Datsun 200sx Service Manual

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I DATSUN I
1980
DATSUN
200SX rl1
i
SERVICE MANUAL
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QUICK REFERENCE INDEX
GENERAl INFORMATION GI
DATSUN M
MAINTENANCE
200SX
ENGINE MECHANICAL E
Model ENGINE LUBRICATION COOLING SYSTEMS LC
S J JO Series
ENGINE FUEL iF
EMISSION CONTROL SYSTEM E

FOREWORD
This service manual has been prepared pri E
ENGINE REMOVAL INSTALLATION
marily for the purpose of assisting service
personnel in providing effective service and
maintenance ofthe 1980 DATSUN 200SX ENGINE CONTROl FUEL EXHAUST SYSTEMS F
This manual includes procedures for main

CLUTCH C
tenance adjustments removal and installa
tion disassembly and assembly of com
ponents and trouble shooting MANUAL TRANSMISSION M
All information illustrations and specifica

tions contained in this manual are based on
AUTOMATIC TRANSMISSION A
the latest product information available at
the time of publication If your DATSUN

PROPELLER SHAFT DIFFERENTIAL CARRIER P
model differs from the specifications con
tained in this manual consult your NISSANI
DATSUN dealer for information FRONT AXlE FRONT SUSPENSION F
The is reserved to make changes in

right
specifications and methods at any time with REAR AXLE REAR SUSPENSION R
out notice
BRAKE SYSTEM B
STEERI NG SYSTEM S
BODY B
NISSAN MOTOR CO LTD
HEATER AIR CONDITIONER H
@ t 979 NISSAN MOTOR CO LTD
Printed in Japan
Not to be reproduced in whole or in part without ELECTRICAL SYSTEM E
the prior written permission of Nissan Motor Com
pany Ltd Tokyo Japan

w
v
I
HOW TO USE THIS MANUAL

This Service Manual is designed as a guide for servicing cars
This manual is divided into 19 sections The first half of the manual presents sections which concern
the engine and the second half presents sections which deal with the chassis and body
A QUICK REFERENCE INDEX is provided on the first page Refer to this index along with the
index of the particular section you wish to consult
The first page of each section lists the contents and gives the page numbers for the respective topics
SE DATA AND SPECIFICATIONS

RVICr are contained in each section
TROUBLE DIAGNOSES AND CpRRECTIONS are also included in each section This feature of the
manual lists the likely causes of trouble and recommends the appropriate corrective actions to be
taken
A list of SPECIAL SERVICE TOOLS is included in each section The special service tools are designed
to assist you in performing repair safely accurlltely quickly and For information concerning how to
obtain special service tools write to the following address

Moore
Kent Corporation Moore
Kent of Canada Ltd
29784 Little ack 2395 Cawthra
RO eville Michigan 48066 Mississauga Ontario
Canada L5A 3P2
The measurements given in this manual are primarily expressed with the Sl unit International System
of Unit and alternately expressed in the metric system and in the yard pound system
The back cover of the manual provides maintenance data for quick reference
In the text the following abbreviations are used

s os Service Data nd Specifications LH R H left Hand Right Hand
J
f Tightening TorQue MOrr AiT Manual Transmission Automatic Transmission
The captions CAUTION and WARNING warn you of steps that must be followed to prevent personal
injury and or damage to some part of the car
N
The proper
IMPORTANT SAFETY NOTICE
performance of service is essential for both the safetY of the mechanic and the efficient
I
functioning of the car
The service methods in this Service Manual are described in such a manner that the service may be per
formed safely and accurately

service tools have been permit safe and proper performance of service Be sure to
Special designed to
use them
Service varies with the used the skills of the mechanic and the tools and parts available
procedures
Accordingly anyone using service procedures tools or parts which are not specifically recommended
by NISSAN must first completely satisfy himself that neither his safety nor the car s safety will be
jeopardized by the service method selected

DATSUN 200SX Model SIlO Series
GI
SECTIONGI
GENERAL INFORMATION
CONTENTS
GENERAL VIE WS GI 2 TIE DOWN GI 5
GI 3 TOWING GI 5
MODEL VARIATION
IDENTIFICATION NUMBER 4
GI SPECIAL SERVICE TOOLS GI 6
LIFTING POINTS AND TOWING GI 5 TIGHTENING TORQUE OF

GI 6
PANTOGRAPH JACK GI 5 STANDARD BOLT
GARAGE JACK AND SAFETY STAND GI 5

Genetal Views GENERAL INFORMATION
GENERAL VIEWS
Hardtop
l
I I O II
r
JI1
c
V dI
r
I
11
I
1 J
Po L
Ll 1
34S
680
S3 0
66 1
1 41
r lU I 11
m
f 1 1
X
g
ll
hF oi 11 I ll
LI 345
1 680
53 O
66 1
J 990 39 0 t 2 400
480
94 5
4
176
t 1 090 42 9
SGIOO2
Unit mm in
Hatchback
c fT d Ii
t I r bt
J
I
I
r
I
iq L
t
J J I iL J J
L 1 345
1 680
53 0
66 1
uJJ
r
Il
1
990 39 0
IY
1 2 400 94 5
T t 090 42 9
4 480 t 4
76
5GI003
Unit mm in
GI 2

GENERAL INFORMATION Model Variation
MODEL VARIATION
Road wheel
Desti Differential
Class Model Engine Transmission Size Offset Tire size
nation carrier
mm in
SIIOFEV
PI FS5W71B
Hardtop
California
PLSIIOAEV
I 3N71B
5J 14 25 185
Hatchback
KPLSIlOFEV
I FS5W71B
0 98 70 SR 14
U S A
KPLSllOAEV
I 3N71B
Hardtop
PLSIlOFEU
I FS5W71B
I
PLSllOAJ
iU
I Z20E
3N71B
HI65B
5 1 2JJ 14 25 185
0 98 70 SR14
Hatchback
KPLSllOFEU
I FS5W71B
Non I KPLSIIOAEU
I 3N71B
California
Hard top
I PLSllOFEN
I FS5W71B
2
Canada
I PLSllOAEN
I 3N71B 4 T x 16 35
38
1
T135
70D16 2
Hatchback
I KPLSllOFEN
I FS5W7IB
I KPLSllOAEN
I 3N71B
I Aluminum wheel Option

2 Spare tire
Prefix and suffix designations
0
K P L SIlO J PST
K Hatchback
I
I LT Sun roof Glass
o Hardtop J S Sport Luxury model
P Z20 engine
P Power steering
L Left hand drive R Sun roof Steel
L Rear window wiper
C Air conditioner
U California
Non model for
U SA
V California model
N Canada model
E E F l
F Manual transmission
A Automatic transmission
0 means no indication
GI 3

IdentificationNiJmber GENERAL INFORMATION
IDENTIFICATION NUMBER
EMISSION CONTROL
INFORMATION LABEL
CAR SERIAL NUMBER
PLATE
SGI004
CAR SERIAL NUMBER
K P SlID x X X X X X
Hatchback r I Car serial number

Z20 engine
Model
ENGINE SERIAL MANUAL TRANSMISSION AUTOMATIC TRANSMISSION

NUMBER NUMBER NUMBER
The engine seria number is stamp The transmission seria number is The transmission serial number
ed on the left side of the cylinder stamped onthe front upper face of the
plate is attached on the right hand side
block transmission case of the transmission case
I
Q
SGIOO6 TM235 AT344
4
GI

GENERAL INFORMATION UftingPointsand Towing
LIFTING POINTS AND TOWING
hook Towing hook

Towing
7
UL
I
r
IW
J @
II 1I
6
Towing hook
Towing hook
Jack up point for pantograph jack

@
A for garage jack
@ Jack up point
Supportable point for safety stand

il
I SG 1007
b All applicable State or Provincial

PANTOGRAPH JACK CAUTION
in Canada laws and local laws
Always place a wood block between
regarding the towing operation
WARNING safety stand and car body when
must be obeyed
a Never get under the car while it supporting body with safety stand
c Before towing make sure that the
is supported only by the jack
transmission axles steering system
Always use safety stands to Apply the garage jack and safety and power train are in good order
support frame when you have to stand to the position indicated below
If any unit is damaged a dolley
in a safe manner
get under the car must be used
b Place wheel chocks at both front
d If the transmission is inoperative
and back of the wheel diagonally tow the car with the rear wheels off
opposite the jack position TIE DOWN the ground or with the propeller
shaft removed
fur
Apply the pantograph jack FRONT SIDE e When the car is towed with its front
nished with the car to the position the
Use front towing hooks for tie wheels on ground secure the
indicated below in a safe manner
a straight ahead
wheel in
down steering
position with the ignition key
REAR SIDE turned in OFF position
t tie down f When towing an automatic trans
Use rear towing hooks for
mission model its rear wheels
GARAGE JACK AND on
do not exceed 30 h 20 MPH

km
SAFETY STAND distance of 30 km 20 miles
and a
WARNING g Release the parking brake and set

TOWING the gearshift lever in Neutral
a When carrying out operations
with the garage jack be sure to position before starting to tow the
CAUTION
car
support the car with safety a It is necessary to use towing
proper
stands
equipment to avoid possible dam
b When jacking up the rear front to the car during a towing
age
of the car place the chocks at
front
operation
the front rear of the
Towing is in accordance with Tow
rear wheels to hold them
ing Procedure Manual at dealer side
GI 5

Specia Service Too s
Tightening 1ueofStandardBolt
TO GENERAL INFORMATION
SPECIAL SERVICE TOOLS
Special Tools play very important The identification code of mainte EMOOOOOOOO Overhaul
Engine
role in the maintenance of cars These tools is made up of 2
nance alphabeli ing Machine
are essential to the safe accurate and calletteIS and digital
8 figures GGOOOOOOOO General Gauge
speedy servicing The heading two letters roughly LMOOOOOOOO Tool
Garage
The working times listed in the classify tools or equipment as HTOOOOOOOO Hand Tool
column under FLAT RATE TIME in
FLAT RATE SCHEDULE are com
puted based on the use of Special STOOOOOOOO Special Tool

Tools KVOOOOOOOO Special Tool
TIGHTENING TORQUE OF STANDARD BOLT

Bolt or nut diam
Grade Bolt or nut size Pitch mm
Tightening torque
eter N ft Ib
mm m kg m
M6 60 10 2 9 3 9 3 04 2 2
0 2 9
25
1 7 8 10 8 0 8 Ll 5 8 8 0
M8 80
10 7 8 10 8 0 8 Ll 5 8 8 0
15 16 22 16 2 2 12 16
4T MIO 10 0
25
1 16 22 16 2 2 12 16
175 26 36 27 3 7 20 27
MI2 12 0
25
1 30 40 3 1 41 22 30
MI4 14 0 5
1 46 62 4 7 63 34 46
M6 6 0 10 5 9 6 9 06 0 7 43 1
5
1 25 I 14 18 1 4 1 8 10 13
M8 8 0
10 I 14 14
18 1 8 10 13
7T MIO 10 0
5
1 I 25 35 2 6 3 6 19 26
25
1 I 26 36 2 7 3 7 20 27
175 I 45 61 46 6 2 33 45
MI2 12 0
125
I 50 68 1
5 6 9 37 50
MI4 14 0 5
1
L 76 103 7 7 10 5 56 76
M6 6 0 10 10 8 O
I 7 8 1 5 8 80
M8 80
25
1
I 19 25 19 25 14 18
10 I 20 27 2 0 2 8 14 20
9T MIO 10 0
15 I 36 50 37 1
5 27 37
125 I 39 51 4 0 2 29
5 38
MI2 12 0
75
1 I 65 88 6 6 9 0 48 65
25
1 I 72 97 3
7 9 9 53 72
MI4 14 0 15
I 109 147 1
11 15 0 80 108
1 Special pam are excluded
2 This standard is applicable to bolu the

having
following marks embossed on the bolt head
Nominal diameter
Grade Mark
M6
4T 4
7T
9T
7
9
TT Nominal diameter of bolt threads Unit
Metric screw threads

mm
GI 6

DATSUN 200SX Model S J J 0 Series
II
MAINTENANCE
CONTENTS
2 MANUAL TRANSMISSION MA 23
MAINTENANCE SCHEDULE MA
MA 4 AUTOMATIC TRANSMISSION MA 24
LUBRICATION CHART
PROPELLER SHAFT AND
RECOMMENDED FUEL AND
DIFFERENTIAL CARRIER MA 24
LUBRICANTS MA 5
FRONT AXLE AND
FUEL MA 5
FRONT SUSPENSION MA 24
LUBRICANTS MA 5
REAR AXLE AND
VISCOSITY NUMBER
SAE MA 5
REAR SUSPENSION MA 27
APPROXIMATE REFILL
BRAKE SYSTEM MA 28
CAPACITIES MA 5
WHEEL AND TIRE fVlA 29
ENGINE MAINTENANCE MA 6
STEERING SYSTEM MA 33
BASIC MECHANICAL SYSTEM MA 6
BODY MA 35
IGNITION AND FUEL SYSTEM MA 9
MA 36
EMISSION CONTROL SYSTEM MA 14 HEATER AND AIR CONDITIONER
MINOR TROUBLE DIAGNOSES SERVICE DATA AND
MA 39
AND CORRECTIONS MA 15 SPECIFICATIONS
MA 39
CHASSIS AND BODY ENGINE MAINTENANCE
MAINTENANCE MA 23 CHASSIS AND BODY
MA 39
ENGINE CONTROl FUEL MAINTENANCE
40
MA
AND EXHAUST SYSTEMS MA 23 SPECIAL SERVICE TOOL
CLUTCH MA 23

Maintenance Schedule MAINTENANCE
MAINTENANCE SCHEDULE
The following tabels list the periodic maintenance servicing required to good emission control
ensure performance good engine performance
and good mechanical condition in DATSUN
The fint 1 600 km 000 miles service is one of the most important services
11 uired to the maximum
nsurw mission control perfonnlnce
and optimuin engine con
Iition
MAINTENANCE OPERATION MAINTENANCE INTERVAL
Periodic maintenance should be performed Kilometers x 1 000 16 t2 24 36 48 60 72

at number of kilometers miles or months Ref rence
Miles x 1 0001 1 7 51 t51 22 5 301 37 5 451
whichever comes first page
Months 6 t2 t8 24 3D 36
EMISSION CONTROL MAINTENANCE CALIFORNIA

Intake exhaust valve clearance @ @ @ @ MA 6
Drive belts A j MA 6
uine
En oil oil filter So NOTE 111 R R R R RO RO MA 7
Engine coolant RO MA 8
Idle rpm
@ MA 12
Fuel filter So NOTE 131 MA 13
Fuel lines hoses piping connections etc I MA 13
Air cleaner filter Soo NOTE 121 @ MA 14
Spark plugs @ MA 9
Ignition wiring MA 9
Air induction v8lv filter So NOTE 121 R MA t4
Vapor lines MA t4
Abbreviations A Adjust A Replace

I I nspect correct replace if necessary
NOTE III If nhicla is under conditions short distance driving extensive idling or driving in dusty conditions change
sever
engine oil every 5 000 km 3

0 00 miles or 3 months whichever comes first
121 More frequent maintenance is required und dusty driving conditions
131 If the vehicle is operated under extreme adverse weather conditions or in ar s where ambient temperaturas are either extremely
low or
extremely high the filter might become clogged In such an event replace the filtimmmiatefy
41 D @ an @ are the maintenance intervals required by California Regulations @ limits the warranty COYIIto these re
placement InterYals and R the uired mainUNInce intervals

Other maintenance items and intervals are recommended by NISSAN MOTOR CO L TO
EMISSION CONTROL MAINTENANCE CALlFORNIA

NON
Intake exhaust valve clearance A A A MA 6
Drjve bel
Engine oil
s
oil filter So NOTE 151

1 R R R
I
R R R
MA 6
MA 7
Engine coolant R MA 8
Idle rpm mixture ratio Idle rpm A A A A MA l0
Mixture ratio MA l0
Fuel filter Soo NOTE 7 MA 13
Fuel lines hoses piping connections etcJ MA 13
Air cleaner filter So NOTE 161 R MA t4
Ignition timing A A A MA l0
Spark plugS R MA 9
Ignition wiring I MA 9
Air induction valve filter except Canada Soo NOTE 61 R MA 14
Vapor lines MA 14
Abbreviations A Adjust RReplace

I Inspect correct replace if necessary
51 If vehicle isoperated under senre conditions short distance driving extensive idling or driving in dusty conditions chenge
engine oil every 5 000 km 3 000 miles or 3 months whichner comes fitst
161 Mor frequent maintenance is required undar dusty
driving conditions
171 If the vehicle is opemed under extreme adverse weather conditions or in areas where ambient
temperatures are either extremely
low or extremely high the filter might become l In such IIn event replace the filter immeduty
dow
81 Maintenance items with are recommended
by NISSAN MOTOR CO L TO
Other maintenance items Ifll required
MA 2

MAINTENANCE Maintenance Schedule
MAINTENANCE OPERATION MAINTENANCE INTERVAL
performed 36 48 60 72
Periodic maintenance should be Kilometers x 1 000 16 t2 24
Reference
at number of kilometers miles or months
451
Miles x 1 000 III 17 5 It51 122 51 130 137 51 page
whichever comes first
Months 6 t2 t8 24 30 36
UNDERHDOD MAINTENANCE
MA 23 24
automatic transmission fluid cillevel leaks
Brake clutch steering gear or
28 33
R R R MA 28
Brake fluid
connections check valve MA 28

Brake booster vacuum hoses
J7
MA
Air conditioning system hoses connections refrigerant leaks
I MA 33
Power steering fluid lines I
UNDER VEHICLE MAINTENANCE
Brake clutch fuel exhaust systems for proper attachment leaks cracks MA 23 28
etc
chafing abrasion deterioration
See NOTE MA 23 24
Manual transmission differential gear oil 19
MA 24 27
Steering gear box linkage suspension parts propeller 588 NOTE 10
34
shaft for damaged loose missing parts
Underbody flush and clean every 12 months
OUTSIDE AND INSIDE MAINTENANCE
MA 26 30
Rotate wheel nspect wheel balance wheel alignment
position 32 yJ
Disc brake pads
other brake components for See NOTE 111 MA 28
wear deterioration leaks
MA 25
Front wheel bearing
Locks hood latch See NOTE 11 L L L MA 35

hinges
anchors MA 35
Seat betts buckles retractors adjuster
clutch forstroke free play operation MA 23 28

Foot brake parking brake
Abbreviations R Replace L Lubricate
I Inspect correct replace if necessary

NOTE 91 When towing a trailer change oil in differential gear every 48 000 km 30 000 miles or 24 months
4 years
suspension ball joint inspection should be performed every 96 000 km 60 000 miles
or
10 Steering linkage front

3 months
operated in areas using road salt or other corrosive materials inspect every 5 000 km 3 000 milesl
or
111 If vehicle is
The above charts show the normal maintenance schedule

Depending upon weather and atmospheric conditions varying road surfaces
individual driving habits and vehicle usage additional or ore frequent
maintenance may be required
MA 3

ctg I
3 ZlmZ z nm
J obo 5Z 2 J
Ic mJ
km
such
advers ambient extrme driVng 000
1111t
TRANSMIO TRANSMIO
In
ELCTROY
6
condit s idling every comes

or
or
extrme wher clogltd low AND

under extr mely become
l erel
Imediatlv WINDOW FLUID FILTER STERING sevare enginewhic ev r

oil
BATERY WINDSHEL REAR WASHER FUEL @OILFTER @ENGIOL extnsive

OIL
operatd
in
or
filter
either might the @ POWER GEAR MANUL AUTOMIC under
doperat d rivng change
months
condit lIre filter
3
replICe
i
or
vehicle dvehicle luance condit s mi000les

the
wheat r temprau
i
the high ev nt
If IV an
If short dusty 3
@@
diferntal
in
24
or
Month @ @ 011 miles

000 000 000 lt
fll
mila
0 130
115 change 30
km
000 cornel
411 24
trailer km000
towing every whicevr
lI
EV RY EV RY 48
1 @
When gear
onth
6 km lt
fil
or
salt 000
UP 6
cornel
LUBRICATE GREAS n
@ OIL@
road
ing
u
every
inspect whicevr
COLANT BEARINGn
OIL ereai
QIQ FLUIO FLUIO 81
moperat d ateril month

in
GEAR GEAR
HINGES LATCH
WHE L CLUTCH BRAKE
3
or
CHANGE CHECK STERING cvehicle or sive 000mile

ANTIFREZ DIFERNTAL
is
ENGI E LOCKS HO D
liSl
fl
FRONT @ If other 3
3 0j

Recommended Fuel and Lubricsnts
MAINTENANCE Approximate Refill Capacities
RECOMMENDED FUEL AND LUBRICANTS
FUEL
Use an unleaded gasoline only of at least 91 research octane number Anti knock index 87
leaded fuel be used ince this will damage the catalytic converter
Under no circumstances should a
LUBRICANTS SAE VISCOSITY

NUMBER
Lubricant Specifications Remarks
ENCEOIL I I I I
I I
APISE ICM 211 JGIIf4l 0
Gasoline engine oil t r
I l 1 lo
Further details refer
Transmission
Gear oil
and steering
API GL4 to recommended SAE
viscosity chart II or
Differential API GL 5 rJ
v
I I
I I
I
dri
I
Automatic T M and power l
DEXRON
Type I r I I I 1
steering fluid
I 1 I I
I
Multi purpose grease NLGI No 2 lithium soap base I I I
r 1
I I
US FMVSS No 116
40
Brake and clutch fluid DOT 3 I
I I
1 1 TI
II c
nII OlIl l 4Oll C11ll l l 101
11 F
Anti freeze Ethylene glycol base T Jl

Nut O Ch
APPROXIMATE REFILL CAPACITIES
liter us measure Imp measure
Fuel tank Hardtop 53 14gal II 5 8 gal
Hatchback 60 15 7 8 gal 13 1 4 gal
Coolant With heater 9 5 IOqt 8 3 8 qt
Without heater 8 8 9 1 4qt 7 3 4 ql
Engine With oil filter 4 1 4 3 8 qt 3 5 8qt
Without oil filter 3 9 4 1 8 qt 3 3 8 ql
Transmission M T 2 0 4 1 4 3 1 2 pt
pt
A T 5 5 7 8 qt 4 7 8 qt
Differential carrier 1 2 3 8 pi 2 pt
Power 12 11 4ql I 1 8 ql
steering system
28
0 5 8 pt 1 2 pt
Steering gear
Windshield washer tank 2 0 21 8 ql 13 4qt
Rear window washer tank 10 1 1 8 qt 7 8 qt
Air conditioning system Compressor oil 27

0 1 fOZ 9 0 oz
9 5 fOZ 9 0
9 oz
Refrigerant 09 1 kg 20 4lb
2 2 0 2 41b
MA 5

Engine Maintenance MAINTENANC E
ENGINE MAINTENANCE
BASIC MECHANiCAL Valve clearance Hod
SYSTEM Intake CD @ 0 30 mm
0 012 in
ADJUSTING INTAKE AND
Exhaust 0 30
@ j mm
EXHAUST VALVE 10 012 i n
0
aEARANCE
No 1 lobe
Using feeler earn
I gauge measure clear
Adjustment should be made while
between valve stem end
ance and
engine is hot rocker arm screw
I Start engine and Feeler gauge should

warm up engine move with a
until water temperature indicator very slight drag SMA001
points to the middle of gauge then
stop engine
Valve clearance adjustment cannot

be made while is in operation
engine Adjust ID ID @ and @ valves
2 Remove valve rocker cover using same procedure as for Step 3
3 Set that of No I
so
high point
cam lobe points down
@ @
8M AQSO Front
D
kG tDf
No 1 earn lobe
2 If the clearance is not within spec ID
OO
ified value loosen rocker arm nut and
turn rocker ann screw to SMA052
provide pro
per clearance
SMA005 3 Hold rocker arm screw and

tighten rocker arm nut
Valve clearance Hod

Intake 0 30 mm
@@
0 012 in
Exhaust ID ID 0 30 mm
When turning crankshaft with 0 012 in

starter remove high tension cable 5 Install valve rocker cover
from ignition coil then turn it
Adjust clearance of half of the

CHECKING AND
valves Adjust only CD @ @ and
ADJUSTING DRIVE BELTS
valves
j
I Visually inspect for cracks or
SMA051
damage
Th belts should not touch the
bottom of the pulley groove

CD 4 dl Rocker arm nut
16 22 N m
2 Check bell tension by pushing
Front
1 6 The belts should deflect by the spe
2 2 kg m
o 1lJf Dt
DFJ 4
12 16 ft b
Recheck clearance
cified amount
Drive belt deflection
000 4
8 12 mm
Turn crankshaft and set so that 0 31 0 47 in
SMA049
high point of No I cam lobe points Applied prening forc
above 98 N 10 kg 22lb
MAS

MAINTENANCE Engine Maintenance
t
J
ilJ
LoCk nut
Idler puUey
Adjust
Loosen
A
Loosen to adjust
I t
Jr
f
Compressor pulley
Alternator
Crank
pulley Idler
pulley
Checking point of drive
belt deflection Adjusting bolt
Adjust
8MA053
3 Adjust belt tension as follows CHANGING ENGINE OIL A milky oil indicates the presence
AND OIL FILTER of cooling water Isolate the cause
1 Start and take corrective measure
engine and warm up engine
until water An oil with extremely low viscosity
temperature indicator
to the middle of gauge then indicates dilution with gasoline
points
stop engine
Fan and alternator belt
2 Remove oil pan drain plug and oil
I Loosen the upper and lower alter fiUer cap and allow oil to drain
3 Clean and install oil pan drain
nator securing bolts until the alterna
plug with washer
tor can be moved slightly WARNING
2 Move the alternator with a prying Be careful not to burn yourself as
the engine oil may be hot

IiJ Oil pan drain plug
bar until the belt tension is within the
20 29 N m
specified range Then tighten the bolts

2 0 3 0 kg m
securely 14 22 ft lb
4 Using Tool remove oil fIlter
1
Air conditioner compressor
and power steering I 1 1 01
011 pump belts
Loosen the idler pulley lock nut
2 Adjust the adjusting bolt until the

belt tension is within the specified
amount
3 Tighten the idler lock nut

puUey
E0036 SLC028
securely
MA 7

Engine Maintenance MAINTENANCE
5 Wipe oil fIlter mounting surface When checking on level park the
with clean rag
a ear on a level surface
6 Smear a little engine oil

gasket of new fIlter
on rubber
W
F
v O
SMA163
3 Drain coolant completely Then
SMA010 flush cooling system
4 Close drain cock and plug
5 Fill radiator with coolant up to
fIller opening observing instructions
7 Install new oil fIlter Hand attached to anti freeze container for
tighten ONLY DO NOT use a wrench mixing ratio of anti freeze to water
to tighten the filter
Cooling water capacity

8 Refill
engine with new recom
9 5 lite 10 US qt
mended engine oil referring to RE
3 8 Imp
8 qtl
COMMENDED LUBRICANTS
CHANGING ENGINE
Check oil level with dipstick 6
COOLANT Run engine for a few minutes If
Oil Capacity necessary add coolant
With oil filter 7 Fill reservoir tank with coolant up
WARNING
41 lite4 3 8 US qt To BVoid the danger of to MAX level
being
5 8Imp qt
3 scalded never attempt to change
Without oil filter the coolant when the is hot
engine I
3 9 lite4 8 US qt
1
3 8 Imp qt When changing engine coolant on
heater equipped model set heater

TEMP control lever at HOT
fully
position
I Open drain cock at bottom of

radiator and remove radiator cap
t CS021
r l ild
E0038 rl 1
t III il 1
rli
I
I
ll
1xrC
Iv
4
8 Install radiator cap
Check drain valve and plug for any
sign ofleakage
9 Start engine Check area around

drain plug and oil fIlter for any sign of LOOSEN
oil leakage CS015
Ifany leakage is evident these parts

have not been properly installed CHECKING DiGINE
10 Run engine until it reaches oper COMPRESSION PRESSURE
ating temperature Then turn it off I Warm up engine until water tem
and wait several minutes Check oil 2 Remove cylinder block drain plug perature indicator points to the middle
level If necessary add engine oil located at left rear of cylinder block of gauge
8
MA

2 Remove au spark plugs on one IGNITION AND SPARK PLUG
side for California models FUEL SYSTEM Resistor

3 Disconnect all harness connectors
Standard built iJl
at injector REPLACING SPARK PLUGS
4 type
Properly attach a compression I Disconnect spark plug wire at
tester to spark plug hole in cylinder boot Do not pull o the wires Standard
being tested BP6ES BPR6ES
type
OK N G
Hot type BPSES BPRSES
Cold type BP7 ES BPR7ES
Install and
4 new spark plugs re
connect high tension cables
All cable are marked to identify

their original locations
SMAO 1 7
8MA042
iYJ Spark plug

15 20 N m
1 5 2 0 kg m
11 14 ft Ibl
S Depress accelerator pedal to open with spark

2 Remove spark plugs
throttle valve fully
plug wrench
6 Crank engine and read gauge indi
cation
Run engine at about 350 rpm CHECKING IGNITION

Engine compression measurement WIRING
should be made as quickly as possi
I Visually check wiring for cracks
ble
damaged and burned terminals
Compression pressure 2 Using an ohmmeter measure the
kPa kg em ps at rpm
resistance between cable tenninal on
Standard
the spark plug side and corresponding
1 177 12 0 171 350
electrode inside cap
Minimum
883 9 0 1281 350
7 Cylinder compression in cylinders

should not be less than 80 of the
highest reading
If cylinder compression in one or
is low pour a small 3 Using feeler check new

more cylinders gauge
into
quantity of engine oil cylinders spark plug gap
through the spark plug holes and retest If it is not within specified range Resistance
side ele trode
compression set gap by bending Less than 30 000 ohms
If adding oil helps the compres SMA 166
sion pressure chances are that Side electrode
piston rings are worn or damaged 08 0 9 mm

Gap
if
If pressure stays low valve may be 0 035 1
10 03t
Shake the wire while measuring re
sticking or seating improperly for intermittent

sistanee to check
If cylinder compression in any two brake
adjacent cylinders i low and if
3 If the resistance is more than the
adding oil doe not help the com
limit cable from cap and
pression there is leakage past the remove
gasketed surface check the cable resistance only
Oil and water in combustion cham If resistance is still more than the
bers can result from this problem SMA019 limit replace cable assembly
MA 9

Engine Maintenance MAINTENANCE
ilrness cOiriecti ri
ADJUSTlNGIDLERPM Efl
WARNING
Vacuum hoses
ADJUSTING IGNITION a WIlen selector lever is shifted to
Air intako system Oil filler cap oil
TIMING AND position apply
level gauge etc
0 parking
CHECKING MIXTURE RATIO brake and block both front and
2 Connect engine tacho ter and
Non California models reanvheels with chocks
timing light in dieir proper pOsitions
Preparation
b When racing engine on auto
3 On air conditioner equipped
matic transmission equipped
mode s checks should be carried out
1 Mako sure thauhofollowing parts sure that shift
whilo tho oi conditioner is OFF modelsimake
in order lever is in Nor P position
are good 4 On automatic transmiuion equip
Battery checks should be carried
and depress brake pedal to pre
peel modols
vent forward 8of car
SUI
Ignition system ift lever is in O position
out while s
c After tha adjustment has been
made shift thelever to the N
or P position and remove
wheel chocks
Maintenance procaclure
START
Start engine and wann up engine until water

temperature indicator points to the middle
of gauge
I E
Open engine hood
Run engine at about 2 000 rpm for abou
2 undet noload
1 Run engine at idle speed
For Canada For U S A
Di nnect hose from air induction pipe
I and amtall proper cap on air induction pipe

t
Race engine two or three times under no

load
Then run engine for one minute at idle
speed
Check idle speed
M nuai lransmiRion
t
7oo 100 tpm
wic
Autom Transmission
700 100 rpm in D position
N G
OK j
Adjust idle SPeed by turning idle opeed
I adjusting screw
j
b this maintenance operation at 1 600 km
I
I
YES
1 000 miles service or rechecking idle
I CO
@
INO g@
b
MA l0
i @@
of
Check ignition ti ing with ning

ir t
8 f 20 B T D C
O K
N G f
Adjust ignition timin g by turn g ditri
1
r
ut
I after loosening bolts which secure distributor
SMA059
I Race erigine two or

three times under 00
load then run engine at idle speed

I
r
Check CO with CO meter
Note
e
When
Use
When
CO
warmed up
measuring
into tail pipe more
CO
than
iniert probe
4 m 16 in
0
meter alter engine is fully
adjusting idle CO at high

I
J
OK
1 t
3 1
I Turn off engine and connect air induction

If
Adjust CO
air flow meter
SMA061
by turning air by pass screw
rhose to air induction pipe on
altitude adjust to obtain following

When adjusting CO remove blind plug
valua i from air by pass screw
Start engine After adjustment install the plug on air
Unit m ft
flow meter
Altitude fdte 00
r
600 t 200
2 7
2 000 4 000 load then run engine at idle speed
1 200 1 800
3 8
4 000 6 000
Above 1 800
I Check idle speed
5 0 M nu 1 Transmission
6 000
t
700 100 rpm
J
r
L
Automatic Tr nsmission
7 1 100 rpm in 0 position

SMA263
OK
I N G Adjust idle speed by turning idle speed ad

L
I justing screw l
END
MA ll

intIine M itit ance MAINTENANCE
ADJUSTING IDLE RPM WARNING

California models a When selector lever is shifted to
0 position apply parking
Preparation brake and block both front and
1 On air conditioner equiPPed mod fear wheels with chocks
els checks should be carried b Whe
out racing engine on auto
while the air conditioner is OFF matic transmission equipped
2 On automatic transmission models make sure that shift
equip
ped models checks should be carried lever is in N or P position
out while shift lever is in Ou position and brake
depress pedal to pre
vent forward surge of car

c After the adjlUtrDent has been
made shift the lever to the N
or P position and remove
wheel chockS
Intenailce procedure
START
1
Start engine and warm up engine until water
temperature indicatQf points to the middle
of gauge
j
8 SMA020
Open engine hood

Run engine about 2 000 rpm for about
2 minutes undeJ load
no
SMA022
1
Run eDsine at Idle speed
Check idle speed

1
Maal Bnsmiaion
Tl
700 100 rpm
Automatic Transmission
700 f 1 rpm Un D position
f
SMA263
O K
tG
dj st idle speed by turning idle speed ad
I IJg
JustJ screw
I
END
1
MA 12

CHECKING FUEL LINES

Hoses piping Fuel return pipe
connections etc
I Check fuel line for leaks particu
l
larly around connection of fuel pipe To fuel tan rbm f el tank
and fuel hose

2 Retighten loose connections and
Fuel damper
replace any damaged or defonned pipe
parts
rFue
t
Fuel pump
Fuel pipe l
tr btor J J
Jf 1j
Injector W W W
SMA034 SMA062
CAUTION
a 00 not reuse fuel hose clamp after
loosening
b Tighten high pressure rubber hose
3mmlo 12inl
clamp so that clamp end is 3 mm
0 12 in from hose end
wider than other
or screw 1
position portions
of clamp is flush With hose end fl f
Tightening torque specifications J Fuel hose clamps
are the Same for all rubber hose 1 0 1 5N m
10 10 0 15
clamps m
kg
1 1 ft Ibl E F976 E F336A
07 I
When tightening ose clamp 8n ure
that screw does not come into con
tact with adjacent parts
the
2 Disconnect fuel pump relay 2 har 3 After engine stall crank
REPLACING FUEL
connector with engine runnin engine twice or three times
FILTER ness
4 Turn ignition switch off and con
The fuel fIlter is designed especially Relay bracket nect fuel pump 2 hamess connec
relay
for use with the EFI systerri It should tor
be replaced as an assembly 2 Unfasten clamps securing fuel
I Follow the procedure below to re hoses to the outlet and inlet sides of
duce fuel pressure to zero fuel fIlter and disconnect fuel hoses
Be careful not to spill fuel over

CAUTION
engine lrtment
comP Place a rag to ab
Before disconnecting fuel hose release
so b fuel
fuel pressure from fuel line to elimi
nate danger SEF131
I Start the engine
MA 13

Engine Maintenanpe MAINTENANCE
3 Remove fuel mter Remove air

3 cleaner cover and Remove air induction valve case
remove air cleaner ftIter from air cleaner and take out air in
duction valve fIlter Then instaIl new
air induction valve filter
I
When replacing pay strict attention
V to
so
which direction the valve i facing
that exhaust gas will not flow back
ward
tJl
SMA264
SMA065
4 To instaIl fuel mter reverse the

order of removal 4 InstaIl air cleaner mter with UP
mark facing upward J 1
REPLACING AIR CLEANER

FILTER
The viscous paper type air cleaner
filter does not require any deaning

operation between renewal
Disengage air duct
SMA039
CHECKING VAPOR LINES
Check all hoses and fuel tank filler

cap for leaks
I I Dsiconnect the vent line
vapor
connecting carbon canister to fuel
tank
1 EMISSION CONTROL
2 Connect a 3 way connector a
SMA063 S YSTEM
manometer and a cock or an equiva
REPLACING AIR INDUCTION lent 3 way carge cock to the end of
VALVE FILTER the vent line

3
2 Disengage EAt Exhaust Air Supply pressure into the vapor
Induction hose from vent line tIuough the cock little by
System air in
duction pipe little until pressure becomes to the
below
Leakage test pressure

3 923 kPa 400 mmll20
15 75 in H20
4 Shut the cock and

completely
leave it unattended
r SMA036 5 After 5 minutes

2 measure the
height of the liquid in manometer
1 Air induction valve case
J 2 Air induction valve Pressure variation
3 Air induction valve rdter Less then 0245 kPe
4 25
Air cleaner mmH20 0 98 inH201
MA 14

Minor Trouble Diagnoses and Corrections
MAINTENANCE
IY When filler cap does not close
completely the height should drop to

3 923 kPII
zero in short time
a 400 mmH20 15 75 inH20
2 If the height does not drop to
zero in a short time when iller cap is

removed it is the cause of a staCfy
hose AII Check valve
Manometer
In case the vent line is stuffy the

Fuel filler cap
breathing in fuel tank is not thorough
ly made thus causing insufficient
@
delivery
lock
replaced
of fuel to engine or vapor
It must therefore be repaired or

Carbon canister
1 EC091A
MINOR TROUBLE DIAGNOSES AND CORRECTIONS
Condition Probable cause Corrective action
CANNOT CRANK Improper grade oil Replace with proper grade oil
ENGINE OR SLOW
Partially discharged battery Charge battery
CRANKING
Malfunctioning battery Replace
Loose fan belt Adjust
Trouble in charging system Inspect
Wiring connection trouble in starting circuit Correct
Malfunctioning ignition switch Repair or replace

Malfunctioning starting motor Repair or replace
starting circuit
Trouble shooting procedure on
Switch on the starting motor with head lights ON
When head dim

lights go off considerably
or
a Check battery
b Check connection and cable
c Check starting motor
Whenhead lights stay bright
a Check wiring connection between battery and starting

motor
b Check ignition switch

c Check starting motor
MA 15

Minor TrrJUbleDiagnoses end MAINTENANCE
Correctiops
ENGINE WILL CRANK NORMALLY BUT WILL NOT START
In this case the following trouble causes may exist but in many cases ignition system or fuel system i1 in trouble
Ignition system in trouble
Fuel system in troubk

Valve mecluznism does not work properly
Low compression
shooting
Trouble procedure
Check spark plug fIrstly by following procedure
Disconnect high tension cable from one spark plug and hold it
about 10 mm 39
0 in from the engine metal part and crank the
engine
Good spark occurs
a Check spark plug

b Check ignition timing
c Check fuel system
d Check revolution trigger signal
e Check cylinder compression
No spark occurs Very high current Check the current flow in primary circuit
Inspect primary circuit for short

Check distributor pick up coil operation
Check IC ignition system
ENGINE CRANKS Low or cunenL

no Check for loose terminal or disconnection in
NORMALLY BUT circuit
primary
WI L OT ART
5 Check for burned points
Ignition system in Malfunctioning distributor pick up coil Replace

trouble
Improper air gap Adjust
Leak at rotor cap and rotor Clean or replace
Malfunctiflning spark plug Clean adjust plug gap or replace
Improper ignition timing Adjust
Malfunctioning ignition coil Replace
Disconnection of high tension cable Replace
Loose connection disconnection
or 41 Repair or replace
primary circuit
Irregnlar revolution trigger pulse Replace IC ignition unit
Malfunctioning IC ignition unit Replace

Fuel system Lack of fuel Supply
malfunction
Damaged electronic fuel injection harness or Replace
relay
Malfunctioning fuel pump Usten to opera Replace

ting sound
For inspection procedures for
Damaged control unit Replace electronic fuel injection sys
Seized injector Usten to operating sound tern components refer to

Replace
Engine Fuel section
Malfunctioning air flow meter Replace
Damaged water temp sensor
Repl ce
MA 16

MAINTENANCE Minor Trouble Diagnoses and Corrections
Fuel system Malfunctioning pressure regulator Replace

malfunction
Dirty fuel f1lter Replace
Dirty or clogged fuel pipe Clean
fuel tank breather pipe Repair and clean

Clogged
Low normal torque replace gasket
co prellion Incorrect spark plug tightening or damaged Tightefl to or
gasket
Improper grade engine oil or low viscosity Replace with proper grade oil
Incorrect valve clearance Adjust
Compression leak from valve seat Lap valves
Sticky valve stem Correct or replace valve and valve guide

Weak or damaged valve springs Replace valve springs
Compression leak at cylinder head gasket Replace gasket
Sticking or defective piston ring Replace piston rings

Worn piston ring or cylinder Overhaul engine
Trouble shooting procedure
Pour the engine oil from plug hole and then measure
cylinder compression
Compression increases Trouble in cylinder or piston ring
Compression does not change Compression leaks from valve cylinder head
or head gasket
UNSTABLE
ENGINE IDLING
Ignition system Malfunctioning ignition system spark plug Replace

in trouble high tension cable distributor IC ignition
unit ignition coil etc
Incorrect basic ignition timing Adjust
Engine mechanical Loose manifold and cylinder head bolts Retighten bolts
system in trouble Incorrect valve clearance Adjust
Fuel system air cleaner f1lter Replace f1lte

Clogged
malfunction
Incorrect idle adjustme nt Adjust
Damaged manifold gaskets Replace gasket
Intake air leakage at following points Repair or replace

Dipstick
Oil filler cap
Blow by hoses
Intake air duct air flow meter to throttle
chamber etc
MA 17

Minor Trouble DiagnolJts and Correctiom MAINTE ANCE
Fuel system Damaged electronic fuel injection harness Replace

malfunction For
Seized injector Usten to operating sound inspection
Replace
procedures for
Malfunctioning air regulator During warm Replace electronic fuel
up driving only
injection sys
Damaged control unit Replace tern compo
Damaged water and air nents refer to
temp sensor Replace
Engine Fuel
Malfunctioning throttle valve switch Repair or replace Section
Irregular fuel pressure Replace pressure regulator
Low compression Previously mentioned
Others P C V valve
Malfunctioning Check or replace
Malfunctioning E G R control system COrrect or replace
HIGH ENGINE
IDLE SPEED
Fuel system Incorrect adjustment of idle speed adjusting Correct

malfunction screw
Malfunctioning air regulator Replace

For inspection procedures for air regulator
refer to Engine Fuel section
Others Throttle valve is opened at idle

excessively Replace throttle chamber
Malfunctioning IC D
F Replace
Dragged accelerator linkage Check and correct accelerator linkage
Malfunctioning Vacuum Control Valve Check or replace if necessary

VC V
ENGINE POWER
BELOW NORMAL
Low compression Previously mentioned
Ignition system in Incorrect ignition timing Adjust

trouble
Malfunctioning spark plugs Clean adjust or replace plugs
Malfunctioning distributor pick up coil Replace

Fuel system Throttle valve does not open fully Adjust
For inspection proce
malfunction
Damaged electronic fuel injection harness Replace dures for electronic
Seized injector Usten to operating sound Replace fuel injection system
Malfunctioning air flow meter components refer to

Replace
Engine Fuel Section
Malfunctioning throttle valve switch Repair or replace
Irregular fuel pressure Replace pressure regulator if necessary
Clogged fuel pipe Replace if necessary
Dirty or clogged fuel ftIter Replace

Fuel pwnp will not work properly Replace
MA 18

MAINTENANCE Minor Trouble Diagnosessnd Corrections
Air intake system Clogged air cleaner filter Replace filter

malfunction Air leaking from manifold gasket Replace gasket
Intake air leakage at following points Repair or replace

Dipstick
Oil ftller cap
Blow by hoses
chamber
etc
Overheating Insufficient coolant Replenish

Loose fari belt Adjust fan belt
Worn or damaged fan belt Replace
Malfunctioning thermostat Replace
Malfunctioning water pump Replace
Clogged or leaky radiator Flush repair or replace

Malfunctioning radiator ftller cap Replace
Air in cooling system Retighten each part of cooling system
Improper engine oil grade Replace with proper grade oil
Incorrect ignition timing Adjust
Malfunctioning thermostat Replace
Replace with specified octane fuel

Improper octane fuel
Othe
tire pressure Inflate to specified pressure

Improper
Dragging brake Adjust
Clutch slipping Adjust
Malfunctioning E G R control system Correct or replace
NOISY ENGINE
Use right gear in driving

Car knocking Overloaded engine
Disassemble cylinder head and clean car

Carbon knocking
bon
Timing knocking Adjust ignition timing
Fuel knocking Use specified octane fuel
Preignition misusing of spark plug Use specified spark plug
Mechanical knocking
Crankshaft bearing This strong dull noise increases when engine This is caused by worn or damaged bearings
is accelerated To locate the cause a or unevenly worD crankshaft Renew bear
knocking place
misfire on each cylinder If the noise stops ings and adjust or change crankshaft
by the misfire this cylinder generates the Check lubrication system
noise
MA 19

Minor Trouble Diagnoseund Corrections MAINTENANCE
Connecting rod This is a little higher pitched noise than the Same as the case of crankshaft bearings
bearing knocking crankshaft knocking and also increases
when engine is accelerated Cause a misfue
on each cylinder and if the noise diminishes
almost completely this crankshaft bearing
generates the noise
Piston and cylinder When you hear an overlapping metallic noise This may cause an abnonnal wearing of
noise which increases its magnitude with the cylinder and lower compression which in
revolution of engine and which decreases turn will cause a lower out put power and
engine is wanned up this noise is caused by excessive consumption ofoil

piston lUId cylinger To locate the place
cause a misfue on each cylinder Overhaul engine
Piston pin noise This noise is heard at each highest and This may cause a wear on piston pin or
lowest dead end of piston To locate the piston pin hole
place cause a misfire on each cylinder Renew piston and piston pin assembly
Water pump noise This noise may be caused by worn or Replace water pump with a new one
damaged bearings or
by the uneven surface
of sliding parts
Others An improper adjustment of valve clearance Adjust

Noiseoftinringchmn Adjust the tension of chmn
An excessive end crankshaft

play on Disassemble engine and renew main bearing
Others Wear clutch

on pilot bushing Renew bushing and adjust drive shaft
This noise will be heard when clutch is

disengaged
ABNORMAL
COMBUSTION
backfire after fire
on
run etc
Ignition system Improper ignition tinring Adjust ignition timing

in trouble
Improper heat range of spark plugs Use specified spark plugs
Fuel system Intake air leakage at following points Repair or replace

malfunction Dipstick
Oil f1l1er cap
Blow
by hoses
chamber
etc
Damaged electronic fuel injection harness Replace For inspection procedures for
Damaged control unit Replace electronic fuel injection sys
tern refer
Malfunctioning air flow meter Replace components to
Engine Fuel Section

Damaged water temp sensor Replace J
MA 20
MAINTENANC E Minor Trouble Diagnoses and Corrections
Defective cylinder head Improperly adjusted valve clearance Adjust

etc
Excess carbon in combustion chamber Remove head and get rid of carbon
alve spring after fire it with a new one
Damaged v
backfire Replace
Others Malfunctioning E G R control system Correct or replace
EXCESSIVE OIL
CONSUMPTION
Oil leakage Loose oil drain plug Tighten it
Loose oil pan gasket Renew gasket tighten it

or damaged or
Loose or damaged chain cover gasket Renew gaskei or tighten it
Damaged oil seal in front and rear of Renew oil seal
crankshaft
Lo rocker gasket Renew gasket it but not too

e or damaged cover or tighten
much
Improper tightening of oil fIlter Renew gasket and tighten it with the proper
torque
Loose or damaged oil pressure switch Renew oil pressure switch or tighten it
I I
Cylinder and piston wear Overhaul cylinder and renew piston

Improper location of piston ring or reversely Remount piston rings
assembled piston ring
Damaged piston rings Renew rings

Repair r renew piston and cylinder
Worn piston ring groove and ring Renew piston and piston ring
Fatigue ofvalve oil seal lip Replace seal lip with a new one
Worn valve stem Renew valve or guide
Others Inadequate quality of engine oil Use the designated oil
Engine overheat Previously mentioned
POOR FUEL
ECONOMY
Engine power Previously mentioned

below normal
Fuel system Exceeding idling revolution it to the designated

Adjust rpm
malfunction
Fuel leakage from fuel line Repair replace or tighten the connection of
fuel pipes
Damaged electronic fuel injection harness Replace

control unit For inspection procedures for
Damaged Replace
electronic fuel injection sys
Malfunctioning air flow meter Replace
tern components refer to
air temperature sensor Replace
Damaged Engine Fuel Section
Malfunctioning throttle valve switch Replace
Irregular fuel pressure Replace pressure regulator if necessary
MA 21

Minor Trouble Diagnoses and Correctiom MAINTENANCE
TROUBLE IN OTHER
FUNCTIONS
Decreased oil pressure oil Use the designated oil

Inadequate quality
Overheat Previously mentioned
Malfunctioning oil pump regulator valve Disassemble oil pump and repair or renew it
Functional deterioration ofoil pump Repair or replace it with a new ne
Blocked oil f1lter Renew it
Increased clearance in various sliding parts Disassemble and replace the worn parts with
new ones
Blocked oil strainer Clean it
Malfunctioning o gauge pressure switch Replace it with a new one
Excessive wear on the Oil pressure decreases Previously mentioned

sliding parts contamination of oil
Damaged quality or
Exchange the oil with proper one and
change element
Air leakage from air intake duct Repair or replace
Damaged air cleaner element
Change
Overheat or overcoat Previously mentioned
Improper fuel mixture Check the fuel system
Scuffing of sliding Decrease ofoil pressure Previously mentioned

parts
Insufficient clearances Readjust to lIie designated clearances
Overheat Previously mentioned
Improper fuel mixture Check the fuel system
MA 22

MAINTENANCE Chassis and Body Mainwnance
CHASSIS AND BODY MAINTENANCE
ENGINE CONTROL CHECKING CLUTCH I Adjust pedal height with pedal

SYSTEM stopper Then tighten lock nut
FUEL AND EXHAUST
Check clutch system for proper at
2 Adjust pedal free play with master
SYSTEMS cylinder push rod Then tighten lock
tachment leaks chafing abrasion de
nut
terioration etc
CHECKING FUEL AND
8 Pedal free play means the following
EXHAUST SYSTEM
total measured at position of pedal
Check fuel and exhaust systems for
pad
condition connections and leaks
Play due to clevis pin and clevis
pin hole in pedal lever

Fuel system
Play due to piston and piston
@j
rod
b Depress nd release clutch pedal
over its entire stroke to ensure that
@
J SMA101
the clutch
ly without
ference and binding

linkage operates
squeak noise
smooth
inter
MANUAL
SMA034 TRANSMISSION
CHECKING CLUTCH PEDAL
CHECKING MANUAL
Exhaust system HEIGHT AND FREE PLAY
TRANSMISSION OIL LEVEL
Check clutch pedal height and free
Neyer start engine while checking
play Adjust if necessary
oilleyel
Master cylinde push rod

Pedal stopper
ff
@ 4f
itner plug
SMA 147
r1
iLl
lotf
Lock nut
fl7 8
w
51
11 8
8
8 71
S
2 5
18
35
25 ft
kg
Ibl
m Fill to this level
SMA 1 03
111 10 8
5 8 8
1 2
71
CLUTCH h CHANGING MANUAL
CHECKING CLUTCH FLUID A

TRANSMISSION OIL
LEVEL AND LEAKS
InSU1ator
I Drain oil completely
FIOor
j H
fl N m kg m ft lb SMA102
Add to MAX level
Pedal height H
168 174 mm 6 61 6 85 in
Padal free play A

SMA1QO J 5 0 04 SMA104
mm 020 in
MA 23

Chassis and Body Maintenance MAINTENANCE
2 Refill transmission and check oil CHECKINGAUTOMAnC CHECKING DIFFEREN11AL

level TRANSMISSION FLUID CARRIER OIL LEVEL
CONDITION
Check fluid for contamination to

determine condition of automatic
transmission If fluid is very dark or
smells burned the frictional material

clutches band etc may need reo
t
placemen
Fill to this level

25ft lb
S MA10B
Oil capacity
CHANGING DIFFERENTIAL
2 0 liten 41 4 USJit CARRIER OIL
31 2 Imp pt
I Drain oil completely
Oleck fluid for contamination CV 59 98 N m
6 10 m
kg 72ft
blL
AUTOMATIC
TRANSMISSIQN
CHECKING AUTOMATIC
TRANSMISSION FLUID
LEVEL
I Check under following conditions
I W SMA109
Check fluid for smell
i Place selector lever in P SMA107
pARK position and idle engine carrier and

2 Refill differential
2 Maintain fluid temperature at 50
check oil level
to80DC 122 to 176DF
2 Add oil if necessary
Use only automatic transmission

fluid OEXRON identifica
having
tions in 3N71B automatic trans
iSlion
ER SHAFT
PROPELI
AND DIFFERENTIAL
CAR IER
cv 59 98 N m
Q CHECKING PROPELLER 6 101qjm

43 lb
72ft SMA11Q
SHAFT
J
Check propeller shaft replace if
Oil capacity
necessary
1 1liten 2 8 US pt
3
2 Imp pt
FRONT AXLE AND

FRONT SUSPENSION
Add to H level
Do not overfill CHECKING FRONT AXLE
AND SUSPENSION PARTS
Oteek tube surfaces Block rear wheels with chock and

I
fOJ denu or cracks
raise front of car and then support it
SMA106 SMA231 Oleck tightening torque
with safety stand Refer to lifting
MA 24

MAINTENANCE Chsssis and Body Maintensnce
Points and Towing Section GI 4 Check suspension ball joint for Threaded portion of spindle
2 Shake each front wheel by hold grease leakage and ball joint dust cover Contact surface between wheel
ing upper and lower surfaces of tires as for damage bearing washer and outer wheel
shown
bearing
Hub hub cap and O ring
Grease seal lip
dl
nng
SMA111
Multi purpose
grease point
Check suspension parts for loose 5 SMAl16
Remove wheel and tire assembly
ness wear or damage 6 Check front axle parts for crack
Retighten all loose nuts and bolts or damage
to the specified torque Refer to Sec Replace worn parts
tion FA for tightening torque Refer to Front Axle Section FA
3 Tighten wheel bearing nut
Replace all worn parts as described 7 Remove brake pads
under Front Suspension Section FA Refer to section BR
J 25
i 29N m
8 Check wheel bearing 12 5 3 0 kg m
18 lbl
22ft
If there is any axial end play or if
wheel bearing does not smoothly turn
adjust bearing to specifications
Replace worn or damaged bearings
Refer to Front Axle Section FA
o
Strut upper end SMAT17
4 Turn wheel hub several times in

both directions to seat wheel bearing
correctly
SMAllS
3 Check strut Shock absorber for

oil leakage or damage ADjUSTING WHEEL
BEARING PRELOAD
After wheel bearing has been reo
placed or front axle has been reo
assembled be sure to adjust wheel SMAllS
bearing preload as described below
I Before adjustment thoroughly

J clean all parts to prevent possible en
try of dirt
2 Apply recommended multi pur
pose grease sparingly to the following
parts 5 Again tighten wheel bearing nut
MA 25

ChassiundBodyMainl11nance MAINTENANCE
6 Turn back wheel bearing nut with 9 Spread otterpin In

Toe
in 600
Measure toe in and make necessary
adjustments Use the following pro
cedure when making adjustments
I Raise front of car and mark a base
line across the tread of left and right

wheels
Base line
F A265
Tumbac kA Within600 SMA119
10 Install hub cap with new O ring
7 Fit adjusting cap and new cotter
pin SMA123
CHECKING WHEEL 2 Set wheels in a straight ahead

ALIGN MENT position and then lower front of car
3 Measure toe in and make neces
Before checking front wheel align
ment be sure to make a
sary adjustments
preliminary
inspection of all front end parts lines parallel to
Tire pressure center line of body

Wheel bearing axial play
Suspension ball joint
Steering gear housing looseness at
frame
Steering linkage and connections

Shock absorber oparation
8 Measure wheel bearing preload
Tighten each front axle and suspen
and axial play
sion pam
Measure car height when not
loaded
Toein Unladen
Repair or replace the damaged por
tion o 2 mm O O OS inl
or parts
0 12 On both sides
Sid slip Reference datal

Out 1 mm n 1 mmlm
900 Camber caster and kingopln Out 0 012 in In 0 012 in ftl
Axial play 0 mm 0 in inclination

1 b
Wh ring prelo
As measured wh Camber caster and king pin inclina Toe in can be
at 1 hub bolt adjusted by varying
tion are preset at the
With new parts factory and can the length of steering side rods
69 14 7 N not be adjusted
10 7 1 5 kg 1 5 3 31bl
If camber caster in
With US8 t parts
or king pin
20 7B N clination alignment is not within speci
2
10 0 8 kg 0 4 1 8 Ib fications check pertinent parts
SMA121
Repair or replace as necessary
Camber
40 50
Caster
1045 315
Repeat above procedures until cor
Kingpin inclination
rect starting torque is obtained SMA265
7025 SOSS
MA 26

MAINTENANCE Chassis and Body Maintenance
Unladen 2 Remove stopper pin of turning Turning angle of outer wheel will
Fuel tank radiator and engine oil radius gauge and then fully rotate automatically be set by adjusting turn
of inner wheel to specified
tank all full steering wheel to the right and left ing angle
Spare tire jack hand tools mats in measure turning angle on inner wheel values
position and make necessary adjustments

All tires inflated to specified pres 3 After adjustment lock adjusting
lock nut
sure
All accumulation of mud dirt and
road deposits removed from chassis

and underbody
If side rods have been disassembled
set the distance between lock nuts to
the value A prior to
specified reo
assembling
FA632
REAR AXLE AND

REAR SUSPENSION
Front wheel turning angle
JJ When inner wheel
Toe ut turns CHECKING REAR AXLE
200
AND SUSPENSION PARTS
Outer wheel 18 70
Check rear axle and suspension
Sid red length An Full turns On power steering mo
71 0 mm 12 795 in dels wheel turning force at cir parts for looseness wear or damage
Retighten all loose nuts and bolts
ssn05 cumference of steering wheell of 98
the Refer to Sec
147 N 10 15 kg 22 33 Ib with to specified torque
tion RA fortightening torque
at idle
engine
Lock side rod bar lock nut that
Replace aU worn parts as instructed
a so
Inner wheel 330 350
ball joint on outer socket is 770
Outer wheel 270 290 under Rear Suspension Section RA
with respect to that on inner
socket
b Make sure that adjusting bar is
screwed in eam socket at least 25 Check tightening torque

mm 0 98 in
4 After correct toe in has been ob

tained tighten side rod bar lock nuts
Iil 78 98 N m
8 0 10 0 kg m
58 72 ft lb
Front wheel turning engle
I Set wheels in straight ahead posi

tion and then move car foward until
front wheels rest on turn ng radius
gauge properly
SMA129
MA 27

OIl1Sfisand Body Maintenance MAINTENANCE
CIieck brake fluidleve

BRAKE SYSTEM 2 Pad wear liniit
3 Check for leaks
CHECKING BRAKE FLUID

LEVEL AND LEAKS
CHECKING BRAKE BOOSTER 1
Add to MAX level

VACUUM HOSES
ll A
coNNECTIONS AND I TT
CHECK VALVE
PIId war limit tAt
1 Check condition of vacuum hoses N22 2 mm 0 08 in
and connections AN12H 2 mm 0 08 in
2 Check vacuum hoses and check

valve for air tightness SMA266
Refer to Section BR for pad re
SMA 130
placement
Rotor repair limit

If fluid level i extremely low
check brake system for leaks
CHANGING BRAKE FLUID SMA 125
I Change brake fluid

Use same procedure IS in air bleed
to brake fluid in CHECKING BRAKE SYSTEM

ing change ystem
Thi operation should be done for one I Check brake system fr proper
wheel at a time Refer to Section BR attachment leaks chafmg abrasion ROtor repair limit B
deterioration etc N22 10 5 mm 10 413 in
CAUTION AN12H 8 6 mm 339 in
0
SMA267
Never reuse brake fluid because its

characteristic is chang2d by oxidiza
tion as well as contains the foreign CHECKING FOOT BRAKE
material and dirt
1 Check brake pedal free height and
free play
Adjust if necessary
Brake b
P
hl
SMA 133
t 0
i
1
CHECKING DISC BRAKE Ck nut
l12 15
I Check condition of disc brake j 11 2 1 5
components 9 11
Lock nut
1 16 22
1I 6
1 2 12 16
Insulator
Air bleed valve
l6 9 8 N Oteck caliper
3
m
O7 O operation and Floor h

9kg
5 1 6 5ft lb inspect for
beck pads for wear X leaks
SMA131 Refill until new fluid appears l
SMA134 SMA140 N m kgm Ct tb
MA 28

h Measure lever stroke in a straight

Pedal free height
155 161 mm 6 10 6 34 in line at center of grip
Pedal free play a
Tread wear indicator Tire tread
1 5 mm 0 04 0 20 in Pulling force
196N 120 kg 44 Ib
1 Adjust pedal free height with

t
I
brake lamp switch Then tighten lock l
nut
Adjust pedal free play with brake

n I
booster input rod Then tighten lock L
Lever stroke
1 I
WH024
nut
0
90 100 mm 0
the following 3 54 3 94 nl
Pedal free play mean
Number of notches 7 8 SMA 142
total measured at position of pedal 2 Remove pebbles glass or any
in
pad other foreign material embedded
Play due to clevis pin and clevis pin tire treads
hole in pedal lever 2 Use adjuster to adjust lever stroke 3 Check tread and side walls for
Play due to piston and piston rod cracks holes separation or damage
4 Check tire valves for air leakage
2 Check brake pedal depressed
height
I
Tire Inflation
I
I
I Check tire pressure If necessary
Lock t
fiU
adjust it to the specified value indi
d cated in the label attached to the car

v
also found in Owner s Manual or
SMA143
S D S
Tire pressure should be easured

DeprltSSllKl height
when tire is cold
Mor ln
thi 60 mm 2 36 in SMA141 3 Bend parking brake warning lamp
switch plate down so that brake warn
ing light when ratchet at
If depressed height i below the parking

comes on
brake lever is moved back one J

rireinflation
specified value check brake system for notch and goes out when returned to
leaks accumulation of a r or any ab its original positi

on I pressure label
l
normality regarding component parb
master cylinder adju ier etc I and
make the necessary repain WHEEL AND TIRE
I
CHECKING TIRE CONDITION
SMA268
Tire condition
1 Tires are provided with tread

wear indicator at six places around 2 After inflating tires valves should
tire circumference indicating 1 6 mm be checked for leakage Whenever tire
CHECKING PARKING BRAKE 1 16 in tread depth When tires wear pressure is checked be sure to tighten
I Pull lever with specified amount and then marks appear replace them valve caps firmly by hand to keep dust
and water out
of force with new ones
MA 29

ChaS3is and BodyMainrenanaJ MAINTENANCE
Abnormal tire wear

Radial tires
Correct abnormal tire wear ac
Right front Right rear

cording to the chart shown below
c l
c
Measure and adjust lc

c l
@
Underinflation both
Left front Left
sides ar plessure rear
Incorrect wheel camber Repair replace

or
4 WHEELS
i one side wear axle and suspension

SMA126
1 1 1 parts
J Hard cornering Reduce speed
1111
Lack of rotation Rotate tires
allll j ll
TIRE REPLACEMENT
Shoulder wear
CAUTION
Overinflation Measure and adjust Different types of tires Rich es bias
pressure bias belted and radial S murt not
tirl
IfI t
lack of rotation Rotate tires
be mixed under any cinumstances
Mind use of different types of tiies
can adversely affect car handling and
may cause driver to lose control

i
ii ii Ii
I
a When replacing worn or damaged

Center wear
tire use a replacement tire of the
Incorrect toe Adjust toe in size and load carrying
Feathered edge same capaci
j ty as that with which the car WIS
l I
Ii aquipped when manufactUred The
1 Ii
II 1 1 use of different size and or load
t
1i capacity ti will not only horten

I l tire service life but may also resuh
I I I
I in a serious accident
r i
II I b Do not use tires and wheels other
than those recommeooed and do
Toein or out
toe wear
not mix tire of different brandt or
lncorrect camber or Repair replace

or
tread patterns
caster axle and suspension The use of tire and wheels other
H l parts than those recommended or the
I il if
Repair replace
Ij m
or
Malfunctioning suspen mixed use of tires of diffarent
necessary reinstall
1
I
Iij fIll
sion brands or 1ead patterns can ad
Unbalanced wheel Balance replace
or
11 I
versely affect the ride braking
o
j I
I
lf
Out round brake Correct or replace
handling ground clearance body
f 1 1
ll ll drum
Ii 1 to tire clearance and sp et
tom8ter
Other mechanical condi Correct or replace calibration
dons
Uneven wear c It it recommended that new tires be
Lack of rotation Rotate tires installed in pain on the same axle
tire it
SMA068
When replacing only one
should be paired with the most
tread to equalize braking traction

d When replacing original tires with
those tires of 8n optional recom
mended size and of different diam

TIRE ROTATION etc Front tires also tend to wear un
ator tha speedometer must ba ra
1 Tires tend to wear unevenly and evenly because of improperly aligned calibrated
become unbalanced after a certain front wheels
To replace tire with a in a
running distance Uneven tire wear 2 Accordingly to equaliZe tire wear 1 a
jack
often results in tire noise which is it is necessary to rot8te tires periodh safe manner refe to lifting Points
attributed to axle gears bearing Section GI for jacking up
rear cally
30
MA

Precautions whenuslng
WARNING T type tire
spa
Never get under car while it is sup
Pe iodically check tire inflation pres
ported only by jack sure and always keep it at 60 psi
Always use safety stands to support 412 kPa
side member of body construction Align nuts with bolt
Do not drive car at speed faster
holes in wheel and
when you must get beneath car
50 MPH
than 80 km h
evenly tighten nuts
each one a little The T type spare tire is designed
at time spare
a only fpr tempora ry use as a
2 To install wheel tighten wheel Dismount it and keep it as a spare as
nuts in criss cross fashion soon as the standard tire repair has
been completed
Do not enter into an automatic car
SMA071 wash with the T type spare tire
fitted
Do not attach a tire chain
3 Tighten wheel nuts evenly with Do not use the T type spare tire on
a wheel wrench in criss cross fashion other cars
Be sure to check the wheel nuts for Do not make a sharp turn or apply
after the aluminum wheel the brake suddenly while driving
tightness
has been Nn for the first 1 000 km As soon as the tread wear indicator
SMA069 600 milesl also in cases of repairing becorries visible replace the tire
flat tire tire rotation etc Retighten with a new one
if necessary Mounting and dismounting to and
from the road wheel can be carried
Wheel nut
out in the same manner as any ordi
Aluminum whee nary tin

Use of wheel balance is unneces ary
To install an aluminum wheel pro CAUTION
ceed as followS Two types of wheel nuts are used one
CAUTION
I Snugly tighten four nuts after the is designed for use with steel wheel
If the car is equipped with aluminum
wheel is and the other for use with aluminum
positioned wheels be sure to use the wheel nuts
wheel 00 not mix different types of
for steel wheel on the r typ spare tire
wheel nuts
wheel Never us the wheel nuts for
aluminum wheel on the spare tire
wheel
For aluminum For steel
wheels wheels
The spare tire wheel may come off the
only only
axle and cause personal injury if the
nuts for aluminum wheels are
r wheel
C used on
TIRE REPAIR
the spare tire wheel
J
t 78 98 N m
the
10 0 kg m Inspect tire following proce
18 0
SMA070 58 72 ft Ibl SMA234 dure shown below If any defect is pre
sent repair or replace as necessary
1 Apply soapy solution or submerge
Be careful not to smear thread tire and wheel or tube in water after
ed portion of bolt and nut and seat inflating it to specified pressure

of nut with oil or grease 2 Inspect for leaks
3 Specially inspect for leaks around
valve or wheel rim and along tread
T TYPE SPARE TIRE
4 Note bead and rim where leakage
Size T135 70D16 occurs Wipe water away from any
2 Slightly pull the wheel back to
The T type spare tire is designed for area which leaks air bubbles and then
properly align the nuts with bolt holes
emergency use only mark place with chalk
in the wheel and tighten the nuts as
The spare tire can be used repeatedly S Remove object which caused
much as possible with your fingers for emergency situations p uncture and seal the point
MA 31

Chassis and Body Maintenance MAINTENANCE
a When repairing B puncture use 8
tire repair kit furnished by any tire WARNING B B
dealer instructions pro When while tire is being inflated

following
vided with kit bead snipS over safety hump it
A A
b If 8 puncture is too or there is might break Thus to avoid serious
large
lome damage to tire fabric repair personal injury never stlinll over
should be carried out by authorized tire when inflating it Never inflate
tire ller
to a pressure greater than 40 psi
275kPa
6 Discard when any of the following If beads fail to seat It that presRlre
problems occurs deflate the tire lubricate it again
SMA074
Broken or damaged bead wire and then reinflate it If the tira is
Ply or tread separation overinflated the bead might break LaterIII runout A and ill rvnout B
Worn fabric damage S I wheel Lea thin

on tubeless possibly resulting in serious pl r
0 mm 10 039 in
1
tire sunal injury Aluminum wheel Lea than
Cracked or damaged side wall 5 mm10 020 in
0
Tires with tread wear indicator ence between

Diff right and left la
btrel
runout
showing etc WHEEL INSPEcnON
S Lea then
5 mm
0 O 02O in
Inspect wheel taking care of the
CAUTION Aluminum I Lea than
When tire take extra

following points in order to ensure 2mm
0 llOB In
replacing care O
satisfactory steering condition as well
n t to damage tire bead rim flange as maximum tire life If any defect is
and bead seat
present repair or replace as uy
necess 4 Replace wheel when any of the
I Check wheel rim especially rim following problems occurs
Do not U58 tire irons to force beads flange and bead seat for rust distor Bent dented or heavily rusted
away from wheel flange
rim that is tion cracks or other faults which Elongated bolt holes
always tire device might air leaks Function of Excessive lateral radial runout
use replacement cause or
whenever tirei r moved tubeless tire depends on a good seal Air leaks through welds
between tire bead and wheel rim Wheel nuts will not stay tight
7 Install tire noting the following 2 Thoroughly remove rust dust
items oxidized rubber or sand from wheel
Wheel balance
rim
a Install valve core aOd inflate to
Rim bead seets should be ct aned Inspect wheel and tire for wheel
proper pressure CheC the loceting balance and correct it if unbalance is
with the following
rings of the tire to be sure they present taking the
Steel wheel following points
show around the rim flanges on into consideration
Wire brush coarse steel wool etc
both sides I Correct unbalance when the
Aluminum wheel
b Check valves 10rleakage efter in symptom of unbalance appears as
Neutral detergent cloth ole
flating tires wheel tramps and wheel shimmy
c Be IUfe to valve caps 3 Examine wheel rim for lateral and
tighten firmly 2 Balance wheel and tire both
by hand radial runout using dial gauge
statically end dynamically
MA 32

Ianeln wheels
STEERING SYSTEM
WARNING CHECKING STEERING GEAR

When balancing wheel and tire on
OIL LEVEL AND LEAKS
the car be SlIre to observe the
equipment manufacturers instruc

tions carefully
Cause Wheel static unbalance Wheel dynamic unbalance
Symptom
Wheel tramp
of Wheel
Wheel shimmy shimmy
unbalance
Corrective Balance statically Balance dynamically

action
Place balance
Wheel shimmy
weights here
Check fluid reaks
o o Add fluid
SMA604
Wheel
tramp
Place balance
weights
here
o CHECKING POWER
STEERING FLUID
AND LINES
leavy I Mter stopping the engine check

Location
oi11evel in reservoir
Wheel shimmy
Check dipstick on HOT ide at
SMA075
normal operating temperature or
COLD ide when oil i cold

a Be sur to place correct balance
weights on inner edge of rim Add recommended oil if necessarY

b Do not put more than two weights
on each side CAUTION
Two type 6f balance not overfill
c weight are 00
used one is designed for use with
steel wheel and tha other for u e
with aluminum wheel Do not mix
different types of balance weights

d Properly rebalance the wheel and
ti e whenever puncture is repaired

I c 1
Maximum allowable unbalanCl at
rim flange
10 g 0 35 oz
UIllIfII
Bal
Oil level should
n
weight
10 6Og 35 2 120z
O
be maintained
at 10 D 10 35 od interval
A within this range
SMA076 SMA12
MA 33
Chassis and Body UJJlce
Mainte MAINTENANCE
2 Inspect line condition and check

for leaks
Check for fluid leaks

SMA190
CHECKING STEERING GEAR

BOX AND LINKAGE
Steerlna aeer box
Check parts for looseness wear or
damage Retighten if neccessary

Refer to Section ST for tightening
torque
Steerlna Ilnkeae
Check parts for looseness wear or
damag Retighten if necessary

Refer to Section ST for tightening
torque
Check ball joints and idler for
grease leakage
arm
Q Ch ck grease leakage
Check for any missing parts cotter Check tightening torque

SMA 145
pins washer etc
34
MA
BODY
LUBRICATING LOCKS HINGES AND HOOD LATCH
i
Lubrication points
c TlI
SMA191
CHECKING SEAT BELTS BUCKLES RETRACTORS

ANCHORS AND ADJUSTER
O1eck retractors for smooth

operation
SMA232
MA 35

is and Body Maintenance
Cha MAINTENANCE
HEATER AND AlII CONDITIONER

CHECKING REFRIGERANT LEVEL
L Open doors fully 4 Set temperature lever to maxi about five minutes Judge according to
the following table
2 Start the engine mum cold position
3 Set air conditioner switch to 5 Set blower to maximum speed
ON position
6 Checlc sight glass after the lapse of
Amount of
refrigerant Insufficient Suitable Too much refrigenmt

Almost no refrigerant
Check item
Almost difference High side is

pressure High pressure side is High pressure side is
Temperature of high pressure no
and low pressure lines between high pressure warm and low pressure hot and low pressure abnormally hot
and low pressure side side is fairly cold side is cold
temperature
Almost transparent No bubbles can be seen

State in sight glass Bubbles flow continu The bubbles are seen
Bubbles will at intervals of 1 2 Bubbles may appear

ously
disappear am som seconds when engine speed is
thing like mist will raised and lowered

flow when lIf iglrant
is nearly gone No clear differencr exists betwen thMe two
conditions
n
nl r I n
AC256 AC257 AC258
is Both press re on high Both on high Both pres ures on high

Pressure of system High pressure side pressures
abnormally low and tow pressure sides and low pressure sides and low pressure sides
are slightly low are nonnal are abnormally high
top compnssor im Check fot gas leakage Discharge refrigerant

Repair
repaiI alequited re from serVice val e of
mediately and con
overall plenish and charge low pressure side
duct an
ch k system
a The seen through the sight

bubbl the amount when it exceeds 2DoC CHECKING COMPRESSOR
glass are influenced by tha ambiant 68DF In higher temperatura the DRIVE BELT
temperature Since the ere
bubbl bubble ara easy to show up Refer to Engine Maintenance for
hard to how up in comparatively b When the screen in the receiver
inspection and adjustment
low temperature below 20De drier i clogged tha bubble will
68d Fh it i possible that a lightly appear en if the emount of refrig

larger amount of refrigetant would erant is normal In this case the
be filled if upplied aCCOrding to outlet side pipe of tha raceiver drier
the ight glass Be u to chock bacome considerebly cold
36
MA
CHECKING HOSES AND

PIPES 111 1
I I lI
Check heater and air conditioner Engine
hoses pipes due to in
for damaged or
terference or friction with adjoining

parts If damage is minor repair
co ressor
those affected hose or pipes If damage
is major and if there is the possibility
the a
of encountering holes replace
affected parts
Carefully check hoses and pipes o

especially thOle located CIOM to moy
I
ing parts Or sharp edge of panel
I
L Condenser
SMA233
CHECKING REFRIGERANT
LEAKS
Conduct a leak test with halide or
electric leak detector whenever leakage

of refrigerantsuspected and when
is
Sampling tube
conducting service
operations which
are accompanied by disassembly or Flame adjusting lines
loosening of connection fittings
MoIJor check point
I Compressor
Compressor shaft seal rotate the
compressor by hand
Flexible hose connections
Front and rear head gaskets
Service valve
2 Condenser
SMA150
Condenser pipe fitting
Condenser inlet and outlet pipe
connections
3 Refrigerant lines The following information and checking for leakage

Flared section of high pressure and cautions should be kept in mind when
low pressure flexible hoses

line connections
4 Evaporator housing
Inlet and outlet line connections
Expansion valve
Suction throttle valve
37
MA

Chassis end Body Maint mance MAINTENANCE
If a halide leak detector is used de leaking by the color of the flame as

If a gas leak is detecteil proceed as
termine whether or not there is gas indicated in the chart below follows
I Check torque on the connection
fitting and if too loose tighten to the

Propane type Butane type proper torque Oieck for gas leakage
with a leak detector
NO LEAK Greenish blue Pale blue 2 Ifleakage continues even after
SMALL LEAK Yellow the fitting has been retightened dis
Bright blue
LARGE LEAK
charge refrigerant from system discon
Purple Vivid green
nect the
fittings and check it eating
face for damage Always replace even
if damage is slight
3 Che k compressor oil and add oil
if required
4 Oiarge refrigerant and recheck for
Since gas leaks If no leaks are found evacu

refrigerant gas is heavier than
WARNING ate and charge system
ai mall leaks can be
easily detect
a Never inhale the fumes produced
ed by placing sampling tube direct
by combustion of J nt gas
ly below the check point OFF SEASON MAl ANCE
since they are toxic
If eny trace of oil i noted at and
b Never use halide torch in Even in the off season turn the
a place
around connection fittings it is a
where combustible compressor for 10 minutes at least
or explosive
sure indication that refrigerant is month
gas is present once a by running the engine at
le king idling rpm
38
MA

MAINTENANCE Service Data and Specifications
SERVICE DATA AND SPECIACATIONS

Emission control system
ENGINE MAINTENANCE Unit kPa mmH20 inH201
INSPECTION AND ADJUSTMENT Supplied pressure 3 923 400 15 751

Vapor line
Basic leakage es
meclanlcal system Pressure variation Less than 0 245 25 0 981
Valve clearance mm in Hot Cold
TIGHTENING TORQUE
Intake 0 30 10 Ot 2 0 2t 10 008
N m m
kg ft Ib
Unit
Exhaust 0 30 O Ot 2 0 23 10 0091
Rocker arm nut 16 22 t 6 22 12 t6

Drive belt defle tion
Fan Alternator Air condi

Oil pan drain plug 20 29 20 30 t4 22
tioner compressor and
8 t210 3t 0 47
Power steering oil pump
mm in
I Spark plug t5 20 15 20 tt t4
Fuel hose clamp 10 t 5 O tO 0 t5 07 1
Applied pressed force 98110 221

N kg lb
3 mm 0 12 in
Compression pressure
kPa kg cm2 psil rpm
Standard t t77lt2 0 17t1350
Minimum 883 9 0 t 281 350

h
At ambient temperature 200C 680F After checking valve l
@
clearance while engine is cold Iso check it when engine is hot
if it remains within the Jpecifi value If it does not

to
Fuel hose clamping position EF335A
rudjunit
CHASSIS AND BODY

MAINTENANCE
Inition and fuel system
INSPECTION AND ADJUSTMENT
Spark plug
Clutch Unit mm inl
Type Plug gap t68 17416 61 851

6
Pedal height H
in
mm
Standard Hot type Cold type
5 10 04 0 20
Pedal free play AU
U S A IStBnd
ard
8P6ES 8P5ES 8P7ES 08
0 03t
0 9
Front axle and front suspension

I Opti on
8PR6ES 8PR5ES 8PR7ES
0 035
0
ResUor built in type Axial play inl
mm 01
Canada I I
Wheel bearing Pl eload
High tension cable resistance ohm
I Less than 30 000
As measured at wheel hub bolt
9
6 t4 710 7 15 15 3 3
With nBW pBrts N Ikg lbl
Ignition timing idle speed and idle CO With used part N Ikg Ibl 20 8
7 2
0 08 04 81
t
california
on Wheel alignment
1 models
Califronhi models
1 Camber degree 40 SO
20 B T D 60 B T D C degree 1045 3015
I I
t
8 C Carter
ManuOl tran mission
l 700 100 700 l 100
Kingpin inclination degree 7025 8055
20 B T D 60 B T O
I I
Automatic tran mission l
8 C C
o 2 mm 10 0 08 inl
lin 0 position I 700 tOO 700 tOO Toe in Unladenl
0 12 On both sides
Idle mixture screw
1 3i t
is preset and Out 1 mm In 1 mm m
CO at idling speed Side Reference data
No air slip
sealed at factory Out 0 012 in In 0 012 in ftl
MA 39

SpecialSi rvice Tool MAINT NANCE
Standard ide rod Wheel rim lateral and radial LeCs than 1 0 0 039
mmlinl 71 0 80
12
A in
mm
length runout 05 10 020 02
Front wheel turning angle Difference between right Less than 0 5 0 020 1
in
mm
turns IWhen inner
out
Toe
end left lateral 02
runout 10 008 2
wheel i 200 I degree
Outer wheel 18 70 Wheel balance
Maximum allowable gr ozl to 10 35

Full turn degree unbelance im
at flange
Inner wheel 33 350
10 60 10 35 2 121
Tire balancing weight gr loz
Outer wheel 270 29
Spac ng to 10 351
On power steering models wheel turning force lat circumference 1 Steet wheel
of steering wheel of 98 147 N 110 15 kg 22 33 Ib with en 2 Aluminum wheel
gine at idle
Brake s stem Unit mm lin

TIGHTENING TORQUE
N22 081
210
Pad wear limit Unit N m
kg fb
ft
AN12H 2 10001
Clutch
N22 10 5 10 4131 Pedal stopper lock nut 8
7 8
11 8
0 2
1 5 8 8 7
Rotor repair limit
AN12H 8 6 10 339 Master cylinder push
8
7 118 8
0 2
t 8 8 7
5
rod lock nut
Pedal height h 155 16116 10 6 341
Manual transmission
Pede fre8 play a 5 04
10 201
0
Drain and filler plugs 25 34 25 35 18 25
Pedal depressed height More than 60 f2 36

Propeller shaft and dif
ferential carrier
Parking brake
Differential carrier
Lever stroke 8t pullirig 90 100 13 54 941
3
59 98 6 10 43 72
drain and filler plugs
0 0 t96N 120 kg 44lbll
Front axle and front

Number of notches 7 8
suspension
Side rod lock nut 78 98 80 to O 58 72
Brake system
Wheel and tire Air bleed vatve 69 88 07 O 51 65
Recommended Id tire inflation pressure Brake lamp switch

12 15 12 1 5 9 11
lock nut
7OSR14
t85 26 psi 1177 kPaI
Brake booster input
16 22 6
1 22 12 16
00 not use in excess of rod k nut
Tire size
Spare tire 80 kmlh 150 MPHI
70DI6
T135 Wheel and tire
60 psi 1412 kPa Wheel nut 78 98 80 to O 58 72
Tire prlSlure should be checked when tires are COLD
SPECIAL SERVICE TOOL
Tool number
Tool name
No
Kent Moore
ST19320000 Oil fIlter wrench
SJ
125664
40
MA

DATSUN 200SX Model S 0 Series
ENGINE MECHANICAL
CONTENTS
ENGINE COMPONENTS CONNECTING ROD EM ll

Outer parts EM 2 CRANKSHAFT EM l1
ENGINE COMPONENTS MAIN BEARING AND
Body parts EM 3 CONNECTING ROD BEARING EM 12

ENGINE DISASSEMBLY EM 4 MISCELLANEOUS COMPONENTS EM 12
PRECAUTION EM 4 ENGINE ASSEMBLY EM 14
DISASSEMBLING ENGINE OVERALL EM 4 PRECAUTIONS EM 14
DISASSEMBLING PISTON AND ASSEMBLING CYLINDER HEAD EM 14
CONNECTING ROD EM 6 ASSEMBLING PISTON AND
DISASSEMBLING CYLINDER HEAD EM 6 CONNECTING ROD EM 15
DISASSEMBLING INTAKE MANIFOLD EM 6 ASSEMBLING INTAKE MANIFOLD EM 16
INSPECTION AND REPAIR EM 7 ASSEMBLING ENGINE OVERALL EM 16
CYLINDER HEAD EM 7 SERVICE DATA AND
VALVE EM 8 SPECIFICATIONS EM 20
VALVE SPRING EM 8 INSPECTION AND ADJUSTMENT EM 20
ROCKER ARM AND ROCKER SHAFT EM 8 TIGHTENING TORGUE EM 24
GAMSHAFT AND CAMSHAFT BEARIN EM 8 TROUBLE DIAGNOSES AND
CYLINDER BLOCK EM 9 CORRECTIONS EM 25
PISTON PISTON PIN AND SPECIAL SERVICE TOOLS EM 27
PISTON RING EM lO

EngineComponenrs Outer parts ENGINE MECHANICAL
ENGINE COMPONENTS Outer parts
l34
I
5
3
44
4 5 25 33 1
l
IIigb temion coble
A
E tube
Exhaust manifold
E G R ValVe
l16
1 21
16 2 1
Starter t2 t5
l16
1 21 motor
2 t
iti6 Intake manifold
12
157 16 87 116
Alternator adjusting bar
Fan belt
Intake manifold st y
J 29 39
3 0 4 0 22
P C V valve
Oil pump
J N m
tgm ft lb
5 8
1 11 SEM136
EM 2

ENGINE MECHANICAL Engine Components Body parts
ENGINE COMPONENTS Body parts
Valve rocker cover
Valve rocker and shaft assembly

@ Exhaust
tntake
Vatve cotter
9
eam shaft Spring retainer
If 22
1
16 16 2 2 2
Rubber e Oil seal
plug Spring seat
Camshalt snap ring

sprocket
Cylinder head bolt
j Valve gUide
If 69 18 Valve at
1 0 8 0 51 58
Cylinder head
Cylinder liner
Only for service
Cylinder block
Front l cove
t51
t6
116
Drive
plate
151
16
116
Oil drain plug If N ft lb

m kg m
If 20 29 2 0 3 0 14 22 EM137
EM 3

EqgineDisas emb
y ENGINE MECHANICAL
ENGINE DISASSEMBLY
PRECAUTION Crankshaft pulley Use suitable tool 2 Power steering pump bracket and
on air conditioner
Arrange the disassembled parts on
equipped model throttle chamber stay if equipped
3 Intake manifold
the parts stand in accordance with mbly includ
ing water inlet water pipes water out
their assembled locations sequence
let vacuum tubes E G R valve throt
etc so that the parts will be reas
sembled to their tie chamber and EFI parts lnjecturs

original locations
Place mating marks on the parts if fuel pipes air regulator etc
necessary
DISASSEMBLING
ENGINE OVERALL
SEMl39
MOUNTING ENGINE
ON tK
WOi STAND
5 Remove engine left side parts
I Remove following parts located
Distributor cap and high tension
at rear and right side of engine
cables SEM 142
Starter otor
Distributor
Transmission
Exhaust manifold with air in
Clut h cover assembly using Tool
duction tubes after removing 4 And
KV30100100 or
torque convertor follpwing parts
E G R tube Oil f1Iter using Tool STl932ciOOO
Intake manifold stays
Oil pressure switch
Alternator and its bracket
Spark plugs
Engine mounting bracket
2 Install engine attachment to 7 Remove engine bottom side parts
cylinder block Then mount the Oilpump and oil pump drive
engine on the work stand spindle
Gussets
SEM140
Compressor ret
brac if equipped
Oil level gauge REMOVING BODY PARTS
SEMl38 Engine mounting bracket 8 Remove oil pan and oil strainer
Spark plugs 9 Remove valve rocker cover
6 Remove engine right side parts 10 Remove cylinder head assembly
3 Drain out engine oil and coolant I Cylinder block PC V
to valve
1 Remove camshaft
sprocket and
hose
slowly lower timing chain
REMOVING OUTER PARTS

4 Remove engine front side parts
Fan
Drive belts
Belt tensioner for steering if
powI
equipped
Alternator adjusting bar
Water pump
Vacuum tube assembly for distribu
tot and canister
EM4

ENGINE MECHANICAL Engine Disassembly
2 Loosen head bolts in the ing rod and cap corresponding to

cylinder
each cylinder Care should betaken
sequence shown
to avoid wrong combination includ
ing bearing
13 Remove flywheel and end plate
WARNING
When removing flywheel be careful
not to drop it
SEM144
1 Chain tensioner
2 Slack side chain guide
3 Remove bolts securing cylinder
3 Tension side chain guide
head to front cover
4 0 il thrower
4 Remove cylinder head 5 Oil PUJlP drive gear
head from 6 Crankshaft sprocket
When removing cylinder
engine installed on car follow the
If it is hard to extract crankshaft
instructions below
sprocket use a suitable puller
14 Remove crankshaft
8 Turn crankshaft until No 1 piston
is at TD C on its compression 1 Remove main bearing caps with
stroke bearings
b To facilitate assembling operation When bearing cap
8 loosening main
scribe a mark on timing chai and
bolts loosen from outside in se
camshaft sprocket with paint

quence
before removal
b Use Tool to remoye center and rear
c Support timing chain by utilizing main bearing caps Keep them in

Tool between timing chains
order
EM286
12 Remove piston and connecting

rod assembly KVIOI041S0
I Remove connecting rod bearing
cap with bearing

2 Push out piston with connecting
rod toward cylinder head side
EM608
J l
J1c
C
j
f Remove rear oil seal
I r
G 0
II Remove front side parts

II O EJ S7
I Front cover
2 Chain tensioner and chain guide 8 Piston can be easily removed by T

3 carbon off top face of
Timing chain scraJiing
4 Oil thrower oil pump drive gear
and crankshaft sprocket b
cylinder
Numbers are
with a scraper
stamped on connect
@rb EM1QO
EM 5

fTlbly
Sl
EngineOisa ENGINE MECHANICAL
3 Remove crankshaft DISASSEMBLING 3 Fuel and vacuum tube assembly

4 Remove main bearings at block 4 Fuel pressure regulator
CYLINDER HEAD
side 5 Injectors
1 Remove rocker shaft assembly
15 Remove baffle and steel net 6 Throttle control cable bracket
plate
together with securing bolts
from cylinder block
a Do not remove bolu at No 1 and 2 Remove cooling system parts
No 5 brackeU since rocker shaft
bracket and rocker will spring out
b When loosening bolts evenly loosen
from outside in sequence
1 Water outlet
2 Thermostat
3 Water gallery
4 Water outlet
SEM145
5 Semol housing
6 Water pipe
DISASSEMBLING
PISTON AND 2 Remove camshaft
CONNECTING ROD 3 Remove valves valve springs and 3 Remove following emission con
1 Remove piston rings with a ring relating parts using Too trol system parts referring to Section
remOver EC
E G R control valve
ST12070000 Thermal vacuum valveS
Nota installed direction of inlet and
outletfor reassembly
Vacuum control valve

Positive crankcase ventilation valve
4 Remove following miscellaneous
parts
Fast idle control device if equip
ped
Plugs
Vacuum connectors
Keep the disassembled parts in
2 Press piston pin out using press order Note installed direction of outl t
and Too for r mbly
Water temperature sensors
5 Disassemble intake manifold
body
ST13030001
DISASSEMBLING
INTAKE MANIFOLD
EM156
1 Remove following fuel system
to Section EF
parts referring
the disassembled parts in I Throttle chamber
Keep
order 2 Air regulator
6
EM

ENGINE MECHANICAL lnspectionandRepair
INSPECTION AND REPAIR
CYLINDER HEAD stem with a micrometer in three Replacement of valve guide

places top center and bottom
1 To remove old guides use Tool
CYLINDER HEAD MATING 2 Measure valve guide hore at center
S111033000 and a press under a
FACE using telescope hole gauge 2 ton pressure or a hammer
I Make a visual check for cracks and Drive them out toward rocker
flaws cover Heated cylinder head will
2 Measure the surface of cylinder facilitate the operation
head on cylinder block side for 2 Ream cylinder head valve guide
warpage hole using Tool at room temperature

If beyond the specified limit
Reaming bore
correct with a surface grinder
12 185 12 196 mm
Warpage of surface F A 0 4797 0 4802 in

limit 0 1 mm 0 004 int T Mr
h
10
oP
1 L j1 @
ItCil I
C
d
SEM150
SEM152
SEM14g
3 Subtract the highest reading of
valve stem diameter from valve guide
bore to obtain the stem to guide clear
Surface grinding li it 3 Fit snap ring on new valve guide
ance
The grinding limit of cylinder head and press the guide into head until
is determined Stem to guide clearance
by the cylinder block snap ring comes with in contact
in limit 0 1 mm 10 004 in
grinding an engine cylinder head surface after heating
Depth of cylinder head grinding is cylinder head to 150 to 2000C 302 to
A 2 Expedient method 3920F
Depth of cylinder block grinding is Pry valve in lateral direction and
Valve guide of 0 2 mm 0 008 in
8 measure deflection at stem end with
oversize diameter is available for
dial gauge
limit service Refer to S D S
A B 0 2 mm 10 008 in Stem end deflection 4 Ream the bore 1001
using
limit 0 2 mm 0 008 in STl1032000
Reaming bore
Valve should be moved in parallel
8 000 018
8 mm
VALVE GUIDE with rocker arm Generally a large 0 3150 0 3157 in
amount of wear occurs in this
Measure the clearance between direC
tion
valve and valve If the
guide stem 5 Correct valve seat sur ace with
clearance exceeds the specified limit new valve gUide as the axis
replace the worn parts or both valve
and valve guide In this case it is
essential to detennine if such a clear

ance has been caused by a worn Or
VALVE SEAT INSERTS
bent valve stem or by a worn valve
Check valve seat inserts for any
guide
evidence of pitting at valve contact
surface and reseat or replace if worn
Determining clearance
out excessively
Precise method Correct valve seat surface with Tool
SEM151
I Measure the diameter of valve and grind with a grinding compound
EM

Inspection and Repair ENGINE MECHANICAL
Valve seat insert of 5 min

0 0 020 VALVE
in oversize is available for service
I Check each of the intake and
Refer to S O S
exhaust valve for worn damaged or
defonned valve head or stem Correct
J or replace
Refer to
the valve that is faulty
os
S
2 Valve face or valve stem end sur
face should betefaced by using a valve
grinder
Valve head margin EM113
Limit 0 5 mm 10 020 inl

Grinding of valve stem end
Limit 0 5 mm 10 020 in
ROCKER ARM AND
ROCKER SHAFT
1 Check rocker anns and shafts for
a When repa nng valve seat check
sign of wear or damage and if worn
valve guide for wear beforehand If
excessively replace rocker arm and or
worn replace it Then correct valve
shaft
seat
2 Check oil clearance between
b The Tool should be used with both
rocker arm and rocker shaft
hands for uniform cutting
Rocker arm to shaft clearance
0 007 0 049 mm
EM111
10 0003 0 0019 inl
CAMSHAn AND
vALVE SPRING
Replacement valve seat insert CAMSHAn BEARING
1 Check valve spring for squareness
I Old insert can be removed by using a steel square and surface plate CAMSHAFT BEARING
until it The If spring is out of square S
boring out collapses more
CLEARANCE
machine deplh stop should be set so than specified limit replace with new
continue Measure the inside diameter of cam
that boring cannot beyond ones
shaft bearing withan inside dial gauge
the bottom face of the insert recess in
Out of square S
and the outside diameter of camshaft
cylinder head Outer
with micrometer If any
2 Select a suitable valve seat insert 0 063 in
journal a
Limit 1 6 mm
malfunction is found replace camshaft
and check its outside diameter Inner
3 Machine cylinder head recess to or cylinder head assembly
the concentric circles to valve guide Camshaft bearing clearance
center limit 0 1 mm 10 004 inl
4 Ream the cylinder head recess at
room temperature Refer to S O S

5 Heat cylinder head 10 a temper
J
ature of 150 to 2000C 302 to 3920 F
6 Fit inserl ensuring that it beds on
the bottom face of its recess and
caulk more than 4 points

7 Valve seats newly fitted should be
cut or ground using Tool ST1l65000l 0
at the
iBEM29s
specified dimensions as shown
in S O S
SEM154
8 Apply small amount of fine
to valve Measure the free length and the
grinding compound contacting 2
face and put valve into guide Lap tension of each spring If the Illeasured CAMSHAFT ALIGNMENT
valve against its seat until proper valve value exceeds the specified limi I re
seating is obtained Remove valve and place spring I Check camshaft camshaft journal
then clean valve and valve seat Refer to S s

O and cam surface for bend wear or
8
EM

ENGINE MECHANICAL ItJSPectionand Repair
4 When out of round

damage If beyond the specified limits wear taper or
is minor and within the limit remove

replace the parts
2 A bend value is one half of the the step at the topmost portion of
total indicator reading obtained when cylinder using a ridge reamer or other
camshaft is turned one full revolution similar tool
with a dial gauge at center journal If cyl inder bore has worn beyond
the wear limit cylinder
use liner
Camshaft bend
Undersize cylinder liners are avail
Total indicator readingl
in able for service Refer to S D S
limit 0 10 mm 10 0039
IntarferenC8 fit of cylinder liner
EM540
0 08 to 0 09 mm
0 0031 to 0 0035 in
Surface grinding limit
The grinding limit of cylinder block is

determined by the cylinder head grind CYLINDER BORING
ing in an engine
When any cylinder needs boring all
Depth of cylinder head grinding is
other cylinders must also be bored at
A
the same time
Depth of cylinder block grinding is
SEM156 8
Determining bore size
limit
A B 0 2 mm 0 008 in 1 Determine piston oversize accord
ing to amount of wear of cylinder

3 Measure camshaft cam height If
3 Using a bore gauge measure cylin
beyond the specified limit replace Ovenize pistons are available for
der bore for wear out of round or
camshaft service Refer to S D S
taper If those are excessive rebore
Wear limit of com height the cylinder walls by means of a 2 The size to which cylinders must
0 25 mm 10 0098 in boring machine Measurement should be honed is determined by adding
clearance the
be taken along bores for taper and piston tocylinder to
4 Measure camshaft end play If around bores for out of round piston skirt diameter A
beyond the specified limit replace Refer to S O S
camshaft or cylinder head assembly of
Out round X y
Taper A B
Camshaft end play
limit 0 2 mm 0 008 in
FA
J 1
I
zU 0 791
IiIL
60 12 361
T
III I
A
I
t
flit SEM714
17 X in
I Unit mm
EM422
L
CYUNDER BLOCK
1 Visually check cylinder block for
cracks or flaws
EM126
2 Measure the top of cylinder block
cylinder head mating face for
the
warpage If it exceeds specified Dimen ion
limit correct with a grinder distance from center of pinl
Warpage of surfaC8 I
EM124
Approximately
limit 0 1 mm 0004 in 20 mm 0 79 in
EM 9

In5PectionandRepair ENGINE MECHANICAL
Rebored size calculation

l Ring should be placed to diilmeter
D A B
I
C A 0 005 to at upper or lower limit of ring travel
0 025 mm 0 0002 to 0 0010 in If ring gap exceeds the specified
where limit replace ring
D Honed diameter
A Skirt diameter Ring gap
as measured
B Piston to wall clearance
t Limit 1 0 mm 0 039 in
C Machining allowance
0 02 mm 0 0008 in
l
J l EM641
Borin g
CAUTION
a To prevenl strain due to
cuning
heat bore the cylinders in the order
of 2
41 3 PISTON
b Before boring any cylinder install PISTON PIN
main bearing AND PISTON RING
caps in place and
tighten to the
specification so that
the crankshaft bearing bores will PISTON When
8 piston ring only is to be
not become distorted from the without
I Scrape carbon off piston and ring replaced cylinder bore
boring operation grooves with a carbon scraper and a being corrected measure the gap at
the bottom of cylinder where the
curved steel wire The wire will be
wear is minor
useful in cleaning bottom land of ring
3 Do not cut too much out of cylin b Oversize piston available
groove Oean out oil slots in bottom rings are
der bore at a time Cut only 0 05 rnm for service 0 5 mm 0 020 inl 1 0
land of oil ring groove
0 0020 in or so in diameter at a time 0 039 in oversize
2 mm
Check for damage scratches and
4 As a final step cylinders should
wear Replace if such a fault is de
be honed to size
tected
5 Measure the fmished cylinder bore PISTON PIN
for f round or
out tapered part 1 Check the of piston pin in
Refer to D S
S
fitting
PISTON RING to piston pin hole to be such an extent
Measurement ofjust machined
a
I Measure the side clearance of rings that it can be pressed smoothly by
cylinder bore requires utmost care in ring grooves as each ring is installed fmger at room temperature This pis
since it is expanded by cutting heat
If side clearance exceeds the speci ton pin must be a tight press fit into
fied limit replace piston together with connecting rod

piston ring
Side clearance
Measuring piston cyllnder
to
clearance
6 This clearance can be checked

easily by using feeler gauge and a
a
spring balance hooked on feeler gauge

measuring the amount of force re
quired to pull
gauge oU t from between
piston and cylinder
Feeler gauge used
0 04 mm 0 0016 in
Extracting force
2 Measure oil clearance between pis
2 0 14 7 N
0 2 1 5 0 4 3 3 Ibl
EM129 ton pin and piston If it is excessive
kg
replace piston pin together with pis
a When cl ton
measuring slOWly
pull feeler gauge straight upward 2 Measurering gap with a feeler Piston pin dearance
to piston
b It is recommended that piston and
gauge placing ring squarely in cylinder 0 006 0 013 mm
cylinder be heated to 200C 680F using piston 0 0002 0 0005 in
EM 10

ENGINE MECHANICAL Inspectionsnd Repair
CONNECTING ROD CRANKSHA

I If a connecting rod has any flaw
CRANK JOURNAL AND PIN
on both sides of the thrust face and
it I Repair or replace as required If
the large end correct or replace
faults are minor correct with fme
2 Check connecting rod for bend or
crocus cloth
torsion using a connecting rod aligner
If bend or torsion exceeds the limit 2 Check with a micrometer journals
and crank pins for taper and of
out
correct or replace
round Measurement should be taken
Bend and torsion
along journals for taper and around
per 100 mm 3 94 in length
limit 0 05 mm 10 0020 in
journals for of
out round
If out of round or taper exceeds the
specified limit replace or repair 2 Install crankshaft in cylinder
of
Out round X Y block and measure crankshaft free end
limit 0 03 mm 0 0012 in play at center bearing
Taper A BI End play
Limit 0 03 mm 0 0012 in
limit 0 3 mm 10 012 inl
A B
EM133
3 Install connecting rods with bear
ings on to corresponding crank pins

and measure the thrust clearance If
I
EP EM767
the measured value exceeds the limit

replace such connecting rod
Big end play 3 After regrinding crankshaft finish
Limit 0 6 mm 0 0024 in it to the necessary size indicated in the REPLACING PILOT BUSHING
chart under D S
S
by using an crankshaft
To replace rear pilot
adequate undersize bearing according bushing proceed as follows
to the extent of required repair I Pull out bushing using Tool
BEND AND END PLAY
I Crankshaft can be checked for

bend by placing it on V blocks and
using a dial gauge with its indicating
finger resting on center journal
Bend value is half of the total indi

cator reading obtained when crank
shaft is turned one full revolution
If bend exceeds the specified limit
When replacing conneCting rod
replace or repair
select so that weight difference be
tween each cylinder is within 7 g 0 25 Bond

