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Service Manual Nissan Engine Model P

1. 29 Number of Piston Rings Compression s 2 SO YD Roe XV Type of Piston s e on o Steel strut Material of Piston s c c e c ct c co c t LO EX Valve Timing Inlet Valve open degrees B T D C s 1 Inlet Valve closed degrees A B D C 50 Exhaust Valve open degrees B B D C 52 Exhaust Valve closed degrees A T D C 12 Valve Tappet Clearance Inlet Valve hot mm s sss e s 038 0 4 Exhaust Valve hot mm s cs 0 38 0 4 Ignition Method s dii Rae battery amp Ignition coil Ignition Timing B T B 109 450 Firing Order sono 1 5 3 6 2 4 Starting Method s Startor Motor amp Crank Handle IGNITION SYSTEM Ignition Coil Model gt HITACHI CIZ 01 Distributor Model HITACHI D608 01 D608 51A 60 series Type of Spark Advancer gt Centrifugal amp Vacuum Control ne I ET Sparking plug Model Maker Diameter nm 4 Sparking Clearance mm 60 75 Number of pole Insulating Material FUEL SYSTEM Carburetor Original Model BS4E or N K or HITACHI 14 1 Porcelain Stromberg Type VC42 1A 680 Series vc42 4 5 cu E690
2. um vU e t d SM MIT AA VT Service Shop 6 zl t Me u ME en er Fran E MAL EE ee eil M afia NISSAN ENGINE MODEL P SERVICE MANUAL G a NISSAN MOTOR CO LTD 5 TOKYO JAPAN NISSAN ENGINE MODEL P SERVICE MANUAL _ an A NISSAN MOTOR CO LTD aE gt Me E 4 gt xt TOKYO JAPA FOREWORD This manual has been complied for pourpose of assisting NISSAN distributors and dealers for effective service and maintenance of the Model engine Model P engine has been used for the various models of vehicles such as Model 680 Model 4W73 and Model 60 series Each assembly of major components is described in detail In addi tion comprehensive instructions are given for assembling and ins pection of these assemblies The difference between Model 680 4W73 and 60 are also given in this manual as far as engine concerned It is emphasiged that the only genuine Nissan Spare Parts should be used as replacements CONTENTS GENERAL INFORMATIONS SPECIF IC ATIONS sn ttn m eO tn PERFORMANCE CURVES OF NISSAN MODEL P ENGINE GENERAL INSPECTION OF ENGINE s SHORT CUT FOR TROUBLE SHOOTING SECTION L CYLINDER amp CYLINDER HEAD ees Cylinder 4444 LEE 1 1 1 2 Cylinder head m
3. 80 DATA Hitachi VC42 1A for Model 680 VC42 4 for Model 4W73 and 60 series VC42 5A FR40 Downdraft throttle and choke valve linked 42 mm 1 6535 in 36 x 17 x 10 mm l 417 in x 669 in x 0 393 in No 143 for Model 680 No 135 for Model 4W73 and 60 Throat diameter Venturi diameter Main jet Main air bleed No 70 Slow jet No 55 Slow air bleed No 210 Power jet No 110 Slow by pass hole Needle valve diameter C dimension Accelerating pump bore Idler hole diameter Choke valve Fuel level height Power valve start open Degree throttle valve open at full choke Output stroke accel pump Pressure on fuel 4x 1mm 0 1575 in 0 0394 in 2 0 mm 0 0787 in 7 8mm 0 3070 in 19 m 0 7480 in 2 0 mm 0 0787 in Poppet valve 20 22mm 0 7874 0 8661 in 110mm hg 4 3307 in 11 1 8 cc 0 1098 cu in 0 3 kg cm 4 26 1b sq in 1 Functioning of the Main Carburetting System The fuel which has been sent under constant pressure from the fuel pump is gent into the float chamber by the action of the float needle valve and float The vent pipe becomes the vent passage subject to negative pressure and is connected to the interior of the float chamber In spite of the variations in the resistance of the air cleaner act to keep the fuel level constant thereby maintaining the op
4. The dial gauge hand will instantly and automatically indicate the slightest variation in the cylinder bores In use the dial gauge is simply inserted in the cylinder bore and moved up and down its full length It is then turned spirally or completely roted at as may be desired taking readings at each point In this manner all variations in the cylinder walls from top to bottom may be determined If a master gauge corresponding with the exact diameter of a standard cylinder bore is used to set the dial gauge it is easy to determine the oversize piston to use as well as the amount of metal which must be removed from the cylinder walls to make them true 17 Cylinder Boring When it becomes necessary to rebore the cylinders of an engine to install oversize pistons the instructions furnished by the manufacturer of the equipment used should be carefully followed In this engines the piston clearance is allowed on the piston and this must be taken into consideration when setting the cutter in the boring bar The piston to be fitted should be checked with a micrometer measuring just below the lower ring groove and at right angles to the piston pin The cylinder should be bored to the same diameter as the piston If micrometer is not available to measure the piston the cylinder should be bored 0 002 less than the oversize piston to be fitted For example when fitting a 0 020 oversize piston the cylinder should be bored 0 018 overs
5. 0006 0 0014 in SPARK PLUG Model B 54E or B 6E Size of thread 14 mm Gap 0 6 0 7 mm 9 1 CHECK amp REPAIR 1 Ignition Coil When the ignition coil is found unreliable test it by comparing with a new one 1 Test of Primary Coil 2 Usually misfiring of spark plug will occur when the ignition coil fails to supply enough secondary voltage due to poor insulation over heating or internal fault of primary winding In this case measure the amount of electric current from battery to pri mary coil by connecting an ammeter of thirty amperes capacity between the battery and primary coil The primary current generally is about 4 5 amperes at the instance the circuit is closed and will settles at about 3 5 amperes If the ammeter indicates a flow of current over six amperes it suggests that the coil is short circuited If it registers no current flowing through the circuit it is because the coil wire is broken and a new coil should be used Test of Secondary Coil Pull coil wire out of distributor cap remove the cap and crank the engine until distributor points are fully closed Turn on ignition switch hold the 95 cap end of coil secondary wire about 3 8 inch away from metal part of engine and open breaker points with fingers If a good spark jumps from wire to the metal part the coil is in good con dition If the spark is weak or absent the coil is to be blamed provided that condenser and ignitio
6. 0098 in 0 50 mm 0 0197 in 12 A T D C 43 mm 1 692 36 2 mm 1 425 in 49 Seat angle Inlet and exhaust Seat width inlet and exhaust Stem diameter Inlet Exhaust Length inlet and exhaust Lift overall Working clearance VALVE GUIDES Length Inlet amp exhaust Outside diameter Inside diameter Hole for valve guide diameter Valve stem clearance inlet Valve stem clearance exhaust VALVE SPRINGS Free length Fitted length and load Number of working coils Diameter of coil wire Core diameter TAPPETS Type Diameter Length 45 1 4 1 8 mm 0 055 in 0 071 in Limit of use 3 32 in 8 650 8 637 mm 0 3405 0 3400 in 8 640 8 627 mm 0 3401 0 3396 in 131 5 mm 5 1772 in 9 6 mm 0 378 in 0 38 0 40mm 0 015 0 016 in Water 80 C 72 mm 2 8346 in 15 048 15 030 mm 0 5923 0 3916 in 8 685 8 700 mm 0 3419 0 3425 15 000 15 018 mm 0 5905 0 5912 in 0 035 0 063 mm 0 0013 0 0024 in 0 045 0 073 mm 0 0017 0 0028 in 57 5 mm 2 2638 49 5 mm at 23 5 kg 1 9488 in at 52 lb 5 3 4 turns 4 5 mm 0 1771 in 33 5 33 Omm 1 3189 1 2992 in Holiow barrel 23 990 23 975 mm 0 9445 0 9438 in 55 mm 2 1653 in 50 ROCKER MECHANISM Pu
7. FG60 4W73 Maker PP HITACHI Dia of Throttle Valve mm e essee oo 42 Dia of Ventury Tube mm 36 17 10 Dia of High Speed Jet mm l 43 VC42 14 4 5 Dia of Low Speed Jet lt 0 55 Dia of Economizer Jet nm 4 3 10 Draft Direction e Downward Air Cleaner Type soe 6 Bath Maker e Tsuchiya Number 1 Fuel Feed Pump Type Diaphragm Maker Showa Seiki Kyosan Denki LUBRICATING SYSTEM Method Type of Oil Pump Type of Oil Filter Oil Pan Capacity itr COOLING SYSTEM Method Radiator of Water Pump Thermostat BATTERY Model Voltage Capacity amp hr Number Terminal grounded Pressure Feed Gear Pump Paper Filter lt 5 3 680 series 6 7 60 series Forced ann with Centrifugal Pump Fin and Tube Type Pump Peliet 2SMC 4 12 volt 60 20 hr rating E690 120A n positive __ ______________________ GENERATOR Model Maker gs C SES HITACHI Type of Winding eos oe e n n n n s s Shunt wound Voltage M 2 a 09 9 34 o1 422 9 12 volt Capacity kw gt esf im s n n n n n nS s 2 2007 Type of Voltage Regulator et t nt Carbon pile RIS 50 G140 07 F680 E690 STARTING MOTOR Model Ee E OF de duode MFB HRZ Maker eos os S n n n n I
8. It is necessary to continue the grinding process until an even matt surface is produced on the seating and the valve face On completion the valve seats and ports should be throughly cleaned with gasoline soaked rag and dried and the subjected to a compressed air blast The valves should be washed in gasoline and all traces of grinding compound removed 53 Ensure that the cylinder head and cylinder block joint faces are clean The cylinder head gasket is marked upper face TOP so that it will be placed head in correctly Place the gasket into position and fit the cylinder head securing bolts finger tight They screw into cylinder block at the front and rear bolts holes on the manifold side and guide the head into position Insert the push rods replacing them in the posi tions from which they were taken Screw back all the tappet adjusting screws Replace the rocker assembly and screw down the securing nuts finger tight Evenly tighten the cylin der head bolts diagonally from the center to out side finally pulling them down a torque wrench set 55 65 ft lb Reset the valve clearances and finally check them when the engine not so hot or cold The cylin der head bolts may pull down slightly more after the engine has attained its normal working temperature in which case the valve clearance will have to be checked again and reset if necessary 0 38 0 40 nn at 60 C 4 6 TIMING GEAR 4 CAMSHAFT If there
9. b Check the insulation of wire If it is broken and grounded to the body of generator replace or repair Check terminals If found detached or loose tighten securely 2 Generator troubles Remove the wires from A and F terminals of the generator Connect these two terminals with a different wire Have another piece of wire ready for later use With the engine funning at about 1000 rpm connect one end of the third wire to A terminal and ground the other the generator body with light bouch If then a remarkable spark occures the generator is in good order Note This method of test is used only when a voltmeter is not available If the voltmeter is at hand connect the meter to A and E terminals leaving the original wire as it is and read the amount of volt regis tered by the meter 107 d Check the wirings inside the generator Broken or shorted wire should be replaced or repaired Check the armature coil and field coil If their wires are broken or shorted replace the complete part Check commutator brushes If they are found worn and not contacting with the commutator or if the spring is found broken replace these parts If the surface of commutator is found extremely scored replace or re dress Check the brush holder If it is shorted due to poor insulation repair 3 Troubles of voltage regulator c Den If the regulator cover is found making contact wit
10. 10 2 CAUTIONS FOR HANDLING GENERATOR l Keep always clean the inside and outside of the generator 2 When the generator is disassembled wash the parts with gasoline excepting the field coil and armature coil 3 In case of assembling blow away the dirt and dust by the compressed air And when assembling make sure all connections are tightened securely 4 After assembling feed eight to ten drops of engine oil to the armature shaft bearing 104 5 To set the generator on the engine don t adjust the fan belt too tightly The proper tention of belt is to have one inch deflection when pushed with a thumb 6 the engine is to be run with lead wire disconnected between the generator and battery ground the wire of the generator If not ground the generator will be burnt 7 The terminal of circuit must be tightly fastened and kept clean 10 3 CARBON PILE TYPE VOLTAGE REGULATOR zm DPile pressure screw G Carbon pile G Pile holder Moving core 5 Compression spring Yoke G Magnet coil B Flux adjusting screw DATA Type Hitachi R115 02 Voltage adjustment Caron pile No load voltage setting 15 16 volt generator 2500 rpm Flux screw locating voltage 8 10 volt generator 2500 rpm Cut out relay point gap 0 7 0 9mm 0 028 0 035 Armature air gap point closed 0 25 0 45 mm 0 010 0 18 in Cut in voltage 12 5 13 5 volt generator 1300 rpm Reverse curr
11. battery and a 30 amperes ammeters ready for the use of test Build up a circuit connection from generator A terminal through ammeter to negative pole of the battery Also connect generator body and positive pole of battery with a wire Then the generator will turn as a motor Checking the flow of current in this manner locate the inside trouble of the generator 1 If the ammeter indicates a discharging rate of less than five amperes and 2 3 if the generator keeps running amoothly with a slight sound and it should be regarded as perfect condition If the generator fails to run the troubles is in the circuit In the above test if ammeter reading is over five amperes discharges it any mean a short or grounding of internal circuit provided that the gene rator is mechanically in good shape Usually the mier trouble is located in defective armature If the generator turns in the above test but if the ammeier needle vibrates there must be a short circuit internally lf the ammeter shows a discharging rate of below four amperes there must be a poorly contacing or highly resistance part in the internal circuit 2 Internal Troubles of Generator By the above test a idea of the location of trouble can obtained However to go into the detail it is recommended to make test on a universal electric tester If the tester is not available an armature growler Fig 6 can be used 110 1 Low Charging Current W
12. be 55 65 ft lb 14 Check of Charging Rate of Generator It should read more than 10 amperes at the engine speed of 30 40 km hr Refer to Electrical 15 Diagnosis of Engine by Means of Vacuum Gauge See Fig 2 Oil and Rings in In case 3 gauge hand Poor Condition drops to zero and Remains in lower comes back to about reading in Case 2 23 when opening and closing throttle Leaky Valve Loose Valve Stem Guide Drops about two divi vibrztes fast between sons M and 18 Weak Valve Spring Late Timing of Late Ignition Spark Plug Gap From 10 to 22 when Valves Timing too Small or Brea accelerating engine as Point Contact and becomes greater Remains steady be Remains steady be Improper as increasing speed tween 8 to 15 tween 14 to 17 Floats between 14 and 16 Leaky Cylinder Head Choked Muffler Carburetor fs Out Gasket Normal at first drops of Adjustment Floats regularly be to zero and then Floats slowly between Leaky Gasket of Intake Manifold or Carbaretor Indicates 5 or less tween 5 and 19 builds up to 16 13 and 17 Fig 2 Diagnosis of Engine by Vacuum Gauge 4 9 SHORT CUT 1 Piping system 2 1 Leakage 2 of fuel The fuel level too high or over flowing 3 4 5 Carburetor 1 2 Improper fast ening of jet 3 screws or dam aged washer 4 5 6 Adjustment 3 1 rburetor 2 Repair lt 3 4 10 FOR TROUBLE SHOO
