rear cover 12 Stopper clipe 24 Through boit Removal Disconnect battery ground cable Disconnect black wire with yellow tracer from magnetic switch terminal and black battery cable from battery terminal of magnetic switch Remove two bolts securing starting motor to gear case Pull starter assembly forward and remove starting motor Installation Instal
5. 86 REAR 86 Removal and Disassembly 86 Inspection 87 88 Brakes MASTER CYLINDER Removal Remove the clevis pin connecting the push rod with the brake pedal and disengage the master cylinder from the pedal Disconnect the brake tube from the master cylinder Screw out master cylinder fixing nuts and remove the master cylinder from the dash board Installation Installation is a reversal of the removal procedure but the following operation should be added Adjust the pedal height by changing the push rod length of the master cylinder Bleed air out of the master cylinder FRONT DISC BRAKE Description Figure 130 shows the relation of forces working brake pedal is depressed hydraulic pressure from the master cylinder forces the piston of wheel cylinder out of the caliper bore and thrusts inner pad forward un til it contacts disc and simultaneously pushes outer pad by reaction force These forces cause rotating moment which increases reac tion force This is called self energizing ac tion this SC brake it is around 5 As pad wears movement of piston is in creased and when seal is deflected more than its elastic deformation piston will slide out ward causing slip between seal and piston thus assuring constant clearance between pad
6. 69 TEMPERATURE SENSOR 69 1 69 Installation r u u 69 FUEL PUMP 69 Removal and Disassembly 69 Inspection 70 Assembly u na feet 70 able of Contents CARBURETOR 78 Removal 73 Disassembly 73 Float 74 ANTI DIESELING SOLENOID 74 Removal 74 Installation 74 BOOST CONTROLLED DECELERATION DEVICE 74 Assembly and Installation 74 Cleaning and Inspection 74 SETS 75 COOLING SYSTEM DRAINING amp FLUSHING 78 WATER PUMP 78 Removals er ERR 78 Disassembly 79 Inspection 79 79 79 Removal and Installation 79 RADIATOR 79 Removal and Installation 79 Inspection 80 BRAKES MASTER CYLINDER 82 82 82 FRONT DISC BRAKE
7. sone 0 8 to 1 1 5 8 to 7 9 Oil charging pipe to case 0 55 100 75 4 0 to 5 4 0 55 0 0 75 4010 5 4 30 to 4 0 22 tw 29 Dust cover to converter housing 422222222222 42224 Selector range lever to manual shaft Selector rod lock nut 2 0 8 to 1 0 5 8 to 7 2 Control lever Lets 16 22 tto tod Control lever bracket to _ 0 3310 0 45 2 610 3 1 Control lever knob to lever sens 0 2019 0 25 1410 Turn back two turns after tightening Specifications PROPELLER SHAFT SERVICE DATA AND SPECIFICATIONS Propeller shaft Length x out dia x in dia mm in For Sedan 1 080 x 63 5 x 60 3 42 5 x 2 5 x 2 4 For Wagon 1 242 x 75 0 x 71 8 48 9 x 3 0 x 2 8 Axial play of the spider journal 0 08 mm 0 0315 in Sieeve yoke spline to mainshaft 0 0 08 mm 0 0 0031 in Spline lash wear limit 0 5 mm 0 0197 in Maximum run out of propeller shaft 0 6 mm 0 0236 in Spider journal diameter wear limit 0 15 mm 0 0059 in Permissible unbalance Dynamic 35 gr cm 0 486 in oz at 5 800 r p m Thickness of available snap rings Standard white 2 00 mm 0 0787 in Oversize yellow 2 02 mm 0 0795 in red 2 04 mm 0 0803 in green 2 06 mm 0 0811 in blue 2 08 mm 0 0819 in brown 2 10 mm 0 0827 in colo
8. 35 to 5 30 to 48 Spark timing control system Throttle switch operating angle 118 359 LI6 510 40 116 620 A T amp M T 459 Thermo switch operating temperature C CF 5 tO 13 41 to 55 Adjustment of operating pressure of B C D D B C D D set pressure AIT mmHg 7480 20 18 9 0 787 M T mmHg inHg esses 500 20 19 7 0 787 Air cleaner A T C Valve opening temperature SQ SEX usan a aka Ries 37 5 to 48 100 to 118 Condition CANNOT CRANK ENGINE OR SLOW CRANKING Maintenance amp Tune up TROUBLE SHOOTING Probable cause Improper grade oil Discharged battery Defective battery Loose fan belt Trouble in charge system Wiring connection trouble in starting circuit Detective ignition switch Defective starter motor Trouble shooting procedure on starting circuit Switch on the starting motor with light ON When light goes off or dims considerably a Check battery Corrective action Replace with proper grade oil Charge battery Replace Adjust Inspect Correct Repair replace Repair or replace b Check connection and cable Check starter motor When light stays bright a Check wiring connection between battery and starter motor b Check starter switch c Check sta
9. 106 BLEEDING CLUTCH SYSTEM 106 TRANSMISSION 109 INSTALLATION 111 4 SPEED TRANSMISSION 113 Removal and Installation 113 RECOMMENDATIONS 113 BODY WORK er 9 n t9 n n n 4 Bar Removal and Adjustment SPECIFICATIONS 4 4 Table of Contents SPARK PLUGS 122 VALVES pc Sieh ere ER ERO 122 OTE PUMP 122 GENERAL 123 ELECTRICAL 123 MANUAL TRANSMISSION 127 CARBURETOR 131 CLUTCH o 134 ENGINE TORQUE amp INFORMATION 136 TUNE UP 138 LUBRICANTS SAE 138 CAPACITIES amp PRESSURES 139 AUTOMATIC TRANSMISSION 140 PROPELLER SHAFT 144 BRAKE CHASSIS amp WHEEL ALIGNMENT 146 NOTES 147 Maintenance amp VALVE CLEARANCE 6 FAN eC 6 ENGINE OIL 6 OIL FILTER 6 7 Nissan Long Life Coolant 7 COMPRESSION
10. 60 1 24 091 033 016 020 35 41 1 5 3 6 2 4 5 Pulley 750 6 20 with Selex ADJUSTMENT OF IDLING Adjust the engine at norma idling setting Engine idling Idling timing rpm degree retard side 5 BTDC vehicle vehicle 650 in D range Recommended Lubricants SAE Temperature Under 19 19 37 0 Engine 10W 30 10W 30 1057 30 10 30 10W 40 1057 40 10W 40 designation 5W 20 10W 20M 20W 40 MS SD SE ar 205 Gear 50 90 90 140 designation 2 MPS 40W may temperatures be used for over 90 high speeds Capacities and Pressures 2 6 front 19 0 10 8 11 3 11 0 11 0 11 4 11 4 11 4 9 3 10 8 11 3 11 9 eee 42 1 7 10 8 PL521 44 38 128 21 18 HLS30 47 43 232 3 2 15 9 9 3 Cooling Swetem fete Specifications Normal Marimum Model Engine Transmission ReAll efter Different Crenkeasr Draining pts Fuel cowant Refl Pressure preasur fter Drain pei psi ing qts With Witheut Aute P ter F ter total 4 capacity Speed Speed Speed O TM O SzTM _ 160 38 420 5 2 and rear PLANO 33 30 38 2 0 SPLAIO N A 42 4 6 18 PALL 3 1 3 8 4 7 2 2 RIAH N A 3 5 4 3 1 9 SPE3I1I 4 3 4 6 20
11. 0 014 8 000 to 8 015 0 3150 0 2156 Ed 0 005 to 0 029 0 0002 to 0 0011 sas 4 972 to 4 090 0 1959 to 0 1965 tene 5 000 to 5 018 0 1969 to 0 1976 0 01 to 0 046 0 0004 to 0 0018 Specifications SPARK PLUGS SERVICE DATA AND SPECIFICATIONS Applied engine 116 and 118 Size screw dia x reach 14 x 19 mm in 0 55 x 0 75 Pl in 0 7 to 0 8 SEP ee 0 028 to 0 031 Tightening torque 1 5 to 2 5 kg m ft lb 11 0 to 15 0 VALVES 42 0 to 42 2 1 654 to 1 661 33 0 to 33 2 1 299 to 1 307 H Valve head diameter mm in In 42 0 to 42 2 1 654 to 1 661 Li8 35 0 to 35 2 1 378 to 1 386 2 2 t is 114 9 to 115 2 4 524 to 4 535 mm in 118 115 7 to 116 0 4 555 to 4 567 Valve stem diameter L16 7 965 to 7 980 0 3136 to 0 3142 118 in 7 945 10 7 960 0 3128 to 0 3134 Valve seat angle In amp 45930 lightening torque Oil pump mounting bolts kg m ft Ib u u et 1 1 to 1 5 80 to 11 Oil pump cover bolts kg m ft Ib e 0 7 to 1 0 5 1 to 7 2 nut regulator valve kg m ft lb ess 4 to 5 29 to 26 Specifications Oil pressure at idling kg cm 15 59 0 8 to 2 8 11 to 40 Regulator valve spring Free length mim In ue teer us 52 5 2 067 Pressured length mm mi paqu rhe d 34 8 1 370 Regulator valve opening pressure kg cm Ib sq in e 3 5 t0 5
12. 6 1868 gt 700 37 R 40 50 12 590 95 gt 65 NA NA N A 090 50 12 Neg 500 60 gt 72 60 n 6 000 20 L16 50 60 21510 12 Neg 480 60 gt 79 60 12 700 28 WPLS10 40 50 1 520 40 50 60 PLS21 L521 L24 NA 12 Neg 160 60 101 60 12 gt 500 49 A12 12 Neg 420 63 gt 65 60 12 gt 700 37 U _ _ _ Less than More than Electrical Specifications AC Regulator Engine Part Charge Indicater Relay Vettage Regulator Model Core Back Air CoreGap HerkGap AirGep _ Regulatcd tia fin Gap in Voltage fin fin f n fin Mitsubishi 032 0414 032 048 032 044 028 038 032 040 012 016 RLA 1 J Mitsubishi 032 043 032 047 032 043 028 035 032 039 012 018 14 15 RL2220B5 R Mitsubishi 032 043 032 047 032 043 028 035 032 035 012 016 14 15 RL 2B U20 Mitsubishi 035 047 030 043 030 043 032 047 032 043 012 016 13 5 14 5 RI 2220B5 L16 Hitachi 007 020 024 016 020 035 039 032 047 012 016 14 15 TL Z 17 1 24 Hitachi 032 039 016 024 024 039 012 016 14 3 15 3 1 12 37 SOF 1 Hitachi 032 039 016 024 024 039 012 016 14 3 15 3 TLI2 37 50F Right virt in regulator case left unit in TL1Z 17 Left unit in regulator case right unit in TL1Z 17 NOTE Right and left are determi
13. 82 Description erect res 82 1 82 Disassembly 84 Inspection and Repair 84 Piston Seal Replacement 85 Assembly and Installation Dm 85 Pad 86 REAR BRAKE 86 Removal and Disassembly 86 Inspection 87 88 SUSPENSION RECOMMENDATIONS 90 STEERING STEERING GEAR COMPONENTS 92 RECOMMENDATIONS 92 ASSEMBLY 93 STEERING LINKAGE 93 REAR DRIVE amp SUSPENSION SHOCK ABSORBERS 96 Removal ite RR e LIE ranura 96 Inspection 96 Installation 96 DRIVE SHAFT 97 RECOMMENDATIONS 97 CLUTCH REMOVAL ss 102 RELEASE BEARING 102 REPAIR i226 icm DIIS 103 Refacing Pressure Plate 103 ADJUSTMENT 104 INSTALLATION 104 MASTER CYLINDER 105 Removal irren 105 Disassembly Sea a 105 Inspection 106 Assembly ioo ccs iic p ye RR P 106
14. NIN S SITSERS JAR DRAKE PUBLISHERS INC DATSUN 510 RANGE 1969 1973 MAINTENANCE 5 REPAIR IMANUATM BY DRAKE AUTOMOTIVE EDITORS Quick Reference Index MAINTENANCE amp TUNE UP 5 STEERING 91 ENGINE 21 REAR DRIVE amp SUSPENSION 95 ELECTRICAL SYSTEM 39 CLUTCH 99 FUEL SYSTEM 67 TRANSMISSION 107 COOLING SYSTEM 77 BODY WORK 115 BRAKES 81 SPECIFICATIONS 119 FRONT SUSPENSION 89 We endeavor to incorporate the latest man changes and up to date specificatio da time of publication While e effort is made to attain accuracy the Publisher not be held respo manu iid cturing changes typographic errors omissions Upon compiling the information contained her we havg tried to be brief nd sirnple combination of photogra cake illustratio make useful tool DRAKE PUBLISHERS INC 381 PARK AVENUE SOUTH NEW YORK NY 10016 ISBN 87749 302 2 Published 1973 Drake Publishers Inc 381 Park Avenue South New York N Y 10016 Drake Publishers Inc 1973 Printed in the United States of America Table o Gontents MAINTENANCE TUNE UP VALVE CLEARANCE 6 BELT 6 ENGINE OIL 6 OIL FILTER 6 7 Nissan Long Life Coolant 7 COMPRESSI
15. P aoc DISTRIBUTOR SPECIFICATIONS Centrifugal Vacuum Advance Spring Year Medel or Distributer Angle Tenslen Start Int Full Inches ef Full Adv Engina Part Inch Degrees Ounces Vacuum Int Dist Degres rem rpm te Stort Vacuum Plunger 1966 67 R 0407 51 018 Hitechi 1 1 1 43 0 j Q 4 7 5 5 9 12 12 6 022 50 54 400 550 1800 Mitsubishi EN 561 a gt ns 1966 68 4 0411 53 016 50 55 1 171 43 o 2 11 15 4 7 5 5 6 9 13 022 450 2400 0407 52 018 49 55 1 1 1 43 0 1 5 0 6 00 5 10 10 13 020 400 500 1900 1968 72 1 16 2410 58 017 31 143 5 5 6 0 504 0 022 450 1000 1500 1971 72 1 24 0612 52 016 35 41 1 1 43 o 5 1209 9 84 5 914 9 17 7 920 500 1000 1400 1200 2412 63 017 1 1 1 43 0 5 0 12 5 60 seo 9 5 12 022 550 1200 2190 ___ advance daactiveted with Selex cerb Specifications Electrical Specifications Battery and Starter Engine Battery Starter Model Lock Test No Load Test Capacity Volte fironuded Ampa Volts Targas Amps Vela rpm ere Amp Itre Terminal fft 3 Length fin Y P 60 12 Neg NA NA 50 12 Po lt 500 80 277 6 1 700 12 Po lt 500 95 gt 20 60 n lt 7 000 1 10 50 12 Neg
16. 7 Test Result 8 BATTERY 8 IGNITION TIMING 29 POINTS wa ate 9 CONDENSER 9 SPARK PLUGS 10 CARBURETOR 10 Idle Limiter Cap 11 CHECKING amp ADJUSTING DASH POT Automatic Transmission Only 11 Installed on Engine 11 DUAL POINT DISTRIBUTOR 12 Cap and Rotor Head Ste etus 12 Point cc ite WE Eee u Tas 12 Phase Difference 12 TUNE UP GUIDE 14 VALVE CLEARANCE Valve clearance adjustment is performed with the engine not running The initial adjust ment is made while the engine is cold Remove the air cleaner Unbolt and remove the camshatt cover Each valve must be ad justed with the valve completely closed that is the rocker arm should be at the base lowest point of the cam lobe Loosen the locking nut and turn the adjusting screw until the specified clearance is obtained as checked with a fuel gauge between the rocker arm and camshatt Straighten the locking nut Repeat this procedure on each valve turning the engine over by hand to position each valve as necessary Temporarily replace the camshatt cover with two or three bolts and warm up the engine Remove the cover and recheck the valve clearance according to the warranty cer tifi
17. gnition 3 Retarded breaker point Indi Condesor s Distributor 89 DISTRIBUTOR CONSTRUCTION Distributor model Applied engine D410 66A 118 D410 67 116 The distributor for 116 and 1 18 engines has two breaker points located opposite to each other with a phase difference as shown in Figure 90 The difference in phase can be adjusted by turning the adjusting screw phase difference of 7 crank angles is adop ted Two breaker points which consists of ad vance and retard breakers are placed in par allel with each other in the primary ignition circuit The retard breaker point works when the relay is switched and the advance breaker point works when the relay is swit ched OFF See Fig 91 Resistor Advanced Condenser B atatter Rotor head Spark plug 1 99 Externa View of Distributor The distributor follows the conventional de sign except for the dual points i e breaker plate with contact points centrifugal advance mechanism vacuum unit drive shaft and rotor Figures 92 and 93 show an exploded view of the unit Disassembly To disassemble follow the below procedure Take off cap and disconnect rotor head Remove vacuum controller Remove contact set Unscrew two contact set serews remove contact breaker as
18. Replace Replace Repair or replace Supply Replace Clean Repair or replace Check and adjust Correct Adjust Disassemble and clean Repair and clean Replace Tighten to normal torque or replace gasket Replace with proper grade oil Adjust Remove cylinder head and lap valves Correct or replace valve and valve guide Replace valve springs Replace gasket Replace piston rings Overhaul engine Trouble in cylinder or piston ring Compression leaks from valve cylinder head or head gasket UU J U Condition IMPROPER ENGINE IDLING Fuel system in trouble Low compression Others ENGINE POWER NOT UP TO NORMAL Low compression ignition system in trouble Fuel system in trouble Air intake system in trouble Maintenance amp Tune up Probable cause Clogged or damaged carburetor jets Incorrect idle adjustment Clogged air cleaner Defective manifold gaskets or carbureto insulator Improper float level adjustment Incorrect valve clearance Extremely low revolution Poor acceleration above 1 000 rpm Twin carb Defect or malfunction of the ignition system spark plug high tension cable breaker point ignition coil etc Incorrect basic ignition timing Incorrect valve clearance B C D D adjustment incorrect Damaged vacuum control solenoid Sticked anti stall dash pot Incorrect ignition t
19. Vohsele First Second Third Fourth Fifth Reverse 1600 2 900 1 562 1 000 None 3 015 L2 00207 30 173 1 00 None 6 46 1 520 3 657 9 177 1419 1 000 3 638 4941 3099 1 726 1 000 None 6 462 PL521 3 857 9 177 1 419 1 000 None 3 638 358 100 Nom Now 4195 3 197 1 725 1 00 None None 4 195 77778394 294 149 100 None 5 159 3 945 2 403 1 490 1 000 None 5 159 3 1785 100 Noe Now 4195 7777894 240 149 100 None 5159 3 857 2177 1419 1 000 3 638 RL411 3 382 2 013 1 312 1 000 None 3 385 SPL311 PL510 SPL310 3 515 2 140 1 328 1 000 None 4 597 SMOH 790 188 1000 32 2999 WPLiO 9 217 149 150 Noe 3638 3 382 2 013 1 312 1 000 None 3 634 3 382 2 013 1 312 1 000 None 3 634 HLS30 3 549 2 197 1 420 1 000 None 3 164 2 957 1 857 131 1 000 859 9 922 1 110 KLB110 3 757 2 169 1 404 1 000 None 3 640 D L60 transfer case ratios are 2 264 and 1 1 Condition Probable cause Corrective action Loosened bolts such as side flange side Tighten the bolts to specified torque retainer or gear carrier Defective gasket or O ring Replace defective parts with new ones Loose filler or drein plug Tighten the plug Clogged or damaged breather Repair or replace Specifications SERVICE DATA AND SPECIFICATIONS Nomina diameter of ring gear mm 160 6 30 Gear carrier material Malleable Gear ratio number of teeth u T
20. Who shared his triumphs dWragedies This book will give every racing enthusiast afresh Lively and look at some of the world smost island courageous y Puis HM M Uc a Du ma ACCESSORIES REI by Edward J me the latest autom Ve accessory developments and Fep iring adjustment and thods for the automobile owner and the professional mechanic cusses air conditioning brak release Signals cigarette lighters electric clocks turn signal 2 x 4 1 wer seats power window lifts speedometers and windshield washers and wipers There i section devoted to controls for the e handicapped zc pv SBN 87749 1291 39 gt ELECTRO cpu ECTS FOR CAR AND GARAGE by Marston This book contains a icore of simple and very useful electric devices that can be made at home for the car and garage Included circuits for the car that warn of danger from ice and overheating an automatic _ windshield wiper tontro and an automatic sidelight switch Two projects that will be of great help in the garage are a self r gulating battery charger and a speed control for electric drills lectri owners 7 and cians SBN 87749 132 i 553 95 TUNING YOUR BRITISH SPORTSCAR by Charles Williams 22 2 This book will kelp o owners of British made cars tun
21. 1 cylinder spark plug wire and install a tachometer Set idling speed to approximately 800 rpm Check ignition timing if it is 5 B T D C Betore Top of Dead Center by the use of timing light If necessary adjust it as follows Loosen set screw to such an extent that distributor can be moved by hand Adjust ignition timing to 5 B T D C Lock distributor set screw and make sure that timing is correct Ignition timing 5 Retard side 12 Advance side POINTS Check the distributor breaker points ab normal pitting and wear Replace if necessary Make sure they are in correct alignment Fig 6 Adjusting ignition timing full contact and that point dwell and gap are correct Clean and apply distributor grease to the cam and wick Note Do not apply grease excessively Point gap 0 0177 to 0 0217 in Dwell angle 49 to 55 degrees CONDENSER Clean outlet of condenser lead wire and check for loose set screw Retighten if necessary Check condenser capacity with a capacity meter Condenser insulation resistance may be also checked using a tester by adjusting its range to measure large resistance value When condenser is normal the tester pointer swings largely and rapidly and moves gradually back to the infinite side When the pointer does not stay still or it points zero in resistance replacement is necessary Fig 8 Checking distributor point gap l m 1 _ Maintenance