Total indicator reading bushing
ozl in the condition of piston and 2 Before installing a new
limit 0 10 mm 0 0039 in clean bushing hole

connecting rod assembly thoroughly
EM 11

r
Inspection8ndRepair ENGINE MECHANICAL
3 Insert pilot bushing until distance 2 Install hearing and bearing cap
MISCELLANEOUS
between flange end and pilot bushing with the bolts tightened to the speci
is the specified distance A fied torque COMPONENTS
Distance A rJJ Main bearing cap bolt CAMSHA SPROCKET
Approximately 44 54 N m
I Check tooth surface for flaws or
40 mm 0 157 in 14 5 5 m
kg
33
wear Replace sprocket if any fault is
40 ft lb
found
Do not turn crankshaft while the 2 Install sprocket on camshaft and
plastigage is being inserted check for runout
If runout exceeds the specified
3 Remove bearing and cap Com limit replace camshaft sprocket
pare width of plastigage at its widest
Runout
part with the scale printed in plasti Total indicator reading
gage envelope Limit 0 1 mm 0 004 inl
Main bearing clearance
EM719
Limit 0 12 0 0047 in
When installing pilot bushing be

careful not to damage edge of pilot
bushing and not to insert exceuiYely
MAIN BEARING
SEM157
AND CONNECTING
ROO BEARIN
MAIN BEARING
I Thoroughly clean all bearings and 3 If clearance exceeds the specified

check for scratches melt score or
value replace bearing with an under
wear
size bearing and grind crankshaft
Replace bearings if any fault is
journal adequately
detected
Refer to D S
S
2 Measure bearing clearan as CHAIN
follows Check chain for damage excessive
I Cut plastigage to the width of
a
CONNECTING ROD BEARING wear at roller links if faulty
Replace
bearing and place it in parallel with I Measure connecting rod bearing
crank journal axis getting clear of the
clearance in the same manner as above
oil hole CHAIN TENSIONER
rJJ Connecting rod bearing cap nut AND CHAIN GUIDE
44 54 N m
Check for wear and breakage Re
14 5 5 5 kg m
place if necessary
33 40 ft lb
Sale rod dearance

Connecting bearing FLYWHEEL
Limit 0 12 mm 0 0047 in
Plastigage I Check the clutch disc contact
2 If clearance exceeds the specified surface on flywheel for damage or
value bearing with an under
repl ce wear Repair or replace if necessary
size bearing and grind the crankpin 2 Measure runout of the clutch disc
adequately contact surface with a dial gauge Ifit
EM141
Refer to S D S exceeds the specified limit replace it
EM 12

and Repair
ENGINE MECHANICAL Inspection
Runout 3 Check tooth surfaces of ring gear It is good practice to renew oil seal
Total indicator reading for flaws or wear whenever engine is overhauled

Limit 0 15 mm 10 0059 in Replace if necessary
about 180 to
ReplaC8 ring gear at
2200C 356 to 4280F
F
FRONT AND
REAR OIL SEAL Front
l 1
Check front and rear oil seals for
worn or folded sealing lip or oil
over
leakage If necessary replace with a

new seal When installing a new seal
Front L
pay attention to its mounting direc Rear
EM150
tion
EM 13

EngineAS3embly ENGINE MECHANICAL
ENGINE ASSEMBLY
PRECAUTIONS
I When installing sliding part such
as bearings
the
be sure to apply engine oil d
on sliding urfaces
2 Use new packings and oil seals
3 Be to follow
sure specified
tightening torque and order
4 Apply sealant to the following
c
points
Do not apply sealant too much
Apply sealant at these points EM152
1 Front side of cylinder lock
Mating surface with front cover and
top of front cover a When in taIling valve apply engine

oil on the valva stem and lip of
4 Front and rear side of cylinder valve oil seal
head b Check whether the valve face i free
Mating surfaces with rubber plug from foreign matter
c Inner and outer valve springs are of
an uneven pitd1 type I nstall valve

Apply sealant
spring with its narrow pitch side
painted at cylinder head id
Painted sid
Narrow
111
c
pitchwWlde Pltch
SEMl58
SEM202
2 Rear side of cylinder block
Each side of rear main bearing cap

2 Make up valve rocker shaft as
and each corner of cylinder block
sembly
Cylinder block Rear main bearing cap Install rocker shaft bracket valve
rocker andspring on valve rocker
ASSEMBUNG shaft observing the following
10 79 O gSI CYLINDER HEAD

I Install valve and valve spring
4iR
Points to be applied with sealant
i
N
I Set valve spring inner and outer
seat and valve oil seal
2 Install valve valve spring inner
and outer valve spring retainer Com

J
Unit mm in press springs and fit valve spring collets

EM151
by using Tool
Oil seal tor 0

Inner spring
faces
cover
Bottom side of cylinder block
Step portions at four
cylinder block to front chain

and cylinder block to rear main
mating sur t1 @
Install above order
Wf
1 Rocker bracket 4
SEM161
Spring
2 Rocker shaft 5 Rocker arm
bearing cap SEM160

3 Bolt
EM 14

ENGINE MECHANICAL Engine Assembly
and the aid of Tool is necessary

I Intake rocker shaft has identifi
cation mark slit on front surface but When pressing piston pin in con
exhaust rocker shaft does not necting rod apply engine oil to pin
e
Plae upside
2 Both rocker shafts should be as and small end of connecting rod
sembled so that punched marks on
front surfaces come to upside Marks

are used to identify oil hole direction
Slits
SEM164
ST13030001
4 Mount valve rocker shaft

assembly
Intake on cylinder head by accommodating SEM156
to knock pin of the head Then tight

en to the specified torque
Front 0 Exhaust SEM162
lil Rocker shaft bracket bolt
b Arrange so that oil jet of connect
15 25 N m
ing rod big end is directed toward
1 5 2 5 kg m
the right side of cylinder block
11 18 ft lb
3 Valve rocker is same for intake
and exhaust and also No 1 and 3
No a Tighten bolts gradually in two to
cylinder and provides identification three stages outwardly from center

mark Similarly the one for No 2
I bracket
and No 4 cylinder provides mark 2 b When tightening bolts make space
4 Be careful not to miss original under cylinder head since some
location of rocker shaft brackets For valves will open and interfered
this purpose identification marks are
provided on each bracket and cylinder t

head
EM151
A Z Marked on cylinder head

c Connecting rods are marked at side
of end for the de

big identifying
signated cylinder
2 Install piston rings
Install so that stamped mark on
Z
ring faces upward
is chromium plated
v a Top ring on
Marked on brackets SEM163

After head liner contacting face
5 assembling Ll1IU r
turn camshaft until No 1 piston is at b Second ring has larger taper surface
TD C than top ring
on its compression stroke
c In the combined oil ring upper rail
is the same as lower one
ASSEMBLING
PISTON AND Marked side
To prevent rocker shaft brackeu
CONNECTING ROD
from slipping out of rocker shafts
insert bracket bolts any bolt will dol

I Assemble pistons piston pins and r
into bolt holes of No 1 and No 5
rocker shaft bracket

connecting rods of the designated cyl
inder 1 101
Piston is pressed into connect
a pin
3 Mount camshaft onto cylinder rod and fitting force is from
ing
head placing dowellpin at front end 4 9 to 14 7 kN 0 5 to 1 5 t 0 6 to
EM158
1 7 US ton 0 49 to 1 48 Imp tonl
to top position
EM 15

Engine Assembly ENGINE MECHANICAL
4
ASSEMBLING Install lower main bearings and 4 Apply sealanl to side oil seals
and tighten bolts to specified
INTAKE MANIFOLD caps Then install those into rear main bear
torque ing cap

Assemhle in the reveorder of
and with the specified l
C Main bearing cap bolt
disassembly
4454 N m
torque if designated
45 5 kg m
Refer to Disassembling Intake
33 40 ft lb
Manifold
a When installing thermostat and its
housing refer t
J Section LC a Apply sealant to each side of rear
b When main bearing caP and each corner
installing emission control
J
of cylinder block Refer to Pre
system parts and fuel system parts n
cautions I
refer to Sections EC and E F respec
tively
b Arrange the parts so that tha arrow I S
f5
EM724
mark on bearing cap faces toward
the front of
engine
c Prior to tightening bearing cap
bolts placo bearing cap in proper 5 Install rear oil seal using Tool
ASSEMBLING position by shifting crankshaft in
ENGINE OVERALL the axial direction

d Tighten bearing cap bolts gradually
INSTALLING BODY PARTS in separating two to three stages
and outwardly from center bearing

1 In the first place mount cylinder
in sequence
block on work stand refer to engine
overall diSassembly
2 Install baffle and steel net @ CD @ J
plate
into crankcase I
3 Install crankshaft
Set SEM166
1 upper main
bearings at the
proper portion of cylinder block
a Only center bearing No 3 is a

a When installing oil seal give coating
flanged type
of engine oil to sealing lip and
b All bearings
inter No 2 and No 4 ill L I mating shaft to prevent scratches
are the same type @ V @ and folded lip Also apply
No coating
c Front bearing 11 is also the
of oil to peripherY of oil seal
same type as rear bearing No 5
b Install oil seal with its dust seal lip
d Upper and After securing bearing cap bolts
lOwer bearings ara not e
at outside
interchangeable Upper ones have ascertain that crankshaft turn
oil groove smoothly

6 Install rear end plate and fly
Front wheel
Rear p Make sure that there exists proper
of crankshaft at center bear
end play l
C Flywheel fixing bolt
III III ill Upper
ing 137
14
157 N
16
m
kg
IT IT I a
m
Crankshaft end play
wwer
Limit 0 3 mm 0 012 in 101 116 ft lb
HS
ga4
1 H3 N2 HI
SEM168
2 Apply engine oil to main bearing

surfaces on both sides of cylinder
block and cap
3 Install crankshaft EM327
EM 16

ENGINE MECHANICAL EngineAssembly
When installing flywheel wipe oil Arrange connecting rods and con
or foreign matter away from fitting necting rod caps so that the cylinder
surfaces numbers face in the same direction
7 Install pistons with connecting

rod
1 Install them into corresponding
cylinder using Tool
J SEM167
SEM169
3 Make
that there exists proper
sure
1 Chain tensioner
EM544 end play at connecting rod big end
2 Slack side chain guide
Refer to Inspection and Repair
3Temion side chain guide
8 Install cylinder head assembly 4 Oil thrower
through gasket by accommodating 5 Oil pump drive gear

a Apply engine oil to sliding parts knock of block 6 Crankshaft sprocket
b
pin cylinder as
Arrange so that the front mark on 7 Timing chain
follows
piston head faces to the front of
1 Thoroughly clean cylinder block 1 Install crankshaft sprocket oil
engine and head surface
Install shown below pump drive gear and oil thrower
c piston ring as
apply sealant to mating

po not sur
a Make sure that the mating marks of
c
Top ring face of cylinder block and head
crankshaft sprocket faces to the
fi Oil ring
front
2 Turn crankshaft until No 1 piston
upper rail
b Install oil pump drive gear so that
J0
is at T D C on its compression stroke
large chamfered inner side faces
3 When
ll Oilring installing cylinder head
rearward
make SUre that all valves
expander are apart
Piston pin direction from head of pistons 2 Install chain guide cylinder
fJ loosen adjusting screws
If necessary
of rocker ann block

to
to draw valves in 3 Set chain on camshaft sprocket

secon 4 and crankshaft sprocket by aligning
Temporarily tighten two center
Oil ring lower ail EM725
bolt each mating mark Then install cam
shaft sprocket to camshaft

CfJ Cylinder head bolt ITemporary
20 N m 2 kg m 14 ft lbl CfJ Camshaft sprocket bolt
2 Install connecting rod bearing 118 157 N m
caps 12 16 m
kg
rod a Final tightening should be carried
CfJ Connecting bearing ClIp nut 87 116ft lb
out after installing chain and front
44 54 N m
cover
14 5 5 5 kg m
b Do not rotate crankshaft and cam
33 40 ft lb
shaft separately because valyes will
hit head of pistons
c Always use new cylinder head
gasket
EM329 SEM170
9 Install front side parts
EM 17

mbly
EngineA ENGINE MECHANICAL
a Set timing chain by aligning its mat e Note that different length of bolts 12 Install valve rocker cover with
ing marks with those of crankshaft are used gasket
sprocket and cemshaft sprocket on bolt
the right hand side
CiJ Front cover
fl Valve rocker cover bolt
Size M8 7 8 9 8 N m
b Camshaft sProcket should be in
10 16 N m 8
0 1 0 m
kg
stalled by accommodating its No 2
1 0 1 6 kg m 5 8 7 2 ft lbl
hole to knock pin of camshaft
7 12 ft bl
a Rocker cover bolts should be
Size M6
No 2 hole tightened in cross
criss fathian
9
3 9 8 N m
b Always use new rocker cover
0 4 1 0 m
kg
saskat
2 9 7 2 ft bl
Install crankshaft 13 Install oil strainer and oil pan with

6 pulley
gasket
fl Crankshaft pulley bolt
118 157 N m fl Oil strainer bolt
112 16 kg m 10 16 N m
87 116 ft lbl 11 0 1 6 m
kg
7 12 ft lbl
Oil pan bolt

10 Tighten cylinder head bolts to the 5 9 9 8 N m
4 Install chain guide and chain ten specifiedtorque in several steps and in 0 6 1 0 kg m
sioner the sequence shown below 43 2 ft lbl

7
fl Chain guide and tensioner bolt a Apply sealant to the designated

5 9 98 N portions Refer to Precautions
0 6 1 0 b Oil pan should be tightened in criss
m 4 3
kg 7 2 ft b
cross pattern
Adjust the protrusion of chain
oil pan
c Always use new gasket
tensioner spindle to 0 mm 0 in with
slack side chain guide

INSTALLING OUTER PARTS
14 Install
following parts in the reo
verse order of
disassembly and with
SEM172 the specified torque if designated
Refer to Disassembling Outer Parts
and S O S for tightening torque
fl Cylinder head bolt I Engine bottom side parts
69 78 N m
When installing oil pump and dis
7 0 8 0 m
kg
tributor driving spindle in front cover
51 58 ft lb
refer to Section LC
2 Engine right side parts

Be to
a sure tighten bolts securing
a Whe installing intake manifold to
cylinder head to front cover
5 Install front cover with gaskets b has been operated for facilitate work previously set the
After engine
observing the following several minutes if securing bolts and nut with wash
retighten neces
at lower and center side as il
a Before installing frontcover press sary ers
new oil seal in the cover with dust lustrated

I I Adjust valve clearance to cold
seal
lip at outside
b specifications referring to Section
Apply alant to the sealing por MA
tions Refer Precau
designated to
tions Valve clearance Cold

c Apply lithium grease to Intake 21
0 mm 0 008 in
sealing lip
of oil seal Exhaust 23
0 mm 0 009 inl
d Check the height difference be At ambient 200C

temperature
tween 680F
cylinder block upper face
and front cover upper face Its dif After engine has been assembled
ference must be less than 0 15 mm
finally adjust clearance to hot speci Temporarily set olts and nut
0 0059 inl fications SEM173
EM 18

ENGINE MECHANICAL EngineAssembly
b When connecting pipes

vacuum re DISMOUNTING ENGINE ENGINE TUNE UP
fer to Section EC FROM WORK STAND 17 Referring Section MA
c When installing oil filter refer to to finally
15 Dismount engine in the reverse
Section LC adjust following items
order of mounting and install engine 1 Drive belts deflection
3 Engine left side parts right side and rear side parts remained 2 Valve clearance
with thespecified torque if designated Warm up engine until water tem
a When installing distributor tern
Refer to Mounting Engine on Work perature indicator points to middle of
porarilv tighten ignition timing ad
just screws at center of adjusting Stand and S s for tightening tor
D gauge then adjust clearance to hot
holes que specifications

b When installing high tension cable When installing clutch assembly Valve clearance IHotl
clamp those as iIIustrat d Tool KV30100100
use Intake 0 30 mm 0 012 in
Exhaust 0 30 mm 0 012 in
16 Fill engine oil and coolant to the
specified level after engine has been 3 Ignition timing
installed on car Refer to Section MA 4 Idle rpm
4 Engine front side parts
EM 19

Setvice Data and Spec fication ENGINE MECHANICAL
SERVICE DATA AND SPECIFICATIONS
Valve seat
Seal insert dimensions
CYLINDER HEAD
Intake Unit mm
in
Cylinder head
Limit
I
Head surface flatness rnm lin 01 10 0041
xL l
I
Q
Valve guIde Unit mm On
I
EXHAUST o
83 8 510 327 0 3551 dia
SEM177
t
r 45
Contacting face angle
310 2
INTAKE Contacting width 18 0 047 0 0711

Stendard 12
Snap ring groove W
r
10 45 097 45 113
Standard
11 7755 776
1
UtO 7 11010 421 0 433
SEM175
Outer diameter 0
Service
45 597
11 1952
45 613
1 1958
intake Exhaust
Exhaust Unit mm in
4 10 6
10 Il 10 4 10 6 I h
10 409 04
11 O 409 0 417
Fir
il V P I I
f iJ J IJ
1 1
c
INTAKE EXHAUST
EM116 SEM118
cr 45
C mtactlng face angle
St8ndari
i Service
Contacting width 07S

O
StaruWd 1 5 1 9 0 059
Valve guide 12 023 12 03412 223 12 234 W
Outer diameter 0 0 4733 0 47381 10 4812 0 48171
40 080 40 096
Valve Standard
guide 115779 1 57861
Inner diameter d 8 000 8 01810 3150 0 31571
Outer diameter 0
Finished size 40 597 40 613
Service
1 5983 t 59891
Cyhnder head valve guide 11 985 11 996 2 85 12 196
hole diameter 8 10 4718 0 4723
1 10 4797 0 4802
essdiameter
Cylinder head seat m Unit mm in
Interference fit of valve

0 027 0 049 0 0011 0 0019
45 000 45 016
I
guide nsen
For standard 11 7717 1 77231
Standard Limit In
45 500 45 516
For service insert
0 020 0053 111913 1 79201
Stem to
clearance
guide Iln 10 0008 0OO21
0 040 0 073
0 1 0 004
For standard insert
40 000 40 016
11 5748 1 5754
I Ex
0 0016 0 0029 EX
40 500 40 516
Stem end deflection 0 2 10 OOSI

I For service insert 11 5945 1 59511
EM 20

ENGINE MECHANICAL Service Dara and Specificstions
Interference fit of seat insert Unit mm in VALVE SPRING
Standard Following data ere common to both intake and exhaust

0 081 0 113
In Unit mm in
10 0032 0 00441
Service
0 064 0 096 I Standard limit
Standard
Ex
0 0025 0 00381
Free I Outer 49 7711 9594
height
Service
0 081
0 0032
0 113
0 00441
I Inner 44 1011 7362
mm N
40 0 226 23 01 40 189119
0 31
Outer kg
Assem 1575 50 7 1 575 42 61
Machining dimensions of seat Unit mm in bled lin lb
height mm N
Intake Exhaust 35 0 87 18 91
tension 35 0 108111 0
Inner Ikg 1 3783 24 31 11 19
3783 61
linllbl
I I Outer 2 2 0 0871
I i Cut 0
Y 90 I o
l square
Inner 19 10 075
r
L41 6
11638
41 8J
1 646 dia
L 374
11 472
37 6
1
1 4801 dia
1
ROCKER ARM AND ROCKER SHA
Unit mm in
SEM179 SEM180
1 I Standard
Rocker
I
arm to shaft
VALVE Unit mm On clearance
I 0 007 0 049 0 0003 0 0019
T CAMSHA AND CAMSHAFT BEARING
H D 1
j Camshaft Unit mm Ii
J Standard Limit
I
M L Outer diameter of cam 32 935 32 955
shaft journal 112967 1 29741
SEM181
Camihaft bend at center
I I Standard Limit
journal Total indicator O to 0 00391
42 0 42 2 readi n91
Valve head
diameter H
I I In
11 654 1 66tl
I Camihaft nd pl 0 2 10 008
38 0 38 2
I I Ex
1496 1 504
Valve length L
iln
122
4 835
8 123 1
4 846
11
I Ex
123 6
14 866
123
4 8781
9
t
l EM871
Valve stem
diameter 0
I I In
Cam height A
In
38 477 38 527
0 25 0 00981
11 5148 1 51681
Ex
Valve fBee angle Camshaft bearing Unit mm tin

45 30
C
Standard Limit
Valve head margin I In 05 10 020

Inner diameter
33 000 33 025
M 112992 1
05 0 020 3002
Cemshaft journal
0 045 0 090
I
Grinding of valve
05 10 020 to bearing clearance 01 10 004
stem end 10 0018 0 0028
Oil clearance
EM 21

Service Datasnd Specifications ENGINE MECHANICAL
CYLINDER BLOCK PISTON PISTON RING AND PISTON PIN
Cylinder block Unit f11m io

Piston Unit rnm in
A 1J 120 10 791
1111
6012
1111 I
0 i
I A
f
P X
Front
V
cr a About 20
Standard
10 791
985
84
3
EM714
85 035
34781
EM422 13 3459
0 50 10 01971 85 465 85 515

Standard limit
Piston diameter A
Oversize 13 3648 3 36671
Surface flatness 0 110 004

1 00 10 03941 85 965 86 015
3 3844 3 38641
Inner 85 000 85 050 Oersize
02 0 0081
diameter 13 3465 3 34841
Out of
Less than Side clearance of piston ring
Cylinder Unit mm Unl
round
bore 0 01510 00061
IX VI
Standard Limit
Less than
Taper A B 0 040 0 073
I
0 01510 00061 Top ring
10 0016 0 00291
Differene in inner dia Less then 0 1 0 0041

02 10 0081 0 030 0 063
I
meter between cylinders 0 05 0 00201 Second ring
0 0012 0 00251
Piston to cylinder 0 025 0045
clearance 10 0010 0 00181

I Oil ring
Feeler gauge ex
tracting force N
20 14 710 2 Ring gap Unit mm in
with gauge kg 15 04 3 31
thickness 0 04 Ib
mrn 0 0016 in 1 Standard Limit
0 25 0 40
Wear limit
I Top ring 10 0098
0 15
01571
0
0 30
Second 1 0 10 0391
ring 10 0059 0 01181
0 30 0 90
Oil ring 10 0118 0 03541
Cylinder liner for s Piston pin

Unit mmlin
Unit mm in
Standard
40 10 1571 89 00 89 05
Undersize 13 5039 3 5059 Piston pin outside
I
di
20 993 20 998 0 8265 0 82671
meter
45 0 1711 89 50 89 55
Outside diameter
Undersize 13 5236 3 6256 Piston pin hole diameter 21 001 21 008 10 8268 0 82711
5 010 1971 90 00 90 05 Piston pin to piston

Undersize 13 5433
0 08
3 54531
0 09
I c lea ance
Interference fit of
0 006 0 01310 0002 0 00051
piston
Interference fit of cylinder liner
0 0031 0 0035
I pin to c onnecting rod
0 015 0 035 10 0006 0 oot41
EM 22

ENGINE MECHANICAL ServiceOataandSpecifications
CONNECTING ROD BEARING

Unit mm in
Bearing clearence Unit mm in
1 Standard Limit
Connecting rod bend or

I Standard Limit
torsion per 100 mrn 0 03 0 00121 0 05 10 00201 0 020 0 062

3 94 inllength
I Main bearing clearance
0 0008 0 0024
0 1210 00471
02 03 rod 0 0 055
I Connecting beeting 025

Bid end plev
0 008 0 0121
0 6 0 0241
I clearance 0 001 0 0 00221

0 12 0 00471
Main bearing undersize Unit mm in
CRANKSHAFT
Unit mm lin
a
A
I
t1b S
Bearing top
thickness T
Cran k
diameter
EM738
jou rnal
I
8 1822 1835 54 942 54 955
STD
10 0717 0 0722 12 1631 2 1636
EM790
1 947 1 960 54 692 54 705
I
I Journal diameter
Pin diameter B
A 54
49 961
942 54 955 2 1631
49 974 19670
2 16361
1 96751
I 0 25 10 00981 Undersize
0 0767 0 07721 2 1532 2 15371
2 072 2 085 54 442 455

54
I S 42 97 43 0311 6917 169411 I 0 50 0 01971 Undersize

I 0 0816 0 08211 2 1434 2 14391
2 197 2 210 54 192 54 205
Taper
of
Out round X V
B
A
I 0 0865 0 08701 12 1335 2 13411
8 2 322 2 335 53 942 53 955
1 I
A
00 0 0394 Undersize
0 0914 0 09191 2 1237 2 12421
o EM715
Connecting rod bearing undersize

Standard Limit Unit rnm Onl
Taper of journal and Crankpin

J I
Less than Bearing top
I pin A S O Of 0 00041
003 0 00121
I
thickness T ciiameter
I
of round of Journal less than 493
1 1 506 49 961 49 974
IOut and pin X Y 001 0 00041

0 03 10 00121
I STD
0 0588 0 05931 0 9670 1 9675
Crankshaft bend Total 1 618 1 631 49 711 49 724
I
Less than
I indicator reeding 0 05 0 00201

0 10 0 00391
10 0637 0 06421 1 9571 1 95761
0 05 O lB 1 743 1 756 49 461 474

49
I Crenksheft free end plav

10 0020 0 00711
03 10 0121
0 0686 0 06911 t 9473 194791
Pilot bushing inserting 1868 1881 49 211 49 224
I distance
40 0 1571
I 0 7510 02951 UDdersize
0 0735 0 07411 1 9374 193791
EM 23

Service DatallndSpecifications ENGINE MECHANICAL
MISCELLANEOUSCOMPONENH Engine left side
Camshaft sprocket Unit N m

m
kQ ft lb
Runaut Total indf

I 08
I
Distributor support bolt 3 9 78 4
0 2 9 58
mm in Limit Q 1 0 004
cator readingl
Exhaust manifold bolt
Flywheel
I and nut
16 21 1 6 2 1 12 15
I E G R tube nut 34 44 35 4 5 25 33
Runout frotsl iodi
I cator reading
mm in Limit 0 15 10 0059
I E A I
Air
tube nut
conditioner cern
34 44 35 45 25 33
I pressor bracket bolt

44 54 45 55 33 40
ENGINE TUNE UP
Engine top side
Valve clearance Unit mm in
1 Hot Cald I Cylinder head bolt 69 78 70 80 51 58
head to front
Cylinder
I Intake 0 3010 012 0 21 0 008
I COYer bolt
3 9 78 4 08
0 29 58
I Exhaust 0 30 10 012 0 23 0 009

I Rocker shaft bracket bott 15 25 1 5 2 5 11 18
At ambient temperature 200C 168 F
Whenever valve clearances areadjusted to cold specific tions

I Camshaftsprocket bolt 118 157 12 16 87 116
98 08 1 0 58 72
check thd the clearances satisfy hot specifications and edjust again I Rocker cover bolt 7 8
if necessary
11 14
I Spark plug 15 20 1 5 20
16 22 1 6 22 12 16
I Rocker arm nut
TIGHTENING TORQUE
Engine bottom side
Engine front side
Unit N m m
kg ft lb I Min bearing cap bolt 44 54 45 5 5 33 40
Connecting rod big end

Front cover bolt
M8 10 16 1 0 1 6 7 12 I nut
4454 45 5 5 33 40
M6 3 9 9 8 04 1 0 2 9 7 2 t Oil strainer bolt 10 16 10 1 6 7 12
Oil pan bolt 59 98 06 1 0 43 7 2

I Chain guide bolt 5 9 98 06 1 0 43 72
20 29 20 3 0 14 22
Oil pan drain plug
I Chain tensionetr bolt 5 9 9 8 06 1 0 43 7
Oil pump bolt 11 15 1 1 5 8 11

Water pump bolt
M6 3 9 98 04 10 29 7 2
Gusset to cylinder block
43 58 44 5 9 32 43
bolt
M8 10 16 1 01 6 7 12
Crankshaft pulley bolt 118 157 12 16 87 116

Engine rear side
Engine right side I Flywheel bolt TI

M 137 157 14 0 t6 0 101 116
116
I Water inlet bolt 10 16 1 0 1 6 7 12 I Drive plate bolt Arr 137 157 14 0 16 0 101
12 15
I Water outlet bolt 10 16 1 0 1 6 7 12 1 Clutch cover bolt T
M 16 21 16 2 1
Intake manifold bolt and Torque converter bolt

39 49 40 50 29 36
I nut
16 21 1 6 2 1 12 15
AfT
39 3 0 4 0 22 29
I Alternator bracket bolt 39 59 40 60 29 43 Starter motor bolt 29
Transmission to cylinder
Alternator to adjusting 58 44 5 9 32 43
I 14 43
20 29 20 3 0 22 block
bar bolt bolt
ransmission to gUet
IT
Engine mounting bracket 44 43
I 3 0 40 22 43 58 59 32
29 39 29 bolt
bo1t Same fot left side
EM 24

ENGINE MECHANICAL Trouble Diagnoses and Corrections
TROUBLE DIAGNOSES AND CORRECTIONS
I Noisy engine
Piston and connecting Seized piston pin Replace piston with pin
rod knocking
Seized piston in cylinder Recondition cylinder and replace piston
with pin
Broken piston ring Replace ring and or recondition cylinder
Realign rod replace rod

Improper connecting rod alignment or
Seized or loose connecting rod bearing Replace
Knocking of crank Seized or loose main bearing Replace

shaft and hearing Bent crankshaft replace
Repair or
Uneven wear of journal Correct
Excessive crankshaft end play Replace center bearing
Timing chain noise Improper chain tension Adjust

Worn and or damaged chain Replace
Worn sprocket Replace
Worn and or broken chain guide and or Replace

tension mechanism
adjusting
Camshaft and valve Improper valve clearance Adjust

mechanism knocking Worn rocker bearing Replace
Worn rocker face Replace
Loose valve stem in guide Replace guide
Weakened valve spring Replace
Seized valve Replace
Camshaft knocking Excessive camshaft bearing clearance Replace

Excessive axial play Replace thrust plate
Wom earn gear Replace
Water pump knocking Improper shaft end play Replace water pump assembly
Broken impeller Replace water pump assembly
II Other mechanical troubles
Stuck valve Improper valve clearance Adjust

Insufficient clearance between valve stem Clean stem or ream guide
and guide
Weakened or broken valve spring Replace
Seized or damaged valve stem Replace or clean
Poor quality fuel Use good fuel
EM 25

TroubleDiagnosessndCorrections ENGINE MECHANICAL
Probable cause Corrective action

Condition
Seized valve seat Improper valve clearance Adjust
Weakened valve spring Replace

Thin valve head edge Replace valve
Narrow valve seat Reface
Overheating Repair or replace
Over speeding Drive at proper speed

Stuck valve guide Repair
Shortage of engine oil Add or replace oil

Excessively worn
cylinder and piston Dirty engine oil Clean crankcase replace oil and oil filter
element
Use proper oil

Poor quality ofoil
Overheating Repair or replace
Wrong assembly of piston with connecting Repair or replace

rod
Improper piston ring clearance Adjust

Broken piston ring Replace
air cleaner Clean

Dirty
Mixture too rich Adjust
over run Drive at proper speeds

Engine
Stuck choke valve Clean and adjust
Start correct way

Overchoking
Add oil
Faulty connecting Shortage of engine oil
rod low oil pressure Correct
Poor quality engine oil Use proper oil
surface of crankshaft Grind and replace bearing

Rough
oil passage Clean
Clogged
Bearing worn or eccentric Replace
Bearing improperly assembled Correct
loose bearing Replace

Incorrect connecting rod alignment Repair or replace
Faulty crankshaft Shortage of engine oil Add or replace

bearing low oil pressure Correct
Poor oil Use specified oil

quality engine
Crankshaft journal worn or of
out round Repair
in crankshaft Clean
Clogged oil pasSage
Bearing worn or eccentric Replace
Correct
Bearing improperly assembled
crankshaft
Eccentri or bearing Replace
EM 26
ENGINE MECHANICAL Special Service Tools
Tool number
Tool name
Kent Moore No
KV30 100 100 Clutch aligning bar
KVlO105001 Engine attachment
ST050lS000 Engine stand assembly

126023
CD ST050l1000 Engine stand
126023 2
CVST05012000 Base
126023 1

Special Service Tools ENGINE MECHANICAL
Tool number
Tool name
Kent Moore No
KVIOlO39SO Valve guide reamer set
125618
D STlI08l000 Reamer
125618 3 12 2 mm 0 480 in dia
@ STlI032000 Reamer D
125618 2 8 0 mm 315
0 in dia
@ STl1320000 Drift
@
125618 1
@
STl165000 I Valve seat cutter set
STl6610001 Pilot bushing puller

123907
KVlOI05500 Crankshaft rear oil seal

01
125640 drift
EM03470000 Piston ring compressor
EM 28

SECTION
LC
ENGINE LUBRICATION
COOLING SYSTEMS
CONTENTS
TEM COUPLlNG LC 7
ENGINE LUBRICATION SYSTEM LC 2
LUBRICATION CIRCUIT LC 2 SERVICE DATA AND

01 L PUMP LC 3 SPECIFICATIONS LC 8
GENERAL SPECIFICATIONS LC 8
OIL PRESSURE REGULATOR VALVE LC 4
LC 4 INSPECTION AND ADJUSTMENT LC 8

OIL FILTER
OIL PRESSURE RELIEF VALVE LC 4 TIGHTENING TORQUE LC 8
COOLING SYSTEM LC 5 TROUBLE DIAGNOSES AND

COOLING CIRCUIT LC 5 CORRECTIONS LC 9
LUBRICATION SYSTEM LC 9
RADIATOR LC 6
COOLING SYSTEM LC 9
THERMOSTAT LC 6
WATER PUMP LC 7 SPECIAL SERVICE TOOL LC 10

Engine LubriCstion System ENGINE LUBRICATION COOLING SYSTEMS
ENGINE LUBRICATION SYSTEM
LUBRICATION CIRCUIT
SLC021
j Oil pan
I
Oil gallery in
cylinder block Oil strainer
I
I
By pass passage
Oil pump
I Regulator valve
I
Intermittently
oiling portion j Pump drive gear
r
Oil passage Oil filter
I Relief valve
I
l
Main Cylinder head
aring
f I oil gallery
I
I Con ecting rod
bearing II Oil J et
II Chain tensioner
I I Center earn bracket
I
I Connecting rod
II Timing chain
I Rocker shaft
I
I A
Rocker arm
Piston Pin pis Cam bracket
l ton and cylinder
I
I t j t
Timing chain
Cam surface
I Camshaft bearing I I and front cover
I
S LC022
LC 2

ENGINE LUBRICATION COOLING SYSTEMS Engine Lubrication System
bolt
OIL PUMP lfJ Oil pump cover
6 9 9 8 N m
0 7 1 0 kgm
REMOVAL
5 1 7 2 ft lb
1 Remove distributor cap
2 Turn crankshaft so that No 1

41 Punch mark Always replace with a
a new gasket
piston is at T D C its
compression
on
b Outer rotor should be assembled so
Oil hole
stroke by ascertaining the position of
th at the chamfered side faces to oil
distributor head rotor and timing mark
pump body
crank
on pulley
Remember position of he rotor E L009
under above condition
California models 3 Using a new gasket install oil
J ii9
pump and drive spindle assembly
Front
SLC025
SLC074
Califomia
Non models
4 that the INSPECTION

Make sure tip of the drive
spindle fits distributor fitting hole 1 Inspect the following for wear or
securely damage
5 Tighten bolts securing oil pump to
Front Pump body and cover
front cover Pump rotors and rotor shaft
Oil pump 2 Using a feeler gauge check the
lfJ mounting bolts
11 15 N m Ying
follo Clearances
111 1 5 kg m Wear limit

8 11 ft lb Rotor tip clearance CD
0 20 mm 0 0079 in
6 Install distributor cap Outer rotor to
body clearance V
0 50 mm 0 020 in
DISASSEMBLY AND
3 Remove oHpump body with drive
ASSEMBLY
spindle assembly
INSTALLATION
I Make sure that distributor head

@ 1 @1 LC026
EL032 I
rotor is in the same position as it was
before removal of oil pump 1 Oil pump body 5 Oil pump cover
2 Outer rotor 6 Regulator valve

2 Fill pump housing with engine oil 3 Using a feeler gauge and a straight
3 Inner rotor and 7 Regulator spring
then align punch mark of drive spindle
shaft 8 Regulator cap edge check the following gap @ or
with hole in oil pump 4 Gasket @ without gasket
LC 3

EngineLubricationSystem ENGINE LUBRICATION COOLING SYS1 EMS
Rotor to straight edge @ OIL PRESSURE

Less than
REGULATOR VALVE
0 06 mm 0 0024 in
Oi pump body to
straight edge @
Less than INSPECTION
0 03 mm 0 0012 in
Check valve sliding surface and
valve spring and replace entire valve
Then rotor side clearance rotor to
assembly if necessary
bottoni cover clearance with gasket
should satisfy the following specifica
tion S lC028
Wear limit
Rotor side clearance
0 20 mm 0 0079 in OIL PRESSURE
RELIEF VALVE
INSPECTION
With oil f1lter rellloved check valve

E L076
unit for operation Inspect for a
cracked or broken valve If replace
Ilent is necessary remove valve by

prying it out with a screwdriver InstaII
a new valve in place by tapping it
N
S LC027
OIL FILTER
REMOVAL AND
INSTALLATION
Pump
serviced
rotors
separately
body are damaged
and body are
If pump rotors or
or worn
not
replace
When removing oil f1lter
When installing it lightly
oil seal and fasten it by hand
use Tool
coat oil on a
pump rotor set or entire oil pump as Do not overtighten filter or oil
sembly leakage may occur 5 LC029
LC4

ENGINE LUBRICATION COOLING SYSTEMS Cooling System
COOLING SYSTEM
COOLING CIRCUIT
Radiator to water pump
o Water pump to cylinder block and heater core
Cylinder block to cylinder head
1 Cylinder head to intake manifold
Thermostat to radiator
Radiator to reservoir tank
5 LC030
WARNING
To avoid serious peRonal injury
never remove I
Idiator
Radiator cap cap quickly
F Reservoir tank
when engine is hot Sudden release
of cooling system pressure is very
t dal1llerous
Radiator Thermostat If it is necessary to remove Iadiator
A cap when Iadiator is hot turn cap

L slowly counterclockwise to the fillt
stop After all pressure in the coo
Water pump
ing system is released turn cap
passing the stop and remove it
Cylinder block
H Heater
I J Thermostat housing
t
f
Cylinder head
l Intake manifold
SLC031
LC5
Cooling System ENGINE LUBRICATION COOLING SYSTEMS
RADIATOR Inspection ofradiator cap

THERMOSTAT
First check rubber seal cap for
on
REMOVAL AND tears cracks or deterioration after

REMOVAL AND
INSTALLATION cleaning it Then install radiator INSTALLATION
cap on a tester If cap does not hold or
I Drain coolant into a clean con 1 When removing drain coolant
will not release at the
tainer specified pres
partially and disconnect upper radiator
sure replace cap
2 Remove air cleaner inlet pipe hose at water outlet
3 Remove air duct with bracket Cap relief pressure 2 Install thennostat and water out
88 kPa
after loosening clamps and screws at 0 9 kg cm2 13 psi let as illustrated
portion illustrated
ET012 SLC033
1 Jiggle valve 3 Gasket

2 Thermostat 4 Water outlet
4 Disconnect radiator upper and 2 Inspection of water leakage

lower hoses and reservoir tank hose With radiator cap removed apply INSPECTION
5 Remove radiator shroud attach test pressure to radiator on a car
Inspect thennostat for the follow
ing screws and place radiator shroud If leakage is detected repair or
ing and replace if necesS3l
close to engine Radiator shroud can replace radiator I Valve seating condition at ordi
be removed after removing radiator
Leakage test pressure nary temperature It should seat
6 On a car with automatic transmis 157 kPa 1 6 kg cm2 tightly
sian disconnect cooler inlet and outlet
23psil 2 Valve opening temperature and
lines from radiator
maximum valve lift Refer to SDS
7 Remove radiator
8 Install radiator in the reverse se
quence of removal and refill cooling
i
system with coolant to specified level
Refer to Section MA
INSPECTION
Inspect radiator cap and water
y
I
SLC037
VJj
leakage using cap tester
SLC034
3 Then check if valve closes at SOC

90F below valve opening tempera
ture
It is necessary to check a new ther
mostat before installing it in engine
6
LC

ENGINE LUBRICATION COOLING SYSTEMS Cooling System
WATER PUMP cf N m kg ln ft Ib
Belt dcllcction mm in fN kg Ib
DISASSEMBLY
Water pump is made of aluminum 7
@ M6 3 9 9 810 4 1 0 2 9 21
and its bearing outer race is of a press M8 10 16 10 16 7 121
fit type For this reason water pump

should not be disassembled
INSPECTION
a 1210 31 0 47 98 10 22
Inspect pump assembly for the
following conditions and replace if Pump gasket
necessary Always replace
I Badly rusted or corroded body
assembly and vane

fan
pump with
Water
2 Excessive end play or roughness coupling
of bearings in operation
If excessive mechanical seal squeak Fan belt

occurs when engine is running use
suitable water pump seal lubricant to

SLC035
prevent squeak
TEM COUPLlNG
DISASSEMBLY
The coupling is so designed that it
cannot be disassembled
INSPECTION
Inspect the coupling for oil leakage

or bend of bimetal If necessary reo
place as a pump assemhly
C0077
1 Bi metal thermostat 4 Bearing

2 Slide valve 5 Driving chamber for ON
3 ReseIVe chamber for QFF 6 Coupling part Labyrinth
Le
r
ENGINE LUBRICATION COOLING SYSTEMS

ServiceDataandSpecifications
GENERAL SPECIFICATIONS RADIATOR
I Oil pump
Trochoid type
CaP relief pressure kPa kg cm2 psi 88 0 9 13
Leakage Ikg cm2 psi

I Oil filter Full flow and cartridge type
test pressure kPa 157 116 231
Oil pressure relief valve

8
59 13 6
Valve
opening pressure
0 60 0 75 8 5 10 7
kPa kg cm2 psH THERMOSTAT
Down flow corrugated fin
I Redietor
and tube type 1
Valve opening tom
Standard Frigid type Tropical type
I Thermostat
I Water pump
Wax type
Centrifugal type
I perature oC OF 1801
82 8811901 76 170
Max valve lift 8 95 8 100
coupling
Tem
Fen speed at water 2 150 60 1401

I mm oC Un oF I 10 31 203 10 31 212
8 90
3t
O 194
pump
speed 4000 rpm Less than 1 650lbelow 50 122
rp oC OF
WATER PUMP
I
Fan belt deflection
INSPECTION AND ADJUSTMENT mm lin N Ikg Ibl I 8 12 10 31 0 98 10 221

471
OIL PUMP Unit mm in
1 Standard Wear limit
Less then
Rotor tip clearance 0 20 10 0079
0 12 0 00471
Outer rotor body

to 0 15 0 21
clearance 10 0059 llO831
0
I 0 50 0 197
I
Rotor side clearance 004 0 08
rotor to bottom cover 0 0016 0 00311
I 0 20 1 00079
OIL PRESSURE REGULATOR VALVE TIGHTENING TORQUE

Unit N m ft lb
Free m
kg
length
52 5 2 0671
jn
mm Oil pump 11 15 1 5
1 8 11
mounting bolu
Re ulator
valve
spring
Installed lengthl
loed 8 1
34 77
3701 5 85 3
I Oil pump cover bolts 69 8
9 0 7 1 0 5 1 72
mm in N 7 9 8 7 174 19 21 Regulator valve cap 39 49 4 5 29 36

Ikg lbl
Water pump securing
Regulator valve opening bolt
343 412
pressure M6 39 8
9 04 1 0 29 72
13 5 4 2 50 601 3 000
kPa kg cm2 psi rpm Me 10 16 10 16 7 12
8
LC

ENGINE LUBRICATION COOLING SYSTEMS Trouble Diagnoses and Corrections
LUBRICATION SYSTEM
Oil leakage Damaged or cracked pump body cover Replace

Oil leakage from gasket and oil seal Replace
Oil leakage from regulator valve Tighten or
replace
Oil leakage from blind plug Replace
Decreased oil Lack of oil in engine oil pan G orrect

pressure Clean
Dirty oil strainer or replace
Damaged or worn
pump rotors Replace
Malfunctioning regulator Replace

Use of poor quality engine oil Replace
Warning light Decreased oil pressure Previously mentioned

remains on
Oil pressure switch unserviceable Replace
engine running
Electrical fault Check circuit
Noise Excessive backlash in pump rotors Replace
COOLING SYSTEM
Water Damaged radiator seams Repair

leakage
Leaks from heater connections or plugs Repair
Leak from water pump shaft seal Replace as pump assembly
Leak from water temperature gauge Tighten

Leaks from gaskets or small cracks Tighten or use Nissan Cooling System Sealer
or equivalent
Loose joints Tighten
Damaged cylinder head gasket Replace
Check engine oil for contamination and refill
as necessary
Water leakage Cracked cylinder block Replace

Check engine oil in crankcase fonnixing
with water by pulling oil level gauge
Cracked cylinder head Replace

Loose cylinder head bolts Tighten
LC 9

Special Service Tool ENGINE LUBRICATION COOLING SYSTEMS
Condition Probable cause C arrective action
Poor circulation Restriction in system Check hoses for crimps and clear the system
of rust and sludge by flushing radiator
Insufficient coolant Replenish

Inoperative water pump Replace
Inoperative thennostat Replace
Corrosion Excessive impurity in water Use soft clean water rain water is satis
factory
Infrequent flushing and draining of system Cooling system should be drained and flush
ed thoroughly at least twice a year Perma
nent antifreeze Ethylene glycol base can
be used throughout the seasons of a year
Overheating Malfunctioning thennostat radiator cap and Replace

fan coupling
Radiator fm choked with mud chaff etc Clean out air passage thoroughly by using air
pressure from engine side of radiator

Incorrect ignition and valve timing
Adjust
Dirty oil and sludge in engine Refill
Inoperative water pump Replace

Restricted radiator Flush radiator
Inaccurate temperature gauge Replace

in water
Impurity Use soft clean water
Overcooling Malfunctioning thennostat Replace

Inaccurate temperature gauge Replace
Noise Squeak at water pump mechanical seal Use suitable water pump seal lubricant or
replace as pump assembly
Damaged or worn water pump bearing Replace as pump aSsembly
Tool number
Tool name
Kent Moore No
STl9320oo0 Oil filter wrench

125664
00
LC l0

SECTIONEF
ENGINE FUEL
CONTENTS
DESCRIPTION EF 2 DESCRIPTION EF 24
EFI SYSTEM EF 4 PREPARATIONS FOR INSPECTION EF 24
EF 4 INSPECTION EF 24
FEATURES
EFI SYSTEM OPERATION EF 4 INSPECTION PROCEDURE TABLE EF 25
EF 4 EFI CIRCUIT DIAGRAM EF 28

FUEL FLOW SYSTEM
FLOW SYSTEM EF 5 COMPONENT PARTS INSPECTION EF 29
AIR
EF 5 FUEL PRESSURE CHECK EF 29
ELECTRICAL FLOW SYSTEM
EF 7 FUE L PUMP EF 29
FUEL TION
INJEC CONTROL
EF 7 FUEL DAMPER EF 29
FUEL INJECTION TIMING
EF 7 FUEL FILTER EF 29
FUEL INJECTION QUANTITY
INJECTOR EF 29
EFI SYSTEM COMPONENT PARTS
EF 11 PRESSURE REGULATOR EF 30
CONSTRUCTION AND FUNCTION
EF 11 AIR FLOW METER EF 30
FUEL FLOW SYSTEM
EF 30
AIR FLOW SYSTEM EF 13 AIR TEMPERATURE SENSOR
EF 15 AIR REGULATOR EF 31
ELECTRICAL SIGNAL SYSTEM
THROTTLE CHAMBER EF 31
PRECAUTIONS FOR AN EFI
EF 18 DASH POT EF 31
ENGINE
EF 19 WATER TEMPERATURE SENSOR EF 32
REMOVAL AND INSTALLATION
EF 19 EF 32
INJECTOR AND FUEL PIPE THROTTLE VALVE SWITCH
EF 20 EF 33
PRESSURE REGULATOR VACUUM SWITCH
EF 20 SENSOR EF 33
AIR REGULATOR ALTITUDE
EF 20 EF 33
WATER TEMPERATURE SENSOR DROPPING RESISTOR
EF 20 EF 34
THROTTLE VALVE SWITCH RELAY
EF 20 EF 34
THROTTLE CHAMBER CONTROL UNIT
DASH POT EF 21 CHECKING AIR LEAKAGE IN
EF 21 AIR INTAKE SYSTEM EF 35

VACUUM SWITCH
EF 21 FUEL HOSES EF 35
ALTITUDE SENSOR CHECKING
DROPPING RESISTOR EF 21 SERVICE DATA AND
EF 21 SPECIFICATIONS EF 36
CONTROL UNIT
EF 22 EF 36
RELAY GENERAL SPECIFICATIONS
EF 22 EF 36
AIR CLEANER INSPECTION AND ADJUSTMENT
EF 22 EF 36
AIR FLOW METER TIGHTENING TORQUE
EF 22
AIR TEMPERATURE SENSOR TROUBLE DIAGNOSES AND
EF 22 EF 37
FUEL FILTER CORRECTIONS
FUEL PUMP AND FUEL DAMPER EF 23 TROUBLE SHOOTING CHART EF 37
23
F CHECKING AND ADJUSTING IDLE RPM
FUEL HOSE
ELECTRICAL SYSTEM INSPECTION EF 24 IGNITION TIMING AND MIXTURE
RATIO EF 43

Description ENGINE FUEL
DESCRIPTION
SYSTEM DIAGRAM
fUEL UNE
VACUUM LINE
INPUT SIGNAL
OUTPUT SIGNAL
f Fuel tank
i
I
r
J
ili
Fuelmter
t essure regulatm h
Fuel pump
cu witch California modelA

L
Air valve
Switching module
inducti
ln
Air cleaner
Idle speed adjus ing screw

i
dlJ
Ji t
r
Ai
nwmei
Air pipe
r
0
L b y
I
1r fj
Air temperature
pall semOl
ew
EA
tube
Oil pressure
switch
1 II I c
J
a
8j 8
ON
1ST
I s
lliru
IC
J
I
Fuel pump relay
U
Ignition coil
0
Ih
Ignition switch
lt1
Control unit
California models
q
SEF081
EF 2

I
TC
Ci
i
II
0
i0i
pump pex
yuel aIn
d
fue
oor
5en
model
AltiudeCalifornia unit
contro
A
I
f tot
tes1
wltchmodels
l iforni
Drop ing or
Vacu m
n
ternpetaW
re
ltCl 11
A MI
Perature
tem
Wate sensot

EFI System Openltion ENGINE FUEL
EFI SYSTEM FEATURES

into electronic
operating conditions
The EFl system utilizes electronic
The Electronic Fuel Injection EFI signals These signals are sent to the
supply unit where the optimum in elements such as integrated circuits

system is used to control fuel control
ICs resistors thennistors etc for
electrically place of the
in conven jector open valve time period is com
to the infonnation electrically controlling the amount of

tional carburetor system puted according
The EFl system employs various stored in the memorY for control of fuel injected corresponding to changes
types of sensors to convert the engine fuel injection quantity in engine operations Because of this
use of electronic components this
system is able to provide a quick

For detecting engine operation response to changes in operating con
Various sensors
I ditions and serves to improve the
1 Electrical signal
engine perfonnance and to reduce
Control unit
I For calculating optimum fuel injecti on fuel consumption and hannful gases
Electrical signal
Injector I For injecting fuel
EFISYSTEM OPERATION
FUEL FLOW SYSTEM

Fuel is sucked from the fuel tank
into the fuel pump from which it is
discharged under pressure As it flows

through the mechanical fuel damper
pulsation in the fuel flow is damped
Then the fuel is filtered in the fuel
filter goes through the fuel line and is
injected into the intake manifold cyl

inder branch from the injector
Surplus fuel is led through the pres
sure regulator and is returned to the
fuel tank The pressure regulator con
trois the injection pressure in such a
un
manner the pressure difference
that J
between the fuel pressure and the in

take manifold vacuum is
kPa 55
2 kg cm 3 psi
36
always 250
J
n
L r
D
SEFQ83
4
EF

ENGINE FUEL EFISystemOperation
AI R FLOW SYSTEM
Intake air from the air cleaner is
metered at the air flow meter flows

Idle speed
through the throttle chamber and into adjusting Air cleaner
screw
the intake manifold and then flows 11 R A
0
through each intake manifold branch AirflOwm ter f
into the cylinder Air flow during LA S unit
i
driving is controlled by the throttle Throttle I
valve located in the throttle chamber chamber
L
During idling operation the throttle
Air pipe LAir by pass
valve is in the almost closed position screw
and the air is led through the by pass

line between air pipe and throttle
chamber In this case the quantity of

suction air is adjusted by means of the
idle speed adjusting screw During
warming up operation the air flow is
bypassed through the air regulator to SEF084
increase engine rpm
respondence with the present air injector open valve time period The
ELECTRICAL FLOW
flow In the EFI control unit of the EFI system deter
system the injection
SYSTEM
pressure is held constant at 250 kPa mines this pulse width duration ac
The suction air flow varies with the 55

2 kg cm2 3 psi and the area
36 cording to information electrical sig
movement of the air flow meter and of the injector noule hole is also con nals from various
types of sensors
the quantity of fuel to be injected stant Therefore the fuel injection thereby controlling the fuel injection
should be controlled correctly in cor quantity can be determined by the quantity
l 11 I
Vacuum switch California models
Switching module
L
Injector
Air flOW
Air Air temperature

by pass
sensor
f
screw
s Control unit
SEF085
EF 5

EFI SystemOperation ENGINE FUEL
SIGNALS FOR CONTROl

UNIT
the duration of the pulse computed in
An electrical signal from each sen for computation The open vaIve tiJUe
is introduced into the control unit the control unit
sor period of the injector is controlled by
Temperature of cooling
I water
WATER TEMPERA11JRE
I SENSOR I
Opening of L TIlROITLE VLAVE
I H TempctalUIel
AIR TEMPERATURE
throttle valve SWITCH of mtake air
SENSOR
IGNmON COIL
IGNITION Starting
I Engme rpm
H NEGATIVE
TERMINAL SWITCHH
START position operation
take
VACUUM SWITCH
California models
HI vacuum
manifOldl
Quantity of AIR FLOW
intake air H METER
Atmospheric
INJECTOR
ALTITUDE SENSOR
California modet
H preuure I
SEF169
Rotation of the is detected

INDEPENDENT SIGNALS OF
When starting the engine the fuel engine
the
CONTRDL UNIT pump operated by the current
is by monitoring both generation
supplied through fuel pump relays of the alternator and the engine oil
Fuel pump operation moni
2 and 1 After the engine starts pressure Because of this dual
the fuel pump continues to operate toring system fuel pump operation
IGNrIlON SWITCH IGNITION SWITCH
be assured rota
START IG
using current supplied from fuel can during engine
tion even if one of these monitor
pump relay 2 monitoring the en
units should fail

gine revolution and fuel pump reo
ENGINE REVOLUTION
If the engine stalls completely due
lay 1
ALTERNATOR OIL rRf5SURE
to a malfunction the offuel
I l TERMINAL
II SWITCH
I If the engine stalls for
fuel pump relay 2 receives the en
some reason
is stopped
supply
at once this system iJU
r gine stall signal and stops feeding proves safety in case of engine mal
FUEL pU
lp ULAY
I current thereby stopping the opera function
tion of the fuel pump
FUEL PlJlIP RELAY
I
fUEL PUMP
I EF37
1
EF 6
ENGINE FUEL Fuel Injection Control
FUEL INJECTION CONTROL
FUEL INJECTION TIMING as the basis for providing engine rota
tion but the is not controlled

injector
Crank angle by this factor alone For example the
o
8400 fuel should be enriched when starting
Cylinder 1200 2400 3600 4800 6000 7200
v
the engine or in the full throttle posi
10
I
I 1k tion For providing this enrichment
the control unit computes the quan
f 1 tity of fuel to be added to the basic

injection quantity by using signals
I l sent from each sensor It causes the
I m total quantity of fuel to be injected

4
I 71 i
c Warm up enrichment
Start of injection fJ Ignition point Intake valve opens
Fuel is increased according to the
SEF086
cooling water temperature monitored
by the water temperature sensor This
enrichment is zero when the cooling
water temperature is above 40 to 600C

104 to l400F
The engine repetitive four
has a FUEL INJECTION Enrichment ratio is changed by
stroke cycle compression
suction 4 ON or OFF of idle contact
QUANTITY
combustion exhaust Fuel injection
The fuel is the
is made just prior 10 the beginning of injection quantity
sum of the basic injection quantity Intake air temperature
the suction stroke in each cylinder
which is the basis of the injection enrichment
However this situation is not the
enrichment Ihat is
quantity and the
same for the EFI system Fuel injection is increased accord
The fuel injectors are electrically
used to correct the basic injection
ing to the intake air moni
temperature
in in the control quantity in correspondence with the
connected parallel tored by the
air temperature sensor
various conditions
unit All injectors receive the injection This enrichmen I is zero when the
signal from the control unit simul Fuel Basic
intake air temperature is above 400C
taneously Therefore injection is made Enrich 104OF
injection injection
independently of the engine stroke ment
quantity quantity
cycle suction compression combus
tion and exhaust In the cylin
four Cold start enrichment
der engine injeCtion is made once Cold start enrichment
providedes
after receiving the ignition signal from BASIC INJECTION improved ability in cold
starting
the ignition coil two times weather with the ignition switch on
QUANTITY
The required fuel quantity is at START during the cranking opera
The engine rpm infonnation
tained after fuel injection is made tion and when the water temperature
and load state information are
twice during one stroke cycle suction is lower than 400C 1040F The
created by two signals which pro
compression combustion exhaust In vide for the rolation of the engine elapsed time and amount of this en
other words one injection of fuel richment is detennined by the water

One of these two signals is sent out
provides only half the fuel quantity from the ignition coil that detects the temperature and cranking speed
necessary for operation of one stroke
engine rpms The other one is the
cycle of the engine signal sent from the air flow meter Stsrt enrichment
Fuel in this EFI system is not in
which monitors the suction air quan
jected directly into the cylinder but When the ignition switch is in the
tity The injection quantity deter
is injected into the outside portion of START position during cranking
mined by these signals is caIled the
the intake Valve Therefore the air operation a constant amount of fuel
basic injection quantity
fuel mixture is sucked into the cylin is increased irrespective of the cooling
der when the in take valve opens to water temperature
start the suction stroke In other When Cold start enrichment
the air fuel mixture is kept ENRICHMENT reaches this START enrich
strokes zero
outside the intake valve The basic injection quantity is used ment will then occur
EF 7

FUtJllnjection Control ENGINE FUEL
EXAMPLE OF FUEL INJECTION QUANTITY
Cold start
Intake air temperature It DoC 320F constant and water temperature rises from DoC 320 F
AFTER START ehmenl
ch
llnitlon
Waler lempcurcsensor 1 FULL nriehmen
Throltle ahe switch
FTER IDLE at
enrichrne r
I vacuumswitcb
COlD
Thrbllle i lw switch
switch
Ignition Iertemperaluresenlor
START
nridunent
IDLE chmenl
Throttle VlIlve tIIltch QOLING WATER

TEMPERAnJRE orichm
Witertemperalure I P R RE
KE IR
Ol
sen
TA
I AirtempcratureleDSOl
ic
Bots luel njection
quantity
Air fiometcr
Inition oil
Vcbide cooditioll
Janition IWjlcb
Threl
e VlIlve switch
Vacuum switch
California models
Water temperature OOe nor 200C 6110FI 40 C l04on 600C 140oF 8 oC 11760F lIo0e ConSlant
17601
Intake lemper iIturc oGC 32oF Const nt
On California models the Full enrichment ctinted when the vacuum switch ON when the Full throttle contact is ON
Hot restart
Intake air temperature at Isoe constant and
S90F water temperature rises from 600e I400F
AFTER START ehment
INTAKE AIR TEMPERAltlRE enrichment

1F niliOn ch
W t r emperalure Ilensm
FULL enrichment Throttle nlve switdl
vacuum switch
Ijl nilion ilch

i
ricbmcnt
W telh
sensor
lIUl
mpcl
TluoltlevlIlYeswilCh
Air 1 lemar
w I
sie fuel injeclion qUlrnlity
Air nometer
Inilion II
Vehicle
Vehicle condition nkinr Idlinl ConstanHpecd drivina
starling
ON
Ignilionswitch START
FULL
THROTTLE OFF
ThronlevoIhe s itch IDLE cION OFF
rontac10N
Vaeuum ilch
OFF ON OFF
California 1odeb
WOItet empcnlure 600 140l
F 800e 176l
F 800C 117b 01IConst ntJ
J ke
In l ure
emper ISoC S90F Constant
On California models the Fun enrichment ctinted ben the vacuum switch is ON when the FuU throttle ntutis ON SEF344
8
EF
ENGINE FUEL Fuellnjection Control
After start enrichment when the accelerator pedal is not Full enrichment
depressed the throttle valve switch

When the ignition switch is turned The full enrichment provides
idle contact is ON to provide ad
from the START to ON position smooth full throttle driving perfonn
ditional fuel injection
after cranking operation the start ance
or cold start enrichment becomes
zero The after start enrichment is California models

provided compensate for
to this
The full enrichment is activated
sudden decrease in fuel quantity The
After Idle enrichment when the intake manifold vacuum is
after start enrichment decreases
below 3
21 kPa
The after idle enrichment pro 160 mmHg 30
6
gradually as time passes finally be when the throttle valve open
vides smooth acceleration when the ac
inHg or
coming zero and is detennined by
celerator pedal is depressed to start the ing is more than 450
cooling water temperature
vehicle
The California
Non models
after idle enrichment de
creases gradually as time passes finally The full enrichment is activated
Idle enrichment
becoming zero and is detennined by when the throttle valve opening is
When the engine is idling that is cooling water temperature more than 450
ENRICHMENT SIGNAL AND SIGNAL SOURCE CHART
Water Air
Throttle valve switch I Vacuum Ignition
Ignition coil
witch
tempera tempera Full switch Remarks
Idle California negative
Fuel ture sensor ture sensor throttle START
contact models terminal
enrichment contact
Cold start 0 0 0
Start 0
After start 0 0 1
1 Ignition switch
START ON
Idle 0
2 2 Idle contact
0
After idle 0
ON OFF
Full 0 0
0
Warm up 0
Intake air
0
temperature
9
EF

Fuel Injection Control ENGINE FUEL
FUEL SHUT OFf

dur not require fuel The graph below shows the fuel
Fuel off
shut is accomplished
shut off tange
ing deceleration when the engine does
Manual nmodels
Automatic transmission models
3 OC
3 000
@
S 2 600
I s
2 600
e
@ e
1 0
2 200
2 200 0
1 Il
S 0
9 1 800
I 1 800 @
@
1 400
1 400
1
@
1 000
I
oooi @
water
@
temperature
Cooling
Cooling watertemperature
at 80 C 1I6 F
at 80 C 1I6 F
Fuel is shut off and fuel is

Fuel is shut off and fuel is Deceleration from zone A
Deceleration from zone A
in tone Ci injected again in zone C
injected again
Fud is shut off and fuel is
Fuel is shut off and fuel is Deceleration from zone B1
Deceleration from rone B injected again in zone en
injected again in zone e
D from zone B2 Fuel is Dot shut off

Deceleration from zone e Fuel is not shut off
Deceltration from zone e Fuel is not shut off

Engine rpm increased in order Fuel is not shut ofT in zones
of e S and A
C and B in zone A Engine rpm increased in order
Fuel is not shut off in zones
Idle switch ON downhill A
fuel is shut off orue S2 Bl and
en B2 and Bl in
driving etc
Idle switch ON downhill
z one A fuel is shut off
driving etc
SEF095
ALTITUDE COMPENSATION
California models
The density of ail becomes thin

in proportion to the altitude so that
the air fuel ratio becomes riche t
high altitude
The altitude compensator is a
device to correct air fuel mixture to

an optimum ratio automatically
EF l0

ENG IN E FU EL EFI System Component Parts Construction and Function
EFI SYSTEM COMPONENT PARTS CONSTRUCTION

AND FUNCTION
FUEL FLOW SYSTEM

FUEL PUMP
Fuel pump relay Fuel pump

Battery
El 1
i
P 1
I
Oilpres ureswitch
s II
Normal flow Outlet

Ignition I
Relief valve actuated switch IG Fuel

pump relay 2
due to clogged discharge Alternator
line Normal switch position
Nhene ine When nline

opped opEration
Allenulor
L rmilUll
Inl ON 011
OLlprclSurt
witch
Fuel Fuel
IGN SW Oil 1
Alternator pump pump
position prellure pump
I relay 2
relay
No No
START ON II Actuate
generate pressure
ON Gentrate Normal ON Actuak
Actuate
ON Failure NOllTUI1 ON
ON atc
Gencr Failure ON Actuate
No
ON lailure Fwure OFF
actuate
No No No
OFF OFF
actuate
teneralt prcuure
SEF096
The fuel pump wet type In the vane the roller is to the START position for cranking
employs a pump
construction whe e a vane

pump with pushed outward by centrifugal force operation the fuel pump is actuated
roller is directly coupled to a motor when the pump rotates and is pressed irrespective of the conditions of the
fIlled with fuel This construction pro against the outer wall This rotary alternator and the engine oil pressure
vides superior coupling characteristics portion and surrounding wall are not swjtch
between the pump and motor and coaxial and pumping is perfonned After starting the engirie the igni
tion switch is ON the alternator
greater safety in case of fire by the change in clearance between
the wall and the rotary portion Thus operates and the engine oil pressure
when the clearance is large fuel is switch is open through rotation of the
RoUer
sucked in when it decreases fuel is engine th reby actuating the fuel
discharged pump
The relief valve in the pump is
If the alternator stops and the en
designed to open when the pressure in
gine oil pressure decreases for some re
the fuel line rises over 294 to 44I kPa 2 contact is
ason the fuel pump relay
3 0 to 5
4 kg cm2 43 to 64 psi due
turned to II and the fuel pump
to malfunction in the pressure system relay l is turned OFF Then the fuel
The check valve prevents abrupt the
pump is stopped through ignition
Outlet drop of pressure in the fuel pipe when switch remains in the ON position
E F252A the engine
stopping In this manner fuel supply is cut off
for safety purposes when the engine

Operation accidentally stops during driving
When the ignition switch is turned
EF l1

EFI 1 Component Parts Constroction and Function ENGINE FUEL
FUEL DAMPER solenoid valve principle When iI
driving pulse is
applied to the coil built
into the injector the plunger is pulled

into the solenoid thereby opening the
needle valve for fuel injection The
quantity of injected fuel is in propor
tion to the duration of the
Fuel pulse
outlet pplied from the control unit
SEF099
SEF097 1 Injector lower rubber insulator

2 Injector lower holder
3 Injector upper rubber insula or
4 Injector upper holder

The fuel damper is provided to 5 Injector
suppress pulsation in fuel flow dis

charged from the fuel pump No ad
justment is allowed on this damper
in the pump
Change discharge pres FJectric terminal
sure is monitored by the diaphragm o le
and spring which vary the volume of

the fuel chamber for suppressing pul li
sation
11 I
f
Filter
FUEL FILTER
SEF098
Fuel outlet
Il
R j
PRESSURE REGULATOR chaniber by the diaphragm Intake

manifold vacuum is introduced into
To intake manifold
the air chamber
t thereby keeping
Fuel inlet differential pressure constant causing
EF256A Air chamber excessive fuel to return to the
fuel
Diaphragm tank the
through return side port
This constant differential pressure
The fuel f1lter is between Fuel inlet
placed provides optimum fuel injection in
the fuel and the injector and
damper every mode of engine operation
is used to remove matter in the
foreign
fuel Water in the fuel is collected at
the bottom of the f1lter casing SEF100 kPa kg em psi
196
2 0 Fuel pressure
28
t
u
98 250 kPa 2 55 kg
The pressure regulator controls the em
10
INJECTOR e 36 6 si
pressure of fuel so that a pressure 14
The injector receives the pulse difference of 250 kPa 55
2 kgjcm 0 I D
tmospheric
e
CSSW
Ttme
signal from the control unit and in 3 psi
36 can be maintained between 98 Foil ManiCotd
jects the fuel toward the intake valve the fuel pressure and intake manifold 10 throttle
Idling vacuum
in the cylinder head 14
vacuum The pressure regulator is
The injector operates on the divided into the air chamber and fuel E F258A
EF 12

EN GIN E FU E L E FI System Component Parts Construction and Function
AIR FLOW SYSTEM

AIR FLOW METER
35
Ro
Damper plate 33
Helical spring
U R
To intake manifold
32
Potentiometer
R
IB
RJO
34
Air temperature sensor
25
From air cleaner Terminal number
By pass port
fi
sensor
Air temperature
Potentiometer
To EFI harness
EF441A
The air flow meter measures the control unit for computation AIR REGULATOR
quantity of intake air and sends a The flap is able to rotate to an
to the control unit so that the angle where an

equilibrium between
signal
base pulse width can be detennined the air flow pressure and the return Electric
for correct fuel coil spring can be main terminal

injection by the injec torque lhe
of
tor Theair provided

flow meter is tained The damper chamber and
with flap in the air passage As the

a damper plate are provided as a damper
air flows through the passage the flap for the flap so that the flap will not be
rotates and its angle of rotation is disturbed by pulsation in manifold
electronically monitored to count the vacuum during operation
air flow rate The damper plate is interlinked
specifically the angle of rota

More with the flap and as the flap rotates
tion flap is monitored by a
of the the compensating plate rotates in the
potentiometer provided inside as a damper chamber keeping a very small Shutter
potential difference V When the flap clearance between the chamber wall Sleeve
deflects along with a change in the During idling operation when the Air outlet
intake air flow rate the terminal @ amount of intake air is extremely rHeater
mounted to the flap shaft slides on small the air flows parallel with the
the variable resistor R from RI to R9 that
flap through the by pass port so
causing the voltage across tenninals the specified intake air flow can be
@ and@tochange provided correctly

A constant voltage VB battery The air passage is provided with the SEF101
voltage is applied across terminals @ air temperature sensor and the by pass
air flow rate is air by pass screw which
and @ Then the port has the
converted into the voltage ratio the idle mixture ratio The air regulator bypasses the
signal regulates
V VB which in turn is sent to the throttle valve to control the quantity
EF 13

EN GIN E FU EL
EFI ystBrn Component Pans Construction and Function
of air for increaSing the engine idling

Characteri5tics curve COLD
speed when starting the engine at a bi 40
metal temperature of below 800C I412

3
30 32 1 30
176OF c
built in 1 059
A bimetal and a heater are
e
to the air When the ignition 20 21 5 759
regulator 2
switch is turned to the START posi l 706
16 5 583
on engine running electric current
or 10
flows through the heater and the bi 353 2 5 88 Air inlet

a
metal as it is heated by the heater 0
0
hegins to move and closes the air pas 20 0 20 40 60 80
The air passage

g 4 32 68 104 140 176
sage in a few minutes
remains cloSed until the engine is stop Tempetature oe FJ
ped and the bimetal temperature drops
800C 176OF 0 Initial bimetal temperature 200e 68 HOT
to below
30
e 1 059
s 20
I A UNIT Idle speed

adjusting screw unit
Throttle valve remains closed dur 10 ri o 177
2 5
I
8 8
1 Bimetal
2 Shutter
ing engine idling and the air required 2 4 6 8 10
g 3 Heater
for idling passes through by pass line Thne mmwU SEF102
between air pipe and throttle chamber
Idle adjustment is made by the idle
1A S
speed adjusting screw at the
j dicr
unit
L c JFj
AIR PIPE pi
The air pipe located on the line be Intake manifold
tween the air flow meter and the
A S unit
I
throttle chamber prevents the pulsat
ing of the intake air
THROTTLE CHAMBER
The throttle chamber located be
tween the air flow meter and the in Airduc

take manifold is equipped with a
valves
air flow
This valve controls the intake
in response to accelerator
dr Air flow meter
pedal movement
SEF106
The air passage is a two barrel type
which consists of a primary side and a
secondary side A venturi is provided ThIottle valve witch
on the primary side
When the opening angle of the Primaty throttle valve

primary throttle valve reaches 350 the
secondary throttle valve will be
opened by a linkage which is connect
I
Secondary throttle valve
ed to the primary throttle valve
The rotary shaft of the primary IH
throttle valve is connected to the
throttle valve switch
J SEF104
EF 14
EN GIN E FU EL EFI System Component Parts Construction and Function
DASH POT Automatic

transmission models
The dash pot is attached to the

Dash pot
throttle chamber The dash pot pre
vents the throttle valve from closing Air
abruptly and thus stalls the engine
Throttle passage
The throttle valve will gradually reo
lever
turn to the idle opening position Throttle
during deceleration h
L valve
SEF105
ELECTRICAL SIGNAL WATER TEMPERATURE

SENSOR
SYSTEM
CHARACTERISTICS CURVE
WATER TEMPERATURE
SENSOR
The water temperature sensor built
30
20
I I
I
7 0 114 kn at IOoC l40F
into the thermostat housing monitors 10
change in cooling water temperature 8

6
and transmits a signal for the fuel AIR TEMPERATURE
SENSOR 4 2 1 2 9 Jen at 200C
q
I
enrichment to change the pulse dura c 3
I 680F
tion during the wann up period 2
J
8
0 68 100 kn I
I
The temperature sensing unit em I t SOOC 1220
ploys a thermistor which is very sensi 0
1
I
tive in the low 0 6
temperature range
4
0
The electrical resistance of the ther
0
1
mistor decreases in response to the
0 2
31
water rise
temperature
I L
0 06
30 20 0 20 40 60 80
AIR TEMPERATURE SENSOR
Air temperature 22 4 32 68 104 140 176
The air temperature sensor buHt sensor
Temperature Oc OF
SEF101
into the air flow meter monitors
change in the intake air temperature

and transmits a signal for the fuel
enrichment to change the pulse dura Idl contact
tion
The temperature sensing unit em The idle contact closes when the
ploys a thermistor which is very sensi throttle valve is positioned at idle and
tive in the low temperature range opens when it is at any other position
The electrical resistance of the ther The idle contact compensates for
istor decreases in response to the air idle wann and after idle
up en
temperature rise richment and sends the fuel shut off

signal
Full throttle contact

THROTTLE VALVE SWITCH The full throttle contact closes only
The throttle valve switch is attach when the throttle valve is positioned at
ed to the throttle chamber and ac full throttle more than 45 degree
tuates in response to accelerator pedal opening of the throttle valve The
movement This switch has two sets contact is open while the throttle valve
of contact points One set monitors is at any other position
Full throttle
the idle position and the other set The full contact compensates for contact
monitors full throttle position full enrichment SEF108
EF 15

EFI System Component Parts Construction and Function ENGINE FUEL
VACUUM SWITCH
California models Switching charact8ristics
The vacuum switch

Terminal @ @
compensates
ON hn
for the full enrichment by controll

ing the intake manifold
switch consists of a vacuum
vacuum This
diaphragm
j
and a microswitch
When the intake manifold vacuum

OFFj
3 kPa
21
lowers during acceleration the tension
160 mmHg 6 30 inHg
of the the
spring will push diaphragm
Vacuum Vacuum
back and open the contact of the increase decrease
microswitch This will cause the
Intake
switching module to transmit an ON Battery manifold
signal to the control unit j uum
To control
unit
@
l
@
@
r
Switching moule
j
SEF217
ALTITUDE SENSOR
california models
O1aracteristics curve
This altitude sensor is a device to
obtain the electric in

signal
m
nn
proportion
U u
6
to altitude for the electronic control
s
unit 0
This altitude sensor is composed of 2 6

c
the bellows the magnet and the mag

o
neto resistance element At high alti
tude the bellows extends and changes Altitude 500 1 800
m ft 1 641 5 906
the position of the magnet installed
at the tip of bellows The magneto Atmospheric
pressure
resistance element senses the position Bellows kPa 95 4 814
of the magnet and transfonns to the mmHg 716 611
To inHgJl 28 2 24 1
electric signal
control unit
The electric signal from the altitude
sensor is
transmitted to the elec ronic
if
control unit and ihe injection duration m
of the injectors is detennined to ob
tain the optimum air fue ratio by the J
electronic control unit Magnet j
Magneto resistance element SEF113 SEF275
CONTROL UNIT valve timeperiod is controlled to

provide optimum quantity of fuel
an
The control unit is connected to to

according the engine characteristics
the EFI harness by means of a multi The control unit consists of
mainly
connector and the EFI harness is three integrated circuits fonned on the
connected to other sensoIS
printed circuit board This construe
The essential role of the control tion provides superior control unit
unit is to a pulse Upon
generate reliability
receiving an electrical signal from each
sensor the control unit generates a
pulse whose duration injector open EF323A
EF 16

EN G IN E FU EL EFI System Component Parts Construction and Function
DROPPING RESISTOR
The dropping resistor is used to

lower the source voltage to a level
suitable for the
The dropping
in series with the
the source
injector
resistor is connected
injector It reduces
voltage to approximately
1 4 of the source voltage These resis
I I
tors protect the injectors from a1terna
tor voltage surges and from the effects
of other components in the vehicle s

electrical system Electric
tenninal
Resistor
L 1 I
tL
I I r
SEF114
I
RELAY
Battery Dropping
EFI relay Fusible link resistor Injector
81
I I I
The EFI relay serves to activate the
electronic fuel system

l o
injection
through the ignition switch Control unit
5 I 1
IG
Fuel pump relay 1 and 2
Ignition switch SEF115
The fuel pump relay serves to ac
tivate the fuel pump For 9peration of
the fuel pwnp refer to Fuel Pump
EFI HARNESS
One wiring harness is used to con
nect lines between the control unit
and the related major units

The 35 pin connector of the EFI
harness is connected to the control
unit and runs to the engine compart
ment The harness runs to various
units the air flow meter throttle

valve switch vacuum switch air regu
lator altitude sensor water tempera
ture sensor dropping resistor and in
jector etc
Dropping resistor
Battery supplies power to injector I II I
I
and control unit through fusible link Air flow meter
designed especially for EFl 1
i 7 SEF116
EF 17

c p1
lj
I
rn
ia is
there fuel
when
a g e n t s
i
n
mp1lcla suficentlY
pump hose clamp
fuel
operate
a n t H r c e z
fuel hose
iMJ reule fuel
inuse
not ruel not not
00 nO 00 Do Tighten
rev
when not
pedal do
totaC len staring
ENGINE car
EfI
en
dept S
not
ItarUPi
afte1
unec arUY
dtatelY
Imrnt engine
EFl cvicng Do up
or
AN leak
avoid tight
i l 5 p e c t i n g
to
FOR directly v
to
a
when
pOWe carefulY even
point
bntery meter ocnotur tero i
fol wing
PRECAUTIONS
floW ke
the
ap lY air should int
to
not
Do inlectan Randle dalT ge Ther
air
in
tentlon
clo
PaY bater and

no
is
groubantder power
coil 91n preventrec ption
of
igniton as
instaled along hatnes ththerate idling
conector extrme devlop dam ge
disconect operating
is
an
in
in
1
em
to
to
due operation dIY

rne
off
bateic is
is
cable Efl iure engine
engine fceder fsitodme Maunike t whUe
55 10
turn
madjcent alfunctio degrnadoeise pl1Itaducnect reciv4anlt oposite

to
harne cause reulting
t
olt
to
e
lhlesUes h
atempt whUe ante na

12 interferen
e
ij
e
can t
end
EFI
volt l thus rne
then UJe
Alwl
EFt removing
etc parts
Qurce Do cable route control
1I
con ect con ection

i
not
surge
h
sylten and
a
condesr tolCcir ut external circuit Keep BefotO switch cable If

EFt from
EFl
poor high and Keep away
Securely A ly
an of Ie

ENGINE FUEL Removalsnd Installstion
regulator to intake mani 8 Unfasten hose clamp on fuel in

INJECTOR AND pressure
fold jector and remove fuelinjector from
FUEL PIPE 5 Remove boits securing fuel pipe fuel pipe
1 Follow the procedure below to and pressure regulator Place a rag under injector when dis
reduce fuel pressure to zero
connecting fuel pipe to prevent splash
CAUTION
fuel hose release
J ing of fuel
Before disconnecting
nate danger
Start the engine

I
2 Disconnect the harness connector
of fuel pump relay 2 while the engine

is running
Reibracket
SEF099
1 Injector lower rubber insulator

2 Injector lower holder
3 Injector upper rubber insulator
4 Injector upper holder

i5 Injector
SEF119
SEF131 6 Remove screws securing fuel injce 9 To install injector and fuel pipe
tors reverse the order of removal
3 After the engine stalls crank the a When installing injector check that
engine two or three times there are no scratches or abrasion at

4 Turn the ignition switch OFF lower rutiber insulator and securely
5 Reconnect the harness connector install it making sure it is air tight
of fuel pump relay 2 b For installation of fuel hose refer
w to Fuel Hose
If the engine 1 not start remove
fuel relay 2 I
a rness connector
pump
and crank the engine for bout 5 sec
conds
Then the switch

turn gnition INJECTOR RUBBER HOSE
OFF
If necessary replace injector rubber
2 Remove or disconnect the follow
7 Remove hose proceed as follows
fuel pipe assembly by
ing parts and connectors
Accelerator wire pulling out fuel pipe injector and
Injector harness connector pressure regulator as an assembly Removal
VC valve hose and air regulator

hoses
Air regulator and its harness con
nectar
Vacuum hose at the fuel pipe con
nection end
3 Disconnect fuel feed hose and

fuel return hose from fuel pipe
Place a rag under fuel pipe to pre Socket Y 20 mm 0 79 in
vent splashing of fuel

EF551
4 Remove vacuum hose connecting
EF 19

Remolialand InstBllatioh ENGINE FUEL
1 On injector rubber hose measure 2 Remove pressure regulator from 3 Remove air pipe to facilitate reo
off a point approx 20 mm 0 79 in fuel pipe assembly moval of water temperature sensor
from socket end 4 Disconnect water
3 To install pressure regulator reo temperature
2 Heat iron 150 watt for
soldering verse the order of removal sensor harness connector and then re
15 minutes Cut hose into braided water
move temperatur sensor by
reinforcement from mark to socket For installation of fuel hose refer turning it counterclockwise
end to Fuel Hose 5 To install water ture sen
t Ult
Do not feed soldering iron until it r reverse the f of removal
Ordi
touches injector tail piece AIR REGULATOR Be sure to install copper washer
when installing watar temperature
CAUTION sensor
a Be careful not to damage socket
plastic connec1or etc with solder
ing iron
b Never piece injector in a vise when THROTTLE VALVE
disconnecting rubber hose SWITCH
3 Then pull rubber hose out with

hand
Installation
1 Clean exterior of injector tail I Disconnect ground cable from

piece
battery
2 Wet inside of new rubber hose
2 Unfasten clamp on each side of
With fUel
hose and disconnect hose
3 Push end of rubber hose with
3 Remove setscrews and remove
hose socket onto injector tail piece by air regulator
hand as far as they will go 4 Disconnect electric connector
Clamp is not necessary at this con from air regulator 1 Disconnect battery ground cable
nection S To install air regulator 2 Disconnect throttle valve switch

reverse
the order of removal harness co ector
CAUTION 3 Remove screws securing throttle

After properly connecting fuel hose valve switch to throttle chamber
to injector check connec1ion for fuel WATER 4 Slowly pull throttle valve witch
leakage TEMPERATURE toward you
5 To install throttle valve witch
SENSOR
reverse the order of removal
6 After installation adjust position
PRESSURE of throttle valve sWitch
REGULATOR Refer to Throttle Valve Switch
under the heading Component Parts
Inspection
Fuel pipe assembly
THROTTLE
CHAMBER
1 Disconnect battery ground cable
I
2 Remove hoses tube and air duct
Disconnect battery ground cable
from throttle chamber
SEF122 2 Remove radiator cap Drain
3 Disconnect throttle valve switch
coolant by opening drain plug harness connector
I Remove the fuel injector fuel 4 Remove accelerator wire from
CAUTION
pipe and pressure regulator as an as throttle lever
The coolant should not be drained
sembly from the intake manifold Re 5 Remove bolts
until it securing throttle
has cooled off completely
fer to Injector and Fuel Pipe for reo chamber to intake manifold The
Otherwise burns may be incuned
moval throttle chamber can be removed
EF 20

ENGINE FUEL Remova and Installation
2 Remove dash pot from throttle 5 To install altitude sensor reverse

6 To install throttle chamher reo
chamber the order of removal

verse the order of removal
3 To install dash pot reverse the
Gasket should be replaced by new order of removal

one each time the tle
throt chamber is 4 After installation adjust dash pot
removed touch speed Refer to Dash Pot under
the heading of Component Parts DROPPING
Inspection
Throttle chamber RESISTOR
VACUUM SWITCH
ft lbl
J
i N m m
lkg
18 22 8
1 2 2 13 161
SEF128
SEF126
Do not adjust throttle valve stopper

SEF141 1 Disconnect ground cable from
screw as it is properly adjusted at
battery
factory
2 Remove air cleaner and air flow
I Disconnect battery ground cable meter as an assembly Refer to Air
2 Disconnect vacuum hose and har Cleaner for removal
ness connector from vacuum switch 3 Disconnect harness connector
3 Remove vacuum switch from from dropping resistor
bracket 4 Remove dropping resistor attach
4 To install vacuum switch reverse screw
ing
the order of removal 5 To install dropping resistor re
verse the order of removal
ALTITUDE SENSOR
CONTROL UNIT
The control unit is mounted on the
DASH POT left side dash panel
Dash pot Left side dISh panel SEF323
0
1 Throttle
chamber 1 Disconnect ground cable from
IJ SEF142
battery
2 Remove control unit
Refer to Control Unit for removal
3 Remove altitude sensor attaching
Remove throttle chamber bolts I Turn ignition switch OFF and
Refer to throttle chamber for reo 4 Disconnect harness connector then disconnect ground cable from
moval from altitude sensor battery
EF 21

Remoraland Instalstion ENGINE FUEL
I Oisconnect battery ground cable DiSConnect battery ground cable

CAUTION and remove relay bracket 2 Disconnect air ducts and hoses
Before disconnecting EFI harness at 2 Disconnect harness connector connecting air cleaner and air flow
connector be sure to turn meter
3511in 3 Remove relay from relay bracket
switch 0 FF and than dis To install relay reverse the order 3 Remove air cleaner cover
ignition 4
connect ground cable from battery to of removal 4 Remove bolts securing air fiow
prevent control unit from being dam meter
S Disconnect ham cOnnector

aged
and remove air flow meter
2 Remove LH dash side finisher 6 To install air flow meter reverse
3 Pull lock lever back and discon AIR CLEANER the order of removal
nect 3S pin connector from control
unit
4 Remove bolt which secures con
trol unit to LR dash side panel and
remove control unit

5 To install control unit reverse the
order of removal AIR TEMPERATURE

SENSOR
CAUTION The air temperature sensor is built
When inserting 35pin connector into
into the air flow meter and cannot be
control unit be careful nol to bend at unit When
SEF132
removed as a single replace
break terminals ment of air t mper ture 8eDSOI is
necessary the entire air flow meter

assembly should be rep d
I Disconnect ground cable from
battery
2 Disconnect air ducts and hoses
connecting r cleaner and r flow

meter
FUEL FILTER
3 Remove I A
s unit from air
RELAY cleaner
The relays are installed on the relay 4 Remove bolts securing air cleaner
bracket to air cleaner bracket and detach air
cleaner with air flow meter as an as
Inside relay brKket sembly

5 Disconnect air flow meter harness
connector
6 Remove air flow meter from air
cleaner Refer to Air Flow Meter for
removal
7 To install air cleaner reverse the
Fuel pump order of removal

telay l
I Reduce fuel line pressure to zero
Refer to item I under the heading
SEF130
AIR FLOW METER Injector and Fuel Pipe
2 Unfasten clamps securing fuel
Relay bncket hoses to the outlet and inlet sides of
fuel fIlter and disengage fuel hoses
I
Be careful not to spill fuel over en
I
l Place a rag to ab
gine compartment
sorb fuel
3 Remove fuel fIlter
4 To install fuel fdter reverse the
I order of removal
S For installation of fuel hose refer
SEF131 to Fuel Hose
EF 22

ENGINE FUEL RemovalBnd Installation
tightening hose clamp

FUEL PUMP AND c Tighten high pressure rubber hose d When ensure
clamp so thilt clamp end is 3 mm that screw does not come into
FUEL DAMPER
0 12 in from hose end or screw contact with adjacenl parts
1 Disconnect ground cable from
position wider than other portions
battery of clamp is flush with hose end
2 Reduce fuel line pressure to zero pressure fuel hoses into
Tightening torque specifications are Insert high
Refer to item 1 under the heading In
the same for all rubber hose clamps their proper positions as instructed
jector and Fuel Pipe helow
3 Raise the rear portion of car with
a jack and block wheels Insert rubber hose until its
Type @
4
Temporarily clamp hose between end contacts unit
fuel tank and fuel pump of rubber
Type @ Push end hose
S Unfasten clamps and the suction onto fuel pipe until it contacts inner
side of fuel pump and outlet side of
bulge
fuel damper and disconnect fuel
Type @ Push end of injector rubber
hoses SEF138
hose onto fuel pipe until it is 28 mm
Be sure to receive fuel into B suit If from end of
Clamps 1 10 in pipe
able container 1 0 1 5N m
Type @ Push end of rubber hose

0 10 0 15 m 07
kg 1 1 f lbl
with hose socket onto unit by hand
as far as they will go Clamp is not

l
3 mm 10 12 in
necessary at this connection
li
II@ EF336A
To fuel tank From fuel tank
n
6 Disconnect fuel
connector
pump harness
n
Fuel damper
7 Remove bolts which secure fuel
lmp
p bracket to body and remove
fuel pump and fuel damper as an as
sembly from bracket

8 Fuel pump and fuel damper
be removed
can
@
L Fuel ftlter
9 To install fuel pump and fuel
damper reverse the order of removal

10 For installation of fuel hose refer
to Fuel Hose
Fuel pipe
mblY
FUEL HOSE
ure
Pre
Make sure that all low pressure fuel
regulator
hoses are fully inserted and are free
from undue strain before
When removing
pressure fuel hose

or
clamping
installing high
observe the follow
I
ing @
CAUTION
a
b
Do not
loosening
reuse fuel hose
Clean dull and dirt from parts with

clamps after J fJ
SEF139
8d
compreS air when assembling
EF 23

Electrical System Inspection ENGINE FUEL
ELECTRICAL SYSTEM INSPECTION
For items to be checked

DESCRIPTION INSPECTION refer to
Inspection Procedure Table
Electrical system inspection can be To inspect the electrical system use
perfonned by using the EFI ANA a circuit tester

Continuity test can be
LYZER J 25400 perfonnedeasily by measuring resist RESISTANCE
ance and voltage between terminals of MEASUREMENT
CAUTION 35 pin EFI harness connector installed I Set circuit tester in the Ohm R
When checking
the electrical system on car
range
with EFI ANAL VZER be sure to use 2 Check continuity between ter
the proper adapter harness CAUTION minals @ and @ shown in the
Do not touch the circuit tester
probe Inspection Procedure table
If the analyzer is not available use to any unnecessary pin on the 35pin
the could dam Body ground should be mad by
following procedures connector Doing so cause
connecting unpainted metal such
age to the circuit tester 81
bolt
Resistance measurement
Fl
1 1 B
r
PREPARATIONS FOR
INSPECTION I
VEHICLE PREPARATIONS r l
1 Turn ignition switch to OFF L
l8
i i
position II
1
CAUTION
Before disconnecting and connecting
jj I
U
electrical connectors ensure that igni
tion SWilch is in the 0FF position
2 Disconnect battery ground cable

3 Disconnect lead wire from S
tenninal of starter motor
3 After steps I through 11 above
4 DiscQnnect va uum it hharness
sw have all been completed proceed to
connector California models
5
step 12 only for California models
Arrange so that air flow meter
I Connect the vacuum switch har
flap can be pushed manually from air
ness connector and disconnect the
cleaner side
hose in the line between the vacuum
6 Disconnect 35 pin EFI harness
switch and the intake manifold
connector from control unit
2 Disconnect the throttle valve
switch and altitude sensor harness con
CAUTION
nectar
a Before disconnecting EFI harness at
35 pin connector ensure that igni 3 Check continuity when no pres
tion swilch is in the sure is applied to vacuum switch
OFF posi
tion 4 Apply a pressure below 3 kPa
21
b Be 160 mmHg 6 30 inHg to vacuum
extremely careful not to break 5
Bring back vacuum switch a1ti
switch by orally sucking port back and
or bend 35 pin when disconnecting tude sensor and throttle valve switch
terminal check continuity
to their original condition
EF 24

ENGINE FUEL Electrical System Inspection
tester to body metal 8 Turn ignition switch ON and

VOLTAGE
measure voltage in step 24
MEASUREMENT Body earth should be made by con
1 Set circuit tester in the DC Volt necting with unpainted metal such as 7 Turn ignition switch OFF
bolt 8 Connect EFI harness connector
DC V range
2 4 to control unit
Securely connect battery ground Contact positive probe of circuit
9 Connect 2 pin alternator con
cable tester to tenninal @ shown in the
nectar
3 Connect negative probe of circuit Inspection Procedure table
10 Bring air flow meter back to
its original condition
Fl
2
6 I INSPECTION
101
26
9 g O PROCEDURE TABLE
27
0
1811
l1
1
L HOW TO USE
L13
U i4
1 1 fJU 1
ured
After measuring compare meas
values with standard values to
determine whether circuits parts are
I
malfunctioning or not
IT EF452A 2 When a malfunctioning circuit is
located again check measurements in

volved in that circuit In this case
check ignition switch circuit tester
range probe etc to be certain they

S I Turn ignition switch ON and
Inspection with ignition switch in are set at proper positions
START position measure voltage in each step of nspec
tion Procedure Table from 16 to 22

1 Set ignition switch on START CAUTION
and measure voltage in each step of 2 Turn ignition switch OFF
a Before connecting EFI harness at
3 Disconnect oil switch
Inspection Procedure Table from 13 to pressure 35 pin connector ensure that igni
14 harness connector
tion switch is in the 0 FF posi
2 Turn ignition switch OFF 4 Turn ignition switch ON and
tion
3 Connect lead wire to S ter measure voltage in step 23 b When inserting 35 pin connector
minal of starter roptor S Turn ignition switch OFF
into control unit insert
6
slowly
4 Set ignition switch on START Connect oil pressure switch har
securely and straight being careful
and measure voltage in step 1 S ness connector
not to bend or break 35 pin termi
with switch in 7 Disconnect alternator 2 pin con
6 Inspection igiIition nals
ON position nector L and S terminals
EF 25

Ifo I
mZ Cl Zm C mr
valve
Judgment tnrotle
c o n
Measurd value harnes e t r
Disconet
2
value switch above above n n side kn kn n
n 9kn 9kn 400 500 600 vot a

Standr vacum 300 300
or or
2St09n minatnaifkoeld
2 2
to to to
Except Qand on wn on on
n
Below 1kO
2 Below 1kn 100 200
2
to to
HoSO Iwn
400 Batery podtion
Disconet
I
at
OFF
on
2 above above
680F 680F kPa vacum bac
k
in
condit or or
manifold vacum 3
to is
or unit
o ntrol flap deprcs5ed deprsed 680P 20 C 680P 20 C

it ake
to
21
inHg
port
IWitch
ration Rel aied ully Rel ased OC elow below 30
sucking condit abnormality
n
op
J
met r Fully 2p BlOae Below t6

ap lied 6 o
igni
from I I
presu minHg orignal oril y

is
switch of
Auxilary conetr aPuirflsohw side

vacu m
preu re switch 160 switch their
No Ap ly
a by
to
that
enlUfO indcation
harnes clen er
an
Be air 34
hose 30 24 27 senor E
terminab not
Is
Checktrminal
EFI
from
dbconet altiude this
I
pin and
J
8
pushed 32 IS IS IS
vol p
35 26 21
and
conet
A
and
terminal
be
Circuit tester range can switch batery

conetr n v
US flap vavel elctrial below

Igniton switch motor met r harnes OFF throtle START
TABLE stare flow
air switch swilch conectira dfshtiy
drop
vacum conetr
that and
terminal so
vacum switch source switch regulator may
PROCEDU circuit
Inspection
negative Arange
3
batery models
potenimr
now
circuit
and
met r resi tor
1
harnels
Conect senor
model altiude
cir uit
and
switch
back terminal
Bring
i g n i t o n
models batery control pump
air
power igniton and disconetg vAlotholusph

negative betwon unit betwen relay Before Body
a
Earth
E
INSPECTO Step
Disconet Californa
1
Air slidng and
Canforla switch
Vacum
12 Californ Conect 131
Circuit Bnd Circuit fuel Note
I
14
m T1 N

m Z G Zm T1 C m r I
lg
Judgment J
Measured value
voltage voltage
value
defl cts voltage SY
Standr
O
Pointer Batery Above ov Batery Batery positon

uOF
engi e
condit turni g in
i
or
terminals condit switch
operation invole it
lIS
S
and
orignal igniton
its
that
abnormality
or
Auxilary step 1 UL to
back ensure indcation

conetr
I
met r an
terminals I
Be perfoming
in
E E
pin
2
E
flow
air
terminab
and
not
is
this
Check
j
A
care 18
2 6 5 7
27 28 21
I
21
alternao 21 Bring
2
L
conetrs voltage
Exerci batery
Circuit tester range v v
Disconet v
terminals elctrial below

Igniton switch CAUTION START ON ON
2
ON S
conetr conetr and conetig slightly

drop
Check hames pump
uL
and
t
pump
1 2 3 4
i g n i t o n a 1 t e r switch fuel cir uitl h a r n e s may

terin circuit Injector Injector Injector Injector cir uts for conetr
al
control cir uit for fuel
disconetg vAlothlotaugghe
t
cirCu
2
switch 2 2
and cir uits relay pres u switch switch relay switch switch relay Earth
S
b a t e
relaysource models pump pres u
and r y regulator pump regulator pump pin
2
Body
Inspection mot r tcoirig elr
oil
injce
droping EFI f
senIOr betwen fuel

and
oil
presu igniton presure igniton air air
dtemator Before E
Batery unjt Altiude Californa Circuit switch nator alternao operatIon

and and fuel and fuel
and
at ery resi tor citorr uits
stare Igniton POWC oil oil a b
Batery relay Check operation Con ect Batery relay Check operation Con ect
2 2
for Note
Step Conect 15 16 17 16 19 20 21 22 Disconet 23 1 24 1
m N

I mZ Zm T1 C m r
s i10
SEF183
eQ
VACUM SWITCH Clforn modol
I
IGNTO
I
l t
J I
9
2 7 14 15 18 19 l21 24 2526278 10 32 33 34
TEMP
T
SENOR
I
FLOW R
r
R A
I
L AlA MET R
14 Jjln
11
NO
FUL SW
THROLE VALVE
0
CYLINOER
131 1O
11l
121 l
DLE
INJECTOA 111
j
l
N
Jre U
ALTIUDE SENOR Celforn models
c
TEMP it
oo
WATER 37 38 40 4 f
GROUND Is
anaina operation
DROPING RESITO 43
FUEL PUMP Whln
il
in
OFF
PUMP AV cp
P R E S U
I
SWITCH engine nop ed

1
Ei OIL ON
RELAY F t A
REI
I
cp When
DIAGRM
EFI
PUMP
TEANOR
2
LAiterno terminal prul re switch

I
TCH
FUEL RELAY RT
0 0 0
Oil
SW 5TA 0
AL L
ON 0
IGNTO OFf
IGNTO SWITCH FUSIBLE LINK BATERY

CIRUT
B IG 1
FUSE
FUSIBLE LINK oc
BLE
FUS LINK
e 0J
S
IG
t t
c
B
J
EFI
mn ex
ENGINE FUEL Component Parts Inspection
COMPONENT PARTS INSPECTION
2 Disconnect electric connectors

FUEL PRESSURE At idling
from injectors
CHECK Approximately
206 kPa 3 Check continuity between the
1 Follow the procedure below to terminals Continuity sho ld
12 1 kg cm2 30 psi two
reduce fuel pressure to zero exist If not injectorCs
The moment accelerator pedal is are faulty
fully depressed
CAUTION Approximately
Before disconnecting fuel hose release
255 kPa
2 6 kg em2 37 psi
it
danger
P
nate
4 If fuel pressure is not as specified
LJ
replace pressure regulator and repeat
I Start the engine fuel pressure check
Tf
2 Disconnect the harness connector If below the specified value check
of fuel pump relay 2 while the engine for clogged or defonned fuel lines and
is running if necessary replace fuel pump as an
assembly or check valve

r SEF144
v br cket
Rel
FUEL PUMP
FUNCTIONAL TEST
L OPERATING SOUND CHECK
After disconnecting alternator
terminal or oil pressure switch connec
Engine can run
tor set ignition switch at ON posi
tion Then make sure that fuel pump 1 Start the engine and run it at idle
SEF131
is heard If not check Attach the tip of screwdriver to each
operating sound a
all fuel pump circuits If all circuits are injector to ensure that it sounds while
checked out OK eplace fuel pump operating
2 All injectors are functioning prop
3 After the engine stalls crank the
two three times erly if click sound is heard at regular
engine or
intervals Note however that as en
4 Turn the ignition switch OFF
gine speed increases click intervals
5 Reconnect the harness connector FUEL DAMPER shorten
of the fuel pump relay 2
If noise from fuel pump is abnor
2 Connect a fuel pressure gauge and
mally loud replace fuel damper J
between fuel pipe and fuel hose of fuel recheck for noise
J
1
ftIter
FUEL FILTER
If the car is operated under extreme
adverse weather conditions or in areas
where ambient temperature is either

extremely low or extremely high the
fuel ftIter might become clogged In

such an event replace the fuel ftIter l
1I
immediately
INJECTOR
Engine cannot run
CONTINUITY CHECK 1 Crank the engine and check that

3 Start engine and read fuel pres 1 Disconnect ground cable from injectors produce operating sounds to
sure battery indicate operation

gauge
EF 29

ComponentParttlnspection ENGINE FUEL
2 If a different sound is produced 2 Measure the resista

nce between
from any particular injector that tenninals @ and @ The standard

resistance is 200 to 500 ohms
injector is faulty
3 If no sound is heard from all
injectors check harnesses referring to
Electrical System Inspection

4 If harnesses are nonnal check
operathm ofcontrol unit
EF327A
CHECKING RAP
PRESSURE EF483A
REGULATOR Fully open the flap by hand to

check that it opens smoothly without
Refer to Fuel Pressure Check for
binding If it doesn t it is out oforder
inspection
3 While sliding flap measure resist
ance between tenninals @ and @ If

resistance is at any value other 1aJl
t 0
AIR FLOW METER and 0Cl
ohm air flow meter is nonnaJ
CHECKING TlOMETER
Potentiometer @
RO @
RI
R
t @
EF318A
iJ
UlI
i I
LJ
EF319A
R
@
SEF146
AIR TEMPERATURE
SENSOR
CHECKING INUITY
I Measure the outside air tempera
I Measure the resistance between ture
@ and@ The standard 2 Measure resistance between ter

terminals
minals @ and @ of the air flow
resistance is 100 to 400 ohms
meter connector
CHECKING INSULATION
RESISTANCE
Check insulation resistance between

the air flow meter body and anyone
of the tennin s@ @ @and @ If
continuity exists the air flow meter is
EF482A
out oforder
30
EF