13. body after draining oil from drain plug The filter element should be changed at each 4 000 miles or at shorter intervals if the oil get dirty sooner In assembling be sure the tightening bolts tightly in place and new packing and gasket are used if considered to leak the oil The capacity of engine oil should be checked every day The oil capacity is measured by the oil level gauge provided at the right side of cylinder The oil level must be kept between the upper and lower lines of the gauge Change engine oil every 1 500 miles in its degree of viscosity Select a good quality of oil 63 Drain plug Fig 7 Sectional view of oil filter tightening torque Center bolt 2 2 5 kg m Relief valve opening pressure 0 6 7 5 kg cm 64 SERVICE NEWS REFERENCE NO OF SERVICE JOURNAL AND BULLETIN 65 SERVICE NEWS REFERENCE g gt ta ue e z o lt lt 5 CONTENTS BULLETIN 66 SECTION 7 COOLING SYSTEM Radiator Fan Th 4 4 is Water pump i ha AT Cylinder head Cylinder block Qu Fig 1 7 1 WATER PUMP FAN amp FAN BELT 15 14 13 18 11 16 12 Water pump body Cover Vane and shaft Pulley Seal retainer spring Seal retainer Rubber seal Bakelite seal Vane snap ring 10 Water pump shaft bearing 5 11 Bearing spacer 12 Front seal plate
14. end of the piston pin must be approximately 3mm 1 8 in out of the piston boss face so that the connecting rod is position in the center of piston pin 26 must hold piston only on the boss face Return spring Special Tool P Engine Piston pin Fitting NT 4245 Fig 6 Inorder to avoid distortion of piston during press fitting pin into the con rod the inner ribs and the base of pin boss is slightly modified and also the oil ring groove depth is slightly deepen for the newly adopted combined oil ring 2 3 PISTON RING AND PISTON PIN All compression rings are marked with the word Top cast in the upper side of the ring When installing compression rings make sure the side marked Top is toward the top of the piston Piston rings are furnished in standard size as well as 0 005 0 010 0 020 0 030 0 040 0 050 0 060 To properly fit new piston rings proceed as follows Slip the ring into the cylinder pressing it down about 2 inches into the bore with a piston This will square the ring in the cylinder Check the gap between the ends of the ring with a feeler gauge This should be from 0 006 to 0 015 0 010 to 0 015 0 25 0 38 mm 2nd amp oil 0 006 to 0 012 0 15 0 30 mm if the space between the ends of ring is less than 0 005 remove the ring and with a fine file dress the ends until proper clearance is obtained Fit each ring separately Carefully remove ali particle
15. kg cm 49 5 57 lb in at running speed 4 5 6 7 Refer to the line up of Lubrication System Check of Spark Plug The gap should be adjusted to 0 6 0 7 mm 0 024 0 028 Refer to Ignition System Check of Compression Pressure of Cylinder The compression pressure should be over 135 pounds per square inch when measured by rotating engine with starting motor The difference of pres sure at each cylinder should not exceed 10 pounds per square inch This test Should be made under the conditions temperature of cooling water at 70 80 all spark plugs removed and the throttle and choke valves of carburetor completely open Check of Distributor Adjust the point gap at 0 020 inch Check of Ignition Timing Adjust the timing at 2 before top dead center crank angle 8 9 Check of Carburetor Refer to Fuel System Check of Fuel Pump and Strainer Refer to Fuel System 10 Check of Tension of the Fan Belt When pressed by a hinge the deflection of fan belt should be 25 mm in at the middle of water pump pulley and crank shaft pulley 11 Check of the Valve Tappet Clearance Adjust the clearance at 0 38 0 40 mm 0 015 0 016 in at 60 C for both intake and haust valves when engine is suf ficiently warmed 12 Check of Slow for Carburetor Refer to Fuel System 13 Check of Tighteness of Cylinder Head Bolts Adjust them to
16. mI 218444 SECTION 2 PISTON PISTON RING PISTON amp CONNECTING ROD 2 1 Piston 2 2 2 3 Piston ring and piston pin Come eer mm 2 4 4444442 4 4 44 4 2 5 Connecting rod 6 660606896016 SECTION 3 CRAN KSHAFT 4 4 4 3 Disassembling of crankshaft 3 2 Rear bearing seal ar rr SECTION 4 CAMSHAFT VALVE TAPPET amp TIMING 4 1 Removal of cylinder head s seer reer rece II 4 2 Removal of valves PPP ILL EE 4 3 Replacement 4 4 Valve grinding ahve 9 2 9 4 4 5 Refitting the cylinder 4 6 Timing gear amp camshaft nnn III te SECTION 5 MANIFOLD ssh HI RII hehehe 5 1 Removal gu wow Oe 5 2 Inspection 5 3 Heat control assembly 24444 SECTION 6 LUBRICATION SYSTEM e n KM 6 1 Adjustment of oil regulator 6 2 Oil filter rte hmmm SECTION 7 COOLING S
17. mm 2 9448 2 9291 in 74 68 74 42 mm 2 9402 2 929 in Thumb fit at 20 C 68 F Press fit 1 5 3 5 metric ton 29 Slip the outside of the ring into the groove and roll it entirely around the groove to make sure that the ring is free and does not bind in the groove at any point Proper clearance of the piston ring in its groove is very important and when fit ting new rings the following clearance should be adhered to At the top ring a 0 002 feeler 0 001 0 015 should be very free but 0 003 feeler should cause the ring to lock in the groove At the second or oil control groove the 0 002 feeler should produce a light drag If a ring of proper size is not available select one which fits slightly tight grind the ring an emery No 1 placed upon the flat plate Rub the lower side evenly making sure the ring will not warp LOCATION OF RING GAP The leakage of compression pressure is often caused from the improper location of ring gap in relocation to each other When assembling the rings locate the gap of first compression ring toward Front Direction the second ring at 180 angle toward Rear Direction of the engine and the oii ring at same direction of first compression ring 2 4 The engines from the number P 31592 are assembled with combined ring This new ring compose of two side rails and a special spacer is designed to control the quantity of oil up and blow by gas This flexible type which follow
18. standard size as well as 0 0025 0 005 over size Note Over size pistons for service use are as follows Piston is usually supplied as Set piston with pin For Connecting rod 12100 58000 Piston pin bolt clamp type 12010 58022 12011 58002 12024 95960 12010 58023 12012 58002 12024 95960 12010 58024 12013 58002 12024 95960 12010 58025 12015 58002 12024 95960 12010 58026 12016 58002 12024 95960 12010 58027 12017 58003 12024 95960 12010 58028 12018 58003 12024 95960 12010 58029 12019 58003 12024 95960 For use with combined oil ring amp bolt locking type corrod Set piston w pin std 12010 58022 piston 12011 58002 Pin piston 12024 95960 23 Set conrod w bush 12130 58002 As8 y conrod 12100 58000 Rod connecting 12104 58000 Washer spring 9 15116 Bolt hex 1 34632 Cap conrod 12106 58000 Bolt conrod 12109 58000 Nut hex 9 11246 Palnut 12112 58000 Bush conrod std 12111 58001 Pin piston std 12024 95960 Pin piston O S 0 06 mm 12028 95960 Pin piston S 0 12 mm 12025 95960 Service Bpare parts Pin piston O S 0 25 mm 12026 95960 Fig 1 13 84 13 59 mm Fig 2 24 2 2 Interchangeability New con rod can be used with former type piston pin Former con rod can not used with the new piston pin Applied model All P engine Applied from Es P 32473 for 680 series Except Fire Eng
19. the bearing back plate and the thrust washer and correct the clearance of it Fig 41 3 2 REAR BEARING SEAL This rear main bearing is sealed by a wick type seal installed in a groove machined in the block and cap To install a new wick seal at the rear main bearing cap insert the packing in the groove with the fingers Then using a rounded tool roll the packing into the groove When rolling the packing start at one end and roll the packing to the center of the groove Then starting from the other end again roll toward the center The above procedure insures that the wick is firmly pressed into the bottom of the groove The small portion of the wick which protrudes from the groove at each end should be cut flush with the surface of the bearing cap To prevent the possibility of pulling the wick out of the groove while cutting off the ends it is recommended that a round block of wood the same diameter as the crankshaft glange be used to hold the packing firmly in position while the ends are being cut off If it should become necessary to replace the upper half of the wick seal it will be necessary to remove the engine from the chassis and remove the crank shaft The procedure for installing the wick in the cylinder block is exactly the same as for installing it in the bearing cap 1 Wash and clean the crankshaft and bearings 2 Apply marking compound lightly over each journal of crankshaft 3 Install upper
20. tip of pump injector This fuel had previously been drawn from the float chamber through the check valve and stored below the piston This action 82 provides the necessary acceleration If the accelerator is depressed further the throttle valve will open further Then which its opening becomes 110 mm Hg from the fully closed position the end of power valve rod moves down together with descent of the connecter to push down the valve Simultaneously a new fuel passage is formed between the float chamber and main jet and the fuel of the float chamber enters through the fuel port is metered by the power jet goes out of the end of the main jet and is ejected from the injection nozzle together with fuel of the main carburetting system As a result and extremely righ mixture is supplied Because the various parts such as the venturi jets and air bleeds of this carbu retor have been designed and constructed go as to provide optimum fuel air mixtures practically no adjustment other than that for slow speed and fuel level is necessary Choke valve PEE 76 ACH gt Fig 6 1 4 N PT AN SY F NY SS SS Air check bowl Air bleed main Nozzle packing 0 1 0 25 mm Nozzle Washer 119 The parts mentioned above have been assembled in accordance with the re sults of rigid tests Therefo
21. too big Insufficient fastening of main jet Leakage in the power jet valve The level of fuel is too high Disorder of air cleaner The porcelain part of spark plug is white i Uneven running of engine Back firing in carburetor Engine overheat particularly the exhaust pipe overheats Engine power diminishes Poor adjustment of carburetor Instrusion of air from the throttle valve shaft and the fitting flange Back fire Insufficient acceleration Knocking 14 Jets tampered or remodelled imitation parts used Too lean mixture Wrong ignition timing Pre ignition Catch fire due to engine overheat Disorder of ignition system Insufficient seating of engine valves or broken valve springs Disorder f accelerating pump Clogging of accelerating pump injector hole Leakage from accelerating pump check ball vaive Disorder of distributor governor Wrong ignition timing Poor adjustment of carburetor Erroneous adjustment of carburetor Improper fuel relating to compression ratio Dirty cylinder inside Wrong ignition timing Pre ignition Disorder of spark plug SECTION 1 CYLINDER amp CYLINDER HEAD DATA Diameter of cylinder bore Thickness of cylinder wali Difference of top and bottom bore Difference between the longer and shorter diameter inside of an oval bore of cylinder Main bearing housing dia Block cylinder head surface warpage Tightening tor
22. vacuum gauge in the inlet port of the upper body Operate the rocker arm with hand three or four times to its full stroke The gauge should show 450mm hg vacuum and keep it for more than three seconds To check the pump without gauges choke the inlet and outlet ports with fingers and push the rocker arm After about three seconds let go the finger from inlet port Also let go the finger from outlet port after about five seconds Ifa strong suction sound is heard in the former and if a strong blow out sound is heard in the latter case you can assume the pump is in good working shape After the pump has been installed to the engine Connect the gasoline pipe on the side of inlet port leaving intact the pipe on the outlet side Rotate the engine six or seven turns with the crank handle and see if gasoline flows out from the outlet port Connect the gasoline pipe to the outlet port and tighten up connections Run the engine idling and check connections if they are fuel and air tight 8 3 CARBURETOR The carburetor used is the Hitachi Model VC 42 and is of the down draft type It is equipped with a boost type power system and the main carburetting system consisting of a triple venturi and an air ventilation pipe a low speed carburetting system a piston type accelerating pump and a fuel economizer system The car buretor functions appropriately for each of the various conditions of starting idling medium speed high speed and accelerating
23. water is introuduced in the system cylinder block or cylinder head is liable to crack or warp 73 So keep the engine is stopped before feeding cold water it will not circu late the water and will have undesirable effect During the cold winter or whenever is liable to freeze never fail to drain water from the radiator and engine Be sure to open both drain cocks at the bottom of the radiator and at the rear right side of the engine to completely drain the water 74 REFERENCE SERVICE NEWS g gt e n un Fu 2 JOURNAL AND BULLETIN CONTENTS SERVICE NEWS REFERENCE JOURNAL AND 9 gt m 2 o z CONTENTS BULLETIN 76 SECTION 8 FUEL SYSTEM 8 1 FUEL PUMP Diaphragm spring Free length Fitted length amp load Rocker arm spring Free length Valve spring Free length Valve thickness Performance Max output Max outlet pressure Max suction vacuum Hand primer output Upper body Valve retainer Cap Diaphragm Valve Connector Rocker arm Rocker arm spring Rocker arm pin 10 Lever 11 Hand primer pin 12 Packing cap 13 Diaphragm spring 14 Lower body 15 Valve 16 Diaphragm Fuel Pump Mechanical diaphragm pump 60 4 61 6 mm 2 3779 2 4251 in 22 mm at 9 5 10 5 kg 0 8661 in at 21 231 29 5 30 5 mm 1 1614 in 1 2007 in 7 05 7 15mm 0 2776 0 2815
24. 0 28 mm 0 0059 0 0110 Tightening torque of cap bolt 5 5 kg m 40 ft lb Every time a connecting rod is removed from an engine or a new connecting rod is being installed it should be checked for alignment on connecting rod alignment fixture as shown in figure Place the piston pin in the eye of the rod and tighten the clamp screw Place the connecting rod on the aligner arbor and tighten the con necting rod bolts If there is any bent or twist correct it with a bend ing bar Next install the piston and check the alignment as the illustration The maximum allowable limit of bend is 0 004 The bearing metal should have a good contacting surface over an area more than 70 of it Such a bearing too much clearances between the carnk pin and big end of the connecting rod will be found scored over the sur faces of the metal And in extrem cases the metal surfaces will even tually be cracked If the metal is so much own replace with new bearings Check connecting rod end clearance Fig 10 between the upper half of the connecting rod and the side of the crank pin with feeler gauge Lock the connecting rod bolts nuts by installing new pal nuts The pal nuts must be installed with the open side of the nut toward the end of the bolt As a final and last checkto be sure that the assembly will travel true with the bore check the clearance between the crank pin and connecting rod side This should not b