22. 77 2800 20 40 1022 73 77 5 072 77 5 1299 2 _ 1966 67 R 3 433 x 2 630 apo 97 32 96 6000 103 4000 54 60 87 3 66 9 1595 U 20 3 433 x 3 267 120 92 U corbe 132 4400 30 40 87 3 x 23 1981 9 135 0 6000 Selex corbs 13 4800 150 6000 1960 71 L 16 3 266 x 2 902 97 3 96 5600 100 3600 54 60 83 2 x 73 76 1595 1 24 3 266 x 2 902 146 151 5600 146 4400 54 40 83 2 x 73 76 2393 1200 2 874 x 2 756 71 5 4 6000 70 4000 43 50 73 x 69 97 1171 1972 L 36 3 268 x 2 962 97 3 95 5600 100 3600 54 60 i 63 2 73 76 1595 i 1 24 3 268 x 2 902 146 151 6 5600 146 4400 54 40 83 2 x 73 76 2393 t 1200 2 874 x 3 75 73 5 69 6000 70 4000 43 50 73 x 69 97 1171 Specifications TUNEUP SPECIFICATIONS Spark Plugs Distributer Ignitien Timing Car E Firing t Het Idle Year Medel er Type Pelnt Owsil Order Degrees Mark Speed Engine Inch Gep Angle BTDC Location Inch Degrees 1966 68 J 027 031 015 022 50 55 1 1 3 4 2 pulley 1966 67 R 027 031 018 022 50 54 1 3 4 2 Pulley 400 Hitachi 56 61 Mitsubishi u 20 027 031 016 020 49 55 1 2 4 2 16 Pulley 600 1968 72 t 16 i 031 035 017 022 49 55 1 3 4 2 19 Pultey 1970 72 1200 929 032 017 022 49 55 1 3 4 2 7
23. 91 51 JOJOINGIED JO pews 75051 2qn 4 212204 S l 21110141 d ZI 217200 ejpuussedAq d II Hr u2A eus jf 4 01 21042 puz 6 1014 p329 q Is d 8 12014 _ m xf Puel System CARBURETOR Removal Remove air cleaner Disconnect fuel and vacuum lines from car buretor Remove throttle lever Remove four nuts and washers retaining car buretor to manifold Life carburetor off manifold Remove and discard the gasket used between carburetor and manifold Replace it if necessary E Disassembly Do not remove throttle plates Carburetor assembly Remove throttle return spring from primary side 55 r As ETO38 1 Ventui 4 Secondary 2 Main air bleed 5 Primary 3 Emuleion take Fig 120 Removing Thermostat 1 Fast idle cam 2 Diaphragm cheunber ETO39 Fig 121 Removing Diaphragm Chamber Remove pump lever and pump rod Remove cam connecting rod Remove thermostat cover by unscrewing three set screws Needle valve Stopper plate Filter Filter set 1 Chock chamber ETO41 2 Thermostat cover 3 Pump lever 4 Throttle return spring 5 Pump rod Fig 123 Removing Venturies Fig 124 B C D D Securing Screws _ Fuel System Remove choke chamber b
24. H Free stroke of pedal head 25 mm 0 984 in Pressing strength at full stroke 13 kg 33 lb Master cylinder clutch Dia master cylinder 15 87 mm 5 8 in Allowable max clearance between cylinder and piston 0 13 mm 0 0051 in Tightening torque Clutch assembly securing bolt 2 4 2 6 kg m 17 4 18 8 ft lb 135 Specifications ENGINE TORQUE Cylinder head belts Cennecting red belts 185 1200 240 1 519 32 5 te 39 8 Ist turn 32 5 Mat turn 22 5 2nd turn 47 0 2nd turn 39 8 93 1 te 27 5 19 5 te 23 9 19 51 23 9 i 47 0 te 54 2 101 2 36 1 te 43 4 32 5 te 29 8 687 je 75 9 32 5 t 39 8 heft gear 8 9 te 34 7 36 2 te 43 4 36 21 43 4 pump bolts ate E bolts Crank pulley bolis er i 2 9 te 4 3 2 9 te 5 1 am 4 0 te 12 3 6 5 te 10 1 i i n 108 te 116 315 7 te 230 1 115 7 te 130 PISTONS PINS RINGS CRANKSHAFT amp BEARINGS Ring End Gap Model i Yeer or Clearance Comp Engine Inch 7 1966 68 J Ole 098 013 R 00t 006 0016 012 U 20 0012 006 002 012 eem L 16 00164 006 1 24 00t6
25. It must also be replaced when swell wear deformation due to fatigue and damage etc are found Damaged dust cover oil reservoir and cap etc should be replaced Piston spring and inlet valve spring must also be replaced when they are broken or weak Replace clutch hose and tube if any abnormal signs of damage or deformation are found Assembly This is accomplished by reversing the disassembling procedure but the following points should be observed Prior to assembly piston cup should be soaked in brake fluid Install piston cup taking care it is correctly faced Coat well brake fluid to cylinder and piston and assemble them Installation Installation is a reversal of the removal procedure but the following operation should be added Adjust the pedal height by changing the push rod length Bleed air out of the hydraulic system BLEEDING CLUTCH SYSTEM Remove the bleed screw dust cap of the operating cylinder open the bleed screw ap proximately three quarters of a turn and at tach a tube immersing the open end into a clean receptacle containing a small amount of brake fluid Fill the master cylinder reservoir with the recommended fluid and by using slow full strokes pump the clutch pedal until the fluid entering the container is free from air bub bles Screw up the bleed screw on a down stroke of the pedal remove the bleed tube and replace the dust cap Transmission
26. amp Tune up capacity Retard side 0 05 Micro Farad Advance side 0 22 F Micro Farad Condenser insulation resistance 5MQ Mega ohms SPARK PLUGS Remove and clean plugs in a sand blast cleaner Inspect each spark plug Make sure that they are of the specified heat range In spect insulator for cracks and chips Check both center and ground electrodes If they are excessively worn replace with new spark plugs File center electrode flat Set the gap to 0 028 to 0 031 in using proper adjusting tool Tighten plugs to 11 0 to 15 0 ft lb torque CARBURETOR Idle mixture adjustment requires the use of a CO meter When preparing to adjust idle mixture it is essential to have the meter thoroughly warmed and calibrated Warm up engine sufficiently Continue engine operation for one minute at idling speed Adjust throttle adjusting screw so that engine speed is 800 rpm in N range for automatic transmission 080 Fig 9 Checking plug point Check ignition timing if necessary adjust it to the specifications 5 800 rpm retard side Adjust idle adjusting screw so that CO per centage is 1 5 0 5 Repeat the procedures as described in items 3 and 5 above so that CO percentage is 1 5 0 5 at 800 rpm Caution a On automatic transmission equipped model check should be done in the D range Be sure to apply parking brake and t
27. gal 1 Imper pal 1 Imper gal 610 6 0 1 X US gal Without heater 1 Imper gal With heater Check for oil leaks past gasketed flange If any leakage is found retighten just enough to stop leakage It retightening is no longer etfec tive replace filter as an assembly When installing oil filter tighten by hand Note Do not overtighten oil filter lest leakage should occur COOLANT Nissan Long Life Coolant L L C is an ethylene glycol base product con taining chemical inhibitors to protect the cooling system from rusting and corrosion 2 L L C does not contain any glycerine ethyl or alcohol It will not evaporate or boil away and can be used with either high or low temperature thermostats It flows freely tran sfers heat efficiently and will not clog the passages in the cooling system The L L C must not be mixed with other product This coolant can be used throughout the seasons of the year Whenever any coolant is changed the cooling system must be flushed and refilled with a new coolant Check the level 127 C 261 F Freeze protection 15 C 5 F 359 31 F 6 4 1 X US gal X Imper gal 6 8 1 US gal X Imper gal COMPRESSION When it becomes necessary to check cylinder compression it is essential to remove all spark plugs The purpose of this test is to determine whe
28. in the primary ignition circuit The retarded breaker point works when the relay is turned ON and the advanced breaker point works when the relay is turned OFF Cap and Rotor Head Cap and rotor head must be inspected at regular intervals In addition remove cap and clean all dust and carbon deposits from cap and rotor from time to time If cap is cracked or is leaking replace with a new one Point Standard gaps of both points are 0 0177 to 0 0217 in If the gap is off the standard ad justment must be made by loosening point screws Gap gauge is required for adjustment Both gaps must be checked from time to time When point surface is rough take off any irregularities with tine sand paper of No 500 or 600 or with oil stone At this time grease must be supplied to cam shalt and cam heel not apply ex cessively When wear on each breaker point is noticeable replace points together with con tact arm Fig 14 Checking of distributor breaker point gap Maintenance amp Tune up Point gap C 018 to 0 022 in Dwell angle 49 to 55 If point gap is adjusted by examining dwell angle install distributor on engine and proceed as tollows Disconnect wiring harness of distributor trom engine harness Using a lead wire connect B black of engine harness and B of distributor harness t advance side Adjust dwell angle of advance side by loosening point screw Disconnect lea
29. 0 50 to 71 Specifications GENERAL SPECIFICATIONS Cylinder arrangement Displacement Bore and stroke Valve arrangement Firing order Engine idle M T A T Compression ratia Engine idle manifold mmHg inHg at idle rpm M T AIT Oil pressure Warm at 3 000 rpm 4 in line cu in 1 595 62 80 1 770 108 01 mm 83 x 73 7 3 2677 x 2 9016 85 x 78 3 3465 x 3 0709 O H C 1 3 4 2 1 3 4 2 800 650 in D range 8 5 430 16 9 390 15 4 in 7 range kg cm psi 3 5 to 4 0 49 8 to 56 9 _ o N P nSrI tT Q a XsANwxIS O _ _ Manual Transiiiszon STARTING MOTOR SPECIFICATIONS A T Automatic Transmission Distributor Specifications Ne Lead Engine Distributor Centrifuge Advance Vacuum Advance Curtent e Start End Sta End Ampa irom deg in Ho ides rpm in Hg 0 J Hitachi 450 1115 8 3947 69 6 D411 53 2 400 13 4 o L16 Hitachi 450 108 5 9 D410 58 1 500 12 4 L24 Hitachi 450 6 29 558 7 9 0606 52 1 000 9 6 12 Hitachi 550 1258 98 6 5 60 0412 63 2 100 13 8 Brush Starter Spring Current Number Tenslen Draw Lbs Amps 1967 68 Mitsubishi 1 3 2 1 500 ME Y2R 1966 68 Hitachi 1 5 1 8 300 114 92 1966 67 Hitachi 1 5 1 8 500 114 91A 1968 72 Hitachi 1 5 1 8 480 5114 103 1969 72 Hitechi 1 5 1 8 460 5 114 122 1971 72 Hitech 1 5 1 8 420 114 87L O
30. 43 5 4 20 7 5 54 20 with two twin choke carburetors 79 1 320 38 32 4 3 18 1520 1 521 38 32 42 1 7 PL510 52 44 6 4 1469 17 WPLSIO 52 44 8 4 11 4 2 1 5 4 N A 6 6 9 N A 4 8 57 74 4 6 8 4 3 4 4 3 4 6 9 0 34 43 13 9 0 34 43 13 5 7 N A N A 5 9 2 1 2 5 6 68 6 34 13 7 2 with heater 6 8 2 6 3 4 13 7 2 with heater 6 8 26 34 13 7 4 with heater 8 5 3 4 4 3 13 5 7 N A 13 LB110 29 43 M 0 4 8 pts without power takeoff 7 8 pts trnnsfer case 2 1 5 pts vil cooler Specifications Valve spring Manual detent Pressure regulator Pressure modifier ist 2nd shift 2nd 3rd shift 2nd 3rd timing Throttle back up Solenoid downshift Sevond tock 0 9 5 6 Throttle relief 0 0354 0 2205 0 2 4 8 Orifice check 0 0078 0 1890 045 83 go 0 0177 0 3268 Secondary 07 85 0 0276 0 3346 AUTOMATIC TRANSMISSION Valve spring chart Installed Mean Wire dia di No of Free length m active coil mm in Length Load nim in mm in kg Ib 1 3 6 0 32 4 26 5 5 5 905121 0 2362 1 276 1 043 12 12 10 5 43 0 23 5 2 8 40 0472 0 3134 1 693 0 925 6 2 04 8 0 18 5 9 0 0 1 0 0157 10 3150 0 728 0 3543 0 2 0 6 6 0 32 0 16 0
31. Blow all passages and castings with com pressed air and blow off all parts until dry Note Do not pass drills or wires through calibrated jets or passages as this may enlarge orifice and seriously affect car buretor calibration Check all parts for wear If wear is noted defective parts must be replaced Note especially the following Push connecting rod of diaphragm chamber and block passage of vacuum by finger And when connecting rod becomes free check for leakage of air and damage of diaphragm Check float needle and seat for wear If wear is noted assembly must be replaced Check throttle and choke shaft bores in throt tle chamber and choke chamber for wear or out of roundness Inspect idle adjusting needle for burrs or ridges Such a condition requires replacement Inspect gaskets to see if they appear hard or brittle or if edges are torn or distorted If any such condition is noted they must be replaced Fuel System Check filter screen for dirt or lint Clean and if it is distorted or remains plugged replace Check linkage for operating condition Inspect operation of accelerating pump Pour fuel into float chamber and make throttle lever operate And check condition of fuel in jection from the accelerating nozzle JETS The carburetor performance depends on jets and air bleeds That is why these components must be fabricated with utmost care To clean them use cleaning solvent and blow air
32. of the output voltage and current flows from voltage regulator N terminal to E ter minal or ground through the coil as shown in Figure 78 by the dotted line arrow marks Then the coil VC1 is excited and the movable contact point P5 comes into contact with voltage winding side contact point P6 This action causes to turn off the warning lamp and complete the voltage winding circuit as shown by the full line arrow marks When the alternator speed is increased or the voltage starts to rise excessively the movable contact point P2 is separated from the primary side contact P1 by the magnetic force of coil VC2 Therefore register R1 is applied into the rotor circuit and output voltage is decreased As the output voltage is decreased the movable contact point P2 and primary side contact P1 comes into contact once again and the alternator voltage in creases Thus the rapid vibration of the movable contact point voltage constant When the alternator speed is further in creased or the voltage starts to rise ex cessively the movable contact point P2 Electrical System comes into contact with secondary side contact point Then the rotor current is shut off and alternator output voltage is decreased im mediately This action causes to separate movable contact P2 from secondary contact Thus the rapid vibration of the movable contact
33. quiasse rosu puoo 12 19 2558 01002 WANNA quioss 10129405 195 1261109 quiasse 1940219 quiosse 1010Y 9195 yas 811145 10012407 219412558 Lydiam 2001 07 419556 AjqQuiasse 125 quiasse 112498 t c Iz 0 61 81 91 51 p gt a 4 4 5 jo SJUeUCdWOD 6 Fig 95 Unscrewing Breaker Sets Screws Fig 96 Removing Contact Breaker Fig 97 Removing Knock Pin 073 Electrical System EE074 Fig 98 Removing Rotation Parts Fig 99 Removing t Fig 100 Exploded View Also check to be sure that weight pin on spring A is in slit in cam plate with a clearance between the two at beginning and end of governor operation Meanwhile weight pin on opposite side comes in short rectangular hole Shaft center Off set Driven slit off set direction Governor weight Clearance for start and end of advancing angle Rectangular hook Governor spring Cam plate Weight pin Circular hook Governor spring A Rotor positioning tip Q b 0 5 EEO77 Fig 101 Setting Governor s Spring and Cam IGNITION COIL Primary terminal Secondary terminal Cap Spring Side core Primary coil Secondary coil Insulator oil DM CQ l Center core Segment ll Case Fig 102 Construction It does not leave clearanc
34. washers that have been removed Keep tools and work benches clean j j Exhaust Intake EM107 Fig 41 Valve components 4 Keep the necessary parts and tools ready near at hand sure to follow specified tightening torque order Applying sealant Use sealant to eliminate water and leaks Parts requiring sealant are Front cover gasket Front side of cylinder block and cover gasket See Figure 42 Front cover Top of front cover see Figure 42 Main bearing cap and cylinder block Each side of rear main bearing cap and each corner of cvlinder block See Figure 43 Cylinder block Set portions at four mating surfaces tcvlinder block to tront chain cover and cvlinder block to rear main bearing cap See Figure 44 Note Do not apply sealant too much Cylinder Head Valve assembly and valve spring Fig 42 Applying sealant Front cover and gasket 20 to 25 mm 0 787 to 0 984 Points to be applied sealant amp M151 7 y N 4 25 to 30 m d 0 984 to 1 181 in N Fig 43 Applying sealant Main bearing cap and cylinder block Using special tool Valve Lifter ST12070000 set valve spring seat in position and tit valve guide with oil seal Assemble valve in the order shown below valve inner and outer valve springs spring retainer valve collet and valve rocker guide Notes a Check whether the valve face is
35. without operation After replacement is over start engine and check to be sure that fuel is not leaking and that anti dieseling solenoid is in good con dition Notes a Do not allow adhesive getting on valve Failure to follow this caution would result in improper valve performance or clogged fuel passage b In installing valve use caution not to hold body directly Instead use special tool tightening nuts as required After installing a new solenoid check to be certain that there is no leakage cracks or otherwide deformation BOOST CONTROLLED DECELERATION DEVICE Remove 0 by unscrewing three securing screws 1 Do not unscrew three B C D D assembly screw 2 When installing after screwing three securing screws 1 rescrew three B C D D assembly screws 2 in order to prevent the warp of B C D D body Tighten torque 17 to 35 in Ib Assembly and Installation Follow disassembly and removal procedures in reverse Replace gaskets if necessary In disassembling interlock link and related components be careful not to bend or deform any of components Careful reassembly will restore smooth operation of all interlock parts Cleaning and Inspection Dirt gum water or carbon contamination in or on exterior moving parts of a carburetor are often responsible for unsatisfactory perfor mance For this reason efficient carburetion depends upon careful cleaning and inspection while servicing
36. y U float chamber top to fuel level Specifications 021 208 Das 298 w vOt9ZG 075 3 s BP 0 901 08171 ri VEO ovs 001 oo 76 BL 2501 f ponp np 95 5 395 729 Syl 901 OBI I nie 0557 143 orit Sr 06 BL 201 Merpueop 29 38023 021 snp pus 22s 5 025 329809 GII 201 9 OZET yI Fr 001 ep 08 96 58 PQUOUIN ia yupumop Das wory 051 ep puc 99s 59 AEAF 0 2 gp 22108 OOF STI FZ0 I I8 1 94 oyid Sex 00 gy 08 96 48 5011 091 wany 104000 our 2109102 421524204 ym d 001 015 sc 01 SET 291 ONH d H 5 3 EP 4 5 ta T 7 s d 7 5 3 EEN vt T H o R EE j i 5 5 5 Ba i 5 lt f 2 gt H 3 ER ot a z x z 2 pr ar AE 81018212245 132 Specifications rr eee pug 0114113 sis 97 jen januoo oos 395 Das 9 2 02s Das 995 001 925 OG oll 08 Sei b20 T 1811 908990 qs GLI 020 097 22 280 08 86 SIC LBL 501 Tory H 21 0557 addy ouoa2 ns
37. 0 625 0 0236 0 2362 1 260 0 630 1 4 0 7 6 2 41 0 17 0 1 40 0 0276 0 2441 1 614 0 669 3 1 0 7 5 5 15 0 32 5 27 0 0 55 0 0276 0 2165 1 280 1 063 1 2 0 8 6 5 36 0 18 8 1 92 0 0315 0 2559 1 417 0 740 4 2 0 55 5 0 12 0 22 0 12 5 0 60 0 0217 0 1969 0 866 0 492 1 3 0 55 5 0 33 5 21 0 0 60 0 0217 0 1969 1 319 0 827 1 3 26 8 19 0 2 19 1 055 0 748 4 8 21 5 11 5 0 01 0 846 0 453 0 02 5 0 21 8 7 5 0 215 0 858 0 2953 0 5 5 5 25 1 10 5 1 10 0 988 0 413 2 4 Specifications SERVICE DATA AND SPECIFICATIONS General specifications Torque converter a Stall torque ratio esse Transmission a ena TI Control elements Band brake Multiple disc brake One way clutch Gear ratio Reverse Selector positions P Park R Reverse Neutral 2 2nd lock l Lock Oil pump Type ie nece a E DAT Number of pump esee eec eR E toe eie Capacity eres ete e EE Er e Peto Hydraulic control system sss Lubrication system Coolingsystem entente Ir aceite Multiple disc clutch Symmetrical 3 element 1 stag