EN G IN E FU EL Component Parts Inspection
shutter to open
3 The relationship between the out AIR REGULATOR 4 Pry air regulator
with a flat b1ade screwdriver then
side air temperature and resistance is
I Starting engine and pinch rubber close If shutter opens and closes
shown in the following graph hose between intake manifold and air
smoothly it is operating properly If
regulator not replace
WATER MPERATURE
n SENSOR AND
Engine speed decreases during
AIR TEMPERATURE SENSOR
warm up OK
CHARACTERISTIC CURVE Engine speed remains unchanged
after warm up OK THROTTLE
30 r EJ
i
TC CHAMBER
1 Make that throttle valve
r 1 r i0
sure
Air moves smoothly when throttle lever is
regulator
manipulated
4 2 1 to 2 9 k at 20oe
2 Make sure that by pass port is free
3
8 2
O
I
6SIo
6tFknl
00
from obstacles and is clean
lat2520Fl0oC Do notadjust throttle valve stopper

I
screw as it is adjfactustoryed
g
4
0
0 3
J l
0 2
0 1
O OS I
0 06 Shutter is opened during engine
30 20 0 20 40 60 SO
22 4 32 6S 104 140 176
warm thereby increasing quantity
up
of intake air causi ng engine speed to
Temperature Oc OF
increase Engine speed decreases when
EF334A
Throttle lever
passage is narrowed by pinching hose
during warm up After warm up

shutter closes Therefore F127
engine speed
If test results are far from the range remains unchanged when passage is
indicate in the the air tern narrowed hose after
graph by pinching
perature sensor is out of order The air up
warm
temperature sensor should e replaced 2 Disconnect electric connector of DASH POT

air flow meter assembly regulator and check continuity
as an air 1 Set engine speed to 1 500 rpm
Continuity should exist If not air under no load
regulator is faulty 2 Check the dash pot to make sure

3 Disconnect hoses from both ends in contact
that the rod end comes
CHECKING INSULATION of air regulator and visually check to witli the adjusting screw when the rod
RESISTANCE see if air regulator shutter opens is fully extended or when no back
Check insulation resistance between The shutter opening at a tempera
pressure is presentat the diaphragm
ture of 200C 680F is as shown in
terminal @ ana air flow meter body
If continuity exists the air tempera following figure Adjusting screw
ture is out of order The air I
sensor
Air flow rea at approximately
terpperature sc nsor and air flow meter 200C 6SoF
should be replaced as an assembly
SEF149
Directioll of hi metal If necessary the

3 adjust adjusting
movement with screw so that the rod end comes into
E F328A increasing temperature contact with the adjusting screw
31
EF

CompOfJentParu Inspection ENGINE F1JEL
WATER WATER TEMPERATURE SENSOR AND To adjust position of throttle valve
TEMPERATURE AIR TEMPERA11JRE SENSOR switch with engine off proceed as
follows
SENSOR CHARACTERISTIC CURVE
When clearance A between throt
T
CHECKING INSULATION
RESISTANCE g 7
U
010114 kn al
I j I
lOoC 1401
tle valve stopper
valve shaft lever is
screw
3 mm
0
and throttle
0 012 in
I adjust throttle valve switch position so
1 Check continuity between the 10L
8
j that idle switch is changed from ON
sensor body and each of the tenni 6 j
to OFF
nals at sensor 4 2 1 to 2 9 kn at lOoe
3 i If clearance between throttle valvo
I I 6tF and throttle valve shaft
g 21 0 68 to 100 kn I stopper screw
II I aISOoC
1220FI lever is 3
0 mm 0 012 in engine
speed will become specified rpm
0 3
i
Ht I
0
0
2r u
gggL 1
30 20 0 20 40 60 80
1 22 4 32 68 104
140 176
Temperature DC COF
EF334A
2 If continuity exists is
the sensor
out of order Shim
THROTTLE VALVE
SWITCH
CHECKING CONTINUITY ADJUSTING SWITCH
1 POSITION
Dip the sensor into water main
tained at a temperature of 200C Disconnect throttle valve switch

680F 800C 1760F etc and read connector Changing idle switch from ON
its resistance 2 Connect ohmmeter between ter to OFF correspond to change
minals @ and @ and make sure from 0 to infinite ohms in resist
continuity eXists ance between terminals @and@
3 Adjust
throttle valve switch posi
tion with retaining screw so that idle
CHECKING fULL THROTTLE
switch may be changed from ON to cONTAcT
OFFwhen engine speed is specified
1 Connect ohmmeter between ter
idle rpm 70 rpm M T Neutral
minals @ @ and
r and make sure
A T N position under no load
continuity does not exist
rr EF329A
2 If the sensor resistance with re
spect to the coolant temperature is not

held within the range specified in the
graph the water temperature sensor i

o
may be o t of order SEF153
EF 32

ENG INE FU EL Component Parts Inspection
2 Depress accelerator pedal to floor Vacuum gauge
If continuity exists between tenninals

@ and full throttle contact is
functioning properly
CHECKING INSULATION
RESISTANCE
Resistance lkn Voltmeter
1
I I
ova
EB o 0
Battery Regstan
12V 30kn
1
o SEF324
o
SEFl54
ALTITUDE SENSOR
Connect ohmmeter between engine I the
Connect test lead wires as
and tenninals @ @ and @ Ohm
follows
meter reading mould be infInite
i Battery
12V
VACUUM SWITCH
Jf
1 Remove vacuum switch III Voltmeter
2 Connect the test lead wire as

0
follows 4 SEF166
3 Measure the output voltage
Conditions Output voltage 2 Measure the output voltage 43 and 38 No 2 cylinder
More thOriO 5V OK 43 and 37 No 1 cylinder

No pressure is ap
Approximately 3 If the test results are not the The resistance should be approxi
plied to vacuum
battery voltage the altitude sensor is mately 6 ohms O K
switch speCification
malfunctioning
Apply a pressure
below 3 kPa
21
160 mmHg
30
6 inHg to OV
vacuum switch by
DROPPING
orally ucking RESISTOR
port back
l
Conduct resitance checks on drop
ping resistor between the following
points
4 If the test results are not the
the switch is 43 and 41 No 4 cylinder
specifications vacuum
SEF155
malfunctioning 43 and 40 No 3 cylinder
EF 33

Cpmpopentp 5Per Von
ral N INE FUEL
RELAY
I Disconnect 3 Test
battery ground cable continuity through relay the following chart
2 Remove relay from car with an ohmmeter in accordance with
EFI relay and fuel I

pump relay
direct current iI ppUed
d
rp Chcck terminals
Normal condition
112V
bet t uololls CDond@ I
Tell resultl CoatiDuity
f
nu
1 1 j
@
@
@
Yea
No
Ya
Yes
No
Yes Coritiilufty should ex

iIt
No Continuity IhotiId not abt
IZVIliNct
aIIfIW I
Fuel pump relay 2 NDnIaI
c
a llllilod
lkll
@ @
2 7 nau
J
0tndIaIIlt
l CD 00
@@
y
No
y
No
No
D T
t I
j@
j@
No
y
y
YQ C cUII
CO nol alA
1inulll
ct
c
o
a c Ir I
SEFl56
CONTROL UNIT 3 Use flat plate tenninals 3 mm 0 12 4 Starting engine or cranking en
in wide 0 8 mm 0 031 in thick gine check iitspection lamp to see if it

CHECKING ELECTRIC
male terminals Place flat plate flashes at
IGNAL TO INJECTORS
as
regular interval If so elec
terminals parallel with each other ttic signals are being properly trans
I Inspection lamp as shown in and keep distance between inside mitted to injectors
figure blow is required for thiS test faces 2 mm 0 08 in
The n secUre a The engine should be cranked at a
terminals by wrapping insulation
speed of more IariSO
tJ rpm
tape or with suitable terminal body b The control unit may fail to gener
2 Disconnect injector harness ate correct
con a pulse signal at an
nector low
excessiwely battery voltage It is
3 Connect inspection lamp to injec nded
recomm therefore that a
tor harness connector battery voltage of more than 9 volts

be applied during the cranking
operation
E F353
Make inspection lamp as follows

1 Prepare 12V 3W lamp
2 Prepare socket and set lamp in it
34
EF

EN GIN E FU EL Component Parts Inspection
CHECKING FUEL SHUT OFF 3 Increase engine speed to each speed ill each zone as shown in chart
FUNCTION zone respectively and release acce below

lerator pedal Check inspection lamp
1 Wann up engine sufficiently While inspection lamp is off fuel
2 Connect inspection lamp to injec illumination

off
shut is operational
tor harness connector Check inspection lamp with engine
Automatic transmission models Manual transmission m els

3 000
3 000
I @
2 600 2 6001
e @ e
e
e 2 200
0
2 200 0
51
51 @
5 t 800 1 800
c
@
t 400 1 400
1 000
@
1 000
@ @
Cooling water temperature Cooling water temperature

at 800C 1760F
at 80C 1760F
Since the air flow meter used in connections cracks or deterioration

CECKING AIR
the electronic injection system
fuel Retighten loose connections and
LEAKAGE IN AIR defonned
directly measures the quantity of in replace any damaged or
INTAKE SYSTEM take air to permit the supply of the parts Replace any fuel hose whose
inner surface is deformed scratched or
Make sure even a slight air leak optimum fuel quantity for each cylin
does not occur der chafed
When inspecting the electronic fuel For replacement of high pressure
injection system pay particular atten fuel hose refer to Fuel Hose under the
tion to hose connections oil
CHECKING FUEL heading Removal and InstaUation
dipstick
filler cap etc for any indication of air HOSES
leaks Check fuel hoses for leakage loose
EF 35

Service OatasndSpecificatiom ENGINE FUEL
GENERAL SPECIFICATIONS I Dash pot T h speed

ou rpm Approx 1 500
Manifold vacuum when vacuum Approx 21 3 kPa

I Design voltage V 12 Vacuum
switch switch is changed from OFF 160 mmHg
6 30 i Hil
di kPa t cm2 294 44113 0 4 5 to ON
fuel off
Cut
pump
I charge pressure psi 43 641
Altitude
Design current A 5 1
I leos or
Output voltage V Above 0 5
ing Resistance
Pressure
regulator pressure
Regulated kpa
psi
kgem
2SO 12 55 36 31
IDr resistor Per resistor
fl Approx 6
I
Airflow
meter
Design voltage V 12
I
Air
Design voltage V 12 I
I
Air flow quantitY
regulator m cuft hr 19 0 611l
IAt 200C I68 FlJ
i votteee V 12 I TIGHTENING TORQUE
I
Control Consumption wattage lb
ft
unit At idling W 15 I Unit N m
8 2 2 13 16
At full throttle W 140
J I Throttle chamber 18 22 1
1 0 15 0 1 0 15 01 1
I A I hOSl lp
clBn
Futtl hose clBr11ping position

fuel
B
pressul kPa kg em
A t dr1n9 Appro 206 12 1 301
measure PII 3mmIO l2in
iog point
between The moment acce 2
kPa kg Iem
Q
fuel eretor pedal is Approx 255 2 6 37
PSI
filter and fully depre1sed
fuel pi
Fuel
Coil resistance n 2 35
injector
EF336A
Airflow @ @ n 100 400

metar
Potentia @ @ fl 200 SOO
meter
resistance @ @ fl Except 0 and
Air tem
peratu re At tOOC t4OFI kfl 10 114
sensor
water
tempera
At 200C 168OF kfl 2 1 9
2
lUre
sensor
therml
At5OC t22F kfl 0 68 1 0

tor re
sistance
Air Heater coil

n 25 90
reQulstor resistance
Engine speed Specified idle rpm

Throttle
wh enl dll SWltch 70 in Neutn
vaI rpm
is changed from MfT in N pasi
SWitch tion
ON to OFF AfT
EF 36
EN GIN E FU EL Trouble Diagnoses and Corrections
TROUBLE SHOOTING CHART
The EFl system can be checked in Save time by perfonning a quick Inspection Instructlone
accordance with the shooting
trouble check if all harness connecton espe Before checking the EFI system be
chart cially the 35 pin connector and air sure to observe the instructions below
securely in
If any abnonnaIity is found in any flow meter connector are
Failure to do so could result in damage
inspection item refer to the Inspec place Connector terminals are free to the control unit or cause fuel line
tion section and carry out further from corrosion and deformation leakage
inspection following the procedures Pull all connecton off and recon
described therein nect after inspecting terminals

CAUTION
Note that any component part 2 Since the EFI system accurately
When connecting or
disconnecting EFI
excepting some of the EFI system meters the intake air flow through an
harness connector to or tom any EFI
if it is air flow meter even a slight air leak
must be replaced as an assembly unit enlUre that the ignition switch is
found to be faulty since will improper air fuel ratio
no repairing cause an
in the OFF position and that the
is allowed resulting in faulty engine operation
I battery terminal is discon
due to excessive air
nected Removing and ins18l1ing the
For this reason a thorough inspec
Checke before inspection connectors with the ignition switch
tion for leaks should be made at the
left in the ON position will damage
Before attempting any test check oil ftller cap dipstick blow by hoses control unit
the following items to ensure that air flow meter to throttle chamber air
nothing has been overlooked duct etc

3 Make sure the ignition and start Replace fuel hoses if they are de
I The greatest problem source with
satisfactory and the fonned scratched or chafed Do not
a system of this type lies in the ing systems are
reuse fuel hose clamps after removal
connections between components battery is in good condition
Condition Probable cause Check and corrective action
Disconnect high tension cable from one

Engine will not start Improper ignition system
or hard to start spark plug and check for hot spark
Intake air leakage at following points Check for intake air leaks and repair or
P C V valve V C valve dipstick seal oil replace if necessary

ftller cap blow by hoses
Air flow meter hoses and clamps
Manifold gaskets etc
Fuel pump does not work Disconnect starter motor S temtinal and
ignition switch in START position

listen for fuel pump and pressure regulator
operating sound
If no sound is heard check fuel pump con
trol circuit
Then to the following checks
proceed
Fuel pump
Alternator L terminal
Oil pressure switch
Fuel pump relays I and 2
Improper ignition signal input Check ignition signal input
EF 37

Trouble Diagnoses and ComJCtion ENGINE FUEL
Malfunctioning EFI relay or control unit or Connect a lead wire to ignition coil negative
injector terminal With ignition switch ON attach
other end ofleadwire to engine body for a
short period and repeat it rapidly
listen to each injector sound with a screw
driver
Results
a Injectors click every second break check
the following circuits
e Water temperature sensor
Air 0 lJleter potent r

ete
Start signal cirelli t
Air regulator
b Injectors do not click check the follow

ing circuits
Control unit power input circuit

Ignition coil trigger input circuit
Control unit ground circuit
e Injector circuit
Problem in the following circuits Check each circuit Then proceed to Com
Vater temperature sensor ponent checks
Air flow meter potentionietef
Start signal circuit
Poorly chaIged battery Check charge circuit

Recharge battery if necessary
Engine starts then Improper ignition signal input Check ignition signal input
stalls
Malfunctioning EFI relay or control unit or Connect a lead wire to ignition coil negative
injector terminal With ignition switch ON attach
other end of lead wire to engine body for a
short period and repeat it rapidly

listen to each injector sound with a screw
driver
Results
a Injectors click every second break check
fuel pump circuit
b Injectors do not click check the follow
ing circuits
Start signal circuit
circuit
Injector
Fuel pump does not work With ignition switch in ON position dis
connect oil pressure switch harness connec
tor alternator L tenninal
Listen for fuel pump and pressure regulator

operating sound
If no sound is heard check fuel pump con
trol circuit
38
EF

ENGINE EUEL Trouble Dia9nosessnd Corrections
Then proceed to the following checks

Fuel pump
Alternator L tenninal
Oil pressure switch
Fuel pump relays I and 2
Improper wate temperature sensor circuit Check circuit

iI
Malfunctioning air regulator Check air regulator and replace if necessary
Note If these tests are satisfactory prOceed

to Engine will not start
Engine idles too fast exhaust valve clearance Adjust valve clearance
Improper intaJ
e an
cannot be adjust Malfunctioning throttle valve Check that plate is closing when throttle is
ed with idle speed
released and replace if necessary
adjusting screw or en
Malfunctioning air regulator To check air regulator proceed to the
gine idle is unstable
following steps
Start engine
Pinch offhose to air regulator
Results
al Ifidle speed drops perfonn circuit test
Ifno fault is found replace air regulator
b If idle speed remains high or unstable
perfonn the following checks
Check for manifold vacuum leaks includ
ing at P CV valve V C valve dipstick

nd oil f1ller cap seals
If no problem is found perfonn the fol
lowing circuit tests
Throttle valve switch idle contact and
full throttle contact
Va 9u urp switch
Water temperature sensor

Control Jtit ground circuit
rJ r
Air flow meter potentiometer

Air regwator and fuel pump circuit
l 1Inj ctor circuit
Then proceed to Component checks
Engine misfIres Improper ignition circuit Check ignition circuit
Improper EFI harness connectors Pull EFI harness connectors apart and check
for looseness and corrosion including
in
groimd circuits Do not forget ignition
put lead
Improper fuel line Check fuel line for blockage

Tank strainer
Fuel filter
Injectors
Fuel pipes
39
EF

Trouble Oisgnosesand Corrections ENGINE FUEL
Malfunctioning control unit Tap control unit while driving to see if this
aggravates or aIleviates the problem If so
try another control unit
Improper fuel pressure Perfonn fuel pressure test
improper EFI circuit Perfonn all circuit tests

Then perfonn Component checks
Engine will not re Lor t

f ignition system Check IC ignition unit pick up coil and igni
volve lack of tion coil
power
Malfunctioning throttle valve Make sure throttle plate is opening fully
when accelerator is fuI1ydepressed
Malfunctioning air flow meter Check air flow meter mechanical movement
Using a finger push flap open checking that

it opens smoothly and fully
Improper fuel line Check fuel line for blockage
Tank strainer
Fuel fdter
Fuel pipes
Problem in the followiIlg circuits Check each circuit

Ignition coil trigger input circuit Thin perfonn Component checks
circuit
Injector
Vacuum switch
Altitude sensor
Air re ator and fuel pump circuit
Hesitation stumble Improper ignition system Check ignition system

on acceleration
Malfunctioning air flow meter Check air flow meter mechanical movement
Using a finger check for smooth flap move
ment
Intake air leakage at following points Check for intake air leaks
P C V valve
V C valve
Dipstick and oil filler cap seals

Manifold gaskets
Air flow meter hoses etc
Improper idle ll adjustment

CO Check idle ll if necessary adjust it
CO
Improper EFI circuit Perfonn complete circuit test

Then perfonn Components checks
40
EF

ENGINE FUEL Trouble Diagnoses and Corrections
Poor gas mileage or Improper ignition timing or ignition system Check ignition timing
CO reading too Check ignition system for hot spark
high air cleaner f1lter Check air cleaner f1lter and replace if
Improper
necessary
Problem in the following circuits Check each circuit

Water temperature sensor Then proceed to Component checks
Vacuum switch

Air regulator and fuel pump circuit
Injector cirellits
Surge Malfunctioning air flow meter Check air flow meter mechanical movement
Using a fmger check flap movement for
smooth operation
Intake air leakage at the following points Check for intake air leaks
P v valve
C
Dipstick and oil ftller cap seals
Manifold gaskets
Improper idle CO adjustment Check idle CO if necessary adjust it
Problem in the followirig circuits Check each circuit

Throttle valve switch idle contact and Then proceed to Component checks
Vacuum switch
Altitude sensor
Air regulator and fuel pump circuit

Injector circuit
Backfuing Intake air leakage at the following points Check for intake air leaks
P C V valve
V C valve
Dipstick and oil ftller cap seals

Manifold gaskets
Improper fuel pressure nn fuel pressure test

Perf
Improper idle CO adjustment Check idle CO if necessary adjust it
41
EF

Trouble Diagnoses and Corrections ENGINE FUEL
Problem in the folloWing circuits Check each circuit

e Throttle valve switch idle contact and Then proceed to the Component checks
fulllhrottle contact
Vacuum switch
e Aidlow meter potentiometer
e Water temperature sensor
Altitude sensor
e Ignitioncoil trigger input circuit
e Control unit power input circuit
e
Injector circuit
Afterfire or Problem in the following circuits Check each circuit

a g Throttle valve switch idle contact and Then proceed to Component checks
fulllhrottle contact
Vacuum switch
e Air flow meter potentiometer
Injection circuit
e START
signal input
COMPONENT CHECKS
To be performed only after circuit tests are completed
Air flow meter Fuel system

Control
Injector Air unit
Problem Relay Resist
sound
Flap
regulator replace Fuel pres Injector
opera ance
ment sure test leakage
tion means
Engine will not start X X

I X X X X X X
Idle too high or too rougli X X

I X X
Engine misfires X
I X X X X
Lack of power engine

X X X X X
will not rev
Hesitation stumble X X X X
Poor gas mileage or
CO X X X X X
toohigh
Engine surgAs
I I X X X X X
Backfiring I I X X X X
Afterbuming
I I X X X X X
42
EF

EN GIN E FU EL Trouble Diagnoses and Corrections
Preparation 6 On automatic transmission equip

CHECKING AND should be carried
pad models checks
ADJUSTING IDLE 1 Make sure that the following parts
out while shift lever is in 0 position
ingood order
RPM IGNITION are
Battery
TIMING AND WARNING
e gnition system
MIXTURE RATIO a When selector lever is shifted to
E F I harness connectors
0 position apply parking
PRECAUTION Vacuum hoses
brake and block both front and
Ai intake system
a To discourage tlImpering with the rear wheels with chocks
Oil filler cap oil level gauge etc
idle mixtu adjus1ing screw on b When racing engine on auto
2 Connect engine tachometer and
California model it is sealed withH matic transmission equipped
steel blind plug attar adjustment of timing light in their proper positions models make Rife that shift
So the 3 When measuring CO insert
lever is in N P
idle mixture at factory or position
probe int tail more than 0 4 m
blind plug should not be removed pipe and brake pedal to pre
depress
16 inl
during routine maintenance except vent forward RI rge of car
4 Use CO meter after it is fully
that case as directed by official in c After the adjuS1ment has been
d up
warm
spection to lower exhaust emis made shift the lever to the N
5 On air conditioner equipped
sion or P position and remove
models checks should be carried out
b Adjusting mixture uling other than wheel shocks
while the air conditioner i OFF
the method below may violate
federal and or California or other
tate and provincial laws
Inspection procedure
START
Start engine and warm up engine until waL

temperature indicator points to he middle
of gauge S M
Open engine hood
Run engine at about 2 000 rpm for about

2 minutes under noload
SMA021
For Canada
1 Run engine at idling speed
I For u S A
Disconnect hose from aii indUction pipe

and install proper cap on air induction
pipe
t
load
Then run e e for one minute at idle
speed
Check idle speed
MfT 700 z tOO rpm
f
AfT 700 t100 rpm Un 0 position
SMA263
N G
O K
idle spee4 ad
Adjust idle speed by turning
justing screw
I
@
@ @
43
EF

Trouble eund
Diagno Ctions
Cof1l ENGINE fUEL
jiJ @ @@
OIeck ignition timing with timing Ught
Cllifomia
Nol1 Californil
a zo a T D C 6 ZO B T D C
OK J N G
Adjust ignition timing by turning distributor

I aftedoosening bolts which secure distributor
I
I SMA059
Race engine two or three times under n
load then run engine at idle Ipced
0Ieclr idle CO with CO

meter
I
OK
f t
C
Non
11
3
I
liforni
0
N G
C lifornia
less than 4
Does engine run smoothly

r OIeck the following
Following hoses for proper connections

YES VaCWlm hoses
Blow by hoses
Air regulatOJ hOle
Air duct hoses
Canister purge hoses
Air leaks at throttle chamber mounting
and intake manifold
OK
I NG
I Correct or replace malfunctioning parts
Remove blind plug from air PUl

by SCItW
California
on air flow meter
models
Turn off engme and
I
remove
Californi models
air flow meter from cu
Steel plug
califomia
Non models
Rubber plug
canrornia
Noii
r
models
I
Note Alter drilling be ure Drill a hoJi in steel plug wbich
to I
L
remove dlaviDgs and dUll
1
t seab air by pass screw and
remove steel plug
Race engine two or tluee times under Imta11 air flow meter on car
noload then run engine at idling speed

r Start engine and
engine until
warm
ter
up
temperature indicator pOints

to e middle of gauge
@U @ @
44
EF

ENGINE FUEL Trouble Disgnosesand Correcrions
n n @
Onlyfor owrOtnia
non
When adjUltina idle CO
models
at high
cp
altitude adjust to obtain foUowing Adjust CO by turning air by pass
val screw on r
ai flow meter
Unit m ft Idle CO 1 3 1 0lI
I Altitude Idle CO
IN G IO K SMA061
600 1 200
I 2 000 4 000
2 7
Not adjustable in this case
Comct or replace air flow meter or
Install blind plug on air flowmeter I
1 200 1 800
I 4 000 6 000
3 8 other malfunctioned parts of fuel
injection SYstem
California
Calitom
Non e
HIM steel plug
Original rubber plug
iI Above 1 800
6 000
5 0
Non alifornia models
Turn off engine and
California models
remove air flow meter

from Cat
Insertnew steel plug hed

fumi as a service
part with its convex aide up into air by pass

screw Tap steel plug with suitable bar
thereby inltalling steel plug on air flow

meter
Air by pass I
screw SE F 348
Install air flow meter on Cat

Start engine and warm up engine until
water
temperature indicator points to the
For U S A middle of gauge
For Canada
For Canada
I For U A
S
Turn off engine and connect air induction

hose to air induction pipe
Start engine
I
t Race engine two or three times under no
J load then run engine at idle

L
L
Oleck idle speed
r
MfT 7OO 100rpm
AfT 1100 rpm
700 in 0 position
O K
I N G Adjust idle speed by turning idle speed ad

justing screw
END
45
EF

DATSUN 200SX Model S r r 0 Series
SECTIONEC
EMiSSiON CONTROL SYSTEM
CONTENTS
EMISSION CONTROL DEVICES EC 2 SPARK TIMING CONTROL SYSTEM EC 15

GENERAL DESCRIPTION EC 3 DECELERATION CONTROL SYSTEM
CRANKCASE EMISSION CONTROL lntake
I manifold vacuum control type
EC1
SYSTEM EC 5 CATALYTIC CONVERTER EC 17
DESCRIPTION EC 5 EVAPORATIVE EMISSION
INSPECTION EC 5 CONTROL SYSTEM EC19
EXHAUST EMISSION CONTROL DESCRIPTION EC19
SYSTEM EC 6 OPERATION EC 20
DESCRIPTION EC 6 INSPECTION EC 21
AIR INDUCTION SYSTEM A IS l EC 6 SERVICE DATA AND
EXHAUST GAS RECIRCULATION E G R l SPECIFICATIONS EC 23
CONTROL SYSTEM EC 9 TIGHTENING TORQUE EC 23

5 Z C 0 Z I0 0 r C
lClIm 3
io a li a I
m Cii C
l
T X X X
X X X X X X X X X X
A
models
Can da T
X X X X X X X X X X X X X
M
T
X X X X X X X X X X X
models
X X X X
A
Z20E SIlO Californa A

s
U
DEVICS
Non for M
X X X X X X X X X X X X X X X
T
X X X X X X X X X X X X X X X X X
A
CONTRL models
Californa T
M
X X X X X X X X X X X X X X X X X
EMISON model
Engine
model
Car
A
Type Type
B
1
Type Type Type

2
valve valve valve

3
valve
V
C
P
sensor plug plugs control sy tem

sy tem
ventilao
T T
bar el
T
V V P
2
senor switch V V B
I
2
induction induction wisytthem wisytthem wisyttehm convert crank se

duct
air
chamber valve switch temprau sensor
pipe flow temp ratue
met r
r e g u l a t o r
for for
ignitor ignitor Water

temprauair air
Cat lyic Canister Positve

R R
Throtle Throtle Vacu m Water Altiude

R
Fresh Air Air Air Air IC IC Exhaust Exhaust G

E
G
E
G
E
sy tem
Item inlet
Catlyzer Evaport Crankcse ventilao sytem
Fuel
Igniton sy tem
R
sy tem sy tem sy tem

S
I G
Air Air A E
Pl
EMISSION CONTROL SYSTEM General DeScription
ENERAL DESCRIPTION
There are three types of control 2 Exhaust emission control system Periodic inspections and necessary
systems which are as follows 3 Evaporative emission control servicing of these systems should be
1 Closed type crankcase emission system perfonned to keep hannful emissions
control system to a minimum
CALIFORNIA MODELS

Thermal vacuum valve
Throttle chamber lntake manifold
Airregulator
Airpipe
01IL 11
i I
T
n
1
IT
f
en I I
i rr J
u j
c
tP Catalytic convert
Ported
Ported
Venturi
vacuum
vacuum
vacuum
Distributor
EG R
ji
r
Manifold vacuum
f o C
ri 1
I Air
Idle adjust aew umt Ii If
Distributor lj f Canister purge

A I tube
Canister Q Secondary air

Air induction valve
Carbon monoxide hydrocarbon
l L J Ail cleaner
0 Carbon dioxide gas water
Fuel tank vapor vent line
BEeoo
3
EC
General Cription
De EMISSION CONTROL SYSTEM
CALIFORNIA
NoN MODELS For U S A

Intau Thenn2 ftOUum valve
Throttlechamber
mmifOId G R ntve
Airregulator
P tube
B
H
ta
ell I
il b i
Air pipe 0
n II
I I
raL
I 1
1 VV T Valve
I
f no
T
v l
1J
J E G R tube
J I
It J
J
l
1 J
u II
t
b C2Wytic cooverler
Ported vacuum Distributor
Sf
II C Porled vacuum EG R
MalfIOr
f
t
1
Venturi vacuum
ldIeadjusls unit
Distributor r
J Air
A I lube
E Canister purge
t
Omister
dL y Air valve
mducti Q Secondary air
f Oirbon monoXide
1 hydrocarbon
J Air cleaner
Q Carbon dioxide gas water
SECOO2
CANADA MODELS
acuum con
Throttle chamber
Intake manif ld
t vacuum vaIve
E R
G val
n i J
i
M pipe
1 J
kL Ji 1 II
I
PT
B val
I
I E G
R tube
Ported vacuum Distributor

Ported vacuum EG R
7 1
r Air
II 21 ta rter
gr
yticcon Canister purge
Idle adjust saew Y

t
Distributor
t
JA
r J
1 JF
1t
Muffier
Q sair
Exces
Carbon monoxide hydrocarbon

9 Cubon dioxide gas water
Canister

SECOO3
4
EC

EM ISSION CONTRO L SYSTEM Crankcase Emission Control System
CRANKCASE EMISSION CONTROL SYSTEM
DESCRIPTION INSPECTION
Tills system returns blow by gas to The ventilating air is then drawn
p C V VALVE AND FILTER
both the intake manifold and air pipe through the tube connecting air pipe
The positive crankcase ventilation to rocker cover into the crankcase With engine running at idle remove
P C V valve is provided to conduct Under full throttle condition the the ventilator hose from P C V valve
crankcase blow by gas to the intake manifold vacuwn is insufficient to if the valve is working a hissing noise
manifold draw the blow by flow through the will be heard as air passes through the
During partial throttle operation of valve and its flow goes through the valve and a strong vacuum should be
the engine the intake manifold sucks tube connection in the reverse diIee felt immediately when a finger is
the blow by gas through the P C V lion placed over valve inlet
valve On cars with an excessiveiy high
Nonnally the capacity of the valve blow by some of the flow will go
air
is sufficient to handle any blow by and through the tube connection to
a small amount of ventilating air pipe under all conditions
Seal type oil level gauge
Flame arrester
iC Intake manifold
v
J l VENTILATION HOSE
r J 1 Check hoses and hose connections
T
for leaks
R L Air
Throttle chamber
pipe 2 Disconnect all hoses and dean
with compressed air
P C V valve If any hose cannot be free of
obstructions replace
Steel net Ensure that flame arrester is surely
Fresh air
inserted in hose between air pipe and
Blow by gas rocker cover
SECOO4
ET277
EC 5

ExhaurtEmission Control System EM ISSION CONTROL SYSTEM
EXHAUST EMISSION CONTROL SYSTEM
DESCRIPTION
The exhaust emission control system is made up of following
Non California models

Emission control system California models Canada models
for U S A
TypeA Type B
Air induction system Air induction valve Air induction valve
EA tube E A tube
Type 2 Type 1 Type 3

E G R valve E G R valve E G R valve
E G R system Thermal vacuum valve Thennal vacuum valve Thennal vacuum valve
3 port type 3 2
port type port type
TYpe A2 A3 TYpe A I A3 P T valve
B
VV Tvalve V V T valve
Thermal vacuum valve Thennal vacuum valve

Spark timing control system 3 port 3 port type
type
Type A2 A3 Type A I A3
Catalyst Catalytic converter Catalytic converter Catalytic converter
AIR INDUCTION
exhaust manifold vacuum conditions secondary air can
SYSTEM A I S The exhaust pressure in the exhaust be drawn into the exhaust manifold in
manifold usually pulsates in response proportion to the vacuum
DESCRIPTION
to the opening and closing of the Therefore the air induction system
The air induction system A IS is exhaust valve and it decreases below A IS reduces CO and HC emissions
designed to send dary
seco air to the atmospheric pressure periodically in exhaust gases The system consists
exhaust manifold utilizing a vacuum If a secondary air intak pipe is of two air induction valves a filter
caused by exhaust pulsation in the opened to the atmosphere under and hoses
I TypeA
Aircleaner
cy
Injector
n II
Wf
E l tube
A
SECOO6
EC 6

EM ISSION CO NTROL SYSTEM Exhaust Emission Control System
TypeB Air induction valve

Air cleaner
Filter
Exhaust
manifold
E A tube
SECOC
Air induction valve case I Air induction valve
The air induction valve case which Two reed valves are installed in the
consists of two reed valves a valve case air cleaner When the exluiust pressure
and a fIlter is attached to the air is below atmospheric pressure nega

tive pressure secondary air is sent to
cleaner
There are two types of air induc the exhaust manifold
tion valve cases The type A is equip When the exhaust pressure is above
valves
ped with two hose connectors and is atmosphericpressure the reed
air from sent
installed on California models and the prevent secondary being
B is with one connector back to the air cleaner
type equipped EC921
and is installed on all Californla
non
models except Canada
TypeA
To exhaust manifold
Air Induction pipe

1
n
The secondary air fed from the air
SEC009
induction valve goes through the
O
M Dlkwrtd
iillQl EA tube to the exhaust manifold
Air filter SEC059
B Type A
Type
pipe
To exhaust manifold
rEAl
Airinduction
valve
Z
From air
S ealmg
induction
rubber
valve
Air induction valve filter
The air induction valve fIlter is in

1 stalled at the dust side of the air
LAirfi er
cleaner It purifies secondary air to be
SEC060
sent to the exhaust manifold
EC 7

Exhaust Emission Control System EM ISSION CO NTROL SYSTEM
The air induction pipe can then be AIr induction valve and fDter
TypeB
taken out Installation is in the reverse
I Disconnect air induction hose at
sequence of removal
air induction pipe side Suck or blow
E A I
pipe hose to make sure that air flows only
the air induction
on pipe side
REMOVAL
AND INSTALLATION TypeB
SEC016
Air Induction valve and filter
Remove the valve and fIlter on the
air cleaner The air induction valve and
valve fIlter can then be taken out easi

ly Installation is in the reserve se
2 Check air induction valve for
quence of removal
binding ordamage At the same time
check fIlter for damage or plugging If
necessary replace Filter should be
replaced periodically in accordance

with Maintenance Schedule
SECQ12
INSPECTION
Air Induction pipe Preliminary Inspection

Remove nut securing the pipe to SEC016
Check hose for looseness flatting
the exhaust manifold At the same damage or faulty connections and
time the
remove screws securing the each part for proper installation If
bracket and rubber hose clamp nere
ry replare
EC 8

EM ISSION CO NTROL SYSTEM Exhaust Emission Control System
EXHAUST GAS RECIRCULATION E G R CONTROL SYSTEM
DESCRIPTION
I during combustion This results in a from the exhaust manifold to the
In the exhaust gas recirculation reduction of the nitrogen oxide NOx E GR chamber The exhaust gas is
system a part fthe exhaust gas is content in the exhaust gas then controlled in quantity by the
returned to the combustion chamber When the E G R control valve is E GR valve and is introduced into
to lower the spark flaine temperature of the exhaust gas is led the intake manifold
open some
Type2 From air pipe

JJ
JT
All
n o Throttle
II I chamber
venturi
1 II 1 Throttle
valve
Advance EG R
oontrollinel r
vacuum
port
Engine
coolant
E G R valve
L J Type A2
L Thermal vacuum valve
valve Type A3
t Thermal vacuum
Exhaust gas from exhaust manifold

SEC017
Type IL rom air pipe

l
D
I Air
0 Throt e
chamber
II venturi
I Throttle
1 It valv e
Ad ance controlline E GR
vacuum
port
Engine
coolant
E G R valve
T0
r If I
L J
L Thermal
Thermal
vacuum
vacuum
uve Type A3
v
valve Type AI
Exhaust gas from exhaust manifold SEC018
EC 9

Exhaust Emission Control System EM ISSION CONTROL SYSTEM
Type 3
Air
I I
I
ro
lL
LJ
I Vacuum port
I
rEngine coolant
L
Exhaust gu from exhaust manifold
SEC309
OPERATION
The operation of the system is as follows
Type 2
Water temperature I Thermal vacuum valve V V T valve E GR

Oc oF Type A3 control system
Type A2 Venturi vacuum Exhaust gas pressure Operation
High Low
Below 15 59
I High High Closed
Open Closed Not actuated
I Low High
Low Low Open
High Low
15 60 Leak Closed
J High High Closed
Slightly
59 140 I Low High actua ted
Low Low Open Not actuated
High Low
High High Closed

60 95 Closed Closed Actuated
203 Low High
140
High Low
High Closed
Above 95
High
Closed Open Not actuated
203 Low High
Low Low Open
EC IO

EM ISSION CONTROL SYSTEM Exhaust Emission Control System
Type I
Thermal vacuum valve V V T valve E G R

Water temperature
control system
Oc eF Type Al Type A3 Venturi vacuum Exhaust gas pressure Operation
High Low
High Closed
High Not actuated
Below 60 140 Open Closed
Low High
Low Low Open
High Low
Closed Actuated
High High I
60 95 Closed Closed
140 203
Low High
Low
High
Above 95 Closed Open

I High High Closed
Not actuated
203 I Low High
1 Low Low Open
TYpe 3
1 B P T valve
E G R
Water temperature Exhaust gas pressure
Thermal vacuum valve Operation control system
Oc em kPa mmHzO inHzO
Below 0 206 324

0 21 33 0 82 30
i Open
Below Closed Not actuated
122
50
Above 0 206 324
0 21 33 0 82 30
1 Closed
Below 0 206 324

0 21 33 0 82 30
1 Open Not actuated
Above 50 122 Open
Above 0 206 324
0 21 33 0 82 30
1 Closed Actuated
idle or at full Thermal vacuum valve

With the engine at and destinatiol For identification
car
is stamped 3 port type
throttle the E G R control valve doses purposes the part number
to deactivate the E G R system regard on the recessed portion at the top of Two thermal vacuum valves are
less of water temperature operation of the valve installed one on the upper side of the
the thermal vacuum valve and V It T intake manifold and the other on the
valve or B P T valve lower side These thennal vacuum
valves detect the temperature of the

engine cooling water The valve shaft is
pushed up or down by the thennal
expansion force of wax which depends

on the temperature This action opens
E G R control valve and closes the valve which causes the
G d
The E G R control valve controls E GR control vacuum line to be
the quantity of exhaust gas to be led opened or closed to the atmosphere
to the intake manifold through vertical
movement of the taper valve connect

I I ID When the valve opens
throttle chamber vacuum
air from the
signal line is
I
ed to the diaphragm to which vacuum ur introduced and while the venturi
SEC019 V T valve
is applied in response to the opening vacuum transducer V con
of the throttle valve 4 Valve trolorifice and E G R valve diaphragm

1 Diaphragm spring
E G R control valve construction 2 Diaphragm 5 Valve seat are exposed to the atmosphere the
and type vary with transmission type 3 Valve shaft 6 Valve chamber E G R operation will not function
EC

Exhaust Emission Control System EMISSION CONTROL SYSTEM
Thermal vacuum valve 8P T valve

Type A2
port
2 type
To E G R The PT
B valve monitors exhaust
control line The 2 port type thennal activate the
vacuum pressure to diaphragm
JQ valve is mounted the
engine
on controlling throttle chamber vacuum
From
r air cleaner
thennostat housing It detects engine applied to the E G R control valve In
coolant temperature by means of a other words the amount of recircu

JQ built in bi metal and opens or closes tated exhaust gas varies with the posi
Orifice the vacuum pa ge in the thermal tion of the E G R valve regulated by

vacuum valve the operating condition of the engine
When the vacuum passage is open
the throttle chamber vacuum signal is
Q the of the
To E G R ubber ClIp
applied to diaphragm control1ine
To distributor
advance E G R control valve to actuate the
Air
control line per valve connected to the dia
phragm
Wax
SEC020
f
Exhaust pressure SEC20a
TypeAI
From
I
1
rair cleaner metal
Bi
REMOVAL
1 Spiing
AND INSTALLATION
SEC023
Q
n To E G R
control line E G Ii controi valve
and E G R tube
I O
Venturi vacuum transducer 1 Remove nuts which secure

j V V T valve
E G R tube and P tube to E G R
B
IQ The vVT valve monitors the valve and disconnect tubes from valve
To distributor
advance pressure of the exhaust gas which 2 Disconnect vacuum hose and
1
control line actuates the diaphragm @ and the remove securing E G R control
nuts
venturi vacuum which in turn activate valve to Intake Manifold The E G R
the diaphragm 1 @ This valve con control valve can then be taken out
trols the throttle vacuum in order to
Wax
ctivate the E G R control valve J
In other words the amount of reo
SEC021 circulated exhaust gas varies with the

position of the E G R valve regulated
TypeAJ by the operating condition of the
From air c1eanCi engine
Spring
Ii 1 EG R Control
E GR control
Vatve
C control line
Air bleed
orifice
ported vacuum
1
Spark
advance
control
I vacuum
line
CAUTION
T Pay attention not 10 give damage to

Air pipe
Exhaust gas packing of E 6 R control valve
Wax t pressu SEC024
3 Installation is in the reverse

1 Diaphragm 3 Diaphragm
SEC022
2 Diaphragm sequence of removal
EC 12

EM ISSIONCONTROL SYSTEM Exhaust Emission Control System
a When installing a new E G R valve

Type A3
verify it is of the same type model
number and identification mark

etc l as that which was previo slY
installed
b Always install a new gasket
SEC029 SEC030
The thennal vacuum valve is made

of plastic Consequently care should V V T valve 4 Installation is in the reverse
be taken to avoid damaging it On
1 Disconnect vacuum tubes on the sequence ofremoval
U S A models two valves are located
on the intake manifold One is located V V T valve When replacing the B P T valve
on the front side of the intake mani 2 Disconnect screws which secure
with new co f rm that the type
fold The other is located under the V V T valve to bracket number on new part is the same as
end of the intake manifold On 3 Disconnect back pressure tube that

rear on
former one
Canada models the valve is located from V V T valve

on B P T valve
the intake manifold The V V T valve can then be taken J
i mounting screw
3 7 5 0 N m
out
I Drain engine coolant about one Q 38 0 51 kg m
liter 2 7 3 7 ft lb
2 Disconnect vacuum hoses and

unscrew the thermal vacuum valve
Then the valve can be removed
3 Installation is in the reverse INSPECTION
sequence of removal
Be sura to sealer to threads of

Entire system
a apply
the valve prior to installing a new l Make a thorough visual check of
valve EG R control system If necessary
b When installing a new thermal SEC029 wipe away oil to facilitate inspection
vacuum valve be sure that color If any hoses are cracked or broken
and shape are correct replace
2 With engine stopped
4 Installation is in the reverse inspect
Type A2 E G R control valve for any indication
sequence of removal
of binding or sticking by moving dia
V V T valve
When replacing the
that the type
phragn Of c ntrol valve up ds with
with a new one verify a fmger J
number on the noYi part is the same as
3 With engine running inspect
that on the former one
EG R control valve and thennal
J
i V V T valve mounting
i
crew vacuum valve for nonn 1 operation
37 5 0 N m Place your finger on diaphragm of
J 0 38 0 51 kg m E G R control valve to ensure that the
27 3 7 lb
ft valve functions as described below
SEC026
8P T valve r
1 Remove vacuum tube on the
B P T valve
2 Remove screws securing B P T

valve to the bracket
3 Disconnect back pressure tube
from BP T valve
The B P T valve can then be taken
SEe027 SEC031
out
EC 13
Emission Co
Exhau 1
System IM ISSION CONTROL SYSTEM
vacuuin is present at the end E G R corit ol valve
E GR control valve side of

Dismount E G R control valve
vacuum hose
from engine
1 Apply vacuum to E G R control
Type Al TypeA2
valve referring to the following figure
If the valve moves to full position it is
nonnal
GR
E control valve will remain
open for more than 30 seconds after

vacuum has cut off
SECOO2
1 When temperature of the engine

coolant is low
Below ISoC S90F
California models
Below 6001400F
Non California modals
Below SOOC 1220F I I

Canada models
seC018
ucsl
Make sure that E G R control valve
is
does not operate when engine speed
increased from idle to 2 000 2 500
check E GR control
2 Visually
rpm valve for wrinkle or deforms
Canada damage
2When temperature of the engine Airregulatort lion
coolant is high f
Above ISoC S90F
California models
Above 600C 1400F
Above SOOC 1220F

Canada models
Dismount thennal vacuum valve

1 Make sure that E G R control
is
TV J
V C035
from engine
valve operates when engine speed
increased from idle to 2 000 2 SOO
Before dismounting drain engine
rpm coolant from engine
2 If EG R control valve does not Ifvacuum pressure is either weak or
it as follows thermal Apply to thennal vacuum
operate properly check nonexistent replace vacuum
valve Ifvacuum Pse ss lJe is valve and check to be sure that ther
Disconnect one end KG R control vacuum
of which detected replace E G R valve mal vacuum valve opens closes in

or
valve side vacuum h
3 way connecter to c to engine coolant tempera
connects
E G R control valve If any difficulty is encountered in ture as specified

from idle to the condition of any com Thennal vacuum valve should open
Increase engine speed judging
2 000 2 SOO rpm ponent during above inspection check or close at a
temperature specified
that thennal the questionable component inde below completing the vacuum
Make sure vacuum
valve is closed and that throttle pendently as follows pa5Sage
EC 14

EMISSION CONTROL SYSTEM Exhaust Emission Control System
Thermal vacuum valve operating temperature 2 Apply vacuum pressure above

0 785 kPa 80 mmH20 135 inH20
Operating temperature Oc OF to V V T valve and check for leakage
Type Applied model
Leak Open Close as shown below If a leak is discover
ed valve
replace
Wax 60 95 Below 60 140 Non California
Type AI 140 203 Above 95 203 for U S A
Wax 15 60 60 95 Below 15
California
Type A2 59 140 140 203 59
Wax Above 95 Below 95 Apply pressure
Type A3 I 203
I 203 U S A above
0 785 kPa
80 aO
mmH
Above 50 Below 50
Bi metal
122
1 122
Canada 3 15 inH OI
SEC038
Canada
CAUTION
Do not allow water to gel inside the
thermal Vllcuum valve B P T valve
1 Disconnect two cuum hoses on
B P T valve
s A
U 2 Plug one of two ports of B P T
valve
Apply a pressure above 0 490 kPa
50 mmH20 197 inH20 to B P T
valve and orally suck back other port
of B P T valve as shown below to

check for leakage If a leak is noted
replace valve
1OC1 EC242
SEC036 Apply pressure above

V V T valve 0 490 kPII 50 mmH20 1 97 inH201
EC381 A
1 Apply a
pressure above 1 961 kPa
200 mmH20 7 87 inH20 to V V T
valve and check it for leakage as shown
below Ifa leak is noted replace vaive
SPARK TIMING
CONTROL SYSTEM
DESCRIPTION
The spark timing control system is

designed to control the distributor
Apply vacuum above vacuum advance under varying
t 1 961 kP driving
conditions so as to reduce HC and
SEC037 200 mmH20 7 87 inH OJ
NOx emissions
EC 15
ExhsustEmissionControlSystem EMISSION CONTROL SYSTE
OPERATION REMOVAL
AND INSTALLATION
The operation of the system is as follows

Thennal vacuum valve
Water temperature Spark timing The thermal vacuum valve designs
Oc OF AI A2 A3 control system are exactly the same as those used in
Type Type
the E G R control system Refer to
Below 15 59 Closed Closed Actuated the instructions under the headirig
EGR control system for removal
15 60 59 140 Open Closed Not actuated
and installation procedures
60 95 140 203 Closed Closed Actuated
Above 95 203 Closed Open Not actuated
This system does no1 operate with tha engine at iale

INSPECTION
port
3 type TypeAi
Two thennal vacuum valves are Entire system

From
A
installed the upper side of the J rair cleaner
II
one on I Ensure that vacuum hoses are
intake manifold and the other on the I properly connected to their con
lower side These thennal vacuum 19
valves detect the of the
1 I Q controllme
temperature 2 Make sure that distributor vacuum
engine coo ling wa ter The valve shaft is controller functions properly
pushed up or down by the thennal I 3 Set timing light
expansion force of wax which depends 4 Check thennal vacuum valve
on the temperature This action opens
beginning with a cold engine
and closes the valve which causes the iQ 1 Using a timing light check the
distnbutor
or closed to the
vacuum line to be opened
atmosphere
l
I To distributor
a4vance
spark timing while temperature gauge
is in the C position
coIitrolline
When the valve opens the vacuum
signal line will open to the

phere stopping the distributor
atmos
vacuum
I
from advancing Wax
SEC021
TypeA2
To E G R
control line TYpe A3
e
From
C
From
air cleaner aircleaner

Spring
I
lQ
t1
ii n SEC039
Valve
iiCE G R
control line
Q
2 Using a timing light ensure that
e Q ce
control the spark timing retards from its pre

To distributor
advance
vacuum vious position when temperature gauge
line
i
control line changes from the C position to the
middle position
i1i 3 Wann up the engine until coolant
I Wax
temperature gauge pointer moves to
Wax
middle position of scale Ensure that
the spark timing advances from its
SEC020 SEC022
previous position
EC 16

EMISSION CONTROL SYSTEM Exhaust Emission ControJ System
To check for operation of thermal from the 3 way connector through the
follows air hose and vacuum control valve To
valve proceed as
the air
keep oil consumption low as
enters the intake manifold vacum

will be maintained at less than the
specified level
Vacuum control valve VC V

Remove thermal vacuum valve from To check for operating proceed as

SEC040
follows
engine Inhale air from port of spark
timing control system and check to be I Disconnect one end Air regulator
sure that thermal vacuum valve opens side of air hose connecting 3 way
If spark timing does not change reo or closes in response to its tempera connector to V C V
place thennal vacuum valve ture 2 Make sure that vacuum control
valve operates when engine speed is
decreased from 3 500 4 000 to idle
Place on the hose end to

finger
Thermal vacuum valve operating temperature
check for valve operation
3 If the intake manifold vacuum is
Operating temperature Oc F
not present at the end of air hose
Type
Open Close replace vacuum control valve
Below 15 59
Al A2 15 60 59 140
Wax Type Above 60 140
Above 95 203 Below 95 203

Wax Type A3
DECELERATION
CAUTION
00 not allow water 10 enter the ther CONTROL SYSTEM
mal vacuum valve
Intake manifold
vacuum control type
DESCRIPTION
The deceleration control system is
to control the intake mani
CATALYTIC
designed
fold vacuum under decelerating driving CONVERTER
condition 59 as to reduce the oil con
DESCRIPTION
sumption
The catalytic converter accelerates
the chemical reaction of hydrocarbons
HC and carbon monoxide CO in
the exhaust gas and changes them into

OPERATION
non hannful carbon dioxide CO
This system is used to force air and water H O This chemical

the proper
directly into the intake manifold w en reactionprocess requires
amount of air which is induced y the
preset vacuum level has been at
the
tained thus preventing excessive in air induction valve Refer t the item
creases in the intake manifold vacuum A IS This air is called secondary

SECQ36 Air is directed air
during deceleration
EC 7

Exhaust Emission ContrQl System EM ISSION CONTROL SYSTEM
INSPECTION
Preliminary Inspection
Visually check condition of all

component parts including hoses
tubes and wires replace if
necessary
Refer to Air Induction System for
ft inspection
Catalytic converter L MufIIer

Ci converter
SEC043
Whether catalytic converter is
normal or not can be checked by

observing variation in CO percentage
The is as follows
checking procedure
Apply parking brake Shift gears
OPERATION
into Neutral for manual trans
Exhaust emitted from mission and N or P for auto
gas the
contains hannful sub matic transmission position
engine some
stances due to incomplete combustion

in the combustion chamber The air California models
induction system is designed to reduce I Visually check catalytic converter

the content of such substances in the for cracks
damage or
exhaust gas In this system the 2 Adjust engine idle speed Refer
secondary aicisJed from the air in to g Idle RPM for adjustment
Mjus
duction valve and into the
injected SEC044 3 Race engine 500
1 to 2 000 rpm
exhaust manifold With this injection two or three times under no load
of the secondary air hydrocarbons 4 speed increases readjust
If idle
HC and carbon monoxide CO in it tospecified speed with throttle
the exhaust gas are gradually oxidized adjusting screw
with oxygen 0 in the secondary air SWann up engine for about four
and converted into hannful
non carbon minutes at 2 000 rpm under no load
dioxide CO and water H O 6 Measure CO at idle
percentage
Thecatalytic converter further speed After step S has been com
cleans engine exhaust gas Through pleted wait for one minute before
catalytic action it changes residual making CO percentage measurement

hydrocarbons and carbon monoxide SEe04S 7 If CO percentage measured in step
contained in exhaust gas into carbon 6 is less than 03 the catalytic con
dioxide and water before exhaust gas verter is nonnal
is discharged to the atmosphere 3 Installation is in the reverse
8 If CO percentage measured in step
6 is over 3
0 recheck Al S arid
sequence ofremoval
air induction valve Then per
replace
form inspection steps S and 6
CAUTION 9 CO
if percentage is still over 3
0
REMOVAL a Be careful damage catalytic
not to in step 8
catalytic converter is mal
AND INSTALLATION converter when handling functioning Replace catalytic con
b Newr wet catalyzer with wa1er oil verter
I Jack up the car
etc
Apply parking brake and place

wheel chocks
fJ Lower shelter bolt
2 Remove Califomia
Non models
screws securing lower 6 3 8 3 N m
shelter of catalytic converter 0 64 0 85 I VisuaIly check catalytic converter

m
kg
Loosen flange bolts connecting 4 6 6 1 ft lb for damage or crack
catalytic converter to front and converter bolt 2 idle
rear Catalytic Adjust engine speed and CO
exhaust tubes 31 42 N Refer
m percentage toAdjusting Idle
Catalytic converter assembly can 3 2 4 3 m
kg RPM and Mixture Ratio for adjust
then be taken out 23 31 ft bl ment
EC 18

EMISSION CONTROL SYSTEM Evaporative Emission Control System
3 Race engine 500

1 to 2 000 rpm 5 Wann up engine for about four 8 If CO percentage measured in step
two Or three times under no load and minutes at 2 000 rpm under no lmid S is over 3
0 recheck AJ S and
make sure that specified CO 6 Measure CO percentage at idle
per replace air induction valve Tlien per
centage is obtained speed After step 4 has been com fonn inspection steps 4 and 5
4 Remove cap and connect air hose pleted wait for one minute before 9 If CO percentage is still over 3
0
to air induction v
a1ve making CO percentage measurement in step 7
catalytic converter is mal
If idle speed increases readjust it 7 If CO percentage measured in step functioning Replace catalytic con
to specified speed with throttle adjust 5 is less than 3
0 the catalytic con verter
ing screw verter is normal
EVAPORATIVE EMISSION CONTROL SYSTEM
DESCRIPTION
This system is made of the
up S Vacuum signal line
Theevaporative emission control following 6 Canister purge line
system is used to reduce hydrocarbons 1 Fuel tank with 7
positive sealing filler Vapor liquid separator Hatchback
emitted to the atmosphere from the
cap models
fuel system This reduction of hydro 2 Fuel check valve Removal and installation of above
carbons is accomplished by activated
3 Vapor vent line components are described in Section
charcoals in the carbon canister 4 Carbon canister FE
Fuel Hller cap

Pressure regulator Vacuum reliet
Fuelf1lter Vapor liquid separator

HATCHBACK model OnlY
Fuel return line
Fuel check
valve
Fuel reed line

I
Z
Fuel tank
c I
81
Fuel danlper J
Electrical
fuel pump
f 1 Fuel mjector
sending unit

Vapor storage
canister
Intake manifold
Canister
purge line
SEC046
EC 19
Etlaporative Emission ContlOlSystrm EMISSION CONTROL SYSTEM
rr
OPERATION tank are directed to the carbon canis coals and stored there when the engine
char
ter which is filled with activated nmning
is not
Fuel vapors from the sealed fuel
HARDTOP models
POsitive Sea
lli1g gas cap
J111
Vacu1
lline7 with aCllum relief valve
L
vapor
jFUel
LJ
I r
I
vent line
ri Fuel che
Intake ffil IlifOldJ

t
f fJ
ij
Freshair
j
Fuet vapor
L Fuel tank
SEC041
HATCHBACK modeb
Yaporjliquid
separator
Vacuum signal line Purge control ialve
7
L J
Fuel vapor
LJ
I r vent line
sitive sealing gas
G cap with vacuum
1
relief valve
Fuel check
tr I
I
Fixed orifice
Con tant purge i

lice
Intake manifold
J S
Si
J
i
iji ji
Fresh air
Fuel vapor LFUe tank
SEC048
EC 20

EM ISSION CONTROL SYSTEM Evaporative Emission Control System
The canister retains the vapor until 3 Engine speed increases INSPECTION
it ispurged by the air drawn through
the purge line towards the intake FUEL TANK AND VAPOR
To carburetor CJ
manifold while the engine is operaiing
Ported vacuum VEfo T LINE
When the engine runs at idle the purge
To intake
control valVe is closed Only a small Check all hoses and tank
fuel IDler
manifold
cap
amount of purge air flows into the @
2 Disconnect the vent line
intake manifold through the constant vapor
carbon canister to fuel
purge orifice As the engine speed in Onnecting
C
iank
creases and the ported vacuum rises
Fresh air 3 Connect a 3 way connector
higher the purge control valve opens a
F el vapor manometer and a cock or an equiva

and the vapor is drawn into the intake
lent 3 way cock
manifold through both the fixed charge to the end of
orifice and the constant purge orifice the vent line

1 Diaphragm 4 Constant fixed 4 Supply fresh air into the vapor
2 Pltrge control orifice
valve 5 Activated carbon vent line through t e cock little by
I Engine does not operate
3 Fixed orifice 6 Filter little until pressure becomes 3 923 kPa
400 mmH20 15 75 inH20
From
fuel
tank 3way connector 3 kPo 400 mmH20 15 75 inH 2 0
i Cock
I Air Manometer Check valve
umuu 11
l
N
fl
Fuel vapor Fuel filler cap
SEC049
1
2
Diaphragm
Purge control
valve
4
5
Constant fixed
orifice
Activated carbon
@
Carbon canister
3 Fixed orifice
EC091A
5 Shut the cock

Engine operates at idle completely and Iy made thus causing insufficient de
leave it unattended livery of fuel to engine or vapor lock
6 After 5 minutes
2 the It must therefore be
measure repaired or
height of the liquid in the manometer replaced

7 Variation in height should remain
with 245
0 kPa 25 mmH20 0 98
inH20
8 When filler cap does not close
completely the height should drop to
zero in a short time CARBON CANISTER PURGE
9 If the does not
Fresh air height drop to CONTROL VALVE
Fuel vapor zero in a short time when filler cap is
SEC050 Check for fuel vapor leakage in the
removed it is the cause of a stuffy
1 Diaphragm 4 Constant fixed distributor vacuum line at diaphragm
hose
2 Purge control orifice of carbon canister purge control valve
valve 5 Activated carbon In the vent line is
case stuffy the To check for leakage proceed as
3 Fixed orifice 6 Filter
breathing in fuel tank is not thorough follows
EC 21

Evaporative Emi on Control smem EMISSION CONTROL SYSTEM
I Disconnect rubber nose in he I Disconnect thb l

ub ber llooe on the FUn TANK VACUUM
line between Tconnector and carbon line between the steel pipe of the RnlEF VALVE
canister at T onnector engine and canister
Remove fuel filler it
2 Inhale air into the
opening of 2 Force air into the opening of the cap and see
functions properly
rubber hse running to vacuum hole in rubber hose which runs to tiJe carbon
I Wipe clean valve housing and have
carbon canister and ensure that there canIster and ensure that there are
it in your mouth
is no leak leaks
2 Inhale air A slight resistance ac
cornpaniedby valve indicates that
valve is in good mechanical condition
Note also that by further inhaling air
the resistance should be disappeared as
valve clicks
3 If valve is clogged or if no resist
ance is felt replace cap as an assem
bled unit
EF199 SEC052 r
3 If there is a leak remove top 3 If there are no leaks remove

cover from purge control valve and control valve and check the
purge
check for dislocated or cracked dia constant purge orifice for leak If
phragm If necessary replace dia necessary clean the constant purge
phragm kit
which is made up oLa orifir
retainer diaphragm and spring
ET500
Cover
Diaphragm
Retainer
t Diaphragm spring
FUEL CHECK VALVE
1 Blow air through connector on
fuel tank side

SEC053
A considerable resistance should be
felt at the mouth and a portion of air

flow be directed toward the engine
2 Blow air through connector on
EF200
engine side
CARBON CANISTER FLTER
Air flow should be smoothly direct
Check for a contaminated element ed toward fuel tank
Element can be removed at the 3 If fuel check valve is suspected of
bottom of canister installed on car not being properly functioning in steps
body I and 2 above replace
CARBON CANISTER r ltank
CONSTANT PURGE ORIFICE
Check the constant purge flow in

the intake manifold vacuum line at
the constant purge orifice of carbon
1
Q
e
tm
l
Evaporative fuel flow
canister Fresh air flow
To check the purge flow proceed

as follows EC090A
EC 22

EM ISSION CONTROL SYSTEM Service Data and Specifications
TIGHTENING TORQUE
Unit N m m
kg ft lb Unit N m kg m ft Ib
E G R tube securing nut 34 44 3 5 45 25 33 V V T valve mounting
E A I tube securing nut 34 44 35 45 25 33 Iscrew

3 7 5 0 0 38 0 51 2 7 3 7
P T valvo mounting
Less than
22
Less than
2 2
Less than
1 6 18
screw
3 7 5 0 038 0 51 27 3 7
I Catalytic converter bolt 31 42 3 2 43 23 31
EC 23

DATSUN 200SX Mod 1 S II 0 Series
SECTIONER
ENGINE REMOVAL INSTAllATION
CONTENTS
ER
ENGINE REMOVAL AND
INSTALLATION
CONSTRUCTION
ER 2
ER 2
INSTALLATION
SERVICE DATA AND
SPECIFICATIONS ER 5
5g
ER 2 ER 5
REMOVAL TIGHTENING TORQUE

Engine Removal and Installation ENGINEREMOVAL INSTALLATION
ENGINE REMOVAL AND INSTALLATION
CONSTRUCTION
87
Iii 30 40
3 1 4 1 22
8 7
19
Iii 30 40
Iii 44
4 5
54
5 5 33 0
1 3 1 4 1 22 30
31 42
3 2 4 3 23 31
Iii N m m
Itg ft b
SERD01
REMOVAL CAUTION
4 Turn the ignition switch OFF
5 Reconnect tJie harness connector
It is much easier to remove Before disconnecting fuel hose release
engine
of fuel pump rel y 2
and transmission as a single unit than fuel pressure from fuel line to elimi
to remove them separately After reo nate danger
moval F nd shCll ld b uBI
engine can be separated from r co to
IStart the engine
transmission assembly protect car body
2 Disconnect the harness connector
2 Disconnect the negative
of fuel pump battery
relay 2 while the en cable
gine is running
WARNING
On air condition r aquipped mod ls
a Place wheel chocks in front of
destined for California remon tho
front wheels and in rear of rear Relay bracket
battery to facili this operation
wheel
b Be sure to hoist engine and 3 Drain engine coolant
jack
up transmission in a safe man 4 Remove hood
nero Mark tho location of hood hinges
C You should not remove the on hood to facilitot correct reinsta
engine until the exhaust system lotion
has completely cooled off
Otherwise you may burn your CAUTION
self and or fire may break out in Have an assistant help you so as to PII
SEF131
fuel line vent damage to body
5 Remove aU wires and hoses where

I FoUow the procedure below to 3 After the engine staUs crank the
indicated by the arrows in the figure
reduce fuel pressure to zero engine two or three times below
ER 2

ENGINE REMOVAL INSTALLATION Engine Removs and In tallation
1
r
I
Yr
p
t
1
u
J
o
0 o
SER003
Air conditioner equipped 2 Remove compressor Power steering equipped

models Place removed compressor as shown models
below Remove power steering oil pump
Remove compressor foUowing the
procedures below Ne er d ilCherge gas from compres foUowing the procedures below
I Remove oil pump drive belt
I Remove compressor drive belt sor while service repair work is being
To this belt loosen both To remove this belt loosen both
remove performed
idler puUey nut and adjusting bolt idler puUey nut and adjusting bolt
P fi
qa
9
III
ey nut
5
a
n
1
I
djUS ing
l I
11 AOO
ER 3
Engine Removal and Installation ENG INE REMOVAL INSTALLATION
2 Remove oil pump

Place removed oil pump as shown
below
Never drain oil from oil pump while
sorvice repair rk i being perfonnod
Mk
ar mgp 1
SER010
I SER024
g Disconnect speedometer cable Plug open holes in rear extension

9 Disconnect down shift solenoid hown
housing as
wire and inhibitor switch wire AfT
only
6 Remove transmission control link
age as foUows
1 Manual transmission
12 Attach suitable wires to

engine
E 33 iW sIingers and raise engine using a hoist
to take the weight off front and rear
10 Disconnect vacuum hose AfT mount insulators
only
2 Automatic transmission
WARNING
BeforB raising engine try loosening
wires two or three times to make
sure it is safe to do so
I3 Remove rear engine mounting

support body
to aUaching bolts
II Remove clutch operating cylinder
7 Remove radiator and radiator front exhaust tube and propeUer shaft
shroud
Place marks on propeller haft be
On air conditioner equipped mo fora remo al to facilitate reinstall
dels remove oil cooler ho tion
ER 4

INSTALLATION ServiceDataandSpecifications
ENGINE REMOVAL
tion MA for checking and adjust

14 Remove front engine mounting INSTALLATION
ing drive belts
bolts InstaU in the reverse order of reo
InstaU power steering oil pump and
15 Raise engine and transmission and moval observing the foUowing adjust belt
remove them from car as a single unit
When installing be lure to check Refer to Pump Belt Adjustment
that electrical are
heme correcdy Section ST for adjustment
WARNING exhaust front tube
connected 3 When installing
When raising engine be especially on exhaust manifold be sure to instaU
careful not to knock it against ad I When installing first secure rear
a new gasket
jacent parts engine support bracket to rear mount 4 When reinstalling the hood foUw
ing insulator ing engine instaUation be sure that it
2 Refer to pertinent section when centered and that hood
is properly
16 Set engine and transmission on an
installing and adjusting any parts lock operates securely Refer to Hood
engine stand Adjust accelerator control system Section BF for adjuslment
Refer to Engine Control System 5 Add the correct amount of engine
Section FE for adjustment coolant
InstaU air conditioner compressor 6 For automatic transmission mod
and adjust belt els add the same amount of automatic
Refer to Engine Maintenance See transmission fluid as was drained
TIGHTENING TORQUE
N m
m
kg ft Ib
Unit
30 40 3 1 41 22 30
Front engine support bracket to cylinder block
Front 31 42 3 2 43 23 31
engine support bracket to mounting insulator
31 42 3 2 43 23 31
Front mounting insulator to body
44 54 45 5 5 33 40
Compressor to bracket
19 25 19 2 6 14 19
Steering oil pump to bracket
118 09 12 65 87
Rear mounting insulator to transmission 8
8 8
11 09 12 65 8 7
Rear mounting insulator to mounting member
20 42 2 4 3 14 31
Mounting member to body
Exhaust maniflold to exhaust tube 20 25 2 0 2 6 14 19
Clutch 30 40 3 1 4 1 22 30
operating cylinder to engine
ER S

DATSUN 200SX Mode S 110 Series
SECTIONFE
ENGINE CONTROL FUEL
EXHAUST SYSTEMS
CONTENTS
FE 6
ENGINE CONTROL SYSTEM FE 2 INSPECTION
ADJUSTMENT FE 2 INSTALLATION FE 7
REMOVAL FE 3 EXHAUST SYSTEM FE S
INSPECTION
INSTALLATION
FUEL SYSTEM
FE 3
FE 3
4
FE
REMOVAL
INSPECTION
INSTALLATION
FE 9
FE 9
FE 9
GII
REMOVAL FE 5

EngjneControISyltem ENGINE CONTROL FUEL EXHAUST SYSTEMS
ENGINE CONTROL SYSTEM
Adjusting bet nut
Ptdal free play

o 2 mm 0 0 08 in
arm
Iii 2 9 3 9
t
frPedaI
0 3 0 4
2 2 29
Pedal arm
brlcket
j aI t etum
PlUIll
ft lb
Iii N m kg m
SFEQ01
ADJUSTMENT a Depress accelerator pedal to make
Iura its
linkage moves lIDootItly
ACC RATOR WIllE without jamming or dragging re
lease pedal to make lure it returns
Adjust accelerator pedal free play
to specifICation using adjusting nuts to its original position smoothly
b Check to see if throttle valve fully
open when accelerator pedal i
completely depressed and if it

returns to idle when releasad
c Pedal height adjustment i not
necessary since its height is deter

mined by stopper
SFEOO3
FE 2

ENGINE CONTROL FUEL EXHAUST SYSTEMS Engine Control System
REMOVAL INSPECTION
I Check pedal return spring for rust
ACCELERATOR WIRE damage if
fatigue or Replace neces
lock nuts and sary

I Loosen adjusting
2 Check accelerator wire cases
disconnect accelerator wire from car
socket and fastening locations for rust
buretor
damage or looseness Repair or replace
if necessaiy
INSTALLATION
To instaU reverse the order of
removal
SFE155
a Check accelerator controrparts for
improper contact with any ad
jacent parts
it b When connecting accelerator wire
2 Remove nylon coUar by pushing
be careful not to twilt or scratch its
toward wire end and disconnect
ACCELERATOR PEDAL inner wire
accelerator wire from pedal ann
c On automatic transmission models
Remove nylon collar and discon
nect accelerator wire from tip of pedal depress accelerator pedal to make
su
arm
that kickdown switch turn
when throttie alve is fully open

Then remove pedal arm assembly on
and t t push rod mo properly

by removing pedal arm bracket retain
r
ing 01t
SFE154
3 Remove pedal stopper bracket

and extract accelerator wire toward
EF156
passenger compartment
FE 3

rl I
m ZG Zm n o z l0 o r T1 C m r ll mX J Ic C l C
llC llm s C
l
m r en enI mi
m
unit m Itg
8 fHb
18N 1
13
fHb
I
k
pate
c
0
1
tank uge
uel
ing
O
tank
14
Iii
4
1 10 m
kg
m
Fuel N
Iii
hose
fil er hoae
check hOle
vol Fuel outlet
Fuel Fuel fetum
Fuel
Hatchback
tube
tube tulx
outlet
return
Fuel
Fuel
Enporatin
Hardtop
cap
fil er ho
hole
tube fil er
Fuel
fil er
Fuel Ventilao Fuel
II m Q Qom
mJ
o

ENGINE CONTROL FUEL EXHAUST SYSTEMS Fuel System
Evaporation hose
REMOVAL
Fuel filler hose Hardtop
WARNING
When replacing fuel line parts be
sure to observe the following
a put a CAUTION INFLAM
MABLE sign in workshop
b Be sure to furnish workshop
with an asphyxiator
c Be sure to disconnect battery
ground cable before conducting
operations
d Put drained fuel in
an explosion
proof container and put on lid FUEL TANK GAUGE UNIT

securely
I Disconnect battery ground cable
5 Remove bolts which secure fuel
2 Remove protector from luggage
tank in place and dismount fuel tank
compartment and disconnect harness
FUEL TANK for fuel tank gauge unit Also remove
rubber grommet
1 Remove battery ground cable
frofuel tank 3 Turn lock plate counterclockwise
2 Drain fuel
and extract fuel lank gauge unit
the
compartment and then remove
foUowing parts
Harness connector for fuel tank
gauge unit
Ventilation hose
18N m
Evaporation hoses SFE012 1 4 3ft lb

Fuel filler hose Hatchback
Hardtop
Harness connector
Ventilation hose
RESERVOIR TANK
Hatchback
FUEL FILLER TUBE AND
I Remove battery ground cable HOSE
R H
compartment Also remove
2 Drain fuel if fuel overfloWs when
speaker and side lower flnisher
nnector disconnecting both fuel filler tube and
HatchbackrHaineiS
A
b1J
o
Ventilation hose
o
hose
3
filler
Open fuel filler lid
cap and remove
remove
fuel
fuel
fIller
attaching bolt
l
G
i
o
SFE010
SFE013
1
I j
4 Remove the foUowing parts from
underside offloor
3 hoses and
2 uel filler p
Fuel outlet hose Remove evaporation
SFE016
Fuel return hose then remove reservoir tank
FE S

Fuel System ENGINE CONTROL FUEL EXHAUST SYSTEMS
4 Remove fuel filler tube and hose

Hardtop cl1eckvalve
as follows
Hardtop
1 Disconnect fuel filler hose from D
k underside of floor
fuel al
9
2 Remove protectors from luggage
compartment and disconnect ventila
tion hose
Remove fuel check valve bracket

and then extract both fuel filler tube
SFEO
and hose
FUEL PUMP DAMPER

AND FILTER
Refer to Section EF
INSPECTION
FUEL TANK
Check fuel tank for cracks or defor

Ifo
mauon replacl
ecessary
Hatchback
Remove protectors from
luggage FUEL TUBE
compartment Also remove rear speak
Fuel tubes are serviced as an assem
FUEL TANK GAUGE UNIT
er and side lower fmisher from right
bly er do not disconnect any
How Refer to Fuel Tank Gauge Unit Jor
side of luggage
compartment Dis
fuel line unless absolltely necessary
cc mnect evaporation hoses ventilation inspection Section EL
hose and fuel filler hose from fuel I Disconnect batlery ground cable
2 Drain fuel from fuel tank
tank and then remove fuel filler tube FUEL FILLER TUBE
3 Loosen fuel hose and
arid hose clamps AND HOSE
disconnect fuel tube at each end
Inspect aU hoses and tubes for
Fuel filler t be Plug hose and tube openi ng to
1 cracks fatigue sweating or deteriora
1 filler 110 I prevent entry of dust or dirt while
tion
removing
Replace any hose or tube that is
damaged
FUEL CHECK VALVE
Refer to Fuel Check Valve for

inspection Section EC
SFE018
FUEL TUBE
Replact any fuel tube 1hat is crack

ed rusted coUapsed or deformed
FUEL CHECK VALVE
Remove fuel check valve as fol FUEL PUMP FUEL DAMPER

4 Remove fuel tube clamps and fuel
lows AND FUEL FILTER
pump bracket from underbody Re
Remove protectors from luggage move fuel tubes and fuel Refer to Fuel
pump as an Pump Fuel Damper
compartment Disconnect fuel check assembly Leave brake tube on under and Fuel Filter for component parts
valve from evaporation hose body inspection Section EF
6
FE

ENGINE CONifROL FUEt EXHAUST SYSTEMS FueISysll1
b Fasten fuel tube clamp on und r result in lea ge from around hose
INSTALLATION connections Do not twist smash
body ecurely Failure to follow or
InstaU any parts of the fuel system this caution could result in damage ventilation and evaporation hoses
in the reverse order of removal routed
to the of fuel tube when they are Be sure to
urfe
Observe the foUowing notes and refer twist and tube retain them with clips securely
c Do not kink or ole
to Fuel Filter Fuel Pump Fuel Fuel tank
when they are routed f gauge unit
Darnper aod Fuel Hose for removal
d Run the and check for leak When installing fuel tank gauge
engine
aod instaUation Section EF unit align tlle projection of fuel
at connection
Fuel tank retaining bolt Fuel tank tank gauge unit with the notch in
GJ e
14 18 N m Install fuel filler hose etter fuel fuel tank and tighten it ecurely Be
1 4 1 8 kg m tank has been mounted in place sure to install fuel tank gauge unit
10 13ft lb Failure to follow this rule could with Q ring in place
a Install ho e clamp ecurely Do not

avoid damag
tighten excessively to
ing hose
FE 7

C m r Ii mX I C J Jlm J
11 m Zc Z m o ZlDo r
lI
m J Iic f f f m3
8 2
7
1
1l 8
8 b
8
mountig
8 8
7
7
0
5
H 2
1 8 ft
Iii 8
8
8 m
0
5
kg
1fJ7
mutner l
m
N
Rear Iii
2
1
8
0
ounli 8
8
op er H
murtle
8
j
I
7
bond Iii
fj
7
8
Exhaust
IUmer rUbJer 8l12
8
RiIl8 8
8
7
0
31l
convert 23
7 Catlyic tube
inulatOJ
7
ePaust heat
8
1 Front lower
58
tir18
82
11
81
mu er
Lower mountlos bncket
5
6
8 9
0 3
0
7 4
flermo
32
Iii 9
0 2
2
mu
Up er raCket gg 1i
1
@ @
LIii tube
I
6
3
exhau
2
7
2
8
5
9
8 0
Front
4
5
3
82 9
0
1
11 2
8 Iii
8
0
7
Iii
m0
m Co
ENGINE CONTROL FUEL EXHAUST SYSTEMS ExhBustSystem
REMOVAL INSTALLATION
InstaU the exhaust system parts in
FRONT TUBE the reverse order of removal
1 Remove catalytic converter lower

ifl Exhaust manifold to front
shelter tube nuts
26 31 N m
2 7 3 2 kg m
20 23 ft lb
Front tube mounting bracket

SF E026 nuts
7 8 11 8 N m
0 8 1 2 kg m
5 8 8 7 ft lb
Catalytic converter attching

bolts
31 42 N m
3 2 4 3 kg m
23 31 ft lb
EXHAUST MUFFLER
Rear muffler mounting insulator
L lift up car with a frame hoist nut
2 Remove catalytic converter lower
7 8 11 8 N m
shelter
0 8 1 2 kg m
3 Remove bolts attaching exhaust
5 8 8 7 ft lb
2 Remove bolts or nuts attaching muffler to catalytic converter remove
Muffler band stopper attaching
front exhaust tube to exhaust mani rear muffler mounting nut and rubber bolts
fold and front tube mounting bracket Dismount exhaust muffler
rings 7 8 11 8N m
Front tube can then be removed through underbody and rear axle case 0 8 1 2 kg m
5 8 8 ift lb
Muffler mounting bracket B
7 8 11 8 N m
0 8 1 2 kg m
5 8 8 7 ft lb
Heet hieiil plate ecuring

I bolt
2 9 4 9 N m
Exhaust muffler
0 3 0 5 kg m
SFE025
1 U SF E027
2 2 3 6 ft lb
a Keep sufficient clearance between

exhaust and
system components
underbody adjacent parts
b ga ket for catalytic con
Replace
verter and for front tube with new
one when removed
c After inStallation check that
CATALYTIC CONVERTER mounting brackets and mounting

rubbers are free from undue stress
Remove catalytic converter lower INSPECTION If any of the above part i not
shelter and remove catalytic converter
I Check muffler and tubes for installed properly excessive noise
cmcks damage or corrosion or vibrations may be transmitted to
CAUTION
the car body
Be careful not Replace any parts that is damaged
a to damage catalytic all tube
beyond limits d With engine running check
converter when handling 2 for exhaust gas leaks
Replace bracket and hanger rub connection
b Never wet catalytic converter with
ber parts that are cracked fatigued or and entire for unusual
system
water oil m
sweated noises
FE 9

S
S
E1 AUS
L
ROL fU
CON
NG N II
II
q
o
E
1 1
fj jj
oJ
6
P
A
Q
O
j
e
SFI

DATSUN 200SX Mode S II 0 Series
SECTIONCL
CLUTCH
CONTENTS
HYDRAULIC CLUTCH CONTROL CL 2 PILOT BUSHING CL 9

CLUTCH PEDAL
l
Ci 2 SERVICE DATA AND
CLUTCH MASTER CYLINDER CL 2 SPECIFICATIONS CL 11
OPERATING CYLINDER CL 4 GENERAL SPECIFICATIONS clli

LINE t 5 INSPECTION AND ADJUSTMENT CL 11
CLUTCH
BLEEDING CLUTCH SYSTEM CL 5 TIGHTENiNG TORQUE CL11
CLUTCH UNIT C 7 TROUBLE DIAGNOSES AND

CLUTCH DISC AND COVER CL 7 CORRECTIONS CL12
RELEASE CL 9 SPECIAL SERVICE TOOLS CL14

BEARING
Refer to Section MA Clutch for
CHECKING CLUTCH PEDAL HEIGHT AND FREE

PLAY

Hydraulic utJ
C h Conrrol CLUTCH
HYDRAULIC CLUTCH CONTROL
CLUTCH PEDAL Co I nstall clevis pin on tha left of
Q clutch pedal and attach snap pin sa
REMOVAL
2
1 Remove instrument lower cover
Pry off snap pin and take out clev
rD l
d
curaly
I nstall return
Figure
spring
on this
as
page
shown in
is pin G
2 After clutch ped
assembly adjust
aI height and free play
0 Refer Checking Clutch Pedal
to
o
SC
Height and Free Play Section MA
l002
tV Pedal rtoppar lock nut
B
7 11 8N m
10 8 12 kg m
5 8 8 7 ft lbl
INSTAllATION
Install clutch in reverse
I pedal or
SCLOOl der of removal
Observe foUowing
1 li ring
a Apply to boss of clutch
grea ped
1 Return spring
3Oevi pin al return spring and fiih rum pin
4 Stopper bolt
5 Outchpedal
3 Remove stopper bolt

CLUTCH MASTER
4 Remove E ring on fulcrum pin
CYLINDER
then remove clutch pedal and return
spring
REMOVAL
I Remove snap pin from clevis pin
2 Pull out clevis pin
3 Disconnect clutch tube
4 Remove master cylinder
INSPECTIoN SCL003
Inspect the foUowing parts If ab

nonnalities are found repair or replace
the affected parts
I Clutch pedal bushing D at boss b Firmly attach E ring to fulcrum When disconnecting clutch tube be
fulcrum pin and E ring sure to draining clutch fluid
recei
V @ for pin
into a container Use of rags is also
wear deformation or damage
suggestad to keep adjacent parts and
Bushing iJ p fitted If it shows
area dean
sign of abnonnality replaca pedal as
sembly
2 Clevis pin @ for wear or damage
and snap pin @ for any deformation
CAUTION
3 Pedal @ pedal pad j and pedal
When disconnecting dutch tube use
stopper @ or clutch switch for de
suitable flare nut wrench
formation or damage Never use an open end wrench or
4 Return spring @ for fatigue or
adjustable wrench
SCL0Q4
damage
Cl 2

CLUTCH Hydniulic Clutch Control
DISASSEMBLY
ir
Reservoir band
Lock nut
lii7 8 118
0 8 12
5 8 8 7
Return spring
1 Iii 7
8 118 0 8 12 5 8 8 7
Stoppetbol
Iii N m m fHb
kg
SCL005
for wear If the clearance between

I Remove dust cover and take off
CAUTION
stopper ring cylinder bore and piston exceeds
Never detach reservoir If it is removed
specified value replace piston as
for any reason discard it and install
sembly or master cylinder assembly
new one
Cearance between cylinder
bore and piston
Le than 0 15 mm
0 0059 in
3 Check condition of piston cup

and dust cover Always replace them
INSPECTION after disassembly
t1 SCLOO6
CAUTION
4 Check aU recesses openings
internal passages to ensure that they
and
To clean or wash all parts of master are clean and free from foreign matter
cylinder clean brake fluid must be

used Never use mineral oils such as
2 Then the push rod and stopper and kerosene It will ruin the
gasoline
can be taken out rubber parts of the hydraulic system
3 Loosen stopper bolt and take it
out
4 The piston spring seat and return ASSEMBLY

1 Check cylinder bore and piston
spring can be taken out
for score or rust and if fo nd replace I Apply grease to cylinder body
Discard piston cup and ust cover 2 Check cylinder bore and piston and piston cup
sliding part
CL3

Hydraulic C1u t
h Control CLUTCH
2 Install piston assembly to cylinder

CAUTION
body
To clean or wash all parts of operating
Be careful not to damage piston cylinder clean brake fluid must be
cup used
4 Make sure that master cylinder Never USe mineral oils such is gasoline
I
operates normally and kerosene It will ruin the rubber
5 Make sure thai piston can move parts of the hydraulic system
maximum siroke smoothly
Stopper bolt fTI
1 5 29N m sc L001 I Check cylinder bore and piston
0 15 0 3 for score or rust and if found
k9 m replace
1 1 2 2 ft
lb 2 Check cylinder bore and piston
for wear If clearance between cylinder
CAUTION
bore and piston is more than the
When disconnecting clutch tube use
suitable flare nut wrench specified value replace piston or oper

INSTALLATION
Never use an open end wrench or ating cylinder assembly
InstaU clutch master cylinder in
adjustable wrench Cearance between cylinder bore
reverse order of removal Observe
and piston
foUowing
less than 0 15 mm
2 Remove lock spring then dis
I Bleed air out of hydraulic system 0 0059 in
engage hose from bracket
Refer to Bleeding Clutch System
3 Remove clutch hose from er
oj 3 Check condition of piston cup
2 Adjust pedal height and pedRl free
ating cylinder and dust
play Refer to Checking Clutch Pedal cover Always replace them
4 Remove operating cylinder
HeiRht and Free Play Section MA after disassembly
heck bleeder holno be surnhat
Master cylinder to dash panel
it is clean
HCUring nut
7 8 11 8 N m DISASSEMBLY
0 8 2
1 m
kg I Remove dust and
8
5 8 7 ft bl
cover push rod
2 Remove piston and piston cup as
Clutch tube flare nut ASSEMBLY
an assembly
15 18 N m
Discard piston cup and dun cover Assemble operating cylinder in

1 5 1 8 m
kg
order of
11 13ft b
reverse disassembly Observe
3 Remove bleeder screw following
Push rod lock nut
I Prior to
7 8 11 8N m assembly dip a new
08 1 2 m
kg pis10n cup in clean brake fluid To
5 8 8 7 ft bl install piston cup on piston pay
particular attention to its direc ion
2 Dip cylinder nd pis10n in clean
CAUTION brake fluid before assembly
When connecting dutch tube use Tool
GG94310000 I
J
When tightening flare nut hold

hand to prevent it from twist CL222 INSTALLATION
pi by
in9 Install operating cylinder in reverse
1 Push rod 5 Piston cup
2 Dwt 6 order of removal Observe foUowing
cover Operating cylinder
3 Piston spring 7 Bleeder screw
Bleed air thoroughly from clutch
4 Piston
hydraulic system Refer to Bleeding
OPERATING Clutch System
CYUNDER 8 When operating cylinder is r moved

from or installed on elutch hou
INSPECTION
ing withoutdisconnecting clutch
REMOVAL
Visually inspect all disassembled hose from operating cylinder loos
L lo9sen clutch tl be flare nut at
parts and replace parts which are worn en bleeder scrow so that push rod
the bracket on side member or damage moves lightly
4
Cl

CLUTCH Clutch Control
Hydraulic
b Exercise care not to warp or twist 3 Remove clutch hose from oper
CAUTION
Be install
clutch hose sure to ating cylinder flare nut Tool
hose from exhaust
When tightening use
clutch away 4 Disconnect clutch tube from mas
GG94310000
tube ter cylinder
When tightening flare nut hold 5
c Remove clamp fixing clutch tube
from
pipe by hand to prevent it to dash panel
twisting
CAUTION
When connecting clutch tube use Tool
GG94310000 INSTALLATION
Wipeopening ends of hydraulic

the
Bleeder line to any foreign matter

remove
i
l screw
6 9 8 8 N m before making connections
0 7 0 9 I Install clutch tube

kg m
I Connect clutch tube to master

5 1 6 5 ft lb
Operating cylind r clutch cylinder with flare nut

BLEEDING CLUTCH
10
2 Fix clutch tube to dash panel
housing securing bolts SYSTEM
30 40 N m with clamp
flare nut
3 1 41 kg m 3 Then tighten The hydraulic clutch system must
30 ft lb be bled whenever clutch line has been

22 i
l Clutch hose to master
disconnected or air has entered it
Clutch hose to operating cylinder cylinder
17 21 N m 15 18 N m I Remove cap of reservoir and top
1 7 2 1 kg m 1 5 1 8 with recommended brake fluid
kg m up
12 15 ft lb t1 13 ft lb
2 Install clutch hose on operating
with a gasket in place

cylinder
Use new gasket
Clutch hose to operating
i
l
cylinder I
17 21 N m
1 7 2 1 kg m o
CLUTCH UNE 12 15 ft lb
SC LoDe
INSPECTION 3 end of hose with

Engage opposite
Check clutch lines tube and hose bracket Install lock spring fixing hose
for evidence of cracks deterioration to bracket

or 2 Thoroughly clean mud and dust
other damage Replace if necessary a When tightening flare nut hold from bleeder screw of operating
around
If leakage occurs at or
pipe by hand to prevent it from cylinder so that outlet hole is free
joints retighten and if necessary re
twisting from foreign material Install
any
place damaged parts b Exercise care not to warp or twist bleeder hose vinyl hose on bleeder
clutch hose screw
Place the other end of it in a con

REMOVAL 4 Connect clutch tube to hose with
tainer filled with brake fluid
flare nut and tighten it
CAUTION
i
l Flare nut
When disconnecting clutch tube use
15 18 N m
suitable flare nut wrench

1 5 1 8 kgm
Never use an open end wrench or
11 13 ft lb
adjustable wrench
5 Check distance between clutch

I Disconnect clutch tube from be
line and adjacent parts especially
clutch hose at bracket on side memo tween hose and exhaust tube
ber 6 Bleed air out of hydraulic sys1em
2 Remove lock spring then disen Refer to Bleeding Clutch System J
SCL009
from bracket
gage hose for adjustment
CL 5

Hydraulic Clutch Control CLUTCH
3 Have a co worker depress clutch 4 Close bleeder screw quickly as b Brake fluid containing no air runs
pedal two or three times With clutch clutch pedal is on down stroke out of bleeder screw in a solid
pedal depressed fully loosen bleeder S Allow clutch pedal 10 return slow stream without air bubbles
screw to bleed air out of clutch ly with bleeder screw closed c Pay close attention to clutch fluid
system 6 steps 3 through 5 until
Repeat no leve in reservoir during bleeding
air bubble shows in the vinyl hose operation
CD Depress pedal two or three times
d Add brake fluid to reservoir only
l
G Bleeder screw
dlll 69 8 N m up to
h f tl leyel qo not
overfill
0 7 0 9 m
kg
I
I ilr
y 7
5 1
several tim s
6 5 fHbl
Depress and release dutch pedal

then check for external
CAUTION
a Do not use
re
during bleeding operation

brake fluid drained
CJy hydraulic leaks at connections b Exercise care not to

splash brake
j Brake fluid fluid on exterior finish as it will
@ a containing air i white
SCL010 and has visible air bubbles damage the paint
c When tightening flare nut use Tool
GGg4310000
6
CL

CLUTCH Clutch Unit
CLUTCH UNIT
CLUTCH DISC AND COVER
SCLOll
REMOVAL Be sure to turn them out in a crisscross solvent to remove dirt and grease
I Remove transmission from engine fashion before making inspection and adjust
Refer to Removal Section MT ment
2 Insert Tool into clutch disc hub
Flywheel end pressure plate

Check friction surface of Ilywheel
@ and pressure plate for scoring or
roughness Slight roughness may be
smoothed by using fine emery cloth If
surface is deeply scored or grooved
the part should be replaced
Clutch disc assembly
Inspect clutch disc for worn or oily

4 Remove clutch disc and cover
facings loose rivets and broken or
assembly loose torsional springs
I If facings are oily disc should be

replaced In this case inspect trans
3 Loosen bolts attaching clutch INSPECTION front
mission cover oil seal pilot
cover to Ilywheel one turn each at a Wash all disassembled parts except bushing engine rear oil seals and other
time until spring pressure is released disc assembly in suitable cleaning points for oil leakage
CL 7

C1Ul1h Unit CLUTCH
2 The disc should also be replaced Backlash
when facings are worn locally or worn Less than 0 4 mm 10 016 inl
down to the limit
specified
Wear limit of facing A
Less than 0 3 mm 10 012 inl
Clutch
II I
cover assembl
1 Check end surface of diaphragm
c
ril l
l spring for wear If excessive wear is
F
Q l
I
I
found replace clutch cover assembly
2 Measure height of diaphragm
SCL018
A
springs as outlined below
I Place Tool ST20050100 on Tool Also unevenness of diaphragm
ST200500 10 and then tighten clutch spring toe height should be wilhin the
CL336
cover assembly on base plate by using specified limit
Tool ST20050051
Unevenness of diaphragm spring
toe height
Less than 0 5 mm 0 020 in
3 Check disc plate for runout when
ST20050051
ever the old disc or a new one is
If unevenness of
installed diaphragm spring
4 If runout exceeds the specified
ST20050010
jST20050100 toe height
adjust spring
beyond specified value
height with Tool
value at outer circumference of facing
1 A
ST20050240
place or repair disc
@
Runout limit
3 Inspect thrust rings for wear or
total indicator reading
damage As these parts are invisible
Less than 0 5 mm 0 020 in
CL 151 from outside shake cover assembly up
R from hub center and down to listen for chattering
95 mm 3 74 in
noise or lightly hammer on rivets for a
slighily cracked noise Any of 1hese

2 Measure height A at several
noises indicates need of replacement as
CAUTION vernier
points with a caliper depth a complete
When repairing disc plate never hold it assembly
gauge
forcibly with pliers or bend it exces
siveIy otherwise facing will be dam Oiaphragnt spring height A
31 6 33 6 mm
aged
11 244 1 323inl
INSTALLATION
I Apply a light coat of in
grease
c1uding molybdenum disulphide
10
transmission main drive gear splines
Slide clutch disc on main drive gear
several times Remove clutch disc and

wipe off excess lubri
cant pushed off
by disc hub
Take special care to prevent grease
CL 12 l
SCL014
or oil from getting on cluteh faeing
2 Reins1a11 clutch disc and clutch

5 Check fit of disc hub ontransmis cover assembly Support clutch disc
sion main drive gear splines for smooth If and cover assemblies with Tool
height A of spring end
sliding If splines are worn clutch disc KV30100100
beyond specified value dju t lll
spri
or main drive
gear should be replaced height with Tool ST20050240 1 Be ure to keep disc faeings fly
that backlash exceeds the specified
necessary replace clutch cover as wheel and pressure plate clean and
value at outer edge of clutch disc sembly dry
8
CL

CLUTCH Clutch Unit
and rotate 4 Transmission main drive gear

Hold bearing inner race
outer race while applying pressure to splines Use grease including molybde
If the rough num disulphide
it bearing rotation is or
hould be
KV30100100 noisy replace bearing A mall mount of gre
coatad to tho bov points If too
much lu ricant is applied it wilt run
INSTALLATION out on the friction plltes when hot re
I Assemble release bearing on lulting in damaged clutch disc facing
sleeve using a press
CL340 3 After lubricating install with
l j drawal lever
assembly in
release bearing and sleeve
position Connect them
l I with holder spring
3 Install clutch cover assembly
Each bolt should be tightened one
turn at a time in a crisscross fashion
til Clutch cover bolt
16 21 N m
1 6 2 1 kg m
u
12 15lt lb SCL015
4 Remove clutch aligning bar

5 Reinstall transmission Refer to Do not depress outer race
Installation Section MT 2 Before SMT010

during assembly lubri
or
cate the following points with a light

coat of multi purpose grease
1 Inner groove of release bearing 4 Reinstall transmission Refer to

RELEASE BEARING sleeve Installation Section MT
REMOVAL
1 Remove transmission from engine

Refer to Removal Section MT
2 Disconnect holder spring from
bearing sleeve
3 Remove release bearing and sleeve
assembly from transmission case
PILOT BUSHING
as an
front cover L
4 Take clutch release bearing out REMOVAL
from bearing sleeve using a universal SCL016
I Remove transmission from engine
puller and a suitable adapter
Refer to Removal Section MT
2 Remove clutch disc and cover
Contact surfaces of withdrawal assembly Refer to Clutch Disc and

2
lever lever ball pin and bearing sleeve Cover for removal
Remove in crank
3 Bearing sleeve sliding surface of 3 pilot bushing
transmission case front cover shaft with TooL
CLt45
INSPECTION
Check for abnormal wear on con
tact surface of withdrawal lever ball

SMT016 CLOSS
pin and bearing sleeve
9
CL

OutdWnit CLUTCH
INSPECTION Distance A 3 InstaU clutch disc and clutch

4 0 mm 0 157 inl
Check pilot bushing for fit in bore cover assembly Refer to Clutch Disc
and Cover for installation
of crank5haft
Check surface of 4 Install transmission Refer In
inner pilot Do not oil
to
bushing staUa1ion Section MT
bushing for wear roughness or bell
mouthed condition If pilot bushing is When inserting pilot bushing be
worn or damaged replace When
careful not to d amage edge of pilot
bushing is damaged be sure to check

bushing
transmission main drive gear at the
same time
Pilot bushing
INSTALLATION
1 Before installing a new bushing
thoroughly clean bushing hole
2 Inser1 pilo1 bushing until distance
A between flange end and pilot
EM719
bushing is specified distance
CL10

CLUTCH Service Data and Specifications
aUTCH DISC Unit mm In

GENERAL SPECIFICATIONS
aUTCH CONTROL SYSTEM

I Model 200CBL
I
I
Wear limit offacing surface to rivet
03 10 0121
I Type of clutch control Hydraulic hood
Runout limit 0 5 10 0201

I
aUTCH MASTER CYLINDER
Distance of checking point
nout
9513 741
Ilnnar diameter mmOn 15 88 81

15 from the hub center
Maximum backlash of spline
aUTCH OPERATING CYLINDER I at outer edge of disci

0 4 10 016
adjustable
Non
TV
aUTCH COVER Unit mm lin
Inner diameter jn
mm 17 46 111161
I Model C200S
31 6 33 6
aUTCH DISC
I Type 200CB L
I Dioph ag m spring ho ght
11 244 13231
Unevenness of diophragm spring toe
I Less than 05 0 020

Facing size height
0
2 130 x 3 5
Outer die x Inner die x Thickness
87
17 x 5 12 x 0 1381
mm inl
PILOT BUSHING
Thickness of disc assembly
Free mm in 8 50 9 20
Inserted distance of pilot bushing
Installed mmUnl
10 3346
76
10 299
80
0
0 315
36221
I mrn in
4 0 10 1571
Number of torsion springs 6
aUTCH COVER TIGHTENING TORQUE

C200S Unit N kg m ft Ib
Type m
Full load N lb 3 923 1400 882 Pedal stopper bolt lock

Ikg
I 78 11 8 08 12 58 8 7
nut
Maner cylinder push cd
I 7 8 11 8 08 12 5 8 87
lock nut
Master cylinder stopper 1 2 2

15 2 9 0 15 03
INSPECTION AND ADJUSTMENT bolt
Master cylinder securing 08 1 2 58 8 7

78 118
aUTCH PEDAL nut
18 15 8
1 11 13
I Pedal height H in
mm 168 174 16 61 6 85 Clutch fube flare nut 15
5 10 04 0 201 08 12 5 8 87
l Pedal free play AU in
mm
I Push rod lock nut 78 118
Dporating cylindor
I 6 9 88 0 7 09 5 1 65
aUTCH MASTER CYLI NDER bleeder screw
I
Clearance between
and pilton
cylinder bore
mm Unl
I Loss than 0 15 10 0059
j Operating cylinder
lecuring bolt
30 40 3 1 4 1 22 30
Clutch hose to operating 12 15

17 21 7 2 1
1
aUTCH OPERATING CYLINDER cylinder securing nut
Clutch securing
J
cover
Clearance between cylinder bore
I I
12 15
I
16 21 1 6 2 1
Lessthan 0 15 10 00591
and piston mrn in bolt
CL 11

I
TroUble DiagnosesBnd Corrections CLUTCH
aUTCH SLIP
Slipping of clutch may be noticeable when any of the following symptoms is encountered during operation
I Car will not respond to engine speed during acceleration
2 Insufficient car speed

I Lack of power during uphill driving
4 Increasing of fuel consumption
Some of the above conditions may also be attributable to engine problem First determine whether engine or clutch is caus
ing the problem

If slipping clutch is left unheeded wear and or overheating will occur on clutch facing such an exten1that it is
to no longer
serviceable
TO TEST FOR SLIPPING CLurCH proceed as follows
Inspection
Insure that parking brake is engaged Disengage clutch and shift transmission
gears into TOP Gradually increase engine
speed while simultaneously engaging clutch If engine stops while clutch is being engaged clutch is functioning properly If
car does not move and the engine does not slop clutch is slipping
Clutch facing hardened or wet with oil Repair or replace

Clutch facing excessively worn
Replace Replace iLengine
transmi ion oil seal is faulty
Diaphragm spring weak or damaged Replace
Flywheel or pressure plate warped Repair or replace
Particles in return port of master cylinder Clean or replace faulty paris
Piston fails to return to its original posi1ion
Clutch tube deformed or crushed Replace
aUTCH DRAGS
Dragging clutcl
is particul r1y noticeable when shifting
gears especially into low gear
TO TEST FOR DRAGGING CLUTCH proceed to inspection
Inspection
Disengage clutch and shift gears into Reverse Shift gears into Neutral gradually increasing engine speed After a short inter
mission shift gears into Reverse If noise is heard while
gears are being shifted clutch is dragging
CL 12

CLUTCH Trouble Diagnoses and Corrections
Clutch disc hub splines worn or rusted

Replace or remove rust and
coat with grease
Oil leakage at master cylinder operating cylinder tube or hose Replace faulty parts
Air in hydraulic system Bleed air
Insufficient pedal stroke
Adjust
Clutch disc runout or warped Replace
Diaphragm spring fatigued Replace
04
Piston cup deformed or
damaged Replace
Lack of grease on pilot bushing Coat with grease
Clutch facing wet with oil Replace if
Replace engine
transmission oil seal is faulty
CLUTCH CHATTERS
Clutch chattering is usually noticeable when car is just rolled off with clutch partially engaged
Oil on clutch facing Replace

Clutch facing hardened Replace
Clutch facing warped
Repair or replace
Pressure plate worn or
warped Replace
Engine mounting loose or rubber deteriorated Tighten or replace
Clutch facing rivets loose
Replace
NOISY CLUTCH
Release bearing sleeve damaged or

improperly lubricated
Replace
Pilot bushing worn jammed or damaged Replace
Clutch facing rivets loose
Replace
Disc plate cracked Replace
Clutch disc torsion springs fatigued Replace
RABBIT HOPPING CLUTCH
When rabbit hopping of clutch occurs car will not rol1 off smoothly from a
standing star1 or clutch will be engaged be
fore clutch pedal is fully depressed
Oil On clutch facing Replace

Clutch facing worn or rivets loose
Replace
Flywheel pressure plate warped or worn
Replace
Mounting bolts on engine or power train loose Tighten
CL 13