25. 1 5 mm 0 590 2 8 litres min or over 0 74 gal USA cam 1000 rpm suction height 600 mm Q3 6 in 220 250 mm hg 8 66 9 84 in hg 400 15 7 in mm hg or over Approximate 200 cc 12 2 cu in 10 strokes 77 8 2 REPAIR OF FUEL PUMP 1 Measurement of Rocker Arm Before disassembling the fuel pump measure the gap between the rocker arm and the flange of lower body with a square and a scale as illustrated in Fig and check the wear of rocker arm rocker link and pin When the play of the arm is taken up the above mentioned gap should be 1 9 64 inch and if found less than this it is because the rocker arm link and pin are excessively worn and therefore it needs remedy The gap measurement is determined by pushing the arm teward the body until the resistance of diaphragm spring is felt as well as the rocker arm and the rocker link leave no clearance at the shaft of diaphragm Camshaft eccentric Fig 2 Construction of Fuel Pump and Measurement of Rocker Arm Wear 2 Inspection of Parts Wash and clean the parts with gasoline and blow tith compressed air before making the inspection Undermentioned items should be specially attended 1 Whether or not gasoline is infiltrating due to the wear or damage of dia phragm 2 Whether or not there is any crack or wear in the connecting part of dia phragm shaft and link 3 Whether or not the contacting surfaces at rocker arm cam and th
26. 13 Rear seal plate 14 Felt cover plate 15 Felt seal 16 Shim 17 Bearing snap ring 18 Lubricator fitting EEE Fig 2 Sectional View of Water Pump 67 DATA Water pump type Centrifugal Pulley ratio 1 28 to 1 Fan blade Number 4 Diameter 476 mm 18 7 in Thickness 1 6 mm Fan belt V Angle of V 40 degrees 1175 1181 mm 46 250 46 500 25 mm 1 in Type Length outer Detlection tension adjustment 7 2 REPAIR OF WATER PUMP In case of troubles in the water pump such as water leakage worn or burnt ball bearings of the pump shaft remove the unit to repair It is better to remove the radiator before the water pump is displaced 1 Disassembly of Water Pump 1 Remove fan blade from the water pump pulley removing the eight screws 2 Move the generator toward the engine after loosening bolts holding the generator and take off the fan belt 3 Remove the by pass rubber hose at water outlet spacer 4 Remove three bolts which hold the water pump body to the cylinder block 68 5 Draw out cotter pin in the castle nut on the pump shaft and remove nut and washer Pull out pump pulley from the shaft using a puller and remove woodruff key 6 Remove four bolts fastening water pump cover to its body and displace the cover and gasket 7 Take vane from bearings in pump body assembly a this ope ration is to b
27. 3 Fuel Leaks from the Gasoline Tank a First locate the leaking spot and mark it with a chalk and drain the fuel completely b Blow the compressed air into the tank and expel out the stagnant gas therein Get it dried completely 89 Repair completely the leaking spot by soldering or oxygen welding If the broken spot is comparatively spacious a steel plate of proper size is to be patched thereto Failure to expel the gas staying in the tank will induce a dangerous explosion at the time of wilding operation Good care is invited to this matter 2 Trouble and Check of Gasoline Gauge The trouble in gasoline gauge is attributable to the trouble in tank unit dash unti and poor wirings Check them as foliows 1 Remove the terminal of tank unit and set on ignition switch Alternately touch and detouch the terminal to chassis and look at movernent of indi cator in dash unit If then the indicator oscilates quickly across the dial from E to F dash unit and wirings are in good condition Replace the tank unit to locate the trouble 2 In case the indicator does not move in the above test try to earth the wire running from the back of dash unit to tank unit If the indicator moves the wiring is no good 3 In case the indicator does not move in the above mentioned test earth the wiring from battery to dash unit If spark is seen it indicates the trouble is in dash unit Defective dash unit should be replaced 4 In case o
28. ERENCE SERVICE NEWS BULLETIN NO OF SERVICE JOURNAL AND CONTENTS 114 SECTION 11 STARTOR MOTOR DATA Type Voltage Power Starting current voltage Lock torque Pinion gear type Pinion gear number of teeth Flywheel gear number of teeth Gear ratio Pinion shaft diameter Amendment wear limit Shaft and bushing clearance Amendment wear limit Commutator diameter Amendment wear limit Irregular wear limit Out of round limit Brush length Amendment limit Brush spring tension 11 1 REPAIR 1 Removal Hitachi 5114 20 4W Series 5114 21 E690 5114 22 L4W Series 5114 23 680 690 60 12 volt 1 0 KW 1 4 HP Less than 420 amp 9 5 volt Over 1 8 kgm 130 ft lb Sliding over running clutch 9 146 16 2 1 14 2 mm 0 559 in 0 1 mm 0 004 0 076 0 030 mm 0 003 0 0012 in 0 2 mm 0 008 in 34 mm 1 3386 in 3 0 mm 0 1181 in 0 3 mm 0 0118 in 0 05 mm 0 002 in 16 3 mm 0 6417 in 11 3 mm 0 4448 0 9 kg 1 98 15 1 Remove the startor pedal and remove startor motor from engine 2 Loosen two through screws and remove head cover 3 Remove armature shaft center bearing and pull out armature 4 Remove shift lever from head cover 5 Remove pinion and clutch assembly 6 Remove foot switch 2 Inspection of parts Inspect each parts after cleaning and judge if it be reusable or not Reusable parts should be am
29. NCE JOURNAL AND 2 gt nl o z CONTENTS BULLETIN 118 SECTION 12 BATTERY DATA Model Voltage Capacity Plate per cell Specific gravity of electrolyte Electrolyte level Initial charging current Ground earth terminal Electrolyte capacity Weight dry 2SMC 12 60AH 20H rate 19 10 99 1 270 1 280 3 8 in above plate 10 amp positive 3 5 3 6 ltr 0 92 0 95 U S Gal Approx 20 kg 44 1b 12 1 HANDLING OF BATTERY 1 Battery has to be inspected from time to time during service The most important matter is to keep it fully charged Check of the specific gravity is the means to detect how much the battery is charged The specific gravity fluctuates according to the atmospheric temperature Therefore temperature is to be taken into consideration The full charged condition of battery is shown with the specific gravity at around 1 280 in hot weather or 1 300 in cold weather To check the specific gravity use the hydrometer Fig 1 Hydrometer 119 if the specific gravity is found below 1 200 it means the battery is over dis charged and should be recharged If an excessive discharging is kept on it will do harm to the battery Discharging should not be allowed beyond the minimum specific gravity Check the volume of electrolyte in the cell and fill it from time to time up to the level as high as 3 8 inch above the plate
30. NSPECTION Manifold flanges must be all on the same plane Inspect manifolds for warpage by placing their flanges on a flat surface i If it is found warped resurface on surface cutting equipment Also check for cracks and breakages and replace if defective 5 3 HEAT CONTROL ASSEMBLY This assembly deflects a parts of the hot exhaust gas to and around the intake manifold by a valve and facilitates fuel evaporation Heat control has a thermostatic spring controling the above action automatically If this spring is worn replace it When installing manifolds place new gaskets Gaskets between intake and exhaust manifolds and gasket between cylinder head and manifold assembly 57 REFERENCE SERVICE NEWS NO OF SERVICE JOURNAL AND CONTENTS BULLETIN 58 SECTION 6 LUBRICATION Gub SYSTE ivi E Sue Pin _ 9 21225 pec eee Oil pump 9 15408 driving bc 4 spindle assembly Relief valve Oil pump body Shaft Drive gear Drive shaft pin Idler shaft Bottom Driven pump cover gear 1 11412 9 15115 9 15114 1 11520 Fig 2 Components of Oil Pump 59 As showing in Fig 3 the engine oil forced out by the oil pump is ramified into two series and the one circulating through crank shaft main bearings con necting rods camshaft bearings tappet valve rocker arm and other lubricating by connecting rod splshes the postons and cylinder wa
31. TING Damage of fuel pipe or insufficient soldering Insufficient tightening or damage of union nut on the fuel pipe Worn needle valve and seat in float chamber Dust at needle valve and seat in the float chamber or incomplete move ment of needle valve Fuel infiltrated in the float The float is too heavy due to the weight of solder Too much pressure of fuel pump or too big needle valve seat hole Improper fastening of needle valve seat 885 Improper fastening of screws on the cover of the float chamber Loose emulsion outer tube Improper fastening of pump injector Improper fastening of low speed jet Improper fastening of the upper and lower bodies of carburetor or pre sence of cracks Poor adjustment for low speed Clogging of low speed jet or the jet of improper size used Loose fastening of low speed jet Crack on the joint surface of the upper and lower bodies of carburetor or fastening Improper assembling of the throttle valve Poor idling Hard to start or unable to start in cold climate Engine and etc Carburetor Engine and other parts N 11 Intrusion of air due to worn throttle valve shaft i Air leaking from carburetor flange and intake manifold flange Difference of compression of each cylinder Irregularity of spark plug gaps Poor quality of spark plugs or use of different kinds Improper ignition timing Intrusion of air
32. YSTEM IINE ee 7 1 Water pump fan amp fan belt srt I mmm mg ttt 7 2 Repair of water pump 9 9 V nA 824 m a d P 7 3 Radiator thermostat amp heat indicator Page SECTION 8 FUEL SYSTEM Haus Fei ite er ER 77 8 1 Fuel pump 77 8 2 Repair of fuel pump 444 4 78 8 3 Carburetor Cr 80 8 amp 4 Adjustment ot carburetor 84 8 5 Air cleaner 4 Ro Ule Oise WE 87 8 6 Gasoline strainer 87 8 7 Gasoline tank amp gasoline gauge 89 SECTIO 9 IGNITION SYSTEM 93 9 1 Check amp repair rr 95 9 2 Adjustment 4 100 SECTION 10 GENERATING SYSTEM s n 9 103 10 1 Generator 4 103 10 2 Cautions for handling generator 104 10 3 Carbon pile type voltage regulator 105 10 4 Troubles and remedy of generator and regulator 106 10 5 Test of generator g
33. a hand If the iron piece is attached to the armature core the armature coil is shorted and should be replaced 10 6 WIRING OF GENERATOR VOLTAGE REGULATOR AND OUT PUT ADJUSTMENT 1 Wiring 1 Connection of wire c f Fig 7 Be sure each wires is connected to its right place on both the generator and regulator Also each wire should be tightly in place especially the one grounded to the terminal E Make it also sure that electrical resistance at the terminal be minimized by clean tight connection Regulator A terminal to Generator A terminal to Ammeter to battery x F 7 to Generator F terminal s E 3 to E to body 111 2 Size of wires The following sizes are to be selected for different wirings From A on generator to A on voltage regulator 5 5 sq mm B amp S gauge No 8 From voltage regulator B through ammeter to battery From voltage regulator F to generator 0 9 sq mm B amp S gauge No 16 From E on both regulator and to body Fig 7 Wiring Diagram 55 Ammeter D C 0 15A Motor 1 Variable speed Battery Volt meter 0 15V Fig 8 Universal Electric Tester Variable resistance 0 0 2 ohm 30 Amp S Switch on volt meter 2 Adjustment Reference should be made to the wiring diagram shown Fig The adjustment of a generator is better done by the use of a universal tester illustlated in Fig 8 1 Adjustment of voltage reg
34. adjusted so that the belt has 1 2 3 4 inch free movement as illustrated in Fig 7 make the adjustment Loosen No 1 bolt first and next No 2 Move the generator and push the belt with a hand that there is a free movement of 25mm on the bolt Fasten the bolts If the belt is adjusted too loose it would make the belt to slip resulting in performanc of the fan and generator as well as premature wear of the belt and the overheating of engine in summer If it is held too tight bearing would be damaged 71 Fig 7 Adjustment of Fan Belt 7 3 RADIATOR THERMOSTAT amp HEAT INDICATOR DATA RADIATOR Type Pressurized Water tube pressure type 0 4 0 5 kg cm 5 7 7 1b sq in Model 680 4W73 60 16 ltr 16 ltr 17 5 4 227 U S Gal 4 6U S Gal Cooling water capacity THERMOSTAT Type Pellet Temperature to start open 71 5 74 5 C 160 166 F Temperature full open 86 5 89 5 C 187 193 REPAIR OF RADIATOR 1 Cleaning of Cooling System Neglect of the cleaning of radiator for a long while or use of improper or impure water for cooling purpose bring forth the overheating as formation of rust and sediment in radiator and water pump will result in poor water circulation To clean the radiator proceed as follows 1 Drain the cooling water by opening the drain cock at the bottom of the radiator 2 Loosen the clamps of radiator inlet h
35. alve begins to function Adjustment of Connecting Rod Insert the connecting rod into choke Connecting rod lever post Keeping downward the arrow marked on the choke lever post set ite tip to the side groove of the connecting rod and fix it up with setscrew As for its position it is so arranged that when the choke valve is totally closed the opening degree of throttle valve will stand at 11 Fig 11 86 8 5 AIR CLEANER Cleaning of Air Cleaner 1 The air cleaner serves to clean the air before it is suctioned into the cylinder If the cleaner has been in service for a considerable Jength of time without having been cleaned the accumulated dusts within the cleaner interferes free passage of the air This will re sult in poor engine performance and increased fuel consumption As any dust particle in the air will cause pre mature wear of cylinder wall air cleaner should not be dispensed with and it should be kept clean all the time by periodical inspection and cleaning 2 To clean the apparatus unscrew the 8 wing nut on top of the cap and remove b for Model 680 the cap Take out the steel wires and clean them in gasoline Fill the bowl Fig 12 Air Cleanes with engine oil up to the specified level Reinstall the wires after having been dried and soaked with oil 3 The cleaning of the apparatus should be made every 3 000 miles If however the vehicle is used customarily in dusty district
36. ammeter needle surges showing a charge unless the trouble is in the ammeter check the following 1 Cisorder of external wiring a b Wiring may be about to be broken replace it In case the insulation of v ire is torn and is grounded to the bodv replace or correct it 108 1 Test of field coil grounding Dis connect the earth wire of field coil and ground one of the terminal of the growler Touch an end of the other side of the growler to the terminal of the field coil If then testing Jamp is illuminated the field coil has a short circuit If does not light the field coil is in good condition In the dormer case replace the coil 2 Lead wire test Contact the two wires of the growler to both ends of the lead wire and if the lamp lights the wire is If not the wire is defective and should be replaced Fig 6 Armature Growler 3 Test of positive brush With the end of a wire of growler grounded and the other wire touched to the positive brush if the test lamp lights the brush holder is grounded and it should be replaced 4 Test of grounding of armature To check the armature whether or not it is grounded contact one of the growler wires to the armature shaft and the other to the commutator seg ment If the test lamp lights the armature is grounded and should be re placed 5 Short circuit of armature Place the armature on the growler and put a piece iron on the armature with