38. 0 to 36 Transmission case to rear extension 2 15 10 15 pan to transmission case eee 0 5 to 0 7 3 6 10 5 1 Servo piston retainer to transmission case 2 0 5 to 0 7 3 6 lo 5 1 Piston stem when adjuting band brake sse 12091 5 8 7 to 10 5 Piston st m lock m t conve ttd eto e b uc 1 5 to 4 0 11 to 29 One way clutch inner race to transmission 1 3 to 1 8 9 4 to 13 Control valve body to transmission case l 0 55 to 0 75 4 0 to 5 4 Lower valve body to upper valve body eee 0 25 100 35 1 9 to 2 5 Side plate to control valve body eese 0 25 100 35 1 9t0 2 5 Nut for control valve reamet boll Less 0 5 to 0 7 3 6 to 5 1 Oil strainer to lower valve body eese 0 25 to 0 35 1 910 2 5 0 5t00 7 3 6154 Oil pump housing to oil pump cover 0 6 to 0 8 4 4 to 5 8 Governor valve body to oil distributor Inhibitor switch to transmission case ss 0 5 to 0 7 3 6 to 5 1 Manual shaft lock nut esee 3 0 to 4 0 22 to 29 Lock nut for oil cooler pipe connector to transmission 3 0 to 5 0 22 to 36 Oil cooler pipe connecting nut u 07101 5 0 to 7 9 Test plug oil pressure inspection hole ian ao eoe e nece desc 1 4 to 2 1 10 to 15 Support actuator parking rod inserting position to rear extension
39. 00 on th clutch disc hub spring to support the clutch b Coil spring type Temporarily lock the release lever with the release lever stopper Note If the release lever stopper is not placed under each levers the release lever will be over loaded with excessive force when the clutch assembly is removed Loosen the six bolts which are holding the cover assembly to the flywheel a turn at a time by diagonal selection until the spring pressure is relieved Remove the screws completely and lift the clutch assembly away from the flywheel Note Be sure not to soil with grease or oil the surface of the disc RELEASE BEARING Replace if there is rough spot or wear on the release lever control surface or if the inside wear causes too much play If it is judged that the remaining grease is not enough because of the leakage replace the bearing If the clearance between the transmission front cover and the inside diameter of the sleeve is more than 0 5 mm 0 0197 in or there is step wear at the contacting surface with the withdrawal lever replace or repair Replace if there is excessive wear or defor mation Fig 152 Clutch Cover Assembly Diaphragm Spring Type gt y 4t EE p G BN Eu ar Fig 154 Removing Release Bearing REPAIR Refacing Pressure Plate The pressure plate can be refaced if the sur face is rough or has uneven wear In th
40. 0009 0017 Mala Beerings Bearing Sheft End Play Inch 002 006 002 006 002 012 002 012 012 002 012 Inch Pisten Pin Diemeter Shaft B Shah Bearing Inch Diameter Cleerance Diemeter Clearance Inch tach 1 860 001 0005 002 002 2 046 001 001 002 0027 2 045 0013 0034 82 1 967 0006 00246 1 967 0004 0026 1 770 0008 002 Specifications VALVE ADJUSTMENT Velve Lash Valve Angles Volve Stem Clearance Stem Diameter Medel Inch Degrees pring Inch inch Year or Pressure Engine Intake Exhavet Seat Face Lbs In Intake Exhavs Inteke Exhavst 1966 68 4 014 014 45 44 001 001 004 0 34 0 14 004 R 0170 9170 45 44 001 001 004 0 34 9 34 004 0 20 0020 2D 45 44 0004 002 00 9 34 0 34 006 1968 72 L 16 010 9120 45 44 001 2 01 004 0312 9 312 004 1970 72 1 24 010 0120 45 44 001 001 004 9 312 0 312 004 1200 O14 014 45 44 001 001 004 0 312 9 312 004 jig __ __ Engine het ENGINE GENERAL SPECIFICATIONS _ _ _ I Pisten Maximum Year Medel or Bere amp Streke Displacement Maximum Terque Nermal q Engine inches Cuble Inches Ratle Brake Lbs Oll Pressure d ec rpm rp Pounds es SUCCO DUE 1966 68 1 2 874 3 055 79 79 27 47 5200
41. 10 6 0 417 10 8 0 425 11 0 0 433 11 2 0 441 11 4 0 449 11 6 0 457 Rear clutch Number of drive plates 24 Number of driven plates 4 mm 19 1 5 0 039 to 0 059 Thickness of retaining plate mm 2 1111 4 8 0 189 Low amp reverse brake Number of drive plates 222 2 uu 4 Number of driven plates 4 Clearance 0 80 to 1 05 0 031 to 0 041 Thickness of retaining plate mm in 2 22200 11 8 0 465 12 0 0 472 12 2 0 480 12 4 0 488 12 6 0 496 12 8 0 504 Brake band Piston size Big 64 2 520 u a ciere eri usya 40 1 575 Control valve assembly Stamped mark on strainer 2 Governor assembly Stamped mark on governor body 35 SY Specifications Engine idling and stall revolution Engine with emission contro device Idling revolution Ip nessun Sasha SUA ACER 650 at D position 800 at N position Stall revolution J 1 800 to 2 000 Tightening torque kg m ft Ib Drive plate to crankshaft 42222 14 010 16 0 101 to 116 Drive plate to torque converter 222222222202 4 0 to 5 0 30 to 36 Converter housing to engine srein aaa 4 0 to 5 0 30 10 36 Transmission case to converter housing ees 4 0 to 5 0 3
42. 116 ft Ib Piston direction Thrust direction ring Fig 56 Installing piston rod assembly NS 3 164 Fig 57 Piston ring direction Fig 58 Installing connecting Insert pistons in corresponding cylinder using special tool Piston Ring Compressor EM03470000 Notes Apply engine oil to sliding parts Arrange so that the notch mark on piston head faces to the front of engine Install piston rings at 180 to each other avoiding their fit in the thrust and piston pin directions install connecting rod caps Tightening torque for L16 23 to 28 ft lb for L18 33 to 40 ft lb Note Arrange connecting rods and con necting rod caps so that the cylinder num bers face in the same direction Make sure that there exists proper end play at connecting rod big end Big end play 0 0079 to 0 0118 in Install cylinder head assembly Thoroughly clean cylinder block and head sur face Do not apply sealant to any other part of cvlinder block and head surface Fig 59 Checking big end play Turn crankshaft until No 1 piston is at on its compression stroke Make sure that camshait sprocket location notch and plate oblong groove are aligned at their correct positions When installing cylinder head make sure that all valves are apart heads of pistons Do not
43. 3 700 37 10 with A T model for U S and Canada 4 111 37 9 Drive pinion preload adjusted by ET TE A A Shim Drive Pinion Preload kg cm 1 without oil seal u u u u U U 10 6 1 to 8 7 with oil seal 8 to 11 7 0 to 9 6 At companion flange bolt hole ea without oil seal 2 0 to 2 9 4 4 to 6 4 with seal 2 3 to 3 2 5 1 to 7 1 Thickness of pinion height adjusting washer 0 1217 0 1228 0 1240 0 1252 0 1264 0 1276 0 1287 0 1299 0 1311 0 1323 0 1335 0 1346 0 1358 0 1370 0 1382 0 1394 0 1406 0 1417 0 1429 0 1441 Specifications Thickness of pinion bearing adjusting spacer and washer mm in Spacer 2 222 56 2 2 2126 56 4 2 2205 56 6 2 2283 56 8 2 2362 57 0 2 2441 51 2 2 2520 Washer 2 59 0 1020 2 57 0 1012 2 55 0 1004 2 53 0 0996 2 51 0 0958 2 49 0 0980 2 47 0 0972 2 45 10 0965 2 43 0 0957 2 41 0 0949 2 39 0 0941 2 37 0 0933 2 35 0 0925 2 33 0 0917 2 31 0 0909 Side gear and pinion mate Thickness of side gear thrust washer Bo ME 0 75 to 0 80 0 0295 to 0 0315 0 80 to 0 85 0 0315 to 0 0335 0 85 to 0 90 0 0335 to 0 0354 Backlash in pinion mate and side gear or clearanc
44. 30 1520 89 6 492 499 1 50 501750 1920 408 126 4 29 30 PL510 953 504 504 1 25 418 38 39 92 20 33 30 WPL510 953 502 496 2 DIO 12 24 7 50 28 39 29 30 33 30 1591 896 402 499 3 50 50 150 190 08 12 6 34 2930 PL521 HLS30 807 533 530 2 95 2 55 20 120 50 08 20 11 40 32 33 31 24 3 25 12 40 32 24 LBI10 KLB110 00 0 488 490 40 140 1 10 35 139 1 05 16 34 755 4244 35 37 Se li i i 0 Unloaded notes AUTO BODY REPAIRING AND REFINISHING by Weston quU mc ua This book delves deeply into the highly competitive auto body repair trade Every phase is auto to like new condition Topics such 85 construction materials welding hand tools and auto body design are just a few of the major areas clearly explained in this text Designed to serve as a shop manual auto body men and as reference tool for the owners of auto repair shops it is for any well equipped school shop or library 2 TR SBN 877490309 s z MOTOR RACING THE GRAND Hx GREATS by Barrie Gill fle Barrie Gil the internationally famous racing expert has created book that offers portraits ten E dt Juan Manuel Fangio Denny Hulm Mike Hawthorn Jim Jack Brabham Bruce McLaren Nand J ackie Stewart Each man is discussed in this book by the sports writers who knew him the best and
45. Charging relay Normal relay operating voltage is 8 to 10V as measured at alternator A terminal Relay it self however operates at 4 to 5V Use a DC voltmeter and set up circuit as shown in Figure 89 1 grounded 2 Start engine and keep idle 3 Take voltmeter reading 0 Volt 1 Check for continuity be tween terminals of re gulator and alternator 2 Alternator circuit defective if continuity exists Pilot lamp remains lit Check fan belt ten 2 If correct remove Connect positive terminal of voltmeter to regulator lead terminal with negative terminal Below 5 2 Volts and adjust as necessary Pilot lamp relay assernbly is in good condition 058 1 Wrench 2 Crosshead screwdriver 3 Adjusting screw 4 Lock nut Fig 88 Adjusting Regulating Voltage Over 5 2 Volts Pilot lamp remains Ht Pilot lamp relay coil or contact points out of order Replace regulator sion regulator Over 5 2 Volts amp docs not lit TROUBLE DIAGNOSES AND CORRECTIONS Including alternator Condition Sticking brushes Dirty brushes and slip rings Loose connections or broken leads No output Open stator winding Open rotor winding Open diodes Shorted rotor Shorted stator Grounded terminal Broken fan belt Corrective action Correct or replace brushes and bru
46. Completely drain the cooling system engine and transmission lubricant Remove blow by hose from rocker cover and remove air cleaner Remove the radiator grille Disconnect the battery cable and remove the battery off the car Take olf both upper and lower radiator hoses by removing the hose clamps Then loosen the fixing bolts of the radiator and take it out in sequence Note If equipped with automatic tran smission remove the torque convertor cooling pipes from the radiator Remove engine fan and pulley Fig 20 Removing clutch operating cylinder Engine Disconnect the fuel tube from the fuel pump If equipped with heater remove its hoses at engine attachment Disconnect accelerator control linkage and choke wire at the carburetor side Disconnect the wirings the starter alter nator ignition coil oil pressure switch and thermal transmitter Remove the clutch operating cylinder and its return spring Disconnect the speedometer cable Disconnect flat attaching plug connector from the reverse lamp switch Disconnect the shift rods and select rods and then remove the cross shaft assembly bv removing the cross shaft bracket from the side member Disconnect the front exhaust tube trom the exhaust manifold Disconnect the center tube from the rear tube and remove the front tube and center tube assembly Disconnect the propeller shatt by disconnec ting it from the compa
47. H ____ don ppd 681 noya 51871 B S vst X BUS 105 SUID Buuds 86 00 80 6 Ott 8 78611 6 1 191 To 15871 0257 ER rac 21 Suuds 86 srg 000 210 9 X L8 L 6971 org1 _ l l 2 O uU n P 902 X sus 105 Buuds 86 STS 920 510 9 X LBL 581 01 0726 pos 015714 yU 1 X 31 S SI O70 510 X 85 11145 LUG 08 099 90 ert 9 09 0 9 020 510 9 kot 811 891 tro 0767145 150 IU Td B I 681 281 1 gst 005 19 Ol 920 810 9 Ste XLSL 61 1881 nr oT 81 atl X 00 S 22 Sands Os 88 020 elo 9 XSTL 955 921 521 VN 1 8 x69 51 050 110 55 961 081 991 m po 3997 pionna Joata pup shag 2p jo yadap X APRo suuds moug aix do 20 1929 sdi unam wawie ON mP 2 5 TPA suoneogpeds ym Specifications SERVICE DATA AND SPECIFICATIONS Pressure spring Free length sedis ce eS eee Veris 52 3 mm 2 059 in Fitted length a
48. ICH direction Carburetor stopper 9 tich 450 1 8 rotation CO lcan idle limiter ETO31 Fig 11 Setting idle limiter cap Fig 12 Dash pot adjustment CHECKING AND ADJUSTING DASH POT Automatic Transmission only Proper contact between throttle lever and dash pot stem provides normal dash poi per lormance Adjustment of the proper contact can be made by dash pot set screw normal set can not be obtained between dash pot stem and throttle arm rotate dash pot to the proper position Installed On Engine It is necessary that the idling speed of engine and mixture have been well turned up and engine is sufficiently warm throttle valve by hand and read engine speed when dash pot just touches the stopper lever Adjust the position of dash pot by turning nut until engine speed is in the range of 1 600 to 1 800 rpm Then fasten loosened lock nut Make sure that the engine speed is smoothly reduced from 2 000 to 1 000 rpm in about three seconds Ia Advanced breaker point 2 Retarded breaker point 3 Phase difference Fig 13 Dual point distributor DUAL POINT DISTRIBUTOR Distributor has two breaker points located posite each other with a phase difference as shown in Figure 13 The difference in phase can be adjusted by the adjusting screw A phase difference of 7 crank angles is adopted Those two breaker points are placed parallel
49. ISTRIBUTOR SPECIFICATIONS AND SERVICE DATA Distributor type D410 66A Specifications Make Applied engine vehicle Firing order Rotating direction Ignition timing degree Idling adjustment M T A T Dwel angle degree Condenser capacity zF Advanced isde Retarded side Phase difference degree lt All distributors 2 Point gap Point pressure Shaft dismeter lower part Housing inner diameter Clearance between shaft and housing Repair limit of clearance Shaft diameter upper paz Cam inner diameter Clearance hetween shaf and cam Weight pivot diainetc Weight hole diameter Clearance between pi ot and hole HITACHI L18 610 1 3 4 2 Counterclockwise 5 B T DC 59 800 rpm 59 650 rpm in D range 49 ta 55 0 2 to 0 24 0 05 15 7 at crank angle in kg Ib mm in Roc rpm mm in Lesser oos P inm in usu eec ctt mm mm 2 mm in mm in mm in L16 510 and 620 eee 0 45 to 0 55 0 0177 to 0 0217 Advanced and Retarded side equally 0 50 to 0 65 1 10 to 1 43 12 430 to 12 440 0 4894 to 0 4898 12 450 to 2 468 0 4902 to 0 4909 0 010 to 0 038 0 0004 10 0 0015 0 08 0 0031 0 0002 0 3150
50. NDATIONS 92 ASSEMBLY boa tok 93 Steering STEERING GEAR COMPONENTS Et Steering gear housing Shim worm bearing Ass y bearing steering worm Ass y nut ball Ass y column steering Sha t steering sector Cover sector shaft Screw adjusting roller shaft ring housing cover Comp jacket column Ass y bearing column Fig 144 Steering Gear Components RECOMMENDATIONS Due to the need for a large number of special mended that repairs to the steering com tools and alignment equipment it is recom ponents be left to a completely equipped shop Steering ASSEMBLY Tightening torque 1 8 to 2 5 kg m 13 0 to 18 1 ft Ib Apply grease here when I assembling Gear arm E loan Tightening torque i 12 5 to 14 kg m 99 to 101 ft 1b The standard distance between the bottom of the T groove and the surface of the housing at the neutral position IV Tightening torque 1 8 to 2 5 kg m 13 0 to 18 1 ft lb Select the shims so that the clearance comes to be Tightening torque 1 8 to 2 5 kg m 13 0 to 18 1 ft 1b 22224 Method the gear assembly BEARING PRE LOAD ADJUSTMENT Adjust the thickness of the worm adjust shim so that the rev torque of the steering wheel comes to be 4 0 to 6 0 kg cm 55 to 83 in oz before the sector shaft is fitted 1 Place the sector shaft on the neutral point 2 Adjus
51. ON 7 Test Result 5 2 ear een ie 8 8 IGNITION 9 POINT 9 CONDENSER 9 5 8 10 CARBURETOR 10 Idle Limiter Cap 1i CHECKING amp ADJUSTING DASH POT Automatic Transmission Only 11 Installed on 11 DUAL POINT DISTRIBUTOR 12 and Rotor Head 12 Point elo TO 12 Phase Difference 12 TUNE UP GUIDE 14 TROUBLE SHOOTING 15 ENGINE DESCRIPTION 22 23 INSTALLATION 24 DISASSEMBLY 24 Pistons Connecting Rods 27 Cylinder Head 27 ASSEMBLY 27 Cylinder Head 28 Piston and Connecting Rods 29 Engine cesis dan rax deles 30 OILPUMP REUS 36 Removal iecore IEEE S E 36 Installation 37 ELECTRICAL SYSTEM STARTER 40 Lev e ark 40 CHARGING CIRCUIT DESCRIPTION 40 ALTERNATOR 41 Description 41
52. YE AABFO H qua Y 1181 Pe I ee cm 0261 9 82 lt 4 Ionquoo 29 Das 385 SII 228 Jat Coyne 001 081 SIT OZI 6961 Tort 09271 8 91 020 ost gb VLO SSZ OFS Sst 906 OTT 917 yespumop 95 aes 38s Dax das E 901 981 051 591 20171 09271 Sc 4vQ oI 081 er 611 Sy6 UT eH 917 3Jeap pis 2443 ns L AA9y5 H 40 5 sy 400U 08 1 ozn 330 2 UIA oos HHdkk 9SF I x os LECT 510 09 081 PLI ozn yeipepis 4 ns 181 ozn yerpapis 9443 ns 9 A8CH H 10 S AAStH H 1 9 560 86V Wis y 2443 ns AABCH H 5 1 pus ISS ttr Meipueop 15971 616 320143 0567 29 Des 325 Jas wud E pnp 001 001 221 811 95061 819 101 OBUT 90 VOG I 093 005 LY 8 1 801 6 SI Leg 201 HNH uta f Specifications SIC Suyds 911477 17 186 000 zio 9 867 X 601 MU ulwqivp 65 X 06 S 008 ow 10 9 Ue X988 69 1 udurqdwp ots 1
53. ake out piston apply air or hydraulic pressure from inlet hole Remove the rubber seal from the groove on the cylinder Remove the retainer and wiper seal and then it can be easily taken out Inspection Repair Check the cylinder assembly for oil leakage and any damage and replace the cylinder assembly if any abnormal condition is detec ted on it Note Unlike the wheel cylinder cup of drum brakes the piston seal of SC type disc brake has three important functions sealing retracting piston and automatic adjusting If pistonseal is damaged replace whole cylinder assembly as a unit However if it is necessary to replace piston seal replace wiper seal at the same time When pads are replaced two or three times cylinder assembly or seal should be replaced though they still seem to be in good condition Fig 135 Removing Piston Check the pad for wear and crack replace if it is damaged or become worn to less than 0 04 in in thickness not including the metal backing plate Check the caliper for damages and replace it if any damage is detected Check the rotor and if it shows score ex cessive out of roundness and so forth recon ditioning by machining is required Limit of reconditioning in thickness is 0 331 in Standard rotor thickness 0 0394 in Runout of the rotor should be less than 0 0048 in total indicator reading If any abnormal condition such as crack distortion or excessive run
54. alve and valve spring Blow valve assembly with breath to examine its function Check diaphragm for small holes cracks or wear Check rocker arm for wear at the portion in Check rocker arm pin for wear A worn pin may cause oil leakage Check all other components for any abnor malities and replace with new parts if necessary Assembly Reverse the order of disassembly Closely ob serve the following instructions Use new gaskets Fig 116 Schematic View of Fuel Pump Puel System Fig 117 Removing Pole Rod Lubricate rocker arm rocker arm link and rocker arm pin before installation To test the function proceed as follows Position fuel pump assembly about 3 3 ft above fuel level of fuel strainer and connect a pipe from strainer to fuel pump Operate rocker arm by hand If fuel is drawn up soon after rocker arm is released fuel pump is functioning properly Fig 118 Structure of Fuel Pump AWS Q Nm Fuel pump cap Cap gasket Valve packing Ass y Fuel pump valve Ass y Valve retainer Diaphragm A ss y Diaphragm spring Pull rod Lower body seal washer Lower body seal Inlet connector Outlet connector Rocker arm spring Rocker arm Rocker arm side pin Fuel pump packing Spacer fuel pump to cylinder block 3111019 2104 5524 yof 9qnj uossnut n 191 mops pooiq 0 92 Q 95 1 0c 61 8I LI