Special Service Tools CLUTCH
Tool number
Tool name
Kent Moore No
KV30100100 Clutch aligning bar
CLJI 1
2
ST20050100 Distance piece
@
ST200500 10 Base plate
39
ST20050051 Set bolt
ST200S0240 Diaphragm spring adjusting wrench
STI 661 000I Pilot bushing puUer

123907
n
o
GG94310000 Flare nut torque wrench
lII1A
IIIIlII
CL14
DATSUN 200SX Mode S II 0 Series
MANUAL TRANSMISSION
CONTENTS
REMOVAL AND INSTALLATION MT 2 REPLACEMENT OF BEARINGS MT14
REMOVAL MT 2 SERVICE DATA AND

INSTALLATION MT 2 SPECIFICATIONS MT16
GENERAL SPECIFICATIONS MT16

5 SPEED TRANSMISSION
MT 3 INSPECTION AND ADJUSTMENT MT16
Model FSsW71B
MT 6 TIGHTENING TORQUE MT17
REAR EXTENSION
TRANSMISSION CASE MT 7 TROUBLE DIAGNOSES AND

CORRECTIONS MT18
FORKS AND FORK RODS MT 8
GEARS AND SHAFTS MT 9 SPECIAL SERVICE TOOLS MT22

REPLACEMENT OF OIL SEALS MT14

Removal and Inrtallation MANUAL TRANSMISSION
REMOVAL 3 When installing control lever be

sure to multi purpose grease to
I
apply
Disconnect battery ground cable
sliding parts as shown below
2 Remove accelerator linkage
J Jack up car anI
support its
weight
on safety stands Use a hydraulic hoist Control lever
or open pit if available Bushing
Make sure that safety is insured
4 Grease
Disconnect front exhaust tube
coating
TM335
Grease
coating
12 Loosen rear engine mount secur

SMT142 Striking guide
ing nuts CD tempobirily and remove
crossmember mounting nuts

00
4 Remove filler and fill 1rans
plug
mission with recommended gear oiI
o
the level of 1he plug hole
Oil capacity
2 0 liten
41 2Imp I
ll
P1
lJ
5 sealant to threads of filler
Apply
plug and instaU filler plug to transmis
5 Disconnect wires from reverse
sionc
back up lamp Top and O D gear
if so equipped switches iJ Filler plug
6 Disconnect speedometer cable 25 34 N m
7 I3 Remove starter motor

Remove propeUer shaft 5
2 5
3 m
kg
14 Remove bolts securing 1ransmis
Refer to Propeller Shaft Section 18 25 ft lb
sian to
PO for removal engine
Then support the engine and trans 6 Tighten bolts securing transmis
mission with tion to engine

jacks and slide transmis
Plug up opening in rear extension
sion rearward away ffom engine and 43 58 N
to prevent oil from flowing out iJ @ m
remove from the car

4 4 9
5 kg
32 43 ft bl
8 Remove clutch operating cylinder CAUTION
@ 25 35N m
9 Support engine by placing a jack Take care in dismounting transmission 26 3 81qjm
under oil pan with a wooden block not to strike any adjacent parts and
19 28ft lb
used between oil pan and jack main drive gear
CAUTION
00 not place jack under oil pan drain INSTALLATION
plug Install the transmission in reverse
order of removal paying attention to
the foUowing points

10 Support transmission wi1h a trans I Before installing clean mating
mission jack surfaces of engine rear plate and trans
H mission case
I Remove console box Refer to 2 Before instaUing lightly apply
Console Box Section BF for removal grease to spline parts of clutch disc
2 Place transmission control lever in and main drive gear And also apply 7 Lubricate oil seal lip and bushing
neutral position and remove E ring and grease to moving surfaces of control on rear extension with gear oil for ini
control lever lever and striking rod tial lubrication
MT 2

3 ZC r I Z CJl 3 en CJl o Z I
iaI iiig Cl It l l
en m m C f0 Z en 3 en en 5z 3 o Q 1
C1I JJ C1I e OJ
lb
ft
15
m
12
kg
seal 1
2
m
leal
E
N
oil 6
1
Oil to 17
Iii
oil 21
12
gear 3
Ap ly 6
23
25
22
14
18 bolts 25
5 of
0 3
18
thread
3
5 5
0 2 3
2
to
34 5
switch 29
pll 8
2
20
25
seal nt 34
Neutral Iii Fil er Iii
Ap ly
plug 25
Iii
22 Drain
14
0
0
Bearing plate
f 2
2
29
20
14
0
3
Adapter
0
on Iii
witch
2
29
gear 20
J
i
rTOP
lampowS Revet
22
14
0
29
cover
Front
20
Iii

5 speed ModeIFS5W71BJ
lTlissiof1
Trafl MANUAL TRANSMISSION
3rd main gear
SnaPrinB
Main drive gear ball bearing
Washer
Snap rinB
Apply gear oil to needle

bearq
3rd 11 4th synchronizet hub
pread spring Pay attention to its direction
Shifting imert
r
G
1st a 2nd synchronizer hub

2nd main gear
123
CounterJbaCt lock nut
ifJ 98 127
10 0 13 0 12 94
counter geu
Apply gear oil to

needle bearing
Counter front bearing Snap ring
Woodruff key Reverse idlet sear bearing
Reverse idler throt washer

Shim
Reverse idler shaft
Refer to transmission case for assembly
Iii N m kg m ft b
SMT040
4
MT

MANUAL TRANSM ISSION 5 speed Transmission Model FS5W71BJ
Striking guide
E rinB
O
r rJ
StoPper guide pic
ControlleYer
Lock pin spri plUS
J fRetum
Apply gear oil to O Apply locking sealer
to thread of bolt t
j Iii
Retrun pri 7 8 9 8 O g 10 Check prins
plunger 5 8 7 2
25 19 2 5 14 18
Return
SPriDl
checking Check ball pl1lll
Apply locking sealer
to thread of bolt
1 bushing
@
Check prins
Check ball
5
0
qeontrol ever
J
Controlleverb ahUw
Interlock baD
Retainins Pin
3m 4th Cork rod Reverse OD shift Cork
Ioterlock baD
3m 4th shift Cork
Iii 19 25
19 2 5 14 18
Iii lm k8 m lb
Ct
SMT150
MT 5
54peed fTJission
TT8Il ModeJ FS5W71B MANUAL TRANSMISSION
REAR EXTENSION
DISASSEMBLY
I Wipe off dirt and grease

@NEur 4
2
3
Drain oil
Remove 0 0 gear switch if so
1
W
equipped
4 @
Remove E ring and stopper guide
pin In
SMT006 SMT007
5 InstaU plunger return spring and

INSPECTION return spring plug
I Clean with solvent and check for
cracks or cavities by means of dyeing
test
TM337 2 Check mating surface of rear ex
tension for small nicks projection or
sealant
If fesr extension is worn or

bushing
5 Remove return spring plug retum it as an a
ssembly of
pla
spring and plunger from rear exten bushing and rear extension housing
sion
SMT041
ASSEMBLY
1 PlUJl8O
I Stand transmission 2 Return spring
case assembly
3 Return spring plug
on wooden plates of more than 20 rom
0 79 in thick
2 Clean mating surfaces of adapter
plate and rear extension 6 Apply sealant to stopper guide
3 Apply sealant to mating surface pin then instaU stopper guide pin and
of adapter plate E ring
SMT003 7 InstaU 0 0 gear switch if so
equipped
8 Make sure that gears operate
smoothly
6 Remove rear extension
4 InstaU rear extension as foUows

SMTOOS I Se gears at Neutral
2 Turn striking guide counterclock
wise 9 Install drain plug
3 Set striking guide at Neutral Iil 25 34 N m
7 Remove lock pin and then remove 4 Aligh end of striking lever with 2 5 35 fD
kg
striking rod cutout portion of fork rod 18 25 ft
lbl
6
MT
MANUAL TRANSMISSION speed
5 Transmission Model FS5W71B
6 Fit main drive bearing snap ring

TRANSMISSION INSPECTION
7 Select countershaft front bearing
CASE 1 Clean with solvent and check for
shim as foUows
cracks or pits by means of dyeing test Measure A
1 height
2 Check mating surface of transmis
DISASSEMBLY
sion case for small nicks projection or
1 Remove rear extension Refer to
sealant
Rear Extension for disassembly
2 Remove dust cover release bear
and withdrawal lever ASSEMBLY
ing
1 clean mating surfaces of adapter
I
plate and transmission case
2 Stand transmission case on wood

en plates of more than 20 mm O 79 in
thick
3 Apply sealant to mating surface of TM371
transmission case
1 Tranlmission case
2 Counter gear front bearing

3 Counter gear
2 Select a shim of thickness A
measured
Counter geer front
3 Remove front cover and gasket bearing him
Detach countershaft front Refer to S O S

bearing
shim
4 Remove main drive bearing snap
ring
4 Slide gear assembly onto adapter
plate by lightly tapping with a soft
8 Clean mating surfaces of front
hammer
cover and transmission case
9 Apply grease to shim selected to

r tain it on front cover
10 Lubricate seal lip and main drive

shaft with gear oil then instaU new
gasket and front cover

II Apply sealant to threads of
through bolts and tighten them to
transmission case
5 Separate transmission case from 5 Make certain that mainshaft roo
adapter plate tates freely
Iii 111 21 N m
11 6 2 1 kg m
12 151t lbl
rmrl
SMT015
12 light coat of multi pur

Apply a
TM153 SMT014
pose grease
MT 7

XpeerI Transmission Mode FS5W71BJ MANUAL TRANSMISSION
ASSEMBLY
I InstaU 1st 2nd 3rd 4th and
rC QD Rev shift forks and 1st 2nd

Fork rod fork rod then secure with retaining
1st l 2nd
pin
Interlock
SMT016
ball
13 InstaU dust cover release bearing

Fl Chect baD
and withdrawal lever @ ED

14 Assemble Rear Extension Refer TM198A
to Rear Extension for assembly
6 Drive out retaining pins

2 InstaU two 2 interlock baUs
3 InstaU 3rd 4th fork rod then
secure with retaining pin
FORKS AND FORK

RODS
DISASSEMBLY
SMT019
7 Drive out fork rods and remove
interlock baUs and check baUs
Rear Extension for disassembly Be careful lose
not to three 3
2 Remove transmission case Refer
check balls and four 4 interlock
to Transmission Case for 4 InstaU two 2 interlock baUs
disassembly balls
3 Set up Tool on adapter plate 5 InstaU O D Rev shift fork and
4 Place above assembly in a vise fork rod then with

secure retaining
pin
INSPECTION
Clean with solvent and check for

wear scratches projection damage or
other faulty conditions Replace any
part which is worn or darnaged
TM754
one 6
5 Remove check baU 6 InstaU check baIls and check
plugs and
check springs SMT137
springs
MT B

MANUAL TRANSMISSION 5 speed Transmission Model FS5W71B
7 Apply locking sealer to check
ball plugs and install them
dl 19 25 N m
1 9 2 5 kg m
14 18 ft lb
TM398
TM757
S Drive out counter 0 0 gear and

6 Remove counter drive gear snap bearing
ring
7 Draw out counter drive gear with
main drive gear
a Check ball plug for 1st 2nd fork

rod is longer than that for Rey
shift fork rod and 3rd 4th fork
rod
b To insure that interlock plunger is
installed properly slide 3rd 4th

fork rod and operata the other fork
rod Make lure that the gear except

3rd or 4th gear does not m sh
6 Remove revene counter gear and
8 Apply gear oil to all sliding sur spacer

Remove ring from reverse
faces and check to see 1hat shift rods snap
When drawing out main drive gear idler shaft and remove reverse idler
operate correctly and gears are en
gaged smoothly mbly b car ful not to drop pilot gear
9 Install caseRefer to n edle bearing and baulk ring 7 Remove snap rings steel ball
transmissio speedometer gear and bearing
Transmission Case for assembly
10 Install rear extension Refer to
Rear Extension for assembly

3rd meln geer
I Remove snap ring and thrust

washer
2 Draw out 3rd 4th synchronizer
GEARS AND SHAFTS and 3rd gear
f
I
DISASSEMBLY KV32101330
o D geer end reverse geer
drive and counter TM760

Mein drive end counter 1 Remove main
drive geer drive gears Refer to Gears and Shafts
Remove rear xtension for disassembly

1 Refer to
Remove 3rd main gear Refer to 8 Remove mainshaft nut thrust
2
Rear Extension for disassembly washer reverse main gear 00
Gears and Shafts for disassembly
2 Remove transmission case Refer
3 Measure 0 0 ge r end play Refer synchronizer and D gear
O
to Transmission Case for disassembly
Remove to Gears and Shafts for inspection
3 forks and fork rods
4 Mesh 2nd and reverse gears Re 1st end 2nd mein geer end
Refer 10 Forks and Fork rods for dis
lease staking on counter gear nut and counter eer
assembly
mainshaft nut and loosen these nuts
4 Measure g r end play Refer to I Draw out mainshaft assembly
Remove counter gear nut
Gears and Shafts for inspection together with counter gear by tapping
S Mesh 2nd and reverse gear then Removed nuts should be discarded rear end of mainshaft and counter
draw out counter front bearing nd should not be reused gear
MT 9

5
s iJeed Trantmiision Model FS5W71B MANUAL lRANSMISSION
Synchronizer 0 D Tighten mainshaft lock nut to

Hold front of mainshaft assembly
specified limit and tneasure end
by hand being careful not to drop I Remove circlip wiih snap ring
play to insure thai it is within
counter gear plier
2 Remove band specified limit
syncbro ring
If end play is not within specified
brakes anchor block and thrust block
limit disassemble and check parts
I
for condition
J Replace any part which

damaged
is worn or
W1
TM rT
INSPECTION
Bearing
iEndPmY
Mainshaft o
I Thoroughly clean bearing and dry bushing

with compressed air
2 Remove thrust washer steel baU CIJE
1 st gear and needle bearing CAUTION
Be careful not to lose teel ball Do not allow the bearings to spin SMT025
retaining thlUlt washer Because it will damage the race and
balls Turn them slowly by hand
3 Press ou1 1st gear rnainshaft bush
Standard end play
ing together with 2nd gear and 1st
1st lI88r
2nd synchronizer
q2 3
0 lm
tD
Wlliin priising oiirliii liing holif 0106
0 0 0134 inl
mainshaft by hand 081 notto drop it
2nd gear
0 12 0 19 mm
H
0 0047 0075
0 in
r 3rd gar
0 13 037 mm
10 0051 0 0146 in
00 5thl gear
0 10 0 11 mm
TM372
0 0039 0 0061 in
Reverse idlar gear
05
0 0 50 mm
ST30031000
0 0020 0 0197 inl
2 When race and baU surfaces are
worn or rough or when balls are
TM049A of
out round or rough replace bearing
with a new one
3 Replace needle bearing if worn or

Baulk ring
damaged
I Replace baulk ring if found to be
Synchronizer
lat a 2nd and 3rd a 4th deformed cracked or otherwise dam
Disassemble aged excessively

synchronizer
Gears snd ahafts
I Check all gears for excessive wear
G chips or cracks replace as required

2 Check shaft for bending crack
wear d worn spline if necessary
Q sleeve
Shifting insert
replace
3 Measure gear end play
It is necessary to measure end

before disassembling mainshaft and
play
SMT026
SMT02A after reassembling mainshaft
MT10
MANUAL TRANSMISSION speed
5 Transmission Model FS5W71B
ASSEMBLY ing inserts in three slots in syncliro

2 Place baulk ring in position on
nizer hub put coupling sleeve on

gear cone
While holding baulk ring against Adapter plate synchronizer hub
as far as it will go measure gap I Place new dowel pin mainshaft
gear
between baulk ring and outer gear bearing on adapter plate and tap them
If the clearance is smaUer than
wear limit discard baulk ring
Adapter plate
Dowel pin 2 places
B8Ulk ring to glar clearance
Standard
Mainshaft
1 20 1 60 mm bearing7
0 0472 0 0630 in
Wear limit 1fU11

Lathan 0 8 mm
0 031 in
Unit mm in
SMT027
2 Insert reverse idler shaft Synchronizer G D

3 InstaU bearing retainer
Position synchronizer ring band
brake thrust block and anchor block
on overdrive clutch gear install circlip
SMT140 D
JH
rjeU
ShlftlnB Insert
Band brake
Replace if
excessively
worn worn
unevenly deformed or damaged

Anchor block
4 Tighten each screw then stake it

at two points
I
I
r
L J
Thrust block
SMT064
A
TM449
5 InstaU counter rear bearing with a
Oil seals
soft hammer
1st and 2nd main Bear
1 Replace oil seal if sealing lip is
deformed or cracked Also discard oil I Assemble 2nd gear needle bearing
seal if spring is out of position Refer 2nd gear baulk ring 1st 2nd syn
Synchronizer chronizer assembly I st baulk
to Replacement of Oil Seals gear
1st 2nd and 3rd 4th
2 Check the oil seal lip contacting ring I st gear bushing needle bearing
with shaft if necessary replace oil seal I Assemble coupling sleeve and hub 1st gear steel baU and thrust washer
and shaft as a set 2 Position spread springs and shift on mainshaft
MTll

PeedTrsn
5 ission Model FS5W71B MANUAL TRANSMISSION
Before installing Sle8I boll and 2 Press counter gear into adapter Be RU to align of baulk
thru t washer apply gr a to tham plate with inserts
ring
2 Apply gear oil to mainshaft pilot

bearing and install it on mainshafl
KV31100401
TM358
TM O
2 Set Tool and place adapter plate

3 Position needle bearing 3rd main
assembly on it
gear baulk ring and 3rd 4th

For counter gear and For mainshaft and synchronizer assembly on the front of
id
rever e shaft 3 InstaU main drive with
idler shaft
rever gear
mainshaft
counter drive gear
Assemble 3rd4th synchronizer
Assembfe counter driy
hub paying attention to its direction gear paying
IoU J attention to its direction
ID f31100401
lJ
koles for reverie idler shaft
TM438
Front
Front
3 Press mainshaft assembly to
adapter plate
Vl
SMT031
SMT065
4 Install thrust washer on mainshaft 4 Press counter drive gear onto
and secure it with snap ring of counter gear

proper
1hickness that will minimize clearance
of groove in mainshafl
KV3H00401
Mainshaft front snspring
ST23860000
Refer to S O S
TM439
3rd main and counter 8ear
I Tap new woodruff keys until they

are seated securely KV31100400
n TM442
Main drive gear and counter drive
TM441
cHOJ L gear should be handled as a matched
set When replacing main driva gear or
counter drive gear be sure to replace

8S 8 set of main drive gear and nter
Main drive and counter driva gear
drive 8ear
Counter drivege ar snap ring
1 Install baulk ring on synchronizer Rafer to S O S
MT12

5 speed Transmission Mode FS5W71S
MANUAL TRANSM ISSION
a Assemble O O reverse synchro nizer Conversion of torque

5 Secure counter drive gear with
hub paying attention to its direc
snap ring that will minimize clearance Mainshaft nut should be tightened
of groove in countershaft tion with Tool When
to specified torque
doing so the amount of torque to be
read on wrench needle should be

modified according to the foUowing
chart
Front
If 137 167 N m
14 17 kg m
101 123 ft lb
ST22520000 C
0
o
TM366 TM297A
6 Press counter gear
onto counter gear

front bearing
b Main
ed set
When
00
goor should be handled
replacing
gear and countor 0 0
main 0 0
as a motch
gear and
f1 O lOm
33 ft
0
Lm f
rr
counter 0 0 gear be sure to re
place as a set of main 0 0 and

counter 0 0 gears
e
ST22360002 S z
3 Assemble reverse counter gear u
c
u Vi
overdrive counter gear
limitll ne7 J
4 Assemble new mainshaft nut
tighten temporarily
it
and u
C
1O
147 1 Upp r
uun
5 InstaU bearing
s
u
00
135 1 0 it
KV31100400
n TM443
c
0
o
e
o
90
ASSEMBLY
O D gear and reverae gear

u
80
11
i 04 0 5 66 0 7 0 8
m
I After front side is assembled as

5
1 20 25
semble reverse counter spacer snap ft
ring spacer needl

bearing reverse SMT034
idler gear spacer and snap ring

6 Mesh 2nd and reverse gear and
tighten mainshaft lock nut and count

7 Stake mainshaft lock nut and
er gear lock nut
counter gear lock nut with a punch
Fr
I I
J
L
ST22520000
w
TM451 Iii 137 167 N m
114 0 17 0 kgm
101 123ft lbl
2 Assemble O D reverse synchro SMT044

nizer hub reverse gear aD gear
bushing needle bearing O D gear iJ Counter gear lock nut
assembly steel baU and thrust washer 98 127 N m
on mainshaft rear side Before instaU 10 0 13 0 kg m 8 Measure gear end play Refer to
ing a steel baU apply grease to it 72 94 ft lbl Gears and Shafts for inspection
MT13

speed Transmission Model FS5W77BJ
5 MANUAL TRANSMISSION
9 FIt soap ring then assemble main 5 Remove front Ier

CO
3 Apply coat of gear oil to oil seal
shaft rear bearing 6 Remove oil seal surface then drive new seal into place
ST223500i
TM068A
10 Fit thick snap ring to mainshaft 7 Apply coat of gear oil 0 oil seal 4 InstaU propeller shaft Refer to
rear
beapng to eliminate end play surface then drive new seal into
place PropeUer Shaft Section PD for instal
Mainshaft rear bearing snap ring lation
Refer to S O S
ST23800000
II Assemble soap rings steel baU and PreS
speedometer drive gear REPLACEMENT OF
Y
Z
12 InstaU forks and fork rods Refer
o
BEARINGS
to Forks and Fork Rods for assembly J
13 InstaU transmission case Refer to MAIN DRIVE AND
oV
Transmission Case assembly
for COUNTER FRONT
7
14 InstaU rear extension Refer to
Rear Extension for assembly
80 SMT036
1 Remove main drive and counter
drive gear Refer tb Gears and Shafts
for disassembly
2 Remove main drive gear snap
8 Lubricate seal lip and main drive ring and spacer
shaft with gear oil 3 Remove main drive bearing
REPLACEMENT OF 9 Install front cover in reverse order
OIL SEALS of removal
FRONT COVER OIL SEAL
It is necessary to remove transmis REAR EXTENSION OIL

sion unit from oil seal SEAL
car Replace as
follows Rear extension oil seal can be

Remove transmission Refer to replaced without removing transmis
RemovaL sion Replace oil seal as follows
2 Wipe offdirt and grease I Remove propeller shaft Refer to
TM349
3 Drain oil Shaft Section PD for
PropeUer reo
4 Remove dust cover release bear movaL
ing and withdrawal lever 2 Remove oil seal 4 Press new main drive bearing
Press
SMT037
SMT038
MT14

5 speed Transmifi1iion Model FS5W71B
MANUAL TRANSMISSION
5 Place main drive bearing spacer

CAUTION
on main drive bearing and secure main
When pressing out bearing gear hold
drive bearing with thicker snap ring shaft by hand so as not to drop it
that wiD eliminate end play
Main drive gear snap ring
Refer to S OS III
Countenhaft
6 Mesh 2nd and reverse gear then rear bearing
draw out counter front bearing
TM754
I
I
11
5 Remove main drive and counter

drive gear Refer to Gears and Shafts
TM351
for disassembly
6 Remove main gear Refer
reverse
to Gears and Shafts for disassembly

7 Draw out mainshaft assembly 11 Press counter rear bearing onto
TM398
together with counter gear by tapping adapter plate
rear end of main shaft and counter
12 InstaU mainshaft bearing onto
gear
adapter plate
7 Press counter gear front bearing Hold front of meinshaft essembly
13 I nstaU bearing retainer and align
onto counter gear by hand being careful not to drop
bearing retainer with reverse idler shaft
counter gesr
at the cut out portion of the shafl
14 Tigh1en and stake each screw at

ST23860000 two points
KV31100400
n TM442
TP 347
8 InstaU main drive and counter

8 Remove bearing retainer
for assembly
15 Install main drive and counter

for assembly
16 InstaU reverse main gear Refer to
Gears and Shafts for assembly
17 InstaU transmission case Refer to
Transmission Case for assembly
18 InstaU rear extension Refe to
MAINSHAFT AND Rear Extension for
SMT039
assembly
COUNTER REAR

Rear Extension for disassembly
MAINSHAFT REAR AND
2 Remove transmission case Refer 9 Replace mainshaft bearing by new
COUNTER REAR END
to Transmission Case for disassembly one
countershaft bear Refer to Gears and Shafts for disas

3 Set up Tool on adapter plate 10 Press out rear
4 Place above assembly in a vise ing sembly and assembly
MT15

Service Data sndSpecificatiom MAN UAL TRANSMISSION
GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT
Transmission model FS5W71 B

GEAR END PLAY Unit mm in
No of speed 5
1 to 4th Warner FS5W718

Synchromesh type
5th Servo
1 st main gear 0 27 0 34 0 0106 0 0134

Shift type
2nd main gear 0 12 0 19 00047 00075
3rd main gear 0 13 0 3710 0051 0 01461

3 5
5th main gear 0 10 0 17 0 0039 0 00671
L Rev idler gasr 005 0 50 0 0020 0 0197
r
2 4 R
aEARANCE BETWEEN BAULK RING AND
GEAR
Unit rnm in
Gear All models

ratio
1st 3 321
2nd 2077 I Standard 120 1 60 10 0472 0 06301
3rd 308
1 I Wear limit 0 810 0311
4th 1 000
5th 0 864
Rev 3 382
AVAILABLE SNAP RING

Number of teeth Drive 22
1st 33 Main drlv s er b erlns

2nd 28
Mainshett
3rd 26 Thickness mm in Part number
5th 19
1 73 0 06811 32204 78005
Rev 36
1 80 10 0709 32204 78000

Drive 31
1st 1 1 87 0 0736 32204 78001
Counter 2nd 19
1 94 0 07641 32204 78002
shaft 3rd 28
5th 31 2 01 0 07911 32204 78003
Rev 15
2 0810 0819 32204 78004
Rev idler shaft 23
Speedometer gear ratio lB 6
Malnsheft front
Oil capacity II US pt Imp pt
12 0 4 14 3 121
Thickness mm in Part number
14 0 055 32263 E9000
15 10 0591 32263 E9001
16 0 063 32263 E9002
MT 16

MANUAL TRANSM ISSION Service Data and Specifications
Maln haft rear end besrlna TIGHTENING TORQUE
Thickness mm lin Part number

1 Unit N m m
kg ft b
1 0 043 32228 20100

I Transmission installation
32228 20101 30
1 2 0 0471
I Clutch operating cylinder 30 40 3 1 41 22
32228 20102 59 32 43
1 3 0 0511
I Transmission to engine 43 58 44
14 0 0551 32228 20103 Gusset transmission
I
to 35 2 6 3 6 19 26
25
transmission
3 2 43 23 31
Counter drive aear

I Crossmember to body 31 42
Rear mounting insulator
I 31 42 32 43 23 31
to crossmember
Thickness mm lin Part number
Rear mounting insulator

1 4 0 055
1 5 0 059
32215 E9000
32215 E9oo1
I to reaf extension
31 42 32 4 3 23 31
Transmission case to
I 2 1
16 21 16 12 15
rear extension
16 0 0631 32215 E9oo2
Starter motor to
I 3 0
29 39 40 22 29
transmission
I Gear assembly
Bearing retainer to
AVAILABLE SHIM
I adapter plate
16 23 16 2 3 12 17
Counter front bearlna Mainshaft lock nut 137 167 14 0 17 0 101 123
Unit mm in
Counter gear lock nut 98 127 10 0 13 0 72 94
D Rear extension to
12 15
16 21 16 2 1
A transmission case
@ Front cover to
16 21 16 2 1 12 15
transmission case
I Filler plug 25 34 25 35 18 25
1 Transmission case
18 25
j Drain plug 25 34 25 3 5
2 Counter gear front bearing
3 Counter gear 20 34 20 35 14 25
Ball pin
TM371 4 Shim
88 11 8 09 1 2 6 5 8 7
Striking lever lock nut
A Thickness of shim Part number
Check ball plug 19 25 19 2 5 14 18
3 42 3 51
0 1 0 0041 32218 E9000 Speedometer sleeve
0 1346 0 13821 39 49 04 05 2 9 3 6
installation
3 32 3 41
0 2 10 0081 32218 E9001
0 1307 0 13431 20 29 2 0 3 0 14 22
up
Back lamp switch
3 22 3 31
03 0 012 32218 E9002 Return spring plug 7 8 98 08 1 0 58 72
0 1268 0 1303
3 12 3 21
0 4 0 016 32218 E9003
0 1228 0 1264
3 02 3 11
0 5 0 0201 32218 E9004
0 1189 0 12241
2 92 3 01
0 6 0 024 32218 E9005
0 1150 0 11851
MT17

TroubleDiagnosesa Correctiofl MANUAL TRANSMISSION
Noise
Check level and color of oil

Level color N G I Level and color OK
L
Add replace oil If oil leaks
repair cause
Check noise
I
NOise does not stop Noise stops
Shift gears and loco te which
0
OK gear position makes noise
Noise in Neutral Noise in position other than

I Neutral
Disengage clutch to
see if noise stops
I
Noise does not stop Noise stops
Noise outside transmission Noise in transmission Noise may
Check engine and dutch be caused by variations in engine

etc torque
Adjust engine idle speed
Noise
L
occurs in a
specific Noise occurs in all positions High roaring noise occurs in Gears grate while synchro
gear position and peaks at except Neutral and peaks at all positions and peaks 8t nizing
specific engine rpm and a specific car speed specific engine rpm
stops with gears in TOP
I
position
1
1
Noise appears to occur in
Noise source appears to be
located in differential L
carrier Check differential Noise occurs while shifting Noise occurs when stroking
transmission Disassemble carrier and eliminate cause gears further after shifting gears
and check gear in which of noise
noise occurs for
surface nd bearings
meshing
l
1 Moving parts couplings
Replace gear and or bearing Refer to 1he section Faulty gears etc of transmission
Synchromesh Mechanism interfering with other parts
MIlS

MANUAL TRANSMISSION DiTroubl
sgnoseundCoeir ctions
Gear jumping out of mesh
L
Locilte position where gears jump out of mesh
Check for free play in control lever
Shifting is accomplished without problems

Check interference of control lever with
console and check rubber boot of control
lever for fatigue

N G K
O
I
front
Adjust or replace Check for fatigue play etc on
and rear engine mounts
I
N G OK
Problem may be inside transmission

Adjust or replace
Disassemble and check transmission
Check end play of jump out gear

I
End play excessive End play O K
Check for engaging damage or wear on

Replace
coupling sleeve synchronizer hub and clutch
gear of main gear
I
Damage or wear OK
Replace Check for wear or damage on check ball and

fatigue or breaks on check spring
I
Damage or wear O K
Check for wear or deformation of fork rod

Replace
ball groove
Wear or deformation OK
Check for play of

wear or
jump
out synchro
Replace
nizer and mainshaft splines
I
No wear or play
Wear or play
Replace Check for wear or damage on bearings of main

shaft and countershaft Replace if worn
MT19

Trouble Disgnoseund CDrrections MANUAL TRANSMISSION
Faulty synchromesh mechanism

Noise occurs while shifting gears
Locate position where improper synchro
meshing occurs
Check
L
disengaging of clutch Refer to
Clutch Drags Section CL for trouble
diagnoses and corrections
N G
I O K
Repair or replace Problem may be inside transmision

Disassemble and check transmission
Measure baulk ring

1
clearance
to
gear
Refer to Baulk Ring for inspection
Clearance
N G Clearance K
O
l
Check for w ar on chamfered
Replace baulk ring
of baulk
area ring
I
Chamfered area worn Chamfered area not worn
1
Replace
Check contact
1
pattern of baulk ring and
tapered cone ofclutch gear
Improper contact Proper contact
l l
Replace baulk ring Check spread spring for any
break or bending
Spread spring
I
broken bent Spread spring not broken bent
1
Replace Check for wear
1 deformation
of insert
Refer to Shifting Inset for
inspection
MT 20

MANUAL TRANSMISSION Trouble Diagnoseund Correction
Difficult gear meshing shifting
Shift gears up and down while operating car to
see if gears shift smoothly
Shift gears while engine is OFF

OK
N G I
Check for proper installa Check engine idle speed

tion of control lever N G I OK
N G O c I
Adjust Check for improper dis

engaging of clutch
Repair or replace
Check for improper oper
ation of clutch operating
cylinder master cylinder
I
Operation
N G Operation OK
Repair clutch Check lubrication oil level

and color
I
N G OK
Add replace oil
Check for smooth shifting while

car is operating
N G OK
Instructs customers in correct
Problem may be inside transmission Remove trans shifting method

mission from car disassemble it and check it for source
of difficult meshing shifting of gears
L
Check operation of striking rod
Ox
N G I
Repair or replace Check operation of fork rod
Check for possible

1
bent fork rod or scratched case
N G K
O Scratched bent I
L Check engaging of hub cou
Replace Check gear end faces and gear bores Replace
pling sleeve clutch gear etc
for any sign of stickingjamming
If detected replace faulty parts I
MT 21

Special Service Tools MANUAL TRANSMISSION
Tool number Tool name

Kent Moore No
ST2381000l Adapter setting plate

125693
KV311 00300 Fork rod pin punch

9
ST30031000 Bearing puUer
125733 1
KV311 004 n Transmission press stand

Lo rQ OJ
rUoLh
ST23860000 Counter gear drift
ST22360002 Bearing drift

125679
ST22520000 Wrench
ST23800000 Transmission drift

ifi
125691
KV32 101330 Bearing puUer
ST22350000 Mainshaft bearing drift

125678
MT 22

MANUAL TRANSMISSION Special Service Tools
Tool number
Tool name
Kent Moore No
ST33400001 OU seal drift

126082
MT23

DATSUN 200SX Mode S 110 Series
SECTION
AT
AUTOMATIC TRANSMISSION
CONTENTS
FINAL ASSEMBLY
DESCRIPTION AT 2 44
AT
HYDRAULIC CONTROL UNIT AND TROUBLE SHOOTING AND
VALVES AT 3 DIAGNOSES AT51
HYDRAULIC CONTR L CIRCUITS AT 5 PRELIMINARY CHECKS
MINOR ADJUSTMENTS Prior to road testing AT 51

AT 25
REMOVAL AND INSTALLATION DIAGNOSTIC ROAD TEST AT 52
AT 28
TRANSMISSION ASSEMBLY PRESSURE TESTING
AT 28 AT 54
MAJOR OVERHAUL OPERATIONS AT30 STALL TESTING AT 55

SERVICE NOTES FOR SERVICE DATA AND
DISASSEMBL Y AT31 SPECIFICATIONS AT 52
DISASSEMBLY AT31 SPECIAL SERVICE TOOLS AT 53
COMPONENT PARTS AT 34

Description AUTOMATIC TRANSMISSION
1
DEScRIPTION
The 3N7l B transmission is a fully FLUID RECOMMENDATION Identification of number
automatic unit consisting primarily of arrangementa
Use DEXRON type automatic
a 3 element hydraulic
torque converter
transmission fluid only
and two planetary gear sets Two
IAPO AUTOIlATle TllAIISIIISSlOll CO lTO
inultiple
disc clutches a multiple
disc
MODEL X 23
01
brake brake band and one way clutch
provide the friction elements necessary NO 7601234

to obtain the desired function of the
two planetary gear sets

A IDENTIFICATION NUMBER
hydraulic control system is used
to operate the friction elements and Number designation
Stamped position
automatic shift controls
The plate is attached to the right
hand side of transmission 7601234
case
TORQUE CONVERTER
The torque converter is attached to
L Serial production
mber forthe month
the crankshaft through a flexible drive
Month of production
plate Heat generated in the torque
1 Jan 2 Fob no
converter is dissipated by circulating

X Oct Y N01 Z Dec
the transmission fluid through an on
in the radiator Lat
to water type cooler denoting
figu
tho year A DJ
lower tank
The welded construction of the tor
que converter prohibits disassembly or

service unless highly specialized equip
ment is available AT344
Tightening torque T of bolts

and nuts N m m
kg fHb
@ T 39 49 4 5 29 36
@ T 137 157 14 16 101 116
G
@ if @ T 44 54 4 5 5 5 33 40
1 Transmission case 8 One way clutch 14 Oil pan @ T 5 9 7 8 0 6 0 8 4 3 5 8
2 Oilpump 9 Low Reverse brake IS Control valve @ T 4 9 6 9 0 5 0 73 6 5 1
3 Frorit clutch 10 Oil distributor T 20 25 2 0 2 5 14 18
16 1npot shaft
4 Band brake 11 JQvemor 17 oonverter @T 13 l8 LJ 18 9 13
Torque
5 Rear clutch 12 Outputshaft 18 Converter housing @ T 4
5 7 4 0 55 0 75 4 05 4
6 Front planetary gear 13 Rear extension 19 Driplate CD T 2 5 3 4 0 25 0 35 1
8 2 5
7 Rear planetary gear
AT312
AT 2

AUTOMATIC TRANSM ISSIO N aulic
Hydi Control Unit and Valves
HYDRAULIC CONTROL UNIT AND VALVES
hydraulic or automatic control

The FLOW CONTROL VALVES Pressure modified valve
system is comprised of four 4 basic The pressure modifier valve assists

groups the pressure supply system Manual valve the mainline pressure regulator valve in
the pressure regulating system the
The manual valve is moved manual lowering mainline pressure during high
flow control valves and the friction
ly by the car operator to select the speed light load conditions such as
elements
different drive ranges steady speed cruise Governor pres
sure working against a spring opens
the valve which aUows modified throt
1 2 Shift valve
tle pressure to work against the pres
PRESSURE SUPPLY SYSTEM
The 1 2 shift valve automaticaUy sure regulator valve spring lowering
The pressure supply system consists shifts the transmission from first to mainline pressure Lower operating
of a gear type oil pump driven by the second or from second to first depend pressure under light load reduces oil
engine through the torque converter ing upon governor and throttle pres temperature and increases transmis
The pump provides pressure for aU sure along with accelerator position siOli life
hydraulic and lubrication needs solenoid downshift valve See Hy
draulic Control Circuits Drive 2
Throttle back up valve
2 3 Shift valve
The throttle back up valve assists
PRESSURE REGULATOR
VALVES
The shift valve automatically
2 3 the vacuum throttle valve to increase
shifts the transmission from second to line pressure when the manual valve is
The pressure regulating valves con from top to second de
top gear or shifted either to 2 or I range
trol the output pressure of the oil
pending up governor and throttle
pump accelerator position sole Second lock valve
pressure or
noid downshift valve See Hydraulic The second lock valve is used to
Pressure regulator valve Control Circuits Drive 3 Range
bypass the 1 2 shift valve to maintain
The pressure regulator valve con
the band apply pressure in 2 posi
trols mainline pressure based on 2 3 Timing valve tion The valve is also used as an oil
throttle opening for the
operation of restrictive orifice
For 23 shifts a pass ge for the 1 2 shift valve band
the band clutches and brake
slows the application fluid to the front apply pressure in D D and
clutch while the slower reacting band I Range
Governor valve This
is allowed to release prevents a
The governor valve tranSffi ts re hard 2 3 or 3 2 shift Under heavy
gulated pressure based on car

speed load however the engine will tend to
to the shifi valves to control upshifts run away during the 2 3 or 3 2 shift
and downshifts pause therefore a 2 3 timing valve
using throttle and governor pressure is
Vacuum throttle valve used to bypass the restrictive orifice CLUTCHES AND BAND
during such heavy load conditions SERVOS

The vacuum throttle valve transmits
the clutches
regulated pressure based on engine The servo pistons of
Solenoid downshift valve low reverse brake and band are moved
load vacuum This pressure controls
valve is hydraulicaUy to the clutches
the pressure regulator valve Also this The solenoid downshift engage
electrically when the brake and apply the band The clutch
pressure is applied to one end of the activated ac
and pistons released by

shift valves in opposition to governor celerator is floored causing a forced prake are
tension and band piston is

pressure which acts on the other end downshift from top to second top to spriT
1g
released by spring tension and hy
of the shift valves controlling upshift fi st or second to first gear depending
and downshift speeds upon car speed draulic pressure
governor pressure
AT3

Hydl7lUlic Control Unit and Valves AUTOMATIC TRANSM ISSIO N
Control valVe
rTil
SV
AT094
1 Pressure regulating valve 6 Vacuum throttle valve

2 Manual valve 7 Throttle up
back valve
3 lst 2nd shift valve 8 Solenoid down shift valve
4 lnd 3rd shift valve 9 Second lock v8Ive
5 Pressure modifier valve 10 2 3 timing valve
4
AT

AUTOMATIC TRANSMISSION Hydraulic Control Unitsnd Valves
OIL CHANNEL Oil Channels in Case Front Face
IDENTIFICATION
The circuit numbers shown in each
Hydraulic Control Circuit are classified

as follows according to the function
Pressure source of the line 7
Operating line pressure for

friction elements
12 3 4 5 6 8 9 10 1112
line pressure 13
Auxiliary
Torque converter pressure 14
Governor pre ure 15

AT106
Throttle system pressure

16 17 18 19
Oil Channels in Case Face

Oil Channels in Oil Pump
Oil pump discharge hole 7

r 90
o
Oil pump discharge hole 7 Governor pressure 15
i
fj J
Torque converter 0
0
i
Torque converter pressure 14 pressure l4 0
Servo release
q Rear clutch pressure 1 Rear clutch pressure 10 Governor feed pressure 1
Front clutch pressure 11 Servo tightening
pressure 1 1
P suction hole lnl
LOiiJ pressure 9
unm o 0
a
Front clutch rr I
I
Low reverse brake pressure 12f
0
0
pressure 11 U Jj
o sucti e
J
0
P
AT107
AT10S
MECHANICAL OPERATION
In the 3N71 B automatic transmission each part operates as shown in the foUowirig table at each gear select position
Gutch Low Band servo One

Gear Parking
Range reverse way
ratio pawl
Front Rear brake Operation Release clutch
on
Park on
on
Reverse 2 182 on on
Neutral
on
Dl Low 458
2 on
Drive D2 Second 1458 on on
D3 1000 on
Top on on on
2 Second 1458 on on
12 Second 1458 on on
I Low 458
2 on on
The low reverse brake is applied in 1 range to prevent free wheeling when coasting and allows engine braking
AT 5

Hydraulic Control Cirtuirs AUTOMATIC TRANSMISSION
HYDRAULIC CONTROL CIRCUITS
P RANGE PARK arking Mechanism

I
Power flow
In P range the shifl linkage

actuated parking pawl meshes in a gear
splined to the output shaftpreventing
movement of the car When the engine
is running the low and reverse brake is
applied by pressure from the manual
Uve
v passing through the 1 2 shift
valye
F Locr
11 AT086
Fluid flow
Manual Valve 4 Downshift Valve 13 2nd 3rd Shift valve
1st 2nd Shift Valve
Throttle Back up Valve
5 Ist 2nd Shift Valve 12

hottle Back up Va ve
1
I
y Low Reverse Brake
I
6
AT

AUTOMATIC TRANSM ISSION Hydraulic Control Circuits
Oil Pressure Circuit Diagram P range park
11
TorQu t
conv
0 I
r
nh r c h
rIf h gm
j E J
@1
I
TIC Oil
r
Slllt
rl j
IY
O
l
ro 01
10
Oi I cooler
j 9
l I olu
t r
r I l volv
Rnt lubrication
o
II
I I oIll
Drain
01
14
JJI II oL
Front
lL
1 LLl
lubricati
x
fir
0
1
0
1
1 J Throttl
drain
1
I r p
16 13
I
1
1
C
JLSII J
2Z 15
II
1J
x
x
J
1
IE 2no
vol
3 d Ii mino
Sh
2
t
I
J ji
l
II
j
I
I
I ck
6
I
@
r3
II I
I
I
CD P ur
otor
II I
II
Monuol
YOI
xn
ru
I
Not Mork d X ort droin
I
llrr Itr
prulUr lGoy rnor fud pt r
Lin rnor
Secondory
lOlv
Qovunar
Primo
OO lIOr olv
Go lpr1U1lI1
t
I Torqu t
con r pr r
Th ro lI r
pr AT455
AT 7

Hydraulic ContrrJI Circvits AUTOMATIC TRANSMISSION
R RANGE REVERSE Mechaitical Operation during R Range
Power flow
Front gear set Rear gear set
With the selector lever in R Output
range the front clutch is applied to Input through front
transmit clockwise clutch
engine torque
the Held
through connecting shell to the by low reverse
brake
Sun gear The clockwise rotation ofthe
sun gear causes the planet gears to
rotate counterclockwise With the low
and reverse brake holding the rear
planet carrier the rear internal gear

AT329
splined to the output shaft turns
counterclockwise in a reduction ratio Low reverse brake ON

Front clutch ON
of approximately 2 18 to I
Front clutch ON
Rear clutch OFF
Low and reverse brake ON
Brak band servo OFF Pressure release
way
One clutch Overrunning
AT085
Fluid flow
Manual Valve 4 Downshift Valve I3 2nd 3rd Shift Valve
L Ist 2nd Shift Valve
5 Ist 2nd Shift Valve 12 Throttle Back up Valve

I
Brake
y Low Reverse
6 Pressure Regulator Valve
L 2nd 3rd Shift Valve 10 Band Servo Release Side
II
1 Front Clutch
8
AT

AUTOMATIC TRANSM ISSIO N Hydraulic Control Circuits
Oil Pressure Circuit Diagram R range Reverse
broil
rt Brok
Torque l ton r Front RlOr
I h band
h
0 I
l
I
TIC Oil
cr volu
reOlollalnil
trJI
kill
l r
J 12
Oil cool
1 1
1
l
U
T I JUI T
Oral 01
i
I 11 LL l h
fi
IL J ThMII
drain
val
l
ID
24
Ool
6
l r
rl
I
I
jJ
x
x
G9 2nd 3rd
olv
liming
I
II
lxjJ i @
r
M
O k
uff
II
1
n ui
CD p ator
Jr
L J
U lr 1
vci I
r
u
l l
No
lrto
Markld X dfoin
1 x
Lin preuur Go rnor ud pr ur
Secondory Primor
r go rnOI lGlv go itlr 1
01
L G av rnor prn ure
fm Torqu COMut r ll
prl
Th ronl pr un
AT456
AT 9
Hydraulic Control Cirwiu AUTOMATIC TRANSM ISSION
N RANGE NEUTRAL
Power flow
In elements
ange no friction
are in use thus no power is trans
mitted to the output shaft
AT10

N
Oil Pressure Circuit Diagram range Neutral
F e
ll
Torql conv rt r Front
lItCh
Oil
1i
x
I
12
I
Bond X
YO @
Vacuum
Throtllt
Ihrottl bacll up own i1t OIY
oh wolv
Oi I cooler
I
RIO I ealia
flL 4
i
I
T11 r1I 1t
Drain
101
Front
t
lubricaf Orifice
11
18
I
chlcll
fol a
1
Drain 01
1 L
Throttle
t drain
I rI5
11
101
10
c o I JI
Z2 I
II
t1J fLx
x
x 5
l
J
Xl r t 2
ShiflIllGIY
dl
II
21
IV II I
6
ilL @ d lock
II
6 frO I
I
CD P
otor
II I
OI
r
@
jULj
I
Not Worked
on drain
I
lint prUSUft Go rnor ud pr nur
Slcondar Primory
OOv
nor
01 00 rnor vol
G o no prlssure
conyut r
nI
tI Torqu pnn
ft
Th rottl ur
p AT457
AT11

Hydraulic Centrol Circuits AUTOMATIC TRANSM ISSIO N
D RANGE LOW GEAR Mechanical Operation during 61 Range
Power flow
Front Rear gear set
gear set
With the shift selector in D low Output shaft
gear engine torque is transmitted
through the applied rear clutch to the Held by one way
in1ernal gear of the fron1 gear set The clutch
clockwise rotation of the front inter
nal gear causes the fron t planet gears
to rotate clockwise driving the com
pound sun gear counterclockwise The

front planetary carrier is splined 10 the
output shaft This causes the planet

Input from front
gears to drive the sun gear instead of to reai gear set
Output gear set
walking around the sun gear This AT330
counterclockwise rotation of the sun
gear causes the rear planet to

gears
rotate clockwise With the one way
clutch holding the rear planet carrier
the rear planetary gears turn the rear
internal gear and outpu1 shaft clock
wise in a reduction ratio of
approxi
mately 46
2 to I
Front clutch OFF

Rear clutch ON
Lo and reverse brake OFF
Brake band servo OFF
One way clutch HOLDING
AT081
Fluid flow
Manual Valve Governor Valve 15 Pressure Modifier Valve
2nd 3rd Shift Valve
Ist 2nd Shift Valve
2nd 3rd Timing Valve
Ist 2nd Shift Valve
J Rear Clutch
2 Second Lock Valve
3 Second Lock Valve
L Orifice Check Valve 2nd 3rd Shift Valve
AT12

Oil Pressure Circuit Diagram D1 range Low gear
Front Rlar Brake Low Q nd

cluleh cl utch bond r v 1 brake
Oi I pump
1
1
t
1
o Bond
Torqu
rl
ean r
I t
I b
I
7
ervo
2 3 Shill OI
t 6 It
Pres
valv
ur
rlQulo1 or
L
l
1
Throttle
pr sur
J t
t
1
@
Governor
I
pressure
lint pr s ur
Governor pre sure
Torque conyerter pressure
Throttle prlssure
AT446
AT13

Hydraulic Control Circuim AUTOMATIC TRANSMISSION
D RANGE 2ND GEAR MechariicaI Operation dtiring D2 Range
Power flow Front gear set Rear gear set
Io D range the brake band is

applied to hold the connecting sheU
and sun gear stationary Engine
torque through the applied rear clutch
is delivered to the internal gear of the
front gear set in a clockwise rotation

Clockwise rotation of the internal gear
causes the planet gears to walk
around the stationary sun gear in a
clockwise direction This causes the
output shafl which is splined to the
front planet carrier to turn in a clock AT331
wise direction with a reduction ratio

of about 146 to I
Front clutch OFF

Rear clutch ON
LOw and revelSe biake OFF
Ike band
llr servo ON
One way clutch OFF
AT079
Fluid flow
As car speed and governor pressure overcomes the force of the 1 2 shift the upshift position which directs line
increase the governor pressure acting valve spring and line pressure This pressure through the 2nd lock valve
on the end of the 1 2 shift valve aUows the 1 2 shift valve to move to and on to the brake band
2nd 3rd Shift Valve
Ist 2rid Shift Valve
Ist 2nd Shift Valve 8 Second Lock Valve 9 Band Servo
Apply Side
4 Rear Clutch
I
2 Second Lock Valve
3 Second Lock Valve

I
L Orifice Check Valve 2nd 3rd Shift Valve
AT 14

2nd gear
Oil Pressure Circuit Diagram D2 range
Front Reor Brake Low and

clutch clutch ba nd revers broke
Oil pump
t
Tor q ua J
f
conYerter
I
2 hjf
llvOIV
tl t
r t
Pressure
r oulator t
valve
1Itrrr 1ltrrr 1Itrrr

u
l Throttl e
pressure
P RND21
It
j
@Govern or
pressure
Line pressure
Gover or pressure
Torque converter pressure
Throlll prellur
AT448
AT15

Hydraulic Control Circuits AUTOMATIC TRANSM ISS10 N
t
D RANGE 3RD GEAR Mechanical Ojleiation during D3 Range
Power flow Front gear set Rear gear set
In on range engine torque is Input through front

and rear clutches
transmitted through both clutches
The front clutch turns the internal
gear of the forward gear set clockwise Output
shaft
The clutch turns the sun gears in a
rear
clockwise direction also With both the

internal gear and the sun gear of the
forward gear set turning in the same
direction at the same speed the planet
gears are locked in position and turn

A T332
as a unit The output shaft splined to
the forward planet carrier turns at a Front clutch ON Rear clutch ON
ratio of I I
Il
AT083
Front clutch ON
Rear clutch ON
Low and reverse brake OFF
Brake band servo OFF Presswe release
One way clutch OFF
Fluid flow
Governor pressure increases to the valve When the 2nd 3rd shift valve release the brake band The car is now
point that it can overcome the com opens pressure passes through the in D or direct drive the rear clu tch
bined forces of spring and throttle valve lands to the 2 3 timing valve and was already applied
pressure and move the 2nd 3rd shift on to apply the front clutch and
2nd 3rd Shift Valve
lst 2nd Shift Valve
Ist 2nd Shift Valve 8 Second Lock Valve 9 Band Servo
J Rear Clutch
I
Ii Apply
i
I
Side
2 Second Lock Valve Band Servo is released

t
3 Second Lock Valve I
LOrifiCe Check Valve 2nd 3rd Shift Valve 10

TIBand Servo Relea Side
I
42nd 3rd Timing Valve I Front
II Clutch
1
AT16

AUTOMATIC TRANSM ISSIO N Hydraulic Control Cirruit3
Oil Pressure Circuit Diagram 3rd gear

D3 range
Fronf Rear Brake Low and

clutch clutch bond rever brake
Oi I pump
t
t
0 Bond
JJ
To rq ue
c anYlrter
JI 1
y W r
r
Pressure
re QU lator
valve
l
t
sY
t
I
if Throttle
t tr
PRN021
Il
Ya
t
Iv
t
pressure
t lo
@
Governor
pressure
L in pressure
Governor pressure
IIDJWq Torque eonv rter pr ur
AT449
Iijp
I Throlll preuur
AT 17

Hydraulic Control Circuits AUTOMATIC TRANSMISSION
D RANGE KICKDOWN
To achieve a forced downshift from

3rd to 2nd the car be
speed must
under approximately 100 km h 60
MPH from 2nd to 1st it must be
under approximately 50 h 30
km
MPH FuUy depressing the accelerator
pedal energizes the downshift sole

noid which opens the solenoid down
shift valve Oil pressure is then exerted
against the shift valves Between 50

and 100 h 30 and 60 MPH this
km
pressure wiD close the 2nd 3rd shift
valve against governor pressure and the
car downshifts When the car speed is
below 50 h 30 MPH the
km I st 2nd
shift valve will be closed and the 1rans

mission will be in 1 st gear As car
speed and governor pressure increase

the shift valves automaticaUy reopen
AT IS

Oil Pressure Circuit Diagram D range kickdown shift valves in 2nd gear position
Torqul conv rl r Front Rlor
Oil
Iutch ClutCh
SD o
d
t
J1 y
I
r 3r
I
I J
TIC on ro
rog o p V 0 O
lID
i
1
Vacuum
lu i I
throttl
i1
i
own
01
all COOler
It 01
II
N
lI
RI hlbri cot ion
I
m
U
S
8 j I
14
Oraln
vohl oz
I Front
n
8
lubriCQtif
l i 18 16
d
Yol
W Throttle
drain
10 1
J
X
L
I
1
l
@Z 3n Shift
I
I Yol
Hmu u
C J
JI
Z2
Jr
5
X
J
11 j
g 2nda vI
3rd limine
r
1 B
pul 2 d
I
r
D 1Qto t
ii
lJlu r
I N
23
Tr
I 1
f
yol
@
l
Ol
PRND2 I
Hot Worbd l ore Oroln
IIo U
Lin pr r Govlrnor fud p uunl
L
GOY flU
pr u Primor
rrror yo Y
90
lt
Tor4 c on I r
pr sure
v
Th r011l pr ur
AT458
AT19

Hydraulic Control CilCuil AUTOMATIC TRANSMISSIO N
2 RANGE 2ND GEAR Fluid flow opening the valve and aUowing pres
Line from the manual sure to pass into the line of the
The 2 position is used to pressure
range
yalve the second lock valve throttle valve thus assuring adequate
lock he car in 2nd gear preventing opens
downshifts under any con against spring pressure As this valve throttle pressure even during decelera
upshifts or
The downshift solenoid valve is
opens pressure then passes to apply tion
ditions
the band servo Line pressure also used as apassage for line pressure to
flows to the throttle back up valve lock the 1 2 and 2 3 shift valves
Power flow
Power flow in 2 range is the same
as in D1 range
2nd 3rd Shift Valve
L Is1 2nd Shift Valve
lst 2nd Shift Valve
Rear Clutch
I
2 Second Lock Valve 9 Band Servo Apply Side
I
4 Solenoid Downshift Valve 13 3rd Shift Valve
t2nd 1st 2nd Shift Valve
Throttle Back up Valve 17 Vacuum Throttle Valve 16 Pressure Modifier Valve
2nd 3rd Shift Valve
Throttle Drain Valve
Pressure Regulator Valve
AT 20

Oil Pressure Circuit Diagram 2 range 2nd gear
Torqvt conv r1 r Rlor
r
r
v
l
r it 12
I
@
Vacuum
9 10 Ihrottlt boc k up downall ft volv
01 yolv
ll
Oil cooler
14
t 6
Drain
olv
Front
lubricatit
f
Drain volv
I I I
WI Throttl
drain
01
l r 13
11
l
@2nr3rd01Shift
1
1
In
22
II i
x
1
21
Q Pr or
J 6
II
6
Iau otor
01 1
Manual
@
I
R
f
P
worktd X or droln
No
lint pr ur l o rnor
t d pr urel Primory
nor volvl
QO
l S Gatnor p U l Ur
r
i 1 Torque con pt
JA
Th rottl pt fI
AT459
AT 21

Hydraulic Control Circuiu AUTOMATIC TRANSMISSION
1 RANGE second I as governor pressUre pre Fluid flow Low gear

LOW AND 2ND GEAR vents the 1 2 shift valve from closing
Manual pressure passing through
The I
range position is used to the 1 2 shift valve is used to close the
lock the car in 1 st gear preventing any Power flow
1 2 shift valve 1 2 up
preventing a
upshifts If the selectorJever is moved The power flow in I differs slight shift Manual pressure passing through
to the 1 position while the car is Iy from D in that the low and reverse the downshift valve locks the 2 3 shift
moving at high speeds the transmis band is applied to hold the valve closed
rear gear along with applying addi
sion will not shift into fIrst gear until set planet carrier providing engine tional c1 sing pressure to the 1 2 shift
car speed slows to approximately 50
braking Power flow in I is 1he same valve
km h 30 MPH Instead i1 will shift to as in D
Manual alYe 1 Governor Valve 15 Pressure Modifier Valve
2nd lnl Tuning Valve
2nd lrd Shift Valve
lst 2nd Shift Valve
to lst 2nd Shift Valve
jRear Clutch I
4 Solenoid Downshift Valve 13 lrd Shift Valve
t2nd Ist 2nd Shift Valve
5 Ist 2nd Shift Valve 12 lbrottle Back up Valve
I Low Ii Reverse Brake

I
FluId flow l gear
2n
Manual Valve 1 Governor Valve 15 Pressure Modifier Valve
2nd lnl Shift Valve
1st 2nd Shift Val
1st 2nd Shift Valve 8 Second Lock Valve Band
91 I
Servo
Apply Side
j Rear Clutch I
4 Solenoid Downshift Valve 13 lrd Shift Valve
t2nd 1st 2nd Shitt Valve
Throttle up
Back Valve 17 1 Pressure Modifier Valve
2nd lrd Shift Valve
3rd
2nd Timing Valve
Throttle Drain Valve
Pressure Regulator Valve
5 bt 2ndShiftValve
AT 22

Oil Pressure Circuit Diagram II range Low gear
La and
br
Srok
Torqul r
con Rlor bond
C m con o
cllutth
C
oPhrogm
Et
I
J
II
p j
IJI
I
Jir
I
11 cooler
u r
I
t
1 1
o i
CI
9
I
10
I
1@ 12
Vacuum
throttl
1
01
Throttl
back up
ll
vol
OIUOld
1 1 XII
downlhlft
lol
Rlor lubricalion II r
1
I i
I i
f 1
Drain
yo
c
J I
Ij l
Front
lubriCG
ltc Ie 16
X
Oroln Yol
wr
tu ThroW
drain
vol
1
I
@2nct 3rd Shift
val
D ft
II
m
I
x
rl
u II
11
1 lr
CD P UI
otor I n
f j J
ij
N
Lin prusur
dX d
Goy
ooo
rnor tud pr un
Secondory
Qov rnor
X
01
jl Primory
90 Ie r
nor 1
101
G ov rnor
pr t ul
converler
3
0
A
Torqul preure
Th oltl pre
ure
AT460
AT 23

Hydraulic Control Circuits AUTOMATIC TRANSMISSIO N
jjPressure Circuit Diagram 12 range 2nd gear
La and
broil
Torqu an
c rt r Front R or
uum oot ol
clufeh hro m
tuteh
J
2 6
17
t
1
Oil cool
TIC Oil
re9U
pt
Olloro I
Rlor lubrication
u
oro
l
lI
oB 0
JI I
Th t1
bocll up
101
b
JJ III
IItIOl1
downahi
11i
g tyol
n
Orain
0 01
4
Iii II II
FrOnt
11
lub icotic
1
Or ain 1 01
Throttl
drain
f 1
101
I
1
L 3tdSllift
@2n
10 101
r
S I i I
@2nd 3rdliminv
vol
It 3 ldI I zo
r
1
Sh
I
r
ii tJJ I
l u
D nou
Pr
vol
otor
uro I I
Manual
2
r 6
L
PRND2 I f1 n
Not Mork d X on drain w

I
Lute pru Gov rnor d pt urt
S condor PtimOI
90t ftOI YQlv Q 0Vllnol olv
Goy rnOt
prlS U
T
T
rquI COn pr lur
Th otll p nut
AT461
AT 24

AUTOMATIC TRANSM ISSION Minor Adjustments
MINOR ADJUSTMENTS
the transmission to downshift on part

KICKDOWN SWITCH
Kick down switch throttle
ADJUSTMENT 7
The kickdown switch is located at DIAGNOSIS

the upper post of the accelerator Switch can be heard clicking and the
pedal inside the car transmission still does not kickdown

When the pedal is fuUy depressed a
Check the of the switch
continuity
click can be heard just before the using a continuity tester Also check
pedal bottoms out If the click is not for available current

heard loosen the locknut and extend
the switch until the pedal lever makes SA TOO 1 The car upshifts at approximately 65
contact with the switch and the switch and 110 km h 40 and 70 MPH only
clicks The kickdown switch may be internal
ly shorted When the switch is short
Do not allow the switch to make ed there is continuity through the
contact too soon This would cause switch in any position
Wiring Diagram
t
1 mO R
re
o
BATTERY
ST ON t CC OFF
FUSIBLE
J
LINK
D
J
WB
BW
iDf
W
rIl
I BW
6 r
8 r WR
IGNITION ANO
ACCESSORY RE
1J
IGNITION SWITCH
MAIN HARNESS
WB
rJ
lIl
Q
0 0
O
0 0 l U
O
0
O O
Ul
O O
0 0 UI 0
D
J
O D
o 0 0000 O O
q o 0 D
l Q
FUSE BLOCK
G
I
J
I
rOl
G1 0
J
E S
No 2
8 iO
K1CKDOWN
DOWNSHIFT
SOLENOID I I SWITCH
SEL490
AT 25

Minor Adjustmentt AUTOMATIC TRANSM ISSIO N
INHIBITOR SWITCH
current to pass from the starter only wires should have
ADJUSTMENT con1inuity when the
when the lever is placed in the p lever is in the P and
or Nfl positions
The inhibitor switch has two major N range Red and black R B wires should
functions It allows the back
up lights A continuity tester may be used to have continuity when the shift lever is
to illuminate when the shift lever is check the inhibitor switch for proper moved to R range
in the reverse range It also acts
placed operation
as a neutraJ safety switch allowing B
The two black and yeUow Y
Wiring DIagram
00
00 BACK UP LAMP R H
gg
ii RB RB
00
B
8
o
BODY HARNESS
BO
BACK UP LAMP LH
R W
E
B TTE
a O WR
5T ON ACC Off
J J I11LBw J
we
BW W 2
c
1 g g
0
6 rr w IGNITION AND lJ
ACCESSORY R
IGNITION SWITCH
MAIN HARNESS
ii O U ii ii ii o
N
0 0 0 0 0 0 0 0 0 0
r o o o 0
o
I Q 0 Q o
FUSE BLOCK r BY
Lw B
t
BR
r
I LW
I
m
a
co
III
Ii INHIBITOR RELAY
flfj@
s
J l Dl C BR
ENGINE
No 2
HARNESS
l
q G Do
oo
RB
on
oU
we c
J CJO
M
LW J
STARTER MOTOR
INHIBITOR SWITCH
SEL491
AT 26

AUTOMATIC TRANSM ISSIO N Minor Adjustments
I Place the manual valve in Neutral VACUUM DIAPHRAGM

F R N D
vertical position I ROD ADJUSTMENT
I 1
2 Remove the screw as illustrated
The vacuum diaphragm and the
length of diaphragm rod help deter
its
Grommets
mine the shift patterns of the transmis
sion It is essen1ial that the correct
r
length rod be installed

J 1 Disconnect vacuum hose at
and dia
diaphragm
I
Lock nuts vacuum remove

c
nJ4I Front
SAT099
phragm from transmission case
2 Using a dep1h gauge measure
Be sure vacuum throttle
depth L
valve is pushed into valve body as far
Place shift lever in D range as possible
2 Loosen locknuts and move shift 3 Check L depth with chart
lever until D is properly aligned and below and select proper length rod
car is in D range
3 Loosen the attaching bolts 3 locknut
Tighten
4 Using an aligning pin move the Recheck P and Range 1 posi
switch until the pin falls into the hole tions As a be sure you
safety measure
in the rotor L Depth
can feel full detent when shift lever is
in P If you unable to
placed are
make adjustment grommets may

an
be badly damaged and should

worn or
be replaced
SAT002
1 Note seated valve body

2 Transmission case wall
3 Diaphragm rod
4 Valve body side plate
5 Vacuum throttle valve
Vacuum diaphragm rod selection

5 Tighten the attaching bolts
6 Recheck for continuity If faulty
L in Rod length mm in Part number
the switch Measured depth mm
replace
Under 55
25 1 0059 29 0 142
1 31932 XOI03
10098 10256 29 5 161

1 31932 XOlO4
25 65 26 05
26 15 26 55 10295 10453 30 0 181

1 31932 XOIOO
26 65 2705 1 0492 1 0650 5

30 1 201 31932 XOlO2
Over 15
27 1 0689 310 1220 31932 XOIOI
MANUAL LINKAGE
ADJUSTMENT BRAKE BAND ADJUSTMENT 3 Back off band servo piston stem
two complete turns

The adjustment of the manual Proper brake band adjustment
an important adjustment of results in smooth between 1st
linkage is shifting
the auto tic transmission Move the 2nd and 2nd 3rd
Although the CAUTION
shift lever from the P range to adjustment is very simple it is im 00 not back off EXCESSIVElY on
Range I you should be able to feel portant to use an accurate torque adjusting stem as anchor block may
the detents in each range wrench fall out of place
If the detents cannot be felt or the I Loosen locknut
is im Tigh1en locknut
pointer indicating the range 2 Torque band servo piston stem to 4 to approximately
properly aligned the linkage needs 12 I5
to N m 2 to 15 kg
1 m 9 to II 20 N m 2 kg m 14 ft lb while hold
adjustment ft lb ing band servo piston stem stationary
AT 27

Removal and Installation AUTOMATIC TRANSMISSION
TRANSMISSION eating fInger of a dial gauge rested

CAUTION
ASSEMBLY Do not the under the oil
against plate
place jack
Maximum allowable runout
When dismounting the automatic pan drain plug
0 5 mm 0 020 in
tran on from a car pay attention
to the foUowing points
12 Detach converter housing dust
I Before dismounting the transmis
cover Remove bolts securing torque
sion rigidly inspect it by using the
converter to drive plate
Troublneg
shooti Chart and dis
mount it only when it is necessary
2 Dismount the transmission with

utmost care
serving the
and when mounting ob
tightening torque indicated

QOOOO
on another table do Dot exert exces
sive force
AT268
2 InstaUation of torque converter

line up notch in torque converter
REMOVAL
with that in oil pump Be extremely
In dismounting the automatic Before careful not to put undue stress on
removing torque converter
transmission from a car proceed as inscribe chalk maria on two parts so parts when installing torque converter
foUows that they may be replaced in their

I Disconnect battery cable
ground original positions at assembly
from terminal
2 13 Remove rear engine mount se
Jack up car and support it on
safety stands We recommend a curing bolts and crossmember mount

hydraulic hoist or open pit be utilized ingbolts
14 Remove starter motor
if available
15 Remove bolts securing transmis
Observe all
safety regulations
3 Remove propeUer shaft sion to engine After removing these
bolts support engine and transmission
Plug up the opening in the rear ex
with jack and lower the jack graduaUy
tension to oil from ATl16
prevent flowing until transmission can be removed and
out
take out transmission under the car
4 Disconnect front exhaust tube Plug up openings such as oil charg

3 When conneCting torque converter
5 Disconnect selector lever
range ing pipe oil co ler tubes etc to transmissionmeasure distance A
from manual shaft
to be certain that they are correctly
6 Disconnect wire connections at CAUTiON assembled
inhibitor switch Take care when dismounting transmis
sion not to strike any Distance A
7 Disconnect vacuum tube from adjacent parts
and wire More than 21 5 mm 0 846 in
vacuum diaphragm connee
tions at downshift solenoid
8 Disconnect cable
speedometer
A
from rear extension
INSTALLATION
9 Disconnect oil charging pipe
10 Disconnect oil cooler inlet and InstaUation of automatic transmis
sion on car is in reverse order of re
outlet tubes at transmission case
II moval However observe the foUowing

Support engine by locating a jack
under oil pan with a woden block used installation notes
between oil pan and jack Support Drive plate tUnout

transmission by means of a transmis
Turn crankshaft one fuU turn and
sion jack measure drive plate runout with indi ATl17
AT 28

AUTOMATIC TRANSM ISSION Removal and Installation
4 Bolt converter to drive plate 9 Check inhibitor switch for oper time transmission is shifted
marks ation
Align chalk painted across Seepage AT52 for Checking En
Starter should be brought into
both parts during disassembling pro gine Idle
operation only when selector lever is
cesses
in P and N it should 12 Check to be that line pressure
positions sure
5 After converter is installed rotate is correct To do this refer to page
not be started when lever is in D
crankshaft several turns and check to AT 54 for Line Pressure Test
2 I and R positions
be sure that transmission rotates freely Perform staU test described in
Back up lamp should also light 13 as
without binding R
when selector lever is placed in page AT 55
6 Pour recommended automatic
position
transmission fluid up to correct level
IO Check fluid level in transmission
oughoil charge pipe
page AT
For detailed procedure see
7 Connect manual lever to shift rod
51
Operation should be carried out with
11 Move selector lever through aU
manual and selector levers in N
positions to be sure that transmission
8 Connect inhibitor switch wires
operates correctly
With hand brake applied rotate
a Refer to pages AT 26 and 27 for at idling Without disturbing
engine
Inhibitor Switch Adjustment the above setting move selector lever
b Inspect and adjust switch as above through N to D to 2 to I
whenever it has to be removed for and to R A slight shock should be

service felt by hand gripping selector each
AT 29

Major OlllHhaul Operations AUTOMATIC TRANSMISSIO N
MAJOR OVERHAUL OPERATIONS
Input shaft
Torque converter
Needleb
reftTsebraJce
Bearing race
Needle bearins
L
Needle bearing
Output abaft
Oil chaIJing pipe
iI
Speedometer pinion
Valve body
otIl
L et
L Parking mechanism
SAn01
AT 30

AUTOMATIC TRANSMISSIO N Major Overhaul Operations
SERVICE NOTES
FOR DISASSEMBLY
Before proceeding with dis
assembly thoroughly clean the outside

of the transmission It is important to
prevent the internal parts of the trans
mission from becoming contaminated
by dirt or other foreign matter

Disassembly should be dne in a
clean work area
Use a nylon cloth or paper towel
for wiping parts clean Common shop

rags can leave lint that might interfere
4 Unscrew and remove vacuum dia 7 Remove control valve body
with the transmission s operation
rod and a
phragm diaphragm ring
Bolts of 3 different lengths are
used Care must be taken to identify
individual bolt lengths and locations
Remove manual valve from valve

to prevent valve
DISASSEMBLY body as a precaution
from dropping out accidentaUy
1 Remove torque converter drain
transmission fluid through end of rear
and transmission on
extension place
TooL
SA T006
5 Remove speedometer lock plate

retaining bolt Remove speedometer
pinion
SAnoa
8 Loosen band piston

servo
steIl
locknut piston stem to
and tighten
prevent front clutch drum from drop

2 Remove converter housing ping out when removing front pump
SAT102
6 Remove oil pan and inspect

its
contents An analysis of any foreign
matter can indicate the types of prob

lems to look for If the fluid is very
contains for SATOOB
SAT003 dark smells burned or
eign particles the frictional material

clutches band may need replace
A tacky film that will not wipe
men
clean indicates varnish build up which 9 Remove input shaft from pump
3 Unscrew and remove downshift can cause valves servo and clutches to Attach Tool to pump and remove
solenoid and a ring stick and may inhibit pump pressure Do not aUow front Clutch to
pump
AT31

Major Olll1rhaul Operations AUTOMATIC TRANSMISSIO N
come out of position and drop onto
floor
Take care that shaft is not inserted
backward during reassembly
I
AT124
SAT012
15 Back out about haIf way band

To prevent brake Iin inus from bolt air gun
servo ajtaching Using an
cracking or peeling do not stretch the carefuUy apply pressure to loosen
flexible band unnecessarily Before re band servo Remove band servo retain
moving the brake band elwaYI secure ing bolts and puu band servo
it with a clip as shown in the figure be
low
Leave the clip i ition fter ra

10 Remove front clutch thrust
moving the brake band
washer and bearing race
Flexible type
bend I
nk
oW 157
Unit mm in
ApprOXimately
16 Remove rear planetary carrier
SAT106 2 0 08 dia wire clip snap ring and rear planetary carrier
SAT010
13 Remove pump thrust bearing and

II Back off band servo piston stem rear clutch thrust washer
to release band
17 Remove output shaft s ap ring
SAT013
SAT011
14 Remove rear clutch hub front
planetary carrier and connecting sheU

12 Remove brake band strut Brake rear clutch thrust bearing front plane
band front and rear clutch assemblies tary carrier thrust washer and thrust
may be removed together bearing
32
AT

AUTOMATIC TRANSM ISSIO N Major Overhaul Operations
18 Remove rear connecting drum

with internal annulus gear
SAT020
SATon
25 Remove one way clutch inner
race return thrust washer low and
22 Be careful not to lose parking reverse return spring and spring thrust
pawl spring and retainer washer ring
19 Pry off one end of snap
ring with
a screwdriver Remove snap ring from
low and reverse brake assembly while o
applying plier force in direction of

arrow
I
01
L
C J
EiL l
J
0
O 0
CJ
r 11 AT021
26 Using an air gun with a tapered

rubber tip carefuUy apply air pressure
23 Remove outpu1 shaft with gover to remove low and reverse brake
nor piston
20 Tilt extension housing upward

and remove low and reverse brake
clutch assembly
SAT022
washer 27 Pry off rings CD from both

24 Remove governor thrust snap
and needle bearing ends of parking brake lever @ and
Remove one way clutch inner race remove the lever Back off manual
hex head slotted bolts using shaft lock nut @ and remove manual
attaching
21 Remove rear extension Tool plate @ and parking rod ID
AT 33

MsjorOverhaulOpsrstions AUTOMATIC TRANSMISSION
6 Using a feeler gauge and straighf

1 clearance between gears
edge measure
and pump cover
Standard clearance
0 02 0 04 mm
0 0008 0 0016 in
Replace if the clearance exceeds

0 08 mm 0 0031 in
AT133 u SAT024
28 Remove inhibitor switch and
manual shaft by loosening two se 3 Inspect gears and aU internal sur
cming bolts faces for faults and visible wear

4 Measure clearance between outer
gear and crescent
Standard e
dearanc
0 14 21
0 mm
0 0055 0 0083 in
COMPONENT PARTS
The transmission consists of many
Replace if the clearance exceeds
small parts that are quite alike in 25
0 mm 0 0098 in
construction yet machined to very
7 Measure clearance between seal
c1 e
oIerances When disassembling
parts be sure to place them in order iD ring and ring groove
part rack so they can be put back in Standard clearanca

the unit in their proper positions AU 0 04 0 16 mm
parts should be carefuUy cleaned with 0 0016 0 0063 in
a purpose non flanunable sol

general
vent before inspection or reassembly Replace if the clearance exceeds
Gaskets seals and similar parts should 0 16 mm 0 0063 in
be replaced It is also very important Of course it is good practice to reo
to perform functional tests whenever SAT025 place aU seal rings during an overhaul
it is designated
1earance
l
OIL
I
PUMP
Remove front
5 Measure clearance between outer
J Sealring
w
pump gasket and gear and pump housing
O ring Inspect pump body pump
yw
Standard dearance
shaft and ring groove areas for wear
0 05 20
0 mm
11
0 0020 0 0079 in
Replace
25
0 mm
if the clearance
0 0098 in
exceeds
4 I AT1 5
w SAT023
8 Mount pump housing in Tool Set
up pump housing with inner and outer

pump on it and instaU pump
gears
2 Remove pump cover from pump cover to pump housing Temporarily
SAT026
housing assemble oil pump
AT 34

AUTOMATIC TRANSM J SJON Major Overhaul Operations
Totar indicator reading 10 Tighten

pump securing bolts to
Less than 0 07 mm specified torque
0 0028 in
Oil pump
b housing to oil pump
t
1 cover
5 9 7 8 N m
t 0 6
4 3
8 kg
0
5 8 ft lb
m
AT166
Recheck run out Replace Q ring
and gasket
9 Set run out of the cover to within 0

ST25580001
specified total indicator reading AT264
FRONT CLUTCH
ring
O
Spring retainer
Dish plate
Driven plate steel plate
Drive plate riction plate
Snap ring
SAT086
35
AT
Major Overhaul Operstions AUTOMATlG TRANSMISSIO N
1 Using a screwdriver remove large Standard driplate thickness

clutch retaining plate snap ring 50
1 1 65 mm
0 0591 0 0650 in
J
L 7 Check for snapring weak

1
wear on
C or broken coil springs and warped

spring retainer
J 20
0 79 S Lubricate clutch drum hub and
Cut off hatched portion
seals and instaU inner seal and piston
seal as illustrated Be careful not to
Unit mm in
ATl48
stretch seals during installation
Neyer a mbl clutch dry Iways

lubri to its components thoroughly
4 Remove spring retainer and

springs
2 Remove clutch plate assembly
SAT031
SAT029
AT1S0
9 Assemble piston being careful not

5 For easy removal of piston from to aUow seal to kink or become
drum mount clutch on pump Use an damaged during instaUation After in
air gun with tapered rubber tip to
a stalling turn piston by hand to ensure
3 Compress clutch springs and carefully apply air pressure to loosen that there is no binding
remove snap ring from spring retainer piston from drum
SAT030
6 Check clutch drive plate facing for

When Tool is to b used cut and retainer
wear or darnage Drive plate thickness 10 Reassemble spring
with
toe tips of th legs grinding must no1 be less than 1 4 mm 0 055 ReinstaU soap ring Be sure snap ring is
wheel in properly seated
AT 36

AUTOMATIC TRANSMISSION Major Overhaul Operations
13 Measure clearance between re REAR CLUTCH

tainer plate and snap ring
Specified clearance
1 6 2 0 mm 0 063 0 079 in
If necessarytry other retaining

having different thicknesses un
plates
til correct clearance is obtained
Available retaining plate
Thickness Part number

mm
in
10 6 0 417 31537 XOIOO
II Install dish plate with dish facing
10 8 0 425 31537 XOIOI
outward
31537 X0102 AT153
110 433
0
1 Rear clutch drum 6
Snap ring
112 0 441 31537 XOI03
2 Piston Spring retainer
7
II 4 0 449 31537 XOI04 3 Dished plate 8 Snap ring

4 Coilspring 9 Drive plate
116 0 457 31537 X0105
5 Retaining plate 10 Driven plate
Service procedures for rear clutch

are essentially the same as those for
front clutch with the foUowing ex
SA T033 ception
Specified clearance betWeen
retainer plate and snap ring

0 8 1 6 mm
0 031 0 063 in
12 Now install driven plate steel SA T034
plate then a drive plate friction
plate and repeat in this order until

correct number of plates has been 14 Testing front clutch
instaUed check Service Data and With front clutch assembled on oil
Specifications for proper quanti1y of pump cover direct a jet of air into
plates Now install retainer plate and hole in clutch drum for definite clutch
snap ring operation
SAT035
Test rear clutch
AT152
1 Snap ring
2 Retainer plate
3 Drive plate Friction plate
4 Drive plate Steel plate
III
5 Dish plate
AT157
AT37

Maior Overhaul Operations AUTOMATIC TRANSMISSIO N
Inspect band friction material for

LOW REVERSE BRAKE
If cracked chipped or burnt
wear
spots are apparent replace the

band
Piston
Spring thrust ring

Low and reverse return spring
Return tluust washer
SAT036
Dishplatc
Driven plate Steel plate
Drivc platc Friction plate Check band components for

servo
Retainer plate wear and scoring Rep ace piston

a rings and aU other components as
Snap ring
necessary
SAT094
brake for DriY 4l plate thickness

Examine low and reverse
Standard
damaged clutch drive plate facing
1 90 2 05 mm
and worn soap ring
10 0748 0 0807 in
Check drive plate facing for wear or
Allowabl limit
damage if necessary replace
1 8 mm 10 071 in
Test piston return spring for weak

ness Discard if it is too weak
GOVERNOR
BRAKE BAND AND BAND SERVO

To control valve 3
11
I Gornot
prc 15
1 Anchor end pin

2 Band strut
3 Apply
4 4
Release
5 Return spring From control valve
6 Band servo piston stem Linc prcssur I J
7 Band servo piston
ATQ90
8 Servo retaines
9 Brake band assembly
1 Primary governor 4 Oil distributor
10 Trammission case
2 Secondary governor 5 Output shaft
AT290
3 Governor valve body
AT 38
Disassemble governor and check Governor valve sprIng chart

valves for indication of burning or
scratches Inspect springs for weak
ness or burning Replace parts as Free length
necessary and reassemble As installed I
I
Do not interchange components of
primary
valves
and secondary governor Lm mWire dia
0
SAT039
Assemble governor on oil distribu
D l
t
tor
Governor valve body

distributor
to oil
aOlriMI IIlI1
SAT038
InstaUed
Outer No of Free
Wire dia active Load
Valve spring coil dia length Length
coil in in N kg lb
mm in in
mm mm mm
Primary governor 0 45 8 75 5 0 218 7 5 2 109
0 0177 3445
0 0 858 0 295 0 215 474
0
0 70 9 20 5 5 25 1 10 5 10 788
Secondary governor
0 3622 0 988 413
0 100 426
2
0 0276
that have been damaged by over

PLANETARY CARRIER Clearance
heating wiD have a blue discolora
The planetary carrier cannot be
tion
1
divided into its individual components
rI
If any the is
part of component
faulty replace the carrier as a unit
Check clearance between pinion 1

washer and
feeler
planetary carrier with a
J
Standard clearance
0 20 0 70 mm
In AT167
0 0079 0 0276 in
Replace if the clearance exceeds Check planetary gear sets for

SAT040
in
080 mm 0 0315 darnaged or worn gears Gear sets
AT 39

MajorOverlJaulOperations AUTOMATIC TRANSMISSION
CONTROL VALVE BODY relief check valve baU and related sleeve aod plug and second lock valve
The valve body contains many pre springs aod spring Place each loose part on a
4 Remove side plate A rack to retain

cision parts and pressure correct sequence of as
requires extreme care
when parts are removed and serviced regulator valve spring spring seat sembly
Place removed parts on a parts rack so
they be put back in the valve

can
body
in the same
positions and sequences Spring seal
Care will also prevent springs and smaU

Spring
parts from becoming scattered or lo t
L Remove oil strainer aod its attach

ing screws nuts and bolts
II
L Side plate A
SAT041
SA T042
2 Disassemble valve body and it
remaining attaching bolts and nuts to

carefully separate lower body separa
tor plate and upp r body
5 Remove ide B 2nd 3rd

plate spring aod the kickdown valve and
timing valve and spring vacuum throt spring Place each loose part on a rack
tle valve thro1tle back up valve and to retain sequence of assembly
2nd 3rd timing valve
HT61000800
AT168 Spring
9 9
Q J IOIi
J
c
I a
9I 19uDdI
io
J L
uii I
l
1 I
AT1 9
Throttle back up valve
down
Kick vaive
3 valve body separation do
During
not scatter or lose orifice check valve Side plate B
servo orifice check valve and thro11le SAT043
40
AT

6 Remove side C removed when

plate pressure Manual valve was
modifier valve and spring 2nd 3rd valve body was removed from trans
shift valve spring and plug and I st mission Include valve in subsequent
2nd shift valve and and service sequence
spring inspection
Place each loose part on a rack to
retain sequence of assembly
d@4tt h 1fu
It 1 nib
fkq T
AJ
2M
J L
i
35t1t
w
k w Mw
l
ml
9 Check separator plate for
I
iiJU
PbEH1 1
i1 Wip j1 11 jtltwmJ
111
j
scratches
sary
cause
or
Scratches
oil to
damage Replace if neces
bypass
or score marks
correct oil passages
can
and result in system malfunction

Jt
1 II @n vun
bOdY I
Lower valve Spring
Plug
Co nDllD
o
Spring
C o
11
o
Pressure modifier valve
bo
0
1 it 2 n d shif t valve nnn

0 0
0 0
Spnng 0
1
oo
0
nd 3rd shift valve
I
g I
Slde plate e
SAT046
A A I
10 Check oil passages in upper and
SAT044
lower valve bodies for varnish deposits
scratches Or otber damage that would
impair valve movement Check thread
Precaution for inspection During cleaning do not remove the ed holes and related bolts and screws
sharp edges of the valve When edges for stripped threads replace as needed
A
newly manufactured valve body
are rounded or scratched entry is pro II Test valve springs for weakened
represents precision manufactured
vided for dirt or foreign matter to load condition Refer to Valve Body
valves assembled with close tolerances
work into the sides of the valves and Spring Chart for spring specifications
into precision bores of the valve body
If inspection reveals excessive clear hinder valve movement
The valves may be cleaned using
ances 0 03mm 0 0012 in or more
alcohol or lacquer thinner The valve
between the valves and the valve body
bodies be dip cleaned with a good
can
bores replace the en1ire valve body
carburetor cleaner or lacquer thinner Valve body spring chart
rather than attempt rework
Do not leave valve bodies
If one or more valves are sticking SUbmerged
in carburetor cleaner
from varnish deposits or burns resulJ longer than five
minutes Rinse parts thoroughly and Free length
ing from deteriorated oil or overhea1
dry As installed I
ing you may be able to clean the I
Lubricate all parts in clean auto

valves and valve bodies Always use
matic transmission fluid before reas
croeus
scratch
cloth which is
as
the
it
very fme type
of cutting material Never use emery
cloth is
valves
too
a
coarse
or valve
and
bores
can
sembly
7 Check valves for signs of burning
Replace if beyond clean up
i5
l
O r ij
Wire dia
0
Scratches can lead to future deposits 8 Check oil strainer for general con
of varnish or foreign matter dition Replace if necessary SAT039
41
AT
Major Overflaul Operations AUTOMATIC TRANSM ISSIO N
InstaUed
Outer coil
Valve Wire dia No of Free length
spring
in dia Length Load
mm active coil mm in
mm in in N
mm kg lb
Manual detent 3
1 3
7 15 4
32 26 5 53 9
0 051 0 287 276
1 1 043 5 12 1
Pressure regulator valve 12 7

11 13 43 0 5
27
5
23
0 047 0 461 1 693 0 925 28 62
Pressure modifier valve 04 4

8 5 18 5 9 0 10
0 016 331
0 0 728 354
0 1
0 0 2
1st 2nd shift valve 0 6 6 6 32 0

16 16 0 6 129
0 024 0 260 260
1 0 630 0 625 1 378
2nd 3rd shift valve 0 7 6 9 18 41 0 17 0 13 73

0028 0 272 1 614 0 669 I 40 3 09
2nd 3rd timing valve 0 7 6 2 15 32 5 27 0 39

5
0 028 0 244 280
1 1 063 0 55 1
21
Throttle back up valve 0 8 3

7 14 36 0 18 8 18 83
0 031 0 287 1 417 0740 1 92 4 23
Solenoid downshift valve 55

0 5 55 12 22 0 5
12 5 88
0 0217 0 2185 0 866 492
0 0 60 1
32
Second lock valve 0 55 55

5 16 33 5 210 5 88
0 0217 0 2185 319
1 0 827 060 32
1
Throttle relief check valve 09 5

6 14 26 8 19 0 2148
0 035 0 256 1055 0 748 2 19 4 83
Orifice check valve
0 23 5 0 12 15 5 5
11 0 10
0 0091 0 197 0 610 453
0 0 01 0 02
Servo orifice check valve
42
AT

AUTOMATIC TRANSM ISSIO N Major Dverhsul Operations
12 Assemble side plate A group of side plate and fmger tighten screws side plate C group in same manner as
parts into lower valve body Reins1aU Assemble side pla1e B group and A group
Sid Pia
Spring seat
talA Cl
Pressure llat
regl
Pressure
r sleevei
J@
U
regulator plug
Second lock valve
Upper valve body
Manual valve
SAT095
13 Tighten screws
15 Install upper and lower valves
cD Side plate to valve body
2 5
cD Upper snd lower VBlves
3 4 N m
2 5 3 4 N m
0 25 0 35 kg m
0 25 0 35 kg m
1 8 2 5 ft lb
1 8 2 5 ft lb
Reamer bolt
4 9 6 9 N m
0 5 0 7 kg m
14 Install orifice check valve valve
3 6 5 1 fNb
spring 1hrottle relief valve spring and
steel ball in valve body AT173
Orifice check valve
ST25160000
16 Install oil strainer
cD Oil strsiner to valve body

2 5 3 4 N m
fO 25 0 35 kg m
1 8 2 5 ft lb
The manual valve is inserted into

the valvB body when the latter is in
AT430
stalled in the transmission
43
AT

Majo OverhaulOperations AUTOMATIC TRANSMISSION
FINAL ASSEMBLY bearing bearing race snap ring and

iUustration as a guide to instaUation
the foUowing procedures and locations

When installing assembling needle O ring seal ring use
gE
do 0
a
0
c 2
Q Q
0
c
u
5 8
Co e O
Q
C Q
i
QC
S
oU d
e ll
0
3
8 C
e
oS Q
u
Co
e @
cii r
1 ll
Ji
a8 Q
a 5 Q
U
Q
U
H e e
C
S
d
@
Co
a
j
Q
U
@Q 1
zj
5
8
e
I l
f
il
d
e U
e
S
C
a 5
C
f
Q
Co a
s 8
z
cii
S
e
Co IS
SA T099
44
AT

AUTOMATIC TRANSMISSION Major Overhaul Operations
with the fmal 4 Align and start hex head slotted

I Before proceeding
it is im bolts into inner race from of case
assembly of all components rear
portant to verify that the case housing

and parts are clean and free from dust
dirt and foreign matter use air gun WARNING

Check that return spring is centered
Have tray available with clean trans
a
on race before tightening

mission fluid for lubricating parts
Petroleum be used
jeUy can to
secure washers during installation All

new seals and rings should have been Tighten the bolts
installed before beginning final as

J
G One way clutch inner race to
semb ly
transmission case
13 18 N m
1 3 1 8 kg m
9 13 ft lb
7 Using an air gun with a tapered

I
I i rubber tip check low and reverse
i
l
7 brake operation
i
ST25570001 lfiu
ST25490000
GG91060000
SAT047
2 Lubricate and instaU low and
reverse piston into the case
5 Install steel dished pla1e first then

steel and friction plates and fmaUy
and snap
retaining plate ring
8 InstaU governor thrust washer and

needle bearing
3 InstaU thrust ring piston return
thrust washer and

spring one way
clutch inner race
6 After low and reverse brake has

Oe been completely assembled measure
JGOC
c
clearance between snapring and re

o
tainer plate If measurement exceeds

j
o
o
c
GOo 0
cl
0
IIU
l
specifications it can be adjusted by
replacing retainer plate with one of a 9 Slide distributor as
1
Co
governor
different thickness sembly shaft from fron1 of
f9 output
on
JP
r Low and reverse brake clearance shaft Install shaft and governor dis
o o
s 0 80 1 25 mm tributor into case using care not to

r II ISTOZl 0 0315 0 0492 inl damage distributor rings
45
AT

Major Overhaul Operations AUTOMATIC TRANSMISSION
c
D CO
V
j a
10 InstaU one into one 13 Install mapring shaft 16
way sprag on Adjust front end playas foUows
way clutch outer race attached to
connecting drum
Arrow on sprag must face front of
transmission Front end p1aY
1 JLv
r
l J CC
j
14 Secure thrust bearing and thrust
washer with petroleum jeUy and instaU
rear planetary carrier SAT091
Front clutch 5 Transmission case

II InstaU
connecting drum with thrust washer 6 Oil pump ga5Ket
sprag by rotating drum clockwise using 2 Oil pump cover 7 Oil pump cover
a slight pressure and wobbling to aIign 3 Front clutch
bearing race
4 Rear clutch
plates with hub and sprag assembly
Connecting drum should now be free
to rotate clockwise only This check
will verify that sprag is correctly in

stalled and operative
I Assemble front and rear clutches

SATOSS
front internal gear front planetary
carrier and connecting sheU Secure
thrust bearings with petroleum jeUy
15 Install rear planetary carrier snap
ring
This snap ring is thinner than 8
clutch drum snap ba sure you

ring so
are using correct size If you have in

sufficient spaco to install snap ring
int drum groove pull connecting I
4
drum forward a far as possible This
will give you sufficient groove clear
12 InstaU rear in1ernal SATOS7
gear anco to install drum nap ring
46
AT

AUTOMATIC TRANSM 15510 N Major Overhaul Operations
2 Install assembly into transmission from face of clutch drum to top of 6 Install thrust washer Measure
caSe Check that parts are properly thrust bearing race dilliension B from top of oil pump shaft to thrust
seated before proceeding with washer dimension D
measurements
I
L fffi
llV
pumpU
Oil
@ SAT061
SAT096
1 Depth gauge
SAT05S
2 Front clutch drum
3 Rear clu tch drum
4 Thrust bearing
3 lsing a dial gauge or caliper with a
seven inch base measure from rear
hub thrust race to case dimen

bearing
sion A
7 Difference between dimension A
0 1 mm 0 004 in B and C D is
front end play and must be within

3
specified value
Specified front end play

cID @ SAT059
0 5 0 8 mm
0 020 0 031 inl

1 Dial gauge 5 Measure from top of oil pump
2 Front clutch drum shaft to gasket installed dimension C
3 Transmission case
Front end be
play can adjusted
4 Bearing race with front clutch thrust washers of
5
6
Thrust bearing
Rear clutch drum 1
c G k
different thickness
Available front clutch thrust washer

I
I ty S
I 0 059 31528 XOlO6
oilPump 7
1 0 067 31528 XOl05
SAT063
19 075
0 31528 XOIOO
2 1 0 083 31528 XOIOI
3
2 0 091 31528 XOI02
fU 0
5
2
2 7
0 098
106
0
31528 XOlO3
31528 XOI04
4 Assemble front and rear clutch

drum assemblies and lay them 17 Adjust total end playas follows
together
l1at on bench Be sure rear hub thrust This adjustment is seldom required
bearing is properly seated Measure III SAT064

because this type of thrust bearing and
47
AT

Major Overhaul Operations AUTOMATIC TRANSMISSION
will normally show very little 18 Install brake band band strut and 21 Mount oil oil
race
pump gasket on
We also have standard taler band Lubricate Orings with

wear a servo servo pump petroleum jelly Align
ance of 0 25 to 0 50 mm 0 0098 to before installing Care should be taken pump to transmission case and install
0 0197 in However we are present to avoiddamaging O rings when re
n
ing correct checking procedure mbling
i
C1l E r
i SAT069
Tott
play
Jf
22 Adjust band Make sure that brake
band strut is correctly installed
SA T092
19 Install and torque the retainer Torque piston tern to specified v
Jue
bolts Loosen piston stem Back off two full turns and secure
Front clutch 5 Transmission case
thrust washer with lock nut

6 Oil pump ga5ket
2
rfl Servo piston retainer bolt
Oil pump cover 7 Oil pump cover
3 Front clutch
9
4 9N
6 m rfl Piston stem
be aring race
4 Rear 5
0 0 7 m
kg 12 15 N m
clutch
3 6 5 1 ft b 1 2 1 5 m
kg
9 11 ft bl
1 Meamre dimension A using in
Piston stem lock nut
structions in steps 1 2 and 3 15 39N
under No 16 above 1 5 4 0 m
kg
2 Measure dimension C using in
11 29 ft lb
structions in 5 under
step N 16
above
GG91060000
3 Difference between dimension
AQ I mm 0 004 in and C is total
end play and it must be within speci
fied value
Specified total end play

0 25 0 50 mm
0 00980 0197 inl
ST25490000
If difference Jletwen A2
Q mm
0 008 in and C is not within taler 20 Finger tighten brake band servo SAT070
ance select proper size oil pump cover
piston stem enough to prevent brake
bearing race band and strut from falling out Do
not adjust bnlke band at this time
Available oil pump cover
bearing race
12 0 047 31556 XOlOO
14 0 055 31556 XOIOI 23 Before proceeding with installa

tion of valve body assembly perform a
16 0 063 31556 XOI02
fmal air check of all assembled com
18 0071 31556 XOI03
ponenjs This will ensure that you
20 0079 31556 XOI04 have not overlooked tightening of any
2 2 bolts or damaged any seals during as
0 087 31556 XOl05
sembly
48
AT

AUTOMATIC TRANSMISSIO N Major Overhaul Operations
Air check point Q Rear extension to transmission 29 Check pump to transmission align
case I11ent and install converter housing
20 25 N m
2 0 2 5 kg m
dl 44 54 N m
4 5 5 5 kg m
14 18 ft Ib
33 40 ft Ibl
1 Band servo apply 9

2 Rear clutch 1
Front clutch 11
3 Band servo release 10 SA T014
4 Governor feed 1
5 Low reverse brake 12
27 Install control valve body Be sure
manual valve is in alignment with 30 Before installing vacuum dia

4 Using an air gun with a tapered of hole
selector pin phragm valve measure depth
rubber tip perform air checks
in which it is inserted This measure
ment determines correct rod length to
ensure proper performance

u
o
tK
o oo1
SAT078
28 Tighten control valve body attach
ing bolts 1 Note seated valve body
2 Transmission case wall
25 Check that parking pawl pin dl 5 4 74N m
Vacuwn
3 diaphrngm
spring and washer are assembled 0 55 0 75 kg m 4 Diaphragm rod
correctly 4 0 5 4 ft Ibl 5 Valve body side plate
6 Vacuum throttle valve
Control valve body bolts

6 vary in length
attaching
Care must be taken to
ensure that each bolt is returned to
c correct hole
0 l o
0
1
o
2 o
SAT073
26 Install rear extension
49
AT
Major Overhsul Operations AUTOMATIC TRANSM15510 N
Throttle modulator valve rod selectioo
Measured depth L mm in Rod length mm in Part number
Under 55
25 J 0059 29 0 142
1 31932 XOI03
25 65 26 05 1 0098 1 0256 5
29 161
1 31932 XOI04
15
26 55
26 1 0295 1 0453 30 0 l81
l 31932 XOlOO
26 65 27 05 10492 1 0650 5
30 201
1 31932 XOI02
Over 27 15 1 0689 310 1 0
22 31932 XOIOI
31 Install vacuum diaphragm 34 Install inhibitor switch Check for

proper operation in each range using a
circuit tester Refer to Minor Adjust

ment
37 Carefully inspect torque converter

for damage Check converter hub for
SAT082
grooves caused by hardened seals Also
32 Before installing down shift sole check bushing contact area
noid check to verify that it is oper

ating properly Use a hot lead and
ground to check solenoid
35 Before installing oil
pan check
alignment and operation of control
lever and parking pawl
engagement
Blow mechanism with air to clean
Make fmal check to be sure all bolts
are installed in valve body
38 Lubricate oil pump lip seal and

A converter neck before installing con
verter
Install converter being sure that
converter is properly meshed with oil
33 Install down shift solenoid
pump drive gear
@J
36 Install oil pan with new gasket
tfl Oil pan to transmission ease
E
F
4 9
0 5
6 9 N
0 7
m
kg m
SATOS1
3 6 5 1 ft Ibl
50
AT

AUTOMATIC TRANSMISSION Trouble shootingsndDiagnoses
TROUBLE SHOOTING AND DIAGNOSES
1 Converter housing sian front seal

PRELIMINARY
Rubber O ring of oil pump housing Crankshaft oil seal
CHECKS Prior to Bolts of converter
Oil pump housing oil seal transmis housing to case
road testing
f CD
I I
Verify customer complaint
The customer should supply as
much information as possible includ

that
ing any unusual characteristics
accompany the lcaoimnpt 1 II 8

1
IL
Fluid level
I II I I I
To properly check l1uid level
1 Place car on a level surface
2 Put chocks in place and

wheel
parking brake securely
apply
3 Warm up engine on fast idle
4 Return engine to curb idling speed
5 Slowly move the gear selector O
through tlie entire shift pattern

and return it to park
6 Remove the dipstick clean it and
replace it fully in the filler tube
If filse if o
7 Quickly remove it again and read
the level
2 Transmission and rear extension Vacuum diaphragm and downshift
The L dipstick indi
mark on the Junction of transmission and rear solenoid
cates the transmission is approximate extension Speedometer pinion sleeve
ly 0 4 liter 7 8 US pt 3 4 Imp pt Oil cooler tube connectors Rear extension oil seal
low Add only clean Dexron transmis
Oil pr ssure inspection ports
sion l1uid or
equivalent
Fluid leakage
To detect a l1uid leak

I Raise car
2 Clean area
suspected of leaking
3 Start engine apply foot brake
selector in drive and
place gear
wait a few minutes
4 Stop engine I
5 Check for fresh leakage
If the transmission breather is 8US
pected
I Raise car
2 Clean the area around the breather
3 Run the car at highway speeds
4 Check the breather for fresh leak
age
To aid in locating leaks use the
SAT104
following list of seals and gaskets
AT 51

TroublfHhootingand DilJgnoses AUTOMATIC TRANSM 15510 N
Fluid condition
pIAGN STIC ROAD 3 Neutral
Manually shift the selector
Transmission fluid color and tex TEST gear
in transmission from P to N and note quality In

ture can aid greatly
neutral no clutches or bands are ap
trouble shooting When checking l1uid Prior to road testing perform the
plied and there should be no move
level examine the transmission l1uid preliminary inspections outlined
ment Note results
and note its color texture and odor earlier If the is not equipped with
car
Some common fonns of contami a tachometer install a portable tacho 4 Drive Range
nation are listed below in the And also install Manually shift the gear selector to
tneter car a
I Dark or Black Fluid suitable vacuum gauge and pressure ran e 0 and note shift quality
With a burned odor gauge If the customer has a specific Drive the car through all automatic
Worn friction material complaint select road conditions shifts and in all gear ranges Note shift
Without an odor similar to those described g steep
e quality and timing km h MPH
Slight engine coolant leak hills freeways etc check for slippage noise or other
in radiator Follow the test sequence as out abnormal conditionS
If necessary
2 Milky Pink Fluid Water Contami lined in this section and mark the drive the test sequence under different
nation results on the Symptom Chart on page throttle openings e g light medium
Coolant leak AT 59 It may be necessary to repeat or full throttle
Road water sections of the test under different 5 Range 2
entering
throttle conditions medium Manually shift the gear selector to
through filler tube or breath g light
e
er or full throttle After completing the range 2 Check for

slippage hesita
3 Varnished Fluid light to dark road test compare the test results to tion or abnormal condition The trans
brown and tacky Oxidation lIIe Trouble shooting Chart on page mission should remain in 2nd gear
AT 56
Over or Underfilling regardless of car speed or engine re
Overheating volutions Note re lts