37. and lower bearings in their own position and install the crankshaft in the cylinder 4 Rotate the crankshaft back and forth Remove the crankshaft and check the contacting condition of bearings 43 5 The upper half bearings have to make contact evenly and more than 70 of its contacting area If any insufficient contact is found replace it with a new 6 The lower half bearings also should be making contact evenly over 70 of the area Sometimes excessive clearance of the lower half bearings to the journal makes it impossible to show the contacting condition In sucha case replace with the undersized bearing Make shift repair can be made in case of absolute necessity by filling off the cap and bearing to take up the clearance Re check the bearing fit after the above work Repeat the work until you are sure satisfactory fit is obtained 7 After checking the contacting condition wipe off marking compound and apply engine oil plentifully 8 Install the seventh bearing and cap and tighten with a regular force Check the tighteness by rotating the crankshaft Fig 7 Tightening Torque of Main Bearing Cap Bolt 9 Proceed to the next bearing in the same manner and have all the bearings adjusted 10 bearing fit is properly adjusted on all journals the crankshaft can be rotated by grasping No 2 and No 5 crank pins or No 3 and No 4 crank pins with a slight starting but without any resistance after starte
38. ank pin is dam aged correct those defects Support the No 1st and No 7th journals with Fig 3 Apply a dial gauge to sixth fifth fourth third and second journals and rota the shaft to see if there is the deviation of more than 0 002 inch The belt shaft should be corrected with a press Support and rotate the crankshaft same as the said way apply a dial guage to the flange the part to connect the flywheel If the surface of flange is wabbling more than 0 001 0 025 mm have it fixed up When the journal or crank is worn flat oval or if they are scored cut or rough beyond the limit 0 004 or over replace it with a new one Clear out throughly the oil passage by blowing out with a compressed air Main bearing is manufactured to be easily removed with the crankshaft in place Avoid repeated use of old bearings Check throughly before it is installed Such a bearing as excessively worn out or making poor contact or having scores cuts rough or hardened surfaces are to be replaced Carefully inspect the side thrust part of the No 1 bearing and if there is any wear take up the wear by removing the shims and washer placed between the thrust washer and crankshaft If the wear is beyond the regular side thrust clearance of 0 004 0 007 replace these shims 13 1000 in 6 1000 in 2 1000 in When replace these shims tap up the crank gear with a adapter and measure the clearance between
39. carburetor closed And if unusual noise is heard when the motor is crank ing the engine check the flywheel ring gear for provable trouble 2 3 4 Inspection and trouble shooting 1 Poor Cranking Power a Check the specific gravity of electrolyte in the battery and see it is over 1 270 b Check battery cable ground cable and each connections for tighteness c Check foot switch for perfect contact 2 When motor does not revolve Stem of foot switch button is adjusted too short and fails to make contact Screw out button until the length of stem become enough to act b Poor connection of battery cables Disconnect the terminal and clean and tightly connect again 3 In case pinion gear does not mesh with flywheel ring gear when armature is revolving a Stem of foot switch button is too long Adjust it b Fiywheel ring gear teeth are excessively worn Replace the ring gear 4 In case the pinion gear and flywheel ring gear bind In case this trouble has occurred shift the transmission into high speed gear and jerk the car back and forth then gears will be released b Remove motor from engine check gears or head cover bushing for wear and check armature shaft for distortion Amend or replace if necessary 116 n 5 In case of excessive noise in revolving check the flywheel ring gear and replace if gear teeth are worn out 117 SERVICE NEWS REFERE
40. ce Standard height of valve spring 7 05 7 15 mm and if it is found extremely fatigued replaced with new spring In case there is an extreme amount of play at the contact surface of rocker arm and camshaft or when rocker arm pin hole ig worn too much replace the arm with a new To correct the above condition disassemble the body and remove the dia phragm Install a packing of thick paper between the lower body and dia phragm and raise the relative position of diaphragm shaft with the lower body In case the contact surface of rocker arm and rocker link is worn replace the arm and link altogether But for a makeshift repair emboss the link at the part where it contacts the arm by means of exygen welding and then finish the surface with file Also a simpler repair can be done by using paper dia phragm as explained in 4 8 In case the contact part of diaphragm shaft and rocker link is worn out re place the diaphragm assembly 9 In case the rocker arm spring is fatigued broken or bent replace free of spring is 29 5 30 5 mm 6 7 4 Over Flow of Gasoline from Carburetor 1 In case spring pressure of diaphragm is tampered and made too strong it will happen that gasoline overflows from the float chamber Don t monkey with the pressure of locker arm spring 2 In case fuel pump is installed on cylinder block be sure to use the flange gasket The failure of installing the gasket is su
41. continue feeding gasoline to the engine when the latter is over heated Inspection 1 Cleaning of the Screen After long run screen become clogged with dust and the bowl is depositted with dust and water in its bottom and will result in poor straining efficiency 2 Check Periodically In case of dust and dirts are depositted therein remove bowl and screen clean up completely with gasoline and compressed air 88 8 7 GASOLINE TANK amp GASOLINE GAUGE 2 1 Resistance wire Q Terminal G Float Fig 14 Gasoline Gauge Tank Unit and Dash Unit Fuel tank capacity Model 680 60 110 50 ltrs 29 13 U S Gal Repair of Gasoline Tank amp Gasoline Gauge 1 Troubles of Gasoline Tank and Repairs 1 The gasoline pipe of tank unit is clogged with dust or water In this case remove tank unit and blow the pipe with compressed air in the reverse way to the flow of fuel Take off the drain plug at the bottom of tank and clean inside of tank 2 Fuel does not come into the gasoline pipe This happens when the ventilation hole in the filler cap is clogged with dust In this case the tank would take vacuum effect which prevent the flow of fuel into the fuel pipe Clean up the ventilation hole b The gasoline pipe of tank unit is bent and dows not reach the fuel level The lower end of pipe should be 5 8 inch above the bottom therefore if other wise remove the tank unit and correct the bent pipe
42. d 11 After above work is completed be sure to lock the cap boits with torque rench with the scale 44 SERVICE NEWS REFERENCE NO OF SERVICE JOURNAL AND BULLETIN um CONTENTS REFERENCE SERVICE NEWS NO OF SERVICE BULLETIN 2 lt lt 8 CONTENTS SECTION 4 CAMSHAFT VALVE TAPPET amp TIMING Bracket bolt poi 5 Rocker shaft clip Set screw Washer Rocker shaft bracket A Loek ng Inside Rocker shaft bracket B xn Outside spriug Valve rocker Bush Right side Valve rocker p 4 Left side Valve Valve cotter retainer Expansion plug 13209 58000 B Valve spring er amp intake 13238 58000 rubber amp Ex Valve lifter Exhaust valve Intake Cam shaft valve AT 7 70 1518 r iio Abe ME nen a 70 151 13005 58000 drive gear Cam shaft bearing Fig 1 Camshaft Valve amp Lifter DATA CAMSHAFT Material Journal diameter Cam height Fuel pump cam offset Runout of camshaft Drive Cam gear number of teeth Bearing clearance Backlash of camshaft gear and crank gear Special steel forging 49 149 49 124 mm 1 9349 1 9339 in 48 945 48 920 rnm 1 9270 1 9260 in 48 641 48 616 mm 1 9150 1 9140 in 48 336 48 311 mm 1 9030 1 9020 in 41 246 mm 1 6238 3 00 3 10mm 0 1181 0 1220 in Not to exceed 0 025 mm 0 001
43. d of the float and the upper surface of the chamber cover If thig distance is from 20 to 22 mm the adjustment is correct Fig 9 If not extract the float holding pin remove the float and adjust the angle of the contact plate as shown in the photograph Be careful in making this adjustment because if the bending is forced the arm may be broken off from the float Also because the needle valve is not headed be careful not to let it drop out together with its spring 8S Fig 10 6 Check the seating of the needle valve to the valve seat If leakage exists replace the needle valve assembly As described previously the power jet starts to function when the throttle valve opening becomes 110 mm This adjustment is determined by the position of the adjusting nut of the power valve rod If the position of this not is on the low side the functioning of the power jet will be delayed and if it is on the high side the functioning will be hastened For correct adjustment press down lightly with a finger on the power valve rod as shown in the accompanying illustration until the resis tance of the power valve is felt then hold this position Move the throttle lever until its matching mark coince des with that on boss part The throttle valve opening will then be 110 mm Then raise or lower the adjusting nut so that connecting plate just touches the upper surface of the adjusting nut i e the point at which the power v
44. e cylinder head is removed the valves be take out To do this compress the valve spring with the valve spring compressor Remove the cotters of valve retainer Release the valve spring retainer and oil seal from stem Withdraw the valves from the guide 4 3 REPLACEMENT The diameter of exhaust valve head are smaller than the inlet valve To re place the valves insert each valve into its guide and replace the spring oil seals retainer and compress the valve spring Refit the valve cotters and secure them by releasing the compressor Remove the compressor 4 4 VALVE GRINDING Before replacement of the cylinder head the valves and their seats should be examined for signs of pitting or burnt platches and distortion If these conditions are present the valve seats must be recut before attempting to grinding the valves wilst distorted valve head should be corrected or the valve renewed Only the minimum amount of metal should be removed in the trueing process 52 When grinding a valve on to its sealing the valve face should be smeared lightly with grinding paste and then lapped in with a suction type grinding tool The valve must be ground to its seat with a semi rotary motion A light coil spring interposed between the valve head and the port will assist considerably when lifting the valve in order to rotate the face to a different position This should be done frequently to spread the grinding compound evenly
45. e done with the use of press When the hammer is used in stead never fail to use a copper hammer and tap the end of shaft lightly If other wise you are likely to bend the shaft or damage the screw threads Now the vane assembly will come off from pump body together with five accessories such as seal retainer spring seal retainer rubber seal bakelite seal and vane snap ring 8 Remove the vane snap ring first and the seal retainer spring seal retainer rubber seal and bakelite seal are removed from the vane assembly 9 In case shaft bearing or felt seals ia in bad shape remove shaft bearing snap ring and take out the front seal plate washer shim shaft bearing bearing spacer rear seal plate felt cover plate and felt seal from washer pump body 2 Assembly of Water Pump In order to assemble the parts after having finished necessary repair works invert the order of disassembling work mentioned above However the following care is to be taken in handling 1 Put the vane assembly with the shaft pointing upward Grease the shaft lightly and insert the seal retainer spring so that the smaller diameter comes to the bottom of the shaft 2 See that the rubber seal fits the shaft with proper tighteness The proper tighteness is deter mined by the rubber seal sliding on the shaft when pushed lightly with fingers After having assembled the vane assembly with water seal system 1 seal retain
46. e less than 0 004 0 10 mm 33 Fig 12 Inserting Piston amp Connecting Rod Insert each piston and connecting rod assembly into the cylinder from which in was taken it is essential that the F mark on the boss of the piston is positioned towards the engine front The oil hole of big end of connecting rod must be positioned and toward the side of manifold Compress the piston rings with inserting piston using tool and gently tap the top of the piston with the end of the wooden bar until the piston is clear of the piston unit clamp 34 Now push the piston down the cylinder block until the big end of the connecting rod just protrudes through the bottom of the cylinder bore then position upper half bearing shells SERVICE NEWS REFERENCE g gt 9 2 Q lt 4 lt 2 2 CONTENTS BULLETIN 36 SECTION 3 CRANKSHAFT DATA CRANKSHAFT Material Construction Diameter of main journals No 1 Special steel forging With forged counter weight 68 229 68 204 mm 2 6862 2 6852 69 300 69 275 mm 2 7283 2 7273 in Not to exceed 0 0125 mm 0 0005 in 57 150 37 131 mm 2 2500 2 2492 in Not to exceed 0 0125 mm 0 0005 Not to exceed 0 075 mm 0 003 in at center bearing 0 03 0 096 mm 0 0012 0 0037 0 125 0 150 mm 0 005 0 006 i
47. e link are worn 78 4 Whether or not locker arm and diaphragm shaft are worn or cracked 5 Whether or not diaphragm spring arm spring and valve spring are fatigued 6 Whether or not there is wear or deformation in valve and seat 3 Troubles Causes and Repairs 1 Poor fuel supply This will happen when gasoline leaks due to crack damage or fatigue of diaphragm Replace a new diaphragm 2 In case of diaphragm spring is fatigued or broken new one must be re placed The regular height of spring are one inch for inner and two inch for outer spring Any spring of less height has to be replaced 3 In case fuel or air leaks through cap gasket check cap bolts for tighteness If this does not stop the leakage gasket is to be replaced 4 In case the screen is clogged with dusts wash it with gasoline 5 In case there is leak in inlet or outlet valve check if valve is bent and re place with a new one if necessary Allowable limit of bend is 0 001 inch When the contact surfaces of valve seat and valve are found in poor condition remove the outlet valve seat and polish the face with a fine oil stone The inlet vaive seat is not removable from body Therefore to amend the sur face of valve seat use a cutter and grinder When the surface of valve is not smooth polish the valve lightly on a glass plate coated with fine emery compound Standard thickness of valve is 1 16 inch If worn beyond the limit repla