55. and disc Removal Jack up the vehicle and support it on stands and remove the wheel Disconnect the front brake hose from the brake tube Note Plug up the brake tube with a wooden peg to avoid spilling fluid during work on caliper Screw out bolts fixing to the knuckle flange and remove the caliper assembly Push rod ass y Dust cover Stopper ring Piston ass y Piston ass y Secondary piston cap Piston Primary piston cap Master cylinder body Reservoir band ass y Reservoir on O h Reservoir ass y Filter Bleeder screw Check valve spring Check valve ass y Valve cap gasket Valve cap Fig 129 Tandem Master Cylinder Brakes Cylinder Piston seal Wiper seal Retainer Piston Clip Shim Pad Caliper plate Torsion spring Cotter pin 2 Nut Y li Washer bui m Support bracket Hold down pin Pivot pin Mounting bracket Spring O Fig 130 Front Disc Brake otating direction Forward ia Fig 131 Sectional View of Front Disc Brake Fig 134 Removing Brake Disc Remove the spindle nut and the disc hub and separate the rotor from the hub assembly Disassembly Remove the anti rattle clip from the caliper plate and then pick up the pad Remove the tension springs and pull the cylin der out of the caliper plate To t
56. and side electrodes in parallel Set spark plug gap to specification Install spark plugs and torque each plug to 11 to 15 ft lb Connect spark plug wires Cleaning and Regap Clean spark plugs in a sand blast type cleaner Avoid excessive blasting Clean and remove carbon or oxide deposits but do not wear away porcelain If deposits are too stub born discard plugs Fig 104 Setting Spark Plug Gap TROUBLE SHOOTING IGNITION Spark length Trouble location Distributor No sparks at all Ignition coil High tension cable 1 to 2 mm 0 0394 to 0 0787 in or irregular Defective insulation of condenser Breakage of lead wire on low tension side Defective insulation of cap and rotor head Point does not open or close Wire breakage or short circuit of coil Wire coming off Defective insulation Point pap too wide Oil sticking on point Point burnt too much Causes Remedies Replace Repair Replace Repair Replace with new one Repair Replace Correct Clean Replace Less than 6 mm 0 2362 Engine misses Engine causes knocking very often Engine does not give enough power Troubles Trouble location Electrical System Causes Remedies Spark plugs Distributor Ignition coil High tension code Spark plugs Distributor Spark plugs Distributor Spark plugs Electrode gap t
57. as well as the special tools necessary it is recommended that internal repairs be left to a fully equip ped shop 113 Work FRONT FENDER Removal and Installation er Removal and Installation TRUNK LID Removal and Installation Torsion Bar Removal and Body Work FRONT FENDER Removal and Installation Remove the radiator grill head light and head light finisher Remove al bolts securing the fender and then remove the fender Installation of the fender is the reversal of the procedure given for removal Fig 171 Removing the Fender Fg 172 Removing the Hood HOOD Removal and Installation Open hood and place a protective cover over the front fenders to prevent damage to pain ted areas Scribe pencil the location of the hinge straps on under surface of hood the bolts attaching the hinge to the hood With the aid of a helper remove the hood Fig 173 Removing the Hood Support Rod END WRENCH w TRUNK LID abeo 2 a aea m Fig 174 Removing Trunk Lid Using screw driver shown Figure 173 remove the hood support rod from the support bracket Installation of the hood is the reversal of the procedure given for removal However align t
58. ate 103 ADJUSTMENT 104 INSTALLATION 104 MASTER CYLINDER 105 Removal ys as um ays d Rs 105 Disassembly 105 Inspection 106 Assembly 106 106 Clutch FLY WHEEL RING GEAR 10 Clutch disc Bearing sleeve Clutch release bearing Clutch cover assembly with plat Bearing sleeve holder spring Bolt Dust cover Lock washer Return spring Clutch withdrawal lever Withdrawa lever push Retainer spring Lock nut 150 Clutch Diaphragm Spring Type Clutch disc Clutch assembly Clutch cover Pressure plate Pressure plate bolt Eye bolt pin Pressure spring Release lever Retainer spring Bearing sleeve Clutch release bearing Bearing sleeve holder spring Dust cover Return spring Lock nut Withdrawal lever p Release lever seat Lock nut Release lever support Retaining spring Bolt Lock washer Clutch withdrawal lever an Aw k Q Pressure spring retainer Fig 151 Clutch Coil Spring Type Cluteh ES xis ia f 8 H 2 gt k 1 E 102 REMOV AL Remove the transmission assembly from the engine a Diaphragm spring type Fully insert a special tool Clutch aligning Bar ST206000
59. cates Readjust as necessary Replace the cover using a new gasket if the old gasket appears flattened or broken Run engine and check for leaks from the gasket Valve clearance Unit mm Intake 0 20 0 008 Exhaust 0 25 0 010 Intake 0 25 0 010 Warm SM M gt Feeler gauge Fig 1 Adjusting valve clearance Maintenance amp Tune up FAN BELT Check cracks or damage Replace if necessary Adjust belt tension It is correct i deflection is 0 315 to 0 472 in when thumb pressure 22 0 lb is applied midway between fan and alter nator pulleys ENGINE OIL Check if oil is diluted with water or gasoline Brain and refill oil if necessary Notes a A milky oil indicates the presence of cooling water Isolate the cause and take corrective measure b An oil with extremely low viscosity in dicates dilution with gasoline Check oil level If below the specified level raise it up to the H level Engine oil capacity including oil filter Maximum H level 4 U S qts Minimum L level 3 US qts OIL FILTER The filter is of a cartridge type ETOO7 Fig 2 Drive belt tension Maintenance 6 Tune up Percent concentration Sea level Boiling point 0 9 kg cm cooling system pressure 124 C 255 F 109 C 228 F Water capacity 544 1 U S gal X Imper gal 6 5 1 X US gal 6 0 Z 1 U S
60. clean thoroughly with carbon tetrachloride or gasoline b After lining installation and bonding grind the lining face to a diameter equal to that of the brake drum Check and adjust cams for their smooth operation Springs If they are considerably weak replace them Check the brake disc for distortion Check the bore of the wheel cylinder for wear sign of rust and damage If the clearance between the cylinder and the piston exceeds 0 0059 in replace them When the wheel cylinder is overhauled it is recommendable to replace cups even if ap parently in satisfactory conditions and they must be replaced if deformed due to damage crack corrosion and ageing Assembly Assemble in the reverse order of disassembly Be careful not to smear the brake linings with oil or grease Apply thinly to the sliding areas such as shoes and discs cam adjuster stud and spacer Adjust the shoe clearance and bleed the hydraulic system Front Suspension Strut mounting insulator Coil spring Strut assembly Suspension cross member Stabilizer Tension rod Transverse link Steering knuckle arm PPY ES Fig 143 Front Suspension Assembly RECOMMENDATIONS Due to the need for a large number of special mended that repairs to the front end be left to tools and alignment equipment it is recom a completely equipped shop Steering STEERING GEAR COMPONENTS 92 RECOMME
61. d wire from B black of distributor harness and then connect it to Y vellow of distributor Retard side Adjust dwell angle of retard side by loosening point screw Aiter adjustment disconnect lead wire then connect engine harness and distributor har ness securely Phase Difference check phase difference install distributor on engine and proceed as follows Disconnect wiring harness of distributor from engine harness Using a lead wire connect B black of engine harness and B of distributor harness Advance side See Figure 15 Lead wire Z 22 Adjuster plate set screws EE135 Fig 15 Connect lead wire Maintenance amp Tune up Spark timing control system for Automatic Transmission Throttle SW Engine start Partial throttle opening ON Wide throttle opening OFF and high speed crousing Adjuster plate set screws 136 Fig 17 With engine idling adjust ignition timing by rotating distributor to specifications 12 800 rpm advance side Disconnect lead wire from B black of distributor harness and then connect it to Y t yellow of distributor harness Retard side With engine still idling check to determine that phase delay is 7 degrees in terms of crank shaft angular displacement Spark timing Phase difference 4 Crank angle adjusting place Fig 18 Phase difference adjusting scale To correct further proceed a
62. e 109 If the temperature of suction air is low when the engine is running the air control valve closes the underhood air inlet and introduces hot air through the cover which is installed on the exhaust manifold See Figure 110 When the temperature of suction air around the sensor reaches 37 5 100 F or above the sensor actuates to open the air control valve When the temperature of suction air around the sensor further rises and reaches above 48 C 118 F the air control valve completely opens to prevent the entrance of hot air and allows under hood air alone to be introduced into the carburetor See Figure 111 AIR CONTROL VALVE The air control valve acts in the manner described previously and the temperature of suction air around the sensor is always kept at about 43 C 110 F When the engine is operating under heavy load the air control valve fully opens the un Air inlet pipe Vacuum motor ass y Temperature sensor ass y Hot air pipe Air control valve Idle compresator Dukun Fig 109 Automatic Temperature Control Air Cleaner To manifold Diaphragm spring Diaphragm Vacuum hose Air bleed valve Partially open Hot air 1 Hot air pipe 1 Airinlet pipe 8 Temperature sensor 2 Ais control vawe aseubly ECOG Fig 110 Hot Air Delivery Mold During Cold Engine Operation Underhood air Air intet pipe 6 Air bleed valve 2 control va
63. e 2 phase torque converter coupling Su ua wak 20 1 3 speed forward and one speed reverse with planetary gear train The transmission is placed in neutral The output shaft is fixed The engine can be started TATUM Backward running The transmission is in neutral The engine can be started Up downshifts automatically to and from 1st nd and top Fixed at 2nd Fixed at low or downshifts from 2nd Internally intermeshing involute gear pump Automatic transmission fluid Dexron type 5 5 liters 5 7 8 U S qis 4 7 8 Approximately 2 7 liters 2 7 8 U S qts 2 3 8 Imp qts in torque converter Controlled by detecting the negative pressure of intake manifold and the revolution speed output shaft Forced lubrication by an pump Water cooled by a circulation type auxiliary cooler located at the radiator d 6 i Specifications and adjustment Automatic transmission assembly Model code number enses sense eese et ns then sese bad a aetas aa X0400 Torque converter assembly Stamped mark on the esses inertem 16 B Front lutch Number of drive plates Number of driven plates 3 Clearance p 1 6 to 1 8 0 0630 to 0 0709 Thickness of retaining plate 02 22
64. e between side gear and thrust washer 0 1 to 0 2 0 0039 to 0 0079 Ring gear Backlash between ring gear and drive pinion RP 0 1 to 0 2 0 0039 to 0 0079 Runout of rear side of ring gear gear PA RN TAE Less than 0 05 0 0020 of side retainer adjusting shim 0 20 0 0079 0 25 0 0098 0 30 0 0118 0 40 0 0158 0 50 0 0197 Side bearing standard with mm in 20 0 0 7874 Specifications Carburetor Specifications az n 55 2 d 16 EP Pio ii t H SERE e lt z L d HE 1 i 80 180 880 S P with emission control 180 ML 79 150 PL410 d 2 7 2 s El 145 750 1320 M ALL 850 L520 i M a J 850 PL411 J with emission control L520 1 581 R 87 950 3 with 23 39 with 0 87 emission 38W 5 M 70 959 control with 38W 6 en es 020 87 3 SU type 950 020 See Mikuni text Solex ee 020 32 17 with 8 87 with emission 46W 5 N 25 950 contro with 46W 7 Pon 4 L16 071 87 1 510 959 o N L18 071 87 150 with emission 950 130 contro L24 23 N 27 87 with 079 950 emission control HLS30 eee 12 T with 780 emission control LB110 KLB110 _ F
65. e either at the start and end of advancing With unit assembled check to be sure that driven slit and rotor position tip 9 are set in the same direction See Figure 101 After assembly check operation of governor before installing it on engine Ignition timing should be tested with unit mounted on engine IGNITION COIL Description The ignition coil is of an oil filled type The ig nition coil case is filled with oil which has good insulating and heat radiating charac teristics The ignition coil has a greater ratio between the primary and secondary windings to step up the battery voltage to the high voltage to cause stronger sparks to jump the spark plug gap The cap is made of alkyd resin which offers high resistance to electric arc and increased insulation Overheating The resistor in the ignition coil circuit helps produce strong sparks from starting to high speed full power operation The internal resistor limits to a maximum safe flow of the primary current through the coil and distributor contact points Thus it protects the contact points during slow speed operation when they are closed for long inter vals The ignition coil and resistor should be han dled as a matched set SPARK PLUGS Description The spark plugs are of the resistor type having 0 551 in threads and 0 0276 to 0 0315 in gap The inspection and cleaning should be made every suitable maintenance period If necessary r
66. e push Remove the clutch aligning bar release lever stopper rod Disconnect the clutch hose from the master Refit the release bearing and transmission cylinder and drain out the fluid case Remove the securing bolts and take off the Note In assembling a clutch disc be sure master cylinder assembly from the car to apply small amount of Multipurpose grease MILG 2108 or 10924 to the disc splines Neglecting this caution will result Disassembly in clutch slippage Remove the filler cap and drain out the fluid Clutch Pull back the rubber boot and remove the snap ring and then the push rod and ring can be removed Unscrew the piston stopper screw and remove the piston assembly completely The piston assembly can be separated by lif ting the spring seat edge over the shouldered end of the piston Inspection Prior to inspection all parts should be cleaned or washed Note To clean or wash all parts of master cylinder operating cylinder and pipings clean brake fluid must be used Never use mineral oils such gasoline and kerosene etc as to do so will ruin the rub ber parts of the hydraulic system To do so will ruin the the hydraulic parts of the hydraulic system Check cylinder and piston for abnormal one sided wear and damage and replace if found If the clearance between cylinder and piston is more than 0 005 in replace cylinder Renew piston cup principle when disassembled
67. e them for maximum power and speed TUNING ec YOURBRITISH SPORTSCAR gives a non technical but practical guide to how family cars can be made to behave more like sport cars An added feature is a list of major American suppli rs of the British made auto parts discussed in this book TUNING YOUR BRITISH SPORTSCAR i is profusely illustrated with E many photos and diagrams ms Lr 8 87749 165 8 7 95 discussed amp nd explained in light of the correct repair techniques and tools tO be used to return damaged ge Each project is described by lucid and easily understandable instructions and illustrated by clear C diagrams All necessary components listed for each device This book willbe of great value to qut contenders for th honor of being the gre t st driv r of them all Graham Hill Stirling Moss Jochen ae 4
68. eadlights 37 5 50 PL521 37 5 Front turn parking 25 8 Tail stop 25 8 Rear tum 25 Backup 25 Interior 6 License plate 8 PL510 Headlights 37 5 WPLS510 a5 Front parking turn 25 8 Tail turn 25 8 Stop 25 Backup 25 License plate 8 Interior 10 HLS30 Headlights 50 40 Side marker turn 23 7 Side marker license plate 75 7 Stop 23 Rear tum 83 93 Instrument warning glove 3 compartment clock Four way flasher 23 Inspection 8 Specifications 126 WIRING DIAGRAMS f 228 BIN 5 OPTIONAL EQUIPMENT WPL510 antomatic transmission Specifications 21 510 standard transmission MANUAL TRANSMISSION APPLICATION OF TRANSMISSION MODELS Type of Transmission Applied Model Speedometer gear Final gear ratio N510 S U NL510 S U R3W65L 3 Forward speed JN510SU JNL510S Ist 3 263 Column shift Warner type synchromesh 2nd 1 645 3rd 1 000 Rev 3 355 P510 S U PL510 S WP510U WPL510 NL510 S T JN510TU F4W63L P510 S TU JNL510 S T 1st 3 382 PL510 S T 2nd 2013 N510TU 3rd 1 312 P510TKU PL510TK 1 000 a Forward speed RPL510SWTU PL510TU Floor shift Warner type synchromesh FAW63L 1st 3 657 WP510TU 2nd 2 177 WP 510T 3rd 1 419 4th 1 000 Rev 3 638 Specifications Manual Transmission Ratios
69. eplace Note spark plugs installed on engine must be of the same brand and number of heat range Fig 103 Spark Plugs Electrical System Electrical Inspection Remov spark plug wire by pulling on boot not on wire itself Remove spark plugs Check electrodes and inner and outer por celains of plugs noting the type of deposits and the degree of electrode erosion Normal Brown to grayish tan deposits and slight electrode wear indicate correct spark plug heat range Carbon fouled Dry fluffy carbon deposits on the insulator and electrode were mostly caused by slow speed driving in city weak ig nition too rich fuel mixture dirty air cleaner etc It is advisable to replace with plugs having hotter heat range Oil fouled Wet black deposits show excessive oil entrance into combustion chamber through worn rings and pistons or excessive clearance between valve guides and stems If the same condition remains after repair use a hotter plug Overheating White or light gray insulator with black or gray brown spots and bluish burnt electrodes indicate engine overheating Moreover the appearance results from in correct ignition timing loose spark plugs low fuel pump pressure wrong selection of fuel a hotter plug etc It is advisable to replace with plugs having colder heat range After cleaning dress electrodes with a small fine file to flatten the surfaces of both center
70. free from foreign matter b The L16 and 1 18 engines use double type valve springs Valve rocker pivot assembly Screw valve rocker pivots joined with lock nuts into pivot bushing Camshatt assembly Set locating plate and install camshaft in cylinder head carefully Do not damage the bearing inside The oblong groove of locating Points to applied sealant EM152 Fig 44 Applying sealant Cylinder block ST12070000 Fig 45 Installing valve plate must be directed toward the front side or engine Install camshaft sprocket on camshaft and tighten it together with fuel pump cam to the specified torque Tightening torque 86 to 116 ft lb At this time check camshatt end play EM155 Fig 48 Installing piston pin Install rocker arms by pressing down valve springs with a screwdriver Install valve rocker springs After assembling cylinder head turn cam shatt until No 1 piston is at T D C on its compression stroke Piston and Connecting Rod Assemble pistons piston pins and connecting rods to the designated cylinder Notes a Piston is pressed into connecting rod and fitting force is 0 5 to 1 5 tons and the aid of special tool Piston Pin Press Stand ST13030001 is necessary When pressing piston pin in connec ting rod apply engine oil to pin and small end of connecting rod b Arrange so that oil jet of connecting lod big end is directed toward the right side of cyl