6 Range I
Engine Idle Manually shift the gear selector to
Check and adjust idle to specifica range I Note shift quality It
tions ROAD TESTING should however downshift im
Idling speed mediately to 2nd gear and downshift

L Park Range
700 i 100 rpm at 0 range Place the gear selector in P
again to gear as road speed de
1st
range
creases Accelerate and decelerate in
and start the engine Stop the engine
Engine 011 and coolant levels 1st gear to determine engine braking
and repeat the procedure in all other
Prior to road testing check engine Note results
and neutral In the
ranges park car
oil and coolant levels and fill as neces
The transmission should not shift
should be locked in position unable to
sary into 1st gear from 0
roll or move Mark all results on the range if tha car
Symptom Chart road speed is above approximately 50

Shift linkage km h 30 MPHI
2 Reverse
Start in park position depress Manually shift the gear selector
detent button and slowly move the from P to R and note shift quali 7 Record line pressure and governor
gear selector through all The Drive the
ranges ty car in reverse long pressure at each range and at each
detent clicks should enough detect other throttle
correspond to slippage or vacuum in accordance with
with the range indicator abnormalities Note results the pressure testing described below
52
AT

AUTOMATIC TRANSM 15510 N shooting
Trouble and Diagnoses
Car speed and line pressure when shifting gears
Intake manifold vacuum Car speed Propeller shaft Line pressure

Gearshift
kPa mmHg inHg km h MPH revolutions rpm kPa kgem2 psi
0 O2 60 68 38 42 1 970 2 220
0 107 66
0 0 115 71 3 480 3730 530 686
Kiekdown 0 0 105 97 65 60 3 410 3 160 5 4 7 0 77 100
0 0 53 45 33 28 1720 1470
0 O2 23 31 14 19 750 1 000
3
13 100 3 94 O2 0 63 70 39 44 2 040 2 290 441 598
0 0 40 32 25 20 1 300 1 050 4 5 6 1 64 87
O2 0 II 18 7 II 350 600
o Full throttle I I 54 46 33 29 1750 1 500 706

549
5 6 7 2 80 102
40 0 300 1181 I I 54 46 33 29 1 750 500

1 549 706
5 6 7 2 80 102
Car speed can be calculated by the following formula
2 x x rx Np x 60
v 0 0307 x Np 1
RF x 1 000
where V Car speed km h
Np Propeller shaft revolution rpml

RF Final gear ratio 13 700
r Tire effective radius m 185nO SR14 0 301 m
The ratio of circumference of a circle

to its diameter 3 141
2xll xrxNPx60
v 0 01905xNp
RF x 360
63
where V Car speed MPH
Np Propeller shaft revolution rpm

RF Final gear ratio 3 700
r Tire effective radius in 18SnO SR14 85

11 in
The ratio of circum of a circle
to its diameter 3 14
53
AT

shooting
Trouble 8m iagnoses AUTOMATIC TRANSMISSION
Shift schedule
1 2 2 t
Full throttle Kickdown range
1t2 t3
1
13 3
2
2Y3 3
000 3 94 I
E 26 7
I
f 200 7 87
l c
I
I
I
0 I
S
r
3 40 0 1 112
I
e 300 11 81 I
E E
I I
d I
0 3
53
I
5 I OO 15 75 I
I
I
66 7 I
500 19 69 c
0 500 1 000 1 500 2 000 2 500 3 000 3 500 4 000
Propeller shaft revolution rpm
kmfh 0 10 20 30 40 50 60 70 80 90 100 120 130 140

I
Car speed
MPH 10 20 30 40 50 60 70 80 SAT105
PRESSURE TESTING At idling

The 3N71 B transmission is pro
vided with three pressure test ports Range Line pressure kPa kg cm2 psi
Only two are useful for transmission

R 412 549 4 2 5 6 60 80
trouble shooting line Pressure and
Governor Pressure
D 314 373 3 2 3 8 46 54
ST2505S001
2 588 1 147 6 0 117 85 166
314 373 3 2 3 8 46 54
At tall test
AT454
Range Line pressur kPa kg cm2 psi
1 Line pressure
R 1402 589
1 3
14 16 2 203 230
2 Governor pressure
3 Servo release pressure
D 971 1 089 9 9 1
11 141 158
LINE PRESSURE
2 1 000 1 147 10 2 117 145 166
I Install pressure gauge to line pres
sure port
When shift lever is in 0 971 1 089 9 9 1
11 141 158
2 or 1 install pressure
range
gauge to port CD and when in R

range install pressure gauge to port @
shown above Locate the gauge so it Key points of pressure testing are
can be seen by driver Measure line al Pressure idle Look for hould kPa 1 0
at a teady not exceed 98
pressure at idling and at stall test rise in pressure as car speed in kg cm2 15 p n Ex i pressure
2 Road test and note pressure
car cre under light load drop may indicate an internal leak at a
under different throttle conditions bl drop b hift clutch seal
Pr ur tween point servo or
54
AT

Trouble shootingandOiagnoses
AUTOMATIC TRANSMISSION
Cut back point rotation is gradually increased from 5 Quickly note the engine stall
release throt
indicates stall point The car speed and out speed and immediately
The cut back point a
shaft rotation at that cut back tle

point where line pressure changes from put
point indicated in chart below
high to low value a output shaft are as
Stall revolution
1 650 1 950 rpm
Intake manifold vacuum Car speed Propeller shaft revolutions

6 Place shift lever in R range and
kPa mmHg inHg km h MPH rpm
above test in D
repeat same as
range
o 0 0 40 48 25 30 1 310 1 560
If stall test indicates proper stall re
3
13 100 3 94 20 28 13 17 660 910 volution in D no further tost
range
ing is necessary
GOVERNOR PRESSURE
CAUTION STALL TEST ANALYSIS
I Install pressure gauge to governor
a Transmission and engine fluid levels
it I Satisfactory results in 0
pressure port Locate the ga ge so should be checked and fluid
range
alwavs indicates rear clutch one way clutch
can be seen by driver added as needed
2 Road test car and note pressure at of transmission apd sprag flutch of
b Run engine at 1 200 rpm to attain
converter are
different road speeds Gov mor pres torque functioning pro
proper warm up
sure directly with road speed
increases perly
c During test never hold throttle
2 Stall revolution in 0 range 1st
and should always be less than line
wide open for more than 5 seconds
gear is above car specified
pressure d Do Not test more than two gear
The rear clutch is faulty
ranges without driving car to cool 3 Stall revolution in R is
range
off engine and transmission
above specified revolution for 0
range
Low and Reverse Brakes are faulty
4 Stall revolution in 0 range 1St
STALL TESTING gear is below specified revolution
STALL TEST PROCEDURE Converter sprag clutch is faulty
The stall test is an effective method
slipping or engine is not performing
of testing clutch and band holding 1 Install a tachometer where it can
to rque converter be seen by driver during test properly

ability one way
clutch operation and engine perform 2 Set hand brake and block wheels
3 Start engine and shift lever If converter sprag clutch is frozen
ance A stall test should only be per place
formed as a last resort because of the in D range car will have poor high speed perfor
If clutch is
high l1uid temperature it generates and 4 Apply foot brake and accelerate mance converter sprag
the excessive load it places on the to wide open throttle Do not hold slipping car will be sluggish up to 50
60 km h 30 40 MPHl
engine and transmission throttle open longer than five seconds or or
AT 55

Troubleshooting Bnd Diagnoses AUTOMATIC TRANSM IS ION
CHART ON CAR OFF CAR

TROUBLE SHOOTING
J c
E it
c
fi s
S e
s
J
L
0 2
Numbers are arranged in order of s

a
Cf7 u c 0
probability Perform inspections t M O l

CO E 0
starting with number one and work o e
Eib
13
4 C
tIf
ti e fe 5fJ
ing up Circled numbers indicate 0 S l
t
that the transmission must be aOClO c

J fj
t s
co
Sf c 0
fi f GJ E 00
removed from the car a 0 f t S 1

e
f l 0 I CI ra 11
R
0
tCI J f e
0
ii EEo Jsou
E o cfJB E S
Cir OIl c
ag
t o I t 0 0 c
i i CO
g Ct C
i8 cSg jl
r J
Ur Q M
d oS J5 cE 3C5C5 It
Engine
ranges
does not start in Nn P
2 3
I
Engine starts in range other than N
2
and p
Transmi sion noise in P and N

2 @
ranges
Car when changing into P

moves
range or gear does not dis

parking I V
engage when shifted out of P range
N 3 2
Car runs in range I @
Car will not run in R range but
runsin 0 2 and I ranges 2 3 5 6 4 J
@@ @ @
Clutch slips Very poor acceleration
Car braked when shifting into R 321 @ CID @

range
Sharp shock in shifting from N to

D 2 3 4 @
range
Car will not run in 0 range but

and
2 3 @
runs in 2 R ranges
Car will not run in D I 2

3
ranges but rims in R range I 2 4 5 6 7 @ @
Clutch slips Very poor acceleration
Clutches or brakes slip somewhat

I 2 6 3 5 7 4 @@
in tarting
Excessive creep I
No creep at all 2 3 5 4 @@ D
@
Failure to change gear from I st
I 2 3 56874 @ @ @
to 2nd
Failure to change gear from 2nd

@
2 3 56874 @
to 3rd
Too high a gear change point from I 2 3 5 6 4 D

1st to 2nd from lnd to 3rdu
Gear change directly from 1st to

2 4 3 I CID @
3rd occurs
IN CAR OFF CAR
AT 56

AUTOMATIC TRANSM 15510 N Troubleshooting and Diagnoses
ON CAR OFF CAR
f
o
i tf
S fi
s
ff rJ
5
Numbers are arranged in order of i e
If 0
probability Perform inspect ons l it
o
starting with number one and work ii

Je
0
0 N
ing up Circled numbers indicate or
Ei a E 5fj
that the transmission must be 0 e c
c g 3 or fj or
removed from the car J0

Ug 0 i5 e B
t tJ o
u
1 E
E o
0 t 3
u
a E Ei c
0 fJ E
o s g o
S 0 0 S r
f1 g v
c
0 0
6 Jt rJJ C5tE o d iJ
ct s
388
a shock in change from
I
Too sharp
1st
I 2 4 5 3 @
to 2nd
Too sharp a shock in change from

2 3 3 5 4
2nd to 3rd @
Almost no shock or clutches
slipping in change from 1st to I 2 3 4 6 8 7 5 @ @

2nd
Almost no shock or slipping in

change from 2nd to 3rd 123 4 6 8 7 5 @ @ j
Engine races extremely
Car braked by gear change from

lst to 2nd
2 @
I@ CID
Car braked by gear change from

2nd to 3rd
3 2
@I
Maximum speed not attained I 2 4 5 7 6 3 8 j
Acceleration poor
Failure to change gear from

@@@I@
2nd
346 5 2 CD@ @
3rd to
Failure to change gear from 2nd

to 1st or from 3rd to lst
346152 CD @
Gear change shock felt during

deceleration I 2 3 4 5 6
by releasing CD
accelerator pedal
Too high a change point from 3rd

to 2nd from 2nd to 1st
I I 2 3 4 5 6 CD
Kickdown does not operate when
depressing pedal in 3rd within 2 4 5 3 @ CD

kick down car speed
Kickdown operates or engine over
runs when
depressing pedal in 3rd I 2 3 5 6 7 4 @ @
beyond kick down car speed limit
Races extremely or slips in changing

from 3rd to 2nd when depress 2 4 6 5 3 CD@ @ @
ing pedal
ON CAR OFF CAR

r I
AT 57

ble
Trl shooting and S
OiagnOSJ AUTOMATIC TRANSM IS IO N
ON CAR OFF CAR
1
n
2
n
Numbers arranged in order of
are 0 r
probability Perform inspections
e
starting with number one and work fi Q
0 fi
E v
ing up Circled numbers indicate f e J E
IV IV
c
t
g e J
C 0
that the transmission must be a lO
I i
f e
removed from the car 0 g 5 2 c c IV
9 gj
0 a Q
g 0
0 t
o
8E
2 f
eo 8
ii S
tl 0
G
gag u
e
IV G
C E E 0 0 tl
o
io
II
f 0 0 c 0
l 1iO e tiC c r S lI C 0 t o
601JitSJi c rl 6 rt J 6 5 E2 cEo
Car will not run in any range 2 3 5
641 CVID I @I
Transmission noise in D 2
I and R ranges
2
I@ @
I @ @
Failure to change from 3rd to

2nd when changing lever into 2 4 5 3 @
2 range
Gear change from 2nd to 1st

or from 2nd to 3rd in 2 2 3
range
No shock at change from I to

2 range or engine races 123 4 5 7 8 6 @ @
extremely
Failure to change from 3rd to

2nd when shifting lever into 2 4 5 763 @@ @
I range
Engine brake does not operate

in
Gear
1 range
2 4
531 I@ I
change from 1st to 2nd
or from 2nd to 3rd in I 2
@
range
Does not change from 2nd

to 1st in 1 range
I 2 4 5 6 7 3
I I @
@I I
large shock changing from
2nd to st in range
2 4 3
I I @
I
Transmission overheats 3 4
I 2 6 8 7 5
I @@I@@@I@ I @
Oil shoots out during operation
White smoke emitted from 3 5 8 4 @
6 2 7 @@ @@@ @
exhaust pipe during operation
Offensive smell at oil charging

pipe
2
I@@@ @
@I @
I@
ON CAR OFF CAY
AT 58

AUTOMATIC TRANSM 15510 N Troubleshooting and Diagnoses
ROAD TEST SYMPTOM CHART
I
SHIFT QUALITY S2
I
0
g l
8
z t
I e
e l
I
x
I
I
1 if
f is
x
g t
t
0
o r 0 t
t Z 5 u COMMENTS
PARK I ENG START

I I I I I I I I L
RANGE
HOWING
I I I I I I I
R Man shift P R
I I I I I I I I I
RANGE
REVERSE
I I I I I
I Man shift R N
I I I I I I I I I
N
RANGE I ENG START
I I I I I I I I I
IN II I I I I I I I I
I Man shift N D
I I I I I I I I I
lIst I I I I I I I I
I Auto shift 2
I I I I I I
I 2nd
I I I I I I I
D
RANGE
I Auto shift 2 3
I I I I I I I I
I 3rd
I I I I I I I
Decel 3 2
I I I I I
I Kickdown 3 2
j I I I I I
I Decel 2 1
I I I I I
I Kickdown 2 1
I I I I I I
2 I Man shift 0 2
I I I I
RANGE
I 2nd I I I I I I
I shift Man 2 1
I I I
I Man shift 0 1
I I I
RANGE I Acceleration
I I I
I
Engine I I I I
Braking
I I I I i
AT 59

TroublNhoovng and Diagnoses AUTOMATIC TRANSM 15510 N
TROUBLE SHOOnNG GUIDE FOR 3N71B AUTOMATIC TRANSMISSION
Order Test item Procedure
Checking Oil level gauge Check gauge for oil level and leakage before and after each
test
2 Downshift solenoid Check for sound of operating solenoid when res ing
dep
accelerator pedal fully with ignition key ON
3 Manual linkage Check by into P R D 2 and

shifting I
ranges with selector lever
4 Inhibitor switch Check whether starter operates in N and P ranges only

and whether reverre lamp operates in R range only
5 Engine idling rpm Check whether idling rpm meet standard

6 Vacuum pressure of vacuum Check whether vacuum pressure is more than 60 0 kPa 450
pipe mmHg 17 72 inHg in idling and whether it decreases with
increasing rpm
7 Operation in each range Check whether transmission engages positively by shifting
N D 2 N and N R range
while idling with brake applied
8 Creep of car Check whether there is any creep in D I and R

ranges
Stall test I Oil pressure before testing Measure line pressures in D 2 I and OR range while
idling
2 Stall test Measure engine rpm and line pressure in D 2 and
R ranges during full throttle operation
Temperature of torque converter oil used in test should be

from 60 to l000C 140 to 2120Fl i e
sufficiently warmed
up but not overheated
CAUTION
To cool oil between each stall test for 0 2 T and
R ranges idle
engine i e rpm at about 200
1
rpm for
more than 1 minute in P range Measuremenl time must
not be more than 5 seconds
3 Oilpressure after testing Same as item I
Road test 1 Slow acceleration Check car speeds and engine rpm in shifting up 1st 2nd
Ist2nd range and 2nd 3rd range while running with lever in 0
2nd 3rd and engine vacuum pressure of about 3 kPa
range 13 100
mmHg 3 94 inHg
2 Quick acceleration item I above
Same as except with engine vacuum pressure of
1st 2nd o kPa 0 mmHg 0 inHg ie in position just before
2nd 3rd kickdown
3 down
Kick Check whether th
operation kickdown operates and measure the time
3rd 2nd or 2nd 1st delays while running at 30 40 50 60 70 h 19
km 25 31
37 43 MPH in Os range
60
AT

AUTOMATIC TRANSMISSION Trouble shooting and Diagnoses
Order Test item Procedure
4 Shift down Check carspeeds and engine rpm in shifting down from 3rd
Ds 02 D1 2nd 1st sequentially while coasting with accelerater
pedal released in D3 range and engine vacuum pressure of

about 60 0 kPa 450 mmHg 1772 inHg
5 Shift down Check for shifting down D I and engine braking and
D 12 11 further for shifting down I and engine braking after
I
shifting the lever into I range with the accelerator pedal

released and the engine vacuum pressure of 0 kPa 0 mmHg
o inHg while driving at about 50 km h 30 MPH in D3
range
6 Shift down Check for quick shifting down 0 2 and engine braking
0 2 after shifting the lever into 2 range while driving at about
50 km h 30 MPH in 0 range
Also check for locking of the transmission in 2nd gear ratio

regardless of car speed
7 Shift up Check for failure of the transmission to shift up during
l acceleration when starting in range
11 12
8 Shift up or down when start Check the transmission for not shifting up or down during
ing in 2 range acceleration or deceleration when starting in 2 range
9 Parking Confirm that vehicle will not move on grade when shifting to
P range
Others Abnormal shock oil leakage Enter into record conditions observed during these tests such
as gear noise abnormal clutch noise and acceleration per

formance
AT 51

Service Datund Specifications AUTOMATIC TRANSMISSION
General specifications
Automatic transmission
I Number of drive plates 5
3N718 Number of driven

model 5
Reo plates
Stall torque ratio 2 0 t cl
Clearance mm in 08 1 6 0 031 0 063
l st 2 458
Thickness of retain
835 10 32871
Transmission
I 2nd 1458 ing plate mm
Un
gear fatio
I Top 1000 Number of drive plates 5
I Reverse 2 182 Number of driven
Oil
Automatic transmiuion fluid
Oexron type Low

I plates
Clearance mm lin
5
80 125
0
5 5 liters e
I 10 0315 0 04921
15 7 8 US qt 4 7 8 Imp qtl verse Thickness of Thickness

Part number
Oil capacity Approximately 2 7 liters brake retaining plate in
mm
12 7 8 US qt 2 8 Imp qt
torque converter 7 810 3071 31667 X0500
8 0 10 315 31667 X0501
8 2
10 323 31667 X0502
8AI0 33tl 31667 X0503
8 6 10 3391 31667 X0504
8 8 10 346 31667 X0505
Specifications and adjustment Brake band
Automatic transmission
Piston size 64 2 52
Big dia
assembly mmlin
Model code number X2305 Small dia 40 1157
Torque converter
assembly Control valve assembly
Stamped mark on the
G Stamped mark on strainer LRJ
TIC
Governor assembly
Number of drive plates
I 3 Stamped mark on
35
governor body
Number of driven
3
plates
Clearance mm
in 1 6 2 0 0063 0 0791
Front
Thickness of Thicknesi
clutch Part number
retaining plate mmOnl
10 610 4171 31537 X0100
10 8 10 4251 31537 X0101

110 10 433 3t537 X0102
Stall revolution
t1 210 44t 31537 X0103
114 10 449 31537 X0104
116 10 457 31537 X0105

I Stall revolution rpm 1 650 1 950
62
AT

AUTOMATIC TRANSM 15510 N Specisl Service Tools
Tightening torque
N m ft Ib Unit Nm m
kg ft Ib
Unit m
kg
Drive plate to Side plate to control 0 25 0 35 18 2 5

137 157 14 0 16 0 101 116 25 34
crankshaft valve body
plate to Nut forcontrol valve

Drive torque
39 49 40 50 29 36 4 9 69 05 0 7 36 5t
reamer bolt
converter
Oil strainer to lower

Converter to 04 22 29
housing 49 40 50 29 36 2 9 3 9 0 3
39 valve body
engine
Transmission case to Governor valve body to

4 5 5 5 33 40 49 6 9 05 07 36 5 1
44 54
oil distributor
converter housing
Oil pump to
Transmission case to housing 06 0 8 43 5 8
20 25 2 0 2 5 14 18 5 9 713
rear extension oil pump cover
Inhibitor switch to
Oil pen to transmission 49 69 0 5 0 7 36 5 t
49 69 05 0 7 3 6 51
transmission case
ca
Manual shaft lock nut 29 39 30 40 22 29

Servo piston retainer 9
4 69 0 5 0 7 36 5 1
to transmission case
Oil cooler pipe to

29 49 3 0 50 22 36
stem when transmission case
Piston 11
12 15 12 1 5 9
adjusting band brake
Test plug oil pressure 14 21 14 2 1 10 15
15 39 1 5 4 0 11 29 nspecticn hole
Piston stem lock nut
way
One clutch inner Support actuator
t3 18 13 18 9 13
race to transmission case parking rod nserting 78 10 8 08 11 513 8 0
positionl to rear
Control valve body to extension

5 4 74 0 55 0 75 40 5 4
transmission case
Turn back two turns aftar tightening

Lo
v lv body to
I upper valve body

2 5 34 0 25 0 35 18 25
SPECIAL SERVICE TOoLs
Tool number
Tool name
Kent Moore No
ST07870000 Transmission case stand

ST07860000
125607
ST25850000 Sliding hammer
125721
GG91060000 Torque wrench

GG930 10000
J25703
AT 53

Special Service Toofs AUTOMATIC TRANSM 15510 N
Tool number
Tool name
Moore
Kent No
ST25420001 Clutch spring compressor

ST2542000Q
126063
ST25320001 Snap ring remover
125710
o
ST2557000 I Hex head extension

ST2557000Q
J25718
ST25490000 Socket extension

ST255 1200 I
125713
HT62350000 Spinner handle
ST25160000 Torque driver
ST25580001 Oil pump assembling gauge
Q
125719
HT6 I 000800 Hexagon wrench
j
ST2505S001 Oil pressure gauge set
125695
64
AT
DATSUN 200SX Model S rJ 0 Series
SECTIONP D
PROPELLER SHAFT
DIFFERENTIAL CARRIER
CONTENTS
PROPEUER SHAFT ASSEMBL Y PD 9
Model 3S63A PD 2 DIFFERENTIAL CASE PD 9
GENERAL INSPECTION PD 2 DIFFERENTIAL CARRIER PD l0
PROPELLER SHAFT VIBRATION PD 2 ADJUSTMENT PD 11
REMOVAL AND INSTALLATION PD 3 SIDE BEARING ADJUSTMENT PD l1
INSPECTION PD 3 PINION HEIGHT ADJUSTMENT PD 13
PROPELLER SHAFT RUNOUT PD 3 FINAL VERIFICATION PD 15
FLANGE YOKE AND SLEEVE YOKE PD 3 SERVICE DATA AND

JOURNAL AXIAL PLAY PD 3 SPECIFICATIONS PD 16
REPAIR PD 3 PROPELLER SHAFT PD 16

PD 3 GENERAL SPECIFICATIONS PD 16
CENTER BEARING
SERVICE DATA PD 16
DIFFERENTIAL CARRIER Final drive
Model H165B PD 5 TIGHTENING TORQUE PD 16
PREPARATION FOR DISASSEMBLY PD 6 DIFFERENTIAL CARRIER PD 16
REMOVAL PD 6 GENERAL SPECIFICATIONS PD 16 1ft

PRE DISASSEMBLY INSPECTION PD 6 SERVICE DATA PD 16
TOOTH CONTACT PD 6 TIGHTENING TORQUE PD 17
DISASSEMBLY PD 7 TROUBLE DIAGNOSES AND

DIFFERENTIAL CARRIER PD 7 CORRECTIONS PD 17
DIFFERENTIAL CASE PD B PROPELLER SHAFT PD 17
PD 9 DIFFERENTIAL CARRIER PD 1B
INSPECTION
SPECIAL SERVICE TOOLS PD 19

PropellerSheft Model 3S63A PROPELLER SHAFT 8 DIFFERENTIAL CARRIER
PROPELLER SHAFT
Model 3S63A
Propeller shaft
Locking nut
2nd tube
Flange nut type
Companion flange
b245 294
U 25 30
Washer 217
181
Apply a coat of PUIJlOse
muIti lithium Nut and washer type
grease containing molybdenum disulfide
if 196 235 ill
to the end face of the center bearing
20 24
and both sides of the washer
VI 145 174
fJ 24 32
4
2 3 3
17 24
Center bearing
Install center bearing with F
ffiuk toward front of car
Center bearing
support
Propeller lhaft
1st tube
V
if 32
2 4 3 3
17 24
fJ N m
kg m ft tb
S PD11
GENERAL PROPELLER SHAFT

VIBRATION
INSPECTION
To check and correct an
Inspect propeller shaft tube surface
for dents or cracks unbalanced propeller shaft proceed as
If shaft follows
damaged replace propeller
assembly I Remove undercoating and other
If center bearing is noisy or foreign material which could upset
damaged replace center bearing shaft balance and check shaft vibra
If journal is damaged or worn re
tion by road tesi
place propeller shaft assembly 2 If shaft vibration is noted during
road test disconnect propeUer shaft at
differential carrier companion flange
rotate companion flange 180 degrlies
3 Again check shaft vibration If
and reconnect propeller shaft
VIbration still persists replace propel
ler shaft assembly
PD 2

PROPELLER SHAFT DIFFERENTIAL CARRIER PropellerShaft Mode 3S63A
REMOVAL AND
Connecting
INSTALLATION portion
Put match marks on Cushion

I l1anges and
separate propeller shaft from differen
tial carrier
c c r
SPD124 SPD10B
REPAIR
INSPECTION
CENTER BEARING
I Put match marks on l1anges and
PROPELLER SHAn RUNOUT
separate 2nd tube from 1st tube
Inspect propeller shaft runout If
ronout exceeds specifications replace
2 Remove center bearing bracket propeller shaft assembly
I I @
Runout limit
06 mm 0 024 in
1 roS c
KO
itM
I
SPD109
J SPD106 2 Put
and shaft
match marks on the l1ange
3 Draw out propeller shaft from FLANGE YOKE AND SLEEVE

transmission and end YOKE
plug up rear
of transmission rear extension housing If l1ange yoke and sleeve yoke are
damaged or worn replace propeller Q

shaft assembly
o
aU SPD110
Plug t 3 Remove locking nut with Tool
SPD105
SP0107
4 To install reverse the foregoing
procedure using reference marks in

removal JOURNAL AXIAL PLAY
the
Install the center bearing on
Inspect journal for axial play if
bracket with the surface of the there is
contact
play replace propeller shaft
cushion facing upward assembly
PD 3

PropellerShsft Model 3S63A PROPELLER SHAFT DIFFERENTIAL CARRIER
4 Remove companion l1ange with 6 Install center bearing Be 8

new sure
Tighten locking nut using Tool
puller to install center bearing with OF
mark toward front of car
Apply a coat of multi purpose lith
iuin grease containing molybdenum di

sulfide to the end faoe of the cente
L bearing and both sides of the washer
SP0116
l
C Cent r
baring locking nut
Flange nut type Ntit and type

wash
245 294 N m 196 235 N m

5 Remove center bearing with Tool
25 30 m
ka 20 24 m
ka
and press
181 217 It lb 145 1741t bl
@
SPD125
9 Stake the nut

7 Insert the washer into the end of
1 iLsP0113 the center bearing Align the mark on
and install the

thecompanion flange
companion flange
Care should be token when setting
Tool in press to make sure that parting
line of Tool is right angle to support
fixture of press This is to prevent
Tool from bending 9
OK N G
center bearing
liC f Washer
Companion flange
Locking nut 10 mark and connect
Align the 1st
SPD115
and 2nd tubes
I
Ji
Support
fIxture
4
PD

0
ni
ai
S
t1
l
Q c0 oJ
l
I J
l 0
i
m n S0
Jl
Jo JtJ
t S
on 1 00 O
st
diP
inll
de
S
43
36
10 11
59
49
6
5
Outct a
oeatIDS
8
511 side
J@111911
acep
te
@
tu a taCe l
i1
MY adiustifl l
sbin
oet rni tW
DJ es
Lock Side tnict
t
hatt
tial
mate
Olfter 1 case 6
n
nWP
y
n
nllSOllt 011
ir set
t
0
18
lfl
R
inl II I
I tn 0
ill K
Bac 13 005
IffW YI o
e l
Dti
e ace
CD J
ble
te1
p
waYtp
race ft
et b
inln
er
t
s
llht
ne nesS inII
col1 Jacet
S
15
UStinS Det n thick

18
wot
p
5
3
Vil on ad
Drive ca outer 34 5
1
to 10
P
1
15 on
@ in
11
vep ONI btained
0
et Hatt
Yt
lreplace
1
iI
un
0
of
11
10
Gas
valuen
u
l 1
8
O
00
43
ty
Ditfel nt catiet HI
19
1
to Ct
ad g
P
l1
plte
ue 1
6
M
as ern
t
1 10
u 13
Ie
dl @
ftna1 a
L
replace
oil
front aY
A
Corvaniot l
ll1

Differential Carrier Final drive Model H165B PROPELLER SHAFT DIFFERENTIAL CARRIER
PREPARATION FOR PRE DISASSEMBLY

INSPECTION
DISASSEMBLY llnce
Cleal
I 0 10 20
0 mm
Check backlash of ring gear with
REMOVAL a dial indicator at several points If it is
llO39 00078 inl
10
I Jack up rear of car and support not within specification adjust it re
it by placing safety stands under rear ferring to SIDE BEARING ADJUST

axle case referring to section GI MENT
2 Remove drain and drain gear
plug
oil
Backlash
0 13 0 18 mm SPD004
10 0051 0 0071 inl
TOOTH CONTACT
Gear tooth contact pattern check is

necessary to verify correct relationship
between ring gear and drive pinion
SP 0002
Hypoid gear set which are not posi
tioned properly may be noisy or have
short life or both With a pattern
SPD121
check the most desirable contact for
low noise level and long life can be as
sured
3 Remove propeller shaft and rear Check

2 Check runout of ring gear with a
axle shafts Refer to Section RA for dial indicator If it is over specifica I Thoroughly clean ring and
gear
removal and plug up rear end of tran tion hypoid gear set or differential drive pinion teeth
mission rear extension housing should be replaced 2 Sparingly apply
case a mixture of
When backlash varies excessively in powdered ferric oxide and oil or equiv
different places the variance may have alent to 3 or 4 teeth of ring gear drive
side
resulted from foreign matter caught
between ring gear and differential case
SP0105
I
Runout limit
0 04 mm
10 0016 in
SPOOD5
4 Loosen bolts securing differential SPD003

carrier to rear axle case and take out
3 Hold companion flange steady by
differential carrier hand and rotate the ring gear in both
5 Mount differential C3rrieron Tool directions
3 Check tooth contact referring to

TOOTH CONTACT
4 Check backlash of side gear
Using
a thickness gauge measure clearance
between side gear and differential case
If it is not within specification
adjust it by selecting side gear thrust

washer Refer to S s
O SPoooa
6
PD

PROPELLER SHAFT DIFFERENTIAL CARRIER Oifferent sl Carrier Finsl drivel Model H1658
Adjustment
H I contact F ce contact Toe contaCt Flank cont8ct
To correct increase thickness of pinion To correct reduce thickness of pinion

height adjusting washer in order to bring height adjusting washer in order to make
drive pinion close to ring gear drive pinion go away from ring gear
c
V
Correct tooth conae1
SPD007
2 Remove side
DISASSEMBLY bearing caps
1 Put match mark on one side of
side bearing cap with paint or punch
to ensure that it is replaced in proper
position during reassembly

Bearing caps are bored
line during
manufacture and should be put back
in their
1W
original place
SP 0009
3 Using a pry bar remove differen

tial case assembly
Be careful to keep the side bearing
1 08
outer
don
races together with inner
mix them up
race
SP0011
PD 7

Differential Carrier Final drive Model H165B PROPELLER SHAFT DIFFERENTIAL CARRIER
4 Remove drive pinion nut with DIFFERENnAL CASE

TooL I Remove side bearing inner race
with TooL
To prevent damage to bearing

engage puller paws with groaBe
careful not to confuse left and right
hand parts
S
1 ST3305100l
SPOOl
SPD012
8 Remove pmlOn bearing outer
race using a brass drift
5 Remove companion l1ange with

puller
SP0020
SPD017
ST3305200Q
9 Remove collapsible spacer from
drive pinion
SPD014 1 ij SPD021
10 Pull out rear bearing inner race
with a press and Tool
Care should be taken when setting

6 Remove drive pinion with soft Tool in press to maka sura that parting
hammer line of Tool is a right angle to support
fixture of press This is to prevent
bonding Tool
SPD022
Soft hammer 2 Remove ring gear by spreading

out lock straps and loosening ring gear
SP0018 bolts in a cross
criss fashion
OK N G
lie
Remove oil seal by prying up with

a largescrewdriver and remove front
pinion bearing inner race
Do this carefully so as not to scratch

Support
seal bore with screwdriver Cover end fIXture
of screwdriver with a SPD023
rag
8
PD

H1658
PROPELLER SHAFT DIFFERENTIAL CARRIER Differential Carrier Final drive Model
3 Tap ring gear off gear case using a

ASSEMBLY
soft hammer
Assembly should be done in the
@
Tap evenly all around to keep ring reverseorder of disassembly while
gear from binding e making any necessary inspections and
adjust
1ents
@4S @@
PRECAUTION
a Arrange shims and washers to in
e stall them correctly
b Thoroughly clean the surfaces on
@ SPD026
which shims washers and
bearings
bearing caps are installed
c Apply gear oil when installing
bearings
SPD024 d Pack recommended multi purpose
grease cavity
inlo between lips
when fitting oil seal
INSP CTION
I Clean disassembled parts com
4 Drive out mate shaft lock pletely

pinion
Repair or replace any damaged or
pin with Tool from ring gear side DIFFERENTIAL CASE
faulty parts I Install pinion mate gears side
When replacing drive pinion or ring gears and thrust washers into differen
gear replace with 8 new hypoid tia case
gear set 2 Fit pinion mate shaft

3 clearance between rear
Adjust
face of side gear and thrust washer by
selecting side gear thrust washer Refer
to S D S
and
O II
SP0027
tt
Feeler
Draw out mate shaft
B
5 pinion
Clurance
rota e pinion mate gears out of the c
0 10 O 20mm
case and remove side gears and thrust 0 0039
0 0079 in
washers
5P0029
2 Thefollowing parts should be
replaced by new ones each time they
are removed
4 Insta l pinion mate shaft lock pin
CD Gasket
@Frontoilseal using a
punch
Make lock pin is flush with
ID Collapsible spacer sure
@ Lock strap case
@
SPD122
Put marks on gears and thrust
washer so that they can be reinstalled
in their original positions from which

SP0028 5P0030
they were removed
PD 9

Differential Carrier fFinaldrive Model H 65B PROPEbLER SHAFT DIFFERENTIAL CARRIER
5 Place ring gear on differential case DIFFERENTIAL CARRiER 5 Using Tool carefully fit a new oil
and install new lock straps and bolts
I seal into carrier
Press fit front and rear bearing
Tighten bolu in a cross fa
crisl outer races using Tools Make lure oil seal is flush with end
shion lightly tapping bolt head with
of carrier and apply purpose
multi
a hammer
grease into cavity d lips
Then bend up lock straps to lock
the bolts in place
L
Iii 7S
IS O
58
gSN
10 0
72 ft
m
bl
kG l
A
ST33400001
SP 0035
1
2 Select pmlOn height adjusting

SPDQ37 iI
washer to PINION HEIGHT
referring
6 Place a new collapsible spacer on
ADJUSTMENT
drive pinion and lubricate rear bearing
3 Install pinion height adjusting
with gear oil and insert it in gear
washer in drive pinion bevel side
carrier
toward gear and press fit rear bearing
inner race in it using press and Tool
6 Select side bearing adjusting
shims referring to SIDE BEARING
ADJUSTMENT
7 Install the shims behind each bear
ing and press on the bearings using
Tool
SP003S
7 Install companion l1ange and hold

it firmly Insert drive pinion into
4 Lubricate front bearing with gear companion flange by tapping its head
oil and place it in gear carrier with a soft hammer
SPD033
ST33052000
SPD034 SPD045
PD IO

PROPELLER SHAFT DIFFERENTIAL CARRIER Differential Carrier Final drive Model H165B
8 Hold companion l1ange with Tool 10 Install differential case assembly When the differential case side
and and side miter races into dif gear carrier is replaced or
temporarily tighten pinion nut bearing bearing or
until there is no axial play ferential carrier and install side bear when the ring gear backlash or side
bearing is out of specifica

ing cap preload
Ascertain that threaded portion of tions side bearing shims of proper
Tap on the cap with 8 soft ham
drive pinion and pinion nut are free
thickness should be installed
mer to settle it in the carrier
from oil or grease
The bearing cap should be installed
with the marks put 8t disassembly
aligned
Required Tools
D Weight Block ST32501 000

@Master Gauge ST33741000
@ Base Plate
@ Dial Indicator
SP 0040
@ j@R
I
9 Tighten pinion nut by degrees to
tl
the specified preload while checking D
0f
IiJ 49 59 N m
the preload with Tools 5 0 60 kg m
36 431t IOI
When checking preload turn drive
pinion in both directions several times

set bearing rollers If
@ SPD048
l
SPD044
I Thickness of shim can be calcu
lated by following equation

Preload II
with oilMan ADJUSTMENT

Left side T A C O H
07 1 0Nom
0 01 0 20 E
SIDE BEARING
7 10 x
kliJ
cm I I
6 1 8 7in lb
ADJUSTMENT side T2 8 0 H
Right
I x 0 01 0 09 F I
J Drive pinion nut L
137 294 N m
14 30 kg m
Side CAUTION
101 217 ft Ib
bearing To avoid any confusion while calcula
CAUTION ting it is absolutely necessary to stay

with metric system
The preload is achieved
by using the
If you measure anything in inches the
permanent collapsible
set of spacer
So here if an over preload results from results should be converted into the
Side bearing
excessive turning of the pinion nut shim metric system
SPD046 adjulting
the spacer should be replaced by new
one
PO tt

Differential CarrierfFinal drivel DIFFERENTIAL CARRIER
Model H7658 PROPEllER SHAFT
Where
T2
Left side
o H
Right side
o o
A
U E
G
o
o
mm
Left Side
l
Bearing
B
Stamped on differential
carrier
mm Differences between width

c
of left E or right F
Right Side
side bearing and standard width
Bearing
D
Stamped on differential A B C D and H are dimensional variations in
cue a unit ofl 100 mm against each standard value
SPD126
2 Measure values E and F race and inner race to be measured on The indication should be Ear F
I Attach a dial indicator to the base the opposi e side outer race and place
Left ide bearing E
plate the weight block on that bearing
Right ide bearing F
2 Place the outer race of the op assembly
posite side bearing to be measured If the bearing embly i placed on
3 Place a weight block on that outer
the base plate the bearing width
race and a master gauge on that
cannot be accurately determined due
biock
to its cage being in contact with the
Then the dial indicator scale
adjust base plate
to zero with its tip on the master
gauge
speOS1
Measured
outer race 3 Substitute these values into the
equation to calculate the thickness of

ST3 501000
the shim
Oppo ite side C 0 and
If value ignifying A B
outer race
SP0Q49
H are not given regard them as zero
and calculate
5 Turn the several limes After as check to that

bearing embly ee
4 Remove the master gauge and to settle it and then read the indica end backla h ere pecifica
preload
weight block Place the bearing outer tion of the dial indicator tion If not readjust
PD 12

PROPELLER SHAFT DIFFERENTIAL CARRIER Differential Carrier Final drive Model H165B
Example PINION HEIGHT

ADJUSTMENT
A I H 2
B 2 E l1
O
C 2 F 0 20
D 3
Left side Right side

T A C 0 H xO OI B D H xO 01
T2
0 20 E 0 09 F I I Hiit
l
2 3 2 xO OI xO OI
1 2 3 2
0 20 11
0 0 09 20
0
I
I A I B 2
SP0056
C 2 D 3
I I
0 3 H 2
When replacing the hypoid gear set

2 3
drive pinion bearing or gear carrier
H 2
be sure to adjust the pinion height
4
Adjustment of the pinion height
can be made by adjusting the washer
2 4 2 3 to be installed between the rear
x 0 01 x 0 01
bearing inner rice and the drive pinion
0 04 0 03 head
3 0 04 3 0 03
0 20 0 09 Pinion height adjusting
washer
0 24 0 06
4 0 24 4 0 06
E 11
0 F 20
0
035 0 26
T 035mm T 0 26mm
SPD051
4 Select the proper shims Refer to

SO S
If you cannot find the desired
thickness of shims use shims so that Required Tools

the total thickness is the closest to the
j Height Gauge ST31141 000
calculated value
CV Dummy Shaft ST31942000
ID Feeler Gauge
Example
Left side Right side

CV j
Calculated value T 35
0 mm Calculated value T2 0 26 mm
Used shims
r
L
Thickness Quantity Used shims
I Thickness Quantity
0 20 x 0 20
0 10 x I 10
0 07
0 x 3 0 21
0 05 x I 0 05 0 05 x I 0 05
Total thickness 35
0 mm Total thickness 0 26 mm
SPD058
PD 13

Oifferential Csrrier Final drive Model H165B PROPELLER SHAFT DIFFERENTIAL CARRIER
I Thickness of washer can be cal

CAUTION
culated by following equation
To avoid any confusion while calculat
ing it is necessary to stay with the

r metric system If you measure any
T N H 0 Sl x 0 011 in inches the result should be
thing
I 2 98 I converted to the metric system
Where
n
T
@ D
mm
N s
mm
H D and S are dimensional variations in a

unit of 1 100 mm
against each standard value
SP 0127
2 Assemble Dummy shaft on rear 4 Substitute these values into the

inner and fit
bearing race it into equation to calculate the thickness
carrier of the washer
If value Sigilifying H 0 andS are
and
not given regard them 8S zero
calculate
After essembly check to see that
tooth contact is correct If not
readjust
ST31141000
3 Attach Height Gauge to carrier

Using a feeler gauge measure the
clearance between the height gauge tip
and the dummy shaft face SPD061
PO 14
PROPELLER SHAFT DIFFERENTIAL CARRIER Differential Carrier Final drive Model H1658
Example FINAL VERIFICATION If prelOad i too great remove the
same amount of shims to each side

N 35
0 Check backlash of ring gear with a
If preload i too mall add the
H 4 dial indicator
same amount of shims to each side
D 3
Never add or remove different
S O
amount of shims to each side or ring
T N H 0 S x 0 01
gear beckla h will be changed
2 98
35
0 4 3 0
x 0 01 2 98
I H 4
0 3
S 0
If backlash is too small decrease

2 5P0031
I
thickness of left shim and increase
x 0 01
thickness of right shim by the same
00 amount 3 Check runout of ring gear with a
If backlash is too great reverse the dial indicator

3 N 35
0 above procedure
0 01
Never add or remove from the total
36
0 amount of shims or bearing preload
will be changed
4 36
0
2 98
34
3
T 34
3
SP0003
5 Select the proper washer Refer

to S O S If backlash varies excessively in dif
ferent places the variance may have
If you cannot find the desired SPD066
thickness of washer use washer SO that resulted from foreign matter caught
thickness is the closest to the calcu between the ring gear and the differ
late value entia case

If the backla h varies greatly when
2 Check side bearing preload the runout of the ring gear is within a
Example Hook the tip of a spring balancer
pecified range the hypoid gear set or
on a ring gear bolt differential case should be replaced
Calculated value T 3 34 mm Check the preload by mea
uring the
Used washer T 33
3 4 Finally check for tooth contact
mm rotating resistance in a backlash
pattern
Refer to TOOTH CONTACT
Preload
U ually the pettern will be correct
At ring gear bold
14 7 26 5 N if you have calculated the hims
11 5 2 7 kg correctly and the backla h i correct
3 3 6 01bl
However in extremely rare cales
you will have to use trial nd error
proce until you get a good tooth

contact pattern
The tooth pattem i the best
indieation of how well a differential

SPD067
ha been et up
PO 15

ServiceDataandSpecifications PROPELLER SHAFT DIFFERENTIAL CARRIER
removed
fl Differential carrier fixing bolt
Then fill with gear oil referring to 25 34 N m
Recommended Lubricants Section 2 5 3 5 kg m
MA 18 25 ft Ibl
Drain and filler plugs
59 98 N m
6 10 m
kg
43 72 ft b
Gear oil capacity
1 1 I ita rs
SPDOOS ngrdler 318
2 US pt 2 Imp ptl
Oil level
5 Install the differential carrier in
the car
Gasket should be replaced by new
SPD123
one each time the differential carrier is
PROPELLER SHAn DIFFERENTIAL CARRIER

GENERAL SPECIFlcATIONS Unit mm in GENERAL SPECIFICATIONS
Model 3S63A
I Model H1658
Number of joints 3
I
Rigid axle suspension
TVpe
Banjo typo
Coupling method with transmiSsion Sleeve type
Distance yokes 63 2 481

I Ring gear pitch dianleter mm Unl t65 6 50
Type of journal bearing Shell type I Gear ratio 3 700
Non Disassemblv type

I Number of teeth Ring gear drive pinion 10
37
Shaft lenQth
Spider to spider
1st 3201 2 601
I Oil cepacity 2 US pt Imp pt 1 3 8 21
2
2nd 730 28 741

SERVICE DATA
tst 75 0 2 9531
Shaft outer diameter Drive pinion bearing adjusting mathod Collapsible spacer
2nd 50B 0001
2
Drive pinion preload with front oil seal 0 7 0
N m
cm
kg in lb 7 10 6 t 8 71
SERVICE DATA
Unit mm in I Side
bearing adjusting method Shim
Drive pinion to ring gear 0 3 0 8

I Propeller shaft runout limit 0 6 0 0241
jn
mm 005
0 0 00711
Backlash
Side gear to pinion mate gear
0 0 0 20
TIGHTENING TORQUE Clearance side gear
10 0039 0 00791
to differential case mm in
Unit N m fHb
m
kg
Ring gear nmout limit mm in 0 04 0 00 61
Flange yoke to com
I pani on flange
24 32 24 33 17 24 Side bearing preload at ring gear bolt
N kG lbl 1 5
14 7
27 33
26 5
6 01
Center bearing
locking nut
Flange nut
tvpct 245 294 25 30 8 217
Side bearln adjustin shim
Nut Thickness mm inl Part No

ridwashertvpe 196 235 20 24 45 74
Center bearing support 005 0 00201 38453 28500
I to bracket
8 8 0 9 12 65 8 7 0 07
0
0 00281
0 10 00391
38454
38455
28500
28500
I
Center bearing bracket 020 0 00791 38456
I
25 39 40 28500
2 6 9 29
to body 0 50 10 0 971 38457 28500
PD 16

DIFFERENTIAL CARRIER Corrections
PROPELLER SHAFT Trouble sesand
Diagno
Pinion height adjusting washer Side gear thrust washer
Thickness mm in Part No
0 785 10 0309 38424 04101

3 09 10 12171 38154 U 1500
3 12 10 12281 38154UI501 0 835 10 03291 8424 08000
3 15 0 12401 38154 Ut502 08001

885
0 10 0348 38424
3 181O t252 38154 U1503

1 035 10 04071 38424 08002
3 21 10 12641 38154 U1504
1 185 10 04671 38424 08003
3 2410 12761 38154 U1505
327 0 12871 38154U1506
330 0 1299 38154U1507 TIGHTENING TORQUE

3 33 10 13111 38 154
l1508 Unit N m
m
kg ft Ib
38154 U1509
3 36 10 13231
3 39 0 1335
38154UI510
38154 U1511
I Drive pinion nut 137 294 14 30 101 217
3 42 10 1346
3 4510 13581 38154Ut612 I Ring ge r bolt 78 98 8 10 58 72
3 48 10 1370 38154 U1513

I Side beari ng cap bolt 49 59 5 6 36 43
3 51 0 13821 38154 U1514
3 54 10 t394
38154 U1515 I Drain and filler plugs 59 98 6 10 43 72
38154 UI516 Companion flange to

3 57 10 14061
3 6010 14171
38154 UI517
38154 UI518
I propeller 5h8ft
24 32 24 33 17 24
3 63 10 14291 Difforential io to
I
co
25 34 25 35 18 25
3 66 10 14411 38154 U1519 rear axle case

PROPELLER SHAFT
Vibration during at Worn or damaged journal n

beari prol eller shaft assembly
Repla
medium or high speed dented shaft assembly
Unbalance due to bent or propeller Replace propeller
shaft
Loose propeller shaft installation Retighten

Worn transmission rear extension bushing Replace j
Damaged center bearing Repl ace
U dercoatiIg or mud on he shaft ausing Clean up shaft

unbalance
Balance weights ntissing Replace propeller shaft assembly
Knocking sound during Worn or damaged journal Replace propeller shaft assembly
starting or noise Worn sleeve yoke and mainshaft spline Replace propeller shaft assembly
during coasting on
Loose propeller shaft installation Retighten
propeller shaft
Loose joint installation Replace propellei shaft assembly
bearing or insulator center bear
Damaged center
Repla g
Loose or ntissing bolts at center bearing Replace or tighten bolts

brac t 10 body
noise Dust sleeve yoke rubbing on Straighten out dust cover to remove inter
Scraping cover on
transmission rear extension ference
Whine or whistle Damaged center bearing Replace center bearing
1 0 17
Trouble Diagnoses and Corrections PROPELLER SHAFT DIFFERENTIAL CARRIER
When a differential carrier is sus tites road surface exhaust universal places cannot be corrected by adjust
replacement of parts in dif
pected of being noisy it is advisable to joint propeller shaft wheel bearings ment or
engine transmission or differential ferential carrier

make athorough test to detennine
whether the noise originates in the carrier Noise which originates in other

Condition
Supply oil Rebuild carrier if

Noise on drive coast Shortage of oil gear gear
and l1oat necessary
Incorrect tooth contact between ring gear Adjust tooth contact or replace the hypoid
and drive pinion gear set
Incorrect backlash between ring gear and Adjust backlash or replace the hypoid gear
drive pinion set if necessary
Seized up or damaged ring gear and drive Replace the hypoid gear set
pinion
Seized up damaged or broken drive pinion Replace the pinion bearing and faulty parts
bearing
Seized up damaged or broken side bearing Replace the side bearing and faulty parts
Loose clamp bolts or nuts holding ring gear Clamp them to specified torque and replal
bearing cap etc faulty parts
Noise on turn Seized up damaged or broken side gear and Replace faulty parts
pinion mate gear
Seized up damaged or broken side gear and Replace faulty parts

pinion mate gear thrust washers
Pinion mate gears too tight on their shaft Replace faulty parts
Knocking sound Excessive backlash

during starting or gear Incorrect backlash ring gear drive
to Adjust backlash
shifting pinion or side gear to pinion mate gear
Worn gears or case Replace worn parts
Worn rear axle shaft and side gear spline Replace worn parts
Pinion bearing under preload Adjust preload

Loose drive pinion miL Replace or tighten bolt
Loose boltS and nuts such as ring gear bolts ReplaCe faulty parts or lighten bolts
Replace faulty parts and use recommended

Seizure or breakage Shortage ofoil or use of unsuitable oil
gear oil
Excessively small backlash Adjust backlash and replace as required

Incorrect adjustment of bearings or geats Replace faulty parts
Severe vice
ser due to an excessive loading Replace faulty parts
improper use of clutch
ring gear bolts Replace faulty tighten bolts

Loose bolts and nuts such as parts or
improperly driven Replace damaged oil seal Repair l1ange with

Oil leakage out
Worn damaged or
front oil seal or bruised dented or abnor sandpaper or replace if necessary

mally worn slide face of companion l1ange
Damaged gasket Replace
Loose filler or drain plug Tighten
Clogged or damaged breather Repair or replace
PD 18
PROPELLER SHAFT DIFFERENTIAL CARRIER Special Service Tools
Tool number
Tool name
Kent Moore No
ST050 I SOOO Engine stand

126023
CD ST05011 000 Engine stand

126023 2
Base
@ST05012000
126023 1
ST0636000l Diff attachment
ST3003S000 Drive pinion feaf bearing inner race
125733 puller set
CD ST30031 000 Puller

125733 1
Base
@ST30032000
125733 2
ST30611000 Drive pinion bearing outer race
125742 1 drift bar
ST30613000 Drive pinion rear bearing outer
1257423 race drift
ST30701000 Drive pinion front bearing Quter

125742 2 race drift
6
ST3114S000 Drive pinion setting gauge set
See 125269 01
CD ST31141000 Height gauge
@ST31942000 Dummy shaft
PD 19

Special Service Tools PROPELLER SHAFT DIFFERENTIAL CARRIER
Tool number
Tool name
Kent Moore No
ST3127S000 Preload gauge

See 125765
CD GG91030000 Torque wrench
CV lIT62900000 Socket adapter 1 2 1

@ lIT62940000 Socket adapter 3 8
t
o
e
ST31530000 Drive pinion l1ange wrench

125774
ST32501000 Weight block

125407 3
ST33051001 Diff side bearing puller
ST33052000 Adapter
125797 1
5J
ST33400001 Oil seal fitting tool
126082
ST33741000 Master gauge

See 125407 1 5 mm 0 728 in
18
8
KY311 00300 Solid punch
KY38102100 Diff side bearing drift

125803
PD 20

DATSUN 200SX Model S 110 Series
SECTION
FA
FRONT AXLE FRONT SUSPENSION
CONTENTS
FRONT AXLE AND SERVICE DATA AND

FRONT USPENSION FA 2 SPECIFICATIONS FA 12
FRONT AXLE FA 3 GENERAL SPECIFICATIONS FA 12
FRONT SUSPENSION FA 5 INSPECTION AND ADJUSTMENT FA12
SPRING AND STRUT ASSEMBLY FA 5 TIGHTENING TORQUE FA13
TENSION ROD AND STABILIZER BAR FA 9 TROUBLE DIAGNOSES AND

TRANSVERSE LINK AND CORRECTIONS FA 14
LOWER BALL JOINT FA10 SPECIAL SERVICE TOOLS FA 17
SUSPENSION CROSSMEMBER FA ll
Refer to Section MA Front Axle and Front Su pen ionl

for
ADJUSTING WHEEL BEARING PRELOAD
CHECKING WHEEL ALlGNMENT

lFProntensi
AxleandFronnrSu FRONT XLE FRONT SUSPENSION
FRONT AXLE AND FRONT SUSPENSION
Wheel alignment
Camber caster and kingpin are preset at
factory and cannot be adjusted

The car requiresonly toe in and car
pouure adjustment
Toe in 0 2 mm 0 0 08 in
00 to 0012
RefeI to section MA fot Wheel Alignment
J 25 34
J 59 74
25 3 5 18 25
6 0 7 5 43 54
Strut mounting
insulator
Dust covet
J 16 21
16 2 1 12
Coil SPrinll
J 62 7S
6 3 7 6 46
Strut bly
Suspension croumember
Stabilizer bar
BaUjoint
Tension rod bracket
l J 31 42
3 2 4 3 23 31
llion
Te rod
To body rame
Vcue
Tranl link
J 50 60
5 1 6 1 37 44
J 78 98
8 10 58 72
Wheel bearing
Do not overtighten wheel bearing nuts as this
J N m m
Irg lb
ft
can cawe wheel bearing seizure
Axial play 0 mm 0 in
Preload As measured at wheel bolt with used parts
2 0 7 8 N 0 2 0 81rg 0 4 1 8 lb
SFA 9
When measuring bearing preload do not include
dragging resistance with brake pads
Refer to Section MA for Adju linB Wheelllearing Preload
FA 2

FRONT AXLE FRONT SUSPENSION Front Axle
FRONT AXLE
We seal
@
Inner wheel bearing
Cotter Pin
Baffle plate
@ 38
@j
L
LWheelhub @innerside
Washer
Wheel bearing nut
Adjust wheel bearing preload

Hub cap Refer to Section MA for lD N m
kg m ft lb
Multi purpose grease point

@g inner side Adjusting Wheel Bearing Preload @
SFA120
REMOVAL 4 Work off hub cap

CAUTION
I Block rear wheels with chocks
Be careful not to drop wheel bearing
and raise front of car and then sup
Screwdriver
Refer to
port it with safety stands
Section GI for Lifting Points and

7 Separate outside wheel bearing
Towing inner race and washer
2 Remove wheel and tire assembly 8 Separate brake rotor and hub
3 Remove caliper assembly Refer
to Section BR for removal
O riJ11
5 Pry off cotter pin take out
adjusting cap and wheel bearing nut

Cotter pin must not be reused
6 Remove wheel hub with disc

brake rotor
9 Remove inside wheel bearing

outer race grease seal and outside
outer race
CAUTION
CAUTION
Be careful not to drop wheel bearing
Make sure brake hose is secured and
not twisted FA258
Grease seal mud not be reused
FA 3

FronrAxle FRONT AXLE FRONT SUSPENSION
I I @ Multi
purpo
1 11 1 III SFA 124 grease point SFA126
Y
5 Fix brake rotor to hub

2 Pack hub and hub cap with re
commended purpose
multi grease
Coat oring with recommended
multi purpose grease 38 ft Ib
INSPECTION
Thoroughly dean bearing and each
part and dry with compressed air l O

q
Wh 1 bearing
When race cage or roller sufaces

make noise or are cracked pitted
worn rough or out fround replace
bearing assembly
MuIt
purpo
grease point
Wheel hub SFA125
Check wheel hub for cracks by

means of magnetic flaw detecting or 6 Sparingly apply recommended
multi purpose grease to each part
dyeing test replace if necessary
Threaded portion of spindle
3 Coat each bearing with reCom Bearing washer to bearing contact
Knuckle aplndle
Also check wheel hub

mended purpo
multi gr ing face
replace if 7 Put hub assembly
cracked
on spindle and
damaged When thread is
or
then install washer and wheel bearing
damaged replace strut assembly
nut
8 Adjust wheel bearing preload

Greaae aeal
Roter to Section MA for adjUlt
If grease leakage is detected during ment
removal replace grease seal 9 Install hub cap with a ring on
Replace grease seal at every disas hub
sembly even if it appears good 10 Install brake caliper assembly
Roter to Section BR for installa
tion
II Install wheel and tire
cD 78 98 N m
8 0 10 0 kg m
58 72 ft Ibl
INSTALLATION
Install front axle in the reverse 4 Place inner bea i

J n in hub and
order ofremoval as follows install a new grease seal coating seal
I Install bearing outer race with ing lips with recommended pur
multi
Tool until it seats in hub PO gr
4
FA

FRONT AXLE FRONT SUSPENSION Front Suspension
FRONT SUSPENSION
Croamember auembly
J
I 59 74
Stabilizer bar
or 6 0 7 5 43 54
i J
I
t J
I 25
25
34
3 5 18 25
f8
50 60 To body
J 51 6 1
3744
J
I 62 75 e
6 3 76
J4454
1
45 5 33
1 46 55
J
I 60 72 t b
Tension rod
Z 8
e
tI U t bIY
bracket J
I
tf
J
I 31
23
3 2
42
31
3
t
LTen n
Transverse link
J
I
55 10 0
I
1
oS
I J
I 2 i brI
J
g3
9
9 53 72
j
6 1
J
XI 31 42 12 15 Balljo nta sembly
3 2 4 3 J
I 50 60
23 31 5 1 6 1
J
I N m kg m ft Ib 37 44 SFA128
SPRING AND STRUT ASSEMBLY
J
I 59 74
6 0 7 5
Gland packing
43 54 J
I 25 34
packing kit
2 5 3 5
rstruI Onng
ton rud 3
C
18 25
I uldebusllIng Mountingin u1alor
ShoCk
I
Lock nut
O
b ber kit Mounting bearing
with dust seal
Washer
sPring upper seal
I Inner cylinder
G Bound bumper rubber
Strut outer casing

Strut kit
DUSI cover
1 bearing nut
Adjusting cap
Atterpin
fr
f r
9
J
I SPring
J
J
I 50 60
J
I N m m
kg ft b
Service parts SUUt packing kit Shock absorber kit Strut kit V 5 16 1
37 44 SFAl29
FA 5

FrontSuspension FRONT AXLE FRONT SUSPENSION
REMOVAL AND Dust seal

INSTAllAnON Spring upper seat
Bound
Block rear wheels with chocks and bumper rubber
Coil spring
raise front of car and then support it
Dust cover
with safety stands Refer to Section
GI for Ufting Points and Towing

Remove wheel and tire
assembly CAUTION
3 Remove brake tube and caliper Pay attention not to damaga piston
Refer to Front Disc Brake Section rod
A pply sealing material
BRl
SFA132 3 Remove gland packing with Tool
4 Remove wheel hub and wheel
Retract piston rod by it
bearing if necessary pushing
Strut to
5
GJ hoodledge down until it bottoms
Separate knuckle arm from strut
25 34 N m
lower end
2 5 3 5 m
kg A ST35500001
18 25 ft Ibl
Strut to knuckle arm

J
72
7 3
97 N
9 9 kg
m
m
J
53 72 ft Ibl
KV48100301
r DISASSEMBLY
When disassembling strut assambly
extra caution should be exercised

FA209
to prevent dirt and dust from entering
strut
4 Remove from top of
SFA130 Set up Tools on strut assembly ring
O outer
Compress spring just for enough to casing and draw out guide bushing
permit turning of strut mounting in
sulator by hand
6 Support strut assembly with a
suitable stand
7 Remove strut upper end HT7t730000
SFA135
ST35652001
SFA133
5 Lift out piston rod together with
cylinder
2 Remove lock nut from top of Piston rod piston rod guide innlr
piston rod
cylinder and bottom valvl are adjusted
SFA 31
to provide precilion mating surfaces
8 Draw out strut assembly from car J

LX Ind should
it
be hlndled IS I matched
9 Install strut and spring assembly

Lift out
in reverse order of removal
CAUTION
Make sure brake hose is secured and
not twisted
SFA134
When installing steering knuckle
arm to the strut assembly apply Separate following parts
suitable sealing material to portion Strut mounting insulator
FA275
indicated in figure Strut mounting bearing
FA 6

FRONT AXLE FRONT SUSPENSION FrontSuspension
6 Drain l1uid thoroughly from inner Inner diameter Strut mounting insulator
cylinder and outer casing Inner cylinder rubber to

Replace if cemented
30 02 30 10 mm
metal portion are melted or cracked
1 1819 1 1850 in
Rubber parts should also be replaced
if deteriorated
r Guide bushing Strut mounting bearing
Replace if inspection reveals ab

normal noise or excessive rattle in
axial direction
iJ
SFA136 ASSEMBLY
Before assembly clean away all dirt
to prevent any possible entry of dirt

i important Maximum runout
Thi operation very
into strut assembly
since performance of strut varies with Inner cylinder
Less than 0 2 0 008 in I Install strut

amount of fluid filled within strut mm assembly on Tool
KV4810030 I
2 Install piston rod and inner
INSPECTION cylinder shock absorber kit
Wash all
Blow
parts except for noome
tallic parts clean with suitable sol
vent and dry with compressed air
dirt and dust off of non

r
t
metallic parts using compressed air O Piston rod
8 Oil oozing out at and around gland cYlinder

Y
packing does not call for strut SFA137
M
f
maintenance If oil leaks part pring
at check piston rod and gland
Piston rod
the of
packing to correct cause
problem If oil leakage occurs on

Inspect rod for cracks
piston SFA139
welded portion of outer strut defoffilation other Re

or damage
casing replace strut assembly place shock absorber kit
b If hock absorber itself is malfunc Inspect threads for cracks or ot her
tioning replace as shock absorber damage Replace shock absorber
3 Pour correct amount of fluid
kit including pillion rod cylinder kit
U e NISSAN GENUINE STRUT
bottom valve and guide bushing
Rod diameter F LUI 0 or equivalent
19 965 19 975 mm
Gland packing Oring and Capacity

0 7860 0 7864 in
325 m2
fluid
Maximum runout
11 0 US 110z 11 4 11 ozl
Imp
Less than 0 1 mm 0 004 inl
Replace with new gland packing
and O ring or replace with fresh l1uid
whenever strut is disassembled
Inner cylinder and

outer casing
Inspect inner cylinder and outer

casing for cracks deformation or
other damage As for inner cylin
der replace shock absorber kit As

for outer casing replace strut
SFA138
assembly
FA 7
Front Suspension FRONT AXLE FRONT SUSPENSION
Place 7 Tighten gland packing

4 guide bushing
Guide shing
bu
ST3SS00001
1
Cylinder LJ
fl98 118 N m
10 12kg m
72 87ft
FA280
SFA140
4 SFA143
Reinstall strut on Toot

10
KV48 10030 I
c
LorIw Compress coil spring ing Tool

1L u
packing
Lubricate sealing lip of gland
f
O 1m
0 3ftl
Lm ft 1tch HT71730000
108 11 80
E 98 10 12
88 9 65
Converted torquel
B
o p
78 8 58 SFA14S
3
o
12 Set up coil pring with Tool
SFA141
59 6 43 HT71730000 on spring lower seat of
strut
u
13 Lubricate parts indicated in
6 Install gland packing using Tool 0 3 0 4 0 5 06
N m
q ft lb m
figure
Be careful not to damage sealing SFA144 10 5
1 2 0
L Effective length of torque wrench ft
lip
trut from Tool

8 Remove
KV48100301
9 After the above steps have been
completed air should be removed

from shock absorber syst m
Repeat above procedure

timal 10 that air will ba bled out from
everal
At
hown 48
SFA1
strut thoroughly al
SFA142
279
FA
FA 8
FRONT AXLE FRONT SUSPENSION Front Suspension
14 Mount following part as shown in

figure Coil spring
G Lock nut
Mounting insulator
c
Bear ing With dust Seal mi I
I I
Sprmg seat
spnng eat
Bound bumper rubber SFA149

d Place pnng
Spnng InstallatIon
In po ilton
Dust cover
TENSION ROD AND STABIUZER BAR
Hf71730000
LJ
e
KV48100301
braCketlj
rl1
SFA147
Stabilizer
IV 31 42
3 2 4 3 23 411 IV 50 60
To tension rod bracket 5 1 6 1
37 44
IV 44 54
cJO
In I
Install
place to
bound bumper rubber
prevent piston rod from

in 4 5
33
5 5
40
Tension rod J l
falling by its own weight
Install mounting bearing so that it
To
bracket
tension rod
Transverse link J t1
A
points in correct direction IV 16 21
15 Tighten new piston rod self lock 16 2 1
in nut 1215
IV N m kg m ftIb
SFA150
IV 59 74N m
i6 0 1 5k
43 54 ft Ibl
Remove under cover
Set load of car
Uvd If correctly installed white mark

painted on stabilizer bushing seat
can be seen from both sides of car

Always install the stabilizer which
has the while mark on it on the left
transverse link
FA148
When installing a bushing do not
allow it to project beyond the sur
face area of lhe washer

Do not allow the bushings and
washers to come in contact with
grease oil soapy water etc

16 Remove Tool HT71730000 on
strut assembly
After placing spring inposition
between upper and lower spring seatl
release eompreaor greduelly
FA 9
Front Suspension FRONT AXLE FRONT SUSPENSION
7 Separate following parts

White mark I Ball joint to knuckle arm using
Left side
only 1IT72520000 press
White mark
Both sides
SFA152
r
Stabilizer position SFA155
4 strut lower end to

Separate FA712
knuckle arm
CD
I Unk bushing to transverse link
using Set Tool ST36720000
SFAl53
4 Collar
1 Tluust washer
2 Tension lod bracket
5 Bu hins
3 Tension rod
5 Remove following parts from
transverse link
I Balljoint
Stabilizer
rG
f
I
SFA159
TRANSVERSE UNK Tension rod
AND LOWER
BALL JOINT
8 Install transverse link and lower
ball joint in the reverse order of re
moval noting the following

I Wh n instelling link
tremver
spindle insert it from rear lide of
suspension crOS3
I To instell link
transye first
vtJ temporerily tighten nuts securing
9 SFA1511 tren ve link spindl which con
neeu transven link to suspension

Front
6 Remove transverse link from crossmember
SFAl54
crossmember I Finel tightening hould be carried
out lit curb weight with tire on
ground
REMOVAL AND
I Make ure mating urfeof bu h
INSTAllATION
ing is clean end free from oil end
I Block ear wheels with chocks
gre
and raise front of car and then up I Install tren e link bushing u ing
port it with safety tand Refer to set Tool ST36720000
tfl Knuckl erm to strut IISIllmbly
Towing
72 97 N m
2 Remove wheel and tire assembly
17 3 9 9 ni
kg
3 Separate knuckle arm to side rod
SFAl58
53 72 lb
ft
using Tool
FA 10
FRONT AXLE FRONT SUSPENSION FrontSuspension
To lubricate remove plug and

Ball joint to knuckle arm
install nipple in its

97 120 N m grease place
9 8 122 kg m Pump grease slowly until old grease
71 88 ft Ibl
is completely forced out After greas
Ball link ing reinstall plug

joint to transvene
50 60 N m
5 1 6 1 m
kg
37 44 ft Ibl
Transverse link to crossmember

When a pressure
high grease gun is
62 75 N m
16 3 7 6
used operate the grease gun carefully
kg m
so that grease is injected slowly and

46 55 ft lb
out from 6 Raise up engine
grease does not come
new
the clamp ponion Support weight of engine to remove
load from engine mounting

7 Remove suspension crossmember
from body frame
INSPECTION
SUSPENSION
Transv rs link
CROSSMEMBER
Check for signs of cracks distor
tion or other damage Replace if REMOVAL AND

any of above conditions are beyond
INSTALLATION
repair
Ifrubber bushing shows evidence of I Bl6ck rear wheels with chocks
cracking replace with a new one and raise front of car and then sup
Refer to
port it with safety stands
8 Install suspension crossmember in
Towing
Ball Joint order of removal
reverse
2 Remove wheel and tire assembly
BaIl joint is assembled at the
Crossmember to transverse link
3 Remove under cover f
factory and cannot be disassembl
62 75 N m
ed Check ball stud turning torque

6 3 7 6 m
kg
with nut in place on ball stud
46 55 ft Ibl
If excessively higher or lower than
Engine mounting insulator to
specifications and ball joint is pro
crossmember
perly lubricated replace 31 42 N m
3 2 4 3 kg m
Turning torque
23 31 ft Ibl
New parts
Crossmember to body frame
3 9 9 8 N m
40 100 Bolt Center

kltcm
31 42 N m
35 87 in Ibl
3 2 4 3 kg m
Used parts
23 31 ft Ibl
2 0 7 8N m
20 80 kg em
Nut Both sidesl
60 72 N m
17 69 in Ibl
6 1 7 3 kg m
44 53 ft Ib
2 Check conditional dust cover If
found to be cracked excessively
ball joint with 4 Remove transverse link from
beyond use replace a INSPECTION
crossmember Refer to Tran vene
new one
Check suspension crossmember for
3 Lubricate ball joint with recom Link and Lower Ball joint
crossmember evidence of deformation or cracking if
mended multi purpose grease regular S Separate suspension
ly from engine mounting insulator necessary replace
FA l1

Service OstBsndSpecifications FRONT AXLE FRONT SUSPENSION
GENERAL SPECIFICATIONS INSPECTION AND ADJUSTMENT
COIL SPRING WHEEL ALIGNMENT Unladen 1
1 Camber degree 40 50
3015
Dimension
DxL
Color Spring I Caster degree 045
d identification constant
Kingpin inclination degree 1025 S055
12 2 30
mm in 0 2 0 0 081
386 erem 1
Right in
Toe
0 480 5 12 White 2
degree 2 0 12
5 201
With power
steering Front wheel Inside 330 350 3

12 2 130 1716 N mm
turning ngle
392 Pink 1 270
Lah 75
1 kg mm Full turn degree Outside 290 3
10 480 5 12 Yellow 2
98 0Iblin
5 43
Front wheel Inside 200
out
Toe
2 2 30 70
Without turns degree Outside 18
x 3S6 Cream 1
power
0 480 x 5 12 White 2 1 Tankful of fuel radiator coolant and engine oil full
steering 5 20 Spare tire jack hand tools mats in designed position
2 On both sides
d x 0 xL Wire diameter mm lin x Coil diameter mm in 3 On power steering models
x Free length mm in tat circumference of steering wheel of
wheel turning force
98 147N 10 15 kg 22 33 Ibl with engine at idle
WHEEL BEARING
STRUT MBLY
ASSE Wheel bearing axial 0 01
play mm in
I Shock absorber type HYdraulic

N m
Shock absorber fluid 25 29
I kg m
325 110 114 3 0 18 22
mQ US fl fl ozl 2 5
OZ Imp Wheel bearing nut lbl
ft
19 965 19 975 tightening torque
l Piston rod diameter in

mm
Return
10 7860 0 7864
degree 600
angle
30 02 30 10
linneI
cylinder inner mm in With
diameter 11 1819 1 1850 N m
new 0 39 083
an
kg
I Stroke mm in 172 16 77 gre
se 1
lbl
in
14 0 S 5 3 5 741
Expansion
Damping force
t 0 3 m 11 0 hI
I N kg Ibl
588 tOO 132
With
used
N m
cm
kg
0 10 0 44
Compression Wheel 10 45 09 3 91
I
see gro
J43 135 77 in lbl
N k9 lb bearing se l
starting
torque With
new N 69 14 7
At grease Ik9 lbl fO 7 1 5 1 5 33
wheel seal
hub
bolt With
STABILIZER BAR usad N 20 7B
grease Ik9 lb 10 2 0 8 04 18
se t
I Bar diameter mm in t9 10 75
FA 12

FRONT AXLE FRONT SUSPENSION ServiceOataandSpecifications
LOWER BAlL JOINT
N m
New 39 98
kg em
parts 140 100 35 871
in Ibl
Turning torque
N m
Used 20 7 8
kg em
parts 120 80 17 691
Ibl
TIGHTENING TORQUE
I Unit
I N m
I kg m ft Ib
I Hub
I Wheel hub nut

I 78 98 8 10
I 58 72
I Disc brake
I Rotor to hub
I 38 52
I 3 9 5 3
I 28 38
I Strut
I Strut to hoodledge 25 34 2 5 3 5 18 25
Piston rod sei Iocklng
I nut
59 74 60 75 43 54
Gland packing 9B 118 10 0 12 0 U2 87
Strut to knuckle arm 72 97 7 3 9 9 53 72
to strut 72 97 7 3 9 9 53 72
Caliper
Knuckle arm
Knuckle side rod
I
arm to
I 54 98 5 5 10 0 40 72
ball joint
FA 13

Diagnoses and Corrections FRONT AXLE FRONT SUSPENSION
JlTroeu

Vibration shock and shimmy of steering Improper tire pressure Adjust

wheel Imbalance and deformation of road wheel Correct the imbal
ance or replace
Vibration Loose connection of each part
Unevenly wom tire or insufficient tight Replace or tighten
and of each part of Iini age cause vibra
wear
ening ofwheel nuts
tion of front wheels and steering wheel
vibration This is very noticeable when trav Improperly adjusted or wom front wheel Adjust or tighten
elling on rough road bearing
Faulty wheel alignment Adjust
Shock When the front wheels are travelling
Wom transverse link bushings Replace
on bumpy roads the play of the steering
linkage is transmitted to the steering wheel Insufficiently tightened steering gear hous Retighten
This is especially noticeable when travelling ing
on rough road Wear of steering linkage Replace faulty parts
Wom suspension ball joint Replace

Shimmy Abnormal vibration of the front
suspension system and the whole steering Excessive backlash due to
improper adjust Adjust correctly
linkage which occurs at specific speeds ment of the steering gear box
Damaged idler arm Replace

Worn column bearing weakened column Replace or retighten
bearing spring or loose clamp
Malfunction of shock absorber inside the Replace or retighten
strut or loose installation bolts
Imbalance of carlevel Correct the imbal

ance
Car pulls to right or left Improper tire pressure or insufficient tight Adjust or tighten
When drivin with hands off the steering

ening ofwheel nuts
wheelan a flat road the car gently swerves Difference in wear and tear of right and left Replace tires
to right or left tire treads
A faulty rear lII ellSion may also b8 the Incorrect adjustment or abrasion of front Adjust or replace
caUI8 of this problem and therefore 188 also wheel bearing
Sectinn RA twisted front spring Replace
Collapsed or
Incorrect wheel alignment Adjust

Incorrect brake adjustment binding Adjust
Worn rubber bushings for transverse link and Replace
tension rod
Deformed steering linkage and transverse Replace

link and tension rod
Imbalance of car level Correct the imbal

ance
FA 14
FRONT AXLE FRONT SUSPENSION Trouble Diagnoses and Corrections
Corrective action
Condition Probable cause
Improper tire pressure Adjust

Instability of car
Worn rubber bushings for transverse link and Replace
tension rod
Worn or deformed steering linkage and Replace

transverse link
Incorrect adjustment of steering gear Adjust
Deformed or unbalanced road wheel Correct or replace
Stiff steering wheel Improper tire pressure Adjust

Checking up procedure Insufficient lubricants or mixing impurities Replenish grease or
in box excessively worn replace the part

steering gear or
Jack up front wheels detach the steering

steering linkage
gear arm and operate the steering wheel
Stiff or damaged suspension ball joint or Replace
and
lack of grease
and
If it islight check steering linkage
Worn or incorrectly adjusted wheel bearing Replace or adjust
suspension parts
If it is heavy check steering gear and steer Worn or damaged steering gear and bearing Replace
ing column parts Incorrectly adjusted steering gear Adjust
Deformed steering linkage Replace
Damaged strut mounting bearing Replace
Damaged or stiff piston or shock absorber Replace

in the strut
piston rod
Interference of steering column with turn Replace
signal swi tch
Excessive steering wheel play Incorrectly adjusted steering gear housing Adjust
Worn steering linkage Replace
Improperly fitted gear housing Retighten
Incorrectly adjusted wheel bearing Adjust
Worn transverse link and tension rod bush Replace

ings
Noises Improper tire pressure Adjust

Insufficient lubricating oil and grease for Replenish lubrica
suspension baU joint and steering linkage or ting oil and grease
their breakage or replace
Loose steering gear bolts linkage and sus Retighten

pension parts
Faulty shock absorber inside the strut Replace
Faulty wheel bearing Replace
Worn steering linkage and steering gear Replace
Worn transverse link and tension rod bush Replace
ings
Broken or coUapsed coil spring Replace
FA 15

Trouble DiagnmsundCorTfICtions FRONT AXLE FRONT SUSPENSION
Loose stabilizer bar installation bolts and Retighten

nuts
Loose strut to hoodledge installation nuts Retighten
Grating tire noise Improper tire pressure Adjust

Deformed knuckle spindle and suspension Replace
linkage
Jumping of disc wheel Improper tire pressure Adjust

Imbalanced road wheels Adjust
Faulty shock absorber Replace
Faulty tire Replace
Deformed wheel rim Replace
Excessively or partially worn tire Improper tire pressure Adjust

Faulty wheel bearing Replace
Incorrect brake adjustment Adjust
Tires not rotated Rotate tires at re
commended inter
val
Rough and improper driving manner Drive more gently
FA 16

FRONT AXLE FRONT SUSPENSION Special Service Tool
Tool number
Kent Moore No Tool name
KV401021S0 Bearing outer race drift set
CD ST35325000 Drift bar

@KV40102110 Drift A
@KV40102120
V
Drift B
@KV40102130
CID KV40 102140
Screw A
Screw B
V
@KV40102150 Screw C
KV48100301 Strut and steering gear

I
housing attachment
J
HT71730000 Coil spring compressor
ST35500001 G land packing wrench

125825
ST35530000 Gland packing guide

125827
tL
HT72520000 Ball joint remover
ST36720000 Transverse link

125847 bushing replacer
3
t
ST35652001 Clamp
o
FA 17
SECTIONRA
REAR AXLE REAR SUSPENSION
CONTENTS
REAR AXLE RA 2 SERVICE DATA AND

REAR AXLE RA 2 SPECIFICATIONS RA 8
REAR AXLE ASSEMBLY RA 2 GENERAL SPECIF ICA TIONS RA 8
REAR AXLE SHAFT AND WHEEL INSPECTION AND ADJUSTMENT RA 8
BEARING RA 3 TIGHTENING TORGUE RA 8
REAR SUSPENSION RA 5 TROUBLE DIAGNOSES AND

REAR SUSPENSION RA 5 CORRECTIONS RA 9
STABILIZER BAR RA 6 SPECIAL SERVICE TOOLS RA lO

SHOCK ABSORBER RA 6
COIL SPRING RA 7
UPPER LINK AND LOWER LINK RA 7
GII

RearAxle REAR AXLE REAR SUSPENSION
REAR AXLE
REAR AXLE REAR AXLE ASSEMBLY
Removal and Inatallatlon
Oil w
Block front wheels Place stands
Install using oil seal
Support under differential carrier with
drift KV40100300
garage jack
BeuiDg coner
Installed by a
p ing
force of 29 49 kN
I
3 5t 3 3 5 5 US ton
Rear axle cue end shim 3 0 49 Imp ton I

0 075 0 0030
Thickne
0 150 0 0059
0 225 0 0089
0 300 0 0118
I
L
A
1l
lteatherCOP
Breather 2 Remove stabilizer bar Refer to
72 Filler PI Stabilizer Bar for installation
4
1
72 SAA013
It
I SAA017
3 Disconnect propeller shaft Refer

Rear axle cue end shim PO brake
to section for removal
J22
C 26
hydraulic line and parking brake cable
2 2 2 7 16 20
J
C 78 98 CAUTION
8 10 58 72 BeuiDg
When removing or
installing brake
Ax1ease tubes use Tool GG94310000
I II
Axle shafl
Bearingcol1ar
Bearing spacer
Gap C
w
0iI C
fiJ
W
Gap C 0 0 1 0 0 004
Aal shaft Beerin8
fIanse side ide
1r
f J J
C
Unit
N m
rom
kg
in
m ft Ib t ec
SAA014
SRA018
RA 2

REAR AXLE REAR SUSPENSION Rear Axle
4 Disconnect shock absorber lower 2 Disconnect parking brake cable

end on each side and brake tube
When removing shock absorber low
er end from bracket squeeze shock

absorber and lift it out right above
to accommodate embossment inside
bracket
F
p c
7 Release jack and pull it out

I
i y
II
I
I I
3 Remove caliper and rotor Re
move nuts securing baffle plate
l RA485
It
Installation is in reverse order of

R A486 removal
Refer to Upper Link and Lower
Link for installation of upper link and 4 Draw out axle shaft
lower link
Rear axle shaft

5 Lower jack and remove coil spring In p ction
on each side
Check axle case for yield deforma
tion or cracks and replace if necessary
jf
REAR AXLE SHAFT AND
WHEEL BEARING
SAA026
R mov 1 nd dl mbl
I Block front wheels Place stands

Remove rear wheel 5 Remove oil seal
6 Raise jack to
Disconnect upper link and lower link
at axle case side

previous position
A SAA027
RA 3
Rear Axle REAR AXLE REAR SUSPENSION
6 Cut collar with cold chisel Take 2 Press load

new bearing collar by a Gap C
axle sheft of 29 to 49 kN 3 to 5 ton 3 3 to 5 5
care not to damage less than 0 1 mm 0 004 in
US ton 3 0 to 4 9 Imp Ion Ions
Shim thickness d
W
Baffle plate
SRA028
II IIII
AA559
SRA030
7 Remove wheel bearing and collar

Rear axle case end him
3 Install oil seal packing cavity be
Refer to S OS
tween sealing lips with recommended
L
multi purpose grease
6 Measure end play of axle shaft
l
AA492 KV40100300
SAA031
Inspection SAA032
Check axle shaft for straightness

cracks damage wear or distortion 4 Insert axle shaft into axle case
Axial end play
Check lip of oil seal for damage de
applying multi purpose grease to the
0 05 0 40 mm
formation or wear
outer periphery of bearing collar Re 0 0020 0 0157 in
Check bearing for wear or damage move guide when distance A be
tween axle l1ange and is 70 to
bearing fl Differential gear carrier fixing
90 mm 2 76 to 3 54 in
Assembly and Installation nut
I Install bearing spacer with cham 20 25 N m
fer ide facing axle haft 2 0 2 5 kg
flange Insert m
wheel
CD 14
bearing with seal ido facing ollie 18 ft lbl
haft flange Oil drain and filler plug
1 59 98 N m
6 0 10 0 kg m
43 72 ft Ibl
J 9 AJ r Brake tube flare nut
15 18 N m
A 70 90mm 1 5 1 8 kg m
CD 12 76 54
3 in
RA560 11 13 ft lb
1 Rear axle shaft Brake 3way connector fixing bolt

2 Rear axle shaft gune ST37840000 17 20 N m
3 Rear axle case 1 7 2 0 kg m

4 Oil seal
SRAQ29 12 14 ft Ibl
Wheel nut
5 Adjust gap C between wheel 78 98 N

1 Bait 4 Adapter plate m
2 Rear axle shaft 5 Bearing spacer bearing and axle tube end by selecting 8 0 10 0 kg m
3 Bame plate 6 Wheel bearing shim 58 72 ft Ibl
4
RA

REAR AXLE REAR SUSPENSION Rear Suspension
REAR SUSPENSION
REAR SUSPENSION
dl 15 20 5
1 2 0 11 14
@
e
e
e1
Coil Spring
l D color
Purple YeUow
1 Shock absorber
Upper link bolt
8 0 51 58
dl 3 7 50
0 38 0 51
2 7 3 7
Lower link bushing

Replaceable
Removed or installed
by a pressing force of
39 69 KN 4 11
4 4 7 7 US ton
39 6 9 Imp ton
7 58 Differ in length from upper link bolt

78 0 8 0 51
Differ in length from upper link bolt
2 1 12 15
dl N m
kg ft lb
dl16 21 16 2 1 12
SAA033
AA 5

Rear Suspension REAR AXLE REAR SUSPENSION
STABILIZER BAR Inspection Inspection

I Check stabilizer bar for evidence Test shock absorber and compare
Remoyal
of deformation or cracks replace if with specifications given in S O S
Remove stabilizer bar necessary Replace if necessary
2 Check rubber parts to be sure Check for oil leakage and cracks
they are not deteriorated or cracked Also check shaft for bending
replace if necessary Inspect rubber bushings for dam
P age cracks and deformation Re

Installation place parts if necessary
II
fI a
c
Install
not to
InstJ U
fining
Install
stabilizer bar
on
bolt
axle case lide
attaching
being careful
confuse right and left sides
rubber bushing with metal
bushing so
COIL SPRING
Remoyal end Installation
I Block front wheels Place stands

SRA017 Support under differential carrier with
that bolt is inside the car
garage jack
Front
21
SRA016
11 6 2 1
2 Disconnect shock absorber lower
IV 16 2111 6 2 1 12 end
IV N m
kg m ft Ib
SRA035
SHOCK ABSORBER
s C
Remoyal and Installation
I Disconnect upper end
C
SRA038
LIV6
L7 0
78N
IY
ml
80 kg m 51 58 ft lbl
14ft lbl
1
T
SAA038
c
fl ilr
L7 0 8 0 kg m 51 58 ft lbl
3 Lower
coil springs
jack slowly
on each side
and remove
In lturggage
unk room
SRA037
i r
2 Disconnect lower end md remme
shock absorber
I
I
t
r
Squeeze shock absorber and lift it
out right above to accommodate em
t RA486
bossment inside bracket
6
RA

REAR AXLE REAR SUSPENSION Rear Suspension
Inspection Inspection Installation
Check coil spring for yield defor Check for signs of cracks distor a bolts for
Securing use with lower
mation or cracks other Replace if
tion or damage link differ in length from those for
Test spring and compare with speci beyond repair upper link If used wrong securing
fications given in S D S bolts cannot be tightened securely
Check all rubber parts for wear b When installing upper link install
cracks damage or deformation Re one end of upper link on car body
place if necessary Bushing replacement make sure that link is level and
For lower link only then tighten link securely Next in
stall the other end of link on axle
UPPER LINK AND LOWER If rubber bushing shows evidence of side andsecurely tighten link while
LINK cracks replace it using Tool tires ground
are on
Upper link bushing is secured by c When installing lower link securely

Removal
adhesion and cannot be removed Re tighten link while tires are on
Remove upper link or lower link place as an assembly as necessary ground
alone by removing bolt on each end
It is link til Shock absorber lower end
possible to remove one
CAUTION 69 78 N m
assembly alone from car
00 not tap end face of bushing direct 7 0 8 0 m
kg
ly with a hammer as deformation may 51 58 ft Ibl
result in loose bolt Upper link fixing bolt and nut
69 78 N m
7 0 8 0 kg m
Removed or 51 58 ft Ibl
installed by a
Lower link fixing nut
pressing force of
69 78 N m
39 69 KN
4 71 4 4 7 0 8 0 kg m
7 7 US ton 51 58 ft Ibl
39 69 Imp
ton KV40101420
RA495
LI g
lr BUshing
KV401O
t
47 a
j w
SRA039
RA 7

ServireDataandSpecifications REAR AXLE REAR SlJSPENSION
REAR AXLE
GENERAL SPECIFICATIONS
SHOCK ABSORBER Unit mm in End play mm On 0 05 OAO 10 0020 0 01571
I Maximum length L 525 120 67 Thickness mm n Part umber
I Stroke 146 5 75
Thickness of rear xle
075
0 10 00301 43036 H5000
0 1SO 10 00591 43036 H5oo1

case end shim
0 225 10 00891 43036 HS002

L
0 300 10 01181 43036 H5003
C 0
SRA090
COIL SPRING
I Wire diameter mm in 10 010 3941
I in 90 13 541
mm
Coil diameter
I Free length mm in 362 14 251 TIGHTENING TORQUE

7 75
I Effective turns
Unit N m
m
kg ft Ib
Spring
I
constant
17 46 178 99 71 nut
N Ib inl Broke tube flare 15 18 15 8
1 11 13
mm
kg mm
Brake caliper fixing bolt 38 52 39 5 3 28 38

Identification color
Baffle plate fixing ut 22 26 2 2 2 7 16 20

Yellow PurPle
1 Propeller shaft to
panion flange connecting
com
Refer to PO section
ll0
nut
Wheel nut 78 98 80 10 0 58 72
Drain and filler plugs 59 98 60 10 0 43 72
5 RA040
Differential carrier
I
to
20 25 20 2 5 14 18
axlll case nut
Shock absorber upper
INSPECTION AND ADJUSTMENT I end nut

15 20 15 2 0 11 14
Shock absorber lower

SHOCK ABSORBER
I end nut
69 78 7 0 80 51 58
I SHOCK ABSORBER DAMPING FORCE at 03 m 11 0 hIls

I Upper link fixing bolt 69 78 7 0 8 0 51 58
I Expansion N kg lbl 490 686 50 70 110 154

I Upper link fixing nut 69 78 7 0 80 51 58
I Compression N kg Ib 245 402 25 41 55 901

I Lower link fixing nut 69 78 7 0 80 51 58
RA B
REAR AXLE REAR SUSPENSION Trouble Diagnoses and Corrections
When rear axle and suspension is peller shaftengine transmission rear axle and rear suspension
suspected of being noisy it is advis wheel bearings suspension
or In case of oil leak first check if
able to make thorough test to deter Noise which originates in other there is any damage or restriction in
mine whether the noise originates places cannot be corrected by adjust breather
in the tires road surface exhaust pro ment or replacement of parts in the
Noise unusual sound Loose wheel nuts Tighten

One or more securing bolts loose Tighten to specified torque
Lack oflubricating oil or grease Lubricate as required
Faulty shock absorber Replace
Incorrect adjustment of rear axle shaft end Adjust
play
Damaged or worn wheel bearing Replace

Worn spline portion of axle shaft
rear
Replace if necessary
Loose journal connections etc Tighten to torque
Unbalance of wheel and tire Balance
Damage of the rubber parts such as link Replace damaged parts

bushing shock absorber mounting bush
ing
Faulty propeller shaft journal Replace as a propeller shaft assembly

Breakage of coil spring Replace
Instability in driving Loose wheel nuts

Tighten to specified torque
This problem is also Damaged link rubber
rear bushings Replace
related to the front
Worn shock absorber
Replace
suspension For trouble
Incorrect wheel alignment
diagnosis also refer to Adjust
the FA section Spring wear Replace
Oil leakage Damaged oil seal on rear axle shaft Replace

Oil leakage from the differential carrier Replace parts as required
Damaged grease sea of rear axle shaft Replace
RA 9

Special Service Tools REAR AXLE REAR SUSPENSION
Tool number
Tool name
knt Moore No
GG943 I 0000 Flare nut torque wrench
KV4010I0OO Rear axle stand

J 1
25604
ST36230000 Sliding hammer

J 25840
lIT72480000 Rear axle shaft bearing puller
ST38210000 Wheel bearing collar press stand

J 25869
1
KV40100300 Rear axle oil seal drift

J 25405
ST37840000 Rear axle shaft guide
KV40l0l4S0 Link rubber bushing drift

@
CD KV4010141O Drift
V KV40101420
@
KV40101430
KV40101440
Drift
Base
Ring useless
h
RA I0

DATSUN 200SX Model S II 0 Series
SECTIONBR
BRAKE SYSTEM
CONTENTS
DESCRI PTION BR 2 BRAKE BOOSTER BR 14

SERVICE BRAKE BR 3 PARKING BRAKE BR 16
BRAKE PEDAL BR 3 PARKING BRAKE BR 16
MASTER CYLINDER BR 4 SERVICE DATA AND
BRAKE HYDRAULIC LINE BR 5 SPECIFICATIONS BR 1B
BLEEDING HYDRAULIC SYSTEM BR 5 GENERAL SPECIFICATIONS BR 18
NP VALVE BR 6 INSPECTION AND ADJUSTMENT BR 18
FRONT DISC BRAKE N22 BR 6 TIGHTENING TORQUE BR 19
FRONT DISC ROTOR BR TROUBLE DIAGNOSES AND
9
REAR DISC BRAKE AN12H BR lO CORRECTIONS BR 20
REAR DISC ROTOR BR 13 SPECIAL SERVICE TOOL BR 22
Refe to Section MA Brake System for
CHECKING FOOT BRAKE

CHECKING PARKING 8RAKE

ription
CH BRAKE SYSTEM
DESCRIPTION
way
3
connector
Pulling hrake lever
Brake hOle Front disc brake
SBR001
The brake system is a hydraulically assist device which utilizes engine with a mechanically operated parking
controlled dual line type which intake manifold vacuum brake mechanism
operates independently on front and The NP valve is a pressure control The pad clearances of the front and
rear wheels device for the rear brakes rear brakes are automatically adjusted
The brake booster is a
power The rear disc brake is equipped
BR 2
BRAKE SYSTEM Service Brake
SERVICE BRAKE
BRAKE PEDAL
R H
f
i7 8
l 10 8 i7 8
l 10 8 0 8 1 5 8 8 0
Input rod Input rod lock nut
0 8 1
SnaPrin 5 8 8 0
l16
i 22 16 2 2 12
t
10 8 0 8 1 5 8 8 0
Pin
Pedal bracket
l7
i 8 11 8 0 8 2 5 8
1 8 7
LH Itf
ring
E
i7 8
l 10 8 0 8 1 58
l13
ki 18 3
1 8 9
1 13
Return spring
t
l Brakelamp witCh
Lock nut
l12
i 15 12 15 9 11
Pedal stopper
Be sure to insert Lubricating

Brake pedal
from LH side point
l
i N m kg m fHb SBR120
REMOVAL I Check brake pedal for bend

o 2 Check return springs for fatigue
I Remove pedal bracket assembly 3 Check clevis for deformation
with brake pedal M T only
2 Disconnect clevis from brake 00 and crack at welded part
lf
O@
pedal
o I INSTALLTION
When removing clevis pin be careful @II
not to damage c ip of the clevi pin
I Apply coating of recommended
multi purpose grease to sliding portion
and return coil spring
2 Adjust brake pedal after installa
tion is completed Refer to Section
MA for adjustment
lil Fulcrum pin fixing bolt

SBR122 7 8 10 8 N m
0 8 1 1 kg m
5 8 8 0 ft lb
SBR121 Input rod lock nut

INSPECTION 16 22 N m
3 Remove fulcrum pin Brake pedal Check brake pedal for the following 1 6 2 2 kg m
can then be taken out items servicing as necessary 12 16 ft lb
3
BR

Service Brake BRAKE SYSTEM
MASTER CYLINDER
H
piston return spring
Reservoir cap Secondary pilton
Fillet
Reservoir
pilton
Prim
Primary piston return spring
teek Yalve
88 8 0 9 0 58 65
0 9 5 1 6 5
tfJ 6 9 8 8 0 7
J
l N m m
ii ft Ib
88 8 0 9 0 58 65
SBA009
DISASSEMBLY
Secondary piston
The brake master cylinder is avail
able only in TOKICO make There is

no interchangeability of repair kits or
component part between NABCO and
TOKICO makes
tha kit
When replacing repair or
component part rtain tha brand

Primary piston
of the brake master cylindar body Ba
sure to part of the same make as SBR011 SBR013
the former ones
I Pry off stopper ring

3 Disassemble piston assembly
5 Unscrew plugs for disassembling
check valve
L Secondary piston
assembly
Primary piston
uembly
a INSPECTION
I Clean all parts in a brake l1uid

2 Check the parts for evidence of
SBR012 abnoimal wear or damage
3 Check piston cylinder
to clear
ance
2 Remove stopper screw Primary

Piston linder clearance
and secondary assemblies can 4 Remove piston cups and discard
piston Less than 0 15 mm 0 0059 in
then be taken out them
4
BR

BRAKE SYSTEM SelYice Brake
2 Install bleeder hose on bleeder

ASSEMBLY Brake tube Lock spring
I valve With brake pedal fully depress
a Replace piston cups and packing ed open bleeder valve to exhaust air
with new ones
Then close bleeder valve and allow
b Apply braka fluid or rubber gre
brake pedal to return Repeat bleeding
to Iiding contact urface of ports
operation until no air bubbles show in
to focilitata aaembly of master cyl
hose
inder
a Be careful not to pla h br ka fluid
J
i Chock 01 0 plug on painted areas
78 88 m
N
b Brake fluid containing air is white
8 0 9 0 m
kg SBA006
and contain air bubbles
58 65 ft Ibl
c Brake fluid containing no air runs
a After installation is completed out of bleeder valve in a solid
bleed brake system Refer to
free of air bubbles
stream
Bleeding Hydraulic System
BRAKE BLEEDING
HYDRAULIC LINE HYDRAULIC SYSTEM
1 Top up reservoir with recom
INSPECTION
mended brake l1uid
Check brake lines tubes and hoses
for evidence of cracks deterioration or a Do not mix two different brand
other faulty braka fluid

damage Replace any
parts b C refully monitor brake fluid le el
If leakage occurs at end around at master cylinder during bleeding

SBR003
joints Ie tighten or if necessary operation
replace faulty parts c Do not reuse drained brake fluid
REMOVAL AND 3 Bleed air in the following se

INSTALLATION
Rear wheel
quence Master cylinder
To remove brake tube disconnect Front wheel
flare nuts on both ends and remove
Air bleeder I
retainers and clips J
i e
6 9 8 8 N m
0 7 0 9 kg m
CAUTION 5 1 6 5 ft Ibl
When removing or installing brake
tubes use Tool GG94310000
SBROOS
To remove brake hose first remove
l1are nut securing brake tube to

hose then withdraw lock spring
Next disconnect the other side
Do not twist brake ho e
BR 5

Do notdisassemble NP val e
NP VALVE
Brake tube f1ere nut
wheel If
e Front
cylinder 15 18 N m
Front wheel 11 5 1 8 m
kg
cylinder 11 13 ft Ibl
NP waive to body
3 9 4 9 N m
4 0 5 Irg m
0
2 9 3 6 ft lbl
SBROO1
FRONT DISC BRAKE N22
9 9 53 72
J12
i 91 1 3
a1
Dustse
Piston eal cfuc bJake grease
Apply
Replace at each disassembly
Cy1inder body
r ainingring
aet
You holder
Installed by pressing force
II
D
Minimum thickness 196 294N
20 30 leg 44 66 Ib
10 5 0 413
I
1
Yoke
Spring
rupj 21 16 2 1 12 15
Pad
WeaJ limit
1 lb
Jt
J
i N m m
Ieg
Unit rom in
J 2 0 08 SBA014
6
BR
PAD REPLACEMENT
CAUTION
I Remove clip Remove pad pins Piston can be easily pushed in by
holding springs with finger hand but if pushed too far groove
of piston will go inside of piston
seal At this point if
piston is pressur
ed or moved piston seal will be
damaged If piston pushedhas been
in too far caliper
remove assembly
and disassemble it Then push piston
out in direction shown by arrow
Assemble it again referring to the

following
Piston seal
SBA015
Piston B Y
2 Normal
POSitiOn
2 Detach pads
Do not push too far

CAUTION
After removing pads do not depress BR780
brake pedal or pistons will jump

out REMOVAL
I Disconnect brake tube

Install inner Pull yoke to
4 pad
outer side
SBRG16
3 Open bleeder valve Push piston SBA230
B piston in until dust seal

outer
groove of piston B coincides with

end surface of retaining ring on dust
seal
2 Remove caliper assembly
5 Install outer pad

Coat the following points with
recommended pad grease
Cylinder body to pad clearance
Pad pin to pad clearance
Pad pin holes of cylinder body
Do not grllll8 friction face of pIId
Then install pad ftxing parts pre

viously removed
BR 7

Service Bl1lke BRAKE SYSTEM
DISASSEMBLY 4 Remove piston seal Gripper and oke holder
Piston seal must be replaced at

Remove pads Check for wear cracks or other
each d bly
Remove damage Replace if any fault is detect
fIXing bolt and separate
ed
yoke and cylinder body
01
ASSEMBLY
I Apply rubber or brake l1uid
D SBR020
grease
to seal grooves and seals Install piston
BR740 seals taking care not to damage them
INSPECTION
CAUTION
Use bfllke fluid to clean Never use
J minefllloil
BA741 Cllnder bod SBR021
I Check inside surface of cylinder

for score rust wear damage or
2 Remove yoke holder retaining
presence of foreign substance If any
rings and dust seals from both pistons surface fault i detected 2 Apply rubber grease or brake
replace
cylinder body l1uid to sliding portions Insert pistons
2 MinoJ damage from Just of
CAUTION
Dust seal foreign sub tances may be eliminated
Iniert piston A in direction shown by
by polishing surface with a fme emery
arrow Q1 and piston B in direction
cloth If damage is major cylindCJ
assembly must be replaced shown by BrroW 02
Yoke
B When inserting pistons be careful
Check for wear cracks or other
not to insert too far Refer to Pad
damage Replace if any fault i detect
for assembly
Replacement
ed
8R742 b Instan piston A 10 that its yoko
groove coincides with yoke groove
of cylinder
3 Push out pistons from cylinder
PIston
tonA
Check piston for score rust wear
damage or presence of foreign sub

stances Replace if any fault is detect PistonB
ed 1
t
CAUTION Q2
Piston sliding surface is plated 00 not

I
polish with emery paper eveil if rust or
foreign matter is sticked on sliding
surface
SBR019
BR B

BRAKE SYSTEM Vice
Se Brake
3 Install dust seal and clamp secure

CAUTION
ly with retaining ring When pressing yoke inlo yoke holder
Apply recommended disc brake
a be to insert yoke vertically so as
su re
grease to sealing surface of dUlt not to crack or chip yoke holder If