48. ed through the ud 7n ei slow speed air bleed The fuel 2 is then regulated suitably by the 3 d slow speed adjusting screw is injected 2 id hit The by pass port consists Bek of a lengthwise slot and 1mm N 3 hole and delivers the mixture Ni N uS NER for slow speed when the open NE NINN NSN check valy 5 oo ing of the throttle valve is ex IN NA Nr tremely small However as T Washer the throttle valve gradually jet EAM opens the mixture is ejected Bir SDN Ne from the hole and the transi tion from slow speed to inter mediate speed is made smooth ly without irregularities such as pauses in the action Throttle valve shaft Fig 4 3 Functioning of the Accelerating Pump and Economizer The accelerating device of this carburetor is of the piston type synchronized with the throttle valve shaft It is equipped with the pump piston and pump injector which temporarily supply a rich mixture and the power valve and power jet which supply a very rich mixture when sudden acceleration or high power is required The device functions as follows If while the vehicle is being driven at a constant speed the accelerator pedal is pressed down for acceleration the pump piston descends in accordance with the descent of the connecting plate and injects the fuel below into the venturi from the
49. ended if necessary 1 Check distorted armature and amend commutator out of round by lather Be sure there is an air gap between armature and field core 2 Full contact brush on the commutator should be maintained The best way is to clean and redress the commutator holding a fine sand paper against 115 it and revolving the armature with a hand Brush which is worn to a length of less than a half inches should be re placed 3 Inspect pinion gear for crack 4 Polish outside of armature and inside of core if they are rusty and coat with oil 5 Clean and redress the contact surface of switch 6 Check wirings for perfect insulation and replace defective parts 7 If any specific part of armature is found to be burnt make careful test for insulation 8 Replace head cover bushing if excessively worn 3 Assembly and testing 1 Coat all friction surfaces with engine oil and assemble the parts in the reverse order of disassembly Carefully tighten the terminals of each wire and be sure they are well insulated Adjust the length of switch button so as the shift lever will make contact with the cutton instantly after the pinion gear is engaged with flywheel ring gear 4 Test performance with fully charged battery 5 Starting torque must be over eleven feet pounds 6 When motor is tested on engine it should ordinally crank the engine at a speed of about eight revolutions per minutes with the throttle valve of
50. enever valve are ground to maintain factry limits and clearances as only by maintaining these limits and clearances can good engine economy and performance be obtained Checking Valve Guide Lack of power and noisy valves in many instances can be traced to worn valve guides The clearance between the vlave guides and the valve stem is very important The intake guides should be checked with a new intake valve and the exhaust be checked with a new exhaust valve because the diameters of the stems are different 21 SERVICE NEWS REFERENCE g gt ua 2 a z 2 9 CONTENTS BULLETIN 22 SECTION 2 PISTON PISTON RING PISTON PIN amp CONNECTING ROD 2 1 PISTON The pistons are made of LO EX aluminum alloy with three ring groove located above the piston pin The skirt is elliptic These pistons are furnished in standard size as well as 0 010 0 020 0 030 0 040 0 050 0 060 i Any time a piston is removed from the cylinder it should be examined for carbon on the inside and any carbon deposit removed This helps keep the engine oil clean The piston pin is fixed 1 5 mm off set towards the thrust direction at the center of piston The pistons are serviced with the piston pin fitted in them Should it become necessary to install oversize piston pins The proper fit of the piston pin is a thumb push fit at 20 C The piston pins are serviced in
51. ent 5 ampere Number of carbon piles 45 The carbon pile system is 50 designed that its electrical resistance will de crease when higher pressure is applied and will increase when lower pressure is applied With this function the carbon pile placed in the circuit line of generator field coil in series control the pressure by means of a combinatian of magnet and plate spring The higher voltage produced by the generator willexert less pres sure and therefore more resistance the lower voltage will induce more pressure and therefore less resistance For instance when the generated voltage is too high strong current flows through the magnetic coil 6 and attracts the moving plate 4 of the pile and lessens the tension of pressure spring This will increase the electrical resis tance of the carbon pile 1 and reduce field current of the generator the re sult of it the voltage will be reduce 105 Fig 5 Voltage Regulator in Model 4W73 On the contrary when the voltage of the electric current from generator drops very low the carbon pile system will function in inverse order as described above and raise the voltage Thus the voltage will be stabilized all the time This regulator has no current limitter It is because the magnetic coil of voltage regulator incorporates a current coil when functions to automaticaly regulate the resistance of the carbon pile when excessive current flows and reduce the vol tage so
52. er spring seal retainer rubber seal bakelite seal vane snap ring check whether the unit is in proper working order The unit is in good shape if the bakelite seal snaps back to its proper place when depressed with a thumb and freed If the seal does not return instantly and without drag it is due to weakness of the seal re tainer spring or too tight fitting of the rubber seal Remove such a seal and inspect the bore of the seal and if found blamable for stiff fitting rebore until it fite properly On the contrary if the cause is found in weak seal re tainer spring replace it with a new spring In order to assemble shaft bearing etc first insert the vane assembly to the pump body Cover the felt seal with sufficient grease and set it to the shaft together with felt cover plate and rear seal plate Then in stall the shaft bearing spacer shim washer front seal plate and snap spring 5 In fastening the cover to the pump body with four screws proceed as follows for two screws in the upper middle use spring washers for the one positioned lower left facing toward the pump use a copper washer and for the fourth screw in the lower right use shake proof washer them have to be screwed up tightly The reason for using the copper washer is that it prevents water leaking through the screw hole 6 After installing the cover on pump body put the woodruff key on the shaft and fix water pump pulle
53. etween piston and and body Pressure Running Idling Sump capacity Oil Spur 8 39 40 39 35 mm 1 5511 1 5492 in 29 960 29 935 mm 1 1795 1 1785 in 3 18 3 23 mm 0 1251 0 1271 in 12 976 12 958 mm 0 5108 0 5101 in 190 2 189 8 mm 7 4882 7 4724 in 0 025 0 075 mm 0 001 0 003 if over 0 008 in Replace 0 040 0 115 mm 0 0016 0 0045 in 0 150 0 260 mm 0 006 0 010 Built in pump body Min 0 5 kg cm 7 Ib in at running speed 2 24 kg 30 3 mm high 0 002 0 0025 in If over 0 005 in Replace 3 5 4 0 kg cm 50 57 in 0 5 kg cm 7 1b sq in at oil temp 70 80 C 5 3 litres 1 4 gal U S A 5 MS No 20 For temperature above 30 C MS No 30 62 Check the clearance between the drive gear and bump body The clearance should be 0 150 0 260 mm If this clearance or others which showed in the series data should too much over replace the gear with a new part depending on whichever may be the cause of the excessive clearance 6 2 OIL FILTER The oil filter is mounted on the left side of the engine As for the oil filter which serves to filter of engine oil within the oil pan is of the full flow type using the paper elements This elements should be taken out for periodical check and cleaning For disassembling unscrew the cap bolt of the center shaft at the top of filter
54. f no spark is seen when the wiring from the battery is grounded it indicates the trouble is in wiring SERVICE NEWS REFERENCE JOURNAL AND BULLETIN 9 gt amp un z CONTENTS 91 SERVICE NEWS REFERENCE BULLETIN NO OF SERVICE JOURNAL AND CONTENTS 92 SECTION 9 IGNITION SYSTEM D Battery Startor motor G Generator 9 Voltage regulator Ammeter Ignition switch Ignition coil Condenser Breaker point 49 Distributor Spark plug Fig 1 Ignition System Circuit DATA IGNITION COIL Hitachi CIZ 01 12 volt 3 95 at 20 C 68 F 10M 80 C 176 F Type Primary voltage Primary coil resistance Insulation resistance Current consumption approx Running 1 4 Amp distributor 1800 rpm Stall 2 0 Amp 0 N0 6 PISTON DISTRIBUTOR Type Hitachi D608 01 D608 02 water proof Ignition timing 10 B T D C Automatic advance system Centrifugal and vacuum Advance angle characteristic Advance start at engine rpm 1000 rpm Max advance angle 34 at 3600 rpm crankshaft Breaker point gap 0 45 0 55 mm 0 018 0 021 in angle 35 40 at point gap 0 5 mm 0 020 in Contact arm spring tension 500 600 gr 17 6 21 loz Condenser capacity 0 20 0 24 Micro farad Insulation resistance SM for over Clearance distributor shaft and bushing 0 015 0 035 mm 0
55. from the intake mani fold or the rubber tube joint of the window shield wiper is leaky No fuel supply to the carburetor Intrusion of air from the throttle valve shaft and its flange fixing the same Use of poor quality fuel too much mixture of substitute fuel such as alcohol kerosene etc Erroneous use of choke button _ Imperfect insulation of high tension wiring Poor ignition current due to the under charging of battery Disorder of ignition circuit Troubles of spark plugs accumula tion of carbon damage by heat ir regularity of gaps condensation of lubricating oil and water poor quality etc Insufficient compression of cylinder Air intrusion into the intake manifolds Insufficient seating of engine valves or broken or weak valve springs Hard to start or unable to start in hot climate Insufficient speed and power Carburetor Engine Carburetor Engine ge mos pa Insufficient cranking speed of starting motor Poor quality lubricating oil No fuel supply to the carburetor Too lean mixture due to poor adjust ment for low speed Erroneous use of choke button Insufficient tightening of upper and lower body or damage of gasket Trouble of engine valves or broken valve springs Poor ignition or insufficient cranking speed of starting motor due to drop of battery voltage Disorder of ignition circuit Trouble of startor mo
56. gt HITACHI Volt Power vs hp LLL 12 10 5114 23 5114 21 E690 PERFORMANCE CURVES OF NISSAN MODEL P ENGINE 1 81 14 dH 18 uofduinsuog ong Fo E acne ee HR EE 220 gr HP h 1600 r p m 145 HP 3800 r p m 32 5 kg m 2000 m bal N Max Torque 5 4 B H P ep ED E Eur EL Ic ELE GREE LE s e N Min Fuel Consumption Max Sunsi 9 dH 38104 exeag Engine Revolutions X100 r p m LEFT SIDE ENGINE ENGINE RIGHT SIDE GENERAL INSPECTION OF ENGINE In order to maintain the engine at the best condition a periodical and orderly adjustment have to be made 1 2 Check of Cooling Water The cooling system must be full of water which is required to be soft and Gan to the line up of Cooling System Check of Battery The quantity of electrolyte is required to be as much as 3 8 inch above the plates The specific gravity should be more than 1 220 kg The voltage at each cell should be more than 17 5 volt on the excell tester 3 Refer to the line up of Electrical Check of Engine Oil The oil capacity is 6 2 ltr The oil level should be between the upper and lower lines of the oil level gauge The standard oil pressure is 3 5 4
57. h the wiring resulting in a short circuit repair the cover In case any wire in the reguiator is shorted or broken replace or re pair If the contact points of cut out relay do not close when pushed with a finger it is because the core and moving plate are stuck Make adjust ment Note In making this test be sure to have the battery disconnecting Next hook up a voltmeter fifteen volt to B and E terminal of the regulator With the engine running at 1000 rpm close the contact points of cut out relay with a finger Read the voltmeter registration and if it is found more than closing voltage the cut out relay must be blamed for such troubles as mentioned in d to f be low Cut out relay may have a shorted or broken coil replace the relay complete Cut out relay is out of proper adjustment and the closing voltage is unduly high Bring the adjusting arm down to obtain proper adjustment The current coil may be broken or shorted If so replace cut out relay complete When the cut out relay is O K ed and the volt meter reading is below closing voltage or zero the trouble will be in voltage regulator In case voltage is low raise up the voltage by turning the adjusting screw for variable flux to the counter clock wise In case of wear or damage of carbon pile replace it and adjust again When the magnetic coil of voltage regulator is broken or shorted re place it 3 Fluctuation of Charging Current When the
58. hen the ammeter keeps on registering unreasonably low rate of charging current check first the ammeter If it is found in good order locate the trouble and remedy in the following order 1 Troubles of External wiring If any wire is worn or broken replace or repair When any terminal is found loose tighten securely 2 Troubles of regulator a b When there is any shorted or broken wire replace or repair Check the cut out relay and if the contact points are dirty or pitted dress with a fine file or emery cloth When the adjusted voltage is too low turn counter clock wise the adjusting screw for variable flux and increase the voltage d Check the resister for pile coil If it is burnt and shorted replace Check the magnetic coil If any part of the coil is shorted or broken replaced 3 Troubles in Generator a b When the surface of commutator is dirty or extremely rough polish remedy the surface Check commutator brushes If their contact with commutator is poor redress the brush surface or replace Check coil of armature and of field as well as wiring connection If any broken part is disclosed replace or repair 2 No Current If the ammeter registers no charge at all trouble may be worse than described above unless the ammeter is out of action check and remedy as follows 1 Troubles in external wiring a If any wire is broken or about to break replact it
59. in Helical gear 54 0 01 0 10 mm 0 0004 0 004 0 1 0 15mm limit of use 0 25 mm 48 CAMSHAFT BEARINGS Type Front bearing Out dia before fitting Inside dia reamed in position Length Housing diameter Second bearing Outside dia before fitting Inside dia reamed in position Length Housing diameter Third bearing Outside dia before fitting Inside dia reamed in position Length Housing diameter Rear bearing Outside dia before fitting Inside dia reamed in position Length Housing diameter Undersize available VALVES Timing Inlet opens Inlet closes Exhaust opens Exhaust closes Head diameter inlet valve Head diameter exhaust valve Thinwall steel backed white metal 52 555 52 530 mm 2 0690 2 0680 in 49 303 49 238 mm 1 9410 1 9384 in 29 49 29 24 mm 1 1610 1 1511 in 52 476 52 541 mm 2 0659 2 0684 in 62 375 52 350 mm 2 0619 2 0609 in 49 123 49 058 mm 1 9339 1 9313 in 19 0 mm 0 748 in 52 273 52 248 mm 2 0579 2 0569 in 52 070 52 045 mm 2 0500 2 0489 in 48 818 48 753 mm 1 9220 1 9194 in 19 mm 0 748 51 740 51 943 mm 2 0370 2 0450 in 51 740 51 715 mm 2 0370 2 0360 in 48 488 48 423 mm 1 9090 1 9064 in 31 8 mm 1 2519 in 51 664 51 638 mm 2 034 2 033 0 25 mm 0