71. ghting circuit damaged wiring Head lamps dim High resistance in light circuit engine running above idle Check light wiring and replace or tape damaged wires Light wiring insulation damaged producing momentary short High voltage regulator setting Adjust voltage regulator Loose connections lighting Check circuit for loose connections circuit Lights burn cut frequently Recharge battery and correct cause Loose connections lighting Tighten connections circuit Burned out bulbs Replace bulbs or seated beam unit Open or corroded contacts in light Replace lighting switch ing switch Replace turn signal and lighting switches Light will not Discharged battery light Open or corroded contacts in turn signal and lighting switches Switch faulty Replace switch Wires broken disconnected or Make necessary repairs loose Balb burned out Replace bulb Loose connection ground Tighten loose connection ed lamp body perly ground lamp body Faulty flasher unit Replace flasher unit Burned out parking or tail lamp on Replace bulb that side Stop lamps will not light Turning signal lamps light with out blinking Blinking side too fast Loose contact of bulb Make necessary repair Imprope
72. gine at 2 500 rpm for several minutes After racing for several minutes ammeter reading below SA After racing for several minutes ammeter reading over 5A Fully charged battery available 1 Replace with fully charged battery 2 Check to see if current falls below 5 Fully charged battery not available i Connect a 0 25 ohm resistor in series Current falls below 5A Current does not fall below 5A Recharge battery and see if current falls below 5A 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 voltmeter out of limits shown in table the following chart Regulator functioning properly Regulator out of order Have it repaired at authorized shop Electrical System Regulator model TL1Z 57 and TL1Z 58 HITACHI Temperature C F 10 14 0 32 10 50 20 68 30 86 40 104 Voltage be approx 0 3 higher than the rated for two to three minutes af ter engine is started or more specifically when regulator becomes self heated Measurements should then be made within one minute after starting engine or when regulator is cold d The regulator is of a temperature com pensating type Before measuring voltage be sure to measure surrounding tem pera
73. he hinges within the scribe marks TORSION BAR Body Work Adjustment To adjust the hood release the hinge attaching bolts and move the hood to the desired position After the adjustment has been made tighten the hinge bolts TRUNK LID Removal and Installation Open trunk lid and place a cover over the rear fenders and rear panel to protect them from damage to painted area With the aid of a helper remove the trunk lid attaching bolts and remove trunk lid See Fig 174 Torsion Bar Removal and Adjustment Remove torsion bar fixing wire then using a screw driver as shown in Fig 175 remove the torsion bar The tension of the torsion bar can be adjusted by changing the location of the bar with the use of a screw driver Outside handle Outside handle rod Clip Pull knob Escutcheon Spring clip Inside handle Remote control Lock ass y Striker Key cylinder Bell crank Q9 Um mew ME Fig 176 Door Lock Mechanism Work Fig 177 Window Regulator 1 2 3 4 5 6 7 8 9 Front door glass Bottom channel Front regulator 55 Regulater handle Raller guide i Stopper Connecting clip Nylon washer Rear door glass Rear regulater ass y Specifications STARTER 120 DISTRIBUTOR 121 SPARK PLUGS 122 VALVES o VER Iu 122 OIL PUMP 122
74. hermostat housing thermostat and water outlet in their positions Do not forget to install gasket Install rocker cover Note Bond gasket to rocker cover using sealant Then install rocker cover to cylinder head Install spark plugs Connect distributor to plug high tension lead wire Install engine mount bracket on left hand side Install clutch assembly L16 and L18 0 2 0 0079 0 25 0 0098 0 25 0 0098 0 30 0 0118 Tightening torque 8 7 to 15 9 ft lb Using an overhead hoist and lifting cable hoist engine up away from engine stand and then down onto engine carrier Install alter nator bracket adjusting bar alternator fan pulley fan and fan belt in this order Then check to be sure that deflection of fan belt is Press 10 kg 22 2 1b Pumch mark Oil hole ELOO9 Fig 73 Aligning punch mark and oil hole held within 0 315 to 0 472 in when thumb pressure is applied midway between pulleys pressed force is about 22 0 lb Install engine mount bracket right hand oil filter oil pressure switch oil level gauge and water drain plug When installing an oil filter fasten it on cylinder block by hand Note Do not overtighten filter or oil leakage may occur Pour engine oil up to specified level OIL PUMP Removal Remove distributor Drain engine oil Remove front stabilizer Remove splash shield board Remove oil pump body with drive
75. igh speed Connect DC voltmeter 15 30V DC ammeter 15 30A battery and resistor 0 25 ohms with cables as shown Check to be sure that all electrical loads such as lamps air conditioner radio etc are discon nected Before starting engine be sure to make short circuit with a cable between fuse side ter minal of resistor 0 250 and negative side terminal of ammeter Failure to follow this caution causes needle of ammeter to swing violently and resulting in damaged ammeter Refer to the following chart to determine if regulator and relative parts are in good con dition Notes a Do not measure voltage im mediately after driving Do this while regulator is cold b To measure voltage raise engine speed gradually from idling to rated speed 054 1 Point 10 Lock nut 2 Charge relay con ct Adjust spring 3 Connecting spring 12 4 Armature 13 3mm 0 1181 dia 5 Core gap screw 6 Yoke gap 14 4 0 1575 dia 7 Yoke screw 8 Adjusting screw 15 Contact set 9 Voltage regulator contact b Construction of charge relay Fig 84 Structural View Electrical System REGULATOR GENERATOR Short circuit here between fuse side terminal and termina of ammeter before starting the operation RESISTOR FOR MEASUREMENT AMMETER VOLTMETER 10A 30v Fig 85 Measuring Regulator Voitage with Regulator on Vehicle t Start engine 2 Rotate en
76. il spring Bumper rubber Spring seat Shock absorber Drive shaft Differential mounting member Differential carrier Fig 147 Rear Axle on Suspension SHOCK ABSORBER Removal Open the trunk and remove the trunk finisher assembly Remove the double nuts which fasten the up per end of the rear shock absorber to the body Remove the shock absorber from its lower mounting bracket on the axle housing Inspection Test the shock absorber and replace if necessary Check for oil leakage and cracks Also check the shaft for straightness the rubber bushings for damage cracks and deformation Replace the parts if necessary Installation Installation of the shock absorber is the rever sal of the procedure given for removal eee ee Fig 148 Installation of Rear Shock Absorber Upper End Rear Drive amp Suspension DRIVE SHAFT Drive shaft Boot band Flange yoke Drive shaft ball Snap ring Oil seal Ball spacer Sleeve yoke Needle bearing Drive shaft stopper Sleeve yoke plug Snap ring Rubber boot Spider journal Fig 149 Drive Shaft RECOMMENDATIONS necessary it is recommended that the Due to the large number of special tools overhaul of the differential be left to a required and the advanced knowledge properly equipped shop 102 RELEASE BEARING 102 REPAIR u uu q hae elses eng a Bice 103 Refacing Pressure Pl
77. iming Defective spark plugs Defective distributor points Malfunction of choke system Clogged fuel pipe or floating valve Dirty or clogged fuel strainer Fuel pump will not work properly Clogged carburetor jets Clogged air cleaner Air inhaling from manifold gasket or carburetor gasket Replace M Corrective action Clean or replace Adjust Replace element Replace gasket or insulator Adjust Previously mentioned Adjust Adjust Loosen idling adjusting nuts about a half turn Replace Adjust Adjust Adjust Replace Previously mentioned Adjust Clean adjust or replace plugs Dress or condenser replace points Also check Adjust Clean Replace Repair or replace Disassemble and clean Replace element Replace gasket Maintenance 6 Tune up Condition Overheating Overcooling Others NOISY ENGINE Car knocking Mechanical knocking Crankshaft bearing knocking Connecting rod bearing knocking Piston and cylinder noise Insufficient coolant Loose fan belt Worn or defective fan belt Defective thermostat Defective water pump Clogged or leaky radiator Defective radiator filler cap Air in cooling system Improper engine grade Incorrect ignition timing Defective carburetor lean mixture Defective thermostat Improper octane fuel Improper tire press
78. inder Bore iin Brake D D Front Rear NN Front Rear Front Reer L60 Drum Drum 1 000 1 000 1 150 115 15 PL410 Drum Drum 875 1 000 838 NAA SPL310 Drum 875 1 000 2938 PL411 Drum Drum 875 1 000 938 9 0 9 0 RL411 Disc Drom 875 200 2928 SPL311 Disc Drum 150 2 125 813 11 2 9 0 SRL311 Disc Drum 750 2 125 15 11 2 9 0 L320 Drum Drum T 100 100 L520 L524 Drum Drum 150 150 T30 10 0 100 510 Drum 350 2000 81 91 990 WPL510 Dise Drum 150 2 000 9 1 9 0 PL521 Drum Drum N A 100 100 HLS30 Disc Drum 875 2 125 875 10 7 90 1 110 KLB110 Disc Drum 8688 1 894 688 8 4 80 Chassis and Wheel Alignment Specifications Model Wheel Alignment Wheel Track in Caster deg Camber deg Tee in Kingpin Wheel Pivot base tin Inclina Ratio deg fin tion Outer deg Wheel Wheet Front Rear Range Pre Range Pre ferred ferved Set Set ting ting L60 886 546 55 3 1 30 1730 12 16 6745 28 25 32 715 pee aaa aaam WL60 984 546 553 1 30 1730 12 16 6 45 28 25 92 TAS PL410 938 475 47 0 190 120 06 13 6 30 36 2826 SPL310 898 478 471 1 30 1 96 06 13 6 34 36 28 36 937 415 472 0 145 06 13 615 36 2896 RL411 937 475 472 0 1 45 13 615 36 3896 SPL311 898 502 472 ray 1525 08 12 635 3616 29 20 SRL311 898 502 472 1 30 1995 08 12 635 26 16 29 20 1390 972 461 467 3 30 1 30 08 12 6 31 29
79. inder block c Be sure to install piston in cylinders with notch mark of piston head toward the front of engine Front mark notch Oil hoie EM157 Fig 49 Assembling piston and connecting rod Marked side E i pen M 7 158 Fig 50 Installing piston ring 5 t li n Install piston rings Install top and second rings in right position with the marked side up Top ring is chromium plated on liner con tacting face Second ring has larger taper surface than top ring Im the combined oil ring upper rail is the same aslower one Vix hearings on connecting rod and ting rod cap Note Clean the back side of bearing carefully Engine The first step in engine assembly is to bolt special tool Engine Attachment ST05260001 to right hand of cylinder block In suc cession install block in another special tool Engine Stand ST0501S000 with engine bot tom up Set main bearings at the proper portion of cylinder block Install plate including cylinder block net Notes Only center bearing No 3 is a flanged type All inter bearings No 2 and No 4 are the same type Fig 51 Main bearings Front bearing No 1 is also the same type as rear bearing No 5 The difference is that an oil hole is provided in the front bearing All bearings except No 1 bearing have an interchangeability bet
80. ip Installation Install sensor and gasket assembly in the proper positions See Figure 113 Insert clip Be sure to hold sensor at its correct position in Fig 113 to avoid damage See Fig 114 Press fit clips into pipe while straightening tabs Note Use care not to damage sensor Connect hoses to their proper positions See Figure 115 FUEL PUMP Removal and Disassembly Remove fuel pump assembly by unscrewing two mounting nuts and disassemble in the following order 1 Pipe 2 Catch 3 Fixed with adhesive 4 Hose 5 Tab 6 Clip 7 Gasket Fig 113 installing Sensor Fig 114 Inserting Clip Fuel System Separate upper body and lower body by un screwing body set screws Take off cap and cap gasket by removing cap screws Unscrew elbow and connector Take off valve retainer by unscrewing two valve retainer screws and two valves are easily removed To remove diaphragm press down its center against spring force With diaphragm pressed down tilt it until the end of pull rod touches the inner wall of body Then release the diaphragm to unhook push rod Use care Fig 115 Connecting Hoses Outlet vaive Diaphragm Diaphragm spring Inlet valve Rocker arm Am VO N during his operation not to damage diaphragm or oil seal Drive out rocker arm pin by using a press or hammer Inspection Check upper body and lower body for cracks Check valve assembly for wear on v
81. iring by unscrewing lock nuts RESISTANCE TROUBLE SHOOTING SPEEDOMETER Condition Probable cause Corrective action Correct setting Improper setting of speedometer cable union nut Speedometer does not operate Broken speedometer cabie Replace cable Broken speedometer drive gears Replace meter Defective speedometer Replace meter Excessive bend in speedometer Correct cable installation or re place cable Swing of pointer Replace speedometer Broken speedometer drive gear Defective speedometer Replace speedometer Unsteady pointer Correct setting Improper setting of speedometer cable union nut Defective speedometer cable Replace cable Defective speedometer Replace speedometer Excessive bend lack of lubricant and twist of meter cable inner wire Defective speedometer Replace speedometer 6 Improper gearing of second and Replace speedometer third gears in speedometer Improper feed caused by deforma Replace speedometer tion of pinion carrier Strange sound Replace or lubricate cable synchronized with running speed Inaccurate indication of pointer Defective odometer Fig 108 Heater System Electrical System TROUBLE SHOOTING HEATER Pecan we Hot air does not come out Motor does not operate Ope
82. is case the tension of clutch springs working on the pressure plate will be weakened Clutch Fig 155 Installing Release Bearing The refacing limit is 1 0 mm 0 0394 in from specified standard dimension If it needs to be cut more than 1 0 mm 0 0394 in the unit must be replaced After refacing the out of flatness should be less than 0 1 mm 0 0039 in Clutch 104 Note In case of tbe diaphragm spring type the pressure plate should not be refaced at any times Replacing Release Bearing Removing the bearing Remove the bearing by using universal puller Pressing the bearing in There are two types of the release bearing Specification of both bearings is quite the same but particular attention is required because of different construction when in stalling the bearing into the bearing sleeve as follows Diaphragm spring type Release Bearing Fitting press fit the bearing in place on the bearing sleeve with the force of 400 kg 880 1bs applied at the outer race as shown in Fig 155 ADJUSTMENT Screw the center pillar into the base plate and slip the high finger over the pillar Adjust the height of the release levers by screwing or unscrewing the eye bolt nuts un til the height when rotated just contact the highest point on the tip of the release levers Fig 156 Adjusting Release Lever Height Replace the height finger and pillar by the clutch actuating mechanism and actuate the cl
83. l pan gasket Loose or damaged chain cover gasket Defective oil seal in front and rear of crankshaft Loose or damaged locker cover gasket Improper tightening of oil filter Loose damaged oil pressure switch Corrective action This may cause a wear on piston pin or piston pin hole Renew piston and piston pin assembly Replace water pump with a new one Adjust Adjust the tension of chain Disassemble engine and renew main bearing Renew bush and adjust drive shaft Adjust ignition timing Use specified spark plugs Replace them with new parts Disassemble carburetor and check it Adjust the level and check needle valve Adjust Adjust Remove head and get rid of carbon Replace it with a new one Tighten it Renew gasket or tighten it Renew gasket or tighten it Renew oil seal Renew gasket or tighten it but not too much Renew gasket and tighten it with the proper torque Renew oil pressure switch or tighten it t Maintenance 6 Tune up Maintenance amp Tune up Condition Probable cause Excessive consumption Others POOR FUEL ECONOMY See the explanation of the power decrease Others TROUBLE iN OTHER FUNCTIONS Decreased oil pressure Excessive wear on the sliding parts Seuffing of sliding parts Cylinder and piston wear Improper location of piston ring gap reversely asse
84. lation is the reversal of removal CHARGING CIRCUIT DESCRIPTION The charging circuit consists of the battery alternator regulator and necessary wiring to connect these parts The purpose of this system is to convert mechanical energy from the engine into electrical energy which is used to operate all electrically operated units and to keep the battery fully charged When the ignition switch is set to ON current flows from the battery to ground through the ignition switch voltage regulator IG terminal primary side contact point PL movable contact point P2 voltage regulator terminal alternator F terminal coil and alternator E terminal as shown in Figure 77 by full line arrow marks Then the rotor in the alternator is excited On the other hand current flows from the battery to ground through the ignition switch warning lamp voltage regulator L terminal lamp side contact point P4 movable contact point P5 and voltage regulator E terminal as shown by dotted line arrow marks Then the warning lamp lights When the alternator begins to operate three phase alternating current is induced in the stator coil This alternating current is rec tified by the positive and negative silicon diodes The rectified direct current output reaches the alternator A and E terminals On the other hand the neutral point voltage reaches N and E terminals nearly a half
85. lve fully open 3 Diaphragm spring 7 Hot air pipe 4 Diaphragm 8 Temperature sensor 5 Vacuum hoses assembly ECOOB Fig 111 Underhood Air Delivery Mold During Engine Operation System derhood air inlet to obtain full power dless of the temperature around sensor This control of carburetor air temperatures allows leaner carburetor calibration with ac companying reduced emissions than conven tional controls and also eliminates carburetor icing Idle Compensator The idle compensator is essentially a ther mostatic valve to compensate for excessive enriching of the mixture as a result of high idle temperatures When the under the hood temperatures are high the bimetal located in the air cleaner is heated by intake hot air and lifts the valve to open This permits additional fresh air that is properly calibrated by the 1 4 mm 0 055 in dia orifice compensates for the increased richness of into the intake manifold and the air fuel mixture in order to maintain smooth idle engine operation The idle compensator thermostatic valve par tially opens at 65 C 149 F and fully opens at 75 C 167 F Never attempt to disassemble this unit since it is sealed for tightness and properly adjusted for valve timing TEMPERATURE SENSOR Removal Flatten tabs of clip with pliers Pull off hoses Note Note the respective positions of hoses from which they were removed Take off sensor and cl