1
yoke holder is damaged or pl8uing
b Be careful not to deform dust seal force is out of specification replace
c Wipe off excess grease with alcohol with a new one
i
n
I
Preaing force SBR232
196 294 N
20 30 kg
44 66 Ibl Rotor repair limit
Maximum runout
Total indicator reading at
center of rotor pad contact

su rface
0 12 mm 0 0047 in
SBR022
3 Pariille lism
BR959
4 Install yoke holder to piston A

Install gripper to yoke Apply a
coating of 1 soap water to inner wall
6 Install pads Refer to Pad Replace
of gripper and drive in collar
ment for installation
ll
T FRONT DISC ROTOR
L
SBR233
REMOVAL AND
INSTALLATION Rotorrepair limit
Refer to section FA Maximum parallelism
Circumferential direction
0 07 mm 0 0028 in
BR745
INSPECTION
I Sliding surface 4 Thickness

If there are cracks or considerable
Standard thickness
5 Install yoke to yoke holder and chips repair or replace
2 Runout 12 5 mm 0 492 inl
supporting end of piston B press yoke
into yoke holder by using press or Adjust wheel bearing correctly Rotor repair limit
hands Measure mnout Minimum thickness
10 5 mm 0 413 in
BR 9

2 I
C1l m en en lm 3
aIII IIa a It n m aII III I
IIz NZ I
in
Pring mm SBA037
Unit
body Return
Retainer CyUnder
r
A lever
Tog le
Ipring
Yoke
I
cover
ke
Spring
spring
thicknes 339
lueal
Anti
Minmu
0
Rotor 6
grease
rins brake instaling
when
ap ly sides
Retain g to
sure both
Shim Be to
Pad
limit 063
0
Wear 6
J
o

BRAKE SYSTEM Service Breke
PAD REPLACEMENT Nissan silicone based grease or equiva

I Remove clip Remove pad pins lent
holding springs with finger Silicone based greasing points

Friction surface of yoke and cyl
inder body
LL Cylinder body pad pin hole
Then install pads fIxing parts pre
viously removed
REMOVAL
I Disconnect brake tube
5 Install pads and shims

SBR03B
Position outer piston so that por
tion of cutout is level and install pad

by aligning this portion with protru
2 Detach pads and shims sion at back of pad
CAUTION Align
After removing peds do not ss
dep
breke pedel or pistons will jump out
SBA041
Ie I
I
J 1
2 Remove caliper assembly
Ie D
J
r
7 rf
Jrr BR191A
1 Coat the following points with re

1111
commended pad grease
I
I
Cylinder body to pad clearance
Y oke to pad clearance
SBRD42
Pad pin to pad clearance
3 Retract outer piston into cylinder
Pad pin to bracket clearance
body by turning it clockwise and push
ing it in Be careful not to demell8 8 Do not grease friction face of pad DISASSEMBLY
dust seal b Be sure to apply pad grease to both I Separate cylinder body from
sides of shims
yoke by pushing it
Fllt blade screwdriver
BR173A
SBR234
4 Move yoke until clearances to in

stall pads are equal with a lever placed 2 Check that the following points 2 Remove retaining rings and dust
between rotor and yoke are coated with silicone based grease seals
BR II
ServiceBrake BRAKE SYSTEM
Replace dust seal at each di m 6 Disassemble outer piston by re
bly moving snap ring B
Snap rilll
BAlBOA
Piston 2 hole in
SBA043 SBR045 Engage square key plate
with push rod Also engage convex in
3 Drive out piston assembly by key plate in concave in piston

7 Disassemble inner piston by re
pushing outer piston in
moving snap rings A and C
Snap ring remover
SBR048
SBRD46
3 Install spring seat spring spring
cover and snap ring A with suitable
4 Remove piston seals
8 Remove hand brake lever press and drift
toggle
Replace piston seal at each
di
sembly by removing return spring and nut
Remove dust seal and cam
Nut
Return spong
tt
Drift
Toggle lever
8
5 Disengage piston assembly

SBA044
LDust
Caml seal
SBR047
4
gle
When installing parking brake tog
lever after assembling piston turn
SBA235
by cam in direction parking brake opera

turning inner and outer pistons tes
ASSEMBLY
I Before assembling apply thin
coat of rubber grease to the following
e Groove in push rod and new O ring Toggle lever
Strut ends
Oil seal
Piston seal
Inside of dust seal
Securely install oil seal in specified
direction
BR 12

5 Apply rubber grease or brake l1uid II Coat the following points with REAR DISC ROTOR
to seal grooves and seals silicone based grease
6 Install piston seals Frictional surfaces of yoke and cyl
REMOVAL AND
inderbody INSTAUATION
Cylinder body pad pin hole
Remove caliper and rotor can be
taken out
fi
INSPECTION
I Sliding surface
o If there are cracks or considerable
chips repair or replace
2 Runout
Adjust wheel bearing correctly
SBA044
Measure runout at the center of rotor
pad contact surface
7 Apply rub ber grease or brake l1uid
to sliding portions
8 Apply rubber grease to one hole
Diameter 1 5 mm 0059 in of l
outer piston as the figure shows Then
insert
arrow
piston assembly
1
in direction of H SBR243
I
Silicone based greasing point
1 Yoke 3 Pad pin

2 Cylinder body
rl 12 Assemble yoke and cylinder with

retainer
Rotor repair limit
j
out on
Inne pi
l QI YOke
Retainer
Maximum runout
Total indicotor reading at
center of rotor pad contact
surfacel
fJ
0 15 mm 0 0059 in
3 Parallelism
Di m r
1 5 mm 0 059 in
r SBR049
L SBR245
13 Install pads Refer to Pad Replace
ment for installation
9 Install dust seals and clamp se

INSTAUATION
curely with retaining rings
10 bolt
Install yoke spring fl Coliper fixing SBR050
38 52 N m
Rotor repair limit
3 9 5 3 kg m
Maximum parallelism
28 38 ft Ib
Circumferential diroctionl
After installation depress brake 0 07 mm 0 0028 in
pedal few times to properly adjust
brake pad to rotor clearance and 4 Thickness
check for oil leakage When brake
Sblndard thicknou
pedal stroke is constant brake
pad to 9 6 mm 378
0 in
rotor clearance is properly adjusted It
Rotor repair limit
will be automatically adjusted by
Minimum thickness
BR181A
depressing brake pedal 8 6 mm 0 339 in
BR 13

BRAKE BOOSTER
D
IJp hngm
Cheek valve
Pisto
I
j Valve turn spring
11 0
Fins rJ
Fulcrum
plate
l I
ID
Front meD
SBR059
INSPECTION 2 Start
engine and increase engine 3 If vacuum pressure drops more
speed Stop engine when vacuum is than the specified value correct
Air tight test No load 66 7 kPa 500 mmHg 19 69 inHg the cause in accordance with the
1 Connect following chart

a vacuum gauge between
check valve and brake booster
Maximum vacuum leekege

15 seconds after engine is stopped
3 3 kPa
25 mmHg 0 98 inHg
J 60
coo
HI J
76
SBR216 saRD D
Air leakage at check valve Inspect check valve
Air leakage at output rod seal
Air leakage between valve body and seal Replace brake booster as an assembly
Air leakage at valve plunger seat
Damaged piping or joints Repair or replace
BR 14

Air tight test Under loed Maximum vacuum leakage Operetlng test
15 second after engine i toppedl 1 Connect an oil pressure gauge to
Keep brake pedal fully depressed
3 3 kPa brake line at connection on master
Following procedures are same
25 mmHg 0 98 inHg cylinder
as for noload conditions
2 Install a pedal force gauge on
brake pedal
Probable cause Corrective action 3 Start engine and increase engine
speed until a vacuum pressure of 66 7
Air leakage at check valve Inspecl check valve kPa 500 mmHg 19 69 inHg is reo
gistered on vacuum pressure gauge

Damaged diaphragm With asteady vacuum pressure of 66 7
Replace brake booster as
kPa 500 mmHg 19 69 inHg measure
Air leakage at poppet assembly seat and an assembly
oil pressure with respect to each pedal
valve body
operating force
Relationship between oil pressure
and pedal operating force is illustrated
in Fig If test results are not as speci
Check velve 4 Whenpressure is applied to the fied check brake booster for con
brake booster side of check valve and
Remove check valve dition in manner described under
valve does n open replace check
Inspection before removal of this
valve with a new one
unit
Also check brake line for evidence
M T model of l1uid leakage
de
ManVifOI
1 Determine whether source of pro
j @
blem is in brake booster or check
With cooler Lc valve Before you reach a final conclu
Brake booster side

sion always inspect check valve fint
SBR061
SBR063
2 Apply a vacuuin pressure of 26 7

kPa 200 mmHg 7 87 inHg to the
port of check valve on the brake

booster side 11 770 120 1 710
I I
I
M
e
10 190
9 810 100
110 1 500
1 420 I
II jj
Manifold side
8 830
1 850
90 1 280
80 1 140 1
I
e 6 860 10 1 000
l
jf
I
e 5 880 60 850
4 900 50 710 f 66
I
tfl
u
ii 3 920 40 510
If I
2 940 30 430 J
S I
L
u
1 960 20 280
980 10 140
r J
td J I I
M
Brake booster side 0

o 981 1 961
SBR062
100 221 200 441
Rod operating force N kg lb
3 If pressure drops more

vacuum
than the specified value in 15 seconds

check valve with 8
replace a new one
0
0
0 6 6
Maximum vacuum leakage 6
of check 01 0
Pedal operating force N kg Ib
1 3 kPo
SBR074
10 mmHg 0 39 inHg
BR 15

S8rvics Brake BRAKE SYSTEM
REMOVAL Check length

r
To remove brake booster detach Langth AH
the 9 75 10 00 mm 10 384 0 394 in
following points
u
j
B
BR110A
1 1
S8A064 BR109A INSTAllATION
IiJ M cylinder to brake booster

7 8 10 8N m
10 8 1 1 kg m
2 If length is not within specifica 58 8 0 ft Ibl
tions replace brake booster assembly
Brake booster to body
7 8 10 8 N m
10 8 1 1 kg m
ADJUSTMENT 58 80 fHbl
Input rod length
Output rod length Input rod lock nut
Adjust length by turning clevis 16 22 N m
PV seno cannot be adjusted as Length 8 11 6 2 kgm
output rod thread portion is secured 130 mm 5 12 in 12 16 fHb
by adhesion
PARKING BRAKE
PARKING BRAKE
REMOVAL
Control lever and front cable

Front cable
Remove console box
Disconnect harness connector Re

move control lever
SBA066
SBR067
BR 16

BRAKE SYSTEM Parking Brake
2 Remove grommet rubber and

CAUTION
lock plate Disconnect cable adjuster
Be careful
control lever
not to deform or damage
L
Front cable clevis pin and cotter
l
pin are available as Hrvice parts
t IJ
r
SBRQ73
SBA068
Rear cable
Disconnect cable adjuster INSPECTION

Remove lock plate and strap or
I Check control lever for wear or
3 Pull front cable out into driver s cable clamp other damage Replace if necessary
compartment 2 Replace worn or fatigued spring

3 Check wires for discontinuity or
deterioration Replace if necessary

4 Replace malfunctioning warning
light or switch
5 Check parts at each connection
and if found deformed or damaged
replace
INSTALLATION
SBR071
When installing front cable to le r
SBA069
u specified elevis pin end cotter pin
I Apply a coat of grease to sliding

contact surfaces
4 If necessaryseparate front cable 2 Remove lock plate and disconnect 2 Adjust parking brake system after
from parking brake lever by breaking rear cable from lever by removing completed Refer to Sec
installation is
tion MA for adjustment
pin and replace front cable cotter pin
BR 17

Service OataandSpecifications lAKE
Bf SYSTEM
GENERAL SPECIFICATIONS BRAKE BOOSTER
I Type DiscN22 Maximum vacuum leakage 15 s8cond after

3 3 25 0 981
engine iutopped kPa mmHg inHg
J Cylinder inner die mm in 53 98 2 1 8
Front Output rod length A

9 75 10 00
Pad mm lin 52 9 x 9 7 x 76 2
mmlin
0 3839 0 39371
Width x thickness x
length 2 083 x 0 382 x 3 0001
Input rod length S mmlin 130 5 12
I Rotor outer die mm in 253 5 9 98
I Type Disc AN12 H
r
I Cylinder inner die mm in 40 4611 5929
r
Rear
Pad
IW
I
in 42 0 x 10 3 56 8
I
mm x
Width x thic ness xlength 1 654 x 0 406 x 2236
IMa ter
I
cyljnde
Rotor outer dia
inner die
mm
mm
in
in
269
22 23
10 59
7 8
J
I Brak
NP valve
booster type
Split point
kPalkg cm2 psi reducing
452
2
P75
25 356 x 04
I
J BR109A
r
B
8Rll0A
ratio

BRAKEPEDAL CHECKYALYE
Unit mm in Maximum vacuum

leakage 15 seconds after
26 7 kPa 200 mmHg 7 87 inHg pressure 13 to 0 391
I Pedal play 8 5 0 04 0 201 is applia

tJ kPa mmHg inHg
I Depressed height d More than 60 2 36
I Pedal height h 155 t6t 6 10 6 34 DISC BRAKE
Unit mm in
PARKING BRAKE
Type
N22 AN12H
1 Pulling force N kg Ibl 196 20 441 Item
I Number of notches 7 8
I
Pad wear limit
2 0 0079 16 10 0631
I Stroke mm in 90 100 3 54 3 941

Minimum thickness
Rotor repair limit

0 1210 0047 0 15 10 0059
Maximum I unout
MASTER CYLINDER
Maximum palallelism 0 07 0 00281
clearance between
I
N8ble
Allo Less than
cylinder and piston mmOnl 0 15 0 0059 I Minimum thickness 10 5 0 413 8 6 0 339
BR 18

BRAKE SYSTEM Service Oat1l and Specifications
TIGHTENING TORQUE
Unit N m ft Ib
m kg
Brake tube flare nut 15 18 15 18 11 13
I Brake hose connector 17 20 17 20 t2 t4
I Air bleeder valw 69 88 7

0 9
0 5 1 65
Fulcrum pin fixing bolt 78 10 8 08 11 5 8 8 0
Brake booster to body 7B 10 8 OB 11 5 8 8 0
I nput rod lock nut 16 22 16 22 12 16
Flange to shell ver 7 8 10 8 0 8 11 5 8 80
broke
I
Mascylinder to
78 10 8 0 8 11 5 8 80
booster
IIXI
I Front disc
I
per
72 97 7 3 9 9 53 72
bolt
I
Front disc rotor fixing
36 52 3 9 5 3 28 38
bolt
Rear disc caliper fixing

38 52 3 9 5 3 28 38
bolt
Baffle plate fixing bolt 22 26 2 2 2 7 18 20
Brake lamp switch lock
I nut
12 15 1 2 1 5 9 11
I way
3 connectOr bol t 17 20 1 7 2 0 12 14
I NP valve to body 39 49 4 05
0 2 9 3 6
BR 19

Trouble Diagnoses and Corrections BRAKE SYSTEM
Excessive pedal travel Low brake l1uid level or empty master Fill and bleed as necessary Test for source
cylinder reservoir of leakage by examining aIllmes and connec
tions
Leakage in master cylinder Overhaul master cYlinder

Deteriorated check valve Replace check valve and bleed system
Air in system Bleed system
Faulty brake adjustment Adjust pad to rotor Inspect auto

clearance
adjuster operation
Excessive lateral play on disc caused by Replace or adjust faulty parts
loose or worn wheel bearings or steering
parts
Spongy pedal Low fluid level in master cylinder JoP with fluid and inspect fa leakage
Air in system Correct as necessary
Faulty brake adjustment Adjust pad to rotor clearance Inspect auto
adjuster operation
Reservoir filler cap vent hole clogged Clean and bleed system
SwaDen hose due to deterioration or use of Replace hose and bleed system
poor quality hose
Distorted brake moes or excessively worn Replace faulty parts

or cracked brake drum
Soft or swaDen caliper seals Drain hydraulic system l1ush with alcohol
and replace ail seals
Use of a brake l1uid with too low boiling Replace with specified brake fluid and bleed
point system
Poor braking effect Fluid leakage in brake line Check master cylinder piping and caliper for
leaks and repair
Low brake fluid level or empty master Fill and bleed as necessary
cylinder reservoir
Air in brake lines Bleed system
Grease oil mud or water on pads Clean brake and check for
mechani cause
of problem Replace pads

Deterioration of pads Replace
Local fit of pads Shave or replace
Pads excessively worn Replace
Master cylinder Or caliper assembly in poor Repair or replace

conditions
Frozen or seized caliper pistons on disC Disa semble caliper and free up a required
brakes
Binding mechanical linkage at brake pedal Free up as required
BR 20
BRAKE SYSTEM Trouble Diagnoses and Corrections
Unbalanced brakes Improper tire inflation Inflate to correct pressure
Improper auto adjustment of pad to rotor Readjust

clearance
Grease oil mud or water on pads Clean brake mechanism and check for cause
of problem Replace pads
Mud in rotor Clean
Deterioration ofpads Replace

Excessive wear of pads Replace
Caliper cylinder in poor condition Repair or replace
Looseness of caliper assembly securing bolts Fasten or replace
Scored or of
out round rotor Recondition or replace rotor as required
Check for improper pad contact with rotor
and grind pad if necessary
Incorrect adjustment of wheel bearings Adjust or replace

Incorrect adjustment of wheel alignment Adjust
Brakes fade Brake l1uid has too low boiling point Drain and flll system with approved l1uid
Use of improper pads Replace

Brake rotor is of
out round Repair or replace as necessary
Hydraulic connections master cylinder and Repair as necessary

caliper cylinders are corroded or damaged
Bleed screw is open Close screw and bleed system
Brakes drag Pedal linkage is binding or output rod adjust Lubricate linkage check pedal return spring
is too long
ment for condition and adjust output rod as neces
sary
Master cylinder compensator part is ob Blowout matter with compressed

foreign
structed air
Seized master cylinder piston Disassemble master cylinder and replace

piston Bleed system
Poor pad condition Clean and repair
Poor caliper cylinder condition Repair or replace

Deformation of piston cups Replace
Poor condition of caliper because of faulty Replace piston seals
piston seals
Excessive ronout of rotor Turn rotor on lathe or
replace
Hand brake will not return Check and repair
Clogged master cylinder return port Clean
Clogged brake lines Check and clean
Incorrect adjustment of wheel bearings Adjust or repair

Improper pad to rotor clearance Adjust
No free travel in brake pad return Adjust pedal height
BR 21

SpeciafService Tool BRAKE SYSTEM
Brake chatters Groove or of

out round rotor Grind or replace as required
Loose or bent support plate Tighten support plate bolts to specified
torque or replace plate
Distorted pads Replace as necessary
Grease or brake fluid on pads Replace pads
Brake squeal Dirty or scored rotor Blowout assembly with compressed air or
refmish rotor
Bend support plate Replace faulty unit
Glazed or contaminated pad Grind pad to eliminate glaze If it doesn t

replace pad
Pedal pulsates Lateral roDout of brake rotor is excessive Check with dial indicator turrting disc by
hand Ifrunout exceeds specification
repair
or
replace disc
Excessive variation in thickness of brake Measure around disc face with micrometer
rotor surfaces Replace disc as required
Rear lock Improper tire pressures Check and adju t

under light brake Excessive wear of tires Check and replace
pedal force
Faulty NP valve Replace
Rear lock Improper tire pressures Check and adjust

under heavy brake Excessive wear of tires Check and replace
pedal force
Poor front braking effect
Grease oil mud or water on pads Clean or replace

Excessive wear pads Replace
Local fit pads Shave or replace
Master cylinder or
caliper cylinder in Repair or replace
poor condition
Tool number
Tool name
Kent Moore No
GG943 10000 Flare nut torque wrench

u
BR 22

SECTIONST
STEERING SYSTEM
CONTENTS
STEERING SYSTEM ST 2 SERVICE DATA AND

STEERING WHEEL AND COLUMN ST 3 SPECIFICATIONS ST 21
STEERING WHEEL ST 3 GENERAL SPECIFICATIONS ST 21
STEERING LOCK ST 3 INSPECTION AND ADJUSTMENT ST 21
STEERING COLUMN Collapsible type ST 4 TIGHTENING TORQUE ST 22
STEERING GEAR Model VRB47l ST 6 TROUBLE DIAGNOSES AND

CORRECTIONS ST 23
POWER STEERING GEAR
SPECIAL SERVICE TOOLS ST 25
Model I P S 56l
AIiID Oil PUMP ST 10
STEERING LINKAGE ST 19

50
lTIr pO
SST
Cl
Iti Wi
fft
36
46
8
46
38 I
n
gteaoil
ste 1
P
ap 3 29 3
603
Purl
direction
UI
haft ternbW
3
8
m n8
tcet 0 6
g
1
frame
3
di d to
snou
dam or not 5 5
a 3
5
thaft MoIti
2
m
21 of
wil
to do 101 35
c
0
wor1 62 bOdY5
62 fod
case ap lied coupUns
a 4
tj
notpole
0
to
end IID
bea 45
0
nllpt
2 l a
bt1 51
column omtuuer nOStIldtne dleshafuUlt cancel
5 e
4 49 52
ctOS
umntube
n Wheninsu
lins
@
0
I1L 52
l
8
sttik at be ll fotc tube 35

39 10 cer 22
Vlbe l 3
a ltefu
c S utJ
ttt
40
3
lbCl
tlU
teerl Vv 0
and
bendin5 column
in
not
5
1
DO ste rin ith
W age co fie age eo
ef
Ne
4ue
co
in
et
jael 1
0
rm
a
Ste lng
IY
Ste ing 3
69
1C
n
29 to
tad
lon Side
t
I
r
i1
s
ll
@
et
bracl
B tod
28
OS
mount 9 tad 12
8
1
24 haft 46
11 12 055 58
ClOS
9
8 tub IY 38 bly
40
nd 0 and
31
column
I 3 0 0
0
10 arm
S
18
2
u
6
tat le 23 5
atm 0
8
e
503 d
nuc
Ste B tad
KnUc
3 5
98
56L bOdY
4
tame Side 9s
62 0
2
0
3
ol 18 1
52
Ste til
S
54
r
42 bOdy J
81m 0
141 3
51 ann
hot 22 idle I
12
rod
eto
s
10
ute
pipins
0
1
0
3
and
aun
dote rit iscon ect
S be
fif4
inatl1
lleJ
ro
40 uto d
l ing
1I and pte 1JVI 69 eaI d
pipins tad
t
0 Il
V 0
29 To and
nt11l
cOlumn
d lle
ca
l Il
g
1l 00 nd
em1M 5
de
5
nl
COvel
tOd
98
54
gnuc 0
1
meel ttlnS emovlng gtound dutt
SId Q
St When l
altetY Eacb

STEERING SYSTEM Steering Wheel and Column
STEERING WHEEL AND COLUMN
I Remove steering wheel using Tool

STEERING WHEEL 8T27180001
2 Remove steering column shell
REMOVAL cover

2 Remove horn pad and steering
wheel nut y
1 Upward
SST069
Igi
2 Install steering wheel
ahead
on column
Ii
shaft in a straight position SST072
SST067
3 Break self shear type screws with
a drill or other appropriate tool
4 Remove screws and disconnect
steering lock
3 Remove steering wheel using
Tool screw
Self shear type
CAUTION
SSTU70
Do not strike end of steering column
shaft with a hammer Striking shaft
will damage bearing or column shaft
3 Tighten steering wheel nut
J n
l 51 N m
13B 52 kg m
27 38 ft lb Screw SST073
80001
INSTALLATION
I Align steering lock hole in steering

column tube with mating portion of
steering 10cL
SST068 SST071
2 Install and self shear type
screws
screws and then cut off self shear type

screw heads
4 After installing steering wheel
bJm it clockwise and counterclock
wise for catch or drag Also
checking
check horn operation
V
STEERING LOCK
V
INSTALLATION
Inltall ltaering wheel in the
reverse order of removal Observe the REMOVAL Self shear screw
following instructions Before removing steering lock dis

SST074
I Apply grease to sliding portions connect battery ground cable
ST3

Steering Wheel and Column STEERING SYSTEM
STEERING COLUMN Collapsible tYPe
Steering column asRmbly

Never in any case should undue
stress be applied to steering column
fJ 37 51
in axial direction 3 8
When installing do not apply bending
force to steering column S
Steerinj k
Cn tte
Jacket tube bracket
Steerins
fJ 3 4 44 0 35 0 45 2 5 eel oolw
To dash panel
S eerillj oolumn bly
tiJ 13 18 3
1 18 9 13
To instrument panel
Steerillj oolumn
Cnuplinj Plat 16 aaembly
Column band
j fJ 39 49 4 0 5 0 29 36
To worm shaft
Z32 38 3 3 3 9
To stub shaft
24 28
@ N m rn
kj ft Jb Pl S 56L only
Model
SST125
REMOVAL
4 Remove steering column shell Remove
6 heater duct from dash
I Disconnect
battery ground cable covers
panel side
2 Remove bolt securing stub shaft 5 Remove combination switch as
or worm shaft and universal joint or sembly

rubber coupling
al
SST078
SST076
3 Remove steering wheel Refer to
Steering Wheel
4
ST

I
STEERI NG SYSTEM Steering Wheel and Column
7 Remove jacket tube bracket from 2 Set wheels in a straight ahead INSPECTION
dash panel position I When

steering wheel can not be
3 Fit steering column assembly on
rotated smoothly check the steering
to stub shaft or worm shaft
column for the following matters and
Carefully install so that punch mark
replace faulty parts
at top ond of column haft fece I Check column bearings for darn
upward
age or unevenness If so lubricate with
J
4 Tighten stub shaft or worm shaft recommended multi purpose grease or
securing bolts temporarily to upport replace with a new one as steering

upper side of steering column assem
column assembly
bly 2 Check jacket tube for deforma
5 tion or breakage and replace if neces
Tighten column mounting bracket
SST079
temporarily sary
6 After sliding jacket tube bracket 3 Check column spring and replace
to dash panel tighten nuts to retain if damaged or weakened
8 Remove column mounting 2 When the
it car comes into light
bracket collision check the following parts
Iil 3 4 4 4 N m
and replace if necessary

0 35 0 45 kg m
I Jacket tube
2 5 3 3 ft Ibl
Measure dimension L
When jacket tube is crushed
7 Tighten stub shaft or worm shaft
dimension L is reduced
securing bolts and then tighten column
p mounting bracket securing bolts

JJ Worm shaft to
Model VRB4711
coupling
j I or SST1 39
39
29
40
49 N
5 0 kg
36 ft Ibl
m
m
L1
t
F
LL J
Stub shaft to universal joint Column length L
Modell P S 56Ll Model VRB47L

9 Draw out steering column assem
179 mm 7 05 in
32 38 N m
bly from room side ModoII P S 56L
3 3 3 9 m
kg 180 mm 7 09 in
24 28 ft Ibl SSTOBO
Column mounting bracket

13 18 N m
1 3 1 8 kg m
9 13 ft Ibl
INSTALLATION
Install steering column in reverse CAUTION 2 Column mounting bracket
order of removal I Mike Rife that Iny undue strea is Make sure column mounting
not Ipplied to rubber coupling bracket touches block
I Remove column band and then b To Ivoid dlmlging bolt or serrl Standard B dimension is 0 mm 0
installcentering band lS
P 56L tions align groove in stub shaft or in
equipped model only worm shaft with bolt hole in rubber When jacket is crushed dimension
coupling B is increased
9 Remove centering band and then

jg
install column band PS
l 56L
model only
equipped
@ 10
Steering
Install
Wheel
steering wheel Refer to
8 After installation make sure that

SST126 Centering band ST835
steering wheel turns smoothly
ST 5
m
Steering Gear Model VRB47L STEERING SYSTEM
STEERING GEAR Model VRB47L
Lock nut
cp 29 3913 0 4 0 22 29
F l1
d1erpl
J 15 25 15 25
11 18 SeetorsIWlCOV
v to
0
Lo
Goskel
J
rt Adjustm shim
5 314 25 32 181 231
Oil I
Refer to S O S
Removed oil seal must not be used agJ l1L
Sector shar adjusting 0
saew
When adjustirj h use
backla it Adjustins Pilla
When adjust wonn bearing
preload use it
Sector maft
BaD nut and worm assembly
Be a rcful not to allow ball nut to run
down to either end of worm

The end ofba1l guides will be lamag
if nut is rotated until it stops at the em
Steering gear housing of wonn
Do not detach ball nut from worm shaft
assembly
If necessary replace ball nut and worm
assembly with sector shaft
147
N q m ft Ib
15 94 108 J
I m
SST081
Worm shaft to rubber couplin

J
I 39 49 4 0 5 0 29 36
the
Align groove in worm shaft with
the bolt hole in rubber coupling
flange
yoke and prcssooupling bolt through
the undercut section of wonn shaft
Undercut section
1
Sector shaft to idler arm
J 127 147 13 15 94
I 108
Remove gear arm
Sf29020001
Install gear arm
Gear housing to frame

four
Align grooves of gear arm
J52
1 625 3 6 3 38 46
serrations with four projections
of sector shaft serrations and
install and tighten lock washer J
I N m m ft Ib
q
and nut
SST082
ST 6
STEERING SYSTEM Steering Gear Model VR847L
DISASSEMBLY
CAUTION
Before disassembling by hand
a Be careful not to allow ball nut to
make sure external is clean and free
from dust and dirt andthoroughly
7fY run down to either end of worm
0
Ends of ball guides will be damaged
drain gear fluid by removing filler if nut is until it stops It end
plug of worm
1 Place steering gear in a vice using
b Do not detach ball nut from worm
Tool KV48100301 in place
shaft assembly
2 Set worm gear in a straight
ahead
If necessary replace entire unit as
position
SST083
en assembly
c Do not remove sector shaft needle
bearings from steering gear housing

If necessary replace entire gear
5 Remove sector shaft cover from housing IS an asSembly
sector shaft
6 Remove sector shaft oil seal if
necessary
ST725
3 Remove sector shaft cover fixing

bolts
SST086
KV48100301 SST084
9 Remove oil seal from adjusting

plug using Tool
4f
7 Loosen adjusting plug lock nut
L using Tool
ST35322000
4 Remove sector shaft with sector
shaft cover
CAUTION SST087
a When pulling sector shaft out be

careful not to damage oil seal or
SST085
associated parts
b 00 not remove sector shaft needle
bearings from steering gear housing
If necessary replace gear housing ASSEMBLY AND
8 Draw out worm
gear with worm
assembly ADJUSTMENT
bearing
Before assembling and adjusting by
hand meke ure each pert i elean
and lubricate with fluid
geer
Fill paee between Iing lip of
new ctor h ft and adju ting plug
oil 1 with rlICOmmendad multi
purpose grease
ST7
Steering Gear fModel VR847U STEERING SYSTEM
Worm bearins preload lock Tooh 2 Install sector oil adjusting

5 Tighten nut using cover
screw with sector shaft

1 Fit worm gear assembly with
KV48101500
worm bearing in gear housing
Adjusting screw
KV48101400
SST091
SST094
SST088
6 After tightening lock nut check
worm bearing preload to make sure 3 Set worm gear in a straight ahead
it is within specification
position
2 Install adjusting Tool
plug using 4 Insert sector shaft and sector
KV48101400 assembly with into
cover gasket
3 Adjust worm bearing preload gear housing
using Tools Sector shaft end play Carefully insert sector shaft in
place using care not to scratch oil seal
Select suitable adjusting shim and
CAUTION
adjust end play between sector shaft
Always adjust worm bearing preload and adjusting screw
by turning adjusting plug in tighten Sector shaft adjusting screw shims

direction
Refer to S O S
Rotate worm shaft a few turns in Adjusting him
both directions to settle down worm

Upper
bearing
Worm
and measure preload
bearing preload with oil sean

sector
side
cover
I
0 39 059 N m
40 6 0 kg em 35 52 lb Sector shaft end play

O Ol 0 03 mm
10 0004 0 0012 n
5 Tighten sector cover to gear
housing
Steering gear preload

I Press oil seal to steering gear
housing using Tool

Before pressing oil seal coat seal
4 contacting face of oil seal with gear

Apply suitable liquid sealant
around lock nut inner surface fluid
f
1iJ15 25 N m
sealant 11 5 5 kg
2 m 11
Apply
6 Pour recommended gear oil into

assembly through flller hole and
install ftller plug
Adj usting plug refill

Specified capaeity
Lock nut Approximetely 0 28 liter
SST090 5 8 US pt 112 Imp pt
8
ST

STEERING SYSTEM Steering Gear Model VR841Li
2 move freely
Sector shaft If ball nut does not
7 Tighten adjusting screw so that gear
over entire stroke replace assembly
preload is within specification Check gear tooth surface for
pitting burrs cracks or any other Be careful not to damage ball nut
CAUTION and if
damage replace necessary
guide tuba whi Ie check is being made
Always adjust steering gear preload by 2 Check sector shaft for distortion
turning adjusting screw in tighten on its serration and replace if neces
direction Also CAUTION
sary check gear housing for
deformation Be caraful not to allow ball nut to run
Rotate worm a fsw turn in down to either end of worm

gear
both directions to settle down steering
gear and then measure steering gear

preload in a streight
lhead position
Steering worm assembl
I Inspect ball nut gear tooth sur

face and teplace if pitting burrs
wear or any other damage is found
2 Ball nut must rotate smoothly on
worm gear If found too tight assem
LScrewdriver J bly should be replaced

Check rotation of ball nut as Beulng
Steerinlllilear total preload
1
Inspect worm bearing for wear
with oil follows I
Less than 1 23 N m 12 5 cm
kg
I Move ball nut to either end of pitting or any other damage Replace
10 9 in I b
04 06 N m worm gear and gradually stand as requried
4 6
kll
cm 3 5 5 2 in Ib worm shaft and ball nut assembly until
higher than at worm bearing
When replacing worm bearing
ball nut moves downward on worm
praia replace it as 8 set of bearing and
SST097
gear under its own weight outer race
2 If sector shaft needle bearings are
8 If found to be outside of above worn damaged replace as an as

or
steering gear preload specifications sembly of gear housing and bearings
readjust adjusting screw until correct

steering gear preload is obtained Oil eal
Discard any oil seal which has once

INSPECTION
Wash clean all the disassembled
Downward
J been
sealing lip
removed
is
Replace oil seal if
deformed or cracked
own
weight
Also discard oil seal if spring is fa
parts in solvent and check for condi SST098
tion tigued or dislocated
ST 9

Power Steering lear Model I P S 56L andOil PUTflP STEERING SYSTEM
POWER STEERING GEAR Model IP S 56L AND OIL PUMP
DESCRIPTION
The integral power steering unit is a components are as folloW
Po r steering s stem Oil pump
gear housing into which a control valve
2 pool valve type and power Reservoir tank

The power steering gear is licensed cylin
der built compactly The major Power steering gear
I1Y ZF company in West Germany are
Oil piping
Reservoir tank
cfl 2 9 4 9 0 3 0 5 2 2 3 6 cfl 32 38
Gear assembly 3 3 3 9 24
To stub shaft
cfl 49 69 5 0 7 0 36 51
To each hoses
cfl 52 6i 5 3 6 3 38 46
To body frame
High pressure hose

and piping
cfl 2 9 4 9 0 3 0 5 22 3 6
To suspension aossmember
cfl N m kgm ft tb SST12T
Power steering gear Co Should disassembly of integral

CAUTION
power steering gear remain un
The integral power steering gear is a The parts which can be disassem
finished for any reason indicate it
an accurate oil pressure mechanism bled are strongly J and
as Half Disassembled and COVllr
In disassembling it be careful to keep neverdisassemble other parts than
iron powder and other foreign parts with a clean cover
dust the specified ones If parts not
d Hands should be cleaned immedi
particles out ofthe gear housing indicated in the manual are also
ately before disassembly
Only the sealing parts of the gear d Ied replace the assembly e Do not use a rag Be sure to use
assembly can be replaced The remain instead of bling those parts
nylon paper cloth
or
b Disassembly of integral power steer
ing parts must be replaced as an gear f Be sure to follow procedures and
assembly ing gear should be performed in a cautions indicated in the Service
place l5 dean as p ssible although Manual
a dust preventing device is not reo
quired
ST10
PowerSteeringGear Model I P S 56L andOilPump
STEERING SYSTEM
ring
O
Breather
I
cap lock nut
Breather
l6
i 9
screw
8 8 0 7
cf l28
i
Copper washer
34 2 9 3 5 21 25
l26
i
@ 32
J V 2 7 3 3 20 24
fill
@
rins
O
Sector shaft Between sector
adjusting screw cover to gear
housing
Sector shaft
Worm end nlve
mbly With
interm i te
t
cov l
Special washer Small
OUseal
Special washer La
IJle
0 DUst sea1
ru 20
2 7 3 3
24
0il1e3 1
In rear cover
apring
ospring washer
Nut
tY
I l127
i 147 13 15 94 108
Once removed must not be used again To gear arm and sector shaft
l
i N m Icg m ft lb
SST033
011 pump and r volr tank
Malfunctioning Replace as an oil
pump assembly
STll

Power Steering Gear Model I P S 56L and Oil Pump STEERING SYSTEM
REMOVAL
Before removing clean exterion of gear housing and oil pump with steam and dry with compressed air
Steering gear
51
Joint to stub shaft

J 32 38 3 3 3 9
t 24 28
Plug openings of gear housing and

Sector sIWI to sou ann
securely locate hose connectors

J 127
t 147 13 15 94 108
at a position higher than oil pump
and cover with rag
i
Be extremely cucful to prevent
entry of foreign matter into
hoses through connectou
Install gear
Align fOUI
arm
grooves of gear
of sector shaft serrations and

arm
serrations with four projections

j1 J
t N m
m
kg fHb
R points
install and tighten lock washer g
and nut
SST128
Oil pump resevoir tank

and each hose
1 Remove air duct at air cleaner

2 Loosen oil pump pulley lock nut
Turn belt adjusting bolt counter
clockwise
5 Remove oil pump and reservoir

tank 6 Disconnect hoses from oil pump
7 Remove oil pump brackets and
other brackets from engine
8 Unfasten hose clamps and remove
hoses from suspension crossrnember
INSTAUATION AND
ADJUSTMENT
3 Remove oil pump belt
4 Loosen not hoses In tall in the reverse
remove at steering gear
pump order of removal
ST 12

Model I P S 56LJ and Oil Pump
STEERING SYSTEM Power Steering Gear
Fluid level 2 Turn steering wheel to right to

Pressure gauge
left several times calibrate
I Check fluid level in oil pump
3 Hold steering wheel at each lock 9 807 kP 100 kg em2
assembly with dipstick whether fluid
position for five seconds and carefully 1 422 psi
level is on HOT side at normal operat
check the following points for fluid
on COLD side
ing temperature or
leakage To oil pump To control
when oil is cold outlet t
Oil seal at rear cover valve
Intermediate cover Y
Adjusting screw lock nut
fSTi7091000
1 Sector shaft oil seal Shut off valve
Add lllm IOK Sector cover O ring

Oil pressure line connectors
SST036
Q e Oil pump and reservoir tank
4 OK CAUTION
Do not hold steering wheel at lock
position for more thin fifteen seconds
SST133 It I time
Hydreulic system check

Do not overfill with fluid To determine whether problem is
Nanna operating temperature i 60 insteering gear or oil pump measure
to 8o C 1760F
140 to
operating pressure
When running engine make sure Before conducting hydraulic system
fluid level variations in opening oil check belt tension and
test carefully 5 valve
Open off
shut at Tool
pump ere Ie than 2 mm 0 08 in condition of driving pulley
ST27091000
2 Check fluid level and leakage Tires must be inflated to normal
6 Check fluid level adding fluid if
Recommended fluid is Automatic pressu reo
necessary
Transmission Fluid Oexron Type I Check fluid level and fluid leak 7 Run engine at idle for 3 to 5
Refer to Seetion MA for Recom
age adding oil if necessary seconds
mended Lubricant
8 Stop engine and check fluid level
Fluid with oil pump adding fluid if necessary

capacity
reservoir tank each hose and 9 Run engine and check fluid level
steering gear assembly again adding oil if necessary
Approximately 10 Turn steering wheel fully in left
1 2 1 1 4 US qt or right until fluid reaches operating
1 118 Imp qt
temperature
Be sure that all connections are
Pump belt edJustment tight

Adjust oil pump belt tension Expel any air from system
I I Slowly close shut off valve with

Pump belt adjusting bolt steering wheel fully turned in left or
Thumb pressure
911Nj10kg 221b right and lightly touch wheel stopper
I
Lock nut
71 CAUTION
Do not close shut off valve for more
thin fifteen seconds as this would
abnormally increase lubricant tem

G 2 Run engine
IJ perature and cause undue pump weir
Make sure temperature of fluid in
deflection
I Oil pump belt
8 12 mm
10 31 OA7 in
SST134 pump rises to 60 to 800 C 140 to
Wilh valve fully closed pump pres
1760 F with a tamperature indicator
sure should be at maximum
3 Stop engine
Check fluid leekege
4 Set Tool Normal preuure
I Run engine at idle speed or 1 000 Gauge must be between fl

shut About 5 394 kPa 55 kg cm2
valve and oil pump 782 psi at idling
rpm
ST 13

Power Steering Gear Model IP S 56LJ and Oil Pump STEERING SYSTEM
12 If pressure increases beyond upper 3 Check steering wheel turning tor

limit pressure relief valve in oil pump que when steering wheel has been
is not functioning properly Replace as
turned 3600 from straight ahead posi
oil pump assembly tion
13 If with shut offvalve fully closed
Steering wheel turning force
pressure drops the problem is in 29 4 34 3 N
Replace as oil
pump pump assembly 3 0 3 5 kg 6 6 7 7 Ib
pump assembly at circumference of steering wheel
After I
checking hydraulic system
add fluid as necessary then complete I SST137
ly bleed air out of system
Operation should be perfonned

making sure that fluid level is kept
wi in specified limit
Repeat this operation until air
bleeding is completed
Bleeding h draullc s stem 10 If air cannot be bled completely SST13B
I Raise front end of car until wheels in 1
steps through 9 proceed as fol
clear ground lows
2 Run engine I With engine runing at 1 000 to
1 500 rpm repeat step 9 INSPECTION AND
Make lure temperature of fluid in
2 Turn steering wheel to right and ADJUSTMENT
pUmp rises to 60 to BOO C 140 to 176
o left from lock to lock five to ten
F with B temperature indicator
times Carefully check fluid leakage Wash dean all d bled parts
3 Check fluid level adding fluid if with steering wheel held at each lock in suitable cleaning solyent and ch k
nece sary
position for five seconds thejr condition
Check Sealing portion
CAUTION Adjusting screw nut O ring
00 not hold steering wheel at lock Sector shaft cover O ring
position for more than fifteen seconds Sector sl1aft oil seals
at a time Rear housing oil seal
Intermediate cover Q rings
Discard any oil seal and O ring
which have once been removed
Replace oil seal and O ring if sealing

surface is deformed or cracked
Steering wheel turning

torque check Steering gear turning torque
measurement
I Park car on a level dry surface
I Measure turning torque at 3600
4 Run and set parking b rake firmly
engine for 3 to 5 seconds
5 2 Bring power steering fluid up to position
Stop engine adding fluid if nes
I Install steering gear on Tool
sary adequate operating temperature Ap
6 proximately 60 to 80 C 140 to
Quickly turn steering wheel all the
and left ten times end 1760FII
way to right
lightly touch whee stoppen
It is easy to bring power steering
7 Check fluid level adding fluid if
fluid up to adequate operating tern
necessary
perature by idling engine and at the
8 Start engine at idle
same time turning steering wheel
Repeat steps 4 through 8 until air
from left to right for about two
will be bled from pump
minutes Alternatively drive car
9 With steering wheel fully turned several miles
to left
open bleeder screw to expel Tires must be inflated to normal
air and then tighten bleeder screw SST040
pressure
ST 14

STEE ING SYSTEM Power Steering Gear Model I P S 56LJ and Oil Pump
ahead position is position

2 Turn stub shaft all the way to Straight 8
right and left several times where stub shaft is turned two turns
3 Measure turning torque at 3600 by 450 from lock position
position from straight ahead position 3 Disconnect sector shaft cover bolt
Tool Do not loosen adjusting screw lock
using
nut
I Do not turn lock nut unless neces
4
sary otherwise it will damage O ring
resulting in an oil leak

i 28
l 34 N m
m 21 25 h Ibl
12 9 35
kg SST043
Measure turning torque If they are

not within specifications replace gear
assembly
J
DISASSEMBLY
Stub shaft can be turned by wrap
ping vinyl tape around serration Before disassembly measure turn 4 Draw out sector shaft
of stub shaft and fitting Knock end of shaft
area ing torque out sector
wrench lOcket If they not within specifica

are approximately 20 mm 0 79 in
If it is beyond specification gear tions replace steering gear assembly
must be replaced as an assembly
20mm
CAUTION 0 79 nl
Each oil sealing parts dust seal
2 Measure turning torque at
washers and snap ring
special once
straight ahead position
removed must not be used again
I Set worm gear in a straight ahead
position
position is 8 position AdJusting screw lock nut se 1
Straight
ahead
where stub shaft is turned two turns Remove adjusting screw lock nut
by 450 from lock position and replace a ring SST046
2 Measure turning torque using

Tool
5 Connect a roll of plastic fIlm to
sector shaft
Turning torque at streight
h d position Plastic film
l0
i 10 0 39 N m Thickness 0 1 mm 0 004 in
1 4 cm
kg 09 3 5 in lb
Length x width
higher than t 3600
O 200 x 200 mm 7 87 x 7 87 in
mg
LJJ Lock nut
Copper washer
SST044
1 Plastic film
Sector sh ft 011 se 1
I Install steering gear on Tool
KV48l00301
5 After adjustment is completed 2 Set stub shaft in a straight ahead
SST065
tighten lock nut position
ST 15
Power Steering Gear Model I P S 56LJ end Oil Pump STEERING SYSTEM
Rear housing seal

6 PuiI out sector shaft by harid CAUTION
Install gear Tool KV48l00301
Attach plartie film to two bearings on a When worm assembly is removed
in a vise
located inside gear housing while piston may turn and come off
2 Loosen not remove rear cover Hold
simuttaneously pulling out sector shaft under iU own
weight piston
that will drop into bolts to prevent it from turning
so bearings not
housing If piston to intermediate cover
clearance exceeds 45 mm 1 77 in
7 Remove snap ring by looseninll ulating
recin ball will
be out of groove of worm do not
reinstall piston but replace the en
tire assembly
b Take care not to damage tellon ring
at piston end wilen removing
fs SSTQ47
3 Turn sector shaft clockwise slight
ST697
through
8 Remove rear
sembly upside down
cover
stub shaft end on top of workbench
CAUTION
and
turn worm as
lightly tap
ly to raise intermediate cpver
piston Do not strike shaft with a hammer or
pry it with a screwdriver
8 Remove dust seal special wash

ers and oil seal
Apply blade of screwdriver to oil
seal I ightly so that it will not damage
inner side of gear housing Q

g
I J t I
Special washer A Smail

I
sea
0ru
Oil
n
d L4i
Special
B
SST050
lL ST701
4 Turn stub shaft counterclockwise

and place piston in its
Dustseal w worm gear
straight ahead position

snapring
SST048 S Remove sector shaft
Refer to Seetor Shalt Seal for disas
sembly
6 Remove rear cover bolts
7 Pull out rear cover intermediate

9 Remove rear housing oil seal
9 Remove a ring cover with worm gear assembly
ST702
SST049 ST700
ST 16
STEERING SYSTEM Power Steering Gear Model I P S 56LI and Oil Pump
2 Install O rings both sides of

10 Remove O ring on both sides of on
CAUTION
intermediate cover intermediate cover with new ones
a Be careful that teflonring at piston
Apply a thin coat of vaseline to end is not damaged during insertion
new C rings prior to their installa of gear housing
tion b When worm assembly is halfway
Be careful not to install wrong inserted teflon ring is deflected
O rings as some of them resemble Insert remaining part of worm as
in size sembly paying particular attention
Take care nol to damage teflon ring
on corner of sector hole
Be sure that teflon ring settles in its
Intermediate cover
correct position
SST051
ASSEMBLY
AdJusting
Insert
screw lock nut
into
se 1
tJ SST054
new a ring adjusting

screw lock nut
Before thin coat
inserting apply a
of vaseline to O ring
Inort C ring to make sure it fits
into groove
oring 3 Fit rear cover onto intermediate
r cover with worm gear assembly
CAUTION
a Do not tilt ballbearing
b Make sure that O
rings are not pro
truding or extruding
L Adjusting screw
lock nut
SST052
Re r housing se 1
I Install oil seal using

rear
housing
Tool
Before installing oil seal apply

recommended multi purpose greM to
5 Gradually tighten rear housing
bolts in a criss cross fashion
lips
ST705
4 Insert worm gear assembly with

rear cover and intermediate cover into
cross
Criss fashion SST055
SST053
gear housing
ST 17
Power Sreering Gear Model I P S 56LJ and Oil Pump STEERING SYSTEM
2 Install a new snap ring into gear

CAUTION
housing
L If bolts are tightened while wonn
assembly is tilted inner seals will

CAUTION
Q G
be dam8llld Tighten bolts while a Turn soap ring to make sure it fits
assembly is level into groove
If wonn assembly is tilted stub b Always inslllll snap ring with its
shaft s turning torque will be in rounded edges facing oil seal
creased
b Check O rings to ensure lhat they
do not protrude or extrude ST696
6 Install sector shaft into gear hous

ing
R face
Refer to Sector Shaft Oil Seal for 5 Wrap vinyl tape around serration
Imide snap ring
assembly area of sector shaft

The reason is that vinyl
7 Check turning torque Outside tape pre
vents oil seal lip from being damaged
Refer to Inspection and Adjust I during insertion
talling snap ring SST058
ment
6 Gradually insert sector shaft into
Sector shaft 00 se 1 gear housing being careful not to dam
I Press new oil seal and dust cover age oil seal
using Toot When insening seetor shaft into

When be lure to
irstalling use new gear housing remove plastic film 8e
3 Fit new O ring into sector shaft
oil seal dust cover and special careful not to drop bearings into gear
washen cover
housing
Before installing apply a thin coat
Before installing apply a thin coat 7 bolts
Tighten sector cover
of vueline to new oil seal and dust of vaseline to O ring
seal
Make certain that O ring is installed
IIi
properly and not
damaged by sec
24ft lb
Special washer tor shaft
Small
00 SST056
ST695
8 Check steering gear turning torque

Refer to and Adjust
Inspeetion
ment
4 Set piston worm gear at straight If there is 8 great difference be

al1ead position tween values of turning torque be
Turn piston rllck about 100 to 150 fore and after disassembly it must
toward youself with your finger be assumed that some new problem
This is for smooth insertion of lec has occurred It will be ary to
nece
tor gear replace the entire assembly
ST 18

STEERING SYSTEM Steering Linkage
STEERING LINKAGE
BaD joints
IiJ 31 42 Be careful not to damage dust
I
3 2 4
3 23 31 cover
To body frame nut to the specified

Tighten
torque and align the cotter
@ pin hole inthe tightening
IiJ 29 69 direction
3 0 7 0 22 51 Be sure to insert new cotter
Outer ball joint Side rod adjusting bar To rod bend it
cros
pin and ecurely
Inner ball joint
IiJ 78 98 Gear ann
8 0 10 0
58 72
J
CroSlrod
Cotter
Front PinV
Side rod assembly
Side rod adjusting bar
IiJ Model vRB47L
29 69 3 0 7 0 22 51 When adjusting toe in use it
To knuckle arm and cross rod

Make sure that side rod bar
is crewed in socket 25
@ mm
Multil urpose greasing points P S 56L
Modell
54 98 55 10 0 40 72 0 98 in OJ more
IiJ Nm m
ks ft Ib
To knuckle arm and cross rod SST099
6 Install steering linkage in the

REMOVAL AND
INSTALLATION reverse order ofremoval
L Jack up front of car and support J

G Gear arm to seetor shaft
it n thesafety stands 127 147 N m
2 Block rear wheels with chocks 13 15 kg m
3 Remove gear arm using tool 94 108lt lb
Idler arm to body frame

31 42 N m
Gear housing
3 2 4 3 kg m
23 31lt lbl
SST010 Side rod to knuckle arm
Gear arm
Model VRB47L
29 69 N m
from knuckle 13 0 7 0 kg m
5 Remove side rod
22 51lt lb
ann using Tool Modell P S 56L
n
54 98 N m
5 5 10 0 kg m
40 72 ft Ib
SST0100
7 After installing steering linkage

check wheel alignment and if neces
sary adjust
Refer to Seetion MA for adjust
STa8l
4 Remove idler ment
ann assembly
ST 19

Steering Linkage STEERING SYSTEM
DISASSEMBLY INSPECTION AND REPAIR
Side rod w
@@ Ball joint
I Remove both side rods from cross
I When ball stud is worn or axial
rod using Tool HT72520000
2 Separate outer and inner ball
I play exists
joint with a new

replace
one
side rod ball
rod
joints from side adjusting bar 2 When dust cover is broken or
J
Z I deformed be sure to replace with a
Inner ball joint i J new one
SST104 Initial turning torque

Ball joint
0 5 2 5 N m
2 Press bushing into idler body and 5 25 cm

kg
insert shaft of idler arm bracket 4 3 21 7 in b
catefully until bushing protrudes Swivel pin
Le than
Lock nut
J
t 54 69 N m
2 5 N m 25 22 in b
cm
kg
SST102 5 5 7 0 kg m
40 51 ft b
Idler arm essembly
Check rubber bushing of idler arm
Cross rod and side rod
for breakage wear or play and if
Idler arm assembly I When side rod ball join ts and side necessary replace
rod adjusting bar are separated adjust Initial turning torque
Remove nut and separate each
side rod length correctly
Less than
part
Adjustment should be done be 7 8 N m 80 69 in bl
cm
kg
tween lock nuts
eNut Apply grease to idler arm assembly
StandardJength A at recommended intervals
71 mm 12 80 in
o
BU5hing Cross rod and side rod
Check side rod and cross rod for
breakage bend or crack and replace

Idler
t
ann
with a new one if
necessary
Flxlns location
SST013
Check fixing location nuts and
Unit mm in
SST105
cotter pins for looseness play or
breakage When looseness or play is

found check for wear on tapered
2 Tighten side rod portion of ball stud gear of idler
adjusting bar arm
ASSEMBLY lock nut arm
Assemble When reassembling each ball joint

steering linkage in the l
r 78 98 N m
cotter
reverse order of disassembly observing use new pi s
18 0 10 0 kg m
the following instructions

58 72 ft b
a Lock side rod adjusting bar lock
nut so that ball joint on outer

Idler erm assembly
socket is 770 with respeet to that
To assemble idler arm proceed as on inner socket
follows b Make that bar is

sure adjusting
I Apply coat of multi purpose sa ewed in each socket at least 25
grease to bushing mm 0 98 inl
ST20
STEERING SYSTEM Service Data and Specifications
GENERAL SPECIFICATIONS Adjusting shim thickness
Steering column Collapsible column
1575 1600 10 0620 0 0630 48213 80100
Standard column length L mm
in
VRB47L equipped model 179 7 05 1550 1575 0 0610 0 06201 48214 60100
IP S 56L equipped model 180 7 09 1 525 1550 10 0600 0 0610 48215 801 00
1500 1 525 10 0591 0 06001 48216 80100
1475 1500 0 0581 0 0591 48217 80100
LL h L
1450 1 475 0 0571 0 0581 48218 80100
SST080
I 01 pad y I IUS p Imp p Approx 0 26 15 8 1 2
I Steering gear model VR847L IP S 56L

Model I P 5 56L
Turns of steering wheelan the
I
car
3 5 3 1 8 1210 31 47
0
Lock lock Oil pump belt deflection inl
mm
at 98 N 110 kg 22 Ib
I Steering gear ratio 18 0 20 5 17 0

Steering wheel turning force
At circumference of
4
29 34 3
steering wheel 13 0 3 5 6 6 7 71
N kg Ib
Oil pump maximum pressure

I kPa kg cm2 psi
5 394 55 782
I
Normal operating temperature at fluid
VR847L IP S 56L
Oc 10FI I 60 80 140 1761
Front wheel full turning angle

I Fluid capacity USqt lmpqt IAPprox 1 2 1 1 4 1 1 8
33 33 350 Steering gear turning torque

Inner wheel degree 350
N m
cm
kg Ib
Outer wheel 270 290 270 290
degr e
3600 position from straight
ehead
Less than 1 2 12 101
position
Minimum turning radius
5 7 18 71
Wall to wall mlttl
Straight
ahead position As com 0 10 0 3911 4
pared with steering wheel turned
Steering wheel axial play mm in 01
0 0 9 35 higher
3600
Steering wheel play mm inl Less than 35 1 381
On power steering models

Wheel turning force at circumference of steering wheel
of 98 147 N 10 15kg 22 231b with engine at idle
STEERING GEAR
Model VRB47L
Worm bearing preload With oil seal 4

0 06 STEERING LINKAGE
N m
cm
lkg Ibl 6 3 5 5 21
14
Initial turning torque
Steering gear preload With oil seall Less than N m
cm
kg in Ib
N in Ib 1 5 9
10 Ball joint 05 2 5 15 25 43 7
21
m
cm
kg 23112
Swivel pin Less than 2 5 25 221

Backlash at gear arm top end
o 01 0 0004
In neutral mm lin
Idler arm Lessthan 7 8 80 69
End play
01
0 0 03 Standard side rod length
Between sector shaft and adjusting 71 0 795
12
0 0004 0 00121 jnl
mm
screw mm tinl
ST 21

Service Data and Specifications STEERING SYSTEM
TIGHTENING TORQUE Model I P S 56L
STEERING COLUMN Unit N m

kg m ft lb
Unit Stub
m
N m
kg ft Ib shaft to joint 32 38 33 9
3 24 28
I Steering
I
wheel ut 37 51 8
3 5 2 27 38 Steeing ge housing
I
to
52 62 53 63 38 46
bOOy frame
Jacket tube blacket
I I
to
dush panel
Stee ing column

3 4 44 0 5 0
451 25 3 3
I Sector shaft to gear arm 127 147 13 15

I 94 108
I I
mount Rea
I
cove
to gea
I
13 18 18 9 13 26 32 2 7 3 3 20 24
iog bracket
3
11 housing
Jacket tube
I
mounting
I
Secto shaft
I
cove to goa
bracket
34 44 0 35 0
451 2 5 3 3
housing
26 32 27 33
I 20 24
Sector shaft
Coupling fixing nut adjusting
VRB47L equipped
mod 1 only
15 22 1 5 22 11 16 screw lock nut
28 34 2 9 3 5
I 21 25
I 0 pump to bracket 26 36 27 37
I 20 27
I Hose to oil pump 29 49 30 50

I 22 36
Oii oi tank to
I
se en
glne compartment
29 49 03 05
I 2 2 36
Hose to suspension c oss
STEERING GEAR
member
l 29 49 03 05
I 22 36
I
Hose to gear housing 49 69 50 70 36 51
Model VRB47L
Unit N m
m
kg lb
ft
STEERING LINKAGE
I Worm shaft to coupling 39 49 4 5 29 35
Unit N m n
kg lb
ft
Steering gear housing to
52 52 5 3 53 38 46
body frame
Idler arm to body frame 31 42 32 43 23 31
Sector shaft to gear arm 127 147 13 15 94 108
8all stud end swiVIII pin 29 59 30 7 0 22 51
Adjusting plug lock nut 245 314 25 32 181 231

I Idler arm
nut 54 69 5 5 70 40 51
Sector shaft cover bolt 15 25 15 2 5 11 18
Sect shaft adjusting

I Side rod bar lock nut 78 98 80 10 0 58 72
I screw lock nut

29 39 30 40 22 29 I P S
Side rod
56L equipped model only
assembly 54 69 N m 15 5 7 0 kg m 40 511t b
ST 22
STEERI NG SYSTEM Trouble Oiagnoses and Corrections
refer to
Except for the following probalbe causes and corrective actions
section
Trouble Diagnoses and Corrections in Front Axle and Front Suspension

Condi1ion
Excessive wheel play Insufficiently tightened or improperly in Retighten

stalled steering gear housing
Damaged steering linkage or ball joint Replace faulty parts
Incorrect adjustment of steering gear Adjust
Vibration shock or Insufficiently tightened or improperly in Retighten

shimmying of steering stalled steering gear housing
wheel Wear of steering Replace faulty parts
linkage
Damaged idler arm Replace
Worn column bearing weakened column Replace or retighten
bearing spring or loose clamp
Car pulls to right or Deformed steering linkage and or suspension Replace

left link
Insufficient lubricants mixing impurities Replenish grease or replace the part

Stiff or heavy steering or
wheel in steering linkage or excessively worn steer
ing linkage
Worn or damaged steering gear and bearing Replace
Incorrectly adjusted steering gear Adjust
Deformed steering linkage Replace
Interference of steering column with turn Adjust

signal switch
ST 23

r
Trouble tJS and Corrections

DiagnO STEERING SYSTEM
POWER STEERING
Oil pressure does not

Pump drive belt slipping on pulley Readjust belt tension
build up
Pump malfunctioning Replace
Oil leaking through hose joints Replace or retighten copper washer
Oil leaking through power steering Replace sealing parts at steering gear
Steering wheel moves Lack of oil in oil pump Refill

heavily Air present in oil Bleed air
Oil pressure too low See Hydraulic system check
Wheel alignment out of specifications or air Re inflate tires to correct pressure

a1ign or
pressure in tires too low
Steering gears improperly engaged Replace gear assembly

Steering column out of alignment Repair or replace
Worn or
damaged ball joint at suspension Replace
and steering linkage
Idler arm dragging Repair or
replace
Steering wheel fails to Refer to items marked above

return
Front wheel caster improperly adjusted Readjust
Internal gears dragged or gouged Replace gear assembly
Steering effort is not Oil leakage in steering gear Replace sealing parts
the same in both
Stuffy oil passage in steering gear Replace gear assembly
directions
Unstable running Wheel bearing not properly adjusted Readjust

Stuck or damaged control valve in steering Replace gear assembly
gear
Front wheel alignment not properly Readjust

Excessive steering gear play Readjust backlash replace
or gear assembly
Play at suspension and linkage ball joint Replace
Noisy pump Lack of oil in oil pump Refill
Hoses or oil filter clogged Clean or if necessary replace
Loose pulley Repair

Belt noisy or slapping Readjust tension
Broken pump part Replace
ST 24

STEERING SYSTEM Special Service Tools

Unit application
Tool number
Tool name
Kent Moore No Model VRB47L P S 56L
Modell
ST27l80001 Steering wheel puller

125726
1i
KV48 100301 Strut steering gear box
125729 attachment x x
ST3127S000 Preload gauge

See 125765
Torque wrench
CD GG91030000 Socket adapter i
CD
See 125765 Socket adapter
X X
@ HT62940000
@
@HT62900000
ST29020001 Steering gear arm puller

J25725 X X
HT72520000 Ball joint remover
KV48 101 500 Lock nut wrench
wrench
KV48 101 400 Adjusting plug
X
ST27091000 Pressure gauge

X
Shut ff valve
ST 25

Special Service Tools STEERING SYSTEM
Tool number
Moore
Kent No
Tool name
I Unit application
I Model VRB47L Model IP S 56L
KV48I 009S0 Oil seal drift set

126367
CD KV48lO091O Drift
x
@ KV48100920 Adapter
@ KV48100930 Adapter
CDsT35322000 Front wheel bearing drift
@ST35325000 Drift bar x
ST 26

DATSUN 200SX Model S II 0 Series
SECTIONBF
BODY
CONTENTS
END BF 2 REAR WINDOW Hardtop BF 22

BODY FRONT
FRONT BUMPER Shock absorber type BF 2 BACK WINDOW Hatchback BF 24
RADIATOR GRILLE BF 3 TRIM AND MOLDING BF 26
FRONT APRON BF 3 ROOM TRIM BF 26
FRONT SIGHT SHIELD BF 3 BODY SIDE TRIM AND MOLDING BF 27
FRONT FENDER BF 3 REAR PARCEL SHELF Hardtop BF 28
HOOD BF 4 INSTRUMENT AND SEAT BF 29
DOOR BF 6 INSTRUMENT BF 29
DOOR BF 7 CONSOLE BOX BF 31
BF 11 SEAT BF 31
BODY REAR END
REAR BUMPER Shock absorber type BF 11 SEAT BELT BF 32
TRUNK LID Hardtop BF 12 SUN RDOF BF 34
BACK DOOR Hatchback BF13 REMOVAL AND INSTAllATION BF 34
WINDSHIELD AND WINDOWS BF 16 BODY ALIGNMENT BF 35

WINDSHIELD BF 16 DESCRIPTION BF 35
REAR OUARTER WINDOW Hardtop BF 19 ENGINE COMPARTMENT BF 35
REAR QUARTER WINDOW Hatchback BF 21 UNDERBODY BF 36

BF 37
OPERA WINDOW Hardtop BF 22 SPECIAL SERVICE TDOLS
OPERA WINDOW Hatchback BF 22

Body FronrEnd BODY
BODY FRONT END
FRONT BUMPER Shock absorber type
Front bumper
Shock absorber
31 42
3 2 4 3
23 31
59 78
6 0 8 0 43 58
B wq
bucket
OYerrider
N m rn
Icg ftlb
SBF126
distance from top edges to ground

REMOVAL AND
meets the specifications
INSTAUATION
2 Disconnect front combination
lamp connectOIs
3 Remove bolts
securing
special
shock absorber to front bumper assem
bly then remove front bumper assem
bly
4 Remove shock absorber from car
body
CAUTION
p p
The shock absorber is filled with a
high pressure gas and should not be
t
disassembled drilled or exposed to
an open flame
5 Installation is in reverse order of

Unit 111m in Section A A SBF121
removal
ADJUSTMENT
Place car OB II flat surface under 2 After adjustment tighten bolts
Bumper height curb weight conditions Tires must be and nuts securely
that inflated to rated pressure

I Adjust bumper height so
BF 2
BO DY Body Front End
RADIATOR GRILLE FRONT APRON FRONT SIGHT

SHIELD
REMOVAL AND REMOVAL AND
INSTALLATION INSTALLATION
REMOVAL AND
1 Open engine hood 1 Remove front bumper assembly INSTALLATION
2 Remove radiator grille Refer to Front Bumper for removal 1 Remove headJamp fmisher and
2 Remove front apron
headlamp
2 Remove radiator grille
3 Remove front bumper assembly
4 Remove front sight shield
1
Jf
removal
Installadon is in reverse order of
SBF129
Q 1
SBF130
CAUTION
a Radiator grille is made of plastic
removal
so do not use excessive force
b Take Clre to oil away from When installing front apron be sure
keep
radiator to sea mating surface of front fender 5
grille Installation is in reverse order of
and front apron removal
FRONT FENDER
Section A A
Seal completely to mating surface of

fender and hoodJedse
IR
a
ff
i
J
J1A
SBF131
BF 3

Body Front End BO DY
REMOVAL AND 5 Installation is in reverse order of

CAUTION
INSTALLATIoN removal
Fender panel and hoodledge are
I Disconnect battery ground cable When
secured with sealant Before removing installing front fender apply
2 Remove front bumper assembly sealant to
front fender be sure to remove seal mating surface of front
Refer to Front Bumper Assembly for lender and hoodledge
ent
removal and installation
3 Remove fender protector sight
shield front apron and fender stay
4 Remove bolts attaching front
fender and then remove front fender
HOOD
Hood
Striker
Hood louver
Torsion bar
Hood hinv
Cowl grille
Hood lock
Hood rear
molding
Hood control
cable
SBF132
REMOVAL AND I 3 Installation is in reverse order of

INSTALLATION removal Adjust hood Refer to Ad
justment
Hood
I Open hood and remove washer

tube Torsion bar
2 Support hood and remove bolts I Open hood
attaching hood hinge and then remove 2 Support hood and remove each
hood 7 torsion bar end of
by disengaging
lIB 21 N m
torsion bar from hood
11 6 21 hinge Use a
m
kg 12 15fHb S8F133
suitable screwdriver
BF 4

BODY Body F ontEnd
2 Disconnect lock control wire from 2 Loosen bolts attaching hood lock
lock then hood and hood up or down and side
hood and remove move
lock to side until it is set in optimum posi

tion when opened and closed
SBF134
JLlI
3 Installation is in
removal
reverse order of SBF136 t SBF138
Lubricate sliding surface of tor
sion bar
After hood adjustment ensure
lower that clearance between hood and

3 Remove left instrument
all
cover Refer to Instrument Lower fenders is nearly equal at points
Hood hinge Cover for removal

4 Remove hood lock control knob
I engine hood
Remove
and then draw cable out through pas
2 Remove wiper arm and then re
senger compartment
move windshield lower grille Bumper rubber
3 Remove torsion bar and then
removal Adjust hood Refer to Hood Raise two hood bumpers until hood
remove hood hinge
is flush with fenders
Adjustment
Hood lock attaching bolU
CAUTION fj
16 21 N m Fende r
Remove hinge onlv after torsion bar
HO d
1 6 2 1 kg m alaI 0101
has been removed
12 15 ft lb
7 J
I
1
Check hood lock control operation
I @
I
@
Unit mm in SBF139
ADJUSTMENT 1 Adjust bolt

t7 2 2 Bumper rubber
3 Lock nut
Hood and lock
4 Weld nut
SBF135 I Loosen bolts attaching hood
hinge and move hood forward or

backward and side to side until it is Ensure that rubber bumpers come
set in optimum position in contact with mating panels

removal
bolt
fj Hinge attaching
39 4 9 N m
0 4 0 5 kg m
2 9 3 6 ft lbl
Hood lock and lock control
I Remove bolts attaching hood

SBF137
lock
BF 5

Door BODY
DOOR
Door gtus
Door outside moulding II

i1
Doot stabilizer
Outside haodle
rail
Front guide
liar
npper
It
i
@
t
lnad hand1e
J
screen
Ann
Door fmisher
SBf140
BF 6
BODY Door
DOOR 4 Remove bolts attaching door win

dow to guide channel
REMOVAL AND
INSTAlLATION
Door aasembly
Support door with a stand or jack

Place a rag between door and stand
or jack O
SBF142
2 Remove door from hinges
c
SSF144
I I 5 Remove sealing screen
When removing sealing screen be

00
W careful not to allow it to come in con
S
taet with Remove door stabilizer
adjacent parts
6 Remove door glass by pulling it
r
6 Installation is in order of
reverse upwards and away from door
0 C
JL removal
8 To prevent water from entering

affix seal
7 Remove regulator attaching bolts
SBF141 passenger compartment

ing SCreen firmly with adhesive tape
or bonding
agent
b With door window closed use set
pins to install regulator handle as
removal Adjust Door Refer to Ad
shown in Figure below
justment
l
t Door hinge securing bolts
16 22 N m
1 6 2 2 kg m
SBF145
12 16 ft lb
Front
300
Front door trim r

1 Lower door 8 Remove
glass fully regulator assembly
2 Remove ann rest and door inside through large access hole in door
handle escutcheon panel
BF879B
3 Remove regulator handle by pry
ing out set pin
Door glass and regulator
2
Remove door trim
r
Remove door outer molding
Front
o 3 Remove both front and rear
t upper stoppers
SBF146
SF879B
IY hf
J
Rear uppe
opper
I 9 Installation is in
removal Door
reverse
glass adjustment
order of
Refer
4 Remove door fmisher with suit to
Front upper stopper Adjustment
able tool and pry door fmisher clip
off door inner Apply grease to sliding surfaces of
panel SBF143
regulator and guide channel
BF 7

Door BODY
Door lock and lock control
Door outside handle Inside lock knob
I Imide handle
Jb
t
Key cylinder
l
s
Imide handle escutcheoD
Door lock
SBF147
Remove door trim ADJUSTMENT

2 Remove door Refer to Door
glass
Glass for removal Door assembly
3 Jl emove door inside handle at

taching screws door lock assembly
attaching screws and crank
bell attach
ing screw
4 Disconnect key rod from key

cylinder and then remove door lock
and lock control
5
6
Remove door outside handle
Installation is in
rcptoval
reverse order of
Il
j
Apply
leven and
grease to
springs
sliding surfaces of 4
d i
SBF148
I Loosen bolts attaching door hinge bolts attaching hinge to rear of front
to body side Move door up or down lender
and forward or backward until it is 2 Loosen bolts door
attaching hinge
correctly positioned to door side Move door from side to
Using an offset wrendl remove side until it is set in optimum position
BF B

BODY Ooor
Door glas Tilt adjustment Upper side of glass

Before door window glass proper positioning may cause water or I Loosen front and rear upper
adjusting
check body side weatherstrip to ensurl dust leaks stopper securing bolts and front and
that it is properly positioned as im Adjust window glass as follows rear guide rail securing nuts
2 Adjust door regulator so that

upper side of glass is parallel with
body side weatherstrip
@1f @
1 ln ut adjustment
at waist area
2 Gut
In adjustment
upper side ofgalss
Regulator
3 Tilt adjustment SBF153
upper side of glass

4 Glass upper stop
adjustment
5 Glass fore and
aft adjustment 3 After adjustment tighten guide
rail securing nuts and guide channel
securing bolts
SBF149
In out At waist area

adjustment 11 2 mm 0 441 in
1 Loosen nuts securing upper ends
of both front and rear guide rails
Glass upper stop adjustment

height of glass by
idi
I Adjust rear
rfjV I
I l
II
changing upper rear stopper position
ll t
J
Jr Side roof rail
j
SBF151
C
Front
SBF 150
out
In adjustment Upper side of glass
1 Loosen nuts securing lower end of
guide rail and turn adjusting bolts
until glass is set in position as n
showni Door glass
Figure below SBF154
Side roof rail
2
3
direction
waist
Raise window
Turn upper
or
completely
adjusting bolts
between glass and rubber seal for door

molding is 112
in one
the other until distance
441
0 in
14
10 55
17 mmLn
0 67
crt g
inlrOoorgla
mm
SBF152
as shown in Figure below
BF 9

Door BODY
2 Adjust front height of glass by Door lock and lock control 2 Turn adjusting nut until clearance
changing upper front stopper position I Move rank front and rear
between outside handle rod and door
bell
until free play of lock knob is mini lock lever is 0 to I mm 0 to 0 04 in
@ mum Check lock knob and inside

handle to insure that they are flush
ri with each other when lock is engaged Adjust nut
Tighten lock knob attaching screws
il 11i I U 0 1mm
After completing adjus1ment en

UI J
P
SBF158 0 0 04 inl
sure that each adjustment is within Mter adjustment check to deter

SBF157
specified limit mine if door lock operates correctly
BF l0

BODY Body Rear End
BODY REAR END
REAR BUMPER Shock absorber type
i31
J 42 3 2 4 3 23 31
bracket
umper ll
mounti
Rear bumper
Shock absorber
mder
O
S
i
Bumper face
if
13 7 9
t
J 59
i 78 6 8 43 58
side molding
J
i N m kg m fHb
SBF159
REMOVAL AND
INSTALLATION
I battery ground cable
Disconnect
2 Disconnect reverse
lamp harness
3 Remove special bolts securing
shock absorber to bumper assembly
and detach bumper assembly M 600 23 62
4 Remove shock absorber from car
body
CAUTION
512 544
The shock absorber is filled with a
20 16 21 42
high pressure gas and should not be

disassembled drilled or exposed to t
an open flame M 600 23 621
removal
Installation is in
ADJUSTMENT
reverse order of
Unit mm in
t Section A A SBF160
Bumper height
under bolts
I Adjust bumper height so that Place car on a flat surface 2 After adjustment tighten
distance from top edges to ground curb weight conditions Tires must and nuts securely
meets the specifications be inflated to rated pressure
BF ll

Rear End
Body BQDY
3
TRUNK LID Installation is in reverse order of
removal
Hardtop
I
REMOVAL AND
INSTAUATION
Trunk lid
2
I Open
trunk opener cable
Support trunk
trunk lid
lid
and
and
remove
remo
Trunk lid lock end striker
I Remove trunk rear fmisher

l i
SBF163
2 Remove trunk lid attaching bolts
bolts attaching trunk lid to hinge
then remove trunk lid and then remove striker
3 Remove lock attaching bolts and 4 Installation is in reverse order of
then remove lock removal
Trunk lid opener
III

removal
AdjUst trunk lid Refer to Adjust

ment
Trunk lid bolts

i
G securing
39 4 9 N m
0 4 0 5 kg m
2 9 3 6 ft lb
SBF164
Torsion bar 1 Remove rear seat cushion and rear ADJUSTMENT

seat back
I Open trunk lid T un Il an oc k
2 trunk lid and 2 Remove kicking plate
Support remove
3 Remove trunk lid lock attaching I Loosen bolts attaching trunk lid
each torsion bar by disengaging end
ion bar from bolts and then remove trunk lid lock hinges Move trunk lid forward or
of to trunk lid Use a
4 Trun up floor carpet near trunk backward and side to side until it is
suitable screwdriver
lid opener handle set in optimum position
S Remoye trunk lid opener handle
6
7
Remove trunk lid opener cable
Installation is in reverse order of
v
removal
Fasten trunk opener cable securely

with adhesive tape
SBF166
BF 12

BODY Body Rear End
2 Loosen bolts attaching trunk lid BACK DOOR CAUTION

lock Move trunk lid lock forward or
Hatchback a Be careful not to scralch back door
backward and side to side until it is
staV when installing A scralched
correctly positioned when opened and
REMOVAL AND staV mav cause gas leakage
closed
INSTALLATION b Back door staV contents are under
pressure 00 not take apart punc

I Back door ture applv heat or fire
Back door lock end lock

cylinder
I back door
Open
J3 9 49N m 2 Remove luggage rear fmisher
10 4 05 kg m
3 Remove back door lock from rear
2 9 3 6 f1
lbl SBF166
panel
SBF168
Trunk lid opener
Adjust trunk lid opener until clear Open back door

ance between trunk lid control cable 2 Mark hinge locations on body for 1 0
end and control lever is within 1 mm
proper reinstallation i 0
0 04 in when trunk lock is engaged 3 Support back door by hand and

remove back door to back door stay Q
Clearance Less than bolts Remove rear roof rail trim and
0 04 in SBF 169
1 mm disconnect rear defogger and rear win
Lock dow wiper harness connector and

hose
Locking lever
4 Support back door by hand and 4 Remove rear combination lamp
back door to back door hinge and then remove lock
remove cylin4er
A AdjusUble 5 mm 1
10 20 inl
attaching bolts Then remove back
door
men
This operation requires two
SBF167
CAUTION
Place rags between roof and upper end
of back door to avoid damaging paint
ed surfaces

removal
Back door stay retaining bolt

l
t
16 21 N m 5 Installation is in reverse order of
1 6 2 1 kg m r mova Adjust back door referring

12 15 ft lb to Back Door for adjustment
BF 13

8OdyRearEnd BODY
Back door opener
Back door lock cable
SBF171
I back door 2 To make side

Open toide adjustment 5 To obtain snug fit between back
a
2 Remove luggage rear finisher back door left

move to or right as door and weatherstrip loosen down
3 Remove back door lock from to obtain clearance
required an equal stopper securing screw Loosen back
rear panel between back door and rear fender on door lock attaching bolts enough to
4 Remove rear seat cushion and both sides move lock working lock up or down
seat back 3 To make aft and from side to side

rear and
fore adjustment as required
5 Remove kicking plate move back door in and
fore aft direc
6 Turn up floor carpet riear back tion required to obtain an equal
door opener handle clearance between back door and roof
h
7
and
8
9
Turn
remove
up luggage room
back door opener handle

Remove back door opener cable
Insta1Iation is in reverse
carpet
order of
1f
7
removal
P
U 0
Fastan back door opener control

y
cable securely with adhesive tape P
l4
SBF172
ADJUSTMENT
BF6848
Back door end striker
Back door be with

can adjusted
bolts attaching back door to back door
and back door lock
hinge 6 After desired adjustment is ob
I Loosen bolts attaching back door After alignment is made
4 properly tained tighten back door lock attach
to back door hinge tighten bolts securely ing bolts securely
BF 14

BODY Body Rear End
7 to set with Back door lock Balik door opener

Adjust down stopper
hollow of back door then tighten Adjust clearance between rear door
Adjust back door lock and key
securing opener cable end and locking plate
down stopper screws
rod until they are correctly positioned
when door lock is engaged as shown when door is locked until it is within
in Figure below range indicated in Figure below
v
r
0
o 0
C
J
II
c
o
BF6868 0 mm
0 004 Locking lever

inl
Key rOd Adjust nut
SBF173 SBF174
BF 15

Winrhhieldand Windows BODY
WINDSHIELD AND WINDOWS
REMOVAL
WINDSHIELD
I Protect hood front fenders in
to
pre mixed one part sealant
A
th
strum tpanelandftoot ns
cement windshield glass to windshield
covers
is available
opening 2 Remove ndshield front
pers
After using this sealant it is highly
pillar gamishes and windshield garnish
recommended that the car should reo
Refer to Roof Trimming for re
main stationary for about 24 hours moval
so that the sealant can cure welL
3 Remove front pillar moldings
Upper windshield molding is in 4 With a sharp cutting knife cut BF331 B
stalled with a continuous plastic mold
off ma1erial gttached to
caulking
ing fastener Then 1 Adhesive caulking material
upper and lower moldings reo
2 Glass
move moldings
3 Knife cur
Cut here
7 Cut off caulking material around

entire perimeter of glass as follows
Using knife cut through part

I a
of caulking material
2 Secure one end of steel music
re 05 mm 0 020 in in diameter
to a piece of wood that can serve as a
BF330B
handle
I Windshield glass
2 Windshield molding Using long nose pliers insert other
3 Body end of re through caukling material
4 Double faced adhesive tape at edge of glass then secure that end
5 Molding falteDU of re to another wood handle
6 Sealant
5 from inside car strip 3 With the aid of an assistant
7 Dam Reaching
dam rubber from around windshield carefully cut puJi re through caulk
glass ing material around entire perimeter of

ndow using a sawing motion
CAUTION
a Use Genuine Nissan
Sealant Kit
72891 U7425 or equivalent Seal
ant kit consists of Piimer A Primer

E dam caution label and sealant
which is made from silicone Using I 1
Ye I
this kit proceed to operations de
scribed in removal and installation
Bf288B
b Do not use sealant if it is more than BF35 B
six months old

c Open cartridge only at the time of
use
S From inside push glass up
car
d Keep Primen and sealant in a cool
and out ofwindow opening
dry place ldeally sealant should be razor blade or sharp
stored in
9 Using a
a
refrigerator remove caulking material
scraper
along entire edge of windshield
opening leaving it about 10 to 2 0

WARNING mm 0 039 to 0079 in thick
heat flames away 6 With asharp cutting knife cut
Keep or open
sealant i ilicon
IS Primen are flammable off caulking material along edge of If millual re
entire window opening move all traces of it
BF 16

BO DY Windshield and Windows
5 With sponge furnished with

CAUTION Molding Primer A apply a light coat of Primer
fastener
a When body painted surface is to cleaned area of glass
scra1Ched be sure to repair with
paint
b Identificetion of used adhesive
material can be accomplished as
follows
1 Cut e piece of gxcess
smell
sealant from glass or windshield
opening flange
2 Stick small piece of sealant on IlIMERA
the end of knife or the like and
hold it over flame from match or 3 Apply glass sealant beside mold
BF376B
Iighler until it igniles ing fastener
Polysulfide burns with a clear
flamg and very small amount
a
of white smoke or no smoke and

CAUTION
its odor is very objectionable
00 not apply Primer A to glass open
heavy sulfur dioxide
ing flanges
Polyurethane burns with a
dirty flame and emit black
smoke and very little odor
Silicone glows with little or 6 With sponge furnished with
flame and emits white smoke Primer E apply light a coat of Primer
no
Sealant
and very little odor 8 F 3338
to original caulking material left on
Burnt residue is white ash glass opening flange
3 Clean glass surface where the
sealant will be applied and dam with Residual sealant
non lead gasoline
About
0 79 in
20 mm
ijIMERE
WJ
BF377B
INSTALLATION
Cleaning area
L Clean contacting face of body

with non lead gasoline BF531
CAUTION
00 not allow oil or waler 4 Install dam in ide
grease rubber to of
to get on clean surfaces from dirty windshield glass 8 mm 31
0 in
hands or tools inboard from edge of glass and cut off

excess amount at its ends
If residual sealant is silicone r8
2 Install molding fastener on upper
move all traces of it
windshield opening as follows
1 Heat molding fastener and con

tacting face of body up to about 400C
I040 F using a heat giltl
hADam Dam CAUTION
Allow Primers to dry for 10 to 15
minutes before proceeding to the next
2 Attach molding fastener to body GlaSS
step
and press it more than 490 kPa 5
kg em 71 psi using a suitable roller 7 Insert cartridge in Caulking Hand
Make certain that molding fastener Gun ST08810000 and place smooth
t
Unit mm in
does not come off from body as continuous bead on glass 11 mm
8F955
shown 0 43 in above glass surfaces
BF 17

WincMield and Windows BODY
attach caution label

After installing
to glass surface
CAUTION
LEAVE ONE WINDOW
OPEN SLlGtlTlT
FOR THREE OATS
This is to protett f04 ew wfndshield

nstallation from ure lnduC8d
pre
BF335B
Iuks before the ubb 1 has com
pletely ulconizecl
BF6988
Dam 10 on glass 10 aid
Apply pressure
inseating on plate
II Wipe excess caulking material Be lure that it does not obstruct
off molding fasteners edges of glass visibility The label noting the faet
mm o nl that sealing will be impaired if door
and body
12 Remove is opened osed with window
Section A A
protective covers or
13 Water test immediately using a dosed before sealant has dried will
cold water spray be furnished with the kit

BF782B
Do not direct stream of water at
fresh adhesive material Allow water to
spill over edges of glass If leaks are

CAUTION
encountered useCaulking Hand Gun
Cut off nozzle end of cartridge as AdviSB the user of the fact that car
to work in additional caulking material
shown below should not be driven on rough roads
at leak point or surfaces until sealant has properly
14 Install all previously removed
wlcanized
parts
70
h 1
Reference Period required for sealant to dry to desired hardness
Unit days
0 311 Relative humidity
90 50 25
Unit mm in BF957
Temperature oC F
25 77 15 5
2 6
10 50 3 3
5 10
10 14 10 17 34
Pierce sealing film with needle
install cartridge on hand gun
CAUTION to leak area while

REPAIRING LEAKS Apply water
Sealant starts to harden 15 minules
pushing on glass
after it is 1herefore wind Leaks repaired without
be reo
applied can
Mark extent of leak point
shield glass should be installed in moving and reinstalling glass in the
windshield opening in body wi1hin following manner
15 minutes of applying sealant I To stop leaks lint remove mold 3 Apply Primer and then sealant to
leak points following procedures
ings in area ofleak
8 windshield glass with shown below
Support 2 Mark location of leak
SuckerST08800000
9 Install windshield glass on If water is leaking between caUlking
CAUTION
opening flange so that clearances be matarial and Kfy or between glass
b Primar to old sil one
Do not apply
tween windshield glass and body are and caulking material cietermine ex
sealant
about 7 mm in tent of leak by pushing glass outward
28
0
BF 18
BODY Windshield and Windows
TrUn
PrUner E
1
sulant
PDIYlulphide or
polyureth ne
l
4
Silicone 81lant Work into joints
BF498B
REAR QUARTER WINDOW Hardtop

J
I
I
I Rear quarter window glaM
Rear upper stopper
Front upper stopper 0 Jt f

V
D
Guide plate
Ann rest
Regulator handle
SBF175
BF 19

Winchhield and Windows BODY
L Remove cushion and

rear seat 8 Installation is in reverse order of ciut
In adJu t nt
rear seat back removal Glass refer to
adjustment Upper lde of g
2 Remove regulator handle and rear
Adjustment
side finisher Adjust rear quarter window glass
Apply grease to sliding surfaces of
3 Remove air outlet grille and seaI position as shown in Figure below
regulator and guide channel
ing screen using adjusting bolt located on lower
4 Remove upper stoppers and nuts end of guide plate
attaching glass to reguI tor Remove

roof
guide plate attaching nuts Side rai
ADJUSTMENT
In out adJu tment I

mmLn gr
At wa
t erea
14 17
Close rear quarter window com
inlV
0 55 061
Door glass
pletely Adjust position of adjusting
SBFl52
bolt securing upper end of guide
plate until distance between glass

and waist molding rubber
rear quarter
seal is I 1 2 mm 0 441 in as shown
2 mm
11 441
0 in
5 Remove both window
quarter
glass and guide plate tIuough top
opening
Angle adJu tment
Close door glasses and rear quarter

window glass completely to ensure
that tear quarter window glass is align

ed with door glasses and fits body
SBF161
side weatherstripping
Rear quarter
Wide
win ow glass
SBFl77 Narrow I
I
6 Remove bolts attaching regulator L L Door window glass
Glass adjusted too far to forward sI adjusted too far to

Gla rear
ID em
Glass inclined
liD UD
7 Draw out regulator tIuough lower

SBF179
opening
BF 20

BODY Windshield and Windows
G1 ss upper stop dJustment 4 Remove regulator attaching bolts

and detach regulator
Adjust two upper stoppers until dimensions glass fully raised indi
glass and side roof rails are set at cated in Figure below
00
f
0
0 06
Side roof rail 0
5l
III
Door glass y Q SBF18
SBF154 SBF180
5 Remove air outlet grille and rear
fender molding
REAR QUARTER WINDOW Hatchback
SBF184
6 Remove rear body side retainer
rwindow
Quarte
b
regulator
SBF185
SBF181
7 Remove quarter window attaching

screws then remove quarter window
1 Remove rear seat cushion and

seal back I
2 Remove regulator handle rear
side fmisher and top luggage side

finisher and remove sealing screen
3 Remove bolts attaching glass to
regulator
f SBFl 2
BF 21

Windlilield and Windows BO DY
8 Installation is in reverse order of OPERA WINDOW

removal
To prevent leakage through

water
Hatchback Rubber
door fasten sealing screen securely Glass

REMOVAL AND
using adhesive tape or bonding agent
INSTALLAnON
1 Remove rear seat cushion seat
back rear side finisher and luggage

side upper fInisher
2 Remove air outlet grille y 1 SBF189

3 Remove opera window attaching
nuts then remove window

removal
OPERA WINDOW
Hardtop
REAR WINDOW Hardtop
REMOVAL AND
INSTALLATION
1 Remove rear seat cushion seat
back and rear side fmisher

2 Remove assist grip and rear corner
fmisher
Sedan
CD
SB 187
3 Remove opera window attaching

nuts then remove window
1 Weatherstrip
2 Window glass
3 Molding set
4 Roof panel @
5 Outer panel
SBF361
REMOVAL ness at coMectors Place protective

SBF188 L Place protective covers on back co r on rear panel
door and rear fenders 3 Remove rear window molding by
2 ve
Rem parsel shelf lUId rear side prying out molding
garnishes after removing rear seat 4 Attach two Suckers ST08800000
4 Installation is in reverse order of cushion and back from body Then to glass beforehand for convenience in
removal disconnect rear window defogger har lifting out rear window glass
BF 22

BO V
O Windshield and Windows
5 From inside passenger compart 3 With rear window glass supported 3 With aid of a helper carefully
ment apply hand pressure to edges of and centered in opening
body in position and center rear window glass
and weather check relationship between glass and in opening in body supporting it with
rear window glass remove
Sucker ST08800000
strip lip from body flange starting opening around entire perimeter of
from top to sides Use a conventional glass 4 When glass and weatherstrip are
screwdriver covered with cloth or 1 Entire inside surface of glass properly positioned in opening slowly
other suitable tool and carefully put should be in contact with opening pull ends of cord with another person
weatherstrip over body flange 2 Curvature of glass should con pushing glass from outside starting
form to that of opening from lower center of rear window glass
3 Mark any section of opening to to seal lip of weatherstrip on opening
be reformed Remove glass and reform flange

opening as required Cord should be pulled first across
J
4 Install rear window glass as bottom of glass then up each side and
follows fmally across top
rO 1 Install rear window weatherstrip 5 Carefully tap around rear window

to glass glass to assist in seating weatherstrip
on
flange
Never tap or hammer at glass to
t
8F229B position
6 After rear window weatherstrip is

free from body flange with aid of a
helper carefully remove rear window

glass with Suckers ST08800000
BF647
INSTALLATION
It important that rear window
is BF650
2 Insert strong cord in groove of
a
opening body be checked throughly
in
before installation of rear window weatherstrip where opening flange fits

Insert Cord that ib ends are at
glass so
Procedure below includes checking bottom center of glass
of rear window opening in body

L Check re f window weatherstrip
and rear window opening in body for
any irregularities
2 Stick Suckers ST08800000 on
rear window glass With aid ofanother

BF649
person carefully position glass in
in body
opening
CAUTION
Care should be exercised to make
BF648
Certain glass does not strikebody
1
metal during installation Edge chips Windshield glass
removed
2 cord
Draw 5 Install all previously
can lead to future breaks
3 Weatherstrip parts
BF 23

Windshield and Windows BODY
BACK WINDOW Hatchback
REMOVAL
Back wbldow gWs
lumm
S8F19Q
l Remove both de molding and 1 Wipe any trace of butyl tape off 3 Using a heat gun heat adhesive
corner molding glass and door panel using non leaded side of butyl tape to 700C IS80F
2 Remove four glass retainers gasoline 4 Apply bonding agent to points
Affix butyl tape to entire surface of glass as shown in Figures below
3 Disconnect rear defogger harness 2
of glass as shown in Figure below
if so equipped
4 Remove welt from inside pas
senger compartment
S Remove butyl tape with a putty
knife then remove back 1dowil C
glass
r5
1 B
Jr 6 mm
tyltape
0 24 in
Cross section B B SBF193
J
r
t
butyl tape starting
Be sure to affix
at point A figure bon and ending I I

O
2OO 7 41 in
at point A and overlap some length of
mm
SBF191
4 points
tape at point A
Use care to a oidtouching adhesive
INSTALLATION side of butyl tape with fingen as
of 8 mm 0 31 in stains reduce
Use butyl tape finger prints or may SBF194
or equi alent when replacing glass adhesi e force of tape
BF 24
BODY Windshield and WindOM
5 window with with a rubber faced haJ11ffier until 9 Tighten all four retainers securely
Support rear glass
Sucker ST08800000 glass fits panel at all points as shown and attach corner molding
6 With help of an assistant
the 10 Do not apply vibration or shocks
window glass close to open to glass for at least one hour after
bring rear Be careful notto scratch molding
of window and connect glass has been installed Direct water
ing flange rear
rear window defogger harness toward periphery of glass to deter
window mine if there is water leak inside

7 Carefully position rear
4 5mm
win
glass on opening flange of rear
0 16 o 20in
G S passenger compartment
dow II Remove excess or protruded butyl
Check rear window
c
Butyltape tape
glass to ensure
that all side dearances upper side J

ml
lower side left side and right side Backdoor
panel
are equal
8 Temporarily tighten four reo SBF195

tainers and lightly tap around glass
BF 25

Trimand Molding BODY
TRIM AND MOLDiNG
ROOM TRIM
Hardtop
AssistgriP
HeadIinins
Rear L upper
garnish
Room lamp mbly
hieJd
Wirul upper prnish
Sun riser
SBF196
REMOVAL AND 9 Remove rear window upper gar

INSTALLATlqN nish
I Remove front pillar garnish
I
if ii 1 tl
SBF198
r
SBF199
BF197
5 Remove rear seat cushion and

back
6 Remove assist grip Hardtop or
coat hanger Hatchback

7 Remove rear side finisher
2 Remove sun visor and holder
8 Remove rear corner finisher 10 Remove head lining
3 Remove room lamp assembly Hardtop or luggage upper side II Installation is in reverse order of
4 Remove roof side garnish finisher Hatchback removal
BF 26

BO DY Trim and Molding
BODY SIDE TRIM AND MOLDING
HARDTOP
Rear sid finisher
Kicking plate
SBF200
HATCHBACK
Rear body side retainer Rear side finisher
SBF201
BF 27

Trim and Molding BO DY
REAR PARCEL SHELF Hardtop
SBF202
BF 28

dSeat
ent an
IrislflJ
600
S EA1
AND
NS1 RUtAEN1
ftEtlT
STRU
II
1u
ia
ll
g
II
i
5g J
II
0
lit
l
e

Instrument and Seat BODY
Instrument panel
SBF204
Disconnect battery ground cable 8 Remove heater control attaching 9 Remove defroster grille
2 Remove steering wheel Refer to screws and floor attaching bolts 10 Remove instrument securing bolts
Steering Wheel ST section for re
instrument
and then remove assembly
moval
by pulling it out
3 Remove shell cover and com
bination switch j removal
4 Remove instrument lower cover
and side ventilator duct

S Remove cluster lid D Remove
console box
6 Disconnect wlOng connectors
from junction block

7 Disconnect cable
speedometer
harness connectors and antenna cable SBF205
BF 30

BODY lnStromentBndSeat
CONSOLE BOX
SBF206
REMOVAL AND
SEAT
INSTALLATION
I Remove screws
attaching console FRONT SEAT
box and slide console box rearward
2 Remove parking brake and lift
out console box
I
1
S6 F207
ifi16 22N m
11 6 22 m 12
kg

removal SBF208
BF 31

Instrumenund Seat BO DY
REAR SEAT
SEAT BELT
Hardtop
FRONT SEAT BELT
SBF211
itJ Seat belt anchorage bolt

SBF209
24 31 N m
2 4 2k
3
Hatchback
17 23 ft Ib
l
iiiJ
rJ
SBF210
BF 32

BODY Instrument and Seat
REAR SEA r r
BEL
HARDTOP HATCHBACK
J2434N
1 m
12 4 32 k m g
J
I 24 34N m
17 23ft lbl 24 32kg m
17 23 ft lbl
SBF212
BF 33

Sun Roof BODY
SUN ROOF
Bndet
EICutcheon
Sun roof handle
Safety catch
Sun roof rmi5her
SBF213
DRAIN HOSES
REMOVAL AND
INSTALLATION
SUN ROOF
1 To unlock safety catch slide the

safety catch knob all the way to the
left
2 roof handle knob
Depress sun
and push handle up to disengage it
from link
SBF215
SBF214
I Remove roof trim front pillar After installing drain h s emure
trim rear pillar trim and da side 1hat watar is property drained outside
3 Remove sun roof trim and then remove drain hoses car with no seepage into passenger
4 Installation is in reverse order of 2 Installation is in reverse order of compartment
removal removal
34
BF

BODY BodyAlignment
BODY ALIGNMENT
MEASUREMENT 2 When a measuring tape is used

DESCRIPTION
OPERATIONS check to be sure there is no elonga
DIMENSION LINES
tion twisting or bending
When car body measurements are
indicated in the thick

If a part or parts of the car body
All dimensions taken in accordance with the
interferes with measurement when
drawings illustrations are the standard line careful consideration should be
cannot
using the measuring tape you
design values given to the following points
I Black dimension line Indicates a 1 Measurement method
measure the distance or length accu
distance from a phantom line of the I When a tram tracking gauge is used
rately
to to be measured A and B to equal 2 Measurement point
car body a point adjust pointe
and cannot be measured with a meas
lengths as shown in the figure be Measurements should be taken at
uring tape or tram tracking gauge low Check the pointe and
gauge the center of mounting holes
2 Thin line Indicates a direct or itself to make sure there is no free
an actual distance or length between play
twopoints and can be measured with a
measuring tape or tram tracking gauge
An asterisk following the value I IB
A
at the measuring point indicates that
the measuring point on the other side
is symmetrically the same value
f
ENGINE COMPARTMENT
Unit mm in
SBF216
BF 35

Ij
it I
tD o o
cz IIIaIIo
I
6
0
I
i 166
51
13
19
IS
95
2
75 r 40
Lcp
2 r
t 1
r RCLUIe centrli 1
I
17
1
o
tO
Eq 0l
7
I 4J 7i 7
9
86
111
9118
4S9
Oalumin
c 9
I
9 69
8
t
df EO I
f
il
t
J
If
I
C 85
0
7
SctlonC 0 945 n
21
1 24 0
008
0
575
0
6
21
1
1
31
02 008 PIXNG VIEW
97tO
1
6 10 STG SIDE
0 2
db ntf
1
l
93tO 3 69 9
m FOa 917
lide lde 9
1
3
n 70 H H
8
400
ALOWNCE
R
S5 37 L
B
mHo oJ L 1
l 5
s IJ
n
1
1
c SetionB 11
L
D
I
L
if I
L
I
0
u
Front flo r 2
008l
I
14
95l
0
1
I
I
L
l31
I
0
87
31
91tO
N m7
36
lfv
J
r
sOtO 1
J0
c
17
IJ5
0 5
l 51N
695
I
Il
I
q 0 2
o 0
V
W
i i 0i I
0A 3
n
4 h rl
J
1C 11
ol N
r
2 tt l L
l
Fronlu ocnIrli
I
I 70S
I
I
II 11
i
I
l I t 1 7
1 1
39
Nol Ih J if
tt I
IolJ11
68 161
I
i
6
f
I l1
1
I
ig 61
L I
U
28 3
8 45
91
g1
i 14
h
rr
19
A
109 611
I
0
y
l
8
p
A j U
Se lion
LG
9
If J
1 r i
line
H H
o
76 tum
rnmlin
R L
I4 D
Cu no L
Unit
Fm
en
l
c

Service Tools
BODY Special
Tool number
Tool name
Kent Moore No
ST08800000 Sucker
ST08810000 Caulking hand gun

8W
BF 37

DATSUN 200SX Model S 11 0 Series
SECTIONHA
HEATER AIR CONDITIONER
CONTENTS
SERVICE PROCEDURE
I HEATER I PRECAUTIONS FOR REMOVAL AND
HA 24
INSTALLATION HA 24
DESCRIPTION HA 2
REFRIGERANT LINES HA 25
HEATER SYSTEM HA 2
COMPRESSOR IDLER PULLEY HA 25
HEATER COMPONENTS HA 2
COMPRESSOR HA 26
AIR FLOW HA 3
CONDENSER HA 26
SERVICE PROCEDURES HA 4
RECEIVER DRIER ILlOUID TANK HA 26
HEATER CONTROL ASSEMBLY HA 4
FAST IDLE ACTUATOR HA 27
HEATER UNIT HA 5
COOLER RELAY HA 27
BLOWER UNIT HA 6
HA 6
COOLING UNIT HA 27
RESISTOR
AMBIENT SWITCH HA 27
HEATER DUCT HA 7
EXPANSION VALVE AND SUCTION THROTTLE
REAR HEATER DUCT HA 7
VALVE HA 28
DEFROSTER NOZZLE HA 7
AIR CONDITIONER CONTROL ASSEMBLY HA 28
VENTI LATOR DUCT HA 7
BLOWER UNIT HA 28
ELECTRICAL CIRCUIT HA B
RESISTOR HA 28
SCHEMATIC HA 8
MAGNET VALVE HA 2B
WIRING DIAGRAM HA 8
TROUBLE DIAGNOSES
COMPRESSOR SWP167 HA 29
PRECAUTIONS HA 30
AND CORRECTIONS HA 9
COMPRESSOR CLUTCH HA 30
SHAFT SEAL HA 32
SIDE COVER
I AIR CONDITIONER I HA 33
REAR END COVER AND REAR CYLINDER
HEAD HA 34
DESCRIPTION HA l0
REPLACEMENT OF CYLINDER HA 35
REFRIGERATION CYCLE HA l0
ELECTRICAL CIRCUIT HA 37
AIR CONDITIONING COMPONENTS HA ll
SCHEMATIC HA 37
LOCATION OF ELECTRICAL AND VACUUM
WIRING DIAGRAM HA 38
UNIT HA 12
TROUBLE DIAGNOSES
AIR FLOW HA 12
AND CORRECTIONS HA 39
GENERAL SERVICE HA 13
AIR CONDITIONER DIAGNOSES 39
HA
PRECAUTIONS HA 13
BLOWER MOTOR DIAGNOSES 4l
HA
INSTALLING MANIFOLD GAUGE HA 13
COMPRESSOR CLUTCH DIAGNOSES 43
HA
HANDLING REFRIGERANT SERVICE CAN
COMPRESSOR DIAGNOSES 45
HA
TAP HA 14
FAST IDLE CONTROL DEVICE DIAGNOSES 47
HA
DISCHARGING REFRIGERANT HA 14
SERVICE DATA
EVACUATING AND CHARGING REFRIGERANT
AND SPECIFICATIONS 48
HA
SYSTEM HA 14
GENERAL SPECIFICATIONS 48
HA
COMPRESSOR OIL LEVEL CHECK HA 16
INSPECTION ANO ADJUSTMENT 48
HA
PERFORMANCE TEST HA 17
TIGHTENING TOROUE 48
HA
PERFORMANCE CHART HA 17
SPECIAL SERVICE TOOLS 4
HA
PERFORMANCE TEST DIAGNOSES HA 20
Ref to Section MA Heater and Air Conditioner for