60. ine E P 32423 for 60 series E PF 2686 for all P type fire engine NEW CON ROD Set piston w pin std 12010 58100 For use with combined oil ring amp Piston 12011 58100 press fit type con rod Pin piston 12024 58000 Applied model AH P engine Applied from E P 31592 25 12130 58003 12100 58001 12104 58001 None None 12106 58000 12109 58000 9 11246 12112 58000 12111 58001 12024 58000 12028 58000 12025 58000 12026 58000 For Connecting rod 12100 58001 Piston pin tight press fit type Sm pe pin Set con w bush Ass y con rod Rod connecting Washer spring Bolt hex Cap con rod Bolt con rod Nut hex Palnut Bush con rod std Pin piston std Pin piston O S 0 06 mm Pin piston O S 0 12 mm Pin piston O S 0 25 mm 12010 58107 12010 58100 12011 58002 12024 58000 12010 58101 12012 58002 12024 58000 12010 58102 12013 58002 12024 58000 12010 58103 12015 58002 12024 58000 12010 58104 12016 58002 12024 58000 12010 58105 12017 58003 12024 58000 12010 58106 12018 58003 12024 58000 12019 58003 12024 58000 PISTON Piston pins are tightly fitted in the connecting rods It is advisable to use a special assembling tool NT 4245 shown in the following figure 6 To ease the fitting coat light engine oil on the outer surface of pin and inside of con rod pin hole before press in When assembling with the special tool the
61. is an excessive amount of end play in the camshaft it is necessary to remove the gear and camshaft assembly and correct the falts When the camshaft and gear assembled to the engine it is im portant that the punch marks on both the camshaft and crankshaft gear must be fitted as Fig 7 The cam shaft will then be in its proper posi tion so that the valves will open and close in the proper relation to the movement of the position After the camshaft and crank shaft gears are in their proper places check the crankshaft timing gear for run out with a dial indica tor This should not exceed 0 15mm Then check backlash of the camshaft gear This should not exceed 0 25 mm 54 REFERENCE SERVICE NEWS JOURNAL AND BULLETIN gt ES ua f 9 2 CONTENTS 55 REFERENCE SERVICE NEWS BULLETIN NO OF SERVICE JOURNAL AND CONTENTS 56 SECTION 5 MANIFOLD 5 1 REMOVAL Remove intake and exhaust manifolds assembly from cylinder head These manifolds are held together at the center bos by the stud bolts After removal wash and clean both intake and exhaust manifolds 16174 58000 11 Manifold gasket P to cylinder head Intake gasket to manifold Intake amp Jexhaust manifold 14022 58000 14021 58000 3 3 59020 1 2 li 21 AN gt a 2 4 2 11638 1 9156 45 14006 58000 te Los Fig 1 5 2 I
62. ize Cylinder Hone After a cylinder has been ebored within 0 002 of the size desired it should be refinished or polished with a cylinder hone In operation the hone is placed into the cylinder bore and expanded until it can just be turned by hand The hone is then operated up and down in the bore until it begins to run free During this operation kerosene should be used as a cutting fluid to keep the stones of hone clean This procedure should be followed until the piston being fitted can be pushed through the cylinder on a 0 0025 feeler gauge The feeler gauge must be inserted vertically 90 around piston from the piston and draw out the feeler gauge with the scale under 1 3kg powers 18 19 1 2 CYLINDER HEAD Cyl head height all length 97 06 mm Combustion chamber volume 86 72 0 5 Length of Cyl head 119 mm Warpage of surface Within 0 004 0 1 mm Tightening torque Cyl head bolt 55 65 ft lb 7 6 9 0 Rocker bracket bolt 31 36 ft lb 4 3 5 0 One of the most important units of any overhead valve engine is the cylinder head It contains not only the combustion chambers and spark plugs but the valves inlet ports exhaust ports and the necessary water passages to maintain the proper temperature of these important parts No maintenance operation is more important than valve grinding from the stand point of engine economy and performance Extreme care should therefore be used wh
63. l on lower side of spacer with gap approximately 20 30 mm right of spacer ends 31 Final Inspection Check final assembly to make certain Rails are not off spacer Gaps of rails and spacer are nor lined straight Spacer assembly be turned manually with ease Spacer gap is directly over piston boss Installing Pistons into Cylindera Use steel band tool for installing pistons into cylinders For Niflex Oil Ring Install two rails so that each gaps are 45 from spacer gap Lower Rail Gap Upper Rail Spacer Gap NIFLEX Fig 9 2 5 CONNECTING ROD DATA Material Steel forging F500 Length center to cetner 200 199 9 mm 7 874 7 870 in Big end housing width 31 55 31 50 mm 1 2422 1 2402 in Big end housing diameter 60 180 60 199 mm 2 3693 2 3700 Thinwall steel backed white metal Type Overall length 25 9 26 1 mm 1 0196 1 0275 Outside diameter 60 199 mm 2 3700 in 32 Thickness Standard 1 508 1 500 0 593 0 0590 Undersize available 0 25 mm 0 010 in 1 633 1 625 mm 0 0643 0 0640 in 0 50 mm 0 020 1 758 1 750 mm 0 0692 0 0689 0 75 mm 0 030 1 883 1 875 mm 0 0741 0 0738 in 1 00 mm 0 040 2 008 2 000 mm 0 0790 0 0787 Big end bearing clearance 0 010 0 064 mm 0 0004 0 0025 in Connecting rod side clearance 0 15
64. ld it 1 8 inch away from the en gine block Turn on the ignition switch Turn the distributor to the right until the spark is seen from the high tention wire Stop there and fasten the clamps of the distributor tightly Connect the spark plug wires Finally tighten all the terminals and connections 101 SERVICE NEWS REFERENCE Rl 2 gt lt Of og 2 CONTENTS BULLETIN 102 SECTION 10 GENERATING SYSTEM Generator Voltage regulator Ammeter Battery Fig 1 Generating System 10 1 GENERATOR PS Frame Terminal RD es commutator LINE SH Brush spring VAN yj 9 Field coil f ONG err 00 Armature 2 Ball bearing Fan pulley Throw bolt Fig 2 Sectional View of Generator 103 DATA Fig 3 Generator Type Voltage Output amp x Volt Pulley ratio Shaft runout limit Commutator diameter Wear limit Qut of round limit irregular wear limit Brush length Amendment limit Brush spring tension Armature core clearance Field coil pole core screws Torque wrench setting HITACHI G115 09 12 volt 200W 13V x 15A 1 84 1 Not to exceed 0 1 mm 0 004 in 37 mm 1 4567 2 0 m 0 0079 in 0 05 mm 0 002 in 0 3 mm 0 012 16 mm 0 630 il mm 0 433 500 700 gr 17 6 24 6 oz 0 3 mm 0 012 in 6 7kg m 44 51 Ib ft
65. lls The oil regulator is instrument to adjust the pressure of oil so as to keep it at specified pressure This adjustment can be done by either increasing or de creasing the number of pressure adjusting washers 6 1 ADIUSTMENT OF OIL REGULATOR Remove the fixing bolts of the pump body at the connecter of driving spindle The oil regulator is attached directly to the oil pump Oil pressure should be kept 3 5 4 0 kg cm Fig 3 Lubrication of Engine Fig 4 Disconnect Oil Pump from the Block Insert regulator valve into the oil pump body and measure the clearance A Fig 5 between end of valve and stop pin This clearance between the end of valve where spring contact should be 18 mm wem Stop pin Y M RE 2 4 Fig 5 Setting the Stop Pin 61 RELIEF VALVE SPRING Free Length of Length when Compressive Thickness of Adjusting Valve Spring fitted Load Washer 41 5 mm 1 mm and 2 mm 0 040 0 080 After inspecting the above points calculate thickness of the adjusting washer following the equation below and assemble it Thickness of adjusting washer A 18 mm 30 3 mm DATA OIL PUMP Type of gear Number of teeth Gear diameter Gear length Knock pin diameter Oil pump shaft Diameter Length Gear back lash Gear vertical clearance Gear in body clearance regulator Oil regulator Measurement of oil pressure regulator Pressure of regulator spring Clearance b
66. mbly 1 5 3 5 kg at 0 0025 feeler gauge 20 650 20 663 mm 0 8130 0 8135 in 1 5 mm 0 059 Not to exceed 15 gr 0 5 Not to exceed 5 gr 0 5 oz PISTON RING Compression ring No 1 Compression ring No 2 Oil control ring Oversize rings available Compression ring groove width Oil control ring groove width Compression ring width Oil control ring width Tension Compression No 1 Compression No 2 Oil control Ring Gap Compression No 1 Compression No 2 Oil control Ring groove clearance Compression 1 amp 2 Oil control PISTON PIN Diameter Standard Oversize available 0 062 mm Oversize available 0 125 mm Length Fit Inner bevel type chrome plated Taper type Slotted scraper chrome plated 0 12 0 25 0 50 0 75 1 00 1 25 1 50 mm 0 005 0 010 0 020 0 030 0 040 0 050 0 060 2 477 2 490 mm 0 0974 0 0980 in 4 72 4 74 mm 0 1858 0 1866 3 8 3 6 mm 0 1496 0 1417 3 3 3 5 mm 0 1299 0 1377 in 0 25 0 40 mm 0 0098 0 0157 0 15 0 30 mm 0 0039 0 0118 0 15 0 30 mm 0 0059 0 0118 0 04 0 05 mm 0 0016 0 0020 in 0 025 0 070 mm 0 001 0 003 20 653 20 648 mm 0 8131 0 8126 20 722 20 710 mm 0 8158 0 8153 in 20 785 20 773 mm 0 8183 0 8178 in 74 8 74 4
67. n 0 07 0 13 0 76 mm 0 003 0 005 0 030 in 23 774 23 800 mm 0 9359 0 9370 in Pilot bearing length 31 8 mm 1 252 in Number of teeth crankshaft 27 No 2 Out of round limit Crankpin diameter Out of round limit Runout of crankshaft Main journal clearance Crankshaft end play float Shims available for above Pilot bearing hole diameter 37 MAIN BEARING Type Thinwall steel backed white and clevite metal F500 Number of bearings 7 Length No 1 33 8 mm 1 3307 in White No 2 3 5 6 26 mm 1 0236 in Clevite No 4 41 mm 1 6142 in Clevite No 7 49 mm 1 9291 in Clevite Outside diameter 73 025 mm 2 8749 in Inside diameter No 1 68 283 68 299 mm 2 6883 2 6889 in No 2 No 7 69 355 69 371 mm 2 7304 2 7311 in Thickness white metal 0 1 0 2 mm 0 004 0 008 in Undersize available 0 12 0 25 0 75 1 00 1 25 1 50 mm 0 005 0 010 0 020 0 030 0 040 0 050 0 060 Tightening torque of bearing cap bolt 10 11 kg m 72 80 ft lb 98 3 1 DISASSEMBLING OF CRANKSHAFT When the crankshaft is being removed check it carefully in the following order and remedy any defect according to the requirements called for Measure the journal and crank pin with a micrometer and if they are oval shaped or tapered more than 0 002 or of the surface of journal or cr
68. n of each of a distributor assemble them and check the dis tributor assembly on a universal electric tester to check the performance of the distributor By this test we obtain accurate knowledge of the advancing angle spark condition profile of cam etc 2 Ignition Timing After installing ail the parts of ignition system set the ignition timing as follows 100 Crank the engine slowly by hand until No 1 piston comes to the top of compression stroke Set the mark on the crank pulley in line with a peinter on the timing gear case cover Loosen the screw of octane selector and set the indicator to 0 and tighten the screw Loosen the screw at the bottom of the distributor Remove the cap and adjust the contact point gap to 0 020 measured with thick ness gauge Connect one of the wires of the timing lamp tester to the primary wire of the distributor and connect other wire to earth Turn ignition switch on Adjust the distributor so as the timing lamp is lighted when the distributor body is turned to the right until the point begins to open and the lamp is off when the point is lightly pushed with a finger i Connect No 1 spark plug wire to the distributor at its terminal to which the rotor arm is facing and connect other wires in counter clockwise order and follow ing the firing order of 1 5 3 6 2 4 When a lamp tester is not available proceed as follows Pull out the high tension wire at the cap and ho
69. n switch are in good order For more perfect testing use a universal electric testing machine and check the spark gap Testing machine is illustrated in Fig 2 Distributor 1 Removal and Assembly a To remove the distributor from the engine take off cotter pin and re move the stud washer and spring Then remove screw take out the distributor together with the clamp arm To install it loosen the clamp of the distributor Rotate the cam and the distributor will be settled at a point Then tighten all condition Distributor can also be removed from the engine by simply loosing the screw of the clamp arm but generally this method is not taken except the case as engine is overhauled this method is adopted ignition timing must be adjusted thoroughly before the distributor is installed After the parts of distributor have been taken apart clean the inside with gasoline and remove any rust at the part where it is connected to the engine as the rust will result in poor grounding of the distributor Before assembling supply three or four drops of engine oil to the felt at the center of cam Check the grease cup and make sure the distributor shaft in sufficiently lubricated 2 Trouble Burning of the point When the points are burnt due to long service improper point gap or defective condenser remove the breaker arm and contact arm Redress the contacting surface of the point with a fine file and adjust their gap af
70. of the tester terminal to the lead wire of condenser and the other end to the bracket of condenser f the tester bulb lights it indicates the condenser is short circuited 98 i 3 Flow for just a moment 200 volts current either of direct or alter native through lead wire and body of the condenser After a minute or two approach the end of lead wire to about 1 16 inch distance from the body of condenser If a sprak jumps the gap the condenser is assumed to be O K On the contrary if the condenser becomes heated when the current is supplied as described above or if there is no spark when the lead wire is approached to the body the conden ser is probably defective 3 Vacuum Control The vacuum control is installed on the distributor as illustrated in Fig It is connected to hole below the throttle valve of carburetor and automatically ajusts ignition timing together with the governor of distributor Possible troubles of vacuum control are air leakage due to poor connection of pipe and inefficiency due to broken diaphragm inside such case the vacuum control does not work even when the engine is accelerated To locate these troubles check the pipe connection and if they are good the trouble may be in diaphragm Remove the vacuum control and install a new dia phragm 4 Spark Plug The spark plug used on Nissan is N G K B54E or B 6E model and screw size is fourteen millimeter It is essential for spark
71. on and to prevent it from be coming leaky 2 Preasure Test of Radiator After disassembling and cleaning of a radiator test it by water pressure of more than 5 pounds per square inch to locate any leaky spot As even a little leakage will cause overheating while running the leaks must be repaired by sold ering 3 The Cooling Water 1 Cooling water must be filled always up to the overflow pipe at the top of radiator 2 Hard water or water containing alkali substance is to be avoided for use of cooling water Such water liable to form scale or sediments and will cause poor circu lation of cooling water with the result of an overheating 3 After an inevitable use of improper water fill up the system with solution of two pounds washing soda and four gallons of warm water and make the solution circulate the system by running the engine at low speed for twenty or thirty minutes Then open the drain cocks located at the right of en gine of the cylinder block and the radiator to drain the whole solution To leave no drops of the solution within the system clean the radiator with flashing water three or four times ar Care must be taken in filling up the cooling system with soda solution or at the time of overflowing due to boiling of the solution in circulation 80 88 not to let the liquid splash over the painted parts 88 otherwise the paint color would be affected 4 When the engine has been overheated and old