86. m Same as the case of crankshaft bearings This may cause an abnormal wearing of cylinder and lower compression which in turn will cause a lower out put power and excessive consumption of Overhaul engine Condition Probable cause Piston pin noise This noise is heared at each highest and lowest dead end of piston To locate the place cause a misfire on each cylinder This noise may be caused by worn or damaged bearings or by the uneven surface of sliding parts Water pump noise Others An improper adjustment of valve clearance Noise of timing chain An excessive end play on crankshaft Note This noise will be heared when clutch is disengaged Wear on clutch pilot bushing be heared when Note This noise will clutch is disengaged ABNORMAL COMBUSTION back fire after fire run on etc Improper ignition timing Improper ignition timing Improper heat range of spark plugs Fuel system in trouble Damaged carburetor or manifold gasket back fire after fire Defective carburetor jet improper function of the float Uneven idling Run Defective cytinder head Improperly adjusted valve clearance etc Excess carbon in combustion chamber Damaged valve spring back fire after fire EXCESSIVE OIL CONSUMPTION Oil leakage Loose oil drain plug Loose or damaged oi
87. mbled piston ring Damage piston rings Worn piston ring groove and ring Fatigue of valve oil seal lip Worn valve stem Inadequate quality of engine oil Engine overheat Exceeding idting revolution Defective acceleration recovery Fuel leakage Inadequate quality Overheat Defective function of oil pump regulator valve Functional deterioration of oil pump Blocked oil filter Increased clearance in various sliding parts Blocked oil strainer Troubles in oil gauge pressure switch Oil pressure decreases Defective quality or contamination of oil Defective air cleaner Overheat or overcool Improper fuel mixture Decrease of oil pressure Insufficient clearances Overheat Improper fuel mixture Corrective action Overhaul cylinder and renew piston Remount piston rings Renew rings Repair or renew piston and cylinder Renew piston and piston ring Replace seal lip with a new one Renew valve or guide Use the designated Previously mentioned Adjust it to the designated rpm Adjust it Repair or tighten the connection of fuel pipes Use the designated oil Previously mentioned Disassemble oil pump and repair or renew it Repair or replace it with a new one Renew it Disassemble and replace the worn parts with new ones Clean it Replace it with a new one Previously mentioned Exchange the oil with proper one and change element Cha
88. mission incorporates an oil cooler for the transmission fluid Removal and Installation Drain coolant into a clean container Remove front grille Cooling System Fig 128 Radiator for Manual Transmission Disconnect radiator upper and lower hoses On a vehicle with automatic transmission disconnect cooler intet and outlet lines from radiator Remove bolts retaining radiator from radiator side supports and remove radiator upwards Install radiator in reverse sequense of removal Inspection Radiator cap should be checked for pressure at regular tune up intervals First check rubber seal on cap for tears cracks or deterioration after cleaning it Then install radiator cap on a tester If cap does not hold pressure or will not release at the proper pressure replace cap Also inspect radiator for water leakage using a cap tester under applying a pressure of 17 lb sq in If such the defect is detected repair or replace radiator Brakes MASTER CYLINDER 82 Removal z seu E 82 82 FRONT DISC BRAKE 82 Description oce rv 82 Removal az dias 82 84 Inspection and Repair 84 Piston Seal Replacement 85 Assembly and Installation 85
89. mp load 29 2 mmAd x2 kg 1 1H9in A7 4 4 15 Out of right angle Adis PD 5 100 mm 0 1968 3 937 in Allowable min spring 135 Clutch release lever Release bearing to diaphragm spring release lever clearance 1 2 1 4 mm 0 0472 0 0351 in Diaphragm spring to flywheel height 34 0 2 1 0 mm 1 752 4 0 0394 Release lever to flywheel height 50 5 0 05 min 1 988 0 0197 in Clutch disc Facing size Outer dia x inside dia x thickness 200 x 120 x 3 5 mm 7 87 x 5 120 x 0 140 in Total friction area 362 cm 56 11 Thickness of disc assembly Free Me HH nennen 8 6 9 0 mm 0 2386 0 2543 in Compressed 7 65 7 95 mm 0 3012 0 3130 Material 505 17 50 Number of torsion spring 6 Allowable min depth of rivet head from facing surface 0 3 mm 0 0118 in Allowable facing run out 1 0 5 mm 0 0197 in Allowable free play of spline 0 mm 0 0157 in Pressure plate Allowable refacing limit 1 0 mm 0 0394 in Clutch Pedal height when not depressed 182 mm 7 17 in R H 207 mm 8 150 in L
90. n or re Regulator leasing accelerator pedal noise present Fuel System AIR CLEANER ELEMENT 68 AUTOMATIC TEMPERATURE CONTROL AIR CLEANER 68 AIR CONTROL VALVE 68 Idle Compensator 69 TEMPERATURE SENSOR 69 Removal socio REB 69 69 FUEL PUMP 69 Removal and Disassembly 69 Inspection 70 70 CARBURETOR 73 Removal sqa he ero 73 Disassembly 73 Float Chamber 74 ANTI DIESELING SOLENOID 74 Removal ei ides 74 74 BOOST CONTROLLED DECELERATION DEVICE 74 Assembly and Installation 74 Cleaning and Inspection 74 JETS icd ei 75 Fuel System AIR CLEANER ELEMENT The air cleaner element is of a viscous paper type and does not require any cleaning until replacement Note Do not brush or blast element before replacement AUTOMATIC TEMPERATURE CONTROL AIR CLEANER The automatic temperature control air cleaner is provided with a temperature sensor and a vacuum operated valve The vacuum ac ted upon the air control valve is controlled by the sensor See Figur
91. n or short circuit of feed Check and repair wiring harness harness Defective switch Replace switch Fan cannot be rotated Defective motor Replace motor smoothly by hand Fin is clogged Clean fin Hot air does Slow rotation of fan Replace motor not come out although less fan is rotating Looseness of fan installation Repair Air temperature is low Hot water Defective water pump Repair water pump does not E circulate Bending or clogging of connecting Check or clean piping hose Defective hot water cock Air is left in the hose Purge air out of hose Water tem Defective thermostat Replace thermostat perature is low Water leakage Defective water hose Replace water hose from eaten Loose clipping of water hose Retighten clip Defective cylinder head gasket Replace gasket Improper soldering of heater core Solder leaking position Defroster hose ig removed Correct connection Bend or break of defroster hose Correct or replace Looseness of heater support Tighten completely Looseness of each fixing screw Retighten each screw TROUBLE SHOOTING RADIO Replace Pilot lamp does Melt away fuse not light when switch is on Inspect and tighten Defective defroster Vibrating noise Improper connection of cable or connector Broken pil
92. ned with the regulator terminals or harness plug downward 124 Make and type Vehicle model Applied engine 510 118 HANSHIN 5 15 1 Applied resister Primary voltage RC 15 Spark gap mm in Primary resistance at 209 68 F Secondary resistance at 20 C 68 F External resistor at 20 C 68 F 11 210 16 8 1 3 to 1 7 HANSHIN 5 15 2 TN Specifications Light Bulb Specifications Model Usage Wettage 180 Headlights 50 42 Front parking turn 21 6 Stop tail tum 21 8 License plate 10 Instrument panel 8 Flasher warning light L5 PL410 Headlights 37 5 50 37 5 Parking 8 Turn 25 License plate 8 Interior Jight 5 Backup 25 Warning lights 1 5 Instrument 5 SPL310 Headlights 50 40 Front parking turn 25 5 Tail stop 21 6 License plate 8 Interior 6 Instruments warning 1 5 Inspection lamp 8 Radio 1 2 PL411 Headlights 37 5 50 RLAiI 37 5 Side markers 8 Tail 8 License plate 8 Stop 25 Backup 25 Interior 5 Fog 35 Inspection 8 Parking 8 Tum 25 Instrument 3 Warning 1 5 SPL311 Headlight 50 40 SRL311 Front turn parking 25 8 Stop tail tum 25 8 620 116 HITACHI C6R 601 5660 1510 Model Usage Wattage Backup 15 License plate 8 5 Side marker 8 L520 Headlights 27 5 50 50 Front parking turn 25 8 25 8 Rear turn backup 25 License plate 8 Interior 6 L521 H
93. nge element Previously mentioned Check the fue system Previously mentioned Readjust to the designated clearances Previously mentioned Check the fuel system DESCRIPTION eee 22 1 23 INSTALLATION 24 DISASSEMBLY 24 Pistons and Connecting Rods 27 Cylinder Head 27 ASSEMBLY 27 Cylinder Head 28 Piston and Connecting Rods 29 BN Bin 2 a sese d In esas 30 OIL PUMP port beta Fu 36 Removal u uui em I ERIS 36 Installation 37 Engine DESCRIPTION The 116 and 118 engines feature valves wedge shaped combustion chamber alminum heads and fully balanced 5 bearing koa crankshait to turn out smooth dependable power The cylinder block is cast in a single unit featuring deep skirting These engines are equipped with a single Fig 19 Cross section view 2 barrel downdrait carburetor that incor porates special device to control emissiuns Experience has shown that it is much easier to remove the engine with transmission as a single unit than to remove the engine only The engine can then be separated from the transmission assembly REMOVAL Scribe alignment marks on hood around hood hinges and remove hood trom hinges
94. nion flange of the gear carrier Jack up transmission little then remove the rear engine mounting cross mem ber by removing the fixing bolts of the engine mounting insulator mounting cross member and hand brake cable clamp Fig 21 Lifting engine Remove the fixing bolts securing the front engine mounting insulators to cross member Hook with cable or chain to the stringers hooks which are installed on the engine cylinder head one at the front and the other at the rear At this lifting lower the jack placed under the transmission gradually draw off the jack at adequate stage hoist up engine observing the tension of wire and adjusting the position of chain block so that the engine tilts in order to make it cleared off the body At this lifting take care that accessories installed on the body side do not touch the engine and transmission INSTALLATION Reverse the removal procedure but do not con nect any parts to the engine steadily until the engine mounting insulators have been replaced and power unit weight is taken by them DISASSEMBLY Remove transmission trom engine Thoroughly drain engine oil and coolant by removing drain plugs Place engine assembly on the engine stand Remove tan and fan pulley Remove engine mounting Remove oil filter Remove oil pressure switch Install engine attachment to cylinder block using bolt holes securing alternator bracket and wa
95. o lock both front and rear wheels with wheel chocks b Hold brake pedal while stepping down on accelerator pedal Otherwise car will rush out dangerously On automatic transmission equipped model make sure that the adjustment has been made with the selector lever in N position And then check the specifications with the lever in D position Insure that CO per cent and idle speed are as follows Idling rpm 650 CO percentage 1 5 0 5 Readjust by turning in or out throttle ad justing screw or idle adjusting screw if still out Notes 8 Do not attempt to screw down idle ad Throttle adjusting screw 2 2 Idle adjusting screw Fig 10 Throttle and idle adjusting screws Maintenance amp Tune up justing screw completely to avoid damage to tip which will tend to cause malfunc tions b After idle adjustment has been made shift the lever to N or range for automatic transmission c Remove wheel chocks when running Idle Limiter Cap Do not remove this idle limiter cap unless necessary If this unit is removed it is necessary to re adjust it at the time of in stallation To adjust proceed as follows After adjusting throttle or idle speed ad justing screws check to be sure that the amount of CO contained in exhaust gases meets the established standard Install idle limiter cap in position making sure that the adjusting screw further turn 1 8 rotation in the CO R
96. on Link Pert Output Generator Number rpm 1 320 Engine compartment the L520 right rear L521 J Mitsubishi 2 500 24 5 PL521 5203 1 PL510 Rs Mitsubishi 2 500 245 ACK 12X2R 215 L60 Engine compartment high temp right fender well U20 Mitsubishi 2 500 23 SPL311 Inside glove compartment AS2030A2 SRL311 116 Hitachi 2 500 22 LB110 Under instrument panel Between battery LT13041 KLB110 right of steering column and alternator 124 Hitachi 2 500 gt 34 HLS30 Under ash tray in console At alternator 11145 35 5 000 gt 45 at starter A12 Hitachi 2 500 gt 24 LT135 05 5 000 gt 33 M M M gt than EMISSION CONTROL DIAGRAMS IGNITION KEY IGNITION COtL DUAL POINT OSTRIBUTOR RETARDED GWITCH DETECTING CLOSE THROTTLE POSITION Datsun emission control system manual transmission IGNITION SWITCH TO DISTRIBUTOR BE SWITCH DETECTING WIDE OPEN THROTTLE POSITION SWITCH DETECTING CLOSE THROTTLE POSITION Datsun emission control system with automatic transmission Electrical System 1 prom CARBURETOR AIR CLEANER FROM PPT FUEL TANK VAPOR VENT LINE FLOW GUIDE VALVE The valve opens when the pressure is over 4 in Hg Datsun evaporative emission control system Electrical System x T Primary garal L 1
97. on them Larger inner numbers stamped on the jets indicate larger diameters Accordingly main and slow jets with larger numbers provice richer mixture and the smaller num bers the leaner mixture Inversely the main and slow air bleeds which are for air to pass through make the fuel leaner if they bear larger numbers and the smaller numbers the richer fuel Gooling System DRAINING amp FLUSHING 78 WATER PUMP 78 Removal enel due II 78 Disassembly 79 Inspection 79 79 THERMOSTAT 79 Removal and Installation 79 RADIATOR 79 Removal and Installation 79 Fig 125 Cooling System DRAINING AND FLUSHING To drain the cooling system remove the radiator cap release the drain cock at the bot tom of the radiator and drain plug on the right side of the cylinder block If the heater system is installed set the heater temp erature control valve at open position After the coolant is drained completely close the drain cock and plug and refill the system with clean water WATER PUMP The water pump is of a centrifugal type which is mounted on the engine front cover The fan and pulley are bolted at the pulley hub The pump shaft is supported by a double row ball bearing press fit in an alumin
98. oo wide Too much carbon Broken neck of insulator Expiry of plug life Dirty point Improper point gap Leak of electricity of cap and rotor head Defective insulation of condenser Defective arm Defective spring of arm Breakage of lead wire Worn out or shaky breaker plate Worn out or shaky distributor shaft Layer short circuit or use of inferior quality Deterioration of insulation and leak of electricity Dirty Leak of electricity at upper porcelain insulater Improper and advance timing Coming off or breakage of governor spring pin or a hole of governor portion worn out Burnt too much Improper and retarded timing Defective function of governor Dirty point Point gap too narrow Dirty Correct or replace Clean or replace Replace Replace Clean Correct Repair or replace Replace Oil shaft Replace assembly Replace Replace assembly Replace assembly Replace with good one Replace Clean Repair or replace Correct the fitting Correct or replace Replace Replace Correct the fitting Replace assembly Clean Correct Clean After cleaning spark plugs renew firing sur face of electrodes with file mentioned above Then gap spark plugs to 0 0276 to 0 0315 in using a round wire feeler gauge All spark plugs new or used should have the gap checked and reset by bending ground electrode HEATER UNIT REMOVAL D
99. ot lamp Replace Improper switch operation Repair or replace Pilot lamp lights Improper connection of antenna Tighten but sound does not come out Improper connection of speaker Tighten Improper circuit of radio itself Consult Service Shop of radio manufacturer Electrical System NOISE PREVENTION CHART Ignition system Do not worry about high tension cord because anti noise cable is used Noise present synchronized High tension cord with engine revolution Keep choke wire away from ignition coil as far poss ble ignition coil Set 0 5 F condenser at primary side B terminal of ignition coil Note the condenser is set st sc ondary or primary breaker side engine will not work property Connect with bond wire between engine and ignition coil locating area of body Secure ground of ignition coil Secure contact of carbon electric pole and rotor Distributor Eliminate excessive tips at rotor pole or cap pole scrubbing by driver Check stagger between rotor starter Charging Set 0 5 4 F condenser at charging terminal Sound of alternating current Alternator present Note Do not add more condenser If more condenser is added alter nator coil will be broken Set 0 5 F condenser at or terminal of voltage regulator When pressing dow
100. out is detected replace the rotor Piston Seal Replacement If oil leakage is found on the piston seal it should be replaced paying attention to the following points After disassembly rinse the cylinder bore with brake fluid Insert new seal into the groove taking great care not to damage the seal Attach the wiper seal Apply a thin coating of specified grease to the cylinder bore Fig 136 Measuring Runout of Disc Brakes Clean the piston Check that no damage exists on piston surface Insert the piston Take care that the relieved position of the piston faces pivot pin Insert first two inches gently avoiding tilting Assembly and Installation Clean the mounting surface and disc Attach the disc to the hub Install the hub to the knuckle spindle Insert the piston into the cylinder till the face of piston head becomes almost flush with the face of the retainer of Lhe wiper seal Install the cylinder into the caliper plate and secure place two torsion springs Assemble the hold down pin spring washer and nut in this order to support bracket Insert a cotter pin to the nut Secure the mounting bracket and caliper plate with the pivot washer spring washer and nut in that order Tighten nut completely and set a cotter pin Pry up and hold down bracket by a screw driver and hook up to the upper end of the mounting bracket Turn the caliper plate to make sure that it can