CHECKING REFRIGERANT LEVEL
CHECKING REFRIGERANT LEAKS
Reflr to Section MA Basic MechaniClI Systam for
CHECKING AND ADJUSTING DRIVE BELTS

r
Desrription HEATER
DESCRIPTION
HEATER SYSTEM
To defroster nozzle
To ventilator duct To Yentilator

duct
c o t Fresh air
Intakedoor
Jr 5L lLJU J
J
eciJculatiOD
I
nn
J
JUlT
au
Floor
door L j 1I11
i
hJ
L
1b To ear
r
S er I Air mix
L
door Blower motor
To floor To floor To rear To floor

heater
Side view duct Heater core
SHA113
HEATIE R COMPONENTS
Side defroster
QDterddroster oo
Blower motor
IIJrffi5
Side defrolter
noule Heater core f oClfj
I
Water coet
Heater duct
Heater control
assembly Side ventilatnr

duct
fritch
AirSUide
0 Air uide
C tiniaher
eonaol
SHA114
HA 2

HEATER Description
AIR FLOW
VENT position
Fresh air
FRESH
positio7n j
1
VE po t n
1
I
r o
5
if
to
tjJ
C
li Il
l H
Jc
111111111111 rlrl
1I
the desired position Side view
BIL BI Ievel position TOVentil torduc

roster
ll l
1
brr
L
o
17
i
jfd
lij
o
Move the lever L
the desired O
pos
To floor To rear To floor
heater duct
DEF position
DEF POsition FRESH
positixJD1
o
Move thelever
E
3
1ky
l r
the desired
position
HEAT position
To defroster nozzle
FRESH POsit
HEAT POsitioo
7
II
J o
4 tb1 L
Move the lever
daired POI V To floor To rear To floor
heater duct
REC position Recirculation
TpoIition
REC7
ition
Tf rl
oo
jJ
Move the Ie
r
J
o
0 If sL r tjfT
Il
LTCi t
I
J
lllllll
J
the desired Ji Y
io
SHA116
J
HA
f
ServkeProcedut HEATER
SERVICE PROCEDURE
HEATER CONTROL
ASSEMBLY
REMOVAL AND Always conduct
INSTAUATION
I Tenn DIQ
I @ I
I Remove instrument lower covers
and cluster lids

2 Disconnect
heater unit and blower unit
control cab les from r Wuntinatioo lamp
3 DiscOnnect harness connectors
and wire terminal

ground
SHA116
@
IDumination
4 Remove pivot pin lamp
I Terminal OFF 2 3 I
I @ II I
L I
I
@ I
I 0
I
I
I @ I
I
SHA117
QD
@
I
Iv
I
16 i1 I
SHA118
5 Remove heater control assembly

6 Installation is in the reverse order ADJUSnNG HEATER
REC position
of removal CONTROL
Alter installing adjust control cable

Inbke door control cable
by ref ring to Adjusting Heater Con I
trol I Set air intake lever at REC posi
tion
2 Connect control cable to air in

INSPECTION
take door lever while pushing lever to
its Closed position
Fan switch
3 Securely clamp the cable while
Test continuity through switch cable outer in direction
pushing case
with a test lamp or ohnuneter of arrow
SHA119
4
HA

H EATER Service Procedures
Air mix door control cable Water cock control linkage 6 Radio sound balancer and stereo
I Settemperature lever at max I Set air mix door cassette deck
lever at max
COLD position COW 7 Stay ofinstrument panel
position
2 Connect control cable to air mix 2 Securely clamp control rod while
door lever while pushing lever to its pushing water cock lever to its full
full open position closed position
3 Securely clamp
pushing cable outer
the
case
ble
ca
in direction
while
I
of arrow
c
I4f
c
a
1
M M Max COLD position
Adjusting saew
r
Max COLD position
8 Rear heater duct
SHA18Q SHA122
A1rcontrol ceble
I Set air control HEATER UNIT SHA 125

lever at DEF
position
2 Connect REMOVAL AND
control cable to side
while INSTALLATION
linkage pushing the linkage in
direction of arrow I Set TEMP lever to max HOT 19 Center ventilator duct
3 Securely clamp the cable while position and drain engine coolant
pushing cable outer case in direction 2 Disconnect heater hoses from
of arrow heater unit
3 Remove foUowing Wis
DEF position I Front seats
2 Console box
3 Floor carpet
I 4 Instrument lower and
covers
1
I cluster lids I
5 Side ventilator duct on the left

hand side
SHA126
SHA121
SHA123
HA 5
Service Procedures HEATER
10 Air lower outlets

guides at r Il core
Clean fms and check for water leak

age
BLOWER UNIT
REMOVAL AND
INSTAlLATION
r I Remove instrument lower oover
SHA1 29 and cluster lid on tIie right hand

2 Disconnect control cable and
harness connector from blower unit
Right side guide 3 Remove blower unit

2 Remove air control linkage secur
ing screws
SHA127
I
SHA132
4 Disoonnect wire harness connec SHA130
tions 4 Installation is in the reverse order

5 Remove heater J1it
1 with heater of removal
lntrohssembly heater unit
5eparate by
case re
Adju 1 corrtrolcablebi
r
moving clips referring to Adjusting Heater Control

4 Assemble heater unit in the reo
verse order of disassembly

DISASSEMBLY
a After installing heater core and
I Remove blower D otor
water cock lKljust water cock co
trol linkage by referring to Adjust
ing Heater Control

b When assembling air control link
age set it as illustrated
SHA128
6 Remove heater control assembly

Refer to the item o Heater Control
Assembly
7 Installation is in the reverse order
of removal
2 Separate blower unit case by reo
After
installing heater unit lKljust
moving clips
control coble by referring to Adjusting SHA131
Heater Control
RESISTOR
INSPECTION
DISASSEMBLY AND REMOVAL AND
ASSEMBLY Ce e INSTALLAnON
I Remove heater core witli water If it is cracked or deformed re I Remove instrument cluster lid
cock place 2 Remove resistor from heater unit
6
HA

HEATER Service Procedures
REAR HEATER D CT VENTILATOR DUCT

REMOVAL AND REMOVAL AND
INSTALLATION INSTALLATION
Refer to the item on Heater Unit
Center ventilator duct
Refer to the item on Heater Unit
Side ventilator duct
DEFROSTER NOZZLE Left ide

Temperature
fuse Refer to the item on Heater Unit
REMOVAL AND
IN TALLATION RighUide
Proceed after removing instrument
Front window defroster

assembly
nozzle
Resistorw Proceed after reJlK ving instrument

SHA134
assembly 3 F
3 Install resistor so that temperature

fuse locates at upper side
J
INSPECTION c
Test continuity using test lamp or
ohmmeter SHA139
jf Foot ventilator duct

SHA137
@ I
I
J Side window defroster nozzle

lower covers and cluster lids
uCD o@ Left side
HEATER DUCT
SHA 140
REMOVAL AND
INSTALLATION
lower cover and cluster lid on the right
hand side
Right side
SHA136
HA 7

Electrical Cirwir HEATER
ELECTRICAL CIRCUIT
SCHEMATIC
TO WIPER
TO AI R CONOlTlONER SWITCH
I FUSE ISA
u
RESISTOR BLOWER MOToR
O
1
1M
I c
W
I
n
u
r IGNITION
RELAY
Jl LAM
1
15
I c
J r
FAN SWITCH L ILLUMINATION

CONTROL SWITCH
BATTERY IGNITION
SWITCH
B Q I
FUSIBLE LINK
SHA141
WIRING DIAGRAM
RESISTOR
4J
BLOWER
MOTOR
j LHJ
3
J
TO WI fR
P
ow JI TO AIR
CONDITIONER
It SWITCH
f j
LIGHTING
SWITCH
4 e FAN SWt reH

00 FUSE
2
tl GN
RELAY
T ON
IUUIIIINATION
L P
1 IG IITION
SWITCH
ILlUMlNATIONC J
CONTROL
SWI reH FUSIBLE LINK
i
f BATTERY
SHA 14
S
HA

HEATER Trouble Diagnoses and Corrections
Condition Probab Ie cause Corrective ction
Insufficient heating
performance
No heated air Cooling water temperature too low Check thermostat
discharged Replace as necessary
Heater core plugged Clean
Insufficient cOoling water level Refill
Malfunctioning air mix door Adjust control cable
Malfunctioning water cock Adjust control cable Check water cock

Replace as necessary
Insufficient air flow Blower motor speed too low Check motor terminal voltage
to floor Repair poor connection and discontinuity
Replace motor if necessary
Malfunctioning floor door Adjust control cable
Insufficient defrosting
performance
Cold air discharged Refer to No heated air discharged
Insufficient air flow Malfunctioning floor door or faulty seal Adjust control cable
to defroster Defroster nozzle plugged Clean
Leak at defroster duct to nozzle connection Correct
Heated air discharged Water cock not operating properly Adjust control cable Check water cock
with lever in VENT Replace as necessary
Mode door not operating properly or seal Adjust control cable
damaged
Blower motor does Refer to Trouble Diagnoses and Corrections

not operate Air conditioner
Control lever drags Inner wire rubbing against outer case end Adjust control cable
Control cable bent excessively Correct
Malfunctioning doorn door levers etc Check and correct
Outside air comes in Air intake door not operating properly Repair or rep ce
with AIR control control cable

Control cable out of adjustment Adjust
lever REC
Noise from blower Loose bolt in blower motor Check and tighten loose bolts
motor
HA 9

Description AIR CONDITIONER
DESCRIPTION
REFRIGERATION CYCLE
Compressor
The low pressure refrig
erant is compressed
to a h SU1C and
pJe High pressure Low pressure
high Jle gas liquid
N
i
l High presswe Low pre
1 1
0 sure
t
liquid gas
r
Is
Outside air
I l l
Recirculation air
u V
Condenser Evaporator
The heated and com The refrigerant liquid
lPIl I
pressed refrigerant gas evaporates and cools
Iv
xyyv
J
from the compressor the air
I
condenses to aliquid
w
o w b
R drier qw
v i t e
Stores the liquid refrig fL
erant and
JJ
removes w
moisture and foreign Blower motor

particles as the refrig
erant circulates within
the system
tmfJ Controls the enporat
ins pressure and pi

vents
the frost
e fomation of
Expansion valve
i
DeliVers sprayed refrig
erant to the eVaporator
High pressure valve Low pmmue switch to facilitate refrigerant
Discluuges refrigerant Tums OFF at pressures h hl and con
to atmosphere at pres trols the amount of re

below 196 IcPa 2 81
lfes above 3 727 IcPa em 2 28 psi cutting frigerant possing the
38 kgfem2 540 psi compressOI power
orifke
supply
SHA 142
HA l0

AIR CON DITION ER Description
AIR CONDITIONING COMPONENTS
a
o
I
1I
5
s
a
o
l
L
e
8
j
j
SH 143
HA ll

ription
Desr AIR CONDITIONER
LOCATION OF ELECTRICAL AND VAcuuM UNIT
SHA1
AIR FLOW
through cooling unit
Air
flow at any position VENT same as that of HEATER except that passes
aU air discharged with blower unit
B L HEAT DEF and REC is the
O ide air
To To
defroster ventilator n
nozzlll duct To delio tor now 1
Ventilator door
1t
7u
r
1
T
ilJ
t iIllJlL
1Mi 7
1 i lr
Qjr mower motor
To floor
Side view
To f1oor To
rear
heater
duct
ll To floor
Heater core
SMA 146
J
HA 12
J
AIR CONDITIONER General Service
i
i
GENERAL
r
SERVICE
PRECAUTIONS INSTALLING MANIFOLD GAUGE
WARNING
Hoses for the low pressure valve suction valve and high pressure valve discharge
1 Since direct conlllct of the liquid valve should be connected securely to high and low respectively on the manifold
refrigerant with your skin will
Refer to identification marks on
compressor
muse frostbite always be careful
when handling the refrigerant
Always wear goggles to protect
your eyes when working around
the system
2 The refrigerant service conllliner
has safe strength However if
a
handled incorrectly it will ex Low pressure High pressure

plode Therefore always follow gauge gauge
the instructions on the label In

store it in a hot Manifold
particular never
gauge
location above S20C 1260F
ordrop it from
high height
a
Before connecting
3 The refrigerant gas is odorless hoses close valves
and colorless and breath ing may completely
become difficult due to the lack
of oxygen Since the refrigerant
gas is heavier than air and will

lay close to the floor be espe
cially careful when handling it in
small confined spaces
Q
4 The refrigerant itseit is nonflam
mable However
phosgene gas is
a toxic gas
produced when
it conlllCb fire and special care is
therefore required when check
1fT
Vacuum
o en
R 12
pump
ing for leaks in the system with a Refrigerant
can SH A045
halide torch
5 Do not steam clean on the sys
tem especially condenser since
excessively high pressure will

build up in the system resulting
in explosion of the system
Connection to service v lve Disconnection from
I Funy close both valves of mani

fold gauge Connect high and low
r service valve
I Fully close both valves of mani
pressure charging hoses to manifold fold gauge
gauge
2 Remove caps from service valves
Connect high and low pressure charg
ing hoses to service valves in system
Close
S 2 Quickly disconnect two
hoses from service valves and install
caps on service valves

charging
I Cap 4
Packing CAUTIDN
2 Service valve 5 Check valve Do not over tighten valve cap
3 Cha rging hose
HA 13
General Service AIR CONDITION ER
HANDLING EVACUATING AND

REFRIGERANT CHARGING
SERVICE CAN TAP REFRIGERANT
I SYSTEM
The foUowing procedures apply to
conventional can taps

For correct usage refer to the EVACUATING REFRIGERANT
manufacturer s instructions SYSn W
Purging air
I Connect charging hose between I InstaU manifold gauge on system
W
manifold gauge and can tap and discharge refrigerant from system
2 FuUy turn in close valve stem of Add until pressure reaches atmospheric
manifold gauge pressure
3 Fl 12
Attach can tap to refrigerant can
by turning can tap handle fuUy SHA04S
counterclockwise WARNING
4 Make a hole in refrigerant can by Securely connect high pressure dis
turning can tap handle clockwise charge service valve to that of

manifold gauge with a hose also
DISCHARGING connect low pressure suction
n REFRIGERANT service valve to that of manifold
Car tap handle gauge
The pressurized refrigerant gas in
side the system must be discharged at
Needle
a pressure approaching atmospheric
pressure prior to evacuating refrigerant 2 Connect center charging hose to
inside the system vacuum pump
r I Close high and low pressure 3 Close both valves of manifold
Refrigerant valves of manifold gauge fuUy
gauge fuUy Then start vacuum pump
an 2 Connect two charging hoses of 4 Open low pressure v alve and SlIck
manifold gauge to their respective old refrigerant from system
service vavles
SHA046
WARNING
Securely connect high pressure dis
charge service valve to that of
manifold gauge with a hose also
5 cOnnect low pressure suction

TUrn the handle fully counter
service valve to that of manifol
clockwise to raise the needle Refriger
gauge
ant gas will flow up to the manifold
gauge p
3 Open both manifold gauge valves Open Oose
and
n discharge refrigerant from system
40
U0 SHA060
LO
SHA041
rJ High
1
Slowly Slowly
5 When low pressure gauge reading
6 Purge air from charging hose by has reached toapproximately 66 7 kPS
loosening charging hose nut at mani 40
500 mrnHg 19 69 inHg slowly open
fold gauge SHA949
high pressure valve
HA 14

AIR CONDITION ER GeneralSefYice
MA section When refrigerant charging peed i
3 Discharge refrigerant again and slow immerse refrigerant can in water
then evacuate system heated to a temperature of about
400c I1Q4OFl for a short time
WARNING
CHARGING REFRIGERANT
a Under no circumstances the re
SYSTEM
0
Low lligh frigerant can be wanned in water
I Evacuate refrigerant system heated to
a temperature of over
2 Close manifold gauge valves 520C 1260F
securely and disconnect charging hose b A blow torch
W lOpen from
or stove must
vacuum pump never be used to warm up the
3 Purge air from center charging can
hose
00 SHA051
I Connect center charging hose to
refrigerant can through can top
2 Break seal of and
refrigerant can
purge air
has Immerse
6 When pressure inside system zl in water
i
6 kPa 710 A 12
dropped to 94 mmHg heated to
27 95 inHg fully close both valves of about
400C
manifold gauge and
stop vacuum r
1040F
Let it stand for 5 to 10 minutes
pump for a short
in this state and confIrm that the I time
reading does not rise AC184A
B The low pressure gauge reads lower
by 3 3 kPa 25 mmHg 0 98 inHg 2 ln case of charging liquefied re

air
per 300 m 1 000 itl elevation 1 Purging
frigerant
Perform evacuation according to
the following table

k fold
Open high
gauge
pressure valve of mani
and charge liquefied reo
frigerant into system with can upside

Elevation Vacuum of system R 12
down
m ft kPa mmHg inHg
SHA048
CAUTION
0 0 94 6 710 27 95
When charging liquefied refrigerant
300 I 000 3 685 26 97
91
4 Charge refrigerant into system into the system with the can turned
600 2 000 0 660 25 98
88 I I n case of charging re igerant gas upside down to reduce charging tima
900 3 000 84 6 635 25 00 Open high and low pressure valves charge it only through high pressure
of manifold gauge and charge refriger discharge service valve After com
Valuesshow reading ofthe ant into system pletion of
charging the compressor
low pressure gauge should always be turned several times
manually
b The rate of ascension of the low
pressure gauge should be leIS than

3 3 kPa 25 mmHg 0 98 inHg in
five minutes
If the pressure rises or the specified

Low
negative pressure ean not be obtained
there is aleak in the system In this

ease repair the leak as described in the lt lt
O
following o
W n
I Charge system with a can of t

refrigerant about 0 4 kg 0 9 Ib
9ft Open Close Open
r
Refer to Charging Refrigerant
t
2 Check for refrigerant leakage with
a leak detector Repair any leakages SHA052 10 SHAOS
found Refer to Checking for Leaks
HA 15

General SefVice AIR CONDITION ER
5 When refrigerant charginiJ sPeed Refrigerant capacity doors of car Opernte compressor at
slows down while running
charge it 0 9 1 1 kg 2 0 2 4Ib engine idling speed 1 000 rpm or be
the compressor for ease of charging low with controls set for maximum
After having taken the steps up to 3 cooling and high blower speed for 20
above proceed with cahrging in the to 30 minutes in order to return com
following order pressor oil to compressor

I Shut off high pressure valve of
Measure the a
manifold gauge mount or
2 Run the engine at idling speeds charged refriger
below 1 ant with a scale
500 rpm
Make a note of
3 Set mode ON
dial temperature dial the amount
and fan lever at maximum 0001 and charged from i
speed respectively
4 Charge refrigerant while oon
can
AC252
11
1
trolling low pressure gauge reading at MAX FAN
MAX COLD SPEED
275 kPa 8 kg em2 40 psi or less
2 The state of the bubbles in sight
by turning in or out low pressure valve
glass should only be used for checking
SHA376
of manifold gauge whgther the amount of charged r
frigerant is small or not Refer to
WARNING Level Section
Checking Refrigerant
l
NgVl
wrge mrigerant through MAl charged refriger
The amount of 2 Stop the engine and discharge re
high pressure side discharge side ant can be correctly judged by means of system and then
frigerant remove
of systerri since this will fon

e nt of discharge pressure oompressor from the car
frigerant back into refrigerant can
8 Close manifold gauge valves Then
3 Remove oompressor drain plug
and can may explode Drain compressor oil from oompressor
detach charging hoses from service
oil siunp and measure the amount
valves of system Be sure to install
valve cap on service valve

9 ConIum that there are no leaks in
Run at
system by checking with a leak detec
tor
idling
Refer to Checking for Leaks MA
1 section
Conducting a performance test

w
prior to removing manifold gauge is 8
good service operation Refer to Per
formance Test
aose SHA056
t
T
COMPRESSOR OIL
Residual l
oille
Q
LEVEL CHECK 160 190 m
5 4 6 4 US OZ
The oil used to lubricate the com
SHA054
5 6 6 7 Imp fl ozl
pressor circulate into the system from
the ail sump while compressor i 4 If the amount is below the above
operating Therefore to correctly values may have leaked
refrigerant
6 When is
refrigerant can empty measure compressor oil the amount of Conduct leak tests on connections of
fully close both valves of manifold oil flowing in the system must be each system and if necessary repair or
gauge and replace refrigerant can with considered If a considerable amount

replace faulty parts
a new one of of
leakage refrigerant gas occurs 5 Check the purity of the oil If the
Before ftom
charging refrigerant tha leakage of compressor oil is also oil contains chips or other foreign
new can purge air from inside charg considered material clean oil sump with new oil
ing hose When checking the level of oom 6 Discard the used oil and fill with
7 Charge the specified amount of pressor oil or when replacing any the sanie amount of new oil as was
refrigerant into system by weighing w

r
ent part ofthe system use the drained when removing compressor If
charged refrigerant with scale Owr following service procedure This helps the residual oil level is below the
lg will cause discharge pressure
chargi to return oil to oompressor minimum level add additional oil to
to rise I all windows all
Fully open or reach the minimum level
HA 16

AIR CONDITIONER Performance Te t
PERFORMANCE TEST
PERFORMANCE CHART
TEST CONDITION
Testing must be performed as follows
Car location Indoors or in the shade outside wind velocity Less than 2 m 7 ft sec
Doors Closed
Door window Open

Hood Open
MODE dial Max COLD position
TEMP dial Max COLD position
FAN lever 4 positions

Engine speed 1 500 rpm constant
Manifold gauge Connect manifold gauge to high discharge and low suction service valves
Measurement of discharge air temperature Center outlet grille
Measurement ofinside air relative

humidity and temperature Blower assembly inlet
Measurement of ambient air relative

humidity and temperature A point 1 m 3 ft in front of condenser
HA 17

Performance Test AIR CONDITIONER
TEST READING
Inside air Recirculating air

at blower assembly inlet
Discharge air temperature at center ventilator
Relative humidity Air temperature oCoF

Oc OF
15 59 4 5 5 2 40 41
20 68 65 75 44 46
25 77 8 7 9 8 48 50
40 50
30 86 8
10 2
12 51 54
35 95 12 9 14 5 55 58
40 104 15 0 17 0 59 63
15 59 5 2 5 8 41 42
5
8 46 47
20 68 5
7
25 77 8
9 110 50 52
50 60
30 86 12 2 5
13 54 56
35 95 5
14 16 2 58 61
40 104 17 0 18 9 63 66
15 59 5 8 6 5 42 44
20 68 5
8 94 47 49
25 77 11 0 12 3 52 54
60 70
30 86 J3 5 15 2 56 59
35 95 16 2 18 2 61 65
40 104 18 9 1
21 66 70
15 59 5
6 1
7 44 45
20 68 94 3
10 49 51
25 77 12 3 13 7 54 57
70 80
30 86 15 2 17 0 59 63
35 95 18 2 2 65
20 68
40 104 1
21 23 5 70 74
15 59 1
7 7 9 45 46
53
I 25 68 3
10 n5 51
13 7 0
15 57 59
80 90
I 30 77
17 0 18 6 63 65
I 35 86
r 40 95 20 2 22 2 68 72
23 5 26 0 74 79
I 45 104
HA 18

AIR CONDITIONER Performance Test
Ambient air
Pressure high Discharge side Pressure low Suction side
Relative humidity Temperature kPa kg cm2 psi kPa kg em2 psi

oCF
500 657 93 2 1
98
15 59
1
5 6 7 73 95 0 95 100 5
13 14 2
755 834 103 0 112 8

20 68
5 109
8 121 105 15
1 14 9 16 4
7 7
922 1 010 l22 1i 3

137
25 77
94 3
10 134 146 125 I 40 17 8 19 9
40 65
1 079 1 196 142 2 156 9
30 86
110 12 2 156 173 I 45 1 60 20 6 22 8
1 245 1 373 156 9 5

176
35 95
7
12 14 0 181 199 1 60 1 80 22 8 25 6
1 393 1 550 5
176 1
196
40 104
14 2 15 8 202 225 180 2 00 25 6 4
28
657 726 1
98 li2 8
15 59
6 7 74 95 105 100 15
01 14 2 i6 4
1
834 922 112 8 132 4

20 68
5
8 94 121 134 15
1 35
1 16 4 2
19
1 010 1 118 3
137 152 0
25 77 22 0
65 90
3
10 II 4 146 162 140 55
1 19 9
1 196 1 314 156 9 171 6

30 86
12 2 4
13 173 191 1 60 75
1 22 8 24 9
1 372 1 510 176 5 1

196
35 95
0 154 199 219 1 80 2 00 25 6 4
28
14
1 550 1 716 1
196 220 7
40 104
15 8 5 225
17 249 2 00 2 25 28 4 32 0
a The pressure will change in the will drop If the test reveals that there is any
following manner with manges in b The temperature will change in the abnormality in system pressure isolate
cond itions following manner with changes in the cause and repair Refer to Per
When blowerspeed is low dis conditions formance Test Diagnoses
charge drop
pressure will When the 8rrmient air temperature
When the relative humidity of in is low the outlet air temperature
take air is low discharge pressure will becomg low
HA 19

Perfonnance t
Te AIR CONDITIONER
PERFOR NCE As to the method of a performance indicateS a range baSed on the lissump
test refer to the item of Performance tion that the air conditioning system is
TEST DIAGNOSES
Test in good order This range is described
Characteristics revealed on the in PERFORMANCE CHART
manifold gauge rcading for the air
conditioning system are shown in the In the following table the portion
following smeared with ink on sam gauge scale
I INSUFFICIENT REFRIGERANT CHARGE
Insufficient cooling Refrigerant is small I Leak test

1 or
Bubbles appear in sight leaking a little 2 Repair leak

3 Charge system
glass
00 @
EVKUatB
and
as
recharge system
necessary
@
AC352A
ALMOST NO REFRIGERANT
I Stop compressor immedi
ately
No cooling action Serious refrigerant leak 1 Leak test
2
In sight glass appear a lot Discharge system
of bubbles or something 3 Repair leak s
00 like mist 4 Replace receiver drier if

neCessary
5 Check oil level
6 Evacuate and recharge
system
@ @
AC353A
I FAULTY EXPANSION VALVE I

Sight cooling Expansion valve restricts If valve inlet reveals sweat
frosted expan refrigerant flow or frost

Sweating or
sion valve inlet Expansion valve is clog IDischarge system
ged 2 Remove valve and clean
0
Expansion valve is in it Replace it if neces
operative sary
Valve stuck closed 3 Evacuate system
Thermal bulb has 4 Charge system
lost charge
@ @ If valve does not operate
IDischarge system
2 Replace valve
3 Evacuate and charge
AC354A
system
HA 20

AIR CONDITION ER Performance rest
Condition Probable cause CorreCtive action
Insufficient cooling Expansion valve allows too Check valve for operation
much refrigerant through If suction side does not
010
Sweated suction line
evaporator show a pressure decrease
replace valve
@ @
fg fi f AC355A No cooling Faulty expansion valve L Discharge system
2 Replace valve
Sweating or frosted sue
3 Evacuate and replace
tion line
system
0
@ @
AC356A
FAULTV SUCTION
I THROTTLE VALVE Insufficient cooling

Frosted evaporator
Suction
inoperative
throttle valve is I
2
Discharge system
Replace valve
system
C0
@ @
AC357A
Insufficient cooling Suction throttle valve I Discharge system

restricts refrigerant flow 2 Replace valve
system
0
@ @
AC358A
HA 21
Perfonnance Test AIR CON DITION ER
I AIR IN SYSTEM
I
Insufficient cooling Air mixed with refrigerant IDischarge system
r in system 2
Sight glass shows occasion Replace receiver drier
al bubbles 3 Evacuate and charge
010
system
@ @
AC359A
I MOISTURE IN SYSTEM
I
After operation for a Drier is saturated with I Discharge system
while pressure on suction moisture Moisture has fro 2 drier
Replace receiver
side show at
may vacuum zen expansion valve twice if necessary
pressure reading During Refrigerant flow is restrict 3 Evacuate system com
010 this
air
warning
condition
will be
shows 39 kPa
6 psi vibration
warm
of this
discharge
As
reading
0 4 kg cm2
a
ed
4
pletely
minute
times
Repeat
evacuating three
Recharge system
30
@ @
AC360A
I FAULTY CONDENSER
I
No cooling action engine Usually a
malfunctioning Check fan belt and
may overheat condenser fluid coupling
Bubbles appear in sight e Check condenser for
glass of drier dirt accumulation
Suction line i very hot Check engine cooling

system for overheat
t Check for refrigerant
overcharge
00
If pressure remains high
in spite of all above ac
tions taken remOW8 and
inspect the condenser for
possible oil dogging

@ @
AC361 A
HA 22

AIR CONDITIONER SelViceProceduref
I HIGH PRESSURE LINE BLOCKED

I
Insufficient cooling Drier clogged or restrie I Discharge system
tion in high pressure line 2 Remove receiver drier
Frosted high
6
pressure
or strainer and replace
liquid line
it

system
@ @
AC362A
I FAULTY COMPRESSOR
I
Insufficient cooling Internal problem in com I Discharge system
pressor or damaged gasket 2 Remove and check
and valve compressor
00
3 Repair or replace com
pressor
4 Check oil level
5 Replace receiver drier

@ @ system
AC363A
TOO MUCH OIL IN

Insufficient cooling Too much oil circulates Refer to Oil Level Check
SYSTEM Excessivel
with refrigerant causing for correcting oil level
the cooling capacity of the
system to be reduced
r
0
@ @
AC364A
HA 23

AIR CONDITIONER
ServiceProcedu
s
SERVICE PROCEDURE
4 After
PRECAUTIONS FOR disconnectinll tubes plug all
openings immediately to prevent

REMOVAL AND
entrance of dirt and moisture
INSTALLATION
When replacing refrigerant cycle

components observe the following
1 Discormect battery ground cable
2 Before starting work be sure to
discharge system
SHA059
I uamnr
s
WARNING
Gradually loosen discharge side Plug
hOse fitting and remove it after
remaining pressure has been re SH A058
IlIIsed
3 When disconnecting or connecting

tubes be sure to use wrenches on
both tubes
7 Check tightening torque of con
nedions tolpecification
8 Make sure refrigerant line is
clamped securely
Check all componenb t insure
5 Compressed air must never be neither damaged interfere
they are nor
usad to dean dirty line Clean with with adjacent parts

refrigerant gas 9 Conduet leak test and make sure
6 When connecting tubes install that there is no leak from connections
new a ring never reuse used one into 10 Determine quantity of oil to be
connection and be sure to apply com into compressor
charged by referring
pressor oil to seating surface and 0 to Compressor Oil Level Check in
SHA057
ring General SerYi
HA 24

AIR CONDITIONER ServiceProcedure
REFRIGERANT LINES
Insull new Oing into each connection

of tubes
OloUng unit
10 8 0 8 1 5 8 8 0
J15
i 20 1
5 2 0 11 14
J
i N m kg m ft lb
SHA148
J125
i 29 5
2 3 0 18 22
COMPRESSOR IDLER PULLEY
REMOVAL AND
Loosen
INSTAlLATION
1 Rem e under cover
2 Loosen idler pulley lock nut and
fully loosen adjusting bolt

3 Remove drive belt
4 Remove idle pulley assembly
ofremoval
Refer to Section MA for adjusting

drive belt
Adjusting bolt
SHA149
HA 25

ServiceProcedures AIR CONDITIONER
COMPRESSOR CONDENSER
REMOVAL AND
INSTALLATION
I Remove radiator grille
2 Remove stay for hood locI
upport
401 lines from
3 Disconnect refrigerant
condenser
4 Remove condenser
of l l
INSPECTION
and outlet
Inspect joints of inlet
pipes for cracks and scratches Upon
rmding any problem which may cause
gas to leak repair or replace con
denser
Condenser fIns or air passage clog
5414 5 with dirt insect or leaves will
ged
Q N ft lb SHA150
m m
kg reduce cooling effIciency of con
denser In such a case clean fms or a
passages with ed air

compr
3 Remove with it CAUTION

R MOVAL AND compressor
Do not clean condenser with steIIm Be
INSTALLATION clutch facing up
sure to use cold water or compressed
I Operate compressor if possible at air
CAUTION
engine idling peed with air condi Do not attempt to leave the com
tioner controls set for maximum cool
pressor on its side or upside down for
ing and high blowerspeed for 10 to IS
more than 10 minutes IS 1IIe com RECEIVER DillER
minutes with all windows open to
pressor oil will enter the low pressure
return oil into compressor
chambers If under that condition Liquid tank
2 Remove compressor drive beh
compressor should be operated sud
Refer to the item on Compressor
denly interllll damage would result
Idler Pulley To expel oil from chambers hand
3 Disconnect high discharge and
crank compressor several times in its
low uction fleXible hose from com
installed condition
pressor
4 DiScOnnect compressor clutch
harness
5 Remove compressor of removal
1 DiSconnect air induction pipe When conneeting high and low

flexible hoses to compressor install
SHA152
new O ring into connectiQn
REMOVAL AND
INSTALLATION
I Disconnect refrigerant line from

receiver drier
J CAUTION
5HA317
Plug all openings to e
enttem
of din and moistUre into l1lC iver
drier
2 Remove ignition coils
HA 26
AIR CONDITIONER ServiceProcedures
2 Disconnect harness for low pres 2 Disconnect refrigerant lines from 3 Assembly is in the reverse order of
Sure switch cooling unit disassembly

3 Remove receiver drier 3 Remove cooling unit with drain
4 Installation is in the reverse order tube
of removal
INSPECTION
INSPECTION V
c
Check receiver drier for leaks or
If necessary Check for cracked or deformed

damage replace
case
Ev por tor mbly

FAST IDLE I Clean fms and check for corro
ACTUATOR sion If fins are corroded replace
Drain tu SHA155
From
Q F IC D magnet valve
CAUTION
Do not clean evaporator with steam
Be sure to use cold IIIIIter or com
pressed lir
of removal
FrOmair 2 Check for gas leaks at expansion

regulator tube valve and suction throttle valve If
SHA 153 there are leaks retighten orreplace the

Intake manifold
defective part with a new assembly
DISASSEMBLY AND
ASSEMBLY
INSPECTION
Refer to Trouble Diagnoses and

Expansion valve
Corrections AMBIENT SWITCH
REMOVAL AND
COOLER RELAY INSTALLATION
f 6
SHA154 SHA157
Thermo bulb
SHA378
COOLING UNIT I Remove instrument lower cover
and cluster lid

REMOVAL AND
2 Disconnect harness connector and
INSTAlLATION
I Remove clips fIxing upper case to remove ambient switch
I Remove instrument lower cover lower case 3 Installation is in the reverse order
and cluster lid 2 Withdraw evaporator assembly of removal
HA 27

ServiceProcedvres AIR CONDITIONER
INSPECTION AIR CONDITIONER RESISTOR

CONTROL ASSEMBLY Refer to Resistor in Heater
REMOVAL AND
INSTALLATION
r Refer to Heater Control Assembly

MAGNET VALVE
1101 INSPECTION
INSPECTION
Ambient F an switch
Continuity
temperatwe
Refer to Fan Switch in Heater
Above 2 SoC 00
Ves
36 410F
Air conditioner switch
Below O 30C
No @
0 370F
Air passing
SHA158 Applied
I voltage CDOO@
I OV 0
0
1
EXPANSION VALVE I 12V
I
AND SUCTION SHA162
THROTTLE VALVE
Thermo bulb Electrical conductivity

Clamp and wrap
with heat insulator Ch CD 2 3 @ CID

c
ON 0 0
0
OFF
lnle
IUwnination lamp is located between

anCl
CD 00 SHAle1
I I I IlJ outle
Suction throttle valve

L Service valve
SHA169
Do not disassemble val neces

BLOWER UNIT
sary replace as Iy Refer to Blower Unit in Heater
HA 28

II C l
5 z rn
I
0Z j
II l 10
f en t
8 rnff0
14
4b
f
m
k8
m
ring
O
ket bOlt
1
N
and hell gas ling fiXing
til seat lnd s
piece piece spring cover cavet

pl ug
25
@
14
13
0
seal seal in
Shaft Shaft
29 30 31 32
Compreso
33 34 3S
D
a
36 37 38
Silencer Silencer Silencer Gasket Side Side
22 2
5
3 8
1
0
3
@ 20
34
screw
til18 bearing cover ring
til29
nut washet and asemblY Gasket Front mouCointi g l Felt Retainer
end
ji1
tl
iJJ
5
2
LOCK LOCK PuloY Coil asembly 23 24 2S 26 21
2
0 20 21 22
@JJ
2
v
@ 35
0
28
0
4 bolt
j 3
iling
as5fmb1y cover cover

1
head
til2 hub
cylinder pump end end 8her
w9 nut nut
Qutch
Gear Rear Rear nd Shan Hub S18paoet 19
pipe
Oll Rear
a
16 11
14 15
11 12 13
8
2
21 20
5
25 2 18
3
12
til
asemblY
6
L1 ring
cylinder
O
6
head plate
covet roing
1
11
cylinder valVe end pipe
Gasket Front suction Gaslo Key Compreso Gasket Rear on

pm
til16 et
nock
j 7
89
10
56
34
1 2
1
21
2 15
8 t
1 13
til18 l

Compressor SWP167J AIR CONDHIONER
2 3 o l
C 1 Shaft nut
2 Hub nut
3 Clutch hub
4 Key
5 Shaft seal seat
r
Y 6 Shaft seal
i1lfJl i 7 Front end cover
A
I 8 Front cylinder head
iMt l 9
10
11
Suction valve plate
Silencer spring
Silencer piece
t
YJt tf 4
r 12 Thrust bearing
13 Side cover
II
I 11 J 14
15
16
Rear cylinder head
Compressor shaft
Rear end cover
c
l
17 Oilp ump
18 Rear
cylinder
4 19 Oilpipe
1 20 Swash plate
21 Shoe disc
22 Front cylinder
@l
23 Drive ball
24 Shell
2S Needle bearing
26 Clutchcoil
27 Pulley and bearing assembly
SHAl64
PRECAUTIONS low pressure side and purge air at the 3 Make sure that terminal voltage at
I
high pressure side magnetic coil is above 105V
all openings in compressor to
Plug
prevent from entering of moisture and
foreign matter
2 00 nc
tleave the compressor on
its side oruplide down for more than
10 minutes as the lubricating oil will
REMOVAL
enter the low pressure chambers If
under that condition I Using Tool KV99412302 hold
compressor
clutch hub With suitable socket
should be operated suddenly internal
would result wrench remove shaft nut from shaft
damage To expel oil
from chambe crank
hand com
2 Then using Tool remove clutch
pressor several times in its installed COMPRESSOR hub nut Remove spacers
condition CWTCH
3 Before replacing with the new
compressor complately drain oil from The most common problem is

the new compressor and fill with an clutch Service
slippage procedures
emount of oil equaling that remaining are listed below Exercise care
in the old compressor I Clearance between clutch hub and
4 When replacing parts or oil pulley should be 0 5 to 0 8 mm 0D20
always replace gaskets Oing and oil to ODJI in at all peripheral points
eal with new ones 2 Make sure that there is no oil or
5 When storing a compressor be dirt on friction surfaces of clutch disc

sure to fill it with refrigerant to pre clutch hub and Remove any
pulley
Add AC024A
vent rusting refrigerant at the oil or dirt with a dry rag
HA 30

AIR CONDITION ER Compressor SWPI67J
3 Using Tool remove clutch hub ifJ Coil mounting screw
2 7 3A
Thread tool into the bore of clutch m
N
hub hold tool with wrench and then 0 28 0 35 kg m
thread in center bolt 2 0 5 ft lb

2
AC028A
six
7 Using an impact tool loosen
ACQ25A coil mounting screws Use of the im AC029
pact tool is advisable as screws have

been calked
2 Using a plastic mallet drive pulley
and bearing assembly onto the neck of
4 With an ordinary screwdriver
the installed coil assembly Turn the
flatten lock washer tab
pulley making sure that there is no
noise and that rotation is free Also

make sure that there is no pulley play
3 Position lock washer and lock nut
in place Using Tool KV994123IO

tighten lock nut firmly With lock
washer tab and lock nut cutouts
matched bend the tab with the screw

AC680
driver Proceed
carefully to avoid
bearing cage damage
ifJ Lock nut

AC026A and 25 27 N
8 Remove coil mounting screws m
2 5 8 kg
separate coil assembly 1 m
18 20 It lb
4 Fit key and clutch hub to the
5 Tool loosen lock nut Re shaft Select spacer which

adjusting
Using INSPECTION
move lock nut and lock washer gives the correct clearance between the
I Check the friction surfaces of the
pulley and clutch hub
clutch for damage due to excessive
Hub nut
heat o excessive grooving due to ifJ
18 21 N m
slippage If necessary replace coil
1 8 2 1 m
kg
assembly and
pulley and bearing
13 15lt lb
dutch hub as a set
2 Oil or dirt n the friction surfaces

5 Tighten shaft nut with locking
should be cleaned with a suitable
solvent and a dry rag agent in place
3 Check coil for shorted or opened ifJ Shaft nut
16 17 N m
binding leads
AC027 A 1 6 1 m
7kg
11 6 12 3lt lb
INSTALLATION
I Using a Phillips screwdriver

6 Using a thickness gauge measure
tighten coil assembly mounting screws
the clutch hub to pulley clearance
6 Remove pulley and bearing as in analternating pattern After screws
clearance
sembly When the assembly can not be have been frrmly tightened puncWock Hub to pulley
removed by hand use a
puller Tooi each at one location to prevent loosen 5
0 0 8 mm
KV994123I3 and Tool KV99412312 ing 020

0 0 031 in
HA 31

lSOr
Comprt SWPI67 AIR CQN OITlON ER
If the specified clearance is not 2 Cormect charging hose to re
obtained replace adjusting spacer and frigerant can Install Tool

rcadjust KV994CI552 to other end of charging
hose and insert it into hole in middle
of blind cover at low pressure side
5 Wrap shaft end with ra8 Apply

refrigerant pressure of 196 to 490 kPa
2 to 5 kg em 28 to 71 psi thrnugh
low pressure line of compressor until
shaft seal seat is received at rag
INSPECTION
AC029A
I Check the carbon seal surface of
CAUTION
a Do not use air to prevent entry of shaft seal for damage
When replacing compressor dutch moisture dust ete
a
embly doforget
not br k in b If shaft slllll seat is not plucked out
operation accomplished by engaging llll
ins it again and apply refrigerant Carbon seal
and disengaging the clutch some thirty
pressure
times Break in Contact surCace
operation raises the
level of transmitted torque
KV994C1552
KV994C4531
KV994C4533
SHAFT SEAL KV994C4559
REMOVAL AC035
I Remove drain plug drain

thereby
ing the oil
2 Remove clutch hub 2 Check Q ring and the carbon seal
pulley and
contact surface of shaft seal seat for
bearing assembly and coil assembly
Proceed according to information damage Make sure that O ring contact
under surface at front end cover is not

Compressor Clutch
3 Using snap ring pliers compress damaged
SHA165
and remove retainer ring
6 Insert Tool through the open end Contact

of front end cover Depress the carbon surface
seal and hook the tool at the case pro
jection of shaft seal Slowly pull out

the tool thereby removing shaft seal
ACS05
INSTALlATION
Do not re use shaft seal seat and
4 To remove shaft seal seat proceed shaft seal
KV994U32
as follows
CAUTION
I Plug high discharge and low
In placing a new seal on the IIIIIrk
suction pressure openings of com
belich mllke sure that the contact
pressor using Tool KV994C4548 or
surface faces upwerd Take necessary
blind cover and gasket which are in
stalled service compressor steps to avoid damage
on
HA 32

AIR CONDITIONER SWPI67
Compressor
Make that the shaft seal 3 of charge 4 Remove silencer springs pieces
I sure con Open valve can top
tact surface is free of dirt and amply refrigerant from low pressure side and and O rings Do not damage O ring
lubricated with compressor oil purge air from high pressure side by surface of silencer piece during this
2 Cap Tool KV994l2322 to the top loosening blind cap process Discard used O rings
end of compressor shaft 4 Conduct a leak test If there is a
3 Using Tool KV9941232l insert leak remove and then install again
shaft seal with shaft seal case and shaft

cutout aligned KV994C1552
KV994C4531
Apply force
what to the left and
to turn the seal some
right Insure that

KV994C4534
KV994C4559
9
shaft seal seats in the shaft
properly
O ring
cutout
Piece
Silencer
pnng
AC207
INSPECTION
I Make sure that side cover gasket
surface and shell gasket surface are not
damaged
AC037 2 Make sure that silencer pieces and
t
shell contact surfaces in contact with
O ring are not damaged
4 Fit O ring to the outside groove of 3 Do not reuse old gasket and O
lbiJ
shaft seal seat making sure that it rings
SHA166
scats properly
5 Apply an ample coat of oil to INSTALLATION
contact surface and shaft seal t so
Do not the compressor
tap on
that seat easily slides on inner side of

shalt
front end cover
SIDE COVER I Place the mounting swface of side
Also apply a thin coat of grease or
cover upward
oil to shaft Push shaft seal seat iilto
REMOVAL 2 Make sure that holes of cylinder
front end cover until it bottoms up to
and shell are alignedand install O
I Drain oil
land
2 Loosen and remove eight side rings
6 Using snap ring pliers compress
in an alternate 3 Coat O ring and the area around
retainer ring and fit it into front end cover mounting bolts
shell hole with an ample amount of
cover Seat retainer ring firmly in the pattern Note that two silencer springs
oil Using Tool
inside the cover will force up side compressor
groove KV99412328 install O ring into the
7 Install Tool KV99412329 to com cover
shell hole Then install silencer piece
pressor shaft and turn shaft 5 to 6 with Tool KV99412327
turns clockwise Then check for gas
4 Coat the gasket surface of shell
leakage as follows with oil and
compressor position
I Plug high and low pressure joints gasket and side cover
into compressor Using Tool 5 Hold side cover in place by hand

KV994C4548 or blind cover and and thread in eight mounting bolts
gasket which are installed on service Tighten these boIts evenly in an alter
compressor nating pattern

2 Connect charging hose to low bolt
lfJ Side cover
pressure gauge of manifold gauge 18 20 N m

Install Tool KV994C1552 to other AC687
1 8 2 0 m
kg
end of charging hose and insert it into 13 14lt lb
hole in middle of blind cover at low
pressure side 6 Fill with compressor oil

Connect center hose of manifold 3 Remove side cover and side cover 7 Upon completion of the above
gauge to referlgerant can gasket Discard the gasket operations cOnduct a gas leak test by
HA 33

Compressor SWP167 AIR CONDITION ER
referring to the item Installation INSTALLATION

under the topic Shaft Seal Do not reuse old and
gasket ring
O
I Using suitable blocks position

compressor with the front face down
ward and the rear upward
2 Insert two pins in the rear of

AR Np CQV cylinder
AND REAR 3 Coat both surfaces of cylinder
CYLINDER HEAD head gasket with compressor oil and
AC042
align gaaket with cylinder
REMOVAL 4 Install suction valve plate making
slife that the three S properly
valV
L Drain oil
align with cylinders and gasket cut
2 Remove five rear end cover
outs
mounting bolts with Tool Starting at
5 Remove O ring gasket and two
the lop loosen all bolts one turn in an
pins Discard the ring
O and gasket
alternating pattern Then remove bolts 6 Remove rear cylinder head
in turn
suction valve plate and gasket Discard
the gasket Carefully remove suction
valve plate avoiding defonnation
7 When removal proves difficult use
Tool Insert this tool into hole in cyl

inder head With the nut in frrm con
tact with the back side of cylinder
head tighten the bolt slowly to break
loose the head AC224
AC6 8
5 Install cylinder head gasket and

ring
O in the order listed q at gasket
and ring
O beforehand with an ample
amount of compressor oil
3 rear end cover and
Grasp carefully
it from compressor
separate Tap the
flange lightly and alternately as reo
quired with a plastic mallei AC210
Do not reuse old and

gasket ring
O
AC045
INSPECTION
I Make sure that the gasket contact
surface is free of damage
2 If replacement of rear end cover
AC689 connector and check valve is neces
sary replace rear end cover with anew
one
3 Check suction valve plate and

cylinder head for broken valves
4 Remove pump gear Do not allow 4 Check pump gear for wear and
pump gear to damage the surface damage
HA 34
AIR CONDITION ER Compressor SWP167
6 Fit pump gear to rear end cover 6 Using long nose pliers or other 9 Remove shaft seal from the shaft
suitable tool out oil pipe Proceed 10 Remove pins
gasket
7 Carefully fit rear end cover to the pull two
rear of compressor carefully as oil pipe is easily bent cylinder head suction valve
plate and
gasket When removing two pins
CAUTION proceed carefully to amid cylinder
Unless oil pipe hIS been removed do head damage Do not deform suction
not attemp t the following steps valve plate in removing suction valve
plate Discard oil gasket
CAUTION
Do not deform R1ction valve plate
when removing it
INSTALLATION
AC211
I Using suitable blocks face
cylinder assembly upward Insert two

8 Using Tool KV99412330 tighten pins Position gasket and suction valve
up five bolts in an alternating pattern plate in the order listed while making
AC212
starting at the top Do not f9rget lock sure that three valves of suction valve
washers aligned with the cylinder and
plate are
fl Rear end cover bolt gasket cutouts Coat gasket with com
7 With the front facing downward
29 34N m pressor oil prior to assembly Gaskets
3 0 3 5 support compressor shell Using a and suction valve plates are the same
kg
22 25 It lb plastic mallet tap at the rear end of for front and rear The cylinder head
the shell flange driving shell straight with the smaller numbers of holes goes
downward Discard front end cover to the front Do not mix front an
9 Fill with compressor oil
gasket
10 Upon completion of the above rear parts
operation conduct a leak test by re
ferring to the topic under Shaft
Seal
REPLACEMENT OF
CYLINDER
REMOVAL
bBJ
AC213 1 ACOS1
l
I Drain oil
2 Remove compressor clutch assem
bly Refer to Compressor Clutch 8 Detach front end cover from
3 Using ring pliers
snap remove cylinder assembly Using a plastic
shaft seal retainer ring Then remove mallet drive end cover upward Re
shaft seal seat Refer to Shaft Seal frain from excessive force to avoid
Removal of shaft seal is not absolutely cover damage
necessary It may be removed when
cylinder assembly i removed from
front end
facilitates work
cover In fact this approach
tj
4 Remove side cover Refer to Side 1 AC052
Cover
5 Remove rear end cover Refer to
Rear End Cover and Rear Cylinder 2 Align shaft seal with the shaft
Head Remove O ring gasket two cutaway Firmly seat shaft seal at the
pins cylinder head suction valve shaft land Attempt to turn shaft seal
plate and gasket in the order listed to the left and right confirming that it
This exposes the AC050
rear part of cylinder is seated properly
HA 35

r
Compre SWP767 AIR CONDITION ER
3 Place gasket on cylinder head and 7 Continue with work up to instal

install front end cover Coat gasket lation of rear end cover according to
with compressor oil beforehand Installation under Rear End Cover
Gasket differs for the front and rear and Rear Cylinder Head
Make sure that the correct gasket is 8 Continue with work up to instal
used After completing this work lation of side cover according to
gasket protruding end
from front Installation under Side Cover
cover andcylinder head should be 9 Install shaft seal s t according to
adjusted by hand instructions in Installation under

Shaft Seal
AC690 10 Install and adjust compressor
clutch acoording to instructions in
Installation under Compressor

Clutch
5 Turnover the asSembled shell and
II Fill with oompressor oil and
cylinder assembly so that the front
tighten oil plug with copper gasket in
D may face downward
6 Coat oil pipe and ring
O with an place
t OJ J
SIlencer hole
ample amount of oil Insert oil pipe at til Oil plug
the rear of the cylinder After making 18 20 rn
N
sure that the hole lines are matched as 8

1 2 0 rn
kg
AC053
in 4 continue with 13 14 ft lb
specified step
stepp 6 work
12 Conduct a leak
st by referring
te
4 Fit gasket to front end cover to the topic under Shaft Seal
Then bring the shell into place over
the cylinder assembly At this tin1e
make sure that the two holes of side

cover and the cylinder holes are
matched Note that later adjustment

will no longer be possible as inside
and outside diameters of these are not
perfectly round Note that moving the

shen up and down may cause the
AC226
gasket to slip out of place
HA 36
AIR CONDITIONER ElectricaICirr
uit
ELECTRICAL CIRCUIT
SCHEMATIC
OFF position BLOWER

RESISTOR FUSE
MOTOR 20A
M
5A
OFF
AMBIENT AIC
SWITCH SWITCH IGNITION
0 LOW RELAY
D O D 7 PRESSURE
SWITCH
IGNITION
ft tJ
SWITCH
I RELAY
01
Ie
COOLER o
1 1 L
BATTERY R
FUSIBLE
COMPR ESSQR F IC O
LINK
MAGNET MAGNET
VALVE
CLUTCH
VENT B L HEAT DEF and RECIRC position

BLOWER FUSE
RESISTOR MOTOR 20A
M
AMBI ENT
OFF OFF SWITCH
O
D G 8
fl
0
FAN
SWITCH
LOW
PRESSURE
n
S 2
fP
SWITCH IGNITION
SWITCH
D
BATTERY R
COMPRESSOR F IC O FUSIBLE
MAGNET MAGNET LINK
CLUTCH VALVE
BLOWE R
AC positIon RESISTOR MOTOR
ON
GJ A
r
DDonO
n
a
I G
IGNITION
SWITCH
G
BATTERY R
F IC O
COMPRESSOR FUSIBLE
MAGNET
MAGNET LINK
VALVE
CLUTCH
SHA 146
HA 37

5z
Co z o
il1
C
II
9
JJ
ER E O
COloPRESOR
l
GIleUCI
I
C
oO IoI 1
11
l
Ilo GIle
lll c
IoI
I
J
t
II11CI
S Gf lla
It
PRES URE1
0
aJJ I
Il11CI
S
1I01l
IIl
UI
ll
tkMP
ON
f
l
0
J
Ul
I
lOIlER
1I01l
II11CI
S
COlOl1 I
lCI
RESI 10R
IR S
IlI
f
I
lEI IROUI MP
t
15 C
1
Gll
ll I
t
I
Il11CI
S
fUSIl
E
M010R
4IER Il
IGl 10 l
N
a
all
I
COl RO
I
JI
I
IIIIlG
IGI
UI
Iu
1I01l Ill1CI
S
1l
II11CI
S

AIR CONDITIONER TroubleOiagnosesandCorrecrionr
TROUBLE DIAGNOSES AND CQRRECTIONS
AIR CONDITIONER DIAGNOSES
Insufficient cooling
Bubbles in sight glass No bubbles in sight glass
Check refrigeration line for gas leaks and repair leaks if any Charge reo
With manifold gauge check system
to correct level In of too many leaks stop compressor dig
frigerant case
pressures
charge the system evacuate and recharge the system As necessary replace
Measure temperature of discharge air
receiver drier
Refer to Performance Test
Air in system may cause bubbles in sight glass
System pressure and temperature of discharge air are abnormal Refer to

Temperature of discharge air is ab
Performance Test Diagnoses for detail normal but system pressure is
normal
Suction pressure
Suction pressure Discharge pressure is high
ishigh while
is high Check air flow system
discharge pres
sure is low
Overcharge of refrigerant
Discharge some refrigerant
Expansion valve to correct level
is open exces Air is mixed in Discharge sys Valve or gasket
sively and drier of compressor is
tern replace
Replace expan Evacuate and recharge system damaged Check grommets on car s dash panel
sian valve Condenser s fin is dented or Repair or replace for air leaks check other seals of
clogged with dust compressor car
Clean exterior surface with
water
Suction pressure is low
at receiver drier outlet has Fin and tllbe of evaporator have Expansion valve is close excessively
Pipe
some dents or gas leakage from thermo bulb
low temperature Receiver drier
is restricted Replace receiver Replace or repair evaporator Replace expansion valve
drier
HA 39

Trouble Diagnoseund Conectiom AIR CON DITION ER
Noisy
Compressor OFF Compressor ON
I
r
Bearings of compres Blower motor makes Belt is loose Compressor itself When engine rpm Is
sor clutch idler noise belt makes noise changed there are
or
Adjust
pulley make noise Repair or replace Repair or replace resonant sounds
Repair blower motor compressor Retighten compres

sor bracket bolts
Blower motor does not Compressor does not
rotate run
Refer to Blower Motor Refer to Compressor Clutch

Diagnosesu Diagnoses and Compressor DiagnoseS
F IC D does not operate
Refer to Fast Idle
Control Device Diagnoses
40
HA

AIR CON DITION ER Trouble Diagnosesand Corrections
BLOWER MOTOR DIAGNOSES
Condition
II II
Test conditions Check
Probable cause
Battery OK
Fusible link Red and green OK
Quick check Check that wiper and washer operate
Ignition switch OK
Ifthey do not operate check fuse l5A in fuse
Ignition relay OK
block at first
O K
Fuse 20A in fuse block
Position of ignition switch ACC

Position of fan sWitch ON
I Blower motor does not run

I
Remove instrument lower cover and
cluster lid
Connect test light to blue white
wire leading to blower motor
I
Ught ON Ugh OFF
Ground SHA168
Ground blue black wire leading to

blower motor
I
Motor does not
I
Motor runs
fun I
Faulty blower motor without SHA169
problem in lead wire connection
t
Replace
@ @
41
HA

TroubieDiagnosesandCorrections AIR CONDITIONER
Broken lead wire Check fan switch for con
between ignition ductivity

relay and blower Refer to Fan Switch
motor
t Motor
I runs
I
Motor does not
Repair
I run
Faulty fan switch without problem

in lead wire connection
I Check resistor for conductivity
Refer to Resistor
t I
Replace N G ot
I
Faulty resistor without problem Check other lead wire and connection
lead e connection
Replace
I Speed ofblower motor does not change

J1
Remove instrument lower cover and
cluster lid
Check resistor on heater unit

Refer to Resistor
N G O K
I I
Faulty resistor without problem
t
Check other lead wire and connection
in lead wire connection
l
Replace
42
HA

AI R CO N 0 ITIO N ER Trouble Diagnosesand Corrections
COMPRESSOR CLUTCH DIAGNOSES I J Condition
Test conditions
I I Check
I Probable
I cause
OK
Battery
OK
Fusible link Red and green Check that wiper and washer operate
Quick check
OK
Ignition switch
OK
Ignition relay
Fuse I SA in fuse block OK

Position of fan switch ON
Position of air conditioner switch ON
I Compressor clutch is not engaged
Connect two wires leading to low pressure switch

I
I I
Clutch is engaged Clutch is not engaged
AC371 A
1 Check refrigerant level
OK
I N G
I
L
Faulty low pressure switch without Connect test light to blue black wire
problem lead yire connection leading to magnet clutch o
I I AC373A
Replace light ON light OFF
Insufficient re
frigerant
t
Add
Ground earth terminals leading to Connect wire between two termi

magnet clutch 0 00 re
Clutch is Clutch is Clutch is

1 Clutch i
@j @
not engaged engaged engaged not engaged
I I SHA17G
@ @
HA43

Trouble Diagnore end Correction AIR CON DiTtON ER
@ Ii @
Remove
without pro
Faulty magnet clutch instrument
blem in lead wire connection
lower cover
and
t rlid
clust
Repair
Broken ground
wire of magnet
clutch
t
Repair
Faulty cooler relay without problem

in lead wire connection leading to ambient temperature
switch
SHA 174
I I
Clutch is Clutch is
Replace engaged not engaged

I
Faulty ambient temperature Connect wire between green and
switch without problem in lead blue wire leading to air conditioner

wire connection switch
I
Clutch is ClutCh1is no
engaged
Replace engaged
U
J
SHA 175
Faulty air conditioner switch Check other lead wire

without problem in lead wire
and connection
connection
Replace
HA44

AIR CONDITIONER Trouble Diagnosesand Corrections
COMPRESSOR DIAGNOSES
Compressor clutch is engaged but compressor does not run
I
Clutch slipping
I I Belt slipping
II Seizured compressor
Check and gap of clutch Check belt tension and adjust it Internal problem in compressor cyl
readjust
Clean oil or dust on contact sur If belt is worn out or damaged inder
face ofclutch replace it Check system
If slipping continues replace com Repair or replace if necessary
pressor clutch
High torque
Overcharge of refrigerant
1 Air in refrigeration system
Discharge refrigerant gas to an extent that sight glass Discharge system from service valve on discharge side
of receiver drier has only a few bubbles Evacuate and recharge the system
Engine speed 1 500 rpm
Check for discharge pres

sure OK if discharge pres
Discharge pressure
reduced
is not
I When torque is still great repair or replace compressor
I
sure is reduced
45
HA

Trouble Diagnoseund Corrections AIR CONDITION ER
Compressor oil leaking Compressor is noisy
Air blow on spot where oillcak evidence is found

Then check for refrigerant leaks using leak detecror
Noisy only when clutch Noisy when clutch is
is engaged not engaged
I
Check for loose compres Remove compressor belt

Refrigerant leaking No refrigerant leaking sor mounting bolts Turn pulley of compres
Retighten bolts sor clutch by hand and
check for noise Ifnoise

is heard repair compres
Repair or replace sor clutch
Wipe clean oil with rag Compressor drive belt
compressor
is loose Adjust belt
tension
Ifcompressor is still
noisy repair or replace
compressor
46
HA

AIR CONDITIONER Trouble Diagnoses and Corrections
FAST IDLE CONTROL DEVICE DIAGNOSES
II q Condition
Test condition Check

I I
I Probable
Battery OK I cause
Fusible link Red and green OK

Quick check Check that wiper and washer operate
Ignition switch OX
Ignition relay OK
IS
Fuse in fuse block OX

Position offan switch ON
Position of air conditioner switch ON
F LC D is not operated
II
Check operation of compressor clutch
I
j
I
Clutch is not engaged
Check electric circuit of clutch reo Run

Outch is engaged
engine at idle speed

D
ferring to compressor clutch dia Disconnect vacuum LC
F D magnet SHA177
gnoses valve to F LC D device hose at

F LC D magnet valve and check
vacuum
I I
Vacuum N G Vacuum O K
I
Faulty lC D magnet valve

F
Disconnect vacuum l C D magnet
F
valve lo F LC D device hose at
l C D device and check
F vacuum
I I
Replace Vacuum O K Vacuum N G
j 1
Faulty l C D device
F
J I Broken vacuum hose
J Check
vacuum
Replace Repair
Fl C D
device
SHA17S
47
HA

Setvice Data and Specifications AIR CONDITIONER
GENERAL SPECIFICATIONS TIGHTENING TORQUE
COMPRESSOR Unit N m
k ft lb
Model SWP167 Compressor bracket to

44 54 45 55 33 40
cylinder block
TVpe Swash plate
Compressor to
I Displacement cm3 cu inl rev

167110 191 compressor bracket
44 54 45 5 33 40
I Cylinder bore x stroke in

mm 37
11 465x 1 0121
2 25 7 Refrigerant line connec
tion
Low pressure line 25 29 25 3 0 18 22
I Direction of fotation ClOckwise
High pressure line 15 20 20 11 14
5
11
I Type of driving belt A type
flexible hose to
corilpreuor
8
7 10 8
lOB 1 1 58 0
LUBRICATING OIL Compressor
I Type SUNISO 5GS

Coil mounting screw 2 7 3 4
I 0 28 035
1 2 0 2 5
I Capacity ml US fl OZ Imp fI 02 270 19 1 9 51

Lock nut 25 27
12 5 2 8
I 18 20
Hub nut 18 21
11 8 2 1
I 13 15
REFRIGERANT Shaft nut 16 17

6
11
1 7
111 6 12 3
Type R 12 Side cover bolt 18 20

11 8 20
I 13 14
Capacity kg UbI 09 1 12 0 411

2 Reaf end coyer bolt 29 34
13 0 35
I 22 25
Oil plug 18 20
11 8 20
I 13 14

ENGINE IDLING SPEED Unit rpm
Transmission When Ale is ON
About 900
Manual
cidjustablel
Non
About 1000
Automatic At N rangsl
adjustable
Nori
BELT TENSION
Fan belt Applied

pressure
mm UnlN kg Ibl
18 1210 31 0 4711
98 110 221
COMPRESSOR
Clutch hub to pulley 5 0 8
clearance
in
mm 0
10 020 0 0311
48
HA

AIR CONDITIONER SpecialService Tools
Tool nwnber
Tool name
Kent Moore No
KV99412302 Clutch hub wrench

J94878 1
KV99412305 Hub nut socket

124878 2
KV99412306 Clutch hub puller

124878 3
KV99412310 Lock nut socket

1248784
KV99412313 Puller adapter

QD
126066
KV99412312 Puller pilot

125472
KV994C1552 Charge nozzle
KV994C4548 Blind cover set
CD KV994C453I Blind cover
@KV994C4532 Gasket Useless 3 @
@ KV994C4533 Gasket
c
@ KV994C4534 Gasket 1 11 1
0 39 0 39 0 61 0 51
@KV994C4559 Bolt
Unit rom in
HA49

Special Service Tools AIR CONDITION ER
Tool number
Tool name
Kent Moore No
KV9941232I Shaft seal remover and

126067 installer
KV99412322 Shaft seal pilot

125473
o
KV99412329 Shaft handle socket
126072
KV99412327 Silencer piece installer
KV99412328 O ring insta11er
KV99412330 Allen socket
KV99412315 Cylinder head remover
HA 50

SECTIONE L
ELECTRICAL SYSTEM
CONTENTS
POWER SUPPLY ROUTING EL 2 SERVICE DATA AND SPECIFICATIONS EL 37
SCHEMATICIPOWER SUPPLY ROUTING EL 2 LIGHTING SYSTEMS EL 38
FUSE EL 3 BULB SPECIFICATIONS EL 38

FUSIBLE LINK EL 3 COMBINATION SWITCH EL 38
EL 3 HEAD LAMP EL 40
IGNITION SWITCH
EXTERIOR LAMPS 43
IGNITION AND ACCESSORY RELAY EL 3 EL
BATTERY EL 4 INTERIOR LUGGAGE COMPARTMENT

CHECKING ELECTROLYTE LEVEL EL 4 AND STEP LAMPS EL 51
CHECKING SPECIFIC GRAVITY EL 4 INSTRUMENT PANEL ILLUMINATION EL 54

CHARGING EL 5 METERS GAUGES AND
BATTERY FREEZING EL 5 WARNING SYSTEMS EL 56

BATTERY TESTING EL 5 COMBINATION METER EL 56
SERVICE DATA AND SPECIFICATIONS EL 7 WARNING DISPLAY EL 65
STARTING SYSTEM EL 8 WARNING CHIME EL 70
SCHEMATIC EL B WIPER AND WASHER EL 73
WIRING DIAGRAM EL 8 WINDSHIELD WIPER AND WASHER EL 73

STARTING SYSTEM REAR WINDOW WIPER AND WASHER EL 79
TROUBLESHOOTING EL 9 ELECTRICAL ACCESSORIES EL 81
STARTER MOTOR ELla REAR WINDOW DEFOGGER EL 81
SERVICE DATA AND SPECIFICATIONS EL 16 REMOTE CONTROL DOOR MIRROR EL 83

EL 17 CLOCK EL 85
CHARGING SYSTEM
EL 17 HORN EL 87
DESCRIPTION
SCHEMATIC EL 18 AUDIO EL 89
WIRING DIAGRAM EL 18 AUTOMATIC SPEED CONTROL

CHARGING SYSTEM DEVICE A S C D EL 94
TROUBLESHOOTING EL 19 DESCRIPTION EL 94
ALTERNATOR EL20 TROUBLE DIAGNOSES EL 95
IC VOLTAGE REGULATOR EL 23 COMPONENT PARTS EL 99
SERVICE DATA AND SPECIFICATIONS EL25 ELECTRICAL UNIT LOCATION EL 104
IGNITION SYSTEM EL 26 EL 106

WI RING HARNESS
IC EL 106
IGNITION SYSTEM CABLE COLORS
HARNESS EL 106
TROUBLESHOOTING EL28 LAYOUT
DISTRIBUTOR IC type EL31
IC IGNITION UNIT EL35

Power Supply Routing ELECTRICAL SYSTEM
POWER SUPPLY ROUTING
CAUTION Before starting to worll on any J system disconnect battery ground cable
SCHEMATIC POWER SUPPLY ROUTING
Q 8
f T BATTERY 1
ci C CD FUSIBLE LINK
t I sr
BOg
A I
occ
l
Or
0
0
E1 I
IGNITION SWITCH
16 Q
J I
S5 I
l l
o
IGNITION AND
z
a ACCESSORY
in
ir
w
1
RELAY
J
I
f
o I FUSE BLOCK
L HEADLAMP
STOP LAMP
i HAZARD FLASHER
HORN
V
CIGARETTE LIGHTER CLOCK LAMP MONITOR
w z VOLT GAUGE
0
t w
t i INTERIOR LAMP STEP LAMP LUGGAGE COM
z
PERTMENT LAMPS KEWARNING
u
TAIL CLEARANCE SIDE MARKER AND LICENSE PLATE

LAMPS METER ILLUMINATION
7HEATER OR AIR CONDITIONER BLOWER MOTOR

1
7 AIR CONDITIONER WIPER AND WASHER WINDSHIELD AND REARl
RAOIO POWER ANTENNA
w REAR WlNDOW DEFOGGER

a
TURN SIGNAL BACKUP LAMPS WARNING LAMPS

TACHOMETER GAUGES SEAT BELT WARNING WARNING DISPLAY SEL365
EL 2
ELECTRICAL SYSTEM Power Supply Routing
FUSE FUSIBLE UNK IGNITION AND

LOCAnON ACCESSORY RELAY
LOCATION
The ignition and accessory relay

are located on the right side of the
dash panel Refer to page EL 104
INSPECTION
Ground is made at case attaching
bolt and tenninal rJ
SEL277
SEL275
INSPECTION
CAUTION
a If fusible link should melt it is
c possible
supply
that critical circuit
or large current
power
carrying
l l circuit is shorted In such a case
SE L279
I
check and eliminate
CI
cause
carefully
of problem
b Never wrap periphery of fusible
c SE L276
link with vinyl tape Extreme care
should be taken with this link to
ensure thet it does not come into
8 If fuse is blown be sure to elimi contact with any other wiring har
nate cause of the problem before ness or vinyl or rubber parts
installing new fuse
b Never use fuse of more than speci A melted fusible link can be detect
fied rating ed either by visual inspection or by n

c Do not install fuse in oblique feeling with fmger tip If its condition
direction always snap it into fUle is questionable use circuit tester or
holder properly test lamp
IGNITION SWITCH
S 1G
B A
sr
Q B From battery
T Key warning switch
IN OUT
01
g
c
5 A To accessOIY system
s
k
U o
5
IG
s
To tionsystem
To starting system
I g
SEL369
EL3

Battery ELECTRICAL SYSTEM
BATTERY
St 0 0007 t 20
CHECK G O
WARNING
Naver touch positive and negative SPECIFIC GRAVITY Where
termill8ls at the same time with St Specific gravity of

Read hydrometer and thermal
could J electrolyte at tOC
bare hands This result in
gauge indications at eye level S20 Specific gravity of
injury
Reed top level with leale electrolyte corrected
at 20C 680F
Thermal gauge t Electrolyte temperature

CAUTION r
a If it becomes necessary to start the
engine with a booster battery end

jumper cables the booster battery
voltage must not ex 12 volts
Examples
or the control unit of the fuei 1 When electrolyte temperature is
injection system and other electric
350C 950F and specific gravity of
components will be damaged
b If the electrolyte is L2 O specific gravity
battery cables are discon
nected corrected at 20 C 680F is 1243
they should be tighdy SE L045
2 When electrolyte temperature is
clamped to the battery terminals to
O c 320F and specific gravity of
secure a
good contact 200C
2 Correct specific gravity et electrolyte is 210
1 specific gravity
1680 Fl corrected at 200C 680F is 1
196
j specific gravity 50
130 1
CHECKING
128
@
ELECTROLYTE
E
LEVEL
u
Co
Check for electrolyte level in each E

B
cell u
g
o
u
Overflow Correct Shomse

o
t j t 1t Co
114
121
1
10
1
EE358 I I I I r I
10 o 10 40 SO
32
14 SO 104 122
Electrolyte temperature oC OF
If the level is low fUI with distilled
water SEL096
EL 4

ELECTRICAL SYSTEM Battery
3 Determine charging state of bat

BATTERY FREEZING
tery
CAUTION 1 1 JI J
Examples Usa extreme caution to avoid freezing
Charging state of battery whose battery Ie 0
4@ Qo I
max charging specific gravity is 1
26
and whosespecific gravity corrected at
200C 680F is 1 243 is 92 0 1

m
For battery whose charging U 14
10
o
specific gravity is 1 28 charging state 20 4

SE L047
00
is 82 at a corrected specific gravity 0 22

of 200C 680F 40 0 o
O
SO 55
60 76
Specific plvity 1 Set voltmeter to low range
680F 70 94 I I
20oC 2 Touch negative lead of voltmeter
80 1I2 L I
I to
1 04
1 08 16
1 24
1 32
1 to negative battery post
12
1 20
1 28
1
3Touch positive lead of voltmeter
EE004 SpecifIC oreleclrolyte
Iflvil
to top of battery and move it around
If reading goes over 0 5 volts then

clean off top of battery and retest
70 80 90 100 3 BATTERY CAPACIlY TEST
nditian l
Charsin
SE L097
BATTERY TESTING
4 Recharge battery if its rate drops
below 7m of full charge I PRELIMINARY CHECKS Visual
Inspection
Dirt SEL048
Clogged
vents
I
lfil fil W Check
Corrosion r 8 A M rating
Cracks I
Warped
Y I
case 1 With battery connected to tester
CHARGING
as shown turn load knob until a draw
SEL046 of 3 times the battery rating is shown
CAUTION
Example Battery rating 60 AH Turn
a Carry out charging with negative
load to 180 A draw
cab Ie removed
2 Hold this draw for 15 seconds
b Do not allow electrolyte tempera thim look at voltage If voltage re
ture to go over 450C 1130 Fl
Check battery rating against that mains at 9 6 volts or above THE
1
Clean terminal with of original factory equipment BATTERY IS GOOD You need not
corroded e
2 Check for cracks and warpage of perform any further tests If voltage
brush and common soda
baking solu
tion the case drops below 9 6 volts then proceed to

3 Make sure cables are clean and next test
tight 4 THREE MINUTE CHARGE

WARNING
4 Check acid level TEST To be performed only if
a Keep battery away from open
5 Make sure vents are not clogged battery has failed Capacity Test in step
flame while it is being charged
6 Make sure top of battery is clean nwnber 3
b When connecting charger con
2 BATTERY LEAKAGE TEST 1 Connect a good quality battery
nect leads first then turn on
Check to make sure battery is not Remove cell caps
cherger 00 not turn on charger
discharging across top between two 2 Tum charger to a fast charge rate
first as this may cause a spark
posts not over 40 A
EL 5

Battery ELECTRICAL SYSTEM
5 Now put positive probe in ceU 7 When you get to point where
nearest the positive post Put negative positive probe is in last cell of battery
I probe in next cell down Record touch negative probe to negative post
reading Record this reading

o 0Jol
nnlol
J SE L049
ee
9
3 After three minutes check volt

meter reading If it is over 15 5 volts SEL051 SE L053
16 for Maintenance Free Batteries

5
battery should be replaced If it is
below 5 volts
15 then proceed to step
8 You should now have
nwnber 5 seven
5 CELL TEST UNPER CHARGE readings Now add the fIrSt reading to
Connect tester and battery charger as down the last this will give you six readings
6 Continue on the battery
in step number 4 Set to fast charge They should aU be within 0 2 two
recording reading each time
rate 35 40 A tenths volt of each other If one cell
I Turn varies more than this amount from any

to low range voltmeter
other then battery is bad and must be
2 Attach special cell probes to
voltmeter leads replaced
3 Touch positive probe to battery
2 4
positive terminal
4 Stick black probe in 2 6
battery cell
24
the 2 6
nearest batteiy positive post
2 6 02
WRITE DOWN voltmeter reading
2 6 26
26
SE L052
02
SEL050
6
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Starting System ELECTRICAL SYSTEM
STARTING SYSTEM
SCHEMATIC
OFF Ace ON ST
C
l
g
1
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LINK
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sr 5
IGNITION SW
I
C 0
1 1
o
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FUSIBLE FUSE
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ACCESSORY RELAY
@ INHIBITOR SW
BATTERY
STARTER MOTOR 1 o 0
@INHIBITOR RELAY
SEL098
WIRING DIAGRAM
Cf R
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@ oJ
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BW
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@WB
LW ao I
SEL099
STARTER MOTOR @ INHIBITOR SW
EL 8
m rm0 II1 n r rn rn Im s I
ill g
Check itch and

batery and stare
c o n e t i stare switch magnetic tground erminal ground stare
tinhbitor ransmio
s
K
and switch
engine m a g n e t i c bolts
magnetic and
Magnetic Remove replace switch Bad batery cable coneti s stare

O
Tight Mechani l problem Short Overhaul Igniton

in in
Stare betwen switch Bad and bad Open Overhaul Bad switch Overhaul
than cir uit Automaic
J1
rt 0
conetrs
in
J
than
J
turns less than than More SV O Stare turn Open relay
not
Stare fast 60A draws 60A More V
I Less IV click
staring scale negative stare No does
150A
normal key
than
Stare more B
switch to
drops low lead
in
c o n e C t
to
i to
than hold that lead good
in to
stop e ng i n e to
Spe d back but lead

magnetic conetd Crank voltage cir uit voltme r negative batery positve Make engine turns
so
Less not of
wire start docs
negative of
stare
r
engine
Turn Con ect terminal Hold housing Crank
f
coil
Move terminal Terminal bat ery Testing ground
to
Plug Start over stare I

2 3 4 Click
than
4 than
More l50A than Less IV
More IV
cable
range stare coil draw stare batery terminal
positve 50 A and positve cable terminal stare distrbuo
scale
SHOTING betwen
s
curent to
drew from in
to
to to 5
0 5V
I
from Not drops low lead of the

lead Not uM
than than
voltage cir uit voltme r positve batery negative switch conetd wire ground engine
it
curent bateiy am etr cthabISle wire cap read

to
out wire and
ISOA Less Less switch
tarter coil engine
than slow
jumper terminal
ting Discon e t Con ect betw en terminal Pull distrbuo
s t a r e
Testing positve Turn Touch post Con ect magnetic Terminal
out for of coil and
Conect positve magnetic

I
Crank Crank
TROUBLE Te I
t
at
turns
2 3
t
Light
4
Less Spe d I
2 3
Pull cap
4 5 on
positve bayonet
or
charged igniton switch

SYTEM
at Y
Click Stare in scale to to

B
than
Fully r wire lead
drops low lead lead Yelow Leave More lSV
start Ustart Yelow Con ect negative somen
this
mvoltage agnetic positve batery negative Black switch wire
to
batery k
Black betw en Have Stare voltme r

of
c o n e t d engine
coil
STARING
to light
igniton Usualy stare light batery
I
Testing Iwitch cir uit Turn Con ect terminal Con ect conetr magnetic wire Ground Crank
for
I
I
1 I
1
the oc
key N key No
I
Check I
Turn Pull
at
off test and terminal turn I 2 3 4 5
m reO

StBrtingSystem ElECTRICAL SYSTEM
STARTER MOTOR
Reductlon
Non ear type
J 74
l 9 8 0 75 100 5 4 7 2
Mqnetic lWitcl asoembly

Ocarance Q between
Pinion front edge and pinion stopper
0 3 2 5 0 012 0 098
Dust 00 Adjllllin8 er
Adjust clearance 2
Washer thickness
0 5 0 020
0 8 0
0 31
Dust cover
ring
E
Brush
Brush min length
12 0 47
Brush spring
Tension 13 7 17 7N
14 18 kg 3 1 4 0 Ib
Ileu 00
metal
Through bo
J3
l 7 5 0
0 38 0 51 27
Commutator min dia

39 154 Center bracket
5114 180F only
Depth of insulating mica
0 5 0 8 0 020 0 031 Pinion assembly
Armature shaft bend Pinion stopper

s
Les than 0 08 0 0031
J
l N m
lcg m ft4b
Unit mm in
SE L007
EL10
ELECTRICAL SYSTEM Starting System
Reduction r typo
Dust cover Adjusting washer

Adjust clearance
washer thickness
Through bolt
0 5 0 020
0 8 0 031
co
f
v
ring
Q
Drush
Brush min length
11 0 43
Center bearing
Brush holder
Brush spring
Tension 15 1 19 6 N 16 2 0 k8 3 5 4 41b
Field coil
3 1
Commutator min
dia
29 1
14
i6
C 3 8 3
Depth of insulating mica 0 64 0 85 4 6
0 5 0 8
0 020 0 031
ring
O
Pinion gear
i
C N m kg m fHb Difference in
Unit mm in Packing
height of pinion
0 3 5
1
0 012 0 059 Gear ca
SE LOOS
ELll

r Starting System ELECTRICAL SYSTEM
DISASSEMBLY RedueUon rtJpe

I Remove magnetic switch assemb
Non ucUon r tJP
ly
2 Remove torsion spring
1 Remove magnetic switch
3 Remove through bolts and rear
cover
CAUTION
Ba careful not to damage ring
O
SEL011
4 Remove yoke armature and brush
holder as an assembly from center
housing
5 Remove yoke
CAUTiON
Be careful not to knock brush com
mutator or coil against Iny edjacent

plrt
2 Remove rear cover
1 Remove dust cover E ring and

thrust washer s
2 Remove brush holder setscrews

3 Remove through bolts
6 Withdraw armature and shift

lever
EE61 6
5 Remove center housing

SE LOtO
I
6 Remove pinion gear
7 Lift up brush springs
8 Remove brushes from brush
holder
SE L019
3 Lift p brush springs

7 Remove overrunning clutch
Remove pinion stopper clip push
ing pinion stopper toward clutch
side
EE616
EEt50
9 Remove brush holder

Pinion stopper clip
4 Remove brush holder EE277
10 Remove yoke
EL12
ELECTRICAL SYSTEM Starring System
INSPECTION
t
Field coD
I Continuity test between field

J
coil positive terminal and positive 0 5 0 8 mm
brushes
SE L030
i
Correct
f l 1
Commutator
SEL107 Bru h prlnll i
No continuity Replace field coil

Check brush spring
Spring tension
Non reduction gear type

tension
1T1in
Incorrect
EE021
13 7 17 7 N
14 1 8 kg
2 Ground test between field coil
3 1 4 0Ib 3 Check diameter of commutator
positive terminal and yoke
Reduction gear type Commutator minimum diameter
19 6 N
15 7 Non reduction gear tYpe
Positive 1 6 2 0 kg 32 mm 11 26 in
terminal 3 5 4 4 Ib Reduction geor type
29mm 11 14inl
Not in the specified value Repair Less than specified value

or replace Replace
Sprin scale
SEL 1 oS
Conlinuity exists Replace field
coil
WI
SEL 109
SEL031
4 Ground test between each com

Bru h mutator bar and shaft
Check the surface condition of

brush contact
Arm ture mbl
Loose contact Replace
Check wear ofbrush I Check commutator surface
Minimwn length of brush Rough Sand lightly with No 500
Non reduction goor typo sandpaper

2 Check depth of insulating mica
12 mm 0 47 in
from commutator surface
Reduction goor typo
0 43 in Less than 0 2 mm 0 008 in
1 mm
Undercut to 0 5 0 8 mm 0 020
EE022
Excessive wear Replace 0 031 in
EL 13

Scarting System ELECTRICAL SYST M
Continuity exists Replace PInIOn caN burin Iii8taoI Reduction gear type
5 Short test with annature tester ndilctlon
Non ear type
Compare difference en in height
growler and a piece of iron over
Check clearance between bearing of pinion when it u pushed out with
armature core
metal and armature shaft
magnetic switch energized and when it
u by hand until it touches
Iearingmetl l
I to Irmatuinhaft pulled out
dearance stopper
H
Less thin 0 2 mm 0 008 in Difference 1
03 1 5 mm
More than specified value
Replace 0 012 0 059 inl
Pushoutwitb
Ball b rln PoD out by electric
Reduction ar tyP hand until current
pinion stops
Holding outer race with fmger
EEQ23
rotate bearing
Any play or bind Replace
1 r
Plate vibrates Replace 0
r
6 Continuity test between two
Me n tIc switch mbly L
segments side by side Difference
No continuity I Con1inuity test between sn e SEL016
Replace
terminal and switch body
No continuity Replace
2 Continuity test between tenni Not in the specified value Adjust
naIs S and M by adjusting washers
No continuity
r runnln clutch mbly Replace Adjusting washer thielmo
0 6 mm 10 020 in
1 Inspect smooth sliding of pinion
08 mm 0 031 in
gear
Abnormal resistance ASSEMBLY
Repair
2 Inspect pinion teeth Apply e to gear case and rear
gre
Excessive rubbing Replace cover bearing metal ond Ipply oil TESnNG
to pinion slightly Perform nc tut
CAUTION load
No test
Flywbeel ring gear also must be in duction
Non 8type
Il
spected With the switch on push pinion
p
back to remove all slack ond me
ure
the clearance en between pinion

front edge and pinion stopper
J
t
b
Brush hold r
Clearince 2
Ground test between negative side 3
0 25 mm
of brush holder and another positive 0 012 0 098 in
Voltmeter Ammeter
side
Capacity 300A
SE LOSS
r I
J Specifications
Refer to s
sn
L
Dlqnos of test
e I Low with lold

no and high
SEL015
speed
current draw
EE025
I Tight dirty or worn bearings

Not in the specified value 2 Bent annature shaft loosened
Adjust or
Continuity exists Replace by adjusting washer s field probe
EL14

ELECTRICAL SYSTEM ing
Sta Sysrem
co
3 Shorted armature coil Shunt
4 A grounded armature offield coil 1 Disconnect lead wire which con
2 Failure to operate with high cur
nects terminal M of magnetic switch
rent draw
jrJ and starting motor teoninal and con

I A grounded or open field coil
nect a jumper wire in its place
2 Burned out commutator bar
2 Connect terminal S of magnetic
Weak brush spring tension
switch and positive tJ terminal ofbat
Thrust out of mica in commutator
tery with a jumper wire
3
Loose contact between brush and
commutator
Low current draw and low no

1 CI SEL012
3 Connect negative
battery and starting motor body with
e terminal of
ajumper wire Plunger should be pull

load speed ed in by force
I Loo e connections
4 Disconnect wire from ter
S rle coil jumper
2 Dirty commutator
minal M
3 Burned out commutator bar I Connect terminal M of magne 5 If plunger continues to be pulled
tic switch and negative e terminal of in with wire disconnected from
jumper
battery with a jumper lead wire terminal M shunt coil is
oJ properly
2 Connect terminal S of magnetic
functioning
switch and positive tJ terminal of bat
r
netlc wttch rn bllltr tery with a jumper wire
3 With these connections having

I Disconnect lea wire from termi
i
been made if plunger is pulled in by
nal M of magnetic iwitch
force series coil i properly function
2 Connect terminal M and posi
tive tJ terminal of battery with a ing
jumper lead wire

3 Connect starter motor body and
negative e terminal of battery with a
jumper lead wire

4 Pull pinion gear all the way out
1 CI SEL014
with your hands

5 Release your hand from pinion
gear
6 If pinion gear returns to its origi t
nal position magnetic switch is pro
SE L013
perly functioning
EL15

Starting System ELECTRICAL SYSTEM
SERVICE DATA AND SPEciFICATIONS
STARTER MOTOR
Type S114 l80F

I S114 229E S114 255A
Non reduction gear type ction gear type

Red
Applied model
sA
U A T
I U SA MfT Canada A T MfT
System voltage V 12
Terminal voltage V 115 11
No load Current A Less than 60 Less than 100
Revolution rpm
IMore th 6
ooolMore than 7 000 More than 3 900
Outer diamet r of commutator mm in

I More than 39 1
54 More than 29 14
1
Minimum length of brush mm in

1 12 047 11 043
13 7 17 7 15 7 19 6
Brush spring tension N kg lb
14 18 3 1 4 0 16 2 0 5
3 4
Clearance between bearing metal

mm in Less than 0 2 0 008
and armature shaft
Clearance between pinion

mm in 03 5 0 012
2 0 098
front edge and pinion stopper
3
0 5
1
Difference in height of pinion mm in
0 012 0 059
EL16
ELECTRICAL SYSTEM Charging System
CHARGING SYSTEM
the value it then

DESCRIPTION When the voltage at terminal B is exceeds specified
higher than battery voltage current flows through the zener diode ZD
The charging circuit consists of a produced at the stator flows to re closing the circuit consisting of transis
charge the battery While the battery is tor TrJ and resistor R1 At this
battery an alternator incorporating an
current neither flows through

IC voltage regulator and wiring that being recharged the voltage at termi point
nal L to that of terminal transistor Tr to ground nor to the
connects ihese parts is equal
B At this point there is no voltage rotor thereby reducing the voltage
IWith the ignition switch in ON the
differential on either side of the charge generated at the stator
circuit between transistor Tr I of the
and is warning lamp which causes the charge When voltage generated at terminal
IC voltage regulator ground
is reduced to the specified value
closed Current from the battery then warning lamp to turn off In other S
flows along ihe route shown by the words current does not flow from the transistor allows current to flow
the increasing the
arrow in Figure turning on the charge battery to terminal L Accordingly through rotor
warning lamp and flowing on through current flow through the rotor is taken generating voltage
at the stator In this manner output voltage from
terminal L to excite the rotor over by current produced
When ihe alternator The circuit between terminal F and the alternator does not rise above the
begins to oper
is then closed specified value by the ON OFF opera
ate three phase alternating current is Tr 1
The IC voltage regulator monitors tion of the rotor coil through the IC
produced in the stator coil This alter
nating by the posi

current is rectified generating voltage to be applied to the voltage regulator
tive and negative silicon diodes battery at terminal S When current
IB
1
RJ
I 0 D3
is
011 CHARGE LAMP
J
0
Q
7
a
L
R
T
T
0 IGN ITION
a 0
t010
STATOR COIL
t
D4 Di
F
A
R
@ R2 Wv
R
SW1TC1 67
BATTERY
ld T
zo
AI
e
ALTE RNATOR itT IC VOLTAGE REGULATOR
SE LOSS
EL 17

Chargmg System ELECTRICAL SYSTEM
SCHEMATIC
OFF ACC ON sr
FUSIBLE g
LINK
g
Sf
IGNITION 1m
IGNITION AND
I r
FUSE CHARGE
WARNING
ACCESSORY RELAY LAMP
t
FUSIBLE
LINK B L 5
1I
BATTERY
ALTERNATOR
SEl100
WIRING DIAGRAM
t l m
f8 BATTE RY
fUSIBLE
L1NK@
Bj
1 i6AgCOFF
BW
1
IG
lffLBW J
6 s if
r WR
IGNITION AND
ACCESSORY RELAY
t
l
@
IGNITION SW
R@
WB
f@tI
a c
0 s 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 u JCJ
O
FUSE BmCK
c
G
I I
l
fii@ If l
i rt
CJ I WhIte
L
E W
CONDENSER
@
v a
J
L fil WR fil WR COMBINATION METER
S W W
I
@
II
C RGE
I
ALTERNATOR
B
i
S d G
1
@
J
@
For radio noise prewntion
SEL10
ELlS

III
CHARGING SYSTEM TROUBLE SHOOTING

alternator A 30 Volt voltmeter and suitable The alternator can be checked eaSi
Before conducting an
tlie battery i fully are necessary for the test ly by referring to the Inspection Table
test make sure that test probes
charged
With alternator side L terminal out

Bumed
grounded internal short occurs bulb Replace
when diode is short circuited and Proceed
to A
@ Disconnect Light OFF
connector 5
L 11 ht OFf L and g ound J
Ignition Lioht Faulty IC RG
switch ON
Check light
L lead wue
Checl light
Lag ht ON I
Connect con
nec or S
and
l
F
e ON
I Rep I ace
I
for operation for operation or
und
light ON term mal
Che ck light
Ligh t OFF 1 FauI ty A G
C
I
I Dim light for operalion
Engine idling
rs I Faulty A C G l
t 1
Check light
for operation J I Contact positive lead
ofvoltmcter B on
Light ON
terminal and negative lead to L terminal
More thanO
5 I Faulty A C G
I
Light OFF Engine idling
Measure the
1 voltage
8
across
and L Less thanO SV I OK

terminals
Engine speed
1 500 rpm
Dim light
Ligh ting
switch ON
Check light
for operation
Light OFF
Engine speed
1 500 rpm
J
Mure than IS SV
I Faulty 1C RG
Replace
1
Measure 8
teoninal volt 13 to 15V
age
11 Uao fully clio be

Make sure S
21 Light ming lith tenninal is con Engine idlins
AC G Ar porta t IC ngulo nected correctly Lighting
switch ON
Il
RG IC ngulOtor Check light
O K ICI is in good condition for operation
3 WMn I F tty AC G IOft 1118r
ren
natoI from car end nble

da inspect and
correct or e
I eultv parts
I Faulty A
4 M od of nding F 18rmiMI
Light ON eG
I
Contlct tip of r with brush and ttKh
to body
Light OFF I OK
61 T S L SAT E
on rear cover of
El19

111
Charging System ELECTRICAL SYSTEM
ALTERNATOR
than 316 0 244 Resistance per phuc
LRl60 Slip ingdia more
n
listancc
Re at lOoe 680f I 3 8 n Rear bearing la 200C 680 I 0 051
Rotor
Front bearing
6 0 lcg m 33 43 ft lb
Rear cover
Ie ro1use rtBulator
Min brush length 7 5 0 295

Brushassembly
Spring pressure 2 501 3 383 N
255 345 I 8 99 12 17 oz
Diode SOl plate a mbly SEL060
Unit mm in
DISASSEMBLY 5 Pull rear bearing off rotor assem
bly
I Remove through bolts
2 front cover from rear

Separate
cover
fA
UD
1 SE L062
l
J
4 Separate rotor front cover SEL064
Remove setscrews from bearing re

SELOSl
tainer
3 Remove pulley and fan

SE L06S
I Place rear cover side of rotor in a
vice
SEL083
2 Remove pulley nut
EL 20
6 Disconnect stator coil lead wires 2 Ground test Diode
from diode terminals

Perform a continuity test on diodes
in both directions using an ohmmeter
Circuit tester terminal

Conduction
Positive Negative
plate Diode
Holder plate
I terminal
Yes
Diode plate
SE L069
terminal
I Holder plate
Nn
plate Diode
I
EE623
No
Rear cover terminal
Continuity exists Replace rotor

Diode plate
7 Remove brush assembly with IC

terminal
I Rear cover
Yes
regulator
8 Remove diode holder
CAUTION
Po ltlve dlod
Pllce Ind insullton in order
peckin
10 thlt they cen be placad back in
Stator
their originll p or locations from
which they were removed

I Continuity test
t
e
0
j EE536
ca l I 0
1 Diode holder plate

2 Positive diode
SEL070
Conduction test is N G Replace
EE624
diode assembly
No continuity Replace stator
INSPECTION Me tlve diode
Rotor
2 Ground test
Continuity test
@
EE537
cover
3 Rear
SEL071 4 Nega live diode
SEL068
Conduction test is N G Replace

No continuity Replace Continuity exists diode assembly
rotor Replace stator
EL21

ChargingSY tWn ELECTRICAL SYSTEM
dlode
Sub 3 Check brush pig tail fur damage 4 Before installing front and rear
Damaged Replace sides of alternator push brush up with
Direction of current
4 Check brush spring pressure fmgers and retain brush by inserting
Measure brush spring pressure with brush lift into brush lift hole from
brush projected approximately 2 mm outside
0 08 in from brush holder
Bru
Spring pressure 1
00
2 501 3 383 N
255 345 g o
8 99 12 17 0
When brush is worn pressure de i
crease epproximatoly 0 196 N 20 g

0 710 1 per lmm O 04 in r
Conduction test is N G
diode
sub Replace
2 mm 10 08 in
CAUTION
If it isneceSSlry to remove iliode
sub
pinch diode lead wire with 8 pair of

plien to prevent heat transfer from
nT
solde ing iron to dil de when unsolder I
ing connection
eeOEf
EE541
Brush Not in the specified value Re
place
I Check smooth movement of
5 After front and
brush installing rear
Not smooth Check brush holder sides of alternator pull brush lift by
and clean ASSEMBLY pushing toward center
2 Check brush for wear Do not
Assemble alternator in the reverse pull brush lift by pushing
Min brush order of toward outside of it will
length disassembly noting the cover as
7 5 mm 0 295 in follo ng damage slip ring sliding urface

1 When soldering each stator coil 6 Tighten through bolt
lead wire to diode assembly terminal
carry out the operation as fast as l
C Through bolts
3 4 39 N m
possible
2 When 0 35 0 40 kg m
installing diode A ter
2 5 2 9 ft Ib
minal install insulating bushing cor
rectly
3 Tighten pulley nut and make sure
that deflection of V groove is proper
l
C Pulley nut
EE651 44 59 NofII
5 6 0 kg
m
33 43 lb
ft
Less than the specified value Re

Vllroove deflection
place 0 3 mm 0 012 in
EL 22
IC VOLTAGE 1 Resistor R 1 S Gradually decrease resistance of
REGULATOR 10 ohms 20 watts x I variable resistor Rv from 300 ohms

2 Variable resistor and V2
measure voltage between
DESCRIPTION Rv O to 300 terminals E and F
ohms 20 watts x I Voltage V 2 should increase at a

The regulator consists essentially of
3 Batteries I and 2 certain point to as high as voltage
integrated circuits incorporating tran 12 volts x2 VI 10 to 13 volts
sistors These transistors interrupt and 4 DC voltmeter Ifthere is such a variation
admit current flow to the alternator
o to 30 volts x 1 Regulator is functioning properly
rotor coil thus maintaining its output
No variation
voltage at a constant value Unlike in a 2 Measure voltage V I at battery
mechanical type regulator electron 13 volts
Regulator is out of order
an Not within 10 to Re
ic relay employing transistors is
charge or replace battery
utilized These ransistors are enclosed
in a very compact sealed case The
L 1
Ie regulator
electronic relay is soldered to the
brush assembly inside the alternator
Should any problem with the relay
1 Ie regulator
L
JI L
arise it should be replaced together

with the brush assembly
attached to the stator coil

generating voltage
On the
charge warning lamp circuit a diode is
to monitor
at the stator so that crT
3
I
r
I
l J1 SEL090
when the monitored

voltage and SE LOB7
charging voltage
equal during
are
6 Hold variable resistor Rv at the
reharging the charge warning lamp is
same voltage as VI 10 to 13 volts
turned off Accordingly a charge 3 Measure voltage V2 Measure voltage V4
warning relay is not employed in this
Below 2 0 volts Regulator is
circuit
functioning properly
L 11
IC e umlol
1 Ic egulato
1
L
EFLSB cr
n
l r
t
1t J
SEL091
SE LOB6
SE LOBB Voltage V4 is within specified range
indicated in Figure
4 Measure voltage V 3
INSPECTION
Not within 20 to 26 volts Re
Remove IC regulator and brushes at
charge or replace either or both
the same time as outlined in Dis batteries
assemb4t and Assembly section under
the heading Alternator
CAUTION
When performing test continuously
1 Ie la tor
regu
II
resistor If it L
may generate heat
becomes high temperature stop test
ing for a while to avoid
burning
i
I The following test equipment and T
accessories are required SE L089
EL 23

Charging System ELECTRICAL SYSTEM
Example 7 Reconnect wlftng as shown in

When temperature of regulator case voltage V4 is within range ofl4to 15 Fugure and repeat steps 5 and 6
is 4O C I04OF regulator is normal if volts If voltage V 4 is 0 5 to 2 0 wolb
higher than that in step 6 regulator

is functioning properly If it i not
replace
1 j
Ie regulator
o
o u
o
r
z
o
IU
1 J SEl093
m M 10
cHI I IIIIM ll21l IwICIJlICIUICIMl l UlGl
Rc ul tor case
temperature Oc OF
SE L092
EL 24

ALTERNATOR
Type lR16047
Applied model All
Nominal rating V A 60
12
Ground polarity Negative
Minimum revolution under no load

rpm Less than 1 050
When 14 volts is applied
More than 45 2 500

Hot current A rpm
output
More than 60 5 000
Pulley ratio 2 09
output voltage v 144 15 0

Regulated
Minimum length of brush mm in 7 5 0 295
Brush spring pressure N g oz 501

2 383
3 255 345 8 99 12 17
Slip ring outer diameter mm in 31 6 244

1
EL 25

Ignition System ELECTRICAL SYSTEM
IGNITION SYSTEM
e t
1 og
t
WB
BW iP
w@ 0
0
lJlJ
Jf
IGNITION AND 1
ACCESSORY RELA
IGNITION SW
9@
B
@
rw
0
i
0
E
0 0 0
o
0 0
o
0
Q
0 0
o
o
0 0 0 0 0 0 0
f r
@ California models
FUSE BLOCK Non

@ California models
l f ia models Califomia
INon models
Q TERMINAL BLOCK
VB
O
G a
L a
@ DISTRIBUTOR
we
CIl e L
@
B cJ
0
I n
I
I
if
J j
0
JiljlJ1J1J
u
@L 8 Q @L SPARK PLUGS
@
J J
SPAR K PLUGS
I
@ @ @
ff
IGNITION COIL IGNITION COIL
ff
IGNITION COIL
SEL 102
EL 26

ELECTRICAL SYSTEM Ignition System
CHECKING PROCEDURE JUDGMENT indicated If a fault is found correct

the problem before continuing If all
No start condition Spark occur
tests indicate OK replace the Ie
1C ignition system OK
Ignition Unit DO NOT REPLACE
once check In this case
1C ignition system and THE UNIT UNTILL ALL TESTS
Sparking
1 switch to OFF component parts need not be checked HAVB BEEN COMPLETED AND
Turn ignition
beyond this INDICATE OK
position No spark occurs on sparks are
2 Disconnect EF1 fusible link con
intermittent
nector
N G 1 When performing the following
1C ignition system
teltS multitester which can
Proceed with tests below USI a
CAUTION measure accurately in the following

Before disconnecting EFI fusible link ronge 0 to 20V D C 0 to 1 0000 0
Manual testlna of
connector enlllre thet ignition switch to 10V A C 0 to oOOn
50
IC lanltlon sstem
is in OFF position 2 If possible tart the vehicles and
uslna a voltmeter 15 minute with
let it run for 5 to
3 Disconnect high tension cable from 1C Ignition System is best checked the hood closed Thi bring all
will
distributor using J 26350 Transistor Ignition componenu to normal operating tem