72. or Hook up a volt meter to B and E terminals of regulator as already described With the engine running at 1000 rpm speed check troubles by voltmeter 109 3 4 Where the adjusted voltage of the regulator is too high reduce the voltage by turning counter clowise the adjusting screw for variable flux b When the spring for pile pressure is weak it should be replaced In case the magnetic coil of the regulator is broken or shorted replace it with a new one d If the resister for pile coil is broken or shorted replace the coil Troubles of the battery If it so happens that the actual rate of charge current is always higher than the reading of the volt meter the trouble is located in the battery Cut out relay defective If the ammeter registers a discharge while the engine is running at a charg ing speed the cause of trouble is no doubt in defective cut put relay of the voltage regulator Check as follows a If the points of the cut out relay do not open check their closing voltage The voltage will be infallibly found to very low recover normal condition push the adjusting arm up and make the spring tension to correct the closing voltage to the rated value 12 5 13 5 volts b If the spring plate of the cut out relay is found coming apart from the moving coil and is found swinging replace the cut out relay complete 10 5 TEST OF GENERATOR 1 Motoring Test Have a fully charged
73. ose and the outlet hose on the sides of radiator and disconnect them from the engine 72 3 Plug up the inlet hose opening that connects with cylinder water outlet uns a wood block of proper diameter and securing it in place with the clamp 4 Remove the radiator filler cap and pour in pure water letting it to run out freely from the outlet hose 5 The cylinder water jacket is cleaned in the same manner as for radiator Clean water is poured in from the cylinder water outlet and drained from the radiator outlet hose When the water tubes of radiator core are clog ged and cause overheating remove the radiator from the chassis to clean it 6 First remove radiator from the chassis 7 Plug up the outlet port at the bottom of radiator and fill water up to the top of radiator tubes Pus 8 Heat the soldered seam of radiator core and upper tank with a burner so that they are separated Never heat the soldered seam when the radiator ig empty If other wise the heat will melt away the soldered parts of the radiator tubes and will cause leakage P PEN 9 Scrape off completly the scales and other impurities in the water tubes with thin stick and flash the insides of water tube and lower tank with clean water 10 After finishing the above operation assemble the core and upper tank by soldering MO Care must be taken to make the connections strong enough to withstand vibrations of the vehicle in leakage by moti
74. plugs to be kept clean and accurate spark gap is 0 6 0 7 mm 0 024 0 028 a Adjusting of Gap At first clean it completely with the spark plug cleaner If the cleaner is not available use a brush or waste cloth to remove and clean the carbon Also check carefully whether or not there is any damage on the porcelain 99 After that adjust the spark gap to the said inch with thickness gage When spacing the electlodes to obtain correct gap always work on the ground side of the electlode only Never attemp to adjust the gap by bending the electlode which is in the center of the core b Diagnosing Engine Condition through by Spark Plug b 1 the inside of a spark plug is well dry and its white porcelain is in light brown colour without any carbon element this cylinder is assumed to be making a satisfactory combustion b 2 Accumulation of carbon in the spark plug indicates that the engine is supplied with too rich mixture and therefore its combustion is imperfect b 3 When the spark plug is found wet with gasoline it means the spark plug is missing b 4 When there is an accumulation of carbon like coal powders or when it is wet with oil it indicates the engine oil is pumped up into the cylinder If due consideration is paid to the above condition of the spark plug whenever it is removed fairly accurate diagnosis of the cylinder is pos sibly made 9 2 ADIUSTMENT 1 Test of Distributor Efficiency After inspectio
75. que of main bearing cap bolts 85 69 85 739 mm 3 376 in 3 3754 in The limit for over size piston i8 0 06 in 5 15 mm 13 64 in Use sleeve if over size more that 0 060 in The outer diameter of sleeve should be less than 3 5695 in Less than 0 025 mm 0 001 in Less than 0 025 mm 0 001 limit of use 0 08 in 73 73 025 mm 2 874 2 875 in Not to exceed 0 1 mm 0 004 10 11 kgm 72 80 ft Ib 15 The engine is a six cylinder valve in head type equipped with counter balanced crank shaft The displacement of this engine is 3956 cc it develops 145 horsepower at 3800 revolutions per minute SAE Maximum torque is 32 5kgm at 2000 rpm The illustration Fig 2 shows a view of the engine assembly in side cross section 5426 3745 Fig 2 Sectional View of the Engine Repair operations when it becomes necessary to overhaul an engine assembly it should be completely disassembled and all parts throughly cleaned before starting the overhaul operations In order to simplifty the following instructions we well cover the repair of the various parts in the order in which an overhaul job would be performed Checking Cylinders By far the best method to be used indetermining the condition of a cylinder in an engine preparatory to reconditioning is the use of a dial gauge such as is shown Fig 3 l6 Fig 3 Checking Cylinder Walls with Dial Gauge
76. ravity Vokage drops continuously Inside trouble When the specific gravity is low the electrolyte is liable to freeze in cold weather Therefore case must be taken not to let the specific gravity drops Keeping the battery fully charged in winter season Freezing of electrolyte causes unexpected troubles such as the damage of the cell Freezing point of electrolyte at different specific gravity are under Specific gravity 550 120 10 11 The low atmospheric temperature will decrease the battery efficiency and will also make lubricating oil heavier Both combined the battery will be imposed a heavy load during cold weather in starting an engine This will make it all the more necessary to keep the battery well charged in cold weather A battery will self discharge more or less This makes it necessary to check the charged condition when the battery has been left unused for a long while If it has been kept unused for more than month it should be fully re charged and afterward it should be charged lightly about once a month To prevent leakage of electrolyte keep the vent pluge tight Be sure the small ventilation hole in the plug is kept allowing free passage of gas from the cell When electrolyte is overflowed on the outside of a battery wipe it with alkali solution to neutralize the acid and keep it dry all the time On Nissan vehicles the positive pole is grounded When the battery is discharged to the ex
77. re arbitrarily varying them must be avoided How ever as a general rule making a jet larger will making it smaller will make the mixture leaner make the mixture richer and If an air bleed is made large the mixture will become leaner if it is made smaller the mixture will become richer 83 8 4 ADJUSTMENT OF CARBURETOR The slow speed adjusting is made by means of the throttie valve adjusting screw and the slow speed adjusting screw The throttle valve adjusting screw regulates the rotational speed for slow speed Screwing it in causes the speed to increase and unscrewing it causes the speed to decrease The slow speed adjusting screw adjusts the fuel air mixture ratio Screwing it in cause the mixture to become leaner unscrewing it causes the mixture to become richer The siow speed adjustment must be made with correct coordination between the settings of these two adjusting screws The procedure is as follows Fig 1 First set the engine speed approximately at slow speed of 350 to 400 rpm by means of the throttle valve adjusting screw 2 Next adjust the slow speed adjusting screw so that the engine rotates smoothly 3 Then adjust the rotating speed pre Needle valve cisely with the throttle valve adjusting screw If the slow speed adjusting screw in with too much force its tip will be damaged and become the causes of improper operation therefore be careful in screwing it in If even when this screw i
78. re to cause overflow 3 In case gasoline leaks the cause will either the diaphragm is cracked damaged or worn out Replace it with new one If the ventilation hole of the lower body is clogged with dirts gasoline will leak into the engine oil pan resulting in diluted engine oil 79 5 Attention for Assembling the Pump 1 Don t tamper the spring pressure of valve diaphragm and locker arm by com pressing or expanding 2 When setting the inlet and outlet valves in the upper body as well as valve seats and gaskets be sure the valves seat snugly in place 3 Always use a new cap gasket in the upper body 4 After assembling check the air tight conditon and free action of valve If the valve action is not good it is due to the poor fitting of valve valve spring and spring holder To obtain air tight valves they must seat snugly in the valve seats and the springs should not be bent 5 In assembling the upper and lower bodies line up screw holes of upper and lower body and diaphragm Push rocker arm toward the body go that the dia phragm is at the bottom of its stroke Then tighten the body screws making it sure that the diaphragm does not wrinkle along its edge This care will help diaphragm move up and down freely and insure a long life 6 Inspection When the assembling is finished the following items are to be checked before installing 1 The distance from the rocker arm to the flange of lower body is 2 Set
79. s When the level is allowed to be as low as to expose the plates it will not only do harm to the plates but also will result in decreasing efficiency If the electrolyte is found to be too much the liquid is liable to overflow from the case with the result of causing corrosion of metal parts Keep the regular height of liquid level If the replacement or replenishment is necessary due to dirt of fllow out of electro lyte fill the diluted solution of sulphuric acid having the specific gravity of about 1 260 Under no circumstances the diluted sulphric acid solution should be used except for this replacement and replenishment The increase of specific aravity resulting from replenishment of diluted sulphuric acid will shorten the life of battery you have any doubt as to the reliability of speci fic gravity check up the condition of charge with the Ex cell tester This is a method to judge the condition of charge by the drop of voltage at the time of heavy discharge In using this tester contact the arms to both terminals of each cell for accertain length of time as specified on the tester Fig 2 Ex cell Tester More than 1 75 volt at 1 200 specific Charge and specific gravity good gravity Less than 1 75 volt less than 1 200 specific gravity Fully discharged Less than 1 75 volt more than 1 200 specific gravity Too much specific gravity More than 1 75 volt less than 1 200 specific gravity Too little specific g
80. s more fre quent cleaning is advisable 8 6 GASOLINE STRAINER 4 Bowl 2 Clamp nut Strainer element Fig 13 Gasoline Strainer Ass y 87 Repair of Gasoline Strainer 1 Instructions for Disassembly and Assembly of Gasoline Strainer 1 To remove the bowl from the body loosen the strainer nut and remove the wire to a side Take off the bolt nut and washer from the wire and remove bowl gasket and screen 2 Wash those disassembled parts with clean gasoline and blow with compressed air 3 a rule the strainer bowl gasket has to be replaced The used gasket is not air tight 4 Strainer body is made of aluminum alloy Take good care not to break threads of each connection 5 Pay attention not to tighten the strainer nut so excessively that the gasket and bowl are broken 6 When installing the strainer assembly the strainer bracket should be cleaned sufficiently Dust and dirt on the bracket surface prevent plug from keeping air tight 2 Poor Feeding of Fuel Causes of this trouble are as follows 1 When the screen is clogged with dirts 2 Air leaks from the bowl gasket 3 Air leaks from strainer nut strainer connector or plug as the result of imperfect tightening 3 Disorder of Non return Valve This is caused from either corrosion or wear of valve seat which makes it hard to open or shut In this case replace a new valve and flatten the seat Sometimes the troubles in non return valve will dis
81. s closely the sur face of the cylinder walls even when they are slightly out of round will perform better sealling Side rail gap 0 2 0 8mm 0 5 RIKVENT Side rail tension 3 5 10 5 k8 NIFLEX RIKVENT NIFLEX Set Piston Ring Second Oil Remark Niflex 12033 58004 From P 31592 amp Spare parts Rikvent 12033 58005 From P 31592 amp Spare parte Niflex 12034 58002 Spare parts only Rikvent 12034 58003 Niflex 12035 58002 Rikvent 12035 58003 Niflex 12036 58002 Rikvent 12036 58003 Niflex 12037 58002 Rikvent 12037 58003 Niflex 12038 58002 Rikvent 12038 58003 Niflex 12039 58002 Rikvent 12039 58003 Niflex 12040 58002 Rikvent 12040 58003 PrPrerprresessosess Instructions for Installing Combined Type Oil Ring Following instructions and illustrations are mainly for Rikvent but as for Niflex oil rings it is just the same as for Rikvent except the position of rail gap angle 45 Installing Spacer Install spacer in bottom groove with spacer gap over piston boss For easy installation hold one end of spacer in the groove and fit it gradually around into the groove Make sure spacer ends are butted properly as shown below Top Rail Use either of the two steel rails no right or wrong side Holding ends of spacer with thumb Place one end of rail on top side of spacer ends Coil rail across ends and on around into the groove Botton Rail Install remaining steel rai
82. s of carbon from the faces of the ring grooves in the piston and inspect the grooves for burrs or nicks that might cause the rings to hang up DATA PISTON Type Flat head invar steel strut Material Aluminum alloy Lo Ex Weight 445 460 gr 15 692 16 226 oz Diameter of piston skirt Standard 85 650 85 699 mm 3 3719 3 3739 Over size 0 12 mm 85 775 85 824 mm 3 3769 3 3788 Over size 0 25 mm 85 900 85 949 mm 3 3818 3 3837 Over size 0 50 mm 86 150 86 199 mm 3 3916 3 3935 in Over size 0 75 mm 86 400 86 499 mm 3 4015 3 4034 Over size 1 00 mm 86 650 86 699 mm 3 4113 3 4132 in Over size 1 25 mm 86 900 86 949 mm 3 4212 3 4231 Over size 1 50 mm 87 150 87 199 mm 3 4310 3 4329 in Difference of major and minor diameter 0 30 0 34 mm 0 012 0 0135 in Width of ring groove Compression 2 530 2 555 mm 0 0996 0 1005 in Oil 4 765 4 790 mm 0 1876 0 1885 Depth of ring groove Compression 4 045 4 120 mm 0 1592 0 1692 4 045 4 120 mm 0 1592 0 1692 in Distance from the top of piston to center of pin hole 53 25 53 35 mm Clearance between cylinder wall and piston measured at skirt 0 031 0 049 mm 0 0012 0 0019 28 Checking of feeler gauge Diameter of piston pin hole Off set of piston pin hole Weight difference of piston only Weight difference of piston and connecting rod asse