101. point P2 or breaking and completing the rotor circuit maintains an alternator out put voltage constant ALTERNATOR Description Alternator Vehicle 510 and 610 models except for Canada LT150 05B 510 and 610 models 17160 19 for Canada LT135 13B 620 model Removal Disconnect negative battery terminal Disconnect two lead wires and connector from alternator i Ignition switch g lamp Generator warnin To ignition coil 4 Alternator Voltage regulator Fig 77 Charging Circuit 1 2 R s 8 5 78 Charging Circuit 2 TROUBLE DIAGNOSES CORRECTIONS Probable cause Discharged battery Condition Corrective action Starting motor will not operate Charge or replace battery Defective solenoid switch Repair or replace solenoid switch Loose connections of terminal Defective brushes Defective starting motor Clean and tighten terminal Replace brushes Remove starting motor and make test Noisy starting motor Loose securing bolt Tighten bolt Wom pinion gear Replace pinion gear Poor lubrication Fill in Wom commutator Disassemble motor Wom brushes Replace brushes Discharged battery Loose connection of terminal Wom brushes Locked brushes Starting motor Charge or replace battery cranks slowl
102. r AUTOMATIC TRANSMISSION 11 Governor 12 Output shaft 13 Rear extension 14 Oi pan 15 Control valve 16 input shaft 17 Torque converter 18 Converter housing 19 Drive plate Fig 170 Cross Sectional 77147 771 WEF ait Tightening torque T of D T bolts and nuts 4105 kg m 29 to 36 ft lb BT 1410 16 kgm Dr 101 to 116 46 OT 0 610 0 8 4 3 to 5 8 ft lb View of 3N71B Automatic Transmission tol E AT260 0 5 to 0 7 kg m 3 6 to 5 1 ft lb 2 0 to 2 5 kg m 14 to 18 ft lb 1 3 to 1 8 kg m 9 4 to 13 ft Ib 0 55 to 0 75 kg m 4 0 to 5 4 ft lb 0 25 to 0 35 kg m 1 9 to 2 5 ft lb Transmission 4 SPEED TRANSMISSION Removal and Installation Removal and installation of the 4 forward speed transmission are similar to the procedure given for the 3 speed transmission However the 4 speed transmission is of the floor shift type therefore in addition to com pleting the operations described in the section covering the 3 forward speed transmission it will be necessary to remove the shift lever from the control lever bracket On the 4 speed transmission the rear engine mounting sup port is securely placed between the upper sup port plate and rubber insulator on one hand and the lower support plate and rubber in sulator on the other RECOMMENDATIONS Due to the complexity of setting up a disassembled transmission
103. r capacity of bulb Replace bulb Faulty mechanism of turn signal Switch Turn indicator 1 doeg not retum automati cally Replace with new parts TROUBLE SHOOTING HORN Condition Probable cause Corrective action Horn does not Fuse is burned out Replace fuse operate ae Improper contact of horn button Check and repair horn button Open circuit of harness Repair or replace harness Improper contact of each terminal Correct each terminal Dead battery Charge battery Improper contact of horn relay Correct point Open circuit or wrong ground con nection of horn interior Reptace or repair horn Adjust adjusting screw Correct contact Wear of horn point Improper contact of fuse or con nector Low volume improper tone Open circuit of harness Improper contact of horn point Correct horn point Wear of horn point Adjust adjusting screw Crack in diaphragm Replace horn RADIO Removal Disconnect all connections HORN RELAY Remove tuning knob and volume control knob Remove ashtray HORN TERMINAL 2 m Remove cluster lid unscrewing four cluster lid fixing screws Separate cluster lid finisher board and radio Fig 107 Horn Relay W
104. rain out coolant Disconnect connector of heater to engine well hot water pipe Remove defroster hose Disconnect connector motor Remove the two heater control wires at heater unit Remove the four bolts and take out ventilator Remove the four heater unit fixing bolts and detach heater unit Electrical System 9 YSN 104 uOISSiUUSUPJ 1 jenue SOL Bt Electrical System 4 9 WSN 20 401551581 onBuojny ypa 90 H 44 mi az M ie 1 Lx a J wei n H ij D WVYSVIC Electrical System TROUBLE SHOOTING HEADLIGHT Probable cause Corrective action Head lamps dim Partly discharged battery Charge battery engine idling or Defective cells in battery Replace battery shut off High resistance in llght circuit Check head lamp circuit including ground connection Make necessary repairs Faulty sealed beam units Replace sealed beam units Check lighting circuit including ground connection Make necessary repairs Faulty sealed beam units Replace sealed beam units Faulty voltage control unit Test voltage control and generator Make necessary repairs Lights flicker Loose connections or damaged Tighten connections and check for wires in li
105. rless 2 12 mm 0 0835 in pink 2 14 mm 0 0843 in Tightening torque Fixing nuts of flange yoke to 2 0 2 7 kg m companion flange 14 20 ft Ib 144 Specifications Tightening torque kg m ft Ib Drive pinion nut 17 to 20 122 9 to 144 6 Ring gear bolt 7 to 8 50 6 to 57 8 Side retamer bolt 22 S Cu 0 9 to 1 2 6 5 to 8 7 Side flange fix bolt J eese ttes 1 9 to 2 6 13 7 to 18 8 Rear cover fix bolt usss asas aa q a 1 9 to 2 6 13 7 to 18 8 Rear cover to mounting member lock nut esee 6 to 8 43 4 to 57 8 Differential carrier to suspension member fix bolt 5 to 7 36 2 to 50 6 Differential to drive shaft fix bolt 5 to 6 36 2 to 43 4 Differential mounting member self lock nut sss 7 to 10 50 6 to 72 3 Companion flange to propeller shaft fix bolt 2 0 to 2 7 14 5 to 19 5 Oil drain and filler plug 22222222000 eerte 4 to 6 28 9 to 43 4 Oil capacity about liter U S qt Imper qt sess 0 8 7 8 3 4 Adjusting methods Variation numbers expressed by aaa mm x 0 01 Dummy shaft Use Drive pinion adjusting formula 1 T W N H D 5 x 0 01 0 2 Side bearing adjusting formula T1 A C G1 D x 0 01 0 76 E T2 B D G2 x 0 01 0 76 F Specifications Brake Specifications Model Type Brake Cyl
106. ront side of cylinder block and front cover gasket as shown in Figure 42 Apply sealant only to the top of front cover as shown in Figure 42 Install front cover with head gasket place Check the height difference between cylinder block upper face and front cover upper face Its difference must be less than 0 0059 in Note that different types of bolts used Apply a lithium grease to sealing lip of oil seal Tightening torque Size M8 0 315 7 2 to 11 6 ft lb Size M6 0 236 in 2 9 to 5 8 ft lb Install crankshaft pulley and water pump then set No 1 piston at T D C on its com pression stroke Crankshaft pulley nut tightening torque 86 8 to 115 7 ft lb Fig 64 Front cover bolts Finally tighten head bolts to the specified torque in three steps according to the tightening sequence as shown in Figure 60 Note that two types of bolts are used Tightening torque Fst turn 28 9 ft lb 2nd turn 443 4 ft lb 3rd turn 47 0 to 61 5 tt Ib Notes Be sure to tighten two small bolts After engine has been operated for several minutes if necessary retighten Install oif pump and distributor driving spin dle into front cover Fig 66 Cylinder head bolts Tightening torque 8 0 to 10 8 ft lb Notes Assemble oil pump and drive spindle making driving spindle mark face to oil pump hole install oil pump together with drive spin dle so that the projection on its top i
107. rotate crankshaft and separately because valves will hit heads ot pistons Temporarily tighten two bolts 1 2 shown in Figure 60 Tightening torque 14 5 ft lb Install cranksahtt sprocket and distributor drive gear and fit oil thrower Note Make sure that the mating marks of crankshaft sprocket faces to the front Install timing chain Fig 60 Tightening sequence Fuel pump drive cam Chain guide Chain tensioner Crank sprocket Cam sprocket Chain guide 42 links Q b U 169 Fig 61 Installing timing chain Notes Make sure that crankshaft and camshaft keys point upwards Set timing chain by making its mating marks align with those of crankshaft sprocket and camshaft sprocket at the right hand side There are forty two chain links between two mating marks of timing chain 2 hole is factory adjusted When chain stretches excessively adjust camshaft sprocket at No 3 hole Use a set of timing marks and location hole numbers Install chain guide to cylinder block Install chain tensioner Note Adjust the protrusion of chain ten sioner spindle to 0 in Press new oil seal in front cover front cover oil seal should be replaced when front cover is disassembled _ Chain tensioner SY Assy 0 mm 0 in TM 4 Fig 63 Installing front cover Install front cover with gasket in place Notes Apply sealant to f
108. rpm Standard 171 350 Minimum 128 350 BATTERY Check electrolyte level in each battery cell Unscrew each filler cap and inspect fluid level If the tluid is low add distilled water to bring the level up approximately 0 394 to 0 787 in above the plates Do not overfill Measure the specific gravity of battery elec trolyte Clean top of battery and terminals with solution of baking soda and water Rinse olf and dry with compressed air Top of battery Full charge value at 20 C 68 F Frigid climates Over 1 22 1 28 Over 1 18 1 23 Over 1 20 1 26 Permissible value Tropical climates Other climates ib Fig 4 Testing compression pressure Fig 5 Checking specific gravity of battery electrolyte must be clean to prevent current leakage bet ween terminals and Irom positive terminal to hold down clamp In addition to current leakage prolonged cumulation of acid and dirt on top ot battery may cause blistering of the material covering connector straps and corrosion of straps After tightening terminals coat them with petroleum vaseline to protect them from corrosion Maintenance amp Tune up IGNITION TIMING Check spark plugs and distributor breaker points for condition Thoroughly wipe off dirt and dust from timing mark on crank pulley and timing indicator on and front cover Warm up engine sufficiently Install a timing light on No
109. rter inotor Ignition system in trouble Fuel system trouble Low compression Maintenance amp Probabie cause Low or no current Burned distributor point Improper point gap Defective condenser Leak at rotor cap and rotor Defective spark plug Improper ignition timing Defective ignition coil Disconnection of high tension cable Loose connection disconnection primary circuit Lack of fuel Dirty fuel strainer Dirty or clogged fue pipe Fuel pump will not work properly Carburetor choke will not work properly Improper adjustment of float level Improper idling Dirty or clogged carburetor Clogged breather pipe of fuel tank Damaged anti dieseling solenoid Incorrect spark plug tightening or defective gasket Improper grade engine oil or low viscosity Incorrect valve clearance Compression leak from valve seat Sticky valve stem Weak or defective valve springs Compression leak at cylinder head gasket Sticking or defective piston ring Worn piston ring or cylinder Trouble shooting procedure Pour the engine oil from plug hole and then measure cylinder compression Compression increases Compression does not change Corrective action Check for loose terminal disconnection in primary circuit Check for burned points Repair or replace Adjust Replace Clean or replace Clean adjust plug gap or replace Adjust
110. s ELOOS Fig 69 Adjusting valve clearance located 11 25 a m position At this time the smaller bow shape will be placed toward the front Do not forget to install gasket Install fuel pump water inlet elbow and front engine slinger in their positions Fuel pump tightening torque Note Do not forget to install fuel pump spacer and packings inserted between spacer and block spacer and fuel pump Install oil strainer oil pan gasket and oil pan Notes Apply sealant to the step portions at four mating surfaces as shown in Figure 44 Tightening oil pan should be performed in criss cross pattern and finally to 4 3 to 6 5 ft lb torque Adjust valve clearance to the specified dimen sions Tightening torque 36 2 to 43 4 ft lb Notes First set clearance to the cold specifications After engine has been assembled run it for at least several minutes finally adjust the clearance to the warm specifications Install rear engine slinger exhaust manifold and intake manifold Tightening torque 8 7 to 11 6 ft lb Valve clearance mm Exhaust Engine Install distributor assembly Install carburetor assembly and carburetor sulator with stamp facing upward Tightening torque 3 6 to 7 2 ft lb Install fuel pipes and vacuum hose pipes and hoses should be clamped securely being careful not to allow them to in terfere with adjacent or surrounding parts Install t
111. s follows Referring to Figure 16 turn out adjuster plate set screw 1 2 to 2 turns The serew is located at contact set on retard side Using a notch in adjuster place as a hold turn adjuster plate as required until correct delay is obtained Ignition is retarded when plate 1s turned counterclock wise Note Refer to graduations on breaker plate to make adjustment easier One graduation corresponds crankshaft angular displacement of 4 degrees Tighten adjuster plate set screws to secure the adjustment Make sure that the ignition timing of advance side is the specifications After adjustment remove lead wire and con nect wiring harness of distributor to engine harness securely Maintenance amp Tune up TUNE UP GUIDE Ignition and fuel system Ignition timing degree 5 B T D C Distributor Point gap DUE mm 0 45 to 0 55 0 0177 to 0 0217 Dwell angle degrees ee buds 49 to 55 Condenser capacity TTE etu sae s advance side 0 22 Condenser insulation resistance Idling adjustment Manual Transmission degreefrpm 2222 222 591800 retard side Automatic Transmission degreefrpm 591650 retard side D range 1 5 0 5 Dash pot adjustment aG u aus 1 600 to 1 800 Anti dieseling solenoid tightening torque kg em indb
112. sed surface of the piston thoroughly Push the piston enough into the cylinder bore Insert new pad into the caliper plate REAR BRAKE Removal and Disassembly Jack up the vehicle and support it on stands and remove the wheels Fig 140 Removing Pad Brakes Fig 141 Sectional View of Rear Brake Release the parking brake and disconnect the cross rod from the lever of the rear wheel cylinder Remove the brake drum Remove the return springs and then take out the brake shoe assemblies Disconnect the brake tube from the wheel cylinder Remove the wheel cylinder by removing com ponents as in the order of dust cover plates and adjust shims then it is ready to be removed from the brake disc The wheel cylinder is easily disassembled by removing the snap ring and dust cover Remove the adjuster assembly Remove the brake disc Inspection Drums If they show score excessive out of roundness and so forth reconditioning by machining is required Drum inside out of roundness below 0 0020 in Nominal inner diameter of the drum is 8 999 in Limit of reconditioning in diameter is 9 040 in Linings If shoe linings are incompletely seated soiled or greasy or deteriorated due to excess heating repair or replace them If the thickness of the lining is found less than 0 0591 in replace it Notes a If oil or grease is found in Brakes Fig 142 Sectionat View of Rear Brake _linings
113. sembly Pull knock pin out and disconnect collar to remove the entire rotating parts z 1 Advanced breaker point 2 Retarded breaker point 3 Phase difference Fig 91 External View of Dual Points Electrical System When cam is to be removed first remove set screw since shaft head is fastened by the screw to hold cam down Put match mark across cam and shaft so that original com bination can be restored at assembly When governor weight and spring are discon nected be careful not to stretch or deform governor spring After disassembling apply grease to governor weights Assembly Assembly can be made in reverse sequence of disassembly Refer to Figure 101 for replacement and reassembly of governor spring and cam In assembling distributor use caution so that rotor head positioning tip at cam is set on governor spring circular hook side Then weight pin for governor spring A with circular hook comes in long rectangular hole 4 Condenser 7 Governor weight 2 Rotor head 5 Shaft 8 Cap t Center carbon 3 Breaker plate Contact 6 Housing 9 Side plug Fig 92 Construction Electrical System Alquwasse yeg iutod 103 quiosse 2114 1 Quod 10j quiasse aim pea M2195 101 2558 1osuapuoy aed quiasse uoqie gt quiesse de 10101115101 9126 Quod 10J
114. sh springs Clean Retighten or solder connections Replace leads if necessary Repair or replace stator Replace rotor Replace diodes Replace rotor Repair or replace stator Replace insulator Replace belt Electrical System Replace wire Check regulator operation and repair or replace as required Broken neutral wire color of wire is white Excessive output Defective voltage regulator Poor grounding of alternator and voltage Retighten terminal connection regulator terminal Broken ground wire color of wire is black Replace wire Retighten or replace belt Correct replace brushes and springs if necessary Replace brush springs Check regulator operation and repair or replace as required Loose or worn fan belt Low output Sticking brushes Low brush spring tension Defective voltage regulator Dirty slip rings Clean Partial short ground open in stator winding Partially shorted or grounded rotor winding Replace stator Replace rotor Replace diode Open or defective diode Retighten mounting bolts Noisy alternator Loose mounting Loose drive pulley Retighten pulley correctly Defective ball bearing Replace bearing Improperly seated brushes Seat brushes correctly Alternator Fuses and Fusible Links Aiternator Model Fuse Box Locati
115. slide smoothly Install the caliper assembly to the knuckle flange Fig 137 Assembling Piston Seals and Retainer Brakes Attach a shim to inner pad for noise proof and heat insulation Be sure to set the inner pad first Draw the caliper plate enough toward inside toward center of chassis Insert lower cuts on both ends of the pad into the mounting bracket and then push the pad until the pad contacts the piston Draw the caliper plate toward outside Insert upper cuts and center indentation of outer pad into the caliper plate Attach the anti rattle clip Be sure the direc tion coincides as indicated by the sticker on the clip Pad Replacement The clearance between the pad and rotor is adjusted automatically Check the pad for wear after the first 6 000 miles and every 3 000 miles and thereafter Pad thickness is easily checked by removing the anti rattle clip When linings become worn to less than 0 04 in in thickness not in cluding the metal backing plate replace all pads Note Always replace the pads in full sets of four using genuine parts Remove the road wheel Remove the anti rat tle clip from the caliper plate Fig 138 Removing Anti Rattle Clip Loosen the bleed screw Pull the caliper plate outwards outward of chassis Push the piston in by 0 118 to 0 157 in Outer pad is loosened and can be easily pulled out Draw the caliper plate inwards and remove inner pad Wipe expo
116. spindle assembly ELO11 Fig 75 Installing pump Installation Before installing oil pump engine turn crankshaft so that No 1 piston is at T D C Fill pump housing with engine oil then align punch mark of spindle with hole in oil pump as shown in Figure 73 Using a new gasket install oil pump and drive spindle assembly so that the projection on its top is located in 11 25 a m position at this time the smaller bow shape will be placed toward the front as shown in Figure 74 Ascertain whether the engagement is order or not by checking the top of spindle through distributor fitting hole Tighten bolts securing oil pump to front cover Electrical System Removal 40 CHARGING CIRCUIT DESCRIPTION 40 ALTERNATOR 41 Deseription eL ARR EV Rat C 41 Removal 41 Installation ATTE 44 VOLTAGE REGULATOR 44 Description 44 Measure of Voltage 45 47 Charging Relay 48 ALTERNATOR 49 FUSES amp FUSIBLE LINKS 49 EMISSION CONTROL DIAGRAMS 50 DISTRIBUTOR 52 52 Disassembly 52 Assembly exe E DER DU 53 IGNITION