4 will make it easier to
4 Keeping high tension cable end Analyzer However if an analyzer is perature and
to 5 mrn 0 16 to 0 20 in away from not available a ohm

volt milliammeter diagnose intermittent problems
engine block rotate starter motor and V OM may be used to diagnose 3 It is not necessary to disconnect
check whether sparks occur across the transistorignition malfunctions While the harness connecton when perform
clearance this method requires more time it can ing the tests which follow Simply
nevertheless results insert the meter probes into the back
provide accurate
Follow the steps in the sequence of appropriate connector cavity
EL27

Ignition SyrnJm ELECTRICAL SYSTEM
IC IGNITION SYSTEM TROUBLE SHOOTING
TEST TEST METHOD CONDITIONS RESULT ACTION
1 Battery Voltage Ignition key in OFF

no load position 11 5 12 5volts Proceed to Step 2
Reading
olts 2 Connect voltmeter as
12
Battery charging
ilIusua ted tnd sct to
scale system or starting
Highscale appropriate
Low t
J Scale
3 Read and record battery Below 11 5 yolts
system
Refer to
Faulty
applicable
scale selector voltage reading sections in Sen ice
Manual to correct
Battery voltage
D
1 the situation
2 Battery I Connect yoltmeter as Voltage reading

Battery O K
Cranking Black negative illustrated and set to greater than 9 6
VoUage
Red positi e
Proceed to Step 3
appropriate scale volts
2 Remove coil wire from

pOlitive
l distributor cap and
ground it
Battery charging
system or
starting
Voltage reading system Faulty
3 Read voltmeter while less than 9 6 Refer to applicable
cranking engine f9 I ap volts secti9ns in rvice
I 4
proximately 15 seconds
Record voltage reading
Manual to correct
the situation
Battery cranking
SEU03 voltage D
3 Secondary 1 Conn eel ohmmeter Resistance
as
Distiibutor cap and
Wiring illustrated and measure readings high tensioo cables
the resistance of each less than 30 000 QK
high tension cable ohms Proceed to Step 4
Resistance Replace high tensiou

readings cable s and or
greater than distributor cap as
30 000 ohms required
EF125
4 Ignition Coil I Ignition key in OFF California models Ignition coil sec
Secondary position 7 400 000
11 ondary windittp
Circuit ohms
2 Coil wire removed from Gllifornia
Non OK
coil models Proceed to step 8
8 200 12 400 for California
3 Connect ohmmeter as ohms
illustrated
Resistance reading Faulty ignition coil
not between
replace
7 400 11 000
Terminal
ohms
California models
or 8 200 12 400
ohms Non
California models
SEU04
S Power Supply L Connect voltmeter 35
Circuit Reaeptacle illustrated and set to 115 12 5 yolts Proceed to Step 6

appropriate scale
Below 11 5 volts Check wiring from
2 Turn ignition key to
ignition switch to
ON position
ICunit
catifomia
Non
models only
5EL078
Continued n xtpage
EL 28
CONDITIONS RESULT ACTION

TEST TEST METHOD
Power Ground coil output wire Connect voltmeter as Voltage reading is

6 Supply
while performing test illustrated and set to less than 1 volt
Circuit
appropriate sCale below battery
Cranking Proceed to Step 7
2 PUU out coil wire from cranking voltage
and is greater
distributor cap and
t an 8 6 volts
ground it
3 Tum key to START Voltage reading is Check ignition switch

position and observe more than I volt and wiring from
below switch to Ie unit
voltmeter while engine battery
is cranking cranking voltage
and or is below
canfornia
Non
8 6 volts
models only SE L079
7 Connect voltmeter as
Ignition
to 12 5 volts Proceed to Step 9
Primary illustrated and set 5
11
scale
Circuit appropriate
in Below 1 15 volts Proceed to Step 8
2 Ignition key ON
position
california
Non
mode1sonly SELOBO
Coil Ignition key in OFF California models Ignition coil primary

8 Ignition 1 range
Primary position 104 127 ohms winding O K
Circuit california
Non Check switch
2 Coil wire removed from ignition
models
coil and wiring from
0 84 102 ohms
Connect ohmmeter
ignition switch to
3 as
Resistance coil and IC unit

illustrated reading
not between
coil
104 127 ohms Faulty ignition
California models replace
or 0 84 1 02 ohms
california
Non
EE567 models
9 JC Unit I Connect voltmeter as
illustrated and set to 0 5 volts or less Proceed to Step 10

Ground
Circuit appropriate scale
2 Pull out coil wire from Check distributor

distributor cap and ground wiring from
it chassisground to
ground More than 0 5
battery including
3 Tum key to START volts
battery cable
and observe
position connections
tifomia
ca
Non voltmeter while engine
is cranking
models only SELOS1
Coil I Engine is at or above

10 up
Pick
Ground coil seoondary Proceed to Step 11
Approximately
Resistance normal operating
while cranking 400 ohms
temperature
l
in OFF Ohmmeter reading Check op
pick coil
2 Ignition key
and wiring to it
position substantially ex
falls below
0 3 Connect ohmmeter as
ceeds or
the 400 ohms

california
Non dD illustrated and set to
specifications
models only arr r te scale
SE L082
Needle If No Spark
II up
Pick Coil I Engine is at or above
Ground coil secondary while cranking
normal operating Wavers condition stiD exists
Output
2
temperature
Connect voltmeter and

@ replace IC
ignition unit
set to the low a c volt Check physical con
Needle steady
scale J Sj dition of pick up
Turn START coil and reluctor

3 key to
position and observe the Check wiring and
california
Non
needle movement
the engine is cranking

while
@ connections between
up
pick coil and IC
models only SE L083 SEL 105 ignition unit
Continued n xt pIIg
EL 29

Ignition System ELECTRICAL SYSTEM
TEST TEST METHOD CONDITIONS RESULT ACTION
12 Power Supply 1 Connect voltmeter as
Circuit illustrated and set to II S 12 Svolts

Ie ignition
uni appropriate scale
2 Turn ignition key to Below 11 5 volts Check wiring from

ON position ignition switch Co
ICunit
California models
only SEL084
EL30

ELECTRICAL S YSTEM Ignition System
DISTRIBUTOR le type
California models
Cap aSJembly
Carbon point
Y
Shaft a
mbly
g
I Ro orhead
RoUpin
RelUclor
Cap setter
S tor
r Magnet
it
ICignitionunit
G j
ll
Ell
J
J
Setter unit
Vacuu m controller
ow
connecting
Q
Il Breaker plate
I @ assembly
Packing
li@
r
Rotor shaft
1 sembIY
w
t
Thru er
GovernorWeight
Cl @ Governor ng
COllaJ se c
SE lOOl
EL31

Ignition Symm ELECTRICAL SYSTEM
CaJifomia
Non models
J
cap mbly
Shart uoembly
Rotor bead usembly
RoUpin
Reluctor
Housing
0 Stator
Magnet assembly
Grommet
up
Pick coil usembly
Ie ignition
unit
Vacuum
controller Breaker plate

mbly
Rotor shaft
CoUar usembly
Governor Prins
Governor weisht
SE L201
CHECKING AND Vacuum ad ce mechanism mecha st el balls or pivot Apply grease to
ADJUSTMENT nical parts steel balls or if necessary replace

I Check vacuum inlet for signs of breaker plate as an assembly
Cap and rotor head leakages at its connection
Check cap and rotor head for dust 2 Check vacuum diaphragm for air
carbon deposits and crack leak

If leak is found replace vacuum Centrifugal ad ce
controller assembly al parts

mechanil
Advance mechanlsma 3 Inspect breaker plate for smooth When cause of engine malfunction
moving i traced to centrifugai advance mecha
Specifications
If plate doe not move smoothly nical parts use distributor tester to
Refer to D this condition could be due to sticky check its characteristics
EL32

If nothing is wrong with its charac 10 Mark rotor shaft and drive shaft
teristics conceivable causes are faulty Remove packing from the top of rotor
or abnonnal wear of driving part or shaft and remove rotor shaft
others So do not disassemble it
In the event ofimproper character

istics check c osely rotor shaft assem
bly governor weight and shaft

If any of the above parts are mal
place the parts

functioning
SE L004
DISASSEMBLY
California models EE706
7 Remove fixing plate

I Take off cap and remove rotor
Mark housing and fixing plate
head
II Mark one of the govemor springs
2 Pry reluctor from shaft
and its bracket Also mark one of the
governor weights and its pivot pins
12 Carefully unhook and remove
governor springs
13 Remove governor weights Apply
after dis
grease to governor weights
assembling
SE LOOS
SEL002
8 Remove collar 1 Take off cap and rotor head

2 IC unit
Remoye ignitio
CAUTION 3 Remove stator and magnet
When removing reluctor be careful 4 controller
Remove vacuu
not to distort or damage tha teeth
3 Remove IC ignition unit and unit
setter
4 Remove stator and magnet
EE104
EE746
9 Remove rotor shaft and drive
shaft
5 Using two pry bars or suitable

SE L003 puller pry reluctor from shaft
CAUTION
When removing reluctor be careful
5 Remove vacuum control assem
not to distort or damage the teeth
bly
6 Remove braker plate
Before disassembling be sure to 6 Remove roll pin
EE705
mark housing and fixing plate 7 Remove up
pick coil assembly
EL33

Ignition System ELECTRICAL VSTEM
S
8 Remove breaker piate assembly
EE706
EE703
3 When
12 Mark one ofthe gov rnor spring installing pinion on shaft
be sure to install
and its bracket Also mark one pinion gear correcily
9 Punch knock pin out and remove
of the governor weights and its pivot to position where it was installed
pinion 4 Apply
pins S to the top of rotor
grei
unhook and shaft as required
13 Carefully remove
5 Check the opera1ion of governor
governor springs
before installing distributor on engine
14 Remove governor weights Ap
ply grease to governor weights after 6 properly ienter stator and reluc
tor before tightening

disassembling
Stenderd eir gep
0 3 0 5 mm
@W EE704
0 012
CeIifomia model
0 020 in
3
10 Remove rotor shaft and drive
ASSEMBLY
shaft assembly
To assemble reverse the order of
disassembly Carefully observe the fol
03 5 mm
0
lowing instruction
SEL0ll6 012
10 020
0 in
Celifomia
Non model
CAUTION
Before inslallinglC ignition unit make
sure mati R1rfaces of IC ignition unit
and distributor are clean and free from
dust sand and moisture
EE705
Align match marks so that part

are assembled to their original posi
tions EE148
11 Mark rotor shaft and drive shaft 2 Ensure that reluctor is properly
Remove packing from the top of rotor oriented when installing on shaft Al
shaft and unscrew rotor shaft setscrew ways drive in new roll shown
pin as 7 Adjust ignition timing after distri
Remove rotor shaft in Figure butor is installed on engine
EL34

ELECTRICAL SYSTEM Ignirion System
IC IGNITION UNIT conductor Ie device and is mounted 3 Duty coritrol circuit
in the distributor This circuit ls the ratio of the

contn
DESCRIPTION The IC ignition unit has the fol ignition coil primary current ON OFF
lowing circuits time periods in one cycle of ignition
California modals
operation
Spark timing signal ffi9nitoring
In the conventional distributor the circuit This is equivalent to the dwell angle
ignition timing is detected by the cam of the conventional point type dis
This circuit detects the
ignition
and breaker arm while in this distribu tributor In order to provide high
signal sent from the distributor pick
tor it is detected by the reluctor on performance spark firing over a wide
up coil and amplifies the signal
the shaft and the pick up coil provided 2 Lock preventing circuit range of driving speeds this duty can
in place of the breaker The amount of be controlled by the source voltage
This circuit cuts off the ignition
tic flux passing through the and the ambient well
magn
coil primary current when the ignition temperature as
pick up coil is changed when the reluc asby the engine rpm
switch is ON and the engine is sta
tor rotates and then the electrical 4 Power switching circuit
tionary
signal generated in the pick up coil
is This circuit is used to make or
If the ignition coil primary current
This electric signal i s conducted break directly the primary circuit cur
is allowed to flow under such condi
into the Ie ignition unit which makes rent of the ignition coil
tions excessive current will be drawn
and breaks the primary current run To ensure efficient operation of the
because of low internal resistance of
ning through the ignition coil and Ie igniti9n unit these four circuits are
the ignition coil
generates high voltage in the secondary result manufactured in one assembly
This can in an abnormal
winding
temperature rise in the ignition coil or
The centrifugal and vacuum ad
discharged battery These malfunc
vance mechanisms employ the conven
be this lock
tional mechanical type
tions can prevented by
circuit
The Ie unit utilizes semi preventing
ignition a
California models
Ignition swih h
8 To distributor
Ex side
To distributor
In side
Battery
ffi f I
A I
8 f s 8
8
I I I r
1 01
101 101 Lo 1
I I I I
coil Ignition coil
Ignition
Spark timing ill

j
Duty
signal monitoring control ClfCU
circuit
Lock prevellting
circuit
SEL085
EL35

Ignition Smem ELECTRICAL SYSTEM

This can result in an abnormal 5 Current limiting circuit
The Ie ignition unit utilizes a temperature rise in the ignition coil or This circuit controls the current
Ie device and is discharged battery These malfunc
conductor
mi value so that excessive current will not
mounted the side surface of the tions be this lock
on can prevented by flow trough the power witching
distributor circuit
preventing circuit
The IC ignition unit has the follow 3 Duty control circuit To ensure efficient of the
operation
ing circuits This circuit controls the ratio of the IC ignition unit these five circuits
I ignition coil primary OFF
ON
Spark timing signal monitoring current are manufactured in one assembly
circuit time periods in one cycle of ignition The conductor
semi IC is utilized
This circuit detects the
ignition operation for all these circuits except the power
signal sent from the distributor pick This is equivalent to the dwellangle switching circuit The power witching
up coil and amplifies the signal of the conventional point type dis circuit uses one power transistor and
2 Lock preventing circuit tributor In order to provide high the circuit is arranged on the ceramic
This circuit cuts off the ignition perfonnancespark firing over a wide substrate together with resistors capa
coil primary current when the ignition this duty can
range of driving speeds citors and diodes
switch is ON and the engine is station be controlled by the source voltage Each component part ofthis unit is
ary and the ambient temperature as well highly reliable however should any
If the ignition coil primary current as by the engine rpm be found the entire
part faulty
is allowed to flow under such condi 4 Power switching c rcuit
assembly must be replaced
tions excessive current will be drawn This circuit is used to make or
because of low internal resistance of break the primary circuit

directly
the ignition coil current of the ignition coil
Califomia
Non models
Battery
CD
Ige51Ch
i
B
eh
I
I J
101 101
2P
J
L
Ignition coil rOl II connector
rBCl
r
Sparkti ing sig al Duty control Power switching

circuit circuit
monitoring ClICUlt
G
Lock Current timating

Pick up coil Preventing circuit circuit
Lu
Distributor IC ignition unit
SEL094
EL36
ELECTRICAL SYSTEM Ignition Sysrem
DISTRIBUTOR
I Type o5
D4N9 04
D4N9 09
D4K9 D4K9 1O
I pplied model California Califomia

Non Canada
I Transmission I A T I M T AT M T
I Firing order
I 134 2
I Rotating direction I Coun terc10ckwise
I Air gap mm in
1 3
0 0 5 0 012 0 020
I Cainsulation resistance Mn I More than 50
Rotor head insulation

Mn More than 50
resistance
I cap carbon point length mm in

I 10 39
0 12 0 47
00 3
9 00 3
9 00 3
9 00 3
9
70 2 76 70 2 76 70 2 76 70 2 76
50
3 12 0 50
3 12 0 50
2 12 0 50
2 12 0
Vacuum advance
90 3 54 90 54
3 90 54
3 90 54
3
Distributor degree distributor
3 50 3
13 3 50 13 3 2 50 147 50
2 14 7
kPa mmHg inHgH
100 3 94 100 3 94 11 0 33
4 110 33
4
100 3
33 100 3
33 10 3
33 100 3
33
250 9 84 250 9 84 250 9 84 250 9 84
Centrifugal advance 00 900

700
00 700
00 700
00
Distributor degree 50
3 1 100 30 1 000 30 1 000
50 1 700
distributor rpm 50 1 500 60 1 600 60 1 600
IGNITION COIL
Type CIT 38 CIT 30
Applied model California California

Non
Primary voltage v 12
More than 7 0 28
Spark gap mm in
Primary resistance
104 27
1 0 84 1 02
at 200C 680 F n
Secondary resistance 74 110 8 2 4

12
at 200C 680F
SPARK PLUG
Applied model s A
U Canada
Standard BP6ES BPR6ES
Type Hot BP5ES BP4ES BPR5ES BPR4ES
Cold BP7ES BPR7ES
Size Screw dia x reach mm in 14 x 19 0 55 x 0 75
Plug gap mm in 08 0 9 0 031 0 035
Optional for sA
U
EL 37
Lighting Systems ELECTRICAL SYSTEM
LIGHTING SYSTEMS
CAUTION Before starting to work on any part of electricel system disconneet battery ground ceble
BULB SPECIFICATIONS COMBINATION

SWITCH
SAE
Item Wattage
trade number REMOVAL AND
INSPECTION
Headlamp
Type I High 50 4651 1 Remove steering wheel
Type 11 High Low 40 60 4652 2 Remove steering column cover
3 Disconnect all combination switch

Front combination lamps
wires
Tum signal Clearance 27 8 1157
4 Loosen retaining screw and re
Rear combination lamps move combination switch

Stoprrail 27 8 1157 5 To install combination switch
Turn signal 27 1156
a1ign protrusion on switch body wiih
Side marker lamp hole on steering column and tighten
Front 34 158 retaining screw
Rear 34 158
Back up lamp 27 1156
license plate lamp 80r 10 67
Interior lamp 10
Spot lamp 8
Step lamp 5
Luggage compartment lamp

Hatchback 5
Hardtop 34 158
SE L283
Combination meter
Illumination and brake warning lamp 4
3 158
Waming and monitor lamp 2
Turn signal and beam indicator lamp 34 158
14
Cigarette lighter illumination lamp
Heater Airon control panel
illumination lamp 4
3 158
Glove box lamp 34 158
Cruise control switch lamp 14
Selector lever illumination lamp

AT model 34 158
EL38

ELECTRICAL SYSTEM LighringSystems
INSPECTION
Test continuity through switch

with a test lamp or ohmmeter
OFF
1st
2nd
ON
OFF
JI
111f UUJUUU I
o
OFFI ON
1r
I
o iF
TURN SIGNAL SWITCH WIPER AND WASHER SWITCH

90
LEVER 1 WIPER
1 1
i NIL I
INT L O HI
I
111
12
1i
IOFF X l
WITH
TINE CONTRod
If f
LIGHTING
1 OFF
SWITCH
1ST 2ND
tJ tu rq
1 ABC A Be A 8 C I
zuni AAQ SWITCH
0 I
I
tf M UMJ nON
22
SEL310
EL39

HEADLAMP
SCHEMATIC HEADLAMP
FUSIBLE LINK FUSE

HEAOLAMP A H
@
c
r
udi LIGHTING SWITCH
C0 l BATTERY
HEAD LAMP MONITOR
I c
o
FUSE j
l
HEADLAMP SENSOR
HEAD LAMP LH
CD t
rI
@ 1 SEL371
Headlamps do not come Burnt fusible link Correct cause and replace fusible link
oneither high or low Burnt fuse Correct cause and replace fuse
beams
Loose connection or open circuit Check wiring and or repair connection
Faulty lighting switch Replace if necessary

High low beam comes on when CD and
@ CD and @ terminals of hamess con
nector to lighting switch are connected with

test lead including lOA fuse
Faulty headlamp sensor Replace if necessary

No ground Clean and tighten ground terminal
High beam cannot be Faulty lighting switch Replace if necessary

switched to low beam High low beam comes on when CD and
vice versa
or
@ D and @ terminals of hamess con
nector to lighting switch are connected with

test lead including lOA fuse
Headlamps dim Partly discharged or down

run battery Measure specific gravity of electrolyte and
recharge replace battery if necessary
or
Inoperative charging system Measure voltage at headlamp terminals

If it is less than 12 8V check charging
system for proper operation
Poor ground or loose connection Clean and or tighten
Headlamp lights on Loose headlamp connection Repair

only one side
Faulty headlamp Replace
EL40

ELECTRICAL SYSTEM Lighting Systems
WIRING DIAGRAM HEADLAMP
ill
FUSIBLE
OW
@
LINK
o
BATTERY
t r
HEADLAMP R H LIGHTING SWITCH
I OFF 1ST 2ND

RY
ir
fi @
4 R r 4 R r 4
I
a
RR V lL 661 t
@ RY1th D Ll3 0
Tr RW
1
R II
jR
Y RW
I H gXZ 6 6 g
@
II COMBINATION
r Green METER
White
J
I
gg lQ
QrJ @giJ gglrgg
l
I g CI
@ I
I
O U @ HEADL MP
MONITOR
HEADLAMP LH
HEAD LAMP
0@ @
SENSOR
D
RY DO
DO
RL
RW
@ @l
@
SE L372
EL 41

LIGHTING SWITCH AIMING ADJUST ENT Low beam
Refer to Combination Switch To adjust vertical aim use adjusting Turn headlamp low beam on
screw on upper side of headlamp and

horizontal aim use adjusting U Horizo tal 230 48 43
to adjust
n
center line I
HEADLAMP SENSOR screw on side of headlamp
Ofheadlam p Wf Th
fP t
Location CD
is located on
Q2
The headlamp sensor
the relay bracket Refer to page EL i

105
il i
Inspection
Gwu 7
s R W
j
Unit nun in
BE298D
Ught swi1ch on
1
Before checking headlamp sensor
SEL291 that
that 11 bulb Adjust headl mps SO upper
ensure meet specifi
cations edge of hot pot is equ 1 in h ight
1 Vertical adjustment
to heedl mp height
2 Horizontal adjumnent
b Dotted lines in illustration show
canter of headl mp
High beam
Bafor m king headl mp Imlng
With II unit outer
djustment ob rve the following type lamps
instruction lamps covered tum headlamps to
11 tires infl ted to correct high beam

Keep
pressures
U
b Place car and tester on one and
e
same flat urf
All bulbs in good ordllr 2 volts
c See th t there is no load in car
Bulb removed 12volu
cool nt oil filled up
engine to
SEl373
correct level and H
full fuel tank
other than the driver or equivalent
weight pl ced in driver s position
When performing headlamp aiming

Unit in
adjustment use an aiming machine mm
BE2990
aiming wall screen or headlamp tester
For operating instructions
of any
aimer it should be in good repair
calibrated and used according to 8 Adjust high beams so that main axis
respective operation manuals supplied of light is p rallel to center line of

with the unit body
If any aimer is not available aiming b Dotted lines in illustration show
adjustment can be done as follows center of headl mp
EL42

EXTERIOR LAMPS
CAUTION Do not wipe lens surface using cloth dampered with gesoline
SCHEMATIC TAIL CLEARANCE SIDE MARKER LICENSE PLATE AND STOP LAMPS
FRONT SIDE REAR SIDE

oI
2t 1ST OFF
MARKER LAMP R H MARKER
LAMP RH
i
jlmfr
c
o
STOP
FUSE
@ I
CLEARANCE
STOP LAMP SWITCH j @ TAIL
c
o
LICENSE
FUSE
TAIL LAMP PLATE LAMP
MONITOR
r c
o @
FUSE
IFUSIBLE
LINK
STOP LAMP
MONITOR
l TAIL
fJ I
L
BATTERY Il
CLEARANCE STOP
I TAl L ANO STOP
REAR SIDE
SIDE
r LAMP SENSOR
MAR KER
Q
EJ FRONT
MARKER LAMP LH
LAMP LH
SE L315
SCHEMATIC TURN SIGNAL AND HAZARD WARNING LAMPS
IGNITION
OACC SWITCH
o
r 4c 1
FUSleLE
LINK
c
o
Sf
L C
IGNITION AND
ACCESSORY RELAY
0
g
FUSE HAZARD SWITCH
FUSIBLE
LINK
HAZARD
FLASHER
T
c
o Fl UNIT
IN
g
FUSE
f
I BATTERY
L
TURN SIGNAL
I FLASHER UNIT TURN SIGNAL
TURN
Fl SWITCH
fl PILOT LAMP R H
@
TURN
FRONT RE
R
COMBINATION COMBINATION
LAMP
l LAMP
TURN PILOT LAMP LH TURN
E1 t3 eL37
EL 43

WIRING DIAGRAM TAIL CLEARANcE SIDE MARKER AND UCENSE PLATE LAMPS
R W
FUSIBLE LINK
@
I
Et
BATTERY I
J
FRONT SlOE
1
MARKER LAMP
R H
I
n
@89 ll
FRONT COMBINA
TION LAMP R H
1 GW
8
@
I OF 1ST 2ND
GW
ABCABCABC
@
jI
Lg
I
I100
00
3
4
5
I
G
@
White LICENSE PLATE

LIGHTING SWITCH
LAMP
e r
il
GW l
Ij
00
@ 00
00 lI ltJ
i
GW
1B
V
00
00 ill
ft
@
WL
e
gg
00
@
ill
@o f rHATC CK
TAIL
M
@ gg Black
FRONT COMBINA
TION LAMP LH
GB
O
i5
g
WGH
B I
TOP
ry
TAIL LA
I
P
II
@
wARD
WG
LH
I I a
fB 14
@I JtU@ Gll
J@
@j
L@j
W l TAIL AND STOP
Gf
Y
LAMP SENSOR
FRONT SIDE
MARKER LAMP REAR SIDE MARKER
LH I LAMP LH
SEL316
ELM
WIRING DIAGRAM STOP LAMP
BATTERY
COMBINATION METER
01
IU L
y Au2
U
G CID
STOP LAMP
I FUSIBLE STOP LAMP SWITCH MONITOR
LINK
@
@
II @
Bluel
II
J@
ggggllggt
J
White
J
IF
J
@
HATCHBACK
STOP AND
TAIL LAMP
R H
0 0
@
B
l
W GY YG
HARDTOP
f
w L f YG I
41
tJ I
fB
I
@
STOP LAMP
I
10
L
J
R H
15
10
c LIi rII J
B1
20
White Black
o ooooo
10
Iqj OOIIOOOO
oo
11
0000 OJ @
10
5
1
@ I
rO@ Cill
FUSE BLOCK I HATCHeACK
STOP AND
TAIL LAMP
LH
@
f I u
B
tf11 l YG
@ rHARDTOP
TAIL AND STOP

LAMP SENSOR
@
@I
STOP LAMP
I
L
LH
I
SEli71
EL 45

Lighring Systems ELECTRICAL SYSTEM
WIRING DiAGRAM TUm SIGNAL AND HAZARD WARNING LAMPS
IGNITION SWITCH
I CJT ICJN
t
iI ST
i U9Q
FUSIBLE
@i R
rn @
A
IG
s
0 0 J
b Q
LINK
@ IGNITION AND
I ACCESSORY
G1 W RELAY
WB
BATTERY
BW
3 FUSE BLOCK
B
HAZARD FLASHER UNIT
l
j
I @ GBbTCHBACK
m
J
BI fP
@ GY
l 1 co
J
t B
r J B
HAZARD SWITCH
GB r
I HARDTOP
l
FRONT COMBI
2 0
8 GB1 I O
NATION LAMP R H
JG 3
4 8
D I
I
0 t I
u GB S I
L J
TURN SIGNAL REAR COMBINATION

FLASHER UN IT LAMP R H
L
G C
B TURN SIGNAL SWITCH

LN
@
i
R
1t
f
@
j I
Y
GB
I@
t@
I II
i CD aJ
I@
6 REAR COMBINATION
a
IG
1
een
I
i
IWhi e
Ilt@ 00
White
r
LAMP LH
c
l
Y
oc 1 GR
111
I
I
00
FRONT COMBI ll
I fi
I I
NATION LAMP LH
@ OOllOO OilfJ
00 0000 co
COMBINATION B
L @2
1
ill METER J
@ R a L H RH
ro
@ I
I GRi fll l
jJif
r1 i
B
ID J
t P I
I GR
L 8
PILOT LAMP
SEL379
46
EL

SCHEMATIC BACK UP LAMP
FUSIBLE IGN 1TI0N BACK UP LAMP

OACC SWITCH R H
c
o
LINK
if CON 1
@
C C
FUSIBLE BACK UP
I BATTERY
LINK LAMP LH
IGNITION AND BACK UP LAMP
L
ACCESSORY SWITCH
@
I RELAY
INHIBITOR SWITCH 3
1
@
SEL380
WIRING DIAGRAM BACK UP LAMP
FUSE BLOCK
1 IGNITION AND
ACCESSORY RELAY @
9 @@ BACK UP LAMP
R H
@
Jl RB RB
t
BB
00
00
i @
@
@
F T
White
BW
WR
IGNITION
SWITCH
B
G
@
I@
RB
o tf R
FUSIBLE
LINK @@
B 1@
I
C
ll
a
ll
a C
o
INHIBITOR
9 Q@ 0 O@
SWITCH
BATTERY
@
11 11 I@ t
RBB
t BACK UP
LAMP SWITCH
@
@
L H
UP
BACK LAMP
SEL381
47
EL

Lighting Systems ELECTRICAl YSTEM
Clearance side marker lleense plate and tail lamps
Neither left nor Burnt fuse Correct cause and replace

right lamp lights Loose connection or open circuit Check wiring and connection
or repair
Faulty lighting switch Replace if necessary
Lamps light when CD and @ terminals of
harness connector to combination switch are
connected with test lead including 15A

fues
Fa1llly tail and stop lamp sensor Tail lamp Replace t

li1 and stop hunp sensor
only
Lamp on only one Burnt bulb

Replace
side lights
Loose bulb Repair lamp socket
Stop lamps
Neither left nor right Burnt fuse Correct cause and replace
lamp lights
Faulty stop switch Conduct continuity test and replace if neces
sary
Faulty tail and stop lamp sensor Replace if necessary

Stop lamps light when @ and @ terminals
of main harness connector to tail and
stop
lamp sensor are connected with test lead
including lOA fuse
Lamp on only one side Bumt bulb

Replace
lights Loose bulb Repair lamp socket
EL48

Turn slgnsl and hazard warnIng flasher lamps
Turn signals do not Bumt fuse Correct cause and replace

operate Loose connection or
open circuit Check wiring and or repair connection
Hazard waming
Faulty flasher unit Replace
lamps operate
Faulty turn signal switch Conduct continuity test and replace if neces
sary
Faulty hazard switch Replace if necessary
Turn signals operate when CD and @
terminals of harness connector to hazard
switch are connected with test lead including
lOA fuse
Hazard warning Burnt fuse Correct and

cause replace
do not
lamps Faulty hazard warning flasher unit Replace
operate
Turn signals Faulty hazard switch Replace if necessary
Left Right side lamps operate when @
operate
@ and @ terminals of harness connector
to hazard switch are connected with test
lead including lOA fuse
Turn signals and Faulty hazard switch if necessary

Replace
hazard warning lamps
Loose connection Reconnect finnly
do not operate
No flasher click is Burnt bulb Replace

heard
Faulty flasher unit Replace flasher unit
Loose connection Reconnect finnly
Flashing cycle is too Bulb other than specified wattage being Replace with one specified
slow pilot lamp does used
not go out or too

Burnt bulbs Replace
fast
Loose connection Reconnect firmly
Flashing cycle is Burnt bulb Replace

irregular Loose connection Repair
Bulbs other than specified wattage being Replace with one specified
used
EL 49

Lighting Symms ELECTRICAL SYSTEM
LIGHTING SWrTCH AND TURN SIGNAL FLASHER

TURN SIGNAL Ct1
SWI1 UNIT AND HAZARD
Refer to Combination Switch FLASHER UNIT
STOP LAMP SWITCH Location
Inspection

with an ohmmeter
VJ
Bulb in good ord Ap
2 volts
Bulb removed Approx Steering
12wofts column
Turn signal flasher
SEL385
Hazard flasher unit unit
Z97
SEL
NORMAL PUSH
POSITION PLUNGER
Tail lamp
CD
@ 6 light switch on
BACK UP LAMP SWITCH
SE L36S
Automatic transmleslon
The up
back lamp switch is built
Adjustment into the inhibitor switch Refer to
Refer to MA section AT section
Manual transmlealon
The back up Jamp switch IS ID
stalled on the manual transmission

case
Bulb in good ord r Approx
2 volts
Bulb nmoved Approx OJ
12voltl
TAIL AND STOP LAMP SEL386
SENSOR Transistor built In
Removal and installation

HAZARD SWITCH
Before removing tail and stop
lamp sensor detach rear wheelhouse Inspection
fInisher See page EL 105
on SEL298
Before checking tail end top lamp

senIOr en ure that aU bulb meet
specifications
Inspection
lt
145
Stop lamp OM
OF
SEL296
Stop lamp switch on
EL 50

ELECT RICAL SYSTEM Lighting Systems
INTERIOR WGGAGE COMPARTMENT AND STEP LAMPS
CAUTION 00 not wipe lens surface

using cloth dampered with gasoline
SCHEMATIC INTERIOR LUGGAGE COMPARTMENT AND STEP LAMPS

Hatchback model with Interior lamp timer
INTERIOR LAMPS
WITH SPOT LAMPI
6 6 6 011
STEP LAMP RH
INTERIOR
LAMP
TIMER
ij o
DOOR SWITCH RH
1
FUSE
j
C
o
DOOR SWITCH LH
FUSIBLE LINK
LUGGAGE o 0
COMPARTMENT
LAMP
1
BATTERY
III STEP LAMP LH
L
1 n
SEL3a7
EL 51

WIRI NG DIAGRAM INTERIOR LAMP STEP LAMP AND LUGGAGE COMPARTMENT LAMP
FUSE BLOCK
i BATTERY
81 11
US BL
u I 0 0 0 0
LINK @
lG
l IWITH INTERIOR LAMP TIMER
INTERIOR LAMPS @
STEP LAMP A H
i
00
lR BR
INTERIOR 6 b 6 ro I A
LAMP TIMER lG J
c
RG
LUGGAGE COMPART @@
MENT LAMP HATCHBACK eR
@ RG DOOR
CH
nO
1f
O
Wl@
II
@
fB@ TRUNK ROOM LAMP
4
rif31 HARDTOP
@
11
1 RG
I a U Black CD
W Rr
@
DOOR SWITCH LH
@ I
4 I@ fY
BR
CC Whi
Hgg
RG
H
RB
CD
l
CD
a a 10
000 h iB
o V
tSiB
R
@I
@ 6 W
I @ iR tt
on
White
l
19b 21 iY
I
7I STEP LAMP LH
00
B ER J
c
BR
B
J
c
RG
ib @ @ @
WITHOUT INTERIOR LAMP TIMER
IrO
II
k9
1
jl
INTERIOR LAMP
LUGGAGE COMPART
J
BR
@ DOOR
h
o
CD
a
co a
MENT LAMP IHA TCHBACK
@ SWITCH R H
W @
White RG
B D 0 J
Q
a r9l@ 0
i@ @ TRUNK ROOM LAMP
HARDTOP
I a
I 00
DOOR SWITCH LH
L
I i
t
CD
I @ RG
@ o
t
@
ao 0 0
J 00 0
lR
2
@ @
@
SEL388
EL 52

INTER I OR LAMP INTERIOR LAMP TI MER

Ic built In
Bulb replacement
Location
Without spot lamp
The interior lamp timer is attached
Remove lens by inserting a f1at
to the upper side of instrument frame
blade screwdriver into switch hole To
Refer to page EL 104
avoid lens damage blade portion
should be covered with a cloth before
insertion
Inspection
DOOR SWITCH
Inspection
Door switch LR
@
SEl393
Circuit tester indication
As door is closed tester indication

should linearly increase from 0 to ap
proximately 10 volts after 10 seconds
SEL391
With spot lamp
1 Open cover with a f1at blade
DOOR I
screwdriver inserted into front of I CLOSE OPEN
FOR USE
cover To avoid cover damage blade

I 0 KEY AND
portion should be covered with a LIGHT
cloth before insertion

126 WARNING
INTERIOR
2 Remove attaching bolts and de
tach interior lamp assembly g I LAMP
EL 53

INSTRUMENT PANEL ILLUMINATION

SCHEMATIC INSTRUMENT PANEL IUUMINATION AND CIGARETTE LlGHlER
LIGHTING FUSE
Off 1ST 2ND
FUSE
SWITCH
I ABC ABC ABC
c
3
I
I
CIGARETTE
LIGHTER LAMP
COMBINATION
METER
OPTICAL FIBER
o KEY
r
13
i FUSI LE
ILLUMINATION
ASH TRAY LAMP
bLINK ILLUMINATION
CONTROL
RHEOSTAT 3
8
GLOVE BOX LAMP
TEMPERATURE
CONTROL PANEL
RADIO
13
AS C D ILLUMINATION
MAIN SWITCH
T
BATTERY
I
L
CIGARETTE 3
LIGHTER LAMP AfT POSITION
I INDICATOR LAMP
SEL396
IUUMINATION I ROL
RHEOSTAT
Transistor bult ln
8pectlon
Battery fe E
SEL303
EL 54

rRICAL
ELEC SYSTEM Lighting Systems
WIRING DIAGRAM INSTRUMENT PANEL ILLUMINATION AN CIGALETTE LIGHTER
f T
GW IAO
I
C A C A
q
2i q
@ LJ
a
Lg 1 a 6 06
I 0
1ill aa
l
@ nun
i
LIGHTING SWITCH
FUSE e LOCK
0 0
@
@ @
L9B1
GW
t
0
00
00
0 fi 0
I
I
@
I
@ AS C D GW
METER
MAIN SWITCH
I
LgS AND KEY

ILLUMINATION
l IllUMINATION
COMBINATION METER
CiD
@r
G ij D
LgB
r ILLUMINATION
@ CONTROL RHEOSTAT
HEATER CONTROL
PANEL ILLUMINATION
@
LY ll
SleLE
K Jo
B
GW
@ @
B B
CIGARETTE LIGHTER
flJ Lgg
il I
Lv LY S D
GW
GW GW I @GLOVEBOX LAMP
White
@ LgB B
Eli LgB e
Gw I
BATTERY
@
f
ASH TRA Y LAMP
8
T @ Bluel
@
GW
II aa
V
L9
a B
SIGW
AfT POSITION
INDICATOR LAMP
191
RADIO
ILLUMINATION
AS C D equipped models
@
SEL396
EL 55

Meters Gaugesafld Warning Systems ELECTRICAL SYSTEM
METERS GAUGES AND WARNING SYSTEM
CAUTION Before starting to work on eny part of electrical system disconnect battery ground cable
COMBINATION METER
R O A ANI 1 tTA TION
SE L397
EL 56

ELECTRICAL SYSTEM Meters Gauges andWarning System
INSPECTION
3
0
80
o
JO
@ID lUTI r5Tl
S
OUAFlTZ
so 1
o
o rei 0
o
0
i
b mJ
rnm Optical fiber
w Beam indicator
mill Key illwninati9
w
ill j
J f1Q m lli ll
lamp
Charge warning J EJ
U ITJ m m IllJ
lamp Illumination lamp
ReaI defogger
indicator lamp
J
lliumination lamp
G a e0@8@
A A
111 11 J i f
Jn8 L
n
@ c0
w
ey
0
0 c
u 0 0
0
o
CD
1
o
J 15 I
o
o u
L 1
ll
o
w
II
w
o
l l @
1 Temperature gauge 12 Left turn indicator lamp 20 Clock Power source

2 Seat belt warning lamp 13 Charge WaIning lamp 21 Oil pressure warning lamp
4 Power source
14 Rear defogger indicator lamp 22 Clock Illumination
5 Right twn indicator lamp IS IDumination lamps 24 Brake warning lamp
6 Fuel gauge 16 Illumination lamps 25 OU presswe gauge
7 Beam indicator lamp 17 Tail lamp monitor lamp 28 Door warning lamp
8 Tachometer Signal
18 Headlamp monitor lamp
10 Ground
19 Stop lamp monitor lamp
SE L398
EL 57

Merers Gauges and Warning Systems ELECTRICAL SYSTEM
SCHEMATIC TACHOMETER GAUGES AND WARNiNG LAMPS
IGNITION
FUSIBLE
SWITCH
LINK
UUUUUJ FUSE
FUSIBLE Od 0 C
LINk
RESIS
0 IGNITIO N TOR
IGNITION AND
COIL
ACCESSORY RELAY
T
I BATTERY
A J
I VOLT GAUGE o
ALTERNATOR
a
CI
0
4
C t Z Z
1lja 115
CI J II w
IDCI
J
Zo a za 0
r
WC Oa
J a Z J
o
z g g
1
f
w
a II
0 W
io
u
w
y
w
Qi Q
w
Ga a
J
C
J
1 0
J J
i
I
6f
J 0J
r
n
tJ 6V ni I 1 41 i
a
u
z IW Ot
JCJ w O
J w
T
U w
Cl Jc 0
Cl
a z lLCJ a u
w 10
J aO
a 0
JZ o
w
0
SE L399
WIRING DIAGRAM TACHOMETER
l RG GD
T I
I FUSIBLE J
Et LINK
L
2 3
0
a
BATTERY a
0 0
e
D@ TACtOYETER
COMBINATION METER
IGNITION SWITCH
a
L9W
Ih
I
00 IOOri tf7i
OOOIl y
S1 ON ACe OFF
@ B
0 B
I
G
White
i
BW G
II
IT
I
l I
I@
t
rL9
WR
L9W
t
L9WiL9
IGNITION AND ACCESSORY RELAY
l
CJ
IGNITION
@ WB G COIL
@
FUSE BLOCK
Bl@ RESISTOR
SEL405
EL 58

ELECTRICAL SYSTEM Meters Gauges and Warning Systems
WIRING DIAGRAM OIL PRESSURE GAUGE AND WARNING LAMP WATER TEMPERATURE
FUEL AND VOLT GAUGE
I 10 ACQON Sf
1 O
6
CfW
IGNITION
FUSIBLE
BW
rn
WR
II
II I
S
6t
6
SWITCH
LINK
E9
BATTERY
rn IGNITION AND
t FUSE 1l
ACCESSORY
RELAY
BLOCK
I B
J@
FUEL TANK
I GAUGE UNIT
I @
@ J 0
I
y
@
White
JU r
f 1
i@
I
@
G COMBINATION METER
B
Jr
@ lJg Jlgg VOLTGAUGE
LY
Y OIL PRESSURE
GAUGE
VOLTAGE
I Green
EGULATOR
@60@
TEMPERATURE
OJ AUGE
VOLTAGE
REGULATOR
@
@
@ 0 I
I
s co
V 6Hv
FUEL GAUGE
I @ 0
@
U@ @ 7 OIL PRESSURE
LY
WARNING LAMP
RC
362
J
B 4
0
1 Y8
1l
u Iu n
1ll
5
YW
OIL PRESSURE THERMAL
SENDING UNIT TRANSMITTER

@
SEL404
EL 59

Mere17i Gauges and Warning Sysrems ELECTRICAL SYSTEM
WIRING DIAGRAM CHARGE DOOR AND BRAKE WARNING LAMP
IGNITION SWITCH
Off I
X ON 5T
WR B 9 Q
m J
D 6 I
I
WJ
FUSIBLE LINK
@
rn
BW I
g
o
BATTERY
t
1
w
WB
r
I BW
m
FUSE BLOCK
IGNITION AND t1
ACCESSORY
RELAY @
I 1Wh
jJ
el
@lil
I 00
00
00
BULB CHECK RELAY
C
is DOOR SWITCH R H
04
i rr
R Br J4
BR
t B
s 4
@
@ I B
@
1
@
R
I G
Green
BRAKE FLUID G
LEVEL SWITCH BR
@
@
L Qtl YG
@ DOOR SWITCH L H
OO
r
@l @
PARKING BRAKE SWITCH

BJ
@o
WR
WR
8
gfgfllg
JI
White
ill
BR J lI 0
e 0
o DYG
@
l COMBINATION METER
@
2
w
W
W a a
4 0
G J 0
ALTERNATOR a
u 0
a m
J
@
2
L @ wr BR
TERMINAL
@ G
d 3
@
SEL368
EL 60
Water temperature gauge
Gauge does not Faulty thermal transmitter or loose terminal Replace thermal transmitter or correct ter
connection minal connection

operate
wire to thermal transmitter is
When ground
ed gauge pointer fluctuates
Faulty water temperature gauge Replace water temperature gauge
Gauge indicates only Faulty thermal transmitter Replace thermal transmitter
maximum temperature Gauge pointer returns to original position

when ignition switch is turned off
Faulty water temperature gauge Replace water temperature gauge
Gauge pointer indicates maximum tempera

ture even after ignition switch is turned off
Gauge does not operate Faulty water temperature gauge Replace water temperature gauge
accurately Loose Correct connector terminal contact

or poor connection
011 pressure gauge
Oil pressure gauge Faulty oil pressure sending unit or loose Replace oil pressure sending unit or correct
does not operate terminal connection terminal connection
Gauge indicates only Faulty oil pressure gauge unit Replace

maximum pressure Gauge pointer retums to original position
when ignition switch is tumed off
Faulty oil pressure gauge Gauge pointer Replace

indicates maximtim pressure even after igni
tion switch is turned off
Fuel level gailge
Fuel level gauge Faulty fuel gauge tank unit fuel gauge tank unit
Replace
does not operate Pointer deflects when fuel gauge tank unit
wire is grounded
yellow
Faulty fuel level gauge Replace
Pointer indicates only Faulty fuel gauge tank unit Replace

F position Faulty fuel level gauge Replace
Fuel level gauge does Faulty fuel gauge tank unit Replace
not operate accurately Faulty fuel gauge Replace fuel level gauge
Poor or loose connection Correct connector teoninal contact
Faulty gauge voltage regulator Replace gauge assembly
Volt gauge
Volt gauge does not Faulty volt gauge Replace
operate or abnormally Loose or poor connection Check wiring and or repair connection
indicates
EL 61
Meters Gauges and Warning System ELECTRICAL SYSTEM
Charge and brake warning lamps
Lamp does not glow Burnt bulb or loose bulb Replace bulb or correct
when ignition switch
Loose or poor connection Correct connector terminal contacts
is turned ON with
out Faulty printed circuit board

Replace
running engffi e
Faulty bulb check relay Replace
Faulty alternator Repair or replece
Chellle werning lemp Faulty charging system Inspect charging system
Lamp does not go out
when engine is started
Brake warning lamp Faulty parking brake switch When parking Replace
Lamp does not go out brake lever i released
Faulty brake fluid level switch When brake Replace

fluid level is nonnal
Oil pre sure and door warning lamps
Ojl pressure warning oil unit or loose

Faulty pressure sending r
Replace or correct connection
lamp terminal connectio

Lamp does not light When lead wire connected to sending unit
when ignition switch is grounded warning lamp lights
is set to ON
Burnt bulb or looSe bulb Replace bulb or correct
Lamp does not go out Lack of engine oil Check oil level and add oil as required
while engine is being Oil pressure too low Inspect engine oil pressure system
operated
unit
Faulty oil pressure sending Replace
Door warning lamp Faul1y door switch Replace
Lamp does not glow Burnt bulb orloose bulb
with door opened and Replace bulb or correct
engine running
Tachometer
Tachometer pointer Loose or poor connection Repair

deflects
Faulty resistor Replace resistor
Faulty tachometer Repair or replace tachometer

Tachometer pointer Loose or poor connection Repair
will not move
Faulty tachometer Repair or replace tachometer
EL 62

ELECTRICAL SYSTEM Merers Gauges and Warning System
f
pe dometer nVi

Condition
Neither Loose speedometer cable union nut Retighten

speedometer
pointer nor odometer side Replace speedometer cable
Broken speedometer cable Meter or
ol erates Transmission side
transmission Repl transmission speedometer pinion

Damaged speedometer pinion ce
gear gear
Faulty speedometer Replace speedometer
Unstable speedometer Improperly tightened or loose speedometer Retighten

pointer cable union nut
Replace speedometer cable

Damaged speedometer cable
Faulty speedometer Replace speedometer
Unusual sound occurs in Excessively bent or twisted speedometer Replace or lubricate
increase in cable inner wire or lack oflubrication

response to j
driving speed Faulty speedometer Replace speedometer
Inaccurate speedometer Faulty speedometer Replace speedometer 1
indication
Inaccurate odometer Faulty speedometer Replace speedometer

operation
FUEL TANK GAUGE UNIT a Float For fuel gauge
Removal and Installation
1 E
Refer to FE section
11
Inapectlon
Full t
Fuel tank gauge unit has two func
tions
2
e l
II
i
SEL311
1 4
Empty d
L Unit mm in
SEL312
EL 63
Maters Gauges and Warning Systems ELECTRICAL SYSTEM
b Thermistor For multiwarning BULB CHECK RELAY

display
LocaUon
Test lamp
The bulb check relay is attached to

the relay
s
bracket Refer to pa EL
105
Inspection
l
I ft I
Power
sowce Earth
Water
lll
i
lI
L
w
@
SEL313
SEl406
Testlamp should come on in ap
proximately t1uee minutes after re
moval of thermistor from water
DIODE
For charge warning lamp SEL314
PARKING BRAKE SWITCH

Location
The diode for charge warning lamp

is fastened to harness with tape on
the right side of the dash panel Refer
to page EL 109
RESISTOR FOr tachometer

and EFI system
DOOR SWITCH A 2 2 kfl resistor for tachometer
Refer to page EL 53 and EFI system is located near the
Plirklng brike p lIed on ignition coil

Parking bnke released n
SEL309
TACHOMETER
Removal d Installation
1 Remove combination meter

BRAKE FLUID LEVEL 2 Remove tachometer attaching
SWITCH bolts
3 Remove tachometer from com
bination meter lower housing

of removal
Float I Approx zson

Float 1 Approx on
SEL310
EL 64

ELECTRICAL SYSTEM Merers Gauges and Warning Systems
SPEEDOMETER
Cable layout
Cable
Speedometor
SEL410
For detailed information regarding

IA S C D refer to page
Ipeed len or
EL 102
Ignition switch ON
WARNING DISPLAY
DESCRIPTION read
Warning lights come on to
The warning display system con aU items in succession one at a
sists of a warning indicator a warning time for 2 seconds
display amplifier and sensors

J
When ignition switch is ON warn
ing display operates as follows

YES
NO
ight
I OFF
I
Abnormality
I
Abnormal indication
I
Eliminate abnormality
I
EL 65

Msters Gauges aM Wa11Iing Systems ELECTRICAL SYSTEM
Display modes
Identification Color Item Warning
Indicates that fuel is less than mately

v 10
I FUEL
fBf I Red Fuel level warning
liters 2 5 8 US gal 2 1 4 Imp gal
Battery electrolyte level Indicates that battery is less than
I BA TTe Orange
warning specified level
electrolyte
Indicates that engine coolant in radiator reservoir

WATE
lllliiD Orange Coolant level warning
tank is less than specified level
Washer fluid level Indicates that windshield washer fluid is less than
IWASH Orange
warning specified level
SCHEMATIC WARNING DISPLAY
BATTERY LEVEL SENSOR RADIATOR LEVEL SENSOR
1 1 f iLr
e
lJl
WASHER LEVEL
SENSOR
FUEL LEVEL SENSOR
H b
IGNITION SWITCH
Ir
OACX
if CON
I
q E
WARNING INDICATOR
WARNING
IGNITION AND DISPLAY
ACCESSORY
RELAY
b AMPLIFIER
BATT
o
FUSE
SEL411
EL 66

ELECTRICAL rEM
SYS Meters Gauges and Waming Systems
WIRING DIAGRAM WARNING DISPLAY
IGNITION SWITCH
tfW WR WR
II
FUSIBLE
@
1ill
BW
LINK
@
EJ
BATTERY
t FUSE eLOCK
J
IGNITION AND fj
1 ACCESSORY
ffEU
i@
V
t n
WARNING
jER
WASf SENSOR INDICATOR
@
L
0 ClI
LY
JClI Lvi
lB
LR
f
RADIATOR WARNING
SENSOR DISPLAY AMPLIFIER
BL
RY
@
@ B
J 1 B J LV
BL
LW
LB
o
0
0
0
LR 0
L 0
i@ YL
BY
FUEL TANK
BATTERY
GAUGE UNIT
SENSOR
@
n C BY
L YL YL
@ EYL I
I
00
B
g Black
00
@
ill
@ @
@ SEL412
Et 67

GaugesandWaming
MI1te ELECTRICAL SYSTEM
i 1
No warning indica1Bd
I N G
Chec
f11se fuse
r Repla
lO K
Check forloose connection at I N G
r Repan connector
warning indicator and amplifier
OX
Replace warning display amplifier
When ignition witch i turned to ON warning lights come on to read all items
in one
succeuion at a time for 2 seconds However warning lights will not come
on even th ugh there i Ibnormality
1
N G
Check sensor Repan or rep Iace sensor
lOX
Check for loose connection N G
Repair or replace
or open circuit
lOX
Check warning indicator for N G
Replace warning indicator
burnt bulb
though th
I Warning light remain on even i no IbnormaJity
1 N G
Check sensor Repan or rep Iace sensor
lO K
Check for loose connection or N G
Repair or replace
open circuit
lOX
EL 68

ELECTRICAL SYSTEM Gauges and
Mete Warning Systems
MULTI WARNING INDICATOR FUEL LEVEL SENSOR
Location
The multi warning indicator is

InllPectlon
Refer to pages EL 63 and 64
w
located in the combination gauge
InllPectlon
WASHER LEVEL SEN R
Location
Empty on
The washer level sensor is located
Norm llev t n
on the bottom of the washer tank
SEL415
o
InllPectlon
j Washer
Q BATTERY LEVEL SENSOR
Inspection
@@ Radiator
the
Before inspection
is
make sure that
is
battery charged and the fluid
Fuel ftlled up to correct level
1 Disconnect sensor ha ess connec
SEl414
tor
eID Battery 2 Make sure that there is about 8

volts when voltmeter positive and
SEL413 negative teoninals are connected to

battery fluid level sensor and battery
COOLANT LEVEL SENSOR negative terminals respectively
Location 8Y
The coolant level sensor is located
MULTI WARNING AMPLIFIER on the bottom of the radiator reser
voir tank
JC bullt ln
Location
InllPectlon
The multi warning amplifier is at
tached to the instrwnent panel frame Coolant level sensor is united with
Before removing it remove cluster the reservoir tank and cannot be re
lid C Refer to page EL104 moved alone BES07D
EL 69

Meters GaugesandWaming ms ELECTRICAL SYSTEM
l A
WARNING CHIME
SCEMATIC SEAT BELT KEY AND LIGHT WARNING
IGNITION
C
ON SWITCH L
c
J a cON
FUSIBLE LINK
0srJ L FUSE
o c c
o LIGHTING SWITCH
FUSIBLE LINK
OFf 1ST 2ND
IGNITION AND
FUSE A a CAB C c
c
r
ACCESSORY RELAY
Ala
BATTERY
g8g2@
L FUSE
I
SEAT BELT WARNING TIMER KEY WARNING
SWITCH
WARNING CHIME
DIODE
6 SEAT BELT
SEAT BELT I II
ING DOOR SWITCH

o
SW ITCH
@ L H
I I
SEL416
TROUBLE DIAGNOSES AND CoRRECTIONS
Licht and key
Warning chime doe Faulty warning

chime Replace
not sound with ignition Loose connection or open circuit Correct connector terminal contacts
key in ignition switch
or
lighting switch on Faulty door sWitch Repair or
replace
when driver side door Faulty key warning chime switch Repair or replace
is open
Faulty lighting system Clearance lamp does Correct
not light
Seat belt
Chime does not sound Faulty eat belt switch Repair or replace
and warning lamp does
Faulty seat belt warning timer Replace
not glow with ignition
switch on
Loose connection or open circuit Correct connector terminal contacts
Either chime or Loose connection or open circuit Correct connector terminal contacts
warning lamp does not Burnt bulb
Replace
operate with proper
condition Faulty chime Replace
EL 70
WIRING DIAGRAM SEAT BELT KEY AND LIGHT WARNING
IGNITION SWITCH
I aa ON S1
Of
I B
It O R WR
41
iA g
FUSIBLE aw
IG o
LINK
@
41
IS g
@
G
e
BATTERY
a
I n
W
WB
aw aJl I
5 5
1 I I
1
IGNITION AND
ACCESSORY
REALY
Ii
@
O
DOOR SWITCH LH @ @
LIGHTING SWITCH
rVR I
r I
2ND
nJ
lVR
OFf 1ST
oo YR
no GW ABCABCAB
U9 Uo GW JtGW
GW GW GW
1 9 0009
o
I @
White
Lg 41
41 IillJJ l4
oObo
@ 15 888 g gg
SEAT BELT TIMER
A KEY WARNING SWITCH
YB RG a iO
w DlJ c oonU
WARNING CHIME
11
COMBINATION
R
illY Blue @ METER
SEAT BELT SWITCH

w
il L9Y
GD
2
2
YB e B
2k
gm Br
rtfJ1J
SEAT BELT
l@
WARNING LAMP
@
t J
l
fi
Whhe
@
SEL417
EL 71

Gauges and Warning
Mete Systems ELECTRICAL SYSTEM
KEY WARNiNG SWITCH SEAi BELT WARNING Inspeictloil

TIMER
Refer to Ignition switch
Location
DOOR SWITCH L H The seat belt warning timer is

located on the back side of the dash
Refer to
page 53
El board on the right side
Refer to page EL 104
SEAT BELT SWITCH Battery
Inspection
w
l IElTl
UTl
OUT I
I
SEL418
I After about 6 secondl
Battery
SEL41
w
SEL420
WARNING CHIME
Uc built In DIODE For door awltch
Location Location
The warning chime is located on The diode for the door switch is
the back side of the dashboard on the fastened to body hamess with tape
right side near the injection block
EL 72

ELECTRICAL SYSTEM Wiper and Washer
WIPER AND WASHER
CAUTION Before starting to work on any part of electrical system disconnect battery ground cable
SCHEMATIC WINDSHIELD WIPER AND WASHER With time control
IGNITION
OACC SWITCH
C
J f CON 1
FUSIBLE LINK
OJ
o c c
r
FUSIBLE LINK FUSE
IGN ITlON AND

ACCESSORY RELAY
WIPER MOTOR
I SATTERY
L
I INTERMITTENT
WIPER AMP
AUTO
WIPER SWITCH
RETURN
DEVICE
11 WIPER
WASHER MOTOR
f HI LO INIp
o
@
gg
8
JU
1
1r SE L422
EL73
Wiperand Washer ELECTRICAL SYSTEM
WIRING DIAGRAM WINDSHIELD WIPER AND WASHER
IGNITION SWITCH
OfF
f
@
R
rl
iC i r
FUSIBLE
LINK @ WR1
LB
I
lG
Sf
0 P
0
o
B
BATTERY BL
I 4
t J
I FUSE BLOCK
@
IGNITION AND
ACCESSORY
RELAV
ld
O@
WIPER MOTOR
o
l @ I
I
M
I
L
1
Le
GL
WIP ER SWITCH
W
WI PER
ff INIlO HI
INTERMITTENT
WIPER AMPLI F I ER
@j I
L
LB
LR gg
I G
@ It
LJ T og9
llifl
L
ill
ga I B 5IJO
I LV LV
80
l OOO
00 I LR LW
L I
LW
L
@
@
LI @
WASHER MOTOR
U @ @ With time control
Ji@
SE L423
EL 74

ELECTRICAL SYSTEM Wiper and wsher
Windshield Mqtor Broken armature worn motor brush or Replace motor
wiper does not seized motor shaft

operate
Power Blown fuse Check circuit
short bumt component in
supply and side motor or other part for operation
cable and correct problem
Loose open or broken wiring Correct
Improper grounding Correct
Switch I Improper switch contact Correct
link Foreign material interrupts movement of Correct

link mechanism
Disconnect link rod Correct
Seized or rusted arm shaft Lubricate or replace arm shaft
Circuit Faulty circuit breaker Replace circuit breaker

breaker
Windshield Motor Short circuit of motor armature worn Replace motor or lubricate bearing with
wiper operat motor brush or seized motor shaft engine oiL
ing speed is
Power Low source voltage Measure voltage check other electrical
too slow
supply and parts for operation and take corrective
cable action for power supply if necessary
link Humming occurs on motor in ann operat Lubricate or replace

ing cycle due to seized arm shaft
Switch Improper switch contact Conduct continuity test and replace if

necessary
Circuit Faulty circuit breaker Replace circuit breaker
breaker
Windshield dotor Motor brush for either low or high speed Replace motor
wiper speed 9 n iswom

not be adjusted
correctly
Stops Motor Contaminated auto return relay co tacts Remove auto return device cover and
c c de
0 any or improper contact due to foreign mat clean contacts carefully so as not to
v where ter form relay plate
00
9
2 c e
0 Does dotor Incomplete auto return operation Con Remove auto return device Cover and
u
0
not tact is not interrupted correct relay pla e bending
stop
Washer motor Bumt fuse Corre t c use and replace fuse

does not operate
Faulty switch Replace
when pushing
washer switch on
Faulty washer motor Replace
Loose or poor connection contact at Repair
motor or switch
Washer motor operates but Clogged washer nozzle Clean nozzle or replace
washer fluid is not ejected
EL 75

Wiper and Washer ELECTRICAL SYSTEM
Intermittent windshield w1p
The sign for action
A Measure voltage across positive B Check continuity of all wiper intermittent amplifIer
and negative terminals of in switch positions D Check continUity in wiper motor
termittent amplifier with a circuit C Check continuity of terminals of circuit
tester wiper motor wiper switch and E Altemator or battery is faulty
Wipers do not operate intermittently but line voltage below 10 volts A Replace if necessary
operate at Low and High speeds Faulty wiper switch B Corrector replace
ifneceuary
Faulty wiring A e Repair or replace
if necessary
Faulty intermittent amplifIer Replace
Faulty wiper switch Replace
Intermittent speed is too short for proper line voltage too high A Replace if necessary
wiping
Faulty wiper motor D Replace if necessary
Faulty intermittent amplifier Repbce
Intermittent speed is too long for proper line voltage below 10 volts A Replace if necessary
wiping Faulty wiper switch B Correct or replace

if necessary
if necessary
Faulty intermittent amplifier Replace
Wipers do not shut off Faulty wiper motor D Replace if necessary
Wipers operate intermittently with wiper Faulty wiper switch B Conect or replace
if neCessary
switch OFF
if necessary
Intermittent speed is erratic Excessive line voltage fluctuation E Correct or replace

if necessary
Faulty wiper switch B Correct or replace
if necessary
Faulty wiring A C Repair or replace

if necessary
Faulty wiper motor D Replace if necessary
Faulty intermittent amplifIer Replace
Wipers make a complete wiping stroke only line voltage below 10 volts A Replace if necessary
one time with wiper switch ON but do not Faulty intermittent amplifier Replace
continue operation
Wiper motor is not interconnected when Poor connections c Repair or replace

washer switch is but intermittent if necessary
depressed Faulty intermittent amplifier Replace
operation is normal
Wipers do not make a complete Wlpmg Faulty intermittent amplifier Repbce

stroke when washer switch is fIrst turned on
and is quickly turned off
EL 76

ELECTRICAL SYSTEM Wiper and Washer
WINDSHIELD WIPER
OJ
SEL319
CAUTION Be careful not to bend linkage during removal
Inspection
uL
urff
M P B
Motor should run t low speed

SEL321
Auto return
deVicez
Stop position
I Ii M E
Motor should run at high speC

SEL322
EL77

Wiper Bnd Washer ELECTRICAL SYSTEM
WIPER AND WASHER 1
SWITCH
OnlY time
Combination switch control tYP
Refer to
D
I
1
e
A
i B
JIDECO
IInERMI WIPER
AMPLIFIER
Test lamp repeatedly comes OD SE 27
SE L323
IC bullt ln
Location
Adjustment B
3 Disconnect lead wire
The intennittent wiper amplil18r is
Test lamp should go out and come
attached to the relay bracket Refer to
back on in a few second
page EL 105
Inepectlon
Be careful not to connect lead wir
to incorrect te minals
20 10 791
20 10 191
Connect test lead wire
Unit mm in SE L324
JIDECO
I
WINDSHIELD WASHER SEL 28
Wash r nozzl adJus
iA
l
J
Only time
11018 69 11016 69 JIDECO control type
i
F
100 13 941 dili 100 3 94 41
BE L326
1 rPr1 II
F1 Jf
i
10116
410116 141 1
W 2 Make sure that test

oil when negative lead wire A is
lamp comes
con
I
JlDECO
I
SEL329
Unit mm in SEL325
nected
EL 78

ELECTRICAL SYSTEM Wipe and Washer
REAR WINDOW WIPER AND WASHER

r
SCHEMATIC REAR WINDOW WIPER AND WASHER
IGN ITION SWITCH

AUTO RETURN
ACC
DEVICE
o
y C
ON
FUSIBLE Osr
LINK
WI PER WASHER
REAR
FUSIBLE ON OFF ON f
WINDOW
L1N WIPER
I
I
MOTOR
REAR
b
W WASHER MOTOR
r
I BATTERY
c
C C
Jo
FUSE @ o
REAR WINDOW
IGNITION AND
WIPER AND
ACCESSORY
WASHER
RELAY
SEL434
WIRING DIAGRAM REAR WINDOW WIPER AND WASHER
o
@
L
Eflf 1 E3
IGNITION
AND
Uf
ACCESSORY
BATTERY FUSIBLE @ RELA Y
LINK
Off
6
Age J D
i
o
ci
IG I
o S
LB
W
WR
hl@
I
IGNITION SWITCH LB
BL L
c
r
r B
o 0 0
o FUSE BLOC
o
o 0
Lvi
1@
v
J
8
1
I
DcQ
@
to
LB L
o U
REAR WAS iER @
MOTOR 5
CD
L
1P1 LB LB
REAR WINDOW WIPER W LW

ANO WASHER SWITCH
lw RWIP
Ia
l
t f N V L @ L 19y
u 0
r
00 Lg
LA @
I 1
0 J L Y
i b LW
REAR WINDOW
WIPER MOTOR
SEL 35
EUll
WtperandWasher ELECTRICAL SYSTEM
REAR WlfiiDOW WIPER I spectlon
rU
u
i I
7
j I
i
0
t
1 B
t
J
1
i i
SEL367 IO return device
BXP
S E
t
Stop position
1 S PE SEL332
REAR WINDOW WIPER SWITCH AND WASHER SWITCH
Inspection
Washer on I
r Washer Wiper
IXI
Auto return I OFF ON OFF ON
Wi r
tl
t
SE L336
EL 80

ELECTRICAL SYSTEM Electrical Accessories
ELECTRICAL ACCESSORIES
CAUTION Before muting to work on any part of electrical system disconnect battery ground cable
REAR WINDOW DEFOGGER

SCHEMATIC REAR WINDOW DEFOGGER
Ace IGNITION
O L
ON SWITCH
c
o c IGNITION AND
FUSIBLE LINK ACCESSORY
RELAY
u
w REAR WINDOW
c
o Q C 0 DEFOGGER
FUSIBLE LINK FUSE
L
I BATTERY @
MON ITOR LAMP
1
DEFOGGER 1
I SWITCH 0 0
SEL436
WIRING DIAGRAM REAR WINDOW DEFOGGER IGNITION SWITCH
iJ ig R WR
FUSIBLE LINK BW II14

BATTERY
@ IGNITION AND
0 I
ACCESSORY RELAY
FUSE BLOCK
I @
I
Ji W
WB
I
BW
J
@ @
LB LB LB
2
4 J@ocr
c
iJ @
@
190 I
e
@ r li @
White 8 rl
gg
8
1 DEFOGGER
SW ITCH
e iN REAR WINDOW
o
00 DEFOGG ER
4 LB
t e LB
L L
COMBINATION METER
e @
L
le @
B
White
B
1
00
J
r
D @
J
0
B
LB J co
00
LB
@ 2
MONITOR
@
d gg@ LAMP
i@ SE L437
EL 81

ElliCtrical Accessories ELECTRICAL SYSTEM
REAR WINOOW DEFOCCER 2 If a mairieni is burned oill Circuit Repair pI L

SWITCH tester registers 0 or 12 volts
I Wipe broken heat wire and its
surrounding area clean with a cloth
Inspection
H dampened in alcohol
2 AppJy of c duc
t
snuillam
tive silver composition to tip of draw
lffl ing pen
belore
Shake silver
use
on container
3 Place ruler on glass along broken

V
line Deposit conductive silver com
12 Volt SEL264 position on break with drawing pen

Slightly overlap existing heat wire on
both sides preferably 5 mm 0 0
2
in ofthe break
1 1 H
rTI Heat wire

00
1
reak
ON
12
0 0
IV
aValt
E l265
Drawing pen
Lf Unit mm in
OFF eE540
SEL338
3 To locate burned out
point move
probe to left and right along filament 4 Wipe clean silver composition
to determine point where tester needle from tip of drawing pen
swings abruptly 5 After repair has been completed
check repaired wire for continuity
This ch ck should be conducted 10
1 J
minutes after silver composition is
deposited
REAR WINDOW DEFOGGER

1M
j
0
test
6
Do not touch
is
Apply
being
a
conducted
repaired
constant stream of hot

rea while
FILAMENTS
air directly to the repaired area for
Inspection VJ approximately 20 minutes with a heat

gun A minimum distance of 3 em
I SEL266
Attach probe circuit tester in
12 in should be kept between re
volt range to middle portion of each
paired area and hot air outlet Ifa heat
filament
gun is not available let the repaired
area dry for 24 hours
H FUament maintenance
r j
m
Repair equipment
Z 1 Conductive silver composition
I
Dupont No 4817 or equivalent

2 Ruler 30 em 12 in Jong
3 Drawing pen
4 Heat gun
V
6 Volts normll filam nt 5 Alcohol
SEL
263
6 Cloth
EL B2

ELECTRICAL SYST M Electrical Accessories
REMOTE CONTROL DOOR MIRROR
SCHEMATIC REMOTE CONTROL DOOR MIRROR
DOOR MIRROR SWITCH

DOOR MIRROR
1 FUSIBLE LINK FUSE

SWITCH R H LH
I R l u 0 I R l U 0
I
I BATTERY
L
i
00 00 oOOob
9 0
uO
J 00 bo
0
10 0 0 0
1
OQ IQO
r@ r@
DOOR MIRROR RH DOOR MIRROR LH
SEL440
DOOR MIRROR DOOR MIRROR SWITCH
Removal and Inatallatlon

Inspection
Remove door mirror securing bolt
and disconnect harness connector
5
4
a o
S L442
I 1 R L U 0 I
11 9 I
I
I 0
I
I 1
I
15 J 0
6
oJ II
c
I EL444
Ell 8J

Electrical Accessories ELECTRICAL SYSTEM
WIRING DIAGRAM REMOTE CONTROL DOOR MIRROR
9
rrR @ o@w
1
FUSE BLOCK
BATTERY
DOOR MIRROR DOOR MIRROR

SWITCH LH SWITCH R H
RLUD
RLIUD
rU U tJ
a
a
CJ
r11 t
CO 5
I I
III
II
CO
a Clco
@ i
@
rTIl rm
iil il
J
R
III DOOR MIRROR
DOOR MIRROR
R H LH
SEL441
EL B4

aOCK
SCHEMATIC CLOCK Digital
IGNITION SWITCH
ACe
C FUSE
l C o
L FUSIBLE OST
LINK
a
T 5
BATTERY I
rJ s
L
FUSE 0
FUSIBLE
I LINK u
II
In
FROM
II ILl LI
LIGHTING SWITCH
digital display
Day light brightness selection for 1
SEL438
DIGITAL CLOCK Turn it counterclockwise for for DAY adjustment

hour adjustment To adjust the current minute and
Adjustment Turn it clockwise for minute second select MIN SEC with the
adjustment SELECT knob and depress the
SELECT knob
Push it to set the time to the ADJUST knob to set the time to
Depress the SELECT knob and nearest hour 00 00
display will project HOUR MIN For example when adjusting the
When the battery cable is detached
MONTH DAY and M1N SEC time for 10 00 first set the time be
and reinstalled the will auto
display
in that sequencec tween 9 30 and 10 29 Then push
matically return to 12 00
the knob usly
simuJt with the
lcement
annou of 10 00
ADJUST knob To the first select
adjust day
To adjust the time fust select MONTH DAY with the SE
HOUR MIN with SELECT LECT knob then tum the AD
knob then use the ADJUST knob JUST knob counterclockwise for
in the following manl er MONTH adjustment or clockwise
EL 85

WIRING DIAGRAM CLOCK
BATTERY
1ll
@I FUSIBLE
LINK
D WR
ST lCCOff
ON
000 B
I
J
8
b
IGNITION SWITCH
I
00
1 WR
LB
W
J
1 L
j j@
J
J
W u w
i I j
I
C IJ
Green White
@ og
iOOOOIIO oooo
l
ho
o Ii00
1 0 L
@ J 01 O@ COMBINATION METER
I H
@ @
L
TO L1GHT
SWITC H
@
G 3
J
2
L
@
EL 86

ELECTRICAL S YSTEM EIectncal Accessories
HORN
SCHEMATIC HORN
Surge killer
B
HORN
f 0
RELAY
o C
I
HOr TN 1
1 FUSIBLE
LINK
FUSE 1
SATTERY
Q
I HORN
Q
HORN
SEl445
WIRING DIAGRAM HORN
8 0
6 Bfl gW
r
BATTERY
LINK
@
FUSE BLOCK
HORN
i
RELAY
1
D G a
@ @ J
r I
HORN R H
I
f l N
l
D
l BG
D
2
HORN BUTTON
3
I U
@l 0 I
COMBINATION SWITCH
@G
HORN L H
SEL446
EL 87

TRoUliLE DIAGNOSES AND CORRECTIONS
Neither high nor low Burnt fuse Correct and fuse

cause replace
horn operates
Faulty hom button contact Repair horn button
Hom sounds when CD terminal of instru
ment harness conn ctor to combination

switch is grounded
Faulty hom relay Replace

Hom sounds when @ and @ terminals of
engine harness to horn relay are connected
with a test lead including lOA fuse
Loose connection or open cfrcuit Check wiring and or repair connection
High Low horn Faulty horn or loose hom terminal Correct horn terminal connection
connec or replace
does not operate tion horn
Break in wire to horn Repair
Horn does not stop circuited

Short horn button and or hom Repair horn button or its wiring
to sound button lead wire
When ins1rument harness is disconnected
from combination switch horn stops sound
ing
Faulty hom relay Replace
Reduced volume and Loose or poor connector contact Repair

or tone quality Fuse relay horn and or horn button
Faulty homo Replace
HORN Inspection HORN BUTTON
The horn button is attached to the

combination switch Refer to page
EL39
rJ
HI to
SEL340
@CD@
HORN RELAY
Locstion
The horn relay is located beneath

the relay bracket Refer to page EL
105 Battery
EL 88

ELECTRICAL Elecrrical Accessories
SYSTEM
AUDIO
SCHEMATIC AUDIO
IGNITION
SWITCH
y
E OST
LINK
m
BATTERY I
L I I
6
I
OeCK
J01
RADIO
000000 V
DOOR SPEAKER R H REAR SPEAKER R H
t II
E
DOOR SPEAKER LH REAR SPEAKER LH
SEL447
SCHEMATIC POWER ANTENNA
POWER ANTENNA
SWITCH
IGNITION SWITCH
ACC
I u N 0
C
o
CON
0
1
FUSE
FUSIBLE LINK OST
l
0
u
BATTERY
I
POWER ANTENNA
L
f
t MOTOR
3
SEL449
EL 89

Electrical ELECTRICAL
Accessories SYSTEM
WIRING DIAGRAM AUDIO
REAR
SPEAKER
DWR
RH
ffih
o
BATTE YU FUSIBLE @
LINK
Sf
1J
Block @
I @
o
J I
I
LW
I
v
J
lgW tk@Y @
illY LR
m
4YJ
rT
LB
LyR
@
I
REAR
SPEAKER
i L
I
a
J 0 01
l@
I
B
DOOR SPEAKER
IBlue
Green
L
DOOR
LH SPEAKER
R H
a m a 15i
I 0000
0000 00
J 0
@
t J
II II I
YUi U
@ @ @
Irml
9 0
FUSE
RADIO DECK
SE 1448
EL 90

ELECTRICAL SYSTEM Elecrrical Accessories
WIRING DIAGRAM POWER ANTENNA
FUSIBLE
BATTERY LINK
re I D
G ftWR
1 IGNITION SWITCH
ST ON ACC Off
@
g J
I
@
mtl
8 1 1 WR
I
LBi
RW
FUSE BLOCK
B W
s
Whitel@
ill
I I s
s s c
0
s a
a cO
l Q
@B
@
White
J
L
Il
n
i I
l
Bluel
i
Green
nht
0
I
w @
@
@ Ifg lIgg1gitl I o
1I000ill
I
1
lIt 000000
s
@ @
IICD
I
POWER
CD
ANTENNA
@L1f3J SWITCH
I U N D
@r
Ig
POWER
ANTENNA
MOTOR
SEL450
EL 91

RADIO Antenna trimmer adjustment
The antenna trimmer should be

Removal and InataUatlon in the
adjusted following cases
Prior to removing radio and sound Fading and weak AM reception

balancer remove cluster lid C Mter installation of n w antenna
feeder cable or radio receiver
Inspection Before adju ingt be sure to check
harness and antenna feeder cable con
necton for proper connection
1 SEL4S3
Extend antenna completely
2 Turn radio on and turn volume
control to increase speaker volume
3 Tune in the weakest sta1ion bare
ly audible on dial at the range around
14 1 400 kHz
CAUTION
4 Turn antenna trinuner to left or
00 not turn antenna trimmer more
right slowly and set it in the position than half
one turn
where reception is strongest
POWER ANTENNA
Feeder cable routing
SEL346
Alway route feeder cable away from other harne
EL 92

HI 4 CI OST u s YAX T S IP I
YEO
5
3C
l
r
n
O CT
OIlUl Q l O o E SC R
IP IO
T N DJO
kQTY f r
r
r
s c I
f 1 20081 Combined 1IIlIDtJ81 80 20082
26 9
ANY ITEMS NOT SHIPP D271 ARErIMMED1ATELY
c
BACK ORDERED NO
RETURNS
CLAIMSAI
WED UNLESS MADE WITHIN
ACCEPTED
off INVOI CE
r fo UNAUTHORIZED
c 74 654
10 DAYS
herein
FROM DATE
were In
produced
nd
ompllilnce with all
provisions
ThiS is to
of the Fair Labor Standards Act of 1938
best of knowledge with
rtity that the 900ds
amended It is
sting price egulations
Intention o amply the prices here Invoiced do comply to
tJ1e
SHIPPING 114l

Power antenna motor NOISE PREVENTION PARTS

CAUTION
Do not allow motor to keep running
when antenna rod is Condenser
fully extended or
retrected
Ignition coil
Alternator
Bonding wire
Body to engine rocker cover
II Power antenna switch
The power antenna switch is
grounding located on cluster lid C Refer to BF

Securely tighten antenna
bolts section
v @CD
SE L348
i SEL349
and weak radio reception

I Fading Noisy radio reception
1
Stop engine and turn off all other See Fading and
Check feeder cable connections
N G I
switches
I
I Unchanged
weak reception
Kl Connect or repair
Revised
1
Check ignition cables
Check antenna ground
I K
O
O N G I l Replace
KJ T 1 ghten secure Iy N G
Check noise prevention parts
Adjust antenna trimmer

Condenser bonding wire
I
O
O
Kl N G
Retighten or replace
Kj Check spark plugs
Replace radio OK
Replace
N G
Revised I
1 Unchanged
Faulty speaker Check feeder cable routing
OK
Faulty radio N G
Repair
Replace radio
I
I
Revised Faulty speaker
Unchanged
Faulty radio
EL 93

Automatic Speed Control Device A S C D ELECTRICAL SYSTEM
AUTOMATIC SPEED CONTROL DEVICE AS C D
CAUTION Before starting to wort on any part of e1ectricel system disconnect battery ground ceble
DESCRIPTION The construction of this system and and the actual speed picked up by the
The Automatic Speed Control the location of each component part speed sen or
Device subsequently referred to as are shown onpage EL I04 and 105 The rvo valve converts this signal
A SC D i a combined unit of The AS C D controller generates into corre ponding and oper
vacuum
electronic circuits with vacuum me an electrical signal equivalent to the ates the actuator which adjusts the
chanisms difference between the preset speed throttle valve opening
SCHEMATIC A S C D
IGNITION SWITCH
FUSIBLE LINK OACC
L
L
Y
FUSIBLE LINK
I Y
gr I FUSE
BATTERY FUSIBLE LINK FUSE

I I O
Y
C
cY IGNITION AND
ACCESSORY RELAY
1
TO LIGHTING SOLENOID VALVE
MAIN SWITCH
SY TE
Neutral xmtion
I l
OFF
ON
I
r ON
@
CRUISE
Y
rc @
L JATOR
ACl
ll
TO
I INTAKE
MANIFOLD
RELAY SERVO VALVE
EJ r I
STOP LAMP SET SWITCH

OPEN
Q
SWITCH
CONTROLLER
I
I I CLOSED
STOP
8
o 0
SWITCH t THROTTLE
LEVER
SPEED
INHIBITOR
SWITCH
INHIBITOR
RELAY
SENSOR
I
SELAOO
EL 94

r
D
ELECTRICAL SYSTEM Auramatic Speed Control Device A S C
FUNCTION AND OPERATION lhe switch depressed lhe controller R I y ly
cancels the preset car speed The release is

v ve lhe safety
M ln swttch The controller will preset lhe car
valve wliich shuts off the atmospheric
The main switch has a holding type speed at which lhe car is running when passage to lhe vacuum line when the
the switch is released
of circuit system activates
When the main switch is turned ON
Speed s nsor
wilh lhe ignition switch ON lhe Actu tor
Contaln d In speedom t r
exciting coil of the relay will be ener The actuator causes ihe throttle to
gized and the relay will turn ON lhus The speed sensor is generating two
open and close by vacuum
through
supplying current to lhe system pulses per revolution of the meter lhe servo valve
cable
Although the main switch automatical
ly retums to its original position the output voltage range and lhe
The
Stop wttch
current is sentthrough lhe relay and duty cycle must be controlled prop
The stop switch is used to release
fed to the exciting coil via lhe main erly
lhe system When the brake pedal is
switch in this way lhe relay will
S ryo y ly depressed this switch cuts off lhe
remain ON When the ignition switch
power supply to the A S C D circuil
is tumed off lhe relay will also turn TransdUc r
off And the relay will remain in The servo valve causes the vacuum
until lhe main switch is Stop I mp switch
operative valve and atmospheric valve to open or
turned ON even if the ignition switch close according to the input current This switch causes the stop light to
is set to ON and the from the operate At the same time the oper
adjusts vacuum
circuit is
intake manifold ating signal of the stop light
sent to lhe controller in order to re
Controll r lease the system
S t swttch The ontrol er

c compares the preset
Inhibitor r lliy
The set switch has an OFF
ON speed with the actual car speed and
in The inhibitor relay releases the
switch type of circuil maintains preset speed by
the
When the set switch is depressed creasing or decreasing the current s C D
A system when the selector is
set to N P position
lhe CRUISE light illuminates Wilh flowing through the servo valve or
TROUBLE DIAGNOSES
TEST CONDITIONS DIAGNOSIS

2 A S C D cable must be securely
If a malfunction is found be sure installed with proper adjustment
WARNING
to check lhe following before perform 3 Vacuum hoses must be properly
All following system tests can be
the abnorrrial conditions
ing system tesl attached wilh no
I All wiring harness connectors such as vacuum leakage sharp bends performed withoutrunning engine
Avoid making test while driving car
must be securely connected or kinks
or running engine
Indicator light will not glow even if ON button of main switch is depressed with ignition switch ON
1 L
Burnt bulb Faulty main switch Faulty A S C D relay
EL 95

r
Automatic Speed Control DBVice A S

CD i ELECTRICAL SYSTEM
if let switch is depressed and released 81 proper car speed with main
Cruise light will not glow eyen
switch ON Speed not set in system 1
1
With main switch ON battery voltage 12V is present between terminals @
and V of harness connector
position other than Ip and
Set automatic transmission selector lever at any
NW
I position
YES
to
Open circuit
Faulty or unproperly adjuSted Faulty inhibitor switch

stop switch
When set switch is depressed with main switch ON battery voltage 12V is
presentbetween terminals @ and V ofhamess connector
YES NO
1
Faulty set switch
With main switch ON manually rotate meter cable slowly

Con1inuity between terminals CD and @ofharness connector exists two
times a rotation
YES
1 to
Faulty controller Faulty speed sensor
EL 96
ELECTRICAL SYSTEM Automatic Speed Control Device A S C D
Cruise light illuminates when speed setting operation i made but peed is not actually set
A
To servo
valve
When battery voltage 12V is applied to the release valve terminal the
following are possible

1 With
2 With
A
A
closed
opened
no suction is
suction is
possible
begun at
at
B
B
tlLL 1 B
YES I I
To actuator
to LJ
BE089D
Faulty release valve

It
Servo valve Refer to Servo Valve for Inspection

operates normally
YES NO
1
Faulty servo valve
Actuator operates smoothly when actuator vacuum port is suctioned TItis

operation must be performed with A S C D cable released
YES
1 lNO
Faulty controller Faulty actuator
EL 97

Automatic Speed Control Device A SC D ELECTRICAL SYSTEM
Other maHunctlon
Condition Probable cause Corrective act on
Set speed is cancelled Bent meter cable excessive meter needIe Check and repair meter cable or renew
deflection cable
controller Renew
Faulty
Pulsation of set speed Excessive play or binding of A S C D Adjust

cable
in vacuum hose Check and repair piping route

Leakage or clogging or renew
hose
Binding in actuator Renew actuator
Faulty servo valve Renew servo valve
Faulty controller Renew controller
Excessive setting error Excessive play or binding in sC D

A Readjust
cable
Leakage or clogging in vacuum hose Check and repair piping route or renew
hose
Faulty actuator Renew actuator
Faulty servo valve Renew servo valve
Faulty speed sensor Renew speed sensor
Speed drops immediately Excessive play in A S C D cable Readjust

after setting
Leakage or clogging in vacuum hose Check and repair piping route or renew
hose
Faulty release valve Ren w rele valve
Faulty servo valve y

Rene servo valve
Cancel circuit inoperative Faulty controller Renew controller
EL 98

ELECTRICAL SYSTEM Automatic Speed Control Device A S C D
COMPONENT PARTS
VACUUM ROUTING
Adjusting nut
Lock nut
Actuator
f
I
To vacuum check valVe
Air conditioner
equipped model
ToF I C D
SEL392
EL 99
Automatic Speed ntrol Device IA S C D ELECTRICAL SYSTEM
WiltiNG OIAGRAM1A S CO
IGNITION AND ACCESSORY RElAY

W
t3@
ffi lJWR r D
f 5T
TT
ON ACC Off
FUSIBLE
LINK
@
J
J
tg g s 1T
l B
I
@
o s tf W
WR
W
IGNITION TCH
we
r
o 0 FUSE
VB
QI
0
BLOCK STcp LAMP
SWI STeP SWITCH
1 C1 SET SWITCH
INHIBITOR
5C D
A
RELAY RELEASE SERVO U
L
AS C D CONTROLLER
v V E
Ir I
f II@
jG J
I
J a CD a a C a J
J CD
I i
@ YL
@ @ @ I 1
I
I I L
BL
m m vn
i
I
1 m
Cl
I LgB W
J m
lOr 1
Whits
m 171
@
iJ
Y
l@
J CD C C
@
I
@ l
I W
XI
@1r
@ Cl
III 11 1 0 I
AS C D SPEED SENSOR
MAIN SWITCH
SEL3M
EUOO
ELECTRICAL SYSTEM Automatic Speed Control Device AS C D
A S C D CABLE I Normal condition

In ectlon
I Visually check actuator for dam

Removal and Inatallatlon Check ports Airflow
age Or deformation
I Disconnect cable from actuator 2 Make that actuator moves
sure
CD V
1 Loosen lock nut at actuator smoothly without binding when dia Yes
2 Remove rubber boots CD @
phragm is pushed by hand
3 V @
Apply vacuum to actuator If
diaphragm moves to full position it is
normal
2 12V direct current is applied be
Plug hose with vacuum applied
tween terminals
Make sure that laJor
act remains in full
position
Check ports Airflow
CD V Yes
CD @ No
V @
1 Actuator 3 Cable
2 Rubber boot 4 Lock nut
2 Loosen lock nut at intake mani

fold bracket
SOLENOID VALVE
3 To install the cable reverse the BE100D
order of removal
Location
Exercise care when removing and
CAUTION Refer to page EL 99
installing wire so as not to deform
wire end When checking actuator by applying
In ctlon
vacuum do not apply engina vacuum
1 Measure the resistance between
directly
Adjustment
terminals
A S C D
When installing adjust
Circuit tester indication
cable as follows
RELEASE VALVE 25 30n
Without depressing the accelerator
pedal adjust the adjusting nut until 2 Check to be sure that output
Location
cable free play is within specified value vacuum of valve is proper
Refer to page EL 99
at throttle lever should be
This check performed
Then tighten lock nut with the valve installed on car
In ction
Free play
0 08
23m 0 12 in 1 Measure the resistance between
CAUTION
terminals
Do not inc ease tension of cable With servo valve connected to system
Circuit tester indication do not
excessively as this may cause throttle apply current to servo valve Be
25 30 n
lever to rotate sure to disconnect solenoid valve sida
2 Check to be sure that the valve vacuum hose
or closes by blowing air
ACTUATOR opens through
port on actuator side
Removal and Installation i Disconnect solenoid valve side
Battery 12V 1 Actuator side vacuum hose at solenoid valve and
I Disconnect battery ground cable 2 Serio valve side connect vacuum gauge
2 Disconnect cable from actuator 3 Atmosphere side 2 Start engine and warm up engine
Refer to A SC D cable for reo
until water temperature indicator
moval
3 Disconnect
A S C D release valve
vacuum hose from
n points to the
3 Apply 3A
O
middle of gauge
direct current be
ZP tween tenninals
4 Remove bolt attaching actuator
I
to body Using about 20n 5W variable resis
5 To install actuator reverse the CD
E L409
tor adjust so that a current of 0 3A
S
order of removal will flow
EL 101

Automatic Speed Control Device AoS C O ELECTRICAL SYSTEM
Variable
resistor Ammeter
I I O 3A
Ir l 0
Yacuumgauge
Battery
e
73 11 3 kP
12V
1 II
55 85 mmHg
2 17 3 35 inHg
Solenoid valve
side
IlL
I
I
I
To intake
l manifold
Servo valve
BE730D
SPEED SENSOR MAIN SWITCH

Lead switch type
Inspection light with an ohmmeter in accordance
Location Test continuity through switch or with the chart
following
The is built into the
speed sensor
speedometer
f
I Off
OND
II 1Il1
3
l
lieAulSE CIN11lfiIl
Inspection
must be made with
2Er
I
Inspection SE L424
speed sensor installed to speedometer

TurDing speedometer SlowlY by
hand test continuity of speed sensor
circuit Switch position

Normal ON OFF
Continuity existstwo times Check terminal
a turn K
O
Q @ No Yes No
nro
Q @ No Yes No
A @
ID
@
@
Yes
Yes
Yes No
@ j Yes
@ j Yes
9JD
Yes Continuity should exist

No Continuity should not exist
EL 102
ELECTRICAL SYSTEM Automatic Speed Control Device AS C D
SET SWITCH Adjustment Inspection
Refer to MA section
Inspection
with an ohmmeter
A S C D RELAY
Location
a
r c
1
The A S C D relay is located on
the relay bracket Refer to page EL @ @

105
r NORMAL PUSH
1 OPSTION SWITCH
INHIBITOR RELAY
11 9
12 6 For A S C D 0
a o
SE L425
Location
t I
L
The inhibitor relay is located on
Gr @
the relay bracket Refer to page EL
SEL433
STOP SWITCH 105
Inspection l2V direct current is
Test continuity through switch Check terminals Normal condition applied between terminals
with an ohmmeter @and@
Yes
@ @
Yes No
@ @
Yes
CD @ No
NORMAL @
PUSH Yes Continuity should exist
POSITION PLUNGER
No Continuity should not exist
f
11 9
126
SEL431 A S C D CONTROLLER
CAUTION
lC built In
Do not touch the circuit tester probe
to eny unnecessery terminal on con
Location
Adjustment troller Doing so could cause damage
The controller is located on the left
of the stop switch is
to controller
Adjustment
dash side panel Refer to page EL I04
the same as the stop lamp switch
Refer to MA section a Handle controller carefully to avoid
Inspection damage
Controller must not be checked as a b Keep controller away from electric
STOP LAMP SWITCH noise to prevent A S C D
single part Check controller for opera source
and Ie
tion as a system referring to Diag system from malfunctioning
Inspection circuit etc from being degraded
nosis
Rofer to page sO
El
EL 103

Electrical Unit Location ELECTRICAL SYSTEM
ELECTRICAL UNIT LOCATION
Ignition arid
accessory
relay
sea tbelt
timer
HI
control
unit
SE L432
to C v
EL 104
cJ
ELECTRICAL SYSTE M Electrlca I Unit Location
Air conditioner relay
Magnet valve Air con
Fuel pump relay l

EFI relay
7
A S C D relay
III
I
Headlamp
sensor
@
Inhibitor relay
Intermittent wiper
amplifier
Hatchback lardtop
I
nso
Tai1 and stop lamp
114
Tail nd lamp sensor
EL 105

Wiring Harness ELECTRICAL YStEM
WIRING HARNESS
CABLE COLORS
Cable colors are generally used as
shown in the following table
Circuit system Base color
B
Starting and ignition system Black
W
Charging system
White
R
lighting system Red
G
Signal system Green
Y
Instrument system
Yellow
L 8r Lg
Others
Blue Brown light green
B
Grounding system
mack
HARNESS LAYOUT
For easy identification connectors indicated in the system wiring diagram have the same numbers as those used in the har
ness layout schematic
@
@@
Ii w
CJ QOYG
YG
@@
Instrument harness
Wiring diagram Main harness
SEL461 SEL 2
EL 106

ELECTRICAL SYSTEM WiringHBrn8S
SCHEMATIC
Hatchback 4
1 Main harness
2 InstTumcnt harness
3 EFI harness
4 Body harness
S Door harness
6 Console harness
7 Back door harness

8 Fuel pump harness
Hardtop
SE L463
EL 107

tJ
CALIS SlE
Is ELEClf
ttARtlESS
e
n Il
i
ar
e CO
I
10
i
g
e
0 I
0 e
s
5
n a
6
iio t
o
U t
I1i
li
Z
e
ts u
a
5 iS
ll
iJ
e
g g 9 t
11 u
a
ti
ii
l
e II
a i d
t
5
0
i
@ @
@@ j
@ @
i u
Ii
l
U
s
@@ @ et
ga
ooo
ucn r
@ @@
@
g9
l
a idod
c a
Ol
1l 9
a
U
A
l
0oi a
t j
5e S6 eJ
d
eil
0
a otIS
tt
J
p p
i
@
@@@
i i aPo
Po
Po e
a IIi JJ 4
2l
J
t 8c e q
g
i i
e
Po SE
s
58 5 II PoPoal
ss s
5
e i
nl gi i1
1 l1 n
@@@
@@@@@@@@@
d
m rm n l0n r Ul Ul lm s I
5 if 3
c
r
c
@Bl
@
r t 2
H
R
switch
switch switch
main switch switch wiper
miror D
Haz rd Igniton Windshel

C
Door
S
@ @ @ i@ @@
H unit L
Am panel L
unit
lamp harnes harnes contrle contrle harnes flasher sfilgasnhaelr m5iWriotcrh
cons le control door
Indicator
D D
C C EFI
To Heater To S
A A
S
To Haz rd Turn Door

@ 1Jjl @ @ @ @
Earth
relay relay
harnes H
White Black switch

lamp ac es ory ac es ory timer
R unit
chime harnes switch White Gre n Black Blue @l lID brake switch
Warni g To
and and
interio Igniton Igniton belSeatt do r
To
block m o t r
Fuse Heater Thermo
c o n d i t e r @@@@@@
Air To To To To To To
belt
Parking Seat
@ @ @ @ @ @@ @ @@ @@@8 m
m 0CO

I
m mn tIJ n I m3
zIIIICI ze
rheosta met r met r met r

control aenlOr timer indcator switch amplifer
peed Ughter ilumnato pby lamp Bbck Blue Gre n White
muinado combinat combinat combinat

lamp wambtg ante a dl
I
tray box @ @ 8 @
D
Interio Multi Audio Power garet Ash Wamlns Glove

C
S
To To To A To To To To
@ @ @ @ @ @ @ ID @ @ @ @ @ @ @ @ @
III m I III
m Q

mr mnt n r en CIl lm 3 I
S i
IIo 0 azIIII
fr rr
Earth
mot r
hameu defog er wiper defog er
door To@ To@ Rear Rear Rear
Back @ @ @ @@
n
L
lamp
lamp R
harnes unit
L
ante a marker omparten speaker switch fupelump tagnkauge earth

U
U R
L
lamp L
combinat
L
lamp
up
Back
Rear Power Side Lug age Rear Door Fuel Body To
@ @ @ ffi @ @ @ @ ill @
H n R
R R L
senor senor H
R lamp lamp lamp
HH U
n H
lamp lamp lamp R R L
White Black R
combinat combinat Licens Licens combinat

R
stop stop lamp lamp lamp

8 @ switch speaker and and marker
l
Tr
up
Door To@ To@ Rear Tail Tail Side Rear Rear Back Rear
J
To To
@ @ @ @ @ @ @ @ @ @ ill ill @ @ ill m r In
mr

mI m 0 o r
ir
o1S
f
a
L
harnes
ante na switch pfuumelp
power Door To
@@ @
a
L
lamp a
L
aaa
R L
lamp
lamP lampL lamP
up
Back Licen up
Backcombinato marker
Rear Side
@ @ @ @ @l
a
R
awltch aenlOr senIOr a

R
lamp
a
unit a
a
a
R lamp lamP lamP lamp tlon lamP gauge
L R
ro m speaker tank lamLicPon

R
top atop
WhitO Black switch defOSler comb U
speaker ro m earth and and marker
I@ll ide Rw Trunk lear Fuel
Tol@l Door Rear Rear Trunk Body Tail Tail
To
@Y @ @1 @ @ @
@1 @1 @ @ @ @ @1 @
n
ELECTRICAL SYSTEM Wiring Harness
ENGINE ROOM HARNESS NO 2
@ Kickdown rwitch Arr

@ Inhibitor switch Am
@ Inhibitor rwitch Am
@ bmp rwitch Mm
Rever
@
@
Starter motor
Oil pressUIe sending unit
I I f
r
0
J fr
@ To I@
fr2 @ @
@ To@
II
@ To I@ 11
1
J
@
@
SEL460
EL 113

i 4

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TIIUNK
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INCH TO METRIC CONVERSION TABLE METRIC TO INCH CONVERSION TABLE
Rounded of for automotivo use Rounded off for automotive use
inches inches mm inches

inches mm mm mm
I 100
110
2 54
2 79
610
620
49
15
15 75
1
2
0394
079
51
52
2 008
2 047
I
I 120 3 05 630 16 00 3 118 53 2 087
4 157 54 2 126
I 130 3 30 640 16 26
I 140 3 56 650 16 51 5 197 55 2 165
150 3 81 660 16 76 6 236 56 2 205
160 4 06 670 17 02 7 276 57 2 244
170 4 32 680 17 27 8 315 58 2 283
4 57 690 17 53 9 354 59 323

2
180
190 4 83 700 17 78 10 394 60 362
2
200 5 08 710 18 03 11 433 61 402

2
210 5 33 720 18 29 12 472 62 441
2
220 5 59 730 18 54 13 512 63 480

2
230 5 84 740 18 80 14 551 64 2 520
240 6 10 750 19 05 15 591 65 2 559
250 6 35 760 19 30 16 630 66 2 598
6 60 770 19 56 17 669 67 2 638

260
270 6 86 780 19 81 18 709 68 2 677
280 711 790 20 07 19 748 69 2 717
290 7 37 800 20 32 20 787 70 2 756
300 7 62 810 20 21 827 71 2 795
310 7 87 820 20 83 22 866 72 2 835
320 8 13 830 21 08 23 906 73 2 874
330 8 38 840 21 34 24 945 74 2 913
340 8 64 850 21 59 25 984 75 2 953
350 8 89 860 21 84 26 1 024 76 2 992
360 9 14 870 22 10 27 1 063 77 3 031
370 40
9 880 22 35 28 1 102 78 3 071
380 9 65 890 22 61 29 1 142 79 110

3
181
1 80 3 150
I 390 9 91 900 22 86 30
189
3
I 400 10 16 910 23 11 31 1 220 81
41
10 920 23 37 32 1 260 82 3 228
410
10 67 23 62 33 299
1 83 3 268
420 930
940 23 88 34 1339 84 307
3
I 430 10 92
440 1118 950 24 11 35 378

1 85 346
3
f 450 1143 960

970
24 38
24 64
36
37
1417
1457
86
87
386
3
425
3
I 460 1168
I 470 11 94 980 24 89 38 1496 88 3465

12 19 990 25 15 39 1 535 89 3 504
480
490 45
12 1000 25 40 40 575
1 90 3 543
500 12 70 2 000 50 80 41 1614 91 3 583
510 12 95 3 000 76 20 42 1 654 92 3 622

520 13 21 4 000 101 60 43 1 693 93 3 661
530 13 46 5 000 127 00 44 1732 94 3 701
540 13 72 6 000 40
152 45 772
1 95 3 740
550 13 97 7 000 177 80 46 1 811 96 3 780
560 14 22 8 000 203 20 47 1 850 97 3 819
570 48
14 9 000 228 60 48 1890 98 3 858
14 73 10 000 254 00 49 1929 99 3 898
580
14 99 20 000 508 00 50 1 969 100 3 937
590
600 15 24
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EXPORT SERVICE DEPARTMENT
NISSAN MOTOR CO LTD

17 1 Ginza 6Chome Chuo ku Tokyo 104 Jap
Issued February 1 811 020200
Publication No Bll
SMOE UO
Printed in Japan

Datsun 200sx Service Manual

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v

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Model ENGINE LUBRICATION COOLING SYSTEMS LC

EMISSION CONTROL SYSTEM E

personnel in providing effective service and

This manual includes procedures for main

All information illustrations and specifica

the time of publication If your DATSUN

tained in this manual consult your NISSANI

DATSUN dealer for information FRONT AXlE FRONT SUSPENSION F

The is reserved to make changes in

NISSAN MOTOR CO LTD

HEATER AIR CONDITIONER H

@ t 979 NISSAN MOTOR CO LTD

pany Ltd Tokyo Japan

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HOW TO USE THIS MANUAL

index of the particular section you wish to consult

SE DATA AND SPECIFICATIONS

obtain special service tools write to the following address

RO eville Michigan 48066 Mississauga Ontario

Canada L5A 3P2

In the text the following abbreviations are used

formed safely and accurately

jeopardized by the service method selected

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GENERAL VIE WS GI 2 TIE DOWN GI 5

LIFTING POINTS AND TOWING GI 5 TIGHTENING TORQUE OF

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I Aluminum wheel Option

Prefix and suffix designations

o Hardtop J S Sport Luxury model

L Left hand drive R Sun roof Steel

L Rear window wiper

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CAR SERIAL NUMBER

CAR SERIAL NUMBER

Hatchback r I Car serial number

ENGINE SERIAL MANUAL TRANSMISSION AUTOMATIC TRANSMISSION

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LIFTING POINTS AND TOWING

hook Towing hook

Jack up point for pantograph jack

Supportable point for safety stand

b All applicable State or Provincial

do not exceed 30 h 20 MPH

WARNING g Release the parking brake and set

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SPECIAL SERVICE TOOLS

puted based on the use of Special STOOOOOOOO Special Tool

TIGHTENING TORQUE OF STANDARD BOLT

1 Special pam are excluded

2 This standard is applicable to bolu the

Metric screw threads

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MAINTENANCE OPERATION MAINTENANCE INTERVAL

Periodic maintenance should be performed Kilometers x 1 000 16 t2 24 36 48 60 72