83. s screwed float in a certain amount the mixture is still too rich check to see that the slow speed air bleed is not clogged that the fuel level is not too high and that the seating of the float needle valve is good 84 Adjusting the Fuel Level If the fuel level in the float chamber is too high the fuel consumption will be high and over flowing will be caused On the other hand if the fuel level is too low the mixture will be too lean therefore it must be maintained at the correct level In general when the engine adjustments are to be made the fuel level in the float chamber must first be adjusted correctly Otherwise correct adjustment cannot be made Without special equipment the correctness of the fuel level cannot be determined directly Ordinarily the following method will produce the correct level 1 2 3 4 5 First remove the fuel pipe from the float chamber cover Remove the three float chamber cover screws and take off the cover Turn carburetor cover upside down so that the float is on top and the float needle valve is held in its closed position by the weight of the float Lift the float with a finger then gently lower it until the flap like contact plate of the float just touches the upper end of the needle valve and hold the float in this position without pressing down on the needle valve spring With the float in this position check the distance 1 1 between the lower surface of the en
84. sh rods Length Stem diameter Rocker shaft Length Outside diameter Rocker arm bushing Type Outside diameter Inside diameter reamed in position Inside diameter before reamed Clearance between shaft and bush Rocker arm Bore Lever ratio Tightening torque of rocker B bolt 388 mm 7 15 mm 0 2815 in 641 mm 25 24 in 20 000 19 971 mm 0 7874 0 7862 in Rolled phosphorus bronze bushing 23 45 23 43 mm 0 9232 in 0 9244 in 20 020 20 033 mm 0 7882 0 7887 in 19 98 19 93 mm 0 7865 0 7846 in 0 02 0 054 mm 0 0008 0 0021 in 22 40 22 37 mm 0 8818 0 8807 in 1 47 1 4 3 5 0 kgm 4 1 REMOVAL OF CYLINDER HEAD Drain the cooling water by opening the radiator and cylinder block side drain taps Disconnect the radiator hose Remove the air cleaner carburetor rocker cover and the inlet and exhaust manifolds Detach high tension cables and remove the spark plugs Remove the rocker cover and the cork washer Detach the manifold assembly Take off the rocker assembly for getting to slacken the cylinder head bolts at same time Withdraw the push rods Keeping them in the order of removal The cylinder head can now be lifted from the cylinder block To facilitate detaching the cylinder head joint tap each side of the cylinder head 51 is Uy wo Fig 3 4 2 REMOVAL VALVES After th
85. ss them down with a fine file or emery cloth e In case the voltage coil of the cut out relay is shorted or broken replace the cut out relay f When the current coil of cut out relay is found broken or about to be broken replace the cut out relay g When the carbon plate of the automatic voltage regulator is found dam aged replace the plate h Kf there is any broken or shorted wire in the magnetic ooi for the vol tage regulator repiace the part i If the resistance coil of the voltage regulator is shorted or its wire broken replace the coil Troubles of generator a If the brushes are found making poor contact remedy or replace the brush b Weak or refective spring should be repaired or replaced When the surface of commutator is found rough turn down a lathe d If there is any short or damaged on the armature coil repair or re place it If any broken or shorted wiring is located in the generator replace or repair 4 Over Chatgins If the ammeter registers anbormal high charged condition it means that the generated voltage is too high Check causes as follows 2 Troubles of external wiring The lead wire between generator A terminal and voltage regulator A ter minal may be rubbing against the lead wire connecting generator F terminal and voltage regulator F terminal with the result of exposure of wires and short circuit Repair the exposed wires or replace Troubles of regulat
86. t 110 10 6 Wiring of generator voltage regulator and out put adjustment 111 SECTION 11 STARTER MOTOR 115 11 1 Repair 115 SECTION 12 BATTERY RI oe E nen 119 12 1 Handling of battery EX 119 GENERAL INFORMATIONS SPECIFICATIONS ENGINE PROPER Model t t n Pagine for 680 60 amp 4W73 Series Maker Nissan Motor Co Ltd Kind of Engine e s s pangling Engine Cooling e 2 57 o c o3 5 9 t9 2 Water Cylinder Arrangement ee er ne See beim 6 Cycles C P 4 Combustion Chamber 4220 02 04 420 Bath tube type Cylinder Head eomm t t t on Over head valve Bore x Stroke nm 2 85 7 114 3 Total Displacement Volume 5555 3 956 gt Compression Ratio Dc 4 4 7 6 1 Compression Pressure Ib ry 200 ipi 9 5 157 Maximum Horse Power HP rpm S A E e 145 3800 Maximum Torque m kg rpm 235 ft ibs 2000 rpm s 32 5 2000 Minimum Fuel Consumption at Ful Load g P S h rpm eec gt gt 220 1600 Engine Dimensions mm Length gt Fan to o Fly wheel e e e gt 904 Width Rear Support right to Air Cleaner left 655 Height Air Cleaner to Oil s e s 882 Engine Weight Equipped dry kg
87. tent that the electrolyte specific gravity shows lower than 1 180 remove the battery from the car and have it recharged from the other power source 121 REFERENCE SERVICE NEWS BULLETIN NO OF SERVICE JOURNAL AND CONTENTS 122
88. ter installation Adjustment of point gap Loosen the lock screw Turn the adjusting screw until point gap is 0 020 inch with the heel of contact arm riding on a lobe of cam Tighten lock screw recheck gap Wear of heel of contact arm and wear of cam When the contact arm is new its fibre heel will wear and harden quickly If it is left attended the cam will wear soon To prevent wearing coat the cam with a small amount of grease at the time of each inspection Short circuit contact arm and arm spring The breaker plate pin which holds the contact arm is furnished with an insulator Also the arm spring has a bakelite washer as a insulator at terminal connection If these insulators are loose or in poor shape the primary current will be grounded and will lead to misfiring Keep them tightly in placed and if contact arm is short circuited at the pin hole replace it with a new one GREASE GAP ADJUST SCREW Improper tension of contact arm spring When the tension of contact arm spring is too strong it induces quick wear of fibre heel and cam When the spring is too weak it cause misfiring at high engine speed Never change the bending of spring recklessly Standard spring tension is from nineteen to twenty two ounces measured at the contacting point just before it starts to open When replacing a new contact arm scrape the hole of contact arm as it can be easily in stalled and freely work on
89. that it will not exceed a limit Note The voltage regulator of vibrating point type has the current limitter independently This is because to prevent the generator from burning by the excessive high voltage caused by contact point of voltage regula tor melted and fused on account of sparks at the points However the carbon pile type has no contact point which may cause this trouble 10 4 TROUBLE AND REMEDY OF GENERATOR AND REGULATOR The charging current of generator equipped with voltage regulator is increased or decreased in direct proportion to the charged condition of battery In normal driving where the battery approaches fully charged condition the current from the generator will drop and stabilize at five to six amperes This is to prevent the battery from being overcharged and therefore should not be mistaken of the gene rator 106 2 3 c When the terminal is loosened tighten securely Troubles in the voltage regulator Set the volt meter between the B and E terminal of the regulator with the engine running at 1000 rpm check troubles by voltmeter a In case the cover of regulator is contacting with the inside electric circuit repair the cover When the wire of the regulator is broken or shorted replace or remedy c If the contact points of the cut out relay are found unstably closing and opening replace the cut out relay d When the face of contact points of cut out relay are pitted or rough dre
90. the breaker plate pin When it is not working easily the regular spring tension will not be strong Fig 4 Distributor Governor enough to work on the contact arm and will cause misfiring at high D Governor weight speed as in the case of weak spring G Governor spring f Short circuit bf distributor cap There will be a short circuit when distributor cap has cracks and it will cause misfiring Replace with a new cap g Distributor rotor If the distributor rotor has any crack or if it is excessively worn replace it with a new rotor h Governor There is an automatic advancing system of centrifugal governor type placed under the breaker plate in the distributor Sometimes it may happen the governor fails to work at the high speed due to dragging or friction In such a case the engine will lose its power on account of the faulty ignition timing Push or pull the cam on the shaft to the left as far as it goes The release the cam and if it snaps back quickly the system is in good condition Condenser troubles Almost all of condenser troubles are short of circuit The shorted condenser weakens the secondary voltage burns distri butor points and causes the engine revolution to become irregular or to stop condenser is shorted replace with a new one Test of Condenser 1 1 When sparks are weak the condenser is suspected of trouble test it by comparing with a new one i 2 Using a lighting tester touch one
91. timum mixture_ration constant As the intake air passes through the throat of the venturi the air flow velo city through the throat becomes high and the air pressure near the opening of the injection nozzle becomes lower than the atmospheric pressure that is it becomes negative Because of this suction the fuel stored in the float chamber Main air bleed Nozzle Adjusting washer Fig 3 81 Mey nos is metered by the main jet and drawn out through the injection nozzle Simulta neously the air entering thorough the main air bleed mixes well with this fuel which is then expelled as a fine spray from the tip of the injection nozzle The float valve spring is located within the float needle valve assembly and prevents the fuel level from rising excessively or overflowing because of the move ments during operation 2 Functioning of the Slow Speed Carburetting System This system operates for the slow speeds idling During slow speed opera tion the throttle valve is opened only slightly of course and the air flow rate is low Consequently the main carburetting system is inactive The mixture for the slow speed operation is created principally by the negative pressure deveioped below the throttle valve The functioning of the slow speed system is as follows The fuel in the float cham Power valve Piston ber is by passed at the main jet to the slow jet by which it is metered and mixes with the air which has enter
92. tor Dirty intake manifold Excessive resistance for suction due to partial clogging of air cleaner Insufficient fuel supply due to vapour lock in fuel pump and pipe Disorder of fuel pump Clogged main jet power jet or main air bleed Wrong assembling and adjustment of carburetor ignorance of relative sizes of venturi tube main jet main air bleed etc Too much friction and resistance of bearings and other parts Insufficient compression of cylinder Overheating of engine Poor cooling system Wrong setting of octane selector Disorder of ignition system Misfire of any spark plug Brakes dragging due to poor adjustment Carburetor Overheating of engine Engine and others Judgement Air mixture is too rich Cause Judgement Air mixture is too lean Cause 2 13 Wrong assembling of carburetor ignor ance of relative sizes of venturi tube main jet main air bleed Too much friction and resistance Poor cooling system Inefficiency of cooling effect of radiator Poor circulation of lubricating oil Wrong ignition timing Wrong setting of octane selector Over loading The porcelain part of spark plug gets stained black with the carbon The color of exhaast gas is black and has the unpleasant odour Uneven running of engine Wrong assembling and adjustment of carburetor ignorance of relative sizes of venturi tube main jet main air bleed etc The jet hole is
93. ulator Connect the voltmeter to the A terminal of the regulator and run the generator at 2000 rpm with no load Adjust the voltage while reading the meter When the voltage is too high turn clock wise the adjusting screw for variable flux Fig 9 and the voltage will drop The vice versa will raise the voltage Each quarter of a turn of the screw is equal to 1 volt The adjusting screw for pile pressure may be utilized for voltage adjust ment i 112 2 Fig 9 Adjusting Screw for Variable Flux However it is used only when the carbon pile has beer reassembled after repair work In this case turning the screw clockwise will raise the voltage and the vice versa As the ammount of current is automatically regulated to specified limits this type of the regulator is not provided with a current limitter Adjustment of cut out realy Connect the volt meter to the A terminal of the regulator and while reading the meter gradually increase the generator speed until the point of the cut out relay starts to close The voltage at that moment shown by the voltmeter should be 12 5 to 13 5 volts If it is found higher push down the adjusting arm to decrease the spring tension If on the contrary the closing voltage is lower raise arm up to increase the spring tension The points will open when the ge Fig 10 nerator is slowed down and its out put is reduced to three amperes or less 113 REF
94. y Examine turning the pulley if the vane assembly runs smoothly 7 In assembling the pump always use new gaskets for cover and body Better result would be obtained if the new gaskets are coated with shallac or white lead before they are replaced for keeping water tight effect 3 Water Pump Troubles and Remedies Ordinary troubles in the water pump are water leakage vibration wabbling and noises 1 Causes of water leakage Rubber seal in bad shape Bakelite seal in bad shape Retainer spring fatigued Friction surfaces of pump body and bakelite seal worn Body or cover gasket in poor shape Wrong or loose screws of the pump cover Wrong or loose screws of the pump body Worn vane shaft bearings or bent shaft Any one of the above will cause water leakage and damaged or worn out parts have to be replaced and loose screws have to be tightened up in order to stop the leakage The wear of the friction surface of the pump body can be reground 2 Causes of vibration wabbling and noises a Worn or burnt ball bearing b Bent vane assembly shaft c Loose pump body screws Of the above burnt ball bearing is caused from poor supply of oil Replace it with a new one and feed grease sufficiently through lubricator fit ting in the pump body Periodical supply of chassis grease to water pump is to be made for each 1 000 kilometre run 4 Adjustment of Fan Belt The tension of fan belt is to be

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