117. t cover Remove chain tensioner Remove timing chain Remove oil thrower crankshaft worm gear and chain drive sprocket Remove piston and connecting rod assembly Take otf connecting rod bearings and keep them in order Remove flywheel Be careful not to drop it Remove main bearing caps Use special tool Crankshaft Main Bearing Cap Puller ST1651S0000 to remove center and rear main bearing caps Keep them in or der Remove rear oil seal Remove crankshaft Remove baffle plate and cylinder block net Pistons and Connecting Rods Remove piston rings with a ring remover Press out piston pin Keep the disassembled parts in order 5112070000 Fig 40 Cylinder Head Loosen valve rocker pivot lock nut and remove rocker arm by pressing down valve spring Note Take care not to lose valve rocker guide Remove camshalt Note At this time take care not to damage camshaft bearings and cam lobes Remove valves Take care not to lose valve spring seat oil seal valve collet and valve rocker guide Note Be sure to leave camshaft bearing intact Because the bearing center is liable to be out of alignment ASSEMBLY Precautions Use thoroughly cleaned parts Particularly make sure that oil holes are clear of foreign matter When installing sliding parts such as bearings be sure to apply engine oil to them Use new packings and oil seals Do not reuse lock
118. t the location of the sector shaft by tuming the adjust screw os that the sector shaft and the ball nut hit each other 3 Lock the adjust screw with the lock nut temporarily 4 Move the gear for several times from the side of the gear arm E and make sure it turns smoothly 5 After this the backlash on the top of the gear arm should be between 0 to 0 1 mm 0 to 0 0039 in at the neutral point 6 If the backlash is more than 0 1 mm 0 0039 in screw in the adjust screw further and repeat the the processes of 2 to 5 until it comes within the standard figure 7 Finally screw in the adjust screw by 1 8 to 1 6 turn and lock it firmly with the lock nut OILING Apply gear oi MP90 about 0 33 liters 3 4 U S pts 5 8 Imper pts STANDARD BACKLASH The backlash should be 0 on the radius 22 75 mm 0 896 of the sector pitch when the backlash on the neutral point is 0 and the turning angle of the sector shaft is 0 Fig 145 Sectional View of Steering Gear STEERING LINKAGE Fig 146 Front Bottom View of Steering Linkage on Vehicle Rear Drive amp Suspension SHOCK ABSORBERS 96 Removal iere Ru 96 Inspection 96 Installation tes 96 DRIVE SHAFT 97 RECOMMENDATIONS 97 x Rear Drive amp Suspension Suspension member Suspension arm Member mounting insulator Differentia mounting insulator Co
119. te the jack under the 3 Fig 164 Removing Propeller Shaft Fig 165 Disconnecting Speedometer Cable Fig 167 Detaching Clutch Operating Cylinder oil drain plug prevent damage to the oil pan insert a wooden block between the pan and jack Remove the two bolts attaching the tran smission to the rear engine mount Place a jack under the transmission and remove the four bolts fixing the rear engine mounting cross member to the body Transmission Lower the jack supporting the engine to in cline the engine in a rearward direction This will allow sufficient room for the transmission to be removed Remove the starting motor and the bolts at taching the clutch housing to the engine Lower the jack gradually and withdraw the transmission INSTALLATION Installation of the transmission is the reversal of the procedure given for removal However attention should be given to the following points Notes a Fill the transmission with the recommended gear oil MP 90 capacity 0 45 U S gal b Adjust the clutch operating cylinder at the push rod so that the play at the with drawal lever will be 0 087 in Fig 169 4 Forward Speed Transmission Transmission 00 t v Transmission case Oil pump Front clutch Band brake Rear clutch Front planetary gear Rear planetary gear One way clutch Low amp Reverse brake Oil distributo
120. ter drain plug Set engine on the stand Remove oil level gauge Remove clutch assembly Remove high tension cable Remove spark plugs Remove thermostat housing Fig 23 Removing thermostat housing Fig 25 Removing camshaft sprocket Remove rocker cover Remove camshaft sprocket Remove carburetor Remove cylinder head assembly Loosen bolts Remove intake and exhaust manifolds trom 1 to 10 as shown in Figure 26 Note For the convenience of cylinder head replacement special tool Chain Remove crank pulley Stopper ST17420001 is prepared to sup port timing chain during the service operation By using this tool timing Remove fuel pump marks on crankshaft sprocket and timing Remove engine mounting L H Remove water pump Remove fuel pump drive cam MEN P9 TA u H P r a NUN i OLUR i CUNT lt Dr gt PI RC EMOS2 Fig 26 Cylinder head bolt loosening sequence EMO95 ele U 2 Fig 28 Removing oil strainer and pump Fig 31 Removing piston and connecting rod assembly 097 t 1 Fig 35 Removing buffle plate and net ST 13030001 Fig 39 Removing camshaft REPRE chain will be unchanged So the work for aligning timing marks will be saved so much Invert engine Remove oil pan and oil strainer Remove oil pump and its drive spindle Remove fron
121. ther there is excessive leakage past the piston rings head gasket etc To test the engine should be heated to the operating temperature and throttle and choke valves opened Cylinder compression in cylinders should not be less than 80 of the highest reading Dif F 0 32 10 14 20 4 30 22 40 40 50 58 001 Fig 3 Protection concentration _ Maintenance amp Tune up ferent compression in two or more cylinder usually indicates an improperly seated valve or broken piston ring Low compression in cvlinders can result from worn piston rings This trouble may usually he accampanied hy excessive fuel consumption Test Result If cvlinder compression in one or more cylin deis is low pour a small quantity of engine into cvlinders through the spark plug holes and retest compression Ir adding oil helps the compression pressure the chances are that rings are defective H pressure stays low the likelihood is that valve is sticking or seating improperly I cylinder compression in any two adjacent cylinders is low and if adding oil does not help the compression this could be leakage past the gasketed surface Oil and water in combustion in any two ad jacent cylinders is low and if adding oil does not help the compression this could be leakage past the gasketed surface Oil and water in combustion chambers can result from this trouble Compression pressure psi at
122. tlet adjacent to the inlet manifold The function of thermostat is to control the flow of coolant facilitating fast engine warm up and regulating coolant temperature The thermostats are designed to open and close at predetermined temperatures and not operating properly should be removed and tested as listed below Removal and Installation Drain coolant partially Disconnect upper radiator hose at water outlet Cooling System Fig 127 Removing Thermostat Loosen two securing nuts and remove water outlet gasket and thermostat from ther mostat housing After checking thermostat satisfactorily in stall replacing with a new housing gasket Reinstall water outlet and tighten securing nuts Replenish coolant and check for leaks RADIATOR The radiator is a conventional down flow type having the top and bottom tanks to distribute the coolant flow uniformly through the ver tical tube of the radiator core The radiator filler cap is designed to maintain a pre set pressure 0 9 kg em2 13 lb sq in above atmospheric pressure The relief valve consists of a blow off valve and a vacuum valve It helps to prevent coolant loss from boiling for by raising the pressure on the coolant On the contrary as the pressure is reduced below atmospheric pressure the vacuum valve allows air to re enter the radiator preventing the formation of vacuum in the cooling system The bottom tank on cars equipped with the automatic trans
123. ture and correct measurements ac cording to the table in the left hand side Adjustment the result of above measurement when regulating voltage is deviated from rated value adjust regulator in accordance with the following instructions 1 Inspect contact surface and if rough lightly polish surface with fine emery paper 500 or 600 2 Measure each gap and adjust if necessary Adjust core gap and point gap in that order No adjustment is required for yoke gap 3 Adjusting core gap Loosen screw 4 0 1575 diameter which is used to secure contact set on yoke and move contact upward or downward properly See Figure 80 4 Adjusting point gap Loosen screw 3 mm 0 1181 m diameter used to secure upper contact and move upper con Voltage V 14 75 to 15 75 14 60 to 15 60 14 45 10 15 45 14 30 to 15 30 14 15 to 15 15 14 00 to 15 00 056 1 Contact set 2 Thickness gauge 3 4 mm 0 1575 in dia screw 4 Crosshead screwdriver Fig 86 Adjusting Core Gap 1 Thickness gauge 2 3mm 0 1181 in d a screw 3 Crosshead screwdriver 4 Upper contact Fig 87 Adjusting Point Gap tact upward or downward adequately See Figure 87 5 Adjusting voltage Adjust regulating voltage as follows Electrical Sy Loosen lock nut securing adjusting screw Turn this screw clockwise to increase or coun terclockwise to decrease regulating voltage See Figure 88
124. um die cast pump body The bearings are permanently lubricated and sealed to prevent loss of lubricant and entry of dirt The pump contains an impeller that turns on a steel shaft which rotates in the ball bearings and the volute chamber is built in the front cover assembly The inlet of the pump is connected to the radiator lower tank by a hose Removal Drain coolant into a clean container Loosen four bolts retaining fan shroud to radiator and remove shroud Fig 126 Removing Water Pump Loosen belt then remove fan blade and pulley from hub Remove five bolts pump assembly and gasket from front cover Disassembly The water pump body is made of aluminum and its bearing outer race is press fit For this reason the body shaft bearing should not be disassembled Inspection Inspect pump assembly for the following con ditions and replace it if necessary Badly rusted or corroded body assembly and vane Excessive end play or roughness of bearings in operation Installation Make sure to clean the gasket surfaces on pump and front cover Always use new gasket when installing pump assembly Be sure to tighten bolts uniformly Fill cooling system and check for leaks at pump Install fan pulley and fan blade and tighten fixing bolts securely Install belt and adjust for proper tension THERMOSTAT A wax pellet type thermostat is mounted in the thermostat housing at the cylinder head water ou
125. ure Dragging brake Clutch slipping Overloaded engine Carbon knocking Timing knocking Fuel knocking Preignition misusing of spark plug This strong dull noise increases when engine is accelerated To locate the place cause a misfire on each cylinder If the noise stops by the misfire this cylinder generates the noise This is 2 little higher pitched noise than the crankshaft knocking and also increases when engine is accelerated Cause a misfire on each cylinder and if the noise deminishes almost completely this crankshaft bearing generates the noise When you hear an overlapping metalic noise which increases its magnitude with the revolution of engine and which decreases as engine is warmed up this noise is caused by piston and cylinder To locate the place cause a misfire on each cylinder Corrective action Replenish Adjust fan belt Replace Replace Replace Flush repair or replace Replace Retighten each part of cooling system Replace with proper grade oil Adjust Overhaul carburetor Replace Replace with specified octane fuel Inflate to specified pressure Adjust Adjust Use right gear in driving Disassemble cylinder head and remove carbon Adjust ignition timing Use specified octane fuel Use specified spark plug This is caused by worn or damaged bearings or unevenly worn crankshaft Renew bearings and adjust or change crankshaft Check lubrication syste
126. utch several times by operating the handle Note This will enable the parts to settle down on their knife edges Replace the height finger and recheck the height of the release levers checked for run out as near the edge as possible if the error is more than 0 020 in adjust until it is true within spec limit INSTALLATION It is important to keep friction facings free from oil or grease Place the disc assembly on the flywheel with the longer chamfered splined end of the disc assembly towards the transmission Set the position of the disc assembly by a dummy drive shaft which fit the splined bore of the disc assembly hub and the pilot bearing of the flywheel Tighten six bolts which ar holding the clutch cover assembly to the flywheel a turn at a time by diagonal selection Note There are two dowels the flywheel to locate the clutch cover Fig 157 Actuating Clutch Cylinder Spring seat Piston stopper Return spring Valve stem stop Stopper ring Piston Stopper gasket Boots Secondary cup Gasket ring Oil reservoir Piston cup Push rod Reservoir band Supply valve seat Push rod head Reservoir Supply valve Weld nut Cap Supply valve spring Lock nut Pipe seat 1 2 3 4 5 6 7 8 Fig 158 Clutch Master Cylinder Remove the dummy shaft these bolts are MASTER CYLINDER fully tightened Tightening torque should be 11 to 16 lb ft Removal Remove the clevis pin installed at th
127. w of LT 160 19 Loosen adjusting bolt Installation Eemove alternator driv belt Installation is the reversal of removal Remove parts associated with alternator from OLTAGE REGULATOR engine Description The regulator consists basically of a voltage Remove alternator from vehicle regulator and a charge relay The voltage regulator has sets of contact points lower set and upper set to control alternator voltage An armature plate placed between the two sets of contacts moves upward or downward or vibrates The lower contacts when closed complete the field circuit direct to ground and the upper contacts when closed complete the field circuit to ground through a resistance field coil and produces alternator output The charge relay is similar in construction to the voltage regulator When the upper contacts are closed ignition warning lamp goes on Fig 83 View of Removing Cover Point 10 Adjust spring 1 2 Lower contact 11 Coil 3 Armature 12 3 mm 0 1181 in dia 3 Core gap screw 5 Yoke yap 13 4 mm 0 1575 in dia 6 Connecting spring screw 7 Yoke 14 Contact set amp Adjusting screw 15 Upper contact 9 Lock nut a Construction of voltage regulator Electrical System VOLTAGE REGULATOR Measurement of Voltage Regulator voltage is measured with regulator assembled with alternator When measuring voltage with regulator mounted on vehicle it 15 necessary to rotate engine at h
128. ween upper and lower bearings engine oil to main bearing surfaces on both sides of cylinder block and Install crankshaft Install main bearing cap and tighten bolts to specified torque Tightening torque 32 5 to 39 8 ft lb Notes Apply sealant to each side of rear main bearing cap and each corner of cylinder block as shown in Figure 43 Arrange the parts so that the arrow mark on bearing cap faces toward the front of engine Prior to tightening bearing cap bolts place bearing cap in proper position by shifting crankshaft in the axial direction Tighten bearing cap bolts gradually separating two to three stages and out wardly from center bearing in the sequence as shown in Figure 52 After securing bearing cap bolts ascer tain that crankshaft turn smoothly Fig 52 Torque sequence bolts sure that there exists proper end play at cranksahtt Crankshaft end play 0 0020 to 0 0071 in Fig 54 Driving side oil seal Fig 55 Instalting rear oil seal Install side oil seals into rear main bearing cap Prior to installing apply sealant to these seals Install rear oil seal using special tool Crankshatt Rear Oil Seal Dritt ST15310000 Apply a lithium grease to sealing lip of oil seal Install end plate Install flywheel securely and tighten bolts to specitied torque Tightening torque 101 to
129. y Clean and tighten terminal Replace brushes Inspect brush spring tension or repair brush holder Starting motor Clean and repair cranks slowly Dirty or worn commutator Armature rubs field coil Replace assembly Defective solenoid switch Repair or replace switch Starting motor Wom pinion Replace pinion operates but does Locked pinion guide Repair pinion guide not crank engine Worn ring gear Replace ring gear Defective solenoid switch Defective gear teeth Starting motor will Repair or replace solenoid switch not disengage even ignition switch is turned off Replace defective gear 00 9 0 t d l2 Electrical System Pulley assembly Eront cover Front bearing Rotor Rear bearing Brush assembly Rear cover Diode set plate assembly Diode cover Through bolts Fig 79 Exploded View of LT 150 05B LT 135 13B Pulley assembly Front cover Front bearing Rotor Rear bearing Stator Diode set plate assembly Rear cover Brush assembly Diode cover Through bolts 120 Fig 80 Exploded View of LT 160 19 2 i TER EEO32 1 Front bearing 4 2 Rotor Rearcover 3 Stator 6 Encased diode Fig 81 Sectional View of LT 150 05B LT 135 138 1 Front bearing 5 Rear cover 2 Rotor 6 Brush holder assembly 3 Startor 7 Diode EE 121 4 Pulley Fig 82 Sectional Vie
130. y unscrewing four set screw and remove throttle return spring from secondary side Separate float chamber and throttle chamber by unscrewing four set screws Float Chamber Remove diaphragm chamber assembly and diaphragm chamber gasket Remove fast idle cam cam spring and counter lever Remove filter set screw nipple filter needle valve and stopper plate Remove cylinder plate pump cover piston piston return spring and inlet valve by un screwing two set screws Remove injector spring and outlet valve Remove small venturies main air bleeds and emulsion tubes from primary and secondary sides Remove slow jet and slow air bleed Remove primary and secondary main jets Remove level gauge cover float chamber level gauge rubber seal float shaft colour and float Remove power valve Remove return plate sleeve fast idle lever spring hanger and throttle lever ANTI DIESELING SOLENOID Removal Solenoid is cemented at factory Use a pair of pliers to loosen body out of position Installation Before installing a solenoid it is essential to clean ali threaded parts of carburetor and solenoid Supply screws in holes and turn them in two or three pitches First without disturbing the above setting coat all exposed threads with adhesive the Stud Lock of LOCTITE or equivalent Then torque screws to 30 to 48 in lb After installing anti dieseling solenoid leave carburetor more than 12 hours

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